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Z250D

LZ250D

SERVICE MANUAL

60V-28197-3E-11

290484

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Summary of Contents for Z250D

Page 1: ...Z250D LZ250D SERVICE MANUAL 60V 28197 3E 11 290484 ...

Page 2: ...manual Important information 1 Particularly important information is distinguished in this manual by the following notations 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 CAUTION A CAUTION ind...

Page 3: ...nformation 1 GEN INFO Specifications 2 SPEC Periodic checks and adjustments 3 CHK ADJ Fuel system 4 FUEL Power unit 5 POWR Lower unit 6 LOWR Bracket unit 7 BRKT Electrical systems 8 ELEC Troubleshooting 9 TRBL SHTG Index ...

Page 4: ...es and benefits 1 6 Cylinder body and cylinder head 1 6 Pistons and connecting rods 1 7 Fuel injection pumps 1 8 Flywheel magnet 1 9 ECM Electronic Control Module 1 10 Injector drivers 1 12 Idle silencer 1 13 Power unit mounting bolts 1 14 Cooling water inlet 1 15 Transmission components 1 16 Technical tips 1 17 Electronic control system 1 17 Partial cylinder operation 1 18 Fail safe control 1 19 ...

Page 5: ...Checking the outboard motor mounting height 1 23 Checking the remote control cables 1 23 Checking the steering system 1 24 Checking the gear shift and throttle operation 1 24 Checking the power trim and tilt system 1 24 Checking the engine start switch and engine shut off switch 1 24 Checking the cooling water pilot hole 1 25 Test run 1 25 Break in 1 25 After test run 1 25 ...

Page 6: ...ot reusable 6 Dowel pin 2 7 Bolt 4 M10 40 mm 8 Drain screw 1 9 Grommet 1 10 Bolt 1 M10 45 mm 11 Bolt 1 M8 60 mm 12 Thrust washer 1 13 Propeller 1 14 Washer 1 15 Washer 1 16 Cotter pin 1 Not reusable 17 Propeller nut 1 18 Trim tab 1 LOWR Lower unit 6 19 62Y5A11 Removing the drive shaft 1 Remove the drive shaft assembly and pinion and then pull out the forward gear Disassembling the drive shaft 1 In...

Page 7: ...e electric current Symbols 7 to B in an exploded diagram indicate the grade of lubricant and the lubrication point 7 Apply 2 stroke outboard motor oil 8 Apply water resistant grease Yamaha grease A 9 Apply molybdenum disulfide grease 0 Apply corrosion resistant grease Yamaha grease D A Apply low temperature resistant grease Yamaha grease C B Apply injector grease Symbols C to H in an exploded diag...

Page 8: ...sing an air compressor Protect your hands and feet by wearing pro tective gloves and safety shoes when neces sary Parts lubricants and sealants Use only genuine Yamaha parts lubricants and sealants or those recommended by Yamaha when servicing or repairing the out board motor Under normal conditions the lubricants men tioned in this manual should not harm or be hazardous to your skin However you s...

Page 9: ...e center and moving outward Non reusable parts Always use new gaskets seals O rings cot ter pins circlips etc when installing or assembling parts Disassembly and assembly 1 Use compressed air to remove dust and dirt during disassembly 2 Apply engine oil to the contact surfaces of moving parts before assembly 3 Install bearings with the manufacture identification mark in the direction indi cated in...

Page 10: ...al number The outboard motor serial number is stamped on a label attached to the port clamp bracket 1 Model name 2 Approved model code 3 Transom height 4 Serial number Applicable models Z250DETO LZ250DETO Model name Approved model code Starting serial No Z250DETO 60V X 1000001 U 1000001 LZ250DETO 60W X 1000001 U 1000001 ...

Page 11: ... to reduce friction The spark plugs have been offset from the center of the cylinder head to keep the fuel injectors away from high temperatures The fuel injectors are located on the exhaust side of the combustion chambers Fuel is injected toward the tumble due to scavenging to obtain the optimum air fuel mixture Special twin corrugated washers have been adopted in the injectors to prevent fuel in...

Page 12: ... The piston rings have been processed with a hard chrome plating that has a thickness of 50 microns The big end bearings have been processed with 18 rollers 2 rollers more than those of the VX250 250C and with oil grooves around the outer race of the bearings The small ends of the connecting rods have been processed with a special heat treatment Oil grooves have been processed around the outer per...

Page 13: ...r High pressure fuel injection obtains a better air fuel mixture due to finer atomization CAUTION Do not disassemble the fuel injection pumps The proper facilities and special service tools are required to reassemble them 1 Fuel pump drive unit 2 High pressure fuel pump with pressure regulator 3 Fuel return hose 4 Pressure equalizing pipe 5 Fuel pressure sensor 6 Fuel rail 7 Injector 1 8 Injector ...

Page 14: ...n made available for use with an accessory battery 1 Fuse 2 Battery 1 3 Battery 2 4 Lighting coil 5 Control circuit 6 Blue 7 Black 8 Rectifier Regulator unit 9 Isolator cable optional È Charging circuit É Charging output Ê Charging current A Ë Engine speed r min S60V1160 G R R G G B 93 mm 3 66 in 3 8 m 12 5 ft 2 7 m 9 ft 88 mm 3 46 in 1 2 3 4 4 È É 0 55 1 000 2 000 3 000 4 000 5 000 6 000 Ê Ë 10 1...

Page 15: ...ted for installing the ECM and injector driver brackets and to reduce vibration conducting from the engine CAUTION Do not apply fuel or oil to the grommets otherwise they can be damaged 1 Silicon grommet navy blue 2 ECM and injector drivers mounting bracket S60V1170 168 mm 6 61 in 180 mm 7 09 in 126 mm 4 96 in Z200 Z200N Z250 Z250D 135 mm 5 31 in ECM ECM S60V1180 1 2 Features and benefits ...

Page 16: ...t the electrical components from water 1 Large electrical component cover The memory in the ECM has been increased from 128 bytes to 256 bytes to expand the functions of the YDIS A communication cable with a USB connector has been made available 1 USB connector S60V1190 1 S60V1200 1 ...

Page 17: ...injector drivers have been adopted to make the surrounding components compact Maintenance has been made easy and low cost for replacing the driver has been obtained S60V1210 170 mm 6 69 in 96 mm 3 78 in 180 mm 7 09 in 175 mm 6 89 in Z200 Z200N Z250 Z250D Features and benefits ...

Page 18: ...Thank you very much for your reading Please click here and go back to the website Then you can download the complete manual instantly No waiting ...

Page 19: ...re led into the idle silencer from the upper case and expanded and then dis charged into the atmosphere The idle hole has been positioned higher at the rear of the bottom cowling to decrease the resis tance of the exhaust back pressure 1 Upper case 2 Silencer 3 Idle hole 4 Atmosphere È Exhaust gas water É Water S60V1220 2 1 3 4 È É ...

Page 20: ...e thread holes and crystallizes Also the bolts can be removed even if corroded particles have collected in and choked the bolt holes because the sealing agent also acts as an insulator As a result servicing such as removing the power unit has been made easy NOTE Clean the bolt surface and then apply LOCTITE 572 to the bolt to act as a sealing agent when reus ing the power unit mounting bolts 1 Sea...

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