Yamaha Z200N Manual de usuario

68F-28197-Z9-A1

WORLDWIDE

Z200N

LZ200N

Z200Y

LZ200Y

USA, CANADA

SERVICE MANUAL

290369

PREFACE

This manual has been prepared by the Yamaha Motor Company, Ltd. primarily for use by

Yamaha dealers and their trained mechanics when performing maintenance procedures and

repairs to Yamaha equipment. It has been written to suit the needs of persons who have a

basic understanding of the mechanical and electrical concepts and procedures inherent in the

work, for without such knowledge attempted repairs or service to the equipment could render

it unsafe or unfit for use.

Because the Yamaha Motor Company, Ltd. has a policy of continuously improving its prod-

ucts, 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.

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 another

2-stroke engine oil with a BIA-certified TC-W3 rate.

Z200N, LZ200N

SERVICE MANUAL

1st Edition, October 1999

No part of this publication may be

reproduced or transmitted in any form or by

any means including photocopying and

recording without the written permission of

the copyright holder.

Such written permission must also be

obtained before any part of this publication

is stored in a retrieval system of any nature.

Printed in Japan

P/N 68F-28197-Z9-A1

HOW TO USE THIS MANUAL

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

check operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and

the course of action required 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 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 Z200NETO LZ200NETO

USA and

Canada name Z200TR LZ200TR

Indication Z200NETO LZ200NETO

IMPORTANT INFORMATION

In this Service Manual particularly important information is distinguished in the following

ways.

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 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.

HOW TO USE THIS MANUAL

The main points regarding removing/installing and disassembling/assembling procedures

are shown in the exploded views.

The numbers in the exploded views indicate the required sequence of the procedure and

should be observed accordingly.

Symbols are used in the exploded views to indicate important aspects of the procedure.

A list of meanings for these symbols is provided on the following page.

It is important to refer to the job 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)

In addition to tightening torques, the dimensions of the bolts or screws are also men-

tioned.

Example:

Bolt or screw size : diameter (D)

length (L)

In addition to the exploded views and job instruction charts, this manual provides individ-

ual illustrations when further explanations are required to explain the relevant procedure.

10 ×25 mm

SYMBOLS

Symbols

are designed as thumb-

tabs to indicate the content of a chapter.

General information

Specifications

Periodic inspections and adjustments

Fuel system

Power unit

Lower unit

Bracket unit

Electrical systems

Trouble analysis

Symbols

indicate specific data.

Special tool

Specified liquid

Specified engine speed

Specified torque

Specified measurement

Specified electrical value

[Resistance (

Ω

), Voltage (V), Electric current

(A)]

Symbol

in an exploded diagram

indicate the grade of lubricant and the loca-

tion of the lubrication point.

Apply Yamaha 2-stroke outboard motor oil

(TC-W3)

Apply water resistant grease

(Yamaha grease A, Yamaha marine grease)

Apply molybdenum disulfide oil

Symbols

Nin an exploded diagram

indicate the grade of the sealing or locking

agent and the location of the application

point.

IApply Gasket Maker®

JApply Yamabond #4

(Yamaha bond number 4)

KApply LOCTITE®No. 271 (Red LOCTITE)

LApply LOCTITE®No. 242 (Blue LOCTITE)

MApply LOCTITE®No. 572

NApply silicon sealant

GEN

INFO SPEC

INSP

ADJ FUEL

POWR

LOWR

BRKT –+

ELEC

TRBL

ANLS

GM 4

271

242

572

LT LT

CONTENTS

GENERAL INFORMATION 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

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

IDENTIFICATION

............................................................................................ 1-1

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

1-1

GEN

INFO

IDENTIFICATION

SERIAL NUMBER

The outboard motor’s serial number is

stamped on a label which is attached to the

port side of the clamp bracket.

NOTE:

If the serial number label is removed,

“VOID” marks will be appear on the label.

Model name

Approved model code

Transom height

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 -

LZ200NETOLZ200TR —6K1 X:100101 -

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