1987-1989 Yamaha 150/175/200HP 2-Stroke Outboard Service & Repair Manual

1987 - 1989 OUTBOARD SERVICE MANUAL Model : 200ETLF, 200ETLG, 200ETLH, 200ETXF, 200ETXG, 200ETXH, L200ETXG, PROV150F, PROV150G, PROV150LH, V6EXCELLF 6J9281972100 *6J9281972100*

150H, 175H, 200H, V6 EXCEL ProV150H, L150H, L200H SERVICE MANUAL © 1986 by Yamaha Motor Corporation, U.S.A. 1st edition, NOVEMBER 1986 All rights reserved. Any reprinting or unauthorized use without the written permissionof Yamaha Motor Corporation, U.S.A. isexpresslyprohibited. Printed in U.S.A. P/N. LIT-18616-00-25

EXTERNAL VIEW V6 Excel 150HP,175HP,200HP _!°°'

NOTICE HOW TO USE THIS This manual was written by the Yamaha Motor MAN UAL Company primarily for use byYamaha dealersand PARTICULARLY IMPORTANT INFOR- their qualifiedmechanics. It is not possibleto put MATION an entire mechanic's education into one manual, This material is distinguished by the following so it is assumed that persons using this book to notation. perform maintenance and repairs on Yamaha outboard motors have a basic understanding of the NOTE: mechanical concepts and procedures inherent in A NOTE provides key information to make pro- outboard motors repair technology. Without such cedures easier or clearer. knowledge, attempted repairs or service to this modelmay render it unfit to use and/or unsafe. !i!!!iii_i_ii_i_iiiiiiiiii:iil Yamaha Motor Company, Ltd. is continually striv- A CAUTION indicates special procedures that ing to improve all models manufactured by must be followed to avoid damage to the out- Yamaha. Modifications and significant changes board motors. in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where WARNIN( : applicable, appear in future editions of this manual. A WARNING indicates special procedures that must be followed to avoid injury to a outboard motors operator or person inspecting or repair- ing the outboard motors. MANUAL FORMAT All of the procedures in this manual are organiz- ed in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection 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/Damage-, Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures. OPERATING SEQUENCE Part numbers ((_), (_, (_...)in this manual indicate the sequence of disassembly, assembly, and inspection procedures.

(_ (_ SYMBOL MARKS (Refer to the illustration) r-e Symbol marks @ to (_ are designed as thumb EN tabs to indicate the chapter's number and _ {_ AL_..._ i _i content. _ [e_wa (_ General information (_) Periodic inspections and adjustments (_) Fuel system and carburetion @ Power head overhaul (_ (_ ® Lower unit overhaul [L I 1_: i I [ _ ® Electricalsystem (_ Remote control OWR ELEC ® Appendices ® RMOTI CO,T, ,I. +='1 (_ Symbol marks _ to (_ indicate specific data as ® [8_) _ the following items: ® Recommended oil @ @ (_ Recommended grease ]_ i_ (_ Zighteningtorque (_ Wear limit @ Engine speed (_) Resistance @ @ J Symbol marks @ to @ in the exploded diagram j | indicate of lubricant and location grade of lubri- ,IE Q cation point. (_ Apply engine oil (_ Gear caselubricant @ @ (_ Apply marine grease _m,_ _ Symbol marks @ to (_ in the exploded diagram indicate grade of sealing agent and location of (_) sealing agent point. @ Apply GASKET MAKER @ Quick gasket

INDEX GENERAL INFORMATION GEN INFO PERIODIC INSPECTIONS AND ADJUSTMENTS INSP ADJ FUEL SYSTEM AND CARBURETION FUEL POWER HEAD OVERHAUL _: LOWER UNIT OVERHAUL '_ ELECTRICAL SYSTEM i .,I.- REMOTE CONTROL RMOT APPENDICES APPX

I GEN ,.o111' [ CHAPTER1 GENERAL INFORMATION OUTBOARD MOTOR IDENTIFICATION ...................................... 1- 1 MODEL AND SERIAL NUMBER .......................................... 1- 1 ENGINE SERIAL NUMBER .............................................. 1- 1 IMPORTANT INFORMATION .............................................. 1-2 GASKET AND SEALS .................................................. 1- 2 CIRCLIPS ............................................................ 1- 2 LOCK WASHERS AND COTTER PINS .................................... 1- 2 BEARINGS AND OI L SEALS ............................................ 1- 2 TECHNICAL FEATURES .................................................. 1- 3 GENERAL .......................................................... 1- 3 ELECTRICAL ........................................................ 1- 6 POWER TRIM AND TILT ............................................... 1-10 OIL INJECTION SYSTEM .............................................. 1-15 OVERHEAT AND OIL LEVELWARNING SYSTEM .......................... 1-21 YAMAHA MICRO-COMPUTER IGNITION SYSTEM (Y.M.I.S.) (V6 Excel) ........ 1-25 FUNCTIONS OF Y.M.I.S ................................................. 1-28 Y.M.I.S. OPERATION NOTES ............................................ 1-35 SWITCH PANEL DESIGNED FOR TWIN-ENGINE MOUNT .................... 1-36 LOWER UNIT ............................................................ 1-42 CONSTRUCTION ...................................................... 1-42 SHIFT MECHANISM .................................................. 1-44 PROPELLER AND PROPELLER SELECTION .................................. 1-48 FUNCTION OF THE PROPELLER ........................................ 1-48 MOVEMENT OF THE PROPELLER IN THE WATER .......................... 1-48 PROPELLER PITCH .................................................... 1-49 PROPELLER SELECTION .............................................. 1-50 HIGH PERFORMANCE PROPELLER ...................................... 1-52 COOLING SYSTEM ...................................................... 1-53 SPECIAL TOOLS ........................................................ 1-55 FOR TUNE-UP ........................................................ 1-55 FOR ENGINE SERVICE ................................................ 1-56 FOR LOWER UNIT SERVICE ............................................ 1-58 FOR LOWER UNIT SERVICE (L200, L150) ................................ 1-62 FOR POWER TRIM AND TILT .......................................... 1-63 FOR ELECTRICAL COMPONENTS ....................................... 1-63 FOR ELECTRICAL COMPONENTS (V6 Excel) .............................. 1-64 FOR RIGGING ........................................................ 1-64 SEALING AGENTS AND LUBRICANTS ...................................... 1-65 SEALING AGENTS .................................................... 1-65 LUBRICANTS ........................................................ 1-65

[GE"I I OUTBOARD MOTOR IDENTIFICATION INFO GENERAL INFORMATION OUTBOARD MOTOR IDENTIFICA- TION MODEL AND SERIAL NUMBER The model and serial number plate is attached to the port side clamp bracket. @ Number plate @ Starting serial numbers: / i Ii_iiiii!ii_i_ii!iiiiii_!iiii!ili!i!iiil _ lii_ii(i_il i_iii_Aiiii!il / 150H L: 403875_ YAMAHAliiiiiiiiiiiiii!iiiiiiiiiiiiiiiiii!iiiiiiiil ] ×: 51694- 175H L: 401442 X: 751257 ~ /YAMAHA M()TOR CO.,LTD.\ / 200H L: 401412_ /MADE IN J,_PAN \ I X: 752053_ /PAYS D'ORI31NE JAPON \.,) V6EXCELH L: 300106 / _ X: 700115 _ L150 X: 700488 _ L200H X: 700524 ProV150H L: 302441 (_) Model name (_ Approved model No. (_) Transom height @ Serial number ENGINE SERIAL NUMBER The engine serial number is stamped on the plate _T attached to the cylinder body. NOTE: Designs and specifications are subject to change without notice. I-_ _ Engine serial number 1-1

°E. 1 INFO j IMPORTANT INFORMATION IMPORTANT INFORMATION GASKETS AND SEALS 1. All gasketsand sealsshouldbe replacedwhen an engine is overhauled. All gasket surfaces and oil seal lips must be cleaned. 2. Properlyoil all mating parts and bearingsdur- ing reassembly. CIRCLIPS 1. All circlips should be inspected carefully (_/(_ before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circllp, make sure that the /////_/_/_'////_/ sharp edged corner is positioned opposite to the thrust it receives. See the sectional view f below. (_) (_ Thrust (_ Shaft (_ Circlip @ Sharp edged corner LOCK WASHERS AND COTTER PINS 1. All lock washers and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the ring nut flat(s) after the ring nut has been properly tightened. (_ Lock washer BEARINGS AND OIL SEALS 1. Install the bearing(s) with their manufacturer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.). When installing bearings liberally oil the bearings. (_ Bearing Do not use compressed air to spin the bearings dry. This causes damage ta the bearing surfaces. ,nsta,, sea,,s i c marine grease to outside diameter of the oil seal(s). (_ Oil seal 1-2

GEN --=,== TECHNICAL FEATURES INFO | TECHNICAL FEATURES GENERAL 150HP, 175HP, 200HP and ProV150 Engine: Top cowling: (ProV150) The engine features smooth A special design for bass acceleration and increased fishing is adopted, power at high speeds, Mount rubbers: To ensure boating stability at high speeds, newly designed mount rubbers are (_) used. Power trim and tilt: P.T.T. tilt angles ranging Cooling waterinlet: from 8° to 28° , and the The water inlet is so shaped additional 4° negative trim that a sufficient amount of to permit the boat to be cooling water can be sucked in a parallel running posi- in with a high-mounted tion quickly, engine. Bracket unit: Bracket unit allowing P.T.T. to operate with negative ._l trim. Speedometer sensor: The speedometer sensor is so installed that the meter Lower case: readings are always Correct 1. It is streamlined to mini- with a high-mount engine, mize water resistance so that the boat speed can be increased. 2. Full engine performance can be displayed with the Gears: (ProV150) engine in a high mount The gear design allows to and high trim position. mount a high speed, high pitch propeller. 1-3

1987-1989 Yamaha 150/175/200HP 2-Stroke Outboard Service & Repair Manual

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