Yamaha 150A User manual

64C-28197-Z8-11
SERVICE
MANUAL
150A, 150F,
L150F, D150H,
175D, 200F,
L200F, 200G,
225D

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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.
150A, 150F, L150F, D150H, 175D,
200F, L200F, 200G, 225D
SERVICE MANUAL
 1998 Yamaha Motor Co., Ltd.
1st Edition, October 1998
All rights reserved.
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.

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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
inspection operations.
For instance, the condition of a faulty component will precede an arrow symbol and the
course of action required will follow the symbol.
• 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 150AET L150AET 150FETO L150FETO 150GETO
USA and
Canada name C150TR — — S150TR — L150TR P150TR
Indication 150AET L150AET 150FETO S150FETO L150FETO LS150FETO 150GETO
Model name D150HETO 175AET 175DETO 175FETO 200AET L200AET
USA and
Canada name D150TR — — S175TR P175TR — —
Indication D150HETO 175AET 175DETO S175DETO 175FETO 200AET L200AET
Model name 200FETO L200FETO 200GETO 225DET 225DETO
USA and
Canada name 200TR S200TR — L200TR P200TR — —
Indication 200FETO S200FETO L200FETO LS200FETO 200GETO 225DET 225DETO

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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.
SPECIFICATIONS
These are given in bold type at each procedure. It is not necessary to 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 system Pre-mixed Pre-mixed Oil injection Oil injection Oil injection
Model name D150HETO 175AET 175DETO 175FETO 200AET L200AET
USA and
Canada name D150TR — — S175TR P175TR — —
Lubrication system Oil injection Pre-mixed Oil injection Oil injection Pre-mixed Pre-mixed
Model name 200FETO L200FETO 200GETO 225DET 225DETO
USA and
Canada name 200TR S200TR — L200TR P200TR — —
Lubrication system Oil injection Oil injection Oil injection Pre-mixed Oil injection

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HOW TO USE THIS MANUAL
1 The main points regarding removing/installing and disassembling/assembling procedures
are shown in the exploded views.
2 The numbers in the exploded views indicate the required sequence of the procedure and
should be observed accordingly.
3 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.
4 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)
5 In addition to tightening torques, the dimensions of the bolts and screws are also men-
tioned.
Example:
Bolt and screw size : bolt and screw diameter (D) × length (L)
6 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.
d
D
10 ×25 mm
D
L

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SYMBOLS
Symbols 1 to 9 are designed as thumb-
tabs to indicate the content of a chapter.
1 General information
2 Specifications
3 Periodic inspections and adjustments
4 Fuel system
5 Power unit
6 Lower unit
7 Bracket unit
8 Electrical systems
9 Trouble analysis
Symbols 0 to E indicate specific data.
0 Special tool
A Specified liquid
B Specified engine speed
C Specified torque
D Specified measurement
E Specified electrical value
[Resistance ( Ω ), Voltage (V), Electric current
(A)]
Symbol F to H in an exploded 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 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
12
34
56
78
90
AB
CD
EF
GH
IJ
KL
MN
GEN
INFO SPEC
INSP
ADJ FUEL
POWR
LOWR
BRKT –+
ELEC
TRBL
ANLS
T
R
.
.
E
AM
GM 4
271
LT
242
LT
572
LT LT
SS

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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

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1
2
3
4
5
6
7
8
9
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 ............................................................... 1-7

1-1
GEN
INFO
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IDENTIFICATION
IDENTIFICATION 1
SERIAL NUMBER
The outboard motor’s serial number is
stamped on a label which is attached to the
port clamp bracket.
NOTE:
As an antitheft measure, a special label on
which the outboard motor’s serial number
is stamped is bonded to the port clamp
bracket. The label is specially treated so
that peeling it off causes cracks across the
serial number.
1 Model name
2 Approval model code
3 Transom height
4 Serial number
S67H1010
1020
STARTING SERIAL NUMBERS
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: 350991 -
L150FETO —6K0 L: 350142 - S200TR X: 506004 -
L150TR — X: 501152 - L200FETO —6K1 L: 350141 -
150GETO P150TR 6J9 L: 502379 - L200TR — X: 501625 -
D150HETO D150TR — L: 601301 - 200GETO P200TR 61H L: 502516 -
175AET —
6G5
L: 302440 - 225DET —
6K7
L: 400393 -
X: 701017 - X: 500160 -
175DETO — L: 350273 - 225DETO — L: 450255 -
S175TR — X: 501252 - X: 550266 -

1-2
GEN
INFO
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SAFETY WHILE WORKING
SAFETY WHILE WORKING 1
The procedures given in this manual are
those recommended by Yamaha to be fol-
lowed by Yamaha dealers and their
mechanics.
FIRE PREVENTION
Gasoline (petrol) is highly flammable.
Petroleum vapor is explosive if ignited.
Do not smoke while handling gasoline and
keep it away from heat, sparks and open
flames.
1030
VENTILATION
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.
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 protective
shoes if appropriate to the work you are
doing.
1050
OILS, GREASES AND SEALING
FLUIDS
Use only genuine Yamaha oils, greases and
sealing fluids or those recommended by
Yamaha.
1060

1-3
GEN
INFO
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SAFETY WHILE WORKING
Under normal conditions of use, there
should be no hazards from the use of the
lubricants mentioned in this manual, but
safety is all-important, and by adopting
good safety practices, any risk is minimized.
A summary of the most important precau-
tions is as follows:
1. While working, maintain good stan-
dards of personal and industrial
hygiene.
2. Clothing which has become contami-
nated with lubricants should be
changed as soon as practicable, and
laundered before further use.
3. Avoid skin contact with lubricants; do
not, for example, place a 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 wiping purposes.
GOOD WORKING PRACTICES
1. The right tools
Use the recommended special tools to
protect parts from damage. Use the
right tool in the right manner – do not
improvise.
2. Tightening torque
Follow the tightening torque instruc-
tions. When tightening bolts, nuts and
screws, tighten the large sizes first, and
tighten inner-positioned fixings before
outer-positioned ones.
1070

1-4
GEN
INFO
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SAFETY WHILE WORKING
3. Non-reusable items
Always use new gaskets, packings, O-
rings, split-pins, circlips, etc., on reas-
sembly.
1080
DISASSEMBLY AND ASSEMBLY
1. Clean parts 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.

1-5
GEN
INFO
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SPECIAL TOOLS
SPECIAL TOOLS 1
Using the correct special tools recom-
mended by Yamaha, will aid the work and
enable accurate assembly and tune-up.
Improvising and using improper tools can
damage the equipment.
NOTE:
• For U.S.A. and Canada, use part numbers
that start with “J-”, “YB-”, “YM-”, “YU-”
or “YW-”.
• For others countries, use part numbers
that start with “90890-”.
MEASURING
1 Tachometer
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
90890-07003
0 Hydraulic pressure gauge
P/N. 90890-06776
A Up-relief valve attachment
P/N. 90890-06773
Down-relief valve attachment
P/N. 90890-06774
1b
23
45
67
89
0A
a

1-6
GEN
INFO
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SPECIAL TOOLS
B Digital tester
P/N. J-39299
90890-06752
C Peak voltage adapter
P/N. YU-39991 ................................ a
90890-03169 ........................... b
D Spark gap tester
P/N. YM-34487 ............................... a
90890-06754 ........................... 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
JTest harness
P/N. YB-06770, YB-38831,
YB-38832
90890-06770, 90890-06771,
90890-06772
Cb
B
a
Dba
EF
IJ
GH

1-7
GEN
INFO E
SPECIAL TOOLS
REMOVING AND INSTALLING
1Flywheel magnet assembly holder
P/N. YB-06139 ................................ a
90890-06522 ........................... b
2Universal puller
P/N. YB-06117 ................................ a
90890-06521 ........................... b
3Bearing/oil seal attachment
P/N. YB-06196 ................................ a
90890-06610, 90890-06637 .... b
4Driver rod
P/N. YB-06071
90890-06602, 90890-06604,
90890-06605, 90890-06606,
90890-06652
5Bearing/oil seal attachment
P/N. YB-06205
90890-06663
6Bearing/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
7Piston ring compressor
P/N. YU-33294 ................................ a
90890-06530 ........................... b
8Bearing separator
P/N. YB-06219 ................................ a
90890-06534 ........................... b
9Guide plate stand
P/N. 90890-06538
0Guide plate
P/N. 90890-06501
1ba
3
ba
45
6
90
7ba
8ba
2ba

1-8
GEN
INFO E
SPECIAL TOOLS
ABearing puller
P/N. 90890-06535
BBearing/oil seal attachment
P/N. 90890-06659, 90890-06660,
90890-06661, 90890-06662
CRing nut wrench
P/N. YB-34447
90890-06512
DRing nut wrench extension
P/N. YB-06513
90890-06513
EPropeller shaft housing puller
P/N. YB-06207 ................................ a
YB-06502 ................................ b
90890-06502
FCenter bolt
P/N. 90890-06504
GSlide hammer
P/N. YB-06096
90890-06531
HSmall universal claws
P/N. 90890-06536
IBearing/oil seal depth plate
P/N. YB-06213, YB-34474 .............. a
90890-06603 ........................... b
JDrive shaft holder
P/N. YB-06201
90890-06520
KPinion nut holder
P/N. 90890-06505
LPinion nut holder attachment
P/N. 90890-06508
MBearing/oil seal attachment
P/N. 90890-06609, 90890-06612,
90890-06631, 90890-06633,
90890-06636, 90890-06653
NBearing puller
P/N. YB-06029, YB-06247
90890-06523
OLarge universal claws
P/N. 90890-06532
AB
CD
FG
H
JK
LM
NO
Eba
Iba

1-9
GEN
INFO E
SPECIAL TOOLS
PSlide hammer attachment
P/N. YB-06335
90890-06514
QRing nut wrench
P/N. YB-42223
RBearing/oil seal attachment
P/N. YB-42225
SBearing/oil seal attachment
P/N. YB-42227
TBearing/oil seal attachment
P/N. YB-42229
90890-06607
UPinion nut holder
P/N. YB-42224
VEnd screw wrench
P/N. YB-06548
90890-06548
WEnd screw wrench
P/N. YB-06175-1A
XUniversal puller
P/N. YB-06540
90890-06540
PQ
RS
TU
VW
X

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SPEC
1
2
3
4
5
6
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

2-1
SPEC
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GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS 2
Item Unit
Model
Worldwide 150AET L150AET 175AET 200AET L200AET
USA C150TR ————
Canada —————
DIMENSION
Overall length
mm (in) 828 (32.6)
Overall width
mm (in) 600 (23.6)
Overall height
(L)
mm (in) 1,577 (62.1) — 1,577 (62.1) —
(X)
mm (in) 1,703 (67.0)
Boat transom height
(L)
mm (in) 508 (20.0) — 508 (20.0) —
(X)
mm (in) 635 (25.0)
WEIGHT
(with aluminum
propeller)
(L)
kg (lb) 178 (392.4) — 178 (392.4) —
(X)
kg (lb) 182 (401.2) — 182 (401.2) —
(with stainless steel
propeller)
(L)
kg (lb) 180 (396.8) — 180 (396.8) —
(X)
kg (lb) 184 (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
cm
3
(cu. in) 2,596 (158.4)
Bore × stroke
mm (in) 90.0 × 68.0 (3.54 × 2.68)
Compression ratio
6.2 6.0 5.9
Compression pressure
kPa (kg/cm
2
) 745 (7.45) 892 (8.92)
Spark plugs (NGK)
BR8HS-10/BR8HS-10
*1
Number of carburetors
3
Enrichment system
Choke valve
Intake system
Reed valve
Induction system
Loop charge
Exhaust system
Through prop boss
Lubrication system
Pre-mix
Cooling system
Water
*1
: For china