Yamaha 150AET User manual

E
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

1-1
GEN
INFO
E
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 -

1-5
GEN
INFO
E
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

2-6
SPEC E
GENERAL SPECIFICATIONS
* PON: Pump Octane Number
RON: Research Octane Number
Exhaust system Through prop boss
Lubrication system Oil injection Pre-mix Oil
injection
Cooling system Water
Ignition system Microcomputer (CDI)
Starting system Electric
Advance type Mechanical and microcomputer
FUEL AND OIL
Fuel type Unleaded regular gasoline
Fuel rating *PON
RON
86
91
Engine oil type 2-stroke outboard engine oil
Engine oil grade TC-W3
Engine oil capacity
(engine oil tank) L (US qt,
lmp qt)
0.9 (0.95, 0.79) — 0.9
(0.95,
0.79)
(sub-oil tank) L (US qt,
lmp qt)
10.5 (11.1, 9.2) — 10.5
(11.1,
9.2)
Gear oil type Hypoid gear oil SAE 90
Gear oil total quantity cm3(US oz,
lmp oz)
980
(33.1, 34.5)
870
(29.4, 30.6)
980
(33.1, 34.5)
BRACKET
Trim angle
(at 12˚ boat transom)
Degree –4 - 16
Tilt-up angle Degree 70
Steering angle Degree 35 + 35
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 Counterclock-
wise
Clockwise
Item Unit
Model
Worldwide 175FETO 200FETO L200FETO 200GETO 225DET 225DETO
USA P175TR 200TR S200TR — L200TR P200TR ——
Canada P175TR — S200TR — — P200TR ——

3-1
INSP
ADJ
E
MAINTENANCE INTERVAL CHART
MAINTENANCE INTERVAL CHART 3
Use the following chart as a guide to general maintenance intervals.
Dependant on operating conditions, adjust the maintenance intervals accordingly.
Item Remarks
Initial Every Refer
to page
10 hours
(Break-in)
50 hours
(3 months)
100 hours
(6 months)
200 hours
(1 year)
TOP COWLING
Top cowling fit Inspect 3-2
FUEL SYSTEM
Fuel line Inspect 3-2
Fuel filter Clean/inspect 3-3
Carburetor Clean 4-17
POWER UNIT
Water leakage Inspect —
Motor exterior Inspect —
Exhaust leakage Inspect —
Cooling water passage Clean/flush —
CONTROL SYSTEM
Carburetor synchroni-
zation
Inspect/adjust 3-6
Engine idling speed Inspect/adjust 3-7
Remote control shift
cable
Inspect/adjust 3-11
Remote control
throttle cable
Inspect/adjust 3-11
OIL INJECTION SYSTEM
Oil tank water drain Clean —
Oil pump lever Inspect/adjust 3-12
POWER TRIM AND TILT UNIT
Power trim and tilt fluid Inspect 3-16
LOWER UNIT
Gear oil Change 3-17
Lower unit leakage Inspect 3-19
Propeller Inspect 6-3, 6-27,
6-51
GENERAL
Anodes Inspect/replace 3-19
Battery Inspect/charge (every month) 3-20
Spark plugs Clean/adjust/replace 3-21
Wiring and connectors Adjust/reconnect —
Bolts and nuts Tighten —
Lubrication points Grease 3-23

4-4
FUEL
E
4
Order Job/Part Q’ty Remarks
8 Fuel filter 1
9 Bolt 1
10 Fuel filter bracket 1
11 Fuel filter cap 1
12 Fuel filter element 1
13 O-ring 1
14 Fuel filter cup 1
For installation, reverse the removal
procedure.
4020
FUEL JOINT AND FUEL FILTER

5-1
POWR
E
FLYWHEEL MAGNET ASSEMBLY
FLYWHEEL MAGNET ASSEMBLY 5
REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY 5
Å S150F, LS150F, S175D, S200F, LS200F/S150TR, L150TR, S175TR, S200TR, L200TR
ı Oil injection and 225DET models
Ç Pre-mix except for 225DET models
Order Job/Part Q’ty Remarks
1 Flywheel magnet assembly cover 1
2 Flywheel magnet assembly nut 1
3 Washer 1
4 Flywheel magnet assembly 1
5 Woodruff key 1
For installation, reverse the removal
procedure.
5010

5-28
POWR
E
5
5
Order Job/Part Q’ty Remarks
9 Gasket 2
10 Thermo switch 2
11 Engine cooling water
temperature sensor
1
12 Bolt 2
13 Ground lead 2
14 Bolt 28
15 Cylinder head 2
16 Gasket 2
For installation, reverse the removal
procedure.
5250
Not reusable
Not reusable
CYLINDER HEADS

5-50
POWR
E
CYLINDER BODY ASSEMBLY
INSTALLING THE CRANKSHAFT
ASSEMBLY 5
Install:
• Cylinder body
• Crankshaft assembly
NOTE:
• Align the crankshaft labyrinth ring end
gaps with their respective locating pins.
• Install the bearing locating pins into the
cylinder body.
5570
INSTALLING THE PISTON AND
CONNECTING ROD ASSEMBLIES 5
Install:
• Piston and connecting rod assembly
NOTE:
• Before installing the piston and connect-
ing rod assemblies, lubricate the cylinder
walls with 2-stroke outboard engine oil.
• Reinstall the piston and connecting rod
assemblies in their original cylinders.
• Install the piston and connecting rod
assemblies with the “S” mark in the star-
board side cylinders, and those with the
“P” mark in the port side cylinders.
• The “UP” mark on the piston crown must
face towards the flywheel.
Piston ring compressor
YU-33294 / 90890-06530
5580
5590

6-39
E
LOWR
PROPELLER SHAFT HOUSING ASSEMBLY
(COUNTER ROTATION MODELS)
INSPECTING THE DOG CLUTCH
Inspect:
• Dog clutch
Damage/wear → Replace.
INSPECTING THE PROPELLER SHAFT
Inspect:
• Propeller shaft
Damage/wear → Replace.
ASSEMBLING THE PROPELLER
SHAFT HOUSING
1. Install:
• Needle bearing
Å For USA and Canada
ı Except for USA and Canada
Needle bearing installation
position a
24.75 - 25.25 mm
(0.974 - 0.994 in)
Bearing/oil seal attachment .... 1
YB-06196 / 90890-06610
Driver rod .................................. 2
YB-06071 / 90890-06604
Bearing/oil seal depth plate .... 3
90890-06603
6231
Å
6086
ı
2. Install:
• Oil seal
Oil seal installation position a
4.75 - 5.25 mm (0.187 - 0.207 in)
Bearing/oil seal attachment
YB-06195 / 90890-06633
6232

6-54
E
LOWR
6
Order Job/Part Q’ty Remarks
8 Spacer 1
9 Washer 2
10 Wave washer 1
11 Impeller 1
12 Woodruff key 1
For installation, reverse the removal
procedure.
6330
WATER PUMP (DUAL PROPELLER MODELS)

6-70
E
LOWR
INNER PROPELLER SHAFT ASSEMBLY
(DUAL PROPELLER MODELS)
INNER PROPELLER SHAFT ASSEMBLY (DUAL PROPELLER MODELS) 6
DISASSEMBLING/ASSEMBLING THE INNER PROPELLER SHAFT ASSEMBLY
Order Job/Part Q’ty Remarks
1 Spring 1
2 Pin 1
3 Front dog clutch 1
4 Front gear assembly 1
5 Washer 1 (with oil groove a)
6 Spring 1
Continued on next page.
6430

6-80
E
LOWR
SHIMMING (REGULAR ROTATION MODELS)
(FOR USA AND CANADA)
SELECTING THE FORWARD GEAR
SHIMS
NOTE:
Find the shim thickness (T1) by selecting
shims until the specified value (M0) is
obtained with the special tool.
6525
1. Measure:
• Specified measurement (M)
Out of specified value (M0) →Adjust.
Measuring steps
(1) Calculate the specified value (M0).
NOTE:
• “F” is the deviation of the lower case
dimension from standard. It is stamped
on the trim tab mounting surface of the
lower case in 0.01-mm units. If the “F”
mark is missing or unreadable, assume an
“F” value of “0”, and check the backlash
when the unit is assembled.
• If the “F” mark is negative (–), then sub-
tract the “F” value from the measure-
ment.
Example:
If “F” is “+5”, then
M0 = 1.60 + (+5)/100 mm
= 1.60 + 0.05 mm
= 1.65 mm
If “F” is “–3”, then
M0 = 1.60 + (–3)/100 mm
= 1.60 – 0.03 mm
= 1.57 mm
Specified value (M0) =
1.60 + F/100 mm
6526
6530

6-92
E
LOWR
BACKLASH (REGULAR ROTATION MODELS)
Measuring steps
(1) Set the shift rod into the neutral posi-
tion.
Shift rod wrench
YB-06052 / 90890-06052
6645
(2) Load the reverse gear by installing the
propeller without the spacer 1 and
then tighten the propeller nut.
T
R
.
.
Propeller nut
10 Nm (1.0 m • kgf, 7.2 ft • lb)
6665
(3) Install the backlash indicator onto the
drive shaft (on the 22.4 mm (0.88 in)
diameter portion of the drive shaft).
(4) Install the dial gauge onto the lower
unit and have the dial gauge plunger
contact the mark on the backlash indi-
cator.
(5) Set the lower unit upside down.
(6) Slowly turn the drive shaft clockwise
and counterclockwise. When the drive
shaft stops in each direction, measure
the backlash.
Backlash indicator .................... 1
YB-06265 / 90890-06706
Magnetic-base plate................. 2
YB-07003 / 90890-07003
Dial gauge set ........................... 3
YU-03097 / 90890-01252
Magnetic base........................... 4
YU-34481 / 90890-06705
6670

6-118
E
LOWR
BACKLASH (DUAL PROPELLER MODELS)
BACKLASH
(DUAL PROPELLER MODELS) 6
NOTE:
• Do not install the water pump compo-
nents when measuring the backlash.
• Measure both the forward and reverse
gear backlashes.
• If both the forward and reverse gear back-
lashes are larger than specification, the
pinion may be too high.
• If both the forward and reverse gear back-
lashes are smaller than specification, the
pinion may be too low.
MEASURING THE FRONT GEAR
BACKLASH
1. Measure:
• Front gear backlash
Out of specification →Adjust.
Measuring steps
(1) Set the shift rod into the neutral posi-
tion.
(2) Install the propeller shaft housing
puller so it pushes against the inner
propeller shaft.
Front gear backlash
0.19 - 0.59 mm (0.007 - 0.023 in)
Shift rod wrench
YB-06052 / 90890-06052
Propeller shaft housing puller . 1
YB-06502 / 90890-06502
Universal puller......................... 2
YB-06540 / 90890-06540
T
R
.
.
Universal puller
10 Nm (1.0 m • kgf, 7.2 ft • lb)
6645
2
1
6807