Yamaha Z150P Manual

68L-28197-ZA-AX
WORLDWIDE
Z150P, LZ150P,
Z150Q, Z175G,
Z150Z, LZ150Z,
VZ150Z, Z175Z,
Z175H, Z200N,
LZ200N, Z200P
LZ200Z, VZ200Z
USA, CANADA
VZ175Z, Z200Z,
SERVICE MANUAL
292067
SUPPLEMENTARY

E
PREFACE
This Supplementary Service Manual has been prepared to introduce the modification and
additional information for the Z200N and LZ200N. Also, new information for Z150P, LZ150P,
Z150Q, Z175G, Z175H and Z200P based on Z200N and LZ200N is included. For complete ser-
vice information and procedures, it is necessary to add the following manual with the corre-
sponding sections in this Supplementary Service Manual.
Z200N, LZ200N SERVICE MANUAL: 68F-28197-Z9-A1
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.
Z150P, LZ150P, Z150Q,
Z175G, Z175H, Z200N, LZ200N, Z200P
SUPPLEMENTARY SERVICE MANUAL
©2000 by Yamaha Motor Co., Ltd.
1st Edition, May 2000
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan

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
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 Z150PETO LZ150PETO Z150QETO Z175GETO Z175HETO Z200NETO LZ200NETO Z200PETO
USA and
Canada name Z150TR LZ150TR VZ150TR Z175TR VZ175TR Z200TR LZ200TR VZ200TR
Indication Z150PETO LZ150PETO Z150QETO Z175GETO Z175HETO Z200NETO LZ200NETO Z200PETO

E
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.

E
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 or screws are also men-
tioned.
Example:
Bolt or screw size : 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

E
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 I in an exploded diagram
indicate the grade of lubricant and the loca-
tion of the lubrication point.
FApply Yamaha 2-stroke outboard motor oil
GApply water resistant grease
(Yamaha grease A, Yamaha marine grease)
HApply molybdenum disulfide grease
IApply corrosion resistant grease
(Yamaha grease D)
Symbols Jto Oin an exploded diagram
indicate the grade of the sealing or locking
agent and the location of the application
point.
JApply Gasket Maker®
KApply Yamabond #4
(Yamaha bond number 4)
LApply silicon sealant
MApply LOCTITE®No. 271 (Red LOCTITE)
NApply LOCTITE®No. 242 (Blue LOCTITE)
OApply LOCTITE®No. 572
12
34
56
78
90
AB
CD
EF
GH
IJ
KL
MNO
GEN
INFO
SPEC
INSP
ADJ
FUEL
POWR
LOWR
BRKT
–+
ELEC
TRBL
ANLS
T
R
.
.
E
AM
DGM
4LT
SS
271
LT
242
LT
572
LT

E
GENERAL INFORMATION
IDENTIFICATION ............................................................................................... 1
SERIAL NUMBER........................................................................................ 1
STARTING SERIAL NUMBERS .................................................................. 1
SPECIAL TOOLS................................................................................................ 2
MEASURING ............................................................................................... 2
REMOVING AND INSTALLING .................................................................. 5
SPECIFICATIONS
GENERAL SPECIFICATIONS............................................................................. 8
MAINTENANCE SPECIFICATIONS................................................................. 14
POWER UNIT............................................................................................. 14
LOWER UNIT............................................................................................. 16
ELECTRICAL .............................................................................................. 16
POWER UNIT............................................................................................. 20
LOWER UNIT............................................................................................. 22
ELECTRICAL .............................................................................................. 22
DIMENSIONS ............................................................................................ 26
TIGHTENING TORQUES................................................................................. 31
SPECIFIED TORQUES............................................................................... 31
GENERAL TORQUES................................................................................ 33
PERIODIC INSPECTION AND ADJUSTMENT
MAINTENANCE INTERVAL CHART............................................................... 34
FUEL SYSTEM ................................................................................................. 36
MEASURING THE FUEL PRESSURE
(MEDIUM-PRESSURE FUEL LINE).......................................................... 36
CHECKING THE FUEL PRESSURE (MECHANICAL FUEL PUMP).......... 37
CHECKING THE MECHANICAL FUEL PUMP OIL LEVEL........................ 38
CHANGING THE MECHANICAL FUEL PUMP OIL .................................. 38

E
CONTROL SYSTEM......................................................................................... 39
ADJUSTING THE THROTTLE POSITION SENSOR................................. 39
ADJUSTING THE REMOTE CONTROL SHIFT CABLE
(EXCEPT FOR Z150Q, Z175H/VZ150, VZ175) ......................................... 41
ADJUSTING THE REMOTE CONTROL SHIFT CABLE
(FOR Z150Q, Z175H/VZ150, VZ175) ........................................................ 42
ADJUSTING THE CRANK POSITION SENSOR....................................... 42
OIL INJECTION SYSTEM................................................................................ 43
AIR BLEEDING THE OIL INJECTION SYSTEM........................................ 43
CHECKING THE ELECTRIC OIL PUMP..................................................... 44
POWER TRIM AND TILT SYSTEM ................................................................. 44
CHECKING THE POWER TRIM AND TILT FLUID LEVEL ........................ 44
ADJUSTING THE TRIM SENSOR CAM................................................... 45
LOWER UNIT ................................................................................................... 46
CHECKING THE GEAR OIL LEVEL ........................................................... 46
CHANGING AND CHECKING THE GEAR OIL ......................................... 46
CHECKING THE LOWER UNIT (FOR AIR LEAKS)................................... 47
GENERAL ......................................................................................................... 48
CHECKING THE SPARK PLUGS............................................................... 48
CHECKING THE IGNITION TIMING ......................................................... 49
MEASURING THE COMPRESSION PRESSURE ..................................... 51
LUBRICATION POINTS............................................................................. 52
FUEL SYSTEM
MEDIUM-PRESSURE FUEL LINE ................................................................... 53
REDUCING THE FUEL PRESSURE
(MEDIUM-PRESSURE FUEL LINE).......................................................... 53
CHECKING THE PRESSURE REGULATOR.............................................. 53
VAPOR SEPARATOR....................................................................................... 56
REMOVING/INSTALLING THE VAPOR SEPARATOR............................. 56
ELECTRIC FUEL PUMP.................................................................................... 58
DISASSEMBLING/ASSEMBLING THE ELECTRIC FUEL PUMP ............. 58
DRIVE BELT ..................................................................................................... 61
REMOVING/INSTALLING THE DRIVE BELT............................................ 61
HIGH-PRESSURE FUEL LINE ASSEMBLY..................................................... 63
DISASSEMBLING/ASSEMBLING THE HIGH-PRESSURE FUEL LINE
ASSEMBLY............................................................................................... 63

E
MECHANICAL FUEL PUMP ............................................................................ 66
DISASSEMBLING/ASSEMBLING THE MECHANICAL
FUEL PUMP BODY................................................................................... 66
POWER UNIT
POWER UNIT ................................................................................................... 69
REMOVING/INSTALLING THE EXHAUST EXPANSION CHAMBER ..... 69
INSTALLING THE APRON ........................................................................ 71
REED VALVES ................................................................................................. 72
CHECKING THE REED VALVE ASSEMBLY ............................................. 72
CRANKCASE.................................................................................................... 72
ASSEMBLING THE OIL SEAL HOUSING ................................................ 72
CYLINDER BODY ASSEMBLY ........................................................................ 73
DISASSEMBLING THE UPPER BEARING HOUSING ............................. 73
ASSEMBLING THE UPPER BEARING HOUSING ................................... 73
LOWER UNIT
LOWER UNIT (REGULAR ROTATION MODELS) .......................................... 74
REMOVING/INSTALLING THE LOWER UNIT ......................................... 74
PROPELLER SHAFT HOUSING ASSEMBLY
(REGULAR ROTATION MODELS) ................................................................. 76
DISASSEMBLING THE PROPELLER SHAFT HOUSING ......................... 76
ASSEMBLING THE PROPELLER SHAFT HOUSING ............................... 77
DRIVE SHAFT (REGULAR ROTATION MODELS).......................................... 78
REMOVING/INSTALLING THE DRIVE SHAFT......................................... 78
REMOVING THE PINION .......................................................................... 80
DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY .............. 80
DISASSEMBLING THE FORWARD GEAR ASSEMBLY .......................... 80
ASSEMBLING THE FORWARD GEAR ASSEMBLY ................................ 81
ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY .................... 81
INSTALLING THE PINION ........................................................................ 82
LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS)..................... 83
DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY ....... 83
DISASSEMBLING THE LOWER CASE ASSEMBLY ................................ 84
ASSEMBLING THE LOWER CASE ASSEMBLY ...................................... 84

E
LOWER UNIT (COUNTER ROTATION MODELS).......................................... 85
REMOVING/INSTALLING THE LOWER UNIT ......................................... 85
PROPELLER SHAFT HOUSING ASSEMBLY
(COUNTER ROTATION MODELS)................................................................. 87
ASSEMBLING THE PROPELLER SHAFT HOUSING ............................... 87
DRIVE SHAFT (COUNTER ROTATION MODELS) ......................................... 88
REMOVING/INSTALLING THE DRIVE SHAFT......................................... 88
REMOVING THE PINION .......................................................................... 90
REMOVING THE REVERSE GEAR............................................................ 90
DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY .............. 90
DISASSEMBLING THE REVERSE GEAR ASSEMBLY............................. 90
ASSEMBLING THE REVERSE GEAR ASSEMBLY................................... 91
ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY .................... 92
INSTALLING THE REVERSE GEAR.......................................................... 92
INSTALLING THE PINION ........................................................................ 93
LOWER CASE ASSEMBLY (COUNTER ROTATION MODELS) .................... 93
ASSEMBLING THE LOWER CASE ASSEMBLY ...................................... 93
SHIMMING (REGULAR ROTATION MODELS)
(FOR USA AND CANADA) ............................................................................. 94
SELECTING THE REVERSE GEAR SHIMS............................................... 95
SHIMMING (REGULAR ROTATION MODELS) (FOR WORLDWIDE) ........... 97
SELECTING THE REVERSE GEAR SHIMS............................................... 98
BACKLASH (REGULAR ROTATION MODELS)............................................ 100
MEASURING THE FORWARD GEAR BACKLASH ................................ 100
MEASURING THE REVERSE GEAR BACKLASH................................... 102
SHIMMING (COUNTER ROTATION MODELS)
(FOR USA AND CANADA) ........................................................................... 105
SELECTING THE FORWARD GEAR SHIMS .......................................... 106
SHIMMING (COUNTER ROTATION MODELS) (FOR WORLDWIDE)......... 108
BACKLASH (COUNTER ROTATION MODELS) ........................................... 109
MEASURING THE FORWARD GEAR BACKLASH ................................ 109
MEASURING THE REVERSE GEAR BACKLASH................................... 110