YAMAHA 200A, L200A PARTS CATALOGUE

200A

L200A

SERVICE MANUAL

290446

60H-28197-5E-11

NOTICE

This manual has been prepared by Yamaha 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 Yamaha has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. 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.

Important information

Particularly important information is distinguished in this manual by the following notations:

⁄The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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.

A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

200A, L200A

SERVICE MANUAL ©2002 by Yamaha Motor Co., Ltd.

1st Edition, February 2002 All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

is expressly prohibited. Printed in Japan

Contents

– +

GEN INFO

General information

General information

How to use this manual ................................................................................................	1-1
Manual format ...........................................................................................................	1-1
Symbols ....................................................................................................................	1-2
Safety while working .....................................................................................................	1-3
Fire prevention ..........................................................................................................	1-3
Ventilation .................................................................................................................	1-3
Self-protection ...........................................................................................................	1-3
Parts, lubricants, and sealants ..................................................................................	1-3
Good working practices ............................................................................................	1-4
Disassembly and assembly ......................................................................................	1-4
Identification ..................................................................................................................	1-5
Applicable models .....................................................................................................	1-5
Serial number ...........................................................................................................	1-5
Features and benefits ...................................................................................................	1-6
Hour meter ................................................................................................................	1-6
Exhaust components (Factory option) ......................................................................	1-7
Piston and cylinder ...................................................................................................	1-8
Connecting rod .........................................................................................................	1-9
Gasket.....................................................................................................................	1-10
Reduction gear and clutch ......................................................................................	1-11
Power unit mount bolt .............................................................................................	1-12
Propeller selection ......................................................................................................	1-13
Propeller size ..........................................................................................................	1-13
Selection .................................................................................................................	1-13
Predelivery checks ......................................................................................................	1-14
Checking the fuel system ........................................................................................	1-14
Checking the gear oil ..............................................................................................	1-14
Checking the battery ...............................................................................................	1-14
Checking the outboard motor mounting position ....................................................	1-14

60H5E11

	Checking the remote control cables........................................................................	1-15
	Checking the steering system .................................................................................	1-15
	Checking the gearshift and throttle operation	1-15
			1
	Checking the tilt sytem ............................................................................................	1-15
	Checking the engine start switch and engine stop switch, engine shut-off switch .........	1-16
	Checking the pilot water outlet ................................................................................	1-16
	Test run ...................................................................................................................	1-16
	Break-in ..................................................................................................................	1-17
	After test run ...........................................................................................................	1-17

60H5E11

GEN INFO

General information

How to use this manual

Manual format

The format of this manual has been designed to make service procedures clear and easy to understand. Use the information below as a guide for effective and quality service.

1 Parts are shown and detailed in an exploded diagram and are listed in the components list.

2Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions.

3Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and lubrication point.

4 The components list consist of parts and part quantities, as well as bolt, screw, O-ring, and hose dimensions.

5 Service points regarding removal, checking, and installation are shown in individual illustrations to explain the relevant procedure.

NOTE:

For troubleshooting procedures, see Chapter 9, “Troubleshooting.”

2

POWR	Power unit

Removing the exhaust cover

1. Remove the pressure control valve.

60H50250

2.Remove the exhaust outer cover, and the exhaust inner cover.

60H50260

60H50265

NOTE:

Loosen the bolts in the sequence shown.

3.Remove the cylinder block exhaust inner cover.

4.Check the pressure control valve for cracks or damage. Also check the pressure control valve seat for deformation. Replace them if necessary.

60H50270

5.Check the spring for fatigue or deformation. Replace it if necessary.

6.Check the exhaust cover for distortion or corrosion. Replace it if necessary.

				Exhaust / Cylinder head
Cylinder head
		13
			14
		1
				3	A
			2
				4	5
					6
					7	8
						9	5
					15
			11	12			3
					10
						60H50280	1
No.	Part name	Q’ty		Remarks
1	Gasket	2
2	Cylinder head	2
3	Thermo switch	2
4	Gasket	2
5	Cylinder head cover	2
6	Gasket	2
7	Thermostat	2
8	Thermostat cover	2
9	Bolt	8	M6 x 40 mm
10	Bolt	36 M6 x 30 mm
11	Bolt	24 M8 x 60 mm					4
12	Clamp	1
13	Bolt	2	M8 x 20 mm
14	Engine hanger	1
15	Spark plug	6

60H50275

5-21

60H5E11

60H5E11

5-22

5

1-1

60H5E11

How to use this manual

Symbols

The symbols below are designed to indicate the content of a chapter.

General information

Fuel system

Bracket unit

1

GEN

FUEL

BRKT

INFO

Specifications

Power unit

Electrical systems

SPEC

POWR

ELEC

Periodic checks and adjustments Lower unit

Troubleshooting

CHK

LOWR

TRBL

ADJ

SHTG

Symbols 1 to 6 indicate specific data.

1	2	3	4	5	6
				T
				.
				R
				.
1 Special tool			4 Specified tightening torque
2 Specified oil or fluid			5 Specified measurement
3 Specified engine speed			6 Specified electrical value

(Resistance, Voltage, Electric current)

Symbols 7 to B in an exploded diagram indicate the grade of lubricant and the lubrication point.

7

8

9

0

A

B

E

7 Apply Yamaha 4-stroke motor oil	A Apply low temperature resistant grease
8 Apply water resistant grease (Yamaha grease A)	(Yamaha grease C)
9 Apply molybdenum disulfide grease	B Apply injector grease

0Apply corrosion resistant grease (Yamaha grease D)

Symbols C to H in an exploded diagram indicate the type of sealant or locking agent and the application point.

C

D

E

F

G

H

C Apply Gasket Maker	F Apply LOCTITE 242 (Blue)
D Apply Yamabond 4	G Apply LOCTITE 572
E Apply LOCTITE 271 (Red)	H Apply silicon sealant

60H5E11

1-2

GEN INFO

General information

Safety while working

To prevent an accident or injury and to ensure quality service, follow the safety procedures provided below.

Fire prevention

Gasoline is highly flammable.

Keep gasoline and all flammable products away from heat, sparks, and open flames.

Ventilation

Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If inhaled in large quantities they may cause loss of consciousness and death within a short time. When test running an engine indoors (e.g., in a water tank) be sure to do so where adequate ventilation can be maintained.

Self-protection

Protect your eyes by wearing safety glasses or safety goggles during all operations involving drilling and grinding, or when using an air compressor.

Protect your hands and feet by wearing protective gloves and safety shoes when necessary.

Parts, lubricants, and sealants

Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the outboard motor.

Under normal conditions, the lubricants mentioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants.

1.Maintain good standards of personal and industrial hygiene.

2.Change and wash clothing as soon as possible if soiled with lubricants.

3.Avoid contact with skin. Do not, for example, place a soiled rag in your pocket.

4.Wash hands and any other part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made.

5.To protect your skin, apply a protective cream to your hands before working on the outboard motor.

1-3

60H5E11

		Safety while working
6. Keep a supply of clean, lint-free cloths for	Disassembly and assembly
wiping up spills, etc.	1.	Use compressed air to remove dust and
		dirt during disassembly.		1
Good working practices	2.	Apply engine oil to the contact surfaces of
Special tools
Use the recommended special tools to protect		moving parts before assembly.

parts from damage. Use the right tool in

	the right manner-do not improvise.	3. Install bearings with the manufacture iden-
		tification mark in the direction indicated in
		the installation procedure. In addition, be
		sure to lubricate the bearings liberally.
		4. Apply a thin coat of water-resistant grease
		to the lip and periphery of an oil seal be-
		fore installation.
		5. Check that moving parts operate normally
		after assembly.
	Tightening torques
	Follow the tightening torque specifications
	provided throughout the manual. When tight-
	ening nuts, bolts, and screws, tighten the
	large sizes first, and tighten fasteners starting
	in the center and moving outward.
	Non-reusable parts
	Always use new gaskets, seals, O-rings, cot-
	ter pins, circlips, etc., when installing or
	assembling parts.

60H5E11

1-4

GEN INFO

General information

Identification

Applicable models

This manual covers the following models.

Applicable models

200AET,L200AET

Serial number

The outboard motor serial number is stamped on a label attached to the port clamp bracket.

60H10000

1 Model name

2 Approved model code

3 Transom height

4 Serial number

NOTE:

If the serial number label is removed, VOID marks will appear on the label.

	Model name	Approved	Starting
		model code	serial No.
	200AET	60H	L: 800101-
			X: 850101-
	L200AET	60J	X: 800101-

1-5

60H5E11

Identification / Features and benefits

Features and benefits

Hour meter

A hour meter is incorporated for easier control of interval time for the periodic maintenance.

As the main switch is turned on, all segments light up for 2 seconds to check that the Light Emitting 1 Diode is not failed.

Then, the meter indicates the total of hours which the engine has been run since manufacture. The indicated hour is the accumulated time detected by the pulse signal from the lighting coil. The accumulated hour is held forever, and cannot reset.

		Hour meter
	Hour meter
		Grand (B)
	Pulse	Power source (Y)
	(G/W)
Lighting			(R)	Main
coil		Rectifier
		Regulator	Fuse	switch
	(G)

(B)

Flywheel magnet

(B)

Battery

Wiring diagram

G/W : Green/White

G	: Green
Y	: Yellow
B	: Black
R	: Red

60H10010

60H5E11

1-6

GEN INFO

General information

Exhaust components (Factory option)

The cylindrical components have been painted externally and internally after the anodic oxide coating to make a film for additional corrosion-resistance.

Muffler

Exhaust guide plate

Exhaust manifold extension (Muffler 2)

Exhaust manifold

For X transom

	60H10030
1-7	60H5E11

Features and benefits

Piston and cylinder

Following items have been given to improve the durability for the piston and cylinder.

A hard anodic oxide coating has been given to the piston pin boss and piston ring groove of the #1

and #2 piston. 1 Multilayer plating has been given to the piston ring.

The cylinder sleeve without the exhaust slit has been adopted not to accumulate some deposits, which can prevent the piston rings from entwining.

Also, the shape of the exhaust port has been given the gradual curve design to obtain the best engine performance and avoid scuffing of the piston ring.

Hard anodic oxide coating

Piston

Exhaust slit

Exhaust port

Scavenging port

Cylinder sleeve	Cylinder sleeve
(Previous models)	(New models)

60H10040

60H5E11

1-8

GEN
INFO	General information

Connecting rod

A process of the carburizing and quenching has been given to the inside of the small end to increase the strength.

The small end bearing has been given 18 rollers, adding one roller from the previous model, to increase the durability.

The mating face of the big end bearing has been given a large area to increase the rigidity after assembling the bearing cap, which increases the rigidty.

Also, a silver plating (30-40µ) has been given to the outside portion of the big end to increase the less friction.

Carburizing and quenching

Identification mark

Bearing with 18 rollers

Silver plating

Larger mating face

Connecting rod and bearings

	60H10050
1-9	60H5E11

Features and benefits

Gasket

The intake manifold gasket has been given a silicon bead to increase more sealer.

1

Silicon bead

Silicon bead

Gasket with silicon bead

60H10060

60H5E11

1-10

GEN INFO

General information

Reduction gear and clutch

The process of the double shot-peening has been given to the surface of the teeth portion of the pinion gear, forward gear and dog clutch to increase the durability.

Dog clutch

Forward gear

	Pinion gear
	60H10070
1-11	60H5E11

Features and benefits

Power unit mount bolt

A fully threaded bolt coated with a sealing material to the thread portion has been adopted for mounting the power unit.

This gives a sealing function to the bolt, which will help prevent the bolt from sticking by the salt water 1 entering into the thread hole and crystallizing .

Also, the bolt can come out by turning, due to the full thread structure and the sealing material having a function as an insulator, even if the bolt hole has been choked with corroded particles.

Therefore, an easier servicing such as removing the power unit can be obtained.

NOTE:

Apply a sealing material such as LOCTITE 572 to the bolt thread if the bolt is reused.

Bolt

Sealing material

Corroded particles

Bolt hole

Coating with a sealing material

Full threaded bolt

60H10080

60H5E11

1-12

GEN INFO

General information

Propeller selection

The performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boating and steering capabilities. An incorrect choice could adversely affect performance and could also seriously damage the engine.

Use the following information as a guide for selecting a propeller that meets the operating conditions of the boat and the outboard motor.

Propeller size

The size of the propeller is indicated on the propeller blade or outside of the propeller boss.

-

S60C1110

-

Selection

When the engine speed is at the full throttle operating range (4,500 – 5,500 r/min), the ideal propeller for the boat is one that provides maximum performance in relation to boat speed and fuel consumption.

Regular rotation model

Propeller size (in)	Material
13 1/2 x 23-M
13 3/8 x 23-M
13 3/8 x 25-M
13 3/4 x 17-M
13 3/4 x 19-M2
13 3/4 x 21-M	Stainless steel
14 x 19-M
14 1/2 x 17-M
14 5/8 x 16-M
15 1/4 x 15-M
15 3/4 x 13-M
Counter rotation model
Propeller size (in)	Material
13 3/4 x 17-ML
13 3/4 x 19-ML
13 3/4 x 21-ML	Stainless steel
13 3/8 x 23-ML
14 1/2 x 17-ML

S60C1125

A Propeller diameter (in inches)

B Propeller pitch (in inches)

C Propeller type (propeller mark)

1-13

60H5E11

Features and benefits / Propeller selection

Predelivery checks

To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below.

Checking the fuel system

1.Check that the fuel hoses are securely connected and that the fuel tank is full with fuel.

60H00000

Use pre-mixed fuel only.

Fuel and oil mixing ratio is 50:1. For breakin period, 25:1 mixture shall be used.

Checking the gear oil

1. Check the gear oil level.

60H30450

Checking the battery

1.Check the capacity, electrolyte level, and specified gravity of the battery.

	Recommend battery:	1
	CCA / SAE (Minimum) : 380 (A)
	CCA / EN (Minimum) : 430 (A)
	RC (Minimum) : 124 (Minute)
	20HR (Minimum) : 70 (AH)
	JIS: 65D31-95E41
	Electrolyte specified gravity:
	1.280 at 20°C (68°F)

2.Check that the red and black battery cables are securely connected.

Checking the outboard motor mounting position

1.Check that the anti-cavitation plate is aligned with the bottom of the boat. If the mounting height is too high, cavitation will occur and propulsion will be reduced.

Also, the engine speed will increase abnormally and cause the engine to overheat. If the mounting height is too low, water resistance will increase and reduce engine efficiency.

S60C1160

NOTE:

The optimum mounting height is affected by the combination of the boat and the outboard motor. To determine the optimum mounting height, test run the outboard motor at different heights.

2.Check that the clamp brackets are secured with the mounting bolts.

60H5E11

1-14

GEN INFO

General information

Checking the remote control cables

1.Set the remote control lever to the neutral position and fully close the throttle lever.

2.Check that the basic ignition timing adjusting screw 1 on the magnet control lever is in contact with the stopper 2 on the crankcase when the throttle lever is in the fully closed position.

Checking the steering system

1. Check that the steering operates smoothly.

60H30110

3.Check that the set pin on the shift rod is aligned with the arrow mark A on the bottom cowling .

60H30427

60H10420

The shift/throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) B.

60H10090

2.Check that there is no interference with wires, hoses, or remote control cable when the outboard motor is steered.

Checking the gearshift and throttle operation

1.Check that the gearshift operates smoothly when the remote control lever is shifted from neutral into forward or reverse.

2.Check that the throttle operates smoothly when the remote control lever is shifted from the fully closed position to the fully open

position A.

N

F R

S60C1210

Checking the tilt system

1.Check that the outboard motor tilts up and down smoothly when operating the power trim and tilt unit.

	60H10095
1-15	60H5E11

	Predelivery checks
2. Check that there is no abnormal noise pro-	Checking the pilot water outlet
duced when the outboard motor is tilted up	1. Start the engine, and check that cooling wa-
or down.
	ter is discharged from the pilot water outlet.		1
3. Check that there is no interference with
wires, hoses, or remote control cable when
the tilted-up outboard motor is steered.
4. Check that the trim meter points down when
the outboard motor is trimmed all the way
down.
Also check that the trim meter moves to-	60H30100
ward up position when the outboard motor
is trimmed up.	Test run
Checking the engine start switch and	1. Start the engine, and then check the en-
	gine idle speed after the engine has been
engine stop switch, engine shut-off	warmed up.
switch

1.Check that the engine starts when the engine start switch is turned to START.

60H10097

2.Check that the engine turns off when the engine start switch is turned to OFF.

3.Check that the engine turns off when the engine shut-off cord is pulled from the engine shut-off switch.

2.Check that the gearshift operates smoothly.

3.Operate at trolling speed.

4.Run the outboard motor for one hour at 3,000 r/min or at half throttle, then for another hour at 4,000 r/min or at 3/4 throttle.

5.Check that the outboard motor does not tilt up when shifting into reverse and that water does not flow in over the transom.

NOTE:

The test run is part of the break-in operation.

S60C1220

60H5E11

1-16

GEN INFO

General information

Break-in

Perform the break-in operation in the following four stages.

1.Keep the engine running at idle for the initial ten minutes.

After test run

1.Check for water in the gear oil.

2.Check for fuel leakage in the cowling.

3.After a test run and while the engine is at idle, flush the cooling water passage with fresh water using the flushing kit.

60H10100

2. Fifty minutes at 3,000 r/min. or less.

60H10110

3. One hour at 4,000 r/min. or less.

60H10120

4.For another eight hours, run at 5,000 r/min. or less, with repeated wide-open-throttle operation that lasts five minutes or less.

	60H10130
1-17	60H5E11

SPEC

Specifications

	Genral Specifications ....................................................................................................	2-1
	Maintenance specifications ..........................................................................................	2-3
	Power Unit.................................................................................................................	2-3
			2
	Lower Unit .................................................................................................................	2-4
	Electrical ...................................................................................................................	2-5
	Dimentions ................................................................................................................	2-7
	........................................................................................................Tightening torques	2-9
	Specified torques ......................................................................................................	2-9
	General torques ......................................................................................................	2-10

60H5E11

SPEC

General Information

Genral Specifications

Item	Unit		Model
			200AET		L200AET
Dimension
Overall length	mm (in)		828(32.6)
Overall width	mm (in)		600(23.6)
Overall height
(L)	mm (in)		1,577(62.1)		–
(X)	mm (in)		1,703(67.0)
Transom height
(L)	mm (in)		516(20.3)		–
(X)	mm (in)		642(25.3)
Weight(*1)
(L)	kg (lb)		180(396)		–
(X)	kg (lb)		184(405)		186(410)
Performance
Maximum output	kW(HP)		147.1(200) @ 5,000 r/min
Full throttle operating range	r/min		4,500 - 5,500
Maximum fuel consumption	L(US gal,Imp gal)/hr		81(21.4,17.8) @ 5,500 r/min
Idle speed	r/min		700
Power unit
Type			2-stroke,90,V6
Total displacement	cm3 (cu. in)		2,596(158.4)
Bore x Stroke	mm (in)		90.0(3.54) x 68.0(2.68)
Compression ratio			5.9
Minimum compression pressure(*2)	kPa(kg/cm2)		520(5.2)
Control system			Remote control
Starting system			Electric motor
Enrichment system			Choke valve
Ignition control system			CDI
Ignition timing	Degree		ATDC7-BTDC18
Advance pick up timing	Degree		ATDC 7
Maximum generator output	V,A		12,14 @ 5,500 r/min
Spark plug(*3)			B8HS-10,BR8HS-10
Cooling system			Water
Exhaust system			Through propeller boss
Lubrication system			Pre-mixed fuel (50:1)

(*1) Includes a stainless steel propeller and excludes oil and rigging parts. (*2) At 20°C(68°F) and sea level.

(*3) BR8HS-10 is for Carib and China version.

2-1

60H5E11

				Genral Specifications
Item	Unit			Model
			200AET		L200AET
Fuel and oil
Fuel type			Regular unleaded gasoline
Fuel rating	RON(*4)			84
Engin oil type			2-stroke outboard motor oil
Engin oil grade	NMMA-certified			TCW-3
							2
Gear oil type			Hypoid gear oil
Gear oil grade	API			GL-4
	SAE			90
Gear oil quantity	cm3 (oz)		980(34.5)		870(30.6)
Bracket unit	Degree
Trim angl (At 12° boat transom)				– 4 – 16
Tilt-up angle	Degree			70
Steering angle	Degree			35+35
Drive unit
Gear shift positions				F-N-R
Gear ratio				1.86(14/26)
Reduction gear type			Spiral bevel gear
Clutch type				Dog clutch
Propeller shaft type				Spline
Propeller direction (Rear view)			Clocklwise		Counterclockwise
Propeller ID mark			M		ML
Electrical
Recommend battery
CCA / SAE (Minimum)	A			380
CCA / EN (Minimum)	A			430
RC (Minimum)	Minute			120
20HR (Minimum)	AH			70
JIS			65D31-95E41

(*4) RON; Reseach Octance Number

60H5E11

2-2

SPEC

General Information

Maintenance specifications

Power unit

Item	Unit			Model
		200AET			L200AET
Power unit
Compression pressure*	kPa		700 (7.0, 101.5)
(reference data)	(kgf/cm2, psi)
Compression pressure*	kPa			520 (5.2, 75.4)
(minimum)	(kgf/cm2, psi)
Cylinder heads
Warpage limit	mm (in)			0.1 (0.04)
(lines indicate straightedge po-
sition)
Cylinders
Bore size	mm (in)	90.00 - 90.02 (3.5433 - 3.5441)
Bore size limit	mm (in)			90.10 (3.5472)
Taper limit	mm (in)			0.08 (0.0031)
Out-of-round limit	mm (in)			0.05 (0.0020)
Pistons
Piston diameter (D)	mm (in)	89.895	- 89.915 (3.5392 - 3.5400)
Measuring point (H)	mm (in)			10 (0.39)
Piston pin boss inside diameter	mm (in)	23.074-23.085 (0.9084-0.9089)
Oversize piston
1st	mm (in)			+ 0.25 (0.0098)
Oversize piston diameter	mm (in)	90.145	- 90.165 (3.5490 - 3.5498)
2nd	mm (in)			+ 0.5 (0.0196)
Oversize piston diameter	mm (in)	90.395	- 90.415 (3.5589 - 3.5596)
Piston pins
Outside diameter	mm (in)	23.065	- 23.070 (0.9081 - 0.9083)
Piston rings
Top ring, 2nd ring
Dimension B	mm (in)	1.97	- 1.99 (0.0776 - 0.0783)
Dimension T	mm (in)	2.7	- 2.9 (0.1063 - 0.1142)
End gap	mm (in)	0.3	- 0.4 (0.0118 - 0.0157)
Measuring point (H)	mm (in)			20 (0.79)
Side clearance	mm (in)	0.02	- 0.06 (0.0008 - 0.0024)

*Measuring conditions:

Ambient temperature 20°C (68°F), wide open the throttle valve and the choke valve, with plugs disconnected from all cylinders.

The figures are for reference only.

2-3

60H5E11

		Maintenance specifications
Item	Unit	Model
		200AET		L200AET
Connecting rods
Small-end inside diameter	mm (in)	28.070 - 28.082 (1.1051 - 1.1056)
Big-end inside diameter	mm (in)	46.010 - 46.025 (1.8114 - 1.8120)
Big-end side clearance	mm (in)	0.12 - 0.26 (0.0047 - 0.0102)
Small-end axial play limit	mm (in)	2.0 (0.08)
						2
Crankshaft
Crankshaft journal Diameter	mm (in)	53.975 - 53.991 (2.1250 - 2.1256)
Crank pin Diameter	mm (in)	35.985 - 36.000 (1.4167 - 1.4173)
Run-out limit	mm (in)	0.03 (0.0012)
Thermostats
Opening temperature	°C (°F)	50 (122)
Fully open temperature	°C (°F)	60 (140)
Valve open lower limit	mm (in)	3.0 (0.12)
Carburetor
ID mark		64E01
Main jet	#	No.1,3:150 / No.2,4:154 / No.5:152 / No.6:158
Main air jet	#		270
Pilot jet	#		84
Pilot air jet	#		60
Pilot screw	turns out	1 1/8 ± 1/4 (7/8 - 1 3/8)
Float height (with gasket)	mm (in)	15.5 - 16.5 (0.61 - 0.65)
Engine idle speed	r/min	675 - 725
Reed valves
valve stopper height	mm (in)	6.5 (0.26)
warpage limit	mm (in)	0.2 (0.08)
Lower unit
Item	Unit	Model
		200AET		L200AET
Gear backlash
Pinion-to-forward gear	mm (in)	0.25 - 0.46		0.21 - 0.43
		(0.0098 - 0.0181)		(0.0083 - 0.0169)
Pinion-to-reverse gear	mm (in)	0.74 - 1.29		0.98 - 1.30
		(0.0291 - 0.0508)		(0.0386 - 0.0512)
Pinion shims	mm	0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Forward gear shims	mm	0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Reverse gear shims	mm	0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Propeller shaft shims	mm	—		0.10, 0.12, 0.15, 0.18,
				0.30, 0.40, 0.50
Drive shaft	mm (in)
Run-out limit		0.1 (0.0039)
Propeller shaft	mm (in)
End play		—		0.25 - 0.35
				(0.0098 - 0.0138)

60H5E11

2-4

SPEC				General Information
Electrical

Item		Unit		Model
			200AET		L200AET
Ignition system
Ignition timing
(standard ignition timing)		Degree		ATDC 7
(full advance)		Degree		BTDC 18
Piston position
(full advance)		mm (in)		2.05 (0.0807)
Pulser coil output peak voltage
(W/B - W/L, W/Br - W/Y, W/G - W/R)
at cranking 1(*1)		V		2.5
at cranking 2(*1)		V		2.0
at 1,500 r/min		V		9.5
at 3,500 r/min		V		16.0
Pulser coil resistance(*2)		Ω		256 - 384
(W/B - W/L, W/Br - W/Y, W/G - W/R)
Charge coil output peak voltage
(Br - R)
at cranking 1(*1)		V		80
at cranking 2(*1)		V		90
at 1,500 r/min		V		165
at 3,500 r/min		V		165
(L - B/R)
at cranking 1(*1)		V		30
at cranking 2(*1)		V		30
at 1,500 r/min		V		160
at 3,500 r/min		V		165
Charge coil resistance(*2)
(Br - R)		Ω		428 - 642
(L - B/R)		Ω		64.4 - 96.6
CDI unit output peak voltage
(B/W - B)
at cranking (loaded)		V		65
at 1,500 r/min		V		140
at 3,500 r/min		V		135
Spark plug gap		mm (in)	1.0 - 1.1 mm (0.039 - 0.043 in)
Ignition spark gap		mm (in)		6 (0.24)
Spark plug cap resistance		Ω		4.0 - 6.0
Ignition coil resistance
Primary coil (B/W-B)	Ω	at 20°C (68°F)		0.18 - 0.24
Secondary coil (LEAD-B)	Ω	at 20°C (68°F)		3.26 - 4.88
Thermoswitch
ON		°C (°F)	84 - 90 (183 - 194)
OFF		°C (°F)	60 - 74 (140 - 165)
Choke solenoid
Resistance		Ω		3.4 - 4.0

(*1)	Cranking 1: unloaded Cranking 2: loaded
(*2)	The figures are for reference only.

2-5

60H5E11

			Maintenance specifications
Item		Unit	Model
			200AET		L200AET
Starter motor
Type			Bendix
Output		kW	1.1
Cranking time limit		Second	30
Brushes
			17 (0.67)				2
Standard length		mm (in)
Wear limit		mm (in)	10 (0.39)
Commutator
Standard diameter		mm (in)	33 (1.30)
Wear limit		mm (in)	32 (1.26)
Mica
Standard undercut		mm (in)	0.8 (0.031)
Wear limit		mm (in)	0.2 (0.008)
Charging system
Fuse		A	20
Lighting coil output peak
voltage	(G - G/W)
at cranking(*1)		V	3
at 1,500 r/min(*1)		V	20.0
at 3,500 r/min(*1)		V	50.0
Lighting coil resistance(*2)		Ω	0.20 - 0.30
	(G - G/W)
Rectifier Regulator output
peak voltage	(R - B)
at 1,500 r/min(*1)		V	18
at 3,500 r/min(*1)		V	45
Charging current		V, A	12, 14
		at 6,000 r/min
Power trim and tilt system
Trim sensor
Setting resistance		Ω	9 - 11
Resistance	(P - B)	Ω	9 - 379
Fluid type			ATF Dexron II
Brushes
Standard length		mm (in)	9.8 (0.386)
Wear limit		mm (in)	4.8 (0.189)
Commutator
Standard diameter		mm (in)	22 (0.87)
Wear limit		mm (in)	21 (0.83)
Hydraulic pressure (UP)		MPa (kgf/cm2)	10 - 12 (100 - 120)
	(DOWN)	MPa (kgf/cm2)	6 - 9 (60 - 90)

(*1) Unloaded

(*2) The figures are for reference only.

60H5E11

2-6

SPEC				General Information
Dimensions

Exterior mm(in)

426(16.8)

660(26.0)

35

300(11.8)

	788(31.0)		631(24.8)	205(8.1)
L: 946(37.2)	X: 1,072(42.2)	L: 516(20.3)	X: 642(25.3)	26(1.0)	45(1.8)
			210(8.3)

31(1.2)

				L: 1,032(40.6)
569(22.4)				X: 1,144(45.0)
188(7.4)			543(21.4)
		74(2.9)

173(6.8)

L: 48(1.9)

X: 61(2.4)

12

	4
L: 54(2.1)
X: 62(2.4)	634(25.0)

70

L: 762(30.0) X: 837(33.0)

2-7

60H5E11