YAMAHA 225G, 250B, L250B PARTS CATALOGUE

225G, 250B, L250B

SERVICE

MANUAL

65L-28197-Z8-11

E

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 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.

225G, 250B, L250B

SERVICE MANUAL

1998 Yamaha Motor Co., Ltd.

1st Edition, November 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 reference 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 follows.

	Model name	200HETO	225FETO	L225FETO	225GETO	250BETO	L250BETO
	USA and	V200TR	S225TR	L225TR	V225TR	S250TR	L250TR
	Canada name
	Indication	200HETO	225FETO	L225FETO	225GETO	250BETO	L250BETO

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.

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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 outboard motor.

NOTE:

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

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HOW TO USE THIS MANUAL

1The main points regarding removing/installing and disassembling/assembling procedures are shown in the exploded views.

2The numbers in the exploded views indicate the required sequence of the procedure and should be observed accordingly.

3Symbols 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.

4It 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 providing 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)
			D

d

5In addition to tightening torques, the dimensions of the bolts and screws are also mentioned.

Example:

Bolt and screw size

: bolt and screw diameter (D) × length (L)

10 × 25 mm

D

L

6In addition to the exploded views and job instruction charts, this manual provides individual illustrations when further explanations are required to explain the relevant procedure.

E

12

GEN			SPEC
INFO

34

	INSP	FUEL
	ADJ

56

POWRLOWR

78

BRKT

ELEC

– +

90

TRBL

ANLS

AB

CD

T .

R .

EF

E

GH

A

M

IJ

GM

4

KL

LT	LT
271	242

MN

LT	SSLT

572

SYMBOLS

Symbols 1 to 9 are designed as thumbtabs 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

ESpecified electrical value

[Resistance (Ω), Voltage (V), Electric current (A)]

Symbol F to H in an exploded diagram indicate the grade of lubricant and the location of the lubrication point.

FApply Yamaha 2-stroke outboard motor oil (TC-W3)

GApply water resistant grease

(Yamaha grease A, Yamaha marine grease)

H Apply molybdenum disulfide oil

Symbols I to N in an exploded diagram indicate the grade of the sealing or locking agent and the location of the application point.

I Apply Gasket Maker

JApply Yamabond #4 (Yamaha bond number 4)

K Apply LOCTITE No. 271 (Red LOCTITE) L Apply LOCTITE No. 242 (Blue LOCTITE) M Apply LOCTITE No. 572

N Apply silicon sealant

		E
CONTENTS
GENERAL INFORMATION					1
		INFOGEN
SPECIFICATIONS					2
		SPEC
PERIODIC INSPECTIONS AND					3
ADJUSTMENTS
		INSPADJ

FUEL SYSTEM

POWER UNIT

FUEL 4

POWR 5

LOWER UNIT LOWR 6

BRACKET UNIT								7
	BRKT
								8
			– +
ELECTRICAL SYSTEMS
	ELEC

TROUBLE ANALYSIS	9
ANLSTRBL

	GEN
	INFO			E
				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

2

3

4

5

6

7

8

9

GEN INFO

IDENTIFICATION

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IDENTIFICATION

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

1020

STARTING SERIAL NUMBERS

The starting serial number blocks are as follows:

Model name				Approval	Starting
World-	USA		Canada	model	serial
wide				code	number
200HETO	V200TR		—	66X	L: 000589 ~
225FETO	S225TR		S225TR	62J	X: 102470 ~
					U: 200423 ~
L225FETO	L225TR		—	62K	X: 100950 ~
					U: 200132 ~
225GETO	V225TR		—	66K	L: 300483 ~
250BETO	S250TR		S250TR	61A	X: 102033 ~
					U: 200711 ~
L250BETO	L250TR		—	61B	X: 101047 ~
					U: 200263 ~

1-1

GEN INFO

SAFETY WHILE WORKING

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SAFETY WHILE WORKING

The procedures given in this manual are those recommended by Yamaha to be followed 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

1040

1050

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.

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.

OILS, GREASES AND SEALING FLUIDS

Use only genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha.

1060

1-2

GEN INFO

SAFETY WHILE WORKING

E

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 precautions is as follows:

1.While working, maintain good standards of personal and industrial hygiene.

2.Clothing which has become contaminated 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 wipingrag in your pocket.

4.Hands and any other part of the body which have been in contact with lubricants or lubricant-contaminated clothing, should be thoroughly washed with hot water and soap as soon as practicable.

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-

1070	tions. When tightening bolts, nuts and
	screws, tighten the large sizes first, and
	tighten inner-positioned fixings before
	outer-positioned ones.

1-3

GEN INFO

SAFETY WHILE WORKING

E

3.Non-reusable items

Always use new gaskets, packings, O- rings, split-pins, circlips, etc., on reassembly.

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.

1-4

GEN INFO

SPECIAL TOOLS

SPECIAL TOOLS

E

Using the correct special tools recommended 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-”.
1		• For others countries, use part numbers
a	b		that start with “90890-”.

		MEASURING
		1	Tachometer
			P/N. YU-08036-A ............................	a
2	3		90890-06760 ...........................	b
		2	Pressure tester
			P/N. YB-35956
			90890-06762
		3	Mity vac
			P/N. YB-35956
			90890-06756
4	b	4	Pinion height gauge
a			P/N. YB-06441	a
			90890-06702 ...........................	b
		5	Dial gauge set
			P/N. YU-03097
			90890-01252
		6	Magnetic base
5	6		P/N. YU-34481
			90890-06705
		7	Digital caliper
			P/N. 90890-06704
		8	Backlash indicator
			P/N. YB-06265
7	8		90890-06706
		9	Magnetic base attaching plate
			P/N. YB-07003
			90890-07003
		0	Fuel pressure gauge
			P/N. YB-06766
9	0		90890-06766

1-5

	GEN			SPECIAL TOOLS
	INFO					E
					A Hydraulic pressure gauge
	A			B
					P/N.	90890-06776
					B Up-relief valve attachment
					P/N.	90890-06773
					Down-relief valve attachment
					P/N.	90890-06774
					C Digital tester
	C				P/N. J-39299
						90890-06752
					D Peak voltage adapter
					P/N. YU-39991 ................................ a
						90890-03169 ........................... b
					E Spark gap tester
	D				P/N. YM-34487 ............................... a
	a			b		90890-06754 ........................... b
					F Diagnostic indicator
					P/N. YB-06765
						90890-06765
					G Shimming gauge
					P/N. YB-06439, YB-06440
	E				H Shimming plate
					P/N.	90890-06701
	a			b
					I Shift rod wrench
					P/N. YB-06052
						90890-06052
					J Test harness
					P/N. YB-06443, YB-06767,
						YB-06768, YB-06769,
						YB-06770, YB-38831,
	F			G		YB-38832
						90890-06757, 90890-06767,
						90890-06768, 90890-06769,
						90890-06770, 90890-06771,
						90890-06772

H I

J

1-6

	GEN			SPECIAL TOOLS
	INFO						E
					REMOVING AND INSTALLING
1
				b	1	Flywheel magnet assembly holder
	a					P/N. YB-06139	a
						90890-06522 ...........................	b
					2	Universal puller
						P/N. YB-06117 ................................	a
2						90890-06521 ...........................	b
					3 Bearing/oil seal attachment
	a			b
						P/N. YB-06196 ................................	a
						90890-06610 ...........................	b
					4	Driver rod
						P/N. YB-06071
						90890-06604, 90890-06605,
3						90890-06606, 90890-06652
	a			b	5 Bearing/oil seal attachment
						P/N. YB-06432
					6	Bearing/oil seal attachment
						P/N. YB-06194, YB-06246,
4				5		YB-06276-B, YB-06337,
						YB-06430
						90890-06622, 90890-06656,
						90890-06657, 90890-06658
					7	Piston ring compressor
6						P/N. YU-33294 ................................	a
						90890-06530	b
					8	Bearing separator
						P/N. YB-06219 ................................	a
						90890-06534 ...........................	b
					9	Guide plate stand
						P/N. 90890-06538
					0	Guide plate
						P/N. 90890-06501

7

ab

8

ab

90

1-7

	GEN			SPECIAL TOOLS
	INFO						E
					A Bearing puller
	A			B
						P/N.	90890-06535
					B Bearing/oil seal attachment
						P/N.	90890-06659, 90890-06661,
							90890-06662
	C			D	C Ring nut wrench
						P/N.	90890-06510
					D Ring nut wrench
						P/N. YB-06048
					E Propeller shaft housing puller
						P/N. YB-06207 ................................ a
	E			b			90890-06502 ........................... b
	a				F	Center bolt
						P/N.	90890-06504
					G Slide hammer
						P/N. YB-06096
							90890-06531
	F			G	H Small universal claws
						P/N.	90890-06536
					I Bearing/oil seal depth plate
						P/N. YB-06213, YB-06433 .............. a
							90890-06603 ........................... b
					J Drive shaft holder
	H					P/N. YB-06201
							90890-06520
					K Pinion nut holder
						P/N.	90890-06505
	I				L Pinion nut holder attachment
				b		P/N.	90890-06507
	a				M	Bearing/oil seal attachment
						P/N.	90890-06636, 90890-06653,
							90890-06654, 90890-06655
					N Bearing puller
						P/N. YB-06029
	J			K			90890-06523
					O Large universal claws
						P/N.	90890-06532

LM

NO

1-8

	GEN			SPECIAL TOOLS
	INFO				E
					P Slide hammer attachment
	P			Q
					P/N. YB-06335
					90890-06514
					Q Puller bolt
					P/N. YB-41707
	R			S	R Bearing/oil seal attachment
					P/N. YB-06437
					S Bearing/oil seal attachment
					P/N. YB-06435
					T Bearing/oil seal attachment
					P/N. YB-06434
	T			U	U End screw wrench
					P/N. YB-06175-2B, YB-06548
					90890-06541, 90890-06544,
					90890-06548

1-9

	SPEC				E
				CHAPTER 2
				SPECIFICATIONS
	GENERAL SPECIFICATIONS..........................................................................				2-1
	MAINTENANCE SPECIFICATIONS................................................................				2-3
		POWER UNIT............................................................................................			2-3
		LOWER UNIT............................................................................................			2-5
		ELECTRICAL .............................................................................................			2-5
		DIMENSIONS ...........................................................................................			2-9
	TIGHTENING TORQUES ..............................................................................				2-11
		SPECIFIED TORQUES ............................................................................			2-11
		GENERAL TORQUES .............................................................................			2-13

1

2

3

4

5

6

7

8

9

SPEC

GENERAL SPECIFICATIONS

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GENERAL SPECIFICATIONS

						Model
Item	Worldwide	Unit	200HETO	225FETO		L225FETO	225GETO		250BETO		L250BETO
	USA		V200TR	S225TR		L225TR	V225TR		S250TR		L250TR
	Canada		—	S225TR		—	—		S250TR		—
DIMENSION
Overall length		mm (in)	864 (34.0)	854 (33.6)			864 (34.0)		854 (33.6)
Overall width		mm (in)
					562 (22.1)
Overall height
(L)		mm (in)	1,685 (66.3)		—		1,685 (66.3)			—
(X)		mm (in)	—	1,785 (70.3)			—		1,785 (70.3)
(U)		mm (in)	—	1,912 (75.3)			—		1,912 (75.3)
Boat transom height
(L)		mm (in)	508 (20.0)		—		508 (20.0)			—
(X)		mm (in)	—	635 (25.0)			—		635 (25.0)
(U)		mm (in)	—	762 (30.0)			—		762 (30.0)
WEIGHT
(with stainless steel
propeller)
(L)		kg (lb)	235.5 (519)	—		—	235.5 (519)		—		—
(X)		kg (lb)	—	237 (523)		239 (538)	—		237 (523)		239 (538)
(U)		kg (lb)	—	242 (534)		244 (539)	—		242 (534)		244 (539)
PERFORMANCE
Maximum output		kW (hp) @	147.1 (200)		165.5 (225)				183.9 (250)
		5,000 r/min
Full throttle operating		r/min			4,500 - 5,500
range
Maximum fuel
		L (US gal,	100 (26.4,	94 (24.8, 20.7)			107 (28.3, 23.5)
consumption		lmp gal)/hr	22.0)
		@ 5,500 r/min
POWER UNIT
Type						2 stroke - V
Number of cylinders					6
Displacement		cm3 (cu. in)			3,130 (191.0)
Bore × stroke		mm (in)			90.0 × 82.0 (3.54 × 3.23)
Compression ratio
			Cylinders	Cylinders #1 - #4: 6.0			Cylinders #1 - #4: 5.9
			#1 - #4: 5.4	Cylinders #5 - #6: 5.8			Cylinders #5 - #6: 5.7
			Cylinders
			#5 - #6: 5.2
Fuel system
					Electronic fuel injection
Fuel injection system						Sequential injection
Intake system						Reed valve
Induction system						Loop charge
Starting system						Electric
Ignition control						Microcomputer (CDI)
system
Alternator output						12 - 35A
Spark plugs (NGK)
			BR8HS-10				BR9HS-10
			2-1

SPEC

GENERAL SPECIFICATIONS

E

					Model
Item	Worldwide	Unit	200HETO	225FETO	L225FETO	225GETO		250BETO	L250BETO
	USA		V200TR	S225TR	L225TR	V225TR		S250TR	L250TR
	Canada		—	S225TR	—	—		S250TR	—
Cooling system					Water
Exhaust system					Through prop boss
Lubrication system					Oil injection
FUEL AND OIL
Fuel type				Unleaded regular gasoline
Fuel rating		*PON			86
		RON			91
Engine oil type				2-stroke outboard engine oil
Engine oil grade					TC-W3
Engine oil capacity
(engine oil tank)		L (US qt,			1.2 (1.27, 1.06)
		lmp qt)
(sub-oil tank)		L (US qt,			10.5 (11.1, 9.2)
		lmp qt)
Gear oil type					Hypoid gear oil SAE 90
Gear oil total quantity		cm3 (US
			1,150 (38.9, 40.5)		1,000	1,150 (38.9, 40.5)			1,000
		oz, lmp oz)			(33.8, 35.2)				(33.8, 35.2)
BRACKET
Trim angle		Degree	–4 - 16	–3 - 16		–4 - 16		–3 - 16
(at 12˚ boat transom)
Tilt-up angle		Degree
					70
Steering angle		Degree			35 + 35
DRIVE UNIT
Gear shift positions					F-N-R
Gear ratio					1.81 (29/16)
Reduction gear type					Spiral bevel gear
Clutch type					Dog clutch
Propeller shaft type					Spline
Propeller direction
			Clockwise		Counter-	Clockwise			Counter-
(rear view)					clockwise				clockwise
Propeller mark
			M	T/M	TL/ML	M		T/M	TL/ML
ELECTRICAL
Battery capacity		Ah (kC)			100 (360)
Minimum cold		A			512
cranking performance

*PON: Pump Octane Number RON: Research Octane Number

2-2

	SPEC			GENERAL SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

POWER UNIT

E

						Model
	Item	Worldwide	Unit	200HETO	225FETO	L225FETO	225GETO	250BETO	L250BETO
		USA		V200TR	S225TR	L225TR	V225TR	S250TR	L250TR
		Canada		—	S225TR	—	—	S250TR	—
	CYLINDER HEADS
	Warpage limit		mm (in)			0.1 (0.004)
	(lines indicate
	straightedge position)
	CYLINDERS
	Bore size		mm (in)		90.00 - 90.02 (3.543 - 3.544)
	Wear limit		mm (in)			90.1 (3.55)
	Taper limit		mm (in)			0.08 (0.003)
	Out-of-round limit		mm (in)			0.05 (0.002)
	PISTONS
	Piston diameter		mm (in)		89.840 - 89.860 (3.5370 - 3.5378)
	(D)
	Measuring point (H)		mm (in)			10 (0.4)
	Piston-to-cylinder		mm (in)		0.155 - 0.161 (0.0061 - 0.0063)
	clearance
	<Limit>		mm (in)			0.201 (0.0079)
	Oversize piston diameter
	1st		mm (in)			90.15 (3.549)
	2nd		mm (in)			90.40 (3.559)
	PISTON RINGS
	Type					Keystone
	(B)		mm (in)			2.0 (0.079)
	(T)		mm (in)			2.8 (0.110)
	End gap (installed)		mm (in)		0.30 - 0.40 (0.012 - 0.016)
	<Limit>		mm (in)			0.60 (0.024)
	Side clearance		mm (in)		0.02 - 0.06 (0.001 - 0.002)
	CRANKSHAFT
	Runout limit		mm (in)			0.05 (0.002)
			2-3

SPEC

GENERAL SPECIFICATIONS

E

						Model
Item	Worldwide	Unit	200HETO	225FETO		L225FETO	225GETO		250BETO	L250BETO
	USA		V200TR	S225TR		L225TR	V225TR		S250TR	L250TR
	Canada		—	S225TR		—	—		S250TR	—
CONNECTING	RODS
Small-end axial		mm (in)			2.0 (0.08)
play limit (F)
Big-end side		mm (in)		0.12 - 0.26 (0.005 - 0.010)
clearance (E)
OIL INJECTION PUMP
ID mark						65L00
Oil discharge		cm3 (US oz,			39.6 ± 7.8
(for 3 minutes)		Imp oz) @		(1.339 ± 0.264, 1.397 ± 0.275)
		1,500 r/min
Bleeding						Screw type
REED VALVES
Reed valve stopper		mm (in)	9.0 ± 0.3	7.9 ± 0.3			9.0 ± 0.3 (0.35 ± 0.01)
height a			(0.35 ±	(0.31 ± 0.01)
			0.01)
Warpage limit b		mm (in)			0.2 (0.008)
THERMOSTATS
Opening temperature		˚C (˚F)			48 - 52 (118 - 126)
Full-open temperature		˚C (˚F)			60 (140)
Valve open lower limit		mm (in)			3 (0.12)
ENGINE SPEED
Idling speed		r/min			730 ± 30

2-4

SPEC

MAINTENANCE SPECIFICATIONS

E

LOWER UNIT

Model

Item

Worldwide

Unit

200HETO

225FETO

L225FETO

225GETO

250BETO

L250BETO

USA

V200TR

S225TR

L225TR

V225TR

S250TR

L250TR

Canada

—

S225TR

—

—

S250TR

—

GEAR BACKLASH

Pinion - forward gear

mm (in)

0.19 - 0.40

0.32 - 0.52

0.19 - 0.40

0.32 - 0.52

(0.007 - 0.016)

(0.013 -

(0.007 - 0.016)

(0.013 -

0.020)

0.020)

Pinion - reverse gear

mm (in)

0.64 - 0.93 (0.025 - 0.037)

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

ELECTRICAL

Model

Item

Worldwide

Unit

200HETO

225FETO

L225FETO

225GETO

250BETO

L250BETO

USA

V200TR

S225TR

L225TR

V225TR

S250TR

L250TR

Canada

—

S225TR

—

—

S250TR

—

IGNITION SYSTEM

Ignition timing

Degree

ATDC 10

ATDC 8 - BTDC 17.8

ATDC 10

ATDC 8 - BTDC 17.8

- BTDC 20

- BTDC 18

CDI unit

(B/O, B/Y, B/L,

B/Br, B/G, B/W – B)

Output peak voltage lower

limit

@ cranking 1

V

80

@ cranking 2

V

100

@ 1,500 r/min

V

150

@ 3,500 r/min

V

130

Charge coil

(R – Br, B/R – L)

Output peak voltage lower

limit

@ cranking 1

V

85

@ cranking 2

V

110

@ 1,500 r/min

V

150

@ 3,500 r/min

V

150

Pulser coil

(W/R, W/Y, W/G,

W/B, W/L, W/Br – B)

Output peak voltage lower

limit

@ cranking 1

V

3.0

@ cranking 2

V

3.0

@ 1,500 r/min

V

16

@ 3,500 r/min

V

30

*Cranking 1: Open circuit voltage. Cranking 2: Loaded circuit voltage.

2-5

SPEC

MAINTENANCE SPECIFICATIONS

E

							Model
Item		Worldwide	Unit	200HETO	225FETO		L225FETO	225GETO		250BETO	L250BETO
		USA		V200TR	S225TR		L225TR	V225TR		S250TR	L250TR
		Canada		—	S225TR		—	—		S250TR	—
IGNITION CONTROL		SYSTEM
Crank position sensor
	(G/W – G/L)
Crank-position-sensor-to-			mm (in)		0.5 - 1.5 (0.02 - 0.06)
flywheel gap
Output peak voltage lower
limit
@ cranking 1			V			6.0
@ cranking 2			V			0.5
@ 1,500 r/min			V			3.0
@ 3,500 r/min			V			4.0
Engine cooling water
temperature sensor
Resistance		(B/Y – B/Y)
@ 5˚C (41˚F)			kΩ			128
@ 20˚C (68˚F)			kΩ			54 - 69
@ 100˚C (212˚F)			kΩ			3.02 - 3.48
Throttle position sensor
Input voltage		(O – R)	V			4.75 - 5.25
Output voltage		(P – O)	V			0.48 - 0.52
Thermo switch		(P – B)
		OFF → ON	˚C (˚F)			84 - 90 (183 - 194)
		ON → OFF	˚C (˚F)			60 - 74 (140 - 165)
FUEL CONTROL SYSTEM
Oxygen density sensor
Heater resistance (W – W)			Ω			100
Output voltage		(Gy – B)	V			0.0 - 1.0
Atmospheric pressure sensor
Output voltage			V			3.2 - 4.6
(at 101.32 kPa)		(P – B)
Intake air temperature sensor
Output voltage			V			3.4 - 5.3
(at 20 ˚C (68 ˚F))		(B/Y – B/Y)
High-pressure fuel pump			Ω			0.53 - 0.57
resistor resistance
STARTING SYSTEM
Fuse 1			V-A			14-80
Fuse 2			V-A			12-30

*Cranking 1: Open circuit voltage. Cranking 2: Loaded circuit voltage.

2-6

SPEC

MAINTENANCE SPECIFICATIONS

E

Model

Item

Worldwide

Unit

200HETO

225FETO

L225FETO

225GETO

250BETO

L250BETO

USA

V200TR

S225TR

L225TR

V225TR

S250TR

L250TR

Canada

—

S225TR

—

—

S250TR

—

STARTER MOTOR

Type

Bendix

Output

kW

1.1

Rating

Second

30

Brushes

Standard length

mm (in)

16.0 (0.63)

Wear limit

mm (in)

12.0 (0.47)

Commutator

Standard diameter

mm (in)

33.0 (1.30)

Wear limit

mm (in)

31.0 (1.22)

Mica

Standard undercut

mm (in)

0.8 (0.03)

Wear limit

mm (in)

0.2 (0.01)

CHARGING SYSTEM

Rectifier/regulator

(R – B)

Output peak voltage lower

limit

@ cranking 1

V

—

@ cranking 2

V

—

@ 1,500 r/min

V

12

@ 3,500 r/min

V

12

Lighting coil

(G – G)

Output peak voltage lower

limit

@ cranking 1

V

—

@ cranking 2

V

—

@ 1,500 r/min

V

14

@ 3,500 r/min

V

14

OIL FEED PUMP CONTROL

SYSTEM

Oil level sensor

(engine oil tank)

Float position a

mm (in)

2.5 - 5.5 (0.10 - 0.22)

“OFF”

Float position b

mm (in)

32.5 - 35.5 (1.28 - 1.40)

“ON”

Float position c

mm (in)

76 - 79 (2.99 - 3.11)

“ON”

Oil level gauge

(sub-oil tank)

Float position d “ON”

mm (in)

150 - 153 (5.91 - 6.02)

*Cranking 1: Open circuit voltage. Cranking 2: Loaded circuit voltage.

2-7

SPEC

MAINTENANCE SPECIFICATIONS

E

							Model
Item	Worldwide		Unit	200HETO	225FETO		L225FETO	225GETO	250BETO		L250BETO
	USA			V200TR	S225TR		L225TR	V225TR	S250TR		L250TR
	Canada			—	S225TR		—	—	S250TR		—
POWER TRIM AND	TILT
SYSTEM
Trim sensor
Resistance		(P – B)	Ω	582 -	494 - 742			582 -	494 - 742
				873				873
Resistance		(O – B)	Ω
						800 -		1,200
POWER TRIM AND TILT
MOTOR
Fluid type							ATF Dexron II
Brushes
Standard length			mm (in)	9.8	12.0 (0.47)			9.8	12.0 (0.47)
				(0.39)				(0.39)
Wear limit			mm (in)	4.8	4.0 (0.16)			4.8	4.0 (0.16)
				(0.19)				(0.19)
Commutator
Standard diameter			mm (in)	22.0	25.0 (0.98)			22.0	25.0 (0.98)
				(0.87)				(0.87)
Wear limit			mm (in)	21.0	24.0 (0.94)			21.0	24.0 (0.94)
				(0.83)				(0.83)
Mica
Standard undercut			mm (in)	1.35		—		1.35		—
				(0.05)				(0.05)
Wear limit			mm (in)	0.85		—		0.85		—
				(0.03)				(0.03)

2-8

	SPEC			MAINTENANCE SPECIFICATIONS	E
	DIMENSIONS

		Symbol							Models
		Worldwide	Unit	200HETO		225FETO		L225FETO		225GETO		250BETO		L250BETO
		USA		V200TR		S225TR		L225TR		V225TR		S250TR		L250TR
		Canada			—	S225TR		—			—	S250TR		—
	L1		mm (in)	591	(23.3)	566	(22.3)			591(23.3)		566 (22.3)
	L2		mm (in)	179 (7.0)		181 (7.1)				179 (7.0)			181 (7.1)
	L4		mm (in)	685	(27.0)	673	(26.5)			685	(27.0)	673 (26.5)
	L5	(L)	mm (in)	61	(2.4)		—			61	(2.4)		—
		(X)	mm (in)		—	69	(2.7)				—		69 (2.7)
		(U)	mm (in)		—	89	(3.5)				—		89 (3.5)
	L6	(L)	mm (in)	1,045 (41.2)			—			1,045 (41.2)			—
		(X)	mm (in)		—	1,155 (45.5)					—	1,155 (45.5)
		(U)	mm (in)		—	1,271 (50.0)					—	1,271 (50.0)
	L7		mm (in)	624	(24.6)	631	(24.8)			624	(24.6)	631 (24.8)
	H1	(L)	mm (in)	950	(37.4)		—			950	(37.4)		—
		(X)	mm (in)		—	1,077 (42.4)					—	1,077 (42.4)
		(U)	mm (in)		—	1,203 (47.4)					—	1,203 (47.4)
	H2		mm (in)	735	(28.9)	710	(28.0)			735	(28.9)	710 (28.0)
	H3		mm (in)				216 (8.5)
	H4	(L)	mm (in)	515	(20.3)		—			515	(20.3)		—
		(X)	mm (in)		—	642	(25.3)				—	642 (25.3)
		(U)	mm (in)		—	768	(30.2)				—	768 (30.2)
	H6	(L)	mm (in)	768	(30.2)		—			768	(30.2)		—
		(X)	mm (in)		—	846	(33.3)				—	846 (33.3)
		(U)	mm (in)		—	923	(36.3)				—	923 (36.3)
	H7		mm (in)	268	(10.6)	242 (9.5)				268	(10.6)		242 (9.5)
	H9		mm (in)	923	(36.3)	818	(32.2)			923	(36.3)	818 (32.2)
	W1		mm (in)				281 (11.1)
	W5		mm (in)	419	(16.5)	420	(16.5)			419	(16.5)	420 (16.5)

2-9

SPEC

MAINTENANCE SPECIFICATIONS

E

		Symbol				Models
		Worldwide	Unit	200HETO	225FETO	L225FETO	225GETO	250BETO	L250BETO
		USA		V200TR	S225TR	L225TR	V225TR	S250TR	L250TR
		Canada		—	S225TR	—	—	S250TR	—
	B1		mm (in)			125.4 (4.9)
	B2		mm (in)			254 (10.0)
	B3		mm (in)			163.5 (6.4)
	B4		mm (in)			50.8 (2.0)
	B5		mm (in)			180 (7.1)
	B6		mm (in)	367 (14.4)	411 (16.2)		367 (14.4)	411 (16.2)
	B9		mm (in)			18.5 (0.7)
	C3		mm (in)	82 (3.2)	79 (3.1)		82 (3.2)	79 (3.1)
	D1		mm (in)			13 (0.5)
	D2		mm (in)			55.5 (2.2)

2-10

SPEC

MAINTENANCE SPECIFICATIONS

E

TIGHTENING TORQUES

SPECIFIED TORQUES

Part to be tightened			Thread size		Tightening torques
				Nm		m • kgf		ft • lb
POWER UNIT
Intake silencer			M6	3		0.3		2.2
Fuel injection unit			M6	10		1.0		7.2
Fuel filter nut holder			M6	8		0.8		5.8
Oil pump			M6	7		0.7		5.1
Emergency switch			—	4		0.4		2.9
Flywheel magnet assembly			M20	190		19		137
Negative battery lead			M8	18		1.8		13
Junction box cover			M5	3		0.3		2.2
Power unit mount			M8	21		2.1		15
Starter motor lead			M6	9		0.9		6.5
Atmospheric pressure sensor			M6	3		0.3		2.2
Intake air temperature sensor			M12	8		0.8		5.8
Shift cutoff switch			M4	3		0.3		2.2
Starter motor			M8	30		3.0		22
Oxygen density sensor cover			M6	9		0.9		6.5
Oxygen density sensor bracket			M6	14		1.4		10
Oxygen density sensor			M18	49		4.9		35
Knocking sensor			—	28		2.8		20
Engine cooling water temperature sensor			—	15		1.5		11
Reed valve assembly			M6	10		1.0		7.2
Reed valve			M5	3		0.3		2.2
Reed valve stopper			M3	1		0.1		0.7
Pressure control valve cover		1st	M6	4		0.4		2.9
		2nd		8		0.8		5.8
Spark plug			M14	25		2.5		18
Cylinder head cover		1st	M6	4		0.4		2.9
		2nd		8		0.8		5.8
Cylinder head		1st	M8	15		1.5		11
		2nd		28		2.8		20
Exhaust cover		1st	M6	4		0.4		2.9
		2nd		8		0.8		5.8
Torsional damper			M32	100		10		72
		1st	M6	4		0.4		2.9
Crankcase		2nd		8		0.8		5.8
		1st	M10	20		2.0		14
		2nd		40		4.0		29
		1st		28		2.8		20
		2nd		45		4.5		33
Connecting rod			M8
		3rd		0		0		0
		4th		28		2.8		20
		5th		45		4.5		33
			2-11