YAMAHA 200A, L200A PARTS CATALOGUE

200A L200A

60H-28197-5E-11

290446

SERVICE MANUAL

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

1st Edition, February 2002

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd. is expressly prohibited.

Printed in Japan

General information

Specifications

Periodic checks and adjustments

Fuel system

Power unit

GEN

INFO

SPEC

CHK

ADJ

FUEL

POWR

Lower unit

Bracket unit

Electrical systems

Troubleshooting

Index

LOWR

BRKT

–+

ELEC

TRBL SHTG

GEN

INFO

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

Checking the tilt sytem............................................................................................1-15

Checking the engine start switch and engine stop switch, engine shut-off switch.........

Checking the pilot water outlet................................................................................1-16

Test run ...................................................................................................................1-16

Break-in ..................................................................................................................1-17

After test run ...........................................................................................................1-17

1-16

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

with tightening instructions.

3 Symbols 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.”

POWR

Removing the exhaust cover

1. Remove the pressure control valve.

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

Power unit

60H50250

60H50260

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.

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.

60H50265

60H50270

60H50275

Cylinder head

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 12 Clamp 1 13 Bolt 2 M8 x 20 mm 14 Engine hanger 1 15 Spark plug 6

Exhaust / Cylinder head

60H50280

5-21

1-1

60H5E11

5-22

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

GEN

INFO

Specifications Power unit Electrical systems

SPEC

Periodic checks and adjustments Lower unit Troubleshooting

CHK

ADJ

Symbols 1 to 6 indicate specific data.

123456

1 Special tool 2 Specified oil or fluid 3 Specified engine speed

FUEL

POWR

LOWR

BRKT

ELEC

TRBL

SHTG

4 Specified tightening torque 5 Specified measurement 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.

7890AB

7 Apply Yamaha 4-stroke motor oil 8 Apply water resistant grease (Yamaha grease A) 9 Apply molybdenum disulfide grease 0 Apply 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.

CDEFGH

C Apply Gasket Maker D Apply Yamabond 4 E Apply LOCTITE 271 (Red)

A Apply low temperature resistant grease

(Yamaha grease C)

B Apply injector grease

F Apply LOCTITE 242 (Blue) G Apply LOCTITE 572 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.

Parts, lubricants, and sealants

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

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.

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 wiping up spills, etc.

Good working practices

Special tools

Use the recommended special tools to protect parts from damage. Use the right tool in the right manner-do not improvise.

Tightening torques

Follow the tightening torque specifications provided throughout the manual. When tightening nuts, bolts, and screws, tighten the large sizes first, and tighten fasteners starting in the center and moving outward.

Disassembly and assembly

1. Use compressed air to remove dust and dirt during disassembly.

2. Apply engine oil to the contact surfaces of moving parts before assembly.

3. Install bearings with the manufacture identification 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 before installation.

5. Check that moving parts operate normally after assembly.

Non-reusable parts

Always use new gaskets, seals, O-rings, cotter 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

200AET

L200AET

Approved

model code

60H

60J

Starting

serial No.

L: 800101X: 850101X: 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 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.

Pulse (G/W)

Lighting coil

Flywheel magnet

Hour meter

Rectifier Regulator

(G)

(B)

Wiring diagram

Grand (B)

Power source (Y)

(R)

Fuse

Battery

Main switch

(B)

G/W

: Green/White

: Green

: Yellow

: Black

: Red

60H5E11

60H10010

1-6

GEN

INFO

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.

Exhaust guide plate

General information

Muffler

Exhaust manifold

Exhaust manifold extension (Muffler 2)

For X transom

1-7

60H10030

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. 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

Cylinder sleeve

Exhaust slit

Exhaust port

Scavenging port

Cylinder sleeve

(New models)(Previous models)

60H5E11

60H10040

1-8

GEN

INFO

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.

General information

Carburizing and quenching

Silver plating

Identification mark

Bearing with 18 rollers

Larger mating face

1-9

Connecting rod and bearings

60H10050

60H5E11

Features and benefits

Gasket

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

Silicon bead

60H5E11

Silicon bead

Gasket with silicon bead

60H10060

1-10

GEN

INFO

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.

General information

1-11

Dog clutch

Forward gear

Pinion gear

60H10070

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 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

60H5E11

Full threaded bolt

60H10080

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.

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

A Propeller diameter (in inches) B Propeller pitch (in inches) C Propeller type (propeller mark)

S60C1110

S60C1125

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

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

Checking the battery

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

Recommend battery: 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.

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

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.

60H30110

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

Checking the steering system

1. Check that the steering operates smoothly.

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.

60H30427

60H10420

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

B.B.

1-15

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

60H5E11

Predelivery checks

2. Check that there is no abnormal noise produced when the outboard motor is tilted up or down.

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 toward up position when the outboard motor is trimmed up.

Checking the engine start switch and engine stop switch, engine shut-off switch

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

Checking the pilot water outlet

1. Start the engine, and check that cooling water is discharged from the pilot water outlet.

60H30100

Test run

1. Start the engine, and then check the engine idle speed after the engine has been warmed up.

2. Check that the gearshift operates smoothly.

3. Operate at trolling speed.

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.

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.

60H5E11

S60C1220

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.

60H10100

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

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.

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.

1-17

60H10130

60H5E11

SPEC

Specifications

Genral Specifications....................................................................................................2-1

Maintenance specifications..........................................................................................2-3

Power Unit................................................................................................................. 2-3

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

Dimension

Overall length Overall width Overall height

(L) (X)

Transom height

(L) (X)

Weight(*1)

(L) (X)

Performance

Maximum output Full throttle operating range Maximum fuel consumption Idle speed

Power unit

Type Total displacement Bore x Stroke Compression ratio Minimum compression pressure(*2) Control system Starting system Enrichment system Ignition control system Ignition timing Advance pick up timing Maximum generator output Spark plug(*3) Cooling system Exhaust system Lubrication system

mm (in) mm (in)

kg (lb) kg (lb)

kW(HP)

r/min

L(US gal,Imp gal)/hr

r/min

(cu. in)

mm (in)

kPa(kg/cm

)

Degree Degree

V, A

Model

200AET L200AET

828(32.6) 600(23.6)

1,577(62.1) –

1,703(67.0)

516(20.3) –

642(25.3)

180(396) – 184(405) 186(410)

147.1(200) @ 5,000 r/min 4,500 - 5,500

81(21.4,17.8) @ 5,500 r/min

700

2-stroke,90,V6

2,596(158.4)

90.0(3.54) x 68.0(2.68)

5.9

520(5.2)

Remote control

Electric motor

Choke valve

CDI

ATDC7-BTDC18

ATDC 7 12,14 @ 5,500 r/min B8HS-10,BR8HS-10

Water

Through propeller boss

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

Fuel and oil

Fuel type Fuel rating Engin oil type Engin oil grade Gear oil type Gear oil grade

Gear oil quantity

Bracket unit

Trim angl (At 12° boat transom) Tilt-up angle Steering angle

Drive unit

Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction (Rear view) Propeller ID mark

Electrical

Recommend battery

CCA / SAE (Minimum) CCA / EN (Minimum) RC (Minimum) 20HR (Minimum) JIS

RON(*4)

NMMA-certified

API

SAE

(oz)

Degree Degree Degree

A A

Minute

Model

200AET L200AET

Regular unleaded gasoline

2-stroke outboard motor oil

TCW-3

Hypoid gear oil

GL-4

980(34.5) 870(30.6)

– 4 – 16

35+35

F-N-R

1.86(14/26)

Spiral bevel gear

Dog clutch

Spline

Clocklwise Counterclockwise

MML

380 430 120

65D31-95E41

(*4) RON; Reseach Octance Number

60H5E11

2-2

SPEC

General Information

Maintenance specifications

Power unit

Item Unit

Power unit

Compression pressure* (reference data) Compression pressure* (minimum)

Cylinder heads

Warpage limit

(lines indicate straightedge position)

Cylinders

Bore size Bore size limit Taper limit Out-of-round limit

Pistons

Piston diameter (D) Measuring point (H) Piston pin boss inside diameter Oversize piston

1st

Oversize piston diameter

2nd

Oversize piston diameter

Piston pins

Outside diameter

Piston rings

Top ring, 2nd ring

Dimension B Dimension T End gap Measuring point (H) Side clearance

kPa

(kgf/cm2, psi)

kPa

(kgf/cm

, psi)

mm (in)

mm (in) mm (in) mm (in) mm (in)

mm (in) mm (in) mm (in)

mm (in) mm (in) mm (in) mm (in)

mm (in)

mm (in) mm (in) mm (in) mm (in) mm (in)

Model

200AET L200AET

700 (7.0, 101.5)

520 (5.2, 75.4)

0.1 (0.04)

90.00 - 90.02 (3.5433 - 3.5441)

90.10 (3.5472)

0.08 (0.0031)

0.05 (0.0020)

89.895 - 89.915 (3.5392 - 3.5400) 10 (0.39)

23.074-23.085 (0.9084-0.9089)

+ 0.25 (0.0098)

90.145 - 90.165 (3.5490 - 3.5498)

+ 0.5 (0.0196)

90.395 - 90.415 (3.5589 - 3.5596)

23.065 - 23.070 (0.9081 - 0.9083)

1.97 - 1.99 (0.0776 - 0.0783)

2.7 - 2.9 (0.1063 - 0.1142)

0.3 - 0.4 (0.0118 - 0.0157) 20 (0.79)

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

Connecting rods

Small-end inside diameter Big-end inside diameter Big-end side clearance Small-end axial play limit

Crankshaft

Crankshaft journal Diameter Crank pin Diameter Run-out limit

Thermostats

Opening temperature Fully open temperature Valve open lower limit

Carburetor

ID mark Main jet Main air jet Pilot jet Pilot air jet Pilot screw Float height (with gasket) Engine idle speed

Reed valves

valve stopper height warpage limit

mm (in) mm (in) mm (in) mm (in)

mm (in) mm (in) mm (in)

°C (°F) °C (°F) mm (in)

# # # #

turns out

mm (in)

r/min

mm (in) mm (in)

Model

200AET L200AET

28.070 - 28.082 (1.1051 - 1.1056)

46.010 - 46.025 (1.8114 - 1.8120)

0.12 - 0.26 (0.0047 - 0.0102)

2.0 (0.08)

53.975 - 53.991 (2.1250 - 2.1256)

35.985 - 36.000 (1.4167 - 1.4173)

0.03 (0.0012)

50 (122) 60 (140)

3.0 (0.12)

64E01

No.1,3:150 / No.2,4:154 / No.5:152 / No.6:158

270

84 60

1 1/8 ± 1/4 (7/8 - 1 3/8)

15.5 - 16.5 (0.61 - 0.65) 675 - 725

6.5 (0.26)

0.2 (0.08)

Lower unit

Item Unit

Gear backlash

Pinion-to-forward gear

Pinion-to-reverse gear

Pinion shims Forward gear shims Reverse gear shims Propeller shaft shims

Drive shaft

Run-out limit

Propeller shaft

End play

mm (in)

mm mm mm mm

mm (in)

Model

200AET L200AET

0.25 - 0.46 0.21 - 0.43

(0.0098 - 0.0181) (0.0083 - 0.0169)

0.74 - 1.29 0.98 - 1.30

(0.0291 - 0.0508) (0.0386 - 0.0512)

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 — 0.10, 0.12, 0.15, 0.18,

0.30, 0.40, 0.50

0.1 (0.0039)

— 0.25 - 0.35

(0.0098 - 0.0138)

60H5E11

2-4

SPEC

Electrical

General Information

Item Unit

Ignition system

Ignition timing (standard ignition timing) (full advance) Piston position (full advance) Pulser coil output peak voltage (W/B - W/L, W/Br - W/Y, W/G - W/R)

at cranking 1(*1) at cranking 2(*1) at 1,500 r/min

at 3,500 r/min Pulser coil resistance(*2) (W/B - W/L, W/Br - W/Y, W/G - W/R) Charge coil output peak voltage (Br - R)

at cranking 1(*1)

at cranking 2(*1)

at 1,500 r/min

at 3,500 r/min (L - B/R)

at cranking 1(*1)

at cranking 2(*1)

at 1,500 r/min

at 3,500 r/min Charge coil resistance(*2) (Br - R) (L - B/R) CDI unit output peak voltage (B/W - B)

at cranking (loaded)

at 1,500 r/min

at 3,500 r/min Spark plug gap Ignition spark gap Spark plug cap resistance Ignition coil resistance

Primary coil (B/W-B)

Secondary coil (LEAD-B)

Thermoswitch

ON OFF

Choke solenoid

Resistance

Degree Degree

mm (in)

V V V V

Ω

V V V V

Ω Ω

V V

V mm (in) mm (in)

Ω

Ω at 20°C (68°F) Ω at 20°C (68°F)

°C (°F) °C (°F)

Ω

Model

200AET L200AET

ATDC 7

BTDC 18

2.05 (0.0807)

2.5

2.0

9.5

16.0

256 - 384

90 165 165

30 160 165

428 - 642

64.4 - 96.6

65 140 135

1.0 - 1.1 mm (0.039 - 0.043 in) 6 (0.24)

4.0 - 6.0

0.18 - 0.24

3.26 - 4.88

84 - 90 (183 - 194) 60 - 74 (140 - 165)

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

Starter motor

Type Output Cranking time limit Brushes

Standard length Wear limit

Commutator

Standard diameter Wear limit

Mica

Standard undercut Wear limit

Charging system

Fuse Lighting coil output peak voltage (G - G/W)

at cranking(*1) at 1,500 r/min(*1) at 3,500 r/min(*1)

Lighting coil resistance(*2)

(G - G/W) Rectifier Regulator output peak voltage (R - B)

at 1,500 r/min(*1) at 3,500 r/min(*1)

Charging current

Power trim and tilt system

Trim sensor

Setting resistance

Resistance (P - B) Fluid type Brushes

Standard length

Wear limit Commutator

Standard diameter

Wear limit Hydraulic pressure (UP)

(DOWN)

Second

mm (in) mm (in)

V V V

Ω

V V

V, A

at 6,000 r/min

Ω Ω

mm (in) mm (in)

mm (in)

mm (in) MPa (kgf/cm MPa (kgf/cm

Model

200AET L200AET

Bendix

1.1 30

17 (0.67) 10 (0.39)

33 (1.30) 32 (1.26)

0.8 (0.031)

0.2 (0.008)

20.0

50.0

0.20 - 0.30

18 45

12, 14

9 - 11

9 - 379

ATF Dexron II

9.8 (0.386)

4.8 (0.189)

22 (0.87) 21 (0.83)

)

10 - 12 (100 - 120)

6 - 9 (60 - 90)

(*1) Unloaded (*2) The figures are for reference only.

60H5E11

2-6

SPEC

Dimensions

Exterior

General Information

426(16.8)

300(11.8)

569(22.4)

mm(in)

660(26.0)

L: 1,032(40.6) X: 1,144(45.0)

788(31.0)

L: 516(20.3)

L: 946(37.2)

X: 1,072(42.2)

631(24.8)

205(8.1)

26(1.0)

X: 642(25.3)

210(8.3)

173(6.8)

45(1.8)

L: 48(1.9) X: 61(2.4)

543(21.4)188(7.4)

74(2.9)

L: 762(30.0)

X: 837(33.0)

2-7

31(1.2)

L: 54(2.1) X: 62(2.4)

634(25.0)

60H5E11

+ 251 hidden pages

YAMAHA 200A, L200A PARTS CATALOGUE

Contents

General information

Specifications