YAMAHA Z200N, LZ200N, Z200Y, LZ200Y PARTS CATALOGUE

USA, CANADA

WORLDWIDE

Z200N
LZ200N

Z200Y
LZ200Y

SERVICE MANUAL

290369

68F-28197-Z9-A1

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.

CAUTION

USE UNLEADED STRAIGHT GASOLINE ONLY

• Gasoline containing lead can cause performance
lose and engine damage.

• Do not use gasoline mixed with oil (premix).

• Use YAMALUBE 2 stroke outboard oil or another
2-stroke engine oil with a BIA-certified TC-W3 rate.

Z200N, LZ200N

SERVICE MANUAL

©1999 Yamaha Motor Co., Ltd.

1st Edition, October 1999

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.

Printed in Japan

P/N 68F-28197-Z9-A1

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
check operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and
the course of action required will follow the symbol, e.g.,

• Bearings

Pitting/scratches → Replace.

To assist you in finding your way through this manual, the section title and major heading is
given at the top of every page.

MODEL INDICATION

Multiple models are mentioned in this manual and their model indications are noted as fol­lows.

E

Model name Z200NETO LZ200NETO

USA and

Canada name

Indication Z200NETO LZ200NETO

Z200TR LZ200TR

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.

E

IMPORTANT INFORMATION

In this Service Manual particularly important information is distinguished in the following
ways.

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

WARNING

Failure to follow WARNING instructions could result in severe injury or death
operator, a bystander, or a person inspecting or repairing the outboard motor.

to the machine

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.

1

2

HOW TO USE THIS MANUAL

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

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

3

Symbols are used in the exploded views to indicate important aspects of the procedure.
A list of meanings for these symbols is provided on the following page.

4

It is important to refer to the job instruction charts at the same time as the exploded views.
These charts list the sequence that the procedures should be carried out in, as well as 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)

E

D

d

5

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

Example:
Bolt or screw size : diameter (D) × length (L)

6

In addition to the exploded views and job instruction charts, this manual provides individ-

10 × 25 mm

D

L

ual illustrations when further explanations are required to explain the relevant procedure.

1

2

3

4

5

6

7

8

9

0

A

B

C

D

E

F

G

H

E

12

GEN

INFO

34

SPEC

INSP

FUEL

ADJ

56

POWR

78

BRKT

90

LOWR

–+

ELEC

TRBL

ANLS

AB

SYMBOLS

Symbols 1 to 9 are designed as thumb­tabs to indicate the content of a chapter.

General information
Specifications
Periodic inspections and adjustments
Fuel system
Power unit
Lower unit
Bracket unit
Electrical systems
Trouble analysis

Symbols 0 to E indicate specific data.

Special tool
Specified liquid
Specified engine speed
Specified torque
Specified measurement
Specified electrical value
[Resistance (
(A)]

Ω

), Voltage (V), Electric current

CD

T

.

R

.

EF

E

GH

A

IJ

GM

KL

LT

271

MN

LT

572

M

LT

242

SS

LT

4

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

Apply Yamaha 2-stroke outboard motor oil
(TC-W3)
Apply water resistant grease
(Yamaha grease A, Yamaha marine grease)
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
J Apply 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

®

CONTENTS

E

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTIONS AND
ADJUSTMENTS

FUEL SYSTEM

GEN

INFO

SPEC

INSP

ADJ

FUEL

1
2
3
4

POWER UNIT

LOWER UNIT

BRACKET UNIT

ELECTRICAL SYSTEMS

POWR

LOWR

BRKT

–+

ELEC

5
6
7
8

TROUBLE ANALYSIS

TRBL

ANLS

9

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

IDENTIFICATION ............................................................................................ 1-1

SERIAL NUMBER ..................................................................................... 1-1

STARTING SERIAL NUMBERS ............................................................... 1-1

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1

SAFETY WHILE WORKING

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

MEASURING ............................................................................................ 1-5

REMOVING AND INSTALLING ............................................................... 1-8

............................................................................................. 1-5

............................................................................ 1-2

2
3
4
5
6
7
8
9

1

2

3

4

GEN

INFO

IDENTIFICATION

E

IDENTIFICATION

SERIAL NUMBER

The outboard motor’s serial number is
stamped on a label which is attached to the
port side of the clamp bracket.

NOTE:

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

Model name
Approved model code
Transom height
Serial number

STARTING SERIAL NUMBERS

The starting serial number blocks are as fol­lows:

1

Model name Approved

Worldwide USA Canada

Z200NETO Z200TR Z200TR 6G6 X:100101 -

LZ200NETOLZ200TR — 6K1 X:100101 -

model

code

Starting

serial

number

1-1

GEN

INFO

SAFETY WHILE WORKING

E

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.

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.

1

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.

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 instruc­tions. 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

3.Non-reusable items

DISASSEMBLY AND ASSEMBLY

1.Clean parts with compressed air when

2.Oil the contact surfaces of moving parts

E

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

disassembling.

before assembly.

3.After assembly, check that moving parts
operate normally.

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

1

SPECIAL TOOLS

E

1

a

2

4

6

78

9

b

3

5

ba

SPECIAL TOOLS

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 USA and Canada, use part numbers
that start with “J-”, “YB-”, “YM-”, “YS-”,
“YU-” or “YW-”.

• For worldwide, use part numbers that
start with “90890-”.

MEASURING

Tachometer

P/N. YU-08036-A ............................ a

90890-06760 ........................... b

2

Fuel pressure gauge
P/N. YB-06766

90890-06786

3

Mity vac
P/N. YB-35956

90890-06756

4

Pressure tester
P/N. YB-35956

90890-06762

5

Digital caliper
P/N. 90890-06704

6

Pinion height gauge

P/N. YB-34432-7, YB-34432-11 ...... a

90890-06702 ........................... b

7

Shimming gauge
P/N. YB-34446-1, YB-34446-3,

YB-34446-4, YB-34446-7,
YB-34446-8

8

Shimming gauge
P/N. YB-34468-1, YB-34468-2

9

Shimming plate
P/N. 90890-06701

0

Shift rod wrench

P/N. YB-06052 ................................ a

90890-06052 ........................... b

1

0

ba

1-5

GEN

INFO

AB

C D

E

G

H

a

I

J

SPECIAL TOOLS

F

ba

b

ba

Magnetic base
P/N. YU-34481

90890-06705

B

Magnetic base attaching plate
P/N. YB-07003

90890-07003

C

Backlash indicator
P/N. YB-06265

90890-06706

D

Dial gauge set
P/N. YU-03097

90890-01252

E

Hydraulic pressure gauge
P/N. 90890-06776

F

Up-relief valve attachment
P/N. 90890-06773
Down-relief valve attachment
P/N. 90890-06774

G Digital tester

P/N. J-39299 ................................... a

90890-06752 ........................... b

H Peak voltage adapter

P/N. YU-39991 ................................ a

90890-03169 ........................... b

I Spark gap tester

P/N. YM-34487 ............................... a

90890-06754 ........................... b

J Test harness

P/N. YB-06443, YB-06767,

YB-06768, YB-06769,
YB-06779, YB-06787,
YB-06788
90890-06757, 90890-06767,
90890-06768, 90890-06769,
90890-06779, 90890-06787,
90890-06788

K Diagnostic indicator

P/N. YB-06765

90890-06765

A

E

K

1-6

GEN

INFO

SPECIAL TOOLS

E

L Diagnostic unit

Check the engine condition by using a
personal computer when it is connected
to the Electronic Control Unit (ECU).

Diagnosis:
Indicates the name of a failed part.

Diagnosis record:

Displays the name of the part whose diag­nosis is detected, along with the engine
running total hours.

Static test:

Checks operation sound and ignition sparks
by activating the electric fuel pump, electric
oil pump, injector and spark plug while the
engine is stopped.

Dynamic test:
Checks the engine for operation through
any change in its speed by stopping the
operation of the spark plug on each cylinder
while the engine is in the neutral position.

Engine monitor:
Indicates information on the sensors and
switches by converting it to each value
while the engine is running.

Data logger:
Indicates in numeric values the engine
speed, throttle opening voltage, oxygen
density sensor voltage, water temperature
sensor voltage and fuel pressure sensor
voltage that occurred within 13 minutes.

ECU information:
Displays the ECU identification number.

NOTE:

To use any of these functions a personal
computer, connection cables, adapter and
communication software are required.
The personal computer should be compati­ble with Windows
CD-ROM and the RS232C terminal.

®

95/98, equipped with a

1-7

GEN

INFO

1

2

3

4

5

67

SPECIAL TOOLS

ba

ba

ba

ba

ba

E

REMOVING AND INSTALLING

1 Flywheel magnet assembly holder

P/N. YB-06139 ................................ a

90890-06522 ........................... b

2 Universal puller

P/N. YB-06117 ................................ a

90890-06521 ........................... b

3 Bearing/oil seal attachment

P/N. YB-06205 ................................ a

90890-06663 ........................... b

4 Piston ring compressor

P/N. YU-33294 ................................ a

90890-06530 ........................... b

5 Bearing separator

P/N. YB-06219 ................................ a

90890-06534 ........................... b

6 Guide plate stand

P/N. 90890-06538

7 Guide plate

P/N. 90890-06501

8 Bearing puller

P/N. 90890-06535

9 Small universal claws

P/N. 90890-06536

0 Ring nut wrench

P/N. YB-34447 ................................ a

90890-06512 ........................... b

A Ring nut wrench extension

P/N. 90890-06513

8 9

0

ba

A

1-8

GEN

INFO

B

ab

CD

EF

G

I

K

M

O

SPECIAL TOOLS

H

J

L

N

P

E

B Propeller shaft housing puller

P/N. YB-06207 ................................ a

90890-06502 ........................... b

C Center bolt

P/N. 90890-06504

D Slide hammer

P/N. YB-06096

90890-06531

E Drive shaft holder

P/N. YB-06201

90890-06520

F Pinion nut holder

P/N. 90890-06505

G Pinion nut holder attachment

P/N. 90890-06508

H Bearing puller

P/N. YB-06029, YB-06247

90890-06523

I Large universal claws

P/N. 90890-06532

J Driver rod

P/N. YB-06071

90890-06604, 90890-06605,
90890-06606, 90890-06652

K Bearing/oil seal depth plate

P/N. 90890-06603

L Bearing/oil seal attachment

P/N. YB-06194, YB-06196, YB-06246

M Bearing/oil seal attachment

P/N. YB-06195, YB-06258

N Bearing/oil seal attachment

P/N. YB-06200

O Bearing/oil seal attachment

P/N. YB-06336

P Bearing/oil seal attachment

P/N. 90890-06610, 90890-06612,

90890-06631, 90890-06633,
90890-06636, 90890-06653,
90890-06654

Q Bearing/oil seal attachment

P/N. 90890-06619, 90890-06622

R Bearing/oil seal attachment

P/N. 90890-06629

Q

R

1-9

GEN

INFO

ST

UV

W

YZ

SPECIAL TOOLS

X

E

S Bearing/oil seal attachment

P/N. 90890-06637

T Bearing/oil seal attachment

P/N. 90890-06659, 90890-06660,

90890-06661, 90890-06662

U Slide hammer attachment

P/N. YB-06335

90890-06514

V End screw wrench

P/N. YB-06548

90890-06548

W End screw wrench

P/N. YB-06175-1A

X Universal holder

P/N. YU-01235

90890-01235

Y Sheave holder

P/N. YS-1880-A

90890-01701

Z Universal puller

P/N. YB-06540

90890-06540

1-10

SPEC

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

SPECIFIED TORQUES ............................................................................ 2-11

GENERAL TORQUES ............................................................................. 2-13

.............................................................................. 2-11

E

1
2
3
4
5
6
7
8
9

SPEC

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

Model

Item Unit

DIMENSION

Overall length mm (in) 792 (31.2)
Overall width mm (in) 554 (21.8)
Overall height

(X) mm (in) 1,782 (70.2)

Boat transom height

(X) mm (in) 635 (25.0)

WEIGHT

(with aluminum propeller)

(X) kg (lb) 218 (480.6)

(with stainless steel propeller)

(X) kg (lb) 222 (489.4)

PERFORMANCE

Maximum output (ISO) kW (hp)

Full throttle operating range r/min 4,500 - 5,500
Maximum fuel consumption L (US gal,

POWER UNIT

Type 2 stroke - V
Number of cylinders 6
Displacement cm
Bore × stroke mm (in) 90.0 × 68.0 (3.54 × 2.68)
Compression ratio Cylinders #1 - #4: 6.4

Fuel system Electronic fuel injection
Fuel injection system Sequential injection
Intake system Reed valve
Induction system Loop charge
Starting system Electric
Ignition control system Microcomputer
Alternator output V - A 12 - 45
Spark plugs (NGK) BKR7ES-11
Cooling system Water
Exhaust system Through propeller boss
Lubrication system Oil injection

Worldwide Z200NETO LZ200NETO

USA Z200TR LZ200TR

Canada Z200TR —

147.1 (200)

@ 5,000 r/min

68 (18.0, 15.0)

lmp gal)/hr

@ 5,500 r/min

3

(cu. in) 2,596 (158.4)

Cylinders #5 - #6: 6.1

E

2

2-1

SPEC

GENERAL SPECIFICATIONS

Model

Item Unit

Worldwide Z200NETO LZ200NETO

USA Z200TR LZ200TR

Canada Z200TR —

FUEL AND OIL

Fuel type Unleaded regular gasoline
Fuel rating *PON

RON

86

91
Engine oil type 2-stroke outboard engine oil
Engine oil grade TC-W3
Engine oil capacity

(engine oil tank)
(sub-oil tank)

L (US qt, lmp qt)
L (US qt, lmp qt)

0.9 (0.95, 0.79)

10.5 (11.1, 9.2)
Gear oil type Hypoid gear oil SAE 90
Gear oil total quantity cm

3

(US oz,

980 (33.1, 34.5) 870 (29.4, 30.6)

lmp oz)

BRACKET

Trim angle

Degree –4 - 16

(at 12˚ boat transom)
Tilt-up angle Degree 70
Steering angle Degree 32 + 32

DRIVE UNIT

Gear shift positions F-N-R
Gear ratio 1.86 (26/14)
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Spline
Propeller direction

Clockwise Counterclockwise

(rear view)

Propeller mark M ML

ELECTRICAL

Battery capacity Ah (kC) 100 (360)
Minimum cold cranking

A 512

performance

E

* PON: Pump Octane Number (Research octane + Motor octane)/2

RON: Research Octane Number

2-2

SPEC

MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

POWER UNIT

Model

Item Unit

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 (D) mm (in) 89.845 - 89.869 (3.5372 - 3.5381)
Measuring point (H) mm (in) 10 (0.4)
Piston-to-cylinder clearance mm (in) 0.150 - 0.156 (0.0059 - 0.0061)

<Limit> mm (in) 0.206 (0.0081)

Oversize piston diameter

1st mm (in) 90.11 (3.548)
2nd mm (in) 90.36 (3.557)

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)

Worldwide Z200NETO LZ200NETO

USA Z200TR LZ200TR

Canada Z200TR —

E

2

2-3

SPEC

Item Unit

CONNECTING RODS

Small-end axial play
limit (F)

Big-end side
clearance (E)

OIL INJECTION PUMP

ID mark 68F00
Bleeding Screw type

REED VALVES

Reed valve stopper height a

MAINTENANCE SPECIFICATIONS

Model

Worldwide Z200NETO LZ200NETO

USA Z200TR LZ200TR

Canada Z200TR —

mm (in) 2.0 (0.08)

mm (in) 0.12 - 0.26 (0.005 - 0.010)

mm (in) 9.0 ± 0.35 (0.35 ± 0.01)

E

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 700 ± 30

2-4

SPEC

MAINTENANCE SPECIFICATIONS

LOWER UNIT

Model

Item Unit

GEAR BACKLASH

Pinion - forward gear mm (in) 0.25 - 0.46

Pinion - reverse gear mm (in) 0.74 - 1.29

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

Worldwide Z200NETO LZ200NETO

USA Z200TR LZ200TR

Canada Z200TR —

0.21 - 0.43

(0.010 - 0.018)

(0.029 - 0.051)

(0.008 - 0.017)

0.97 - 1.29

(0.038 - 0.051)

ELECTRICAL

Model

Item Unit

IGNITION SYSTEM

Ignition timing (#1) Degree ATDC 3 - BTDC 17
Fuse 1 V-A 12-80
Fuse 2 V-A 12-30
Fuse 3 V-A 12-20
Control unit (B/O, B/Y, B/L,

B/Br, B/G, B/W – R/Y)

Output peak voltage lower
limit

Pulser coil (W/R, W/Y, W/G,

W/B, W/L, W/Br – B)

Output peak voltage lower
limit

Worldwide Z200NETO LZ200NETO

USA Z200TR LZ200TR

Canada Z200TR —

@ cranking 1 V —

@ cranking 2 V 140
@ 1,500 r/min V 205
@ 3,500 r/min V 220

@ cranking 1 V 5.0

@ cranking 2 V 5.0
@ 1,500 r/min V 20
@ 3,500 r/min V 35

E

* Cranking 1: Open circuit voltage.

Cranking 2: Loaded circuit voltage.

2-5

SPEC

Item Unit

IGNITION CONTROL SYSTEM

Crank position sensor (G/L)

Crank-position-sensor-to­flywheel gap

Output peak voltage lower
limit

Engine cooling water
temperature sensor

Resistance (B/Y – B/Y)

Throttle position sensor

Input voltage (O – R) V 4.75 - 5.25
Output voltage (P – O) V 0.50 ± 0.02

Thermo switch (P – B)

FUEL CONTROL SYSTEM

Oxygen density sensor

Heater resistance (R/W – B)
Output voltage (Gy – B/W) V 0.0 - 1.0

Atmospheric pressure sensor

Output voltage (at 101.32 kPa)

Intake air temperature sensor

Resistance (B/Y – B/Y) kΩ 1.5 - 4.0

Injector driver

(O/R – Pu/R, O/B – Pu/B,

O/Y – Pu/Y, O/G – Pu/G,

O/L – Pu/L, O/W – Pu/W)

Output peak voltage lower
limit

MAINTENANCE SPECIFICATIONS

Model

Worldwide Z200NETO LZ200NETO

USA Z200TR LZ200TR

Canada Z200TR —

mm (in) 1.0 ± 0.5 (0.04 ± 0.02)

@ cranking 1 V 4.5

@ cranking 2 V 4.0
@ 1,500 r/min V 13
@ 3,500 r/min V 20

@ 5˚C (41˚F) kΩ 128

@ 20˚C (68˚F) kΩ 54 - 69

@ 100˚C (212˚F) kΩ 3.02 - 3.48

OFF → ON ˚C (˚F) 84 - 90 (183 - 194)
ON → OFF ˚C (˚F) 60 - 74 (140 - 165)

Ω

2 - 100

V 3.2 - 4.6

(P – B)

@ cranking 1 V 65

@ cranking 2 V 60
@ 1,500 r/min V 65
@ 3,500 r/min V 65

E

* Cranking 1: Open circuit voltage.

Cranking 2: Loaded circuit voltage.

2-6

SPEC

Item Unit

Fuel pressure sensor

Output voltage (P – B) V 2.8 - 3.2

Water detection switch

Float position a “ON” mm (in) 47

STARTER MOTOR

Type Sliding gear
Output kW 1.4
Cranking time limit Second 30
Brushes

Standard length mm (in) 15.5 (0.61)
Wear limit mm (in) 9.5 (0.37)

Commutator

Standard diameter mm (in) 29.0 (1.14)
Wear limit mm (in) 28.0 (1.10)

Mica

Standard undercut mm (in) 0.5 - 0.8 (0.02 - 0.03)
Wear limit mm (in) 0.2 (0.01)

CHARGING SYSTEM

Rectifier/regulator (R – B)

Output peak voltage lower
limit

Lighting coil (G – G)

Output peak voltage lower
limit

MAINTENANCE SPECIFICATIONS

Model

Worldwide Z200NETO LZ200NETO

USA Z200TR LZ200TR

Canada Z200TR —

a

@ cranking 1 V —

@ cranking 2 V 7.5
@ 1,500 r/min V 12.7
@ 3,500 r/min V 12.7

@ cranking 1 V 7.5

@ cranking 2 V 8.0
@ 1,500 r/min V 12
@ 3,500 r/min V 12

E

* Cranking 1: Open circuit voltage.

Cranking 2: Loaded circuit voltage.

2-7

Ω

±

Ω

SPEC

Item Unit

OIL FEED PUMP CONTROL
SYSTEM

Oil level sensor
(engine oil tank)

Float position a
“OFF”

Float position b
“ON”

Float position c “ON” mm (in) 53 - 56 (2.09 - 2.20)

Oil level switch (sub-oil tank)

Float position d “ON” mm (in) 150 - 153 (5.91 - 6.02)

POWER TRIM AND TILT SYSTEM

Trim sensor

Setting resistance
Resistance (P – B)
Resistance (O – B)

POWER TRIM AND TILT MOTOR

Fluid type ATF Dexron
Brushes

Standard length mm (in) 9.8 (0.39)
Wear limit mm (in) 4.8 (0.19)

Commutator

Standard diameter mm (in) 22.0 (0.87)
Wear limit mm (in) 21.0 (0.83)

Mica

Standard undercut mm (in) 1.35 (0.05)
Wear limit mm (in) 0.85 (0.03)

MAINTENANCE SPECIFICATIONS

Model

Worldwide Z200NETO LZ200NETO

USA Z200TR LZ200TR

Canada Z200TR —

mm (in) 3 - 6 (0.12 - 0.24)

mm (in) 33 - 36 (1.30 - 1.42)

80
582 - 873

Ω

800 - 1,200

12

E

II

2-8

SPEC

DIMENSIONS

H9

H2

H7

H4

MAINTENANCE SPECIFICATIONS

L7 L6

L2 L1

W5

E

W1

H1

H3

L5

H6

L4

Symbol

Worldwide Z200NETO LZ200NETO

USA Z200TR LZ200TR

Canada Z200TR —
L1 mm (in) 613 (24.1)
L2 mm (in) 180 (7.1)
L4 mm (in) 646 (25.4)
L5 mm (in) 69 (2.7)
L6 mm (in) 1,150 (45.3)
L7 mm (in) 574 (22.6)
H1 mm (in) 1,074 (42.3)
H2 mm (in) 708 (27.9)
H3 mm (in) 211 (8.3)
H4 mm (in) 643 (25.3)
H6 mm (in) 850 (33.4)
H7 mm (in) 308 (12.1)
H9 mm (in) 835 (32.9)
W1 mm (in) 277 (10.9)
W5 mm (in) 396 (15.6)

Unit

Models

2-9