YAMAHA Z200N, LZ200N, Z200Y, LZ200Y PARTS CATALOGUE

WORLDWIDE

Z200N

LZ200N

USA, CANADA

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

E

HOW TO USE THIS MANUAL

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy 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.

	Model name	Z200NETO	LZ200NETO
	USA and	Z200TR	LZ200TR
	Canada name
	Indication	Z200NETO	LZ200NETO

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 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.

E

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 or screws are also mentioned.

Example:

Bolt or screw size

10 × 25 mm

: diameter (D) × length (L)

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

4

FUEL

POWER UNIT

5

POWR

LOWER UNIT

6

LOWR

BRACKET UNIT

7

BRKT

8

– +

ELECTRICAL SYSTEMS

ELEC

TROUBLE ANALYSIS	9
ANLSTRBL

	GEN			E
	INFO
				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 ...............................................................	1-8

1

2

3

4

5

6

7

8

9

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.

1 Model name

2 Approved model code

3 Transom height

4 Serial number

STARTING SERIAL NUMBERS

The starting serial number blocks are as follows:

Model name			Approved	Starting
			model	serial
Worldwide	USA	Canada
			code	number
Z200NETO	Z200TR	Z200TR	6G6	X: 100101 -
LZ200NETO	LZ200TR	—	6K1	X: 100101	-

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.

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

E

3.Non-reusable items

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

DISASSEMBLY AND ASSEMBLY

1.Clean parts with compressed air when disassembling.

2.Oil the contact surfaces of moving parts 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

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 USA and Canada, use part numbers
			that start with “J-”, “YB-”, “YM-”, “YS-”,
			“YU-” or “YW-”.
1		• For worldwide, use part numbers that
a	b		start with “90890-”.

		MEASURING
		1	Tachometer
2	3		P/N. YU-08036-A ............................	a
			90890-06760 ...........................	b
		2	Fuel pressure gauge
			P/N. YB-06766
			90890-06786
4	5	3	Mity vac
			P/N. YB-35956
			90890-06756
		4	Pressure tester
			P/N. YB-35956
6			90890-06762
		5	Digital caliper
a	b
			P/N. 90890-06704
		6	Pinion height gauge
			P/N. YB-34432-7, YB-34432-11 ......	a
			90890-06702 ...........................	b
		7	Shimming gauge
7	8		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
9			P/N. 90890-06701
		0	Shift rod wrench
			P/N. YB-06052 ................................	a
			90890-06052 ...........................	b
0
a	b

1-5

	GEN			SPECIAL TOOLS
	INFO						E
					A Magnetic base
	A			B
					P/N. YU-34481
						90890-06705
					B Magnetic base attaching plate
					P/N. YB-07003
						90890-07003
	C			D	C Backlash indicator
					P/N. YB-06265
						90890-06706
					D Dial gauge set
					P/N. YU-03097
	E			F		90890-01252
					E Hydraulic pressure gauge
					P/N.	90890-06776
					F Up-relief valve attachment
					P/N.	90890-06773
	G				Down-relief valve attachment
				b	P/N.	90890-06774
	a				G Digital tester
					P/N. J-39299 ...................................		a
						90890-06752 ...........................	b
					H Peak voltage adapter
	H				P/N. YU-39991 ................................		a
	a			b		90890-03169 ...........................	b
					I Spark gap tester
					P/N. YM-34487 ...............................		a
						90890-06754 ...........................	b
					J Test harness
					P/N. YB-06443, YB-06767,
	I					YB-06768, YB-06769,
	a			b		YB-06779, YB-06787,
						YB-06788
						90890-06757, 90890-06767,
						90890-06768, 90890-06769,
						90890-06779, 90890-06787,
						90890-06788
	J				K Diagnostic indicator
					P/N. YB-06765
						90890-06765

K

1-6

GEN INFO

SPECIAL TOOLS

E

LDiagnostic 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® 95/98, equipped with a CD-ROM and the RS232C terminal.

1-7

	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
2						P/N. YB-06117 ................................	a
				b		90890-06521 ...........................	b
	a				3	Bearing/oil seal attachment
						P/N. YB-06205 ................................	a
						90890-06663 ...........................	b
					4	Piston ring compressor
						P/N. YU-33294 ................................	a
3						90890-06530 ...........................	b
	a			b	5 Bearing separator
						P/N. YB-06219 ................................	a
						90890-06534 ...........................	b
					6	Guide plate stand
4						P/N. 90890-06538
	a			b	7 Guide plate
						P/N. 90890-06501
					8	Bearing puller
						P/N. 90890-06535
5					9	Small universal claws
	a			b		P/N. 90890-06536
					0	Ring nut wrench
						P/N. YB-34447 ................................	a
						90890-06512 ...........................	b
					A Ring nut wrench extension
6				7		P/N. 90890-06513

89

0

ab

A

1-8

	GEN			SPECIAL TOOLS
	INFO					E
					B Propeller shaft housing puller
	B
				b	P/N.	YB-06207 ................................ a
	a					90890-06502 ........................... b
					C Center bolt
					P/N.	90890-06504
					D Slide hammer
	C			D	P/N. YB-06096
						90890-06531
					E Drive shaft holder
					P/N. YB-06201
						90890-06520
					F Pinion nut holder
	E			F	P/N.	90890-06505
					G Pinion nut holder attachment
					P/N.	90890-06508
					H Bearing puller
					P/N. YB-06029, YB-06247
						90890-06523
	G			H	I Large universal claws
					P/N.	90890-06532
					J Driver rod
					P/N. YB-06071
						90890-06604, 90890-06605,
	I			J		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
	K			L	P/N. YB-06195, YB-06258
					N Bearing/oil seal attachment
					P/N. YB-06200
					O Bearing/oil seal attachment
					P/N. YB-06336
	M			N	P Bearing/oil seal attachment
					P/N.	90890-06610, 90890-06612,
						90890-06631, 90890-06633,
						90890-06636, 90890-06653,
						90890-06654
	O			P	Q Bearing/oil seal attachment
					P/N.	90890-06619, 90890-06622
					R Bearing/oil seal attachment
					P/N.	90890-06629

QR

1-9

GEN	SPECIAL TOOLS
INFO		E
		S Bearing/oil seal attachment
S	T	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
U	V	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
W	X	90890-01235
		Y Sheave holder
		P/N. YS-1880-A
		90890-01701
		Z Universal puller
		P/N. YB-06540
		90890-06540

YZ

1-10

	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

E

GENERAL SPECIFICATIONS

					Model
Item	Worldwide	Unit	Z200NETO			LZ200NETO
	USA		Z200TR			LZ200TR
	Canada		Z200TR			—
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)			147.1 (200)
		@ 5,000 r/min
Full throttle operating range		r/min		4,500 - 5,500
Maximum fuel consumption		L (US gal,		68 (18.0, 15.0)
		lmp gal)/hr
		@ 5,500 r/min
POWER UNIT
Type				2 stroke - V
Number of cylinders					6
Displacement		cm3 (cu. in)		2,596 (158.4)
Bore × stroke		mm (in)	90.0 × 68.0 (3.54 × 2.68)
Compression ratio			Cylinders #1 - #4: 6.4
			Cylinders #5 - #6: 6.1
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

2-1

SPEC

GENERAL SPECIFICATIONS

E

				Model
Item	Worldwide	Unit	Z200NETO		LZ200NETO
	USA		Z200TR		LZ200TR
	Canada		Z200TR		—
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, lmp qt)	0.9 (0.95, 0.79)
(sub-oil tank)		L (US qt, lmp qt)	10.5 (11.1, 9.2)
Gear oil type			Hypoid gear oil SAE 90
Gear oil total quantity		cm3 (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

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

2-2

	SPEC			MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

POWER UNIT

E

				Model
Item	Worldwide	Unit	Z200NETO		LZ200NETO
	USA		Z200TR		LZ200TR
	Canada		Z200TR		—
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)

2-3

SPEC

MAINTENANCE SPECIFICATIONS

E

				Model
Item	Worldwide	Unit	Z200NETO		LZ200NETO
	USA		Z200TR		LZ200TR
	Canada		Z200TR		—
CONNECTING	RODS
Small-end axial play		mm (in)		2.0 (0.08)
limit (F)
Big-end side		mm (in)	0.12 - 0.26 (0.005 - 0.010)
clearance (E)
OIL INJECTION PUMP
ID mark				68F00
Bleeding			Screw type
REED VALVES
Reed valve stopper height a		mm (in)	9.0 ± 0.35 (0.35 ± 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		700 ± 30

2-4

SPEC

MAINTENANCE SPECIFICATIONS

E

LOWER UNIT

Model

Item

Worldwide

Unit

Z200NETO

LZ200NETO

USA

Z200TR

LZ200TR

Canada

Z200TR

—

GEAR BACKLASH

Pinion - forward gear

mm (in)

0.25 - 0.46

0.21 - 0.43

(0.010 - 0.018)

(0.008 - 0.017)

Pinion - reverse gear

mm (in)

0.74 - 1.29

0.97 - 1.29

(0.029 - 0.051)

(0.038 - 0.051)

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

Z200NETO

LZ200NETO

USA

Z200TR

LZ200TR

Canada

Z200TR

—

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

@ cranking 1

V

—

@ cranking 2

V

140

@ 1,500 r/min

V

205

@ 3,500 r/min

V

220

Pulser coil

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

W/B, W/L, W/Br – B)

Output peak voltage lower

limit

@ cranking 1

V

5.0

@ cranking 2

V

5.0

@ 1,500 r/min

V

20

@ 3,500 r/min

V

35

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

2-5

SPEC

MAINTENANCE SPECIFICATIONS

E

						Model
Item		Worldwide		Unit	Z200NETO		LZ200NETO
			USA		Z200TR		LZ200TR
			Canada		Z200TR		—
IGNITION CONTROL	SYSTEM
Crank position sensor			(G/L)
Crank-position-sensor-to-				mm (in)	1.0 ± 0.5 (0.04 ± 0.02)
flywheel gap
Output peak voltage lower
limit
@ cranking 1				V		4.5
@ cranking 2				V		4.0
@ 1,500 r/min				V		13
@ 3,500 r/min				V		20
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		0.50 ± 0.02
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			(R/W – B)	Ω		2 - 100
Output voltage		(Gy – B/W)		V		0.0 - 1.0
Atmospheric pressure sensor
Output voltage (at 101.32 kPa)				V		3.2 - 4.6
			(P – B)
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
@ cranking 1				V		65
@ cranking 2				V		60
@ 1,500 r/min				V		65
@ 3,500 r/min				V		65

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

2-6

SPEC

MAINTENANCE SPECIFICATIONS

E

			Model
Item	Worldwide	Z200NETO	LZ200NETO
	USA	Unit	LZ200TR
		Z200TR
	Canada	Z200TR	—
Fuel pressure sensor
Output voltage	(P – B)	V	2.8 - 3.2
Water detection switch
Float position a “ON”		mm (in)	47
	a
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
	@ cranking 1	V	—
	@ cranking 2	V	7.5
@ 1,500 r/min		V	12.7
@ 3,500 r/min		V	12.7
Lighting coil	(G – G)
Output peak voltage lower
limit
	@ cranking 1	V	7.5
	@ cranking 2	V	8.0
@ 1,500 r/min		V	12
@ 3,500 r/min		V	12

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

2-7

SPEC

MAINTENANCE SPECIFICATIONS

E

					Model
Item		Worldwide	Unit	Z200NETO		LZ200NETO
		USA		Z200TR		LZ200TR
		Canada		Z200TR		—
OIL FEED PUMP CONTROL
SYSTEM
Oil level sensor
(engine oil tank)
Float position a			mm (in)	3 - 6 (0.12 - 0.24)
“OFF”
Float position b			mm (in)	33 - 36 (1.30 - 1.42)
“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			Ω		80 ± 12
Resistance		(P – B)	Ω		582 - 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 (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)

2-8

	SPEC			MAINTENANCE SPECIFICATIONS	E
	DIMENSIONS

L7

L6

L2 L1

W1

H9	W5
	H2
	H7

H4

H1

H6

H3

L5

L4

	Symbol		Models
	Worldwide	Unit	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)

2-9