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Yamaha 150AET - User Manual

Yamaha 150AET
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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 refer-
ence 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 fol-
lows.
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.
Model name 150AET L150AET 150FETO L150FETO 150GETO
USA and
Canada name
C150TR S150TR L150TR P150TR
Indication 150AET L150AET 150FETO S150FETO L150FETO LS150FETO 150GETO
Model name D150HETO 175AET 175DETO 175FETO 200AET L200AET
USA and
Canada name
D150TR S175TR P175TR
Indication D150HETO 175AET 175DETO S175DETO 175FETO 200AET L200AET
Model name 200FETO L200FETO 200GETO 225DET 225DETO
USA and
Canada name
200TR S200TR L200TR P200TR
Indication 200FETO S200FETO L200FETO LS200FETO 200GETO 225DET 225DETO

Other manuals for Yamaha 150AET

Questions and Answers

Summary

How to Use This Manual

Manual Format

Details how procedures are organized in a sequential, step-by-step format.

Model Indication

Explains how multiple model indications are noted in the manual.

Illustrations

States that illustrations represent all designated models.

Cross References

Explains that cross references are kept to a minimum.

Identification and Serial Numbers

Serial Number Location

Describes the location of the outboard motor's serial number on a label.

Starting Serial Numbers

Lists the starting serial number blocks for various models.

Special Tools for Service

Measuring Tools

Lists and describes various measuring tools with their part numbers.

Flywheel Magnet Assembly

Removing and Installing Flywheel Magnet Assembly

Provides instructions for removing and installing the flywheel magnet assembly.

Cylinder Body Assembly Procedures

Installing the Crankshaft Assembly

Details the steps for installing the crankshaft assembly into the cylinder body.

Installing Piston and Connecting Rod Assemblies

Guides the installation of piston and connecting rod assemblies with notes.

Propeller Shaft Housing Assembly

Inspecting the Dog Clutch

Describes inspection of the dog clutch for damage or wear.

Inspecting the Propeller Shaft

Describes inspection of the propeller shaft for damage or wear.

Assembling the Propeller Shaft Housing

Provides steps for installing the needle bearing and oil seal.

Inner Propeller Shaft Assembly

Disassembling and Assembling Inner Propeller Shaft

Details the process of disassembling and assembling the inner propeller shaft.

Shimming for Forward Gear

Selecting Forward Gear Shims

Explains how to select shims to achieve a specified value for forward gear.

Backlash Measurement (Dual Propeller Models)

Measuring Front Gear Backlash

Details the procedure for measuring front gear backlash.

Summary

How to Use This Manual

Manual Format

Details how procedures are organized in a sequential, step-by-step format.

Model Indication

Explains how multiple model indications are noted in the manual.

Illustrations

States that illustrations represent all designated models.

Cross References

Explains that cross references are kept to a minimum.

Identification and Serial Numbers

Serial Number Location

Describes the location of the outboard motor's serial number on a label.

Starting Serial Numbers

Lists the starting serial number blocks for various models.

Special Tools for Service

Measuring Tools

Lists and describes various measuring tools with their part numbers.

Flywheel Magnet Assembly

Removing and Installing Flywheel Magnet Assembly

Provides instructions for removing and installing the flywheel magnet assembly.

Cylinder Body Assembly Procedures

Installing the Crankshaft Assembly

Details the steps for installing the crankshaft assembly into the cylinder body.

Installing Piston and Connecting Rod Assemblies

Guides the installation of piston and connecting rod assemblies with notes.

Propeller Shaft Housing Assembly

Inspecting the Dog Clutch

Describes inspection of the dog clutch for damage or wear.

Inspecting the Propeller Shaft

Describes inspection of the propeller shaft for damage or wear.

Assembling the Propeller Shaft Housing

Provides steps for installing the needle bearing and oil seal.

Inner Propeller Shaft Assembly

Disassembling and Assembling Inner Propeller Shaft

Details the process of disassembling and assembling the inner propeller shaft.

Shimming for Forward Gear

Selecting Forward Gear Shims

Explains how to select shims to achieve a specified value for forward gear.

Backlash Measurement (Dual Propeller Models)

Measuring Front Gear Backlash

Details the procedure for measuring front gear backlash.

Overview

This document serves as a comprehensive service manual for a range of outboard motor models, providing detailed instructions for maintenance, repair, and assembly.

Function Description

The manual outlines procedures for various components of the outboard motor, including the power unit, drive unit, and lower unit. It covers tasks such as engine assembly, propeller shaft housing assembly, water pump installation, and backlash adjustments. The manual emphasizes the use of correct special tools to ensure accurate assembly and tune-up, warning against improvisation to prevent equipment damage.

Important Technical Specifications

The manual covers a wide array of models, including 150AET, L150AET, 150FETO, L150FETO, 150GETO, D150HETO, 175AET, 175DETO, 175FETO, 200AET, L200AET, 200FETO, L200FETO, 200GETO, 225DET, and 225DETO, along with their USA and Canada names (e.g., C150TR, S150TR, L150TR, P150TR).

Engine Specifications:

  • Exhaust System: Through prop boss.
  • Lubrication System: Oil injection or Pre-mix Oil injection (depending on model).
  • Cooling System: Water.
  • Ignition System: Microcomputer (CDI).
  • Starting System: Electric.
  • Advance Type: Mechanical and microcomputer.

Fuel and Oil:

  • Fuel Type: Unleaded regular gasoline.
  • Fuel Rating: 86 or 91 RON (Research Octane Number).
  • Engine Oil Type: 2-stroke outboard engine oil.
  • Engine Oil Grade: TC-W3.
  • Engine Oil Capacity (engine oil tank): 0.9 L (0.95 US qt, 0.79 Imp qt).
  • Engine Oil Capacity (sub-oil tank): 10.5 L (11.1 US qt, 9.2 Imp qt).
  • Gear Oil Type: Hypoid gear oil SAE 90.
  • Gear Oil Total Quantity: 980 cm³ (33.1 US oz, 34.5 Imp oz) for most models; 870 cm³ (29.4 US oz, 30.6 Imp oz) for L200FETO.

Bracket:

  • Trim Angle (at 12° boat transom): -4 to 16 degrees.
  • Tilt-up Angle: 70 degrees.
  • Steering Angle: 35 + 35 degrees.

Drive Unit:

  • Gear Shift Positions: F-N-R (Forward-Neutral-Reverse).
  • Gear Ratio: 1.86 (26/14).
  • Reduction Gear Type: Spiral bevel gear.
  • Clutch Type: Dog clutch.
  • Propeller Shaft Type: Spline.
  • Propeller Direction (rear view): Clockwise or Counterclockwise (for L200FETO).

Torque Specifications:

  • Flywheel magnet assembly nut: 190 Nm (19 m·kgf, 137 ft·lb) for Oil injection and 225DET models; 165 Nm (16.5 m·kgf, 120 ft·lb) for Pre-mix except for 225DET models.
  • Cylinder head bolts (1st step): 4 Nm (0.4 m·kgf, 2.9 ft·lb).
  • Cylinder head bolts (2nd step): 8 Nm (0.8 m·kgf, 5.8 ft·lb).
  • Cylinder head bolts (1st step, specific bolts): 15 Nm (1.5 m·kgf, 11 ft·lb).
  • Cylinder head bolts (2nd step, specific bolts): 30 Nm (3.0 m·kgf, 22 ft·lb).
  • Propeller nut (for backlash measurement): 10 Nm (1.0 m·kgf, 7.2 ft·lb).
  • Universal puller (for propeller shaft housing puller): 10 Nm (1.0 m·kgf, 7.2 ft·lb).

Special Tools:

  • Tachometer: P/N. YU-08036-A / 90890-06760.
  • Pressure tester: P/N. YB-35956 / 90890-06762.
  • Mity vac: P/N. YB-35956 / 90890-06756.
  • Pinion height gauge: P/N. YB-34432-7, YB-34432-11, YB-34432-97 / 90890-06702.
  • Dial gauge set: P/N. YU-03097 / 90890-01252.
  • Magnetic base: P/N. YU-34481 / 90890-06705.
  • Digital caliper: P/N. 90890-06704.
  • Backlash indicator: P/N. YB-06265 / 90890-06706.
  • Magnetic base attaching plate: P/N. YB-07003 / 90890-07003.
  • Hydraulic pressure gauge: P/N. 90890-06776.
  • Up-relief valve attachment: P/N. 90890-06773.
  • Down-relief valve attachment: P/N. 90890-06774.
  • Piston ring compressor: YU-33294 / 90890-06530.
  • Shift rod wrench: YB-06052 / 90890-06052.
  • Bearing/oil seal attachment: YB-06196 / 90890-06610.
  • Driver rod: YB-06071 / 90890-06604.
  • Bearing/oil seal depth plate: 90890-06603.
  • Bearing/oil seal attachment (for oil seal): YB-06195 / 90890-06633.
  • Propeller shaft housing puller: YB-06502 / 90890-06502.
  • Universal puller: YB-06540 / 90890-06540.

Installation Positions:

  • Needle bearing installation position: 24.75 - 25.25 mm (0.974 - 0.994 in).
  • Oil seal installation position: 4.75 - 5.25 mm (0.187 - 0.207 in).

Backlash Specifications:

  • Front gear backlash: 0.19 - 0.59 mm (0.007 - 0.023 in).

Usage Features

The manual is structured for ease of use, with procedures organized in a sequential, step-by-step format. It includes illustrations for all designated models to aid understanding. Cross-references are kept to a minimum, directing users to relevant sections or chapters.

Model Identification:

  • The manual provides a table of model names, USA and Canada names, and their corresponding indications for easy reference.
  • Outboard motor serial numbers are stamped on a label attached to the port clamp bracket. This label is specially treated to crack if peeled off, serving as an anti-theft measure. The label includes the model name, approval model code, transom height, and serial number. Starting serial number blocks are also provided.

Troubleshooting:

  • The manual uses an arrow symbol (→) to indicate the course of action required for faulty components (e.g., "Pitting/scratches → Replace" for bearings).

Maintenance Features

The manual includes a detailed "Maintenance Interval Chart" as a guide for general maintenance, with intervals adjustable based on operating conditions.

Maintenance Intervals:

  • Initial (Break-in): 10 hours.
  • Every: 50 hours (3 months), 100 hours (6 months), 200 hours (1 year), and every month (for battery inspection/charge).

Maintenance Tasks:

  • Top Cowling: Inspect fit.
  • Fuel System: Inspect fuel line, clean/inspect fuel filter, clean carburetor.
  • Power Unit: Inspect water leakage, motor exterior, exhaust leakage, clean/flush cooling water passage.
  • Control System: Inspect/adjust carburetor synchronization, engine idling speed, remote control shift cable, remote control throttle cable.
  • Oil Injection System: Clean oil tank water drain, inspect/adjust oil pump lever.
  • Power Trim and Tilt Unit: Inspect power trim and tilt fluid.
  • Lower Unit: Change gear oil, inspect lower unit leakage, inspect propeller.
  • General: Inspect/replace anodes, inspect/charge battery, clean/adjust/replace spark plugs, adjust/reconnect wiring and connectors, tighten bolts and nuts, grease lubrication points.

Reusable/Non-reusable Parts:

  • Gaskets for cylinder heads are explicitly marked as "Not reusable" and must be replaced during assembly.

Installation Procedures:

  • For most installation steps, the manual instructs to "reverse the removal procedure," simplifying instructions.
  • Specific instructions are provided for installing components like the crankshaft assembly (aligning labyrinth ring end gaps and bearing locating pins) and piston and connecting rod assemblies (lubricating cylinder walls, reinstalling in original cylinders, orienting "S" and "P" marks for starboard and port sides respectively, and ensuring "UP" mark faces the flywheel).

Yamaha 150AET Specifications

General IconGeneral
BrandYamaha
Model150AET
CategoryOutboard Motor
LanguageEnglish

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