This Service & Repair Manual covers the Yamaha LIT 18616 02 82 z150c 2004 outboard motor. Designed for reliable performance, this internal combustion engine is built to the high engineering standards expected of Yamaha products. This manual is specifically for the 2004 model year and details various engine configurations including the Z150C, Z175C, and Z200C series, along with their respective power units and lower units.
This comprehensive 316-page English language manual provides essential information for the maintenance and repair of your Yamaha outboard motor. It includes detailed sections on scheduled maintenance, lubrication, inspection schedules, break-in procedures, and test runs. Furthermore, it covers critical technical specifications, electrical system details, and torque specifications for various components. Owners, mechanics, and technicians will find this manual an indispensable resource for ensuring the optimal performance and longevity of their Z150C, LZ150C, VZ150C, Z175C, VZ175C, Z200C, LZ200C, and VZ200C models.
Do you want to service & repair your Yamaha (L)Z150C, VZ150C, (V)Z175C, (L)Z200C, VZ200C 2004 yourself? We can help you with the official certified Service & Repair manual; just push the button INSTANT DOWNLOAD on the left side, download the file and you can start right away.
This manual covers the following model(s):
Z150C 2004
LZ150C 2004
VZ150C 2004
Z175C 2004
VZ175C 2004
Z200C 2004
LZ200C 2004
VZ200C 2004
We only sell original manuals; the quality of the files is exceptionally good. When you print the file, the pictures are of good quality and very bright. WE DO NOT SELL ANY COPIED MANUALS, ONLY THE ORIGINAL!!!!
In this manual you have the following chapters:
General information
How to use this manual
Manual format
Symbols
Safety while working
Fire prevention
Ventilation
Self-protection
Parts, lubricants, and sealants
Good working practices
Disassembly and assembly
Identification
Applicable models
Serial number
Propeller selection
Propeller size
Selection
Predelivery checks
Checking the fuel system
Checking the gear oil level
Checking the engine oil level
Checking the battery
Checking the outboard motor mounting height
Checking the remote control cables
Checking the steering system
Checking the gear shift and throttle operation
Checking the power trim and tilt system
Checking the engine start switch and engine stop lanyard switch
Checking the cooling water pilot hole
Test run
Break-in
After test run
Specifications
General specifications
Maintenance specifications
Power unit (Z150 models)
Lower unit (Z150 models)
Electrical (Z150 models)
Power unit (Z175 models)
Lower unit (Z175 models)
Electrical (Z175 models)
Power unit (Z200 models)
Lower unit (Z200 models)
Electrical (Z200 models)
Dimensions
Tightening torques
Specified torques
General torques
Periodic checks and adjustments
Special service tools
Maintenance interval chart
Top cowling
Checking the top cowling
Fuel system
Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector)
Checking the fuel filter
Checking the high-pressure fuel pump gear oil level
Changing the high-pressure fuel pump gear oil
Power unit
Checking the engine oil level
Checking the drive belt
Checking the spark plugs
Checking the thermostats
Checking the cooling water passage
Control system
Checking the engine idle speed
Adjusting the throttle cable
Checking the gear shift operation
Oil injection system
Adjusting the oil pump link rod
Power trim and tilt unit
Checking the power trim and tilt operation
Checking the power trim and tilt fluid level
Lower unit
Checking the gear oil level
Changing the gear oil
Checking the lower unit for air leakage
Checking the propeller
General
Checking the anodes
Checking the battery
Lubricating the outboard motor
Fuel system
Special service tools
Hose routing
Fuel hoses and fuel pipes
Fuel filter
Fuel pump
Checking the fuel pumps
Disassembling the fuel pumps
Assembling the fuel pumps
Oil injection system
Checking the check valve
Checking the oil filter
Checking the oil tank
Assembling the oil tank
Installing the oil pump
Bleeding the oil injection system
Throttle body assembly and vapor separator
Measuring the fuel pressure (medium-pressure fuel line)
Checking the pressure regulator
Reducing the fuel pressure (medium-pressure fuel line)
Disconnecting the medium-pressure fuel hose joint
Removing the throttle body assembly
Removing the medium-pressure fuel hose clamps
Installing the medium-pressure fuel hose clamps
Removing the electric fuel pump filter
Checking the vapor separator
Installing the electric fuel pump filter
Installing the throttle body assembly
Synchronizing the throttle valves
Adjusting the throttle position sensor
High-pressure fuel line
High-pressure fuel pump
Installing the joints
Installing the fuel pipes
Installing the fuel injectors
Power unit
Special service tools
Power unit
Checking the compression pressure
Removing the drive belt and sprockets
Checking the drive belt and sprockets
Installing the sprockets and drive belt
Removing the power unit
Removing the flywheel magnet
Removing the stator coil and pulser coil
Removing the starter motor
Intake manifold
Removing the intake manifold
Checking the reed valve
Throttle lever and shift position switch
Cylinder head
Removing the cylinder head
Checking the cylinder head
Exhaust cover
Removing the exhaust cover
Checking the pressure control valve
Installing the pressure control valve
Crankcase
Lower unit
Special service tools
Lower unit (regular rotation model)
Removing the lower unit
Removing the water pump and shift rod
Checking the water pump and shift rod
Propeller shaft housing (regular rotation model)
Removing the propeller shaft housing assembly
Disassembling the propeller shaft assembly
Disassembling the propeller shaft housing
Checking the propeller shaft housing
Checking the propeller shaft
Assembling the propeller shaft assembly
Assembling the propeller shaft housing
Drive shaft and lower case (regular rotation model)
Removing the drive shaft
Disassembling the drive shaft housing
Disassembling the forward gear
Disassembling the lower case
Checking the pinion and forward gear
Checking the bearings
Checking the drive shaft
Checking the lower case
Assembling the lower case
Assembling the forward gear
Assembling the drive shaft housing
Installing the drive shaft
Installing the propeller shaft housing
Installing the water pump and shift rod
Installing the lower unit
Shimming (regular rotation model)
Shimming
Selecting the pinion shims
Selecting the forward gear shims
Selecting the reverse gear shims
Backlash (regular rotation model)
Measuring the forward and reverse gear backlash
Lower unit (counter rotation model)
Removing the lower unit
Removing the water pump and shift rod
Checking the water pump and shift rod
Propeller shaft housing (counter rotation model)
Removing the propeller shaft housing assembly
Disassembling the propeller shaft assembly
Disassembling the forward gear
Disassembling the propeller shaft housing
Checking the propeller shaft housing
Checking the propeller shaft
Assembling the propeller shaft housing
Drive shaft and lower case (counter rotation model)
Removing the drive shaft
Disassembling the drive shaft housing
Disassembling the reverse gear
Disassembling the lower case
Checking the pinion and reverse gear
Checking the bearings
Checking the drive shaft
Checking the lower case
Assembling the lower case
Assembling the reverse gear
Assembling the drive shaft housing
Installing the drive shaft
Installing the propeller shaft housing
Installing the water pump and shift rod
Installing the lower unit
Shimming (counter rotation model)
Shimming
Selecting the pinion shims
Selecting the reverse gear shims
Selecting the forward gear shims
Selecting the propeller shaft shims
Backlash (counter rotation model)
Measuring the forward and reverse gear backlash
Bracket unit
Special service tools
Bottom cowling
Upper case
Disassembling the upper case
Checking the upper case
Removing the drive shaft bushing (X-transom model)
Checking the drive shaft bushing (X-transom model)
Installing the drive shaft bushing (X-transom model)
Assembling the upper case
Steering arm
Removing the steering arm
Installing the steering arm
Installing the upper case
Power trim and tilt unit
Removing the power trim and tilt unit
Checking the hydraulic pressure
Disassembling the power trim and tilt motor
Checking the power trim and tilt motor
Assembling the power trim and tilt motor
Removing the reservoir
Disassembling the gear pump housing
Checking the gear pump
Assembling the gear pump housing
Disassembling the tilt cylinder and trim cylinders
Checking the tilt cylinder and trim cylinder
Assembling the tilt piston and trim pistons
Assembling the power trim and tilt unit
Bleeding the power trim and tilt unit
Installing the power trim and tilt unit
Bleeding the power trim and tilt unit (built-in)
Clamp brackets
Removing the clamp brackets
Installing the clamp brackets
Adjusting the trim sensor cam
Power trim and tilt electrical system
Checking the fuse
Checking the power trim and tilt relay
Checking the power trim and tilt switch
Checking the trim sensor
Electrical systems
Special service tools
Checking the electrical components
Measuring the peak voltage
Measuring the lower resistance
Electrical components
Port view
Starboard view
Junction box assembly
Aft view
Top view
Wiring harness
Ignition and ignition control system
Checking the ignition spark
Checking the spark plug caps
Checking the ignition coils
Checking the ECM
Checking the pulser coil
Checking the crank position sensor
Checking the crank position sensor air gap
Checking the throttle position sensor
Checking the sensor assembly
Checking the engine temperature sensor
Checking the thermoswitches
Checking the shift position switch
Checking the ECM main relay
Fuel control system
Checking the injector drivers
Checking the fuel pressure sensor
Checking the water detection switch
Checking the electric fuel pump
Checking the electric fuel pump relay
Checking the injector driver relay
Checking the oxygen density sensor
Starting system
Checking the fuses
Checking the starter relay
Starter motor
Disassembling the starter motor
Checking the starter motor pinion
Checking the armature
Checking the brushes
Checking the magnet switch
Checking the starter motor operation
Charging system
Checking the stator coil
Checking the Rectifier Regulator
Oil feed pump control system
Checking the electric oil pump
Checking the oil level sensor
Checking the emergency switch
Checking the oil pump (remote oil tank)
Troubleshooting
Special service tools
Yamaha Diagnostic System
Introduction
Power unit
Self-diagnosis
Diagnosing the electronic control system
Language: English
Format: PDF
Pages: 316
If you have a request, dont hesitate to ask us
Do you want to service & repair your Yamaha (L)Z150C, VZ150C, (V)Z175C, (L)Z200C, VZ200C 2004 yourself? We can help you with the official certified Service & Repair manual; just push the button INSTANT DOWNLOAD on the left side, download the file and you can start right away.
This manual covers the following model(s):
Z150C 2004
LZ150C 2004
VZ150C 2004
Z175C 2004
VZ175C 2004
Z200C 2004
LZ200C 2004
VZ200C 2004
We only sell original manuals; the quality of the files is exceptionally good. When you print the file, the pictures are of good quality and very bright. WE DO NOT SELL ANY COPIED MANUALS, ONLY THE ORIGINAL!!!!
In this manual you have the following chapters:
General information
How to use this manual
Manual format
Symbols
Safety while working
Fire prevention
Ventilation
Self-protection
Parts, lubricants, and sealants
Good working practices
Disassembly and assembly
Identification
Applicable models
Serial number
Propeller selection
Propeller size
Selection
Predelivery checks
Checking the fuel system
Checking the gear oil level
Checking the engine oil level
Checking the battery
Checking the outboard motor mounting height
Checking the remote control cables
Checking the steering system
Checking the gear shift and throttle operation
Checking the power trim and tilt system
Checking the engine start switch and engine stop lanyard switch
Checking the cooling water pilot hole
Test run
Break-in
After test run
Specifications
General specifications
Maintenance specifications
Power unit (Z150 models)
Lower unit (Z150 models)
Electrical (Z150 models)
Power unit (Z175 models)
Lower unit (Z175 models)
Electrical (Z175 models)
Power unit (Z200 models)
Lower unit (Z200 models)
Electrical (Z200 models)
Dimensions
Tightening torques
Specified torques
General torques
Periodic checks and adjustments
Special service tools
Maintenance interval chart
Top cowling
Checking the top cowling
Fuel system
Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector)
Checking the fuel filter
Checking the high-pressure fuel pump gear oil level
Changing the high-pressure fuel pump gear oil
Power unit
Checking the engine oil level
Checking the drive belt
Checking the spark plugs
Checking the thermostats
Checking the cooling water passage
Control system
Checking the engine idle speed
Adjusting the throttle cable
Checking the gear shift operation
Oil injection system
Adjusting the oil pump link rod
Power trim and tilt unit
Checking the power trim and tilt operation
Checking the power trim and tilt fluid level
Lower unit
Checking the gear oil level
Changing the gear oil
Checking the lower unit for air leakage
Checking the propeller
General
Checking the anodes
Checking the battery
Lubricating the outboard motor
Fuel system
Special service tools
Hose routing
Fuel hoses and fuel pipes
Fuel filter
Fuel pump
Checking the fuel pumps
Disassembling the fuel pumps
Assembling the fuel pumps
Oil injection system
Checking the check valve
Checking the oil filter
Checking the oil tank
Assembling the oil tank
Installing the oil pump
Bleeding the oil injection system
Throttle body assembly and vapor separator
Measuring the fuel pressure (medium-pressure fuel line)
Checking the pressure regulator
Reducing the fuel pressure (medium-pressure fuel line)
Disconnecting the medium-pressure fuel hose joint
Removing the throttle body assembly
Removing the medium-pressure fuel hose clamps
Installing the medium-pressure fuel hose clamps
Removing the electric fuel pump filter
Checking the vapor separator
Installing the electric fuel pump filter
Installing the throttle body assembly
Synchronizing the throttle valves
Adjusting the throttle position sensor
High-pressure fuel line
High-pressure fuel pump
Installing the joints
Installing the fuel pipes
Installing the fuel injectors
Power unit
Special service tools
Power unit
Checking the compression pressure
Removing the drive belt and sprockets
Checking the drive belt and sprockets
Installing the sprockets and drive belt
Removing the power unit
Removing the flywheel magnet
Removing the stator coil and pulser coil
Removing the starter motor
Intake manifold
Removing the intake manifold
Checking the reed valve
Throttle lever and shift position switch
Cylinder head
Removing the cylinder head
Checking the cylinder head
Exhaust cover
Removing the exhaust cover
Checking the pressure control valve
Installing the pressure control valve
Crankcase
Lower unit
Special service tools
Lower unit (regular rotation model)
Removing the lower unit
Removing the water pump and shift rod
Checking the water pump and shift rod
Propeller shaft housing (regular rotation model)
Removing the propeller shaft housing assembly
Disassembling the propeller shaft assembly
Disassembling the propeller shaft housing
Checking the propeller shaft housing
Checking the propeller shaft
Assembling the propeller shaft assembly
Assembling the propeller shaft housing
Drive shaft and lower case (regular rotation model)
Removing the drive shaft
Disassembling the drive shaft housing
Disassembling the forward gear
Disassembling the lower case
Checking the pinion and forward gear
Checking the bearings
Checking the drive shaft
Checking the lower case
Assembling the lower case
Assembling the forward gear
Assembling the drive shaft housing
Installing the drive shaft
Installing the propeller shaft housing
Installing the water pump and shift rod
Installing the lower unit
Shimming (regular rotation model)
Shimming
Selecting the pinion shims
Selecting the forward gear shims
Selecting the reverse gear shims
Backlash (regular rotation model)
Measuring the forward and reverse gear backlash
Lower unit (counter rotation model)
Removing the lower unit
Removing the water pump and shift rod
Checking the water pump and shift rod
Propeller shaft housing (counter rotation model)
Removing the propeller shaft housing assembly
Disassembling the propeller shaft assembly
Disassembling the forward gear
Disassembling the propeller shaft housing
Checking the propeller shaft housing
Checking the propeller shaft
Assembling the propeller shaft housing
Drive shaft and lower case (counter rotation model)
Removing the drive shaft
Disassembling the drive shaft housing
Disassembling the reverse gear
Disassembling the lower case
Checking the pinion and reverse gear
Checking the bearings
Checking the drive shaft
Checking the lower case
Assembling the lower case
Assembling the reverse gear
Assembling the drive shaft housing
Installing the drive shaft
Installing the propeller shaft housing
Installing the water pump and shift rod
Installing the lower unit
Shimming (counter rotation model)
Shimming
Selecting the pinion shims
Selecting the reverse gear shims
Selecting the forward gear shims
Selecting the propeller shaft shims
Backlash (counter rotation model)
Measuring the forward and reverse gear backlash
Bracket unit
Special service tools
Bottom cowling
Upper case
Disassembling the upper case
Checking the upper case
Removing the drive shaft bushing (X-transom model)
Checking the drive shaft bushing (X-transom model)
Installing the drive shaft bushing (X-transom model)
Assembling the upper case
Steering arm
Removing the steering arm
Installing the steering arm
Installing the upper case
Power trim and tilt unit
Removing the power trim and tilt unit
Checking the hydraulic pressure
Disassembling the power trim and tilt motor
Checking the power trim and tilt motor
Assembling the power trim and tilt motor
Removing the reservoir
Disassembling the gear pump housing
Checking the gear pump
Assembling the gear pump housing
Disassembling the tilt cylinder and trim cylinders
Checking the tilt cylinder and trim cylinder
Assembling the tilt piston and trim pistons
Assembling the power trim and tilt unit
Bleeding the power trim and tilt unit
Installing the power trim and tilt unit
Bleeding the power trim and tilt unit (built-in)
Clamp brackets
Removing the clamp brackets
Installing the clamp brackets
Adjusting the trim sensor cam
Power trim and tilt electrical system
Checking the fuse
Checking the power trim and tilt relay
Checking the power trim and tilt switch
Checking the trim sensor
Electrical systems
Special service tools
Checking the electrical components
Measuring the peak voltage
Measuring the lower resistance
Electrical components
Port view
Starboard view
Junction box assembly
Aft view
Top view
Wiring harness
Ignition and ignition control system
Checking the ignition spark
Checking the spark plug caps
Checking the ignition coils
Checking the ECM
Checking the pulser coil
Checking the crank position sensor
Checking the crank position sensor air gap
Checking the throttle position sensor
Checking the sensor assembly
Checking the engine temperature sensor
Checking the thermoswitches
Checking the shift position switch
Checking the ECM main relay
Fuel control system
Checking the injector drivers
Checking the fuel pressure sensor
Checking the water detection switch
Checking the electric fuel pump
Checking the electric fuel pump relay
Checking the injector driver relay
Checking the oxygen density sensor
Starting system
Checking the fuses
Checking the starter relay
Starter motor
Disassembling the starter motor
Checking the starter motor pinion
Checking the armature
Checking the brushes
Checking the magnet switch
Checking the starter motor operation
Charging system
Checking the stator coil
Checking the Rectifier Regulator
Oil feed pump control system
Checking the electric oil pump
Checking the oil level sensor
Checking the emergency switch
Checking the oil pump (remote oil tank)
Troubleshooting
Special service tools
Yamaha Diagnostic System
Introduction
Power unit
Self-diagnosis
Diagnosing the electronic control system
Language: English
Format: PDF
Pages: 316
If you have a request, dont hesitate to ask us
