1999–2003 Yamaha 150 HP, 200 HP V6 Outboard Service Manual (P/N 67H28197Z811)

This service manual covers the listed 1999–2003 Yamaha 150 HP and 200 HP V6 two-stroke outboards in the SX150, LX150, PX150, DX150, SX200, and LX200 families. Yamaha publication 67H-28197-Z8-11 is the first edition, dated October 1998.

Navigation and wiring detail: The technical chapters are not text-searchable. Embedded bookmarks cover all nine chapters and individual procedures. Small wiring labels require zooming; some connector numerals remain indistinct, and labels are clipped at the split in the final two-page wiring diagram.

• Powerhead repair: Power unit removal, crankcase disassembly, crankshaft and piston inspection, connecting-rod service, and reed-valve checks.

• Fuel injection: Vapor separator and high-pressure fuel pump disassembly, pressure-regulator testing, fuel-injector service, and throttle position sensor adjustment.

• Oil injection and controls: Oil-pump synchronization, discharge testing and bleeding, throttle valve synchronization, idle adjustment, and remote-control shift and throttle cable adjustment.

• Lower-unit repair: Separate procedures for regular rotation, counter rotation, and dual propeller models, including water-pump service, shimming, and backlash measurement.

• Bracket and trim systems: Steering-arm and swivel-bracket service, power trim and tilt disassembly, hydraulic pressure testing, bleeding, and motor repair.

• Electrical troubleshooting: Ignition and charging tests, starter-motor overhaul, sensor checks, self-diagnosis codes, and EFI troubleshooting charts.

Written primarily for Yamaha dealers and their trained mechanics, this manual assumes an understanding of the mechanical and electrical principles used in outboard service.

Fuel Injection and Oil Delivery

Fuel-system repair covers both pressure circuits, including diaphragm fuel pumps, injector filters, the vapor separator float and needle valve, and the high-pressure pump mounting and seals. Pressure-regulator tests supplement the fuel-pressure checks.

The oil sections distinguish the engine-mounted injection pump from the electric sub-oil-tank feed pump. The bleeding procedure warns that running the engine without the specified supplemental lubrication can cause engine seizure.

Powerhead Inspection and Reassembly

Crankcase, crankshaft, piston, and connecting-rod procedures include cylinder-bore checks, ring clearances, labyrinth-ring inspection, and bearing service. Cylinder #1 has different piston dimensions and clearances from cylinders #2–#6, helping you match parts and inspection limits during powerhead repair.

Thermostat testing and cooling-water pressure-control valve inspection accompany cylinder-head service. Reed-valve checks include warpage and stopper-height specifications.

Lower-Unit Variants and Gear Setup

L150J/LX150 and L200J/LX200 use counter-rotation procedures; D150N/DX150 has dedicated dual-propeller sections covering inner and outer propeller shafts, front and rear dog clutches, and shaft-shim selection.

Regular-rotation procedures distinguish the 150L/PX150 gearset from 150J/SX150 and 200J/SX200. Shimming instructions separate U.S./Canadian tool setups from those for other markets. The dual-propeller assembly notes identify the outer shaft's threads and splines as a damage risk to the oil-seal lip.

Bracket, Power Trim and Tilt Service

Trim-system coverage extends to the reservoir, gear pump, shuttle and relief valves, trim and tilt rams, and free piston. Hydraulic pressure tests and separate bleeding procedures address work on the bench and on the installed unit.

Bracket sections cover the upper case, exhaust manifold, clamp brackets, steering arm, and swivel bracket.

Electrical Schematics and Fault Diagnosis

Wire Harness views show connector positions and wire-color codes. Ignition Control System, Fuel Control System, and Oil Feed Pump Control System schematics support circuit tracing, while the Trouble Analysis Chart links symptoms to inspection sections.

Flash-code diagnosis uses Yamaha diagnostic indicator YB-06765 / 90890-06765. Peak-voltage tests specify adapter YU-39991 / 90890-03169, with separate CDI, charge-coil, and pulser-coil checks to help isolate weak-spark faults.

CDI-unit and stator-assembly procedures cover removal and installation alongside electrical testing. Sensor tests address the oxygen density sensor, crank position sensor, coolant and intake-air temperature sensors, and atmospheric pressure sensor.

Factory Specifications and Service Precautions

Reference data includes component torque tables, fuel and hydraulic pressure specifications, oil capacities, wear limits, and electrical test values.

Fuel-system and powerhead work involves pressurized gasoline and mechanical hazards; follow Yamaha's precautions and consult a qualified marine technician when needed.

PDF Contents and Included Pages

The download is a single, printable 380-page PDF in English: 377 publication pages, two added title pages, and one final Canadian contact page. The publication pages already include the two-page wiring diagram, original back cover, and four blank pages.