Yamaha F200A Supplementary Service Manual Download

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SERVICE MANUAL

292087

60L-28197-3D-1X

SUPPLEMENTARY

F200A

FL200A

https://www.boat-manuals.com/

Summary of Contents for F200A

Page 1: ...SERVICE MANUAL 292087 60L 28197 3D 1X SUPPLEMENTARY F200A FL200A https www boat manuals com...

Page 2: ...S 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 CA...

Page 3: ...N INFO Specifications 2 SPEC Periodic checks and adjustments 3 CHK ADJ Fuel system 4 FUEL Power unit 5 POWR Lower unit 6 LOWR Bracket unit 7 BRKT Electrical systems 8 ELEC Troubleshooting 9 TRBL SHTG...

Page 4: ...on 7 Predelivery checks 8 Checking the fuel system 8 Checking the gear oil 8 Checking the engine oil 8 Checking the battery 8 Checking the outboard motor mounting height 9 Checking the remote control...

Page 5: ...ce tools 27 Maintenance interval chart 28 Bracket unit Power trim and tilt unit 30 Assembling the gear pump 30 Electrical systems Fuel control system 31 Checking the fuel injector 31 Checking the low...

Page 6: ...d are listed in the components list 2 Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions 3 Symbols are used to indicate impor...

Page 7: ...ols 7 to A in an exploded diagram indicate the grade of lubricant and the lubrication point 7 Apply Yamaha 4 stroke motor oil 8 Apply water resistant grease Yamaha grease A 9 Apply molybdenum disulfid...

Page 8: ...number The outboard motor serial number is stamped on a label attached to the port clamp bracket 1 Model name 2 Approved model code 3 Transom height 4 Serial number Applicable models F200AET FL200AET...

Page 9: ...Power source for diagnosis lamp 36 Diagnosis signal 26 Personal computer Starboard bank Port bank Ground for power source 42 Ground for unit 32 Thermo switch 37 Neutral switch 31 6 Emergency engine s...

Page 10: ...2 and 5 3 and 6 group injection TDC 720 180 120 TDC TDC TDC TDC Crankshaft angle Cylinder Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6 Ignition Injection Ignition Injection Ignit...

Page 11: ...sion Combustion Exhaust Intake Compression Expansion Compression Combustion Exhaust Intake Compression Intake Compression Combustion Exhaust Intake Compression Compression Combustion Exhaust Intake Co...

Page 12: ...ade or outside of the propeller boss a Propeller diameter in inches b Propeller pitch in inches c Propeller type propeller mark Selection When the engine speed is at the full throttle operating range...

Page 13: ...TE If the engine oil is above the maximum level mark H drain sufficient oil until the level is between H and L If the engine oil is below the minimum level mark L add sufficient oil until the level is...

Page 14: ...ion of the boat and the outboard motor To determine the optimum mounting height test run the outboard motor at differ ent heights 2 Check that the clamp brackets are secured with the clamp bolts Check...

Page 15: ...board motor tilts up and down smoothly when operating the power trim and tilt unit 2 Check that there is no abnormal noise produced when the outboard motor is tilted up or down 3 Check that there is n...

Page 16: ...n shifting into reverse and that water does not flow in over the transom NOTE The test run is part of the break in operation Break in During the test run perform the break in operation in the followin...

Page 17: ...4 14 5 Power unit Type V6 4 stroke DOHC 24 valves Cylinder quantity 6 Displacement cm3 cu in 3 352 204 5 Bore stroke mm in 94 0 80 5 3 70 3 17 Compression ratio 9 9 Control system Remote control Star...

Page 18: ...uantity L US qt lmp qt 1 15 1 22 1 01 1 00 1 06 0 88 Bracket Trim angle at 12 degree boat transom Degree 3 16 Tilt up angle Degree 70 Steering angle Degree 32 32 Drive unit Gearshift positions F N R G...

Page 19: ...H mm in 5 0 2 Piston to cylinder clearance mm in 0 075 0 080 0 0029 0 0031 Piston pin boss bore mm in 21 02 21 03 0 8276 0 8280 Piston pins Outside diameter mm in 21 00 0 827 Piston rings Top ring Dim...

Page 20: ...0 013 0 001 Head diameter A Intake mm in 34 85 35 15 1 3720 1 3839 Exhaust mm in 29 85 30 15 1 1752 1 1870 Face width B Intake mm in 2 11 0 0831 Exhaust mm in 2 43 0 0957 Seat contact width C Intake...

Page 21: ...meter mm in 62 968 62 992 2 4791 2 4800 Crankpin diameter mm in 49 976 50 000 1 9676 1 9685 Crankpin width mm in 21 50 21 55 0 8465 0 8484 Runout limit mm in 0 03 0 0012 Crankcase Crankshaft main jour...

Page 22: ...pen lower limit mm in 4 3 0 17 Engine speed Engine idle speed r min 650 750 Item Unit Model F200AET FL200AET Gear backlash Pinion to forward gear mm in 0 21 0 44 0 008 0 017 0 35 0 70 0 014 0 028 Pini...

Page 23: ...in loaded V 260 Spark plug gap mm in 1 1 0 043 Ignition coil resistance Primary coil R Y B O R Y B Y R Y B W 1 5 1 9 Secondary coil spark plug wire spark plug wire k 19 6 35 4 Throttle position sensor...

Page 24: ...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 Fuse A 5 20 30 Stator coil output peak voltage G G at cranking unloaded V 10 at 1 5...

Page 25: ...sistance 9 11 Resistance P B 9 387 6 Fluid type ATF Dexron II Brushes Standard length mm in 12 0 0 47 Wear limit mm in 4 0 0 16 Commutator Standard diameter mm in 25 0 0 98 Item Unit Model F200AET FL2...

Page 26: ...SPEC Specifications 21 60L3D1X Dimensions Exterior S60L2130 W5 A1 T1 W1 L7 H9 H1 H11 H2 H4 H3 H7 H8 H10 L8 L5 A2 H6 L9 L4 A3 12 C3 L2 L1 L10 L6 https www boat manuals com...

Page 27: ...2 0 L10 mm in 75 3 0 H1 X mm in 1 078 42 4 H2 mm in 727 28 6 H3 mm in 216 8 5 H4 X mm in 643 25 3 H5 mm in H6 X mm in 847 33 3 H7 mm in 361 14 2 H8 mm in 39 1 5 H9 mm in 880 34 6 H10 mm in 45 1 8 H11...

Page 28: ...00AET B1 mm in 125 4 9 B2 mm in 254 10 0 B3 mm in 163 6 4 B4 mm in 51 2 0 B5 mm in 180 7 1 B6 mm in 411 16 2 B7 mm in B8 mm in B9 mm in 19 0 7 C2 mm in C3 mm in 79 3 1 D1 mm in 13 0 5 D2 mm in 56 2 2...

Page 29: ...8 0 8 5 8 Power unit bolt M9 M10 42 4 2 30 Flywheel magnet nut 240 24 174 PTT relay nut 4 0 4 2 9 Starter relay lead bolt M6 4 0 4 2 9 Battery cable nut 9 0 9 6 5 Starter motor bolt M8 29 2 9 21 Recti...

Page 30: ...e stud bolt 1st M8 25 2 5 18 2nd 90 Crankcase bolt 1st M10 40 4 0 29 2nd 90 1st M8 14 1 4 10 2nd 28 2 8 20 Lower unit regular rotation model Trim tab bolt M10 43 4 3 31 Lower unit bolt M10 47 4 7 34 P...

Page 31: ...2 2 16 Friction plate screw M6 4 0 4 2 9 Trim stopper nut 36 3 6 25 Power trim and tilt unit Power trim and tilt unit bolt M10 44 4 4 32 Reservoir bolt M8 18 1 8 13 Reservoir cap M12 7 0 7 5 1 Manual...

Page 32: ...stener assemblies in a crisscross fashion and pro gressive stages until the specified torque is reached Unless otherwise specified torque specifications require clean dry threads Components should be...

Page 33: ...wer unit Engine oil Check before each use Change Oil filter Change Oil pump Check Timing chain Check replace 1 000 hours or 5 years Chain tensioner Check replace Timing belt 2 Check replace Valve clea...

Page 34: ...retighten the cylinder head and crankcase bolts Lower unit Gear oil Change Impeller Woodruff key Check replace 500 hours or 30 months Oil seals Check replace Propeller Check before each use General A...

Page 35: ...nd ball B into the gear housing 1 5 5 Install the filters C and gear pump D by installing the bolts E then tightening them to the specified torque 6 Install the manual valve F T R Gear pump bracket bo...

Page 36: ...If out of specification measure the fuel injector resistance 5 Measure the resistance of the fuel injec tors Replace if out of specification Digital circuit tester 90890 03174 Peak voltage adaptor 908...

Page 37: ...e high pressure fuel pump 2 Replace if there is no sound NOTE After the engine start switch is turned to ON the high pressure fuel pump will oper ate for 5 seconds Check the operation of the low press...

Page 38: ...bove NOTE The amount of memory and the amount of free space on the hard disk differs depending on the computer Using this software while there is not enough free space on the hard disk may cause error...

Page 39: ...then the CD ROM drive icon and then double click the Setup exe icon to start up the installer Fig 1 Fig 1 4 Click the Next button to start the installation process Fig 2 Fig 2 Yamaha Diagnostic Syste...

Page 40: ...pears Click the Yes button to update this program or click the No button to quit the installation Fig 3 Fig 3 NOTE To quit the installation click the Cancel button The following dialog box appears Fig...

Page 41: ...button to start copying the program files NOTE To go back to the previous dialog box step 4 click the Back button To quit the installation click the Cancel button Fig 5 NOTE If the Yamaha Diagnostic S...

Page 42: ...ox appears Click the Finish button to quit the installation program Fig 8 NOTE Install the Database file before installing the Yamaha Diagnostic System otherwise the program will not operate correctly...

Page 43: ...1 Turn on your computer and start up Windows 95 Windows 98 Windows Me or Windows 2000 2 From the taskbar at the bottom of your computer screen click the Start button fig 9 point to Programs and then...

Page 44: ...s any key to go to the first menu See fig 11 Fig 10 4 Click the Update database F1 button or press the F1 key on your keyboard Fig 11 Fig 11 NOTE Do not click the Starting service tool Enter button or...

Page 45: ...omputer s hard drive automati cally Any earlier version of the database saved on the hard drive will be overwritten 6 Click the OK button to start copying the database files Fig 12 Fig 12 NOTE If an e...

Page 46: ...ancel button or press the Esc key on your key board Fig 14 NOTE Display the program and database information to check version Fig 15 To display information click the title in the first menu screen whi...

Page 47: ...mple The flash pattern in the illus tration indicates code number 23 a Light on 0 33 second b Light off 4 95 seconds c Light off 0 33 second d Light off 1 65 seconds 4 If a flash pattern listed in the...

Page 48: ...nal 19 Incorrect battery voltage 23 Incorrect intake air temperature sensor signal 28 Incorrect neutral switch signal 29 Incorrect intake air pressure sensor signal 37 Incorrect idle speed control sig...

Page 49: ...10 Checking the tilt system 10 D Diagnosing the electronic control system 42 Dimensions 21 E Electrical 18 Electronic control system 4 F Features and benefits 4 Fuel control system 31 Fuel injection...

Page 50: ...the information that is provided herein Applicable Service Manual 69J 28197 3D 11 290435 WRONG CORRECT P 2 7 Spark plug gap 11 mm 0 43 in Spark plug gap 1 1 mm 0 043 in P 9 1 Yamaha Diagnostic System...

Page 51: ...https www boat manuals com...

Page 52: ...motor P Trim sensor Q Battery R Intake air temperature sensor S Main relay T Oil pressure sensor U Power trim and tilt switch To warning indicator To remote control To trim meter To computer To diagn...

Page 53: ...https www boat manuals com...

Page 54: ...YAMAHA MOTOR CO LTD Printed in the Netherlands Aug 2001 1 3 1 CR F200AET FL200AET E https www boat manuals com...

Page 55: ...B P B Y B B Y B Y R B W R Y R Y R R B W R Y B Y B O R B W R Y P W P B L W G Lg R Y W Sb P B Br P B B P Gy W B W R W G W G B W R 1 1 4 6 4 2 3 6 5 2 3 5 1 2 3 4 5 6 1 2 3 4 5 6 B B R R Y R Y R Y R Y R...

Page 56: ...R Y B W L Y O R O Y O B Y G R Y R Y W B L W L W P B R Y G B P B B B B R 1 4 6 5 3 R B B B B B B O B P P B O P B B B Br B Sb Y G Br R Lg Sb Sb O Lg Lg W B G Y G B R Y R Y P W L W R B B Br G Gy L Lg O...

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Yamaha F200A, Supplementary Service Manual

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