Yamaha F200G Owner'S Manual Download Page 51

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Engine control system

NOTICE

ECM02471

Although the buzzer will stop when the en-
gine is started and the control lever is
moved to the forward or reverse position,
do not use the outboard motor. Otherwise,
serious engine damage could occur.

U6DV72E0.book Page 45 Friday, December 19, 2014 3:38 PM

Summary of Contents for F200G

Page 1: ...Read this manual carefully before operating this outboard motor OWNER S MANUAL F200G FL200G F200G1 FL200G1 6DV 28199 72 E0 U6DV72E0 book Page 1 Friday December 19 2014 3 38 PM ...

Page 2: ...carefully before operating this outboard motor Keep this manual onboard in a waterproof bag when boating This manual should stay with the outboard motor if it is sold U6DV72E0 book Page 1 Friday December 19 2014 3 38 PM ...

Page 3: ...en your machine and this manual If there is any question concerning this manual please consult your Yamaha dealer To ensure long product life Yamaha recom mends that you use the product and perform the specified periodic inspections and main tenance by correctly following the instruc tions in the owner s manual Any damage resulting from neglect of these instructions is not covered by warranty Some...

Page 4: ...orsepower rating 11 Mounting outboard motor 11 Yamaha Security System if equipped 11 Digital electronic control requirements 12 Battery requirements 12 Battery specifications 12 Mounting battery 12 Multiple batteries 13 Propeller selection 13 Counter rotation models 13 Start in gear protection 13 Engine oil requirements 14 Fuel requirements 14 Gasoline 14 Muddy or acidic water 15 Anti fouling pain...

Page 5: ...ry voltage alert 38 6Y8 Multifunction speed fuel meters 38 6Y8 Multifunction speedometers 39 6Y8 Multifunction fuel management meters 40 Optional meters 40 Engine control system 42 Alert system 42 Digital Electronic Control alert 42 Overheat alert 42 Low oil pressure alert 43 Water separator alert 44 Installation 46 Installation 46 Mounting the outboard motor 46 Operation 48 First time operation 4...

Page 6: ...9 Periodic maintenance 69 Replacement parts 70 Severe operating conditions 70 Maintenance chart 1 71 Maintenance chart 2 73 Greasing 74 Inspecting spark plug 75 Inspecting engine idle speed 76 Changing engine oil 76 Inspecting wiring and connectors 80 Inspecting propeller 80 Removing propeller 81 Installing propeller 81 Changing gear oil 82 Inspecting and replacing anode s 84 Checking battery for ...

Page 7: ...rocution EMU33661 Power trim and tilt Body parts can be crushed between the mo tor and the clamp bracket when the motor is trimmed or tilted Keep body parts out of this area at all times Be sure no one is in this area before operating the power trim and tilt mechanism The power trim and tilt switches operate even when the main switch is off Keep people be away from the switches whenever working ar...

Page 8: ...boating fatalities EMU40281 Personal flotation devices PFDs Have an approved PFD on board for every occupant Yamaha recommends that you must wear a PFD whenever boating At a minimum children and non swimmers should always wear PFDs and everyone should wear PFDs when there are potentially hazardous boating conditions EMU33732 People in the water Always watch carefully for people in the wa ter such ...

Page 9: ...action to avoid collisions Re member boats do not have brakes and stopping the engine or reducing throttle can reduce the ability to steer If you are not sure that you can stop in time before hitting an obstacle apply throttle and turn in an other direction EMU33791 Weather Stay informed about the weather Check weather forecasts before boating Avoid boating in hazardous weather EMU33881 Passenger ...

Page 10: ...number is stamped on the label attached to the digital electronic control box Record your digital electronic control serial number in the spaces provided to assist you in newly connecting the digital electronic control to the outboard motor TIP Consult your Yamaha dealer if you have any questions concerning the digital electronic control serial number 1 Outboard motor serial number location 1 Seri...

Page 11: ...ompa nied with EC DoC EC DoC contains the fol lowing information Name of Engine Manufacture Model name Product code of model Approved model code Code of conformed directives EMU25207 CE Marking Outboard motors affixed with this CE mark ing conform with the directives of 2006 42 EC 94 25 EC 2003 44 EC and 2004 108 EC EMU46132 Compliance mark and manu factured date label Engines affixed with this la...

Page 12: ...sing Equipment Regulations Manufactured date The manufactured date is stamped on the la bel for the engines that conform to the regu lations for U S Environmental Protection Agency EPA The models that manufac tured exclusively for the Oceanian countries may not have manufactured date on the la bel 1 Compliance mark and manufactured date label location 1 Regulatory Compliance Mark RCM 1 ZMU07736 ZM...

Page 13: ...d any manuals supplied with the boat Read all labels on the outboard motor and the boat If you need any additional information contact your Yamaha dealer EMU33836 Warning labels If these labels are damaged or missing contact your Yamaha dealer for replacements 2 1 3 ZMU07865 U6DV72E0 book Page 7 Friday December 19 2014 3 38 PM ...

Page 14: ...or remove electrical parts when starting or during operation 2 WARNING EWM01672 Read Owner s Manuals and labels Wear an approved personal flotation de vice PFD Attach engine shut off cord lanyard to your PFD arm or leg so the engine stops if you accidentally leave the helm which could prevent a runaway boat EMU33851 Other labels 1 2 ZMU06191 3 ZMU05710 U6DV72E0 book Page 8 Friday December 19 2014 ...

Page 15: ...133 Symbols The following symbols mean as follows Notice Warning Read Owner s Manual Hazard caused by continuous rotation Electrical hazard ZMU05696 ZMU05664 ZMU05665 ZMU05666 U6DV72E0 book Page 9 Friday December 19 2014 3 38 PM ...

Page 16: ...NGK LFR6A 11 Spark plug gap 1 0 1 1 mm 0 039 0 043 in Steering system Remote steering Starting system Electric starter Starting carburetion system Fuel injection Valve clearance IN cold engine 0 17 0 24 mm 0 0067 0 0094 in Valve clearance EX cold engine 0 31 0 38 mm 0 0122 0 0150 in Battery rating CCA SAE 680 1150 A Battery rating MCA ABYC 770 1370 A Battery rating RC SAE 160 minutes Battery ratin...

Page 17: ...vere in stability Before installing the outboard motor s con firm that the total horsepower of your out board motor s does not exceed the boats maximum horsepower rating See the boat s capacity plate or contact the manufacturer EMU40491 Mounting outboard motor WARNING EWM02501 Improper mounting of the outboard mo tor could result in hazardous conditions such as poor handling loss of control or fir...

Page 18: ...rd motor which you have purchased Prior to use of the digital electronic control unit set it in order to operate your outboard motor only Otherwise it will not be possible to operate the outboard motor Perform setting of the outboard motor and the digital electronic control unit in the follow ing cases If a used outboard motor is installed If the digital electronic control unit is re placed If the...

Page 19: ...e your throttle setting to stay within the recommended engine speed range when carrying lighter loads Yamaha recommends to use a propeller suit able for the Shift Dampener System SDS For further information consult your Yamaha dealer To check the propeller see page 80 EMU36313 Counter rotation models Standard outboard motors rotate clockwise Counter rotation models rotate counterclock wise and are...

Page 20: ...f gasohol gasohol con taining ethanol E10 and that containing methanol Ethanol can be used if the ethanol content does not exceed 10 and the fuel meets the minimum octane ratings E85 is a fuel containing 85 ethanol and must not be used in your outboard motor All ethanol Recommended engine oil YAMALUBE 4 or 4 stroke outboard motor oil Recommended engine oil grade 1 SAE 10W 30 10W 40 5W 30 API SE SF...

Page 21: ...ecessary the boat bottom can be coated with an anti foul ing paint approved for your area to inhibit ma rine growth Do not use anti fouling paint which includes copper or graphite These paints can cause more rapid engine corrosion EMU40302 Outboard motor disposal re quirements Never illegally discard dump the outboard motor Yamaha recommends consulting the dealer about discarding the outboard moto...

Page 22: ... standards have 20 lower emis sions than One Star Low Emission engines EMU40351 Three Stars Ultra Low Emission The three star label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003 2008 ex haust emission standards Engines meeting these standards have 65 lower emissi...

Page 23: ...r Resources Board s Sterndrive and Inboard marine engine 2009 exhaust emission standards Personal Watercraft and Outboard marine engines may also comply with these standards Engines meeting these standards have 90 lower emissions than One Star Low Emission engines ZMU01704 ZMU05663 U6DV72E0 book Page 17 Friday December 19 2014 3 38 PM ...

Page 24: ...rd equipment on all models order from dealer 6 4 3 10 2 1 7 9 2 5 8 ZMU07738 1 Top cowling 2 Cowling lock lever 3 Clamp bracket 4 Power trim and tilt unit 5 Anode 6 Flushing device 7 Anti cavitation plate 8 Trim tab anode 9 Propeller 10 Cooling water inlet U6DV72E0 book Page 18 Friday December 19 2014 3 38 PM ...

Page 25: ...39 1 Ignition coil 2 Oil dipstick 3 Cowling lock lever 4 Power trim and tilt switch 5 Oil level plug 6 Oil filler cap 7 Fuse box 8 Fuel filter 9 Cooling water inlet 10 Gear oil drain screw U6DV72E0 book Page 19 Friday December 19 2014 3 38 PM ...

Page 26: ... single type 3 Digital electronic control twin type 4 Switch panel for use with twin type 5 Start Stop switch panel for use with twin type 6 All Start Stop switch panel for use with twin type 7 Engine shut off switch 8 Clip 9 Remote control transmitter 10 Receiver U6DV72E0 book Page 20 Friday December 19 2014 3 38 PM ...

Page 27: ...2101 The remote control transmitter is not completely waterproof Do not sub merge the transmitter or operate it un derwater If the transmitter is submerged dry it with a soft dry cloth SET MENU CANCEL 1 4 6 3 2 5 7 SET MODE SET MODE ZMU07205 1 Tachometer unit Square type 2 Tachometer unit Round type 3 Speedometer unit Square type 4 Speed fuel meter unit Square type 5 Speed fuel meter unit Round ty...

Page 28: ...eafter as a standard practice Refer to local hazardous waste regulations when disposing of transmitter batteries The Yamaha Security System permits reg istration of up to 5 remote control transmit ters It is recommended that you have at least 2 transmitters at all times in case one is lost or damaged Consult your Yamaha dealer for details EMU38603 Receiver if equipped The receiver controls the ECM...

Page 29: ...y Shift not operable Only throttle op eration available Off Shift and throttle not operable Yamaha Security System mode Digital electronic control active indicator Lock Off Unlock Light 1 Control lever 2 Digital electronic control active indicator 3 Digital electronic control alert indicator 4 Free throttle switch 5 Throttle friction adjuster 6 Power trim and tilt switch 1 Control lever 2 Digital ...

Page 30: ...celerate Digital electronic control for twin type has the function of automatically synchronizing the engine speeds of both engines of the port and starboard sides EMU35003 Free throttle switch In neutral keep this switch pressed move the control lever forward and release the switch after the digital electronic control ac tive indicator starts blinking While the indica tor blinks you can open or c...

Page 31: ... control will then engage forward and reverse normally EMU35252 Throttle friction adjuster A friction device provides adjustable resis tance to movement of the control lever and can be set according to operator preference To increase resistance turn the adjuster clockwise To decrease resistance turn the adjuster counterclockwise WARNING EWM01771 If the friction is too small the control le ver coul...

Page 32: ...d become en tangled preventing it from functioning Avoid accidentally pulling the cord during normal operation Loss of engine power means the loss of most steering control Also without engine power the boat could slow rapidly This could cause peo ple and objects in the boat to be thrown forward EWM00123 EMU41552 Main switch The main switch controls the ignition system its operation is described be...

Page 33: ...he Start Stop button allows all engines to start or turn off EMU35154 Power trim and tilt switch on digital electronic control The power trim and tilt system adjusts the outboard motor angle in relation to the tran som Pressing the switch up trims the outboard motor up and then tilts it up Press ing the switch down tilts the outboard motor down and trims it down When the switch is released the out...

Page 34: ...e the risk of falling overboard and could distract the operator increasing the risk of collision with another boat or an obstacle EMU35161 Power trim and tilt switches twin type The power trim and tilt system adjusts the outboard motor angle in relation to the tran som Pushing the switch up trims the outboard motor up and then tilts it up Press ing the switch down tilts the outboard motor down and...

Page 35: ...trim tab rear end to the port side A in the figure If the boat tends to veer to the right starboard side turn the trim tab end to the starboard side B in the figure NOTICE ECM00841 The trim tab also serves as an anode to protect the engine from electrochemical corrosion Never paint the trim tab as it will become ineffective as an anode EMU26342 Tilt support lever for power trim and tilt model To k...

Page 36: ...ing device The flushing device is used to clean the cool ing water passages of the outboard motor using a garden hose and tap water For in structions on using the flushing device see page 68 EMU41311 Fuel filter The fuel filter functions to remove foreign ma terial and separate water from the fuel If wa ter separated from the fuel exceeds a specific volume the alert system will activate For fur th...

Page 37: ... the engine is be ing warmed up and goes off when warming up is finished EMU41661 Engine synchronization indicator In twin types this display appears while the engines are under engine synchronization control It goes off when engine synchroniza tion control is released 1 Directional keypad 2 Set button 3 Cancel button 4 Menu button 5 Display 1 Shift position display 2 YAMAHA SECURITY SYSTEM indica...

Page 38: ...g NOTICE ECM01593 Do not continue to run the engine if the overheat alert indicator blinks Serious engine damage will occur Do not continue to operate the engine if a alert device has activated Consult your Yamaha dealer if the problem can not be located and corrected EMU41691 Low oil pressure alert If the engine oil pressure drops too low the pop up window will appear Press the set button to chan...

Page 39: ...ss the set button to change to normal display and the water sep arator alert indicator will start to blink Stop the engine immediately and see page 90 of this manual to drain the water from the fuel filter Get back to the port soon and con sult a Yamaha dealer immediately NOTICE ECM00911 Gasoline mixed with water could cause damage to the engine EMU41721 Low battery voltage alert The pop up window...

Page 40: ... or chang ing indicator systems see the attached oper ation manual EMU36185 6Y8 Multifunction tachometers The tachometer shows the engine revolutions per minute It has functions of trim meter ad justing trolling speed cooling water engine temperature display battery voltage display total hour trip hour display oil pressure dis play water detection alert engine trouble alert and periodic maintenanc...

Page 41: ... Water detection alert indicator 7 Battery voltage 8 Oil pressure 4 stroke models 1 Set button 2 Mode button 1 Tachometer 2 Water detection alert indicator 2 3 1 4 5 6 7 8 ZMU05416 SET MODE 1 2 ZMU05417 1 10 9 8 7 6 2 3 4 5 ZMU05418 3 Engine trouble alert maintenance indicator 4 Trim meter 5 Multifunction display 6 Battery voltage 7 Cooling water engine temperature 8 Oil pressure 4 stroke models 9...

Page 42: ...sary If the alert device has activated while the appropriate engine oil quantity is maintained consult your Yamaha dealer NOTICE ECM01602 Do not continue to run the engine if the low oil pressure alert device has activated Serious engine damage will occur EMU36222 Overheat alert If the engine temperature rises too high while cruising the overheat alert indicator will start to blink The engine spee...

Page 43: ...151 Water separator alert This indicator will blink if water has accumu lated in the water separator fuel filter while cruising In such an event stop the engine immediately and see page 90 of this manual to drain the water from the fuel filter Get back to the port soon and consult a Yamaha dealer immediately NOTICE ECM00911 Gasoline mixed with water could cause damage to the engine EMU36161 Engine...

Page 44: ...y using the set and mode but tons as described in this section If the speed sensor is installed the unit can also show the trip display However even if the speed sen sor is not installed the trip display can be shown by connecting an optional sensor to the unit In addition if optional sensors are connected to the unit water surface temper ature display depth display and clock will also be availabl...

Page 45: ...cting an optional sensor to the unit In addition if op tional sensors are connected to the unit wa ter surface temperature display depth display and clock will also be available For the optional sensors consult your Yamaha dealer After the main switch is first turned on all the displays come on as a test After a few sec onds the gauge will change to normal oper ation For more information see the o...

Page 46: ...t turned on all the displays come on as a test After a few sec onds the gauge will change to normal oper ation For more information see the operation man ual originally supplied with the meter EMU41731 Optional meters Various meters can be installed onto the out board motor according to user preference For details consult your Yamaha dealer Analog tachometer 1 Set button 2 Mode button 1 Speedomete...

Page 47: ...Instruments and indicators 41 Trim meter ZMU04581 U6DV72E0 book Page 41 Friday December 19 2014 3 38 PM ...

Page 48: ...rouble on shifting or throttle get back to the port soon and have a Yamaha dealer inspect or repair the outboard motor EMU41923 Overheat alert This engine has an overheat alert device If the engine temperature rises too high the alert device will activate The engine speed will automatically de crease to about 2000 r min The overheat alert indicator of the 6Y8 Multifunction Tachometer will light or...

Page 49: ...overheating If the alert system has activated stop the engine and tilt the outboard motor up to check the cooling water inlet for clogging If the alert system has still activated tilt the overheated outboard motor up and return to the port EMU41933 Low oil pressure alert If the oil pressure drops too low the alert de vice will activate The engine speed will automatically de crease to about 2000 r ...

Page 50: ...ressure EMU41942 Water separator alert The outboard motor is equipped with a water separator alert system If water separated from the fuel exceeds a specific volume the alert system will activate The water separator alert indicator of the 6Y8 Multifunction Tachometer will come on or blink The pop up window will appear on the Multi Display The buzzer will sound intermittently when the control lever...

Page 51: ...ough the buzzer will stop when the en gine is started and the control lever is moved to the forward or reverse position do not use the outboard motor Otherwise serious engine damage could occur U6DV72E0 book Page 45 Friday December 19 2014 3 38 PM ...

Page 52: ... engine boats mount the outboard motor on the cen terline keel line of the boat For twin engine boats mount the outboard motors equidis tant from the centerline Consult your Yamaha dealer or boat manufacturer for fur ther information on determining the proper mounting location EMU26936 Mounting height boat bottom The mounting height of your outboard motor affects its efficiency and reliability If ...

Page 53: ...bstructions to the smooth flow of water such as the design or condition of the boat or ac cessories such as transom ladders or depth finder transducers can create air borne water spray while the boat is cruising If the outboard motor is oper ated continuously in the presence of air borne water spray enough water could enter the engine through the air intake opening in the top cowling to cause se v...

Page 54: ... severe engine damage ECM00802 EMU41223 Procedure for breaking in engine Your new engine requires a period of 10 hours break in so that mating surfaces of moving parts wear in evenly Operate the engine in the water under load in gear with a propeller installed for 10 hours as follows When breaking in the engine avoid extended idling rough water and crowded areas 1 For the 1st hour of operation Ope...

Page 55: ...ove the top cowling from the bottom cowling To remove the top cowling pull the cowling lock levers and lift up the top cowling EMU36443 Fuel system WARNING EWM00061 Gasoline and its vapors are highly flamma ble and explosive Keep away from sparks cigarettes flames or other sources of ig nition WARNING EWM00911 Leaking fuel can result in fire or explosion Check for fuel leakage regularly If any fue...

Page 56: ... the complete range of motion and each le ver should return completely to the idle po sition EMU40363 Engine shut off cord lanyard Check the engine shut off cord and clip for damage such as cuts breaks and wear EMU40994 Engine oil 1 Place the outboard motor in a vertical position not tilted NOTICE If the out board motor is not level the oil level indicated on the oil dipstick may not be accurate E...

Page 57: ...alling top cowling 1 Check the rubber seal for damage If the rubber seal is damaged have it replaced by a Yamaha dealer 2 Check that the rubber seal is seated all the way around the bottom cowling 3 Check that all of the cowling lock levers are pulled outward 4 Align the 3 protrusions on the top cowl ing with the corresponding holders on the bottom cowling and then place the top cowling on the bot...

Page 58: ...or accidentally falls Body parts can be crushed between the motor and the clamp bracket when the motor is trimmed or tilted Be sure no one is near the outboard mo tor before performing this check 1 Check the power trim and tilt unit for any sign of oil leaks 2 Operate each of the power trim and tilt switches on the digital electronic control and engine bottom cowling if equipped to check that all ...

Page 59: ...t the outboard motor down Check that the tilt rod and trim rods operate smoothly EMU36583 Battery Check that the battery is in good condition and fully charged Check that the battery connections are clean secure and covered by insulating covers The electrical contacts of the battery and cables must be clean and properly connected or the battery will not start the engine Refer to the battery manufa...

Page 60: ...e filler opening or funnel to help prevent electrostatic sparks 7 Fill the fuel tank but do not overfill WARNING Do not overfill Otherwise fuel can expand and overflow if the temperature increases EWM02611 8 Tighten the fuel tank cap securely 9 Wipe up any spilled gasoline immediate ly with dry rags Dispose of rags properly according to local laws or regulations EMU40252 Operating engine WARNING E...

Page 61: ...rd 1 If equipped with the Yamaha Security System If the lock mode of the Yamaha Security System is selected use the re mote control transmitter to select the un lock mode Short beep will sound twice when unlocking the Yamaha Security System For further information see page 22 TIP If you lost track of the current security mode press the lock or unlock button to reset the security system The signal ...

Page 62: ... the main switch to on wait 10 seconds then crank the engine again ECM00193 When starting the engine using the Start Stop button press the button to start the engine The indicator for the starting engine will come on When starting the engine using the Start Stop button on the All Start Stop switch panel press the button to start the all engines TIP When the main switch is turned to start with the ...

Page 63: ...2 Shifting While the boat is tightly moored and without applying throttle confirm that the engine shifts smoothly into forward and reverse and back to neutral EMU41821 Stop switches Perform the following procedure to check that the main switch and engine shut off switch operate properly Check that the engine stops when the main switch is turned to the off position or press the Start Stop button Ch...

Page 64: ...rious injury It could also damage the shift mechanism Do not shift into reverse while traveling at planing speeds Loss of control boat swamping or damage to the boat could occur The boat is not equipped with a separate braking system Water resistance stops it af ter the throttle lever is moved back to idle The stopping distance varies depending on gross weight water surface conditions and wind dir...

Page 65: ...arming up a cold engine the troll ing speed cannot be decreased below the specified engine idle speed EMU27822 Stopping engine Before stopping the engine first let it cool off for a few minutes at idle or low speed Stop ping the engine immediately after operating at high speed is not recommended EMU41841 Procedure for stopping engine 1 The engine can be turned off either by pressing the Start Stop...

Page 66: ...low down and or readjust the trim angle The trim angle of the outboard motor helps determine the position of the bow of the boat in the water Correct trim angle will help im prove performance and fuel economy while reducing strain on the engine Correct trim angle depends upon the combination of boat engine and propeller Correct trim is also affected by variables such as the load in the boat sea co...

Page 67: ...bow of the boat is down it is easier to accelerate from a standing start onto plane Bow Up Too much trim out puts the bow of the boat too high in the water Performance and econ omy are decreased because the hull of the boat is pushing the water and there is more air drag Excessive trim out can also cause the propeller to ventilate which reduces per formance further and the boat may por poise hop i...

Page 68: ...the outboard motor up and down Body parts can be crushed between the outboard motor and the clamp bracket when the outboard mo tor is trimmed or tilted NOTICE ECM00993 Before tilting the outboard motor follow the procedure under Stopping engine in this chapter Never tilt the outboard motor while the engine is running Se vere damage from overheating can re sult To prevent the cooling water passages...

Page 69: ... the motor cannot be trailered in the normal running position use an addi tional support device to secure it in the tilt position For more detailed in formation see page 66 ECM01642 4 Once the outboard motor is supported with the tilt support lever press the pow er trim and tilt switch down to re tract the trim rods NOTICE Make sure that the trim rods retracts completely during mooring This protec...

Page 70: ...d motor can be tilted up partially to allow operation in shallow water NOTICE ECM02361 Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when set ting up for and cruising in shallow water Otherwise severe damage from overheat ing can result EMU35237 Procedure for power trim and tilt models 1 Place the control lever in neutral 1 Ti...

Page 71: ... brackish water or water high in other minerals flush the cool ing system with fresh water to minimize cor rosion and clogging of the cooling water passages with deposits Also rinse the exte rior of the outboard motor with fresh water Operating in water containing mud sand silt debris or vegetation Mud sand silt debris and vegetation in the water may restrict water flow into the cooling water inle...

Page 72: ...clog the fuel line causing engine start difficulty or malfunction Leaking fuel is a fire hazard When trailering the boat close the fuel valve to prevent fuel from leaking The outboard motor should be transported and stored in the normal running position If there is insufficient road clearance in this po sition then trailer the outboard motor in the tilt position using a motor support device such a...

Page 73: ...he air intake ECM01841 For further information see page 69 3 Remove the top cowling and propeller 4 Install the flushing attachment over the cooling water inlet and then turn on the water supply NOTICE Do not run the engine without supplying it with cool ing water Either the engine water pump will be damaged or the engine will be damaged from overheating Before starting the engine be sure to suppl...

Page 74: ...oard motor thoroughly EMU41072 Lubrication 1 Change the gear oil For instructions see page 82 Check the gear oil for the pres ence of water that indicates a leaky seal Seal replacement should be performed by an authorized Yamaha dealer prior to use 2 Lubricate all grease fittings For further details see page 74 TIP For long term storage fogging the engine with fogging oil is recommended Contact yo...

Page 75: ...41 2 Drain the cooling water completely out of the outboard motor Clean the body thoroughly EMU28462 Checking painted surface of outboard motor Check the outboard motor for scratches nicks or flaking paint Areas with damaged paint are more likely to corrode If necessary clean and paint the areas A touch up paint is available from your Yamaha dealer EMU2850C Periodic maintenance WARNING EWM01872 Th...

Page 76: ... part of inferior quality may malfunction and the resulting loss of control could endanger the operator and pas sengers Yamaha genuine parts and acces sories are available from your Yamaha dealer EMU34152 Severe operating conditions Severe operating conditions involve one or more of the following types of operation on a regular basis Operating continuously at or near maxi mum engine speed rpm for ...

Page 77: ...e engine should be flushed with clean water after each use The symbol indicates the check ups which you may carry out yourself The symbol indicates work to be carried out by your Yamaha dealer Item Actions Initial Every Page 20 hours 3 months 100 hours 1 year 300 hours 3 years 500 hours 5 years Anode s external Inspection or re placement as nec essary 84 Anode s internal 1 Inspection or re placeme...

Page 78: ...tube Inspection and greasing Impeller water pump housing Inspection or re placement as nec essary Impeller water pump housing Replacement OCV Oil Control Valve filter Replacement Power trim and tilt unit Inspection 52 Propeller propeller nut cotter pin Inspection or re placement as nec essary 80 PCV Pressure Control Valve Inspection or re placement as nec essary Spark plug s Inspection or re place...

Page 79: ...nd ad justment Cooling water inlet Inspection 18 Main switch stop switch Inspection or re placement as nec essary Wire harness con nections wire cou pler connections Inspection or re placement as nec essary Yamaha Me ter gauge Inspection Item Actions Every Page 1000 hours Exhaust guide ex haust manifold Inspection or re placement as nec essary Timing belt Replacement Item Actions Initial Every Pag...

Page 80: ...enance 74 EMU46110 Greasing Yamaha grease A water resistant grease Yamaha grease D corrosion resistant grease for propeller shaft and trim rods ZMU08001 U6DV72E0 book Page 74 Friday December 19 2014 3 38 PM ...

Page 81: ...ion coil cover 2 Remove the bolt that is securing the igni tion coil and then remove the ignition coil NOTICE Do not use any tools to remove or install the ignition coil Oth erwise the ignition coil coupler could be damaged ECM02331 3 Remove the spark plug WARNING When removing or installing a spark plug be careful not to damage the in sulator A damaged insulator could al low external sparks which...

Page 82: ... testing is con ducted with the outboard motor in the water 1 Start the engine and allow it to warm up fully in neutral until it is running smoothly 2 Inspect the engine idle speed If the en gine idle speed is out of specification consult a Yamaha dealer or other quali fied mechanic EMU44531 Changing engine oil WARNING EWM00761 Avoid draining the engine oil immediate ly after stopping the engine T...

Page 83: ...e dipstick NOTICE Overfilling the en gine with engine oil could cause leak age or damage If the oil level is above the upper mark extract engine oil until the oil level is between the upper and lower marks ECM02271 7 Leave the outboard motor for 5 10 min utes 8 Remove the oil dipstick and wipe it clean 9 Insert the dipstick and remove it again Be sure to completely insert the dipstick into the dip...

Page 84: ... your Yamaha dealer Change the oil more often when operating the engine under adverse conditions such as extended trolling Changing the engine oil by draining the oil 1 Put the outboard motor in an upright po sition not tilted NOTICE If the out board motor is not level the oil level indicated on the oil dipstick may not be accurate ECM01862 2 Start the engine Warm it up and keep the idle speed for...

Page 85: ...ld cause leakage or damage If the oil level is above the upper level mark drain until the level meets the speci fied capacity ECM01851 9 Leave the outboard motor for 5 10 min utes 10 Remove the oil dipstick and wipe it clean 11 Insert the dipstick and remove it again Be sure to completely insert the dipstick into the dipstick guide otherwise the oil level measurement will be incorrect 12 Recheck t...

Page 86: ...uch as extended trolling EMU29116 Inspecting wiring and connectors Inspect that each connector is engaged se curely Inspect that each ground lead is properly secured EMU41671 Inspecting propeller WARNING EWM02681 You could be seriously injured if the en gine accidentally starts when you are near the propeller Before inspecting remov ing or installing the propeller move the control lever to the neu...

Page 87: ...G EWM00771 On counter rotation models be sure to use a propeller intended for counterclock wise rotation These propellers are identi fied with the letter L after the size indication on the propeller Otherwise the boat could move in the opposite direction from that expected NOTICE ECM00502 Make sure to use a new cotter pin and bend the ends over securely Otherwise the propeller could come off durin...

Page 88: ...oil WARNING EWM00801 Be sure the outboard motor is securely fastened to the transom or a stable stand You could be severely injured if the outboard motor falls on you Never get under the lower unit while it is tilted even when the tilt support lever or knob is locked Severe injury could oc cur if the outboard motor accidentally falls 1 Tilt the outboard motor so that the gear oil drain screw is at...

Page 89: ... flexible or pressurized filling device inject the gear oil into the gear oil drain screw hole 6 Put a new gasket on the oil level plug When the oil begins to flow out of the oil level plug hole insert and tighten the oil level plug to the specified torque 7 Put a new gasket on the gear oil drain screw Insert and tighten the gear oil drain screw to the specified torque 1 Gear oil drain screw 2 Gas...

Page 90: ...sonous and caus tic and batteries generate explosive hy drogen gas When working near the battery Wear protective eye gear and rubber gloves Do not smoke or bring any other source of ignition near the battery The procedure for checking the battery varies for different batteries This procedure con tains typical checks that apply to many bat teries but you should always refer to the battery manufactu...

Page 91: ...rminal first Then connect the black battery cable to the NEGATIVE terminal 3 The electrical contacts of the battery and cables must be clean and properly con nected or the battery will not start the engine Connecting an accessory battery optional If connecting an accessory battery consult your Yamaha dealer about correct wiring It is recommendable to install the fuse to the iso lator lead as shown...

Page 92: ...s and re move the battery from the boat 4 Clean maintain and store the battery according to the manufacturer s instruc tions EMU38661 Storing the battery When storing your Yamaha outboard motor for prolonged periods of time 2 months or longer remove the battery and store it in a cool dry place Check the battery and charge it if necessary 1 Starboard side engine 2 Port side engine 3 Red cable 4 Bla...

Page 93: ...Q Has the battery cell of the remote control transmitter discharged A Operate from spare remote control trans mitter or replace battery cell by a Yamaha dealer Q Are battery connections loose or corrod ed A Tighten battery cables and clean battery terminals Q Is battery capacity weak or low A Check battery condition Use battery of recommended capacity Starter will not operate Q Is your Yamaha Secu...

Page 94: ...stem clogged A Inspect for pinched or kinked fuel line or other obstructions in fuel system Q Is fuel contaminated or stale A Fill tank with clean fresh fuel Q Is fuel filter clogged A Clean or replace fuel filter Q Are ignition parts malfunctioning A Have serviced by a Yamaha dealer Q Has alert system activated A Find and correct cause of alert Q Is spark plug gap incorrect A Replace spark plug Q...

Page 95: ...ired or replaced Q Is propeller pitch or diameter incorrect A Install correct propeller to operate out board motor at its recommended speed r min range Q Is outboard motor mounted at incorrect height on transom A Have outboard motor adjusted to proper transom height Q Has alert system activated A Find and correct cause of alert Q Is boat bottom fouled with marine growth A Clean boat bottom Q Are s...

Page 96: ... serviced by a Yamaha dealer Engine vibrates excessively Q Is propeller damaged A Have propeller repaired or replaced Q Is propeller shaft damaged A Have serviced by a Yamaha dealer Q Are weeds or other foreign material tan gled on propeller A Remove and clean propeller Q Are outboard motor mounting bolts loose A Tighten bolts or have serviced by a Yamaha dealer Q Is steering pivot loose or damage...

Page 97: ... fire hazard If a fuse has blown replace the fuse accord ing to the following procedure 1 Turn the main switch to the off position 2 Remove the fuse box cover 3 When replacing the main fuse or isolater fuse remove the screws and then re move the fuse Install the spare fuse and then tighten the screws 4 When replacing a fuse other than the main fuse or isolater fuse remove the fuse using the fuse p...

Page 98: ...RNING EWM02543 Gasoline is highly flammable and its va pors are flammable and explosive Do not perform this procedure on a hot or running engine Allow the engine to cool There will be fuel in the fuel filter Keep away from sparks cigarettes flames or other sources of ignition Some fuel will spill during this proce dure Catch the fuel in a rag Wipe up any spilled fuel immediately The fuel filter mu...

Page 99: ...tor alert indicator remains off and the buzzer does not sound If the water sep arator alert indicator blinks or the buzzer sounds have your Yamaha dealer check the outboard motor NOTICE Although the buzzer will stop when the engine is started and the control lever is moved to the forward or reverse position do not use the outboard motor Other wise serious engine damage could occur ECM02481 EMU3350...

Page 100: ...Components diagram 18 Control functions checking 50 Cooling water 57 Cowling lock lever 30 D Digital Electronic Control alert 42 Digital Electronic Control box 23 Digital electronic control requirements 12 Digital electronic control serial number 4 Digital electronic control active indicator 23 Digital electronic control alert indicator 24 E EC Declaration of Conformity DoC 5 Electric shock 1 Emer...

Page 101: ...or checking 51 Outboard motor disposal requirements 15 Outboard motor painted surface checking 69 Outboard motor safety 1 Outboard motor serial number 4 Overheat alert 32 36 42 Overloading 2 P Passenger training 3 Passengers 2 People in the water 2 Periodic maintenance 69 Personal flotation devices PFDs 2 Power trim and tilt 1 Power trim and tilt switch bottom cowling 28 Power trim and tilt switch...

Page 102: ...p and down 62 Top cowling installing 51 Top cowling removing 49 Transporting and storing outboard motor 66 Trim tab with anode 29 Trimming outboard motor 60 Trolling 58 Troubleshooting 87 W Warming up engine 57 Warning labels 7 Water separator alert 33 37 44 Water separator alert indicator blinks while cruising 92 Weather 3 Wiring and connectors inspecting 80 Y Yamaha Security System if equipped 1...

Page 103: ...U6DV72E0 book Page 97 Friday December 19 2014 3 38 PM ...

Page 104: ...Printed on recycled paper Printed in Japan January 2015 0 1 1 CR U6DV72E0 book Page 1 Friday December 19 2014 3 38 PM ...

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Yamaha F200G, Owner'S Manual

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Summary of Contents for F200G

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