Yamaha FL200C Owner'S Manual Download

Page: 69 / 100

Maintenance

Fuel line (High pres-
sure)

Inspection

Fuel line (High pres-
sure)

Inspection or replace-
ment as necessary

Fuel line (Low pres-
sure)

Inspection

Fuel line (Low pres-
sure)

Inspection or replace-
ment as necessary

Fuel pump

Inspection or replace-
ment as necessary

Fuel/engine oil leakage

Inspection

Gear oil

Replacement

Greasing points

Greasing

Clamp bracket bolt
(through tube)

Inspection and greas-
ing

Impeller/water pump
housing

Inspection or replace-
ment as necessary

Impeller/water pump
housing

Replacement

OCV (Oil Control Valve)
filter

Replacement

Power trim and tilt unit

Inspection

Propeller/propeller
nut/cotter pin

Inspection or replace-
ment as necessary

PCV (Pressure Control
Valve)

Inspection or replace-
ment as necessary

Shift link/shift cable

Inspection, adjust-
ment or replacement
as necessary

Spark plug(s)

Inspection or replace-
ment as necessary

Ignition coils/ignition
coil leads

Inspection or replace-
ment as necessary

Water from the cooling
water pilot hole

Inspection

Throttle link/throttle
cable/throttle pick-up
timing

Inspection, adjust-
ment or replacement
as necessary

Thermostat

Inspection or replace-
ment as necessary

Timing belt

Inspection or replace-
ment as necessary

Item

Actions

Initial

Every

20 hours

(3 months)

100 hours

(1 year)

300 hours

(3 years)

500 hours

(5 years)

U6P27AE0.book Page 63 Friday, December 6, 2013 6:17 PM

Summary of Contents for FL200C

Page 1: ...Read this manual carefully before operating this outboard motor OWNER S MANUAL F200C FL200C F225B FL225B F225C 6P2 28199 7A E0 U6P27AE0 book Page 1 Friday December 6 2013 6 17 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 U6P27AE0 book Page 1 Friday December 6 2013 6 17 PM ...

Page 3: ...r 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 count...

Page 4: ...ments 11 Battery specifications 11 Mounting battery 11 Multiple batteries 11 Propeller selection 11 Counter rotation models 12 Start in gear protection 12 Engine oil requirements 12 Fuel requirements 13 Gasoline 13 Anti fouling paint 13 Outboard motor disposal requirements 14 Emergency equipment 14 Components 15 Components diagram 15 Remote control box 16 Remote control lever 17 Free accelerator 1...

Page 5: ...eaking in engine 40 Getting to know your boat 40 Checks before starting engine 40 Fuel level 41 Remove cowling 41 Fuel system 41 Controls 42 Engine shut off cord lanyard 42 Engine oil 42 Engine 42 Flushing device 42 Install cowling 43 Checking power trim and tilt system 44 Battery 45 Filling fuel 45 Operating engine 46 Sending fuel 46 Starting engine 46 Checks after starting engine 48 Cooling wate...

Page 6: ...king propeller 73 Removing propeller 73 Installing propeller 74 Changing gear oil 75 Inspecting and replacing anode s 78 Checking battery for electric start models 79 Connecting the battery 79 Disconnecting the battery 81 Trouble Recovery 82 Troubleshooting 82 Temporary action in emergency 85 Impact damage 85 Running single engine twin engines 85 Replacing fuse 86 Power trim and tilt will not oper...

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: ...own in the illustration Re cord this number in the space provided for reference in case you need a new key EMU37292 EC Declaration of Conformity DoC This outboard motor conforms to certain por tions of the European Parliament directive re lating to machinery Each conformed outboard motor accompa nied with EC DoC EC DoC contains the fol lowing information Name of Engine Manufacture Model name Produ...

Page 11: ...General information 5 1 CE marking location ZMU06040 U6P27AE0 book Page 5 Friday December 6 2013 6 17 PM ...

Page 12: ...nual Read 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 EMU33834 Warning labels If these labels are damaged or missing contact your Yamaha dealer for replacements U6P27AE0 book Page 6 Friday December 6 2013 6 17 PM ...

Page 13: ...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 U6P27AE0 book Page 7 Friday December 6 2013 6...

Page 14: ...5133 Symbols The following symbols mean as follows Notice Warning Read Owner s Manual Hazard caused by continuous rotation Electrical hazard ZMU05696 ZMU05664 ZMU05665 ZMU05666 U6P27AE0 book Page 8 Friday December 6 2013 6 17 PM ...

Page 15: ...g 624 lb FL225BET 283 kg 624 lb Performance Full throttle operating range 5000 6000 r min Rated power F200CET 147 1 kW 200 HP F225BET 165 5 kW 225 HP F225CET 165 5 kW 225 HP FL200CET 147 1 kW 200 HP FL225BET 165 5 kW 225 HP Idle speed in neutral 600 700 r min Power unit Type 4 stroke DOHC V6 24 valves Total displacement 3352 cm 204 5 c i Bore stroke 94 0 80 5 mm 3 70 3 17 in Ignition system TCI Sp...

Page 16: ...mmended gear oil YAMALUBE outboard gear oil or Hypoid gear oil Recommended gear oil grade SAE 90 API GL 4 Gear oil quantity F200CET 1 150 L 1 216 US qt 1 012 Imp qt F225BET 1 150 L 1 216 US qt 1 012 Imp qt F225CET 0 920 L 0 972 US qt 0 810 Imp qt FL200CET 1 000 L 1 057 US qt 0 880 Imp qt FL225BET 1 000 L 1 057 US qt 0 880 Imp qt Tightening torque Spark plug 25 Nm 2 55 kgf m 18 4 ft lb Propeller nu...

Page 17: ...o not put flammable items or loose heavy or metal objects in the same compartment as the battery Fire explosion or sparks could result EWM01821 EMU36301 Multiple batteries To connect multiple batteries such as for multiple engine configurations or for an ac cessory battery consult your Yamaha dealer about battery selection and correct wiring EMU41602 Propeller selection Next to selecting an outboa...

Page 18: ...amaha ap proved remote control units are equipped with start in gear protection device s This feature permits the engine to be started only when it is in neutral Always select neutral be fore starting the engine EMU41953 Engine oil requirements Select an oil grade according to the average temperatures in the area where the outboard motor will be used If oil grades listed under Recommended en gine ...

Page 19: ...mage or engine performance problems It is recommended that you install a water separating marine fuel filter assembly 10 mi cron minimum between your boat s fuel tank and outboard motor when using ethanol Eth anol is known to allow moisture to be ab sorbed into boat fuel tanks and systems Moisture in the fuel can cause corrosion of metallic fuel system components starting and running complaints an...

Page 20: ...ncy equipment Keep the following items onboard in case there is trouble with the outboard motor A tool kit with assorted screwdrivers pliers wrenches including metric sizes and electrical tape Waterproof flashlight with extra batteries An extra engine shut off cord lanyard with clip Spare parts such as an extra set of spark plugs Consult your Yamaha dealer for details U6P27AE0 book Page 14 Friday ...

Page 21: ...ller 5 Cooling water inlet 6 Clamp bracket 7 Cowling lock lever s 8 Water separator 9 Power trim and tilt switch 10 Flushing device 11 Tilt support lever 12 Remote control box binnacle mount type 13 Switch panel for use with binnacle type 14 Remote control box binnacle mount type 15 Switch panel for use with binnacle type 16 Digital speedometer 17 Digital tachometer 18 Fuel management meter U6P27A...

Page 22: ...1 4 6 3 2 5 ZMU05429 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 type 6 Fuel management meter unit Square type 1 Power trim and tilt switch 2 Remote control lever 3 Free accelerator 4 Throttle friction adjuster 2 1 3 4 ZMU04572 U6P27AE0 book Page 16 Friday December 6 2013 6 17 PM ...

Page 23: ...r button can only be pushed when the remote control lever is in the neutral position After the button is pushed the throttle be gins to open after the remote control lever is moved at least 35 After using the free accelerator return the remote control lever to the neutral position The free accelerator button will return auto 1 Remote control lever 2 Power trim and tilt switch 3 Free accelerator 4 ...

Page 24: ...ched to the engine shut off switch for the engine to run The cord should be attached to a secure place on the operator s clothing or arm or leg Should the operator fall overboard or leave the helm the cord will pull out the clip stopping ignition to the engine This will prevent the boat from running away under power WARNING At tach the engine shut off cord to a secure place on your clothing or you...

Page 25: ...lation to the tran som Pushing the switch up trims the outboard motor up and then tilts it up Push ing the switch down tilts the outboard motor down and trims it down When the switch is released the outboard motor will stop in its current position For instructions on using the power trim and tilt switch see pages 50 and 52 EMU26156 Power trim and tilt switch on bottom cowling The power trim and ti...

Page 26: ...r instructions on using the power trim and tilt switches see pages 50 and 52 TIP On the dual engine control the switch on the remote control grip controls both outboard motors at the same time EMU26245 Trim tab with anode WARNING EWM00841 An improperly adjusted trim tab could cause difficult steering Always test run af ter the trim tab has been installed or re placed to be sure steering is correct...

Page 27: ...the normal running position use an additional support device to secure it in the tilt position EMU31422 Cowling lock lever pull up type To remove the top cowling pull up the cowl ing lock lever s and lift off the cowling To in stall the top cowling place it in its original position and then move the cowling lock le ver s downward to lock it in place TIP When installing the cowling check to be sure...

Page 28: ...sing a garden hose and tap water TIP For details on usage see page 59 EMU35564 Fuel filter Water separator This engine has a combination fuel filter wa ter separator and associated alert system If water separated from the fuel exceeds a spe cific volume the alert device of 6Y8 Multi function Tachometer will activate Activation of alert device 1 Cowling lock lever s 1 Cowling lock lever s ZMU05347 ...

Page 29: ...8 Multifunction Tachometer will blink The buzzer will sound intermittently only when the gear shift is in neutral If the alert system has activated stop the engine and consult a Yamaha dealer imme diately U6P27AE0 book Page 23 Friday December 6 2013 6 17 PM ...

Page 30: ... to the desired using the power trim and tilt switch If the trim angle of your motor exceeds the trim operating range the top segment on the trim meter display will blink EMU26652 Hour meter This meter shows the number of hours the engine has been run It can be set to show the total number of hours or the number of hours for the current trip The display can also be turned on and off To change the ...

Page 31: ...r further in formation on reading the indicator see page 36 NOTICE ECM00053 Do not continue to run the engine if the overheat alert indicator is on Serious en gine damage will occur EMU26603 Digital speedometer This gauge shows the boat speed and other information All segments of the display will light momen tarily after the main switch is turned on and will return to normal thereafter EMU36062 Sp...

Page 32: ...n the face of the gauge points to trip meter clock or voltmeter EMU26692 Trip meter This gauge displays the distance the boat has traveled since the gauge was last reset The trip distance is shown in kilometers or miles depending upon the unit of measure ment selected for the speedometer To reset the trip meter to zero press the set and mode buttons at the same time The trip distance is kept in me...

Page 33: ...ay will auto matically turn on and blink Get back to the port soon if an alert device has activated For charging the battery con sult your Yamaha dealer EMU26742 Fuel management meter The fuel management meter shows the state of the fuel consumption while the engine is running All segments of the display will light momen tarily after the main switch is turned on and will return to normal thereafte...

Page 34: ...displays for fuel flow to the starboard en gine only for fuel flow to the port engine only or for total fuel flow both en gines EMU36091 Fuel consumption meter Fuel econo my meter Twin engine speed syn chronizer The display shows either the fuel consump tion meter the fuel economy meter or the twin engine synchronizer To change the display press the mode button repeatedly until the indicator on th...

Page 35: ...ividual engines may slightly vary in their fuel consumption due to manufacturing variations These variations can be even greater if the engines are of different year models In addition variations in propel lers even of the same basic dimensions of the same design can also cause a slight variation in fuel consumption EMU26783 Twin engine speed synchronizer This gauge displays the difference in engi...

Page 36: ...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 maintenance notification If the cooling water pressure sensor is in stalled the unit can also show the cooling water...

Page 37: ... Stop the engine immediately if the buzzer sounds and the low oil pressure alert indica tor blinks Check the engine oil quantity and replenish oil if necessary 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 ...

Page 38: ...ice has activated Consult your Yamaha dealer if the problem can not be located and corrected EMU36151 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 85 of this manual to drain the water from the fuel filter Get back to the port soon and consult a Yamaha dealer imme...

Page 39: ...peed and has the functions of fuel meter to tal fuel consumption display fuel economy display fuel flow display and system voltage display The chosen display is selected by 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 connectin...

Page 40: ...is select ed by using the set and mode buttons as described in this section In addi tion the speedometer can show the desired unit of measurement such as km h mph or knots If the speed sensor is installed the unit can also show the trip display However even if the speed sensor is not installed the trip display can be shown by connecting an optional sensor to the unit In addition if op tional senso...

Page 41: ...economy display and remaining fuel display The chosen display is selected by using the set and mode buttons as described in this section For more information see the operation manual originally supplied with the meter 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 operation man...

Page 42: ...rged Check the cooling water inlet for clogging Dual engine drive users If the overheat alert system of one engine ac tivates the engine will slow down To switch off the alert activation on the engine not af fected by overheating turn off the main switch of the engine overheating If the alert system has activated stop the engine and tilt the outboard motor up to check the cooling water inlet for c...

Page 43: ...switch off consult your Yamaha dealer Twin engine drive users If the low oil pressure alert system of one en gine activates both engines will slow down and the buzzer will sound To switch off the alert activation on the engine not affected by low oil pressure turn off the main switch of the engine with the low oil pressure ZMU01828 ZMU04583 OFF START ON ON OFF START ZMU05827 U6P27AE0 book Page 37 ...

Page 44: ...unt 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 EMU26935 Mounting height boat bottom The mounting height of your outboard motor affects its efficiency and reliability If it is mounted to...

Page 45: ... 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 vere engine ...

Page 46: ... evenly TIP Run the engine in the water under load in gear with a propeller installed as follows For 10 hours for breaking in engine avoid extend ed idling rough water and crowded areas 1 For the first hour of operation Run the engine at varying speeds up to 2000 r min or approximately half throttle 2 For the second hour of operation Increase engine speed as much as nec essary to put the boat on p...

Page 47: ... 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 fuel leakage is found the fuel sys tem must be repaired by a qualified me chanic Improper repairs can make the outboard unsafe to operate EMU36452 Check for fuel leaks Check for fuel l...

Page 48: ...CE If the out board motor is not level the oil level indicated on the oil dipstick may not be accurate ECM01862 2 Remove the oil dipstick and wipe it clean 3 Insert the oil dipstick completely and re move it again 4 Check that the oil level on the oil dipstick is between the upper and lower marks Consult your Yamaha dealer if the oil lev el is not at the proper level or if it appears milky or dirt...

Page 49: ... 4 Check to be sure it fits properly in the rubber seal 5 Move the levers to lock the cowling as shown NOTICE If the top cowling is not installed correctly water spray under the top cowling can damage the engine or the top cowling can blow off at high speeds ECM01992 After installing check the fitting of the top cowling by pushing it with both hands If the top cowling is loose have it repaired by ...

Page 50: ...e each of the power trim and tilt switches on the remote control and en gine bottom cowling to check that all switches work 3 Tilt the outboard motor up and check that the tilt rod and trim rods are extend ed completely F200C FL200C F225B FL225B F225C 4 Use the tilt support lever to lock the mo tor in the up position Operate the tilt down switch briefly so the motor is sup ported by the tilt suppo...

Page 51: ...ontacts of the battery and cables must be clean and properly connected or the battery will not start the engine Refer to the battery manufacturer s instruc tions for checks for your particular battery EMU30027 Filling fuel WARNING EWM01831 Gasoline and its vapors are highly flam mable and explosive Always refuel ac cording to this procedure to reduce the risk of fire and explosion Gasoline is pois...

Page 52: ...make sure that the boat is tightly moored and that you can steer clear of any obstructions Be sure there are no swimmers in the water near you When the air vent screw is loosened gasoline vapor will be released Gaso line is highly flammable and its vapors are flammable and explosive Refrain from smoking and keep away from open flames and sparks while loosening the air vent screw This product emits...

Page 53: ...uld slow rapidly This could cause people and objects in the boat to be thrown forward 1 Place the remote control lever in neutral TIP The start in gear protection device prevents the engine from starting except when in neu tral 2 Attach the engine shut off cord to a se cure place on your clothing or your arm or leg Then install the clip on the other end of the cord into the engine shut off switch ...

Page 54: ...ng water passages are frozen it may take a while for water to start flowing out of the pilot hole NOTICE ECM01811 If water is not flowing out of the pilot hole at all times while the engine is running overheating and serious damage could occur Stop the engine and check whether the cooling water inlet on the lower case or the cooling water pilot hole is blocked Consult your Yamaha dealer if the pro...

Page 55: ...ure there are no swimmers or obstacles in the water near you NOTICE ECM01611 Warm up the engine before shifting into gear Until the engine is warm the idle speed may be higher than normal High idle speed can prevent you from shifting back to neutral If this occurs stop the en gine shift to neutral then restart the en gine and allow it to warm up To shift out of neutral 1 Pull the neutral interlock...

Page 56: ...2 Procedure 1 Turn the main switch to off 2 Remove the key if the boat will be left un attended TIP The engine can also be stopped by pulling the cord and removing the clip from the en gine shut off switch then turning the main switch to off EMU27863 Trimming outboard motor WARNING EWM00741 Excessive trim for the operating condi tions either trim up or trim down can cause boat instability and can ...

Page 57: ...djust the outboard motor trim angle using the power trim and tilt switch To raise the bow trim out press the switch up To lower the bow trim in press the switch down Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions EMU27913 Adjusting boat trim When the boat is on plane a bow up attitude results in less drag greater sta...

Page 58: ...cult and dangerous TIP Depending on the type of boat the outboard motor trim angle may have little effect on the trim of the boat when operating EMU27948 Tilting up and down If the engine will be stopped for some time or if the boat is moored in shallows the out board motor should be tilted up to protect the propeller and lower case from damage by collision with obstructions and also to re duce sa...

Page 59: ...he outboard motor be sure to support it with the tilt support knob or tilt support lever Otherwise the out board motor could fall back down suddenly if oil in the power trim and tilt unit or in the power tilt unit loses pres sure EWM00263 NOTICE Do not use the tilt support lever or knob when traile ring the boat The outboard motor could shake loose from the tilt support and fall If the motor canno...

Page 60: ... the power trim and tilt mechanism ECM00253 F200C FL200C F225B FL225B F225C EMU42702 Procedure for tilting down 1 Push the power trim and tilt switch up until the outboard motor is support ed by the tilt rod and the tilt support lever becomes free 2 Release the tilt support lever F200C FL200C F225B FL225B F225C 3 Push the power trim and tilt switch down to lower the outboard motor to the desired p...

Page 61: ...ing up for and cruising in shallow water Otherwise severe damage from overheating can result EMU32923 Procedure for power trim and tilt models 1 Place the remote control lever in neutral 2 Slightly tilt the outboard motor up to the desired position using the power trim and tilt switch WARNING Using the power trim and tilt switch on the bot tom cowling while the boat is moving or engine is on could...

Page 62: ...ges with fresh water to prevent them from becoming clogged Also rinse the outside of the outboard motor with fresh wa ter Cruising in muddy turbid or acidic water Water in some areas can be acidic or with a lot of sediment in it such as muddy or turbid cloudy water After operating in such water flush the cooling passages with fresh water to prevent corrosion Also rinse the outside of the outboard ...

Page 63: ...f there is insufficient road clearance in this po sition then trailer the outboard motor in the tilt position using a motor support device such as a transom saver bar Consult your Yamaha dealer for further details When the outboard motor is tilted prolonged time for mooring or trailering the boat close the fuel valve EMU30042 Storing outboard motor When storing your Yamaha outboard motor for prolo...

Page 64: ...th cooling water Either the engine water pump will be damaged or the engine will be damaged from overheating Before starting the engine be sure to supply water to the cooling water pas sages Avoid running the outboard motor at high speed while on the flushing attachment otherwise over heating could occur ECM02001 3 Cooling system flushing is essential to prevent the cooling system from clog ging u...

Page 65: ...poonful of clean engine oil into each cylin der Crank the engine several times manually Reinstall the spark plug s 6 Remove the flushing attachment EMU41321 Draining the gasoline from the vapor sep arator Gasoline in the vapor separator must be drained before storing the outboard motor Have a Yamaha dealer drain the gasoline from the vapor separator EMU28403 Lubrication 1 Install the spark plug s ...

Page 66: ...g after flushing the engine ECM00542 TIP When flushing the engine with the boat in the water tilting up the outboard motor un til it is completely out of the water will achieve better results F200C FL200C F225B FL225B For cool ing system flushing instructions see page 57 EMU44341 Cleaning the outboard motor When cleaning the outboard motor the top cowling must be installed 1 Wash the exterior of t...

Page 67: ...cement parts are necessary use only genuine Yamaha parts or parts of equivalent design and quality Any 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 ...

Page 68: ...e 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 20 hours 3 months 100 hours 1 year 300 hours 3 years 500 hours 5 years Anode s external Inspection or replace ment as necessary Anode s cylinder head thermostat cov er Inspection or replace ment as necessary Anodes exhaust cov er cooling wat...

Page 69: ...lt unit Inspection Propeller propeller nut cotter pin Inspection or replace ment as necessary PCV Pressure Control Valve Inspection or replace ment as necessary Shift link shift cable Inspection adjust ment or replacement as necessary Spark plug s Inspection or replace ment as necessary Ignition coils ignition coil leads Inspection or replace ment as necessary Water from the cooling water pilot ho...

Page 70: ...ire harness connec tions wire coupler con nections Inspection or replace ment as necessary Yamaha Meter gauge Inspection Item Actions Every 1000 hours Exhaust guide ex haust manifold Inspection or replace ment as necessary Timing belt Replacement Item Actions Initial Every 20 hours 3 months 100 hours 1 year 300 hours 3 years 500 hours 5 years U6P27AE0 book Page 64 Friday December 6 2013 6 17 PM ...

Page 71: ...e 65 EMU28944 Greasing Yamaha grease A water resistant grease Yamaha grease D corrosion resistant grease for propeller shaft F200CET FL200CET F225BET FL225BET U6P27AE0 book Page 65 Friday December 6 2013 6 17 PM ...

Page 72: ...Maintenance 66 F225CET U6P27AE0 book Page 66 Friday December 6 2013 6 17 PM ...

Page 73: ...e securing the ignition coil and then remove the ignition coil Do not use any tools to remove or install the ignition coil otherwise the igni tion coil coupler may get damaged 3 Remove the spark plug If electrode ero sion becomes excessive or if carbon and other deposits are excessive you should replace the spark plug with an other of the correct type WARNING When removing or installing a spark pl...

Page 74: ...utboard motor use a diagnostic ta chometer for this procedure Results may vary depending on whether testing is con ducted with the flushing attachment in a test tank or 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 Once the engine has warmed up verify whether the idle speed is set to specifi cation For idle speed spe...

Page 75: ...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 5 10 minutes 3 Stop the engine and leave it for 5 10 min utes 4 Remove the top cowling 5 Remove the oil filler cap Pull out the dip stick and use the oil changer to e...

Page 76: ...d and corrected ECM01623 12 Install the top cowling 13 Dispose of used oil according to local regulations TIP For more information on the disposal of used oil consult 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 ...

Page 77: ...rain screw and gasket while holding the container under the drain hole Let the oil drain completely Wipe up any spilled oil immediately TIP If the oil does not drain easily change the tilt angle or turn the outboard motor to port and starboard to drain the oil 1 Oil filler cap 1 Bolt 2 Apron 1 Bolt 2 Apron 1 Drain screw 2 Gasket 1 2 1 ZMU05973 2 1 ZMU02145 U6P27AE0 book Page 71 Friday December 6 2...

Page 78: ...e sure the level falls between the upper and lower marks Consult your Yamaha dealer if the oil level is out of specified level 13 Start the engine and make sure that the low oil pressure alert indicator remains off Also make sure that there are no oil leaks NOTICE If the low oil pressure alert indicator comes on or if there are oil leaks stop the engine and find the cause Continued operation with ...

Page 79: ...y and remove the clip from the engine shut off switch Turn off the battery cut off switch if your boat has one Do not use your hand to hold the propeller when loosening or tightening the propeller nut Put a wood block between the anti cavi tation plate and the propeller to prevent the propeller from turning Checkpoints Check each of the propeller blades for ero sion from cavitation or ventilation ...

Page 80: ...e a new cotter pin and bend the ends over securely Otherwise the propeller could come off during oper ation and be lost 1 Apply Yamaha marine grease or a corro sion resistant grease to the propeller shaft 2 Install the thrust washer spacer if equipped and propeller on the propeller shaft NOTICE Make sure to install the thrust washer before installing the propeller Otherwise the lower case and prop...

Page 81: ...g the pro peller nut to the specified torque tighten the nut further to align the slot with the hole EMU42573 Changing gear oil F200C FL200C F225B FL225B 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 1 Cotter pin 2 Propeller nut 3 Washer 4 Spacer 5 Propeller 6 Thrust washer 1 Cotter...

Page 82: ... 4 Remove the oil level plug and gasket to allow the oil to drain completely NOTICE Check the used gear oil after it has been drained If the gear oil is milky or contains water or a large amount of metal particles the gear case may be damaged Have a Yamaha dealer check and repair the outboard motor ECM00714 TIP For disposal of used oil consult your Yamaha dealer 5 Put the outboard motor in a verti...

Page 83: ...se Be careful not to lose the bolt and nut 4 Remove the gear oil drain screw and gasket The screw is magnetic so a small quantity of metal particles on the end of the screw is normal Simply remove them NOTICE If there is an excessive quantity of metal particles on the magnetic gear oil drain screw this can indicate lower unit problem Con sult your Yamaha dealer ECM01901 5 Remove the oil level plug...

Page 84: ...oved earlier EMU29317 Inspecting and replacing anode s Yamaha outboard motors are protected from corrosion by sacrificial anodes Inspect the external anodes periodically Remove scales from the surfaces of the anodes Consult a Yamaha dealer for replacement of external anodes NOTICE ECM00721 Do not paint anodes as this would render them ineffective Recommended gear oil YAMALUBE outboard gear oil or ...

Page 85: ...ries but you should always refer to the battery manufacturer s instructions NOTICE ECM01921 A poorly maintained battery will quickly deteriorate 1 Check the electrolyte level 2 Check the battery s charge If your boat is equipped with the digital speedome ter the voltmeter and low battery alert functions will help you monitor the bat tery s charge If the battery needs charg ing consult your Yamaha ...

Page 86: ...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 in the illustration For the fuse size be sure to follow local regulations For example for USA the ABYC rules E 11 should be observed Single engine 1 Red cable 2 Black cable 3 Battery Z...

Page 87: ...irst to avoid a short circuit and dam age to the electrical system ECM01941 3 Disconnect the positive cable s and re move the battery from the boat 4 Clean maintain and store the battery according to the manufacturer s instruc tions 1 Starboard side engine 2 Port side engine 3 Red cable 4 Black cable 5 Isolator leads with circuit protection 6 Fuse 7 Battery for starting 8 Battery for accessories 9...

Page 88: ... dealer Q Is shift lever in gear A Shift to neutral Engine will not start starter operates Q Is fuel tank empty A Fill tank with clean fresh fuel Q Is fuel contaminated or stale A Fill tank with clean fresh fuel Q Is fuel filter clogged A Clean or replace filter Q Is starting procedure incorrect A See page 46 Q Has fuel pump malfunctioned A Have serviced by a Yamaha dealer Q Are spark plug s foule...

Page 89: ... a Yamaha dealer Q Is air vent screw on fuel tank closed A Open air vent screw Q Is choke knob pulled out A Return to home position Q Is motor angle too high A Return to normal operating position Q Is carburetor clogged A Have serviced by a Yamaha dealer Q Is fuel joint connection incorrect A Connect correctly Q Is throttle valve adjustment incorrect A Have serviced by a Yamaha dealer Q Is battery...

Page 90: ...ncorrect type A Inspect spark plug s Clean or replace with recommended type Q Are weeds or other foreign matter tangled on gear housing A Remove foreign matter and clean lower unit Q Is fuel system obstructed A Check for pinched or kinked fuel line or other obstructions in fuel system Q Is fuel filter clogged A Clean or replace filter Q Is fuel contaminated or stale A Fill tank with clean fresh fu...

Page 91: ...teering pivot loose or damaged A Tighten or have serviced by a Yamaha dealer EMU29434 Temporary action in emergen cy EMU29442 Impact damage WARNING EWM00871 The outboard motor can be seriously damaged by a collision while operating or trailering Damage could make the out board motor unsafe to operate If the outboard motor hits an object in the wa ter follow the procedure below 1 Stop the engine im...

Page 92: ...Replace it with a spare one of the proper amperage WARNING EWM00632 Substituting an incorrect fuse or a piece of wire could allow excessive current flow This could cause electric system damage and a fire hazard Consult your Yamaha dealer if the new fuse immediately blows again 1 Electrical cover 2 Fuse puller 3 Spare fuse 10 A 15 A 20 A 30 A 60 A 1 Electric throttle valve ECM Electronic con trol m...

Page 93: ...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 This procedure will allow some fuel to spill Catch fuel in a rag Wipe up any spilled fuel immediately The fuel filter must be reassembled carefully with the O ring filter cup and hoses in place Improper assembly or replacement could result i...

Page 94: ...he water in the filter cup by soak ing it up with a rag 7 Firmly screw the filter cup onto the filter housing NOTICE Be careful not to twist the water detection switch lead when screwing the filter cup onto the filter housing ECM01971 8 Connect the water detection switch cou pler securely until a click is heard 9 Fasten the water detection switch lead with the holder 1 Holder 1 Water detection swi...

Page 95: ...e outboard motor after returning to port EMU33502 Treatment of submerged motor If the outboard motor is submerged immedi ately take it to a Yamaha dealer Otherwise some corrosion may begin almost immedi ately NOTICE Do not attempt to run the outboard motor until it has been com pletely inspected ECM00402 1 Holder U6P27AE0 book Page 89 Friday December 6 2013 6 17 PM ...

Page 96: ...removing 41 Cruising in salt water or other conditions 56 D Digital speedometer 25 Digital tachometer 24 Draining the gasoline from the vapor separator 59 E EC Declaration of Conformity DoC 4 Electric shock 1 Emergency equipment 14 Emergency running single engine in an 85 Emergency temporary action in 85 Engine checking 42 Engine oil 42 Engine oil changing 68 Engine oil filling 40 Engine oil requi...

Page 97: ...l number 4 Overheat alert 32 36 Overheat alert indicator 25 Overloading 2 P Passenger training 3 Passengers 2 People in the water 2 Periodic maintenance 61 Personal flotation devices PFDs 2 Power trim and tilt 1 Power trim and tilt switch bottom cowling 19 Power trim and tilt switch remote control 19 Power trim and tilt switches twin binnacle type 20 Power trim and tilt system checking 44 Power tr...

Page 98: ... and down 52 Transporting and storing outboard motor 57 Trim meter 24 Trim tab with anode 20 Trimming outboard motor 50 Trip meter 26 Troubleshooting 82 Twin engine speed synchronizer 29 V Voltmeter 27 W Warming up engine 48 Warning labels 6 Water separator alert 32 Water separator alert indicator 30 Water separator alert indicator blinks while cruising 87 Weather 3 Wiring and connectors inspectin...

Page 99: ...U6P27AE0 book Page 93 Friday December 6 2013 6 17 PM ...

Page 100: ...Printed on recycled paper Printed in Japan January 2014 0 2 1 CR U6P27AE0 book Page 1 Friday December 6 2013 6 17 PM ...

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Yamaha FL200C, Owner'S Manual

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