Yamaha Z200 Owner'S Manual Download

Page: 67 / 98

Maintenance

EMU28874

Maintenance chart (additional)

Water pump

Inspection / replace-
ment

High pressure fuel
pump drive belt

Inspection / replace-
ment

High pressure fuel
pump oil level

Inspection / filling

Oil pump

Inspection / adjustment

Oil tank water drain

Inspection / cleaning

Spark plug(s)

Cleaning / adjustment /
replacement

Item

Actions

Every

500 hours (2.5 years)

1000 hours (5 years)

High pressure fuel
pump drive belt

Replacement

Fuel filter (vapor sepa-
rator tank)

Replacement

Item

Actions

Initial

Every

10 hours

(1 month)

50 hours

months)

100

hours (6
months)

200

hours (1

year)

Summary of Contents for Z200

Page 1: ...Z200 LZ200 OWNER S MANUAL 68F 28199 19 U S A Edition LIT 18626 07 00...

Page 2: ...EMU25071 ZMU01690 Read this owner s manual carefully before operating your outboard motor...

Page 3: ...tor CAUTION ECM00700 A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor NOTE A NOTE provides key information to make procedures easier or clearer Yamaha c...

Page 4: ...m and tilt switches twin binnacle type 18 Trim tab with anode 18 Tilt support lever for power trim and tilt or hydro tilt model 19 Top cowling lock levers 19 Flushing device 20 Water separator 20 Tach...

Page 5: ...leaning and anticorrosion measures 57 Battery care 57 Flushing power unit 58 Cleaning the outboard motor 59 Checking painted surface of motor 59 Periodic maintenance 59 Replacement parts 59 Maintenanc...

Page 6: ...information 83 Important warranty information for U S A and Canada 83 YAMAHA MOTOR CORPORATION U S A OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY 85 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA O...

Page 7: ...pped with the mo tor the key identification number is stamped on your key as shown in the illustration Record this number in the space provided for reference in case you need a new key EMU25221 Emissi...

Page 8: ...oard s 2001 ex haust emission standards Engines meeting these standards have 75 lower emissions than conventional carbureted two stroke en gines These engines are equivalent to the U S EPA s 2006 stan...

Page 9: ...may not only cause engine damage but also adversely affect fuel consumption Consult your dealer for correct use Never operate after drinking alcohol or tak ing drugs About 50 of all boating fatali ti...

Page 10: ...d shut off the engine Do not illegally discard empty containers used to replace or replenish oil For the correct processing of empty containers consult the dealer where you purchased the oil When repl...

Page 11: ...sion could result EMU30471 Label WARNING EWM01411 Hot surface under this cover during and after operation To avoid burns do not touch finned resistor with bare hands EMU25465 Caution labels EMU30430 L...

Page 12: ...ou should always move in such a way that the operator of the other vessel can see what you are doing The general prudential rule This rule is called Rule 2 in the International Rules and says In obeyi...

Page 13: ...should be aware of when driving your boat around oth er vessels Narrow channels and bends When navigating in narrow channels you should keep to the right when it is safe and practical to do so If the...

Page 14: ...are passed on the starboard right side when proceeding from open wa ter into port and black buoys are to port left side When navigating out of port your posi tion with respect to the buoys should be r...

Page 15: ...FLAMMABLE AND EXPLOSIVE Do not smoke when refueling and keep away from sparks flames or other sources of ignition Stop engine before refueling Refuel in a well ventilated area Refuel portable fuel tan...

Page 16: ...inimum octane ratings Yamaha does not recommended gasohol containing methanol because it can cause fuel system damage or engine performance problems EMU25660 Engine oil Use Yamalube 2 M outboard oil I...

Page 17: ...r oper ating load Yamaha dealers stock a range of propellers and can advise you and install a propeller on your outboard that is best suited to your ap plication NOTE Select a propeller which will all...

Page 18: ...cowling lock lever s 3 Trim tab anode 4 Propeller 5 Cooling water inlet 6 Anti cavitation plate 7 Anode 8 Tilt support lever 9 Flushing device 10 Power trim and tilt switch 11 Water separator 12 Remo...

Page 19: ...5429 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 Square typ...

Page 20: ...hift out of neutral first pull the neutral in terlock trigger up EMU26211 Neutral throttle lever To open the throttle without shifting into ei ther forward or reverse put the remote con trol lever in...

Page 21: ...he free accelerator return the remote control lever to the neutral position The free accelerator button will return au tomatically to its set position The remote control will then engage forward and r...

Page 22: ...e lanyard to clothing that could tear loose Do not route the lanyard where it could become entan gled preventing it from functioning Avoid accidentally pulling the lanyard during normal operation Loss...

Page 23: ...he power trim and tilt switch see pages 47 and 49 EMU26151 Power trim and tilt switch on bottom engine cowling The power trim and tilt switch is located on the side of the bottom engine cowling Press...

Page 24: ...MU26241 Trim tab with anode The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force WARNING EWM00840 An improperly a...

Page 25: ...tboard motor top cowling pull up the front and rear lock levers Then lift off the cowling When the cowling check to be sure it fits properly in the rubber seal Then lock the cowling again by moving th...

Page 26: ...ning device The water separator warning indicator will blink The buzzer will sound intermittently only when the gear shift is in neutral If the warning system has activated stop the engine and consult...

Page 27: ...pe This indicator shows the engine oil level If the oil level falls below the lower limit the warning indicator will start to blink For fur ther information see page 34 CAUTION ECM00030 Do not operate...

Page 28: ...ents come on NOTE The speedometer displays km h mph or knots according to operator preference Se lect the desired unit of measurement by set ting the selector switch on the back of the gauge See the i...

Page 29: ...the mode button chang es the display format in the following pat tern Total hours Trip hours Display off Resetting the trip hours Simultaneously pressing the set and mode buttons for more than 1 seco...

Page 30: ...is indicated by eight segments When all segments are showing the fuel tank is full CAUTION ECM00860 The Yamaha fuel tank sensor differs from conventional sensors Incorrectly setting the selector switc...

Page 31: ...ver a one hour period at the cur rent rate of engine operation If twin engines are installed on your boat the fuel flow meter displays the total fuel flow of both the port and starboard engines It als...

Page 32: ...To reset the total fuel consumption to zero press the set and mode buttons at the same time EMU26770 Fuel economy This gauge displays the distance per liter or gallon when cruising and is only for ref...

Page 33: ...ress the mode button repeatedly until the indicator on the face of the gauge points to synchronizer NOTE If the two engines speeds are not synchro nized while cruising they can be synchro nized by adj...

Page 34: ...rding to the setting made using the set and mode but tons For details see the attached operation manual 1 Set button 2 Mode button 1 Tachometer 2 Trim meter 3 Multifunction display 4 Cooling water pre...

Page 35: ...oil level warning indicator blinks check the oil level and add the oil if necessary If the warning device has activated while the appropriate engine oil level is maintained consult your Yamaha dealer...

Page 36: ...dealer immediately CAUTION ECM00910 Gasoline mixed with water could cause damage to the engine Engine trouble warning This indicator will blink when the engine mal functions while cruising Get back t...

Page 37: ...s are connected to the unit trip display water surface temperature display depth display and clock will be available For the optional sensor consult your Yamaha dealer The speed fuel meter unit is ava...

Page 38: ...y water surface tempera ture display depth display and clock will be available For the optional sensor consult your Yamaha dealer NOTE After the main switch is first turned on all the displays come on...

Page 39: ...eration man ual EMU26801 Warning system CAUTION ECM00090 Do not continue to operate the engine if a warning device has activated Consult your Yamaha dealer if the problem can not be located and correc...

Page 40: ...ot affected by overheating turn off the main switch of the engine over heating EMU26846 Oil level warning and oil filter clogging warning Oil injection models This engine has an oil level warning syst...

Page 41: ...E The warning for oil filter clogging is similar to the warnings for low oil level and overheat ing To make troubleshooting easier check for engine overheating first then oil level and finally oil fil...

Page 42: ...does not have a capacity plate consult the boat manufacturer The information presented in this sec tion is intended as reference only It is not possible to provide complete in structions for every pos...

Page 43: ...tion and the desired use Test runs at different heights can help deter mine the optimum mounting height Con sult your Yamaha dealer or boat manufacturer for further information on de termining the pro...

Page 44: ...full throttle for more than 5 minutes at a time 5 After the first 10 hours Operate the engine normally EMU27103 Preoperation checks WARNING EWM00080 If any item in the preoperation check is not workin...

Page 45: ...MU27221 Operation after a long period of storage When operating the engine after a long peri od 12 months of storage proceed as fol lows 1 Start the engine Leave it idling WARNING EWM00090 Do not touc...

Page 46: ...sed deposits in the combustion chamber When enough de posits collect piston rings begin sticking Performance drops and engine wear in creases dramatically While many additives available may reduce dep...

Page 47: ...US gal 0 8 Imp gal can be added 2 Turn on the main switch The Yamaha oil injection system will automatically feed oil from the remote oil tank to the engine oil tank 3 Operate the engine normally CAU...

Page 48: ...than 300 cm3 0 32 US qt 0 26 Imp qt 1500 cm3 1 6 US qt 1 31 Imp qt or less Add oil see page 40 Red Yellow Green 300 cm3 0 32 US qt 0 26 Imp qt or less more than 1500 cm3 1 6 US qt 1 31 Imp qt Check o...

Page 49: ...tain carbon monoxide a col orless odorless gas which could cause brain damage or death when inhaled Symptoms include nausea dizziness and drowsiness Keep cockpit and cab in areas well ventilated Avoid...

Page 50: ...preventing it from functioning Avoid accidentally pulling the lanyard during normal operation Loss of en gine power means the loss of most steering control Also without engine power the boat could slo...

Page 51: ...models 1 After starting the engine allow it to idle for 3 minutes to warm up Failure to do so will shorten engine life 2 Check for a steady flow of water from the cooling water pilot hole CAUTION ECM0...

Page 52: ...ipped and move the remote control lever quickly and firmly from neutral to forward EMU27785 Reverse automatic reverse lock and power trim and tilt models WARNING EWM00190 When operating in reverse go...

Page 53: ...stop switch then turning the main switch to off EMU27861 Trimming outboard motor The trim angle of the outboard motor helps determine the position of the bow of the boat in the water Correct trim angl...

Page 54: ...for any signs of instabil ity or control problems Improper trim angle can cause loss of control If equipped with a power trim and tilt switch located on the bottom cowling use the switch only when th...

Page 55: ...n 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...

Page 56: ...efore tilting the outboard motor stop the engine by following the procedure on page 47 Never tilt the outboard mo tor while the engine is running Severe damage from overheating can result Do not tilt...

Page 57: ...r tilt switch down to retract the trim rods CAUTION ECM00250 Be sure to retract the trim rods complete ly during mooring This protects the rods from marine growth and corrosion which could damage the...

Page 58: ...for shallow water cruising Return the outboard motor to its normal position as soon as the boat is back in deeper water CAUTION ECM00260 Do not tilt the outboard motor up so that the cooling water inl...

Page 59: ...Cruising in other conditions Cruising in salt water After operating in salt water flush the cooling water passages with fresh water to prevent them from becoming clogged with salt de posits NOTE For...

Page 60: ...1 cu in Bore stroke 90 0 68 0 mm 3 54 2 68 in Ignition system TCI Spark plug with resistor NGK BKR7EKU Spark plug gap 1 5 1 6 mm 0 059 0 063 in Control system Remote control Starting system Electric S...

Page 61: ...m the tilt sup port and fall If the motor cannot be trail ered in the normal running position use an additional support device to secure it in the tilt position The outboard motor should be trailered...

Page 62: ...ooling water passag es CAUTION ECM00310 Avoid running the outboard motor at high speed while on the flushing attachment otherwise overheating could occur 5 Cooling system flushing is essential to prev...

Page 63: ...down the exterior of the outboard motor with fresh water and dry off com pletely 2 Spray the outboard motor exterior with Yamaha Silicone Protectant Part No LUB SILCNE 13 00 CAUTION ECM01401 Do not sp...

Page 64: ...ht after operation for the most thorough flushing CAUTION ECM01530 Do not perform this procedure while the engine is running The water pump may be damaged and severe damage from overheating can result...

Page 65: ...NING EWM01070 Be sure to turn off the engine when you perform maintenance unless otherwise specified If you or the owner is not famil iar with machine servicing this work should be done by your Yamaha...

Page 66: ...ns Initial Every 10 hours 1 month 50 hours 3 months 100 hours 6 months 200 hours 1 year Anode s external Inspection replace ment Anode s internal Inspection replace ment Battery Inspection charging Co...

Page 67: ...spection filling Oil pump Inspection adjustment Oil tank water drain Inspection cleaning Spark plug s Cleaning adjustment replacement Item Actions Every 500 hours 2 5 years 1000 hours 5 years High pre...

Page 68: ...0 When removing or installing a spark plug be careful not to damage the insulator A damaged insulator could allow external sparks which could lead to explosion or fire The spark plug is an important e...

Page 69: ...to the correct torque NOTE If a torque wrench is not available when you are fitting a spark plug a good estimate of the correct torque is 1 4 to 1 2 a turn past fin ger tight Have the spark plug adju...

Page 70: ...the outboard motor in the water 1 Start the engine and allow it to warm up fully in neutral until it is running smooth ly NOTE Correct idling speed inspection is only possi ble if the engine is fully...

Page 71: ...sure no one is under the outboard motor before performing this test 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 remote con...

Page 72: ...spark plugs Also place the shift control in neutral turn the main switch to off and re move the key and remove the lanyard from the engine stop switch Turn off the battery cut off switch if your boat...

Page 73: ...ed with the letter L after the size indication on the propeller Otherwise the boat could move in the opposite direction from that expected CAUTION ECM00340 Be sure to install the thrust washer be fore...

Page 74: ...west point pos sible 2 Place a suitable container under the gear case 3 Remove the gear oil drain screw and gasket NOTE If a magnetic gear oil drain screw is equipped remove all metal particles from t...

Page 75: ...ot paint anodes as this would render them ineffective NOTE Inspect ground leads attached to external anodes on equipped models Consult a Yamaha dealer for inspection and replace ment of internal anode...

Page 76: ...evel at least once a month Fill to the manufacturer s rec ommended level when necessary Top up only with distilled water or pure de ionized water suitable to use in batter ies 2 Always keep the batter...

Page 77: ...om wire equivalent to the starting battery cable WARNING EWM00600 Use of smaller wire could lead to a fire NOTE If a battery selector switch is desired consult your YAMAHA dealer about correct wiring...

Page 78: ...hould be kept as clean of ma rine growth as possible If necessary the boat bottom can be coated with an anti foul ing paint approved for your area to inhibit marine growth Do not use anti fouling pain...

Page 79: ...Have serviced by a Yamaha 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 st...

Page 80: ...damaged A Have serviced by 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 nor...

Page 81: ...d or of incorrect 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...

Page 82: ...RNING EWM00870 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...

Page 83: ...operated after a main fuse has blown charging capabili ty will be insufficient and the engine will not start NOTE Consult your Yamaha dealer if the new fuse immediately blows again EMU29522 Power trim...

Page 84: ...The fuel filter must be reassembled carefully with the O ring filter cup and hoses in place Improper assembly or replacement could result in a fuel leak which could result in a fire or explosion hazar...

Page 85: ...If the battery is discharged to 9 volts or below the electric fuel pump will not operate WARNING EWM01021 Use this procedure only in an emergen cy to return to the nearest port for re pairs When the e...

Page 86: ...trical components when starting or op erating the motor You could get an electrical shock EMU29581 Emergency starting engine 1 Remove the top cowling 2 Remove the flywheel cover 3 Prepare the engine f...

Page 87: ...ocedure CAUTION ECM00900 If the emergency switch is held up too long too much oil will be pumped into the engine oil tank overflowing it Re lease the switch when oil reaches the upper level line on th...

Page 88: ...begin almost immedi ately If you cannot immediately take the outboard motor to a Yamaha dealer follow the proce dure below in order to minimize engine dam age EMU29790 Procedure 1 Thoroughly wash awa...

Page 89: ...83 Consumer information EMU29811 Important warranty information for U S A and Canada...

Page 90: ...Consumer information 84...

Page 91: ...Consumer information 85 EMU29820 YAMAHA MOTOR CORPORATION U S A OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY...

Page 92: ...Consumer information 86...

Page 93: ...Consumer information 87...

Page 94: ...Consumer information 88 EMU29841 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA...

Page 95: ......

Page 96: ...Printed in Japan May 2006 0 2 1 Printed on recycled paper...

Page 97: ...d tail OUTBOARD MOTOR MODEL AND SERIAL NUMBER From I D label on clamp bracket MOD LE ET NO DE S RIE DU MOTEUR HORS BORD sur l tiquette d identification de la presse de fixation For Dealer Use Only A l...

Page 98: ...PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT Warranty card 04 2 17 03 2 41 PM Page 2...

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Yamaha Z200, Owner'S Manual

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