Related Manuals for Yamaha F200A
Summary of Contents for Yamaha F200A
- Page 1 F200A FL200A SUPPLEMENTARY SERVICE MANUAL 292087 60L-28197-3D-1X https://www.boat-manuals.com/...
- Page 2 NOTE: A NOTE provides key information to make procedures easier or clearer. F200A, FL200A SUPPLEMENTARY SERVICE MANUAL ©2001 by Yamaha Motor Co., Ltd. 1st Edition, August 2001 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
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Page 3: Table Of Contents
Contents General information INFO Specifications SPEC Periodic checks and adjustments Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT – Electrical systems ELEC Troubleshooting TRBL SHTG Index https://www.boat-manuals.com/... -
Page 4: General Information
General information How to use this manual ..................1 Manual format....................1 Symbols......................2 Identification...................... 3 Applicable models ..................3 Serial number ....................3 Features and benefits ..................4 Electronic control system................4 Ignition and fuel injection timing ..............5 Technical tips .................... -
Page 5: Specifications
Fuel control system ..................31 Checking the fuel injector ................31 Checking the low-pressure fuel pump and high-pressure fuel pump ..32 Troubleshooting Yamaha Diagnostic System ................33 Introduction....................33 Getting started .................... 33 Self-diagnosis....................42 Diagnosing the electronic control system ........... 42 Index......................... -
Page 6: How To Use This Manual
INFO General information How to use this manual Only chapters containing revisions or additional items in the base manual have been included in this manual. Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. -
Page 7: Symbols
Symbols 7 to A in an exploded diagram indicate the grade of lubricant and the lubrication point. 7 Apply Yamaha 4-stroke motor oil 0 Apply corrosion resistant grease 8 Apply water resistant grease (Yamaha grease A) (Yamaha grease D) 9 Apply molybdenum disulfide grease... -
Page 8: Identification
INFO General information Identification Applicable models This manual covers the following models. Applicable models F200AET, FL200AET Serial number outboard motor serial number stamped on a label attached to the port clamp bracket. 1 Model name 2 Approved model code 3 Transom height 4 Serial number Approved Starting... -
Page 9: Features And Benefits
Identification / Features and benefits Features and benefits Electronic control system The ECM controls the ignition timing, the fuel injection timing, the fuel injection volume, and the ISC and it maintains a stoichiometric air-fuel ratio in all operating conditions, including starting and idling. Also, the ECM converts the signals from the input sensors and sends instructions to each part. -
Page 10: Ignition And Fuel Injection Timing
INFO General information Ignition and fuel injection timing This engine adopted the group injection system that the fuel required for one combustion is injected twice per one cycle. Therefore, the injector driving circuits can be integrated to 3 circuits and a simpler electrical struc- ture is obtained. -
Page 11: Technical Tips
Features and benefits / Technical tips Technical tips Fuel injection control The F200 injects fuel simultaneously to the following cylinder pairs: #1 and #4, #2 and #5, and #3 and #6. Optimal injection timing is provided in accordance with the operating conditions of the engine. -
Page 12: Propeller Selection
INFO General information a Propeller diameter (in inches) Propeller selection b Propeller pitch (in inches) The performance of a boat and outboard c Propeller type (propeller mark) motor will be critically affected by the size and type of propeller you choose. Propellers Selection greatly affect boat speed, acceleration, When the engine speed is at the full throttle... -
Page 13: Predelivery Checks
Propeller selection / Predelivery checks Predelivery checks Checking the engine oil 1. Check the oil level. To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel. -
Page 14: Checking The Outboard Motor Mounting Height
INFO General information Checking the outboard motor mounting height 1. Check that the anti-cavitation plate is aligned with the bottom of the boat. If the mounting height is too high, cavitation will occur and propulsion will be reduced. Also, the engine speed will increase abnormally and cause the engine to overheat. -
Page 15: Checking The Steering Wheel
Predelivery checks Checking the steering wheel Checking the tilt system 1. Check the steering friction for proper 1. Check that the outboard motor tilts up adjustment. and down smoothly when operating the power trim and tilt unit. 2. Check that steering operates smoothly. -
Page 16: Checking The Cooling Water Pilot Hole
INFO General information Checking the cooling water pilot hole 1. Start the engine, and then check that cooling water is discharged from the cooling water pilot hole. S60L1170 È Hour After test run 1. Check for water in the gear oil. S60L1160 2. -
Page 17: General Specifications
Predelivery checks / General specifications General specifications Model Item Unit F200AET FL200AET Dimension Overall length mm (in) 892 (35.1) Overall width mm (in) 634 (25.0) Overall height mm (in) 1,805 (71.1) Boat transom height mm (in) 635 (25.0) (*1) Weight kg (lb) 269 (593) Performance... - Page 18 SPEC Specifications Model Item Unit F200AET FL200AET Fuel and oil Fuel type Regular unleaded gasoline Fuel rating PON* Engine oil type 4-stroke motor oil Engine oil grade SE, SF, SG, or SH 10W-30 or 10W-40 Engine oil quantity (with oil filter replacement) 6.0 (6.3, 5.3) (US qt, lmp qt) (without oil filter replacement)
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Page 19: Power Unit
General specifications / Maintenance specifications Maintenance specifications Power unit Model Item Unit F200AET FL200AET Power unit Minimum compression 880 (8.8, 125) pressure* (kgf/cm , psi) Lubrication oil pressure kPa (kgf/cm 650 (6.5, 924) psi) at 700 r/min Cylinder heads Warpage limit mm (in) 0.1 (0.004) (lines indicate straightedge... - Page 20 SPEC Specifications Model Item Unit F200AET FL200AET Oil ring Dimension B mm (in) 2.40–2.47 (0.0945–0.0972) Dimension T mm (in) 2.3–2.7 (0.091–0.106) End gap mm (in) 0.15–0.60 (0.0059–0.0236) Side clearance mm (in) 0.04–0.13 (0.0016–0.0051) Camshafts Intake (A) mm (in) 45.30–45.40 (1.7835–1.7874) Exhaust (A) mm (in) 45.35–45.45 (1.7854–1.7894)
- Page 21 Maintenance specifications Model Item Unit F200AET FL200AET Valve lifters Valve lifter outside diameter mm (in) 32.98–33.00 (1.2984–1.2992) Valve lifter-to-cylinder head mm (in) 0.02–0.05 (0.0008–0.0020) clearance Valve shims Valve shim thickness mm (in) 2.320–2.960 (0.0913–0.1165) (in 0.020 mm increments) Connecting rods Small-end inside diameter mm (in) 21.00 (0.827)
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Page 22: Spec
SPEC Specifications Model Item Unit F200AET FL200AET Oil pump Discharge L (US gal, 8.8 (2.32, 1.94) at 97–103 °C (207–217 °F) Imp gal)/min with 10W-40 engine oil at 700 r/min Pressure 138 (1.38, 19.62) (kgf/cm , psi) Relief valve opening pressure 529–647 (5.29–6.47, 75.22–92.00) (kgf/cm , psi) -
Page 23: Electrical
Maintenance specifications Electrical Model Item Unit F200AET FL200AET Ignition and ignition control system Ignition timing (engine idle speed) Degree Pulser coil output peak voltage (W/R – B, W/B – B, W/G – B) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Ω... - Page 24 SPEC Specifications Model Item Unit F200AET FL200AET Fuel control system Fuel injector output peak (*1) voltage (R/Y – O/R, R/Y – O/B, R/Y – O/Y, R/Y – O/R, R/Y – O/B, R/Y – O/Y) at 1,500–3,000 r/min (loaded) 38–40 (*1) Fuel injector resistance Ω...
- Page 25 Maintenance specifications Model Item Unit F200AET FL200AET Power trim and tilt system Trim sensor Ω Setting resistance 9–11 Ω Resistance (P – B) 9–387.6 Fluid type ATF Dexron II Brushes Standard length mm (in) 12.0 (0.47) Wear limit mm (in) 4.0 (0.16) Commutator Standard diameter...
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Page 26: Dimensions
SPEC Specifications Dimensions Exterior 12˚ S60L2130 60L3D1X https://www.boat-manuals.com/... - Page 27 Maintenance specifications Model Symbol Unit F200AET FL200AET mm (in) 651 (25.6) mm (in) 219 (8.6) mm (in) — mm (in) 673 (26.5) mm (in) 59 (2.3) mm (in) 1,155 (45.5) mm (in) 618 (24.3) mm (in) 230 (9.1) mm (in) 52 (2.0) mm (in) 75 (3.0)
- Page 28 SPEC Specifications Clamp bracket S60L2140 Model Symbol Unit F200AET FL200AET mm (in) 125 (4.9) mm (in) 254 (10.0) mm (in) 163 (6.4) mm (in) 51 (2.0) mm (in) 180 (7.1) mm (in) 411 (16.2) mm (in) — mm (in) — mm (in) 19 (0.7) mm (in)
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Page 29: Tightening Torques
Maintenance specifications / Tightening torques Tightening torques Specified torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Fuel system Fuel filter holder bolt Fuel filter bracket bolt Intake air temperature sensor — Low-pressure fuel pump bracket bolt Fuel cooler nut —... - Page 30 SPEC Specifications Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Timing chain tensioner bolt Spark plug — Cylinder head bolt 90° Engine hanger bolt Cooling water cover bolt Starboard cylinder head plug — Cylinder block plug — Engine temperature sensor —...
- Page 31 Tightening torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Upper case mount nut — Engine oil drain bolt Apron stay — Pressure control valve — Upper exhaust guide bolt Oil strainer bolt Oil pan bolt Exhaust manifold bolt Muffler bolt Baffle plate screw Clamp bracket self-locking nut...
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Page 32: General Torques
SPEC Specifications General torques Special service tools This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this man- ual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion and pro- gressive stages until the specified torque is Test harness (2 pins) -
Page 33: Maintenance Interval Chart
Tightening torques / Special service tools / Maintenance interval chart Maintenance interval chart Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Initial Every Item Remarks Top cowling Top cowling fit Check... -
Page 34: Chk
Periodic checks and adjustments Initial Every Item Remarks Lower unit Gear oil Change Impeller/Woodruff key Check/replace (500 hours or 30 months) Oil seals Check/replace Propeller Check (before each use) General Anodes/Trim tab Check/replace Battery Check/charge Wiring and connectors Adjust/reconnect (*4) Nuts and bolts Tighten Lubrication points... -
Page 35: Power Trim And Tilt Unit
Maintenance interval chart / Power trim and tilt unit Power trim and tilt unit Assembling the gear pump 1. Install the drive gears 1, dowel pins 2, balls 3, and shuttle pistons 4 into the gear housing 1 5. 2. Install the gear housing 2 6. Up-relief lock screw a height (from the top of the gear housing): 1.8–2.0 mm (0.071–0.079 in) -
Page 36: Elec
– ELEC Electrical systems Fuel control system Fuel injector output peak voltage Checking the fuel injector (use as reference): 1. Remove the intake silencer and discon- #1 Red/yellow (R/Y) – nect the fuel injector coupler. Orange/red (O/R) #2 Red/yellow (R/Y) – 2. -
Page 37: Checking The Low-Pressure Fuel Pump And High-Pressure Fuel Pump
5 seconds. • Check the operation of the low-pressure fuel pump 3 using the “Stationary test” of the Yamaha Diagnostic System. * Change step 3 and the note in the F225 service manual to that mentioned above. 60L3D1X... -
Page 38: Trbl Shtg
Me, or Windows 2000 NOTE: • Before installing the Yamaha Diagnostic System, check that your computer meets the specified requirements. For detailed information on the system requirements. • It is strongly recommended that you exit all other programs before running the installer. - Page 39 Yamaha Diagnostic System 3. Double-click the My Computer icon, then the CD-ROM drive icon, and then double-click the Setup.exe icon to start up the installer. (Fig. 1) Fig. 1 4. Click the Next button to start the installation process. (Fig. 2) Fig.
- Page 40 SHTG Troubleshooting NOTE: If the Yamaha Diagnostic System has already been installed onto your computer, the following dia- log box appears. Click the Yes button to update this program, or click the No button to quit the installation. (Fig. 3) Fig.
- Page 41 Yamaha Diagnostic System 5. Check the target directory and the program name for the Yamaha Diagnostic System, which are displayed in the dialog box. Click the Next button to start copying the program files. NOTE: • To go back to the previous dialog box (step 4), click the Back button.
- Page 42 Click the Finish button to quit the installation program. Fig. 8 NOTE: Install the Database file before installing the Yamaha Diagnostic System, otherwise the program will not operate correctly. For installation procedures refer to “UPDATING THE DATABASE” on the next page.
- Page 43 Yamaha Diagnostic System Updating the database NOTE: When installing the Yamaha Diagnostic System program for the first time, be sure to update the database. 1. Turn on your computer and start up Windows 95, Windows 98, Windows Me, or Windows 2000.
- Page 44 TRBL SHTG Troubleshooting 3. After about three seconds the display will automatically go to the first menu display, or you can click or press any key to go to the first menu. (See fig. 11.) Fig. 10 4. Click the Update database [F1] button or press the F1 key on your keyboard. (Fig. 11) Fig.
- Page 45 Yamaha Diagnostic System 5. Insert the compact disc into the computer’s CD-ROM drive. NOTE: • All the database files will be copied from the compact disc to the computer’s hard drive automati- cally. • Any earlier version of the database saved on the hard drive will be overwritten.
- Page 46 To display information, click the title in the first menu screen while pressing the Shift key or press the Enter key while pressing Shift key. (See fig. 11.) Fig. 15 8. To quit the Yamaha Diagnostic System from the first menu (see fig. 11), press the Esc key on your keyboard. 60L3D1X...
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Page 47: Self-Diagnosis
Yamaha Diagnostic System / Self-diagnosis Self-diagnosis Diagnosing the electronic control system 1. Connect the special tools to the outboard motor as shown. L/W,L/W • Trouble code indication Example: The flash pattern in the illus- tration indicates code number 23. a: Light on, 0.33 second b: Light off, 4.95 seconds... - Page 48 TRBL SHTG Troubleshooting Code Symptom Normal Incorrect pulser coil signal Incorrect engine temperature sensor signal Incorrect throttle position sensor signal Incorrect battery voltage Incorrect intake air temperature sensor signal Incorrect neutral switch signal Incorrect intake air pressure sensor signal Incorrect idle speed control signal Incorrect oil pressure sensor signal...
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Page 49: Index
Technical tips..........6 Test run ............11 Tightening torques........24 Electrical ............18 Electronic control system ....... 4 Yamaha Diagnostic System ......33 Features and benefits ........4 Fuel control system........31 Fuel injection control ........6 General specifications........12 General torques ........... - Page 50 Spark plug gap Spark plug gap 11 mm (0.43 in) 1.1 mm (0.043 in) <P. 9-1> → → → → Yamaha Diagnostic System (upgrade) Yamaha Diagnostic System (upgrade) 68F-2819K-10 68F-WS853-01 <P. 9-1, 9-61> → → → → Diagnostic flash indicator 4...
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Page 52: Wiring Diagram
Wiring diagram F200AET, FL200AET 1 Low-pressure fuel pump Color code 2 Low-pressure fuel pump driver : Black 3 High-pressure fuel pump relay : Brown 4 High-pressure fuel pump : Green 5 Idle speed control : Gray 6 Fuel injector : Blue 7 Spark plug : Light green 8 Ignition coil... - Page 53 https://www.boat-manuals.com/...
- Page 54 YAMAHA MOTOR CO., LTD. Printed in the Netherlands Aug. 2001 – 1.3 × 1 CR (F200AET, FL200AET) https://www.boat-manuals.com/...
- Page 55 F200AET, FL200AET — — — R/Y1 — L/R3 B B B B B B R/Y1 Y/G3 B B B B B B R/Y4 R/Y5 R/Y6 1 2 3 4 5 6 Lg R Sb Br/W Br/W Br/W S60LWD03 https://www.boat-manuals.com/...
- Page 56 L/R3 R/Y1 Br/W S60LWD04 https://www.boat-manuals.com/...