Yamaha F200TR Manuals

Manuals and User Guides for Yamaha F200TR. We have 2 Yamaha F200TR manuals available for free PDF download: Service Manual, Rigging Manual

Yamaha F200TR Service Manual (323 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 11.71 MB

Gen Info General Information

4
- Important Information
  2
- Table of Contents
  4
- General Information
  4
- How to Use this Manual
  
  6
  - Manual Format
    6
  - Specifications
    6
  - Symbols
    7
- Safety While Working
  
  8
  - Fire Prevention
    8
  - Ventilation
    8
  - Self-Protection
    8
  - Parts, Lubricants, and Sealants
    8
  - Good Working Practices
    9
  - Disassembly and Assembly
    9
- Identification
  
  9
  - Applicable Models
    9
  - Serial Number
    9
  - General Information
    10
- Features and Benefits
  
  11
  - Newly Developed V6 4-Stroke Engine
    11
  - Valve Train System
    14
  - Intake System
    16
  - Exhaust System
    16
  - Fuel System
    18
  - PTT (Power Trim and Tilt) Unit
    22
- Technical Tips
  
  23
  - Fuel Injection Control
    23
  - Fail-Safe Function Table
    25
  - PTT (Power Trim and Tilt) Unit
    26
  - Cooling System
    31
  - Lubrication System
    31
- Propeller Selection
  
  32
  - Propeller Size
    32
  - Selection
    32
- Predelivery Checks
  
  33
Spec Specifications

37
- General Specifications
  
  38
- Maintenance Specifications
  
  40
  - Power Unit
    40
  - Lower Unit
    43
  - Electrical
    44
  - Dimensions
    48
- Tightening Torques
  
  51
  - Specified Torques
    51
  - General Torques
    54
Chk Adj/Chk Adj

55
- Chk Adj
  
  56
- Special Service Tools
  
  56
- Periodic Checks and Adjustments
  
  56
- Maintenance Interval Chart
  
  57
- Top Cowling
  
  59
  - Checking the Top Cowling
    59
- Fuel System
  
  59
- Power Unit
  
  60
- Control System
  
  64
- Power Trim and Tilt Unit
  
  70
  - Checking the Power Trim and Tilt Operation
    70
  - Checking the Power Trim and Tilt Fluid Level
    71
- Lower Unit
  
  71
- General
  
  73
  - Checking the Anodes
    73
  - Checking the Battery
    74
  - Lubrication
    75
Fuel Fuel System

77
- Special Service Tools
  
  78
- Fuel System
  
  78
- Hose Routing
  
  79
  - Fuel and Blowby Hoses
    79
- Intake Silencer, Fuel Filter, and Fuel Pump
  
  80
- Vapor Separator
  
  82
  - Removing the Hose Clamps
    84
  - Installing the Hose Clamps
    84
  - Checking the Check Valve
    84
  - Reducing the Fuel Pressure
    84
  - Checking the Vapor Separator
    85
- Intake Manifold and High-Pressure Fuel Line
  
  86
- Throttle Control
  
  90
Powr Power Unit

98
- Special Service Tools
  
  100
- Power Unit
  
  102
  - Checking the Compression Pressure
    113
  - Checking the Oil Pressure
    113
  - Checking the Oil Pressure Sensor
    114
  - Checking the Valve Clearance
    114
  - Replacing the Timing Belt
    120
  - Removing the Power Unit
    122
  - Removing the Oil Filter
    124
  - Removing the Timing Belt and Sprockets
    124
  - Checking the Timing Belt and Sprockets
    125
  - Installing the Sprockets and Timing Belt
    126
- Cylinder Head
  
  128
  - Removing the Cylinder Head
    132
  - Checking the Valve Springs
    133
  - Checking the Valves
    133
  - Checking the Valve Guides
    134
  - Replacing the Valve Guides
    134
  - Checking the Valve Seat
    135
  - Refacing the Valve Seat
    135
  - Checking the Camshaft
    137
  - Checking the Timing Chain Tensioner
    138
  - Checking the Timing Chain
    138
  - Checking the Cylinder Head
    138
  - Installing the Valves
    139
  - Installing the Cylinder Head
    140
- Cylinder Block
  
  142
  - Disassembling the Cylinder Block
    146
  - Checking the Piston Diameter
    146
  - Checking the Cylinder Bore
    147
  - Checking the Piston Clearance
    147
  - Checking the Piston Rings
    147
  - Checking the Piston Ring Grooves
    148
  - Checking the Piston Ring Side Clearance
    148
  - Checking the Piston Pin Boss Bore
    148
  - Checking the Piston Pin
    149
  - Checking the Connecting Rod Small End Inside Diameter
    149
  - Checking the Connecting Rod Big End Side Clearance
    149
  - Checking the Crankshaft
    149
  - Checking the Crankpin Oil Clearance
    150
  - Selecting the Connecting Rod Bearing
    151
  - Checking the Crankshaft Main Journal Oil Clearance
    152
  - Selecting the Crankshaft Main Bearing
    153
  - Disassembling the Oil Pump
    154
  - Checking the Oil Pump
    154
  - Assembling the Oil Pump
    154
  - Assembling the Piston and Cylinder Block
    155
  - Checking the Thermostat
    159
  - Installing the Power Unit
    159
Lowr Lower Unit

162
- Special Service Tools
  
  164
- Lower Unit
  
  164
- Lower Unit (Regular Rotation Model)
  
  166
- Propeller Shaft Housing (Regular Rotation Model)
  
  172
- Drive Shaft and Lower Case (Regular Rotation Model)
  
  178
  - Removing the Drive Shaft
    180
  - Disassembling the Drive Shaft Housing
    180
  - Disassembling the Forward Gear
    180
  - Disassembling the Lower Case
    180
  - Checking the Pinion and Forward Gear
    181
  - Checking the Bearings
    181
  - Checking the Drive Shaft
    181
  - Checking the Lower Case
    181
  - Assembling the Lower Case
    181
  - Assembling the Forward Gear
    182
  - Assembling the Drive Shaft Housing
    182
  - Installing the Drive Shaft
    182
  - Installing the Propeller Shaft Housing
    183
  - Installing the Water Pump and Shift Rod
    183
  - Installing the Lower Unit
    185
- Shimming (Regular Rotation Model)
  
  187
  - Shimming
    188
  - Selecting the Pinion Shims
    188
  - Selecting the Forward Gear Shims
    189
  - Selecting the Reverse Gear Shims
    190
- Backlash (Regular Rotation Model)
  
  191
  - Measuring the Forward and Reverse Gear Backlash
    191
- Lower Unit (Counter Rotation Model)
  
  192
- Propeller Shaft Housing (Counter Rotation Model)
  
  198
- Drive Shaft and Lower Case (Counter Rotation Model)
  
  204
  - Removing the Drive Shaft
    206
  - Disassembling the Drive Shaft Housing
    206
  - Disassembling the Reverse Gear
    206
  - Disassembling the Lower Case
    206
  - Checking the Pinion and Reverse Gear
    207
  - Checking the Bearings
    207
  - Checking the Drive Shaft
    207
  - Checking the Lower Case
    207
  - Assembling the Lower Case
    207
  - Assembling the Drive Shaft Housing
    208
  - Installing the Drive Shaft
    209
  - Installing the Propeller Shaft Housing
    209
  - Installing the Water Pump and Shift Rod
    210
  - Installing the Lower Unit
    211
- Shimming (Counter Rotation Model)
  
  213
  - Shimming
    214
  - Selecting the Pinion Shims
    214
  - Selecting the Reverse Gear Shims
    215
  - Selecting the Forward Gear Shims
    215
  - Selecting the Propeller Shaft Shims
    217
- Backlash (Counter Rotation Model)
  
  219
Brkt Bracket Unit

220
- Special Service Tools
  
  222
- Bottom Cowling
  
  224
- Upper Case, Steering Arm, Swivel Bracket and Clamp Brackets
  
  228
  - Draining the Engine Oil
    234
  - Disassembling the Oil Pan
    234
  - Checking the Oil Strainer
    234
  - Assembling the Oil Pan
    234
  - Removing the Steering Arm
    236
  - Installing the Steering Arm
    237
  - Installing the Upper Case
    238
  - Removing the Power Trim and Tilt Unit
    238
  - Removing the Clamp Brackets
    239
  - Installing the Clamp Brackets
    239
  - Installing the Power Trim and Tilt Unit
    239
  - Adjusting the Trim Sensor
    240
- Power Trim and Tilt Unit
  
  242
  - Disassembling the Power Trim and Tilt Motor
    248
  - Checking the Power Trim and Tilt Motor
    248
  - Assembling the Power Trim and Tilt Motor
    249
  - Checking the Hydraulic Pressure
    250
  - Disassembling the Gear Pump
    252
  - Disassembling the Tilt Cylinder and Trim Cylinders
    253
  - Checking the Reservoir
    255
  - Checking the Tilt Cylinder and Trim Cylinder
    255
  - Checking the Valves
    255
  - Checking the Filters
    256
  - Checking the Gear Pump
    256
  - Checking the Gear Pump Housing
    256
  - Assembling the Gear Pump
    256
  - Assembling the Tilt Ram
    257
  - Assembling the Trim Rams
    258
  - Installing the Tilt Cylinder
    259
  - Installing the Trim Rams
    259
  - Installing the Power Trim and Tilt Motor
    260
  - Installing the Reservoir
    261
  - Installing the Tilt Ram
    261
- Bleeding the Power Trim and Tilt Unit
  
  262
  - Not Installed
    262
  - Built-In
    263
- Power Trim and Tilt Electrical System
  
  264
  - Checking the Fuse
    265
  - Checking the Power Trim and Tilt Relay
    265
  - Checking the Power Trim and Tilt Switch
    266
  - Checking the Trim Sensor
    266
Elec Electrical Systems

267
- Electrical Systems
  
  268
- Special Service Tools
  
  268
  - Troubleshooting
    269
- Checking the Electrical Components
  
  269
  - Measuring the Peak Voltage
    269
  - Measuring the Lower Resistance
    269
- Electrical Components
  
  270
  - Starboard and Rear Views
    270
  - Port View
    271
  - Front View
    272
  - Top View
    273
- Wiring Harness
  
  274
- Ignition and Ignition Control System
  
  277
  - Checking the Ignition Spark Gap
    278
  - Checking the Ignition Coil
    278
  - Checking the ECM
    279
  - Checking the Pulser Coil
    279
  - Checking the Throttle Position Sensor
    279
  - Checking the Intake Air Temperature Sensor
    280
  - Checking the Engine Temperature Sensor
    280
  - Checking the Thermoswitch
    281
  - Checking the Shift Cut Switch
    281
  - Checking the Neutral Switch
    281
  - Checking the Main Relay
    282
- Fuel Control System
  
  283
  - Checking the Low-Pressure Fuel Pump and High-Pressure Fuel Pump
    285
- Starting System
  
  286
  - Checking the Fuse
    287
  - Checking the Wiring Harness (10 Pins)
    287
  - Checking the Starter Relay
    287
- Starter Motor
  
  288
  - Removing the Starter Motor Pinion
    290
  - Checking the Starter Motor Pinion
    290
  - Checking the Armature
    290
  - Checking the Brushes
    291
  - Checking the Magnet Switch
    291
  - Checking the Starter Motor Operation
    291
- Charging System
  
  292
  - Checking the Stator Coil
    293
  - Checking the Rectifier Regulator
    293
  - Trbl Shtg
    296
  - Troubleshooting
    296
  - Special Service Tools
    296
  - Yamaha Diagnostic System
    296
  - Power Unit
    300
  - Bracket Unit
    309
  - Electrical Systems
    313
  - Self-Diagnosis
    314
  - Diagnosing the Electronic Control System
    314

Yamaha F200TR Rigging Manual (226 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 7.75 MB

Table of Contents

5
Propellers

59
- Propeller Specifications
  
  60
  - Propeller Types
    60
  - Propeller Identification
    62
- 2009 Propeller Applications
  
  63
- Propeller Selection
  
  63
- Wot Operation Range Table
  
  69
- Remote Controls
  
  71
  - Remote Control Applications
    72
  - Remote Switch Applications
    85
  - Remote Control Cables
    94
  - Remote Control Attachment Kit
    96
  - Steering Hook
    98
  - Steering Guide Attachment Kit
    101
  - Conventional Wire Harness
    103
  - Digital Electronic Control Wire Harness
    105
Tiller Handles

107
- 6X4 Multi-Function Tiller Handle
  
  108
- Steering Friction Contents
  
  117
Conventional Gauge (6Y5 & 6Y7)

119
- Mounting the Meters
  
  122
  - Meter Mounting Procedure
    122
  - Analog Gauge Illumination (6Y7 Type)
    122
- Analog Tachometer
  
  123
  - Analog Tachometer Applications
    123
  - Analog Tachometer Dimensions
    124
  - Pole Number Set up
    124
- Digital Tachometer
  
  125
  - Digital Tachometer Applications
    125
  - Digital Tachometer Dimensions
    125
  - Pole Number Set up
    126
- Speedometer
  
  127
  - Speedometer Applications
    127
  - Speedometer Dimensions
    128
  - Water Pressure Damper (Op)
    128
  - Speedometer Tube Routing
    129
  - Digital Speedometer Set up
    129
- Fuel Management Gauge
  
  130
  - Fuel Management Gauge Applications
    130
  - Fuel Management Gauge Dimensions
    131
  - Fuel Sender Installation
    132
  - Wiring Description
    133
  - Fuel Management Gauge Set up
    135
  - Fuel Mgt Gauge with Speedometer Set up
    135
- Analog Trim Meter
  
  136
  - Analog Trim Meter Applications
    136
  - Analog Trim Meter Dimensions
    136
  - Trim Sender Adjustment
    136
- Coolant Pressure Meter
  
  137
  - Coolant Pressure Meter Applications
    137
  - Coolant Pressure Meter Dimensions
    137
- Coolant Temp. Meter
  
  138
- Hour Meter
  
  144
  - Hour Meter Applications
    144
  - Wiring the Mechanical Hour Meter
    145
  - Wiring the Digital Hour Meter
    145
- Voltage Meter
  
  146
  - Voltage Meter Applications
    146
  - Voltage Meter Dimensions
    146
  - Wiring the Voltage Meter
    146
- Fuel Meter
  
  147
  - Fuel Meter Applications
    147
  - Fuel Meter Dimensions
    147
- Charge Warning Unit
  
  148
  - Charge Warning Unit Applications
    148
- Wire Harnesses
  
  149
  - Remote-Oil Tank Harness
    149
  - Additional Accessory Lead
    149
  - Meter Harness
    150
  - Lamp Switch
    151
  - Combination Trim and Oil Lead 1
    151
  - Combination Trim and Oil Lead 2
    151
  - Trim Meter Lead
    151
  - Pt/T Switch Lead Extension
    152
  - Trim and Oil Lead
    152
  - Fuel Management Gauge Harness
    152
  - Lighting Coil Extension Harness
    152
  - Rectifier Kit
    152
- Wiring Diagrams
  
  153
  - Wire Color Code
    153
  - Digital Meter
    154
  - Analog Meter (6Y7)
    159
  - Interchangeability between Tachometer and Engine
    161
  - Grommet Description
    164
Digital Network Gauge (6Y8)

167
- Digital Network Gauge Compatible Model
  
  168
- Digital Network Gauge Application
  
  168
  - Square Style Gauge Application
    168
- Digital Network Gauge Dimensions
  
  169
  - Round Style Gauge Application
    169
  - Square Style Gauge Dimensions
    169
  - Round Style Gauge Dimensions
    170
- Optional Equipments
  
  171
  - Multi-Sensor Application
    171
  - Fitting Plate
    171
  - Speed Sensor Kit
    172
  - Coolant Pressure Sensor Kit
    172
- Wire Harness
  
  173
  - Main Bus Wire
    173
  - Pigtail Bus Wire
    173
  - Fuel Tank / Gps Wire
    174
  - Hub
    174
- Wiring Diagrams
  
  175
  - FUEL INJECTED F50-F250 [Mechanical RC] & HPDI ENGINES
    175
  - F350/F300/F250 [Digital Electronic Control]
    178
- Initial Gauge Setup
  
  183
- Troubleshooting
  
  184
- Basic Requirements
  
  185
- Nmea0183 Compatible Equipments Connection
  
  185
Battery

187
- Recommended Battery
  
  188
- Battery Cable Length
  
  189
- Battery Wiring
  
  190
Appendix

195
- Model Name Designation
  
  196
  - Us & Canada Model Identification
    197
  - New Us & Canada Model Identification Code
    197
- Fuel System Vacuum Pressure Standard
  
  198
  - Fuel Hose Routing Resistance Measuring Method
    198
  - Lowest Vacuum Pressure Standard
    199
- Portable Fuel Tanks (Typical)
  
  200
- Fuel Pipes (Typical)
  
  200
- Pre-Delivery Inspection (Pdi) Checks
  
  201
- Conventional Rigging Kit Contents
  
  202
  - Digital Tachometer Kit
    202
  - Digital Tachometer and Speedometer Kit
    202
  - Twin-Motor Kit
    203
  - Remote Oil Tank Kit (for 2-Stroke Engine)
    204
- Digital Network Gauge Rigging Kit Contents
  
  205
- 2009 Manufacturing Start Serial Number
  
  219

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Yamaha F200TR Manuals

Yamaha F200TR Service Manual (323 pages)

Table of Contents

Gen Info General Information

How to Use this Manual

Safety While Working

Identification

Features and Benefits

Technical Tips

Propeller Selection

Predelivery Checks

Spec Specifications

General Specifications

Maintenance Specifications

Tightening Torques

Chk Adj/Chk Adj

Chk Adj

Special Service Tools

Periodic Checks and Adjustments

Maintenance Interval Chart

Top Cowling

Fuel System

Power Unit

Control System

Power Trim and Tilt Unit

Lower Unit

General

Fuel Fuel System

Special Service Tools

Fuel System

Hose Routing

Intake Silencer, Fuel Filter, and Fuel Pump

Vapor Separator

Intake Manifold and High-Pressure Fuel Line

Throttle Control

Powr Power Unit

Special Service Tools

Power Unit

Cylinder Head

Cylinder Block

Lowr Lower Unit

Special Service Tools

Lower Unit

Lower Unit (Regular Rotation Model)

Propeller Shaft Housing (Regular Rotation Model)

Drive Shaft and Lower Case (Regular Rotation Model)

Shimming (Regular Rotation Model)

Backlash (Regular Rotation Model)

Lower Unit (Counter Rotation Model)

Propeller Shaft Housing (Counter Rotation Model)

Drive Shaft and Lower Case (Counter Rotation Model)

Shimming (Counter Rotation Model)

Backlash (Counter Rotation Model)

Brkt Bracket Unit

Special Service Tools

Bottom Cowling

Upper Case, Steering Arm, Swivel Bracket and Clamp Brackets

Power Trim and Tilt Unit

Bleeding the Power Trim and Tilt Unit

Power Trim and Tilt Electrical System

Elec Electrical Systems

Electrical Systems

Special Service Tools

Checking the Electrical Components

Electrical Components

Wiring Harness

Ignition and Ignition Control System

Fuel Control System

Starting System

Starter Motor

Charging System

Yamaha F200TR Rigging Manual (226 pages)

Table of Contents

Table of Contents

Top Cover Pictograph Description

Uncrating Procedure (for Typical Steel Frame)

Mounting the Outboard Motor

Mounting the Remote Oil Tank

Outboard Motor Dimensions

Propellers