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F200B
Yamaha F200B Service Manual
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3-3
RIG
GING
Rigging information
Clamp bracket
TIP:
The dimension values may include reference values.
mm (in)
79 (3.1)
180 (7.1)
163.5 (6.4)
254 (10.0)
55.5 (2.2)
411 (16.2)
163.5 (6.4)
125.4 (4.9)
125.4 (4.9)
180 (7.1)
13 (0.5)
50.8 (2.0)
18.5 (0.7)
13 (0.5)
52 (2.0)
102 (4.0)
102 (4.0)
20 (0.8)
71
73
Table of Contents
General Information
5
Default Chapter
2
Important Information
2
Table of Contents
5
Safety While Working
6
Electric Shock
6
Handling of Gasoline
6
Hot Part
6
Propeller
6
Rotating Part
6
Ventilation
6
Handling of Gas Torch
7
Handling of Sealant
7
Part, Lubricant, and Sealant
7
Self-Protection
7
Working with Crane
7
Disassembly and Assembly
8
Non-Reusable Part
8
Special Service Tool
8
Tightening Torque
8
How to Use this Manual
9
Manual Format
9
Abbreviation
10
Lubricant, Sealant, and Thread Locking Agent
12
Symbol
12
Special Service Tool
14
Specification
22
Model Features
24
General Feature
24
Model Designation
25
Serial Number
26
Model Data
27
Dimension and Weight
27
Performance
27
Power Unit
27
Lower Unit
28
Bracket Unit
28
Fuel and Oil Requirement
28
Battery Requirement
29
PTT Fluid Requirement
29
Electrical System Technical Data
30
Ignition Timing Control System
30
Fuel Injection Control System
31
Engine Speed Control System
31
PTT System
32
Charging System
33
Starting System
33
Gauge/Sensor
34
Fuel System Technical Data
34
Fuel System
34
Power Unit Technical Data
35
Power Unit
35
Cylinder Head Assembly
35
Crankcase Assembly
36
Lower Unit Technical Data
38
Lower Unit Assembly (Regular Rotation Model)
38
Lower Unit Assembly (Counter Rotation Model)
38
Bracket Unit Technical Data
39
PTT System
39
Specified Tightening Torque
40
Rigging Information
40
Fuel System
40
Power Unit
40
Lower Unit (Regular Rotation Model)
42
Lower Unit (Counter Rotation Model)
42
Bracket Unit
42
PTT Unit
43
General Tightening Torque
44
Tech Fea/Tech Fea
45
Tech Fea
46
Technical Features and Description
46
Electronic Control System
46
Engine Control System Component
47
Actuator, Sensor, and Switch
48
Electronic Fuel Injection Control
49
Digital Ignition Control
50
VCT Control
51
Knock Control
52
Over-Rev Control and Alert Control
53
ETV Control
54
Fail-Safe Control
55
Power Unit System
56
Shimless Valve Lifter
56
Fuel System FUEL
57
Fuel System
59
Blowby Gas Reburning System
59
Vapor Gas Treatment
60
Lubrication System
61
Lubrication Diagram
61
Cooling System
62
Cooling Diagram
62
Intake and Exhaust System
66
Intake and Exhaust Diagram
66
Lower Unit
67
Drive Shaft Spring (F250G and FL250G)
67
Propeller Damper Cooling (F250G and FL250G)
68
Rigging Information
69
Outboard Motor Installation
70
Rigging Information
70
External Dimensions
71
F200Bet, Fl200Bet, F250Get, Fl250Get
71
Clamp Bracket
72
Crate Top Cover Pictograph Description
73
Uncrating Procedure
74
Outboard Motor Mounting
75
Outboard Motor Mounting Height
77
Rigging Grommet Mounting
78
Rigging Grommet Description
78
Installing the Shift Cable and Throttle Cable
78
Installing the Wiring Harness
80
Installing the Isolator Lead (Optional)
80
Installing the Battery Cable
81
Installing the Speed Sensor (Optional)
81
Installing the Water Pressure Sensor (Optional)
82
Installing the Rigging Grommet
83
Remote Control Box and Switch Panel Installation
84
Battery Installation
85
Battery Cable Routing Without House (Accessory) Battery
85
Battery Cable Routing with House (Accessory) Battery
87
System Diagram
93
Rigging Recommendation
97
Extension Length Recommendation for Battery Cable
97
Propeller Selection
98
Propeller Size
98
Selection
98
Troubleshooting
101
Ydis
102
Feature
102
Hardware Requirement
102
Function
103
Connecting the Communication Cable to the Outboard Motor
106
Troubleshooting
102
Outboard Motor Troubleshooting
107
Troubleshooting Procedure
107
Troubleshooting the Power Unit Using the YDIS
107
Trouble Code and Checking Step
119
Troubleshooting the Power Unit Using the Diagnostic Flash Indicator
119
Troubleshooting the Power Unit (Trouble Code Not Detected)
120
Troubleshooting the PTT Unit
126
Troubleshooting the Lower Unit
127
Electrical System
128
Electrical Component
130
Port
130
Starboard
131
Fuse Holder
132
Rear
133
Top
134
Electrical System
130
Wiring Harness Routing
135
Port
135
Starboard
138
Rear
141
Top
144
Bottom Cowling
147
Circuit Diagram
151
ECM Coupler Layout
153
Checking the Electrical Component
155
Using the YDIS
155
Measuring the Peak Voltage
155
Using the Digital Tester
156
Engine Control System and Component
156
Checking the Main Relay
156
Checking the Engine ECM Circuit
157
Checking the APS
158
Checking the APS Circuit
159
Checking the ETV and TPS
160
Checking the ETV Motor Relay
161
Checking the ETV and TPS Circuit
162
Checking the Cam Position Sensor
163
Checking the OCV
166
Checking the Oil Pressure Sensor
168
Checking the Water Pressure Sensor (Optional)
169
Checking the Speed Sensor (Optional)
170
Fuel Control Unit and Component
172
Checking the Water Detection Switch
172
Checking the Fuel Injector
173
Checking the Low-Pressure Fuel Pump and High-Pressure Fuel Pump
175
Checking the High-Pressure Fuel Pump Relay
176
Checking the Vapor Shut-Off Valve
177
Charging Unit and Component
179
Checking the Lighting Coil
179
Checking the Rectifier Regulator
180
Ignition Unit and Component
182
Checking the Ignition Spark
182
Checking the Ignition Coil
182
Checking the Pulser Coil
184
Checking the Air Temperature Sensor
185
Checking the Air Pressure Sensor
186
Checking the Engine Temperature Sensor
188
Checking the Thermoswitch
189
Checking the Shift Cut Switch
190
Checking the Neutral Switch
192
Checking the Knock Sensor
193
Checking the Engine Shut-Off Switch
194
Starting Unit and Component
194
Checking the Starter Relay
194
Checking the Engine Start Switch
195
Removing the Starter Motor
198
Checking the Starter Motor Pinion
198
Disassembling the Starter Motor
198
Checking the Armature (Starter Motor)
200
Checking the Brush Holder and Brush
200
Assembling the Starter Motor
201
Installing the Starter Motor
203
PTT Electrical System
203
Checking the PTT Relay
203
Checking the PTT Switch (Bottom Cowling)
204
Checking the Trim Sensor
205
Fuel System
208
Hose Routing
210
Fuel Hose and Blowby Hose
210
Vapor Gas Hose
212
Cooling Water Hose
214
Fuel System
210
Fuel System
216
Reducing the Fuel Pressure
216
Disconnecting the Quick Connector
216
Connecting the Quick Connector
217
Measuring the Fuel Pressure
217
Checking the Pressure Regulator
219
Fuel Filter Assembly
220
Removing the Fuel Filter Assembly
222
Checking the Fuel Filter Assembly
222
Disassembling the Fuel Filter Assembly
223
Checking the Fuel Filter Element
223
Checking the Fuel Cup Assembly
223
Assembling the Fuel Filter Assembly
223
Installing the Fuel Filter Assembly
223
Intake Manifold
226
Removing the Intake Silencer
226
Removing the Intake Manifold
226
Checking the Intake Manifold
227
Checking the Air Temperature Sensor
227
Installing the Intake Manifold
227
Installing the Intake Silencer
228
Removing the Throttle Body Assembly
232
Checking the Canister Check Valve
232
Checking the Vacuum Hose
233
Installing the Throttle Body Assembly
233
Canister, Throttle Body, and Surge Tank
237
Removing the Canister, Throttle Body, and Surge Tank
237
Checking the ETV
237
Checking the Air Pressure Sensor
237
Checking the Vapor Shut-Off Valve
237
Checking the Canister
237
Installing the Canister, Throttle Body, and Surge Tank
238
Low-Pressure Fuel Pump
241
Removing the Low-Pressure Fuel Pump
241
Checking the Low-Pressure Fuel Pump
241
Checking the Primer Pump
241
Installing the Low-Pressure Fuel Pump
242
Draining the Fuel
244
Removing the Vapor Separator
244
Installing the Vapor Separator
244
Vapor Separator and High-Pressure Fuel Pump
246
Disassembling the Vapor Separator
248
Checking the High-Pressure Fuel Pump
249
Checking the Vapor Separator
249
Checking the Check Valve
249
Assembling the Vapor Separator
250
Fuel Injector
252
Removing the Fuel Injector
254
Checking the Fuel Rail
254
Checking the Quick Connector
255
Installing the Fuel Injector
255
Power Unit
257
Power Unit (Check and Adjustment)
260
Checking the Compression Pressure
260
Checking the Oil Pressure
260
Checking the Pulser Coil Air Gap
260
Checking the Valve Clearance
261
Adjusting the Valve Clearance
263
Power Unit
260
Power Unit Assembly
265
Removing the Power Unit
267
Installing the Power Unit
270
Flywheel Magnet
275
Removing the Flywheel Magnet
275
Checking the Pulser Coil
276
Installing the Flywheel Magnet
276
Wiring Harness
279
Removing the Wiring Harness
279
Installing the Wiring Harness
282
Starter Motor
286
Removing the Starter Motor
287
Installing the Starter Motor
287
Fuse Box
288
Removing the Rectifier Regulator
291
Checking the Rectifier Regulator Anode
291
Removing the Junction Box
291
Installing the Junction Box
292
Installing the Rectifier Regulator
292
Engine ECM
295
Removing the Engine ECM
295
Installing the Engine ECM
295
Timing Belt
297
Removing the Timing Belt
297
Checking the Timing Belt
298
Installing the Timing Belt
298
Cylinder Head Cover
303
Removing the Cylinder Head Cover
303
Checking the Spark Plug
303
Installing the Cylinder Head Cover
303
Camshaft
305
Removing the Driven Sprocket and Camshaft
307
Checking the Sprocket
308
Checking the Valve Lifter
308
Checking the Camshaft
309
Installing the Camshaft and Driven Sprocket
309
Exhaust Cover
315
Removing the Exhaust Cover
316
Checking the Exhaust Cover Anode
316
Installing the Exhaust Cover
316
Cylinder Head
317
Removing the Cylinder Head
320
Disassembling the Cylinder Head
320
Checking the Cylinder Head
321
Checking the Valve Spring
321
Checking the Valve
321
Checking the Valve Guide
322
Replacing the Valve Guide
322
Checking the Valve Seat
323
Refacing the Valve Seat
324
Checking the Cylinder Head Anode
326
Assembling the Cylinder Head
326
Installing the Cylinder Head
327
Cooling Water Passage Cover
329
Removing the Cooling Water Passage Cover
331
Checking the Cooling Water Passage Cover Anode
331
Checking the Knock Sensor
331
Installing the Cooling Water Passage Cover
331
Crankcase
333
Removing the Oil Filter Bracket
335
Removing the Oil Pump Assembly
335
Removing the Crankcase Cover
335
Disassembling the Oil Pump Assembly
336
Checking the Oil Pump Assembly
336
Assembling the Oil Pump Assembly
336
Installing the Crankcase Cover
337
Installing the Oil Pump Assembly
337
Installing the Oil Filter Bracket
338
Disassembling the Cylinder Block
343
Checking the Thermostat
344
Checking the Piston Diameter
345
Checking the Cylinder Bore
345
Checking the Piston Ring
345
Checking the Piston Ring End Gap (Reference)
345
Checking the Piston Ring Groove
346
Checking the Piston Ring Side Clearance
346
Checking the Piston Pin Boss Inside Diameter
346
Checking the Piston Pin
346
Checking the Connecting Rod Small End Inside Diameter and Big End Inside Diameter
347
Checking the Connecting Rod Big End Side Clearance
347
Checking the Crankshaft
347
Checking the Crankcase Bolt
348
Checking the Crankpin Oil Clearance
348
Selecting the Crankpin Bearing
349
Checking the Crankshaft Journal Oil Clearance
350
Selecting the Crankshaft Journal Bearing
351
Crankshaft Journal Bearing Selection Table
353
Checking the Cylinder Block Anode
354
Assembling the Cylinder Block
354
Ptt Cylinder
531
Predelivery Check
545
Wiring Diagram
567
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Yamaha F200B Specifications
General
Brand
Yamaha
Model
F200B
Category
Outboard Motor
Language
English
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