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F200C
Yamaha F200C Service Manual
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69J1D11
4-14
1
2
3
4
5
6
7
8
9
No.
Part name
Q
’
ty
Remarks
1B
r
a
c
k
e
t
1
2
Joint
1
3
Magnet control lever
1
4P
i
n
4
5
Shaft
1
6B
r
a
c
k
e
t
1
7B
o
l
t
2
M
6
×
20 mm
8
Washer
2
9
Bushing
5
10
Gear
2
11
Throttle control lever
1
12
Circlip
1
13
Bolt
1
14
Wave washer
1
15
Washer
1
16
Throttle cam
1
17
Spring
1
18
Bolt
2
M6
×
14 mm
19
Bracket
2
20
Bolt
1
M8
×
20 mm
21
Terminal
1
22
Starter motor lead
1
23
Bolt
1
M6
×
14 mm
24
Bolt
5
M6
×
45 mm
Throttle control
90
92
Table of Contents
Gen Info General Information
4
Default Chapter
2
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
Checking the Fuel System
33
Checking the Gear Oil
33
Checking the Engine Oil
33
Checking the Battery
33
Checking the Outboard Motor Mounting Height
34
Checking the Remote Control Cables
34
Checking the Steering Wheel
35
Checking the Gearshift and Throttle Operation
35
Checking the Tilt System
35
Checking the Engine Start Switch and Engine Stop Lanyard Switch
35
Checking the Cooling Water Pilot Hole
36
Test Run
36
Break-In
36
After Test Run
36
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
Checking the Fuel Joint and Fuel Hoses (Fuel Joint-To-Fuel Injector)
59
Measuring the Fuel Pressure (High-Pressure Fuel Line)
60
Checking the Fuel Filter
60
Power Unit
60
Checking the Engine Oil
60
Changing the Engine Oil Using an Oil Changer
61
Changing the Engine Oil by Draining It
61
Replacing the Oil Filter
62
Checking the Timing Belt
63
Replacing the Timing Belt
63
Checking the Valve Clearance
63
Checking the Spark Plugs
63
Checking the Thermostat
64
Checking the Cooling Water Passage
64
Control System
64
Checking the Throttle Link and Throttle Cable Operation
64
Adjusting the Throttle Link and Throttle Cable Operation (with a Stop Bolt)
65
Adjusting the Throttle Link and Throttle Cable Operation (Without a Stop Bolt)
66
Checking the Gearshift Operation
67
Checking the Engine Idle Speed
68
Checking the Ignition Timing
70
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
Checking the Gear Oil Level
71
Changing the Gear Oil
72
Checking the Lower Unit (for Air Leakage)
73
Checking the Propeller
73
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
Removing the Pressure Regulator
92
Disconnecting the High-Pressure Fuel Hose Joint
92
Checking the Fuel Injector
92
Checking the Idle Speed Control (ISC)
92
Synchronizing the Throttle Valve
93
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
Removing the Lower Unit
170
Removing the Water Pump and Shift Rod
170
Checking the Water Pump and Shift Rod
171
Propeller Shaft Housing (Regular Rotation Model)
172
Removing the Propeller Shaft Housing Assembly
174
Disassembling the Propeller Shaft Assembly
174
Disassembling the Propeller Shaft Housing
174
Checking the Propeller Shaft Housing
175
Checking the Propeller Shaft
175
Assembling the Propeller Shaft Assembly
176
Assembling the Propeller Shaft Housing
176
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
Removing the Lower Unit
196
Removing the Water Pump and Shift Rod
196
Checking the Water Pump and Shift Rod
197
Propeller Shaft Housing (Counter Rotation Model)
198
Removing the Propeller Shaft Housing Assembly
200
Disassembling the Propeller Shaft Housing
200
Checking the Propeller Shaft Housing
201
Checking the Propeller Shaft
201
Assembling the Propeller Shaft Housing
202
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
Other manuals for Yamaha F200C
Owner's Manual
117 pages
5
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Yamaha F200C Specifications
General
Brand
Yamaha
Model
F200C
Category
Outboard Motor
Language
English
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