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L200A
Yamaha L200A Service Manual
281 pages
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200A
L200A
60H-28197-5E-11
290446
SER
VIC
E MANUAL
2
Table of Contents
Gen Info
4
Default Chapter
2
Important Information
2
General Information
3
Specifications
3
Troubleshooting
3
Table of Contents
4
How to Use this Manual
6
Manual Format
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
10
Applicable Models
10
Serial Number
10
Features and Benefits
11
Hour Meter
11
Exhaust Components (Factory Option)
12
Piston and Cylinder
13
Connecting Rod
14
Gasket
15
Reduction Gear and Clutch
16
Power Unit Mount Bolt
17
Propeller Selection
18
Propeller Size
18
Selection
18
Predelivery Checks
19
Checking the Fuel System
19
Checking the Gear Oil
19
Checking the Battery
19
Checking the Outboard Motor Mounting Position
19
Checking the Remote Control Cables
20
Checking the Steering System
20
Checking the Gearshift and Throttle Operation
20
Checking the Tilt Sytem
20
Checking the Engine Start Switch and Engine Stop Switch, Engine Shut-Off Switch
21
Checking the Pilot Water Outlet
21
Test Run
21
Break-In
22
After Test Run
22
Spec Specifications
23
Genral Specifications
24
Maintenance Specifications
26
Power Unit
26
Lower Unit
32
Tightening Torques
32
Specified Torques
32
General Torques
33
Periodic Checks and Adjustments
34
Periodic Checks and Adjustments
36
Special Service Tools
36
Maintenance Interval Chart
37
Top Cowling
38
Checking the Top Cowling
38
Hour Meter
38
Checking the Hour Meter
38
Fuel System
38
Checking the Fuel Joint and Fuel Hoses (Fuel Joint - to - Carburetor)
38
Checking the Fuel Filter
39
Power Unit
39
Checking the Spark Plugs
39
Checking the Thermostat
40
Checking the Cooling Water Passage
40
Control System
41
Checking the Throttle Cable Operation
41
Checking the Ignition Timing (with Timing Light)
41
Checking the Ignition Timing
42
Adjusting the Ignition Timing
43
Checking the Carburetor Synchronization
47
Adjusting the Carburetor Synchronization
48
Adjusting the Engine Idle Speed
49
Adjusting the Carburetor Pickup Timing
50
Adjusting the Choke Solenoid
51
Adjusting the Throttle Link and the Throttle Cable Operation
51
Checking the Gearshift Operation
52
Power Trim and Tilt Unit
52
Checking the Power Trim and Tilt Operation
52
Checking the Power Trim and Tilt Fluid Level
53
Lower Unit
54
Checking the Gear Oil Level
54
Changing the Gear Oil
54
Checking the Lower Unit (for Air Leakage)
55
Checking the Propeller
56
Checking the Anodes
56
Checking the Battery
56
Lubrication
57
General
56
Fuel Fuel System Fuel System
59
FUEL Fuel System
60
Special Service Tools
60
Hose Routing
61
Fuel Hoses
61
Fuel Filter, Fuel Pump, Fuel Joint
62
Checking the Fuel Joint
65
Checking the Fuel Filter
65
Checking the Fuel Pump
66
Disassembling the Fuel Pump
67
Assembling the Fuel Pump
67
Carburetor
68
Disassembling the Carburetor
71
Checking the Carburetor
71
Assembling the Carburetor
72
Power Unit
73
Special Service Tools
74
Power Unit
74
Checking the Compression Pressure
75
Removing the Power Unit
87
Removing the Flywheel Magnet
88
Removing the Electrical Components
88
Intake Manifold
90
Removing the Intake Manifold
91
Exhaust
93
Removing the Exhaust Cover
94
Cylinder Head
95
Removing the Cylinder Head
96
Cylinder Block
98
Removing the Crankcase
100
Removing the Piston, Connecting Rod Assembly, and the Crankshaft
101
Piston, Connecting Rod
102
Disassembling the Piston, and the Connecting Rod Assembly
103
Checking the Cylinder Block
103
Checking the Piston
104
Checking the Connecting Rod
106
Checking the Crankshaft
106
Installing the Crankshaft
107
Assembling the Piston and Connecting Rod
108
Installing the Piston and Connecting Rod
109
Installing the Cylinder Head
110
Mounting the Exhaust Cover
112
Mounting the Intake Manifold
112
Mounting the Coils
113
Installing the Power Unit
113
Lower Unit
116
Special Service Tools
118
Lower Unit
118
Lower Unit (Regular Rotation Model)
120
Lower Unit (Regular Rotation Model)
121
Removing the Lower Unit
124
Removing the Water Pump and Shift Rod
125
Checking the Water Pump and Shift Rod
125
Propeller Shaft, Propeller Shaft Housing (Regular Rotation Model)
127
Removing the Propeller Shaft Housing Assembly
129
Disassembling the Propeller Shaft Housing Assembly
129
Checking the Propeller Shaft Housing Assembly
130
Assembling the Propeller Shaft Housing Assembly
131
Disassembling the Propeller Shaft Assembly
132
Checking the Propeller Shaft Assembly
132
Assembling the Propeller Shaft Assembly
133
Drive Shaft and Lower Case (Regular Rotation Model)
134
Removing the Drive Shaft and Forward Gear
135
Disassembling the Lower Case
135
Checking the Drive Shaft Housing
136
Assembling the Drive Shaft Housing
136
Checking the Forward Gear
137
Assembling the Forward Gear
137
Checking the Drive Shaft
138
Checking the Pinion Gear
138
Assembling the Lower Unit (Regular Rotation Model)
138
Installing the Lower Case
138
Installing the Water Pump
141
Installing the Speedometer Hose
141
Installing the Lower Unit
142
Shimming (Regular Rotation Model)
144
Shimming
145
Selecting the Pinion Shims
145
Selecting the Forward Gear Shims
146
Selecting the Reverse Gear Shims
147
Backlash (Regular Rotation Model)
148
Measuring the Forward and Reverse Gear Backlash
148
Lower Unit (Counter Rotation Model)
150
Lower Unit (Counter Rotation Model)
151
Removing the Lower Unit
154
Removing the Water Pump and Shift Rod
155
Checking the Water Pump and Shift Rod
155
Propeller Shaft, Propeller Shaft Housing (Counter Rotation Model)
157
Removing the Propeller Shaft Housing Assembly and Propeller Shaft
159
Checking the Propeller Shaft Assembly
160
Disassembling the Propeller Shaft Housing Assembly
161
Checking the Propeller Shaft Housing Assembly
161
Assembling the Propeller Shaft and Propeller Shaft Assembly
161
Drive Shaft and Lower Case (Counter Rotation Model)
163
Removing the Drive Shaft and Reverse Gear
164
Disassembling the Lower Case
164
Checking the Drive Shaft Housing
165
Assembling the Drive Shaft Housing
165
Checking the Reverse Gear
166
Assembling the Reverse Gear
166
Checking the Drive Shaft
166
Checking the Pinion Gear
166
Assembling the Lower Unit (Counter Rotation Model)
167
Installing the Lower Case
167
Installing the Water Pump
169
Installing the Speedometer Hose
170
Installing the Lower Unit
170
Shimming (Counter Rotation Model)
172
Shimming
173
Selecting the Pinion Shims
173
Selecting the Reverse Gear Shims
174
Selecting the Forward Gear Shims
175
Selecting the Propeller Shaft Shims
176
Backlash (Counter Rotation Model)
178
Measuring the Forward and Reverse Gear Backlash
178
Brkt Bracket Unit Bracket Unit
181
BRKT Bracket Unit
182
Special Service Tools
182
Bottom Cowling
183
Upper Case
187
Removing the Upper Case
191
Disassembling the Upper Case
191
Checking the Upper Case
193
Assembling the Upper Case
193
Power Trim and Tilt Unit
196
Bleeding the Power Trim and Tilt Unit (Built-In)
196
Removing the Power Trim and Tilt Unit
198
Checking the Hydraulic Pressure of the Power Trim and Tilt Unit
199
PTT Motor and Reservoir
202
Disassembling the PTT Motor
204
Checking the PTT Motor
205
Assembling the PTT Motor
206
Disassembling the Reservoir
209
Disassembling the Gear Pump Unit
209
Checking the Reservoir and Gear Pump Unit
211
Assembling the Reservoir and Gear Pump Unit
211
Tilt Cylinder and Trim Cylinder
213
Tilt Cylinder and Trim Cylinder
215
Disassembling the Tilt Cylinder and Trim Cylinder
215
Checking the Tilt Cylinder and Trim Cylinder
215
Assembling the Power Trim and Tilt Unit
217
Bleeding the Power Trim and Tilt Unit
220
Installing the Power Trim and Tilt Unit
221
Sreering Arm
223
Removing the Steering Arm
223
Installing the Steering Arm
223
Clamp Brackets
227
Disassembling the Clamp Brackets
227
Assembling the Clamp Brackets
227
Install the Upper Case
228
Adjusting the Trim Sensor Cam
228
Electrical Systems
230
Electrical Systems
232
Special Service Tools
232
Checking the Electrical Components
233
Measuring the Peak Voltage
233
Measuring the Lower Resistance
233
Electrical Components
234
Starboard View
234
Port View
235
Top View
236
Rear View
237
Wiring Harness
238
Ignition System
239
Checking the Ignition Spark Gap
240
Checking and Replacing the Spark Plug Caps (Standard Type)
240
Checking the Plug Cap (with Resister Type)
241
Checking the Ignition Coil
242
Checking the Pulser Coil
242
Checking the Charge Coil
243
Checking the CDI Unit
244
Checking the Thermoswitch
244
Starting System
245
Checking the Fuse
246
Checking the Wiring Harness (10 Pins)
246
Checking the Starter Relay
246
Starter Motor
247
Removing the Starter Motor Pinion
249
Checking the Starter Motor Pinion
249
Checking the Armature
249
Checking the Brushes
250
Choke Solenoid
250
Checking the Choke Solenoid
250
Charging System
251
Checking the Lighting Coil
252
Checking the Rectifier Regulator
252
Power Trim and Tilt
253
Checking the Power Trim and Tilt Relay
254
Checking the Power Trim and Tilt Switch / Trailer Switch
254
Checking the Trim Sender
254
Troubleshooting
255
Power Unit
256
Starting System
256
Ignition System
258
Fuel System
259
Compression Pressure
260
Fuel System
261
Ignition System
262
Power Unit
263
Air Intake System
264
Fuel System
265
Ignition System
266
Cooling System
268
Bracket Unit
269
Lower Unit
272
Electrical System
273
Wiring Diagram
278
Other manuals for Yamaha L200A
Owner's Manual
122 pages
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Yamaha L200A Specifications
General
Horsepower
20 hp
Fuel Type
Gasoline
Cooling System
Water-cooled
Starting System
Manual
Shaft Length
15 in
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