Yamaha 200A Service Manual

SERVICE MANUAL29208760L-28197-3D-1XSUPPLEMENTARYF200AFL200A

GEN INFOGeneral information560L3D1XIgnition and fuel injection timingThis engine adopted the group injection system that the fuel required for one com

60L3D1X6Technical tips1Fuel injection controlThe F200 injects fuel simultaneously to the following cylinder pairs: #1 and #4, #2 and #5, and #3and #6.

GEN INFOGeneral information760L3D1XPropeller selection1The performance of a boat and outboardmotor will be critically affected by the sizeand type of

60L3D1X8Predelivery checks1To make the delivery process smooth andefficient, the predelivery checks should becompleted as explained below.Checking the

GEN INFOGeneral information960L3D1XChecking the outboard motor mounting height1. Check that the anti-cavitation plate isaligned with the bottom of the

60L3D1X10Checking the steering wheel1. Check the steering friction for properadjustment.2. Check that the steering operatessmoothly.3. Check that ther

GEN INFOGeneral information1160L3D1XChecking the cooling water pilot hole1. Start the engine, and then check thatcooling water is discharged from thec

60L3D1X12General specifications2Item UnitModelF200AET FL200AETDimensionOverall length mm (in) 892 (35.1)Overall width mm (in) 634 (25.0)Overall height

SPECSpecifications1360L3D1XFuel and oilFuel type Regular unleaded gasolineFuel rating PON*RON8691Engine oil type 4-stroke motor oilEngine oil grade AP

60L3D1X14Maintenance specifications2Power unitItem UnitModelF200AET FL200AETPower unitMinimum compression pressure*kPa (kgf/cm2, psi)880 (8.8, 125)Lub

NOTICEThis Supplementary Service Manual has been prepared to introduce new service and new datainformation for the F200 and FL200 which is based on th

SPECSpecifications1560L3D1XOil ringDimension 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.

60L3D1X16Valve liftersValve lifter outside diameter mm (in) 32.98–33.00 (1.2984–1.2992)Valve lifter-to-cylinder head clearancemm (in) 0.02–0.05 (0.000

SPECSpecifications1760L3D1XLower unitOil pumpDischargeat 97–103 °C (207–217 °F) with 10W-40 engine oilL (US gal, Imp gal)/min at 700 r/min8.8 (2.32, 1

60L3D1X18ElectricalItem UnitModelF200AET FL200AETIgnition and ignition control systemIgnition timing(engine idle speed) Degree TDCPulser coil output p

SPECSpecifications1960L3D1XFuel control systemFuel injector output peak voltage(*1) (R/Y – O/R, R/Y – O/B, R/Y – O/Y, R/Y – O/R, R/Y – O/B, R/Y – O/Y)

60L3D1X20Power trim and tilt systemTrim sensorSetting resistanceΩ 9–11Resistance (P – B)Ω 9–387.6Fluid type ATF Dexron IIBrushesStandard length mm (in

SPECSpecifications2160L3D1XDimensionsExteriorS60L2130W5A1T1W1L7H9H1H11H2H4H3H7H8H10L8L5A2H6L9 L4A312˚C3L2 L1L10L6

60L3D1X22Symbol UnitModelF200AET FL200AETL1 mm (in) 651 (25.6)L2 mm (in) 219 (8.6)L3 mm (in) —L4 mm (in) 673 (26.5)L5 (X) mm (in) 59 (2.3)L6 (X) mm (i

SPECSpecifications2360L3D1XClamp bracketSymbol UnitModelF200AET FL200AETB1 mm (in) 125 (4.9)B2 mm (in) 254 (10.0)B3 mm (in) 163 (6.4)B4 mm (in) 51 (2.

60L3D1X24Tightening torques2Specified torquesPart to be tightened Thread sizeTightening torquesN·mkgf·mft·lbFuel systemFuel filter holder bolt M6 8 0.

ContentsGeneral information1GEN INFOSpecifications2SPECPeriodic checks and adjustments3CHK ADJFuel system4FUELPower unit5POWRLower unit6LOWRBracket un

SPECSpecifications2560L3D1XTiming chain tensioner bolt M6 12 1.2 8.7Spark plug — 25 2.5 18Cylinder head bolt 1stM1019 1.9 142nd 37 3.7 273rd 90°1stM81

60L3D1X26Upper case mount nut — 72 7.2 52Engine oil drain bolt M14 27 2.7 19Apron stay — 80.85.8Pressure control valve — 80.85.8Upper exhaust guide bo

SPECSpecifications2760L3D1XGeneral torquesThis chart specifies tightening torques forstandard fasteners with a standard ISOthread pitch. Tightening to

60L3D1X28Maintenance interval chart3Use the following chart as a guideline for general maintenance.Adjust the maintenance intervals according to the o

CHK ADJPeriodic checks and adjustments2960L3D1XNOTE:(*1) If equipped with a portable fuel tank.(*2) Be sure to replace the timing belt every 1,000 hou

60L3D1X30Power trim and tilt unit7Assembling the gear pump1. Install the drive gears 1, dowel pins 2,balls 3, and shuttle pistons 4 into thegear housi

ELECElectrical systems– +3160L3D1XFuel control system8Checking the fuel injector1. Remove the intake silencer and discon-nect the fuel injector couple

60L3D1X32Checking the low-pressure fuel pump and high-pressure fuel pump1. Disconnect the starter relay lead (brownlead) 1 to prevent the engine from

TRBLSHTGTroubleshooting3360L3D1XYamaha Diagnostic System9IntroductionHardware requirementsMake sure that your computer meets the following requirement

60L3D1X343. Double-click the My Computer icon, then the CD-ROM drive icon, and then double-click theSetup.exe icon to start up the installer. (Fig. 1)

60L3D1XGeneral informationHow to use this manual... 1Manual format...

TRBLSHTGTroubleshooting3560L3D1XNOTE:If the Yamaha Diagnostic System has already been installed onto your computer, the following dia-log box appears.

60L3D1X365. Check the target directory and the program name for the Yamaha Diagnostic System, which aredisplayed in the dialog box.Click the Next butt

TRBLSHTGTroubleshooting3760L3D1XFig. 76. After the installation is completed, the following dialog box appears.Click the Finish button to quit the ins

60L3D1X38Updating the databaseNOTE:When installing the Yamaha Diagnostic System program for the first time, be sure to update thedatabase.1. Turn on y

TRBLSHTGTroubleshooting3960L3D1X3. After about three seconds the display will automatically go to the first menu display, or you canclick or press any

60L3D1X405. 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 compute

TRBLSHTGTroubleshooting4160L3D1X7. When the database is updated a confirmation screen is displayed.To quit, click the OK button or press the Enter key

60L3D1X42Self-diagnosis9Diagnosing the electronic control system1. Connect the special tools to the outboardmotor as shown.NOTE:When performing this d

TRBLSHTGTroubleshooting4360L3D1XCode Symptom01 Normal13 Incorrect pulser coil signal15Incorrect engine temperature sensor signal18Incorrect throttle p

60L3D1X44123456789A.After test run ... 11Applicable models... 3Ass

60L3D1XSpecificationsGeneral specifications... 12Maintenance specific

Appendix60L3D1XIncorrect information was included in the “Maintenance specification” and “Special service tools” inthe current Service Manual.Please m

Wiring diagramF200AET, FL200AET1 Low-pressure fuel pump2 Low-pressure fuel pump driver3 High-pressure fuel pump relay4 High-pressure fuel pump5 Idle s

YAMAHA MOTOR CO., LTD.Printed in the NetherlandsAug. 2001 – 1.3 × 1 CR(F200AET, FL200AET)(E)

F200AET, FL200AETR/Y L/RL/RR/YB/WG/WG/WG/WG/WBr/WBr/WW/RW/BB/WW/GG/WG/WBLgR SbG/WG/WGGG/WGGR/YLLBL/RR/YR/YR/YL/RB/WBBBRR/Y R/Y BR/YR/YR/YR/YR/YR/BBR/Y

G/RR/YL4B6L/R3R/Y1B/WR/YR/YR/YR/YR/YO/RO/YO/BR/Y R/Y R/YB/YP/WW/GW/BW/RB/YP/GR/Y R/YO/RB/YR/Y O/BR/YR/YO/YB/OR/Y B/W L/YO/RO/YO/BY/GR/YR/YW/B L/WL/WP/

GEN INFOGeneral information160L3D1XHow to use this manual1Only chapters containing revisions or additional items in the base manual have been included

60L3D1X2SymbolsThe symbols below are designed to indicate the content of a chapter.General informationSpecificationsPeriodic checks and adjustmentsFue

GEN INFOGeneral information360L3D1XIdentification1Applicable modelsThis manual covers the following models.Serial numberThe outboard motor serial numb

60L3D1X4Features and benefits1Electronic control systemThe ECM controls the ignition timing, the fuel injection timing, the fuel injection volume, and