Yamaha FL200B Manuals

Manuals and User Guides for Yamaha FL200B. We have 2 Yamaha FL200B manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha FL200B Service Manual (579 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 37.2 MB

General Information

5
- 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
- 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
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
- 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
- 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
- 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
- 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

Yamaha FL200B Owner's Manual (90 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 4.08 MB

Important Manual Information
3
Table of Contents
5
Safety Information

8
- Outboard Motor Safety
  8
  - Propeller
    8
  - Rotating Parts
    8
  - Hot Parts
    8
  - Electric Shock
    8
  - Power Trim and Tilt
    8
  - Engine Shut-Off Cord (Lanyard)
    8
  - Gasoline
    8
  - Gasoline Exposure and Spills
    8
  - Carbon Monoxide
    9
  - Modifications
    9
- Boating Safety
  9
  - Alcohol and Drugs
    9
  - Personal Flotation Devices
    9
  - People in the Water
    9
  - Passengers
    9
  - Overloading
    9
  - Avoid Collisions
    9
  - Weather
    10
  - Passenger Training
    10
  - Boating Safety Publications
    10
  - Laws and Regulations
    10
General Information

11
- Identification Numbers Record
  11
  - Outboard Motor Serial Number
    11
  - Key Number
    11
- EC Declaration of Conformity (Doc)
  11
- CE Marking
  11
- C-Tick Label
  12
- Read Manuals and Labels
  13
  - Warning Labels
    13
Specifications and Requirements

16
- Specifications
  16
- Installation Requirements
  17
  - Boat Horsepower Rating
    17
  - Mounting Motor
    18
- Remote Control Requirements
  18
- Battery Requirements
  18
  - Battery Specifications
    18
  - Mounting Battery
    18
  - Multiple Batteries
    18
- Propeller Selection
  18
  - Counter Rotation Models
    19
- Start-In-Gear Protection
  19
- Engine Oil Requirements
  19
- Fuel Requirements
  20
  - Gasoline
    20
- Muddy or Acidic Water
  20
- Anti-Fouling Paint
  20
- Motor Disposal Requirements
  21
- Emergency Equipment
  21
- Emission Control Information
  21
  - U.S. Insular Areas
    21
Components

23
- Components Diagram
  23
Instruments and Indicators

32
- Digital Tachometer
  32
  - Tachometer
    32
  - Trim Meter
    32
  - Hour Meter
    32
  - Low Oil Pressure-Alert Indicator
    33
  - Overheat-Alert Indicator
    33
- Digital Speedometer
  33
  - Speedometer
    33
  - Fuel Gauge
    34
  - Trip Meter / Clock / Voltmeter
    34
  - Fuel Level-Alert Indicator
    35
  - Low Battery Voltage-Alert Indicator
    35
- Fuel Management Meter
  35
- 6Y8 Multifunction Meters
  38
- 6Y8 Multifunction Tachometers
  38
  - Start-Up Checks
    39
  - Low Oil Pressure-Alert
    39
  - Overheat Alert
    39
  - Water Separator Alert
    39
  - Engine Trouble Alert
    40
  - Low Battery Voltage-Alert
    40
- 6Y8 Multifunction Speed & Fuel Meters
  40
Engine Control System

42
- Alert System
  42
  - Overheat Alert
    42
  - Low Oil Pressure Alert
    42
Installation

44
- Mounting the Outboard Motor
  44
Operation

46
- First-Time Operation
  46
  - Fill Engine Oil
    46
  - Breaking in Engine
    46
  - Getting to Know Your Boat
    46
- Checks before Starting Engine
  46
  - Fuel Level
    46
  - Remove Cowling
    47
  - Fuel System
    47
  - Controls
    47
  - Engine Shut-Off Cord (Lanyard)
    48
  - Engine Oil
    48
  - Engine
    48
  - Flushing Device
    49
  - Install Cowling
    49
  - Checking Power Trim and Tilt System
    50
  - Battery
    51
- Filling Fuel
  51
- Operating Engine
  51
  - Sending Fuel
    52
  - Starting Engine
    52
- Checks after Starting Engine
  54
  - Cooling Water
    54
- Warming up Engine
  54
  - Electric Start Models
    54
- Checks after Engine Warm up
  54
  - Shifting
    54
  - Stop Switches
    54
- Stopping Boat
  55
- Stopping Engine
  55
  - Procedure
    56
- Trimming Outboard Motor
  56
  - Adjusting Trim Angle (Power Trim and Tilt)
    56
  - Adjusting Boat Trim
    57
- Tilting up and down
  58
  - Procedure for Tilting up (Power Trim and Tilt Models)
    58
  - Procedure for Tilting down (Power Trim and Tilt Models)
    60
- Shallow Water
  61
  - Power Trim and Tilt Models
    61
- Cruising in Other Conditions
  61
Maintenance

62
- Transporting and Storing Outboard Motor
  62
  - Storing Outboard Motor
    62
  - Procedure
    63
  - Lubrication
    64
  - Flushing Power Unit
    64
  - Cleaning the Outboard Motor
    65
  - Checking Painted Surface of Outboard Motor
    65
- Periodic Maintenance
  65
  - Replacement Parts
    66
  - Severe Operating Conditions
    66
  - Maintenance Chart 1
    67
  - Maintenance Chart 2
    69
  - Greasing
    70
  - Cleaning and Adjusting Spark Plug
    71
  - Inspecting Idle Speed
    72
  - Changing Engine Oil
    72
  - Inspecting Wiring and Connectors
    74
  - Checking Propeller
    74
  - Removing Propeller
    75
  - Installing Propeller
    75
  - Changing Gear Oil
    77
  - Inspecting and Replacing Anode(S)
    78
  - Checking Battery (for Electric Start Models)
    79
  - Connecting the Battery
    79
  - Disconnecting the Battery
    81
Trouble Recovery

82

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Yamaha FL200B Manuals

Yamaha FL200B Service Manual (579 pages)

Table of Contents

General Information

Safety While Working

How to Use this Manual

Lubricant, Sealant, and Thread Locking Agent

Special Service Tool

Specification

Model Features

Model Data

Electrical System Technical Data

Fuel System Technical Data

Power Unit Technical Data

Lower Unit Technical Data

Bracket Unit Technical Data

Specified Tightening Torque

General Tightening Torque

Tech Fea/Tech Fea

Tech Fea

Technical Features and Description

Electronic Control System

Power Unit System

Fuel System

Lubrication System

Cooling System

Intake and Exhaust System

Lower Unit

Rigging Information

Outboard Motor Installation

Rigging Information

External Dimensions

Crate Top Cover Pictograph Description

Uncrating Procedure

Outboard Motor Mounting

Outboard Motor Mounting Height

Rigging Grommet Mounting

Remote Control Box and Switch Panel Installation

Battery Installation

System Diagram

Rigging Recommendation

Propeller Selection

Troubleshooting

Ydis

Troubleshooting

Outboard Motor Troubleshooting

Electrical System

Electrical Component

Electrical System

Wiring Harness Routing

Circuit Diagram

ECM Coupler Layout

Checking the Electrical Component

Engine Control System and Component

Fuel Control Unit and Component

Charging Unit and Component

Ignition Unit and Component

Starting Unit and Component

PTT Electrical System

Fuel System

Hose Routing

Fuel System

Fuel System

Fuel Filter Assembly

Intake Manifold

Canister, Throttle Body, and Surge Tank

Low-Pressure Fuel Pump

Vapor Separator and High-Pressure Fuel Pump

Fuel Injector

Power Unit

Power Unit (Check and Adjustment)

Power Unit

Power Unit Assembly

Flywheel Magnet

Wiring Harness

Starter Motor

Fuse Box

Engine ECM

Timing Belt

Cylinder Head Cover