Yamaha Z200N Manuals

Manuals and User Guides for Yamaha Z200N. We have 5 Yamaha Z200N manuals available for free PDF download: Service Manual, Supplementary Service Manual, Owner's Manual

Yamaha Z200N Service Manual (392 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 12.7 MB

Table of Contents

7
- General Information
  6
- Periodic Inspections and Adjustments
  6
  - Table of Contents
    7
  - Identification
    10
- Specifications
  6
- Chapter 1
  10
- Serial Number
  10
- Starting Serial Numbers
  10
- Safety While Working
  11
  - Fire Prevention
    11
  - Ventilation
    11
  - Self-Protection
    11
  - Oils, Greases and Sealing Fluids
    11
  - Good Working Practices
    12
  - Disassembly and Assembly
    13
- Special Tools
  14
  - Measuring
    14
  - Removing and Installing
    17
Specifications

21
- Chapter 2 Specifications
  22
- General Specifications
  22
- Spec
  22
- Maintenance Specifications
  24
  - Power Unit
    24
  - Lower Unit
    26
  - Electrical
    26
  - Dimensions
    30
- Tightening Torques
  32
  - Specified Torques
    32
  - General Torques
    34
Insp Adj

36
- Chapter 3
  38
- Maintenance Interval Chart
  38
- Fuel System
  40
- Top Cowling
  40
  - Checking the Top Cowling Fit
    40
- Control System
  44
- Cooling System
  49
  - Checking the Cooling Water Discharge
    49
- Oil Injection System
  49
- Power Trim and Tilt System
  52
  - Checking the Power Trim and Tilt Fluid Level
    52
- Insp Adj
  53
  - Adjusting the Trim Sensor Cam
    53
- Lower Unit
  53
- General
  55
  - Checking the Anodes
    55
  - Checking the Battery
    56
  - Checking the Spark Plugs
    57
  - Lubrication Points
    59
- Insp Adj
  55
Chapter 4 Fuel System

60
Chapter 5 Power Unit

118
- Powr
  118
  - Flywheel Magnet Assembly
    121
- Removing the Flywheel Magnet Assembly
  121
- Installing the Flywheel Magnet Assembly
  122
- Power Unit
  123
  - Disconnecting/Connecting the Leads
    123
  - Disconnecting/Connecting the Hoses
    125
  - Removing/Installing the Exhaust Expansion Chamber
    126
  - Installing the Apron
    128
  - Removing/Installing the Power Unit
    129
  - Suspending the Power Unit
    130
  - Installing the Power Unit
    130
- Stator Assembly
  131
  - Removing/Installing the Stator Assembly
    131
- Control Unit
  133
  - Removing/Installing the Control Unit Assembly
    133
- Fuse Holder
  135
  - Removing/Installing the Fuse Holder
    135
  - Disassembling/Assembling the Fuse Holder
    136
- Junction Box Assembly
  137
  - Removing/Installing the Junction Box Assembly
    137
  - Disassembling/Assembling the Junction Box Assembly
    140
- Wire Harnesses
  142
- Starter Motor
  147
  - Removing/Installing the Starter Motor
    147
- Oxygen Density Sensor
  148
  - Removing/Installing the Oxygen Density Sensor
    148
  - Installing the Oxygen Density Sensor
    150
- Reed Valves
  153
  - Checking the Reed Valve Assembly
    153
- External Fittings
  154
  - Removing/Installing the External Fittings
    154
- Cylinder Head Covers
  157
  - Removing/Installing the Cylinder Head Covers
    157
  - Checking the Thermostats
    159
- Cylinder Heads
  160
  - Removing/Installing the Cylinder Heads
    160
  - Checking the Cylinder Heads
    162
- Exhaust Covers
  163
  - Removing/Installing the Exhaust Covers
    163
  - Checking the Pressure Control Valve
    165
- Crankcase
  166
  - Removing/Installing the Crankcase
    166
  - Assembling the Oil Seal Housing
    168
  - Installing the Crankcase
    168
- Cylinder Body Assembly
  169
Chapter 6 Lower Unit

184
Propeller Shaft Housing Assembly (Regular Rotation Models)

202
- Checking the Bearings
  203
- Checking the Propeller Shaft Housing
  203
- Checking the Reverse Gear
  203
- Assembling the Propeller Shaft Housing
  204
- Checking the Dog Clutch
  204
- Checking the Propeller Shaft
  204
- Installing the Propeller Shaft Housing Assembly
  205
- Drive Shaft (Regular Rotation Models)
  206
  - Removing/Installing the Drive Shaft
    206
  - Removing the Pinion
    208
  - Disassembling the Drive Shaft Housing Assembly
    208
  - Disassembling the Forward Gear Assembly
    208
  - Checking the Pinion
    209
  - Checking the Drive Shaft
    209
  - Checking the Drive Shaft Housing
    209
  - Checking the Bearings
    209
  - Assembling the Forward Gear Assembly
    209
  - Assembling the Drive Shaft Housing Assembly
    210
  - Installing the Pinion
    211
- Lower Case Assembly (Regular Rotation Models)
  212
- Lower Unit (Counter Rotation Models)
  215
  - Removing/Installing the Lower Unit
    215
  - Removing the Propeller
    217
  - Removing the Trim Tab
    217
  - Checking the Propeller
    217
  - Installing the Propeller
    218
- Water Pump (Counter Rotation Models)
  219
- Shift Rod Assembly (Counter Rotation Models)
  223
  - Removing/Installing the Shift Rod Assembly
    223
  - Removing the Shift Rod Assembly
    224
- Propeller Shaft Housing Assembly (Counter Rotation Models)
  225
- Housing Assembly
  229
  - Straighten
    229
    
    Claw Washer Tabs
    229
  - Remove
    229
    
    Ring Nut
    229
    
    Claw Washer
    229
    
    6050 Ring Nut Wrench
    229
  - Disassembling the Propeller Shaft Housing Assembly
    230
  - Disassembling the Forward Gear Assembly
    230
  - Checking the Forward Gear
    230
  - Checking the Bearings
    230
  - Checking the Propeller Shaft Housing
    230
  - Checking the Dog Clutch
    231
  - Checking the Propeller Shaft
    231
  - Assembling the Propeller Shaft Housing
    231
  - Installing the Propeller Shaft Assembly
    232
  - Installing the Propeller Shaft Housing Assembly
    232
- Removing the Propeller Shaft
  229
- Drive Shaft (Counter Rotation Models)
  233
  - Removing/Installing the Drive Shaft
    233
  - Removing the Pinion
    235
  - Removing the Reverse Gear
    235
  - Disassembling the Drive Shaft Housing Assembly
    235
  - Disassembling the Reverse Gear Assembly
    235
  - Checking the Pinion
    236
  - Checking the Drive Shaft
    236
  - Checking the Drive Shaft Housing
    236
  - Checking the Bearings
    236
  - Assembling the Reverse Gear Assembly
    237
  - Assembling the Drive Shaft Housing Assembly
    237
  - Installing the Reverse Gear
    238
  - Installing the Pinion
    238
- Lower Case Assembly (Counter Rotation Models)
  239
- Shimming (Regular Rotation Models) (for Usa and Canada)
  242
  - Selecting the Pinion Shims
    243
  - Selecting the Forward Gear Shims
    245
  - Selecting the Reverse Gear Shims
    247
- Shimming (Regular Rotation Models) (for Worldwide)
  249
  - Selecting the Pinion Shims
    250
  - Selecting the Forward Gear Shims
    252
  - Selecting the Reverse Gear Shims
    253
- Backlash (Regular Rotation Models)
  255
  - Measuring the Forward Gear Backlash
    255
  - Measuring the Reverse Gear Backlash
    257
- Shimming (Counter Rotation Models) (for Usa and Canada)
  259
- Shimming (Counter Rotation Models) (for Worldwide)
  266
- Backlash (Counter Rotation Models)
  273
  - Measuring the Forward Gear Backlash
    273
  - Measuring the Reverse Gear Backlash
    274
- Brkt
  278
- Elec
  322
- Trbl Anls
  381

Yamaha Z200N Service Manual (386 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 8.67 MB

How to Use this Manual
5
Chapter 1. General Information

8
- Good Working Practices
  11
- Disassembly and Assembly
  12
- Removing and Installing
  16
Chapter 2. Specifications

19
- General Specifications
  20
- General Torques
  32
Chapter 3. Periodic Inspections and Adjustments

33
- Maintenance Interval Chart
  35
- Checking the Fuel Filter
  38
- Adjusting the Throttle Position Sensor
  42
- Adjusting the Engine Idling Speed
  43
- Checking the Drive Belt
  45
- Changing and Checking the Gear Oil
  51
- Checking the Battery
  53
- Checking the Spark Plugs
  54
- Lubrication Points
  56
Chapter 4. Fuel System

57
Chapter 5. Power Unit

115
Chapter 6. Lower Unit

180
Chapter 7. Bracket Unit

273
Chapter 8. Electrical Systems

316
- Electrical Components
  319
- Wire Harness
  324
- Measuring a Low Resistance
  328
- Ignition System
  329
- Checking the Ignition Spark Gap
  330
- Measuring the Pulser Coil Output Peak Voltage
  333
- Checking the Spark Plug Caps
  334
- Ignition Control System
  335
- Checking the Shift Position Switch
  339
- Fuel Control System
  340
- Checking the Intake Air Temperature Sensor
  345
- Checking the Fuel Injectors
  346
- Checking the Water Detection Switch
  348
- Starting System
  349
- Checking the Magnetic Switch Relay
  357
- Charging System
  359
- Oil Feed Pump Control System
  362
- Power Trim and Tilt System
  365
- Checking the Armature
  371
Chapter 9. Trouble Analysis

373
- Wiring Diagram
  383

Yamaha Z200N Supplementary Service Manual (304 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 9.12 MB

English

7
- General Information
  
  6
  - Table of Contents
    7
- Identification
  
  13
  - Serial Number
    13
  - Starting Serial Numbers
    13
- Special Tools
  
  14
  - Measuring
    14
  - Removing and Installing
    17
- General Specifications
  
  20
- Specifications
  
  20
- Maintenance Specifications
  
  26
  - Power Unit
    26
  - Lower Unit
    28
  - Electrical
    28
  - Power Unit
    32
  - Lower Unit
    34
  - Pinion Nut
    96
    
    Drive Shaft Holder
    96
    
    YB-06201 / 90890-06520 Pinion Nut Holder
    96
    
    90890-06505 Pinion Nut Holder Attachment
    96
  - Oil Seals
    101
  - Needle Bearing
    101
    
    Bearing/Oil Seal Attachment
    101
    
    YB-06196 / 90890-06610 Driver Rod
    101
  - Puller so It Pushes against the Propel
    123
  - Ler Shaft
    123
    
    Propeller Shaft Housing Puller . 1
    123
    
    YB-06207 / 90890-06502 Universal Puller
    123
    
    YB-06117 Guide Plate
    123
    
    90890-06501 Center Bolt
    123
    
    Center Bolt 10 N • M (1.0 Kgf • M, 7.2 Ft • Lb)
    123
  - Drive Shaft (on the 22.4 MM (0.88 In)
    124
  - Diameter Portion of the Drive Shaft)
    124
    
    Backlash Indicator
    124
  - Unit and Have the Dial Gauge Plunger
    124
  - Contact the Mark on the Backlash Indi- Cator
    124
    
    YB-07003 / 90890-07003 Dial Gauge Set
    124
    
    YU-03097 / 90890-01252 Magnetic Base
    124
Français

159
- Identification
  
  165
  - Numero de Serie
    165
  - Numeros de Debut de Serie
    165
- Outillage Special
  
  168
  - Depose Et Installation
    169
- Specifications Generales
  
  172
  - Moteur
    174
  - Partie Electrique
    175
  - Dimensions
    176
    
    Attache de Bague D'étanchéité/ Roulement
    253
    
    Tige D'entraînement
    253
  - Ecrou de Pignon
    254
    
    Outil de Maintien D'arbre de Transmission
    256
    
    Attache de Support D'écrou de
    256
    
    Pignon
    256

Yamaha Z200N Owner's Manual (232 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 3.19 MB

Table of Contents
7
Informations De Sécurité
13
Instructions Pour Le Carburant
17
Essence
19
Huile Moteur
19
Choix De La Batterie
21
Choix De L'hélice
21
Dispositif De Protection Contre Le Demarrage En Prise
25
Proteccion Contra El Arranque
25
Composants De Base
27
Main Components
28
Operations of Controls and Other Functions
32
Remote Control
32
Trim Tab
42
Power Trim/Tilt Switch
44
Digital Tachometer
46
Digital Speedometer
52
Fuel Management Meter
58
Tilt Support Lever
66
Top Cowling Lock Levers
66
Flushing Device
66
Warning System
68
Overheat Warning
68
Oil Level Warning / Oil Filter Clogging Warning
70
Water Separator Warning
72
Engine Trouble Warning
74
Operation
76
Installation
78
Mounting the Outboard Motor
80
Breaking in (Running In) Engine
86
Pre-Operation Checks
88
Operation after a Long Period of Storage
92
Filling Fuel and Engine Oil
94
Filling Fuel
94
Filling Oil
94
Starting Engine
102
Warming up Engine
108
Shifting
110
Forward
110
Reverse
110
Stopping Engine
112
Trimming Outboard Motor
114
Adjusting Trim Angle
116
Tilting Up/Down
120
Cruising in Other Conditions
124
Cruising in Salt Water
124
Cruising in Turbid Water
124
Entretien
127
Transporting and Storing Outboard Motor
140
Trailering Outboard Motor
140
Storing Outboard Motor
140
Periodic Maintenance
150
Replacement Parts
150
Maintenance Chart
152
Greasing
158
Cleaning and Adjusting Spark Plug
160
Checking Top Cowling
162
Checking Fuel System
164
Inspecting Fuel Filter
166
Inspecting Idling Speed
168
Checking Water in Engine Oil Tank
170
Replacing Fuse
172
Checking Wiring and Connectors
172
Exhaust Leakage
172
Water Leakage
172
Checking Power Trim and Tilt System
174
Checking Propeller
176
Changing Gear Oil
180
Inspecting and Replacing Anode(S)
182
Checking Battery
184
Checking Bolts and Nuts
190
Cleaning Cooling-Water Passages
192
Motor Exterior
194
Coating the Boat Bottom
194
Depannage
197
Restablecimiento En Caso De Problema
197
Troubleshooting
198
Temporary Action in Emergency
210
Impact Damage
210
Running Single Engine
210
Power Trim/Tilt Will Not Operate
212
Starter Will Not Operate
214
Low Oil Level Warning Activates
218
Treatment of Submerged Motor
222
Índice
225

Yamaha Z200N Owner's Manual (86 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 4.15 MB

Table of Contents
5
General Information
7
Identification Numbers Record
7
Outboard Motor Serial Number
7
Key Number
7
EC Label
7
Safety Information
8
Important Labels
9
Warning Labels
9
Caution Labels
10
Fueling Instructions
10
Gasoline
11
Engine Oil
11
Battery Requirement
11
Battery Specifications
11
Propeller Selection
11
Start-In-Gear Protection
12
Basic Components
13
Main Components
13
Remote Control
14
Remote Control Lever
15
Neutral Interlock Trigger
15
Neutral Throttle Lever
15
Free Accelerator
16
Throttle Friction Adjuster
16
Engine Stop Lanyard Switch
17
Main Switch
17
Power Trim and Tilt Switch on Remote Control or Tiller Handle
18
Power Trim and Tilt Switch on Bottom Engine Cowling
18
Power Trim and Tilt Switches (Twin Binnacle Type)
19
Trim Tab with Anode
19
Tilt Support Lever for Power Trim and Tilt or Hydro Tilt Model
20
Top Cowling Lock Levers
20
Flushing Device
21
Water Separator
21
Digital Tachometer
21
Oil Level Indicator (Digital Type)
22
Overheat Warning Indicator (Digital Type)
22
Speedometer (Digital Type)
22
Trim Meter (Digital Type)
23
Hour Meter (Digital Type)
23
Trip Meter
24
Clock
24
Fuel Gauge
24
Fuel Warning Indicator
25
Low Battery Voltage Warning Indicator
25
Fuel Management Meter
25
Fuel Flow Meter
26
Fuel Consumption Meter
26
Fuel Economy
26
Twin-Engine Speed Synchronizer
27
6Y8 Multifunction Meters
28
Tachometer Unit
28
Speed & Fuel Meter Unit
31
Speedometer Unit
32
Fuel Management Meter
33
Warning System
34
Overheat Warning (Twin Engines)
34
Oil Level Warning and Oil Filter Clogging Warning
34
Operation
36
Installation
36
Mounting the Outboard Motor
36
Breaking in Engine
37
Procedure for HPDI Models
38
Preoperation Checks
38
Fuel
38
Oil
39
Controls
39
Engine
39
Operation after a Long Period of Storage
39
Filling Fuel and Engine Oil
40
Filling Fuel for Models Without a Fuel Joint
40
Filling Oil for Oil Injection Models
40
Oil Level Indicator Operation
42
Operating Engine
43
Feeding Fuel
43
Starting Engine
43
Warming up Engine
45
Electric Start and Prime Start Models
45
Shifting
45
Forward
46
Control Models)
46
Reverse (Automatic Reverse Lock and Power Trim and Tilt Models)
46
Stopping Engine
47
Procedure
47
Trimming Outboard Motor
47
Adjusting Trim Angle
48
Adjusting Boat Trim
49
Tilting up and down
49
Procedure for Tilting up (Power Trim and Tilt Models / Power Tilt Models)
50
Procedure for Tilting down (Power Trim and Tilt Models / Power Tilt Models)
51
Cruising in Shallow Water
52
Power Trim and Tilt Models / Power Tilt Models
52
Cruising in Other Conditions
53
Maintenance
54
Specifications
54
Transporting and Storing Outboard Motor
55
Storing Outboard Motor
56
Procedure
56
Lubrication (Oil Injection Models)
57
Battery Care
58
Flushing Power Unit
58
Cleaning the Outboard Motor
59
Checking Painted Surface of Motor
59
Periodic Maintenance
60
Replacement Parts
60
Maintenance Chart
61
Maintenance Chart (Additional)
62
Greasing
63
Cleaning and Adjusting Spark Plug
63
Checking Fuel System
64
Inspecting Idling Speed
65
Checking Water in Engine Oil Tank
65
Checking Wiring and Connectors
65
Exhaust Leakage
66
Water Leakage
66
Checking Power Trim and Tilt
66
System
66
Checking Propeller
67
Removing the Propeller
68
Installing the Propeller
68
Changing Gear Oil
69
Inspecting and Replacing Anode(S)
70
Checking Battery (for Electric Start Models)
70
Connecting the Battery
71
Disconnecting the Battery
72
Checking Top Cowling
72
Coating the Boat Bottom
73
Trouble Recovery
74
Troubleshooting
74
Temporary Action in Emergency
77
Impact Damage
77
Running Single Engine
77
Replacing Fuse
78
Power Trim and Tilt / Power Tilt Will Not Operate
78
Water Separator Warning Indicator Blinks While Cruising
79
Starter Will Not Operate
80
Emergency Starting Engine
81
Engine Fails to Operate
82
Low Oil Level Warning Activates
82
Treatment of Submerged Motor
83
Procedure
83

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Table of Contents

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Yamaha Z200N Service Manual (386 pages)

Table of Contents

Chapter 1. General Information

Chapter 2. Specifications

Chapter 3. Periodic Inspections and Adjustments

Chapter 4. Fuel System

Chapter 5. Power Unit

Chapter 6. Lower Unit

Chapter 7. Bracket Unit

Chapter 8. Electrical Systems

Chapter 9. Trouble Analysis

Yamaha Z200N Supplementary Service Manual (304 pages)

Table of Contents

English

General Information

Identification

Special Tools

General Specifications

Specifications

Maintenance Specifications

Français

Identification

Outillage Special

Specifications Generales

Yamaha Z200N Owner's Manual (232 pages)

Table of Contents

Yamaha Z200N Owner's Manual (86 pages)

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