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Manuals
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Yamaha Manuals
Outboard Motor
Z200N
Service manual
Yamaha Z200N Service Manual
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Also See for Z200N
:
Service manual
(392 pages)
,
Supplementary service manual
(304 pages)
,
Owner's manual
(232 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Illustrations
Model Indication
Important Information
How to Use this Manual
Symbols
Contents
Chapter 1. General Information
Identification
Serial Number
Starting Serial Numbers
Safety While Working
Fire Prevention
Ventilation
Self-Protection
Good Working Practices
Disassembly and Assembly
Special Tools
Measuring
Diagnosis
Diagnosis Record
Static Test
Dynamic Test
Removing and Installing
Chapter 2. Specifications
General Specifications
Maintenance Specifications
Power Unit
Dimensions
Tightening Torques
Specified Torques
General Torques
Chapter 3. Periodic Inspections and Adjustments
Maintenance Interval Chart
Top Cowling
Checking the Top Cowling Fit
Fuel System
Checking the Fuel Line
Checking the Fuel Filter
Measuring the Fuel Pressure
Checking the Fuel Pressure
Measuring Steps
Checking the Mechanical Fuel Pump Oil Level
Changing the Mechanical Fuel Pump Oil
Control System
Synchronizing the Throttle Valves
Adjusting the Throttle Position Sensor
Adjusting the Engine Idling Speed
Adjusting the Remote Control Shift Cable
Adjusting the Remote Control Throttle Cable
Checking the Drive Belt
Adjusting the Crank Position Sensor
Checking the Cooling Water Discharge
Oil Injection System
Checking the Oil Strainer
Synchronizing the Oil Pump
Air Bleeding the Oil Injection System
Checking the Electric Oil Pump
Power Trim and Tilt System
Checking the Power Trim and Tilt Fluid Level
Adjusting the Trim Sensor Cam
Lower Unit
Checking the Gear Oil Level
Changing and Checking the Gear Oil
Recommended Gear Oil
Total Amount
Checking the Lower Unit
Checking the Anodes
Checking the Battery
Checking the Spark Plugs
Lubrication Points
Chapter 4. Fuel System
Flywheel Magnet Assembly Cover
Removing/Installing the Flywheel Magnet Assembly Cover
Medium-Pressure Fuel Line
Removing/Installing the Medium-Pressure Fuel Line
Reducing the Fuel Pressure
Disconnecting the Fuel Hose Joint
Checking the Pressure Regulator
Vapor Separator
Removing/Installing the Vapor Separator
Removing the Hose Clamps
Installing the Hose Clamps
Disassembling/Assembling the Vapor Separator
Removing the Electric Fuel Pump Filter
Installing the Electric Fuel Pump Filter
Removing/Installing the Pressure Regulator
Electric Fuel Pump
Disassembling/Assembling the Electric Fuel Pump
Throttle Control Lever Cam
Removing/Installing the Throttle Control Lever Cam
Air Temperature Sensor
Installing the Throttle Position Sensor
Drive Belt
Removing/Installing the Drive Belt
Removing the Drive Sprocket
Removing the Driven Sprocket
Installing the Driven Sprocket
Installing the Drive Sprocket
Installing the Drive Belt
Injector Driver
Removing/Installing the Injector Driver
Removing the Injector Driver Coupler
Disassembling/Assembling the Injector Driver
High-Pressure Fuel Line Assembly
Removing/Installing the High-Pressure Fuel Line Assembly
Disassembling/Assembling the High-Pressure Fuel Line Assembly
Mechanical Fuel Pump
Disassembling/Assembling the Mechanical Fuel Pump Body
Disassembling/Assembling the Mechanical Fuel Pump Assembly
Low Pressure Fuel Line
Removing/Installing the Low-Pressure Fuel Line
Disassembling/Assembling the Low-Pressure Fuel Line
Checking the Check Valve
Fuel Filter
Disassembling/Assembling the Fuel Filter
Fuel Pump
Disassembling/Assembling the Fuel Pump
Checking the Fuel Pumps
Removing/Installing the Oil Injection System
Disassembling/Assembling the Oil Injection System
Oil Tank
Disassembling/Assembling the Oil Tank
Chapter 5. Power Unit
Flywheel Magnet Assembly
Removing/Installing the Flywheel Magnet Assembly
Removing the Flywheel Magnet Assembly
Flywheel Magnet Assembly Holder
Universal Puller
Installing the Flywheel Magnet Assembly
Disconnecting/Connecting the Leads
Disconnecting/Connecting the Hoses
Removing/Installing the Exhaust Expansion Chamber
Installing the Apron
Removing/Installing the Power Unit
Suspending the Power Unit
Installing the Power Unit
Stator Assembly
Removing/Installing the Stator Assembly
Control Unit
Removing/Installing the Control Unit Assembly
Fuse Holder
Removing/Installing the Fuse Holder
Disassembling/Assembling the Fuse Holder
Junction Box Assembly
Removing/Installing the Junction Box Assembly
Disassembling/Assembling the Junction Box Assembly
Wire Harnesses
Removing/Installing the Main Wire Harness
Removing/Installing the Sub Wire Harness
Removing/Installing the Injector Wire Harness
Starter Motor
Removing/Installing the Starter Motor
Oxygen Density Sensor
Installing the Oxygen Density Sensor
Reed Valves
Removing/Installing the Reed Valves
Checking the Reed Valve Assembly
External Fittings
Removing/Installing the External Fittings
Cylinder Head Covers
Removing/Installing the Cylinder Head Covers
Checking the Thermostats
Removing/Installing the Cylinder Heads
Checking the Cylinder Heads
Exhaust Covers
Removing/Installing the Exhaust Covers
Checking the Pressure Control Valve
Crankcase
Removing/Installing the Crankcase
Assembling the Oil Seal Housing
Installing the Crankcase
Cylinder Body Assembly
Disassembling/Assembling the Cylinder Body Assembly
Disassembling/Assembling the Piston and Connecting Rod Assemblies
Disassembling/Assembling the Crankshaft Assembly
Disassembling the Upper Bearing Housing
Removing the Bearing and Oil Pump Drive Gear
Checking the Cylinder Body
Checking the Pistons
Calculating the Piston-To-Cylinder Clearance
Checking the Piston Pins and Small-End Bearings
Checking the Piston Rings
Checking the Oil Pump Driven Gear
Checking the Labyrinth Rings
Checking the Crankshaft
Installing the Oil Pump Drive Gear
Installing the Bearing
Installing the Piston Rings and Piston
Assembling the Upper Bearing Housing
Installing the Crankshaft Assembly
Installing the Piston and Connecting Rod Assemblies
Chapter 6. Lower Unit
Removing/Installing the Lower Unit
Removing the Propeller
Removing the Trim Tab
Checking the Propeller
Installing the Propeller
Water Pump
Removing/Installing the Water Pump
Checking the Impeller Housing
Checking the Impeller and Impeller Housing Cup
Checking the Woodruff Key
Installing the Impeller and Impeller Housing
Shift Rod Assembly
Removing/Installing the Shift Rod Assembly
Removing the Shift Rod Assembly
Removing/Installing the Propeller Shaft Housing Assembly
Disassembling/Assembling the Propeller Shaft Housing
Disassembling/Assembling the Propeller Shaft Assembly
Removing the Propeller Shaft Housing Assembly
Disassembling the Propeller Shaft Housing
Propeller Shaft Housing Assembly
Checking the Reverse Gear
Checking the Bearings
Checking the Propeller Shaft Housing
Checking the Dog Clutch
Checking the Propeller Shaft
Assembling the Propeller Shaft Housing
Installing the Propeller Shaft Housing Assembly
Drive Shaft
Removing/Installing the Drive Shaft
Removing the Pinion
Disassembling the Drive Shaft Housing Assembly
Disassembling the Forward Gear Assembly
Checking the Pinion
Checking the Drive Shaft
Assembling the Forward Gear Assembly
Assembling the Drive Shaft Housing Assembly
Installing the Pinion
Lower Case Assembly
Disassembling/Assembling the Lower Case Assembly
Disassembling the Lower Case Assembly
Checking the Drive Shaft Sleeve
Checking the Needle Bearing
Assembling the Lower Case Assembly
Disassembling/Assembling the Propeller Shaft Housing Assembly
Selecting the Pinion Shims
Selecting the Forward Gear Shims
Selecting the Reverse Gear Shims
Measuring the Reverse Gear Backlash
Shimming
Selecting the Pinion Shims
Selecting the Reverse Gear Shims
Selecting the Forward Gear Shims
Selecting the Propeller Shaft Shims
Selecting the Reverse Gear
Chapter 7. Bracket Unit
Bottom Cowling
Removing/Installing the Bottom Cowling
Disassembling/Assembling the Bottom Cowling
Disassembling/Assembling the Shift Rod Assembly
Upper Case Assembly
Removing/Installing the Upper Case Assembly
Disassembling/Assembling the Upper Case Assembly
Exhaust Manifold Assembly
Clamp Brackets
Removing/Installing the Clamp Brackets
Steering Arm
Removing/Installing the Steering Arm
Swivel Bracket Assembly
Disassembling/Assembling the Swivel Bracket Assembly
Power Trim and Tilt Unit
Removing/Installing the Power Trim and Tilt Unit
Removing the Power Trim and Tilt Unit
Bleeding the Power Trim and Tilt Unit
Reservoir and Power Trim and Tilt Motor
Checking the Reservoir
Checking the Gear Pump Housing Filter
Installing the Power Trim and Tilt Motor
Filling the Reservoir
Measuring the Hydraulic Pressure
Tilt Ram Assembly and Gear Pump Unit
Removing the Tilt Ram End Screw
Removing the Gear Pump Unit
Disassembling the Gear Pump Unit
Checking the Tilt Ram
Checking the Gear Pump Unit
Assembling the Gear Pump Unit
Installing the Gear Pump Unit
Installing the Tilt Ram
Trim Ram Assemblies and Free Piston
Removing the Trim Ram End Screws
Removing the Free Piston
Checking the Trim Rams
Checking the Free Piston
Checking the Trim Ram Cylinders
Installing the Free Piston
Installing the Trim Rams
Chapter 8. Electrical Systems
Electrical Components
Port View
Starboard View
Aft View
Top View
Wire Harness
Electrical Component Analysis
Digital Circuit Tester
Measuring the Peak Voltage
Peak Voltage Adaptor
Measuring a Low Resistance
Ignition System
Checking the Ignition Spark Gap
Checking the Fuses
Checking the Fuse Holder
Measuring the Control Unit Output Peak Voltage
Measuring the Pulser Coil Output Peak Voltage
Checking the Spark Plug Caps
Ignition Control System
Measuring the Crank Position Sensor Output Peak Voltage
Measuring the Engine Cooling Water Temperature Sensor Resistance
Checking the Thermo Switch Continuity
Checking the Oil Level Sensor Continuity
Measuring the Throttle Position Sensor Output Voltage
Checking the Shift Position Switch
Fuel Control System
Checking the Oxygen Density Sensor
Checking the Atmospheric Pressure Sensor
Checking the Intake Air Temperature Sensor
Checking the Fuel Injectors
Checking the Fuel Pressure Sensor
Checking the Water Detection Switch
Starting System
Checking the Wire Harness Continuity
Checking the Wire Connections
Checking the Starter Relay
Disassembling/Assembling the Starter Motor
Removing the Starter Motor Pinion
Checking the Starter Motor Pinion
Checking the Armature
Measuring the Brushes
Checking the Magnetic Switch Relay
Charging System
Measuring the Rectifier/Regulator Output Peak Voltage
Measuring the Lighting Coil Output Peak Voltage
Oil Feed Pump Control System
Checking the Oil Level Sensor/Switch Continuity
Checking the Emergency Switch
Checking the Oil Pump
Power Trim and Tilt System
Checking the Power Trim and Tilt Relay
Checking the Trailer Switch Continuity
Measuring the Trim Sensor Resistance
Disassembling/Assembling the Power Trim and Tilt Motor
Removing the Stator
Removing the Brush
Checking the Armature
Installing the Brush
Installing the Armature
Installing the Stator
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This manual is also suitable for:
Lz200n
Z200y
Lz200y
Z200neto
Lz200neto
Z200tr
...
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Lz200tr
6g6
6k1
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