User Manuals: Yamaha Z200TR Outboard Motor

Manuals and User Guides for Yamaha Z200TR Outboard Motor. We have 3 Yamaha Z200TR Outboard Motor manuals available for free PDF download: Service Manual, Supplementary Service Manual, Rigging Manual

Yamaha Z200TR Service Manual (387 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 8 MB

Illustrations
3
Model Indication
3
Important Information
4
How to Use this Manual
5
Symbols
6
Contents
7
Chapter 1. General Information

8
- Identification
  9
- Serial Number
  9
- Starting Serial Numbers
  9
- Safety While Working
  10
- Fire Prevention
  10
- Ventilation
  10
- Self-Protection
  10
- Good Working Practices
  11
- Disassembly and Assembly
  12
- Special Tools
  13
- Measuring
  13
- Diagnosis
  15
- Diagnosis Record
  15
- Static Test
  15
- Dynamic Test
  15
- Removing and Installing
  16
Chapter 2. Specifications

19
- General Specifications
  20
- Maintenance Specifications
  22
- Power Unit
  22
- Dimensions
  28
- Tightening Torques
  30
- Specified Torques
  30
- General Torques
  32
Chapter 3. Periodic Inspections and Adjustments

33
- Maintenance Interval Chart
  35
- Top Cowling
  37
- Checking the Top Cowling Fit
  37
- Fuel System
  37
- Checking the Fuel Line
  37
- Checking the Fuel Filter
  38
- Measuring the Fuel Pressure
  39
- Checking the Fuel Pressure
  39
- Measuring Steps
  39
- Checking the Mechanical Fuel Pump Oil Level
  40
- Changing the Mechanical Fuel Pump Oil
  40
- Control System
  41
- Synchronizing the Throttle Valves
  41
- Adjusting the Throttle Position Sensor
  42
- Adjusting the Engine Idling Speed
  43
- Adjusting the Remote Control Shift Cable
  44
- Adjusting the Remote Control Throttle Cable
  44
- Checking the Drive Belt
  45
- Adjusting the Crank Position Sensor
  46
- Checking the Cooling Water Discharge
  46
- Oil Injection System
  46
- Checking the Oil Strainer
  46
- Synchronizing the Oil Pump
  47
- Air Bleeding the Oil Injection System
  48
- Checking the Electric Oil Pump
  48
- Power Trim and Tilt System
  49
- Checking the Power Trim and Tilt Fluid Level
  49
- Adjusting the Trim Sensor Cam
  50
- Lower Unit
  50
- Checking the Gear Oil Level
  50
- Changing and Checking the Gear Oil
  51
- Recommended Gear Oil
  51
- Total Amount
  51
- Checking the Lower Unit
  52
- Checking the Anodes
  52
- Checking the Battery
  53
- Checking the Spark Plugs
  54
- Lubrication Points
  56
Chapter 4. Fuel System

57
Chapter 5. Power Unit

115
- Flywheel Magnet Assembly
  117
- Removing/Installing the Flywheel Magnet Assembly
  117
- Removing the Flywheel Magnet Assembly
  118
- Flywheel Magnet Assembly Holder
  118
- Universal Puller
  118
- Installing the Flywheel Magnet Assembly
  119
- Disconnecting/Connecting the Leads
  120
- Disconnecting/Connecting the Hoses
  122
- Removing/Installing the Exhaust Expansion Chamber
  123
- Installing the Apron
  125
- Removing/Installing the Power Unit
  126
- Suspending the Power Unit
  127
- Installing the Power Unit
  127
- Stator Assembly
  128
- Removing/Installing the Stator Assembly
  128
- Control Unit
  130
- Removing/Installing the Control Unit Assembly
  130
- Fuse Holder
  132
- Removing/Installing the Fuse Holder
  132
- Disassembling/Assembling the Fuse Holder
  133
- Junction Box Assembly
  134
- Removing/Installing the Junction Box Assembly
  134
- Disassembling/Assembling the Junction Box Assembly
  137
- Wire Harnesses
  139
- Removing/Installing the Main Wire Harness
  139
- Removing/Installing the Sub Wire Harness
  141
- Removing/Installing the Injector Wire Harness
  142
- Starter Motor
  144
- Removing/Installing the Starter Motor
  144
- Oxygen Density Sensor
  147
- Installing the Oxygen Density Sensor
  147
- Reed Valves
  148
- Removing/Installing the Reed Valves
  148
- Checking the Reed Valve Assembly
  150
- External Fittings
  151
- Removing/Installing the External Fittings
  151
- Cylinder Head Covers
  154
- Removing/Installing the Cylinder Head Covers
  154
- Checking the Thermostats
  156
- Removing/Installing the Cylinder Heads
  157
- Checking the Cylinder Heads
  159
- Exhaust Covers
  160
- Removing/Installing the Exhaust Covers
  160
- Checking the Pressure Control Valve
  162
- Crankcase
  163
- Removing/Installing the Crankcase
  163
- Assembling the Oil Seal Housing
  165
- Installing the Crankcase
  165
- Cylinder Body Assembly
  166
- Disassembling/Assembling the Cylinder Body Assembly
  166
- Disassembling/Assembling the Piston and Connecting Rod Assemblies
  169
- Disassembling/Assembling the Crankshaft Assembly
  170
- Disassembling the Upper Bearing Housing
  171
- Removing the Bearing and Oil Pump Drive Gear
  171
- Checking the Cylinder Body
  172
- Checking the Pistons
  173
- Calculating the Piston-To-Cylinder Clearance
  173
- Checking the Piston Pins and Small-End Bearings
  174
- Checking the Piston Rings
  174
- Checking the Oil Pump Driven Gear
  175
- Checking the Labyrinth Rings
  176
- Checking the Crankshaft
  176
- Installing the Oil Pump Drive Gear
  177
- Installing the Bearing
  177
- Installing the Piston Rings and Piston
  177
- Assembling the Upper Bearing Housing
  178
- Installing the Crankshaft Assembly
  179
- Installing the Piston and Connecting Rod Assemblies
  179
Chapter 6. Lower Unit

180
- Removing/Installing the Lower Unit
  184
- Removing the Propeller
  186
- Removing the Trim Tab
  186
- Checking the Propeller
  186
- Installing the Propeller
  187
- Water Pump
  188
- Removing/Installing the Water Pump
  188
- Checking the Impeller Housing
  190
- Checking the Impeller and Impeller Housing Cup
  190
- Checking the Woodruff Key
  190
- Installing the Impeller and Impeller Housing
  190
- Shift Rod Assembly
  192
- Removing/Installing the Shift Rod Assembly
  192
- Removing the Shift Rod Assembly
  193
- Removing/Installing the Propeller Shaft Housing Assembly
  194
- Disassembling/Assembling the Propeller Shaft Housing
  196
- Disassembling/Assembling the Propeller Shaft Assembly
  197
- Removing the Propeller Shaft Housing Assembly
  198
- Disassembling the Propeller Shaft Housing
  198
- Propeller Shaft Housing Assembly
  199
- Checking the Reverse Gear
  199
- Checking the Bearings
  199
- Checking the Propeller Shaft Housing
  199
- Checking the Dog Clutch
  200
- Checking the Propeller Shaft
  200
- Assembling the Propeller Shaft Housing
  200
- Installing the Propeller Shaft Housing Assembly
  201
- Drive Shaft
  202
- Removing/Installing the Drive Shaft
  202
- Removing the Pinion
  204
- Disassembling the Drive Shaft Housing Assembly
  204
- Disassembling the Forward Gear Assembly
  204
- Checking the Pinion
  205
- Checking the Drive Shaft
  205
- Assembling the Forward Gear Assembly
  205
- Assembling the Drive Shaft Housing Assembly
  206
- Installing the Pinion
  207
- Lower Case Assembly
  208
- Disassembling/Assembling the Lower Case Assembly
  208
- Disassembling the Lower Case Assembly
  209
- Checking the Drive Shaft Sleeve
  209
- Checking the Needle Bearing
  209
- Assembling the Lower Case Assembly
  209
- Disassembling/Assembling the Propeller Shaft Housing Assembly
  222
- Selecting the Pinion Shims
  239
- Selecting the Forward Gear Shims
  241
- Selecting the Reverse Gear Shims
  243
- Measuring the Reverse Gear Backlash
  253
- Shimming
  255
- Selecting the Pinion Shims
  256
- Selecting the Reverse Gear Shims
  258
- Selecting the Forward Gear Shims
  259
- Selecting the Propeller Shaft Shims
  261
- Selecting the Reverse Gear
  265
Chapter 7. Bracket Unit

273
- Bottom Cowling
  275
- Removing/Installing the Bottom Cowling
  275
- Disassembling/Assembling the Bottom Cowling
  277
- Disassembling/Assembling the Shift Rod Assembly
  280
- Upper Case Assembly
  281
- Removing/Installing the Upper Case Assembly
  281
- Disassembling/Assembling the Upper Case Assembly
  283
- Exhaust Manifold Assembly
  285
- Clamp Brackets
  287
- Removing/Installing the Clamp Brackets
  287
- Steering Arm
  289
- Removing/Installing the Steering Arm
  289
- Swivel Bracket Assembly
  290
- Disassembling/Assembling the Swivel Bracket Assembly
  290
- Power Trim and Tilt Unit
  292
- Removing/Installing the Power Trim and Tilt Unit
  292
- Removing the Power Trim and Tilt Unit
  294
- Bleeding the Power Trim and Tilt Unit
  294
- Reservoir and Power Trim and Tilt Motor
  296
- Checking the Reservoir
  297
- Checking the Gear Pump Housing Filter
  297
- Installing the Power Trim and Tilt Motor
  298
- Filling the Reservoir
  299
- Measuring the Hydraulic Pressure
  301
- Tilt Ram Assembly and Gear Pump Unit
  304
- Removing the Tilt Ram End Screw
  306
- Removing the Gear Pump Unit
  306
- Disassembling the Gear Pump Unit
  306
- Checking the Tilt Ram
  307
- Checking the Gear Pump Unit
  307
- Assembling the Gear Pump Unit
  308
- Installing the Gear Pump Unit
  309
- Installing the Tilt Ram
  309
- Trim Ram Assemblies and Free Piston
  311
- Removing the Trim Ram End Screws
  312
- Removing the Free Piston
  312
- Checking the Trim Rams
  313
- Checking the Free Piston
  313
- Checking the Trim Ram Cylinders
  313
- Installing the Free Piston
  313
- Installing the Trim Rams
  314
Chapter 8. Electrical Systems

316
- Electrical Components
  319
- Port View
  319
- Starboard View
  320
- Aft View
  322
- Top View
  323
- Wire Harness
  324
- Electrical Component Analysis
  327
- Digital Circuit Tester
  327
- Measuring the Peak Voltage
  327
- Peak Voltage Adaptor
  327
- Measuring a Low Resistance
  328
- Ignition System
  329
- Checking the Ignition Spark Gap
  330
- Checking the Fuses
  331
- Checking the Fuse Holder
  331
- Measuring the Control Unit Output Peak Voltage
  332
- Measuring the Pulser Coil Output Peak Voltage
  333
- Checking the Spark Plug Caps
  334
- Ignition Control System
  335
- Measuring the Crank Position Sensor Output Peak Voltage
  336
- Measuring the Engine Cooling Water Temperature Sensor Resistance
  337
- Checking the Thermo Switch Continuity
  337
- Checking the Oil Level Sensor Continuity
  338
- Measuring the Throttle Position Sensor Output Voltage
  338
- Checking the Shift Position Switch
  339
- Fuel Control System
  340
- Checking the Oxygen Density Sensor
  343
- Checking the Atmospheric Pressure Sensor
  344
- Checking the Intake Air Temperature Sensor
  345
- Checking the Fuel Injectors
  346
- Checking the Fuel Pressure Sensor
  347
- Checking the Water Detection Switch
  348
- Starting System
  349
- Checking the Wire Harness Continuity
  350
- Checking the Wire Connections
  350
- Checking the Starter Relay
  350
- Disassembling/Assembling the Starter Motor
  351
- Removing the Starter Motor Pinion
  355
- Checking the Starter Motor Pinion
  355
- Checking the Armature
  355
- Measuring the Brushes
  356
- Checking the Magnetic Switch Relay
  357
- Charging System
  359
- Measuring the Rectifier/Regulator Output Peak Voltage
  360
- Measuring the Lighting Coil Output Peak Voltage
  361
- Oil Feed Pump Control System
  362
- Checking the Oil Level Sensor/Switch Continuity
  363
- Checking the Emergency Switch
  364
- Checking the Oil Pump
  364
- Power Trim and Tilt System
  365
- Checking the Power Trim and Tilt Relay
  366
- Checking the Trailer Switch Continuity
  367
- Measuring the Trim Sensor Resistance
  367
- Disassembling/Assembling the Power Trim and Tilt Motor
  368
- Removing the Stator
  370
- Removing the Brush
  370
- Checking the Armature
  371
- Installing the Brush
  372
- Installing the Armature
  372
- Installing the Stator
  372
Chapter 9. Trouble Analysis

373
- Trouble Analysis Chart
  374
- Self-Diagnosis
  378
- Diagnosis Code Indication
  378
- Diagnosis the Electronic Control System
  378
- Diagnosis Code Chart
  379
- Troubleshooting for High-Pressure Direct Injection
  380
- Wiring Diagram
  383
- Color Code
  385

Yamaha Z200TR Rigging Manual (226 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 7 MB

Table of Contents

5
Propellers

59
- Propeller Specifications
  
  60
  - Propeller Types
    60
  - Propeller Identification
    62
- 2009 Propeller Applications
  
  63
- Propeller Selection
  
  63
- Wot Operation Range Table
  
  69
- Remote Controls
  
  71
  - Remote Control Applications
    72
  - Remote Switch Applications
    85
  - Remote Control Cables
    94
  - Remote Control Attachment Kit
    96
  - Steering Hook
    98
  - Steering Guide Attachment Kit
    101
  - Conventional Wire Harness
    103
  - Digital Electronic Control Wire Harness
    105
Tiller Handles

107
- 6X4 Multi-Function Tiller Handle
  
  108
- Steering Friction Contents
  
  117
Conventional Gauge (6Y5 & 6Y7)

119
- Mounting the Meters
  
  122
  - Meter Mounting Procedure
    122
  - Analog Gauge Illumination (6Y7 Type)
    122
- Analog Tachometer
  
  123
  - Analog Tachometer Applications
    123
  - Analog Tachometer Dimensions
    124
  - Pole Number Set up
    124
- Digital Tachometer
  
  125
  - Digital Tachometer Applications
    125
  - Digital Tachometer Dimensions
    125
  - Pole Number Set up
    126
- Speedometer
  
  127
  - Speedometer Applications
    127
  - Speedometer Dimensions
    128
  - Water Pressure Damper (Op)
    128
  - Speedometer Tube Routing
    129
  - Digital Speedometer Set up
    129
- Fuel Management Gauge
  
  130
  - Fuel Management Gauge Applications
    130
  - Fuel Management Gauge Dimensions
    131
  - Fuel Sender Installation
    132
  - Wiring Description
    133
  - Fuel Management Gauge Set up
    135
  - Fuel Mgt Gauge with Speedometer Set up
    135
- Analog Trim Meter
  
  136
  - Analog Trim Meter Applications
    136
  - Analog Trim Meter Dimensions
    136
  - Trim Sender Adjustment
    136
- Coolant Pressure Meter
  
  137
  - Coolant Pressure Meter Applications
    137
  - Coolant Pressure Meter Dimensions
    137
- Coolant Temp. Meter
  
  138
- Hour Meter
  
  144
  - Hour Meter Applications
    144
  - Wiring the Mechanical Hour Meter
    145
  - Wiring the Digital Hour Meter
    145
- Voltage Meter
  
  146
  - Voltage Meter Applications
    146
  - Voltage Meter Dimensions
    146
  - Wiring the Voltage Meter
    146
- Fuel Meter
  
  147
  - Fuel Meter Applications
    147
  - Fuel Meter Dimensions
    147
- Charge Warning Unit
  
  148
  - Charge Warning Unit Applications
    148
- Wire Harnesses
  
  149
  - Remote-Oil Tank Harness
    149
  - Additional Accessory Lead
    149
  - Meter Harness
    150
  - Lamp Switch
    151
  - Combination Trim and Oil Lead 1
    151
  - Combination Trim and Oil Lead 2
    151
  - Trim Meter Lead
    151
  - Pt/T Switch Lead Extension
    152
  - Trim and Oil Lead
    152
  - Fuel Management Gauge Harness
    152
  - Lighting Coil Extension Harness
    152
  - Rectifier Kit
    152
- Wiring Diagrams
  
  153
  - Wire Color Code
    153
  - Digital Meter
    154
  - Analog Meter (6Y7)
    159
  - Interchangeability between Tachometer and Engine
    161
  - Grommet Description
    164
Digital Network Gauge (6Y8)

167
- Digital Network Gauge Compatible Model
  
  168
- Digital Network Gauge Application
  
  168
  - Square Style Gauge Application
    168
- Digital Network Gauge Dimensions
  
  169
  - Round Style Gauge Application
    169
  - Square Style Gauge Dimensions
    169
  - Round Style Gauge Dimensions
    170
- Optional Equipments
  
  171
  - Multi-Sensor Application
    171
  - Fitting Plate
    171
  - Speed Sensor Kit
    172
  - Coolant Pressure Sensor Kit
    172
- Wire Harness
  
  173
  - Main Bus Wire
    173
  - Pigtail Bus Wire
    173
  - Fuel Tank / Gps Wire
    174
  - Hub
    174
- Wiring Diagrams
  
  175
  - FUEL INJECTED F50-F250 [Mechanical RC] & HPDI ENGINES
    175
  - F350/F300/F250 [Digital Electronic Control]
    178
- Initial Gauge Setup
  
  183
- Troubleshooting
  
  184
- Basic Requirements
  
  185
- Nmea0183 Compatible Equipments Connection
  
  185
Battery

187
- Recommended Battery
  
  188
- Battery Cable Length
  
  189
- Battery Wiring
  
  190
Appendix

195
- Model Name Designation
  
  196
  - Us & Canada Model Identification
    197
  - New Us & Canada Model Identification Code
    197
- Fuel System Vacuum Pressure Standard
  
  198
  - Fuel Hose Routing Resistance Measuring Method
    198
  - Lowest Vacuum Pressure Standard
    199
- Portable Fuel Tanks (Typical)
  
  200
- Fuel Pipes (Typical)
  
  200
- Pre-Delivery Inspection (Pdi) Checks
  
  201
- Conventional Rigging Kit Contents
  
  202
  - Digital Tachometer Kit
    202
  - Digital Tachometer and Speedometer Kit
    202
  - Twin-Motor Kit
    203
  - Remote Oil Tank Kit (for 2-Stroke Engine)
    204
- Digital Network Gauge Rigging Kit Contents
  
  205
- 2009 Manufacturing Start Serial Number
  
  219

Yamaha Z200TR Supplementary Service Manual (304 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 9 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

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User Manuals: Yamaha Z200TR Outboard Motor

Yamaha Z200TR Service Manual (387 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 Z200TR Rigging Manual (226 pages)

Table of Contents

Table of Contents

Top Cover Pictograph Description

Uncrating Procedure (for Typical Steel Frame)

Mounting the Outboard Motor

Mounting the Remote Oil Tank

Outboard Motor Dimensions

Propellers

Propeller Specifications

2009 Propeller Applications

Propeller Selection

Wot Operation Range Table

Remote Controls

Tiller Handles

6X4 Multi-Function Tiller Handle

Steering Friction Contents

Conventional Gauge (6Y5 & 6Y7)

Mounting the Meters

Analog Tachometer

Digital Tachometer

Speedometer

Fuel Management Gauge

Analog Trim Meter

Coolant Pressure Meter

Coolant Temp. Meter

Hour Meter

Voltage Meter

Fuel Meter

Charge Warning Unit

Wire Harnesses

Wiring Diagrams

Digital Network Gauge (6Y8)

Digital Network Gauge Compatible Model

Digital Network Gauge Application

Digital Network Gauge Dimensions

Optional Equipments

Wire Harness

Wiring Diagrams

Initial Gauge Setup

Troubleshooting

Basic Requirements

Nmea0183 Compatible Equipments Connection

Battery

Recommended Battery

Battery Cable Length

Battery Wiring

Appendix

Model Name Designation

Fuel System Vacuum Pressure Standard

Portable Fuel Tanks (Typical)

Fuel Pipes (Typical)

Pre-Delivery Inspection (Pdi) Checks

Conventional Rigging Kit Contents

Digital Network Gauge Rigging Kit Contents

2009 Manufacturing Start Serial Number

Yamaha Z200TR Supplementary Service Manual (304 pages)

Table of Contents

English

General Information

Identification

Special Tools

General Specifications

Specifications

Maintenance Specifications

Français

Identification

Outillage Special