Yamaha Z200Y Manuals

Manuals and User Guides for Yamaha Z200Y. We have 4 Yamaha Z200Y manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha Z200Y 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 Z200Y Service Manual (392 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 12 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 Z200Y Owner's Manual (122 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 10 MB

Yamaha Z200Y Service Manual (35 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 1 MB

Table of Contents

7
- How to Use this Manual
  3
- General Information
  6
- Periodic Inspections and Adjustments
  6
  - Table of Contents
    7
- Specifications
  6
- Chapter 1
  9
- Identification
  9
- Serial Number
  9
- Starting Serial Numbers
  9
- Safety While Working
  10
  - Fire Prevention
    10
  - Ventilation
    10
  - Self-Protection
    10
  - Oils, Greases and Sealing Fluids
    10
  - Good Working Practices
    11
  - Disassembly and Assembly
    12
- Special Tools
  13
  - Measuring
    13
  - Removing and Installing
    16
Specifications

19
- Chapter 2 Specifications
  20
- Fuel System
  20
- General Specifications
  20
- Power Unit
  22
- Spec
  22
  - Maintenance Specifications
    22
  - Lower Unit
    24
  - Electrical
    24
- Tightening Torques
  30
  - Specified Torques
    30
  - General Torques
    32
- Insp Adj
  33
  - Maintenance Interval Chart
    35

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Yamaha Z200Y Manuals

Yamaha Z200Y 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 Z200Y Service Manual (392 pages)

Table of Contents

Table of Contents

Specifications

Insp Adj

Chapter 4 Fuel System

Chapter 5 Power Unit

Chapter 6 Lower Unit

Propeller Shaft Housing Assembly (Regular Rotation Models)

Yamaha Z200Y Owner's Manual (122 pages)

Yamaha Z200Y Service Manual (35 pages)

Table of Contents

Table of Contents

Specifications

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