2003+ Yamaha 200-225HP Outboards (F200C/LF200C/F225C/LF225C) OEM Service & Repair Manual

F200C LF200C F225C LF225C SERVICE MANUAL 69J-28197-1F-11 LIT-18616-02-76 *LIT186160276*

NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use. Because Yamaha has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual. Important information 1 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor. NOTE: A NOTE provides key information to make procedures easier or clearer. F200C, LF200C, F225C, LF225C SERVICE MANUAL ©2003 by Yamaha Motor Corporation, USA 1st Edition, September 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited. Printed in USA LIT-18616-02-76

Contents General information 1 GEN INFO Specifications 2 SPEC Periodic checks and adjustments 3 CHK ADJ Fuel system 4 FUEL Power unit 5 POWR Lower unit 6 LOWR Bracket unit 7 BRKT Electrical systems 8 ELEC Troubleshooting 9 TRBL SHTG Index – +

GEN INFO 69J1D11 General information How to use this manual ................................................................................. 1-1 Manual format............................................................................................ 1-1 Symbols ..................................................................................................... 1-2 Safety while working...................................................................................... 1-3 Fire prevention........................................................................................... 1-3 Ventilation .................................................................................................. 1-3 Self-protection ........................................................................................... 1-3 Parts, lubricants, and sealants .................................................................. 1-3 Good working practices ............................................................................. 1-4 Disassembly and assembly ....................................................................... 1-4 Identification ................................................................................................... 1-4 Applicable models ..................................................................................... 1-4 Serial number ............................................................................................ 1-4 Features and benefits .................................................................................... 1-6 Newly developed V6 4-stroke engine ........................................................ 1-6 Valve train system ..................................................................................... 1-9 Intake system .......................................................................................... 1-11 Exhaust system ....................................................................................... 1-11 Fuel system ............................................................................................. 1-13 PTT (Power trim and tilt) unit ................................................................... 1-17 Technical tips ............................................................................................... 1-18 Fuel injection control ................................................................................ 1-18 Fail-safe function table ............................................................................ 1-20 PTT (Power trim and tilt) unit ................................................................... 1-21 Cooling system ........................................................................................ 1-26 Lubrication system................................................................................... 1-26 Propeller selection ....................................................................................... 1-27 Propeller size ........................................................................................... 1-27 Selection .................................................................................................. 1-27

69J1D11 1 2 3 4 5 6 7 8 9 Predelivery checks ...................................................................................... 1-28 Checking the fuel system ........................................................................ 1-28 Checking the gear oil ............................................................................... 1-28 Checking the engine oil ........................................................................... 1-28 Checking the battery................................................................................ 1-28 Checking the outboard motor mounting height ........................................ 1-29 Checking the remote control cables ........................................................ 1-29 Checking the steering wheel ................................................................... 1-30 Checking the gearshift and throttle operation .......................................... 1-30 Checking the tilt system........................................................................... 1-30 Checking the engine start switch and engine stop lanyard switch .......... 1-30 Checking the cooling water pilot hole ...................................................... 1-31 Test run ................................................................................................... 1-31 Break-in ................................................................................................... 1-31 After test run ............................................................................................ 1-31

GEN INFO General information 1-1 69J1D11 How to use this manual 1 Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. 1 Parts are shown and detailed in an exploded diagram and are listed in the components list. 2 Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions. 3 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and lubrication point. 4 The components list consists of parts and part quantities, as well as bolt, screw, O-ring, and hose dimensions. 5 Service points regarding removal, checking, and installation are shown in individual illustrations to explain the relevant procedure. NOTE: For troubleshooting procedures, see Chapter 9, “Troubleshooting.”

69J1D11 1-2 1 2 3 4 5 6 7 8 9 Symbols The symbols below are designed to indicate the content of a chapter. General information Specifications Periodic checks and adjustments Fuel system Power unit Lower unit Bracket unit Electrical systems Troubleshooting GEN INFO SPEC CHK ADJ FUEL POWR LOWR BRKT ELEC TRBL SHTG – + Symbols 1 to 6 indicate specific data. 1 Special tool 2 Specified oil or fluid 3 Specified engine speed 4 Specified tightening torque 5 Specified measurement 6 Specified electrical value (resistance, voltage, electric current) Symbols 7 to A in an exploded diagram indicate the grade of lubricant and the lubrication point. 7 Apply Yamaha 4-stroke motor oil 8 Apply water resistant grease (Yamaha grease A) 9 Apply molybdenum disulfide grease 0 Apply corrosion resistant grease (Yamaha grease D) A Apply low temperature resistant grease (Yamaha grease C) Symbols B to G in an exploded diagram indicate the type of sealant or locking agent and the appli- cation point. B Apply Gasket Maker ® C Apply Yamabond No. 4 D Apply LOCTITE ® No. 271 (Red) E Apply LOCTITE ® No. 242 (Blue) F Apply LOCTITE ® No. 572 G Apply silicon sealant 1 2 3 4 5 6 T R . . 7 8 9 0 A E A M D C B C D E F G GM 4 271 LT 242 LT 572 LT SS How to use this manual

GEN INFO General information 1-3 69J1D11 Safety while working 1 To prevent an accident or injury and to ensure quality service, follow the safety procedures provided below. Fire prevention Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If inhaled in large quantities they may cause loss of consciousness and death within a short time. When test running an engine indoors (e.g., in a water tank) be sure to do so where ade- quate ventilation can be maintained. Self-protection Protect your eyes by wearing safety glasses or safety goggles during all operations involv- ing drilling and grinding, or when using an air compressor. Protect your hands and feet by wearing protective gloves and safety shoes when neces- sary. Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the outboard motor. Under normal conditions, the lubricants men- tioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants. 1. Maintain good standards of personal and industrial hygiene. 2. Change and wash clothing as soon as possible if soiled with lubricants. 3. Avoid contact with skin. Do not, for example, place a soiled rag in your pocket. 4. Wash hands and any other part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made. 5. To protect your skin, apply a protective cream to your hands before working on the outboard motor.

69J1D11 1-4 1 2 3 4 5 6 7 8 9 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. Good working practices Special tools Use the recommended special tools to protect parts from damage. Use the right tool in the right manner—do not improvise. Tightening torques Follow the tightening torque specifications provided throughout the manual. When tightening nuts, bolts, and screws, tighten the large sizes first, and tighten fasteners starting in the center and moving outward. Non-reusable parts Always use new gaskets, seals, O-rings, cot- ter pins, circlips, etc., when installing or assembling parts. Disassembly and assembly 1. Use compressed air to remove dust and dirt during disassembly. 2. Apply engine oil to the contact surfaces of moving parts before assembly. 3. Install bearings with the manufacture identification mark in the direction indi- cated in the installation procedure. In addition, be sure to lubricate the bearings liberally. 4. Apply a thin coat of water-resistant grease to the lip and periphery of an oil seal before installation. 5. Check that moving parts operate nor- mally after assembly. Identification 1 Applicable models This manual covers the following models. Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket. Applicable models F200TR, LF200TR, F225TR, LF225TR Safety while working / Identification

GEN INFO General information 1-5 69J1D11 1 Model name 2 Approved model code 3 Transom height 4 Serial number Model name Approved model code Starting serial No. F200TR 60L 1001799– LF200TR 60M 1000373– F225TR 69J 1007259– LF225TR 69K 1002513–

2003+ Yamaha 200-225HP Outboards (F200C/LF200C/F225C/LF225C) OEM Service & Repair Manual

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