2011-2015 Yamaha 200/225//250HP 4-Stroke Outboard Service & Repair Manual

(L)F200A (L)F225A (L)F250 SERVICE MANUAL 6P2-28197-1P-12 LIT-18616-03-36

Preface 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 the Bronze Technical Certificate of the YTA (Yamaha Technical Academy) marine or the equivalent 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. Also, up-to-date parts information is available on YPEC-web. Additional information and up-to-date information on Yamaha products and services are available on Yamaha Service Portal. Important information Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. A NOTICE indicates special precautions that must be taken to avoid damages to the outboard motor or other property. TIP: A TIP provides key information to make procedures easier or clearer. (L)F200A, (L)F225A, (L)F250 SERVICE MANUAL ©2011 by Yamaha Motor Corporation, U.S.A. 1st Edition, June 2011 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-18616-03-36

Contents General information GEN INFO 0 Specification SPEC 1 Technical features and description TECH FEA 2 Rigging information RIG GING 3 Troubleshooting TRBL SHTG 4 Electrical system ELEC 5 Fuel system FUEL 6 Power unit POWR 7 Lower unit LOWR 8 Bracket unit BRKT 9 Maintenance MNT 10 Index Appendix A

GEN INFO 0 General information Safety while working ..................................................... 0-1 Rotating part ............................................................................... 0-1 Hot part ....................................................................................... 0-1 Electric shock ............................................................................. 0-1 Propeller ..................................................................................... 0-1 Handling of gasoline ................................................................... 0-1 Ventilation................................................................................... 0-1 Self-protection ............................................................................ 0-2 Working with crane ..................................................................... 0-2 Handling of gas torch ................................................................. 0-2 Part, lubricant, and sealant ......................................................... 0-2 Handling of sealant ..................................................................... 0-2 Special service tool .................................................................... 0-3 Tightening torque ....................................................................... 0-3 Non-reusable part ....................................................................... 0-3 Disassembly and assembly ........................................................ 0-3 How to use this manual ..................................................... 0-4 Manual format ............................................................................ 0-4 Abbreviation ............................................................................... 0-5 Lubricant, sealant, and thread locking agent .................. 0-7 Symbol ....................................................................................... 0-7 Special service tool ............................................................ 0-9

0-1 GEN INFO General information Safety while working To prevent an accident or injury and to pro- vide quality service, observe the following safety procedures. Rotating part • Hands, feet, hair, jewelry, clothing, personal flotation device straps, and so on, can become entangled with internal rotating parts of the engine, resulting in serious injury or death. • Keep the top cowling installed whenever possible. Do not remove or install the top cowling when the engine is running. • Only operate the engine with the top cowling removed according to the specific instructions in the manual. Keep hands, feet, hair, jewelry, clothing, personal flotation device straps, and so on, away from any exposed moving parts. Hot part During and after operation, engine parts are hot enough to cause burns. Do not touch any parts under the top cowling until the engine has cooled. Electric shock Do not touch any electrical parts while starting or operating the engine. Otherwise, shock or electrocution could result. Propeller Do not hold the propeller with your hands when loosening or tightening the propeller nut. Handling of gasoline • Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. • Gasoline is poisonous and can cause injury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you swallow some gasoline, inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. Ventilation • Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If gasoline vapor or exhaust gas is inhaled in large quantities, it may cause loss of con- sciousness and death within a short time. • When test running an engine indoors (for example, in a water tank) make sure to do so where adequate ventilation can be main- tained.

0-2 0 Self-protection • Protect your eyes by wearing safety glasses or safety goggles during all opera- tions involving drilling and grinding, or when using an air compressor. • Protect your hands and feet by wearing protective gloves and safety shoes when necessary. Working with crane • Outboard motors weighing 18.0 kg (39.7 lb) and over must be carried by a crane. • Use the wire ropes of adequate strength, and lift up the outboard motor using the three point suspension. • If the outboard motor does not have three or more points to be suspended, support it using additional ropes or the like so that the outboard motor can be lifted and carried in a stable manner. Handling of gas torch • Improper handling of a gas torch may result in burns. For information on the proper handling of the gas torch, see the operation manual issued by the manufacturer. • When using a gas torch, keep it away from the gasoline and oil, to prevent a fire. • Components become hot enough to cause burns. Do not touch any hot components directly. Part, lubricant, and sealant Use only genuine Yamaha parts, lubricants, and sealants, or those recommended by Yamaha, when servicing or repairing the outboard motor. Handling of sealant • Wear protective gloves to protect your skin, when using the sealants. • See the material safety data sheet issued by the manufacturer. Some of the sealants may be harmful to human health. Safety while working

0-3 GEN INFO General information Special service tool Use the recommended special service tools to work safely, and to protect parts from dam- age. Tightening torque 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 part Always use new gaskets, seals, O-rings, cotter pins, and so on, when installing or assembling parts. Disassembly and assembly • Use compressed air to remove dust and dirt during disassembly. • Apply engine oil to the contact surfaces of moving parts before assembly. • Install bearings so that the bearing identifi- cation mark is facing in the direction indi- cated in the installation procedure. In addition, make sure to lubricate the bearings liberally. • Apply a thin coat of water resistant grease to the lip and periphery of an oil seal before installation. • Check that moving parts operate normally after assembly.

0-4 0 How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the following information as a guide for effective and quality service. • Parts are shown and detailed in an exploded diagram and are listed in the component list (see 1 in the following figure for an example page). • The component list consists of part names and quantities, as well as bolt and screw dimensions (see 2 in the following figure). • Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and the lubrication points (see 3 in the following figure). • Tightening torque specifications are provided in the exploded diagrams (see 4 in the following figure), and in the related detailed instructions. Some torque specifications are listed in stages as torque figures or angles in degrees. • Separate procedures and illustrations are used to explain the details of removal, checking, and installation where necessary (see 5 in the following figure for an example page). TIP: For troubleshooting procedures, see Chapter 4, “Troubleshooting.” 8-1 LOWR Lower unit Lower unit (regular rotation model) È U-transom model No. Part name Q’ty Remarks 1 Water inlet cover (PORT) 1 2 Bolt 1 M5 40 mm 3 Gasket 2 Not reusable 4 Drain screw 1 5 Water inlet cover (STBD) 1 6 Self-locking nut 1 7 Check screw 1 8 Dowel 2 9 Plate 1 10 Rubber seal 1 11 Bolt 1 M10 45 mm 12 Grommet 1 13 Lower unit 1 14 Spacer 1 15 Propeller 1 16 Cotter pin 1 Not reusable 17 Propeller nut 1 14 20 22 1 2 22 13 15 18 16 19 17 22 21 11 12 25 26 24 6 3 7 8 9 10 8 5 4 3 23 34 33 32 31 30 29 25 35 27 28 42 N m (4.2 kgf m, 31.0 ft lb) 54 N m (5.4 kgf m, 39.8 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 2.3 N m (0.23 kgf m, 1.70 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) È 8-19 LOWR Lower unit 2. Heat the installation area of the taper roller bearing outer race in the lower case with a gas torch, and then install the outer race 2. NOTICE: When heating the lower case, heat the entire installation area evenly. Otherwise, the paint on the lower case could be burned. TIP: Do not reuse a shim if it is any deformed or scratched. 3. While holding the special service tool 3, strike the tool to check that the taper roller bearing outer race is installed properly. If a high-pitched metallic sound is produced when the special service tool is struck, the outer race is installed properly. 4. Install the rollers into the needle bearing outer race, and install the special service tool into the needle bearing assembly 5, and then install the needle bearing assembly 5. TIP: The needle bearing contains 28 rollers. Assembling the forward gear Do not reuse the bearing, always replace it with a new one. 1. Install a new taper roller bearing. Driver rod LL 3: 90890-06605 Bearing outer race attachment 4: 90890-06658 1 2 3 3 4 4 Ball bearing attachment 6: 90890-06655 Bearing outer race puller assembly 7: 90890-06523 Bearing inner race attachment 1: 90890-06659 6 7 5 1 x x 5 2 3 4 1 Safety while working / How to use this manual

0-5 GEN INFO General information Abbreviation The following abbreviations are used in this service manual. Abbreviation Description ABYC American Boat and Yacht Council AFT Aft end API American Petroleum Institute APS Accelerator Position Sensor ATF Automatic Transmission Fluid AWG American Wire Gauge BOW Bow end BTDC Before Top Dead Center C/E Check Engine C/L Centerline CARB California Air Resources Board CCA Cold Cranking Ampere CL Command Link DN Down side DOHC Dual Over Head Camshaft ECM Electronic Control Module EPA Environmental Protection Agency ETV Electronic Throttle Valve EX Exhaust EXH Exhaust F Forward GPS Global Positioning System IN Intake INT Intake ISC Idle Speed Control ISO International Organization for Standardization MCA Marine Cranking Ampere N Neutral OCV Oil Control Valve PCV Pressure Control Valve PON Pump Octane Number PORT Port side PTT Power Trim and Tilt R Reverse RC Reserve Capacity SAE Society of Automotive Engineers STBD Starboard side SW Switch

2011-2015 Yamaha 200/225//250HP 4-Stroke Outboard Service & Repair Manual

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