2013 Yamaha F200F FL200F Outboard Service Manual 6DA-28197-3S-11

Description

2013 Yamaha F200F FL200F Outboard Service Manual

This is the Second Edition service manual released by Yamaha Motor Co., Ltd. in May 2013 for the F200F and FL200F four-stroke outboard motors. It was written primarily for Yamaha dealers and YTA Bronze-certified marine technicians, and it documents the complete service, repair, and diagnostic workflow for both the standard-rotation F200F and the counter-rotation FL200F.

Every procedure is written around the actual engine that sits on the transom — the 2.8-litre, 16-valve, DOHC inline-four with VCT on the intake side, ETV electronic throttle, digital ignition, and a 2-axis balancer. Where a step calls for a Yamaha special service tool, the tool number is given. Where a value must be measured, the tolerance and the measuring condition are given. Where a fastener must be staged, the stages and the angles are shown.

File Details

• Manual type: Service Manual (dealer / technician level)
• Brand / manufacturer: Yamaha Motor Co., Ltd.
• Models covered: F200F, FL200F
• Document number: 6DA-28197-3S-11
• Edition: 2nd Edition, May 2013
• Language: English
• File format: PDF

Chapters Covered

• 0 — General Information: safety while working, rotating parts, hot parts, electric shock, propeller handling, gasoline handling, ventilation, self-protection, working with a crane, gas torch handling, sealant handling, special service tools, tightening torque, non-reusable parts, disassembly and assembly practice, how to use the manual, abbreviations, lubricant and sealant symbols, special service tool listings.
• 1 — Specification: model feature, model name designation, serial number, model data, dimensions and weight, performance, power unit data, lower unit data, bracket unit data, fuel and oil requirements, battery requirement, PTT fluid requirement, electrical system technical data, ignition timing control, fuel injection control, engine speed control, VCT system, PTT system, charging system, starting system, Y-COP, gauge and sensor data, fuel system technical data, power unit technical data, cylinder head assembly, crankcase assembly, lower unit assembly (regular and counter rotation), bracket unit technical data, PTT system data, specified tightening torques, general tightening torque.
• 2 — Technical Feature and Description: engine ECM components, VCT control, rectifier/regulator/isolator, over-revolution control, knock control, shift-cut control, reverse rotation control, battery removal control, warning control, water detection warning, fail-safe control, YDIS, Y-COP, tilt limiter, power unit system overview, shimless valve lifter, offset cylinder, balancer, flywheel and crankshaft, oil cooler, lower unit, Shift Dampener System (SDS), high-pressure and low-pressure fuel pump control, fuel diagram, lubrication diagram, cooling diagram, intake and exhaust diagram.
• 3 — Rigging Information: outboard motor mounting instructions, crate handling, crate top cover pictographs, uncrating, external dimensions, clamp bracket dimensions, installing the outboard motor, mounting height, rigging grommet mounting and description, installing the battery cable, shift cable, throttle cable, main wire harness, Digital Network Gauge harness, conventional gauge harness, rigging grommet, optional equipment including isolator lead, water pressure sensor, speed sensor, water temperature sensor, speedometer hose, tilt limiter, Y-COP installation, remote control receiver ID registration, battery installation with and without house battery, system diagrams, rigging recommendation, battery cable length, propeller selection and size charts.
• 4 — Troubleshooting: YDIS basic components and function, connecting the communication cable, outboard motor troubleshooting procedure, troubleshooting the power unit using the YDIS, trouble code and checking step tables, troubleshooting the power unit when no trouble code is detected, troubleshooting the PTT unit, troubleshooting the lower unit.
• 5 — Electrical System: port and starboard layout, fuse holder, rear, front, top, bottom cowling, ECM circuit diagram, ECM coupler layout, checking the electrical component, using the YDIS, measuring peak voltage, using the digital tester, engine control unit and component checks (main relay, engine ECM circuit, ETV and TPS, ETV motor relay, APS, cam position sensor, OCV, oil pressure sensor), fuel control unit checks (water detection switch, fuel injector, low and high pressure fuel pumps, high-pressure fuel pump relay, vapor shut-off valve), charging unit checks (lighting coil, rectifier/regulator/isolator), ignition unit checks (ignition spark, ignition coil, pulser coil, intake air temperature sensor, intake air pressure sensor, engine temperature sensor, thermo switch, knock sensor, shift cut-off switch, shift position switch, engine shut-off switch), starting unit checks (starter relay, engine start switch), Y-COP checks, starter motor removal, disassembly, inspection, assembly and installation, Digital Network Gauge sensor checks, PTT system checks.
• 6 — Fuel System: hose routing (fuel hose, pressure regulator hose, vapor gas hose, blowby hose, cooling water hose), reducing fuel pressure, disconnecting the quick connector, measuring fuel pressure, checking the pressure regulator, fuel filter (removal, checking, disassembly, element, cup assembly, primer pump, assembly and installation), low-pressure fuel pump (draining, removal, checking, installation), canister and vapor shut-off valve, ETV, fuel injector, intake manifold, vapor separator and APS, vapor separator and high-pressure fuel pump.
• 7 — Power Unit: compression pressure, oil pressure, pulser coil air gap, valve clearance checking and adjustment, power unit assembly for L-transom and X-transom models, removal and installation of the power unit, flywheel magneto, timing belt, starter motor, engine ECM, fuse box, rectifier/regulator/isolator, ignition coil and spark plug, wire harness, camshaft, cylinder head, exhaust cover, oil cooler, cylinder block, crankcase, piston and connecting rod, crankshaft and bearing selection tables.
• 8 — Lower Unit: regular rotation model and counter rotation model sections covering removal, propeller disassembly and assembly including Shift Damper System propellers, water pump and shift rod, propeller shaft housing, drive shaft and lower case, shimming workflow and check sheets, pinion shim (T3) selection, forward gear shim (T1) selection, reverse gear shim (T2) selection, propeller shaft shim (T4) selection, backlash measurement procedures, lower unit air leakage checks and installation.
• 9 — Bracket Unit: shift rod and shift bracket, PTT switch and cowling lock lever, bottom cowling, upper case and mounts for L-transom and X-transom models, oil pan and exhaust manifold, steering arm, clamp bracket and swivel bracket, PTT unit, PTT motor, PTT gear pump, PTT cylinder including tilt ram and trim ram.
• 10 — Maintenance: outline, maintenance interval chart 1 and chart 2, predelivery check, checking the battery, cooling water pilot hole, engine oil level, main switch/stop switch, fuel line, gear oil level, shift link/shift cable and throttle link/throttle cable, outboard motor mounting height, power trim and tilt unit, steering system, test run, break-in schedule, after test run, general periodic maintenance covering anodes, battery, cooling water inlet and pilot hole, engine idle speed and noise, changing engine oil by oil changer or drain bolt, replacing oil filter, exhaust guide and manifold, fuel filter, fuel pump, fuel and engine oil leakage, gear oil change, gear oil level, OCV filter, greasing points, PCV, propeller and propeller nut and cotter pin, PTT fluid level, PTT operation, shift link and shift cable adjustment, spark plug, timing belt, thermostat, throttle link and cable, cowling lock lever, valve clearance, impeller and water pump housing.
• Index and Appendix A: alphabetical index, wiring diagram with how-to-use guide, engine control unit, fuel unit and ignition unit, charging unit, starting unit, PTT unit, control unit, pinion shim selection table, forward gear shim selection chart, reverse gear shim selection chart, counter-rotation shim selection tables and charts.

Across these chapters the manual hands a technician the complete factory service library for one specific outboard: how the 2.8-litre powerhead is built, how the VCT and ETV electronics are wired and tested, how the fuel injection and vapor separator systems are plumbed and diagnosed, how the lower unit is shimmed to the correct backlash, how the bracket and PTT unit are rebuilt, and what every specification and torque figure should be when the job is done. The troubleshooting chapter and the YDIS sections are the diagnostic backbone of the book, and the shimming workflow in chapter 8 is what separates a rebuilt lower unit that runs quietly for years from one that whines itself apart.

Who This Manual Is For

If you work on the F200F or FL200F — as a marine mechanic, a serious owner, or a shop supporting a fleet of Yamaha outboards — this is the document that tells you how the factory wants each job performed. It matters most where the stakes are high: valve clearance adjustment on a shimless-lifter head, timing belt installation, camshaft and VCT assembly, crankshaft bearing selection, lower unit shimming, and PTT hydraulic checks. Those procedures require exact figures and exact sequencing, and that is what this book provides. It is also the manual you want when a trouble code appears and you need the checking steps that correspond to the code, rather than guessing at a sensor.

What You Can Do With It

• Diagnose engine faults through the YDIS workflow and the trouble-code checking tables.
• Service the VCT, ETV, digital ignition, and electronic fuel injection systems.
• Adjust valve clearances using the shimless valve lifter selection method.
• Remove, inspect, and reinstall the timing belt and camshafts.
• Rebuild the lower unit on the bench and shim the pinion, forward gear, and reverse gear back to specification.
• Repair the PTT unit, PTT motor, gear pump, tilt ram, and trim ram, and bleed the system correctly.
• Rig a new or replacement outboard, install the shift and throttle cables, and set up the Y-COP or tilt limiter.
• Run the full maintenance schedule, from engine oil and gear oil changes to greasing points and anode inspection.

IMAGES PREVIEW

The manual is delivered as a downloadable PDF that opens on any phone, tablet, laptop, or desktop, and every page can be printed for the workshop bench. There is no shipping and no waiting — the file is available immediately after purchase, and because it is a digital document you can keep it on every device you use and print only the pages you need for the job in front of you.