Yamaha 200A User manual

200A
L200A
60H-28197-5E-11
290446
SERVICE MANUAL

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
Particularly important information is distinguished in this manual by the following notations:
⁄The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
200A, L200A
SERVICE MANUAL
©2002 by Yamaha Motor Co., Ltd.
1st Edition, February 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
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.
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.

Contents
General information GEN
INFO
Specifications SPEC
Periodic checks and adjustments CHK
ADJ
Fuel system FUEL
Power unit POWR
Lower unit LOWR
Bracket unit BRKT
Electrical systems ELEC
Troubleshooting TRBL
SHTG
Index
–+

60H5E11
GEN
INFO General information
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 ..................................................................................................................1-5
Applicable models.....................................................................................................1-5
Serial number ...........................................................................................................1-5
Features and benefits ...................................................................................................1-6
Hour meter................................................................................................................1-6
Exhaust components (Factory option) ......................................................................1-7
Piston and cylinder ...................................................................................................1-8
Connecting rod .........................................................................................................1-9
Gasket.....................................................................................................................1-10
Reduction gear and clutch ......................................................................................1-11
Power unit mount bolt .............................................................................................1-12
Propeller selection ......................................................................................................1-13
Propeller size ..........................................................................................................1-13
Selection .................................................................................................................1-13
Predelivery checks ......................................................................................................1-14
Checking the fuel system........................................................................................1-14
Checking the gear oil ..............................................................................................1-14
Checking the battery...............................................................................................1-14
Checking the outboard motor mounting position ....................................................1-14
GEN
INFO General information

60H5E11
1
Checking the remote control cables........................................................................1-15
Checking the steering system.................................................................................1-15
Checking the gearshift and throttle operation .........................................................1-15
Checking the tilt sytem............................................................................................1-15
Checking the engine start switch and engine stop switch, engine shut-off switch......... 1-16
Checking the pilot water outlet................................................................................1-16
Test run ...................................................................................................................1-16
Break-in ..................................................................................................................1-17
After test run ...........................................................................................................1-17

60H5E11
GEN
INFO General information
60H5E11
5
A
1
23
4567 8
9
10
11 12
13
14
15
60H50280
1 Gasket 2
2 Cylinder head 2
3 Thermo switch 2
4 Gasket 2
5 Cylinder head cover 2
6 Gasket 2
7 Thermostat 2
8 Thermostat cover 2
9 Bolt 8 M6 x 40 mm
10 Bolt 36 M6 x 30 mm
11 Bolt 24 M8 x 60 mm
12 Clamp 1
13 Bolt 2 M8 x 20 mm
14 Engine hanger 1
15 Spark plug 6
No. Part name Q’ty Remarks
Exhaust / Cylinder head
5-22
Cylinder head
60H5E11
Power unit
POWR
5-21
Removing the exhaust cover
1. Remove the pressure control valve.
60H50250
2. Remove the exhaust outer cover, and the
exhaust inner cover.
60H50260
60H50265
NOTE:
Loosen the bolts in the sequence shown.
3. Remove the cylinder block exhaust inner
cover.
4. Check the pressure control valve for cracks
or damage. Also check the pressure con-
trol valve seat for deformation. Replace
them if necessary.
60H50270
5. Check the spring for fatigue or deforma-
tion. Replace it if necessary.
6. Check the exhaust cover for distortion or
corrosion. Replace it if necessary.
60H50275
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 information below as a guide for effective and quality service.
1Parts are shown and detailed in an exploded diagram and are listed in the components list.
2Tightening torque specifications are provided in the exploded diagrams and after a numbered step
with tightening instructions.
3Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
lubrication point.
4The components list consist of parts and part quantities, as well as bolt, screw, O-ring, and hose
dimensions.
5Service points regarding removal, checking, and installation are shown in individual illustrations to
explain the relevant procedure.
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
1-1
2
4
3
5
1

60H5E11
1
Symbols
The symbols below are designed to indicate the content of a chapter.
General information Fuel system Bracket unit
Symbols 1to 6indicate specific data.
1Special tool
2Specified oil or fluid
3Specified engine speed
Symbols 7to Bin an exploded diagram indicate the grade of lubricant and the lubrication point.
Periodic checks and adjustments Lower unit Troubleshooting
Specifications Power unit Electrical systems
GEN
INFO
SPEC
CHK
ADJ
FUEL
POWR
LOWR
BRKT
ELEC
TRBL
SHTG
4Specified tightening torque
5Specified measurement
6Specified electrical value
(Resistance, Voltage, Electric current)
123456
7Apply Yamaha 4-stroke motor oil
8Apply water resistant grease (Yamaha grease A)
9Apply molybdenum disulfide grease
0Apply corrosion resistant grease
(Yamaha grease D)
AApply low temperature resistant grease
(Yamaha grease C)
BApply injector grease
Symbols Cto Hin an exploded diagram indicate the type of sealant or locking agent and the appli-
cation point.
7890AB
CApply Gasket Maker
DApply Yamabond 4
EApply LOCTITE 271 (Red)
FApply LOCTITE 242 (Blue)
GApply LOCTITE 572
HApply silicon sealant
CDEFGH
T
R
.
.
E
How to use this manual
1-2

60H5E11
GEN
INFO General information
1-3
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 pos-
sible if soiled with lubricants.
3. Avoid contact with skin. Do not, for ex-
ample, 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.
Safety while working
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 adequate
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 pro-
tective gloves and safety shoes when neces-
sary.

60H5E11
1
Safety while working
1-4
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 iden-
tification mark in the direction indicated 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 be-
fore installation.
5. Check that moving parts operate normally
after assembly.
Tightening torques
Follow the tightening torque specifications
provided throughout the manual. When tight-
ening 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.
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.

60H5E11
GEN
INFO General information
Identification
Applicable models
This manual covers the following models.
Applicable models
200AET,L200AET
Serial number
The outboard motor serial number is stamped
on a label attached to the port clamp bracket.
1Model name
2Approved model code
3Transom height
4Serial number
NOTE:
If the serial number label is removed, VOID
marks will appear on the label.
Model name
200AET
L200AET
Approved
model code
60H
60J
Starting
serial No.
L: 800101-
X: 850101-
X: 800101-
60H10000
1-5

60H5E11
1
Features and benefits
Hour meter
A hour meter is incorporated for easier control of interval time for the periodic maintenance.
As the main switch is turned on, all segments light up for 2 seconds to check that the Light Emitting
Diode is not failed.
Then, the meter indicates the total of hours which the engine has been run since manufacture.
The indicated hour is the accumulated time detected by the pulse signal from the lighting coil.
The accumulated hour is held forever, and cannot reset.
Identification / Features and benefits
60H10010
1-6
Hour meter
Rectifier
Regulator
Battery
Fuse
Main
switch
Power source (Y)
Grand (B)
Pulse
(G/W)
Lighting
coil
Flywheel magnet
(G)
(B)
Hour meter
Wiring diagram
(B) G/W
G
Y
B
R
: Green/White
: Green
: Yellow
: Black
: Red
(R)

60H5E11
GEN
INFO General information
Exhaust components (Factory option)
The cylindrical components have been painted externally and internally after the anodic oxide coating
to make a film for additional corrosion-resistance.
60H10030
1-7
For X transom
Exhaust
guide plate
Exhaust manifold
Muffler
Exhaust
manifold
extension
(Muffler 2)

60H5E11
1
Piston and cylinder
Following items have been given to improve the durability for the piston and cylinder.
A hard anodic oxide coating has been given to the piston pin boss and piston ring groove of the #1
and #2 piston.
Multilayer plating has been given to the piston ring.
The cylinder sleeve without the exhaust slit has been adopted not to accumulate some deposits,
which can prevent the piston rings from entwining.
Also, the shape of the exhaust port has been given the gradual curve design to obtain the best engine
performance and avoid scuffing of the piston ring.
60H10040
1-8
Piston
Hard anodic oxide coating
Exhaust slit
Cylinder sleeve
Exhaust port
Scavenging port
Cylinder sleeve
(New models)(Previous models)
Features and benefits

60H5E11
GEN
INFO General information
Larger mating face
Bearing with 18 rollers
Silver plating
Identification mark
Carburizing and quenching
Connecting rod and bearings
Connecting rod
A process of the carburizing and quenching has been given to the inside of the small end to increase
the strength.
The small end bearing has been given 18 rollers, adding one roller from the previous model, to
increase the durability.
The mating face of the big end bearing has been given a large area to increase the rigidity after
assembling the bearing cap, which increases the rigidty.
Also, a silver plating (30-40µ) has been given to the outside portion of the big end to increase the less
friction.
60H10050
1-9

60H5E11
1
Silicon bead
Silicon bead
Gasket with silicon bead
Gasket
The intake manifold gasket has been given a silicon bead to increase more sealer.
60H10060
1-10
Features and benefits

60H5E11
GEN
INFO General information
Reduction gear and clutch
The process of the double shot-peening has been given to the surface of the teeth portion of the
pinion gear, forward gear and dog clutch to increase the durability.
60H10070
1-11
Dog clutch
Forward gear
Pinion gear

60H5E11
1
Coating with a sealing material
Full threaded bolt
Bolt hole
Bolt
Corroded particles
Sealing material
Power unit mount bolt
A fully threaded bolt coated with a sealing material to the thread portion has been adopted for mount-
ing the power unit.
This gives a sealing function to the bolt, which will help prevent the bolt from sticking by the salt water
entering into the thread hole and crystallizing .
Also, the bolt can come out by turning, due to the full thread structure and the sealing material having
a function as an insulator, even if the bolt hole has been choked with corroded particles.
Therefore, an easier servicing such as removing the power unit can be obtained.
NOTE:
Apply a sealing material such as LOCTITE 572 to the bolt thread if the bolt is reused.
60H10080
1-12
Features and benefits

60H5E11
GEN
INFO General information
S60C1110
-
S60C1125
-
Selection
When the engine speed is at the full throttle
operating range (4,500 –5,500 r/min), the ideal
propeller for the boat is one that provides maxi-
mum performance in relation to boat speed and
fuel consumption.
Regular rotation model
Propeller size (in) Material
13 1/2 x 23-M
13 3/8 x 23-M
13 3/8 x 25-M
13 3/4 x 17-M
13 3/4 x 19-M2
13 3/4 x 21-M Stainless steel
14 x 19-M
14 1/2 x 17-M
14 5/8 x 16-M
15 1/4 x 15-M
15 3/4 x 13-M
Counter rotation model
Propeller size (in) Material
13 3/4 x 17-ML
13 3/4 x 19-ML
13 3/4 x 21-ML Stainless steel
13 3/8 x 23-ML
14 1/2 x 17-ML
Propeller selection
The performance of a boat and outboard mo-
tor will be critically affected by the size and type
of propeller you choose. Propellers greatly af-
fect boat speed, acceleration, engine life, fuel
economy, and even boating and steering ca-
pabilities. An incorrect choice could adversely
affect performance and could also seriously
damage the engine.
Use the following information as a guide for
selecting a propeller that meets the operating
conditions of the boat and the outboard motor.
Propeller size
The size of the propeller is indicated on the
propeller blade or outside of the propeller boss.
1-13
APropeller diameter (in inches)
BPropeller pitch (in inches)
CPropeller type (propeller mark)

60H5E11
1
Checking the battery
1. Check the capacity, electrolyte level, and
specified gravity of the battery.
2. Check that the red and black battery cables
are securely connected.
Checking the outboard motor mount-
ing position
1. Check that the anti-cavitation plate is
aligned with the bottom of the boat. If the
mounting height is too high, cavitation will
occur and propulsion will be reduced.
Also, the engine speed will increase abnor-
mally and cause the engine to overheat. If
the mounting height is too low, water resis-
tance will increase and reduce engine effi-
ciency.
S60C1160
NOTE:
The optimum mounting height is affected by
the combination of the boat and the outboard
motor. To determine the optimum mounting
height, test run the outboard motor at different
heights.
2. Check that the clamp brackets are secured
with the mounting bolts.
Recommend battery:
CCA / SAE (Minimum) : 380 (A)
CCA / EN (Minimum) : 430 (A)
RC (Minimum) : 124 (Minute)
20HR (Minimum) : 70 (AH)
JIS: 65D31-95E41
Electrolyte specified gravity:
1.280 at 20°C (68°F)
1-14
Predelivery checks
To make the delivery process smooth and effi-
cient, the predelivery checks should be com-
pleted as explained below.
Checking the fuel system
1. Check that the fuel hoses are securely con-
nected and that the fuel tank is full with fuel.
60H00000
Use pre-mixed fuel only.
Fuel and oil mixing ratio is 50:1. For break-
in period, 25:1 mixture shall be used.
Checking the gear oil
1. Check the gear oil level.
60H30450
Features and benefits / Propeller selection

60H5E11
GEN
INFO General information
FNR
Checking the steering system
1. Check that the steering operates smoothly.
60H10090
2. Check that there is no interference with
wires, hoses, or remote control cable when
the outboard motor is steered.
Checking the gearshift and throttle
operation
1. Check that the gearshift operates smoothly
when the remote control lever is shifted from
neutral into forward or reverse.
2. Check that the throttle operates smoothly
when the remote control lever is shifted from
the fully closed position to the fully open
position A.
S60C1210
Checking the tilt system
1. Check that the outboard motor tilts up and
down smoothly when operating the power
trim and tilt unit.
60H10095
1-15
Checking the remote control cables
1. Set the remote control lever to the neutral
position and fully close the throttle lever.
2. Check that the basic ignition timing adjust-
ing screw 1on the magnet control lever is
in contact with the stopper 2on the crank-
case when the throttle lever is in the fully
closed position.
60H30110
3. Check that the set pin on the shift rod is
aligned with the arrow mark Aon the bot-
tom cowling .
60H30427
60H10420
The shift/throttle cable joint must be screwed
in a minimum of 8.0 mm (0.31 in) B.B.
B.B.
B.