Yamaha F200C User manual

F200C
LF200C
F225C
LF225C
SERVICE MANUAL
69J-28197-1F-11LIT-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 out-
board 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.
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 consists 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.”

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 1to 6indicate specific data.
1Special tool
2Specified oil or fluid
3Specified engine speed
4Specified tightening torque
5Specified measurement
6Specified electrical value
(resistance, voltage, electric current)
Symbols 7to Ain an exploded diagram indicate the grade of lubricant and the lubrication point.
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)
Symbols Bto Gin an exploded diagram indicate the type of sealant or locking agent and the appli-
cation point.
BApply Gasket Maker®
CApply Yamabond No. 4
DApply LOCTITE®No. 271 (Red)
EApply LOCTITE®No. 242 (Blue)
FApply LOCTITE®No. 572
GApply silicon sealant
123456
T
R
.
.
7890A
E
A M D C
BCDEFG
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 pro-
cedures 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 pro-
tective 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 pro-
tect 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 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.
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
1Model name
2Approved model code
3Transom height
4Serial number
Model name Approved
model code
Starting
serial No.
F200TR 60L 1001799–
LF200TR 60M 1000373–
F225TR 69J 1007259–
LF225TR 69K 1002513–

69J1D11 1-6
1
2
3
4
5
6
7
8
9
Features and benefits 1
Newly developed V6 4-stroke engine
The F225 is a newly developed 60-degree V6 4-stroke engine with a very compact and lightweight
design. Its size and weight are almost the same as the V6 2-stroke engines that are in current use.
This F225 offers numerous advantages of a 4-stroke engine. Compared to conventional 2-stroke
models, it emits much cleaner exhaust gases, offers a better fuel economy, and realizes lower noise
levels at idle and full throttle.
Through the newly developed “In-bank exhaust system,”which discharges exhaust gases from the
center of both banks, the engine block and the surrounding equipment have been made compact. In
addition, the six independent intake passages help to achieve a high level of driveability and power
output.
1Electronic Fuel Injection
2In-bank exhaust system
3Pulse tuned long intake tracks
4Individual inside track fuel injectors
S69J1250
60˚
Identification / Features and benefits

GEN
INFO General information
1-7 69J1D11
Crankcase
The crankcase is made of cast aluminum, however steel has been cast into the areas for the crank-
shaft bearings. By distinguishing the area that requires strength from the area that allows the use of
a lighter material, both weight reduction and a stronger construction have been achieved.
The caps for the crankshaft bearings are secured with four bolts to ensure a high level of assembled
rigidity.
1Casted aluminum
2Steel
3Crankcase
4Cylinder block
Crankshaft
The crankshaft has been forged to realize a high-strength and high-rigidity construction. In the 60-
degree V6 cylinder configuration, the crankshaft pins are staggered 60 degrees from each other.
1Crankpin #1
2Crankpin #2
3Crankpin #3
4Crankpin #4
5Crankpin #5
6Crankpin #6
S69J1260
60˚
60˚
60˚
60˚
60˚
60˚
S69J1270

69J1D11 1-8
1
2
3
4
5
6
7
8
9
Piston
The piston has been carved out of a forged stock. To prevent the valves from coming in contact with
the piston, the piston is provided with a valve recess. If the engine goes out of timing and a valve
opens when the piston is at top-dead-center, this recess prevents the valve from coming in contact
with the piston, thus preventing engine damage.
1Valve spring
2Valve seal
3Piston
4Valve stem
5Intake valve
6Intake camshaft
7Valve lifter
8Valve recess
S69J1280
Features and benefits

GEN
INFO General information
1-9 69J1D11
Valve train system
The valve train consists of a total of four camshafts, with two in each bank.
The camshafts are driven with the combination of a belt and chains. The crankshaft turns the belt to
drive the exhaust camshafts in both banks. Chains connect the exhaust camshafts to the intake
camshafts in the cylinder heads to drive the intake camshafts.
In addition, the timing belt offers quieter operation, and the cam chains help to achieve a compact
configuration through the use of individual driven sprockets.
Timing belt
The timing belt, which is driven by the drive sprocket that is attached to the crankshaft, rotates the
driven sprockets that are attached to the exhaust camshafts of both banks. The drive sprocket for
the timing belt is secured to the crankshaft by four bolts, and it can be removed easily for servicing.
In addition, the material of the driven sprockets has been changed from the previous metal to plastic
for weight reduction.
1Driven sprocket
2Timing chain
3Intake camshaft
4Crankshaft
5Drive sprocket
6Timing belt
7Exhaust camshaft
8Hydraulic timing belt tensioner
S69J1290

69J1D11 1-10
1
2
3
4
5
6
7
8
9
Tensioner
A timing chain tensioner is provided at the mid-span of the timing chain, between both camshafts.
The timing chain tensioner uses the force of a spring to maintain its tension. After the engine is
started, oil is pumped into the tensioner, and the resulting pressure causes the tension to increase.
A total of three tensioners are used, one for the timing belt, and one for each timing chain of both
banks, to maintain proper tension and to ensure the reliability of the valve train.
1Intake camshaft
2Exhaust camshaft
3Timing chain
4Timing chain tensioner
5Hydraulic timing belt tensioner
S69J1300
Features and benefits

GEN
INFO General information
1-11 69J1D11
Intake system
Throttle valve
A total of six intake throttle valves are provided, one for each cylinder. Together with the intake
silencer that offers enhanced intake efficiency and the injectors that are provided at each throttle
body, the throttle valves help to improve the intake efficiency of the engine. As a result, this engine
produces a higher power output and realizes better driveability.
1Throttle valve
Exhaust system
In-bank exhaust system
The exhaust passage of the F225 is located in the V bank, a layout that is the opposite of conven-
tional V6 engines. By providing the exhaust passage in the V bank, the engine has been made con-
siderably more compact.
1Exhaust gas
S69J1310
S69J1320

69J1D11 1-12
1
2
3
4
5
6
7
8
9
Exhaust passage during idle
To reduce noise when the engine is idling, the exhaust gas passage of the F225 has adopted a lab-
yrinth construction. During idling, the exhaust gas passes through the passage on the side of the
exhaust guide, and enters the upper case through a hole in the upper case gasket. When it fills the
upper case, the exhaust gas enters another passage on the side of the exhaust guide through
another hole in the upper case gasket. Then, it is discharged through the idle port that is provided in
the upper case.
The exhaust manifold and muffler in the upper case are surrounded by the water jackets to reduce
exhaust noise. The water jackets also help prevent corrosion by preventing the exterior of the
exhaust manifold and muffler from coming in direct contact with the exhaust gas.
1Idle port
2Oil pan
3Exhaust manifold
4Muffler
ÈExhaust gas
ÉWater
S69J1330
Features and benefits

GEN
INFO General information
1-13 69J1D11
Fuel system
The fuel flows in the following order: fuel filter, low-pressure fuel pump, vapor separator, high-pres-
sure fuel pump, and injectors. The excess fuel at the injectors passes through the pressure regula-
tor and fuel cooler, and returns to the vapor separator.
When the engine start switch is turned on, the injectors of all cylinders operate before the pump
relay is actuated to prevent the injectors from sticking.
1Fuel filter
2Low-pressure fuel pump
3Vapor separator
4High-pressure fuel pump
5Fuel injector
6Pressure regulator
7Fuel cooler
S69J1340

69J1D11 1-14
1
2
3
4
5
6
7
8
9
Low-pressure fuel pump
The F225 has adopted a newly developed, low-pressure electrical fuel pump, in place of the low-
pressure mechanical fuel pump used in the previous electronic fuel injection system. With the adop-
tion of the electric pump, the routing of the fuel system has been made more compact. To prevent
the over-pumping of fuel, this pump operates for 10 seconds, and stops for 20 seconds when the
engine is operating at low speeds.
The pump operates constantly if the engine speed is 1,200 r/min or higher, or for several seconds
(which vary by ambient temperature) after the engine is started. At other times, it operates for 10
seconds, and stops for 20 seconds to prevent over-pumping.
1Vapor separator
2Low-pressure fuel pump
3Fuel filter
4On
5Off
610 seconds
720 seconds
S69J1350
Features and benefits

GEN
INFO General information
1-15 69J1D11
Electronic control system
The ECM controls the ignition timing, the fuel injection timing, the fuel injection volume, and the ISC
and it maintains a stoichiometric air-fuel ratio in all operating conditions, including starting and idling.
Also, the ECM converts the signals from the input sensors and sends instructions to each part.
B Z
T
P
P
~
S60L1180
Injector #1,4
40
ISC motor A
ISC motor B
ISC motor C
ISC motor D
Oil pressure warning lamp
Overheat warning lamp
Engine warning lamp
Buzzer
Tachometer
25
High-pressure fuel pump
Low-pressure fuel pump
Battery power source
Main relay
Connector pin position
Main relay
Battery
Rectifire/Regulator
Main switch 28
Power source
for diagnosis
lamp
36
Diagnosis signal
26
Personal
computer
Starboard bank
Port bank
Ground for power source 42
Ground for unit 32
Thermo switch 37
Neutral switch 31
6
Emergency engine stop switch 4
Shift cutoff switch 9
Oil pressure sensor 29
Power source for oil pressure sensor 10
Intake air temperature sensor 7
Engine temperature sensor 35
Ground for sensors 8
Intake air presssure sensor 33
TPS 34
Power source for intake air pressure sensor
11
Power source for TPS 12
Pulser coil #3 13
Pulser coil #2 14
Pulser coil #1 15
Vacancy
DES switch
Vacancy
Ignition coil #1,4
ECM
Ignition coil #2,5
Ignition coil #3,6
Injector #2,5
39
Injector #3,6
20
18
21
19
24
23
27
3
1
17
16
44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
30
2
22
44
43
38