Yamaha F200B, FL200B, F250G, FL250G Service Manual

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F200B

FL200B

F250G

FL250G

SERVICE MANUAL

6DX-28197-5P-11

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.

F200B, FL200B, F250G, FL250G

SERVICE MANUAL

1st Edition, July 2011

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd. is expressly prohibited.

Contents

General information

Specification

Technical features and description

Rigging information

Troubleshooting

Electrical system

GEN

INFO

SPEC

TECH

FEA

RIG

GING

TRBL SHTG

ELEC

Fuel system

Power unit

Lower unit

Bracket unit

Maintenance

Index

FUEL

POWR

LOWR

BRKT

MNT

Appendix

GEN

INFO

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

GEN

INFO

General information

Safety while working

To prevent an accident or injury and to provide 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.

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.

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.

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 consciousness 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 maintained.

0-1

Safety while working

Self-protection

• Protect your eyes by wearing safety glasses or safety goggles during all operations 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.

0-2

GEN

INFO

General information

Special service tool

Use the recommended special service tools to work safely, and to protect parts from damage.

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 identification mark is facing in the direction indicated 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.

0-3

Safety while working / How to use this manual

How to use this manual

Manual format

The format of this manual has been designed to make service procedures clear and easy to understand. 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 fig-

ure), 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.”

LOWR

Lower unit (regular rotation model)

47 N

No. Part name Q’ty Remarks

1 Water inlet cover (PORT) 1 2 Bolt 1 M5 40 mm 3Gasket 2 4 Drain screw 1 5 Water inlet cover (STBD) 1 6 Self-locking nut 1 7 Check screw 1 8Dowel 2

9Plate 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 17 Propeller nut 1

È U-transom model

8-1

Lower unit

33 32

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)

Not reusable

42 N m (4.2 kgf m, 31.0 ft lb)

47 N

m (4.7 kgf m, 34.7 ft lb)

54 N

m (5.4 kgf m, 39.8 ft lb)

LOWR

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.

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.

Driver rod LL 3: 90890-06605 Bearing outer race attachment 4:

90890-06658

Lower unit

NOTICE:

When heating

3 4

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.

Ball bearing attachment 6:

90890-06655

Bearing outer race puller assembly 7:

90890-06523

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.

Bearing inner race attachment 1:

90890-06659

8-19

0-4

GEN

INFO

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

CCA Cold Cranking Ampere

DN Down side

DOHC Dual Over Head Camshaft

ECM Electronic Control Module

General information

EN European Norm (European standard)

ETV Electronic Throttle Valve

EX Exhaust

EXH Exhaust

FForward

GPS Global Positioning System

IEC International Electro-technical Commission

IN Intake

INT Intake

ISC Idle Speed Control

ISO International Organization for Standardization

LAN Local Area Network

N Neutral

OCV Oil Control Valve

PCV Pressure Control Valve

PORT Port side

PTT Power Trim and Tilt

R Reverse

RON Research Octane Number

SAE Society of Automotive Engineers

STBD Starboard side

SW Switch

TCI Transistor-Controlled Ignition

TDC Top Dead Center

0-5

Abbreviation Description

TPS Throttle Position Sensor

UP Upside

VCT Variable Camshaft Timing

W/F Water in Fuel

YDIS Yamaha Diagnostic System

How to use this manual

0-6

GEN

INFO

General information

Lubricant, sealant, and thread locking agent

Symbol

Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points.

Symbol Name Application

Yamaha 4-stroke motor oil Lubricant

Gear oil Lubricant

Water resistant grease (Yamaha grease A)

Molybdenum disulfide grease Lubricant

Corrosion resistant grease (Yamaha grease D)

Low temperature resistant grease (Yamaha grease C)

WR-No.2 grease Lubricant

Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent and the application points.

Symbol Name Application

LOCTITE 518 Sealant

ThreeBond 1280B Sealant

Lubricant

0-7

ThreeBond 1303N Thread locking agent

ThreeBond 1322 Thread locking agent

ThreeBond 1324 Thread locking agent

ThreeBond 1377B Thread locking agent

Lubricant, sealant, and thread locking agent

Symbol Name Application

ThreeBond 1386B Sealant

ThreeBond 1401 Thread locking agent

ThreeBond 1530D Sealant

LOCTITE 242 (blue) Thread locking agent

LOCTITE 271 (red) Thread locking agent

LOCTITE 572 (white) Sealant

Silicone sealant Sealant

0-8

GEN

INFO

General information

Special service tool

For all markets except U.S.A. and Canada Special service tools with Yamaha part numbers (90890/60V-*****) are distributed by the Parts Division.

Drilling plate 90890-06783

YDIS (CD-ROM, Ver. 1.33) 60V-WS853-06

YDIS USB adapter and cable 60V-WS850-00

Peak voltage adapter 90890-03172

Test harness (3 pins) 90890-06869

Vacuum/pressure pump gauge set 90890-06756

Diagnostic flash indicator B 90890-06865

Digital circuit tester 90890-03174

0-9

Ignition tester 90890-06754

Test harness (2 pins) 90890-06867

Special service tool

Fuel pressure gauge adapter B 90890-06942

Fuel pressure gauge 90890-06786

Leakage tester 90890-06840

Flywheel magnet holder 90890-06522

Flywheel puller 90890-06521

Sheave holder 90890-01701

Compression gauge 90890-03160

Compression gauge extension 90890-06563

Valve spring compressor 90890-04019

Valve spring compressor attachment 90890-06320

0-10

GEN

INFO

General information

Valve guide remover/installer 90890-06801

Valve guide installer 90890-06810

Valve guide reamer 90890-06804

Valve seat cutter 30° (intake) 90890-06817

Valve seat cutter 30° (exhaust) 90890-06326

Valve seat cutter 45° (intake) 90890-06816

Valve lapper 90890-04101

Valve seat cutter holder 90890-06316

Valve seat cutter 45° (exhaust) 90890-06325

Valve seat cutter 60° (intake and exhaust) 90890-06324

0-11

Special service tool

Oil filter wrench 90890-06830

Driver rod L3 90890-06652

Needle bearing attachment 90890-06613

Needle bearing attachment 90890-06653

Shift rod socket 90890-06679

Bearing housing puller claw L 90890-06502

Needle bearing attachment 90890-06607

Piston ring compressor 90890-05158

Stopper guide plate 90890-06501

Center bolt 90890-06504

0-12

GEN

INFO

General information

Slide hammer handle 90890-06531

Bearing outer race puller assembly 90890-06523

Bearing separator 90890-06534

Needle bearing attachment 90890-06611

Driver rod SS 90890-06604

Needle bearing attachment 90890-06610

Stopper guide stand 90890-06538

Bearing puller assembly 90890-06535

Bearing depth plate 90890-06603

Bearing inner race attachment 90890-06640

0-13

Special service tool

Needle bearing attachment 90890-06654

Drive shaft holder 6 90890-06520

Pinion nut holder 90890-06715

Bearing inner race attachment 90890-06658

Bearing inner race attachment 90890-06659

Bearing outer race attachment 90890-06628

Ball bearing attachment 90890-06655

Driver rod LL 90890-06605

Driver rod LS 90890-06606

Backlash indicator 90890-06706

0-14

GEN

INFO

General information

Magnet base plate 90890-07003

Dial gauge set 90890-01252

Magnet base B 90890-06844

Ring nut wrench 90890-06578

Ball bearing attachment 90890-06557

PTT oil pressure gauge assembly 90890-06580

Pinion height gauge 90890-06672

Puller head 90890-06514

Cylinder-end screw wrench 90890-06568

PTT piston vice attachment 90890-06572

0-15

Tilt rod wrench 90890-06569

Special service tool

0-16

SPEC

Specification

Model features.................................................................... 1-1

General feature .......................................................................... 1-1

Model designation ...................................................................... 1-2

Serial number ............................................................................. 1-3

Model data .......................................................................... 1-4

Dimension and weight ................................................................ 1-4

Performance............................................................................... 1-4

Power unit .................................................................................. 1-4

Lower unit................................................................................... 1-5

Bracket unit ................................................................................ 1-5

Fuel and oil requirement............................................................. 1-5

Battery requirement.................................................................... 1-6

PTT fluid requirement................................................................. 1-6

Electrical system technical data....................................... 1-7

Ignition timing control system ..................................................... 1-7

Fuel injection control system ...................................................... 1-8

Engine speed control system ..................................................... 1-8

VCT system................................................................................ 1-9

PTT system ................................................................................ 1-9

Charging system ...................................................................... 1-10

Starting system......................................................................... 1-10

Gauge/sensor........................................................................... 1-11

Fuel system technical data ............................................. 1-11

Fuel system .............................................................................. 1-11

Power unit technical data................................................ 1-12

Power unit ................................................................................ 1-12

Cylinder head assembly ........................................................... 1-12

Crankcase assembly ................................................................ 1-13

Lower unit technical data ................................................ 1-15

Lower unit assembly (regular rotation model) .......................... 1-15

Lower unit assembly (counter rotation model) ......................... 1-15

Bracket unit technical data ............................................. 1-16

PTT system .............................................................................. 1-16

Specified tightening torque............................................. 1-17

Rigging information .................................................................. 1-17

Fuel system .............................................................................. 1-17

Power unit ................................................................................ 1-17

Lower unit (regular rotation model) .......................................... 1-19

Lower unit (counter rotation model).......................................... 1-19

Bracket unit .............................................................................. 1-19

PTT unit.................................................................................... 1-20

General tightening torque ............................................... 1-21

SPEC

Specification

Model features

General feature

F200B, FL200B, F250G, and FL250G Overall feature

• Electronic fuel injected, 60° V6, DOHC, 24-valves, VCT, 3352.0 cm

• 6Y8 Multifunction Meter for easy rigging and precision engine information

• Low emission in compliance with EU regulation

a Power unit

• Shimless valve lifters

• Multi-point electronic fuel injection

• Blowby gas reburning system

• Vapor gas treatment system

• Single electronic throttle body

• Long intake manifolds

• Large diameter intake valve heads

• In-bank exhaust system

• Speed sensor and water pressure sensor

(optional)

(204.5 cu. in) engine

b Electrical

• Electronic fuel injection control

• Digital ignition control

• VCT control

• Knock control

• Over-rev control

• Self-diagnosis system

• ETV control

• Fail-safe control

• Conventional or LAN gauges acceptable

• Water-cooled Rectifier Regulator with isola-

tor

c Upper case

• Anodized exhaust passages

d Lower unit

• Hard chromeplated water pump (outer plate cartridge and insert cartridge)

• Anodized lower case and propeller shaft housing (F250G and FL250G)

• Drive shaft spring (F250G and FL250G)

• Propeller damper cooling system (F250G

and FL250G)

1-1

Model designation

F 250 G E T X

12 3 4 5

Model features

None: 2-stroke E: Enduro F: 4-stroke

1 Model category

2 Output horsepower Example: 6/9.9/75/150/250/300 3 Model generation A/B/C/D/F/G/H/J/L/N/P/Q/R/S/T/U/V/X/Y (Repeat from A)

4 Model variation

L: Counter rotating propeller T: High thrust (4-stroke) D: Twin rotating propeller K: Kerosene Z: HPDI

Level 1: Starting method M: Manual start E: Electric start W: Electric start with manual start

Level 2: Control method None: Remote control without tiller handle H: Tiller handle C: Remote control with tiller handle

Level 3: Trim and tilt method None: Manual tilt D: Hydraulic tilt P: PT (Power tilt) T: PT/T (Power trim and tilt)

Transom height

(Drive shaft length)

Level 4: Lubrication system (2-stroke model) None: Premixed fuel with oil model O: Oil injection model

S (15 in) L (20 in) Y (22.5 in) X (25 in) U (31 in)

1-2

SPEC

Specification

Serial number

The outboard motor serial number is indicated on a label affixed to the port clamp bracket.

YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON

Model name

Approved

model code

Starting

serial No.

F200BET 6S1 1002876–

FL200BET 6S2 1001074–

F250GET 6DX 1000001–

FL250GET 6DY 1000001–

1 Model name 2 Approved model code 3 Transom height 4 Serial number

1-3

Model data

Dimension and weight

Model features / Model data

Item Unit

Overall length mm (in) Overall width mm (in) 634.0 (25.0) Overall height

X mm (in) U mm (in) 1956.0 (77.0)

Outboard motor transom height

X mm (in) 643.0 (25.3) U mm (in) 770.0 (30.3)

Weight (SUS)

X kg (lb) 283.0 (624) U kg (lb) 290.0 (639)

(*1) With SUS (stainless steel) propeller

(*1)

F200BET FL200BET F250GET FL250GET

Model

868.0 (34.2)

1829.0 (72.0)

Performance

Item Unit

Maximum output

At 5500 r/ min kW (HP) Full throttle operating range r/min Maximum fuel consumption

At 5500 r/min

Engine idle speed r/min

L (US gal,

Imp gal)/hr

F200BET FL200BET F250GET FL250GET

147.1 (200)

73.7 (19.5, 16.2) 75.6 (20.0, 16.6)

Model

5000–6000

600–700

183.9 (250)

Power unit

Item Unit

Type 4-stroke, DOHC Cylinder quantity V6 Total displacement cm Bore × stroke mm (in) 94.0 × 80.5 (3.70 × 3.17) Compression ratio 9.9 : 1 Control system Remote control Starting system Electric Fuel system Fuel injection Ignition control system TCI Advance type Microcomputer Maximum generator output V, A 12.0, 44.0 Spark plug LFR6A-11(NGK) Firing order 1–2–3–4–5–6 (Normal operation) Cooling system Water Exhaust system Propeller boss Lubrication system Wet sump

(cu. in) 3352.0 (204.5)

F200BET FL200BET F250GET FL250GET

Model

1-4

SPEC

Lower unit

Specification

Item Unit

Gear shift positions F-N-R Gear ratio 2.00 (30/15) Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline

Propeller direction (rear view)

Propeller mark T, M TL, ML T, M TL, ML

F200BET FL200BET F250GET FL250GET

Clock-

wise

Counter-

clockwise

Model

Clock-

wise

Counter-

clockwise

Bracket unit

Item Unit

Trim angle

At 12° boat transom degree –3 to 16 Tilt-up angle degree 70 Steering angle degree 32 + 32 Trim and tilt system PTT

F200BET FL200BET F250GET FL250GET

Model

Fuel and oil requirement

Item Unit

Fuel type Regular unleaded gasoline Minimum fuel octane number RON 84 90 Engine oil 4-stroke motor oil Engine oil grade (*1) (*2) API SE, SF, SG, SH, SJ, SL

SAE 5W-30, 10W-30, 10W-40 Total engine oil quantity (oil pan capacity) (*3) Gear oil type Hypoid gear oil

Gear oil grade (*2)

Gear oil quantity

(*1) If the recommended engine oil grades are not available, use engine oil with an API classifica-

tion of SH, SJ, or SL and an SAE classification of 15W-40, 20W-40, or 20W-50. (*2) Meeting both API and SAE requirements. (*3) For actual engine oil amount required at periodical oil check, see “Power unit technical data”

(1-12).

L (US qt,

Imp qt)

API GL-4

SAE 90

L (US qt,

Imp qt)

F200BET FL200BET F250GET FL250GET

1.150

(1.216,

1.012)

(1.057,

0.880)

Model

5.6 (5.92, 4.93)

1.000 (1.216,

1.012)

1.150

1.000

(1.057,

0.880)

1-5

Battery requirement

Model data

Item Unit

Minimum cold cranking amps

CCA/EN A 711.0

Minimum rated capacity

20HR/IEC Ah 100.0

F200BET FL200BET F250GET FL250GET

Model

PTT fluid requirement

Item Unit

Fluid type ATF Dexron II

F200BET FL200BET F250GET FL250GET

Model

1-6

SPEC

Specification

Electrical system technical data

Ignition timing control system

Item Unit

Spark plug

Gap mm (in) 1.0–1.1 (0.039–0.043)

Ignition coil

Input voltage V 12.0

Pulser coil

Air gap mm (in) 1.4–1.6 (0.055–0.063) Resistance (*1)

At 20 °C (68 °F) Ω 396.0–594.0

Output peak voltage

At cranking (unloaded) V 3.0 At cranking (loaded) V 2.7 At 1500 r/min (loaded) V 14.5 At 3500 r/min (loaded) V 17.8

Cam position sensor

Input voltage V 12.0

Knock sensor

Resistance (*1)

At 20 °C (68 °F) kΩ 504.0–616.0

Air temperature sensor

Resistance (*1)

At 20 °C (68 °F) kΩ 2.21–2.69 At 80 °C (176 °F) kΩ 0.32

Input voltage V 4.75–5.25

Neutral switch

Input voltage V 4.75–5.25

Air pressure sensor

Input voltage V 4.75–5.25 Output voltage

At –20.0 kPa (–0.20 kgf/cm At –46.7 kPa (–0.467 kgf/cm

Engine temperature sensor

Resistance (*1)

At 20 °C (68 °F) kΩ 54.2–69.0 At 100 °C (212 °F) kΩ 3.12–3.48

Thermoswitch

Input voltage (*1) V 11.4 Temperature

Switch ON °C (°F) 84–90 (183–194) Switch OFF °C (°F) 68–82 (154–180)

, –2.9 psi)

, –6.8 psi)

V3.21

V2.16

F200BET FL200BET F250GET FL250GET

Model

(*1) The figures are for reference only.

1-7

Fuel injection control system

Electrical system technical data

Item Unit

Fuel line

Pressure (*1)

Within 5 seconds after engine start switch turned to ON

At engine idle speed

Fuel injector

Resistance (*1)

At 20 °C (68 °F) Ω 12.0

Low-pressure fuel pump

Resistance (*1)

At 20 °C (68 °F) Ω 0.5–4.0

High-pressure fuel pump

Resistance (*1)

At 20 °C (68 °F) Ω 0.3–10.0

Vapor shut-off valve

Resistance (*1)

At 20 °C (68 °F) Ω 30.0–34.0

Water detection switch

Input voltage V 4.75–5.25

kPa

(kgf/cm

psi) kPa

(kgf/cm

psi)

F200BET FL200BET F250GET FL250GET

290.0 (2.90, 42.1)

260.0 (2.60, 37.7)

Model

(*1) The figures are for reference only.

Engine speed control system

Item Unit

Oil pressure sensor

Input voltage V 4.75–5.25 Output voltage (*1)

At 392.0 kPa (3.92 kgf/cm At 784.0 kPa (7.84 kgf/cm

APS

Resistance (*1)

With accelerator lever fully closed

With accelerator lever fully open

Output voltage (*1)

APS 1 and APS 2

, 56.8 psi)

, 113.7 psi)

At 20 °C (68 °F) kΩ 0.8

At 20 °C (68 °F) kΩ 5.3

V2.5

V4.5

F200BET FL200BET F250GET FL250GET

Model

1-8

SPEC

Specification

Item Unit

With remote control lever fully closed

APS 1 V 0.550–0.850

APS 2 V 0.400–1.000 With remote control lever fully open

APS 1 and APS 2 V Above 3.250

TPS

Output voltage (*1)

With throttle valve fully closed

TPS 1 V 0.500–0.700 With throttle valve fully open

TPS 2 V 4.600–4.700

Shift cut switch

Input voltage V 4.75–5.25

(*1) The figures are for reference only.

F200BET FL200BET F250GET FL250GET

Model

VCT system

Item Unit

OCV

Resistance (*1)

At 20 °C (68 °F) Ω 6.7–7.7

Input voltage V 12.0

(*1) The figures are for reference only.

F200BET FL200BET F250GET FL250GET

PTT system

Item Unit

Trim sensor

Free position resistance (*1)

At 20 °C (68 °F) Ω 247.6–387.6

Setting resistance Ω 9.0–11.0

(*1) The figures are for reference only.

F200BET FL200BET F250GET FL250GET

Model

1-9

Charging system

Electrical system technical data

Item Unit

Lighting coil

Resistance (*1)

At 20 °C (68 °F) Ω 0.11–0.17

Output peak voltage

At cranking (unloaded) V 8.3 At 1500 r/min (unloaded) V 44.7 At 3500 r/min (unloaded) V 97.7

Fuse A 60 Rectifier Regulator

Output peak voltage

At 1500 r/min (loaded) V 13.0 At 3500 r/min (loaded) V 13.0

(*1) The figures are for reference only.

F200BET FL200BET F250GET FL250GET

Model

Starting system

Item Unit

Starter motor

Type Sliding gear Output kW 1.4 Cranking time limit second 30

Brush

Standard length mm (in) 15.5 (0.61) Wear limit mm (in) 9.5 (0.37)

Commutator

Standard diameter mm (in) 29.0 (1.14) Wear limit mm (in) 28.0 (1.10) Standard undercut mm (in) 0.5–0.8 (0.02–0.03) Wear limit mm (in) 0.2 (0.01)

F200BET FL200BET F250GET FL250GET

Model

1-10

SPEC

Gauge/sensor

Specification

Item Unit

F200BET FL200BET F250GET FL250GET

Model

Water pressure sensor

Input voltage V 4.75–5.25 Output voltage (*1)

At 392.0 kPa (3.92

kgf/cm

, 56.8 psi)

At 784.0 kPa (7.84

kgf/cm

, 113.7 psi)

V2.5

V4.5

Speed sensor

Input voltage V 4.75–5.25 Output voltage (*1)

At 392.0 kPa (3.92

kgf/cm

, 56.8 psi)

At 784.0 kPa (7.84

kgf/cm

, 113.7 psi)

V2.5

V4.5

(*1) The figures are for reference only.

Fuel system technical data

Fuel system

Item Unit

F200BET FL200BET F250GET FL250GET

Fuel filter assembly

Holding pressure

kPa

Positive pressure

(kgf/cm

, psi) kPa

Negative pressure

(kgf/cm

, psi)

Primer pump

Holding pressure

kPa

Positive pressure

(kgf/cm

, psi)

Vapor separator tank

Float height mm (in) 67.5 ± 2.5 (2.66 ± 0.10)

Canister

Holding pressure

kPa

Positive pressure

(kgf/cm

, psi)

Model

200.0 (2.00, 29.0)

80.0 (0.80, 11.6)

170.0 (1.70, 24.7)

19.6 (0.196, 2.8)

1-11

Electrical system technical data / Fuel system technical data / Power unit technical data

Power unit technical data

Power unit

Item Unit

Cylinder

Minimum compression pressure (*1)

Engine oil

Oil pressure (*2)

At 60 °C (140 °F) with SL 10W-30 engine oil and at 650 r/min At 62 °C (144 °F) with SL 10W-30 engine oil and at 3000 r/min

Timing belt

Installation height mm (in) 2.0 (0.08) Replacement engine oil quantity (at periodic maintenance)

Without oil filter replacement

With oil filter replacement

kPa

(kgf/cm

psi)

kPa

(kgf/cm

psi) kPa

(kgf/cm

psi)

L (US qt,

Imp qt)

L (US qt,

Imp qt)

F200BET FL200BET F250GET FL250GET

630.0 (6.30, 91.4)

507.3 (5.073, 73.6)

700.6 (7.006, 101.6)

4.5 (4.76, 3.96)

4.7 (4.97, 4.14)

Model

(*1) Measuring conditions: Ambient temperature 20 °C (68 °F), wide open throttle, with spark plugs

removed from all cylinders. The figures are for reference only.

(*2) For details of the checking method, see “Checking the oil pressure” (7-1). The figures are for

reference only.

Cylinder head assembly

Item Unit

Cylinder head

Warpage limit mm (in) 0.10 (0.0039)

Journal inside diameter mm (in) 25.000–25.021 (0.9843–0.9851) Valve stem

Diameter

Intake mm (in) 5.477–5.492 (0.2156–0.2162) Exhaust mm (in) 5.464–5.479 (0.2151–0.2157)

Runout

Intake and exhaust mm (in) 0.010 (0.0004)

Valve guide

Inside diameter

Intake and exhaust mm (in) 5.504–5.522 (0.2167–0.2174)

Valve guide clearance

Intake mm (in) 0.012–0.045 (0.0005–0.0018) Exhaust mm (in) 0.025–0.058 (0.0010–0.0023)

Installation height mm (in) 12.500–12.900 (0.4921–0.5079)

F200BET FL200BET F250GET FL250GET

Model

1-12

SPEC

Specification

Item Unit

Valve spring

Free length mm (in) 48.1 (1.89)

Tilt mm (in) 1.7 (0.07) Valve lifter

Outside diameter mm (in) 30.970–30.980 (1.2193–1.2197)

Valve lifter clearance mm (in) 0.020–0.055 (0.0008–0.0022) Camshaft

Cam lobe height

Intake mm (in) 46.311–46.411 (1.8233–1.8272) Exhaust mm (in) 45.360–45.460 (1.7858–1.7898)

Cam lobe width

Intake and exhaust mm (in) 35.950–36.050 (1.4154–1.4193) Journal diameter mm (in) 24.960–24.980 (0.9827–0.9835) Runout mm (in) 0.015 (0.0006)

Valve

Clearance

Intake mm (in) 0.205 ± 0.035 (0.0081 ± 0.0014)

Exhaust mm (in) 0.345 ± 0.035 (0.0136 ± 0.0014) Head diameter

Intake mm (in) 36.400–36.600 (1.4331–1.4409)

Exhaust mm (in) 31.400–31.600 (1.2362–1.2441) Seat contact width

Intake mm (in) 1.100–1.400 (0.0433–0.0551)

Exhaust mm (in) 1.400–1.700 (0.0551–0.0669) Margin thickness

Intake mm (in) 0.500–0.900 (0.0197–0.0354)

Exhaust mm (in) 0.900–1.300 (0.0354–0.0512)

F200BET FL200BET F250GET FL250GET

Model

Crankcase assembly

Item Unit

Cylinder

Bore mm (in) 94.000–94.017 (3.7008–3.7014)

Piston

Diameter mm (in) 93.921–93.941 (3.6977–3.6985) Measuring point mm (in) 13.500 (0.5315) Piston clearance mm (in) 0.075–0.080 (0.0030–0.0031) Ring groove (top) mm (in) 1.230–1.250 (0.0484–0.0492) Ring groove (2nd) mm (in) 1.220–1.240 (0.0480–0.0488) Ring groove (oil) mm (in) 2.510–2.530 (0.0988–0.0996) Pin boss inside diameter mm (in) 21.021–21.031 (0.8276–0.8280) Pin outside diameter mm (in) 21.008–21.017 (0.8271–0.8274) Oversize diameter

1st mm (in) 94.176–94.186 (3.7077–3.7081)

1-13

F200BET FL200BET F250GET FL250GET

Model

Power unit technical data

Item Unit

Piston ring

Top ring

Type Barrel

Dimension height (B) mm (in) 1.200 (0.0472)

Dimension width (T) mm (in) 2.800–3.000 (0.1102–0.1181)

End gap (*1) mm (in) 0.200–0.300 (0.0079–0.0118)

Side clearance mm (in) 0.030–0.050 (0.0012–0.0020) 2nd ring

Type Taper

Dimension height (B) mm (in) 1.170–1.190 (0.0461–0.0469)

Dimension width (T) mm (in) 3.700–3.900 (0.1457–0.1535)

End gap (*1) mm (in) 0.300–0.450 (0.0118–0.0177)

Side clearance mm (in) 0.030–0.070 (0.0012–0.0028) Oil ring

Dimension height (B) mm (in) 2.400–2.470 (0.0945–0.0972)

Dimension width (T) mm (in) 2.300–2.700 (0.0906–0.1063)

End gap (*1) mm (in) 0.150–0.600 (0.0059–0.0236)

Side clearance mm (in) 0.040–0.130 (0.0016–0.0051)

Connecting rod

Small end inside diameter mm (in) 21.022–21.037 (0.8276–0.8282) Big end inside diameter mm (in) 53.015–53.035 (2.0872–2.0880) Big end side clearance mm (in) 0.150–0.300 (0.0059–0.0118) Oil clearance mm (in) 0.028–0.066 (0.0011–0.0026)

Crankshaft

Journal diameter mm (in) 62.968–62.992 (2.4791–2.4800) Crankpin diameter mm (in) 49.976–50.000 (1.9676–1.9685) Runout mm (in) 0.030 (0.0012) Crankpin width mm (in) 21.500–21.550 (0.8465–0.8484)

Crankcase

Oil clearance mm (in) 0.035–0.050 (0.0014–0.0020)

Thermostat

Valve opening temperature °C (°F) 58–62 (136–144) Valve opening stroke mm (in) 0.05 (0.0020) Fully open temperature °C (°F) 70 (158) Fully open stroke mm (in) 4.3 (0.17)

F200BET FL200BET F250GET FL250GET

Model

(*1) The figures are for reference only.

1-14

SPEC

Specification

Lower unit technical data

Lower unit assembly (regular rotation model)

Item Unit

Lower unit

kPa

psi)

Holding pressure

Forward gear backlash (*1) mm (in) 0.26–0.65 (0.0102–0.0256) Reverse gear backlash (*1) mm (in) 0.23–0.88 (0.0091–0.0346) Pinion shim (T3) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Forward gear shim (T1) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Reverse gear shim (T2) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50

Propeller shaft shim (T4) mm —

Propeller shaft

Free play mm (in) —

Runout mm (in) 0.02 (0.0008)

Drive shaft

Runout mm (in) 0.2 (0.008)

(*1) Figures obtained using the special service tools.

(kgf/cm

F200BET F250GET

Model

68.6 (0.686, 9.9)

1.80, 1.90, 2.00, 2.10,

2.20

0.20–0.50 (0.0079–

0.0197)

Lower unit assembly (counter rotation model)

Item Unit

Lower unit

kPa

psi)

Holding pressure

Forward gear backlash (*1) Reverse gear backlash (*1) mm (in) 0.43–0.96 (0.0169–0.0378) Pinion shim (T3) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Forward gear shim (T2) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Reverse gear shim (T1) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Propeller shaft shim (T4) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Propeller shaft

Free play mm (in) 0.25–0.35 (0.0098–0.0138) Runout mm (in) 0.02 (0.0008)

Drive shaft

Runout mm (in) 0.2 (0.008)

(*1) Figures obtained using the special service tools.

(kgf/cm

mm (in) 0.46–0.82 (0.0181–0.0323)

FL200BET FL250GET

Model

68.6 (0.686, 9.9)

1-15

Bracket unit technical data

PTT system

Lower unit technical data / Bracket unit technical data

Item Unit

PTT

Hydraulic pressure (*1)

MPa

Down

Motor brush

Standard length mm (in) 11.5 (0.45) Wear limit mm (in) 4.5 (0.18)

Motor commutator

Standard diameter mm (in) 23.0 (0.91) Wear limit mm (in) 22.0 (0.87) Standard undercut (*1) mm (in) 1.4 (0.06) Wear limit mm (in) 0.9 (0.04)

(*1) The figures are for reference only.

(kgf/cm

psi)

MPa

(kgf/cm

psi)

F200BET FL200BET F250GET FL250GET

6.7–8.7 (67.0–87.0, 971.5–1261.5)

13.0–15.0 (130.0–150.0, 1885.0–2175.0)

Model

1-16

SPEC

Specification

Specified tightening torque

Specified tightening torques are provided for specific nuts, bolts, and screws. When tightening these fasteners, follow the tightening torque specifications indicated throughout the manual to meet the design aims of the outboard motor.

Rigging information

Part to be tightened Screw size

Shift cable locknut Throttle cable locknut Negative battery cable nut Speed sensor Speed sensor adapter bolt Water pressure sensor Water pressure sensor adapter

Fuel system

Part to be tightened Screw size

Fuel cup assembly Intake silencer bolt Intake manifold bolt Throttle body nut Throttle damper plate bolt Canister holder bolt Canister bracket bolt Air pressure sensor bolt Vapor shut-off valve nut Low-pressure fuel pump cover bolt Pressure regulator holder screw Vapor separator cover bolt Float chamber cover screw Needle valve assembly screw Float pin screw Fuel cooler cover screw Vapor separator drain screw

— — — —

— —

—

M6 M6

—

M8 M6 M6 M6

—

M6 M5 M4 M4 M4 M4 M5

—

Tightening torques

N·mkgf·mft·lb

40.43.0

40.43.0 13 1.3 9.6 18 1.8 13.3 10 1.0 7.4 18 1.8 13.3 23 2.3 17.0

Tightening torques

N·mkgf·mft·lb

50.53.7

70.75.2 10 1.0 7.4 13 1.3 9.6 13 1.3 9.6

50.53.7

40.43.0

20.21.5

40.43.0

20.21.5

Power unit

Part to be tightened Screw size

Flywheel magnet nut — 240 24.0 177.0 Pulser coil screw M5 4 0.4 3.0 Power unit mounting bolt M10 42 4.2 31.0 PTT relay terminal bolt M6 4 0.4 3.0 Terminal stud bolt M10 26 2.6 19.2

Rectifier Regulator cover bolt

Rectifier Regulator bolt

1st 2nd 12 1.2 8.9 1st 2nd 12 1.2 8.9

Anode screw M4 3 0.3 2.2

1-17

Tightening torques

N·mkgf·mft·lb

60.64.4

Specified tightening torque

Part to be tightened Screw size

PTT relay terminal nut — 40.43.0 Engine ECM bolt M6 7 0.7 5.2 Timing belt tensioner bolt — 39 3.9 28.8 Pulley bolt M10 39 3.9 28.8

Cylinder head cover bolt

Ignition coil bolt M6 7 0.7 5.2 Spark plug — 25 2.5 18.4 Cylinder head cover plate screw M4 2 0.2 1.5 Adapter plug M14 23 2.3 17.0

Camshaft cap bolt

VCT cap — 32 3.2 23.6 VCT bolt M12 60 6.0 44.3 Driven sprocket bolt M10 60 6.0 44.3

Exhaust cover bolt

Exhaust outer cover plug M18 55 5.5 40.6 OCV bolt M6 7 0.7 5.2 Engine hanger bolt M6 12 1.2 8.9

Cylinder head bolt

Cylinder head bolt (When using a new bolt)

Cylinder head bolt (When reusing the bolt)

Oil pressure sensor — 18 1.8 13.3 Oil filter — 18 1.8 13.3 Oil filter union bolt UNF 34 3.4 25.1

Crankcase cover bolt

Cooling water passage cover bolt M6 12 1.2 8.9 Knock sensor — 32 3.2 23.6 Engine temperature sensor — 15 1.5 11.1 Oil pump cover screw — 40.43.0

Crankcase bolt

Crankcase bolt (length: 93 mm)

1st 2nd 8 0.8 5.9

1st 2nd 17 1.7 12.5

1st 2nd 12 1.2 8.9

1st 2nd 28 2.8 20.7 1st 2nd 60 6.0 44.3 3rd Loosen completely 4th 30 3.0 22.1 5th 60 6.0 44.3 6th 90° 1st 2nd 54 5.4 39.8 3rd Loosen completely 4th 27 2.7 19.9 5th 54 5.4 39.8 6th 90°

1st 2nd 28 2.8 20.7

1st 2nd 90° 1st 2nd 90°

M10

Tightening torques

N·mkgf·mft·lb

80.85.9

60.64.4

14 1.4 10.3

30 3.0 22.1

27 2.7 19.9

14 1.4 10.3

33 3.3 24.3

28 2.8 20.7

1-18

SPEC

Specification

Part to be tightened Screw size

Crankcase bolt (length: 55 mm)

1st 2nd 28 2.8 20.7

Tightening torques

N·mkgf·mft·lb

14 1.4 10.3

Anode bolt M5 7 0.7 5.2 Anode — 30.32.2 Thermostat cover plug M14 23 2.3 17.0

Connecting rod bolt

1st 2nd 23 2.3 17.0

13 1.3 9.6

3rd 90°

Lower unit (regular rotation model)

Part to be tightened Screw size

Check screw

—

Trim tab bolt M10 42 4.2 31.0 Propeller nut

—

Lower case mounting bolt M10 47 4.7 34.7 Drain screw Lower case mounting nut (U-transom model)

— —

Water inlet cover screw M5 1 0.1 0.7 Propeller shaft housing bolt M8 29 2.9 21.4 Grease nipple Pinion nut

— —

Tightening torques

N·mkgf·mft·lb

90.96.6

55 5.5 40.6

90.96.6 47 4.7 34.7

60.64.4

142 14.2 104.7

Lower unit (counter rotation model)

Part to be tightened Screw size

Check screw

—

Trim tab bolt M10 42 4.2 31.0 Propeller nut

—

Lower case mounting bolt M10 47 4.7 34.7 Drain screw Lower case mounting nut (U-transom model) Ring nut

— — —

Water inlet cover screw M5 1 0.1 0.7 Propeller shaft housing bolt M8 29 2.9 21.4 Grease nipple Pinion nut

— —

Tightening torques

N·mkgf·mft·lb

90.96.6

55 5.5 40.6

90.96.6 47 4.7 34.7

108 10.8 79.7

60.64.4

142 14.2 104.7

Bracket unit

Part to be tightened Screw size

Neutral switch screw M4 2 0.2 1.5 Shift cut switch screw M4 2 0.2 1.5 Grease nipple (shift bracket) Shift bracket bolt Shift rod detent bolt

— — —

Flushing hose adapter screw ø650.53.7

Tightening torques

N·mkgf·mft·lb

10.10.7 19 1.9 14.0 18 1.8 13.3

1-19

Specified tightening torque

Part to be tightened Screw size

Upper mounting nut Lower mounting nut Upper mount bracket bolt M10 54 5.4 39.8 Engine oil drain bolt M14 28 2.8 20.7 Baffle plate screw M6 4 0.4 3.0 Apron stay

Oil pan assembly bolt

PCV Oil strainer bolt M6 12 1.2 8.9 Oil pan bolt M8 20 2.0 14.8 Exhaust manifold bolt M8 20 2.0 14.8 Muffler bolt M8 20 2.0 14.8 Grease nipple (clamp bracket and swivel bracket) Self-locking nut (through tube) Trim sensor screw M6 4 0.4 3.0 Friction plate screw M6 4 0.4 3.0

— —

—

M8 20 2.0 14.8

M10 42 4.2 31.0

—

Tightening torques

N·mkgf·mft·lb

72 7.2 53.1 72 7.2 53.1

80.85.9

30.32.2

22 2.2 16.2

PTT unit

Part to be tightened Screw size

PTT unit bolt M10 42 4.2 31.0 Reservoir cap PTT motor bolt M8 19 1.9 14.0 Reservoir bolt M8 19 1.9 14.0 Gear pump bolt M5 7 0.7 5.2 Gear pump bracket bolt M5 7 0.7 5.2 Manual valve Tilt ram Tilt cylinder end screw Tilt piston bolt Trim cylinder end screw Pipe joint adapter Pipe joint

—

— — — — — — —

Tightening torques

N·mkgf·mft·lb

70.75.2

20.21.5 65 6.5 47.9 90 9.0 66.4

70.75.2

160 16.0 118.0

20 2.0 14.8 15 1.5 11.1

1-20

SPEC

Specification

General tightening torque

This chart indicates the tightening torques for standard fasteners with a standard ISO thread pitch.

Width

across

flats (A)

8 mm M5 5 0.5 3.7 10 mm M6 8 0.8 5.9 12 mm M8 18 1.8 13.3 14 mm M10 36 3.6 26.6 17 mm M12 43 4.3 31.7

Screw

size (B)

General torque

specifications

N·mkgf·mft·lb

1-21

TECH

FEA

Technical features and description

Electronic control system ................................................. 2-1

Engine control system component ............................................. 2-2

Actuator, sensor, and switch ...................................................... 2-3

Electronic fuel injection control................................................... 2-4

Digital ignition control ................................................................. 2-5

VCT control ................................................................................ 2-6

Knock control.............................................................................. 2-7

Over-rev control and alert control............................................... 2-8

ETV control................................................................................. 2-9

Fail-safe control........................................................................ 2-10

Power unit system ........................................................... 2-11

Shimless valve lifter.................................................................. 2-11

Fuel system ...................................................................... 2-12

Fuel diagram ............................................................................ 2-12

Blowby gas reburning system .................................................. 2-14

Vapor gas treatment................................................................. 2-15

Lubrication system .......................................................... 2-16

Lubrication diagram.................................................................. 2-16

Cooling system ................................................................ 2-17

Cooling diagram ....................................................................... 2-17

Intake and exhaust system ............................................. 2-21

Intake and exhaust diagram ..................................................... 2-21

Lower unit ......................................................................... 2-22

Drive shaft spring (F250G and FL250G) .................................. 2-22

Propeller damper cooling (F250G and FL250G) ...................... 2-23

TECH

FEA

Technical features and description

Electronic control system

These models use electronic fuel injection control, digital ignition control, VCT control, knock control, over-rev control, alert control, ETV control, and fail-safe control. The engine ECM performs these controls according to the signals sent from various sensors and switches. In addition, the engine ECM has a self-diagnosis function to perform troubleshooting using the YDIS. The 6Y8 Multifunction Meter can be installed as an option.

Air (cowl inside)

Air (cowl outside)

High-pressure fuel pump

Vapor separator

OCV

Ignition coil

Check valve

Filter

Check valve

Fuel injector

Canister

Low-pressure fuel pump

Water separator

Fuel

Water detection switch

Vapor shut-off valve

Air

ETV

TPS

2-1

6Y8 Multi-

function

Meter

OCV

Throttle control

Valve control

Fuel control

Ignition control

Battery

Fuel injector

Engine

ECM

Cam position sensor Pulser coil Air pressure sensor Oil pressure sensor Engine temperature sensor Air temperature sensor Knock sensor APS Shift cut switch Neutral switch Thermoswitch Engine shut-off switch

Water pressure sensor (optional) Speed sensor (optional)

Engine control system component

Electronic control system

1 OCV (STBD) 2 Thermoswitch (STBD) 3 APS 4 Neutral switch 5 Shift cut switch 6 Fuel injector (STBD) 7 Cam position sensor (STBD IN) 8 Ignition coil (STBD) 9 Knock sensor 0 Engine ECM A Ignition coil (PORT) B Cam position sensor (PORT EX) C Pulser coil

D Engine temperature sensor E Thermoswitch (PORT) F OCV (PORT) G Cam position sensor (PORT IN) H Fuel injector (PORT) I High-pressure fuel pump J Low-pressure fuel pump K TPS L Oil pressure sensor M ETV N Air pressure sensor O Vapor shut-off valve P Air temperature sensor

2-2

TECH

FEA

Actuator, sensor, and switch

Engine ECM Determines the engine operating conditions according to the input

Pulser coil Detects the engine speed.

Cam position sensor (PORT EX)

Cam position sensor (PORT IN) Cam position sensor (STBD IN) APS 1 Detect the throttle opening. APS 2 is the main sensor and APS 1 is APS 2

TPS 1 Detect the throttle valve opening. TPS 1 is the main sensor and TPS 2

ETV Opens and closes the throttle valve using a motor. Air pressure sensor Detects the intake air pressure. Air temperature sensor Detects the intake air temperature. Engine temperature sensor Oil pressure sensor Detects the oil pressure. Thermoswitch Detects engine overheating. Knock sensor Detects engine knocking. Shift cut switch Detects when the gear shift moves to the N position. Neutral switch Detects when the gear shift is in the N position. Engine shut-off switch Activates the engine stop function compulsorily. Fuel injector Injects fuel. Ignition coil Activates the ignition. Vapor shut-off valve Controls the amount of vapor gas to be sent from the vapor

OCV Advances or retards the camshaft timing by switching the oil

High-pressure fuel pump Pressurizes the fuel in the vapor separator, and sends the fuel to

Low-pressure fuel pump Sends the fuel from the fuel tank to the vapor separator.

Technical features and description

signals from the sensors, which are installed at various locations on the engine, and sends output signals to operate the actuators to perform the various control functions.

Performs troubleshooting using a self-diagnosis function.

Detects the crankshaft angle and piston positions. Determines each group of cylinders (#1 and #4, #2 and #5, and #3

and #6). Determines the stroke. (For example, distinguishes the compression stroke TDC from the exhaust stroke TDC.) Determines each group of cylinders (#1 and #4, #2 and #5, and #3

and #6). Determines the stroke of each cylinder according to the signals from

both the pulser coil and the cam position sensor (PORT EX). Detects the advance angle on the port camshaft.

Detects the advance angle on the starboard camshaft.

the sub sensor. APS 1 and APS 2 mutually monitor each other for malfunctions.

TPS 2 is the sub sensor. TPS 1 and TPS 2 mutually monitor each other for malfunctions.

Detects the engine temperature.

separator to the intake system.

passages through which the engine oil is sent into the advance chamber or the retard chamber in the rotor vane housing.

the fuel rails.

2-3

Electronic control system

Electronic fuel injection control

In electronic fuel injection control, the engine ECM calculates the precise air and fuel mixture required in each combustion chamber depending on the load and engine speed in order to increase combustion efficiency. The fuel injection amount is controlled by the fuel injector actuation time. There are 2 types of fuel injection timing control: synchronous fuel injection and asynchronous fuel injection. According to the engine operating conditions during the control, the control mode switches automatically between the start-up mode, normal operating mode, and fuel injection cutoff mode. In addition, a multi-point fuel injection system provides the appropriate fuel injection amount for all weather conditions. As a result, the outboard motor starts quickly the first time the engine start switch is turned to START. Also, a fuel injector anti-sticking control has been adopted.

Pulser coil

Cam position sensor

(PORT EX)

Cam position sensor

(PORT IN)

Cam position sensor

(STBD IN)

APS

TPS

Air pressure sensor

Air temperature sensor

Engine temperature sensor

Fuel injector

Engine

ECM

Vapor shut-off

valve

Neutral switch

Engine shut-off switch

Battery

Engine start switch

2-4

TECH

FEA

Digital ignition control

In digital ignition control, the engine ECM determines the optimum ignition timing according to the signals from the sensors and sends the primary current to the ignition coils. According to the engine operating conditions, the basic ignition timing and ignition coil energization time are determined. In addition, various restrictions and compensations are made to determine the actual ignition timing. The ignition timing is also controlled according to the knock control. See “Knock control” (2-7).

Pulser coil

Cam position sensor

(PORT EX)

Cam position sensor

(PORT IN)

Cam position sensor

(STBD IN)

APS

Technical features and description

TPS

Air pressure sensor

Air temperature sensor

Engine temperature sensor

Knock sensor

Shift cut switch

Engine shut-off switch

Battery

Engine

ECM

Ignition coil

Engine start switch

2-5

Electronic control system

VCT control

In VCT control, the engine ECM determines the appropriate intake valve opening timing according to the signals from the sensors. According to the engine operating conditions, the OCVs are operated and the VCT assemblies advance and retard the intake valve opening timing in order to increase the intake and exhaust efficiency at low and mid-range engine speeds and obtain greater acceleration.

Pulser coil

Cam position sensor

(PORT EX)

Cam position sensor

(PORT IN)

Cam position sensor

(STBD IN)

TPS

Engine

ECM

OCV (PORT)

OCV (STBD)

Engine temperature sensor

2-6

TECH

FEA

Knock control

In knock control, the engine ECM receives the knock signal from the knock sensor, which is installed on the cylinder block between the cylinder banks. The engine ECM retards the ignition timing and decreases the engine speed according to the amount of knocking to protect the engine from damage. If the knocking occurs frequently, the ignition timing is retarded until the knocking is no longer detected, and the retarded ignition timing is maintained. Also, a learning function for the knock control has been adopted. The knock control activates according to the following conditions:

temperature

Engine speed

Less than 4500 r/min Knock control does

4500 r/min or more Knock control

Technical features and description

Engine

Less than 20 °C

(68 °F)

not activate

20–25 °C (68–77 °F)

Knock control activates if conditions continue for 0.5 second

activates

More than 25 °C

(77 °F)

Knock control activates

The knock control also activates when the engine temperature sensor is malfunctioning regardless of the preceding conditions.

2-7

Electronic control system

Over-rev control and alert control

In over-rev control and alert control, the engine ECM decreases the engine speed to protect the engine from damage.

Pulser coil

TPS

Fuel injector

Engine temperature sensor

Oil pressure sensor

Engine

ECM

Thermoswitch

Ignition coil

Shift cut switch

Battery

Engine start switch

6Y8 Multifunction

Meter

2-8

TECH

FEA

ETV control

In ETV control, the engine ECM determines the appropriate throttle valve opening according to the signals from the sensors, and controls the throttle valve. The engine ECM is equipped with a learning function that records all of the compensations made by the control to the throttle valve opening for the operating conditions up to that point. In addition, the engine idle speed is controlled using the ETV control.

APS

TPS

Engine temperature sensor

Technical features and description

ETV motor

Shift cut switch

Neutral switch

Battery

Engine start switch

Engine

ECM

Fuel injector

2-9

Electronic control system

Fail-safe control

In fail-safe control, the engine ECM enters the fail-safe mode when an electrical component malfunctions. The fail-safe control system records the trouble codes according to the engine trouble conditions.

Trouble

code

13 Pulser coil C/E No signal

Engine

17 Knock sensor C/E Output voltage is less than 0.90 V or more than 4.00 V.

24, 71, 72Cam position

28 Neutral switch C/E Neutral switch is off during the start-up mode.

73, 74 OCV C/E Open or short circuit in the OCV circuit. 112, 113, 114, 115, 116, 117, 118, 119, 121, 122, 123, 129, 136, 137, 138, 139, 141, 142, 143, 144,

145

124, 125, 126, 127,

128

131, 132, 133, 134,

135

temperature sensor

Air temperature sensor

sensor

Air pressure sensor Oil pressure sensor C/E

Shift cut switch

Thermoswitch

ETV

TPS

APS

Item

LAN

gauge

display

C/E

Trouble conditions to be detected

Open or short circuit in the engine temperature sensor circuit. Output voltage is less than 0.18 V or more than

4.90 V.

Output voltage is less than 0.10 V or more than 4.60 V.

Signal error (irregular)

Output voltage is less than 0.20 V or more than 4.50 V.

Output voltage is less than 0.30 V, more than 4.80 V for 260 seconds, or more than 4.80 V when the engine is stopped. Output voltage is more than 4.50 V, the shift cut switch is on during the start-up mode, or both the neutral switch and shift cut switch are on for 5 seconds. Switch is on when the engine temperature is 40 °C (104 °F) or less, or off when the engine temperature is more than 120 °C (248 °F).

Open or short circuit in the ETV relay and ETV motor circuit.

TPS 1 output voltage is less than 0.35 V or more than

4.80 V, TPS 2 output voltage is less than 2.25 V or more than 4.80 V, or the output voltage difference between TPS 1 and TPS 2 is 2.30 V or more. Open or short circuit in the APS circuit, or the output voltage difference between APS 1 and APS 2 is 0.996 V or more.

2-10

TECH

FEA

Technical features and description

Power unit system

These models are equipped with a V6, 4-stroke engine that has 60° cylinder banks. The power unit features shimless valve lifters, a blowby gas reburning system, a vapor gas treatment system, a single electronic throttle body, long intake manifolds, large diameter intake valve heads, and an inbank exhaust system. The F(L)250G is a new high-output outboard motor for use in various environments. The outboard motor has adopted structural features that improve durability. The F(L)200B is an outboard motor for commercial use.

Shimless valve lifter

Newly designed valve lifters 1 have been adopted instead of the usual valve shims 2. The valve lifters are available in different thicknesses a. Therefore, the valve clearance b can be adjusted by replacing the current valve lifter with a new valve lifter of the appropriate thickness.

Previous V6 model

New V6 model

2-11

Fuel system

Fuel diagram

Power unit system / Fuel system

Primer pump

Fuel filter (with water

separator and water

detection switch)

Low-pressure

fuel pump

Check valve

Filter

Float chamber

Vapor separator assembly

Fuel rail (PORT)

Boat fuel filter (optional)

Canister

Vapor shut-off valve

High-pressure

fuel pump

Boat fuel tank

Check valve

Pressure regulator

Atmosphere (cowl inside)

Atmosphere (cowl outside)

Surge tank

Fuel rail (STBD)

Fuel

injector #6

Intake manifold (PORT)

Combustion chamber #6

È Fuel flow É Air flow Ê Vapor gas flow

injector #4

Combustion chamber #4

Fuel

injector #2

Combustion chamber #2

Fuel

injector #1

Intake manifold (STBD)

Combustion

chamber #1

Fuel

injector #3

Combustion chamber #3

Fuel

injector #5

Combustion chamber #5

È É

2-12

TECH

FEA

Technical features and description

È From the fuel tank

1 Primer pump 2 Fuel filter assembly (with water separator) 3 Low-pressure fuel pump 4 Vapor separator 5 Fuel cooler 6 High-pressure fuel pump 7 Pressure regulator 8 Fuel rail (PORT) 9 Fuel rail (STBD) 0 Fuel injector

2-13

Fuel system

Blowby gas reburning system

A blowby gas reburning system removes any unburned fuel from the blowby gases and sends it to the combustion chambers to be burned.

È Blowby gas flow É Engine oil

1 Intake silencer 2 Blowby gas separator (integrated with cylinder head cover)

È É

2-14

TECH

FEA

Vapor gas treatment

Vapor gases from the vapor separator are collected in the canister, and then gradually discharged into the atmosphere after being absorbed and cleaned by the activated charcoal. After the engine is started, the vapor gases in the canister are drawn into the surge tank through the vapor shut-off valve, which is controlled by the engine ECM, and then sent to the intake manifolds and combustion chambers.

Technical features and description

Combustion chamber Intake manifold

Atmosphere (cowl inside)

Atmosphere (cowl outside)

È Air flow É Vapor gas flow

Check valve

Surge tank

Vapor shut-off valve

Canister

Vapor separator

È É

2-15

Lubrication system

Lubrication diagram

Fuel system / Lubrication system

Piston

Crankpin

(connecting rod big end)

Crankshaft

main journal

Cylinder head

Main gallery

Oil filter

Oil pump with

relief valve

Oil strainer

OCV

Camshaft journal

Oil pressure sensor

Oil pan

Camshaft

passage hole

VCT assembly

Valve and related parts

È Engine oil flow

1 Oil pan 2 Oil strainer 3 Oil pump with relief valve

4 Oil filter 5 Oil pressure sensor 6 OCV 7 VCT assembly

2-16

TECH

FEA

Cooling system

Cooling diagram

Technical features and description

Thermostat (PORT) Thermostat (STBD)

Cylinder block

Flushing device

Muffler

Upper case

Lower case

Exhaust cover (PORT)

Cylinder head (PORT) Cylinder head (STBD)

Cylinder block

Exhaust guide

PCV

Exhaust guide

Exhaust cover (STBD)

Upper

Fuel cooler

Lower

Oil pan

Water pump

Rectifier Regulator

Propeller boss

Trim tab

Water inlet

Water

È Cooling water flow É When flushing the cooling water passage Ê Dynamic water pressure when the boat is cruising (F250G and FL250G)

2-17

Pilot hole

Cooling system

È Cooling water flow É F(L)200B Ê F(L)250G

ÊÉ

1 Water inlet 2 Water pump 3 Oil pan 4 Exhaust guide 5 PCV 6 Thermostat

2-18

TECH

FEA

Technical features and description

È Cooling water flow

1 Cooling water hose (cylinder block to joint) 2 Cooling water hose (joint to joint) 3 Cooling water hose (joint to joint) 4 Cooling water hose (joint to joint) 5 Cooling water hose (joint to joint) 6 Cooling water hose (joint to joint) 7 Cooling water hose (joint to joint) 8 Cooling water hose (thermostat cover

[STBD] to joint)

9 Cooling water hose (joint to cylinder block) 0 Cooling water hose (thermostat cover

[PORT] to cylinder block)

A Cooling water hose (joint to Rectifier

Regulator)

B Cooling water hose (Rectifier Regulator to

joint)

C Cooling water hose (joint to fuel cooler) D Cooling water hose (fuel cooler to joint) E Cooling water hose (joint to joint) F Cooling water pilot hose (joint to cooling

water pilot hole)

G Cooling water hose (cylinder head [STBD]

to adapter [water pressure sensor])

H Flushing hose (flushing hose adapter to

joint)

2-19

Cooling system

I Flushing hose (joint to cooling water

passage cover)

J Speedometer hose

a Fuel cooler b Rectifier Regulator c Cooling water pilot hole (on the bottom

cowling)

d Adapter (water pressure sensor) e Water passage cover (on the cylinder

block)

2-20

TECH

FEA

Technical features and description

Intake and exhaust system

The single electronic throttle valve, which is operated by the engine ECM, enables precise control of the intake air. The intake air is smoothly routed into each combustion chamber through the surge tanks and the long intake manifolds for greater power. The long intake manifolds are designed to increase air flow, thereby boosting low and mid-range torque and resulting in quicker acceleration. The intake system has adopted intake valves with large diameter valve heads to increase the charging efficiency of the intake air. The exhaust gases are cooled with water as they pass through the in-bank exhaust system. For increased performance, the gases are smoothly vented straight down and out through the propeller. The exhaust gas passages are anodized to protect the lower unit from corrosion.

Intake and exhaust diagram

È Intake air flow É Exhaust gas flow

1 Throttle body 2 Surge tank 3 Intake manifold

2-21

È É

4 Exhaust cover 5 Exhaust guide 6 Exhaust manifold 7 Muffler 8 Propeller

Intake and exhaust system / Lower unit

Lower unit

The outer plate cartridge and insert cartridge of the water pump are hard chromeplated for durability and to protect the parts from abrasion due to muddy water. The lower case and propeller shaft housing are anodized.

Drive shaft spring (F250G and FL250G)

The spring pushes the drive shaft toward the water pump and stabilizes the thrust free play of the shaft.

È Spring force É Water pump side

1 Pinion shim 2 Thrust bearing 3 Drive shaft 4 Thrust bearing 5 Spring 6 Washer

2-22

TECH

FEA

Propeller damper cooling (F250G and FL250G)

The water pipe for cooling the propeller damper is incorporated in the lower case. The water intake is located in front of the trim tab to drawn in the water by the dynamic pressure, and the propeller damper is cooled without disturbing the exhaust gas flow. As a result, higher output can be obtained.

Technical features and description

È Cooling water flow

1 Water pipe

2-23

RIG

GING

Rigging information

Outboard motor installation.............................................. 3-1

External dimensions .......................................................... 3-2

F200BET, FL200BET, F250GET, FL250GET............................ 3-2

Clamp bracket ............................................................................ 3-3

Crate top cover pictograph description........................... 3-4

Uncrating procedure.......................................................... 3-5

Outboard motor mounting................................................. 3-6

Outboard motor mounting height..................................... 3-8

Rigging grommet mounting .............................................. 3-9

Rigging grommet description...................................................... 3-9

Installing the shift cable and throttle cable ................................. 3-9

Installing the wiring harness ..................................................... 3-11

Installing the isolator lead (optional)......................................... 3-11

Installing the battery cable........................................................ 3-12

Installing the speed sensor (optional)....................................... 3-12

Installing the water pressure sensor (optional)......................... 3-13

Installing the rigging grommet .................................................. 3-14

Remote control box and switch panel installation........ 3-15

Battery installation........................................................... 3-16

Battery cable routing without house (accessory) battery.......... 3-16

Battery cable routing with house (accessory) battery............... 3-18

System diagram ............................................................... 3-22

Single outboard motor application............................................ 3-22

Twin outboard motor application .............................................. 3-24

Triple outboard motor application............................................. 3-26

Rigging recommendation................................................ 3-28

Extension length recommendation for battery cable ................ 3-28

Propeller selection ........................................................... 3-29

Propeller size............................................................................ 3-29

Selection................................................................................... 3-29

RIG

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Rigging information

Outboard motor installation

• Overpowering a boat could cause severe instability. Do not mount an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer.

• Improper mounting of the outboard motor could result in hazardous conditions, such as poor handling, loss of control, or fire hazards. Consult your dealer or have a Yamaha trained person experienced in proper rigging mount the outboard motor.

Too much weight on the transom could change the center of gravity, buoyancy, operating balance, or performance of the boat, which could cause loss of control or swamping. Consult the boat manufacturer for the maximum engine weight allowable on the transom, which is different from the overall boat capacity. Overloading the transom with an outboard motor that is too heavy could also damage the hull, transom, deck, or helm area, as well as the outboard motor and other equipment.

Before mounting the outboard motor, consult the manufacturer of the engine jack plates or brackets. Excessive loads could damage the engine jack plates, brackets, boat transom, steering system, or engine. This could cause loss of control.

3-1

Outboard motor installation / External dimensions

External dimensions

F200BET, FL200BET, F250GET, FL250GET

453 (17.8)

mm (in)

(*1) T1

723.9 (28.5)

32˚

902 (35.5)

X: 643 (25.3)

X: 1078 (42.4)

U: 1205 (47.4)

752 (29.6)

387 (15.2)

39 (1.5)

(*2)

U: 770 (30.3)

216 (8.5)

219 (8.6)

45 (1.8)

230 (9.1)

317 (12.5)

59 (2.3)

651 (25.6)

75 (3.0)

X: 1155 (45.5)

U: 1272 (50.1)619 (24.4)

67˚

X: 847 (33.3)

U: 924 (36.4)

12˚

(1.0)

X: 52 (2.0) U: 59 (2.3)

–3˚

673 (26.5)

(*1) Minimum distance between the outboard motors in twin or triple installation (*2) Transom height

TIP:

The dimension values may include reference values.

3-2

RIG

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Clamp bracket

Rigging information

mm (in)

180 (7.1)

163.5 (6.4)

180 (7.1)

163.5 (6.4)

411 (16.2)

13 (0.5)

50.8 (2.0)

79 (3.1)

20 (0.8)

254 (10.0)

18.5 (0.7)

55.5 (2.2)

102 (4.0)102 (4.0)

125.4 (4.9)125.4 (4.9)

TIP:

The dimension values may include reference values.

3-3

52 (2.0)

External dimensions / Crate top cover pictograph description

Crate top cover pictograph description

The following pictographs are important when handling the crate. Read the notice and understand what each pictograph means to prevent damage to the outboard motor when handling, transporting, and storing the crate.

Stack limit: Maximum units for storage

Upward

Handle with care

Avoid water

Product barycentric position

Lifting fork insert position

IMPORTANT

This unit delivered to carrier in a good condition. For protection against loss due to damage, inspect thoroughly. If damage is noted, make note on freight bill. Shipper assumes no further liability to the transportation company. Your claim should be filed against carrier for damage of any nature.

3-4

RIG

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Rigging information

Uncrating procedure

1. Check the crate for shipping damage.

2. Remove the top cover.

3. Remove all of the bolts from the bottom

plate, and then remove the frame.

NOTICE: Be careful not to damage the outboard motor.

4. Remove the wrapping, and then check

the outboard motor for concealed damage.

5. Remove the top cowling, and then

remove the flywheel magnet cover 1.

6. Install a lifting harness 2 to the engine

hangers 3.

9. Remove the skeg holder 5.

10. Remove the bolts 6.

7. Tension the lifting harness.

8. Lift up the outboard motor along with the

bottom plate 4 carefully. NOTICE: Make

sure that the lifting harness does not damage any parts of the outboard motor.

3-5

11. Remove the steering retainer, and then install a hydraulic steering cylinder following the recommendation of the manufacturer.

Uncrating procedure / Outboard motor mounting

Outboard motor mounting

Proper mounting of the outboard motor provides better performance, maximum reliability, and the highest customer satisfaction. This chapter contains the specifications necessary to mount the outboard motor, and may vary slightly depending on applications. When mounting the outboard motor, make sure that there is sufficient clearance for the outboard motor to fully tilt up, and to fully move to port and starboard. See “External dimensions” (3-2).

1. For single outboard motor installation, place the outboard motor on the vertical centerline of the boat transom. For the hull without strakes, make a same radius (R) at both sides of hull, and have another measurement points.

C/L

TIP:

• Make sure that the distance e is equal to

• For the distance (T1), see “External dimen-

For triple outboard motor installation, place the center outboard motor so that the C/L of the outboard motor is aligned with the C/L of the boat transom. Place the other 2 outboard motors on both sides so that the distances from the C/L of the outboard motors to the C/L of the boat transom are equal.

distance f.

sions” (3-2).

C/L

È Hull without strakes É Hull with strakes

TIP:

Make sure that the distance a is equal to distance b, and the distance c is equal to distance d.

For twin outboard motor installation, place the outboard motors so that the distance from the C/L of each outboard motor to the C/L of the boat transom are equal on both sides.

T1 T1

3-6

RIG

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Rigging information

TIP:

• Make sure that the distance g is equal to

distance h.

• If the boat has a V shape hull, the center

outboard motor should have longer transom height than the outboard motors on both sides.

• For the distance (T1), see “External dimen-

sions” (3-2).

2. Adjust the position of the outboard motor so that the height of the anti-cavitation plate k is equal to or slightly above the bottom of the boat transom.

TIP:

This mounting height information is for reference only. It is impossible to provide complete instructions for every possible boat and outboard motor combination.

3. Adjust the height of the scale m to the

transom height (H), and place it on the special service tool 1. Secure the special service tool 1 to the boat transom n using screws or vises.

TIP:

For the transom height (H), see “External dimensions” (3-2).

4. When the outboard motor mounting position has been determined, mark the bestsuited 4 symmetrical mounting holes in the boat transom n. Drill the mounting holes perpendicular to the surface of the boat transom using a 13.0 mm (0.5 in) drill bit.

k k

È Single outboard motor installation É Twin outboard motor installation Ê Triple outboard motor installation

C/L

Drilling plate 1: 90890-06783

Mounting hole diameter p:

13.0 mm (0.5 in) or more

3-7

Outboard motor mounting / Outboard motor mounting height

5. Apply sealant to the mounting holes and secure the outboard motor using the included mounting bolts 2, small washers 3, large washers 4, and nuts 5.

NOTICE: Make sure that there is no clearance between the surfaces of the boat transom and the clamp brackets. Otherwise, the clamp brackets or boat transom may be damaged.

2 3

Boat transom thickness (D)

65–75 mm

(2.56–2.95 in)

75–95 mm

(2.95–3.74 in)

5 3

Mounting bolt

M12 × 130 mm

(5.12 in)

M12 × 150 mm

(5.91 in)

Outboard motor mounting height

4-stroke engines are heavier than 2-stroke engines of the same horsepower. Therefore, if a 2-stroke outboard motor is replaced with a 4-stroke outboard motor, the boat will become “stern heavy.” Also, the water line will rise and become closer to the power unit. If the water line is too close to the power head, poor engine performance could result, and water could enter the cylinders and damage the engine. When mounting a 4-stroke outboard motor to a boat, make sure that the mounting height between the water surface and the clamp bracket seating point is not less than the specified minimum mounting height a. Measure the mounting height when the boat is moored and carrying the maximum load.

TIP:

The second hole from the top of each clamp bracket is recommended for the upper mounting bolt.

6. Install the mounting bolts, and then tighten the nuts firmly. NOTICE: Make

sure that the clamp brackets do not bite into the boat transom.

7. Tighten the locknuts firmly.

Minimum mounting height a:

100 mm (3.9 in)

3-8

RIG

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Rigging information

Rigging grommet mounting

Rigging grommet description

a Throttle cable b Extension wiring harness c Water temperature sensor harness

(optional) or water pressure sensor hose (optional)

d Isolator lead (optional) e Battery cable f Conventional gauge lead (optional) or 6Y8

Multifunction Meter harness (optional)

g Fuel hose h Speedometer hose k Shift cable m Flushing hose (commercially available)

3. Remove the rigging grommet 3.

4. Remove the cable holder 4.

Installing the shift cable and throttle cable

Before installing the shift cable and throttle cable, make sure to adjust the cables according to the procedures in the remote control operation manual.

1. Remove the rubber seal 1 from the retaining plate 2.

5. Route the shift cable 5 through the bot-

tom cowling.

6. Fit the cable holder 4 into the groove a

in the shift cable 5, and then install the cable holder 4 along with the shift cable

2. Remove the retaining plate 2.

3-9

Rigging grommet mounting

7. Fully screw in the shift cable joint 6 to the shift cable 5.

8. Move the remote control lever to the N position.

9. Make a mark b on the fully retracted inner cable, and then make a mark c on the fully extended inner cable.

10. Make a mark d in the middle point between the marks b and c, and then align the mark d with the outer cable edge e.

12. Adjust the shift cable joint 6, and then

install the shift cable joint 6 to the pin h.

WARNING! The shift cable joint must be screwed in 8.0 mm (0.31 in) or more.

Dimension k: 8.0 mm (0.31 in) or more

13. Install the clip 9, and then tighten the shift cable locknut 0 to the specified torque.

11. Align the mark f on the bushing 7 with the mark g on the shift bracket 8.

Shift cable locknut 0:

4 N·m (0.4 kgf·m, 3.0 ft·lb)

14. Route the throttle cable A through the

bottom cowling.

15. Fasten the throttle cable A using the cable holder 4 so that the cable holder 4 is fitted into the groove m in the throt- tle cable A.

3-10

RIG

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16. Fully screw in the throttle cable joint B to the throttle cable A.

17. Pull the inner cable so that there is no free play (backlash).

Rigging information

Throttle cable locknut D:

4 N·m (0.4 kgf·m, 3.0 ft·lb)

21. Check the shift cable and throttle cable for proper operation.

Installing the wiring harness

1. Remove the 10-pin coupler a from the holder b on the bracket.

18. Check that the accelerator lever n contacts the stopper p.

19. Adjust the throttle cable joint B, and then connect the throttle cable joint B to the pin r of the accelerator lever n.

WARNING! The throttle cable joint must be screwed in 8.0 mm (0.31 in) or more.

2. Route the extension wiring harness through the bottom cowling.

3. Connect the 10-pin coupler c, and then fasten it using the holders b and d on the bracket.

Dimension s: 8.0 mm (0.31 in) or more

20. Install the clip C, and then tighten the throttle cable locknut D to the specified torque.

3-11

Installing the isolator lead (optional)

1. Remove the cap 1.

2. Route the isolator lead 2 through the

bottom cowling.

3. Connect the isolator coupler a.

Rigging grommet mounting

Installing the battery cable

1. Route the battery cable through the bottom cowling.

2. Connect the negative battery cable a, and then tighten the negative battery cable nut 1 to the specified torque.

3. Connect the positive battery cable b.

Negative battery cable nut 1:

13 N·m (1.3 kgf·m, 9.6 ft·lb)

2. Cut off the tip a of the nipple 2.

3. Install the extension hose 3 to the nipple 2, and then fasten it using the plastic tie

4. Install the rubber cap 2.

Installing the speed sensor (optional)

See 6Y8 Multifunction Meter set up manual for details of the components.

1. Remove the engine ECM cover 1.

TIP:

Cut the extension hose 3 to 50 mm (2.0 in).

4. Install the tube 5.

3-12

RIG

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Rigging information

TIP:

Cut the tube 5 to 600 mm (23.6 in).

5. Remove the bracket 6.

6. Remove the cap 7, and then remove the bracket 8 from the speed sensor coupler b.

Speed sensor adapter bolt A:

10 N·m (1.0 kgf·m, 7.4 ft·lb)

9. Connect the extension hose 3 to the speed sensor adapter 0, and then fasten the extension hose using the plastic tie B.

7. Install the speed sensor 9 to the speed sensor adapter 0, and then tighten the speed sensor 9 to the specified torque.

Speed sensor 9:

18 N·m (1.8 kgf·m, 13.3 ft·lb)

8. Install the speed sensor assembly c, and then tighten the speed sensor adapter bolt A to the specified torque.

10. Connect the speed sensor coupler b.

11. Install the engine ECM cover.

Installing the water pressure sensor (optional)

See 6Y8 Multifunction Meter set up manual for details of the components.

Do not reuse a gasket, always replace it with a new one.

3-13

1. Remove the engine ECM cover 1, and then remove the plug 2.

Rigging grommet mounting

2. Install the water pressure sensor 3 to the water pressure sensor adapter 4, and then tighten the water pressure sensor 3 to the specified torque.

Water pressure sensor 3:

18 N·m (1.8 kgf·m, 13.3 ft·lb)

5. Install the engine ECM cover.

Installing the rigging grommet

1. Route each harness through the proper hole in the rigging grommet. See “Rigging grommet description” (3-9) for the detailed description of the rigging grommet.

2. Align the white tape a on the battery cable with the outer end of the rigging grommet.

3. Install a new gasket 5 and the water

pressure sensor assembly a, and then tighten the water pressure sensor adapter 4 to the specified torque.

Water pressure sensor adapter 4:

23 N·m (2.3 kgf·m, 17.0 ft·lb)

4. Remove the cap, and then connect the

water pressure sensor coupler b.

3. Install the retaining plate 1.

4. Install the rubber seal 2.

TIP:

Make sure that the rubber seal is installed securely.

3-14

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5. Install the rigging tube retainer 3, and then fasten it using the plastic tie 4.

Rigging information

Remote control box and switch panel installation

See the Remote Control Box Operation Manual or Rigging Guide for the installation procedures.

3-15

Remote control box and switch panel installation / Battery installation

Battery installation

• Make sure to connect the battery properly and select the proper cable sizes. Otherwise, a

fire could result.

• When installing an isolator lead to the positive battery terminal or battery switch, over-cur-

rent protection in compliance with ABYC (E-11) must be provided.

Do not reverse the battery connections. Otherwise, the charging system could be damaged.

Battery cable routing without house (accessory) battery

• When only one battery is used for one engine, connect the positive battery cable and isola-

tor lead to the positive battery terminal. If the isolator lead is left unconnected, accidental contact of the isolator lead with the negative terminal of the battery can cause a short circuit, which may result in a fire.

• When using a dual battery installation, a negative battery cable must be installed between

both engine batteries. This cable must be sized equivalent to the engine battery cables or larger AWG cable size in accordance with ABYC specifications.

Isolator lead

Outboard

motor

Red

Black

3-16

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Rigging information

STBD PORT

Isolator lead

Outboard

motor

Black

Red

Isolator lead

Black

Outboard

motor

Outboard

motor

Red

Black

Battery switch

ON/OFF

Red

STBD PORT

Outboard

motor

Red

ON/OFF

Black

Isolator lead

Outboard

motor

Red

ON/OFF

Isolator lead

Black

3-17

Battery switch

Black

Battery installation

STBD PORT

Outboard

motor

Battery switch

ON/OFF

Red

Navigation systems

Black

Red

Black Black Black

Boat systems

Red

Battery cable routing with house (accessory) battery

Outboard

motor

Black

ON/OFF

Red

• When only one battery is used for one engine, connect the positive battery cable and isola-

• When using a house battery, a negative battery cable must be installed between the house

battery and the engine battery. This cable must be sized equivalent to the engine battery cables or larger AWG cable size in accordance with ABYC specifications.

• Battery switches must be capable of meeting intermittent and continuous current ratings

for engines and accessories.

3-18

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Rigging information

Outboard

motor

Isolator lead

Battery switch

Red

Battery switch

ON/OFF

Black

House battery

Outboard

motor

Isolator lead

Black

Battery switch

Red

Outboard

motor

Red

House battery

Isolator lead

Black

House battery

3-19

Battery installation

STBD

Outboard

motor

Black

Battery switch

STBD PORT

Outboard

motor

Isolator lead

Red

Battery switch

ON/OFF

Black

Isolator lead

Battery switch

House battery

Isolator lead

Outboard

motor

Red

ON/OFF

Outboard

motor

Black

PORT

Black

Battery switch

Red

ON/OFF

12 12

Black

Battery switch

Black

House battery

Red

Battery switch

Black

3-20

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Rigging information

STBD

Black

Battery switch

Outboard

motor

Isolator lead

Red

Battery switch

12 12

Black Black

Isolator lead

House battery

Outboard

motor

Red

PORT

Black

STBD PORT

Battery switch

ON/OFF

Outboard

motor

Red

Black

Isolator lead

ON/OFF

Black

Isolator lead

Battery switch

ON/OFF

Red

House batteryHouse battery

Outboard

motor

Black

3-21

Battery installation / System diagram

Color code

B: Black

G: Green

L: Blue

P: Pink

P/B : Pink/Black

R: Red

W : White

System diagram

Single outboard motor application

(*1) Install the waterproof cap to the open terminals.

1 Trim sensor

2 Trim sensor coupler

3 Speed sensor

4 Water pressure sensor

5 Engine ECM

6 Pigtail bus wire

7 Single hub

8 Main bus wire

9 703 remote control box

Y : Yellow

0 Fuse (10 A)

A Terminal resistor

B Tachometer unit

C Fuel meter unit

D Speedometer unit

E GPS

F Engine start switch (with engine shut-off

switch)

G 8 ft power wire

H Fuel tank (fuel level sensor)

a Bus port

b Device port

c Power port

È 703 remote control model

É 704 remote control model

Ê PORT

Ë STBD

3-22

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Rigging information

Hub 1

4P 4P 4P

a b b b a c

(*1)

B YY

(*1) (*1)

R G B Y

B P B P/B

3-23

P P

System diagram

Color code

B: Black

L: Blue

P: Pink

P/B : Pink/Black

W : White

Y : Yellow

Twin outboard motor application

(*1) Install the waterproof cap to the open terminals.

1 Trim sensor

2 Trim sensor coupler

3 Speed sensor

4 Water pressure sensor

5 Engine ECM

6 Pigtail bus wire

7 Terminal resistor

8 Main bus wire

9 8 ft power wire

0 Fuse (10 A)

A Engine start switch (with engine shut-off

switch)

B Tachometer unit

C Fuel meter unit

D Speedometer unit

E Fuel tank (fuel level sensor)

F GPS

G Multisensor (speed, water temperature,

and water depth)

a Bus port

b Device port

c Power port

È PORT

É STBD

3-24

RIG

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Rigging information

a b b b a c

Hub 3

(*1)

4P 4P 4P

BYB YY

B P B P/B

ÈÉ

Hub 2

Hub 1

a b b b a c

(*1)

3-25

P PP P

System diagram

Color code

B: Black

L: Blue

P: Pink

P/B : Pink/Black

W : White

Y : Yellow

switch)

Triple outboard motor application

(*1) Install the waterproof cap to the open terminals.

1 Trim sensor

2 Trim sensor coupler

3 Speed sensor

4 Water pressure sensor

5 Engine ECM

6 Pigtail bus wire

7 Main bus wire

8 Fuse (10 A)

9 Engine start switch (with engine shut-off

0 8 ft power wire

A Terminal resistor

B Tachometer unit

C Fuel meter unit

D Speedometer unit

E Fuel tank (fuel level sensor)

F GPS

G Multisensor (speed, water temperature,

and water depth)

a Bus port

b Device port

c Power port

È PORT

É STBD

3-26

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Rigging information

a b b b a c

Hub 3

(*1)

4P 4P 4P

B P B P/B

ÈÉ

Hub 2

a b b b a c

Hub 1

(*1)

P PP P P P

a b b b a c

Hub 4

(*1)

3-27

System diagram / Rigging recommendation

Rigging recommendation

Extension length recommendation for battery cable

Do not exceed the recommended extension length for the battery cable. Otherwise, the electrical system could be damaged or operate improperly.

To extend the length of battery cables, follow the requirements in the tables for your battery capacity, cable size, and ambient temperature. The maximum total extension length is the total combined length of the positive and negative battery cables. Select an extension battery cable and terminal that meet ABYC requirements or equivalent. Select a battery stud that is best-suited to the terminal size. Solder the cable and terminal connections to prevent them from corroding.

Ambient temperature is 0 °C (32 °F) and above

Battery requirements Cable specifications

Maximum total extension length

Unit

CCA/EN 711.0 Amps

20HR/IEC 100.0 Ah

Minimum

capacity

(Positive battery cable + Negative battery cable)

AWG4

(20 mm

5.4 m (17.7 ft) 9.2 m (30.2 ft)

)

AWG2

(30 mm2)

AWG1/0

(50 mm2)

14.2 m

(46.6 ft)

Ambient temperature is below 0 °C (32 °F)

Battery requirements Cable specifications

Unit

CCA/EN 711.0 Amps

20HR/IEC 83.0 Ah

Minimum

capacity

Maximum total extension length

(Positive battery cable + Negative battery cable)

AWG4

(20 mm

3.5 m (11.5 ft) 6.0 m (19.7 ft) 9.2 m (30.2 ft)

)

AWG2

(30 mm2)

AWG1/0

(50 mm2)

3-28

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Rigging information

Propeller selection

The size and type of propeller that is used will affect the performance of a boat and outboard motor critically. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boating and steering capabilities. An incorrect choice could adversely affect performance and could also damage the engine seriously. Use the following information as a guide for selecting a propeller that meets the operating conditions of the boat and outboard motor.

Propeller size

The size of the propeller is indicated on the propeller boss end, and on the side of the propeller boss.

abc

The propeller sizes listed in the propeller list indicate the following information:

da bc

a Propeller diameter (in inches) b Propeller pitch (in inches) c Propeller type (propeller mark) d Number of propeller blades

Selection

When the engine speed is at full throttle operating range, the ideal propeller for the boat is the one that provides maximum performance in relation to boat speed and fuel consumption.

a Propeller diameter (in inches) b Propeller pitch (in inches) c Propeller type (propeller mark)

Full throttle operating range:

5000–6000 r/min

3-29

Propeller selection

Regular rotation model

Dia. (in) Pitch (in) Mark Material Part number Remarks

13 3/8 23 M S-Steel 6G5-45976-01 13 3/8 25 M S-Steel 6G5-45930-00 13 3/4 17 M2 S-Steel 6G5-45978-03 13 3/4 19 M2 S-Steel 6G5-45974-03 13 3/4 19 M S-Steel 68F-45974-00 13 3/4 21 M S-Steel 6G5-45972-02 13 3/4 21 M S-Steel 68F-45976-00 14 1/4 17 M S-Steel 68F-45972-00 14 1/4 18 M S-Steel 68F-45978-00 14 1/2 15 M S-Steel 68F-45970-00 14 1/2 19 T S-Steel 61A-45974-00 14 1/2 21 T S-Steel 61A-45972-00 14 1/2 23 M S-Steel 6R4-45974-A0 14 7/8 21 M S-Steel 6R4-45972-A0

15 17 T S-Steel 61A-45978-00 15 21 T S-Steel 6D0-45972-00 15 21 T S-Steel 6BR-45B70-00 4 blades 15 22 T S-Steel 6BR-45B72-00 4 blades

15 23 T S-Steel 6BR-45B74-00 4 blades 15 1/4 15 M S-Steel 6G5-45970-02 15 1/4 15 M S-Steel 6R4-45976-A0 15 1/4 17 M S-Steel 6R4-45978-A0 15 1/4 19 M S-Steel 6R4-45970-A1 15 1/4 19 T S-Steel 6D0-45970-00 15 1/2 17 T S-Steel 6D0-45978-00 15 3/4 13 M S-Steel 6G5-45932-00 15 3/4 15 T S-Steel 6D0-45976-00 13 1/2 23 M Aluminum 6G5-45949-00 F200B only 13 3/4 21 M Aluminum 6G5-45943-01 F200B only

14 19 M Aluminum 6G5-45945-01 F200B only 14 1/2 17 M Aluminum 6G5-45947-01 F200B only 14 5/8 16 M Aluminum 6G5-45952-00 F200B only 15 1/4 15 M Aluminum 6G5-45941-00 F200B only

3-30

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Counter rotation model

Dia. (in) Pitch (in) Mark Material Part number Remarks

13 3/8 23 ML S-Steel 6K1-45976-00 13 3/4 17 ML1 S-Steel 6K1-45978-02 13 3/4 19 ML S-Steel 68G-45974-00 13 3/4 19 ML1 S-Steel 6K1-45974-02 13 3/4 21 ML S-Steel 6K1-45972-01 13 3/4 21 ML S-Steel 68G-45976-00 14 1/4 17 ML S-Steel 68G-45972-00 14 1/4 18 ML S-Steel 68G-45978-00 14 1/2 19 TL S-Steel 61B-45974-00 14 1/2 21 TL S-Steel 61B-45972-00 14 1/2 23 ML S-Steel 6R1-45974-A0 14 7/8 21 ML S-Steel 6R1-45972-A0

15 17 TL S-Steel 61B-45978-00

15 21 TL S-Steel 6D1-45972-00

15 21 TL S-Steel 6BS-45B70-00 4 blades

15 22 TL S-Steel 6BS-45B72-00 4 blades

15 23 TL S-Steel 6BS-45B74-00 4 blades 15 1/4 15 ML S-Steel 6K1-45970-01 15 1/4 15 ML S-Steel 6R1-45976-A0 15 1/4 17 ML S-Steel 6R1-45978-A0 15 1/4 19 ML S-Steel 6R1-45970-A1 15 1/4 19 TL S-Steel 6D1-45970-00 15 1/2 17 TL S-Steel 6D1-45978-00 15 3/4 15 TL S-Steel 6D1-45976-00

14 19 ML Aluminum 6K1-45945-00 FL200B only 14 1/2 17 ML Aluminum 6K1-45947-00 FL200B only

Rigging information

3-31

Yamaha F200B, FL200B, F250G, FL250G Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General information

Rotating part

Handling of gasoline

Hot part

Electric shock

Propeller

Ventilation

Self-protection

Working with crane

Handling of gas torch

Part, lubricant, and sealant

Handling of sealant

Special service tool

Tightening torque

Non-reusable part

Disassembly and assembly

How to use this manual

Manual format

Abbreviation

Lubricant, sealant, and thread locking agent

Symbol

Special service tool

Specification

Model features

General feature

Model designation

Serial number

Model data

Dimension and weight

Performance

Power unit

Lower unit

Bracket unit

Fuel and oil requirement

Battery requirement

PTT fluid requirement

Electrical system technical data

Ignition timing control system

Fuel injection control system

Engine speed control system

VCT system

PTT system

Charging system

Starting system

Gauge/sensor

Fuel system technical data

Fuel system

Power unit technical data

Power unit

Cylinder head assembly

Crankcase assembly

Lower unit technical data

Lower unit assembly (regular rotation model)

Lower unit assembly (counter rotation model)

Bracket unit technical data

PTT system

Specified tightening torque

Rigging information

Fuel system

Power unit

Lower unit (regular rotation model)

Lower unit (counter rotation model)

Bracket unit

PTT unit

General tightening torque

Technical features and description

Electronic control system

Engine control system component

Actuator, sensor, and switch

Electronic fuel injection control

Digital ignition control

VCT control

Knock control

Over-rev control and alert control

ETV control

Fail-safe control