Yamaha WaveRunner GP1300R Service manual

WaveRunner

GP1300R

*LIT186160244*

LIT-18616-02-44

SERVICE MANUAL

F1G-28197-1F-11

E

NOTICE

This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.

Because Yamaha has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual.

A10001-0*

WaveRunner GP1300R

SERVICE MANUAL

©2003 by Yamaha Motor Corporation, USA

1st Edition, February 2003

All rights reserved.

Any reprinting or unauthorized use without the written permission of

Yamaha Motor Corporation, USA is expressly prohibited.

Printed in USA

LIT-18616-02-44

E

HOW TO USE THIS MANUAL

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.,

• Bearings

Pitting/scratches

→ Replace.

To assist you in finding your way through this manual, the section title and major heading is given at the top of every page.

ILLUSTRATIONS

The illustrations within this service manual represent all of the designated models.

CROSS REFERENCES

The cross references have been kept to a minimum. Cross references will direct you to the appropriate section or chapter.

E

IMPORTANT INFORMATION

In this Service Manual particularly important information is distinguished in the following ways.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS

INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, passenger(s), a bystander, or a person inspecting or repairing the watercraft.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the watercraft.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

IMPORTANT:

This part has been subjected to change of specification during production.

E

HOW TO USE THIS MANUAL

1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

2 Numbers are given in the order of the jobs in the exploded diagram.

3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).

4 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

5 Dimension figures and the number of parts, are provided for fasteners that require a tightening torque.

Example:

Bolt or screw size 10 × 25 mm : M10 (D)

× 25 mm (L)

D

L

6 Jobs requiring more information (such as special service tools and technical data) are described sequentially.

1

GEN

INFO

3

INSP

ADJ

5

POWR

7

ELEC –

9

A

TRBL

ANLS

+

2

4

SPEC

FUEL

6

8

JET

PUMP

HULL

HOOD

0

B

C

E

G

A

I

GM

K

M

LT

271

LT

572

.

T

R

.

D

F

H

E

M

J

4

L

LT

242

N

SS

E

A50001-1-4

SYMBOLS

Symbols

1 to 9 are designed to indicate the content of a chapter.

1 General Information

2 Specifications

3 Periodic Inspection and Adjustment

4 Fuel System

5 Power Unit

6 Jet Pump Unit

7 Electrical System

8 Hull and Hood

9 Trouble Analysis

Symbols 0 to E indicate specific data.

0 Special service tool

A Specified oil or fluid

B Specified engine speed

C Specified tightening torque

D Specified measurement

E Specified electrical value

(resistance, voltage, electric current)

Symbols

F to H in an exploded diagram indicate the grade of lubricant and the lubrication point.

F Apply Yamaha 2-stroke motor oil

G Apply water resistant grease

(Yamaha grease A, Yamaha marine grease)

H Apply molybdenum disulfide grease

Symbols I to N in an exploded diagram indicate the type of sealant or locking agent and the application point.

I Apply Gasket Maker

J Apply Yamabond No. 4

K Apply LOCTITE 271 (red)

L Apply LOCTITE 242 (blue)

M Apply LOCTITE 572

N Apply silicone sealant

NOTE:

Additional symbols may be used in this manual.

A30000-0

INDEX

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND

ADJUSTMENT

FUEL SYSTEM

POWER UNIT

JET PUMP UNIT

ELECTRICAL SYSTEM

HULL AND HOOD

TROUBLE ANALYSIS

E

GEN

INFO

1

SPEC

2

INSP

ADJ

3

FUEL

4

POWR

5

JET

PUMP

6

– + 7

ELEC

HULL

HOOD

8

TRBL

ANLS

9

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

IDENTIFICATION NUMBERS ......................................................................... 1-1

PRIMARY l.D. NUMBER ........................................................................... 1-1

ENGINE SERIAL NUMBER ...................................................................... 1-1

JET PUMP UNIT SERIAL NUMBER ......................................................... 1-1

HULL IDENTIFICATION NUMBER (H.l.N.) ............................................... 1-1

SAFETY WHILE WORKING...................................................................... 1-2

FIRE PREVENTION .................................................................................. 1-2

VENTILATION ........................................................................................... 1-2

SELF-PROTECTION................................................................................. 1-2

PARTS, LUBRICANTS, AND SEALANTS ................................................ 1-2

GOOD WORKING PRACTICES ............................................................... 1-3

DISASSEMBLY AND ASSEMBLY ............................................................ 1-4

SPECIAL SERVICE TOOLS ........................................................................... 1-5

MEASURING AND DIAGNOSIS ............................................................... 1-5

REMOVAL AND INSTALLATION.............................................................. 1-7

E

5

6

7

8

9

3

4

1

2

GEN

INFO

1

IDENTIFICATION NUMBERS

E

A60700-0*

IDENTIFICATION NUMBERS

PRIMARY l.D. NUMBER

The primary l.D. number is stamped on a label

1 attached inside the engine compartment.

Starting primary l.D. number:

F1G: 800301

ENGINE SERIAL NUMBER

The engine serial number is stamped on a label

1 attached to the engine unit.

Starting serial number:

60T: 1000001

JET PUMP UNIT SERIAL NUMBER

The jet pump unit serial number is stamped on a label attached to the intermediate housing.

HULL IDENTIFICATION NUMBER

(H.l.N.)

The H.l.N. is stamped on a plate

1 attached to the hull on the aft, starboard (right) side.

1-1

GEN

INFO

SAFETY WHILE WORKING

E


To prevent and accident or injury and to ensure quality service, follow the safety procedures provided below.

FIRE PREVENTION

Gasoline is highly flammable.

Keep gasoline and all flammable products away from heat, sparks, and open flames.

1-2

VENTILATION

Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If inhaled in large quantities they may cause loss of consciousness and death within a short time.

When test running an engine indoors (e.g., in a water tank), be sure to do so where adequate ventilation can be maintained.

SELF-PROTECTION

Protect your eyes by wearing safety glasses or safety goggles during all operation involving drilling and grinding, or when using an air compressor.

Protect your hands and feet by wearing protective gloves or safety shoes when necessary.

PARTS, LUBRICANTS, AND

SEALANTS

Use only genuine Yamaha parts, lubricants, and sealants or those recommended by

Yamaha, when servicing or repairing the watercraft.

GEN

INFO


E

Under normal conditions, the lubricants mentioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants.

1. Maintain good standards of personal and industrial hygiene.

2. Change and wash clothing as soon as possible if soiled with lubricants.

3. Avoid contact with skin. Do not, for example, place a soiled rag in your pocket.

4. Wash hands and any other part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made.

5. To protect your skin, apply a protective cream to your hands before working on the watercraft.

6. Keep a supply of clean, lint-free cloths for wiping up spills, etc.

1-3

GOOD WORKING PRACTICES

1. The right tools

Use the recommended special service tools to protect parts from damage. Use the right tool in the right manner—do not improvise.

2. Tightening torques

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.

GEN

INFO


E

3. Non-reusable parts

Always use new gaskets, seals, O-rings, oil seals, cotter pins, circlips, etc., when installing or assembling parts.

DISASSEMBLY AND ASSEMBLY

1. Use compressed air to remove dust and dirt during disassembly.

2. Apply engine oil to the contact surfaces of moving parts during assembly.

3. Install bearings with the manufacture identification mark in the direction indication in the installation procedure. In addition, be sure to lubricate the bearings liberally.

4. Apply a thin coat of water-resistant grease to the lip and periphery of an oil seal before installation.

5. Check that moving parts operate normally after assembly.

1-4

GEN

INFO

1

YU-34899-A

3

YU-03097

4

YU-03112

90890-03112

6

YB-06766

7

YU-03017

90890-06759

SPECIAL SERVICE TOOLS

2

90890-03174

E


Using the special service tools recommended by Yamaha will aid service and enable accurate assembly and tune-up. Improvisations and using improper tools can damage the equipment.

NOTE:

• For USA and Canada, use the special service tools starting with part numbers “J-,”

“YB-,” “YM-,” “YS-,” “YU-,” or “YW-.”

• For all other countries, use the special service tools starting with part number “90890-.”

90890-01252

5

YW-06842

90890-06842

90890-06786

MEASURING AND DIAGNOSIS

1 Digital multimeter

YU-34899-A

2 Digital circuit tester

90890-03174

3 Dial gauge

YU-03097

90890-01252

4 Pocket tester

YU-03112

90890-03112

5 Fuel pressure gauge adapter

YW-06842

90890-06842

6 Fuel pressure gauge

YB-06766

90890-06786

7 Cylinder gauge set

YU-03017

90890-06759

8 Compression gauge

YU-33223-1

90890-03160

8

YU-33223-1 90890-03160

1-5

GEN

INFO

9

YU-39991

A

YM-34487

C

YB-06870

90890-06870

E

YB-06848

90890-06848


0

90890-03172

B

90890-06754

D

YB-06869

90890-06869

F

YB-06849

90890-06849

9 Peak volt meter adapter

YU-39991

0 Peak voltage adapter B

90890-03172

A Spark gap tester

YM-34487

B Ignition tester

90890-06754

C Lighting coil tester (3 pins)

YB-06870

Test harness SMT250-3 (3 pins)

90890-06870

D Air pressure sensor tester (3 pins)

YB-06869

Test harness EJ-II-3 (3 pins)

90890-06869

E Test harness (6 pins)

YB-06848

Test harness FSW-6A (6 pins)

90890-06848

F Test harness (6 pins)

YB-06849

Test harness SM6195021-6 (6 pins)

90890-06849

G Lower unit pressure/vacuum tester

YB-35956-A

Vacuum/pressure pump gauge set

90890-06756

H Yamaha diagnostic system

(CD-ROM only)

60V-WS853-01

E

G

YB-35956-A

90890-06756

H

60V-WS853-01

YAMAHA

DIAGNOSTIC

SYSTEM

INSTALLATION MANUAL

60V-2819K-10

1-6

GEN

INFO

3

YB-06117

5

YB-06151

90890-06519

7

90890-06501

9

90890-06538


1

YW-06551

90890-06551

2

YW-06550

90890-06550

4

90890-06521

6

YB-06096

8

90890-06535

0

90890-06652

E

REMOVAL AND INSTALLATION

1 Coupler wrench

YW-06551

90890-06551

2 Flywheel holder

YW-06550

90890-06550

3 Universal puller

YB-06117

4 Flywheel puller

90890-06521

5 Drive shaft holder (impeller)

YB-06151

Drive shaft holder 5 (impeller)

90890-06519

6 Slide hammer and adapters

(jet pump bearing)

YB-06096

7 Stopper guide plate (jet pump bearing)

90890-06501

8 Bearing puller assembly

(jet pump bearing)

90890-06535

9 Stopper guide stand (jet pump bearing)

90890-06538

0 Driver rod L3 (jet pump bearing)

90890-06652

A Bearing housing needle bearing remover

(jet pump bearing)

YB-06112

Drive shaft needle bearing installer and remover (jet pump oil seal)

YB-06196

B Needle bearing attachment

(jet pump bearing and oil seal)

90890-06614, 90890-06653

A

YB-06112

YB-06196

B

90890-06614

90890-06653

1-7

GEN

INFO

C

YB-06085

E

YB-06071

G

YB-34474

I

YB-06156

90890-06626


D

90890-06634

F

90890-06606

H

YB-06552

90890-06552

E

C Outer race installer—forward gear

(jet pump oil seal)

YB-06085

D Ball bearing attachment (jet pump oil seal)

90890-06634

E Driver handle—large

(intermediate shaft and jet pump)

YB-06071

F Driver rod LS

(intermediate shaft and jet pump)

90890-06606

G Drive shaft needle bearing depth stop

(jet pump bearing)

YB-34474

H Shaft holder (intermediate shaft)

YB-06552

Crankshaft holder 20 (intermediate shaft)

90890-06552

I Drive shaft taper roller bearing cup installer (intermediate shaft)

YB-06156

Bearing outer race attachment

(intermediate shaft)

90890-06626

1-8

SPEC

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS ....................................................................... 2-1

MAINTENANCE SPECIFICATIONS ............................................................... 2-3

ENGINE .................................................................................................... 2-3

JET PUMP UNIT ...................................................................................... 2-4

HULL AND HOOD .................................................................................... 2-5

ELECTRICAL ............................................................................................ 2-5

TIGHTENING TORQUES ................................................................................ 2-8

SPECIFIED TORQUES............................................................................. 2-8

GENERAL TORQUE ............................................................................... 2-14

CABLE AND HOSE ROUTING ..................................................................... 2-15

E

5

6

7

8

9

3

4

1

2

SPEC

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

Unit Item

Model code

Hull

Engine/jet

Dimensions

Length

Width

Height

Dry weight

Maximum capacity

Performance

Maximum output

Maximum fuel consumption

Cruising range

Engine

Engine type

Number of cylinders

Displacement

Bore

× stroke

Compression ratio

#1, #2

#3

Intake system

Scavenging system

Exhaust system

Lubrication system

Cooling system

Starting system

Ignition system

Spark plug model

(manufacturer)

Spark plug gap

Battery

Voltage, capacity

Generator output mm (in) mm (in) mm (in) kg (lb)

Person/kg (lb) kW (PS) at r/min l/h (US gal/h, lmp gal/h) h cm 3 (cu. in) mm (in) mm (in)

V, Ah

A at r/min

Model

GP1300R

F1G

60T

2,930 (115.4)

1,150 (45.3)

1,020 (40.2)

297 (653)

2/160 (353)

121.4 (165) at 7,000

63.0 (16.6, 13.9)

0.95

2-stroke

3

1,297 (79.1)

84

× 78 (3.31 × 3.07)

5.9:1

5.7:1

Reed valve

Loop charge

Wet exhaust/YPVS

Variable oil injection

Water cooled

Electric starter

Digital CDI

BR8ES-11 (NGK)

1.0–1.1 (0.039–0.043)

12, 19

15 at 6,000

E

2-1

SPEC

GENERAL SPECIFICATIONS E

Item Unit

Model

GP1300R

Drive unit

Propulsion system

Jet pump type

Impeller rotation

Transmission

Jet thrust nozzle horizontal angle

Jet thrust nozzle trim angle

Trim system

Reverse system

Fuel and oil

Fuel

Minimum fuel rating

Degree

Degree

Jet pump

Axial flow, single stage

Counterclockwise (viewed from rear)

Direct drive from engine

23 + 23

–5, 0, 5, 10, 15

Manual 5 positions

NA

Oil

Fuel-oil ratio

(wide open throttle)

Fuel tank capacity

RON

*2

Regular unleaded gasoline

PON

*1

86

90

YAMALUBE 2-W

*3

30:1

Oil tank quantity

L (US gal,

Imp gal)

L (US qt,

Imp qt)

60 (15.9, 13.2)

5.5 (1.5, 1.2)

*1

*2

*3

Pump Octane Number = (Motor Octane Number + Research Octane Number)/2

Research Octane Number

YAMALUBE 2-W has been developed for this watercraft and it is available at a Yamaha dealer.

CAUTION:

Use only YAMALUBE 2-W oil. Using another oil can seriously damage the catalytic converter and other engine components.

2-2

SPEC

MAINTENANCE SPECIFICATIONS E

MAINTENANCE SPECIFICATIONS

ENGINE

Item Unit

Model

GP1300R

Cylinder head

Warpage limit

Minimum compression pressure

*1

Cylinders

Bore size

Taper limit

Out-of-round limit

Wear limit

Pistons

Piston diameter mm (in) kPa

(kgf/cm 2 , psi) mm (in) mm (in) mm (in) mm (in)

0.05 (0.002)

640 (6.4, 91)

84.000–84.018 (3.3071–3.3078)

0.080 (0.0031)

0.050 (0.0020)

84.100 (3.3110)

Measuring point

*

Piston-to-cylinder clearance

Wear limit

Piston pin boss inside diameter

Piston rings

Top mm (in) mm (in) mm (in) mm (in) mm (in)

Red: 83.899–83.902 (3.3031–3.3032)

Orange: 83.903–83.906 (3.3033–3.3034)

Green: 83.907–83.910 (3.3034–3.3035)

Purple: 83.911–83.914 (3.3036–3.3037)

11 (0.43)

0.100–0.105 (0.0039–0.0041)

0.155 (0.0061)

22.008–22.020 (0.8665–0.8669)

Type

Dimension (B)

Dimension (T)

End gap

Ring groove clearance

2nd

Type

Dimension (B) mm (in) mm (in) mm (in) mm (in)

Keystone

1.47–1.49 (0.058–0.059)

3.0–3.2 (0.118–0.126)

0.45–0.60 (0.018–0.024)

0.020–0.070 (0.0008–0.0028)

Dimension (T)

End gap

Ring groove clearance

Piston pins

Outside diameter

Wear limit

Connecting rod mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

Keystone

1.47–1.49 (0.058–0.059)

3.0–3.2 (0.118–0.126)

0.45–0.60 (0.018–0.024)

0.020–0.070 (0.0008–0.0028)

21.995–22.000 (0.8659–0.8661)

21.990 (0.8657)

Small end inside diameter mm (in) 26.995–27.008 (1.0628–1.0633)

*1

Measuring conditions:

Engine temperature 48 °C (118 °F), wide open throttle, with spark plugs removed from all cylinders.

The figures are for reference only.

2-3

SPEC


Item Unit

Model

GP1300R

Crankshaft assembly

Crank width 72.95–73.00 (2.872–2.874)

Deflection limit B

Deflection limit C mm (in) mm (in)

Big end side clearance D mm

Maximum small end axial play E mm (in)

0.05 (0.002)

0.15 (0.006)

0.250–0.750 (0.0098–0.0295)

2.000 (0.0787)

E

Throttle body

Model/quantity

Manufacturer

ID mark

Trolling speed

Reed valves

Thickness

Reed valve stopper height

Reed valve warpage limit

Fuel pump

Pump type

Output pressure

Coupling clearance

Vertical

Horizontal

JET PUMP UNIT

Item

Jet pump

Impeller material

Number of impeller blades

Impeller pitch angle

Impeller clearance

Impeller clearance limit

Drive shaft runout limit

Nozzle diameter r/min mm (in) mm (in) mm (in) kPa

(kgf/cm 2 , psi) mm (in) mm (in)

60TA/3

SANSHIN

60T00

1,250–1,450

0.6 (0.024)

10.5–10.9 (0.413–0.429)

1.5 (0.059)

Electrical

320.8–327.2 (3.21–3.27, 45.62–46.53)

0–0.5 (0–0.020)

2–4 (0.079–0.157)

Unit

Degree mm (in) mm (in) mm (in) mm (in)

Model

GP1300R

Stainless steel

4

16.3

0.7–0.9 (0.028–0.035)

0.9 (0.035)

0.30 (0.0118)

85.0–85.6 (3.35–3.37)

2-4

SPEC

HULL AND HOOD


Unit Item

Free play

YPVS cable slack

Throttle lever free play

ELECTRICAL mm (in) mm (in)

Model

GP1300R

0.5–1.5 (0.02–0.06)

4–7 (0.16–0.28)

Unit

Model

GP1300R

Item

Battery

Type

Voltage, capacity

Specific gravity

ECM unit

(B/R – Ground for cylinder #1)

(B/W – Ground for cylinder #2)

(B/Y – Ground for cylinder #3)

Output peak voltage lower limit at cranking at 2,000 r/min at 3,500 r/min

Stator

Pickup coil

(W/R, W/B, W/Y – B)

Output peak voltage at cranking 1 at cranking 2 at 2,000 r/min at 3,500 r/min

Pickup coil resistance 1

(W/R – B)


(W/B – B)


(W/Y – B)

Lighting coil (G – G)

Output peak voltage at cranking 1 at cranking 2 at 2,000 r/min at 3,500 r/min

Lighting coil resistance

(G – G)

Cranking 1: unloaded

Cranking 2: loaded

V, Ah

V

V

V

Fluid

12, 19

1.28

0.8

174

156

V

V

V

6.0

6.0

24

V 40

Ω 459–561

Ω 459–561

Ω 459–561

V

V

V

9.0

7.5

12.5

V 12.5

Ω 0.54–0.66

2-5

E

SPEC


Item

Ignition coil

Minimum spark gap

Primary coil resistance

(B/W – body)

Secondary coil resistance

(B/W – spark plug lead terminal)

Spark plug lead resistance

#1

#2

#3

Rectifier/regulator (R – B)

Output peak voltage

(unloaded) at 3,500 r/min

Starter motor

Type

Output

Rating

Brush length

Wear limit

Commutator undercut

Limit

Commutator diameter

Limit

Starter relay

Rating

Engine temperature sensor

Engine temperature sensor resistance (B/Y – B/Y) at 20 °C (68 °F) at 100 °C (212 °F)

Intake air temperature sensor

Intake air temperature sensor resistance at 0 °C (32 °F) at 80 °C (176 °F)

Atmospheric pressure sensor output voltage (P/G – B/O)

Unit mm (in) k k k k

V kW

Seconds mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

Seconds

Model

GP1300R

10–11 (0.39–0.43)

Ω 0.26–0.36

Ω

3.5–4.7

Ω 6.1–14.3

k

Ω 4.5–10.9

k

Ω 3.3–8.2

14.5

Bendix

0.8

30

12.5 (0.49)

6.5 (0.26)

0.7 (0.03)

0.2 (0.01)

28.0 (1.10)

27.0 (1.06)

30

Ω 54.2–69.0

Ω 3.12–3.48

k

Ω 5.4–6.6

k

Ω

0.29–0.39

V at kPa

(kgf/cm 2 , psi)

4.00 at 101.3 (1.01, 14.4)

1.97 at 50 (0.5, 7.1) V at kPa

(kgf/cm 2 , psi)

V at kPa

(kgf/cm 2 , psi)

0.79 at 20 (0.2, 2.8)

E

2-6

SPEC


Item

Exhaust temperature sensor resistance at 300 °C (572 °F) at 600 °C (1,112 °F) at 900 °C (1,652 °F)

Cooling water temperature sensor resistance at 0 °C (32 °F) at 100 °C (212 °F) at 200 °C (392 °F)

Speed sensor

Output voltage (on pulse)

Output pulse/one full turn

Throttle position sensor

Output voltage (P – B/O) at trolling speed

Fuel sender

Fuel sender resistance

Position A

Position B

Fuel injector

Fuel injector resistance

*1

Oil level sensor

Oil level sensor resistance

Position A

Position B

Position C

Fuse

Rating

Main

Multifunction meter

Electrical bilge pump

*1

The figures are for reference only.

Unit k k

Ω k k

Ω

Ω

Ω

Ω

Ω

V

V

Ω

Ω

Model

GP1300R

73–241

0.86–1.58

64–90

24.0–37.1

0.87–1.18

104–153

11.6

2

0.793–0.807

133.5–136.5

5–7

Ω 13.8

Ω

Ω

Ω

V/A

V/A

V/A

292–308

97–103

0–3

12/20

12/3

12/3

E

2-7

SPEC

TIGHTENING TORQUES


SPECIFIED TORQUES

Part to be tightened

Fuel system

Strap/fuel tank/oil tank – hull

Oil filler hose screw clamp

Retainer/fuel pump module

– fuel tank

1st

2nd

Fuel filler hose screw clamp

Cap screw clamp (fuel tank)

Intake silencer screw clamp

Intake silencer pipe screw clamp

Intake duct – exhaust chamber bracket

Intake duct – generator cover

1st

2nd

1st

2nd

Throttle bodies assembly – throttle bodies bracket 1, 2

1st

2nd

Throttle cable locknut and adjuster

(throttle bodies end)

Intake air temperature sensor – intake silencer case cover

Intake silencer case cover – intake silencer case

Flame arrester – intake silencer case

Fuel rail – throttle bodies

Oil pump cable – oil pump lever

1st

2nd

Oil pump cable locknut and adjuster

Bleed hose stay – exhaust chamber bracket

Oil pump – generator cover

1st

2nd

Air bleed screw

Engine

Spark plug

Muffler cover – muffler

Outer exhaust joint screw clamp

Inner exhaust joint screw clamp

Exhaust joint screw clamp

Eye – muffler

Eye – cylinder head

Muffler stay – cylinder

Part name

Thread size

Q’ty

Bolt

—

Nut

—

—

—

—

Bolt

Bolt

Bolt

—

—

Tapping screw

Screw

Bolt

Bolt

—

Bolt

Bolt

—

—

Bolt

—

—

—

Nut

Bolt

Bolt

M8

—

—

—

—

—

—

M8

M8

M8

—

—

ø6

M5

M6

M5

—

M6

M6

—

—

M6

—

—

—

M10

M10

M10

4

1

9

2

1

1

2

1

2

2

1

1

13

6

3

1

1

1

2

1

3

3

2

2

2

2

4

2

Tightening torques

N•m

9.0

18

9.0

18

3.7

1.3

2.5

2.5

16

0.6

3.2

6.4

9.0

18

11

7.5

1.8

0.8

8.8

2.2

4.4

11

7.6

3.8

7.6

3.4

25

12

2.5

1.5

2.5

39

39

39 kgf•m

0.9

1.8

0.9

1.8

0.9

1.8

1.6

0.06

0.32

0.64

0.37

0.13

0.25

0.25

1.1

0.75

0.18

0.08

0.88

0.22

0.44

1.1

0.76

0.38

0.76

0.34

2.5

1.2

0.25

0.15

0.25

3.9

3.9

3.9

ft•lb

0.6

6.4

1.6

3.2

8.0

6.5

13

6.5

13

6.5

13

2.7

0.9

1.8

1.8

11

0.4

2.3

4.6

8.0

5.4

1.3

5.5

2.7

5.5

2.5

18

8.7

1.8

1.1

1.8

28

28

28

E

Remarks

2-8

SPEC

TIGHTENING TORQUES E


Muffler stay 2 – crankcase

Muffler – muffler stay 2

Exhaust temperature sensor

Cooling water temperature sensor

Muffler stay – catalytic converter housing

1st

2nd

Cover/catalytic converter housing/catalytic converter

– muffler

1st

2nd

Mixing joint – muffler

Exhaust chamber assembly – exhaust manifold

Exhaust chamber stay/ exhaust chamber assembly – exhaust chamber bracket

Exhaust chamber joint – exhaust chamber

1st

2nd

Coupling cover – intermediate housing assembly

Engine unit – engine mount

1st

Exhaust manifold – cylinder

2nd

1st

2nd

Cooling water joint – exhaust manifold

Throttle bodies bracket 1, 2/ throttle bodies joint/balance plate/plate/reed valve assembly – crankcase

Throttle bodies joint/ balance plate/plate/reed valve assembly – crankcase

1st

2nd

1st

2nd

Balance plate/plate/reed valve assembly – crankcase

1st

2nd

Valve stopper/reed valve – reed valve base

YPVS cable holder/YPVS valve cover – cylinder

YPVS valve cover – cylinder

YPVS valve arm – shaft 1, 2, 3

YPVS valve stopper bolt

Part name

Bolt

Bolt

—

—

Thread size

M10

M10

—

—

Q’ty

2

1

1

1

Bolt M10 2

Bolt

Bolt

Bolt

M8

M8

M10

6

6

4

Tightening torques

N•m kgf•m ft•lb

39 3.9

28

39

39

20

15

39

3.9

3.9

2.0

1.5

3.9

28

28

14

11

28

15 1.5

11

33

11

22

3.3

1.1

2.2

24

8.0

16

39 3.9

28

Remarks

Bolt

Bolt

Bolt

Bolt

Bolt

Nut

Bolt

Bolt

Bolt

Bolt

Screw

Bolt

Bolt

Bolt

—

M10

M10

M6

M8

M10

M10

M6

M6

M6

M6

M3

M6

M6

M4

M5

2

6

1

4

10

2

6

4

14

4

7.6

3.8

7.6

24 1.0

2

10 9.8

3 2.8

3

39

39

7.9

17

22

39

22

39

12

3.8

7.6

3.8

9.8

3.8

3.9

3.9

0.79

1.7

2.2

3.9

2.2

3.9

1.2

0.38

0.76

0.38

0.76

0.38

0.76

0.1

0.98

0.98

0.28

0.38

28

28

5.7

12

16

28

16

28

8.7

2.7

5.5

2.7

5.5

2.7

5.5

0.7

7.1

7.1

2.0

2.7

2-9

SPEC



Ground lead – cylinder head

Exhaust chamber stay/ cylinder head – cylinder

Cylinder head – cylinder

Anode – cylinder head

Engine temperature sensor – cylinder

1st

Cylinder – crankcase

Generator cover – crankcase

Generator cover/ground lead – crankcase

2nd

1st

2nd

1st

2nd

Exhaust chamber bracket – crankcase

Cable holder – generator cover

Pickup coil – generator cover

Lighting coil – generator cover

Drive coupling – crankshaft assembly

Flywheel magneto – crankshaft assembly

Starter motor/negative battery lead – crankcase

Starter motor – crankcase

Mount bracket – lower crankcase

Upper crankcase – lower crankcase

1st

2nd

1st

2nd

1st

2nd

3rd

1st

2nd

1st

2nd

1st

2nd

1st

2nd

Jet pump unit

Steering cable joint – jet thrust nozzle

Ride plate – hull

Intake duct – hull

Intake grate – hull

Speed sensor – ride plate

Jet pump unit assembly/impeller housing 2 – transom

Nozzle ring – nozzle

Part name

Thread size

Q’ty

Bolt M6 1

Bolt

Bolt

Screw

—

Bolt

Bolt

Bolt

Bolt

Bolt

Bolt

Bolt

Drive coupling

Bolt

M8

M8

M5

—

M10

M10

M10

M10

M6

M5

M6

—

M10

2

16

2

1

12

7

1

4

2

6

3

1

1

15

50

15

50

22

39

15

39

14

4.9

14

36

Tightening torques


3.8

0.38

2.7

7.6

15

35

22

22

35

4.4

0.76

1.5

3.5

2.2

2.2

3.5

0.44

5.5

11

25

16

16

25

3.2

1.5

2.2

3.9

1.5

5.0

1.5

5.0

3.9

1.4

0.49

1.4

3.6

28

10

3.5

10

25

11

36

11

36

16

28

11

Remarks

Bolt

Bolt

Bolt

Bolt

M8

M8

M8

M8

M6

1

1

6

17

10

74

15

27

15

27

11

9.0

18

9.0

18

7.4

1.5

2.7

1.5

2.7

1.1

0.9

1.8

0.9

1.8

53

11

19

11

19

8.0

6.5

13

6.5

13

A

Nut

Bolt

Bolt

Bolt

Screw

Bolt

Bolt

—

M8

M8

M6

M5

M10

M6

M8

1

4

1

2

4

4

4

4

6.8

17

17

7.4

3.7

40

7.8

15

0.68

1.7

1.7

0.74

0.37

4.0

0.78

1.5

4.9

12

12

5.4

2.7

29

5.6

11

2-10

SPEC



Jet thrust nozzle – nozzle ring

Spout hose screw clamp

Nozzle/impeller duct assembly – impeller housing 1

Water inlet cover/water inlet strainer – impeller duct

Drive shaft nut – drive shaft

Impeller (left-hand threads) – drive shaft

Transom plate – hull

Intermediate housing – bulkhead

Driven coupling – shaft

Grease nipple – intermediate housing

Hull and hood

Handlebar cover – handlebar cover stay

Handlebar cover stay – steering column

Upper handlebar holder/lower handlebar holder – steering column

QSTS converter – hull

QSTS cable 1, 2 locknut

Throttle lever assembly – handlebar

Handlebar switch assembly – handlebar

QSTS grip assembly – handlebar

Grip end – handlebar

QSTS cable housing – cover

Plate/steering column assembly – deck

Steering column assembly – deck

Steering arm – steering column

Magnet – steering arm

Steering cable ball joint – steering arm

Handlebar stopper – steering column housing

QSTS cable locknut

(nozzle ring side)

QSTS cable – hull

QSTS cable end – pin –

QSTS converter

Part name

Bolt

—

Thread size

M8

—

Q’ty

2

1

Bolt M10 4

Bolt

Nut

Impeller

Nut

Bolt

Driven coupling

Nipple

Screw

Screw

Bolt

Nut

—

Screw

Screw

Screw

Bolt

Screw

Nut

Nut

Nut

Screw

Nut

Nut

—

Nut

Nut

M6

—

M22

—

M8

M24

—

M6

M6

M8

M6

—

M5

M5

M6

M5

M4

M8

M8

M8

M5

M6

M10

—

—

M6

1

1

1

4

1

1

4

2

2

2

4

3

1

1

4

4

1

2

2

1

1

1

2

1

2

1

Tightening torques


15 1.5

11

1.2

0.12

0.9

40 4.0

29

Remarks

6.6

74

75

26

17

36

5.4

1.1

2.9

16

5.4

16

3.4

3.4

3.4

1.2

1.0

16

16

16

2.0

5.0

26

3.8

5.9

3.8

0.66

7.4

7.5

2.6

1.7

3.6

0.54

0.11

0.29

1.6

0.54

1.6

0.34

0.34

0.34

0.12

0.1

1.6

1.6

1.6

0.2

0.5

2.6

0.38

0.59

0.38

4.8

53

54

19

12

25

3.9

0.8

2.1

11

3.9

11

2.5

2.5

2.5

0.9

0.7

11

11

11

1.4

3.6

19

2.7

4.3

2.7

2-11

SPEC


Part to be tightened Part name

Thread size

Q’ty

Steering cable locknut

(jet thrust nozzle end)

Steering cable – hull

Steering cable holder – bracket

Speed sensor lead – hull

Hinge assembly – hood

Visor – hood

Hood lock – hood

Hinge assembly – deck

—

Nut

Bolt

Nut

Bolt

Screw

Bolt

Nut

Steering console cover assembly – deck

Steering cable bracket – deck

Buzzer bracket/deck – steering cable bracket

Hood lock assembly – deck

Nut

Bolt

Screw

Nut

Multifunction meter – holder Nut

Steering console cover – side cover Screw

Steering console cover – glove compartment

Screw

Bolt

Bolt

Seat lock assembly – seat

Bracket/deck – projection

Bracket/deck – handgrip

Handgrip – deck

Seat bracket – deck

Battery box/stay – holder

Battery box – deck/bracket

Battery box – electrical box

Nut

Bolt

Nut

Bolt

Nut

Nut

Nut

Nut

Bolt

Nut Battery box/stay – electrical box

Extension bolt – negative battery terminal

Exhaust outlet – hull

—

Hose screw clamp

Sponson – hull

Spout – hull

Rope hole – hull

Bow eye – hull

Flap – hull

Drain plug/packing – hull

Engine mount – hull

Engine damper – hull

Bolt

—

Bolt

Nut

Nut

Bolt

Bolt

Nut

Bolt

Bolt

—

M6

M6

M5

M8

M5

M6

—

M6

—

M6

M5

M6

M8

M5

M6

M6

M6

M6

M10

M8

M8

M8

M6

M8

M8

M8

M6

M6

—

M8

M24

M24

M6

M6

—

M8

M6

1

2

2

2

2

2

2

1

2

1

2

2

2

2

4

2

4

2

2

2

8

1

1

1

4

1

2

1

2

8

1

2

3

3

6

4

8

4

1.3

6.4

6.4

6.4

6.4

26

5.2

5.2

15

8.9

13

13

13

6.4

6.4

3.7

18

5.4

5.4

13

7.4

2.0

17

6.4

Tightening torques


6.5

0.65

4.7

5.4

2.9

2.0

16

1.8

2.9

5.9

6.4

5.9

12

1.0

5.4

16

0.54

0.29

0.2

1.6

0.18

0.29

0.59

0.64

0.59

1.2

0.1

0.54

1.6

3.9

2.1

1.4

11

1.3

2.1

4.3

4.6

4.3

8.7

0.7

3.9

11

0.13

0.64

0.64

0.64

0.64

2.6

0.52

0.52

1.5

0.89

1.3

1.3

1.3

0.64

0.64

0.37

1.8

0.54

0.54

1.3

0.74

0.2

1.7

0.64

0.9

4.6

4.6

4.6

4.6

19

3.8

3.8

11

6.4

9.4

9.4

9.4

4.6

4.6

2.7

13

3.9

3.9

9.4

5.4

1.4

12

4.6

Remarks

2-12

SPEC



Electrical

Cover – electrical box

Part name

Lead retainer – electrical box

Positive battery lead – starter relay

Starter motor lead – starter relay

Rectifier/regulator – electrical box

Coupler bracket – electrical box

Wire harness retainer – electrical box

Ignition coil #1, # 2, #3 – electrical box

Fuse holder stay – electrical box

Main and fuel pump relay – electrical box

Ground leads – electrical box

ECM – hull

Slant detection switch – hull

Nut/spring washer/washer (starter motor lead terminal) – starter motor

Starter motor rear cover/starter motor yoke – starter motor front cover

YPVS servomotor bracket – deck

YPVS servomotor/ throttle cable plastic tie bracket –

YPVS servomotor bracket

Tapping screw

Tapping screw

Bolt

Bolt

Tapping screw

Tapping screw

Tapping screw

Tapping screw

Tapping screw

Tapping screw

Bolt

Nut

Nut

Nut

Bolt

Nut

Nut

Thread size

Q’ty

ø6

ø6

M6

M6

ø6

ø6

ø6

ø6

ø6

ø6

M6

—

—

—

M5

—

—

11

2

1

1

2

2

2

6

1

1

2

2

2

1

2

3

2

Tightening torques

N•m

4.9

4.9

3.4

3.4

3.9

3.4

4.9

3.9

3.4

3.9

7.6

5.4

5.4

8.8

6.4

15

5.4

kgf•m

0.49

0.49

0.34

0.34

0.39

0.34

0.49

0.39

0.34

0.39

0.76

0.54

0.54

0.88

0.64

1.5

0.54

ft•lb

3.5

3.5

2.5

2.5

2.8

2.5

3.5

2.8

2.5

2.8

5.5

3.9

3.9

6.4

4.6

11

3.9

Remarks

2-13

SPEC


Nut A Bolt

8 mm

10 mm

12 mm

14 mm

17 mm

M5

M6

M8

M10

M12

General torque specifications


5.0

8.0

18

36

43

0.5

0.8

1.8

3.6

4.3

3.6

5.8

13

25

31

E

GENERAL TORQUE

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached.

Unless otherwise specified, tightening torque specifications require clean, dry threads.

Components should be at room temperature.

2-14

SPEC

CABLE AND HOSE ROUTING


E

L

5

M-M

7

H

Í Î

20˚

C

Ì

Ì

2

L

K

F

K-K

J

B

A

H 7

J-J

7

H

0

9

C

I-I

8

M

K

L

K

H

G

I

I

J

M

G

H

I

J

I

A

C

B

D

E

E

D

F F

H-H

A

B

7

1

2

B

D

É

Ê

1

3

4

C

Ë

E

1

1

A

D-D

E-E

È

F

5

G

6

F-F

G-G

7

H

I

1 Fuel tank breather hose

2 Cooling water pilot outlet

3 YPVS servomotor

4 Throttle cable

5 QSTS cable

6 Steering cable

7 Speed sensor lead

8 Positive battery lead

9 Cooling water temperature sensor lead

0 Exhaust temperature sensor lead

A Negative battery lead

B Starter motor lead

C YPVS cables

D Atmospheric pressure sensor

E Water separator

F Cooling water pilot outlet hose

G Cooling water outlet hose

H Wire harness

I Electrical bilge pump lead

J Wire harness (generator)

K Wire harness (throttle bodies)

L Ventilation hose

2-15

SPEC

CABLE AND HOSE ROUTING E

L

5

M-M

7

H

Í Î

20

˚

C

Ì

Ì

2

L

K

F

K-K

J

B

A

H 7

J-J

7

H

0

9

C

I-I

8

M

K

L

K

H

G

I

I

J

M

G

H

I

J

I

A

C

B

D

E

E

D

F F

H-H

A

B

7

1

2

B

D

É

Ê

1

3

4

C

Ë

E

1

1

A

D-D

E-E

È

F

5

G

6

F-F

G-G

7

H

I

È Align the parting line on the fuel filler neck with the lot mark on the fuel filler hose.

É To wire harness

Ê To ventilation socket

Ë To fuel tank

Ì Down

Í Up

Î Bow

2-16

SPEC


C

D

E

F

G

H

I

J

A

K

1

A

L

8

M

O

N

B-B

C

8

2

3

4

5

6

E

7

8

9

B

B

C

D

7

F-F

1 Buzzer lead

2 Throttle cable

3 YPVS servomotor

4 YPVS cables


6 Battery breather hose

7 Electrical bilge pump lead

8 Steering cable

9 QSTS cable

0 Speed sensor lead

B A

0

È É Ê

A

5

P

B

7

F

F

E

A Negative battery lead

B Starter motor lead

C Speed sensor coupler

D Oil level sensor coupler

E Buzzer coupler

F Engine stop switch coupler

G Multifunction meter coupler

H Start switch coupler

I ECM coupler

J Slant detection switch

2-17

Ì Ë

P Î Í

D

K Fuel pump coupler

L Atmospheric pressure sensor coupler

M Steering switch coupler

N Wire harness (generator)

O Wire harness (throttle bodies)

P Wire harness

SPEC


C

D

E

F

G

H

I

J

A

K

1

A

L

8

M N

O

B-B

C

8

2

3

4

5

6

E

7

8

9

B

B

C

D

A

5

P

B 7

F-F

È To cylinder #3

É To cylinder #2

Ê To cylinder #1

Ë Cooling water temperature sensor

Ì Exhaust temperature sensor

Í To positive battery terminal

Î To starter motor

7

F

F

E

B A

0

È É Ê

P Î Í

D

Ì Ë

2-18

E

SPEC


B

4

A

6

0

9

1 2 3

A

6

B

4

È

8 7

8

1

7

5

4

5

6

2

8

A

3

9

0 2 6

8

9

C

0

3

1 7

5

1 Bilge hose 1

2 Bilge hose 2

3 Steering cable

4 Bilge hose 3

5 QSTS cable

6 Bilge hose 4

7 Cooling water hose (cooling water inlet)

8 Flushing hose

9 Speed sensor lead

0 Cooling water hose (cooling water outlet)

C

C-C

A Electrical bilge pump lead

È Contact the corrugated tube (bilge hose 1) to the hose screw clamp.

2-19

SPEC


È

C

C

É

1 2

B

4

3

Ë

C-C

Ê

B

A

A

Ò

Ó

Ì

Ñ

D

1 Oil delivery hose #1

2 Sub-wire harness



È Pass the plastic tie through the holes of the rib on the fuel rail.

É Fasten oil delivery hoses #2 and #3 and the engine temperature sensor lead with a plastic tie.

D

Ð

Ï

4

3

Í

Î 1

Ê Fasten the sub-wire harness with the plastic tie on the rib of the fuel rail. Be sure to position the plastic tie so that the fastener is visible from the outside.

Ë Pass the oil bleed hose on the inside of the oil pump cable.

Ì To ECM

Í Pass the oil return hose on the outside of the oil pump cable.

2-20

SPEC


È

C

C

É

1 2

B

4

3

Ë

C-C

Ê

B

A

A

Ò

Ó

Ì

Ñ

D

Î Push the corrugated tube toward the oil pump, and then tape it.

Ï To oil tank

Ð To check valve

Ñ Install the oil hoses into the hose holders so that the holders do not cover the check valve clips.

Ò Pass the intake air temperature sensor lead over the fuel hose.

D

Ð

Ï

4

3

Í

Î 1

Ó Pass the bleed hose under the exhaust chamber bracket. Be sure to install the L-shaped bleed hose toward the oil pump.

2-21

SPEC


Ì

B

Ð

È

É

Ê

Ë

A

1

2

3

Ñ

A

Ò

B

Ï Î Ï Î

Ó

Ö

Õ

Ô

Í

C

D

15˚

Ü 15˚ Ø

×

Ï Û Ú

Ï

Ù

20˚

D C

1 Cooling water hose

(cooling water pilot outlet on port side)

2 Fuel hose

3 Oil return hose

È To throttle lever

É To cooling water pilot outlet on port side

Ê When fastening the corrugated tube of the fuel hose to the intake silencer, slide it toward the fuel pump, and then tighten it with a plastic tie.

Ë To cooling water pilot outlet on starboard side

Ì To electrical box

Í Install the exhaust joint so that it contacts the stoppers on the muffler assembly.

Î Face the red mark end of the cooling hose toward the cylinder head cover, and then install the hose.

Ï Install the hose screw clamps in the direction shown.

2-22

SPEC


Ì

B

Ð

È

É

Ê

Ë

A

1

2

3

Ñ

A

Ò

B

Ï Î Ï Î

Ó

Ö

Õ

Ô

Í

C

D

15˚

Ü 15˚ Ø

×

Ï Û Ú

Ï

Ù

20˚

D C

Ð Contact the corrugated tube to the hose screw clamp (muffler assembly end).

Ñ Strongly pull the plastic tie.

Ò After installing the YPVS servomotor, fasten the throttle cable.

Ó Fasten the exhaust temperature sensor lead.

Ô To cylinder #1

Õ To cylinder #2

Ö To cylinder #3

× Cooling water inlet

Ø Install the white tape end of the negative battery lead to the battery.

Ù Fasten the sub-wire harness and wire harness

(generator).

Ú Fasten the wire harness (generator).

Û Route the sub-wire harness under the cooling water hose.

Ü Install the oil pump cable to the angle shown in the illustration.

2-23

INSP

ADJ

CHAPTER 3

PERIODIC INSPECTION AND ADJUSTMENT

MAINTENANCE INTERVAL CHART .............................................................. 3-1

PERIODIC SERVICE ....................................................................................... 3-2

CONTROL SYSTEM ................................................................................. 3-2

Steering column inspection ................................................................. 3-2

Steering cable inspection and adjustment .......................................... 3-2

Throttle cable inspection and adjustment............................................ 3-3

QSTS cable inspection and adjustment .............................................. 3-4

Trolling speed check ........................................................................... 3-5

FUEL SYSTEM.......................................................................................... 3-7

Fuel line inspection ............................................................................. 3-7

Water separator inspection ................................................................. 3-7

OIL INJECTION SYSTEM ......................................................................... 3-8

Oil line inspection ................................................................................ 3-8

POWER UNIT............................................................................................ 3-9

Spark plug inspection.......................................................................... 3-9

YPVS cable adjustment .................................................................... 3-10

ELECTRICAL .......................................................................................... 3-12

Battery inspection.............................................................................. 3-12

JET PUMP UNIT ..................................................................................... 3-15

Impeller inspection ............................................................................ 3-15

Water inlet strainer inspection........................................................... 3-15

BILGE PUMP........................................................................................... 3-16

Bilge strainer inspection .................................................................... 3-16

Electric bilge pump strainer inspection.............................................. 3-16

GENERAL ............................................................................................... 3-17

Drain plug inspection......................................................................... 3-17

Lubrication points .............................................................................. 3-17

E

5

6

7

8

9

3

4

1

2

INSP

ADJ MAINTENANCE INTERVAL CHART

MAINTENANCE INTERVAL CHART

Use the following chart as a guide to general maintenance.

Adjust the maintenance intervals according to the operating conditions of the watercraft.

E

ITEM

Throttle shaft Inspect

Cooling water passages Flush

Water inlet strainer

Bilge strainer

Inspect, clean

Clean

Electric bilge pump strainer

Impeller

Jet thrust nozzle angle

Inspect, clean

Inspect

Inspect

QSTS mechanism

Throttle lever

Throttle cable

Stern drain plugs

Battery

Rubber coupling

Engine mount

Nuts and bolts

MAINTENANCE INTERVAL

Spark plug

Lubrication points

Intermediate housing

Fuel system

Fuel tank

Oil injection system

Inspect, clean, adjust

Lubricate

Lubricate

Inspect

Clean

Inspect, clean

Inspect, adjust

Check operation

Inspect, adjust

Inspect, replace

Inspect

Inspect

Inspect

Inspect

INITIAL

THEREAFTER

EVERY

10 hours 50 hours 100 hours 100 hours 200 hours

*1

6 months

12 months

*2

12 months

24 months

PAGE

3-9

3-17

*2

3-19

3-7

3-7

3-8

*3

—

—

3-15

3-16

*4

3-16

3-15

3-2

*4

3-4

*4

3-3

3-3

*4

3-17

*5

3-12

—

5-15

—

*1

Grease quantity: 33.0–35.0 cm

3

(1.11–1.18 oz)

*2

Grease quantity: 6.0–8.0 cm

3

(0.20–0.27 oz)

*3

After each use

*4

Before each use

*5

Check the electrolyte level before each use.

3-1

INSP

ADJ CONTROL SYSTEM

E

PERIODIC SERVICE

CONTROL SYSTEM

Steering column inspection

1. Check:

• Steering column

Excessive play

→ Replace the steering column.

Refer to “STEERING COLUMN” in

Chapter 8.

Checking steps:

• Move the handlebar up and down and back and forth.

• Check the excessive play of the handlebar.

3

2

1

3-2

Steering cable inspection and adjustment

1. Measure:

• Jet thrust nozzle distances a and b

Difference

→ Adjust.

Difference of distances a and b:

Maximum 5 mm (0.2 in)

Measurement steps:

• Set the control grip to the neutral position.

• Turn the handlebar lock to lock.

• Measure distances a and b.

• If the difference of distances a and b is not within specification, adjust the cable joint.

2. Adjust:

• Steering cable joint

(steering column end)

Adjustment steps:


• Loosen the locknut 1.

• Disconnect the steering cable joint

2 from the ball joint 3.

• Turn the cable joint in or out to adjust distances a and b.

Turn in

Turn out

Distance a is increased.

Distance b is increased.

INSP


E

WARNING

The cable joint must be screwed in a minimum of 8 mm (0.31 in).

• Connect the cable joint, and then tighten the locknut.

.

T

R

.

Locknut:

6.8 N • m (0.68 kgf • m, 4.9 ft • lb)

NOTE:

If the steering cable cannot be properly adjusted by the cable joint at the steering column end, adjust the cable joint at the jet pump end so that the specified distance is obtained.

Refer to “REMOTE CONTROL CABLES AND

SPEED SENSOR LEAD” in Chapter 8.

Throttle cable inspection and adjustment

1. Measure:

• Throttle lever free play a

Out of specification

→ Adjust.

Throttle lever free play:

4–7 mm (0.16–0.28 in)

2. Adjust:

• Throttle lever free play



• Turn the adjuster

2 in or out until the specified free play is obtained.

Turn in

Turn out

Free play is increased.

Free play is decreased.

• Tighten the locknut.

WARNING

After adjusting the free play, turn the handlebar to the right and left and make sure that the trolling speed does not increase.

3-3

INSP


E

QSTS cable inspection and adjustment

1. Measure:

• Jet thrust nozzle set lengths a and b


→ Adjust.



• Set the jet thrust nozzle in the center position.

• Measure jet thrust nozzle set lengths a and b.

• If lengths a and b are not even, adjust the cable joint.

3-4

2. Adjust:

• QSTS cable




• Remove the nut

2 and pivot pin 3.

• Set the jet thrust nozzle in the center position.

• Turn the cable joint 4 in or out to adjust lengths a and b.

Turn in

Turn out

Length b is increased.

Length a is increased.

WARNING

The cable joint must be screwed in a minimum of 8 mm (0.31 in).

• Connect the cable joint

4 and pivot pin

3, and then tighten the nut 2.

.

T

R

.

Nut:

3.8 N • m (0.38 kgf • m, 2.7 ft • lb)

• Tighten the locknut

1.

T

.

R

.

Locknut:

4 N • m (0.4 kgf • m, 2.9 ft • lb)

INSP


E

NOTE:

If the QSTS cable cannot be properly adjusted by the cable joint at the QSTS converter end, adjust the cable joint at the jet pump end so that the same lengths are obtained. Refer to

“REMOTE CONTROL CABLES AND SPEED

SENSOR LEAD” in Chapter 8.

Trolling speed check

NOTE:

The trolling speed of this model is adjusted automatically by the ECM according to the operating conditions of the watercraft. Therefore, it is not necessary to adjust the trolling speed.

1. Measure:

• Trolling speed


→ Proceed to step

2.

Trolling speed:

1,250–1,450 r/min

Checking steps: (watercraft in water)

• Start the engine and warm it up for a few minutes at 4,000–4,500 r/min to stabilize the trolling speed.

• Measure the trolling speed.

2. If the trolling speed is out of specification, check the following.

If no malfunctions are found after performing all of the checks, replace the throttle bodies.

• Check the spark plugs.

Refer to “Spark plug inspection.”

• Check the throttle cable and oil pump cable.

Refer to “Throttle cable inspection and adjustment.”

Refer to “OIL PUMP” in Chapter 4.

• Check the intake passages.

Refer to “INTAKE DUCT AND INTAKE

SILENCER” in Chapter 4.

Refer to “REED VALVES” in Chapter 5.

Refer to “HOSES” in Chapter 8.

3-5

INSP


E

• Check the exhaust passages.

Refer to “MUFFLER ASSEMBLY” in

Chapter 5.

Refer to “EXHAUST CHAMBER

ASSEMBLY” in Chapter 5.

Refer to “EXHAUST MANIFOLD” in

Chapter 5.

Refer to “EXHAUST SYSTEM” in Chapter 8.

• Measure the fuel pressure.

Refer to “Fuel pressure measurement” in Chapter 4.

• Check the fuel for deterioration, the fuel tank for water accumulation, the fuel lines for clogs or kinks, and the fuel injectors for clogs.

Refer to “FUEL SYSTEM.”

Refer to “FUEL TANK AND FUEL

PUMP MODULE” in Chapter 4.

Refer to “FUEL INJECTION SYSTEM” in Chapter 4.

• Measure the compression pressure.

Refer to “COMPRESSION PRESSURE

MEASUREMENT” in Chapter 5.

• Check the jet pump and impeller.

Refer to “JET PUMP UNIT” in Chapter 6.

• Check the diagnostic codes in the “Diagnosis Record” and check for any malfunctions using the “Static Test” and

“Active Test” of the Yamaha Diagnostic

System.

Refer to “INTRODUCTION” in Chapter

9.

3-6

INSP

ADJ FUEL SYSTEM

3-7

E

FUEL SYSTEM

WARNING

When removing fuel system parts, wrap them in a cloth and take care that no fuel spills into the engine compartment.

Fuel line inspection

1. Check:

• Fuel pump filter

Clog/contaminants → Clean.

Refer to “FUEL TANK AND FUEL

PUMP MODULE” in Chapter 4.

• Fuel hoses

Cracks/damage

→ Replace.

• O-rings (quick connector)

Cracks/damage → Replace the quick connector.

• Fuel pipe

Cracks/damage → Replace the fuel pump.


• Fuel filler hose

• Fuel filler cap

Cracks/damage → Replace.

2. Check:

• Fuel tank


Water accumulation

→ Remove.

NOTE:

To remove water from the fuel tank, remove the cap

1 and use a siphon pump.

.

T

R

.

Fuel tank cap screw clamp:

1.3 N • m (0.13 kgf • m, 0.9 ft • lb)

Water separator inspection

1. Check:

• Water separator

1

Water accumulation

→ Drain.

NOTE:

To drain water from the water separator, remove the drain plug

2.

INSP

ADJ OIL INJECTION SYSTEM

E

OIL INJECTION SYSTEM

Oil line inspection

1. Check:

• Oil filter

Contaminants

→ Clean.

Frays/tears

→ Replace.

• Rubber seal

Cracks/wear

→ Replace.

• Oil hoses

• Oil tank

• Oil filler cap

Cracks/damage

→ Replace.

• Check valve

Malfunction

→ Replace.

CAUTION:

Do not allow the oil tank to become completely empty. If the oil tank becomes empty the oil injection pump must be bled to ensure proper oil flow, otherwise engine damage may occur. Refer to “OIL PUMP” in

Chapter 4.

3-8

INSP

ADJ POWER UNIT

E

POWER UNIT

Spark plug inspection

1. Check:

• Electrodes

1

Damage/wear

→ Replace.

• Insulator color

2

Distinctly different color

→ Check the condition of the engine.

Color guide:

Medium-to-light tan color:

Normal

Whitish color:

Lean air-fuel mixture

Air leakage

Incorrect settings

Blackish color:

Overly rich air-fuel mixture

Electrical malfunction

Excessive oil use

Defective spark plug

2. Clean:

• Spark plug

(using a spark plug cleaner or wire brush)

3. Measure:

• Spark plug gap a


→ Regap.

Spark plug gap:

1.0–1.1 mm (0.039–0.043 in)

3-9

INSP

ADJ POWER UNIT

1

2 a

4. Tighten:

• Spark plugs

T

.

R

.

Spark plug:

25 N • m (2.5 kgf • m, 18 ft • lb)

E

NOTE:

• Before installing a spark plug, clean the gasket surface and spark plug surface. Also, it is suggested to apply a thin coat of anti-seize compound to the spark plug threads to prevent thread seizure.

• If a torque wrench is not available, a good estimate of the correct tightening torque for a new spark plug is to first finger tighten a the spark plug and then tighten it another 1/4 to

1/2 of a turn b.

YPVS cable adjustment

1. Check:

• YPVS valve position

Incorrect position

→ Adjust YPVS cables 1 and 2.

Checking steps:

• Start the engine, and then turn it off.

NOTE:

• Immediately after the engine stop switch is pushed, the YPVS valves extend and retract two times to clean the exhaust ports.

• If the engine is stopped without the engine stop switch being pushed, the YPVS valves extend and retract two times to clean the exhaust ports 30 seconds after the engine is stopped.

• Check that the hole a in the pulley is aligned with the hole in the cylinder when the YPVS valve is fully closed.

3-10

INSP

ADJ POWER UNIT

2. Measure:

• YPVS cable slack a


→ Adjust.

YPVS cable slack:

0.5–1.5 mm (0.02–0.06 in)

E

4 1

3 2

1

2 a

3. Adjust:

• YPVS cables 1 and 2


• Loosen locknuts

1 and 2.

• Turn adjusters

3 and 4 in until there is slack in the cables.

• Align the hole a in the pulley with the hole in the cylinder.

• Insert a 4 mm (0.16 in) diameter pin through the pulley and cylinder holes.

• Turn adjusters

3 and 4 in or out until the specified slack is obtained.

Turn in Slack is increased.

Turn out Slack is decreased.

• Finger tighten locknuts

1 and 2.

• Remove the pin.

• Start the engine, and then turn it off.

• Check the alignment of the holes.

• If the holes are aligned correctly, tighten the locknuts.

• If the holes are aligned incorrectly, repeat the adjustment steps.

3-11

INSP

ADJ ELECTRICAL

E

ELECTRICAL

Battery inspection

WARNING

• Battery electrolyte is poisonous and dangerous, causing severe burns, etc. Electrolyte contains sulfuric acid. Avoid contact with skin, eyes or clothing.

Antidotes

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc., well away.

If using or charging the battery in an enclosed space, make sure that it is well ventilated. Always shield your eyes when working near batteries.

KEEP OUT OF THE REACH OF CHIL-

DREN.

• Be sure to connect the breather hose to the battery. Fire or explosion could result if the breather hose is damaged, obstructed, or not connected properly.

CAUTION:

• Be careful not to place the battery on its side.

• Be sure to remove the battery from the battery compartment when adding electrolyte or charging the battery.

• When checking the battery, make sure that the breather hose is connected to the battery and not obstructed.

3-12

INSP

ADJ ELECTRICAL

E

1. Remove:

• Battery bands

• Negative battery lead

1

• Positive battery lead

2

• Battery

• Battery breather hose

3

WARNING

• When removing the battery, disconnect the negative lead first.

• Remove the battery to prevent acid loss before turning the watercraft on its side to service the impeller, etc.

2. Check:

• Electrolyte level

Low

→ Add distilled water.

The electrolyte level should be between the maximum a and minimum b level marks.

Filling steps:

• Remove the filler caps.

• Add distilled water to the maximum level mark.

• Allow the battery to stand for 20 minutes.

If the electrolyte level drops, add more distilled water until the level reaches the maximum level mark.

CAUTION:

Use only distilled water. Other types of water contain minerals which are harmful to batteries.

3-13

INSP

ADJ ELECTRICAL

3. Check:

• Specific gravity


→ Charge.

Specific gravity at 20 °C (68 °F):

1.28

Charging current:

1.9 A

× 10 h (68.4 kC)

E

4. Install:

• Filler caps

CAUTION:

Before installing the battery, rinse off any electrolyte from the battery box or battery and make sure that the battery is dry.

5. Install:

• Battery breather hose

1

• Battery

• Positive battery lead

2

• Negative battery lead

3 (with terminal extension at negative battery terminal)

• Battery bands

CAUTION:

• Connect the positive lead to the battery terminal first.

• Make sure that the battery leads are connected properly. Reversing the leads can seriously damage the electrical system.

• Make sure that the battery breather hose is properly connected and is not obstructed.

• Coat the terminals with a water-resistant grease to minimize terminal corrosion.

3-14

INSP

ADJ JET PUMP UNIT a

1

JET PUMP UNIT

Impeller inspection

1. Check:

• Impeller

1

Damage/wear

→ Replace.

Nicks/scratches

→ File or grind.

2. Measure:

• Impeller-to-housing clearance a


→ Replace.

Maximum impeller-to-housing clearance:

0.9 mm (0.035 in)

E


• Disconnect the battery leads.

• Remove the intake grate and intake duct.


• Measure the clearance at each impeller blade as shown (a total of four measurements).

• Install the intake duct and intake grate.


• Connect the battery leads.

1 a

3-15

Water inlet strainer inspection

1. Check:

• Water inlet strainer

Contaminants

→ Clean.

Cracks/damage

→ Replace.

Checking steps:

• Remove the ride plate.


• Remove the water inlet cover

1.

• Check the water inlet strainer mesh a.

• Install the water inlet cover.

• Install the ride plate.


.

T

R

.

Water inlet cover bolt:

6.6 N • m (0.66 kgf • m, 4.8 ft • lb)

LOCTITE 572

INSP

ADJ

1

BILGE PUMP

E

BILGE PUMP

Bilge strainer inspection

1. Check:

• Bilge strainer

Contaminants

→ Clean.

Cracks/damage

→ Replace.

Checking steps:

• Remove the bilge strainer case 1 from the bilge strainer.

• Check the bilge strainer and bilge strainer case.

• Install the bilge strainer case.

1

3

2

Electric bilge pump strainer inspection

1. Check:

• Cap

• Strainer

Contaminants

→ Clean.

Checking steps:

• Remove the battery box.

Refer to “BATTERY BOX” in Chapter 8.

• Remove the band 1.

• Remove the cap

2 and strainer 3.

• Check the cap and strainer.

• Install the strainer and cap.

• Install the band.

• Install the battery box.


3-16

INSP

ADJ GENERAL

E

GENERAL

Drain plug inspection

1. Check:

• Drain plugs

Cracks/damage

→ Replace.

• O-rings

Cracks/wear

→ Replace.

• Screw threads

Contaminants

→ Clean.

Lubrication points

1. Lubricate:

• Throttle cable (handlebar end)

Recommended lubricant:

Rust inhibitor

NOTE:

Before lubricating the throttle cable, squeeze the throttle lever and remove the rubber seal

1.

3-17

2. Lubricate:

• QSTS control cables (handlebar end)

Recommended lubricant:

Yamaha marine grease,

Yamaha grease A

(water-resistant grease)

NOTE:

Before lubricating the QSTS control cables, remove the QSTS cable housing cover. Spray the rust inhibitor into the outer cables, and apply grease to the inner cables.

INSP

ADJ GENERAL

3. Lubricate:

• QSTS cables (pulley end)

• YPVS cables

Recommended grease:


Yamaha grease A


E

3-18

4. Lubricate:

• Nozzle pivot shaft

• Steering cable (jet thrust nozzle end)

• QSTS cable (jet thrust nozzle end)



Yamaha grease A


5. Lubricate:

• Steering cable

• Steering cable joint

NOTE:

Disconnect the steering cable joint, and then apply a small amount of grease to it.



Yamaha grease A


INSP

ADJ GENERAL

6. Fill:

• Intermediate housing



Yamaha grease A


Grease quantity:

33.0–35.0 cm 3 (1.11–1.18 oz)

E

NOTE:

Using a grease gun, fill the intermediate housing with the recommended grease through the grease nipples.

3-19

FUEL

CHAPTER 4

FUEL SYSTEM

OIL TANK ........................................................................................................ 4-1

EXPLODED DIAGRAM ............................................................................. 4-1

REMOVAL AND INSTALLATION CHART ................................................ 4-1

SERVICE POINTS .................................................................................... 4-3

Oil line inspection ................................................................................ 4-3

Oil level sensor inspection .................................................................. 4-3

Oil tank inspection............................................................................... 4-3

FUEL TANK AND FUEL PUMP MODULE...................................................... 4-4



SERVICE POINTS .................................................................................... 4-7

Fuel hose disconnection ..................................................................... 4-7

Fuel pump module removal................................................................. 4-7

Fuel sender disassembly .................................................................... 4-7

Check valve inspection ....................................................................... 4-8

Fuel pump filter inspection .................................................................. 4-8

Fuel pump module installation ............................................................ 4-8

Fuel hose connection .......................................................................... 4-8

INTAKE DUCT AND INTAKE SILENCER ...................................................... 4-9



SERVICE POINTS .................................................................................. 4-11

Intake silencer installation ................................................................. 4-11

FUEL INJECTION SYSTEM.......................................................................... 4-12

EXPLODED DIAGRAM ........................................................................... 4-12

REMOVAL AND INSTALLATION CHART .............................................. 4-12

SERVICE POINTS .................................................................................. 4-18

Hose clamp removal ......................................................................... 4-18

Hose clamp installation ..................................................................... 4-18

Fuel hose disconnection ................................................................... 4-18

Fuel line inspection ........................................................................... 4-19

Fuel injector inspection ..................................................................... 4-20

Throttle body inspection .................................................................... 4-20

Fuel hose installation (replacing with new fuel hose)........................ 4-21

Fuel hose connection ........................................................................ 4-22

Throttle cable installation .................................................................. 4-22

Fuel pressure measurement ............................................................. 4-22

E

FUEL

OIL PUMP...................................................................................................... 4-24



SERVICE POINTS .................................................................................. 4-27

Oil pump inspection........................................................................... 4-27

Oil hose inspection............................................................................ 4-27

Check valve inspection ..................................................................... 4-27

Oil pump lever position adjustment ................................................... 4-28

Oil pump bleeding ............................................................................. 4-29

E

5

6

7

8

9

3

4

1

2

FUEL

OIL TANK

OIL TANK

EXPLODED DIAGRAM

E

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name

OIL TANK REMOVAL

Engine unit

Steering console cover assembly

Q’ty Service points

Follow the left “Step” for removal.

Refer to “ENGINE UNIT” in Chapter 5.

Refer to “STEERING CONSOLE COVER” in

Chapter 8.

1 Oil level sensor coupler

2 Plastic tie

1

1 Not reusable

Disconnect the oil filler hose from the oil filler neck.

3 Nut

4 Oil filler neck

5 Rubber seal

1

1

1

4-1

FUEL

OIL TANK


E


6 Breather hose

7 Oil hose

8 Bolt

9 Strap

10 Oil tank

11 Hose screw clamp

12 Oil filler hose

13 Oil level sensor

Q’ty

1

1

1

1

2

2

1

1

Service points

Reverse the removal steps for installation.

4-2

FUEL

OIL TANK

E

SERVICE POINTS

Oil line inspection

1. Check:

• Oil filter

Contaminants

→ Clean.

Frays/tears

→ Replace.

• Rubber seal

Cracks/wear

→ Replace.

• Oil hoses

• Oil filler cap

Cracks/damage

→ Replace.

• Check valve

Faulty

→ Replace.

Oil level sensor inspection

Refer to “INDICATION SYSTEM” in Chapter 7.

Oil tank inspection

1. Check:

• Oil tank

Cracks/damage

→ Replace.

4-3

FUEL

FUEL TANK AND FUEL PUMP MODULE



8

(VENT)

3

2

1

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

16

17

15

13

9

10

11

4

12

E

1st 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib)

2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

5

6

7

13

14

5.9 N • m (0.59 kgf • m, 4.3 ft • Ib)

1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)

20

572

18

19

16 N • m (1.6 kgf • m, 11 ft • Ib)

8

× 18 mm



FUEL TANK REMOVAL

Oil tank


2 Check valve


4 Fuel sender coupler

5 Fuel pump module coupler

Q’ty

1

1

1

1

1

Service points


Refer to “OIL TANK.”

NOTE:

Make sure that the inner seal of the coupler is installed properly before connecting the coupler.

4-4

FUEL



8

(VENT)

3

2

1

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

16

17

15

13

9

10

11

4

12

E

1st 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib)

2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

5

6

7

13

14

5.9 N • m (0.59 kgf • m, 4.3 ft • Ib)

1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)

20


6 Cover

7 Fuel hose

8 Nut

9 Retainer

10 Fuel pump module

11 Seal

12 Fuel sender assembly

13 Hose screw clamp

14 Fuel filler hose

15 Nut

16 Fuel filler neck

Q’ty

1

1

1

1

9

1

1

1

1

2

1

4-5

572

18

19

16 N • m (1.6 kgf • m, 11 ft • Ib)

8

× 18 mm

Service points

FUEL



8

(VENT)

3

2

1

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

16

17

15

13

9

10

11

4

12

E

1st 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib)

2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

5

6

7

13

14

5.9 N • m (0.59 kgf • m, 4.3 ft • Ib)

Step

1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)

17 Rubber seal

18 Fuel tank

19

20

Bolt

Strap

Procedure/Part name

20

572

18

19

16 N • m (1.6 kgf • m, 11 ft • Ib)

8

× 18 mm

Q’ty

1

1

2

2

Service points


4-6

FUEL


E

SERVICE POINTS

Fuel hose disconnection

1. Disconnect:

• Fuel hose

Refer to “FUEL INJECTION SYSTEM.”

2

3

8

6

9

4

7

5

1

1

Fuel pump module removal

1. Remove:

• Nuts

• Retainer

NOTE:

Loosen the nuts in the sequence shown.

2. Remove:

• Fuel pump module

1

NOTE:

Remove the float

2 at an angle to avoid catching it on the fuel tank.

2 b b a a 2 a a 1

4-7

Fuel sender disassembly

1. Disconnect:

• Fuel sender coupler

2. Remove:

• Retainer

1

NOTE:

Push the tabs in the direction of the arrows a, and then slide the retainer 1 in the direction of arrow b.

3. Remove:

• Fuel sender

NOTE:

Push the tabs a in, and then remove the fuel sender

2 in the direction of the arrow b.

FUEL

A

A

1


B

B

E

Check valve inspection

1. Check:

• Check valve

Faulty

→ Replace.

Checking steps:

• Connect a hose to end “A” of the check valve, and then blow into the hose.

Air should come out from end “B.”

• Connect the hose to end “B” of the check valve, and then blow into the hose.

Air should not come out from end “A.”

Fuel pump filter inspection

1. Check:

• Fuel pump filter

1

Clog/contaminants

→ Wash the fuel pump filter in kerosene or gasoline.

8

7

2

4

1

6

3

5

9

4-8

Fuel pump module installation

1. Tighten:

• Nuts

.

T

R

.

Fuel pump module nut:

1st:

3.2 N • m

(0.32 kgf • m, 2.3 ft • lb)

2nd:

6.4 N • m

(0.64 kgf • m, 4.6 ft • lb)

NOTE:

Tighten the nuts in the sequence shown and in two stages.

Fuel hose connection

Refer to “FUEL INJECTION SYSTEM.”

FUEL

INTAKE DUCT AND INTAKE SILENCER



E



INTAKE DUCT AND INTAKE

SILENCER REMOVAL

Exhaust chamber assembly





1 Intake silencer screw clamp

2 Intake silencer

3 Intake silencer pipe screw clamp

4 Intake silencer pipe

5 Plastic tie

2

1

1

1

1 NOTE:

Fasten the fuel hose, oil return hose, and pilot water hose (port side) together with the plastic tie.

4-9

FUEL



E


6 Bolt/collar/grommet

7 Intake duct

Q’ty

1/1/1

1

Service points


4-10

FUEL


55˚ 2

1

E

SERVICE POINTS

Intake silencer installation

1. Install:

• Intake silencer pipe

• Intake silencer pipe screw clamps

1

• Intake silencer

• Intake silencer screw clamp

2

NOTE:

Set the screw clamps in the direction shown.

1

4-11

FUEL

FUEL INJECTION SYSTEM



E

11 N • m (1.1 kgf • m, 8.0 ft • Ib)

1

2

10

8

3

4

7

LT

242

9

8

LT

242

5

6

8 × 30 mm

1st 9.0 N • m (0.9 kgf • m, 6.5 ft • Ib)

2nd 18 N • m (1.8 kgf • m, 13 ft • Ib)



THROTTLE BODIES ASSEMBLY

REMOVAL

Intake silencer pipe

Q’ty

1 Plastic tie 1

Service points



SILENCER.”

NOTE:

Fasten the wire harness (lighting coil, pickup coil, ground lead) and sub-wire harness together with the plastic tie.

2 Sub-wire harness coupler/ throttle switch coupler

3 Engine temperature sensor coupler

1/1

1

4-12

FUEL



E

11 N • m (1.1 kgf • m, 8.0 ft • Ib)

1

2

10

8

3

4

7

LT

242

9

8

LT

242

5

6

8 × 30 mm

1st 9.0 N • m (0.9 kgf • m, 6.5 ft • Ib)

2nd 18 N • m (1.8 kgf • m, 13 ft • Ib)


4 Plastic tie

5 Cover

6 Fuel hose

7 Throttle bodies screw clamp

8 Bolt

9 Throttle bodies assembly

10 Throttle cable

Q’ty

1

Service points

NOTE:

Fasten the sub-wire harness and oil delivery hoses together with the plastic tie.

1

1

3 Tighten the screw clamp until there is no clearance between the spacer and the screw clamp.

2

1

1


4-13

FUEL



4

2

1

2

3



INTAKE SILENCER CASE AND

THROTTLE BODIES REMOVAL

1 Intake air temperature sensor coupler

2 Intake silencer case screw clamp

Q’ty

1

3

Service points


Tighten the screw clamp until there is no clearance between the spacer and the screw clamp.

3 Throttle bodies

4 Intake silencer case

1

1


4-14

E

FUEL



7

7

0.8 N • m (0.08 kgf • m, 0.6 ft • Ib)

5

× 12 mm

5

8

6

4

3

6

2

6 × 30 mm

1.8 N • m (0.18 kgf • m, 1.3 ft • Ib)

572

1

7.5 N • m (0.75 kgf • m, 5.4 ft • Ib)



INTAKE SILENCER CASE

DISASSEMBLY

1 Intake air temperature sensor

2 Tapping screw

3 Intake silencer case cover

4 Gasket

5 Screw

6 Flame arrester

7 Intake silencer case joint

8 Intake silencer case

Q’ty

3

1

6

3

1

13

1

1

Service points

Follow the left “Step” for disassembly.

Reverse the disassembly steps for assembly.

4-15

E

FUEL



5

6

2

3

1

8

6

8.8 N • m (0.88 kgf • m, 6.4 ft • Ib)

6 × 60 mm

6

7

9

10

9

10

11

9

10

E

4

1



THROTTLE BODIES

DISASSEMBLY

1 Hose clamp

2 Fuel hose

3 Grommet

4 Quick connector

5 Sub-wire harness

6 Bolt

7 Fuel rail

8 Spacer

Q’ty

1

3

1

3

1

1

2

1

Service points


Not reusable

4-16

FUEL



5

6

2

3

1

8

6

8.8 N • m (0.88 kgf • m, 6.4 ft • Ib)

6 × 60 mm

6

7

9

10

9

10

11

9

10

E

4

1


9 Fuel injector

10 O-ring

11 Throttle bodies

Q’ty

3

3

1

Not reusable

Service points


4-17

FUEL


SERVICE POINTS

Hose clamp removal

1. Remove:

• Hose clamps

E

CAUTION:

If the hose clamps are removed without cutting the crimp first, the fuel hose can be damaged.

Hose clamp installation

1. Install:

• Hose clamps

WARNING

Do not reuse the hose clamps, always replace them with new ones.

NOTE:

Crimp the hose clamps properly to securely fasten them.

1

2 a

4-18

Fuel hose disconnection

WARNING

Before disconnecting the fuel hoses, remove the fuel tank filler cap to reduce any pressure inside the fuel tank, and then disconnect the negative battery lead to cut off the electric current to the electrical systems.

1. Wrap the quick connector with a cloth, and then rotate the quick connector tab

1 to the stopper position a.

WARNING

If the quick connector is removed suddenly, pressurized fuel can spray out. To gradually release the fuel pressure, be sure to remove the quick connector slowly.

FUEL

2

2

1

FUEL INJECTION SYSTEM a

1

E

CAUTION:

• Do not rotate the quick connector tab

1 past the stopper position a, otherwise the tab can be damaged.

• When the fuel hoses are disconnected, quickly remove the retainer

2 from the quick connector, otherwise the retainer can be lost.

2. Disconnect the fuel hose

1 from the fuel pipe

2 directly.

WARNING

Always reduce the fuel pressure in the fuel line before servicing the line or the fuel pipe. If the fuel pressure is not released, pressurized fuel can spray out.

3. Cover the quick connector and fuel pipe with a plastic bag to prevent damage and to protect them from dirt.

Fuel line inspection

1. Check:

• Fuel hose

Damage/cracks

→ Replace.

• O-rings (quick connector)

Damage/cracks

→ Replace the quick connector.

• Fuel pipe

Damage/cracks

→ Replace the fuel pump.

4-19

FUEL


Fuel injector inspection

E

CAUTION:

The throttle bodies should not be disassembled unnecessarily.

1. Check:

• Fuel injector

Dirt/residue

→ Clean.

Damage

→ Replace.

2. Measure:

• Fuel injector resistance


→ Replace.

Digital multimeter:

YU-34899-A

Digital circuit tester:

90890-03174

Fuel injector resistance

(reference data):

13.8 Ω at 21 °C (70 °F)

3. Check the operation of the fuel injector using the “Stationary Test” of the Yamaha

Diagnostic System.

4-20

Throttle body inspection

1. Check:

• Throttle body

Cracks/damage

→ Replace the throttle bodies.

2. Check:

• Fuel passages

Obstruction

→ Clean.

Checking steps:

• Wash the throttle body in a petroleum based solvent.

Do not use any caustic carburetor cleaning solution.

• Blow out all of passages with compressed air.

FUEL

2

FUEL INJECTION SYSTEM a b

1

E

Fuel hose installation (replacing with new fuel hose)

1. Install:

• Quick connector

1

NOTE:

To install the fuel hose, be sure to align the lot mark a on the fuel hose and the checker tab

2 on the quick connector with the crimped section b of the clamp.

2

A

A-A

1 a

A

2

2. Install:

• Fuel hose

1

NOTE:

• Install the checker tab 2 of the fuel hose in the position shown in the illustration in relation to the throttle bodies.

• Install the clamp with the crimped section at the angle shown in the illustration.

• When replacing the fuel hose with a new one, a checker tab 2 that has half engagement prevention is attached to the quick connector of the hose. If the quick connector is completely installed to the fuel pipe, it is removable.

4-21

FUEL


E

Fuel hose connection

1. Apply a thin coat of engine oil to the contact surfaces of the fuel pipe.

2. Insert the quick connector into the fuel pipe until you hear a “click.”

3. To check the connection of the quick connector, push and pull on the quick connector several times until there is free play of

2–3 mm (0.08–0.12 in).

NOTE:

If free play cannot be obtained, disconnect the fuel hose and check the O-ring for damage and that it is properly installed.

Throttle cable installation

1. Adjust:

• Oil pump lever position

Refer to “OIL PUMP.”

2. Adjust:


Refer to “CONTROL SYSTEM” in Chapter 3.

1

2

Fuel pressure measurement

1. Disconnect:

• Fuel hose

Refer to “Fuel hose disconnection.”

2. Install:

• Fuel pressure gauge adapter

1

• Fuel pressure gauge

2

Fuel pressure gauge adapter:

YW-06842/90890-06842

Fuel pressure gauge:

YB-06766/90890-06786

NOTE:

To connect the fuel pressure gauge adapter, follow the procedures for connecting a fuel hose. (Refer to “Fuel hose connection.”)

4-22

FUEL


E

3. Start the engine and warm it up for several minutes.

4. Measure:

• Fuel pressure


→ Replace the fuel pump module.

Fuel pressure:

320.8–327.2 kPa

(3.21–3.27 kgf/cm

2

,

45.62–46.53 psi)

5. Remove:

• Fuel pressure gauge

• Fuel pressure gauge adapter

NOTE:

To disconnect the fuel pressure gauge adapter, follow the procedures for disconnecting a fuel hose. (Refer to “Fuel hose disconnection.”)

6. Connect:

• Fuel hose

Refer to “Fuel hose connection.”

4-23

FUEL

OIL PUMP

OIL PUMP


E

4

6

5

3

8

3

3

7

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 12 mm

13

11

11 N • m (1.1 kgf • m, 8.0 ft • Ib) 10

5

× 10 mm

572

1

1st 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib)

2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)

2

12 9

6

× 20 mm

1st 3.8 N • m (0.38 kgf • m, 2.7 ft • Ib)

2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)



OIL PUMP REMOVAL


Q’ty

Intake duct

Service points





SILENCER.”

1 Bolt

2 Oil pump cable

1

1 Route the oil pump cable outside of the bleed hose and the oil delivery hoses.

Not reusable 3 Plastic tie




1

1

3

1

4-24

FUEL

OIL PUMP


E

4

6

5

3

8

3

3

7

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 12 mm

13

11

11 N • m (1.1 kgf • m, 8.0 ft • Ib) 10

5

× 10 mm

572

1

1st 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib)

2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)

2

12 9

6

× 20 mm

1st 3.8 N • m (0.38 kgf • m, 2.7 ft • Ib)

2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)


7 Bolt

8 Bleed hose stay

9 Bolt

10 Oil pump assembly

11 Gasket

12 Oil suction hose

13 Oil return hose

Q’ty

1

1

1

1

2

1

1

Not reusable

Service points


4-25

FUEL

OIL PUMP


E



OIL PUMP HOSES AND CABLE

REMOVAL

1 Bleed hose

2 Air bleed screw

3 Gasket

4 Bleed hose stay

5 Oil delivery hose




9 Check valve

Q’ty

1

1

3

1

3

1

1

1

1

Service points



4-26

FUEL

OIL PUMP

E

SERVICE POINTS

Oil pump inspection

1. Check:

• Oil pump

Contaminants

→ Clean.

Damage/wear → Replace.

• Oil pump joint piece

Damage/wear

→ Replace the oil pump.

Oil hose inspection

1. Check:

• Oil hoses


CAUTION:

• If the oil delivery hoses and the oil suction hose are not full of oil, fill them up.

• Bleed the oil pump, delivery hoses, and oil suction hose after installing them.

4-27


1. Check:

• Check valve

Faulty

→ Replace.

Checking steps:




Air should not come out from end “A.”

FUEL

OIL PUMP a

1

2 a

3 b

E

Oil pump lever position adjustment

1. Check:


Incorrect

→ Adjust.

Checking steps:

• Remove the intake duct.


SILENCER.”

• Squeeze the throttle lever to fully open the throttle valve lever.

• Check that the gap of the oil pump lever is 0–0.5 mm (0–0.0197 in) a.

• Install the intake duct.


SILENCER.”

4-28

2. Adjust:



• Remove the intake duct.


SILENCER.”

• Loosen the locknut

1 and adjusting nut

2 of the throttle cable.

• Adjust the throttle cable length to 18.5

±

1.0 mm (0.728

± 0.039 in) a.

• Tighten the locknut and adjusting nut.

CAUTION:

Check that the cover

3 is securely installed.

.

T

R

.

Locknut and adjusting nut:

11 N • m (1.1 kgf • m, 8.0 ft • lb)

• Check that there is free play between the throttle cable and throttle valve lever.

• Squeeze the throttle lever to fully open the throttle valve lever.

• Check that the gap of the oil pump lever is 0–0.5 mm (0–0.0197 in) b.

• Install the intake duct.


SILENCER.”

FUEL

OIL PUMP

1

E

Oil pump bleeding

1. Bleed:

• Oil pump

Bleeding steps:

• Place rags around the air bleed screw

1 to catch any oil that might spill.

• Fill the oil tank with the recommended oil.

NOTE:

If the oil pump is replaced or when the oil suction hose and oil delivery hoses are disconnected from the oil pump, fill the hoses with oil, and then connect them to the oil pump.

After connecting the oil suction hose, be sure to it fasten it with a locking tie.

Recommended engine oil:

YAMALUBE 2-W oil only

• Loosen the air bleed screw 1 two full turns and check that both the oil and air bubbles flow out.

• When there are no air bubbles remaining, tighten the air bleed screw.

• Wipe up any spilt oil.

T

.

R

.

Air bleed screw:

3.4 N • m (0.34 kgf • m, 2.5 ft • lb)

CAUTION:

• Do not run the engine if oil does not flow out of the air bleed screw. Check the oil pump hoses for proper routing and make sure that there are no restrictions in the line.

• Use only YAMALUBE 2-W oil. Using another oil can seriously damage the catalytic converter or other engine components.

4-29

POWR

CHAPTER 5

POWER UNIT

COMPRESSION PRESSURE MEASUREMENT ............................................ 5-1

SERVICE POINTS .................................................................................... 5-1

MUFFLER ASSEMBLY ................................................................................... 5-3



SERVICE POINTS .................................................................................... 5-9

Catalytic converter inspection ............................................................. 5-9

Muffler installation ............................................................................... 5-9

EXHAUST CHAMBER ASSEMBLY.............................................................. 5-10



ENGINE UNIT ................................................................................................ 5-13



SERVICE POINTS .................................................................................. 5-15

Shim removal .................................................................................... 5-15

Engine mount inspection................................................................... 5-15

Coupling clearance inspection .......................................................... 5-15

EXHAUST MANIFOLD .................................................................................. 5-16



REED VALVES.............................................................................................. 5-18



SERVICE POINTS .................................................................................. 5-20

Reed valve inspection ....................................................................... 5-20

YPVS ............................................................................................................. 5-21



SERVICE POINTS .................................................................................. 5-24

YPVS valve inspection ...................................................................... 5-24

YPVS valve installation ..................................................................... 5-24

E

POWR

CYLINDER HEAD.......................................................................................... 5-25


REMOVAL AND INSTALLATION CHART ............................................. 5-25

SERVICE POINTS .................................................................................. 5-27

Cylinder head inspection................................................................... 5-27

CYLINDERS .................................................................................................. 5-28



SERVICE POINTS .................................................................................. 5-30

Cylinder inspection............................................................................ 5-30

PISTONS ....................................................................................................... 5-31



SERVICE POINTS .................................................................................. 5-33

Piston pin clip removal and installation ............................................. 5-33

Piston inspection ............................................................................... 5-33

Cylinder and piston combination ....................................................... 5-34

Piston ring inspection ........................................................................ 5-34

Piston pin and bearing inspection ..................................................... 5-35

Piston installation .............................................................................. 5-36

GENERATOR AND STARTER MOTOR ....................................................... 5-37



SERVICE POINTS .................................................................................. 5-45

Drive coupling removal and installation............................................. 5-45

Flywheel magneto removal and installation ...................................... 5-45

Drive coupling inspection .................................................................. 5-46

Flywheel magneto inspection............................................................ 5-46

Starter clutch assembly inspection.................................................... 5-46

CRANKCASE ................................................................................................ 5-47



SERVICE POINTS .................................................................................. 5-49

Crankcase inspection........................................................................ 5-49

Crankcase installation ....................................................................... 5-49

CRANKSHAFT .............................................................................................. 5-50



SERVICE POINTS .................................................................................. 5-51

Crankshaft inspection........................................................................ 5-51

E

5

6

7

8

9

3

4

1

2

POWR

COMPRESSION PRESSURE MEASUREMENT

E

COMPRESSION PRESSURE

MEASUREMENT

SERVICE POINTS

The following procedure applies to all of the cylinders.

NOTE:

Insufficient compression pressure will result in a loss of performance.

1. Start the engine and warm it up until the engine temperature is 48 °C (118 °F).

2. Remove:

• Seat

3. Disconnect:

• Spark plug caps

4. Remove:

• Spark plugs

CAUTION:

Before removing the spark plugs, blow compressed air into the spark plug wells to clear out any dirt or dust that can fall into the cylinders.

1

5. Install:

• Compression gauge

1

Compression gauge:

YU-33223-1/90890-03160

5-1

POWR

COMPRESSION PRESSURE MEASUREMENT

E

6. Measure:

• Compression pressure


→ Refer to steps (b) and (c).

Minimum compression pressure

(reference data):

640 kPa (6.4 kgf/cm 2 , 91 psi)

Measurement steps: a. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.

WARNING

To prevent sparking, ground all spark plug leads before cranking the engine.

b. If the compression pressure is extremely high, check the cylinder head and piston crown for carbon deposits.

Carbon deposits

→ Eliminate.

c. If the compression pressure is below specification and the compression pressure for each cylinder is unbalanced, squirt a few drops of oil into the cylinder and measure the compression pressure again.

Refer to the following table.

Compression pressure

(with oil applied to the cylinder)

Reading Diagnosis

Higher than without oil

Same as without oil

Piston ring wear, piston wear or damage

→ Replace.

Cylinder head gasket or piston possibly defective

→

Replace.

7. Install:

• Spark plugs

T

.

R

.

Spark plug:

25 N • m (2.5 kgf • m, 18 ft • lb)

5-2

POWR

MUFFLER ASSEMBLY



4

5

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 22 mm

E

É

7

LT

242

2

3

1

6

È



MUFFLER REMOVAL

YPVS servomotor and YPVS servomotor bracket

Battery box

1 Spark plug cap

2 Exhaust temperature sensor coupler

3 Cooling water temperature sensor coupler

4 Cap/bolt

5 Cover

Q’ty

3

1

1

3/3

1

Service points


Refer to “YPVS SERVOMOTOR” in Chapter

7.


5-3

POWR



4

5

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 22 mm

E

É

7

LT

242

1

2

3

6

È

Step

6

Procedure/Part name

Screw clamp/cooling water hose

7 Screw clamp/cooling water hose


1/1 È To cooling water pilot outlet (port)

Route the cooling hose under the exhaust chamber assembly.

1/1 É To cooling water outlet (stern)

Contact the corrugated tube to the hose screw clamp (muffler assembly end).

5-4

POWR



E


8 Outer exhaust joint screw clamp

9 Inner exhaust joint screw clamp

10 Exhaust joint screw clamp

11 Water lock band

12 Nut

13 Bolt

14 Intermediate housing grease hose

15 Eye

Q’ty

2

2

2

4

1

1

1

2

Service points

Slide the outer exhaust joint off.

Slide the water lock off.

NOTE:

To ease removal of the muffler assembly, remove the spark plugs before removing the eye, remove the muffler, and then reinstall the spark plugs.

5-5

POWR



E

Step

16 Bolt

17 Bolt

Procedure/Part name

18 Bolt

19 Bolt

20 Muffler stay 2

21 Muffler assembly

22 Outer exhaust joint

23 Inner exhaust joint

Q’ty

2

1

1

1

1

1

Service points

NOTE:

Remove the cylinder head if it is difficult to remove the muffler assembly.

1

1


5-6

POWR



E



MUFFLER DISASSEMBLY

1 Exhaust temperature sensor

2 Cooling water temperature sensor

3 Bolt

4 Muffler stay

5 Dowel pin

6 Bolt

7 Cover

8 Gasket

9 Catalytic converter housing

10 Gasket

Q’ty

6

1

1

1

1

1

2

1

1

1

Service points


Not reusable

Not reusable

5-7

POWR



E


11 Catalytic converter

12 Gasket

13 Pin

14 Bolt

15 Mixing joint

16 Gasket

17 Muffler

Q’ty

1

1

1

1

2

6

1

Not reusable

Not reusable

Service points


5-8

POWR


SERVICE POINTS

Catalytic converter inspection

1. Check:

• Catalytic converter

Cracks/damage

→ Replace.

E b

(8

6˚)

4

˚

5

(21˚)

45˚

Muffler installation

1. Install:

• Inner exhaust joint

• Outer exhaust joint

• Muffler assembly

• Inner exhaust joint screw clamp

• Outer exhaust joint screw clamp

NOTE:

• Align the projection a on the exhaust joint with the muffler assembly boss.

• Use the angles shown in the illustration as reference to Install the exhaust joint screw clamps.

• Align the parting line of the outer exhaust joint with the top b of the outer exhaust joint screw clamp.

5-9

POWR

EXHAUST CHAMBER ASSEMBLY



E



EXHAUST CHAMBER

ASSEMBLY REMOVAL

Muffler assembly



3 Bolt

4 Bolt

5 Bolt

6 Bolt

7 Exhaust chamber stay



Refer to “MUFFLER ASSEMBLY.”

1/1 È To cooling water pilot outlet (starboard)

2/2 É To cylinder head

3

1

2

2

1

5-10

POWR



E



9 Exhaust chamber assembly

10

11

Gasket

Pin


1/1 Ê From exhaust manifold

1 NOTE:

Before installing the exhaust chamber assembly, connect the cooling water hose and fasten it with the screw clamp to the exhaust chamber (part 8) and place the bolts (part 3) in the bolt holes in the exhaust chamber assembly.

1

2

Not reusable


5-11

POWR



E



EXHAUST CHAMBER

DISASSEMBLY

1 Bolt

2 Bolt

3 Exhaust chamber joint

4 Gasket

5 Pin

6 Exhaust chamber

Q’ty

1

1

5

1

2

1

Service points


Not reusable


5-12

POWR

ENGINE UNIT

ENGINE UNIT


7.9 N • m (0.79 kgf • m, 5.7 ft • Ib)

6

× 25 mm

17 N • m (1.7 kgf • m, 12 ft • Ib)

8

× 40 mm

7

8

572

3

572 a

5

6

1

4

E

2

4

9

4

4

4

4



ENGINE UNIT REMOVAL

Muffler assembly


Silencer pipe and intake duct

Throttle bodies assembly

Oil pump cable


2 Oil suction hose





ASSEMBLY.”


SILENCER” in Chapter 4.

Refer to “FUEL INJECTION SYSTEM” in

Chapter 4.


1/1 Install the cooling water hose with the white paint mark a facing up.

1

5-13

POWR

ENGINE UNIT


7.9 N • m (0.79 kgf • m, 5.7 ft • Ib)

6

× 25 mm

17 N • m (1.7 kgf • m, 12 ft • Ib)

8

× 40 mm

7

8

572

3

572 a

5

6

1

4

4

2

4

9

4

4

4


3 Oil return hose

4 Coupler

5 Bolt/collar

6 Coupling cover

7 Bolt/washer

8 Engine unit

9 Shim

Q’ty

1

9

1/1

1

4/4

1

—

Service points

As required

NOTE:

Install shims in their original positions.


5-14

E

POWR

ENGINE UNIT

E

SERVICE POINTS

Shim removal

1. Remove:

• Shims

NOTE:

To ease reassembly and coupling alignment, remove the shims and organize them in their respective groups (e.g., front right, rear left) prior to removing the mounting bolts.

Engine mount inspection

1. Check:

• Engine mounts

Cracks/damage

→ Replace.

Refer to “ENGINE MOUNTS” in Chapter

8.

Coupling clearance inspection

1. Measure:

• Clearance a

• Clearance b

(with the rubber damper)


→ Adjust.

NOTE:

Measure the clearances using a straightedge and thickness gauge.

Clearance a:

0–0.5 mm (0–0.020 in)

Clearance b:

2–4 mm (0.079–0.157 in)

5-15

2. Adjust:

• Clearances a and b


• Adjust the clearance a by adding or removing shims.

• Adjust the clearance b by moving the engine unit position.

POWR

EXHAUST MANIFOLD



E



EXHAUST MANIFOLD REMOVAL

Engine unit

1 Bolt

2 Bolt

3 Nut

4 Exhaust manifold

5 Gasket

6 Pin

Q’ty

2

1

4

6

1

2

Service points


Refer to “ENGINE UNIT.”

Not reusable


5-16

POWR



E




DISASSEMBLY


2 Bolt

3 Cooling water joint

4 O-ring

5 Exhaust manifold

Q’ty

1/1

6

1

3

1

Service points


Not reusable


5-17

POWR

REED VALVES

REED VALVES


E



REED VALVE REMOVAL

Throttle bodies assembly




Chapter 4.


Oil delivery hoses

1 Grease hose

2 Bolt

3 Throttle bodies bracket 1

4 Throttle bodies bracket 2

5 Throttle bodies joint

6 Bolt

1

18

1

1

3

4

5-18

POWR

REED VALVES


E


7 Balance plate

8 Gasket

9 Reed valve plate

10 Reed valve assembly

11 Screw

12 Valve stopper

13 Reed valve

Q’ty

1

1

1

3

24

6

6

Not reusable

Service points


5-19

POWR

REED VALVES

SERVICE POINTS

Reed valve inspection

1. Check:

• Reed valves

Cracks/damage

→ Replace.

2. Measure:

• Valve warpage a


→ Replace.

Valve warpage limit:

1.5 mm (0.059 in)

3. Measure:

• Valve stopper height b


→ Replace.

Valve stopper height:

10.5–10.9 mm (0.413–0.429 in)

E

5-20

POWR

YPVS

YPVS


E



YPVS REMOVAL





ASSEMBLY.”

1 Bolt

2 YPVS valve cover

3 Gasket

4 Spacer

5 Link joint/cover

6 Circlip

7 Washer

12

3

3

2

2/2

5

5

Not reusable

Not reusable

5-21

POWR

YPVS


E

Step

8 Bolt

Procedure/Part name

9 Shaft 3

10 Shaft 2

11 Shaft 1

12 YPVS valve arm

13 Bolt

1

1

1

3

3

Q’ty

3

Service points

NOTE:

For installation, align the hole a in the

YPVS shaft with the bolt.

5-22

POWR

YPVS


E


14 YPVS valve assembly

15 Oil seal

Q’ty

3

6

Service points

NOTE:

Install the YPVS valves with the recess b facing toward the stern.

NOTE:

If the YPVS shaft is removed, the oil seal must be replaced.


5-23

POWR

YPVS

E

SERVICE POINTS

YPVS valve inspection

1. Eliminate:

• Carbon deposits

(using a rounded scraper

1)

CAUTION:

Do not use a sharp instrument to avoid damaging or scratching the surfaces.

1

2. Check:

• YPVS valve assembly

Cracks/damage/wear

→ Replace.

YPVS valve installation

1. Install:

• Oil seals

Distance a:

1.0–1.5 mm (0.039–0.059 in)

NOTE:

Install the oil seal with the marks b facing inward.

5-24

POWR

CYLINDER HEAD

CYLINDER HEAD


E

2

3

1st 3.8 N • m (0.38 kgf • m, 2.7 ft • Ib)

2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6

× 16 mm

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

2nd 35 N • m (3.5 kgf • m, 25 ft • Ib)

8

× 80 mm

11

10

572

4

8

× 55 mm

572

5

572

1st 22 N • m (2.2 kgf • m, 16 ft • Ib)

2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)

3rd 35 N • m (3.5 kgf • m, 25 ft • Ib)

6

8 × 65 mm

1

25 N • m (2.5 kgf • m, 18 ft • Ib) a

9

E F

9 a

A

7 8

B

7

4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)

5

× 16 mm

8 6

1

5

2

4

3

11

10

D

0 9

C

H G



CYLINDER HEAD REMOVAL

Muffler assembly

1 Spark plug

2 Bolt

3 Ground lead

4 Bolt

5 Bolt

6 Bolt

Q’ty

1

2

3

1

12

4

Service points



NOTE:

Tighten the bolts in the proper sequence as shown and in three stages. (Tighten bolts

G and

H in two stages.)

5-25

POWR

CYLINDER HEAD


2

3

1st 3.8 N • m (0.38 kgf • m, 2.7 ft • Ib)

2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6

× 16 mm

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

2nd 35 N • m (3.5 kgf • m, 25 ft • Ib)

8

× 80 mm

11

10

572

4

8

× 55 mm

572

5

572

1st 22 N • m (2.2 kgf • m, 16 ft • Ib)

2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)

3rd 35 N • m (3.5 kgf • m, 25 ft • Ib)

6

8 × 65 mm

1

25 N • m (2.5 kgf • m, 18 ft • Ib) a

9

E F

9 a

A

7 8

B

7

4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)

5

× 16 mm

8 6

1

5

2

4

3

11

10

D

0 9

C

H G

E


7 Cylinder head

8 Gasket


10

11

Screw

Anode

Q’ty

1

1

2/2

Service points

Not reusable

NOTE:

Face the red mark a end of the cooling water hose toward the cylinder head cover, and then install the hose.

2

2


5-26

POWR

CYLINDER HEAD

E

SERVICE POINTS

Cylinder head inspection

1. Eliminate:

• Carbon deposits


1)

CAUTION:

Do not use a sharp instrument to avoid damaging or scratching the cylinder head or spark plug bore threads.

2. Check:

• Cylinder head water jacket

Corrosion/mineral deposits → Clean or replace.

3. Measure:

• Cylinder head warpage

(using a straightedge and thickness gauge)

Out of specification/score marks

→

Resurface.

Warpage limit:

0.05 mm (0.002 in)

NOTE:

Place 400–600 grit wet sandpaper on a surface plate and resurface the cylinder head using a figure-eight sanding pattern.

5-27

POWR

CYLINDERS

CYLINDERS


E



CYLINDER REMOVAL

YPVS

Cylinder head

1 Engine temperature sensor

2 Bolt

3 Cylinder



Refer to “YPVS.”

Refer to “CYLINDER HEAD.”

1

12 NOTE:

Tighten the bolts in a crisscross pattern and in two stages.

3 NOTE:

Install the cylinders in their original positions.

5-28

POWR

CYLINDERS


E


4 Cylinder gasket

5 Pin

Q’ty

3

6

Not reusable

Service points


5-29

POWR

CYLINDERS

SERVICE POINTS

Cylinder inspection

1. Eliminate:

• Carbon deposits


1)

E

5-30

2. Check:

• Cylinder water jacket

Corrosion/mineral deposits

→ Clean or replace.

• Cylinder inner surface

Score marks

→ Replace.

3. Measure:

• Cylinder bore “D”

(using a cylinder gauge)


→ Replace cylinder and piston as a set.

NOTE:

Measure the cylinder bore parallel to and at a right angle to the crankshaft. Then, average the measurements.

Standard Limit

Cylinder bore

“D”

84.000–

84.018 mm

(3.3071–

3.3078 in)

84.100 mm

(3.3110 in)

Taper “T” —

0.080 mm

(0.0031 in)

Out of round

“R”

—

0.050 mm

(0.0020 in)

D = Maximum (D

1

–D

6

)

T = (Maximum D

1

or D

2

) – (Maximum D

5 or D

6

)

R = (Maximum D

1

, D

3

or D

5

) – (Minimum

D

2

, D

4

or D

6

)

POWR

PISTONS

PISTONS


E



PISTON REMOVAL

Cylinders

1 Piston pin clip

Q’ty

2

Service points


Refer to “CYLINDERS.”

Not reusable

CAUTION:

Do not align the open end of the clip with the piston pin slot a.

2 Piston pin

3 Piston

4 Washer

1

1

2

NOTE:

Install the piston with the arrow b facing towards the exhaust port.

5-31

POWR

PISTONS


E


5 Bearing

6 Piston ring

Q’ty

1

2

Service points

CAUTION:

Align each end gap with its respective locating pin.


5-32

POWR

PISTONS

E

SERVICE POINTS

Piston pin clip removal and installation

1. Remove and install:

• Piston pin clip

NOTE:

Before removing or installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase.

Piston inspection

1. Eliminate:

• Carbon deposits

(from the piston crown and piston ring grooves)

2. Check:

• Piston wall

Score marks

→ Repair with 600–800 grit wet sandpaper or replace.

NOTE:

Lightly sand the piston wall in a crisscross pattern.

3. Measure:

• Piston skirt diameter

(using a micrometer)


→ Replace.

Piston diameter

83.899–83.914 mm

(3.3031–3.3037 in)

Distance a

11 mm (0.43 in)

5-33

POWR

PISTONS

E

4. Calculate:

• Piston-to-cylinder clearance


→ Replace the piston, piston rings, and cylinder as a set.

PISTON

CLEARANCE

=

CYLINDER

BORE

–

PISTON

DIAMETER

Piston-to-cylinder clearance:

0.100–0.105 mm

(0.0039–0.0041 in)

Cylinder and piston combination

Select the appropriate piston to match the cylinder size from the table as follows.

Cylinder size indication a

00–05

06–10

11–15

16–18

Piston color mark

Red

Orange

Green

Purple

NOTE:

New cylinder bore size = 84.000 + a/1,000

Example: a = 12 → 84.012 mm.

Piston ring inspection

1. Measure:

• Side clearance

(using a thickness gauge

1)


→ Replace the piston and piston rings as a set.

Side clearance:

0.020–0.070 mm

(0.0008–0.0028 in)

5-34

POWR

PISTONS

E

2. Measure:

• End gap

(using a thickness gauge

1)


→ Replace the piston rings as a set.

End gap:

0.45–0.60 mm (0.018–0.024 in)

NOTE:

Push the piston ring into the cylinder with the piston crown.

5-35

Piston pin and bearing inspection

1. Check:

• Piston pins

• Bearings

Signs of heat discoloration

→ Replace.

2. Measure:

• Piston pin outside diameter

(using a micrometer

1)


→ Replace.

Piston pin outside diameter:

Standard:

21.995–22.000 mm

(0.8659–0.8661 in)

Limit:

21.990 mm (0.8657 in)

3. Check:

• Piston-pin-to-piston free play

(with the piston pin in the piston as shown)

Free play

→ Replace the piston pin, piston, or both.

POWR

PISTONS

E

4. Check:

• Piston-pin-to-small-end-bearing-toconnecting-rod free play

(at the small end of the connecting rod as shown)

Free play/wear at the small end

→

Replace the piston pin, connecting rod, small end bearing, or all parts.

Piston installation

1. Install:

• Top ring

• 2nd ring

NOTE:

Install the piston rings with the manufacturer’s marks or numbers facing up.

5-36

POWR

GENERATOR AND STARTER MOTOR



E



GENERATOR COVER REMOVAL

Oil pump

1 Bolt

2 Bolt

Q’ty

1

7

Service points



NOTE:

Do not apply locking agent to the bolt that is used to install the ground lead.

3 Ground lead

4 Generator cover

5 Washer

6 Spring

7 Seal 1

1

1

2

1

5-37

POWR



E

Step

8 Pin

9 Bolt

Procedure/Part name

10 Bolt

11 Exhaust chamber bracket

Q’ty

2

2

2

1

Service points


5-38

POWR



E

5

× 14 mm

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

6

LT

242

5

5

× 14 mm

6

LT

242

2

10

5

14 N • m (1.4 kgf • m, 10 ft • Ib)

6

× 35 mm

2

1

9

LT

242

LT

242

3

4

7

5

× 14 mm

5 × 14 mm

6

× 14 mm

14 N • m (1.4 kgf • m, 10 ft • Ib)

8

2

6

5

LT

242

5

× 14 mm

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)



STATOR COIL AND PICKUP

COIL REMOVAL

1 Plastic tie

2 Bolt/washer

3 Bolt

4 Cable holder

5 Bolt

6 Pickup coil

7 Bolt



1 Not reusable

3/3 NOTE:

2

These washers hold the pickup coil leads.

1

Be sure not to pinch the leads between the

6 projections and the washers when installing

3 the bolts.

1

5-39

POWR



5

× 14 mm

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

6

LT

242

5

5

× 14 mm

6

LT

242

2

10

5

14 N • m (1.4 kgf • m, 10 ft • Ib)

6

× 35 mm

2

1

9

LT

242

LT

242

3

4

7

5

× 14 mm

5 × 14 mm

6

× 14 mm

14 N • m (1.4 kgf • m, 10 ft • Ib)

8

2

6

5

LT

242

5

× 14 mm

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)


8 Ground lead

9 Bolt

10 Lighting coil

Q’ty

2

3

1

Service points


E

5-40

POWR



E



GENERATOR ROTOR AND

STARTER MOTOR REMOVAL

1 Drive coupling

2 Flywheel magneto bolt

3 Flywheel magneto

4 Woodruff key

5 Starter clutch assembly

6 Bolt

Q’ty

1

1

1

1

1

2

Service points


NOTE:

Degrease the flywheel magneto where it is coupled to the crankshaft.

5-41

POWR



E


7 Negative battery lead

8 Nut/washer

9 Starter motor lead

10 Starter motor

Q’ty

1

1/1

1

1

Service points


5-42

POWR



E



STARTER CLUTCH

DISASSEMBLY

1 Clip

2 Clip stopper

3 Spring seat

4 Spring

5 Washer

6 Idle gear

7 Circlip

8 Plate

Q’ty

1

1

1

1

1

1

1

1

Service points


Not reusable

5-43

POWR



E


9 Weight

10 Spring ring

11 Pinion gear

Q’ty

3

1

Service points

NOTE:

Install the spring ring after installing the weights, plate, and circlip.

1


5-44

POWR


SERVICE POINTS

Drive coupling removal and installation

1. Remove:

• Drive coupling

Coupler wrench:

YW-06551/90890-06551

Flywheel holder:

YW-06550/90890-06550

E

.

T

R

.

Drive coupling:

36 N • m (3.6 kgf • m, 25 ft • lb)

LOCTITE 572

NOTE:

Install the drive coupling with the same special service tools that were used for removal.

Flywheel magneto removal and installation

1. Remove:

• Flywheel magneto bolt

Flywheel holder:

YW-06550/90890-06550

.

T

R

.

Flywheel magneto bolt:

74 N • m (7.4 kgf • m, 53 ft • lb)

NOTE:

Install the bolt with the same special service tool that was used for removal.

5-45

POWR

È

É


E

2. Remove:

• Generator rotor

Universal puller:

YB-06117

Flywheel puller:

90890-06521

Set bolt:

M8

× 60 mm

È For USA and Canada

É For Worldwide

CAUTION:

To prevent damage to the engine or special service tools, screw in the flywheel puller set bolts evenly and completely so that the puller plate is parallel to the generator rotor.

Drive coupling inspection

1. Check:

• Drive coupling

Damage/wear

→ Replace.

Flywheel magneto inspection

1. Check:

• Ring gear

Damage/wear

→ Replace.

Starter clutch assembly inspection

1. Check:

• Pinion gear

1

• Idle gear

2

Damage/wear

→ Replace.

2. Check:

• Gear movement

Rough movement

→ Replace the defective part(s).

5-46

POWR

CRANKCASE

CRANKCASE


E



CRANKCASE DISASSEMBLY

Pistons

Generator cover and starter motor



Refer to “PISTONS.”

Refer to “GENERATOR AND STARTER

MOTOR.”

1 Bolt

2 Mount bracket

3 Pin

4 Bolt

5 Bolt

6 Bolt

7 Bolt

6

1

16

4

4

6

2

NOTE:

Tighten the bolts in the sequences shown and in two stages if specified.

5-47

POWR

CRANKCASE


E


8 Lower crankcase

9 Pin

10 Crankshaft assembly

11 Upper crankcase

Q’ty

1

2

1

1

Service points


5-48

POWR

CRANKCASE

E

SERVICE POINTS

Crankcase inspection

1. Check:

• Mating surfaces

Scratches

→ Replace the crankcase.

• Crankcase

Cracks/damage

→ Replace.

Crankcase installation

1. Apply:

• Gasket Maker

(to the crankcase mating surfaces)

NOTE:

Before applying Gasket Maker, clean the crankcase mating surfaces.

2. Check:

• Crankshaft

Rough movement

→ Recheck.

NOTE:

Make sure that the crankshaft rotates smoothly after installing it.

5-49

POWR

CRANKSHAFT

CRANKSHAFT


E



CRANKSHAFT REMOVAL

Crankcase

1 Oil seal

2 Bearing

3 Oil seal 1

4 Oil seal 2

5 Crankshaft assembly

Q’ty

1

1

1

1

1

Service points


Refer to “CRANKCASE.”

Not reusable

Not reusable

Not reusable

CAUTION:

Install the bearing locating pins into the grooves in the crankcase body.


*1

EPNOC grease AP #0

5-50

POWR

CRANKSHAFT

E

SERVICE POINTS

Crankshaft inspection

1. Measure:

• Crank width A


→ Replace the crankshaft.

Crank width:

72.95–73.00 mm (2.872–2.874 in)

2. Measure:

• Deflection B

(using a dial gauge)


→ Replace.

Maximum deflection:

B 0.05 mm (0.002 in)

C 0.15 mm (0.006 in)

3. Measure:

• Big end side clearance D

(using a thickness gauge)


→ Replace.

Big end side clearance:

0.250–0.750 mm

(0.0098–0.0295 in)

4. Measure:

• Small end free play E

(using a dial gauge)


→ Replace.

Small end free play limit:

2.000 mm (0.0787 in)

5-51

POWR

CRANKSHAFT

E

5. Check:

• Bearings

Damage/pitting

→ Replace.

NOTE:

• Before checking bearings, thoroughly clean them.

• Immediately after checking the bearings, lubricate them to prevent rust.

6. Check:

• Oil seals

Damage/wear

→ Replace.

5-52

JET

PUMP

CHAPTER 6

JET PUMP UNIT

JET PUMP UNIT.............................................................................................. 6-1



JET THRUST NOZZLE AND NOZZLE RING ................................................. 6-5



IMPELLER DUCT AND IMPELLER HOUSING 1 ........................................... 6-6



IMPELLER DUCT AND DRIVE SHAFT .......................................................... 6-8



SERVICE POINTS .................................................................................. 6-10

Drive shaft removal ........................................................................... 6-10

Impeller inspection ............................................................................ 6-11

Drive shaft inspection........................................................................ 6-11

Drive shaft installation ....................................................................... 6-12

TRANSOM PLATE AND HOSES.................................................................. 6-14



SERVICE POINTS .................................................................................. 6-16

Bilge strainer inspection .................................................................... 6-16

Electric bilge pump inspection........................................................... 6-16

Bilge hose inspection ........................................................................ 6-16

Cooling water hose inspection .......................................................... 6-16

BEARING HOUSING..................................................................................... 6-17



SERVICE POINTS .................................................................................. 6-20

Driven coupling removal and installation........................................... 6-20

Intermediate drive shaft removal....................................................... 6-20

Bearing removal ................................................................................ 6-21

Bearing, intermediate drive shaft, and grease hose inspection ........ 6-21

Driven coupling inspection ................................................................ 6-21

Bearing installation............................................................................ 6-21

Oil seal installation ............................................................................ 6-22

Intermediate housing installation....................................................... 6-23

E

5

6

7

8

9

3

4

1

2

JET

PUMP JET PUMP UNIT

JET PUMP UNIT


E



JET PUMP UNIT REMOVAL

1 Bolt

2 Bolt

3 Intake grate

4 Bolt

5 Intake duct

6 Felt seal

7 Screw

8 Speed sensor

Q’ty

1

4

4

1

1

2

2

1

Service points


NOTE:

Route the speed sensor lead between the jet pump unit and bilge hose 5.

6-1

JET



E


9 Bolt

10 Ride plate

11 QSTS cable joint

12 Plastic tie/bilge hose 5

13 Nut/washer

14 Steering cable joint

15 Screw clamp/spout hose

16 Bolt

17 Bolt

Q’ty

4

1

1

1/1

1/2

1

1/1

1

4

6-2

Service points

JET



E


18 Jet pump unit assembly

19 Dowel pin

20 Impeller housing 2

21 Dowel pin

Q’ty

1

2

1

2

Service points

NOTE:

Clean the mating surfaces before applying

Yamabond No. 4.


6-3

JET



2

FWD



SPEED SENSOR DISASSEMBLY

1 Paddle wheel set

2 Speed sensor

Q’ty

1

1

Service points


Not reusable


6-4

1

E

JET

PUMP JET THRUST NOZZLE AND NOZZLE RING

JET THRUST NOZZLE AND NOZZLE RING


E



JET THRUST NOZZLE AND

NOZZLE RING REMOVAL

Jet pump unit

1 Bolt

2 Collar

3 Jet thrust nozzle

4 Bolt

5 Collar

6 Nozzle ring

Q’ty

2

2

1

2

2

1

Service points


Refer to “JET PUMP UNIT.”


6-5

JET

PUMP IMPELLER DUCT AND IMPELLER HOUSING 1

IMPELLER DUCT AND IMPELLER HOUSING 1


E



IMPELLER DUCT AND IMPELLER

HOUSING 1 REMOVAL

Nozzle ring



Refer to “JET THRUST NOZZLE AND

NOZZLE RING.”

1 Bolt

2 Nozzle

3 Pin

4 Impeller duct assembly

5 Impeller housing 1

6 Pin

2

1

4

1

1

2

NOTE:

Clean the mating surfaces before applying

Yamabond No. 4.

6-6

JET

PUMP IMPELLER DUCT AND IMPELLER HOUSING 1


E


7 Bolt

8 Water inlet cover

9 Seal

10 Water inlet strainer

11 Seal

Q’ty

4

1

1

1

1

Service points


6-7

JET

PUMP IMPELLER DUCT AND DRIVE SHAFT

IMPELLER DUCT AND DRIVE SHAFT


E



IMPELLER DUCT AND DRIVE

SHAFT DISASSEMBLY

1 Impeller

2 Spacer

3 Bolt

4 Cap

5 O-ring

6 Nut

7 Washer

*1

EPNOC grease AP #0



1

1

1

3

1

1 Left-hand threads

1

6-8

JET

PUMP IMPELLER DUCT AND DRIVE SHAFT


E


8 Drive shaft

9 Rear bearing

10 Spacer

11 Front bearing

12 Oil seal

13 Oil seal

14 Impeller duct

*1

EPNOC grease AP #0

Q’ty

1

1

1

1

1

1

1

Not reusable

Not reusable

Not reusable

Not reusable

Service points


6-9

JET

PUMP


SERVICE POINTS

Drive shaft removal

1. Remove:

• Impeller

Drive shaft holder:

YB-06151

Drive shaft holder 5:

90890-06519

E

NOTE:

The impeller has left-hand threads. Turn the impeller clockwise to loosen it.

2. Remove:

• Nut

1


YB-06151


90890-06519

3. Remove:

• Drive shaft

1

NOTE:

Remove the drive shaft using a press.

È

É

4. Remove:

• Rear bearing

Slide hammer and adapters:

YB-06096

Stopper guide plate:

90890-06501

Bearing puller assembly:

90890-06535

Stopper guide stand:

90890-06538


É For Worldwide

6-10

JET

PUMP


E

5. Remove:

• Front bearing

Driver handle—large:

YB-06071

Driver rod L3:

90890-06652

Bearing housing needle bearing remover:

YB-06112

Needle bearing attachment:

90890-06614

NOTE:

Remove the front bearing using a press.

6. Remove:

• Oil seal


YB-06071

Driver rod L3:

90890-06652

Drive shaft needle bearing installer and remover:

YB-06196

Needle bearing attachment:

90890-06653

NOTE:

Remove the oil seals using a press.

Impeller inspection


Drive shaft inspection

1. Check:

• Drive shaft

Damage/wear

→ Replace.

6-11

JET

PUMP


Drive shaft installation

1. Install:

• Oil seals


YB-06071

Driver rod LS:

90890-06606

Outer race installer—forward gear:

YB-06085

Ball bearing attachment:

90890-06634

E

Distance a:

14.2

± 0.2 mm (0.56 ± 0.01 in)

Distance b:

4.7

± 0.2 mm (0.19 ± 0.01 in) a

6-12

2. Install:

• Front bearing

• Drive shaft

NOTE:

Install the front bearing and drive shaft using a press.

Distance a:

23.0

± 0.1 mm (0.906 ± 0.004 in)

3. Install:

• Drive shaft (with front bearing)

• Spacer

• Impeller duct

NOTE:

Press the spacer and the front bearing with a pipe that is more than 33 mm (1.30 in) long, and which has an outer diameter less than

50 mm (1.97 in) and an inner diameter more than 26 mm (1.02 in).

4. Add:

• EPNOC grease AP #0

(between the drive shaft and spacer)

Quantity:

Approximately 1/3 of capacity

JET

PUMP


E

5. Install:

• Rear bearing

Drive shaft needle bearing depth stop:

YB-34474

NOTE:

• Press the bearing inner/outer race at the same time holding the drive shaft and impeller duct.

• If a bearing inner/outer race attachment is not available, use a washer or pipe with an outer diameter of 47–50 mm (1.85–1.97 in) and an inner diameter of 21–25 mm (0.83–

0.98 in).

6. Add:

• EPNOC grease AP #0 (into the cap)

Quantity:

Approximately 1/3 of capacity

7. Install:

• Nut

• Impeller

.

T

R

.

Drive shaft nut:

74 N • m (7.4 kgf • m, 53 ft • lb)

Impeller:

75 N • m (7.5 kgf • m, 54 ft • lb)

LOCTITE 572


YB-06151


90890-06519

6-13

JET

PUMP TRANSOM PLATE AND HOSES

TRANSOM PLATE AND HOSES


E



TRANSOM PLATE AND HOSE

REMOVAL

Exhaust system

Jet pump unit assembly

1 Hose screw clamp


3 Bilge hose 2

Q’ty

3

1

1


5 Hose clamp

1

1

Service points


Refer to “EXHAUST SYSTEM” in Chapter 8.

Refer to “JET PUMP UNIT.”

To cooling water outlet

NOTE:

Route bilge hose 2 under the drive shaft tube.

From cooling water inlet

6-14

JET

PUMP TRANSOM PLATE AND HOSES


E


6 Bilge hose 4

7 Band

8 Electric bilge pump assembly

9 Hose clamp

10 Bilge hose 3

11 Bilge strainer

12 Nut/washer

13 Transom plate

14 Plastic tie/bilge hose 5

Q’ty

1

1

1

1

1

1

4/4

1

1/1

Service points


6-15

JET

PUMP

TRANSOM PLATE AND HOSES

SERVICE POINTS

Bilge strainer inspection


E

Electric bilge pump inspection

Refer to “BILGE PUMP” in Chapter 3.

Refer to “ELECTRIC BILGE PUMP” in Chapter

7.

Bilge hose inspection

1. Check:

• Bilge hoses

Cracks/damage/wear

→ Replace.

Cooling water hose inspection

1. Check:

• Cooling water hoses

Cracks/damage/wear

→ Replace.

6-16

JET

PUMP BEARING HOUSING

BEARING HOUSING


E



BEARING HOUSING REMOVAL

Engine unit

1 Rubber coupling

2 Bolt

3 Intermediate housing assembly

4 Pin

5 Shim




1

2

1

3

— As required

NOTE:

Install shims in their original positions.


6-17

JET



E



BEARING HOUSING

DISASSEMBLY

1 Grease hose

2 Grease nipple

3 Grease nipple stay

4 Nipple

5 Driven coupling

6 Washer

7 Intermediate drive shaft

8 O-ring

Q’ty

1

2

1

1

1

2

1

1

Service points


Not reusable

6-18

JET



E

Step

9 Oil seal

Procedure/Part name

10 Oil seal

11 Oil seal

12 Circlip

13 Bearing

14 Circlip

Q’ty

1

1

1

1

1

1

Not reusable

Not reusable

Not reusable

Not reusable

Service points


6-19

JET

PUMP

BEARING HOUSING

E

SERVICE POINTS

Driven coupling removal and installation

1. Remove and install:

• Driven coupling

.

T

R

.

Driven coupling:

36 N • m (3.6 kgf • m, 25 ft • lb)

LOCTITE 572

Coupler wrench:

YW-06551/90890-06551

Shaft holder:

YB-06552

Crankshaft holder 20:

90890-06552

NOTE:

Install the driven coupling with the same special service tools that were used for removal.

1

Intermediate drive shaft removal

1. Remove:

• Intermediate drive shaft

Removal steps:

• Temporarily install the driven coupling to the intermediate drive shaft.

• Insert a long rod to the intermediate drive shaft.

• Press out the intermediate drive shaft by pushing the rod.

NOTE:

Support the intermediate housing with steel blocks 1 and press the intermediate drive shaft with a rod that is more than 280 mm

(11.02 in) long, and which has an outer diameter less than 13 mm (0.51 in).

6-20

JET

PUMP

BEARING HOUSING

Bearing removal

1. Remove:

• Bearing


YB-06071

Driver rod LS:

90890-06606

Drive shaft taper roller bearing cup installer:

YB-06156

Bearing outer race attachment:

90890-06626

E

NOTE:

• Install the bearing with the same special service tools that were used for removal.

• Support the intermediate housing with steel blocks

1 and remove the bearing using a press.

Bearing, intermediate drive shaft, and grease hose inspection

1. Check:

• Bearing

Rotate the inner race by hand.

Damage/rough movement

→ Replace.


Damage/pitting

→ Replace.

• Grease hose

Cracks/wear

→ Replace.

Driven coupling inspection

1. Check:

• Driven coupling

• Driven coupling damper

Damage/wear

→ Replace.

Bearing installation

1. Install:

• Circlip (rear)

6-21

JET

PUMP

BEARING HOUSING

2. Install:

• Bearing


YB-06071

Driver rod LS:

90890-06606


YB-06156


90890-06626

E

NOTE:

Support the intermediate housing with steel blocks

1 and install the bearing using a press.

a

6-22

Oil seal installation

1. Install:

• Oil seal


YB-06071

Driver rod LS:

90890-06606


YB-06156


90890-06626

NOTE:

Before installing the oil seal, lubricate the clip groove with water-resistant grease.

Distance a:

6.8–7.2 mm (0.27–0.28 in)

2. Install:


Distance a:

9.5–10.5 mm (0.37–0.41 in)

NOTE:

Support the intermediate housing with steel blocks

1 and install the intermediate drive shaft using a press.

JET

PUMP a

BEARING HOUSING b

2

1

3. Install:

• Oil seal

1 [8 mm (0.31 in)]

• Oil seal

2 [10 mm (0.39 in)]

Distance a:

10.3–10.7 mm (0.41–0.42 in)

Distance b:

1.6–2.0 mm (0.06–0.08 in)

E

Intermediate housing installation

1. Install:

• Intermediate housing

• Shim(s)

• Bolts

Installation steps:

• Install the intermediate housing.

• Measure the clearance a at each bolt hole.

• Install the suitable shim from the table below.

Clearance a Shim

0–0.2 mm

(0–0.008 in)

Not needed

0.3–0.7 mm

(0.012–0.028 in)

0.8–1.2 mm

(0.031–0.047 in)

1.3–2.0 mm

(0.051–0.079 in)

0.5 mm

1.0 mm

1.5 mm

.

T

R

.

Intermediate housing bolt:

17 N • m (1.7 kgf • m, 12 ft • lb)

LOCTITE 572

NOTE:

Install shims in their original positions if the intermediate housing is not replaced.

6-23

ELEC – +

CHAPTER 7

ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS........................................................................ 7-1

ELECTRICAL BOX.......................................................................................... 7-2



ECM AND SLANT DETECTION SWITCH ...................................................... 7-7



ELECTRICAL ANALYSIS ............................................................................... 7-8

INSPECTION............................................................................................. 7-8

Digital tester ........................................................................................ 7-8

Low resistance measurement ............................................................. 7-9

Peak voltage measurement ................................................................ 7-9

Peak voltage adapter ........................................................................ 7-10

Test harness .................................................................................... 7-10

IGNITION SYSTEM ....................................................................................... 7-11

WIRING DIAGRAM ................................................................................. 7-11

IGNITION SPARK GAP........................................................................... 7-13

IGNITION SYSTEM PEAK VOLTAGE .................................................... 7-14

BATTERY ................................................................................................ 7-16

FUSE ....................................................................................................... 7-16

SPARK PLUGS ....................................................................................... 7-16

SPARK PLUG LEAD ASSEMBLY........................................................... 7-16

IGNITION COIL ....................................................................................... 7-17

ENGINE STOP SWITCH......................................................................... 7-17

ENGINE TEMPERATURE SENSOR ...................................................... 7-18

INTAKE AIR TEMPERATURE SENSOR ................................................ 7-18

COOLING WATER TEMPERATURE SENSOR...................................... 7-19

EXHAUST TEMPERATURE SENSOR ................................................... 7-19

MAIN AND FUEL PUMP RELAY............................................................. 7-20

THROTTLE POSITION SENSOR ........................................................... 7-20

ATMOSPHERIC PRESSURE SENSOR ................................................. 7-21

SLANT DETECTION SWITCH ................................................................ 7-22

E

5

6

7

8

9

3

4

1

2

ELEC – +

FUEL CONTROL SYSTEM ........................................................................... 7-23

WIRING DIAGRAM ................................................................................. 7-23

FUEL PUMP ............................................................................................ 7-25

FUEL SENDER ....................................................................................... 7-25

FUEL INJECTOR .................................................................................... 7-26


INTAKE AIR TEMPERATURE SENSOR ................................................ 7-26





ATMOSPHERIC PRESSURE SENSOR ................................................. 7-26

SLANT DETECTION SWITCH ................................................................ 7-26

STARTING SYSTEM ..................................................................................... 7-27

WIRING DIAGRAM ................................................................................. 7-27

BATTERY ................................................................................................ 7-28

WIRING CONNECTIONS........................................................................ 7-28

FUSES..................................................................................................... 7-28

START SWITCH...................................................................................... 7-28

STARTER RELAY ................................................................................... 7-29


STARTER MOTOR........................................................................................ 7-30



SERVICE POINTS .................................................................................. 7-33

Armature inspection .......................................................................... 7-33

Brush holder inspection..................................................................... 7-34

Starter motor front cover inspection .................................................. 7-34

CHARGING SYSTEM.................................................................................... 7-35

WIRING DIAGRAM ................................................................................. 7-35

FUSE ....................................................................................................... 7-36

BATTERY ................................................................................................ 7-36

LIGHTING COIL ...................................................................................... 7-36

RECTIFIER/REGULATOR ...................................................................... 7-36

YPVS ............................................................................................................. 7-37

WIRING DIAGRAM ................................................................................. 7-37

FUSE ....................................................................................................... 7-38

BATTERY ................................................................................................ 7-38

PICKUP COIL.......................................................................................... 7-38

LIGHTING COIL ...................................................................................... 7-38

RECTIFIER/REGULATOR ...................................................................... 7-38

E

ELEC – +

YPVS SERVOMOTOR................................................................................... 7-39



SERVICE POINTS .................................................................................. 7-41

YPVS cable removal and installation ................................................ 7-41

YPVS cable inspection...................................................................... 7-41

YPVS servomotor inspection ............................................................ 7-41

YPVS cable adjustment .................................................................... 7-41

OFF THROTTLE STEERING SYSTEM......................................................... 7-42

WIRING DIAGRAM ................................................................................. 7-42

STEERING SWITCH ............................................................................... 7-43

STEPPING MOTOR ................................................................................ 7-43

THROTTLE SWITCH .............................................................................. 7-43

PICKUP COIL.......................................................................................... 7-43


ELECTRIC BILGE PUMP.............................................................................. 7-44

WIRING DIAGRAM ................................................................................. 7-44

ELECTRIC BILGE PUMP........................................................................ 7-45

FUSE ....................................................................................................... 7-45

BATTERY ................................................................................................ 7-45


INDICATION SYSTEM .................................................................................. 7-46

WIRING DIAGRAM ................................................................................. 7-46

FUSE ....................................................................................................... 7-48

BATTERY ................................................................................................ 7-48





OIL LEVEL SENSOR .............................................................................. 7-48

BUZZER .................................................................................................. 7-49

MULTIFUNCTION METER...................................................................... 7-49

Multifunction meter............................................................................ 7-49

MULTIFUNCTION METER REMOVAL ................................................... 7-49

Display function................................................................................. 7-50

Speedometer display ........................................................................ 7-51

Tachometer display........................................................................... 7-51

Hour meter display ............................................................................ 7-52

Voltage meter display........................................................................ 7-52

Fuel level meter display and fuel warning indicator .......................... 7-52

Oil warning indicator.......................................................................... 7-52

Engine overheat warning indicator.................................................... 7-53

Exhaust temperature warning indicator............................................. 7-53

Check engine warning indicator ........................................................ 7-54

Diagnostic display ............................................................................. 7-54

E

ELEC – +

ELECTRICAL COMPONENTS

ELECTRICAL COMPONENTS

Q

P

O

N

M

J

I

H

G

F

E

L

K

D

1 Slant detection switch

2 Fuel pump

3 Atmospheric pressure sensor

4 Multifunction meter

5 Steering switch


7 Throttle position sensor

8 Fuel injectors


0 Throttle switch

A Stepping motor

B Rectifier/regulator

C Electric bilge pump

D Speed sensor

E Battery

F Electrical box

G Cooling water temperature sensor

H Exhaust temperature sensor

I Spark plugs

J Starter motor

K YPVS servomotor

L Lighting coil and pickup coil

M Engine stop switch, engine shut-off switch, and start switch

N Oil level sensor

O Buzzer

P Fuel sender

Q ECM

7-1

1

2

3

6

7

8

9

0

8

A

8

B

C

4

5

E

ELEC – +

ELECTRICAL BOX

ELECTRICAL BOX


E

3.4 N • m (0.34 kgf • m, 2.5 ft • Ib)

6

× 10 mm

12

3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6

× 30 mm

15

13

7 9

8

14

16 17

11

10

27

26

21

25

30

24

2

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

6 × 30 mm

30

29

21

23

21

22

28

20

3

29

4

6

19

18

3.4 N • m (0.34 kgf • m, 2.5 ft • Ib)

6 × 16 mm

31

32

5

28

1

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

6

× 25 mm

1 1

33

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

6 × 25 mm

34

1



ELECTRICAL BOX

DISASSEMBLY

1 Plastic tie

2 Tapping screw

3 Cover

4 Gasket

5 Tapping screw

6 Lead holder

7 Bolt


9 Stator motor lead

Q’ty

2

1

2

1

1

6

11

1

1

Service points


Not reusable

7-2

ELEC – +

ELECTRICAL BOX E


3.4 N • m (0.34 kgf • m, 2.5 ft • Ib)

6

× 10 mm

12

3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6

× 30 mm

15

13

7 9

8

14

16 17

11

10

27

26

21

25

30

24

2

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

6 × 30 mm

30

29

21

23

21

22

28

20

3

29

4

6

19

18

3.4 N • m (0.34 kgf • m, 2.5 ft • Ib)

6 × 16 mm

31

32

5

28

1

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

6

× 25 mm

1 1

33

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

6 × 25 mm

34

1

Service points Step Procedure/Part name

10 Bolt

11 Starter relay

12 Tapping screw

13 Fuse holder stay

14 Tapping screw

15 Main and fuel pump relay

16 Tapping screw

17 Rectifier/regulator

18 Tapping screw

19 Coupler bracket

20 Bolt

Q’ty

1

1

1

1

1

1

2

1

2

1

2

7-3

ELEC – +

ELECTRICAL BOX E


3.4 N • m (0.34 kgf • m, 2.5 ft • Ib)

6

× 10 mm

12

3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6

× 30 mm

15

13

7 9

8

14

16 17

11

10

27

26

21

25

30

24

2

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

6 × 30 mm

30

29

21

23

21

22

28

20

3

29

4

6

19

18

3.4 N • m (0.34 kgf • m, 2.5 ft • Ib)

6 × 16 mm

31

32

5

28

1

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

6

× 25 mm

1 1

33

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

6 × 25 mm

34

1

Service points Step Procedure/Part name

21 Tapping screw

22 Ignition coil #1

23 Ignition coil #1 lead

24 Ignition coil #2


26 Ignition coil #3


28 Spark plug lead #1/cap



31 Fuse (3 A)

Q’ty

6

1

1

1

1

1

1

1/1

1/1

1/1

2

7-4

ELEC – +

ELECTRICAL BOX E


3.4 N • m (0.34 kgf • m, 2.5 ft • Ib)

6

× 10 mm

12

3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6

× 30 mm

15

13

7 9

8

14

16 17

11

10

27

26

21

25

30

24

2

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

6 × 30 mm

30

29

21

23

21

22

28

20

3

29

4

6

19

18

3.4 N • m (0.34 kgf • m, 2.5 ft • Ib)

6 × 16 mm

31

32

5

28

1

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

6

× 25 mm

1 1

33

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

6 × 25 mm

34

1


32 Fuse (20 A)

33 Tapping screw

34 Wire harness

Q’ty

1

2

1

Service points


7-5

ELEC – +

ELECTRICAL BOX

E

3.4 N • m (0.34 kgf • m, 2.5 ft • Ib)

6

× 16 mm

3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6 × 25 mm

1 2 3 4

3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6

× 25 mm

5

Ë

B

A

B

1

2

A

A

B

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 16 mm

Ë

3

B

B

R

B

3 2 1

Br

B

B

B

B

Br

Ê É

È

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6

× 16 mm

Í

Ì

1 Ignition coils

2 Starter relay

3 Fuse holders



Î

Ï

Ð

È White tape

É To starter motor

Ê To positive battery terminal

Ë Install the ignition coil connectors to the electrical box holders.

Ì 40–50 mm (1.57–1.97 in)

Í 20–30 mm (0.79–1.18 in)

Î To cylinder #3

Ï To cylinder #2

Ð To cylinder #1

B

Br

R

: Black

: Brown

: Red

7-6

ELEC – +

ECM AND SLANT DETECTION SWITCH

ECM AND SLANT DETECTION SWITCH


E



ECM AND SLANT DETECTION

SWITCH REMOVAL

1 Nut/washer

2 ECM

3 ECM coupler

4 Nut/washer


6 Slant detection switch coupler

Q’ty

2/2

1

1

2/2

1

1

Service points



7-7

ELEC – +

ELECTRICAL ANALYSIS


INSPECTION

E

CAUTION:

• All measuring instruments should be handled with special care. Damaged or mishandled instruments will not measure properly.

• On instruments powered by dry batteries, check the battery voltage periodically and replace the batteries if necessary.

Digital tester

NOTE:

Throughout this chapter the part numbers of the specified digital testers have been omitted.

Refer to the following part numbers.

Digital multimeter:

YU-34899-A

Digital circuit tester:

90890-03174

“

NOTE:

” indicates a continuity of electricity

(i.e., a closed circuit at the respective switch position).

7-8

ELEC – +


E

Low resistance measurement

NOTE:

• When measuring a resistance of 10

Ω or less with the digital tester, the correct measurement cannot be obtained because of the tester’s internal resistance.

• To obtain the correct value, subtract the internal resistance from the displayed measurement.

• The internal resistance of the tester can be obtained by connecting both of its terminals.

Correct value =

Displayed measurement –

Internal resistance

Peak voltage measurement

NOTE:

• When checking the condition of the ignition system, it is vital to know the peak voltage.

• Cranking speed is dependant on many factors (e.g., fouled or weak spark plugs, a weak battery). If one of these is defective, the peak voltage will be lower than specification.

• If the peak voltage measurement is not within specification, the engine will not operate properly.

• A low peak voltage will also cause components to wear prematurely.

7-9

ELEC – +


E

Peak voltage adapter

NOTE:

• Throughout this chapter the part number of the peak voltage adapters have been omitted. Refer to the following part numbers.

• The peak voltage adapter should be used with the digital tester.

È

É

Peak volt meter adapter:

YU-39991

Peak voltage adapter B:

90890-03172

• When measuring the peak voltage, connect the peak voltage adapter to the digital circuit tester and switch the selector to the DC voltage mode.

NOTE:

• Make sure that the adapter leads are properly installed in the digital circuit tester.

• Make sure that the positive pin (the “+” mark facing up as shown) on the adapter is installed into the positive terminal of the tester.

• The test harness is needed for the following tests.

È Voltage measurement

É Peak voltage measurement

Test harness

Checking steps:

• Disconnect the coupler connections.

• Connect the test harness between the couplers.

• Connect the tester terminals to the terminals which are being checked.

• Run the engine and observe the measurement.

NOTE:

If the lighting coil and pickup coil(s) are measured unloaded, disconnect the test harness from the coupler of the output end.

7-10

ELEC – +

IGNITION SYSTEM

IGNITION SYSTEM

WIRING DIAGRAM

E

2 :

3 :

5 :

6 :

7 :

8 :

10 :

11 :

12 :

13 :

14 :

Y

W

B/Y

B/G

B/O

B/L

O

W/Y

W/B

W/R

L/R

19 :

20 :

27 :

28 :

29 :

30 :

31 :

33 :

34 :

35 :

B/R

O

R/Y

L/B

B

P/G

P

B

B/Y

B/W

B/Y

H

#3

I

B/Y

B/W

B/W

B/R

#2

B/R

#1

B/O

B/O B/Y

B/Y

B/Y

B/Y

B/Y

B/Y

G

B

Pu/B

Pu/R

B/O

B/G

B/Y

G G/B

B/Y

B/G

B/Y

B/O

P

O

B/G

O

B/O

Pu/Y

P

O

G/R

G/Y

R/Y

G/Y

G/R

Pu/Y

Pu/R

Pu/B

B/O B/O

P

O O

O

O

B

W/R

W/B

W/R

B

B W/R W/Y

B/O W/B

B/O

W/Y

G

G G G

B/O

G

B/O

B/O

G

B/O B/O

G G G

B

B

W/R W/Y

W/B

B/O

B/O

B/O

F

1

20 21 22 23

1 2 3

24 25 26 27

4 5 6 7

28 29

8 9

30 31 32

10 11 12 13

33 34 35

14 15 16 17 18 19

R/Y

R/Y

R/Y R/Y

R/Y

L/R

Y

L

R/Y

R/Y

7 6 3 2 4 5 1 8

Br

B

R

R/Y

2

R

3

Y

L/R

R

B

Br

4

R

7

B W

FREE

PUSH

FREE

PUSH

6

W B R Br

5

Br Br

FREE

PUSH

B B

B/O

P

O

B/O

P

O

E

B/O B/G

B

B L/B

L/B

B/O

B

B/O L/B

L/B

B/G

B

G

B R G G G

C

A

R

G

D

B

B

B

W

W

B

B

R

R

Br

Br

B/L

B/L

B/O

B/O

O

O

B/O

O

B/O

P/G

B/O

O

B/O

P/G

B

B

B

B

B

W

B

R

Br

B

R

Br

W

B

B

B

B

W

W

B

B

8

9

0

1 ECM


3 Fuse (20 A)

4 Battery

5 Start switch

6 Engine shut-off switch

7 Engine stop switch




A Rectifier/regulator

B Slant detection switch

C Lighting coil

D Pickup coil

E Atmospheric pressure sensor

F Throttle position sensor

G Engine temperature sensor

H Spark plugs

I Ignition coils

7-11

ELEC – +

IGNITION SYSTEM

WIRING DIAGRAM

E

2 :

3 :

5 :

6 :

7 :

8 :

10 :

11 :

12 :

13 :

14 :

Y

W

B/Y

B/G

B/O

B/L

O

W/Y

W/B

W/R

L/R

19 :

20 :

27 :

28 :

29 :

30 :

31 :

33 :

34 :

35 :

B/R

O

R/Y

L/B

B

P/G

P

B

B/Y

B/W

B/Y

H

#3

I

B/Y

B/W

B/W

B/R

#2

B/R

#1

B/O

B/O B/Y

B/Y

B/Y

B/Y

B/Y

B/Y

G

B

Pu/B

Pu/R

B/O

B/G

B/Y

G G/B

B/Y

B/G

B/Y

B/O

P

O

B/G

O

B/O

Pu/Y

P

O

G/R

G/Y

R/Y

G/Y

G/R

Pu/Y

Pu/R

Pu/B

B/O B/O

P

O O

O

O

B

W/R

W/B

W/R

B

B W/R W/Y

B/O W/B

B/O

W/Y

G

G G G

B/O

G

B/O

B/O

G

B/O B/O

G G G

B

B

W/R W/Y

W/B

B/O

B/O

B/O

F

1

20 21 22 23

1 2 3

24 25 26 27

4 5 6 7

28 29

8 9

30 31 32

10 11 12 13

33 34 35

14 15 16 17 18 19

R/Y

R/Y

R/Y R/Y

R/Y

L/R

Y

L

R/Y

R/Y

7 6 3 2 4 5 1 8

Br

B

R

R/Y

2

R

3

Y

L/R

R

B

Br

4

R

7

B W

FREE

PUSH

FREE

PUSH

6

W B R Br

5

Br Br

FREE

PUSH

B B

B/O

P

O

B/O

P

O

E

B/O B/G

B

B L/B

L/B

B/O

B

B/O L/B

L/B

B/G

B

G

B R G G G

C

A

R

G

D

B

B

B

W

W

B

B

R

R

Br

Br

B/L

B/L

B/O

B/O

O

O

B/O

O

B/O

P/G

B/O

O

B/O

P/G

B

B

B

B

B

W

B

R

Br

B

R

Br

W

B

B

B

B

W

W

B

B

8

9

0

B

Br

G

O

: Black

: Brown

: Green

: Orange

P

R

W

Y

: Pink

: Red

: White

: Yellow

B/G : Black/green

B/L : Black/blue

B/O : Black/orange

B/R : Black/red

B/W : Black/white

B/Y : Black/yellow

L/B : Blue/black

L/R : Blue/red

P/G : Pink/green

R/Y : Red/yellow

7-12

W/B : White/black

W/R : White/red

W/Y : White/yellow

ELEC – +

IGNITION SYSTEM

È

É

È

OK

0 5

E

IGNITION SPARK GAP

WARNING

• When checking the spark gap, do not touch any of the connections of the spark gap tester lead wires.

• When performing the spark gap test, take special care not to let sparks leak out of the removed spark plug cap.

• When performing the spark gap check, keep flammable gas or liquids away, since this test can produce sparks.

1. Check:

• Ignition spark gap

Below specification

→ Check the ECM output peak voltage.

Check the ignition coil for resistance.

Spark gap:

10–11 mm (0.39–0.43 in)

Checking steps:

• Connect the spark plug cap to the spark gap tester.

• Set the spark gap length on the adjusting knob.

Spark gap tester:

YM-34487

Ignition tester:

90890-06754

• Crank the engine and observe the ignition system spark through the discharge window.


É For Worldwide

0 5 10

É

OK

7-13

ELEC – +

IGNITION SYSTEM

E

IGNITION SYSTEM PEAK VOLTAGE

WARNING

When checking the electrical components, do not touch any of the connections of the digital tester lead wires.

NOTE:

• If there is no spark, or the spark is weak, continue with the ignition system test.

• If a good spark is obtained, the problem is not with the ignition system, but possibly with the spark plug(s) or another component.

1. Measure:

• ECM output peak voltage

Below specification

→ Measure the pickup coil output peak voltage.

r/min

V

ECM output peak voltage:

Black/red (B/R) – Ground for cylinder #1

Black/white (B/W) – Ground for cylinder #2

Black/yellow (B/Y) – Ground for cylinder #3

Cranking

0.8

Loaded

2,000

174

3,500

156

NOTE:

To crank the engine, connect the engine shutoff cord (lanyard) to the engine shut-off switch, and then press the start switch and engine stop switch simultaneously.

7-14

ELEC – +

IGNITION SYSTEM

E

2. Measure:

• Pickup coil output peak voltage

Below specification

→ Replace the pickup coil.

Above specification

→ Replace the

ECM.

Test harness (6 pins):

YB-06849

Test harness SM6195021-6

(6 pins):

90890-06849

Pickup coil output peak voltage:

White/red (W/R) – Black (B)

White/black (W/B) – Black (B)

White/yellow (W/Y) – Black (B) r/min

Unloaded

V

Cranking

6.0

6.0

Loaded

2,000 3,500

24 40

NOTE:


3. Measure:

• Lighting coil output peak voltage

Below specification

→ Replace the lighting coil.

Lighting coil tester (3 pins):

YB-06870

Test harness SMT250-3 (3 pins):

90890-06870

Lighting coil output peak voltage:

Green (G) – Green (G) r/min

V

Unloaded

Cranking

9.0

7.5

Loaded

2,000

12.5

3,500

12.5

NOTE:


7-15

ELEC – +

IGNITION SYSTEM

E

4. Measure:

• Rectifier/regulator output peak voltage

Below specification

→ Replace the rectifier/regulator.

Test harness (6 pins):

YB-06848

Test harness FSW-6A (6 pins):

90890-06848 r/min

V

Rectifier/regulator output peak voltage:

Red (R) – Black (B)

Unloaded

3,500

14.5

NOTE:

• Do not use the peak voltage adapter to measure the output voltage.

• Disconnect the output lead of the tester harness.

BATTERY

Refer to “ELECTRICAL” in Chapter 3.

FUSE

Refer to “STARTING SYSTEM.”

SPARK PLUGS

Refer to “POWER UNIT” in Chapter 3.

SPARK PLUG LEAD ASSEMBLY

1. Check:

• Spark plug lead assembly

Cracks/damage

→ Replace.

2. Measure:

• Spark plug lead resistance


→ Replace.

Spark plug lead resistance:

#1: 6.1–14.3 k Ω

#2: 4.5–10.9 k Ω

#3: 3.3–8.2 k Ω

7-16

ELEC – +

IGNITION SYSTEM

IGNITION COIL

1. Measure:

• Primary coil resistance


→ Replace.

Primary coil resistance:

Black/white (B/W) – Body

0.26–0.36

Ω at 20 °C (68 °F)

E

NOTE:

When measuring a resistance of 10

Ω or less with the digital tester, the correct measurement cannot be obtained because of the tester’s internal resistance.

Refer to “Low resistance measurement.”

2. Measure:

• Secondary coil resistance


→ Replace.

Secondary coil resistance:

Black/white (B/W) – Spark plug lead terminal

3.5–4.7 k

Ω at 20 °C (68 °F)

ENGINE STOP SWITCH

1. Check:

• Engine stop switch continuity


→ Replace.

Clip

Engine stop switch continuity

(black coupler)

Position

Lead color

White Black

Installed

Removed

Free

Push

Free

Push

7-17

ELEC – +

IGNITION SYSTEM

E

ENGINE TEMPERATURE SENSOR

1. Measure:

• Engine temperature sensor resistance

(at the specified temperatures)

Out of specifications

→ Replace.

Engine temperature sensor resistance:

20 °C (68 °F): 54.2–69.0 k

Ω

100 °C (212 °F): 3.12–3.48 k

Ω


• Suspend the engine temperature sensor in a container filled with water.

• Slowly heat the water.

• Measure the resistance when the specified temperatures are reached.

INTAKE AIR TEMPERATURE SENSOR

1. Measure:

• Intake air temperature sensor resistance



→ Replace.

Intake air temperature sensor resistance:

0 °C (32 °F): 5.4–6.6 k Ω

80 °C (176 °F): 0.29–0.39 k Ω


• Ice the intake air temperature sensor and measure the resistance when the specified temperature is reached.

• Suspend the intake air temperature sensor in a container filled with water.

• Slowly heat the water.

• Measure the resistance when the specified temperature is reached.

7-18

ELEC – +

IGNITION SYSTEM

COOLING WATER TEMPERATURE

SENSOR

1. Measure:

• Cooling water temperature sensor resistance



→ Replace.

Cooling water temperature sensor resistance:

0 °C (32 °F): 24.0–37.1 k Ω

100 °C (212 °F): 0.87–1.18 k Ω

200 °C (392 °F): 104–153 Ω

E


• Ice the cooling water temperature sensor and measure the resistance when the specified temperature is reached.

• Suspend the cooling water temperature sensor in a container filled with oil.

• Slowly heat the oil.


7-19

EXHAUST TEMPERATURE SENSOR

1. Measure:

• Exhaust temperature sensor resistance



→ Replace.

Exhaust temperature sensor resistance:

300 °C (572 °F): 73–241 k

Ω

600 °C (1,112 °F): 0.86–1.58 k

Ω

900 °C (1,652 °F): 64–90

Ω


• Heat the exhaust temperature sensor using an electric furnace or equivalent.


ELEC – +

IGNITION SYSTEM

8

4

5

1

3

2

7

6

8

4

5

1

3

2

7

6

1234

5678

+ –

+ –

E

MAIN AND FUEL PUMP RELAY

1. Check:

• Main and fuel pump relay continuity


→ Replace.

Checking steps:

• Connect the tester leads between main and fuel pump relay terminals

5, 6, and

7.

• Connect terminal

2 or 3 to the positive battery terminal.


1 to the negative battery terminal.

• Check that there is continuity between the main and fuel pump relay terminals.

• Check that there is no continuity between the main and fuel pump relay terminals after disconnecting terminal

1, 2, or 3.

• Connect the tester leads between main and fuel pump relay terminals

6 and 8.


7 to the positive battery terminal.


4 to the negative battery terminal.

• Check that there is continuity between the main and fuel pump relay terminals.

• Check that there is no continuity between the main and fuel pump relay terminals after disconnecting terminal

4 or 7.

THROTTLE POSITION SENSOR

1. Measure:

• Check the throttle position sensor output voltage using the Yamaha Diagnostic

System.


→ Replace the throttle bodies.

Throttle position sensor output voltage:

Pink (P) – Black/orange (B/O)

0.793–0.807 V

7-20

ELEC – +

IGNITION SYSTEM

È a b c

3 2

B/O

P/G

1 É

E

ATMOSPHERIC PRESSURE SENSOR

1. Measure:

• Atmospheric pressure sensor output voltage


→ Replace.

Air pressure sensor tester

(3 pins):

YB-06869

Test harness EJ-II-3 (3 pins):

90890-06869

Lower unit pressure/vacuum tester:

YB-35956-A

Vacuum/pressure pump gauge set:

90890-06756

Atmospheric pressure sensor output voltage:

Pink/green (P/G) –

Black/orange (B/O)

1 101.3 kPa

(1.01 kgf/cm 2 , 14.4 psi): a 4.00 V

2 50 kPa

(0.5 kgf/cm 2 , 7.1 psi): b 1.97 V

3 20 kPa

(0.2 kgf/cm 2 , 2.8 psi): c 0.79 V

È: Output voltage É: Vacuum pressure


• Disconnect the atmospheric pressure sensor.

• Connect the test harness (3 pins) to the atmospheric pressure sensor.

• Operate the Yamaha Diagnostic System.

• Apply vacuum pressure to the atmospheric pressure sensor and measure the output voltage.

NOTE:

While the Yamaha Diagnostic System is operating, electric power is supplied to the atmospheric pressure sensor.

7-21

ELEC – +

IGNITION SYSTEM

È

UP

É

UP

E

SLANT DETECTION SWITCH

1. Check:

• Slant detection switch continuity


→ Replace.

Position

Lead color

Blue/black

(L/B)

Black/ orange

(B/O)

Normal operation È

Overturned É

7-22

ELEC – +

FUEL CONTROL SYSTEM


WIRING DIAGRAM

8 :

10 :

14 :

20 :

23 :

2 :

5 :

6 :

7 :

Y

B/Y

B/G

B/O

B/L

O

L/R

O

P

24 :

25 :

26 :

27 :

28 :

29 :

30 :

31 :

33 :

Pu/Y

Pu/B

Pu/R

R/Y

L/B

B

P/G

P

B

1

20 21 22 23

1 2 3

24 25 26 27

4

28 29

5 6 7 8 9

30 31 32

10 11 12 13

33 34 35

14 15 16 17 18 19

R/Y

R/Y

R/Y R/Y

R/Y

L/R

Y

R/Y

L

R/Y

7 6 3 2 4 5 1 8

Br

B

R

R/Y

2

R

R

3

Y

L/R

B/O

B/O

B/O

B/O

B/O

B/O

B/O

B/O

B

B

B

B B

R

B

B R

4

R/Y

R/Y

E

#3

R/Y

E

#2

R/Y

E

#1

R/Y

Pu/Y

Pu/B

Pu/Y

R/Y

Pu/B

Pu/R

R/Y

Pu/R

R/Y

R/Y

Pu/B

Pu/R

B/O

B/O O

B/O

Pu/Y

P

B/G

B/Y

G

B/Y

B/G

Pu/R

Pu/B

B/O

G/B O

G/R

G/Y

R/Y

G/Y

G/R

Pu/Y

B/O

P

B

B

B B B

O

P

R/Y

R/Y

O

P

B/O

B/O

B/G

B/O

B/Y

B/O

B/O

B/Y

B/O

B/G

B/Y

B/Y

B/Y

B/Y

B

B

B

C

O

O O

O

D

O

O

L/B

L/B

B

B

L/B

L/B

B/O

B/O

6

L

B

P

B

B

B

B/L

B/L

B/O

B/O

O

O

B/O

B/O

L

P

P

B

B

Gy

L

Gy

B

B

W

B

W

B

B

B

5

7

8

9

0

O

B/O

P/G

O

B/O

P/G

A

1 ECM


3 Fuse (20 A)

4 Battery



7 Fuel sender

8 Fuel pump



A Atmospheric pressure sensor

B Throttle position sensor

C Intake air temperature sensor

D Engine temperature sensor

E Fuel injector

7-23

E

ELEC – +


WIRING DIAGRAM

8 :

10 :

14 :

20 :

23 :

2 :

5 :

6 :

7 :

Y

B/Y

B/G

B/O

B/L

O

L/R

O

P

24 :

25 :

26 :

27 :

28 :

29 :

30 :

31 :

33 :

Pu/Y

Pu/B

Pu/R

R/Y

L/B

B

P/G

P

B

1

20 21 22 23

1 2 3

24 25 26 27

4

28 29

5 6 7 8 9

30 31 32

10 11 12 13

33 34 35

14 15 16 17 18 19

R/Y

R/Y

R/Y R/Y

R/Y

L/R

Y

R/Y

L

R/Y

7 6 3 2 4 5 1 8

Br

B

R

R/Y

2

R

R

3

Y

L/R

B/O

B/O

B/O

B/O

B/O

B/O

B/O

B/O

B

B

B

B B

R

B

B R

4

R/Y

R/Y

E

#3

R/Y

E

#2

R/Y

E

#1

R/Y

Pu/Y

Pu/B

Pu/Y

R/Y

Pu/B

Pu/R

R/Y

Pu/R

R/Y

R/Y

Pu/B

Pu/R

B/O

B/O O

B/O

Pu/Y

P

B/G

B/Y

G

B/Y

B/G

Pu/R

Pu/B

B/O

G/B O

G/R

G/Y

R/Y

G/Y

G/R

Pu/Y

B/O

P

B

B

B B B

O

P

R/Y

R/Y

O

P

B/O

B/O

B/G

B/O

B/Y

B/O

B/O

B/Y

B/O

B/G

B/Y

B/Y

B/Y

B/Y

B

B

B

C

O

O O

O

D

O

O

L/B

L/B

B

B

L/B

L/B

B/O

B/O

6

L

B

P

B

B

B

B/L

B/L

B/O

B/O

O

O

B/O

B/O

L

P

P

B

B

Gy

L

Gy

B

B

W

B

W

B

B

B

5

7

8

9

0

O

B/O

P/G

O

B/O

P/G

A

P

R

W

Y

B : Black

Gy : Gray

L

O

: Blue

: Orange

: Pink

: Red

: White

: Yellow

B/G : Black/green

B/L : Black/blue

B/O : Black/orange

B/Y : Black/yellow

L/B : Blue/black

L/R : Blue/red

P/G : Pink/green

Pu/B : Purple/black

Pu/R : Purple/red

Pu/Y : Purple/yellow

R/Y : Red/yellow

7-24

E

ELEC – +


E

FUEL PUMP

1. Check:

• Fuel pump operating sound

No sound

→ Measure the fuel pressure.


FUEL SENDER

1. Measure:

• Fuel sender resistance


→ Replace.

Float position

A

B

Resistance (

Ω)

133.5–136.5

5–7

7-25

ELEC – +


E

FUEL INJECTOR


Chapter 4.


Refer to “IGNITION SYSTEM.”

INTAKE AIR TEMPERATURE SENSOR



SENSOR








ATMOSPHERIC PRESSURE SENSOR


SLANT DETECTION SWITCH


7-26

ELEC – +

STARTING SYSTEM

STARTING SYSTEM

WIRING DIAGRAM

2 :

27 :

33 :

Y

R/Y

B

1

20 21 22 23

1 2 3

24 25 26 27

4 5 6 7

28 29

8 9

30 31 32

10 11 12 13

33 34 35

14 15 16 17 18 19

R/Y

R/Y

R/Y

R/Y R/Y

R/Y

Y

L/R

Y

2

Br

B

L

R/Y

R

R/Y

7 6 3 2 4 5 1 8

R

R

R

3

B

B

B

B

B

B

E

R

4 R

B

R

Br Br

Br

8

FREE

PUSH

W B R Br

7

FREE

PUSH

Br Br

Br

R

6

B

B R

5

Br

Br

R

R

Br

R

Br

R

1 ECM


3 Fuse (20 A)

4 Starter relay

5 Battery

6 Starter motor

7 Start switch

8 Engine shut-off switch

B

Br

R

Y

: Black

: Brown

: Red

: Yellow

R/Y : Red/yellow

7-27

ELEC – +

STARTING SYSTEM

E

BATTERY


WIRING CONNECTIONS

1. Check:

• Wiring connections

Poor connections

→ Properly connect.

FUSES

1. Check:

• Fuses

Broken

→ Replace.

Fuse rating:

20 A

× 1, 3 A × 2

NOTE:

The 20 A fuse is for the main relay, engine shut-off switch, and rectifier/regulator.

The 3 A fuses are for the multifunction meter and electric bilge pump.

7-28

START SWITCH

1. Check:

• Continuity


→ Replace.

Clip

Start continuity

(natural color coupler)

Position

Red

Leads

Brown

Installed

Removed

Free

Push

Free

Push

ELEC – +

STARTING SYSTEM

STARTER RELAY

1. Check:

• Brown lead terminal

• Black lead terminal

Loose

→ Tighten.

Br

B

E

2. Check:

• Starter relay continuity


→ Replace.

Checking steps:

• Connect the tester leads between the starter relay terminals as shown.

• Connect the brown lead terminal to the positive battery terminal.

• Connect the black lead terminal to the negative battery terminal.

• Check that there is continuity between the starter relay terminals.

• Check that there is no continuity after disconnecting the brown or black lead.



7-29

ELEC – +

STARTER MOTOR

STARTER MOTOR


E



STARTER MOTOR

DISASSEMBLY

Starter motor

Q’ty

1 O-ring

2 Bolt

3 Starter motor front cover

4 O-ring

5 Oil seal retainer

6 Washer

7 Shim

Service points


Refer to “GENERATOR AND STARTER

MOTOR” in Chapter 5.

Not reusable

1

1

1

2

Not reusable

1

1

— As required

Thickness = 0.2 mm, 0.5 mm

7-30

ELEC – +

STARTER MOTOR


E


8 Starter motor rear cover

9 O-ring

10 Shim

11 Armature assembly

12 Nut/spring washer/washer

13 O-ring

14 Brush holder

15 Brush spring

16 Bolt

17 Brush assembly


1

1 Not reusable

— As required

Thickness = 0.2 mm, 0.8 mm

1

1/1/4

1

1

4

1

1

Not reusable

7-31

ELEC – +

STARTER MOTOR


E

Step

18 Spacer

19 Holder

Procedure/Part name

20 Starter motor yoke

Q’ty

1

1

1

Service points


7-32

ELEC – +

STARTER MOTOR

1

SERVICE POINTS

Armature inspection

1. Check:

• Armature shaft

1

Damage/wear

→ Replace.

E

2. Check:

• Commutator

Dirt

→ Clean with 600 grit sandpaper.

7-33

3. Measure:

• Commutator diameter


→ Replace.

Minimum commutator diameter:

27.0 mm (1.06 in)

4. Check:

• Commutator undercut

Contaminants

→ Clean.

NOTE:

Use compressed air to remove all mica and metal particles.

5. Measure:

• Commutator undercut


→ Replace.

Minimum commutator undercut:

0.2 mm (0.01 in)

ELEC – +

STARTER MOTOR

E

6. Check:

• Armature coil continuity


→ Replace.

Armature coil continuity:

Commutator segments

1 Continuity

Segment – laminations

2 No

Segment – armature shaft No continuity

7-34

Brush holder inspection

1. Measure:

• Brush length a


→ Replace.

Minimum brush length:

6.5 mm (0.26 in)

2. Check:

• Brush holder continuity


→ Replace.

Brush holder continuity:

Brush holder – base No continuity

Starter motor front cover inspection

1. Check:

• Starter motor front cover oil seal

Damage/wear

→ Replace the starter motor front cover.

ELEC – +

CHARGING SYSTEM

CHARGING SYSTEM

WIRING DIAGRAM

B

1

R

G

B G G G R

G

G G G

G

G

G

G

G

G

R

2

R

R

B

3

R

4

E


2 Fuse (20 A)

3 Battery

4 Lighting coil

B

G

R

: Black

: Green

: Red

7-35

ELEC – +

CHARGING SYSTEM

FUSE


BATTERY


LIGHTING COIL


RECTIFIER/REGULATOR


E

7-36

ELEC – +

YPVS

WIRING DIAGRAM

YPVS

7 :

10 :

11 :

12 :

13 :

B/O

O

W/Y

W/B

W/R

21 :

22 :

23 :

29 :

33 :

L

G

P

B

B

1

20

1

21 22 23

2 3

24 25 26 27

4 5 6 7

28 29

8 9

30 31 32

10 11 12 13

33 34 35

14 15 16 17 18 19

O

O

O O

O

B/O

B/O

B/O

B/O B/O

B/O

B/O

B/O

B

B B

B

B

B

R

2

R

R

B

5

R

G

B G G G R

G

B R

3

1 ECM

2 Fuse (20 A)

3 Battery

4 YPVS servomotor


6 Lighting coil

7 Pickup coil

B

B B B

B

B B

B

B W/B B/O

W/R W/Y

B/O

W/R

W/B

W/R

W/Y

G

G G G

G

G

B

B

B

W/R W/Y

W/B

G G G

6

7

B

G

L

O

: Black

: Green

: Blue

: Orange

P

R

: Pink

: Red

B/O : Black/orange

W/B : White/black

W/R : White/red

W/Y : White/yellow

O

O L P G

B/O

P

B/O

L

G

O

G L B P O

P

B

4

E

7-37

ELEC – +

YPVS

FUSE


BATTERY


PICKUP COIL


LIGHTING COIL


RECTIFIER/REGULATOR


E

7-38

ELEC – +

YPVS SERVOMOTOR

YPVS SERVOMOTOR


E



YPVS SERVOMOTOR REMOVAL

1 Bolt

2 Cable holder

3 YPVS servomotor coupler

4 Nut/washer

5 YPVS servomotor

6 Throttle cable plastic tie bracket

7 YPVS cable



2

1

1

2/2

1

1

2 Slide the cover.

Cable 2 is identifiable by its white paint mark a.

7-39

ELEC – +

YPVS SERVOMOTOR


E


8 Cover

9 Nut/washer

10 YPVS servomotor bracket

Q’ty

1

3/3

1

Service points


7-40

ELEC – +

YPVS SERVOMOTOR

E

SERVICE POINTS

YPVS cable removal and installation

1. Remove:


Removal steps:

• Remove the YPVS cable holder

1.

• Remove the YPVS cables

2 from both drums.

NOTE:

• YPVS cable 2 is identifiable by its white paint mark a.

• When installing the YPVS cable, make sure that the YPVS cable locknuts

3 are fully turned in.

YPVS cable inspection

1. Check:


Frays/kinks/rough movement

→

Replace.

YPVS servomotor inspection

1. Check:

• Check the YPVS servomotor operation using the Yamaha Diagnostic System.

CAUTION:

Do not disassemble the YPVS servomotor unit. It is a sealed unit and if it is faulty it must be replaced.

YPVS cable adjustment

Refer to “POWER UNIT” in Chapter 3.

7-41

ELEC – +

OFF THROTTLE STEERING SYSTEM


WIRING DIAGRAM

4 :

7 :

9 :

10 :

11 :

12 :

13 :

W/L

B/O

W/L

O

W/Y

W/B

W/R

15 :

16 :

17 :

18 :

27 :

29 :

31 :

G/B

G/R

G

G/Y

R/Y

B

P

B

B

B B

B

B

1

20 21 22 23

1 2 3

24 25 26 27

4 5 6 7

28 29

8 9

30 31 32

10 11 12 13

33 34 35

14 15 16 17 18 19

B

W/L

B

R/Y

W/L

R/Y

R/Y

R/Y R/Y

R/Y

R/Y

2

R/W

B

Y/B

Y/B

R/W

B

R/Y

R/Y

B

W/L

B

W/L

R/Y

W/L

W/L

B

R/Y

B

W/L

O

B/O

B/O

B/O

B/O

O

B/O

B/O

B/O

B/O

B/O

O

O

B

B/O

B

W/R W/Y

W/B

B/O

W/R

W/B

W/R

W/Y

B

B

B

W/R W/Y

W/B

R/Y

R/W

B

R/Y

P

G/R

G/B

G

G/Y

B/O

O

P

B/O

G/Y

R/Y

G/R

O

Y/B

Y/B

B

R/W

6

G/B

B/Y

G

B/G

G/B

B/Y

Pu/R

Pu/B

Pu/Y

B/O

Pu/Y

O

G/Y

R/Y

G/R

B/O

P

R/Y

R/Y

R/Y R/Y

R/Y

R/Y

R/Y

1 ECM

2 Throttle switch

3 Throttle position sensor

4 Stepping motor

5 Pickup coil

6 Steering switch

5

B

G

O

P

: Black

: Green

: Orange

: Pink

B/O : Black/orange

G/B : Green/black

G/R : Green/red

G/Y : Green/yellow

R/W : Red/white

R/Y : Red/yellow

G/Y

G/Y

G G/R

G/B R/Y

R/Y

R/Y

G/R

B/O

B/O

P

O

P

O

G

R/Y

4

G/B

3

W/B : White/black

W/L : White/blue

W/R : White/red

W/Y : White/yellow

Y/B : Yellow/black

E

7-42

ELEC – +


E

STEERING SWITCH

1. Check:

• Steering switch

Refer to “SELF-DIAGNOSIS” in Chapter

9.

Malfunction

→ Check that the steering switch switches on and off when the handlebar is turned to the right and to the left using the “Engine monitor” of the

Yamaha Diagnostic System.

Does not operate

→ Replace.

STEPPING MOTOR

1. Check:

• Check the operation of the stepping motor using the “Stationary test” of the


THROTTLE SWITCH

1. Check:

• Check the operation of the throttle switch using the “Engine monitor” of the


PICKUP COIL




7-43

ELEC – +

ELECTRIC BILGE PUMP


WIRING DIAGRAM

2 :

27 :

Y

R/Y

1

20 21 22 23

1 2 3

24 25 26 27

4 5 6 7

28 29

8 9

30 31 32

10 11 12 13

33 34 35

14 15 16 17 18 19

Y

R/Y

R/Y

R/Y R/Y

R/Y

L/R

Y

R/Y

L

R/Y

7 6 3 2 4 5 1 8

Br

B

R

R/Y

2

R/Y

R

R/Y

3

B

Br

R

B

B

B

B

B

B

B

B

R

R R

Br

E

5

B

Br

Br

B

R/Y

B

R/Y

4

B

1 ECM


3 Fuse (3 A)

4 Battery

5 Electric bilge pump

B

Br

R

Y

: Black

: Brown

: Red

: Yellow

R/Y : Red/yellow

7-44

ELEC – +

Br


B

– +

E


1. Check:

• Electric bilge pump operation

Does not operate

→ Replace.

Checking steps:

• Suspend the electric bilge pump in a container filled with water.

• Connect the brown lead terminal to the positive battery terminal.

• Connect the black lead terminal to the negative battery terminal.

• Check that the water flows from the electric bilge pump hose.

FUSE


BATTERY




7-45

ELEC – +

INDICATION SYSTEM


WIRING DIAGRAM

E

1 :

2 :

5 :

7 :

8 :

G

Y

B/Y

B/O

B/L

20 :

27 :

29 :

32 :

33 :

O

R/Y

B

W/B

B

1

20 21 22 23

1 2 3

24 25 26 27

4 5 6 7

28 29

8 9

30 31 32

10 11 12 13

33 34 35

14 15 16 17 18 19

Y

R/Y

R/Y

R/Y R/Y

R/Y

R/Y

L/R

Y

R/Y

L

R/Y

7 6 3 2 4 5 1 8

Br

B

R

R/Y

2 R

R

3

R/Y 4

R

R/Y

B R

5

B

B B

B

B

B

B

B

W/B

W

B

B R/Y

W/B

R

P

9

B P

B

Pu/B

Pu/R

B/O

B/G

B/Y

G G/B

B/Y

B/G

B/Y B/O

B/O

Pu/Y

P

O

G/R

G/Y

R/Y

G/Y

G/R

Pu/Y

Pu/R

Pu/B

B/O B/O

P

B P

R W B

B/O B/Y

0

R/W

R/W

B/Y

Y

Y L/R

B/Y

R

B/Y

L/R L/B

B/R

L/B L

B/R

B

R/Y

Y

R B

L

R/Y

Y

B/Y

L

L

B

B

C B

A

B/O B/Y

B/Y

B/Y

B/Y

B/Y

8

B

B

B

B

B/O

B/O

B/O

B/O

B/O

B

B/O

B/O

G

B/O

G

B/O

È

B/L

B/L

B/O

B/O

O

O

B/O

B/O

B

B

W

B

W

B

B

B

6

7

1 ECM


3 Fuse (20 A)

4 Fuse (3 A)

5 Battery




9 Fuel sender


A Oil level sensor

B Buzzer

C Speed sensor

È To tachometer

7-46

ELEC – +


WIRING DIAGRAM

E

1 :

2 :

5 :

7 :

8 :

G

Y

B/Y

B/O

B/L

20 :

27 :

29 :

32 :

33 :

O

R/Y

B

W/B

B

1

20 21 22 23

1 2 3

24 25 26 27

4 5 6 7

28 29

8 9

30 31 32

10 11 12 13

33 34 35

14 15 16 17 18 19

Y

R/Y

R/Y

R/Y R/Y

R/Y

R/Y

L/R

Y

R/Y

L

R/Y

7 6 3 2 4 5 1 8

Br

B

R

R/Y

2 R

R

3

R/Y 4

R

R/Y

B R

5

B

B B

B

B

B

B

B

W/B

W

B

B R/Y

W/B

R

P

9

B P

B

Pu/B

Pu/R

B/O

B/G

B/Y

G G/B

B/Y

B/G

B/Y B/O

B/O

Pu/Y

P

O

G/R

G/Y

R/Y

G/Y

G/R

Pu/Y

Pu/R

Pu/B

B/O B/O

P

B P

R W B

B/O B/Y

0

R/W

R/W

B/Y

Y

Y L/R

B/Y

R

B/Y

L/R L/B

B/R

L/B L

B/R

B

R/Y

Y

R B

L

R/Y

Y

B/Y

L

L

B

B

C B

A

B/O B/Y

B/Y

B/Y

B/Y

B/Y

8

B

B

B

B

B/O

B/O

B/O

B/O

B/O

B

B/O

B/O

G

B/O

G

B/O

È

B/L

B/L

B/O

B/O

O

O

B/O

B/O

B

B

W

B

W

B

B

B

6

7

B

G

L

O

: Black

: Green

: Blue

: Orange

P

R

W

Y

: Pink

: Red

: White

: Yellow

B/L : Black/blue

B/O : Black/orange

B/R : Black/red

B/Y : Black/yellow

L/B : Blue/black

L/R : Blue/red

R/W : Red/white

R/Y : Red/yellow

W/B : White/black

7-47

ELEC – +


E

FUSE


BATTERY





SENSOR






OIL LEVEL SENSOR

1. Measure:

• Oil level sensor resistance


→ Replace.

Blue (L) – Black (B)

Float position

A

B

C

Resistance (

Ω)

292–308

97–103

0–3

7-48

ELEC – +


E

BUZZER

1. Check:

• Buzzer

Buzzer does not sound

→ Replace.

Checking steps:

• Connect a 12 V battery to the buzzer coupler as shown.

Positive battery terminal

→

Red (R) terminal

1

Negative battery terminal

→

Black (B) terminal

2

MULTIFUNCTION METER

Multifunction meter

1. Check:

• Multifunction meter

Cracked meter housing

→ Replace the multifunction meter.

Meter is fogged/shows signs of water intrusion


MULTIFUNCTION METER REMOVAL

Refer to “STEERING CONSOLE COVER” in

Chapter 8.

7-49

ELEC – +


E

Display function

1. Check:

• Display function

Does not operate


1 Buzzer

2 Speed sensor

3 ECM

4 Oil level sensor

5 Fuel sender

7-50

B

L

P

R

: Black

: Blue

: Pink

: Red

W

Y

: White

: Yellow

B/R : Black/red

B/Y : Black/yellow

L/B : Blue/black

L/R : Blue/red

R/W : Red/white

L/B

L/B

L/R

L/R

B

R

B/Y

R

W

B

B/Y

R/W

Y

Y

W

L

B

B/R

L

B

R

R/W

2

R

B/R

3

4

1

B

P

P B

5

ELEC – +


E

Speedometer display

1. Check:

• Speedometer display

Does not display

→ Measure the speed sensor output voltage and pulses.

2. Measure:

• Speed sensor output voltage and pulses


→ Replace the speed sensor.

Within specification


Speed sensor output voltage

(dependant on the paddle wheel position):

Less than 400 mV

More than 11.6 V

Output pulse:

2 pulses/1 full turn


• Connect a 12 volt battery to the white three-pin connector (between the red/yellow and black/yellow leads).

• Rotate the paddle wheel by hand and measure the voltage between the yellow and black/yellow leads.

NOTE:

As the paddle wheel is rotated, a squarewave voltage signal a is produced.

• Two pulses occur every time the paddle wheel makes one full turn.

7-51

Tachometer display

1. Check:

• Tachometer display

Does not display

→ Check the engine speed using the “Engine monitor” of the


If there is no malfunction, replace the multifunction meter.

ELEC – +


E

Hour meter display

1. Check:

• Hour meter display

Does not display


Voltage meter display

1. Check:

• Voltage meter display

Does not display

→ Check the battery voltage using the “Engine monitor” of the Yamaha Diagnostic System.

If there is no malfunction, replace the multifunction meter.

Fuel level meter display and fuel warning indicator

1. Check:

• Fuel level meter display and fuel warning indicator

Do not display

→ Measure the fuel sender resistance.

If the fuel sender resistance is within specification, replace the multifunction meter.

2. Measure:

• Fuel sender resistance

Refer to “FUEL CONTROL SYSTEM.”

Oil warning indicator

1. Check:

• Oil warning indicator

Does not display

→ Measure the oil level sensor resistance.

If the oil level sensor resistance is within specification, replace the multifunction meter.

2. Measure:

• Oil level sensor resistance

Refer to “OIL LEVEL SENSOR.”

7-52

ELEC – +


1

E

Engine overheat warning indicator

1. Check:

• Engine overheat warning indicator

Does not operate


Checking steps:

• Start the engine.

• Disconnect the cooling water temperature sensor coupler

1.

• Check that the warning light comes on and that the engine overheat warning indicator is displayed.

1

Exhaust temperature warning indicator

1. Check:

• Exhaust temperature warning indicator

Does not operate


Checking steps:

• Disconnect the exhaust temperature sensor coupler

1.

• Start the engine and warm it up for more than 2 minutes at 4,000 r/min.

• Check that the warning light and exhaust temperature warning indicator blink and that the buzzer sounds intermittently when the engine is started.

7-53

ELEC – +


E

Check engine warning indicator

1. Check:

• Check engine warning indicator

Does not operate


Checking steps:


• Disconnect the coupler of a sensor (e.g., atmospheric pressure sensor) that normally activates the check engine warning indicator when a malfunction occurs.

• Check that the warning light and check engine warning indicator blink and that the buzzer sounds intermittently.

Diagnostic display

1. Check:

• Diagnostic display

Does not display


Checking steps:


• Disconnect the coupler of a sensor (e.g., atmospheric pressure sensor) that is normally displayed when a malfunction occurs. Refer to “SELF-DIAGNOSIS” in

Chapter 9.

• Check that the check engine warning indicator is displayed and that the buzzer sounds.

• Press the select switch

1 for 8 seconds and check if an error code is indicated on the multifunction meter.

7-54

HULL

HOOD

CHAPTER 8

HULL AND HOOD

HANDLEBAR .................................................................................................. 8-1



SERVICE POINTS .................................................................................... 8-6

Handlebar inspection .......................................................................... 8-6

Handlebar switch inspection ............................................................... 8-6

Handlebar assembly installation ......................................................... 8-6

QSTS GRIP ..................................................................................................... 8-8



SERVICE POINTS .................................................................................. 8-10

QSTS cable inspection...................................................................... 8-10

QSTS grip inspection ........................................................................ 8-10

STEERING COLUMN .................................................................................... 8-11



SERVICE POINTS .................................................................................. 8-14

Steering column bushing inspection ................................................. 8-14

Steering column assembly ................................................................ 8-14

REMOTE CONTROL CABLES AND SPEED SENSOR LEAD .................... 8-15



SERVICE POINTS .................................................................................. 8-17

Remote control cable inspection ....................................................... 8-17

Steering cable installation ................................................................. 8-17

Steering cable stopper installation .................................................... 8-17

QSTS cable installation..................................................................... 8-18

QSTS cable stopper installation........................................................ 8-18

HOOD ............................................................................................................ 8-19



STEERING CONSOLE COVER .................................................................... 8-21



BUZZER AND HOOD LOCK......................................................................... 8-25



E

HULL

HOOD

HOSES .......................................................................................................... 8-27



SERVICE POINTS .................................................................................. 8-28

Check valve inspection ..................................................................... 8-28

Ventilation hose installation............................................................... 8-28

SEAT AND HANDGRIP................................................................................. 8-29



SERVICE POINTS .................................................................................. 8-31

Seat lock inspection .......................................................................... 8-31

BATTERY BOX ............................................................................................. 8-32



EXHAUST SYSTEM ...................................................................................... 8-34



SERVICE POINTS .................................................................................. 8-36

Exhaust system inspection................................................................ 8-36

Water lock installation ....................................................................... 8-36

Exhaust component parts assembly ................................................. 8-37

DECK AND HULL.......................................................................................... 8-38



ENGINE MOUNTS......................................................................................... 8-40



E

5

6

7

8

9

3

4

1

2

HULL

HOOD HANDLEBAR

HANDLEBAR


E



HANDLEBAR COVER REMOVAL

1 Screw

2 Handlebar cover

3 Screw

4 Handlebar cover stay

5 Plastic tie

6 Throttle cable

7 Bolt

8 Upper handlebar holder

9 Handlebar assembly

10 Lower handlebar holder

Q’ty

1

4

1

1

4

1

4

2

1

2

Service points



8-1

HULL

HOOD HANDLEBAR


E



HANDLEBAR REMOVAL

QSTS cable (to jet thrust nozzle)

Q’ty

1 Grommet 1

Service points


Refer to “REMOTE CONTROL CABLES

AND SPEED SENSOR LEAD.”

NOTE:

To ease installation, apply soapy water to the grommet.

2 Handlebar switch coupler

3 QSTS cable 2

2

1

4 QSTS cable 1 1

Cable 2 is identifiable by the white tape a wrapped around it.

NOTE:

Route the QSTS cables behind the oil filler hose.

8-2

HULL

HOOD HANDLEBAR


E


5 Handlebar assembly

6 Nut/washer

7 QSTS converter

8 Throttle cable

Q’ty

1

2/2

1

1

Service points


8-3

HULL

HOOD HANDLEBAR


E



HANDLEBAR DISASSEMBLY

1 Plastic tie

2 Bolt

3 Grip end

4 Spacer

5 Screw/spring washer/washer

6 QSTS grip assembly

7 Screw

8 Handlebar switch assembly

9 Spacer 1

10 Screw

Q’ty

1

2

2

1

1/1/1

1

2

1

1

2

Service points


8-4

HULL

HOOD HANDLEBAR


E


11 Throttle lever assembly

12 Handlebar grip

13 Spacer 2

14 Handlebar

Q’ty

1

1

Service points

NOTE:

Apply adhesive to the handlebar and the inner surface of the handlebar grip.

1

1


8-5

HULL

HOOD HANDLEBAR

E

SERVICE POINTS

Handlebar inspection

1. Check:

• Handlebar

Bends/cracks/damage

→ Replace.

Handlebar switch inspection

Refer to “IGNITION SYSTEM” and “START-

ING SYSTEM” in Chapter 7.

Handlebar assembly installation

1. Adjust:

• QSTS cable length a

QSTS cable length:

72 ± 0.5 mm (2.83 ± 0.02 in)

NOTE:

• Before adjusting the QSTS cables, set the control grip to the neutral position.

• Adjust the QSTS cables to the specified length a and be sure to take up any slack if necessary.

2. Install:

• Upper handlebar holders

1

NOTE:

• Align the punch marks a on the handlebar with the top surface of the lower handlebar holders.

• Install the upper handlebar holders with the punch marks b facing forward.

CAUTION:

Clearance c should be narrower than clearance d.

8-6

HULL

HOOD HANDLEBAR

3. Install:

• Throttle cable

NOTE:

Fit the seal into the groove in the bracket.

E

4. Install:

• Plastic tie

1

NOTE:

After inserting the QSTS cables and throttle cable into the grommet, fasten the end of grommet with the plastic tie.

5. Install:

• Handlebar cover

1

NOTE:

When the handlebar cover is in contact with the steering console cover, adjust the handlebar mounting angle so that clearances a and b are equal.

6. Adjust:



7. Adjust:

• QSTS cable


8-7

HULL

HOOD QSTS GRIP

QSTS GRIP


E



QSTS GRIP DISASSEMBLY

QSTS grip assembly

1 Screw/washer

2 Cover

3 Ball

4 Spring

5 QSTS cable 1

6 QSTS cable 2

Q’ty

1/1

1

2

2

1

1

Service points


Refer to “HANDLEBAR.”

Cable 2 is identifiable by the white tape a wrapped around it.

8-8

HULL

HOOD QSTS GRIP


E


7 Screw/washer

8 Collar

9 QSTS shift lock lever

10 Spring

11 Spacer

12 QSTS cable housing cover

13 QSTS shift grip

Q’ty

2/2

1

1

1

1

1

1

Service points


8-9

HULL

HOOD QSTS GRIP

SERVICE POINTS

QSTS cable inspection

1. Check:

• QSTS cables

Frays/kinks/rough movement

→

Replace.

QSTS grip inspection

1. Check:

• QSTS grip

Damage/wear

→ Replace.

E

8-10

HULL

HOOD STEERING COLUMN

STEERING COLUMN


16 N • m (1.6 kgf • m, 11 ft • Ib)

2

3 4

1

5

E



STEERING COLUMN REMOVAL


Steering cable end



Refer to “STEERING CONSOLE COVER.”



1 Steering switch coupler

2 Nut

3 Plate

4 Steering column assembly

5 Rubber seal

1

1

1

4

1


8-11

HULL



13

26 N • m (2.6 kgf • m, 19 ft • Ib)

8

E

1

6

16 N • m (1.6 kgf • m, 11 ft • Ib)

3

11

9

7

2

12

8

× 60 mm

10

4

LT

242

9

5

2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)

2



STEERING COLUMN

DISASSEMBLY

1 Grommet

2 Bolt/washer/nut

3 Steering arm

4 Screw

5 Magnet

6 Shim

Q’ty

7 Washer

8 Steering column

Service points


1

1/2/1

1

1

1

— Install the same number of shims installed originally at the factory.

1

1

8-12

HULL



13

26 N • m (2.6 kgf • m, 19 ft • Ib)

8

E

1

6

16 N • m (1.6 kgf • m, 11 ft • Ib)

3

11

9

7

2

12

8

× 60 mm

10

4

LT

242

9

5

2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

2


9 Bushing

10 Plastic tie

11 Screw clamp

12 Steering switch

13 Steering column housing

5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)

Q’ty

2

1

1

1

1

Service points


8-13

HULL


SERVICE POINTS

Steering column bushing inspection

1. Check:

• Bushings

Damage/wear

→ Replace.

E

2. Check:

• Steering column


5

1

2

4

1 4

60˚

3

3

20–40 mm

(0.79–1.57 in)

2

Steering column assembly

1. Install:

• Steering switch

1

• Screw clamp

2

• Plastic tie

3

NOTE:

Fasten the steering switch lead

4 with the plastic tie

3 as shown in the illustration.

2. Install:

• Bushings

• Steering column

• Washer

• Shim(s)

• Magnet

• Screw

• Steering arm

• Bolt

• Washers

• Nut

CAUTION:

Make sure that the steering switch and magnet 5 do not contact each other.

8-14

HULL

HOOD

REMOTE CONTROL CABLES AND

SPEED SENSOR LEAD

REMOTE CONTROL CABLES AND SPEED SENSOR LEAD


E



REMOTE CONTROL CABLES

AND SPEED SENSOR LEAD

REMOVAL

1 Speed sensor coupler

2 Cap

3 Nut

4 Screw

5 Speed sensor

6 Steering cable end

7 Bolt

8 Steering cable holder

9 Nut

Q’ty

1

1

4

1

1

1

1

1

1

Service points


8-15

HULL

HOOD




E


10 Seal

11 Steering cable

12 Nut

13 Pin

14 QSTS cable end

15 Nut

16 Seal

17 QSTS cable

Q’ty

1

1

1

1

1

1

1

1

Service points


8-16

HULL

HOOD



SERVICE POINTS

E

WARNING

When routing the cables, do not grasp the cable by the outer crimped sheath or steel end. This could deform or loosen the cable end due to extreme angles and or pressure.

Always hold the cables by the bracket or outer cover below the crimp.

If a cable becomes damaged, replace it.

Never attempt to repair a damaged cable.

Remote control cable inspection

1. Check:

• Steering cable

• QSTS cable

Frays/kinks/rough movement →

Replace.

Steering cable installation

1. Install:

• Steering cable (jet pump end)

Steering cable set length a

(jet pump end):

13.5–15.5 mm (0.53–0.61 in)

WARNING

The steering cable must be screwed in a minimum of 8 mm (0.31 in).

1

8-17

Steering cable stopper installation

1. Install:

• Steering cable stopper

WARNING

Be sure to fit the steering cable into the groove

1 in the steering cable bracket.

HULL

HOOD



QSTS cable installation

1. Install:

• QSTS cable (jet pump end)

QSTS cable set length a

(jet pump end):

12.0–14.0 mm (0.47–0.55 in)

E

WARNING

The QSTS cable must be screwed in a minimum of 8 mm (0.31 in).

QSTS cable stopper installation

1. Install:

• QSTS cable stopper

WARNING

Be sure to fit the projection 1 on the QSTS cable stopper into the groove in the outer cable.

8-18

HULL

HOOD HOOD

HOOD


6 × 14 mm

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

7

6

6 × 14 mm

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

1

11

2 3 4 5 8

5

× 20 mm

1.0 N • m (0.1 kgf • m, 0.7 ft • Ib)

10

9

16 N • m (1.6 kgf • m, 11 ft • Ib)



HOOD REMOVAL

1 Bolt

2 Screw

3 Seal washer

4 Visor

5 Pop nut

6 Bolt

7 Hood lock

8 Hood

Q’ty

2

1

1

8

1

2

8

8

Service points


E

8-19

HULL

HOOD HOOD


6 × 14 mm

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

7

6

6 × 14 mm

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

1

2 3 4 5 8

5

× 20 mm

1.0 N • m (0.1 kgf • m, 0.7 ft • Ib)

16 N • m (1.6 kgf • m, 11 ft • Ib)

11

10

9

Step

9 Nut

10 Plate

Procedure/Part name

11 Hinge assembly

Q’ty

2

1

1

Service points


E

8-20

HULL

HOOD STEERING CONSOLE COVER

STEERING CONSOLE COVER


8 × 25 mm

9

8

2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

5

× 19 mm

5

6

4

E

2

2.9 N • m (0.29 kgf • m, 2.1 ft • Ib)

6 × 25 mm

3

1

7

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

16 N • m (1.6 kgf • m, 11 ft • Ib)




REMOVAL

Handlebar assembly

1 Plastic tie

2 Multifunction meter coupler

3 Nut/washer

4 Bolt/washer

5 Screw

6 Plate

Q’ty

1

5

2/2

4/4

2

1

Service points


Refer to “HANDLEBAR.”

8-21

HULL



8 × 25 mm

9

8

2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

5

× 19 mm

5

6

4

E

2

2.9 N • m (0.29 kgf • m, 2.1 ft • Ib)

6 × 25 mm

3

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

1

7

16 N • m (1.6 kgf • m, 11 ft • Ib)


7 Nut/washer

8 Bolt/square ring

9 Steering console cover assembly

Q’ty

2/2

2/2

1

Service points

NOTE:

To ease removal, remove the oil filler cap.


8-22

HULL



5

1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)

5

× 20 mm

6

E

2

9

1

2.9 N • m (0.29 kgf • m, 2.1 ft • Ib)

6 × 18 mm

8

2

7

4

3

1.8 N • m (0.18 kgf • m, 1.3 ft • Ib)




DISASSEMBLY

1 Screw

2 Side cover

3 Nut

4 Holder


6 Screw

Q’ty

2

1

4

2

1

4

Service points


8-23

HULL



5

1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)

5

× 20 mm

6

E

2

9

1

2.9 N • m (0.29 kgf • m, 2.1 ft • Ib)

6 × 18 mm

4

3

2

1.8 N • m (0.18 kgf • m, 1.3 ft • Ib)


7 Glove compartment

8 Pop nut

9 Steering console cover

Q’ty

1

4

1

Service points


8

7

8-24

HULL

HOOD BUZZER AND HOOD LOCK

BUZZER AND HOOD LOCK


E



BUZZER AND HOOD LOCK

REMOVAL


Steering cable






1 Ring nut

2 Buzzer

3 Bolt

4 Bracket

5 Bracket

6 Nut

1

1

2

1

1

3

8-25

HULL

HOOD BUZZER AND HOOD LOCK


E


7 Bolt

8 Hood lock assembly

9 Grommet

10 Atmospheric pressure sensor coupler


Q’ty

2

1

1

1

1

Service points


8-26

HULL

HOOD HOSES

HOSES


E



HOSE REMOVAL

Engine unit


1 Plastic tie

2 Ventilation hose

3 Ventilation duct

4 Plastic tie

5 Check valve

6 Oil tank breather hose


Q’ty

1

2

1

1

4

2

2

Service points





8-27

HULL

HOOD HOSES

E

SERVICE POINTS


1. Check:

• Check valve

Faulty

→ Replace.

Checking steps:




Air should not come out from end “A.” a a

Ventilation hose installation

1. Install:

• Ventilation hose

NOTE:

Insert the ventilation hose into the ventilation fitting until it reaches the bend a in the fitting.

8-28

HULL

HOOD SEAT AND HANDGRIP

SEAT AND HANDGRIP


E



SEAT AND HANDGRIP

REMOVAL

1 Seat

2 Bolt

3 Seat lock

4 Nut

5 Projection

6 Washer

7 Rubber ring

8 Nut/washer

Q’ty

1

1

1

2/2

1

1

1

2

Service points


8-29

HULL



E

Step

9 Bolt

10 Bolt

Procedure/Part name

11 Handgrip

12 Bracket

Q’ty

2

2

1

1

Service points


8-30

HULL


SERVICE POINTS

Seat lock inspection

1. Check:

• Seat lock

Damage/wear

→ Replace.

E

8-31

HULL

HOOD BATTERY BOX

BATTERY BOX


E



BATTERY BOX REMOVAL

1 Battery band

2 Fire extinguisher container

3 Battery band

4 Bolt

5 Negative battery lead

6 Terminal extension

7 Bolt


9 Clip/breather hose

10 Battery

11 Bolt

Q’ty

1

1

1

1

1

1

1

1

1/1

1

1

Service points


8-32

HULL

HOOD BATTERY BOX


E


12 Cap nut/washer/bolt

13 Electrical box

14 Cap nut/washer

15 Holder

16 Holder

17 Cap nut/washer

18 Battery box

19 Stay

Q’ty

2/2/2

1

2/2

1

1

2/2

1

Service points

NOTE:

Before installing the battery box, route the battery leads and battery breather hose through the holes in the battery box.

1


8-33

HULL

HOOD EXHAUST SYSTEM

EXHAUST SYSTEM


10

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

8

11

7

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

6

6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

6 × 30 mm

5

4

8

4

1

9

13

2.5 N • m (0.25 kgf • m, 1.8 ft • Ib)

3

2

12

E



EXHAUST SYSTEM REMOVAL

Battery box

1 Flotation

2 Exhaust joint clamp

3 Exhaust joint

4 Hose screw clamp

5 Rubber hose

6 Bolt

7 Seal

Q’ty

1

3

1

1

2

1

1

Service points


Refer to “BATTERY BOX.”

8-34

HULL



10

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

8

11

7

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

6

6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

6 × 30 mm

5

4

8

4

1

9

13

2.5 N • m (0.25 kgf • m, 1.8 ft • Ib)

3

2

12

E


8 Hose screw clamp

9 Water tank

10 Rubber hose

11 Exhaust outlet

12 Water lock band

13 Water lock

Q’ty

2

1

1

1

1

1

Service points

NOTE:

Remove parts 8 to 11 as a set.


8-35

HULL


SERVICE POINTS

Exhaust system inspection

1. Check:

• Water lock band

Cracks/damage

→ Replace.

2. Check:

• Rubber hoses

Burns/cracks/damage

→ Replace.

3. Check:

• Water lock

Cracks/leaks

→ Replace.

4. Check:

• Water tank

Cracks/damage/leaks

→ Replace.

E

2 a

1

Water lock installation

1. Install:

• Water lock

1

• Water lock band

NOTE:

Install the water lock so that it is 0–5 mm (0–

0.2 in) a high in relation to the bulkhead 2.

8-36

HULL

HOOD b

EXHAUST SYSTEM

E

Exhaust component parts assembly

1. Install:

• Exhaust outlet

• Rubber hose

• Water tank

NOTE:

• Insert the exhaust outlet 45–50 mm (1.77–

1.97 in) a into the rubber hose.

• Make sure that there is a distance of 10 mm

(0.39 in) b between the parting lines of the exhaust outlet and the rubber hose.

• Insert the water tank 45–50 mm (1.77–1.97

in) c into the rubber hose.


(1.77 in) d between the parting lines of the water tank and rubber hose.

d b a c d

8-37

2. Install:

• Rubber hose

NOTE:

• Install the rubber hose 45–50 mm (1.77–1.97

in) a into the water lock.


(0.39 in) b between the parting lines of the water lock and the rubber hose.

• Install the rubber hose 45–50 mm (1.77–1.97

in) c into the water tank.


(1.18 in) d between the parting lines of the water tank and rubber hose.

HULL

HOOD DECK AND HULL

DECK AND HULL


E



DECK AND HULL DISASSEMBLY

1 Bolt

2 Bow eye

3 Nut

4 Rope hole fitting

5 Nut

6 Spout

7 Bolt

8 Sponson

Q’ty

1

6

2

1

2

2

1

2

Service points


NOTE:

Install the starboard and port side sponsons at the same position.

8-38

HULL

HOOD DECK AND HULL


E

Step

9 Bolt

10 Flap

Procedure/Part name

11 Nut/washer

12 Screw/washer

13 Drain plug

14 Seal

Q’ty

8

2

4/4

4/4

2

2

Service points


8-39

HULL

HOOD ENGINE MOUNTS

ENGINE MOUNTS


E



ENGINE MOUNT REMOVAL

Engine unit

1 Bolt

2 Damper 1

3 Damper 2

4 Bolt

5 Engine mount

6 Liner

Q’ty

1

8

4

1

4

4

Service points




8-40

TRBL

ANLS

CHAPTER 9


INTRODUCTION.............................................................................................. 9-1

FEATURES ............................................................................................... 9-1

Functions............................................................................................. 9-1

CONTENTS............................................................................................... 9-1

HARDWARE REQUIREMENTS................................................................ 9-2

OPERATING.................................................................................................... 9-3

CONNECTING THE COMMUNICATION CABLE TO THE

WATERCRAFT......................................................................................... 9-3

TROUBLE ANALYSIS..................................................................................... 9-4

TROUBLE ANALYSIS CHART.................................................................. 9-4

SELF-DIAGNOSIS .................................................................................... 9-7

E

5

6

7

8

9

3

4

1

2

TRBL

ANLS INTRODUCTION E

INTRODUCTION

FEATURES

The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods.

By connecting your computer to the ECM (Electronic Control Module) of a watercraft using the communication cable, this software can be used to display sensor data and data stored in the ECM on a computer’s monitor.

If this software is run on Microsoft Windows

®

95, Windows 98, Windows Me, Windows 2000, or

Windows XP the information can be displayed in colorful graphics. Also, the software can be operated using either a mouse or a keyboard.

In addition, the data for the main functions (Diagnosis, Diagnosis record, Engine monitor, and Data logger) can be saved on a disk or printed out.

Functions

1. Diagnosis: Each sensor’s status and each ECM diagnosis code or item is displayed. This enables you to find malfunctioning parts and controls quickly.

2. Diagnosis record: Sensors that had been activated and ECM diagnostic codes that have been recorded are displayed. This allows you to check the watercraft’s record of malfunctions.

3. Engine monitor: Each sensor’s status and the ECM data are displayed while the engine is running. This enables you to find malfunctioning parts quickly.

4. Stationary test: With the engine off, ignition, fuel injection, stepping motor, YPVS, and the electric fuel pump are checked. These tests can be performed quickly.

5. Active test: With the engine running, each firing cylinder has dropped and the engine speed is checked for changes to determine whether the cylinder is malfunctioning. These tests can be performed quickly.

6. Data logger: From the data stored in the ECM, at least two items of 78 seconds of recorded data are displayed on a graph. In addition, the operating time as compared to the engine speed and the total operating time are displayed. This allows you to check the operating status of the engine.

7. Some files: Lets you select and run other applications while continuing to run the diagnostic program.

CONTENTS

1. Software (1)

2. Adapter (1)

3. Communication cable (1)

4. Instruction Manual (1)

5. Installation Manual (1)

1 2 3

Fig. 1

YAMAHA

DIAGNOSTIC

SYSTEM

INSTRUCTION MANUAL

60V-2819U-11

4

YAMAHA

DIAGNOSTIC

SYSTEM

INSTALLATION MANUAL

60V-2819K-10

5

9-1

TRBL

ANLS INTRODUCTION

HARDWARE REQUIREMENTS

Make sure that your computer meets the following requirements before using this software.

E

Computer:

Operating system:

IBM-compatible computer

Microsoft (Windows 95), Windows 98, Windows Me, Windows 2000, or

Windows XP (English version)

CPU:

Windows 95/98: i486X, 100 MHz or higher (Pentium 100 MHz or higher recommended)

Windows Me/2000: Pentium, 166 MHz or higher (Pentium 233 MHz or higher recommended)

Windows XP: Pentium, 300 MHz or higher (Pentium 500 MHz or higher recommended)

Memory:

Windows 95/98:

Windows Me:

Windows 2000:

Windows XP:

16 MB or more (32 MB or more recommended)




Hard disk free space: 20 MB or more (40 MB or more recommended)

Drive:

Display:

CD-ROM drive

VGA (640

×

480 pixels), (SVGA [800

×

600 pixels] or more recommended)

256 or more colors

Mouse: Compatible with the operating systems mentioned above

Communication port: RS232C (Dsub-9 pin) port, USB port

Printer: Compatible with the operating systems mentioned above

NOTE:

• The amount of memory and the amount of free space on the hard disk differs depending on the computer.

• Using this software while there is not enough free space on the hard disk could cause errors and result in insufficient memory.

• This software will not run properly on some computers.

• When starting up this program, do not start other software applications.

• Do not use the screen saver function or the energy saving feature when using this program.

• If the ECM is changed, restart the program.

• Window XP is a multiuser operating system, therefore, be sure to end this program if the login user is changed.

• The USB adapter cannot be used with Windows 95.

For operating instructions of the Yamaha Diagnostic System, refer to the “Yamaha Diagnostic System Instruction Manual.”

9-2

TRBL

ANLS OPERATING

OPERATING

CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT

Model: GP1300R

Top view

E

1

3

2

1 3-pin communication coupler

2 Wire harness coupler

3 Multifunction meter coupler

NOTE:

Be careful not to pinch the communication cable between the hood and the deck or to damage it.

9-3

TRBL

ANLS TROUBLE ANALYSIS


NOTE:

Before consulting the “TROUBLE ANALYSIS CHART,” check the following items.

1. Check that the battery is charged and that its specified gravity is within specification.

2. Check that there are no incorrect wiring connections.

3. Check that all wiring connections are properly secured and that they are not rusty.

4. Check that the engine shut-off cord (lanyard) is connected to the engine shut-off switch.

5. Check that fuel is reaching the throttle bodies.

E

TROUBLE ANALYSIS CHART

Symptom Check items

Applicable part Chapter

9-4

FUEL SYSTEM

Fuel tank

Fuel tank breather hoses

Fuel hose

Fuel filter

Fuel pump

Fuel injectors

POWER UNIT

Compression pressure

Cylinder head gaskets

Cylinder block

Crankcase

Piston rings

Pistons

Bearings

Reed valves

Seals

Bearing housing

Drive couplings

Rubber coupling

Cooling water hose (pilot)

Cooling water hoses

Water passages

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

4

4

4

4

4

4

TRBL


Symptom Check items


JET PUMP UNIT

Impeller duct

Impeller

Intake grate

Bearings

Intake duct

Water inlet hose

Bilge hoses

Bilge strainer

Bilge hose joints

ELECTRICAL

Ignition system, fuel control system

• Pickup coils

• ECM

• Ignition coils

• Slant detection switch

• Engine stop switch

• Engine shut-off switch

• Spark plugs

• Main and fuel pump relay

• Exhaust temperature sensor

• Atmospheric pressure sensor

• Intake air temperature sensor

• Engine temperature sensor

• Throttle position sensor

• Cooling water temperature sensor

6

6

6

6

3

6

6

6

6

7

7

7

7

7

3

7

7

7

7

7

7

7

7

E

9-5

TRBL


Symptom

E

Check items


Starting system

• Start switch

• Starter relay

• Starter motor

YPVS

• YPVS unit

Charging system

• Lighting coil

• Rectifier/regulator

• Fuses

• Battery leads

• Battery

Electric bilge pump

• Electric bilge pump

HULL AND HOOD

Steering column

Water lock

Exhaust hose

Muffler

Drain plugs

7

7

7

—

3

7

8

8

8

8

8

7

7

7

7

9-6

TRBL

ANLS


E

SELF-DIAGNOSIS

With the engine running, press the select button

1 for 8 seconds and check if an error code is indicated on the multifunction meter.

Code

01

13

15

18

19

22

23

47

48

53

54

55

59

64

65

66

67

Symptom

Normal

Pickup coil malfunction

Engine temperature sensor malfunction

Throttle position sensor (TPS) malfunction

Incorrect battery voltage

Atmospheric pressure sensor malfunction

Intake air temperature sensor malfunction

Slant detection switch malfunction

Incorrect data transmission

Exhaust temperature sensor malfunction

Stepping motor malfunction

Steering switch malfunction

Memory data malfunction

YPVS servomotor malfunction

Cooling water temperature sensor malfunction

Stepping motor stuck closed

Stepping motor stuck open

If the Yamaha Diagnostic System is not used to check the symptoms listed in the table, the error codes can be checked easily with the self-diagnosis in the multifunction meter. However, if there are numerous error codes displayed, be sure to check them with the


9-7

GP1300R

G

È

G B/O

B/O

G

1

1 2 3 4 5 6 7 8 9 10 11 12

G Y W W/L B/Y B/G B/O B/L W/L O W/Y W/B

13 14 15 16 17 18 19 20 21 22 23 24

W/R L/R G/B G/R G G/Y B/R O L G P Pu/Y

25 26 27 28 29 30 31 32 33 34 35

Pu/B Pu/R R/Y L/B B P/G P W/B B B/Y B/W

L/R

G/B

G/R

G

G/Y

B/R

O

L

G

P

Pu/Y

Pu/B

Pu/R

R/Y

B

P/G

P

L/B

W/B

B

Y

W

W/L

B/Y

B/G

B/O

B/L

W/L

O

W/Y

W/B

W/R

B/Y

B/W

3

O

O

O O O O

O

B

B

B B B B B B B

B

B

B /O

O

2

B /O

B /O

P /G

B /O

P/G

B/O

O

B /O

B /O

B /O

B/O

B/O

B/O

B/O

B/O

B/O

B/O

B/O

B/O

B/O

B

P

O P B L G

O

G

G

L

L

B /O

P

O

P

B/O

L

G

O

B

B B B B

B

L B

P B

B

Gy

B

L

L Gy P B

P

B

B/O

B L/B

L/B

L/B

B/O

S T

U

FREE

PUSH

B W

B

V

FREE

PUSH

W B R Br

W

W

FREE

PUSH

Br Br

Br

W

W

W B

B

R

R Br

Br

Br

W B R Br

X

R/Y

W/B

B

W/L

W/L

B

R/Y

B

W/B

R

B P

R/Y

R/W

B

W

B

R W B

R

R/W

R/W

B/Y

Y

Y

B/Y

L/R

L/R L/B

B/R

L/B

B/R L

L

R/Y

R/Y

Y

B/Y

Y

R

B/Y

R B

B L

L

B

O

Q P

B

Y/B

Y/B

B

R/W

N

B

W/R

B

B/O W/B

W/R W/Y

B/O

W/B

W/R

B

W/Y

G

B B

W/R W/Y

W/B

G G G

L G G G

#3 #1

#2

G

G

M

B

B

B

4

5

#1

5 5

#2 #3

R

B/R B/W B/Y

6 7 7

B

B

B/R

B B

B/W

B

B/Y

B B

B

B

R

R

9 R

Br

R/Y

R/Y

Br

Br

8

R

R

R

Br

Y

B

R/Y R/Y

L/R

L

R/Y

R

R/Y R/Y

R/Y Br

R/Y Y

B

R

L/R

L

R/Y R/Y R/Y

R/Y R/Y R/Y

R

B

B

B

G

B

B

R

=

B

B

A

R

G

B R G G G

C

Y/B

R/W Y/B

B

B

B

R/W

B R/Y

B/O

R/Y

O B/O

B/O

B/O B/L

B/L

Br O

B

B Br

B

B W

W B

B B

O

P

G

R/Y

B W/L R/Y W/L

W/L

B

R/Y

B

W/L

R/Y

G/R

G

G/B

O

R/Y

B

W/L

R/Y

G/R

G/Y

B/Y

B/G

P

Pu/Y

Pu/B

Pu/R

B/O

B/O

B/O

P

B/O

O G/Y

G/B

B/Y G

B/G

Pu/Y

Pu/R

Pu/B

B/O

G/B

B/Y

G/Y O

Pu/Y

R/Y

G/R

B/O

P

R/Y

O

G/B

G

G/R

G/Y

B/Y

B/G

P

Pu/Y

Pu/B

Pu/R

B/O

B/O

B/O

D

E

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

F

B/O

B/G B/O

K

B/G

B/O

H

#1

Pu/R

H

#2

Pu/B

H

#3

Pu/Y

O P B/O

R/Y

R/Y Pu/R

R/Y R/Y

R/Y Pu/B R/Y Pu/Y

B/O

B/O B/Y

B/Y

G/B

R/Y

G

G/R

R/Y

G/Y

B/Y

B/Y B/Y

B/Y

G/Y

G

R/Y

J

R/Y

G/R

G/B

I

GP1300R-CWD

WIRING DIAGRAM

GP1300R

1 ECM


3 YPVS servomotor

4 Spark plugs

5 Ignition coils

6 Fuse (20 A)

7 Fuses (3 A)


9 Starter relay

0 Starter motor

A Battery

B Rectifier/regulator

C Throttle switch

D Electrical bilge pump

E Exhaust temperature sensor

F Cooling water temperature sensor

G Throttle position sensor

H Fuel injectors

I Engine temperature sensor

J Stepping motor

K Intake air temperature sensor

L Lighting coil

M Pickup coil

N Steering switch

O Oil level sensor

P Buzzer

Q Speed sensor

R Multifunction meter

S Fuel pump

T Fuel sender

U Engine stop switch

V Engine shut-off switch

W Start switch

X Slant detection switch

È To tachometer

Color code

L

O

P

R

B

Br

: Black

: Brown

G : Green

Gy : Gray

: Blue

: Orange

: Pink

: Red

W

Y

: White

: Yellow

B/G : Black/green

B/L : Black/blue

B/O : Black/orange

B/R : Black/red

B/W : Black/white

B/Y : Black/yellow

G/B : Green/black

G/R : Green/red

G/Y : Green/yellow

L/B : Blue/black

L/R : Blue/red

P/G : Pink/green

Pu/B : Purple/black

Pu/R : Purple/red

Pu/Y : Purple/yellow

R/W : Red/white

R/Y : Red/yellow

W/B : White/black

W/L : White/blue

W/R : White/red

W/Y : White/yellow

Y/B : Yellow/black

YAMAHA MOTOR CORPORATION, USA

Printed in USA

Feb. 2003 – 0.0

× 1 CR

(E)

Yamaha WaveRunner GP1300R Service manual

WaveRunner

SERVICE MANUAL

NOTICE

HOW TO USE THIS MANUAL

INDEX

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND

ADJUSTMENT

FUEL SYSTEM

POWER UNIT

JET PUMP UNIT

ELECTRICAL SYSTEM

HULL AND HOOD

TROUBLE ANALYSIS

CHAPTER 1

GENERAL INFORMATION

CHAPTER 2

SPECIFICATIONS

CHAPTER 3

PERIODIC INSPECTION AND ADJUSTMENT

CHAPTER 4

FUEL SYSTEM

CHAPTER 5

POWER UNIT

CHAPTER 6

JET PUMP UNIT

CHAPTER 7

ELECTRICAL SYSTEM

+ –

+ –

CHAPTER 8

HULL AND HOOD

CHAPTER 9

TROUBLE ANALYSIS

×

×

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Table of contents

Languages

GP1200R WaveRunner 2001