Yamaha FX140 WaveRunner 2003 Service manual

WaveRunner
FX140
SERVICE MANUAL
*LIT186160238*
LIT-18616-02-38
F1B-28197-1E-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 FX140
SERVICE MANUAL
©2002 by Yamaha Motor Corporation, USA
1st Edition, February 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-02-38
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 tools and technical data) are described
sequentially.
E
1
A50001-1-4
2
GEN
INFO
SYMBOLS
Symbols 1 to 9 are designed as thumb-tabs
to indicate the content of a chapter.
SPEC
3
1
2
3
4
5
6
7
8
9
4
INSP
ADJ
FUEL
5
6
JET
PUMP
POWR
7
General Information
Specifications
Periodic Inspection and Adjustment
Fuel System
Power Unit
Jet Pump Unit
Electrical System
Hull and Hood
Trouble analysis
8
–
ELEC
9
+
HULL
HOOD
Symbols 0 to E indicate specific data:
0
0
A
B
C
D
E
TRBL
ANLS
A
B
C
D
Special tool
Specified liquid
Specified engine speed
Specified torque
Specified measurement
Specified electrical value
[Resistance (Ω), Voltage (V), Electric current (A)]
T.
R.
E
Symbol F to H in an exploded diagram indicate the grade of lubricant and the location of
lubrication point:
F
E
G
H
A
I
M
J
4
GM
K
L
LT
LT
271
242
M
N
LT
572
SS
F Apply YAMALUBE 4-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 grade of the sealing or locking agent,
and the location of the application point:
I
J
K
L
M
N
Apply Gasket Maker®
Apply Yamabond #4 (Yamaha bond number 4)
Apply LOCTITE® No. 271 (Red LOCTITE)
Apply LOCTITE® No. 242 (Blue LOCTITE)
Apply LOCTITE® No. 572
Apply silicone sealant
NOTE:
In this manual, the above symbols may not be
used in every case.
E
A30000-0
INDEX
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENT
FUEL SYSTEM
POWER UNIT
JET PUMP UNIT
GEN
INFO
SPEC
INSP
ADJ
FUEL
POWR
JET
PUMP
–
ELECTRICAL SYSTEM
HULL AND HOOD
TROUBLE ANALYSIS
+
ELEC
HULL
HOOD
TRBL
ANLS
1
2
3
4
5
6
7
8
9
GEN
INFO
E
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
OILS, GREASES AND SEALING FLUIDS ................................................ 1-2
GOOD WORKING PRACTICES ............................................................... 1-3
DISASSEMBLY AND ASSEMBLY ............................................................ 1-4
SPECIAL TOOLS ............................................................................................ 1-5
MEASURING............................................................................................. 1-5
REMOVAL AND INSTALLATION.............................................................. 1-8
1
2
3
4
5
6
7
8
9
GEN
INFO
IDENTIFICATION NUMBERS
E
A60700-0*
IDENTIFICATION NUMBERS
PRIMARY l.D. NUMBER
The primary l.D. number is stamped on a label
attached to the inside of the engine compartment.
Starting primary l.D. number:
F1B: 800101
ENGINE SERIAL NUMBER
The engine serial number is stamped on a
label attached to the engine unit.
Starting serial number:
60E: 000101
JET PUMP UNIT SERIAL NUMBER
The jet pump unit serial number is stamped on
a label attached to the intermediate housing.
Starting serial number:
60E: 800058
HULL IDENTIFICATION NUMBER
(H.l.N.)
The H.l.N. is stamped on a plate attached to
the aft deck.
1-1
GEN
INFO
SAFETY WHILE WORKING
E
SAFETY WHILE WORKING
The procedures given in this manual are those
recommended by Yamaha to be followed by
Yamaha dealers and their mechanics.
FIRE PREVENTION
Gasoline (petrol) is highly flammable.
Gasoline vapor is explosive if ignited.
Do not smoke while handling gasoline (petrol)
and keep it away from heat, sparks, and open
flames.
VENTILATION
Gasoline vapor is heavier than air and is
deadly if inhaled in large quantities. Engine
exhaust gases are harmful to breathe. When
test-running an engine indoors, maintain good
ventilation.
SELF-PROTECTION
Protect your eyes with suitable safety spectacles or safety goggles when grinding or doing
any operation which may cause particles to fly
off.
Protect hands and feet by wearing safety
gloves or protective shoes if appropriate to the
work you are doing.
OILS, GREASES AND SEALING
FLUIDS
Use only genuine Yamaha oils, greases, and
sealing fluids or those recommended by
Yamaha.
1-2
GEN
INFO
SAFETY WHILE WORKING
E
Under normal conditions of use there should
be no hazards from the use of the lubricants
mentioned in this manual, but safety is allimportant, and by adopting good safety practises any risk is minimized. A summary of the
most important precautions is as follows:
1. While working, maintain good standards of
personal and industrial hygiene.
2. Clothing which has become contaminated
with lubricants should be changed as soon
as practicable and laundered before further use.
3. Avoid skin contact with lubricants (e.g., do
not place a soiled rag in your pocket).
4. Hands and any other part of the body
which have been in contact with lubricants
or lubricant-contaminated clothing should
be thoroughly washed with hot water and
soap as soon as practicable.
5. To protect the skin, the application of a
suitable barrier cream to the hands before
working is recommended.
6. A supply of clean lint-free cloths should be
available for wiping purposes.
GOOD WORKING PRACTICES
1. The right tools
Use the recommended special tools to
protect parts from damage. Use the right
tool in the right manner – do not improvise.
2. Tightening torque
Follow the tightening torque instructions.
When tightening bolts, nuts and screws,
tighten the larger sizes first and tighten
inner-positioned fixings before outer-positioned ones.
1-3
GEN
INFO
SAFETY WHILE WORKING
E
3. Non-reusable items
Always use new gaskets, packings, Orings, oil seals, split-pins, circlips, etc., on
reassembly.
DISASSEMBLY AND ASSEMBLY
1. Clean parts with compressed air when disassembling.
2. Oil the contact surfaces of moving parts
during assembly.
3. After assembly, check that moving parts
operate normally.
4. Install bearings with the manufacturer’s
markings on the side exposed to view and
liberally oil the bearings.
CAUTION:
Do not spin bearings with compressed air
because this will damage their surfaces.
5. When installing oil seals, apply a light coat
of water-resistant grease to the outside
diameter.
1-4
GEN
INFO
SPECIAL TOOLS
E
SPECIAL TOOLS
Using the correct special tools recommended
by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvisations
and using improper tools can damage the
equipment.
1 YU-03097
NOTE:
• For U.S.A. and Canada, use part numbers
starting with “J-”, “YB-”, “YM-”, “YS-”, “YU-” or
“YW-”.
• For other countries, use part numbers starting with “90890-”.
90890-01252
MEASURING
2 90890-06583
3
1 Dial gauge
P/N. YU-03097
90890-01252
2 Dial gauge stand
P/N. 90890-06583
3 Dial gauge needle
P/N. 90890-06584
4 Dial gauge stand set
P/N. YW-06585
90890-06585
5 Pocket tester
P/N. YU-03112
90890-03112
6 Digital circuit tester
P/N. YU-34899-A
90890-03174
7 Carburetor synchronizer
P/N. YU-08030
8 Vacuum gauge
P/N. 90890-03094
Vacuum attachment
P/N. 90890-03060
9 Test connector
P/N. YW-06862
90890-06862
0 Fuel pressure gauge adapter
P/N. YW-06842
90890-06842
90890-06584
4 YW-06585
90890-06585
5 YU-03112
6
7 YU-08030
8
9 YW-06862
0 YW-06842
90890-03112
90890-06862
YU-34899-A
90890-03174
90890-03094
90890-03060
90890-06842
1-5
GEN
INFO
A YB-06766
B 90890-06582
SPECIAL TOOLS
C YU-03017
90890-06759
90890-03160
E YU-39991
90890-03172
F YM-34487
90890-06754
G YB-06792
H YB-06791
I YB-06770
J YB-06790
K YB-06793
L YB-06777
90890-06770
90890-06793
A Fuel pressure gauge
P/N. YB-06766
90890-06786
B Compression gauge extension
P/N. 90890-06582
C Cylinder gauge set
P/N. YU-03017
90890-06759
D Compression gauge
P/N. YU-33223-1
90890-03160
E Peak voltage adapter
P/N. YU-39991
90890-03172
F Spark gap tester
P/N. YM-34487
90890-06754
G Test harness (2 pins)
P/N. YB-06792
90890-06792
H Test harness (3 pins)
P/N. YB-06791
90890-06791
I Test harness (3 pins)
P/N. YB-06770
90890-06770
J Test harness (6 pins)
P/N. YB-06790
90890-06790
K Test harness (3 pins)
P/N. YB-06793
90890-06793
L Test harness (3 pins)
P/N. YB-06777
90890-06777
90890-06786
D YU-33223-1
90890-06792
E
90890-06791
90890-06790
90890-06777
1-6
GEN
INFO
M YB-06769
90890-06769
SPECIAL TOOLS
E
M Test harness (3 pins)
P/N. YB-06769
90890-06769
N Vacuum/pressure pump gauge set
P/N. YB-35956-A
90890-06756
O Yamaha diagnostic system for Watercraft
P/N. 60E-85300-01
P Yamaha diagnostic system for Watercraft
(CD-ROM only)
P/N. 60E-WS853-00
N YB-35956-A
90890-06756
O 60E-85300-01
P 60E-WS853-00
YAMAHA DIAGNOSTIC SYSTEM
for Watercraft
INSTALLATION MANUAL
60E-2819K-10
1-7
GEN
INFO
SPECIAL TOOLS
E
REMOVAL AND INSTALLATION
1 YU-38411
90890-01426
2 YW-06551
1 Oil filter wrench
P/N. YU-38411
90890-01426
2 Coupler wrench
P/N. YW-06551
90890-06551
3 Sheave holder
P/N. YS-01880-A
90890-01701
4 Rotor puller
P/N. YM-01082
90890-01080
5 Rotor holder
P/N. YU-01235
90890-01235
6 Valve spring compressor
P/N. YM-04019
90890-04019
7 Valve spring compressor attachment
P/N. YM-4114 (ø19 mm)
90890-04114 (ø19 mm)
YM-4108 (ø22 mm)
90890-04108 (ø22 mm)
8 Valve guide remover
P/N. YM-04111 (ø4.0 mm)
90890-04111 (ø4.0 mm)
YM-04116 (ø4.5 mm)
90890-04116 (ø4.5 mm)
9 Valve guide installer
P/N. YM-04112 (ø4.0 mm)
90890-04112 (ø4.0 mm)
YM-04117 (ø4.5 mm)
90890-04117 (ø4.5 mm)
0 Valve guide reamer
P/N. YM-04113 (ø4.0 mm)
90890-04113 (ø4.0 mm)
YM-04118 (ø4.5 mm)
90890-04118 (ø4.5 mm)
90890-06551
3 YS-01880-A
4 YM-01082
5 YU-01235
6 YM-04019
7 YM-4114 (ø19 mm)
8 YM-04111 (ø4.0 mm)
9 YM-04112 (ø4.0 mm)
0 YM-04113 (ø4.0 mm)
90890-01701
90890-01235
90890-04114 (ø19 mm)
YM-4108 (ø22 mm)
90890-04108 (ø22 mm)
90890-04112 (ø4.0 mm)
YM-04117 (ø4.5 mm)
90890-04117 (ø4.5 mm)
90890-01080
90890-04019
90890-04111 (ø4.0 mm)
YM-04116 (ø4.5 mm)
90890-04116 (ø4.5 mm)
90890-04113 (ø4.0 mm)
YM-04118 (ø4.5 mm)
90890-04118 (ø4.5 mm)
1-8
GEN
INFO
A
B
SPECIAL TOOLS
90890-06813 (60°)
90890-06814 (45°)
90890-06815 (30°)
90890-06811 (ø4.0 mm)
90890-06812 (ø4.5 mm)
C
YM-91043-C
90890-05158
F
YB-06096
G 90890-06501
H
90890-06535
I 90890-06536
J
90890-06538
K 90890-06652
L
YB-06151
90890-06519
A Valve seat cutter
Intake
P/N. 90890-06813 (60°)
90890-06814 (45°)
90890-06815 (30°)
Exhaust
P/N. 90890-06315 (60°)
90890-06312 (45°)
90890-06328 (30°)
B Valve seat cutter holder
P/N. 90890-06811 (ø4.0 mm)
90890-06812 (ø4.5 mm)
C Valve seat cutter set
P/N. YM-91043-C
D Piston ring compressor
P/N. YM-08037
90890-05158
E Drive shaft holder (impeller)
P/N. YB-06151
90890-06519
F Slide hammer set (jet pump bearing)
P/N. YB-06096
G Stopper guide plate (jet pump bearing)
P/N. 90890-06501
H Bearing puller (jet pump bearing)
P/N. 90890-06535
I Bearing puller claw 1 (jet pump bearing)
P/N. 90890-06536
J Stopper guide stand (jet pump bearing)
P/N. 90890-06538
K Drive rod L3 (jet pump bearing)
P/N. 90890-06652
L Needle bearing attachment
(jet pump bearing and oil seal)
P/N. YB-06112, YB-06196
90890-06614, 90890-06653
90890-06315 (60°)
90890-06312 (45°)
90890-06328 (30°)
D YM-08037
E
E
YB-06112
YB-06196
90890-06614
90890-06653
1-9
GEN
INFO
M YB-06085
N YB-06071
P YB-06552
90890-06552
SPECIAL TOOLS
E
M Ball bearing attachment
(jet pump oil seal)
P/N. YB-06085
90890-06634
N Driver rod
(intermediate shaft and jet pump)
P/N. YB-06071
90890-06606
O Bearing inner/outer race attachment
(jet pump bearing)
P/N. YB-34474
P Shaft holder (intermediate shaft)
P/N. YB-06552
90890-06552
Q Bearing outer race attachment
(intermediate shaft)
P/N. YB-06156
90890-06626
90890-06634
O
90890-06606
Q
YB-06156
YB-34474
90890-06626
1-10
SPEC
E
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................................... 2-1
MAINTENANCE SPECIFICATIONS ............................................................... 2-3
ENGINE .................................................................................................... 2-3
JET PUMP UNIT ......................................................................................2-6
HULL AND HOOD .................................................................................... 2-6
ELECTRICAL ............................................................................................ 2-6
TIGHTENING TORQUES ................................................................................ 2-9
SPECIFIED TORQUES.............................................................................2-9
GENERAL TORQUE ............................................................................... 2-17
CABLE AND HOSE ROUTING ..................................................................... 2-18
1
2
3
4
5
6
7
8
9
SPEC
GENERAL SPECIFICATIONS
E
GENERAL SPECIFICATIONS
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
Displacement
Bore × stroke
Compression ratio
Exhaust system
Lubrication system
Cooling system
Starting system
Ignition system
Ignition timing
Spark plug model
(manufacturer)
Spark plug gap
Battery capacity
Generator output
Drive unit
Propulsion system
Jet pump type
Impeller rotation (from rear)
Transmission
Gear ratio
Jet thrust nozzle horizontal
angle
Jet thrust nozzle trim angle
Trim system
Reverse system
Model
FX140
Unit
F1B
60E
mm (in)
mm (in)
mm (in)
kg (lb)
Person/kg (lb)
3,340 (131.5)
1,230 (48.4)
1,160 (45.7)
362 (798)
3/240 (530)
kW (PS) @ r/min
l/h (US gal/h,
lmp gal/h)
h
103 (140) @ 10,000
44 (11.6, 9.7)
3
cm (cu. in)
mm (in)
Degree
1.59
4-stroke, L4, DOHC
998 (60.9)
74.0 × 58.0 (2.91 × 2.28)
11.4:1
Wet exhaust
Dry sump
Water cooled
Electric starter
TCI
BTDC 35–ATDC 5
CR9EB (NGK)
mm (in)
V/Ah
A @ r/min
0.7–0.8 (0.028–0.031)
12/19
14–16 @ 6,000
Degree
Jet pump
Axial flow, single stage
Counterclockwise
Direct drive from engine
19/28 (0.68)
24 + 24
Degree
–10, –5, 0, 5, 10
Manual 5 positions
Reverse gate
2-1
SPEC
GENERAL SPECIFICATIONS
Item
Fuel and oil
Fuel type
Minimum fuel rating
Fuel tank capacity
Engine oil type
Engine oil grade
Engine oil quantity
(without oil filter replacement)
(with oil filter replacement)
E
Model
FX140
Unit
PON*
RON*
L (US gal,
Imp gal)
Regular unleaded gasoline
86
90
70 (18.5, 15.4)
4-stroke motor oil
SE, SF, SG, SH, or SJ
10W-30
4.3 (4.5, 3.8)
API
SAE
L (US qt,
Imp qt)
L (US qt,
Imp qt)
L (US qt,
Imp qt)
2.0 (2.1, 1.8)
2.2 (2.3, 1.9)
PON*: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2
RON*: Research Octane Number
2-2
SPEC
MAINTENANCE SPECIFICATIONS
E
MAINTENANCE SPECIFICATIONS
ENGINE
Item
Cylinder head
Warpage limit
Compression pressure*1
Cylinder
Bore size
Taper limit
Out-of-round limit
Wear limit
Camshaft
Drive system
Intake A
Exhaust A
Intake and
exhaust B
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaftcap clearance
Max.camshaft runout
Timing chain
Model/number of links
Tensioning system
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
Valve head diameter A
Intake
Exhaust
Valve face width B
Intake
Exhaust
Unit
Model
FX140
mm (in)
0.1 (0.004)
kPa
(kgf/cm2, psi)
1,350 (13.5, 192)
mm (in)
mm (in)
mm (in)
mm (in)
74.060–74.075 (2.9157–2.9163)
0.08 (0.003)
0.05 (0.002)
74.2 (2.9213)
mm (in)
mm (in)
mm (in)
Chain drive
32.25 (1.270)
32.65 (1.285)
25.00 (0.984)
mm (in)
mm (in)
mm (in)
24.5 (0.9646)
24.44–24.45 (0.9622–0.9626)
0.05–0.08 (0.0020–0.0031)
mm (in)
0.03 (0.0012)
DID SCR-0412SV/130
Automatic
mm (in)
mm (in)
0.11–0.20 (0.0043–0.0079)
0.25–0.34 (0.0098–0.0134)
mm (in)
mm (in)
22.9–23.1 (0.9016–0.9094)
24.4–24.6 (0.9606–0.9685)
mm (in)
mm (in)
1.76–2.90 (0.0693–0.1142)
1.76–2.90 (0.0693–0.1142)
*1: At 760 mmHg and 20 °C (68 °F)
2-3
SPEC
MAINTENANCE SPECIFICATIONS
Item
Valve seat width C
Intake
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-guide
clearance
Intake
Exhaust
Valve stem runout
E
Unit
Model
FX140
mm (in)
mm (in)
0.9–1.1 (0.0354–0.0433)
0.9–1.1 (0.0354–0.0433)
mm (in)
mm (in)
0.5–0.9 (0.0197–0.0354)
0.5–0.9 (0.0197–0.0354)
mm (in)
mm (in)
3.975–3.990 (0.1565–0.1571)
4.460–4.475 (0.1756–0.1762)
mm (in)
mm (in)
4.000–4.012 (0.1575–0.1580)
4.500–4.512 (0.1772–0.1776)
mm (in)
mm (in)
mm (in)
0.010–0.037 (0.0004–0.0015)
0.025–0.052 (0.0010–0.0020)
0.01 (0.0004)
Valve spring
Free length
Intake
mm (in)
Exhaust
mm (in)
Installed length
Intake
mm (in)
Exhaust
mm (in)
Spring limit
Intake
Degree/mm (in)
Exhaust
Degree/mm (in)
Piston
Piston-to-cylinder clearance
mm (in)
Piston diameter
mm (in)
Measuring point H*
mm (in)
Wear limit
mm (in)
Piston pin boss inside diameter
mm (in)
Piston pins
Outside diameter
mm (in)
Wear limit
mm (in)
2-4
38.90 (1.53)
40.67 (1.60)
34.50 (1.36)
35.00 (1.38)
2.5/1.7 (0.067)
2.5/1.8 (0.071)
0.10–0.11 (0.0039–0.0043)
73.955–73.970 (2.9116–2.9121)
5 (0.2)
0.17 (0.0067)
17.002–17.013 (0.6693–0.6698)
16.991–17.000 (0.6689–0.6693)
16.971 (0.6681)
SPEC
MAINTENANCE SPECIFICATIONS
Item
B
B
Model
FX140
Unit
Piston ring
Top ring
T
Type
Dimension (B × T)
End gap (installed)
Ring groove clearance
2nd ring
Type
T
Dimensions
(B × T)
End gap (installed)
Ring groove clearance
Oil ring
Dimensions
T
(B × T)
End gap (installed)
Ring groove clearance
Connecting rod
Big end oil clearance
Bearing color code
Small end inside diameter
Crankshaft
E
B
mm (in)
mm (in)
mm (in)
Barrel
0.90 × 2.75 (0.04 × 0.11)
0.38–0.55 (0.0150–0.0217)
0.030–0.065 (0.0012–0.0026)
mm (in)
Taper
0.80 × 2.80 (0.03 × 0.11)
mm (in)
mm (in)
0.49–0.69 (0.0193–0.0272)
0.020–0.055 (0.0008–0.0022)
mm (in)
1.50 × 2.60 (0.06 × 0.10)
mm (in)
mm (in)
0.29–0.59 (0.0114–0.0232)
0.040–0.160 (0.0016–0.0063)
mm (in)
0.016–0.040 (0.0006–0.0016)
1. Brown 2. Black 3. Blue 4. Green
17.005–17.018 (0.6694–0.6699)
B
B
mm (in)
B
A
Crank width A
Deflection limit B
Crankshaft journal oil clearance
Bearing color code
Throttle body
Type/quantity
Manufacturer
ID mark
Trolling speed
Fuel pump
Pump type
Output pressure
mm (in)
mm (in)
mm (in)
304.8–306.0 (12.00–12.05)
0.03 (0.0012)
0.020–0.057 (0.0008–0.0022)
1. Brown 2. Black 3. Blue 4. Green 5. Yellow
40EIS/4
Mikuni
60E00
1,600–1,800
r/min
kPa
(kgf/cm2, psi)
2-5
Electrical
310–330 (3.1–3.3, 45–47)
SPEC
MAINTENANCE SPECIFICATIONS
Item
Oil filter
Oil filter type
Oil pump
Oil pump type
Rotor tip clearance
Oil pump housing clearance
Rotor (feed pump)
Rotor (scavenge pump)
E
Model
FX140
Unit
Cartridge type
mm (in)
Trochoid
0.09–0.15 (0.004–0.006)
mm (in)
mm (in)
0.09–0.17 (0.0035–0.0067)
0.09–0.19 (0.0035–0.0075)
Unit
Model
FX140
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
Stainless steel
3
16.3
0.35–0.45 (0.01384–0.0177)
0.6 (0.0236)
0.3 (0.0118)
86.5–87.1 (3.41–3.43)
Degree
mm (in)
mm (in)
mm (in)
mm (in)
HULL AND HOOD
Item
Free play
Throttle lever free play
Unit
Model
FX140
mm (in)
4–7 (0.16–0.28)
ELECTRICAL
Item
Battery
Type
Capacity
Specific gravity
ECM unit
(B/R – Ground for cylinder
#1 and #4)
(B/W – Ground for cylinder
#2 and #3)
Output peak voltage lower
limit
@cranking
@2,000 r/min
@3,500 r/min
Unit
Model
FX140
V/Ah
Fluid
12/19
1.28
V
V
V
7
258
258
2-6
SPEC
MAINTENANCE SPECIFICATIONS
Item
Stator
Pulser coil (W – B, R – B)
Output peak voltage
@cranking 1
@cranking 2
@2,000 r/min
@3,500 r/min
Lighting coil
(G – G)
Output peak voltage
@cranking 1
@cranking 2
@2,000 r/min
@3,500 r/min
Pulser coil resistance
Pulser coil resistance 2
Lighting coil resistance
Minimum charging current
Ignition coil
Minimum spark gap
Primary coil resistance
Secondary coil resistance
Spark plug lead resistance
#1
#2
#3
#4
Rectifier/regulator
(R – B)
Output peak voltage (loaded)
@3,500 r/min
Starter motor
Type
Output
Rating
Brush length
Wear limit
Commutator undercut
Limit
Commutator diameter
Limit
Starter relay
Rating
E
Unit
Model
FX140
V
V
V
V
4
4
23
38
V
V
V
V
Ω (color)
Ω (color)
Ω (color)
A @ r/min
9
8
11
12
459–561 (W – B, R – B)
459–561 (W – B, R – B)
0.54–0.66 (G – G)
14 @ 6,000
mm (in)
Ω (color)
kΩ
7–8 (0.28–0.31)
1.53–2.07 (B/W – R)
12.5–16.9
kΩ
kΩ
kΩ
kΩ
6.4–14.9
5.9–13.8
4.7–11.1
4.4–10.5
V
14.5
kW
Seconds
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
Constant mesh
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)
Seconds
30
Cranking 1: unloaded
Cranking 2: loaded
2-7
SPEC
MAINTENANCE SPECIFICATIONS
Item
Thermoswitch
ON temperature (Engine)
OFF temperature (Engine)
ON temperature (Exhaust)
OFF temperature (Exhaust)
Engine temperature sensor
Engine temperature sensor
resistance
(B/Y – B/Y)
@ 20 °C (68 °F)
@ 100 °C (212 °F)
Intake air temperature sensor
Intake air temperature sensor
resistance
@ 0 °C (32 °F)
@ 80 °C (176 °F)
Intake air pressure sensor
output voltage (P/G – B/O)
Speed sensor
Output voltage (on pulse)
Output pulse/one full turn
Throttle position sensor
Output voltage (P – B/O)
@ trolling speed
Cam position sensor
Output voltage (G/O – B/O)
Position A
Position B
Fuel sender
Fuel sender resistance
Position A
Position B
Oil pressure switch
Oil pressure switch continuity
pressure
Fuel injector
Fuel injector resistance
Fuse
Rating
Main
Multifunction meter
Electrical bilge pump
E
Unit
Model
FX140
°C (°F)
°C (°F)
°C (°F)
°C (°F)
84–90 (183–194)
70–84 (158–183)
94–100 (201–212)
80–94 (176–201)
kΩ
kΩ
54.2–69.0
3.12–3.48
kΩ
kΩ
V @ kPa
(kgf/cm2, psi)
V @ kPa
(kgf/cm2, psi)
V @ kPa
(kgf/cm2, psi)
5.4–6.6
0.29–0.39
4.00 @ 101.3 (1.01, 14.4)
V
11.6
2
V
0.760 ± 0.016
V
V
More than 0.8
Less than 4.8
Ω
Ω
91–93
6–8
kPa
(kgf/cm2, psi)
128 (12.8, 18.2)–166 (1.66, 23.6)
Ω
14.0–15.0
V/A
V/A
V/A
12/20
12/3
12/3
1.97 @ 50 (0.5, 7.1)
0.79 @ 20 (0.2, 2.8)
2-8
SPEC
TIGHTENING TORQUES
E
TIGHTENING TORQUES
SPECIFIED TORQUES
5.5
3.8
0.38
2.7
7.6
0.76
5.5
2.5
0.25
1.8
3
15
39
15
39
5.0
1.5
3.9
1.5
3.9
0.5
11
28
11
28
3.6
M5
2
3.5
0.35
2.5
Nut
—
1
15
1.5
11
Screw
Screw
Screw
Screw
M6
M5
M5
M6
1
2
2
2
5.0
3.5
3.5
5.0
0.5
0.35
0.35
0.5
3.6
2.5
2.5
3.6
Screw
M6
2
5.0
0.5
3.6
Screw
M4
2
2.0
0.2
1.4
M8
3
Bolt
M6
2
Bolt
M6
2
Screw
M5
1
Bolt
M8
2
Bolt
M8
1
Screw
M6
Screw
1st
2nd
1st
2nd
1st
2nd
Air filter case stay 2 –
cylinder head
Fuel rail – throttle bodies
Intake air pressure sensor –
bracket 1
Intake air temperature sensor –
bracket 1
Bracket 1 – fuel rail
Fuel pipe – fuel rail
Bracket 2 – fuel rail
Throttle stop guide – throttle bodies
Throttle stop screw bracket –
throttle bodies
Throttle position sensor –
throttle bodies
2-9
LT
Bolt
LT
8
242
M8
LT
Bolt
572
2
LT
0.76
M4
572
7.6
Bolt
LT
2.7
2
572
0.38
M6
LT
3.8
Bolt
242
13
4
LT
1.8
M6
572
18
Bolt
LT
6.4
1
4
2
572
0.88
—
M8
M5
E
8.8
Nut
Bolt
Screw
LT
2.3
4.6
4.3
11
1.8
2.4
4.7
2.7
5.5
1.2
2.4
8.0
16
9
242
0.32
0.64
0.59
1.6
0.25
0.33
0.65
0.38
0.76
0.17
0.33
1.1
2.2
—
572
3.2
6.4
5.9
16
2.5
3.3
6.5
3.8
7.6
1.7
3.3
11
22
Nut
Remarks
LT
Fuel hose bracket/wire
harness bracket 2 –
air filter case
Wire harness bracket 2 –
air filter case
Air filter case stay 1 –
exhaust pipe 3
Tightening torque
N•m kgf•m
ft•lb
271
Fuel system
1st
Retainer/fuel pump module
– fuel tank
2nd
Fuel filler neck/rubber seal – deck
Fuel tank belt/fuel tank – hull
Air filter case cover – air filter case
1st
Flame arrester –
throttle bodies
2nd
1st
Throttle cable holder –
air filter case
2nd
1st
Fuel hose holder –
fuel hose bracket
2nd
1st
Throttle bodies –
throttle body joint
2nd
Air filter case –
1st
air filter case stay 1/
2nd
air filter case stay 2
Wire harness bracket 1/
1st
sub wire harness –
2nd
air filter case
Thread
Q’ty
size
LT
Part name
271
Part to tightened
TIGHTENING TORQUES
Exhaust pipe 1 –
exhaust pipe stay
Exhaust pipe 2 –
exhaust pipe 1
Exhaust pipe 1 –
exhaust manifold 1/
exhaust manifold 2
0.44
3.2
—
2
2nd
4.4
0.44
3.2
1st
5th
9th
2nd
6th
10th
3rd
7th
11th
4th
8th
12th
1st
2nd
1st
2nd
1st
2nd
1st
6th
2nd
7th
3rd
8th
4th
9th
5th
10th
1st
2nd
3rd
2.0
15
39
2.0
15
39
2.0
15
39
2.0
15
39
3.7
7.6
15
42
15
42
39
39
39
39
39
39
39
39
39
39
22
22
35
0.2
1.5
3.9
0.2
1.5
3.9
0.2
1.5
3.9
0.2
1.5
3.9
0.37
0.76
1.5
4.2
1.5
4.2
3.9
3.9
3.9
3.9
3.9
3.9
3.9
3.9
3.9
3.9
2.2
2.2
3.5
1.4
11
28
1.4
11
28
1.4
11
28
1.4
11
28
2.7
5.5
11
30
11
30
28
28
28
28
28
28
28
28
28
28
16
16
25
Bolt
M10
1
Bolt
M10
1
Bolt
M10
1
Bolt
M10
1
Bolt
M6
3
Bolt
M8
2
Bolt
M10
1
Nut
—
1
Nut
—
1
Nut
—
1
Nut
—
1
Nut
—
1
Bolt
M8
10
2-10
LT
4.4
—
1st
271
3.2
LT
0.44
572
4.4
LT
3.2
2
572
0.44
—
LT
4.4
—
242
5.5
LT
0.76
242
7.6
LT
2
242
M6
LT
Bolt
242
12
12
5.6
LT
1.7
1.7
0.78
572
17
17
7.8
LT
4
1
1
242
Exhaust pipe stay –
crankcase
M8
—
M6
Remarks
LT
Exhaust pipe end –
exhaust pipe 3
Bolt
—
Bolt
1st
2nd
Tightening torque
N•m kgf•m
ft•lb
242
Exhaust pipe 3 –
crankcase
Thread
Q’ty
size
E
Engine
Engine unit – engine mount
Oil filter
Coupling cover
Thermoswitch (exhaust) –
exhaust pipe 3
Outer exhaust joint clamp –
exhaust pipe 3/exhaust
pipe 2
Inner exhaust joint clamp –
exhaust pipe 3/exhaust
pipe 2
Part name
LT
Part to tightened
E
242
SPEC
TIGHTENING TORQUES
Bolt
M6
4
Bolt
M6
8
Bolt
M5
10
Bolt
M5
3
Bolt
M6
2
Bolt
M6
24
Screw
M4
1
Bolt
M6
12
Bolt
M8
Bolt
—
2-11
0.19
1.4
4.4
0.44
3.2
1
1.9
4.4
3.7
7.6
3.7
7.6
3.7
1.4
10
18
0.19
0.44
0.37
0.76
0.37
0.76
0.37
0.14
1.0
1.8
1.4
3.2
2.7
5.5
2.7
5.5
2.7
1.0
7.2
13
M6
2
7.9
0.79
5.7
—
1
28
2.8
20
LT
1.9
LT
2
242
M6
LT
Bolt
242
2
LT
M10
572
Bolt
572
2
5.5
5.5
11
20
1.4
11
28
1.4
11
28
2.7
5.5
2.7
5.5
2.7
5.5
LT
—
0.76
0.76
1.5
2.8
0.2
1.5
3.9
0.2
1.5
3.9
0.37
0.76
0.37
0.76
0.37
0.76
572
Nut
7.6
7.6
15
28
2.0
15
39
2.0
15
39
3.7
7.6
3.7
7.6
3.7
7.6
E
4
5.5
LT
M8
0.76
572
Bolt
7.6
LT
3
2
2.7
572
M6
M6
0.37
LT
Bolt
Bolt
3.7
572
3
LT
M6
572
Bolt
LT
4
572
M6
E
LT
Bolt
572
5
E
M8
E
Bolt
LT
6
572
Oil tank stay/reduction
1st
drive gear case –
2nd
oil separator
Cover (ground lead) – oil tank
Ground lead – oil tank
1st
Oil tank – reduction drive
gear case
2nd
1st
Oil tank – oil tank stay
2nd
3rd
1st
Oil tank stay – cylinder
2nd
head
3rd
1st
Bracket (coupling cover) –
oil tank
2nd
1st
Hanger – oil tank cover
2nd
1st
Oil tank cover – oil tank
2nd
Oil breather plate 1/
1st
oil breather plate 2 –
2nd
oil tank cover
1st
Baffle plate – oil tank
2nd
1st
Oil strainer – oil tank
2nd
1st
Oil cooler cover – oil tank
2nd
Anode – oil tank
1st
Oil pump assembly –
reduction drive gear case
2nd
Drain plug (engine oil)
Oil pump housing cover 1/oil pump
housing – oil pump housing cover 2
Drive coupling – drive shaft
M8
Remarks
E
Water jacket – oil tank
Bolt
Tightening torque
N•m kgf•m
ft•lb
22
2.2
16
22
2.2
16
35
3.5
25
22
2.2
16
22
2.2
16
35
3.5
25
3.7
0.37
2.7
7.6
0.76
5.5
LT
Exhaust manifold 2 –
cylinder head
1st
2nd
3rd
1st
2nd
3rd
1st
2nd
Thread
Q’ty
size
572
Exhaust manifold 1 –
cylinder head
Part name
LT
Part to tightened
E
572
SPEC
TIGHTENING TORQUES
Cylinder head – crankcase
1st
2nd
1st
2nd
2
Bolt
M8
7
Bolt
M6
1
10
1.0
7.2
Bolt
M8
4
15
28
1.5
2.8
11
20
Nut
—
1
18
1.8
13
A
Bolt
Bolt
M8
M8
1
1
M10
8
Bolt
Bolt
M10
M8
1
6
0.49
1.8
1.5
5.0
7.5
2.4
3.5
13
11
36
54
17
A
Bolt
4.9
18
15
50
75
24
Bolt
M5
3
4.9
0.49
3.5
Bolt
M5
4
4.9
0.49
3.5
Bolt
M6
2
14
1.4
10
Bolt
—
Bolt
M6
—
M6
3
4
1
Bolt
M6
1
14
13
10
3.7
7.6
1.4
1.3
1.0
0.37
0.76
10
9.4
7.2
2.7
5.5
Bolt
M6
6
12
1.2
8.7
Bolt
M6
1
10
1.0
7.2
Bolt
M6
2
10
1.0
7.2
Bolt
M6
10
10
1.0
7.2
Bolt
M6
18
10
1.0
7.2
Bolt
M7
2
24
2.4
17
Bolt
M7
2
24
2.4
17
Bolt
Bolt
M8
M6
2
3
Nut
—
2
Nut
—
8
40
10
20
64
20
49
4.0
1.0
2.0
6.4
2.0
4.9
29
7.2
14
46
14
35
2-12
242
LT
LT
LT
LT
242
242
LT
LT
572
572
E
E
E
LT
242
E
572
E
E
LT
LT
M6
572
Bolt
572
Remarks
E
Holder (relief valve) –
reduction drive gear case
1st
Bearing housing –
reduction drive gear case
2nd
Battery negative lead –
starter motor
Starter motor lead – starter motor
Starter motor – crankcase
1st
Generator cover –
crankcase
2nd
Rotor – crankshaft
Rotor – starter clutch
Washer/pulser coil lead and lighting
coil lead – generator
Pulser coil – generator cover
Holder (wire harness) –
generator cover
Lighting coil – generator cover
Spark plug
Camshaft position sensor
1st
Cooling water pipe –
cylinder
2nd
Cylinder head cover –
cylinder head
Timing chain tensioner cap bolt
Timing chain tensioner –
cylinder head
Exhaust camshaft cap –
cylinder head
Intake camshaft cap –
cylinder head
Exhaust camshaft sprocket –
exhaust camshaft
Intake camshaft sprocket –
intake camshaft
Hanger – cylinder head
Tightening torque
N•m kgf•m
ft•lb
3.7
0.37
2.7
7.6
0.76
5.5
15
1.5
11
28
2.8
20
E
1st
2nd
1st
2nd
Thread
Q’ty
size
LT
Reduction drive gear case
– crankcase
Part name
271
Part to tightened
E
E
SPEC
TIGHTENING TORQUES
7.6
0.76
5.5
Nut
—
1
6.8
0.68
4.9
Bolt
Bolt
Bolt
Screw
Bolt
Bolt
Bolt
Bolt
Nut
Bolt
Bolt
Bolt
Nut
Bolt
Bolt
M8
M8
M6
M5
M10
M6
M6
M8
—
M6
M8
M6
—
M8
M8
4
4
4
4
4
1
4
1
1
6
2
1
1
2
2
17
20
7.8
3.7
40
7.8
6.8
8.3
26
7.8
20
7.8
7.8
15
15
1.7
2.0
0.78
0.37
4.0
0.78
0.68
0.83
2.6
0.78
2.0
0.78
0.78
1.5
1.5
12
14
5.6
2.7
29
5.6
4.9
6.0
19
5.6
14
5.6
5.6
11
11
Bolt
M10
4
40
4.0
29
2-13
LT
2.7
2
572
0.37
M6
LT
3.7
Bolt
572
3
LT
M6
LT
LT
LT
LT
LT
LT
LT
LT
LT
LT
LT
2.7
5.5
2.7
5.5
271
Bolt
3.7
7.6
3.7
7.6
LT
2
572
M6
LT
Bolt
572
8
E
—
8.7
8.7
25
14
E
Nut
12
12
35
20
LT
1
2
1
572
M6
M6
—
E
Bolt
Screw
—
LT
10
6.1
8.7
14
8.7
8.7
5.6
11
572
M9
0.84
1.2
2.0
1.2
1.2
0.78
1.5
49 ± 5°
1.2
1.2
3.5
2.0
120 ± 5°
0.37
0.76
0.37
0.76
LT
Bolt
8.4
12
20
12
12
7.8
15
572
1
1
1
13
10
572
—
M6
M8
M6
M6
242
—
Bolt
Bolt
Bolt
Bolt
572
5.5
242
0.76
242
7.6
242
2
572
M6
271
Bolt
242
11
242
1.5
242
Reverse gate stay – jet pump
Reverse gate – reverse gate stay
Lever 1 – Reverse gate stay
Lever 2– Reverse gate stay
Nozzle ring – nozzle
Jet thrust nozzle – nozzle ring
Nozzle/impeller duct assembly –
impeller housing 1
15
LT
Roller – reverse gate stay
1
242
Oil pipe – lower crankcase
Cover – lower crankcase
Oil filter bolt – lower crankcase
1st
Connecting rod cap
2nd
1st
Thermostat housing cover
– Thermostat housing
2nd
1st
Pressure control valve –
upper crankcase
2nd
Collar/pressure control
1st
valve housing cover –
2nd
pressure control housing
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
Rubber plate – bracket
—
LT
1st
2nd
3rd
—
Remarks
271
Lower crankcase –
upper crankcase
Bolt
Tightening torque
N•m kgf•m
ft•lb
10
1.0
7.2
LT
Plug (vacuum pressure)
Engine temperature sensor –
crankcase
Thermoswitch (engine) –
crankcase
Oil pressure switch
Anode cover – anode
Anode cover – cylinder head
Oil pan – lower crankcase
Thread
Q’ty
size
M6
4
271
Part name
LT
Part to tightened
E
572
SPEC
TIGHTENING TORQUES
4
6.6
0.66
4.8
Nut
—
1
69
6.9
50
Impeller
M22
1
27
2.7
19
Nut
Screw
Bolt
Driven
coupling
—
M5
M8
4
1
3
26
3.7
17
2.6
0.37
1.7
19
2.8
12
M24
1
36
3.6
25
Nipple
—
1
5.4
0.54
3.9
Bolt
M8
4
20
2.0
14
Bolt
M6
2
1.1
0.11
0.8
Screw
M6
4
1.1
0.11
0.8
Screw
M6
4
0.9
0.09
0.7
Nut
—
2
5.4
0.54
3.9
Screw
M5
2
3
0.3
2.2
Screw
M5
2
3.4
0.34
2.5
Screw
Bolt
M6
M5
1
2
3.4
1.2
0.34
0.12
2.5
0.9
Screw
M4
1
1
0.1
0.7
Nut
—
4
20
2.0
14
Nut
—
1
6.8
0.68
4.9
Nut
—
1
3
0.3
2.2
Nut
—
1
3.8
0.38
2.7
Nut
—
1
5.9
0.59
4.3
Nut
—
1
3.8
0.38
2.7
Nut
—
1
2.9
0.29
2.1
Nut
Nut
—
—
1
2
5.9
5.4
0.59
0.54
4.3
3.9
Nut
—
1
6.4
0.64
4.6
2-14
572
LT
LT
LT
572
LT
LT
LT
271
242
572
572
LT
M6
572
Bolt
LT
Remarks
242
Grease nipple – intermediate
housing
Hull and hood
Handlebar holder – steering master
Handlebar cover stay –
steering master
Handlebar cover –
handlebar cover stay
Handle boss cover –
steering master
QSTS converter – hull
Throttle lever assembly –
handlebar
Handlebar switch assembly –
handlebar
QSTS grip assembly – handlebar
Grip end – handlebar
Cable housing –
QSTS grip assembly
Steering master – deck
Steering cable ball joint –
steering arm
QSTS cable locknut
(QSTS converter side)
QSTS cable locknut
(nozzle ring side)
QSTS cable grommet – hull
QSTS cable end pin –
QSTS converter
Shift cable locknut
(reverse gate side)
Shift cable grommet – hull
Shift cable holder – shift lever base
Steering cable locknut
(steering arm side)
Tightening torque
N•m kgf•m
ft•lb
LT
Driven coupling – shaft
Thread
Q’ty
size
242
Water inlet cover/water inlet
strainer – impeller duct
Drive shaft nut – drive shaft
Impeller (left-hand threads) –
drive shaft
Transom plate – hull
Bilge strainer holder – bulkhead
Intermediate housing – bulkhead
Part name
LT
Part to tightened
E
242
SPEC
TIGHTENING TORQUES
—
—
—
M6
M4
M5
2
1
4
4
4
4
5.4
5.9
5.4
5.4
1.5
3.9
0.54
0.59
0.54
0.54
0.15
0.39
3.9
4.3
3.9
3.9
1.1
2.8
Bolt
M5
4
3.9
0.39
2.8
Nut
Bolt
Bolt
—
M6
M6
4
8
4
6.9
5.4
5.4
0.69
0.54
0.54
5.0
3.9
3.9
Bolt
M6
2
5.4
0.54
3.9
Bolt
Nut
Nut
Bolt
Screw
Nut
Screw
M6
—
—
M6
M6
—
M6
2
2
2
2
2
2
3
5.4
5.4
20
5.4
5.4
4.2
5.4
0.54
0.54
2.0
0.54
0.54
0.42
0.54
3.9
3.9
14
3.9
3.9
3.0
3.9
Screw
M6
3
5.4
0.54
3.9
Bolt
Nut
Nut
Nut
Nut
Nut
Bolt
Nut
M6
—
—
—
—
—
M6
—
1
4
2
1
1
4
4
4
5.4
5.2
15
26
26
5.2
6.4
18
0.54
0.52
1.5
2.6
2.6
0.52
0.64
1.8
3.9
3.8
11
19
19
3.8
4.6
13
Nut
—
6
5.4
0.54
3.9
Bolt
M6
6
Bolt
Nut
Nut
Nut
Bolt
Nut
M8
—
—
—
M6
—
10
2
4
1
4
3
3.7
12
16
15
15
5.4
5.4
5.4
0.37
1.2
1.6
1.5
1.5
0.54
0.54
0.54
2.7
8.8
12
11
11
3.9
3.9
3.9
2-15
LT
Nut
Nut
Nut
Bolt
Screw
Bolt
271
3.9
LT
0.54
242
5.4
LT
2
242
—
LT
Nut
271
4.3
LT
0.59
242
5.9
LT
1
271
—
LT
Nut
271
4.7
LT
0.65
242
6.5
LT
1
271
—
LT
Nut
Remarks
271
Tightening torque
N•m kgf•m
ft•lb
LT
Protector (bow) – hull
Thread
Q’ty
size
572
Steering cable locknut
(jet thrust nozzle side)
Steering cable grommet – hull
Steering cable bracket –
steering cable holder
Steering cable bracket – deck
Speed sensor lead grommet – hull
Front hood assembly – deck
Service lid 1 – deck
Service lid 2– deck
Panel – steering console cover
Multifunction meter –
steering console cover
Mirror – steering console cover
Side cover – deck
Bracket (side cover) – deck
Steering console cover –
glove box
Hood lock assembly
Steering console cover – deck
Glove compartment – deck
Shift lever handle – shift lever
Latch – glove compartment
Pilot water outlet – hull
Shift lever plate – deck
Shift lever plate –
deck/shift lever base assembly
Shift lever – base assembly
Hand grip – deck
Front seat stay – deck
Seat lock projection – deck beam
Seat lock projection – deck
Rear seat stay – deck
Seat lock assembly – seat
Deck beam – deck
Plate/rubber hose/exhaust valve –
hull
1st
Exhaust joint protector 1 –
Exhaust joint protector 2
2nd
Sponson – hull
Cleat – deck
Cleat – hull
Spout – hull
Part name
LT
Part to tightened
E
271
SPEC
TIGHTENING TORQUES
Cover – electrical box
Starter motor lead– electrical box
Battery positive lead –
electrical box
Fuse holder stay – electrical box
ECM – electrical box
Bracket (coupler) – electrical box
Slant detection switch – electrical
box
Main and fuel pump relay
Rectifier/regulator
Ignition coil – oil tank
Ignition coil cover – ignition coil
case
Ignition coil – ignition coil case
LT
LT
M6
M6
M8
M5
2
2
4
4
5.4
5.4
17
4.9
0.54
0.54
1.7
0.49
3.9
3.9
12
3.5
ø5
18
4.9
0.49
3.5
M6
1
7.6
0.76
5.5
A
Screw
M6
1
7.6
0.76
5.5
A
ø6
1
3.9
0.39
2.8
ø6
4
3.9
0.39
2.8
ø6
1
3.9
0.39
2.8
ø6
2
3.9
0.39
2.8
ø6
1
3.9
0.39
2.8
ø6
2
3.9
0.39
2.8
M6
3
7.6
0.76
5.5
ø6
10
4.9
0.49
3.5
ø6
4
4.9
0.49
3.5
Tapping
screw
Tapping
screw
Tapping
screw
Tapping
screw
Tapping
screw
Tapping
screw
Bolt
Tapping
screw
Tapping
screw
2-16
LT
LT
Bolt
Bolt
Bolt
Screw
Tapping
screw
Screw
572
Remarks
271
Tightening torque
N•m kgf•m
ft•lb
13
1.3
9.4
2.0
0.2
1.4
17
1.7
12
6.4
0.64
4.6
572
Bolt
Bolt
Bolt
Bolt
Thread
Q’ty
size
M6
2
M5
4
M8
8
M6
4
271
Bow eye – hull
Drain plug/packing – hull
Engine mount – hull
Engine damper – hull
Electrical
Battery box – hull
Battery box/spacer – hull
Electrical box – bulk head
Terminal cover – electrical box
Part name
LT
Part to tightened
E
572
SPEC
SPEC
TIGHTENING TORQUES
Nut A
Bolt B
8 mm
10 mm
12 mm
14 mm
17 mm
M5
M6
M8
M10
M12
E
GENERAL TORQUE
General torque
specifications
N•m kgf•m ft•lb
5.0
0.5
3.6
8.0
0.8
5.8
18
1.8
13
36
3.6
25
43
4.3
31
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.
2-17
SPEC
CABLE AND HOSE ROUTING
E
CABLE AND HOSE ROUTING
1
1
BOW
DOWN
DOWN
7
F
A-A
20˚
UP
8
E
G
9
G
A
D
1
BA
6
B-B
F
F
B
C
C
5
F-F
D
C
1
E
6
G
5
E
C-C
5
0
+
E-E
2
D
6
A
B
3
3
4
2
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
Fuel tank breather hose
QSTS cable
Steering cable
Shift cable
Electrical box lead
Speed sensor lead
Cooling water pilot outlet
Cooling water pilot outlet hose
Cooling water pilot outlet
Battery negative lead
2-18
Battery positive lead
Battery
Throttle cable
Fuel hose
Cooling water pilot outlet hose
Handlebar switch lead
Electrical bilge pump lead
4
D-D
SPEC
CABLE AND HOSE ROUTING
E
1
3
2
5
5
4
C
B
A
B
A
B
A
E
01 C D
F
C
D
F
B
3
A
G
MAIN
3A
3A
20A
3A
3A
3A
3A
3A
3A
0
SPARE
5
E
6
7
8 E
A
5
B
D
9
0
5
E-E
F
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
Throttle cable
Handlebar switch lead
QSTS cable
Buzzer lead
Fuel tank breather hose
Ignition coil lead
Battery positive lead
Starter motor lead
Wire harness
Fuel hose
2-19
Shift cable
Steering cable
Electrical box lead
Cooling water pilot outlet hose
Battery negative lead
Battery breather hose
Speed sensor lead
8
SPEC
CABLE AND HOSE ROUTING
2
1
E
3
4 5
6
7
8
4
6
7
2
5
2 0 È
9
A
5
2
H
1
8
0
2
G
F
B
C
8
E
D
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
Cooling water hose (cooling water inlet)
Bilge hose 1
Electric bilge pump
Bilge hose 4
Cooling water hose (from thermostat)
Bilge hose 3
Bilge hose 2
Cooling water hose (from exhaust pipe)
Electrical box
QSTS cable
Battery positive lead
Speed sensor lead
Electric bilge pump lead
Bilge strainer
Battery negative lead
Steering cable
Shift cable
Flushing hose
È Pass the QSTS cable between in bilge hose.
2-20
SPEC
CABLE AND HOSE ROUTING
E
Ê
È
Î
Ë Ë
Ë
1
B
Ì
C
Í
Õ
1
É
A
Ë
Ö ×
Ï
A
C
B
D
E
D
Ð
F
Ì
Ø
Ê
Ó
5
Ð
4
3
Ò
Ì
Ô
F
1
2
3
4
5
Ë
Ð
Ò
E
Ñ
2
D-D
Ë From exhaust manifold
Ì To install the hose, align the white paint mark on
the cooling water hose with the projection of
hose joint.
Í Insert the cooling water hose until it contacts the
joint.
Î To cooling water pilot outlet on port side
Ï To cooling water outlet at stern
Ð Cooling water inlet
Ñ To oil tank
Thermostat
Pressure control valve
Cooling water hose (cooling water inlet)
Battery negative lead
Breather hose
È To cooling water pilot outlet on starboard side
É To cooling water outlet on starboard side of
stern
Ê To pressure control valve
2-21
SPEC
CABLE AND HOSE ROUTING
E
Ê
È
Î
Ë Ë
Ë
1
B
Ì
C
Í
Õ
1
É
A
Ë
Ö ×
Ï
A
C
B
D
E
D
Ð
F
Ì
Ø
Ê
Ó
5
Ð
4
Ë
Ð
3
Ò
Ì
Ô
F
Ò
E
Ñ
2
D-D
Ö Bundle the cooling water pilot outlet hose and
the cooling water hoses, pass a plastic locking
tie through the stay hole, and then fasten the tie.
× Insert the cooling water hose to the paint mark.
Ø Fasten the cooling water hose tube contacting
the hose joint.
Ò To exhaust pipe
Ó To install the hose, align the white paint mark on
the cooling water hose with the parting line on
the hose joint.
Ô Fasten the cooling water hose and battery negative lead. Slide the tie in the direction shown.
Õ Bundle the cooling water pilot outlet hose and
cooling water hose, and then fasten them
together with the oil tank boss with a plastic
locking tie.
2-22
SPEC
CABLE AND HOSE ROUTING
E
0
9
Ë
É
1
B
A
È
Ê
2
A
8
7
6 5 4
3
A
1
1
B
A-A
1
2
3
4
5
6
7
8
9
0
A Oil pressure switch lead
Wire harness
Ground lead
Wire harness coupler
Cam position sensor coupler
Thermoswitch (exhaust)
Thermoswitch (exhaust) coupler
Oil pressure switch coupler
Pulser coil coupler
Thermoswitch (engine) coupler
Lighting coil coupler
È
É
Ê
Ë
2-23
To electrical box
To cam position sensor
To oil pressure switch
To engine temperature sensor
SPEC
CABLE AND HOSE ROUTING
E
1
2
A
ÊÉ
A
È
5
7Í
4
3
Ë
Ì
Î
Ï
6
B
9
8
0
D
Ï
A-A
Î
Ñ
1
2
3
4
5
6
7
8
9
0
Ð
Engine temperature sensor coupler
Lighting coil coupler
Pulser coil coupler
Thermoswitch (engine) coupler
Thermoswitch (engine)
Starter motor
Engine temperature sensor
Engine temperature sensor lead
Thermoswitch (engine) lead
Lighting coil lead
2-24
SPEC
CABLE AND HOSE ROUTING
E
1
2
A
ÊÉ
A
È
5
7Í
4
3
Ë
Ì
Î
Ï
6
B
9
8
0
D
Ï
A-A
Î
Ñ
Ð
Ð Route the starter motor and battery negative
leads behind the cooling water hose.
Ñ Route the starter motor lead over the cooling
water hose.
È
É
Ê
Ë
Ì
Í
To generator
To engine temperature sensor
To thermoswitch (engine)
To thermoswitch (engine) coupler
To engine temperature sensor coupler
Route the starter motor lead to the outside of the
engine temperature sensor.
Î To starter relay
Ï To battery negative terminal
2-25
INSP
ADJ
E
CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENT
MAINTENANCE INTERVAL CHART .............................................................. 3-1
PERIODIC SERVICE .......................................................................................3-2
CONTROL SYSTEM ................................................................................. 3-2
Steering master inspection..................................................................3-2
Steering cable inspection and adjustment .......................................... 3-2
Throttle cable inspection and adjustment............................................3-3
QSTS cable inspection and adjustment ..............................................3-5
Shift cable inspection and adjustment................................................. 3-7
Trolling speed check and adjustment.................................................. 3-8
FUEL SYSTEM.......................................................................................... 3-9
Fuel line inspection .............................................................................3-9
POWER UNIT.......................................................................................... 3-10
Valve clearance adjustment ..............................................................3-10
Engine oil level check........................................................................3-16
Engine oil change — using oil changer............................................. 3-18
Air filter element clean....................................................................... 3-20
Spark plug inspection........................................................................3-21
ELECTRICAL .......................................................................................... 3-23
Battery inspection.............................................................................. 3-23
JET PUMP UNIT .....................................................................................3-26
Impeller inspection ............................................................................3-26
Water inlet strainer inspection........................................................... 3-27
BILGE PUMP........................................................................................... 3-27
Bilge strainer inspection .................................................................... 3-27
Electric bilge pump strainer inspection.............................................. 3-28
GENERAL ...............................................................................................3-28
Drain plug inspection.........................................................................3-28
Lubrication points .............................................................................. 3-29
1
2
3
4
5
6
7
8
9
INSP
ADJ
MAINTENANCE INTERVAL CHART
E
MAINTENANCE INTERVAL CHART
The following chart should be considered strictly as a guide to general maintenance intervals.
Depending on operating conditions, the intervals of maintenance should be changed.
(●) This mark indicates maintenance that you may do yourself.
(❍) This mark indicates work to be done by a Yamaha dealer.
THEREAFTER
PAGE
EVERY
10 hours 50 hours 100 hours 100 hours 200 hours
6
12
12
24
months months months months
●
●
●
●
Inspect, clean, adjust
3-21
●
●
Lubricate
3-29
❍*1
●*2
●*2
Lubricate
3-31
❍
❍
Inspect
3-9
❍
❍
Clean
3-9
❍
❍
Inspect, clean
3-9
❍
❍
❍
Inspect
3-8
❍
❍
Inspect
—
● (after
—
Flush
every use)
❍
❍
Inspect, clean
3-27
❍
❍
Clean
3-27
MAINTENANCE INTERVAL
ITEM
Spark plug
Lubrication points
Intermediate housing
Fuel system
Fuel tank
Fuel filter
Trolling speed
Throttle shaft
Cooling water passages
Water inlet strainer
Bilge strainer
Electric bilge pump
strainer
Impeller
Steering cable
Steering master
QSTS mechanism
Shift cable and
mechanism
Throttle cable
Stern drain plugs
INITIAL
❍
❍
3-28
●
●
❍
●
●
❍
3-26
3-2
3-2
❍
❍
3-5
Inspect, adjust
❍
❍
3-7
Inspect, adjust
Inspect, replace
●
❍
●
❍
3-3
3-28
❍
❍
3-23
Inspect, clean
Inspect
Inspect
Inspect
Inspect, adjust
Battery
Inspect
Rubber coupling
Engine mount
Nuts and bolts
Air filter
Engine oil
Engine oil filter
Valve clearance
Inspect
Inspect
Inspect
Inspect
Replace
Replace
Inspect, adjust
●
●
❍
● (before
every use)
● (inspect
fluid level
before
every use)
❍
❍
❍
❍
❍
❍
❍
❍
●
❍
❍
*1: Grease capacity: 33.0–35.0 cm3 (1.11–1.18 oz)
*2: Grease capacity: 6.0–8.0 cm3 (0.20–0.27 oz)
3-1
—
5-7
—
3-20
3-18
3-18
3-10
INSP
ADJ
CONTROL SYSTEM
E
PERIODIC SERVICE
CONTROL SYSTEM
Steering master inspection
1. Inspect:
• Steering master
Excessive play → Replace the steering
master.
Refer to “STEERING MASTER” in
Chapter 8.
Inspection steps:
• Move the handlebar up and down and
back and forth.
• Check the excessive play of the handlebar.
Steering cable inspection and adjustment
1. Inspect:
• Jet thrust nozzle clearance a, b
Difference → Adjust.
Inspection steps:
• Set the control grip in the neutral position.
• Turn the handlebar from lock to lock.
• Measure clearances a and b.
• If clearances a and b are not the same,
adjust them.
2. Adjust:
• Steering cable joint
(steering master end)
Adjustment steps:
• Set the control grip in the neutral position.
• Loosen the locknut 1.
• Disconnect the steering cable joint 2
from the ball joint 3.
• Turn the cable joint in or out for adjusting
the clearance.
3-2
Turn in
Clearance a is increased.
Turn out
Clearance b is increased.
INSP
ADJ
CONTROL SYSTEM
E
WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).
• Connect the cable joint and tighten the
locknut.
T.
Locknut:
6.4 N • m (0.64 kgf • m, 4.6 ft • lb)
R.
NOTE:
If the steering cable cannot be properly
adjusted by the cable joint at the steering master end, adjust the cable joint at the jet pump
end so that the same clearances are obtained.
Refer to “REMOTE CONTROL CABLES AND
SPEED SENSOR LEAD” in Chapter 8.
Throttle cable inspection and adjustment
NOTE:
Before adjusting the throttle lever free play,
adjust the trolling speed.
1. Measure:
• Throttle lever free play a
Out of specification → Adjust.
Throttle lever free play:
4–7 mm (0.16–0.28 in)
3-3
INSP
ADJ
CONTROL SYSTEM
E
2. Adjust:
• Throttle lever free play
Adjustment steps:
NOTE:
• When not replacing the throttle cable or
removing the cable from the throttle body,
adjust the throttle cable free play by following steps (f) through (j).
• When replacing the throttle cable or
removing the cable from the throttle body,
adjust the throttle cable free play by following steps (a) through (k).
a. Remove the air filter case cover 1 and
flame arrester.
b. Pull back the cover 2.
c. Loosen the locknut 3.
d. Turn the adjusting nut 4 to adjust the
length a.
Throttle cable installation length:
18.4 ± 1.0 mm (0.72 ± 0.04 in)
NOTE:
Apply locking agent (LOCTITE®) to the
threads of the adjusting nut 4.
e. Push in the cover 2.
f. Remove the handlebar cover.
g. Loosen the locknut 5.
h. Turn the adjuster 6 in or out until the
specified free play is obtained.
Turn in
Free play is increased.
Turn out
Free play is decreased.
i. Tighten the locknut.
NOTE:
• When adjusting the throttle cable at the
throttle body, fully open the throttle lever
and check that the butterfly valve is fully
open.
• If the throttle cable free play cannot be
adjusted properly, replace the throttle
cable.
3-4
INSP
ADJ
CONTROL SYSTEM
E
j. Install the handlebar cover.
T.
R.
Handlebar cover screw:
1.1 N • m (0.11 kgf • m, 0.8 ft • lb)
LOCTITE® 242
k. Install the flame arrester and air filter
case cover.
T.
R.
Flame arrester bolt:
1st:
3.3 N • m
(0.33 kgf • m, 2.4 ft • lb)
2nd:
6.5 N • m
(0.65 kgf • m, 4.7 ft • lb)
LOCTITE® 242
Air filter case cover screw:
2.5 N • m (0.25 kgf • m, 1.8 ft • lb)
LOCTITE® 572
WARNING
After adjusting the free play, turn the handlebar to the right and left and make sure
that the trolling speed does not increase.
QSTS cable inspection and adjustment
1. Measure:
• Jet thrust nozzle set length a, b
Difference → Adjust.
Measurement steps:
• Set the control grip in the neutral position.
• Set the jet thrust nozzle in the center
position.
• Measure the jet thrust nozzle set length
a and b.
• If a and b length are not even, adjust
the cable joint.
3-5
INSP
ADJ
CONTROL SYSTEM
E
2. Adjust:
• QSTS cable
Adjustment steps:
• Set the control grip in the neutral position.
• Loosen the locknut 1.
• Remove the nut 2 and pivot pin 3.
• Set the jet thrust nozzle in the center
position.
• Turn the cable joint 4 for adjusting.
Turn in
Length a is increased.
Turn out
Length b is increased.
WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).
• Connect the cable joint 4 and pivot pin
3 and tighten the nut 2.
T.
Nut:
3.8 N • m (0.38 kgf • m, 2.7 ft • lb)
R.
• Tighten the locknut 1.
T.
Locknut:
3 N • m (0.3 kgf • m, 2.2 ft • lb)
R.
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.
3-6
INSP
ADJ
CONTROL SYSTEM
E
Shift cable inspection and adjustment
1. Check:
• Reverse gate stopper lever position
Incorrect → Adjust.
Checking steps:
• Set the shift lever to the reverse position.
• Check that the reverse gate 1 contacts
the stopper 2 on the bracket and the
lever 3 contacts the reverse gate.
• Set the shift lever to the forward position.
• Check that the lever 4 has been shifted
over the bracket 5.
5
4
2. Adjust:
• Shift cable joint
Adjustment steps:
• Loosen the locknut 1.
• Disconnect the cable joint 2 from the ball
joint 3.
• Situate the reverse gate to the stopper on
the bracket and the lever to the reverse
gate.
• Turn the cable joint to align it with the ball
joint.
Turn in
Shortens.
Turn out
Lengthens.
• Turn out the cable joint nine times a to
extend cable 7 mm (0.28 in) from the
aligned position.
WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).
• Connect the cable joint and tighten the
locknut.
T.
R.
3-7
Locknut:
2.9 N • m (0.29 kgf • m, 2.1 ft • lb)
INSP
ADJ
CONTROL SYSTEM
E
Trolling speed check and adjustment
1. Measure:
• Trolling speed
Out of specification → Adjust.
Trolling speed:
1,600–1,800 r/min
Checking steps: (Watercraft on water)
• Start the engine and allow it to warm up
for a 15 minutes.
• Check the engine trolling speed using the
tachometer of the multifunction meter or
using the Yamaha Diagnostic System.
2. Adjust:
• Trolling speed
Adjustment steps:
• Remove the air filter case cover 1.
• Start the engine.
• Turn the throttle stop screw 2 in or out
until the specified speed is obtained.
Turn in a
Increase trolling speed.
Turn out b
Decrease trolling speed.
• Install the air filter case cover.
T.
R.
3-8
Air filter case cover screw:
2.5 N • m (0.25 kgf • m, 1.8 ft • lb)
LOCTITE® 572
INSP
ADJ
FUEL SYSTEM
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. Inspect:
• Fuel strainer 1
Clog/contaminants → Clean.
• Fuel pump filter
Clog/contaminants → Clean.
Refer to “FUEL TANK AND FUEL
PUMP MODULE” in Chapter 4.
• Fuel hose
Damage/cracks → Replace.
• O-rings (quick connector)
Damage/cracks → Replace the quick
connector.
• Fuel pipe
Damage/cracks → Replace the fuel
pump.
Refer to “FUEL INJECTION SYSTEM”
in Chapter 4.
• Fuel filler hose
• Fuel tank
• Fuel filler cap
Cracks/damage → Replace.
1
2. Inspect:
• Water separator 1
Water accumulation → Drain.
1
NOTE:
If need the water draining, remove the drain
plug 2.
2
3-9
INSP
ADJ
POWER UNIT
E
POWER UNIT
Valve clearance adjustment
The following procedure applies to all of the
valves.
NOTE:
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.
1. Remove:
• Air filter case
Refer to “FUEL INJECTION SYSTEM”
in Chapter 4.
2. Remove:
• Spark plugs
• Cylinder head cover
• Cylinder head cover gasket
Refer to “CAMSHAFTS” in Chapter 5.
3. Install:
• Dial gauge needle
• Dial gauge stand 1
(into spark plug hole #1)
• Dial gauge 2
2
1
Dial gauge stand:
90890-06583
Dial gauge needle:
90890-06584
Dial gauge stand set:
YW-06585/90890-06585
Dial gauge:
YU-03097/90890-01252
3-10
INSP
ADJ
POWER UNIT
E
4. Measure:
• Valve clearance
Out of specification → Adjust.
Valve clearance (cold):
Intake valve:
0.11–0.20 mm
(0.0043–0.0079 in)
Exhaust valve:
0.25–0.34 mm
(0.0098–0.0134 in)
EX
IN
Measurement steps:
• Turn the drive coupling counterclockwise,
and then check if cylinder #1 is at TDC of
the compression stroke with a dial gauge.
NOTE:
TDC on the compression stroke can be
found when the camshaft lobes are turned
away from each other.
• Measure the valve clearance with a thickness gauge 1.
NOTE:
• If the valve clearance is incorrect, record
the measured reading.
• Measure the valve clearance in the following sequence.
1
Valve clearance measuring sequence
Cylinder #1 → #2 → #4 → #3
È Bow side
• To measure the valve clearances of the
other cylinders, starting with cylinder #1
at TDC, turn the drive coupling counterclockwise as specified in the following
table.
É Degrees that the crankshaft is turned clockwise
Ê Cylinder
Ë Combustion cycle
É
0
#1
Ê
#2
180
360
540
Ë
Ë
Ë
#3
#4
720
Ë
3-11
Cylinder #2
180°
Cylinder #4
360°
Cylinder #3
540°
INSP
ADJ
POWER UNIT
E
5. Remove:
• Timing chain tensioner cap bolt 1
• Gasket
1
6. Turn the timing chain tensioner rod fully
clockwise with a thin screwdriver 1.
NOTE:
Make sure that the tensioner rod has been fully
set clockwise.
1
7. Remove:
• Intake camshaft caps
• Exhaust camshaft caps
• Timing chain
(from the camshaft sprockets)
• Intake camshaft
• Exhaust camshaft
NOTE:
• Refer to “CAMSHAFTS” in Chapter 5.
• When removing the timing chain and camshafts, fasten the timing chain with a wire to
prevent it from falling into the crankcase.
3-12
INSP
ADJ
POWER UNIT
E
8. Adjust:
• Valve clearance
Adjustment steps:
• Remove the valve lifter 1 and the valve
pad 2.
1
2
NOTE:
• Cover the timing chain opening with a rag
to prevent the valve pad from falling into
the crankcase.
• Make a note of the position of each valve
lifter 3 and valve pad 4 so that they can
be installed in the correct place.
• Select the proper valve pad from the following table.
Valve pad thickness
range
Nos.
120–240
Available valve
pads
1.20–
25 thicknesses in
2.40 mm 0.05 mm increments
NOTE:
• The thickness a of each valve pad is
marked in hundredths of millimeters on
the side that touches the valve lifter.
• Since valve pads of various sizes are originally installed, the valve pad number
must be rounded in order to reach the
closest equivalent to the original.
a
148
• Round off the original valve pad number
according to the following table.
Last digit
Rounded value
0 or 2
0
5
5
8
10
EXAMPLE:
Original valve pad number = 148 (thickness
= 1.48 mm)
Rounded value = 150
• Locate the rounded number of the original valve pad and the measured valve
clearance in the valve pad selection
table. The point where the column and
row intersect is the new valve pad number.
3-13
INSP
ADJ
POWER UNIT
E
NOTE:
The new valve pad number is only an
approximation. The valve clearance must
be measured again and the above steps
should be repeated if the measurement is
still incorrect.
6
5
• Install the new valve pad 5 and the valve
lifter 6.
NOTE:
• Lubricate the valve pad with molybdenum
disulfide grease.
• Lubricate the valve lifter with molybdenum
disulfide oil.
• The valve lifter must turn smoothly when
rotated by hand.
• Install the valve lifter and the valve pad in
the correct place.
• Install the exhaust and intake camshafts,
timing chain and camshaft caps.
T.
Camshaft cap bolt:
10 N • m (1.0 kgf • m, 7.2 ft • lb)
R.
NOTE:
• Refer to “Camshaft installation — CAMSHAFTS” in Chapter 5.
• Lubricate the camshafts, camshaft lobes
and camshaft journals.
• First, install the exhaust camshaft.
• Align the camshaft marks with the camshaft cap marks.
• Turn the crankshaft clockwise several full
turns to seat the parts.
• Measure the valve clearance again.
• If the valve clearance is still out of specification, repeat all of the valve clearance
adjustment steps until the specified clearance is obtained.
3-14
INSP
ADJ
POWER UNIT
E
Intake
MEASURED
CLEARANCE
0.00–0.02
0.03–0.07
0.08–0.10
0.11–0.20
0.21–0.22
0.23–0.27
0.28–0.32
0.33–0.37
0.38–0.42
0.43–0.47
0.48–0.52
0.53–0.57
0.58–0.62
0.63–0.67
0.68–0.72
0.73–0.77
0.78–0.82
0.83–0.87
0.88–0.92
0.93–0.97
0.98–1.02
1.03–1.07
1.08–1.12
1.13–1.17
1.18–1.22
1.23–1.27
1.28–1.32
1.33–1.37
120 125 130 135
120
120 125
120 125 130
140
125
130
135
145
130
135
140
150
135
140
145
155
140
145
150
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
120 125 130 135 140 145 150
120
120 125
120 125 130
120 125 130 135
120 125 130 135 140
120 125 130 135 140 145
155
125
130
135
140
145
150
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
ORIGINAL VALVE PAD NUMBER
165 170 175 180 185 190 195 200 205 210
150 155 160 165 170 175 180 185 190 195
155 160 165 170 175 180 185 190 195 200
160 165 170 175 180 185 190 195 200 205
STANDARD CLEARANCE
165 170 175 180 185 190 195 200 205 210 215
170 175 180 185 190 195 200 205 210 215 220
175 180 185 190 195 200 205 210 215 220 225
180 185 190 195 200 205 210 215 220 225 230
185 190 195 200 205 210 215 220 225 230 235
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
230 235 240
235 240
Example:
240
Intake valve clearance (cold)
160
145
150
155
215
200
205
210
220
205
210
215
225
210
215
220
230
215
220
225
235
220
225
230
220
225
230
235
240
225 230 235 240
230 235 240
235 240
240
240
225
230
235
0.11–0.20 mm (0.0043–0.0079 in)
Rounded value 150
Measured valve clearance is 0.24 mm (0.0094 in)
Replace pad 150 with pad 160
Pad No. 150 = 1.50 mm (0.0591 in)
Pad No. 160 = 1.60 mm (0.0630 in)
Exhaust
MEASURED
CLEARANCE
0.00–0.01
0.02–0.06
0.07–0.11
0.12–0.16
0.17–0.21
0.22–0.24
0.25–0.34
0.35–0.37
0.38–0.42
0.43–0.47
0.48–0.52
0.53–0.57
0.58–0.62
0.63–0.67
0.68–0.72
0.73–0.77
0.78–0.82
0.83–0.87
0.88–0.92
0.93–0.97
0.98–1.02
1.03–1.07
1.08–1.12
1.13–1.17
1.18–1.22
1.23–1.27
1.28–1.32
1.33–1.37
1.38–1.42
1.43–1.47
1.48–1.52
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
ORIGINAL VALVE PAD NUMBER
165 170 175 180 185 190 195 200 205 210 215
135 140 145 150 155 160 165 170 175 180 185
140 145 150 155 160 165 170 175 180 185 190
145 150 155 160 165 170 175 180 185 190 195
150 155 160 165 170 175 180 185 190 195 200
155 160 165 170 175 180 185 190 195 200 205
160 165 170 175 180 185 190 195 200 205 210
STANDARD CLEARANCE
165 170 175 180 185 190 195 200 205 210 215 220
170 175 180 185 190 195 200 205 210 215 220 225
175 180 185 190 195 200 205 210 215 220 225 230
180 185 190 195 200 205 210 215 220 225 230 235
185 190 195 200 205 210 215 220 225 230 235 240
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
230 235 240
235 240
Example:
240
Exhaust valve clearance (cold)
160
130
135
140
145
150
155
220
190
195
200
205
210
215
225
195
200
205
210
215
220
230
200
205
210
215
220
225
235
205
210
215
220
225
230
240
210
215
220
225
230
235
225 230 235 240
230 235 240
235 240
240
0.25–0.34 mm (0.0098–0.0134 in)
Rounded value 170
Measured valve clearance is 0.44 mm (0.0173 in)
Replace pad 170 with pad 185
Pad No. 170 = 1.70 mm (0.0669 in)
Pad No. 185 = 1.85 mm (0.0728 in)
3-15
INSP
ADJ
POWER UNIT
E
9. Remove:
• Dial gauge
• Dial gauge stand
• Dial gauge needle
10. Install:
• All removed parts
NOTE:
For installation, reverse the removal procedure.
Engine oil level check
1. Place the watercraft in a horizontal position.
2. Check:
• Engine oil level
Checking steps:
CAUTION:
• When checking the oil level in water,
stay clear of other boats. The watercraft could be drifted away by the current or wind.
• Do not run the engine for more than 15
seconds without supplying water,
when checking the oil level on land.
The engine could overheat.
• Do not run the engine with too much or
not enough oil in the oil tank. Oil could
spray out or the engine could be damaged.
3-16
INSP
ADJ
POWER UNIT
E
• Remove the oil filler cap 1 and check for
oil on the dipstick 2.
• If there is no oil on the dipstick, pour
enough oil so that the tip of the dipstick
comes into contact with the oil, and then
install the filler cap.
• In water
a. Place the watercraft in water, and then
start the engine.
b. Run the engine at 7,000 r/min or more
for more than 5 minutes.
c. Run the engine at trolling speed for 2–
3 minutes.
d. Stop the engine.
• On land
a. Connect the flushing hose connector to
the watercraft.
b. Start the engine, and then turn on the
water supply.
c. Run the engine at trolling speed for 6–
8 minutes.
d. Turn the water supply off, and then
stop the engine.
CAUTION:
When checking the oil level on land, be
sure to connect a garden hose to the
watercraft for proper water supply.
NOTE:
If the ambient temperature is less than
15 °C (59 °F), run the engine for an additional 5 minutes.
• Remove the oil filler cap 1, wipe the dipstick 2 clean, insert it back into the filler
hole, and then remove it again to check
the oil level.
NOTE:
The engine oil should be between the minimum level mark a and maximum level
mark b.
3-17
INSP
ADJ
POWER UNIT
E
• If the engine oil is below the minimum
level mark a, add sufficient oil of the recommended type to raise it to the correct
level.
• If the engine oil is above the maximum
level mark b, extract sufficient oil using
an oil changer to lower it to the correct
level.
NOTE:
If the oil temperature is low, the reading on
the dipstick will be low, and if the temperature is high, the reading on the dipstick will
be high.
Engine oil change — using oil changer
WARNING
Avoid changing the engine oil immediately
after turning the engine off. The oil is hot
and should be handled with care to avoid
burns.
CAUTION:
• Do not run the engine with too much or
not enough oil in the oil tank. Oil could
spray out or the engine could be damaged.
• Do not run the engine for more than 15
seconds without supplying water, when
checking the oil level on land.
The engine could overheat.
• Be sure to change the engine oil after the
first 10 hours of operation, and every 100
hours thereafter or at the start of a new
season, otherwise the engine will wear
quickly.
1. Warm the engine up, and then put the
watercraft in a horizontal position.
3-18
INSP
ADJ
POWER UNIT
E
2. Remove:
• Oil filler cap 1
1
3. Insert the tube of an oil changer into the oil
filler hole.
4. Operate the oil changer to extract the oil.
5. If the oil filter is also to be replaced, perform the following procedure.
Replacing steps:
• Place a rag under the oil filter.
• Remove the oil filter 1 with an oil filter
wrench 2.
1
2
Oil filter wrench:
YU-38411/90890-01426
• Lubricate the O-ring 3 of the new oil filter
with a thin coat of engine oil.
CAUTION:
Make sure the O-ring 3 is positioned
correctly in the groove of the oil filter.
• Tighten the new oil filter to specification
with an oil filter wrench.
T.
R.
3-19
Oil filter:
17 N • m (1.7 kgf • m, 12 ft • lb)
INSP
ADJ
POWER UNIT
E
6. Pour the specified amount of the recommended engine oil into the oil filler hole.
7. Fill:
• Oil tank
(with the specified amount of the recommended engine oil)
Recommended oil:
SAE 10W-30
API SE, SF, SG, SH, SJ
Oil quantity:
Total amount:
4.3 L (4.5 US qt, 3.8 Imp qt)
With oil filter replacement:
2.2 L (2.3 US qt, 1.9 Imp qt)
Without oil filter replacement:
2.0 L (2.1 US qt, 1.8 Imp qt)
CAUTION:
When starting the engine make sure the
dipstick is securely fitted into the oil tank.
8. Install:
• Oil filler cap
Air filter element clean
1. Remove:
• Air filter case cover 1
3-20
INSP
ADJ
POWER UNIT
E
2. Remove the air filter element and check it
for dirt and oil. Replace the air filter element if there is any oil buildup.
CAUTION:
• Make sure that the air filter element is
installed in the filter case properly.
• Do not start the engine with the air filter
element removed, otherwise the engine
could be damaged.
• If cleaning the air filter element, use cold
or lukewarm water and let it air dry completely. Do not use detergent or an solvent to clean the air filter element, or dry
it with heat or compressed air, otherwise
it could be damaged.
3. Install:
• Air filter case cover
T.
R.
Air filter case cover screw:
2.5 N • m (0.25 kgf • m, 1.8 ft • lb)
LOCTITE® 572
Spark plug inspection
1. Remove:
• Air filter case cover 1
2. Remove:
• Air filter element
CAUTION:
Be careful not to get any foreign substances or water in the air intake port and
spark plug hole.
3-21
INSP
ADJ
POWER UNIT
E
3. Inspect:
• Electrodes 1
Damage/wear → Replace.
• Insulator color 2
Distinctly different color → Check the
engine condition.
Color guide:
Medium to light tan color:
Normal
Whitish color:
Lean fuel mixture
Air leak
Incorrect settings
Blackish color:
Overly rich mixture
Electrical malfunction
Defective spark plug
4. Clean:
• Spark plug
(with a spark plug cleaner or wire brush)
5. Measure:
• Spark plug gap a
Out of specification → Regap.
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
6. Tighten:
• Spark plug
T.
Spark plug:
13 N • m (1.3 kgf • m, 9.4 ft • lb)
R.
NOTE:
• Before installing the spark plug, clean the
gasket surface and spark plug surface. Also,
it is suggested to apply a thin film of antiseize 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 finger tighten a the
spark plug and then tighten it another 1/4 to
1/2 of a turn b.
3-22
INSP
ADJ
POWER UNIT/ELECTRICAL
E
7. Install:
• Air filter element
• Air filter case cover
T.
R.
Air filter case cover screw:
2.5 N • m (0.25 kgf • m, 1.8 ft • lb)
LOCTITE® 572
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 CHILDREN.
CAUTION:
Be careful not to place the battery on its
side.
Make sure to remove the battery from the
battery compartment when adding battery
electrolyte or charging the battery.
When checking the battery, make sure the
breather hose is connected to the battery
and not obstructed.
3-23
INSP
ADJ
ELECTRICAL
1
E
1. Remove:
• Bands
• Battery negative lead 1
• Battery positive lead 2
• Battery
• Battery breather hose 3
2
3
WARNING
• When removing the battery, disconnect
the negative lead first.
• Remove the battery to prevent acid loss
during turning the machine on its side for
the impeller service.
2. Inspect:
• Electrolyte level
Low → Add distilled water.
The electrolyte level should be between
the upper a and lower b level marks.
Filling steps:
• Remove each filler cap.
• Add distilled water.
• When the electrolyte level reaches the
upper level mark, allow the cell to stand
for 20 minutes. If the electrolyte level
drops, add more distilled water so the
level reaches the upper level mark.
CAUTION:
Use only distilled water. Other types of
water contain minerals which are harmful
to batteries.
3-24
INSP
ADJ
ELECTRICAL
E
3. Inspect:
• Specific gravity
Out of specification → Charge.
Specific gravity at 20 °C (68 °F):
1.28
Charging current:
1.9 amps × 10 hrs
4. Install:
• Filler caps
CAUTION:
Before installation, rinse off any fluid from
the battery box and battery and make sure
that the battery is dry before installing it.
3
5. Install:
• Battery breather hose 1
• Battery
• Battery positive lead 2
• Battery negative lead 3
• Bands
2
1
CAUTION:
• Connect the positive lead to the battery
terminal first.
• Make sure 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.
3-25
INSP
ADJ
JET PUMP UNIT
E
JET PUMP UNIT
Impeller inspection
1. Check:
• Impeller 1
Damage/wear → Replace.
Nicks/scratches → File or grind.
2. Measure:
• Impeller-to-housing clearance a
Out of specification → Replace.
Max. impeller-to-housing
clearance:
0.6 mm (0.0236 in)
Measurement steps:
• Remove the battery leads.
• Remove the intake grate and intake duct.
Refer to “INTAKE GRATE, RIDE PLATE,
AND INTAKE DUCT” in Chapter 6.
• Measure the clearance at each impeller
blade as shown (a total of three measurements).
• Install the intake duct and intake grate.
Refer to “INTAKE GRATE, RIDE PLATE,
AND INTAKE DUCT” in Chapter 6.
• Install the battery leads.
3-26
INSP
ADJ
JET PUMP UNIT/BILGE PUMP
E
Water inlet strainer inspection
1. Inspect:
• Water inlet strainer
Contaminants → Clean.
Cracks/damage → Replace.
Inspection steps:
• Remove the ride plate.
Refer to “INTAKE GRATE, RIDE PLATE,
AND INTAKE DUCT” in Chapter 6.
• Remove the rubber plate.
Refer to “JET PUMP UNIT” in Chapter 6.
• Remove the water inlet cover 1.
• Inspect the water inlet strainer mesh a.
• Install the water inlet cover.
• Install the rubber plate.
Refer to “JET PUMP UNIT” in Chapter 6.
• Install the ride plate.
Refer to “INTAKE GRATE, RIDE PLATE,
AND INTAKE DUCT” in Chapter 6.
BILGE PUMP
Bilge strainer inspection
1. Inspect:
• Bilge strainer
Contaminants → Clean.
Cracks/damage → Replace.
1
Inspection steps:
• Remove the deck beam.
Refer to “SEATS AND HAND GRIP” in
Chapter 8.
• Remove the coupling cover.
• Disconnect the bilge strainer 1 from the
bilge strainer holder.
• Inspect the bilge strainer.
• Install the coupling cover.
• Install the deck beam.
Refer to “SEATS AND HAND GRIP” in
Chapter 8.
3-27
INSP
ADJ
BILGE PUMP/GENERAL
Electric bilge pump strainer inspection
1. Inspect:
• Cap
• Strainer
Contaminants → Clean.
Inspection steps:
• Remove the band 1.
• Remove the cap 2 and strainer 3.
• Inspect the cap and strainer.
• Install the strainer and cap.
• Install the band.
1
3
2
GENERAL
Drain plug inspection
1. Inspect:
• Drain plugs
Cracks/damage → Replace.
• O-rings
Cracks/wear → Replace.
• Screw threads
Contaminants → Clean.
3-28
E
INSP
ADJ
GENERAL
E
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.
2. Lubricate:
• Throttle cable (throttle body end)
Recommended lubricant:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
3. 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.
4. Lubricate:
• QSTS cables (pulley end)
Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
3-29
INSP
ADJ
GENERAL
E
5. Lubricate:
• Nozzle pivot shaft
• Steering cable (nozzle end)
• QSTS cable (nozzle end)
Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
6. Lubricate:
• Steering cable
• Steering cable joint
• Shift cable
• Shift cable joint
NOTE:
Disconnect the joints and apply a small
amount of grease.
Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
3-30
INSP
ADJ
GENERAL
E
7. Fill:
• Intermediate housing
1
Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
Grease quantity:
Initial 10 hours:
33.0–35.0 cm3 (1.11–1.18 oz)
Every 100 hours or 12 months:
6.0–8.0 cm3 (0.20–0.27 oz)
NOTE:
Fill the intermediate housing with the recommended grease through the grease nipple 1.
3-31
FUEL
E
CHAPTER 4
FUEL SYSTEM
FUEL TANK AND FUEL PUMP MODULE......................................................4-1
EXPLODED DIAGRAM .............................................................................4-1
REMOVAL AND INSTALLATION CHART ................................................ 4-1
SERVICE POINTS .................................................................................... 4-4
Fuel hose disconnection ..................................................................... 4-4
Fuel pump module removal.................................................................4-4
Fuel sender disassembly .................................................................... 4-4
Check valve inspection ....................................................................... 4-5
Rollover valve inspection .................................................................... 4-5
Fuel level sender inspection................................................................4-5
Fuel tank inspection ............................................................................4-5
Fuel hose inspection ...........................................................................4-5
Fuel pump filter inspection ..................................................................4-6
Fuel strainer inspection ....................................................................... 4-6
Fuel pump module installation ............................................................ 4-6
Fuel hose connect............................................................................... 4-6
FUEL INJECTION SYSTEM............................................................................4-7
EXPLODED DIAGRAM .............................................................................4-7
REMOVAL AND INSTALLATION CHART ................................................ 4-7
SERVICE POINTS .................................................................................. 4-16
Hose clamps removal........................................................................4-16
Hose clamps installation ................................................................... 4-16
Fuel hose disconnection ................................................................... 4-16
Fuel line inspection ...........................................................................4-17
Fuel hose installation (replacing with new fuel hose)........................ 4-18
Fuel hose connection ........................................................................4-18
Throttle body removal ....................................................................... 4-18
Fuel injector inspection ..................................................................... 4-19
Throttle body inspection .................................................................... 4-19
Throttle body installation ................................................................... 4-20
Throttle bodies synchronization ........................................................ 4-21
Fuel pressure measurement ............................................................. 4-26
1
2
3
4
5
6
7
8
9
FUEL
FUEL TANK AND FUEL PUMP MODULE
E
FUEL TANK AND FUEL PUMP MODULE
EXPLODED DIAGRAM
1st
4
9
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
3
6
1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)
2
17
18
16
7
10
1
2
8
11
13
5.9 N • m (0.59 kgf • m, 4.3 ft • Ib)
14
12
19
14
15
21
22
LT
572
4.2 N • m (0.42 kgf • m, 3.0 ft • Ib)
20
23
LT
572
16 N • m (1.6 kgf • m, 11 ft • Ib)
8 × 18 mm
REMOVAL AND INSTALLATION CHART
Step
1
2
3
Procedure/Part name
FUEL TANK REMOVAL
Service lid 1
Service lid 2
Ventilation hose
Engine unit
Rollover valve
Fuel tank breather hose
Check valve
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “FRONT HOOD” in Chapter 8.
From ventilation fitting
Refer to “ENGINE UNIT” in Chapter 5.
NOTE:
When removing the pump module only, it is
not necessary to remove the engine unit.
1
2
1
4-1
FUEL
FUEL TANK AND FUEL PUMP MODULE
E
EXPLODED DIAGRAM
1st
4
9
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
3
6
1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)
2
17
18
16
7
10
1
2
8
11
13
5.9 N • m (0.59 kgf • m, 4.3 ft • Ib)
14
12
19
14
15
21
22
LT
572
4.2 N • m (0.42 kgf • m, 3.0 ft • Ib)
20
23
LT
572
16 N • m (1.6 kgf • m, 11 ft • Ib)
8 × 18 mm
Step
4
5
6
7
8
9
10
11
12
Procedure/Part name
Fuel tank breather hose
Fuel sender coupler
Fuel pump module coupler
Cover
Fuel hose
Nut
Retainer
Fuel pump module
Packing
Q’ty
1
1
1
1
1
9
1
1
1
4-2
Service points
NOTE:
Make sure that the inner seal of the coupler
is installed properly before connecting the
coupler.
FUEL
FUEL TANK AND FUEL PUMP MODULE
E
EXPLODED DIAGRAM
1st
4
9
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
3
6
1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)
2
17
18
16
7
10
1
2
8
11
13
5.9 N • m (0.59 kgf • m, 4.3 ft • Ib)
14
12
19
14
15
21
22
LT
572
4.2 N • m (0.42 kgf • m, 3.0 ft • Ib)
20
23
LT
572
16 N • m (1.6 kgf • m, 11 ft • Ib)
8 × 18 mm
Step
13
14
15
16
17
18
19
20
21
22
23
Procedure/Part name
Fuel sender assembly
Hose clamp
Fuel filler hose
Nut
Fuel filler neck
Rubber seal
Bolt
Fuel tank assembly
Strainer
Bolt
Fuel tank belt
Q’ty
1
2
1
1
1
1
2
1
1
2
2
Service points
Reverse the removal steps for installation.
4-3
FUEL
FUEL TANK AND FUEL PUMP MODULE
E
SERVICE POINTS
Fuel hose disconnection
1. Disconnect:
• Fuel hose
Refer to “FUEL INJECTION SYSTEM”.
8
7
3
2
Fuel pump module removal
1. Remove:
• Nuts
• Retainer
5
NOTE:
Loosen the nuts in the sequence shown.
1
6
9
4
2. Remove:
• Fuel pump module 1
1
NOTE:
Remove the float 2 at an angle because it
could catch on the fuel tank.
2
Fuel sender disassembly
1. Disconnect:
• Fuel sender coupler
a
2. Remove:
• Retainer 1
b
NOTE:
Push the tabs in direction of arrows a and
slide the retainer 1 in direction of arrow b.
a1
3. Remove:
• Fuel sender
a
NOTE:
Push the tabs a and remove the fuel level
sender 2 in the direction of the arrow b.
b
a
2
4-4
FUEL
FUEL TANK AND FUEL PUMP MODULE
A
B
A
B
A
B
A
B
E
Check valve inspection
1. Check:
• Check valve
Faulty → Replace.
Checking steps:
• Connect a hose to the end of check valve
“A” and blow into it.
Air should come out from end “B”.
• Connect the hose to the end of check
valve “B” and blow into it.
Air should not come out from end “A”.
Rollover valve inspection
1. Check:
• Rollover valve
Faulty → Replace.
Checking steps:
• Connect a hose to the end of rollover
valve “A” and blow into it.
Air should come out from end “B”.
• Connect the hose to the end of rollover
valve “B” and blow into it.
Air should not come out from end “A”.
Fuel level sender inspection
Refer to “FUEL CONTROL SYSTEM” in
Chapter 7.
Fuel tank inspection
1. Inspect:
• Fuel tank
Cracks/damage → Replace.
Fuel hose inspection
Refer to “FUEL INJECTION SYSTEM”.
4-5
FUEL
FUEL TANK AND FUEL PUMP MODULE
E
Fuel pump filter inspection
1. Inspect:
• Fuel pump filter 1
Clog/contaminants → Wash the fuel
pump filter in kerosene or gasoline.
1
Fuel strainer inspection
1. Inspect:
• Fuel strainer
Clog/contaminants → Clean.
2
3
7
5
T.
8
Fuel pump module installation
1. Tighten:
• Nuts
4
1
R.
9
6
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.
Fuel hose connect
Refer to “FUEL INJECTION SYSTEM”.
4-6
FUEL
FUEL INJECTION SYSTEM
E
FUEL INJECTION SYSTEM
EXPLODED DIAGRAM
3.3 N • m (0.33 kgf • m, 2.4 ft • Ib)
2nd 6.5 N • m (0.65 kgf • m, 4.7 ft • Ib)
6 × 7 mm
4
1st
2.5 N • m (0.25 kgf • m, 1.8 ft • Ib)
5 × 70 mm
1
2
LT
LT
572
5
242
6
16
22
3
E
18
17
21
20
20 19
11 N • m (1.1 kgf • m, 8.0 ft • Ib)
2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)
8 × 50 mm
1st
12
7
13
LT
8
572
10
14
LT
A
15
572
9
11
4 × 8 mm
1st 1.7 N • m (0.17 kgf • m, 1.2 ft • Ib)
2nd 3.3 N • m (0.33 kgf • m, 2.4 ft • Ib)
6 × 14 mm
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)
1st
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
Procedure/Part name
THROTTLE BODIES REMOVAL
Screw
Air filter case cover
Air filter
Bolt
Flame arrester
6
Spring
Q’ty
2
1
1
4
1
4
4-7
Service points
Follow the left “Step” for removal.
NOTE:
When removing the flame arrester, slide the
springs off.
FUEL
FUEL INJECTION SYSTEM
E
EXPLODED DIAGRAM
3.3 N • m (0.33 kgf • m, 2.4 ft • Ib)
2nd 6.5 N • m (0.65 kgf • m, 4.7 ft • Ib)
6 × 7 mm
4
1st
2.5 N • m (0.25 kgf • m, 1.8 ft • Ib)
5 × 70 mm
1
2
LT
LT
572
5
242
6
16
22
3
E
18
17
21
20
20 19
11 N • m (1.1 kgf • m, 8.0 ft • Ib)
2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)
8 × 50 mm
1st
12
7
13
LT
8
572
10
14
LT
A
15
572
9
11
4 × 8 mm
1st 1.7 N • m (0.17 kgf • m, 1.2 ft • Ib)
2nd 3.3 N • m (0.33 kgf • m, 2.4 ft • Ib)
Step
7
8
9
10
11
12
13
14
15
16
Procedure/Part name
Throttle cable
Bolt
Throttle cable holder
Cover
Fuel hose
Bolt
Fuel hose holder
Clamp
Clamp
Bolt
6 × 14 mm
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)
1st
Q’ty
1
2
1
1
1
2
1
1
1
8
4-8
Service points
Not reusable
FUEL
FUEL INJECTION SYSTEM
E
EXPLODED DIAGRAM
3.3 N • m (0.33 kgf • m, 2.4 ft • Ib)
2nd 6.5 N • m (0.65 kgf • m, 4.7 ft • Ib)
6 × 7 mm
4
1st
2.5 N • m (0.25 kgf • m, 1.8 ft • Ib)
5 × 70 mm
1
2
LT
LT
572
5
242
6
16
22
3
E
18
17
21
20
20 19
11 N • m (1.1 kgf • m, 8.0 ft • Ib)
2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)
8 × 50 mm
1st
12
7
13
LT
8
572
10
14
LT
A
15
572
9
11
4 × 8 mm
1st 1.7 N • m (0.17 kgf • m, 1.2 ft • Ib)
2nd 3.3 N • m (0.33 kgf • m, 2.4 ft • Ib)
Step
17
18
19
20
21
22
Procedure/Part name
Throttle bodies
Intake air pressure sensor coupler
Intake air temperature sensor
coupler
Fuel injector coupler
Throttle position sensor coupler
Joint connector
6 × 14 mm
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)
1st
Q’ty
1
1
1
Service points
4
1
2
Reverse the removal steps for installation.
4-9
FUEL
FUEL INJECTION SYSTEM
E
EXPLODED DIAGRAM
1st
7
8.8 N • m (0.88 kgf • m, 6.4 ft • Ib)
2nd 18 N • m (1.8 kgf • m, 13 ft • Ib)
8 × 35 mm
9
6
13
8
LT
1st
12
242
15 N • m (1.5 kgf • m, 11 ft • Ib)
9
2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)
8 × 16 mm
LT
11
572
25
23
10
17
24
1st
18
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
4
LT
2
5
271
14
15
LT
242
3
6 × 16 mm
kgf
m,
2.7 ft • Ib)
3.8 N • m (0.38
•
1
16
20
21
5 × 14 mm
1.8 N • m (0.18 kgf • m, 1.3 ft • Ib)
LT
572
LT
271
19
6 × 16 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)
22
8 × 16 mm
1st 15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)
3.4 N • m (0.34 kgf • m, 2.5 ft • Ib)
5 × 14 mm
5 × 14 mm
2.5 N • m (0.25 kgf • m, 1.8 ft • Ib)
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
Procedure/Part name
AIR FILTER CASE REMOVAL
Throttle bodies
Clamp/breather hose
Band
Lighting coil coupler
Thermoswitch coupler (engine)
Pulser coil coupler
Thermoswitch coupler (exhaust)
Camshaft position sensor coupler
Q’ty
1/1
1
1
1
1
1
1
4-10
Service points
Follow the left “Step” for removal.
Unfasten the wire harness.
From wire harness bracket 2
From wire harness bracket 2
From wire harness bracket 2
From wire harness bracket 1
From wire harness bracket 1
FUEL
FUEL INJECTION SYSTEM
E
EXPLODED DIAGRAM
1st
7
8.8 N • m (0.88 kgf • m, 6.4 ft • Ib)
2nd 18 N • m (1.8 kgf • m, 13 ft • Ib)
8 × 35 mm
9
6
13
8
LT
1st
12
242
15 N • m (1.5 kgf • m, 11 ft • Ib)
9
2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)
8 × 16 mm
LT
11
572
25
23
10
17
24
1st
18
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
4
LT
2
5
271
14
15
LT
242
3
1
16
271
19
Procedure/Part name
Wire harness coupler
Bolt
Air filter case
Bolt
Wire harness bracket 1
Sub wire harness
Bolt
Fuel hose bracket
Screw
Wire harness bracket 2
20
5 × 14 mm
1.8 N • m (0.18 kgf • m, 1.3 ft • Ib)
LT
6 × 16 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)
22
21
LT
572
Step
8
9
10
11
12
13
14
15
16
17
6 × 16 mm
kgf
m,
2.7 ft • Ib)
3.8 N • m (0.38
•
8 × 16 mm
1st 15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)
3.4 N • m (0.34 kgf • m, 2.5 ft • Ib)
5 × 14 mm
5 × 14 mm
2.5 N • m (0.25 kgf • m, 1.8 ft • Ib)
Q’ty
1
3
1
2
1
1
2
1
1
1
4-11
Service points
FUEL
FUEL INJECTION SYSTEM
E
EXPLODED DIAGRAM
1st
7
8.8 N • m (0.88 kgf • m, 6.4 ft • Ib)
2nd 18 N • m (1.8 kgf • m, 13 ft • Ib)
8 × 35 mm
9
6
13
8
LT
1st
12
242
15 N • m (1.5 kgf • m, 11 ft • Ib)
9
2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)
8 × 16 mm
LT
11
572
25
23
10
17
24
1st
18
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
4
LT
2
5
271
14
15
LT
242
3
1
16
271
19
Procedure/Part name
Grommet
Throttle body joint
Band
Bolt
Air filter case stay 1
Band
Bolt
Air filter case stay 2
20
5 × 14 mm
1.8 N • m (0.18 kgf • m, 1.3 ft • Ib)
LT
6 × 16 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)
22
21
LT
572
Step
18
19
20
21
22
23
24
25
6 × 16 mm
kgf
m,
2.7 ft • Ib)
3.8 N • m (0.38
•
8 × 16 mm
1st 15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)
3.4 N • m (0.34 kgf • m, 2.5 ft • Ib)
5 × 14 mm
5 × 14 mm
2.5 N • m (0.25 kgf • m, 1.8 ft • Ib)
Q’ty
1
4
2
2
2
1
1
1
Service points
Reverse the removal steps for installation.
4-12
FUEL
FUEL INJECTION SYSTEM
E
EXPLODED DIAGRAM
5 × 7 mm
3.5 N • m (0.35 kgf • m, 2.5 ft • Ib)
5 × 15 mm
3.5
N • m (0.35 kgf • m, 2.5 ft • Ib)
17
18
5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)
6 × 50 mm
1
8
2
9
3.5 N • m (0.35 kgf • m, 2.5 ft • Ib)
2
5 × 15 mm
10 1
15 N • m (1.5 kgf • m, 11 ft • Ib)
3
14
11
15
16
6 × 10 mm
5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)
23
21
5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)
6 × 9 mm
24
25
26
27
12
13
22
7
6
23
4
28
20
29
30
31
19
2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
6 × 9 mm
4 × 12 mm
5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)
5
4
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
Procedure/Part name
THROTTLE BODY
DISASSEMBLY
Screw/washer
Spacer
Fuel rail
Intake vacuum hose
Joint
Injector
Grommet
Screw
Intake air pressure sensor
Nut
Q’ty
3/3
3
1
3
1
4
4
2
1
1
4-13
Service points
Follow the left “Step” for disassembly.
Not reusable
FUEL
FUEL INJECTION SYSTEM
E
EXPLODED DIAGRAM
5 × 7 mm
3.5 N • m (0.35 kgf • m, 2.5 ft • Ib)
5 × 15 mm
3.5
N • m (0.35 kgf • m, 2.5 ft • Ib)
17
18
5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)
6 × 50 mm
1
8
2
9
3.5 N • m (0.35 kgf • m, 2.5 ft • Ib)
2
5 × 15 mm
10 1
15 N • m (1.5 kgf • m, 11 ft • Ib)
3
14
11
15
16
6 × 10 mm
5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)
23
21
5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)
6 × 9 mm
24
25
26
27
12
13
22
7
6
23
4
28
20
29
30
31
19
2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
6 × 9 mm
4 × 12 mm
5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)
Step
11
12
13
14
15
16
17
18
19
20
21
22
Procedure/Part name
Intake air temperature sensor
Screw
Bracket 1
Screw
Fuel pipe
O-ring
Screw
Bracket 2
Screw
Throttle stop guide
Screw
Throttle stop screw bracket
Q’ty
1
1
1
2
1
1
2
1
2
1
2
1
4-14
5
4
Service points
Not reusable
FUEL
FUEL INJECTION SYSTEM
E
EXPLODED DIAGRAM
5 × 7 mm
3.5 N • m (0.35 kgf • m, 2.5 ft • Ib)
5 × 15 mm
3.5
N • m (0.35 kgf • m, 2.5 ft • Ib)
17
18
5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)
6 × 50 mm
1
8
2
9
3.5 N • m (0.35 kgf • m, 2.5 ft • Ib)
2
5 × 15 mm
10 1
15 N • m (1.5 kgf • m, 11 ft • Ib)
3
14
11
15
16
6 × 10 mm
5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)
23
21
5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)
6 × 9 mm
24
25
26
27
12
13
22
7
6
23
4
28
20
29
30
31
19
2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
6 × 9 mm
4 × 12 mm
5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)
Step
23
24
25
26
27
28
29
30
31
Procedure/Part name
Screw/spring
Bypass air screw
Spring
Washer
O-ring
Screw
Throttle position sensor
O-ring
Throttle bodies
Q’ty
4/4
4
4
4
4
2
1
1
1
5
4
Service points
Not reusable
Not reusable
Reverse the disassembly steps for
assembly.
4-15
FUEL
FUEL INJECTION SYSTEM
E
SERVICE POINTS
Hose clamps removal
1. Remove:
• Hose clamps
CAUTION:
If the hose clamps are removed without
cutting the joint first, the fuel hose will be
damaged.
Hose clamps 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.
Fuel hose disconnection
WARNING
Before disconnecting the hose, remove the
fuel tank filler cap to reduce any pressure
inside the fuel tank, and then disconnect
the battery negative 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.
1
WARNING
2
If the quick connector is removed suddenly, pressurized fuel could spray out. To
gradually release the fuel pressure, be sure
to remove the quick connector slowly.
a
4-16
FUEL
FUEL INJECTION SYSTEM
E
CAUTION:
• Do not rotate the quick connector tab 1
past the stopper position a, otherwise it
could be damaged.
• When the fuel hoses are disconnected,
quickly remove the retainer 2 from the
quick connector, otherwise the retainer
could be lost.
2. Disconnect the fuel hose 1 from the fuel
pipe 2 directly.
1
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 could spray out.
2
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. Inspect:
• Fuel hose
Damage/cracks → Replace.
• O-rings (quick connector)
Damage/cracks → Replace the quick
connector.
• Fuel pipe
Damage/cracks → Replace the fuel
pump.
4-17
FUEL
FUEL INJECTION SYSTEM
Fuel hose installation (replacing with new
fuel hose)
1. Install:
• Fuel hose 1
a
2
E
NOTE:
• To install the fuel hose, be sure to align the
white mark a of the fuel hose with the
checker tab 2 of the quick connector.
• 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.
1
2
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 is not obtained, disconnect the fuel hose
and check the O-ring for damage and that it is
properly installed.
Throttle body removal
1. Remove:
• Throttle body
1
CAUTION:
Do not bend the fuel pipe 1.
4-18
FUEL
FUEL INJECTION SYSTEM
E
Fuel injector inspection
CAUTION:
The throttle bodies should not be disassembled unnecessarily.
1. Check:
• Injector
Dirt/residue → Clean.
Damage → Replace.
2. Measure:
• Fuel injectors resistance
Out of specification → Replace.
Digital circuit tester:
YU-34899-A/90890-03174
Fuel injector resistance:
14.0–15.0 Ω at 20 °C (68 °F)
3. Check the operation of the fuel injector
using the “Stationary Test” of the Yamaha
Diagnostic System.
Throttle body inspection
1. Check:
• Throttle body
Cracks/damage → Replace the throttle
bodies.
4-19
FUEL
FUEL INJECTION SYSTEM
E
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.
Throttle body installation
1. Install:
• Throttle body
1
CAUTION:
Do not bend the fuel pipe 1.
2. Install:
• Fuel hose 1 (throttle body side)
• Clamp
a
NOTE:
Install the fuel hose with the white mark a facing up.
1
3. Adjust:
• Throttle lever free play
Refer to “CONTROL SYSTEM” in Chapter 3.
4-20
FUEL
FUEL INJECTION SYSTEM
E
Throttle bodies synchronization
1. Remove:
• Throttle bodies
• Air filter case
2. Adjust:
• Throttle bodies synchronization
Adjustment steps:
NOTE:
The bypass air screw 1 should not be
adjusted. However, if it is necessary to
remove the bypass air screw, be sure to
note the number of times the screw is
turned from its set position. When installing
the screw, be sure to tighten the screw the
same number of turns as noted at removal.
If the number of turns is not known, turn the
screw approximately 2.5 times counterclockwise from the fully closed position.
CAUTION:
Do not start the engine when removing
the fuel hose. Fuel can spurt out when
the fuel pump is operated.
a. Loosen the throttle stop screw 2 and
synchronizing screws #1 3, #2 4, and
#3 5 until released from the levers.
NOTE:
• Only butterfly valve #2 should be fully
closed and the other valves should be
halfway closed.
• Check the valve for light leaks with a
flashlight. If there are no light leaks, the
valve is fully closed.
b. Turn synchronizing screw #2 4 clockwise approximately 7 times until it starts
to contact the lever.
NOTE:
• Butterfly valves #2 and #3 should be fully
closed. Butterfly valve #2 opens if the
screw is turned more than 7 times.
• If butterfly valves #2 and #3 are not fully
closed, close the valves by adjusting synchronizing screw #2 4.
4-21
FUEL
FUEL INJECTION SYSTEM
E
c. Turn synchronizing screw #1 3 clockwise approximately 7 times until it starts
to contact the lever.
NOTE:
• Butterfly valve #1 should be fully closed.
Butterfly valves #2 and #3 open if the
screw is turned more than 7 times.
• If butterfly valves #1, #2, and #3 are not
fully closed, close the valves by adjusting
synchronizing screw #1 3.
d. Turn synchronizing screw #3 5 clockwise approximately 7 times until it starts
to contact the lever.
NOTE:
• Butterfly valve #4 should be fully closed.
Butterfly valves #1, #2, and #3 open if the
screw is turned more than 7 times.
• If all butterfly valves are not fully closed,
close the valves by adjusting synchronizing screw #3 5.
e. Check that all butterfly valves are fully
closed and that they open simultaneously.
#1
#3
#2
#4
NOTE:
If all butterfly valves are not fully closed,
close the valves by repeating steps a–d.
6
f. Turn the throttle stop screw 2 clockwise
approximately 1.5 times until it starts to
contact the throttle lever.
g. Remove the plugs 6.
h. Install the carburetor synchronizer 7 or
vacuum gauge 8.
È
7
Carburetor synchronizer:
YU-08030
Vacuum gauge:
90890-03094
É
8
4-22
FUEL
FUEL INJECTION SYSTEM
E
NOTE:
For best results, use a vacuum gauge
(commercially obtainable), like 9 or 0
shown in the illustration, that has four
adapters.
0
9
È For USA and Canada
É For worldwide
i. Install the throttle bodies.
NOTE:
Adjust the throttle body synchronization
with the air filter case uninstalled.
j. Connect the fuel hose and clamp.
k. Connect the Yamaha Diagnostic System.
l. Remove the sub wire harness from the
air filter case, and then connect it to the
throttle bodies and main wire harness.
m. Connect the test harness (3 pin) to the
throttle position sensor A.
A
Test harness (3 pins):
YB-06793/90890-06793
n. To start the ECM normally, start the
Yamaha Diagnostic System.
B/O
CAUTION:
If the Yamaha Diagnostic System and
ECU are started, fuel can spurt out. Be
sure to connect the fuel hoses and throttle bodies when adjusting the throttle
position sensor.
P
B
NOTE:
Use the test connector B to start the ECU
normally only if the Yamaha Diagnostic
System is not available.
Test connector:
YW-06862/90890-06862
o. Measure the throttle position sensor output voltage (DC). Adjust the throttle position sensor A position if out of
specification.
4-23
FUEL
FUEL INJECTION SYSTEM
E
Throttle position sensor output
voltage:
Pink (P) – Black/Orange (B/O)
0.8 ± 0.1 V
NOTE:
• To decrease the output voltage, turn the
throttle position sensor clockwise.
• Slightly tighten the throttle position screw.
p. Start the engine and let it run at trolling
speed for 20 minutes.
NOTE:
• Warm the engine up in the water.
• While checking the engine temperature
with the Yamaha Diagnostic System,
warm the engine up until the engine temperature is 50 °C (122 °F).
q. Adjust the throttle stop screw 2 until
trolling speed is within specification.
1,740
1,720
r/min
1,700
1,680
Trolling speed:
1,660
1,640
1,620
1,600
0
5
10
15
20
25 30
35 40 45
50
˚C
Season
Temperature
Specified
engine speed
Summer
30 °C (86 °F)
or more
1,650 r/min
Winter
10 °C (50 °F)
or less
1,720 r/min
Spring/
Fall
20 °C (68 °F)
1,680 r/min
r. Adjust each cylinder to the cylinder differences shown in the table using synchronizing screws 3–5 and using
cylinder #2 as the standard.
4-24
FUEL
FUEL INJECTION SYSTEM
E
Vacuum pressure at trolling
speed:
Cylinder
difference
Cylinder
#1
Example
–30 ± 10 mmHg –210 ± 10 mmHg
(–4.00 ±
(–27.99 ±
1.33 kPa,
1.33 kPa,
–1.2 ± 0.4 inHg) –8.3 ± 0.4 inHg)
#2
Standard*0
–180 mmHg
(–23.99 kPa,
–7.1 inHg)
#3
0 ± 10 mmHg
(0 ± 1.33 kPa,
0 ± 0.4 inHg)
–180 ± 10 mmHg
(–23.99 ±
1.33 kPa,
–7.1 ± 0.4 inHg)
#4
–20 ± 10 mmHg –200 ± 10 mmHg
(–2.67 ±
(–26.66 ±
1.33 kPa,
1.33 kPa,
–0.8 ± 0.4 inHg) –7.8 ± 0.4 inHg)
Standard*: When setting the specified
engine speed, the value is zero.
NOTE:
Always maintain the specified trolling speed
when making this adjustment.
s. Measure the throttle position sensor output voltage. Adjust the throttle position
sensor A position if out of specification.
Throttle position sensor output
voltage:
Pink (P) – Black/Orange (B/O)
0.760 ± 0.016 V
3. Remove:
• Throttle bodies
• Air filter case
4. Remove:
• Carburetor synchronizer or vacuum
gauge
5. Install:
• Plugs
6. Install:
• Air filter case
• Throttle bodies
4-25
FUEL
FUEL INJECTION SYSTEM
E
Fuel pressure measurement
1. Disconnect:
• Fuel hose
Refer to “Fuel hose disconnection”.
2
2. Install:
• Fuel pressure gauge adapter 1
• Fuel pressure gauge 2
1
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”.)
3. Start the engine and arrow it to warm up
for several minutes.
4. Measure:
• Fuel pressure
Out of specification → Replace the fuel
pump module.
Fuel pressure:
310–330 kPa
(3.1–3.3 kgf/cm2, 45–47 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”.
4-26
POWR
E
CHAPTER 5
POWER UNIT
ENGINE UNIT .................................................................................................. 5-1
EXPLODED DIAGRAM ............................................................................. 5-1
REMOVAL AND INSTALLATION CHART ................................................ 5-1
SERVICE POINTS .................................................................................... 5-4
Compression pressure measurement ................................................. 5-4
Oil filter removal and installation ......................................................... 5-6
Engine unit removal ............................................................................ 5-6
Shim removal ...................................................................................... 5-7
Engine mount inspection..................................................................... 5-7
Coupling clearance inspection ............................................................ 5-7
EXHAUST PIPE 3............................................................................................ 5-8
EXPLODED DIAGRAM ............................................................................. 5-8
REMOVAL AND INSTALLATION CHART ................................................ 5-8
EXHAUST PIPES 1 AND 2............................................................................ 5-11
EXPLODED DIAGRAM ........................................................................... 5-11
REMOVAL AND INSTALLATION CHART .............................................. 5-11
EXHAUST MANIFOLD .................................................................................. 5-13
EXPLODED DIAGRAM ........................................................................... 5-13
REMOVAL AND INSTALLATION CHART .............................................. 5-13
OIL TANK ...................................................................................................... 5-15
EXPLODED DIAGRAM ........................................................................... 5-15
REMOVAL AND INSTALLATION CHART .............................................. 5-15
SERVICE POINTS .................................................................................. 5-22
Oil tank removal ................................................................................ 5-22
Oil strainer inspection........................................................................ 5-23
Oil tank installation ............................................................................ 5-23
POWR
OIL PUMP...................................................................................................... 5-26
EXPLODED DIAGRAM ........................................................................... 5-26
REMOVAL AND INSTALLATION CHART .............................................. 5-26
SERVICE POINTS .................................................................................. 5-27
Oil pump removal .............................................................................. 5-27
Oil pump inspection........................................................................... 5-27
Oil strainer inspection........................................................................ 5-27
Oil pump installation.......................................................................... 5-28
REDUCTION DRIVE GEAR .......................................................................... 5-29
EXPLODED DIAGRAM ........................................................................... 5-29
REMOVAL AND INSTALLATION CHART .............................................. 5-29
SERVICE POINTS .................................................................................. 5-34
Drive coupling removal...................................................................... 5-34
Drive shaft removal ........................................................................... 5-34
Oil pump driven gear inspection........................................................ 5-34
Relief valve inspection ...................................................................... 5-34
Drive shaft installing .......................................................................... 5-35
Drive coupling installation ................................................................. 5-35
GENERATOR AND STARTER MOTOR ....................................................... 5-36
EXPLODED DIAGRAM ........................................................................... 5-36
REMOVAL AND INSTALLATION CHART ............................................. 5-36
SERVICE POINTS .................................................................................. 5-41
Flywheel magneto removal ............................................................... 5-41
Starter clutch inspection.................................................................... 5-41
Flywheel magneto installation ........................................................... 5-43
CAMSHAFTS................................................................................................. 5-44
EXPLODED DIAGRAM ........................................................................... 5-44
REMOVAL AND INSTALLATION CHART .............................................. 5-44
SERVICE POINTS .................................................................................. 5-49
Camshaft removal ............................................................................. 5-49
Camshaft inspection.......................................................................... 5-50
Camshaft sprockets inspection ......................................................... 5-52
Timing chain tensioner inspection..................................................... 5-52
Camshaft installation......................................................................... 5-53
E
1
2
3
4
5
6
7
8
9
POWR
CYLINDER HEAD.......................................................................................... 5-57
EXPLODED DIAGRAM ........................................................................... 5-57
REMOVAL AND INSTALLATION CHART ............................................. 5-57
SERVICE POINTS .................................................................................. 5-59
Cylinder head removal ...................................................................... 5-59
Cylinder head inspection................................................................... 5-59
Cylinder head installation .................................................................. 5-60
VALVES AND VALVE SPRINGS.................................................................. 5-62
EXPLODED DIAGRAM ........................................................................... 5-62
REMOVAL AND INSTALLATION CHART ............................................. 5-62
SERVICE POINTS .................................................................................. 5-64
Valve removal ................................................................................... 5-64
Valve spring inspection ..................................................................... 5-65
Valve inspection ................................................................................ 5-65
Valve guide inspection ...................................................................... 5-66
Valve guide replacement................................................................... 5-67
Valve seat inspection ........................................................................ 5-69
Valve seat reface .............................................................................. 5-70
Valve installation ............................................................................... 5-72
CRANKCASE ................................................................................................ 5-74
EXPLODED DIAGRAM ........................................................................... 5-74
REMOVAL AND INSTALLATION CHART .............................................. 5-74
SERVICE POINTS .................................................................................. 5-79
Crankcase disassembly .................................................................... 5-79
Crankcase inspection........................................................................ 5-80
Timing chain inspection..................................................................... 5-80
Crankcase assembly......................................................................... 5-80
CONNECTING RODS AND PISTONS .......................................................... 5-84
EXPLODED DIAGRAM ........................................................................... 5-84
REMOVAL AND INSTALLATION CHART .............................................. 5-84
SERVICE POINTS .................................................................................. 5-86
Connecting rod and piston removal .................................................. 5-86
Cylinder and piston inspection .......................................................... 5-87
Piston ring inspection ........................................................................ 5-88
Piston pin inspection ......................................................................... 5-89
Connecting rod inspection................................................................. 5-91
Connecting rod and piston installation .............................................. 5-93
E
POWR
CRANKSHAFT .............................................................................................. 5-97
EXPLODED DIAGRAM ........................................................................... 5-97
REMOVAL AND INSTALLATION CHART .............................................. 5-97
SERVICE POINTS .................................................................................. 5-98
Crankshaft removal ........................................................................... 5-98
Crankshaft inspection........................................................................ 5-98
Crankshaft installation.....................................................................5-101
THERMOSTAT ............................................................................................5-102
EXPLODED DIAGRAM .........................................................................5-102
REMOVAL AND INSTALLATION CHART ............................................5-102
SERVICE POINTS ................................................................................5-104
Thermostat inspection.....................................................................5-104
Thermostat installation ....................................................................5-104
PRESSURE CONTROL VALVE..................................................................5-105
EXPLODED DIAGRAM .........................................................................5-105
REMOVAL AND INSTALLATION CHART ............................................5-105
SERVICE POINTS ................................................................................5-109
Pressure control valve inspection ...................................................5-109
E
POWR
ENGINE UNIT
E
ENGINE UNIT
EXPLODED DIAGRAM
7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)
6 × 25 mm
11
4
LT
12
6
572
10
3
7
17 N • m (1.7 kgf • m, 12 ft • Ib)
8 × 40 mm
LT
17 N • m (1.7 kgf • m, 12 ft • Ib)
8 × 28 mm
15
2
13
LT
572
271
9
9
8
1
5
14
9
17 N • m (1.7 kgf • m, 12 ft • Ib)
REMOVAL AND INSTALLATION CHART
Step
Procedure/Part name
ENGINE UNIT REMOVAL
Engine oil
Q’ty
Service lid 1
Battery negative and positive lead
Throttle cable and fuel hose
1
2
Water lock and exhaust joint
Oil filter
Bolt
1
4
5-1
Service points
Follow the left “Step” for removal.
Drain.
Refer to “POWER UNIT” in Chapter 3.
Refer to “FRONT HOOD” in Chapter 8.
Refer to “ELECTRICAL BOX AND
IGNITION COIL BOX” in Chapter 7.
Refer to “FUEL INJECTION SYSTEM” in
Chapter 4.
Refer to “EXHAUST SYSTEM” in Chapter 8.
POWR
ENGINE UNIT
E
EXPLODED DIAGRAM
7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)
6 × 25 mm
11
4
LT
12
6
572
10
17 N • m (1.7 kgf • m, 12 ft • Ib)
8 × 40 mm
LT
17 N • m (1.7 kgf • m, 12 ft • Ib)
8 × 28 mm
3
7
15
2
13
LT
572
271
9
9
8
1
5
14
9
Step
3
4
5
6
7
8
9
10
11
12
Procedure/Part name
Electrical box
Clamp/cooling water hose
Clamp/cooling water hose
Clamp/cooling water hose
Clamp/cooling water hose
Clamp/cooling water hose
Coupler
Grease hose
Bolt/collar
Coupling cover
Q’ty
1
1/1
1/1
1/1
1/1
1/1
5
1
1/1
1
5-2
17 N • m (1.7 kgf • m, 12 ft • Ib)
Service points
Cooling water pilot outlet
Cooling water pilot outlet
Cooling water outlet
Cooling water outlet
Cooling water inlet
POWR
ENGINE UNIT
E
EXPLODED DIAGRAM
7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)
6 × 25 mm
11
4
LT
12
6
572
10
17 N • m (1.7 kgf • m, 12 ft • Ib)
8 × 40 mm
LT
17 N • m (1.7 kgf • m, 12 ft • Ib)
8 × 28 mm
3
7
15
2
13
LT
572
271
9
9
8
1
5
14
9
Step
13
14
15
Procedure/Part name
Bolt/washer
Shim
Engine unit
Q’ty
4/4
*
1
17 N • m (1.7 kgf • m, 12 ft • Ib)
Service points
Reverse the removal steps for installation.
*: As required.
5-3
POWR
ENGINE UNIT
E
SERVICE POINTS
Compression pressure measurement
The following procedure applies to all of the
cylinders.
NOTE:
Insufficient compression pressure will result in
a loss of performance.
1. Measure:
• Valve clearance
Out of specification → Adjust.
Refer to “POWER UNIT” in Chapter 3.
2. Warm the engine up, and then put the
watercraft in a horizontal position.
3. Remove:
• Air filter case cover 1
• Air filter element
4. Disconnect:
• Spark plug cap
5. Remove:
• Spark plug
CAUTION:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it
from falling into the cylinders.
2
6. Install:
• Compression gauge extension 1
• Compression gauge 2
1
Compression gauge extension:
90890-06582
Compression gauge:
YU-33223-1/90890-03160
5-4
POWR
ENGINE UNIT
E
7. Measure:
• Compression pressure
Out of specification → Refer to steps (b)
and (c).
Minimum compression pressure
(reference data):
1,080 kPa
(10.8 kgf/cm2, 157 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.
NOTE:
The difference in compression pressure
between cylinders should not exceed 100
kPa (1 kgf/cm2, 14 psi).
b. If the compression pressure is extremely
high, check the cylinder head, valve surfaces and piston crown for carbon deposits.
Carbon deposits → Eliminate.
c. If the compression pressure is below the
minimum specification, squirt a few drops
of oil into the cylinder and measure
again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading
Diagnosis
Higher than
without oil
Piston wear or
damage → Repair.
Same as without
oil
Piston ring(s),
valves, cylinder
head gasket or piston possibly defective → Repair.
8. Install:
• Spark plug
T.
R.
5-5
Spark plug:
13 N • m (1.3 kgf • m, 9.4 ft • lb)
POWR
ENGINE UNIT
E
9. Install:
• Air filter element
• Air filter case cover
T.
R.
Air filter case cover screw:
2.5 N • m (0.25 kgf • m, 1.8 ft • lb)
LOCTITE® 572
Oil filter removal and installation
1. Remove:
• Oil filter 1
Oil filter wrench 2:
YU-38411/90890-01426
1
2
T.
Oil filter:
17 N • m (1.7 kgf • m, 12 ft • lb)
R.
NOTE:
Install the oil filter with the same special tool
that was used for removal.
Engine unit removal
1. Remove:
• Engine unit
Removal steps:
CAUTION:
Lift the engine unit carefully trying not to
hit it on the deck or letting it fall hard on
the hull.
• Suspend the engine unit using all three
engine hangers, and then separate the
unit from the engine mount.
• Remove the hoist cable from the front
engine hanger and use the two rear
engine hangers to suspend the engine
unit.
• Lift the engine unit out vertically while
turning it clockwise.
5-6
POWR
ENGINE UNIT
E
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. Inspect:
• Engine mounts
Cracks/damage → Replace.
Refer to “ENGINE MOUNT” in Chapter
8.
Coupling clearance inspection
1. Measure:
• Clearance a
• Clearance b
(with the rubber damper)
Out of specification → Adjust.
NOTE:
Measure the clearances with 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)
2. Adjust:
• Clearance a and b
Adjustment steps:
• Adjust the clearance a by adding or
removing shims.
• Adjust the clearance b by moving the
engine unit position.
5-7
POWR
EXHAUST PIPE 3
E
EXHAUST PIPE 3
EXPLODED DIAGRAM
2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
5th 15 N • m (1.5 kgf • m, 11 ft • Ib)
9th 39 N • m (3.9 kgf • m, 28 ft • Ib)
10 × 35 mm
Ê
1st
2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
6th 15 N • m (1.5 kgf • m, 11 ft • Ib)
10th 39 N • m (3.9 kgf • m, 28 ft • Ib)
10 × 35 mm
3
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
6
10
4
5
17
18
LT
16
1
572
È
13
15 14
LT
242
2
É
LT
7
4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)
2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)
1st
572
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
1st
12
11
9
8
LT
LT
242
242
4th 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
8th 15 N • m (1.5 kgf • m, 11 ft • Ib)
12th 39 N • m (3.9 kgf • m, 28 ft • Ib)
10 × 45 mm
3rd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
7th 15 N • m (1.5 kgf • m, 11 ft • Ib)
11th 39 N • m (3.9 kgf • m, 28 ft • Ib)
10 × 45 mm
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
Procedure/Part name
EXHAUST PIPE 3 REMOVAL
Engine unit
Air filter case
Q’ty
Clamp/cooling water hose
Clamp/cooling water hose
Clamp/cooling water hose
Bolt
Thermoswitch (exhaust)
1/1
2/1
2/1
2
1
5-8
Service points
Follow the left “Step” for removal.
Refer to “ENGINE UNIT”.
Refer to “FUEL INJECTION SYSTEM” in
Chapter 4.
È For cooling water outlet on stern side
É For cooling water pilot outlet on port side
Ê From water jacket
POWR
EXHAUST PIPE 3
E
EXPLODED DIAGRAM
2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
5th 15 N • m (1.5 kgf • m, 11 ft • Ib)
9th 39 N • m (3.9 kgf • m, 28 ft • Ib)
10 × 35 mm
Ê
1st
2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
6th 15 N • m (1.5 kgf • m, 11 ft • Ib)
10th 39 N • m (3.9 kgf • m, 28 ft • Ib)
10 × 35 mm
3
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
6
10
4
5
17
18
LT
16
1
572
È
13
15 14
LT
242
2
É
LT
7
4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)
2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)
1st
572
11
LT
242
242
4th 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
8th 15 N • m (1.5 kgf • m, 11 ft • Ib)
12th 39 N • m (3.9 kgf • m, 28 ft • Ib)
10 × 45 mm
7
8
9
10
11
12
13
14
Procedure/Part name
Exhaust joint clamp
Exhaust joint clamp
Bolt
Bolt
Bolt
Collar
Exhaust pipe 3
Bolt
Exhaust pipe end
9
8
LT
Step
6
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
1st
12
Q’ty
2
2
1
1
2
1
1
3
1
5-9
3rd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
7th 15 N • m (1.5 kgf • m, 11 ft • Ib)
11th 39 N • m (3.9 kgf • m, 28 ft • Ib)
10 × 45 mm
Service points
Slide the outer exhaust joint for exhaust
manifold side
POWR
EXHAUST PIPE 3
E
EXPLODED DIAGRAM
2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
5th 15 N • m (1.5 kgf • m, 11 ft • Ib)
9th 39 N • m (3.9 kgf • m, 28 ft • Ib)
10 × 35 mm
Ê
1st
2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
6th 15 N • m (1.5 kgf • m, 11 ft • Ib)
10th 39 N • m (3.9 kgf • m, 28 ft • Ib)
10 × 35 mm
3
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
6
10
4
5
17
18
LT
16
1
572
È
13
15 14
LT
242
2
É
LT
7
4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)
2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)
1st
572
11
242
4th 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
8th 15 N • m (1.5 kgf • m, 11 ft • Ib)
12th 39 N • m (3.9 kgf • m, 28 ft • Ib)
10 × 45 mm
Procedure/Part name
Gasket
Inner exhaust joint
Exhaust joint seal
Outer exhaust joint
9
8
LT
Step
15
16
17
18
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
1st
12
Q’ty
1
1
1
1
LT
242
3rd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
7th 15 N • m (1.5 kgf • m, 11 ft • Ib)
11th 39 N • m (3.9 kgf • m, 28 ft • Ib)
10 × 45 mm
Service points
Not reusable
Reverse the removal steps for installation.
5-10
POWR
EXHAUST PIPES 1 AND 2
E
EXHAUST PIPES 1 AND 2
EXPLODED DIAGRAM
4th 39 N • m (3.9 kgf • m, 28 ft • Ib)
9th 39 N • m (3.9 kgf • m, 28 ft • Ib)
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)
8 × 75 mm
1st
3rd 39 N • m (3.9 kgf • m, 28 ft • Ib)
8th 39 N • m (3.9 kgf • m, 28 ft • Ib)
4
39 N • m (3.9 kgf • m, 28 ft • Ib)
6th 39 N • m (3.9 kgf • m, 28 ft • Ib)
1st
4
E
5
13
È
7
È
12
6
4
8
E
5th 39 N • m (3.9 kgf • m, 28 ft • Ib)
10th 39 N • m (3.9 kgf • m, 28 ft • Ib)
2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)
7th 39 N • m (3.9 kgf • m, 28 ft • Ib)
2
4
11
LT
242
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 42 N • m (4.2 kgf • m, 30 ft • Ib)
10 × 35 mm
1st
3
LT
E
242
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 42 N • m (4.2 kgf • m, 30 ft • Ib)
8 × 45 mm
1st
9
242
LT
1
10
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)
8 × 125 mm
1st
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
Procedure/Part name
EXHAUST PIPES 1 AND 2
REMOVAL
Exhaust pipe 3
Generator cover
Bolt
Bolt
Exhaust pipe stay
Nut
Exhaust pipe 2
Gasket
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “EXHAUST PIPE 3”.
Refer to “GENERATOR AND STARTER
MOTOR”.
2
1
1
5
1
1
5-11
Not reusable
POWR
EXHAUST PIPES 1 AND 2
E
EXPLODED DIAGRAM
4th 39 N • m (3.9 kgf • m, 28 ft • Ib)
9th 39 N • m (3.9 kgf • m, 28 ft • Ib)
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)
8 × 75 mm
1st
3rd 39 N • m (3.9 kgf • m, 28 ft • Ib)
8th 39 N • m (3.9 kgf • m, 28 ft • Ib)
4
39 N • m (3.9 kgf • m, 28 ft • Ib)
6th 39 N • m (3.9 kgf • m, 28 ft • Ib)
1st
4
E
5
13
È
7
È
12
6
4
8
E
5th 39 N • m (3.9 kgf • m, 28 ft • Ib)
10th 39 N • m (3.9 kgf • m, 28 ft • Ib)
2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)
7th 39 N • m (3.9 kgf • m, 28 ft • Ib)
2
4
11
242
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 42 N • m (4.2 kgf • m, 30 ft • Ib)
10 × 35 mm
1st
LT
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 42 N • m (4.2 kgf • m, 30 ft • Ib)
8 × 45 mm
Procedure/Part name
Dowel pin
Clamp/cooling water hose
Bolt
Bolt
Exhaust pipe 1
Gasket
Dowel pin
Q’ty
2
2/2
4
6
1
1
2
9
3
E
242
1st
Step
7
8
9
10
11
12
13
LT
242
LT
1
10
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)
8 × 125 mm
1st
Service points
È From cooling water inlet
Not reusable
Reverse the removal steps for installation.
5-12
POWR
EXHAUST MANIFOLD
E
EXHAUST MANIFOLD
EXPLODED DIAGRAM
a
1
È
5
LT
8
242
10
4
LT
242
6
3
5
LT
10
7
242
LT
2
242
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)
8 × 70 mm
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)
8 × 55 mm
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)
8 × 95 mm
1st
9
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)
8 × 95 mm
1st
REMOVAL AND INSTALLATION CHART
Step
1
Procedure/Part name
EXHAUST MANIFOLD REMOVAL
Exhaust pipes 1 and 2
Joint assembly
Q’ty
1
Service points
Follow the left “Step” for removal.
Refer to “EXHAUST PIPES 1 AND 2”.
È To pressure control valve
NOTE:
Install the cooling water hose with the
white mark a facing up.
2
3
4
5
Bolt
Bolt
Exhaust manifold 1
Dowel pin
2
4
1
2
5-13
POWR
EXHAUST MANIFOLD
E
EXPLODED DIAGRAM
a
1
È
5
LT
8
242
10
4
LT
242
6
3
5
LT
7
242
LT
2
242
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)
8 × 70 mm
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)
8 × 55 mm
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)
8 × 95 mm
1st
Step
6
7
8
9
10
9
10
Procedure/Part name
Bolt
Bolt
Exhaust manifold 2
Gasket
Dowel pin
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)
8 × 95 mm
1st
Q’ty
1
4
1
1
2
Service points
Not reusable
Reverse the removal steps for installation.
5-14
POWR
OIL TANK
E
OIL TANK
EXPLODED DIAGRAM
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
1st
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 35 mm
2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)
3rd 39 N • m (3.9 kgf • m, 28 ft • Ib)
1st
24
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 20 mm
LT
2
572
3
4
23
5
LT
1
È
11
4
16 15
572
14
5
E
Í
9
8
b
Ë
19
Ê
LT
572
7
6
25
12
13
10
Ì
26
a
29
27
18
17
20
LT
26
572
LT
572
28
6
21
LT
572
A
22
É
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 30 mm
10 × 70 mm
1st 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
6 × 12 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
1st
2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)
3rd 39 N • m (3.9 kgf • m, 28 ft • Ib)
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)
6 × 16 mm
8 × 80 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
1st
REMOVAL AND INSTALLATION CHART
Step
Procedure/Part name
OIL TANK REMOVAL
Engine unit
Air filter case
Q’ty
Ignition coil box
1
2
3
4
Thermostat housing
Clamp/cooling water hose
Bolt
Water jacket
Gasket
1/1
4
1
1
5-15
Service points
Follow the left “Step” for removal.
Refer to “ENGINE UNIT”.
Refer to “FUEL INJECTION SYSTEM” in
Chapter 4.
Refer to “ELECTRICAL BOX AND
IGNITION COIL BOX” in Chapter 7.
Refer to “THERMOSTAT”.
È To exhaust joint
Not reusable
POWR
OIL TANK
E
EXPLODED DIAGRAM
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
1st
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 35 mm
2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)
3rd 39 N • m (3.9 kgf • m, 28 ft • Ib)
1st
24
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 20 mm
LT
2
572
3
4
23
5
LT
1
È
11
4
16 15
572
14
5
E
Í
9
8
b
Ë
19
Ê
LT
572
7
6
25
12
13
10
Ì
26
a
29
LT
572
17
20
LT
26
572
LT
A
22
É
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 30 mm
10 × 70 mm
1st 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
6 × 12 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
1st
2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)
3rd 39 N • m (3.9 kgf • m, 28 ft • Ib)
Step
5
6
27
18
572
28
6
21
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)
6 × 16 mm
8 × 80 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
1st
Procedure/Part name
Clamp/breather hose
Clamp/breather hose
Q’ty
2/1
2/1
7
8
9
10
Bolt
Collar
Oil separator
Clamp/breather hose
3
2
1
1/1
11
Clamp/breather hose
1/1
5-16
Service points
É To oil pump
Align the mark a of the breather hose with
the parting line of the oil separator.
Ê To air filter case
Mark b
Ë From cylinder head cover
POWR
OIL TANK
E
EXPLODED DIAGRAM
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
1st
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 35 mm
2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)
3rd 39 N • m (3.9 kgf • m, 28 ft • Ib)
1st
24
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 20 mm
LT
2
572
3
4
23
5
LT
1
È
11
4
16 15
572
14
5
E
Í
9
8
b
Ë
19
Ê
LT
572
7
6
25
12
13
10
Ì
26
a
29
LT
572
17
20
LT
26
572
LT
A
22
É
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 30 mm
10 × 70 mm
1st 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
6 × 12 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
1st
2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)
3rd 39 N • m (3.9 kgf • m, 28 ft • Ib)
Step
12
13
14
15
16
17
18
19
20
21
22
27
18
572
28
6
21
Procedure/Part name
Clamp/cooling water hose
Clamp/cooling water hose
Bolt
Collar
Band
Bolt
Cover
Gasket
Bolt
Ground lead
Bolt
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)
6 × 16 mm
8 × 80 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
1st
Q’ty
1/1
1/1
1
1
1
3
1
1
2
2
4
5-17
Service points
Ì From cooling water inlet
Í From pressure control valve
Not reusable
POWR
OIL TANK
E
EXPLODED DIAGRAM
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
1st
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 35 mm
2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)
3rd 39 N • m (3.9 kgf • m, 28 ft • Ib)
1st
24
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 20 mm
LT
2
572
3
4
23
5
LT
1
È
11
4
16 15
572
14
5
E
Í
9
8
b
Ë
19
Ê
LT
572
7
6
25
12
13
10
Ì
26
a
29
LT
572
17
20
LT
26
572
LT
A
22
É
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 30 mm
10 × 70 mm
1st 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)
6 × 12 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
1st
2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)
3rd 39 N • m (3.9 kgf • m, 28 ft • Ib)
Step
23
24
25
26
27
28
29
27
18
572
28
6
21
Procedure/Part name
Nut
Oil tank
Pin
O-ring
Connector
Bolt
Oil tank stay
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)
6 × 16 mm
8 × 80 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
1st
Q’ty
2
1
2
4
2
2
1
Service points
Not reusable
Reverse the removal steps for installation.
5-18
POWR
OIL TANK
E
EXPLODED DIAGRAM
5
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 20 mm
3
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 25 mm
1st
1st
6
8
1.9 N • m (0.19 kgf • m, 1.4 ft • Ib)
2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)
5 × 14 mm
1st
7
4
LT
LT
572
9
13
12
11
572
18
14
E
15
LT
572
5 × 35 mm
E
16
10
1.9 N • m (0.19 kgf • m, 1.4 ft • Ib)
2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)
17
1st
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 14 mm
1st
19
E
20
22
23
21
1
E
LT
572
6 × 20 mm
18
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
1st
20
2
LT
572
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
19 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
4 × 15 mm
6 × 20 mm
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
1st
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
Procedure/Part name
OIL TANK DISASSEMBLY
Bolt/washer
Bracket/grommet
Bolt
Hunger
Oil filter cap
Packing
Bolt
Oil tank cover
Gasket
Bolt
Q’ty
2/2
2/2
4
2
1
1
8
1
1
10
5-19
Service points
Follow the left “Step” for disassembly.
Not reusable
POWR
OIL TANK
E
EXPLODED DIAGRAM
5
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 20 mm
3
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 25 mm
1st
1st
6
8
1.9 N • m (0.19 kgf • m, 1.4 ft • Ib)
2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)
5 × 14 mm
1st
7
4
LT
LT
572
9
13
12
11
572
18
14
E
15
LT
572
5 × 35 mm
E
16
10
1.9 N • m (0.19 kgf • m, 1.4 ft • Ib)
2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)
17
1st
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 14 mm
1st
19
E
20
22
23
21
1
E
LT
572
6 × 20 mm
18
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
1st
Step
11
12
13
14
15
16
17
18
19
20
Procedure/Part name
Oil breather plate 1
Oil breather plate 2
Gasket
Bolt
Baffle plate
Bolt
Oil strainer
Bolt
Oil cooler cover
Gasket
20
2
LT
572
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
19 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
4 × 15 mm
6 × 20 mm
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
1st
Q’ty
1
1
1
3
1
2
1
24
2
2
5-20
Service points
Not reusable
Not reusable
POWR
OIL TANK
E
EXPLODED DIAGRAM
5
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 20 mm
3
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 25 mm
1st
1st
6
8
1.9 N • m (0.19 kgf • m, 1.4 ft • Ib)
2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)
5 × 14 mm
1st
7
4
LT
LT
572
9
13
12
11
572
18
14
E
15
LT
572
E
5 × 35 mm
16
10
1.9 N • m (0.19 kgf • m, 1.4 ft • Ib)
2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)
17
1st
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 14 mm
1st
19
E
20
22
23
21
1
E
LT
572
6 × 20 mm
18
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
1st
Step
21
22
23
Procedure/Part name
Screw
Anode
Oil tank
20
2
LT
572
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
19 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
4 × 15 mm
6 × 20 mm
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
1st
Q’ty
1
1
1
Service points
Reverse the disassembly steps for
assembly.
5-21
POWR
OIL TANK
E
SERVICE POINTS
Oil tank removal
1. Remove:
• Oil tank
NOTE:
Loosen the oil tank bolts and nuts in the
sequence shown.
3
1
2
4
8
6
7
5
5
2. Remove:
• Oil tank cover
• Gasket
8
1
4
2
3
6
4
6
7
7
3. Remove:
• Oil breather plate 1
• Oil breather plate 2
• Gasket
3
10
5
NOTE:
Loosen the oil tank cover bolts in the sequence
shown.
9
2
8
1
NOTE:
Loosen the oil breather plate bolts in the
sequence shown.
5-22
POWR
OIL TANK
E
4. Remove:
• Oil cooler covers
• Gaskets
9
1
NOTE:
Loosen the oil cooler cover bolts in the
sequence shown.
8
12
2
7
3
6
4
5
10
11
Oil strainer inspection
1. Check:
• Oil strainer 1
Damage → Replace.
Contaminants → Clean with engine oil.
Oil tank installation
1. Install:
• Oil cooler covers
• Gaskets
4
12
NOTE:
Tighten the oil cooler bolts in the sequence
shown.
5
1
11
6
T.
R.
10
9
7
8
3
2
5-23
Oil cooler cover bolt:
1st:
3.7 N • m
(0.37 kgf • m, 2.7 ft • lb)
2nd:
7.6 N • m
(0.76 kgf • m, 5.5 ft • lb)
POWR
OIL TANK
7
2. Install:
• Gasket
• Oil breather plate 2
• Oil breather plate 1
8
1
2
6
5
E
4
3
9
NOTE:
Tighten the oil breather plate bolts in the
sequence shown.
10
T.
R.
4
3. Install:
• Gasket
• Oil tank cover
1
8
5
7
6
3
Oil breather plate bolt:
1st:
1.9 N • m
(0.19 kgf • m, 1.4 ft • lb)
2nd:
4.4 N • m
(0.44 kgf • m, 3.2 ft • lb)
NOTE:
Tighten the oil tank cover bolts in the
sequence shown.
2
T.
R.
5-24
Oil tank cover bolt:
1st:
3.7 N • m
(0.37 kgf • m, 2.7 ft • lb)
2nd:
7.6 N • m
(0.76 kgf • m, 5.5 ft • lb)
POWR
OIL TANK
E
4. Install:
• Oil tank
NOTE:
Tighten the oil tank nuts and bolts in the
sequence shown.
2
6
3
8
T.
R.
2
7
5
1
2
3
4
1
5-25
Bolt 1:
1st:
15 N • m (1.5 kgf • m, 11 ft • lb)
2nd:
28 N • m (2.8 kgf • m, 20 ft • lb)
Nut 2, bolt 3:
1st:
2.0 N • m
(0.20 kgf • m, 1.4 ft • lb)
2nd:
15 N • m (1.5 kgf • m, 11 ft • lb)
3rd:
39 N • m (3.9 kgf • m, 28 ft • lb)
POWR
OIL PUMP
E
OIL PUMP
EXPLODED DIAGRAM
1.4 N • m (0.14 kgf • m, 1.0 ft • Ib)
2nd 10 N • m (0.1 kgf • m, 7.2 ft • Ib)
6 × 25 mm
1st
1.4 N • m (0.14 kgf • m, 1.0 ft • Ib)
2nd 10 N • m (0.1 kgf • m, 7.2 ft • Ib)
6 × 95 mm
1st
LT
572
3
4
7
LT
572
7
1
5
2
6
18 N • m (1.8 kgf • m, 13 ft • Ib)
8 × 12 mm
8
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
Procedure/Part name
OIL PUMP ASSEMBLY
REMOVAL
Oil tank
Clamp/breather hose
Drain plug/washer
Bolt
Bolt
Oil pump assembly
Gasket
Pin
Strainer
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “OIL TANK”.
1/1
1/1
8
4
1
1
2
1
Drain engine oil.
Not reusable
Reverse the removal steps for installation.
5-26
POWR
OIL PUMP
E
SERVICE POINTS
Oil pump removal
1. Remove:
• Oil pump assembly
NOTE:
Loosen the oil pump bolts in the sequence
shown.
5
7
6
9
8
12
3
11
1
2
4
10
Oil pump inspection
1. Check:
• Oil pump operation
Rough movement → Replace the defective part(s).
Oil strainer inspection
1. Check:
• Oil strainer 1
Damage → Replace.
Contaminants → Clean with engine oil.
5-27
POWR
OIL PUMP
E
Oil pump installation
1. Install:
• Oil pump assembly
NOTE:
• Align the projection a on the oil pump
assembly with the slit b on the oil pump
driven gear shaft.
• Tighten the oil pump bolts in the sequence
shown.
a
b
T.
R.
8
6
7
4
1
5
10
2
12
11
9
3
5-28
Oil pump assembly bolt:
1st:
1.4 N • m
(0.14 kgf • m, 1.0 ft • lb)
2nd:
10 N • m (1.0 kgf • m, 7.2 ft • lb)
POWR
REDUCTION DRIVE GEAR
E
REDUCTION DRIVE GEAR
EXPLODED DIAGRAM
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 55 mm
1st
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)
8 × 40 mm
1st
9
8
LT
572
12
2
11
LT
4
572
10
9
12
10
E
LT
3
572
7
6
5
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 35 mm
1st
LT
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)
8 × 70 mm
1st
572
6
1
LT
572
5
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)
8 × 100 mm
1st
28 N • m (2.8 kgf • m, 20 ft • Ib)
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
Procedure/Part name
REDUCTION DRIVE GEAR
REMOVAL
Generator cover
Oil pump
Drive coupling
Bolt
Bolt
Bolt
Bolt
Bolt
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “GENERATOR AND STARTER
MOTOR”.
Refer to “OIL PUMP”.
1
1
1
1
2
4
5-29
POWR
REDUCTION DRIVE GEAR
E
EXPLODED DIAGRAM
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 55 mm
1st
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)
8 × 40 mm
1st
9
8
LT
572
12
2
11
LT
4
572
10
9
12
10
E
LT
3
572
7
6
5
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 35 mm
1st
LT
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)
8 × 70 mm
1st
572
6
1
LT
572
5
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)
8 × 100 mm
1st
28 N • m (2.8 kgf • m, 20 ft • Ib)
Step
7
8
9
10
11
12
Procedure/Part name
Reduction drive gear case
Gasket
Pin
Circlip
Reduction drive gear
Washer
Q’ty
1
1
2
2
1
2
Service points
Not reusable
Not reusable
Reverse the removal steps for installation.
5-30
POWR
REDUCTION DRIVE GEAR
E
EXPLODED DIAGRAM
A
*1
15
13
E
14
16
E
5 × 10 mm
9
10
11
9
18
17
12
*1
11
21
8
20
19
E
E
E
E
7
6
1
4
2
E
3
5
E
E
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)
8 × 40 mm
1st
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 16 mm
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
*1:
Procedure/Part name
REDUCTION DRIVE GEAR
DISASSEMBLY
Oil pump driven gear
Bolt
Holder
Spring
Relief valve
Bolt
Bearing housing
Pin
Q’ty
1
1
1
1
1
4
1
2
EPNOC grease AP #0
5-31
Service points
Follow the left “Step” for disassembly.
POWR
REDUCTION DRIVE GEAR
E
EXPLODED DIAGRAM
A
*1
15
13
E
14
16
E
5 × 10 mm
9
10
11
9
18
17
12
*1
11
21
8
20
19
E
E
E
E
7
6
1
2
E
E
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 16 mm
Step
9
10
11
12
13
14
Circlip
Driven gear
Washer
Circlip
Oil seal
Bearing
Q’ty
2
1
2
1
2
1
15
16
17
Drive shaft
Circlip
Circlip
1
1
1
*1:
3
5
E
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)
8 × 40 mm
1st
Procedure/Part name
4
EPNOC grease AP #0
5-32
Service points
Not reusable
Not reusable
Not reusable
NOTE:
Remove parts 12 to 15 as a set.
Not reusable
Not reusable
Not reusable
POWR
REDUCTION DRIVE GEAR
E
EXPLODED DIAGRAM
A
*1
15
13
E
14
16
E
5 × 10 mm
9
10
11
9
18
17
12
*1
11
21
8
20
19
E
E
E
E
7
6
1
2
E
Procedure/Part name
Bearing
Circlip
Bearing
Reduction drive gear case
3
5
E
E
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)
8 × 40 mm
1st
Step
18
19
20
21
4
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 16 mm
Q’ty
1
1
1
1
Service points
Not reusable
Not reusable
Not reusable
Reverse the disassembly steps for
assembly.
*1
: EPNOC grease AP #0
5-33
POWR
REDUCTION DRIVE GEAR
E
SERVICE POINTS
Drive coupling removal
1. Remove:
• Drive coupling 1
1
4
NOTE:
While holding the flywheel magneto 2 with the
sheave holder 3, loosen the drive coupling
with coupler wrench 4.
Coupler wrench:
YW-06551/90890-06551
Sheave holder:
YS-01880-A/90890-01701
3
2
Drive shaft removal
1. Remove:
• Circlip
• Drive shaft
NOTE:
Press in the direction of the arrow.
Oil pump driven gear inspection
1. Check:
• Oil pump driven gear 1
Cracks/damage/wear → Replace.
1
Relief valve inspection
1. Check:
• Relief valve 1
• Spring 2
Damage/wear → Replace the defective
part(s).
1
2
5-34
POWR
REDUCTION DRIVE GEAR
E
Drive shaft installing
1. Install:
• Drive shaft
NOTE:
Press in the direction of the arrow.
2. Install:
• Oil seals 1
Distance a:
8.9–9.3 mm (0.35–0.37 in)
a
1
Drive coupling installation
1. Install:
• Drive coupling 1
1
4
NOTE:
While holding the flywheel magneto 2 with the
sheave holder 3, tighten the drive coupling
with coupler wrench 4.
Coupler wrench:
YW-06551/90890-06551
Sheave holder:
YS-01880-A/90890-01701
2
3
5-35
POWR
GENERATOR AND STARTER MOTOR
E
GENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM
18 N • m (1.8 kgf • m, 13 ft • Ib)
8 × 30 mm
A
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
3
4
1
5 2
A
15
6
22
16
75 N • m (7.5 kgf • m, 54 ft • Ib)
10 × 47 mm
E
21
20
18
13
17
8
A
E
19
7
10
E
9
LT
11
5 × 10 mm
572
12
24 N • m (2.4 kgf • m, 17 ft • Ib)
8 × 20 mm
14
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 50 N • m (5.0 kgf • m, 36 ft • Ib)
10 × 60 mm
1st
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
Procedure/Part name
GENERATOR COVER AND
FLYWHEEL MAGNET REMOVAL
Engine unit
Nut/washer
Starter motor lead
Bolt
Battery negative lead
Starter motor
Band
Lighting coil coupler
Pulser coil coupler
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “ENGINE UNIT”.
1/1
1
2
1
1
1
1
1
5-36
POWR
GENERATOR AND STARTER MOTOR
E
EXPLODED DIAGRAM
18 N • m (1.8 kgf • m, 13 ft • Ib)
8 × 30 mm
A
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
3
4
1
5 2
A
15
6
22
16
75 N • m (7.5 kgf • m, 54 ft • Ib)
10 × 47 mm
E
21
20
18
13
17
8
A
E
19
7
10
E
9
LT
11
5 × 10 mm
Step
9
10
11
12
13
14
15
16
17
18
19
572
12
24 N • m (2.4 kgf • m, 17 ft • Ib)
8 × 20 mm
14
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 50 N • m (5.0 kgf • m, 36 ft • Ib)
10 × 60 mm
1st
Procedure/Part name
Bolt
Holder
Bolt
Generator cover
Dowel pin
Packing
Idle gear shaft
Idle gear
Bolt/washer
Rotor
Bolt
Q’ty
1
1
8
1
2
1
1
1
1/1
1
6
5-37
Service points
Not reusable
Not reusable
POWR
GENERATOR AND STARTER MOTOR
E
EXPLODED DIAGRAM
18 N • m (1.8 kgf • m, 13 ft • Ib)
8 × 30 mm
A
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
3
4
1
5 2
A
15
6
22
16
75 N • m (7.5 kgf • m, 54 ft • Ib)
10 × 47 mm
E
21
20
18
13
17
8
A
E
19
7
10
E
9
LT
11
5 × 10 mm
Step
20
21
22
572
12
24 N • m (2.4 kgf • m, 17 ft • Ib)
8 × 20 mm
14
15 N • m (1.5 kgf • m, 11 ft • Ib)
2nd 50 N • m (5.0 kgf • m, 36 ft • Ib)
10 × 60 mm
1st
Procedure/Part name
Starter clutch
Starter gear
Woodruff key
Q’ty
1
1
1
Service points
Reverse the removal steps for installation.
5-38
POWR
GENERATOR AND STARTER MOTOR
E
EXPLODED DIAGRAM
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
5 × 10 mm
1
LT
242
7
1
LT
1
242
6
3
3
2
5
LT
LT
242
2
242
4
6 × 14 mm
14 N • m (1.4 kgf • m, 10 ft • Ib)
5 × 14 mm
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
6 × 33 mm
14 N • m (1.4 kgf • m, 10 ft • Ib)
REMOVAL AND INSTALLATION CHART
Step
1
2
3
Procedure/Part name
GENERATOR DISASSEMBLY
Bolt/washer
Bolt
Pulser coil
4
Bolt
Q’ty
3/3
4
2
2
5-39
Service points
Follow the left “Step” for disassembly.
NOTE:
There washers holds the pulser coil lead.
Make sure to not pitch the lead between the
projection and the washer when installing
the bolt.
POWR
GENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
5 × 10 mm
1
LT
242
7
1
LT
1
242
6
3
3
2
5
LT
LT
242
242
2
4
6 × 14 mm
14 N • m (1.4 kgf • m, 10 ft • Ib)
5 × 14 mm
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
6 × 33 mm
14 N • m (1.4 kgf • m, 10 ft • Ib)
Step
5
6
7
Procedure/Part name
Holder
Bolt
Lighting coil
Q’ty
1
3
1
Service points
Reverse the disassembly steps for
assembly.
5-40
E
POWR
GENERATOR AND STARTER MOTOR
E
SERVICE POINTS
Flywheel magneto removal
1. Remove:
• Flywheel magneto bolt 1
• Washer
NOTE:
While holding the flywheel magneto 2 with the
sheave holder 3, loosen the flywheel magneto
bolt.
Sheave holder:
YS-01880-A/90890-01701
2. Remove:
• Flywheel magneto 1
• Woodruff key
NOTE:
While holding the flywheel magneto with
sheave holder 2, remove the flywheel magneto with the rotor puller 3.
Rotor puller:
YM-01082/90890-01080
Starter clutch inspection
1. Check:
• Starter clutch rollers 1
Damage/wear → Replace.
5-41
POWR
1
GENERATOR AND STARTER MOTOR
E
2. Check:
• Starter clutch 1
• Starter gear 2
Burrs/chips/roughness/wear → Replace
the defective part(s).
2
a
3. Check:
• Starter clutch gear’s contacting surfaces
a
Damage/pitting/wear → Replace the
starter clutch gear.
4. Check:
• Starter clutch operation
Checking steps:
• Install the starter gear 1 onto the starter
clutch 2 and hold the starter clutch.
• When turning the starter gear clockwise
È, it should turn freely, otherwise the
starter clutch is faulty and must be
replaced.
• When turning the starter gear counterclockwise É, the starter clutch and the
starter gear should engage, otherwise
the starter clutch is faulty and must be
replaced.
5-42
POWR
GENERATOR AND STARTER MOTOR
E
Flywheel magneto installation
1. Install:
• Woodruff key
• Flywheel magneto
• Washer
• Flywheel magneto bolt
NOTE:
• Clean the tapered portion of the crankshaft
and the flywheel magneto hub.
• When installing the flywheel magneto, make
sure the woodruff key is properly seated in
the keyway of the crankshaft.
• Lubricate the flywheel magneto bolt and
washer with engine oil.
2. Tighten:
• Flywheel magneto bolt 1
NOTE:
While holding the flywheel magneto 2 with the
sheave holder 3, tighten the flywheel magneto bolt.
T.
Flywheel magneto bolt:
75 N • m (7.5 kgf • m, 54 ft • lb)
R.
Sheave holder:
YS-01880-A/90890-01701
CAUTION:
Do not reuse the flywheel magnet bolt and
washer, always replace them with new
ones.
5-43
POWR
CAMSHAFTS
E
CAMSHAFTS
EXPLODED DIAGRAM
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 16 mm
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
1st
7
È
a
6
5
3
2
É
LT
4
572
8
12
LT
572
9
10
14
11
E
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 22 mm
13
1
13 N • m (1.3 kgf • m, 9.4 ft • Ib)
REMOVAL AND INSTALLATION CHART
Step
Procedure/Part name
CYLINDER HEAD COVER
REMOVAL
Air filter case
Q’ty
1
2
Spark plug
Clamp/breather hose
4
1/1
3
4
5
6
Bolt
Camshaft position sensor
Clamp/cooling water hose
Rubber seal
1
1
1/1
1
Service points
Follow the left “Step” for removal.
Refer to “FUEL INJECTION SYSTEM” in
Chapter 4.
5-44
È To oil tank
White mark a
É To thermostat
POWR
CAMSHAFTS
E
EXPLODED DIAGRAM
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 16 mm
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
1st
7
È
a
6
5
3
2
É
LT
4
572
8
12
LT
572
9
10
14
11
E
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 22 mm
13
1
13 N • m (1.3 kgf • m, 9.4 ft • Ib)
Step
7
8
9
10
11
12
13
14
Procedure/Part name
Bolt
Cooling water pipe
O-ring
Bolt
Rubber mount
Cylinder head cover
Cylinder head cover gasket
Timing chain guide (top side)
Q’ty
1
1
1
6
6
1
1
1
Service points
Not reusable
Not reusable
Reverse the removal steps for installation.
5-45
POWR
CAMSHAFTS
E
EXPLODED DIAGRAM
6 × 35 mm
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
10
11
10
11
10
11
24 N • m (2.4 kgf • m, 17 ft • Ib)
7 × 11 mm
E
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 35 mm
17
E
7
16
E
8
12
18
E
8
24 N • m (2.4 kgf • m, 17 ft • Ib)
7 × 11 mm
E
9
14
8
M
13
20
15
E
6
M
19
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 8 mm
2
5
1
4
6 × 25 mm
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
3
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
Procedure/Part name
CAMSHAFT REMOVAL
Cylinder head cover
Reduction drive gear case
Cap bolt
Gasket
Bolt
Timing chain tensioner
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “REDUCTION DRIVE GEAR”.
NOTE:
When removing camshafts it is not necessary to remove the reduction drive gear
case.
1
1
2
1
5-46
Not reusable
POWR
CAMSHAFTS
E
EXPLODED DIAGRAM
6 × 35 mm
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
10
11
10
11
10
11
24 N • m (2.4 kgf • m, 17 ft • Ib)
7 × 11 mm
E
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 35 mm
17
E
7
16
E
8
12
18
E
8
24 N • m (2.4 kgf • m, 17 ft • Ib)
7 × 11 mm
E
9
14
8
M
13
20
15
E
6
M
19
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 8 mm
2
5
1
4
6 × 25 mm
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
Step
5
6
7
8
9
10
11
12
13
14
15
Procedure/Part name
Timing chain tensioner gasket
Timing chain guide (exhaust side)
Bolt
Intake camshaft cap
Dowel pin
Bolt
Exhaust camshaft cap
Dowel pin
Intake camshaft
Bolt
Intake camshaft sprocket
Q’ty
1
1
18
3
6
10
3
6
1
2
1
5-47
3
Service points
Not reusable
NOTE:
During removal, the dowel pins may still be
connected to the camshaft caps.
POWR
CAMSHAFTS
E
EXPLODED DIAGRAM
6 × 35 mm
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
10
11
10
11
10
11
24 N • m (2.4 kgf • m, 17 ft • Ib)
7 × 11 mm
E
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 35 mm
17
E
7
16
E
8
12
18
E
8
24 N • m (2.4 kgf • m, 17 ft • Ib)
7 × 11 mm
E
9
14
8
13
M
20
15
E
6
M
19
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 8 mm
2
5
1
4
6 × 25 mm
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
Step
16
17
18
19
20
Procedure/Part name
Exhaust camshaft
Bolt
Exhaust camshaft sprocket
Pin
Timing chain guide (intake side)
Q’ty
1
2
1
1
1
3
Service points
Reverse the removal steps for installation.
5-48
POWR
CAMSHAFTS
E
SERVICE POINTS
Camshaft removal
1. Install:
• Dial gauge needle
• Dial gauge stand 1
(into spark plug hole #1)
• Dial gauge 2
2
1
Dial gauge stand:
90890-06583
Dial gauge needle:
90890-06584
Dial gauge stand set:
YW-06585/90890-06585
Dial gauge:
YU-03097/90890-01252
2. Turn the drive coupling counterclockwise,
and then check if cylinder #1 is at TDC of
the compression stroke with a dial gauge.
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
EX
IN
3. Make an alignment mark a on the timing
chain and camshaft sprockets.
a
5-49
POWR
CAMSHAFTS
E
4. Remove:
• Timing chain tensioner 1
• Gasket
1
3
6
7
10
5
3 9
4
8 6
9
13 17
8
2
16 12 1
5 7
10 4
1115
1814 2
5. Remove:
• Camshaft caps
• Dowel pins
1
NOTE:
Loosen the intake and exhaust camshaft cap
bolts in the sequence shown.
6. Remove:
• Intake camshaft 1
• Exhaust camshaft 2
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire 3.
Camshaft inspection
1. Check:
• Camshaft lobes
Blue discoloration/pitting/scratches →
Replace the camshaft.
2. Measure:
• Camshaft lobe dimensions a and b
Out of specification → Replace the camshaft.
Minimum cam lobe dimensions:
Intake camshaft:
a 32.25 mm (1.270 in)
b 25.00 mm (0.984 in)
Exhaust camshaft:
a 32.65 mm (1.285 in)
b 25.00 mm (0.984 in)
5-50
POWR
CAMSHAFTS
E
3. Measure:
• Camshaft runout
Out of specification → Replace.
Maximum camshaft runout:
0.03 mm (0.0012 in)
4. Measure:
• Camshaft-journal-to-camshaft-cap
clearance
Out of specification → Measure the
camshaft journal diameter.
Camshaft-journal-to-camshaftcap clearance:
0.05–0.08 mm (0.0020–0.0031 in)
8
5
4
1
6
16 10
7
11 13
2
6 2
3
9
3 7 18
14 12
9 15
8 4
1 5 17
Measurement steps:
• Install the camshaft into the cylinder head
(without the dowel pins and camshaft
caps).
• Position a strip of Plastigauge® 1 onto
the camshaft journal as shown.
• Install the dowel pins and camshaft caps.
10
NOTE:
• Tighten the intake and exhaust camshaft
cap bolts in the sequence shown.
• Do not turn the camshaft when measuring
the camshaft journal-to-camshaft cap
clearance with the Plastigauge®.
T.
Camshaft cap bolt:
10 N • m (1.0 kgf • m, 7.2 ft • lb)
R.
• Remove the camshaft caps and then
measure the width of the Plastigauge®
1.
5-51
POWR
CAMSHAFTS
E
5. Measure:
• Camshaft journal diameter a
Out of specification → Replace the camshaft.
Within specification → Replace the cylinder head and the camshaft caps as a
set.
Camshaft journal diameter:
24.44–24.45 mm
(0.9622–0.9626 in)
Camshaft sprockets inspection
1. Check:
• Camshaft sprocket
Wear/damage → Replace the camshaft
sprockets and timing chain as a set.
a
b
1
2
1/4 of a tooth
Correct
Timing chain
Camshaft sprocket
Timing chain tensioner inspection
1. Check:
• Timing chain tensioner
Cracks/damage/rough movement →
Replace.
Checking steps:
• While lightly pressing the timing chain
tensioner rod by hand, turn the tensioner
rod fully clockwise with a thin screwdriver
1.
• Remove the screwdriver and slowly
release the timing chain tensioner rod.
• Make sure that the timing chain tensioner
rod comes out of the timing chain tensioner housing smoothly. If there is rough
movement, replace the timing chain tensioner.
5-52
POWR
CAMSHAFTS
E
Camshaft installation
1. Install:
• Exhaust camshaft sprocket 1
• Intake camshaft sprocket 2
(with the special tool 3)
Rotor holder:
YU-01235/90890-01235
NOTE:
Install the camshaft sprocket with the punch
mark a facing outside.
T.
Camshaft sprocket bolt:
24 N • m (2.4 kgf • m, 17 ft • lb)
R.
2. Install:
• Exhaust camshaft
• Intake camshaft
• Exhaust camshaft caps
• Intake camshaft caps
Installation steps:
• Turn the drive coupling counterclockwise,
and then check if cylinder #1 is at TDC of
the compression stroke with a dial gauge.
• Install the timing chain onto both camshaft sprockets and then install the camshaft sprockets onto the camshafts.
CAUTION:
Do not turn the crankshaft when installing the camshaft to avoid damage or
improper valve timing.
NOTE:
• Make sure that the punch marks a on the
camshafts face up.
• Be sure to align the alignment mark b
made during removal to install the timing
chain and camshaft sprockets.
b
5-53
POWR
CAMSHAFTS
8
5
4
1
6
16 10
7
11 13
2
6 2
3
9
3 7 18
14 12
9 15
8 4
1 5 17
E
• Install the exhaust and intake camshaft
caps.
10
NOTE:
Gradually tighten the intake and exhaust
camshaft cap bolts in 2–3 steps in the
sequence shown.
T.
Camshaft cap bolt:
10 N • m (1.0 kgf • m, 7.2 ft • lb)
R.
NOTE:
Make sure that the punch marks c on the
camshafts are aligned with the arrow marks
d on the camshaft caps.
Out of alignment → Reinstall.
• Remove the wire from the timing chain.
3. Install:
• Timing chain tensioner
Installation steps:
• While lightly pressing the timing chain
tensioner rod by hand, turn the tensioner
rod fully clockwise with a thin screwdriver
1.
NOTE:
Make sure that the tensioner rod has been
fully set clockwise.
• With the timing chain tensioner rod
turned all the way into the timing chain
tensioner housing (with the thin screwdriver still installed), install the gasket and
the timing chain tensioner 2 onto the cylinder block.
3
3
2
WARNING
Always use a new gasket.
5-54
POWR
CAMSHAFTS
E
• Tighten the timing chain tensioner bolts
3 to the specified torque.
NOTE:
The “UP” mark on the timing chain tensioner should face up.
T.
Timing chain tensioner bolt:
10 N • m (1.0 kgf • m, 7.2 ft • lb)
R.
• Remove the screwdriver, make sure the
timing chain tensioner rod releases, and
then tighten the cap bolt to the specified
torque.
T.
Cap bolt:
10 N • m (1.0 kgf • m, 7.2 ft • lb)
R.
4. Turn:
• Drive coupling
(several turns counterclockwise)
5. Check:
Turn the drive coupling counterclockwise, and then check if cylinder #1 is at
TDC of the compression stroke with a
dial gauge.
• Camshaft punch mark a
Make sure that the camshaft punch
mark is aligned with the arrow mark b
on the camshaft cap.
Out of alignment → Adjust.
Refer to the installation steps above.
6. Measure:
• Valve clearance
Out of specification → Adjust.
Refer to “POWER UNIT” in Chapter 3.
5-55
POWR
CAMSHAFTS
E
7. Install:
• Cylinder head cover gasket
• Cylinder head cover
NOTE:
• Apply Gasket Maker® onto the mating surfaces of the cylinder head cover gasket and
cylinder head.
• Tighten the cylinder head cover bolts stages
and in a crisscross pattern.
T.
R.
5-56
Cylinder head cover bolt:
12 N • m (1.2 kgf • m, 8.7 ft • lb)
POWR
CYLINDER HEAD
E
CYLINDER HEAD
EXPLODED DIAGRAM
20 N • m (2.0 kgf • m, 14 ft • Ib)
2nd 49 N • m (4.9 kgf • m, 35 ft • Ib)
1st
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 12 mm
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 55 mm
20 N • m (2.0 kgf • m, 14 ft • Ib)
2nd 64 N • m (6.4 kgf • m, 46 ft • Ib)
1st
3
E
5
E
5
5
E
5
5
E
4
E
2
E
6
1
LT
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 12 mm
7
271
8
40 N • m (4.0 kgf • m, 29 ft • Ib)
8 × 20 mm
REMOVAL AND INSTALLATION CHART
Step
1
2
3
Procedure/Part name
CYLINDER HEAD REMOVAL
Engine unit
Air filter case
Exhaust pipe 3
Exhaust pipes 1 and 2
Oil tank
Intake and exhaust camshaft
Bolt
Hunger
Bolt
Q’ty
2
1
3
5-57
Service points
Follow the left “Step” for removal.
Refer to “ENGINE UNIT”.
Refer to “FUEL INJECTION SYSTEM” in
Chapter 4.
Refer to “EXHAUST PIPE 3”.
Refer to “EXHAUST PIPES 1 AND 2”.
Refer to “OIL TANK”.
Refer to “CAMSHAFTS”.
POWR
CYLINDER HEAD
E
EXPLODED DIAGRAM
20 N • m (2.0 kgf • m, 14 ft • Ib)
2nd 49 N • m (4.9 kgf • m, 35 ft • Ib)
1st
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 12 mm
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 55 mm
20 N • m (2.0 kgf • m, 14 ft • Ib)
2nd 64 N • m (6.4 kgf • m, 46 ft • Ib)
1st
3
E
5
E
5
5
E
5
5
E
4
E
2
E
6
1
LT
10 N • m (1.0 kgf • m, 7.2 ft • Ib)
6 × 12 mm
7
271
8
40 N • m (4.0 kgf • m, 29 ft • Ib)
8 × 20 mm
Step
4
5
6
7
8
Procedure/Part name
Nut/washer
Nut/washer
Cylinder head
Cylinder head gasket
Dowel pin
Q’ty
2/2
8/8
1
1
2
Service points
Not reusable
Reverse the removal steps for installation.
5-58
POWR
CYLINDER HEAD
E
SERVICE POINTS
Cylinder head removal
1. Remove:
• Cylinder head bolts 1
2. Remove:
• Cylinder head nuts
NOTE:
Loosen the cylinder head nuts in the sequence
shown.
Cylinder head inspection
1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
• spark plug bore threads
• valve seats
2. Check:
• Cylinder head
Damage/scratches → Replace.
• Cylinder head water jacket
Mineral deposits/rust → Eliminate.
5-59
POWR
CYLINDER HEAD
E
3. Measure:
• Cylinder head warpage
Out of specification → Replace the cylinder head.
Cylinder head warpage limit:
0.1 mm (0.004 in)
Measurement steps:
• Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
• Measure the warpage.
• If the limit is exceeded, replace the cylinder head.
Cylinder head installation
1. Install:
• Cylinder head
NOTE:
• Pass the timing chain through the timing
chain cavity.
• Lubricate the cylinder head nuts with engine
oil.
• Tighten the cylinder head nuts in the
sequence shown.
T.
R.
5-60
Cylinder head nut 1, 2:
1st:
20 N • m (2.0 kgf • m, 14 ft • lb)
2nd:
49 N • m (4.9 kgf • m, 35 ft • lb)
Cylinder head nut 3:
1st:
20 N • m (2.0 kgf • m, 14 ft • lb)
2nd:
64 N • m (6.4 kgf • m, 46 ft • lb)
POWR
CYLINDER HEAD
E
2. Tighten:
• Cylinder head bolts 1
NOTE:
Lubricate the cylinder head bolts with engine
oil.
T.
R.
5-61
Cylinder head bolt:
10 N • m (1.0 kgf • m, 7.2 ft • lb)
POWR
VALVES AND VALVE SPRINGS
VALVES AND VALVE SPRINGS
EXPLODED DIAGRAM
10
11
12
13
14
1
2
3
4
5
3
E
12
15
16
6
7
E
18
9
8
17
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
Procedure/Part name
VALVES AND VALVE SPRINGS
REMOVAL
Cylinder head
Intake valve lifter
Intake valve pad
Intake valve cotter
Intake valve upper spring seat
Intake valve spring
Intake valve oil seal
Intake valve lower spring seat
Intake valve
Intake valve guide
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “CYLINDER HEAD”.
12
12
24
12
12
12
12
12
12
5-62
E
POWR
VALVES AND VALVE SPRINGS
E
EXPLODED DIAGRAM
10
11
12
13
14
1
2
3
4
5
3
E
12
15
16
6
7
E
18
9
8
17
E
Step
10
11
12
13
14
15
16
17
18
Procedure/Part name
Exhaust valve lifter
Exhaust valve pad
Exhaust valve cotter
Exhaust valve upper spring seat
Exhaust valve spring
Exhaust valve oil seal
Exhaust valve lower spring seat
Exhaust valve
Exhaust valve guide
Q’ty
8
8
16
8
8
8
8
8
8
Service points
Reverse the removal steps for installation.
5-63
POWR
VALVES AND VALVE SPRINGS
E
SERVICE POINTS
Valve removal
1. Remove:
• Valve lifter 1
• Valve pad 2
NOTE:
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Remove:
• Valve cotters 1
NOTE:
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
2 and attachment 3.
Valve spring compressor:
YM-04019/90890-04019
Valve spring compressor
attachment:
(for the intake valve)
YM-4114/90890-04114
(for the exhaust valve)
YM-4108/90890-04108
3. Remove:
• Upper spring seat 1
• Valve spring 2
• Valve 3
• Oil seal 4
• Lower spring seat 5
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
5-64
POWR
VALVES AND VALVE SPRINGS
E
Valve spring inspection
1. Measure:
• Valve spring free length a
Out of specification → Replace the
valve spring.
Valve spring free length:
Intake valve spring:
38.90 mm (1.53 in)
Exhaust valve spring:
40.67 mm (1.60 in)
2. Measure:
• Valve spring tilt a
Out of specification → Replace the
valve spring.
Valve spring tilt:
Intake valve spring:
1.7 mm (0.067 in)
Exhaust valve spring:
1.8 mm (0.071 in)
Valve inspection
1. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
2. Check:
• Valve face
Pitting/wear → Replace the valve.
3. Measure:
• Valve margin thickness a
Out of specification → Replace the
valve.
Valve margin thickness:
0.5–0.9 mm (0.0197–0.0354 in)
5-65
POWR
VALVES AND VALVE SPRINGS
E
4. Measure:
• Valve stem diameter a
Out of specification → Replace the
valve.
Valve stem diameter a:
Intake valve:
3.975–3.990 mm
(0.1565–0.1571 in)
Exhaust valve:
4.460–4.475 mm
(0.1756–0.1762 in)
5. Measure:
• Valve stem runout
Out of specification → Replace the
valve.
NOTE:
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always
replace the oil seal.
Valve stem runout:
0.01 mm (0.0004 in)
Valve guide inspection
NOTE:
Before checking the valve guide make sure
that the valve stem diameter is within specification.
5-66
POWR
VALVES AND VALVE SPRINGS
E
1. Measure:
• Valve guide inside diameter a
Valve guide inside diameter:
Intake:
4.000–4.012 mm
(0.1575–0.1580 in)
Exhaust:
4.500–4.512 mm
(0.1772–0.1776 in)
a
2. Calculate the valve stem-to-valve guide
clearance as follows. Replace the valve
guide if out of specification.
Valve stem-to-valve guide
clearance = valve guide inside
diameter – valve stem diameter:
Intake:
0.010–0.037 mm
(0.0004–0.0015 in)
Exhaust:
0.025–0.052 mm
(0.0010–0.0020 in)
Valve guide replacement
1. Remove the valve guide 1 by striking the
special service tool from the combustion
chamber side.
1
Valve guide remover:
Intake (4.0 mm):
YM-04111/90890-04111
Exhaust (4.5 mm):
YM-04116/90890-04116
5-67
POWR
VALVES AND VALVE SPRINGS
E
2. Install the new valve guide 2 by striking
the special service tool from the camshaft
side until the valve guide clip 3 contacts
the cylinder head.
2
NOTE:
Apply engine oil to the surface of the new
valve guide.
E
3
Valve guide remover:
Intake (4.0 mm):
YM-04111/90890-04111
Exhaust (4.5 mm):
YM-04116/90890-04116
Valve guide installer:
Intake (4.0 mm):
YM-04112/90890-04112
Exhaust (4.5 mm):
YM-04117/90890-04117
3. Insert the special service tool into the
valve guide 2, and then ream the valve
guide.
NOTE:
• Turn the valve guide reamer clockwise to
ream the valve guide.
• Do not turn the reamer counterclockwise
when removing the reamer.
2
Valve guide reamer:
Intake (4.0 mm):
YM-04113/90890-04113
Exhaust (4.5 mm):
YM-04118/90890-04118
4. Measure:
• Valve guide inside diameter
Valve guide inside diameter:
Intake:
4.000–4.012 mm
(0.1575–0.1580 in)
Exhaust:
4.500–4.512 mm
(0.1772–0.1776 in)
5-68
POWR
VALVES AND VALVE SPRINGS
E
Valve seat inspection
1. Eliminate carbon deposits from the valve
with a scraper.
2. Apply a thin, even layer of Mechanic’s
blueing dye (Dykem) onto the valve seat.
3. Lap the valve slowly on the valve seat with
a valve lapper (commercially obtainable)
as shown.
4. Measure the valve seat contact width a
where the blueing dye is adhered to the
valve face. Reface the valve seat if the
valve is not seated properly or if the valve
seat contact width is out of specification.
Replace the valve guide if the valve seat
contact is uneven.
Valve seat contact width a:
0.9–1.1 mm (0.0354–0.0433 in)
5-69
POWR
VALVES AND VALVE SPRINGS
E
Valve seat reface
1. Reface the valve seat with the valve seat
cutter.
Valve seat cutter holder:
Intake (4.0 mm):
90890-06811
Exhaust (4.5 mm):
90890-06812
Valve seat cutter:
30° (intake):
90890-06815
45° (intake):
90890-06814
60° (intake):
90890-06813
30° (exhaust):
90890-06328
45° (exhaust):
90890-06312
60° (exhaust):
90890-06315
Valve seat cutter set:
YM-91043-C
2. Cut the surface of the valve seat with a 45°
cutter by turning the cutter clockwise until
the valve seat face has become smooth.
a Slag or rough surface
CAUTION:
Do not over cut the valve seat. Be sure to
turn the cutter evenly downward at a pressure of 40–50 N (4–5 kgf, 8.8–11 lbf) to prevent chatter marks.
3. Use a 30° cutter to adjust the contact width
of the top edge of the valve seat.
b
b Previous contact width
30˚
5-70
POWR
VALVES AND VALVE SPRINGS
E
4. Use a 60° cutter to adjust the contact width
of the bottom edge of the valve seat.
b
b Previous contact width
60˚
5. Use a 45° cutter to adjust the contact width
of the valve seat to specification.
b
b Previous contact width
c Specified contact width
c
45˚
6. If the valve seat contact area is too wide
and situated in the center of the valve
face, use a 30° cutter to cut the top edge
of the valve seat, a 60° cutter to cut the
bottom edge to center the area and set its
width.
b Previous contact width
7. If the valve seat contact area is too narrow
and situated near the top edge of the valve
face, use a 30° cutter to cut the top edge
of the valve seat. If necessary, use a 45°
cutter to center the area and set its width.
b Previous contact width
8. If the valve seat contact area is too narrow
and situated near the bottom edge of the
valve face, use a 60° cutter to cut the bottom edge of the valve seat. If necessary,
use a 45° cutter to center the area and set
its width.
b Previous contact width
5-71
POWR
VALVES AND VALVE SPRINGS
E
9. Apply a thin, even layer of lapping compound onto the valve seat, and then lap
the valve using a valve lapper (commercially obtainable).
CAUTION:
Do not get the lapping compound on the
valve stem and valve guide.
10. After every lapping procedure, be sure to
clean off any remaining lapping compound
from the cylinder head and the valve.
11. Check the valve seat contact area of the
valve again.
Valve installation
1. Install:
• Lower spring seat 1
• Oil seal 2
• Valve 3
• Valve spring 4
• Upper spring seat 5
(into the cylinder head)
NOTE:
• Make sure that each valve is installed in its
original place. Refer to the following
embossed marks.
Right and left intake valve(-s): “4XV:”
Middle intake valve(-s): “4XV.”
Exhaust valve(-s): “5LV”
• Install the valve spring with the larger pitch
a facing up.
b Smaller pitch
5-72
POWR
VALVES AND VALVE SPRINGS
E
2. Compress the valve spring, and then
install the valve cotter 1 using a thin
screwdriver with a small amount of grease
applied to it.
Valve spring compressor:
YM-04019/90890-04019
Valve spring compressor
attachment:
(for the intake valve)
YM-4114/90890-04114
(for the exhaust valve)
YM-4108/90890-04108
3. Lightly tap the valve spring retainer with a
plastic hammer to set the valve cotter
securely.
NOTE:
Apply engine oil to the valve shims and valve
lifters before installation.
5-73
POWR
CRANKCASE
E
CRANKCASE
EXPLODED DIAGRAM
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
8.4 N • m (0.84 kgf • m, 6.1 ft • Ib)
20 N • m (2.0 kgf • m, 14 ft • Ib)
8 × 40 mm
LT
7
271
LT
9 10 11
572
1
8
15 N • m (1.5 kgf • m, 11 ft • Ib)
2
6
3
A
22
23
4
21
5
LT
22
572
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
20
7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)
2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)
3rd 49 ± 5˚
9 × 105 mm
1st
LT
6 × 70 mm
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
572
E
17
20
LT
572
E
18
19 16
15
14
LT
572
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
12
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
LT
572
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 25 mm
13 12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
REMOVAL AND INSTALLATION CHART
Step
Procedure/Part name
OIL PAN AND CRANKCASE
REMOVAL
Engine unit
Air filter case
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “ENGINE UNIT”.
Refer to “FUEL INJECTION SYSTEM” in
Chapter 4.
Refer to “EXHAUST PIPE 3”.
Refer to “EXHAUST PIPES 1 AND 2”.
Refer to “EXHAUST MANIFOLD”.
Refer to “GENERATOR AND STARTER
MOTOR”.
Refer to “OIL TANK”.
Exhaust pipe 3
Exhaust pipes 1 and 2
Exhaust manifold
Generator cover
Oil tank
5-74
POWR
CRANKCASE
E
EXPLODED DIAGRAM
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
8.4 N • m (0.84 kgf • m, 6.1 ft • Ib)
20 N • m (2.0 kgf • m, 14 ft • Ib)
8 × 40 mm
LT
7
271
LT
9 10 11
572
1
8
15 N • m (1.5 kgf • m, 11 ft • Ib)
2
6
3
A
22
23
4
21
5
LT
22
572
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
20
7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)
2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)
3rd 49 ± 5˚
9 × 105 mm
1st
LT
6 × 70 mm
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
572
E
17
20
LT
572
E
18
19 16
15
14
LT
572
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
12
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
Step
1
2
3
4
5
6
7
Procedure/Part name
Oil pump
Reduction drive gear case
Cylinder head
Timing chain
Engine temperature sensor
Washer
Bolt
Thermoswitch (engine)
Oil pressure switch
Bolt
LT
572
Q’ty
1
1
1
2
1
1
1
5-75
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 25 mm
13 12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
Service points
Refer to “OIL PUMP”.
Refer to “REDUCTION DRIVE GEAR”.
Refer to “CAMSHAFTS”.
POWR
CRANKCASE
E
EXPLODED DIAGRAM
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
8.4 N • m (0.84 kgf • m, 6.1 ft • Ib)
20 N • m (2.0 kgf • m, 14 ft • Ib)
8 × 40 mm
LT
7
271
LT
9 10 11
572
1
8
15 N • m (1.5 kgf • m, 11 ft • Ib)
2
6
3
A
22
23
4
21
5
LT
22
572
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
20
7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)
2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)
3rd 49 ± 5˚
9 × 105 mm
1st
LT
6 × 70 mm
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
572
E
17
20
LT
572
E
18
19 16
15
14
LT
572
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
12
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
Step
8
9
10
11
12
13
14
15
16
17
18
Procedure/Part name
Bolt
Anode cover
Grommet
Anode
Bolt
Bolt
Oil pan
Gasket
Bolt
Bolt
Bolt
LT
572
Q’ty
1
1
1
1
4
9
1
1
2
1
7
5-76
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 25 mm
13 12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
Service points
Not reusable
POWR
CRANKCASE
E
EXPLODED DIAGRAM
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
8.4 N • m (0.84 kgf • m, 6.1 ft • Ib)
20 N • m (2.0 kgf • m, 14 ft • Ib)
8 × 40 mm
LT
7
271
LT
9 10 11
572
1
8
15 N • m (1.5 kgf • m, 11 ft • Ib)
2
6
3
A
22
23
4
21
5
LT
22
572
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
20
7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)
2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)
3rd 49 ± 5˚
9 × 105 mm
1st
LT
6 × 70 mm
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
572
E
17
20
LT
572
E
18
19 16
15
14
LT
572
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
12
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
Step
19
20
21
22
23
Procedure/Part name
Cap
Bolt/washer
Lower crankcase
Dowel pin
Dowel pin/O-ring
LT
572
Q’ty
4
10/10
1
2
1/1
5-77
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 25 mm
13 12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
Service points
Not reusable
Reverse the removal steps for installation.
POWR
CRANKCASE
E
EXPLODED DIAGRAM
6 × 10 mm
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
1
2
E
A
3
8
E
7
6
35 N • m (3.5 kgf • m, 25 ft • Ib)
5
4
LT
572
12 N • m (1.2 kgf • m, 8.7 ft • Ib)
6 × 12 mm
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
Procedure/Part name
OIL PIPE AND OIL FILTER BOLT
REMOVAL
Crankshaft
Bolt
Oil pipe
O-ring
Screw
Cover
O-ring
Oil filter bolt
Lower crankcase
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “CRANKSHAFT”.
1
1
2
2
1
1
1
1
Not reusable
Not reusable
Reverse the removal steps for installation.
5-78
POWR
CRANKCASE
E
SERVICE POINTS
6
10
13
H
9
4
2
5
1
3
Crankcase disassembly
1. Remove:
• Oil pan bolts
8
NOTE:
• Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
• Loosen the bolts in decreasing numerical
order (refer to the numbers in the illustration).
• The numbers embossed on the oil pan indicate the oil pan tightening sequence.
12
7 11
F
B
D
J
8
6
2
4
0
9
3
1
5
7
C
A
E
I
2. Remove:
• Crankcase bolts
NOTE:
• Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
• Loosen the bolts in decreasing numerical
order (refer to the numbers in the illustration).
• The numbers embossed on the crankcase
indicate the crankcase tightening sequence.
G
3. Remove:
• Lower crankcase
CAUTION:
Tap on one side of the crankcase with a
soft-face hammer. Tap only on reinforced
portions of the crankcase, not on he crankcase mating surfaces. Work slowly and
carefully and make sure the crankcase
halves separate evenly.
M9 × 105 mm bolts: 1–0
M6 × 55 mm bolts: A–F
M6 × 55 mm bolts: G, H
M6 × 70 mm bolts: I
M6 × 55 mm bolts: J
5-79
POWR
CRANKCASE
E
4. Remove:
• Dowel pins
Crankcase inspection
1. Thoroughly wash the crankcase halves in
a mild solvent.
2. Thoroughly clean all the gasket surfaces
and crankcase mating surfaces.
3. Check:
• Crankcase
Cracks/damage → Replace.
• Oil delivery passages
Obstruction → Blow out with compressed air.
Timing chain inspection
1. Check:
• Timing chain 1
Damage/stiffness → Replace the timing
chain and camshaft sprockets as a set.
Crankcase assembly
1. Lubricate:
Crankshaft journal bearings
(with the recommended lubricant)
Recommended lubricant:
Engine oil
5-80
POWR
CRANKCASE
E
2. Apply:
• Gasket Maker®
(onto the crankcase mating surfaces)
GM
1
NOTE:
Do not allow any Gasket Maker® to come into
contact with the oil gallery or crankshaft journal
bearings.
12
1
3. Install:
• Dowel pins 1
• O-ring 2
H
F
B
D
J
8
6
2
4
0
9
3
1
5
7
C
A
E
F
B
D
J
8
6
2
4
0
9
3
1
5
7
C
A
E
I
H
I
4. Install:
• Crankcase bolts
NOTE:
• Lubricate the bolt 1–0 threads and washers with engine oil.
• Finger tighten the crankcase bolts.
M9 × 105 mm bolts: 1–0
M6 × 55 mm bolts: A–F
M6 × 55 mm bolts: G, H
M6 × 70 mm bolts: I
M6 × 55 mm bolts: J
G
5. Tighten:
• Crankcase bolts 1–0
NOTE:
• Do not reuse crankcase bolts 1–0.
• The tightening procedure of crankcase bolts
1–0 is angle controlled, therefore tighten
the bolts using the following procedure.
G
5-81
POWR
CRANKCASE
E
Tightening steps:
• Tighten the bolts in the tightening
sequence cast on the crankcase.
T.
R.
Crankcase bolt 1–0:
1st:
7.8 N • m
(0.78 kgf • m, 5.6 ft • lb)
• Loosen and retighten the crankcase bolts
in the proper tightening sequence as
shown.
T.
R.
Crankcase bolt 1–0:
2nd:
15 N • m (1.5 kgf • m, 11 ft • lb)
• Tighten the crankcase bolts further to
reach the specified angle 49° in the
proper tightening sequence as shown.
T.
R.
Crankcase bolt 1–0:
Final:
Specified angle 49 ± 5°
WARNING
When the bolts are tightened more than
the specified angle, do not loosen the
bolt and then retighten it.
Replace the bolt with a new one and perform the procedure again.
CAUTION:
• Do not use a torque wrench to tighten
the bolt to the specified angle.
• Tighten the bolt until it is at the specified angle.
NOTE:
When using a hexagonal bolt, note that the
angle from one corner to another is 60°.
5-82
POWR
H
CRANKCASE
J
F
B
D
8
6
2
4
0
9
3
1
5
7
C
A
E
6. Tighten:
• Crankcase bolts A–J
NOTE:
Tighten the bolts in the tightening sequence
cast on the crankcase.
G
T.
Crankcase bolt A–J:
12 N • m (1.2 kgf • m, 8.7 ft • lb)
R.
I
E
7. Tighten:
• Oil pan bolts
6
10
13
9
4
2
5
1
3
NOTE:
Tighten the bolts in the tightening sequence
cast on the oil pan.
8
12
7 11
T.
R.
5-83
Oil pan bolt:
12 N • m (1.2 kgf • m, 8.7 ft • lb)
POWR
CONNECTING RODS AND PISTONS
E
CONNECTING RODS AND PISTONS
EXPLODED DIAGRAM
10
11
12
E
E
4
5
6
8
7
9
E
E
3
2
1
1st
20 N • m (2.0 kgf • m, 14 ft • Ib)
2nd 120 ± 5˚
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
Procedure/Part name
CONNECTING RODS AND
PISTONS REMOVAL
Crankcase
Nut
Connecting rod cap
Big end lower bearing
Piston pin clip
Piston pin
Piston
Connecting rod
Q’ty
8
4
4
8
4
4
4
5-84
Service points
Follow the left “Step” for removal.
Separate
Refer to “CRANKCASE”.
Not reusable
Not reusable
POWR
CONNECTING RODS AND PISTONS
E
EXPLODED DIAGRAM
10
11
12
E
E
4
5
6
8
7
9
E
E
3
2
1
1st
20 N • m (2.0 kgf • m, 14 ft • Ib)
2nd 120 ± 5˚
Step
8
9
10
11
12
Procedure/Part name
Bolt
Big end upper bearing
Top ring
2nd ring
Oil ring
Q’ty
8
4
4
4
4
Service points
Not reusable
Reverse the removal steps for installation.
5-85
POWR
CONNECTING RODS AND PISTONS
E
SERVICE POINTS
1
Connecting rod and piston removal
The following procedure applies to all of the
connecting rods and pistons.
1. Remove:
• Connecting rod cap 1
• Big end bearings
NOTE:
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
2. Remove:
• Piston pin clips 1
• Piston pin 2
• Piston 3
• Connecting rod 4
CAUTION:
Do not use a hammer to drive the piston
pin out.
NOTE:
• For reference during installation, put identification marks on the piston crown.
• Before removing the piston pin, deburr the
piston pin clip’s groove and the piston’s pin
bore area.
5-86
POWR
CONNECTING RODS AND PISTONS
E
3. Remove:
• Top ring
• 2nd ring
• Oil ring
NOTE:
When removing a piston ring, open the end
gap with your fingers and lift the other side of
the ring over the piston crown.
Cylinder and piston inspection
The following procedure applies to all of the
cylinders and pistons.
1. Check:
• Piston wall
• Cylinder wall
Vertical scratches → Replace the cylinder, and the piston and piston rings as a
set.
2. Measure:
• Piston-to-cylinder clearance
c
b
a
D2
D1
d
D4
D3
e
D6
D5
Measurement steps:
• Measure cylinder bore “C” with the cylinder bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the
cylinder. Then, find the average of the measurements.
Cylinder bore “C”
74.060–74.075 mm
(2.9157–2.9163 in)
Taper limit “T”
0.08 mm (0.003 in)
Out of round “R”
0.05 mm (0.002 in)
“C” = maximum of D1–D6
“T” = maximum of D1–D5 (direction d)
and D2–D6 (direction e)
“R” = maximum of D2–D1 (measuring
point a) and D6–D5 (measuring point c)
5-87
POWR
CONNECTING RODS AND PISTONS
E
• If out of specification, replace the piston
and piston rings as a set.
• Measure piston skirt diameter “P” with the
micrometer.
a 5 mm (0.2 in) from the bottom edge of the
piston
Piston size “P”
Standard
73.955–73.970 mm
(2.9116–2.9121 in)
• If out of specification, replace the piston
and piston rings as a set.
• Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance:
0.10–0.11 mm (0.0039–0.0043 in)
<Limit>: 0.17 mm (0.0067 in)
• If out of specification, replace the piston
and piston rings as a set.
Piston ring inspection
1. Measure:
• Piston ring side clearance
Out of specification → Replace the piston and piston rings as a set.
NOTE:
Before measuring the piston ring side clearance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
Piston ring groove:
Top ring:
0.030–0.065 mm
(0.0012–0.0026 in)
2nd ring:
0.020–0.055 mm
(0.0008–0.0022 in)
5-88
POWR
CONNECTING RODS AND PISTONS
E
2. Install:
• Piston ring
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with the
piston crown.
a 5 mm (0.2 in)
3. Measure:
• Piston ring end gap
Out of specification → Replace the piston ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is excessive, replace all three piston rings.
Piston ring end gap:
Top ring:
0.38–0.55 mm
(0.0150–0.0217 in)
2nd ring:
0.49–0.69 mm
(0.0193–0.0272 in)
Oil ring:
0.29–0.59 mm
(0.0114–0.0232 in)
Piston pin inspection
The following procedure applies to all of the
piston pins.
1. Check:
• Piston pin
Blue discoloration/grooves → Replace
the piston pin and then check the lubrication system.
5-89
POWR
CONNECTING RODS AND PISTONS
E
2. Measure:
• Piston pin outside diameter a
Out of specification → Replace the piston pin.
Piston pin outside diameter:
16.991–17.000 mm
(0.6689–0.6693 in)
<Limit>: 16.971 mm (0.6681 in)
3. Measure:
• Piston pin bore diameter (in the piston)
b
Out of specification → Replace the piston.
Piston pin bore diameter
(in the piston):
17.002–17.013 mm
(0.6693–0.6698 in)
4. Calculate:
• Piston-pin-to-piston clearance
Out of specification → Replace the piston pin.
Piston-pin-to-piston clearance =
Piston pin bore diameter (in the piston)
b – Piston pin outside diameter a
Piston-pin-to-piston clearance:
0.002–0.042 mm
(0.0001–0.0017 in)
5-90
POWR
CONNECTING RODS AND PISTONS
E
Connecting rod inspection
1. Measure:
• Crankshaft-pin-to-big-end-bearing
clearance
Out of specification → Replace the big
end bearings.
Crankshaft-pin-to-big-endbearing clearance:
0.016–0.040 mm
(0.0006–0.0016 in)
Measurement steps:
The following procedure applies to all of the
connecting rods.
CAUTION:
Do not interchange the big end bearings
and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing
clearance and prevent engine damage,
the big end bearings must be installed in
their original positions.
• Clean the big end bearings, crankshaft
pins, and the inside of the connecting rod
halves.
• Install the big end upper bearing into the
connecting rod and the big end lower
bearing into the connecting rod cap.
NOTE:
Align the projections a on the big end bearings with the notches b in the connecting
rod and connecting rod cap.
1
• Put a piece of Plastigauge® 1 on the
crankshaft pin.
• Assemble the connecting rod halves.
5-91
POWR
CONNECTING RODS AND PISTONS
E
d
NOTE:
• Do not move the connecting rod or crankshaft until the clearance measurement
has been completed.
• Lubricate the bolts threads and nut seats
with molybdenum disulfide grease.
• Make sure the “Y” mark c on the connecting rod faces towards the front side of
the crankshaft.
• Make sure the characters d on both the
connecting rod and connecting rod cap
are aligned.
c
• Tighten the connecting rod nuts.
Refer to “Connecting rod and piston
installation”.
• Remove the connecting rod and big end
bearings.
Refer to “Connecting rod and piston
removal”.
• Measure the compressed Plastigauge®
width e on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select
replacement big end bearings.
e
2. Select:
• Big end bearings (P1–P4)
NOTE:
• The numbers stamped into the crankshaft
web and the numbers on the connecting rods
are used to determine the replacement big
end bearing sizes.
• “P1”–”P4” refer to the bearings shown in the
crankshaft illustration.
P4
P1
P2
P3
5-92
POWR
CONNECTING RODS AND PISTONS
E
For example, if the connecting rod “P1” and the
crankshaft web “P1” numbers are “5” and “1”
respectively, then the bearing size for “P1” is:
Bearing size of P1:
“P1” (connecting rod) –
“P1” (crankshaft web)
5 – 1 = 4 (green)
5G
BEARING COLOR CODE
P1 P2 P3 P4
1
brown
2
black
3
blue
4
green
Connecting rod and piston installation
The following procedure applies to all of the
pistons and connecting rods.
1. Install:
• Top ring
• 2nd ring
• Oil ring
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
2. Install:
• Piston 1
• Connecting rod 2
• Piston pin 3
• Piston pin clip 4
NOTE:
• Apply engine oil onto the piston pin.
• Make sure that the “Y” mark a on the connecting rod left when the arrow mark b on
the piston is pointing up. Refer to the illustration.
• Reinstall each piston into its original cylinder
(numbering order starting from the front: #1
to #4).
5-93
POWR
CONNECTING RODS AND PISTONS
E
3. Offset:
• Piston ring end gaps
a
b
c
d
È
Top ring
Lower oil ring rail
Upper oil ring rail
2nd ring
Intake side
4. Lubricate:
• Piston
• Piston rings
• Cylinder
(with the recommended lubricant)
Recommended lubricant:
Engine oil
5. Lubricate:
• Bolt threads
• Nut seats
(with the recommended lubricant)
Recommended lubricant:
Molybdenum disulfide grease
6. Lubricate:
• Crankshaft pins
• Big end bearings
• Connecting rod inner surface
(with the recommended lubricant)
Recommended lubricant:
Engine oil
5-94
POWR
CONNECTING RODS AND PISTONS
E
7. Install:
• Big end bearings
• Connecting rod assembly 1
(into the cylinder and onto the
crankshaft pin)
• Connecting rod cap
(onto the crankshaft pin)
NOTE:
• Align the projections on the big end bearings
with the notches in the connecting rods and
connecting rod caps.
• Be sure to reinstall each big end bearing in
its original place.
• While compressing the piston rings with piston ring compressor 2, install the connecting
rod assembly into the cylinder with the other
hand.
• Make sure the “Y” marks a on the connecting rods face towards the front side of the
crankshaft.
• Make sure the characters b on both the connecting rod and connecting rod cap are
aligned.
Piston ring compressor:
YM-08037/90890-05158
8. Align:
• Bolt heads
(with the connecting rod)
5-95
POWR
CONNECTING RODS AND PISTONS
E
9. Tighten:
• Connecting rod nuts
WARNING
• Replace the connecting rod bolts and
nuts with new ones.
• Clean the connecting rod bolts and nuts.
NOTE:
The tightening procedure of the connecting rod
nuts is angle controlled, therefore tighten the
nuts using the following procedure.
Tightening steps:
• Tighten the connecting rod nuts to the
specified torque.
T.
R.
Connecting rod nut:
1st:
20 N • m (2.0 kgf • m, 14 ft • lb)
• Tighten the connecting rod nuts further to
reach the specified angle 120°.
T.
R.
Connecting rod nut:
Final:
Specified angle 120 ± 5°
WARNING
When the nuts are tightened more than
the specified angle, do not loosen the
nut and then retighten it.
Replace the nut with a new one and perform the procedure again.
CAUTION:
• Do not use a torque wrench to tighten
the nut to the specified angle.
• Tighten the nut until it is at the specified angle.
NOTE:
When using a hexagonal nut, note that the
angle from one corner to another is 60°.
5-96
POWR
CRANKSHAFT
E
CRANKSHAFT
EXPLODED DIAGRAM
3
3
1
2
2
REMOVAL AND INSTALLATION CHART
Step
Procedure/Part name
CRANKSHAFT REMOVAL
Crankcase
Q’ty
Connecting rod caps
1
2
3
Crankshaft
Crankshaft journal lower bearing
Crankshaft journal upper bearing
Service points
Follow the left “Step” for removal.
Separate
Refer to “CRANKCASE”.
Refer to “CONNECTING RODS AND
PISTONS”.
1
5
5
Reverse the removal steps for installation.
5-97
POWR
CRANKSHAFT
E
SERVICE POINTS
Crankshaft removal
1. Remove:
• Crankshaft 1
• Crankshaft journal lower bearings
(from the lower crankcase)
• Crankshaft journal upper bearings
(from the upper crankcase)
1
NOTE:
Identify the position of each crankshaft journal
bearing so that it can be reinstalled in its original place.
Crankshaft inspection
1. Measure:
• Crankshaft runout
Out of specification → Replace the
crankshaft.
Maximum crankshaft runout:
0.03 mm (0.0012 in)
2. Check:
• Crankshaft journal surfaces
• Crankshaft pin surfaces
• Bearing surfaces
Scratches/wear → Replace the crankshaft.
3. Measure:
• crankshaft-journal-to-crankshaft-journalbearing clearance
Out of specification → Replace the
crankshaft journal bearings.
Crankshaft-journal-to-crankshaftjournal-bearing clearance:
0.020–0.057 mm
(0.0008–0.0022 in)
5-98
POWR
CRANKSHAFT
E
CAUTION:
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaftjournal-to-crankshaft-journal-bearing clearance and prevent engine damage, the
crankshaft journal bearings must be
installed in their original positions.
a
Measurement steps:
• Clean the crankshaft journal bearings,
crankshaft journals, and bearing portions
of the crankcase.
• Place the upper crankcase upside down
on a bench.
• Install the crankshaft journal upper bearings 1 and the crankshaft into the upper
crankcase.
1
b
NOTE:
Align the projections a of the crankshaft
journal upper bearings with the notches b
in the upper crankcase.
2
• Put a piece of Plastigauge® 2 on each
crankshaft journal.
NOTE:
Do not put the Plastigauge® over the oil
hole in the crankshaft journal.
• Install the crankshaft journal lower bearings into the lower crankcase and assemble the crankcase halves.
NOTE:
• Align the projections a of the crankshaft
journal lower bearings with the notches b
in the lower crankcase.
• Do not move the crankshaft until the
clearance measurement has been completed.
5-99
POWR
CRANKSHAFT
E
• Tighten the bolts to specification in the
tightening sequence cast on the crankcase.
Refer to “Crankcase assembly”—
“CRANKCASE”.
• Remove the lower crankcase and the
crankshaft journal lower bearings.
• Measure the compressed Plastigauge®
width c on each crankshaft journal.
If the crankshaft-journal-to-crankshaftjournal-bearing clearance is out of specification, select replacement crankshaft
journal bearings.
c
4. Select:
• Crankshaft journal bearings (J1–J5)
J1
J2
J3
J4
NOTE:
• The numbers stamped into the crankshaft
web and the numbers stamped into the lower
crankcase are used to determine the
replacement crankshaft journal bearing
sizes.
• “J1–J5” refer to the bearings shown in the
crankshaft illustration.
• If “J1–J5” are the same, use the same size
for all of the bearings.
J5
For example, if the crankcase “J1” and crankshaft web “J1” numbers are “5” and “2” respectively, then the bearing size for “J1” is:
Bearing size of J1:
“J1” (crankcase) – “J1” (crankshaft web)
5 – 2 = 3 (blue)
J5 J4 J3 J2 J1
BEARING COLOR CODE
J1 J2 J3 J4 J5
5-100
1
brown
2
black
3
blue
4
green
5
yellow
POWR
CRANKSHAFT
E
Crankshaft installation
1. Install:
• Crankshaft journal upper bearings
(into the upper crankcase)
• Crankshaft journal lower bearings
(into the lower crankcase)
a
b
NOTE:
• Align the projections a on the crankshaft
journal upper bearings with the notches b in
the upper crankcase.
• Be sure to install each crankshaft journal
bearing in its original place.
2. Lubricate:
• Crankshaft pins
• Connecting rod inner surface
(with the recommended lubricant)
Recommended lubricant:
Engine oil
5-101
POWR
THERMOSTAT
E
THERMOSTAT
EXPLODED DIAGRAM
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 35 mm
1st
a
3
É
3
4
1
7
9
8
LT
572
6
5
2
1
È
REMOVAL AND INSTALLATION CHART
Step
Q’ty
1
2
3
Procedure/Part name
THERMOSTAT REMOVAL
Band
Clamp/cooling water hose
Clamp/cooling water hose
4
Clamp/cooling water hose
1/1
5
6
7
Band/grease hose
Bolt
Thermostat housing cover
1/1
2
1
2
1/1
2/1
5-102
Service points
Follow the left “Step” for removal.
È For cooling water outlet on stern side.
NOTE:
Install the cooling water hose with the white
mark a facing up.
É For cooling water pilot outlet on starboard
side.
POWR
THERMOSTAT
E
EXPLODED DIAGRAM
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 35 mm
1st
a
3
É
3
4
1
7
9
8
LT
572
6
5
2
1
È
REMOVAL AND INSTALLATION CHART
Step
8
9
Procedure/Part name
Thermostat
Thermostat housing
Q’ty
1
1
Service points
Reverse the removal steps for installation.
5-103
POWR
THERMOSTAT
E
SERVICE POINTS
Thermostat inspection
1. Check:
• Thermostat 1
Does not open at 50–60 °C (123–
141 °F) → Replace.
Checking steps:
• Suspend the thermostat in a container
filled with water.
• Slowly heat the water.
• Place a thermometer in the water.
• While stirring the water, observe the thermostat and thermometer’s indicated temperature.
2
3
1
4
1
2
3
4
È
É
Thermostat
Thermometer
Water
Container
Fully closed
Fully open
NOTE:
If the accuracy of the thermostat is in doubt,
replace it. A faulty thermostat could cause serious overheating or over cooling.
2. Check:
• Thermostat housing cover
• Thermostat housing
Cracks/damage → Replace.
3. Check:
• Cooling system
Leaks → Repair or replace any faulty
part.
Thermostat installation
1. Install:
• Thermostat housing 1
• Thermostat 2
• Thermostat housing cover
5-104
POWR
PRESSURE CONTROL VALVE
E
PRESSURE CONTROL VALVE
EXPLODED DIAGRAM
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
1st
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 45 mm
È
È
È
È
LT
572
11
9
10
Ì
1
8
3
8
2
É
Ê
É
3
6
2
4
5
4
Ë
7
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
Procedure/Part name
PRESSURE CONTROL VALVE
REMOVAL
Exhaust manifold
Clamp/cooling water hose
Clamp/cooling water hose
Clamp/cooling water hose
Clamp/cooling water hose
Joint
Clamp/cooling water hose
Joint
Clamp/cooling water hose
Q’ty
1/1
2/2
2/1
2/1
1
1/1
1
2/1
5-105
Service points
Follow the left “Step” for removal.
Refer to “EXHAUST MANIFOLD”.
È From exhaust manifold
É To exhaust pipe
Ê To oil tank
Ë From cooling water inlet
Ì To oil tank
POWR
PRESSURE CONTROL VALVE
E
EXPLODED DIAGRAM
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
1st
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 45 mm
È
È
È
È
LT
572
11
9
10
Ì
1
8
3
8
2
É
Ê
É
3
6
2
4
5
4
Ë
7
REMOVAL AND INSTALLATION CHART
Step
9
10
11
Procedure/Part name
Bolt
Pressure control valve assembly
Gasket
Q’ty
3
1
1
5-106
Service points
Not reusable
Reverse the removal steps for installation.
POWR
PRESSURE CONTROL VALVE
E
EXPLODED DIAGRAM
9
5
6
4
7
8
6
3
2
LT
572
1
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 40 mm
1st
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
Procedure/Part name
PRESSURE CONTROL VALVE
DISASSEMBLY
Bolt
Collar
Pressure control valve housing
cover
Spring
Pressure control valve
Gasket
Plate
Q’ty
Service points
Follow the left “Step” for disassembly.
2
2
1
1
1
2
1
5-107
Not reusable
POWR
PRESSURE CONTROL VALVE
E
EXPLODED DIAGRAM
9
5
6
4
7
8
6
3
2
LT
572
1
Step
8
9
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 40 mm
1st
Procedure/Part name
Grommet
Pressure control valve housing
Q’ty
1
1
Service points
Reverse the disassembly steps for
assembly.
5-108
POWR
PRESSURE CONTROL VALVE
E
SERVICE POINTS
Pressure control valve inspection
1. Check:
• Pressure control valve 1
• Spring 2
Damage/wear → Replace the defective
part(s).
2. Check:
• Pressure control valve housing cover
• Pressure control valve housing
Cracks/damage → Replace.
3. Check:
• Cooling system
Leaks → Repair or replace any faulty
part.
5-109
JET
PUMP
E
CHAPTER 6
JET PUMP UNIT
INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT....................................6-1
EXPLODED DIAGRAM .............................................................................6-1
REMOVAL AND INSTALLATION CHART ................................................ 6-1
JET PUMP UNIT.............................................................................................. 6-3
EXPLODED DIAGRAM .............................................................................6-3
REMOVAL AND INSTALLATION CHART ................................................ 6-3
REVERSE GATE ............................................................................................. 6-6
EXPLODED DIAGRAM .............................................................................6-6
REMOVAL AND INSTALLATION CHART ................................................ 6-6
SERVICE POINTS .................................................................................... 6-9
Lever 1 installation ..............................................................................6-9
Lever 2 installation ..............................................................................6-9
JET THRUST NOZZLE AND NOZZLE RING ............................................... 6-10
EXPLODED DIAGRAM ...........................................................................6-10
REMOVAL AND INSTALLATION CHART .............................................. 6-10
IMPELLER DUCT AND IMPELLER HOUSING 1 .........................................6-11
EXPLODED DIAGRAM ...........................................................................6-11
REMOVAL AND INSTALLATION CHART .............................................. 6-11
IMPELLER DUCT AND DRIVE SHAFT ........................................................ 6-13
EXPLODED DIAGRAM ...........................................................................6-13
REMOVAL AND INSTALLATION CHART .............................................. 6-13
SERVICE POINTS .................................................................................. 6-15
Drive shaft removal ...........................................................................6-15
Impeller inspection ............................................................................6-16
Drive shaft inspection........................................................................6-16
Drive shaft installation ....................................................................... 6-17
JET
PUMP
TRANSOM PLATE AND HOSES.................................................................. 6-19
EXPLODED DIAGRAM ...........................................................................6-19
REMOVAL AND INSTALLATION CHART .............................................. 6-19
SERVICE POINTS .................................................................................. 6-22
Bilge strainer inspection .................................................................... 6-22
Electric bilge pump inspection........................................................... 6-22
Bilge hose inspection ........................................................................6-22
Cooling water hose inspection .......................................................... 6-22
BEARING HOUSING.....................................................................................6-23
EXPLODED DIAGRAM ...........................................................................6-23
REMOVAL AND INSTALLATION CHART .............................................. 6-23
SERVICE POINTS .................................................................................. 6-26
Driven coupling removal and installation...........................................6-26
Intermediate drive shaft removal.......................................................6-26
Bearing removal ................................................................................ 6-27
Bearing, intermediate drive shaft, and grease hose inspection ........ 6-27
Driven coupling inspection ................................................................6-27
Bearing installation............................................................................6-28
Oil seal installation ............................................................................6-28
Intermediate housing installation.......................................................6-29
E
1
2
3
4
5
6
7
8
9
JET
PUMP
INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT
E
INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
Procedure/Part name
INTAKE GRATE, RIDE PLATE,
AND INTAKE DUCT REMOVAL
Bolt
Bolt
Intake grate
Screw
Speed sensor
6
Bolt
Q’ty
2
2
1
4
1
4
6-1
Service points
Follow the left “Step” for removal.
NOTE:
Route the speed sensor lead between the
jet pump unit and the bilge hose.
JET
PUMP
INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT
E
EXPLODED DIAGRAM
Step
7
8
9
10
Procedure/Part name
Ride plate
Bolt
Intake duct
Felt packing
Q’ty
1
4
1
1
6-2
Service points
Not reusable
Reverse the removal steps for installation.
JET
PUMP
JET PUMP UNIT
E
JET PUMP UNIT
EXPLODED DIAGRAM
6.8 N • m (0.68 kgf • m, 4.9 ft • Ib)
6 × 22 mm
14 N • m (1.4 kgf • m, 10 ft • Ib)
8 × 24 mm
9
7
LT
8
271
2.2 N • m (0.22 kgf • m, 1.6 ft • Ib)
5
6
LT
A
242
2
4
12
11
40 N • m (4.0 kgf • m, 29 ft • Ib)
10 × 95 mm
1
LT
572
10
14
13
4
4
LT
3
572
6.8 N • m (0.68 kgf • m, 4.9 ft • Ib)
15
M
4
6 × 80 mm
7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)
REMOVAL AND INSTALLATION CHART
Step
Q’ty
1
2
3
Procedure/Part name
JET PUMP UNIT REMOVAL
Shift cable joint
QSTS cable joint
Bilge hose
4
5
6
Nut/washer
Steering cable joint
Clamp/spout hose
1/2
1
1/1
1
1
1
6-3
Service points
Follow the left “Step” for removal.
NOTE:
Route the speed sensor lead between the
jet pump unit and the bilge hose.
JET
PUMP
JET PUMP UNIT
E
EXPLODED DIAGRAM
6.8 N • m (0.68 kgf • m, 4.9 ft • Ib)
6 × 22 mm
14 N • m (1.4 kgf • m, 10 ft • Ib)
8 × 24 mm
9
7
LT
8
271
2.2 N • m (0.22 kgf • m, 1.6 ft • Ib)
5
6
LT
A
242
2
4
12
11
40 N • m (4.0 kgf • m, 29 ft • Ib)
10 × 95 mm
1
LT
572
10
14
13
4
4
LT
3
572
6.8 N • m (0.68 kgf • m, 4.9 ft • Ib)
15
M
4
Step
7
8
9
10
11
12
13
14
15
Procedure/Part name
Bolt
Collar
Rubber plate
Bolt
Bolt
Jet pump unit assembly
Dowel pin
Impeller housing 2
Dowel pin
Q’ty
4
4
2
1
4
1
2
1
2
6 × 80 mm
7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)
Service points
Reverse the removal steps for installation.
6-4
JET
PUMP
JET PUMP UNIT
E
EXPLODED DIAGRAM
1
2
FWD
REMOVAL AND INSTALLATION CHART
Step
1
2
Procedure/Part name
SPEED SENSOR DISASSEMBLY
Paddle wheel set
Speed sensor
Q’ty
1
1
Service points
Follow the left “Step” for disassembly.
Not reusable
Reverse the disassembly steps for
assembly.
6-5
JET
PUMP
REVERSE GATE
E
REVERSE GATE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
Procedure/Part name
REVERSE GATE REMOVAL
Clamp/spout hose
Bolt
Washer
Collar
Reverse gate assembly
Nut
Bolt
Washer
Q’ty
1/1
2
2
2
1
1
1
2
6-6
Service points
Follow the left “Step” for removal.
JET
PUMP
REVERSE GATE
E
EXPLODED DIAGRAM
Step
9
10
11
12
13
14
15
16
17
Procedure/Part name
Roller
Bolt
Reverse gate stay
Nut
Washer
Bolt
Lever 1
Spacer
Nut
Q’ty
1
6
2
1
1
1
1
1
1
6-7
Service points
JET
PUMP
REVERSE GATE
E
EXPLODED DIAGRAM
Step
18
19
20
21
22
23
24
Procedure/Part name
Washer
Bolt
Washer
Collar
Spring
Lever 2
Washer
Q’ty
1
1
1
1
1
1
1
Service points
Reverse the removal steps for installation.
6-8
JET
PUMP
REVERSE GATE
E
SERVICE POINTS
Lever 1 installation
1. Install:
• Bolt 1
• Lever 1 2
• Spacer 3
• Reverse gate 4
• Washer 5
• Nut 6
Lever 2 installation
1. Install:
• Bolt 1
• Washer 2
• Collar 3
• Spring 4
• Lever 2 5
• Washer 6
4
NOTE:
• When installing the spring, hook the spring
end a to lever 2 and spring end b to the
reverse gate, as shown in the illustration.
• When installing the lever 2, hook the lever 2
end c to lever 1 end d, as shown in the
illustration.
b
a
d
c
2. Install:
• Washer 1
• Nut 2
3. Check:
• Lever 1 and lever 2 movements
Stick → Reassemble lever 1 and
lever 2.
6-9
JET
PUMP
JET THRUST NOZZLE AND NOZZLE RING
E
JET THRUST NOZZLE AND NOZZLE RING
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
Procedure/Part name
JET THRUST NOZZLE AND
NOZZLE RING REMOVAL
Jet pump unit
Reverse gate
Bolt
Collar
Jet thrust nozzle
Bolt
Washer
Collar
Nozzle ring
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “JET PUMP UNIT”.
Refer to “REVERSE GATE”.
2
2
1
2
2
2
1
Reverse the removal steps for installation.
6-10
JET
PUMP
IMPELLER DUCT AND IMPELLER HOUSING 1
E
IMPELLER DUCT AND IMPELLER HOUSING 1
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
Procedure/Part name
IMPELLER DUCT AND IMPELLER
HOUSING 1 REMOVAL
Nozzle ring
Bolt
Nozzle
Pin
Impeller duct assembly
Impeller housing 1
Pin
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “JET THRUST NOZZLE AND
NOZZLE RING”.
4
1
2
1
1
2
6-11
NOTE:
Clean the contacting surfaces before applying the Yamabond #4 (Yamaha bond number 4).
JET
PUMP
IMPELLER DUCT AND IMPELLER HOUSING 1
E
EXPLODED DIAGRAM
Step
7
8
9
10
11
Procedure/Part name
Bolt
Water inlet cover
Packing
Water inlet strainer
Packing
Q’ty
4
1
1
1
1
Service points
Reverse the removal steps for installation.
6-12
JET
PUMP
IMPELLER DUCT AND DRIVE SHAFT
IMPELLER DUCT AND DRIVE SHAFT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
*1
Procedure/Part name
IMPELLER DUCT AND DRIVE
SHAFT DISASSEMBLY
Impeller
Spacer
Bolt
Cap
O-ring
Nut
Washer
Q’ty
1
1
3
1
1
1
1
: EPNOC grease AP #0
6-13
Service points
Follow the left “Step” for disassembly.
Left-hand threads
E
JET
PUMP
IMPELLER DUCT AND DRIVE SHAFT
EXPLODED DIAGRAM
Step
8
9
10
11
12
13
14
Procedure/Part name
Drive shaft
Rear bearing
Spacer
Front bearing
Oil seal
Oil seal
Impeller duct
Q’ty
1
1
1
1
1
1
1
Service points
Not reusable
Not reusable
Not reusable
Not reusable
Reverse the disassembly steps for
assembly.
*1
: EPNOC grease AP #0
6-14
E
JET
PUMP
IMPELLER DUCT AND DRIVE SHAFT
E
SERVICE POINTS
Drive shaft removal
1. Remove:
• Impeller
Drive shaft holder:
YB-06151/90890-06519
NOTE:
The impeller has left-hand threads. Turn the
impeller clockwise to loosen it.
2. Remove:
• Nut 1
Drive shaft holder:
YB-06151/90890-06519
3. Remove:
• Drive shaft 1
NOTE:
Remove the drive shaft with a press.
4. Remove:
• Rear bearing
È
Slide hammer set:
YB-06096
Stopper guide plate:
90890-06501
Bearing puller:
90890-06535
Bearing puller claw 1:
90890-06536
Stopper guide stand:
90890-06538
É
È For USA and Canada
É For worldwide
6-15
JET
PUMP
IMPELLER DUCT AND DRIVE SHAFT
5. Remove:
• Front bearing
Drive rod:
YB-06071
Driver rod L3:
90890-06652
Needle bearing attachment:
YB-06112/90890-06614
NOTE:
Remove the front bearing with a press.
6. Remove:
• Oil seal
Drive rod:
YB-06071
Driver rod L3:
90890-06652
Needle bearing attachment:
YB-06196/90890-06653
NOTE:
Remove the oil seals with press.
Impeller inspection
Refer to “JET PUMP UNIT” in
Chapter 3.
Drive shaft inspection
1. Inspect:
• Drive shaft
Damage/wear → Replace.
6-16
E
JET
PUMP
IMPELLER DUCT AND DRIVE SHAFT
E
Drive shaft installation
1. Install:
• Oil seals
Driver rod:
YB-06071/90890-06606
Ball bearing attachment:
YB-06085/90890-06634
Distance a:
14.2 ± 0.2 mm (0.56 ± 0.01 in)
Distance b:
4.7 ± 0.2 mm (0.19 ± 0.01 in)
2. Install:
• Front bearing
• Drive shaft
NOTE:
Install the front bearing and drive shaft with a
press.
a
Distance a:
23 ± 0.1 mm (0.91 ± 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
6-17
JET
PUMP
IMPELLER DUCT AND DRIVE SHAFT
E
5. Install:
• Rear bearing
Bearing inner/outer race
attachment:
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 46 mm (1.81 in) and an
inner diameter of 20 mm (0.79 in).
6. Add:
• EPNOC grease AP #0 (into the cap)
Quantity:
Approximately 1/3 of capacity
7. Install:
• Nut
• Impeller
Drive shaft holder:
YB-06151/90890-06519
6-18
JET
PUMP
TRANSOM PLATE AND HOSES
E
TRANSOM PLATE AND HOSES
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
Procedure/Part name
TRANSOM PLATE AND HOSES
REMOVAL
Exhaust system
Jet pump unit assembly
Hose clamp
Cooling water hose
Bilge hose 1
4
5
Hose clamp
Cooling water hose
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “EXHAUST SYSTEM” in Chapter 8.
Refer to “JET PUMP UNIT”.
2
1
1
1
1
6-19
Cooling water outlet (exhaust pipe)
NOTE:
Route the bilge hose 1 under the drive shaft
tube.
Cooling water inlet
JET
PUMP
TRANSOM PLATE AND HOSES
E
EXPLODED DIAGRAM
Step
6
7
8
9
10
11
12
13
14
15
Procedure/Part name
Hose clamp
Cooling water hose
Bilge hose 2
Hose clamp
Bilge hose 3
Band
Electric bilge pump assembly
Hose clamp
Bilge hose 4
Screw
Q’ty
2
1
1
1
1
1
1
1
1
1
6-20
Service points
Cooling water outlet (thermostat)
JET
PUMP
TRANSOM PLATE AND HOSES
E
EXPLODED DIAGRAM
Step
16
17
18
19
20
Procedure/Part name
Bilge strainer holder
Bilge strainer
Nut/washer
Transom plate
Bilge hose 5
Q’ty
1
1
4/4
1
1
Service points
Reverse the removal steps for installation.
6-21
JET
PUMP
TRANSOM PLATE AND HOSES
E
SERVICE POINTS
Bilge strainer inspection
Refer to “JET PUMP UNIT” in
Chapter 3.
Electric bilge pump inspection
Refer to “BILGE PUMP” in Chapter 3.
Refer to “ELECTRIC BILGE PUMP” in
Chapter 7.
Bilge hose inspection
1. Inspect:
• Bilge hoses
Cracks/damage/wear → Replace.
Cooling water hose inspection
1. Inspect:
• Cooling water hoses
Cracks/damage/wear → Replace.
6-22
JET
PUMP
BEARING HOUSING
E
BEARING HOUSING
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
Procedure/Part name
BEARING HOUSING REMOVAL
Engine unit
Rubber coupling
Bolt
Intermediate housing assembly
Pin
Shim
Q’ty
1
3
1
2
*
Service points
Follow the left “Step” for removal.
Refer to “ENGINE UNIT” in Chapter 5.
NOTE:
Install the shims in their original locations.
Reverse the removal steps for installation.
*: As required
6-23
JET
PUMP
BEARING HOUSING
E
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
Procedure/Part name
BEARING HOUSING
DISASSEMBLY
Grease hose
Nipple
Driven coupling
Washer
Intermediate drive shaft
O-ring
Q’ty
1
1
1
1
1
2
6-24
Service points
Follow the left “Step” for disassembly.
JET
PUMP
BEARING HOUSING
E
EXPLODED DIAGRAM
Step
7
8
9
10
11
12
Procedure/Part name
Oil seal
Oil seal
Oil seal
Circlip
Bearing
Circlip
Q’ty
1
1
1
1
1
1
Service points
Not reusable
Not reusable
Not reusable
Not reusable
Reverse the disassembly steps for
assembly.
6-25
JET
PUMP
BEARING HOUSING
E
SERVICE POINTS
Driven coupling removal and installation
1. Remove and install:
• Driven coupling
Coupler wrench:
YW-06551/90890-06551
Shaft holder:
YB-06552/90890-06552
NOTE:
• Install the driven coupling with the same special tools that were used for removal.
• Check that the shaft holder and intermediate
drive shaft are properly engaged.
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 driven coupling
shaft.
• Press out the intermediate drive shaft by
pushing the rod.
NOTE:
Support the intermediate housing with steel
blocks 1 and press the driven coupling shaft
with a rod that is more than 210 mm (8.27 in)
long, and which has an outer diameter less
than 16 mm (0.63 in).
1
6-26
JET
PUMP
BEARING HOUSING
E
Bearing removal
1. Remove:
• Bearing
Driver rod:
YB-06071/90890-06606
Bearing outer race attachment:
YB-06156/90890-06626
NOTE:
• Install the bearing with the same special
tools that were used for removal.
• Support the intermediate housing with steel
blocks 1 and press the bearing.
Bearing, intermediate drive shaft, and
grease hose inspection
1. Inspect:
• Bearing
Rotate the inner race by hand.
Damage/rough movement → Replace.
• Intermediate drive shaft
Damage/pitting → Replace.
• Grease hose
Cracks/wear → Replace.
Driven coupling inspection
1. Inspect:
• Driven coupling
• Driven coupling damper
Damage/wear → Replace.
6-27
JET
PUMP
BEARING HOUSING
E
Bearing installation
1. Install:
• Circlip (rear)
2. Install:
• Bearing
Driver rod:
YB-06071/90890-06606
Bearing outer race attachment:
YB-06156/90890-06626
NOTE:
Support the intermediate housing with steel
blocks 1 and press the bearing.
Oil seal installation
1. Install:
• Oil seal
a
Driver rod:
YB-06071/90890-06606
Bearing outer race attachment:
YB-06156/90890-06626
NOTE:
Before installing the oil seal, lubricate the clip
glove with water resistant grease.
Distance a:
6.8–7.2 mm (0.27–0.28 in)
2. Install:
• Intermediate drive shaft
Distance a:
45.5–46.5 mm (1.79–1.83 in)
NOTE:
Support the intermediate housing with steel
blocks 1 and press the driven coupling shaft.
6-28
JET
PUMP
a
BEARING HOUSING
E
3. Install:
• Oil seal 1 [8 mm (0.31 in)]
• Oil seal 2 [11 mm (0.43 in)]
b
Distance a:
10.3–10.7 mm (0.41–0.42 in)
Distance b:
0.6–1.0 mm (0.02–0.04 in)
2
1
Intermediate housing installation
1. Install:
• Intermediate housing
• Shim
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 thickness
0–0.2 mm
(0–0.008 in)
No need
0.3–0.7 mm
(0.012–0.028 in)
0.5 mm
0.8–1.2 mm
(0.031–0.047 in)
1.0 mm
1.3–2.0 mm
(0.051–0.079 in)
1.5 mm
NOTE:
Install the shim(s) to the original position if the
intermediate housing is not replaced.
6-29
ELEC
–
+
E
CHAPTER 7
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS........................................................................ 7-1
ELECTRICAL BOX AND IGNITION COIL BOX .............................................7-2
EXPLODED DIAGRAM .............................................................................7-2
REMOVAL AND INSTALLATION CHART ................................................ 7-2
ELECTRICAL ANALYSIS ............................................................................. 7-11
INSPECTION........................................................................................... 7-11
Digital tester ......................................................................................7-11
Low resistance measurement ........................................................... 7-12
Peak voltage measurement ..............................................................7-12
Peak voltage adaptor ........................................................................7-13
Test harness ....................................................................................7-13
IGNITION SYSTEM ....................................................................................... 7-14
WIRING DIAGRAM ................................................................................. 7-14
IGNITION SPARK GAP...........................................................................7-16
IGNITION SYSTEM PEAK VOLTAGE ....................................................7-17
BATTERY ................................................................................................7-19
FUSE ....................................................................................................... 7-19
SPARK PLUGS ....................................................................................... 7-19
SPARK PLUG LEAD ASSEMBLY........................................................... 7-19
IGNITION COIL ....................................................................................... 7-20
ENGINE STOP SWITCH.........................................................................7-20
ENGINE TEMPERATURE SENSOR ......................................................7-21
INTAKE AIR TEMPERATURE SENSOR ................................................ 7-21
THERMOSWITCH (ENGINE).................................................................. 7-22
THERMOSWITCH (EXHAUST) ..............................................................7-22
MAIN AND FUEL PUMP RELAY............................................................. 7-23
THROTTLE POSITION SENSOR ........................................................... 7-24
CAM POSITION SENSOR ...................................................................... 7-25
INTAKE AIR PRESSURE SENSOR........................................................ 7-26
SLANT DETECTION SWITCH ................................................................7-27
1
2
3
4
5
6
7
8
9
ELEC
–
+
FUEL CONTROL SYSTEM ...........................................................................7-28
WIRING DIAGRAM ................................................................................. 7-28
FUEL PUMP ............................................................................................ 7-30
FUEL SENDER ....................................................................................... 7-30
FUEL INJECTOR ....................................................................................7-31
MAIN AND FUEL PUMP RELAY............................................................. 7-31
OIL PRESSURE SWITCH....................................................................... 7-31
THERMOSWITCH (ENGINE).................................................................. 7-31
THERMOSWITCH (EXHAUST) ..............................................................7-31
SLANT DETECTION SWITCH ................................................................7-31
STARTING SYSTEM .....................................................................................7-32
WIRING DIAGRAM ................................................................................. 7-32
BATTERY ................................................................................................7-33
WIRING CONNECTIONS........................................................................7-33
FUSE ....................................................................................................... 7-33
START SWITCH......................................................................................7-33
STARTER RELAY ...................................................................................7-34
STARTER MOTOR........................................................................................ 7-35
EXPLODED DIAGRAM ...........................................................................7-35
REMOVAL AND INSTALLATION CHART ............................................. 7-35
SERVICE POINTS .................................................................................. 7-38
Armature inspection ..........................................................................7-38
Brush holder inspection..................................................................... 7-39
Starter motor front cover inspection .................................................. 7-39
CHARGING SYSTEM....................................................................................7-40
WIRING DIAGRAM ................................................................................. 7-40
FUSE ....................................................................................................... 7-41
BATTERY ................................................................................................7-41
LIGHTING COIL ......................................................................................7-41
RECTIFIER/REGULATOR ...................................................................... 7-41
ELECTRIC BILGE PUMP.............................................................................. 7-42
WIRING DIAGRAM ................................................................................. 7-42
ELECTRIC BILGE PUMP........................................................................7-43
E
ELEC
–
+
INDICATION SYSTEM .................................................................................. 7-44
WIRING DIAGRAM ................................................................................. 7-44
FUSE ....................................................................................................... 7-45
BATTERY ................................................................................................7-45
LIGHTING COIL ......................................................................................7-45
RECTIFIER/REGULATOR ...................................................................... 7-45
ECM.........................................................................................................7-45
ENGINE TEMPERATURE SENSOR ......................................................7-45
THERMOSWITCH (ENGINE).................................................................. 7-45
THERMOSWITCH (EXHAUST) ..............................................................7-45
BUZZER .................................................................................................. 7-45
OIL PRESSURE SWITCH....................................................................... 7-46
MULTIFUNCTION METER...................................................................... 7-46
Multifunction meter............................................................................7-46
MULTIFUNCTION METER REMOVAL ...................................................7-46
Display function................................................................................. 7-47
Speedometer display ........................................................................7-48
Tachometer display...........................................................................7-49
Hour meter display ............................................................................7-49
Voltage meter display........................................................................7-49
Low oil pressure warning indicator....................................................7-49
Fuel level meter display and fuel warning indicator .......................... 7-49
Overheat warning indicator ...............................................................7-50
Engine trouble warning indicator.......................................................7-50
Diagnostic display ............................................................................. 7-51
E
ELEC
–
+
ELECTRICAL COMPONENTS
E
ELECTRICAL COMPONENTS
L
K
J
I
1
H
G
F
2
3
4
E
D
C
5
6
B
A
7
0
9
8
1
2
3
4
5
6
7
8
9
Thermoswitch (engine)
Starter motor
Engine temperature sensor
Spark plugs
Ignition coils
Electrical box
Battery
Speed sensor
Electric bilge pump
0
A
B
C
D
E
F
G
H
Cam position sensor
Fuel injectors
Thermoswitch (exhaust)
Oil pressure switch
Intake air pressure sensor
Intake air temperature sensor
Throttle position sensor
Lighting coil and pulser coil
Engine stop switch, engine
shut-off switch and start switch
7-1
I
J
K
L
Buzzer
Fuel pump
Fuel sender
Multifunction meter
ELEC
–
+
ELECTRICAL BOX AND IGNITION COIL BOX
E
ELECTRICAL BOX AND IGNITION COIL BOX
EXPLODED DIAGRAM
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 16 mm
4
17 N • m (1.7 kgf • m, 12 ft • Ib)
8 × 28 mm
A
A
5 × 20 mm
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
11
3
LT
(VENT)
572
7
22
5
6
9
LT
23
572
8
1516
A
2
1
LT
271
12
23
23
23
21
20
23
23
17
19 18
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 30 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 10 mm
E
LT
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
572
23
10
14
13
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 12 mm
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
Procedure/Part name
ELECTRICAL BOX REMOVAL
Battery negative lead
Battery positive lead
Clip/breather hose
Band
Battery
Damper
Bolt
Bolt
Q’ty
1
1
1/1
2
1
1
2
2
7-2
Service points
Follow the left “Step” for removal.
ELEC
–
+
ELECTRICAL BOX AND IGNITION COIL BOX
E
EXPLODED DIAGRAM
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 16 mm
4
17 N • m (1.7 kgf • m, 12 ft • Ib)
8 × 28 mm
A
A
5 × 20 mm
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
11
3
LT
(VENT)
572
7
22
5
6
9
LT
23
572
8
1516
A
2
1
LT
271
12
23
23
23
21
20
23
23
17
19 18
LT
Step
9
10
11
12
13
14
15
16
17
18
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 30 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 10 mm
E
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
572
23
10
14
13
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 12 mm
Procedure/Part name
Battery box
Spacer
Bolt
Screw
Terminal cover
Gasket
Screw
Starter motor lead
Bolt
Cover
Q’ty
1
2
4
4
1
1
1
1
3
1
7-3
Service points
Not reusable
ELEC
–
+
ELECTRICAL BOX AND IGNITION COIL BOX
E
EXPLODED DIAGRAM
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 16 mm
4
17 N • m (1.7 kgf • m, 12 ft • Ib)
8 × 28 mm
A
A
5 × 20 mm
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
11
3
LT
(VENT)
572
7
22
5
6
9
LT
23
572
8
1516
A
2
1
LT
23
23
23
21
20
23
14
13
23
17
19 18
LT
Step
19
20
21
22
23
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 30 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 10 mm
E
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
572
23
10
271
12
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 12 mm
Procedure/Part name
Gasket
Bolt
Ground lead
Holder
Coupler
Q’ty
1
2
2
1
15
Service points
Not reusable
NOTE:
Disconnect all couplers.
Reverse the removal steps for installation.
7-4
ELEC
–
+
ELECTRICAL BOX AND IGNITION COIL BOX
E
EXPLODED DIAGRAM
1
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
5 × 30 mm
2
3
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
6 × 20 mm
24
25
26
21
22 20
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
19 16
6 × 16 mm
6 × 30 mm
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
18
23
12
17
13
14
27
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
6 × 30 mm
10
8
15
9
4
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
6 × 16 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 12 mm
7
5 × 20 mm
5
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
6
11
6 × 10 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
4
4
4
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
Procedure/Part name
ELECTRICAL BOX
DISASSEMBLY
Tapping screw
Cover
Gasket
Clamp
Screw
Terminal cover
Gasket
Screw
Q’ty
18
1
1
3
4
1
1
2
7-5
Service points
Follow the left “Step” for disassembly.
ELEC
–
+
ELECTRICAL BOX AND IGNITION COIL BOX
E
EXPLODED DIAGRAM
1
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
5 × 30 mm
2
3
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
6 × 20 mm
24
25
26
21
22 20
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
19 16
6 × 16 mm
6 × 30 mm
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
18
23
12
17
13
14
27
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
6 × 30 mm
10
8
15
9
4
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
6 × 16 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 12 mm
7
5 × 20 mm
5
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
6
6 × 10 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
Step
9
10
11
12
13
14
15
16
17
18
Procedure/Part name
Battery positive lead
Starter motor lead
Wire harness
Tapping screw
Fuse holder stay
Screw
Starter relay
Clamp
Tapping screw/washer
ECM
11
4
Q’ty
1
1
1
1
1
1
1
2
4/4
1
7-6
4
4
Service points
ELEC
–
+
ELECTRICAL BOX AND IGNITION COIL BOX
E
EXPLODED DIAGRAM
1
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
5 × 30 mm
2
3
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
6 × 20 mm
24
25
26
21
22 20
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
19 16
6 × 16 mm
6 × 30 mm
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
18
23
12
17
13
14
27
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
6 × 30 mm
10
8
15
9
4
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
6 × 16 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 12 mm
7
5 × 20 mm
5
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
6
6 × 10 mm
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
Step
19
20
21
22
23
24
25
26
27
Procedure/Part name
Tapping screw
Bracket
Joint connector
Tapping screw
Slant detection switch
Tapping screw
Main and fuel pump relay
Tapping screw
Rectifier/regulator
11
4
Q’ty
1
1
2
2
1
1
1
2
1
4
4
Service points
Reverse the disassembly steps for
assembly.
7-7
ELEC
–
+
ELECTRICAL BOX AND IGNITION COIL BOX
E
EXPLODED DIAGRAM
1
6
4
2
7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)
6 × 28 mm
3
5
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
Procedure/Part name
IGNITION COIL BOX REMOVAL
Air filter
Q’ty
Spark plug cap
Holder
Ignition coil coupler
Bolt/washer
Ignition coil box
Collar
4
1
2
3/3
1
3
Service points
Follow the left “Step” for removal.
Refer to “FUEL INJECTION SYSTEM” in
Chapter 4.
Reverse the removal steps for installation.
7-8
ELEC
–
+
ELECTRICAL BOX AND IGNITION COIL BOX
EXPLODED DIAGRAM
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
6 × 19 mm
4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)
6 × 24 mm
2
1
1
4
2
3
5
6
4
6
5
7
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
Procedure/Part name
IGNITION COIL BOX
DISASSEMBLY
Tapping screw
Holder
Ignition coil cover
Tapping screw
Ignition coil
Hightention code
Ignition coil case
Q’ty
Service points
Follow the left “Step” for disassembly.
10
2
1
4
2
4
1
Reverse the disassembly steps for
assembly.
7-9
E
ELEC
–
+
ELECTRICAL BOX AND IGNITION COIL BOX
3
2
4
5
E
6
7
1
UP
È
8
Ê
1
1
9
4
4
3
3
2
2
1
2
3
4
5
6
7
8
9
È To ignition coil
É To battery positive terminal
Ê To starter motor
Starter relay
Fuse holder
ECM
Joint connector
Joint connector
Main and fuel pump relay
Rectifier/regulator
Slant detection switch
Ignition coil
7-10
É
ELEC
–
+
ELECTRICAL ANALYSIS
E
ELECTRICAL ANALYSIS
INSPECTION
CAUTION:
• All measuring instruments should be handled with special care. Damaged or mishandled instruments will not measure
properly.
• On an instrument powered by dry batteries, check the battery’s voltage periodically and replace the batteries if
necessary.
Digital tester
NOTE:
Throughout this chapter the digital tester’s part
number has been omitted. Refer to the following part number.
Digital circuit tester:
YU-34899-A/90890-03174
NOTE:
“
” indicates a continuity of electricity;
i.e., a closed circuit at the respective switch
position.
7-11
ELEC
–
+
ELECTRICAL ANALYSIS
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 prematurely wear.
7-12
ELEC
–
+
ELECTRICAL ANALYSIS
E
Peak voltage adaptor
NOTE:
• Throughout this chapter the peak voltage
adaptor’s part number has been omitted.
Refer to the following part number.
• The peak voltage adaptor should be used
with the digital tester.
Peak voltage adaptor:
YU-39991/90890-03172
È
• When measuring the peak voltage, connect
the peak voltage adaptor to the digital circuit
tester and switch the selector to the DC voltage mode.
NOTE:
• Make sure that the adaptor leads are properly installed in the digital circuit tester.
• Make sure that the positive pin (the “+” mark
facing up as shown) on the adaptor is
installed into the positive terminal of the
tester.
• The test harness is needed for the following
tests.
É
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 pulser coil(s) are measured unloaded, disconnect the test harness
on the output side coupler.
7-13
–
ELEC
+
IGNITION SYSTEM
E
IGNITION SYSTEM
WIRING DIAGRAM
Y
Br
13 : B/R
15 : G/O
17 : L/B
18 : R/Y
19 : P/G
20 : P
21 : B/Y
27 : B
28 : B/W
2 :W
3 : P/W
4 :P
5 : B/Y
6 : B/O
7 :Y
8 :O
9 : W/R
10 : W/B
11 : L/R
B
L/R
L
1
R/Y
R/Y
3
R/Y
R/Y
2
R/Y
R
R
4 3 2 1
8 7 6 5
R
P
R
R
P
Br B
R/Y
R/Y
R/Y
R
O
12 3 456
R/Y
7 8
O O P
P R R R
4
Y
L/R
P/W
5
6
W B
B
Pu/B
R/Y
R
Br
W B
FREE
PUSH
FREE
PUSH
B/O
Pu/G
P/W
Pu/R
B
Bu/Y
Br
W
R
B/Y
W
G/O
O
P/W
P
P/G
B/Y
B
R/Y
B/O
Pu/B
B
W
B
B/O
B
B/O
Pu/Y
Pu/R
K
Pu/G
FREE
7 PUSH
B/O
G/O
R/Y
R
B
L/B
B/R
R/Y
R
R
Br
Br
B/O
Br
P
W
W/R
B
R
P
B/W
P
B
B/O
B/O
R
B/O
A
W/B
P
B/O
C
B/O
B/W
R
B/O
B/Y
G
B/O
R/Y
G
R
W B
R
F
B
G
B/O
G
B/Y
B/Y
0
B/Y
B
G
B/Y
B/O
G
B/Y
G
B/W
B/O
G
G
R
R
I
P/G
B/W
#2
J
D
E
O
G
G
B/O
G
B/O
B/O
B/O
O
H
I
B/O
B/O
B/O
1
2
3
4
5
6
7
8
9
G
E
P
#3
9
B
B/O
I
J
B
B/O
#4
I
P
B/W
#1
8
B
P
R
Br Br
ECM
Main and fuel pump relay
Fuse (20A)
Battery
Engine shut-off switch
Engine stop switch
Start switch
Thermoswitch (exhaust)
Thermoswitch (engine)
0
A
B
C
D
E
F
G
H
Engine temperature sensor
Slant detection switch
Cam position sensor
Rectifier/regulator
Lighting coil
Pulser coil
Intake air temperature sensor
Intake air pressure sensor
Throttle position sensor
7-14
I Spark plug
J Ignition coil
K Oil pressure switch
–
ELEC
+
IGNITION SYSTEM
E
WIRING DIAGRAM
Y
Br
13 : B/R
15 : G/O
17 : L/B
18 : R/Y
19 : P/G
20 : P
21 : B/Y
27 : B
28 : B/W
2 :W
3 : P/W
4 :P
5 : B/Y
6 : B/O
7 :Y
8 :O
9 : W/R
10 : W/B
11 : L/R
B
L/R
L
1
R/Y
R/Y
3
R/Y
R/Y
2
R/Y
R
R
4 3 2 1
8 7 6 5
R
P
R
R
P
Br B
R/Y
R/Y
R/Y
R
O
12 3 456
R/Y
7 8
O O P
P R R R
4
Y
L/R
P/W
5
6
W B
B
Pu/B
R/Y
R
Br
W B
FREE
PUSH
FREE
PUSH
B/O
Pu/G
P/W
Pu/R
B
Bu/Y
Br
W
R
B/Y
W
G/O
O
P/W
P
P/G
B/Y
B
R/Y
B/O
Pu/B
B
W
B
B/O
B
B/O
Pu/Y
Pu/R
K
Pu/G
FREE
7 PUSH
B/O
G/O
R/Y
R
B
L/B
B/R
R/Y
R
R
Br
Br
B/O
Br
P
W
W/R
B
R
P
B/W
P
B
B/O
B/O
R
B/O
A
W/B
P
B/O
C
B/O
B/W
R
B/O
B/Y
G
B/O
R/Y
G
R
W B
R
F
B
G
B/O
G
B/Y
B/Y
0
B/Y
B
G
B/Y
B/O
G
B/Y
G
B/W
B/O
G
G
R
R
I
P/G
B/W
#2
J
E
O
G
D
G
G
B/O
G
B/O
B/O
O
H
I
B/O
B/O
B/O
B
Br
G
L
O
P
R
W
Y
B/O
E
P
#3
: Black
: Brown
: Green
: Blue
: Orange
: Pink
: Red
: White
: Yellow
9
B
B/O
I
J
B
B/O
#4
I
P
B/W
#1
8
B
P
R
Br Br
B/O
B/R
B/W
B/Y
G/O
L/B
L/R
P/G
P/W
: Black/orange
: Black/red
: Black/white
: Black/yellow
: Green/orange
: Blue/black
: Blue/red
: Pink/green
: Pink/white
7-15
R/Y : Red/yellow
W/B : White/black
W/R : White/red
ELEC
–
+
IGNITION SYSTEM
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.
È
1. Check:
• Ignition spark gap
Below specification → Check the ECM
output peak voltage.
Check the ignition coil for resistance.
Spark gap:
7–8 mm (0.28–0.31 in)
É
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-34487/90890-06754
• Crank the engine and observe the ignition system spark through the discharge
window.
È
È For USA and Canada
É For worldwide
É
7-16
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
pulser coil output peak voltage.
Replace the ECM.
Test harness (2 pins):
YB-06792/90890-06792
ECM output peak voltage:
Black/red (B/R) – Ground
Black/white (B/W) – Ground
r/min
V
Loaded
Cranking
2,000
3,500
7
258
258
NOTE:
B/R – Ground for cylinder #1 and #4.
B/W – Ground for cylinder #2 and #3.
To crank the engine, connect the engine shutoff cord (lanyard), and then press the start
switch and engine stop switch simultaneously.
7-17
ELEC
–
+
IGNITION SYSTEM
E
2. Measure:
• Pulser coil output peak voltage
Below specification → Replace the
pulser coil.
Test harness (3 pins):
YB-06791/90890-06791
Pulser coil output peak voltage:
White (W) – Black (B)
Red (R) – Black (B)
r/min
V
Unloaded
Loaded
Cranking
4
4
2,000
3,500
23
38
NOTE:
To crank the engine, connect the engine shutoff cord (lanyard), and then press the start
switch and engine stop switch simultaneously.
3. Measure:
• Lighting coil output peak voltage
Below specification → Replace the lighting coil.
Test harness (3 pins):
YB-06770/90890-06770
Lighting coil output peak voltage:
Green (G) – Green (G)
r/min
V
Unloaded
Loaded
Cranking
9
8
2,000
3,500
11
12
NOTE:
To crank the engine, connect the engine shutoff cord (lanyard), and then press the start
switch and engine stop switch simultaneously.
7-18
ELEC
–
+
IGNITION SYSTEM
E
4. Measure:
• Rectifier/regulator output voltage
Below specification → Replace the rectifier/regulator.
Test harness (6 pins):
YB-06790/90890-06790
Rectifier/regulator output
voltage:
Red (R) – Black (B)
Loaded
r/min
3,500
V
14.5
NOTE:
• Before measuring the output peak voltage,
make sure that the battery is fully charged.
• The output voltage gradually increases after
the engine is started, therefore, maintain the
specified engine speed for approximately 1
minute to measure the output voltage.
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. Inspect:
• Spark plug lead assembly
Cracks/damage → Replace.
2. Measure:
• Spark plug lead resistance
Out of specification → Replace.
Spark plug lead resistance:
#1: 6.4–14.9 kΩ
#2: 5.9–13.8 kΩ
#3: 4.7–11.1 kΩ
#4: 4.4–10.5 kΩ
7-19
ELEC
–
+
IGNITION SYSTEM
E
IGNITION COIL
1. Measure:
• Primary coil resistance
Out of specification → Replace.
Primary coil resistance:
Black/white (B/W) – Red (R)
1.53–2.07 Ω at 20 °C (68 °F)
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
Out of specification → Replace.
Secondary coil resistance:
12.5–16.9 kΩ at 20 °C (68 °F)
ENGINE STOP SWITCH
1. Check:
• Engine stop switch continuity
Out of specification → Replace.
Engine stop switch continuity
(black coupler)
Clip
Installed
Removed
7-20
Position
Free
Push
Free
Push
Lead color
White
Black
ELEC
–
+
IGNITION SYSTEM
E
ENGINE TEMPERATURE SENSOR
1. Measure:
• Engine temperature sensor resistance
(at the specified temperature)
Out of specification → Replace.
Engine temperature sensor
resistance:
20 °C (68 °F): 54.2–69.0 kΩ
100 °C (212 °F): 3.12–3.48 kΩ
Measurement steps:
• Suspend the engine temperature sensor
in a container filled with water.
• Slowly heat the water.
• Measure the resistance when the specified temperature is reached.
INTAKE AIR TEMPERATURE SENSOR
1. Measure:
• Intake air temperature sensor resistance
(at the specified temperature)
Out of specification → Replace.
Intake air temperature sensor
resistance:
0 °C (32 °F): 5.4–6.6 kΩ
80 °C (176 °F): 0.29–0.39 kΩ
Measurement steps:
• 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.
7-21
ELEC
–
+
IGNITION SYSTEM
E
THERMOSWITCH (ENGINE)
1. Check:
• Thermoswitch (engine) continuity
(at the specified temperature)
Out of specification → Replace.
Thermoswitch (engine) continuity
temperature:
a 84–90 °C (183–194 °F)
b 70–84 °C (158–183 °F)
1 No continuity
2 Continuity
È Temperature
É Time
Checking steps:
• Suspend the thermoswitch (engine) in a
container filled with water.
• Place a thermometer in the water.
• Slowly heat the water.
• Measure the continuity when the specified temperature is reached.
THERMOSWITCH (EXHAUST)
1. Check:
• Thermoswitch (exhaust) continuity
(at the specified temperature)
Out of specification → Replace.
Thermoswitch (exhaust)
continuity temperature:
a 94–100 °C (201–212 °F)
b 80–94 °C (176–201 °F)
1 No continuity
2 Continuity
È Temperature
É Time
Checking steps:
• Suspend the thermoswitch (exhaust) in a
container filled with water.
• Place a thermometer in the water.
• Slowly heat the water.
• Measure the continuity when the specified temperature is reached.
7-22
ELEC
–
+
IGNITION SYSTEM
E
MAIN AND FUEL PUMP RELAY
1. Check:
• Main and fuel pump relay continuity
Faulty → Replace.
Checking steps:
• Connect the tester leads between the
main and fuel pump relay terminals 5, 6
and 7.
• Connect the terminals 2 or 3 to the positive battery terminal.
• Connect the 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 terminals 2, 3 or 1.
• Connect the tester leads between the
main and fuel pump relay terminals 7
and 8.
• Connect the terminals 4 to the negative
battery terminal.
• Connect the terminal 6 to the positive
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 terminals 4 or 6.
UP
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
+
–
–
+
7-23
ELEC
–
+
IGNITION SYSTEM
E
THROTTLE POSITION SENSOR
1. Measure:
• Throttle position sensor output voltage
Out of specification → Adjust the throttle
bodies synchronization.
Refer to “FUEL INJECTION SYSTEM”
in Chapter 4.
1
B/O
Test harness (3 pins):
YB-06793/90890-06793
Test connector:
YW-06862/90890-06862
P
2
Throttle position sensor output
voltage:
Pink (P) – Black/Orange (B/O)
0.760 ± 0.016 V
Measurement steps:
• Connect the test harness (3 pins) to the
throttle position sensor 1.
• To start the ECM normally, use the
Yamaha Diagnostic System. Use the test
connector 2 to start the ECU normally
only if the Yamaha Diagnostic System is
not available.
• Measure the throttle position sensor output voltage.
7-24
ELEC
–
+
IGNITION SYSTEM
E
CAM POSITION SENSOR
1. Measure:
• Cam position sensor output voltage
Out of specification → Replace.
Test harness (3 pins):
YB-06777/90890-06777
Cam position sensor output
voltage:
Green/orange (G/O) –
Black/orange (B/O)
Position
Voltage (V)
A
More than 0.8
B
Less than 4.8
Measurement steps:
• Remove the cam position sensor.
• Connect the test harness (3 pins) to the
cam position sensor.
• Operate the Yamaha Diagnostic System.
• Measure the output voltage when holding
a screwdriver to the sensor and when
holding it away from the sensor.
NOTE:
When operating the Yamaha Diagnostic System, electric power is supplied to the cam position sensor.
7-25
ELEC
–
+
IGNITION SYSTEM
E
INTAKE AIR PRESSURE SENSOR
1. Measure:
• Intake air pressure sensor output voltage
Out of specification → Replace.
Test harness (3 pins):
YB-06769/90890-06769
Vacuum/pressure pump gauge
set:
YB-35956-A/90890-06756
B/O
P/G
Intake air pressure sensor output
voltage:
Pink/green (P/G) –
Black/orange (B/O)
1 101.3 kPa
(1.01 kgf/cm2, 14.4 psi):
a 4.00 V
2 50 kPa
(0.5 kgf/cm2, 7.1 psi):
b 1.97 V
3 20 kPa
(0.2 kgf/cm2, 2.8 psi):
c 0.79 V
È
a
È: Output voltage
b
Measurement steps:
• Remove the intake air pressure sensor.
• Connect the test harness (3 pins) to the
intake air pressure sensor.
• Operate the Yamaha Diagnostic System.
• Apply vacuum pressure to the intake air
pressure sensor and measure the output
voltage.
c
3
2
1
É: Vacuum pressure
É
NOTE:
When operating the Yamaha Diagnostic System, electric power is supplied to the intake air
pressure sensor.
7-26
ELEC
–
+
IGNITION SYSTEM
E
SLANT DETECTION SWITCH
È
1. Check:
• Slant detection switch continuity
Out of specification → Replace.
UP
É
Lead color
Position Blue/black
(L/B)
UP
Normal
operation È
Overturned É
7-27
Black/
orange
(B/O)
ELEC
–
+
FUEL CONTROL SYSTEM
E
FUEL CONTROL SYSTEM
WIRING DIAGRAM
Br
3 : P/W
5 : B/Y
7 :Y
8 :O
17 :L/B
18 : R/Y
19 : P/G
Y
B
L/R
20 : P
21 : B/Y
12 : W/B
23 : Pu/Y
24 : Pu/B
25 : Pu/R
26 : Pu/G
L
1
R/Y
R/Y
R
R
4 3 2 1
8 7 6 5
R/Y
R/Y
3
R
R
R/Y
P
R
R
P
R/Y
R/Y
O
2
R/Y
R/Y
12 3 456 7 8
P R R
O O
R/Y
4
Y
L/B
P/W
L/R
P/W
Pu/B
R/Y
B/O
L
Pu/G
Pu/R
L
Bu/Y
P/W
B/Y
O
F
L
B
B
P
P/G
B/G
B/Y
B
Pu/B
Pu/Y
6
Pu/R
Pu/G
5
B
B/O
L/B
R/Y
B
B/G
7
P
B
B/O
P
B
B
B
R/Y
B
A
R/Y
R/Y
B
B
P
B/O
R/Y
R/Y
P
B/O
P
B
B/O
Pu/R
E
B/O
B/O
B/O
Pu/R
P
#1
R/Y
P
R/Y
B/O
B/O
E
B
B/Y
B/O
B/Y
B/Y
B/O
R/Y
B/Y
R/Y
B/O
Pu/Y
E
Pu/Y
P/G
R/Y
O
Pu/G
O
E
R/Y
B/O
B/O
O
B/O
P
O
#4
D
P
R/Y
1
2
3
4
5
6
7
8
9
B/Y
B/O
P/G
R/Y
Pu/G
0
B/Y
B/Y
C
B/O
#3
ECM
Main and fuel pump relay
Fuse (20A)
Battery
Fuel pump
Multifunction meter
Fuel sender
Thermoswitch (exhaust)
Thermoswitch (engine)
B/O
B/O
0
A
B
C
D
E
F
7-28
9
B
B/O
B
Pu/B
#2
P
B/O
Pu/B
8
B
Engine temperature sensor
Slant detection switch
Intake air temperature sensor
Intake air pressure sensor
Throttle position sensor
Fuel injector
Oil pressure switch
B/O
ELEC
–
+
FUEL CONTROL SYSTEM
E
WIRING DIAGRAM
Br
3 : P/W
5 : B/Y
7 :Y
8 :O
17 :L/B
18 : R/Y
19 : P/G
Y
B
L/R
20 : P
21 : B/Y
12 : W/B
23 : Pu/Y
24 : Pu/B
25 : Pu/R
26 : Pu/G
L
1
R/Y
R/Y
R
R
4 3 2 1
8 7 6 5
R/Y
R/Y
3
R
R
R/Y
P
R
R
P
R/Y
R/Y
O
2
R/Y
R/Y
12 3 456 7 8
P R R
O O
R/Y
4
Y
L/B
P/W
L/R
P/W
Pu/B
R/Y
B/O
L
Pu/G
Pu/R
L
Bu/Y
P/W
B/Y
O
F
L
B
B
P
P/G
B/G
B/Y
B
Pu/B
Pu/Y
6
Pu/R
Pu/G
5
B
B/O
L/B
R/Y
B
B/G
7
P
B
B/O
P
B
B
B
R/Y
B
A
R/Y
R/Y
B
B
P
B/O
R/Y
R/Y
P
B/O
P
B
B/O
Pu/R
E
B/O
B/O
B/O
Pu/R
P
#1
R/Y
P
R/Y
B/O
B/O
E
B
B/Y
B/O
B/Y
B/Y
B/O
R/Y
B/Y
R/Y
B/O
Pu/Y
E
P/G
Pu/Y
R/Y
O
Pu/G
O
E
R/Y
B/O
B/O
P
#4
D
P
: Black
: Brown
: Green
: Blue
: Orange
: Pink
: Red
: White
: Yellow
B/O
O
O
R/Y
B
Br
G
L
O
P
R
W
Y
B/Y
B/O
P/G
R/Y
Pu/G
0
B/Y
B/Y
C
B/O
#3
B/O
B/O
B/O
B/O
B/Y
G/O
L/B
L/R
P/G
P/W
Pu/B
Pu/G
: Black/orange
: Black/yellow
: Green/orange
: Blue/black
: Blue/red
: Pink/green
: Pink/white
: Purple/black
: Purple/green
7-29
Pu/R
Pu/Y
R/Y
W/B
W/R
9
B
B/O
B
Pu/B
#2
P
B/O
Pu/B
8
B
: Purple/red
: Purple/yellow
: Red/yellow
: White/black
: White/red
ELEC
–
+
FUEL CONTROL SYSTEM
E
FUEL PUMP
1. Check:
• Fuel pump operating sound
Fuel pump does not sound → Measure
the fuel pressure.
Refer to “FUEL INJECTION SYSTEM”
in Chapter 4.
NOTE:
After the engine is stopped, the fuel pump will
operate for 10 seconds.
FUEL SENDER
1. Measure:
• Fuel sender resistance
Out of specification → Replace.
Float
position
7-30
Resistance (Ω)
A
91–93
B
6–8
ELEC
–
+
FUEL CONTROL SYSTEM
E
FUEL INJECTOR
Refer to “FUEL INJECTION SYSTEM”
in Chapter 4.
MAIN AND FUEL PUMP RELAY
Refer to “IGNITION SYSTEM”.
OIL PRESSURE SWITCH
Refer to “IGNITION SYSTEM”.
THERMOSWITCH (ENGINE)
Refer to “IGNITION SYSTEM”.
THERMOSWITCH (EXHAUST)
Refer to “IGNITION SYSTEM”.
SLANT DETECTION SWITCH
Refer to “IGNITION SYSTEM”.
7-31
–
ELEC
+
STARTING SYSTEM
E
STARTING SYSTEM
WIRING DIAGRAM
Br
Y
B
L/R
L
R
4 3 2 1
8 7 6 5
1
R/Y
R/Y
R/Y
R/Y
R
R
2
R/Y
P
P
O
R/Y
12 3 456 7 8
7
R/Y
18
R/Y
R
R R
Y
3
R
B
B
Br
B
B
B
B
Br
4
B
R
8
W B
FREE
PUSH
7
R
Br
Br Br
5
FREE
PUSH
B
Br
6
Br
R
R
Br
Br
R
1
2
3
4
5
6
7
8
ECM
Main and fuel pump relay
Fuse (20A)
Starter relay
Starter motor
Battery
Start switch
Engine shut-off switch
B
Br
R
Y
R/Y
7-32
: Black
: Brown
: Red
: Yellow
: Red/yellow
ELEC
–
+
STARTING SYSTEM
E
BATTERY
Refer to “ELECTRICAL” in Chapter 3.
WIRING CONNECTIONS
1. Check:
• Wiring connections
Poor connections → Properly connect.
FUSE
1. Check:
• Fuse broken
Broken → Replace.
Fuse rating:
3A, 20A
NOTE:
20A fuse is for main relay, engine shut-off
switch and rectifier/regulator.
3A fuse is for multifunction meter and electric
bilge pump.
START SWITCH
1. Check:
• Continuity
Out of specification → Replace.
Start continuity
(natural color coupler)
Clip
Installed
Removed
7-33
Position
Free
Push
Free
Push
Leads
Red
Brown
ELEC
–
+
STARTING SYSTEM
E
STARTER RELAY
1. Inspect:
• Brown lead terminal
• Black lead terminal
Loose → Tighten.
2. Check:
• Starter relay
Faulty → 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 the
brown or black lead is removed.
Br
B
7-34
ELEC
–
+
STARTER MOTOR
E
STARTER MOTOR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
Procedure/Part name
STARTER MOTOR
DISASSEMBLY
Starter motor
O-ring
Bolt
Starter motor front cover
O-ring
Oil seal retainer
Washer
Shim
Q’ty
1
2
1
1
1
1
*
*: As required
7-35
Service points
Follow the left “Step” for disassembly.
Refer to “GENERATOR AND STARTER
MOTOR” in Chapter 5.
Not reusable
Not reusable
t = 0.2 mm, 0.5 mm
ELEC
–
+
STARTER MOTOR
E
EXPLODED DIAGRAM
Step
8
9
10
11
12
13
14
15
16
17
Procedure/Part name
Starter motor rear cover
O-ring
Shim
Armature assembly
Nut/spring washer/washer
O-ring
Brush holder
Brush spring
Bolt
Brush assembly
Q’ty
1
1
*
1
1/1/4
1
1
4
1
1
*: As required
7-36
Service points
Not reusable
t = 0.2 mm, 0.8 mm
Not reusable
ELEC
–
+
STARTER MOTOR
E
EXPLODED DIAGRAM
Step
18
19
20
Procedure/Part name
Spacer
Holder
Starter motor yoke
Q’ty
1
1
1
Service points
Reverse the disassembly steps for
assembly.
7-37
ELEC
–
+
STARTER MOTOR
E
SERVICE POINTS
Armature inspection
1. Inspect:
• Armature shaft 1
Damage/wear → Replace.
1
2. Inspect:
• Commutator
Dirt → Clean with 600 grit sandpaper.
3. Measure:
• Commutator diameter
Out of specification → Replace.
Min. commutator diameter:
27.0 mm (1.06 in)
4. Check:
• Commutator undercut
Contaminants → Clean.
NOTE:
Remove all mica and metal particles with compressed air.
5. Measure:
• Commutator undercut
Out of specification → Replace.
Min. commutator undercut:
0.2 mm (0.01 in)
7-38
ELEC
–
+
STARTER MOTOR
E
6. Inspect:
• Armature coil continuity
Out of specification → Replace.
Armature coil continuity:
Commutator segments 1
Continuity
Segment - Laminations 2
No continuity
Segment - Armature shaft No continuity
Brush holder inspection
1. Measure:
• Brush length a
Out of specification → Replace.
Min. brush length:
6.5 mm (0.26 in)
2. Check:
• Brush holder continuity
Out of specification → Replace.
Brush holder continuity:
Brush holder - Base
No continuity
Starter motor front cover inspection
1. Inspect:
• Starter motor front cover oil seal
Damage/wear → Replace the starter
motor front cover.
7-39
ELEC
–
+
CHARGING SYSTEM
E
CHARGING SYSTEM
WIRING DIAGRAM
1
B
R
G
G
2
B G G G R
R
G
G
R
R
G
4
G
G
G
G
B
3
1
2
3
4
Rectifier/regulator
Fuse (20A)
Battery
Lighting coil
B
G
R
7-40
: Black
: Green
: Red
ELEC
–
+
CHARGING SYSTEM
E
FUSE
Refer to “STARTING SYSTEM”.
BATTERY
Refer to “ELECTRICAL” in Chapter 3.
LIGHTING COIL
Refer to “IGNITION SYSTEM”.
RECTIFIER/REGULATOR
Refer to “IGNITION SYSTEM”.
7-41
ELEC
–
+
ELECTRIC BILGE PUMP
E
ELECTRIC BILGE PUMP
WIRING DIAGRAM
Br
Y
B
L/R
L
1
R/Y
R/Y
R/Y
4 3 2 1
8 7 6 5
R
R/Y
R
R
2
P
P
R/Y
O
R/Y
12 3 456 7 8
R
R/Y
7
R
R/Y
18
R/Y
Y
3
R/Y
B
R
B
Br
B
B
B
Br
B
R
5
R
R/Y
Br
B
B
B
Br
R/Y
B
4
1
2
3
4
5
ECM
Main and fuel pump relay
Fuse (3A)
Battery
Electric bilge pump
B
Br
R
Y
R/Y
7-42
: Black
: Brown
: Red
: Yellow
: Red/yellow
ELEC
–
+
ELECTRIC BILGE PUMP
E
ELECTRIC BILGE PUMP
Br
1. Check:
• Electric bilge pump operation
Incorrect → Replace.
B
–
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 the water flows from the electric
bilge pump hose.
+
7-43
ELEC
–
+
INDICATION SYSTEM
E
INDICATION SYSTEM
WIRING DIAGRAM
Y
Br
B
L/R
1
L
R
R
4 3 2 1
8 7 6 5
R/Y
R/Y
R
R
P
2
R/Y
R/Y
R/Y
3
P
O
12 3
3 12 21 4
R/Y
Br
R/Y
R/Y
56
4
Br
R/Y
R
P P P R R
7 1
Y
B
P/W
5
B
P/W
G
B
R/Y
W
B
R
W/B
6
G
W/B
R/Y
P/W
B/O
B
P
B/O
B
B
P
D
P
B
B/O
W B R
B/O
7
B
P
P
0
P
B
B/O
B/O
B/Y
L/B
Y
B
R/W
L/R
B/Y
B/O
B/O
B/Y
B/Y
B/Y
R/W
B/Y
B
B/G
L/R
L/B
B/G
8
B
9
B/Y
Y
B/O
B
R
P
B
B/Y
B/O
R/Y
B/O
B
R
B/Y
Y
P
B/O
B
R/Y
B/O
B/O
B/O
B/O
C
B
B/O
A
B/O
1 ECM
2 Main and fuel pump
relay
3 Fuse (20A)
4 Fuse (3A)
5 Battery
6 Tacho pulse
7 Thermoswitch
(exhaust)
8 Thermoswitch
(engine)
9 Engine temperature
sensor
0 Multifunction meter
A Fuel sender
B Speed sensor
C Buzzer
D Oil pressure switch
B
Br
G
O
P
R
W
Y
B/O
7-44
: Black
: Brown
: Green
: Orange
: Pink
: Red
: White
: Yellow
: Black/orange
B/Y
P/W
R/Y
W/B
: Black/yellow
: Pink/white
: Red/yellow
: White/black
ELEC
–
+
INDICATION SYSTEM
E
FUSE
Refer to “STARTING SYSTEM”.
BATTERY
Refer to “ELECTRICAL” in Chapter 3.
LIGHTING COIL
Refer to “IGNITION SYSTEM”.
RECTIFIER/REGULATOR
Refer to “IGNITION SYSTEM”.
ECM
Refer to “IGNITION SYSTEM”.
ENGINE TEMPERATURE SENSOR
Refer to “IGNITION SYSTEM”.
THERMOSWITCH (ENGINE)
Refer to “IGNITION SYSTEM”.
THERMOSWITCH (EXHAUST)
Refer to “IGNITION SYSTEM”.
BUZZER
1. Check:
• Buzzer
Buzzer does not sound → Replace.
Checking steps:
• Connect the battery (12 V) to the buzzer
coupler as shown.
Battery positive terminal →
Red (R) terminal 1
Battery negative terminal →
Black (B) terminal 2
7-45
ELEC
–
+
INDICATION SYSTEM
E
OIL PRESSURE SWITCH
1. Measure:
• Oil pressure switch continuity
Out of specification → Replace.
Vacuum/pressure pump gauge
set:
YB-35956-A/90890-06756
Oil pressure switch continuity
pressure:
128 kPa (1.28 kgf/cm2, 18.2 psi) –
166 kPa (1.66 kgf/cm2, 23.6 psi)
MULTIFUNCTION METER
Multifunction meter
1. Check:
• Multifunction meter
Cracked meter housing → Replace the
multifunction meter.
Meter is fogged/shows signs of water
intrusion → Replace the multifunction
meter.
MULTIFUNCTION METER REMOVAL
Refer to “STEERING
COVER” in Chapter 8.
7-46
CONSOLE
ELEC
–
+
INDICATION SYSTEM
E
Display function
1. Check:
• Display function
Not operate → Replace the multifunction meter.
L/B
B
L/B
B
R
L/R
L/R
B/Y
B/Y
1
R
R/W
2
R/W
Y
Y
W
R
R
3
W
B
B
B/G
B
4
B
1
2
3
4
Buzzer
Speed sensor
ECM
Fuel sender
B
R
W
Y
B/G
B/Y
L/B
L/R
R/W
7-47
: Black
: Red
: White
: Yellow
: Black/green
: Black/yellow
: Blue/black
: Blue/red
: Red/white
B/G
ELEC
–
+
INDICATION SYSTEM
E
Speedometer display
1. Check:
• Speedometer display
Does not display → Measure the speed
sensor output voltage and pulses.
Without specification → Replace the
multifunction meter.
2. Measure:
• Speed sensor output voltage and pulses
Out of specification → Repair or
replace.
Speed sensor output voltage
(dependant on the paddle wheel
position):
Less than 400 mV/
More than 11.6 V
Output pulse:
2 pulses/one-full turn
Measurement steps:
• Apply DC 12 voltage to the white color
three-pin connector (between the red/yellow and black/yellow leads).
• Rotate the paddle wheel by hand and
measure the voltage between the black
and 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.
7-48
ELEC
–
+
INDICATION SYSTEM
E
Tachometer display
1. Check:
• Tachometer display
Does not display → Check the engine
speed using the “Engine monitor” of the
Yamaha Diagnostic System.
Replace the multifunction meter.
Hour meter display
1. Check:
• Hour meter display
Does not display → Replace the multifunction meter.
Voltage meter display
1. Check:
• Voltage meter display
Does not display → Check the battery
voltage using the “Engine monitor” of
the Yamaha Diagnostic System.
Replace the multifunction meter.
Low oil pressure warning indicator
1. Check:
• Low oil pressure warning indicator
No operating → Check the oil pressure
switch using the “Engine monitor” of the
Yamaha Diagnostic System.
Replace the multifunction meter.
Fuel level meter display and fuel warning
indicator
1. Check:
• Fuel level meter display and fuel warning indicator
Does not display or not operating →
Measure the fuel sender resistance.
Replace the multifunction meter.
2. Measure:
• Fuel sender
Refer to “FUEL CONTROL SYSTEM”.
7-49
ELEC
–
+
INDICATION SYSTEM
E
Overheat warning indicator
1. Check:
• Overheat warning indicator
Not operating → Replace the multifunction meter.
Checking steps:
• Disconnect the thermoswitch (engine)
connector 1 (blue) or engine temperature sensor connector 2 (black) or thermoswitch (exhaust) 3 connector.
• Connect the jumper lead to the female
terminal of the disconnected connector.
• Check that the multifunction meter overheat warning indicator comes on and the
buzzer sounds.
Engine trouble warning indicator
1. Check:
• Engine trouble warning indicator
Not operating → Replace the multifunction meter.
Checking steps:
• Remove the coupler of the sensor indicated in the multifunction meter.
• Check if “Irregular” is indicated in the
Diagnosis Record of the Yamaha Diagnostic System.
• Start the engine and check that the
engine check warning indicator comes on
and the buzzer sounds.
7-50
ELEC
–
+
INDICATION SYSTEM
E
Diagnostic display
1. Check:
• Diagnostic display
Does not display → Replace the multifunction meter.
1
Checking steps:
• Remove the coupler of the sensor indicated in the multifunction meter.
• Check if “Irregular” is indicated in the
Diagnosis Record of the Yamaha Diagnostic System.
• Start the engine and check that the
engine check warning indicator comes on
and the buzzer sounds.
• Press the hour meter/voltmeter display
select switch 1 and the speedometer
display switch 2 for 8 seconds and
check if an error code is indicated on the
multifunction meter.
2
7-51
HULL
HOOD
E
CHAPTER 8
HULL AND HOOD
HANDLEBAR ..................................................................................................8-1
EXPLODED DIAGRAM .............................................................................8-1
REMOVAL AND INSTALLATION CHART ................................................ 8-1
SERVICE POINTS .................................................................................... 8-6
Handlebar inspection ..........................................................................8-6
Handlebar switch inspection ............................................................... 8-6
Handlebar assembly installation .........................................................8-6
QSTS GRIP ..................................................................................................... 8-8
EXPLODED DIAGRAM .............................................................................8-8
REMOVAL AND INSTALLATION CHART ................................................ 8-8
SERVICE POINTS .................................................................................. 8-10
QSTS cable inspection...................................................................... 8-10
QSTS grip inspection ........................................................................8-10
STEERING MASTER.....................................................................................8-11
EXPLODED DIAGRAM ...........................................................................8-11
REMOVAL AND INSTALLATION CHART .............................................. 8-11
SERVICE POINTS .................................................................................. 8-14
Steering master components inspection ...........................................8-14
REMOTE CONTROL CABLES AND SPEED SENSOR LEAD ....................8-15
EXPLODED DIAGRAM ...........................................................................8-15
REMOVAL AND INSTALLATION CHART .............................................. 8-15
SERVICE POINTS .................................................................................. 8-18
Remote control cables inspection .....................................................8-18
Steering cable (jet pump end) installation .........................................8-18
Steering cable stopper installation ....................................................8-18
QSTS cable (jet pump end) installation............................................. 8-19
QSTS cable stopper installation........................................................ 8-19
Shift cable (jet pump end) installation ............................................... 8-19
Shift cable holder installation ............................................................ 8-20
Shift cable stopper installation .......................................................... 8-20
Remote control cables adjustment....................................................8-20
1
2
3
4
5
6
7
8
9
HULL
HOOD
FRONT HOOD ...............................................................................................8-21
EXPLODED DIAGRAM ...........................................................................8-21
REMOVAL AND INSTALLATION CHART .............................................. 8-21
STEERING CONSOLE COVER .................................................................... 8-25
EXPLODED DIAGRAM ...........................................................................8-25
REMOVAL AND INSTALLATION CHART .............................................. 8-25
SERVICE POINTS .................................................................................. 8-31
Glove compartment assembly installation.........................................8-31
HOSES ..........................................................................................................8-32
EXPLODED DIAGRAM ...........................................................................8-32
REMOVAL AND INSTALLATION CHART .............................................. 8-32
SHIFT LEVER................................................................................................8-34
EXPLODED DIAGRAM ...........................................................................8-34
REMOVAL AND INSTALLATION CHART .............................................. 8-34
SERVICE POINTS .................................................................................. 8-37
Base assembly.................................................................................. 8-37
Shift lever .......................................................................................... 8-37
SEATS AND HAND GRIP ............................................................................. 8-38
EXPLODED DIAGRAM ...........................................................................8-38
REMOVAL AND INSTALLATION CHART .............................................. 8-38
SERVICE POINTS .................................................................................. 8-41
Seat lock inspection ..........................................................................8-41
EXHAUST SYSTEM ......................................................................................8-42
EXPLODED DIAGRAM ...........................................................................8-42
REMOVAL AND INSTALLATION CHART .............................................. 8-42
SERVICE POINTS .................................................................................. 8-45
Exhaust system inspection................................................................8-45
Exhaust component parts sub-assembly ..........................................8-45
Exhaust system installation...............................................................8-46
E
HULL
HOOD
DECK AND HULL.......................................................................................... 8-47
EXPLODED DIAGRAM ...........................................................................8-47
REMOVAL AND INSTALLATION CHART .............................................. 8-47
ENGINE MOUNT ........................................................................................... 8-49
EXPLODED DIAGRAM ...........................................................................8-49
REMOVAL AND INSTALLATION CHART .............................................. 8-49
HULL REPAIR ......................................................................................... 8-50
Shallow scratches ............................................................................. 8-50
Deep scratches ................................................................................. 8-50
Cracks and punctures ....................................................................... 8-51
Insert nut ........................................................................................... 8-52
Graphic removal................................................................................ 8-54
Graphic installation............................................................................8-54
E
HULL
HOOD
HANDLEBAR
E
HANDLEBAR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
Procedure/Part name
HANDLEBAR COVER REMOVAL
Screw
Handlebar cover
Pad
Bolt
Handlebar cover stay
Throttle cable
Bolt
Upper handlebar holder
Q’ty
4
1
1
2
1
1
4
2
Service points
Follow the left “Step” for removal.
NOTE:
Position the corrugated tube for the throttle
cable as shown in the illustration so that the
tube attaches to the end of the outer throttle
cable.
Reverse the removal steps for installation.
8-1
HULL
HOOD
HANDLEBAR
E
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
Procedure/Part name
HANDLEBAR REMOVAL
QSTS cable (to jet thrust nozzle)
Q’ty
Nut/washer
QSTS converter
QSTS cable 2
QSTS cable 1
Handlebar switch coupler
Buzzer coupler
Screw
Handle boss cover
Band
2/2
1
1
1
2
1
4
1
2
8-2
Service points
Follow the left “Step” for removal.
Refer to “REMOTE CONTROL CABLES
AND SPEED SENSOR LEAD”.
with white tape a
HULL
HOOD
HANDLEBAR
E
EXPLODED DIAGRAM
Step
10
11
12
13
Procedure/Part name
Hose packing
Buzzer
Handlebar assembly
Grommet
Q’ty
1
1
1
Service points
Not reusable
NOTE:
• Pass the QSTS cable and handlebar
switch lead through the handle boss
cover, and then install the handlebar
assembly.
• Install the sponges of the QSTS cables as
shown and make sure that the grommet is
installed to the deck securely.
2
Reverse the removal steps for installation.
8-3
HULL
HOOD
HANDLEBAR
E
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
Procedure/Part name
HANDLEBAR DISASSEMBLY
Bolt
Grip end
Spacer
Screw/spring washer/washer
QSTS grip assembly
Special nut
Screw
Q’ty
2
2
1
1/1/1
1
1
2
8-4
Service points
Follow the left “Step” for disassembly.
NOTE:
Tighten the screw from the engine stop
switch side.
HULL
HOOD
HANDLEBAR
E
EXPLODED DIAGRAM
Step
8
9
10
11
12
Procedure/Part name
Handlebar switch assembly
Screw
Throttle lever assembly
Handlebar grip
Handlebar
Q’ty
1
2
1
1
Service points
NOTE:
Apply adhesive to the handlebar and the
inner surface of the handlebar grip.
1
Reverse the disassembly steps for
assembly.
8-5
HULL
HOOD
HANDLEBAR
E
SERVICE POINTS
Handlebar inspection
1. Inspect:
• Handlebar
Bends/cracks/damage → Replace.
Handlebar switch inspection
Refer to “STARTING SYSTEM” in
Chapter 7.
Handlebar assembly installation
1. Install:
• Bands 1
NOTE:
After inserting the QSTS cables, buzzer lead,
handlebar switch lead and throttle cable into
the grommets, tie the end of grommets with
the bands.
2. Install:
• Upper handlebar holder 1
NOTE:
• Align the punch marks a on the handlebar
with the top surface of the handlebar holder.
• The upper handlebar holder should be
installed with the punch mark b facing forward.
CAUTION:
Clearance c should be narrower than
clearance d.
Reference clearance:
c: 1.5 mm (0.06 in)
d: 3.5 mm (0.14 in)
8-6
HULL
HOOD
HANDLEBAR
E
3. Install:
• Throttle cable
NOTE:
Fit the seal into the groove in the bracket.
4. 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
trim grip to the neutral position.
• Adjust the QSTS cable lengths a to the
specified length and be sure to take up any
slack.
5. Install:
• Handlebar cover 1
NOTE:
When the handlebar cover is in contact with
the steering boss cover, adjust the handlebar
mount angle so that the clearance a and b
are equal.
6. Adjust:
• Throttle cable free play
Refer to “CONTROL SYSTEM” in Chapter 3.
7. Adjust:
• QSTS cable
Refer to “CONTROL SYSTEM” in Chapter 3.
8-7
HULL
HOOD
QSTS GRIP
E
QSTS GRIP
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
Procedure/Part name
QSTS GRIP DISASSEMBLY
QSTS grip assembly
Screw/washer
Cover
Ball
Spring
QSTS cable 1
QSTS cable 2
Q’ty
1/1
1
2
2
1
1
8-8
Service points
Follow the left “Step” for disassembly.
Refer to “HANDLEBAR”.
with white tape a
HULL
HOOD
QSTS GRIP
E
EXPLODED DIAGRAM
Step
7
8
9
10
11
12
13
Procedure/Part name
Screw/washer
Spacer
QSTS shift lock lever
Spring
Spacer
Cable housing
QSTS grip
Q’ty
2/2
1
1
1
1
1
1
Service points
Reverse the disassembly steps for
assembly.
8-9
HULL
HOOD
QSTS GRIP
E
SERVICE POINTS
QSTS cable inspection
1. Inspect:
• QSTS cables
Frays/kinks/rough movement →
Replace.
QSTS grip inspection
1. Inspect:
• QSTS grip
Damage/wear → Replace.
8-10
HULL
HOOD
STEERING MASTER
E
STEERING MASTER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
Procedure/Part name
STEERING MASTER REMOVAL
Steering console cover
Steering cable end
Q’ty
Bolt/washer
Steering arm
Nut/washer
Steering master assembly
Bolt
1/1
1
4/4
1
4
Service points
Follow the left “Step” for removal.
Refer to “STEERING CONSOLE COVER”.
Refer to “REMOTE CONTROL CABLES
AND SPEED SENSOR LEAD”.
Reverse the removal steps for installation.
8-11
HULL
HOOD
STEERING MASTER
E
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
Procedure/Part name
STEERING MASTER
DISASSEMBLY
Bolt/washer
Stay
Spring
Bolt/washer
Lower housing
Spring
Bushing
Bushing
Upper housing
Tilt lever
Q’ty
2/2
1
1
6/6
1
1
1
1
1
1
8-12
Service points
Follow the left “Step” for disassembly.
HULL
HOOD
STEERING MASTER
E
EXPLODED DIAGRAM
Step
11
12
13
14
15
16
17
18
19
Procedure/Part name
Tilt stopper
Bolt/nut/holder
Retainer
Steering shaft assembly
Steering tube
Bolt/washer/spring washer
Cap
Shaft 1
Cross piece
Q’ty
1
4/4/4
2
1
1
2/2/2
1
1
1
Service points
Reverse the disassembly steps for
assembly.
8-13
HULL
HOOD
STEERING MASTER
E
SERVICE POINTS
Steering master components inspection
1. Inspect:
• Each component part
Damage/wear → Replace the steering
master.
8-14
HULL
HOOD
REMOTE CONTROL CABLES AND
SPEED SENSOR LEAD
E
REMOTE CONTROL CABLES AND SPEED SENSOR LEAD
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
Procedure/Part name
REMOTE CONTROL CABLES
AND SPEED SENSOR LEAD
REMOVAL
Service lid 1
Front seat assembly
Glove compartment
Steering cable end
Nut/washer
Bracket
Nut
Steering cable holder
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “FRONT HOOD”.
Refer to “SEATS AND HAND GRIP”.
Refer to “STEERING CONSOLE COVER”.
1
2/2
1
2
1
8-15
HULL
HOOD
REMOTE CONTROL CABLES AND
SPEED SENSOR LEAD
EXPLODED DIAGRAM
Step
6
7
8
9
10
11
12
13
14
15
Procedure/Part name
Nut
Steering cable
Packing
Speed sensor coupler
Nut
Cap
Screw
Speed sensor
Shift cable end
Nut
Q’ty
1
1
1
1
1
1
4
1
1
2
8-16
Service points
E
HULL
HOOD
REMOTE CONTROL CABLES AND
SPEED SENSOR LEAD
E
EXPLODED DIAGRAM
Step
16
17
18
19
20
21
22
23
24
25
Procedure/Part name
Shift cable holder
Nut
Shift cable
Packing
Nut
Pin
QSTS cable end
Nut
QSTS cable
Packing
Q’ty
2
1
1
1
1
1
1
1
1
1
Service points
Reverse the removal steps for installation.
8-17
HULL
HOOD
REMOTE CONTROL CABLES AND SPEED SENSOR
LEAD
E
SERVICE POINTS
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 outer cover
below the crimp.
If a cable becomes damaged replace it.
Never attempt to repair a damaged cable.
Remote control cables inspection
1. Inspect:
• Steering cable
• QSTS cable
• Shift cable
Frays/kinks/rough movement →
Replace.
Steering cable (jet pump end) installation
1. Install:
• Steering cable
Steering cable set length a
(jet pump end):
14.5 mm (0.57 in)
WARNING
The steering cable must be screwed in at
least 8 mm (0.31 in).
Steering cable stopper installation
1. Install:
• Steering cable stopper
WARNING
Be sure to the steering cable stopper into
the groove in the outer cable as shown in
the illustration.
8-18
HULL
HOOD
REMOTE CONTROL CABLES AND
SPEED SENSOR LEAD
E
QSTS cable (jet pump end) installation
1. Install:
• QSTS cable (jet pump end)
QSTS cable set length a
(jet pump end):
13.6 mm (0.54 in)
WARNING
The QSTS cable must be screwed in more
than 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.
Shift cable (jet pump end) installation
1. Install:
• Shift cable (jet pump end)
Shift cable set length a
(jet pump end):
13.6 mm (0.54 in)
WARNING
The shift cable must be screwed in more
than 8 mm (0.31 in).
8-19
HULL
HOOD
REMOTE CONTROL CABLES AND
SPEED SENSOR LEAD
E
Shift cable holder installation
1. Install:
• Shift cable holders
NOTE:
Install the shift cable holders so that mark a
and mark b are in the positions shown in the
illustration.
Shift cable stopper installation
1. Install:
• Shift cable stopper
WARNING
Be sure to fit the projection 1 on the shift
cable stopper into the groove in the outer
cable.
Remote control cables adjustment
Refer to “CONTROL SYSTEM” in Chapter 3.
8-20
HULL
HOOD
FRONT HOOD
E
FRONT HOOD
EXPLODED DIAGRAM
6 × 10 mm
7
6
2
6 × 18 mm
LT
242
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 18 mm
8
4
LT
242
LT
242
9
LT
271
3
5
6 × 30 mm
11 10
1
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
1.5 N • m (0.15 kgf • m, 1.1 ft • Ib)
4 × 8 mm
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
Procedure/Part name
FRONT HOOD REMOVAL
Nut/washer
Front hood assembly
Bolt
Bolt
Hinge assembly
Bolt
Hood lock assembly
Q’ty
4/4
1
4
2
1
2
1
8-21
Service points
Follow the left “Step” for removal.
HULL
HOOD
FRONT HOOD
E
EXPLODED DIAGRAM
6 × 10 mm
7
6
2
6 × 18 mm
LT
242
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 18 mm
8
4
LT
242
LT
242
9
LT
271
3
5
6 × 30 mm
11 10
1
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
Step
8
9
10
11
Procedure/Part name
Bolt
Service lid 1
Screw
Service lid 2
Q’ty
4
1
4
1
1.5 N • m (0.15 kgf • m, 1.1 ft • Ib)
4 × 8 mm
Service points
Reverse the removal steps for installation.
8-22
HULL
HOOD
FRONT HOOD
E
EXPLODED DIAGRAM
4
1
5
7
6
10
2
7
3
6
1
8
9
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
Procedure/Part name
HINGE DISASSEMBLY
Circlip
Pin (long)
Hinge
Pin (short)
Damper stay
Collar
Grommet
Q’ty
2
1
1
1
1
2
2
8-23
Service points
Follow the left “Step” for disassembly.
HULL
HOOD
FRONT HOOD
E
EXPLODED DIAGRAM
4
1
5
7
6
10
2
7
3
6
1
8
9
Step
8
9
10
Procedure/Part name
Clamp
Damper boots
Damper
Q’ty
1
1
1
Service points
Not reusable
Reverse the disassembly steps for
assembly.
8-24
HULL
HOOD
STEERING CONSOLE COVER
E
STEERING CONSOLE COVER
EXPLODED DIAGRAM
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
5 × 20 mm
7
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
8
5
6
10
LT
9
4
242
5
3
11
LT
1
242
2
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
5 × 20 mm
REMOVAL AND INSTALLATION CHART
Step
1
2
Procedure/Part name
METER AND MIRROR REMOVAL
Handlebar assembly
Service lid 1
Clamp
Multifunction meter coupler
3
4
5
Bolt
Panel
Band
Q’ty
1
3
4
1
1
8-25
Service points
Follow the left “Step” for removal.
Refer to “HANDLEBAR”.
Refer to “FRONT HOOD”.
NOTE:
The handlebar switch coupler and buzzer
coupler have been disconnected.
HULL
HOOD
STEERING CONSOLE COVER
E
EXPLODED DIAGRAM
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
5 × 20 mm
7
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
8
5
6
10
LT
9
242
5
4
3
11
LT
1
242
2
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
5 × 20 mm
Step
6
7
8
9
10
11
Procedure/Part name
Bolt
Multifunction meter
Hose packing
Grommet
Nut/washer
Mirror
Q’ty
4
1
1
1
4/4
2
Service points
Not reusable
Reverse the removal steps for installation.
8-26
HULL
HOOD
STEERING CONSOLE COVER
E
EXPLODED DIAGRAM
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 22 mm
5
1
5
3
6
2
2
2
6
4
4
2
2
3
LT
271
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 22 mm
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
Procedure/Part name
SIDE COVER REMOVAL
Cup holder
Bolt
Side cover
Nut/washer
Bolt
Bracket
Q’ty
Service points
Follow the left “Step” for removal.
1
8
2
4/4
4
2
Reverse the removal steps for installation.
8-27
HULL
HOOD
STEERING CONSOLE COVER
E
EXPLODED DIAGRAM
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 30 mm
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 18 mm
8 × 22 mm
4
2
11
7
8 × 30 mm
LT
242
9
LT
242
8
12
6
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 14 mm
5
LT
271
3
1
10
20 N • m (0.2 kgf • m, 14 ft • Ib)
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
Procedure/Part name
STEERING CONSOLE COVER
AND GLOVE BOX ASSEMBLY
REMOVAL
Nut/washer
Bolt
Nut/washer
Bolt
Bolt
Shift handle lever
Q’ty
2/2
2
2/2
2
2
1
8-28
Service points
Follow the left “Step” for removal.
HULL
HOOD
STEERING CONSOLE COVER
E
EXPLODED DIAGRAM
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 30 mm
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 18 mm
8 × 22 mm
4
2
11
7
8 × 30 mm
LT
242
9
LT
242
8
12
6
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 14 mm
5
LT
271
3
1
10
20 N • m (0.2 kgf • m, 14 ft • Ib)
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
Step
7
8
9
10
11
12
Procedure/Part name
Bolt
Steering console cover
Q’ty
2
1
Hood lock assembly
Nut/washer
Bolt
Glove compartment assembly
1
2/2
2
1
Service points
NOTE:
To remove the console cover easily, pull the
tilt lever up.
Reverse the removal steps for installation.
8-29
HULL
HOOD
STEERING CONSOLE COVER
E
EXPLODED DIAGRAM
3
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 14 mm
5
2
2
6
LT
4
271
4
1
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
Procedure/Part name
GLOVE COMPARTMENT
DISASSEMBLY
Glove compartment
Hinge assembly
Lid
Gear assembly
Screw
Latch
Q’ty
Service points
Follow the left “Step” for disassembly.
1
2
1
2
2
1
Reverse the disassembly steps for
assembly.
8-30
HULL
HOOD
STEERING CONSOLE COVER
E
SERVICE POINTS
Glove compartment assembly installation
1. Install:
• Hinge assembly
NOTE:
When installing the hinge assembly, make
sure that the springs are in the position shown.
8-31
HULL
HOOD
HOSES
E
HOSES
EXPLODED DIAGRAM
(VENT)
D
FW
1
2
7
8
3
(VENT)
1
2
1
1
6
4
5
5
(VENT)
4 6
8
3
7
4.2 N • m (0.42 kgf • m, 3.0 ft • Ib)
4.2 N • m (0.42 kgf • m, 3.0 ft • Ib)
REMOVAL AND INSTALLATION CHART
Step
Procedure/Part name
HOSES REMOVAL
Fuel tank
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “FUEL TANK AND FUEL PUMP
MODULE” in Chapter 4.
NOTE:
When removing the ventilation hose and
fuel tank breather hose, it is not necessary
to remove the fuel tank.
1
2
3
Band
Ventilation hose
Fuel tank breather hose
4
2
2
8-32
HULL
HOOD
HOSES
E
EXPLODED DIAGRAM
(VENT)
D
FW
1
2
7
8
3
(VENT)
1
2
1
1
6
4
5
5
(VENT)
8
3
Procedure/Part name
Clamp
Cooling water hose
Nut
Cooling water pilot outlet
Packing
7
4.2 N • m (0.42 kgf • m, 3.0 ft • Ib)
4.2 N • m (0.42 kgf • m, 3.0 ft • Ib)
Step
4
5
6
7
8
4 6
Q’ty
2
2
2
2
2
Service points
Reverse the removal steps for installation.
8-33
HULL
HOOD
SHIFT LEVER
E
SHIFT LEVER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
Procedure/Part name
SHIFT LEVER REMOVAL
Side cover
Shift cable
Bolt
Shift lever handle
Bolt
Washer
Shift lever
Q’ty
2
1
1
1
1
8-34
Service points
Follow the left “Step” for removal.
Refer to “STEERING CONSOLE COVER”.
Refer to “REMOTE CONTROL CABLES
AND SPEED SENSOR LEAD”.
HULL
HOOD
SHIFT LEVER
E
EXPLODED DIAGRAM
Step
6
7
8
9
10
Procedure/Part name
Screw
Base assembly
Nut/washer
Screw
Plate
Q’ty
3
1
3/3
3
1
Service points
Reverse the removal steps for installation.
8-35
HULL
HOOD
SHIFT LEVER
E
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
Procedure/Part name
BASE DISASSEMBLY
Bolt/washer
Plate
Spring
Actuator
Roller
Shaft
Shift arm
Q’ty
Service points
Follow the left “Step” for disassembly.
2/2
1
1
1
1
1
1
Reverse the disassembly steps for
assembly.
8-36
HULL
HOOD
SHIFT LEVER
E
SERVICE POINTS
Base assembly
1. Install:
• Shift arm
• Shaft
Installation steps:
• Install the shift arm 1 so that it comes in
contact with the stopper 2 as shown.
• Install the shaft 3 to the base so that it
come in contact with the stopper 4 as
shown.
Shift lever
1. Install:
• Shift lever
a
b
NOTE:
To install the shift lever, align the arrow mark
a on the shift lever with the punch mark b on
base assembly.
8-37
HULL
HOOD
SEATS AND HAND GRIP
E
SEATS AND HAND GRIP
EXPLODED DIAGRAM
2
1
4
6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)
6 × 40 mm
4
6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)
6 × 40 mm
10
3
20
LT
3
11
12
8 × 30 mm
LT
271
8 × 30 mm
271
6 × 25 mm
14
7
21
15
17
8
9
18
13
18
5
6
26 N • m (2.6 kgf • m, 19 ft • Ib)
16
19
5.2 N • m (0.52 kgf • m, 3.8 ft • Ib)
18 N • m (1.8 kgf • m, 13 ft • Ib)
15 N • m (1.5 kgf • m, 11 ft • Ib)
5.2 N • m (0.52 kgf • m, 3.8 ft • Ib)
26 N • m (2.6 kgf • m, 19 ft • Ib)
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
Procedure/Part name
SEATS AND HAND GRIP
REMOVAL
Rear seat assembly
Front seat assembly
Bolt
Seat lock assembly
Seat storage compartment
Nut/washer
Bolt/washer
Deck beam
Q’ty
1
1
4
2
1
4/4
4/4
1
8-38
Service points
Follow the left “Step” for removal.
HULL
HOOD
SEATS AND HAND GRIP
E
EXPLODED DIAGRAM
2
1
4
6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)
6 × 40 mm
4
6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)
6 × 40 mm
10
3
20
LT
3
11
12
8 × 30 mm
LT
271
8 × 30 mm
271
6 × 25 mm
14
7
21
15
17
8
9
18
13
18
5
6
26 N • m (2.6 kgf • m, 19 ft • Ib)
16
19
5.2 N • m (0.52 kgf • m, 3.8 ft • Ib)
18 N • m (1.8 kgf • m, 13 ft • Ib)
15 N • m (1.5 kgf • m, 11 ft • Ib)
5.2 N • m (0.52 kgf • m, 3.8 ft • Ib)
26 N • m (2.6 kgf • m, 19 ft • Ib)
Step
9
10
11
12
13
14
15
16
Procedure/Part name
Nut
Projection
Washer
Packing
Nut
Bolt
Rear seat stay
Nut
Q’ty
1
1
1
1
4
4
2
1
8-39
Service points
HULL
HOOD
SEATS AND HAND GRIP
E
EXPLODED DIAGRAM
2
1
4
6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)
6 × 40 mm
4
6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)
6 × 40 mm
10
3
20
LT
3
11
12
8 × 30 mm
LT
271
8 × 30 mm
271
6 × 25 mm
14
7
21
15
17
8
9
18
13
18
5
6
26 N • m (2.6 kgf • m, 19 ft • Ib)
16
19
5.2 N • m (0.52 kgf • m, 3.8 ft • Ib)
18 N • m (1.8 kgf • m, 13 ft • Ib)
15 N • m (1.5 kgf • m, 11 ft • Ib)
5.2 N • m (0.52 kgf • m, 3.8 ft • Ib)
26 N • m (2.6 kgf • m, 19 ft • Ib)
Step
17
18
19
20
21
Procedure/Part name
Projection
Washer
Nut/washer
Bolt
Hand grip
Q’ty
1
2
4/4
4
1
Service points
Reverse the removal steps for installation.
8-40
HULL
HOOD
SEATS AND HAND GRIP
SERVICE POINTS
Seat lock inspection
1. Inspect:
• Front seat lock
• Rear seat lock
Damage/wear → Replace.
8-41
E
HULL
HOOD
EXHAUST SYSTEM
E
EXHAUST SYSTEM
EXPLODED DIAGRAM
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
10
9
12
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
11
3
14
13
8
7
4
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
1
5
2
6
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
REMOVAL AND INSTALLATION CHART
Step
Procedure/Part name
EXHAUST SYSTEM REMOVAL
Deck beam
Jet pump unit assembly
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “SEATS AND HAND GRIP”.
Refer to “JET PUMP UNIT” in Chapter 6.
NOTE:
When removing the water lock and exhaust
joint, it is not necessary to remove the jet
pump unit.
1
2
3
4
Band
Exhaust joint clamp
Hose clamp
Water lock
1
1
1
1
8-42
HULL
HOOD
EXHAUST SYSTEM
E
EXPLODED DIAGRAM
10
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
9
12
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
11
3
14
13
8
7
4
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
1
5
2
6
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
Step
5
6
7
8
9
10
11
12
13
14
Procedure/Part name
Exhaust joint clamp
Exhaust joint
Nut/washer
Exhaust valve
Hose clamp
Rubber hose
Hose clamp
Water tank
Rubber hose
Plate
Q’ty
1
1
6/6
1
Service points
NOTE:
Remove parts 8 to 14 as a set.
1
1
1
1
1
1
Reverse the removal steps for installation.
8-43
HULL
HOOD
EXHAUST SYSTEM
E
EXPLODED DIAGRAM
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
2nd 12 N • m (1.2 kgf • m, 8.8 ft • Ib)
6 × 25 mm
1st
1
2
LT
572
4
3
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
Procedure/Part name
EXHAUST JOINT DISASSEMBLY
Bolt
Exhaust joint protector 1
Exhaust joint protector 2
Exhaust joint pipe
Q’ty
Service points
Follow the left “Step” for disassembly.
6
1
1
1
Reverse the disassembly steps for
assembly.
8-44
HULL
HOOD
EXHAUST SYSTEM
E
SERVICE POINTS
Exhaust system inspection
1. Inspect:
• Water lock band
Cracks/damage → Replace.
2. Inspect:
• Rubber hoses
Burns/cracks/damage → Replace.
3. Inspect:
• Water lock
Cracks/leaks → Replace.
4. Inspect:
• Water tank
Cracks/damage/leaks → Replace.
Exhaust component parts sub-assembly
1. Install:
• Rubber hose
• Plate
NOTE:
Be sure to fit the projections on the rubber
hose with the grooves in the plate.
2. Install:
• Rubber hoses
• Water tank
NOTE:
• Be sure to insert the rubber hose to the line
a on the water tank.
• Make sure that there is a surface distance of
47 mm (1.9 in) b between the parting lines
of the water tank and rubber hose.
• Align the parting line c of the rubber hose
with the parting line d of the water tank.
b
a
c
a
d
8-45
HULL
HOOD
EXHAUST SYSTEM
E
Exhaust system installation
1. Install:
• Exhaust joint
NOTE:
Be sure to fit the slit a on the exhaust joint
with the projection b on the exhaust pipe.
b
a
2. Install:
• Water lock
NOTE:
Be sure to insert the rubber hose to the line a
on the water lock.
a
8-46
HULL
HOOD
DECK AND HULL
E
DECK AND HULL
EXPLODED DIAGRAM
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 22 mm
13 N • m (1.3 kgf • m, 9.4 ft • Ib)
17
16 N • m (1.6 kgf • m, 12 ft • Ib)
8 × 35 mm
LT
16
271
15 N • m (1.5 kgf • m, 11 ft • Ib)
5 3
5
4
18
12
2
7
13
8
6
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
1
11
10
9
5 × 25 mm
•
kgf
•
m,
1.4
ft
•
Ib)
2.0 N m (0.2
15
13
14
15 N • m (1.5 kgf • m, 11 ft • Ib)
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
Procedure/Part name
DECK AND HULL DISASSEMBLY
Nut
Spout
Nut
Cleat
Plate
Bolt
Sponson
Nut/washer
Screw/washer
Drain plug
Q’ty
1
1
2
1
2
10
2
4/4
4/4
2
8-47
Service points
Follow the left “Step” for disassembly.
HULL
HOOD
DECK AND HULL
E
EXPLODED DIAGRAM
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
6 × 22 mm
13 N • m (1.3 kgf • m, 9.4 ft • Ib)
17
16 N • m (1.6 kgf • m, 12 ft • Ib)
8 × 35 mm
LT
16
271
15 N • m (1.5 kgf • m, 11 ft • Ib)
5 3
5
4
18
12
2
7
13
8
6
5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)
1
11
10
9
5 × 25 mm
•
kgf
•
m,
1.4
ft
•
Ib)
2.0 N m (0.2
Step
11
12
13
14
15
16
17
18
Procedure/Part name
Packing
Nut
Q’ty
2
4
Plate
Cleat
Packing
Nut/washer
Bolt
Protector
4
2
2
3/3
4
1
15
13
14
15 N • m (1.5 kgf • m, 11 ft • Ib)
Service points
NOTE:
To remove the cleat, remove the exhaust
system first.
Reverse the disassembly steps for
assembly.
8-48
HULL
HOOD
ENGINE MOUNT
E
ENGINE MOUNT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
Procedure/Part name
ENGINE MOUNT REMOVAL
Engine unit
Bolt
Damper 1
Damper 2
Bolt
Engine mount
Liner
Q’ty
4
1
1
8
4
2
8-49
Service points
Follow the left “Step” for removal.
Refer to “ENGINE UNIT” in Chapter 5.
Stern side
Reverse the removal steps for installation.
HULL
HOOD
ENGINE MOUNT
E
HULL REPAIR
Shallow scratches
1. Sand the scratches with 400 grit sandpaper (either wet or dry) until the scratches
are smooth. Then, sand the scratches
once again with 600 grit sandpaper (either
wet or dry).
Deep scratches
1. Remove any sharp or rough edges from
the hull surface.
2. Sand the scratches and a 1-inch circumference around them with 80 grit sandpaper (either wet or dry).
3. Clean the entire area with acetone and let
it completely dry.
4. Mix gel-coat and gel-coat thickener to form
a putty, and then add the catalyst to the
putty.
5. Apply the putty, spread it with a squeegee,
and then cover the putty with wax paper.
6. When the putty has set, sand it. Smooth
the area with 80–400 grit sandpaper
(either wet or dry) and a sanding block.
7. Clean the area with a dry cloth and then
polish it.
WARNING
Resins, catalysts, and solvents are flammable and toxic; only use them in a well-ventilated area and keep them away from open
flames and sparks. Always follow the manufacturer’s instructions and warnings.
8-50
HULL
HOOD
ENGINE MOUNT
E
Cracks and punctures
NOTE:
Before attempting to repair any cracks or
punctures, refer to “WATERCRAFT FRP
REPAIR MANUAL”.
1. Remove any damaged fiberglass.
2. Cut the damaged area and separate it
approximately 0.25 inch.
3. On the outside of the hull, grind the separated edge of the area to less than 5° as
shown.
4. Working from inside the hull, grind the
damaged area approximately 4 inches
beyond the damage.
5. Clean the area with acetone, apply BP-1
or an equivalent primer onto both sides of
the damaged area, and then allow it to
cure for approximately 30 minutes.
6. Cover a piece of cardboard with wax paper
1 and then cover the damaged area with
it.
7. Combine the polyester resin and the catalyst, and then apply the mixture onto the
hull.
8. Install a glass mat 2 (2 inches smaller
than the ground area).
9. Apply the resin.
10. Install a 20 oz. fiberglass cloth 3 (1 inch
smaller than the glass mat).
11. Apply the resin.
12. Install another glass mat 4 (1 inch smaller
than the ground area).
13. When the resin has hardened remove the
piece of cardboard.
14. Finish the outer surface.
Refer to steps (3)–(7) in the “Deep
scratches” section.
8-51
HULL
HOOD
ENGINE MOUNT
E
Insert nut
NOTE:
Use the insert nut when:
• A pop nut which was attached to the hull
slipped off or,
• When a bolt which was fastened to an insert
nut or pop nut broke.
Part No.
Part
name
Remarks
EW2-62733-09
Nut
Stainless
steel, M6
• Nut 1
• Thread direction 2
• Slot to be threaded 3
NOTE:
Drilling size
Material
Pilot hole diameter
FRP or SMC
9.1–9.2 mm (0.36 in)
Brass
9.4 mm (0.37 in)
Example 1:
NOTE:
Before attempting to install the insert nut, refer
to “WATERCRAFT FRP REPAIR MANUAL”.
The insert nut is used to repair the pop nut
designed for the ride plate.
(By repairing the FRP portion, the insert nut
can be used for all models.)
1. Remove:
• Pop nut
2. Clean the surface to be scarfed and the
inside of the hull with acetone.
3. Scarf the shaded portion of the hull.
8-52
HULL
HOOD
ENGINE MOUNT
E
4. First, apply tape 1 to the inner surface of
the hull and then laminate fiberglass mats
over the tape with resin.
NOTE:
When it is possible to work inside the hull, laminate the mats from the inside.
5. Sand the outer surface of the hull until it is
smooth.
6. Install the ride plate.
7. Drill a 20 mm (0.79 in) deep hole in the
center of the laminated fiberglass layers
with a 9.2 mm (0.36 in) diameter drill bit.
8. Pass the bolt 2 through the insert nut and
lock the bolt with the nut 3 as shown.
9. Screw in the insert nut so that the top is
flush with the FRP surface.
10. Loosen the locknut and remove the bolt.
CAUTION:
● Only
use a steel bolt with a tensile
strength of 8T or more.
● If the bolt is inferior in strength or is made
of stainless steel it may break.
• Bolt 2
• Locknut 3
Example 2:
The brass insert nut, which is designed for the
Super Jet ride plate or the intake screen, is
used as follows.
NOTE:
If the bolt is broken, drill it out.
1. Drill a hole in the hull.
NOTE:
• First, use a small-diameter drill bit followed
by drill bits of gradually increasing diameter.
• Use a 9.4 mm (0.37 in) drill bit for the final
drilling.
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2. To prevent water from entering the urethane foam, apply silicone sealant to the
inside of the hole as shown.
3. Install the insert nut as explained in
“Example 1”.
• Brass insert nut 1
• Hull 2
• Urethane foam 3
• Silicone sealant 4
Graphic removal
1. Hold a hair dryer approximately 1.5 inches
above the graphic 1.
2. Apply heat to one corner of the graphic.
3. Slowly peel off the heated portion of the
graphic and continue working until you
reach the opposite corner and the entire
graphic is removed.
4. After the graphic is removed, clean the
entire bow area with isopropyl alcohol to
remove any residual adhesive.
Graphic installation
1. Mix 1 tablespoon of liquid detergent and
water in a 1-quart spray bottle.
2. Remove the backing from the new
graphic.
3. Spray the soap and water mixture onto
both sides of the graphic, and also onto
the hull area where the graphic will be
installed.
NOTE:
Spraying the front of the graphic with the soap
and water mixture will protect it from being
scratched during installation.
4. Align the graphic onto the fitting area of
the hull and position it with a squeegee.
NOTE:
Be sure to remove any air bubbles from the
graphic with the squeegee. Work from the top
of the graphic down and slide the squeegee
outwards from the graphic’s center line.
5. Allow the graphic to dry before waxing or
using the watercraft.
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CHAPTER 9
TROUBLE ANALYSIS
INTRODUCTION.............................................................................................. 9-1
FEATURES ............................................................................................... 9-1
Functions............................................................................................. 9-1
CONTENTS............................................................................................... 9-1
HARDWARE REQUIREMENTS................................................................9-2
GETTING STARTED .......................................................................................9-3
INSTALLING THE YAMAHA DIAGNOSTIC SYSTEM UNDER
Windows 95, Windows 98, Windows Me, Windows 2000,
or Windows XP ......................................................................................... 9-3
UPDATING THE DATABASE.................................................................... 9-7
OPERATING.................................................................................................. 9-11
CONNECTING THE COMPUTER TO THE WATERCRAFT .................. 9-11
CONNECTING THE COMMUNICATION CABLE TO THE
WATERCRAFT....................................................................................... 9-12
Models: FX140 .................................................................................. 9-12
OPENING THE YAMAHA DIAGNOSTIC SYSTEM ................................9-13
SELECTING COMMANDS FROM THE MAIN MENU ............................ 9-16
Two ways to select command: .......................................................... 9-16
EXPLANATION OF EACH COMMAND .................................................. 9-17
1. Diagnosis ......................................................................................9-17
2. Diagnosis record ...........................................................................9-17
3. Engine monitor .............................................................................. 9-17
4. Stationary test ............................................................................... 9-17
5. Active test......................................................................................9-17
6. Data logger....................................................................................9-18
7. ECM No......................................................................................... 9-18
8. Exit ................................................................................................9-18
DIAGNOSIS............................................................................................. 9-19
Operating procedure: ........................................................................9-19
Print................................................................................................... 9-20
Save .................................................................................................. 9-21
DIAGNOSIS RECORD ............................................................................9-23
Deleting diagnosis record in the ECM:.............................................. 9-24
ENGINE MONITOR................................................................................. 9-26
Operating procedure: ........................................................................9-27
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STATIONARY TEST ............................................................................... 9-28
Sparking ignition coil procedure: .......................................................9-28
Operating injector procedure:............................................................ 9-33
Operating the electric fuel pump: ......................................................9-35
ACTIVE TEST ......................................................................................... 9-38
Dropping a cylinder: ..........................................................................9-39
DATA LOGGER....................................................................................... 9-41
Monitor item selection ....................................................................... 9-41
Data display item selection ...............................................................9-42
Data comparison graph..................................................................... 9-43
Engine operating hours according to engine speed.......................... 9-44
ECM No. .................................................................................................. 9-45
EXIT.........................................................................................................9-46
Operating procedure: ........................................................................9-46
UNINSTALLING THE YAMAHA DIAGNOSTIC SYSTEM.......................9-47
TROUBLESHOOTING...................................................................................9-50
APPENDIX..................................................................................................... 9-51
SETTING THE DESKTOP AREA............................................................ 9-51
TROUBLE ANALYSIS...................................................................................9-53
TROUBLE ANALYSIS CHART................................................................9-53
Self-diagnosis....................................................................................9-57
1
2
3
4
5
6
7
8
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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 are 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. This enables you to
find malfunctioning parts quickly.
4. Stationary test: With the engine off, ignition, fuel injection, and the electric fuel pump are
checked. These tests can be performed quickly.
5. Active test: With the engine running, each firing cylinder drops and the engine speed is
checked for changes to determine if 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. ECM No.: The ECM part number is displayed.
CONTENTS
1. Software (1)
2. Adapter (1)
3. Communication cable (1)
4. Instruction Manual (1)
5. Installation Manual (1)
(with CD-ROM)
YAMAHA DIAGNOSTIC SYSTEM
for Watercraft
YAMAHA DIAGNOSTIC SYSTEM
for Watercraft
INSTRUCTION MANUAL
INSTALLATION MANUAL
60E-2819K-10
60E-2819U-10
1
2
Fig. 1
9-1
3
4
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HARDWARE REQUIREMENTS
Make sure that your computer meets the following requirements before using this software.
Computer:
IBM-compatible computer
Operating system:
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:
16 MB or more (32 MB or more recommended)
Windows Me:
32 MB or more (64 MB or more recommended)
Windows 2000:
64 MB or more (128 MB or more recommended)
Windows XP:
128 MB or more (256 MB or more recommended)
Hard disk free space:
20 MB or more (40 MB or more recommended)
Drive:
CD-ROM drive
Display:
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
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.
• This software is not compatible with USB ports. Be sure to install it into a PC that has an RS232C
(Dsub-9 pin) port.
• 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.
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GETTING STARTED
This section provides information on installing the Yamaha Diagnostic System under Windows 95,
Windows 98, Windows Me, Windows 2000, or Windows XP.
INSTALLING THE YAMAHA DIAGNOSTIC SYSTEM UNDER Windows 95,
Windows 98, Windows Me, Windows 2000, or Windows XP
NOTE:
• Before installing the Yamaha Diagnostic System, check that your computer meets the specified
requirements. For detailed information on the system requirements, see page 2.
• It is strongly recommended that you exit all other programs before running the installer.
1. Turn on your computer and start up Windows 95, Windows 98, Windows Me, Windows 2000, or
Windows XP.
2. Insert the compact disc into the computer’s CD-ROM drive.
3. Double-click the My Computer icon, then the CD-ROM drive icon, and then double-click the
Setup.exe icon to start up the installer. (Fig. 2)
Fig. 2
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4. Click the Next button to start the installation process. (Fig. 3)
Fig. 3
NOTE:
If the Yamaha Diagnostic System has already been installed onto your computer, the following dialog box appears.
Click the Yes button to update this program, or click the No button to quit the installation. (Fig. 4)
Fig. 4
NOTE:
• To quit the installation, click the Cancel button. The following dialog box appears.
Fig. 5
• To quit the installation program, click the Exit Setup button.
• To resume the installation, click the Resume button. (Fig. 5)
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5. Check the target directory and the program name for the Yamaha Diagnostic System which are
displayed in the dialog box.
Click the Next button to start copying the program files.
NOTE:
• To go back to the previous dialog box (step 4), click the Back button.
• To quit the installation, click the Cancel button.
Fig. 6
Fig. 7
Fig. 8
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6. After the installation is completed, the following dialog box appears.
Click the Finish button to quit the installation program.
Fig. 9
NOTE:
Install the Database file before using the Yamaha Diagnostic System, otherwise the program will not
operate correctly. For installation procedures, refer to “UPDATING THE DATABASE” on the next
page.
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UPDATING THE DATABASE
NOTE:
When installing the Yamaha Diagnostic System for the first time, be sure to update the database.
1. Turn on your computer and start up Windows 95, Windows 98, Windows Me, Windows 2000, or
Windows XP.
2. From the taskbar at the bottom of your computer screen, click the Start button (fig. 10), point to
Programs, and then click YAMAHA DIAGNOSTIC SYSTEM for WaterCraft to open the
Yamaha Diagnostic System window. (Fig. 11)
Fig. 10
3. After about three seconds the display will automatically go to the first menu display, or you can
click or press any key to go to the first menu. (See fig. 12.)
Fig. 11
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4. Click the Update database [F1] button or press the F1 key on your keyboard. (Fig. 12)
Fig. 12
1 First menu
2 Click to update database
NOTE:
• Do not click the Starting service tool [Enter] button or press the Enter key on your keyboard until
the database has been updated, otherwise the program will not operate correctly.
• To quit the update of the database, press the ESC key on your keyboard.
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5. Insert the compact disc into the computer’s CD-ROM drive.
NOTE:
• All the database files will be copied from the compact disc to the computer’s hard drive automatically.
• Any earlier version of the database saved on the hard drive will be overwritten.
6. Click the OK button or press the Enter key on your keyboard to start copying the database files.
(Fig. 13)
Fig. 13
NOTE:
If an error message appears and the program stops operating, follow the error message. (Fig. 14)
Fig. 14
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7. When the database is updated a confirmation screen is displayed.
To quit, click the OK button or press the Enter key on your keyboard. (Fig. 15)
To return to the first menu screen, click the Cancel button or press the Esc key on your keyboard.
Fig. 15
NOTE:
If the OK button is clicked, the program is exited.
Start the program again and check that the database version indicated in the first menu is J1.00.
(Fig. 16)
Fig. 16
1 Program version
2 Database version
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OPERATING
CONNECTING THE COMPUTER TO THE WATERCRAFT
NOTE:
Be sure to use the enclosed communication cable to connect the computer and adapter to the
watercraft.
1. Quit any applications that are running, and then turn off the computer.
2. Connect the communication cable to the 3-pin communication coupler of the watercraft, the
adapter, and the communication port of your computer.
1
Fig. 17
1 Adapter
NOTE:
Use either the COM1 or COM2 port, and, if necessary, set the serial port as specified in the computer’s manual. Set the serial port where the RS232C (Dsub-9 pin) cable is connected to COM1 or
COM2.
3. Connect a 12 V battery to the watercraft.
NOTE:
The following items should be checked before starting the Yamaha Diagnostic System.
• The battery is properly charged and its specific gravity is within specification.
• There are no incorrect wiring connections.
• Wiring connections are properly secured and are not rusty.
• There is enough fuel in the fuel tank.
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CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT
Models: FX140
Top view
1
2
3
Fig. 18
1 3-pin communication coupler
2 Wire harness coupler
3 Meter coupler
NOTE:
Be careful not to pinch the communication cable between the hood and the deck or to damage it.
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OPENING THE YAMAHA DIAGNOSTIC SYSTEM
1. Push the start switch to start the engine.
2. Turn on your computer and start up Windows 95, Windows 98, Windows Me, Windows 2000, or
Windows XP.
3. From the taskbar at the bottom of your computer screen, click the Start button (Fig. 19), point to
Programs, and then click YAMAHA DIAGNOSTIC SYSTEM for WaterCraft.
Fig. 19
4. Open the Yamaha Diagnostic System window. (Fig. 20) After about three seconds the display
will automatically go to the first menu, or click or press any key to go to the first menu. (See fig.
21.)
Fig. 20
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5. Click the Starting service tool [Enter] button or press the Enter key on your keyboard.
(Fig. 21)
Fig. 21
1 First menu
2 Click to start service tool
NOTE:
• If an error message appears and the program stops operating, follow the error messages.
• If the program doesn’t start, an error message will explain the problem. If the program doesn’t start
and an error message is not displayed, the cause of the problem is most likely insufficient computer memory.
• To cancel, press the ESC key on your keyboard.
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6. Click or press any key to display the main menu.
Fig. 22
NOTE:
If a diagnosis record is stored in the ECM, “Diagnosis record available,” appears as a confirmation
message before the Main Menu is displayed. (Fig. 23)
Fig. 23
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SELECTING COMMANDS FROM THE MAIN MENU
Eight commands appear in the Main Menu. Select a command in any of the following three ways.
Two ways to select command:
• Move the mouse pointer over the selected command (a or b) until it appears as a finger mark,
and then click the selected command.
• Press the number key (1–8) corresponding to the selected command.
Fig. 24
1 Main menu
NOTE:
If the Main Menu is displayed and the engine is turned off, electric power is supplied to the ECM for
30 minutes and commands can be carried out.
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EXPLANATION OF EACH COMMAND
1. Diagnosis
The diagnosis codes, their corresponding part name, the diagnosing results, and the diagnostic criteria are listed.
List of items:
Condition of coils (pulser coils)
Condition of sensors (throttle position sensor, intake air temperature sensor, intake air pressure
sensor, engine temperature sensor, and cam position sensor)
Condition of battery (battery voltage)
Operation of switches (slant detection switch)
2. Diagnosis record
The diagnosis code, its corresponding part name, oil pressure warning, overheat warning, the time
of occurrence, and the total operation hours are listed. This command enables you to check the
record of malfunctions, which will assist in reducing troubleshooting time. In addition, the diagnostic
codes of malfunctions that have occurred can be deleted from the ECM.
The items are the same as those listed above for Diagnosis.
3. Engine monitor
The input signal of each sensor for the ECM is displayed.
In addition, the sensing item that is displayed can be changed.
Sensing items:
Sensors (throttle position sensor, intake air temperature sensor, intake air pressure sensor, and
engine temperature sensor)
Voltage system (battery voltage)
Switches (engine shut-off switch, oil pressure switch, thermoswitch, and slant detection switch)
Operation signals (ignition and injectors)
4. Stationary test
With the engine off, operation tests are performed.
Test items:
Spark ignition coil for each cylinder
Fuel injector for each cylinder
Operation of the electric fuel pump
5. Active test
With the engine running, operation tests are performed.
Test items:
Dropped cylinder
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6. Data logger
Two out of six items (engine speed, battery voltage, throttle position, intake air pressure, engine
temperature, and oil pressure) are selected and 78 seconds of their recorded data are displayed on
a graph. The operating time as compared to the engine speed and the total operating time are also
displayed.
7. ECM No.
The ECM part number and model information are displayed.
8. Exit
The program is exited.
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DIAGNOSIS
The diagnosis codes of malfunctions recorded in the watercraft’s ECM, the diagnosis codes’ corresponding part name, the results of the diagnosis, and the condition of the part are listed.
Eight items can be displayed at one time.
Fig. 25
1 Other than Normal will be highlighted in red and will be listed from the top
2 Displays troubleshooting procedures for selected code.
Operating procedure:
Select the code number that you wish to view a diagnosis for by either clicking it or pressing the up
or down arrow keys on your keyboard.
NOTE:
• Items where “Normal” does not appear in the Result column are displayed at the top of the list.
• The selected code is highlighted in light blue and its confirmation procedure is displayed below the
table.
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Print
By selecting the Print command in the Diagnosis, Diagnosis record, Engine monitor, or Data logger
mode, the data from the corresponding window can be printed.
1. Click the Print [F1] button or press the F1 key on your keyboard. The Print dialog box is displayed. (Fig. 26)
Fig. 26
2. Specify the printer, the printing range, and the number of copies to be printed.
Fig. 27
1 Select printer
2 Select the number of copies
3 Select which page to print
3. Click the OK button to begin printing.
To cancel printing, click the Cancel button.
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Save
By selecting the Save command in the Diagnosis, Diagnosis record, Engine monitor, or Data logger
mode, the corresponding data can be saved on a disk.
Operating procedure:
1. Click the Save [F2] button or press the F2 key on your keyboard. The Save As dialog box is
displayed. (Fig. 28)
Fig. 28
Fig. 29
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2. Select the disk and folder where the data will be saved and specify its file name. (Fig. 30)
Fig. 30
1 Choose folder to save in
2 Choose type of data
3 Input file name
3. Click the Save button to save the data.
To cancel saving, click the Cancel button. (Fig. 30)
The data you saved can be viewed in Microsoft® Excel. (Fig. 31)
Fig. 31
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DIAGNOSIS RECORD
The diagnosis codes of malfunctions that have been recorded in the watercraft’s ECM, the diagnostic codes’ corresponding part name, and the time when the malfunctions occurred are listed.
A maximum of five items can be displayed at one time. The oldest occurrence appears on top. In
addition, diagnosis codes stored in the ECM can be deleted.
Fig. 32
1 Displays time of occurrence
2 Displays troubleshooting procedures for selected code.
NOTE:
When a Diagnosis record is not available, “Diagnosis Record is unavailable” is displayed. (Fig. 33)
Fig. 33
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Deleting diagnosis record in the ECM:
1. Select the item that you wish to delete by either clicking it or pressing the up or down arrow keys
on your keyboard.
NOTE:
• The selected code is highlighted in light blue.
• Check that the items deleted are normal in the Diagnosis Record. If the items remain irregular,
they will appear as irregular in the Diagnosis Record even if you try to delete them they are
undeletable.
Fig. 34
2. Click the Delete [F3] button or press the F3 key on your keyboard. (See fig. 33.) A confirmation
message appears. (Fig. 35)
Fig. 35
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3. Click the OK button or press the Enter key on your keyboard. (Fig. 35) The selected item is
deleted. To cancel deleting the item, click the Cancel button or press the Esc key on your keyboard.
NOTE:
If an error occurs while an item is being deleted, an error message appears. Follow the instructions
that appear in the error message. (Fig. 36)
Fig. 36
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ENGINE MONITOR
WARNING
Do not use the Engine Monitor function to check the engine condition while operating a
watercraft, otherwise you could become distracted, which could result in a collision.
CAUTION:
Be sure to avoid splashing water on the computer, adapter, and communication cable, and
to avoid damaging them with strong sudden jolts or vibration.
The data from the ECM of the watercraft is displayed.
Ten items can be displayed at one time. To view the other items, scroll the display. Displayed items
can be changed as necessary.
Fig. 37
1 Click to go to item selection display
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Operating procedure:
1. To scroll the display and view other items, click or in the scroll bar, or press the up or down
arrow keys on your keyboard.
2. To change a displayed item, click the Select [F3] button or press the F3 key on your keyboard.
3. Select an item by either clicking it or pressing the up or down arrow keys on your keyboard, and
then press the space bar. (Fig. 38)
Fig. 38
1 Selected items
NOTE:
• Selected items have a light blue background. Items that are not selected have a blue background.
The box to the left of items that are being moved are light blue. Items that are not selected appear
in blue.
• At initialization, all items are displayed.
4. Click the OK button or press the Enter key on your keyboard. The Engine monitor window
appears. To cancel the monitor, click the Cancel button or press the Esc key on your keyboard.
(Fig. 38)
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STATIONARY TEST
Selecting this command displays a window where stationary tests (spark ignition coil #, operate
injector #, and operate electric fuel pump) can be selected.
WARNING
Avoid clicking the Execute and Cancel buttons repeatedly, otherwise the ECM or PC will not
work properly and they could be damaged.
Fig. 39
1 Explanation of selected item
2 Confirmation item before the test
Sparking ignition coil procedure:
A voltage is applied to the ignition coil of the selected cylinder, a spark is created in the spark gap
tester, and then the ignition system is checked. Five sparks are created within five seconds.
WARNING
• Do not touch any connections of the spark gap tester lead wires.
• Do not let sparks leak out of the removed spark plug cap.
• Keep flammable gas or liquids away since this test will produce sparks.
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1. Select the test that you wish to perform by either clicking it or pressing the up or down arrow
keys on your keyboard. (Fig. 39)
NOTE:
• Make sure that the engine is not running.
• The selected item is highlighted in light blue.
• The details of the selected test are displayed in the column on the right, and the items that must
be either checked or performed before the test can start are displayed below the table.
• Only one item can be selected at one time.
• A special tool (spark gap tester YM-34487/90890-06754) is needed.
2. Connect the spark plug cap of the cylinder that will be tested to the spark gap tester.
Spark gap tester
È YM-34487 / É 90890-06754
3. Set the spark gap length on the adjusting knob.
Ignition spark gap: 7–8 mm (0.28–0.31 in)
È
É
Fig. 40
Fig. 41
4. Select the cylinder number where the spark gap tester is connected, and then click the Select
button or press the Enter key on your keyboard. (Fig. 39)
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5. Click the Execute button or press the Enter key on your keyboard. (Fig. 42)
Fig. 42
Fig. 43
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NOTE:
If the engine is running an error message is displayed. Follow the instructions that appear. (Fig. 44)
Fig. 44
6. While checking the information that appears in the Test situation column, follow the test
instructions in the messages that are displayed. (See fig. 43.)
NOTE:
If an error occurs while the test is being performed, an error message is displayed. Follow the
instructions that appear in the error message. (Fig. 45)
Fig. 45
7. To stop the stationary test, click the Cancel button. (See fig. 43.)
8. Observe the spark through the discharge window of the spark gap tester.
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9. To perform the test again to the same cylinder, click the Execute button or press the Enter key
on your keyboard. To perform the test on a different cylinder, click the Return [ESC] button or
press the Esc key on your keyboard to return to main menu where a different test can be
selected. (Fig. 46)
Fig. 46
NOTE:
If an error occurs while the test is being performed, the following message is displayed. (Fig. 47)
Fig. 47
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Operating injector procedure:
A voltage is applied to the injector of the selected cylinder, the injector is activated, and then the fuel
system is checked. The fuel is injected 20 times within two seconds.
WARNING
• Do not perform the test with the injector removed from the throttle body or with any fuel
system parts removed. High-pressure fuel could spurt out.
• When performing this operation, keep all sparks, flames, or other sources of ignition away
from the testing area. Gasoline is highly flammable.
1. Select the test that you wish to perform by either clicking it or pressing the up or down arrow
keys on your keyboard. (Fig. 48)
Fig. 48
NOTE:
• Make sure that the engine is not running.
• The selected item is highlighted in light blue.
• The details of the selected test are displayed in the column on the right, and the items that must
be either checked or performed before the test can start are displayed below the table.
• Only one item can be selected at one time.
• Make sure that there is fuel in the fuel tank, otherwise an error will occur and the test cannot be
performed.
2. Select the cylinder to be tested, and then click the Select button or press the Enter key on your
keyboard. (Fig. 48)
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3. Click the Execute button or press the Enter key on your keyboard. (Fig. 49)
Fig. 49
NOTE:
If an error occurs while the test is being performed, an error message is displayed. Follow the
instructions that appear.
4. Listen to the operating sound of the injector of the cylinder being tested.
Fig. 50
WARNING
Do not touch the injector connector.
9-34
TRBL
ANLS
OPERATING
E
5. To perform the test again on the same cylinder, click the Execute button or press the Enter key
on your keyboard. To perform the test on a different cylinder, click the Return [ESC] button or
press the Esc key on your keyboard to return to the window where a different test can be
selected. (Fig. 51)
Fig. 51
CAUTION:
Do not test the same cylinder three or more times, otherwise the spark plug insulator could
be damaged.
Operating the electric fuel pump:
A voltage is applied to the electric fuel pump, the electric fuel pump is operated, and then the fuel
system is checked. The electric fuel pump is operated for ten seconds.
WARNING
• Do not perform the test with the injector removed from the throttle body or with any fuel
system parts removed. High-pressure fuel could spurt out.
• When performing this operation, keep all sparks, flames, or other sources of ignition away
from the testing area. Gasoline is highly flammable.
NOTE:
Make sure that there is fuel in fuel tank, otherwise an error will occur and the test cannot be performed.
9-35
TRBL
ANLS
OPERATING
E
1. Select the test to be performed, and then click the Select button or press the Enter key on your
keyboard. (Fig. 52)
Fig. 52
NOTE:
• Make sure that the engine is not running.
• The selected item is highlighted in light blue.
• The details of the selected test are displayed in the column on the right, and the items that must
be either checked or performed before the test can start are displayed below the table.
• Only one item can be selected at one time.
9-36
TRBL
ANLS
OPERATING
E
2. Click the Execute button or press the Enter key on your keyboard. (Fig. 53)
Fig. 53
NOTE:
If an error occurs while the test is being performed, an error message is displayed. Follow the
instructions that appear.
3. Listen to the operating sound of the electric fuel pump.
4. To perform the test again, click the Execute button or press the Enter key on your keyboard. To
perform a different test, click the Return [ESC] button or press the Esc key on your keyboard to
return to the window where a different test can be selected. (Fig. 54)
Fig. 54
9-37
TRBL
ANLS
OPERATING
E
ACTIVE TEST
Selecting this command displays a window where active tests can be selected.
WARNING
Avoid clicking the Execute and Cancel buttons repeatedly, otherwise the ECM or PC will not
work properly and they could be damaged.
Fig. 55
NOTE:
The test can be carried out while the engine is running. It is not possible to carry out the test while
the watercraft is running.
9-38
TRBL
ANLS
OPERATING
E
Dropping a cylinder:
Start the engine and observe the changes in engine speed for 20 seconds.
For the first ten seconds operate all four cylinders, and then stop one cylinder for five seconds. For
the last five seconds operate all four cylinders.
A screen that allows you to select which ignition and fuel to cut is displayed.
1. Select which ignition and fuel you wish to cut by either clicking it or pressing the up or down
arrow keys on your keyboard. (Fig. 55)
NOTE:
• Release the throttle lever.
• The selected item is highlighted in light blue.
• The details of the selected test are displayed in the column on the right, and the items that must
be either checked or performed before the test can start are displayed below the table.
• Only one item can be selected at one time.
2. Click the Select button or press the Enter key on your keyboard. (Fig. 55)
3. Start the engine.
4. Click the Execute button or press the Enter key on your keyboard. (Fig. 56)
Fig. 56
9-39
TRBL
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OPERATING
E
NOTE:
If the engine is not running, an error message is displayed. Follow the instructions that appear. (Fig.
57)
Fig. 57
5. While checking the information that appears beside Test situation and Engine Speed, follow
the test instructions in the messages that are displayed. (Fig. 56)
NOTE:
If an error occurs while the test is being performed, an error message is displayed. Follow the
instructions that appear. (Fig. 58)
Fig. 58
6. To perform the test again on the same cylinder, click the Execute button or press the Enter key
on your keyboard. To perform a different test, click the Return [ESC] button or press the Esc
key on your keyboard to return to the window where a different test can be selected.
9-40
TRBL
ANLS
OPERATING
E
DATA LOGGER
Monitor item selection
A window appears that allows you to select the Data comparison graph or the Engine operating
hours according to engine speed.
Fig. 59
1 Triangle mark
Operating procedure:
1. Select the desired item by either clicking it or pressing the up or down arrow keys on your keyboard. (Fig. 59)
NOTE:
A triangle appears to the right of the selected item.
2. Press the Enter key on your keyboard. The window of the selected item is displayed.
(Fig. 59)
9-41
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OPERATING
E
Data display item selection
A window appears that allows you to select the items to be graphed. No more than two items can be
displayed.
Fig. 60
1 Selected items
Operating procedure:
1. Select the desired items by either clicking them or pressing the up or down arrow keys on your
keyboard, then pressing the space bar. (Fig. 60)
NOTE:
• Selected items have a light blue background. Items that are not selected have a blue background.
The box to the left of items that are being moved are light blue. Items that are not selected appear
in blue.
• At initialization, Engine speed [r/min] is selected.
2. Click the Graph button or press the Enter key on your keyboard. (Fig. 60) The Data comparison window is displayed. (See fig. 61.)
9-42
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OPERATING
E
Data comparison graph
A line graph appears with the items selected in the Data display item selection window on the vertical axes and the Time before engine stop on the horizontal axis. (Fig. 61)
Fig. 61
NOTE:
• The item on the left vertical axis is graphed with a solid line and the item on the right vertical axis
is graphed with a dotted line.
• Although the engine is running, graphs do not show the present engine condition. It displays the
value at the time the Enter key on your keyboard was pressed in the Monitor item selection.
9-43
TRBL
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OPERATING
E
Engine operating hours according to engine speed
The operating hours as compared to the engine speed and the total operating hours are displayed.
(Fig. 62)
Fig. 62
A window is displayed showing the amount of hours that the engine is operated at each engine
speed range.
NOTE:
• Although the engine is running the displayed time refers to the added hours until the Data logger
starts.
• The sum of the Engine operating hours according to engine speed is not equal to the total
hours of operation since the hours are rounded to two decimals.
9-44
TRBL
ANLS
OPERATING
E
ECM No.
The ECM part number of the watercraft is read from the ECM and is displayed. (Fig. 63)
Fig. 63
9-45
TRBL
ANLS
OPERATING
E
EXIT
The program is exited.
Operating procedure:
1. Click the Exit button or press any number key (1–8).
Fig. 64
2. Click the OK button or press the Enter key on your keyboard to exit the program.
To cancel exiting the program, click the Cancel button or press the Esc key on your keyboard.
(Fig. 65)
Fig. 65
9-46
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OPERATING
E
UNINSTALLING THE YAMAHA DIAGNOSTIC SYSTEM
Use the following procedure to uninstall the Yamaha Diagnostic System.
1. Exit all programs before running the uninstaller.
2. From the taskbar at the bottom of your computer screen, click the Start button, point to Settings, and then open the Control Panel.
3. In the Control Panel dialog box, double-click Add/Remove Programs. (Fig. 66)
Fig. 66
4. Select YAMAHA DIAGNOSTIC SYSTEM for WaterCraft and click the Add/Remove button.
(Fig. 67)
Fig. 67
9-47
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OPERATING
E
5. Click the Yes button in the confirmation window to uninstall the utility software. To cancel the
uninstall operation of the utility software, click the No button. (See figs. 68–70.)
Fig. 68
Fig. 69
Fig. 70
9-48
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OPERATING
E
6. If the following message appears, click the Details... button.
Fig. 71
1 Uninstall completed. Some elements could not be removed. You should manually remove items related to
the application.
7. Check the contents of the message. If an element could not be removed, delete it manually.
Fig. 72
1 Elements that could not be removed.
9-49
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TROUBLESHOOTING
E
TROUBLESHOOTING
Error content
Communication cable
related error occurs
Cause
Action
Communication cable is disconnected.
Connect communication cable
between the computer’s communication port and 3-pin communication coupler of the watercraft.
Battery is disconnected from the
watercraft.
Connect battery to watercraft.
The battery voltage is below 12 V.
Connect battery of 12 V or higher.
The hardware does not meet the
requirements to operate this
application.
Use a computer that meets the
specified hardware requirements.
YDIS.exe is not installed in application directory.
If YDIS.exe is not found in the
application directory, install the
application again.
Other application (Service tool) is
already in operation.
Quit the application in operation,
since two applications (Service
tool) cannot be operated simultaneously.
Application related error
occurs
Error message “Program file or
Database file is not installed
properly. Please install again.” is
displayed.
Install program file or database
file again.
Database related error
occurs
Error message “Database files
are not installed properly. Please
update again.” is displayed.
Update database again.
Error message “System file not
found ######.###.” is displayed.
The database is not applicable to
communication with ECM.
Update database to correspond
to ECM.
Incorrect fonts on
screen
The computer language does not
correspond to the application.
Use a computer that operates the
required operating system.
When executing the stationary test or active test
the test cannot be
ended even if the Cancel is clicked.
Execute and Cancel buttons have
been clicked more than necessary, and the ECM or PC does
not operate properly.
Turn off your PC.
Push the engine stop switch and
reset the ECM.
Application does not
start
9-50
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ANLS
APPENDIX
E
APPENDIX
SETTING THE DESKTOP AREA
Use the following procedure to set the Yamaha Diagnostic System desktop area.
Compatible with VGA (640 × 480 pixels) or SVGA (800 × 600 pixels) or more recommended
1. From the taskbar at the bottom of your computer screen, click the Start button, point to Settings, and then open the Control Panel.
2. In the Control Panel, double-click Display. (Fig. 73)
Fig. 73
3. Select Settings and slide the Desktop area slider. (Fig. 74)
Fig. 74
1 Slider
9-51
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APPENDIX
E
4. Click the OK button in the confirmation window to set the display area. To cancel, click the Cancel button. (See figs. 75–76.)
Fig. 75
Fig. 76
9-52
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TROUBLE ANALYSIS
E
TROUBLE ANALYSIS
NOTE:
The following items should be checked before the “TROUBLE ANALYSIS CHART” is consulted.
1. The battery is charged and its specified gravity is within specification.
2. There are no incorrect wiring connections.
3. Wiring connections are properly secured and are not rusty.
4. The engine shut-off cord (lanyard) is installed onto the engine shut-off switch.
5. Fuel is reaching the throttle body.
TROUBLE ANALYSIS CHART
POOR BATTERY CHARGING
IRREGULAR WARNING INDICATION
BILGE INCREASE
LOOSE STEERING
Check elements
LOW OIL PRESSURE
OVERHEATING
LIMITED ENGINE SPEED
POOR PERFORMANCE
ENGINE WILL NOT STOP
POOR ACCELERATION
ENGINE STALLS
HIGH IDLING
ROUGH IDLING
HARD STARTING
ENGINE WILL NOT START
Trouble mode
Relative part
FUEL SYSTEM
Fuel tank
Fuel tank breather hose
Fuel hose
Fuel filter
Fuel pump
Fuel injectors
Trolling speed
Air filter
9-53
Reference
chapter
4
4
4
4
4
4
3
3
TRBL
ANLS
TROUBLE ANALYSIS
POOR BATTERY CHARGING
IRREGULAR WARNING INDICATION
BILGE INCREASE
LOOSE STEERING
Check elements
LOW OIL PRESSURE
OVERHEATING
LIMITED ENGINE SPEED
POOR PERFORMANCE
ENGINE WILL NOT STOP
POOR ACCELERATION
ENGINE STALLS
HIGH IDLING
ROUGH IDLING
HARD STARTING
ENGINE WILL NOT START
Trouble mode
E
Relative part
POWER UNIT
Compression
Cylinder head gaskets
Cylinder block
Crankcase
Piston rings
Pistons
Bearings
Thermostat
Valve(s) and valve seat(s)
Valve clearance adjusting
pad(s)
Camshaft(s)
Timing chain
Oil pump
Engine oil
Oil filter
Oil pressure switch
Bearing housing
Drive couplings
Rubber coupling
Pilot water hose
Water hose
Water passage
9-54
Reference
chapter
5
5
5
5
5
5
5
5
5
3
5
5
5
3
3
7
5
5
5
5
5
5
TRBL
ANLS
TROUBLE ANALYSIS
POOR BATTERY CHARGING
IRREGULAR WARNING INDICATION
BILGE INCREASE
LOOSE STEERING
Check elements
LOW OIL PRESSURE
OVERHEATING
LIMITED ENGINE SPEED
POOR PERFORMANCE
ENGINE WILL NOT STOP
POOR ACCELERATION
ENGINE STALLS
HIGH IDLING
ROUGH IDLING
HARD STARTING
ENGINE WILL NOT START
Trouble mode
E
Relative part
Reference
chapter
JET PUMP UNIT
Duct
Impeller
Intake grate
Bearings
Intake duct
Water inlet hose
Bilge hose
Bilge strainer
Bilge hose joint
ELECTRICAL
Ignition system, fuel control system
• Pulser coils
• ECM
• Ignition coils
• Slant detector switch
• Engine stop switch
• Engine shut-off switch
• Spark plugs
• Main and fuel pump relay
• Thermoswitch
• Intake air pressure sensor
• Intake air temperature
sensor
• Engine temperature
sensor
• Throttle position sensor
• Cam position sensor
9-55
6
6
6
6
6
6
6
3
6
7
7
7
7
7
7
3
7
7
7
7
7
7
7
TRBL
ANLS
TROUBLE ANALYSIS
POOR BATTERY CHARGING
IRREGULAR WARNING INDICATION
BILGE INCREASE
LOOSE STEERING
Check elements
LOW OIL PRESSURE
OVERHEATING
LIMITED ENGINE SPEED
POOR PERFORMANCE
ENGINE WILL NOT STOP
POOR ACCELERATION
ENGINE STALLS
HIGH IDLING
ROUGH IDLING
HARD STARTING
ENGINE WILL NOT START
Trouble mode
E
Relative part
Starting system
• Start switch
• Starter relay
• Starter motor
Charging system
• Lighting coil
• Rectifier/regulator
• Fuses
• Battery leads
• Battery
Electric bilge pump
• Electric bilge pump
HULL AND HOOD
Steering master
Water lock
Exhaust hose
Muffler
Drain plugs
9-56
Reference
chapter
7
7
7
7
7
7
—
3
7
8
8
8
8
8
TRBL
ANLS
TROUBLE ANALYSIS
E
Self-diagnosis
With the engine running, press the hour meter/
voltmeter display select switch 1 and the
speedometer display switch 2 for 8 seconds
and check if an error code is indicated on the
multifunction meter.
Code
1
2
Symptom
13
Incorrect pulser coil signal
15
Incorrect engine temperature
sensor signal
18
Incorrect throttle position sensor
signal
19
Incorrect battery voltage
23
Incorrect intake air temperature
sensor signal
24
Incorrect cam position sensor
signal
29
Incorrect intake air pressure sensor
signal
39
Incorrect oil pressure sensor signal
47
Incorrect slant detection switch
signal
48
Incorrect data transmission
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
Yamaha Diagnostic System.
9-57
WIRING DIAGRAM
FX140
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
Fuse (20A)
Fuse (3A)
Starter relay
Slant detection switch
Main and fuel pump relay
ECM
Rectifier Regulator
Cam position sensor
Thermoswitch (exhaust)
Oil pressure switch
Thermoswitch (engine)
Engine temperature sensor
Intake air pressure sensor
Intake air temperature sensor
Throttle position sensor
Fuel injector
Ignition coil
Spark plug
Pulser coil
Lighting coil
Battery
Starter motor
Electrical bilge pump
Fuel pump
Fuel sender
Engine stop switch
Engine shut-off switch
Start switch
Meter
Speed sensor
Buzzer
È To tachometer
Color code
B
Br
G
L
O
P
R
W
Y
B/G
B/O
B/R
B/W
B/Y
G/O
L/B
L/R
P/G
P/W
Pu/B
Pu/G
Pu/R
Pu/Y
R/Y
R/W
W/B
W/R
: Black
: Brown
: Green
: Blue
: Orange
: Pink
: Red
: White
: Yellow
: Black/green
: Black/orange
: Black/red
: Black/white
: Black/yellow
: Green/orange
: Blue/black
: Blue/red
: Pink/green
: Pink/white
: Purple/black
: Purple/green
: Purple/red
: Purple/yellow
: Red/yellow
: Red/white
: White/black
: White/red
YAMAHA MOTOR CORPORATION, USA
Printed in USA
Mar. 2002 – ?.? × 1 CR
F1B-28197-1E-11
(FX1000-A)
(E_1)
FX140
G
G
B
G
B/O
B/O
B
B
P/W
B/O
G/O
P
B/O
G
W/R
B/O
W/B
B/O
B/O
3
R
P/G
R
R
Br
2
R
R/Y
Pu/Y
P
B/O
B
B
P
B/O
W
R
B
P
B/Y
B/Y
B/Y
B/Y B/Y
0
Pu/G
R/Y
P/W
B/O
B/O R/Y
G/O
B/Y
Pu/R
B
R/Y
B
G/O
O
P
P
B/O
B
1
B/O
P/W
R/Y
B
P
B/O
2
8
R/Y
Pu/B
R/Y
Br Br
B/O
P
R R
R/Y
O
A
D
P/G
B
B/Y
B/Y
O
P/G
B/O
B/O
C
Pu/Y
Pu/R
4
9
Pu/G
B/O
R/Y
B/O
B/O
B/O
B/O
B/O
R/Y
P
E
L/B
L/B
5
C
L/B
L
Pu/G
L/R
Pu/Y
Pu/B
Pu/R
O
Br
R/Y
Y
R/Y
A
R
R/Y
B/R
G
R
B
R/Y
R/Y
B
R/Y
#4
#3
R
B/W
P
B/W
#2
R
#4
#3
#2
#1
F
F
F
F
H
H
H
H
GGG
I
P
B/O
R
L
N
G
O
È
G
W/B
W
R/Y
K
B
L B
B
B
W
R
R/Y
6
L
M
B
B
2 3 4 5 6 7 8 9 10
G
W P/W
Br
O W/R W/B
11 12 13 15 17 18 19 20 21 23
Y
B
B/Y Pu/Y
24 25 26 27 28
Pu/B Pu/R Pu/G B B/W
R/Y
D
R
B
7
G
G
G
B/O
B
B/G
B
B
R
L/B
L/R
L/B
L/R
B
B/G
B
B/O
Y
B/Y
R/W
B
U
L
R/W
Y
B/Y
R/Y
R
Br B
B/Y
B
P
T
1
S
R
P
B/O
B
P
W
R
Br
R/Y
L/R W/B B/R G/O L/B R/Y P/G
B
Br
R/Y
P B/Y B/O Y
Br Br
FREE
PUSH
W
B
Br
R/Y
Br
Br
R/Y
R/Y
R
FREE
PUSH
B
W
R
W B
W
FREE
PUSH
G
B/W
Q
B
J
P
O
R W
B
R
R
R/Y
B
B/W
R
R/Y
#1
B
A
C
123
C
B
Br
R/Y R/Y R/Y Br
R
R R/Y B
B
L
B/O
Y
L/R
L/B
R/Y
R
4
5
D
P
O Pu/R Pu/Y R/Y
P/G B/Y Pu/B B/O Pu/G
B/O B/O
B/O B/O
R/Y R/Y
R/Y R/Y
O
E
O
O
P
R
P
P
O
R/Y
R/Y
R/Y
R/Y
R/Y
B/W
Pu/G
B
Pu/B
Pu/R
Pu/Y
W/B
B/Y
P
P/G
G/O
B/R
W/B
W/R
B/O
B/Y
W
G
P/W
6
F
F
F
F
D
A
GH
B
D
B/Y W/B B/O P G/O R/Y Pu/B B/Y P/G
P W/R P/W R/Y Pu/G Pu/Y Pu/R O
P
B
B/Y
G
G
G
P
W/B
W/R
B/O
P/W
P
R/Y
G/O
B/O
B/O
B
B
8
9
0
A
B
I
J
B/W
R/Y
B/R
R/Y
7
P
D
O
Pu/R Pu/Y Pu/G
P/G B/Y Pu/B R/Y B/O
C
R
B
G
G
G
B
B/O
R/Y
L
R/Y
W/B
G
W
Br
R
B
B
B
B/O
M
N
O
P
Q
R
S
È