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Yamaha Waverunner VXS VX1800 Service Manual

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WaveRunner
VXS
VX1800 (F2W)
VXR
VX1800A (F2W)
SERVICE MANUAL
F2W-28197-ZU-11

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  Summary of Contents for Yamaha Waverunner VXS VX1800

  • Page 1 WaveRunner VX1800 (F2W) VX1800A (F2W) SERVICE MANUAL F2W-28197-ZU-11...
  • Page 2 Preface This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained me- chanics when performing maintenance procedures and repairs to Yamaha equipment. It has been writ- ten to suit the needs of persons who have the Bronze Technical Certificate of the YTA (Yamaha...
  • Page 3: Table Of Contents

    Contents General information Specification Maintenance Fuel system Power unit Jet pump unit Electrical system Hull and hood Troubleshooting Appendix...
  • Page 4: General Information

    General information Safety while working............1-1 Rotating parts ................1-1 Hot parts..................1-1 Electric shock ................1-1 Impeller..................1-1 Handling of gasoline..............1-1 Ventilation................... 1-1 Self-protection ................1-1 Working with crane..............1-2 Handling of heat gun ..............1-2 Parts, lubricants, and sealants ........... 1-2 Handling of sealants..............
  • Page 5 General information RiDE system................1-23 RiDE motor................1-24 ETV system ................1-25 Shift control ................1-26 Engine control system .............. 1-28 Deck and hull................1-31 Lubrication system ..............1-32 Hose routing ................1-33 Cooling water flow ..............1-34...
  • Page 6: Safety While Working

    Safety while working Safety while working Handling of gasoline • Gasoline is highly flammable. Keep gasoline To prevent an accident or injury and to provide and all flammable products away from heat, quality service, observe the following safety sparks, and open flames. procedures.
  • Page 7: Working With Crane

    Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants, and sealants, or those recommended by Ya- maha, when servicing or repairing the water- craft.
  • Page 8: Handling Of Sealants

    Safety while working Handling of sealants • Wear protective gloves to protect your skin, when using the sealants. • See the material safety data sheet issued by the manufacturer. Some of the sealants may be harmful to human health. Disassembly and assembly •...
  • Page 9: Identification Number

    The primary I.D. number is stamped on a label attached to the inside of the engine compart- ment. PRI-I.D. MODEL YAMAHA MOTOR CO., LTD. ASSEMBLED IN U.S.A. FROM AMERICAN AND JAPANESE COMPONENTS. 1. Jet pump unit name ASSEMBLÉ AUX ÉTATS-UNIS DE PIÈCES AMÉRICAINES ET JAPONAISES.
  • Page 10: How To Use This Manual

    How to use this manual How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. •...
  • Page 11: Conditions When Testing And Adjusting

    How to use this manual Conditions when testing and adjusting Conditions can affect specifications when checking, measuring and making some adjustments. Service data in this manual was determined under the following conditions: • Electrical resistance for components such as pickup coils and sensors was measured at 20 °C (68 °F).
  • Page 12 How to use this manual Abbreviation Description Upside YDIS Yamaha Diagnostic System...
  • Page 13: Adhesive, Lubricant, Sealant, And Thread Locking Agent

    Adhesive, lubricant, sealant, and thread locking agent Symbols Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points. Symbol Name Application YAMALUBE 4W or Yamaha 4-stroke motor oil Lubricant Water resistant grease Lubricant (YAMALUBE MARINE GREASE) Molybdenum disulfide grease...
  • Page 14: Special Service Tool

    Special service tool Special service tools numbered “YB/YM/YS/YU/YW-*****” are distributed by K & L. Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division. Special service tool with part number 90890-06884/LIT-YDIS2-01-KT is distributed by the Marine Ser- vice Division.
  • Page 15 Special service tool Reference Tool name/Tool No. Illustration pages Fuel pressure gauge adapter 90890-06946 Fuel pressure gauge adapter YB-06946 Fuel pressure gauge 90890-06753 Fuel pressure gauge YU-03153M Compression gauge 90890-03160 Compression gauge YU-33223 YU-33223 Compression gauge extension 90890-06563 Exhaust pipe wrench 5-17, 5-17 90890-06726 Exhaust pipe wrench...
  • Page 16 Special service tool Reference Tool name/Tool No. Illustration pages Leakage tester 5-29 90890-06840 Valve spring compressor 5-47, 5-53 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attachment 5-47, 5-53 90890-04114 Compressor adapter YM-04114 Valve guide remover/installer 5-49, 5-50 90890-06801 Valve guide remover YB-06801 Valve guide installer 5-50...
  • Page 17 Special service tool Reference Tool name/Tool No. Illustration pages Valve seat cutter holder 5-51 90890-06812 Valve seat cutter 30° 5-51 90890-06720 Valve seat cutter 45° 5-51 90890-06325 Valve seat cutter 60° 5-51 90890-06324 Valve seat cutter 30° 5-51 90890-06818 Valve seat cutter 45° 5-51 90890-06555 Valve seat cutter 60°...
  • Page 18 Special service tool Reference Tool name/Tool No. Illustration pages Shaft holder 5-59, 5-59, 90890-06721 5-63, 5-64, Shaft holder 5-64, 5-65, YW-06721 5-65 Drive handle 5-59, 5-59, 90890-06722 5-63, 5-64, Drive handle 5-65, 5-65 YW-06722 Flywheel puller 5-60 90890-06723 Flywheel puller YW-06723 Rotor puller 5-60...
  • Page 19 Special service tool Reference Tool name/Tool No. Illustration pages Ball bearing attachment 5-61 90890-06657 Driver handle (large) 5-61, 5-61, YB-06071 6-12 Forward gear outer race installer 5-61 YB-41446 Bearing pressure C 5-61 90890-02393 Forward bearing race installer 5-61 YB-06258 Piston ring compressor 5-86 90890-05158 Piston ring compressor...
  • Page 20 Special service tool Reference Tool name/Tool No. Illustration pages Stopper guide stand 6-11, 6-12, 90890-06538 6-20 Slide hammer 6-11, 6-12, YB-06096 6-20 Driver rod L3 6-12 90890-06652 Driver rod SL 6-12 90890-06602 Needle bearing attachment 6-12 90890-06609 Driveshaft needle bearing installer and re- 6-12 mover YB-06194...
  • Page 21 Special service tool Reference Tool name/Tool No. Illustration pages Shaft holder 6-20, 6-22 90890-06730 Shaft holder YW-06730 Bearing puller legs 6-20 YB-06523 Needle bearing attachment 6-21, 6-21, 90890-06654 6-21 Needle bearing installer 6-21, 6-21, YB-06434 6-21 Bearing attachment 6-22, 6-22 90890-06727 Bearing attachment YW-06727...
  • Page 22 Special service tool Reference Tool name/Tool No. Illustration pages Peak voltage adapter B 7-10 90890-03172 Peak volt adapter YU-39991 Ignition checker (Spark gap tester) 7-11 90890-06754 Spark checker YM-34487 Test harness (2 pins) 7-12 90890-06851 Test harness (3 pins) 7-13 90890-06870 Test harness (3 pins) YB-06870...
  • Page 23 Special service tool Reference Tool name/Tool No. Illustration pages Throttle sensor adjusting lead FWY–3 7-27 90890-06857 Test harness (3 pins) YB-06857 1-18...
  • Page 24: Model Feature

    Model feature Model feature General feature The F2W features a hull and deck that are based on those of the F2X and is equipped with an 1812 cm³ engine. While retaining the stability and comfort of the F2X, the acceleration performance and maximum speed have been improved by increasing the output of the engine.
  • Page 25: Model Equipment Comparison Table

    Model feature Model equipment comparison table Model Total length 3.34 m (131.5 in) 3.35 m (131.9 in) Width 1220 mm (48.0 in) Dry weight 347 kg (765 lb) 348 kg (767 lb)  Reboarding step “1” — Front seat “2” Normal seat Cruiser seat : Equipped...
  • Page 26: Technical Tips

    Technical tips Technical tips Engine control The ECM controls ignition timing and fuel injection with information received from the sensors and switches installed on the engine as well as utilizing the base map saved in the ECM. Part name Function Detects the opening angle of the ETV.
  • Page 27 Technical tips Part name Function 13 APS Detects the opening angle of the throttle lever. Detects when the handlebar is turned all the way to the right or 14 Steering sensor left. 1-22...
  • Page 28: Ride System

    Technical tips RiDE system Unlike previous systems with mechanical shifting and Q.S.T.S., the RiDE motor is driven through elec- tric signals in order to conduct shifting and trim operations. With electrical operation, conventional cables are not used. By using the RiDE lever and electric trim switch unit incorporated into the left handlebar switch, shifting and trim operations are easy to control.
  • Page 29: Ride Motor

    Technical tips RiDE motor The RiDE lever employs the same part used for the throttle lever that incorporates the APS. An RPS (RiDE position sensor) is built into the RiDE lever. The RiDE motor is an assembly part that includes the shift motor and trim motor, a shift position sensor that detects the position of each motor, the trim position sensor, and a built-in SCU to control each mo- tor.
  • Page 30: Etv System

    Technical tips ETV system The F2W is equipped with the same throttle lever as that of the F2S. The throttle lever has an APS which senses the degree of throttle opening and converts the status into electronic signals, delivering the information to the ECM. The ECM controls the ETV based on the input signals of the APS.
  • Page 31: Shift Control

    Technical tips Shift control The reverse gate on RiDE models is in the F position when the engine is stopped. When the engine is started, the reverse gate returns to the N position automatically. The ECM calculates the throttle lever opening angle and RiDE lever opening angle to control shifting. Engine speed and reverse gate positions are also controlled.
  • Page 32 Technical tips Condition Lever Reverse gate Trolling → Neutral Neutral → Reverse Engine stopped 1-27...
  • Page 33: Engine Control System

    Technical tips Engine control system Item Condition Action Remarks Cancel: • Stop the engine and wait for 30 seconds or more. • Engine temperature • Engine temperature is rises rapidly in a below 140 °C (248 °F) • Opening angle of the ETV short time.
  • Page 34 Technical tips Item Condition Action Remarks • Opening angle of the ETV is fixed to the default opening angle. ETV failed, or open or ETV failure • Maximum engine speed is short circuit is detect- — control limited to approximately ed in ETV circuit.
  • Page 35 Technical tips Item Condition Action Remarks Off-throttle Control is activated Engine speed is increased steering when all of the follow- to approximately 3500 r/min (OTS) control ing conditions are for a few seconds. present: • Engine speed ex- ceeds 6000 r/min for a few seconds or —...
  • Page 36: Deck And Hull

    Technical tips Deck and hull The F2W uses the same type of hull and deck that the F2X uses. However, the seats are different from the seats of the F2X. The VXR uses a cruiser seat for the front seat in order to increase the comfort of the operator.
  • Page 37: Lubrication System

    Technical tips Lubrication system The engine features a wet-sump lubrication system. The oil pan carries out the scavenging function and the engine uses a feed oil pump ASSY. The blowby gas from the cylinder head cover is sent directly to the oil separator tank. 11.
  • Page 38: Hose Routing

    Technical tips Hose routing A. From flushing hose connector B. From transom plate C. To cooling water pilot outlet D. To drain joint (transom plate) E. To drain joint F. For water draining when engine is stopped G. Cooling water flow H.
  • Page 39: Cooling Water Flow

    Technical tips Cooling water flow A. From flushing hose connector B. From transom plate C. To cooling water pilot outlet D. To drain joint E. To exhaust valve F. For water draining when engine is stopped G. Cooling water flow 1-34...
  • Page 40 Technical tips — MEMO — 1-35...
  • Page 41: Specification

    Specification Model data ................2-1 Fuel system technical data ..........2-3 Fuel system ................2-3 Power unit technical data ..........2-4 Power unit .................. 2-4 Cylinder head ASSY..............2-4 Crankcase ASSY................ 2-5 Jet pump unit technical data..........2-7 Jet pump unit................2-7 Electrical technical data ............
  • Page 42: Model Data

    Model data Model data Model code Hull Engine Jet pump Dimensions and weight Length VX1800-P 3340 mm (131.5 in) VX1800A-P 3350 mm (131.9 in) Width 1220 mm (48.0 in) Height 1190 mm (46.9 in) Dry weight VX1800-P 347 kg (765 lb) VX1800A-P 348 kg (767 lb) Maximum people on board 3 person...
  • Page 43 Model data Shift operation F–N–R Reverse system Reverse gate Fuel and oil Recommended fuel Regular unleaded gasoline Minimum octane rating (PON) Minimum octane rating (RON) Fuel tank total capacity 70 L (18.5 US gal, 15.4 Imp.gal) Recommended engine oil YAMALUBE 4W or 4-stroke motor oil Recommended engine oil grade API API SE, SF, SG, SH, SJ, SL Recommended engine oil type SAE...
  • Page 44: Fuel System

    Fuel system technical data Fuel system technical data Fuel system Throttle body Manufacturer Mikuni Type/quantity F1-IM60–11/1 ID mark 6BH 00 Fuel pump Pump type Electrical Fuel pressure 345.0–355.0 kPa (3.45–3.55 kgf/cm², 50.0–51.5 psi)
  • Page 45: Power Unit

    Power unit technical data Power unit technical data Power unit Compression pressure Minimum 780 kPa (7.8 kgf/cm², 113.1 psi) Oil cooler Water passage holding pressure 200 kPa (2.0 kgf/cm², 29.0 psi) Thermostat Valve opening temperature 58 °C (136 °F) Fully open temperature 70 °C (158 °F) Fully open stroke 4.3 mm (0.17 in)
  • Page 46: Crankcase Assy

    Power unit technical data Valve guide Inside diameter-intake 5.504–5.522 mm (0.2167–0.2174 in) Inside diameter-exhaust 5.504–5.522 mm (0.2167–0.2174 in) Stem to guide clearance-intake 0.012–0.045 mm (0.0005–0.0018 in) Limit 0.080 mm (0.0032 in) Stem to guide clearance-exhaust 0.025–0.058 mm (0.0010–0.0023 in) Limit 0.100 mm (0.0039 in) Valve guide installation height 12.3–12.7 mm (0.48–0.50 in)
  • Page 47 Power unit technical data 2nd ring Type Taper Height (B) 1.170–1.190 mm (0.0461–0.0469 in) Width (T) 2.600–2.800 mm (0.1024–0.1102 in) End gap (installed) 0.450–0.600 mm (0.0177–0.0236 in) Limit 0.850 mm (0.0335 in) Side clearance 0.020–0.060 mm (0.0008–0.0024 in) Limit 0.120 mm (0.0047 in) Oil ring Height (B) 2.370–2.470 mm (0.0933–0.0972 in)
  • Page 48: Jet Pump Unit

    Jet pump unit technical data Jet pump unit technical data Jet pump unit Impeller housing Inside diameter 155.35–155.45 mm (6.116–6.120 in) Limit 156.45 mm (6.1594 in) Impeller clearance 0.350–0.450 mm (0.0138–0.0177 in) Limit 0.60 mm (0.0236 in) Impeller Material Stainless steel Diameter 155 mm (6.10 in) Number of impeller blade...
  • Page 49: Electrical Technical Data

    Electrical technical data Electrical technical data Ignition system ECM unit Output peak voltage at cranking (loaded) (reference data) 2.5 V Output peak voltage at 2000 r/min (loaded) (reference data) 2.6 V Output peak voltage at 3500 r/min (loaded) (reference data) 2.6 V Pickup coil Output peak voltage at cranking (unloaded)
  • Page 50 Electrical technical data Thermo sensor Input voltage 4.75–5.25 V Resistance at 0°C (32°F) 24.0–37.1 kΩ Resistance at 100°C (212°F) 0.87–1.18 kΩ Engine temperature sensor Input voltage 4.75–5.25 V Resistance at 20°C (68°F) 54.2–69.0 kΩ Resistance at 100°C (212°F) 3.12–3.48 kΩ Intake air temperature sensor Input voltage 4.75–5.25 V...
  • Page 51: Fuel System

    Electrical technical data RPS output voltage difference 0.1 V or less RPS 1 Input voltage 4.75–5.25 V RPS 2 Input voltage 4.75–5.25 V ETV relay Input voltage 12 V (battery voltage) Cam position sensor Input voltage 4.75–5.25 V Output voltage (position a, c) More than 4.8 V Output voltage (position b) Less than 0.8 V...
  • Page 52: Meter System

    Electrical technical data Meter system Remote control transmitter Battery CR2016 Rating Remote control receiver Input voltage 12 V (battery voltage) Output voltage 11–12 V Multifunction meter unit Input voltage 12 V (battery voltage) Buzzer Input voltage 11–12 V Speed sensor Output voltage (dependant on the paddle wheel position) Less than 400 mV/More than 11.6 V...
  • Page 53: Specified Tightening Torque

    Specified tightening torque Specified tightening torque General tightening torque Specified tightening torques are provided for This chart indicates the tightening torques for specific nuts, bolts, and screws. Tightening standard fasteners with a standard ISO thread torque specifications are provided in the ex- pitch.
  • Page 54: Cable And Hose Routing

    Cable and hose routing Cable and hose routing Starboard bow view 14,15 10. Remote control receiver antenna 1. RiDE motor lead 11. Remote control receiver lead 2. APS lead 12. Fuel tank breather hose (water separator 3. RPS lead to ventilation socket) 4.
  • Page 55: Top View

    Cable and hose routing Top view 14 12 2-14...
  • Page 56 Cable and hose routing 1. Remote control receiver antenna 2. Remote control receiver lead 3. Fuel tank breather hose (water separator to ventilation socket) 4. APS lead 5. Steering cable 6. Wire harness 7. Speed sensor lead 8. Negative battery lead 9.
  • Page 57: Port View

    Cable and hose routing Port view 11. Fuel tank breather hose (water separator 1. Remote control receiver antenna to ventilation socket) 2. Steering sensor lead 12. Cooling water pilot outlet hose 3. Buzzer lead 13. Remote control receiver lead 4. Fuel tank breather hose (fuel tank to water separator) 5.
  • Page 58: Coupler Layout

    Cable and hose routing Coupler layout 1 2 3 1. Trim switch coupler (black) 2. APS coupler (black) 3. RPS coupler (gray) 4. Steering sensor coupler (black) 5. Buzzer coupler (black) 6. Buzzer/LED coupler (white) 7. Communication coupler (gray) 8. Speed sensor coupler (white) 9.
  • Page 59 Maintenance Maintenance interval chart ..........3-1 Periodic service..............3-3 Fuel line check ................3-3 Fuel filler cap and water separator check........3-3 Fuel tank check ................3-3 Water inlet strainer check............3-3 Cooling water hose check ............3-3 Engine oil level check..............3-4 Engine oil replacement...............
  • Page 60: Maintenance Interval Chart

    Maintenance interval chart Maintenance interval chart The following chart should be considered strictly as a guide to general maintenance intervals. Depending on the operating conditions, the maintenance intervals should be changed. Perform the pre-operation checks and post-operation checks before performing periodic maintenance. Initial Thereafter every Item...
  • Page 61 Maintenance interval chart Initial Thereafter every Item Operation 50 hours or 100 hours or 200 hours or page 10 hours 12 months *1 12 months *1 24 months *1 Check for exhaust  3-10 Exhaust system leakage, and check hoses and clamps Check breather hose ...
  • Page 62: Periodic Service

    Periodic service Periodic service TIP: Fuel line check To drain water from the water separator “1”, 1. Remove the service lid. loosen the drain plug “3”. 2. Check the fuel hoses and hose connec- tions for fuel leakage. 3. Check the fuel hoses. Replace if cracked or damaged.
  • Page 63: Engine Oil Level Check

    Periodic service 2. Check the cooling water hoses. Replace if 5. If the engine oil is above the maximum lev- cracked or damaged. el mark, extract oil using an oil changer to lower it to the correct level. 3. Check the cooling water hose routing and the clamps.
  • Page 64: Oil Filter Replacement

    Periodic service Oil filter wrench “2” 90890-06830 Oil filter wrench “2” YB-06830 4. Install the oil filter “1”, and then tighten it to the specified torque. TIP: Make sure to clean up any oil spills. 6. Add the recommended engine oil up to the specified level through the oil filler hole.
  • Page 65: Battery And Battery Lead Check

    Periodic service Battery and battery lead check TIP: Be careful not to get water or any other foreign substances in the spark plug holes. Battery electrolyte is poisonous and dan- gerous, causing severe burns, etc. Electro- lyte contains sulfuric acid. Avoid contact 2.
  • Page 66: Steering Master Check

    Periodic service 3. Check the specific gravity of the electro- Steering master check lyte. Charge the battery if below specifica- 1. Turn the handlebar lock to lock and push it tion. back and forth. Specific gravity 1.265 4. Check the battery leads and terminals for corrosion.
  • Page 67: Trim Rod Check

    Periodic service 5. Disconnect the joint and apply a small Recommended lubricant amount of grease. YAMALUBE MARINE GREASE 3. Connect the trim rod joints to the ball joints. 4. Check the trim rod for rod end disconnec- tion and check the locknut for looseness. 5.
  • Page 68: Air Intake Hose Check

    Periodic service 4. Start the engine. Immediately after the en- gine has started, supply water. Do not run the engine over 4000 r/min on land. Also, do not run the engine for more than 15 seconds without supplying water, otherwise the engine could overheat. 5.
  • Page 69: Exhaust System Check

    Periodic service 3. Check the breather hose routing and the clamps. See “Cable and hose routing” (2-13). Impeller check Make sure to remove the battery before checking the jet pump unit. 1. Check the impeller from the jet intake side. 2.
  • Page 70: Drain Plug Check

    Periodic service 10. Check the bilge hose routing and the TIP: clamps. Place your hand under the bilge strainer to check for clog or dirt. Drain plug check 1. Check the O-ring “1” of drain plug “2”. Re- place if cracked or damaged. 2.
  • Page 71 Periodic service Gauge stand “1” 90890-06725 Dial gauge needle “2” 90890-06584 Dial gauge stand set “2” Camshaft wrench “1” YB-06585 90890-06724 Dial gauge set “3” Camshaft wrench “1” 90890-01252 YW-06724 Dial indicator gauge “3” 4. Measure the intake and exhaust valve YU-03097 clearances of the specified cylinders.
  • Page 72: Rubber Coupling Check

    Periodic service 7. Measure the intake and exhaust valve clearances of the specified cylinders.   — —   — — : Specified cylinder —: Not applicable 8. Adjust the valve clearance if out of specifi- cation. See “Valve clearance adjustment” (5-40).
  • Page 73 Fuel system Air filter case and fuel hose ..........4-1 Fuel hose disconnection............. 4-3 Fuel pressure measurement ............4-3 Fuel hose disassembly............... 4-4 Air filter element check ............... 4-4 Fuel hose assembly ..............4-4 ETV and fuel injector ............4-6 ETV check ..................
  • Page 74 Air filter case and fuel hose Air filter case and fuel hose 13 Nm (1.3 kgf · m, 9.6 ft · Ib) 17 Nm (1.7 kgf · m, 12.5 ft · Ib) 3.5 Nm (0.35 kgf · m, 2.58 ft · lb) ’...
  • Page 75 Air filter case and fuel hose 13 Nm (1.3 kgf · m, 9.6 ft · Ib) 17 Nm (1.7 kgf · m, 12.5 ft · Ib) 3.5 Nm (0.35 kgf · m, 2.58 ft · lb) ’ Part name Remarks ×...
  • Page 76: Air Filter Case And Fuel Hose

    Air filter case and fuel hose Fuel hose disconnection Before checking the fuel system, remove the battery, and then remove the fuel filler cap to reduce any pressure inside the fuel tank. 1. Spread apart the ends of the retainer “a”, and then pull the retainer up.
  • Page 77: Fuel Hose Disassembly

    Air filter case and fuel hose 4. Measure the fuel pressure. Replace the Fuel hose assembly fuel pump module if out of specification. Fuel pressure Do not reuse a clamp, always replace it with 345.0–355.0 kPa (3.45–3.55 kgf/cm², a new one. Otherwise, fuel could leak. 50.0–51.5 psi) 1.
  • Page 78 Air filter case and fuel hose Distance “b” 17 mm (0.67 in) Distance “c” 34.5 mm (1.36 in) Distance “d” 1 mm (0.04 in)
  • Page 79: Etv And Fuel Injector

    ETV and fuel injector ETV and fuel injector 13 Nm (1.3 kgf · m, 9.6 ft · Ib) 24 Nm (2.4 kgf · m, 17.7 ft · Ib) ’ Part name Remarks Plastic tie × Bolt 58 mm Gasket Not reusable ×...
  • Page 80: Etv Check

    ETV and fuel injector ETV check • Do not disassemble the ETV. • Do not loosen the throttle stop screw nut or turn the throttle stop screw. • Do not loosen or remove the throttle valve shaft screws. 2. While turning the fuel injectors “1” slowly to the left and right, install them to the fuel rail “2”.
  • Page 81 ETV and fuel injector Fuel rail bolt “3” 13 Nm (1.3 kgf·m, 9.6 ft·lb) 4. Route the wire harness, and then connect the cam position sensor coupler “a”, fuel injector couplers “b”, and ignition coil cou- plers “c”. 5. Fasten the wire harness using the plastic ties “1”.
  • Page 82: Fuel Tank And Fuel Pump Module

    Fuel tank and fuel pump module Fuel tank and fuel pump module 3.5 Nm (0.35 kgf · m, 2.58 ft · lb) 6 Nm (0.6 kgf · m, 4.4 ft · Ib) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 3.5 Nm (0.35 kgf ·...
  • Page 83 Fuel tank and fuel pump module 3.5 Nm (0.35 kgf · m, 2.58 ft · lb) 6 Nm (0.6 kgf · m, 4.4 ft · Ib) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 3.5 Nm (0.35 kgf · m, 2.58 ft · lb) ’...
  • Page 84: Fuel Tank Removal

    Fuel tank and fuel pump module Fuel tank removal Before checking the fuel system, remove the battery, and then remove the fuel filler cap to reduce any pressure inside the fuel tank. 1. Extract the fuel using a siphon pump “1”. TIP: 7.
  • Page 85: Fuel Pump Module Removal

    Fuel tank and fuel pump module Fuel pump module removal 1. Remove the fuel pump module “1”. When removing the fuel pump module, make sure that the rubber caps do not come off. TIP: Remove the fuel pump module “1” at an angle Fuel pump module check so that the float “a”...
  • Page 86: Fuel Filler Cap Check

    Fuel tank and fuel pump module 2. Install the stopper “1”, and then connect the fuel sender coupler “a”. TIP: Make sure that the hooks “b” on the stopper “1” are securely hooked onto the fuel pump mod- ule. A. Upright B.
  • Page 87: Fuel Tank Installation

    Fuel tank and fuel pump module Fuel tank installation 1. Install the fuel tank “1”, and then fasten the fuel tank using the straps “2”. TIP: • Install the straps “2” so that the rubber band portions “a” of the straps are positioned on top.
  • Page 88 Fuel tank and fuel pump module Fuel filler neck nut “4” 6 Nm (0.6 kgf·m, 4.4 ft·lb) 4. Install the fuel filler hose “1”, and then tight- en the clamps “2” to the specified torque. 5. Check that the distance “a” is within speci- fication.
  • Page 89 Power unit Engine unit (check and adjustment)......... 5-1 Compression pressure check............. 5-1 Engine unit................5-2 Exhaust manifold ............... 5-3 Engine unit and coupling cover........5-5 Engine mount ..............5-6 Engine unit removal..............5-7 Engine mount and spacer check ..........5-10 Engine unit installation .............
  • Page 90: Power Unit

    Power unit Cylinder head cover ............5-31 Camshaft ................5-32 Camshaft removal ..............5-34 Camshaft sprocket removal............5-35 Camshaft check................ 5-35 Camshaft journal oil clearance check........5-36 Timing chain tensioner check........... 5-37 Camshaft sprocket installation ..........5-37 Camshaft installation ..............5-38 Valve clearance adjustment .............
  • Page 91 Power unit Cylinder block and electrical part........5-67 Oil separator tank and oil pan......... 5-69 Anode check................5-71 Oil pan assembly..............5-71 Oil separator tank cover installation ......... 5-71 Crankcase, connecting rod, and piston ......5-73 Crankcase disassembly ............5-75 Connecting rod and piston removal..........
  • Page 92: Engine Unit (Check And Adjustment)

    Engine unit (check and adjustment) Engine unit (check and 8. Measure the compression pressure for all cylinders according to steps 6 and 7. adjustment) Compression pressure check TIP: Make sure that the battery voltage is more than Measuring conditions: Ambient temperature 12 V.
  • Page 93: Engine Unit

    Engine unit Engine unit 5 Nm (0.5 kgf · m, 3.7 ft · Ib) ’ Part name Remarks × Screw 12 mm Grommet Engine cover Clamp Antenna holder Plastic tie Clamp Clamp Plastic tie RiDE motor coupler...
  • Page 94: Exhaust Manifold

    Exhaust manifold Exhaust manifold 26 Nm (2.6 kgf · m, 19.2 ft · Ib) 13 Nm (1.3 kgf · m, 9.6 ft · Ib) 23 Nm (2.3 kgf · m, 17.0 ft · lb) 42 Nm (4.2 kgf·m, 31.0 ft·lb) 13 Nm (1.3 kgf ·...
  • Page 95 Exhaust manifold 26 Nm (2.6 kgf · m, 19.2 ft · Ib) 13 Nm (1.3 kgf · m, 9.6 ft · Ib) 23 Nm (2.3 kgf · m, 17.0 ft · lb) 42 Nm (4.2 kgf·m, 31.0 ft·lb) 13 Nm (1.3 kgf · m, 9.6 ft · Ib) 2.5 Nm (0.25 kgf ·...
  • Page 96: Engine Unit And Coupling Cover

    Engine unit and coupling cover Engine unit and coupling cover 17 Nm (1.7 kgf · m, 12.5 ft · Ib) 17 Nm (1.7 kgf · m, 12.5 ft · Ib) ’ Part name Remarks × Bolt 28 mm × Bolt 25 mm Collar Coupling cover...
  • Page 97: Engine Mount

    Engine mount Engine mount 5.5 Nm (0.55 kgf · m, 4.06 ft · lb) 17 Nm (1.7 kgf · m, 12.5 ft · Ib) ’ Part name Remarks × Bolt 35 mm Engine mount Liner × Bolt 21 mm Spacer ×...
  • Page 98: Engine Unit Removal

    Engine mount Engine unit removal 7. Remove the plastic tie “2”, and then dis- connect the quick connector “3” from the fuel rail. See “Fuel hose disconnection” Before removing the engine, make sure to (4-3). take adequate measures to protect the deck opening from damage.
  • Page 99 Engine mount 18. Remove the plastic tie “2”, and then dis- connect the RiDE motor couplers “a” and “b”. 14. Disconnect the fuel pump module coupler “a”. 19. Place a rag under the oil filter “1”, and then remove the oil filter “1”. TIP: Make sure to clean up any oil spills.
  • Page 100 Engine mount 27. Remove the electrical box “1”. 23. Disconnect the cooling water hoses “1” and “2”. 28. Remove the coupling cover “1”. 24. Remove the stay “3”. 29. Loosen the engine mounting bolts “1”. 25. Loosen the clamp “1”. 30.
  • Page 101: Engine Mount And Spacer Check

    Engine mount 32. Suspend the engine unit using all 3 engine TIP: hangers, and then separate the unit from • Write down the position of each engine the engine mounts and move it forward to mount so that it can be installed in its original disconnect the coupling.
  • Page 102 Engine mount TIP: Do not install the rubber coupling until the cou- pling clearance adjustment has been made. Clearance “a” Less than 1 mm (0.039 in) (without rubber coupling) Clearance “b” 2–4 mm (0.079–0.157 in) Available shim thicknesses 0.10, 0.30, 0.50, 1.00, 2.00 mm 9.
  • Page 103 Engine mount Clearance “a” Electrical box bolt “2” Less than 0.5 mm (0.020 in) 17 Nm (1.7 kgf·m, 12.5 ft·lb) (with rubber coupling) 17. Install the muffler “1” into the water lock, Clearance “b” and then tighten the exhaust manifold 2–4 mm (0.079–0.157 in) bolts “2”...
  • Page 104 Engine mount Clamp “1” 2.5 Nm (0.25 kgf·m, 1.84 ft·lb) 19. Install the stay “1”, and then tighten the stay bolts “2” and “3” to the specified torques in 2 stages. 20. Connect the cooling water hoses “4” and “5”, and then fasten them using the clamps “6”...
  • Page 105 Engine mount 33. Connect the remote control receiver cou- pler “a”, and then fasten the wire harness using the plastic tie “1”. 34. Install the antenna holders “2”. 29. Fasten the wire harness using the plastic ties “1”. 35. Install the air filter case “1”, and then tight- en the air filter case bolts “2”...
  • Page 106 Engine mount 40. Install the engine cover “1”, and then tight- 43. Fill the engine with engine oil. See “Engine en the engine cover screws “2” to the oil replacement” (3-4). specified torque. 44. Connect the positive battery lead, and then connect the negative battery lead.
  • Page 107: Muffler

    Muffler Muffler 20 Nm (2.0 kgf·m, 14.8 ft·lb) 15 Nm (1.5 kgf·m, 11.1 ft·lb) 29 Nm (2.9 kgf·m, 21.4 ft·lb) 2.5 Nm (0.25 kgf·m, 2.58 ft·lb) 200 Nm (20.0 kgf·m, 147.5 ft·lb) 20 Nm (2.0 kgf·m, 14.8 ft·lb) 20 Nm (2.0 kgf·m, 14.8 ft·lb) 20 Nm (2.0 kgf·m, 14.8 ft·lb) 20 Nm (2.0 kgf·m, 14.8 ft·lb) 35 Nm (3.5 kgf·m, 25.8 ft·lb)
  • Page 108: Exhaust Pipe Disassembly

    Muffler Exhaust pipe disassembly heat-resistant gloves. Otherwise, burns could result. 15° 15° 1. Remove the exhaust pipe “1”. TIP: Heat the area “a” of exhaust pipe “1” to approx- imately 200 °C (392 °F) using a heat gun. 15° 15° Exhaust pipe wrench “2”...
  • Page 109: Wire Harness

    Wire harness Wire harness 7 Nm (0.7 kgf·m, 5.2 ft·lb) ’ Part name Remarks Spring washer × Bolt 30 mm Negative battery lead Starter motor × Bolt 35 mm Thermostat housing Thermostat a: Hole Holder Grommet Plastic tie Plastic tie Plastic tie Wire harness 5-18...
  • Page 110: Electrical Box

    Electrical box Electrical box 5 Nm (0.5 kgf·m, 3.7 ft·lb) 5 Nm (0.5 kgf·m, 3.7 ft·lb) 5 Nm (0.5 kgf·m, 3.7 ft·lb) 4 Nm (0.4 kgf·m, 3.0 ft·lb) 5 Nm (0.5 kgf·m, 3.7 ft·lb) 5 Nm (0.5 kgf·m, 3.7 ft·lb) ’...
  • Page 111 Electrical box 5 Nm (0.5 kgf·m, 3.7 ft·lb) 5 Nm (0.5 kgf·m, 3.7 ft·lb) 5 Nm (0.5 kgf·m, 3.7 ft·lb) 4 Nm (0.4 kgf·m, 3.0 ft·lb) 5 Nm (0.5 kgf·m, 3.7 ft·lb) 5 Nm (0.5 kgf·m, 3.7 ft·lb) ’ Part name Remarks Holder ×...
  • Page 112: Starter Motor And Wire Harness Removal

    Electrical box Starter motor and wire harness removal 1. Disconnect the starter motor lead “1” and negative battery lead “2”, and then remove the starter motor “3”. 6. Remove the plastic ties “1”, and then dis- connect the thermo switch coupler “a”, en- gine temperature sensor coupler “b”, intake air pressure sensor coupler “c”, in- take air temperature sensor coupler “d”,...
  • Page 113: Wire Harness And Starter Motor Installation

    Electrical box sor coupler “e”, and thermo switch coupler “f”, and then fasten the wire harness using the plastic ties “1”. TIP: Fasten the wire harness at the gray tape “g” us- ing the plastic tie. 3. Measure the thermostat valve opening “a” at the specified water temperatures.
  • Page 114 Electrical box 6. Install the starter motor “1”, and then con- nect the negative battery lead “2” and starter motor lead “3”. 7. Tighten the starter motor lead nut “4” to the specified torque. Starter motor lead nut “4” 7 Nm (0.7 kgf·m, 5.2 ft·lb) 5-23...
  • Page 115: Intake Manifold

    Intake manifold Intake manifold 15 Nm (1.5 kgf · m, 11.1 ft · Ib) 16 Nm (1.6 kgf·m, 11.8 ft·Ib) 31 Nm (3.1 kgf·m, 22.9 ft·Ib) 10 Nm (1.0 kgf·m, 7.4 ft·lb) 20 Nm (2.0 kgf·m, 14.8 ft·lb) 1322D 1322D 16 Nm (1.6 kgf·m, 11.8 ft·Ib) 31 Nm (3.1 kgf·m, 22.9 ft·Ib) 19 Nm (1.9 kgf ·...
  • Page 116 Intake manifold 15 Nm (1.5 kgf · m, 11.1 ft · Ib) 16 Nm (1.6 kgf·m, 11.8 ft·Ib) 31 Nm (3.1 kgf·m, 22.9 ft·Ib) 10 Nm (1.0 kgf·m, 7.4 ft·lb) 20 Nm (2.0 kgf·m, 14.8 ft·lb) 1322D 1322D 16 Nm (1.6 kgf·m, 11.8 ft·Ib) 31 Nm (3.1 kgf·m, 22.9 ft·Ib) 19 Nm (1.9 kgf ·...
  • Page 117: Oil Level Pipe Installation

    Intake manifold Oil level pipe installation 6. Fasten the grommet “1” using the clamp “2”. 1. Pass the clamp “1” through the oil level pipe “2”. 2. Install the oil level pipe plate “3”, the grom- met “4”, and a new O-ring “5” onto the oil level pipe “2”.
  • Page 118: Oil Cooler, Oil Pump, And Drive Gear

    Oil cooler, oil pump, and drive gear Oil cooler, oil pump, and drive gear 11 Nm (1.1 kgf · m, 8.1 ft · Ib) 80 Nm (8.0 kgf · m, 59.0 ft · Ib) 18 Nm (1.8 kgf · m, 13.3 ft · Ib) 19 Nm (1.9 kgf ·...
  • Page 119 Oil cooler, oil pump, and drive gear 11 Nm (1.1 kgf · m, 8.1 ft · Ib) 80 Nm (8.0 kgf · m, 59.0 ft · Ib) 18 Nm (1.8 kgf · m, 13.3 ft · Ib) 19 Nm (1.9 kgf · m, 14.0 ft · Ib) 12 Nm (1.2 kgf ·...
  • Page 120: Oil Pump And Oil Pump Drive Gear Removal

    Oil cooler, oil pump, and drive gear Oil pump and oil pump drive gear removal 1. Remove the oil pump. 2. Hold the drive coupling “1” using the spe- cial service tool “2”. Leakage tester “2” 90890-06840 Water passage holding pressure 200 kPa (2.0 kgf/cm², 29.0 psi) Oil pump check Coupler wrench “2”...
  • Page 121 Oil cooler, oil pump, and drive gear 3. Turn the bolt “1” counterclockwise, and Oil pump bolt “4” then tighten it to the specified torque. 11 Nm (1.1 kgf·m, 8.1 ft·lb) Oil pump drive gear bolt “1” 80 Nm (8.0 kgf·m, 59.0 ft·lb) 4.
  • Page 122: Cylinder Head Cover

    Cylinder head cover Cylinder head cover 10 Nm (1.0 kgf · m, 7.4 ft · Ib) 13 14 6 Nm (0.6 kgf · m, 4.4 ft · Ib) 1530D 25 Nm (2.5 kgf · m, 18.4 ft · Ib) 1280B ’...
  • Page 123: Camshaft

    Camshaft Camshaft 16 Nm (1.6 kgf · m, 11.8 ft · Ib) 21 Nm (2.1 kgf · m, 15.5 ft · Ib) 20 Nm (2.0 kgf · m, 14.8 ft · Ib) 10 Nm (1.0 kgf·m, 7.4 ft·lb) ’ Part name Remarks ×...
  • Page 124 Camshaft 16 Nm (1.6 kgf · m, 11.8 ft · Ib) 21 Nm (2.1 kgf · m, 15.5 ft · Ib) 20 Nm (2.0 kgf · m, 14.8 ft · Ib) 10 Nm (1.0 kgf·m, 7.4 ft·lb) ’ Part name Remarks Camshaft sprocket ×...
  • Page 125: Camshaft Removal

    Camshaft Camshaft removal When installing the camshafts, piston #1 must be positioned at TDC. Therefore, do not turn the crankshaft after removing the camshafts. 1. Install the special service tools into spark plug hole #1. Dial gauge set “1” 90890-01252 Dial indicator gauge “1”...
  • Page 126: Camshaft Sprocket Removal

    Camshaft Camshaft wrench “1” 90890-06724 Camshaft wrench “1” YW-06724 2. Remove the intake camshaft sprocket and exhaust camshaft sprocket. Camshaft check 1. Check the camshaft lobes. Replace if pit- 5. Remove the timing chain guide (exhaust ted or scratched. side). 2.
  • Page 127: Camshaft Journal Oil Clearance Check

    Camshaft Runout 4. Install the dowel pins “1”, intake camshaft 0.015 mm (0.0006 in) caps “2” and “3”, and exhaust camshaft caps “4” and “5”. Limit 0.05 mm (0.0020 in) TIP: When installing the camshaft caps, make sure Camshaft journal oil clearance check that the arrow marks “a”...
  • Page 128: Timing Chain Tensioner Check

    Camshaft Timing chain tensioner check 1. While pushing the timing chain tensioner rod “a”, turn the timing chain tensioner [11] housing “b” in direction “c” until the groove [10] [12] “d” in the tensioner rod is aligned with the snap ring “e”. [11] [12] [10]...
  • Page 129: Camshaft Installation

    Camshaft • When installing an original camshaft sprock- et, make sure to align the marks “b” made during removal. 3. Install the timing chain guide (exhaust side). 4. Install the exhaust camshaft “1”, intake 2. Hold the camshaft sprocket using the spe- camshaft “2”, and timing chain “3”.
  • Page 130 Camshaft [11] [10] [12] [11] [12] [10] 7. Tighten the camshaft cap bolts “1” to the 5. Install the dowel pins “1”, intake camshaft specified torque in the order [1], [2], and so caps “2” and “3”, and exhaust camshaft caps “4”...
  • Page 131: Valve Clearance Adjustment

    Camshaft 10. While squeezing the ends of the snap ring Timing chain tensioner bolt “3” “e” so that it fits into the groove “d” in the 10 Nm (1.0 kgf·m, 7.4 ft·lb) timing chain tensioner rod “a”, release the Oil pipe bolt “6” tensioner rod slowly until it is locked in 20 Nm (2.0 kgf·m, 14.8 ft·lb) place.
  • Page 132 Camshaft 3. Remove the valve lifters “1” and valve 7. Install the selected valve pad “1” and valve pads “2”. lifter “2”. TIP: Write down the position of each valve lifter “1” and valve pad “2” so that they can be installed in their original positions.
  • Page 133 Camshaft Dial gauge set “1” 90890-01252 Dial indicator gauge “1” YU-03097 Dial gauge needle “2” 90890-06584 Dial gauge stand set “2” YB-06585 Gauge stand “3” 90890-06725 12. Position piston #4 at TDC by turning the drive coupling “1” 360° counterclockwise using the special service tool “2”.
  • Page 134: Valve Pad Selection Table

    Camshaft Valve pad selection table Intake Measured Original valve pad number clearance 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.00– 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 0.03–0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 0.07–0.10...
  • Page 135 Camshaft Exhaust Measured Original valve pad number clearance 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.00– 135 140 145 150 155 160 165 170 175 180 185 190 195 0.02–...
  • Page 136: Cylinder Head

    Cylinder head Cylinder head 55 Nm (5.5 kgf·m, 40.6 ft·lb) 90˚ 42 Nm (4.2 kgf · m, 31.0 ft · Ib) 10 Nm (1.0 kgf · m, 7.4 ft · Ib) 12 Nm (1.2 kgf · m, 8.9 ft · Ib) ’...
  • Page 137: Valve And Valve Spring

    Valve and valve spring Valve and valve spring ’ Part name Remarks Valve lifter Valve pad Valve cotter Upper spring seat Valve spring Lower spring seat Intake valve Exhaust valve Valve seal Not reusable Valve guide Not reusable Cylinder head 5-46...
  • Page 138: Cylinder Head Disassembly

    Valve and valve spring Cylinder head disassembly Valve spring compressor “1” 1. Remove the valve lifters “1” and valve 90890-04019 pads “2”. Valve spring compressor “1” YM-04019 TIP: Valve spring compressor attachment “2” Write down the position of each valve lifter “1” 90890-04114 and valve pad “2”...
  • Page 139: Valve Check

    Valve and valve spring Face width-intake 2.260–2.830 mm (0.0890–0.1114 in) Face width-exhaust 2.260–2.830 mm (0.0890–0.1114 in) 2. Measure the valve margin thickness “a”. Free length-intake 45.58 mm (1.79 in) Free length-exhaust 45.58 mm (1.79 in) Limit 43.30 mm (1.70 in) Margin thickness-intake 2.
  • Page 140: Valve Guide Check

    Valve and valve spring Valve guide removal 1. Insert the special service tool “1” into the combustion chamber side of the valve guide “2”. 2. Strike the special service tool “1” to drive the valve guide “2” out of the cylinder head.
  • Page 141: Valve Seat Check

    Valve and valve spring Valve guide remover/installer “1” Inside diameter-intake 90890-06801 5.504–5.522 mm (0.2167–0.2174 in) Valve guide remover “1” Inside diameter-exhaust YB-06801 5.504–5.522 mm (0.2167–0.2174 in) Valve guide installer “2” Valve seat check 90890-06810 1. Remove carbon deposits from the valves Valve guide installer “2”...
  • Page 142: Valve Seat Refacing

    Valve and valve spring Valve seat cutter holder 90890-06812 Intake: Valve seat cutter 30° 90890-06720 Valve seat cutter 45° 90890-06325 Valve seat cutter 60° 90890-06324 Exhaust: Valve seat cutter 30° 90890-06818 Valve seat cutter 45° 90890-06555 Seat contact width-intake Valve seat cutter 60° 1.400–1.600 mm (0.0551–0.0630 in) 90890-06323 Limit...
  • Page 143 Valve and valve spring a. Previous contact width a. Slag or rough surface b. Specified contact width 3. Adjust the top edge of the valve seat con- 6. Check the valve seat contact area of the tact width using a 30° cutter. valve “Valve seat check”...
  • Page 144: Cylinder Head Assembly

    Valve and valve spring • If the valve seat contact area is too narrow 2. Install the valve “1”, valve spring seat “2”, and situated near the bottom edge of the valve spring “3”, and valve spring retainer valve face, cut the bottom edge of the valve “4”...
  • Page 145: Cylinder Head Installation

    Valve and valve spring 3. Compress the valve spring, and then in- Cylinder head installation stall the valve cotters “1”. 1. Install the dowel pins “1”, a new gasket “2”, the cylinder head ASSY “3”, the washers “4”, and the cylinder head bolts “5”, and then tighten the cylinder head bolts “5”...
  • Page 146: Generator Cover Assy And Flywheel Magneto

    Generator cover ASSY and flywheel magneto Generator cover ASSY and flywheel magneto 26 Nm (2.6 kgf·m, 19.2 ft·lb) 250 Nm (25.0 kgf·m, 184.4 ft·lb) 80 Nm (8.0 kgf·m, 59.0 ft·lb) 24 Nm (2.4 kgf·m, 17.7 ft·lb) 250 Nm (25.0 kgf·m, 184.4 ft·lb) 50 Nm (5.0 kgf·m, 36.9 ft·lb) 250 Nm (25.0 kgf·m, 184.4 ft·lb) ’...
  • Page 147 Generator cover ASSY and flywheel magneto 26 Nm (2.6 kgf·m, 19.2 ft·lb) 250 Nm (25.0 kgf·m, 184.4 ft·lb) 80 Nm (8.0 kgf·m, 59.0 ft·lb) 24 Nm (2.4 kgf·m, 17.7 ft·lb) 250 Nm (25.0 kgf·m, 184.4 ft·lb) 50 Nm (5.0 kgf·m, 36.9 ft·lb) 250 Nm (25.0 kgf·m, 184.4 ft·lb) ’...
  • Page 148: Generator Cover

    Generator cover Generator cover 15 Nm (1.5 kgf·m, 11.1 ft·lb) 15 Nm (1.5 kgf·m, 11.1 ft·lb) ’ Part name Remarks × Bolt 15 mm Holder × Bolt 15 mm × Bolt 10 mm Washer × Bolt 30 mm Stator coil Oil seal Not reusable Circlip...
  • Page 149: Drive Coupling Removal

    Generator cover Drive coupling removal 3. Hold the transfer shaft “1” using the special service tool “2”, and then remove the drive coupling “3” using the special service tool heat-resistant gloves. Otherwise, “4”. burns could result. 1. Heat the holder “1” and drive coupling “2” for 20–30 minutes using a heat gun “3”.
  • Page 150 Generator cover 3. Hold the flywheel magneto “1” using the special service tools “2” and “3”, and then loosen the special nut “4”. TIP: • Loosen the special nut “4” until it can no lon- ger be turned. • Use a hexagon bit socket “5” with a length of 150 mm (5.91 in) or more and a width across flats of 12 mm.
  • Page 151: Generator Cover Assy Disassembly

    Generator cover Flywheel puller “2” 90890-06723 Flywheel puller “2” YW-06723 Rotor puller “3” 90890-01080 Stator rotor puller “3” YM-01080-A 6. Hold the flywheel magneto “1” using the 3. Remove the ball bearing “1”. special service tool “2”, and then loosen the starter clutch bolts “3”.
  • Page 152: Generator Cover Assy Assembly

    Generator cover 3. Turn the starter gear “2” counterclockwise “b” and check that it does not turn. Replace if it turns. 3. Install a new oil seal “1”. Generator cover ASSY assembly 1. Install a new ball bearing “1”. A. Worldwide B.
  • Page 153: Flywheel Magneto Assembly

    Generator cover TIP: Pass the pickup coil lead “a” between the gen- erator cover and the bolt hole “b”, and then se- cure the lead by installing the washer “4”. Sheave holder “2” 90890-01701 Primary sheave holder “2” YS-01880-A Flywheel magneto bolt “3” 24 Nm (2.4 kgf·m, 17.7 ft·lb) 3.
  • Page 154 Generator cover 2. Clean the tapered portion “a” of the crank- shaft and inner surface “b” of the flywheel magneto “1”. 3. Install a new Woodruff key “2” and the fly- wheel magneto “1”. Shaft holder “2” 90890-06721 Shaft holder “2” YW-06721 Drive handle “3”...
  • Page 155 Generator cover Shaft holder “2” 90890-06721 0° Shaft holder “2” 60° YW-06721 Drive handle “3” 90890-06722 120° 60° Drive handle “3” YW-06722 Crankshaft holder “5” 90890-06732 Crankshaft holder “1” Crankshaft holder “5” 90890-06732 YW-06562 Crankshaft holder “1” YW-06562 Transfer shaft “4” Shaft holder “2”...
  • Page 156: Drive Coupling Installation

    Generator cover Crankshaft holder “2” Shaft holder “2” 90890-06732 90890-06721 Crankshaft holder “2” Shaft holder “2” YW-06562 YW-06721 Shaft holder “3” Drive handle “3” 90890-06721 90890-06722 Shaft holder “3” Drive handle “3” YW-06721 YW-06722 Drive handle “4” Special nut “4” 90890-06722 250 Nm (25.0 kgf·m, 184.4 ft·lb) Drive handle “4”...
  • Page 157 Generator cover 2. Hold the transfer shaft using the special 5. Hold the drive coupling “1” using the spe- service tool “1”, and then tighten the drive cial service tool “2”, and then turn the hold- coupling “2” to the specified torque using er “3”...
  • Page 158: Cylinder Block And Electrical Part

    Cylinder block and electrical part Cylinder block and electrical part 19 Nm (1.9 kgf · m, 14.0 ft · Ib) 11 Nm (1.1 kgf · m, 8.1 ft · Ib) 1322D 20 Nm (2.0 kgf · m, 14.8 ft · Ib) 15 Nm (1.5 kgf ·...
  • Page 159 Cylinder block and electrical part 19 Nm (1.9 kgf · m, 14.0 ft · Ib) 11 Nm (1.1 kgf · m, 8.1 ft · Ib) 1322D 20 Nm (2.0 kgf · m, 14.8 ft · Ib) 15 Nm (1.5 kgf · m, 11.1 ft · Ib) ’...
  • Page 160: Oil Separator Tank And Oil Pan

    Oil separator tank and oil pan Oil separator tank and oil pan 10 Nm (1.0 kgf · m, 7.4 ft · Ib) 9 Nm (0.9 kgf · m, 6.6 ft · Ib) 2 Nm (0.2 kgf · m, 1.5 ft · Ib) 12 Nm (1.2 kgf ·...
  • Page 161 Oil separator tank and oil pan 10 Nm (1.0 kgf · m, 7.4 ft · Ib) 9 Nm (0.9 kgf · m, 6.6 ft · Ib) 2 Nm (0.2 kgf · m, 1.5 ft · Ib) 12 Nm (1.2 kgf · m, 8.9 ft · Ib) 20 Nm (2.0 kgf ·...
  • Page 162: Anode Check

    Oil separator tank and oil pan Anode check Oil pipe bolt “1” 1. Check the anode. Replace if eroded. 1st: 0.3 Nm (0.03 kgf·m, 0.2 ft·lb) Clean if there is grease, oil, or scales. 2nd: 12 Nm (1.2 kgf·m, 8.9 ft·lb) Oil pipe stay bolt “2”...
  • Page 163 Oil separator tank and oil pan [10] [11] 5-72...
  • Page 164: Crankcase, Connecting Rod, And Piston

    Crankcase, connecting rod, and piston Crankcase, connecting rod, and piston 50 Nm (5.0 kgf · m, 36.9 ft · Ib) 51 Nm (5.1 kgf·m, 37.6 ft·lb) 90˚ 10 Nm (1.0 kgf · m, 7.4 ft · Ib) 30 Nm (3.0 kgf·m, 22.1 ft·lb) 10 Nm (1.0 kgf ·...
  • Page 165 Crankcase, connecting rod, and piston 50 Nm (5.0 kgf · m, 36.9 ft · Ib) 51 Nm (5.1 kgf·m, 37.6 ft·lb) 90˚ 10 Nm (1.0 kgf · m, 7.4 ft · Ib) 30 Nm (3.0 kgf·m, 22.1 ft·lb) 10 Nm (1.0 kgf · m, 7.4 ft · Ib) 90˚...
  • Page 166: Crankcase Disassembly

    Crankcase, connecting rod, and piston Crankcase disassembly TIP: 1. Place the crankcase upside down on a For reference during installation, make identifi- bench. cation marks “a” on the connecting rod cap, connecting rod, connecting rod bearings, and 2. Remove the crankcase “1”. piston crown.
  • Page 167: Cylinder Block Check

    Crankcase, connecting rod, and piston Cylinder block check TIP: 1. Measure the cylinder bore (D1–D6) at When measuring the piston pin boss inside di- measuring points “a”, “b”, and “c”, and in ameter “a”, do not measure it at the oil grooves direction “d”...
  • Page 168 Crankcase, connecting rod, and piston Top ring End gap (installed) 0.300–0.450 mm (0.0118–0.0177 in) Limit 0.700 mm (0.0276 in) 2nd ring End gap (installed) 0.450–0.600 mm (0.0177–0.0236 in) Limit 0.850 mm (0.0335 in) a. Top ring Oil ring b. 2nd ring End gap (installed) c.
  • Page 169: Piston Pin Check

    Crankcase, connecting rod, and piston a. Top ring side clearance b. 2nd ring side clearance c. Oil ring side clearance Top ring Side clearance 0.020–0.060 mm (0.0008–0.0024 in) Limit 0.110 mm (0.0043 in) Outside diameter 2nd ring 21.991–22.000 mm (0.8658–0.8661 in) Side clearance Limit 0.020–0.060 mm (0.0008–0.0024 in)
  • Page 170: Crankshaft Pin Oil Clearance Check

    Crankcase, connecting rod, and piston TIP: • Install the connecting rod bearings “1” in their original positions. • Fit the protrusion “a” on each bearing into the slots “b” in the connecting rod cap “3” and connecting rod “2”. 3. Put a piece of Plastigauge “1” on the crankshaft pin, parallel to the crankshaft.
  • Page 171: Connecting Rod Big End Side Clearance Check

    Crankcase, connecting rod, and piston 6. Before installing the connecting rod onto • Do not turn the connecting rod or crankshaft the crankshaft, assemble the connecting until the crankshaft pin oil clearance mea- rod, which the connecting rod bearings surement has been completed. were installed in step 2, to the crankshaft kept in the current condition.
  • Page 172: Connecting Rod Bearing Selection

    Crankcase, connecting rod, and piston 2. Check the crankshaft pin size number “a” on the crankshaft web. P1 P2 P3 P4 3. Select the suitable color “a” for the con- necting rod bearing from the table. Calculation formula: Connecting rod bearing size number = con- necting rod size number - crankshaft pin size number Big end side clearance...
  • Page 173 Crankcase, connecting rod, and piston 2. Place the cylinder block upside down on a • Do not turn the crankshaft until the journal oil bench. clearance measurement has been complet- 3. Install the crankshaft bearings “1” into the cylinder block and crankcase. TIP: •...
  • Page 174: Crankshaft Bearing Selection

    Crankcase, connecting rod, and piston [11] 55545 [12] [10] [6] [8] If “J1”–“J5” are the same: Crankcase bolt “1” 10 Nm (1.0 kgf·m, 7.4 ft·lb) 8. Remove the crankcase and measure the width “a” of the compressed Plastigauge on each crankshaft journal. Replace the crankshaft bearings if out of specification.
  • Page 175: Connecting Rod And Piston Installation

    Crankcase, connecting rod, and piston Calculation formula: Crankshaft bearing size number = crank- case journal size number - crankshaft jour- nal size number Bearing size number Bearing color Brown Black 2. Install the oil ring “1”, 2nd ring “2”, and top Blue ring “3”.
  • Page 176 Crankcase, connecting rod, and piston 5. Install the upper bearing into the connect- ing rod “2” and lower bearing into the con- necting rod cap “3”. TIP: • Install the connecting rod bearings “1” in their original positions. • Fit the protrusion “a” on each bearing into the slots “b”...
  • Page 177: Crankcase Assembly

    Crankcase, connecting rod, and piston Piston ring compressor “1” TIP: 90890-05158 After installation, check that section “a” is flush Piston ring compressor “1” by running your finger across the surface. YM-08037 12. Install half of the crankshaft bearings “1” 17. Tighten the connecting rod bolts “2” to the into the cylinder block.
  • Page 178 Crankcase, connecting rod, and piston 3. Install the dowel pin “1” and a new O-ring “2”. 4. Apply sealant to the mating surface of the crankcase. [10] Crankcase bolt “2” 1st: 30 Nm (3.0 kgf·m, 22.1 ft·lb) 2nd: 90° 6. Install the crankcase bolts “1”, and then tighten them to the specified torque in the order [1], [2], and so on.
  • Page 179 Crankcase, connecting rod, and piston [11] [12] [10] [6] [8] Crankcase bolt “1” 10 Nm (1.0 kgf·m, 7.4 ft·lb) 5-88...
  • Page 180 Crankcase, connecting rod, and piston — MEMO — 5-89...
  • Page 181 Jet pump unit Intake grate and ride plate..........6-1 Jet pump unit..............6-2 Jet pump unit removal ..............6-3 Impeller check ................6-3 Jet pump unit installation............6-3 Trim rod adjustment ..............6-4 Jet thrust nozzle angle adjustment..........6-5 Reverse gate ............... 6-7 Nozzle and nozzle ring............
  • Page 182: Intake Grate And Ride Plate

    Intake grate and ride plate Intake grate and ride plate 17 Nm (1.7 kgf · m, 12.5 ft · Ib) 4 Nm (0.4 kgf · m, 3.0 ft · Ib) 17 Nm (1.7 kgf · m, 12.5 ft · Ib) ’...
  • Page 183: Jet Pump Unit

    Jet pump unit Jet pump unit 15 Nm (1.5 kgf · m, 11.1 ft · Ib) 2.5 Nm (0.25 kgf · m, 1.84 ft · lb) 17 Nm (1.7 kgf · m, 12.5 ft · Ib) 1207B 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 40 Nm (4.0 kgf ·...
  • Page 184: Jet Pump Unit Removal

    Jet pump unit Jet pump unit removal TIP: The illustration shows the case where the disk brake piston tool “3” is used to remove the jet Make sure to remove the battery before re- pump unit “1”. moving the jet pump unit. 1.
  • Page 185: Trim Rod Adjustment

    Jet pump unit 1207B 3. Install the jet pump unit, and then tighten the bolts “1” and “2” to the specified torques. 4. Tighten the jet pump unit bolt “3”. Spout hose clamp “2” 2.5 Nm (0.25 kgf·m, 1.84 ft·lb) Steering cable joint nut “7”...
  • Page 186: Jet Thrust Nozzle Angle Adjustment

    Jet pump unit Turn out Distance “a” is increased. Turn in Distance “b” is increased. Distance “c” 8.0 mm (0.31 in) or more 6. Connect the trim rod joints, and then tight- en the locknut to the specified torque. Locknut 4 Nm (0.4 kgf·m, 3.0 ft·lb) 5.
  • Page 187 Jet pump unit Turn in Distance “a” is increased. Turn out Distance “b” is increased. Distance “c” 8.0 mm (0.31 in) or more 5. Connect the steering cable joint to the ball joint, and then tighten the locknut to the specified torque.
  • Page 188: Reverse Gate

    Reverse gate Reverse gate 20 Nm (2.0 kgf · m, 14.8 ft · Ib) ’ Part name Remarks Spring × Bolt 25 mm Collar Reverse gate Washer Ball joint × Bolt 35 mm Collar × Bolt 25 mm Reverse gate stay...
  • Page 189: Nozzle And Nozzle Ring

    Nozzle and nozzle ring Nozzle and nozzle ring 16 Nm (1.6 kgf·m, 11.8 ft·lb) 16 Nm (1.6 kgf·m, 11.8 ft·lb) ’ Part name Remarks × Bolt 25 mm Collar Jet thrust nozzle Nozzle ring Washer Ball joint...
  • Page 190: Impeller Housing And Impeller Duct Assy

    Impeller housing and impeller duct ASSY Impeller housing and impeller duct ASSY 40 Nm (4.0 kgf·m, 29.5 ft·lb) 1 Nm (0.1 kgf·m, 0.7 ft·lb) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) ’ Part name Remarks Clamp Spout hose a: Yellow paint mark ×...
  • Page 191: Impeller, Drive Shaft, And Impeller Duct

    Impeller, drive shaft, and impeller duct Impeller, drive shaft, and impeller duct 74 Nm (7.4 kgf · m, 54.6 ft · Ib) 330 Nm (33.0 kgf·m, 243.4 ft·lb) ’ Part name Remarks Impeller × Bolt 20 mm O-ring Not reusable Washer Spacer O-ring...
  • Page 192: Impeller Duct Assy Disassembly

    Impeller, drive shaft, and impeller duct Impeller duct ASSY disassembly 1. Remove the impeller “1”. 4. Remove the ball bearing “1”. Drive shaft holder 6 “2” 90890-06520 Driveshaft holder “2” YB-06201 2. Remove the cap “1”, O-ring “2”, and nut “3”.
  • Page 193: Impeller Housing Check

    Impeller, drive shaft, and impeller duct Driver rod L3 “3” 90890-06652 Driver handle (large) “3” YB-06071 Needle bearing attachment “4” 90890-06609 Driveshaft needle bearing installer and remover “4” YB-06194 Impeller housing check 1. Measure the impeller housing inside diam- eter “a”. Replace if out of specification. A.
  • Page 194 Impeller, drive shaft, and impeller duct 3. Install the drive shaft “1” (along with the ball bearing “2”) and spacer “3”. Bearing attachment “4” 90890-06728 Bearing attachment “4” YW-06728 4. Apply EPNOC grease AP #0 to the space between the drive shaft “1” and the spacer “2”.
  • Page 195: Impeller Duct, Impeller Housing, And Nozzle Installation

    Impeller, drive shaft, and impeller duct 6. Install the washer “1”, and then tighten the drive shaft nut “2” to the specified torque. 7. Apply EPNOC grease AP #0 to the inside of the cap “3”, and then install a new O-ring “4”...
  • Page 196 Impeller, drive shaft, and impeller duct Impeller duct bolt “5” 40 Nm (4.0 kgf·m, 29.5 ft·lb) 6-15...
  • Page 197 Transom plate and hoses Transom plate and hoses 26 Nm (2.6 kgf · m, 19.2 ft · Ib) 6 Nm (0.6 kgf · m, 4.4 ft · Ib) 26 Nm (2.6 kgf · m, 19.2 ft · Ib) ’ Part name Remarks Clamp Cooling water hose...
  • Page 198 Transom plate and hoses 26 Nm (2.6 kgf · m, 19.2 ft · Ib) 6 Nm (0.6 kgf · m, 4.4 ft · Ib) 26 Nm (2.6 kgf · m, 19.2 ft · Ib) ’ Remarks Part name Bilge hose Plastic tie Clamp Cooling water hose...
  • Page 199: Transom Plate And Hoses

    Transom plate and hoses Bilge strainer check 1. Check the bilge strainer. See “Jet vacuum bilge draining system check” (3-10). Transom plate installation 1. Clean the mating surfaces of the transom plate “1”. 2. Apply silicone sealant to the mating sur- face of the transom plate “1”.
  • Page 200: Intermediate Housing

    Intermediate housing Intermediate housing 17 Nm (1.7 kgf·m, 12.5 ft·lb) 3 Nm (0.3 kgf·m, 2.2 ft·lb) 205 Nm (20.5 kgf·m, 151.2 ft·lb) ’ Part name Remarks Rubber coupling × Bolt 48 mm Shim As required Dowel pin Driven coupling Washer Intermediate drive shaft O-ring Not reusable...
  • Page 201: Intermediate Housing Removal

    Intermediate housing Intermediate housing removal 1. Remove the engine unit. See “Engine unit removal” (5-7). 2. Remove the intermediate housing “1”. TIP: If shims “2” are installed, remove the shims and write down the position of each removed shim so that it can be installed in its original position. 3.
  • Page 202: Intermediate Housing Assembly

    Intermediate housing 4. Remove the circlips “1”, and then remove the ball bearing “2” using a press. Needle bearing attachment “2” 90890-06654 Needle bearing attachment “3” Needle bearing installer “2” 90890-06654 YB-06434 Needle bearing installer “3” Distance “a” YB-06434 6.5 ± 0.2 mm (0.26 ± 0.01 in) Intermediate housing assembly 4.
  • Page 203: Intermediate Housing Installation

    Intermediate housing Distance “a” 3.7 ± 0.3 mm (0.17 ± 0.01 in) 8. Install the washer “1”, and then tighten the driven coupling “2” to the specified torque. Bearing attachment “3” 90890-06728 Bearing attachment “3” YW-06728 6. Install a new oil seal “1”. Shaft holder “3”...
  • Page 204 Intermediate housing Intermediate housing bolt “2” 17 Nm (1.7 kgf·m, 12.5 ft·lb) 6-23...
  • Page 205 Intermediate housing — MEMO — 6-24...
  • Page 206: Electrical System

    Electrical system Electrical components ............7-1 Engine ..................7-1 Deck and hull................7-2 Electrical box ................7-3 ECM circuit diagram ..............7-4 ECM coupler layout ..............7-7 Electrical analysis .............. 7-9 Electrical component check using the YDIS....... 7-9 Power supply to the ECM............7-9 Peak voltage measurement............
  • Page 207 Electrical system Fuel system ..............7-29 Fuel injector check ..............7-29 Fuel pump relay check ............. 7-29 Fuel pump module check ............7-30 Starting system ..............7-31 Fuse check ................7-31 Handlebar switch (left) check ........... 7-31 Main relay check ..............7-31 Starter relay check ..............
  • Page 208: Electrical Components

    Electrical components Electrical components Engine 1. Spark plug and ignition coil 2. Cam position sensor 3. Electrical box 4. Thermo sensor 5. Rectifier/regulator 6. Starter motor 7. Oil pressure switch 8. ETV (TPS) 9. Intake air pressure sensor 10. Fuel injector 11.
  • Page 209: Deck And Hull

    Electrical components Deck and hull 1. Remote control receiver 2. Steering sensor 3. APS (electric throttle without wire cable) 4. RPS (electric shift without wire cable) 5. Speed sensor 6. Buzzer 7. Fuel pump module and fuel sender 8. Multifunction meter 9.
  • Page 210: Electrical Box

    Electrical components Electrical box 9 15 10 11 15. Spare fuse 1. Fuse box 16. Fuel pump relay 2. Slant detection switch 17. ETV relay 3. ECM 4. Starter relay 5. Fuse (10 A) (ETV relay) 6. Fuse (10 A) (fuel pump relay) 7.
  • Page 211: Ecm Circuit Diagram

    Electrical components ECM circuit diagram Rectifier / Stator Fuel injector #1 regulator coil Fuse Fuel injector #2 (20 A) Fuse (10 A) Fuel injector #3 µ Main relay Fuel injector #4 ¥ Fuse (3 A) Ignition coil #1 7.Engine 9.Remote start switch control receiver º...
  • Page 212 Electrical components Oil pressure switch ß 37.Thermo switch Engine shut-off switch ç 46.ETV ¶ 39.APS motor APS 1 Ground APS 2 TPS 1 Ground 35.ECM TPS 2 APS full Ground close switch Ground 43.RPS 50.SCU 44.RPS 1 Ground 45.RPS 2 Ground...
  • Page 213 Electrical components 50. SCU 1. Rectifier/regulator 2. Stator coil a. Ground 3. Fuse (20 A) 4. Fuse (10 A) 5. Main relay 6. Fuse (3 A) 7. Engine start switch 8. Fuse (30 A) 9. Remote control receiver 10. Starter relay 11.
  • Page 214: Ecm Coupler Layout

    Electrical components ECM coupler layout 1 2 3 4 5 6 7 27 28 29 30 31 32 33 54 55 56 57 58 59 60 61 8 9 10 11 12 13 34 35 36 37 38 39 62 63 64 65 66 67 68 69 14 15 16 17 18 19 40 41 42 43 44 45...
  • Page 215 Electrical components Connecting part Color Connecting part Color Immobilizer serial — — White communication Engine shut-off White ETV relay power switch Red/Yellow source (contact) — — Sensor ground Black/Orange — — TPS ground Black/Orange — — TPS 1 Pink — —...
  • Page 216: Electrical Analysis

    Electrical analysis Electrical analysis Power supply to the ECM Push the unlock button “a” on the remote con- Electrical component check using the trol transmitter so that power is supplied to the YDIS ECM. When checking the TPS, APS, RPS or other sensors, use the YDIS.
  • Page 217: Test Lead Preparation

    Electrical analysis • Use the peak voltage adapter with the rec- ommended digital circuit tester. • Connect the positive pin of the peak voltage adapter to the positive terminal of the digital circuit tester, and the negative pin to the neg- ative terminal.
  • Page 218: Ignition System

    Ignition system Ignition system Ignition spark check When performing the spark gap check, keep flammable gas or liquids away, since this test can produce sparks. 1. Connect the YDIS. 2. Remove the ignition coil for the cylinder Input voltage that will be tested. 12 V (battery voltage) Red/Yellow (R/Y)–Black (B) 3.
  • Page 219: Pickup Coil Check

    Ignition system #1 B/R #2 B/W #3 B/Y #4 B/G Test harness (2 pins) “1” Output peak voltage 90890-06851 #1 Black/Red (B/R)—Black (B) #2 Black/White (B/W)—Black (B) Output peak voltage #3 Black/Yellow (B/Y)—Black (B) White (W)–Black (B) #4 Black/Green (B/G)—Black (B) Unloaded Loaded Loaded...
  • Page 220: Charging System

    Charging system Charging system Stator coil check 1. Disconnect the stator coil coupler “a”, and then connect the special service tool “1”. 2. Measure the stator coil output peak volt- age. Resistance 0.27–0.40 Ω Green (G)–Green (G) 5. Connect the stator coil coupler. Rectifier/regulator check 1.
  • Page 221 Charging system Output voltage Red (R)–Black (B) Loaded r/min 2000 3500 3. Disconnect the special service tool. 4. Remove the rectifier/regulator. See “Ex- haust manifold” (5-3). A. Worldwide B. U.S.A. and Canada 5. Check the rectifier/regulator for continuity. Replace if out of specification. Rectifier/regulator continuity (testing diode mode) TIP:...
  • Page 222: Control System

    Control system Control system 6. Check the oil pressure switch for continui- ty. Replace if out of specification. Oil pressure switch check 1. Disconnect the oil pressure switch coupler Oil pressure switch continuity “a”. Terminal thread “a”– Pressure Body “b” 2.
  • Page 223: Thermo Sensor Check

    Control system 5. Check the thermo switch for continuity Input voltage when the specified temperatures are 4.75–5.25 V reached. Replace if out of specification. Black/Blue (B/L)–Black/Orange (B/O) 3. Remove the thermo sensor. See “Muffler” (5-16). 4. Suspend the thermo sensor in a container filled with water, and then slowly heat the water.
  • Page 224: Intake Air Temperature Sensor Check

    Control system 2. Supply power to the ECM, and then mea- Intake air temperature sensor check sure the input voltage at the engine tem- 1. Measure the ambient temperature. perature sensor coupler terminals (wire 2. Connect the YDIS to display “Intake tem- harness end).
  • Page 225: Intake Air Pressure Sensor Check

    Control system 4. Disconnect the vacuum hose from the in- take air pressure sensor. 5. Connect the special service tool “1” to the intake air pressure sensor. 6. Connect the YDIS to display “Intake air pressure”. 7. Apply negative pressure to the intake air pressure sensor slowly and check that the 8.
  • Page 226 Control system TIP: Operate the throttle lever “1”, and then check the TPS 2 output voltage and throttle valve opening angle at the fully open position “B”. TPS 2 output voltage with the throttle le- ver fully open 4.60–4.70 V a.
  • Page 227: Etv Circuit Continuity

    Control system 3 2 1 6 5 4 Input voltage 4.75–5.25 V Orange (O)–Black/Orange (B/O) ETV circuit continuity 8. Connect the ETV coupler. Terminal No. Color ETV circuit continuity code Coupler “a” Coupler “b”, “c” 1. Disconnect the ETV coupler “a” and ECM couplers “b”...
  • Page 228: Aps Circuit Continuity

    Control system APS full close switch TIP: The actual APS output voltage may vary ac- Throttle lever position YDIS display cording to environmental conditions. 5. Disconnect the APS coupler “a”. 6. Supply power to the ECM, and then mea- sure the input voltage at the APS coupler terminals (wire harness end).
  • Page 229: Etv Relay Check

    Control system 2. Check the ETV relay. See “Main relay 2. Check the wire harness for continuity. check” (7-31). Replace if there is no continuity. 3. Measure the input voltage between the ter- minal “a” and ground. 3 2 1 6 5 4 30 29 Input voltage...
  • Page 230: Rps Check

    Control system RPS check 3. Squeeze the RiDE lever to the fully open position, and then check the voltage differ- ence between RPS 1 and RPS 2. Measure RPS 1 and RPS 2 are components of the the RPS input voltage if out of specifica- RiDE lever, which cannot be disassembled.
  • Page 231: Scu Relay Check

    Control system 2. Check the SCU relay. See “Main relay 2. Check the wire harness for continuity. Re- check” (7-31). place if there is no continuity. 3. Measure the input voltage between the ter- minal “a” and ground. 3 2 1 6 5 4 Input voltage 12 V (battery voltage)
  • Page 232: Electric Trim Switch Check

    Control system Electric trim switch check Electric trim switch resistance (reference 1. Connect the YDIS to display “Trim up data) switch” and “Trim down switch”. Free 5.6 kΩ 2. Push the electric trim switches “1” and “2”. Sky blue (Sb)–Black (B) Switch “1”...
  • Page 233: Slant Detection Switch Check

    Control system 5. Supply power to the ECM, and then mea- sure the output voltage when a screw- driver is passed under the cam position sensor in direction “A”. Replace the cam position sensor if out of specification. Input voltage 4.75–5.25 V Blue/Black (L/B)–Black/Orange (B/O) 3.
  • Page 234: Steering Sensor Check

    Control system Steering sensor check 5. Connect the special service tool “1” to the steering sensor coupler. 1. Connect the YDIS to display “Steering sensor.” 6. Supply power to the ECM, and then mea- sure the output voltage when the handle- 2.
  • Page 235: Earth Plate Check

    Control system ECM circuit continuity Terminal “46”–Ground Terminal “62”–Ground Continuity Terminal “67”–Ground Terminal “70”–Ground 4. Connect the ECM couplers. Earth plate check 1. Remove the earth plate. 2. Check the continuity between each termi- nal “a” and the housing “b”. Replace the earth plate if there is no continuity.
  • Page 236: Fuel System

    Fuel system Fuel system Fuel pump relay check 1. Remove the fuse box cover and fuel pump Fuel injector check relay “1”. 1. Connect the YDIS. 2. Using the “Stationary test” of the YDIS, lis- ten for the fuel injector operation sound. 3.
  • Page 237: Fuel Pump Module Check

    Fuel system 5. Install the fuel pump relay and fuse box cover. Fuel pump module check 1. Connect the YDIS. 2. Using the “Stationary test” of the YDIS, lis- ten for the fuel pump module operation sound. 3. Disconnect the fuel pump module coupler A.
  • Page 238: Starting System

    Starting system Starting system Fuse check 1. Check the fuse for continuity. Replace if there is no continuity. Engine stop switch continuity Engine stop White (W)– Clip “1” switch “2” Black (B) Free No continuity Installed “A” Handlebar switch (left) check Pushed Continuity 1.
  • Page 239: Starter Relay Check

    Starting system Starter relay check 1. Slide the boot away from the starter relay terminal “1”, and then measure the input voltage between the starter relay terminal “1” and ground. TIP: The positive battery lead is marked with yel- lowish green tape “a”. Relay terminals continuity Terminal “c”–Terminal “d”...
  • Page 240 Starting system Starter relay continuity Battery lead “c”–“d” Terminal “a”–“b” Connected Continuity 6. Install the starter relay. 7-33...
  • Page 241: Starter Motor

    Starter motor Starter motor 9 Nm (0.9 kgf·m, 6.6 ft·lb) 7 Nm (0.7 kgf·m, 5.2 ft·lb) 12 11 ’ Part name Remarks × Bolt 120 mm Starter motor rear cover Packing seal Not reusable Front cover Packing seal Not reusable Plate Starter motor yoke Armature...
  • Page 242: Starter Motor Operation

    Starter motor Starter motor operation 1. Remove the starter motor. See “Wire har- ness” (5-18). 2. Hold the starter motor in a vise using alu- minum plates on both sides. 3. Connect the positive battery lead “1” to the starter motor terminal bolt “a”. 4.
  • Page 243: Brush Holder Check

    Starter motor Armature continuity Commutator seg- Continuity ment “a” Segment “a”–Arma- No continuity ture core “b” Segment “a”–Arma- No continuity ture shaft “c” Brush holder continuity Brush holder check Brush “a”–Brush “b” 1. Measure the brush length “a”. Replace the Brush “c”–Brush “d”...
  • Page 244: Remote Control System

    6. Measure the battery voltage. Replace the remote control transmitter battery if below specification. TIP: Refer to local hazardous waste regulations when disposing of transmitter batteries. Yamaha Security Number of beeps System mode 1 beep Lock Unlock Rating...
  • Page 245: Remote Control Receiver Check

    Remote control system 2. Connect the remote control receiver cou- TIP: pler. Install the battery (CR2016) “1” with the posi- tive side “a” facing down. 3. Disconnect the multifunction meter cou- pler “a” from the remote control receiver. 4. Supply power to the ECM, and then mea- sure the remote control receiver output voltage at the multifunction meter coupler terminal (wire harness end) and ground.
  • Page 246 Remote control system 2. Push the lock button “a” or unlock button “b” to transmit the ID code from the remote control transmitter to be registered. TIP: • At this time, the system enters the registra- tion mode to register the first code. All exist- 4.
  • Page 247: Indication System

    Indication system Indication system Multifunction meter check 1. Check the multifunction meter external ap- pearance. Replace the multifunction meter if there is cracked meter housing, fogged meter, or water intrusion. 2. Supply power to the ECM, and then check that all indicator lights “a” and display ele- ments “b”...
  • Page 248: Fuel Level Meter Display And Fuel Level Warning Indicator Check

    Indication system 4. Connect the positive battery lead to the terminal “a”, and the negative battery lead to the terminal “b”. 5. Connect the tester leads between the ter- minal “c” and terminal “b”. 6. Rotate the paddle wheel “d” by hand and measure the output voltage between the terminal “c”...
  • Page 249: Diagnostic Display Check

    Indication system 3. If the light and indicator do not blink, check 3. Check that the oil pressure warning indica- the “Diagnosis record” of the YDIS. If a di- tor “a”, the check engine warning indicator agnosis record is available and the light “b”, and the “WARNING”...
  • Page 250: Buzzer Check

    Indication system and remain on, and the buzzer sounds 5. Check that the buzzer sounds. Replace continuously. After 30 seconds, check that the buzzer if does not sound. the buzzer stops. 6. Install the buzzer. See “Steering master” 4. If the light and indicator do not blink, check (8-12).
  • Page 251 Indication system — MEMO — 7-44...
  • Page 252: Hull And Hood

    Hull and hood Steering pad and handlebar cover ........8-1 Handlebar and handlebar switch ........8-2 Lead routing ................8-3 Handlebar installation..............8-3 Front hood ................8-6 Side cover ................8-8 Center cover ............... 8-9 Steering master ASSY ............. 8-11 Steering master ..............
  • Page 253 Hull and hood Rear section..............8-31 Spout installation ..............8-33 Reboarding step installation (VXR) .......... 8-33 Deck and hull ..............8-34...
  • Page 254: Steering Pad And Handlebar Cover

    Steering pad and handlebar cover Steering pad and handlebar cover 5.5 Nm (0.55 kgf · m, 4.06 ft · lb) 0.5 Nm (0.05 kgf · m, 0.37 ft · lb) ’ Part name Remarks × Screw 16 mm Upper handlebar cover Steering pad ×...
  • Page 255: Handlebar And Handlebar Switch

    Handlebar and handlebar switch Handlebar and handlebar switch 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 3.5 Nm (0.35 kgf · m, 2.58 ft · lb) 2 Nm (0.2 kgf · m, 1.5 ft · Ib) 3.5 Nm (0.35 kgf · m, 2.58 ft · lb) 21 Nm (2.1 kgf ·...
  • Page 256: Lead Routing

    Handlebar and handlebar switch Lead routing 1. Wrap the packing “1”, making sure to align the upper edge of the packing with the up- per edges of the tape markings “a” and “b”, on the handlebar switch (right) lead “2” and handlebar switch (left) leads “3”.
  • Page 257 Handlebar and handlebar switch Clearance (reference data) Handlebar switch bolt (left) “2” “b”: 0.4 mm (0.02 in) 3.5 Nm (0.35 kgf·m, 2.58 ft·lb) “c”: 1.1 mm (0.09 in) 4. Install the handlebar switch (right) “1”, and then tighten the bolts “2” to the specified Handlebar holder bolt “3”...
  • Page 258 Handlebar and handlebar switch 7. Install the washers “3” and bolts “4”, and then tighten the bolts “4” to the specified torque. TIP: Align the slit “a” in the handlebar grip “2” with the stopper bolt “5”. Handlebar grip end bolt “4” 7 Nm (0.7 kgf·m, 5.2 ft·lb)
  • Page 259: Front Hood

    Front hood Front hood 3.5 Nm (0.35 kgf · m, 2.58 ft · lb) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 2.5 Nm (0.25 kgf · m, 1.84 ft · lb) ’...
  • Page 260 Front hood 3.5 Nm (0.35 kgf · m, 2.58 ft · lb) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 2.5 Nm (0.25 kgf · m, 1.84 ft · lb) ’...
  • Page 261: Side Cover

    Side cover Side cover 5.5 Nm (0.55 kgf · m, 4.06 ft · lb) 5.5 Nm (0.55 kgf · m, 4.06 ft · lb) 5.5 Nm (0.55 kgf · m, 4.06 ft · lb) 5.5 Nm (0.55 kgf · m, 4.06 ft · lb) 5.5 Nm (0.55 kgf ·...
  • Page 262: Center Cover

    Center cover Center cover 2.5 Nm (0.25 kgf · m, 1.84 ft · lb) 5.5 Nm (0.55 kgf · m, 4.06 ft · lb) 5.5 Nm (0.55 kgf · m, 4.06 ft · lb) 4 Nm (0.4 kgf · m, 3.0 ft · Ib) ’...
  • Page 263 Center cover 2.5 Nm (0.25 kgf · m, 1.84 ft · lb) 5.5 Nm (0.55 kgf · m, 4.06 ft · lb) 5.5 Nm (0.55 kgf · m, 4.06 ft · lb) 4 Nm (0.4 kgf · m, 3.0 ft · Ib) ’...
  • Page 264: Steering Master Assy

    Steering master ASSY Steering master ASSY 17 Nm (1.7 kgf · m, 12.5 ft · Ib) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) ’ Part name Remarks × Bolt 18 mm Cable stopper Steering cable Plastic tie ×...
  • Page 265 Steering master Steering master 4 Nm (0.4 kgf · m, 3.0 ft · Ib) 4 Nm (0.4 kgf · m, 3.0 ft · Ib) 4 Nm (0.4 kgf · m, 3.0 ft · Ib) 16 Nm (1.6 kgf · m, 11.8 ft · Ib) 7 Nm (0.7 kgf ·...
  • Page 266: Steering Master

    Steering master 4 Nm (0.4 kgf · m, 3.0 ft · Ib) 4 Nm (0.4 kgf · m, 3.0 ft · Ib) 4 Nm (0.4 kgf · m, 3.0 ft · Ib) 16 Nm (1.6 kgf · m, 11.8 ft · Ib) 7 Nm (0.7 kgf ·...
  • Page 267: Steering Arm Assy Installation

    Steering master Steering arm ASSY installation 1. Install the steering arm ASSY “1” to the steering shaft. 2. Install the nut “2” to the steering arm “1”. 3. Align the tab “a” on the plate “3” with the projection “b” on the arm. 4.
  • Page 268: Steering Cable And Speed Sensor Lead

    Steering cable and speed sensor lead Steering cable and speed sensor lead 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 4 Nm (0.4 kgf · m, 3.0 ft · Ib) 7 Nm (0.7 kgf ·...
  • Page 269: Steering Cable Installation (Steering Master End)

    Steering cable and speed sensor lead Steering cable installation (steering master end) If a cable becomes damaged, replace it. Never attempt to repair a damaged cable. 1. Install the steering cable “1” and cable stopper “2”, and then tighten the bolt “3” to the specified torque.
  • Page 270: Seat And Handgrip

    Seat and handgrip Seat and handgrip 16 Nm (1.6 kgf · m, 11.8 ft · Ib) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 16 Nm (1.6 kgf · m, 11.8 ft · Ib) 26 Nm (2.6 kgf · m, 19.2 ft · Ib) 7 Nm (0.7 kgf ·...
  • Page 271 Seat and handgrip 16 Nm (1.6 kgf · m, 11.8 ft · Ib) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 16 Nm (1.6 kgf · m, 11.8 ft · Ib) 26 Nm (2.6 kgf · m, 19.2 ft · Ib) 7 Nm (0.7 kgf ·...
  • Page 272 Ventilation hose and water separator Ventilation hose and water separator 4 Nm (0.4 kgf · m, 3.0 ft · Ib) ’ Part name Remarks Rivet Ventilator Plastic tie Ventilation hose Plastic tie Plastic tie Fuel tank breather hose Fuel tank breather hose Rivet Plate Water separator...
  • Page 273 Ventilation hose and water separator 4 Nm (0.4 kgf · m, 3.0 ft · Ib) ’ Remarks Part name Plastic tie Seal Not reusable Clamp Cooling water hose Cooling water pilot outlet Holder 8-20...
  • Page 274: Ventilation Hose And Water Separator

    Ventilation hose and water separator Cooling water pilot outlet installation 1. Install a new seal “1” and the cooling water pilot outlet “2”, and then tighten the cooling water pilot outlet nut “3” to the specified torque. TIP: Align the protrusion “a” with the slit “b”. Cooling water pilot outlet nut “3”...
  • Page 275: Exhaust System

    Exhaust system Exhaust system 3.5 Nm (0.35 kgf · m, 2.58 ft · lb) 24 23 22 5.5 Nm (0.55 kgf · m, 4.06 ft · lb) 3.5 Nm (0.35 kgf · m, 2.58 ft · lb) 5.5 Nm (0.55 kgf · m, 4.06 ft · lb) 3.5 Nm (0.35 kgf ·...
  • Page 276 Exhaust system 3.5 Nm (0.35 kgf · m, 2.58 ft · lb) 24 23 22 5.5 Nm (0.55 kgf · m, 4.06 ft · lb) 3.5 Nm (0.35 kgf · m, 2.58 ft · lb) 5.5 Nm (0.55 kgf · m, 4.06 ft · lb) 3.5 Nm (0.35 kgf ·...
  • Page 277: Exhaust System Installation

    Exhaust system Exhaust system installation 1. Install the plate “1” onto the rubber hose “2”. TIP: Make sure to fit the projections “a” on the rub- ber hose “2” with the grooves in the plate “1”. Rubber hose clamp “2” 3.5 Nm (0.35 kgf·m, 2.58 ft·lb) 4.
  • Page 278 Exhaust system Rubber hose clamp “2” 3.5 Nm (0.35 kgf·m, 2.58 ft·lb) 6. Install the band. 8-25...
  • Page 279 RiDE motor RiDE motor 4 Nm (0.4 kgf · m, 3.0 ft · Ib) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 17 Nm (1.7 kgf · m, 12.5 ft · Ib) 11 Nm (1.1 kgf · m, 8.1 ft · Ib) ’...
  • Page 280: Ride Motor

    RiDE motor RiDE motor removal 5. Remove the speed sensor “1” and ride plate “2”. 1. Remove the deck beam “1”. 6. Disconnect the shift rod joint “1”. 2. Remove the plastic tie “1”, and then dis- connect the RiDE motor couplers “a” and “b”.
  • Page 281: Ride Motor Installation

    RiDE motor 10. Remove the RiDE motor “1”. RiDE motor nuts “2” 17 Nm (1.7 kgf·m, 12.5 ft·lb) RiDE motor bolts “3” 17 Nm (1.7 kgf·m, 12.5 ft·lb) 3. Install the shift arm “1” and trim arm “2”, and then tighten the shift arm bolt “3” and trim arm bolt “4”...
  • Page 282 RiDE motor 7. Turn the shift rod joint so that the 2 holes “d” face in the same directions, and then tighten the locknut “4” to the specified torque. 10. Install the ride plate “1”, and then tighten the ride plate bolts “2” to the specified torque.
  • Page 283: Ride System Initialization

    RiDE motor TIP: Align the mark “a” on the rubber hose “3” with the mark “b” on the water tank “1”. 17. Install the deck beam “1”, and then tighten the deck beam nut “2” to the specified torque. Rubber hose clamp “2” 3.5 Nm (0.35 kgf·m, 2.58 ft·lb) 14.
  • Page 284: Rear Section

    Rear section Rear section 16 Nm (1.6 kgf · m, 11.8 ft · Ib) 5.5 Nm (0.55 kgf · m, 4.06 ft · lb) 17 16 2.5 Nm (0.25 kgf · m, 1.84 ft · lb) 2 Nm (0.2 kgf · m, 1.5 ft · Ib) 16 Nm (1.6 kgf ·...
  • Page 285 Rear section 16 Nm (1.6 kgf · m, 11.8 ft · Ib) 5.5 Nm (0.55 kgf · m, 4.06 ft · lb) 17 16 2.5 Nm (0.25 kgf · m, 1.84 ft · lb) 2 Nm (0.2 kgf · m, 1.5 ft · Ib) 16 Nm (1.6 kgf ·...
  • Page 286: Spout Installation

    Rear section Spout installation 1. Install the spout “1”, and then tighten the spout nut “2” to the specified torque. 2. Connect the hose “3”, and then tighten the spout hose clamp “4” to the specified torque. TIP: Face the mark “a” toward the BOW. Reboarding step bolt “2”...
  • Page 287: Deck And Hull

    Deck and hull Deck and hull 16 Nm (1.6 kgf · m, 11.8 ft · Ib) 1.5 Nm (0.15 kgf · m, 1.11 ft · lb) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 13 Nm (1.3 kgf ·...
  • Page 288 Deck and hull 16 Nm (1.6 kgf · m, 11.8 ft · Ib) 1.5 Nm (0.15 kgf · m, 1.11 ft · lb) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 13 Nm (1.3 kgf ·...
  • Page 289 Deck and hull 16 Nm (1.6 kgf · m, 11.8 ft · Ib) 1.5 Nm (0.15 kgf · m, 1.11 ft · lb) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 7 Nm (0.7 kgf · m, 5.2 ft · Ib) 13 Nm (1.3 kgf ·...
  • Page 290 Deck and hull — MEMO — 8-37...
  • Page 291: Troubleshooting

    Troubleshooting YDIS ..................9-1 Basic components ..............9-1 Function..................9-2 Connecting the communication cable to the watercraft....9-4 Engine unit troubleshooting ..........9-5 Using the YDIS for engine unit troubleshooting ......9-5 Diagnostic code table ..............9-7 Diagnostic code and checking step..........9-8 Engine unit troubleshooting (diagnostic code not detected)..
  • Page 292 YDIS YDIS The Yamaha Diagnostic System uses precision fault diagnosis to offer better serviceability at a time when there is increasing demand for service tools for electronically controlled products. It provides quick, reliable, safe, and reasonable service, and is intended to obtain customer satisfaction. The Ya- maha Diagnostic System features updated software and expanded tool functions that allow it to re- spond to new models and technologies, maintaining compatibility with regulations.
  • Page 293: Ydis

    YDIS Function 1. Diagnosis: Each sensor’s status and each ECM diagnostic code or item is displayed. This enables you to find malfunctioning parts and controls quickly. The diagnostic codes displayed are the same as those described in “Diagnostic code and checking step” in this chapter. 2.
  • Page 294 YDIS When the communication cable is used to connect a computer to the ECM, the ECM record data can be saved and viewed on the computer. The saved ECM record data can also be viewed offline. Engine speed Ref. TPS voltage*2 No-wake mode APS 1 Ref.
  • Page 295: Connecting The Communication Cable To The Watercraft

    YDIS TIP: To perform the SCU initial learning, see the YDIS (Ver. 2.20) Instruction Manual. Connecting the communication cable to the watercraft TIP: Be careful not to pinch the communication cable between the front hood and the deck or to damage it. a.
  • Page 296: Engine Unit Troubleshooting

    Engine unit troubleshooting Engine unit troubleshooting TIP: • Before troubleshooting the engine unit, make sure that fresh fuel of the specified type has been used. • Check that all wiring connections are secured properly and that they are not corroded or rusty. •...
  • Page 297 Engine unit troubleshooting If the multifunction meter is turned on before the problem is solved, the information display will indicate the diagnostic code “c” and the “WARNING” indicator light “a” will blink. If the engine is started, the “WARNING” indicator light “a” and the check engine warning indicator “b” blink and the buzzer sounds intermittently for 30 seconds.
  • Page 298: Diagnostic Code Table

    Engine unit troubleshooting Diagnostic code table : Indicated —: Not indicated Diagnostic code output YDIS Code No. Item Multifunc- Diagnosis tion meter Diagnosis record Pulser coil    (Pickup coil)    Engine temperature sensor    Battery voltage Air temperature sensor ...
  • Page 299: Diagnostic Code And Checking Step

    Engine unit troubleshooting Diagnostic code and checking step *1: This symptom may only be exhibited in certain environmental conditions. —: Not applicable Diag- nostic Item Symptom Checking steps page code Measure the pickup coil output 7-12 peak voltage. Measure the pickup coil resis- Pulser coil 7-12 Engine will not start...
  • Page 300 Engine unit troubleshooting Diag- nostic Item Symptom Checking steps page code Measure the cam position 7-25 sensor input voltage. Check the orange (O), green/orange (G/O), and Cam position Engine speed is limited black/orange (B/O) cam posi- sensor tion sensor leads for continui- Measure the cam position 7-25 sensor output voltage.
  • Page 301 Engine unit troubleshooting Diag- nostic Item Symptom Checking steps page code Check the steering sensor op- 7-27 eration using the YDIS. Measure the steering sensor 7-27 input voltage. Steering sensor Normal operation Check the orange/red (O/R), white/blue (W/L), and black/or- ange (B/O) steering sensor leads for continuity.
  • Page 302 Engine unit troubleshooting Diag- nostic Item Symptom Checking steps page code Check the ETV coupler termi- nals for corrosion and rust. Check the green (G) and blue ETV system Engine speed is limited (L) ETV leads for continuity. Check the ECM circuit for con- 7-27 tinuity.
  • Page 303 Engine unit troubleshooting Diag- nostic Item Symptom Checking steps page code Check the ECM circuit for con- 7-27 tinuity. Check the ETV relay for conti- 7-22 nuity. Check the charging system. • Stator coil output peak volt- 7-13 7-13 • Stator coil resistance 7-13 •...
  • Page 304 Engine unit troubleshooting Diag- nostic Item Symptom Checking steps page code Check the ECM circuit for con- 7-27 tinuity. Check the ETV relay for conti- 7-22 nuity. Check the charging system. • Stator coil output peak volt- 7-13 7-13 • Stator coil resistance 7-13 •...
  • Page 305 Engine unit troubleshooting Diag- nostic Item Symptom Checking steps page code Check that there is no foreign matter on the rotating part of Engine speed is limited the reverse gate. Shifting is impossible Replace the RiDE motor. 8-26 Engine speed is limited Replace the RiDE motor.
  • Page 306: Engine Unit Troubleshooting (Diagnostic Code Not Detected)

    Symptom 1: Engine does not crank. Symptom 2 Cause Checking step page Yamaha Security System Check that the Yamaha Security 7-37 set to lock mode System is set to the unlock mode. Check the battery voltage and spe- Discharged battery cific gravity.
  • Page 307 Engine unit troubleshooting Symptom 2 Cause Checking step page Battery performance de- Check the battery voltage and spe- crease cific gravity. Stator coil malfunction Check the stator coil 7-13 Discharged battery Check the battery lead and terminal Short, open, or loose con- for proper connection.
  • Page 308 Engine unit troubleshooting Symptom 2 Cause Checking step page Fuel leakage Check the fuel hose. Blown fuse Check the fuse for continuity. 7-31 Clogged fuel pump filter Clean the fuel pump filter. 4-12 Check the fuel pump module opera- 4-12 tion sound using the YDIS.
  • Page 309 Engine unit troubleshooting Symptom 2 Cause Checking step page Spark plug malfunction Check the spark plug. Ignition coil malfunction Check the ignition spark. 7-11 Measure the ignition coil input volt- 7-11 age (from the battery). Spark plug does not Short, open, or loose con- Check the red/yellow (R/Y), spark (some cylin- nection in ignition coil cir-...
  • Page 310 Engine unit troubleshooting Symptom 1: Limited engine speed Symptom 2 Cause Checking step page Check the cooling water pilot outlet — for water discharge. Clogged cooling water pas- sage Check the water inlet strainer. Check the cooling water passage. 1-33 Thermostat malfunction Check the thermostat.
  • Page 311 Engine unit troubleshooting Symptom 1: Discharged battery Symptom 2 Cause Checking step page Battery performance de- Check the battery voltage and spe- crease cific gravity. Loose connection of bat- Check the battery lead and terminal tery terminal for proper connection. —...
  • Page 312 Engine unit troubleshooting — MEMO — 9-21...
  • Page 313: Appendix

    Appendix Wiring diagram ..............A-1 How to use the wiring diagram ........... A-1 VXS, VXR................... A-2...
  • Page 314: Wiring Diagram

    Wiring diagram Wiring diagram How to use the wiring diagram Legend symbols in the wiring diagrams Double colors wire No wire connector Color code : Pink/Black : Black : Pink/Green : Brown : Pink/Red : Black/Green : Pink/White : Black/Blue Pu/B : Purple/Black : Black/Orange...
  • Page 315 VXS, VXR Multifunction meter APS (electric throttle Remote control receiver Fuel sender without wire cable) Fuse box R Br Buzzer FREE Starter motor PUSH PULL Br Br FREE PUSH Speed sensor Handlebar switch (left) Starter relay Battery 1 4 8 12 1 8 14 20 3 7 11 14 Joint coupler 2...
  • Page 316 Wiring diagram A. To entry box B. Antenna a. Fuse (10 A) (fuel pump relay) b. Fuse (3 A) (not used) c. Fuse (20 A) (main relay) d. Fuse (10 A) (main relay) e. Fuse (10 A) (ETV relay) f. Fuse (3 A) (remote control receiver) g.
  • Page 318 Mar. 2015 CR...

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