Yamaha LST1200X1999 Service Manual
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Yamaha LST1200X1999 Service Manual

Yamaha LST1200X1999 Service Manual

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1999~2003
LS2000/LX210/AR210
ALL LST1200 (LS2000) MODELS
LIT-18616-SB-01

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Summary of Contents for Yamaha LST1200X1999

  • Page 1 1999~2003 LS2000/LX210/AR210 ALL LST1200 (LS2000) MODELS LIT-18616-SB-01...
  • Page 160 2000 LST1200Y Supplementary Service Manual...
  • Page 161 LST1200Y Supplementary Service Manual © 2000 Yamaha Motor Corporation, U.S.A. 1st Edition, January 2000 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, including photocopying and recording, without the written permission of the copyright holder.
  • Page 162 PREFACE This Supplementary Service Manual has been prepared to introduce new service and data for the LST1200Y. For complete service information, it is necessary to use this Supplementary Service Manual together with the following manual: LST1200X SERVICE MANUAL: LIT-18616-02-06 For what is not mentioned in this manual, please refer to the descriptions for LST1200 in the above Service Manual.
  • Page 163 TABLE OF CONTENTS INFO GENERAL INFORMATION IDENTIFICATION NUMBERS ..........1 PRIMARY I.D.
  • Page 164 TABLE OF CONTENTS INFO JET PUMP JET PUMP CLEAN-OUT PORTS ..........18 EXPLODED DIAGRAM .
  • Page 165 Apply Gasket Maker® Apply Yamabond #4 (Yamaha bond No. 4) Apply LOCTITE® No. 271 (Red LOCTITE) Apply LOCTITE® No. 242 (Blue LOCTITE) Apply LOCTITE® No. 567 (PST)
  • Page 166 GENERAL INFORMATION INFO A60700-0* IDENTIFICATION NUMBERS PRIMARY I.D. NUMBER The Primary I.D. number is stamped on a label attached to the deck under the rear seat. Starting Primary I.D. Number: F0R-100101~ ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the crankcase.
  • Page 167 SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Code LST1200 Hull Engine Dimensions: Length 19’6” (5.9 m) Width 8’ (2.4 m) Draft 18” (.5 m) Dry weight 2100 lb. (955 kg) Performance: Maximum output (each engine) 135hp @ 6750 Maximum fuel consumption (W.O.T.) 28.0 gal/hr (106 L/hr) @ 6730rpm Cruising range...
  • Page 168 SPEC MAINTENANCE SPECIFICATIONSx MAINTENANCE SPECIFICATIONS ENGINE Item Unit LST1200 Cylinder Head: Warpage limit in (mm) 0.004” (0.1mm) Compression pressure kg/cm (KPa) — Cylinder: Bore size in (mm) 3.307 ~ 3.308” (84.00 ~ 84.02mm) Taper limit in (mm) 0.003” (0.08mm) Out of round limit in (mm) 0.002”...
  • Page 169 SPEC MAINTENANCE SPECIFICATIONS Item Unit LST1200 Crankshaft Assembly: Crank width “A” in (mm) 2.439 ~ 2.441” (61.95 ~ 62.00mm) Deflection limit “B” in (mm) 0.002” (0.05mm) Big end side clearance “C” in (mm) 0.010 ~ 0.030” (0.25 ~ 0.75mm) Maximum small end in (mm) 0.08”...
  • Page 170 SPEC MAINTENANCE SPECIFICATIONSx HULL AND HOOD Item Unit LST1200 Free Play: Throttle lever free play in (mm) 0.16 ~ 0.28” (4 ~ 7mm) Choke cable free play in (mm) 0.04 ~ 0.24” (1 ~ 6mm) ELECTRICAL Item Unit LST1200 Battery: Type Marine group 24 dual purpose 675cca...
  • Page 171 SPEC MAINTENANCE SPECIFICATIONS Item Unit LST1200 Lighting Coil: Test points Color code Ω Resistance 0.56 ~ 0.84 Peak voltage (open cranking) 5.6 (min) Peak voltage (closed cranking) 5.6 (min) Peak voltage (2000 RPM) 23.8 (min) Peak voltage (3500 RPM) 28.1 (min) Charging current A/rpm 6 ~ 8/5, 500...
  • Page 172 SPEC MAINTENANCE SPECIFICATIONS COOLING WATER FLOW DIAGRAM As shown in the illustration below, the pilot used to cool the sides of muffler 2 and the water exits the engine from the upper side of exhaust outer cover. Afterward, it is mixed with the exhaust joint.

  • Page 173: Tightening Torque

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE SPECIFIED TORQUE Part To Be Tightened Part Name Size m•kg ft•lb Remarks Engine: Electric box Bolt Electric Box Cover Bolt Mounting bolt Bolt Reed valve Screw Exhaust ring Bolt Muffler stay Bolt Exhaust Chamber Ass’y Bolt At cylinder Bolt...
  • Page 174 SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE (Continued) SPECIFIED TORQUE Part To Be Tightened Part Name Size m•kg ft•lb Remarks Jet Unit: Mounting Bolt Bolt 13.7 Impeller Housing/Duct Bolt 13.7 Transom Plate Bolt 13.7 Intake duct Bolt 13.7 Intake grate Bolt 13.7 Impeller (left-hand threads) Bolt Reverse Gate...
  • Page 175 SPEC MAINTENANCE SPECIFICATIONS GENERAL TORQUE General Torque Specifications This chart specifies the torques for tightening Nut A Bolt B standard fasteners with standard clean dry ISO M•kg ft•lb threads at room temperature. Torque specifica- tions for special components or assemblies are 8 mm given in applicable sections of this manual.
  • Page 176 INSP PERIODIC INSPECTION AND ADJUSTMENT JET PUMP UNIT Clean-out cap inspection 1. Remove: Clean-out cap 1 2. Inspect: Rubber seal Crack/Damage ➔ Replace. Locking mechanism Wear/Damage ➔ Replace 3. Install: Clean-out cap NOTE: Align the projection of the clean-out cap with the recess of the clean-out opening.
  • Page 177 FUEL FUEL SYSTEM FUEL AND OIL SYSTEM EXPLODED DIAGRAM FUEL LINE AND OIL SYSTEM 9. Starboard Oil Pump 1. Fuel Tank 10. Port Oil Filter 2. Main Fuel Pickup 11. Starboard Oil Filter 3. Port Fuel Petcock 12. Res Fuel Pickup 4.
  • Page 178 FUEL FUEL SYSTEM FUEL TANK EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Service Points Follow the “Step” order for removal. FUEL TANK REMOVAL Fuel Remove the fuel in the tank. Rear Seat Base Assembly Refer to “SEAT FITTINGS” in Chapter 8. Hose Band Fuel Filler Hose Hose Band...
  • Page 179 FUEL FUEL SYSTEM FUEL SYSTEM EXPLODED DIAGRAM...
  • Page 180 FUEL FUEL SYSTEM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Service Points FUEL SYSTEM DISASSEMBLY Follow the “Step” order for removal. Hose Fitting Screw Insert, Fuel Tank 1 Gasket Screw Insert, Fuel Tank 2 Fuel Level Sensor Pad, Fuel Tank NOTE: One pad cut in half is placed on each side of the forward tank stays...
  • Page 181 FUEL FUEL SYSTEM FUEL PUMP EXPLODED DIAGRAM...
  • Page 182 FUEL FUEL SYSTEMx REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Service Points FUEL PUMP DISASSEMBLY Follow the “Step” order for removal. Carburetor Assembly Refer to “CARBURETOR REMOVAL.” Pump Cover Gasket Clear Diaphragm O-ring Diaphragm Body Assembly Check Valve Bushing, Fuel Pump Diaphragm O-Ring...
  • Page 183 PUMPx PUMP JET PUMP CLEAN-OUT PORTS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Qty (ea.) Service Points JET PUMP CLEAN-OUT Follow the “Step” order for removal. PORTS REMOVAL NOTE: Follow cap installation instructions in “JET PUMP UNIT INSPECTION,” Chapter 3. Screw Clean-out Tray Set height a = 0.5”...
  • Page 184 ELEC ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAM...
  • Page 185 ELEC ELECTRICAL SYSTEM HULL HARNESS...
  • Page 186 ELEC ELECTRICAL SYSTEM Step Procedure / Part Name Qty (ea.) Service Points HULL HARNESS #3 Follow the “Step” order for removal. REPLACEMENT Battery Leads Blower Motor Leads Hull harness to Deck harness Access: Engine compartment connector Clean-out tray Refer to “JET PUMP CLEAN-OUT PORTS”...
  • Page 187 ELEC ELECTRICAL SYSTEM ENGINE HARNESS...
  • Page 188 ELEC ELECTRICAL SYSTEM Step Procedure / Part Name Qty (ea.) Service Points ENGINE HARNESS #2 Follow the “Step” order for removal. REPLACEMENT (ea.) Battery Leads Engine harness #2 to Hatch Access: Engine compartment switch harness connector Remote control assembly Refer to “REMOTE CONTROL SYSTEM” in Chapter 8 Neutral switch connector Engine harness #2 to main...
  • Page 189 ELEC ELECTRICAL SYSTEM DECK HARNESS...
  • Page 190 ELEC ELECTRICAL SYSTEM Step Procedure / Part Name Service Points DECK HARNESS REPLACEMENT Follow the “Step” order for removal. Battery leads Oil sending unit lead Stern light socket Disconnect leads Seat base board Refer to “SEAT FITTINGS” in Chapter 8 Fuel sending unit lead Horn leads Access: Helm pod...
  • Page 191 ELEC ELECTRICAL SYSTEM STEREO HARNESS...
  • Page 192 ELEC ELECTRICAL SYSTEM Step Procedure / Part Name Service Points STEREO HARNESS #5 Follow the “Step” order for removal. REPLACEMENT Battery leads Speaker Remote control assembly Refer to “REMOTE CONTROL SYSTEM” in Chapter 8 Stereo remote keypad connectors Stereo harness #5 to harness lead #3 connector Stereo harness #5 to meter panel For accessory outlet (Pu/R and B)
  • Page 193 ELEC ELECTRICAL SYSTEM METER PANEL BACK VIEW WIRING DIAGRAM 1 Starboard Tach 6 Nav Lights Switch 2 Speedometer 7 Courtesy Light Switch 3 Port Tach 8 Radio Switch 4 Fuel Gauge 9 Bilge Switch 5 Horn Switch Blower Switch...
  • Page 194 ELEC ELECTRICAL SYSTEM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Qty (ea.) Service Points METER PANEL DISASSEMBLY Follow the “Step” order for removal. Disconnect Wiring Set Screw Choke Knob Choke Cable Main Switch Nut w/ washer) Meter Panel Ass’y Nut (w/ flat and lock washer) Tachometer Speedometer...
  • Page 195 ELEC ELECTRICAL SYSTEM SWITCH AND COMPONENT WIRING DIAGRAM 1 Circuit Breaker 8 Radio 2 Stereo Switch 9 Courtesy Light 3 Courtesy Light Switch Blower Motor 4 Blower Switch Bilge Pump 5 Bilge Pump Switch Horn 6 Horn Switch Stern Light 7 Navigation Light Switch Bow Light...
  • Page 196 ELEC ELECTRICAL SYSTEM Step Procedure / Part Name Qty (ea.) Service Points STEREO Follow the “Step” order for removal. Faceplate Trim Push down gently at the outer edges to release the lower tabs, then lift to remove Stereo harness #6 connector Stereo remote connector Antenna connector Screw, machine...
  • Page 197 ELEC ELECTRICAL SYSTEM STEREO TROUBLESHOOTING Stereo does not come on. Check: Fuses and breakers Out of specification ➔ Replace 2. Measure voltage to stereo Out of specification ➔ Check switch and wiring Disconnect Remote Keypad and retest Replace stereo Stereo Voltage Red (R) ~ Black (B) Yellow (Y) ~ Black (B) 12VDC...
  • Page 198 ELEC ELECTRICAL SYSTEM STEREO REMOTE CONTROL Check: Fuse 1 2. Measure: Voltage to remote Out of specification ➔ Inspect harness. Remote Control Input Voltage Red(R) ~ Black (B) 12V DC 3. Measure: Voltage from remote (button depressed) Out of specification ➔ Replace stereo remote control.
  • Page 199 HULL HULL AND DECK DECK BIMINI TOP...

  • Page 200: Hull And Deck

    HULL HULL AND DECK DECK REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Qty (ea.) Service Points BIMINI TOP Follow the “Step” order for removal. Place in the stored position Refer to Owners Manual Mounting pins Bimini top assembly Pivot screw Bimini canvas Rivet...
  • Page 201 HULL HULL AND DECK DECK REMOTE CONTROL SYSTEM EXPLODED DIAGRAM...
  • Page 202 HULL HULL AND DECKx DECK REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Service Points REMOTE CONTROL UNIT Follow the “Step” order for removal. REMOVAL Screw, Oval Head Plate, Remote Control Washer Screw, Flat Head Clevis Pin Screw, Plate Plate, Retaining Remote Control Assembly Screw...
  • Page 203 HULL HULL AND DECK DECK HATCH FITTINGS EXPLODED DIAGRAM...
  • Page 204 HULL HULL AND DECKx DECK REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Service Points SKI LOCKER HATCH Follow the “Step” order for removal. DISASSEMBLY Screw, Tapping Ski Locker Hatch Hinge Screw, Pan Head Latch Screw, Tapping Latch Plate CLEAN-OUT HATCH DISASSEMBLY Screw, Tapping...
  • Page 205 HULL HULL AND DECK DECK HELM POD ASSEMBLY EXPLODED DIAGRAM...
  • Page 206 HULL HULL AND DECKx DECK REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Service Points HELM POD DISASSEMBLY Follow the “Step” order for removal. Locker, Console Seal, Locker Rivet (w/ washer) Fire Extinguisher Case (w/cap) Screw Latch Seal, Windshield Windshield Screw (w/ washer and nut) Hinge...
  • Page 207 2001 LST1200Z Supplementary Service Manual...
  • Page 208 LST1200Z Supplementary Service Manual © 2000 Yamaha Motor Corporation, U.S.A. 1st Edition, October 2000 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, including photocopying and recording, without the written permission of the copyright holder.
  • Page 209 PREFACE This Supplementary Service Manual has been prepared to introduce new service and data for the LST1200Z. For complete service information, it is necessary to use this Supplementary Service Manual together with the following manual: LST1200X SERVICE MANUAL: LIT-18616-02-06 LST1200Y SUPPLEMENTARY SERVICE MANUAL LIT-18616-02-23 For what is not mentioned in this manual, please refer to the descriptions for LST1200 in the above Service Manual.
  • Page 210 TABLE OF CONTENTS GENERAL INFORMATION SYMBOLS ..............1 IDENTIFICATION NUMBERS .
  • Page 211 Apply Gasket Maker® Apply Yamabond #4 (Yamaha bond No. 4) Apply LOCTITE® No. 271 (Red LOCTITE) Apply LOCTITE® No. 242 (Blue LOCTITE) Apply LOCTITE® No. 567 (PST)
  • Page 212 GENERAL INFORMATION INFO A60700-0* IDENTIFICATION NUMBERS PRIMARY I.D. NUMBER The Primary I.D. number is stamped on a label attached to the deck under the rear seat. LST1200Z Starting Primary I.D. Number: F0R 700101~ ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the crankcase.
  • Page 213 SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Code LST1200 Hull Engine Dimensions: Length 19’6” (5.9 m) Width 8’ (2.4 m) Draft 18” (.5 m) Dry weight 2100 lb. (955 kg) Performance: Maximum output (each engine) 135hp @ 6750 Maximum fuel consumption (W.O.T.) 28.0 gal/hr (106 L/hr) @ 6750rpm Cruising range...
  • Page 214 SPEC MAINTENANCE SPECIFICATIONSx MAINTENANCE SPECIFICATIONS ENGINE Item Unit LST1200 Cylinder Head: Warpage limit in (mm) 0.004” (0.1mm) Compression pressure kg/cm (KPa) — Cylinder: Bore size in (mm) 3.307 ~ 3.308” (84.00 ~ 84.02mm) Taper limit in (mm) 0.003” (0.08mm) Out of round limit in (mm) 0.002”...
  • Page 215 SPEC GENERAL SPECIFICATIONS ENGINE Item Unit LST1200 Crankshaft Assembly: Crank width “A” in (mm) 2.439 ~ 2.441” (61.95 ~ 62.00mm) Deflection limit “B” in (mm) 0.002” (0.05mm) Big end side clearance “C” in (mm) 0.010 ~ 0.030” (0.25 ~ 0.75mm) Maximum small end in (mm) 0.08”...
  • Page 216 SPEC MAINTENANCE SPECIFICATIONSx HULL AND HOOD Item Unit LST1200 Free Play: Throttle lever free play in (mm) 0.16 ~ 0.28” (4 ~ 7mm) Choke cable free play in (mm) 0.04 ~ 0.24” (1 ~ 6mm) ELECTRICAL Item Unit LST1200 Battery: Type Marine group 24 dual purpose 675cca...
  • Page 217 SPEC GENERAL SPECIFICATIONS Item Unit LST1200 Lighting Coil: Test points Color code Ω Resistance 0.56 ~ 0.84 Peak voltage (open cranking) 5.5 (min) Peak voltage (closed cranking) 5.5 (min) Peak voltage (2000 RPM) 20 (min) Peak voltage (3500 RPM) 25 (min) Charging current A/rpm 6 ~ 8/5, 500...
  • Page 218 INSP PERIODIC INSPECTION AND ADJUSTMENT 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 may need to be adjusted. Initial Every Page 10 Hours 50 Hours 100 Hours 200 Hours...
  • Page 219 FUEL FUEL SYSTEM FUEL AND OIL SYSTEM EXPLODED DIAGRAM FUEL LINE AND OIL SYSTEM 7. Port Oil Pump 1. Fuel Tank 8. Starboard Oil Pump 2. Port Fuel Valve 9. Port Oil Filter 3. Starboard Fuel Valve 10. Starboard Oil Filter 4.
  • Page 220 FUEL FUEL SYSTEM FUEL TANK EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Service Points Follow the “Step” order for removal. FUEL TANK REMOVAL Fuel Remove the fuel in the tank. Rear Seat Base Assembly Refer to “SEAT FITTINGS” in Chapter 8. Hose Band Fuel Filler Hose Hose Band...
  • Page 221 FUEL FUEL SYSTEM FUEL SYSTEM EXPLODED DIAGRAM...
  • Page 222 FUEL FUEL SYSTEM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Service Points Follow the “Step” order for removal. FUEL SYSTEM DISASSEMBLY Hose Fitting Fuel Valve Insert, Fuel Tank Gasket Fuel Level Sensor Remove wire connector counterclockwise Pad, Fuel Tank Follow the “Step”...
  • Page 223 JET PUMP PUMP JET PUMP CLEAN-OUT PORTS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Service Points Follow the “Step” order for removal. JET PUMP CLEAN-OUT PORTS REMOVAL NOTE: Follow cap installation instructions in “JET PUMP UNIT INSPECTION,” Chptr. 3 Screw Clean-out Tray NOTE:...
  • Page 224 PUMP JET PUMP CLEANOUT HATCH SWITCH INSPECTION/REINSTALLATION 1/2” (12.5mm) 1. Open the cleanout hatch and remove the black inspection plug below the switches. 2. Measure the set height of the switch and adjust to 1/2” (12.7mm), if necessary. 3. After the switch height is set, reach through the inspection hole and pull a few inches of the slack in the switch wiring out through the hole.
  • Page 225 ELEC ELECTRICAL SYSTEM STEREO HARNESS...
  • Page 226 ELEC ELECTRICAL SYSTEM Step Procedure / Part Name Service Points STEREO HARNESS #5 Follow the “Step” order for removal. REPLACEMENT Battery leads Speaker Remote control assembly Refer to “REMOTE CONTROL SYSTEM” in Chapter 8 Stereo remote keypad connectors Stereo harness #5 to harness lead #3 connector Stereo harness #5 to meter panel For accessory outlet (Pu/R and B)
  • Page 227 ELEC ELECTRICAL SYSTEM METER PANEL BACK VIEW WIRING DIAGRAM 1 Starboard Tach 6 Nav Lights Switch 2 Speedometer 7 Courtesy Light Switch 3 Port Tach 8 Radio Switch 4 Fuel Gauge 9 Bilge Switch 5 Horn Switch Blower Switch Indicator Panel...
  • Page 228 ELEC ELECTRICAL SYSTEM METER PANEL BACK VIEW EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Qty (ea.) Service Points METER PANEL DISASSEMBLY Follow the “Step” order for removal. Disconnect Wiring Set Screw Apply Loctite #242 Choke Knob Choke Cable Main Switch Nut w/ washer)
  • Page 229 ELEC ELECTRICAL SYSTEM INDICATOR PANEL WIRING DIAGRAM 1 9 Pin Plug Connector 2 Indicator Panel 3 Warning Buzzer...
  • Page 230 ELEC ELECTRICAL SYSTEM INDICATOR PANEL 1. Check: Bulbs and buzzer function. Turn the port key switch to the ON position. The port engine overheat, low fuel, power on and low oil lights should glow and you will hear 3 beeps from the warning buzzer. The warning lights will go out after a few seconds and the power on light will contin- ue to glow dimly.
  • Page 231 ELEC ELECTRICAL SYSTEM LOW OIL WARNING 1. Check: Disconnect the 9-pin indicator connec- tor behind the instrument panel and test according to the table below. Bulb glows after 1 to 2 minutes and buzzer beeps 5 times. Not working Repair wiring or replace indicator assembly as needed.
  • Page 232 ELEC ELECTRICAL SYSTEM OIL SWITCH 1. Check: Continuity Out of specification Replace. Oil Switch Continuity: Leads Position Purple Yellow Bottom O——————O FUEL GAUGE 1. Check: Indication Out of specification Replace. Fuel Meter Indication: Leads Indication Pink Black “F” O—————O “E” NOTE: The meter should be battery powered for this inspection.
  • Page 233 TRBL TROUBLE ANALYSIS ANLS TROUBLE ANALYSIS NOTE: Verify the following before “trouble analysis”: 1. Battery is charged and its specific gravity is in specification. 2. All wire connections are correct. 3. Wiring connections are securely made and without any corrosion. 4.
  • Page 234 TRBL TROUBLE ANALYSIS ANLS Trouble Mode Trouble modeI Items to be checked Relative part Reference Chapter POWER UNIT (cont.) Pilot water hose Water hose Water passage JET PUMP UNIT Duct Impeller Intake screen Bearing Duct intake Water inlet hose Bilge hose Bilge strainer Bilge hose joint ELECTRICAL...
  • Page 235 © 2000 YAMAHA MOTOR CORPORATION, USA LIT-18616-02-29...
  • Page 236 2002 LST1200A (A-A) Supplementary Service Manual...
  • Page 237 LST1200A (A-A) Supplementary Service Manual © 2001 Yamaha Motor Corporation, U.S.A. 1st Edition, October 2001 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, including photocopying and recording, without the written permission of the copyright holder.
  • Page 238 PREFACE This Supplementary Service Manual has been prepared to introduce new service and data for the LST1200Z. For complete service information, it is necessary to use this Supplementary Service Manual together with the following manual: LST1200X SERVICE MANUAL: LIT-18616-02-06 LST1200Y SUPPLEMENTARY SERVICE MANUAL LIT-18616-02-23 LST1200Z SUPPLEMENTARY SERVICE MANUAL LIT-18616-02-29 For what is not mentioned in this manual, please refer to the descriptions for LST1200 in the above Service Manual.
  • Page 239 TABLE OF CONTENTS GENERAL INFORMATION SYMBOLS ..............1 IDENTIFICATION NUMBERS .
  • Page 240 Apply Gasket Maker® Apply Yamabond #4 (Yamaha bond No. 4) Apply LOCTITE® No. 271 (Red LOCTITE) Apply LOCTITE® No. 242 (Blue LOCTITE) Apply LOCTITE® No. 567 (PST)
  • Page 241 GENERAL INFORMATION INFO A60700-0* IDENTIFICATION NUMBERS PRIMARY I.D. NUMBER The Primary I.D. number is stamped on a label attached to the deck under the rear seat. LST1200A (LS2000) Starting Primary I.D. Number: F0R 750101~ LST1200A-A (LX2000) Starting Primary I.D. Number: F0R 703001~ ENGINE SERIAL NUMBER The engine serial number is stamped on a label...
  • Page 242 SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Code LST1200 Hull Engine Dimensions: Height 52” (1.32 m) Length 19’6” (5.9 m) Width 8’ (2.4 m) Draft 18” (.5 m) Dry weight 2100 lb. (955 kg) Performance: Maximum output (each engine) 135hp @ 6750 Maximum fuel consumption (W.O.T.) 28.0 gal/hr (106 L/hr) @ 6750rpm...
  • Page 243 SPEC MAINTENANCE SPECIFICATIONSx MAINTENANCE SPECIFICATIONS ENGINE Item Unit LST1200 Cylinder Head: Warpage limit in (mm) 0.004” (0.1mm) Compression pressure kg/cm (KPa) — Cylinder: Bore size in (mm) 3.307 ~ 3.308” (84.00 ~ 84.02mm) Taper limit in (mm) 0.003” (0.08mm) Out of round limit in (mm) 0.002”...
  • Page 244 SPEC GENERAL SPECIFICATIONS ENGINE Item Unit LST1200 Crankshaft Assembly: Crank width “A” in (mm) 2.439 ~ 2.441” (61.95 ~ 62.00mm) Deflection limit “B” in (mm) 0.002” (0.05mm) Big end side clearance “C” in (mm) 0.010 ~ 0.030” (0.25 ~ 0.75mm) Maximum small end in (mm) 0.08”...
  • Page 245 SPEC MAINTENANCE SPECIFICATIONSx HULL AND HOOD Item Unit LST1200 Free Play: Throttle lever free play in (mm) 0.16 ~ 0.28” (4 ~ 7mm) Choke cable free play in (mm) 0.04 ~ 0.24” (1 ~ 6mm) ELECTRICAL Item Unit LST1200 Battery: Type Marine group 24 Dual Purpose 675CCA...
  • Page 246 SPEC GENERAL SPECIFICATIONS Item Unit LST1200 Lighting Coil: Test points Color code Ω Resistance 0.56 ~ 0.84 Peak voltage (open cranking) 5.5 (min) Peak voltage (closed cranking) 5.5 (min) Peak voltage (2000 RPM) 20 (min) Peak voltage (3500 RPM) 25 (min) Charging current A/rpm 6 ~ 8/5, 500...
  • Page 247 INSP PERIODIC INSPECTION AND ADJUSTMENT 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 may need to be adjusted. Initial Every Page 10 Hours 50 Hours 100 Hours 200 Hours...
  • Page 248 ELEC ELECTRICAL SYSTEM STEREO HARNESS...
  • Page 249 ELEC ELECTRICAL SYSTEM Step Procedure / Part Name Service Points STEREO HARNESS #5 Follow the “Step” order for removal. REPLACEMENT Battery leads Stereo harness #5 to harness leads Stereo harness #5 to accessory Access: Passenger pod outlet leads Stereo harness #5 to stereo For accessory outlet (Pur/Red and B) harness #6 connectors Stereo harness #5...
  • Page 250 ELEC ELECTRICAL SYSTEM METER PANEL BACK VIEW WIRING DIAGRAM 1 Starboard Tach 6 Nav Lights Switch 2 Speedometer 7 Courtesy Light Switch 3 Port Tach 8 Radio Switch 4 Fuel Gauge 9 Bilge Switch 5 Horn Switch Blower Switch Indicator Panel...
  • Page 251 ELEC ELECTRICAL SYSTEM METER PANEL BACK VIEW EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Qty (ea.) Service Points METER PANEL DISASSEMBLY Follow the “Step” order for removal. Disconnect Wiring Set Screw Apply Loctite #242 Choke Knob Choke Cable Main Switch Nut w/ washer)
  • Page 252 ELEC ELECTRICAL SYSTEM OIL SWITCH 1. Check: ● Continuity Out of specification ➔ Replace. Oil Switch Continuity: Leads Position Tan/Black Black Bottom O——————O FUEL GAUGE 1. Check: ● Indication Out of specification ➔ Replace. Fuel Meter Indication: Leads Indication Pink Black “F”...
  • Page 253 ELEC TROUBLE ANALYSIS TROUBLE ANALYSIS NOTE: Verify the following before “trouble analysis”: 1. Battery is charged and its specific gravity is in specification. 2. All wire connections are correct. 3. Wiring connections are securely made and without any corrosion. 4. Lanyard is installed on the engine stop switch. 5.
  • Page 254 TRBL TROUBLE ANALYSIS ANLS Trouble Mode Trouble modeI Items to be checked Relative part Reference Chapter POWER UNIT (cont.) Pilot water hose Water hose Water passage JET PUMP UNIT Duct Impeller Intake screen Bearing Duct intake Water inlet hose Bilge hose Bilge strainer Bilge hose joint ELECTRICAL...
  • Page 255 © 2001 YAMAHA MOTOR CORPORATION, USA LIT-18616-02-41...
  • Page 256 LS2000/LX210/AR210 LS2000/LX210/AR210 2003 LST1200-B (A-B, B-B, and D-B) Supplementary Service Manual...
  • Page 257 LST1200-B (A-B, B-B and D-B) Supplementary Service Manual © 2003 Yamaha Motor Corporation, U.S.A. 1st Edition, January 2003 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, including photocopying and recording, without the written permission of the copyright holder.
  • Page 258 PREFACE This Supplementary Service Manual has been prepared to introduce new service and data for the 2003 LST1200 models. For complete service information, it is necessary to use this Supplementary Service Manual together with the following manual: LST1200X SERVICE MANUAL: LIT-18616-02-06 LST1200Y SUPPLEMENTARY SERVICE MANUAL LIT-18616-02-23 LST1200Z SUPPLEMENTARY SERVICE MANUAL LIT-18616-02-29 LST1200A (A-A) SUPPLEMENTARY SERVICE MANUAL LIT-18616-02-41...
  • Page 259 TABLE OF CONTENTS GENERAL INFORMATION SYMBOLS ..............1 IDENTIFICATION NUMBERS .
  • Page 260 Apply Gasket Maker® Apply Yamabond #4 (Yamaha bond No. 4) Apply LOCTITE® No. 271 (Red LOCTITE) Apply LOCTITE® No. 242 (Blue LOCTITE) Apply LOCTITE® No. 567 (PST)
  • Page 261 GENERAL INFORMATION INFO A60700-0* IDENTIFICATION NUMBERS PRIMARY I.D. NUMBER The Primary I.D. number is stamped on a label attached to the deck in the engine compart- ment. LST1200-B (LS2000) Starting Primary I.D. Number: F0R 750101~ LST1200A/B-B (LX210) Starting Primary I.D. Number: F0R 703001~ LST1200D-B (AR210) Starting Primary I.D.
  • Page 262 SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Code LST1200 Hull Engine Dimensions: Height* 54.5” (1.38 m) LS/LX, 101.5” (2.58 m) AR Length 19’6” (5.9 m) Width 8’ (2.4 m) Draft 18” (.5 m) Dry weight 2100 lb. (955 kg) Performance: Maximum output (each engine) 135hp @ 6750 Maximum fuel consumption (W.O.T.) 28.0 gal/hr...
  • Page 263 SPEC MAINTENANCE SPECIFICATIONSx MAINTENANCE SPECIFICATIONS ENGINE Item Unit LST1200 Cylinder Head: Warpage limit in (mm) 0.004” (0.1mm) Compression pressure kg/cm (KPa) — Cylinder: Bore size in (mm) 3.307 ~ 3.308” (84.00 ~ 84.02mm) Taper limit in (mm) 0.003” (0.08mm) Out of round limit in (mm) 0.002”...
  • Page 264 SPEC GENERAL SPECIFICATIONS ENGINE Item Unit LST1200 Crankshaft Assembly: Crank width “A” in (mm) 2.439 ~ 2.441” (61.95 ~ 62.00mm) Deflection limit “B” in (mm) 0.002” (0.05mm) Big end side clearance “C” in (mm) 0.010 ~ 0.030” (0.25 ~ 0.75mm) Maximum small end in (mm) 0.08”...
  • Page 265 SPEC MAINTENANCE SPECIFICATIONSx HULL AND HOOD Item Unit LST1200 Free Play: Throttle lever free play in (mm) 0.16 ~ 0.28” (4 ~ 7mm) Choke cable free play in (mm) 0.04 ~ 0.24” (1 ~ 6mm) ELECTRICAL Item Unit LST1200 Battery: Type Marine group 24 Dual Purpose 675CCA...
  • Page 266 SPEC GENERAL SPECIFICATIONS Item Unit LST1200 Lighting Coil: Test points Color code Ω Resistance 0.56 ~ 0.84 Peak voltage (open cranking) 5.5 (min) Peak voltage (closed cranking) 5.5 (min) Peak voltage (2000 RPM) 20 (min) Peak voltage (3500 RPM) 25 (min) Charging current A/rpm 6 ~ 8/5, 500...
  • Page 267 INSP PERIODIC INSPECTION AND ADJUSTMENT 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 may need to be adjusted. Initial Every Page 10 Hours 50 Hours 100 Hours 200 Hours...
  • Page 268 ELEC ELECTRICAL SYSTEM STEREO HARNESS...
  • Page 269 ELEC ELECTRICAL SYSTEM Step Procedure / Part Name Service Points STEREO HARNESS #5 Follow the “Step” order for removal. REPLACEMENT Battery leads Stereo harness #5 to harness Access: Passenger pod leads Stereo harness #5 to accessory For accessory outlet (Pur/Red and B) outlet leads Stereo harness #5 Reverse the removal steps for installation.
  • Page 270 ELEC ELECTRICAL SYSTEM METER PANEL BACK VIEW – (LS2000/LX210 MODELS) WIRING DIAGRAM 1 Starboard Tach 6 Nav Lights Switch 2 Speedometer 7 Courtesy Light Switch 3 Port Tach 8 Radio Switch 4 Fuel Gauge 9 Bilge Switch 5 Horn Switch Blower Switch Indicator Panel...
  • Page 271 ELEC ELECTRICAL SYSTEM METER PANEL BACK VIEW - AR10 Model WIRING DIAGRAM 1 Starboard Tach 6 Nav Lights Switch 2 Speedometer 7 Courtesy Light Switch 3 Port Tach 8 Radio Switch 4 Fuel Gauge 9 Bilge Switch 5 Horn Switch Blower Switch Indicator Panel...
  • Page 272 HULL HULL AND DECK DECK SWIMSTEP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Qty (ea.) Service Points SWIMSTEP REMOVAL Follow the “Step” order for removal. Nut 5/16”-18 Nylon Lock Washer 5/16” Flat Screw 5/16”-18 x 2-1/4” Ladder, Transom Platform BRACKET REMOVAL...
  • Page 273 HULL HULL AND DECK DECK WAKEBOARD TOWER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Qty (ea.) Service Points UPPER TOWER DISASSEMBLY Follow the “Step” order for removal. Bolt Support tower or use an assistant to prevent damage to aluminum tubing. Upper Tower Assembly SUPPORT ASSEMBLIES Nut 5/8”-11 Nylon Lock...
  • Page 274 TRBL TROUBLE ANALYSIS ANLS TROUBLE ANALYSIS NOTE: Verify the following before “trouble analysis”: 1. Battery is charged and its specific gravity is in specification. 2. All wire connections are correct. 3. Wiring connections are securely made and without any corrosion. 4.
  • Page 275 TRBL TROUBLE ANALYSIS ANLS Trouble Mode Trouble modeI Items to be checked Relative part Reference Chapter POWER UNIT (cont.) Pilot water hose Water hose Water passage JET PUMP UNIT Duct Impeller Intake screen Bearing Duct intake Water inlet hose Bilge hose Bilge strainer Bilge hose joint ELECTRICAL...

  • Page 276: Wiring Diagram

    WIRING DIAGRAM BATTERY RED/BLACK RED/BLACK KEY SWITCH CLEANOUT ENGINE SHUT-OFF SWITCH ASSEMBLY (RIGHT) HATCH SWITCH (RIGHT) BLK WHT BLK WHT WHT BLK RED YEL SHIFTER (RIGHT) BRN BRN BLK WHT FREE (OFF) PULL PUSH (ON) START RF SPEAKER 4 OHM GRY/WHT ENGINE LF SPEAKER...
  • Page 277 © 2003 YAMAHA MOTOR CORPORATION, USA LIT-18616-03-41...

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