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Yamaha WaveRunner Service Manual

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Table of Contents
WaveRunner
FX High Output
FX Cruiser High Output
SERVICE MANUAL
*LIT186160283*
Lit-18616-02-83

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  Summary of Contents for Yamaha WaveRunner

  • Page 1 WaveRunner FX High Output FX Cruiser High Output SERVICE MANUAL *LIT186160283* LIT-18616-02-83 F1S-28197-1G-11...
  • Page 2: Lit-18616

    NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
  • Page 3 HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
  • Page 4 IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, passenger(s), a bystander, or a person inspecting or repairing the watercraft.
  • Page 5 HOW TO USE THIS MANUAL 1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 2 Numbers are given in the order of the jobs in the exploded diagram. 3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
  • Page 6: Current:

    Symbols F to H in an exploded diagram indi- cate the grade of lubricant and the lubrication point. F Apply Yamaha 4-stroke motor oil G Apply water resistant grease (Yamaha grease A, Yamaha marine grease) H Apply molybdenum disulfide grease...
  • Page 7 INDEX A30000-0 GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND ADJUSTMENT INSP FUEL SYSTEM FUEL POWER UNIT POWR JET PUMP UNIT PUMP – ELECTRICAL SYSTEM ELEC HULL AND HOOD HULL HOOD TROUBLE ANALYSIS TRBL ANLS...
  • Page 8: Table Of Contents

    INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION NUMBERS ................. 1-1 PRIMARY l.D. NUMBER ................1-1 ENGINE SERIAL NUMBER ..............1-1 JET PUMP UNIT SERIAL NUMBER ............1-1 HULL IDENTIFICATION NUMBER (H.l.N.)..........1-1 SAFETY WHILE WORKING..............1-2 FIRE PREVENTION .................. 1-2 VENTILATION ................... 1-2 SELF-PROTECTION.................
  • Page 9: Primary L.d. Number

    IDENTIFICATION NUMBERS INFO A60700-0* IDENTIFICATION NUMBERS PRIMARY l.D. NUMBER The primary l.D. number is stamped on a label attached to the inside of the engine compart- ment. Starting primary l.D. number: F1S: 800101 ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the engine unit.
  • Page 10: Safety While Working

    Protect your hands and feet by wearing protec- tive gloves or safety shoes when necessary. PARTS, LUBRICANTS, AND SEALANTS Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the watercraft.
  • Page 11: Good Working Practices

    SAFETY WHILE WORKING INFO Under normal conditions, the lubricants men- tioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants. 1. Maintain good standards of personal and industrial hygiene.
  • Page 12: Disassembly And Assembly

    SAFETY WHILE WORKING INFO 3. Non-reusable parts Always use new gaskets, seals, O-rings, oil seals, cotter pins, circlips, etc., when installing or assembling parts. DISASSEMBLY AND ASSEMBLY 1. Use compressed air to remove dust and dirt during disassembly. 2. Apply engine oil to the contact surfaces of moving parts during assembly.
  • Page 13: Special Tools

    SPECIAL TOOLS INFO SPECIAL TOOLS Using the correct special tools recommended by Yamaha, will aid the work and enable accu- rate assembly and tune-up. Improvisations and using improper tools can damage the equipment. NOTE: • For U.S.A. and Canada, use part numbers starting with “J-”, “YB-”, “YM-”, “YS-”, “YU-”...
  • Page 14: Table Of Contents

    SPECIAL TOOLS INFO B Fuel pressure gauge P/N. YB-06766 YB-06766 90890-06786 90890-06786 C Compression gauge extension P/N. 90890-06582 D Cylinder gauge set P/N. YU-03017 90890-06759 90890-06582 YU-03017 E Compression gauge 90890-06759 P/N. YU-33223-1 90890-03160 F Peak volt meter adapter P/N. YU-39991 G Peak voltage adapter B P/N.
  • Page 15: Removal And Installation

    Current: YB-06777 Test harness HM090-3 (3 pins) P/N. New: 90890-06877 Current: 90890-06777 O Lower unit pressure/vacuum tester P/N. YB-35956-A Vacuum/pressure pump gauge set P/N. 90890-06756 P Yamaha diagnostic system 60V-85300-02 P/N. 60V-85300-02 Q Yamaha diagnostic system P/N. 60V-WS853-02 60V-WS853-02 YAMAHA DIAGNOSTIC...
  • Page 16 SPECIAL TOOLS INFO 5 Universal magneto and rotor holder YU-01235 YB-06111 P/N. YU-01235 90890-01235 Rotor holder P/N. 90890-01235 6 Bearing housing needle bearing installer (reduction drive gear) P/N. YB-06111 7 Ball bearing attachment (reduction drive gear) P/N. 90890-06631 8 Forward gear bearing cup installer 90890-06631 YB-06726-B (reduction drive gear)
  • Page 17 SPECIAL TOOLS INFO E Valve seat cutter Intake 90890-06813 (60°) 90890-06315 (60°) 90890-06814 (45°) 90890-06312 (45°) P/N. 90890-06813 (60°) 90890-06815 (30°) 90890-06328 (30°) 90890-06814 (45°) 90890-06815 (30°) Exhaust P/N. 90890-06315 (60°) 90890-06312 (45°) 90890-06328 (30°) 90890-06811 (ø4.0 mm) YM-91043-C F Valve seat cutter holder 90890-06812 (ø4.5 mm) P/N.
  • Page 18 SPECIAL TOOLS INFO O Bearing housing needle bearing remover (jet pump bearing) YB-06112 90890-06614 YB-06196 90890-06653 P/N. YB-06112 Drive shaft needle bearing installer and remover (jet pump oil seal) P/N. YB-06196 P Needle bearing attachment YB-06085 90890-06631 (jet pump bearing, oil seal, and reduction drive gear) P/N.
  • Page 19 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ............... 2-1 MAINTENANCE SPECIFICATIONS ............... 2-3 ENGINE ....................2-3 JET PUMP UNIT ..................2-6 HULL AND HOOD ..................2-6 ELECTRICAL .................... 2-7 TIGHTENING TORQUES ................2-9 SPECIFIED TORQUES................2-9 GENERAL TORQUE ................2-17 CABLE AND HOSE ROUTING ..............2-18...
  • Page 20 SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Item Unit FX High Output FX Cruiser High Output Model code Hull Engine/jet Dimensions Length mm (in) 3,340 (131.5) Width mm (in) 1,230 (48.4) Height mm (in) 1,160 (45.7) Dry weight kg (lb) 350 (772) Maximum capacity Person/kg (lb) 3/240 (530)
  • Page 21 SPEC GENERAL SPECIFICATIONS Model Item Unit FX High Output FX Cruiser High Output Fuel and oil Fuel type Regular unleaded gasoline Minimum fuel rating PON* RON* Fuel tank capacity 70 (18.5, 15.4) (US gal, Imp gal) Engine oil type 4-stroke motor oil Engine oil grade SE, SF, SG, SH, SJ, SL 10W-30...
  • Page 22 SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model Item Unit FX High Output FX Cruiser High Output Cylinder head Warpage limit mm (in) 0.1 (0.004) Compression pressure 1,150 (11.5, 164) (kgf/cm , psi) Cylinder Bore size mm (in) 76.000–76.015 (2.9921–2.9927) Taper limit mm (in) 0.08 (0.003) Out-of-round limit...
  • Page 23 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX High Output FX Cruiser High Output Valve seat width C Intake mm (in) 0.9–1.1 (0.0354–0.0433) Exhaust mm (in) 0.9–1.1 (0.0354–0.0433) Valve margin thickness D Intake mm (in) 0.5–0.9 (0.0197–0.0354) Exhaust mm (in) 0.5–0.9 (0.0197–0.0354) Valve stem diameter Intake mm (in)
  • Page 24 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX High Output FX Cruiser High Output Piston ring Top ring Type Barrel Dimension (B × T) 0.90 × 2.75 (0.04 × 0.11) mm (in) End gap (installed) mm (in) 0.32–0.44 (0.0126–0.0173) Ring groove clearance mm (in) 0.030–0.065 (0.0012–0.0026) 2nd ring...
  • Page 25 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX High Output FX Cruiser High Output Oil filter Oil filter type Cartridge type Oil pump Oil pump type Trochoid Rotor tip clearance mm (in) 0.09–0.15 (0.0035–0.0059) (scavenge pump) Oil pump housing clearance Rotor (feed pump) mm (in) 0.09–0.17 (0.0035–0.0067) Rotor (scavenge pump)
  • Page 26 SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model Item Unit FX High Output FX Cruiser High Output Battery Type Fluid Capacity V/Ah 12/19 Specific gravity 1.28 ECM unit (B/R – R/Y, B/W – R/Y, B/Y – R/Y, B/L – R/Y) Output peak voltage lower limit @cranking (loaded) @2,000 r/min (loaded) @3,500 r/min (loaded)
  • Page 27 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX High Output FX Cruiser High Output Starter relay Rating Seconds Thermoswitch ON temperature (engine) °C (°F) 84–90 (183–194) OFF temperature (engine) °C (°F) 70–84 (158–183) ON temperature (exhaust) °C (°F) 94–100 (201–212) OFF temperature (exhaust) °C (°F) 80–94 (176–201) Engine temperature sensor...
  • Page 28 SPEC TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Fuel system 0.32 Retainer/fuel pump module — – fuel tank 0.64 Fuel filler neck/rubber seal – deck — 0.59 Fuel tank belt/fuel tank –...
  • Page 29 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Engine Engine unit – engine mount Bolt Oil filter — — Coupling cover – intermediate Bolt 0.78 housing Thermoswitch (exhaust) – Bolt 0.76 exhaust pipe 3 Outer exhaust joint clamp –...
  • Page 30 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Oil tank – oil tank stay — Oil tank stay – cylinder Bolt head Band/collar – oil tank Bolt 0.76 0.37 Bracket (coupling cover) – Bolt oil tank 0.76...
  • Page 31 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb — Generator cover – crankcase Bolt Rotor – crankshaft Bolt Rotor – starter clutch Bolt Washer/pickup coil lead and Bolt 0.49 lighting coil lead – generator cover Pickup coil –...
  • Page 32 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Thermoswitch (engine) – Bolt 0.76 crankcase Oil pressure switch — — 0.84 Anode cover – anode Bolt Anode cover – upper crankcase Bolt Oil pan –...
  • Page 33 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb QSTS cable ball joint – nozzle ring — 0.78 Nozzle/impeller duct assembly – Bolt impeller housing 1 Water inlet cover/water inlet Bolt 0.66 strainer –...
  • Page 34 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb QSTS cable end pin – — 0.38 QSTS converter Shift cable locknut — 0.29 (reverse gate side) Shift cable grommet – hull — 0.59 Shift cable holder –...
  • Page 35 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Hand grip – deck — 0.52 Front seat stay – deck — Seat lock projection – deck beam — Seat lock projection – deck —...
  • Page 36 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Tapping Bracket (coupler) – electrical box ø6 0.39 screw Slant detection switch – electrical Tapping ø6 0.39 screw Main and fuel pump relay – Tapping ø6 0.39...
  • Page 37 SPEC CABLE AND HOSE ROUTING CABLE AND HOSE ROUTING DOWN DOWN 1 Steering switch lead A Negative battery lead 2 Fuel tank breather hose B Positive battery lead 3 QSTS cable C Battery 4 Steering cable D Throttle cable 5 Shift cable E Fuel hose 6 Speed sensor lead F Handlebar switch lead...
  • Page 38 SPEC CABLE AND HOSE ROUTING MAIN S P A R E 1 Steering switch lead A Fuel hose J Remote control unit lead 2 Throttle cable B Shift cable K Remote control unit antenna 3 Handlebar switch lead C Steering cable 4 QSTS cable D Electrical box lead 5 Buzzer lead...
  • Page 39 SPEC CABLE AND HOSE ROUTING È 1 Cooling water hose (cooling water inlet) A QSTS cable 2 Bilge hose 1 B Positive battery lead 3 Electric bilge pump C Speed sensor lead 4 Bilge hose 4 D Electric bilge pump lead 5 Cooling water hose (from thermostat) E Bilge strainer 6 Bilge hose 3...
  • Page 40 SPEC CABLE AND HOSE ROUTING Ê Ï Ë Ë Ë Ë È Î Í Ì Ö Õ Ð É Ñ Ì × Ê Ó Ñ Ë Ô Ø Ò Ì Ò 1 Thermostat È To cooling water pilot outlet on Í...
  • Page 41 SPEC CABLE AND HOSE ROUTING Ê Ï Ë Ë Ë Ë È Î Í Ì Ö Õ Ð É Ñ Ì × Ê Ó Ñ Ë Ô Ø Ò Ì Ò Î Bundle the cooling water pilot outlet hose and Ó...
  • Page 42 SPEC CABLE AND HOSE ROUTING Ê Ï Ë Ë Ë Ë È Î Í Ì Ö Õ Ð É Ñ Ì × Ê Ó Ñ Ë Ô Ø Ò Ì Ò Õ Bundle the cooling water hose (cylinder head × Fasten the end of the cooling water hose tube cover to thermostat) and cooling water hose (star- that is contacting the hose joint with a plastic tie.
  • Page 43 SPEC CABLE AND HOSE ROUTING É Ì È Ë Ê 1 Wiring harness A Cam position sensor coupler 2 Ground lead B Oil pressure switch lead 3 Wiring harness coupler 4 Noise filter È To electrical box 5 Oil pressure switch coupler É...
  • Page 44 SPEC CABLE AND HOSE ROUTING Ë Ê É Î Ì Í Ï È Ð Ð Ï Ñ Ò 1 Engine temperature sensor coupler 2 Lighting coil coupler 3 Pickup coil coupler 4 Thermoswitch (engine) coupler 5 Thermoswitch (engine) 6 Starter motor 7 Engine temperature sensor 8 Engine temperature sensor lead 9 Thermoswitch (engine) lead...
  • Page 45 SPEC CABLE AND HOSE ROUTING Ë Ê É Î Ì Í Ï È Ð Ð Ï Ñ Ò È Fasten the engine temperature sensor lead, ther- Î Route the starter motor lead to the outside of the moswitch lead, and lighting coil lead with a plastic engine temperature sensor lead.
  • Page 46 INSP CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART .............. 3-1 PERIODIC SERVICE ..................3-2 CONTROL SYSTEM ................. 3-2 Steering master inspection..............3-2 Steering cable inspection and adjustment .......... 3-2 Throttle cable inspection and adjustment..........3-3 QSTS cable inspection and adjustment ..........3-5 Shift cable inspection and adjustment..........
  • Page 47: Maintenance Interval Chart

    INSP MAINTENANCE INTERVAL CHART MAINTENANCE INTERVAL CHART The following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the intervals of maintenance should be changed. THEREAFTER MAINTENANCE INTERVAL INITIAL PAGE EVERY 10 hours 50 hours 100 hours 100 hours 200 hours ITEM months months...
  • Page 48 INSP CONTROL SYSTEM PERIODIC SERVICE CONTROL SYSTEM Steering master inspection 1. Inspect: • Steering master Excessive play → Replace the steering master. Refer to “STEERING MASTER” in Chapter 8. Inspection steps: • Move the handlebar up and down and back and forth. •...
  • Page 49 INSP CONTROL SYSTEM WARNING The cable joint must be screwed in more than 8 mm (0.31 in). • Connect the cable joint and tighten the locknut. Locknut: 6.4 N • m (0.64 kgf • m, 4.6 ft • lb) NOTE: If the steering cable cannot be properly adjusted by the cable joint at the steering mas- ter end, adjust the cable joint at the jet pump...
  • Page 50 INSP CONTROL SYSTEM 2. Adjust: • Throttle lever free play Adjustment steps: NOTE: • When not replacing the throttle cable or removing the cable from the throttle body, adjust the throttle cable free play by fol- lowing steps (f) through (j). •...
  • Page 51 INSP CONTROL SYSTEM h. Install the handlebar cover. Handlebar cover screw: 1.1 N • m (0.11 kgf • m, 0.8 ft • lb) LOCTITE 242 i. Install the ribbon sub assemblies and air filter case cover. Ribbon sub assembly bolt: 6.5 N •...
  • Page 52 INSP CONTROL SYSTEM 2. Adjust: • QSTS cable Adjustment steps: • Set the control grip in the neutral position. • Loosen the locknut 1. • Remove the nut 2 and pivot pin 3. • Set the jet thrust nozzle in the center position.
  • Page 53 INSP CONTROL SYSTEM Shift cable inspection and adjustment 1. Check: • Reverse gate stopper lever position Incorrect → Adjust. Checking steps: • Set the shift lever to the reverse position. • Check that the reverse gate 1 contacts the stopper 2 on the bracket and the lever 3 contacts the reverse gate.
  • Page 54 • Start the engine and allow it to warm up for a 15 minutes. • Check the engine trolling speed using the tachometer of the multifunction meter or using the Yamaha Diagnostic System. 2. Adjust: • Trolling speed Adjustment steps: •...
  • Page 55 INSP FUEL SYSTEM FUEL SYSTEM WARNING When removing fuel system parts, wrap them in a cloth and take care that no fuel spills into the engine compartment. Fuel line inspection 1. Inspect: • Fuel pump filter Clog/contaminants → Clean. Refer to “FUEL TANK AND FUEL PUMP MODULE”...
  • Page 56 INSP FUEL SYSTEM/POWER UNIT Water separator inspection 1. Inspect: • Water separator 1 Water accumulation → Drain. NOTE: If need the water draining, remove the drain plug 2. POWER UNIT Valve clearance adjustment The following procedure applies to all of the valves.
  • Page 57 INSP POWER UNIT 4. Measure: • Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake valve: 0.11–0.20 mm (0.0043–0.0079 in) Exhaust valve: 0.25–0.34 mm (0.0098–0.0134 in) Measurement steps: • Turn the drive coupling counterclockwise, and then check if cylinder #1 is at TDC of the compression stroke with a dial gauge.
  • Page 58 INSP POWER UNIT 5. Remove: • Timing chain tensioner cap bolt 1 • Gasket 6. Turn the timing chain tensioner rod fully clockwise with a thin screwdriver 1. NOTE: Make sure that the tensioner rod has been fully set clockwise. 7.
  • Page 59 INSP POWER UNIT 8. Adjust: • Valve clearance Adjustment steps: • Remove the valve lifter 1 and the valve pad 2. NOTE: • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. •...
  • Page 60 INSP POWER UNIT NOTE: The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect. • Install the new valve pad 5 and the valve lifter 6.
  • Page 61 INSP POWER UNIT Intake MEASURED ORIGINAL VALVE PAD NUMBER CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00–0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03–0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.08–0.10...
  • Page 62 INSP POWER UNIT 9. Remove: • Dial gauge • Dial gauge stand • Dial gauge needle 10. Install: • All removed parts NOTE: For installation, reverse the removal proce- dure. Engine oil level check 1. Check: • Engine oil level Checking steps: CAUTION: •...
  • Page 63 NOTE: • The engine cannot be started if the Yamaha Security System is in the lock mode. • For information on the Yamaha Security System, see the owner’s manual. • Run the engine at trolling speed for 6 minutes or more, and then stop the engine.
  • Page 64 INSP POWER UNIT • Remove the filler cap again and check that the oil level is between the minimum level mark a and maximum level mark b on the dipstick. • If the engine oil is below the minimum level mark a, add sufficient oil of the rec- ommended type to raise it to the correct level.
  • Page 65 INSP POWER UNIT 2. Remove: • Oil filler cap 1 3. Insert the tube of an oil changer into the oil filler hole. 4. Operate the oil changer to extract the oil. 5. If the oil filter is also to be replaced, per- form the following procedure.
  • Page 66 INSP POWER UNIT 7. Fill: • Oil tank (with the specified amount of the recom- mended engine oil) Recommended oil: SAE 10W-30 API SE, SF, SG, SH, SJ, SL Oil quantity: Total amount: 4.5 L (4.8 US qt, 4.0 Imp qt) Without oil filter replacement: 2.1 L (2.2 US qt, 1.8 Imp qt) With oil filter replacement:...
  • Page 67 INSP POWER UNIT 2. Remove the air filter element and check it for dirt and oil. Replace the air filter ele- ment if there is any oil buildup. CAUTION: • Make sure that the air filter element is installed in the filter case properly. •...
  • Page 68 INSP POWER UNIT 3. Inspect: • Electrodes 1 Damage/wear → Replace. • Insulator color 2 Distinctly different color → Check the engine condition. Color guide: Medium to light tan color: Normal Whitish color: Lean fuel mixture Air leak Incorrect settings Blackish color: Overly rich mixture Electrical malfunction...
  • Page 69 INSP POWER UNIT 6. Tighten: • Spark plug Spark plug: 13 N • m (1.3 kgf • m, 9.4 ft • lb) NOTE: • Before installing the spark plug, clean the gasket surface and spark plug surface. Also, it is suggested to apply a thin film of anti- seize compound to the spark plug threads to prevent thread seizure.
  • Page 70 INSP ELECTRICAL ELECTRICAL Battery inspection WARNING Battery electrolyte is poisonous and dan- gerous, causing severe burns, etc. Electro- lyte contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidotes External: Flush with water. Internal: Drink large quantities of water or milk.
  • Page 71 INSP ELECTRICAL 1. Remove: • Bands • Battery negative lead 1 • Battery positive lead 2 • Battery • Battery breather hose 3 WARNING • When removing the battery, disconnect the negative lead first. • Remove the battery to prevent acid loss during turning the machine on its side for the impeller service.
  • Page 72 INSP ELECTRICAL 3. Inspect: • Specific gravity Out of specification → Charge. Specific gravity at 20 °C (68 °F): 1.28 Charging current: 1.9 amps × 10 hrs 4. Install: • Filler caps CAUTION: Before installation, rinse off any fluid from the battery box and battery and make sure that the battery is dry before installing it.
  • Page 73 INSP JET PUMP UNIT JET PUMP UNIT Impeller inspection 1. Check: • Impeller 1 Damage/wear → Replace. Nicks/scratches → File or grind. 2. Measure: • Impeller-to-housing clearance a Out of specification → Replace. Maximum impeller-to-housing clearance: 0.35–0.45 mm (0.0138–0.0177 in) Measurement steps: •...
  • Page 74 INSP BILGE PUMP BILGE PUMP Bilge strainer inspection 1. Inspect: • Bilge strainer Contaminants → Clean. Cracks/damage → Replace. Inspection steps: • Remove the deck beam. Refer to “SEATS AND HAND GRIP” in Chapter 8. • Remove the coupling cover. •...
  • Page 75 Before lubricating the throttle cable, squeeze the throttle lever and remove the rubber seal 2. Lubricate: • Throttle cable (throttle body end) Recommended lubricant: Yamaha marine grease, Yamaha grease A (Water resistant grease) 3. Lubricate: • QSTS control cables (handlebar end)
  • Page 76 INSP GENERAL 4. Lubricate: • QSTS cables (pulley end) Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) 5. Lubricate: • Nozzle pivot shaft • Steering cable (nozzle end) • QSTS cable (nozzle end) Recommended grease: Yamaha marine grease,...
  • Page 77 INSP GENERAL 7. Fill: • Intermediate housing Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) Grease quantity: Initial 10 hours: 33.0–35.0 cm (1.11–1.18 oz) Every 100 hours or 12 months: 6.0–8.0 cm (0.20–0.27 oz) NOTE: Fill the intermediate housing with the recom- mended grease through the grease nipple 1.
  • Page 78 FUEL CHAPTER 4 FUEL SYSTEM ARRANGEMENT OF THE THROTTLE BODY COMPONENTS COUPLERS ....................4-1 FUEL TANK AND FUEL PUMP MODULE............4-2 EXPLODED DIAGRAM ................4-2 REMOVAL AND INSTALLATION CHART ..........4-2 SERVICE POINTS ..................4-5 Fuel hose disconnection ..............4-5 Fuel pump module removal..............4-5 Check valve inspection ...............
  • Page 79 ARRANGEMENT OF THE THROTTLE BODY FUEL COMPONENTS COUPLERS ARRANGEMENT OF THE THROTTLE BODY COMPONENTS COUPLERS Ê É È Í Ë Ì 1 Bypass valve motor coupler È To wiring harness Í Fasten the ring, which is 2 Joint coupler É Route throttle cable attached to the sub-wiring har-...
  • Page 80 FUEL FUEL TANK AND FUEL PUMP MODULE FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 1.3 N •...
  • Page 81 FUEL FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 1.3 N • m (0.13 kgf • m, 0.9 ft • Ib) 5.9 N •...
  • Page 82 FUEL FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 1.3 N • m (0.13 kgf • m, 0.9 ft • Ib) 5.9 N •...
  • Page 83 FUEL FUEL TANK AND FUEL PUMP MODULE SERVICE POINTS Fuel hose disconnection 1. Disconnect: • Fuel hose Refer to “FUEL INJECTION SYSTEM”. Fuel pump module removal 1. Remove: • Nuts • Retainer NOTE: Loosen the nuts in the sequence shown. 2.
  • Page 84 FUEL FUEL TANK AND FUEL PUMP MODULE Rollover valve inspection 1. Check: • Rollover valve Faulty → Replace. Checking steps: • Connect a hose to the end of rollover valve “A” and blow into it. Air should come out from end “B”. •...
  • Page 85 FUEL FUEL TANK AND FUEL PUMP MODULE Fuel pump module installation 1. Tighten: • Nuts Fuel pump module nut: 1st: 3.2 N • m (0.32 kgf • m, 2.3 ft • lb) 2nd: 6.4 N • m (0.64 kgf • m, 4.6 ft • lb) NOTE: Tighten the nuts in the sequence shown.
  • Page 86 FUEL FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM EXPLODED DIAGRAM 6.5 N • m (0.65 kgf • m, 4.7 ft • Ib) 2.5 N • m (0.25 kgf • m, 1.8 ft • Ib) 6 × 7 mm 5 × 70 mm 22 N •...
  • Page 87 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 6.5 N • m (0.65 kgf • m, 4.7 ft • Ib) 2.5 N • m (0.25 kgf • m, 1.8 ft • Ib) 6 × 7 mm 5 × 70 mm 22 N • m (2.2 kgf • m, 16 ft • Ib) 8 ×...
  • Page 88 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 6.5 N • m (0.65 kgf • m, 4.7 ft • Ib) 2.5 N • m (0.25 kgf • m, 1.8 ft • Ib) 6 × 7 mm 5 × 70 mm 22 N • m (2.2 kgf • m, 16 ft • Ib) 8 ×...
  • Page 89 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 2nd 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 30 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 39 N •...
  • Page 90 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 2nd 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 30 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 39 N •...
  • Page 91 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 2nd 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 30 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 39 N •...
  • Page 92 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 5 × 15 mm 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib) 8 × 18 mm 6 × 10 mm 5.0 N •...
  • Page 93 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 5 × 15 mm 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib) 8 × 18 mm 6 × 10 mm 5.0 N •...
  • Page 94 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 5 × 15 mm 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib) 8 × 18 mm 6 × 10 mm 5.0 N •...
  • Page 95 FUEL FUEL INJECTION SYSTEM SERVICE POINTS Hose clamps removal 1. Remove: • Hose clamps CAUTION: If the hose clamps are removed without cutting the joint first, the fuel hose will be damaged. Hose clamps installation 1. Install: • Hose clamps WARNING Do not reuse the hose clamps, always replace them with new ones.
  • Page 96 FUEL FUEL INJECTION SYSTEM CAUTION: • Do not rotate the quick connector tab 1 past the stopper position a, otherwise it could be damaged. • When the fuel hoses are disconnected, quickly remove the retainer 2 from the quick connector, otherwise the retainer could be lost.
  • Page 97 FUEL FUEL INJECTION SYSTEM Fuel hose installation (replacing with new fuel hose) 1. Install: • Fuel hose 1 NOTE: • To install the fuel hose, be sure to align the white mark a of the fuel hose with the checker tab 2 of the quick connector. •...
  • Page 98 90890-03174 Fuel injector resistance: (reference data) 11.5–12.5 Ω at 20 °C (68 °F) 3. Check the operation of the fuel injector using the “Stationary Test” of the Yamaha Diagnostic System. Throttle body inspection 1. Check: • Throttle body Cracks/damage → Replace the throttle bodies.
  • Page 99 Bypass valve motor inspection 1. Inspect: • Hoses Damage/cracks → Replace. 2. Check: • Check the bypass valve motor operation using the Yamaha Diagnostic System. Throttle body installation 1. Install: • Throttle body CAUTION: Do not bend the fuel pipe 1.
  • Page 100 FUEL FUEL INJECTION SYSTEM Throttle bodies synchronization 1. Remove: • Throttle bodies • Air filter case 2. Adjust: • Throttle bodies synchronization Adjustment steps: NOTE: The bypass air screws 1 should not be adjusted. However, if it is necessary to remove the bypass air screw, be sure to note the number of times the screw is turned from its set position.
  • Page 101 FUEL FUEL INJECTION SYSTEM c. Turn synchronizing screw #1 3 clock- wise approximately 7 times until it starts to contact the lever. NOTE: • Butterfly valve #1 should be fully closed. Butterfly valves #2 and #3 open if the screw is turned more than 7 times. •...
  • Page 102 Adjust the throttle body synchronization with the air filter case uninstalled. j. Connect the fuel hose and clamp. k. Connect the Yamaha Diagnostic Sys- tem. l. Remove the sub wiring harness from the air filter case, and then connect it to the throttle bodies and main wiring harness.
  • Page 103 NOTE: • Warm the engine up in the water. • While checking the engine temperature with the Yamaha Diagnostic System, warm the engine up until the engine tem- perature is 50 °C (122 °F). q. Adjust the throttle stop screw until trolling 1,740 speed is within specification.
  • Page 104 FUEL FUEL INJECTION SYSTEM Vacuum pressure at trolling speed: Cylinder Cylinder Example difference –18 ± 10 mmHg –230 ± 10 mmHg (–2.45 ± (–30.68 ± 1.33 kPa, 1.33 kPa, –0.8 ± 0.4 inHg) –9.1 ± 0.4 inHg) –212 mmHg Standard*0 (–28.23 kPa, –8.3 inHg) –11 ±...
  • Page 105 FUEL FUEL INJECTION SYSTEM Fuel pressure measurement 1. Disconnect: • Fuel hose Refer to “Fuel hose disconnection”. 2. Install: • Fuel pressure gauge adapter 1 • Fuel pressure gauge 2 Fuel pressure gauge adapter: YW-06842/90890-06842 Fuel pressure gauge: YB-06766/90890-06786 NOTE: To connect the fuel pressure gauge adapter, follow the procedures for connecting a fuel hose.
  • Page 106 POWR CHAPTER 5 POWER UNIT ENGINE UNIT ....................5-1 EXPLODED DIAGRAM ................5-1 REMOVAL AND INSTALLATION CHART ..........5-1 SERVICE POINTS ..................5-4 Compression pressure measurement ..........5-4 Oil filter removal and installation ............5-6 Engine unit removal ................5-6 Shim removal ..................5-7 Engine mount inspection..............5-7 Coupling clearance inspection ............
  • Page 107 POWR OIL PUMP...................... 5-25 EXPLODED DIAGRAM ................5-25 REMOVAL AND INSTALLATION CHART ..........5-25 SERVICE POINTS .................. 5-30 Oil pump inspection................5-30 Check valve inspection ..............5-30 Oil strainer inspection................5-31 Oil pump installation................5-31 REDUCTION DRIVE GEAR ................5-32 EXPLODED DIAGRAM ................5-32 REMOVAL AND INSTALLATION CHART ..........5-32 SERVICE POINTS ..................
  • Page 108 POWR CYLINDER HEAD..................5-63 EXPLODED DIAGRAM ................5-63 REMOVAL AND INSTALLATION CHART ..........5-63 SERVICE POINTS .................. 5-65 Cylinder head removal ..............5-65 Cylinder head inspection..............5-65 Cylinder head installation ..............5-66 VALVES AND VALVE SPRINGS..............5-68 EXPLODED DIAGRAM ................5-68 REMOVAL AND INSTALLATION CHART ..........5-68 SERVICE POINTS ..................
  • Page 109 POWR CRANKSHAFT ....................5-103 EXPLODED DIAGRAM .................5-103 REMOVAL AND INSTALLATION CHART ..........5-103 SERVICE POINTS ................5-104 Crankshaft removal .................5-104 Crankshaft inspection..............5-104 Crankshaft installation..............5-107 THERMOSTAT ....................5-108 EXPLODED DIAGRAM .................5-108 REMOVAL AND INSTALLATION CHART ..........5-108 SERVICE POINTS ................5-110 Thermostat inspection..............5-110 Thermostat installation ..............
  • Page 110 POWR ENGINE UNIT ENGINE UNIT EXPLODED DIAGRAM 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 6 × 25 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 28 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 ×...
  • Page 111 POWR ENGINE UNIT EXPLODED DIAGRAM 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 6 × 25 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 28 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 ×...
  • Page 112 POWR ENGINE UNIT EXPLODED DIAGRAM 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 6 × 25 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 28 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 ×...
  • Page 113 POWR ENGINE UNIT SERVICE POINTS Compression pressure measurement The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: • Valve clearance Out of specification → Adjust. Refer to “POWER UNIT” in Chapter 3. 2.
  • Page 114 POWR ENGINE UNIT 5. Measure: • Compression pressure Out of specification → Refer to steps (b) and (c). Minimum compression pressure (reference data): 1,150 kPa (11.5 kgf/cm , 164 psi) Measurement steps: a. With the throttle wide open, crank the engine until the reading on the compres- sion gauge stabilizes.
  • Page 115 POWR ENGINE UNIT 7. Install: • Ignition coils • Air filter element • Air filter case cover Ignition coils bolt: 7.6 N • m (0.76 kgf • m, 5.5 ft • lb) LOCTITE 572 Air filter case cover screw: 2.5 N • m (0.25 kgf • m, 1.8 ft • lb) LOCTITE 572 Oil filter removal and installation 1.
  • Page 116 POWR ENGINE UNIT Shim removal 1. Remove: • Shims NOTE: To ease reassembly and coupling alignment, remove the shims and organize them in their respective groups (e.g., front right, rear left) prior to removing the mounting bolts. Engine mount inspection 1.
  • Page 117 POWR EXHAUST PIPE 3 EXHAUST PIPE 3 EXPLODED DIAGRAM 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 5th 15 N • m (1.5 kgf • m, 11 ft • Ib) 6th 15 N •...
  • Page 118 POWR EXHAUST PIPE 3 EXPLODED DIAGRAM 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 5th 15 N • m (1.5 kgf • m, 11 ft • Ib) 6th 15 N •...
  • Page 119 POWR EXHAUST PIPE 3 EXPLODED DIAGRAM 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 5th 15 N • m (1.5 kgf • m, 11 ft • Ib) 6th 15 N •...
  • Page 120 POWR EXHAUST PIPES 1 AND 2 EXHAUST PIPES 1 AND 2 EXPLODED DIAGRAM 4th 39 N • m (3.9 kgf • m, 28 ft • Ib) 22 N • m (2.2 kgf • m, 16 ft • Ib) 9th 39 N • m (3.9 kgf • m, 28 ft • Ib) 2nd 22 N •...
  • Page 121 POWR EXHAUST PIPES 1 AND 2 EXPLODED DIAGRAM 4th 39 N • m (3.9 kgf • m, 28 ft • Ib) 22 N • m (2.2 kgf • m, 16 ft • Ib) 9th 39 N • m (3.9 kgf • m, 28 ft • Ib) 2nd 22 N •...
  • Page 122: Exhaust Manifold

    POWR EXHAUST MANIFOLD EXHAUST MANIFOLD EXPLODED DIAGRAM È 22 N • m (2.2 kgf • m, 16 ft • Ib) 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N •...
  • Page 123 POWR EXHAUST MANIFOLD EXPLODED DIAGRAM È 22 N • m (2.2 kgf • m, 16 ft • Ib) 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N •...
  • Page 124: Oil Tank

    POWR OIL TANK OIL TANK EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 15 N •...
  • Page 125 POWR OIL TANK EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 15 N •...
  • Page 126 POWR OIL TANK EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 15 N •...
  • Page 127 POWR OIL TANK EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 7.6 N •...
  • Page 128 POWR OIL TANK EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 7.6 N •...
  • Page 129 POWR OIL TANK EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 7.6 N •...
  • Page 130 POWR OIL TANK SERVICE POINTS Oil tank removal 1. Remove: • Oil tank NOTE: Loosen the oil tank bolts and nuts in the sequence shown. 2. Remove: • Oil tank cover • Gasket NOTE: Loosen the oil tank cover bolts in the sequence shown.
  • Page 131 POWR OIL TANK 4. Remove: • Oil cooler covers • Gaskets NOTE: Loosen the oil cooler cover bolts in the sequence shown. Oil strainer inspection 1. Check: • Oil strainer 1 Damage → Replace. Contaminants → Clean. Oil tank installation 1.
  • Page 132 POWR OIL TANK 2. Install: • Gasket • Oil breather plate 2 • Oil breather plate 1 NOTE: Tighten the oil breather plate bolts in the sequence shown. Oil breather plate bolt: 1st: 1.9 N • m (0.19 kgf • m, 1.4 ft • lb) 2nd: 4.4 N •...
  • Page 133 POWR OIL TANK 4. Install: • Oil tank NOTE: Tighten the oil tank nuts and bolts in the sequence shown. Bolt 1: 1st: 15 N • m (1.5 kgf • m, 11 ft • lb) 2nd: 39 N • m (3.9 kgf • m, 28 ft • lb) LOCTITE 572 Nut 2, bolt 3: 1st:...
  • Page 134 POWR OIL PUMP OIL PUMP EXPLODED DIAGRAM 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N • m (2.8 kgf • m, 20 ft • Ib) 8 × 100 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N •...
  • Page 135 POWR OIL PUMP EXPLODED DIAGRAM 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N • m (2.8 kgf • m, 20 ft • Ib) 8 × 100 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N •...
  • Page 136 POWR OIL PUMP EXPLODED DIAGRAM 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 4 × 12 mm 20 N • m (2.0 kgf • m, 14 ft • Ib) 8 × 70 mm 20 N • m (2.0 kgf • m, 14 ft • Ib) 8 ×...
  • Page 137 POWR OIL PUMP EXPLODED DIAGRAM 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 4 × 12 mm 20 N • m (2.0 kgf • m, 14 ft • Ib) 8 × 70 mm 20 N • m (2.0 kgf • m, 14 ft • Ib) 8 ×...
  • Page 138 POWR OIL PUMP EXPLODED DIAGRAM 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 4 × 12 mm 20 N • m (2.0 kgf • m, 14 ft • Ib) 8 × 70 mm 20 N • m (2.0 kgf • m, 14 ft • Ib) 8 ×...
  • Page 139 POWR OIL PUMP SERVICE POINTS Oil pump inspection 1. Check: • Oil pump housing cover 1 1 • Oil pump housing cover 2 2 • Oil pump housing 1 3 • Oil pump housing 2 4 Cracks/damage/wear → Replace the defective part(s).
  • Page 140 POWR OIL PUMP Oil strainer inspection 1. Check: • Oil strainer 1 Damage → Replace. Contaminants → Clean. Oil pump installation 1. Install: • Oil pump assembly NOTE: Align the projection a on the oil pump shaft with the slit b on the oil pump driven gear shaft.
  • Page 141 POWR REDUCTION DRIVE GEAR REDUCTION DRIVE GEAR EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 55 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N •...
  • Page 142 POWR REDUCTION DRIVE GEAR EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 55 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N •...
  • Page 143 POWR REDUCTION DRIVE GEAR EXPLODED DIAGRAM 5 × 10 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REDUCTION DRIVE GEAR Follow the left “Step” for disassembly. DISASSEMBLY Oil pump drive shaft Drive shaft Collar Oil seal Not reusable Circlip Not reusable Bearing...
  • Page 144 POWR REDUCTION DRIVE GEAR EXPLODED DIAGRAM 5 × 10 mm Step Procedure/Part name Q’ty Service points Circlip Not reusable Bearing Not reusable Reduction drive gear case Reverse the disassembly steps for assembly. : EPNOC grease AP #0 5-35...
  • Page 145 POWR REDUCTION DRIVE GEAR SERVICE POINTS Drive coupling removal 1. Remove: • Reduction drive gear housing 2. Remove: • Drive coupling 1 NOTE: While holding the drive shaft 2 with the rotor holder 3, loosen the drive coupling with the coupler wrench 4.
  • Page 146 POWR REDUCTION DRIVE GEAR 2. Remove: È • Circlip • Reduction drive gear bearing Slide hammer and adapters: YB-06096 Stopper guide plate: 90890-06501 Bearing puller assembly: 90890-06535 Stopper guide stand: 90890-06538 É È For USA and Canada É For worldwide Oil pump drive shaft inspection 1.
  • Page 147 POWR REDUCTION DRIVE GEAR Bearing installing 1. Install: • Reduction drive gear bearing NOTE: Install the reduction driver gear bearing using a press. Driver handle—large: YB-06071 Driver rod LS: 90890-06606 Outer race installer—forward gear: YB-06085 Ball bearing attachment: 90890-06631 È 2.
  • Page 148 POWR REDUCTION DRIVE GEAR 3. Install: È • Collar • Rear bearing NOTE: • Install the front bearing using a press. • Before installing the rear bearing, hold both the inner and outer races of the front bearing in place as shown with a pipe that is at least 40 mm (1.57 in) long and has an outer diam- eter of 70 mm (2.76 in) and an inner diame- É...
  • Page 149 POWR REDUCTION DRIVE GEAR Drive shaft installation 1. Install: • Drive shaft • Collar NOTE: Press the into the reduction drive gear case with a pipe that is more than 30 mm (1.18 in) long, and which has an outer diameter of approximately 35 mm (1.97 in) and an inner diameter of approximately 28 ±...
  • Page 150 POWR GENERATOR AND STARTER MOTOR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 30 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 50 N •...
  • Page 151 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 30 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 50 N •...
  • Page 152 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 30 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 50 N •...
  • Page 153 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 10 mm 6 × 14 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) 5 × 14 mm 4.9 N •...
  • Page 154 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 10 mm 6 × 14 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) 5 × 14 mm 4.9 N •...
  • Page 155 POWR GENERATOR AND STARTER MOTOR SERVICE POINTS Flywheel magneto removal 1. Remove: • Flywheel magneto bolt 1 • Washer NOTE: While holding the flywheel magneto 2 with the sheave holder 3, loosen the flywheel magneto bolt. Sheave holder: YS-01880-A/90890-01701 2. Remove: •...
  • Page 156 POWR GENERATOR AND STARTER MOTOR 2. Check: • Starter clutch 1 • Starter gear 2 Burrs/chips/roughness/wear → Replace the defective part(s). 3. Check: • Starter clutch gear’s contacting surfaces Damage/pitting/wear → Replace the starter clutch gear. 4. Check: • Starter clutch operation Checking steps: •...
  • Page 157 POWR GENERATOR AND STARTER MOTOR Flywheel magneto installation 1. Install: • Woodruff key • Flywheel magneto • Washer • Flywheel magneto bolt NOTE: • Clean the tapered portion of the crankshaft and the flywheel magneto hub. • When installing the flywheel magneto, make sure the woodruff key is properly seated in the keyway of the crankshaft.
  • Page 158 POWR CAMSHAFTS CAMSHAFTS EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 ×...
  • Page 159 POWR CAMSHAFTS EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 ×...
  • Page 160 POWR CAMSHAFTS EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 ×...
  • Page 161 POWR CAMSHAFTS EXPLODED DIAGRAM 6 × 35 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 24 N • m (2.4 kgf • m, 17 ft • Ib) 7 × 11 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 ×...
  • Page 162 POWR CAMSHAFTS EXPLODED DIAGRAM 6 × 35 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 24 N • m (2.4 kgf • m, 17 ft • Ib) 7 × 11 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 ×...
  • Page 163 POWR CAMSHAFTS EXPLODED DIAGRAM 6 × 35 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 24 N • m (2.4 kgf • m, 17 ft • Ib) 7 × 11 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 ×...
  • Page 164 POWR CAMSHAFTS SERVICE POINTS Camshaft removal 1. Install: • Dial gauge needle • Dial gauge stand 1 (into spark plug hole #1) • Dial gauge 2 Dial gauge stand: 90890-06583 Dial gauge needle: 90890-06584 Dial gauge stand set: YW-06585/90890-06585 Dial gauge: YU-03097/90890-01252 2.
  • Page 165 POWR CAMSHAFTS 5. Remove: • Camshaft caps • Dowel pins NOTE: Loosen the intake and exhaust camshaft cap bolts in the sequence shown. 6. Remove: • Intake camshaft 1 • Exhaust camshaft 2 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire 3.
  • Page 166 POWR CAMSHAFTS 3. Measure: • Camshaft runout Out of specification → Replace. Maximum camshaft runout: 0.03 mm (0.0012 in) 4. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance: 0.03–0.06 mm (0.0012–0.0024 in) Measurement steps: •...
  • Page 167 POWR CAMSHAFTS 5. Measure: • Camshaft journal diameter a Out of specification → Replace the cam- shaft. Within specification → Replace the cyl- inder head and the camshaft caps as a set. Camshaft journal diameter: 24.46–24.47 mm (0.9630–0.9634 in) Camshaft sprockets inspection 1.
  • Page 168 POWR CAMSHAFTS Camshaft installation 1. Install: • Exhaust camshaft sprocket 1 • Intake camshaft sprocket 2 (with the special tool 3) Universal magneto and rotor holder: YU-01235 Rotor holder: 90890-01235 NOTE: Install the camshaft sprocket with the punch mark a facing outside. Camshaft sprocket bolt: 24 N •...
  • Page 169 POWR CAMSHAFTS • Install the exhaust and intake camshaft caps. NOTE: Gradually tighten the intake and exhaust camshaft cap bolts in 2–3 steps in the sequence shown. Camshaft cap bolt: 10 N • m (1.0 kgf • m, 7.2 ft • lb) NOTE: Make sure that the punch marks c on the camshafts are aligned with the arrow marks...
  • Page 170 POWR CAMSHAFTS Timing chain tensioner bolt: 10 N • m (1.0 kgf • m, 7.2 ft • lb) • Remove the screwdriver, make sure the timing chain tensioner rod releases, and then tighten the cap bolt to the specified torque. Cap bolt: 10 N •...
  • Page 171 POWR CAMSHAFTS 7. Install: • Cylinder head cover gasket • Cylinder head cover NOTE: • Apply Gasket Maker onto the mating sur- faces of the cylinder head cover gasket and cylinder head. • Tighten the cylinder head cover bolts stages and in a crisscross pattern.
  • Page 172 POWR CYLINDER HEAD CYLINDER HEAD EXPLODED DIAGRAM 20 N • m (2.0 kgf • m, 14 ft • Ib) 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 2nd 121 ± 5˚ 6 × 12 mm 20 N • m (2.0 kgf • m, 14 ft • Ib) 10 N •...
  • Page 173 POWR CYLINDER HEAD EXPLODED DIAGRAM 20 N • m (2.0 kgf • m, 14 ft • Ib) 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 2nd 121 ± 5˚ 6 × 12 mm 20 N • m (2.0 kgf • m, 14 ft • Ib) 10 N •...
  • Page 174 POWR CYLINDER HEAD SERVICE POINTS Cylinder head removal 1. Remove: • Cylinder head bolts 1 2. Remove: • Cylinder head nuts NOTE: Loosen the cylinder head nuts in the sequence shown. Cylinder head inspection 1. Eliminate: • Combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag-...
  • Page 175 POWR CYLINDER HEAD 3. Measure: • Cylinder head warpage Out of specification → Replace the cyl- inder head. Cylinder head warpage limit: 0.1 mm (0.004 in) Measurement steps: • Place a straightedge 1 and a thickness gauge 2 across the cylinder head. •...
  • Page 176 POWR CYLINDER HEAD 2. Tighten: • Cylinder head bolts 1 NOTE: Lubricate the cylinder head bolts with engine oil. Cylinder head bolt: 10 N • m (1.0 kgf • m, 7.2 ft • lb) 5-67...
  • Page 177 POWR VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points VALVES AND VALVE SPRINGS Follow the left “Step” for removal. REMOVAL Cylinder head Refer to “CYLINDER HEAD”. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat...
  • Page 178 POWR VALVES AND VALVE SPRINGS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Not reusable Exhaust valve lower spring seat Exhaust valve Exhaust valve guide Not reusable...
  • Page 179 POWR VALVES AND VALVE SPRINGS SERVICE POINTS Valve removal 1. Remove: • Valve lifter 1 • Valve pad 2 NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place.
  • Page 180 POWR VALVES AND VALVE SPRINGS Valve spring inspection 1. Measure: • Valve spring free length a Out of specification → Replace the valve spring. Valve spring free length: Intake valve spring: 38.90 mm (1.53 in) Exhaust valve spring: 40.67 mm (1.60 in) 2.
  • Page 181 POWR VALVES AND VALVE SPRINGS 4. Measure: • Valve stem diameter a Out of specification → Replace the valve. Valve stem diameter a: Intake valve: 3.975–3.990 mm (0.1565–0.1571 in) Exhaust valve: 4.465–4.480 mm (0.1758–0.1764 in) 5. Measure: • Valve stem runout Out of specification →...
  • Page 182 POWR VALVES AND VALVE SPRINGS 1. Measure: • Valve guide inside diameter a Valve guide inside diameter: Intake: 4.000–4.012 mm (0.1575–0.1580 in) Exhaust: 4.500–4.512 mm (0.1772–0.1776 in) 2. Calculate the valve stem-to-valve guide clearance as follows. Replace the valve guide if out of specification. Valve stem-to-valve guide clearance = valve guide inside diameter –...
  • Page 183 POWR VALVES AND VALVE SPRINGS 2. Install the new valve guide 2 by striking the special service tool from the camshaft side until the valve guide clip 3 contacts the cylinder head. NOTE: Apply engine oil to the surface of the new valve guide.
  • Page 184 POWR VALVES AND VALVE SPRINGS Valve seat inspection 1. Eliminate carbon deposits from the valve with a scraper. 2. Apply a thin, even layer of Mechanic’s blueing dye (Dykem) onto the valve seat. 3. Lap the valve slowly on the valve seat with a valve lapper (commercially obtainable) as shown.
  • Page 185 POWR VALVES AND VALVE SPRINGS Valve seat reface 1. Reface the valve seat with the valve seat cutter. Valve seat cutter holder: Intake (ø4.0 mm): 90890-06811 Exhaust (ø4.5 mm): 90890-06812 Valve seat cutter: 30° (intake): 90890-06815 45° (intake): 90890-06814 60° (intake): 90890-06813 30°...
  • Page 186 POWR VALVES AND VALVE SPRINGS 4. Use a 60° cutter to adjust the contact width of the bottom edge of the valve seat. b Previous contact width 60˚ 5. Use a 45° cutter to adjust the contact width of the valve seat to specification. b Previous contact width c Specified contact width 45˚...
  • Page 187 POWR VALVES AND VALVE SPRINGS 9. Apply a thin, even layer of lapping com- pound onto the valve seat, and then lap the valve using a valve lapper (commer- cially obtainable). CAUTION: Do not get the lapping compound on the valve stem and valve guide.
  • Page 188 POWR VALVES AND VALVE SPRINGS 2. Compress the valve spring, and then install the valve cotter 1 using a thin screwdriver with a small amount of grease applied to it. Valve spring compressor: YM-01253/90890-04019 Valve spring compressor attachment: (for the intake valve) YM-4114/90890-04114 (for the exhaust valve) YM-4108/90890-04108...
  • Page 189 POWR CRANKCASE CRANKCASE EXPLODED DIAGRAM 8.4 N • m (0.84 kgf • m, 6.1 ft • Ib) 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 20 N • m (2.0 kgf • m, 14 ft • Ib) 6 ×...
  • Page 190 POWR CRANKCASE EXPLODED DIAGRAM 8.4 N • m (0.84 kgf • m, 6.1 ft • Ib) 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 20 N • m (2.0 kgf • m, 14 ft • Ib) 6 ×...
  • Page 191 POWR CRANKCASE EXPLODED DIAGRAM 8.4 N • m (0.84 kgf • m, 6.1 ft • Ib) 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 20 N • m (2.0 kgf • m, 14 ft • Ib) 6 ×...
  • Page 192 POWR CRANKCASE EXPLODED DIAGRAM 8.4 N • m (0.84 kgf • m, 6.1 ft • Ib) 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 20 N • m (2.0 kgf • m, 14 ft • Ib) 6 ×...
  • Page 193 POWR CRANKCASE EXPLODED DIAGRAM 6 × 10 mm 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 35 N • m (3.5 kgf • m, 25 ft • Ib) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points OIL PIPE AND OIL FILTER BOLT Follow the left “Step”...
  • Page 194 POWR CRANKCASE SERVICE POINTS Crankcase disassembly 1. Remove: • Oil pan bolts NOTE: • Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. •...
  • Page 195 POWR CRANKCASE 4. Remove: • Dowel pins Crankcase inspection 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • Crankcase Cracks/damage → Replace. • Oil delivery passages Obstruction →...
  • Page 196 POWR CRANKCASE Crankcase assembly 1. Lubricate: Crankshaft journal bearings (with the recommended lubricant) Recommended lubricant: Engine oil 2. Apply: • Gasket Maker (onto the crankcase mating surfaces) NOTE: Do not allow any Gasket Maker to come into contact with the oil gallery or crankshaft journal bearings.
  • Page 197 POWR CRANKCASE 5. Tighten: • Crankcase bolts 1–0 NOTE: • Do not reuse crankcase bolts 1–0. • The tightening procedure of crankcase bolts 1–0 is angle controlled, therefore tighten the bolts using the following procedure. Tightening steps: • Tighten the bolts in the tightening sequence cast on the crankcase.
  • Page 198 POWR CRANKCASE CAUTION: • Do not use a torque wrench to tighten the bolt to the specified angle. • Tighten the bolt until it is at the speci- fied angle. NOTE: When using a hexagonal bolt, note that the angle from one corner to another is 60°. 6.
  • Page 199 POWR CONNECTING RODS AND PISTONS CONNECTING RODS AND PISTONS EXPLODED DIAGRAM 20 N • m (2.0 kgf • m, 14 ft • Ib) 2nd 120 ± 5˚ REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CONNECTING RODS AND Follow the left “Step”...
  • Page 200 POWR CONNECTING RODS AND PISTONS EXPLODED DIAGRAM 20 N • m (2.0 kgf • m, 14 ft • Ib) 2nd 120 ± 5˚ Step Procedure/Part name Q’ty Service points Bolt Not reusable Big end upper bearing Top ring 2nd ring Oil ring Reverse the removal steps for installation.
  • Page 201 POWR CONNECTING RODS AND PISTONS SERVICE POINTS Connecting rod and piston removal The following procedure applies to all of the connecting rods and pistons. 1. Remove: • Connecting rod cap 1 • Big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.
  • Page 202 POWR CONNECTING RODS AND PISTONS Cylinder and piston inspection The following procedure applies to all of the cylinders and pistons. 1. Check: • Piston wall • Cylinder wall Vertical scratches → Replace the cylin- der, and the piston and piston rings as a set.
  • Page 203 POWR CONNECTING RODS AND PISTONS • If out of specification, replace the piston and piston rings as a set. • Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance: 0.10–0.11 mm (0.0039–0.0043 in) <Limit>: 0.17 mm (0.0067 in) •...
  • Page 204 POWR CONNECTING RODS AND PISTONS 2. Install: • Piston ring (into the cylinder) NOTE: Level the piston ring in the cylinder with the piston crown. a 5 mm (0.2 in) 3. Measure: • Piston ring end gap Out of specification → Replace the pis- ton ring.
  • Page 205 POWR CONNECTING RODS AND PISTONS Piston pin inspection The following procedure applies to all of the piston pins. 1. Check: • Piston pin Blue discoloration/grooves → Replace the piston pin and then check the lubri- cation system. 2. Measure: • Piston pin outside diameter a Out of specification →...
  • Page 206 POWR CONNECTING RODS AND PISTONS Connecting rod inspection 1. Measure: • Crankshaft-pin-to-big-end-bearing clearance Out of specification → Replace the big end bearings. Crankshaft-pin-to-big-end- bearing clearance: 0.016–0.040 mm (0.0006–0.0016 in) Measurement steps: The following procedure applies to all of the connecting rods. CAUTION: Do not interchange the big end bearings and connecting rods.
  • Page 207 POWR CONNECTING RODS AND PISTONS NOTE: • Do not move the connecting rod or crank- shaft until the clearance measurement has been completed. • Lubricate the bolts threads and nut seats with molybdenum disulfide grease. • Make sure the “Y” mark c on the con- necting rod faces towards the front side of the crankshaft.
  • Page 208 POWR CONNECTING RODS AND PISTONS For example, if the connecting rod “P ” and the crankshaft web “P ” numbers are “5” and “1” respectively, then the bearing size for “P ” is: Bearing size of P “P ” (connecting rod) – “P ”...
  • Page 209 POWR CONNECTING RODS AND PISTONS 3. Offset: 90˚ • Piston ring end gaps È a Top ring, oil ring expander spacer b 2nd ring, lower oil ring rail c Upper oil ring rail È Exhaust side 4. Lubricate: • Piston •...
  • Page 210 POWR CONNECTING RODS AND PISTONS 7. Install: • Big end bearings • Connecting rod assembly 1 (into the cylinder and onto the crankshaft pin) • Connecting rod cap (onto the crankshaft pin) NOTE: • Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps.
  • Page 211 POWR CONNECTING RODS AND PISTONS 9. Tighten: • Connecting rod nuts WARNING • Replace the connecting rod bolts and nuts with new ones. • Clean the connecting rod bolts and nuts. NOTE: The tightening procedure of the connecting rod nuts is angle controlled, therefore tighten the nuts using the following procedure.
  • Page 212 POWR CRANKSHAFT CRANKSHAFT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CRANKSHAFT REMOVAL Follow the left “Step” for removal. Crankcase Separate Refer to “CRANKCASE”. Connecting rod caps Refer to “CONNECTING RODS AND PISTONS”. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Reverse the removal steps for installation.
  • Page 213 POWR CRANKSHAFT SERVICE POINTS Crankshaft removal 1. Remove: • Crankshaft 1 • Crankshaft journal lower bearings (from the lower crankcase) • Crankshaft journal upper bearings (from the upper crankcase) NOTE: Identify the position of each crankshaft journal bearing so that it can be reinstalled in its origi- nal place.
  • Page 214 POWR CRANKSHAFT CAUTION: Do not interchange the crankshaft journal bearings. To obtain the correct crankshaft- journal-to-crankshaft-journal-bearing clear- ance and prevent engine damage, the crankshaft journal bearings must installed in their original positions. Measurement steps: • Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase.
  • Page 215 POWR CRANKSHAFT • Tighten the bolts to specification in the tightening sequence cast on the crank- case. Refer “Crankcase assembly”— “CRANKCASE”. • Remove the lower crankcase and the crankshaft journal lower bearings. • Measure the compressed Plastigauge width c on each crankshaft journal. If the crankshaft-journal-to-crankshaft- journal-bearing clearance is out of speci- fication, select replacement crankshaft...
  • Page 216 POWR CRANKSHAFT Crankshaft installation 1. Install: • Crankshaft journal upper bearings (into the upper crankcase) • Crankshaft journal lower bearings (into the lower crankcase) NOTE: • Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase.
  • Page 217 POWR THERMOSTAT THERMOSTAT EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 35 mm 5.9 N • m (0.59 kgf • m, 4.3 ft • Ib) É...
  • Page 218 POWR THERMOSTAT EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 35 mm 5.9 N • m (0.59 kgf • m, 4.3 ft • Ib) É...
  • Page 219 POWR THERMOSTAT SERVICE POINTS Thermostat inspection 1. Check: • Thermostat 1 Does not open at 50–60 °C (123– 141 °F) → Replace. Checking steps: • Suspend the thermostat in a container filled with water. • Slowly heat the water. • Place a thermometer in the water. •...
  • Page 220 POWR COOLING WATER HOSE COOLING WATER HOSE EXPLODED DIAGRAM È È È È É Ë Ê Ì Ê Í REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points COOLING WATER HOSE Follow the left “Step” for removal. REMOVAL Exhaust manifold Refer to “EXHAUST MANIFOLD”.
  • Page 221 PUMP CHAPTER 6 JET PUMP UNIT INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT........6-1 EXPLODED DIAGRAM ................6-1 REMOVAL AND INSTALLATION CHART ..........6-1 JET PUMP UNIT....................6-4 EXPLODED DIAGRAM ................6-4 REMOVAL AND INSTALLATION CHART ..........6-4 REVERSE GATE ..................... 6-6 EXPLODED DIAGRAM ................6-6 REMOVAL AND INSTALLATION CHART ..........
  • Page 222 PUMP TRANSOM PLATE AND HOSES..............6-20 EXPLODED DIAGRAM ................6-20 REMOVAL AND INSTALLATION CHART ..........6-20 SERVICE POINTS .................. 6-23 Bilge strainer inspection ..............6-23 Electric bilge pump inspection............6-23 Bilge hose inspection ................6-23 Cooling water hose inspection ............6-23 BEARING HOUSING..................6-24 EXPLODED DIAGRAM ................6-24 REMOVAL AND INSTALLATION CHART ..........
  • Page 223 INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT PUMP INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points INTAKE GRATE, RIDE PLATE, Follow the left “Step” for removal. AND INTAKE DUCT REMOVAL Bolt Bolt Intake grate...
  • Page 224 INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Ride plate Bolt Intake duct Felt packing Not reusable Reverse the removal steps for installation.
  • Page 225 INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT PUMP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SPEED SENSOR DISASSEMBLY Follow the left “Step” for disassembly. Holder Paddle wheel set Not reusable Speed sensor Reverse the disassembly steps for assembly.
  • Page 226 JET PUMP UNIT PUMP JET PUMP UNIT EXPLODED DIAGRAM 6.8 N • m (0.68 kgf • m, 4.9 ft • Ib) 14 N • m (1.4 kgf • m, 10 ft • Ib) 6 × 22 mm 8 × 24 mm 2.2 N •...
  • Page 227 JET PUMP UNIT PUMP EXPLODED DIAGRAM 6.8 N • m (0.68 kgf • m, 4.9 ft • Ib) 14 N • m (1.4 kgf • m, 10 ft • Ib) 6 × 22 mm 8 × 24 mm 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib) 40 N •...
  • Page 228 REVERSE GATE PUMP REVERSE GATE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REVERSE GATE REMOVAL Follow the left “Step” for removal. Clamp/spout hose Bolt Washer Collar Reverse gate assembly Bolt Washer Roller...
  • Page 229 REVERSE GATE PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Bracket Reverse gate stay Washer Bolt Lever 1 Spacer Washer...
  • Page 230 REVERSE GATE PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Collar Bolt Washer Collar Spring Lever 2 Washer Reverse the removal steps for installation.
  • Page 231 REVERSE GATE PUMP SERVICE POINTS Lever 1 installation 1. Install: • Bolt 1 • Lever 1 2 • Spacer 3 • Reverse gate 4 • Washer 5 • Nut 6 Lever 2 installation 1. Install: • Bolt 1 • Washer 2 •...
  • Page 232 JET THRUST NOZZLE AND NOZZLE RING PUMP JET THRUST NOZZLE AND NOZZLE RING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points JET THRUST NOZZLE AND Follow the left “Step” for removal. NOZZLE RING REMOVAL Jet pump unit Refer to “JET PUMP UNIT”.
  • Page 233 Follow the left “Step” for removal. HOUSING 1 REMOVAL Nozzle ring Refer to “JET THRUST NOZZLE AND NOZZLE RING”. Bolt Nozzle NOTE: Clean the contacting surfaces before apply- ing the Yamabond #4 (Yamaha bond num- Impeller duct assembly ber 4). Impeller housing 1 Bolt 6-11...
  • Page 234 IMPELLER DUCT AND IMPELLER HOUSING 1 PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Water inlet cover Packing Water inlet strainer Packing Reverse the removal steps for installation. 6-12...
  • Page 235 IMPELLER DUCT AND DRIVE SHAFT PUMP IMPELLER DUCT AND DRIVE SHAFT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points IMPELLER DUCT AND DRIVE Follow the left “Step” for disassembly. SHAFT DISASSEMBLY Impeller Left-hand threads Spacer Bolt/washer O-ring Not reusable Washer...
  • Page 236 IMPELLER DUCT AND DRIVE SHAFT PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Drive shaft Rear bearing Not reusable Spacer Front bearing Not reusable Oil seal Not reusable Oil seal Not reusable Impeller duct Reverse the disassembly steps for assembly.
  • Page 237 IMPELLER DUCT AND DRIVE SHAFT PUMP SERVICE POINTS Drive shaft removal 1. Remove: • Impeller Drive shaft holder: YB-06151 Drive shaft holder 5: 90890-06519 NOTE: The impeller has left-hand threads. Turn the impeller clockwise to loosen it. 2. Remove: • Nut 1 Drive shaft holder: YB-06151 Drive shaft holder 5:...
  • Page 238 IMPELLER DUCT AND DRIVE SHAFT PUMP 4. Remove: È • Rear bearing Slide hammer and adapters: YB-06096 Stopper guide plate: 90890-06501 Bearing puller assembly: 90890-06535 Stopper guide stand: 90890-06538 É È For USA and Canada É For worldwide 5. Remove: •...
  • Page 239 IMPELLER DUCT AND DRIVE SHAFT PUMP 6. Remove: • Oil seal Driver handle—large: YB-06071 Driver rod L3: 90890-06652 Drive shaft needle bearing installer and remover: YB-06196 Needle bearing attachment: 90890-06614 NOTE: Remove the oil seals with press. Impeller inspection Refer to “JET PUMP UNIT” in Chapter 3.
  • Page 240 IMPELLER DUCT AND DRIVE SHAFT PUMP 2. Install: • Front bearing • Drive shaft NOTE: • Install the front bearing and drive shaft with a press. • Press the front bearing with a pipe that is more than 85 mm (3.35 in) long, and which has an inner diameter of 25 mm (0.98 in).
  • Page 241 IMPELLER DUCT AND DRIVE SHAFT PUMP 5. Install: • Rear bearing Bearing inner/outer race attachment: YB-34474 NOTE: • Press the bearing inner/outer race at the same time holding the drive shaft and impel- ler duct. • If a bearing inner/outer race attachment is not available, use a washer or pipe with an outer diameter of 46 mm (1.81 in) and an inner diameter of 20 mm (0.79 in).
  • Page 242 TRANSOM PLATE AND HOSES PUMP TRANSOM PLATE AND HOSES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points TRANSOM PLATE AND HOSES Follow the left “Step” for removal. REMOVAL Exhaust system Refer to “EXHAUST SYSTEM” in Chapter 8. Jet pump unit assembly Refer to “JET PUMP UNIT”.
  • Page 243 TRANSOM PLATE AND HOSES PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Hose clamp Cooling water hose Cooling water outlet (thermostat) Bilge hose 2 Hose clamp Bilge hose 3 Band Electric bilge pump assembly Hose clamp Bilge hose 4 Bilge strainer 6-21...
  • Page 244 TRANSOM PLATE AND HOSES PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Nut/washer Transom plate Bilge hose 5 Reverse the removal steps for installation. 6-22...
  • Page 245 TRANSOM PLATE AND HOSES PUMP SERVICE POINTS Bilge strainer inspection Refer to “JET PUMP UNIT” in Chapter 3. Electric bilge pump inspection Refer to “BILGE PUMP” in Chapter 3. Refer to “ELECTRIC BILGE PUMP” in Chapter 7. Bilge hose inspection 1.
  • Page 246: Bearing Housing

    BEARING HOUSING PUMP BEARING HOUSING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BEARING HOUSING REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT” in Chapter 5. Rubber coupling Bolt Intermediate housing assembly NOTE: Shim Install the shims in their original locations.
  • Page 247 BEARING HOUSING PUMP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BEARING HOUSING Follow the left “Step” for disassembly. DISASSEMBLY Grease hose Nipple Driven coupling Washer Intermediate drive shaft O-ring Not reusable 6-25...
  • Page 248 BEARING HOUSING PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Oil seal Not reusable Oil seal Not reusable Oil seal Not reusable Circlip Not reusable Bearing Not reusable Circlip Not reusable Reverse the disassembly steps for assembly. 6-26...
  • Page 249 BEARING HOUSING PUMP SERVICE POINTS Driven coupling removal and installation 1. Remove and install: • Driven coupling Coupler wrench: YW-06551/90890-06551 Shaft holder: YB-06552 Crankshaft holder 20: 90890-06552 NOTE: • Install the driven coupling with the same spe- cial tools that were used for removal. •...
  • Page 250 BEARING HOUSING PUMP Bearing removal 1. Remove: • Bearing Driver handle—large: YB-06071 Driver rod LS: 90890-06606 Drive shaft taper roller bearing cup installer: YB-06156 Bearing outer race attachment: 90890-06626 NOTE: • Install the bearing with the same special tools that were used for removal. •...
  • Page 251 BEARING HOUSING PUMP Bearing installation 1. Install: • Circlip (front) 2. Install: • Bearing Driver handle—large: YB-06071 Driver rod LS: 90890-06606 Driveshaft taper roller bearing cup installer: YB-06156 Bearing outer race attachment: 90890-06626 NOTE: Support the intermediate housing with steel blocks 1 and press the bearing.
  • Page 252 BEARING HOUSING PUMP 2. Install: • Intermediate drive shaft • Circlip (rear) NOTE: Hold the bearing in place as shown with a pipe that is more than 80 mm (3.15 in) long, and which has an outer diameter of 51 mm (2.00 in) and an inner diameter of 26 mm (1.02 in).
  • Page 253 – ELEC CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS................ 7-1 ELECTRICAL BOX..................7-2 EXPLODED DIAGRAM ................7-2 REMOVAL AND INSTALLATION CHART ..........7-2 ELECTRICAL ANALYSIS ................7-9 INSPECTION..................... 7-9 Digital tester ..................7-9 Low resistance measurement ............7-10 Peak voltage measurement ..............7-10 Peak voltage adapter ................7-11 Test harness ..................7-11 IGNITION SYSTEM ..................
  • Page 254 – ELEC STARTING SYSTEM ..................7-29 WIRING DIAGRAM ................. 7-29 BATTERY ....................7-30 WIRING CONNECTIONS................7-30 FUSE ....................... 7-30 START SWITCH..................7-30 STARTER RELAY ...................7-31 REMOTE CONTROL UNIT ..............7-31 STARTER MOTOR..................7-32 EXPLODED DIAGRAM ................7-32 REMOVAL AND INSTALLATION CHART ..........7-32 SERVICE POINTS .................. 7-35 Armature inspection ................7-35 Brush holder inspection..............
  • Page 255 Check the engine warning indicator ..........7-50 REMOTE CONTROL SYSTEM ..............7-51 WIRING DIAGRAM ................. 7-51 REMOTE CONTROL SYSTEM...............7-52 Yamaha Security System indicator ...........7-52 Low-rpm mode indicator..............7-52 Diagnostic display ................7-53 Checking the remote control transmitter ...........7-53 Transmitter registration ..............7-55...
  • Page 256 – ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 1 Thermoswitch (engine) B Oil pressure switch K Fuel sender 2 Starter motor C Sensor assembly L Multifunction meter 3 Engine temperature sensor D Bypass valve motor M Remote control unit 4 Spark plugs and ignition coils E Throttle position sensor 5 Electrical box F Lighting coil and pickup coil...
  • Page 257: Electrical Box

    – ELEC ELECTRICAL BOX ELECTRICAL BOX EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 16 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 28 mm 5 ×...
  • Page 258 – ELEC ELECTRICAL BOX EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 16 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 28 mm 5 × 20 mm 4.9 N •...
  • Page 259 – ELEC ELECTRICAL BOX EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 16 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 28 mm 5 × 20 mm 4.9 N •...
  • Page 260 – ELEC ELECTRICAL BOX EXPLODED DIAGRAM 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 20 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 ×...
  • Page 261 – ELEC ELECTRICAL BOX EXPLODED DIAGRAM 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 20 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 ×...
  • Page 262 – ELEC ELECTRICAL BOX EXPLODED DIAGRAM 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 20 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 ×...
  • Page 263 – ELEC ELECTRICAL BOX È É Ê 1 Starter relay È To ignition coil 2 Fuse holder É To battery positive terminal 3 ECM Ê To starter motor 4 Joint connector 5 Joint connector 6 Main and fuel pump relay 7 Rectifier/regulator 8 Slant detection switch...
  • Page 264: Electrical Analysis

    – ELEC ELECTRICAL ANALYSIS ELECTRICAL ANALYSIS INSPECTION CAUTION: • All measuring instruments should be han- dled with special care. Damaged or mis- handled instruments will not measure properly. • On an instrument powered by dry batter- ies, check the battery’s voltage periodi- cally replace batteries...
  • Page 265 – ELEC ELECTRICAL ANALYSIS Low resistance measurement NOTE: • When measuring a resistance of 10 Ω or less with the digital tester, the correct measure- ment cannot be obtained because of the tester’s internal resistance. • To obtain the correct value, subtract the internal resistance from the displayed mea- surement.
  • Page 266 – ELEC ELECTRICAL ANALYSIS Peak voltage adapter NOTE: • Throughout this chapter the peak voltage adapter’s part number has been omitted. Refer to the following part number. • The peak voltage adapter should be used with the digital tester. Peak volt meter adapter: YU-39991 È...
  • Page 267: Ignition System

    – ELEC IGNITION SYSTEM IGNITION SYSTEM WIRING DIAGRAM 3 : G/O 28 : L/B 4 : W 30 : R/Y 5 : P 33 : P/G 34 : P 6 : P/W 35 : B/Y 9 : O 12 : W/R 42 : B/L Br B 13 : W/B...
  • Page 268 – ELEC IGNITION SYSTEM WIRING DIAGRAM 3 : G/O 28 : L/B 4 : W 30 : R/Y 5 : P 33 : P/G 34 : P 6 : P/W 35 : B/Y 9 : O 12 : W/R 42 : B/L Br B 13 : W/B 43 : B/Y...
  • Page 269 – ELEC IGNITION SYSTEM IGNITION SPARK WARNING • When checking the spark gap, do not touch any of the connections of the spark gap tester lead wires. • When performing the spark gap test, take special care not to let sparks leak out of the removed spark plug cap.
  • Page 270 – ELEC IGNITION SYSTEM IGNITION SYSTEM PEAK VOLTAGE WARNING When checking the electrical components, do not touch any of the connections of the digital tester lead wires. NOTE: • If there is no spark, or the spark is weak, continue with the ignition system test. •...
  • Page 271 – ELEC IGNITION SYSTEM 2. Measure: • Pickup coil output peak voltage Below specification → Replace the pickup coil. Above specification → Replace the ECM. Test harness (3 pins): New: YB-06877 Current: YB-06777 Test harness HM090-3 (3 pins): New: 90890-06877 Current: 90890-06777 Pickup coil output peak voltage: White (W) –...
  • Page 272 – ELEC IGNITION SYSTEM NOTE: To crank the engine, connect the engine shut- off cord (lanyard) to the engine shut-off switch, and then press the start switch and engine stop switch simultaneously. 4. Measure: • Rectifier/regulator output voltage Below specification → Replace the recti- fier/regulator.
  • Page 273 – ELEC IGNITION SYSTEM IGNITION COIL 1. Measure: • Primary coil resistance Out of specification → Replace. Primary coil resistance: 1.19–1.61 Ω at 20 °C (68 °F) NOTE: When measuring a resistance of 10 Ω or less with the digital tester, the correct measurement cannot be obtained because of the tester’s internal resistance.
  • Page 274 Checking steps: • Measure the ambient temperature. • Connect a computer to the watercraft and use the Yamaha Diagnostic System to display the intake air temperature. • If the ambient temperature and the dis- played intake air temperature differ by more than ±...
  • Page 275 – ELEC IGNITION SYSTEM THERMOSWITCH (ENGINE) 1. Check: • Thermoswitch (engine) continuity (at the specified temperature) Out of specification → Replace. Thermoswitch (engine) continuity temperature: a 84–90 °C (183–194 °F) b 70–84 °C (158–183 °F) 1 No continuity È Temperature 2 Continuity É...
  • Page 276 – ELEC IGNITION SYSTEM MAIN AND FUEL PUMP RELAY 1. Check: • Main and fuel pump relay continuity Faulty → Replace. Checking steps: • Connect the tester leads between the main and fuel pump relay terminals 5, 6 and 7. •...
  • Page 277 1. • To start the ECM normally, use the Yamaha Diagnostic System. Use the test connector 2 to start the ECM normally only if the Yamaha Diagnostic System is not available. • Measure the throttle position sensor out- put voltage.
  • Page 278 • To measure the output voltage, pass the screwdriver under the measuring positions A, B (center), and C of the cam position sen- sor in order. • When operating the Yamaha Diagnostic Sys- tem, electric power is supplied to the cam position sensor. 7-23...
  • Page 279 – ELEC IGNITION SYSTEM NOISE FILTER 1. Check: • Noise filter continuity Out of specification → Replace. Noise filter continuity: Black (B) – Red (R) No continuity SLANT DETECTION SWITCH È 1. Check: • Slant detection switch continuity Out of specification → Replace. É...
  • Page 280 – ELEC FUEL CONTROL SYSTEM FUEL CONTROL SYSTEM WIRING DIAGRAM 33 : P/G 5 : P 6 : P/W 35 : B/Y 8 : B/Y 37 : Pu/G 9 : O 38 : Pu/Y 14 : L 39 : Pu/B 40 : Pu/R 28 : L/B 30 : R/Y...
  • Page 281 – ELEC FUEL CONTROL SYSTEM WIRING DIAGRAM 33 : P/G 5 : P 6 : P/W 35 : B/Y 8 : B/Y 37 : Pu/G 9 : O 38 : Pu/Y 14 : L 39 : Pu/B 40 : Pu/R 28 : L/B 30 : R/Y 1 2 3 4 5 6 7 8...
  • Page 282 – ELEC FUEL CONTROL SYSTEM FUEL PUMP 1. Check: • Fuel pump operating sound Fuel pump does not sound → Measure the fuel pressure. Refer to “FUEL INJECTION SYSTEM” in Chapter 4. NOTE: After the engine is stopped, the fuel pump will operate for 10 seconds.
  • Page 283 – ELEC FUEL CONTROL SYSTEM FUEL INJECTOR Refer to “FUEL INJECTION SYSTEM” in Chapter 4. MAIN AND FUEL PUMP RELAY Refer to “IGNITION SYSTEM”. OIL PRESSURE SWITCH Refer to “INDICATION SYSTEM”. THERMOSWITCH (ENGINE) Refer to “IGNITION SYSTEM”. THERMOSWITCH (EXHAUST) Refer to “IGNITION SYSTEM”. SLANT DETECTION SWITCH Refer to “IGNITION SYSTEM”.
  • Page 284: Starting System

    – ELEC STARTING SYSTEM STARTING SYSTEM WIRING DIAGRAM 1 2 3 4 5 6 7 8 R Br Br Br FREE FREE PUSH PUSH 11 15 14 18 12 3 4 13 123456789 0ABCDEFGH 1 ECM 0 Remote control unit : Black 2 Main and fuel pump relay A Fuel pump...
  • Page 285 – ELEC STARTING SYSTEM BATTERY Refer to “ELECTRICAL” in Chapter 3. WIRING CONNECTIONS 1. Check: • Wiring connections Poor connections → Properly connect. FUSE 1. Check: • Fuse broken Broken → Replace. Fuse rating: 3A, 20A NOTE: 20A fuse is for main relay, engine shut-off switch and rectifier/regulator.
  • Page 286 – ELEC STARTING SYSTEM STARTER RELAY 1. Inspect: • Brown lead terminal • Black lead terminal Loose → Tighten. 2. Check: • Starter relay Faulty → Replace. Checking steps: • Connect the tester leads between the starter relay terminals as shown. •...
  • Page 287 – ELEC STARTER MOTOR STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STARTER MOTOR Follow the left “Step” for disassembly. DISASSEMBLY Starter motor Refer to “GENERATOR AND STARTER MOTOR” in Chapter 5. O-ring Not reusable Bolt Starter motor front cover O-ring...
  • Page 288 – ELEC STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Starter motor rear cover O-ring Not reusable Shim t = 0.2 mm, 0.8 mm Armature assembly Nut/spring washer/washer 1/1/4 O-ring Not reusable Brush holder Brush spring Bolt Brush assembly *: As required 7-33...
  • Page 289 – ELEC STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Spacer Holder Starter motor yoke Reverse the disassembly steps for assembly. 7-34...
  • Page 290 – ELEC STARTER MOTOR SERVICE POINTS Armature inspection 1. Inspect: • Armature shaft 1 Damage/wear → Replace. 2. Inspect: • Commutator Dirt → Clean with 600 grit sandpaper. 3. Measure: • Commutator diameter Below specification → Replace. Minimum commutator diameter: 27.0 mm (1.06 in) 4.
  • Page 291 – ELEC STARTER MOTOR 6. Inspect: • Armature coil continuity Out of specification → Replace. Armature coil continuity: Commutator segments 1 Continuity Segment - Laminations 2 No continuity Segment - Armature shaft No continuity Brush holder inspection 1. Measure: • Brush length a Below specification →...
  • Page 292: Charging System

    – ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM 1 Rectifier/regulator : Black 2 Fuse (20A) : Green 3 Battery : Red 4 Lighting coil 7-37...
  • Page 293 – ELEC CHARGING SYSTEM FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in Chapter 3. LIGHTING COIL Refer to “IGNITION SYSTEM”. RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM”. 7-38...
  • Page 294: Electric Bilge Pump

    – ELEC ELECTRIC BILGE PUMP ELECTRIC BILGE PUMP WIRING DIAGRAM 1 2 3 4 5 6 7 8 1 ECM : Black 2 Main and fuel pump relay : Brown 3 Fuse (3A) : Red 4 Battery : Yellow 5 Electric bilge pump : Blue/red 6 Remote control unit : Red/yellow...
  • Page 295 – ELEC ELECTRIC BILGE PUMP ELECTRIC BILGE PUMP 1. Check: • Electric bilge pump operation Incorrect → Replace. Checking steps: • Suspend the electric bilge pump in a con- – tainer filled with water. • Connect the brown lead terminal to the positive battery terminal.
  • Page 296 – ELEC OFF THROTTLE STEERING SYSTEM OFF THROTTLE STEERING SYSTEM WIRING DIAGRAM 18 : 12 : 20 : 13 : 29 : 16 : 30 : 17 : 34 : Pu/B Pu/Y Pu/R Pu/G Pu/R Pu/G Pu/Y Pu/B 1 ECM : Black : Red/yellow 2 Steering switch...
  • Page 297 For checking instructions, refer to “SELF-DIAGNOSIS” in Chapter 9. Malfunction → Use the “Engine monitor” of the Yamaha Diagnostic System to check that the steering switch switches on and off when the handlebar is turned to the right and to the left.
  • Page 298 – ELEC INDICATION SYSTEM INDICATION SYSTEM WIRING DIAGRAM 1 2 3 4 5 6 7 8 1 21 30 15 18 16 1 ECM 0 Multifunction meter 2 Main and fuel pump relay A Fuel sender 3 Fuse (20A) B Speed sensor 4 Remote control unit C Buzzer 5 Battery...
  • Page 299 – ELEC INDICATION SYSTEM WIRING DIAGRAM 1 2 3 4 5 6 7 8 1 21 30 15 18 16 : Black : Red : Blue/red : Brown : White : Blue/yellow : Green : Yellow P/W : Pink/white : Gray : Black/blue R/W : Red/white : Blue...
  • Page 300 – ELEC INDICATION SYSTEM FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in Chapter 3. MAIN AND FUEL PUMP RELAY Refer to “IGNITION SYSTEM”. Refer to “IGNITION SYSTEM”. ENGINE TEMPERATURE SENSOR Refer to “IGNITION SYSTEM”. THERMOSWITCH (ENGINE) Refer to “IGNITION SYSTEM”. THERMOSWITCH (EXHAUST) Refer to “IGNITION SYSTEM”.
  • Page 301 – ELEC INDICATION SYSTEM OIL PRESSURE SWITCH 1. Measure: • Oil pressure switch continuity Out of specification → Replace. Lower unit pressure/vacuum tester: YB-35956-A Vacuum/pressure pump gauge set: 90890-06756 Oil pressure switch continuity pressure: 128 kPa (1.28 kgf/cm , 18.2 psi) – 166 kPa (1.66 kgf/cm , 23.6 psi) MULTIFUNCTION METER...
  • Page 302 – ELEC INDICATION SYSTEM Display function 1. Check: • Display function Does not operate → Replace the multi- function meter. 1 Remote control unit : Black : Black/green 2 Buzzer : Gray : Black/blue 3 Speed sensor : Pink : Black/yellow 4 ECM : Red : Blue/black...
  • Page 303 – ELEC INDICATION SYSTEM Speedometer display 1. Check: • Speedometer display Does not display → Measure the speed sensor output voltage and pulses. 2. Measure: • Speed sensor output voltage and pulses Out of specification → Repair or replace. Within specification → Replace the mul- tifunction meter.
  • Page 304 1. Check: • Voltage meter display Does not display → Check the battery voltage using the “Engine monitor” of the Yamaha Diagnostic System. Replace the multifunction meter. Low oil pressure warning indicator 1. Check: • Low oil pressure warning indicator No operating →...
  • Page 305 – ELEC INDICATION SYSTEM Overheat warning indicator 1. Check: • Overheat warning indicator Does not operate → Replace the multi- function meter. Checking steps: • Start the engine. • Disconnect the thermoswitch (engine) connector 1 (blue), engine temperature sensor connector 2 (black) or ther- moswitch (exhaust) 3 connector.
  • Page 306: Remote Control System

    – ELEC REMOTE CONTROL SYSTEM REMOTE CONTROL SYSTEM WIRING DIAGRAM 14 : L 37 : Pu/G 1 2 3 4 5 6 7 8 15 : W/B 38 : Pu/Y 21 : L/R 39 : Pu/B 30 : R/Y 40 : Pu/R 31 : Y Pu/B Pu/Y...
  • Page 307 Yamaha Security System indicator 1. Check: • Yamaha Security System indicator Check that the “SECURITY” indicator light 1 comes on when the Yamaha Security System is deactivated (i.e., the engine can be started). Does not come on → Measure the remote control unit output voltage.
  • Page 308 – ELEC REMOTE CONTROL SYSTEM Diagnostic display 1. Check: • Diagnostic display Does not display → Replace the multi- function meter. Checking steps: • Start the engine. • Disconnect the coupler of a sensor (e.g,. engine temperature sensor) that is nor- mally displayed when a malfunction occurs.
  • Page 309 – ELEC REMOTE CONTROL SYSTEM Yamaha Number of Engine Security beeps startability System mode 1 beep Lock Unable Unlock 2 beeps Able (normal mode) Unlock 3 beeps (low-rpm Able mode) • Press the unlock button for more than 4 seconds to select the low-rpm mode.
  • Page 310 – ELEC REMOTE CONTROL SYSTEM Transmitter registration 1. Register: • Remote control transmitter 1 ID codes can be added or re-registered by connecting the entry box 2. Registration steps: • Connect the entry box. • Transmit the ID code from the remote control transmitter to be registered.
  • Page 311 – ELEC REMOTE CONTROL SYSTEM Replacing of the transmitter battery CAUTION: • Do not allow any water, dust, or dirt to enter the remote control transmitter case when replacing the battery. • Make sure that no foreign material is trapped between the upper case and lower case of the remote control transmit- ter during assembly.
  • Page 312 HULL HOOD CHAPTER 8 HULL AND HOOD HANDLEBAR ....................8-1 EXPLODED DIAGRAM ................8-1 REMOVAL AND INSTALLATION CHART ..........8-1 SERVICE POINTS ..................8-6 Handlebar inspection ................8-6 Handlebar switch inspection ............... 8-6 Handlebar assembly installation ............8-6 QSTS GRIP ..................... 8-8 EXPLODED DIAGRAM ................8-8 REMOVAL AND INSTALLATION CHART ..........
  • Page 313 HULL HOOD STEERING CONSOLE COVER ..............8-26 EXPLODED DIAGRAM ................8-26 REMOVAL AND INSTALLATION CHART ..........8-26 SERVICE POINTS .................. 8-32 Glove compartment assembly installation.........8-32 HOSES ......................8-33 EXPLODED DIAGRAM ................8-33 REMOVAL AND INSTALLATION CHART ..........8-33 SHIFT LEVER....................8-35 EXPLODED DIAGRAM ................8-35 REMOVAL AND INSTALLATION CHART ..........
  • Page 314 HULL HANDLEBAR HOOD HANDLEBAR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR COVER REMOVAL Follow the left “Step” for removal. Screw Handlebar cover Bolt NOTE: Position the corrugated tube for the throttle Handlebar cover stay cable as shown in the illustration so that the Throttle cable tube attaches to the end of the outer throttle...
  • Page 315 HULL HANDLEBAR HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR REMOVAL Follow the left “Step” for removal. QSTS cable (to jet thrust nozzle) Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”. Nut/washer QSTS converter with white tape a QSTS cable 2 QSTS cable 1...
  • Page 316 HULL HANDLEBAR HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Hose packing Not reusable Buzzer NOTE: Handlebar assembly • Pass the QSTS cable and handlebar switch lead through the handle boss cover, and then install the handlebar assembly. • Install the sponges of the QSTS cables as shown and make sure that the grommet is installed to the deck securely.
  • Page 317 HULL HANDLEBAR HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR DISASSEMBLY Follow the left “Step” for disassembly. Bolt Grip end Spacer Screw/spring washer/washer 1/1/1 QSTS grip assembly Special nut NOTE: Screw Tighten the screw from the engine stop switch side.
  • Page 318 HULL HANDLEBAR HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Handlebar switch assembly Screw Throttle lever assembly Handlebar grip NOTE: Apply adhesive to the handlebar and the inner surface of the handlebar grip. Handlebar Reverse the disassembly steps for assembly.
  • Page 319 HULL HANDLEBAR HOOD SERVICE POINTS Handlebar inspection 1. Inspect: • Handlebar Bends/cracks/damage → Replace. Handlebar switch inspection Refer to “STARTING SYSTEM” in Chapter 7. Handlebar assembly installation 1. Install: • Bands 1 NOTE: After inserting the QSTS cables, buzzer lead, handlebar switch lead and throttle cable into the grommets, tie the end of grommets with the bands.
  • Page 320 HULL HANDLEBAR HOOD 3. Install: • Throttle cable NOTE: Fit the seal into the groove in the bracket. 4. Install: • Handlebar cover 1 NOTE: When the handlebar cover is in contact with the steering boss cover, adjust the handlebar mount angle so that the clearance a and b are equal.
  • Page 321 HULL QSTS GRIP HOOD QSTS GRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points QSTS GRIP DISASSEMBLY Follow the left “Step” for disassembly. QSTS grip assembly Refer to “HANDLEBAR”. Screw/washer Cover Ball Spring QSTS cable 1 with white tape a QSTS cable 2...
  • Page 322 HULL QSTS GRIP HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Screw/washer Spacer QSTS shift lock lever Spring Spacer Cable housing QSTS grip Reverse the disassembly steps for assembly.
  • Page 323 HULL QSTS GRIP HOOD SERVICE POINTS QSTS cable inspection and adjustment 1. Inspect: • QSTS cables Frays/kinks/rough movement → Replace. 2. Adjust: • QSTS cable length a QSTS cable length: 72 ± 0.5 mm (2.83 ± 0.02 in) NOTE: • Before adjusting the QSTS cables, set the trim grip to the neutral position.
  • Page 324 HULL STEERING MASTER HOOD STEERING MASTER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING MASTER REMOVAL Follow the left “Step” for removal. Steering console cover Refer to “STEERING CONSOLE COVER”. Steering cable end Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”.
  • Page 325 HULL STEERING MASTER HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Magnet Steering switch Reverse the removal steps for installation. 8-12...
  • Page 326 HULL STEERING MASTER HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING MASTER Follow the left “Step” for disassembly. DISASSEMBLY Bolt/washer Stay Spring Bolt/washer Lower housing Spring Bushing Bushing Upper housing Tilt lever 8-13...
  • Page 327 HULL STEERING MASTER HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Tilt stopper Bolt/nut/holder 4/4/4 Retainer Steering shaft Steering tube Bolt Shaft 1 Cross piece Reverse the disassembly steps for assembly. 8-14...
  • Page 328 HULL STEERING MASTER HOOD SERVICE POINTS Steering master components inspection 1. Inspect: • Each component part Damage/wear → Replace the steering master. 8-15...
  • Page 329 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REMOTE CONTROL CABLES Follow the left “Step” for removal. AND SPEED SENSOR LEAD REMOVAL Service lid 1 Refer to “FRONT HOOD”.
  • Page 330 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Steering cable Seal Speed sensor coupler Screw Speed sensor Shift cable end 8-17...
  • Page 331 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Shift cable holder Shift cable Seal QSTS cable end QSTS cable Packing Reverse the removal steps for installation. 8-18...
  • Page 332 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD SERVICE POINTS WARNING When routing the cables, do not grasp the cable by the outer crimped sheath or steel end. This could deform or loosen the cable end due to extreme angles and or pressure. Always hold the cables by the outer cover below the crimp.
  • Page 333 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD QSTS cable (jet pump end) installation 1. Install: • QSTS cable (jet pump end) QSTS cable set length a (jet pump end): 13.6 mm (0.54 in) WARNING The QSTS cable must be screwed in more than 8 mm (0.31 in).
  • Page 334 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD Shift cable holder installation 1. Install: • Shift cable holders NOTE: Install the shift cable holders so that mark a and mark b are in the positions shown in the illustration. Shift cable stopper installation 1.
  • Page 335 HULL FRONT HOOD HOOD FRONT HOOD EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 10 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 18 mm 5.4 N •...
  • Page 336 HULL FRONT HOOD HOOD EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 10 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 18 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 ×...
  • Page 337 HULL FRONT HOOD HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HINGE DISASSEMBLY Follow the left “Step” for disassembly. Circlip Pin (long) Hinge Pin (short) Damper stay Collar Grommet 8-24...
  • Page 338 HULL FRONT HOOD HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Band Damper boots Damper Reverse the disassembly steps for assembly. 8-25...
  • Page 339 HULL STEERING CONSOLE COVER HOOD STEERING CONSOLE COVER EXPLODED DIAGRAM 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 5 × 20 mm 6.9 N • m (0.69 kgf • m, 5.0 ft • Ib) 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 5 ×...
  • Page 340 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 5 × 20 mm 6.9 N • m (0.69 kgf • m, 5.0 ft • Ib) 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 5 ×...
  • Page 341 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 22 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SIDE COVER REMOVAL Follow the left “Step” for removal. Cup holder Holder Bolt...
  • Page 342 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 30 mm 6 × 18 mm 6 × 22 mm 8 ×...
  • Page 343 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 30 mm 6 × 18 mm 6 × 22 mm 8 ×...
  • Page 344 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 14 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points GLOVE COMPARTMENT Follow the left “Step” for disassembly. DISASSEMBLY Glove compartment Hinge assembly...
  • Page 345 HULL STEERING CONSOLE COVER HOOD SERVICE POINTS Glove compartment assembly installation 1. Install: • Hinge assembly NOTE: When installing the hinge assembly, make sure that the springs are in the position shown. 8-32...
  • Page 346 HULL HOSES HOOD HOSES EXPLODED DIAGRAM (VENT) (VENT) (VENT) 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HOSES REMOVAL...
  • Page 347 HULL HOSES HOOD EXPLODED DIAGRAM (VENT) (VENT) (VENT) 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) Step Procedure/Part name Q’ty Service points Clamp Cooling water hose Cooling water pilot outlet Seal Reverse the removal steps for installation.
  • Page 348 HULL SHIFT LEVER HOOD SHIFT LEVER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SHIFT LEVER REMOVAL Follow the left “Step” for removal. Side cover Refer to “STEERING CONSOLE COVER”. Shift cable Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”.
  • Page 349 HULL SHIFT LEVER HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Screw Base assembly Nut/washer Screw Plate Reverse the removal steps for installation. 8-36...
  • Page 350 HULL SHIFT LEVER HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BASE DISASSEMBLY Follow the left “Step” for disassembly. Bolt/washer Plate Spring Actuator Roller Shaft Shift arm Reverse the disassembly steps for assembly. 8-37...
  • Page 351 HULL SHIFT LEVER HOOD SERVICE POINTS Base assembly 1. Install: • Shift arm • Shaft Installation steps: • Install the shift arm 1 so that it comes in contact with the stopper 2 as shown. • Install the shaft 3 to the base so that it come in contact with the stopper 4 as shown.
  • Page 352 HULL SEATS AND HAND GRIP HOOD SEATS AND HAND GRIP EXPLODED DIAGRAM 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 ×...
  • Page 353 HULL SEATS AND HAND GRIP HOOD EXPLODED DIAGRAM 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 8 ×...
  • Page 354 HULL SEATS AND HAND GRIP HOOD EXPLODED DIAGRAM 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 8 ×...
  • Page 355 HULL SEATS AND HAND GRIP HOOD SERVICE POINTS Seat lock inspection 1. Inspect: • Front seat lock • Rear seat lock Damage/wear → Replace. 8-42...
  • Page 356 HULL EXHAUST SYSTEM HOOD EXHAUST SYSTEM EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 3.7 N •...
  • Page 357 HULL EXHAUST SYSTEM HOOD EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 3.7 N •...
  • Page 358 HULL EXHAUST SYSTEM HOOD EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 3.7 N •...
  • Page 359 HULL EXHAUST SYSTEM HOOD SERVICE POINTS Exhaust system inspection 1. Inspect: • Water lock band Cracks/damage → Replace. 2. Inspect: • Rubber hoses Burns/cracks/damage → Replace. 3. Inspect: • Water lock Cracks/leaks → Replace. 4. Inspect: • Water tank Cracks/damage/leaks → Replace. Exhaust component parts sub-assembly 1.
  • Page 360 HULL EXHAUST SYSTEM HOOD Exhaust system installation 1. Install: • Exhaust joint NOTE: Be sure to install the projections a on the exhaust pipe and exhaust joint into the slots b in the joint. 2. Install: • Water lock NOTE: Be sure to insert the rubber hose to the line a on the water lock.
  • Page 361 HULL DECK AND HULL HOOD DECK AND HULL EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 13 N • m (1.3 kgf • m, 9.4 ft • Ib) 6 ×...
  • Page 362 HULL DECK AND HULL HOOD EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 13 N • m (1.3 kgf • m, 9.4 ft • Ib) 6 ×...
  • Page 363 HULL ENGINE MOUNT HOOD ENGINE MOUNT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ENGINE MOUNT REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT” in Chapter 5. Bolt Damper 1 Damper 2 Bolt Engine mount Liner...
  • Page 364 TRBL ANLS CHAPTER 9 TROUBLE ANALYSIS INTRODUCTION....................9-1 FEATURES ....................9-1 Functions..................... 9-1 CONTENTS....................9-1 HARDWARE REQUIREMENTS..............9-2 OPERATING....................9-3 CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT..................9-3 Top view....................9-3 TROUBLE ANALYSIS..................9-4 TROUBLE ANALYSIS CHART..............9-4 SELF-DIAGNOSIS ..................9-8...
  • Page 365 ANLS INTRODUCTION FEATURES The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ECM (Electronic Control Module) of a watercraft using the com- munication cable, this software can be used to display sensor data and data stored in the ECM on a computer’s monitor.
  • Page 366 • Windows XP is a multiuser operating system, therefore, be sure to end this program if the login user is changed. • The USB adapter cannot be used with Windows 95. For operating instructions of the Yamaha Diagnostic System, refer to the “Yamaha Diagnostic Sys- tem Instruction Manual”.
  • Page 367 TRBL OPERATING ANLS OPERATING CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT Top view 1 3-pin communication coupler 2 Wiring harness coupler 3 Meter coupler NOTE: Be careful not to pinch the communication cable between the hood and the deck or to damage it.
  • Page 368 TRBL TROUBLE ANALYSIS ANLS TROUBLE ANALYSIS NOTE: Before consulting the “TROUBLE ANALYSIS CHART,” check the following items. 1. Check that the battery is charged and that its specified gravity is within specification. 2. Check that there are no incorrect wiring connections. 3.
  • Page 369 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part chapter POWER UNIT Compression Cylinder head gaskets Cylinder block Crankcase Piston rings Pistons Bearings Thermostat Valve(s) and valve seat(s) Valve clearance adjusting pad(s) Camshaft(s) Timing chain Oil pump Engine oil Oil filter Oil pressure switch Bearing housing...
  • Page 370 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part chapter JET PUMP UNIT Duct Impeller Intake grate Bearings Intake duct Water inlet hose Bilge hose Bilge strainer Bilge hose joint ELECTRICAL Ignition system, fuel control system • Pickup coils •...
  • Page 371 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part chapter Starting system • Start switch • Starter relay • Starter motor Charging system • Lighting coil • Rectifier/regulator • Fuses • Battery leads — • Battery Electric bilge pump •...
  • Page 372 Bypass valve motor malfunction Steering switch malfunction Intake air system malfunction If the Yamaha Diagnostic System is not used to check the symptoms listed in the table, the error codes can be checked easily with the self-diagnosis in the multifunction meter. How-...
  • Page 373 WIRING DIAGRAM FX High Output, FX Cruiser High Output 1 Fuse (20 A) Color code 2 Fuse (3 A) : Black 3 Starter relay : Brown 4 Slant detection switch : Green 5 Main and fuel pump relay : Blue 6 ECM : Orange 7 Rectifier/regulator...
  • Page 374 FX High Output, FX Cruiser High Output Pu/Y Pu/B Pu/G Pu/R Br Br Pu/R Pu/G 3 4 6 7 9 10 11 Pu/Y Pu/B 12 13 14 15 16 18 Pu/R Pu/B Pu/Y Pu/G R Br Br Br FREE FREE FREE PUSH PUSH...
  • Page 375 Pu/B Pu/G Pu/R Pu/Y Pu/G Pu/B Pu/R Pu/Y Pu/B Pu/G Pu/Y Pu/R B/R B/W Pu/R Pu/Y Pu/G Pu/B È É...
  • Page 376 YAMAHA MOTOR CORPORATION, USA Printed in USA × 1 CR Feb. 2004 –...
  • Page 377 WaveRunner FX Cruiser FX High Output FX Cruiser High Output SUPPLEMENTARY SERVICE MANUAL *LIT186160293* LIT-18616-02-93 F1X-28197-1H-1X...
  • Page 378: F1S-28197-1G

    A10001-0* WaveRunner FX/FX Cruiser FX High Output/FX Cruiser High Output SUPPLEMENTARY SERVICE MANUAL ©2005 by Yamaha Motor Corporation, USA 1st Edition, December 2005 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited.
  • Page 379 HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
  • Page 380 IMPORTANT INFORMATION In this Supplementary Service Manual particularly important information is distinguished in the fol- lowing ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, passenger(s), a bystander, or a person inspecting or repairing the watercraft.
  • Page 381 HOW TO USE THIS MANUAL 1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 2 Numbers are given in the order of the jobs in the exploded diagram. 3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
  • Page 382: Specifications

    Symbols F to I in an exploded diagram indi- cate the grade of lubricant and the lubrication point. F Apply Yamaha 4-stroke motor oil G Apply water resistant grease (Yamaha grease A, Yamaha marine grease) H Apply ThreeBond 1104J or ThreeBond 1280B...
  • Page 383: Periodic Inspection And

    INDEX A30000-0 GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND ADJUSTMENT INSP FUEL SYSTEM FUEL POWER UNIT POWR JET PUMP UNIT PUMP – ELECTRICAL SYSTEM ELEC HULL AND HOOD HULL HOOD TROUBLE ANALYSIS TRBL ANLS...
  • Page 384 GENERAL INFORMATION IDENTIFICATION NUMBERS ................1 PRIMARY l.D. NUMBER ................1 ENGINE SERIAL NUMBER ................. 1 JET PUMP UNIT SERIAL NUMBER ............1 HULL IDENTIFICATION NUMBER (H.l.N.)..........1 SPECIAL TOOLS ....................2 MEASURING....................2 SPECIFICATIONS GENERAL SPECIFICATIONS ................3 MAINTENANCE SPECIFICATIONS ..............7 ENGINE .......................
  • Page 385 PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART ............... 41 PERIODIC SERVICE ..................42 CONTROL SYSTEM .................. 42 Steering master inspection..............42 Steering cable inspection and adjustment ........... 42 Throttle cable inspection and adjustment..........43 GENERAL ....................45 Drain plug inspection................45 Lubrication points .................
  • Page 386 Overheat warning indicator ..............67 Check engine warning indicator ............68 Diagnostic display ................68 REMOTE CONTROL SYSTEM (For FX High Output/FX Cruiser High Output)..........69 WIRING DIAGRAM ..................69 REMOTE CONTROL SYSTEM..............71 Yamaha Security System indicator ............71 Low-rpm mode indicator............... 72...
  • Page 387 HULL AND HOOD HANDLEBAR ....................73 EXPLODED DIAGRAM (For FX/FX High Output) ........73 REMOVAL AND INSTALLATION CHART ..........73 EXPLODED DIAGRAM (For FX Cruiser/FX Cruiser High Output)..... 74 REMOVAL AND INSTALLATION CHART ..........74 EXPLODED DIAGRAM ................75 REMOVAL AND INSTALLATION CHART ..........75 SERVICE POINTS ..................
  • Page 388 SHIFT LEVER....................111 EXPLODED DIAGRAM ................111 REMOVAL AND INSTALLATION CHART ..........111 SEATS AND HAND GRIP ................112 EXPLODED DIAGRAM ................112 REMOVAL AND INSTALLATION CHART ..........112 REBOARDING STEP (For FX Cruiser/FX Cruiser High Output)....115 EXPLODED DIAGRAM ................115 REMOVAL AND INSTALLATION CHART ..........
  • Page 389: Identification Numbers

    IDENTIFICATION NUMBERS INFO A60700-0* IDENTIFICATION NUMBERS PRIMARY l.D. NUMBER The primary l.D. number is stamped on a label attached to the inside of the engine compart- ment. Starting primary l.D. numbers: F1X: 800101 F1Y: 800101 ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the engine unit.
  • Page 390 SPECIAL TOOLS INFO SPECIAL TOOLS Using the correct special tools recommended by Yamaha, will aid the work and enable accu- rate assembly and tune-up. Improvisations and using improper tools can damage the equipment. NOTE: • For U.S.A. and Canada, use part numbers starting with “J-”, “YB-”, “YM-”, “YS-”, “YU-”...
  • Page 391 SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Item Unit FX High Output FX Cruiser High Output Model code Hull Engine/jet Dimensions Length mm (in) 3,340 (131.5) Width mm (in) 1,230 (48.4) Height mm (in) 1,160 (45.7) 1,240 (48.8) Dry weight kg (lb) 372 (820) 380 (838) Maximum capacity...
  • Page 392 SPEC GENERAL SPECIFICATIONS Model Item Unit FX High Output FX Cruiser High Output Fuel and oil Fuel type Regular unleaded gasoline Minimum fuel rating PON* RON* Fuel tank capacity 70 (18.5, 15.4) (US gal, Imp gal) Engine oil type 4-stroke motor oil Engine oil grade SE, SF, SG, SH, SJ, SL 10W-30...
  • Page 393 SPEC GENERAL SPECIFICATIONS Model Item Unit FX Cruiser Model code Hull Engine/jet Dimensions Length mm (in) 3,340 (131.5) Width mm (in) 1,230 (48.4) Height mm (in) 1,160 (45.7) 1,240 (48.8) Dry weight kg (lb) 384 (847) 392 (864) Maximum capacity Person/kg (lb) 3/240 (530) Performance...
  • Page 394 SPEC GENERAL SPECIFICATIONS Model Item Unit FX Cruiser Fuel and oil Fuel type Regular unleaded gasoline Minimum fuel rating PON* RON* Fuel tank capacity 70 (18.5, 15.4) (US gal, Imp gal) Engine oil type 4-stroke motor oil Engine oil grade SE, SF, SG, SH, SJ, SL 10W-30 Engine oil quantity...
  • Page 395 SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model Item Unit FX High Output FX Cruiser High Output Cylinder head Warpage limit mm (in) 0.1 (0.004) Compression pressure 1,150 (11.5, 164) (kgf/cm , psi) Cylinder Bore size mm (in) 76.000–76.015 (2.9921–2.9927) Taper limit mm (in) 0.08 (0.003) Out-of-round limit...
  • Page 396 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX High Output FX Cruiser High Output Valve seat width C Intake mm (in) 0.9–1.1 (0.0354–0.0433) Exhaust mm (in) 0.9–1.1 (0.0354–0.0433) Valve margin thickness D Intake mm (in) 0.85–1.15 (0.0335–0.0453) Exhaust mm (in) 0.85–1.15 (0.0335–0.0453) Valve stem diameter Intake mm (in)
  • Page 397 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX High Output FX Cruiser High Output Piston ring Top ring Type Barrel Dimension (B × T) 0.90 × 2.75 (0.04 × 0.11) mm (in) End gap (installed) mm (in) 0.32–0.44 (0.0126–0.0173) Ring groove clearance mm (in) 0.030–0.065 (0.0012–0.0026) 2nd ring...
  • Page 398 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX High Output FX Cruiser High Output Oil filter Oil filter type Cartridge type Oil pump Oil pump type Trochoid Rotor tip clearance mm (in) 0.09–0.15 (0.0035–0.0059) (scavenge pump) Oil pump housing clearance Rotor (feed pump) mm (in) 0.09–0.17 (0.0035–0.0067) Rotor (scavenge pump)
  • Page 399 SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model Item Unit FX High Output FX Cruiser High Output Battery Type Fluid Capacity V/Ah 12/19 Specific gravity 1.28 ECM unit (B/R – R/Y, B/W – R/Y, B/Y – R/Y, B/L – R/Y) Output peak voltage lower limit @cranking (loaded) @2,000 r/min (loaded) @3,500 r/min (loaded)
  • Page 400 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX High Output FX Cruiser High Output Starter relay Rating Seconds Thermoswitch ON temperature (engine) °C (°F) 84–90 (183–194) OFF temperature (engine) °C (°F) 70–84 (158–183) ON temperature (exhaust) °C (°F) 94–100 (201–212) OFF temperature (exhaust) °C (°F) 80–94 (176–201) Engine temperature sensor...
  • Page 401 SPEC MAINTENANCE SPECIFICATIONS ENGINE Model Item Unit FX Cruiser Cylinder head Warpage limit mm (in) 0.1 (0.004) Compression pressure 1,350 (13.5, 192) (kgf/cm , psi) Cylinder Bore size mm (in) 74.060–74.075 (2.9157–2.9163) Taper limit mm (in) 0.08 (0.003) Out-of-round limit mm (in) 0.05 (0.002) Wear limit...
  • Page 402 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX Cruiser Valve seat width C Intake mm (in) 0.9–1.1 (0.0354–0.0433) Exhaust mm (in) 0.9–1.1 (0.0354–0.0433) Valve margin thickness D Intake mm (in) 0.85–1.15 (0.0335–0.0453) Exhaust mm (in) 0.85–1.15 (0.0335–0.0453) Valve stem diameter Intake mm (in) 3.975–3.990 (0.1565–0.1571) Exhaust...
  • Page 403 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX Cruiser Piston ring Top ring Type Barrel Dimension (B × T) 0.90 × 2.75 (0.04 × 0.11) mm (in) End gap (installed) mm (in) 0.19–0.31 (0.0075–0.0122) Ring groove clearance mm (in) 0.030–0.065 (0.0012–0.0026) 2nd ring Type Taper...
  • Page 404 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX Cruiser Oil filter Oil filter type Cartridge type Oil pump Oil pump type Trochoid Rotor tip clearance mm (in) 0.09–0.15 (0.0035–0.0059) (scavenge pump) Oil pump housing clearance Rotor (feed pump) mm (in) 0.09–0.17 (0.0035–0.0067) Rotor (scavenge pump) mm (in) 0.09–0.15 (0.0035–0.0059)
  • Page 405 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX Cruiser Stator Pickup coil (W – B, R – B) Output peak voltage @cranking (unloaded) @cranking (loaded) @2,000 r/min (loaded) @3,500 r/min (loaded) Lighting coil (G – G) Output peak voltage @cranking (unloaded) @2,000 r/min (unloaded) @3,500 r/min (unloaded) Ω...
  • Page 406 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX Cruiser Intake air temperature sensor Intake air temperature sensor resistance (B/Y – B/O) @ 0 °C (32 °F) kΩ 5.4–6.6 @ 80 °C (176 °F) kΩ 0.29–0.39 Intake air pressure sensor Output voltage (P/G –...
  • Page 407 SPEC TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Hull and hood Handlebar cover (for FX/FX High Screw 0.11 Output) Handlebar cover stay (for FX/FX Bolt 0.11 High Output) Upper handlebar cover (for FX Screw 0.11...
  • Page 408 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Side ornament Screw 0.22 Center cover — 0.54 Hood lock — 0.64 Compass sensor and air tempera- — 0.38 ture sensor Shift lever assembly —...
  • Page 409 SPEC CABLE AND HOSE ROUTING CABLE AND HOSE ROUTING DOWN È 1 Fuel tank breather hose A Electrical bilge pump lead H Remote control unit 2 Cooling water pilot outlet hose B Electrical box lead (FX High Output/FX Cruiser 3 Cooling water pilot outlet C Throttle cable High Output) 4 Negative battery lead...
  • Page 410 SPEC CABLE AND HOSE ROUTING È É 4 5 6 7 Ì Ì Ë Ê Í Í Ë 1 Buzzer lead 0 Shift cable F Remote control unit antenna 2 Steering sensor lead A QSTS cable (FX High Output/FX Cruiser 3 Handlebar switch assembly B Steering cable High Output)
  • Page 411 SPEC CABLE AND HOSE ROUTING È É 4 5 6 7 Ì Ì Ë Ê Í Í Ë È Fasten the handlebar switch assembly lead, fuel Ë Connect the left operation button lead coupler level sensor lead, speed sensor lead, and elec- (natural) to the multifunction meter lead coupler trical box lead securely with a plastic tie.
  • Page 412 SPEC CABLE AND HOSE ROUTING È É Ë É Ê È Í MAIN S P A R E Ì 1 Shift cable B Water separator 2 Steering cable C Ignition coil lead 3 Fuel hose D Starter motor positive lead 4 Throttle cable E Wiring harness 5 Cooling water pilot outlet hose...
  • Page 413 SPEC CABLE AND HOSE ROUTING È É Ë É Ê È Í MAIN S P A R E Ì È To ventilation socket É To fuel tank Ê Route the fuel tank breather hose as shown in the illustration. Ë Bow Ì...
  • Page 414 SPEC CABLE AND HOSE ROUTING Ë Ì È È Ê É Ê É Í 1 Throttle cable 9 Remote control unit antenna 2 QSTS cable (FX High Output/FX Cruiser High Output) 3 Handlebar switch lead 4 Grommet È Less than 10 mm (0.39 in) 5 Hose packing É...
  • Page 415 SPEC CABLE AND HOSE ROUTING Ë Ì È È Ê É Ê É Í Ê Position the QSTS cable packing in the opening in the grommet so that the plastic tie is fastened around both the grommet and the packing. Ë...
  • Page 416 SPEC CABLE AND HOSE ROUTING È 1 Cooling water hose (cooling water inlet) A QSTS cable 2 Bilge hose 1 B Positive battery lead 3 Electric bilge pump C Speed sensor lead 4 Bilge hose 4 D Electric bilge pump lead 5 Cooling water hose (from thermostat) E Bilge strainer 6 Bilge hose 3...
  • Page 417 SPEC CABLE AND HOSE ROUTING È È È Ê Í Ë É È Ì È Î Ï Ð 1 Wiring harness A Cam position sensor coupler Ì Fasten the plastic tie with its 2 Ground lead B Oil pressure switch lead end facing downward.
  • Page 418 SPEC CABLE AND HOSE ROUTING Ó Ë Ê Î É Ì Í Ï Ð È Ô Õ Ð Ð Ï Ï Ò Ñ Ñ Ò 1 Engine temperature sensor coupler È Fasten the engine temperature sensor lead, 2 Lighting coil coupler thermoswitch lead, and lighting coil lead with a 3 Pickup coil coupler plastic tie.
  • Page 419 SPEC CABLE AND HOSE ROUTING Ó Ë Ê Î É Ì Í Ï Ð È Ô Õ Ð Ð Ï Ï Ò Ñ Ñ Ò Î Route the starter motor lead to the outside of the Ô FX High Output/FX Cruiser High Output Õ...
  • Page 420 SPEC CABLE AND HOSE ROUTING (For FX/FX Cruiser) CABLE AND HOSE ROUTING (For FX/FX Cruiser) Ê Ù Ë Ë Ë Ë Ï È Î Í Ì Ö × É Ð Ñ Ì Ø Ê Ô Ñ Ë Ú Õ Ó Ì...
  • Page 421 SPEC CABLE AND HOSE ROUTING (For FX/FX Cruiser) Ê Ù Ë Ë Ë Ë Ï È Î Í Ì Ö × É Ð Ñ Ì Ø Ê Ô Ñ Ë Ú Õ Ó Ì Ò Ó Í When installing the cooling water hoses, be sure Ò...
  • Page 422 SPEC CABLE AND HOSE ROUTING (For FX/FX Cruiser) Ê Ù Ë Ë Ë Ë Ï È Î Í Ì Ö × É Ð Ñ Ì Ø Ê Ô Ñ Ë Ú Õ Ó Ì Ò Ó Ö Bundle the cooling water hose (cylinder head Ø...
  • Page 423 SPEC CABLE AND HOSE ROUTING (For FX/FX Cruiser) È É Ê Î Ï Ë Ì Í 1 Intake air temperature sensor coupler È Route the throttle cable between the sub-wiring 2 Intake air pressure sensor coupler harness. 3 Fuel injector #4 coupler É...
  • Page 424 SPEC CABLE AND HOSE ROUTING (For FX/FX Cruiser) È É Ê Î Ï Ë Ì Í Î Fasten the ring, which is attached to the sub- wiring harness, to the sensor bracket with a plastic tie. Face the end of the plastic tie towards the sensor.
  • Page 425 CABLE AND HOSE ROUTING (For FX High Output/ SPEC FX Cruiser High Output) CABLE AND HOSE ROUTING (For FX High Output/FX Cruiser High Output) Ê Ù Ë Ë Ë Ï Ë È Î Í Ì Ö Õ É Ð Ñ Ì...
  • Page 426 CABLE AND HOSE ROUTING (For FX High Output/ SPEC FX Cruiser High Output) Ê Ù Ë Ë Ë Ï Ë È Î Í Ì Ö Õ É Ð Ñ Ì × Ê Ó Ñ Ë Ô Ø Ò Ì Ò Í...
  • Page 427 CABLE AND HOSE ROUTING (For FX High Output/ SPEC FX Cruiser High Output) Ê Ù Ë Ë Ë Ï Ë È Î Í Ì Ö Õ É Ð Ñ Ì × Ê Ó Ñ Ë Ô Ø Ò Ì Ò Õ...
  • Page 428 CABLE AND HOSE ROUTING (For FX High Output/ SPEC FX Cruiser High Output) Ê É È Í Ë Ì 1 Bypass valve motor coupler È To wiring harness Ì Fasten the sub-wiring harness 2 Joint coupler É Route throttle cable to the joint coupler bracket with 3 Sensor assembly coupler between the sub-wiring har-...
  • Page 429: Fuel System

    INSP MAINTENANCE INTERVAL CHART MAINTENANCE INTERVAL CHART The following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the intervals of maintenance should be changed. MAINTENANCE INTERVAL INITIAL THEREAFTER EVERY 10 hours 50 hours 100 hours 100 hours 200 hours ITEM 6 months 12 months 12 months 24 months Spark plug...
  • Page 430 INSP CONTROL SYSTEM PERIODIC SERVICE CONTROL SYSTEM Steering master inspection 1. Inspect: • Steering master Excessive play → Replace the steering master. Refer to “STEERING MASTER”. Inspection steps: • Move the handlebar up and down and back and forth. • Check the excessive play of the handle- bar.
  • Page 431 INSP CONTROL SYSTEM 2. Adjust: • Steering cable joint (steering master end) Adjustment steps: • Set the control grip in the neutral position. • Loosen the locknut 1. • Disconnect the cable joint 2 from the ball joint 3. • Turn the cable joint 2 in or out for adjust- ing the distances a and b.
  • Page 432 INSP CONTROL SYSTEM 2. Adjust: • Throttle lever free play Adjustment steps: NOTE: • When not replacing the throttle cable or removing the cable from the throttle body, adjust the throttle cable free play by fol- lowing steps (d) through (h). •...
  • Page 433 INSP CONTROL SYSTEM/GENERAL h. Install the handlebar cover. Handlebar cover screw: 1.1 N • m (0.11 kgf • m, 0.8 ft • lb) LOCTITE 242 i. Install the ribbon sub assemblies and air filter case cover. Ribbon sub assembly bolt: 6.5 N •...
  • Page 434 2. Lubricate: • Throttle cable (throttle body end) • Throttle bodies (throttle cable pulley, throttle cam, and return spring) Recommended lubricant: Yamaha marine grease, Yamaha grease A (Water resistant grease) 3. Lubricate: • QSTS control cables (handlebar end) Recommended lubricant:...
  • Page 435 INSP GENERAL 4. Lubricate: • QSTS cables (pulley end) Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) 5. Lubricate: • Nozzle pivot shaft • Steering cable (nozzle end) • QSTS cable (nozzle end) Recommended grease: Yamaha marine grease,...
  • Page 436 INSP GENERAL 7. Fill: • Intermediate housing Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) Grease quantity: Initial 10 hours: 33.0–35.0 cm (1.11–1.18 oz) Every 100 hours or 12 months: 6.0–8.0 cm (0.20–0.27 oz) NOTE: Fill the intermediate housing with the recom-...
  • Page 437 – ELEC ELECTRICAL COMPONENTS (For FX/FX Cruiser) ELECTRICAL COMPONENTS (For FX/FX Cruiser) 1 Thermoswitch (engine) B Oil pressure switch K Electric fuel pump 2 Starter motor C Bypass valve motor L Fuel level sensor 3 Engine temperature sensor D Intake air pressure sensor M Left operation button 4 Spark plugs and ignition coils E Intake air temperature sensor...
  • Page 438 ELECTRICAL COMPONENTS (For FX High Output/ – ELEC FX Cruiser High Output) ELECTRICAL COMPONENTS (For FX High Output/FX Cruiser High Output) 1 Thermoswitch (engine) 8 Electric bilge pump G Engine stop switch, engine 2 Starter motor 9 Cam position sensor shut-off switch, start...
  • Page 439 ELECTRICAL COMPONENTS (For FX High Output/ – ELEC FX Cruiser High Output) J Electric fuel pump K Fuel level sensor L Left operation button M Multifunction meter N Right operation button (FX Cruiser High Output) O Remote control unit P Compass sensor and air temperature sensor (FX Cruiser High Output)
  • Page 440 – ELEC OFF THROTTLE STEERING SYSTEM OFF THROTTLE STEERING SYSTEM WIRING DIAGRAM 18 : 12 : 20 : 13 : 27 : 16 : 30 : 17 : 34 : Pu/B Pu/Y Pu/R Pu/G Pu/R Pu/G Pu/Y Pu/B 1 ECM : Black : Green/yellow 2 Steering sensor...
  • Page 441 • Check that the following is displayed in the “Engine Monitor” window of the Yamaha Diagnostic System. • Use the same procedure to check that the steering sensor operates correctly when the handlebar is turned to both the left and right.
  • Page 442 – ELEC INDICATION SYSTEM INDICATION SYSTEM WIRING DIAGRAM (For FX Cruiser High Output) 1 2 3 4 5 6 7 8 1 21 30 15 18 16 1 ECM 0 Multifunction meter 2 Main and fuel pump relay A Fuel level sensor 3 Fuse (20 A) B Speed sensor and water temperature sensor 4 Remote control unit...
  • Page 443 – ELEC INDICATION SYSTEM WIRING DIAGRAM (For FX Cruiser High Output) 1 2 3 4 5 6 7 8 1 21 30 15 18 16 : Black : Black/blue : Green : Black/orange : Blue : Black/yellow : Orange : Blue/black : Pink : Blue/red : Red...
  • Page 444 – ELEC INDICATION SYSTEM WIRING DIAGRAM (For FX High Output) 1 2 3 4 5 6 7 8 1 21 30 15 18 16 1 ECM 0 Multifunction meter 2 Main and fuel pump relay A Fuel level sensor 3 Fuse (20 A) B Speed sensor 4 Remote control unit C Buzzer...
  • Page 445 – ELEC INDICATION SYSTEM WIRING DIAGRAM (For FX High Output) 1 2 3 4 5 6 7 8 1 21 30 15 18 16 : Black : Black/green : Red/yellow : Green : Black/blue W/B : White/black : Gray : Black/orange : Blue : Black/yellow : Orange...
  • Page 446 – ELEC INDICATION SYSTEM WIRING DIAGRAM (For FX/FX Cruiser) 4 3 2 1 8 7 6 5 31 1 1 ECM 8 Thermoswitch : Black : Black/orange 2 Main and fuel pump (engine) : Brown : Black/yellow 9 Engine temperature relay : Green : Blue/black...
  • Page 447 – ELEC INDICATION SYSTEM MULTIFUNCTION METER Multifunction meter 1. Check: • Multifunction meter Cracked meter housing → Replace the multifunction meter. Meter is fogged/shows signs of water intrusion → Replace the multifunction meter. Operation button 1. Check: • Left operation button continuity Out of specification →...
  • Page 448 – ELEC INDICATION SYSTEM MULTIFUNCTION METER REMOVAL Refer “STEERING CONSOLE COVER”. OPERATION BUTTON REMOVAL Refer “STEERING CONSOLE COVER”.
  • Page 449 – ELEC INDICATION SYSTEM Display function (for FX Cruiser High Output) 1. Check: • Display function Does not operate → Replace the multi- function meter. 1 Remote control unit : Black : Blue/black 2 Buzzer : Green : Blue/red 3 Compass sensor : Blue : Blue/yellow 4 ECM...
  • Page 450 – ELEC INDICATION SYSTEM Display function (for FX High Output) 1. Check: • Display function Does not operate → Replace the multi- function meter. 1 Remote control unit : Black : Black/yellow 2 Buzzer : Gray G/W : Green/white 3 Speed sensor : Pink : Blue/black 4 ECM...
  • Page 451 – ELEC INDICATION SYSTEM Display function (for FX/FX Cruiser) 1. Check: • Display function Not operate → Replace the multifunc- tion meter. 1 Buzzer : Black G/W : Green/white 2 Speed sensor : Red : Blue/black 3 ECM : White : Blue/red 4 Fuel level sensor : Yellow...
  • Page 452 – ELEC INDICATION SYSTEM Compass display (for FX Cruiser High Output) 1. Check: • Compass display Incorrect reading → Replace the com- pass sensor. Checking steps: • Using a compass for reference, point the watercraft north. • Turn on the multifunction meter and check that “NORTH”...
  • Page 453 – ELEC INDICATION SYSTEM Speedometer/average speed/tripmeter dis- play (for FX Cruiser High Output) 1. Check: • Speedometer/average speed/tripmeter display Does not display → Measure the speed sensor output voltage. DC V 2. Measure: • Speed sensor output voltage Out of specification → Replace the speed sensor.
  • Page 454 – ELEC INDICATION SYSTEM Water temperature display (for FX Cruiser High Output) 1. Check: • Water temperature display Incorrect reading → Measure the speed sensor (water temperature sensor) resistance. Checking steps: • Measure the ambient water temperature. • Turn on the multifunction meter and check the water temperature displayed on the meter.
  • Page 455 • Fuel consumption per hour, fuel con- sumption per kilometer/mile display Does not display → Check the fuel injec- tion duration using the “Engine monitor” of the Yamaha Diagnostic System. Replace the multifunction meter. Overheat warning indicator 1. Check: • Overheat warning indicator Does not operate →...
  • Page 456 – ELEC INDICATION SYSTEM Check engine warning indicator 1. Check: • Check the engine warning indicator Does not operate → Replace the multi- function meter. Checking steps: • Start the engine. • Disconnect the coupler of a sensor (e.g., engine temperature sensor) that normally activates the check engine warning indi- cator when a malfunction occurs.
  • Page 457 REMOTE CONTROL SYSTEM (For FX High Output/ – ELEC FX Cruiser High Output) REMOTE CONTROL SYSTEM (For FX High Output/FX Cruiser High Output) WIRING DIAGRAM 14 : L 37 : Pu/G 1 2 3 4 5 6 7 8 15 : W/B 38 : Pu/Y 21 : L/R 39 : Pu/B...
  • Page 458 REMOTE CONTROL SYSTEM (For FX High Output/ – ELEC FX Cruiser High Output) WIRING DIAGRAM 14 : L 37 : Pu/G 1 2 3 4 5 6 7 8 15 : W/B 38 : Pu/Y 21 : L/R 39 : Pu/B 30 : R/Y 40 : Pu/R 31 : Y...
  • Page 459 Yamaha Security System indicator 1. Check: • Yamaha Security System indicator Check that the “SECURITY” indicator light 1 comes on when the Yamaha Security System is deactivated (i.e., the engine can be started). Does not come on → Measure the remote control unit output voltage.
  • Page 460 REMOTE CONTROL SYSTEM (For FX High Output/ – ELEC FX Cruiser High Output) Low-rpm mode indicator 1. Check: • Low-rpm mode indicator Does not come on → Replace the multi- function meter. Checking steps: • Press the unlock button 1 of remote con- trol transmitter for more than four sec- onds to select the low-rpm mode.
  • Page 461 HULL HANDLEBAR HOOD HANDLEBAR EXPLODED DIAGRAM (For FX/FX High Output) REMOVAL AND INSTALLATION CHART Step Q’ty Service points Procedure/Part name STEERING PAD REMOVAL Follow the left “Step” for removal. Screw Handlebar cover Bolt Handlebar cover stay Reverse the removal steps for installation.
  • Page 462 HULL HANDLEBAR HOOD EXPLODED DIAGRAM (For FX Cruiser/FX Cruiser High Output) REMOVAL AND INSTALLATION CHART Step Q’ty Service points Procedure/Part name STEERING PAD REMOVAL Follow the left “Step” for removal. Screw Screw (black) Lower handlebar cover Upper handlebar cover NOTE: Be sure to insert the projection on the upper handlebar cover completely into the grom- met.
  • Page 463 HULL HANDLEBAR HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Q’ty Service points Procedure/Part name HANDLEBAR HOLDER Follow the left “Step” for removal. REMOVAL Throttle cable NOTE: Be sure to remove the throttle cable seal as shown in the illustration. Bolt Upper handlebar holder Reverse the removal steps for installation.
  • Page 464 HULL HANDLEBAR HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Q’ty Service points Procedure/Part name HANDLEBAR REMOVAL Follow the left “Step” for removal. QSTS cable (to jet thrust nozzle) Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”. Nut/washer QSTS converter With white tape a QSTS cable 2 QSTS cable 1...
  • Page 465 HULL HANDLEBAR HOOD EXPLODED DIAGRAM Step Q’ty Service points Procedure/Part name Screw Handle boss cover Plastic tie Hose packing Not reusable Throttle cable NOTE: Position the corrugated tube for the throttle cable as shown in the illustration so that the tube attaches to the end of the outer throttle cable.
  • Page 466 HULL HANDLEBAR HOOD EXPLODED DIAGRAM Step Q’ty Service points Procedure/Part name NOTE: Handlebar assembly • Pass the QSTS cable and handlebar switch Handlebar switch lead lead through the handle boss cover, and Grommet then install the handlebar assembly. • Install the sponges of the QSTS cables as shown and make sure that the grommet is installed to the deck securely.
  • Page 467 HULL HANDLEBAR HOOD SERVICE POINTS È Handlebar assembly installation 1. Install: • Plastic ties 1 • QSTS cables 2 • Handlebar switch lead 3 • Throttle cable 4 NOTE: After inserting the QSTS cables, handlebar switch lead and throttle cable into the grom- É...
  • Page 468 HULL HANDLEBAR HOOD 3. Connect: • Throttle cable Installing steps (for FX/FX High Output): • Route the throttle cable 1 over the han- dlebar 2, and then install the throttle cable end into the throttle lever. • Make sure that the throttle cable, QSTS cable 3, and handlebar switch lead 4 pass through the opening a in the center of the steering boss cover.
  • Page 469 HULL HANDLEBAR HOOD 4. Install: • Throttle cable seal Installing steps: • Install the throttle cable end into the throt- tle lever. • Fit the seal 1 into the groove in the bracket as shown. • Pull the throttle cable 2 in the direction of the arrow shown in the illustration, and then fit the end of the seal 3 around inner cable.
  • Page 470 HULL STEERING MASTER HOOD STEERING MASTER EXPLODED DIAGRAM 8 × 35 mm 20 N • m (2.0 kgf • m, 14 ft • Ib) 6 × 60 mm 8 × 30 mm REMOVAL AND INSTALLATION CHART Step Q’ty Service points Procedure/Part name STEERING MASTER REMOVAL Follow the left “Step”...
  • Page 471 HULL STEERING MASTER HOOD EXPLODED DIAGRAM 8 × 35 mm 20 N • m (2.0 kgf • m, 14 ft • Ib) 6 × 60 mm 8 × 30 mm Step Q’ty Service points Procedure/Part name Nut/washer Steering master assembly Bolt Reverse the removal steps for installation.
  • Page 472 HULL STEERING MASTER HOOD EXPLODED DIAGRAM 8 × 30 mm 5 × 16 mm 6 × 25 mm 8 × 30 mm REMOVAL AND INSTALLATION CHART Step Q’ty Service points Procedure/Part name STEERING MASTER Follow the left “Step” for disassembly. DISASSEMBLY Steering shaft FX Cruiser/FX Cruiser High Output...
  • Page 473 HULL STEERING MASTER HOOD EXPLODED DIAGRAM 8 × 30 mm 5 × 16 mm 6 × 25 mm 8 × 30 mm Step Q’ty Service points Procedure/Part name Bolt Bracket 2 Bolt/nut Left housing Spring holder Spring 1 Lever Lock Spring 2 Right housing...
  • Page 474 HULL STEERING MASTER HOOD EXPLODED DIAGRAM 8 × 30 mm 5 × 16 mm 6 × 25 mm 8 × 30 mm Step Q’ty Service points Procedure/Part name Steering tube Rubber seal Bushing Steering master assembly Reverse the disassembly steps for assembly.
  • Page 475 HULL STEERING MASTER HOOD SERVICE POINTS Steering master components inspection 1. Inspect: • Each component part Damage/wear → Replace. Rubber seal installation 1. Apply: • Instant adhesive (onto the mating surfaces of the rubber seal 1 and steering master assembly NOTE: After assembling the steering master assem- bly 2, apply instant adhesive onto the mating...
  • Page 476 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Q’ty Service points Procedure/Part name REMOTE CONTROL CABLES Follow the left “Step” for removal. AND SPEED SENSOR LEAD REMOVAL Service lid 1 Refer to “FRONT HOOD”.
  • Page 477 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD EXPLODED DIAGRAM Step Q’ty Service points Procedure/Part name Screw Speed sensor FX/FX Cruiser/FX High Output Speed sensor and water FX Cruiser High Output temperature sensor Shift cable end Plastic tie Grommet Shift cable holder Bolt...
  • Page 478 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD EXPLODED DIAGRAM Step Q’ty Service points Procedure/Part name Shift cable bracket Shift cable Seal QSTS cable end QSTS cable Packing Reverse the removal steps for installation.
  • Page 479 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD SERVICE POINTS Steering cable removal 1. Remove: • Steering cable Removal steps: • Rotate the steering stopper plate 1 on the steering stopper clockwise and remove it from the steering stopper plate •...
  • Page 480 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD SERVICE POINTS Steering cable installation 1. Install: • Steering cable Installing steps: • Connect the cable joint 1 to the ball joint • Insert the projection 3 on the steering cable completely into the indentation 4 in the steering stopper.
  • Page 481 HULL FRONT HOOD HOOD FRONT HOOD EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 18 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 18 mm 6 ×...
  • Page 482 HULL FRONT HOOD HOOD EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 18 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 18 mm 6 × 30 mm 5.4 N •...
  • Page 483 HULL FRONT HOOD HOOD SERVICE POINTS Rivet Installation 1. Install: • Rivets Installing steps: • Insert a rivet completely in the holes in both the service lid 1 and inner hull. • Push in the rivet pin 2 until it clicks and is flush with the top of the rivet.
  • Page 484 HULL FRONT HOOD HOOD EXPLODED DIAGRAM 1.1 N • m (0.11 kgf • m, 0.8 ft • Ib) 5 × 17 mm 1.1 N • m (0.11 kgf • m, 0.8 ft • Ib) 5 × 17 mm 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib) 5 ×...
  • Page 485 HULL FRONT HOOD HOOD EXPLODED DIAGRAM 1.1 N • m (0.11 kgf • m, 0.8 ft • Ib) 5 × 17 mm 1.1 N • m (0.11 kgf • m, 0.8 ft • Ib) 5 × 17 mm 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib) 5 ×...
  • Page 486 HULL FRONT HOOD HOOD SERVICE POINTS Ornament disassembly 1. Disassembly: • Center ornament • Left ornament • Right ornament Removal steps: • From the bottom side of the front hood 1, push the projections 2 on the center ornament shown in the illustration and remove the ornament from the double- sided tape.
  • Page 487 HULL FRONT HOOD HOOD Visor installation 1. Install: • Visor Installing steps: • Install the bushings 1 onto the screws 2 as shown in the illustration. • Install the visor and tighten the screws, making sure to hold the nuts so that they do not turn.
  • Page 488 HULL FRONT HOOD HOOD Ornament installation 1. Install: • Left ornament • Right ornament • Center ornament Installing steps: • Peel off the backing of the double-sided tape 1 on the watercraft. • Install the left and right ornaments from the sides as shown in the illustration.
  • Page 489 HULL MIRROR HOOD MIRROR EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 23 mm 6 × 22 mm 6 × 23 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) REMOVAL AND INSTALLATION CHART Step Q’ty...
  • Page 490 HULL MIRROR HOOD EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5 × 15 mm 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5 × 15 mm 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5 ×...
  • Page 491 HULL STEERING CONSOLE COVER HOOD STEERING CONSOLE COVER EXPLODED DIAGRAM 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib) 5 × 15 mm 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5 × 12 mm REMOVAL AND INSTALLATION CHART Step Q’ty...
  • Page 492 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib) 5 × 15 mm 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5 × 12 mm Step Q’ty Service points Procedure/Part name...
  • Page 493 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib) 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib) 5 × 15 mm 5 × 15 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 ×...
  • Page 494 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib) 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib) 5 × 15 mm 5 × 15 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 ×...
  • Page 495 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 6 × 22 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 5 × 24 mm 6 × 30 mm 3.8 N • m (0.38 kgf • m, 2.7 ft • Ib) 6.4 N •...
  • Page 496 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 6 × 22 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 5 × 24 mm 6 × 30 mm 3.8 N • m (0.38 kgf • m, 2.7 ft • Ib) 6.4 N •...
  • Page 497 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Q’ty Service points Procedure/Part name CENTER COVER DISASSEMBLY Follow the left “Step” for disassembly. Damper Grommet Damper Damper Hinge assembly Gear assembly Lid lock...
  • Page 498 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM Step Q’ty Service points Procedure/Part name Plug Center cover Reverse the disassembly steps for assembly.
  • Page 499 HULL SHIFT LEVER HOOD SHIFT LEVER EXPLODED DIAGRAM 6 × 30 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 30 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) REMOVAL AND INSTALLATION CHART Step Q’ty...
  • Page 500 HULL SEATS AND HAND GRIP HOOD SEATS AND HAND GRIP EXPLODED DIAGRAM 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 6 × 25 mm 8 × 30 mm 8 × 30 mm 26 N •...
  • Page 501 HULL SEATS AND HAND GRIP HOOD EXPLODED DIAGRAM 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 6 × 25 mm 8 × 30 mm 8 × 30 mm 26 N • m (2.6 kgf • m, 19 ft • Ib) 5.4 N •...
  • Page 502 HULL SEATS AND HAND GRIP HOOD EXPLODED DIAGRAM 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 6 × 25 mm 8 × 30 mm 8 × 30 mm 26 N • m (2.6 kgf • m, 19 ft • Ib) 5.4 N •...
  • Page 503 REBOARDING STEP (For FX Cruiser/FX HULL Cruiser High Output) HOOD REBOARDING STEP (For FX Cruiser/FX Cruiser High Output) EXPLODED DIAGRAM 15 N • m (1.5 kgf • m, 11 ft • Ib) 15 N • m (1.5 kgf • m, 11 ft • Ib) 8 ×...
  • Page 504 REBOARDING STEP (For FX Cruiser/FX HULL Cruiser High Output) HOOD SERVICE POINTS Reboarding step installation 1. Install: • Reboarding step Installing steps: • Fasten the brackets on both sides of the reboarding step in the down position with a plastic tie 1 as shown in the illustra- tions so that they will not return to the up position.
  • Page 505 HULL DECK AND HULL HOOD DECK AND HULL EXPLODED DIAGRAM 2.4 N • m (0.24 kgf • m, 1.7 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 25 mm 13 N • m (1.3 kgf • m, 9.4 ft • Ib) 6 ×...
  • Page 506 HULL DECK AND HULL HOOD EXPLODED DIAGRAM 2.4 N • m (0.24 kgf • m, 1.7 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 25 mm 13 N • m (1.3 kgf • m, 9.4 ft • Ib) 6 ×...
  • Page 507 HULL DECK AND HULL HOOD EXPLODED DIAGRAM 2.4 N • m (0.24 kgf • m, 1.7 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 25 mm 13 N • m (1.3 kgf • m, 9.4 ft • Ib) 6 ×...
  • Page 508 HULL CLEAT ASSEMBLY (For FX Cruiser High Output) HOOD CLEAT ASSEMBLY (For FX Cruiser High Output) EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Q’ty Service points Procedure/Part name CLEAT DISASSEMBLY Follow the left “Step” for disassembly. The following procedure applies to both of the cleat assembly.
  • Page 509 HULL CLEAT ASSEMBLY (For FX Cruiser High Output) HOOD SERVICE POINTS Cleat cover installation 1. Install: • Cleat cover NOTE: Make sure that the word “YAMAHA” a on the cleat covers faces outward as shown in the illustration.
  • Page 510 Bypass valve motor malfunction Steering sensor malfunction Intake air system malfunction If the Yamaha Diagnostic System is not used to check the symptoms listed in the table, the error codes can be checked easily with the self-diagnosis in the multifunction meter. How-...
  • Page 511 FX/FX Cruiser 2 3 4 16 5 6 7 15 1 8 12 11 10 9 13 14 3 2 1 1 2 3 1 2 3 4 5 6 1 2 3 4 5 6 FREE FREE FREE PUSH PUSH PUSH 1 3 4 6 2 5...
  • Page 512 WIRING DIAGRAM FX/FX Cruiser 1 Fuse (20 A) Color code 2 Fuse (3 A) : Black 3 Starter relay : Brown 4 Noise filter : Green 5 Cam position sensor : Blue 6 Oil pressure switch : Orange 7 Thermoswitch (exhaust) : Pink 8 Intake air pressure : Red...
  • Page 513 FX High Output/FX Cruiser High Output FREE FREE FREE PUSH PUSH PUSH 8 4 2 6 9 5 3 1 2 3 4 16 5 6 7 15 1 8 12 11 10 9 13 14 3 2 1 Pu/W Pu/W 3 2 1 4 1 2 3 4 5 6...
  • Page 514 WIRING DIAGRAM FX High Output/FX Cruiser High Output 1 Fuse (20 A) Color code 2 Fuse (3 A) : Black 3 Starter relay : Brown 4 Noise filter : Green 5 Cam position sensor : Gray 6 Oil pressure switch : Blue 7 Thermoswitch (exhaust) : Orange...
  • Page 515 YAMAHA MOTOR CORPORATION, USA Printed in USA × 1 CR Dec. 2005 –...

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