Page 2 WaveRunner FX HO FB1800 (F2T) FX Cruiser HO FB1800A (F2T) FX SHO FA1800 (F2S) FX Cruiser SHO FA1800A (F2S) SERVICE MANUAL LIT-18616-03-41 F2S-28197-1R-11...
Page 3 Preface 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 the Bronze Technical Certificate of the YTA...
Page 4 Contents General information INFO Specification SPEC Maintenance Fuel system FUEL Power unit POWR Jet pump unit PUMP Electrical system ELEC Hull and hood HULL HOOD Troubleshooting TRBL SHTG Appendix...
Page 5 INFO General information Safety while working ............ 1-1 Rotating part ................1-1 Hot part ..................1-1 Electric shock ................1-1 Impeller ..................1-1 Handling of gasoline ..............1-1 Ventilation .................. 1-2 Self-protection ................1-2 Working with crane ..............1-2 Handling of heat gun ..............1-3 Part, lubricant, and sealant ............
Page 6 Engine control system ............. 1-28 YDIS .................. 1-31 New functions ................1-32 Menu item ................1-32 Logging ..................1-33 Engine ................1-34 Lubrication system ..............1-35 Hose routing (FX SHO, FX Cruiser SHO) ....... 1-36 Hose routing (FX HO, FX Cruiser HO) ........1-37 Cooling water flow ..............
Page 7 INFO General information Safety while working To prevent an accident or injury and to pro- vide quality service, observe the following safety procedures. Rotating part • Hands, feet, hair, jewelry, clothing, personal flotation device straps, and so on, can become entangled with internal rotating parts of the engine or jet pump unit, result- ing in serious injury or death.
Page 8 Safety while working Ventilation Working with crane • Gasoline vapor and exhaust gas are • When moving the watercraft, or when lifting heavier than air and extremely poisonous. If the engine during removal or installation, gasoline vapor or exhaust gas is inhaled in make sure to use a crane with a lifting large quantities, it may cause loss of con- capacity that is equal to or more than the...
Page 9 Use the recommended special service tools to work safely, and to protect parts from dam- age. Part, lubricant, and sealant Use only genuine Yamaha parts, lubricants, and sealants, or those recommended by Yamaha, when servicing or repairing the watercraft. Tightening torque Follow the tightening torque specifications provided throughout the manual.
Page 10 Safety while working Non-reusable part Always use new gaskets, seals, O-rings, cot- ter pins, and so on, when installing or assem- bling parts. Disassembly and assembly • Use compressed air to remove dust and dirt during disassembly. • Apply engine oil to the contact surfaces of moving parts before assembly.
Page 11 General information Identification number Primary I.D. number The primary I.D. number is stamped on a label attached to the inside of the engine compartment. YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON a Engine name PRI-I.D. b Engine type MODEL YAMAHA MOTOR CO., LTD.
Page 12 Identification number Y A M...
Page 13 INFO General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. •...
Page 14 International Organization for Standardization Off-throttle steering system Pump Octane Number PORT Port side Research Octane Number Revolutions Per Minute Society of Automotive Engineers STBD Starboard side STERN Stern side Transistor Controlled Ignition Top Dead Center Throttle Position Sensor Upside YDIS Yamaha Diagnostic System...
Page 15 Adhesive, lubricant, sealant, and thread locking agent Symbol Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points. Symbol Name Application YAMALUBE 4W or Yamaha 4-stroke motor oil Lubricant Water resistant grease Lubricant (YAMALUBE MARINE GREASE) Molybdenum disulfide grease Lubricant...
Page 16 Adhesive, lubricant, sealant, and thread locking agent Symbol Name Application LOCTITE 572 (white) Sealant LOCTITE 648 (green) Thread locking agent Silicone sealant Sealant 1-10...
Page 17 Special service tool Special service tools numbered “YB/YM/YS/YU/YW-*****” are distributed by K & L. Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division. Special service tools with part number 90890-06883 is distributed by the Marine Service Division.
Page 18 Special service tool Fuel pressure gauge Exhaust pipe wrench YU-03153M 90890-06726 Fuel pressure gauge Leakage tester 90890-06753 90890-06840 Compression gauge Coupler wrench YU-33223 90890-06729 Compression gauge Bearing puller assembly 90890-03160 90890-06535 Compression gauge extension Stopper guide plate 90890-06563 90890-06501 1-12...
Page 19 INFO General information Stopper guide stand Valve guide installer 90890-06538 90890-06810 Valve spring compressor Valve guide reamer YM-04019 YM-01196 90890-04019 90890-06804 Compressor adapter Valve lapping tool YM-04114 YM-A8998 Valve spring compressor attachment Valve lapper 90890-04114 90890-04101 Valve guide remover Neway valve seat kit YB-06801 YB-91044 Valve guide remover/installer...
Page 20 Special service tool Valve seat cutter Flywheel puller Intake 90890-06723 90890-06720 (30°) 90890-06325 (45°) 90890-06324 (60°) Exhaust 90890-06818 (30°) 90890-06555 (45°) 90890-06323 (60°) Rotor puller 90890-01080 Crankshaft holder 90890-06732 Primary sheave holder YS-01880-A Sheave holder 90890-01701 Shaft holder 90890-06721 Driver handle (small) YB-06229 Driver handle 90890-06722...
Page 21 INFO General information Driver rod LS Forward bearing race installer 90890-06606 YB-06258 Bearing outer race attachment Bearing pressure C 90890-06627 90890-02393 Driver handle (large) Piston ring compressor YB-06071 YM-08037 Forward gear outer race installer Piston ring compressor YB-41446 90890-05158 Ball bearing attachment Driveshaft holder 90890-06657 YB-06201...
Page 22 Special service tool Slide hammer Bearing attachment YB-06096 90890-06728 Driveshaft needle bearing installer and Shaft holder remover 90890-06730 YB-06194 Bearing puller legs Driver rod L3 YB-06523 90890-06652 Needle bearing installer Needle bearing attachment YB-06434 90890-06609 Needle bearing attachment Bearing attachment 90890-06654 90890-06727 1-16...
Page 23 INFO General information YDIS 2 starter kit Spark checker 90890-06883 YM-34487 Ignition tester (Spark gap tester) 90890-06754 ****** ****** Digital multimeter YU-34899-A Test harness (3 pins) YB-06877 90890-06877 Peak volt adapter YU-39991 Test harness (3 pins) YB-06870 90890-06870 Digital circuit tester 90890-03189 Test harness (2 pins) YW-06850...
Page 24 Special service tool Vacuum/pressure pump gauge set 90890-06756 Test harness (6 pins) YB-06872 90890-06849 Test harness (8 pins) YB-06879 90890-06879 1-18...
Page 25 INFO General information Model feature General feature (FX SHO, FX Cruiser SHO) The F2S is equipped with a newly designed NanoXcel hull and deck. The body length has increased compared to the previous model (F1W). The 6CS engine installed into the F2S is based on a high output, 1.8L supercharged 6AN engine with changes to the lubrication system.
Page 26 Model feature General feature (FX HO, FX Cruiser HO) The F2T is equipped with the same hull and deck as the F2S. The 6CR engine installed into the F2T is based on a high output, 1.8L 6CN engine with changes to the lubrication system.
Page 27 INFO General information Model equipment comparison table Model FX HO FX Cruiser HO FX SHO FX Cruiser SHO Total length 3.56 m (140.2 in) Width 1.23 m (48.4 in) Dry weight 373 kg (822 lb) 374 kg (825 lb) 386 kg (851 lb) 387 kg (853 lb) Normal seat a Cruiser seat b...
Page 28 Model feature Hull and deck The F2S and F2T share the same newly designed NanoXcel hull and deck. The length has increased by 190 mm (7.5 in) compared to the previous model, the F1W. The enlarged body has allowed for a bigger seat and boarding platform, more gear capacity, and enhanced riding comfort. The form of the hull improves the handling of the vehicle, and it also is designed to improve agility in spite of the increases in weight.
Page 29 INFO General information A Previous FX series B New FX series 1-23...
Page 30 Technical tips Model feature / Technical tips Technical tips Engine control The ECM controls ignition timing and fuel injection with information received from the sensors and switches installed on the engine as well as utilizing the base map saved in the ECM. 1-24...
Page 31 INFO General information A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO Part name Functions a Cam position sensor Detects the rotational position of the camshaft. b Slant detection switch Detects whether the watercraft is capsized. Properly controls ignition timing, fuel injection timing and c ECM volume, opening angle of the ETV, and fail-safe function with information received from the sensors and switches.
Page 32 Technical tips ETV system The F2S and F2T are equipped with a newly developed throttle lever. The throttle lever has an APS which senses the degree of throttle opening and converts the status into electronic signals, delivering the information to the ECM. The ECM controls the ETV based on the input signals of the APS.
Page 33 INFO General information Mechanical Neutral In addition to the F and R positions, an N position has been added to the F2S and the F2T. The shift lever is used to change the shift position. The shift lever will not slide unless the shift lock lever a is held.
Page 34 Technical tips Engine control system Item Condition Action Remarks Overheat • Engine temperature • Opening angle of the ETV Cancel: warning rises rapidly in a is regulated. • Stop the engine and wait control short time. • Maximum engine speed is for 30 seconds or more.
Page 35 INFO General information Item Condition Action Remarks Battery Battery lead is Control is performed using disconnection disconnected during the same actions as the ETV warning normal operation. failure control. Idle speed Throttle lever is in the Engine speed is limited to Engine speed is limited to control fully closed (idle)
Page 36 Technical tips Item Condition Action Remarks Slant detection Control is activated Ignition and fuel injection are Cancel: control when all of the cut to all cylinders and the Engine is stopped. following conditions engine is stopped. (The check engine warning are present: indicator does not come on •...
Page 37 • Displays the communications status. Communicating: c Communications error: d • For details of operation methods, see the YDIS (Ver. 2.00) instruction manual. • These tools are restricted for use by Yamaha service technicians of distributors or dealers only. 1-31...
Page 38 YDIS New functions • The settings function now enables switching of the language (English, French, Spanish, Japa- nese). The units for measurement cannot be changed. • By connecting commercially available external instruments, the external input function enables display of this information on the engine monitor. •...
Page 39 INFO General information Logging In version 2.00, it is possible to configure items to be logged, and logging intervals. Configure log- ging, and disconnect the USB cable between the computer and the adapter to start logging. Because the computer is not connected during logging, the adapter can be placed within the bow storage compartment.
Page 40 Engine YDIS / Engine Engine The new 6CS engine is derived from the modified 6AN engine, and the new 6CR engine is based on the modified 6CN engine. Main points of change include discarding the scavenging pump, external breather, simplifying the lubrication system. The parts surrounding the timing chain have been changed to those used in the 6BH engine in order to increase usage of common parts.
Page 41 INFO General information Lubrication system The 6CS and 6CR engines feature a wet-sump lubrication system. The oil pump assy. is different from the oil pump assy. that was used for the base engine and does not contain a scavenge oil pump.
Page 42 Engine Hose routing (FX SHO, FX Cruiser SHO) A From flushing hose connector B From transom plate C To cooling water pilot outlet on port side D To drain joint (transom plate) E To drain joint F To drain joint G To cooling water pilot outlet on starboard side H For water draining when engine is stopped I Cooling water flow...
Page 43 INFO General information Hose routing (FX HO, FX Cruiser HO) A From flushing hose connector B From transom plate C To cooling water pilot outlet on port side D To drain joint (transom plate) E To drain joint F To drain joint G For water draining when engine is stopped H Cooling water flow I Blowby gas flow...
Page 44 Engine Cooling water flow A From flushing hose connector B From transom plate C To cooling water pilot outlet on port side D To drain joint E To exhaust valve F To cooling water pilot outlet on starboard side G For water draining when engine is stopped H FX SHO, FX Cruiser SHO I FX HO, FX Cruiser HO 1-38...
Page 45 INFO General information — MEMO — 1-39...
Page 46 SPEC Specification Model data ................. 2-1 Model code ................2-1 Dimensions and weight ............. 2-1 Performance ................2-1 Power unit ................. 2-1 Jet pump unit ................2-2 Fuel and oil requirement ............2-2 Battery requirement ..............2-3 Fuel system technical data ..........2-3 Fuel system ................
Page 47 SPEC Specification Model data Model code Model Item Unit FX HO Cruiser FX SHO Cruiser Hull 6CR/6CR 6CS/6CS Engine/jet Dimensions and weight Model Item Unit FX HO Cruiser FX SHO Cruiser 3560 (140.2) Length mm (in) 1230 (48.4) Width mm (in) 1230 (48.4) Height mm (in)
Page 48 Model data Model Item Unit FX HO Cruiser FX SHO Cruiser Timing chain tensioning system Automatic Ignition system Maximum ignition timing BTDC 25 BTDC 20 degree advance Spark plug LFR6A (NGK) Spark plug gap mm (in) 0.8–0.9 (0.031–0.035) Firing order 1–2–4–3 Oil filter type Cartridge type...
Page 49 SPEC Specification Model Item Unit FX HO Cruiser FX SHO Cruiser Engine oil quantity L (US gal, 4.3 (4.5, 3.8) Total amount Imp.gal) L (US gal, 3.0 (3.2, 2.6) Without oil filter replacement Imp.gal) L (US gal, 3.1 (3.3, 2.7) With oil filter replacement Imp.gal) Battery requirement...
Page 50 Power unit technical data Model data / Fuel system technical data / Power unit technical data Power unit technical data Power unit Model Item Unit FX HO Cruiser FX SHO Cruiser Compression pressure kPa (kgf/ Minimum (*1) 780 (7.8, 113.1) 610 (6.1, 86.8) , psi) Air cooler...
Page 51 SPEC Specification Model Item Unit FX HO Cruiser FX SHO Cruiser Camshaft Cam lobe height Intake mm (in) 41.330–41.430 (1.627–1.631) Limit mm (in) 41.320 (1.626) Exhaust mm (in) 41.220–41.320 (1.623–1.627) Limit mm (in) 41.210 (1.622) Cam lobe width Intake and exhaust mm (in) 31.956–32.056 (1.258–1.262) Runout...
Page 52 Power unit technical data Model Item Unit FX HO Cruiser FX SHO Cruiser Valve guide Inside diameter Intake and exhaust mm (in) 5.504–5.522 (0.2167–0.2174) Stem to guide clearance Intake mm (in) 0.012–0.045 (0.0005–0.0018) Limit mm (in) 0.080 (0.0031) Exhaust mm (in) 0.025–0.058 (0.0010–0.0023) Limit mm (in)
Page 53 SPEC Specification Model Item Unit FX HO Cruiser FX SHO Cruiser Piston ring End gap measuring point mm (in) 6.0 (0.24) Top ring Type Barrel Dimension height (B) mm (in) 1.170–1.190 (0.0461–0.0469) Dimension width (T) mm (in) 2.850–3.050 (0.1122–0.1201) End gap (*1) mm (in) 0.300–0.450 (0.0118–0.0177) Limit...
Page 54 Jet pump unit technical data Power unit technical data / Jet pump unit technical data / Electrical technical data Jet pump unit technical data Jet pump unit Model Item Unit FX HO Cruiser FX SHO Cruiser Impeller housing Inside diameter mm (in) 155.35–155.45 (6.116–6.120) Limit...
Page 55 SPEC Specification Charging system Model Item Unit FX HO Cruiser FX SHO Cruiser Stator coil Output peak voltage At cranking (unloaded) At 2000 r/min (unloaded) 36.4 At 3500 r/min (unloaded) 64.7 Resistance (*1)  At 20 °C (68 °F) 0.31–0.38 Rectifier regulator Output peak voltage At 2000 r/min (loaded)
Page 56 Electrical technical data Model Item Unit FX HO Cruiser FX SHO Cruiser Intake air pressure sensor Input voltage 4.75–5.25 Knock sensor Resistance (*1) At 20 °C (68 °F) k — 504.0–616.0 Output voltage With throttle lever fully closed TPS 1 0.6–0.9 With throttle lever fully open...
Page 57 SPEC Specification Model Item Unit FX HO Cruiser FX SHO Cruiser Steering sensor Input voltage 4.75–5.25 Electric bilge pump Input voltage 12 (battery voltage) ECM unit Input voltage 12 (battery voltage) (*1) The figures are for reference only. Fuel system Model Item Unit...
Page 58 Electrical technical data Model Item Unit FX HO Cruiser FX SHO Cruiser Starter motor Type Constant mesh Output Cranking time limit seconds Commutator diameter mm (in) 27–28 (1.06–1.10) Commutator undercut (*1) mm (in) 0.2–0.7 (0.008–0.028) Brush length mm (in) 5.0–12.5 (0.20–0.49) (*1) The figures are for reference only.
Page 59 SPEC Specification Specified tightening torque Specified tightening torques are provided for specific nuts, bolts, and screws. When tightening these fasteners, follow the tightening torque specifications indicated throughout the manual to meet the design aims of the watercraft. (*1) FX HO FX, Cruiser HO only (*2) FX SHO FX, Cruiser SHO only Fuel system Tightening torques...
Page 60 Specified tightening torque Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb 14.8 Exhaust pipe 1 bolt 14.8 25.8 11.1 Exhaust pipe 2 bolt 21.4 Starter motor lead nut — Slant detection switch screw Starter relay bolt ECM bolt Fuse box assy.
Page 61 SPEC Specification Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb Cam position sensor bolt Engine cover grommet bolt (*1) Camshaft sprocket bolt 13.3 Camshaft cap bolt 11.8 Oil pipe bolt 14.8 Timing chain tensioner bolt Chain guide plate bolt Engine hanger bolt (*1) 31.0 Engine hanger bolt...
Page 62 Specified tightening torque Jet pump unit Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb Intake grate bolt 12.5 Ride plate bolt 12.5 Speed sensor screw Steering cable joint nut — Spout hose clamp (hull end) — Rubber plate bolt Rubber plate nut —...
Page 63 SPEC Specification Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb Mirror bolt Mirror bolt Hood lock bolt Hood lock screw 0.15 1.11 Front hood screw Hinge nut Hinge bolt Damper nut Damper bracket bolt Multifunction meter cover screw Multifunction meter bolt Hood lock hook bolt Shift lever screw...
Page 64 Torque wrench reading (setting value) Specified tightening torque / General tightening torque Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb Rubber hose nut Rubber hose clamp — 0.37 2.73 Ski tow nut 11.8 Spout nut — Stern eye nut 11.8 Drain plug nut Reboarding step assy.
Page 65 SPEC Specification Cable and hose routing Starboard bow view a Right handlebar switch lead j Fuel tank breather hose (water separator b Throttle lever assy. lead to ventilation socket) c Left handlebar switch lead k Fuel tank breather hose (fuel tank to water d Q.S.T.S.
Page 66 Cable and hose routing Top view a Right handlebar switch lead j Fuel tank breather hose (water separator b Throttle lever assy. lead to ventilation socket) c Left handlebar switch lead k Fuel tank breather hose (fuel tank to water d Q.S.T.S.
Page 67 SPEC Specification s Shift cable t Fuel sender lead u Fuel pump module lead v Positive battery lead w Negative battery lead 2-21...
Page 68 Cable and hose routing Port view g h f a Right handlebar switch lead j Fuel tank breather hose (fuel tank to water b Throttle lever assy. lead separator) c Left handlebar switch lead k Remote control receiver antenna d Q.S.T.S. cable l Wiring harness e Reverse sensor lead m Speed sensor lead...
Page 69 SPEC Specification g h f t Multifunction meter lead u Bilge hose (hose joint to drain joint) v Bilge hose (electric bilge pump to hose joint) w Bilge hose joint to drain joint x Flushing hose 2-23...
Page 70 Maintenance Maintenance interval chart ..........3-1 Periodic service ..............3-2 Jet thrust nozzle angle check ............ 3-2 Jet thrust nozzle angle adjustment ..........3-2 Steering master check ............... 3-2 Shift cable and reverse gate check ........... 3-3 Shift cable adjustment ............... 3-3 Q.S.T.S.
Page 71 Maintenance Maintenance interval chart The following chart should be considered strictly as a guide to general maintenance intervals. Depending on the operating conditions, the maintenance intervals should be changed. Maintenance interval Initial Thereafter every 50 hours hours hours hours page Item months months...
Page 72 Periodic service Maintenance interval chart / Periodic service Periodic service Jet thrust nozzle angle check 1. Set the Q.S.T.S. grip to the neutral posi- tion. 2. Turn the handlebar lock to lock. 3. Measure distances a and b. Adjust if out of specification.
Page 73 Maintenance 5. Turn the shift cable joint b in or out until Shift cable and reverse gate check the specified distance b between the 1. Set the shift lever to the reverse position. center of the shift cable joint and the 2.
Page 74 Periodic service Distance a is increased. Q.S.T.S. rod adjustment Turn out Distance b is increased. 1. Set the Q.S.T.S. grip to the neutral posi- Turn in tion. 6. Connect the Q.S.T.S. rod joint b to the ball joint c, and then tighten the locknut 2.
Page 75 Maintenance Specified spark plug (manufacturer): LFR6A (NGK) Spark plug gap b: 0.8–0.9 mm (0.031–0.035 in) 5. Install the spark plugs, and then tighten them to the specified torque. Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb) TIP: TIP: To drain water from the water separator a, Before installing a spark plug, clean the gas- loosen the drain plug b.
Page 76 Periodic service A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO Recommended engine oil: YAMALUBE 4W or 4-stroke motor oil API: SE, SF, SG, SH, SJ, SL SAE: 10W-30, 10W-40, 20W-40, 20W-50 6. If the engine oil is above the maximum level mark b, extract oil using an oil changer to lower it to the correct level.
Page 77 Maintenance 6. Add the recommended engine oil up to Oil filter a: the specified level through the oil filter 18 N·m (1.8 kgf·m, 13.3 ft·lb) hole. Recommended engine oil: TIP: YAMALUBE 4W or 4-stroke motor oil Make sure to clean up any oil spills. API: SE, SF, SG, SH, SJ, SL SAE: 10W-30, 10W-40, 20W-40, 20W-50 4.
Page 78 Periodic service Gauge stand a: 90890-06725 Dial gauge stand set b: YB-06585 Dial indicator gauge c: YU-03097 Dial gauge needle b: 90890-06584 Dial gauge set c: 90890-01252 3. Position piston #1 at TDC by turning the exhaust camshaft sprocket clockwise. Valve clearance (cold) Intake c: 0.14–0.23 mm (0.0055–0.0091 in)
Page 79 Maintenance Impeller check Make sure to remove the battery before checking the jet pump unit. 1. Remove the jet pump unit. See “Jet pump unit removal” (6-4). 2. Check the impeller a. Replace if 3. Install the water inlet strainer b and damaged.
Page 80 Periodic service 1. Remove the battery. NOTICE: When TIP: removing the battery, disconnect the Apply water resistant grease to the terminals negative battery lead first. to minimize corrosion. 2. Check the battery electrolyte level. If the level is at or below the minimum level Bilge strainer check mark a, add distilled water until the level 1.
Page 81 Maintenance Drain plug check 1. Check the O-ring a of each drain plug Recommended lubricant: Rust inhibitor 3. Connect the blowby hose b, and then fasten it using the clamp a. Throttle valve lubrication (FX SHO, FX Cruiser SHO) Throttle valve lubrication (FX HO, FX Cruiser HO) 1.
Page 82 Periodic service Q.S.T.S. cable (handlebar end) Recommended lubricant: lubrication Yamaha grease A 1. Remove the left handlebar grip and Q.S.T.S. grip. TIP: Disconnect the joint and apply a small 2. Lubricate the Q.S.T.S. cable (handlebar amount of grease. end). Nozzle pivot bolt and steering cable lubrication 1.
Page 83 Maintenance Recommended lubricant: Yamaha grease A TIP: Disconnect the joint and apply a small amount of grease. 3. Install the side cover. See “Side cover installation” (8-13). Intermediate housing lubrication 1. Lubricate intermediate housing through the grease nipple a. Recommended lubricant:...
Page 84 FUEL Fuel system Air filter case and fuel hose (FX SHO, FX Cruiser SHO) ..........4-1 Air filter case and fuel hose (FX HO, FX Cruiser HO) ............ 4-3 Fuel hose disconnection ............4-5 Fuel pressure measurement ............. 4-5 Fuel hose disassembly .............. 4-6 Air filter element check ..............
Page 85 FUEL Fuel system Air filter case and fuel hose (FX SHO, FX Cruiser SHO) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 17 N·m (1.7 kgf·m, 12.5 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) Part name Q’ty Remarks Fuel hose assy.  Clamp Quick connector Corrugated tube...
Page 86 Air filter case and fuel hose (FX SHO, FX Cruiser SHO) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 17 N·m (1.7 kgf·m, 12.5 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) Part name Q’ty Remarks Grommet Washer Bracket Plastic tie Holder...
Page 87 FUEL Fuel system Air filter case and fuel hose (FX HO, FX Cruiser HO) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 17 N·m (1.7 kgf·m, 12.5 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) Part name Q’ty Remarks Plastic tie Fuel hose assy. ...
Page 88 Air filter case and fuel hose (FX HO, FX Cruiser HO) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 17 N·m (1.7 kgf·m, 12.5 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) Part name Q’ty Remarks Grommet Washer Bracket Plastic tie...
Page 89 FUEL Fuel system Fuel hose disconnection Before checking the fuel system, remove the battery, and then remove the fuel filler cap to reduce any pressure inside the fuel tank. 1. Spread apart the ends of the retainer a, and then pull the retainer up. Fuel pressure measurement 1.
Page 90 Air filter case and fuel hose (FX HO, FX Cruiser HO) 1. Install new clamps a and the quick con- Fuel pressure: nector b onto the fuel hose c. 345–370 kPa (3.45–3.70 kgf/cm , 49.1–52.6 psi) Fuel hose disassembly 1. Remove the clamps a and quick con- nector b.
Page 91 FUEL Fuel system TIP: • Make sure to align the projection e on the quick connector with the crimped section of the clamp. • Position the crimped sections of the clamps 180° away from each other.
Page 92 Air filter case and fuel hose (FX HO, FX Cruiser HO) / Fuel injector (FX SHO, FX Cruiser SHO) Fuel injector (FX SHO, FX Cruiser SHO) Fuel injector (FX SHO, FX Cruiser SHO) 13 N·m (1.3 kgf·m, 9.6 ft·lb) Part name Q’ty Remarks M8 ...
Page 93 FUEL Fuel system ETV and fuel injector (FX HO, FX Cruiser HO) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 24 N·m (2.4 kgf·m, 17.7 ft·lb) Part name Q’ty Remarks Plastic tie Washer M8  20 mm Bolt Joint Holder...
Page 94 ETV and fuel injector (FX HO, FX Cruiser HO) ETV check (FX HO, FX Cruiser HO) • Do not disassemble the ETV. • Do not loosen the throttle stop screw nut a or turn the throttle stop screw b. • Do not loosen or remove the throttle valve shaft screws c.
Page 95 FUEL Fuel system A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO Fuel rail bolt e: 13 N·m (1.3 kgf·m, 9.6 ft·lb) 4. Install the holders f, and then connect the fuel injector couplers a and ignition coil couplers b.
Page 96 Fuel tank and fuel pump module assy. ETV and fuel injector (FX HO, FX Cruiser HO) / Fuel tank and fuel pump module assy. Fuel tank and fuel pump module assy. 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name...
Page 97 FUEL Fuel system 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks Hook Retainer Fuel pump module assy.  Packing Stopper Fuel sender Fuel tank ...
Page 98 Fuel tank and fuel pump module assy. Fuel pump module removal Before checking the fuel system, remove the battery, and then remove the fuel filler cap to reduce any pressure inside the fuel tank. 1. Remove the fuel pump module assy. a. NOTICE: When removing the fuel Fuel pump module check pump module assy.
Page 99 FUEL Fuel system A Upright B Inverted Fuel filler cap check 1. Install the fuel filler cap a onto the fuel filler neck b, and then hold the fuel filler neck b. 2. Turn the fuel filler cap a clockwise a and check that it clicks when tightened completely.
Page 100 Fuel tank and fuel pump module assy. Fuel pump module nut c: Fuel filler neck nut f: 1st: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 2nd: 7 N·m (0.7 kgf·m, 5.2 ft·lb) TIP: Fuel tank installation Align the protrusion c on the fuel filler neck 1.
Page 101 FUEL Fuel system TIP: Point the arrow mark k toward the fuel tank. 4-17...
Page 102 Fuel tank and fuel pump module assy. — MEMO — 4-18...
Page 103 POWR Power unit Engine unit (check and adjustment) ........ 5-1 Compression pressure check ............ 5-1 Engine unit (FX SHO, FX Cruiser SHO) ......5-2 Engine unit (FX HO, FX Cruiser HO) ........ 5-3 Exhaust manifold (FX SHO, FX Cruiser SHO) ....5-4 Exhaust manifold (FX HO, FX Cruiser HO) .....
Page 104 Air cooler and supercharger assy......... 5-42 Intake assy. (FX SHO, FX Cruiser SHO) ......5-45 Intake assy. (FX HO, FX Cruiser HO) ......5-47 ETV and intake manifold (FX SHO, FX Cruiser SHO) ..........5-48 Air cooler check (FX SHO, FX Cruiser SHO) ......5-49 Supercharger check (FX SHO, FX Cruiser SHO) ....
Page 105 POWR Camshaft check ............... 5-70 Camshaft journal oil clearance check ........5-71 Timing chain tensioner check ..........5-72 Camshaft sprocket installation ..........5-72 Camshaft installation ............... 5-73 Valve clearance adjustment ............ 5-75 Valve pad selection table ............5-78 Cylinder head ..............5-79 Valve and valve spring ...........
Page 106 Crankcase disassembly ............5-110 Connecting rod and piston removal ........5-110 Crankcase check ..............5-111 Cylinder block check ............. 5-111 Piston check ................5-111 Piston clearance check ............5-111 Piston ring check ..............5-111 Piston pin check ..............5-112 Connecting rod check ............5-113 Crankshaft check ..............
Page 107 POWR Power unit Engine unit (check and 8. Measure the compression pressure for all cylinders according to steps 5 and 6. adjustment) Compression pressure check Compression pressure (reference data): FX SHO, FX Cruiser SHO: Make sure that the battery voltage is more 610 kPa (6.1 kgf/cm , 86.8 psi) than 12 V.
Page 108 Engine unit (FX SHO, FX Cruiser SHO) Engine unit (check and adjustment) / Engine unit (FX SHO, FX Cruiser SHO) Engine unit (FX SHO, FX Cruiser SHO) 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name Q’ty Remarks M6  12 mm Screw Grommet Engine cover...
Page 109 POWR Power unit Engine unit (FX HO, FX Cruiser HO) 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name Q’ty Remarks M6  12 mm Screw Grommet Engine cover Clamp Breather hose Antenna holder Clamp Clamp...
Page 110 Exhaust manifold (FX SHO, FX Cruiser SHO) Engine unit (FX HO, FX Cruiser HO) / Exhaust manifold (FX SHO, FX Cruiser SHO) Exhaust manifold (FX SHO, FX Cruiser SHO) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 26 N·m (2.6 kgf·m, 19.2 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb)
Page 111 POWR Power unit 23 N·m (2.3 kgf·m, 17.0 ft·lb) 26 N·m (2.6 kgf·m, 19.2 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 14 15 13 N·m (1.3 kgf·m, 9.6 ft·lb) 2.5 N·m (0.25 kgf·m, 1.84 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb)
Page 112 Exhaust manifold (FX HO, FX Cruiser HO) Exhaust manifold (FX SHO, FX Cruiser SHO) / Exhaust manifold (FX HO, FX Cruiser HO) Exhaust manifold (FX HO, FX Cruiser HO) 26 N·m (2.6 kgf·m, 19.2 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 13 14...
Page 113 POWR Power unit 26 N·m (2.6 kgf·m, 19.2 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 13 14 13 N·m (1.3 kgf·m, 9.6 ft·lb) 2.5 N·m (0.25 kgf·m, 1.84 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb)
Page 114 Exhaust manifold (FX HO, FX Cruiser HO) / Engine unit and coupling cover (FX SHO, FX Cruiser SHO) Engine unit and coupling cover (FX SHO, FX Cruiser SHO) Engine unit and coupling cover (FX SHO, FX Cruiser SHO) 17 N·m (1.7 kgf·m, 12.5 ft·lb) 17 N·m (1.7 kgf·m, 12.5 ft·lb) Part name Q’ty...
Page 115 POWR Power unit Engine unit and coupling cover (FX HO, FX Cruiser HO) 17 N·m (1.7 kgf·m, 12.5 ft·lb) 17 N·m (1.7 kgf·m, 12.5 ft·lb) Part name Q’ty Remarks M8  28 mm Bolt M6  25 mm Bolt Collar Coupling cover M8 ...
Page 116 Engine mount Engine unit and coupling cover (FX HO, FX Cruiser HO) / Engine mount Engine mount 17 N·m (1.7 kgf·m, 12.5 ft·lb) 5.5 N·m (0.55 kgf·m, 4.06 ft·lb) 5.5 N·m (0.55 kgf·m, 4.06 ft·lb) Part name Q’ty Remarks M8  35 mm Bolt Engine mount Liner...
Page 117 POWR Power unit 6. Disconnect the quick connector d from Engine unit removal (FX SHO, FX fuel rail. “Fuel hose Cruiser SHO) disconnection” (4-5). Before removing the engine, make sure to take adequate measures to protect the deck opening from damage. 1.
Page 118 Engine mount 10. Remove the antenna holders l. 11. Disconnect the remote control receiver coupler a. 12. Disconnect sensor switch couplers b. 15. Disconnect fuel pump module coupler d. 13. Disconnect the electric bilge pump coupler c. 16. Disconnect the cooling water hose j from the oil cooler assy.
Page 119 POWR Power unit 18. Disconnect the cooling water hoses o 21. Disconnect the cooling water hoses u, and p from the air cooler. v, and w. 22. Remove the plastic tie x and rectifier regulator y. 23. Disconnect the cooling water hoses z and A.
Page 120 Engine mount 26. Remove the pipe clamp D from the pipe 30. Loosen the engine mounting bolts I. 31. Lift the engine unit slightly, remove the shims J, and then lower the unit. 32. Remove the engine mounting bolts I. 27.
Page 121 POWR Power unit 5. Remove the plastic tie c, and then 35. Lift the engine unit out vertically. disconnect the quick connector d from fuel rail. “Fuel hose disconnection” (4-5). Engine unit removal (FX HO, FX Cruiser HO) 6. Remove the engine cover e. Before removing the engine, make sure to take adequate measures to protect the deck opening from damage.
Page 122 Engine mount 8. Remove the plastic tie j from the 13. Disconnect the electric bilge pump cooling water hose k. coupler c. 9. Remove the electrical box cover l. 14. Remove the wiring harness from the plastic ties n. 10. Remove the antenna holders m. 11.
Page 123 POWR Power unit TIP: Make sure to clean up any oil spills. 19. Remove the holder r and plastic tie s, and then disconnect the thermo sensor coupler e. 16. Disconnect the cooling water hose k from the oil cooler assy. 20.
Page 124 Engine mount 27. Remove the ETV. See “ETV and fuel injector (FX HO, FX Cruiser HO)” (4-9). 28. Loosen the engine mounting bolts F. 29. Lift the engine unit slightly, remove the shims G, and then lower the unit. 30. Remove the engine mounting bolts F. 24.
Page 125 POWR Power unit 32. Lift the engine unit slightly, and then 1. Suspend the engine unit using all 3 lower the front of the unit. Repeat this engine hangers. step until the engine unit can be removed 2. Lower the front of the engine unit. from engine compartment.
Page 126 Engine mount 8. Measure the coupling clearances a and clearances specification, add or remove shims c so that clearances within specification. Clearance a: Less than 1 mm (0.039 in) (without rubber coupling) Clearance b: TIP: 2–4 mm (0.079–0.157 in) Do not install the rubber coupling until the coupling clearance adjustment has been Available shim thicknesses: made.
Page 127 POWR Power unit Clearance a: Electrical box bolt g: Less than 0.5 mm (0.020 in) 17 N·m (1.7 kgf·m, 12.5 ft·lb) (with rubber coupling) 17. Install the muffler assy. h into the water Clearance b: lock, and then tighten the exhaust 2–4 mm (0.079–0.157 in) manifold bolts i and j to the specified 14.
Page 128 Engine mount 24. Fasten the cooling water hose w using TIP: the plastic tie C. Make sure that the pipe on the end of the muffler assy. is installed securely into the water lock. 19. Install the stays l, and then tighten the stay bolts m to the specified torque.
Page 129 POWR Power unit 32. Connect the electric bilge pump coupler 33. Connect the sensor and switch couplers 29. Connect the cooling water hose L, and then fasten it using the clamp M. 34. Connect the remote control receiver coupler g, and then install the antenna holders P.
Page 130 Engine mount Air filter case bolt U: 12 N·m (1.2 kgf·m, 8.9 ft·lb) 39. Install the air filter, air filter case cover V, and air intake pipe W, and then tighten the air intake pipe clamps X to the specified torque. 40.
Page 131 POWR Power unit Engine cover screw 3: 4. Lift the front of the engine unit slightly, 5 N·m (0.5 kgf·m, 3.7 ft·lb) and then lower the unit. Repeat this step until the drive and driven couplings are 43. Install the service lid 4. aligned.
Page 132 Engine mount Available shim thicknesses: TIP: 0.10, 0.30, 0.50, 1.00, 2.00 mm Do not install the rubber coupling until the coupling clearance adjustment has been 9. Lift the engine unit slightly, remove the made. shims, and then lower the engine unit. 6.
Page 133 POWR Power unit 18. Install the muffler assy. h into the water lock, and then tighten the exhaust manifold bolts i and j to the specified torques in 3 stages and in the order a, b, and so on. Engine mounting bolt b: Exhaust manifold bolt i and j: 17 N·m (1.7 kgf·m, 12.5 ft·lb) 1st: 20 N·m (2.0 kgf·m, 14.8 ft·lb)
Page 134 Engine mount Stay bolts m and n: Oil filter wrench D: YB-06830 Oil filter wrench D: 90890-06830 1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb) Oil filter C: 22. Install the rectifier regulator s, and then 18 N·m (1.8 kgf·m, 13.3 ft·lb) tighten the rectifier regulator bolts t to 27.
Page 135 POWR Power unit 30. Connect the electric bilge pump coupler 31. Connect the sensor and switch couplers 34. Install the electrical box cover K. 32. Connect the remote control receiver coupler g, and then install the antenna holders I. 35. Fasten the cooling water hose G using the plastic tie L.
Page 136 Engine mount 36. Install the air filter case M, and then Engine cover screw T: tighten the air filter case bolts N to the 5 N·m (0.5 kgf·m, 3.7 ft·lb) specified torque. 40. Connect the quick connector U to the fuel rail.
Page 137 POWR Power unit Muffler 20 N·m (2.0 kgf·m, 14.8 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 29 N·m (2.9 kgf·m, 21.4 ft·lb) 2.5 N·m (0.25 kgf·m, 2.58 ft·lb) 200 N·m (20.0 kgf·m, 147.5 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb)
Page 138 Muffler Exhaust pipe disassembly Exhaust pipe assembly 1. Install exhaust pipe 3 a, and then tighten it to the specified torque. NOTICE: To allow the LOCTITE 648 to set, wait Use heat-resistant gloves. Otherwise, approximately 1 hour after completing burns could result. this procedure.
Page 139 POWR Power unit Wiring harness assy. (FX SHO, FX Cruiser SHO) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Spring washer M8  30 mm Bolt Negative battery lead Starter motor M6  35 mm Bolt Thermostat housing Thermostat Hole Holder...
Page 140 Wiring harness assy. (FX SHO, FX Cruiser SHO) / Wiring harness assy. (FX HO, FX Cruiser HO) Wiring harness assy. (FX HO, FX Cruiser HO) Wiring harness assy. (FX HO, FX Cruiser HO) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Spring washer...
Page 141 POWR Power unit Electrical box 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name Q’ty Remarks Electrical box cover Plastic tie M6 ...
Page 142 Electrical box 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name Q’ty Remarks Fuse (10 A) Fuse (3 A) Fuse (20 A) Starter relay Starter motor lead...
Page 143 POWR Power unit 5. Disconnect the earth plate couplers k Starter motor and wiring harness and oil pressure switch coupler m. assy. removal (FX SHO, FX Cruiser SHO) 1. Disconnect the starter motor lead a and negative battery lead b, and then remove the starter motor c.
Page 144 Electrical box 5. Disconnect the earth plate couplers k Starter motor and wiring harness and oil pressure switch coupler m. assy. removal (FX HO, FX Cruiser 1. Disconnect the starter motor lead a and negative battery lead b, and then remove the starter motor c.
Page 145 POWR Power unit A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO Starter motor and wiring harness assy. installation (FX SHO, FX Cruiser SHO) 1. Connect the fuel injector couplers a and ignition coil couplers b. Thermostat check 1.
Page 146 Electrical box 4. Connect the pick up coil coupler r, stator coil coupler s, and rectifier regulator coupler t. 5. Connect the ECM couplers u, slant Starter motor lead nut g: detection switch coupler v, ETV relay 7 N·m (0.7 kgf·m, 5.2 ft·lb) coupler w, main and fuel pump relay coupler x, and fuse box couplers y, and Starter motor and wiring harness...
Page 147 POWR Power unit TIP: Fasten the wiring harness at the gray tape g using the holder a. 3. Connect the thermoswitch coupler h, and then fasten the thermoswitch lead using the plastic ties b. 4. Connect the oil pressure switch coupler 7.
Page 148 Air cooler and supercharger assy. Electrical box / Air cooler and supercharger assy. Air cooler and supercharger assy. 20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb)
Page 149 POWR Power unit 20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
Page 150 Air cooler and supercharger assy. 20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb)
Page 151 POWR Power unit Intake assy. (FX SHO, FX Cruiser SHO) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb)
Page 152 Intake assy. (FX SHO, FX Cruiser SHO) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb)
Page 153 POWR Power unit Intake assy. (FX HO, FX Cruiser HO) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb)
Page 154 ETV and intake manifold (FX SHO, FX Cruiser SHO) Intake assy. (FX HO, FX Cruiser HO) / ETV and intake manifold (FX SHO, FX Cruiser SHO) ETV and intake manifold (FX SHO, FX Cruiser SHO) 24 N·m (2.4 kgf·m, 17.7 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) Part name Q’ty...
Page 155 POWR Power unit Air cooler check (FX SHO, FX Cruiser Leakage tester b: 90890-06840 SHO) Air cooler attachment e: 90890-06731 Specified positive pressure (air passage): 100 kPa (1.0 kgf/cm , 14.2 psi) Do not disassemble the air cooler. Supercharger check (FX SHO, FX 1.
Page 156 ETV and intake manifold (FX SHO, FX Cruiser SHO) 4. Tighten the intake manifold stay bolts g and h to the specified torques in 2 stages. Intake manifold stay bolt g and h: 1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 2nd: 30 N·m (3.0 kgf·m, 22.1 ft·lb) 5.
Page 157 POWR Power unit Installation distance a: 49.8 mm (2.0 in) 3. Tighten the intake manifold bolts d and intake manifold nuts e to the specified torques in 2 stages and in the order a, TIP: b, and so on. Make sure that the bottom of the grommet d is at the specified installation distance a from the end of the oil level pipe b.
Page 158 ETV and intake manifold (FX SHO, FX Cruiser SHO) Supercharger installation (FX SHO, FX Cruiser SHO) 1. Remove the supercharger oil filler hole bolt a and gasket b, and then apply engine oil to the supercharger impeller shaft through the oil filler hole a. Supercharger bolt (M8 ...
Page 159 POWR Power unit Air cooler bolt c: 1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb) Air cooler nut d: 1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb) 3. Install the air cooler intake pipe e, and then tighten the air cooler intake pipe clamps f to the specified torque.
Page 160 ETV and intake manifold (FX SHO, FX Cruiser SHO) Boost pipe bolt l: 20 N·m (2.0 kgf·m, 14.8 ft·lb) Boost pipe joint 1 clamp m: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) Boost pipe joint 2 clamp n: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) TIP: •...
Page 161 POWR Power unit Oil cooler and oil pump assy. (FX SHO, FX Cruiser SHO) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 21 N·m (2.1 kgf·m, 15.5 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb)
Page 162 Oil cooler and oil pump assy. (FX SHO, FX Cruiser SHO) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 21 N·m (2.1 kgf·m, 15.5 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb)
Page 163 POWR Power unit Idle gear assy. and drive gear assy. (FX SHO, FX Cruiser SHO) 80 N·m (8.0 kgf·m, 59.0 ft·lb) Part name Q’ty Remarks Shaft Idle gear assy. Circlip Washer Washer Collar M12  58 mm, Left-hand threads Bolt Drive gear assy.
Page 164 Idle gear assy. and drive gear assy. (FX SHO, FX Cruiser SHO) / Oil cooler, oil pump assy. and drive gear (FX HO, FX Cruiser HO) Oil cooler, oil pump assy. and drive gear (FX HO, FX Cruiser HO) Oil cooler, oil pump assy. and drive gear (FX HO, FX Cruiser HO) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 80 N·m (8.0 kgf·m, 59.0 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb)
Page 165 POWR Power unit 11 N·m (1.1 kgf·m, 8.1 ft·lb) 80 N·m (8.0 kgf·m, 59.0 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) Part name Q’ty...
Page 166 Oil cooler, oil pump assy. and drive gear (FX HO, FX Cruiser HO) Oil pump assy., idle gear assy., and Oil pump assy. and oil pump drive drive gear assy. removal (FX SHO, FX gear removal (FX HO, FX Cruiser HO) Cruiser SHO) 1.
Page 167 POWR Power unit 4. Turn the supercharger drive gear b counterclockwise b and check that it does not turn. Replace the drive gear assy. if it turns. Leakage tester b: 90890-06840 Specified positive pressure (water passage): 200 kPa (2.0 kgf/cm , 28.5 psi) Drive gear assy., idle gear assy., and oil pump assy.
Page 168 Oil cooler, oil pump assy. and drive gear (FX HO, FX Cruiser HO) Drive gear assy. bolt b: 80 N·m (8.0 kgf·m, 59.0 ft·lb) 4. Install the idle gear assy. c, collar d, and shaft e. Oil pump assy. bolt i: 11 N·m (1.1 kgf·m, 8.1 ft·lb) Oil pump drive gear and oil pump assy.
Page 169 POWR Power unit Oil pump assy. bolt g: 11 N·m (1.1 kgf·m, 8.1 ft·lb) Oil pump drive gear bolt b: 80 N·m (8.0 kgf·m, 59.0 ft·lb) 4. Fill the oil pump assy. with engine oil through the feed port a. TIP: While turning the oil pump driven gear, make sure to fill the oil pump assy.
Page 170 Cylinder head cover Oil cooler, oil pump assy. and drive gear (FX HO, FX Cruiser HO) / Cylinder head cover Cylinder head cover 10 N·m (1.0 kgf·m, 7.4 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 25 N·m (2.5 kgf·m, 18.4 ft·lb) Part name Q’ty Remarks...
Page 171 POWR Power unit Camshaft (FX SHO, FX Cruiser SHO) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) Part name Q’ty Remarks M10  21 mm Bolt ...
Page 172 Camshaft (FX SHO, FX Cruiser SHO) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) Part name Q’ty Remarks Camshaft sprocket M6  30 mm Bolt Chain guide plate Timing chain guide...
Page 173 POWR Power unit Camshaft (FX HO, FX Cruiser HO) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) Part name Q’ty Remarks M10  21 mm Bolt ...
Page 174 Camshaft (FX HO, FX Cruiser HO) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) Part name Q’ty Remarks Camshaft sprocket M6  30 mm Bolt Chain guide plate Timing chain guide...
Page 175 POWR Power unit Camshaft removal When installing the camshafts, piston #1 must be positioned at TDC. Therefore, do not turn the crankshaft after removing the camshafts. 1. Install the special service tools into spark plug hole #1. Coupler wrench e: 90890-06729 TIP: Make sure that the punch marks a on the camshafts are aligned with the marks b on...
Page 176 Camshaft (FX HO, FX Cruiser HO) 6. Remove the intake camshaft caps and exhaust camshaft caps. TIP: Loosen the camshaft cap bolts in the oppo- site order used for tightening. 7. Remove the intake camshaft j and exhaust camshaft k. Cam lobe height a: Intake: 41.330–41.430 mm (1.627–1.631 in)
Page 177 POWR Power unit TIP: Do not put the Plastigauge over the oil hole in the camshaft journal. 4. Install the dowel pins d, intake camshaft caps e and f, and exhaust camshaft caps g and h. Camshaft runout: 0.015 mm (0.0006 in) Limit: 0.05 mm (0.0020 in) Camshaft journal oil clearance check...
Page 178 Camshaft (FX HO, FX Cruiser HO) 2. While squeezing the ends of the snap TIP: ring e so that it fits into the groove d in Make sure to keep the camshafts level. the timing chain tensioner rod a, release the tensioner rod slowly until it is locked 6.
Page 179 POWR Power unit TIP: • Install each camshaft sprocket with the punch mark a facing outward. • When installing original camshaft sprocket, make sure to align the marks b made during removal. 2. Hold the camshaft sprocket using the special service tool a, and then tighten the camshaft sprocket bolts b to the specified torque.
Page 180 Camshaft (FX HO, FX Cruiser HO) 8. Align the punch marks d on the camshafts with the marks e on the camshaft caps. TIP: When installing the camshaft caps, make sure that the arrow marks c on the camshaft caps point toward the camshaft sprockets. 6.
Page 181 POWR Power unit 11. Install a new gasket l and the timing chain tensioner m onto the cylinder head, and then tighten the timing chain tensioner bolts n temporarily. 12. Install new gaskets o and the oil pipe p to the cylinder head and timing chain tensioner m, and then tighten the oil pipe bolts q temporarily.
Page 182 Camshaft (FX HO, FX Cruiser HO) 10. Measure the intake and exhaust valve clearances of the specified cylinders. TIP: The thickness of each valve pad is marked in hundredths of millimeters on the side that ✔ ✔ — — contacts the valve lifter. ✔...
Page 183 POWR Power unit Coupler wrench g: 90890-06729 13. Measure the intake and exhaust valve clearances of the specified cylinders. ✔ ✔ — — ✔ ✔ — — ✔: Specified cylinder —: Not applicable 5-77...
Page 184 Camshaft (FX HO, FX Cruiser HO) Valve pad selection table Intake Measured Original valve pad number clearance 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.00–0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 0.03–0.06...
Page 185 POWR Power unit Cylinder head 55 N·m (5.5 kgf·m, 40.6 ft·lb) 90° 42 N·m (4.2 kgf·m, 31.0 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) Part name Q’ty Remarks M6  55 mm Bolt  M12  140 mm Bolt Washer Cylinder head assy.
Page 186 Valve and valve spring Cylinder head / Valve and valve spring Valve and valve spring Part name Q’ty Remarks Valve lifter Valve pad Valve cotter Upper spring seat Valve spring Lower spring seat Intake valve Exhaust valve  Valve seal ...
Page 187 POWR POWR Power unit Cylinder head disassembly 3. Remove the valve seals. 1. Remove the valve lifters a and valve Cylinder head check pads b. 1. Remove carbon deposits from the com- bustion chambers. 2. Check the cylinder head water jacket. Clean if there are mineral deposits or rust.
Page 188 Valve and valve spring Valve spring free length a: Valve margin thickness b: Intake and exhaust: Intake and exhaust: 45.58 mm (1.79 in) 0.800–1.200 mm (0.0315–0.0472 in) Limit: 3. Measure the valve stem diameter c. 43.30 mm (1.70 in) Replace if out of specification. 2.
Page 189 POWR Power unit Valve guide remover a: YB-06801 Valve guide remover/installer a: 90890-06801 Valve guide installation 1. Insert the special service tools a and b into the camshaft side of the valve guide c. NOTICE: Do not reuse a valve guide, always replace it with a new one.
Page 190 Valve and valve spring 4. Measure the valve seat contact width a TIP: where the blueing dye is adhered to the • Turn the special service tool d clockwise to valve face. Reface the valve seat if the ream the valve guide. valve is not seated properly or if the valve •...
Page 191 POWR Power unit a Slag or rough surface 3. Adjust the top edge of the valve seat contact width using a 30° cutter. A U.S.A. and Canada B Worldwide Neway valve seat kit: YB-91044 Valve seat cutter holder: 90890-06812 Intake: Valve seat cutter 30°: 90890-06720 Valve seat cutter 45°: 90890-06325 Valve seat cutter 60°: 90890-06324...
Page 192 Valve and valve spring • If the valve seat contact area is too narrow and situated near the bottom edge of the valve face, cut the bottom edge of the valve seat using a 60° cutter to center the area, and then set its width using a 45°...
Page 193 POWR Power unit 4. Tap the valve spring retainer lightly using a plastic hammer to seat the valve cotters g securely. Valve spring compressor e: YM-04019/90890-04019 Compressor adapter f: YM-04114 Valve spring compressor attachment f: 90890-04114 5. Install the valve pads h and valve lifters i in their original positions.
Page 194 Valve and valve spring Cylinder head installation 1. Install the dowel pins a, a new gasket b, the cylinder head assy. c, the wash- ers d, and the cylinder head bolts e, and then tighten the cylinder head bolts e to the specified torques in 2 stages and in the order a, b, and so on.
Page 195 POWR Power unit Generator cover assy. and flywheel magneto 26 N·m (2.6 kgf·m, 19.2 ft·lb) 250 N·m (25.0 kgf·m, 184.4 ft·lb) 80 N·m (8.0 kgf·m, 59.0 ft·lb) 24 N·m (2.4 kgf·m, 17.7 ft·lb) 250 N·m (25.0 kgf·m, 184.4 ft·lb) 50 N·m (5.0 kgf·m, 36.9 ft·lb) 60°...
Page 196 Generator cover assy. and flywheel magneto 26 N·m (2.6 kgf·m, 19.2 ft·lb) 250 N·m (25.0 kgf·m, 184.4 ft·lb) 80 N·m (8.0 kgf·m, 59.0 ft·lb) 24 N·m (2.4 kgf·m, 17.7 ft·lb) 250 N·m (25.0 kgf·m, 184.4 ft·lb) 50 N·m (5.0 kgf·m, 36.9 ft·lb) 60°...
Page 197 POWR Power unit Generator cover 15 N·m (1.5 kgf·m, 11.1 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) Part name Q’ty Remarks M6  15 mm Bolt Holder M5  15 mm Bolt M5  10 mm Bolt Washer M6  30 mm Bolt Stator coil assy.
Page 198 Generator cover Drive coupling removal Use heat-resistant gloves. Otherwise, burns could result. 1. Heat the holder a and drive coupling b for 20–30 minutes using a heat gun c. NOTICE: Be careful not to damage the wiring harness when using the heat gun.
Page 199 POWR Power unit Shaft holder d: 90890-06721 Shaft holder d: 90890-06721 Driver handle e: 90890-06722 Driver handle e: 90890-06722 Crankshaft holder h: 90890-06732 TIP: 5. Remove the flywheel magneto c and • Loosen the special nut f until it can no Woodruff key using the special service longer be turned.
Page 200 Generator cover Primary sheave holder k: YS-01880-A Sheave holder k: 90890-01701 7. Remove the starter clutch. Generator cover assy. disassembly 1. Remove the washer a, pickup coil b, holder c, and stator coil assy. d. A U.S.A. and Canada B Worldwide Driver handle (small) h: YB-06229 Bearing and seal installer i: YW-06356 Driver rod LS j: 90890-06606...
Page 201 POWR Power unit Generator cover assy. assembly 1. Install a new ball bearing a. A U.S.A. and Canada B Worldwide A U.S.A. and Canada Driver handle (large) b: YB-06071 B Worldwide Forward bearing race installer h: Driver handle (large) b: YB-06071 YB-06258 Bearing pressure C i: 90890-02393 Forward gear outer race installer c:...
Page 202 Generator cover 3. Install the flywheel magneto b to the TIP: starter gear e. Pass the pickup coil lead a between the gen- erator cover and the bolt hole b, and then secure the lead by installing the washer m. Flywheel magneto installation Do not reuse a flywheel magneto, special nut, flywheel magneto bolt, transfer shaft,...
Page 203 POWR Power unit Shaft holder i: 90890-06721 Driver handle j: 90890-06722 Crankshaft holder k: 90890-06732 Transfer shaft g: 50 N·m (5.0 kgf·m, 36.9 ft·lb) 9. Using the hexagonal portion of the special service tool k as reference, mark the special service tool i at 0°, 60°, and 120°.
Page 204 Generator cover 60° Shaft holder i: 90890-06721 Driver handle j: 90890-06722 Crankshaft holder k: 90890-06732 Transfer shaft g: 60° 12. Tighten the transfer shaft g to the specified torque using the special service tool k. NOTICE: If the mark d on the Shaft holder i: 90890-06721 transfer shaft g moves past the 120°...
Page 205 POWR Power unit 4. Remove any grease from the threaded Generator cover assy. bolt p: portion of the holder e. 26 N·m (2.6 kgf·m, 19.2 ft·lb) 5. Install the holder e. Drive coupling installation 1. Remove any grease from the threaded portion of the transfer shaft, making sure that the threads are clean and dry.
Page 206 Cylinder block and electrical part (FX SHO, FX Cruiser SHO) Generator cover / Cylinder block and electrical part (FX SHO, FX Cruiser SHO) Cylinder block and electrical part (FX SHO, FX Cruiser SHO) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) Part name Q’ty...
Page 207 POWR Power unit 15 N·m (1.5 kgf·m, 11.1 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) Part name Q’ty Remarks Holder Knock sensor 5-101...
Page 208 Cylinder block and electrical part (FX SHO, FX Cruiser SHO) / Cylinder block and electrical part (FX HO, FX Cruiser HO) Cylinder block and electrical part (FX HO, FX Cruiser HO) Cylinder block and electrical part (FX HO, FX Cruiser HO) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb)
Page 209 POWR Power unit 11 N·m (1.1 kgf·m, 8.1 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) Part name Q’ty Remarks M6  16 mm Bolt Thermoswitch M8  40 mm Bolt Anode assy.
Page 210 Oil separator tank and oil pan Cylinder block and electrical part (FX HO, FX Cruiser HO) / Oil separator tank and oil pan Oil separator tank and oil pan 9 N·m (0.9 kgf·m, 6.6 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 0.3 N·m (0.03 kgf·m, 0.2 ft·lb)
Page 211 POWR Power unit 9 N·m (0.9 kgf·m, 6.6 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 0.3 N·m (0.03 kgf·m, 0.2 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) Part name Q’ty...
Page 212 Oil separator tank and oil pan 5. Install the baffle plate g, and then Anode check tighten the baffle plate bolts h to the 1. Check the anode. Replace if eroded. specified torque. Clean if there is grease, oil, or scales. NOTICE: Do not apply grease, oil, or 6.
Page 213 POWR Power unit 3. Install the oil level pipe assy. onto the cylinder block, and then tighten the oil level pipe plate bolts f and oil level pipe bolt g temporarily. 4. Tighten the oil level pipe plate bolts f to the specified torque.
Page 214 Crankcase, connecting rod, and piston Oil separator tank and oil pan / Crankcase, connecting rod, and piston Crankcase, connecting rod, and piston 50 N·m (5.0 kgf·m, 36.9 ft·lb) 51 N·m (5.1 kgf·m, 37.6 ft·lb) 90° 10 N·m (1.0 kgf·m, 7.4 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 90°...
Page 215 POWR Power unit 50 N·m (5.0 kgf·m, 36.9 ft·lb) 51 N·m (5.1 kgf·m, 37.6 ft·lb) 90° 10 N·m (1.0 kgf·m, 7.4 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 90° Part name Q’ty Remarks M10  30 mm Bolt Bracket Dowel pin...
Page 216 Crankcase, connecting rod, and piston Crankcase disassembly Connecting rod and piston removal 1. Remove the connecting rod cap a, and 1. Place the crankcase upside down on a bench. then remove the connecting rod bearings b and piston and connecting rod c. 2.
Page 217 POWR Power unit A FX SHO, FX Cruiser SHO Crankcase check B FX HO, FX Cruiser HO 1. Check the oil passages. Blow out using compressed air if there are obstructions. 2. Measure the piston pin boss bore diameter Replace Cylinder block check specification.
Page 218 Crankcase, connecting rod, and piston Piston ring dimensions: Piston ring groove: Top ring a: Top ring f: B: 1.170–1.190 mm (0.0461–0.0469 in) 1.210–1.230 mm (0.0476–0.0484 in) 2nd ring g: T: 2.850–3.050 mm (0.1122–0.1201 in) 2nd ring b: 1.210–1.230 mm (0.0476–0.0484 in) Oil ring h: B: 1.170–1.190 mm (0.0461–0.0469 in) T: 2.600–2.800 mm (0.1024–0.1102 in)
Page 219 POWR Power unit Piston pin outside diameter a: 21.991–22.000 mm Crankshaft journal diameter a: (0.8658–0.8661 in) 39.976–40.000 mm Limit: (1.5739–1.5748 in) 21.981 mm (0.8654 in) Crankshaft pin diameter b: 41.976–42.000 mm Connecting rod check (1.6526–1.6535 in) 1. Measure the connecting rod small end inside diameter a.
Page 220 Crankcase, connecting rod, and piston Connecting rod nut: 1st: 51 N·m (5.1 kgf·m, 37.6 ft·lb) 2nd: 90° TIP: • When checking the oil clearance, reuse the removed connecting rod bolts. • Make sure that the “Y” mark c on the con- necting rod faces toward the timing chain drive gear d of the crankshaft.
Page 221 POWR Power unit 2. Check the crankshaft pin size number b on the crankshaft web. P1 P2 P3 P4 3. Select the suitable color c for the connecting rod bearing from the table. Connecting rod big end side clearance: a 0.160–0.262 mm (0.0063–0.0103 in) Limit: 0.5 mm (0.0197 in)
Page 222 Crankcase, connecting rod, and piston Select the size “4”, “Green” connecting rod TIP: bearing. Do not put the Plastigauge b over the oil hole in the main journals of the crankshaft. Crankshaft journal oil clearance check 6. Install the crankcase c and crankcase 1.
Page 223 POWR Power unit 7. Install the crankcase bolts e, and then tighten them to the specified torque in the order a, b, and so on. J1 J2 J3 J4 J5 TIP: If the crankcase journal sizes are the same at all positions, the size number a is stamped only at the “J1”...
Page 224 Crankcase, connecting rod, and piston 2. Assemble the connecting rod b, piston J1 J2 J3 J4 c, piston pin d, and new piston pin clips NOTICE: Do reuse connecting rod cap bolt or piston pin clip, always replace it with a new one. 3.
Page 225 POWR Power unit TIP: TIP: • Make sure to install the piston rings so that Make sure that the “Y” mark on the connect- the “1T” mark on the top ring h and the ing rod faces toward the timing chain drive “2T”...
Page 226 Crankcase, connecting rod, and piston 5. Install the crankcase d and new Crankcase assembly crankcase bolts e, and then tighten the 1. Thoroughly clean all the gasket surfaces crankcase bolts e to the specified and crankcase mating surfaces. torques in 2 stages and in the order a, 2.
Page 227 POWR Power unit Crankcase bolt f: 10 N·m (1.0 kgf·m, 7.4 ft·lb) 5-121...
Page 228 PUMP Jet pump unit Intake grate and ride plate ..........6-1 Jet pump unit ..............6-2 Jet pump unit removal ............... 6-4 Jet pump unit installation ............6-5 Reverse gate ..............6-7 Nozzle and nozzle ring ............6-8 Impeller housing and impeller duct assy......6-9 Impeller, drive shaft, and impeller duct ......
Page 229 PUMP Jet pump unit Intake grate and ride plate 17 N·m (1.7 kgf·m, 12.5 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks M5  12 mm Screw Speed and water temperature sensor FX Cruiser SHO Speed sensor FX SHO, FX HO, FX Cruiser HO M8 ...
Page 230 Jet pump unit Intake grate and ride plate / Jet pump unit Jet pump unit 17 N·m (1.7 kgf·m, 12.5 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty...
Page 231 PUMP Jet pump unit 17 N·m (1.7 kgf·m, 12.5 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks...
Page 232 Jet pump unit Jet pump unit removal Make sure to remove the battery before removing the jet pump unit. 1. Remove the rubber plate bolts a. 7. Disconnect the bilge hose m. 8. Remove the jet pump unit assy. bolts n, o, and p.
Page 233 PUMP Jet pump unit TIP: The illustration shows the case where the disk brake piston tool s is used to remove the jet pump unit. Jet pump unit installation Make sure to remove the battery before Jet pump unit assy. bolt (M10  45 mm) c: installing the jet pump unit.
Page 234 Jet pump unit 9. Connect the steering cable joint o, and 13. Tighten the rubber plate bolts x to the then tighten the steering cable joint nut specified torque. p to the specified torque. Rubber plate bolt x: Steering cable joint nut p: 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) TIP:...
Page 235 PUMP Jet pump unit Reverse gate 20 N·m (2.0 kgf·m, 14.8 ft·lb) Part name Q’ty Remarks Spring M8  25 mm Bolt Collar Reverse gate Washer Ball joint M6  35 mm Bolt Collar M6  25 mm Bolt Reverse gate stay...
Page 236 Nozzle and nozzle ring Reverse gate / Nozzle and nozzle ring Nozzle and nozzle ring 16 N·m (1.6 kgf·m, 11.8 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) Part name Q’ty Remarks M8  20 mm Bolt Collar Jet thrust nozzle Nozzle ring Washer Ball joint...
Page 237 PUMP Jet pump unit Impeller housing and impeller duct assy. 40 N·m (4.0 kgf·m, 29.5 ft·lb) 1 N·m (0.1 kgf·m, 0.7 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Clamp Spout hose M10  125 mm Bolt Bracket Nozzle Impeller housing...
Page 238 Impeller, drive shaft, and impeller duct Impeller housing and impeller duct assy. / Impeller, drive shaft, and impeller duct Impeller, drive shaft, and impeller duct 74 N·m (7.4 kgf·m, 54.6 ft·lb) 330 N·m (33.0 kgf·m, 243.4 ft·lb) Part name Q’ty Remarks Impeller M6 ...
Page 239 PUMP Jet pump unit Impeller duct assy. disassembly 1. Remove the impeller a. 4. Remove the ball bearing g. Driveshaft holder b: YB-06201 Drive shaft holder 6 b: 90890-06520 2. Remove the cap c, O-ring d, and nut A U.S.A. and Canada B Worldwide Slide hammer h: YB-06096 Stopper guide plate i: 90890-06501...
Page 240 Impeller, drive shaft, and impeller duct Impeller housing inside diameter a: 155.35–155.45 mm (6.116–6.120 in) Limit: 156.45 mm (6.160 in) Drive shaft check 1. Measure the drive shaft runout. Replace if out of specification. A U.S.A. and Canada B Worldwide Slide hammer h: YB-06096 Stopper guide plate i: 90890-06501 Bearing puller assembly j: 90890-06535...
Page 241 PUMP Jet pump unit Bearing attachment f: Bearing attachment f: 90890-06728 90890-06728 6. Install the washer i, and then tighten Distance b: the drive shaft nut j to the specified 23.0 ± 0.1 mm (0.91 ± 0.004 in) torque. 3. Install the drive shaft e (along with the 7.
Page 242 Impeller, drive shaft, and impeller duct 4. Apply sealant to the mating surfaces of the nozzle e and impeller duct assy. a. 5. Install the dowel pins d and nozzle e. 6. Install the bracket f, and then tighten the impeller duct bolts g to the specified torque.
Page 243 PUMP Jet pump unit Transom plate and hoses 6 N·m (0.6 kgf·m, 4.4 ft·lb) 26 N·m (2.6 kgf·m, 19.2 ft·lb) 26 N·m (2.6 kgf·m, 19.2 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) Part name Q’ty Remarks Clamp...
Page 244 Transom plate and hoses 6 N·m (0.6 kgf·m, 4.4 ft·lb) 26 N·m (2.6 kgf·m, 19.2 ft·lb) 26 N·m (2.6 kgf·m, 19.2 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) Part name Q’ty Remarks Washer Washer Transom plate Clamp Hose...
Page 245 PUMP Jet pump unit Bilge and hoses 5.5 N·m (0.55 kgf·m, 4.06 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Plastic tie Clamp Bilge hose Bilge hose Hose joint Plastic tie Rivet Holder Bilge hose Clamp Bilge hose Band Electric bilge pump assy.
Page 246 Bilge and hoses 5.5 N·m (0.55 kgf·m, 4.06 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks  Packing Hose joint Clamp Bilge hose Hose joint Drain joint  Packing 6-18...
Page 247 PUMP Jet pump unit Bilge strainer check 1. Check the bilge strainer. See “Bilge strainer check” (3-10). Electric bilge pump strainer check 1. Check the electric bilge pump strainer. See “Electric bilge pump strainer check” (3-10). Transom plate installation 1. Clean the mating surface of the transom plate a.
Page 248 Intermediate housing Bilge and hoses / Intermediate housing Intermediate housing 17 N·m (1.7 kgf·m, 12.5 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 205 N·m (20.5 kgf·m, 151.2 ft·lb) Part name Q’ty Remarks Rubber coupling M8  48 mm Bolt Shim As required Dowel pin Driven coupling...
Page 249 PUMP Jet pump unit 17 N·m (1.7 kgf·m, 12.5 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 205 N·m (20.5 kgf·m, 151.2 ft·lb) Part name Q’ty Remarks 6-21...
Page 250 Intermediate housing Intermediate housing assy. removal 1. Remove the engine unit. See “Engine unit removal (FX SHO, FX Cruiser SHO)” (5-11) or “Engine unit removal (FX HO, FX Cruiser HO)” (5-15). 2. Remove the intermediate housing assy. 3. Remove the oil seals f, g, and h. TIP: If shims b are installed, remove the shims and write down the position of each removed...
Page 251 PUMP Jet pump unit Needle bearing installer p: YB-06434 Needle bearing installer c: YB-06434 Bearing outer race attachment p: Bearing outer race attachment c: 90890-06654 90890-06654 Intermediate housing assy. assembly Distance a: 6.5 ± 0.2 mm (0.26 ± 0.01 in) 4.
Page 252 Intermediate housing 6. Install a new oil seal i. Shaft holder n: 90890-06730 Bearing attachment j: 90890-06727 Coupler wrench o: 90890-06729 Distance c: Driven coupling m: 1.6 ± 0.2 mm (0.06 ± 0.01 in) 205 N·m (20.5 kgf·m, 151.2 ft·lb) 7.
Page 253 ELEC Electrical system Electrical components ............7-1 Engine (FX SHO, FX Cruiser SHO) .......... 7-1 Engine (FX HO, FX Cruiser HO) ..........7-2 Deck and hull ................7-3 Electrical box ................7-4 ECM circuit diagram ..............7-5 ECM coupler layout ..............7-7 Electrical analysis .............
Page 254 Fuel pump module check ............7-29 Starting system ............... 7-30 Left handlebar switch assy. check ........... 7-30 Main and fuel pump relay check ..........7-31 Starter relay check ..............7-32 Starter motor ..............7-33 Starter motor operation ............7-34 Armature check ............... 7-34 Brush holder check ..............
Page 255 ELEC Electrical system Electrical components Engine (FX SHO, FX Cruiser SHO) a Spark plug and ignition coil i Fuel injector b Cam position sensor j Thermoswitch c Electrical box k Intake air temperature sensor d Thermo sensor l Knock sensor e Rectifier regulator m ETV (TPS) f Starter motor...
Page 256 Electrical components Engine (FX HO, FX Cruiser HO) a Spark plug and ignition coil i Intake air pressure sensor b Cam position sensor j Fuel injector c Electrical box k Thermoswitch d Thermo sensor l Intake air temperature sensor e Rectifier regulator m Engine temperature sensor f Starter motor n Earth plate...
Page 257 ELEC Electrical system Deck and hull a Remote control receiver f Buzzer b Compass and air temperature sensor (FX g Fuel pump module and fuel sender h Left handlebar switch assy. Cruiser SHO only) c Steering sensor i Right handlebar switch d APS (electric throttle without wire cable) j Multifunction meter e Speed and water temperature sensor (FX...
Page 258 Electrical components Electrical box a Starter relay i Fuse (3 A) (remote control receiver) b Main and fuel pump relay j Fuse (20 A) (main and fuel pump relay) c ETV relay k Positive battery lead (gray tape) d Slant detection switch l Starter motor lead (white tape) e ECM m Lead (black)
Page 259 ELEC Electrical system CM circuit diagram Stator Rectifier Fuel injector #1 coil regulator Fuse Fuel injector #2 (20 A) Fuel injector #3 Main relay Fuel injector #4 Fuse (3 A) Ignition coil #1 Engine start Remote control switch receiver Fuse (30 A) Ignition coil #2 Starter...
Page 260 Electrical components Knock sensor Oil pressure switch Thermoswitch ETV motor Engine shut-off switch Cruise assist set switch TPS 1 TPS 2 Cruise assist up switch Ground Cruise assist down switch APS full close switch Ground APS 1 Ground APS 2 Ground A FX SHO, FX Cruiser SHO only...
Page 261 ELEC Electrical system ECM coupler layout 1 2 3 4 5 6 7 27 28 29 30 31 32 33 54 55 56 57 58 59 60 61 8 9 10 11 12 13 34 35 36 37 38 39 62 63 64 65 66 67 68 69 14 15 16 17 18 19...
Page 262 Electrical components Lead External connec- Lead External connec- Lead External connec- color tion lead color tion lead color tion lead TPS 2 Pu/R Fuel injector #1 — — TPS power Pu/B Fuel injector #2 — — source ETV relay power Ignition coil #4 —...
Page 263 ELEC Electrical system Electrical analysis TIP: Electrical component check using • Before checking the electrical components, the YDIS make sure that the battery is fully charged. When checking the TPS, APS, or other sen- • If the test leads are connected while using sors, use the YDIS.
Page 264 Ignition system Electrical analysis / Ignition system TIP: • When testing the voltage between the • Before measuring the peak voltage, check terminals of an electrical component all wiring for proper connection and corro- using the digital tester, do not allow any sion, and check that the battery is fully of the leads to touch any metal parts.
Page 265 ELEC Electrical system 5. Disconnect the special service tool, and then install the ignition coils. Ignition coil check #1 B/R #2 B/W 1. Disconnect the ignition coil couplers a. #3 B/Y #4 B/G 2. Supply power to the ECM, and then measure the input voltage at the ignition coil coupler terminals (wiring harness end).
Page 266 Charging system Ignition system / Charging system 2. Measure the pickup coil output peak voltage. Pickup coil resistance at 20 °C (68 °F) (reference data): White (W)–Black (B) 459–561  5. Connect the pickup coil coupler. Test harness (3 pins) a: Charging system YB-06877/90890-06877 Stator coil check...
Page 267 ELEC Electrical system Stator coil output peak voltage: Green (G)–Green (G) Unloaded r/min Cranking 2000 3500 36.4 64.7 3. Disconnect the special service tool. 4. Measure the stator coil resistance. Replace the stator coil assy. if out of specification. Measure rectifier regulator output peak voltage if within specification.
Page 268 Control system Charging system / Control system Rectifier regulator continuity (testing diode mode): Tester lead Display value (V)   (reference data) 0.43–0.51 0.43–0.51 0.43–0.51 0.66–0.74 0.43–0.51 0.43–0.51 0.43–0.51 OL: Indicates an overload TIP: A U.S.A. and Canada Make sure to set the measurement range g B Worldwide when checking the rectifier regulator continu- ity.
Page 269 ELEC Electrical system 2. Supply power to the ECM, and then Oil pressure switch continuity: measure the input voltage between the Terminal thread oil pressure switch coupler terminal Pressure b–Body c (wiring harness end) and ground. Check Below 128–166 kPa the wiring harness if out of specification.
Page 270 Control system 3. Remove the thermoswitch. See “Cylinder Thermo sensor check block and electrical part (FX SHO, FX 1. Disconnect the thermo sensor coupler Cruiser SHO)” (5-100) or “Cylinder block and electrical part (FX HO, FX Cruiser 2. Supply power to the ECM, and then HO)”...
Page 271 ELEC Electrical system 7. Connect the thermo sensor coupler. Engine temperature sensor check 1. Disconnect the engine temperature sen- sor coupler a. 2. Supply power to the ECM, and then measure the input voltage at the engine temperature sensor coupler terminals (wiring harness end).
Page 272 Control system 5. Supply power to the ECM, and then measure the input voltage at the intake air temperature sensor coupler (wiring harness end). Check the wiring harness if out of specification. A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO 8.
Page 273 ELEC Electrical system Intake air pressure sensor input voltage: Orange (O)–Black/Orange (B/O) 4.75–5.25 V 3. Connect the intake air pressure sensor coupler a. 4. Disconnect the vacuum hose from the intake air pressure sensor. 5. Connect the special service tool to the Knock sensor resistance at 20 °C (68 °F) intake air pressure sensor.
Page 274 Control system TIP: TIP: When checking the TPS using the YDIS, do The actual TPS output voltage and throttle not start the engine. valve opening angle may vary according to environmental conditions and engine temper- ature. 2. Squeeze the throttle lever a slowly and check that the displayed throttle valve 5.
Page 275 ELEC Electrical system TPS input voltage: Orange (O)–Black/Orange (B/O) 3 2 1 4.75–5.25 V 6 5 4 8. Connect the ETV coupler. ETV circuit continuity 1. Disconnect the ETV coupler a and ECM couplers b and c. ETV circuit continuity: Terminal No.
Page 276 Control system 6. Supply power to the ECM, and then measure the input voltage at the APS coupler terminals (wiring harness end). Check the APS circuit continuity if out of specification. APS output voltage: Throttle lever position Item Fully closed A Fully open B APS 1 0.68–0.74 V...
Page 277 ELEC Electrical system 2. Check the wiring harness for continuity. Replace if there is no continuity. 3 2 1 6 5 4 ETV relay input voltage: 30 29 Red/Yellow (R/Y)–Ground Red (R)–Ground 12 V (battery voltage) 3. Remove the ETV relay. See “Electrical box”...
Page 278 Control system Cam position sensor input voltage: Orange (O)–Black/Orange (B/O) 4.75–5.25 V 3. Remove the cam position sensor. See “Cylinder head cover” (5-64), and then connect the special service tool a to the cam position sensor and the wiring harness. Test harness (6 pins) a: YB-06872/90890-06849 4.
Page 279 ELEC Electrical system Cam position sensor output voltage: Green/Orange (G/O)– Black/Orange (B/O) Position Voltage (V) c, e More than 4.8 Less than 0.8 5. Disconnect the special service tool a, and then install the cam position sensor. See “Cylinder head cover” (5-64). 6.
Page 280 Control system 4. Hold the spring gauge b at a 90° angle 8. Supply power to the ECM, and then from the handlebar grip, and then pull the measure the input voltage at the steering spring gauge in direction b using a force sensor coupler terminals (wiring harness of approximately 100 N (10 kgf, 22 lbf).
Page 281 ELEC Electrical system 2. Push the right handlebar switches a, b, ECM check c, and d. 1. Disconnect the ECM coupler a. 3. Check that the following is displayed in the “Engine monitor” window of the YDIS. 2. Supply power to the ECM, and then measure the input voltage between the ECM coupler terminal (wiring harness Right handlebar switch operation:...
Page 282 Control system Electric bilge pump check 1. Disconnect the electric bilge pump cou- pler a. 2. Supply power to the ECM, and then measure the input voltage between the electric bilge pump coupler terminals (wiring harness end). Check the wiring harness or electric bilge pump fuse if out of specification.
Page 283 ELEC Electrical system Fuel system 7. Install the fuel injectors. See “Fuel rail and injector installation” (4-10). Fuel injector check 1. Connect the YDIS. 8. Connect the fuel injector couplers. 2. Using the “Stationary test” of the YDIS, Fuel pump module check listen for the fuel injector operation 1.
Page 284 Starting system Fuel system / Starting system Engine start switch continuity: Engine Red (R)– Clip a start switch Brown (Br) Free No continuity Installed A Pushed Continuity Free No continuity Removed Pushed No continuity 3. Connect the left handlebar switch coupler Fuel sender resistance at 20 °C (68 °F) (white coupler).
Page 285 ELEC Electrical system Main and fuel pump relay check Do not reverse the battery leads. Other- wise, the main and fuel pump relay may be seriously damaged. 1. Disconnect the main and fuel pump relay coupler a, and then measure the input voltage between the main and fuel pump relay coupler terminals c or e (wring harness end) and ground.
Page 286 Starting system TIP: The positive battery lead is marked with gray tape a. 3. Install the starter relay. See “Electrical 1 2 3 4 5 6 7 8 box” (5-35). 4. Connect the tester leads between the starter relay terminals b and c. 5.
Page 287 ELEC Electrical system Starter motor 9 N·m (0.9 kgf·m, 6.6 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 12 11 Part name Q’ty Remarks M6  120 mm Bolt Rear cover  Packing Front cover assy.  Packing Plate Starter motor yoke Armature Brush holder assy.
Page 288 Starter motor Starter motor operation 1. Remove the starter motor. See “Starter motor and wiring harness assy. removal (FX SHO, FX Cruiser SHO)” (5-37) or “Starter motor and wiring harness assy. removal (FX HO, FX Cruiser HO)” (5-38). 2. Hold the starter motor in a vise using aluminum plates on both sides.
Page 289 ELEC Electrical system Armature continuity: Commutator Continuity segments c Segment c– No continuity Armature core d Segment c– No continuity Armature core e Brush holder check Brush holder assy. continuity: 1. Measure the brush length a. Replace Brush b–Brush c Brush d–Brush e the brush holder assy.
Page 290 Use a pair of non-conductive tweezers to replace the battery. 6. Measure the battery voltage. Replace the remote control transmitter battery if below specification. Remote control transmitter battery voltage: Yamaha Security Number of beeps System mode 1 beep Lock TIP: Unlock...
Page 291 ELEC Electrical system Transmitter cover screw a: Remote control receiver output voltage 0.1 N·m (0.01 kgf·m, 0.07 ft·lb) (reference data): Blue/Yellow (L/Y)–Ground Remote control receiver check 11.0–12.0 V 1. Disconnect the remote control receiver coupler a, and then measure the input 5.
Page 292 Indication system Remote control system / Indication system Indication system Multifunction meter check 1. Check the multifunction meter external appearance. Replace the multifunction meter if there is cracked meter housing, fogged meter, or water intrusion. 2. Supply power to the ECM, and then check that all indicator lights a and display elements b and c on the multifunction meter come on.
Page 293 ELEC Electrical system 5. Supply power to the ECM, and then Left operation button continuity: measure input voltage Leads multifunction meter coupler terminals Button Position Pu/W (wiring harness end). Replace the wiring Free “Speed/RPM” harness if out of specification. Replace button a ...
Page 294 Indication system 3. Check that the arrow a on the compass 3. Select the water temperature display and air temperature sensor is facing mode of the multifunction meter and toward the bow. check the water temperature displayed on the meter. 4.
Page 295 ELEC Electrical system 2. Connect the positive battery lead to the 2. Connect the positive battery lead to the terminal b, and the negative battery lead terminal b, and the negative battery lead to the terminal c. to the terminal c. 3.
Page 296 Indication system 2. Supply power to the ECM, and then check that the “WARNING” indicator light b and the check engine warning indicator c begin to blink. 4. Supply power to the ECM, and then check that all fuel level segments come on.
Page 297 ELEC Electrical system Oil pressure warning indicator check 1. Disconnect the oil pressure switch cou- pler a, and then ground the terminal. 2. Start the engine, and then increase the engine speed to 4500 r/min or more. 3. Check that the “WARNING” indicator light b and the oil pressure warning indicator blink, buzzer...
Page 298 Indication system Buzzer check 1. Disconnect the buzzer coupler a. 2. Supply power to the ECM, and then measure the input voltage at the buzzer coupler terminals (wiring harness end). Check the wiring harness if out of specification. Buzzer input voltage (reference data): Blue/Red (L/R)–Black/Blue (B/L) 11.0–12.0 V 3.
Page 299 HULL HOOD Hull and hood Steering pad and handlebar cover ........8-1 Handlebar and handlebar switch assy......8-2 Left handlebar switch assy. and throttle lever assy............. 8-4 Cable and lead routing .............. 8-5 Handlebar assy. installation ............8-5 Front hood .................
Page 300 Rear section ..............8-35 Spout installation ..............8-38 Reboarding step assy. installation ........... 8-38 Deck and hull ..............8-39...
Page 301 HULL HOOD Hull and hood Steering pad and handlebar cover 1 N·m (0.1 kgf·m, 0.7 ft·lb) Part name Q’ty Remarks M5  16 mm Tapping screw Upper handlebar cover Steering pad cover Steering pad M6  14 mm Screw Lower handlebar cover...
Page 302 Handlebar and handlebar switch assy. Steering pad and handlebar cover / Handlebar and handlebar switch assy. Handlebar and handlebar switch assy. 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 1 N·m (0.1 kgf·m, 0.7 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb)
Page 303 HULL HOOD Hull and hood 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 1 N·m (0.1 kgf·m, 0.7 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) Part name...
Page 304 Left handlebar switch assy. and throttle lever assy. Handlebar and handlebar switch assy. / Left handlebar switch assy. and throttle lever assy. Left handlebar switch assy. and throttle lever assy. 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) Part name Q’ty Remarks Left handlebar switch assy.
Page 305 HULL HOOD Hull and hood Cable and lead routing 1. Wrap the packing a at the paint marks a on the left handle bar switch assy. lead b, right handle bar switch lead c, and throttle lever assy. lead d. Distance g: 10.0 mm (0.4 in) Handlebar assy.
Page 306 Left handlebar switch assy. and throttle lever assy. 3. Install the right handlebar switch c and throttle lever assy. d, and then tighten the right handlebar switch screws g to the specified torque. Cable locknut i: 16 N·m (1.6 kgf·m, 11.8 ft·lb) Cable length e: Right handlebar switch screw g: 73.0 mm (2.9 in)
Page 307 HULL HOOD Hull and hood Clearance (reference data): n: 0.4 mm (0.02 in) p: 2.4 mm (0.1 in) TIP: • Align the punched marks k on the handle- bar n with the top surface of the steering master q. • The upper handlebar holder o should be installed with the punch mark m facing Q.S.T.S.
Page 308 Front hood Left handlebar switch assy. and throttle lever assy. / Front hood Front hood 1.5 N·m (0.15 kgf·m, 1.11 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb)
Page 309 HULL HOOD Hull and hood 1.5 N·m (0.15 kgf·m, 1.11 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name...
Page 310 Multifunction meter Front hood / Multifunction meter Multifunction meter 2 N·m (0.2 kgf·m, 1.5 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks A FX Cruiser SHO Right operation button assy. B FX SHO, FX HO, FX Cruiser HO Cover Left operation button assy.
Page 311 HULL HOOD Hull and hood 2 N·m (0.2 kgf·m, 1.5 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks Rivet Service lid Rivet Bow locker Plug Band Fire extinguisher box  Rivet Hook Plastic tie A FX Cruiser SHO...
Page 312 Side cover Multifunction meter / Side cover Side cover 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name Q’ty Remarks M6  30 mm Bolt Left side ornament Right side ornament...
Page 313 HULL HOOD Hull and hood Side cover removal Side cover installation 1. Set the shift lever to the reverse position. 1. Set the shift lever to the forward position. 2. Remove the shift lever a. 2. Install the side cover a, and then tighten the side cover bolts b and c and side 3.
Page 314 Center cover Side cover / Center cover Center cover 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name Q’ty Remarks M6  29 mm Bolt M6 ...
Page 315 HULL HOOD Hull and hood 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name Q’ty Remarks  Packing Box cap Packing M6  18 mm Tapping screw Chain ball Transmitter holder...
Page 316 Steering master assy. Center cover / Steering master assy. Steering master assy. 21 N·m (2.1 kgf·m, 15.5 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) Part name Q’ty Remarks...
Page 317 HULL HOOD Hull and hood 21 N·m (2.1 kgf·m, 15.5 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) Part name Q’ty Remarks A FX Cruiser SHO Washer Plastic tie Grommet...
Page 318 Steering master Steering master assy. / Steering master Steering master 4 N·m (0.4 kgf·m, 3.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Steering master assy. M5  15 mm Bolt Bracket Bracket Buzzer...
Page 319 HULL HOOD Hull and hood 4 N·m (0.4 kgf·m, 3.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks  8-19...
Page 320 Steering master Steering shaft check 1. Check the steering shaft. Replace if cracked or damaged. NOTICE: Do not disassemble the board spring a. Oth- erwise, the OTS will not function prop- erly. 4. Assemble the steering master. 5. Apply instant adhesive onto the mating surfaces of the rubber seal j and steering master assy.
Page 321 HULL HOOD Hull and hood Steering cable and speed sensor lead 4 N·m (0.4 kgf·m, 3.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 20 21 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb)
Page 322 Steering cable and speed sensor lead 4 N·m (0.4 kgf·m, 3.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 20 21 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb)
Page 323 HULL HOOD Hull and hood 4 N·m (0.4 kgf·m, 3.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 20 21 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb)
Page 324 Steering cable and speed sensor lead Steering cable installation (steering master end) If a cable becomes damaged, replace it. Never attempt to repair a damaged cable. 1. Insert the projection a on the steering cable completely into the indentation b in the cable stopper assy.
Page 325 HULL HOOD Hull and hood 3. Install the washer d and steering cable TIP: joint nut e, and then tighten the steering Make sure that the edge of the packing c is cable joint nut e to the specified torque. at the specified distance e from the edge of the grommet d.
Page 326 Steering cable and speed sensor lead 2. Adjust the Q.S.T.S. rod set length c. WARNING! The Q.S.T.S. joint must be screwed in more than 8 mm (0.31 in) d. 3. Face the hole e in the joint of the Q.S.T.S. rod a in the direction shown. Distance c: 167.0 ±...
Page 327 HULL HOOD Hull and hood Seat and handgrip 6 N·m (0.6 kgf·m, 4.4 ft·lb) 26 N·m (2.6 kgf·m, 19.2 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) Part name Q’ty Remarks...
Page 328 Seat and handgrip 6 N·m (0.6 kgf·m, 4.4 ft·lb) 26 N·m (2.6 kgf·m, 19.2 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) Part name Q’ty Remarks Watertight storage compartment...
Page 329 HULL HOOD Hull and hood Ventilation hose and water separator 10 13 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks Rivet Induction box Plastic tie Ventilation hose Grommet Plastic tie Fuel tank breather hose 1 Fuel tank breather hose 2 Rivet Water separator Drain bolt...
Page 330 Ventilation hose and water separator 10 13 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks Holder Clamp Cooling water hose Cooling water pilot outlet  Seal A FX SHO, FX Cruiser SHO A FX SHO, FX Cruiser SHO Clamp A FX SHO, FX Cruiser SHO Cooling water hose...
Page 331 HULL HOOD Hull and hood Cooling water pilot outlet installation 1. Install a new seal a and the cooling water pilot outlet b, and then tighten the cooling water pilot outlet nut c to the specified torque. Installation distance a: Cooling water pilot outlet nut c: 30–40 mm (1.18–1.57 in) 4 N·m (0.4 kgf·m, 3.0 ft·lb)
Page 332 Exhaust system Ventilation hose and water separator / Exhaust system Exhaust system 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 21 22 23 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name Q’ty Remarks Negative battery lead...
Page 333 HULL HOOD Hull and hood 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 21 22 23 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name Q’ty Remarks Water lock Water tank Washer Plate Rubber hose...
Page 334 Exhaust system Exhaust system installation TIP: 1. Install the plate a onto the rubber hose Align the mark b on the rubber hose b with the mark c on the water tank e. 4. Install the water lock g and band h. 5.
Page 335 HULL HOOD Hull and hood Rear section 5 N·m (0.5 kgf·m, 3.7 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name...
Page 336 Rear section 5 N·m (0.5 kgf·m, 3.7 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name Q’ty...
Page 337 HULL HOOD Hull and hood 5 N·m (0.5 kgf·m, 3.7 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name...
Page 338 Rear section Spout installation 1. Install the spout a, and then tighten the spout nut b to the specified torque. 2. Connect the hose c, and then tighten the spout hose clamp d to the specified torque. Reboarding step assy. bolt c: 16 N·m (1.6 kgf·m, 11.8 ft·lb) Spout nut b: 5 N·m (0.5 kgf·m, 3.7 ft·lb) Spout hose clamp d:...
Page 339 HULL HOOD Hull and hood Deck and hull 2 N·m (0.2 kgf·m, 1.5 ft·lb) STBD PORT 18 N·m (1.8 kgf·m, 13.3 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) Part name Q’ty Remarks...
Page 340 Deck and hull 2 N·m (0.2 kgf·m, 1.5 ft·lb) STBD PORT 18 N·m (1.8 kgf·m, 13.3 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name Q’ty Remarks M8  40 mm Bolt Collar Sponson...
Page 341 HULL HOOD Hull and hood 2 N·m (0.2 kgf·m, 1.5 ft·lb) STBD PORT 18 N·m (1.8 kgf·m, 13.3 ft·lb) 16 N·m (1.6 kgf·m, 11.8 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) Part name Q’ty Remarks M6 ...
Page 342 TRBL SHTG Troubleshooting YDIS ..................9-1 Function ..................9-1 Basic components ..............9-3 Connecting the communication cable to the watercraft ..... 9-4 Engine unit troubleshooting ..........9-5 Using the YDIS for engine unit troubleshooting ......9-5 Diagnostic code table ..............9-7 Diagnostic code and checking step ...........
Page 343 Troubleshooting YDIS The Yamaha Diagnostic System uses precision fault diagnosis to offer better serviceability at a time when there is increasing demand for service tools for electronically controlled products. It provides quick, reliable, safe, and reasonable service, and is intended to obtain customer satisfaction. The Yamaha Diagnostic System features updated software and expanded tool functions that allow it to respond to new models and technologies, maintaining compatibility with regulations.
Page 344 YDIS 6. Logger graph: Data stored in the ECM for the last 78 seconds (in 6 seconds intervals) is dis- played on a graph. Items: FX SHO, FX Cruiser SHO, FX HO, FX Cruiser HO Engine speed Intake air pressure Battery voltage Engine temperature Oil pressure switch...
Page 345 TRBL SHTG Troubleshooting Basic components ** * ****** ****** Part name Q’ty Remarks YDIS 2 starter kit 90890-06883 CD-ROM Software and instruction manual Adapter USB cable 5 m (16.4 ft) Adapter cap AD harness For external input CAN-Line harness K-Line harness Power supply harness Trigger switch harness Trigger switch extension harness...
Page 346 YDIS Connecting the communication cable to the watercraft a Wiring harness coupler b Meter coupler c K-Line harness coupler d Adapter e USB cable f Adapter cap TIP: Be careful not to pinch the communication cable between the front hood and the deck or to damage...
Page 347 TRBL SHTG Troubleshooting Engine unit troubleshooting TIP: • Before troubleshooting the engine unit, make sure that fresh fuel of the specified type has been used. • Check that all wiring connections are secured properly and that they are not corroded or rusty. •...
Page 348 Engine unit troubleshooting Self-diagnosis While the engine is running, the diagnostic codes a can be checked by pushing the 2 buttons b simultaneously for approximately 8 seconds. TIP: Because the multifunction meter cannot dis- play more than 1 diagnostic code even if there are multiple diagnostic codes, using the YDIS is recommended.
Page 349 TRBL SHTG Troubleshooting Diagnostic code table Diagnostic code output YDIS Code No. Symptom Multifunc- Diagnosis tion meter Diagnosis record  Normal — —    Pulser coil (*1) malfunction Engine temperature sensor    malfunction    Knock sensor malfunction (*2) ...
Page 350 Engine unit troubleshooting Diagnostic code and checking step Diagnos- Item Symptom Checking steps tic code page 1. Measure the pickup coil output peak 7-11 voltage. 2. Measure the pickup coil resistance. 7-11 Pulser coil (*1) Engine will not malfunction start 3.
Page 351 TRBL SHTG Troubleshooting Diagnos- Item Symptom Checking steps tic code page 1. Measure the cam position sensor 7-24 input voltage. 2. Check the orange (O), green/orange Cam position Engine speed (G/O), and black/orange (B/O) cam sensor is limited position sensor leads for continuity. malfunction 3.
Page 352 Engine unit troubleshooting Diagnos- Item Symptom Checking steps tic code page 1. Measure the thermo sensor input 7-16 voltage. Ex. manifold 2. Check the black/blue (B/L) and black/ water temp. Normal orange (B/O) thermo sensor leads for sensor (*1) operation continuity.
Page 353 TRBL SHTG Troubleshooting Diagnos- Item Symptom Checking steps tic code page 1. Check the pink (P), orange (O), pink/ black (P/B), and black/orange (B/O) ETV leads for continuity. 2. Check the TPS output voltage and 7-19 ETV system Engine speed throttle valve opening using the malfunction is limited...
Page 354 Engine unit troubleshooting Diagnos- Item Symptom Checking steps tic code page 1. Check the ECM circuit for continuity. 7-27 2. Check the ETV relay for continuity. 7-23 3. Check the charging system. 7-12 • Stator coil output peak voltage 7-12 •...
Page 355 TRBL SHTG Troubleshooting Diagnos- Item Symptom Checking steps tic code page 1. Check the cooling water passages 2-19 for obstructions. 2. Measure the engine temperature 7-17 sensor resistance. 3. Check that there is no short circuit between the black/yellow (B/Y) and black/orange (B/O) engine...
Page 356 Symptom 2 Cause Checking step page 7-35 Starter motor does Yamaha Security System Check that the Yamaha Security not operate set to lock mode System is set to the unlock mode. Discharged battery Check the battery voltage and specific gravity.
Page 357 TRBL SHTG Troubleshooting Symptom 2 Cause Checking step page Discharged battery Battery performance Check the battery voltage and decrease specific gravity. 7-12 Stator coil malfunction Check the stator coil assy. 8-32 Short, open, or loose Check the battery lead and connection in charging terminal for proper connection.
Page 358 Engine unit troubleshooting Symptom 2 Cause Checking step page Fuel not supplied (all Fuel leakage Check the fuel hose. cylinders) Blown fuse Check the fuse for continuity. 4-14 Clogged fuel pump filter Clean the fuel pump filter. 7-29 Fuel pump module Check the fuel pump module malfunction operation sound using the YDIS.
Page 359 TRBL SHTG Troubleshooting Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited engine speed Symptom 2 Cause Checking step page 4-10 Throttle valve does Throttle valve malfunction Check the ETV. 5-49 not move properly Spark plug does not Spark plug malfunction Check the spark plug.
Page 360 Engine unit troubleshooting Symptom 1: Limited engine speed Symptom 2 Cause Checking step page • Buzzer sounds Clogged cooling water Check the cooling water pilot outlet — intermittently passage for water discharge. • Overheat warning Check the water inlet strainer. indicator blinks 1-38 Check the cooling water passage.
Page 361 TRBL SHTG Troubleshooting Symptom 1: Poor performance Symptom 2 Cause Checking step page Watercraft cannot Jet pump unit malfunction Check the impeller, impeller duct, reach high speeds and intake grate. 6-10 8-35 Water entered hull Check the drain plugs and O-rings for damage.
Page 362 Appendix Wiring diagram ..............A-1 How to use the wiring diagram ........... A-1 FX SHO, FX Cruiser SHO ............A-1 FX HO, FX Cruiser HO............... A-3...
Page 363 Wiring diagram How to use the wiring diagram Legend symbols in the wiring diagrams a Double colors wire b No wire connector Color Code : Pink : Black : Pink/Black : Brown : Pink/Green : Black/Green : Pink/Red : Black/Blue : Pink/White : Black/Orange Pu/B...
Page 365 Printed in U.S.A. Feb. 2012 – **  1 ABE...
Page 366 FX SHO, FX Cruiser SHO Fuel sender Multifunction meter Right Remote control Main and handlebar receiver fuel pump Reverse switch relay switch relay Buzzer R Br Left operation button FREE Compass and Pu/W air temperature PUSH PULL sensor Fuse box Starter motor Speed Br Br...
Page 367 FX HO, FX Cruiser HO A To entry box B Antenna C Nonuse a Fuse (30 A) (battery) b Fuse (20 A) (main and fuel pump relay) c Fuse (10 A) (ETV relay) d Fuse (10 A) (main and fuel pump relay) e Fuse (3 A) (remote control receiver) f Fuse (3 A) (electric bilge pump)
Page 368 FX HO, FX Cruiser HO Multifunction meter Remote control Main and Right handlebar relay fuel Fuel receiver switch Reverse relay pump sender switch R Br Buzzer FREE Left operation button PUSH PULL Left handlebar switch Pu/W Starter motor Br Br FREE PUSH Fuse box...

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