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Yamaha WaveRunner XL1200Ltd Service Manual

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WaveRunner
XL1200Ltd
SERVICE
MANUAL
LIT186160198
LIT-18616-01-98
F0D-28197-Z9-11

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Table of Contents
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  Summary of Contents for Yamaha WaveRunner XL1200Ltd

  • Page 1 WaveRunner XL1200Ltd SERVICE MANUAL LIT186160198 LIT-18616-01-98 F0D-28197-Z9-11...
  • Page 2 Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
  • Page 3: How To Use This Manual

    HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy refer- ence that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
  • Page 4 IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the water vehicle.
  • Page 5 HOW TO USE THIS MANUAL 1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 2 Numbers are given in the order of the jobs in the exploded diagram. 3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
  • Page 6: Periodic Inspection And

    F Apply YAMALUBE 2-W oil G Apply water resistant grease (Yamaha grease A, Yamaha marine grease) H Apply molybdenum disulfide grease Symbols I to N in an exploded diagram indicate the grade of the sealing or locking...
  • Page 7 INDEX A30000-0 GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND ADJUSTMENT INSP FUEL SYSTEM FUEL POWER UNIT POWR JET PUMP UNIT PUMP – ELECTRICAL SYSTEM ELEC HULL AND HOOD HULL HOOD TROUBLE-ANALYSIS TRBL ANLS...
  • Page 8: Table Of Contents

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

    IDENTIFICATION NUMBERS INFO A60700-0* IDENTIFICATION NUMBERS PRIMARY l.D. NUMBER The primary l.D. number is stamped on a label attached to the inside of the engine compartment. Starting primary l.D. number: F0D: 800101 ~ ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the cylinder head.
  • Page 10: Safety While Working

    SAFETY WHILE WORKING INFO SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be fol- lowed Yamaha dealers their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling gasoline (petrol) and keep it away from heat, sparks, and open flames.
  • Page 11: Good Working Practices

    SAFETY WHILE WORKING INFO Under normal conditions of use there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all-important, and by adopting good safety practises any risk is minimized. A summary of the most important precau- tions is as follows: 1.
  • Page 12: Disassembly And Assembly

    SAFETY WHILE WORKING INFO 3. Non-reusable items Always use new gaskets, packings, O- rings, oil seals, split-pins, circlips, etc., on reassembly. DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed air when disassembling. 2. Oil the contact surfaces of moving parts during assembly.
  • Page 13: Special Tools

    SPECIAL TOOLS INFO SPECIAL TOOLS Using the correct special tools recom- mended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvisations and using improper tools can damage the equipment. NOTE: For U.S.A. and Canada, use part numbers starting with “YB-”, “YM-”, “YU-”...
  • Page 14: Removal And Installation

    SPECIAL TOOLS INFO REMOVAL AND INSTALLATION 1. Coupler wrench YW-06550 90890-06550 YW-06551 P/N. YW-06551 90890-06551 90890-06551 2. Flywheel holder P/N. YW-06550 90890-06550 3. Flywheel puller YB-06117 90890-06521 P/N. YB-06117 90890-06521 4. Shaft holder (intermediate shaft) P/N. YB-06552 90890-06552 YB-06552 5. Driver rod 90890-06552 (intermediate shaft and jet pump) P/N.
  • Page 15 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 MAINTENANCE SPECIFICATIONS..............2-3 ENGINE..................... 2-3 JET PUMP UNIT..................2-4 HULL AND HOOD ..................2-4 ELECTRICAL ..................... 2-5 TIGHTENING TORQUES ................2-7 SPECIFIED TORQUES ................2-7 GENERAL TORQUE ................. 2-9 CABLE AND HOSE ROUTING..............2-10...
  • Page 16: Specifications

    SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Item Unit XL1200Ltd MODEL CODE Hull Engine DIMENSIONS Length mm (in) 3,160 (124.4) Width mm (in) 1,220 (48.0) Height mm (in) 1,130 (44.5) Dry weight kg (lb) 354 (780) Vehicle capacity PERFORMANCE Maximum output kW (PS) @ r/min 114.0 (155) @ 7,000 R /h (US gal/h,...
  • Page 17 PON*: Pump Octane Number RON*: Research Octane Number YAMALUBE 2-W*: YAMALUBE 2-W is developed for this water vehicle and available from a Yamaha water vehicle dealer. CAUTION: Use only YAMALUBE 2-W oil. Using another oil can seriously damage the catalytic converter...
  • Page 18: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model Item Unit XL1200Ltd CYLINDER HEAD Warpage limit mm (in) 0.1 (0.004) Compression pressure KPa (kg/cm 500 (5.0) CYLINDERS Bore size mm (in) 80.000 ~ 80.018 (3.1496 ~ 3.1503) Taper limit mm (in) 0.08 (0.003) Out-of-round limit mm (in) 0.05 (0.002)
  • Page 19: Jet Pump Unit

    SPEC MAINTENANCE SPECIFICATIONS Model Item Unit XL1200Ltd CRANKSHAFT ASSEMBLY Crank width A mm (in) 72.95 ~ 73.00 (2.872 ~ 2.874) Deflection limit B mm (in) 0.05 (0.002) Deflection limit C mm (in) 0.15 (0.006) Big end side clearance D mm (in) 0.25 ~ 0.75 (0.010 ~ 0.030) Maximum small end axial mm (in)
  • Page 20: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model Item Unit XL1200Ltd BATTERY Type Fluid Capacity V-Ah (kC) 12 - 19 (68.4) CDI UNIT (B/W – B) Output peak voltage lower limit @cranking 1 @cranking 2 @2,000 r/min @3,500 r/min STATOR Pickup coil (W/R – B/O) Output peak voltage lower limit @cranking 1...
  • Page 21 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit XL1200Ltd RECTIFIER/REGULATOR (R – B) Output peak voltage lower limit @cranking 1 — @cranking 2 @2,000 r/min 12.6 @3,500 r/min 12.6 STARTER MOTOR Brush length mm (in) 12.5 (0.49) Wear limit mm (in) 6.5 (0.26) Commutator undercut mm (in) 0.7 (0.03)
  • Page 22: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size m•kg ft•lb ENGINE Exhaust chamber/stay – bracket Bolt Exhaust chamber stay/ Bolt cylinder head – cylinder Exhaust chamber joint – Bolt exhaust manifold Muffler cover –...
  • Page 23 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size m•kg ft•lb Stator coil – generator cover Bolt Flywheel magneto – crankshaft Bolt Upper crankcase – lower Bolt crankcase Engine bracket – lower Bolt crankcase Drive coupling – crankshaft Coupling Intake silencer plate/carburetor –...
  • Page 24: General Torque

    SPEC TIGHTENING TORQUES GENERAL TORQUE General torque This chart specifies tightening torques for Nut A Bolt B specifications standard fasteners with a standard ISO m•kg ft•lb thread pitch. Tightening torque specifica- 8 mm tions for special components or assemblies 10 mm are provided in applicable sections of this 12 mm manual.
  • Page 25: Cable And Hose Routing

    SPEC CABLE AND HOSE ROUTING CABLE AND HOSE ROUTING 1 Fuel breather hose 9 Ground lead G Battery 2 Pilot water hose 0 Starter motor lead H Battery breather hose 3 QSTS cable A Electrical box lead I Battery positive lead 4 Fuel hose B Generator lead J Battery negative lead...
  • Page 26 SPEC CABLE AND HOSE ROUTING 1 Throttle cable 9 To water/exhaust F To fuel filter 2 Switch box lead temperature sensor G Choke cable 3 QSTS cable 0 To generator H Fuel return hose 4 Buzzer lead A Battery breather hose I Shift cable 5 To pickup coil B Battery negative lead...
  • Page 27 INSP CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART .............. 3-1 PERIODIC SERVICE ..................3-2 CONTROL SYSTEM ................. 3-2 Steering master inspection .............. 3-2 Steering cable inspection and adjustment ........3-2 Throttle cable inspection and adjustment ........3-3 Choke cable inspection and adjustment ......... 3-4 QSTS cable inspection and adjustment ..........
  • Page 28: Maintenance Interval Chart

    INSP MAINTENANCE INTERVAL CHART MAINTENANCE INTERVAL CHART The following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the intervals of maintenance should be changed. Initial Every Refer to Item Remarks 10 hours 50 hours 100 hours 200 hours...
  • Page 29: Periodic Service

    INSP CONTROL SYSTEM PERIODIC SERVICE CONTROL SYSTEM Steering master inspection 1. Inspect: Steering master Excessive play → Replace the steer- ing master. Refer to “STEERING MASTER” in chapter 8. Inspection steps: Move the handlebar up and down and back and forth. Check the excessive play of the han- dlebar.
  • Page 30: Throttle Cable Inspection And Adjustment

    INSP CONTROL SYSTEM WARNING The cable joint must be screwed in more than 8 mm (0.31 in). Connect the cable joint and tighten the locknut. Locknut: 7 Nm (0.7 m • kg, 5.1 ft • lb) NOTE: If the steering cable cannot be properly adjusted at the steering column side, make adjustments at the jet pump side.
  • Page 31: Choke Cable Inspection And Adjustment

    INSP CONTROL SYSTEM Choke cable inspection and adjustment 1. Inspect: Choke knob (pull the choke knob all the way out) Choke knob automatically returns → Adjust. Adjustment steps: Turn in the adjusting nut 1 until the choke knob does not automatically return.
  • Page 32 INSP CONTROL SYSTEM 2. Adjust: QSTS cable Adjustment steps: Set the control grip in the neutral posi- tion. Set the jet nozzle in the center posi- tion. Remove the nut 1 and pivot pin 2. Loosen the locknut 3. Turn the cable joint 4 for adjusting. Length b is increased.
  • Page 33: Shift Cable Inspection And Adjustment

    INSP CONTROL SYSTEM Shift cable inspection and adjustment 1. Check: Reverse gate stopper lever position Incorrect → Adjust. Checking steps: Set the shift lever to the reverse posi- tion. Check to make sure the reverse gate 1 contacts the stopper 2 on the bracket and the lever 3 contacts the reverse gate.
  • Page 34: Ypvs Cable Adjustment

    INSP CONTROL SYSTEM YPVS cable adjustment 1. Check: YPVS valve position Incorrect position → Adjust the YPVS cable. Checking steps: Initiate multi-function meter “START” mode so the display comes Start the engine and then stop it. NOTE: When the engine has been stopped for 3 seconds, the YPVS valve assembly will extend and retract one time.
  • Page 35: Fuel System

    INSP CONTROL SYSTEM/FUEL SYSTEM 3. Adjust: YPVS cables 1 and 2 Adjustment steps: Loosen locknuts 1 and 2. Turn in the adjuster 3 and 4 until there is slack in the cable. Align the hole a in the pulley with the hole in the cylinder.
  • Page 36: Fuel Line Inspection

    INSP FUEL SYSTEM Fuel line inspection 1. Inspect: Fuel filter 1 Contaminants → Replace. Cracks/damage → Replace. Water contamination → Replace and check the fuel tank. Fuel hose Fuel tank Fuel hoses through part Fuel filler cap Cracks/damage → Replace. 2.
  • Page 37: Oil Injection System

    INSP FUEL SYSTEM/OIL INJECTION SYSTEM 2. Adjust: Trolling speed Adjustment steps: Start the engine and allow it to warm up for several minutes. Attach the engine tachometer to the spark plug lead. Engine tachometer: YU-8036-A/90890-06760 Turn the remote throttle stop screw 1 in or out until the specified trolling speed is obtain.
  • Page 38: Power Unit

    INSP OIL INJECTION SYSTEM/POWER UNIT 1. Bleed: Air bleeding steps: Place rags around the air bleed screw 1 to catch any oil that might spill. Fill the oil tank with oil. Recommended engine oil: YAMALUBE 2-W oil only Loosen the air bleed screw 1 two full turns and make sure that both the oil and air bubbles flow out.
  • Page 39: Electrical

    INSP POWER UNIT/ELECTRICAL 3. Measure: Spark plug gap a Out of specification → Regap. Spark plug gap: 1.0 ~ 1.1 mm (0.039 ~ 0.043 in) 4. Tighten: Spark plug Spark plug: 25 Nm (2.5 m • kg, 18 ft • lb) NOTE: Before installing the spark plug, clean the gasket surface and spark plug surface.
  • Page 40 INSP ELECTRICAL Antidote (EXTERNAL): SKIN - Wash with water. EYES - Flush with water for 15 minutes and get immediate medical attention. Antidote (INTERNAL): Drink large quantities of water or milk fol- lowed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention.
  • Page 41 INSP ELECTRICAL 2. Inspect: Electrolyte level Low → Add distilled water. electrolyte level should between the upper 1 and lower 2 level marks. Filling steps: Remove each filler cap. Add distilled water. When the electrolyte level reaches the upper level mark, allow the cell to stand for 20 minutes.
  • Page 42: Jet Pump Unit

    INSP ELECTRICAL/JET PUMP UNIT 5. Install: Battery breather hose 1 Battery Positive lead 2 Negative lead 3 Battery band CAUTION: Connect the positive lead to the battery terminal first. Make sure the battery leads are con- nected properly. Reversing the leads can seriously damage the electrical system.
  • Page 43: Water Inlet Filter Inspection

    INSP JET PUMP UNIT/GENERAL Water inlet filter inspection 1. Inspect: Water inlet filter Contaminants → Clean. Cracks/damage → Replace. Inspection steps: Remove the water inlet cover 1. Inspect the water inlet filter mesh a. Reinstall the removed parts. Bilge strainer inspection 1.
  • Page 44: Lubrication Points

    1. Before lubricating the QSTS control cables, remove the trim grip guide. 2. Lubricate: Throttle cable (carburetor side) Oil pump cable QSTS cables (pulley side) YPVS cables Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) 3-17...
  • Page 45 INSP GENERAL 3. Lubricate: Nozzle pivot shaft Steering cable (nozzle side) QSTS cable (nozzle side) Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) 4. Lubricate: Steering cable Steering cable joint Shift cable Shift cable joint NOTE: Disconnect the joints and apply a small amount of grease.
  • Page 46 FUEL CHAPTER 4 FUEL SYSTEM FUEL COCK AND FUEL FILTER ..............4-1 EXPLODED DIAGRAM ................4-1 REMOVAL AND INSTALLATION CHART ..........4-1 SERVICE POINTS ..................4-2 Fuel filter inspection ................. 4-2 Fuel cock inspection................4-2 CHOKE CABLE ....................4-3 EXPLODED DIAGRAM ................4-3 REMOVAL AND INSTALLATION CHART ..........
  • Page 47 FUEL CARBURETOR ....................4-18 EXPLODED DIAGRAM ................4-18 REMOVAL AND INSTALLATION CHART ..........4-18 SERVICE POINTS ................... 4-21 Diaphragm inspection ..............4-21 Accelerator pump body inspection ..........4-21 Arm inspection ................4-21 Regulator body inspection ............. 4-22 Needle valve inspection ..............4-22 Jet and carburetor body inspection ..........
  • Page 48 FUEL FUEL COCK AND FUEL FILTER FUEL COCK AND FUEL FILTER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points FUEL COCK AND FUEL FILTER Follow the left “Step” for removal. REMOVAL Screw Knob Washer Fuel cock assembly Fuel hose Holder Fuel filter...
  • Page 49: Service Points

    FUEL FUEL COCK AND FUEL FILTER SERVICE POINTS Fuel filter inspection Refer to “FUEL SYSTEM” in chapter 3. Fuel cock inspection 1. Check: Fuel cock Contaminants → Clean. Rough movement → Replace.
  • Page 50: Choke Cable

    FUEL CHOKE CABLE CHOKE CABLE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CHOKE CABLE REMOVAL Follow the left “Step” for removal. Screw Knob Friction adjusting nut Choke cable Reverse the removal steps for installation.
  • Page 51: Oil Tank

    FUEL OIL TANK OIL TANK EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points OIL TANK REMOVAL Follow the left “Step” for removal. Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY” in chapter 5. Intake duct Refer to “INTAKE DUCT AND SILENCER”. Hose clamp Oil filler cap Screw...
  • Page 52 FUEL OIL TANK EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Breather hose Oil hose Bolt Tank belt Oil tank assembly Hose clamp Oil filler hose Oil level sensor Reverse the removal steps for installation.
  • Page 53: Service Points

    FUEL OIL TANK SERVICE POINTS Oil filter inspection Refer to “OIL INJECTION SYSTEM” in chapter 3. Oil level switch inspection Refer to “INDICATION SYSTEM” in chapter 7. Oil tank inspection 1. Inspect: Oil tank Cracks/damage → Replace.
  • Page 54: Fuel Tank

    FUEL FUEL TANK FUEL TANK EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points FUEL TANK REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT” in chapter 5. Oil tank Refer to “OIL TANK”. Hose clamp Fuel filler cap Fuel filler neck...
  • Page 55 FUEL FUEL TANK EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Fuel hose Fuel breather hose Fuel tank assembly Hose clamp Fuel filler hose Hose clamp Fuel sensor assembly One way valve Screw Filter Reverse the removal steps for installation.
  • Page 56: Service Points

    FUEL FUEL TANK SERVICE POINTS Check valve inspection 1. Check: Check valve Faulty → Replace. Checking steps: Connect a hose to the end of check valve “A” and blow into it. Air should come out from end “B”. Connect the hose to the end of check valve “B”...
  • Page 57: Intake Duct And Silencer

    FUEL INTAKE DUCT AND SILENCER INTAKE DUCT AND SILENCER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points INTAKE DUCT AND SILENCER Follow the left “Step” for removal. REMOVAL Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY” in chapter 5. Muffler assembly Refer to “MUFFLER ASSEMBLY”...
  • Page 58 FUEL INTAKE DUCT AND SILENCER EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Hook Silencer case Bolt Filter Silencer plate O-ring Reverse the removal steps for installation. 4-11...
  • Page 59: Carburetor Unit

    FUEL CARBURETOR UNIT CARBURETOR UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CARBURETOR UNIT REMOVAL Follow the left “Step” for removal. Silencer Refer to “INTAKE DUCT AND SILENCER”. Oil pump cable Throttle cable Choke cable Fuel delivery hose Fuel return hose Oil delivery hose...
  • Page 60 FUEL CARBURETOR UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Fuel pump vacuum hose Bolt Bolt Carburetor assembly Gasket Not reusable Reverse the removal steps for installation. 4-13...
  • Page 61 FUEL CARBURETOR UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CARBURETOR UNIT Follow the left “Step” for removal. SEPARATION Hose Hose Accelerator pump hose Remote throttle stop screw assembly Throttle link Choke link 4-14...
  • Page 62 FUEL CARBURETOR UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Cable holder Bolt Carburetor Gasket Not reusable Plate Reverse the removal steps for installation. 4-15...
  • Page 63: Service Points

    FUEL CARBURETOR UNIT SERVICE POINTS Throttle valve synchronization inspection and adjustment 1. Check: Throttle valve synchronization Different clearances → Adjust. Checking steps: Loosen the remote throttle stop screw 1 until untouched the screw end from the throttle lever. Check the each throttle valve is fully closed.
  • Page 64: Choke Cable And Throttle Cable Installation

    FUEL CARBURETOR UNIT Choke cable and throttle cable installation 1. Install: Choke cable 1 Throttle cable 2 Choke cable guide installation position a: 13 ~ 15 mm (0.51 ~ 0.59 in) Throttle cable guide installation position b: 18 ~ 20 mm (0.71 ~ 0.79 in) 2.
  • Page 65: Carburetor

    FUEL CARBURETOR CARBURETOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CARBURETOR DISASSEMBLY Follow the left “Step” for disassembly. Accelerator pump delivery hose Carburetor #3 Accelerator pump fuel hose Carburetor #3 Screw Accelerator pump/carburetor Carburetor #3/carburetor #1 and #2 cover Diaphragm Screw...
  • Page 66 FUEL CARBURETOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Pilot jet Screw Arm pin Spring Screw Needle valve seat holder Needle valve Needle valve seat O-ring Reverse the disassembly steps for assembly. 4-19...
  • Page 67 FUEL CARBURETOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ACCELERATOR PUMP Follow the left “Step” for disassembly. DISASSEMBLY Screw Stay Spring Spring seat Screw Accelerator pump cover assembly Spring Diaphragm Accelerator pump body Reverse the disassembly steps for assembly.
  • Page 68: Service Points

    FUEL CARBURETOR SERVICE POINTS CAUTION: Do not use steel wire for cleaning the jets. This may enlarge the jet diameters and seriously affect performance. Diaphragm inspection 1. Inspect: Diaphragm Damage → Replace. Accelerator pump body inspection 1. Inspect: One way valve Crack/damage →...
  • Page 69: Regulator Body Inspection

    FUEL CARBURETOR Regulator body inspection 1. Inspect: Regulator body Contaminants → Clean. Damage → Replace. Valve (clear film) 1 Damage → Replace. Needle valve inspection 1. Inspect: Needle valve Needle valve seat Contaminants a → Clean. Wear b → Replace. NOTE: Always replace the needle valve and needle valve seat as a set.
  • Page 70: Fuel Pump

    FUEL FUEL PUMP FUEL PUMP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points FUEL PUMP DISASSEMBLY Follow the left “Step” for disassembly. Carburetors Refer to “CARBURETOR”. Screw Fuel pump cover Gasket Not reusable Diaphragm O-ring Diaphragm body 4-23...
  • Page 71 FUEL FUEL PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Rubber diaphragm Diaphragm Packing Fuel filter Reverse the disassembly steps for assembly. 4-24...
  • Page 72: Service Points

    FUEL FUEL PUMP SERVICE POINTS Fuel pump inspection 1. Inspect: Diaphragm Rubber diaphragm Diaphragm body Damage → Replace. Fuel filter inspection 1. Inspect: Fuel filter Clog/contaminants → Clean. Damage → Replace. 4-25...
  • Page 73: Oil Pump

    FUEL OIL PUMP OIL PUMP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points OIL PUMP REMOVAL Follow the left “Step” for removal. Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY” in chapter 5. Intake duct Refer to “INTAKE DUCT AND SILENCER”. Oil pump cable Oil delivery hose Bolt...
  • Page 74 FUEL OIL PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Oil pump assembly Gasket Not reusable Oil hose 1 Oil hose 2 Reverse the removal steps for installation. 4-27...
  • Page 75 FUEL OIL PUMP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points OIL PUMP HOSES AND CABLE Follow the left “Step” for removal. REMOVAL Bleed hose Air bleed screw Gasket Bleed hose stay Oil delivery hose 1 Oil delivery hose 2 Check valve Oil pump cable...
  • Page 76: Service Points

    FUEL OIL PUMP SERVICE POINTS Oil pump inspection 1. Inspect: Oil pump Contaminants → Clean. Damage/wear → Replace. Oil pump joint piece Damage/wear → Replace. Oil hose inspection 1. Inspect: Oil hose Cracks/damage → Clean. CAUTION: If the oil delivery hoses are not full of oil, fill them up.
  • Page 77: Oil Pump Cable Adjustment

    FUEL OIL PUMP Oil pump cable adjustment 1. Check: Oil pump lever position Incorrect → Adjust. Checking steps: Fully close the carburetor throttle valves. Check that the mark a on the oil pump lever is aligned with the mark b on the oil pump body.
  • Page 78 POWR CHAPTER 5 POWER UNIT EXHAUST CHAMBER ASSEMBLY..............5-1 EXPLODED DIAGRAM ................5-1 REMOVAL AND INSTALLATION CHART ..........5-1 MUFFLER ASSEMBLY ................... 5-4 EXPLODED DIAGRAM ................5-4 REMOVAL AND INSTALLATION CHART ..........5-4 SERVICE POINT..................5-8 Catalyst inspection................5-8 EXHAUST MANIFOLD AND LEADS.............. 5-9 EXPLODED DIAGRAM ................
  • Page 79 POWR CYLINDERS....................5-25 EXPLODED DIAGRAM ................5-25 REMOVAL AND INSTALLATION CHART ..........5-25 SERVICE POINTS ................... 5-26 Cylinder inspection ................. 5-26 PISTONS ....................... 5-27 EXPLODED DIAGRAM ................5-27 REMOVAL AND INSTALLATION CHART ..........5-27 SERVICE POINTS ................... 5-29 Piston pin clip removal and installation........5-29 Piston inspection................
  • Page 80 POWR EXHAUST CHAMBER ASSEMBLY EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST CHAMBER Follow the left “Step” for removal. ASSEMBLY REMOVAL Exhaust temperature sensor coupler Cap/bolt Cover Clamp/hose Hose clamp Hose clamp Bolt Bolt...
  • Page 81 POWR EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Exhaust chamber stay Bolt Bolt Exhaust chamber assembly Clamp/hose Gasket Not reusable Outer exhaust joint Inner exhaust joint Reverse the removal steps for installation.
  • Page 82 POWR EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST CHAMBER Follow the left “Step” for disassembly. DISASSEMBLY Bolt Bolt Exhaust chamber joint Gasket Not reusable Exhaust chamber Reverse the disassembly steps for assembly.
  • Page 83 POWR MUFFLER ASSEMBLY MUFFLER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points MUFFLER ASSEMBLY REMOVAL Follow the left “Step” for removal. Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY”. Cylinder head Refer to “CYLINDER HEAD”. Band Ventilation hose Screw...
  • Page 84 POWR MUFFLER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Hose clamp Water lock band Slide the water lock toward back to disconnect the muffler assembly. Bolt Gear case grease hose Bolt Bolt Bolt Muffler stay 2 Muffler assembly Reverse the removal steps for installation.
  • Page 85 POWR MUFFLER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points MUFFLER DISASSEMBLY Follow the left “Step” for disassembly. Exhaust temperature sensor Water temperature sensor Hanger Bolt Muffler stay Bolt Cover Gasket Not reusable...
  • Page 86 POWR MUFFLER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Catalyst housing Gasket Not reusable Catalyst Gasket Not reusable Bolt Mixing joint Gasket Not reusable Muffler Reverse the disassembly steps for assembly.
  • Page 87 POWR MUFFLER ASSEMBLY SERVICE POINT Catalyst inspection 1. Inspect: Catalyst Cracks/damage → Replace.
  • Page 88 POWR EXHAUST MANIFOLD AND LEADS EXHAUST MANIFOLD AND LEADS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST MANIFOLD AND Follow the left “Step” for removal. LEADS REMOVAL Battery lead Refer to “ELECTRICAL BOX” in chapter 7. (negative and positive) Exhaust chamber assembly Refer to “EXHAUST CHAMBER...
  • Page 89 POWR EXHAUST MANIFOLD AND LEADS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Bolt Exhaust manifold Gasket Not reusable Bolt Battery negative lead Nut/washer Starter motor lead Reverse the removal steps for installation. 5-10...
  • Page 90 POWR EXHAUST MANIFOLD AND LEADS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST MANIFOLD Follow the left “Step” for disassembly. DISASSEMBLY Clamp/hose Bolt Joint pipe O-ring Exhaust manifold Reverse the disassembly steps for assembly. 5-11...
  • Page 91 POWR ENGINE UNIT ENGINE UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ENGINE UNIT REMOVAL Follow the left “Step” for removal. Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY”. Muffler assembly Refer to “MUFFLER ASSEMBLY”. Carburetor Refer to “CARBURETOR”...
  • Page 92 POWR ENGINE UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Coupling cover Bolt/washer Engine assembly Shim Install the shims original position. Reverse the removal steps for installation. *: As required 5-13...
  • Page 93 POWR ENGINE UNIT SERVICE POINTS Shim removal 1. Remove: Shims NOTE: To ease reassembly and coupling align- ment, remove the shims and organize them in their respective groups (e.g., front right, rear left) prior to removing the mounting bolts. Engine mount inspection 1.
  • Page 94 POWR REED VALVES REED VALVES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REED VALVE REMOVAL Follow the left “Step” for removal. Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY”. Muffler assembly Refer to “MUFFLER ASSEMBLY”. Carburetor unit Refer to “CARBURETOR UNIT”...
  • Page 95 POWR REED VALVES EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Reed valve assembly Screw Valve stopper Reed valve Reverse the removal steps for installation. 5-16...
  • Page 96 POWR REED VALVES SERVICE POINTS Reed valve inspection 1. Inspect: Reed valves Cracks/damage → Replace. 2. Measure: Valve bending a Out of specification → Replace. Max. valve bending: 0.2 mm (0.01 in) 3. Measure: Valve stopper height b Out of specification → Adjust or replace.
  • Page 97 POWR YPVS YPVS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points YPVS REMOVAL Follow the left “Step” for removal. YPVS cable 1 and 2 Refer to “EXHAUST MANIFOLD AND LEADS”. Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY”.
  • Page 98 POWR YPVS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt (M4) NOTE: During installation, align the hole a in the YPVS shaft with the screw. Circlip Not reusable Shaft 3 Shaft 2 Shaft 1 Washer YPVS valve lever 5-19...
  • Page 99 POWR YPVS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt (M5) YPVS valve assembly NOTE: Oil seal If the YPVS shaft is removed, the oil seal must be replaced. Reverse the removal steps for installation. 5-20...
  • Page 100 POWR YPVS SERVICE POINTS YPVS valve inspection 1. Eliminate: Carbon deposits (with a rounded scraper 1) CAUTION: Do not use a sharp instrument to avoid damaging or scratching the surfaces. 2. Inspect: YPVS valve assembly Crack/damage/wear → Replace. 5-21...
  • Page 101 POWR CYLINDER HEAD CYLINDER HEAD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CYLINDER HEAD REMOVAL Follow the left “Step” for removal. Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY”. Spark plug Bolt NOTE: Tighten the bolts in the proper sequence Bolt as shown and in three stages.
  • Page 102: Exploded Diagram

    POWR CYLINDER HEAD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Cylinder head cover Gasket Not reusable Cylinder head Gasket Not reusable Reverse the removal steps for installation. 5-23...
  • Page 103 POWR CYLINDER HEAD SERVICE POINTS Cylinder head inspection 1. Eliminate: Carbon deposits (with a rounded scraper 1) CAUTION: Do not use a sharp instrument to avoid damaging or scratching the cylinder head or spark plug bore threads. 2. Inspect: Cylinder head water jacket Corrosion/mineral deposits →...
  • Page 104 POWR CYLINDERS CYLINDERS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CYLINDER REMOVAL Follow the left “Step” for removal. YPVS Refer to “YPVS”. Cylinder head Refer to “CYLINDER HEAD”. NOTE: Bolt Tighten the bolts in a crisscross pattern and in two stages.
  • Page 105 POWR CYLINDERS SERVICE POINTS Cylinder inspection 1. Eliminate: Carbon deposits (with a rounded scraper 1) 2. Inspect: Cylinder water jacket Corrosion/mineral deposits → Clean or replace. Cylinder inner surface Score marks → Replace. 3. Measure: Cylinder bore “D” (with a cylinder gauge) Out of specification →...
  • Page 106 POWR PISTONS PISTONS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points PISTON REMOVAL Follow the left “Step” for removal. Cylinders Refer to “CYLINDERS”. Piston pin clip CAUTION: Do not align the open end of the clip with the piston pin slot a.
  • Page 107 POWR PISTONS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bearing Piston ring CAUTION: Align each end gap with its respective locating pin. Reverse the removal steps for installation. 5-28...
  • Page 108 POWR PISTONS SERVICE POINTS Piston pin clip removal and installation 1. Remove and install: Piston pin clip NOTE: Before removing or installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase.
  • Page 109 POWR PISTONS 4. Calculate: Piston-to-cylinder clearance Out of specification → Replace the piston, piston rings and cylinder as a set. PISTON CYLINDER PISTON – CLEARANCE BORE DIAMETER Piston-to-cylinder clearance: 0.100 ~ 0.105 mm (0.0039 ~ 0.0041 in) Cylinder and piston combination Select the appropriate piston to match the cylinder size by the table as follows.
  • Page 110 POWR PISTONS 2. Measure: End gap (with a thickness gauge 1) Out of specification → Replace the piston rings as a set. End gap: 0.45 ~ 0.60 mm (0.018 ~ 0.024 in) NOTE: Push the piston ring into the cylinder with the piston crown.
  • Page 111 POWR PISTONS 4. Check: Piston-pin-to-connecting-rod free play (with the piston pin in the small end of the connecting rod as shown) Free play/small end wear → Replace the piston pin, connecting rod or both. 5-32...
  • Page 112 POWR GENERATOR AND STARTER MOTOR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points GENERATOR COVER REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT”. Oil pump Refer to “OIL PUMP” in chapter 4. Band Bolt Bolt...
  • Page 113 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Spring Packing Bolt Bolt Bracket Reverse the removal steps for installation. 5-34...
  • Page 114 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STATOR COIL AND PICKUP COIL Follow the left “Step” for removal. REMOVAL Bolt NOTE: This washer holds the pickup coil lead. Washer Make sure to not pinch the lead between Cable holder the projection and the washer when Bolt...
  • Page 115 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points GENERATOR ROTOR AND Follow the left “Step” for removal. STARTER MOTOR REMOVAL Drive coupling Flywheel magneto bolt Flywheel magneto Woodruff key Starter clutch assembly Bolt Starter motor Reverse the removal steps for installation.
  • Page 116 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STARTER CLUTCH Follow the left “Step” for disassembly. DISASSEMBLY Clip Not reusable Clip stopper Spring seat Spring Idle gear Circlip Plate 5-37...
  • Page 117 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Weight Spring Pinion gear Reverse the disassembly steps for assembly. 5-38...
  • Page 118 POWR GENERATOR AND STARTER MOTOR SERVICE POINTS Drive coupling removal and installation 1. Remove: Drive coupling Coupler wrench: YW-06551/90890-06551 Flywheel holder: YW-06550/90890-06550 NOTE: Install the drive coupling with the same special tools that were used for removal. Flywheel magneto removal and installation 1.
  • Page 119 POWR GENERATOR AND STARTER MOTOR Drive coupling inspection 1. Inspect: Drive coupling Damage/wear → Replace. Flywheel magneto inspection 1. Inspect: Ring gear Damage/wear → Replace. Starter clutch assembly inspection 1. Inspect: Pinion gear 1 Idle gear 2 Damage/wear → Replace. 2.
  • Page 120: Crankcase Exploded Diagram

    POWR CRANKCASE CRANKCASE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CRANKCASE DISASSEMBLY Follow the left “Step” for disassembly. Pistons Refer to “PISTONS”. Generator cover and starter Refer to “GENERATOR AND STARTER motor MOTOR”. Bolt Mount bracket Bolt Bolt Bolt...
  • Page 121 POWR CRANKCASE EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt NOTE: Tighten the bolts in sequence as shown. Bolt Bolt Lower crankcase Crankshaft assembly Upper crankcase Reverse the disassembly steps for assembly. 5-42...
  • Page 122 POWR CRANKCASE SERVICE POINTS Crankcase inspection 1. Inspect: Mating surfaces Scratches → Replace the crankcase. Crankcase Cracks/damage → Replace. Crankcase installation 1. Apply: ® Gasket Maker (onto the crankcase mating surfaces) NOTE: ® Before applying Gasket Maker clean the crankcase mating surfaces. 2.
  • Page 123 POWR CRANKSHAFT CRANKSHAFT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CRANKSHAFT REMOVAL Follow the left “Step” for removal. Crankcase Refer to “CRANKCASE”. Oil seal Bearing Oil seal Crankshaft assembly CAUTION: Install the bearing locating pins into the grooves in the crankcase body.
  • Page 124 POWR CRANKSHAFT SERVICE POINTS Crankshaft inspection 1. Measure: Crank width A Out of specification → Replace. Crank width: 72.95 ~ 73.00 mm (2.872 ~ 2.835 in) 2. Measure: Deflection B (with a dial gauge) Out of specification → Replace. Max. deflection: B 0.05 mm (0.002 in) C 0.15 mm (0.006 in) 3.
  • Page 125 POWR CRANKSHAFT 5. Inspect: Bearings Damage/pitting → Replace. NOTE: Before inspection, thoroughly clean the bearings. Immediately after inspection, lubricate the bearings to prevent rust. 6. Inspect: Oil seals Damage/wear → Replace. 5-46...
  • Page 126 PUMP CHAPTER 6 JET PUMP UNIT JET PUMP UNIT ..................... 6-1 EXPLODED DIAGRAM ................6-1 REMOVAL AND INSTALLATION CHART ..........6-1 REVERSE GATE....................6-3 EXPLODED DIAGRAM ................6-3 REMOVAL AND INSTALLATION CHART ..........6-3 NOZZLE DEFLECTOR AND NOZZLE RING........... 6-6 EXPLODED DIAGRAM ................
  • Page 127 PUMP BEARING HOUSING..................6-15 EXPLODED DIAGRAM ................6-15 REMOVAL AND INSTALLATION CHART ..........6-15 SERVICE POINTS ................... 6-18 Driven coupling removal and installation........6-18 Driven coupling shaft removal............6-18 Bearing removal................6-18 Bearing, driven coupling shaft, and grease hose inspection ..6-19 Driven coupling inspection ............
  • Page 128 JET PUMP UNIT PUMP JET PUMP UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points JET PUMP UNIT REMOVAL Follow the left “Step” for removal. Bolt Bolt Intake screen Bolt Intake duct Screw Speed sensor Bolt Jet pump cover Shift cable joint QSTS cable joint...
  • Page 129 JET PUMP UNIT PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Clamp/bilge hose Nut/washer Steering cable joint Clamp/spout hose Bolt Bolt NOTE: Jet pump unit assembly Pull the jet pump unit straight back. Dowel pin When installing the jet pump unit, align the drive shaft spline (male) with the intermediate shaft spline (female).
  • Page 130 REVERSE GATE PUMP REVERSE GATE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REVERSE GATE REMOVAL Follow the left “Step” for removal. Clamp/spout hose Bolt Washer Collar Reverse gate assembly Bolt Washer...
  • Page 131 REVERSE GATE PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Roller Bolt Reverse gate stay Washer Bolt Lever Spacer...
  • Page 132 REVERSE GATE PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Washer Collar Spring Lever Bolt Washer Reverse the removal steps for installation.
  • Page 133 NOZZLE DEFLECTOR AND NOZZLE RING PUMP NOZZLE DEFLECTOR AND NOZZLE RING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points NOZZLE DEFLECTOR AND Follow the left “Step” for removal. NOZZLE RING REMOVAL Jet pump unit Refer to “JET PUMP UNIT”. Reverse gate Refer to “REVERSE GATE”.
  • Page 134 IMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCT PUMP IMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points IMPELLER DUCT AND IMPELLER Follow the left “Step” for removal. HOUSING REMOVAL Nozzle ring Refer to “NOZZLE DEFLECTOR AND NOZZLE RING”.
  • Page 135 IMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCT PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Cover Packing Filter Packing Reverse the removal steps for installation.
  • Page 136 IMPELLER DUCT AND DRIVE SHAFT PUMP IMPELLER DUCT AND DRIVE SHAFT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points IMPELLER DUCT AND DRIVE Follow the left “Step” for disassembly. SHAFT DISASSEMBLY Impeller Left-hand threads Spacer Bolt/washer O-ring Washer : EPNOC grease AP #0...
  • Page 137 IMPELLER DUCT AND DRIVE SHAFT PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Drive shaft Rear bearing Not reusable Spacer Front bearing Not reusable Oil seal Oil seal Reverse the disassembly steps for assembly. : EPNOC grease AP #0 6-10...
  • Page 138 IMPELLER DUCT AND DRIVE SHAFT PUMP SERVICE POINTS Drive shaft removal 1. Remove: Impeller Drive shaft holder: YB-06151/90890-06519 NOTE: The impeller has left-hand threads. Turn the impeller clockwise to loosen it. 2. Remove: Nut 1 Drive shaft holder: YB-06151/90890-06519 3. Remove: Drive shaft 1 NOTE: Remove the drive shaft with a press.
  • Page 139 IMPELLER DUCT AND DRIVE SHAFT PUMP Drive shaft installation 1. Install: Oil seal Driver rod: YB-06071/90890-06606 Ball bearing attachment: YB-06156/90890-06634 2. Install: Front bearing Drive shaft NOTE: Install the front bearing and drive shaft with a press. Distance a: 23 ± 0.1 mm (0.91 ± 0.004 in) 3.
  • Page 140: Transom Plate And Hoses

    TRANSOM PLATE AND HOSES PUMP TRANSOM PLATE AND HOSES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points TRANSOM PLATE AND HOSES Follow the left “Step” for removal. REMOVAL Hose clamp Hose Cooling water outlet Bilge hose 1 Hose Cooling water inlet Nut/washer...
  • Page 141 TRANSOM PLATE AND HOSES PUMP SERVICE POINTS Bilge strainer inspection Refer to “JET PUMP UNIT” in chapter 3. Bilge hose inspection 1. Inspect: Bilge hose Cracks/damage/wear → Replace. 6-14...
  • Page 142: Bearing Housing

    BEARING HOUSING PUMP BEARING HOUSING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BEARING HOUSING REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT” in chapter 5. Rubber coupling Bolt/washer Bearing housing assembly NOTE: Shim Install the shims in their original locations.
  • Page 143 BEARING HOUSING PUMP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BEARING HOUSING Follow the left “Step” for disassembly. DISASSEMBLY Grease hose Grease nipple Grease nipple stay Nipple Driven coupling Washer Driven coupling shaft 6-16...
  • Page 144 BEARING HOUSING PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points O-ring Oil seal Oil seal Circlip Bearing Circlip Reverse the disassembly steps for assembly. 6-17...
  • Page 145 BEARING HOUSING PUMP SERVICE POINTS Driven coupling removal and installation 1. Remove and install: Driven coupling Coupler wrench: YW-06551/90890-06551 Shaft holder: YB-06552/90890-06552 NOTE: Install the driven coupling with the same special tools that were used for removal. Driven coupling shaft removal 1.
  • Page 146 BEARING HOUSING PUMP Bearing, driven coupling shaft, and grease hose inspection 1. Inspect: Bearing Rotate the inner race by hand. Damage/rough movement → Replace. Driven coupling shaft Damage/pitting → Replace. Grease hose Cracks/wear → Replace. Driven coupling inspection 1. Inspect: Driven coupling Driven coupling damper Damage/wear →...
  • Page 147 BEARING HOUSING PUMP 2. Install: Driven coupling shaft Distance a: 9.5 ~ 10.5 mm (0.37 ~ 0.41 in) 3. Install: Oil seal 1 [8 mm (0.31 in)] Oil seal 2 [10 mm (0.39 in)] Distance a: 10.3 ~ 10.7 mm (0.41 ~ 0.42 in) Distance b: 1.6 ~ 2.0 mm (0.06 ~ 0.07 in) Bearing housing installation...
  • Page 148 – ELEC CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS................. 7-1 ELECTRICAL BOX................... 7-2 EXPLODED DIAGRAM ................7-2 REMOVAL AND INSTALLATION CHART ..........7-2 ELECTRICAL ANALYSIS ................7-8 INSPECTION..................... 7-8 Digital circuit tester ................7-8 Low resistance measurement ............7-9 Peak voltage measurement.............. 7-9 Peak voltage adaptor ................
  • Page 149 – ELEC CHARGING SYSTEM..................7-26 WIRING DIAGRAM................. 7-26 FUSE ....................... 7-27 BATTERY ....................7-27 LIGHTING COIL ..................7-27 RECTIFIER/REGULATOR................ 7-27 YPVS ......................7-28 WIRING DIAGRAM................. 7-28 FUSE ....................... 7-29 BATTERY ....................7-29 PICKUP COIL ..................7-29 CDI UNIT....................7-29 LIGHTING COIL ..................7-29 RECTIFIER/REGULATOR................
  • Page 150: Electrical Components

    – ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 1 YPVS servomotor 9 Battery 2 Multi-function meter 0 Speed sensor 3 Fuel level sensor A Electrical box 4 Buzzer B Water temperature sensor 5 Oil level sensor C Starter motor 6 Stator coil and pickup coil D Engine stop switch, engine stop lanyard 7 Spark plugs switch and starter switch...
  • Page 151: Electrical Box

    – ELEC ELECTRICAL BOX ELECTRICAL BOX EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ELECTRICAL BOX REMOVAL Follow the left “Step” for removal. Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY” in chapter 5. Exhaust manifold Refer to “EXHAUST MANIFOLD”...
  • Page 152 – ELEC ELECTRICAL BOX EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Damper Bolt Battery box Coupler For multi-function meter Bolt Electrical box Reverse the removal steps for installation.
  • Page 153 – ELEC ELECTRICAL BOX EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ELECTRICAL BOX DISASSEMBLY Follow the left “Step” for disassembly. Clamp Coupler For overheat, exhaust temperature sensor and lighting coil Screw Rectifier/regulator Screw Cover Packing Spark plug lead holder Spark plug lead/cap Screw...
  • Page 154 – ELEC ELECTRICAL BOX EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Ground lead Ignition coil Ignition coil lead Bolt Ground lead Lead Black/Orange Starter motor lead Battery positive lead Fuse lead Starter relay lead Starter relay...
  • Page 155 – ELEC ELECTRICAL BOX EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Lead holder Fuse lead Screw Fuse holder Lead/coupler Screw Coupler bracket CDI unit Screw Lead holder plate Reverse the disassembly steps for assembly.
  • Page 156 – ELEC ELECTRICAL BOX Å To battery positive terminal 1 Ignition coil : Orange ı To starter motor 2 CDI unit : Red Ç Affix the ignition coil connector to 3 Rectifier/regulator : White 4 Fuse holder the electrical box holder. : Black/Orange Î...
  • Page 157: Electrical Analysis

    – ELEC ELECTRICAL ANALYSIS ELECTRICAL ANALYSIS INSPECTION CAUTION: All measuring instruments should be han- dled with special care. Damaged or mis- handled instruments will not measure properly. On an instrument powered by dry batter- ies, check the battery’s voltage periodi- cally replace batteries...
  • Page 158: Low Resistance Measurement

    – ELEC ELECTRICAL ANALYSIS Low resistance measurement NOTE: When measuring a resistance of 10 Ω or less with the digital tester, the correct measurement cannot obtained because of the tester’s internal resistance. To obtain the correct value, subtract the internal resistance from the displayed measurement.
  • Page 159: Test Harness

    – ELEC ELECTRICAL ANALYSIS When measuring the peak voltage, con- Å nect the peak voltage adaptor to the digi- tal tester and switch the selector to the DC voltage mode. NOTE: Make sure that the adaptor leads are properly installed in the digital circuit tester.
  • Page 160: Ignition System

    – ELEC IGNITION SYSTEM IGNITION SYSTEM WIRING DIAGRAM 1 Engine stop switch : Black 2 Engine stop lanyard switch : Orange 3 Lighting coil : Red 4 Pickup coil : White 5 CDI unit : Black/Orange 6 Ignition coil B/W : Black/White 7 Spark plug : Black/Yellow 8 Battery...
  • Page 161: Ignition Spark Gap

    – ELEC IGNITION SYSTEM IGNITION SPARK GAP WARNING When checking the spark gap, do not touch any of the connections of the spark gap tester lead wires. When performing the spark gap test, take special care not to let sparks leak out of the removed spark plug cap.
  • Page 162: Ignition System Peak Voltage

    – ELEC IGNITION SYSTEM IGNITION SYSTEM PEAK VOLTAGE WARNING When checking the CDI unit do not touch any of the connections of the digital tester lead wires. NOTE: If there is no spark, or the spark is weak, continue with the ignition system test. If a good spark is obtained, the problem is not with the ignition system, but possibly with the spark plug(-s) or another compo-...
  • Page 163 – ELEC IGNITION SYSTEM 2. Measure: Pick-up coil output peak voltage Below specification → Replace the pick-up coil. Pick-up coil output peak voltage: White/Red (W/R) – Black/Orange (B/O): 5 V @ cranking 1 2.8 V @ cranking 2 7.9 V @ 2,000 r/min 11 V @ 3,500 r/min NOTE: The starter motor will not operate when the...
  • Page 164: Battery

    – ELEC IGNITION SYSTEM BATTERY Refer to “ELECTRICAL” in chapter 3. FUSE Refer to “STARTING SYSTEM”. SPARK PLUGS Refer to “ELECTRICAL” in chapter 3. SPARK PLUG LEAD ASSEMBLY 1. Inspect: Spark plug lead assembly Cracks/damage → Replace. 2. Measure: Spark plug lead resistance Out of specification →...
  • Page 165: Engine Stop Switch

    – ELEC IGNITION SYSTEM 2. Measure: Secondary coil resistance Out of specification → Replace. Secondary coil resistance: Black/White (B/W) – Spark plug lead terminal 3.5 ~ 4.7 kΩ at 20 ˚C (68 ˚F) ENGINE STOP SWITCH 1. Check: Engine stop switch continuity Out of specification →...
  • Page 166: Exhaust Temperature Sensor

    – ELEC IGNITION SYSTEM EXHAUST TEMPERATURE SENSOR 1. Measure: Exhaust temperature sensor resis- tance (at the specified temperature) Out of specification → Replace. Exhaust temperature sensor resistance: 300 ˚C (572 ˚F): 73 ~ 241 kΩ 600 ˚C (1,112 ˚F): 0.86 ~ 1.58 kΩ 900 ˚C (1,652 ˚F): 64 ~ 90 Ω...
  • Page 167: Starting System

    – ELEC STARTING SYSTEM STARTING SYSTEM WIRING DIAGRAM 1 CDI unit : Black 2 Engine stop lanyard switch : Brown 3 Starter switch : Red 4 Multi-function meter : Red/Yellow 5 Fuse 6 Starter relay 7 Starter motor 8 Battery 7-18...
  • Page 168: Battery

    – ELEC STARTING SYSTEM BATTERY Refer to “ELECTRICAL” in chapter 3. WIRING CONNECTIONS 1. Check: Wiring connections Poor connections → Properly connect. FUSE 1. Check: Fuse holder continuity No continuity → Check the fuse or replace the fuse holder. Fuse holder continuity: Between 1 and 2 Between 3 and 4 2.
  • Page 169: Starter Switch

    – ELEC STARTING SYSTEM STARTER SWITCH 1. Check: Continuity Out of specification → Replace. Starter continuity (red coupler) Leads Lock plate Position Brown Free Installed Push Free Removed Push STARTER RELAY 1. Inspect: Brown lead terminal Black lead terminal Loose → Tighten. 2.
  • Page 170: Starter Motor

    – ELEC STARTER MOTOR STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STARTER MOTOR Follow the left “Step” for disassembly. DISASSEMBLY Starter motor Refer to “GENERATOR AND STARTER MOTOR” in chapter 5. O-ring Bolt Starter motor front cover O-ring Oil seal retainer...
  • Page 171 – ELEC STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Starter motor rear cover O-ring Shim t = 0.2 mm, 0.8 mm Armature assembly Nut/spring washer/washer 1/1/4 O-ring Brush holder Brush spring Bolt Brush assembly *: As required 7-22...
  • Page 172 – ELEC STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Spacer Holder Starter motor yoke Reverse the disassembly steps for assembly. 7-23...
  • Page 173: Service Points

    – ELEC STARTER MOTOR SERVICE POINTS Armature inspection 1. Inspect: Armature shaft 1 Damage/wear → Replace. 2. Inspect: Commutator Dirt → Clean with 600 grit sandpaper. 3. Measure: Commutator diameter Out of specification → Replace. Min. commutator diameter: 27.0 mm (1.06 in) 4.
  • Page 174: Brush Holder Inspection

    – ELEC STARTER MOTOR 6. Inspect: Armature coil continuity Out of specification → Replace. Armature coil continuity: Commutator segments 1 Continuity Segment - Laminations 2 No continuity Segment - Armature shaft No continuity Brush holder inspection 1. Measure: Brush length a Out of specification →...
  • Page 175: Charging System

    – ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM 1 Lighting coil : Black 2 Battery : Green 3 Fuse (20A) : Red 4 Rectifier/regulator G/W : Green/White 7-26...
  • Page 176: Fuse

    – ELEC CHARGING SYSTEM FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in chapter 3. LIGHTING COIL Refer to “IGNITION SYSTEM”. RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM”. 7-27...
  • Page 177: Ypvs

    – ELEC YPVS YPVS WIRING DIAGRAM 1 Lighting coil : Black 2 Pickup coil : Gray 3 CDI unit : Red 4 YPVS servomotor : Black/Orange 5 Fuse : Red/Blue 6 Battery R/W : Red/White 7 Rectifier/regulator W/R : White/Red 7-28...
  • Page 178: Fuse

    – ELEC YPVS FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in chapter 3. PICKUP COIL Refer to “IGNITION SYSTEM”. CDI UNIT Refer to “IGNITION SYSTEM”. LIGHTING COIL Refer to “IGNITION SYSTEM”. RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM”. 7-29...
  • Page 179: Ypvs Servomotor

    – ELEC YPVS SERVOMOTOR YPVS SERVOMOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points YPVS SERVOMOTOR REMOVAL Follow the left “Step” for removal. Bolt Cable holder YPVS servomotor coupler Bolt YPVS servomotor Spacer YPVS cable White tape is for No. 2 cable. Cover Reverse the removal steps for installation.
  • Page 180: Service Points

    – ELEC YPVS SERVOMOTOR SERVICE POINTS YPVS cable removal and installation 1. Remove: YPVS cables 1 and 2 Removal steps: Remove the YPVS cable holder 1. Remove the YPVS cables 2 from the both drams. NOTE: There is a white paint mark a on YPVS cable 2.
  • Page 181: Ypvs Cable Adjustment

    – ELEC YPVS SERVOMOTOR Make sure the servomotor operates properly. NOTE: Make sure the pulley operates three sec- onds after the jumper lead is removed. CAUTION: Do not disassemble the YPVS servomotor unit. It is a sealed unit and if it is faulty it must be replaced.
  • Page 182: Indication System

    – ELEC INDICATION SYSTEM INDICATION SYSTEM WIRING DIAGRAM 1 CDI unit : Black Gy/B : Gray/Black 2 Fuel level sensor : Brown Gy/R : Gray/Red 3 Oil level sensor : Chocolate Gy/Y : Gray/Yellow 4 Buzzer : Green : Blue/Black 5 Multi-function meter : Gray : Blue/Red...
  • Page 183: Fuse

    – ELEC INDICATION SYSTEM FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in chapter 3. LIGHTING COIL Refer to “CHARGING SYSTEM”. RECTIFIER/REGULATOR Refer to “CHARGING SYSTEM”. CDI UNIT Refer to “IGNITION SYSTEM”. WATER TEMPERATURE SENSOR Refer to “IGNITION SYSTEM”. EXHAUST TEMPERATURE SENSOR Refer to “IGNITION SYSTEM”.
  • Page 184: Fuel Level Sensor

    – ELEC INDICATION SYSTEM FUEL LEVEL SENSOR 1. Measure: Fuel level sensor resistance Out of specification → Replace. White/blue (W/L) – Black (B) Float position Resistance (Ω) 757 ~ 803 0 ~ 8 MULTI-FUNCTION METER Multi-function meter 1. Check: Multi-function meter Cracked meter housing →...
  • Page 185: Exploded Diagram

    – ELEC INDICATION SYSTEM EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points MULTI-FUNCTION METER Follow the left “Step” for removal. REMOVAL Multi-function meter coupler Nut/washer Holder Multi-function meter Reverse the removal steps for installation. 7-36...
  • Page 186: Display Function

    – ELEC INDICATION SYSTEM Display function 1. Check: Display function Not operate → Replace the multi- function meter. 1 Oil level sensor : Black Gy/R : Gray/Red 2 Fuel level sensor : Brown Gy/Y : Gray/Yellow 3 Buzzer : Chocolate : Blue/Black 4 Electrical box : Green...
  • Page 187 – ELEC INDICATION SYSTEM Checking steps: Connect the battery terminals to the white six-pin connector as shown. NOTE: If the multi-function meter has been removed from the water vehicle, supply DC 12 voltage to the connector (+: red, –: black) with a battery. Disconnect the blue one-pin connector 1 and make sure the “WARNING”...
  • Page 188: Fuel Level Gauge

    – ELEC INDICATION SYSTEM Fuel level gauge 1. Check: Fuel level gauge Not operating → Replace the multi- function meter. Checking steps: Supply DC 12 voltage to the white six- pin connector (+: red, –: black) with a battery. Disconnect the green two-pin connec- tor (white/blue and black leads).
  • Page 189: Oil Level Gauge

    – ELEC INDICATION SYSTEM Oil level gauge 1. Check: Oil level gauge Not operating → Replace the multi- function meter. Checking steps: Supply DC 12 voltage to the white six- pin connector (+: red, –: black) with a battery. Disconnect the white two-pin connec- tor (blue and black leads).
  • Page 190: Overheat Warning Indicator

    – ELEC INDICATION SYSTEM Overheat warning indicator 1. Check: Overheat 1 warning indicator Not operating → Replace the multi- function meter. Checking steps: Supply DC 12 voltage to the white six- pin connector (+: red, –: black) with a battery. Connect the gray/black and black ter- minals with a jumper lead 1.
  • Page 191 – ELEC INDICATION SYSTEM Make sure the water temperature warning indicator display 3 and the “ ” message 4 display, the “WARNING” lamp 5 operates prop- erly, and the buzzer sounds continuity. 3. Check: Exhaust temperature warning indicator Not operating → Replace the multi- function meter.
  • Page 192: Speed Meter

    – ELEC INDICATION SYSTEM Speed meter 1. Check: Speed meter output voltage Within specification → Check the speed sensor output voltage and pulses. Out of specification → Replace. Speed meter output voltage: 10.5 V Checking steps: Supply DC 12 voltage to the white six- pin connector (+: red, –: black) with a battery.
  • Page 193: Speed Sensor

    – ELEC INDICATION SYSTEM Speed sensor 1. Check: Speed sensor output voltage and pulses Out of specification → Replace. Speed sensor output voltage (dependant on the paddle wheel position): Less than 400 mV/11.6 - 12 V Output pulse: 2 pulses/one-full turn Checking steps: Apply DC 12 voltage to the white three-pin connector (between the red/...
  • Page 194 HULL HOOD CHAPTER 8 HULL AND HOOD HANDLEBAR....................8-1 EXPLODED DIAGRAM ................8-1 REMOVAL AND INSTALLATION CHART ..........8-1 SERVICE POINTS ..................8-6 Handlebar inspection................ 8-6 Handlebar switch inspection............8-6 Handlebar assembly installation ............. 8-6 QSTS GRIP...................... 8-8 EXPLODED DIAGRAM ................8-8 REMOVAL AND INSTALLATION CHART ..........
  • Page 195 HULL HOOD HOSES......................8-24 EXPLODED DIAGRAM ................8-24 REMOVAL AND INSTALLATION CHART ..........8-24 SERVICE POINTS ................... 8-26 Check valve inspection ..............8-26 SHIFT LEVER ....................8-27 EXPLODED DIAGRAM ................8-27 REMOVAL AND INSTALLATION CHART ..........8-27 SHIFT LEVER ....................8-28 EXPLODED DIAGRAM ................
  • Page 196 HULL HANDLEBAR HOOD HANDLEBAR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR COVER REMOVAL Follow the left “Step” for removal. Screw Handlebar cover Band Bolt Handlebar cover stay Throttle cable Bolt Upper handlebar holder Reverse the removal steps for installation.
  • Page 197 HULL HANDLEBAR HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR REMOVAL Follow the left “Step” for removal. QSTS cable (to jet nozzle) Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”. Bolt QSTS converter QSTS cable 2 with white tape QSTS cable 1...
  • Page 198 HULL HANDLEBAR HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Buzzer coupler Screw Handle boss cover Band Handlebar assembly Buzzer Reverse the removal steps for installation.
  • Page 199 HULL HANDLEBAR HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR DISASSEMBLY Follow the left “Step” for disassembly. Bolt Grip end Spacer Screw/washer/spring washer 1/1/1 QSTS grip assembly Screw...
  • Page 200 HULL HANDLEBAR HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Handlebar switch assembly Screw Throttle lever assembly NOTE: Handlebar grip Apply adhesive to the handlebar and the inner surface of the handlebar grip. Handlebar Reverse the disassembly steps for assembly.
  • Page 201 HULL HANDLEBAR HOOD SERVICE POINTS Handlebar inspection 1. Inspect: Handlebar Bends/cracks/damage → Replace. Handlebar switch inspection Refer to “STARTING SYSTEM” in chapter 7. Handlebar assembly installation 1. Install: QSTS cables Buzzer lead Handlebar switch lead Throttle cable NOTE: After inserting the cables and leads into the grommets, tie the end of grommets with the bands 1.
  • Page 202 HULL HANDLEBAR HOOD 3. Adjust: QSTS cable length a QSTS cable length: 77 ± 0.5 mm (3.03 ± 0.02 in) NOTE: Before adjusting the QSTS cables, set the trim grip to the neutral position. Adjust the QSTS cable lengths a to the specified length and be sure to take up any slack.
  • Page 203 HULL QSTS GRIP HOOD QSTS GRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points QSTS GRIP DISASSEMBLY Follow the left “Step” for disassembly. QSTS grip assembly Refer to “HANDLEBAR”. Screw/washer Cover Ball Spring QSTS cable 1 NOTE: QSTS cable 2 QSTS cable 2 has white tape a on its...
  • Page 204 HULL QSTS GRIP HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Screw/washer Spacer QSTS grip position locator Spring Spacer Cable housing QSTS grip Reverse the disassembly steps for assembly.
  • Page 205 HULL QSTS GRIP HOOD SERVICE POINTS QSTS cable inspection 1. Inspect: QSTS cables Frays/kinks/rough movement → Replace. QSTS grip inspection 1. Inspect: QSTS grip Damage/wear → Replace. 8-10...
  • Page 206 HULL STEERING MASTER HOOD STEERING MASTER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING MASTER REMOVAL Follow the left “Step” for removal. Handlebar assembly Refer to “HANDLEBAR”. Steering master cover Refer to “STEERING MASTER COVER”. Bolt/washer Steering arm Nut/washer...
  • Page 207 HULL STEERING MASTER HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING MASTER Follow the left “Step” for disassembly. DISASSEMBLY Bolt/washer Stay Spring Bolt/washer Lower housing Spring Bushing Bushing Upper housing Tilt lever 8-12...
  • Page 208 HULL STEERING MASTER HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Tilt stopper Bolt/nut Retainer Steering shaft assembly Steering tube Bolt/washer/spring washer 2/2/2 Shaft 1 Cross piece Reverse the disassembly steps for assembly. 8-13...
  • Page 209 HULL STEERING MASTER HOOD SERVICE POINTS Steering master components inspection 1. Inspect: Each component part Damage/wear → Replace the steer- ing master. 8-14...
  • Page 210 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REMOTE CONTROL CABLES Follow the left “Step” for removal. AND SPEED SENSOR LEAD REMOVAL Speed sensor coupler Speed sensor...
  • Page 211 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Steering cable holder Steering cable Shift cable end Bolt Shift cable holder 8-16...
  • Page 212 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Shift cable QSTS cable end QSTS cable Reverse the removal steps for installation. 8-17...
  • Page 213 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD SERVICE POINTS Remote control cables inspection 1. Inspect: Steering cable QSTS cable Shift cable Frays/kinks/rough movement → Replace. Steering cable (jet pump side) installation 1. Install: Steering cable a Steering cable set length (jet pump side): 13.5 ~ 15.5 mm (0.53 ~ 0.61 in) WARNING...
  • Page 214 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD QSTS cable (jet pump side) installation 1. Install: QSTS cable (jet pump side) a QSTS cable set length (jet pump side): 12.0 ~ 14.0 mm (0.47 ~ 0.55 in) WARNING The QSTS cable must be screwed in more than 8 mm (0.31 in).
  • Page 215 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD Shift cable stopper installation 1. Install: Shift cable stopper WARNING Be sure to fit the projection 1 on the shift cable stopper into the groove in the outer cable. Remote control cables adjustment Refer to “CONTROL SYSTEM”...
  • Page 216 HULL FRONT HOOD HOOD FRONT HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points FRONT HOOD REMOVAL Follow the left “Step” for removal. Nut/washer Front hood assembly Circlip Damper Bolt Hood lock assembly 8-21...
  • Page 217 HULL FRONT HOOD HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Notch Washer Damper Bolt Plate Mirror Packing Reverse the removal steps for installation. 8-22...
  • Page 218 HULL STEERING MASTER COVER HOOD STEERING MASTER COVER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING MASTER COVER Follow the left “Step” for removal. REMOVAL Handlebar assembly Refer to “HANDLEBAR”. Fuel cock Refer to “FUEL COCK AND FUEL FILTER” in chapter 4.
  • Page 219 HULL HOSES HOOD HOSES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HOSES REMOVAL Follow the left “Step” for removal. Steering master cover Refer to “STEERING MASTER COVER”. Band Ventilation hose Screw Ventilation duct Band Check valve 8-24...
  • Page 220 HULL HOSES HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Oil tank breather hose Fuel tank breather hose Clamp/pilot water hose Nut/washer Pilot water outlet Packing Reverse the removal steps for installation. 8-25...
  • Page 221 HULL HOSES HOOD SERVICE POINTS Check valve inspection 1. Check: Check valve Faulty → Replace. Checking steps: Connect a hose to the end of check valve “A” and blow into it. Air should come out from end “B”. Connect the hose to the end of check valve “B”...
  • Page 222: Shift Lever

    HULL SHIFT LEVER HOOD SHIFT LEVER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SHIFT LEVER REMOVAL Follow the left “Step” for removal. Steering master cover Refer to “STEERING MASTER COVER”. Shift cable Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”.
  • Page 223 HULL SHIFT LEVER HOOD SHIFT LEVER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points Screw Base assembly Nut/washer Screw Plate Reverse the removal steps for installation. 8-28...
  • Page 224 HULL SHIFT LEVER HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BASE DISASSEMBLY Follow the left “Step” for disassembly. Bolt/washer Plate Spring Actuator Roller Shaft Shift arm Reverse the disassembly steps for assembly. 8-29...
  • Page 225 HULL SHIFT LEVER HOOD SERVICE POINTS Base assembly 1. Install: Shift arm Shaft Installation steps: Install the shift arm 1 so that it comes in contact with the stopper 2 as shown. Install the shaft 3 to the base so that it come in contact with the stopper 4 as shown.
  • Page 226 HULL SEATS AND HAND GRIP HOOD SEATS AND HAND GRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SEATS AND HAND GRIP Follow the left “Step” for removal. REMOVAL Rear seat assembly Front seat assembly Bolt Seat lock assembly Nut/washer Notch...
  • Page 227 HULL SEATS AND HAND GRIP HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Rear seat stay Nut/washer Front seat stay Nut/washer Bolt Hand grip Reverse the removal steps for installation. 8-32...
  • Page 228 HULL SEATS AND HAND GRIP HOOD SERVICE POINTS Seat lock inspection 1. Inspect: Front seat lock Rear seat lock Damage/wear → Replace. 8-33...
  • Page 229 HULL EXHAUST SYSTEM HOOD EXHAUST SYSTEM EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST SYSTEM REMOVAL Follow the left “Step” for removal. Hose clamp Band Rubber joint Slide the water lock to back Hose clamp Rubber hose Align mark with weld line Mark a should be upside...
  • Page 230 HULL EXHAUST SYSTEM HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Hose clamp Rubber hose Align hose parting line with tank mark Hose clamp Water tank Hose clamp Rubber hose Align hose parting line with tank parting line Bolt Exhaust outlet Packing Reverse the removal steps for installation.
  • Page 231 HULL EXHAUST SYSTEM HOOD SERVICE POINTS Exhaust system inspection 1. Inspect: Water lock band Cracks → Replace. 2. Inspect: Rubber hoses Burns/cracks/damage → Replace. 3. Inspect: Water lock Cracks/leaks → Replace. Water → Drain. 4. Inspect: Resonator Water tank Cracks/damage → Replace. 8-36...
  • Page 232 HULL DECK AND HULL HOOD DECK AND HULL EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points DECK AND HULL DISASSEMBLY Follow the left “Step” for disassembly. Rope hole bolt Nut/washer Bow eye Rope hole bolt Spout 8-37...
  • Page 233 HULL DECK AND HULL HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Plate Cleat Sponson Spacer Nut/washer Screw/washer Drain plug Packing Reverse the disassembly steps for assembly. 8-38...
  • Page 234 HULL ENGINE MOUNT HOOD ENGINE MOUNT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ENGINE MOUNT REMOVAL Follow the left “Step” for removal. Engine assembly Refer to “ENGINE UNIT” in chapter 5. Bolt Damper 1 Damper 2 Bolt Engine mount Reverse the removal steps for installation.
  • Page 235 HULL ENGINE MOUNT HOOD HULL REPAIR Shallow scratches 1. Sand the scratches with 400 grit sand- paper (either wet or dry) until the scratches are smooth. Then, sand the scratches once again with 600 grit sand- paper (either wet or dry). Deep scratches 1.
  • Page 236 HULL ENGINE MOUNT HOOD Cracks and punctures NOTE: Before attempting to repair any cracks or punctures, refer to “WATER VEHICLE FRP REPAIR MANUAL”. 1. Remove any damaged fiberglass. 2. Cut the damaged area and separate it approximately 0.25 inch. 3. On the outside of the hull, grind the separated edge of the area to less than 5˚...
  • Page 237 HULL ENGINE MOUNT HOOD Insert nut NOTE: Use the insert nut when: A pop nut which was attached to the hull slipped off or, When a bolt which was fastened to an insert nut or pop nut broke. Part Part No. Remarks name Stainless...
  • Page 238 HULL ENGINE MOUNT HOOD 4. First, apply tape 1 to the inner surface of the hull and then laminate fiberglass mats over the tape with resin. NOTE: When it is possible to work inside the hull, laminate the mats from the inside. 5.
  • Page 239 HULL ENGINE MOUNT HOOD 2. To prevent water from entering the ure- thane foam, apply silicone sealant to the inside of the hole as shown. 3. Install the insert nut as explained in “Example 1”. Brass insert nut 1 Hull 2 Urethane foam 3 Silicone sealant 4 Graphic removal...
  • Page 240 TRBL ANLS CHAPTER 9 TROUBLE-ANALYSIS TROUBLE-ANALYSIS..................9-1 TROUBLE-ANALYSIS CHART ..............9-1...
  • Page 241 TRBL TROUBLE-ANALYSIS ANLS TROUBLE-ANALYSIS NOTE: The following items should be checked before the “Trouble-analysis” chart is consulted. 1. The battery is charged and its specified gravity is within specification. 2. There are no incorrect wiring connections. 3. Wiring connections are properly secured and not rusty. 4.
  • Page 242 TRBL TROUBLE-ANALYSIS ANLS Problems Items to be checked Reference Items chapter Rubber coupling Pilot water hose Water hose Water passage JET PUMP UNIT Duct Impeller Intake screen Bearings Intake duct Water inlet hose Bilge hose Bilge strainer Bilge hose joint Valve body ELECTRICAL CDI unit...
  • Page 243 WIRING DIAGRAM 1 Lighting coil 2 Pickup coil 3 CDI unit 4 Oil level sensor 5 Fuel level sensor 6 Buzzer 7 Multi-function meter Gy/B B Br R 8 Speed sensor Gy/R Gy/Y 9 Engine stop switch 0 Engine stop lanyard switch A Start switch B YPVS servomotor Gy/Y...
  • Page 244 YAMAHA MOTOR CO., LTD. Printed in USA × 1 CR Mar. 1999 – (XA1200X) Printed on recycled paper...