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Yamaha WaveRunner GP1200R Service Manual

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WaveRunnerGP1200R
SERVICE MANUAL
*LIT186160215*
LIT-18616-02-15
F0X-28197-ZA-11

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  Summary of Contents for Yamaha WaveRunner GP1200R

  • Page 1 WaveRunnerGP1200R SERVICE MANUAL *LIT186160215* LIT-18616-02-15 F0X-28197-ZA-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: F0X: 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 “J-”, “YB-”, “YM-”, “YU-”...
  • Page 14: Removal And Installation

    SPECIAL TOOLS INFO REMOVAL AND INSTALLATION YW-06551 YW-06550 90890-06550 1. Coupler wrench 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. Drive shaft holder (impeller) P/N. YB-06151 90890-06519 5. Slide hammer set (jet pump bearing) YB-06151 90890-06519 YB-06096...
  • 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 ................2-10 CABLE AND HOSE ROUTING ..............2-11...
  • Page 16: Specifications

    SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Item Unit GP1200R MODEL CODE Hull Engine DIMENSIONS Length mm (in) 2,930 (115.4) Width mm (in) 1,150 (45.3) Height mm (in) 1,020 (40.2) Dry weight kg (lb) 306 (675) 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 = (Motor Octane Number + Research Octane Number)/2 RON*: Research Octane Number YAMALUBE 2-W*: YAMALUBE 2-W is developed for this water vehicles 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 GP1200R 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 GP1200R 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 GP1200R BATTERY Type Fluid Capacity V-Ah (kC) 12 - 19 (68.4) CDI UNIT (B/O – B for cylinder #1) (B/W – B for cylinder #2) (B/Y – B for cylinder #3) Output peak voltage lower limit @cranking 1 @cranking 2...
  • Page 21 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit GP1200R RECTIFIER/REGULATOR (R – B) Output peak voltage lower limit (unloaded) @cranking @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) Limit...
  • Page 22: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size m•kgf ft•lb ENGINE Muffler cover – muffler Bolt Muffler stay – cylinder body Bolt Muffler – muffler stay 2 Bolt Eye – cylinder head Bolt Muffler –...
  • Page 23 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size m•kgf ft•lb Cylinder – crankcase Bolt Generator cover – Bolt crankcase Generator cover/ground Bolt lead – crankcase Bracket – crankcase Bolt Pickup coil – generator cover Bolt Stator coil –...
  • Page 24 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size m•kgf ft•lb Grip end – handlebar Bolt Choke lever assembly – Screw handlebar QSTS cable housing – cover Screw Plate/steering column assembly — – deck Steering column – deck —...
  • Page 25: General Torque

    SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size m•kgf ft•lb Engine mount – hull Bolt Engine mount/plate – hull Bolt Engine damper – hull Bolt GENERAL TORQUE General torque This chart specifies tightening torques for Nut A Bolt B specifications...
  • Page 26: Cable And Hose Routing

    SPEC CABLE AND HOSE ROUTING CABLE AND HOSE ROUTING 20˚ 1 Fuel filter 9 Generator lead G Battery breather hose 2 Fuel breather hose 0 Battery negative lead H Battery positive lead 3 Fuel hose A YPVS cable I YPVS servomotor 4 Pilot water hose B Pilot water outlet 5 Bilge hose...
  • Page 27 SPEC CABLE AND HOSE ROUTING 3 4 5 1 Choke cable 9 To stator assembly F To starter motor positive 2 Steering cable 0 To water temperature sensor terminal 3 Cooling water hose A To cylinder #1 G Battery positive lead 4 QSTS cable B To cylinder #2 H Battery negative lead...
  • Page 28 INSP CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART .............. 3-1 PERIODIC SERVICE ..................3-2 CONTROL SYSTEM ................. 3-2 Steering column 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 29: 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 30: Periodic Service

    INSP CONTROL SYSTEM PERIODIC SERVICE CONTROL SYSTEM Steering column inspection 1. Inspect: Steering column Excessive play → Replace the steer- ing column. Refer to “STEERING COLUMN” in chapter 8. Inspection steps: Move the handlebar up and down and back and forth. Check the excessive play of the han- dlebar.
  • Page 31: 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: 6 Nm (0.6 m • kgf, 4.3 ft • lb) NOTE: If the steering cable cannot be properly adjusted at the steering column side, make sure the steering cable at the jet pump side is set to the specified length.
  • Page 32: Choke Cable Inspection And Adjustment

    INSP CONTROL SYSTEM WARNING After adjusting the free play, turn the han- dlebar to the right and left and make sure that the trolling speed does not increase. Choke cable inspection and adjustment 1. Check: Choke lever operation Incorrect operation → Adjust. Checking steps: Check that the choke lever moves back slightly when it is fully opened.
  • Page 33: Qsts Cable Inspection And Adjustment

    INSP CONTROL SYSTEM QSTS cable inspection and adjustment 1. Measure: Nozzle deflector set length a, b Difference → Adjust. Measurement steps: Set the control grip in the neutral posi- tion. Measure nozzle deflector length a and b. If a and b length are not even, adjust the cable joint.
  • Page 34: Ypvs Cable Adjustment

    INSP CONTROL SYSTEM NOTE: If correct adjustment by using the cable joint at the wheel end is not obtained, adjust the cable joint on the trim nozzle end. Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD” in chapter 8. YPVS cable adjustment 1.
  • 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: Trolling Speed Check And Adjustment

    INSP FUEL SYSTEM 2. Inspect: Water separator 1 Water accumulation → Drain. NOTE: If need the water draining, remove the drain plug 2. Trolling speed check and adjustment 1. Check: Trolling speed Out of specification → Adjust. Trolling speed: 1,350 ± 50 r/min Checking steps (with the vehicle in the water): Start the engine and allow it to warm...
  • Page 37: Oil Injection System

    INSP OIL INJECTION SYSTEM/POWER UNIT OIL INJECTION SYSTEM Oil line inspection Refer to “OIL TANK” in chapter 4. POWER UNIT Spark plug inspection 1. Inspect: Electrodes 1 Damage/wear → Replace. Insulator color 2 Distinctly different color → Check the engine condition. Color guide: Medium to light tan color: Normal...
  • Page 38: Electrical

    INSP POWER UNIT/ELECTRICAL 4. Tighten: Spark plug Spark plug: 25 Nm (2.5 m • kgf, 18 ft • lb) NOTE: Before installing the spark plug, clean the gasket surface and spark plug surface. Also, it is suggested to apply a thin film of anti-seize compound to the spark plug threads to prevent thread seizure.
  • Page 39 INSP ELECTRICAL Batteries generate explosive, hydrogen gas. Always follow these preventive mea- sures: Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). DO NOT SMOKE when charging or han- dling batteries.
  • Page 40 INSP ELECTRICAL 2. Inspect: Electrolyte level Low → Add distilled water. electrolyte level should between the upper a and lower b 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 41: Jet Pump Unit

    INSP ELECTRICAL/JET PUMP UNIT 5. Install: Battery breather hose 1 Battery Battery positive lead 2 Battery negative lead 3 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 42: Water Inlet Strainer Inspection

    INSP JET PUMP UNIT/GENERAL Water inlet strainer inspection 1. Inspect: Water inlet strainer Contaminants → Clean. Cracks/damage → Replace. Inspection steps: Remove the water inlet cover 1. Inspect the water inlet strainer mesh Install the water inlet cover. Bilge strainer inspection 1.
  • Page 43: Lubrication Points

    1. 2. Lubricate: QSTS control cables (handlebar side) Recommended lubricant: Yamaha marine grease, Yamaha grease A (Water resistant grease) NOTE: Before lubricating the QSTS control cables, remove the QSTS cable housing cover.
  • Page 44 GENERAL 4. 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) 5. Lubricate: Nozzle pivot shaft Steering cable (nozzle side) QSTS cable (nozzle side)
  • Page 45 6. Lubricate: Steering cable Steering cable joint NOTE: Disconnect the joints and apply a small amount of grease. Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) 7. Fill: Intermediate housing Recommended grease: Yamaha marine grease, Yamaha grease A...
  • 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 OIL TANK ......................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 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: 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. Engine unit Refer to “ENGINE UNIT” in chapter 5. Steering console cover assembly Refer to “STEERING CONSOLE COVER” in chapter 8.
  • Page 51 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 52: Service Points

    FUEL OIL TANK SERVICE POINTS Oil line inspection 1. Inspect: Oil filter Contaminants → Clean. Frays/tears → Replace. Rubber seal Cracks/wear → Replace. Oil hose Oil tank Oil filler cap Cracks/damage → Replace. Check valve Malfunction → Replace. Oil level switch inspection Refer to “INDICATION SYSTEM”...
  • Page 53: 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. Oil tank Refer to “OIL TANK”. Fuel level sensor coupler Hose clamp Fuel filler neck Rubber seal Fuel reserve hose...
  • Page 54 FUEL FUEL TANK EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Fuel hose Red mark a Fuel return hose Fuel breather hose Fuel tank assembly Hose clamp Fuel filler hose Hose clamp Fuel sensor assembly...
  • Page 55 FUEL FUEL TANK EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points One way valve Screw/washer Filter Screw/washer Sleeve Floatation Bolt Tank bolt 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. Hose clamp Silencer Hose clamp...
  • Page 58 FUEL INTAKE DUCT AND SILENCER EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt/collar/grommet 1/1/1 Intake duct Silencer case Bolt Spark arrester 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 plate Refer to “INTAKE DUCT AND SILENCER”. NOTE: Oil pump cable Before removing the oil pump cable, mark the cable’s installation position for reference when installing the oil pump cable.
  • Page 60 FUEL CARBURETOR UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Red mark a Fuel return hose Oil delivery hose Clamp/fuel pump vacuum hose Remote throttle stop screw 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 Fuel suction Hose Fuel return 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 Not synchronized → 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: 16 ~ 18 mm (0.63 ~ 0.71 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 For carburetor #3 Accelerator pump fuel hose 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. Engine unit Refer to “ENGINE UNIT” in chapter 5. Bolt Bleed hose stay Bolt Oil pump assembly Gasket Not reusable...
  • Page 74 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 75: 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 → Replace. CAUTION: If the oil delivery hoses are not full of oil, fill them up.
  • Page 76: 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 77: Oil Injection Pump Air Bleeding

    FUEL OIL PUMP Oil injection pump air bleeding 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 the recommended oil. NOTE: If the oil pump is replaced or the oil suc- tion hose is reinstalled, bleed air from the oil suction hose by removing it from the oil pump.
  • Page 78 POWR CHAPTER 5 POWER UNIT MUFFLER ASSEMBLY ................... 5-1 EXPLODED DIAGRAM ................5-1 REMOVAL AND INSTALLATION CHART ..........5-1 SERVICE POINT..................5-7 Catalyst inspection................5-7 EXHAUST CHAMBER ASSEMBLY..............5-8 EXPLODED DIAGRAM ................5-8 REMOVAL AND INSTALLATION CHART ..........5-8 ENGINE UNIT ....................5-11 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: Muffler Assembly

    POWR MUFFLER ASSEMBLY MUFFLER ASSEMBLY EXPLODED DIAGRAM 12 Nm (1.2 m • kgf, 8.7 ft • Ib) 6 × 22 mm Å REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points WATER HOSES AND LEADS Follow the left “Step” for removal. REMOVAL YPVS servomotor Refer to “YPVS SERVOMOTOR”...
  • Page 81 POWR MUFFLER ASSEMBLY EXPLODED DIAGRAM 12 Nm (1.2 m • kgf, 8.7 ft • Ib) 6 × 22 mm Å Step Procedure/Part name Q’ty Service points AC magneto coupler Cap/bolt Cover Å For cooling water pilot outlet on port Water hose/clamp side...
  • Page 82 POWR MUFFLER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Hose clamp Slide the outer exhaust joint. Hose clamp Hose clamp Water lock band Slide the water lock. Bolt Intermediate housing grease hose NOTE: Remove the spark plug before removing the eye, and reinstall it to make removing the muffler assembly easier.
  • Page 83 POWR MUFFLER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Bolt Bolt Bolt Muffler stay 2 Muffler assembly NOTE: Remove the cylinder head if it is difficult to remove the muffler assembly. Outer exhaust joint Inner exhaust joint Reverse the removal steps for installation.
  • Page 84 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 Bolt Muffler stay Bolt Cover Gasket Not reusable Catalyst housing...
  • Page 85 POWR MUFFLER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Gasket Not reusable Catalyst Gasket Not reusable Bolt Mixing joint Gasket Not reusable Muffler Reverse the disassembly steps for assembly.
  • Page 86: Service Point

    POWR MUFFLER ASSEMBLY SERVICE POINT Catalyst inspection 1. Inspect: Catalyst Cracks/damage → Replace.
  • Page 87: Exhaust Chamber Assembly

    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 Muffler assembly Refer to “MUFFLER ASSEMBLY”. Å For cooling water pilot outlet on Clamp/hose starboard side Bolt...
  • Page 88 POWR EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Exhaust chamber assembly NOTE: Before installing the exhaust chamber assembly, install the clamp/hose (step No.7) and place the bolts (step No.2) in the bolts holes of the exhaust chamber assembly.
  • Page 89 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 90: Engine Unit

    POWR ENGINE UNIT ENGINE UNIT EXPLODED DIAGRAM 6 × 25 mm 17 Nm (1.7 m • kgf, 12 ft • Ib) 8 × 40 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ENGINE UNIT REMOVAL Follow the left “Step” for removal. Carburetor unit Refer to “CARBURETOR UNIT”...
  • Page 91 POWR ENGINE UNIT EXPLODED DIAGRAM 6 × 25 mm 17 Nm (1.7 m • kgf, 12 ft • Ib) 8 × 40 mm 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.
  • Page 92: Service Points

    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 93: Exhaust Manifold

    POWR EXHAUST MANIFOLD EXHAUST MANIFOLD 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 Engine unit Refer to “ENGINE UNIT”. Bolt Bolt Exhaust manifold Gasket Not reusable Reverse the removal steps for installation.
  • Page 94: Removal And Installation Chart

    POWR EXHAUST MANIFOLD 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 Water pipe O-ring Exhaust manifold Reverse the disassembly steps for assembly. 5-15...
  • Page 95 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. Carburetor unit Refer to “CARBURETOR UNIT” in chapter 4. Bolt NOTE: Tighten the bolts in the proper sequence Reed valve plate as shown.
  • Page 96: Service Points

    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: Ypvs

    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. Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY”. Bolt YPVS valve cover Gasket Not reusable Spacer Link joint/cover Circlip Not reusable 5-18...
  • Page 98 POWR YPVS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Washer NOTE: Bolt During installation, align the hole a in the YPVS shaft with the bolt. Shaft 3 Shaft 2 Shaft 1 YPVS valve arm 5-19...
  • Page 99: Exploded Diagram

    POWR YPVS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt 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: Service Points

    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. YPVS valve installation 1.
  • Page 101: Cylinder Head

    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 NOTE: Bolt Tighten the bolts in the proper sequence Ground lead as shown and in three stages.
  • Page 102 POWR CYLINDER HEAD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Cylinder head cover Gasket Not reusable Cylinder head Gasket Not reusable a white mark Clamp/hose Reverse the removal steps for installation. 5-23...
  • Page 103: Service Points

    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: Cylinders

    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: Service Points

    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: Pistons

    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: Service Points

    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: Cylinder And Piston Combination

    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: Piston Pin And Bearing Inspection

    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: Generator And Starter Motor

    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. Oil pump Refer to “OIL PUMP” in chapter 4. Bolt Bolt Ground lead Generator cover...
  • 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 NOTE: Bolt 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 Battery negative lead 5-36...
  • Page 116 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Nut/washer Starter motor lead Starter motor Reverse the removal steps for installation. 5-37...
  • Page 117 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 5-38...
  • Page 118 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Weight Spring ring Pinion gear Reverse the disassembly steps for assembly. 5-39...
  • Page 119: Service Points

    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 120: Drive Coupling Inspection

    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 121: Crankcase

    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 122 POWR CRANKCASE EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt NOTE: Tighten the bolts in sequence as shown. Bolt Lower crankcase Crankshaft assembly Upper crankcase Reverse the disassembly steps for assembly. 5-43...
  • Page 123: Service Points

    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 124: Crankshaft

    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 gloves in the crankcase body.
  • Page 125: Service Points

    POWR CRANKSHAFT SERVICE POINTS Crankshaft inspection 1. Measure: Crank width A Out of specification → Replace. Crank width: 72.95 ~ 73.00 mm (2.872 ~ 2.874 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 126 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. 5-47...
  • Page 127 PUMP CHAPTER 6 JET PUMP UNIT JET PUMP UNIT ..................... 6-1 EXPLODED DIAGRAM ................6-1 REMOVAL AND INSTALLATION CHART ..........6-1 NOZZLE DEFLECTOR AND NOZZLE RING ........... 6-4 EXPLODED DIAGRAM ................6-4 REMOVAL AND INSTALLATION CHART ..........6-4 IMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCT ....6-5 EXPLODED DIAGRAM ................
  • 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 grate Bolt Intake duct Screw NOTE: Speed sensor Route the speed sensor lead between the jet pump unit and the bilge hose.
  • Page 129 JET PUMP UNIT PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Ride plate QSTS cable joint Bilge hose Nut/washer Steering cable joint Clamp/spout hose Bolt Bolt...
  • Page 130: Jet Pump Unit

    JET PUMP UNIT PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Jet pump unit assembly NOTE: Pull the jet pump unit straight back. Dowel pin When installing the jet pump unit, align the drive shaft spline (male) with the intermediate drive shaft spline (female).
  • Page 131: Removal And Installation Chart

    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”. Bolt Collar Nozzle deflector...
  • Page 132: Impeller Duct, Impeller Housing, And Intake Duct

    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 133 IMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCT PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Water inlet cover Packing Water inlet strainer Packing Reverse the removal steps for installation.
  • Page 134: Impeller Duct And Drive Shaft

    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 O-ring Washer : EPNOC grease AP #0...
  • Page 135 IMPELLER DUCT AND DRIVE SHAFT PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Drive shaft Rear bearing Not reusable Spacer Front bearing Not reusable Oil seal Not reusable Oil seal Not reusable Reverse the disassembly steps for assembly. : EPNOC grease AP #0...
  • Page 136: Service Points

    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 137: Impeller Inspection

    IMPELLER DUCT AND DRIVE SHAFT PUMP 5. Remove: Front bearing Driver rod L3: YB-06071/90890-06652 Needle bearing attachment: YB-06112/90890-06614 NOTE: Remove the front bearing with a press. 6. Remove: Oil seal Driver rod L3: YB-06071/90890-06652 Needle bearing attachment: YB-06196/90890-06653 NOTE: Remove the oil seal with press. Impeller inspection Refer to “JET PUMP UNIT”...
  • Page 138 IMPELLER DUCT AND DRIVE SHAFT PUMP 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. Install: Drive shaft (with front bearing) Spacer Impeller duct NOTE:...
  • Page 139 IMPELLER DUCT AND DRIVE SHAFT PUMP 6. Add: EPNOC grease AP #0 (into the cap) Quantity: Approximately 1/3 of capacity 7. Install: Impeller Drive shaft holder: YB-06151/90890-06519 6-12...
  • 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 Exhaust system Refer to “EXHAUST SYSTEM” in chapter 8. Jet pump unit Refer to “JET PUMP UNIT”.
  • Page 141 TRANSOM PLATE AND HOSES PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Hose Cooling water inlet Nut/washer Transom plate Clamp/bilge hose 2 Screw Bilge strainer holder Bilge strainer Reverse the removal steps for installation. 6-14...
  • Page 142: Service Points

    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. 6-15...
  • Page 143: Bearing Housing

    BEARING HOUSING PUMP BEARING HOUSING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BEARING HOUSING REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT” in chapter 5. Rubber coupling Bolt Intermediate housing assembly NOTE: Shim Install the shims in their original locations.
  • Page 144 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 Intermediate drive shaft 6-17...
  • Page 145 BEARING HOUSING PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points O-ring Oil seal Not reusable Oil seal Not reusable Oil seal Not reusable Circlip Bearing Not reusable Circlip Reverse the disassembly steps for assembly. 6-18...
  • Page 146: Service Points

    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. Intermediate drive shaft removal 1.
  • Page 147: Bearing, Driven Coupling Shaft, And Grease Hose Inspection

    BEARING HOUSING PUMP Bearing, driven coupling shaft, and grease hose inspection 1. Inspect: Bearing Rotate the inner race by hand. Damage/rough movement → Replace. Intermediate drive shaft Damage/pitting → Replace. Grease hose Cracks/wear → Replace. Driven coupling inspection 1. Inspect: Driven coupling Driven coupling damper Damage/wear →...
  • Page 148: Intermediate Housing Installation

    BEARING HOUSING PUMP 2. Install: Intermediate drive shaft Distance a: 9.5 ~ 10.5 mm (0.37 ~ 0.41 in) NOTE: Support the intermediate housing with steel blocks 1 and press the driven cou- pling shaft. 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)
  • Page 149 – 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 ................7-7 INSPECTION..................... 7-7 Digital circuit tester ................7-7 Low resistance measurement ............7-8 Peak voltage measurement.............. 7-8 Peak voltage adaptor ................
  • Page 150 – ELEC CHARGING SYSTEM..................7-25 WIRING DIAGRAM................. 7-25 FUSE ....................... 7-26 BATTERY ....................7-26 LIGHTING COIL ..................7-26 RECTIFIER/REGULATOR................ 7-26 YPVS ......................7-27 WIRING DIAGRAM................. 7-27 FUSE ....................... 7-28 BATTERY ....................7-28 PICKUP COIL ..................7-28 CDI UNIT....................7-28 LIGHTING COIL ..................7-28 RECTIFIER/REGULATOR................
  • Page 151: Electrical Components

    – ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS > 1 Buzzer 9 Battery 2 Fuel level sensor 0 Water temperature sensor 3 Multi-function meter A Starter motor 4 YPVS servomotor B Stator coil and pickup coil 5 Spark plugs C Engine stop switch, engine stop lanyard 6 Exhaust temperature sensor switch and starter switch 7 Electrical box...
  • Page 152: 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. Engine unit Refer to “ENGINE UNIT” in chapter 5. Battery negative lead Refer to “GENERATOR AND STARTER Starter motor lead MOTOR”...
  • 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 water, exhaust temperature sensor and lighting coil Screw Rectifier/regulator Screw Cover Packing Spark plug lead holder Screw Ground lead...
  • Page 154 – ELEC ELECTRICAL BOX EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Ignition coil Ignition coil lead Spark plug lead/cap 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 0 Rectifier/regulator : Black 2 Engine stop lanyard switch A Exhaust temperature sensor : Orange 3 Lighting coil B Water temperature sensor : Red 4 Pickup coil : White 5 CDI unit : Black/orange 6 Ignition coil...
  • 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 electrical components, do not touch any of the connections of the digital tester lead wires. NOTE: If there is no spark, or the spark is weak, continue with the ignition system test. 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: Pickup coil output peak voltage Below specification → Replace the pickup coil. Pickup coil output peak voltage: White/red (W/R) – Black/orange (B/O) Unloaded Loaded r/min Cranking 2,000 3,500 NOTE: The starter motor will not operate when the test harness on the output side coupler is disconnected to measure the unloaded peak voltage for the pickup coil(s).
  • Page 164: Battery

    – ELEC IGNITION SYSTEM 4. Measure: Rectifier/regulator output peak voltage Below specification → Replace the rectifier/regulator. Rectifier/regulator output peak voltage: Red (R) – Black (B) Unloaded r/min Cranking 2,000 3,500 12.6 12.6 NOTE: Make sure the output lead (red lead) of the rectifier/regulator is disconnected when measuring the output peak voltage.
  • Page 165: Ignition Coil

    – ELEC IGNITION SYSTEM IGNITION COIL 1. Measure: Primary coil resistance Out of specification → Replace. Primary coil resistance: Black/white (B/W) – Body 0.26 ~ 0.36 Ω at 20 ˚C (68 ˚F) NOTE: When measuring a resistance of 10 Ω or less with the digital tester, the correct mea- surement cannot be obtained because of the tester’s internal resistance.
  • Page 166: Water Temperature Sensor

    – ELEC IGNITION SYSTEM WATER TEMPERATURE SENSOR 1. Measure: Water temperature sensor resistance (at the specified temperature) Out of specification → Replace. Water temperature sensor resistance: 0 ˚C (32 ˚F): 24.0 ~ 37.1 kΩ 100 ˚C (212 ˚F): 0.87 ~ 1.18 kΩ 200 ˚C (392 ˚F): 0.104 ~ 0.153 kΩ...
  • 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 Fuse (10A) : Red/yellow 5 Fuse (20A) 6 Starter relay 7 Starter motor 8 Battery 7-17...
  • 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 2 and 3 2.
  • Page 169: Starter Switch

    – ELEC STARTING SYSTEM STARTER SWITCH 1. Check: Continuity Out of specification → Replace. Starter continuity (natural color coupler) Leads Lock plate Position Brown Free Installed Push Free Removed Push STARTER RELAY 1. Inspect: Brown lead terminal Black lead terminal Loose →...
  • 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 Not reusable Bolt Starter motor front cover O-ring...
  • Page 171 – ELEC STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Starter motor rear cover O-ring Not reusable Shim t = 0.2 mm, 0.8 mm Armature assembly Nut/spring washer/washer 1/1/4 O-ring Not reusable Brush holder Brush spring Bolt Brush assembly *: As required 7-21...
  • 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. 7-22...
  • 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 7-25...
  • 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”. 7-26...
  • 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 (10A) : Red/blue 6 Fuse (20A) R/W : Red/white 7 Battery W/R : White/red 8 Rectifier/regulator 7-27...
  • 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”. 7-28...
  • Page 179 – 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 Nut/washer YPVS servomotor YPVS cable Slide the cover. White paint mark a is for No.
  • Page 180: Ypvs Servomotor

    – 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 A Fuse (20A) : Black : Black/yellow 2 Fuel level sensor B Exhaust temperature : Brown Gy/B : Gray/black 3 Oil level sensor sensor : Chocolate Gy/R : Gray/red 4 Buzzer C Water temperature : Green...
  • Page 183: Fuse

    – ELEC INDICATION 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”. 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: Display Function

    – ELEC INDICATION SYSTEM Display function 1. Check: Display function Not operate → Replace the multi- function meter. 1 Oil level sensor : Black Gy/B : Gray/black 2 Fuel level sensor : Chocolate Gy/R : Gray/red 3 Buzzer : Green Gy/Y : Gray/yellow 4 Battery : Blue...
  • Page 186: Fuel Level Gauge

    If the jumper lead is installed for more than 30 seconds, the display will auto- matically turn off. Check the fuel level segments is full indicated. YAMAHA Remove the jumper lead 1 from the FUEL HOUR green two-pin connector. Disconnect the jumper lead 2 and...
  • Page 187: Oil Level Gauge

    If the jumper lead is installed for more than 30 seconds, the display will auto- matically turn off. Remove the jumper lead 1 from the white two-pin connector. YAMAHA Disconnect the jumper lead 2 and FUEL HOUR then connect it to green and red ter- minal again.
  • Page 188: Overheat Warning Indicator

    1. Connect the green and red terminals with a jumper lead 2. Make sure the water temperature sym- bol 3 and “WARNING” lamp 4 blinks, and the buzzer sounds intermit- tently. YAMAHA FUEL HOUR MULTI D SPLAY WARNING x1000r/min 2.
  • Page 189 – ELEC INDICATION SYSTEM Make sure the water temperature sym- bol 3 display and “WARNING” lamp YAMAHA 4 on, and the buzzer sounds continu- FUEL HOUR ity. MULTI D SPLAY WARNING x1000r/min 3. Check: Exhaust temperature warning indicator Not operating → Replace the multi- function meter.
  • Page 190: 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 natural color six-pin connector (+: red, –: black) with a battery.
  • Page 191 HULL HOOD CHAPTER 8 HULL AND HOOD HANDLEBAR....................8-1 EXPLODED DIAGRAM ................8-1 REMOVAL AND INSTALLATION CHART ..........8-1 SERVICE POINTS ..................8-7 Handlebar inspection................ 8-7 Handlebar switch inspection............8-7 Handlebar assembly installation ............. 8-7 QSTS GRIP....................8-10 EXPLODED DIAGRAM ................8-10 REMOVAL AND INSTALLATION CHART ..........
  • Page 192 HULL HOOD BUZZER AND HOOD LOCK ................. 8-27 EXPLODED DIAGRAM ................8-27 REMOVAL AND INSTALLATION CHART ..........8-27 HOSES ......................8-30 EXPLODED DIAGRAM ................8-30 REMOVAL AND INSTALLATION CHART ..........8-30 SERVICE POINTS ................... 8-32 Check valve inspection ..............8-32 Ventilation hose installation............
  • Page 193 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 Screw Handlebar cover stay Spiral tube Band...
  • Page 194 HULL HANDLEBAR HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Throttle cable Choke cable Bolt Upper handlebar holder Handlebar assembly Lower handlebar holder Reverse the removal steps for installation.
  • Page 195 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”. Grommet NOTE: Apply soapy water to the grommet for easier installation.
  • Page 196 HULL HANDLEBAR HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points QSTS cable 1 NOTE: Route the QSTS cables behind of the oil filler hose. Nut/washer QSTS converter Throttle cable Choke cable 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 DISASSEMBLY Follow the left “Step” for disassembly. Band Bolt Grip end Spacer Screw/washer/spring washer 1/1/1 QSTS grip assembly Screw Handlebar switch assembly Cable holder...
  • Page 198 HULL HANDLEBAR HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Screw Throttle lever assembly Screw Choke 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 199 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. 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 control grip to the neutral position.
  • Page 200 HULL HANDLEBAR HOOD 3. Install: Throttle cable NOTE: Fit the seal into the glove in the bracket. 4. Install: Band 1 NOTE: After inserting the QSTS cables into the grommet, tie the end of grommet with the band. 5. Install: Spiral tube 1 NOTE: Be sure to install the spiral tube, containing...
  • Page 201 HULL HANDLEBAR HOOD 7. Adjust: Choke lever operation Refer to “CONTROL SYSTEM” in chapter 3. 8. Adjust: Throttle cable free play Refer to “CONTROL SYSTEM” in chapter 3. 9. Adjust: QSTS cable free play Refer to “CONTROL SYSTEM” in chapter 3.
  • Page 202 HULL QSTS GRIP HOOD QSTS GRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points QSTS GRIP DISASSEMBLY Follow the left “Step” for disassembly. QSTS grip assembly Refer to “HANDLEBAR”. Screw/washer Cover Ball Spring QSTS cable 1 with white tape a QSTS cable 2 8-10...
  • Page 203 HULL QSTS GRIP HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Screw/washer Collar QSTS shift lock lever Spring Spacer QSTS cable housing cover QSTS shift grip Reverse the disassembly steps for assembly. 8-11...
  • Page 204 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. 8-12...
  • Page 205 HULL STEERING COLUMN HOOD STEERING COLUMN EXPLODED DIAGRAM kgf, 11 ft 16 Nm (1.6 m • • REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING COLUMN REMOVAL Follow the left “Step” for removal. Steering console cover assembly Refer to “STEERING CONSOLE COVER”.
  • Page 206 HULL STEERING COLUMN HOOD EXPLODED DIAGRAM 16 Nm (1.6 m kgf, 11 ft • • 8 × 60 mm kgf, 19 ft 26 Nm (2.6 m • • kgf, 3.6 ft 5 Nm (0.5 m • • REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty...
  • Page 207 HULL STEERING COLUMN HOOD EXPLODED DIAGRAM 16 Nm (1.6 m kgf, 11 ft • • 8 × 60 mm kgf, 19 ft 26 Nm (2.6 m • • kgf, 3.6 ft 5 Nm (0.5 m • • Step Procedure/Part name Q’ty Service points Washer...
  • Page 208 HULL STEERING COLUMN HOOD SERVICE POINTS Steering column bushing inspection 1. Inspect: Bushings Damage/wear → Replace. 2. Inspect: Steering column inspection Refer to “CONTROL SYSTEM” in chapter 3. 8-16...
  • Page 209 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 210 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Steering cable QSTS cable end QSTS cable Reverse the removal steps for installation. 8-18...
  • Page 211 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD SERVICE POINTS WARNING When routing the cables, do not grasp the cable by the outer crimped sheath or steel end. This could deform or loosen the cable end due to extreme angles and or pressure. Always hold the cables by the bracket or outer cover below the crimp.
  • Page 212 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 213 HULL FRONT HOOD HOOD FRONT HOOD EXPLODED DIAGRAM 6 × 14 mm kgf, 3.6 ft 5 Nm (0.5 m • • 6 × 14 mm kgf, 4.3 ft 6 Nm (0.6 m • • 5 × 10 mm kgf, 0.7 ft 1 Nm (0.1 m •...
  • Page 214 HULL FRONT HOOD HOOD EXPLODED DIAGRAM 6 × 14 mm kgf, 3.6 ft 5 Nm (0.5 m • • 6 × 14 mm kgf, 4.3 ft 6 Nm (0.6 m • • 5 × 10 mm kgf, 0.7 ft 1 Nm (0.1 m •...
  • Page 215 HULL STEERING CONSOLE COVER HOOD STEERING CONSOLE COVER EXPLODED DIAGRAM 8 × 25 mm kgf, 1.4 ft 2 Nm (0.2 m • • 5 × 19 mm kgf, 2.2 ft 3 Nm (0.3 m • • 6 × 24 mm kgf, 3.6 ft 5 Nm (0.5 m •...
  • Page 216 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 8 × 25 mm kgf, 1.4 ft 2 Nm (0.2 m • • 5 × 19 mm kgf, 2.2 ft 3 Nm (0.3 m • • 6 × 24 mm kgf, 3.6 ft 5 Nm (0.5 m •...
  • Page 217 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM kgf, 0.7 ft 1 Nm (0.1 m • • 5 × 20 mm kgf, 2.2 ft 3 Nm (0.3 m • • 6 × 18 mm kgf, 1.4 ft 2 Nm (0.2 m •...
  • Page 218 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM kgf, 0.7 ft 1 Nm (0.1 m • • 5 × 20 mm kgf, 2.2 ft 3 Nm (0.3 m • • 6 × 18 mm kgf, 1.4 ft 2 Nm (0.2 m •...
  • Page 219 HULL BUZZER AND HOOD LOCK HOOD BUZZER AND HOOD LOCK EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BUZZER AND HOOD LOCK Follow the left “Step” for removal. REMOVAL Steering console cover assembly Refer to “STEERING CONSOLE COVER”. Steering cable Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”.
  • Page 220 HULL BUZZER AND HOOD LOCK HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Hood lock assembly Grommet Reverse the removal steps for installation. 8-28...
  • Page 221 HULL BUZZER AND HOOD LOCK HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HOOD LOCK DISASSEMBLY Follow the left “Step” for disassembly. Screw Hood lock button assembly Circlip Washer Hook lever Spring Hood lock body Reverse the disassembly steps for assembly.
  • Page 222 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. Engine unit Refer to “ENGINE UNIT” in chapter 5. Steering console cover assembly Refer to “STEERING CONSOLE COVER”. Band NOTE: Ventilation hose (stern side)
  • Page 223 HULL HOSES HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Band Check valve Oil tank breather hose Fuel tank breather hose Reverse the removal steps for installation. 8-31...
  • Page 224 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 225 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 Seat assembly Bolt Seat lock assembly Notch Washer 8-33...
  • Page 226 HULL SEATS AND HAND GRIP HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Rubber ring Nut/washer Bolt Bolt Hand grip Bracket Reverse the removal steps for installation. 8-34...
  • Page 227 HULL SEATS AND HAND GRIP HOOD SERVICE POINTS Seat lock inspection 1. Inspect: Seat lock Damage/wear → Replace. 8-35...
  • Page 228 HULL BATTERY BOX HOOD BATTERY BOX EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BATTERY BOX REMOVAL Follow the left “Step” for removal. Band Fire extinguisher container Band Bolt Battery negative lead Bolt Battery positive lead Clip/breather hose Battery Cap nut/washer...
  • Page 229 HULL BATTERY BOX HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Holder Cap nut/washer Nut/washer Electrical box NOTE: Battery box Before installing the battery box, route the battery leads and battery breather hose through the holes of the battery box. Stay Reverse the removal steps for installation.
  • Page 230 HULL EXHAUST SYSTEM HOOD EXHAUST SYSTEM EXPLODED DIAGRAM kgf, 2.9 ft 4 Nm (0.4 m • • kgf, 2.9 ft 4 Nm (0.4 m • • kgf, 4.3 ft 6 Nm (0.6 m • • 6 × 30 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty...
  • Page 231 HULL EXHAUST SYSTEM HOOD EXPLODED DIAGRAM kgf, 2.9 ft 4 Nm (0.4 m • • kgf, 2.9 ft 4 Nm (0.4 m • • kgf, 4.3 ft 6 Nm (0.6 m • • 6 × 30 mm Step Procedure/Part name Q’ty Service points Hose clamp...
  • Page 232 HULL EXHAUST SYSTEM HOOD SERVICE POINTS Exhaust system inspection 1. Inspect: Water lock band Cracks/damage → Replace. 2. Inspect: Rubber hoses Burns/cracks/damage → Replace. 3. Inspect: Water lock Cracks/leaks → Replace. 4. Inspect: Water tank Cracks/damage/leaks → Replace. Exhaust component parts sub-assembly 1.
  • Page 233 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. Bolt Bow eye Rope hole fitting Spout Bolt 8-41...
  • Page 234 HULL DECK AND HULL HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Sponson NOTE: Make sure install the starboard and port side sponsons to the same position. Bolt Flap Nut/washer Screw/washer Drain plug Packing Reverse the disassembly steps for assembly.
  • Page 235 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 Liner...
  • Page 236 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 237 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 238 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 239 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 240 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 241 TRBL ANLS CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS ..................9-1 TROUBLE ANALYSIS CHART ..............9-1...
  • Page 242: Fuel Filter

    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 243 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 244 YAMAHA MOTOR CO., LTD. Printed in USA × 1 CR Feb. 2000 – F0X-28197-ZA-11 (GP1200AY) Printed on recycled paper...
  • Page 245 WIRING DIAGRAM COLOR CODE Black Black/yellow GP1200R Brown Gy/B Gray/black Chocolate Gy/R Gray/red Green Gy/Y Gray/yellow Gray Blue/black Blue Blue/red 1 Lighting coil Orange Red/blue Red/white White Red/yellow Yellow White/blue 2 Pickup Black/orange White/red coil 3 CDI unit Black/white Gy/B Gy/Y Gy/R 4 Oil level sensor...