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Yamaha WaveRunner VX 700 Service Manual

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WaveRunner
VX 700
VX 700 (F2V)
SERVICE MANUAL
F2V-28197-ZN-11

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Table of Contents
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  Summary of Contents for Yamaha WaveRunner VX 700

  • Page 1 WaveRunner VX 700 VX 700 (F2V) SERVICE MANUAL F2V-28197-ZN-11...
  • Page 2: Specification

    Preface This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have 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: Table Of Contents

    Contents General information INFO Specification SPEC Maintenance Fuel system FUEL Power unit POWR Jet pump unit PUMP – Electrical system ELEC Hull and hood HULL HOOD Troubleshooting TRBL SHTG Appendix...
  • Page 5: General Information

    INFO General information Safety while working ............. 1-1 Rotating part................1-1 Hot part..................1-1 Electric shock ................1-1 Impeller..................1-1 Handling of gasoline..............1-1 Ventilation................... 1-2 Self-protection ................1-2 Working with crane..............1-2 Handling of heat gun ..............1-3 Part, lubricant, and sealant............1-3 Handling of sealant..............
  • Page 6: Safety While Working

    INFO General information Safety while working To prevent an accident or injury and to pro- vide quality service, observe the following safety procedures. Rotating part • Hands, feet, hair, jewelry, clothing, per- sonal flotation device straps, and so on, can become entangled with internal rotating parts of the engine or jet pump unit, result- ing in serious injury or death.
  • Page 7: Ventilation

    Safety while working Ventilation Working with crane • Gasoline vapor and exhaust gas are • When moving the watercraft, or when lifting heavier than air and extremely poisonous. the engine during removal or installation, If gasoline vapor or exhaust gas is inhaled make sure to use a crane with a lifting in large quantities, it may cause loss of con- capacity that is equal to or more than the...
  • Page 8: Handling Of Heat Gun

    Part, lubricant, and sealant Non-reusable part Use only genuine Yamaha parts, lubricants, Always use new gaskets, seals, O-rings, cot- and sealants, or those recommended by ter pins, and so on, when installing or assem- Yamaha, when servicing or repairing the bling parts.
  • Page 9: Disassembly And Assembly

    Safety while working Disassembly and assembly • Use compressed air to remove dust and dirt during disassembly. • Apply engine oil to the contact surfaces of moving parts before assembly. • Install bearings so that the bearing identifi- cation mark is facing in the direction indi- cated in the installation procedure.
  • Page 10: How To Use This Manual

    INFO General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. •...
  • Page 11: Abbreviation

    How to use this manual Abbreviation The following abbreviations are used in this service manual. Abbreviation Description Bow end Capacitor discharge ignition Exhaust Intake NMMA National Marine Manufacturers Association Pump Octane Number PORT Port side Research Octane Number STBD Starboard side STERN Stern end Top Dead Center...
  • Page 12: Adhesive, Lubricant, Sealant, And Thread Locking Agent

    Adhesive, lubricant, sealant, and thread locking agent Symbol Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points. Symbol Name Application Yamaha 2-stroke motor oil Lubricant Water resistant grease Lubricant (Yamaha grease A) Molybdenum disulfide grease Lubricant...
  • Page 13: Special Service Tool

    Adhesive, lubricant, sealant, and thread locking agent / Special service tool Special service tool Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division. Digital tachometer Driver rod L3 90890-06760 90890-06652 Compression gauge Needle bearing attachment...
  • Page 14 INFO General information Stopper guide stand Drive shaft holder 5 90890-06538 90890-06519 Driver rod LS Digital circuit tester 90890-06606 90890-03174 Ball bearing attachment Peak voltage adapter B 90890-06631 90890-03172 Crankshaft holder 20 Ignition tester (Spark gap tester) 90890-06552 90890-06754 Bearing outer race attachment 90890-06628...
  • Page 15: Model Feature

    The jet pump unit serial number is stamped compartment. on a label attached to the intermediate hous- ing. PRI-I.D. MODEL YAMAHA MOTOR CO., LTD. ASSEMBLED IN U.S.A. FROM AMERICAN AND JAPANESE COMPONENTS. ASSEMBLÉ AUX ÉTATS-UNIS DE PIÈCES AMÉRICAINES ET JAPONAISES. 1 Model name...
  • Page 16 INFO General information — MEMO — 1-11...
  • Page 17: Specification

    SPEC Specification Model data ................2-1 Model code................. 2-1 Dimension and weight ..............2-1 Performance................2-1 Power unit .................. 2-1 Drive unit ..................2-2 Fuel and oil requirement............. 2-2 Battery requirement..............2-2 Fuel system technical data ..........2-3 Fuel system ................2-3 Power unit technical data ..........
  • Page 18: Model Data

    SPEC Specification Model data Model code Model Item Unit VX 700 Hull Engine/jet 6CP/6CP Dimension and weight Model Item Unit VX 700 Length mm (in) 3220 (126.8) Width mm (in) 1170 (46.1) Height mm (in) 1160 (45.7) Dry weight kg (lb) 283 (624) Person/ Maximum capacity...
  • Page 19: Drive Unit

    Model data Drive unit Model Item Unit VX 700 Jet pump type Axial flow, single stage Impeller rotation Counterclockwise (viewed from rear) Transmission Constant mesh 1-speed Jet thrust nozzle horizontal Degree 24 + 24 angle Trim system — Jet thrust nozzle trim angle Degree Fuel and oil requirement Model...
  • Page 20: Fuel System

    SPEC Specification Fuel system technical data Fuel system Model Item Unit VX 700 Carburetor Manufacturer Mikuni Model × quantity BN38 × 2 Type Floatless ID mark 62T03F/03R Main jet (MJ) 120 (front), 130 (rear) Main nozzle (MN) mm (in) 2.5 (0.10) Pilot jet (PJ) 67.5 5/8 ±...
  • Page 21: Crank Case Assy

    Fuel system technical data / Power unit technical data Crank case assy. Model Item Unit VX 700 Cylinder Bore mm (in) 81.000–81.020 (3.1890–3.1898) Bore wear limit mm (in) 81.100 (3.1929) Taper limit mm (in) 0.080 (0.0031) Out-of-round limit mm (in) 0.050 (0.0020) Piston Diameter...
  • Page 22: Jet Pump Unit

    SPEC Specification Jet pump unit technical data Jet pump unit Model Item Unit VX 700 Impeller housing Inside diameter mm (in) 155.35–155.45 (6.116–6.120) Impeller-to-housing mm (in) 0.35–0.45 (0.014–0.018) clearance Clearance limit mm (in) 0.60 (0.024) Impeller Material Stainless steel Blades number Pitch angle Degree 13.2...
  • Page 23: Charging System

    Jet pump unit technical data / Electrical technical data Charging system Model Item Unit VX 700 Charge coil Output peak voltage at cranking (unloaded) at cranking (loaded) at 1500 r/min (loaded) at 3500 r/min (loaded) Resistance (*1) Ω at 20 °C (68 °F) 497.7–608.3 Lighting coil Output peak voltage...
  • Page 24: Starting System

    SPEC Specification Starting system Model Item Unit VX 700 Fuse Rating Main 12/10 Starter motor Type Constant mesh Output Cranking time limit Seconds Commutator diameter mm (in) 27.0–28.0 (1.06–1.10) Commutator undercut (*1) mm (in) 0.2–0.7 (0.008–0.028) Brush length mm (in) 6.5–12.5 (0.26–0.49) (*1) The figures are for reference only.
  • Page 25: Specified Tightening Torque

    Electrical technical data / Specified tightening torque Specified tightening torque Fuel system Screw Tightening torque Part to tightened size N·m kgf·m ft·lb page Fuel cock knob screw ø4 Fuel cock assy./washer nut — Choke knob screw ø3 Choke knob nut —...
  • Page 26 SPEC Specification Screw Tightening torque Part to tightened size N·m kgf·m ft·lb page Reed valve assy. bolt 5-14 Intake manifold bolt 5-14 Thermoswitch bolt 5-16 Spark plug — 18.4 5-16 11.1 5-16 Cylinder head bolt 21.4 5-16 16.2 5-18 Cylinder bolt 28.8 5-18 Anode screw...
  • Page 27: Jet Pump Unit

    Specified tightening torque Jet pump unit Screw Tightening torque Part to tightened size N·m kgf·m ft·lb page Intake grate bolt 29.5 Ride plate bolt 12.5 Cover screw ø5 Steering cable joint nut — 0.68 Jet pump unit assy. bolt 29.5 Rubber plate bolt Rubber plate nut —...
  • Page 28: Hull And Hood

    SPEC Specification Hull and hood Screw Tightening torque Part to tightened size N·m kgf·m ft·lb page ø4 Upper handlebar cover screw ø5 Lower handlebar cover screw ø6 Grip end bolt Left handlebar switch assy. screw ø5 Throttle lever assy. bolt Handlebar holder bolt 14.8 Mirror nut...
  • Page 29: General Tightening Torque

    Specified tightening torque / General tightening torque General tightening torque This chart indicates the tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components and assemblies are provided in the applicable sections of this manual.
  • Page 30: Cooling System

    SPEC Specification Cooling system To exhaust To stern outlet outlet To pilot outlet From flushing hose From jet pump cooling water flow Water lock Exhaust outer cover 1 Exhaust chamber Exhaust ring Cylinder head Cylinder block Stern outlet Exhaust manifold Exhaust outlet Pilot outlet Flushing hose...
  • Page 31: Cable And Hose Routing

    Cooling system / Cable and hose routing Cable and hose routing Starboard bow view 1 Positive battery cable B Fuel tank breather hose 2 Battery breather hose C Oil level sensor lead 3 Flushing hose D Throttle cable 4 Bilge hose E Oil hose 5 Cooling water pilot outlet hose F Steering cable...
  • Page 32: Top View

    SPEC Specification Top view 1 Positive battery cable B Fuel tank breather hose 2 Battery breather hose C Oil level sensor lead 3 Flushing hose D Throttle cable 4 Bilge hose E Oil hose 5 Cooling water pilot outlet hose F Steering cable 6 Choke cable G Wiring harness...
  • Page 33 Cable and hose routing M Fuel hose N Fuel reservoir hose O Negative battery cable 2-16...
  • Page 34: Port View

    SPEC Specification Port view 1 Positive battery cable B Fuel tank breather hose 2 Battery breather hose C Oil level sensor lead 3 Flushing hose D Throttle cable 4 Bilge hose E Oil hose 5 Cooling water pilot outlet hose F Steering cable 6 Choke cable G Wiring harness...
  • Page 35 Cable and hose routing M Fuel hose N Fuel reservoir hose O Negative battery cable 2-18...
  • Page 36 SPEC Specification — MEMO — 2-19...
  • Page 37 Maintenance Maintenance interval chart ..........3-1 Periodic service..............3-2 Steering system................3-2 Steering master check ..............3-2 Throttle lever free play check ............3-2 Throttle lever free play adjustment..........3-2 Fuel system ................3-3 Fuel filter check ................3-3 Fuel hose check ................3-3 Fuel filler cap, fuel filler neck, and hose check.......3-3 Fuel tank check ................3-3 Water separator check ..............3-4 Choke cable check.................3-4...
  • Page 38: Maintenance

    Maintenance Maintenance interval chart The following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the maintenance intervals should be changed. MAINTENANCE INTERVAL INITIAL THEREAFTER EVERY hours hours hours hours PAGE ITEM months months months months...
  • Page 39: Periodic Service

    Maintenance interval chart / Periodic service Periodic service Throttle lever free play adjustment Follow all the steps if the throttle cable has Steering system been replaced. Steering master check 1. Turn the handlebar lock to lock and push it back and forth. After adjusting the throttle lever free play, make sure that the throttle cable is not pulled when the handlebar is turned to the...
  • Page 40: Fuel System

    Maintenance 7. Remove the upper handlebar cover. See Fuel filter check 1. Check the fuel filter 1. Replace the fuel “Steering pad and handlebar cover” (8- filter if cracked or damaged. 8. Slide the rubber cover 4 away from the 2.
  • Page 41: Water Separator Check

    Periodic service Water separator check 1. Check the water separator 1. Drain the water if water has accumulated. 2. Check the O-ring of the drain plug. Replace the O-ring if cracked or dam- aged. See “Water separator check” (8- 21). Oil hose, oil filler cap and rubber seal check 1.
  • Page 42: Compression Pressure Measurement

    Maintenance 4. Measure the spark plug gap b. Replace 3. Stop the engine. if out of specification. 4. Remove the spark plug caps, and then remove the plugs. 5. Install the special service tool 1. Specified spark plug (manufacturer): BR8HS (NGK) Spark plug gap b: 0.6–0.7 mm (0.024–0.028 in) Compression gauge 1: 90890-03160...
  • Page 43: Engine Oil Level Check

    Periodic service Engine oil level check Digital tachometer 1: 90890-06760 Do not allow the oil tank to become com- Trolling speed: 1250–1350 r/min pletely empty. If the oil tank becomes empty the oil injection pump must be bled Trolling speed adjustment to ensure proper oil flow, otherwise 1.
  • Page 44: Nut And Bolt Check

    Maintenance Nut and bolt check 1. Check the engine, deck, and hull for loose bolts and nuts. Tighten if loose. See “Specified tightening torque” (2-8). Jet pump unit Impeller check Make sure to remove the battery before checking the jet pump unit. 3.
  • Page 45: Electrical

    Periodic service 3. Disconnect the steering cable joint 2 from the ball joint 3. 4. Turn the steering cable joint 2 in or out adjust distances WARNING! The steering cable joint must be screwed in more than 8 mm (0.31 in) c. 7.
  • Page 46: Hull And Hood

    Maintenance 5. Install the battery 5, and then install the bands 4. Be careful not to place the battery on its side. 6. Connect the battery breather hose 3. Make sure to remove the battery from the NOTICE: Make sure that the battery battery compartment when adding battery breather hose 3 is properly con- electrolyte or charging the battery.
  • Page 47: Drain Plug Check

    Drain plug check 1. Check the O-ring of each drain plug. Replace if cracked or damaged. See “Drain plug check” (8-29). Recommended lubricant: Yamaha grease A Nozzle pivot shaft and steering cable lubrication 1. Lubricate the nozzle pivot shaft and steering cable.
  • Page 48 Maintenance Recommended lubricant: Yamaha grease A TIP: Disconnect the joint and apply a small amount of grease. 3-11...
  • Page 49 FUEL Fuel system Fuel cock and fuel filter ............. 4-1 Fuel filter check ................4-2 Fuel cock check................4-2 Choke cable ................ 4-3 Oil tank ................4-4 Oil line check ................4-5 Oil level sensor check ..............4-5 Oil tank check................4-5 Fuel tank ................
  • Page 50: Fuel System

    FUEL Fuel system Fuel cock and fuel filter (RES) 2 N • m (0.2 kgf • m, 1.5 ft • Ib) (OUT) (ON) 5 N • m (0.5 kgf • m, 3.7 ft • Ib) Part name Q’ty Remarks M4 × 7 mm Screw Fuel cock knob Washer...
  • Page 51: Fuel Filter Check

    Fuel cock and fuel filter Fuel filter check See “Fuel system” (3-3). Fuel cock check Before checking the fuel system, remove the battery, and then remove the fuel filler cap to reduce any pressure inside the fuel tank. 1. Check the fuel cock. Replace if there is rough movement.
  • Page 52: Choke Cable

    FUEL Fuel system Choke cable 2 N • m (0.2 kgf • m, 1.5 ft • Ib) 2 N • m (0.2 kgf • m, 1.5 ft • Ib) Part name Q’ty Remarks M3 × 6 mm Screw Knob Friction adjusting nut Choke cable...
  • Page 53: Oil Tank

    Choke cable / Oil tank Oil tank (VENT) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 6 N • m (0.6 kgf • m, 4.4 ft • Ib) Part name Q’ty Remarks Clamp Oil filler neck Rubber seal Tank belt Oil level sensor coupler...
  • Page 54: Oil Line Check

    FUEL Fuel system Oil line check 1. Clean the oil filter, and then check the oil filter. Replace if frayed or teared. 2. Check the rubber seal. Replace if cracked or worn. 3. Check the hoses. Replace if cracked or damaged.
  • Page 55: Fuel Tank

    Oil tank / Fuel tank Fuel tank (RETURN) (RES) (VENT) (ON) (VENT) 6 N • m (0.6 kgf • m, 4.4 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 1 N •...
  • Page 56: Check Valve Check

    FUEL Fuel system Check valve check 1. Blow into the end a of the check valve, and make sure that airflow from the end b is unrestricted. Replace if the air flow is restricted. 2. Blow into the end b of the check valve, and make sure that airflow from the end a is restricted.
  • Page 57: Carburetor Unit

    Fuel tank / Carburetor unit Carburetor unit 1 N·m (0.1 kgf·m, 0.7 ft·Ib) 18 N·m (1.8 kgf·m, 13.3 ft·Ib) 8 N·m (0.8 kgf·m, 5.9 ft·Ib) 8 N·m (0.8 kgf·m, 5.9 ft·Ib) Part name Q’ty Remarks Fuel cock knob Turn the fuel cock knob to “OFF”. M5 ×...
  • Page 58 FUEL Fuel system 1 N · m (0.1 kgf · m, 0.7 ft · Ib) 18 N · m (1.8 kgf · m, 13.3 ft · Ib) 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 8 N · m (0.8 kgf · m, 5.9 ft · Ib) Part name Q’ty Remarks...
  • Page 59: Choke Cable And Throttle Cable Installation

    Carburetor unit Choke cable and throttle cable installation 1. Install the choke cable 1 and throttle cable 2, and then tighten the nuts to the specified torque. Choke cable and throttle cable guide installation position a: 14.0 ± 1.0 mm (0.55 ± 0.04 in) Choke cable nut b: 8 N·m (0.8 kgf·m, 5.9 ft·lb) Throttle cable nut c:...
  • Page 60 FUEL Fuel system Carburetor and fuel pump 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 1 N • m (0.1 kgf • m, 0.7 ft • Ib) 1 N • m (0.1 kgf • m, 0.7 ft • Ib) 1.8 N •...
  • Page 61 Carburetor and fuel pump 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 1 N • m (0.1 kgf • m, 0.7 ft • Ib) 1 N • m (0.1 kgf • m, 0.7 ft • Ib) 1.8 N •...
  • Page 62 FUEL Fuel system 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 1 N • m (0.1 kgf • m, 0.7 ft • Ib) 1 N • m (0.1 kgf • m, 0.7 ft • Ib) 1.8 N • m (0.18 kgf • m, 1.3 ft • Ib) 4.4 N •...
  • Page 63: Carburetor And Fuel Pump

    Carburetor and fuel pump Diaphragm check 1. Check the diaphragm. Replace if dam- aged. Arm check 1. Check the arm 1. Repair if bent. Replace if damaged. 2. Measure the arm height a. TIP: Always replace the body assy. and valve (clear film) as a set.
  • Page 64: Fuel Pump Check

    FUEL Fuel system TIP: Before disassembling the carburetor, make sure to note the number of times the speed screw is turned in from its set position to the seated position. Fuel pump check 1. Check the fuel pump gasket, diaphragm, fuel pump diaphragm, fuel pump dia- phragm body, and valve seat.
  • Page 65: Carburetor Assy. Check

    Carburetor and fuel pump Carburetor assy. check 1. Adjust the trolling speed. See “Power unit” (3-4). 4-16...
  • Page 66: Oil Pump

    FUEL Fuel system Oil pump 5 N · m (0.5 kgf · m, 3.7 ft · Ib) 8 N · m (0.8 kgf · m, 5.9 ft · Ib) Part name Q’ty Remarks Band Oil hose Hose clamp Oil delivery hose 1 85 mm (3.35 in) Oil delivery hose 1 70 mm (2.76 in)
  • Page 67: Oil Pump Check

    Oil pump Oil pump check 1. Place rags around the air bleed screw 1 to catch any oil that might spill. • If the oil delivery hoses are not full of oil, 2. Fill the oil tank with the recommended oil. fill them up.
  • Page 68 POWR Power unit Engine unit................5-1 Engine mount ..............5-3 Engine unit removal..............5-4 Engine mount check..............5-6 Engine unit installation ............... 5-6 Exhaust ring ..............5-10 Exhaust chamber assy............ 5-11 Exhaust chamber ............. 5-12 Muffler ................5-13 Reed valves ..............5-14 Reed valve check ..............
  • Page 69 Crankcase ................. 5-30 Crankcase check..............5-32 Crankcase installation .............. 5-32 Crankshaft ................ 5-33 Crankshaft check..............5-34...
  • Page 70 POWR Power unit Engine unit 15 N · m (1.5 kgf · m, 11.1 ft · Ib) 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 5 N ·...
  • Page 71: Engine Unit

    Engine unit 15 N·m (1.5 kgf·m, 11.1 ft·Ib) 8 N·m (0.8 kgf·m, 5.9 ft·Ib) 8 N·m (0.8 kgf·m, 5.9 ft·Ib) 5 N·m (0.5 kgf·m, 3.7 ft·Ib) 17 N·m (1.7 kgf·m, 12.5 ft·Ib) Part name Q’ty Remarks M6 × 25 mm Bolt/collar Coupling cover M8 ×...
  • Page 72: Engine Mount

    POWR Power unit Engine mount 17 N · m (1.7 kgf · m, 12.5 ft · Ib) 17 N · m (1.7 kgf · m, 12.5 ft · Ib) Part name Q’ty Remarks M8 × 35 mm Bolt Engine mount Bolt Bracket Bracket...
  • Page 73: Engine Unit Removal

    Engine mount Engine unit removal 6. Remove the band 6, and then discon- nect the cooling water hose 7. Before removing the engine, make sure to take adequate measures to protect the deck opening from damage. 1. Disconnect the negative battery cable, and then disconnect the positive battery cable.
  • Page 74 POWR Power unit 11. Remove the band E, and then discon- 15. Remove the coupling cover L. nect the fuel hose F. 16. Loosen the engine mounting bolts M. TIP: 17. Lift the engine unit slightly, remove the When removing the fuel hose, remove the shims N, and then lower the unit.
  • Page 75: Engine Mount Check

    Engine mount 19. Suspend the engine unit using an engine hangers, and then separate the unit from the engine mounts and move it forward to disconnect the coupling. NOTICE: When removing the engine unit, take care to avoid causing damage to the hull liner and deck opening.
  • Page 76 POWR Power unit 11. Check that the coupling clearances a Clearance a: and b are within specification. Readjust Less than 1.0 mm (0.039 in) (without if out of specification. rubber damper) Clearance b: 2.0–4.0 mm (0.079–0.157 in) Available shim thicknesses: 0.10, 0.30, 0.50, 1.00, and 2.00 mm 5.
  • Page 77 Engine mount 19. Connect the cooling water hose H to Choke cable and throttle cable guide hose joint I. installation position c: 14.0 ± 1.0 mm (0.55 ± 0.04 in) 20. Connect the exhaust hose J. Choke cable nut d: 8 N·m (0.8 kgf·m, 5.9 ft·lb) Throttle cable nut e: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
  • Page 78 POWR Power unit 23. Install the fuse box assy. O, and then tighten the nuts P to the specified torque. 24. Install the band Q. Electrical box nut P: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 25. Install the plastic ties R. 26.
  • Page 79: Exhaust Ring

    Engine mount / Exhaust ring Exhaust ring 2 N·m (0.2 kgf·m, 1.5 ft·Ib) 2 N·m (0.2 kgf·m, 1.5 ft·Ib) 2 N·m (0.2 kgf·m, 1.5 ft·Ib) 29 N·m (2.9 kgf·m, 21.4 ft·Ib) Part name Q’ty Remarks Band/pilot water hose Clamp Clamp M8 ×...
  • Page 80: Exhaust Chamber Assy

    POWR Power unit Exhaust chamber assy. 2 N · m (0.2 kgf · m, 1.5 ft · Ib) 46 N · m (4.6 kgf · m, 33.9 ft · Ib) 2 N · m (0.2 kgf · m, 1.5 ft · Ib) 39 N ·...
  • Page 81: Exhaust Chamber

    Exhaust chamber assy. / Exhaust chamber Exhaust chamber 8 N·m (0.8 kgf·m, 5.9 ft·Ib) 8 N·m (0.8 kgf·m, 5.9 ft·Ib) Part name Q’ty Remarks M6 × 70 mm Bolt Exhaust outer cover 1 Gasket Not reusable Exhaust inner cover Rubber seal Gasket Not reusable M6 ×...
  • Page 82: Muffler

    POWR Power unit Muffler 21 N · m (2.1 kgf · m, 15.5 ft · Ib) 39 N · m (3.9 kgf · m, 28.8 ft · Ib) È Part name Q’ty Remarks Exhaust chamber See “Exhaust chamber assy.” (5-11). È...
  • Page 83 Muffler / Reed valves Reed valves 8 N·m (0.8 kgf·m, 5.9 ft·Ib) 8 N·m (0.8 kgf·m, 5.9 ft·Ib) 1 N·m (0.1 kgf·m, 0.7 ft·Ib) 4 N·m (0.4 kgf·m, 3.0 ft·Ib) Part name Q’ty Remarks Carburetor assy. See “Carburetor unit” (4-8). M6 ×...
  • Page 84: Reed Valve Check

    POWR Power unit Reed valve check 1. Check the reed valves. Replace if cracked or damaged. 2. Measure the valve warpage a. Replace if out of specification. Valve warpage limit: 0.2 mm (0.01 in) 3. Measure the valve stopper height b. Replace if out of specification.
  • Page 85: Cylinder Head

    Reed valves / Cylinder head Cylinder head 15 N·m (1.5 kgf·m, 11.1 ft·Ib) 29 N·m (2.9 kgf·m, 21.4 ft·Ib) 25 N·m (2.5 kgf·m, 18.4 ft·Ib) 8 N·m (0.8 kgf·m, 5.9 ft·Ib) Part name Q’ty Remarks Exhaust chamber assy. See “Exhaust chamber assy.” (5-11). M6 ×...
  • Page 86: Cylinder Head Check

    POWR Power unit Cylinder head check TIP: Place 400–600 grit wet sandpaper on a sur- face plate and resurface the cylinder head Do not use a sharp instrument to avoid using a figure-eight sanding pattern. damaging or scratching the cylinder head or spark plug bore threads.
  • Page 87: Cylinder

    Cylinder head / Cylinder Cylinder 3 N·m (0.3 kgf·m, 2.2 ft·Ib) 22 N·m (2.2 kgf·m, 16.2 ft·Ib) 39 N·m (3.9 kgf·m, 28.8 ft·Ib) Part name Q’ty Remarks Cylinder head See “Cylinder head” (5-16). M10 × 40 mm Bolt M10 × 55 mm Bolt Cylinder Gasket...
  • Page 88: Cylinder Check

    POWR Power unit Cylinder check 1. Eliminate the carbon deposits (using a rounded scraper 1). 2. Check the cylinder water jacket. Clean or replace the cylinder if there is corrosion or mineral deposits. 3. Check cylinder inner surface. Replace if there are score marks. Standard Limit 81.000–...
  • Page 89 Cylinder Cylinder bolt: 1st: 22 N·m (2.2 kgf·m, 16.2 ft·lb) 2nd: 39 N·m (3.9 kgf·m, 28.8 ft·lb) 5-20...
  • Page 90 POWR Power unit Pistons Part name Q’ty Remarks Cylinder See “Cylinder” (5-18). Piston pin clip Not reusable Piston pin a Arrow mark Piston Washer Bearing Piston ring 5-21...
  • Page 91: Pistons

    Pistons Piston pin clip removal and Piston ring check installation 1. Measure the side clearance (using a thickness gauge 1). Replace the piston TIP: and piston rings as a set if out of specifi- Before removing or installing the piston pin cation.
  • Page 92: Piston Pin And Bearing Check

    POWR Power unit Piston pin and bearing check 1. Check the piston pins and bearings. Replace if there are signs of heat discol- oration. 2. Measure the piston pin outside diameter (using a micrometer 1). Replace if out of specification. Piston installation Align each end gap with its respective locating pin.
  • Page 93 Pistons TIP: • Install the piston with the arrow a facing towards the exhaust port. • Do not align the open end of the clip with the piston pin slot b. 5-24...
  • Page 94: Flywheel Magneto And Base Assy

    POWR Power unit Flywheel magneto and base assy. 36 N · m (3.6 kgf · m, 26.6 ft · Ib) 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 74 N · m (7.4 kgf · m, 54.6 ft · Ib) 1207D 1207D 18 N ·...
  • Page 95 Flywheel magneto and base assy. 36 N·m (3.6 kgf·m, 26.6 ft·Ib) 8 N·m (0.8 kgf·m, 5.9 ft·Ib) 74 N·m (7.4 kgf·m, 54.6 ft·Ib) 1207D 1207D 18 N·m (1.8 kgf·m, 13.3 ft·Ib) 5 N·m (0.5 kgf·m, 3.7 ft·Ib) 8 N·m (0.8 kgf·m, 5.9 ft·Ib) Part name Q’ty Remarks...
  • Page 96 POWR Power unit Starter clutch assy. Part name Q’ty Remarks Clip Not reusable Clip stopper Spring seat Spring Washer Idle gear Circlip Plate Weight Spring ring Pinion gear 5-27...
  • Page 97: Drive Coupling Removal And Installation

    Starter clutch assy. Drive coupling removal and Flywheel magneto bolt: installation 74 N·m (7.4 kgf·m, 54.6 ft·lb) 1. Remove the drive coupling. TIP: Install the bolt with the same special service tool that was used for removal. 2. Remove the flywheel magneto. NOTICE: To prevent damage to the engine or special service tools, screw in the fly- wheel puller set bolts evenly and com-...
  • Page 98: Starter Clutch Assy. Check

    POWR Power unit Starter clutch assy. check 1. Check the pinion gear 1. Replace if damaged or worn. 2. Check the idle gear 2. Replace if dam- aged or worn. 3. Check the gear movement. Replace the defective part(s) if there is rough move- ment.
  • Page 99: Crankcase

    Starter clutch assy. / Crankcase Crankcase 23 N·m (2.3 kgf·m, 17.0 ft·Ib) 52 N·m (5.2 kgf·m, 38.4 ft·Ib) 23 N·m (2.3 kgf·m, 17.0 ft·Ib) 52 N·m (5.2 kgf·m, 38.4 ft·Ib) 15 N·m (1.5 kgf·m, 11.1 ft·Ib) 27 N·m (2.7 kgf·m, 19.9 ft·Ib) Part name Q’ty Remarks...
  • Page 100 POWR Power unit 23 N · m (2.3 kgf · m, 17.0 ft · Ib) 52 N · m (5.2 kgf · m, 38.4 ft · Ib) 23 N · m (2.3 kgf · m, 17.0 ft · Ib) 52 N · m (5.2 kgf · m, 38.4 ft · Ib) 15 N ·...
  • Page 101: Crankcase Check

    Crankcase Crankcase check TIP: 1. Check the mating surfaces. Replace the Be sure that the “F” mark a is on the fly- crankcase if scratched. wheel magneto side. Crankcase installation 1. Apply the Gasket Maker (to the crank- case mating surfaces). TIP: Before applying Gasket Maker, clean the crankcase mating surfaces.
  • Page 102: Crankshaft

    POWR Power unit Crankshaft Part name Q’ty Remarks Crankcase See “Crankcase” (5-30). Oil seal Not reusable Bearing Oil seal 1 Not reusable Drive shaft collar Bearing clip Bearing 2 Crankshaft assy. 5-33...
  • Page 103: Crankshaft Check

    Crankshaft 4. Measure small end free play d (using a Crankshaft check 1. Measure the crank width a. Replace if dial gauge). Replace if out of specifica- tion. out of specification. Maximum small end axial play d: Crank width a: 2.000 mm (0.0787 in) 61.950–62.000 mm (2.4390–2.4409 5.
  • Page 104 POWR Power unit — MEMO — 5-35...
  • Page 105 PUMP Jet pump unit Intake grate and ride plate..........6-1 Jet pump unit..............6-2 Jet pump unit removal ..............6-4 Jet pump unit installation............6-4 Jet thrust nozzle, impeller duct, and impeller housing ............6-5 Impeller duct and drive shaft ..........6-6 Drive shaft removal ..............
  • Page 106: Intake Grate And Ride Plate

    PUMP Jet pump unit Intake grate and ride plate 17 N · m (1.7 kgf · m, 12.5 ft · Ib) 4 N · m (0.4 kgf · m, 3.0 ft · Ib) 40 N · m (4.0 kgf · m, 29.5 ft · Ib) 8 N ·...
  • Page 107 Intake grate and ride plate / Jet pump unit Jet pump unit 7 N·m (0.7 kgf·m, 5.2 ft·Ib) 14 N·m (1.4 kgf·m, 10.3 ft·Ib) 17 N·m (1.7 kgf·m, 12.5 ft·Ib) 2 N·m (0.2 kgf·m, 1.5 ft·Ib) 1 N·m (0.1 kgf·m, 0.7 ft·Ib) 40 N·m (4.0 kgf·m, 29.5 ft·Ib) 8 N·m (0.8 kgf·m, 5.9 ft·Ib) 6.8 N·m (0.68 kgf·m, 4.9 ft·Ib)
  • Page 108 PUMP Jet pump unit 7 N · m (0.7 kgf · m, 5.2 ft · Ib) 14 N · m (1.4 kgf · m, 10.3 ft · Ib) 17 N · m (1.7 kgf · m, 12.5 ft · Ib) 2 N ·...
  • Page 109: Jet Pump Unit Removal

    Jet pump unit Jet pump unit removal Make sure to remove the battery before removing the jet pump unit. 1. Remove the jet pump unit 1. 3. Install the jet pump unit 1, and then tighten the bolts 3, 4, and 5 to the specified torques.
  • Page 110: Jet Thrust Nozzle, Impeller Duct, And Impeller Housing

    PUMP Jet pump unit Jet thrust nozzle, impeller duct, and impeller housing 40 N · m (4.0 kgf · m, 29.5 ft · Ib) 15 N · m (1.5 kgf · m, 11.1 ft · Ib) 40 N · m (4.0 kgf · m, 29.5 ft · Ib) 7 N ·...
  • Page 111: Impeller Duct And Drive Shaft

    Jet thrust nozzle, impeller duct, and impeller housing / Impeller duct and drive shaft Impeller duct and drive shaft Part name Q’ty Remarks M6 × 20 mm Bolt O-ring Not reusable Impeller Drive shaft Oil seal Not reusable Oil seal Not reusable Rear bearing Not reusable...
  • Page 112: Drive Shaft Removal

    PUMP Jet pump unit Drive shaft removal 1. Remove the impeller. Stopper guide plate: 90890-06501 Bearing puller assembly: 90890-06535 Stopper guide stand: 90890-06538 4. Remove the oil seals. Crankshaft holder 20: 90890-06552 TIP: Hold the impeller duct assy. in a vise between two aluminum plates a.
  • Page 113: Impeller Housing Check

    Impeller duct and drive shaft Impeller housing check Driver rod LS: 90890-06606 1. Measure the impeller housing inside Ball bearing attachment: 90890-06634 diameter a. Replace if out of specifica- tion. Distance a: 4.6 ± 0.2 mm (0.18 ± 0.01 in) 2.
  • Page 114 PUMP Jet pump unit Quantity: 20 g (0.7 oz) 5. Install the front bearing. Quantity: 20 g (0.7 oz) 8. Install the impeller. TIP: Press the spacer and the front bearing using a pipe of the proper size [more than 60 mm (2.36 in) long and that has an inner diameter more than 24 mm (0.94 in)].
  • Page 115: Transom Plate And Hoses

    Impeller duct and drive shaft / Transom plate and hoses Transom plate and hoses 26 N·m (2.6 kgf·m, 19.2 ft·Ib) 5.5 N·m (0.55 kgf·m, 4.0 ft·Ib) Part name Q’ty Remarks Exhaust system See “Exhaust system” (8-23). Jet pump unit assy. See “Jet pump unit”...
  • Page 116: Bilge Strainer Check

    PUMP Jet pump unit Bilge strainer check See “Hull and hood” (3-9). Bilge hose check 1. Check the bilge hoses. Replace if cracked or damaged. Cooling water hose check 1. Check the cooling water hoses. Replace if cracked or damage. 6-11...
  • Page 117: Bearing Housing

    Transom plate and hoses / Bearing housing Bearing housing 17 N·m (1.7 kgf·m, 12.5 ft·Ib) 4 N·m (0.4 kgf·m, 3.0 ft·Ib) 7 N·m (0.7 kgf·m, 5.2 ft·Ib) Part name Q’ty Remarks Engine unit See “Engine unit” (5-1). Rubber coupling M8 × 48 mm Bolt Intermediate housing cover Clamp...
  • Page 118: Intermediate Drive Shaft Assy

    PUMP Jet pump unit Intermediate drive shaft assy. Part name Q’ty Remarks Driven coupling Washer Damper Intermediate drive shaft extension Intermediate drive shaft Circlip Not reusable Oil seal Not reusable Bearing Not reusable Oil seal Not reusable Oil seal Not reusable Bearing housing 6-13...
  • Page 119: Joint Removal

    Intermediate drive shaft assy. Joint removal Do not touch the joint or adhesive that was heated by the heat gun with your bare hands; they will be very hot and could cause burns. 1. Set a heat gun 1 to 350 °C (662 °F) and use it for about 20 minutes to heat the joint and adhesive.
  • Page 120: Driven Coupling Removal And Installation

    PUMP Jet pump unit TIP: Drive shaft holder 5: 90890-06519 • Remove any adhesive that is protruding in or around the hole for the intermediate Width a: 27 mm (1.06 in) drive shaft. • After installing the joint, allow the adhesive TIP: to harden for at least 24 hours before plac- •...
  • Page 121: Driven Coupling Check

    Intermediate drive shaft assy. Distance a: Driver rod LS: 90890-06606 6.2 ± 0.2 mm (0.24 ± 0.01 in) Bearing outer race attachment: 90890-06628 Intermediate drive shaft installation 1. Install the intermediate drive shaft. TIP: Remove the bearing and oil seals using a press.
  • Page 122 PUMP Jet pump unit Intermediate drive shaft extension: 36 N·m (3.6 kgf·m, 26.6 ft·lb) TIP: Fit a wrench into the notches in the interme- diate drive shaft extension. 6-17...
  • Page 123 – ELEC Electrical system Electrical components ............7-1 Electrical box ..............7-2 Electrical analysis .............. 7-5 To measure the peak voltage............. 7-5 Ignition system ..............7-5 Ignition coil ................. 7-5 CDI unit ..................7-6 CDI unit resistance ..............7-6 Charge coil ................. 7-7 Pickup coil ..................
  • Page 124: Electrical System

    – ELEC Electrical system Electrical components 1 Multifunction meter 8 Lighting coil, pickup coil, and charge coil 2 Oil level sensor 9 Fuel level sensor 3 Spark plugs 0 Left handlebar switch assy. (Engine stop 4 Electrical box (rectifier regulator, CDI unit, switch, engine shut-off switch, and start starter relay, and ignition coil) switch)
  • Page 125 Electrical components / Electrical box Electrical box 17 N·m (1.7 kgf·m, 12.5 ft·Ib) 4 N·m (0.4 kgf·m, 3.0 ft·Ib) 4 N·m (0.4 kgf·m, 3.0 ft·Ib) 15 N·m (1.5 kgf·m, 11.1 ft·Ib) 3 N·m (0.3 kgf·m, 2.2 ft·Ib) 4 N·m (0.4 kgf·m, 3.0 ft·Ib) 4 N·m (0.4 kgf·m, 3.0 ft·Ib) Part name Q’ty...
  • Page 126 – ELEC Electrical system 17 N · m (1.7 kgf · m, 12.5 ft · Ib) 4 N · m (0.4 kgf · m, 3.0 ft · Ib) 4 N · m (0.4 kgf · m, 3.0 ft · Ib) 15 N ·...
  • Page 127: Electrical Box

    Electrical box Br/W È É Ì Ë Ê Ì To starter motor 1 CDI unit 2 Rectifier regulator 3 Spark plug wires : Black 4 Ignition coil : Brown 5 Starter relay : Green 6 Fuse holder : Orange : Pink È...
  • Page 128: Electrical Analysis

    – ELEC Electrical system Electrical analysis TIP: To measure the peak voltage • Before measuring the peak voltage, check all wiring for proper connection and corro- sion, and check that the battery is fully When measuring the peak voltage, do not charged.
  • Page 129: Cdi Unit

    Electrical analysis / Ignition system Secondary coil resistance at 20 °C (68 °F) (reference data): Spark plug cap – Spark plug cap 14.336–30.464 kΩ CDI unit CDI unit output peak voltage 1. Measure the CDI unit output peak volt- age. 2.
  • Page 130: Charge Coil

    – ELEC Electrical system Br/W Br/W [kΩ] È Br/W 10– 150– 3–11 2–6 Br/W ∞ ∞ ∞ ∞ ∞ ∞ Charge coil output peak voltage: 10– 150– É 3–11 2–6 Brown/White (Br/W) – Black (B) 50– 10– 17– Unloaded Loaded W/R 9–36 9–36 r/min...
  • Page 131: Pickup Coil

    Ignition system Pickup coil Pickup coil resistance at 20 °C (68 °F) Pickup coil output peak voltage (reference data): 1. Measure the pickup coil output peak volt- White/Red (W/R) – Black (B) age. 12.6–15.4 Ω 2. Measure the pickup coil resistance if Thermoswitch below specification.
  • Page 132: Charging System

    – ELEC Electrical system Charging system Lighting coil resistance at 20 °C (68 °F) Lighting coil (reference data): Lighting coil output peak voltage Green (G) – Green (G) 1. Disconnect the lighting coil connectors. 1.143–1.397 Ω 2. Measure the lighting coil output peak Rectifier regulator voltage.
  • Page 133: Starting System

    Charging system / Starting system [kΩ] È È ∞ ∞ ∞ 2–20 1–10 1–10 É É 1–10 2–15 3–30 1–10 2–15 3–30 Engine start switch continuity: È Tester lead + Engine start Red (R) – É Tester lead - Clip 1 switch 2 Brown (Br) Free...
  • Page 134: Starter Relay

    – ELEC Electrical system Starter relay 1. Connect the tester leads between the starter relay terminals 1 and 2. 2. Connect the positive battery lead to the terminal a, and the negative battery lead to the terminal b. 3. Check the continuity between the starter relay terminals 1 and 2.
  • Page 135: Starter Motor

    Starting system / Starter motor Starter motor 5 N·m (0.5 kgf·m, 3.7 ft·Ib) 6 N·m (0.6 kgf·m, 4.4 ft·Ib) Part name Q’ty Remarks O-ring Not reusable M5 × 114 mm Bolt Front cover assy. O-ring Not reusable Washer set Rear cover assy. Armature Brush holder assy.
  • Page 136: Starter Motor Operation

    – ELEC Electrical system Starter motor operation 1. Hold the starter motor in a vise using alu- minum plates on both sides. 2. Connect the positive battery cable to the starter motor terminal bolt. 3. Connect the negative battery cable to the starter motor body, and then check the starter motor operation.
  • Page 137: Front And Rear Cover

    Starter motor Armature continuity: Commutator Continuity segments a Segment a – No continuity Armature core b Segment a – No continuity Armature shaft c Front and rear cover 1. Check the front cover oil seal. Replace the front cover if damaged or worn. 2.
  • Page 138: Indication System

    – ELEC Electrical system 5. Replace or repair the wiring harness if there is no continuity. 6. Replace the multifunction meter if there is continuity. Hour meter operation 1. Check the hour meter display. 2. Replace the multifunction meter if it does not operate correctly.
  • Page 139: Engine Overheat Warning Indicator

    Indication system 3. Replace the fuel level sensor if out of specification. Buzzer 1. Connect the positive battery lead to the terminal 1 and the negative battery lead Float position Resistance (Ω) to the terminal 2. 757.0–803.0 0–8 2. Check that the buzzer sounds. Replace the buzzer if does not sound.
  • Page 140 HULL HOOD Hull and hood Steering pad and handlebar cover ........8-1 Handlebar and handlebar switch assy......8-2 Left handlebar switch assy. and throttle lever assy..8-3 Throttle cable removal..............8-4 Handlebar check ................ 8-4 Left handlebar switch assy. check..........8-4 Handlebar assy.
  • Page 141 Deck and hull ..............8-25 Rear section..............8-27 Drain plug check............... 8-29 Spout installation ..............8-29...
  • Page 142 HULL HOOD Hull and hood Steering pad and handlebar cover 1 N · m (0.1 kgf · m, 0.7 ft · Ib) 1 N · m (0.1 kgf · m, 0.7 ft · Ib) 4 N · m (0.4 kgf · m, 3.0 ft · Ib) Part name Q’ty Remarks...
  • Page 143 Steering pad and handlebar cover / Handlebar and handlebar switch assy. Handlebar and handlebar switch assy. 1 N·m (0.1 kgf·m, 0.7 ft·Ib) 3 N·m (0.3 kgf·m, 2.2 ft·Ib) 20 N·m (2.0 kgf·m, 14.8 ft·Ib) 3 N·m (0.3 kgf·m, 2.2 ft·Ib) Part name Q’ty Remarks...
  • Page 144: Left Handlebar Switch Assy. And Throttle Lever Assy

    HULL HOOD Hull and hood Left handlebar switch assy. and throttle lever assy. Part name Q’ty Remarks Left handlebar switch assy. Engine shut-off cord Stop button assy. Start button assy. Screw Throttle lever assy. E-ring Washer Shaft Lever Spring...
  • Page 145 Left handlebar switch assy. and throttle lever assy. Throttle cable removal 1. Remove the corrugated tube 1. TIP: Face the chamfered end b of the grommet 2. Remove the throttle cable 2. NOTICE: 2 down, with the opening a facing forward. Make sure to remove the throttle cable seal a.
  • Page 146 HULL HOOD Hull and hood 5. Install the left handlebar switch assy. 0, and then tighten the screws A to the specified torque. < Handlebar holder bolt 7: 20 N·m (2.0 kgf·m, 14.8 ft·lb) TIP: Left handlebar switch screw A: •...
  • Page 147 Left handlebar switch assy. and throttle lever assy. 10. Tighten the locknut B, and then slide the rubber cover C to its original position. Grip end bolt G: 1 N·m (0.1 kgf·m, 0.7 ft·lb) Throttle lever free play p: Steering pad and handlebar cover 4.0–7.0 mm (0.16–0.28 in) installation 11.
  • Page 148 HULL HOOD Hull and hood TIP: If the steering pad 3 is not installed securely, the upper handlebar cover 4 cannot be installed properly onto the lower handlebar cover. 3. Install the upper handlebar cover 4, and then tighten the screws 5 and 6 to the specified torque.
  • Page 149 Left handlebar switch assy. and throttle lever assy. / Front hood Front hood 7 N·m (0.7 kgf·m, 5.2 ft·Ib) 4 N·m (0.4 kgf·m, 3.0 ft·Ib) 2 N·m (0.2 kgf·m, 1.5 ft·Ib) 7 N·m (0.7 kgf·m, 5.2 ft·Ib) 7 N·m (0.7 kgf·m, 5.2 ft·Ib) Part name Q’ty Remarks...
  • Page 150 HULL HOOD Hull and hood 7 N · m (0.7 kgf · m, 5.2 ft · Ib) 4 N · m (0.4 kgf · m, 3.0 ft · Ib) 2 N · m (0.2 kgf · m, 1.5 ft · Ib) 7 N ·...
  • Page 151 Front hood Service lid installation Hinge assy. check 1. Install the service lid 1, and then insert a 1. Fully open the front hood and check that rivet completely in the holes in both the it remains in the open position. If the front service lid 1 and inner hull 2.
  • Page 152 HULL HOOD Hull and hood Multifunction meter and engine hatch cover 4 N · m (0.4 kgf · m, 3.0 ft · Ib) 5 N · m (0.5 kgf · m, 3.7 ft · Ib) 5 N · m (0.5 kgf · m, 3.7 ft · Ib) Part name Q’ty Remarks...
  • Page 153 Multifunction meter and engine hatch cover 4 N·m (0.4 kgf·m, 3.0 ft·Ib) 5 N·m (0.5 kgf·m, 3.7 ft·Ib) 5 N·m (0.5 kgf·m, 3.7 ft·Ib) Part name Q’ty Remarks Lid lock hook Revet Plug 8-12...
  • Page 154 HULL HOOD Hull and hood Steering master assy. 17 N · m (1.7 kgf · m, 12.5 ft · Ib) 7 N · m (0.7 kgf · m, 5.2 ft · Ib) Part name Q’ty Remarks Buzzer coupler Steering cable joint M6 ×...
  • Page 155 Steering master assy. / Steering master Steering master 7 N·m (0.7 kgf·m, 5.2 ft·Ib) 4 N·m (0.4 kgf·m, 3.0 ft·Ib) 7 N·m (0.7 kgf·m, 5.2 ft·Ib) 16 N·m (1.6 kgf·m, 11.8 ft·Ib) 7 N·m (0.7 kgf·m, 5.2 ft·Ib) Part name Q’ty Remarks M8 ×...
  • Page 156: Shift Lever Assy. Check

    HULL HOOD Hull and hood Shift lever assy. check 1. Check the shift lever assy. Replace if cracked or damaged. NOTICE: Do not disassemble the shift lever assy. Bushing check 1. Check the bushing. Replace if cracked, damaged, or worn. Steering arm assy.
  • Page 157 Steering master / Steering cable Steering cable 5.9 N·m (0.59 kgf·m, 4.4 ft·Ib) 7 N·m (0.7 kgf·m, 5.2 ft·Ib) 7 N·m (0.7 kgf·m, 5.2 ft·Ib) Part name Q’ty Remarks Service lid See “Front hood” (8-8). Seat assy. See “Seat and handgrip” (8-18). Ride plate/rubber plate See “Intake grate and ride plate”...
  • Page 158: Steering Cable Installation (Jet Pump End)

    HULL HOOD Hull and hood Steering cable installation (steering master end) If a cable becomes damaged, replace it. Never attempt to repair damaged cable. 1. Install the steering cable 1 and steering cable stopper 2, and then tighten the bolt 3 to the specified torque. Steering cable set length a (jet pump end): 14.5 ±...
  • Page 159 Steering cable / Seat and handgrip Seat and handgrip 6 N·m (0.6 kgf·m, 4.4 ft·Ib) 26 N·m (2.6 kgf·m, 19.2 ft·Ib) 5 N·m (0.5 kgf·m, 3.7 ft·Ib) Part name Q’ty Remarks Seat assy. M6 × 40 mm Bolt Seat lock assy. Packing Not reusable Washer...
  • Page 160 HULL HOOD Hull and hood Ventilation hose and water separator È 4 N · m (0.4 kgf · m, 3.0 ft · Ib) 15 N · m (1.5 kgf · m, 11.1 ft · Ib) Part name Q’ty Remarks Oil filler neck See “Oil tank”...
  • Page 161 Ventilation hose and water separator È 4 N·m (0.4 kgf·m, 3.0 ft·Ib) 15 N·m (1.5 kgf·m, 11.1 ft·Ib) Part name Q’ty Remarks Rivet Not reusable Ventilation socket Ventilation pipe Plastic tie Seal Not reusable Clamp Cooling water pilot outlet È To exhaust joint Cooling water hose Plastic tie Band...
  • Page 162: Seat Lock Check

    HULL HOOD Hull and hood Seat lock check 1. Check the seat lock assy. Replace if cracked, damaged, or worn. 2. Check the projection. Replace if dam- aged. Check valve check 1. Blow into the end “A” of the check valve, and make sure that airflow from the end “B”...
  • Page 163 Ventilation hose and water separator Cooling water pilot outlet nut 3: 4 N·m (0.4 kgf·m, 3.0 ft·lb) TIP: Align the projection a with the slit b. Installation distance a: 30–40 mm (1.18–1.57 in) Ventilation hose installation TIP: 1. Install the grommets 1. •...
  • Page 164 HULL HOOD Hull and hood Exhaust system 5 N · m (0.5 kgf · m, 3.7 ft · Ib) 5 N · m (0.5 kgf · m, 3.7 ft · Ib) Part name Q’ty Remarks Ride plate See “Intake grate and ride plate” (6-1). Band Clamp Water lock...
  • Page 165 Exhaust system Exhaust system check 1. Check the rubber hoses. Replace if burned, cracked, or damaged. 2. Check the water lock. Replace if cracked, damaged, or leaked. 8-24...
  • Page 166 HULL HOOD Hull and hood Deck and hull 15 N · m (1.5 kgf · m, 11.1 ft · Ib) 7 N · m (0.7 kgf · m, 5.2 ft · Ib) 13 N · m (1.3 kgf · m, 9.6 ft · Ib) Part name Q’ty Remarks...
  • Page 167 Deck and hull 15 N·m (1.5 kgf·m, 11.1 ft·Ib) 7 N·m (0.7 kgf·m, 5.2 ft·Ib) 13 N·m (1.3 kgf·m, 9.6 ft·Ib) Part name Q’ty Remarks Collar Sponson Rivet Not reusable Fuel cock cover Rivet Not reusable Choke cover 8-26...
  • Page 168 HULL HOOD Hull and hood Rear section 15 N · m (1.5 kgf · m, 11.1 ft · Ib) 5 N · m (0.5 kgf · m, 3.7 ft · Ib) 2 N · m (0.2 kgf · m, 1.5 ft · Ib) 15 N ·...
  • Page 169 Rear section 15 N·m (1.5 kgf·m, 11.1 ft·Ib) 5 N·m (0.5 kgf·m, 3.7 ft·Ib) 2 N·m (0.2 kgf·m, 1.5 ft·Ib) 15 N·m (1.5 kgf·m, 11.1 ft·Ib) 2 N·m (0.2 kgf·m, 1.5 ft·Ib) Part name Q’ty Remarks ø5 × 25 mm Screw Packing Not reusable...
  • Page 170 HULL HOOD Hull and hood Drain plug check 1. Check the drain plug 1 and O-ring 2. Replace if cracked or damaged. Spout installation 1. Install the spout 1, and then tighten the nut 2 to the specified torque. 2. Install the hose 3, and then tighten the clamp 4 to the specified torque.
  • Page 171: Trbl Shtg

    TRBL SHTG Troubleshooting Engine unit troubleshooting ..........9-1 Troubleshooting (engine unit, jet pump unit, charging system)......9-1...
  • Page 172 TRBL SHTG Troubleshooting Engine unit troubleshooting TIP: • Before troubleshooting the engine unit, make sure that fresh fuel of the specified type has been used. • Check that all wiring connections are properly secured and that they are not rusty or corroded. •...
  • Page 173 Engine unit troubleshooting Symptom 1: Engine will not start (engine cranks). Symptom 2 Cause Checking step page Throttle valve does Throttle cable installed Adjust the throttle lever free play. not move properly incorrectly Throttle valve malfunction Check the carburetor. 4-14 Discharged battery Battery performance Check the battery voltage and spe-...
  • Page 174 TRBL SHTG Troubleshooting Symptom 2 Cause Checking step page Fuel not supplied (all Fuel leakage Check the fuel hose. cylinders) Clogged fuel filter Replace the fuel filter. Fuel pump malfunction Check the fuel pump onto the car- 4-14 buretor. Improper low speed screw Adjust the low speed screw.
  • Page 175 Engine unit troubleshooting Symptom 2 Cause Checking step page Compression pres- Compression leakage Measure the compression pres- sure is low sure. Check the cylinder head gasket 5-17 and cylinder head warpage. Check the piston and piston ring for 5-22 damage. Check the cylinder for damage.
  • Page 176 TRBL SHTG Troubleshooting Symptom 1: Poor performance Symptom 2 Cause Checking step page Watercraft cannot Jet pump unit malfunction Check the impeller, impeller duct, reach high speeds and intake grate. Water entered hull Check the drain plugs and O-rings 8-29 for damage.
  • Page 177 Appendix Wiring diagram ................A-1...
  • Page 178: Wiring Diagram

    Wiring diagram VX 700 Color code 1 Thermoswitch : Black 2 Base assy. (Lighting coil, pickup coil, charge coil) : Brown 3 Starter motor : Green 4 Oil level sensor : Blue 5 Fuel level sensor : Orange 6 Multifunction meter : Pink 7 Buzzer : Red...
  • Page 180 YAMAHA MOTOR CO., LTD. Sep. 2010 – ** × 1 CR...
  • Page 181 VX700 PULL...

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Waverunner vx 700 f2v