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Yamaha WaveRunner GP800R Service Manual

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*LIT186160226*
LIT-18616-02-26
WaveRunner
GP800R
SERVICE MANUAL
F0W-28197-1A-11

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  • Page 1 WaveRunner GP800R SERVICE MANUAL *LIT186160226* LIT-18616-02-26 F0W-28197-1A-11...
  • Page 2 NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equip- ment. It has been written to suit the needs of persons who have a basic understanding of the...
  • 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 watercraft.
  • Page 5 HOW TO USE THIS MANUAL 1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 2 Numbers are given in the order of the jobs in the exploded diagram. 3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
  • Page 6 F Apply YAMALUBE 2-W oil or TC-W3 cirtified outboard 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 9: 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 10: 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: F0W: 800101– ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the cylinder head.
  • Page 11: 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. Gasoline vapor is explosive if ignited. Do not smoke while handling gasoline (petrol) and keep it away from heat, sparks, and open flames.
  • Page 12: 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 13: 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 14: 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 15: 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 17 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 18: Specifications

    SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Item Unit GP800R 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) 268 (591) Watercraft capacity PERFORMANCE Maximum output kW (PS) @ r/min 88.2 (120) @ 7,000 R/h (US gal/h,...
  • Page 19 SPEC GENERAL SPECIFICATIONS Model Item Unit GP800R FUEL AND OIL Fuel Regular unleaded gasoline Fuel rating PON* RON* YAMALUBE 2-W or an equivalent TC-W3 certified outboard oil Fuel/oil mixing ratio 30:1 (wide open throttle) Fuel tank capacity R(US gal, 60 (15.9, 13.2) Imp gal) R(US gal, Fuel tank reserve capacity...
  • Page 20: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model Item Unit GP800R CYLINDER HEAD Warpage limit mm (in) 0.1 (0.004) Compression pressure kPa (kg/cm 560 (5.6) 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) Wear limit mm (in)
  • Page 21: Jet Pump Unit

    SPEC MAINTENANCE SPECIFICATIONS Model Item Unit GP800R CRANKSHAFT ASSEMBLY Crank width A mm (in) 72.95–73.00 (2.872–2.874) Deflection limit B mm (in) 0.05 (0.002) Big end side clearance C mm (in) 0.25–0.75 (0.010–0.030) Maximum small end axial mm (in) 2.0 (0.08) play D CARBURETORS Type...
  • Page 22: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model Item Unit GP800R BATTERY Type Fluid Capacity V/Ah (kC) 12/19 (68.4) CDI UNIT (O – B) Output peak voltage lower limit @cranking 1 @cranking 2 @2,000 r/min @3,500 r/min STATOR Charge coil (Br – L) Output peak voltage lower limit @cranking 1...
  • Page 23 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit GP800R RECTIFIER/REGULATOR (R – B) Output peak voltage lower limit (unloaded) @cranking @2,000 r/min 12.5 @3,500 r/min 12.5 THERMO SWITCH On temperature ˚C (˚F) 80 (177) Off temperature ˚C (˚F) 70 (159) STARTER MOTOR Brush length mm (in) 12.5 (0.49)
  • Page 24: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb ENGINE UNIT Engine unit – engine mount Bolt Bolt Bolt Exhaust chamber assembly – muffler stay 1 – muffler stay 3 Bolt Bolt 10th...
  • Page 25 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Drive coupling – crankshaft Drive assembly coupling Generator cover – Bolt crankcase Pickup coil – generator cover Bolt Cable holder – generator cover Bolt Stator coil –...
  • Page 26 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Handlebar switch assembly – Screw handlebar QSTS grip assembly – handlebar Screw Grip end – handlebar Bolt Choke lever assembly – Screw handlebar QSTS cable housing –...
  • Page 27: General Torque

    SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Hand grip – deck Seat bracket – deck Battery box/stay – holder Battery box – bracket/deck Battery box – electrical box Bolt Extension bolt – battery negative Bolt terminal Exhaust outlet –...
  • Page 28: Cable And Hose Routing

    SPEC CABLE AND HOSE ROUTING CABLE AND HOSE ROUTING 20˚ 1 Fuel filter 9 Speed sensor lead G Battery breather hose 2 Fuel tank breather hose 0 Electrical box lead H Battery positive lead 3 Fuel hose A YPVS cables I Starter motor lead 4 Cooling water hose B Cooling water pilot outlet...
  • Page 29 SPEC CABLE AND HOSE ROUTING 1 Oil delivery hose 9 Bilge hoses F To thermoswitch 2 Fuel return hose 0 To multifunction meter G Battery negative lead 3 Fuel suction hose A To stator assembly H Buzzer lead 4 Speed sensor lead B To cylinder #1 I Choke cable 5 QSTS cable...
  • Page 31 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 32: 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 33: 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 34: 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 N • m (0.6 kgf • m, 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 35: 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 36: 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 37: Ypvs Cable Adjustment

    INSP CONTROL SYSTEM NOTE: If the QSTS cable cannot be properly adjusted at the QSTS converter side, make sure the QSTS cable at the jet pump side is set to the specified length. Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD” in chapter 8. YPVS cable adjustment 1.
  • Page 38: Fuel System

    INSP CONTROL SYSTEM/FUEL SYSTEM 3. Adjust: YPVS cables 1 and 2 Adjustment steps: Loosen locknuts 1 and 2. Turn in adjusters 3 and 4 until there is slack in the cables. Align the hole a in the pulley with the hole in the cylinder.
  • Page 39: 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: 1,300 ± 50 r/min Checking steps (with the watercraft in the water): Start the engine and allow it to warm...
  • Page 40: Oil Injection System

    INSP OIL INJECTION SYSTEM/POWER UNIT OIL INJECTION SYSTEM Oil line inspection 1. Inspect: Oil filter Contaminants → Clean. Frays/tears → Replace. Rubber seal Cracks/wear → Replace. Oil hoses Oil tank Oil filler cap Cracks/damage → Replace. Check valve Malfunction → Replace. CAUTION: Do not allow the oil tank to become com- pletely empty.
  • Page 41: Electrical

    INSP POWER UNIT/ELECTRICAL 3. Measure: Spark plug gap a Out of specification → Regap. Spark plug gap: 0.7–0.8 mm (0.028–0.031 in) 4. Tighten: Spark plug Spark plug: 25 N • m (2.5 kgf • m, 18 ft • lb) NOTE: Before installing the spark plug, clean the gasket surface and spark plug surface.
  • Page 42 INSP ELECTRICAL Antidote (INTERNAL): Drink large quantities of water or milk fol- lowed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention. 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).
  • Page 43 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 44: Jet Pump Unit

    INSP ELECTRICAL/JET PUMP UNIT 5. Install: Battery breather hose 1 Battery Battery positive lead 2 Battery negative lead 3 (with termi- nal extension at battery negative ter- minal) Band CAUTION: Connect the positive lead to the battery terminal first. Make sure the battery leads are con- nected properly.
  • Page 45: 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 46: 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 47 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 48 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 50 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 51 FUEL CARBURETOR ....................4-20 EXPLODED DIAGRAM ................4-20 REMOVAL AND INSTALLATION CHART ..........4-20 SERVICE POINTS ................... 4-23 Diaphragm inspection ..............4-23 Accelerator pump body inspection ..........4-23 Arm inspection ................4-23 Regulator body inspection ............. 4-24 Needle valve inspection ..............4-24 Jet and carburetor body inspection ..........
  • Page 52 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 53: 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 54: 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 55 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 56: 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 hoses Oil tank Oil filler cap Cracks/damage → Replace. Check valve Malfunction → Replace. Oil level sensor inspection Refer to “INDICATION SYSTEM”...
  • Page 57: 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 Disconnect the fuel filler hose from the fuel filler neck.
  • Page 58 FUEL FUEL TANK EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Fuel hose Fuel return hose Fuel tank breather hose Fuel tank assembly Hose clamp Fuel filler hose Hose clamp Fuel sensor assembly...
  • Page 59 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 belt Reverse the removal steps for installation.
  • Page 60: 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 61: Intake Silencer

    FUEL INTAKE SILENCER INTAKE SILENCER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points INTAKE SILENCER REMOVAL Follow the left “Step” for removal. Bolt Intake silencer cover Bolt Spark arrester Intake silencer O-ring Reverse the removal steps for installation. 4-10...
  • Page 62: Exploded Diagram

    FUEL CARBURETOR UNIT CARBURETOR UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CARBURETOR REMOVAL Follow the left “Step” for removal. Battery box Refer to “BATTERY BOX” in chapter 8. Intake silencer Refer to “INTAKE SILENCER”. NOTE: Bolt When removing the carburetor, the...
  • Page 63: Exploded Diagram

    FUEL CARBURETOR UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Hose clamp Slide the outer exhaust joint. Hose clamp Floatation Water lock band Bolt Bolt Muffler stay 3 Bolt Nut/washer 4-12...
  • Page 64 FUEL CARBURETOR UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Muffler stay 1 NOTE: Make sure to remove spark plugs before removing the muffler stay 1. Bolt Hose clamp Exhaust chamber assembly Rubber joint Slide the water lock to back Outer exhaust joint Inner exhaust joint 4-13...
  • Page 65 FUEL CARBURETOR UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Å suction Fuel hose ı return NOTE: Use the white marks a on the fuel hoses to distinguish the hose ends. Oil feed hose Choke cable Throttle cable Oil pump cable 4-14...
  • Page 66 FUEL CARBURETOR UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Pulse hose Bolt Bolt Carburetor unit Gasket Not reusable Dowel pin Reverse the removal steps for installation. 4-15...
  • Page 67: Removal And Installation Chart

    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 Pulse hose Å suction Fuel hose ı return Oil feed hose Accelerator pump fuel hose Throttle link Choke link 4-16...
  • Page 68 FUEL CARBURETOR UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Cable bracket Bolt Carburetor Gasket Not reusable Carburetor joint Bolt/washer Fuel hose guide Reverse the removal steps for installation. 4-17...
  • Page 69: Service Points

    FUEL CARBURETOR UNIT SERVICE POINTS Throttle valve synchronization inspection and adjustment 1. Check: Throttle valve synchronization Different clearances → Adjust. Checking steps: Loosen the throttle stop screw 1 until untouched the screw end from the throttle lever. Check the each throttle valve is fully closed a.
  • Page 70: Choke Cable And Throttle Cable Installation

    FUEL CARBURETOR UNIT Choke cable and throttle cable installation 1. Install: Choke cable 1 Throttle cable 2 Choke cable guide installation position a: 13–15 mm (0.51–0.59 in) Throttle cable guide installation position a: 18–20 mm (0.71–0.79 in) 2. Adjust: Throttle lever free play Choke lever operation Refer to “CONTROL SYSTEM”...
  • Page 71: 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 fuel hose Carburetor #1 Screw Accelerator pump/carburetor Carburetor #1/carburetor #2 cover Diaphragm Screw Regulator body Gasket Main jet Pilot jet...
  • Page 72 FUEL CARBURETOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Screw Arm pin Spring Screw Needle valve seat holder Needle valve Needle valve seat O-ring Reverse the disassembly steps for assembly. 4-21...
  • Page 73 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 Spring Diaphragm Accelerator pump body Reverse the disassembly steps for assembly.
  • Page 74: Service Points

    FUEL CARBURETOR SERVICE POINTS NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned in from its set position to the seated position. CAUTION: Do not use steel wire for cleaning the jets. This may enlarge the jet diameters and seriously affect performance.
  • Page 75: 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 76: 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 UNIT”. Screw Fuel pump cover Gasket Not reusable Diaphragm O-ring Diaphragm body 4-25...
  • Page 77 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. 4-26...
  • Page 78: 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. 4-27...
  • Page 79: Oil Pump

    FUEL OIL PUMP OIL PUMP EXPLODED DIAGRAM 6 × 20 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points OIL PUMP REMOVAL Follow the left “Step” for removal. Exhaust chamber assembly Refer to “CARBURETOR UNIT”. Oil pump cable and oil feed Refer to “CARBURETOR UNIT”.
  • Page 80 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 Air bleed screw Gasket Oil feed hose 1 Check valve Oil feed hose 2 Hose joint Oil return hose Oil pump cable...
  • Page 81: 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 feed hoses are not full of oil, fill them up.
  • Page 82: Oil Injection Pump Air Bleeding

    FUEL OIL PUMP 2. Adjust: Oil pump cable Adjustment steps: Loosen the locknut 1 and the adjust- ing nut 2. Fully close the carburetor throttle valves. Adjust the oil pump cable so that the mark a on the oil pump lever is aligned with the mark b on the oil pump body.
  • Page 83 FUEL OIL PUMP Air bleed screw: 5 N • m (0.5 kgf • m, 3.6 ft • lb) CAUTION: Do not run the engine if oil does not flow out of the air bleed screw. Inspect the oil pump hoses for proper routing and make sure there are no restrictions in the line.
  • Page 84 POWR CHAPTER 5 POWER UNIT ENGINE UNIT ....................5-1 EXPLODED DIAGRAM ................5-1 REMOVAL AND INSTALLATION CHART ..........5-1 SERVICE POINTS ..................5-5 Shim removal ..................5-5 Engine mount inspection ..............5-5 Coupling clearance inspection............5-5 EXHAUST CHAMBER ASSEMBLY..............5-6 EXPLODED DIAGRAM ................
  • Page 85 POWR CYLINDERS....................5-20 EXPLODED DIAGRAM ................5-20 REMOVAL AND INSTALLATION CHART ..........5-20 SERVICE POINTS ................... 5-21 Cylinder inspection ................. 5-21 PISTONS ....................... 5-22 EXPLODED DIAGRAM ................5-22 REMOVAL AND INSTALLATION CHART ..........5-22 SERVICE POINTS ................... 5-24 Piston pin clip removal and installation........5-24 Piston inspection................
  • Page 86: Engine Unit

    POWR ENGINE UNIT ENGINE UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ENGINE UNIT REMOVAL Follow the left “Step” for removal. Battery box Refer to “BATTERY BOX” in chapter 8. YPVS cables and YPVS Refer to “YPVS SERVOMOTOR” in servomotor chapter 7.
  • Page 87 POWR ENGINE UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Grease hose Clamp/cooling water hose Å For cooling water pilot outlet on Clamp/cooling water hose starboard side ı For cooling water pilot outlet on port Clamp/cooling water hose side Oil hose Oil return hose...
  • Page 88 POWR ENGINE UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt/collar NOTE: Before removing the engine unit, fix the Coupling cover choke valves to the choke link with a Floatation plastic band, etc. to the fully closed Water lock band position.
  • Page 89 POWR ENGINE UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Shim Engine unit Rubber joint Slide the water lock to back. Reverse the removal steps for installation. *: As required...
  • Page 90: 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 91: 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 Engine unit Refer to “ENGINE UNIT”. Bolt Thermoswitch Hose clamp Slide the outer exhaust joint. Hose clamp Bolt Bolt...
  • Page 92 POWR EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Nut/washer NOTE: Muffler stay 1 Make sure to remove spark plugs before removing the muffler stay 1. Bolt Exhaust chamber assembly Outer exhaust joint Inner exhaust joint Reverse the removal steps for installation.
  • Page 93 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 Nut/washer Bolt Nut/washer Exhaust chamber Gasket Not reusable...
  • Page 94 POWR EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Muffler Screw Plate Gasket Not reusable Reverse the disassembly steps for assembly.
  • Page 95: Exhaust Chamber Joint

    POWR EXHAUST CHAMBER JOINT EXHAUST CHAMBER JOINT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST CHAMBER JOINT Follow the left “Step” for removal. REMOVAL Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY”. a white mark Clamp/cooling water hose Bolt Bolt...
  • Page 96 POWR EXHAUST CHAMBER JOINT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Bolt Exhaust chamber joint Gasket Not reusable Reverse the removal steps for installation. 5-11...
  • Page 97: Exhaust Manifold

    POWR EXHAUST MANIFOLD EXHAUST MANIFOLD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST MANIFOLD REMOVAL Follow the left “Step” for removal. Exhaust chamber joint Refer to “EXHAUST CHAMBER JOINT”. Bolt Bolt Wire harness bracket Exhaust manifold Gasket Not reusable Clamp/cooling water hose...
  • Page 98: Reed Valves

    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 99: 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 100: 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 manifold Refer to “EXHAUST MANIFOLD”. Bolt YPVS valve cover Gasket Not reusable Spacer Link joint/cover Circlip Not reusable Washer 5-15...
  • Page 101 POWR YPVS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt NOTE: During installation, align the hole a in Shaft 2 the YPVS shaft with the bolt. Shaft 1 YPVS valve lever Bolt YPVS valve assembly NOTE: Oil seal If the YPVS shaft is removed, the oil seal must be replaced.
  • Page 102: 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 103: 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 manifold Refer to “EXHAUST MANIFOLD”. NOTE: Bolt Tighten the bolts in the proper sequence as shown and in two stages.
  • Page 104: 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 105: 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 106: 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 107: 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 108 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. 5-23...
  • Page 109: 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 110: 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 111: 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: 0.30–0.45 mm (0.012–0.018 in) NOTE: Push the piston ring into the cylinder with the piston crown. Piston pin and bearing inspection 1.
  • Page 112 POWR PISTONS 4. Check: Piston pin-to-small end bearing-to- connecting rod free play (at the small end of the connecting rod as shown) Free play/small end wear → Replace the piston pin, connecting rod, or small end bearing. 5-27...
  • Page 113: Starter Motor

    POWR STARTER MOTOR STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STARTER MOTOR REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT”. Nut/washer Starter motor lead Bolt Battery negative lead Starter motor Reverse the removal steps for installation.
  • Page 114 POWR FLYWHEEL MAGNETO FLYWHEEL MAGNETO EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points FLYWHEEL MAGNETO Follow the left “Step” for removal. REMOVAL Engine unit Refer to “ENGINE UNIT”. Oil pump Refer to “OIL PUMP” in chapter 4. Bolt Bolt Generator cover...
  • Page 115: Exploded Diagram

    POWR FLYWHEEL MAGNETO EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Drive coupling Bolt Flywheel magneto Woodruff key Starter clutch assembly Reverse the removal steps for installation. 5-30...
  • Page 116: Exploded Diagram

    POWR FLYWHEEL MAGNETO EXPLODED DIAGRAM 14 N • m (1.4 kgf • m, 10 ft • Ib) 6 × 14 mm 5 N • m (0.5 kgf • m, 3.6 ft • Ib) 14 N • m (1.4 kgf • m, 10 ft • Ib) 5 ×...
  • Page 117 POWR FLYWHEEL MAGNETO 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 Washer Idle gear Circlip 5-32...
  • Page 118 POWR FLYWHEEL MAGNETO EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Plate Weight NOTE: Spring ring Install the spring ring after installing the weights, plate and circlip. Pinion gear Reverse the disassembly steps for assembly. 5-33...
  • Page 119: Service Points

    POWR FLYWHEEL MAGNETO 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 FLYWHEEL MAGNETO 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. Check: Gear movement Rough movement →...
  • 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”. Starter motor Refer to “STARTER MOTOR”. Generator cover Refer to “FLYWHEEL MAGNETO”. Bolt Mount bracket 1 Bolt Mount bracket 2...
  • Page 122 POWR CRANKCASE EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Bolt NOTE: Bolt Tighten the bolts in sequence as shown. Bolt Lower crankcase Crankshaft assembly Upper crankcase Reverse the disassembly steps for assembly. 5-37...
  • 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 Bearing clip Bearing Crankshaft CAUTION: Install the bearing locating pins into the grooves 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: 0.05 mm (0.002 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. 5-41...
  • 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

    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: Exploded Diagram

    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: Nozzle Deflector And Nozzle Ring

    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 seals Driver rod L3: YB-06071/90890-06652 Needle bearing attachment: YB-06196/90890-06653 NOTE: Remove the oil seals 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 Cooling water 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 hoses 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 Nipple Driven coupling Washer Intermediate drive shaft O-ring Oil seal Not reusable 6-17...
  • Page 145 BEARING HOUSING PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points 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) Distance b:...
  • Page 150 – 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 ................7-6 INSPECTION..................... 7-6 Digital tester ..................7-6 Low resistance measurement ............7-6 Peak voltage measurement.............. 7-7 Peak voltage adaptor ................
  • Page 151 – ELEC CHARGING SYSTEM..................7-22 WIRING DIAGRAM................. 7-22 FUSE ....................... 7-23 BATTERY ....................7-23 RECTIFIER/REGULATOR PEAK VOLTAGE ........... 7-23 LIGHTING COIL PEAK VOLTAGE............7-23 YPVS ......................7-24 WIRING DIAGRAM................. 7-24 FUSE ....................... 7-25 BATTERY ....................7-25 PICKUP COIL ..................7-25 CDI UNIT....................
  • Page 152: Electrical Components

    – ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 1 Buzzer 9 Thermoswitch 2 Fuel level sensor 0 Starter motor 3 Multifunction meter A Stator coil and pickup coil 4 YPVS servomotor B Engine stop switch, engine stop lanyard 5 Spark plugs switch and starter switch 6 Electrical box C Oil level sensor 7 Speed sensor...
  • Page 153: Electrical Box

    – ELEC ELECTRICAL BOX 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. Electrical box Refer to “BATTERY BOX” in chapter 8. Plastic locking tie Not reusable NOTE: Bolt/collar To separate the battery box from the...
  • Page 154 – ELEC ELECTRICAL BOX EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Starter motor lead/ battery positive lead Fuse Plastic locking tie Not reusable Screw Ignition coil Screw Starter relay...
  • Page 155 – ELEC ELECTRICAL BOX EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Rectifier/regulator Thermoswitch Wire harness CDI unit Electrical box housing Reverse the disassembly steps for assembly.
  • Page 156 – ELEC ELECTRICAL BOX 1 CDI unit : Black 2 Starter relay : Brown 3 Fuse (10A) : Green 4 Ignition coil : Pink 5 Rectifier/regulator : Red 6 Spark plug caps : White...
  • 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: Peak Voltage Measurement

    – ELEC ELECTRICAL ANALYSIS Peak voltage measurement NOTE: When checking the condition of the igni- tion system it is vital to know the peak voltage. Cranking speed is dependant on many factors (e.g., fouled or weak spark plugs, a weak battery). If one of these is defected, the peak voltage will be lower than speci- fication.
  • Page 159: Test Harness

    – ELEC ELECTRICAL ANALYSIS Test harness 90890- Usage 06779 06779 Charge coil and pickup coil Checking steps: Disconnect the coupler connections. Connect the test harness between the couplers. Connect the tester terminals to the ter- minals which are being checked. Run the engine and observe the mea- surement.
  • Page 160: Ignition System

    – ELEC IGNITION SYSTEM IGNITION SYSTEM WIRING DIAGRAM PULL W/B W/R 1 Pickup coil : Black 2 Charge coil : Brown 3 CDI unit : Blue 4 Engine stop switch : Orange 5 Engine stop lanyard switch : Pink 6 Thermoswitch : Red 7 Ignition coil : White...
  • 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: Spark Plugs

    – ELEC IGNITION SYSTEM 3. Measure: Pickup coil output peak voltage Below specification → Replace the pickup coil. Pickup coil output peak voltage: White/red (W/R) – White/black (W/B) Unloaded Loaded r/min Cranking 2,000 3,500 Test harness (8-pin): YW-06779/90890-06779 SPARK PLUGS Refer to “POWER UNIT”...
  • Page 164: Engine Stop Switch

    – ELEC IGNITION SYSTEM 2. Measure: Secondary coil resistance Out of specification → Replace. Secondary coil resistance: Spark plug cap – Spark plug cap 14.3–30.5 kΩ at 20 ˚C (68 ˚F) ENGINE STOP SWITCH 1. Check: Engine stop switch continuity Out of specification →...
  • Page 165: Starting System

    – ELEC STARTING SYSTEM STARTING SYSTEM WIRING DIAGRAM PULL 1 Starter motor : Black 2 Engine stop lanyard switch : Brown 3 Starter switch : Red 4 Fuse (10A) : White 5 Starter relay 6 Battery 7-14...
  • Page 166: 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 holder leads. 2. Check: Fuse holder lead continuity No continuity →...
  • Page 167: Starter Relay

    – ELEC STARTING SYSTEM STARTER RELAY 1. Inspect: Brown lead terminal Black lead terminal Loose → Tighten. 2. Check: Starter relay Faulty → Replace. Checking steps: Connect the tester leads between the starter relay terminals as shown. Connect the brown lead terminal to the positive battery terminal.
  • Page 168: 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 “STARTER MOTOR” in chapter 5. O-ring Not reusable Bolt Starter motor front cover O-ring Not reusable...
  • Page 169 – 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 7-18...
  • Page 170 – ELEC STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Spacer Holder Starter motor yoke Reverse the disassembly steps for assembly. 7-19...
  • Page 171: 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 172: 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 173: Charging System

    – ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM 1 Lighting coil : Black 2 Battery : Green 3 Fuse (10A) : Red 4 Rectifier/regulator G/W : Green/white 7-22...
  • Page 174: Fuse

    – ELEC CHARGING SYSTEM FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in chapter 3. RECTIFIER/REGULATOR PEAK VOLTAGE 1. Measure: Rectifier/regulator output peak voltage Below specification → Measure the lighting coil output peak voltage or replace the rectifier/regulator. Rectifier/regulator output peak voltage: Red (R) –...
  • Page 175: Ypvs

    – ELEC YPVS YPVS WIRING DIAGRAM 1 Pickup coil : Black 2 CDI unit : Brown 3 YPVS servomotor : Green 4 Fuse (10A) : Gray 5 Battery : Blue : Orange : Pink : Red : White W/B : White/black W/R : White/red 7-24...
  • Page 176: 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”. 7-25...
  • Page 177 – 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 178: 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 179: 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 180: Indication System

    – ELEC INDICATION SYSTEM INDICATION SYSTEM WIRING DIAGRAM PULL 1 Lighting coil : Black : Blue/black 2 CDI unit : Brown : Blue/red 3 Fuel level sensor : Green : Red/black 4 Oil level sensor : Gray R/W : Red/white 5 Buzzer : Blue : Red/yellow...
  • Page 181: Fuse

    – ELEC INDICATION SYSTEM FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in chapter 3. LIGHTING COIL Refer to “CHARGING SYSTEM”. RECTIFIER/REGULATOR Refer to “CHARGING SYSTEM”. CDI UNIT Refer to “IGNITION SYSTEM”. THERMOSWITCH Refer to “IGNITION SYSTEM”. BUZZER 1. Check: Buzzer Buzzer does not sound →...
  • Page 182: 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 MULTIFUNCTION METER Multifunction meter 1. Check: Multifunction meter Cracked meter housing → Replace the multifunction meter.
  • Page 183: Display Function

    – ELEC INDICATION SYSTEM Display function 1. Check: Display function Not operate → Replace the multifunc- tion meter. 1 Oil level sensor : Black 2 Fuel level sensor : Green 3 Buzzer : Blue 4 Battery : Pink 5 Speed sensor : Red : Yellow : Blue/black...
  • Page 184: Fuel Level Gauge

    30 seconds, the display will auto- matically turn off. Check the fuel level segments is full indicated. Remove the jumper lead 2 from the green two-pin connector. YAMAHA Disconnect the jumper lead 3 and FUEL HOUR then connect it to green and red ter- MULTI DISPLAY minal again.
  • Page 185: Oil Level Gauge

    30 seconds, the display will auto- matically turn off. Remove the jumper lead 2 from the white two-pin connector. Disconnect the jumper lead 3 and YAMAHA then connect it to green and red ter- FUEL HOUR minal again. Make sure the oil symbol 4 and...
  • Page 186: Overheat Warning Indicator

    3. Connect the pink and black terminals with a jumper lead 4. Make sure the water temperature sym- bol 5 and “WARNING” lamp 6 blinks, and the buzzer sounds intermit- tently. YAMAHA FUEL HOUR MULTI DISPLAY WARNING x1000r/min...
  • Page 187: 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 NOTE: When inspecting the multifunction meter unit or emptying the fuel tank, connect the white/blue and black terminals (green two-pin connector) with a jumper lead 1...
  • Page 188: Speed Sensor

    – ELEC INDICATION SYSTEM Speed sensor 1. Check: Speed sensor output voltage and pulses Out of specification → Replace. Speed sensor output voltage (dependant on the paddle wheel position): Less than 400 mV/ More than 11.6 V Output pulse: 2 pulses/one-full turn Checking steps: Apply DC 12 voltage to the white three-pin connector (between the red/...
  • Page 190 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 191 HULL HOOD BUZZER AND HOOD LOCK ................. 8-28 EXPLODED DIAGRAM ................8-28 REMOVAL AND INSTALLATION CHART ..........8-28 HOSES......................8-31 EXPLODED DIAGRAM ................8-31 REMOVAL AND INSTALLATION CHART ..........8-31 SERVICE POINTS ................... 8-33 Check valve inspection ..............8-33 Ventilation hose installation............8-33 SEATS AND HAND GRIP ................
  • Page 192 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 193 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 194: Handlebar

    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 195 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. Handlebar assembly Nut/washer QSTS converter Throttle cable Choke cable Reverse the removal steps for installation.
  • Page 196 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 197 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 198: Service Points

    HULL HANDLEBAR HOOD SERVICE POINTS Handlebar inspection 1. Inspect: Handlebar Bends/cracks/damage → Replace. Handlebar switch inspection Refer to “IGNITION SYSTEM” and “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 199 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 200 HULL HANDLEBAR HOOD 7. Adjust: Choke lever operation Refer to “CONTROL SYSTEM” in chapter 3. 8. Adjust: Throttle lever free play Refer to “CONTROL SYSTEM” in chapter 3. 9. Adjust: QSTS cable Refer to “CONTROL SYSTEM” in chapter 3.
  • Page 201 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 202 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 203: Service Points

    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 204: Steering Column

    HULL STEERING COLUMN HOOD STEERING COLUMN EXPLODED DIAGRAM m, 11 ft 16 N • m (1.6 kgf • • 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 205 HULL STEERING COLUMN HOOD EXPLODED DIAGRAM 8 × 60 mm m, 11 ft 16 N • m (1.6 kgf • • m, 19 ft 26 N • m (2.6 kgf • • m, 3.6 ft 5 N • m (0.5 kgf •...
  • Page 206 HULL STEERING COLUMN HOOD EXPLODED DIAGRAM 8 × 60 mm m, 11 ft 16 N • m (1.6 kgf • • m, 19 ft 26 N • m (2.6 kgf • • m, 3.6 ft 5 N • m (0.5 kgf •...
  • Page 207: Service Points

    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 208 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 Screw...
  • Page 209: Remote Control Cables And Speed Sensor Lead

    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 210: Removal And Installation Chart

    REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SPEED SENSOR DISASSEMBLY Follow the left “Step” for disassembly. Paddle wheel set Not reusable Speed sensor housing Reverse the disassembly steps for assembly.
  • Page 211: Service Points

    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: Qsts Cable (Jet Pump Side) Installation

    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: Front Hood

    HULL FRONT HOOD HOOD FRONT HOOD EXPLODED DIAGRAM 6 × 14 mm m, 3.6 ft 5 N • m (0.5 kgf • • 6 × 14 mm m, 8.7 ft 12 N • m (1.2 kgf • • 5 × 20 mm m, 0.7 ft 1 N •...
  • Page 214 HULL FRONT HOOD HOOD EXPLODED DIAGRAM 6 × 14 mm m, 3.6 ft 5 N • m (0.5 kgf • • 6 × 14 mm m, 8.7 ft 12 N • m (1.2 kgf • • 5 × 20 mm m, 0.7 ft 1 N •...
  • Page 215: Steering Console Cover

    HULL STEERING CONSOLE COVER HOOD STEERING CONSOLE COVER EXPLODED DIAGRAM 8 × 25 mm 2 N • m (0.2 kgf m, 1.4 ft • • 5 × 19 mm m, 2.2 ft 3 N • m (0.3 kgf • • 6 ×...
  • Page 216: Exploded Diagram

    HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 8 × 25 mm 2 N • m (0.2 kgf m, 1.4 ft • • 5 × 19 mm m, 2.2 ft 3 N • m (0.3 kgf • • 6 × 25 mm m, 3.6 ft 5 N •...
  • Page 217: Removal And Installation Chart

    HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM m, 0.7 ft 1 N • m (0.1 kgf • • 5 × 20 mm m, 2.2 ft 3 N • m (0.3 kgf • • 6 × 18 mm m, 1.4 ft 2 N •...
  • Page 218 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM m, 0.7 ft 1 N • m (0.1 kgf • • 5 × 20 mm m, 2.2 ft 3 N • m (0.3 kgf • • 6 × 18 mm m, 1.4 ft 2 N •...
  • 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. 8-29...
  • 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: Hoses

    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. 8-32...
  • Page 224: Service Points

    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 8-34...
  • 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. 8-35...
  • Page 227: Service Points

    HULL SEATS AND HAND GRIP HOOD SERVICE POINTS Seat lock inspection 1. Inspect: Seat lock Damage/wear → Replace. 8-36...
  • Page 228: Battery Box

    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 Terminal extension Bolt Battery positive lead Clip/breather hose Battery Bolt...
  • Page 229 HULL BATTERY BOX HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Electrical box Cap nut/washer Holder Holder Cap nut/washer Battery box NOTE: 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: Exhaust System

    HULL EXHAUST SYSTEM HOOD EXHAUST SYSTEM EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST SYSTEM REMOVAL Follow the left “Step” for removal. Battery box Refer to “BATTERY BOX”. Jet pump unit assembly Refer to “JET PUMP UNIT” in chapter 6. Floatation Floatation Water lock band...
  • Page 231 HULL EXHAUST SYSTEM HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Water lock Bolt Packing NOTE: Hose clamp Remove parts 11 to 14 as a set. Water tank Rubber hose Exhaust outlet Reverse the removal steps for installation. 8-40...
  • Page 232: Service Points

    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: Deck And Hull

    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 8-42...
  • 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: Engine Mount

    HULL ENGINE MOUNT HOOD ENGINE MOUNT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ENGINE MOUNT REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT” in chapter 5. Bolt Damper Bolt Engine mount Reverse the removal steps for installation.
  • Page 236: Hull Repair

    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: Cracks And Punctures

    HULL ENGINE MOUNT HOOD Cracks and punctures NOTE: Before attempting to repair any cracks or punctures, refer to “WATERCRAFT 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: Insert Nut

    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: Graphic Removal

    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 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 Pilot water hose Water hose Water passage JET PUMP UNIT Duct Impeller Intake grate Bearings Intake duct Water inlet hose Bilge hose Bilge strainer Bilge hose joint Valve body ELECTRICAL CDI unit Lighting coil...
  • Page 246 YAMAHA MOTOR CORPORATION, USA Printed in USA × 1 CR Nov. 2000 — F0W-28197-1A-11 (GP800A)
  • Page 247 COLOR CODE WIRING DIAGRAM Black Yellow GP800R Brown Black/yellow Green Blue/black Gray Blue/red Blue Red/white Orange Red/yellow Pink White/black White/blue White White/red 3 Lighting coil C Oil level sensor 4 Pickup coil 5 Charge coil D Fuel level sensor 7 Starter motor 6 CDI unit 1 Thermoswitch E Multifunction...