Yamaha WaveRunner FX140 Service Manual
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Yamaha WaveRunner FX140 Service Manual

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Table of Contents

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Download this manual See also: Service Manual, Owner's Manual
WaveRunner
FX140
SERVICE MANUAL
*LIT186160238*
LIT-18616-02-38
F1B-28197-1E-11

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Summary of Contents for Yamaha WaveRunner FX140

  • Page 1 WaveRunner FX140 SERVICE MANUAL *LIT186160238* LIT-18616-02-38 F1B-28197-1E-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 equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.

  • Page 3: How To Use This Manual

    HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been compiled to provide the mechanic with an easy to read, handy reference 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, passenger(s), 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 I Apply Gasket Maker ® J Apply Yamabond #4 (Yamaha bond number 4) K Apply LOCTITE ® No. 271 (Red LOCTITE) L Apply LOCTITE ®...
  • 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 compart- ment. Starting primary l.D. number: F1B: 800101 ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the engine unit.

  • 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 followed by Yamaha dealers and their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Gasoline vapor is explosive if ignited.

  • 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 prac- tises any risk is minimized. A summary of the most important precautions 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 dis- assembling. 2. Oil the contact surfaces of moving parts during assembly.

  • Page 14: Special Tools

    SPECIAL TOOLS INFO SPECIAL TOOLS Using the correct special tools recommended by Yamaha, will aid the work and enable accu- rate 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-”, “YS-”, “YU-”...
  • Page 15 SPECIAL TOOLS INFO A Fuel pressure gauge P/N. YB-06766 YB-06766 90890-06786 90890-06786 B Compression gauge extension P/N. 90890-06582 C Cylinder gauge set P/N. YU-03017 90890-06759 90890-06582 YU-03017 90890-06759 D Compression gauge P/N. YU-33223-1 90890-03160 E Peak voltage adapter P/N. YU-39991 90890-03172 YU-33223-1 90890-03160...
  • Page 16 P/N. YB-06769 YB-06769 YB-35956-A 90890-06769 90890-06756 90890-06769 N Vacuum/pressure pump gauge set P/N. YB-35956-A 90890-06756 O Yamaha diagnostic system for Watercraft P/N. 60E-85300-01 P Yamaha diagnostic system for Watercraft (CD-ROM only) 60E-85300-01 P/N. 60E-WS853-00 60E-WS853-00 YAMAHA DIAGNOSTIC SYSTEM for Watercraft...

  • Page 17: Removal And Installation

    SPECIAL TOOLS INFO REMOVAL AND INSTALLATION 1 Oil filter wrench YU-38411 YW-06551 90890-01426 P/N. YU-38411 90890-06551 90890-01426 2 Coupler wrench P/N. YW-06551 90890-06551 3 Sheave holder YS-01880-A YM-01082 P/N. YS-01880-A 90890-01701 90890-01080 90890-01701 4 Rotor puller P/N. YM-01082 90890-01080 5 Rotor holder P/N.
  • Page 18 SPECIAL TOOLS INFO A Valve seat cutter Intake 90890-06813 (60°) 90890-06315 (60°) 90890-06814 (45°) 90890-06312 (45°) P/N. 90890-06813 (60°) 90890-06815 (30°) 90890-06328 (30°) 90890-06814 (45°) 90890-06815 (30°) Exhaust P/N. 90890-06315 (60°) 90890-06312 (45°) 90890-06811 (ø4.0 mm) 90890-06328 (30°) YM-91043-C 90890-06812 (ø4.5 mm) B Valve seat cutter holder P/N.
  • Page 19 SPECIAL TOOLS INFO M Ball bearing attachment (jet pump oil seal) YB-06085 90890-06634 P/N. YB-06085 90890-06634 N Driver rod (intermediate shaft and jet pump) P/N. YB-06071 YB-06071 90890-06606 YB-34474 90890-06606 O Bearing inner/outer race attachment (jet pump bearing) P/N. YB-34474 P Shaft holder (intermediate shaft) P/N.
  • Page 21 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ............... 2-1 MAINTENANCE SPECIFICATIONS ............... 2-3 ENGINE ....................2-3 JET PUMP UNIT ..................2-6 HULL AND HOOD ..................2-6 ELECTRICAL .................... 2-6 TIGHTENING TORQUES ................2-9 SPECIFIED TORQUES................2-9 GENERAL TORQUE ................2-17 CABLE AND HOSE ROUTING ..............2-18...
  • Page 22 SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Item Unit FX140 Model code Hull Engine/jet Dimensions Length mm (in) 3,340 (131.5) Width mm (in) 1,230 (48.4) Height mm (in) 1,160 (45.7) Dry weight kg (lb) 362 (798) Maximum capacity Person/kg (lb) 3/240 (530) Performance Maximum output kW (PS) @ r/min...

  • Page 23: General Specifications

    SPEC GENERAL SPECIFICATIONS Model Item Unit FX140 Fuel and oil Fuel type Regular unleaded gasoline Minimum fuel rating PON* RON* Fuel tank capacity L (US gal, 70 (18.5, 15.4) Imp gal) Engine oil type 4-stroke motor oil Engine oil grade SE, SF, SG, SH, or SJ 10W-30 Engine oil quantity...

  • Page 24: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model Item Unit FX140 Cylinder head Warpage limit mm (in) 0.1 (0.004) Compression pressure 1,350 (13.5, 192) (kgf/cm , psi) Cylinder Bore size mm (in) 74.060–74.075 (2.9157–2.9163) Taper limit mm (in) 0.08 (0.003) Out-of-round limit mm (in) 0.05 (0.002) Wear limit...
  • Page 25 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX140 Valve seat width C Intake mm (in) 0.9–1.1 (0.0354–0.0433) Exhaust mm (in) 0.9–1.1 (0.0354–0.0433) Valve margin thickness D Intake mm (in) 0.5–0.9 (0.0197–0.0354) Exhaust mm (in) 0.5–0.9 (0.0197–0.0354) Valve stem diameter Intake mm (in) 3.975–3.990 (0.1565–0.1571) Exhaust mm (in)
  • Page 26 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX140 Piston ring Top ring Type Barrel Dimension (B × T) 0.90 × 2.75 (0.04 × 0.11) mm (in) End gap (installed) mm (in) 0.38–0.55 (0.0150–0.0217) Ring groove clearance mm (in) 0.030–0.065 (0.0012–0.0026) 2nd ring Type Taper 0.80 ×...

  • Page 27: Jet Pump Unit

    SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX140 Oil filter Oil filter type Cartridge type Oil pump Oil pump type Trochoid Rotor tip clearance mm (in) 0.09–0.15 (0.004–0.006) Oil pump housing clearance Rotor (feed pump) mm (in) 0.09–0.17 (0.0035–0.0067) Rotor (scavenge pump) mm (in) 0.09–0.19 (0.0035–0.0075) JET PUMP UNIT...
  • Page 28 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX140 Stator Pulser coil (W – B, R – B) Output peak voltage @cranking 1 @cranking 2 @2,000 r/min @3,500 r/min Lighting coil (G – G) Output peak voltage @cranking 1 @cranking 2 @2,000 r/min @3,500 r/min Ω...
  • Page 29 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit FX140 Thermoswitch ON temperature (Engine) °C (°F) 84–90 (183–194) OFF temperature (Engine) °C (°F) 70–84 (158–183) ON temperature (Exhaust) °C (°F) 94–100 (201–212) OFF temperature (Exhaust) °C (°F) 80–94 (176–201) Engine temperature sensor Engine temperature sensor resistance (B/Y –...

  • Page 30: 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 Fuel system 0.32 Retainer/fuel pump module — – fuel tank 0.64 Fuel filler neck/rubber seal – deck — 0.59 Fuel tank belt/fuel tank –...
  • Page 31 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Engine Engine unit – engine mount Bolt Oil filter — — Coupling cover Bolt 0.78 Thermoswitch (exhaust) – Bolt 0.76 exhaust pipe 3 Outer exhaust joint clamp –...
  • Page 32 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Exhaust manifold 1 – Bolt cylinder head Exhaust manifold 2 – Bolt cylinder head 0.37 Water jacket – oil tank Bolt 0.76 Oil tank stay/reduction 0.37 drive gear case –...
  • Page 33 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb 0.37 Bolt 0.76 Reduction drive gear case – crankcase Bolt Holder (relief valve) – Bolt reduction drive gear case Bearing housing – Bolt reduction drive gear case Battery negative lead –...
  • Page 34 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Plug (vacuum pressure) Bolt Engine temperature sensor – — — crankcase Thermoswitch (engine) – Bolt 0.76 crankcase Oil pressure switch — — 0.84 Anode cover –...
  • Page 35 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Water inlet cover/water inlet Bolt 0.66 strainer – impeller duct Drive shaft nut – drive shaft — Impeller (left-hand threads) – Impeller drive shaft Transom plate –...
  • Page 36 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Steering cable locknut — 0.65 (jet thrust nozzle side) Steering cable grommet – hull — 0.59 Steering cable bracket – — 0.54 steering cable holder Steering cable bracket –...
  • Page 37 SPEC TIGHTENING TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Bow eye – hull Bolt Drain plug/packing – hull Bolt Engine mount – hull Bolt Engine damper – hull Bolt 0.64 Electrical Battery box – hull Bolt 0.54 Battery box/spacer –...

  • Page 38: General Torque

    SPEC TIGHTENING TORQUES GENERAL TORQUE General torque This chart specifies tightening torques for stan- Nut A Bolt B specifications dard fasteners with a standard ISO thread N•m kgf•m ft•lb pitch. Tightening torque specifications for spe- 8 mm cial components or assemblies are provided in 10 mm applicable sections of this manual.

  • Page 39: Cable And Hose Routing

    SPEC CABLE AND HOSE ROUTING CABLE AND HOSE ROUTING DOWN DOWN 1 Fuel tank breather hose A Battery positive lead 2 QSTS cable B Battery 3 Steering cable C Throttle cable 4 Shift cable D Fuel hose 5 Electrical box lead E Cooling water pilot outlet hose 6 Speed sensor lead F Handlebar switch lead...
  • Page 40 SPEC CABLE AND HOSE ROUTING 0 1 C D MAIN S P A R E 1 Throttle cable A Shift cable 2 Handlebar switch lead B Steering cable 3 QSTS cable C Electrical box lead 4 Buzzer lead D Cooling water pilot outlet hose 5 Fuel tank breather hose E Battery negative lead 6 Ignition coil lead...
  • Page 41 SPEC CABLE AND HOSE ROUTING È 1 Cooling water hose (cooling water inlet) A Battery positive lead 2 Bilge hose 1 B Speed sensor lead 3 Electric bilge pump C Electric bilge pump lead 4 Bilge hose 4 D Bilge strainer 5 Cooling water hose (from thermostat) E Battery negative lead 6 Bilge hose 3...
  • Page 42 SPEC CABLE AND HOSE ROUTING Ê Î È Ë Ë Ë Ë Í Ì Ï Õ Ö × É Ð Ì Ø Ê Ó Ð Ë Ð Ò Ì Ñ Ô Ò 1 Thermostat Ë From exhaust manifold 2 Pressure control valve Ì...
  • Page 43 SPEC CABLE AND HOSE ROUTING Ê Î È Ë Ë Ë Ë Í Ì Ï Õ Ö × É Ð Ì Ø Ê Ó Ð Ë Ð Ò Ì Ñ Ô Ò Ò To exhaust pipe Ö Bundle the cooling water pilot outlet hose and Ó...
  • Page 44 SPEC CABLE AND HOSE ROUTING Ë É È Ê 1 Wire harness A Oil pressure switch lead 2 Ground lead 3 Wire harness coupler È To electrical box 4 Cam position sensor coupler É To cam position sensor 5 Thermoswitch (exhaust) Ê...
  • Page 45 SPEC CABLE AND HOSE ROUTING Í Ê É È Ë Ì Î Ï Ï Î Ð Ñ 1 Engine temperature sensor coupler 2 Lighting coil coupler 3 Pulser coil coupler 4 Thermoswitch (engine) coupler 5 Thermoswitch (engine) 6 Starter motor 7 Engine temperature sensor 8 Engine temperature sensor lead 9 Thermoswitch (engine) lead...
  • Page 46 SPEC CABLE AND HOSE ROUTING Í Ê É È Ë Ì Î Ï Ï Î Ð Ñ È To generator Ð Route the starter motor and battery negative É To engine temperature sensor leads behind the cooling water hose. Ê To thermoswitch (engine) Ñ...
  • Page 47 INSP CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART .............. 3-1 PERIODIC SERVICE ..................3-2 CONTROL SYSTEM ................. 3-2 Steering master inspection..............3-2 Steering cable inspection and adjustment .......... 3-2 Throttle cable inspection and adjustment..........3-3 QSTS cable inspection and adjustment ..........3-5 Shift cable inspection and adjustment..........

  • Page 48: 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. (G) This mark indicates maintenance that you may do yourself. (❍) This mark indicates work to be done by a Yamaha dealer. THEREAFTER MAINTENANCE INTERVAL...

  • Page 49: Periodic Service

    INSP CONTROL SYSTEM PERIODIC SERVICE CONTROL SYSTEM Steering master inspection 1. Inspect: • Steering master Excessive play → Replace the steering master. Refer to “STEERING MASTER” in Chapter 8. Inspection steps: • Move the handlebar up and down and back and forth. •...

  • Page 50: 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: 6.4 N • m (0.64 kgf • m, 4.6 ft • lb) NOTE: If the steering cable cannot be properly adjusted by the cable joint at the steering mas- ter end, adjust the cable joint at the jet pump...
  • Page 51 INSP CONTROL SYSTEM 2. Adjust: • Throttle lever free play Adjustment steps: NOTE: • When not replacing the throttle cable or removing the cable from the throttle body, adjust the throttle cable free play by fol- lowing steps (f) through (j). •...

  • Page 52: Qsts Cable Inspection And Adjustment

    INSP CONTROL SYSTEM j. Install the handlebar cover. Handlebar cover screw: 1.1 N • m (0.11 kgf • m, 0.8 ft • lb) ® LOCTITE k. Install the flame arrester and air filter case cover. Flame arrester bolt: 1st: 3.3 N • m (0.33 kgf •...
  • Page 53 INSP CONTROL SYSTEM 2. Adjust: • QSTS cable Adjustment steps: • Set the control grip in the neutral position. • Loosen the locknut 1. • Remove the nut 2 and pivot pin 3. • Set the jet thrust nozzle in the center position.

  • Page 54: Shift Cable Inspection And Adjustment

    INSP CONTROL SYSTEM Shift cable inspection and adjustment 1. Check: • Reverse gate stopper lever position Incorrect → Adjust. Checking steps: • Set the shift lever to the reverse position. • Check that the reverse gate 1 contacts the stopper 2 on the bracket and the lever 3 contacts the reverse gate.

  • Page 55: Trolling Speed Check And Adjustment

    • Start the engine and allow it to warm up for a 15 minutes. • Check the engine trolling speed using the tachometer of the multifunction meter or using the Yamaha Diagnostic System. 2. Adjust: • Trolling speed Adjustment steps: •...

  • Page 56: Fuel System

    INSP FUEL SYSTEM FUEL SYSTEM WARNING When removing fuel system parts, wrap them in a cloth and take care that no fuel spills into the engine compartment. Fuel line inspection 1. Inspect: • Fuel strainer 1 Clog/contaminants → Clean. • Fuel pump filter Clog/contaminants →...

  • Page 57: Power Unit

    INSP POWER UNIT POWER UNIT Valve clearance adjustment The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 58 INSP POWER UNIT 4. Measure: • Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake valve: 0.11–0.20 mm (0.0043–0.0079 in) Exhaust valve: 0.25–0.34 mm (0.0098–0.0134 in) Measurement steps: • Turn the drive coupling counterclockwise, and then check if cylinder #1 is at TDC of the compression stroke with a dial gauge.
  • Page 59 INSP POWER UNIT 5. Remove: • Timing chain tensioner cap bolt 1 • Gasket 6. Turn the timing chain tensioner rod fully clockwise with a thin screwdriver 1. NOTE: Make sure that the tensioner rod has been fully set clockwise. 7.
  • Page 60 INSP POWER UNIT 8. Adjust: • Valve clearance Adjustment steps: • Remove the valve lifter 1 and the valve pad 2. NOTE: • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. •...
  • Page 61 INSP POWER UNIT NOTE: The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect. • Install the new valve pad 5 and the valve lifter 6.
  • Page 62 INSP POWER UNIT Intake MEASURED ORIGINAL VALVE PAD NUMBER CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00–0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03–0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.08–0.10...

  • Page 63: Engine Oil Level Check

    INSP POWER UNIT 9. Remove: • Dial gauge • Dial gauge stand • Dial gauge needle 10. Install: • All removed parts NOTE: For installation, reverse the removal proce- dure. Engine oil level check 1. Place the watercraft in a horizontal posi- tion.
  • Page 64 INSP POWER UNIT • Remove the oil filler cap 1 and check for oil on the dipstick 2. • If there is no oil on the dipstick, pour enough oil so that the tip of the dipstick comes into contact with the oil, and then install the filler cap.

  • Page 65: Engine Oil Change - Using Oil Changer

    INSP POWER UNIT • If the engine oil is below the minimum level mark a, add sufficient oil of the rec- ommended type to raise it to the correct level. • If the engine oil is above the maximum level mark b, extract sufficient oil using an oil changer to lower it to the correct level.
  • Page 66 INSP POWER UNIT 2. Remove: • Oil filler cap 1 3. Insert the tube of an oil changer into the oil filler hole. 4. Operate the oil changer to extract the oil. 5. If the oil filter is also to be replaced, per- form the following procedure.

  • Page 67: Air Filter Element Clean

    INSP POWER UNIT 6. Pour the specified amount of the recom- mended engine oil into the oil filler hole. 7. Fill: • Oil tank (with the specified amount of the recom- mended engine oil) Recommended oil: SAE 10W-30 API SE, SF, SG, SH, SJ Oil quantity: Total amount: 4.3 L (4.5 US qt, 3.8 Imp qt)

  • Page 68: Spark Plug Inspection

    INSP POWER UNIT 2. Remove the air filter element and check it for dirt and oil. Replace the air filter ele- ment if there is any oil buildup. CAUTION: • Make sure that the air filter element is installed in the filter case properly. •...
  • Page 69 INSP POWER UNIT 3. Inspect: • Electrodes 1 Damage/wear → Replace. • Insulator color 2 Distinctly different color → Check the engine condition. Color guide: Medium to light tan color: Normal Whitish color: Lean fuel mixture Air leak Incorrect settings Blackish color: Overly rich mixture Electrical malfunction...

  • Page 70: Electrical

    INSP POWER UNIT/ELECTRICAL 7. Install: • Air filter element • Air filter case cover Air filter case cover screw: 2.5 N • m (0.25 kgf • m, 1.8 ft • lb) ® LOCTITE ELECTRICAL Battery inspection WARNING Battery electrolyte is poisonous and dan- gerous, causing severe burns, etc.
  • Page 71 INSP ELECTRICAL 1. Remove: • Bands • Battery negative lead 1 • Battery positive lead 2 • Battery • Battery breather hose 3 WARNING • When removing the battery, disconnect the negative lead first. • Remove the battery to prevent acid loss during turning the machine on its side for the impeller service.
  • Page 72 INSP ELECTRICAL 3. Inspect: • Specific gravity Out of specification → Charge. Specific gravity at 20 °C (68 °F): 1.28 Charging current: 1.9 amps × 10 hrs 4. Install: • Filler caps CAUTION: Before installation, rinse off any fluid from the battery box and battery and make sure that the battery is dry before installing it.

  • Page 73: Jet Pump Unit

    INSP JET PUMP UNIT JET PUMP UNIT Impeller inspection 1. Check: • Impeller 1 Damage/wear → Replace. Nicks/scratches → File or grind. 2. Measure: • Impeller-to-housing clearance a Out of specification → Replace. Max. impeller-to-housing clearance: 0.6 mm (0.0236 in) Measurement steps: •...

  • Page 74: Water Inlet Strainer Inspection

    INSP JET PUMP UNIT/BILGE PUMP Water inlet strainer inspection 1. Inspect: • Water inlet strainer Contaminants → Clean. Cracks/damage → Replace. Inspection steps: • Remove the ride plate. Refer to “INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT” in Chapter 6. •...

  • Page 75: Electric Bilge Pump Strainer Inspection

    INSP BILGE PUMP/GENERAL Electric bilge pump strainer inspection 1. Inspect: • Cap • Strainer Contaminants → Clean. Inspection steps: • Remove the band 1. • Remove the cap 2 and strainer 3. • Inspect the cap and strainer. • Install the strainer and cap. •...

  • Page 76: Lubrication Points

    Before lubricating the throttle cable, squeeze the throttle lever and remove the rubber seal 2. Lubricate: • Throttle cable (throttle body end) Recommended lubricant: Yamaha marine grease, Yamaha grease A (Water resistant grease) 3. Lubricate: • QSTS control cables (handlebar end)
  • Page 77 GENERAL 5. Lubricate: • Nozzle pivot shaft • Steering cable (nozzle end) • QSTS cable (nozzle end) Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) 6. Lubricate: • Steering cable • Steering cable joint • Shift cable •...
  • Page 78 INSP GENERAL 7. Fill: • Intermediate housing Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) Grease quantity: Initial 10 hours: 33.0–35.0 cm (1.11–1.18 oz) Every 100 hours or 12 months: 6.0–8.0 cm (0.20–0.27 oz) NOTE: Fill the intermediate housing with the recom- mended grease through the grease nipple 1.
  • Page 79 FUEL CHAPTER 4 FUEL SYSTEM FUEL TANK AND FUEL PUMP MODULE............4-1 EXPLODED DIAGRAM ................4-1 REMOVAL AND INSTALLATION CHART ..........4-1 SERVICE POINTS ..................4-4 Fuel hose disconnection ..............4-4 Fuel pump module removal..............4-4 Fuel sender disassembly ..............4-4 Check valve inspection ............... 4-5 Rollover valve inspection ..............

  • Page 80: Fuel Tank And Fuel Pump Module

    FUEL FUEL TANK AND FUEL PUMP MODULE FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 1.3 N •...
  • Page 81 FUEL FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 1.3 N • m (0.13 kgf • m, 0.9 ft • Ib) 5.9 N •...
  • Page 82 FUEL FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 1.3 N • m (0.13 kgf • m, 0.9 ft • Ib) 5.9 N •...

  • Page 83: Service Points

    FUEL FUEL TANK AND FUEL PUMP MODULE SERVICE POINTS Fuel hose disconnection 1. Disconnect: • Fuel hose Refer to “FUEL INJECTION SYSTEM”. Fuel pump module removal 1. Remove: • Nuts • Retainer NOTE: Loosen the nuts in the sequence shown. 2.

  • Page 84: Check Valve Inspection

    FUEL FUEL TANK AND FUEL PUMP MODULE 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”. •...

  • Page 85: Fuel Pump Filter Inspection

    FUEL FUEL TANK AND FUEL PUMP MODULE Fuel pump filter inspection 1. Inspect: • Fuel pump filter 1 Clog/contaminants → Wash the fuel pump filter in kerosene or gasoline. Fuel strainer inspection 1. Inspect: • Fuel strainer Clog/contaminants → Clean. Fuel pump module installation 1.

  • Page 86: Fuel Injection System

    FUEL FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM EXPLODED DIAGRAM 3.3 N • m (0.33 kgf • m, 2.4 ft • Ib) 2.5 N • m (0.25 kgf • m, 1.8 ft • Ib) 2nd 6.5 N • m (0.65 kgf • m, 4.7 ft • Ib) 5 ×...
  • Page 87 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 3.3 N • m (0.33 kgf • m, 2.4 ft • Ib) 2.5 N • m (0.25 kgf • m, 1.8 ft • Ib) 2nd 6.5 N • m (0.65 kgf • m, 4.7 ft • Ib) 5 ×...
  • Page 88 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 3.3 N • m (0.33 kgf • m, 2.4 ft • Ib) 2.5 N • m (0.25 kgf • m, 1.8 ft • Ib) 2nd 6.5 N • m (0.65 kgf • m, 4.7 ft • Ib) 5 ×...
  • Page 89 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 2nd 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 35 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 39 N •...
  • Page 90 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 2nd 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 35 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 39 N •...
  • Page 91 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 2nd 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 35 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 39 N •...
  • Page 92 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 5 × 7 mm 5 × 15 mm 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib) 6 ×...
  • Page 93 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 5 × 7 mm 5 × 15 mm 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib) 6 ×...
  • Page 94 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 5 × 7 mm 5 × 15 mm 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib) 6 ×...

  • Page 95: Service Points

    FUEL FUEL INJECTION SYSTEM SERVICE POINTS Hose clamps removal 1. Remove: • Hose clamps CAUTION: If the hose clamps are removed without cutting the joint first, the fuel hose will be damaged. Hose clamps installation 1. Install: • Hose clamps WARNING Do not reuse the hose clamps, always replace them with new ones.

  • Page 96: Fuel Line Inspection

    FUEL FUEL INJECTION SYSTEM CAUTION: • Do not rotate the quick connector tab 1 past the stopper position a, otherwise it could be damaged. • When the fuel hoses are disconnected, quickly remove the retainer 2 from the quick connector, otherwise the retainer could be lost.

  • Page 97: Fuel Hose Installation (Replacing With New Fuel Hose)

    FUEL FUEL INJECTION SYSTEM Fuel hose installation (replacing with new fuel hose) 1. Install: • Fuel hose 1 NOTE: • To install the fuel hose, be sure to align the white mark a of the fuel hose with the checker tab 2 of the quick connector. •...

  • Page 98: Fuel Injector Inspection

    Digital circuit tester: YU-34899-A/90890-03174 Fuel injector resistance: 14.0–15.0 Ω at 20 °C (68 °F) 3. Check the operation of the fuel injector using the “Stationary Test” of the Yamaha Diagnostic System. Throttle body inspection 1. Check: • Throttle body Cracks/damage → Replace the throttle bodies.

  • Page 99: Throttle Body Installation

    FUEL FUEL INJECTION SYSTEM 2. Check: • Fuel passages Obstruction → Clean. Checking steps: • Wash the throttle body in a petroleum based solvent. Do not use any caustic carburetor clean- ing solution. • Blow out all of passages with com- pressed air.

  • Page 100: Throttle Bodies Synchronization

    FUEL FUEL INJECTION SYSTEM Throttle bodies synchronization 1. Remove: • Throttle bodies • Air filter case 2. Adjust: • Throttle bodies synchronization Adjustment steps: NOTE: The bypass air screw 1 should not be adjusted. However, if it is necessary to remove the bypass air screw, be sure to note the number of times the screw is turned from its set position.
  • Page 101 FUEL FUEL INJECTION SYSTEM c. Turn synchronizing screw #1 3 clock- wise approximately 7 times until it starts to contact the lever. NOTE: • Butterfly valve #1 should be fully closed. Butterfly valves #2 and #3 open if the screw is turned more than 7 times. •...
  • Page 102 Adjust the throttle body synchronization with the air filter case uninstalled. j. Connect the fuel hose and clamp. k. Connect the Yamaha Diagnostic Sys- tem. l. Remove the sub wire harness from the air filter case, and then connect it to the throttle bodies and main wire harness.
  • Page 103 NOTE: • Warm the engine up in the water. • While checking the engine temperature with the Yamaha Diagnostic System, warm the engine up until the engine tem- perature is 50 °C (122 °F). q. Adjust the throttle stop screw 2 until 1,740 trolling speed is within specification.
  • Page 104 FUEL FUEL INJECTION SYSTEM Vacuum pressure at trolling speed: Cylinder Cylinder Example difference –30 ± 10 mmHg –210 ± 10 mmHg (–4.00 ± (–27.99 ± 1.33 kPa, 1.33 kPa, –1.2 ± 0.4 inHg) –8.3 ± 0.4 inHg) –180 mmHg Standard*0 (–23.99 kPa, –7.1 inHg) –180 ±...

  • Page 105: Fuel Pressure Measurement

    FUEL FUEL INJECTION SYSTEM Fuel pressure measurement 1. Disconnect: • Fuel hose Refer to “Fuel hose disconnection”. 2. Install: • Fuel pressure gauge adapter 1 • Fuel pressure gauge 2 Fuel pressure gauge adapter: YW-06842/90890-06842 Fuel pressure gauge: YB-06766/90890-06786 NOTE: To connect the fuel pressure gauge adapter, follow the procedures for connecting a fuel hose.
  • Page 106 POWR CHAPTER 5 POWER UNIT ENGINE UNIT ....................5-1 EXPLODED DIAGRAM ................5-1 REMOVAL AND INSTALLATION CHART ..........5-1 SERVICE POINTS ..................5-4 Compression pressure measurement ..........5-4 Oil filter removal and installation ............5-6 Engine unit removal ................5-6 Shim removal ..................
  • Page 107 POWR OIL PUMP...................... 5-26 EXPLODED DIAGRAM ................5-26 REMOVAL AND INSTALLATION CHART ..........5-26 SERVICE POINTS .................. 5-27 Oil pump removal ................5-27 Oil pump inspection................5-27 Oil strainer inspection................ 5-27 Oil pump installation................5-28 REDUCTION DRIVE GEAR ................5-29 EXPLODED DIAGRAM ................
  • Page 108 POWR CYLINDER HEAD..................5-57 EXPLODED DIAGRAM ................5-57 REMOVAL AND INSTALLATION CHART ..........5-57 SERVICE POINTS .................. 5-59 Cylinder head removal ..............5-59 Cylinder head inspection..............5-59 Cylinder head installation ..............5-60 VALVES AND VALVE SPRINGS..............5-62 EXPLODED DIAGRAM ................5-62 REMOVAL AND INSTALLATION CHART ..........
  • Page 109 POWR CRANKSHAFT ....................5-97 EXPLODED DIAGRAM ................5-97 REMOVAL AND INSTALLATION CHART ..........5-97 SERVICE POINTS .................. 5-98 Crankshaft removal ................5-98 Crankshaft inspection................ 5-98 Crankshaft installation..............5-101 THERMOSTAT ....................5-102 EXPLODED DIAGRAM .................5-102 REMOVAL AND INSTALLATION CHART ..........5-102 SERVICE POINTS ................5-104 Thermostat inspection..............5-104 Thermostat installation ..............5-104 PRESSURE CONTROL VALVE..............5-105...

  • Page 110: Engine Unit

    POWR ENGINE UNIT ENGINE UNIT EXPLODED DIAGRAM 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 6 × 25 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 28 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 ×...
  • Page 111 POWR ENGINE UNIT EXPLODED DIAGRAM 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 6 × 25 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 28 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 ×...
  • Page 112 POWR ENGINE UNIT EXPLODED DIAGRAM 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 6 × 25 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 28 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 ×...

  • Page 113: Service Points

    POWR ENGINE UNIT SERVICE POINTS Compression pressure measurement The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: • Valve clearance Out of specification → Adjust. Refer to “POWER UNIT” in Chapter 3. 2.
  • Page 114 POWR ENGINE UNIT 7. Measure: • Compression pressure Out of specification → Refer to steps (b) and (c). Minimum compression pressure (reference data): 1,080 kPa (10.8 kgf/cm , 157 psi) Measurement steps: a. With the throttle wide open, crank the engine until the reading on the compres- sion gauge stabilizes.

  • Page 115: Oil Filter Removal And Installation

    POWR ENGINE UNIT 9. Install: • Air filter element • Air filter case cover Air filter case cover screw: 2.5 N • m (0.25 kgf • m, 1.8 ft • lb) ® LOCTITE Oil filter removal and installation 1. Remove: •...

  • Page 116: Shim Removal

    POWR ENGINE UNIT Shim removal 1. Remove: • Shims NOTE: To ease reassembly and coupling alignment, 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 117: Exhaust Pipe 3

    POWR EXHAUST PIPE 3 EXHAUST PIPE 3 EXPLODED DIAGRAM 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 5th 15 N • m (1.5 kgf • m, 11 ft • Ib) 6th 15 N •...
  • Page 118 POWR EXHAUST PIPE 3 EXPLODED DIAGRAM 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 5th 15 N • m (1.5 kgf • m, 11 ft • Ib) 6th 15 N •...
  • Page 119 POWR EXHAUST PIPE 3 EXPLODED DIAGRAM 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 5th 15 N • m (1.5 kgf • m, 11 ft • Ib) 6th 15 N •...

  • Page 120: Exhaust Pipes 1 And 2

    POWR EXHAUST PIPES 1 AND 2 EXHAUST PIPES 1 AND 2 EXPLODED DIAGRAM 4th 39 N • m (3.9 kgf • m, 28 ft • Ib) 22 N • m (2.2 kgf • m, 16 ft • Ib) 9th 39 N • m (3.9 kgf • m, 28 ft • Ib) 2nd 22 N •...
  • Page 121 POWR EXHAUST PIPES 1 AND 2 EXPLODED DIAGRAM 4th 39 N • m (3.9 kgf • m, 28 ft • Ib) 22 N • m (2.2 kgf • m, 16 ft • Ib) 9th 39 N • m (3.9 kgf • m, 28 ft • Ib) 2nd 22 N •...

  • Page 122: Exhaust Manifold

    POWR EXHAUST MANIFOLD EXHAUST MANIFOLD EXPLODED DIAGRAM È 22 N • m (2.2 kgf • m, 16 ft • Ib) 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N •...
  • Page 123 POWR EXHAUST MANIFOLD EXPLODED DIAGRAM È 22 N • m (2.2 kgf • m, 16 ft • Ib) 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N •...

  • Page 124: Oil Tank

    POWR OIL TANK OIL TANK EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 15 N •...
  • Page 125 POWR OIL TANK EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 15 N •...
  • Page 126 POWR OIL TANK EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 15 N •...
  • Page 127 POWR OIL TANK EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 15 N •...
  • Page 128 POWR OIL TANK EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 7.6 N •...
  • Page 129 POWR OIL TANK EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 7.6 N •...
  • Page 130 POWR OIL TANK EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 7.6 N •...
  • Page 131 POWR OIL TANK SERVICE POINTS Oil tank removal 1. Remove: • Oil tank NOTE: Loosen the oil tank bolts and nuts in the sequence shown. 2. Remove: • Oil tank cover • Gasket NOTE: Loosen the oil tank cover bolts in the sequence shown.

  • Page 132: Oil Strainer Inspection

    POWR OIL TANK 4. Remove: • Oil cooler covers • Gaskets NOTE: Loosen the oil cooler cover bolts in the sequence shown. Oil strainer inspection 1. Check: • Oil strainer 1 Damage → Replace. Contaminants → Clean with engine oil. Oil tank installation 1.
  • Page 133 POWR OIL TANK 2. Install: • Gasket • Oil breather plate 2 • Oil breather plate 1 NOTE: Tighten the oil breather plate bolts in the sequence shown. Oil breather plate bolt: 1st: 1.9 N • m (0.19 kgf • m, 1.4 ft • lb) 2nd: 4.4 N •...
  • Page 134 POWR OIL TANK 4. Install: • Oil tank NOTE: Tighten the oil tank nuts and bolts in the sequence shown. Bolt 1: 1st: 15 N • m (1.5 kgf • m, 11 ft • lb) 2nd: 28 N • m (2.8 kgf • m, 20 ft • lb) Nut 2, bolt 3: 1st: 2.0 N •...

  • Page 135: Oil Pump

    POWR OIL PUMP OIL PUMP EXPLODED DIAGRAM 1.4 N • m (0.14 kgf • m, 1.0 ft • Ib) 1.4 N • m (0.14 kgf • m, 1.0 ft • Ib) 2nd 10 N • m (0.1 kgf • m, 7.2 ft • Ib) 2nd 10 N •...

  • Page 136: Service Points

    POWR OIL PUMP SERVICE POINTS Oil pump removal 1. Remove: • Oil pump assembly NOTE: Loosen the oil pump bolts in the sequence shown. Oil pump inspection 1. Check: • Oil pump operation Rough movement → Replace the defec- tive part(s). Oil strainer inspection 1.

  • Page 137: Oil Pump Installation

    POWR OIL PUMP Oil pump installation 1. Install: • Oil pump assembly NOTE: • Align the projection a on the oil pump assembly with the slit b on the oil pump driven gear shaft. • Tighten the oil pump bolts in the sequence shown.

  • Page 138: Reduction Drive Gear

    POWR REDUCTION DRIVE GEAR REDUCTION DRIVE GEAR EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 55 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N •...
  • Page 139 POWR REDUCTION DRIVE GEAR EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 55 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N •...
  • Page 140 POWR REDUCTION DRIVE GEAR EXPLODED DIAGRAM 5 × 10 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 2nd 28 N • m (2.8 kgf • m, 20 ft • Ib) 6 ×...
  • Page 141 POWR REDUCTION DRIVE GEAR EXPLODED DIAGRAM 5 × 10 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 2nd 28 N • m (2.8 kgf • m, 20 ft • Ib) 6 ×...
  • Page 142 POWR REDUCTION DRIVE GEAR EXPLODED DIAGRAM 5 × 10 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 2nd 28 N • m (2.8 kgf • m, 20 ft • Ib) 6 ×...

  • Page 143: Service Points

    POWR REDUCTION DRIVE GEAR SERVICE POINTS Drive coupling removal 1. Remove: • Drive coupling 1 NOTE: While holding the flywheel magneto 2 with the sheave holder 3, loosen the drive coupling with coupler wrench 4. Coupler wrench: YW-06551/90890-06551 Sheave holder: YS-01880-A/90890-01701 Drive shaft removal 1.

  • Page 144: Drive Shaft Installing

    POWR REDUCTION DRIVE GEAR Drive shaft installing 1. Install: • Drive shaft NOTE: Press in the direction of the arrow. 2. Install: • Oil seals 1 Distance a: 8.9–9.3 mm (0.35–0.37 in) Drive coupling installation 1. Install: • Drive coupling 1 NOTE: While holding the flywheel magneto 2 with the sheave holder 3, tighten the drive coupling...

  • Page 145: Generator And Starter Motor

    POWR GENERATOR AND STARTER MOTOR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 30 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 75 N • m (7.5 kgf • m, 54 ft • Ib) 10 ×...
  • Page 146 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 30 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 75 N • m (7.5 kgf • m, 54 ft • Ib) 10 ×...
  • Page 147 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 30 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 75 N • m (7.5 kgf • m, 54 ft • Ib) 10 ×...
  • Page 148 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 10 mm 6 × 14 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) 5 × 14 mm 4.9 N •...
  • Page 149 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 10 mm 6 × 14 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) 5 × 14 mm 4.9 N •...

  • Page 150: Service Points

    POWR GENERATOR AND STARTER MOTOR SERVICE POINTS Flywheel magneto removal 1. Remove: • Flywheel magneto bolt 1 • Washer NOTE: While holding the flywheel magneto 2 with the sheave holder 3, loosen the flywheel magneto bolt. Sheave holder: YS-01880-A/90890-01701 2. Remove: •...
  • Page 151 POWR GENERATOR AND STARTER MOTOR 2. Check: • Starter clutch 1 • Starter gear 2 Burrs/chips/roughness/wear → Replace the defective part(s). 3. Check: • Starter clutch gear’s contacting surfaces Damage/pitting/wear → Replace the starter clutch gear. 4. Check: • Starter clutch operation Checking steps: •...

  • Page 152: Flywheel Magneto Installation

    POWR GENERATOR AND STARTER MOTOR Flywheel magneto installation 1. Install: • Woodruff key • Flywheel magneto • Washer • Flywheel magneto bolt NOTE: • Clean the tapered portion of the crankshaft and the flywheel magneto hub. • When installing the flywheel magneto, make sure the woodruff key is properly seated in the keyway of the crankshaft.

  • Page 153: Camshafts

    POWR CAMSHAFTS CAMSHAFTS EXPLODED DIAGRAM 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 6 × 16 mm 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) È...
  • Page 154 POWR CAMSHAFTS EXPLODED DIAGRAM 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 6 × 16 mm 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) È...

  • Page 155: Camshaft Removal

    POWR CAMSHAFTS EXPLODED DIAGRAM 6 × 35 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 24 N • m (2.4 kgf • m, 17 ft • Ib) 7 × 11 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 ×...
  • Page 156 POWR CAMSHAFTS EXPLODED DIAGRAM 6 × 35 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 24 N • m (2.4 kgf • m, 17 ft • Ib) 7 × 11 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 ×...
  • Page 157 POWR CAMSHAFTS EXPLODED DIAGRAM 6 × 35 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 24 N • m (2.4 kgf • m, 17 ft • Ib) 7 × 11 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 ×...
  • Page 158 POWR CAMSHAFTS SERVICE POINTS Camshaft removal 1. Install: • Dial gauge needle • Dial gauge stand 1 (into spark plug hole #1) • Dial gauge 2 Dial gauge stand: 90890-06583 Dial gauge needle: 90890-06584 Dial gauge stand set: YW-06585/90890-06585 Dial gauge: YU-03097/90890-01252 2.

  • Page 159: Camshaft Inspection

    POWR CAMSHAFTS 4. Remove: • Timing chain tensioner 1 • Gasket 5. Remove: • Camshaft caps • Dowel pins NOTE: Loosen the intake and exhaust camshaft cap bolts in the sequence shown. 6. Remove: • Intake camshaft 1 • Exhaust camshaft 2 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire 3.
  • Page 160 POWR CAMSHAFTS 3. Measure: • Camshaft runout Out of specification → Replace. Maximum camshaft runout: 0.03 mm (0.0012 in) 4. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance: 0.05–0.08 mm (0.0020–0.0031 in) Measurement steps: •...

  • Page 161: Camshaft Sprockets Inspection

    POWR CAMSHAFTS 5. Measure: • Camshaft journal diameter a Out of specification → Replace the cam- shaft. Within specification → Replace the cyl- inder head and the camshaft caps as a set. Camshaft journal diameter: 24.44–24.45 mm (0.9622–0.9626 in) Camshaft sprockets inspection 1.

  • Page 162: Camshaft Installation

    POWR CAMSHAFTS Camshaft installation 1. Install: • Exhaust camshaft sprocket 1 • Intake camshaft sprocket 2 (with the special tool 3) Rotor holder: YU-01235/90890-01235 NOTE: Install the camshaft sprocket with the punch mark a facing outside. Camshaft sprocket bolt: 24 N • m (2.4 kgf • m, 17 ft • lb) 2.
  • Page 163 POWR CAMSHAFTS • Install the exhaust and intake camshaft caps. NOTE: Gradually tighten the intake and exhaust camshaft cap bolts in 2–3 steps in the sequence shown. Camshaft cap bolt: 10 N • m (1.0 kgf • m, 7.2 ft • lb) NOTE: Make sure that the punch marks c on the camshafts are aligned with the arrow marks...
  • Page 164 POWR CAMSHAFTS • Tighten the timing chain tensioner bolts 3 to the specified torque. NOTE: The “UP” mark on the timing chain ten- sioner should face up. Timing chain tensioner bolt: 10 N • m (1.0 kgf • m, 7.2 ft • lb) •...
  • Page 165 POWR CAMSHAFTS 7. Install: • Cylinder head cover gasket • Cylinder head cover NOTE: ® • Apply Gasket Maker onto the mating sur- faces of the cylinder head cover gasket and cylinder head. • Tighten the cylinder head cover bolts stages and in a crisscross pattern.

  • Page 166: Removal And Installation Chart

    POWR CYLINDER HEAD CYLINDER HEAD EXPLODED DIAGRAM 20 N • m (2.0 kgf • m, 14 ft • Ib) 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 2nd 49 N • m (4.9 kgf • m, 35 ft • Ib) 6 ×...
  • Page 167 POWR CYLINDER HEAD EXPLODED DIAGRAM 20 N • m (2.0 kgf • m, 14 ft • Ib) 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 2nd 49 N • m (4.9 kgf • m, 35 ft • Ib) 6 ×...

  • Page 168: Service Points

    POWR CYLINDER HEAD SERVICE POINTS Cylinder head removal 1. Remove: • Cylinder head bolts 1 2. Remove: • Cylinder head nuts NOTE: Loosen the cylinder head nuts in the sequence shown. Cylinder head inspection 1. Eliminate: • Combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag-...

  • Page 169: Cylinder Head Installation

    POWR CYLINDER HEAD 3. Measure: • Cylinder head warpage Out of specification → Replace the cyl- inder head. Cylinder head warpage limit: 0.1 mm (0.004 in) Measurement steps: • Place a straightedge 1 and a thickness gauge 2 across the cylinder head. •...
  • Page 170 POWR CYLINDER HEAD 2. Tighten: • Cylinder head bolts 1 NOTE: Lubricate the cylinder head bolts with engine oil. Cylinder head bolt: 10 N • m (1.0 kgf • m, 7.2 ft • lb) 5-61...

  • Page 171: Exploded Diagram

    POWR VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points VALVES AND VALVE SPRINGS Follow the left “Step” for removal. REMOVAL Cylinder head Refer to “CYLINDER HEAD”. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat...
  • Page 172 POWR VALVES AND VALVE SPRINGS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide Reverse the removal steps for installation.

  • Page 173: Valve Removal

    POWR VALVES AND VALVE SPRINGS SERVICE POINTS Valve removal 1. Remove: • Valve lifter 1 • Valve pad 2 NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place.

  • Page 174: Valve Inspection

    POWR VALVES AND VALVE SPRINGS Valve spring inspection 1. Measure: • Valve spring free length a Out of specification → Replace the valve spring. Valve spring free length: Intake valve spring: 38.90 mm (1.53 in) Exhaust valve spring: 40.67 mm (1.60 in) 2.

  • Page 175: Valve Guide Inspection

    POWR VALVES AND VALVE SPRINGS 4. Measure: • Valve stem diameter a Out of specification → Replace the valve. Valve stem diameter a: Intake valve: 3.975–3.990 mm (0.1565–0.1571 in) Exhaust valve: 4.460–4.475 mm (0.1756–0.1762 in) 5. Measure: • Valve stem runout Out of specification →...

  • Page 176: Valve Guide Replacement

    POWR VALVES AND VALVE SPRINGS 1. Measure: • Valve guide inside diameter a Valve guide inside diameter: Intake: 4.000–4.012 mm (0.1575–0.1580 in) Exhaust: 4.500–4.512 mm (0.1772–0.1776 in) 2. Calculate the valve stem-to-valve guide clearance as follows. Replace the valve guide if out of specification. Valve stem-to-valve guide clearance = valve guide inside diameter –...
  • Page 177 POWR VALVES AND VALVE SPRINGS 2. Install the new valve guide 2 by striking the special service tool from the camshaft side until the valve guide clip 3 contacts the cylinder head. NOTE: Apply engine oil to the surface of the new valve guide.

  • Page 178: Valve Seat Inspection

    POWR VALVES AND VALVE SPRINGS Valve seat inspection 1. Eliminate carbon deposits from the valve with a scraper. 2. Apply a thin, even layer of Mechanic’s blueing dye (Dykem) onto the valve seat. 3. Lap the valve slowly on the valve seat with a valve lapper (commercially obtainable) as shown.

  • Page 179: Valve Seat Reface

    POWR VALVES AND VALVE SPRINGS Valve seat reface 1. Reface the valve seat with the valve seat cutter. Valve seat cutter holder: Intake (4.0 mm): 90890-06811 Exhaust (4.5 mm): 90890-06812 Valve seat cutter: 30° (intake): 90890-06815 45° (intake): 90890-06814 60° (intake): 90890-06813 30°...
  • Page 180 POWR VALVES AND VALVE SPRINGS 4. Use a 60° cutter to adjust the contact width of the bottom edge of the valve seat. b Previous contact width 60˚ 5. Use a 45° cutter to adjust the contact width of the valve seat to specification. b Previous contact width c Specified contact width 45˚...

  • Page 181: Valve Installation

    POWR VALVES AND VALVE SPRINGS 9. Apply a thin, even layer of lapping com- pound onto the valve seat, and then lap the valve using a valve lapper (commer- cially obtainable). CAUTION: Do not get the lapping compound on the valve stem and valve guide.
  • Page 182 POWR VALVES AND VALVE SPRINGS 2. Compress the valve spring, and then install the valve cotter 1 using a thin screwdriver with a small amount of grease applied to it. Valve spring compressor: YM-04019/90890-04019 Valve spring compressor attachment: (for the intake valve) YM-4114/90890-04114 (for the exhaust valve) YM-4108/90890-04108...

  • Page 183: Crankcase

    POWR CRANKCASE CRANKCASE EXPLODED DIAGRAM 8.4 N • m (0.84 kgf • m, 6.1 ft • Ib) 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 20 N • m (2.0 kgf • m, 14 ft • Ib) 6 ×...
  • Page 184 POWR CRANKCASE EXPLODED DIAGRAM 8.4 N • m (0.84 kgf • m, 6.1 ft • Ib) 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 20 N • m (2.0 kgf • m, 14 ft • Ib) 6 ×...
  • Page 185 POWR CRANKCASE EXPLODED DIAGRAM 8.4 N • m (0.84 kgf • m, 6.1 ft • Ib) 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 20 N • m (2.0 kgf • m, 14 ft • Ib) 6 ×...
  • Page 186 POWR CRANKCASE EXPLODED DIAGRAM 8.4 N • m (0.84 kgf • m, 6.1 ft • Ib) 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 20 N • m (2.0 kgf • m, 14 ft • Ib) 6 ×...
  • Page 187 POWR CRANKCASE EXPLODED DIAGRAM 6 × 10 mm 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 35 N • m (3.5 kgf • m, 25 ft • Ib) 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 6 ×...

  • Page 188: Service Points

    POWR CRANKCASE SERVICE POINTS Crankcase disassembly 1. Remove: • Oil pan bolts NOTE: • Loosen each bolt 1/4 of a turn at a time, in 7 11 stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. •...

  • Page 189: Crankcase Inspection

    POWR CRANKCASE 4. Remove: • Dowel pins Crankcase inspection 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • Crankcase Cracks/damage → Replace. • Oil delivery passages Obstruction →...
  • Page 190 POWR CRANKCASE 2. Apply: ® • Gasket Maker (onto the crankcase mating surfaces) NOTE: ® Do not allow any Gasket Maker to come into contact with the oil gallery or crankshaft journal bearings. 3. Install: • Dowel pins 1 • O-ring 2 4.
  • Page 191 POWR CRANKCASE Tightening steps: • Tighten the bolts in the tightening sequence cast on the crankcase. Crankcase bolt 1–0: 1st: 7.8 N • m (0.78 kgf • m, 5.6 ft • lb) • Loosen and retighten the crankcase bolts in the proper tightening sequence as shown.
  • Page 192 POWR CRANKCASE 6. Tighten: • Crankcase bolts A–J NOTE: Tighten the bolts in the tightening sequence cast on the crankcase. Crankcase bolt A–J: 12 N • m (1.2 kgf • m, 8.7 ft • lb) 7. Tighten: • Oil pan bolts NOTE: Tighten the bolts in the tightening sequence cast on the oil pan.

  • Page 193: Connecting Rods And Pistons

    POWR CONNECTING RODS AND PISTONS CONNECTING RODS AND PISTONS EXPLODED DIAGRAM 20 N • m (2.0 kgf • m, 14 ft • Ib) 2nd 120 ± 5˚ REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CONNECTING RODS AND Follow the left “Step”...
  • Page 194 POWR CONNECTING RODS AND PISTONS EXPLODED DIAGRAM 20 N • m (2.0 kgf • m, 14 ft • Ib) 2nd 120 ± 5˚ Step Procedure/Part name Q’ty Service points Bolt Not reusable Big end upper bearing Top ring 2nd ring Oil ring Reverse the removal steps for installation.

  • Page 195: Service Points

    POWR CONNECTING RODS AND PISTONS SERVICE POINTS Connecting rod and piston removal The following procedure applies to all of the connecting rods and pistons. 1. Remove: • Connecting rod cap 1 • Big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.

  • Page 196: Cylinder And Piston Inspection

    POWR CONNECTING RODS AND PISTONS 3. Remove: • Top ring • 2nd ring • Oil ring NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. Cylinder and piston inspection The following procedure applies to all of the cylinders and pistons.

  • Page 197: Piston Ring Inspection

    POWR CONNECTING RODS AND PISTONS • If out of specification, replace the piston and piston rings as a set. • Measure piston skirt diameter “P” with the micrometer. a 5 mm (0.2 in) from the bottom edge of the piston Piston size “P”...

  • Page 198: Piston Pin Inspection

    POWR CONNECTING RODS AND PISTONS 2. Install: • Piston ring (into the cylinder) NOTE: Level the piston ring in the cylinder with the piston crown. a 5 mm (0.2 in) 3. Measure: • Piston ring end gap Out of specification → Replace the pis- ton ring.
  • Page 199 POWR CONNECTING RODS AND PISTONS 2. Measure: • Piston pin outside diameter a Out of specification → Replace the pis- ton pin. Piston pin outside diameter: 16.991–17.000 mm (0.6689–0.6693 in) <Limit>: 16.971 mm (0.6681 in) 3. Measure: • Piston pin bore diameter (in the piston) Out of specification →...

  • Page 200: Connecting Rod Inspection

    POWR CONNECTING RODS AND PISTONS Connecting rod inspection 1. Measure: • Crankshaft-pin-to-big-end-bearing clearance Out of specification → Replace the big end bearings. Crankshaft-pin-to-big-end- bearing clearance: 0.016–0.040 mm (0.0006–0.0016 in) Measurement steps: The following procedure applies to all of the connecting rods. CAUTION: Do not interchange the big end bearings and connecting rods.
  • Page 201 POWR CONNECTING RODS AND PISTONS NOTE: • Do not move the connecting rod or crank- shaft until the clearance measurement has been completed. • Lubricate the bolts threads and nut seats with molybdenum disulfide grease. • Make sure the “Y” mark c on the con- necting rod faces towards the front side of the crankshaft.

  • Page 202: Connecting Rod And Piston Installation

    POWR CONNECTING RODS AND PISTONS For example, if the connecting rod “P ” and the crankshaft web “P ” numbers are “5” and “1” respectively, then the bearing size for “P ” is: Bearing size of P “P ” (connecting rod) – “P ”...
  • Page 203 POWR CONNECTING RODS AND PISTONS 3. Offset: • Piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring È Intake side 4. Lubricate: • Piston • Piston rings • Cylinder (with the recommended lubricant) Recommended lubricant: Engine oil...

  • Page 204: Crankshaft

    POWR CONNECTING RODS AND PISTONS 7. Install: • Big end bearings • Connecting rod assembly 1 (into the cylinder and onto the crankshaft pin) • Connecting rod cap (onto the crankshaft pin) NOTE: • Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps.
  • Page 205 POWR CONNECTING RODS AND PISTONS 9. Tighten: • Connecting rod nuts WARNING • Replace the connecting rod bolts and nuts with new ones. • Clean the connecting rod bolts and nuts. NOTE: The tightening procedure of the connecting rod nuts is angle controlled, therefore tighten the nuts using the following procedure.

  • Page 206: Exploded Diagram

    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 Separate Refer to “CRANKCASE”. Connecting rod caps Refer to “CONNECTING RODS AND PISTONS”. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Reverse the removal steps for installation.

  • Page 207: Crankshaft Inspection

    POWR CRANKSHAFT SERVICE POINTS Crankshaft removal 1. Remove: • Crankshaft 1 • Crankshaft journal lower bearings (from the lower crankcase) • Crankshaft journal upper bearings (from the upper crankcase) NOTE: Identify the position of each crankshaft journal bearing so that it can be reinstalled in its origi- nal place.
  • Page 208 POWR CRANKSHAFT CAUTION: Do not interchange the crankshaft journal bearings. To obtain the correct crankshaft- journal-to-crankshaft-journal-bearing clear- ance and prevent engine damage, the crankshaft journal bearings must installed in their original positions. Measurement steps: • Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase.
  • Page 209 POWR CRANKSHAFT • Tighten the bolts to specification in the tightening sequence cast on the crank- case. Refer “Crankcase assembly”— “CRANKCASE”. • Remove the lower crankcase and the crankshaft journal lower bearings. ® • Measure the compressed Plastigauge width c on each crankshaft journal. If the crankshaft-journal-to-crankshaft- journal-bearing clearance is out of speci- fication, select replacement crankshaft...

  • Page 210: Crankshaft Installation

    POWR CRANKSHAFT Crankshaft installation 1. Install: • Crankshaft journal upper bearings (into the upper crankcase) • Crankshaft journal lower bearings (into the lower crankcase) NOTE: • Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase.

  • Page 211: Thermostat

    POWR THERMOSTAT THERMOSTAT EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 35 mm É È REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty...

  • Page 212: Removal And Installation Chart

    POWR THERMOSTAT EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 35 mm É È REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points...

  • Page 213: Service Points

    POWR THERMOSTAT SERVICE POINTS Thermostat inspection 1. Check: • Thermostat 1 Does not open at 50–60 °C (123– 141 °F) → Replace. Checking steps: • Suspend the thermostat in a container filled with water. • Slowly heat the water. • Place a thermometer in the water. •...
  • Page 214 POWR PRESSURE CONTROL VALVE PRESSURE CONTROL VALVE EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 45 mm È È È...

  • Page 215: Pressure Control Valve

    POWR PRESSURE CONTROL VALVE EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 45 mm È È È È Ì É...
  • Page 216 POWR PRESSURE CONTROL VALVE EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 40 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points...
  • Page 217 POWR PRESSURE CONTROL VALVE EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 40 mm Step Procedure/Part name Q’ty Service points Grommet Pressure control valve housing Reverse the disassembly steps for...

  • Page 218: Service Points

    POWR PRESSURE CONTROL VALVE SERVICE POINTS Pressure control valve inspection 1. Check: • Pressure control valve 1 • Spring 2 Damage/wear → Replace the defective part(s). 2. Check: • Pressure control valve housing cover • Pressure control valve housing Cracks/damage → Replace. 3.
  • Page 220 PUMP CHAPTER 6 JET PUMP UNIT INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT........6-1 EXPLODED DIAGRAM ................6-1 REMOVAL AND INSTALLATION CHART ..........6-1 JET PUMP UNIT....................6-3 EXPLODED DIAGRAM ................6-3 REMOVAL AND INSTALLATION CHART ..........6-3 REVERSE GATE ..................... 6-6 EXPLODED DIAGRAM ................6-6 REMOVAL AND INSTALLATION CHART ..........
  • Page 221 PUMP TRANSOM PLATE AND HOSES..............6-19 EXPLODED DIAGRAM ................6-19 REMOVAL AND INSTALLATION CHART ..........6-19 SERVICE POINTS .................. 6-22 Bilge strainer inspection ..............6-22 Electric bilge pump inspection............6-22 Bilge hose inspection ................6-22 Cooling water hose inspection ............6-22 BEARING HOUSING..................6-23 EXPLODED DIAGRAM ................6-23 REMOVAL AND INSTALLATION CHART ..........
  • Page 222 INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT PUMP INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points INTAKE GRATE, RIDE PLATE, Follow the left “Step” for removal. AND INTAKE DUCT REMOVAL Bolt Bolt Intake grate...
  • Page 223 INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Ride plate Bolt Intake duct Felt packing Not reusable Reverse the removal steps for installation.
  • Page 224 JET PUMP UNIT PUMP JET PUMP UNIT EXPLODED DIAGRAM 6.8 N • m (0.68 kgf • m, 4.9 ft • Ib) 14 N • m (1.4 kgf • m, 10 ft • Ib) 6 × 22 mm 8 × 24 mm 2.2 N •...
  • Page 225 JET PUMP UNIT PUMP EXPLODED DIAGRAM 6.8 N • m (0.68 kgf • m, 4.9 ft • Ib) 14 N • m (1.4 kgf • m, 10 ft • Ib) 6 × 22 mm 8 × 24 mm 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib) 40 N •...
  • Page 226 JET PUMP UNIT PUMP 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 Reverse the disassembly steps for assembly.
  • Page 227 REVERSE GATE PUMP REVERSE GATE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REVERSE GATE REMOVAL Follow the left “Step” for removal. Clamp/spout hose Bolt Washer Collar Reverse gate assembly Bolt Washer...
  • Page 228 REVERSE GATE PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Roller Bolt Reverse gate stay Washer Bolt Lever 1 Spacer...
  • Page 229 REVERSE GATE PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Washer Bolt Washer Collar Spring Lever 2 Washer Reverse the removal steps for installation.
  • Page 230 REVERSE GATE PUMP SERVICE POINTS Lever 1 installation 1. Install: • Bolt 1 • Lever 1 2 • Spacer 3 • Reverse gate 4 • Washer 5 • Nut 6 Lever 2 installation 1. Install: • Bolt 1 • Washer 2 •...
  • Page 231 JET THRUST NOZZLE AND NOZZLE RING PUMP JET THRUST NOZZLE AND NOZZLE RING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points JET THRUST NOZZLE AND Follow the left “Step” for removal. NOZZLE RING REMOVAL Jet pump unit Refer to “JET PUMP UNIT”.
  • Page 232 Follow the left “Step” for removal. HOUSING 1 REMOVAL Nozzle ring Refer to “JET THRUST NOZZLE AND NOZZLE RING”. Bolt Nozzle NOTE: Clean the contacting surfaces before apply- ing the Yamabond #4 (Yamaha bond num- Impeller duct assembly ber 4). Impeller housing 1 6-11...
  • Page 233 IMPELLER DUCT AND IMPELLER HOUSING 1 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. 6-12...

  • Page 234: 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 235 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 Impeller duct Reverse the disassembly steps for assembly.
  • Page 236 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.
  • Page 237 IMPELLER DUCT AND DRIVE SHAFT PUMP 5. Remove: • Front bearing Drive rod: YB-06071 Driver rod L3: 90890-06652 Needle bearing attachment: YB-06112/90890-06614 NOTE: Remove the front bearing with a press. 6. Remove: • Oil seal Drive rod: YB-06071 Driver rod L3: 90890-06652 Needle bearing attachment: YB-06196/90890-06653...
  • Page 238 IMPELLER DUCT AND DRIVE SHAFT PUMP Drive shaft installation 1. Install: • Oil seals Driver rod: YB-06071/90890-06606 Ball bearing attachment: YB-06085/90890-06634 Distance a: 14.2 ± 0.2 mm (0.56 ± 0.01 in) Distance b: 4.7 ± 0.2 mm (0.19 ± 0.01 in) 2.
  • Page 239 IMPELLER DUCT AND DRIVE SHAFT PUMP 5. Install: • Rear bearing Bearing inner/outer race attachment: YB-34474 NOTE: • Press the bearing inner/outer race at the same time holding the drive shaft and impel- ler duct. • If a bearing inner/outer race attachment is not available, use a washer or pipe with an outer diameter of 46 mm (1.81 in) and an inner diameter of 20 mm (0.79 in).

  • Page 240: 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 assembly Refer to “JET PUMP UNIT”.
  • Page 241 TRANSOM PLATE AND HOSES PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Hose clamp Cooling water hose Cooling water outlet (thermostat) Bilge hose 2 Hose clamp Bilge hose 3 Band Electric bilge pump assembly Hose clamp Bilge hose 4 Screw 6-20...
  • Page 242 TRANSOM PLATE AND HOSES PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bilge strainer holder Bilge strainer Nut/washer Transom plate Bilge hose 5 Reverse the removal steps for installation. 6-21...
  • Page 243 TRANSOM PLATE AND HOSES PUMP SERVICE POINTS Bilge strainer inspection Refer to “JET PUMP UNIT” in Chapter 3. Electric bilge pump inspection Refer to “BILGE PUMP” in Chapter 3. Refer to “ELECTRIC BILGE PUMP” in Chapter 7. Bilge hose inspection 1.

  • Page 244: 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 245 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 6-24...
  • Page 246 BEARING HOUSING PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Oil seal Not reusable Oil seal Not reusable Oil seal Not reusable Circlip Bearing Not reusable Circlip Reverse the disassembly steps for assembly. 6-25...
  • Page 247 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 spe- cial tools that were used for removal. •...
  • Page 248 BEARING HOUSING PUMP Bearing removal 1. Remove: • Bearing Driver rod: YB-06071/90890-06606 Bearing outer race attachment: YB-06156/90890-06626 NOTE: • Install the bearing with the same special tools that were used for removal. • Support the intermediate housing with steel blocks 1 and press the bearing. Bearing, intermediate drive shaft, and grease hose inspection 1.
  • Page 249 BEARING HOUSING PUMP Bearing installation 1. Install: • Circlip (rear) 2. Install: • Bearing Driver rod: YB-06071/90890-06606 Bearing outer race attachment: YB-06156/90890-06626 NOTE: Support the intermediate housing with steel blocks 1 and press the bearing. Oil seal installation 1. Install: •...
  • Page 250 BEARING HOUSING PUMP 3. Install: • Oil seal 1 [8 mm (0.31 in)] • Oil seal 2 [11 mm (0.43 in)] Distance a: 10.3–10.7 mm (0.41–0.42 in) Distance b: 0.6–1.0 mm (0.02–0.04 in) Intermediate housing installation 1. Install: • Intermediate housing •...
  • Page 251 – ELEC CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS................ 7-1 ELECTRICAL BOX AND IGNITION COIL BOX ..........7-2 EXPLODED DIAGRAM ................7-2 REMOVAL AND INSTALLATION CHART ..........7-2 ELECTRICAL ANALYSIS ................7-11 INSPECTION................... 7-11 Digital tester ..................7-11 Low resistance measurement ............7-12 Peak voltage measurement ..............7-12 Peak voltage adaptor ................7-13 Test harness ..................7-13 IGNITION SYSTEM ..................
  • Page 252 – ELEC FUEL CONTROL SYSTEM ................7-28 WIRING DIAGRAM ................. 7-28 FUEL PUMP .................... 7-30 FUEL SENDER ..................7-30 FUEL INJECTOR ..................7-31 MAIN AND FUEL PUMP RELAY............. 7-31 OIL PRESSURE SWITCH............... 7-31 THERMOSWITCH (ENGINE)..............7-31 THERMOSWITCH (EXHAUST) ..............7-31 SLANT DETECTION SWITCH ..............7-31 STARTING SYSTEM ..................7-32 WIRING DIAGRAM .................
  • Page 253 – ELEC INDICATION SYSTEM .................. 7-44 WIRING DIAGRAM ................. 7-44 FUSE ....................... 7-45 BATTERY ....................7-45 LIGHTING COIL ..................7-45 RECTIFIER/REGULATOR ..............7-45 ECM......................7-45 ENGINE TEMPERATURE SENSOR ............7-45 THERMOSWITCH (ENGINE)..............7-45 THERMOSWITCH (EXHAUST) ..............7-45 BUZZER ....................7-45 OIL PRESSURE SWITCH............... 7-46 MULTIFUNCTION METER..............7-46 Multifunction meter................7-46 MULTIFUNCTION METER REMOVAL ...........7-46 Display function.................

  • Page 254: Electrical Components

    – ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 1 Thermoswitch (engine) 0 Cam position sensor I Buzzer 2 Starter motor A Fuel injectors J Fuel pump 3 Engine temperature sensor B Thermoswitch (exhaust) K Fuel sender 4 Spark plugs C Oil pressure switch L Multifunction meter 5 Ignition coils D Intake air pressure sensor...
  • Page 255 – ELEC ELECTRICAL BOX AND IGNITION COIL BOX ELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 16 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 ×...
  • Page 256 – ELEC ELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 16 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 28 mm 5 ×...
  • Page 257 – ELEC ELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 16 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 28 mm 5 ×...

  • Page 258: Electrical Box And Ignition Coil Box

    – ELEC ELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 20 mm 3.9 N •...
  • Page 259 – ELEC ELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 20 mm 3.9 N •...
  • Page 260 – ELEC ELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 20 mm 3.9 N •...
  • Page 261 – ELEC ELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 28 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points IGNITION COIL BOX REMOVAL Follow the left “Step”...
  • Page 262 – ELEC ELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 19 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 24 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name...
  • Page 263 – ELEC ELECTRICAL BOX AND IGNITION COIL BOX È É Ê 1 Starter relay È To ignition coil 2 Fuse holder É To battery positive terminal 3 ECM Ê To starter motor 4 Joint connector 5 Joint connector 6 Main and fuel pump relay 7 Rectifier/regulator 8 Slant detection switch 9 Ignition coil...

  • Page 264: 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 265: Low Resistance Measurement

    – ELEC ELECTRICAL ANALYSIS Low resistance measurement NOTE: • When measuring a resistance of 10 Ω or less with the digital tester, the correct measure- ment cannot be obtained because of the tester’s internal resistance. • To obtain the correct value, subtract the internal resistance from the displayed mea- surement.

  • Page 266: Peak Voltage Adaptor

    – ELEC ELECTRICAL ANALYSIS Peak voltage adaptor NOTE: • Throughout this chapter the peak voltage adaptor’s part number has been omitted. Refer to the following part number. • The peak voltage adaptor should be used with the digital tester. Peak voltage adaptor: YU-39991/90890-03172 È...

  • Page 267: Ignition System

    – ELEC IGNITION SYSTEM IGNITION SYSTEM WIRING DIAGRAM 2 : W 13 : B/R 15 : G/O 3 : P/W 4 3 2 1 8 7 6 5 17 : L/B 4 : P 5 : B/Y 18 : R/Y 6 : B/O 19 : P/G 7 : Y...
  • Page 268 – ELEC IGNITION SYSTEM WIRING DIAGRAM 2 : W 13 : B/R 15 : G/O 3 : P/W 4 3 2 1 8 7 6 5 17 : L/B 4 : P 5 : B/Y 18 : R/Y 6 : B/O 19 : P/G 7 : Y 20 : P...

  • Page 269: 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 270: 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. •...
  • Page 271 – ELEC IGNITION SYSTEM 2. Measure: • Pulser coil output peak voltage Below specification → Replace the pulser coil. Test harness (3 pins): YB-06791/90890-06791 Pulser coil output peak voltage: White (W) – Black (B) Red (R) – Black (B) Unloaded Loaded r/min Cranking...

  • Page 272: Battery

    – ELEC IGNITION SYSTEM 4. Measure: • Rectifier/regulator output voltage Below specification → Replace the recti- fier/regulator. Test harness (6 pins): YB-06790/90890-06790 Rectifier/regulator output voltage: Red (R) – Black (B) Loaded r/min 3,500 14.5 NOTE: • Before measuring the output peak voltage, make sure that the battery is fully charged.

  • Page 273: Ignition Coil

    – ELEC IGNITION SYSTEM IGNITION COIL 1. Measure: • Primary coil resistance Out of specification → Replace. Primary coil resistance: Black/white (B/W) – Red (R) 1.53–2.07 Ω at 20 °C (68 °F) NOTE: When measuring a resistance of 10 Ω or less with the digital tester, the correct measurement cannot be obtained because of the tester’s internal resistance.

  • Page 274: Engine Temperature Sensor

    – ELEC IGNITION SYSTEM ENGINE TEMPERATURE SENSOR 1. Measure: • Engine temperature sensor resistance (at the specified temperature) Out of specification → Replace. Engine temperature sensor resistance: 20 °C (68 °F): 54.2–69.0 kΩ 100 °C (212 °F): 3.12–3.48 kΩ Measurement steps: •...

  • Page 275: Thermoswitch (Engine)

    – ELEC IGNITION SYSTEM THERMOSWITCH (ENGINE) 1. Check: • Thermoswitch (engine) continuity (at the specified temperature) Out of specification → Replace. Thermoswitch (engine) continuity temperature: a 84–90 °C (183–194 °F) b 70–84 °C (158–183 °F) 1 No continuity È Temperature 2 Continuity É...

  • Page 276: Main And Fuel Pump Relay

    – ELEC IGNITION SYSTEM MAIN AND FUEL PUMP RELAY 1. Check: • Main and fuel pump relay continuity Faulty → Replace. Checking steps: • Connect the tester leads between the main and fuel pump relay terminals 5, 6 and 7. •...

  • Page 277: Throttle Position Sensor

    1. • To start the ECM normally, use the Yamaha Diagnostic System. Use the test connector 2 to start the ECU normally only if the Yamaha Diagnostic System is not available. • Measure the throttle position sensor out- put voltage.

  • Page 278: Cam Position Sensor

    • Remove the cam position sensor. • Connect the test harness (3 pins) to the cam position sensor. • Operate the Yamaha Diagnostic System. • Measure the output voltage when holding a screwdriver to the sensor and when holding it away from the sensor.

  • Page 279: Intake Air Pressure Sensor

    • Remove the intake air pressure sensor. • Connect the test harness (3 pins) to the É intake air pressure sensor. • Operate the Yamaha Diagnostic System. • Apply vacuum pressure to the intake air pressure sensor and measure the output voltage.

  • Page 280: Slant Detection Switch

    – ELEC IGNITION SYSTEM SLANT DETECTION SWITCH È 1. Check: • Slant detection switch continuity Out of specification → Replace. É Lead color Black/ Position Blue/black orange (L/B) (B/O) Normal operation È Overturned É 7-27...

  • Page 281: Fuel Control System

    – ELEC FUEL CONTROL SYSTEM FUEL CONTROL SYSTEM WIRING DIAGRAM 3 : P/W 20 : P 4 3 2 1 5 : B/Y 21 : B/Y 8 7 6 5 7 : Y 12 : W/B 23 : Pu/Y 8 : O 24 : Pu/B 17 :L/B 25 : Pu/R...
  • Page 282 – ELEC FUEL CONTROL SYSTEM WIRING DIAGRAM 3 : P/W 20 : P 4 3 2 1 5 : B/Y 21 : B/Y 8 7 6 5 7 : Y 12 : W/B 23 : Pu/Y 8 : O 24 : Pu/B 17 :L/B 25 : Pu/R 18 : R/Y...

  • Page 283: Fuel Pump

    – ELEC FUEL CONTROL SYSTEM FUEL PUMP 1. Check: • Fuel pump operating sound Fuel pump does not sound → Measure the fuel pressure. Refer to “FUEL INJECTION SYSTEM” in Chapter 4. NOTE: After the engine is stopped, the fuel pump will operate for 10 seconds.

  • Page 284: Fuel Injector

    – ELEC FUEL CONTROL SYSTEM FUEL INJECTOR Refer to “FUEL INJECTION SYSTEM” in Chapter 4. MAIN AND FUEL PUMP RELAY Refer to “IGNITION SYSTEM”. OIL PRESSURE SWITCH Refer to “IGNITION SYSTEM”. THERMOSWITCH (ENGINE) Refer to “IGNITION SYSTEM”. THERMOSWITCH (EXHAUST) Refer to “IGNITION SYSTEM”. SLANT DETECTION SWITCH Refer to “IGNITION SYSTEM”.

  • Page 285: Starting System

    – ELEC STARTING SYSTEM STARTING SYSTEM WIRING DIAGRAM 4 3 2 1 8 7 6 5 1 2 3 4 5 6 7 8 R Br Br Br FREE FREE PUSH PUSH 1 ECM : Black 2 Main and fuel pump relay : Brown 3 Fuse (20A) : Red...

  • Page 286: 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 broken Broken → Replace. Fuse rating: 3A, 20A NOTE: 20A fuse is for main relay, engine shut-off switch and rectifier/regulator.

  • Page 287: 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. •...

  • Page 288: Starter Motor

    – ELEC STARTER MOTOR STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STARTER MOTOR Follow the left “Step” for disassembly. DISASSEMBLY Starter motor Refer to “GENERATOR AND STARTER MOTOR” in Chapter 5. O-ring Not reusable Bolt Starter motor front cover O-ring...
  • Page 289 – 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 7-36...
  • Page 290 – ELEC STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Spacer Holder Starter motor yoke Reverse the disassembly steps for assembly. 7-37...

  • Page 291: 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 292: 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 293: Charging System

    – ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM 1 Rectifier/regulator : Black 2 Fuse (20A) : Green 3 Battery : Red 4 Lighting coil 7-40...

  • Page 294: Fuse

    – ELEC CHARGING SYSTEM FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in Chapter 3. LIGHTING COIL Refer to “IGNITION SYSTEM”. RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM”. 7-41...

  • Page 295: Electric Bilge Pump

    – ELEC ELECTRIC BILGE PUMP ELECTRIC BILGE PUMP WIRING DIAGRAM 4 3 2 1 8 7 6 5 1 2 3 4 5 6 7 8 1 ECM : Black 2 Main and fuel pump relay : Brown 3 Fuse (3A) : Red 4 Battery : Yellow...
  • Page 296 – ELEC ELECTRIC BILGE PUMP ELECTRIC BILGE PUMP 1. Check: • Electric bilge pump operation Incorrect → Replace. Checking steps: • Suspend the electric bilge pump in a con- – tainer filled with water. • Connect the brown lead terminal to the positive battery terminal.

  • Page 297: Indication System

    – ELEC INDICATION SYSTEM INDICATION SYSTEM WIRING DIAGRAM 4 3 2 1 8 7 6 5 1 2 3 1 ECM 8 Thermoswitch : Black : Black/yellow 2 Main and fuel pump (engine) : Brown P/W : Pink/white 9 Engine temperature relay : Green : Red/yellow...

  • Page 298: Fuse

    – ELEC INDICATION SYSTEM FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in Chapter 3. LIGHTING COIL Refer to “IGNITION SYSTEM”. RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM”. Refer to “IGNITION SYSTEM”. ENGINE TEMPERATURE SENSOR Refer to “IGNITION SYSTEM”. THERMOSWITCH (ENGINE) Refer to “IGNITION SYSTEM”.

  • Page 299: Oil Pressure Switch

    – ELEC INDICATION SYSTEM OIL PRESSURE SWITCH 1. Measure: • Oil pressure switch continuity Out of specification → Replace. Vacuum/pressure pump gauge set: YB-35956-A/90890-06756 Oil pressure switch continuity pressure: 128 kPa (1.28 kgf/cm , 18.2 psi) – 166 kPa (1.66 kgf/cm , 23.6 psi) MULTIFUNCTION METER Multifunction meter...

  • Page 300: Display Function

    – ELEC INDICATION SYSTEM Display function 1. Check: • Display function Not operate → Replace the multifunc- tion meter. 1 Buzzer : Black 2 Speed sensor : Red 3 ECM : White 4 Fuel sender : Yellow : Black/green : Black/yellow : Blue/black : Blue/red R/W : Red/white...

  • Page 301: Speedometer Display

    – ELEC INDICATION SYSTEM Speedometer display 1. Check: • Speedometer display Does not display → Measure the speed sensor output voltage and pulses. Without specification → Replace the multifunction meter. 2. Measure: • Speed sensor output voltage and pulses Out of specification → Repair or replace.

  • Page 302: Tachometer Display

    1. Check: • Voltage meter display Does not display → Check the battery voltage using the “Engine monitor” of the Yamaha Diagnostic System. Replace the multifunction meter. Low oil pressure warning indicator 1. Check: • Low oil pressure warning indicator No operating →...

  • Page 303: Overheat Warning Indicator

    • Remove the coupler of the sensor indi- cated in the multifunction meter. • Check if “Irregular” is indicated in the Diagnosis Record of the Yamaha Diag- nostic System. • Start the engine and check that the engine check warning indicator comes on and the buzzer sounds.

  • Page 304: Diagnostic Display

    • Remove the coupler of the sensor indi- cated in the multifunction meter. • Check if “Irregular” is indicated in the Diagnosis Record of the Yamaha Diag- nostic System. • Start the engine and check that the engine check warning indicator comes on and the buzzer sounds.
  • Page 305 HULL HOOD CHAPTER 8 HULL AND HOOD HANDLEBAR ....................8-1 EXPLODED DIAGRAM ................8-1 REMOVAL AND INSTALLATION CHART ..........8-1 SERVICE POINTS ..................8-6 Handlebar inspection ................8-6 Handlebar switch inspection ............... 8-6 Handlebar assembly installation ............8-6 QSTS GRIP ..................... 8-8 EXPLODED DIAGRAM ................8-8 REMOVAL AND INSTALLATION CHART ..........
  • Page 306 HULL HOOD FRONT HOOD ....................8-21 EXPLODED DIAGRAM ................8-21 REMOVAL AND INSTALLATION CHART ..........8-21 STEERING CONSOLE COVER ..............8-25 EXPLODED DIAGRAM ................8-25 REMOVAL AND INSTALLATION CHART ..........8-25 SERVICE POINTS .................. 8-31 Glove compartment assembly installation.........8-31 HOSES ......................8-32 EXPLODED DIAGRAM ................8-32 REMOVAL AND INSTALLATION CHART ..........
  • Page 307 HULL HOOD DECK AND HULL..................8-47 EXPLODED DIAGRAM ................8-47 REMOVAL AND INSTALLATION CHART ..........8-47 ENGINE MOUNT ................... 8-49 EXPLODED DIAGRAM ................8-49 REMOVAL AND INSTALLATION CHART ..........8-49 HULL REPAIR ..................8-50 Shallow scratches ................8-50 Deep scratches ................. 8-50 Cracks and punctures ...............
  • Page 308 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 Bolt NOTE: Position the corrugated tube for the throttle Handlebar cover stay cable as shown in the illustration so that the Throttle cable tube attaches to the end of the outer throttle...
  • Page 309 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 thrust nozzle) Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”. Nut/washer QSTS converter with white tape a QSTS cable 2 QSTS cable 1...
  • Page 310 HULL HANDLEBAR HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Hose packing Not reusable Buzzer NOTE: Handlebar assembly • Pass the QSTS cable and handlebar switch lead through the handle boss cover, and then install the handlebar assembly. • Install the sponges of the QSTS cables as shown and make sure that the grommet is installed to the deck securely.
  • Page 311 HULL HANDLEBAR HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR DISASSEMBLY Follow the left “Step” for disassembly. Bolt Grip end Spacer Screw/spring washer/washer 1/1/1 QSTS grip assembly Special nut NOTE: Screw Tighten the screw from the engine stop switch side.
  • Page 312 HULL HANDLEBAR HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Handlebar switch assembly Screw Throttle lever assembly Handlebar grip NOTE: Apply adhesive to the handlebar and the inner surface of the handlebar grip. Handlebar Reverse the disassembly steps for assembly.
  • Page 313 HULL HANDLEBAR HOOD SERVICE POINTS Handlebar inspection 1. Inspect: • Handlebar Bends/cracks/damage → Replace. Handlebar switch inspection Refer to “STARTING SYSTEM” in Chapter 7. Handlebar assembly installation 1. Install: • Bands 1 NOTE: After inserting the QSTS cables, buzzer lead, handlebar switch lead and throttle cable into the grommets, tie the end of grommets with the bands.
  • Page 314 HULL HANDLEBAR HOOD 3. Install: • Throttle cable NOTE: Fit the seal into the groove in the bracket. 4. Adjust: • QSTS cable length a QSTS cable length: 72 ± 0.5 mm (2.83 ± 0.02 in) NOTE: • Before adjusting the QSTS cables, set the trim grip to the neutral position.
  • Page 315 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...
  • Page 316 HULL QSTS GRIP HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Screw/washer Spacer QSTS shift lock lever Spring Spacer Cable housing QSTS grip Reverse the disassembly steps for assembly.
  • Page 317 HULL QSTS GRIP HOOD SERVICE POINTS QSTS cable inspection 1. Inspect: • QSTS cables Frays/kinks/rough movement → Replace. QSTS grip inspection 1. Inspect: • QSTS grip Damage/wear → Replace. 8-10...
  • Page 318 HULL STEERING MASTER HOOD STEERING MASTER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING MASTER REMOVAL Follow the left “Step” for removal. Steering console cover Refer to “STEERING CONSOLE COVER”. Steering cable end Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”.
  • Page 319 HULL STEERING MASTER HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING MASTER Follow the left “Step” for disassembly. DISASSEMBLY Bolt/washer Stay Spring Bolt/washer Lower housing Spring Bushing Bushing Upper housing Tilt lever 8-12...
  • Page 320 HULL STEERING MASTER HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Tilt stopper Bolt/nut/holder 4/4/4 Retainer Steering shaft assembly Steering tube Bolt/washer/spring washer 2/2/2 Shaft 1 Cross piece Reverse the disassembly steps for assembly. 8-13...
  • Page 321 HULL STEERING MASTER HOOD SERVICE POINTS Steering master components inspection 1. Inspect: • Each component part Damage/wear → Replace the steering master. 8-14...
  • Page 322 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 Service lid 1 Refer to “FRONT HOOD”.
  • Page 323 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Steering cable Packing Speed sensor coupler Screw Speed sensor Shift cable end 8-16...
  • Page 324 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Shift cable holder Shift cable Packing QSTS cable end QSTS cable Packing Reverse the removal steps for installation. 8-17...
  • Page 325 REMOTE CONTROL CABLES AND SPEED SENSOR HULL 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 outer cover below the crimp.
  • Page 326 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD QSTS cable (jet pump end) installation 1. Install: • QSTS cable (jet pump end) QSTS cable set length a (jet pump end): 13.6 mm (0.54 in) WARNING The QSTS cable must be screwed in more than 8 mm (0.31 in).
  • Page 327 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD Shift cable holder installation 1. Install: • Shift cable holders NOTE: Install the shift cable holders so that mark a and mark b are in the positions shown in the illustration. Shift cable stopper installation 1.
  • Page 328 HULL FRONT HOOD HOOD FRONT HOOD EXPLODED DIAGRAM 6 × 10 mm 6 × 18 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 18 mm 6 × 30 mm 11 10 1.5 N • m (0.15 kgf • m, 1.1 ft • Ib) 4 ×...
  • Page 329 HULL FRONT HOOD HOOD EXPLODED DIAGRAM 6 × 10 mm 6 × 18 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 18 mm 6 × 30 mm 11 10 1.5 N • m (0.15 kgf • m, 1.1 ft • Ib) 4 ×...
  • Page 330 HULL FRONT HOOD HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HINGE DISASSEMBLY Follow the left “Step” for disassembly. Circlip Pin (long) Hinge Pin (short) Damper stay Collar Grommet 8-23...
  • Page 331 HULL FRONT HOOD HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Clamp Not reusable Damper boots Damper Reverse the disassembly steps for assembly. 8-24...
  • Page 332 HULL STEERING CONSOLE COVER HOOD STEERING CONSOLE COVER EXPLODED DIAGRAM 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 5 × 20 mm 6.9 N • m (0.69 kgf • m, 5.0 ft • Ib) 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 5 ×...
  • Page 333 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 5 × 20 mm 6.9 N • m (0.69 kgf • m, 5.0 ft • Ib) 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 5 ×...
  • Page 334 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 22 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 22 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty...
  • Page 335 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 30 mm 6 × 18 mm 8 × 22 mm 8 ×...
  • Page 336 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 30 mm 6 × 18 mm 8 × 22 mm 8 ×...
  • Page 337 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 14 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points GLOVE COMPARTMENT Follow the left “Step” for disassembly. DISASSEMBLY Glove compartment Hinge assembly...
  • Page 338 HULL STEERING CONSOLE COVER HOOD SERVICE POINTS Glove compartment assembly installation 1. Install: • Hinge assembly NOTE: When installing the hinge assembly, make sure that the springs are in the position shown. 8-31...
  • Page 339 HULL HOSES HOOD HOSES EXPLODED DIAGRAM (VENT) (VENT) (VENT) 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HOSES REMOVAL...
  • Page 340 HULL HOSES HOOD EXPLODED DIAGRAM (VENT) (VENT) (VENT) 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) Step Procedure/Part name Q’ty Service points Clamp Cooling water hose Cooling water pilot outlet Packing Reverse the removal steps for installation.

  • Page 341: Shift Lever

    HULL SHIFT LEVER HOOD SHIFT LEVER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SHIFT LEVER REMOVAL Follow the left “Step” for removal. Side cover Refer to “STEERING CONSOLE COVER”. Shift cable Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”.
  • Page 342 HULL SHIFT LEVER HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Screw Base assembly Nut/washer Screw Plate Reverse the removal steps for installation. 8-35...
  • Page 343 HULL SHIFT LEVER HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BASE DISASSEMBLY Follow the left “Step” for disassembly. Bolt/washer Plate Spring Actuator Roller Shaft Shift arm Reverse the disassembly steps for assembly. 8-36...
  • Page 344 HULL SHIFT LEVER HOOD SERVICE POINTS Base assembly 1. Install: • Shift arm • Shaft Installation steps: • Install the shift arm 1 so that it comes in contact with the stopper 2 as shown. • Install the shaft 3 to the base so that it come in contact with the stopper 4 as shown.
  • Page 345 HULL SEATS AND HAND GRIP HOOD SEATS AND HAND GRIP EXPLODED DIAGRAM 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 ×...
  • Page 346 HULL SEATS AND HAND GRIP HOOD EXPLODED DIAGRAM 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 8 ×...
  • Page 347 HULL SEATS AND HAND GRIP HOOD EXPLODED DIAGRAM 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 8 ×...
  • Page 348 HULL SEATS AND HAND GRIP HOOD SERVICE POINTS Seat lock inspection 1. Inspect: • Front seat lock • Rear seat lock Damage/wear → Replace. 8-41...
  • Page 349 HULL EXHAUST SYSTEM HOOD EXHAUST SYSTEM EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 3.7 N •...
  • Page 350 HULL EXHAUST SYSTEM HOOD EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 3.7 N •...
  • Page 351 HULL EXHAUST SYSTEM HOOD EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 12 N • m (1.2 kgf • m, 8.8 ft • Ib) 6 × 25 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points...
  • Page 352 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 353 HULL EXHAUST SYSTEM HOOD Exhaust system installation 1. Install: • Exhaust joint NOTE: Be sure to fit the slit a on the exhaust joint with the projection b on the exhaust pipe. 2. Install: • Water lock NOTE: Be sure to insert the rubber hose to the line a on the water lock.
  • Page 354 HULL DECK AND HULL HOOD DECK AND HULL EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 22 mm 13 N • m (1.3 kgf • m, 9.4 ft • Ib) 16 N •...
  • Page 355 HULL DECK AND HULL HOOD EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 22 mm 13 N • m (1.3 kgf • m, 9.4 ft • Ib) 16 N •...
  • Page 356 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 1 Damper 2 Bolt Engine mount Liner...
  • Page 357 HULL ENGINE MOUNT HOOD HULL REPAIR Shallow scratches 1. Sand the scratches with 400 grit sandpa- per (either wet or dry) until the scratches are smooth. Then, sand the scratches once again with 600 grit sandpaper (either wet or dry). Deep scratches 1.
  • Page 358 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 sepa- rated edge of the area to less than 5°...
  • Page 359 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.
  • Page 360 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, lam- inate the mats from the inside. 5.
  • Page 361 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 •...
  • Page 362 FEATURES ....................9-1 Functions..................... 9-1 CONTENTS....................9-1 HARDWARE REQUIREMENTS..............9-2 GETTING STARTED ..................9-3 INSTALLING THE YAMAHA DIAGNOSTIC SYSTEM UNDER Windows 95, Windows 98, Windows Me, Windows 2000, or Windows XP ..................9-3 UPDATING THE DATABASE..............9-7 OPERATING....................9-11 CONNECTING THE COMPUTER TO THE WATERCRAFT ....9-11 CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT..................
  • Page 363 Data display item selection ...............9-42 Data comparison graph..............9-43 Engine operating hours according to engine speed......9-44 ECM No....................9-45 EXIT......................9-46 Operating procedure: ................9-46 UNINSTALLING THE YAMAHA DIAGNOSTIC SYSTEM.......9-47 TROUBLESHOOTING...................9-50 APPENDIX..................... 9-51 SETTING THE DESKTOP AREA............9-51 TROUBLE ANALYSIS...................9-53 TROUBLE ANALYSIS CHART..............9-53...
  • Page 364 ANLS INTRODUCTION FEATURES The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ECM (Electronic Control Module) of a watercraft using the com- munication cable, this software can be used to display sensor data and data stored in the ECM on a computer’s monitor.

  • Page 365: Hardware Requirements

    TRBL INTRODUCTION ANLS HARDWARE REQUIREMENTS Make sure that your computer meets the following requirements before using this software. Computer: IBM-compatible computer Operating system: Microsoft Windows 95, Windows 98, Windows Me, Windows 2000, or Win- dows XP (English version) CPU: Windows 95/98: i486X, 100 MHz or higher (Pentium 100 MHz or higher recommended) Windows Me/2000: Pentium, 166 MHz or higher (Pentium 233 MHz or higher recommended) Windows XP:...

  • Page 366: Getting Started

    Windows 98, Windows Me, Windows 2000, or Windows XP NOTE: • Before installing the Yamaha Diagnostic System, check that your computer meets the specified requirements. For detailed information on the system requirements, see page 2. • It is strongly recommended that you exit all other programs before running the installer.
  • Page 367 Fig. 3 NOTE: If the Yamaha Diagnostic System has already been installed onto your computer, the following dia- log box appears. Click the Yes button to update this program, or click the No button to quit the installation. (Fig. 4) Fig.
  • Page 368 TRBL GETTING STARTED ANLS 5. Check the target directory and the program name for the Yamaha Diagnostic System which are displayed in the dialog box. Click the Next button to start copying the program files. NOTE: • To go back to the previous dialog box (step 4), click the Back button.
  • Page 369 Click the Finish button to quit the installation program. Fig. 9 NOTE: Install the Database file before using the Yamaha Diagnostic System, otherwise the program will not operate correctly. For installation procedures, refer to “UPDATING THE DATABASE” on the next page.

  • Page 370: Updating The Database

    ANLS UPDATING THE DATABASE NOTE: When installing the Yamaha Diagnostic System for the first time, be sure to update the database. 1. Turn on your computer and start up Windows 95, Windows 98, Windows Me, Windows 2000, or Windows XP.
  • Page 371 TRBL GETTING STARTED ANLS 4. Click the Update database [F1] button or press the F1 key on your keyboard. (Fig. 12) Fig. 12 1 First menu 2 Click to update database NOTE: • Do not click the Starting service tool [Enter] button or press the Enter key on your keyboard until the database has been updated, otherwise the program will not operate correctly.
  • Page 372 TRBL GETTING STARTED ANLS 5. Insert the compact disc into the computer’s CD-ROM drive. NOTE: • All the database files will be copied from the compact disc to the computer’s hard drive automati- cally. • Any earlier version of the database saved on the hard drive will be overwritten. 6.
  • Page 373 TRBL GETTING STARTED ANLS 7. When the database is updated a confirmation screen is displayed. To quit, click the OK button or press the Enter key on your keyboard. (Fig. 15) To return to the first menu screen, click the Cancel button or press the Esc key on your key- board.

  • Page 374: Connecting The Computer To The Watercraft

    3. Connect a 12 V battery to the watercraft. NOTE: The following items should be checked before starting the Yamaha Diagnostic System. • The battery is properly charged and its specific gravity is within specification. • There are no incorrect wiring connections.
  • Page 375 TRBL OPERATING ANLS CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT Models: FX140 Top view Fig. 18 1 3-pin communication coupler 2 Wire harness coupler 3 Meter coupler NOTE: Be careful not to pinch the communication cable between the hood and the deck or to damage it. 9-12...

  • Page 376: Opening The Yamaha Diagnostic System

    Programs, and then click YAMAHA DIAGNOSTIC SYSTEM for WaterCraft. Fig. 19 4. Open the Yamaha Diagnostic System window. (Fig. 20) After about three seconds the display will automatically go to the first menu, or click or press any key to go to the first menu. (See fig.
  • Page 377 TRBL OPERATING ANLS 5. Click the Starting service tool [Enter] button or press the Enter key on your keyboard. (Fig. 21) Fig. 21 1 First menu 2 Click to start service tool NOTE: • If an error message appears and the program stops operating, follow the error messages. •...
  • Page 378 TRBL OPERATING ANLS 6. Click or press any key to display the main menu. Fig. 22 NOTE: If a diagnosis record is stored in the ECM, “Diagnosis record available,” appears as a confirmation message before the Main Menu is displayed. (Fig. 23) Fig.

  • Page 379: Selecting Commands From The Main Menu

    TRBL OPERATING ANLS SELECTING COMMANDS FROM THE MAIN MENU Eight commands appear in the Main Menu. Select a command in any of the following three ways. Two ways to select command: • Move the mouse pointer over the selected command (a or b) until it appears as a finger mark, and then click the selected command.

  • Page 380: Explanation Of Each Command

    TRBL OPERATING ANLS EXPLANATION OF EACH COMMAND 1. Diagnosis The diagnosis codes, their corresponding part name, the diagnosing results, and the diagnostic cri- teria are listed. List of items: Condition of coils (pulser coils) Condition of sensors (throttle position sensor, intake air temperature sensor, intake air pressure sensor, engine temperature sensor, and cam position sensor) Condition of battery (battery voltage) Operation of switches (slant detection switch)
  • Page 381 TRBL OPERATING ANLS 6. Data logger Two out of six items (engine speed, battery voltage, throttle position, intake air pressure, engine temperature, and oil pressure) are selected and 78 seconds of their recorded data are displayed on a graph. The operating time as compared to the engine speed and the total operating time are also displayed.
  • Page 382 TRBL OPERATING ANLS DIAGNOSIS The diagnosis codes of malfunctions recorded in the watercraft’s ECM, the diagnosis codes’ corre- sponding part name, the results of the diagnosis, and the condition of the part are listed. Eight items can be displayed at one time. Fig.
  • Page 383 TRBL OPERATING ANLS Print By selecting the Print command in the Diagnosis, Diagnosis record, Engine monitor, or Data logger mode, the data from the corresponding window can be printed. 1. Click the Print [F1] button or press the F1 key on your keyboard. The Print dialog box is dis- played.
  • Page 384 TRBL OPERATING ANLS Save By selecting the Save command in the Diagnosis, Diagnosis record, Engine monitor, or Data logger mode, the corresponding data can be saved on a disk. Operating procedure: 1. Click the Save [F2] button or press the F2 key on your keyboard. The Save As dialog box is displayed.
  • Page 385 TRBL OPERATING ANLS 2. Select the disk and folder where the data will be saved and specify its file name. (Fig. 30) Fig. 30 1 Choose folder to save in 2 Choose type of data 3 Input file name 3. Click the Save button to save the data. To cancel saving, click the Cancel button.

  • Page 386: Diagnosis Record

    TRBL OPERATING ANLS DIAGNOSIS RECORD The diagnosis codes of malfunctions that have been recorded in the watercraft’s ECM, the diagnos- tic codes’ corresponding part name, and the time when the malfunctions occurred are listed. A maximum of five items can be displayed at one time. The oldest occurrence appears on top. In addition, diagnosis codes stored in the ECM can be deleted.
  • Page 387 TRBL OPERATING ANLS Deleting diagnosis record in the ECM: 1. Select the item that you wish to delete by either clicking it or pressing the up or down arrow keys on your keyboard. NOTE: • The selected code is highlighted in light blue. •...
  • Page 388 TRBL OPERATING ANLS 3. Click the OK button or press the Enter key on your keyboard. (Fig. 35) The selected item is deleted. To cancel deleting the item, click the Cancel button or press the Esc key on your key- board.

  • Page 389: Engine Monitor

    TRBL OPERATING ANLS ENGINE MONITOR WARNING Do not use the Engine Monitor function to check the engine condition while operating a watercraft, otherwise you could become distracted, which could result in a collision. CAUTION: Be sure to avoid splashing water on the computer, adapter, and communication cable, and to avoid damaging them with strong sudden jolts or vibration.
  • Page 390 TRBL OPERATING ANLS Operating procedure: 1. To scroll the display and view other items, click in the scroll bar, or press the up or down arrow keys on your keyboard. 2. To change a displayed item, click the Select [F3] button or press the F3 key on your keyboard. 3.

  • Page 391: Stationary Test

    TRBL OPERATING ANLS STATIONARY TEST Selecting this command displays a window where stationary tests (spark ignition coil #, operate injector #, and operate electric fuel pump) can be selected. WARNING Avoid clicking the Execute and Cancel buttons repeatedly, otherwise the ECM or PC will not work properly and they could be damaged.
  • Page 392 TRBL OPERATING ANLS 1. Select the test that you wish to perform by either clicking it or pressing the up or down arrow keys on your keyboard. (Fig. 39) NOTE: • Make sure that the engine is not running. • The selected item is highlighted in light blue. •...
  • Page 393 TRBL OPERATING ANLS 5. Click the Execute button or press the Enter key on your keyboard. (Fig. 42) Fig. 42 Fig. 43 9-30...
  • Page 394 TRBL OPERATING ANLS NOTE: If the engine is running an error message is displayed. Follow the instructions that appear. (Fig. 44) Fig. 44 6. While checking the information that appears in the Test situation column, follow the test instructions in the messages that are displayed. (See fig. 43.) NOTE: If an error occurs while the test is being performed, an error message is displayed.
  • Page 395 TRBL OPERATING ANLS 9. To perform the test again to the same cylinder, click the Execute button or press the Enter key on your keyboard. To perform the test on a different cylinder, click the Return [ESC] button or press the Esc key on your keyboard to return to main menu where a different test can be selected.
  • Page 396 TRBL OPERATING ANLS Operating injector procedure: A voltage is applied to the injector of the selected cylinder, the injector is activated, and then the fuel system is checked. The fuel is injected 20 times within two seconds. WARNING • Do not perform the test with the injector removed from the throttle body or with any fuel system parts removed.
  • Page 397 TRBL OPERATING ANLS 3. Click the Execute button or press the Enter key on your keyboard. (Fig. 49) Fig. 49 NOTE: If an error occurs while the test is being performed, an error message is displayed. Follow the instructions that appear. 4.
  • Page 398 TRBL OPERATING ANLS 5. To perform the test again on the same cylinder, click the Execute button or press the Enter key on your keyboard. To perform the test on a different cylinder, click the Return [ESC] button or press the Esc key on your keyboard to return to the window where a different test can be selected.
  • Page 399 TRBL OPERATING ANLS 1. Select the test to be performed, and then click the Select button or press the Enter key on your keyboard. (Fig. 52) Fig. 52 NOTE: • Make sure that the engine is not running. • The selected item is highlighted in light blue. •...
  • Page 400 TRBL OPERATING ANLS 2. Click the Execute button or press the Enter key on your keyboard. (Fig. 53) Fig. 53 NOTE: If an error occurs while the test is being performed, an error message is displayed. Follow the instructions that appear. 3.

  • Page 401: Active Test

    TRBL OPERATING ANLS ACTIVE TEST Selecting this command displays a window where active tests can be selected. WARNING Avoid clicking the Execute and Cancel buttons repeatedly, otherwise the ECM or PC will not work properly and they could be damaged. Fig.
  • Page 402 TRBL OPERATING ANLS Dropping a cylinder: Start the engine and observe the changes in engine speed for 20 seconds. For the first ten seconds operate all four cylinders, and then stop one cylinder for five seconds. For the last five seconds operate all four cylinders. A screen that allows you to select which ignition and fuel to cut is displayed.
  • Page 403 TRBL OPERATING ANLS NOTE: If the engine is not running, an error message is displayed. Follow the instructions that appear. (Fig. Fig. 57 5. While checking the information that appears beside Test situation and Engine Speed, follow the test instructions in the messages that are displayed. (Fig. 56) NOTE: If an error occurs while the test is being performed, an error message is displayed.

  • Page 404: Data Logger

    TRBL OPERATING ANLS DATA LOGGER Monitor item selection A window appears that allows you to select the Data comparison graph or the Engine operating hours according to engine speed. Fig. 59 1 Triangle mark Operating procedure: 1. Select the desired item by either clicking it or pressing the up or down arrow keys on your key- board.
  • Page 405 TRBL OPERATING ANLS Data display item selection A window appears that allows you to select the items to be graphed. No more than two items can be displayed. Fig. 60 1 Selected items Operating procedure: 1. Select the desired items by either clicking them or pressing the up or down arrow keys on your keyboard, then pressing the space bar.
  • Page 406 TRBL OPERATING ANLS Data comparison graph A line graph appears with the items selected in the Data display item selection window on the ver- tical axes and the Time before engine stop on the horizontal axis. (Fig. 61) Fig. 61 NOTE: •...
  • Page 407 TRBL OPERATING ANLS Engine operating hours according to engine speed The operating hours as compared to the engine speed and the total operating hours are displayed. (Fig. 62) Fig. 62 A window is displayed showing the amount of hours that the engine is operated at each engine speed range.
  • Page 408 TRBL OPERATING ANLS ECM No. The ECM part number of the watercraft is read from the ECM and is displayed. (Fig. 63) Fig. 63 9-45...
  • Page 409 TRBL OPERATING ANLS EXIT The program is exited. Operating procedure: 1. Click the Exit button or press any number key (1–8). Fig. 64 2. Click the OK button or press the Enter key on your keyboard to exit the program. To cancel exiting the program, click the Cancel button or press the Esc key on your keyboard.
  • Page 410 2. From the taskbar at the bottom of your computer screen, click the Start button, point to Set- tings, and then open the Control Panel. 3. In the Control Panel dialog box, double-click Add/Remove Programs. (Fig. 66) Fig. 66 4. Select YAMAHA DIAGNOSTIC SYSTEM for WaterCraft and click the Add/Remove button. (Fig. 67) Fig. 67 9-47...
  • Page 411 TRBL OPERATING ANLS 5. Click the Yes button in the confirmation window to uninstall the utility software. To cancel the uninstall operation of the utility software, click the No button. (See figs. 68–70.) Fig. 68 Fig. 69 Fig. 70 9-48...
  • Page 412 TRBL OPERATING ANLS 6. If the following message appears, click the Details... button. Fig. 71 1 Uninstall completed. Some elements could not be removed. You should manually remove items related to the application. 7. Check the contents of the message. If an element could not be removed, delete it manually. Fig.

  • Page 413: Troubleshooting

    TRBL TROUBLESHOOTING ANLS TROUBLESHOOTING Error content Cause Action Communication cable Communication cable is discon- Connect communication cable related error occurs nected. between the computer’s commu- nication port and 3-pin communi- cation coupler of the watercraft. Battery is disconnected from the Connect battery to watercraft.
  • Page 414 TRBL APPENDIX ANLS APPENDIX SETTING THE DESKTOP AREA Use the following procedure to set the Yamaha Diagnostic System desktop area. × × Compatible with VGA (640 480 pixels) or SVGA (800 600 pixels) or more recommended 1. From the taskbar at the bottom of your computer screen, click the Start button, point to Set- tings, and then open the Control Panel.
  • Page 415 TRBL APPENDIX ANLS 4. Click the OK button in the confirmation window to set the display area. To cancel, click the Can- cel button. (See figs. 75–76.) Fig. 75 Fig. 76 9-52...

  • Page 416: Trouble Analysis

    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 are not rusty. 4.
  • Page 417 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part chapter POWER UNIT Compression Cylinder head gaskets Cylinder block Crankcase Piston rings Pistons Bearings Thermostat Valve(s) and valve seat(s) Valve clearance adjusting pad(s) Camshaft(s) Timing chain Oil pump Engine oil Oil filter Oil pressure switch Bearing housing...
  • Page 418 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part chapter JET PUMP UNIT Duct Impeller Intake grate Bearings Intake duct Water inlet hose Bilge hose Bilge strainer Bilge hose joint ELECTRICAL Ignition system, fuel control system • Pulser coils •...
  • Page 419 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part chapter Starting system • Start switch • Starter relay • Starter motor Charging system • Lighting coil • Rectifier/regulator • Fuses • Battery leads — • Battery Electric bilge pump •...
  • Page 420 Incorrect oil pressure sensor signal Incorrect slant detection switch signal Incorrect data transmission If the Yamaha Diagnostic System is not used to check the symptoms listed in the table, the error codes can be checked easily with the self-diagnosis in the multifunction meter. How-...
  • Page 422 WIRING DIAGRAM FX140 1 Fuse (20A) Color code 2 Fuse (3A) : Black 3 Starter relay : Brown 4 Slant detection switch : Green 5 Main and fuel pump relay : Blue 6 ECM : Orange 7 Rectifier Regulator : Pink 8 Cam position sensor : Red 9 Thermoswitch (exhaust)
  • Page 424 YAMAHA MOTOR CORPORATION, USA Printed in USA × 1 CR Mar. 2002 – F1B-28197-1E-11 (FX1000-A) (E_1)
  • Page 425 FX140 Pu/Y Pu/R Pu/G Pu/B Pu/G Pu/Y Pu/R Br Br Pu/G Pu/Y Pu/B Pu/R R Br Br Br FREE FREE FREE PUSH PUSH PUSH È Br B 2 3 4 5 6 7 8 9 10 W/R W/B 11 12 13 15 17 18 19 20 21 23 L/R W/B B/R G/O L/B R/Y P/G B/Y Pu/Y 24 25 26 27 28...
  • Page 426 Pu/R Pu/Y Pu/B Pu/G Pu/G Pu/B Pu/R Pu/Y Pu/B Pu/G Pu/Y Pu/R Pu/R Pu/Y Pu/G Pu/B È...

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