Yamaha WaveRunner VXR VX1800A Manuals

Manuals and User Guides for Yamaha WaveRunner VXR VX1800A. We have 1 Yamaha WaveRunner VXR VX1800A manual available for free PDF download: Service Manual

Yamaha WaveRunner VXR VX1800A Service Manual (318 pages)

Brand: Yamaha | Category: Boat | Size: 27.98 MB

Table of Contents

3
- General Information
  
  4
- Safety While Working
  
  6
  - Rotating Parts
    6
  - Hot Parts
    6
  - Electric Shock
    6
  - Impeller
    6
  - Handling of Gasoline
    6
  - Ventilation
    6
  - Self-Protection
    6
  - Working with Crane
    7
  - Handling of Heat Gun
    7
  - Parts, Lubricants, and Sealants
    7
  - Handling of Sealants
    8
  - Special Service Tool
    8
  - Tightening Torque
    8
  - Non-Reusable Parts
    8
  - Disassembly and Assembly
    8
- Identification Number
  
  9
- How to Use this Manual
  
  10
  - Manual Format
    10
  - Conditions When Testing and Adjusting
    11
  - Abbreviation
    11
- Adhesive, Lubricant, Sealant, and Thread Locking Agent
  
  13
  - Symbols
    13
- Special Service Tool
  
  14
- Model Feature
  
  24
  - General Feature
    24
  - Model Equipment Comparison Table
    25
- Technical Tips
  
  26
  - Engine Control
    26
  - Ride System
    28
  - Ride Motor
    29
  - ETV System
    30
  - Shift Control
    31
  - Engine Control System
    33
  - Deck and Hull
    36
  - Lubrication System
    37
  - Hose Routing
    38
  - Cooling Water Flow
    39
Specification

41
- Model Data
  
  42
- Fuel System Technical Data
  
  44
- Fuel System
  
  44
- Power Unit
  
  45
- Power Unit Technical Data
  
  45
  - Cylinder Head ASSY
    45
  - Crankcase ASSY
    46
- Jet Pump Unit
  
  48
- Jet Pump Unit Technical Data
  
  48
- Electrical Technical Data
  
  49
  - Ignition System
    49
  - Charging System
    49
  - Control System
    49
  - Fuel System
    51
  - Starting System
    51
  - Meter System
    52
- Specified Tightening Torque
  
  53
- Torque Wrench Reading (Setting Value)
  
  53
- General Tightening Torque
  
  53
- Cable and Hose Routing
  
  54
  - Starboard Bow View
    54
  - Top View
    55
  - Port View
    57
  - Coupler Layout
    58
Maintenance

59
- Maintenance Interval Chart
  
  60
- Periodic Service
  
  62
  - Fuel Line Check
    62
  - Fuel Filler Cap and Water Separator Check
    62
  - Fuel Tank Check
    62
  - Water Inlet Strainer Check
    62
  - Cooling Water Hose Check
    62
  - Engine Oil Level Check
    63
  - Engine Oil Replacement
    63
  - Oil Filter Replacement
    64
  - Intermediate Housing Lubrication
    64
  - Spark Plug Check
    64
  - Battery and Battery Lead Check
    65
  - Steering Master Check
    66
  - Steering Cable Check
    66
  - Trim Rod Check
    67
  - Shift Rod and Reverse Gate Check
    67
  - Air Intake Hose Check
    68
  - Throttle Valve Lubrication
    68
  - Exhaust System Check
    69
  - Breather Hose Check
    69
  - Impeller Check
    69
  - Jet Thrust Nozzle Check
    69
  - Jet Vacuum Bilge Draining System Check
    69
  - Drain Plug Check
    70
  - Anode Check
    70
  - Valve Clearance Measurement
    70
  - Rubber Coupling Check
    72
  - Engine Mount Check
    72
Fuel System

73
- Air Filter Case and Fuel Hose
  
  76
  - Fuel Hose Disconnection
    76
  - Fuel Pressure Measurement
    76
  - Fuel Hose Disassembly
    77
  - Air Filter Element Check
    77
  - Fuel Hose Assembly
    77
- ETV and Fuel Injector
  
  79
  - ETV Check
    80
  - Fuel Injector Check
    80
  - Fuel Rail and Injector Installation
    80
- Fuel Tank and Fuel Pump Module
  
  82
  - Fuel Tank Removal
    84
  - Fuel Pump Module Removal
    85
  - Fuel Sender Removal
    85
  - Fuel Pump Module Check
    85
  - Check Valve Check
    85
  - Fuel Filler Cap Check
    86
  - Fuel Sender Installation
    86
  - Fuel Pump Module Installation
    86
  - Fuel Tank Installation
    87
Power Unit

89
- Power Unit
  
  90
- Engine Unit (Check and Adjustment)
  
  92
  - Compression Pressure Check
    92
- Engine Unit
  
  93
- Exhaust Manifold
  
  94
- Engine Unit and Coupling Cover
  
  96
- Engine Mount
  
  97
  - Engine Unit Removal
    98
  - Engine Mount and Spacer Check
    101
  - Engine Unit Installation
    101
- Muffler
  
  107
  - Exhaust Pipe Disassembly
    108
  - Exhaust Pipe Assembly
    108
- Wire Harness
  
  109
- Electrical Box
  
  110
- Intake Manifold
  
  115
  - Oil Level Pipe Installation
    117
  - Intake Manifold Installation
    117
- Oil Cooler, Oil Pump, and Drive Gear
  
  118
  - Oil Pump and Oil Pump Drive Gear Removal
    120
  - Oil Cooler Check
    120
  - Oil Pump Check
    120
  - Oil Pump Drive Gear and Oil Pump Installation
    120
- Cylinder Head Cover
  
  122
- Camshaft
  
  123
  - Camshaft Removal
    125
  - Camshaft Sprocket Removal
    126
  - Camshaft Check
    126
  - Camshaft Journal Oil Clearance Check
    127
  - Timing Chain Tensioner Check
    128
  - Camshaft Sprocket Installation
    128
  - Camshaft Installation
    129
  - Valve Clearance Adjustment
    131
  - Valve Pad Selection Table
    134
- Cylinder Head
  
  136
- Valve and Valve Spring
  
  137
  - Cylinder Head Disassembly
    138
  - Cylinder Head Check
    138
  - Valve Spring Check
    138
  - Valve Check
    139
  - Valve Guide Check
    140
  - Valve Guide Removal
    140
  - Valve Guide Installation
    140
  - Valve Seat Check
    141
  - Valve Seat Refacing
    142
  - Cylinder Head Assembly
    144
  - Cylinder Head Installation
    145
- Generator Cover ASSY and Flywheel Magneto
  
  146
- Generator Cover
  
  148
  - Drive Coupling Removal
    149
  - Flywheel Magneto Removal
    149
  - Generator Cover ASSY Disassembly
    151
  - Starter Clutch Operation Check
    151
  - Generator Cover ASSY Assembly
    152
  - Flywheel Magneto Assembly
    153
  - Flywheel Magneto Installation
    153
  - Drive Coupling Installation
    156
- Cylinder Block and Electrical Part
  
  158
- Oil Separator Tank and Oil Pan
  
  160
  - Anode Check
    162
  - Oil Pan Assembly
    162
  - Oil Separator Tank Cover Installation
    162
- Crankcase, Connecting Rod, and Piston
  
  164
  - Crankcase Disassembly
    166
  - Connecting Rod and Piston Removal
    166
  - Crankcase Check
    166
  - Cylinder Block Check
    167
  - Piston Check
    167
  - Piston Clearance Check
    167
  - Piston Ring Check
    167
  - Piston Pin Check
    169
  - Connecting Rod Check
    169
  - Crankshaft Check
    169
  - Crankshaft Pin Oil Clearance Check
    170
  - Connecting Rod Big End Side Clearance Check
    171
  - Connecting Rod Bearing Selection
    172
  - Crankshaft Journal Oil Clearance Check
    172
  - Crankshaft Bearing Selection
    174
  - Connecting Rod and Piston Installation
    175
  - Crankcase Assembly
    177
Jet Pump Unit

181
- Intake Grate and Ride Plate
  
  182
- Jet Pump Unit
  
  183
  - Jet Pump Unit Removal
    184
  - Impeller Check
    184
  - Jet Pump Unit Installation
    184
  - Trim Rod Adjustment
    185
  - Jet Thrust Nozzle Angle Adjustment
    186
- Reverse Gate
  
  188
- Nozzle and Nozzle Ring
  
  189
- Impeller Housing and Impeller Duct ASSY
  
  190
- Impeller, Drive Shaft, and Impeller Duct
  
  191
  - Impeller Duct ASSY Disassembly
    192
  - Impeller Housing Check
    193
  - Drive Shaft Check
    193
  - Impeller Duct ASSY Assembly
    193
  - Impeller Duct, Impeller Housing, and Nozzle Installation
    195
- Transom Plate and Hoses
  
  199
  - Bilge Strainer Check
    199
  - Transom Plate Installation
    199
- Intermediate Housing
  
  200
  - Intermediate Housing Removal
    201
  - Intermediate Housing Disassembly
    201
  - Intermediate Housing Assembly
    202
  - Intermediate Housing Installation
    203
Electrical System

206
- Electrical Components
  
  208
  - Engine
    208
  - Deck and Hull
    209
  - Electrical Box
    210
  - ECM Circuit Diagram
    211
  - ECM Coupler Layout
    214
- Electrical Analysis
  
  216
  - Electrical Component Check Using the YDIS
    216
  - Power Supply to the ECM
    216
  - Peak Voltage Measurement
    216
  - Test Lead Preparation
    217
- Ignition System
  
  218
  - Ignition Spark Check
    218
  - Ignition Coil Check
    218
  - Pickup Coil Check
    219
- Charging System
  
  220
  - Stator Coil Check
    220
  - Rectifier/Regulator Check
    220
- Control System
  
  222
  - Oil Pressure Switch Check
    222
  - Thermo Switch Check
    222
  - Thermo Sensor Check
    223
  - Engine Temperature Sensor Check
    223
  - Intake Air Temperature Sensor Check
    224
  - Intake Air Pressure Sensor Check
    225
  - TPS Check
    225
  - ETV Circuit Continuity
    227
  - APS Check
    227
  - APS Circuit Continuity
    228
  - ETV Relay Check
    229
  - RPS Check
    230
  - RPS Circuit Continuity
    230
  - SCU Relay Check
    231
  - Electric Trim Switch Check
    232
  - Cam Position Sensor Check
    232
  - Slant Detection Switch Check
    233
  - Steering Sensor Check
    234
  - ECM Check
    234
  - Earth Plate Check
    235
- Fuel System
  
  236
  - Fuel Injector Check
    236
  - Fuel Pump Relay Check
    236
  - Fuel Pump Module Check
    237
- Starting System
  
  238
  - Fuse Check
    238
  - Handlebar Switch (Left) Check
    238
  - Main Relay Check
    238
  - Starter Relay Check
    239
- Starter Motor
  
  241
  - Starter Motor Operation
    242
  - Armature Check
    242
  - Brush Holder Check
    243
- Remote Control System
  
  244
  - Remote Control Transmitter Check
    244
  - Remote Control Receiver Check
    245
  - Transmitter Registration
    245
- Indication System
  
  247
  - Multifunction Meter Check
    247
  - Speed Sensor Check
    247
  - Fuel Level Meter Display and Fuel Level Warning Indicator Check
    248
  - Check Engine Warning Indicator Check
    248
  - Diagnostic Display Check
    249
  - Oil Pressure Warning Indicator Check
    249
  - Engine Overheat Warning Indicator Check
    249
  - Buzzer Check
    250
Hull and Hood

252
- Steering Pad and Handlebar Cover
  254
- Handlebar and Handlebar Switch
  255
  - Lead Routing
    256
  - Handlebar Installation
    256
- Front Hood
  259
- Side Cover
  261
- Center Cover
  262
- Steering Master ASSY
  264
- Steering Master
  266
  - Steering Arm ASSY Installation
    267
- Steering Cable and Speed Sensor Lead
  268
  - Steering Cable Installation (Steering Master End)
    269
  - Steering Cable Installation (Jet Pump End)
    269
- Seat and Handgrip
  270
- Ventilation Hose and Water Separator
  274
  - Cooling Water Pilot Outlet Installation
    274
- Exhaust System
  275
  - Exhaust System Installation
    277
- Ride Motor
  280
  - Ride Motor Removal
    280
  - Ride Motor Installation
    281
  - Ride System Initialization
    283
- Rear Section
  284
  - Spout Installation
    286
  - Reboarding Step Installation (VXR)
    286
- Deck and Hull
  287
- Troubleshooting
  
  291
  - Ydis
    293
    
    Function
    293
    
    Connecting the Communication Cable to the Watercraft
    295
  - Engine Unit Troubleshooting
    296
    
    Using the YDIS for Engine Unit Troubleshooting
    296
    
    Diagnostic Code Table
    298
    
    Diagnostic Code and Checking Step
    299
    
    Engine Unit Troubleshooting (Diagnostic Code Not Detected)
    306
- Appendix
  
  313
  - Wiring Diagram
    314

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Yamaha WaveRunner VXR VX1800A Manuals

Yamaha WaveRunner VXR VX1800A Service Manual (318 pages)

Table of Contents

Table of Contents

General Information

Safety While Working

Identification Number

How to Use this Manual

Adhesive, Lubricant, Sealant, and Thread Locking Agent

Special Service Tool

Model Feature

Technical Tips

Specification

Model Data

Fuel System Technical Data

Fuel System

Power Unit

Power Unit Technical Data

Jet Pump Unit

Jet Pump Unit Technical Data

Electrical Technical Data

Specified Tightening Torque

Torque Wrench Reading (Setting Value)

General Tightening Torque

Cable and Hose Routing

Maintenance

Maintenance Interval Chart

Periodic Service

Fuel System

Air Filter Case and Fuel Hose

ETV and Fuel Injector

Fuel Tank and Fuel Pump Module

Power Unit

Power Unit

Engine Unit (Check and Adjustment)

Engine Unit

Exhaust Manifold

Engine Unit and Coupling Cover

Engine Mount

Muffler

Wire Harness

Electrical Box

Intake Manifold

Oil Cooler, Oil Pump, and Drive Gear

Cylinder Head Cover

Camshaft

Cylinder Head

Valve and Valve Spring

Generator Cover ASSY and Flywheel Magneto

Generator Cover

Cylinder Block and Electrical Part

Oil Separator Tank and Oil Pan

Crankcase, Connecting Rod, and Piston

Jet Pump Unit

Intake Grate and Ride Plate

Jet Pump Unit

Reverse Gate

Nozzle and Nozzle Ring

Impeller Housing and Impeller Duct ASSY

Impeller, Drive Shaft, and Impeller Duct

Transom Plate and Hoses

Intermediate Housing

Electrical System

Electrical Components

Electrical Analysis

Ignition System

Charging System

Control System

Fuel System

Starting System

Starter Motor

Remote Control System

Indication System

Hull and Hood

Troubleshooting

Appendix

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