Page 1 WaveRunner GX1800 (F2R) GX1800A (F2C) SERVICE MANUAL LIT-18616-03-18 F2C-28197-1M-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: General Information
Contents General information INFO Specification SPEC Periodic check and adjustment Fuel system FUEL Power unit POWR Jet pump unit PUMP – Electrical system ELEC Hull and hood HULL HOOD Troubleshooting TRBL SHTG...
Page 4: Table Of Contents
Hull design....................1-19 Engine overview ..................1-20 Supercharger assembly................1-21 Air cooler assembly ................. 1-21 ECM......................1-22 Drive shaft ....................1-22 Dual analog meter unit ................1-23 Information display warnings ..............1-24 Self-diagnosis ..................1-24 Yamaha Security System ................ 1-25...
Page 5 INFO Technical tips ....................1-26 Engine control..................1-26 ECM circuit diagram................1-27 ECM coupler layout................1-28 Control system..................1-30...
Page 6: How To Use This Manual
INFO How to use this manual How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. •...
Page 7: Symbols
7 Apply 4-stroke motor oil 8 Apply water resistant grease (Yamaha grease A) 9 Apply molybdenum disulfide grease 0 Apply Epnoc grease AP #0 A Apply Silicone grease Symbols B to H in an exploded diagram indi-...
Page 8: Abbreviation
Intake Overload Off-throttle steering system PORT Port side QSTS Quick Shift Trim System Revolutions Per Minute Society of Automotive Engineers STBD Starboard side STERN Stern end Transistor Controlled Ignition Top Dead Center Throttle Position Sensor Upside YDIS Yamaha Diagnostic System...
Page 9: Safety While Working
Protect your hands and feet by wearing protec- tive gloves and safety shoes when necessary. Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants, and sealants, or those recommended by Yamaha, when servicing or repairing the watercraft. Under normal conditions, the lubricants men- tioned in this manual should not harm or be hazardous to your skin.
Page 10: Good Working Practices
INFO Safety while working 5. Keep a supply of clean, lint-free cloths for wiping up spills, others. 6. Maintain good standards of personal and industrial hygiene. Good working practices Special service tool Use the recommended special service tools to protect parts from damage. Use the right tool in the right manner;...
Page 11: Identification Number
INFO Identification number Identification number Primary I.D. number The primary I.D. number is stamped on a label attached to the inside of the engine compart- ment. Starting primary I.D. number: F2R: 800101 F2C: 800101 Engine serial number The engine serial number is stamped on a label attached to the engine unit.
Page 12: Special Service Tool
4 Dial gauge Special service tool YU-03097 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. • For USA and Canada, use part numbers 90890-01252 starting with “YB-”, “YM-”, “YU-”, or “YW-.”...
Page 13 INFO Special service tool 8 Fuel pressure gauge C Digital multimeter YB-06766 YU-34899-A D Peak voltage adapter 90890-06786 YU-39991 9 Leakage tester 90890-06840 E Digital circuit tester 90890-03174 0 Air cooler attachment F Peak voltage adapter B 90890-06731 90890-03172 A YDIS (connecting kit) 60V-85300-04 G Spark checker YM-34487...
Page 14: Removal And Installation
INFO Special service tool H Test harness (3 pins) Removal and installation YB-06877 1 Oil filter wrench Test harness HM090-3 (3 pins) 90890-06830 90890-06877 2 Exhaust pipe wrench I Lower unit pressure/vacuum tester 90890-06726 YB-35956-A 3 Bearing separator J Vacuum/pressure pump gauge set 90890-06534 90890-06756 4 Slide hammer and adapters...
Page 15 INFO Special service tool 7 Stopper guide stand C Valve spring compressor 90890-06538 YM-04019 90890-04019 8 Shaft holder 90890-06721 D Compressor adapter YM-04114 Valve spring compressor attachment 90890-04114 9 Driver handle 90890-06722 E Valve guide remover YB-06801 90890-06801 0 Bearing inner race attachment 90890-06661 F Valve guide installer YB-06810...
Page 16 INFO Special service tool H Neway valve seat kit M Rotor puller YB-91044 90890-01080 I Valve seat cutter holder N Driver handle (small) 90890-06812 YB-06229 J Valve seat cutter O Driver rod LS 90890-06606 Intake 90890-06720 (30°) 90890-06325 (45°) 90890-06324 (60°) Exhaust 90890-06818 (30°) 90890-06555 (45°)
Page 17 INFO Special service tool S Bearing pressure C X Drive shaft holder 90890-02393 YB-06201 Drive shaft holder 6 90890-06520 T Driver handle (large) YB-06071 Y Driver rod L3 90890-06652 U Forward gear outer race installer YB-41446 Z Drive shaft needle bearing installer and remover YB-06194 V Ball bearing attachment...
Page 18 INFO Special service tool ] Bearing cup installer YB-06167 _ Shaft holder 90890-06730 a Needle bearing installer YB-06434 b Bearing puller legs YB-06523 c Bearing attachment 90890-06727 1-13...
Page 19: Feature And Benefit
INFO Feature and benefit Feature and benefit Watercraft overview The FZR and FZS feature a newly designed hull, which is made of NanoXcel. Because the FZR is designed for 2 riders and the FZS is designed for 3 riders, the shape of the rear seat is different for each model.
Page 20: Rear Seat
INFO Feature and benefit Rear seat The rear seats and handgrips for the FZR and FZS have different shape. Therefore, the rear seats and handgrips are not interchangeable. È È É É È FZR 1 Front seat É FZS 2 Deck beam 3 Rear seat 4 Handgrip 1-15...
Page 21: Telescopic Steering System
INFO Feature and benefit Telescopic steering system The FZR and FZS feature a newly designed steering master. The position of the handlebar can be adjusted up or down to 3 positions using the lock lever. In addition, the watercraft are equipped with an OTS system, which has been used for other models.
Page 22: Shift Lever Assembly
INFO Feature and benefit Shift lever assembly The FZR and FZS feature a new mechanism for the shift lever assembly. Compared to the FX SHO series, the shape of the shift cable bracket and the installation angle of the shift cable have changed.
Page 23: Watertight Compartment
INFO Feature and benefit Watertight compartment The watertight compartment for the FZR and FZS is located under the rear seat. This was changed from the FX SHO series where the watertight compartment is located in front of the handlebar. È É...
Page 24: Hull Design
INFO Feature and benefit Hull design The FZR and FZS feature a newly designed rounded-keel hull. Therefore, the shape of the keel line a is different than the keel line for the FX SHO series. È É È FZR, FZS (Rounded keel) É...
Page 25: Engine Overview
INFO Feature and benefit Engine overview The FZR and FZS feature the same 1.8 L in-line 4-cylinder supercharged engine as the FX SHO series. 1 Oil filler cap 8 4 in 1 exhaust system 2 Ignition coil 9 Oil filter 3 Intake manifold 0 Oil cooler assembly 4 Throttle body assembly...
Page 26: Supercharger Assembly
INFO Feature and benefit Supercharger assembly The supercharger is equipped with a gear-driven impeller that compresses the intake air. The impel- ler uses a step-up gear with 2 steps to transmit the rotation of the crankshaft. The impeller rotates about 10 times faster than the crankshaft. The impeller drive gear is equipped with a one-way clutch;...
Page 27: Ecm
INFO Feature and benefit The FZR and FZS are not equipped with the cruise assist and no-wake mode functions from the FX SHO series. Therefore, the ECM for the FZR and FZS is different than the ECM for the FX SHO series and the ECMs are not interchangeable.
Page 28: Dual Analog Meter Unit
6 “L-MODE” indicator light Comes on when the L-MODE (low-RPM mode) is selected. Comes on when the unlock mode of the Yamaha Security 7 “UNLOCK” indicator light System is selected. Initial operation When the unlock button on the remote control transmitter is pushed, the buzzer sounds 2 or 3 times, the speedometer 2 and tachometer 4 make 1 sweep, the information display 3, the “WARNING”...
Page 29: Information Display Warnings
INFO Feature and benefit Information display warnings “WARNING” Condition Action Buzzer indicator light The fuel The lowest fuel level Flashes Sounds remaining in segment and the intermit- the fuel tank fuel indicator flash. tently drops to about 18 L The engine The engine over- Flashes 5 Sounds...
Page 30: Yamaha Security System
Mode: L-MODE When the Yamaha Security System is set to the lock mode, the current selection for the operation mode, L-mode or normal mode, is saved. Accordingly, when the Yamaha Security System is set to the unlock mode, the number of times that the buzzer sounds will change depending on the cur- rently selected operation mode.
Page 31: Technical Tips
INFO Technical tips Technical tips Engine control The ECM controls ignition timing and fuel injection with information received from the sensors and switches installed on the engine and on the basis of the 3D map saved in the ECM. Part name Functions 1 Cam position sensor Detects the rotational position of the camshaft.
Page 32: Ecm Circuit Diagram
INFO Technical tips ECM circuit diagram Stator Rectifier Fuel injector #1 coil regulator Fuel injector #2 Main relay Fuse (20A) Fuel injector #3 µ Fuse (3A) Fuel injector #4 ¥ Remote control receiver Fuse Engine (30A) start switch Ignition coil #1 Starter º...
Page 33: Ecm Coupler Layout
INFO Technical tips ECM coupler layout 1 2 3 4 5 6 7 27 28 29 30 31 32 33 54 55 56 57 58 59 60 61 8 9 10 11 12 13 34 35 36 37 38 39 62 63 64 65 66 67 68 69 14 15 16 17 18 19...
Page 34 INFO Technical tips Lead External connec- Lead External connec- Lead External connec- color tion lead color tion lead color tion lead TPS 2 Pu/R Fuel injector #1 – – TPS power Fuel injector #2 Pu/B – – source ETV relay power Ignition coil #4 –...
Page 35: Control System
INFO Technical tips Control system Item Condition Action Remarks Reverse with Shift lever is in the Maximum engine speed is Cancel: traction con- reverse position and limited to 3,000 r/min. Shift lever is returned to the trol the reverse sensor forward position.
Page 36 INFO Technical tips Item Condition Action Remarks Cam position Control is activated • Opening angle of the ETV Cancel: sensor failure when the following is regulated. Engine is stopped. control conditions are main- • Maximum engine speed is tained for 10 seconds: limited to approximately •...
Page 37 INFO Technical tips Item Condition Action Remarks L-MODE con- L-MODE is activated. • Opening angle of the ETV Cancel: trol is regulated. L-MODE is deactivated. • Ignition timing is con- trolled. • Maximum engine speed is limited to 5,400 r/min. Slant detec- Control is activated Ignition and fuel injection are...
Page 38 INFO Technical tips — MEMO — 1-33...
Page 39 SPEC Chapter 2 Specification General specification..................2-1 Maintenance specifications ................2-3 Engine ...................... 2-3 Fuel system ....................2-6 Jet pump unit .................... 2-7 Hull and hood ................... 2-7 Electrical ....................2-7 Tightening torques..................2-11 Specified torques..................2-11 General torque..................2-16 Lubrication system ..................
Page 40: General Specification
SPEC General specification General specification Model Item Unit Model code Hull Engine/jet 6AN/6AN Dimensions Length mm (in) 3,350 (131.9) 3,370 (132.7) Width mm (in) 1,230 (48.4) Height mm (in) 1,160 (45.7) Weight Dry weight kg (lb) 366 (807) 369 (813) Maximum capacity Person/kg (lb) 2/160 (353)
Page 41 SPEC General specification Model Item Unit Fuel and oil Fuel type Regular unleaded gasoline Minimum fuel rating PON* RON* Fuel tank capacity 70 (18.5, 15.4) (US gal, Imp.gal) Engine oil type 4-stroke motor oil Engine oil grade SE, SF, SG, SH, SJ, or SL 10W-30, 10W-40, 20W-40, or 20W-50 Engine oil quantity Total amount...
Page 42: Maintenance Specifications
SPEC Maintenance specifications Maintenance specifications Engine Model Item Unit Power unit Compression pressure 610 (6.1, 86.8) (kgf/cm , psi) Air cooler Holding pressure Water passage 200 (2.0, 28.5) (kgf/cm , psi) Air passage 100 (1.0, 14.2) (kgf/cm , psi) Oil cooler Holding pressure Water passage 200 (2.0, 28.5)
Page 43 SPEC Maintenance specifications Model Item Unit Timing chain Model/number of links 97RH2015–152PX/152 Tensioning system Automatic Valve Valve clearance (cold) Intake mm (in) 0.14–0.23 (0.006–0.009) Exhaust mm (in) 0.28–0.37 (0.011–0.015) Valve dimensions Valve head diameter A Intake mm (in) 33.9–34.1 (1.335–1.343) Exhaust mm (in) 28.9–29.1 (1.138–1.146)
Page 44 SPEC Maintenance specifications Model Item Unit Valve spring Free length Intake and exhaust mm (in) 45.58 (1.794) Installed length Intake and exhaust mm (in) 34.00 (1.339) Tilt limit Intake and exhaust mm (in) 2.0 (0.08) Cylinder Bore size mm (in) 86.000–86.015 (3.3858–3.3864) Piston Piston outside...
Page 45: Fuel System
SPEC Maintenance specifications Model Item Unit Connecting rod Bearing color code 1. Brown 2. Black 3. Blue 4. Green Small end inside diameter mm (in) 22.015–22.028 (0.8667–0.8672) Crankshaft Crankshaft journal diameter mm (in) 39.976–40.000 (1.5739–1.5748) Crankshaft pin diameter mm (in) 41.976–42.000 (1.6526–1.6535) Crankshaft runout limit mm (in)
Page 46: Jet Pump Unit
SPEC Maintenance specifications Jet pump unit Model Item Unit Jet pump Impeller housing inside mm (in) 155.35–155.45 (6.116–6.120) diameter Impeller material Stainless steel Number of impeller blades Impeller pitch angle Degree 16.0 Impeller-to-housing clearance mm (in) 0.35–0.45 (0.014–0.018) Impeller clearance limit mm (in) 0.6 (0.024) Drive shaft runout limit...
Page 47 SPEC Maintenance specifications Model Item Unit Charging system Stator coil (G – G) Output peak voltage @cranking (unloaded) @2,000 r/min (unloaded) 42.7 @3,500 r/min (unloaded) 74.0 Stator coil resistance (G – G) Ω @ 20 °C (68 °F) 0.31–0.38 Rectifier regulator (R –...
Page 48 SPEC Maintenance specifications Model Item Unit TPS output voltage with throttle lever fully closed TPS 1 0.6–0.9 with throttle lever fully open TPS 2 4.6–4.7 Throttle valve opening angle with throttle lever fully degree 2.0–8.0 closed with throttle lever fully open degree more than 70 APS output voltage...
Page 49 SPEC Maintenance specifications Model Item Unit Fuel system Fuel injector Ω Fuel injector resistance 11.5–12.5 @ 20 °C (68 °F) Fuel sender Fuel sender resistance (Y– B) @ 20 °C (68 °F) Ω Lower position 133.5–136.5 Ω Upper position 5.0–7.0 Starting system Fuse Rating...
Page 50: Tightening Torques
SPEC Tightening torques Tightening torques Specified torques Tightening torque Thread Refer to Part to tightened size page N·m kgf·m ft·lb Fuel system Fuel pump module assembly nut — Strap bolt 11.8 Fuel rail bolt Fuel tank cap clamp — Fuel filler neck nut —...
Page 51 SPEC Tightening torques Tightening torque Thread Refer to Part to tightened size page N·m kgf·m ft·lb Starter motor bolt 13.3 5-27 Thermostat housing bolt 5-27 Joint 1 hose clamp — 5-31 Boost pipe bolt 14.8 5-31 Joint 2 hose clamp —...
Page 52 SPEC Tightening torques Tightening torque Thread Refer to Part to tightened size page N·m kgf·m ft·lb Camshaft sprocket bolt 17.7 5-52 Chain guide plate bolt 5-52 Engine hanger bolt 5-66 Cylinder head assembly bolt 35.4 5-66 90° Drive coupling 25.0 184.4 5-79 Grommet bracket bolt...
Page 53 SPEC Tightening torques Tightening torque Thread Refer to Part to tightened size page N·m kgf·m ft·lb Steering cable joint nut — Steering cable joint — Spout hose clamp (hull end) — Bracket bolt 12.5 Jet pump unit assembly bolt 29.5 Stay bolt 10.3 Spout hose clamp (jet pump end)
Page 54 SPEC Tightening torques Tightening torque Thread Refer to Part to tightened size page N·m kgf·m ft·lb Front hood assembly bolt 8-15 Mirror assembly nut — 8-15 Damper stay bolt 8-15 Ventilation cover screw 8-17 Hood lock bolt 8-17 Dual analog meter unit cover screw 8-20 Dual analog meter unit bolt 8-20...
Page 55: General Torque
SPEC Tightening torques Tightening torque Thread Refer to Part to tightened size page N·m kgf·m ft·lb Bow eye bolt 8-46 Front protector 1 nut — 8-46 Front protector 1 bolt 0.25 8-46 Front protector 2 nut — 8-46 Sponson bolt 11.8 8-46 Ski tow nut (FZS)
Page 56: Lubrication System
SPEC Lubrication system Lubrication system 1 Intake camshaft 0 Relief valve 2 Exhaust camshaft A Oil pump assembly (scavenge pump) 3 Cylinder block B Oil cooler assembly 4 Crankshaft C Oil filter 5 Oil separator tank D Drive gear assembly 6 Oil pan E Supercharger assembly 7 Oil strainer...
Page 57: Cooling System
SPEC Cooling system Cooling system È Ê É É Ë Ì Í È To hose joint 1 1 Hose joint 2 É To cooling water pilot outlet on port side 2 Hose joint 3 Ê To cooling water pilot outlet on starboard side 3 Hose joint 4 Ë...
Page 58 SPEC Cooling system Ê È É É È From jet pump unit 1 Thermostat housing É To cooling water pilot outlet on port side 2 Air cooler assembly Ê To cooling water pilot outlet on starboard side 3 Oil cooler assembly 2-19...
Page 59: Cable And Hose Routing
SPEC Cable and hose routing Cable and hose routing Starboard bow view 1 Breather hose (head cover to breather 9 Speed sensor lead 0 Remote control receiver antenna assembly) 2 Cooling water hose (exhaust manifold to rectifier A Fuel tank breather hose (ventilation socket to regulator) water separator) 3 Breather hose (breather assembly to intake pipe)
Page 60: Top View
SPEC Cable and hose routing Top view 1 Breather hose (head cover to breather 9 Speed sensor lead assembly) 0 Remote control receiver antenna 2 Dual analog meter lead A Fuel tank breather hose (ventilation socket to 3 Breather hose (breather assembly to intake water separator) pipe) B Wiring harness...
Page 61 SPEC Cable and hose routing I Negative battery cable J Positive battery cable K Battery breather hose L Cooling water hose (jet pump to hose joint 1) M Flushing hose N Cooling water hose (hose joint 1 to hose joint 3) O Buzzer lead 2-22...
Page 62: Port View
SPEC Cable and hose routing Port view A 4 5 C È 1 Dual analog meter lead 9 Speed sensor lead 2 Cooling water hose (exhaust manifold to rectifier 0 Remote control receiver antenna A Fuel tank breather hose (ventilation socket to regulator) 3 Breather hose (breather assembly to intake water separator)
Page 63 SPEC Cable and hose routing A 4 5 C È È Fasten the wiring harness with the plastic tie, I Negative battery cable J Positive battery cable making sure to align the tie with the gray tape on K Battery breather hose the harness.
Page 64 SPEC Cable and hose routing — MEMO — 2-25...
Page 65 Chapter 3 Periodic check and adjustment Maintenance interval chart................3-1 Periodic service ..................... 3-2 Control system................... 3-2 Steering system check ................ 3-2 Jet thrust nozzle steering angle check and adjustment ...... 3-2 Jet thrust nozzle QSTS angle check and adjustment ......3-4 Throttle lever free play check and adjustment ........
Page 66: Maintenance Interval Chart
Maintenance interval chart Maintenance interval chart The following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the maintenance intervals should be changed. THEREAFTER MAINTENANCE INTERVAL INITIAL EVERY 10 hours 50 hours PAGE hours hours hours...
Page 67: Periodic Service
Control system Periodic service Control system Steering system check 1. Check: • Steering system Excessive play → Check the bushings, bolts, and nuts. Refer to “Handlebar assembly removal” in Chapter 8. Checking steps: 1. Turn the handlebar lock to lock, push it back and forth, and up and down.
Page 68 Control system 2. Adjust: • Steering cable joint (steering master end) Adjustment steps: 1. Set the QSTS grip to the neutral position. 2. Loosen the locknut 1. 3. Disconnect the steering cable joint 2 from the ball joint 3. 4. Turn the steering cable joint 2 in or out to adjust the distances a and b.
Page 69: Jet Thrust Nozzle Qsts Angle Check And Adjustment
Control system Jet thrust nozzle QSTS angle check and adjustment 1. Check: • Jet thrust nozzle angle set distances a and b Difference → Adjust the QSTS rod joint. Before measuring the jet thrust nozzle QSTS angle, make sure that the steering position of the jet thrust nozzle is centered.
Page 70: Throttle Lever Free Play Check And Adjustment
Control system 9. If the QSTS rod cannot be properly adjusted using the rod joint at the jet pump end, check the rod joint at the QSTS con- verter end. Refer to “QSTS grip and converter disas- sembly” in Chapter 8. Throttle lever free play check and adjustment 1.
Page 71 Control system 5. If the throttle cable installation length a is out of specification, loosen the locknut 2, and then turn the adjusting nut 3 to adjust the length. 6. Apply locking agent to the threads of the adjusting nut 3, and then tighten the lock- nut 2 to the specified torque.
Page 72 Control system 13. Squeeze the throttle lever 9 to the fully open position and check that the APS pul- ley stopper c contacts the fully open stop- per d on the APS. 14. Release the throttle lever 9 and check that the APS pulley stopper e contacts the fully closed stopper f on the APS.
Page 73: Shift Cable Check And Adjustment
Control system Shift cable check and adjustment 1. Check: • Reverse gate position Incorrect → Adjust the shift cable joint. Checking steps: 1. Set the shift lever to the reverse position. 2. Check that the reverse gate 1 contacts the stopper 2. 2.
Page 74: Trolling Speed Check
Control system / Fuel system 6. Connect the shift cable joint 2 to the ball joint 3, and then tighten the locknut 1 to the specified torque. Locknut: 7 N·m (0.7 kgf·m, 5.2 ft·lb) LOCTITE 572 Trolling speed check 1. Check: •...
Page 75: Fuel Line Check
Fuel system Fuel line check 1. Check: • Fuel pump filter 1 Clog/contaminants → Clean the fuel pump filter. • Fuel hose 2 Cracks/damage → Replace the fuel hose. • Quick connectors 3 Cracks/damage → Replace the quick connector. • Fuel filler hose Cracks/damage →...
Page 76: Water Separator Check
Fuel system / Power unit Water separator check 1. Check: • Water separator 1 Water accumulation → Drain the water. • O-ring Crack/damage → Replace the O-ring. To drain water from the water separator 1, loosen the drain plug 2. Power unit Valve clearance measurement 1.
Page 77 Power unit 3. Position piston #1 at TDC by turning the exhaust camshaft sprocket clockwise with the special service tool. Check that the punch marks c on the cam- shafts are aligned with the alignment marks d on the camshaft caps. Camshaft wrench: 90890-06724 4.
Page 78: Compression Pressure Measurement
Power unit Compression pressure measurement 1. Measure: • Compression pressure Make sure that the battery voltage is more than 12 V. Compression pressure (reference data): 610 kPa (6.1 kgf/cm , 86.8 psi) Measurement steps: 1. Place the watercraft in the water. 2.
Page 79: Engine Oil Level Check
Power unit 8. Install the spark plugs 4, ignition coils 3, bolts 2, and engine cover 1. Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb) Ignition coil bolt: 8 N·m (0.8 kgf·m, 5.9 ft·lb) LOCTITE 572 Engine cover bolt: 5 N·m (0.5 kgf·m, 3.7 ft·lb) Engine oil level check 1.
Page 80: Engine Oil Change
Power unit 2. Remove the oil level gauge 1, wipe the gauge clean, and then install the gauge into the oil level pipe completely. 3. Remove the oil level gauge 1 again to check that the oil level is between the min- imum level mark a and maximum level mark b on the gauge.
Page 81: Oil Filter Replacement
Power unit 3. Remove the oil filler cap 1 and oil level PORT gauge 2. 4. Insert the tube 3 of an oil changer approx- imately 650 mm a into the oil level pipe 5. Operate the oil changer to extract the oil. 6.
Page 82: Air Filter Element Check
Power unit 4. Lubricate the O-ring 2 of the new oil filter with a thin coat of engine oil. NOTICE Make sure the O-ring 2 is positioned cor- rectly in the groove of the oil filter. 5. Tighten a new oil filter to the specified torque with the special service tool.
Page 83: Spark Plug Check
Power unit Spark plug check 1. Remove: • Engine cover 1 • Ignition coil bolts 2 • Ignition coils 3 • Spark plugs 4 • Slide the engine cover rearward, and then lift the cover to remove it. • Be careful not to get water or any other for- eign substances in the spark plug holes.
Page 84: Electrical
Power unit / Electrical 4. Install: • Spark plugs 1 Before installing a spark plug, clean the gasket surface and spark plug surface. Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb) 5. Install: • Ignition coils 2 • Ignition coil bolts 3 •...
Page 85 Electrical NOTICE Be careful not to place the battery on its side. Make sure to remove the battery from the battery compartment when adding battery electrolyte or charging the battery. When checking the battery, make sure the breather hose is connected to the battery and not obstructed.
Page 86: Jet Pump Unit
Electrical / Jet pump unit 4. Install: • Battery 1 • Bands 2 • Battery breather hose 3 • Positive battery cable 4 • Negative battery cable 5 NOTICE Connect the positive battery cable 4 to the battery terminal first. •...
Page 87: Bilge Strainer
Jet pump unit / Bilge strainer 3. Check: • Water inlet strainer 1 Contaminants → Clean the water inlet strainer. Cracks/damage → Replace the water inlet strainer. Bilge strainer Bilge strainer check 1. Remove: • Deck beam assembly Refer to “Engine unit removal 1” in Chapter 5.
Page 88: Electric Bilge Pump Strainer Check
Bilge strainer / General Electric bilge pump strainer check 1. Remove: • Negative battery cable 1 • Band 2 • Electric bilge pump cap 3 • Electric bilge pump strainer 4 2. Check: • Electric bilge pump strainer Contaminants → Clean the cap and strainer.
Page 89: Lubrication Points
5. Install the engine cover. Lubrication points 1. Lubricate: • Steering master assembly Recommended lubricant: Yamaha grease A Lubricating steps: 1. Move the handlebar to the highest posi- tion. 2. Remove the handlebar covers. Refer to “Handlebar cover removal” in Chapter 8.
Page 90 Rust inhibitor 3. Lubricate: • Throttle cable (APS end) • Return spring Recommended lubricant: Yamaha grease A 4. Lubricate: • QSTS cables (handlebar end) • Before lubricating the QSTS cables, remove the QSTS grip assembly from the handlebar. Refer to “Handlebar assembly removal” in Chapter 8.
Page 91 • QSTS rod joint (pulley end) Before lubricating the QSTS cables, remove the rubber plate. Refer to “Jet pump unit removal” in Chapter 6. Recommended lubricant: Yamaha grease A 6. Lubricate: • Nozzle pivot shaft • Nozzle ring pivot shaft • Steering cable (nozzle end) •...
Page 92 • Shift cable joint Before lubricating the shift lever assembly, remove the right side cover. Refer to “Side cover removal” in Chapter 8. Recommended lubricant: Yamaha grease A 9. Lubricate: • Intermediate housing (through the grease nipple 1) Recommended lubricant:...
Page 93 FUEL Chapter 4 Fuel system Fuel tank, fuel pump module, and fuel hose ..........4-1 Fuel tank removal ..................4-1 Fuel hose disconnection................4-4 Quick connector removal................4-4 Fuel pump module removal ............... 4-5 Fuel sender removal.................. 4-5 Rollover valve check.................. 4-6 Check valve check..................
Page 94: Fuel Tank, Fuel Pump Module, And Fuel Hose
FUEL Fuel tank, fuel pump module, and fuel hose Fuel tank, fuel pump module, and fuel hose Fuel tank removal m (0.3 kgf m, 2.2 ft · · · · m (0.6 kgf · m, 4.4 ft · 2nd 6 N 13 N ·...
Page 95 FUEL Fuel tank, fuel pump module, and fuel hose · m (0.3 kgf · m, 2.2 ft · · m (0.6 kgf · m, 4.4 ft · 2nd 6 N · · · 13 N m (1.3 kgf m, 9.6 ft ·...
Page 96 FUEL Fuel tank, fuel pump module, and fuel hose m (0.3 kgf m, 2.2 ft · · · · m (0.6 kgf · m, 4.4 ft · 2nd 6 N 13 N · m (1.3 kgf · m, 9.6 ft ·...
Page 97: Fuel Hose Disconnection
FUEL Fuel tank, fuel pump module, and fuel hose Fuel hose disconnection WARNING • Before checking the fuel system, remove the battery and then remove the fuel tank filler cap to reduce any pressure inside the fuel tank. • Always reduce the fuel pressure in the fuel line before servicing the line or the fuel pipe.
Page 98: Fuel Pump Module Removal
FUEL Fuel tank, fuel pump module, and fuel hose Fuel pump module removal 1. Remove: • Nuts • Retainer Loosen the nuts in the sequence shown. 2. Remove: • Fuel pump module assembly 1 • Remove the fuel pump module assembly 1 at an angle so that the float 2 does not catch on the fuel tank.
Page 99: Rollover Valve Check
FUEL Fuel tank, fuel pump module, and fuel hose Rollover valve check È É 1. Check: • Rollover valve Does not function properly → Replace the rollover valve. Checking steps: 1. Blow into the end a of the rollover valve, and make sure that airflow from the end b is unrestricted.
Page 100: Fuel Line Check
FUEL Fuel tank, fuel pump module, and fuel hose Fuel line check 1. Check: • Fuel hose 1 Cracks/damage → Replace the fuel hose. • Quick connectors 2 Cracks/damage → Replace the quick connector. • Fuel pipe 3 (fuel pump module end) Cracks/damage →...
Page 101: Fuel Tank Check
FUEL Fuel tank, fuel pump module, and fuel hose Fuel tank check 1. Check: • Fuel tank Cracks/damage → Replace the fuel tank. Before removing the fuel tank, it is necessary to remove the engine unit. Refer to “Engine unit removal” in Chapter 5. Fuel injector check 1.
Page 102: Fuel Sender Installation
FUEL Fuel tank, fuel pump module, and fuel hose Fuel sender installation 1. Install: • Fuel sender 1 Installation steps: 1. Install the fuel sender 1. Make sure that the tabs a on the fuel sender 1 are securely seated into the slots b in the fuel pump module.
Page 103: Quick Connector Installation
FUEL Fuel tank, fuel pump module, and fuel hose Quick connector installation 1. Install: • Quick connectors Installation steps: 1. Install the corrugated tube 1, clamps 2, and quick connectors 3 onto the fuel hose WARNING Do not reuse the clamps, always replace them with new ones, otherwise fuel could leak.
Page 104: Fuel Pressure Measurement
FUEL Fuel tank, fuel pump module, and fuel hose • If the fuel hose quick connector 2 is not installed completely onto the fuel pipe 1, the locking slider 3 cannot be pushed down. • Confirm that the fuel hose quick connector is correctly installed by making sure there is a small amount of free play when the quick connector is pulled and pushed.
Page 105 POWR Chapter 5 Power unit Engine unit...................... 5-1 Engine unit removal 1................5-1 Engine unit removal 2................5-3 Engine unit removal 3................5-5 Engine unit removal 4................5-8 Engine mount removal................5-9 Engine unit removal................. 5-10 Breather assembly check ................ 5-15 Hose joint check ..................
Page 106 POWR Oil cooler, oil pump assembly, and drive gear.......... 5-41 Oil cooler and oil pump assembly removal..........5-41 Drive gear removal .................. 5-43 Drive gear assembly removal ..............5-45 Drive gear disassembly ................5-45 Oil cooler assembly check............... 5-46 Oil pump assembly check................ 5-47 Idle gear check ..................
Page 107 POWR Generator cover and flywheel magneto............. 5-79 Generator cover and flywheel magneto removal........5-79 Generator cover disassembly..............5-81 Drive coupling removal ................5-82 Flywheel magneto removal..............5-83 Bearing removal ..................5-85 Idle gear and shaft check ................ 5-85 Starter clutch check ................. 5-85 Bearing installation ..................
Page 108 POWR Engine unit Engine unit Engine unit removal 1 · · · 18 N m (1.8 kgf m, 13.3 ft · m (0.5 kgf · m, 3.7 ft · 18 N · m (1.8 kgf · m, 13.3 ft · 11 12 17 N ·...
Page 109 POWR Engine unit · · · 18 N m (1.8 kgf m, 13.3 ft · m (0.5 kgf · m, 3.7 ft · · · · 18 N m (1.8 kgf m, 13.3 ft 11 12 · · · 17 N m (1.7 kgf m, 12.5 ft Step...
Page 110 POWR Engine unit Engine unit removal 2 · m (0.3 kgf · m, 2.2 ft · · m (0.6 kgf · m, 4.4 ft · È Ê É · · · 18 N m (1.8 kgf m, 13.3 ft É ·...
Page 111 POWR Engine unit · · · m (0.3 kgf m, 2.2 ft · · · m (0.6 kgf m, 4.4 ft È Ê É · · · 18 N m (1.8 kgf m, 13.3 ft É · m (0.8 kgf ·...
Page 112: Engine Unit
POWR Engine unit Engine unit removal 3 · · · m (0.8 kgf m, 5.9 ft · · · 22 N m (2.2 kgf m, 16.2 ft · · · 2nd 42 N m (4.2 kgf m, 31.0 ft · ·...
Page 113 POWR Engine unit · · · m (0.8 kgf m, 5.9 ft · · · 22 N m (2.2 kgf m, 16.2 ft · · · 2nd 42 N m (4.2 kgf m, 31.0 ft 26 N · m (2.6 kgf ·...
Page 114 POWR Engine unit · · · m (0.8 kgf m, 5.9 ft · · · 22 N m (2.2 kgf m, 16.2 ft · · · 2nd 42 N m (4.2 kgf m, 31.0 ft · · · 26 N m (2.6 kgf m, 19.2 ft ·...
Page 115: Engine Unit Removal 2
POWR Engine unit Engine unit removal 4 17 N · m (1.7 kgf · m, 12.5 ft · · · · m (0.8 kgf m, 5.9 ft · · · 17 N m (1.7 kgf m, 12.5 ft Step Q’ty Remarks Part name M8 ×...
Page 116: Engine Mount Removal
POWR Engine unit Engine mount removal · · · m (0.6 kgf m, 4.4 ft · · · m (0.5 kgf m, 3.7 ft · · · m (0.6 kgf m, 4.4 ft · · · 17 N m (1.7 kgf m, 12.5 ft Step Q’ty...
Page 117: Engine Unit Removal
POWR Engine unit Engine unit removal 1. Remove: • Engine unit NOTICE Before removing the engine, make sure to take adequate measures to protect the deck opening from damage. Removal steps: 1. Disconnect the negative battery cable 1 and positive battery cable 2 from the bat- tery.
Page 118 POWR Engine unit 7. Disconnect the APS coupler B, and the 7 dual analog meter unit, sensor, and switch couplers C. 8. Remove the antenna holders D. 9. Disconnect the remote control receiver coupler E. 10. Remove the wiring harness from the 5 plastic ties F.
Page 119 POWR Engine unit 13. Disconnect the breather hose J from the intake pipe K, and then remove the intake pipe K from the supercharger. 14. Unhook the fasteners L, and then remove the air filter case cover M. Remove the air filter case bolts N, and then remove the air filter case O.
Page 120 POWR Engine unit 19. Remove the leads from the plastic ties V. 20. Disconnect the thermo sensor coupler W. 21. Remove the breather hose X. 22. Remove the breather assembly bolts Y and hose Z, and then remove the breather assembly [. 23.
Page 121 POWR Engine unit 30. Remove the muffler assembly bolts k, and then remove the muffler assembly l. When removing the muffler assembly, move it forward and separate it from the water lock. 31. Remove the electrical box bolts m, and then remove the electrical box n.
Page 122: Breather Assembly Check
POWR Engine unit 36. Suspend the engine unit using all 3 engine hangers, and then separate the unit from the engine mounts and move it forward to disconnect the coupling. 37. Lift the engine unit slightly, and then lower the front of the unit. Repeat this step until the engine unit can be removed from the engine compartment.
Page 123: Hose Joint Check
POWR Engine unit Hose joint check 1. Check: • Hose joints 1 Cracks/damage → Replace the hose joints. • Cooling water hoses Cracks/damage → Replace the cooling water hoses. Engine mount check 1. Check: • Engine mounts Cracks/damage → Replace the engine mounts.
Page 124 POWR Engine unit 5. Move the engine unit rearward to connect the coupling 1, and lower the unit onto the engine mounts. Do not install the rubber damper until the cou- pling clearance adjustment has been made. 6. Temporarily install the engine mounting bolts 2.
Page 125 POWR Engine unit 8. Measure the coupling clearance a, and if necessary, add or remove shims 3 so that the clearance is within specification. Available shim thicknesses: 0.10, 0.30, 0.50, 1.00, and 2.00 mm Clearance a: Less than 1.0 mm (0.039 in) (without rubber damper) Clearance b: 2.0–4.0 mm (0.079–0.157 in)
Page 126 POWR Engine unit 13. Install the coupling cover 5 and collar, and then tighten the coupling cover bolt 6 to the specified torque. Coupling cover bolt: 8 N·m (0.8 kgf·m, 5.9 ft·lb) LOCTITE 572 14. Install the electrical box 7, and then tighten the electrical box bolts 8 to the specified torque.
Page 127 POWR Engine unit 17. Install the stay B, and then tighten the stay bolts C to the specified torque. Stay bolt: 1st: 22 N·m (2.2 kgf·m, 16.2 ft·lb) 2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb) LOCTITE 242 18. Connect the cooling water hoses D to the hose joint 3 E.
Page 128 POWR Engine unit 27. Install the oil filter T with the special ser- vice tool. Oil filter wrench: 90890-06830 Oil filter: 18 N·m (1.8 kgf·m, 13.3 ft·lb) 28. Connect the cooling water hose U to the air cooler and cooling water hose V to the thermostat housing.
Page 129 POWR Engine unit 33. Apply adhesive onto the mating surface of the connection _, and then install it. Align the mark c on the connection with the mark d on the intake pipe. 34. Install the intake pipe a, and then tighten the clamps b.
Page 130 POWR Engine unit 42. Connect the APS coupler i, and the 7 dual analog meter unit, sensor, and switch couplers j. 43. Install the engine cover k, and then tighten the engine cover screws l to the specified torque. Hold the engine cover down, and slide the cover forward to install it.
Page 131: Muffler
POWR Muffler Muffler Muffler disassembly · · · m (0.2 kgf m, 1.5 ft · · · 63 N m (6.3 kgf m, 46.5 ft · · · 20 N m (2.0 kgf m, 14.8 ft 15 N · m (1.5 kgf ·...
Page 132 POWR Muffler · · · m (0.2 kgf m, 1.5 ft 63 N · m (6.3 kgf · m, 46.5 ft · · · · 20 N m (2.0 kgf m, 14.8 ft · · · 15 N m (1.5 kgf m, 11.1 ft 2nd 29 N ·...
Page 133: Exhaust Pipe 3 Removal
POWR Muffler Exhaust pipe 3 removal WARNING When using a heat gun, protect your hands by wearing heat-resistant gloves. Compo- nents become hot enough to cause burns. 1. Remove: • Exhaust pipe 3 1 Exhaust pipe wrench: 90890-06726 Heat the area a of exhaust pipe 3 1 to approximately 200 °C (392 °F) with a heat gun.
Page 134: Thermostat And Electrical Component
POWR Thermostat and electrical component Thermostat and electrical component Thermostat and electrical component removal · m (0.8 kgf · m, 5.9 ft · · m (1.8 m · kg, 13.3 ft · 18 N · m (0.5 kgf · m, 3.7 ft ·...
Page 135 POWR Thermostat and electrical component · · · m (0.8 kgf m, 5.9 ft · m (1.8 m · kg, 13.3 ft · 18 N · · · m (0.5 kgf m, 3.7 ft Step Q’ty Remarks Part name Plastic tie Throttle body assembly coupler Intake air pressure sensor coupler Clamp...
Page 136 POWR Thermostat and electrical component · m (0.8 kgf · m, 5.9 ft · · m (1.8 m · kg, 13.3 ft · 18 N · m (0.5 kgf · m, 3.7 ft · Step Q’ty Remarks Part name M8 × 30 mm Bolt Negative battery cable Starter motor...
Page 137: Thermostat Housing Check
POWR Thermostat and electrical component Thermostat housing check 1. Check: • Thermostat housing 1 Cracks/damage → Replace the thermo- stat housing. Thermostat check 1. Check: • Thermostat valve opening a Out of specification → Replace the ther- mostat. Checking steps: 1.
Page 138: Air Cooler, Supercharger, And Throttle Body Assembly
POWR Air cooler, supercharger, and throttle body assembly Air cooler, supercharger, and throttle body assembly Air cooler and supercharger removal · · · · · · 10 N m (1.0 kgf m, 7.4 ft 10 N m (1.0 kgf m, 7.4 ft 2nd 20 N ·...
Page 139 POWR Air cooler, supercharger, and throttle body assembly 10 N · m (1.0 kgf · m, 7.4 ft · 10 N · m (1.0 kgf · m, 7.4 ft · 2nd 20 N · m (2.0 kgf · m, 14.8 ft ·...
Page 140: Intake Assembly Removal
POWR Air cooler, supercharger, and throttle body assembly Intake assembly removal · m (0.5 kgf · m, 3.7 ft · 10 N · m (1.0 kgf · m, 7.4 ft · · m (0.35 kgf · m, 2.6 ft · 3.5 N ·...
Page 141 POWR Air cooler, supercharger, and throttle body assembly · m (0.5 kgf · m, 3.7 ft · · · · 10 N m (1.0 kgf m, 7.4 ft · m (0.35 kgf · m, 2.6 ft · · · · 3.5 N 2nd 20 N m (2.0 kgf...
Page 142: Intake Disassembly
POWR Air cooler, supercharger, and throttle body assembly Intake disassembly · m (1.3 kgf · m, 9.6 ft · 13 N 13 N · m (1.3 kgf · m, 9.6 ft · Step Q’ty Remarks Part name Washer Throttle body assembly Gasket Not reusable M8 ×...
Page 143: Air Cooler Check
POWR Air cooler, supercharger, and throttle body assembly Air cooler check NOTICE The air cooler assembly should not be dis- assembled. 1. Check: • Air cooler assembly Cracks/damage → Replace the air cooler assembly. • Air cooler holding pressure Cannot be maintained → Replace the air cooler assembly.
Page 144: Supercharger Check
POWR Air cooler, supercharger, and throttle body assembly Supercharger check NOTICE The supercharger should not be disassem- bled. 1. Check: • Impeller 1 • Gear 2 Cracks/damage → Replace the super- charger assembly. • Supercharger operation Rough movement → Replace the super- charger assembly.
Page 145: Intake Manifold Installation
POWR Air cooler, supercharger, and throttle body assembly Intake manifold installation ± & 1. Install: • Intake manifold Tighten the bolts to the specified torques in the ² sequence shown. Intake manifold bolt: 1st: 10 N·m (1.0 kgf·m, 7.4 ft·lb) 2nd: 20 N·m (2.0 kgf·m, 14.8 ft·lb) LOCTITE 242 Supercharger installation...
Page 146: Air Cooler Intake Pipe Installation
POWR Air cooler, supercharger, and throttle body assembly 2. Install: • Supercharger Tighten the supercharger bolts 1, and then bolts 2 to the specified torque. Supercharger bolt (M8 × 65 mm) 1: 20 N·m (2.0 kgf·m, 14.8 ft·lb) LOCTITE 242 Supercharger bolt (M6 ×...
Page 147: Boost Pipe Installation
POWR Air cooler, supercharger, and throttle body assembly Boost pipe installation 1. Install: • Boost pipe 1 • Joint 1 2 • Joint 2 3 Installation steps: 1. Install the joint 1 2 and joint 2 3 to the boost pipe 1. •...
Page 148: Oil Cooler, Oil Pump Assembly, And Drive Gear
POWR Oil cooler, oil pump assembly, and drive gear Oil cooler, oil pump assembly, and drive gear Oil cooler and oil pump assembly removal · · · 10 N m (1.0 kgf m, 7.4 ft · m (1.8 kgf · m, 13.3 ft ·...
Page 149 POWR Oil cooler, oil pump assembly, and drive gear · · · 10 N m (1.0 kgf m, 7.4 ft · m (1.8 kgf · m, 13.3 ft · 18 N m (0.8 kgf m, 5.9 ft 21 N · m (2.1 kgf ·...
Page 150 POWR Oil cooler, oil pump assembly, and drive gear Drive gear removal 80 N · m (8.0 kgf · m, 59.0 ft · Step Q’ty Remarks Part name Shaft Idle gear assembly Circlip Washer Washer Collar Bolt Left-hand threads M12 × 58 mm Circlip Oil pump drive gear Bearing...
Page 151 POWR Oil cooler, oil pump assembly, and drive gear · · · 80 N m (8.0 kgf m, 59.0 ft Step Q’ty Remarks Part name Washer Circlip Washer Drive gear clutch Supercharger drive gear 5-44...
Page 152: Drive Gear Assembly Removal
POWR Oil cooler, oil pump assembly, and drive gear Drive gear assembly removal 1. Remove: • Drive gear assembly Removal steps: 1. Hold the drive coupling 1 with the special service tool 2. Coupler wrench 2: 90890-06729 2. Remove the drive gear assembly bolt 3. The drive gear assembly bolt has left-hand threads.
Page 153: Oil Cooler Assembly Check
POWR Oil cooler, oil pump assembly, and drive gear Oil cooler assembly check NOTICE The oil cooler assembly should not be dis- assembled. 1. Check: • Oil cooler assembly Cracks/damage → Replace the oil cooler assembly. • Oil cooler holding pressure Cannot be maintained →...
Page 154: Oil Pump Assembly Check
POWR Oil cooler, oil pump assembly, and drive gear Oil pump assembly check NOTICE The oil pump assembly should not be dis- assembled. 1. Check: • Oil pump assembly • Oil pump driven gear 1 Cracks/damage → Replace the oil pump assembly.
Page 155: Drive Gear Clutch Check
POWR Oil cooler, oil pump assembly, and drive gear Drive gear clutch check 1. Check: • Drive gear clutch Cracks/damage → Replace the drive gear clutch. • Drive gear clutch operation Does not operate properly → Replace the drive gear clutch. NOTICE •...
Page 156: Oil Pump Drive Gear Assembly
POWR Oil cooler, oil pump assembly, and drive gear Oil pump drive gear assembly 1. Install: • Bearing Use a pipe that is at least 22 mm (0.87 in) long and has an outer diameter of 55 mm (2.17 in) and an inner diameter of 45 mm (1.77 in).
Page 157: Oil Pump Assembly Installation
POWR Oil cooler, oil pump assembly, and drive gear Oil pump assembly installation 1. Fill: • Oil pump assembly NOTICE Make sure to fill the oil pump assembly with engine oil through the scavenge and feed ports. Filling steps: 1. Fill the oil pump assembly with engine oil through the feed port a and scavenge port b.
Page 158: Camshaft
POWR Camshaft Camshaft Cylinder head cover removal · m (0.8 kgf · m, 5.9 ft · · m (0.8 kgf · m, 5.9 ft · · · · 25 N m (2.5 kgf m, 18.4 ft · · 10 N m (1.0 kgf m, 7.4 ft ·...
Page 159: Camshaft And Timing Chain Removal
POWR Camshaft Camshaft and timing chain removal · m (0.8 kgf · m, 5.9 ft · · · · 16 N m (1.6 kgf m, 11.8 ft · · · 24 N m (2.4 kgf m, 17.7 ft 20 N ·...
Page 160 POWR Camshaft · m (0.8 kgf · m, 5.9 ft · 16 N · m (1.6 kgf · m, 11.8 ft · · · · 24 N m (2.4 kgf m, 17.7 ft 20 N · m (2.0 kgf · m, 14.8 ft ·...
Page 161: Camshaft Removal
POWR Camshaft Camshaft removal 1. Remove: • Camshafts Removal steps: 1. Install the special service tools 1 and 2 into spark plug hole #1. Gauge stand 1: 90890-06725 Dial gauge stand set: YB-06585 Dial gauge 2: YU-03097/90890-01252 Dial gauge needle: 90890-06584 2.
Page 162 POWR Camshaft 6. Loosen the intake and exhaust camshaft cap bolts in the sequence shown. • For reference during installation, put identifi- cation marks d on the camshaft caps. • Gradually loosen the camshaft cap bolts. 7. Remove the intake camshaft 8 and exhaust camshaft 9.
Page 163: Camshaft Check
POWR Camshaft Camshaft check 1. Check: • Camshaft lobes Pitting/scratches → Replace the cam- shaft. 2. Measure: • Camshaft lobe dimensions a and b Out of specification → Replace the cam- shaft. Camshaft lobe dimensions: Intake: a 40.9 mm (1.610 in) b 32.0 mm (1.260 in) Exhaust: a 41.0 mm (1.614 in)
Page 164 POWR Camshaft 5. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification → Replace the cyl- inder head assembly. Camshaft-journal-to-camshaft-cap clearance: 0.020–0.061 mm (0.0008–0.0024 in) Measurement steps: 1. Remove the valve lifters 1 and valve pads Make a note of the position of each valve lifter and valve pad so that they can be installed in their original positions.
Page 165: Camshaft Sprocket Check
POWR Camshaft Camshaft sprocket check 1. Check: • Camshaft sprockets Damage/wear → Replace the camshaft sprockets and timing chain as a set. Timing chain check 1. Check: • Timing chain Damage/stiffness/wear → Replace the timing chain and camshaft sprockets as a set.
Page 166: Camshaft Installation
POWR Camshaft Camshaft installation 1. Install: • Camshafts Installation steps: 1. Position piston #1 at TDC. Refer to “Camshaft removal.” 2. Install the exhaust camshaft sprocket 1 and intake camshaft sprocket 2. • Install each camshaft sprocket with the punch mark a facing outward. •...
Page 167 POWR Camshaft 7. Install the exhaust camshaft caps and È intake camshaft caps. 8. Apply engine oil to the threads of the cam- shaft cap bolts. 9. Tighten the camshaft cap bolts until the camshaft caps contact the cylinder head. •...
Page 168 POWR Camshaft 15. Install the gasket and the timing chain ten- sioner 8 onto the cylinder block, and then temporarily tighten the timing chain ten- sioner bolts 9. 16. Install the oil pipe 0 to the cylinder block and timing chain tensioner, and then tem- porarily tighten the oil pipe bolts A.
Page 169: Cylinder Head Cover Installation
POWR Camshaft Cylinder head cover installation 1. Install: 1280B • Cylinder head cover Installation steps: 1. Apply sealant onto the locations a of the new cylinder head cover gasket 1. 2. Tighten the cylinder head cover bolts in a crisscross pattern. Cylinder head cover bolt: 8 N·m (0.8 kgf·m, 5.9 ft·lb) LOCTITE 572...
Page 170 POWR Camshaft The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. 4. Round off the original valve pad number according to the following table. Last digit Rounded value 0, 1, 2 4, 5, 6 8, 9...
Page 171 POWR Camshaft Make sure that the punch marks b on the camshafts are aligned with the alignment marks c on the camshaft caps. 12. Measure the intake and exhaust valve clearances of the specified cylinders. :Specified cylinder 13. Install the dial gauge needle and special service tools 3 and 4 into spark plug hole 14.
Page 172 POWR Camshaft 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 0.00–0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 0.03–0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 0.07–0.10...
Page 173: Cylinder Head
POWR Cylinder head Cylinder head Cylinder head assembly removal · m (1.2 kgf · m, 8.9 ft · 12 N 48 N · m (4.8 kgf · m, 35.4 ft · 2nd 90˚ 10 N · m (1.0 kgf · m, 7.4 ft ·...
Page 174: Cylinder Head Disassembly
POWR Cylinder head Cylinder head disassembly Step Q’ty Remarks Part name Valve lifter Valve pad Valve cotter Upper spring seat Valve spring Lower spring seat Intake valve Exhaust valve Valve seal Not reusable Valve guide Not reusable Cylinder head 5-67...
Page 175: Cylinder Head Assembly Removal
POWR Cylinder head Cylinder head assembly removal 1. Remove: × 55 mm) 1 • Cylinder head bolts (M6 × 140 mm) 2 • Cylinder head bolts (M12 Loosen the cylinder head bolts 2 in the sequence shown. Valve removal 1. Remove: •...
Page 176: Valve Spring Check
POWR Cylinder head 2. Measure: • Cylinder head warpage Out of specification → Replace the cyl- inder head. Measurement steps: 1. Eliminate carbon deposits from the com- bustion chambers. 2. Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in the directions shown.
Page 177 POWR Cylinder head 2. Measure: • Valve face width a Out of specification → Replace the valve. Valve face width a: Intake and exhaust: 2.26–2.83 mm (0.089–0.111 in) • Valve margin thickness b Out of specification → Replace the valve. Valve margin thickness b: Intake and exhaust: 0.80–1.20 mm (0.031–0.047 in)
Page 178: Valve Guide Check
POWR Cylinder head Valve guide check 1. Measure: • Valve guide inside diameter a Valve guide inside diameter: Intake and exhaust: 5.504–5.522 mm (0.2167–0.2174 in) 2. Calculate: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve and valve guide. Valve-stem-to-valve-guide clearance = valve guide inside diameter –...
Page 179: Valve Guide Installation
POWR Cylinder head Valve guide installation 1. Install: • Valve guide 1 Installation steps: 1. Insert the special service tools 2 and 3 into the camshaft end of the valve guide NOTICE Do not reuse the valve guide 1, always re- place it with a new one.
Page 180: Valve Seat Check
POWR Cylinder head Valve seat check 1. Measure: • Valve seat contact width Does not seat properly → Reface the valve seat. Measurement steps: 1. Eliminate carbon deposits from the valves and valve seats. 2. Apply a thin, even layer of Mechanic’s blueing dye (Dykem) onto the valve seat.
Page 181: Valve Seat Refacing
POWR Cylinder head Valve seat refacing NOTICE Do not over cut the valve seat. Make sure to turn the cutter evenly downward at a pres- sure of 40–50 N (4–5 kgf, 8.8–11 lbf) to pre- vent chatter marks. Do not turn the special service tool counter- clockwise when refacing the valve seat.
Page 182 POWR Cylinder head 2. Use a 30° cutter to adjust the contact width 30˚ of the top edge of the valve seat. b Previous contact width 3. Use a 60° cutter to adjust the contact width of the bottom edge of the valve seat. b Previous contact width 60˚...
Page 183 POWR Cylinder head • If the valve seat contact width is too narrow and situated near the bottom edge of the valve face, use a 60° cutter to cut the bottom edge of the valve seat, and then use a 45° cutter to center the area and set its width.
Page 184: Valve Installation
POWR Cylinder head Valve installation 1. Install: • Valve seal 1 • Valve 2 • Lower spring seat 3 • Valve spring 4 • Upper spring seat 5 • Valve cotters 6 Installation steps: 1. Install the valve seal 1 onto the valve guide.
Page 185: Cylinder Head Installation
POWR Cylinder head 4. Lightly tap the upper spring seat with a plastic hammer to set the valve cotters 6 securely. Cylinder head installation 1. Install: • Cylinder head Installation steps: 1. Pass the timing chain 1 through the tim- ing chain cavity.
Page 186: Generator Cover And Flywheel Magneto
POWR Generator cover and flywheel magneto Generator cover and flywheel magneto Generator cover and flywheel magneto removal · · · 250 N m (25.0 kgf m, 184.4 ft · · · m (0.8 kgf m, 5.9 ft · · · 26 N m (2.6 kgf m, 19.2 ft...
Page 187 POWR Generator cover and flywheel magneto · · · 250 N m (25.0 kgf m, 184.4 ft · · · m (0.8 kgf m, 5.9 ft 26 N · m (2.6 kgf · m, 19.2 ft · 80 N · m (8.0 kgf ·...
Page 188: Generator Cover Disassembly
POWR Generator cover and flywheel magneto Generator cover disassembly · · · 14 N m (1.4 kgf m, 10.3 ft · m (0.5 kgf · m, 3.7 ft · · · · · m (0.5 kgf · m, 3.7 ft ·...
Page 189: Drive Coupling Removal
POWR Generator cover and flywheel magneto Drive coupling removal WARNING When using a heat gun, protect your hands by wearing heat-resistant gloves. Compo- nents become hot enough to cause burns. 1. Remove: • Holder 1 • Drive coupling 2 Removal steps: 1.
Page 190: Flywheel Magneto Removal
POWR Generator cover and flywheel magneto Flywheel magneto removal WARNING When using a heat gun, protect your hands by wearing heat-resistant gloves. Compo- nents become hot enough to cause burns. 1. Remove: • Generator cover assembly • Transfer shaft assembly 1 Removal steps: 1.
Page 191 POWR Generator cover and flywheel magneto 4. Hold the flywheel magneto 3 with the spe- cial service tools 4 and 5, and then remove the transfer shaft assembly 1 with the special service tool 8. Shaft holder 4: 90890-06721 Driver handle 5: 90890-06722 Crankshaft holder 8: 90890-06732...
Page 192: Bearing Removal
POWR Generator cover and flywheel magneto Bearing removal È 1. Remove: • Oil seal1 • Circlip 2 • Bearing 3 Make sure to remove the circlip before remov- ing the bearing. Driver handle (small): É YB-06229 Bearing and seal installer: YW-06356 Driver rod LS: 90890-06606...
Page 193: Bearing Installation
POWR Generator cover and flywheel magneto 3. Check: • Starter clutch operation É Does not operate properly → Replace the starter clutch assembly. È Checking steps: 1. Install the starter clutch assembly 1 onto the starter gear 2 and hold the starter clutch assembly.
Page 194: Oil Seal Installation
POWR Generator cover and flywheel magneto Oil seal installation È 1. Install: • Oil seal 1 NOTICE Do not reuse the oil seal, always replace it with a new one. Forward bearing race installer: YB-06258 É Bearing pressure C: 90890-02393 È...
Page 195: Flywheel Magneto Installation
POWR Generator cover and flywheel magneto Flywheel magneto installation 1. Install: • Starter clutch assembly 1 • Flywheel magneto 2 • Flywheel magneto bolts 3 • Starter gear 4 Installation steps: 1. Apply engine oil to the starter clutch rollers and contact surface of the starter gear before installation.
Page 196 POWR Generator cover and flywheel magneto 2. Install: • Special nut 1 • Transfer shaft 2 Installation steps: 1. Remove any grease from the special nut 1 and the inner surface of the transfer shaft 2, making sure that the threads of the nut and shaft are clean and dry.
Page 197 3. Apply a line of LT648 onto the end of the crankshaft as shown. 4. Apply recommended lubricant to the mat- ing surfaces between the flywheel mag- neto 2 and the transfer shaft 3. Recommended lubricant: Yamaha grease A 5. Install the transfer shaft assembly 3. 5-90...
Page 198 POWR Generator cover and flywheel magneto 6. Hold the flywheel magneto assembly 2 with the special service tools 4 and 5, and then tighten the transfer shaft assem- bly 3 to the specified torque with the spe- cial service tool 6. Shaft holder 4: 90890-06721 Driver handle 5:...
Page 199 POWR Generator cover and flywheel magneto 10. Tighten the transfer shaft assembly to the specified torque with the special service 60˚ tool 6. NOTICE If the mark a on the transfer shaft assem- bly 3 moves past the 120° mark on the 120˚...
Page 200: Drive Coupling Installation
POWR Generator cover and flywheel magneto Drive coupling installation 1. Install: • Washer 1 • Drive coupling 2 Installation steps: 1. Remove any grease from the threaded portion of the transfer shaft, making sure that the threads are clean and dry. 2.
Page 201 POWR Generator cover and flywheel magneto 2. Install: • Holder 1 Installation steps: 1. Remove any grease from the threaded portion of the holder 1. 2. Apply a ring of LT648 around the unthreaded portion of the holder 1 as shown.
Page 202: Oil Separator Tank And Oil Pan
POWR Oil separator tank and oil pan Oil separator tank and oil pan Oil separator tank and oil pan removal 15 N · m (1.5 kgf · m, 11.1 ft · · m (0.8 kgf · m, 5.9 ft · 20 N ·...
Page 203 POWR Oil separator tank and oil pan · · · · · · 15 N m (1.5 kgf m, 11.1 ft m (0.8 kgf m, 5.9 ft · · · 20 N m (2.0 kgf m, 14.8 ft 15 N ·...
Page 204 POWR Oil separator tank and oil pan 15 N · m (1.5 kgf · m, 11.1 ft · · m (0.8 kgf · m, 5.9 ft · 20 N · m (2.0 kgf · m, 14.8 ft · · · ·...
Page 205: Oil Pan Disassembly
POWR Oil separator tank and oil pan Oil pan disassembly 12 N · m (1.2 kgf · m, 8.9 ft · · · · 12 N m (1.2 kgf m, 8.9 ft · m (0.9 kgf · m, 6.6 ft ·...
Page 206: Oil Separator Tank Cover Removal
POWR Oil separator tank and oil pan Oil separator tank cover removal 1. Remove: • Oil separator tank cover Loosen the oil separator tank cover bolts in the sequence shown. Oil separator tank cover check 1. Check: • Oil separator tank cover Cracks/damage →...
Page 207: Crankcase, Connecting Rod, And Piston
POWR Crankcase, connecting rod, and piston Crankcase, connecting rod, and piston Crankcase, connecting rod, and piston disassembly · m (5.0 kgf · m, 36.9 ft · 50 N 1280B · · · 1st 51 N m (5.1 kgf m, 37.6 ft ·...
Page 208 POWR Crankcase, connecting rod, and piston 50 N · m (5.0 kgf · m, 36.9 ft · 1280B 1st 51 N · m (5.1 kgf · m, 37.6 ft · · m (1.0 kgf · m, 7.4 ft · 10 N 2nd 90˚...
Page 209: Crankcase Disassembly
POWR Crankcase, connecting rod, and piston Crankcase disassembly 1. Remove: • Crankcase bolts (M6 × 70 mm) 1–B • Crankcase bolts (M10 × 85 mm) C–L • Place the crankcase upside down on a bench. • The numbers embossed on the crankcase indicate the crankcase tightening sequence.
Page 210: Crankcase Check
POWR Crankcase, connecting rod, and piston 2. Remove: • Piston pin clips 1 • Piston pin 2 • Piston 3 • Connecting rod 4 • Connecting rod cap bolts 5 For reference during installation, put identifica- tion marks a on the piston crown and con- necting rod.
Page 211: Piston Check
POWR Crankcase, connecting rod, and piston Piston check 1. Check: • Piston wall Vertical scratches → Replace the piston and piston rings as a set. 2. Measure: • Piston outside diameter a Out of specification → Replace the pis- ton. Piston outside diameter a: 85.915–85.930 mm (3.3825–3.3831 in)
Page 212: Piston Ring Check
POWR Crankcase, connecting rod, and piston Piston ring check 1. Measure: • Piston ring dimensions B and T Out of specification → Replace the pis- ton rings as a set. Piston ring dimensions: Top ring B: 1.17–1.19 mm (0.0461–0.0469 in) T: 2.85–3.05 mm (0.112–0.120 in) 2nd ring...
Page 213: Piston Pin Check
POWR Crankcase, connecting rod, and piston 3. Measure: • Piston ring grooves Out of specification → Replace the pis- ton. Before measuring the piston ring grooves, eliminate any carbon deposits from the piston ring grooves. Piston ring groove: Top ring 1.21–1.23 mm (0.0476–0.0484 in) 2nd ring 1.21–1.23 mm (0.0476–0.0484 in)
Page 214: Connecting Rod Check
POWR Crankcase, connecting rod, and piston Connecting rod check 1. Measure: • Connecting rod small end inside diameter a Out of specification → Replace the con- necting rod assembly. Connecting rod small end inside diameter a: 22.015–22.028 mm (0.8667–0.8672 in) Cylinder check 1.
Page 215: Crankshaft Check
POWR Crankcase, connecting rod, and piston Crankshaft check 1. Measure: • Crankshaft journal a diameter • Crankshaft pin b diameter Out of specification → Replace the crankshaft. Crankshaft journal a diameter: 39.976–40.000 mm (1.5739–1.5748 in) Crankshaft pin b diameter: 41.976–42.000 mm (1.6526–1.6535 in) 2.
Page 216 POWR Crankcase, connecting rod, and piston 2. Install the upper bearing into the connect- ing rod and lower bearing into the connect- ing rod cap. • Install the connecting rod bearings in their original positions. • Insert the projection a of each bearing into the slots in the connecting rod cap and con- necting rod.
Page 217 POWR Crankcase, connecting rod, and piston 2. Select: • Connecting rod bearing Selecting steps: 1. Check the connecting rod size number a on the connecting rod. 2. Check the crankshaft pin size number b on the crankshaft web. 3. Select the suitable color c for the con- necting rod bearing from the table.
Page 218: Crankshaft Journal Oil Clearance Check
POWR Crankcase, connecting rod, and piston Crankshaft journal oil clearance check 1. Measure: • Crankshaft journal oil clearance Out of specification → Replace the crankshaft journal bearings. Measurement steps: 1. Clean the bearings, crankshaft journals, and bearing portions of the crankcase and cylinder block.
Page 219 POWR Crankcase, connecting rod, and piston 8. Apply engine oil to the crankcase bolts threads. 9. Tighten the crankcase bolts to the speci- fied torques in 2 stages. • Tighten the crankcase bolts in the sequence shown. • Do not turn the crankshaft until the crank- shaft journal oil clearance measurement has been completed.
Page 220 POWR Crankcase, connecting rod, and piston 2. Select: • Crankshaft main journal bearing Selecting steps: 1. Check the crankcase journal size number a on the crankcase. If the crankcase journal sizes are the same at all positions, the size number a is stamped only at the “J1”...
Page 221: Connecting Rod And Piston Installation
POWR Crankcase, connecting rod, and piston Connecting rod and piston installation 1. Install: • Piston 1 • Connecting rod 2 • Piston pin 3 • Piston pin clips 4 • Connecting rod cap bolts 5 NOTICE Do not reuse the piston pin clips 4 and connecting rod cap bolts 5, always replace them with new ones.
Page 222 POWR Crankcase, connecting rod, and piston 3. Offset: • Piston ring end gap 90˚ a Top ring, oil ring expander spacer b 2nd ring c Upper oil ring rail d Lower oil ring rail È È Front mark 90˚ 4. Install: •...
Page 223: Crankcase Assembly
POWR Crankcase, connecting rod, and piston 5. Tighten: • Connecting rod nuts 1 Use a commercially available angle gauge to tighten the nuts to the specified angle. Connecting rod nut: 1st: 51 N·m (5.1 kgf·m, 37.6 ft·lb) 2nd: 90° Crankcase assembly 1280B 1.
Page 224 POWR Crankcase, connecting rod, and piston 2. Tighten: • Crankcase bolts (M10 × 85 mm) 1 • Crankcase bolts (M6 × 70 mm) 2 Tightening steps: 1. Apply engine oil to the threads of the crankcase bolts and flange surface of the crankcase bolts.
Page 225 PUMP Chapter 6 Jet pump unit Intake grate and ride plate................6-1 Intake grate and ride plate removal ............6-1 Jet pump unit....................6-2 Jet pump unit removal ................6-2 Jet pump unit removal ................6-4 Jet pump unit installation ................6-4 Reverse gate....................
Page 226: Intake Grate And Ride Plate
PUMP Intake grate and ride plate Intake grate and ride plate Intake grate and ride plate removal · · · m (0.7 kgf m, 5.2 ft · · · 17 N m (1.7 kgf m, 12.5 ft · · · ·...
Page 227: Jet Pump Unit
PUMP Jet pump unit Jet pump unit Jet pump unit removal · m (0.2 kgf · m, 1.5 ft · 14 N · m (1.4 kgf · m, 10.3 ft · · m (0.7 kgf · m, 5.2 ft · ·...
Page 228 PUMP Jet pump unit · m (0.2 kgf · m, 1.5 ft · · m (1.4 kgf · m, 10.3 ft · 14 N · m (0.7 kgf · m, 5.2 ft · · m (0.7 kgf · m, 5.2 ft ·...
Page 229: Jet Pump Unit Installation
PUMP Jet pump unit Jet pump unit removal WARNING Make sure to remove the battery before re- moving the jet pump unit. 1. Remove: • Jet pump unit Removal steps: 1. Remove the intake grate 1, speed sensor 2, and ride plate 3. 2.
Page 230 PUMP Jet pump unit Installation steps: 1. Clean the contacting surfaces of the jet pump unit 1 and transom plate 2. 2. Apply sealant to the contacting surfaces of the transom plate 2. 3. Install the jet pump unit 1. Rotate the drive shaft 3 to align the splines on the drive shaft with the splines on the inside of the intermediate drive shaft.
Page 231: Reverse Gate
PUMP Reverse gate Reverse gate Reverse gate removal · · · m (0.1 kgf m, 0.7 ft · · · m (0.8 kgf m, 5.9 ft · · · 20 N m (2.0 kgf m, 14.8 ft · · · m (0.8 kgf m, 5.9 ft ·...
Page 232: Jet Thrust Nozzle And Nozzle Ring
PUMP Jet thrust nozzle and nozzle ring Jet thrust nozzle and nozzle ring Jet thrust nozzle and nozzle ring removal 15 N · m (1.5 kgf · m, 11.1 ft · · m (0.8 kgf · m, 5.9 ft · ·...
Page 233: Impeller Duct And Impeller Housing
PUMP Impeller duct and impeller housing Impeller duct and impeller housing Impeller duct, impeller housing and nozzle removal 1194E 1194E · · · 40 N m (4.0 kgf m, 29.5 ft · · · m (0.7 kgf m, 5.2 ft Step Q’ty Remarks...
Page 234: Impeller Duct And Drive Shaft
PUMP Impeller duct and drive shaft Impeller duct and drive shaft Impeller duct and drive shaft disassembly · · · · · · 69 N m (6.9 kgf m, 50.9 ft m (0.8 kgf m, 5.9 ft · · · 205 N m (20.5 kgf m, 151.2 ft...
Page 235 PUMP Impeller duct and drive shaft · · · · m (0.8 kgf · m, 5.9 ft · 69 N m (6.9 kgf m, 50.9 ft · · · 205 N m (20.5 kgf m, 151.2 ft Step Q’ty Remarks Part name Rear bearing Not reusable...
Page 236: Drive Shaft Removal
PUMP Impeller duct and drive shaft Drive shaft removal 1. Remove: • Impeller 1 • Spacer 2 • Cap 3 • Nut 4 The impeller has left-hand threads. Turn the impeller clockwise to loosen it. Drive shaft holder 5: YB-06201 Drive shaft holder 6 5: 90890-06520 2.
Page 237 PUMP Impeller duct and drive shaft 3. Remove: È • Rear bearing Slide hammer and adapters 1: YB-06096 Stopper guide plate 2: 90890-06501 Bearing puller assembly 3: 90890-06535 Stopper guide stand 4: 90890-06538 É È For USA and Canada É For worldwide 4.
Page 238: Impeller Check
PUMP Impeller duct and drive shaft 5. Remove: È • Front bearing Driver handle (large) 1: YB-06071 Drive shaft needle bearing installer and remover 2: YB-06194 Driver rod L3 3: 90890-06652 Needle bearing attachment 4: 90890-06609 É É È For USA and Canada É...
Page 239: Drive Shaft Installation
PUMP Impeller duct and drive shaft 2. Measure: • Drive shaft runout Out of specification → Replace the drive shaft. Drive shaft runout limit: 0.3 mm (0.012 in) Measuring point a: 310 mm (12.20 in) Drive shaft installation È 1. Install: •...
Page 240 PUMP Impeller duct and drive shaft 3. Install: • Drive shaft assembly (with front bearing) • Spacer Bearing attachment 1: 90890-06728 4. Apply: • EPNOC grease AP #0 (between the drive shaft and spacer) Quantity: 20 g (0.04 lb) 5. Install: •...
Page 241: Impeller Duct, Impeller Housing And Nozzle Installation
PUMP Impeller duct and drive shaft 8. Install: • Spacer 1 • Impeller 2 The impeller has left-hand threads. Turn the impeller counterclockwise to tighten it. Drive shaft holder 3: YB-06201 Drive shaft holder 6 3: 90890-06520 Impeller: 205 N·m (20.5 kgf·m, 151.2 ft·lb) LOCTITE 572 Impeller duct, impeller housing and nozzle installation...
Page 242 PUMP Transom plate and hoses Transom plate and hoses Transom plate and hose removal · m (0.5 kgf · m, 3.7 ft · · · · m (0.6 kgf m, 4.4 ft 45˚ · · · 26 N m (2.6 kgf m, 19.2 ft ·...
Page 243 PUMP Transom plate and hoses · m (0.5 kgf · m, 3.7 ft · · m (0.6 kgf · m, 4.4 ft · 45˚ · · · 26 N m (2.6 kgf m, 19.2 ft · · · m (0.7 kgf m, 5.2 ft Step Q’ty...
Page 244: Transom Plate And Hoses
PUMP Transom plate and hoses · m (0.5 kgf · m, 3.7 ft · · · · m (0.6 kgf m, 4.4 ft 45˚ · · · 26 N m (2.6 kgf m, 19.2 ft · m (0.7 kgf · m, 5.2 ft ·...
Page 245: Water Hose Check
PUMP Transom plate and hoses Water hose check 1. Check: • Bilge hoses • Cooling water hoses Cracks/damage → Replace. Transom plate installation 1. install: • Transom plate Installation steps: 1. Clean the contacting surfaces of the tran- som plate. 2.
Page 246 PUMP Intermediate housing Intermediate housing Intermediate housing removal · · · 17 N m (1.7 kgf m, 12.5 ft Step Q’ty Remarks Part name Engine unit Refer to “Engine unit” in Chapter 5. Rubber damper Band Not reusable Grease hose M8 ×...
Page 247 PUMP Intermediate housing Intermediate housing disassembly · m (0.5 kgf · m, 3.7 ft · · · · 205 N m (20.5 kgf m, 151.2 ft Step Q’ty Remarks Part name Band Not reusable Grease hose Nipple Driven coupling Washer Intermediate drive shaft O-ring Not reusable...
Page 248: Intermediate Housing Removal
PUMP Intermediate housing Intermediate housing removal 1. Remove: • Intermediate housing assembly 1 • Shims 2 Make a note of the position of each removed shim 2 so that it can be installed in its original position. Driven coupling removal 1.
Page 249: Intermediate Drive Shaft And Grease Hose Check
PUMP Intermediate housing 2. Remove: È • Oil seal (front) • Oil seals (rear) Slide hammer and adapters 1: YB-06096 Bearing puller legs 2: YB-06523 Stopper guide plate 3: 90890-06501 Bearing puller assembly 4: 90890-06535 É Stopper guide stand 5: 90890-06538 È...
Page 250: Driven Coupling And Intermediate Housing Check
PUMP Intermediate housing Driven coupling and intermediate housing check 1. Check: • Driven coupling 1 • Rubber damper 2 • Intermediate housing 3 Cracks/damage → Replace. Intermediate housing assembly È 1. Install: • Circlip 1 • Bearing 2 NOTICE Do not reuse the bearing, always replace it with a new one.
Page 251 PUMP Intermediate housing 2. Install: È • Oil seal 1 Driver handle (large) 2: YB-06071 Needle bearing installer 3: YB-06434 Driver rod LS 4: 90890-06606 Bearing outer race attachment 5: 90890-06623 É Distance a: 6.5 ± 0.2 mm (0.26 ± 0.01 in) È...
Page 252: Driven Coupling Installation
PUMP Intermediate housing 6. Install: • Thrust washer 1 NOTICE Do not reuse the thrust washer, always re- place it with a new one. Bearing attachment 2: 90890-06727 Distance a: 4.4 ± 0.3 mm (0.17 ± 0.01 in) Driven coupling installation 1.
Page 253 PUMP Intermediate housing — MEMO — 6-28...
Page 254 – ELEC Chapter 7 Electrical system Engine electrical components ..............7-1 Electrical box....................7-3 Electrical components ................7-3 Electrical box disassembly ................ 7-4 Fuse box disassembly ................7-6 Electrical analysis ..................7-8 Check using the YDIS ................7-8 Input voltage measurement ............... 7-9 Peak voltage measurement...............
Page 255 – ELEC Starting system .................... 7-44 Fuse......................7-44 Left handlebar switch assembly .............. 7-44 Main and fuel pump relay ................ 7-45 Starter relay ..................... 7-47 Starter motor ....................7-49 Starter motor disassembly............... 7-49 Starter motor operation................7-52 Armature....................7-52 Brush holder .................... 7-54 Gear cover....................
Page 256: Engine Electrical Components
– ELEC Engine electrical components Engine electrical components È É 1 Spark plugs and ignition coils B Knock sensor 2 Cam position sensor C Throttle body assembly (TPS) 3 Electrical box D Engine temperature sensor 4 Thermo sensor E Earth plate 5 Rectifier regulator F Stator coil and pickup coil 6 Starter motor...
Page 257 – ELEC Engine electrical components È É È Port bow view 1 Dual analog meter unit É Starboard stern view 2 Steering sensor 3 Buzzer 4 Left handlebar switch assembly 5 Speed sensor 6 Fuel pump module and fuel sender 7 APS 8 Remote control receiver 9 Reverse sensor...
Page 258: Electrical Box
– ELEC Electrical box Electrical box Electrical components 1 Starter relay 2 Main and fuel pump relay 3 ETV relay 4 Slant detection switch 5 ECM 6 Fuse (30 A) (battery) 7 Fuse (10 A) (main and fuel pump relay) 8 Fuse (10 A) (ETV relay) 9 Fuse (3 A) (remote control receiver) 0 Fuse (20 A) (main and fuel pump relay)
Page 259: Electrical Box Disassembly
– ELEC Electrical box Electrical box disassembly · m (0.8 kgf · m, 5.9 ft · · m (0.4 kgf · m, 3.0 ft · · · · m (0.5 kgf m, 3.7 ft Step Q’ty Remarks Part name ECM coupler Main and fuel pump relay coupler ETV relay coupler Slant detection switch coupler...
Page 260 – ELEC Electrical box · · · m (0.8 kgf m, 5.9 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.5 kgf m, 3.7 ft Step Q’ty Remarks Part name a “UP” mark Slant detection switch M6 ×...
Page 261: Fuse Box Disassembly
– ELEC Electrical box Fuse box disassembly · · · m (0.4 kgf m, 3.0 ft 14 13 É È Step Q’ty Remarks Part name ø6 × 25 mm Screw Washer Stay Main and fuel pump relay ETV relay Damper Packing Not reusable Fuse puller...
Page 262 – ELEC Electrical box · · · m (0.4 kgf m, 3.0 ft 14 13 É È Step Q’ty Remarks Part name M6 × 10 mm Bolt Boot a White tape Starter motor cable È To starter motor b Gray tape Positive battery cable É...
Page 263: Electrical Analysis
– ELEC Electrical analysis Electrical analysis Check using the YDIS When checking the TPS, APS, or other sen- sors, use the YDIS. When deleting the diagnosis record in the YDIS, make sure to check the time that the diagnostic codes were detected. When checking the input voltage of a part, the coupler or connector must be disconnected.
Page 264: Input Voltage Measurement
– ELEC Electrical analysis Input voltage measurement Push the unlock button 1 on the remote con- trol transmitter so that power is supplied to the ECM. To check that the remote control transmitter is working correctly, refer to “Remote control transmitter.”...
Page 265: Ignition System
– ELEC Electrical analysis / Ignition system È • Before measuring the peak voltage, check all wiring for proper connection and corrosion, and check that the battery is fully charged. • Use the peak voltage adapter with the rec- ommended digital circuit tester. •...
Page 266 – ELEC Ignition system 4. Using the “Stationary test” of the YDIS, observe the ignition spark through the dis- charge window in the special service tool. WARNING • When checking the ignition spark, do not touch any of the connections of the spe- cial service tool leads.
Page 267 – ELEC Ignition system 3. Measure: • ECM output peak voltage Within specification → Replace the igni- tion coil. Below specification → Check the pickup coil. Refer to “Pickup coil.” WARNING When checking the electrical components, do not touch any of the connections of the digital tester leads.
Page 268: Pickup Coil
– ELEC Ignition system Pickup coil 1. Measure: • Pickup coil output peak voltage Below specification → Measure the pickup coil resistance. Measurement steps: 1. Disconnect the pickup coil coupler 1. 2. Connect the test harness (3 pins) 2 to the pickup coil coupler 1.
Page 269: Charging System
– ELEC Ignition system / Charging system 2. Measure: • Pickup coil resistance Out of specification → Replace the sta- tor coil assembly. Measurement steps: 1. Disconnect the pickup coil coupler 1. 2. Measure the pickup coil resistance. Pickup coil resistance at 20 °C (68 °F) (reference data): White (W) –...
Page 270 – ELEC Charging system 3. Measure the stator coil output peak volt- age. To crank the engine, connect the engine shut- off cord (lanyard) to the engine shut-off switch, and then push the engine start switch and engine stop switch simultaneously. Stator coil output peak voltage: Green (G) –...
Page 271: Rectifier Regulator
– ELEC Charging system Rectifier regulator 1. Measure: • Rectifier regulator output peak voltage Below specification → Check the recti- fier regulator continuity. Measurement steps: 1. Disconnect the rectifier regulator coupler 2. Connect the test harness (2 pins) 2 to the rectifier regulator coupler 1.
Page 272 – ELEC Charging system 2. Check: È • Rectifier regulator continuity Out of specification → Replace the recti- fier regulator. Checking steps: 1. Remove the rectifier regulator. Refer to “Engine unit removal 3” in Chap- ter 5. 2. Check the rectifier regulator continuity. É...
Page 273: Control System
– ELEC Control system Control system Oil pressure switch 1. Measure: • Oil pressure switch input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the oil pressure switch coupler 2. Push the unlock button, and then measure the input voltage between the oil pressure switch coupler terminal (wiring harness end) and ground.
Page 274: Thermoswitch
– ELEC Control system 4. Check the oil pressure switch continuity. Use a commercially available vacuum/pres- sure pump gauge and meter. Oil pressure switch continuity: Terminal thread 1 – Pressure Body 2 Below 128–166 kPa (1.28–1.66 kgf/cm Continuity 18.2–23.6 psi) Above 128–166 kPa (1.28–1.66 kgf/cm No continuity...
Page 275 – ELEC Control system 2. Check: • Thermoswitch continuity (at the speci- fied temperatures) Out of specification → Replace the ther- moswitch. Checking steps: 1. Remove the thermoswitch. Refer to “Oil separator tank and oil pan removal” in Chapter 5. 2.
Page 276: Thermo Sensor
– ELEC Control system Thermo sensor 1. Measure: • Thermo sensor input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the thermo sensor coupler 1. 2. Push the unlock button, and then measure the input voltage at the thermo sensor cou- pler terminals (wiring harness end).
Page 277: Engine Temperature Sensor
– ELEC Control system Engine temperature sensor 1. Measure: • Engine temperature sensor input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the engine temperature sensor coupler 1. 2. Push the unlock button, and then measure the input voltage at the engine tempera- ture sensor coupler terminals (wiring har- ness end).
Page 278: Intake Air Temperature Sensor
– ELEC Control system 4. Measure the resistance when the specified temperatures are reached. Engine temperature sensor resistance (reference data): Black/yellow (B/Y) – Black/yellow (B/Y) 20 °C (68 °F): 54.2–69.0 kΩ 100 °C (212 °F): 3.12–3.48 kΩ Intake air temperature sensor 1.
Page 279 – ELEC Control system 2. Measure: • Intake air temperature sensor input voltage Within specification → Measure the intake air temperature sensor resis- tance. Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the intake air temperature sen- sor coupler 1.
Page 280: Intake Air Pressure Sensor
– ELEC Control system Intake air pressure sensor 1. Measure: • Intake air pressure sensor input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the intake air pressure sensor coupler 1. 2. Push the unlock button, and then measure the input voltage at the intake air pressure sensor coupler terminals (wiring harness end).
Page 281: Knock Sensor
– ELEC Control system Knock sensor 1. Check: • Knock sensor ground connection Knock sensor not grounded when installed → Install the knock sensor cor- rectly. Refer to “Oil separator tank and oil pan removal” in Chapter 5. 2. Measure: •...
Page 282 – ELEC Control system 1. Check: • Throttle valve opening • TPS output voltage Out of specification → Measure the TPS input voltage. Checking steps: When checking the TPS using the YDIS, do not start the engine. 1. Connect a computer to the watercraft and use the YDIS to display “Throttle position sensor 1,”...
Page 283 – ELEC Control system 5. Operate the throttle lever 1, and then check the TPS 2 output voltage and throt- tle valve opening angle at the fully open position É. The actual TPS output voltage and throttle valve opening angle may vary according to environmental conditions and engine tempera- ture.
Page 284: Accelerator Position Sensor
– ELEC Control system 3. Check: • TPS circuit continuity No continuity → Replace the wiring har- ness assembly. Wiring harness is correct → Replace the throttle body assembly. Checking steps: 1. Disconnect the throttle body assembly coupler 1. 2. Disconnect the ECM couplers 2 and 3. 3.
Page 285 – ELEC Control system 1. Connect a computer to the watercraft and use the YDIS to display the “Accelerator position sensor 1” and “Accelerator posi- tion sensor 2.” APS 1 and APS 2 are a single unit, which can- not be disassembled. 2.
Page 286 – ELEC Control system 2. Measure: • APS input voltage Within specification → Measure the APS resistance. Out of specification → Check the APS circuit. Measurement steps: 1. Disconnect the APS coupler 1. 2. Push the unlock button, and then measure the input voltage at the APS coupler termi- nals (wiring harness end).
Page 287 – ELEC Control system 3. Check that the APS pulley stopper c con- tacts the fully open stopper d when the APS pulley is at the fully open position É. 4. Measure the resistance of the APS at the fully closed position and fully open posi- 1 2 3 4 5 6 7 8 tion.
Page 288: Electronic Throttle Valve Relay
– ELEC Control system Electronic throttle valve relay 1. Measure: • ETV relay input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the ETV relay coupler 1. 2. Push the unlock button, and then measure the input voltage between the ETV relay coupler terminals and ground.
Page 289: Cam Position Sensor
– ELEC Control system Cam position sensor 1. Measure: • Cam position sensor input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the cam position sensor cou- pler 1. 2. Push the unlock button, and then measure the input voltage at the cam position sen- sor coupler terminals (wiring harness end).
Page 290: Slant Detection Switch
– ELEC Control system Slant detection switch 1. Measure: • Slant detection switch input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the slant detection switch cou- pler 1. 2. Push the unlock button, and then measure the input voltage at the slant detection switch coupler (wiring harness end).
Page 291: Steering Sensor
– ELEC Control system Steering sensor 1. Check: • Steering sensor operation Does not operate → Measure the steer- ing sensor input voltage. Checking steps: 1. Connect a computer to the watercraft to use the YDIS. 2. Turn the handlebar all the way to the left or right.
Page 292: Reverse Sensor
– ELEC Control system 2. Measure: • Steering sensor input voltage Within specification → Replace the steering sensor. Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the steering sensor coupler 1. 2. Push the unlock button, and then measure the input voltage at the steering sensor coupler terminals (wiring harness end).
Page 293: Ecm Circuit
– ELEC Control system 2. Measure: • Reverse sensor input voltage Within specification → Replace the reverse sensor. Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the reverse sensor coupler 1. 2. Push the unlock button, and then measure the input voltage at the reverse sensor coupler terminals (wiring harness end).
Page 294: Earth Plate
– ELEC Control system 2. Check: • ECM circuit continuity No continuity → Replace the wiring har- ness assembly. Checking steps: 1. Disconnect the ECM couplers 1 and 2. 2. Check the continuity between the ECM coupler terminals 3 (wiring harness end) and ground.
Page 295: Electric Bilge Pump
– ELEC Control system Electric bilge pump 1. Measure: • Electric bilge pump input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the electric bilge pump coupler 2. Push the unlock button, and then measure the input voltage at the electric bilge pump coupler (wiring harness end).
Page 296: Fuel System
– ELEC Fuel system Fuel system Fuel injector 1. Check: • Fuel injector operation sound Does not sound → Measure the fuel injector input voltage. Checking steps: 1. Connect a computer to the watercraft to use the YDIS. 2. Using the “Stationary test” of the YDIS, lis- ten for the fuel injector operation sound.
Page 297: Fuel Pump Module
– ELEC Fuel system 3. Measure: • Fuel injector resistance Out of specification → Replace the fuel injector. Measurement steps: 1. Remove the fuel injector. Refer to “Fuel tank removal” in Chapter 4. 2. Measure the fuel injector resistance. Fuel injector resistance at 20 °C (68 °F) (reference data): 11.5–12.5 Ω...
Page 298 – ELEC Fuel system 2. Measure: • Fuel pump module input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the fuel pump module coupler 2. Push the unlock button, and then measure the input voltage at the fuel pump module coupler terminals (wiring harness end).
Page 299: Starting System
– ELEC Starting system Starting system Fuse 1. Check: • Fuse continuity No continuity → Replace the fuse. Left handlebar switch assembly 1. Check: È • Engine start switch continuity Out of specification → Replace the left handlebar switch assembly. Checking steps: É...
Page 300: Main And Fuel Pump Relay
– ELEC Starting system 2. Check: • Engine stop switch continuity È Out of specification → Replace the left handlebar switch assembly. Checking steps: É 1. Disconnect the left handlebar switch cou- pler. Refer to “Handlebar assembly removal” in Chapter 8. 2.
Page 301 – ELEC Starting system 2. Check: • Main relay continuity Out of specification → Replace the main and fuel pump relay. Checking steps: 1. Remove the main and fuel pump relay. Refer to “Fuse box disassembly.” 2. Connect the tester leads to the main and fuel pump relay terminals 5 and 6 or to the terminals 5 and 7.
Page 302: Starter Relay
– ELEC Starting system Checking steps: 1. Connect the tester leads to the main and fuel pump relay terminals 7 and 8. 2. Connect the positive battery lead to the main and fuel pump relay terminal 6. 3. Connect the negative battery lead to the main and fuel pump relay terminal 4.
Page 303 – ELEC Starting system 2. Check: • Starter relay continuity Out of specification → Replace the starter relay. Checking steps: 1. Remove the starter relay. Refer to “Electrical box disassembly.” 2. Connect the tester leads between the starter relay terminals 1 and 2. 3.
Page 304 – ELEC Starter motor Starter motor Starter motor disassembly · · · m (0.9 kgf m, 6.6 ft · · · m (0.7 kgf m, 5.2 ft Step Q’ty Remarks Part name M6 × 120 mm Bolt Gear cover assembly Circlip Drive gear O-ring...
Page 305 – ELEC Starter motor · · · m (0.9 kgf m, 6.6 ft · m (0.7 kgf · m, 5.2 ft · Step Q’ty Remarks Part name Shim Rear cover Shim Packing Not reusable Armature Brush holder assembly Brush spring Brush holder stay Spring washer Washer...
Page 306 – ELEC Starter motor · · · m (0.9 kgf m, 6.6 ft · · · m (0.7 kgf m, 5.2 ft Step Q’ty Remarks Part name Insulator washer 1 Insulator washer 2 O-ring Not reusable Terminal bolt Lead plate Terminal insulator Plate cover Starter motor yoke...
Page 307: Starter Motor Operation
– ELEC Starter motor Starter motor operation 1. Check: • Starter motor operation Does not operate → Check the starter motor. Checking steps: 1. Hold the starter motor in a vise using alu- minum plates on both sides. 2. Connect the positive battery cable 1 to the starter motor terminal bolt 2.
Page 308 – ELEC Starter motor 2. Measure: • Commutator diameter Out of specification → Replace the armature. Commutator diameter: 27.0–28.0 mm (1.06–1.10 in) 3. Measure: • Commutator undercut a Out of specification → Replace the armature. Commutator undercut a (reference data): 0.2–0.7 mm (0.008–0.028 in) 4.
Page 309 – ELEC Starter motor Brush holder 1. Measure: • Brush length a Out of specification → Replace the brush holder assembly. Brush length a: 5.0–12.5 mm (0.20–0.49 in) 2. Check: • Brush holder continuity Out of specification → Replace the brush holder assembly.
Page 310: Rear Cover
– ELEC Starter motor / Remote control system Rear cover 1. Check: • Rear cover 1 • Metal 2 Cracks/damage → Replace the rear cover assembly. Starter motor assembly 1. Install: • Gear cover assembly Installation steps: 1. Install the ring gear 1, planetary gears 2, and dowel pin to the front cover 3.
Page 311: Remote Control Transmitter
– ELEC Remote control system 2. Push the lock button 5 or unlock button 6 to transmit the ID code from the remote control transmitter to be registered. • At this time, the system enters the registra- tion mode to register the first code. All exist- ing ID codes will be deleted from the remote control receiver.
Page 312 5. Push the lock button 4. The buzzer sounds once. 6. Check that the “UNLOCK” indicator light 2 goes off. While the engine is running, input from the remote control transmitter is not received. Yamaha Security Number of beeps System mode 1 beep Lock Unlock...
Page 313 – ELEC Remote control system 2. Remove the battery 3. 3. Measure the battery voltage. NOTICE • Do not touch the internal parts except the battery. • Do not touch the battery directly with your hands. Use a pair of non-conductive tweezers to replace the battery.
Page 314: Remote Control Receiver
– ELEC Remote control system Remote control receiver 1. Measure: • Remote control receiver input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the remote control receiver coupler 1. 2. Measure the input voltage at the remote control receiver coupler terminals (wiring harness end).
Page 315: Indication System
– ELEC Indication system Indication system Dual analog meter unit 1. Check: • Dual analog meter unit external appear- ance Cracked meter housing/meter is fogged/ shows signs of water intrusion → Replace the dual analog meter unit. 2. Check: • Information display Intermittent or missing segment a →...
Page 316: Switch Assembly
– ELEC Indication system Switch assembly 1. Check: • Switch assembly continuity Out of specification → Replace the switch assembly. Checking steps: 1. Disconnect the switch assembly coupler Refer to “Dual analog meter unit and cover removal” in Chapter 8. 2.
Page 317 – ELEC Indication system 2. Measure: • Speed sensor output voltage Out of specification → Replace the speed sensor. Measurement steps: 1. Disconnect the speed sensor coupler 1. Refer to “Dual analog meter unit and cover removal” in Chapter 8. 2.
Page 318: Fuel Level Meter Display And Fuel Indicator
– ELEC Indication system Fuel level meter display and fuel indicator 1. Check: • Fuel level meter display 1 and fuel indi- cator 2 Do not come on → Replace the dual analog meter unit. Checking steps: 1. Remove the fuel pump module assembly. Refer to “Fuel tank removal”...
Page 319: Diagnostic Display
– ELEC Indication system Diagnostic display 1. Check: • Diagnostic display Does not come on → Check the “Diag- nosis record” of the YDIS. Checking steps: 1. Create a condition so that a diagnostic code is recorded. 2. Push the unlock button. 3.
Page 320: Engine Overheat Warning Indicator
– ELEC Indication system Engine overheat warning indicator 1. Check: • Engine overheat warning indicator Does not come on → Check the “Diag- nosis record” of the YDIS. Checking steps: 1. Disconnect the thermoswitch coupler 1. 2. Connect the jumper lead 2 to the ther- moswitch coupler terminals (wiring har- ness end).
Page 321 – ELEC Indication system 2. Check: • Buzzer operation Does not sound → Replace the buzzer. Checking steps: 1. Remove the buzzer. Refer to “Steering master disassembly” in Chapter 8. 2. Connect the positive battery lead to the terminal 1 and the negative battery lead to the terminal 2.
Page 322 HULL HOOD Chapter 8 Hull and hood Handlebar ....................... 8-1 Handlebar cover removal ................8-1 Handlebar holder removal ................. 8-2 Handlebar assembly removal ..............8-3 Left handlebar switch disassembly............8-5 Handlebar cover removal ................8-6 Throttle cable removal ................8-6 Handlebar check..................
Page 323 HULL HOOD Remote control cables and speed sensor lead......... 8-32 Remote control cables and speed sensor lead removal......8-32 Steering cable installation (steering master end) ........8-34 Steering cable installation (jet pump end) ..........8-35 Shift cable installation (shift lever end) ............ 8-35 Shift cable installation (jet pump end)............
Page 324: Handlebar
HULL HOOD Handlebar Handlebar Handlebar cover removal · m (0.5 kgf · m, 3.7 ft · · · · m (0.1 kgf m, 0.7 ft Step Q’ty Remarks Part name ø5 × 15 mm Screw Upper handlebar cover Steering pad ø6 ×...
Page 325: Handlebar Holder Removal
HULL HOOD Handlebar Handlebar holder removal · · · 20 N m (2.0 kgf m, 14.8 ft Step Q’ty Remarks Part name Throttle cable Corrugated tube M8 × 48 mm Bolt a Punch mark Upper handlebar holder b 0.4 mm (0.02 in) c 2.4 mm (0.09 in)
Page 326: Handlebar Assembly Removal
HULL HOOD Handlebar Handlebar assembly removal · · · m (0.1 kgf m, 0.7 ft · · · m (0.3 kgf m, 2.2 ft · m (0.1 kgf · m, 0.7 ft · · · · m (0.3 kgf m, 2.2 ft ·...
Page 327 HULL HOOD Handlebar · · · m (0.1 kgf m, 0.7 ft · · · m (0.3 kgf m, 2.2 ft · · · m (0.1 kgf m, 0.7 ft · m (0.3 kgf · m, 2.2 ft · · ·...
Page 328 HULL HOOD Handlebar Left handlebar switch disassembly Step Q’ty Remarks Part name Left handlebar switch assembly Engine shut-off cord Stop button assembly Start button assembly ø3 × 8 mm Screw Throttle lever assembly E-ring Washer Shaft Lever Spring...
Page 329: Handlebar Cover Removal
HULL HOOD Handlebar Handlebar cover removal 1. Remove: • Handlebar cover screws 1 • Handlebar covers 2 • Steering pad 3 Move the handlebar 4 to the highest position. Throttle cable removal 1. Remove: • Throttle cable 1 NOTICE Make sure to remove the throttle cable seal 2 as shown.
Page 330: Handlebar Assembly Installation
HULL HOOD Handlebar Handlebar assembly installation 1. Install: • Packing 1 • Grommet 2 • QSTS cables 3 • Throttle cable 4 • Left handlebar switch lead 5 • Plastic ties 6 • Handlebar 7 • Corrugated tube (throttle cable) 8 •...
Page 331 HULL HOOD Handlebar 4. Install the left handlebar switch assembly Align the projection b on the handlebar switch assembly with the handlebar hole c. Left handlebar switch screw: 3 N·m (0.3 kgf·m, 2.2 ft·lb) 5. Install the throttle lever assembly. Tighten the upper bolt first when installing the throttle lever assembly.
Page 332: Handlebar Cover Installation
HULL HOOD Handlebar 3. Install: • Throttle cable • Right handlebar grip Installation steps: 1. Install the throttle cable end into the throt- tle lever. 2. Fit the seal 1 into the groove in the bracket. 3. Pull the throttle cable 2 in the direction of the arrow shown, and then fit the end of the seal 1 around the inner cable.
Page 333: Qsts Grip And Converter
HULL HOOD QSTS grip and converter QSTS grip and converter QSTS grip and converter disassembly STERN 3 mm (0.12 in) 6 mm (0.24 in) · m (0.5 kgf · m, 3.7 ft · 5.9 N · m (0.59 kgf · m, 4.4 ft ·...
Page 334 HULL HOOD QSTS grip and converter STERN 3 mm (0.12 in) 6 mm (0.24 in) · · · m (0.5 kgf m, 3.7 ft · · · 5.9 N m (0.59 kgf m, 4.4 ft · m (0.7 kgf · m, 5.2 ft ·...
Page 335: Qsts Cable Removal
HULL HOOD QSTS grip and converter QSTS cable removal 1. Remove: • QSTS converter 2. Remove: • Cable guide 1 Remove the cable guide 1 with needlenose pliers as shown. 3. Remove: • QSTS cable ends QSTS check 1. Check: •...
Page 336: Qsts Cable Installation
HULL HOOD QSTS grip and converter QSTS cable installation 1. Install: • QSTS cable ends NOTICE • Make sure to fit the QSTS cable end with yellow paint mark a into the STBD hole b of the pulley. STERN • Be careful not to twist the QSTS cables. 2.
Page 337 HULL HOOD QSTS grip and converter 3. Fit the grip 4 into the housing 3. 4. Fit the QSTS cables 1 into the housing Fit the cable with the thin end a into the open- ing with the narrow groove b and the cable with the thick end c into the opening with the wide groove d.
Page 338: Front Hood
HULL HOOD Front hood Front hood Front hood removal · · · m (0.6 kgf m, 4.4 ft · · · m (0.5 kgf m, 3.7 ft · · · m (0.5 kgf m, 3.7 ft · · · m (0.5 kgf m, 3.7 ft ·...
Page 339 HULL HOOD Front hood · · · m (0.6 kgf m, 4.4 ft · · · m (0.5 kgf m, 3.7 ft · · · m (0.5 kgf m, 3.7 ft · · · m (0.5 kgf m, 3.7 ft ·...
Page 340 HULL HOOD Front hood Front hood disassembly · · · m (0.4 kgf m, 3.0 ft · m (0.2 kgf · m, 1.5 ft · Step Q’ty Remarks Part name ø5 × 15 mm Screw M5 × 20 mm Bolt Ventilation cover Packing Not reusable...
Page 341: Damper Check
HULL HOOD Front hood Damper check 1. Check: • Damper assembly Does not hold front hood open → Replace the damper assembly. Hood lock check 1. Check: • Hood lock 1 Does not lock → Check the hood lock installation. Cracks/damage →...
Page 342: Rivet Installation
HULL HOOD Front hood Rivet installation 1. Install: • Rivets Installation steps: Before reinstalling a rivet, hold the rivet flange a with both hands and push the rivet pin per- pendicularly against a hard flat surface until the pin protrudes from the top of the rivet. 1.
Page 343 HULL HOOD Steering console cover Steering console cover Dual analog meter unit and cover removal · · · m (0.2 kgf m, 1.5 ft · · · m (0.4 kgf m, 3.0 ft Step Q’ty Remarks Part name Handlebar assembly Refer to “Handlebar assembly removal.”...
Page 344: Side Cover Removal
HULL HOOD Steering console cover Side cover removal · · · · · · m (0.5 kgf m, 3.7 ft m (0.5 kgf m, 3.7 ft · · · m (0.5 kgf m, 3.7 ft · · · m (0.5 kgf m, 3.7 ft Step Q’ty...
Page 345 HULL HOOD Steering console cover · · · · · · m (0.5 kgf m, 3.7 ft m (0.5 kgf m, 3.7 ft · · · m (0.5 kgf m, 3.7 ft · · · m (0.5 kgf m, 3.7 ft Step Q’ty Remarks...
Page 346 HULL HOOD Steering console cover Center cover removal · m (0.5 kgf · m, 3.7 ft · · · · m (0.4 kgf m, 3.0 ft · m (0.5 kgf · m, 3.7 ft · Step Q’ty Remarks Part name Left induction box Right induction box Bolt...
Page 347 HULL HOOD Steering console cover · m (0.5 kgf · m, 3.7 ft · · · · m (0.4 kgf m, 3.0 ft · · · m (0.5 kgf m, 3.7 ft Step Q’ty Remarks Part name Shift lever assembly ø5 ×...
Page 348: Center Cover Disassembly
HULL HOOD Steering console cover Center cover disassembly · · · m (0.4 kgf m, 3.0 ft Step Q’ty Remarks Part name M5 × 20 mm Bolt Lid lock hook Bracket Grommet Hinge pin Center console box lid Lock 8-25...
Page 349 HULL HOOD Steering console cover Shift lever check 1. Check: • Shift lever assembly Crack/damage → Replace the shift lever assembly. NOTICE Do not disassemble the shift lever assem- bly except the reverse sensor. Shift lever installation 1. Remove: • Band 1 •...
Page 350 HULL HOOD Steering master Steering master Steering master removal · · · 20 N m (2.0 kgf m, 14.8 ft Step Q’ty Remarks Part name Center cover assembly Refer to “Steering console cover.” Steering cable joint Refer to “Remote control cables and speed sensor lead.”...
Page 351: Steering Master Disassembly
HULL HOOD Steering master Steering master disassembly · · · m (0.7 kgf m, 5.2 ft 17 N · m (1.7 kgf · m, 12.5 ft · · · · 17 N m (1.7 kgf m, 12.5 ft · · ·...
Page 352 HULL HOOD Steering master · · · m (0.7 kgf m, 5.2 ft · · · 17 N m (1.7 kgf m, 12.5 ft · · · 17 N m (1.7 kgf m, 12.5 ft · · · m (0.7 kgf m, 5.2 ft ·...
Page 353 HULL HOOD Steering master · · · m (0.7 kgf m, 5.2 ft 17 N · m (1.7 kgf · m, 12.5 ft · · · · 17 N m (1.7 kgf m, 12.5 ft · · · m (0.7 kgf m, 5.2 ft ·...
Page 354: Steering Master Component Check
HULL HOOD Steering master Steering master component check 1. Check: • Bushings Cracks/damage/wear → Replace the bushings. 2. Check: • Steering shaft assembly Cracks/damage → Replace the steering shaft assembly. NOTICE • Do not disassemble the handlebar brack- et a. •...
Page 355: Remote Control Cables And Speed Sensor Lead
HULL HOOD Remote control cables and speed sensor lead Remote control cables and speed sensor lead Remote control cables and speed sensor lead removal · · · m (0.5 kgf m, 3.7 ft 5.9 N · m (0.59 kgf · m, 4.4 ft ·...
Page 356 HULL HOOD Remote control cables and speed sensor lead · · · m (0.5 kgf m, 3.7 ft · · · 5.9 N m (0.59 kgf m, 4.4 ft · · · m (0.7 kgf m, 5.2 ft · · ·...
Page 357: Steering Cable Installation (Steering Master End)
HULL HOOD Remote control cables and speed sensor lead Steering cable installation (steering master end) WARNING If a cable becomes damaged, replace it. Never attempt to repair a damaged cable. 1. Install: • Steering cable Installation steps: 1. Insert the projection a on the steering cable completely into the indentation b in the cable stopper assembly.
Page 358: Steering Cable Installation (Jet Pump End)
HULL HOOD Remote control cables and speed sensor lead Steering cable installation (jet pump end) 1. Install: • Steering cable To adjust the steering cable. Refer to “Jet thrust nozzle steering angle check and adjust- ment” in Chapter 3. Steering cable set length a (jet pump end): 14.5 ±...
Page 359: Hoses
HULL HOOD Hoses Hoses Hose removal · · · m (0.4 kgf m, 3.0 ft È ÉÉ · m (0.4 kgf · m, 3.0 ft · Step Q’ty Remarks Part name Engine unit Refer to “Engine unit” in Chapter 5. Band Not reusable Band...
Page 360 HULL HOOD Hoses · · · m (0.4 kgf m, 3.0 ft È ÉÉ · · · m (0.4 kgf m, 3.0 ft Step Q’ty Remarks Part name Cooling water pilot outlet È To air cooler/É To oil cooler Cooling water hose Rivet Not reusable Ventilation socket...
Page 361: Water Separator Check
HULL HOOD Hoses Water separator check 1. Check: • Water separator 1 Cracks/damage → Replace the water separator. • O-ring 2 Cracks/damage → Replace the O-ring. • Drain plug 3 Cracks/damage → Replace the drain plug. Cooling water pilot outlet installation 1.
Page 362: Seats And Handgrip
HULL HOOD Seats and handgrip Seats and handgrip Seat and handgrip removal É · · · · · · 18 N m (1.8 kgf m, 13.3 ft m (0.5 kgf m, 3.7 ft É È 26 N · m (2.6 kgf ·...
Page 363 HULL HOOD Seats and handgrip É 18 N · m (1.8 kgf · m, 13.3 ft · · m (0.5 kgf · m, 3.7 ft · É È · · · 26 N m (2.6 kgf m, 19.2 ft È ·...
Page 364 HULL HOOD Seats and handgrip É · · · · · · 18 N m (1.8 kgf m, 13.3 ft m (0.5 kgf m, 3.7 ft É È 26 N · m (2.6 kgf · m, 19.2 ft · È ·...
Page 365: Seat Lock Check
HULL HOOD Seats and handgrip Seat lock check 1. Check: • Seat lock assembly 1 Does not lock → Replace the seat lock assembly. • Projection 2 Damage → Replace the projection. Handgrip installation 1. Install: É È • Handgrip 1 •...
Page 366 HULL HOOD Exhaust system Exhaust system Exhaust system and battery removal 3.7 N · m (0.37 kgf · m, 2.7 ft · 3.7 N · m (0.37 kgf · m, 2.7 ft · 21 20 19 · m (0.5 kgf ·...
Page 367 HULL HOOD Exhaust system 3.7 N · m (0.37 kgf · m, 2.7 ft · 3.7 N · m (0.37 kgf · m, 2.7 ft · 21 20 19 · m (0.5 kgf · m, 3.7 ft · · · ·...
Page 368: Exhaust System Check
HULL HOOD Exhaust system Exhaust system check 1. Check: • Rubber hoses Burns/cracks/damage → Replace the rubber hoses. 2. Check: • Water lock 1 • Water tank 2 Cracks/damage/leaks → Replace. Rubber hose installation 1. Install: • Rubber hose 1 Align the projection a on the rubber hose with the alignment mark b on the water tank.
Page 369: Deck And Hull
HULL HOOD Deck and hull Deck and hull Deck and hull disassembly 1 · · · m (0.5 kgf m, 3.7 ft · · · 16 N m (1.6 kgf m, 11.8 ft 13 N · m (1.3 kgf · m, 9.6 ft ·...
Page 370 HULL HOOD Deck and hull · · · m (0.5 kgf m, 3.7 ft · · · 16 N m (1.6 kgf m, 11.8 ft 13 N · m (1.3 kgf · m, 9.6 ft · · · · m (0.5 kgf m, 3.7 ft ·...
Page 371 HULL HOOD Deck and hull Deck and hull disassembly 2 · · · 26 N m (2.6 kgf m, 19.2 ft · · · m (0.2 kgf m, 1.5 ft · m (0.5 kgf · m, 3.7 ft · 15 N ·...
Page 372 HULL HOOD Deck and hull · · · 26 N m (2.6 kgf m, 19.2 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.5 kgf m, 3.7 ft 15 N · m (1.5 kgf ·...
Page 373: Drain Plug Check
HULL HOOD Deck and hull Drain plug check 1. Check: • Drain plug 1 • O-ring 2 Cracks/damage → Replace the drain plug. Front protector 1 installation 1. Install: • Front protectors Apply soapy water to the inner surfaces a of the grommets before installing the projections b of the front protectors.
Page 374 HULL HOOD Deck and hull — MEMO — 8-51...
Page 375 TRBL SHTG Chapter 9 Troubleshooting YDIS......................... 9-1 Introduction....................9-1 Features ....................9-1 Functions..................... 9-1 Contents....................9-5 Operating....................9-5 Connecting the communication cable to the watercraft ...... 9-5 Engine unit troubleshooting ................. 9-6 Using the YDIS for engine unit troubleshooting......... 9-6 Self-diagnosis..................
Page 376: Ydis
TRBL SHTG YDIS YDIS Introduction Features The newly developed YDIS provides quicker detection and analysis of engine malfunctions. By connecting your computer to the ECM of a watercraft using the communication cable, this soft- ware can be used to display sensor data and data stored in the ECM on a computer’s monitor. ®...
Page 377 TRBL SHTG YDIS 3. Engine monitor: Each sensor status and the ECM data are displayed. This enables you to find malfunctioning parts quickly. In addition, the data displayed using the Engine monitor function can be displayed in a graph. Items: FZR, FZS 1 Engine speed 11 Fuel injection duration 21 No-Wake mode switch...
Page 378 TRBL SHTG YDIS 4. Stationary test: Operation tests can be performed with the engine off. Items: FZR, FZS 1 Ignite ignition coil (#1–#4) 2 Operate injector (#1–#4) 3 Operate electric fuel (*1) pump (*1) : Operate fuel pump module 5. Active test: With the engine running, each cylinder is dropped and the engine speed is checked for changes to determine if the cylinder is malfunctioning.
Page 379 TRBL SHTG YDIS 7. ECM record data graph: When a malfunction occurs in the engine control system, 4 seconds (2 seconds before and after the malfunction) of recorded data is saved in the ECM. This data can be displayed on a graph using the “ECM record data graph” of the Data logger function. When the communication cable is used to connect a computer to the ECM, the ECM record data can be saved and viewed on the computer.
Page 380 TRBL SHTG YDIS 8. Some files: Other applications can be selected and run while continuing to run the diagnostic program. Contents 1. CD-ROM (software + instruction manual) 2. Adapter 3. Communication cable Operating Connecting the communication cable to the watercraft 1 Wiring harness coupler 2 Meter coupler 3 3-pin communication coupler...
Page 381: Engine Unit Troubleshooting
TRBL SHTG Engine unit troubleshooting Engine unit troubleshooting • Before troubleshooting the engine unit, make sure that fresh fuel of the specified type has been used. • Check that the battery is charged and that its specific gravity is within specification. •...
Page 382: Self-Diagnosis
TRBL SHTG Engine unit troubleshooting Self-diagnosis With the engine running, press the “Hour Volt” button 1 for approximately 8 seconds and check if a diagnostic code is indicated on the dual analog meter unit. If the YDIS is not used to check the symptoms listed in the “Diagnostic code table,”...
Page 383: Diagnostic Code Table
TRBL SHTG Engine unit troubleshooting Diagnostic code table Diagnostic code output YDIS Code No. Symptom Dual analog Diagnosis meter unit Diagnosis record Normal — — (*1) Pulser coil malfunction (*2) Engine temp sensor malfunction Knock sensor malfunction Battery voltage malfunction (*3) Intake temp sensor malfunction...
Page 384: Diagnostic Code And Checking Step
TRBL SHTG Engine unit troubleshooting Diagnostic code and checking step Refer Diagnos- Item Symptom Checking steps tic code page 1. Measure the pickup coil output peak 7-13 voltage. (*1) 2. Measure the pickup coil resistance. 7-13 Pulser coil Engine will not malfunction start 3.
Page 385 TRBL SHTG Engine unit troubleshooting Refer Diagnos- Item Symptom Checking steps tic code page 1. Check the intake air temperature using 7-23 the YDIS. 2. Measure the intake air temperature 7-23 sensor input voltage. Intake temp Trolling speed 3. Check the black/red (B/R) and black/ (*1) sensor (*3)
Page 386 TRBL SHTG Engine unit troubleshooting Refer Diagnos- Item Symptom Checking steps tic code page 1. Check the steering sensor operation 7-36 using the YDIS. 2. Measure the steering sensor input 7-36 Steering voltage. Normal sensor operation 3. Check the orange/red (O/R), white/ malfunction blue (W/L), and black/orange (B/O) steering sensor wiring harness leads...
Page 387 TRBL SHTG Engine unit troubleshooting Refer Diagnos- Item Symptom Checking steps tic code page 1. Check the TPS output voltage and 7-26 throttle valve opening using the YDIS. 2. Check the ECM circuit for continuity. 7-38 3. Check the ETV relay for continuity. 7-33 4.
Page 388 TRBL SHTG Engine unit troubleshooting Refer Diagnos- Item Symptom Checking steps tic code page Electronic 1. Check the ETV relay and fuse (ETV 7-33 throttle Engine speed 7-44 relay) for continuity. (*1) system is limited 2. Check the ECM circuit for continuity. 7-38 malfunction 1.
Page 389 TRBL SHTG Engine unit troubleshooting Refer Diagnos- Item Symptom Checking steps tic code page 1. Check the ECM circuit for continuity. 7-38 2. Check the ETV relay for continuity. 7-33 3. Check the charging system. • Stator coil output peak voltage 7-14 •...
Page 390 TRBL SHTG Engine unit troubleshooting Refer Diagnos- Item Symptom Checking steps tic code page 1. Check the cooling water passages for 2-18 obstructions. 2. Measure the engine temperature sen- 7-22 sor resistance. 3. Check that there is no short circuit between the black/yellow (B/Y) and black/orange (B/O) engine tempera- ture sensor wiring harness leads*.
Page 391: Engine Unit Troubleshooting (Diagnostic Code Not Detected)
Refer Symptom 2 Cause Checking step to page Starter motor does Yamaha Security System Check that the Yamaha Security 7-56 not operate set to lock mode System is set to the unlock mode. Discharged battery Check the battery voltage and 3-19 specific gravity.
Page 392 TRBL SHTG Engine unit troubleshooting Symptom 1: Engine will not start (engine cranks). Refer Symptom 2 Cause Checking step to page Throttle valve does Throttle lever squeezed Check that the throttle lever is in — not move properly. the fully closed position. Throttle cable installed Adjust the throttle lever free play.
Page 393 TRBL SHTG Engine unit troubleshooting Refer Symptom 2 Cause Checking step to page Fuel not supplied (all Fuel leakage Check the fuel hose. 3-10 cylinders) Blown fuse Check the fuse for continuity. 7-44 Clogged fuel pump filter Clean the fuel pump filter. Fuel pump module mal- Check the fuel pump module 7-42...
Page 394 TRBL SHTG Engine unit troubleshooting Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited en- gine speed Refer Symptom 2 Cause Checking step to page Throttle valve does Throttle cable installed Adjust the throttle lever free play. not move properly incorrectly.
Page 395 TRBL SHTG Engine unit troubleshooting Symptom 1: High engine idle speed Refer Symptom 2 Cause Checking step to page — Throttle cable installed Adjust the throttle lever free play incorrectly. and check the cable rooting. Symptom 1: Limited engine speed Refer Symptom 2 Cause...
Page 396 TRBL SHTG Engine unit troubleshooting Symptom 1: Discharged battery Refer Symptom 2 Cause Checking step to page — Battery performance Check the battery voltage and 3-19 decrease specific gravity. Loose connection of bat- Check the battery cable and 8-43 tery terminal terminal for proper connection.
Page 397 TRBL SHTG Engine unit troubleshooting — MEMO — 9-22...
Page 398 Wiring diagram FZR, FZS 1 Battery Color code 2 Starter motor : Black 3 Fuse (30 A) : Brown 4 Fuse (20 A) : Green 5 Fuse (3 A) : Gray 6 Fuse (10 A) : Blue 7 Fuse (10 A) : Orange 8 Starter relay : Pink...
Page 400 YAMAHA MOTOR CORPORATION, USA Printed in USA × 1 CR Feb. 2009 – (E_1)
Page 401 FZR, FZS 5 6 7 3 2 1 3 2 1 3 2 1 3 2 1 1 2 3 13 14 12 18 15 11 3 4 7 6 16 910 8 4 5 1 3 2 7 6 4 2 1 3 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

This manual is also suitable for:

Waverunner fzr-gx1800a

Yamaha WaveRunner FZR-GX1800 Service Manual

Chapter 1 General Information

Chapter 2 Specification

Chapter 3 Periodic Check and Adjustment

Chapter 4 Fuel System

Chapter 5 Power Unit

Chapter 6 Jet Pump Unit

Chapter 7 Electrical System

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Summary of Contents for Yamaha WaveRunner FZR-GX1800