Yamaha WaveRunner FZR-GX1800 Manuals

Manuals and User Guides for Yamaha WaveRunner FZR-GX1800. We have 1 Yamaha WaveRunner FZR-GX1800 manual available for free PDF download: Service Manual

Yamaha WaveRunner FZR-GX1800 Service Manual

Yamaha WaveRunner FZR-GX1800 Service Manual (401 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 15.84 MB

Table of Contents

Chapter 1 General Information

4
- General Information
  3
  - Table of Contents
    4
- How to Use this Manual
  6
- Manual Format
  6
- Symbols
  7
- Abbreviation
  8
- Safety While Working
  9
- Fire Prevention
  9
- Ventilation
  9
- Self-Protection
  9
- Parts, Lubricants, and Sealants
  9
- Good Working Practices
  10
- Disassembly and Assembly
  10
- Identification Number
  11
- Primary I.D. Number
  11
- Engine Serial Number
  11
- Jet Pump Unit Serial Number
  11
- Hull Identification Number (H.I.N.)
  11
- Special Service Tool
  12
- Measuring
  12
- Removal and Installation
  14
- Feature and Benefit
  19
- Watercraft Overview
  19
- Rear Seat
  20
- Telescopic Steering System
  21
- Shift Lever Assembly
  22
- Watertight Compartment
  23
- Fire Extinguisher Location
  23
- Hull Design
  24
- Engine Overview
  25
- Supercharger Assembly
  26
- Air Cooler Assembly
  26
- Ecm
  27
- Drive Shaft
  27
- Dual Analog Meter Unit
  28
- Information Display Warnings
  29
- Self-Diagnosis
  29
- Yamaha Security System
  30
- Gen Info
  30
- Technical Tips
  31
- Engine Control
  31
- ECM Circuit Diagram
  32
- ECM Coupler Layout
  33
- Control System
  35
Chapter 2 Specification

39
- General Specification
  40
- Engine
  42
- Maintenance Specifications
  42
- Fuel System
  45
- Electrical
  46
- Hull and Hood
  46
- Jet Pump Unit
  46
- Specified Torques
  50
- Tightening Torques
  50
- General Torque
  55
- Lubrication System
  56
- Cooling System
  57
- Cable and Hose Routing
  59
- Starboard Bow View
  59
- Top View
  60
- Port View
  62
Chapter 3 Periodic Check and Adjustment

65
- Maintenance Interval Chart
  66
- Control System
  67
- Jet Thrust Nozzle Steering Angle Check and Adjustment
  67
- Periodic Service
  67
- Steering System Check
  67
- Jet Thrust Nozzle QSTS Angle Check and Adjustment
  69
- Throttle Lever Free Play Check and Adjustment
  70
- Shift Cable Check and Adjustment
  73
- Fuel System
  74
- Trolling Speed Check
  74
- Fuel Line Check
  75
- Power Unit
  76
- Valve Clearance Measurement
  76
- Water Separator Check
  76
- Compression Pressure Measurement
  78
- Engine Oil Level Check
  79
- Engine Oil Change
  80
- Oil Filter Replacement
  81
- Air Filter Element Check
  82
- Spark Plug Check
  83
- Battery Check
  84
- Electrical
  84
- Jet Pump Unit
  86
- Jet Pump Unit Check
  86
- Bilge Strainer
  87
- Bilge Strainer Check
  87
- Drain Plug Check
  88
- Electric Bilge Pump Strainer Check
  88
- General
  88
- Throttle Valve and Engine Internal Components
  88
- Lubrication Points
  89
Chapter 4 Fuel System

93
- Fuel Tank Removal
  94
- Fuel Tank, Fuel Pump Module, and Fuel Hose
  94
- Fuel Hose Disconnection
  97
- Quick Connector Removal
  97
- Fuel Pump Module Removal
  98
- Fuel Sender Removal
  98
- Check Valve Check
  99
- Rollover Valve Check
  99
- Fuel Filler Neck and Hose Check
  100
- Fuel Line Check
  100
- Fuel Pump Module Check
  100
- Fuel Injector Check
  101
- Fuel Injector Installation
  101
- Fuel Tank Check
  101
- Fuel Pump Module Installation
  102
- Fuel Sender Installation
  102
- Fuel Hose Connection
  103
- Quick Connector Installation
  103
- Fuel Pressure Measurement
  104
Chapter 5 Power Unit

105
- Engine Unit
  112
- Engine Unit Removal 1
  112
- Engine Unit Removal 2
  115
- Engine Mount Removal
  116
- Engine Unit Removal
  117
- Breather Assembly Check
  122
- Engine Mount Check
  123
- Engine Unit Installation
  123
- Hose Joint Check
  123
- Muffler
  131
- Muffler Disassembly
  131
- Exhaust Pipe 3 Installation
  133
- Exhaust Pipe 3 Removal
  133
- Thermo Sensor Check
  133
- Thermostat and Electrical Component
  134
- Thermostat and Electrical Component Removal
  134
- Thermostat Check
  137
- Thermostat Housing Check
  137
- Air Cooler and Supercharger Removal
  138
- Air Cooler, Supercharger, and Throttle Body Assembly
  138
- Intake Assembly Removal
  140
- Intake Disassembly
  142
- Air Cooler Check
  143
- Intake Manifold Check
  144
- Supercharger Check
  144
- Throttle Body Assembly Check
  144
- Intake Manifold Installation
  145
- Supercharger Installation
  145
- Air Cooler Intake Pipe Installation
  146
- Boost Pipe Installation
  147
- Oil Cooler and Oil Pump Assembly Removal
  148
- Oil Cooler, Oil Pump Assembly, and Drive Gear
  148
- Drive Gear Assembly Removal
  152
- Drive Gear Disassembly
  152
- Oil Cooler Assembly Check
  153
- Drive Gear Check
  154
- Idle Gear Check
  154
- Oil Pump Assembly Check
  154
- Drive Gear Clutch Check
  155
- Drive Gear Assembly Installation
  156
- Oil Pump Drive Gear Assembly
  156
- Oil Pump Assembly Installation
  157
- Camshaft
  158
- Cylinder Head Cover Removal
  158
- Camshaft and Timing Chain Removal
  159
- Camshaft Removal
  161
- Camshaft Check
  163
- Camshaft Sprocket Check
  165
- Timing Chain Check
  165
- Timing Chain Tensioner Check
  165
- Camshaft Installation
  166
- Cylinder Head Cover Installation
  169
- Valve Clearance Adjustment
  169
- Cylinder Head
  173
- Cylinder Head Assembly Removal
  173
- Cylinder Head Disassembly
  174
- Cylinder Head Assembly Removal
  175
- Cylinder Head Check
  175
- Valve Removal
  175
- Valve Check
  176
- Valve Spring Check
  176
- Valve Guide Check
  178
- Valve Guide Removal
  178
- Valve Guide Installation
  179
- Valve Seat Check
  180
- Valve Seat Refacing
  181
- Valve Installation
  184
- Cylinder Head Installation
  185
- Generator Cover and Flywheel Magneto
  186
- Generator Cover and Flywheel Magneto Removal
  186
- Generator Cover Disassembly
  188
- Drive Coupling Removal
  189
- Flywheel Magneto Removal
  190
- Bearing Removal
  192
- Idle Gear and Shaft Check
  192
- Starter Clutch Check
  192
- Bearing Installation
  193
- Generator Cover Assembly
  194
- Oil Seal Installation
  194
- Flywheel Magneto Installation
  195
- Drive Coupling Installation
  200
- Oil Separator Tank and Oil Pan
  202
- Oil Separator Tank and Oil Pan Removal
  202
- Oil Pan Disassembly
  205
- Oil Pan Check
  206
- Oil Separator Tank Cover Check
  206
- Oil Separator Tank Cover Installation
  206
- Oil Separator Tank Cover Removal
  206
- Crankcase, Connecting Rod, and Piston
  207
- Crankcase, Connecting Rod, and Piston Disassembly
  207
- Connecting Rod and Piston Removal
  209
- Crankcase Disassembly
  209
- Anode Check
  210
- Crankcase Check
  210
- Piston Check
  211
- Piston Ring Check
  212
- Piston Pin Check
  213
- Connecting Rod Check
  214
- Cylinder Check
  214
- Crankshaft Check
  215
- Crankshaft Pin Oil Clearance Check
  215
- Crankshaft Journal Oil Clearance Check
  218
- Connecting Rod and Piston Installation
  221
- Crankcase Assembly
  223
Chapter 6 Jet Pump Unit

225
- Intake Grate and Ride Plate
  226
- Intake Grate and Ride Plate Removal
  226
- Jet Pump Unit
  227
- Jet Pump Unit Removal
  227
- Jet Pump Unit Installation
  229
- Reverse Gate
  231
- Reverse Gate Removal
  231
- Jet Thrust Nozzle and Nozzle Ring
  232
- Jet Thrust Nozzle and Nozzle Ring Removal
  232
- Impeller Duct and Impeller Housing
  233
- Impeller Duct, Impeller Housing and Nozzle Removal
  233
- Impeller Duct and Drive Shaft
  234
- Impeller Duct and Drive Shaft Disassembly
  234
- Drive Shaft Removal
  236
- Drive Shaft Check
  238
- Impeller Check
  238
- Impeller Housing Check
  238
- Drive Shaft Installation
  239
- Impeller Duct, Impeller Housing and Nozzle Installation
  241
- Transom Plate and Hoses
  244
- Transom Plate Installation
  245
- Water Hose Check
  245
- Driven Coupling Removal
  248
- Intermediate Housing Disassembly
  248
- Intermediate Housing Removal
  248
- Intermediate Drive Shaft and Grease Hose Check
  249
- Driven Coupling and Intermediate Housing Check
  250
- Intermediate Housing Assembly
  250
- Driven Coupling Installation
  252
- Intermediate Housing Installation
  252
Chapter 7 Electrical System

254
- Engine Electrical Components
  256
- Electrical Box
  258
- Electrical Components
  258
- Electrical Box Disassembly
  259
- Fuse Box Disassembly
  261
- Check Using the YDIS
  263
- Electrical Analysis
  263
- Input Voltage Measurement
  264
- Peak Voltage Measurement
  264
- Ignition Coil
  265
- Ignition System
  265
- Pickup Coil
  268
- Charging System
  269
- Stator Coil
  269
- Rectifier Regulator
  271
- Control System
  273
- Oil Pressure Switch
  273
- Thermoswitch
  274
- Thermo Sensor
  276
- Engine Temperature Sensor
  277
- Intake Air Temperature Sensor
  278
- Intake Air Pressure Sensor
  280
- Knock Sensor
  281
- Throttle Position Sensor
  281
- Accelerator Position Sensor
  284
- Electronic Throttle Valve Relay
  288
- Cam Position Sensor
  289
- Slant Detection Switch
  290
- Steering Sensor
  291
- Reverse Sensor
  292
- ECM Circuit
  293
- Earth Plate
  294
- Electric Bilge Pump
  295
- Fuel Injector
  296
- Fuel System
  296
- Fuel Pump Module
  297
- Fuse
  299
- Left Handlebar Switch Assembly
  299
- Starting System
  299
- Main and Fuel Pump Relay
  300
- Starter Relay
  302
- Armature
  307
- Starter Motor Operation
  307
- Rear Cover
  310
- Remote Control System
  310
- Starter Motor Assembly
  310
- Transmitter Registration
  310
- Remote Control Transmitter
  311
- Remote Control Receiver
  314
- Dual Analog Meter Unit
  315
- Indication System
  315
- Speed Sensor
  316
- Switch Assembly
  316
- Check Engine Warning Indicator
  318
- Fuel Level Meter Display and Fuel Indicator
  318
- Diagnostic Display
  319
- Oil Pressure Warning Indicator
  319
- Buzzer
  320
- Engine Overheat Warning Indicator
  320
Chapter 8 Hull and Hood

322
- Handlebar
  324
- Handlebar Cover Removal
  324
- Handlebar Holder Removal
  325
- Handlebar Assembly Removal
  326
- Handlebar Check
  329
- Handlebar Cover Removal
  329
- Left Handlebar Switch Assembly Check
  329
- Throttle Cable Removal
  329
- Handlebar Assembly Installation
  330
- Handlebar Cover Installation
  332
- QSTS Grip and Converter
  333
- QSTS Grip and Converter Disassembly
  333
- QSTS Cable Removal
  335
- QSTS Check
  335
- QSTS Cable Installation
  336
- Front Hood
  338
- Front Hood Removal
  338
- Damper Check
  341
- Front Hood Assembly
  341
- Hood Lock Check
  341
- Rivet Removal
  341
- Rivet Installation
  342
- Side Cover Removal
  344
- Center Cover Disassembly
  348
- Steering Master Disassembly
  351
- Hull Hood
  354
- Steering Arm Installation
  354
- Steering Master Component Check
  354
- Remote Control Cables and Speed Sensor Lead
  355
- Remote Control Cables and Speed Sensor Lead Removal
  355
- Steering Cable Installation (Steering Master End)
  357
- Shift Cable Installation (Jet Pump End)
  358
- Shift Cable Installation (Shift Lever End)
  358
- Steering Cable Installation (Jet Pump End)
  358
- Hoses
  359
- Cooling Water Pilot Outlet Installation
  361
- Water Separator Check
  361
- Seat and Handgrip Removal
  362
- Seats and Handgrip
  362
- Handgrip Installation
  365
- Seat Lock Check
  365
- Exhaust System Check
  368
- Rubber Hose Installation
  368
- Deck and Hull
  369
- Drain Plug Check
  373
- Front Protector 1 Installation
  373
- Reboarding Step Installation (FZS)
  373
- Spout Installation
  373
- Features
  376
- Functions
  376
- Introduction
  376
- Ydis
  376
- Engine Unit Troubleshooting
  381
- Using the YDIS for Engine Unit Troubleshooting
  381
- Self-Diagnosis
  382
- Diagnostic Code Table
  383
- Diagnostic Code and Checking Step
  384
- Engine Unit Troubleshooting (Diagnostic Code Not Detected)
  391

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