Yamaha FX HO Service Manual

SERVICE MANUAL

FX High OutputWaveRunner

F1S-28197-1G-11LIT-18616-02-83*LIT186160283*

FX Cruiser High Output

E

NOTICEThis manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trainedmechanics when performing maintenance procedures and repairs to Yamaha equipment. It hasbeen written to suit the needs of persons who have a basic understanding of the mechanical andelectrical concepts and procedures inherent in the work, for without such knowledge attemptedrepairs or service to the equipment could render it unsafe or unfit for use.

Because Yamaha has a policy of continuously improving its products, models may differ in detailfrom the descriptions and illustrations given in this publication. Use only the latest edition of thismanual. Authorized Yamaha dealers are notified periodically of modifications and significantchanges in specifications and procedures, and these are incorporated in successive editions of thismanual.

A10001-0*

WaveRunnerFX High Output, FX Cruiser High Output

SERVICE MANUAL©2004 by Yamaha Motor Corporation, USA

1st Edition, February 2004All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA

is expressly prohibited.Printed in USALIT-18616-02-83

E

HOW TO USE THIS MANUALMANUAL FORMATAll of the procedures in this manual are organized in a sequential, step-by-step format. The informa-tion has been compiled to provide the mechanic with an easy to read, handy reference that containscomprehensive explanations of all disassembly, repair, assembly, and inspection operations.In this revised format, the condition of a faulty component will precede an arrow symbol and thecourse of action required will follow the symbol, e.g.,

• BearingsPitting/scratches → Replace.

To assist you in finding your way through this manual, the section title and major heading is given atthe top of every page.

ILLUSTRATIONSThe illustrations within this service manual represent all of the designated models.

CROSS REFERENCESThe cross references have been kept to a minimum. Cross references will direct you to the appropri-ate section or chapter.

E

IMPORTANT INFORMATIONIn this Service Manual particularly important information is distinguished in the following ways.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

WARNINGFailure to follow WARNING instructions could result in severe injury or death to the machineoperator, passenger(s), a bystander, or a person inspecting or repairing the watercraft.

CAUTION:A CAUTION indicates special precautions that must be taken to avoid damage to the water-craft.

NOTE:A NOTE provides key information to make procedures easier or clearer.

IMPORTANT:This part has been subjected to change of specification during production.

E

HOW TO USE THIS MANUAL1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

2 Numbers are given in the order of the jobs in the exploded diagram.

3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).

4 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names ofparts, notes in jobs, etc.

5 Dimension figures and the number of parts, are provided for fasteners that require a tighteningtorque.

Example:Bolt or screw size : M10 (D) × 25 mm (L)

6 Jobs requiring more information (such as special tools and technical data) are describedsequentially.

10 × 25 mm

D

L

E

A50001-1-4

SYMBOLSSymbols 1 to 9 are designed to indicate thecontent of a chapter.

1 General Information2 Specifications3 Periodic Inspection and Adjustment4 Fuel System 5 Power Unit6 Jet Pump Unit7 Electrical System8 Hull and Hood9 Trouble Analysis

Symbols 0 to E indicate specific data.

0 Special toolA Specified oil or fluidB Specified engine speedC Specified tightening torqueD Specified measurementE Specified electrical value

(resistance, voltage, electric current)

Symbols F to H in an exploded diagram indi-cate the grade of lubricant and the lubricationpoint.

F Apply Yamaha 4-stroke motor oilG Apply water resistant grease

(Yamaha grease A, Yamaha marine grease)H Apply molybdenum disulfide grease

Symbols I to N in an exploded diagram indi-cate the type of sealant or locking agent andthe application point.

I Apply Gasket MakerJ Apply Yamabond No. 4K Apply LOCTITE 271 (red)L Apply LOCTITE 242 (blue)M Apply LOCTITE 572N Apply silicone sealant

NOTE:Additional symbols may be used in this man-ual.

1 2

3 4

5 6

7 8

9 0

A B

C D

E F

G H

I J

K L

M N

GENINFO SPEC

INSPADJ FUEL

POWR JETPUMP

– +ELEC HULLHOOD

TRBLANLS

T R..

E

A M

GM 4

271

LT

242

LT

572

LTSS

E

INDEX

GENERAL INFORMATION 1GEN INFO

SPECIFICATIONS 2SPEC

PERIODIC INSPECTION AND ADJUSTMENT 3INSP

ADJ

FUEL SYSTEM 4FUEL

POWER UNIT 5POWR

JET PUMP UNIT 6JETPUMP

ELECTRICAL SYSTEM 7ELEC

HULL AND HOOD 8HULL HOOD

TROUBLE ANALYSIS 9TRBL ANLS

– +

A30000-0

EGENINFO

1CHAPTER 1

GENERAL INFORMATION

IDENTIFICATION NUMBERS .........................................................................1-1PRIMARY l.D. NUMBER ...........................................................................1-1ENGINE SERIAL NUMBER ......................................................................1-1JET PUMP UNIT SERIAL NUMBER .........................................................1-1HULL IDENTIFICATION NUMBER (H.l.N.)...............................................1-1

SAFETY WHILE WORKING......................................................................1-2FIRE PREVENTION..................................................................................1-2VENTILATION...........................................................................................1-2SELF-PROTECTION.................................................................................1-2PARTS, LUBRICANTS, AND SEALANTS ................................................1-2GOOD WORKING PRACTICES ...............................................................1-3DISASSEMBLY AND ASSEMBLY ............................................................1-4

SPECIAL TOOLS ............................................................................................1-5MEASURING.............................................................................................1-5REMOVAL AND INSTALLATION..............................................................1-7

1-1

EGENINFO IDENTIFICATION NUMBERS

A60700-0*

IDENTIFICATION NUMBERSPRIMARY l.D. NUMBERThe primary l.D. number is stamped on a labelattached to the inside of the engine compart-ment.

Starting primary l.D. number:F1S: 800101

ENGINE SERIAL NUMBERThe engine serial number is stamped on alabel attached to the engine unit.

Starting serial number:6B6: 1000001

JET PUMP UNIT SERIAL NUMBERThe jet pump unit serial number is stamped ona label attached to the intermediate housing.

HULL IDENTIFICATION NUMBER (H.l.N.)The H.l.N. is stamped on a plate attached tothe aft deck.

1-2

EGENINFO SAFETY WHILE WORKING

SAFETY WHILE WORKINGTo prevent and accident or injury and toensure quality service, follow the safety proce-dures provided below.

FIRE PREVENTIONGasoline is highly flammable.Keep gasoline and all flammable productsaway from heat, sparks, and open flames.

VENTILATIONGasoline vapor and exhaust gas are heavierthan air and extremely poisonous. If inhaled inlarge quantities they may cause loss of con-sciousness and death within a short time.When test running an engine indoors (e.g., in awater tank), be sure to do so where adequateventilation can be maintained.

SELF-PROTECTIONProtect your eyes by wearing safety glasses orsafety goggles during all operation involvingdrilling and grinding, or when using an air com-pressor.Protect your hands and feet by wearing protec-tive gloves or safety shoes when necessary.

PARTS, LUBRICANTS, AND SEALANTSUse only genuine Yamaha parts, lubricants,and sealants or those recommended byYamaha, when servicing or repairing thewatercraft.

1-3


Under normal conditions, the lubricants men-tioned in this manual should not harm or behazardous to your skin. However, you shouldfollow these precautions to minimize any riskwhen working with lubricants.

1. Maintain good standards of personal andindustrial hygiene.

2. Change and wash clothing as soon aspossible if soiled with lubricants.

3. Avoid contact with skin. Do not, for exam-ple, place a soiled rag in your pocket.

4. Wash hands and any other part of thebody thoroughly with soap and hot waterafter contact with a lubricant or lubricantsoiled clothing has been made.

5. To protect your skin, apply a protectivecream to your hands before working on thewatercraft.

6. Keep a supply of clean, lint-free cloths forwiping up spills, etc.

GOOD WORKING PRACTICES1. The right tools

Use the recommended special servicetools to protect parts from damage. Usethe right tool in the right manner—do notimprovise.

2. Tightening torquesFollow the tightening torque specificationsprovided throughout the manual. Whentightening nuts, bolts, and screws, tightenthe large sizes first, and tighten fastenersstarting in the center and moving outward.

1-4


3. Non-reusable partsAlways use new gaskets, seals, O-rings,oil seals, cotter pins, circlips, etc., wheninstalling or assembling parts.

DISASSEMBLY AND ASSEMBLY1. Use compressed air to remove dust and

dirt during disassembly.2. Apply engine oil to the contact surfaces of

moving parts during assembly.

3. Install bearings with the manufacture iden-tification mark in the direction indication inthe installation procedure. In addition, besure to lubricate the bearings liberally.

4. Apply a thin coat of water-resistant greaseto the lip and periphery of an oil sealbefore installation.

5. Check that moving parts operate normallyafter assembly.

1-5

EGENINFO SPECIAL TOOLS

SPECIAL TOOLSUsing the correct special tools recommendedby Yamaha, will aid the work and enable accu-rate assembly and tune-up. Improvisationsand using improper tools can damage theequipment.

NOTE:• For U.S.A. and Canada, use part numbers

starting with “J-”, “YB-”, “YM-”, “YS-”, “YU-” or“YW-”.

• For other countries, use part numbers start-ing with “90890-”.

MEASURING1 Dial gauge

P/N. YU-0309790890-01252

2 Dial gauge standP/N. 90890-06583

3 Dial gauge needleP/N. 90890-06584

4 Dial gauge stand setP/N. YW-06585

90890-065855 Pocket tester

P/N. YU-0311290890-03112

6 Digital multimeterP/N. YU-34899-A

7 Digital circuit testerP/N. 90890-03174

8 Carburetor synchronizerP/N. YU-08030

9 Vacuum gaugeP/N. 90890-03094

0 Test connectorP/N. YW-06862Test connector FMY-8P/N. 90890-06862

A Fuel pressure gauge adapterP/N. YW-06842

90890-06842

1

2 3

4

5

9

YU-03097 90890-01252

90890-06583 90890-06584

YW-0658590890-06585

YU-0311290890-03112

90890-03094

A YW-0684290890-06842

7 890890-03174 YU-08030

6 YU-34899-A

0 YW-0686290890-06862

1-6


B Fuel pressure gaugeP/N. YB-06766

90890-06786C Compression gauge extension

P/N. 90890-06582D Cylinder gauge set

P/N. YU-0301790890-06759

E Compression gaugeP/N. YU-33223-1

90890-03160F Peak volt meter adapter

P/N. YU-39991G Peak voltage adapter B

P/N. 90890-03172H Spark gap tester

P/N. YM-34487I Ignition tester

P/N. 90890-06754J Test harness (2 pins)

P/N. New: YB-06867Current: YB-06767

Test harness FWY-2 (2 pins)P/N. New: 90890-06867

Current: 90890-06767K Test harness (3 pins)

P/N. New: YB-06870Current: YB-06770

Test harness SMT250-3 (3 pins)P/N. New: 90890-06870

Current: 90890-06770L Test harness (6 pins)

P/N. YB-06848Test harness FSW-6A (6 pins)P/N. 90890-06848

M Test harness (3 pins)P/N. YB-06793Test harness SMHW099-3 (3 pins)P/N. 90890-06793

B

C D

E

F

H

J K

L M

YB-06766 90890-06786

90890-06582 YU-0301790890-06759

YU-33223-1 90890-03160

YU-39991 90890-03172

YM-34487 90890-06754

YB-06867 (-06767)90890-06867 (-06767)

YB-06870 (-06770)90890-06870 (-06770)

YB-0684890890-06848

YB-0679390890-06793

I

G

1-7


N Test harness (3 pins)P/N. New: YB-06877

Current: YB-06777Test harness HM090-3 (3 pins)P/N. New: 90890-06877

Current: 90890-06777O Lower unit pressure/vacuum tester

P/N. YB-35956-AVacuum/pressure pump gauge setP/N. 90890-06756

P Yamaha diagnostic systemP/N. 60V-85300-02

Q Yamaha diagnostic systemP/N. 60V-WS853-02

N OYB-06877 (-06777)90890-06877 (-06777)

YB-35956-A90890-06756

Q 60V-WS853-02

YAMAHADIAGNOSTIC

SYSTEM

INSTALLATION MANUAL

P 60V-85300-02

REMOVAL AND INSTALLATION1 Oil filter wrench

P/N. YU-38411 90890-01426

2 Coupler wrenchP/N. YW-06551

90890-065513 Sheave holder

P/N. YS-01880-A90890-01701

4 Rotor pullerP/N. YM-01082

90890-01080

1 2

3 4

YU-38411 90890-01426

YW-06551

90890-06551

YS-01880-A90890-01701

YM-0108290890-01080

1-8


5 Universal magneto and rotor holderP/N. YU-01235Rotor holderP/N. 90890-01235

6 Bearing housing needle bearing installer(reduction drive gear)P/N. YB-06111

7 Ball bearing attachment(reduction drive gear)P/N. 90890-06631

8 Forward gear bearing cup installer(reduction drive gear)P/N. YB-06726-B

9 Ball bearing attachment(reduction drive gear)P/N. 90890-06657

0 Valve spring compressorP/N. YM-01253

90890-04019A Valve spring compressor attachment

P/N. YM-4114 (ø19 mm)90890-04114 (ø19 mm)YM-4108 (ø22 mm)90890-04108 (ø22 mm)

B Valve guide removerP/N. YM-04111 (ø4.0 mm)

90890-04111 (ø4.0 mm)YM-04116 (ø4.5 mm)90890-04116 (ø4.5 mm)

C Valve guide installerP/N. YM-04112 (ø4.0 mm)

90890-04112 (ø4.0 mm)YM-04117 (ø4.5 mm)90890-04117 (ø4.5 mm)

D Valve guide reamerP/N. YM-04113 (ø4.0 mm)

90890-04113 (ø4.0 mm)YM-04118 (ø4.5 mm)90890-04118 (ø4.5 mm)

5 6

A B

YU-0123590890-01235

YB-06111

YM-4114 (ø19 mm)90890-04114 (ø19 mm)YM-4108 (ø22 mm)90890-04108 (ø22 mm)

YM-04111 (ø4.0 mm)90890-04111 (ø4.0 mm)YM-04116 (ø4.5 mm)90890-04116 (ø4.5 mm)

7 890890-06631 YB-06726-B

9 090890-06657 YM-0125390890-04019

C DYM-04112 (ø4.0 mm)90890-04112 (ø4.0 mm)YM-04117 (ø4.5 mm)90890-04117 (ø4.5 mm)

YM-04113 (ø4.0 mm)90890-04113 (ø4.0 mm)YM-04118 (ø4.5 mm)90890-04118 (ø4.5 mm)

1-9


E Valve seat cutterIntakeP/N. 90890-06813 (60°)

90890-06814 (45°)90890-06815 (30°)

ExhaustP/N. 90890-06315 (60°)

90890-06312 (45°)90890-06328 (30°)

F Valve seat cutter holderP/N. 90890-06811 (ø4.0 mm)

90890-06812 (ø4.5 mm)G Valve seat cutter set

P/N. YM-91043-CH Piston ring compressor

P/N. YM-0803790890-05158

I Drive shaft holder (impeller)P/N. YB-06151Drive shaft holder 5 (impeller)P/N. 90890-06519

J Slide hammer and adapters (jet pump bearing and reduction drive gear)P/N. YB-06096

K Stopper guide plate (jet pump bearing)P/N. 90890-06501

L Bearing puller assembly (jet pump bearing and reduction drive gear)P/N. 90890-06535

M Stopper guide stand (jet pump bearing and reduction drive gear)P/N. 90890-06538

N Drive rod L3 (jet pump bearing and reduction drive gear)P/N. 90890-06652

90890-06315 (60°)90890-06312 (45°)90890-06328 (30°)

YM-08037 90890-05158

YB-06096

90890-06501 90890-06535

F

H

I J

K L

90890-06811 (ø4.0 mm)90890-06812 (ø4.5 mm)

YB-06151 90890-06519

E 90890-06813 (60°)90890-06814 (45°)90890-06815 (30°)

YM-91043-CG

90890-06538 90890-06652M N

1-10


O Bearing housing needle bearing remover (jet pump bearing)P/N. YB-06112Drive shaft needle bearing installer and remover (jet pump oil seal)P/N. YB-06196

P Needle bearing attachment (jet pump bearing, oil seal, and reduction drive gear)P/N. 90890-06614, 90890-06653

Q Outer race installer—forward gear(jet pump oil seal and reduction drive gear)P/N. YB-06085

R Ball bearing attachment (jet pump oil seal and reduction drive gear)P/N. 90890-06631

S Driver handle—large(intermediate shaft, jet pump, and reduction drive gear)P/N. YB-06071

T Driver rod LS (intermediate shaft, jet pump, and reduction drive gear)P/N. 90890-06606

U Bearing inner/outer race attachment (jet pump bearing)P/N. YB-34474

V Shaft holder (intermediate shaft)P/N. YB-06552Crankshaft holder 20 (intermediate shaft)P/N. 90890-06552

W Drive shaft taper roller bearing cup installer (intermediate shaft and reduction drive gear)P/N. YB-06156Bearing outer race attachment (intermediate shaft and reduction drive gear)P/N. 90890-06624, 90890-06626

YB-06071 90890-06606 S T

YB-0655290890-06552

V

YB-06085 Q

YB-06112 90890-06614O P90890-06653YB-06196

90890-06631R

90890-06624YB-06156W90890-06626

YB-34474U

ESPEC

2

CHAPTER 2SPECIFICATIONS

GENERAL SPECIFICATIONS .......................................................................2-1

MAINTENANCE SPECIFICATIONS ...............................................................2-3ENGINE ....................................................................................................2-3JET PUMP UNIT ......................................................................................2-6HULL AND HOOD ....................................................................................2-6ELECTRICAL ............................................................................................2-7

TIGHTENING TORQUES ................................................................................2-9SPECIFIED TORQUES.............................................................................2-9GENERAL TORQUE...............................................................................2-17

CABLE AND HOSE ROUTING .....................................................................2-18

2-1

ESPEC GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

Item UnitModel

FX High Output FX Cruiser High OutputModel code

Hull F1SEngine/jet 6B6

DimensionsLength mm (in) 3,340 (131.5)Width mm (in) 1,230 (48.4)Height mm (in) 1,160 (45.7)Dry weight kg (lb) 350 (772)Maximum capacity Person/kg (lb) 3/240 (530)

PerformanceMaximum output kW (PS) @ r/min 117.7 (160) @ 10,000Maximum fuel consumption l/h (US gal/h,

lmp gal/h)45 (11.9, 9.9)

Cruising range h 1.56Engine

Engine type 4-stroke, L4, DOHCDisplacement cm3 (cu. in) 1,052 (64.2)Bore × stroke mm (in) 76.0 × 58.0 (2.99 × 2.28)Compression ratio 11.9:1Exhaust system Wet exhaustLubrication system Dry sumpCooling system Water cooledStarting system Electric starterIgnition system TCIIgnition timing Degree BTDC 5–BTDC 32Spark plug model (manufacturer)

CR9EB (NGK)

Spark plug gap mm (in) 0.7–0.8 (0.028–0.031)Battery capacity V/Ah 12/19Generator output A @ r/min 14–16 @ 6,000

Drive unitPropulsion system Jet pumpJet pump type Axial flow, single stageImpeller rotation Counterclockwise (viewed from rear)Transmission Constant mesh 1-speedJet thrust nozzle horizontal angle

Degree 24 + 24

Jet thrust nozzle trim angle Degree –10, –5, 0, 5, 10Trim system Manual 5 positionsReverse system Reverse gate

2-2

ESPEC

PON*: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2RON*: Research Octane Number

Fuel and oilFuel type Regular unleaded gasolineMinimum fuel rating PON* 86

RON* 90Fuel tank capacity L

(US gal, Imp gal)70 (18.5, 15.4)

Engine oil type 4-stroke motor oilEngine oil grade API SE, SF, SG, SH, SJ, SL

SAE 10W-30Engine oil quantity L

(US qt, Imp qt)4.5 (4.8, 4.0)

(without oil filter replacement) L (US qt, Imp qt)

2.1 (2.2, 1.8)

(with oil filter replacement) L (US qt, Imp qt)

2.3 (2.4, 2.0)

Item UnitModel

FX High Output FX Cruiser High Output


2-3

ESPEC MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONSENGINE

Item UnitModel

FX High Output FX Cruiser High OutputCylinder head

Warpage limit mm (in) 0.1 (0.004)

Compression pressure*1 kPa (kgf/cm2, psi)

1,150 (11.5, 164)

CylinderBore size mm (in) 76.000–76.015 (2.9921–2.9927)Taper limit mm (in) 0.08 (0.003)Out-of-round limit mm (in) 0.05 (0.002)Wear limit mm (in) 76.100 (2.9961)

CamshaftDrive system Chain driveIntake A mm (in) 32.55 (1.281)Exhaust A mm (in) 33.00 (1.299)Intake and exhaust B mm (in) 25.00 (0.984)Camshaft cap inside diameter mm (in) 24.5 (0.9646)Camshaft journal diameter mm (in) 24.46–24.47 (0.9630–0.9634)Camshaft-journal-to-camshaft-cap clearance

mm (in) 0.03–0.06 (0.0012–0.0024)

Maximum camshaft runout mm (in) 0.03 (0.0012)Timing chain

Model/number of links DID SCR-0412SV/130Tensioning system Automatic

Valves, valve seats, valve guidesValve clearance (cold)

Intake mm (in) 0.11–0.20 (0.0043–0.0079)Exhaust mm (in) 0.25–0.34 (0.0098–0.0134)

Valve dimensionsValve head diameter A


Valve face width BIntake mm (in) 1.76–2.90 (0.0693–0.1142)Exhaust mm (in) 1.76–2.90 (0.0693–0.1142)

*1 Measuring conditions:Ambient temperature 20 °C (68 °F), wide open throttle, with spark plugs removed from all cylinders.The figures are for reference only.

2-4


Valve seat width CIntake mm (in) 0.9–1.1 (0.0354–0.0433)Exhaust mm (in) 0.9–1.1 (0.0354–0.0433)

Valve margin thickness DIntake mm (in) 0.5–0.9 (0.0197–0.0354)Exhaust mm (in) 0.5–0.9 (0.0197–0.0354)

Valve stem diameterIntake mm (in) 3.975–3.990 (0.1565–0.1571)Exhaust mm (in) 4.465–4.480 (0.1758–0.1764)

Valve guide inside diameterIntake mm (in) 4.000–4.012 (0.1575–0.1580)Exhaust mm (in) 4.500–4.512 (0.1772–0.1776)

Valve-stem-to-valve-guide clearance


Valve stem runout mm (in) 0.01 (0.0004)

Valve springFree length

Intake mm (in) 38.90 (1.53)Exhaust mm (in) 40.67 (1.60)

Installed lengthIntake mm (in) 34.50 (1.36)Exhaust mm (in) 35.00 (1.38)

Spring limitIntake Degree/mm (in) 2.5/1.7 (0.067)Exhaust Degree/mm (in) 2.5/1.8 (0.071)

PistonPiston-to-cylinder clearance mm (in) 0.10–0.11 (0.0039–0.0043)Piston diameter mm (in) 75.895–75.910 (2.9880–2.9886)Measuring point H* mm (in) 5 (0.2)Wear limit mm (in) 0.17 (0.0067)Piston pin boss inside diameter mm (in) 17.002–17.013 (0.6693–0.6698)

Piston pinsOutside diameter mm (in) 16.991–17.000 (0.6689–0.6693)Wear limit mm (in) 16.98 (0.67)

Item UnitModel


2-5


Piston ringTop ring

Type BarrelDimension (B × T) mm (in) 0.90 × 2.75 (0.04 × 0.11)End gap (installed) mm (in) 0.32–0.44 (0.0126–0.0173)Ring groove clearance mm (in) 0.030–0.065 (0.0012–0.0026)

2nd ringType TaperDimensions (B × T) mm (in) 0.80 × 2.80 (0.03 × 0.11)End gap (installed) mm (in) 0.43–0.58 (0.0169–0.0228)Ring groove clearance mm (in) 0.020–0.055 (0.0008–0.0022)

Oil ringDimensions (B × T)

mm (in) 1.50 × 2.60 (0.06 × 0.10)

End gap (installed) mm (in) 0.10–0.35 (0.0039–0.0138)Ring groove clearance mm (in) 0.040–0.160 (0.0016–0.0063)

Connecting rodBig end oil clearance mm (in) 0.016–0.040 (0.0006–0.0016)Bearing color code 1. Brown 2. Black 3. Blue 4. GreenSmall end inside diameter mm (in) 17.005–17.018 (0.6694–0.6699)

Crankshaft

Crank width A mm (in) 304.8–306.0 (12.00–12.05)Deflection limit B mm (in) 0.03 (0.0012)Crankshaft journal oil clearance mm (in) 0.004–0.028 (0.0002–0.0011)Bearing color code 1. Brown 2. Black 3. Blue 4. Green 5. Yellow

Throttle bodyType/quantity 42EIS/4Manufacturer MikuniID mark 6B600Trolling speed r/min 1,550–1,750

Fuel pumpPump type ElectricalFuel pressure kPa

(kgf/cm2, psi)310–330 (3.1–3.3, 45–47)

Item UnitModel


TB

BT

B

T

B B B

A

2-6


JET PUMP UNIT

HULL AND HOOD

Oil filterOil filter type Cartridge type

Oil pumpOil pump type TrochoidRotor tip clearance (scavenge pump)

mm (in) 0.09–0.15 (0.0035–0.0059)

Oil pump housing clearanceRotor (feed pump) mm (in) 0.09–0.17 (0.0035–0.0067)Rotor (scavenge pump) mm (in) 0.09–0.15 (0.0035–0.0059)

Item UnitModel

FX High Output FX Cruiser High OutputJet pump

Impeller material Stainless steelNumber of impeller blades 3Impeller pitch angle Degree 16.8Impeller clearance mm (in) 0.35–0.45 (0.0138–0.0177)Impeller clearance limit mm (in) 0.6 (0.0236)Drive shaft runout limit mm (in) 0.3 (0.0118)Nozzle diameter mm (in) 86.5–87.1 (3.41–3.43)

Item UnitModel

FX High Output FX Cruiser High OutputFree play

Throttle lever free play mm (in) 4–7 (0.16–0.28)

Item UnitModel


2-7


ELECTRICAL

Item UnitModel

FX High Output FX Cruiser High OutputBattery

Type FluidCapacity V/Ah 12/19Specific gravity 1.28

ECM unit(B/R – R/Y, B/W – R/Y,

B/Y – R/Y, B/L – R/Y)Output peak voltage lower limit

@cranking (loaded) V 87@2,000 r/min (loaded) V 86@3,500 r/min (loaded) V 85

StatorPickup coil (W – B, R – B)

Output peak voltage@cranking (unloaded) V 5.2

@cranking (loaded) V 4.7@2,000 r/min (loaded) V 26.1@3,500 r/min (loaded) V 41.3

Lighting coil (G – G)Output peak voltage

@cranking (unloaded) V 9.2@2,000 r/min (unloaded) V 38.5@3,500 r/min (unloaded) V 63.2

Pickup coil resistance (W – B) Ω (color) 459–561Pickup coil resistance (R – B) Ω (color) 459–561Lighting coil resistance (G – G) Ω (color) 0.54–0.66Minimum charging current A @ r/min 14 @ 6,000

Ignition coilPrimary coil resistance Ω 1.19–1.61Secondary coil resistance kΩ 8.5–11.5

Rectifier/regulator (R – B)Output peak voltage

@3,500 r/min (unloaded) V 15.0Starter motor

Type Constant meshOutput kW 0.8Rating Seconds 30Brush length mm (in) 12.5 (0.49)Wear limit mm (in) 6.5 (0.26)Commutator undercut mm (in) 0.7 (0.03)Limit mm (in) 0.2 (0.01)Commutator diameter mm (in) 28.0 (1.10)Limit mm (in) 27.0 (1.06)

2-8


*1 The figures are for reference only.

Starter relayRating Seconds 30

ThermoswitchON temperature (engine) °C (°F) 84–90 (183–194)OFF temperature (engine) °C (°F) 70–84 (158–183)ON temperature (exhaust) °C (°F) 94–100 (201–212)OFF temperature (exhaust) °C (°F) 80–94 (176–201)

Engine temperature sensorEngine temperature sensor resistance (B/Y – B/Y)

@ 20 °C (68 °F) kΩ 54.2–69.0@ 100 °C (212 °F) kΩ 3.12–3.48

Speed sensorOutput voltage (on pulse) V 11.6Output pulse/one full turn 2

Throttle position sensorOutput voltage (P – B/O)

@ trolling speed V 0.756 ± 0.016Cam position sensor

Output voltage (G/O – B/O)Position A V More than 4.8Position B V Less than 0.8Position C V More than 4.8

Fuel senderFuel sender resistance

Position A Ω 133.5–136.5Position B Ω 5–7

Oil pressure switchOil pressure switch continuity pressure

kPa (kgf/cm2, psi)

128 (1.28, 18.2)–166 (1.66, 23.6)

Fuel injectorFuel injector resistance*1 Ω 11.5–12.5

FuseRating

Main V/A 12/20Remote control unit V/A 12/3Electrical bilge pump V/A 12/3

Item UnitModel


2-9

ESPEC TIGHTENING TORQUES

TIGHTENING TORQUESSPECIFIED TORQUES

Part to tightened Part nameThread

sizeQ’ty

Tightening torqueRemarks

N•m kgf•m ft•lbFuel systemRetainer/fuel pump module – fuel tank

1stNut — 9

3.2 0.32 2.32nd 6.4 0.64 4.6

Fuel filler neck/rubber seal – deck Nut — 1 5.9 0.59 4.3Fuel tank belt/fuel tank – hull Bolt M8 4 16 1.6 11 57

2

LT

Fuel tank cap screw clamp – fuel tank cap/fuel tank

— — 1 1.3 0.13 0.9

Fuel filter hose clamp – fuel filter hose/fuel tank/fuel filter neck

— — 2 4.2 0.42 3.0

Air filter case cover – air filter case Screw M5 2 2.5 0.25 1.8 572

LT

Ribbon sub assembly – throttle bodies

Bolt M6 4 6.5 0.65 4.7 242

LT

Throttle cable holder – air filter case

Bolt M6 2 7.6 0.76 5.5 572

LT

Fuel hose holder – fuel hose bracket

Bolt M4 2 3.3 0.33 2.4 572

LT

Throttle bodies – throttle body joint Bolt M8 8 22 2.2 16 E

Air filter case – air filter case stay 1/air filter case stay 2

1stBolt M8 3

8.8 0.88 6.4

242

LT

2nd 18 1.8 13

Wire harness bracket 1/sub wire harness – air filter case

Bolt M6 2 7.6 0.76 5.5 572

LT

Fuel hose bracket/wire harness bracket 2 – air filter case

Bolt M6 2 7.6 0.76 5.5 242

LT

Wire harness bracket 2 – air filter case

Screw M5 1 1.3 0.13 0.9 572

LT

Air filter case stay 1 – exhaust pipe 3

1stBolt M8 2

15 1.5 1127

1

LT

2nd 39 3.9 28

Air filter case stay 2 – cylinder head

1stBolt M8 1

15 1.5 11

271

LT

2nd 39 3.9 28Band – air filter case Screw M5 1 1.3 0.13 0.9Breather cover – air filter case Screw M5 3 1.8 0.18 1.3Fuel rail – throttle bodies Bolt M6 4 5.0 0.5 3.6Sensor assembly – fuel rail Screw M5 2 3.5 0.35 2.5Bracket – throttle bodies Screw M6 3 5.0 0.5 3.6Bracket – bypass valve motor Nut — 2 13 1.3 9.4Throttle stop guide – throttle bodies Screw M6 2 5.0 0.5 3.6Throttle stop screw bracket – throttle bodies

Screw M6 2 5.0 0.5 3.6

Throttle position sensor – throttle bodies

Screw M4 2 2.0 0.2 1.4

2-10


EngineEngine unit – engine mount Bolt M8 4 17 1.7 12 27

1

LT

Oil filter — — 1 17 1.7 12 E

Coupling cover – intermediate housing

Bolt M6 1 7.8 0.78 5.6 572

LT

Thermoswitch (exhaust) – exhaust pipe 3

Bolt M6 2 7.6 0.76 5.5 572

LT

Outer exhaust joint clamp – exhaust pipe 3/exhaust pipe 2

1st— — 2

4.4 0.44 3.2

2nd 4.4 0.44 3.2

Inner exhaust joint clamp – exhaust pipe 3/exhaust pipe 2

1st— — 2

4.4 0.44 3.2

2nd 4.4 0.44 3.2

Exhaust pipe 3 – crankcase*1

1stBolt M10 4

2.0 0.2 1.4

242

LT2nd 15 1.5 11

3rd 39 3.9 28

Exhaust pipe end – exhaust pipe 3

1stBolt M6 3

3.7 0.37 2.7

572

LT

2nd 7.6 0.76 5.5

Exhaust pipe stay – crankcase

1stBolt M8 2

15 1.5 11

242

LT

2nd 42 4.2 30

Exhaust pipe 1 – exhaust pipe stay

1stBolt M10 1

15 1.5 11

242

LT

2nd 42 4.2 30

Exhaust pipe 2 – exhaust pipe 1*1

1stNut — 5

39 3.9 28

E

2nd 39 3.9 28

Exhaust pipe 1 – exhaust manifold 1/exhaust manifold 2

1stBolt M8 10

22 2.2 16

242

LT2nd 22 2.2 16

3rd 35 3.5 25

Exhaust manifold 1 – cylinder head

1stBolt M8 6

22 2.2 1624

2

LT2nd 22 2.2 16

3rd 35 3.5 25

Exhaust manifold 2 – cylinder head

1stBolt M8 5

22 2.2 16

242

LT2nd 22 2.2 16

3rd 35 3.5 25

Water jacket – oil tank1st

Bolt M6 43.7 0.37 2.7

572

LT

2nd 7.6 0.76 5.5Oil tank stay/reduction drive gear case – oil separator

1stBolt M6 3

3.7 0.37 2.7

572

LT

2nd 7.6 0.76 5.5

Cover (ground lead) – oil tank Bolt M6 3 7.6 0.76 5.5 572

LT

Ground lead – oil tank Bolt M6 2 7.6 0.76 5.5 E

Oil tank – reduction drive gear case

1stBolt M8 5

15 1.5 11

572

LT

2nd 39 3.9 28

*1 For details, refer to the tightening procedures in this manual.


sizeQ’ty


N•m kgf•m ft•lb

2-11


Oil tank – oil tank stay1st

Nut — 22.0 0.2 1.4

572

LT2nd 15 1.5 11

3rd 39 3.9 28

Oil tank stay – cylinder head

1stBolt M10 2

2.0 0.2 1.4

572

LT2nd 15 1.5 11

3rd 39 3.9 28Band/collar – oil tank Bolt M6 1 7.6 0.76 5.5 57

2

LT

Bracket (coupling cover) – oil tank

1stBolt M6 2

3.7 0.37 2.7

572

LT

2nd 7.6 0.76 5.5

Hanger – oil tank cover1st

Bolt M6 43.7 0.37 2.7

572

LT

2nd 7.6 0.76 5.5

Oil tank cover – oil tank1st

Bolt M6 83.7 0.37 2.7

572

LT

2nd 7.6 0.76 5.5Oil breather plate 1/oil breather plate 2 – oil tank cover

1stBolt M5 10

1.9 0.19 1.4

E

2nd 4.4 0.44 3.2

Baffle plate – oil tank1st

Bolt M5 31.9 0.19 1.4

E

2nd 4.4 0.44 3.2

Oil strainer – oil tank1st

Bolt M6 23.7 0.37 2.7

E

2nd 7.6 0.76 5.5

Oil cooler cover – oil tank 1st

Bolt M6 243.7 0.37 2.7

572

LT

2nd 7.6 0.76 5.5Anode – oil tank Screw M4 1 3.7 0.37 2.7 E

Oil pump assembly – reduction drive gear case

BoltM6 5 10 1.0 7.2

572

LT1st

M8 415 1.5 11

2nd 28 2.8 20Drain plug (engine oil) Bolt M8 1 20 2.0 14

Strainer – reduction drive gear case

1stBolt M6 2

3.7 0.37 2.72nd 7.6 0.76 5.5

Oil pump housing cover 1 – oil seal housing 1

Bolt M8 1 20 2.0 14

Oil pump housing cover 1/oil seal housing 1/oil pump housing cover 2 – oil pump housing 2

Bolt M8 3 20 2.0 14

Oil pump housing cover 2 – oil seal housing 1

Screw M4 1 2.0 0.2 1.4

Drive coupling – drive shaft — — 1 28 2.8 20 572

LT

Reduction drive gear case – crankcase

1stBolt M6 2

3.7 0.37 2.7

572

LT

2nd 7.6 0.76 5.51st

Bolt M8 515 1.5 11

572

LT

2nd 28 2.8 20Starter motor lead – starter motor Nut — 1 4.9 0.49 3.5 A

Starter motor – crankcase Bolt M8 2 18 1.8 13


sizeQ’ty



2-12


Generator cover – crankcase

1stNut — 2

15 1.5 11

572

LT

2nd 50 5.0 361st

Bolt M10 815 1.5 11

572

LT

2nd 50 5.0 36Rotor – crankshaft Bolt M10 1 75 7.5 54 E

Rotor – starter clutch Bolt M8 6 24 2.4 17Washer/pickup coil lead and lighting coil lead – generator cover

Bolt M5 3 4.9 0.49 3.5 242

LT

Pickup coil – generator cover Bolt M5 4 4.9 0.49 3.5 242

LT

Holder (wire harness) – generator cover

Bolt M6 2 14 1.4 10 242

LT

Lighting coil – generator cover Bolt M6 3 14 1.4 10 242

LT

Spark plug — — 4 13 1.3 9.4Ignition coil – cylinder head cover Bolt M6 4 7.6 0.76 5.5 57

2

LT

Cam position sensor – cylinder head cover

Bolt M6 1 10 1.0 7.2 572

LT

Cooling water pipe – cylinder head

1stBolt M6 1

3.7 0.37 2.7

572

LT

2nd 7.6 0.76 5.5Cylinder head cover – cylinder head

Bolt M6 6 12 1.2 8.7 E

Timing chain tensioner cap bolt Bolt M6 1 10 1.0 7.2Timing chain tensioner – cylinder head

Bolt M6 2 10 1.0 7.2

Exhaust camshaft cap – cylinder head

Bolt M6 10 10 1.0 7.2 E

Intake camshaft cap – cylinder head

Bolt M6 18 10 1.0 7.2 EExhaust camshaft sprocket – exhaust camshaft

Bolt M7 2 24 2.4 17 E

Intake camshaft sprocket – intake camshaft

Bolt M7 2 24 2.4 17 E

Hanger – cylinder head Bolt M8 2 40 4.0 29 271

LT

Cylinder head – upper crankcase*1

Bolt M6 3 10 1.0 7.2 E

1stNut — 2

20 2.0 14

E

2nd 140 ± 5°1st

Nut — 220 2.0 14

E

2nd 121 ± 5°1st

Nut — 620 2.0 14

E

2nd 105 ± 5°Plug (vacuum pressure) Bolt M6 4 10 1.0 7.2Engine temperature sensor – crankcase

— — 1 15 1.5 11

*1 For details, refer to the tightening procedures in this manual.


sizeQ’ty



2-13


Thermoswitch (engine) – crankcase

Bolt M6 2 7.6 0.76 5.5 572

LT

Oil pressure switch — — 1 8.4 0.84 6.1 572

LT

Anode cover – anode Bolt M6 1 12 1.2 8.7 271

LT

Anode cover – upper crankcase Bolt M8 1 20 2.0 14Oil pan – lower crankcase Bolt M6 13 12 1.2 8.7 57

2

LT

Lower crankcase – upper crankcase

Bolt M6 10 12 1.2 8.7 572

LT

1st

Bolt M9 10

7.8 0.78 5.6

E

2nd Loosen completely3rd 15 1.5 114th 49 ± 5°

Oil pipe – lower crankcase Bolt M6 1 12 1.2 8.7 E

Oil filter bolt – lower crankcase — — 1 35 3.5 25 E

Connecting rod cap1st

Nut — 820 2.0 14

M2nd 120 ± 5°

Thermostat housing cover – Thermostat housing

1stBolt M6 2

3.7 0.37 2.7

572

LT

2nd 7.6 0.76 5.5

Thermostat housing holder – oil tank

1stBolt M6 2

3.7 0.37 2.7

572

LT

2nd 7.6 0.76 5.5Grease nipple – thermostat housing cover

— — 1 5.9 0.59 4.3 572

LT

Jet pump unitSteering cable joint – jet thrust nozzle

Nut — 1 6.8 0.68 4.9 242

LT

Ride plate – hull Bolt M8 4 17 1.7 12 572

LT

Intake duct – hull Bolt M8 4 17 1.7 12 242

LT

Intake grate – hull Bolt M6 4 7.6 0.76 5.5 242

LT

Speed sensor – ride plate Screw M5 4 3.7 0.37 2.7 242

LT

Jet pump unit assembly/impeller housing 2 – transom plate

Bolt M10 4 40 4.0 2957

2

LT

Bolt M6 1 7.8 0.78 5.6Rubber plate – bracket Bolt M6 6 6.8 0.68 4.9Bracket – hull Bolt M8 2 14 1.4 10 27

1

LT

Roller – reverse gate stayBolt M8 1 8.3 0.83 6.0

271

LT

Nut — 1 26 2.6 19Reverse gate stay – jet pump Bolt M6 6 7.8 0.78 5.6 24

2

LT

Reverse gate – reverse gate stay Bolt M8 2 20 2.0 14 242

LT

Lever 1 – Reverse gate stay Bolt M6 1 7.8 0.78 5.6 242

LT

Lever 2– Reverse gate stay Nut — 1 7.8 0.78 5.6 242

LT

Shift cable ball joint – lever 1 Nut — 1 7.8 0.78 5.6 242

LT

Spout hose clamp – spout hose/nozzle

— — 1 1.2 0.12 0.9

Nozzle ring – nozzle Bolt M8 2 15 1.5 11 271

LT

Jet thrust nozzle – nozzle ring Bolt M8 2 15 1.5 11 271

LT


sizeQ’ty



2-14


QSTS cable ball joint – nozzle ring Nut — 1 7.8 0.78 5.6Nozzle/impeller duct assembly – impeller housing 1

Bolt M10 4 40 4.0 29 572

LT

Water inlet cover/water inlet strainer – impeller duct

Bolt M6 4 6.6 0.66 4.8 572

LT

Drive shaft nut – drive shaft Nut — 1 69 6.9 50Impeller (left-hand threads) – drive shaft

Impeller M22 1 75 7.5 54 572

LT

Transom plate – hull Nut — 4 26 2.6 19Intermediate housing – bulkhead Bolt M8 3 17 1.7 12 57

2

LT

Driven coupling – shaftDriven

couplingM24 1 36 3.6 25 57

2

LT

Grease nipple – intermediate housing

Nipple — 1 5.4 0.54 3.9 572

LT

Hull and hoodHandlebar holder – steering master Bolt M8 4 20 2.0 14 24

2

LT

Handlebar cover stay – steering master

Bolt M6 2 1.1 0.11 0.8 271

LT

Handlebar cover – handlebar cover stay

Screw M6 4 1.1 0.11 0.8 242

LT

Handle boss cover – steering master

Screw M6 4 0.9 0.09 0.7 242

LT

QSTS converter – hull Nut — 2 5.4 0.54 3.9Throttle lever assembly – handlebar

Screw M5 2 3.5 0.35 2.5

Handlebar switch assembly – handlebar

Screw M5 2 3.4 0.34 2.5

QSTS grip assembly – handlebar Screw M6 1 3.4 0.34 2.5Grip end – handlebar Bolt M5 2 1.2 0.12 0.9 24

2

LT

Cable housing – QSTS grip assembly

Screw M4 1 1 0.1 0.7

Steering master – deck Nut — 4 20 2.0 14Steering cable ball joint – steering arm

Nut — 1 6.8 0.68 4.9

Steering arm – steering master Bolt M8 1 18 1.8 13 271

LT

Steering switch – steering master Bolt M5 2 2.8 0.28 2.1Magneto – steering arm Bolt M5 1 2.8 0.28 2.1QSTS cable locknut (QSTS converter side)

Nut — 1 3 0.3 2.2

QSTS cable locknut (jet pump side) Nut — 1 2.9 0.29 2.1 572

LT

Steering shaft 1 – cap Bolt M5 2 6.8 0.68 4.9 271

LT

Upper housing – lower housing Bolt M6 4 6.8 0.68 4.9Retainer – steering tube Bolt M6 4 6.8 0.68 4.9QSTS cable grommet – hull Nut — 1 5.9 0.59 4.3


sizeQ’ty



2-15


QSTS cable end pin – QSTS converter

Nut — 1 3.8 0.38 2.7

Shift cable locknut (reverse gate side)

Nut — 1 2.9 0.29 2.1 572

LT

Shift cable grommet – hull Nut — 1 5.9 0.59 4.3Shift cable holder – shift lever base Nut — 2 5.4 0.54 3.9Steering cable locknut (steering master side)

Nut — 1 6.4 0.64 4.6

Steering cable locknut (jet pump side)

Nut — 1 6.5 0.65 4.7 572

LT

Steering cable grommet – hull Nut — 1 5.9 0.59 4.3QSTS cable 1 locknut Nut — 1 16 1.6 11QSTS cable 2 locknut Nut — 1 16 1.6 11Steering cable bracket – steering cable holder

Nut — 2 6.4 0.64 4.6

Steering cable bracket – deck Nut — 2 5.4 0.54 3.9Speed sensor lead grommet – hull Nut — 1 5.9 0.59 4.3Hinge assembly – front hood assembly

Bolt M6 6 5.4 0.54 3.9 242

LT

Hood lock assembly – front hood assembly

Bolt M6 2 5.4 0.54 3.9 242

LT

Hinge assembly – deck Nut — 4 5.4 0.54 3.9Service lid 1 – deck Bolt M6 4 5.4 0.54 3.9 27

1

LT

Service lid 2– deck Screw M4 4 1.5 0.15 1.1Panel – steering console cover Bolt M5 4 3.9 0.39 2.8 24

2

LT

Multifunction meter – steering console cover

Bolt M5 4 3.9 0.39 2.8 242

LT

Mirror – steering console cover Nut — 4 6.9 0.69 5.0Side cover – deck Bolt M6 8 5.4 0.54 3.9 27

1

LT

Steering console cover – glove box

Bolt M6 2 5.4 0.54 3.9 242

LT

Hood lock assembly Bolt M6 2 5.4 0.54 3.9Steering console cover – deck Nut — 2 5.4 0.54 3.9Glove compartment – deck Nut — 2 20 2.0 14Shift lever handle – shift lever Bolt M6 2 5.4 0.54 3.9 27

1

LT

Latch – glove compartment Screw M6 2 5.4 0.54 3.9 271

LT

Pilot water outlet – hull Nut — 2 4.2 0.42 3.0Shift lever plate – deck Nut — 3 5.4 0.54 3.9Shift lever plate – deck/shift lever base assembly

Screw M6 3 5.4 0.54 3.9 242

LT

Shift lever – base assembly Bolt M6 1 5.4 0.54 3.9 271

LT

Shift cable ball joint – base assembly

Nut — 1 6.8 0.68 4.9


sizeQ’ty



2-16


Hand grip – deck Nut — 4 5.2 0.52 3.8Front seat stay – deck Nut — 2 15 1.5 11Seat lock projection – deck beam Nut — 1 26 2.6 19Seat lock projection – deck Nut — 1 26 2.6 19Rear seat stay – deck beam Nut — 4 6.4 0.64 4.6Deck beam – deck Nut — 4 18 1.8 13Seat lock assembly – front seat Bolt M6 2 6.4 0.64 4.6 27

1

LT

Seat lock assembly – rear seat Bolt M6 2 6.4 0.64 4.6 271

LT

Plate/rubber hose/exhaust valve – hull

Nut — 6 5.4 0.54 3.9

Hose clamp – rubber hose/water lock

— — 1 3.7 0.37 2.7

Hose clamp – rubber hose/water tank

— — 2 3.7 0.37 2.7

Joint clamp – joint/water lock — — 1 3.7 0.37 2.7Joint clamp – joint/exhaust pipe 3 — — 1 3.7 0.37 2.7Joint clamp – joint/exhaust joint — — 2 2.5 0.25 1.8Sponson – hull Bolt M8 10 16 1.6 12 24

2

LT

Cleat – deck Nut — 2 15 1.5 11Cleat – hull Nut — 4 15 1.5 11Spout – hull Nut — 1 5.4 0.54 3.9

Protector (bow) – hullBolt M6 4 5.4 0.54 3.9 27

1

LT

Nut — 3 5.4 0.54 3.9Bow eye – hull Nut — 2 13 1.3 9.4Drain plug/packing – hull Screw M5 4 2.0 0.2 1.4Engine mount – hull Bolt M8 8 17 1.7 12 57

2

LT

Engine damper – hull Bolt M6 4 6.4 0.64 4.6 271

LT

ElectricalBattery box – hull Bolt M6 2 5.4 0.54 3.9 57

2

LT

Battery box/spacer – hull Bolt M6 2 5.4 0.54 3.9 271

LT

Electrical box – bulk head Bolt M8 4 17 1.7 12 572

LT

Terminal cover – electrical box Screw M5 4 4.9 0.49 3.5

Cover – electrical boxTapping screw

ø5 18 4.9 0.49 3.5

Starter motor lead– electrical box Screw M6 1 7.6 0.76 5.5 A

Battery positive lead – electrical box

Screw M6 1 7.6 0.76 5.5 A

Fuse holder stay – electrical boxTapping screw

ø6 1 3.9 0.39 2.8

ECM – electrical boxTapping screw

ø6 4 3.9 0.39 2.8


sizeQ’ty



2-17


Bracket (coupler) – electrical boxTapping screw

ø6 1 3.9 0.39 2.8

Slant detection switch – electrical box

Tapping screw

ø6 2 3.9 0.39 2.8

Main and fuel pump relay – electrical box

Tapping screw

ø6 1 3.9 0.39 2.8

Rectifier/regulator – electrical boxTapping screw

ø6 2 3.9 0.39 2.8

Ignition coil – cylinder head cover Bolt M6 4 7.6 0.76 5.5 572

LT

Brush assembly/spacer – starter motor yoke

Nut — 1 8.8 0.88 6.4

Starter motor rear cover – starter motor front cover

Bolt M5 2 6.4 0.64 4.6

Cover – remote control transmitterTapping screw

ø2 6 0.1 0.01 0.07


sizeQ’ty



GENERAL TORQUEThis chart specifies tightening torques for stan-dard fasteners with a standard ISO threadpitch. Tightening torque specifications for spe-cial components or assemblies are provided inapplicable sections of this manual. To avoidwarpage, tighten multi-fastener assemblies ina crisscross fashion and progressive stagesuntil the specified tightening torque is reached.Unless otherwise specified, tightening torquespecifications require clean, dry threads. Components should be at room temperature.

Nut A Bolt B General torque specifications

N•m kgf•m ft•lb8 mm M5 5.0 0.5 3.6

10 mm M6 8.0 0.8 5.812 mm M8 18 1.8 1314 mm M10 36 3.6 2517 mm M12 43 4.3 31

2-18

ESPEC CABLE AND HOSE ROUTING

CABLE AND HOSE ROUTING

DOWN

BOW20˚

DOWN

UP

+

I

H-H

G-G

F-F

I

H H

G G

E

B

D

A A

B-B

A-A

C-C

E-E

D-D

2

3

2

54

6

7

6

7

2

9

0

A

B

C

6

9

F

54

3

F

F

B

DC

E

C

1

12

4 5

6

G

E

D

8

HI

1 Steering switch lead2 Fuel tank breather hose3 QSTS cable4 Steering cable5 Shift cable6 Speed sensor lead7 Electrical box lead8 Cooling water pilot outlet9 Cooling water pilot outlet hose0 Cooling water pilot outlet

A Negative battery leadB Positive battery leadC BatteryD Throttle cableE Fuel hoseF Handlebar switch leadG Electrical bilge pump leadH Remote control unit leadI Remote control unit antenna

2-19


3A3AA

S P A R E

20A3A3AMAIN

A

B

C

D

BC

F

D

8

7

2

34

56 6

E

E

A

BC

A2 D E

F G

B4C H

9

9

8

A

6

A6

CB

6

E-E

F

1

I

1

0

K

J

1 Steering switch lead2 Throttle cable3 Handlebar switch lead4 QSTS cable5 Buzzer lead6 Fuel tank breather hose7 Ignition coil lead8 Positive battery lead9 Starter motor lead0 Wire harness

A Fuel hoseB Shift cableC Steering cableD Electrical box leadE Cooling water pilot outlet

hoseF Negative battery leadG Battery breather hoseH Speed sensor leadI Electrical bilge pump lead

J Remote control unit leadK Remote control unit antenna

2-20


5 BA H

C

D

9

E

F

G

8

2

A

91

2

5

0

2

9

6

7

7

6

54321

È

4

A-A

A

A

8

C

D

1 Cooling water hose (cooling water inlet)2 Bilge hose 13 Electric bilge pump4 Bilge hose 45 Cooling water hose (from thermostat)6 Bilge hose 37 Bilge hose 28 Shift cable9 Cooling water hose (from exhaust pipe)0 Electrical box

A QSTS cableB Positive battery leadC Speed sensor leadD Electric bilge pump leadE Bilge strainerF Negative battery leadG Steering cableH Flushing hose

È Pass the QSTS cable between the bilge hoses.

2-21


B

D

G F

A

E-E

Ð

ÏËËË

Ë

Ê

È

É

Õ

Ì

Ñ

Ì

Ó

×

Ñ

Ô

Ì

Ê

Ò

Ò

Ø

Ë

D

A

G

F

B

5

4

1

1

E

E

ÍC-C

Î3

2

C

C

Ö

1 Thermostat2 Cooling water pilot outlet hose3 Cooling water hose4 Cooling water hose (cooling

water inlet)5 Negative battery lead

È To cooling water pilot outlet onstarboard side

É To cooling water outlet on star-board side of stern

Ê To cylinder blockË From exhaust manifoldÌ To install the hose, align the

white paint mark on the coolingwater hose with the projectionof the hose joint.

Í When installing the coolingwater hoses, be sure to pushthem down until they contactthe hose joint.

2-22


B

D

G F

A

E-E

Ð

ÏËËË

Ë

Ê

È

É

Õ

Ì

Ñ

Ì

Ó

×

Ñ

Ô

Ì

Ê

Ò

Ò

Ø

Ë

D

A

G

F

B

5

4

1

1

E

E

ÍC-C

Î3

2

C

C

Ö

Î Bundle the cooling water pilot outlet hose andcooling water hoses, pass a plastic tie through thestay hole, and then fasten the tie.Set the tie in the direction shown.

Ï To cooling water pilot outlet on port sideÐ To cooling water outlet at sternÑ Cooling water inletÒ To exhaust pipe

Ó To install the cooling water hose, align the whitepaint mark on the hose with the parting line on thehose joint.

Ô Fasten the cooling water hose and negative bat-tery lead with a plastic tie. Set the tie in the direc-tion shown.

2-23


B

D

G F

A

E-E

Ð

ÏËËË

Ë

Ê

È

É

Õ

Ì

Ñ

Ì

Ó

×

Ñ

Ô

Ì

Ê

Ò

Ò

Ø

Ë

D

A

G

F

B

5

4

1

1

E

E

ÍC-C

Î3

2

C

C

Ö

Õ Bundle the cooling water hose (cylinder headcover to thermostat) and cooling water hose (star-board cooling water pilot outlet), and then fastenthem with a plastic tie to the oil tank boss. Whenbundling the hoses, make sure that the coolingwater hose (cylinder head cover to thermostat) isrouted on the deck side and that the cooling waterhose (starboard cooling water pilot outlet) isrouted on the engine side.

Ö Insert the cooling water hose to the paint mark.

× Fasten the end of the cooling water hose tubethat is contacting the hose joint with a plastic tie.

Ø Cooling water passage

2-24


BA

A

A-ACB

34

09

56

7

8

2

1Ì

Ë

É

ÈC

A

Ê

0 A

4

B

1 1

1 Wiring harness2 Ground lead3 Wiring harness coupler4 Noise filter5 Oil pressure switch coupler6 Pickup coil coupler7 Thermoswitch (engine) coupler8 Lighting coil coupler9 Thermoswitch (exhaust)0 Thermoswitch (exhaust) coupler

A Cam position sensor couplerB Oil pressure switch lead

È To electrical boxÉ To cam position sensorÊ Fasten the plastic tie with its end facing down-

ward.Ë To oil pressure switchÌ To engine temperature sensor

2-25


A

A

1

2

4

3

75

6

0

98

A-A

Ë ÊÉ

ÌÍ

Î

Ð

Ï

ÑÒÏ

Ð

B

B

È

1 Engine temperature sensor coupler2 Lighting coil coupler3 Pickup coil coupler4 Thermoswitch (engine) coupler5 Thermoswitch (engine)6 Starter motor7 Engine temperature sensor8 Engine temperature sensor lead9 Thermoswitch (engine) lead0 Lighting coil lead

2-26


A

A

1

2

4

3

75

6

0

98

A-A

Ë ÊÉ

ÌÍ

Î

Ð

Ï

ÑÒÏ

Ð

B

B

È

È Fasten the engine temperature sensor lead, ther-moswitch lead, and lighting coil lead with a plastictie. Fasten the engine temperature sensor lead10–20 mm (0.4–0.8 in) from the end of the protec-tive cover of the lead.

É To generatorÊ To engine temperature sensorË To thermoswitch (engine)Ì To thermoswitch (engine) couplerÍ To engine temperature sensor coupler

Î Route the starter motor lead to the outside of theengine temperature sensor lead.

Ï To starter relayÐ To negative battery terminalÑ Route the starter motor and negative battery

leads behind the cooling water hose.Ò Route the starter motor lead over the cooling

water hose.

EINSPADJ

3

CHAPTER 3PERIODIC INSPECTION AND ADJUSTMENT

MAINTENANCE INTERVAL CHART..............................................................3-1

PERIODIC SERVICE.......................................................................................3-2CONTROL SYSTEM .................................................................................3-2

Steering master inspection..................................................................3-2Steering cable inspection and adjustment ..........................................3-2Throttle cable inspection and adjustment............................................3-3QSTS cable inspection and adjustment ..............................................3-5Shift cable inspection and adjustment.................................................3-7Trolling speed check and adjustment..................................................3-8

FUEL SYSTEM..........................................................................................3-9Fuel line inspection .............................................................................3-9Water separator inspection ...............................................................3-10

POWER UNIT..........................................................................................3-10Valve clearance adjustment ..............................................................3-10Engine oil level check........................................................................3-16Engine oil change — using oil changer.............................................3-18Air filter element clean.......................................................................3-20Spark plug inspection........................................................................3-21

ELECTRICAL ..........................................................................................3-24Battery inspection..............................................................................3-24

JET PUMP UNIT .....................................................................................3-27Impeller inspection ............................................................................3-27Water inlet strainer inspection...........................................................3-27

BILGE PUMP...........................................................................................3-28Bilge strainer inspection ....................................................................3-28Electric bilge pump strainer inspection..............................................3-28

GENERAL ...............................................................................................3-29Drain plug inspection.........................................................................3-29Lubrication points ..............................................................................3-29

3-1

EINSPADJ MAINTENANCE INTERVAL CHART

MAINTENANCE INTERVAL CHARTThe following chart should be considered strictly as a guide to general maintenance intervals.Depending on operating conditions, the intervals of maintenance should be changed.

*1: Grease quantity: 33.0–35.0 cm3 (1.11–1.18 oz)*2: Grease quantity: 6.0–8.0 cm3 (0.20–0.27 oz)*3: After every use

MAINTENANCE INTERVAL INITIALTHEREAFTER

EVERYPAGE

10 hours 50 hours 100 hours 100 hours 200 hours

ITEM6

months12

months12

months24

monthsSpark plug Inspect, clean, adjust 3-21Lubrication points Lubricate 3-29Intermediate housing Lubricate *1 *2 *2 3-31Fuel system Inspect 3-9Fuel tank Inspect, clean 3-9Trolling speed Inspect, adjust 3-8Throttle shaft Inspect —Cooling water passages Flush *3 —Water inlet strainer Inspect, clean 3-27Bilge strainer Clean 3-28Electric bilge pump strainer

Inspect, clean 3-28

Impeller Inspect 3-27Jet thrust nozzle angle Inspect, adjust 3-2Steering master Inspect 3-2QSTS mechanism Inspect, adjust 3-5Shift cable and mechanism

Inspect, adjust 3-7

Throttle cable Inspect, adjust 3-3Stern drain plugs Inspect, replace 3-29Battery Inspect 3-24Rubber coupling Inspect —Engine mount Inspect 5-7Nuts and bolts Inspect —Air filter Inspect 3-20Engine oil Replace 3-16Engine oil filter Replace 3-18Valve clearance Inspect, adjust 3-10

3-2

EINSPADJ CONTROL SYSTEM

PERIODIC SERVICECONTROL SYSTEMSteering master inspection

1. Inspect:• Steering master

Excessive play → Replace the steeringmaster.Refer to “STEERING MASTER” inChapter 8.

Inspection steps:• Move the handlebar up and down and

back and forth.• Check the excessive play of the handle-

bar.

Steering cable inspection and adjustment1. Inspect:

• Jet thrust nozzle clearance a, b Difference → Adjust.

2. Adjust:• Steering cable joint

(steering master end)

Inspection steps:• Set the control grip in the neutral position.• Turn the handlebar from lock to lock.• Measure clearances a and b.• If clearances a and b are not the same,

adjust them.

Adjustment steps:• Set the control grip in the neutral position.• Loosen the locknut 1.• Disconnect the cable joint 2 from the ball

joint 3.• Turn the cable joint 2 in or out for adjust-

ing the clearances a and b.

Turn in Clearance a is increased.

Turn out Clearance b is increased.

3-3


NOTE:If the steering cable cannot be properlyadjusted by the cable joint at the steering mas-ter end, adjust the cable joint at the jet pumpend so that the same clearances are obtained.Refer to “REMOTE CONTROL CABLES ANDSPEED SENSOR LEAD” in Chapter 8.

WARNINGThe cable joint must be screwed in morethan 8 mm (0.31 in).

• Connect the cable joint and tighten thelocknut.

T R.

Locknut:6.4 N • m (0.64 kgf • m, 4.6 ft • lb)

Throttle cable inspection and adjustment

NOTE:Before adjusting the throttle lever free play,adjust the trolling speed.

1. Measure:• Throttle lever free play a

Out of specification → Adjust.

Throttle lever free play:4–7 mm (0.16–0.28 in)

3-4


2. Adjust:• Throttle lever free play

Adjustment steps:

NOTE:• When not replacing the throttle cable or

removing the cable from the throttle body,adjust the throttle cable free play by fol-lowing steps (f) through (j).

• When replacing the throttle cable orremoving the cable from the throttle body,adjust the throttle cable free play by fol-lowing steps (a) through (k).

a. Remove the air filter case cover 1 andribbon sub assemblies.

b. Loosen the locknut 2.c. Turn the adjusting nut 3 to adjust the

length a.

Throttle cable installation length:24.4 ± 1.0 mm (0.96 ± 0.04 in)

NOTE:Apply locking agent (LOCTITE) to thethreads of the adjusting nut 3.

d. Remove the handlebar cover.e. Loosen the locknut 4.f. Turn the adjuster 5 in or out until the

specified free play is obtained.

Turn in Free play is increased.

Turn out Free play is decreased.

g. Tighten the locknut.

NOTE:• When adjusting the throttle cable at the

throttle body, fully open the throttle leverand check that the butterfly valve is fullyopen.

• If the throttle cable free play cannot beadjusted properly, replace the throttlecable.

3-5


WARNINGAfter adjusting the free play, turn the han-dlebar to the right and left and make surethat the trolling speed does not increase.

h. Install the handlebar cover.

T R.

Handlebar cover screw:1.1 N • m (0.11 kgf • m, 0.8 ft • lb)LOCTITE 242

i. Install the ribbon sub assemblies and airfilter case cover.

T R.

Ribbon sub assembly bolt:6.5 N • m (0.65 kgf • m, 4.7 ft • lb)LOCTITE 242

Air filter case cover screw:2.5 N • m (0.25 kgf • m, 1.8 ft • lb)LOCTITE 572

QSTS cable inspection and adjustment1. Measure:

• Jet thrust nozzle set length a, b Difference → Adjust.

Measurement steps:• Set the control grip in the neutral position.• Set the jet thrust nozzle in the center

position.• Measure the jet thrust nozzle set length

a and b.• If a and b lengths are not even, adjust

the cable joint.

3-6


2. Adjust:• QSTS cable

NOTE:If the QSTS cable cannot be properly adjustedby the cable joint at the QSTS converter end,adjust the cable joint at the jet pump end sothat the same lengths are obtained. Refer to“REMOTE CONTROL CABLES AND SPEEDSENSOR LEAD” in Chapter 8.

Adjustment steps:• Set the control grip in the neutral position.• Loosen the locknut 1.• Remove the nut 2 and pivot pin 3.• Set the jet thrust nozzle in the center

position.• Turn the cable joint 4 for adjusting.

Turn in Length a is increased.

Turn out Length b is increased.


• Connect the cable joint 4 and pivot pin3 and tighten the nut 2.

T R.

Nut:3.8 N • m (0.38 kgf • m, 2.7 ft • lb)

• Tighten the locknut 1.

T R.

Locknut:3 N • m (0.3 kgf • m, 2.2 ft • lb)

3-7


Shift cable inspection and adjustment1. Check:

• Reverse gate stopper lever positionIncorrect → Adjust.

Checking steps:• Set the shift lever to the reverse position.• Check that the reverse gate 1 contacts

the stopper 2 on the bracket and thelever 3 contacts the reverse gate.

• Set the shift lever to the forward position.• Check that the lever 4 has been shifted

over the bracket 5.

4

5

2. Adjust:• Shift cable joint

Adjustment steps:• Loosen the locknut 1.• Disconnect the cable joint 2 from the ball

joint 3.• Situate the reverse gate to the stopper on

the bracket and the lever to the reversegate.

• Turn the cable joint to align it with the balljoint.

Turn in Shortens.

Turn out Lengthens.

• Turn out the cable joint nine times a toextend cable 7 mm (0.28 in) from thealigned position.



T R.

Locknut:2.9 N • m (0.29 kgf • m, 2.1 ft • lb)LOCTITE 572

3-8


Trolling speed check and adjustment1. Measure:

• Trolling speedOut of specification → Adjust.

Trolling speed:1,550–1,750 r/min

Checking steps: (Watercraft on water)• Start the engine and allow it to warm up

for a 15 minutes.• Check the engine trolling speed using the

tachometer of the multifunction meter orusing the Yamaha Diagnostic System.

2. Adjust:• Trolling speed

Adjustment steps:• Remove the air filter case cover 1.• Start the engine.• Turn the throttle stop screw 2 in or out

until the specified speed is obtained.

Turn in a Increase trolling speed.

Turn out b Decrease trolling speed.

• Install the air filter case cover.

T R.


3-9

EINSPADJ FUEL SYSTEM

FUEL SYSTEM

WARNINGWhen removing fuel system parts, wrapthem in a cloth and take care that no fuelspills into the engine compartment.

Fuel line inspection1. Inspect:

• Fuel pump filterClog/contaminants → Clean.Refer to “FUEL TANK AND FUELPUMP MODULE” in Chapter 4.

• Fuel hoseDamage/cracks → Replace.

• O-rings (quick connector)Damage/cracks → Replace the quickconnector.

• Fuel pipeDamage/cracks → Replace the fuelpump.Refer to “FUEL INJECTION SYSTEM”in Chapter 4.

• Fuel filler hose• Fuel tank• Fuel filler cap

Cracks/damage → Replace.

2. Inspect:• Fuel tank

Cracks/damage → Replace.Water accumulation → Remove.

NOTE:To remove water from the fuel tank, removethe cap 1 and use a siphon pump.

T R.

Fuel tank cap screw clamp:1.3 N • m (0.13 kgf • m, 0.9 ft • lb)

1

3-10

EINSPADJ FUEL SYSTEM/POWER UNIT

Water separator inspection1. Inspect:

• Water separator 1 Water accumulation → Drain.

NOTE:If need the water draining, remove the drainplug 2.

1

2

POWER UNITValve clearance adjustmentThe following procedure applies to all of thevalves.

NOTE:• Valve clearance adjustment should be made

on a cold engine, at room temperature. • When the valve clearance is to be measured

or adjusted, the piston must be at top deadcenter (TDC) on the compression stroke.

1. Remove: • Air filter case

Refer to “FUEL INJECTION SYSTEM”in Chapter 4.

2. Remove:• Ignition coils• Spark plugs • Cylinder head cover• Cylinder head cover gasket

Refer to “CAMSHAFTS” in Chapter 5.

3. Install:• Dial gauge needle• Dial gauge stand 1

(into spark plug hole #1)• Dial gauge 2

Dial gauge stand:90890-06583

Dial gauge needle:90890-06584

Dial gauge stand set:YW-06585/90890-06585

Dial gauge:YU-03097/90890-01252

2

1

3-11

EINSPADJ POWER UNIT

4. Measure:• Valve clearance


Valve clearance (cold):Intake valve:

0.11–0.20 mm (0.0043–0.0079 in)

Exhaust valve:0.25–0.34 mm (0.0098–0.0134 in)

Measurement steps:• Turn the drive coupling counterclockwise,

and then check if cylinder #1 is at TDC ofthe compression stroke with a dial gauge.

NOTE:TDC on the compression stroke can befound when the camshaft lobes are turnedaway from each other.

• Measure the valve clearance with a thick-ness gauge 1.

NOTE:• If the valve clearance is incorrect, record

the measured reading. • Measure the valve clearance in the follow-

ing sequence.

Valve clearance measuring sequence Cylinder #1 → #2 → #4 → #3

È Bow side• To measure the valve clearances of the

other cylinders, starting with cylinder #1at TDC, turn the drive coupling counter-clockwise as specified in the followingtable.

É Degrees that the crankshaft is turned clock-wise

Ê CylinderË Combustion cycle

Cylinder #2 180°

Cylinder #4 360°

Cylinder #3 540°

IN EX

1

7205403601800

#4

#3

#2

#1

É

Ê

Ë

Ë

Ë

Ë

3-12

EINSPADJ POWER UNIT

5. Remove:• Timing chain tensioner cap bolt 1 • Gasket

1

6. Turn the timing chain tensioner rod fullyclockwise with a thin screwdriver 1.

NOTE:Make sure that the tensioner rod has been fullyset clockwise.

1

7. Remove:• Intake camshaft caps• Exhaust camshaft caps• Timing chain

(from the camshaft sprockets)• Intake camshaft• Exhaust camshaft

NOTE:• Refer to “CAMSHAFTS” in Chapter 5. • When removing the timing chain and cam-

shafts, fasten the timing chain with a wire toprevent it from falling into the crankcase.

3-13

EINSPADJ POWER UNIT

8. Adjust:• Valve clearance

Adjustment steps:• Remove the valve lifter 1 and the valve

pad 2.

NOTE:• Cover the timing chain opening with a rag

to prevent the valve pad from falling intothe crankcase.

• Make a note of the position of each valvelifter 3 and valve pad 4 so that they canbe installed in the correct place.

• Select the proper valve pad from the fol-lowing table.

Valve pad thickness range

Available valve pads

Nos. 120–240

1.20–2.40 mm

25 thicknesses in 0.05 mm increments

NOTE:• The thickness a of each valve pad is

marked in hundredths of millimeters onthe side that touches the valve lifter.

• Since valve pads of various sizes are orig-inally installed, the valve pad numbermust be rounded in order to reach theclosest equivalent to the original.

• Round off the original valve pad numberaccording to the following table.

Last digit Rounded value

0 or 2 0

5 5

8 10

EXAMPLE:Original valve pad number = 148 (thickness= 1.48 mm) Rounded value = 150• Locate the rounded number of the origi-

nal valve pad and the measured valveclearance in the valve pad selectiontable. The point where the column androw intersect is the new valve pad num-ber.

1

2

148

a

3-14

EINSPADJ POWER UNIT

NOTE:The new valve pad number is only anapproximation. The valve clearance mustbe measured again and the above stepsshould be repeated if the measurement isstill incorrect.

• Install the new valve pad 5 and the valvelifter 6.

NOTE:• Lubricate the valve pad with molybdenum

disulfide grease. • Lubricate the valve lifter with molybdenum

disulfide oil. • The valve lifter must turn smoothly when

rotated by hand. • Install the valve lifter and the valve pad in

the correct place.

• Install the exhaust and intake camshafts,timing chain and camshaft caps.

T R.

Camshaft cap bolt:10 N • m (1.0 kgf • m, 7.2 ft • lb)

NOTE:• Refer to “Camshaft installation — CAM-

SHAFTS” in Chapter 5.• Lubricate the camshafts, camshaft lobes

and camshaft journals. • First, install the exhaust camshaft. • Align the camshaft marks with the cam-

shaft cap marks. • Turn the crankshaft clockwise several full

turns to seat the parts.

• Measure the valve clearance again.• If the valve clearance is still out of specifi-

cation, repeat all of the valve clearanceadjustment steps until the specified clear-ance is obtained.

6

5

3-15

EINSPADJ POWER UNIT

Intake

Exhaust

MEASURED CLEARANCE

ORIGINAL VALVE PAD NUMBER120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.00–0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 2250.03–0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 2300.08–0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 2350.11–0.20 STANDARD CLEARANCE0.21–0.22 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.23–0.27 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.28–0.32 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.33–0.37 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.38–0.42 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.43–0.47 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.48–0.52 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.53–0.57 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.58–0.62 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.63–0.67 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.68–0.72 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.73–0.77 180 185 190 195 200 205 210 215 220 225 230 235 2400.78–0.82 185 190 195 200 205 210 215 220 225 230 235 2400.83–0.87 190 195 200 205 210 215 220 225 230 235 2400.88–0.92 195 200 205 210 215 220 225 230 235 240 Example:

Intake valve clearance (cold)0.11–0.20 mm (0.0043–0.0079 in)

Rounded value 150Measured valve clearance is 0.24 mm (0.0094 in)

Replace pad 150 with pad 160Pad No. 150 = 1.50 mm (0.0591 in)Pad No. 160 = 1.60 mm (0.0630 in)

0.93–0.97 200 205 210 215 220 225 230 235 2400.98–1.02 205 210 215 220 225 230 235 2401.03–1.07 210 215 220 225 230 235 2401.08–1.12 215 220 225 230 235 2401.13–1.17 220 225 230 235 2401.18–1.22 225 230 235 2401.23–1.27 230 235 2401.28–1.32 235 2401.33–1.37 240

MEASURED CLEARANCE

ORIGINAL VALVE PAD NUMBER120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.00–0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 2100.02–0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 2150.07–0.11 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 2200.12–0.16 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 2250.17–0.21 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 2300.22–0.24 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 2350.25–0.34 STANDARD CLEARANCE0.35–0.37 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.38–0.42 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.43–0.47 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.48–0.52 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.53–0.57 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.58–0.62 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.63–0.67 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.68–0.72 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.73–0.77 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.78–0.82 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.83–0.87 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.88–0.92 180 185 190 195 200 205 210 215 220 225 230 235 2400.93–0.97 185 190 195 200 205 210 215 220 225 230 235 2400.98–1.02 190 195 200 205 210 215 220 225 230 235 2401.03–1.07 195 200 205 210 215 220 225 230 235 240 Example:

Exhaust valve clearance (cold)0.25–0.34 mm (0.0098–0.0134 in)

Rounded value 170Measured valve clearance is 0.44 mm (0.0173 in)

Replace pad 170 with pad 185Pad No. 170 = 1.70 mm (0.0669 in)Pad No. 185 = 1.85 mm (0.0728 in)

1.08–1.12 200 205 210 215 220 225 230 235 2401.13–1.17 205 210 215 220 225 230 235 2401.18–1.22 210 215 220 225 230 235 2401.23–1.27 215 220 225 230 235 2401.28–1.32 220 225 230 235 2401.33–1.37 225 230 235 2401.38–1.42 230 235 2401.43–1.47 235 2401.48–1.52 240

3-16

EINSPADJ POWER UNIT

9. Remove:• Dial gauge• Dial gauge stand• Dial gauge needle

10. Install:• All removed parts

NOTE:For installation, reverse the removal proce-dure.

Engine oil level check1. Check:

• Engine oil level

Checking steps:

CAUTION:• When checking the engine oil level on

water, be careful of other watercraft,boats, swimmers, or obstacles. Thewater current or wind can cause thewatercraft to move and lead to a colli-sion.

• When checking the engine oil level onland, supply water to the cooling waterpassages.

• Make sure that engine has enough oilbut do not overfill. If there is too littleoil, the engine can be damaged. if thereis too much oil, the air filter canbecome saturated with oil, perma-nently damaging the filter and reduc-ing engine performance. Follow thechecking procedure carefully.

• Make sure that debris or water doesnot enter the oil tank filler hole. Debrisor water in the engine oil can causeserious engine damage.

3-17

EINSPADJ POWER UNIT

• Place the watercraft in a horizontal posi-tion or launch the watercraft.

• Remove the rear and front seats.• Remove the oil tank filler cap 1 and

check for oil on the dipstick 2.• If there is no oil on the dipstick, pour

enough oil so that the tip of the dipstickcomes into contact with the oil, and theninstall the filler cap.

• Start the engine.

CAUTION:When starting the engine make sure thedipstick is securely fitted into the oiltank.

NOTE:• The engine cannot be started if the

Yamaha Security System is in the lockmode.

• For information on the Yamaha SecuritySystem, see the owner’s manual.

• Run the engine at trolling speed for 6minutes or more, and then stop theengine.

CAUTION:When checking the oil level on land, besure to connect a garden hose to thewatercraft for proper water supply.

NOTE:If the ambient temperature is 20 °C (68 °F)or less, warm up the engine for an addi-tional 5 minutes.

• Remove the oil tank filler cap 1, wipe thedipstick 2 clean, and then screw the fillercap into the filler hole completely.

3-18

EINSPADJ POWER UNIT

• Remove the filler cap again and checkthat the oil level is between the minimumlevel mark a and maximum level markb on the dipstick.

• If the engine oil is below the minimumlevel mark a, add sufficient oil of the rec-ommended type to raise it to the correctlevel.

• If the engine oil is above the maximumlevel mark b, extract sufficient oil usingan oil changer to lower it to the correctlevel.

NOTE:If the oil temperature is low, the reading onthe dipstick will be low, and if the tempera-ture is high, the reading on the dipstick willbe high.

Engine oil change — using oil changer

WARNINGAvoid changing the engine oil immediatelyafter turning the engine off. The oil is hotand should be handled with care to avoidburns.

CAUTION:• Do not run the engine with too much or

not enough oil in the oil tank. Oil couldspray out or the engine could be dam-aged.

• Do not run the engine for more than 15seconds without supplying water, whenchecking the oil level on land.The engine could overheat.

• Be sure to change the engine oil after thefirst 10 hours of operation, and every 100hours thereafter or at the start of a newseason, otherwise the engine will wearquickly.

1. Warm the engine up, and then put thewatercraft in a horizontal position.

3-19

EINSPADJ POWER UNIT

2. Remove:• Oil filler cap 1

1

3. Insert the tube of an oil changer into the oilfiller hole.

4. Operate the oil changer to extract the oil.

5. If the oil filter is also to be replaced, per-form the following procedure.

6. Pour the specified amount of the recom-mended engine oil into the oil filler hole.

Replacing steps:• Place a rag under the oil filter.• Remove the oil filter 1 with an oil filter

wrench.

Oil filter wrench:YU-38411/90890-01426

• Lubricate the O-ring 2 of the new oil filterwith a thin coat of engine oil.

CAUTION:Make sure the O-ring 2 is positionedcorrectly in the groove of the oil filter.

• Tighten the new oil filter to specificationwith an oil filter wrench.

T R.

Oil filter:17 N • m (1.7 kgf • m, 12 ft • lb)

1

3-20

EINSPADJ POWER UNIT

7. Fill:• Oil tank

(with the specified amount of the recom-mended engine oil)

CAUTION:When starting the engine make sure thedipstick is securely fitted into the oil tank.

8. Install:• Oil filler cap

Recommended oil:SAE 10W-30API SE, SF, SG, SH, SJ, SL

Oil quantity:Total amount:

4.5 L (4.8 US qt, 4.0 Imp qt)Without oil filter replacement:

2.1 L (2.2 US qt, 1.8 Imp qt)With oil filter replacement:

2.3 L (2.4 US qt, 2.0 Imp qt)

Air filter element clean1. Remove:

• Air filter case cover 1

3-21

EINSPADJ POWER UNIT

2. Remove the air filter element and check itfor dirt and oil. Replace the air filter ele-ment if there is any oil buildup.

CAUTION:• Make sure that the air filter element is

installed in the filter case properly.• Do not start the engine with the air filter

element removed, otherwise the enginecould be damaged.

• If cleaning the air filter element, use coldor lukewarm water and let it air dry com-pletely. Do not use detergent or an sol-vent to clean the air filter element, or dryit with heat or compressed air, otherwiseit could be damaged.

3. Install:• Air filter case cover

T R.


Spark plug inspection1. Remove:

• Air filter case cover 1

2. Remove:• Air filter element• Ignition coils

CAUTION:Be careful not to get any foreign sub-stances or water in the air intake port andspark plug hole.

3-22

EINSPADJ POWER UNIT

3. Inspect:• Electrodes 1

Damage/wear → Replace.• Insulator color 2

Distinctly different color → Check theengine condition.

Color guide:Medium to light tan color:

NormalWhitish color:

Lean fuel mixtureAir leakIncorrect settings

Blackish color:Overly rich mixtureElectrical malfunctionDefective spark plug

4. Clean:• Spark plug

(with a spark plug cleaner or wire brush)

5. Measure:• Spark plug gap a

Out of specification → Regap.

Spark plug gap:0.7–0.8 mm (0.028–0.031 in)

3-23

EINSPADJ POWER UNIT

6. Tighten:• Spark plug

NOTE:• Before installing the spark plug, clean the

gasket surface and spark plug surface. Also,it is suggested to apply a thin film of anti-seize compound to the spark plug threads toprevent thread seizure.

• If a torque wrench is not available, a goodestimate of the correct tightening torque for anew spark plug is to finger tighten a thespark plug and then tighten it another 1/4 to1/2 of a turn b.

T R.

Spark plug:13 N • m (1.3 kgf • m, 9.4 ft • lb)

7. Install:• Ignition coils• Air filter element• Air filter case cover

T R.

Ignition coil bolt:7.6 N • m (0.76 kgf • m, 5.5 ft • lb)LOCTITE 572


3-24

EINSPADJ ELECTRICAL

ELECTRICALBattery inspection

WARNINGBattery electrolyte is poisonous and dan-gerous, causing severe burns, etc. Electro-lyte contains sulfuric acid. Avoid contactwith skin, eyes or clothing. AntidotesExternal: Flush with water. Internal: Drink large quantities of water ormilk. Follow with milk of magnesia, beatenegg or vegetable oil. Call physician immedi-ately. Eyes: Flush with water for 15 minutes andget prompt medical attention. Batteries produce explosive gases. Keepsparks, flame, cigarettes, etc., well away. Ifusing or charging the battery in anenclosed space, make sure that it is wellventilated. Always shield your eyes whenworking near batteries. KEEP OUT OF THE REACH OF CHILDREN.

CAUTION:Be careful not to place the battery on itsside. Make sure to remove the battery from thebattery compartment when adding batteryelectrolyte or charging the battery. When checking the battery, make sure thebreather hose is connected to the batteryand not obstructed.

3-25

EINSPADJ ELECTRICAL

1. Remove:• Bands• Battery negative lead 1 • Battery positive lead 2 • Battery• Battery breather hose 3

WARNING• When removing the battery, disconnect

the negative lead first.• Remove the battery to prevent acid loss

during turning the machine on its side forthe impeller service.

2

31

2. Inspect:• Electrolyte level

Low → Add distilled water.The electrolyte level should be betweenthe upper a and lower b level marks.

CAUTION:Use only distilled water. Other types ofwater contain minerals which are harmfulto batteries.

Filling steps:• Remove each filler cap.• Add distilled water.• When the electrolyte level reaches the

upper level mark, allow the cell to standfor 20 minutes. If the electrolyte leveldrops, add more distilled water so thelevel reaches the upper level mark.

3-26

EINSPADJ ELECTRICAL

3. Inspect:• Specific gravity

Out of specification → Charge.

4. Install:• Filler caps

CAUTION:Before installation, rinse off any fluid fromthe battery box and battery and make surethat the battery is dry before installing it.

Specific gravity at 20 °C (68 °F):1.28

Charging current:1.9 amps × 10 hrs

5. Install:• Battery breather hose 1 • Battery • Battery positive lead 2 • Battery negative lead 3 • Bands

CAUTION:• Connect the positive lead to the battery

terminal first.• Make sure the battery leads are con-

nected properly. Reversing the leads canseriously damage the electrical system.

• Make sure that the battery breather hose isproperly connected and is not obstructed.

• Coat the terminals with a water resistantgrease to minimize terminal corrosion.

2

13

3-27

EINSPADJ JET PUMP UNIT

JET PUMP UNITImpeller inspection

1. Check:• Impeller 1

Damage/wear → Replace.Nicks/scratches → File or grind.

2. Measure:• Impeller-to-housing clearance a

Out of specification → Replace.

Maximum impeller-to-housing clearance:

0.35–0.45 mm (0.0138–0.0177 in)

Measurement steps:• Remove the battery leads.• Remove the intake grate and intake duct.

Refer to “INTAKE GRATE, RIDE PLATE,AND INTAKE DUCT” in Chapter 6.

• Measure the clearance at each impellerblade as shown (a total of three measure-ments).

• Install the intake duct and intake grate.Refer to “INTAKE GRATE, RIDE PLATE,AND INTAKE DUCT” in Chapter 6.

• Install the battery leads.

Water inlet strainer inspection1. Inspect:

• Water inlet strainerContaminants → Clean.Cracks/damage → Replace.

Inspection steps:• Remove the ride plate.


• Remove the rubber plate.Refer to “JET PUMP UNIT” in Chapter 6.

• Remove the water inlet cover 1.• Inspect the water inlet strainer mesh a.• Install the water inlet cover.• Install the rubber plate.

Refer to “JET PUMP UNIT” in Chapter 6.• Install the ride plate.


3-28

EINSPADJ BILGE PUMP

BILGE PUMPBilge strainer inspection

1. Inspect:• Bilge strainer

Contaminants → Clean.Cracks/damage → Replace.

Inspection steps:• Remove the deck beam.

Refer to “SEATS AND HAND GRIP” inChapter 8.

• Remove the coupling cover.• Disconnect the bilge strainer case 1

from the bilge strainer.• Inspect the bilge strainer.• Install the coupling cover.• Install the deck beam.

Refer to “SEATS AND HAND GRIP” inChapter 8.

1

Electric bilge pump strainer inspection1. Inspect:

• Cap• Strainer

Contaminants → Clean.

Inspection steps:• Remove the band 1.• Remove the cap 2 and strainer 3.• Inspect the cap and strainer.• Install the strainer and cap.• Install the band.

1

3

2

3-29

EINSPADJ GENERAL

GENERALDrain plug inspection

1. Inspect:• Drain plugs

Cracks/damage → Replace.• O-rings

Cracks/wear → Replace.• Screw threads


Lubrication points1. Lubricate:

• Throttle cable (handlebar end)

NOTE:Before lubricating the throttle cable, squeezethe throttle lever and remove the rubber seal1.

2. Lubricate:• Throttle cable (throttle body end)

Recommended lubricant:Rust inhibitor

Recommended lubricant:Yamaha marine grease, Yamaha grease A (Water resistant grease)

3. Lubricate:• QSTS control cables (handlebar end)

NOTE:Before lubricating the QSTS control cables,remove the QSTS cable housing cover. Spraythe rust inhibitor into the outer cables, andapply grease to the inner cables.


3-30

EINSPADJ GENERAL

4. Lubricate:• QSTS cables (pulley end)

Recommended grease:Yamaha marine grease, Yamaha grease A (Water resistant grease)

5. Lubricate:• Nozzle pivot shaft • Steering cable (nozzle end)• QSTS cable (nozzle end)


6. Lubricate:• Steering cable • Steering cable joint• Shift cable• Shift cable joint

NOTE:Disconnect the joints and apply a smallamount of grease.


3-31

EINSPADJ GENERAL

7. Fill:• Intermediate housing

NOTE:Fill the intermediate housing with the recom-mended grease through the grease nipple 1.


Grease quantity:Initial 10 hours:

33.0–35.0 cm3 (1.11–1.18 oz)Every 100 hours or 12 months:

6.0–8.0 cm3 (0.20–0.27 oz)

1

EFUEL

4

CHAPTER 4FUEL SYSTEM

ARRANGEMENT OF THE THROTTLE BODY COMPONENTS COUPLERS ....................................................................................................4-1

FUEL TANK AND FUEL PUMP MODULE......................................................4-2EXPLODED DIAGRAM .............................................................................4-2REMOVAL AND INSTALLATION CHART ................................................4-2SERVICE POINTS ....................................................................................4-5

Fuel hose disconnection .....................................................................4-5Fuel pump module removal.................................................................4-5Check valve inspection .......................................................................4-5Rollover valve inspection ....................................................................4-6Fuel sender inspection........................................................................4-6Fuel tank inspection ............................................................................4-6Fuel hose inspection ...........................................................................4-6Fuel pump filter inspection ..................................................................4-6Fuel pump module installation ............................................................4-7Fuel hose connect...............................................................................4-7

FUEL INJECTION SYSTEM............................................................................4-8EXPLODED DIAGRAM .............................................................................4-8REMOVAL AND INSTALLATION CHART ................................................4-8SERVICE POINTS ..................................................................................4-17

Hose clamps removal........................................................................4-17Hose clamps installation ...................................................................4-17Fuel hose disconnection ...................................................................4-17Fuel line inspection ...........................................................................4-18Fuel hose installation (replacing with new fuel hose)........................4-19Fuel hose connection........................................................................4-19Throttle body removal .......................................................................4-19Fuel injector inspection .....................................................................4-20Throttle body inspection ....................................................................4-20Bypass valve motor inspection..........................................................4-21Throttle body installation ...................................................................4-21Throttle bodies synchronization ........................................................4-22Fuel pressure measurement .............................................................4-27

4-1

EFUELARRANGEMENT OF THE THROTTLE BODY COMPONENTS COUPLERS

ARRANGEMENT OF THE THROTTLE BODY COMPONENTS COUPLERS

1 Bypass valve motor coupler2 Joint coupler3 Sensor assembly coupler4 Fuel injector #4 coupler5 Fuel injector #3 coupler6 Fuel injector #2 coupler7 Fuel injector #1 coupler8 Throttle position sensor

coupler

È To wiring harnessÉ Route the throttle cable

between the sub-wiring har-ness.

Ê Route the sub-wiring harnessunder the intake vacuum hose.

Ë To fuel injector #3Ì Fasten the sub-wiring harness

to the joint coupler bracket witha plastic tie as shown in theillustration.

Í Fasten the ring, which isattached to the sub-wiring har-ness, to the sensor assemblybracket with a plastic tie. Facethe end of the plastic tietowards the sensor assembly.

1 2 3

45678

3

2

2

AB

AÉ Ê

ÈÍ

Ì

Ë

B

4-2

EFUEL FUEL TANK AND FUEL PUMP MODULE

FUEL TANK AND FUEL PUMP MODULEEXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service pointsFUEL TANK REMOVAL Follow the left “Step” for removal.Service lid 1 Refer to “FRONT HOOD” in Chapter 8.Service lid 2Ventilation hose From ventilation fittingEngine unit Refer to “ENGINE UNIT” in Chapter 5.

NOTE:When removing the pump module only, it isnot necessary to remove the engine unit.

1 Rollover valve 12 Fuel tank breather hose 23 Check valve 1

1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)

8 × 18 mm16 N • m (1.6 kgf • m, 11 ft • Ib)

5.9 N • m (0.59 kgf • m, 4.3 ft • Ib)

4.2 N • m (0.42 kgf • m, 3.0 ft • Ib)

16

1715

3

2

2

17

10

94

5

11

8

18

19

20

21

1312

13

LT

572

LT

572

LT

572

LT

572

2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

1st 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib)

14

6

4-3


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points4 Fuel tank breather hose 1 NOTE:

Make sure that the inner seal of the coupleris installed properly before connecting thecoupler.

5 Fuel sender coupler 1

6 Fuel pump module coupler 17 Cover 18 Fuel hose 19 Nut 910 Retainer 111 Fuel pump module 112 Packing 1

1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)

8 × 18 mm16 N • m (1.6 kgf • m, 11 ft • Ib)

5.9 N • m (0.59 kgf • m, 4.3 ft • Ib)

4.2 N • m (0.42 kgf • m, 3.0 ft • Ib)

16

1715

3

2

2

17

10

94

5

11

8

18

19

20

21

1312

13

LT

572

LT

572

LT

572

LT

572

2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

1st 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib)

14

6

4-4


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points13 Hose clamp 214 Fuel filler hose 115 Nut 116 Fuel filler neck 117 Rubber seal 118 Bolt 219 Fuel tank assembly 120 Bolt 221 Fuel tank belt 2

Reverse the removal steps for installation.

1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)

8 × 18 mm16 N • m (1.6 kgf • m, 11 ft • Ib)

5.9 N • m (0.59 kgf • m, 4.3 ft • Ib)

4.2 N • m (0.42 kgf • m, 3.0 ft • Ib)

16

1715

3

2

2

17

10

94

5

11

8

18

19

20

21

1312

13

LT

572

LT

572

LT

572

LT

572

2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

1st 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib)

14

6

4-5


SERVICE POINTSFuel hose disconnection

1. Disconnect:• Fuel hose

Refer to “FUEL INJECTION SYSTEM”.

Fuel pump module removal1. Remove:

• Nuts• Retainer

NOTE:Loosen the nuts in the sequence shown.

1

496

2

38 7

5

2. Remove:• Fuel pump module 1

NOTE:Remove the float 2 at an angle because itcould catch on the fuel tank.

2

1

Check valve inspection1. Check:

• Check valveFaulty → Replace.

Checking steps:• Connect a hose to the end of check valve

“A” and blow into it.Air should come out from end “B”.

• Connect the hose to the end of checkvalve “B” and blow into it.Air should come out from end “A”.

A A

B B

4-6


Rollover valve inspection1. Check:

• Rollover valveFaulty → Replace.

Fuel sender inspectionRefer to “FUEL CONTROL SYSTEM” inChapter 7.

Fuel tank inspection1. Inspect:

• Fuel tankCracks/damage → Replace.

Fuel hose inspectionRefer to “FUEL INJECTION SYSTEM”.

Checking steps:• Connect a hose to the end of rollover

valve “A” and blow into it.Air should come out from end “B”.

• Connect the hose to the end of rollovervalve “B” and blow into it.Air should not come out from end “A”.

A

B

A

B

Fuel pump filter inspection1. Inspect:

• Fuel pump filter 1 Clog/contaminants → Wash the fuelpump filter in kerosene or gasoline.

1

4-7


Fuel pump module installation1. Tighten:

• Nuts

NOTE:Tighten the nuts in the sequence shown.

Fuel hose connectRefer to “FUEL INJECTION SYSTEM”.

T R.

Fuel pump module nut:1st:

3.2 N • m (0.32 kgf • m, 2.3 ft • lb)

2nd:6.4 N • m (0.64 kgf • m, 4.6 ft • lb)

9

614

8

72 3

5

4-8

EFUEL FUEL INJECTION SYSTEM

FUEL INJECTION SYSTEMEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsTHROTTLE BODIES REMOVAL Follow the left “Step” for removal.

1 Screw 22 Air filter case cover 13 Air filter 14 Bolt 45 Ribbon sub assembly 26 Holder 27 Throttle cable 18 Bolt 29 Throttle cable holder 110 Cover 1

LT

572

LT LT

242

LT

E

AALT

572

LT

LT

572

LT

7

8

91514

12

13

11

10

5 × 70 mm 2.5 N • m (0.25 kgf • m, 1.8 ft • Ib)

6 × 7 mm 6.5 N • m (0.65 kgf • m, 4.7 ft • Ib)

8 × 50 mm 22 N • m (2.2 kgf • m, 16 ft • Ib)

1919

22

20

21

18

23

17

4 × 8 mm3.3 N • m (0.33 kgf • m, 2.4 ft • Ib)

6 × 14 mm7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

3

2

16

65

64

1

4-9


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points11 Fuel hose 112 Bolt 213 Fuel hose holder 114 Clamp 115 Clamp 116 Bolt 817 Throttle bodies 118 Sensor assembly coupler 119 Fuel injector coupler 420 Throttle position sensor coupler 1

LT

572

LT LT

242

LT

E

AALT

572

LT

LT

572

LT

7

8

91514

12

13

11

10

5 × 70 mm 2.5 N • m (0.25 kgf • m, 1.8 ft • Ib)

6 × 7 mm 6.5 N • m (0.65 kgf • m, 4.7 ft • Ib)

8 × 50 mm 22 N • m (2.2 kgf • m, 16 ft • Ib)

1919

22

20

21

18

23

17

4 × 8 mm3.3 N • m (0.33 kgf • m, 2.4 ft • Ib)

6 × 14 mm7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

3

2

16

65

64

1

Not reusable

4-10


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points21 Joint connector 122 Bypass valve motor coupler 123 Ring 1


LT

572

LT LT

242

LT

E

AALT

572

LT

LT

572

LT

7

8

91514

12

13

11

10

5 × 70 mm 2.5 N • m (0.25 kgf • m, 1.8 ft • Ib)

6 × 7 mm 6.5 N • m (0.65 kgf • m, 4.7 ft • Ib)

8 × 50 mm 22 N • m (2.2 kgf • m, 16 ft • Ib)

1919

22

20

21

18

23

17

4 × 8 mm3.3 N • m (0.33 kgf • m, 2.4 ft • Ib)

6 × 14 mm7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

3

2

16

65

64

1

4-11


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsAIR FILTER CASE REMOVAL Follow the left “Step” for removal.Throttle bodies

1 Clamp/breather hose 1/12 Band 1 Unfasten the wiring harness.3 Lighting coil coupler 1 From wiring harness bracket 24 Thermoswitch coupler (engine) 1 From wiring harness bracket 25 Pickup coil coupler 1 From wiring harness bracket 26 Thermoswitch coupler (exhaust) 1 From wiring harness bracket 17 Cam position sensor coupler 1 From wiring harness bracket 1

316

5

1514

24

23

25

1018

17

9

76

13

12

8

11

22

21

4

19

20

LT

271

LT

242

LT

271

1

2

LT

572

LT

LT

242

8 × 30 mm2nd 18 N • m (1.8 kgf • m, 13 ft • Ib)

1st 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib)

1.8 N • m (0.18 kgf • m, 1.3 ft • Ib)5 × 14 mm

1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)5 × 14 mm

1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)

5 × 14 mm

8 × 16 mm2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 16 mm

2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

9

LT

572

LT

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)6 × 16 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)6 × 16 mm

4-12


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points8 Wiring harness coupler 19 Bolt 310 Air filter case 111 Bolt 212 Wiring harness bracket 1 113 Sub wiring harness 114 Bolt 215 Fuel hose bracket 116 Screw 117 Wiring harness bracket 2 1

316

5

1514

24

23

25

1018

17

9

76

13

12

8

11

22

21

4

19

20

LT

271

LT

242

LT

271

1

2

LT

572

LT

LT

242

8 × 30 mm2nd 18 N • m (1.8 kgf • m, 13 ft • Ib)

1st 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib)

1.8 N • m (0.18 kgf • m, 1.3 ft • Ib)5 × 14 mm

1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)5 × 14 mm

1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)

5 × 14 mm

8 × 16 mm2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 16 mm

2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

9

LT

572

LT

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)6 × 16 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)6 × 16 mm

4-13


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points18 Grommet 119 Throttle body joint 420 Band 221 Bolt 222 Air filter case stay 1 223 Band 124 Bolt 125 Air filter case stay 2 1


316

5

1514

24

23

25

1018

17

9

76

13

12

8

11

22

21

4

19

20

LT

271

LT

242

LT

271

1

2

LT

572

LT

LT

242

8 × 30 mm2nd 18 N • m (1.8 kgf • m, 13 ft • Ib)

1st 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib)

1.8 N • m (0.18 kgf • m, 1.3 ft • Ib)5 × 14 mm

1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)5 × 14 mm

1.3 N • m (0.13 kgf • m, 0.9 ft • Ib)

5 × 14 mm

8 × 16 mm2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 16 mm

2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

9

LT

572

LT

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)6 × 16 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)6 × 16 mm

4-14


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsTHROTTLE BODY DISASSEMBLY

Follow the left “Step” for disassembly.

1 Screw 32 Bracket 13 Bolt/nut 2/24 Bypass valve motor 15 Holder 16 Holder 17 Hose #4 18 Hose #3 19 Hose #2 110 Hose #1 1

5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)

6 × 10 mm

5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)

6 × 9 mm

24

252627

28

29

30 31 3221

20

1516

19 17

2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

4 × 12 mm 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)6 × 9 mm

15

1823

2422

3.5 N • m (0.35 kgf • m, 2.5 ft • Ib)

5 × 15 mm

13 N • m (1.3 kgf • m, 9.4 ft • Ib)

5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)

6 × 10 mm

8 × 18 mm

13

1411

12

1

3

105

6

9

8

4

7

2

3

4-15


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points11 Bolt 412 Fuel rail 113 Screw 214 Sensor assembly 115 Intake vacuum hose 316 Joint 117 Fuel injector 418 O-ring 4

19 Grommet 420 Screw 221 Throttle stop guide 122 Screw 2

5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)

6 × 10 mm

5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)

6 × 9 mm

24

252627

28

29

30 31 3221

20

1516

19 17

2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

4 × 12 mm 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)6 × 9 mm

15

1823

2422

3.5 N • m (0.35 kgf • m, 2.5 ft • Ib)

5 × 15 mm

13 N • m (1.3 kgf • m, 9.4 ft • Ib)

5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)

6 × 10 mm

8 × 18 mm

13

1411

12

1

3

105

6

9

8

4

7

2

3

Not reusableNot reusable

4-16


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points23 Throttle stop screw bracket 124 Screw/spring 4/425 Bypass air screw 426 Spring 427 Washer 428 O-ring 429 Screw 230 Throttle position sensor 131 O-ring 132 Throttle bodies 1

Reverse the disassembly steps for assembly.

5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)

6 × 10 mm

5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)

6 × 9 mm

24

252627

28

29

30 31 3221

20

1516

19 17

2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

4 × 12 mm 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)6 × 9 mm

15

1823

2422

3.5 N • m (0.35 kgf • m, 2.5 ft • Ib)

5 × 15 mm

13 N • m (1.3 kgf • m, 9.4 ft • Ib)

5.0 N • m (0.5 kgf • m, 3.6 ft • Ib)

6 × 10 mm

8 × 18 mm

13

1411

12

1

3

105

6

9

8

4

7

2

3

Not reusable

Not reusable

4-17


SERVICE POINTSHose clamps removal

1. Remove:• Hose clamps

CAUTION:If the hose clamps are removed withoutcutting the joint first, the fuel hose will bedamaged.

Hose clamps installation1. Install:

• Hose clamps

WARNINGDo not reuse the hose clamps, alwaysreplace them with new ones.

NOTE:Crimp the hose clamps properly to securelyfasten them.

Fuel hose disconnection

WARNINGBefore disconnecting the hose, remove thefuel tank filler cap to reduce any pressureinside the fuel tank, and then disconnectthe battery negative lead to cut off the elec-tric current to the electrical systems.

1. Wrap the quick connector with a cloth, andthen rotate the quick connector tab 1 tothe stopper position a.

WARNINGIf the quick connector is removed sud-denly, pressurized fuel could spray out. Togradually release the fuel pressure, be sureto remove the quick connector slowly.

1

2 a

4-18

EFUEL

CAUTION:• Do not rotate the quick connector tab 1

past the stopper position a, otherwise itcould be damaged.

• When the fuel hoses are disconnected,quickly remove the retainer 2 from thequick connector, otherwise the retainercould be lost.

2. Disconnect the fuel hose 1 from the fuelpipe 2 directly.

WARNINGAlways reduce the fuel pressure in the fuelline before servicing the line or the fuelpipe. If the fuel pressure is not released,pressurized fuel could spray out.

2

1

1

2

3. Cover the quick connector and fuel pipewith a plastic bag to prevent damage andto protect them from dirt.

Fuel line inspection1. Inspect:

• Fuel hoseDamage/cracks → Replace.

• O-rings (quick connector)Damage/cracks → Replace the quickconnector.

• Fuel pipeDamage/cracks → Replace the fuelpump.

FUEL INJECTION SYSTEM

4-19


Fuel hose installation (replacing with new fuel hose)

1. Install:• Fuel hose 1

NOTE:• To install the fuel hose, be sure to align the

white mark a of the fuel hose with thechecker tab 2 of the quick connector.

• When replacing the fuel hose with a newone, a checker tab 2 that has half engage-ment prevention is attached to the quick con-nector of the hose. If the quick connector iscompletely installed to the fuel pipe, it isremovable.

2

1

a

2

Fuel hose connection1. Apply a thin coat of engine oil to the con-

tact surfaces of the fuel pipe.

2. Insert the quick connector into the fuelpipe until you hear a “click.”

3. To check the connection of the quick con-nector, push and pull on the quick connec-tor several times until there is free play of2–3 mm (0.08–0.12 in).

NOTE:If free is not obtained, disconnect the fuel hoseand check the O-ring for damage and that it isproperly installed.

Throttle body removal1. Remove:

• Throttle body

CAUTION:Do not bend the fuel pipe 1.

1

4-20


Fuel injector inspection

CAUTION:The throttle bodies should not be disas-sembled unnecessarily.

1. Check:• Injector

Dirt/residue → Clean.Damage → Replace.

2. Measure:• Fuel injectors resistance


3. Check the operation of the fuel injectorusing the “Stationary Test” of the YamahaDiagnostic System.

Digital multimeter:YU-34899-A

Digital circuit tester:90890-03174

Fuel injector resistance:(reference data)11.5–12.5 Ω at 20 °C (68 °F)

Throttle body inspection1. Check:

• Throttle bodyCracks/damage → Replace the throttlebodies.

2. Check:• Fuel passages

Obstruction → Clean.

Checking steps:• Wash the throttle body in a petroleum

based solvent.Do not use any caustic carburetor clean-ing solution.

• Blow out all of passages with com-pressed air.

4-21


Bypass valve motor inspection1. Inspect:

• HosesDamage/cracks → Replace.

2. Check:• Check the bypass valve motor operation

using the Yamaha Diagnostic System.

Throttle body installation1. Install:

• Throttle body

CAUTION:Do not bend the fuel pipe 1.

1

2. Install:• Fuel hose 1 (throttle body side)• Clamp

NOTE:Install the fuel hose with the white mark a fac-ing up.

1

a


Refer to “CONTROL SYSTEM” in Chap-ter 3.

4-22


Throttle bodies synchronization1. Remove:

• Throttle bodies• Air filter case

2. Adjust:• Throttle bodies synchronization

Adjustment steps:

NOTE:The bypass air screws 1 should not beadjusted. However, if it is necessary toremove the bypass air screw, be sure tonote the number of times the screw isturned from its set position. When installingthe screw, be sure to tighten the screw thesame number of turns as noted at removal.If the number of turns is not known, turn thescrew approximately 2.5 times counter-clockwise from the fully closed position.

CAUTION:Do not start the engine when removingthe fuel hose. Fuel can spurt out whenthe fuel pump is operated.

a. Loosen the throttle stop screw 2 andsynchronizing screws #1 3, #2 4, and#3 5 until released from the levers.

NOTE:• Only butterfly valve #2 should be fully

closed and the other valves should behalfway closed.

• Check the valve for light leaks with aflashlight. If there are no light leaks, thevalve is fully closed.

b. Turn synchronizing screw #2 4 clock-wise approximately 7 times until it startsto contact the lever.

NOTE:• Butterfly valves #2 and #3 should be fully

closed. Butterfly valve #2 opens if thescrew is turned more than 7 times.

• If butterfly valves #2 and #3 are not fullyclosed, close the valves by adjusting syn-chronizing screw #2 4.

1 1

#1#2#3#4

#1 #2 #3 #4

3 4 5

2

4-23


c. Turn synchronizing screw #1 3 clock-wise approximately 7 times until it startsto contact the lever.

NOTE:• Butterfly valve #1 should be fully closed.

Butterfly valves #2 and #3 open if thescrew is turned more than 7 times.

• If butterfly valves #1, #2, and #3 are notfully closed, close the valves by adjustingsynchronizing screw #1 3.

d. Turn synchronizing screw #3 5 clock-wise approximately 7 times until it startsto contact the lever.

NOTE:• Butterfly valve #4 should be fully closed.

Butterfly valves #1, #2, and #3 open if thescrew is turned more than 7 times.

• If all butterfly valves are not fully closed,close the valves by adjusting synchroniz-ing screw #3 5.

e. Check that all butterfly valves are fullyclosed and that they open simulta-neously.

NOTE:If all butterfly valves are not fully closed,close the valves by repeating steps a–d.

f. Turn the throttle stop screw 2 clockwiseapproximately 1.5 times until it starts tocontact the throttle lever.

g. Remove the plugs 6.h. Install the carburetor synchronizer 7 or

vacuum gauge 8.È For USA and CanadaÉ For worldwide

Carburetor synchronizer:YU-08030

Vacuum gauge:90890-03094

6

#1 #2 #3 #4

7

È

8

É

4-24


NOTE:For best results, use a vacuum gauge(commercially obtainable), like 9 or 0

shown in the illustration, that has fouradapters.

i. Install the throttle bodies.

NOTE:Adjust the throttle body synchronizationwith the air filter case uninstalled.

j. Connect the fuel hose and clamp.k. Connect the Yamaha Diagnostic Sys-

tem.l. Remove the sub wiring harness from the

air filter case, and then connect it to thethrottle bodies and main wiring harness.

m. Connect the test harness (3 pin) to thethrottle position sensor A.

Test harness (3 pins):YB-06793

Test harness SMHW099-3 (3 pins):

90890-06793

n. To start the ECM normally, start theYamaha Diagnostic System.

CAUTION:If the Yamaha Diagnostic System andECM are started, fuel can spurt out. Besure to connect the fuel hoses and throt-tle bodies when adjusting the throttleposition sensor.

NOTE:Use the test connector B to start the ECMnormally only if the Yamaha DiagnosticSystem is not available.

Test connector:YW-06862

Test connector FMY-8:90890-06862

0

9

A

B/O

P

B

4-25


o. Measure the throttle position sensor out-put voltage (DC). Adjust the throttle posi-tion sensor A position if out ofspecification.

Throttle position sensor output voltage:

Pink (P) – Black/orange (B/O)0.756 ± 0.016 V

NOTE:• To decrease the output voltage, turn the

throttle position sensor clockwise.• Slightly tighten the throttle position screw.

p. Start the engine and let it run at trollingspeed for 20 minutes.

NOTE:• Warm the engine up in the water.• While checking the engine temperature

with the Yamaha Diagnostic System,warm the engine up until the engine tem-perature is 50 °C (122 °F).

q. Adjust the throttle stop screw until trollingspeed is within specification.

Trolling speed:

Season Temperature Specified engine speed

Summer 30 °C (86 °F) or more 1,650 r/min

Winter 10 °C (50 °F) or less 1,720 r/min

Spring/Fall 20 °C (68 °F) 1,680 r/min

r. Adjust each cylinder to the cylinder dif-ferences shown in the table using syn-chronizing screws 3–5 and usingcylinder #2 as the standard.

0 5 10 15 20 25 30 35 40 45 50

1,740

1,720

1,700

1,680

1,660

1,640

1,620

1,600

˚C

r/m

in

4-26

EFUEL

3. Remove:• Throttle bodies

4. Remove:• Carburetor synchronizer or vacuum

gauge

5. Install:• Plugs

6. Install:• Air filter case• Throttle bodies

Vacuum pressure at trolling speed:

CylinderCylinder

difference Example

#1

–18 ± 10 mmHg(–2.45 ±

1.33 kPa, –0.8 ± 0.4 inHg)

–230 ± 10 mmHg(–30.68 ± 1.33 kPa,

–9.1 ± 0.4 inHg)

#2 Standard*0–212 mmHg(–28.23 kPa, –8.3 inHg)

#3

–11 ± 10 mmHg(–1.53 ±

1.33 kPa, –0.5 ± 0.4 inHg)

–223 ± 10 mmHg(–29.76 ± 1.33 kPa,

–8.8 ± 0.4 inHg)

#4

+1.0 ± 10 mmHg(+0.04 ±

1.33 kPa, 0 ± 0.4 inHg)

–211 ± 10 mmHg(–28.19 ± 1.33 kPa,

–8.3 ± 0.4 inHg)

Standard*: When setting the specified engine speed, the value is zero.

NOTE:Always maintain the specified trolling speedwhen making this adjustment.

s. Measure the throttle position sensor out-put voltage. Adjust the throttle positionsensor position if out of specification.



T R.

Plug (vacuum pressure):10 N • m (1.0 kgf • m, 7.2 ft • lb)

FUEL INJECTION SYSTEM

4-27


Fuel pressure measurement1. Disconnect:

• Fuel hoseRefer to “Fuel hose disconnection”.

2. Install:• Fuel pressure gauge adapter 1 • Fuel pressure gauge 2

NOTE:To connect the fuel pressure gauge adapter,follow the procedures for connecting a fuelhose. (Refer to “Fuel hose connection”.)

3. Start the engine and arrow it to warm upfor several minutes.

4. Measure:• Fuel pressure

Out of specification → Replace the fuelpump module.

5. Remove:• Fuel pressure gauge• Fuel pressure gauge adapter

NOTE:To disconnect the fuel pressure gaugeadapter, follow the procedures for disconnect-ing a fuel hose. (Refer to “Fuel hose discon-nection”.)

6. Connect:• Fuel hose

Refer to “Fuel hose connection”.

Fuel pressure gauge adapter:YW-06842/90890-06842

Fuel pressure gauge:YB-06766/90890-06786

Fuel pressure:310–330 kPa (3.1–3.3 kgf/cm2, 45–47 psi)

1

2

EPOWR

CHAPTER 5POWER UNIT

ENGINE UNIT..................................................................................................5-1EXPLODED DIAGRAM .............................................................................5-1REMOVAL AND INSTALLATION CHART ................................................5-1SERVICE POINTS ....................................................................................5-4

Compression pressure measurement .................................................5-4Oil filter removal and installation .........................................................5-6Engine unit removal ............................................................................5-6Shim removal ......................................................................................5-7Engine mount inspection.....................................................................5-7Coupling clearance inspection ............................................................5-7

EXHAUST PIPE 3............................................................................................5-8EXPLODED DIAGRAM .............................................................................5-8REMOVAL AND INSTALLATION CHART ................................................5-8

EXHAUST PIPES 1 AND 2............................................................................5-11EXPLODED DIAGRAM ...........................................................................5-11REMOVAL AND INSTALLATION CHART ..............................................5-11

EXHAUST MANIFOLD..................................................................................5-13EXPLODED DIAGRAM ...........................................................................5-13REMOVAL AND INSTALLATION CHART ..............................................5-13

OIL TANK ......................................................................................................5-15EXPLODED DIAGRAM ...........................................................................5-15REMOVAL AND INSTALLATION CHART ..............................................5-15SERVICE POINTS ..................................................................................5-21

Oil tank removal ................................................................................5-21Oil strainer inspection........................................................................5-22Oil tank installation ............................................................................5-22

EPOWR

5

OIL PUMP......................................................................................................5-25EXPLODED DIAGRAM ...........................................................................5-25REMOVAL AND INSTALLATION CHART ..............................................5-25SERVICE POINTS ..................................................................................5-30

Oil pump inspection...........................................................................5-30Check valve inspection .....................................................................5-30Oil strainer inspection........................................................................5-31Oil pump installation..........................................................................5-31

REDUCTION DRIVE GEAR ..........................................................................5-32EXPLODED DIAGRAM ...........................................................................5-32REMOVAL AND INSTALLATION CHART ..............................................5-32SERVICE POINTS ..................................................................................5-36

Drive coupling removal......................................................................5-36Drive shaft removal ...........................................................................5-36Bearing removal ................................................................................5-36Oil pump drive shaft inspection .........................................................5-37Drive shaft inspection........................................................................5-37Bearing installing...............................................................................5-38Drive shaft installation .......................................................................5-40Drive coupling installation .................................................................5-40

GENERATOR AND STARTER MOTOR.......................................................5-41EXPLODED DIAGRAM ...........................................................................5-41REMOVAL AND INSTALLATION CHART .............................................5-41SERVICE POINTS ..................................................................................5-46

Flywheel magneto removal ...............................................................5-46Starter clutch inspection....................................................................5-46Flywheel magneto installation ...........................................................5-48

CAMSHAFTS.................................................................................................5-49EXPLODED DIAGRAM ...........................................................................5-49REMOVAL AND INSTALLATION CHART ..............................................5-49SERVICE POINTS ..................................................................................5-55

Camshaft removal .............................................................................5-55Camshaft inspection..........................................................................5-56Camshaft sprockets inspection .........................................................5-58Timing chain tensioner inspection.....................................................5-58Camshaft installation.........................................................................5-59

EPOWR

CYLINDER HEAD..........................................................................................5-63EXPLODED DIAGRAM ...........................................................................5-63REMOVAL AND INSTALLATION CHART .............................................5-63SERVICE POINTS ..................................................................................5-65

Cylinder head removal ......................................................................5-65Cylinder head inspection...................................................................5-65Cylinder head installation ..................................................................5-66

VALVES AND VALVE SPRINGS..................................................................5-68EXPLODED DIAGRAM ...........................................................................5-68REMOVAL AND INSTALLATION CHART .............................................5-68SERVICE POINTS ..................................................................................5-70

Valve removal ...................................................................................5-70Valve spring inspection .....................................................................5-71Valve inspection ................................................................................5-71Valve guide inspection ......................................................................5-72Valve guide replacement...................................................................5-73Valve seat inspection ........................................................................5-75Valve seat reface ..............................................................................5-76Valve installation ...............................................................................5-78

CRANKCASE ................................................................................................5-80EXPLODED DIAGRAM ...........................................................................5-80REMOVAL AND INSTALLATION CHART ..............................................5-80SERVICE POINTS ..................................................................................5-85

Crankcase disassembly ....................................................................5-85Crankcase inspection........................................................................5-86Timing chain inspection.....................................................................5-86Crankcase assembly.........................................................................5-87

CONNECTING RODS AND PISTONS..........................................................5-90EXPLODED DIAGRAM ...........................................................................5-90REMOVAL AND INSTALLATION CHART ..............................................5-90SERVICE POINTS ..................................................................................5-92

Connecting rod and piston removal ..................................................5-92Cylinder and piston inspection ..........................................................5-93Piston ring inspection ........................................................................5-94Piston pin inspection .........................................................................5-96Connecting rod inspection.................................................................5-97Connecting rod and piston installation ..............................................5-99

EPOWR

CRANKSHAFT ............................................................................................5-103EXPLODED DIAGRAM .........................................................................5-103REMOVAL AND INSTALLATION CHART ............................................5-103SERVICE POINTS ................................................................................5-104

Crankshaft removal .........................................................................5-104Crankshaft inspection......................................................................5-104Crankshaft installation.....................................................................5-107

THERMOSTAT ............................................................................................5-108EXPLODED DIAGRAM .........................................................................5-108REMOVAL AND INSTALLATION CHART ............................................5-108SERVICE POINTS ................................................................................5-110

Thermostat inspection.....................................................................5-110Thermostat installation ....................................................................5-110

COOLING WATER HOSE...........................................................................5-111EXPLODED DIAGRAM .........................................................................5-111REMOVAL AND INSTALLATION CHART ............................................5-111

5-1

EPOWR ENGINE UNIT

ENGINE UNITEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsENGINE UNIT REMOVAL Follow the left “Step” for removal.Engine oil Drain.

Refer to “POWER UNIT” in Chapter 3.Service lid 1 Refer to “FRONT HOOD” in Chapter 8.Battery negative and positive lead Refer to “ELECTRICAL BOX” in Chapter 7.Throttle cable and fuel hose Refer to “FUEL INJECTION SYSTEM” in

Chapter 4.Water lock and exhaust joint Refer to “EXHAUST SYSTEM” in Chapter 8.

1 Oil filter 12 Bolt 4

4

10

11

126

3

7

2

8

1

9

5

9

14

9

13

15

LT

271

LTLT

572

LT

7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)

6 × 25 mm

8 × 28 mm17 N • m (1.7 kgf • m, 12 ft • Ib)

17 N • m (1.7 kgf • m, 12 ft • Ib)

8 × 40 mm17 N • m (1.7 kgf • m, 12 ft • Ib)

LT

572

LT

E

5-2

EPOWR ENGINE UNIT

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points3 Electrical box 14 Clamp/cooling water hose 1/1 Cooling water pilot outlet5 Clamp/cooling water hose 1/1 Cooling water pilot outlet6 Clamp/cooling water hose 1/1 Cooling water outlet7 Clamp/cooling water hose 1/1 Cooling water outlet8 Clamp/cooling water hose 1/1 Cooling water inlet9 Coupler 1010 Grease hose 111 Bolt/collar 1/112 Coupling cover 1

4

10

11

126

3

7

2

8

1

9

5

9

14

9

13

15

LT

271

LTLT

572

LT

7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)

6 × 25 mm

8 × 28 mm17 N • m (1.7 kgf • m, 12 ft • Ib)

17 N • m (1.7 kgf • m, 12 ft • Ib)

8 × 40 mm17 N • m (1.7 kgf • m, 12 ft • Ib)

LT

572

LT

E

5-3

EPOWR ENGINE UNIT

EXPLODED DIAGRAM

*: As required.

Step Procedure/Part name Q’ty Service points13 Bolt/washer 4/414 Shim *15 Engine unit 1


4

10

11

126

3

7

2

8

1

9

5

9

14

9

13

15

LT

271

LTLT

572

LT

7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)

6 × 25 mm

8 × 28 mm17 N • m (1.7 kgf • m, 12 ft • Ib)

17 N • m (1.7 kgf • m, 12 ft • Ib)

8 × 40 mm17 N • m (1.7 kgf • m, 12 ft • Ib)

LT

572

LT

E

5-4

EPOWR ENGINE UNIT

SERVICE POINTSCompression pressure measurementThe following procedure applies to all of thecylinders.

NOTE:Insufficient compression pressure will result ina loss of performance.


Out of specification → Adjust.Refer to “POWER UNIT” in Chapter 3.

2. Warm the engine up, and then put thewatercraft in a horizontal position.

3. Remove:• Air filter case cover 1 • Air filter element• Ignition coils• Spark plugs

CAUTION:Before removing the spark plugs, use com-pressed air to blow away any dirt accumu-lated in the spark plug wells to prevent itfrom falling into the cylinders.

4. Install:• Compression gauge extension 1 • Compression gauge 2

Compression gauge extension:90890-06582

Compression gauge:YU-33223-1/90890-03160

2

1

5-5

EPOWR ENGINE UNIT

5. Measure:• Compression pressure

Out of specification → Refer to steps (b)and (c).

6. Install:• Spark plug

Minimum compression pressure (reference data):

1,150 kPa (11.5 kgf/cm2, 164 psi)

Measurement steps:a. With the throttle wide open, crank the

engine until the reading on the compres-sion gauge stabilizes.

NOTE:The difference in compression pressurebetween cylinders should not exceed 100kPa (1 kgf/cm2, 14 psi).

b. If the compression pressure is extremelyhigh, check the cylinder head, valve sur-faces and piston crown for carbon depos-its.Carbon deposits → Eliminate.

c. If the compression pressure is below theminimum specification, squirt a few dropsof oil into the cylinder and measureagain.

Refer to the following table.

Compression pressure (with oil applied into the cylinder)

Reading Diagnosis

Higher than without oil

Piston ring wear, piston wear or damage → Repair.

Same as without oil

Valves, cylinder head gasket or pis-ton possibly defec-tive → Repair.

T R.

Spark plug:13 N • m (1.3 kgf • m, 9.4 ft • lb)

5-6

EPOWR ENGINE UNIT

7. Install:• Ignition coils• Air filter element• Air filter case cover

Oil filter removal and installation1. Remove:

• Oil filter 1

NOTE:Install the oil filter with the same special toolthat was used for removal.

Engine unit removal1. Remove:

• Engine unit

T R.

Ignition coils bolt:7.6 N • m (0.76 kgf • m, 5.5 ft • lb)LOCTITE 572


Oil filter wrench:YU-38411/90890-01426

T R.

Oil filter:17 N • m (1.7 kgf • m, 12 ft • lb)

Removal steps:

CAUTION:Lift the engine unit carefully trying not tohit it on the deck or letting it fall hard onthe hull.

• Suspend the engine unit using all threeengine hangers, and then separate theunit from the engine mount.

• Remove the hoist cable from the frontengine hanger and use the two rearengine hangers to suspend the engineunit.

• Lift the engine unit out vertically whileturning it clockwise.

1

5-7

EPOWR ENGINE UNIT

Shim removal1. Remove:

• Shims

NOTE:To ease reassembly and coupling alignment,remove the shims and organize them in theirrespective groups (e.g., front right, rear left)prior to removing the mounting bolts.

Engine mount inspection1. Inspect:

• Engine mountsCracks/damage → Replace.Refer to “ENGINE MOUNT” in Chapter8.

Coupling clearance inspection1. Measure:

• Clearance a • Clearance b


NOTE:Measure the clearances with a straightedgeand thickness gauge.

Clearance a:0–0.5 mm (0–0.020 in)

Clearance b:2–4 mm (0.079–0.157 in)

2. Adjust:• Clearance a and b

Adjustment steps:• Adjust the clearance a by adding or

removing shims.• Adjust the clearance b by moving the

engine unit position.

5-8

EPOWR EXHAUST PIPE 3

EXHAUST PIPE 3EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsEXHAUST PIPE 3 REMOVAL Follow the left “Step” for removal.Engine unit Refer to “ENGINE UNIT”.Air filter case Refer to “FUEL INJECTION SYSTEM” in

Chapter 4.1 Clamp/cooling water hose 1/1 È For cooling water outlet on stern side2 Clamp/cooling water hose 2/1 É For cooling water pilot outlet on port side3 Clamp/cooling water hose 2/1 Ê From water jacket4 Bolt 25 Thermoswitch (exhaust) 1

3

6

18

2

7

17

16

10

1211

8 9

131415

5

4

1

LT

572

LT

572

LT

572

LT

572

LT

242

LT

242

7th 15 N • m (1.5 kgf • m, 11 ft • Ib)

3rd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

10 × 40 mm11th 39 N • m (3.9 kgf • m, 28 ft • Ib)

LT

242

8th 15 N • m (1.5 kgf • m, 11 ft • Ib)

4th 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

10 × 45 mm12th 39 N • m (3.9 kgf • m, 28 ft • Ib)

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 16 mm

5th 15 N • m (1.5 kgf • m, 11 ft • Ib)

1st 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

10 × 35 mm9th 39 N • m (3.9 kgf • m, 28 ft • Ib)

6th 15 N • m (1.5 kgf • m, 11 ft • Ib)

2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

10 × 35 mm10th 39 N • m (3.9 kgf • m, 28 ft • Ib)

2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)

1st 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)

6 × 16 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

È

É

Ê

5-9


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points6 Exhaust joint clamp 2 Slide the outer exhaust joint for exhaust

manifold side7 Exhaust joint clamp 28 Bolt 1 NOTE:

Tighten the bolts in the sequence indicated.9 Bolt 110 Bolt 211 Collar 112 Exhaust pipe 3 113 Bolt 314 Exhaust pipe end 1

3

6

18

2

7

17

16

10

1211

8 9

131415

5

4

1

LT

572

LT

572

LT

572

LT

572

LT

242

LT

242

7th 15 N • m (1.5 kgf • m, 11 ft • Ib)

3rd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

10 × 40 mm11th 39 N • m (3.9 kgf • m, 28 ft • Ib)

LT

242

8th 15 N • m (1.5 kgf • m, 11 ft • Ib)

4th 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

10 × 45 mm12th 39 N • m (3.9 kgf • m, 28 ft • Ib)

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 16 mm

5th 15 N • m (1.5 kgf • m, 11 ft • Ib)

1st 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

10 × 35 mm9th 39 N • m (3.9 kgf • m, 28 ft • Ib)

6th 15 N • m (1.5 kgf • m, 11 ft • Ib)

2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

10 × 35 mm10th 39 N • m (3.9 kgf • m, 28 ft • Ib)

2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)

1st 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)

6 × 16 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

È

É

Ê

5-10


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points15 Gasket 1

16 Inner exhaust joint 117 Exhaust joint seal 118 Outer exhaust joint 1


3

6

18

2

7

17

16

10

1211

8 9

131415

5

4

1

LT

572

LT

572

LT

572

LT

572

LT

242

LT

242

7th 15 N • m (1.5 kgf • m, 11 ft • Ib)

3rd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

10 × 40 mm11th 39 N • m (3.9 kgf • m, 28 ft • Ib)

LT

242

8th 15 N • m (1.5 kgf • m, 11 ft • Ib)

4th 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

10 × 45 mm12th 39 N • m (3.9 kgf • m, 28 ft • Ib)

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 16 mm

5th 15 N • m (1.5 kgf • m, 11 ft • Ib)

1st 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

10 × 35 mm9th 39 N • m (3.9 kgf • m, 28 ft • Ib)

6th 15 N • m (1.5 kgf • m, 11 ft • Ib)

2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

10 × 35 mm10th 39 N • m (3.9 kgf • m, 28 ft • Ib)

2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)

1st 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)

6 × 16 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

È

É

Ê

Not reusable

5-11

EPOWR EXHAUST PIPES 1 AND 2

EXHAUST PIPES 1 AND 2EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsEXHAUST PIPES 1 AND 2 REMOVAL

Follow the left “Step” for removal.

Exhaust pipe 3 Refer to “EXHAUST PIPE 3”.Generator cover Refer to “GENERATOR AND STARTER

MOTOR”.1 Bolt 22 Bolt 13 Exhaust pipe stay 14 Nut 5 NOTE:

Tighten the nuts in the sequence indicated.

5 Exhaust pipe 2 1

E

E

E

LT

242LT

242

LT

242

1

94

8

10

12

13

6

7

5

4

4

4

2

3

11

È

È

6th 39 N • m (3.9 kgf • m, 28 ft • Ib)

1st 39 N • m (3.9 kgf • m, 28 ft • Ib)

2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)

1st 22 N • m (2.2 kgf • m, 16 ft • Ib)

8 × 75 mm3rd 35 N • m (3.5 kgf • m, 25 ft • Ib)

8 × 45 mm2nd 42 N • m (4.2 kgf • m, 30 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

10 × 35 mm2nd 42 N • m (4.2 kgf • m, 30 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

9th 39 N • m (3.9 kgf • m, 28 ft • Ib)

4th 39 N • m (3.9 kgf • m, 28 ft • Ib)

7th 39 N • m (3.9 kgf • m, 28 ft • Ib)

2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)

10th 39 N • m (3.9 kgf • m, 28 ft • Ib)

5th 39 N • m (3.9 kgf • m, 28 ft • Ib)

2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)

1st 22 N • m (2.2 kgf • m, 16 ft • Ib)

8 × 125 mm3rd 35 N • m (3.5 kgf • m, 25 ft • Ib)

8th 39 N • m (3.9 kgf • m, 28 ft • Ib)

3rd 39 N • m (3.9 kgf • m, 28 ft • Ib)

5-12

EPOWR EXHAUST PIPES 1 AND 2

EXPLODED DIAGRAM


7 Dowel pin 28 Clamp/cooling water hose 2/2 È From cooling water inlet9 Bolt 410 Bolt 611 Exhaust pipe 1 112 Gasket 113 Dowel pin 2


E

E

E

LT

242LT

242

LT

242

1

94

8

10

12

13

6

7

5

4

4

4

2

3

11

È

È

6th 39 N • m (3.9 kgf • m, 28 ft • Ib)

1st 39 N • m (3.9 kgf • m, 28 ft • Ib)

2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)

1st 22 N • m (2.2 kgf • m, 16 ft • Ib)

8 × 75 mm3rd 35 N • m (3.5 kgf • m, 25 ft • Ib)

8 × 45 mm2nd 42 N • m (4.2 kgf • m, 30 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

10 × 35 mm2nd 42 N • m (4.2 kgf • m, 30 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

9th 39 N • m (3.9 kgf • m, 28 ft • Ib)

4th 39 N • m (3.9 kgf • m, 28 ft • Ib)

7th 39 N • m (3.9 kgf • m, 28 ft • Ib)

2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)

10th 39 N • m (3.9 kgf • m, 28 ft • Ib)

5th 39 N • m (3.9 kgf • m, 28 ft • Ib)

2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)

1st 22 N • m (2.2 kgf • m, 16 ft • Ib)

8 × 125 mm3rd 35 N • m (3.5 kgf • m, 25 ft • Ib)

8th 39 N • m (3.9 kgf • m, 28 ft • Ib)

3rd 39 N • m (3.9 kgf • m, 28 ft • Ib)

Not reusable

Not reusable

5-13

EPOWR EXHAUST MANIFOLD

EXHAUST MANIFOLDEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsEXHAUST MANIFOLD REMOVAL Follow the left “Step” for removal.Exhaust pipes 1 and 2 Refer to “EXHAUST PIPES 1 AND 2”.

1 Joint assembly 1 È To cylinder block

NOTE:Install the cooling water hose with the whitemark a facing up.

2 Bolt 23 Bolt 44 Exhaust manifold 1 15 Dowel pin 2

4

3

2

5

6

710

10

9

8

5

LT

242

LT

242LT

242

LT

242

1

2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)

1st 22 N • m (2.2 kgf • m, 16 ft • Ib)

8 × 70 mm3rd 35 N • m (3.5 kgf • m, 25 ft • Ib)

a

È

2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)

1st 22 N • m (2.2 kgf • m, 16 ft • Ib)

8 × 95 mm3rd 35 N • m (3.5 kgf • m, 25 ft • Ib)

2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)

1st 22 N • m (2.2 kgf • m, 16 ft • Ib)

8 × 55 mm3rd 35 N • m (3.5 kgf • m, 25 ft • Ib)

2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)

1st 22 N • m (2.2 kgf • m, 16 ft • Ib)

8 × 95 mm3rd 35 N • m (3.5 kgf • m, 25 ft • Ib)

5-14

EPOWR EXHAUST MANIFOLD

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points6 Bolt 17 Bolt 48 Exhaust manifold 2 19 Gasket 110 Dowel pin 2


4

3

2

5

6

710

10

9

8

5

LT

242

LT

242LT

242

LT

242

1

2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)

1st 22 N • m (2.2 kgf • m, 16 ft • Ib)

8 × 70 mm3rd 35 N • m (3.5 kgf • m, 25 ft • Ib)

a

È

2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)

1st 22 N • m (2.2 kgf • m, 16 ft • Ib)

8 × 95 mm3rd 35 N • m (3.5 kgf • m, 25 ft • Ib)

2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)

1st 22 N • m (2.2 kgf • m, 16 ft • Ib)

8 × 55 mm3rd 35 N • m (3.5 kgf • m, 25 ft • Ib)

2nd 22 N • m (2.2 kgf • m, 16 ft • Ib)

1st 22 N • m (2.2 kgf • m, 16 ft • Ib)

8 × 95 mm3rd 35 N • m (3.5 kgf • m, 25 ft • Ib)

Not reusable

5-15

EPOWR OIL TANK

OIL TANKEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsOIL TANK REMOVAL Follow the left “Step” for removal.Engine unit Refer to “ENGINE UNIT”.Air filter case Refer to “FUEL INJECTION SYSTEM” in

Chapter 4.Thermostat housing Refer to “THERMOSTAT”.

1 Clamp/cooling water hose 1/1 È To exhaust joint2 Bolt 43 Water jacket 14 Gasket 15 Clamp/breather hose 2/16 Clamp/breather hose 2/1 É To oil pump

Ì

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

57225

21

27

2628

27

23

1916

1718

1514

2012

22

24

5

34

111

106

89

5

7

2

E

6

AA

6 × 35 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

6 × 30 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)

1st 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

3rd 39 N • m (3.9 kgf • m, 28 ft • Ib)

2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 85 mm2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)

1st 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

10 × 70 mm

3rd 39 N • m (3.9 kgf • m, 28 ft • Ib) 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)6 × 16 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 20 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)6 × 12 mm

È

Ë

É

Ê

Ì

13

a

4

LT

572

LT

572

Not reusable

5-16

EPOWR OIL TANK

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points7 Bolt 28 Collar 29 Oil separator 110 Clamp/breather hose 1/1 Ê To air filter case

Mark a 11 Clamp/breather hose 1/1 Ë From cylinder head cover12 Clamp/cooling water hose 1/1 Ì From cooling water inlet13 Bolt 114 Collar 115 Band 116 Bolt 317 Cover 1

Ì

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

57225

21

27

2628

27

23

1916

1718

1514

2012

22

24

5

34

111

106

89

5

7

2

E

6

AA

6 × 35 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

6 × 30 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)

1st 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

3rd 39 N • m (3.9 kgf • m, 28 ft • Ib)

2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 85 mm2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)

1st 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

10 × 70 mm


7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 20 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)6 × 12 mm

È

Ë

É

Ê

Ì

13

a

4

LT

572

LT

572

5-17

EPOWR OIL TANK

EXPLODED DIAGRAM


19 Bolt 220 Ground lead 221 Bolt 222 Nut 223 Bolt 524 Oil tank 125 Oil tank stay 126 Pin 227 O-ring 428 Connector 2


Ì

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

57225

21

27

2628

27

23

1916

1718

1514

2012

22

24

5

34

111

106

89

5

7

2

E

6

AA

6 × 35 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

6 × 30 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)

1st 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

3rd 39 N • m (3.9 kgf • m, 28 ft • Ib)

2nd 39 N • m (3.9 kgf • m, 28 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 85 mm2nd 15 N • m (1.5 kgf • m, 11 ft • Ib)

1st 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

10 × 70 mm


7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 20 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)6 × 12 mm

È

Ë

É

Ê

Ì

13

a

4

LT

572

LT

572

Not reusable

Not reusable

5-18

EPOWR OIL TANK

EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsOIL TANK DISASSEMBLY Follow the left “Step” for disassembly.

1 Bolt/washer 2/22 Bracket/grommet 2/23 Bolt 44 Hunger 25 Oil tank filler cap 16 Packing 17 Bolt 88 Oil tank cover 19 Gasket 110 Bolt 10

E

E

E

E

3

4

9131211

10

1819

20

23

2

1

22 20

21

1917

15

1814

16

786

5

LT

572

LTLT

572

LT

LT

572

LT

LT

572

LT

LT

572

LT

6 × 25 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

5 × 14 mm2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)

1st 1.9 N • m (0.19 kgf • m, 1.4 ft • Ib)

6 × 20 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)6 × 20 mm

2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

6 × 14 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

5 × 35 mm

2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)

1st 1.9 N • m (0.19 kgf • m, 1.4 ft • Ib)

6 × 16 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

4 × 12 mm

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

Not reusable

5-19

EPOWR OIL TANK

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points11 Oil breather plate 1 112 Oil breather plate 2 113 Gasket 114 Bolt 315 Baffle plate 116 Bolt 217 Oil strainer 118 Bolt 2419 Oil cooler cover 220 Gasket 2

E

E

E

E

3

4

9131211

10

1819

20

23

2

1

22 20

21

1917

15

1814

16

786

5

LT

572

LTLT

572

LT

LT

572

LT

LT

572

LT

LT

572

LT

6 × 25 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

5 × 14 mm2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)

1st 1.9 N • m (0.19 kgf • m, 1.4 ft • Ib)

6 × 20 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)6 × 20 mm

2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

6 × 14 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

5 × 35 mm

2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)

1st 1.9 N • m (0.19 kgf • m, 1.4 ft • Ib)

6 × 16 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

4 × 12 mm

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

Not reusable

Not reusable

5-20

EPOWR OIL TANK

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points21 Screw 122 Anode 123 Oil tank 1


E

E

E

E

3

4

9131211

10

1819

20

23

2

1

22 20

21

1917

15

1814

16

786

5

LT

572

LTLT

572

LT

LT

572

LT

LT

572

LT

LT

572

LT

6 × 25 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

5 × 14 mm2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)

1st 1.9 N • m (0.19 kgf • m, 1.4 ft • Ib)

6 × 20 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)6 × 20 mm

2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

6 × 14 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

5 × 35 mm

2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib)

1st 1.9 N • m (0.19 kgf • m, 1.4 ft • Ib)

6 × 16 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

4 × 12 mm

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

5-21

EPOWR OIL TANK

SERVICE POINTSOil tank removal

1. Remove:• Oil tank

NOTE:Loosen the oil tank bolts and nuts in thesequence shown.

3

56 8

9

4

2

1

7

2. Remove:• Oil tank cover• Gasket

NOTE:Loosen the oil tank cover bolts in the sequenceshown.

1

2

6 7

3

4

85

3. Remove:• Oil breather plate 1 • Oil breather plate 2 • Gasket

NOTE:Loosen the oil breather plate bolts in thesequence shown.

3

4 5 6 1

2

78

5-22

EPOWR OIL TANK

4. Remove:• Oil cooler covers• Gaskets

NOTE:Loosen the oil cooler cover bolts in thesequence shown.81 9 12

7

6

51110

3

4

2

Oil strainer inspection1. Check:

• Oil strainer 1 Damage → Replace.Contaminants → Clean.

Oil tank installation1. Install:

• Gaskets• Oil cooler covers

NOTE:Tighten the oil cooler bolts in the sequenceshown.

T R.

Oil cooler cover bolt:1st:

3.7 N • m (0.37 kgf • m, 2.7 ft • lb)

2nd:7.6 N • m (0.76 kgf • m, 5.5 ft • lb)LOCTITE 572

512 4 1

6

7

823

10

9

11

5-23

EPOWR

2. Install:• Gasket• Oil breather plate 2• Oil breather plate 1

NOTE:Tighten the oil breather plate bolts in thesequence shown.

T R.

Oil breather plate bolt:1st:

1.9 N • m (0.19 kgf • m, 1.4 ft • lb)

2nd:4.4 N • m (0.44 kgf • m, 3.2 ft • lb)

6

5 4 3 8

7

21

3. Install:• Gasket• Oil tank cover

NOTE:Tighten the oil tank cover bolts in thesequence shown.

T R.

Oil tank cover bolt:1st:

3.7 N • m (0.37 kgf • m, 2.7 ft • lb)

2nd:7.6 N • m (0.76 kgf • m, 5.5 ft • lb)LOCTITE 572

8

7

3 2

6

5

14

OIL TANK

5-24

EPOWR OIL TANK

4. Install:• Oil tank

NOTE:Tighten the oil tank nuts and bolts in thesequence shown.

T R.

Bolt 1:1st:

15 N • m (1.5 kgf • m, 11 ft • lb)2nd:

39 N • m (3.9 kgf • m, 28 ft • lb)LOCTITE 572

Nut 2, bolt 3:1st:

2.0 N • m (0.2 kgf • m, 1.4 ft • lb)2nd:

15 N • m (1.5 kgf • m, 11 ft • lb)3rd:

39 N • m (3.9 kgf • m, 28 ft • lb)LOCTITE 572

7

51 3

4

6

8

9

2

1

2

2

3

5-25

EPOWR OIL PUMP

OIL PUMPEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsOIL PUMP ASSEMBLY REMOVAL


Oil tank Refer to “OIL TANK”.1 Drain plug/washer 1/1 Drain engine oil.2 Bolt 63 Bolt 14 Bolt 15 Bolt 26 Oil pump assembly 17 Gasket 18 Pin 2

2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 130 mm

6 × 25 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib)

2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 100 mm

2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 80 mm

2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

6 × 16 mm

LT

572

LT

LT

572

LT

18 N • m (1.8 kgf • m, 13 ft • Ib)8 × 12 mm

LT

572

LT

16

8

8

3

4

5

2

7

9

9

10

Not reusable

5-26

EPOWR OIL PUMP

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points9 Bolt 210 Strainer 1


2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 130 mm

6 × 25 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib)

2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 100 mm

2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 80 mm

2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

6 × 16 mm

LT

572

LT

LT

572

LT

18 N • m (1.8 kgf • m, 13 ft • Ib)8 × 12 mm

LT

572

LT

16

8

8

3

4

5

2

7

9

9

10

5-27

EPOWR OIL PUMP

EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsOIL PUMP DISASSEMBLY Follow the left “Step” for disassembly.

1 Bolt 12 Bolt 33 Oil pump housing cover 1 14 Gasket 15 Oil pump housing 1 16 Check valve assembly 17 Oil pump housing 2 18 Gasket 19 Outer rotor (scavenge) 210 Inner rotor (scavenge) 2

E

8 × 70 mm 20 N • m (2.0 kgf • m, 14 ft • Ib)

8 × 20 mm 20 N • m (2.0 kgf • m, 14 ft • Ib)

4 × 12 mm 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

E E

E

2

1

3

20

18

21

224

5

23

179

10

87

10 11

919

616

15

14

13

12

Not reusable

Not reusable

5-28

EPOWR OIL PUMP

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points11 Pin 112 Screw 113 Oil pump housing cover 2 114 Gasket 115 Spring 116 Plunger 117 Pin 118 Pin 119 Oil pump shaft 120 Inner rotor (feed) 121 Outer rotor (feed) 1

E

8 × 70 mm 20 N • m (2.0 kgf • m, 14 ft • Ib)

8 × 20 mm 20 N • m (2.0 kgf • m, 14 ft • Ib)

4 × 12 mm 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

E E

E

2

1

3

20

18

21

224

5

23

179

10

87

10 11

919

616

15

14

13

12

Not reusable

5-29

EPOWR OIL PUMP

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points22 Check valve seat 123 Oil seal 1


E

8 × 70 mm 20 N • m (2.0 kgf • m, 14 ft • Ib)

8 × 20 mm 20 N • m (2.0 kgf • m, 14 ft • Ib)

4 × 12 mm 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

E E

E

2

1

3

20

18

21

224

5

23

179

10

87

10 11

919

616

15

14

13

12

Not reusable

5-30

EPOWR OIL PUMP

SERVICE POINTSOil pump inspection

1. Check:• Oil pump housing cover 1 1 • Oil pump housing cover 2 2 • Oil pump housing 1 3 • Oil pump housing 2 4

Cracks/damage/wear → Replace thedefective part(s).

12

34

2. Measure:• Inner-rotor-to-outer-rotor-tip clearance

a • Outer-rotor-to-oil-pump-housing

clearance b Out of specification → Replace the oilpump.

1 Inner rotor2 Outer rotor3 Oil pump housing

Inner-rotor-to-outer-rotor-tip clearance a:

0.09–0.15 mm (0.0035–0.0059 in)Outer-rotor-to-oil-pump-housing clearance b (scavenge pump):

0.09–0.15 mm (0.0035–0.0059 in)Outer-rotor-to-oil-pump-housing clearance b (feed pump):

0.09–0.17 mm (0.0035–0.0067 in)

3. Check:• Oil pump operation

Rough movement → Replace the defec-tive part(s).

Check valve inspection1. Check:

• Check valve seat 1 • Check valve body 2 • Check valve 3 • Spring 4

Damage/wear → Replace the defectivepart(s).

1 2 3 4

5-31

EPOWR OIL PUMP

Oil strainer inspection1. Check:

• Oil strainer 1 Damage → Replace.Contaminants → Clean.

1

Oil pump installation1. Install:

• Oil pump assembly

NOTE:Align the projection a on the oil pump shaftwith the slit b on the oil pump driven gearshaft.

T R.

Oil pump assembly bolt:M6:

10 N • m (1.0 kgf • m, 7.2 ft • lb)LOCTITE 572

M8:1st:

15 N • m (1.5 kgf • m, 11 ft • lb)

2nd:28 N • m (2.8 kgf • m, 20 ft • lb)LOCTITE 572

a

b

5-32

EPOWR REDUCTION DRIVE GEAR

REDUCTION DRIVE GEAREXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsREDUCTION DRIVE GEAR REMOVAL


Generator cover Refer to “GENERATOR AND STARTER MOTOR”.

Oil pump Refer to “OIL PUMP”.1 Bolt 12 Bolt 13 Bolt 14 Bolt 35 Bolt 1

8

8

911

10119

7

3

2

4

125 4

6

E

LT

572

LT

LT

572

LT

LT

572

LT

LT

572

LT

LT

572

LT

6 × 55 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

28 N • m (2.8 kgf • m, 20 ft • Ib)

6 × 35 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

8 × 40 mm2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 70 mm2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

1

8 × 100 mm2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

5-33


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points6 Reduction drive gear case

assembly1

7 Gasket 18 Pin 29 Circlip 210 Reduction drive gear 111 Washer 212 Drive coupling 1


8

8

911

10119

7

3

2

4

125 4

6

E

LT

572

LT

LT

572

LT

LT

572

LT

LT

572

LT

LT

572

LT

6 × 55 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

28 N • m (2.8 kgf • m, 20 ft • Ib)

6 × 35 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

8 × 40 mm2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 70 mm2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

1

8 × 100 mm2nd 28 N • m (2.8 kgf • m, 20 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

Not reusable

Not reusable

5-34


EXPLODED DIAGRAM


*1: EPNOC grease AP #0

Step Procedure/Part name Q’ty Service pointsREDUCTION DRIVE GEAR DISASSEMBLY


1 Oil pump drive shaft 12 Drive shaft 13 Collar 14 Oil seal 25 Circlip 1

6 Bearing 1

7 Collar 18 Bearing 1

E

E

E

E

34

8

6

5

109

1

*1

AA

*1

5 × 10 mm

E

2

11

7

Not reusableNot reusableNot reusable

Not reusable

5-35


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service points9 Circlip 1

10 Bearing 1

11 Reduction drive gear case 1Reverse the disassembly steps for assembly.

E

E

E

E

34

8

6

5

109

1

*1

AA

*1

5 × 10 mm

E

2

11

7

Not reusableNot reusable

5-36


SERVICE POINTSDrive coupling removal

1. Remove:• Reduction drive gear housing

2. Remove:• Drive coupling 1

NOTE:While holding the drive shaft 2 with the rotorholder 3, loosen the drive coupling with thecoupler wrench 4.

Coupler wrench:YW-06551/90890-06551

Universal magneto and rotor holder:

YU-01235Rotor holder:

90890-01235

1

4

23

Drive shaft removal1. Remove:

• Drive shaft

NOTE:Press in the direction of the arrow.

Bearing removal1. Remove:

• Circlip• Rear bearing• Collar• Front bearing

NOTE:Remove the front bearing, spacer, and rearbearing using a press.

È For USA and CanadaÉ For worldwide

Driver handle—large:YB-06071

Driver rod L3:90890-06652

Bearing housing needle bearing installer:

YB-06111Needle bearing attachment:

90890-06653

È

É

5-37


2. Remove:• Circlip• Reduction drive gear bearing


Slide hammer and adapters:YB-06096

Stopper guide plate:90890-06501

Bearing puller assembly:90890-06535

Stopper guide stand:90890-06538

È

É

Oil pump drive shaft inspection1. Check:

• Oil pump drive shaft 1 Cracks/damage/wear → Replace.

1

Drive shaft inspection1. Check:

• Drive shaft 1 Cracks/damage/wear → Replace.

1

5-38


Bearing installing1. Install:

• Reduction drive gear bearing

NOTE:Install the reduction driver gear bearing usinga press.


Driver rod LS:90890-06606

Outer race installer—forward gear:

YB-06085Ball bearing attachment:

90890-06631

2. Install:• Front bearing

NOTE:Install the front bearing using a press.



Forward gear bearing cup installer:

YB-06726-BBall bearing attachment:

90890-06657

È

É

5-39


3. Install:• Collar• Rear bearing

NOTE:• Install the front bearing using a press.• Before installing the rear bearing, hold both

the inner and outer races of the front bearingin place as shown with a pipe that is at least40 mm (1.57 in) long and has an outer diam-eter of 70 mm (2.76 in) and an inner diame-ter of 30 mm (1.18 in).




YB-06085Bearing outer race attachment:

90890-06624

È

É

4. Install:• Oil seals






90890-06624

Distance a:17.9 ± 0.2 mm (0.70 ± 0.01 in)

Distance b:9.3 ± 0.2 mm (0.37 ± 0.01 in)

a b

È

a b

É

5-40


Drive shaft installation1. Install:

• Drive shaft• Collar

NOTE:Press the into the reduction drive gear casewith a pipe that is more than 30 mm (1.18 in)long, and which has an outer diameter ofapproximately 35 mm (1.97 in) and an innerdiameter of approximately 28 ± 0.5 mm (1.10 ±0.02 in).

Drive coupling installation 1. Install:

• Drive coupling 1

NOTE:While holding the drive shaft 2 with the rotorholder 3, tighten the drive coupling with thecoupler wrench 4.

2. Install:• Reduction drive gear housing




90890-01235

1

4

23

5-41

EPOWR GENERATOR AND STARTER MOTOR

GENERATOR AND STARTER MOTOREXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsGENERATOR COVER AND FLYWHEEL MAGNETO REMOVAL


Engine unit Refer to “ENGINE UNIT”.1 Nut/washer 1/12 Starter motor lead 13 Bolt 24 Battery negative lead 15 Starter motor 16 Band 17 Lighting coil coupler 1

43

21

5

6

8

7

9

10 1113

12

18

16

17

19

2021

15

14

AA

E

E

E

LT

572

LT

572

AA

AA

8 × 30 mm18 N • m (1.8 kgf • m, 13 ft • Ib)

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

10 × 47 mm75 N • m (7.5 kgf • m, 54 ft • Ib)

8 × 20 mm24 N • m (2.4 kgf • m, 17 ft • Ib)

10 × 60 mm2nd 50 N • m (5.0 kgf • m, 36 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

LT

572

LT

572

2nd 50 N • m (5.0 kgf • m, 36 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

5-42


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points8 Pulser coil coupler 19 Nut 210 Bolt 811 Generator cover 112 Dowel pin 213 Gasket 114 Idle gear shaft 115 Idle gear 116 Bolt/washer 1/117 Flywheel magneto 118 Bolt 6

43

21

5

6

8

7

9

10 1113

12

18

16

17

19

2021

15

14

AA

E

E

E

LT

572

LT

572

AA

AA

8 × 30 mm18 N • m (1.8 kgf • m, 13 ft • Ib)

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

10 × 47 mm75 N • m (7.5 kgf • m, 54 ft • Ib)

8 × 20 mm24 N • m (2.4 kgf • m, 17 ft • Ib)

10 × 60 mm2nd 50 N • m (5.0 kgf • m, 36 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

LT

572

LT

572

2nd 50 N • m (5.0 kgf • m, 36 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

Not reusable

Not reusable

5-43


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points19 Starter clutch 120 Starter gear 121 Woodruff key 1


43

21

5

6

8

7

9

10 1113

12

18

16

17

19

2021

15

14

AA

E

E

E

LT

572

LT

572

AA

AA

8 × 30 mm18 N • m (1.8 kgf • m, 13 ft • Ib)

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

10 × 47 mm75 N • m (7.5 kgf • m, 54 ft • Ib)

8 × 20 mm24 N • m (2.4 kgf • m, 17 ft • Ib)

10 × 60 mm2nd 50 N • m (5.0 kgf • m, 36 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

LT

572

LT

572

2nd 50 N • m (5.0 kgf • m, 36 ft • Ib)

1st 15 N • m (1.5 kgf • m, 11 ft • Ib)

5-44


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsGENERATOR DISASSEMBLY Follow the left “Step” for disassembly.

1 Bolt/washer 3/32 Bolt 43 Pickup coil 2 NOTE:

There washers holds the pickup coil lead.Make sure to not pitch the lead between theprojection and the washer when installingthe bolt.

4 Bolt 2

1

7

63

24

5

LT

242

LT

242

LT

242 LT

242

14 N • m (1.4 kgf • m, 10 ft • Ib)6 × 14 mm

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

5 × 14 mm

14 N • m (1.4 kgf • m, 10 ft • Ib)

6 × 33 mm

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)5 × 10 mm

1

1

2

3

5-45


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points5 Holder 16 Bolt 37 Lighting coil 1


1

7

63

24

5

LT

242

LT

242

LT

242 LT

242

14 N • m (1.4 kgf • m, 10 ft • Ib)6 × 14 mm

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

5 × 14 mm

14 N • m (1.4 kgf • m, 10 ft • Ib)

6 × 33 mm

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)5 × 10 mm

1

1

2

3

5-46


SERVICE POINTSFlywheel magneto removal

1. Remove:• Flywheel magneto bolt 1 • Washer

NOTE:While holding the flywheel magneto 2 with thesheave holder 3, loosen the flywheel magnetobolt.

Sheave holder:YS-01880-A/90890-01701

2. Remove:• Flywheel magneto 1 • Woodruff key

NOTE:While holding the flywheel magneto withsheave holder 2, remove the flywheel mag-neto with the rotor puller 3.

Rotor puller:YM-01082/90890-01080

Starter clutch inspection1. Check:

• Starter clutch rollers 1 Damage/wear → Replace.

5-47


2. Check:• Starter clutch 1 • Starter gear 2

Burrs/chips/roughness/wear → Replacethe defective part(s).

3. Check:• Starter clutch gear’s contacting surfaces

a Damage/pitting/wear → Replace thestarter clutch gear.

12

a

4. Check:• Starter clutch operation

Checking steps:• Install the starter gear 1 onto the starter

clutch 2 and hold the starter clutch.• When turning the starter gear clockwise

È, it should turn freely, otherwise thestarter clutch is faulty and must bereplaced.

• When turning the starter gear counter-clockwise É, the starter clutch and thestarter gear should engage, otherwisethe starter clutch is faulty and must bereplaced.

5-48


Flywheel magneto installation1. Install:

• Woodruff key• Flywheel magneto• Washer• Flywheel magneto bolt

NOTE:• Clean the tapered portion of the crankshaft

and the flywheel magneto hub.• When installing the flywheel magneto, make

sure the woodruff key is properly seated inthe keyway of the crankshaft.

• Lubricate the flywheel magneto bolt andwasher with engine oil.

2. Tighten:• Flywheel magneto bolt 1

NOTE:While holding the flywheel magneto 2 with thesheave holder 3, tighten the flywheel mag-neto bolt.

CAUTION:Do not reuse the flywheel magneto bolt andwasher, always replace them with newones.

T R.

Flywheel magneto bolt:75 N • m (7.5 kgf • m, 54 ft • lb)

Sheave holder:YS-01880-A/90890-01701

5-49

EPOWR CAMSHAFTS

CAMSHAFTSEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsCYLINDER HEAD COVER REMOVAL


Air filter case Refer to “FUEL INJECTION SYSTEM” in Chapter 4.

1 Bolt 42 Ignition coil 43 Spark plug 44 Clamp/breather hose 1/1 È To oil tank

Paint mark a 5 Bolt 16 Cam position sensor 1

E

4

6

5

78

1011

15

16

9

LT

572

LT

17

19

18

3

13 N • m (1.3 kgf • m, 9.4 ft • Ib)

10 N • m (1.0 kgf • m, 7.2 ft • Ib)

6 × 16 mm6 × 16 mm

2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 22 mm

a

È

É

6 × 16 mm

12

14

131

2

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 16 mm

LT

572

LT

GM

GM

5-50

EPOWR CAMSHAFTS

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points7 Clamp/cooling water hose 1/1 É To thermostat8 Rubber seal 19 Bolt 110 Cooling water pipe 111 O-ring 112 Bolt 113 Band 114 Collar 115 Bolt 616 Rubber mount 617 Cylinder head cover 1

E

4

6

5

78

1011

15

16

9

LT

572

LT

17

19

18

3

13 N • m (1.3 kgf • m, 9.4 ft • Ib)

10 N • m (1.0 kgf • m, 7.2 ft • Ib)

6 × 16 mm6 × 16 mm

2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 22 mm

a

È

É

6 × 16 mm

12

14

131

2

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 16 mm

LT

572

LT

GM

GM

Not reusable

5-51

EPOWR CAMSHAFTS

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points18 Cylinder head cover gasket 1

19 Timing chain guide (top side) 1Reverse the removal steps for installation.

E

4

6

5

78

1011

15

16

9

LT

572

LT

17

19

18

3

13 N • m (1.3 kgf • m, 9.4 ft • Ib)

10 N • m (1.0 kgf • m, 7.2 ft • Ib)

6 × 16 mm6 × 16 mm

2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 22 mm

a

È

É

6 × 16 mm

12

14

131

2

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 16 mm

LT

572

LT

GM

GM

Not reusable

5-52

EPOWR CAMSHAFTS

EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsCAMSHAFT REMOVAL Follow the left “Step” for removal.Cylinder head coverReduction drive gear case Refer to “REDUCTION DRIVE GEAR”.

NOTE:When removing camshafts it is not neces-sary to remove the reduction drive gearcase.

1 Cap bolt 12 Gasket 13 Bolt 24 Timing chain tensioner 1

E

EE

E

E

E

M

M

10

111011

1011

12

16

17

818

8

8

13

9 14

7

15 6

20

19

1

2

3

45

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 35 mm

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 35 mm

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 25 mm

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 8 mm

24 N • m (2.4 kgf • m, 17 ft • Ib)

7 × 11 mm

24 N • m (2.4 kgf • m, 17 ft • Ib)

7 × 11 mm

Not reusable

5-53

EPOWR CAMSHAFTS

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points5 Timing chain tensioner gasket 1

6 Timing chain guide (exhaust side) 17 Bolt 188 Intake camshaft cap 39 Dowel pin 6 NOTE:

During removal, the dowel pins may still beconnected to the camshaft caps.

10 Bolt 1011 Exhaust camshaft cap 312 Dowel pin 613 Intake camshaft 114 Bolt 215 Intake camshaft sprocket 1

E

EE

E

E

E

M

M

10

111011

1011

12

16

17

818

8

8

13

9 14

7

15 6

20

19

1

2

3

45

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 35 mm

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 35 mm

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 25 mm

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 8 mm

24 N • m (2.4 kgf • m, 17 ft • Ib)

7 × 11 mm

24 N • m (2.4 kgf • m, 17 ft • Ib)

7 × 11 mm

Not reusable

5-54

EPOWR CAMSHAFTS

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points16 Exhaust camshaft 117 Bolt 218 Exhaust camshaft sprocket 119 Pin 120 Timing chain guide (intake side) 1


E

EE

E

E

E

M

M

10

111011

1011

12

16

17

818

8

8

13

9 14

7

15 6

20

19

1

2

3

45

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 35 mm

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 35 mm

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 25 mm

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 8 mm

24 N • m (2.4 kgf • m, 17 ft • Ib)

7 × 11 mm

24 N • m (2.4 kgf • m, 17 ft • Ib)

7 × 11 mm

5-55

EPOWR CAMSHAFTS

SERVICE POINTSCamshaft removal

1. Install:• Dial gauge needle• Dial gauge stand 1

(into spark plug hole #1)• Dial gauge 2

2. Turn the drive coupling counterclockwise,and then check if cylinder #1 is at TDC ofthe compression stroke with a dial gauge.

NOTE:TDC on the compression stroke can be foundwhen the camshaft lobes are turned away fromeach other.

Dial gauge stand:90890-06583

Dial gauge needle:90890-06584

Dial gauge stand set:YW-06585/90890-06585

Dial gauge:YU-03097/90890-01252

2

1

IN EX

3. Make the alignment marks a on the timingchain and camshaft sprockets.a

4. Remove:• Timing chain tensioner 1 • Gasket

1

5-56

EPOWR CAMSHAFTS

5. Remove:• Camshaft caps• Dowel pins

NOTE:Loosen the intake and exhaust camshaft capbolts in the sequence shown.

110763

21418151141075

289451121617136893

6. Remove:• Intake camshaft 1 • Exhaust camshaft 2

NOTE:To prevent the timing chain from falling into thecrankcase, fasten it with a wire 3.

7. Remove:• Exhaust camshaft sprocket 1 • Intake camshaft sprocket 2

(with the special tool 3)



90890-01235

Camshaft inspection1. Check:

• Camshaft lobesBlue discoloration/pitting/scratches →Replace the camshaft.

2. Measure:• Camshaft lobe dimensions a and b

Out of specification → Replace the cam-shaft.

Cam lobe dimensions:Intake camshaft:a 32.55 mm (1.281 in)b 25.00 mm (0.984 in)

Exhaust camshaft:a 33.00 mm (1.299 in)b 25.00 mm (0.984 in)

5-57

EPOWR CAMSHAFTS

3. Measure:• Camshaft runout


Maximum camshaft runout:0.03 mm (0.0012 in)

4. Measure:• Camshaft-journal-to-camshaft-cap

clearanceOut of specification → Measure thecamshaft journal diameter.

Camshaft-journal-to-camshaft-cap clearance:

0.03–0.06 mm (0.0012–0.0024 in)

Measurement steps:• Install the camshaft into the cylinder head

(without the dowel pins and camshaftcaps).

• Position a strip of Plastigauge 1 onto thecamshaft journal as shown.

• Install the dowel pins and camshaft caps.

NOTE:• Tighten the intake and exhaust camshaft

cap bolts in the sequence shown.• Do not turn the camshaft when measuring

the camshaft journal-to-camshaft capclearance with the Plastigauge.

T R.


• Remove the camshaft caps and thenmeasure the width of the Plastigauge 1.

101458

1751481591214

9327618732613111016

5-58

EPOWR CAMSHAFTS

5. Measure:• Camshaft journal diameter a

Out of specification → Replace the cam-shaft.Within specification → Replace the cyl-inder head and the camshaft caps as aset.

Camshaft journal diameter:24.46–24.47 mm (0.9630–0.9634 in)

Camshaft sprockets inspection1. Check:

• Camshaft sprocketWear/damage → Replace the camshaftsprockets and timing chain as a set.

a 1/4 of a toothb Correct1 Timing chain2 Camshaft sprocket

Timing chain tensioner inspection1. Check:

• Timing chain tensionerCracks/damage/rough movement → Replace.

Checking steps:• While lightly pressing the timing chain

tensioner rod by hand, turn the tensionerrod fully clockwise with a thin screwdriver1.

• Remove the screwdriver and slowlyrelease the timing chain tensioner rod.

• Make sure that the timing chain tensionerrod comes out of the timing chain ten-sioner housing smoothly. If there is roughmovement, replace the timing chain ten-sioner.

5-59

EPOWR CAMSHAFTS

Camshaft installation1. Install:

• Exhaust camshaft sprocket 1 • Intake camshaft sprocket 2

(with the special tool 3)

NOTE:Install the camshaft sprocket with the punchmark a facing outside.



90890-01235

T R.

Camshaft sprocket bolt:24 N • m (2.4 kgf • m, 17 ft • lb)

2. Install:• Exhaust camshaft• Intake camshaft• Exhaust camshaft caps• Intake camshaft caps

Installation steps:• Turn the drive coupling counterclockwise,

and then check if cylinder #1 is at TDC ofthe compression stroke with a dial gauge.

• Install the timing chain onto both cam-shaft sprockets, and then install the cam-shaft.

CAUTION:Do not turn the crankshaft when install-ing the camshaft to avoid damage orimproper valve timing.

NOTE:• Make sure that the punch marks a on the

camshafts face up.• Be sure to align the alignment marks b

made during removal to install the timingchain and camshaft sprockets.

b

5-60

EPOWR CAMSHAFTS

• Install the exhaust and intake camshaftcaps.

NOTE:Gradually tighten the intake and exhaustcamshaft cap bolts in 2–3 steps in thesequence shown.

T R.


NOTE:Make sure that the punch marks c on thecamshafts are aligned with the arrow marksd on the camshaft caps.Out of alignment → Reinstall.

• Remove the wire from the timing chain.

101458

1751481591214

9327618732613111016

3. Install:• Timing chain tensioner

Installation steps:• While lightly pressing the timing chain

tensioner rod by hand, turn the tensionerrod fully clockwise with a thin screwdriver1.

NOTE:Make sure that the tensioner rod has beenfully set clockwise.

• With the timing chain tensioner rodturned all the way into the timing chaintensioner housing (with the thin screw-driver still installed), install the gasket andthe timing chain tensioner 2 onto the cyl-inder block.

WARNINGAlways use a new gasket.

• Tighten the timing chain tensioner bolts3 to the specified torque.

NOTE:The “UP” mark on the timing chain ten-sioner should face up.

2

33

5-61

EPOWR CAMSHAFTS

T R.

Timing chain tensioner bolt:10 N • m (1.0 kgf • m, 7.2 ft • lb)

• Remove the screwdriver, make sure thetiming chain tensioner rod releases, andthen tighten the cap bolt to the specifiedtorque.

T R.

Cap bolt:10 N • m (1.0 kgf • m, 7.2 ft • lb)

4. Turn:• Drive coupling

(several turns counterclockwise)

5. Check:Turn the drive coupling counterclock-wise, and then check if cylinder #1 is atTDC of the compression stroke with adial gauge.

• Camshaft punch marks a Make sure that the camshaft punchmarks are aligned with the arrow marksb on the camshaft caps.Out of alignment → Adjust.Refer to the installation steps above.


Out of specification → Adjust.Refer to “POWER UNIT” in Chapter 3.

5-62

EPOWR CAMSHAFTS

7. Install:• Cylinder head cover gasket• Cylinder head cover

NOTE:• Apply Gasket Maker onto the mating sur-

faces of the cylinder head cover gasket andcylinder head.

• Tighten the cylinder head cover bolts stagesand in a crisscross pattern.

T R.

Cylinder head cover bolt:12 N • m (1.2 kgf • m, 8.7 ft • lb)

5-63

EPOWR CYLINDER HEAD

CYLINDER HEADEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsCYLINDER HEAD REMOVAL Follow the left “Step” for removal.Engine unit Refer to “ENGINE UNIT”.Air filter case Refer to “FUEL INJECTION SYSTEM” in

Chapter 4.Exhaust pipe 3 Refer to “EXHAUST PIPE 3”.Exhaust pipes 1 and 2 Refer to “EXHAUST PIPES 1 AND 2”.Oil tank Refer to “OIL TANK”.Intake and exhaust camshaft Refer to “CAMSHAFTS”.

1 Bolt 22 Hunger 13 Bolt 3

E

EE

E EE

2

4

1

8

55

7

9

355

6

LT

271

2nd 121 ± 5˚

1st 20 N • m (2.0 kgf • m, 14 ft • Ib)

2nd 140 ± 5˚

1st 20 N • m (2.0 kgf • m, 14 ft • Ib)

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 12 mm

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 55 mm

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 12 mm

40 N • m (4.0 kgf • m, 29 ft • Ib)8 × 20 mm

5

2nd 105 ± 5˚

1st 20 N • m (2.0 kgf • m, 14 ft • Ib)E

5-64

EPOWR CYLINDER HEAD

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points4 Nut/washer 2/25 Nut/washer 6/66 Nut/washer 2/27 Cylinder head 18 Cylinder head gasket 19 Dowel pin 2


E

EE

E EE

2

4

1

8

55

7

9

355

6

LT

271

2nd 121 ± 5˚

1st 20 N • m (2.0 kgf • m, 14 ft • Ib)

2nd 140 ± 5˚

1st 20 N • m (2.0 kgf • m, 14 ft • Ib)

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 12 mm

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 55 mm

10 N • m (1.0 kgf • m, 7.2 ft • Ib)6 × 12 mm

40 N • m (4.0 kgf • m, 29 ft • Ib)8 × 20 mm

5

2nd 105 ± 5˚

1st 20 N • m (2.0 kgf • m, 14 ft • Ib)E

Not reusable

5-65

EPOWR CYLINDER HEAD

SERVICE POINTSCylinder head removal

1. Remove:• Cylinder head bolts 1

2. Remove:• Cylinder head nuts

NOTE:Loosen the cylinder head nuts in the sequenceshown.

Cylinder head inspection1. Eliminate:

• Combustion chamber carbon deposits (with a rounded scraper)

NOTE:Do not use a sharp instrument to avoid damag-ing or scratching:• spark plug bore threads• valve seats

2. Check:• Cylinder head

Damage/scratches → Replace.• Cylinder head water jacket

Mineral deposits/rust → Eliminate.

5-66

EPOWR CYLINDER HEAD

3. Measure:• Cylinder head warpage

Out of specification → Replace the cyl-inder head.

Cylinder head warpage limit:0.1 mm (0.004 in)

Measurement steps:• Place a straightedge 1 and a thickness

gauge 2 across the cylinder head.• Measure the warpage.• If the limit is exceeded, replace the cylin-

der head.

Cylinder head installation1. Install:

• Cylinder head

NOTE:• Pass the timing chain through the timing

chain cavity.• Lubricate the cylinder head nuts with engine

oil.• Tighten the cylinder head nuts in the

sequence shown.

T R.

Cylinder head nut 1:1st:

20 N • m (2.0 kgf • m, 14 ft • lb)2nd:

121 ± 5°Cylinder head nut 2:

1st:20 N • m (2.0 kgf • m, 14 ft • lb)

2nd:105 ± 5°

Cylinder head nut 3:1st:

20 N • m (2.0 kgf • m, 14 ft • lb)2nd:

140 ± 5°

5-67

EPOWR CYLINDER HEAD

2. Tighten:• Cylinder head bolts 1

NOTE:Lubricate the cylinder head bolts with engineoil.

T R.

Cylinder head bolt:10 N • m (1.0 kgf • m, 7.2 ft • lb)

5-68

EPOWR VALVES AND VALVE SPRINGS

VALVES AND VALVE SPRINGSEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsVALVES AND VALVE SPRINGS REMOVAL


Cylinder head Refer to “CYLINDER HEAD”.1 Intake valve lifter 122 Intake valve pad 123 Intake valve cotter 244 Intake valve upper spring seat 125 Intake valve spring 126 Intake valve oil seal 127 Intake valve lower spring seat 128 Intake valve 129 Intake valve guide 12

E

E

E

8

9

17

18

1615

1413

101112

12

34

5

67

312

Not reusable

Not reusable

5-69


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points10 Exhaust valve lifter 811 Exhaust valve pad 812 Exhaust valve cotter 1613 Exhaust valve upper spring seat 814 Exhaust valve spring 815 Exhaust valve oil seal 816 Exhaust valve lower spring seat 817 Exhaust valve 818 Exhaust valve guide 8


E

E

E

8

9

17

18

1615

1413

101112

12

34

5

67

312

Not reusable

Not reusable

5-70


SERVICE POINTSValve removal

1. Remove:• Valve lifter 1 • Valve pad 2

NOTE:Make a note of the position of each valve lifterand valve pad so that they can be reinstalled intheir original place.

2. Remove:• Valve cotters 1

NOTE:Remove the valve cotters by compressing thevalve spring with the valve spring compressor2 and attachment 3.

Valve spring compressor:YM-01253/90890-04019

Valve spring compressor attachment:

(for the intake valve)YM-4114/90890-04114

(for the exhaust valve)YM-4108/90890-04108

3. Remove:• Upper spring seat 1 • Valve spring 2 • Valve 3 • Oil seal 4 • Lower spring seat 5

NOTE:Identify the position of each part very carefullyso that it can be reinstalled in its original place.

5-71


Valve spring inspection1. Measure:

• Valve spring free length a Out of specification → Replace thevalve spring.

2. Measure:• Valve spring tilt a

Out of specification → Replace thevalve spring.

Valve spring free length:Intake valve spring:

38.90 mm (1.53 in)Exhaust valve spring:

40.67 mm (1.60 in)

Valve spring tilt:Intake valve spring:

1.7 mm (0.067 in)Exhaust valve spring:

1.8 mm (0.071 in)

Valve inspection1. Eliminate:

• Carbon deposits(from the valve face and valve seat)

2. Check:• Valve face

Pitting/wear → Replace the valve.

3. Measure:• Valve margin thickness a

Out of specification → Replace thevalve.

Valve margin thickness:0.5–0.9 mm (0.0197–0.0354 in)

5-72


4. Measure:• Valve stem diameter a


Valve stem diameter a:Intake valve:

3.975–3.990 mm (0.1565–0.1571 in)

Exhaust valve:4.465–4.480 mm (0.1758–0.1764 in)

5. Measure:• Valve stem runout


NOTE:• When installing a new valve, always replace

the valve guide.• If the valve is removed or replaced, always

replace the oil seal.

Valve stem runout:0.01 mm (0.0004 in)

Valve guide inspection

NOTE:Before checking the valve guide make surethat the valve stem diameter is within specifi-cation.

5-73


1. Measure:• Valve guide inside diameter a

2. Calculate the valve stem-to-valve guideclearance as follows. Replace the valveguide if out of specification.

Valve guide inside diameter:Intake:

4.000–4.012 mm (0.1575–0.1580 in)

Exhaust:4.500–4.512 mm (0.1772–0.1776 in)

Valve stem-to-valve guide clearance = valve guide inside diameter – valve stem diameter:

Intake:0.010–0.037 mm (0.0004–0.0015 in)

Exhaust:0.020–0.047 mm (0.0008–0.0019 in)

a

Valve guide replacement1. Remove the valve guide 1 by striking the

special service tool from the combustionchamber side.

Valve guide remover:Intake (ø4.0 mm):

YM-04111/90890-04111Exhaust (ø4.5 mm):

YM-04116/90890-04116

1

5-74


2. Install the new valve guide 2 by strikingthe special service tool from the camshaftside until the valve guide clip 3 contactsthe cylinder head.

NOTE:Apply engine oil to the surface of the newvalve guide.

Valve guide remover:Intake (ø4.0 mm):

YM-04111/90890-04111Exhaust (ø4.5 mm):

YM-04116/90890-04116Valve guide installer:

Intake (ø4.0 mm):YM-04112/90890-04112

Exhaust (ø4.5 mm):YM-04117/90890-04117

3

E

2

3. Insert the special service tool into thevalve guide 2, and then ream the valveguide.

NOTE:• Turn the valve guide reamer clockwise to

ream the valve guide.• Do not turn the reamer counterclockwise

when removing the reamer.

4. Measure:• Valve guide inside diameter

Valve guide reamer:Intake (ø4.0 mm):

YM-04113/90890-04113Exhaust (ø4.5 mm):

YM-04118/90890-04118

Valve guide inside diameter:Intake:

4.000–4.012 mm (0.1575–0.1580 in)

Exhaust:4.500–4.512 mm (0.1772–0.1776 in)

2

5-75


Valve seat inspection1. Eliminate carbon deposits from the valve

with a scraper.

2. Apply a thin, even layer of Mechanic’sblueing dye (Dykem) onto the valve seat.

3. Lap the valve slowly on the valve seat witha valve lapper (commercially obtainable)as shown.

4. Measure the valve seat contact width awhere the blueing dye is adhered to thevalve face. Reface the valve seat if thevalve is not seated properly or if the valveseat contact width is out of specification.Replace the valve guide if the valve seatcontact is uneven.

Valve seat contact width a:0.9–1.1 mm (0.0354–0.0433 in)

5-76


Valve seat reface1. Reface the valve seat with the valve seat

cutter.

2. Cut the surface of the valve seat with a 45°cutter by turning the cutter clockwise untilthe valve seat face has become smooth.

a Slag or rough surface

CAUTION:Do not over cut the valve seat. Be sure toturn the cutter evenly downward at a pres-sure of 40–50 N (4–5 kgf, 8.8–11 lbf) to pre-vent chatter marks.

Valve seat cutter holder:Intake (ø4.0 mm):

90890-06811Exhaust (ø4.5 mm):

90890-06812Valve seat cutter:

30° (intake):90890-06815

45° (intake):90890-06814

60° (intake):90890-06813

30° (exhaust):90890-06328

45° (exhaust):90890-06312

60° (exhaust):90890-06315

Valve seat cutter set:YM-91043-C

3. Use a 30° cutter to adjust the contact widthof the top edge of the valve seat.

b Previous contact width

30˚

b

5-77


4. Use a 60° cutter to adjust the contact widthof the bottom edge of the valve seat.


60˚

b

5. Use a 45° cutter to adjust the contact widthof the valve seat to specification.

b Previous contact widthc Specified contact width

45˚

bc

6. If the valve seat contact area is too wideand situated in the center of the valveface, use a 30° cutter to cut the top edgeof the valve seat, a 60° cutter to cut thebottom edge to center the area and set itswidth.


7. If the valve seat contact area is too narrowand situated near the top edge of the valveface, use a 30° cutter to cut the top edgeof the valve seat. If necessary, use a 45°cutter to center the area and set its width.


8. If the valve seat contact area is too narrowand situated near the bottom edge of thevalve face, use a 60° cutter to cut the bot-tom edge of the valve seat. If necessary,use a 45° cutter to center the area and setits width.


5-78


9. Apply a thin, even layer of lapping com-pound onto the valve seat, and then lapthe valve using a valve lapper (commer-cially obtainable).

CAUTION:Do not get the lapping compound on thevalve stem and valve guide.

10. After every lapping procedure, be sure toclean off any remaining lapping compoundfrom the cylinder head and the valve.

11. Check the valve seat contact area of thevalve again.

Valve installation1. Install:

• Lower spring seat 1 • Oil seal 2 • Valve 3 • Valve spring 4 • Upper spring seat 5

(into the cylinder head)

NOTE:• Make sure that each valve is installed in its

original place. Refer to the followingembossed marks.Right and left intake valve(s): “4XV:”Middle intake valve(s): “4XV.”Exhaust valve(s): “5LV”

• Install the valve spring with the larger pitcha facing up.

b Smaller pitch

5-79


2. Compress the valve spring, and theninstall the valve cotter 1 using a thinscrewdriver with a small amount of greaseapplied to it.

Valve spring compressor:YM-01253/90890-04019

Valve spring compressor attachment:

(for the intake valve)YM-4114/90890-04114

(for the exhaust valve)YM-4108/90890-04108

3. Lightly tap the valve spring retainer with aplastic hammer to set the valve cottersecurely.

NOTE:Apply engine oil to the valve pads and valvelifters before installation.

5-80

EPOWR CRANKCASE

CRANKCASEEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsOIL PAN AND CRANKCASE REMOVAL


Engine unit Refer to “ENGINE UNIT”.Air filter case Refer to “FUEL INJECTION SYSTEM” in

Chapter 4.Exhaust pipe 3 Refer to “EXHAUST PIPE 3”.Exhaust pipes 1 and 2 Refer to “EXHAUST PIPES 1 AND 2”.Exhaust manifold Refer to “EXHAUST MANIFOLD”.Generator cover Refer to “GENERATOR AND STARTER

MOTOR”.

*: Loosen completely

6

2120

20

11109

8

7

2 3

45

16

15 17

18

13

14

12

19

1

LT

271

LT

LT

572

LT

LT

572

LT

LT

572

LT

LT

572

LT

LT

572

LT

E

E

AA

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 70 mm

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 20 mm20 N • m (2.0 kgf • m, 14 ft • Ib)8 × 40 mm

2nd *

3rd 15 N • m (1.5 kgf • m, 11 ft • Ib)

1st 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)

9 × 105 mm

4th 49 ± 5˚

8.4 N • m (0.84 kgf • m, 6.1 ft • Ib)

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 55 mm

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 55 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 16 mm

15 N • m (1.5 kgf • m, 11 ft • Ib)

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 20 mm

18

AA

GM

5-81

EPOWR CRANKCASE

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service pointsOil tank Refer to “OIL TANK”.Oil pump Refer to “OIL PUMP”.Reduction drive gear case Refer to “REDUCTION DRIVE GEAR”.Cylinder head Refer to “CAMSHAFTS”.

1 Timing chain 12 Engine temperature sensor 13 Washer 14 Bolt 25 Thermoswitch (engine) 16 Oil pressure switch 1

6

2120

20

11109

8

7

2 3

45

16

15 17

18

13

14

12

19

1

LT

271

LT

LT

572

LT

LT

572

LT

LT

572

LT

LT

572

LT

LT

572

LT

E

E

AA

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 70 mm

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 20 mm20 N • m (2.0 kgf • m, 14 ft • Ib)8 × 40 mm

2nd *

3rd 15 N • m (1.5 kgf • m, 11 ft • Ib)

1st 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)

9 × 105 mm

4th 49 ± 5˚

8.4 N • m (0.84 kgf • m, 6.1 ft • Ib)

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 55 mm

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 55 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 16 mm

15 N • m (1.5 kgf • m, 11 ft • Ib)

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 20 mm

18

AA

GM

5-82

EPOWR CRANKCASE

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points7 Bolt 18 Bolt 19 Anode cover 110 Grommet 111 Anode 112 Bolt 1513 Oil pan 114 Gasket 115 Bolt 216 Bolt 117 Bolt 7

6

2120

20

11109

8

7

2 3

45

16

15 17

18

13

14

12

19

1

LT

271

LT

LT

572

LT

LT

572

LT

LT

572

LT

LT

572

LT

LT

572

LT

E

E

AA

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 70 mm

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 20 mm20 N • m (2.0 kgf • m, 14 ft • Ib)8 × 40 mm

2nd *

3rd 15 N • m (1.5 kgf • m, 11 ft • Ib)

1st 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)

9 × 105 mm

4th 49 ± 5˚

8.4 N • m (0.84 kgf • m, 6.1 ft • Ib)

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 55 mm

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 55 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 16 mm

15 N • m (1.5 kgf • m, 11 ft • Ib)

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 20 mm

18

AA

GM

Not reusable

5-83

EPOWR CRANKCASE

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points18 Bolt/washer 10/10

19 Lower crankcase 120 Dowel pin 221 Dowel pin/O-ring 1/1


6

2120

20

11109

8

7

2 3

45

16

15 17

18

13

14

12

19

1

LT

271

LT

LT

572

LT

LT

572

LT

LT

572

LT

LT

572

LT

LT

572

LT

E

E

AA

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 70 mm

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 20 mm20 N • m (2.0 kgf • m, 14 ft • Ib)8 × 40 mm

2nd *

3rd 15 N • m (1.5 kgf • m, 11 ft • Ib)

1st 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)

9 × 105 mm

4th 49 ± 5˚

8.4 N • m (0.84 kgf • m, 6.1 ft • Ib)

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 55 mm

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 55 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 16 mm

15 N • m (1.5 kgf • m, 11 ft • Ib)

12 N • m (1.2 kgf • m, 8.7 ft • Ib)

6 × 20 mm

18

AA

GM

Not reusable

Not reusable

5-84

EPOWR CRANKCASE

EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsOIL PIPE AND OIL FILTER BOLT REMOVAL


Crankshaft Refer to “CRANKSHAFT”.1 Bolt 12 Oil pipe 13 O-ring 2

4 Oil filter bolt 15 Lower crankcase 1


E

E

5

1

2

3

4

AA

6 × 10 mm12 N • m (1.2 kgf • m, 8.7 ft • Ib)

35 N • m (3.5 kgf • m, 25 ft • Ib)

Not reusable

5-85

EPOWR CRANKCASE

SERVICE POINTSCrankcase disassembly

1. Remove:• Oil pan bolts

NOTE:• Loosen each bolt 1/4 of a turn at a time, in

stages and in a crisscross pattern. After all ofthe bolts are fully loosened, remove them.

• Loosen the bolts in decreasing numericalorder (refer to the numbers in the illustra-tion).

• The numbers embossed on the oil pan indi-cate the oil pan tightening sequence.

10 6 2 4 8 121511

7315913

14

2. Remove:• Crankcase bolts

NOTE:• Loosen each bolt 1/4 of a turn at a time, in

stages and in a crisscross pattern. After all ofthe bolts are fully loosened, remove them.

• Loosen the bolts in decreasing numericalorder (refer to the numbers in the illustra-tion).

• The numbers embossed on the crankcaseindicate the crankcase tightening sequence.

3. Remove:• Lower crankcase

CAUTION:Tap on one side of the crankcase with asoft-face hammer. Tap only on reinforcedportions of the crankcase, not on he crank-case mating surfaces. Work slowly andcarefully and make sure the crankcasehalves separate evenly.

M9 × 105 mm bolts: 1–0 M6 × 55 mm bolts: A–F M6 × 55 mm bolts: G, H M6 × 70 mm bolts: I M6 × 55 mm bolts: J

1 539 7

I C A E G

8 6 2 4 0

HF B D J

5-86

EPOWR CRANKCASE

4. Remove:• Dowel pins

Crankcase inspection1. Thoroughly wash the crankcase halves in

a mild solvent.

2. Thoroughly clean all the gasket surfacesand crankcase mating surfaces.

3. Check:• Crankcase

Cracks/damage → Replace.• Oil delivery passages

Obstruction → Blow out with com-pressed air.

Timing chain inspection1. Check:

• Timing chain 1 Damage/stiffness → Replace the timingchain and camshaft sprockets as a set.

5-87

EPOWR CRANKCASE

Crankcase assembly1. Lubricate:

Crankshaft journal bearings(with the recommended lubricant)

2. Apply:• Gasket Maker

(onto the crankcase mating surfaces)

NOTE:Do not allow any Gasket Maker to come intocontact with the oil gallery or crankshaft journalbearings.

Recommended lubricant:Engine oil

3. Install:• Dowel pins 1 • O-ring 2

GM

1 12

1

4. Install:• Crankcase bolts

NOTE:• Lubricate the bolt 1–0 threads and wash-

ers with engine oil.• Finger tighten the crankcase bolts.

M9 × 105 mm bolts: 1–0 M6 × 55 mm bolts: A–F M6 × 55 mm bolts: G, H M6 × 70 mm bolts: I M6 × 55 mm bolts: J

1 539 7

I C A E G

8 6 2 4 0

HF B D J

5-88

EPOWR CRANKCASE

5. Tighten:• Crankcase bolts 1–0

NOTE:• Do not reuse crankcase bolts 1–0.• The tightening procedure of crankcase bolts1–0 is angle controlled, therefore tightenthe bolts using the following procedure.

Tightening steps:• Tighten the bolts in the tightening

sequence cast on the crankcase.T R.

Crankcase bolt 1–0:1st:

7.8 N • m (0.78 kgf • m, 5.6 ft • lb)

• Loosen and retighten the crankcase boltsin the proper tightening sequence asshown.

T R.

Crankcase bolt 1–0:2nd:

Loosen completely3rd:

15 N • m (1.5 kgf • m, 11 ft • lb)

• Tighten the crankcase bolts further toreach the specified angle 49° in theproper tightening sequence as shown.

T R.

Crankcase bolt 1–0:Final:

Specified angle 49 ± 5°

WARNINGWhen the bolts are tightened more thanthe specified angle, do not loosen thebolt and then retighten it.Replace the bolt with a new one and per-form the procedure again.

1 539 7

I C A E G

8 6 2 4 0

HF B D J

5-89

EPOWR CRANKCASE

CAUTION:• Do not use a torque wrench to tighten

the bolt to the specified angle.• Tighten the bolt until it is at the speci-

fied angle.

NOTE:When using a hexagonal bolt, note that theangle from one corner to another is 60°.

6. Tighten: • Crankcase bolts A–J

NOTE:Tighten the bolts in the tightening sequencecast on the crankcase.

T R.

Crankcase bolt A–J:12 N • m (1.2 kgf • m, 8.7 ft • lb)

1 539 7

I C A E G

8 6 2 4 0

HF B D J

7. Tighten: • Oil pan bolts

NOTE:Tighten the bolts in the tightening sequencecast on the oil pan.

T R.

Oil pan bolt:12 N • m (1.2 kgf • m, 8.7 ft • lb)LOCTITE 572

10 6 2 4 8 121511

7315913

14

5-90

EPOWR CONNECTING RODS AND PISTONS

CONNECTING RODS AND PISTONSEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsCONNECTING RODS AND PISTONS REMOVAL


Crankcase SeparateRefer to “CRANKCASE”.

1 Nut 82 Connecting rod cap 43 Big end lower bearing 44 Piston pin clip 85 Piston pin 46 Piston 47 Connecting rod 4

EE

E

E

1

2

3

101112

45

6

87

9

2nd 120 ± 5˚

1st 20 N • m (2.0 kgf • m, 14 ft • Ib)

MM

MM

Not reusable

Not reusable

5-91


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points8 Bolt 8

9 Big end upper bearing 410 Top ring 411 2nd ring 412 Oil ring 4


EE

E

E

1

2

3

101112

45

6

87

9

2nd 120 ± 5˚

1st 20 N • m (2.0 kgf • m, 14 ft • Ib)

MM

MM

Not reusable

5-92


SERVICE POINTSConnecting rod and piston removalThe following procedure applies to all of theconnecting rods and pistons.

1. Remove: • Connecting rod cap 1 • Big end bearings

NOTE:Identify the position of each big end bearing sothat it can be reinstalled in its original place.

1

2. Remove:• Piston pin clips 1 • Piston pin 2 • Piston 3 • Connecting rod 4

CAUTION:Do not use a hammer to drive the pistonpin out.

NOTE:• For reference during installation, put an iden-

tification number a on the piston crown.• Before removing the piston pin, deburr the

piston pin clip’s groove and the piston’s pinbore area.

3. Remove: • Top ring • 2nd ring • Oil ring

NOTE:When removing a piston ring, open the endgap with your fingers and lift the other side ofthe ring over the piston crown.

5-93


Cylinder and piston inspectionThe following procedure applies to all of thecylinders and pistons.

1. Check: • Piston wall • Cylinder wall

Vertical scratches → Replace the cylin-der, and the piston and piston rings as aset.

2. Measure: • Piston-to-cylinder clearance

Measurement steps:• Measure cylinder bore “C” with the cylin-

der bore gauge.

Cylinder bore “C” 76.000–76.015 mm (2.9921–2.9927 in)

Taper limit “T” 0.08 mm (0.003 in)

Out of round “R” 0.05 mm (0.002 in)

“C” = maximum of D1–D6

“T” = maximum of D1–D5 (direction d) and D2–D6 (direction e)

“R” = maximum of D2–D1 (measuring point a) and D6–D5 (measuring point c)

• If out of specification, replace the cylin-der, and the piston and piston rings as aset.

• Measure piston skirt diameter “P” with themicrometer.

a 5 mm (0.2 in) from the bottom edge of thepiston

Piston size “P”

Standard75.895–75.910 mm (2.9880–2.9986 in)

D1D2

D3D4

D5D6

d

e

abc

5-94


• If out of specification, replace the pistonand piston rings as a set.

• Calculate the piston-to-cylinder clearancewith the following formula.

Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P”

Piston-to-cylinder clearance:0.10–0.11 mm (0.0039–0.0043 in)<Limit>: 0.17 mm (0.0067 in)

• If out of specification, replace the pistonand piston rings as a set.

Piston ring inspection1. Measure:

• Piston ring side clearance Out of specification → Replace the pis-ton and piston rings as a set.

NOTE:Before measuring the piston ring side clear-ance, eliminate any carbon deposits from thepiston ring grooves and piston rings.

Side clearance: Top ring:

0.030–0.065 mm (0.0012–0.0026 in)

2nd ring:0.020–0.055 mm (0.0008–0.0022 in)

Oil ring:0.040–0.160 mm (0.0016–0.0063 in)

5-95


2. Install:• Piston ring

(into the cylinder)

NOTE:Level the piston ring in the cylinder with thepiston crown.

a 5 mm (0.2 in)

3. Measure: • Piston ring end gap

Out of specification → Replace the pis-ton ring.

NOTE:The oil ring expander spacer’s end gap cannotbe measured. If the oil ring rail’s gap is exces-sive, replace all three piston rings.

Piston ring end gap: Top ring:

0.32–0.44 mm (0.0126–0.0173 in)

2nd ring:0.43–0.58 mm (0.0169–0.0228 in)

Oil ring:0.10–0.35 mm (0.0039–0.0138 in)

5-96


Piston pin inspectionThe following procedure applies to all of thepiston pins.

1. Check: • Piston pin

Blue discoloration/grooves → Replacethe piston pin and then check the lubri-cation system.

2. Measure: • Piston pin outside diameter a

Out of specification → Replace the pis-ton pin.

Piston pin outside diameter: 16.991–17.000 mm (0.6689–0.6693 in)<Limit>: 16.98 mm (0.67 in)

3. Measure: • Piston pin bore diameter (in the piston)

b Out of specification → Replace the pis-ton.

4. Calculate: • Piston-pin-to-piston clearance

Out of specification → Replace the pis-ton pin.

Piston pin bore diameter (in the piston):

17.002–17.013 mm (0.6693–0.6698 in)

Piston-pin-to-piston clearance = Piston pin bore diameter (in the piston) b – Piston pin outside diameter a

Piston-pin-to-piston clearance: 0.002–0.022 mm (0.0001–0.0009 in)

5-97


Connecting rod inspection1. Measure:

• Crankshaft-pin-to-big-end-bearing clearance Out of specification → Replace the bigend bearings.

Crankshaft-pin-to-big-end-bearing clearance:

0.016–0.040 mm (0.0006–0.0016 in)

Measurement steps:The following procedure applies to all of theconnecting rods.

CAUTION:Do not interchange the big end bearingsand connecting rods. To obtain the cor-rect crankshaft-pin-to-big-end-bearingclearance and prevent engine damage,the big end bearings must be installed intheir original positions.

• Clean the big end bearings, crankshaftpins, and the inside of the connecting rodhalves.

• Install the big end upper bearing into theconnecting rod and the big end lowerbearing into the connecting rod cap.

NOTE:Align the projections a on the big end bear-ings with the notches b in the connectingrod and connecting rod cap.

• Put a piece of Plastigauge 1 on thecrankshaft pin.

• Assemble the connecting rod halves.

1

5-98


NOTE:• Do not move the connecting rod or crank-

shaft until the clearance measurementhas been completed.

• Lubricate the bolts threads and nut seatswith molybdenum disulfide grease.

• Make sure the “Y” mark c on the con-necting rod faces towards the front side ofthe crankshaft.

• Make sure the characters d on both theconnecting rod and connecting rod capare aligned.

• Tighten the connecting rod nuts. Refer to “Connecting rod and pistoninstallation”.

• Remove the connecting rod and big endbearings. Refer to “Connecting rod and pistonremoval”.

• Measure the compressed Plastigaugewidth e on the crankshaft pin. If the crankshaft-pin-to-big-end-bearingclearance is out of specification, selectreplacement big end bearings.

c

d

e

2. Select: • Big end bearings (P1–P4)

NOTE:• The numbers stamped into the crankshaft

web and the numbers on the connecting rodsare used to determine the replacement bigend bearing sizes.

• “P1”–”P4” refer to the bearings shown in thecrankshaft illustration.

P4

P3P2

P1

5-99


For example, if the connecting rod “P1” and thecrankshaft web “P1” numbers are “5” and “1”respectively, then the bearing size for “P1” is:

Bearing size of P1:“P1” (connecting rod) – “P1” (crankshaft web)5 – 1 = 4 (green)

BEARING COLOR CODE

1 brown

2 black

3 blue

4 green

5 G

P4P3P2P1

Connecting rod and piston installationThe following procedure applies to all of thepistons and connecting rods.

1. Install: • Oil ring • 2nd ring • Top ring

NOTE:Be sure to install the piston rings so that themanufacturer’s marks or numbers face up.

2. Install: • Piston 1 • Connecting rod 2 • Piston pin 3 • Piston pin clips 4

NOTE:• Apply engine oil onto the piston pin. • When installing the connecting rod to the pis-

ton, make sure that the “Y” mark a on theconnecting rod faces towards the left whenthe exhaust valve recesses b on the pistonface upward. Refer to the illustration.

• Reinstall each piston into its original cylinder(numbering order starting from the front: #1to #4).

5-100


3. Offset: • Piston ring end gaps

a Top ring, oil ring expander spacerb 2nd ring, lower oil ring railc Upper oil ring railÈ Exhaust side

b c

a

È

90˚

45˚

90˚

4. Lubricate: • Piston • Piston rings • Cylinder

(with the recommended lubricant)

Recommended lubricant: Engine oil

5. Lubricate: • Bolt threads • Nut seats


Recommended lubricant: Molybdenum disulfide grease

6. Lubricate: • Crankshaft pins • Big end bearings • Connecting rod inner surface



5-101


7. Install: • Big end bearings • Connecting rod assembly 1

(into the cylinder and onto the crankshaft pin)

• Connecting rod cap (onto the crankshaft pin)

NOTE:• Align the projections on the big end bearings

with the notches in the connecting rods andconnecting rod caps.

• Be sure to reinstall each big end bearing inits original place.

• While compressing the piston rings with pis-ton ring compressor 2, install the connectingrod assembly into the cylinder with the otherhand.

• Make sure the “Y” marks a on the connect-ing rods face towards the front side of thecrankshaft.

• Make sure the characters b on both the con-necting rod and connecting rod cap arealigned.

8. Align: • Bolt heads

(with the connecting rod)

Piston ring compressor: YM-08037/90890-05158

5-102


9. Tighten: • Connecting rod nuts

WARNING• Replace the connecting rod bolts and

nuts with new ones. • Clean the connecting rod bolts and nuts.

NOTE:The tightening procedure of the connecting rodnuts is angle controlled, therefore tighten thenuts using the following procedure.

Tightening steps:• Tighten the connecting rod nuts to the

specified torque.

T R.

Connecting rod nut:1st:

20 N • m (2.0 kgf • m, 14 ft • lb)

• Tighten the connecting rod nuts further toreach the specified angle 120°.

T R.

Connecting rod nut:Final:

Specified angle 120 ± 5°

WARNINGWhen the nuts are tightened more thanthe specified angle, do not loosen thenut and then retighten it.Replace the bolt and nut with a new oneand perform the procedure again.

CAUTION:• Do not use a torque wrench to tighten

the nut to the specified angle.• Tighten the nut until it is at the speci-

fied angle.

NOTE:When using a hexagonal nut, note that theangle from one corner to another is 60°.

5-103

EPOWR CRANKSHAFT

CRANKSHAFTEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsCRANKSHAFT REMOVAL Follow the left “Step” for removal.Crankcase Separate

Refer to “CRANKCASE”.Connecting rod caps Refer to “CONNECTING RODS AND

PISTONS”.1 Crankshaft 12 Crankshaft journal lower bearing 53 Crankshaft journal upper bearing 5


2

2

13

3

E

5-104

EPOWR CRANKSHAFT

SERVICE POINTSCrankshaft removal

1. Remove: • Crankshaft 1 • Crankshaft journal lower bearings

(from the lower crankcase)• Crankshaft journal upper bearings

(from the upper crankcase)

NOTE:Identify the position of each crankshaft journalbearing so that it can be reinstalled in its origi-nal place.

1

Crankshaft inspection1. Measure:

• Crankshaft runout Out of specification → Replace thecrankshaft.

Maximum crankshaft runout: 0.03 mm (0.0012 in)

2. Check: • Crankshaft journal surfaces • Crankshaft pin surfaces

Scratches/wear → Replace the crank-shaft.

• Bearing surfaces Scratches/wear → Replace the crank-shaft journal bearing.

3. Measure:• crankshaft-journal-to-crankshaft-journal-

bearing clearance Out of specification → Replace thecrankshaft journal bearings.

Crankshaft-journal-to-crankshaft-journal-bearing clearance:

0.004–0.028 mm (0.0002–0.0011 in)

5-105

EPOWR CRANKSHAFT

CAUTION:Do not interchange the crankshaft journalbearings. To obtain the correct crankshaft-journal-to-crankshaft-journal-bearing clear-ance and prevent engine damage, thecrankshaft journal bearings must beinstalled in their original positions.

Measurement steps:• Clean the crankshaft journal bearings,

crankshaft journals, and bearing portionsof the crankcase.

• Place the upper crankcase upside downon a bench.

• Install the crankshaft journal upper bear-ings 1 and the crankshaft into the uppercrankcase.

NOTE:Align the projections a of the crankshaftjournal upper bearings with the notches bin the upper crankcase.

• Put a piece of Plastigauge 2 on eachcrankshaft journal.

NOTE:Do not put the Plastigauge over the oil holein the crankshaft journal.

• Install the crankshaft journal lower bear-ings into the lower crankcase and assem-ble the crankcase halves.

NOTE:• Align the projections a of the crankshaft

journal lower bearings with the notches bin the lower crankcase.

• Do not move the crankshaft until theclearance measurement has been com-pleted.

1a

b

2

5-106

EPOWR CRANKSHAFT

• Tighten the bolts to specification in thetightening sequence cast on the crank-case.Refer to “Crankcase assembly”—“CRANKCASE”.

• Remove the lower crankcase and thecrankshaft journal lower bearings.

• Measure the compressed Plastigaugewidth c on each crankshaft journal. If the crankshaft-journal-to-crankshaft-journal-bearing clearance is out of speci-fication, select replacement crankshaftjournal bearings.

c

4. Select: • Crankshaft journal bearings (J1–J5)

NOTE:• The numbers stamped into the crankshaft

web and the numbers stamped into the lowercrankcase are used to determine thereplacement crankshaft journal bearingsizes.

• “J1–J5” refer to the bearings shown in thecrankshaft illustration.

• If “J1–J5” are the same, use the same sizefor all of the bearings.

For example, if the crankcase “J1” and crank-shaft web “J1” numbers are “5” and “2” respec-tively, then the bearing size for “J1” is:

Bearing size of J1:“J1” (crankcase) – “J1” (crankshaft web)5 – 2 = 3 (blue)

BEARING COLOR CODE

1 brown

2 black

3 blue

4 green

5 yellow

J5J4J3J2J1

J1J2J3J4J5

J5J4J3J2J1

5-107

EPOWR CRANKSHAFT

Crankshaft installation1. Install:

• Crankshaft journal upper bearings (into the upper crankcase)

• Crankshaft journal lower bearings (into the lower crankcase)

NOTE:• Align the projections a on the crankshaft

journal upper bearings with the notches b inthe upper crankcase.

• Be sure to install each crankshaft journalbearing in its original place.

a

b

2. Lubricate: • Crankshaft pins • Connecting rod inner surface



5-108

EPOWR THERMOSTAT

THERMOSTATEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsTHERMOSTAT REMOVAL Follow the left “Step” for removal.

1 Band 12 Clamp/cooling water hose 1/1 È For cooling water outlet on stern side.3 Clamp/cooling water hose 2/14 Clamp/cooling water hose 1/1 É For cooling water pilot outlet on starboard

side.5 Band/grease hose 1/16 Bolt 27 Thermostat housing cover 18 Thermostat 1

3

1

3

10

8

7

4

6

5 2

LT

572

LT

572

6 × 35 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

È

É

6 × 70 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

LT

572

LT

572

1312 11

12

5.9 N • m (0.59 kgf • m, 4.3 ft • Ib)

9

5-109

EPOWR THERMOSTAT

EXPLODED DIAGRAM


10 Thermostat housing 111 Bolt 212 Collar 213 Thermostat housing holder 1


3

1

3

10

8

7

4

6

5 2

LT

572

LT

572

6 × 35 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

È

É

6 × 70 mm2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

LT

572

LT

572

1312 11

12

5.9 N • m (0.59 kgf • m, 4.3 ft • Ib)

9

Not reusable

5-110

EPOWR THERMOSTAT

SERVICE POINTSThermostat inspection

1. Check:• Thermostat 1

Does not open at 50–60 °C (123–141 °F) → Replace.

1 Thermostat2 Thermometer3 Water4 ContainerÈ Fully closedÉ Fully open

NOTE:If the accuracy of the thermostat is in doubt,replace it. A faulty thermostat could cause seri-ous overheating or over cooling.

Checking steps:• Suspend the thermostat in a container

filled with water.• Slowly heat the water.• Place a thermometer in the water.• While stirring the water, observe the ther-

mostat and thermometer’s indicated tem-perature.

13

2

4

2. Check:• Thermostat housing cover• Thermostat housing


3. Check:• Cooling system

Leaks → Repair or replace any faultypart.

Thermostat installation1. Install:

• Thermostat housing 1 • Thermostat 2 • Gasket• Thermostat housing cover

5-111

EPOWR COOLING WATER HOSE

COOLING WATER HOSEEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsCOOLING WATER HOSE REMOVAL


Exhaust manifold Refer to “EXHAUST MANIFOLD”.1 Clamp/cooling water hose 1/1 È From exhaust manifold

É To cylinder block2 Clamp/cooling water hose 2/2 Ê To exhaust pipe3 Clamp/cooling water hose 2/1 Ë To cylinder block4 Clamp/cooling water hose 2/15 Joint 16 Clamp/cooling water hose 1/1 Ì To oil tank7 Joint 1 Í From cooling water inlet


1

6

7

4

4

5

3

3

2

2

È

ÈÈ

È

Ê

Ê

Ì

Í

É

Ë

EJET

PUMPCHAPTER 6

JET PUMP UNIT

INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT....................................6-1EXPLODED DIAGRAM .............................................................................6-1REMOVAL AND INSTALLATION CHART ................................................6-1

JET PUMP UNIT..............................................................................................6-4EXPLODED DIAGRAM .............................................................................6-4REMOVAL AND INSTALLATION CHART ................................................6-4

REVERSE GATE.............................................................................................6-6EXPLODED DIAGRAM .............................................................................6-6REMOVAL AND INSTALLATION CHART ................................................6-6SERVICE POINTS ....................................................................................6-9

Lever 1 installation ..............................................................................6-9Lever 2 installation ..............................................................................6-9

JET THRUST NOZZLE AND NOZZLE RING ...............................................6-10EXPLODED DIAGRAM ...........................................................................6-10REMOVAL AND INSTALLATION CHART ..............................................6-10

IMPELLER DUCT AND IMPELLER HOUSING 1 .........................................6-11EXPLODED DIAGRAM ...........................................................................6-11REMOVAL AND INSTALLATION CHART ..............................................6-11

IMPELLER DUCT AND DRIVE SHAFT ........................................................6-13EXPLODED DIAGRAM ...........................................................................6-13REMOVAL AND INSTALLATION CHART ..............................................6-13SERVICE POINTS ..................................................................................6-15

Drive shaft removal ...........................................................................6-15Impeller inspection ............................................................................6-17Drive shaft inspection........................................................................6-17Drive shaft installation .......................................................................6-17

EJET

PUMP

6

TRANSOM PLATE AND HOSES..................................................................6-20EXPLODED DIAGRAM ...........................................................................6-20REMOVAL AND INSTALLATION CHART ..............................................6-20SERVICE POINTS ..................................................................................6-23

Bilge strainer inspection ....................................................................6-23Electric bilge pump inspection...........................................................6-23Bilge hose inspection ........................................................................6-23Cooling water hose inspection ..........................................................6-23

BEARING HOUSING.....................................................................................6-24EXPLODED DIAGRAM ...........................................................................6-24REMOVAL AND INSTALLATION CHART ..............................................6-24SERVICE POINTS ..................................................................................6-27

Driven coupling removal and installation...........................................6-27Intermediate drive shaft removal.......................................................6-27Bearing removal ................................................................................6-28Bearing, intermediate drive shaft, and grease hose inspection ........6-28Driven coupling inspection ................................................................6-28Bearing installation............................................................................6-29Oil seal installation ............................................................................6-29Intermediate housing installation.......................................................6-30

6-1

EJET

PUMPINTAKE GRATE, RIDE PLATE, AND INTAKE DUCTEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsINTAKE GRATE, RIDE PLATE, AND INTAKE DUCT REMOVAL


1 Bolt 22 Bolt 23 Intake grate 14 Screw 45 Speed sensor 1 NOTE:

Route the speed sensor lead between thejet pump unit and the bilge hose.

6 Bolt 4

INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT

6-2

EJET

PUMP INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points7 Ride plate 18 Bolt 49 Intake duct 110 Felt packing 1

Reverse the removal steps for installation.Not reusable

6-3

EJET

PUMP INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT

EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsSPEED SENSOR DISASSEMBLY Follow the left “Step” for disassembly.

1 Holder 12 Paddle wheel set 13 Speed sensor 1


FWD

2

3

1

Not reusable

6-4

EJET

PUMP JET PUMP UNIT

JET PUMP UNITEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsJET PUMP UNIT REMOVAL Follow the left “Step” for removal.

1 Shift cable joint 12 QSTS cable joint 13 Bilge hose 1 NOTE:

Route the speed sensor lead between thejet pump unit and the bilge hose.

4 Nut/washer 1/25 Steering cable joint 16 Clamp/spout hose 1/17 Bolt 6

8 × 24 mm 14 N • m (1.4 kgf • m, 10 ft • Ib)

6 × 22 mm 6.8 N • m (0.68 kgf • m, 4.9 ft • Ib)

6 × 80 mm7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)

2.2 N • m (0.22 kgf • m, 1.6 ft • Ib)

6.8 N • m (0.68 kgf • m, 4.9 ft • Ib)

10 × 95 mm 40 N • m (4.0 kgf • m, 29 ft • Ib)

9

8

7

65

2 411

13

43

10

1

12

15

14

4

4LT

572

LT

572

LT

572

LT

572

LT

242 AA

MM

LT

271

LT

6-5

EJET

PUMP JET PUMP UNIT

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points8 Collar 49 Rubber plate 210 Bolt 111 Bolt 412 Jet pump unit assembly 113 Dowel pin 214 Impeller housing 2 115 Dowel pin 2


8 × 24 mm 14 N • m (1.4 kgf • m, 10 ft • Ib)

6 × 22 mm 6.8 N • m (0.68 kgf • m, 4.9 ft • Ib)

6 × 80 mm7.8 N • m (0.78 kgf • m, 5.6 ft • Ib)

2.2 N • m (0.22 kgf • m, 1.6 ft • Ib)

6.8 N • m (0.68 kgf • m, 4.9 ft • Ib)

10 × 95 mm 40 N • m (4.0 kgf • m, 29 ft • Ib)

9

8

7

65

2 411

13

43

10

1

12

15

14

4

4LT

572

LT

572

LT

572

LT

572

LT

242 AA

MM

LT

271

LT

6-6

EJET

PUMP REVERSE GATE

REVERSE GATEEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsREVERSE GATE REMOVAL Follow the left “Step” for removal.

1 Clamp/spout hose 1/12 Bolt 23 Washer 24 Collar 25 Reverse gate assembly 16 Nut 17 Bolt 18 Washer 29 Roller 1

6-7

EJET

PUMP REVERSE GATE

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points10 Bolt 611 Bracket 112 Reverse gate stay 213 Nut 114 Washer 115 Bolt 116 Lever 1 117 Spacer 118 Nut 119 Washer 1

6-8

EJET

PUMP REVERSE GATE

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points20 Collar 121 Bolt 122 Washer 123 Collar 124 Spring 125 Lever 2 126 Washer 1


6-9

EJET

PUMP REVERSE GATE

SERVICE POINTSLever 1 installation

1. Install:• Bolt 1 • Lever 1 2 • Spacer 3 • Reverse gate 4 • Washer 5 • Nut 6

Lever 2 installation1. Install:

• Bolt 1 • Washer 2 • Collar 3 • Spring 4 • Lever 2 5 • Washer 6 • Collar 7

NOTE:• When installing the spring, hook the spring

end a to lever 2 and spring end b to thereverse gate, as shown in the illustration.

• When installing the lever 2, hook the lever 2end c to lever 1 end d, as shown in theillustration.

4

a cd

b

2. Install:• Washer 1 • Nut 2

3. Check:• Lever 1 and lever 2 movements

Stick → Reassemble lever 1 and lever 2.

6-10

EJET

PUMP JET THRUST NOZZLE AND NOZZLE RING

JET THRUST NOZZLE AND NOZZLE RINGEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsJET THRUST NOZZLE AND NOZZLE RING REMOVAL


Jet pump unit Refer to “JET PUMP UNIT”.Reverse gate Refer to “REVERSE GATE”.

1 Bolt 22 Collar 23 Jet thrust nozzle 14 Bolt 25 Collar 26 Nozzle ring 1


6-11

EJET

PUMP IMPELLER DUCT AND IMPELLER HOUSING 1

IMPELLER DUCT AND IMPELLER HOUSING 1EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsIMPELLER DUCT AND IMPELLER HOUSING 1 REMOVAL


Nozzle ring Refer to “JET THRUST NOZZLE AND NOZZLE RING”.

1 Bolt 42 Nozzle 1 NOTE:

Clean the contacting surfaces before apply-ing the Yamabond #4 (Yamaha bond num-ber 4).

3 Pin 24 Impeller duct assembly 15 Impeller housing 1 16 Pin 27 Bolt 4

6-12

EJET

PUMP IMPELLER DUCT AND IMPELLER HOUSING 1

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points8 Water inlet cover 19 Packing 110 Water inlet strainer 111 Packing 1


6-13

EJET

PUMP IMPELLER DUCT AND DRIVE SHAFT

IMPELLER DUCT AND DRIVE SHAFTEXPLODED DIAGRAM



Step Procedure/Part name Q’ty Service pointsIMPELLER DUCT AND DRIVE SHAFT DISASSEMBLY


1 Impeller 1 Left-hand threads2 Spacer 13 Bolt/washer 3/34 Cap 15 O-ring 16 Nut 17 Washer 1

Not reusable

6-14

EJET


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service points8 Drive shaft 19 Rear bearing 110 Spacer 111 Front bearing 112 Oil seal 1

13 Oil seal 1

14 Impeller duct 1


Not reusable

Not reusableNot reusableNot reusable

6-15

EJET


SERVICE POINTSDrive shaft removal

1. Remove:• Impeller

NOTE:The impeller has left-hand threads. Turn theimpeller clockwise to loosen it.

Drive shaft holder:YB-06151

Drive shaft holder 5:90890-06519

2. Remove:• Nut 1



3. Remove:• Drive shaft 1

NOTE:Remove the drive shaft with a press.

6-16

EJET


4. Remove:• Rear bearing


Slide hammer and adapters:YB-06096

Stopper guide plate:90890-06501

Bearing puller assembly:90890-06535

Stopper guide stand:90890-06538

È

É

5. Remove:• Front bearing

NOTE:Remove the front bearing with a press.



Bearing housing needle bearing remover:


90890-06614

6-17

EJET


6. Remove:• Oil seal

NOTE:Remove the oil seals with press.



Drive shaft needle bearing installer and remover:


90890-06614

Impeller inspectionRefer to “JET PUMP UNIT” in Chapter 3.

Drive shaft inspection1. Inspect:

• Drive shaftDamage/wear → Replace.

Drive shaft installation1. Install:

• Oil seals




YB-06085Ball bearing attachment:

90890-06631

Distance a:14.2 ± 0.2 mm (0.56 ± 0.01 in)

Distance b:4.7 ± 0.2 mm (0.19 ± 0.01 in)

6-18

EJET


2. Install:• Front bearing • Drive shaft

NOTE:• Install the front bearing and drive shaft with a

press.• Press the front bearing with a pipe that is

more than 85 mm (3.35 in) long, and whichhas an inner diameter of 25 mm (0.98 in).

Distance a:23 ± 0.1 mm (0.91 ± 0.004 in)

a

3. Install:• Drive shaft (with front bearing)• Spacer• Impeller duct

NOTE:Press the spacer and the front bearing with apipe that is more than 33 mm (1.30 in) long,and which has an outer diameter less than50 mm (1.97 in) and an inner diameter morethan 26 mm (1.02 in).

4. Add:• EPNOC grease AP #0

(between the drive shaft and spacer)

Quantity:20 g (0.7 oz)

6-19

EJET


5. Install:• Rear bearing

NOTE:• Press the bearing inner/outer race at the

same time holding the drive shaft and impel-ler duct.

• If a bearing inner/outer race attachment isnot available, use a washer or pipe with anouter diameter of 46 mm (1.81 in) and aninner diameter of 20 mm (0.79 in).

Bearing inner/outer race attachment:

YB-34474

6. Add:• EPNOC grease AP #0 (into the cap)

Quantity:20 g (0.7 oz)

7. Install:• Nut• Impeller

T R.

Drive shaft nut:69 N • m (6.9 kgf • m, 50 ft • lb)

Impeller:75 N • m (7.5 kgf • m, 54 ft • lb)LOCTITE 572



6-20

EJET

PUMP TRANSOM PLATE AND HOSES

TRANSOM PLATE AND HOSESEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsTRANSOM PLATE AND HOSES REMOVAL


Exhaust system Refer to “EXHAUST SYSTEM” in Chapter 8.Jet pump unit assembly Refer to “JET PUMP UNIT”.

1 Hose clamp 22 Cooling water hose 1 Cooling water outlet (exhaust pipe)3 Bilge hose 1 1 NOTE:

Route the bilge hose 1 under the drive shafttube.

4 Hose clamp 15 Cooling water hose 1 Cooling water inlet

6-21

EJET


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points6 Hose clamp 27 Cooling water hose 1 Cooling water outlet (thermostat)8 Bilge hose 2 19 Hose clamp 110 Bilge hose 3 111 Band 112 Electric bilge pump assembly 113 Hose clamp 114 Bilge hose 4 115 Bilge strainer 1

6-22

EJET


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points16 Nut/washer 4/417 Transom plate 118 Bilge hose 5 1


6-23

EJET


SERVICE POINTSBilge strainer inspection

Refer to “JET PUMP UNIT” in Chapter 3.

Electric bilge pump inspectionRefer to “BILGE PUMP” in Chapter 3.Refer to “ELECTRIC BILGE PUMP” in Chapter 7.

Bilge hose inspection1. Inspect:

• Bilge hosesCracks/damage/wear → Replace.

Cooling water hose inspection1. Inspect:

• Cooling water hosesCracks/damage/wear → Replace.

6-24

EJET

PUMP BEARING HOUSING

BEARING HOUSINGEXPLODED DIAGRAM


*: As required

Step Procedure/Part name Q’ty Service pointsBEARING HOUSING REMOVAL Follow the left “Step” for removal.Engine unit Refer to “ENGINE UNIT” in Chapter 5.

1 Rubber coupling 12 Bolt 33 Intermediate housing assembly 14 Pin 25 Shim * NOTE:

Install the shims in their original locations.


6-25

EJET


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsBEARING HOUSING DISASSEMBLY


1 Grease hose 12 Nipple 13 Driven coupling 14 Washer 15 Intermediate drive shaft 16 O-ring 2 Not reusable

6-26

EJET


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points7 Oil seal 1

8 Oil seal 1

9 Oil seal 1

10 Circlip 1

11 Bearing 1

12 Circlip 1


Not reusableNot reusableNot reusableNot reusableNot reusableNot reusable

6-27

EJET


SERVICE POINTSDriven coupling removal and installation

1. Remove and install:• Driven coupling

NOTE:• Install the driven coupling with the same spe-

cial tools that were used for removal.• Check that the shaft holder and intermediate

drive shaft are properly engaged.


Shaft holder:YB-06552

Crankshaft holder 20:90890-06552

Intermediate drive shaft removal1. Remove:

• Intermediate drive shaft

NOTE:Support the intermediate housing with steelblocks 1 and press the driven coupling shaftwith a rod that is more than 210 mm (8.27 in)long, and which has an outer diameter lessthan 16 mm (0.63 in).

Removal steps:• Temporarily install the driven coupling to

the intermediate drive shaft.• Insert a long rod to the driven coupling

shaft.• Press out the intermediate drive shaft by

pushing the rod.

1

6-28

EJET


Bearing removal1. Remove:

• Bearing

NOTE:• Install the bearing with the same special

tools that were used for removal.• Support the intermediate housing with steel

blocks 1 and press the bearing.



Drive shaft taper roller bearing cup installer:


90890-06626

Bearing, intermediate drive shaft, and grease hose inspection

1. Inspect:• Bearing

Rotate the inner race by hand.Damage/rough movement → Replace.

• Intermediate drive shaftDamage/pitting → Replace.

• Grease hoseCracks/wear → Replace.

Driven coupling inspection1. Inspect:

• Driven coupling • Driven coupling damper

Damage/wear → Replace.

6-29

EJET


Bearing installation1. Install:

• Circlip (front)

2. Install:• Bearing

NOTE:Support the intermediate housing with steelblocks 1 and press the bearing.



Driveshaft taper roller bearing cup installer:


90890-06626

Oil seal installation1. Install:

• Oil seal

NOTE:Before installing the oil seal, lubricate the clipglove with water resistant grease.



Driveshaft taper roller bearing cup installer:


90890-06626

Distance a:7.0 ± 0.2 mm (0.28 ± 0.01 in)

a

6-30

EJET


2. Install:• Intermediate drive shaft• Circlip (rear)

NOTE:Hold the bearing in place as shown with a pipethat is more than 80 mm (3.15 in) long, andwhich has an outer diameter of 51 mm (2.00in) and an inner diameter of 26 mm (1.02 in).

3. Install:• Oil seal 1 [8 mm (0.31 in)]• Oil seal 2 [11 mm (0.43 in)]

Intermediate housing installation1. Install:

• Intermediate housing• Shim

NOTE:Install the shim(s) to the original position if theintermediate housing is not replaced.

Distance a:46.0 ± 0.5 mm (1.81 ± 0.02 in)

Distance a:10.5 ± 0.2 mm (0.41 ± 0.01 in)

Distance b:0.8 ± 0.2 mm (0.03 ± 0.01 in)

Installation steps:• Install the intermediate housing.• Measure the clearance a at each bolt

hole.• Install the suitable shim from the table

below.

Clearance a Shim thickness

0–0.2 mm (0–0.008 in) No need

0.3–0.7 mm (0.012–0.028 in) 0.5 mm

0.8–1.2 mm (0.031–0.047 in) 1.0 mm

1.3–2.0 mm (0.051–0.079 in) 1.5 mm

ba

2

1

E– +ELEC

7

CHAPTER 7ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS........................................................................7-1

ELECTRICAL BOX..........................................................................................7-2EXPLODED DIAGRAM .............................................................................7-2REMOVAL AND INSTALLATION CHART ................................................7-2

ELECTRICAL ANALYSIS ...............................................................................7-9INSPECTION.............................................................................................7-9

Digital tester ........................................................................................7-9Low resistance measurement ...........................................................7-10Peak voltage measurement ..............................................................7-10Peak voltage adapter ........................................................................7-11Test harness ....................................................................................7-11

IGNITION SYSTEM .......................................................................................7-12WIRING DIAGRAM .................................................................................7-12IGNITION SPARK ...................................................................................7-14IGNITION SYSTEM PEAK VOLTAGE ....................................................7-15BATTERY................................................................................................7-17FUSE.......................................................................................................7-17SPARK PLUGS .......................................................................................7-17IGNITION COIL .......................................................................................7-18ENGINE STOP SWITCH.........................................................................7-18ENGINE TEMPERATURE SENSOR ......................................................7-19SENSOR ASSEMBLY.............................................................................7-19THERMOSWITCH (ENGINE)..................................................................7-20THERMOSWITCH (EXHAUST) ..............................................................7-20MAIN AND FUEL PUMP RELAY.............................................................7-21THROTTLE POSITION SENSOR ...........................................................7-22CAM POSITION SENSOR ......................................................................7-23NOISE FILTER........................................................................................7-24SLANT DETECTION SWITCH ................................................................7-24

FUEL CONTROL SYSTEM ...........................................................................7-25WIRING DIAGRAM .................................................................................7-25FUEL PUMP............................................................................................7-27FUEL SENDER .......................................................................................7-27FUEL INJECTOR ....................................................................................7-28MAIN AND FUEL PUMP RELAY.............................................................7-28OIL PRESSURE SWITCH.......................................................................7-28THERMOSWITCH (ENGINE)..................................................................7-28THERMOSWITCH (EXHAUST) ..............................................................7-28SLANT DETECTION SWITCH ................................................................7-28REMOTE CONTROL UNIT .....................................................................7-28

E– +ELEC

STARTING SYSTEM.....................................................................................7-29WIRING DIAGRAM .................................................................................7-29BATTERY................................................................................................7-30WIRING CONNECTIONS........................................................................7-30FUSE.......................................................................................................7-30START SWITCH......................................................................................7-30STARTER RELAY ...................................................................................7-31REMOTE CONTROL UNIT .....................................................................7-31

STARTER MOTOR........................................................................................7-32EXPLODED DIAGRAM ...........................................................................7-32REMOVAL AND INSTALLATION CHART .............................................7-32SERVICE POINTS ..................................................................................7-35

Armature inspection ..........................................................................7-35Brush holder inspection.....................................................................7-36Starter motor front cover inspection ..................................................7-36

CHARGING SYSTEM....................................................................................7-37WIRING DIAGRAM .................................................................................7-37FUSE.......................................................................................................7-38BATTERY................................................................................................7-38LIGHTING COIL ......................................................................................7-38RECTIFIER/REGULATOR ......................................................................7-38

ELECTRIC BILGE PUMP..............................................................................7-39WIRING DIAGRAM .................................................................................7-39ELECTRIC BILGE PUMP........................................................................7-40FUSE.......................................................................................................7-40BATTERY................................................................................................7-40MAIN AND FUEL PUMP RELAY.............................................................7-40REMOTE CONTROL UNIT .....................................................................7-40

OFF THROTTLE STEERING SYSTEM.........................................................7-41WIRING DIAGRAM .................................................................................7-41STEERING SWITCH ...............................................................................7-42ECM.........................................................................................................7-42PICKUP COIL..........................................................................................7-42THROTTLE POSITION SENSOR ...........................................................7-42BYPASS VALVE MOTOR .......................................................................7-42

E– +ELEC

INDICATION SYSTEM ..................................................................................7-43WIRING DIAGRAM .................................................................................7-43FUSE.......................................................................................................7-45BATTERY................................................................................................7-45MAIN AND FUEL PUMP RELAY.............................................................7-45ECM.........................................................................................................7-45ENGINE TEMPERATURE SENSOR ......................................................7-45THERMOSWITCH (ENGINE)..................................................................7-45THERMOSWITCH (EXHAUST) ..............................................................7-45REMOTE CONTROL UNIT .....................................................................7-45BUZZER ..................................................................................................7-45OIL PRESSURE SWITCH.......................................................................7-46MULTIFUNCTION METER......................................................................7-46

Multifunction meter............................................................................7-46MULTIFUNCTION METER REMOVAL ...................................................7-46

Display function.................................................................................7-47Speedometer display ........................................................................7-48Tachometer display...........................................................................7-49Hour meter display ............................................................................7-49Voltage meter display........................................................................7-49Low oil pressure warning indicator....................................................7-49Fuel level meter display and fuel warning indicator ..........................7-49Overheat warning indicator ...............................................................7-50Check the engine warning indicator ..................................................7-50

REMOTE CONTROL SYSTEM .....................................................................7-51WIRING DIAGRAM .................................................................................7-51REMOTE CONTROL SYSTEM...............................................................7-52

Yamaha Security System indicator ...................................................7-52Low-rpm mode indicator....................................................................7-52Diagnostic display .............................................................................7-53Checking the remote control transmitter ...........................................7-53Transmitter registration .....................................................................7-55Replacing of the transmitter battery ..................................................7-56

7-1

E– +ELEC ELECTRICAL COMPONENTS

ELECTRICAL COMPONENTS

L

M

K

J

I

G

F

E

D

C

B

A

0

987

6

5

4

3

2

1H

1 Thermoswitch (engine)2 Starter motor3 Engine temperature sensor4 Spark plugs and ignition coils5 Electrical box6 Battery7 Speed sensor8 Electric bilge pump9 Cam position sensor0 Fuel injectorsA Thermoswitch (exhaust)

B Oil pressure switchC Sensor assemblyD Bypass valve motorE Throttle position sensorF Lighting coil and pickup coilG Engine stop switch, engine

shut-off switch, and start switch

H Steering switchI BuzzerJ Fuel pump

K Fuel senderL Multifunction meterM Remote control unit

7-2

E– +ELEC ELECTRICAL BOX

ELECTRICAL BOXEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsELECTRICAL BOX REMOVAL Follow the left “Step” for removal.

1 Battery negative lead 12 Battery positive lead 13 Clip/breather hose 1/14 Band 25 Battery 16 Damper 17 Bolt 28 Bolt 2

AAAA

22

11

1413

12

1516

2120

19

22

22

22

1718 22

10

1

9

7

8

65

2

3

4

(VENT)

LT

572

LT

LT

271

LT

LT

572

LT

AA

LT

572

LT

E

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 12 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 16 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 10 mm

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 30 mm

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 16 mm

8 × 28 mm17 N • m (1.7 kgf • m, 12 ft • Ib)

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)5 × 20 mm

22

22

4

7-3


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points9 Battery box 110 Spacer 211 Bolt 412 Screw 413 Terminal cover 114 Gasket 115 Screw 216 Starter motor lead 117 Bolt 318 Cover 1

AAAA

22

11

1413

12

1516

2120

19

22

22

22

1718 22

10

1

9

7

8

65

2

3

4

(VENT)

LT

572

LT

LT

271

LT

LT

572

LT

AA

LT

572

LT

E

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 12 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 16 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 10 mm

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 30 mm

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 16 mm

8 × 28 mm17 N • m (1.7 kgf • m, 12 ft • Ib)

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)5 × 20 mm

22

22

4

Not reusable

7-4


EXPLODED DIAGRAM


20 Bolt 221 Ground lead 222 Coupler 22 NOTE:

Disconnect all couplers.


AAAA

22

11

1413

12

1516

2120

19

22

22

22

1718 22

10

1

9

7

8

65

2

3

4

(VENT)

LT

572

LT

LT

271

LT

LT

572

LT

AA

LT

572

LT

E

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 12 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 16 mm

7.6 N • m (0.76 kgf • m, 5.5 ft • Ib)

6 × 10 mm

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 30 mm

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 16 mm

8 × 28 mm17 N • m (1.7 kgf • m, 12 ft • Ib)

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)5 × 20 mm

22

22

4

Not reusable

7-5


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsELECTRICAL BOX DISASSEMBLY


1 Tapping screw 182 Cover 13 Gasket 14 Clamp 35 Wiring harness 16 Tapping screw 17 Fuse holder stay 18 Wiring harness 19 Fuse 6

2

3

1

1920

18

1716

14 11

15

1312 6

7

8

5

4

22

21

6 × 20 mm3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6 × 30 mm3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6 × 16 mm3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6 × 30 mm

3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6 × 16 mm

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

5 × 30 mm

4

4

9

10

7-6


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points10 Starter relay 111 Clamp 212 Tapping screw/washer 4/413 ECM 114 Tapping screw 115 Bracket 116 Joint connector 217 Tapping screw 218 Slant detection switch 119 Tapping screw 120 Main and fuel pump relay 1

2

3

1

1920

18

1716

14 11

15

1312 6

7

8

5

4

22

21

6 × 20 mm3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6 × 30 mm3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6 × 16 mm3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6 × 30 mm

3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6 × 16 mm

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

5 × 30 mm

4

4

9

10

7-7


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points21 Tapping screw 222 Rectifier/regulator 1


2

3

1

1920

18

1716

14 11

15

1312 6

7

8

5

4

22

21

6 × 20 mm3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6 × 30 mm3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6 × 16 mm3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6 × 30 mm

3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6 × 16 mm

4.9 N • m (0.49 kgf • m, 3.5 ft • Ib)

5 × 30 mm

4

4

9

10

7-8


UP

2 3 4 5 6

7

8

1

ÊÉ

È

1 Starter relay2 Fuse holder3 ECM4 Joint connector5 Joint connector6 Main and fuel pump relay7 Rectifier/regulator8 Slant detection switch

È To ignition coilÉ To battery positive terminalÊ To starter motor

7-9

E– +ELEC ELECTRICAL ANALYSIS

ELECTRICAL ANALYSISINSPECTION

CAUTION:• All measuring instruments should be han-

dled with special care. Damaged or mis-handled instruments will not measureproperly.

• On an instrument powered by dry batter-ies, check the battery’s voltage periodi-cally and replace the batteries ifnecessary.

Digital tester

NOTE:Throughout this chapter the part numbers ofthe specified digital testers have been omitted.Refer to the following part numbers.

NOTE:“ ” indicates a continuity of electricity;i.e., a closed circuit at the respective switchposition.



7-10


Low resistance measurement

NOTE:• When measuring a resistance of 10 Ω or less

with the digital tester, the correct measure-ment cannot be obtained because of thetester’s internal resistance.

• To obtain the correct value, subtract theinternal resistance from the displayed mea-surement.

• The internal resistance of the tester can beobtained by connecting both of its terminals.

Correct value =Displayed measurement – Internal resistance

Peak voltage measurement

NOTE:• When checking the condition of the ignition

system it is vital to know the peak voltage.• Cranking speed is dependant on many fac-

tors (e.g., fouled or weak spark plugs, aweak battery). If one of these is defective,the peak voltage will be lower than specifica-tion.

• If the peak voltage measurement is notwithin specification the engine will not oper-ate properly.

• A low peak voltage will also cause compo-nents to prematurely wear.

7-11


Peak voltage adapter

NOTE:• Throughout this chapter the peak voltage

adapter’s part number has been omitted.Refer to the following part number.

• The peak voltage adapter should be usedwith the digital tester.

• When measuring the peak voltage, connectthe peak voltage adapter to the digital circuittester and switch the selector to the DC volt-age mode.

NOTE:• Make sure that the adapter leads are prop-

erly installed in the digital circuit tester.• Make sure that the positive pin (the “+” mark

facing up as shown) on the adaptor isinstalled into the positive terminal of thetester.

• The test harness is needed for the followingtests.

È Voltage measurementÉ Peak voltage measurement

Peak volt meter adapter:YU-39991

Peak voltage adapter B:90890-03172

È

É

Test harness

NOTE:If the lighting coil and pickup coil(s) are mea-sured unloaded, disconnect the test harnesson the output side coupler.

Checking steps:• Disconnect the coupler connections.• Connect the test harness between the

couplers.• Connect the tester terminals to the termi-

nals which are being checked.• Run the engine and observe the mea-

surement.

7-12

E– +ELEC IGNITION SYSTEM

IGNITION SYSTEMWIRING DIAGRAM

FREEPUSH

W B

FREEPUSH

Br Br

FREEPUSH

W B R BrP/W

P/W

P/W

J

R

R

R/Y

R/YB/L

L/R

R/Y R

R/Y

B/O

B/O

B/Y

B/O

B/O

B/O

B/OB

BRG

B

B/O R/Y

G/O

B/O

R

R/Y

L/R

L

Y

R R/Y

B

G

G/O

R/Y

R/Y

B/Y

B/Y

B/YB/O

B/Y

B/O

W/R

W/B

WB

R

O P

P

R

G

G

G

G

RBW

G

G

B

P

R

W

Br

G

R

B

G G

G

G

G

W

B/O

R

B

P

B/O

B

P

B/O

#4

B/Y

#3

H I

B/W

#2

H I

B/R

#1

B/O

R

R

Br B

B

R

B/O

B/OB/OB/O B/O

W

Br

Br

B

R

R

P

B

P

B

A

C

3

2

B

H

H

D

I

I

F

G

E E

8

5 6

7

9

0

4

R

P

P

O

R

R

R R R P POO

B/OL/B

3 : G/O 4 : W 5 : P 6 : P/W 9 : O12 : W/R13 : W/B21 : L/R22 : B/R

28 : L/B30 : R/Y33 : P/G34 : P35 : B/Y42 : B/L43 : B/Y44 : B/W

1 2 3 4 5 6 7 8

B

B

B

B/O

Br

B/Y O

B/OP/G

R/Y

B B

B

R/Y

R/Y

BB

G

B/O

R/Y

R/Y

R

K

1

P

O

G/B

G

Pu/B

G/YG/R

Pu/G

Pu/Y

Pu/B

P

O

R/Y

Pu/Y

G/Y

G/R

B/Y

P/G

Pu/R

Pu/RPu/G

P/GR/Y

G

G/BB/O

1 ECM2 Main and fuel pump relay3 Fuse (20A)4 Battery5 Engine shut-off switch6 Engine stop switch7 Start switch8 Thermoswitch (exhaust)9 Thermoswitch (engine)

0 Engine temperature sensorA Slant detection switchB Cam position sensorC Rectifier/regulatorD Lighting coilE Pickup coilF Sensor assembly

(intake air temperature, intake air pressure)

G Throttle position sensorH Spark plugI Ignition coilJ Oil pressure switchK Noise filter

7-13


WIRING DIAGRAM

FREEPUSH

W B

FREEPUSH

Br Br

FREEPUSH

W B R BrP/W

P/W

P/W

J

R

R

R/Y

R/YB/L

L/R

R/Y R

R/Y

B/O

B/O

B/Y

B/O

B/O

B/O

B/OB

BRG

B

B/O R/Y

G/O

B/O

R

R/Y

L/R

L

Y

R R/Y

B

G

G/O

R/Y

R/Y

B/Y

B/Y

B/YB/O

B/Y

B/O

W/R

W/B

WB

R

O P

P

R

G

G

G

G

RBW

G

G

B

P

R

W

Br

G

R

B

G G

G

G

G

W

B/O

R

B

P

B/O

B

P

B/O

#4

B/Y

#3

H I

B/W

#2

H I

B/R

#1

B/O

R

R

Br B

B

R

B/O

B/OB/OB/O B/O

W

Br

Br

B

R

R

P

B

P

B

A

C

3

2

B

H

H

D

I

I

F

G

E E

8

5 6

7

9

0

4

R

P

P

O

R

R

R R R P POO

B/OL/B

3 : G/O 4 : W 5 : P 6 : P/W 9 : O12 : W/R13 : W/B21 : L/R22 : B/R

28 : L/B30 : R/Y33 : P/G34 : P35 : B/Y42 : B/L43 : B/Y44 : B/W

1 2 3 4 5 6 7 8

B

B

B

B/O

Br

B/Y O

B/OP/G

R/Y

B B

B

R/Y

R/Y

BB

G

B/O

R/Y

R/Y

R

K

1

P

O

G/B

G

Pu/B

G/YG/R

Pu/G

Pu/Y

Pu/B

P

O

R/Y

Pu/Y

G/Y

G/R

B/Y

P/G

Pu/R

Pu/RPu/G

P/GR/Y

G

G/BB/O

B : BlackBr : BrownG : GreenL : BlueO : OrangeP : PinkR : RedW : WhiteY : Yellow

B/L : Black/blueB/O : Black/orangeB/R : Black/redB/W : Black/whiteB/Y : Black/yellowG/O : Green/orangeL/B : Blue/blackL/R : Blue/redP/G : Pink/green

P/W : Pink/whiteR/Y : Red/yellowW/B : White/blackW/R : White/red

7-14


IGNITION SPARK

WARNING• When checking the spark gap, do not

touch any of the connections of the sparkgap tester lead wires.

• When performing the spark gap test, takespecial care not to let sparks leak out ofthe removed spark plug cap.

• When performing the spark gap check,keep flammable gas or liquids away,since this test can produce sparks.

1. Check:• Ignition spark

Weak → Check the ECM output peakvoltage.Check the ignition coil for resistance.


Checking steps:• Connect the spark plug cap to the spark

gap tester.

Spark gap tester:YM-34487

Ignition tester:90890-06754

• Crank the engine and observe the igni-tion system spark through the dischargewindow.

È

É

7-15


IGNITION SYSTEM PEAK VOLTAGE

WARNINGWhen checking the electrical components,do not touch any of the connections of thedigital tester lead wires.

NOTE:• If there is no spark, or the spark is weak,

continue with the ignition system test.• If a good spark is obtained, the problem is

not with the ignition system, but possibly withthe spark plug(s) or another component.

1. Measure:• ECM output peak voltage

Below specification → Measure thepickup coil output peak voltage.

NOTE:• When measuring the ECM output peak volt-

age while cranking the engine, disconnectthe ignition coil couplers for all cylindersexcept for the cylinder being measured.

• To crank the engine, connect the engineshut-off cord (lanyard) to the engine shut-offswitch, and then press the start switch.

Test harness (2 pins):New: YB-06867Current: YB-06767

Test harness FWY-2 (2 pins):New: 90890-06867Current: 90890-06767

ECM output peak voltage:Black/red (B/R) – Red/yellow (R/Y)Black/white (B/W) – Red/yellow (R/Y)Black/yellow (B/Y) – Red/yellow (R/Y)Black/blue (B/L) – Red/yellow (R/Y)

r/minLoaded

Cranking 2,000 3,500

V 87 86 85

7-16


2. Measure:• Pickup coil output peak voltage

Below specification → Replace thepickup coil.Above specification → Replace theECM.

NOTE:To crank the engine, connect the engine shut-off cord (lanyard) to the engine shut-off switch,and then press the start switch and enginestop switch simultaneously.


Test harness HM090-3 (3 pins):New: 90890-06877Current: 90890-06777

Pickup coil output peak voltage:White (W) – Black (B)Red (R) – Black (B)

r/minUnloaded Loaded


V 5.2 4.7 26.1 41.3

3. Measure:• Lighting coil output peak voltage

Below specification → Replace the light-ing coil.


Test harness SMT250-3 (3 pins):New: 90890-06870Current: 90890-06770

Lighting coil output peak voltage:Green (G) – Green (G)

r/minUnloaded


V 9.2 38.5 63.2

7-17

E– +ELEC

NOTE:To crank the engine, connect the engine shut-off cord (lanyard) to the engine shut-off switch,and then press the start switch and enginestop switch simultaneously.

4. Measure:• Rectifier/regulator output voltage

Below specification → Replace the recti-fier/regulator.

NOTE:• Do not use the peak voltage adapter to mea-

sure the output voltage.• Disconnect the output lead of the tester har-

ness.


Test harness FSW-6A (6 pins):90890-06848

Rectifier/regulator output voltage:

Red (R) – Black (B)

r/minUnloaded

3,500

V 15.0

BATTERYRefer to “ELECTRICAL” in Chapter 3.

FUSERefer to “STARTING SYSTEM”.

SPARK PLUGSRefer to “POWER UNIT” in Chapter 3.

IGNITION SYSTEM

7-18

E– +ELEC

IGNITION COIL1. Measure:

• Primary coil resistanceOut of specification → Replace.

NOTE:When measuring a resistance of 10 Ω or lesswith the digital tester, the correct measurementcannot be obtained because of the tester’sinternal resistance. Refer to “Low resistance measurement”.

Primary coil resistance:1.19–1.61 Ω at 20 °C (68 °F)

2. Measure:• Secondary coil resistance


Secondary coil resistance:8.5–11.5 kΩ at 20 °C (68 °F)

ENGINE STOP SWITCH1. Check:

• Engine stop switch continuityOut of specification → Replace.

Engine stop switch continuity(black coupler)

Clip PositionLead color

White Black

InstalledFree

Push

RemovedFree

Push

IGNITION SYSTEM

7-19


ENGINE TEMPERATURE SENSOR1. Measure:

• Engine temperature sensor resistance(at the specified temperature)Out of specification → Replace.

Engine temperature sensor resistance:

20 °C (68 °F): 54.2–69.0 kΩ 100 °C (212 °F): 3.12–3.48 kΩ

Measurement steps:• Suspend the engine temperature sensor

in a container filled with water.• Slowly heat the water.• Measure the resistance when the speci-

fied temperature is reached.

SENSOR ASSEMBLY1. Check:

• Intake air temperature sensorOut of specification → Replace the sen-sor assembly.

Checking steps:• Measure the ambient temperature.• Connect a computer to the watercraft and

use the Yamaha Diagnostic System todisplay the intake air temperature.

• If the ambient temperature and the dis-played intake air temperature differ bymore than ± 5 °C (± 9 °F), replace thesensor assembly.

7-20


THERMOSWITCH (ENGINE)1. Check:

• Thermoswitch (engine) continuity(at the specified temperature)Out of specification → Replace.

1 No continuity È Temperature2 Continuity É Time

THERMOSWITCH (EXHAUST)1. Check:

• Thermoswitch (exhaust) continuity(at the specified temperature)Out of specification → Replace.

1 No continuity È Temperature2 Continuity É Time

Thermoswitch (engine) continuity temperature:a 84–90 °C (183–194 °F)b 70–84 °C (158–183 °F)

Checking steps:• Suspend the thermoswitch (engine) in a

container filled with water.• Place a thermometer in the water.• Slowly heat the water.• Measure the continuity when the speci-


Thermoswitch (exhaust) continuity temperature:a 94–100 °C (201–212 °F)b 80–94 °C (176–201 °F)

Checking steps:• Suspend the thermoswitch (exhaust) in a

container filled with water.• Place a thermometer in the water.• Slowly heat the water.• Measure the continuity when the speci-


7-21


MAIN AND FUEL PUMP RELAY1. Check:

• Main and fuel pump relay continuityFaulty → Replace.

Checking steps:• Connect the tester leads between the

main and fuel pump relay terminals 5, 6and 7.

• Connect the terminals 2 or 3 to the pos-itive battery terminal.

• Connect the terminal 1 to the negativebattery terminal.

• Check that there is continuity betweenthe main and fuel pump relay terminals.

• Check that there is no continuity betweenthe main and fuel pump relay terminalsafter disconnecting terminals 2, 3 or 1.

• Connect the tester leads between themain and fuel pump relay terminals 7and 8.

• Connect the terminals 4 to the negativebattery terminal.

• Connect the terminal 6 to the positivebattery terminal.

• Check that there is continuity betweenthe main and fuel pump relay terminals.

• Check that there is no continuity betweenthe main and fuel pump relay terminalsafter disconnecting terminals 4 or 6.

UP

– +

87654321

– +

87654321

7-22


THROTTLE POSITION SENSOR1. Measure:

• Throttle position sensor output voltageOut of specification → Adjust the throttlebodies synchronization.Refer to “FUEL INJECTION SYSTEM”in Chapter 4.


Test harness SMHW099-3 (3 pins):

90890-06793Test connector:

YW-06862Test connector FMY-8:

90890-06862



Measurement steps:• Connect the test harness (3 pins) to the

throttle position sensor 1.• To start the ECM normally, use the

Yamaha Diagnostic System. Use the testconnector 2 to start the ECM normallyonly if the Yamaha Diagnostic System isnot available.

• Measure the throttle position sensor out-put voltage.

1

B/O

P

2

7-23


CAM POSITION SENSOR1. Measure:

• Cam position sensor output voltageOut of specification → Replace.

NOTE:• The cam position sensor contains two indi-

vidual sensors as shown in the illustration:sensor 1 1 and sensor 2 2.

• To measure the output voltage, pass thescrewdriver under the measuring positionsA, B (center), and C of the cam position sen-sor in order.

• When operating the Yamaha Diagnostic Sys-tem, electric power is supplied to the camposition sensor.


Test harness HM090-3 (3 pins):New: 90890-06877Current: 90890-06777

Cam position sensor output voltage:

Green/orange (G/O) – Black/orange (B/O)

Position Voltage (V)

A More than 4.8

B Less than 0.8

C More than 4.8

Measurement steps:• Remove the cam position sensor.• Connect the test harness (3 pins) to the

cam position sensor.• Operate the Yamaha Diagnostic System.• Measure the output voltage when a

screwdriver is passed under the camposition sensor in the direction shown.

1

2A

B

C

7-24


NOISE FILTER1. Check:

• Noise filter continuityOut of specification → Replace.

Noise filter continuity:

Black (B) – Red (R) No continuityB G

GR

B

R

SLANT DETECTION SWITCH1. Check:

• Slant detection switch continuityOut of specification → Replace.

Position

Lead color

Blue/black (L/B)

Black/orange (B/O)

Normal operation È

Overturned É

UP

UP

È

É

7-25

E– +ELEC FUEL CONTROL SYSTEM

FUEL CONTROL SYSTEMWIRING DIAGRAM

#4

#3

#2

#1

L/R

P/G

B/Y

B/O

B/O

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

Pu/G

Pu/Y

Pu/B

Pu/R

O

O

P

R/Y

R/Y

R

B/O

B/O

B/O

B/O

B/Y

B/O

P

P

L/RBr

L

Y

R R/Y

R

B

R/Y

R/Y

B/Y

B/Y

B/YB/O

B/Y

O P

P

B/O

R

R R

B/O

B/OB/O

BB

B

R/Y

B

B

L

B

L

B

B

B

B

6

3

2

D

D

D

D

B

C 0

4

R

P

P

O

R

R R O

5 : P 6 : P/W 8 : B/Y 9 : O14 : L28 : L/B30 : R/Y

33 : P/G35 : B/Y37 : Pu/G38 : Pu/Y39 : Pu/B40 : Pu/R

1 2 3 4 5 6 7 8

Pu/G

R/Y

Pu/Y

R/Y

Pu/B

R/Y

Pu/R

R/Y

R/YR/Y

B

L

B

P

B

A

B/OL/B

Y

L/B

B/O

B/O

P

P

B

P

B/O

B

P

B/O

P

B

P

B

8

9

P P O

P/W

P/W

P/W

E

1518

L

F

B/Y O

B/OP/G

PO

G/B

G

Pu/B

G/YG/R

Pu/G

Pu/Y

Pu/B

P

O

R/Y

Pu/Y

G/Y

G/R

B/Y

P/G

Pu/R

Pu/RPu/G

P/GR/Y

G

G/BB/O

B

B

B/OB/O

B/O

5

7

R/Y

R/Y

R/Y

R

1

1 ECM2 Main and fuel pump relay3 Fuse (20A)4 Battery5 Fuel pump6 Multifunction meter7 Fuel sender8 Thermoswitch (exhaust)9 Thermoswitch (engine)

0 Engine temperature sensorA Slant detection switchB Sensor assemblyC Throttle position sensorD Fuel injectorE Oil pressure switchF Remote control unit

7-26


WIRING DIAGRAM

#4

#3

#2

#1

L/R

P/G

B/Y

B/O

B/O

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

Pu/G

Pu/Y

Pu/B

Pu/R

O

O

P

R/Y

R/Y

R

B/O

B/O

B/O

B/O

B/Y

B/O

P

P

L/RBr

L

Y

R R/Y

R

B

R/Y

R/Y

B/Y

B/Y

B/YB/O

B/Y

O P

P

B/O

R

R R

B/O

B/OB/O

BB

B

R/Y

B

B

L

B

L

B

B

B

B

6

3

2

D

D

D

D

B

C 0

4

R

P

P

O

R

R R O

5 : P 6 : P/W 8 : B/Y 9 : O14 : L28 : L/B30 : R/Y

33 : P/G35 : B/Y37 : Pu/G38 : Pu/Y39 : Pu/B40 : Pu/R

1 2 3 4 5 6 7 8

Pu/G

R/Y

Pu/Y

R/Y

Pu/B

R/Y

Pu/R

R/Y

R/YR/Y

B

L

B

P

B

A

B/OL/B

Y

L/B

B/O

B/O

P

P

B

P

B/O

B

P

B/O

P

B

P

B

8

9

P P O

P/W

P/W

P/W

E

1518

L

F

B/Y O

B/OP/G

PO

G/B

G

Pu/B

G/YG/R

Pu/G

Pu/Y

Pu/B

P

O

R/Y

Pu/Y

G/Y

G/R

B/Y

P/G

Pu/R

Pu/RPu/G

P/GR/Y

G

G/BB/O

B

B

B/OB/O

B/O

5

7

R/Y

R/Y

R/Y

R

1

B : BlackBr : BrownG : GreenL : BlueO : OrangeP : PinkR : RedW : WhiteY : Yellow

B/O : Black/orangeB/Y : Black/yellowG/O : Green/orangeL/B : Blue/blackL/R : Blue/redP/G : Pink/greenP/W : Pink/whitePu/B : Purple/blackPu/G : Purple/green

Pu/R : Purple/redPu/Y : Purple/yellowR/Y : Red/yellowW/R : White/red

7-27


FUEL PUMP1. Check:

• Fuel pump operating soundFuel pump does not sound → Measurethe fuel pressure.Refer to “FUEL INJECTION SYSTEM”in Chapter 4.

NOTE:After the engine is stopped, the fuel pump willoperate for 10 seconds.

FUEL SENDER1. Measure:

• Fuel sender resistanceOut of specification → Replace.

Float position

Resistance (Ω)

A 133.5–136.5

B 5–7

7-28


FUEL INJECTORRefer to “FUEL INJECTION SYSTEM”in Chapter 4.

MAIN AND FUEL PUMP RELAYRefer to “IGNITION SYSTEM”.

OIL PRESSURE SWITCHRefer to “INDICATION SYSTEM”.

THERMOSWITCH (ENGINE)Refer to “IGNITION SYSTEM”.

THERMOSWITCH (EXHAUST)Refer to “IGNITION SYSTEM”.

SLANT DETECTION SWITCHRefer to “IGNITION SYSTEM”.

REMOTE CONTROL UNITRefer to “REMOTE CONTROL SYS-TEM”.

7-29

E– +ELEC STARTING SYSTEM

STARTING SYSTEMWIRING DIAGRAM

FREEPUSH

Br BrFREEPUSH

W B R Br

0

11 15 14 18 12 3 4 13

L

R/Y1431 21 30

R

L/R

L

Y

R R/Y

B

R/Y

R/Y

L/R

Y

R

Br

Br

Br

Br

R

Br

R

B

B

R

4

93

2

1

8 7

6

R

P

P

O

R

R

R R

R R

R

1 2 3 4 5 6 7 8

5

Br

B

B

B

B

B

B

LL

Y

L L

B B

AB

BB

B

R/Y

B

R/Y

R

1234567890ABCDEFGH

1 ECM2 Main and fuel pump relay3 Fuse (20A)4 Starter relay5 Starter motor6 Battery7 Start switch8 Engine shut-off switch9 Fuse (3A)

0 Remote control unitA Fuel pump

B : BlackBr : BrownL : BlueR : RedY : YellowL/R : Blue/redR/Y : Red/yellow

7-30



WIRING CONNECTIONS1. Check:

• Wiring connectionsPoor connections → Properly connect.

FUSE1. Check:

• Fuse brokenBroken → Replace.

NOTE:20A fuse is for main relay, engine shut-offswitch and rectifier/regulator.3A fuse is for multifunction meter, electric bilgepump, and remote control unit.

Fuse rating:3A, 20A

START SWITCH1. Check:

• ContinuityOut of specification → Replace.

Start continuity(natural color coupler)

Clip PositionLeads

Red Brown

Installed Free

Push

Removed Free

Push

7-31


STARTER RELAY1. Inspect:

• Brown lead terminal• Black lead terminal

Loose → Tighten.

2. Check:• Starter relay

Faulty → Replace.

Checking steps:• Connect the tester leads between the

starter relay terminals as shown.• Connect the brown lead terminal to the

positive battery terminal.• Connect the black lead terminal to the

negative battery terminal.• Check that there is continuity between

the starter relay terminals.• Check that there is no continuity after the

brown or black lead is removed.

Br

B


7-32

E– +ELEC STARTER MOTOR

STARTER MOTOREXPLODED DIAGRAM


*: As required

Step Procedure/Part name Q’ty Service pointsSTARTER MOTOR DISASSEMBLY


Starter motor Refer to “GENERATOR AND STARTER MOTOR” in Chapter 5.

1 O-ring 12 Bolt 23 Starter motor front cover 14 O-ring 15 Oil seal retainer 16 Washer 17 Shim * t = 0.2 mm, 0.5 mm

Not reusable

Not reusable

7-33


EXPLODED DIAGRAM

*: As required

Step Procedure/Part name Q’ty Service points8 Starter motor rear cover 19 O-ring 110 Shim * t = 0.2 mm, 0.8 mm11 Armature assembly 112 Nut/spring washer/washer 1/1/413 O-ring 114 Brush holder 115 Brush spring 416 Bolt 117 Brush assembly 1

Not reusable

Not reusable

7-34


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points18 Spacer 119 Holder 120 Starter motor yoke 1


7-35


SERVICE POINTSArmature inspection

1. Inspect:• Armature shaft 1

Damage/wear → Replace.1

2. Inspect:• Commutator

Dirt → Clean with 600 grit sandpaper.

3. Measure:• Commutator diameter

Below specification → Replace.

Minimum commutator diameter:27.0 mm (1.06 in)

4. Check:• Commutator undercut


NOTE:Remove all mica and metal particles with com-pressed air.

5. Measure:• Commutator undercut

Below specification → Replace.

Minimum commutator undercut:0.2 mm (0.01 in)

7-36


6. Inspect:• Armature coil continuity


Armature coil continuity:

Commutator segments 1 Continuity

Segment - Laminations 2 No continuity

Segment - Armature shaft No continuity

Brush holder inspection1. Measure:

• Brush length a Below specification → Replace.

Minimum brush length:6.5 mm (0.26 in)

2. Check:• Brush holder continuity


Brush holder continuity:

Brush holder - Base No continuity

Starter motor front cover inspection1. Inspect:

• Starter motor front cover oil sealDamage/wear → Replace the startermotor front cover.

7-37

E– +ELEC CHARGING SYSTEM

CHARGING SYSTEMWIRING DIAGRAM

B

RR

1

2

3

R

R

RGGG

G

G

G

B

G

B

G

G G

G

G

4

1 Rectifier/regulator2 Fuse (20A)3 Battery4 Lighting coil

B : BlackG : GreenR : Red

7-38

E– +ELEC CHARGING SYSTEM



LIGHTING COILRefer to “IGNITION SYSTEM”.

RECTIFIER/REGULATORRefer to “IGNITION SYSTEM”.

7-39

E– +ELEC ELECTRIC BILGE PUMP

ELECTRIC BILGE PUMPWIRING DIAGRAM

21 30

L/R

L

Y

R R/Y

R/Y

R/Y

R

Y

Br

B B

B

B

B

RR

3 7

2

4

5

R

P

P

O

R

B

R

R

R

1 2 3 4 5 6 7 8

R/Y

R/Y

B

Br

R/Y

R/Y

R

R/Y

R/Y R

R/Y

6

15

B

BB

B

L/R

R/Y

B

1

1 ECM2 Main and fuel pump relay3 Fuse (3A)4 Battery5 Electric bilge pump6 Remote control unit7 Fuse (20A)

B : BlackBr : BrownR : RedY : YellowL/R : Blue/redR/Y : Red/yellow

7-40

E– +ELEC ELECTRIC BILGE PUMP

ELECTRIC BILGE PUMP1. Check:

• Electric bilge pump operationIncorrect → Replace.

Checking steps:• Suspend the electric bilge pump in a con-

tainer filled with water.• Connect the brown lead terminal to the

positive battery terminal.• Connect the black lead terminal to the

negative battery terminal.• Check the water flows from the electric

bilge pump hose.

– +

B

Br





7-41

E– +ELEC OFF THROTTLE STEERING SYSTEM

OFF THROTTLE STEERING SYSTEMWIRING DIAGRAM

PO

G/B

G

Pu/B

G/YG/R

Pu/G

Pu/Y

Pu/B

P

O

R/Y

Pu/Y

G/Y

G/R

B/Y

P/G

Pu/R

Pu/RPu/G

P/GR/Y

G

G/BB/O

GG/Y

WRB

W

B

R

W/BB/O

W/R

B/O

B/O

B/O

B/O

W/BB/O

W/RB/OB/OB/O

B/O

O

PB/O

OP

Y/BB

R/W

W/LB/OR/Y

R/Y

R/Y R/YW/L

R/YBB/O

B/O

B/O

B/O

B/O

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

G/Y

R/Y

G

G/R

G/B

R/Y

R/Y

G/RG/B

R/YR/Y

R/YR/Y

G/RGW/LR/YP

18 :20 :29 :30 :34 :

OW/RW/BG/BG/Y

9 :12 :13 :16 :17 :

2

3

4

5

P

PO

R R

R/W

OO

R

Y/B

1

1 ECM2 Steering switch3 Pickup coil4 Throttle position sensor5 Bypass valve motor

B : BlackG : GreenO : OrangeP : PinkW : WhiteB/O : Black/orangeG/B : Green/blackG/R : Green/redG/Y : Green/yellow

R/Y : Red/yellowR/W : Red/whiteW/B : White/blackW/L : White/blueW/R : White/redY/B : Yellow/black

7-42


STEERING SWITCH1. Check:

• Steering switchFor checking instructions, refer to“SELF-DIAGNOSIS” in Chapter 9.Malfunction → Use the “Engine monitor”of the Yamaha Diagnostic System tocheck that the steering switch switcheson and off when the handlebar is turnedto the right and to the left.Does not operate → Replace.

ECMRefer to “IGNITION SYSTEM”.

PICKUP COILRefer to “IGNITION SYSTEM”.

THROTTLE POSITION SENSORRefer to “IGNITION SYSTEM”.

BYPASS VALVE MOTORRefer to “FUEL INJECTION SYSTEM”in Chapter 4.

7-43

E– +ELEC INDICATION SYSTEM

INDICATION SYSTEMWIRING DIAGRAM

G

B B

B

B

B

R

3

R L/R

L

Y

R R/Y

R

B

P

R R

P

W/B

R/Y

B/O

R/YR/YR

R/Y

R/Y

R R P P P

1 2 3 4 5 6 7 8

2

7

6

8

5

B/O

P

P

B

P

B/O

P

B

B/O

P

P

B

B

W

B

P

B/O

P

B

B/Y

B/O B/Y

B/Y

B/YB/O

B/Y

9

B/O

B/OB/O

B/OB/O

B/O

B/O

B/OB/O

B/OB/O

B/O

R/W

B/Y R/Y

L/R B/L

R

P

B

B

B

B/Y

P

AB

C

B

RW

0

B/L L/R

B/Y

R/Y

Y

B/Y

R/W

Y

B R

Y

B

B

B

B

R

1 21 3053515614

P/W

P/W

P/W

D

B/O

R/Y

W/B

B/O

G

4

1

L/BL/YY

L

715 18 16 6

L/R

R/Y

L/R

L/R

L/YL/B

L/RL/B Gy

B/O

O

R/Y

R/Y

R

Gy

1 ECM2 Main and fuel pump relay3 Fuse (20A)4 Remote control unit5 Battery6 Tacho pulse7 Thermoswitch (exhaust)8 Thermoswitch (engine)9 Engine temperature sensor

0 Multifunction meterA Fuel senderB Speed sensorC BuzzerD Oil pressure switch

7-44


WIRING DIAGRAM

G

B B

B

B

B

R

3

R L/R

L

Y

R R/Y

R

B

P

R R

P

W/B

R/Y

B/O

R/YR/YR

R/Y

R/Y

R R P P P

1 2 3 4 5 6 7 8

2

7

6

8

5

B/O

P

P

B

P

B/O

P

B

B/O

P

P

B

B

W

B

P

B/O

P

B

B/Y

B/O B/Y

B/Y

B/YB/O

B/Y

9

B/O

B/OB/O

B/OB/O

B/O

B/O

B/OB/O

B/OB/O

B/O

R/W

B/Y R/Y

L/R B/L

R

P

B

B

B

B/Y

P

AB

C

B

RW

0

B/L L/R

B/Y

R/Y

Y

B/Y

R/W

Y

B R

Y

B

B

B

B

R

1 21 3053515614

P/W

P/W

P/W

D

B/O

R/Y

W/B

B/O

G

4

1

L/BL/YY

L

715 18 16 6

L/R

R/Y

L/R

L/R

L/YL/B

L/RL/B Gy

B/O

O

R/Y

R/Y

R

Gy

B : BlackBr : BrownG : GreenGy : GrayL : BlueO : OrangeP : Pink

R : RedW : WhiteY : YellowB/L : Black/blueB/O : Black/orangeB/Y : Black/yellowL/B : Blue/black

L/R : Blue/redL/Y : Blue/yellowP/W : Pink/whiteR/W : Red/whiteR/Y : Red/yellowW/B : White/black

7-45





ECMRefer to “IGNITION SYSTEM”.

ENGINE TEMPERATURE SENSORRefer to “IGNITION SYSTEM”.

THERMOSWITCH (ENGINE)Refer to “IGNITION SYSTEM”.

THERMOSWITCH (EXHAUST)Refer to “IGNITION SYSTEM”.


BUZZER1. Check:

• BuzzerBuzzer does not sound → Replace.

Checking steps:• Connect the battery (12 V) to the buzzer

coupler as shown.

Battery positive terminal → Red (R) terminal 1

Battery negative terminal → Black (B) terminal 2

7-46


OIL PRESSURE SWITCH1. Measure:

• Oil pressure switch continuityOut of specification → Replace.

Lower unit pressure/vacuum tester:

YB-35956-AVacuum/pressure pump gauge set:

90890-06756

Oil pressure switch continuity pressure:

128 kPa (1.28 kgf/cm2, 18.2 psi) –166 kPa (1.66 kgf/cm2, 23.6 psi)

MULTIFUNCTION METERMultifunction meter

1. Check:• Multifunction meter

Cracked meter housing → Replace themultifunction meter.Meter is fogged/shows signs of waterintrusion → Replace the multifunctionmeter.

MULTIFUNCTION METER REMOVALRefer to “STEERING CONSOLECOVER” in Chapter 8.

7-47


Display function1. Check:

• Display functionDoes not operate → Replace the multi-function meter.

B/L B

L/R

B/YB/Y R/W

PB

R/W

Y Y

R R

W

W

BB

B P

L/R R

BR

1

2

3

4

5

Gy

L/B

L/R

L/Y

L/B

B/L

1 Remote control unit2 Buzzer3 Speed sensor4 ECM5 Fuel sender

B : BlackGy : GrayP : PinkR : RedW : WhiteY : Yellow

B/G : Black/greenB/L : Black/blueB/Y : Black/yellowL/B : Blue/blackL/R : Blue/redR/W : Red/white

7-48


Speedometer display1. Check:

• Speedometer displayDoes not display → Measure the speedsensor output voltage and pulses.

2. Measure:• Speed sensor output voltage and pulses

Out of specification → Repair orreplace.Within specification → Replace the mul-tifunction meter.

Speed sensor output voltage (dependant on the paddle wheel position):

Less than 400 mV/More than 11.6 V

Output pulse:2 pulses/one-full turn

Measurement steps:• Apply DC 12 voltage to the natural color

three-pin connector (between the red/yel-low and black/yellow leads).

• Rotate the paddle wheel by hand andmeasure the voltage between the black/yellow and yellow leads.

NOTE:As the paddle wheel is rotated, a square-wave voltage signal a is produced.

• Two pulses occur every time the paddlewheel makes one-full turn.

7-49


Tachometer display1. Check:

• Tachometer displayDoes not display → Check the enginespeed using the “Engine monitor” of theYamaha Diagnostic System.Replace the multifunction meter.

Hour meter display1. Check:

• Hour meter displayDoes not display → Replace the multi-function meter.

Voltage meter display1. Check:

• Voltage meter displayDoes not display → Check the batteryvoltage using the “Engine monitor” ofthe Yamaha Diagnostic System.Replace the multifunction meter.

Low oil pressure warning indicator1. Check:

• Low oil pressure warning indicatorNo operating → Check the oil pressureswitch using the “Engine monitor” of theYamaha Diagnostic System.Replace the multifunction meter.

Fuel level meter display and fuel warningindicator

1. Check:• Fuel level meter display and fuel warn-

ing indicatorDoes not display → Measure the fuelsender resistance.If the fuel sender resistance is withinspecification, replace the multifunctionmeter.

2. Measure:• Fuel sender resistance

Refer to “FUEL CONTROL SYSTEM”.

7-50


Overheat warning indicator1. Check:

• Overheat warning indicatorDoes not operate → Replace the multi-function meter.

Checking steps:• Start the engine.• Disconnect the thermoswitch (engine)

connector 1 (blue), engine temperaturesensor connector 2 (black) or ther-moswitch (exhaust) 3 connector.

• Connect the jumper lead to the femaleterminal of the disconnected connector.

• Check that the multifunction meter over-heat warning indicator comes on and thebuzzer sounds.

Check the engine warning indicator1. Check:

• Check the engine warning indicatorDoes not operate → Replace the multi-function meter.

Checking steps:• Start the engine.• Disconnect the coupler of a sensor (e.g.,

engine temperature sensor) that normallyactivates the check engine warning indi-cator when a malfunction occurs.

• Check that the warning light and checkengine warning indicator blink and thatthe buzzer sounds intermittently.

7-51

E– +ELEC REMOTE CONTROL SYSTEM

REMOTE CONTROL SYSTEMWIRING DIAGRAM

16 7 6 11 15 14 18 12 3 4 13 10

1234567890ABCDEFGH

L

R/YR/Y

1431 21 1530R

L/R

L

Y

R R/Y

B

R/Y

R/Y

R/Y

L/R

Y

Br

Br

B

B

R

4

73

2

1

6

R/Y

R R

P

P

O

R

R

R

R R

R

1 2 3 4 5 6 7 8

5

B

B

B

B

Y

B

BB

B

W/B

R/Y

B/OB

RW

B

R

R

B

B/L

L/R

B/L

L/YL/B

#4

#3

#2

#1

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

Pu/G

Pu/Y

Pu/B

Pu/R

R/Y

0

0

0

0 Pu/G

R/Y

Pu/Y

R/Y

Pu/B

R/Y

Pu/R

R/Y

R/YR/Y

9

8

W/B

W

W

W A

14 : L15 : W/B21 : L/R30 : R/Y 31 : Y

37 : Pu/G38 : Pu/Y39 : Pu/B40 : Pu/R

W

L/R

L/B GyL/R

L/B L/Y

L/R

L/R

P

O

G/B

G

Pu/B

G/YG/R

Pu/G

Pu/Y

Pu/B

P

O

R/Y

Pu/Y

G/Y

G/R

B/Y

P/G

Pu/R

Pu/RPu/G

P/GR/Y

G

G/BB/O

B

Gy

B

1 ECM2 Main and fuel pump

relay3 Fuse (20A)4 Starter relay5 Starter motor6 Battery7 Fuse (3A)8 Remote control unit

9 Multifunction meter0 Fuel injectorA AntennaB Buzzer

B : BlackBr : BrownGy : GrayL : BlueR : RedW : WhiteY : YellowB/L : Black/blueL/B : Blue/black

L/R : Blue/redL/Y : Blue/yellowPu/B : Purple/blackPu/G : Purple/greenPu/R : Purple/redPu/Y : Purple/yellowR/Y : Red/yellowW/B : White/black

7-52


REMOTE CONTROL SYSTEMYamaha Security System indicator

1. Check:• Yamaha Security System indicator

Check that the “SECURITY” indicatorlight 1 comes on when the YamahaSecurity System is deactivated (i.e., theengine can be started).Does not come on → Measure theremote control unit output voltage.

2. Measure:• Remote control unit output voltage

Within specification → Replace the mul-tifunction meter.Out of specification → Replace theremote control unit.

Remote control unit output voltage:

Blue/yellow (L/Y) – ground11–13 V

Measurement steps:• Disconnect the remote control unit 1

coupler from the multifunction meter.• Measure the remote control unit output

voltage while pushing the unlock buttonof the remote control transmitter.

1

1

L/Y

1

Low-rpm mode indicator1. Check:

• Low-rpm mode indicatorDoes not come on → Replace the multi-function meter.

Checking steps:• Press the unlock button 1 of remote con-

trol transmitter for more than four sec-onds to select the low-rpm mode.

• Check that the beeper sounds threetimes and the “L-MODE” indicator light 2comes on.

1

7-53


Diagnostic display1. Check:

• Diagnostic displayDoes not display → Replace the multi-function meter.

Checking steps:• Start the engine.• Disconnect the coupler of a sensor (e.g,.

engine temperature sensor) that is nor-mally displayed when a malfunctionoccurs. Refer to “SELF-DIAGNOSIS” inChapter 9.

• Check that the check engine warningindicator is displayed and that the buzzersounds.

• Press the select switch 1 for 8 secondsand check the error code indicated on themultifunction meter.

1

Checking the remote control transmitter1. Check:

• Remote control transmitterDoes not operate → Replace the remotecontrol transmitter.

Checking steps:

CAUTION:If the buttons on the remote controltransmitter are pushed but the transmit-ter does not operate, the battery may below.

• Press the lock button 1 of the remotecontrol transmitter. The beeper soundsonce.

• Check that the “SECURITY” indicatorlight goes off and the engine cannot bestarted.

• Press the unlock button 2 of the remotecontrol transmitter for a short time. Thebeeper sounds two or three times.

• Check that the “SECURITY” indicatorlight comes on and the engine can bestarted.

1 2

7-54


Number of beeps

Yamaha Security

System mode

Engine startability

1 beep Lock Unable

2 beepsUnlock

(normal mode)Able

3 beepsUnlock

(low-rpm mode)

Able

• Press the unlock button for more than 4seconds to select the low-rpm mode.

• Check that the beeper sounds threetimes and the “L-MODE” indicator lightcomes on.

NOTE:• If the start switch or the remote control

transmitter is not operated for more than25 seconds, the multifunction meter dis-play and the “L-MODE” indicator light willgo off. To change the modes again, pressthe lock button for a short time, and thenstart the procedures from the lock mode.

• While the engine is running, input from theremote control transmitter is not received.

7-55


Transmitter registration1. Register:

• Remote control transmitter 1 ID codes can be added or re-registeredby connecting the entry box 2.

Registration steps:• Connect the entry box.• Transmit the ID code from the remote

control transmitter to be registered.

NOTE:The remote control transmitters can be reg-istered in any sequence, regardless ofwhether they are original equipment oradditional transmitters.

• At this time, the system enters the regis-tration mode to register the first code. Allexisting ID codes will be deleted from theEEPROM.

• The “SECURITY” indicator light flasheswhen the registration of the ID code hasbeen completed. (If the registration couldnot be completed, the “SECURITY” indi-cator light comes on. Re-transmit the IDcode.)

• After confirming that the registration ofthe ID code has been completed usingthe “SECURITY” indicator light, transmitthe next ID code.

• Register the ID codes for up to fiveremote control transmitters.

• After ID code registration has been com-pleted, disconnect the entry box to exitthe registration mode.

GyB

1

2

7-56


Replacing of the transmitter battery

CAUTION:• Do not allow any water, dust, or dirt to

enter the remote control transmitter casewhen replacing the battery.

• Make sure that no foreign material istrapped between the upper case andlower case of the remote control transmit-ter during assembly.

1. Remove:• Cover

NOTE:Loosen the transmitter cover screws in thesequence shown.

4

1

5 3

2

6

2. Install:• Battery 1

NOTE:Install the battery (CR2016) with the positiveside facing down.

1

3. Install:• Cover

NOTE:Tighten the transmitter cover screws in thesequence shown.

T R.

Transmitter cover screw:0.1 N • m (0.01 kgf • m, 0.07 ft • lb)

3

6

2 4

5

1

EHULLHOOD

CHAPTER 8HULL AND HOOD

HANDLEBAR ..................................................................................................8-1EXPLODED DIAGRAM .............................................................................8-1REMOVAL AND INSTALLATION CHART ................................................8-1SERVICE POINTS ....................................................................................8-6

Handlebar inspection ..........................................................................8-6Handlebar switch inspection ...............................................................8-6Handlebar assembly installation .........................................................8-6

QSTS GRIP .....................................................................................................8-8EXPLODED DIAGRAM .............................................................................8-8REMOVAL AND INSTALLATION CHART ................................................8-8SERVICE POINTS ..................................................................................8-10

QSTS cable inspection and adjustment ............................................8-10QSTS grip inspection ........................................................................8-10

STEERING MASTER.....................................................................................8-11EXPLODED DIAGRAM ...........................................................................8-11REMOVAL AND INSTALLATION CHART ..............................................8-11SERVICE POINTS ..................................................................................8-15

Steering master components inspection ...........................................8-15

REMOTE CONTROL CABLES AND SPEED SENSOR LEAD ....................8-16EXPLODED DIAGRAM ...........................................................................8-16REMOVAL AND INSTALLATION CHART ..............................................8-16SERVICE POINTS ..................................................................................8-19

Remote control cables inspection .....................................................8-19Steering cable (jet pump end) installation .........................................8-19Steering cable stopper installation ....................................................8-19QSTS cable (jet pump end) installation.............................................8-20QSTS cable stopper installation........................................................8-20Shift cable (jet pump end) installation ...............................................8-20Shift cable holder installation ............................................................8-21Shift cable stopper installation ..........................................................8-21Remote control cables adjustment....................................................8-21

FRONT HOOD...............................................................................................8-22EXPLODED DIAGRAM ...........................................................................8-22REMOVAL AND INSTALLATION CHART ..............................................8-22

EHULLHOOD

8

STEERING CONSOLE COVER ....................................................................8-26EXPLODED DIAGRAM ...........................................................................8-26REMOVAL AND INSTALLATION CHART ..............................................8-26SERVICE POINTS ..................................................................................8-32

Glove compartment assembly installation.........................................8-32

HOSES ..........................................................................................................8-33EXPLODED DIAGRAM ...........................................................................8-33REMOVAL AND INSTALLATION CHART ..............................................8-33

SHIFT LEVER................................................................................................8-35EXPLODED DIAGRAM ...........................................................................8-35REMOVAL AND INSTALLATION CHART ..............................................8-35SERVICE POINTS ..................................................................................8-38

Base assembly..................................................................................8-38Shift lever ..........................................................................................8-38

SEATS AND HAND GRIP .............................................................................8-39EXPLODED DIAGRAM ...........................................................................8-39REMOVAL AND INSTALLATION CHART ..............................................8-39SERVICE POINTS ..................................................................................8-42

Seat lock inspection ..........................................................................8-42

EXHAUST SYSTEM ......................................................................................8-43EXPLODED DIAGRAM ...........................................................................8-43REMOVAL AND INSTALLATION CHART ..............................................8-43SERVICE POINTS ..................................................................................8-46

Exhaust system inspection................................................................8-46Exhaust component parts sub-assembly ..........................................8-46Exhaust system installation...............................................................8-47

DECK AND HULL..........................................................................................8-48EXPLODED DIAGRAM ...........................................................................8-48REMOVAL AND INSTALLATION CHART ..............................................8-48

ENGINE MOUNT ...........................................................................................8-50EXPLODED DIAGRAM ...........................................................................8-50REMOVAL AND INSTALLATION CHART ..............................................8-50

8-1

EHULLHOOD HANDLEBAR

HANDLEBAREXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsHANDLEBAR COVER REMOVAL Follow the left “Step” for removal.

1 Screw 42 Handlebar cover 13 Pad 14 Bolt 2 NOTE:

Position the corrugated tube for the throttlecable as shown in the illustration so that thetube attaches to the end of the outer throttlecable.

5 Handlebar cover stay 16 Throttle cable 17 Bolt 48 Upper handlebar holder 2


8-2

EHULLHOOD HANDLEBAR

EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsHANDLEBAR REMOVAL Follow the left “Step” for removal.QSTS cable (to jet thrust nozzle) Refer to “REMOTE CONTROL CABLES

AND SPEED SENSOR LEAD”.1 Nut/washer 2/22 QSTS converter 13 QSTS cable 2 1 with white tape a 4 QSTS cable 1 15 Handlebar switch coupler 26 Buzzer coupler 17 Screw 48 Handle boss cover 19 Band 2

8-3

EHULLHOOD HANDLEBAR

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points10 Hose packing 1

11 Buzzer 112 Handlebar assembly 1 NOTE:

• Pass the QSTS cable and handlebarswitch lead through the handle bosscover, and then install the handlebarassembly.

• Install the sponges of the QSTS cables asshown and make sure that the grommet isinstalled to the deck securely.

13 Grommet 2Reverse the removal steps for installation.

Not reusable

8-4

EHULLHOOD HANDLEBAR

EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsHANDLEBAR DISASSEMBLY Follow the left “Step” for disassembly.

1 Bolt 22 Grip end 23 Spacer 14 Screw/spring washer/washer 1/1/15 QSTS grip assembly 16 Special nut 17 Screw 2 NOTE:

Tighten the screw from the engine stopswitch side.

8-5

EHULLHOOD HANDLEBAR

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points8 Handlebar switch assembly 19 Screw 210 Throttle lever assembly 111 Handlebar grip 1 NOTE:

Apply adhesive to the handlebar and theinner surface of the handlebar grip.

12 Handlebar 1Reverse the disassembly steps for assembly.

8-6

EHULLHOOD HANDLEBAR

SERVICE POINTSHandlebar inspection

1. Inspect:• Handlebar

Bends/cracks/damage → Replace.

Handlebar switch inspectionRefer to “STARTING SYSTEM” inChapter 7.

Handlebar assembly installation1. Install:

• Bands 1

NOTE:After inserting the QSTS cables, buzzer lead,handlebar switch lead and throttle cable intothe grommets, tie the end of grommets withthe bands.

2. Install:• Upper handlebar holder 1

NOTE:• Align the punch marks a on the handlebar

with the top surface of the handlebar holder.• The upper handlebar holder should be

installed with the punch mark b facing for-ward.

CAUTION:Clearance c should be narrower thanclearance d.

T R.

Handlebar holder bolt:20 N • m (2.0 kgf • m, 14 ft • lb)LOCTITE 242

Reference clearance:c: 1.5 mm (0.06 in)d: 3.5 mm (0.14 in)

8-7

EHULLHOOD HANDLEBAR

3. Install:• Throttle cable

NOTE:Fit the seal into the groove in the bracket.

4. Install:• Handlebar cover 1

NOTE:When the handlebar cover is in contact withthe steering boss cover, adjust the handlebarmount angle so that the clearance a and bare equal.

5. Adjust:• Throttle cable free play


6. Adjust:• QSTS cable


8-8

EHULLHOOD QSTS GRIP

QSTS GRIPEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsQSTS GRIP DISASSEMBLY Follow the left “Step” for disassembly.QSTS grip assembly Refer to “HANDLEBAR”.

1 Screw/washer 1/12 Cover 13 Ball 24 Spring 25 QSTS cable 1 16 QSTS cable 2 1 with white tape a

8-9

EHULLHOOD QSTS GRIP

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points7 Screw/washer 2/28 Spacer 19 QSTS shift lock lever 110 Spring 111 Spacer 112 Cable housing 113 QSTS grip 1


8-10

EHULLHOOD QSTS GRIP

SERVICE POINTSQSTS cable inspection and adjustment

1. Inspect:• QSTS cables

Frays/kinks/rough movement → Replace.

2. Adjust:• QSTS cable length a

NOTE:• Before adjusting the QSTS cables, set the

trim grip to the neutral position.• Adjust the QSTS cable lengths a to the

specified length and be sure to take up anyslack.

QSTS cable length:72 ± 0.5 mm (2.83 ± 0.02 in)

QSTS grip inspection1. Inspect:

• QSTS gripDamage/wear → Replace.

8-11

EHULLHOOD STEERING MASTER

STEERING MASTEREXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsSTEERING MASTER REMOVAL Follow the left “Step” for removal.Steering console cover Refer to “STEERING CONSOLE COVER”.Steering cable end Refer to “REMOTE CONTROL CABLES

AND SPEED SENSOR LEAD”.1 Bolt/washer 1/12 Steering arm 13 Nut/washer 4/44 Steering master assembly 15 Bolt 4

8-12


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points6 Bolt 37 Magnet 18 Steering switch 1


8-13


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsSTEERING MASTER DISASSEMBLY


1 Bolt/washer 2/22 Stay 13 Spring 14 Bolt/washer 6/65 Lower housing 16 Spring 17 Bushing 18 Bushing 19 Upper housing 110 Tilt lever 1

8-14


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points11 Tilt stopper 112 Bolt/nut/holder 4/4/413 Retainer 214 Steering shaft 115 Steering tube 116 Bolt 217 Cap 118 Shaft 1 119 Cross piece 1


8-15


SERVICE POINTSSteering master components inspection

1. Inspect:• Each component part

Damage/wear → Replace the steeringmaster.

8-16

EHULLHOOD

REMOTE CONTROL CABLES AND SPEED SENSOR LEAD

REMOTE CONTROL CABLES AND SPEED SENSOR LEADEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsREMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL


Service lid 1 Refer to “FRONT HOOD”.Front seat assembly Refer to “SEATS AND HAND GRIP”.Glove compartment Refer to “STEERING CONSOLE COVER”.

1 Steering cable end 12 Nut/washer 2/23 Bracket 14 Nut 25 Steering cable holder 1

8-17

EHULLHOOD


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points6 Nut 17 Steering cable 18 Seal 19 Speed sensor coupler 110 Nut 111 Cap 112 Screw 413 Speed sensor 114 Shift cable end 115 Nut 2

8-18

EHULLHOOD


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points16 Shift cable holder 217 Nut 118 Shift cable 119 Seal 120 Nut 121 Pin 122 QSTS cable end 123 Nut 124 QSTS cable 125 Packing 1


8-19

EHULLHOOD


SERVICE POINTS

WARNINGWhen routing the cables, do not grasp thecable by the outer crimped sheath or steelend. This could deform or loosen the cableend due to extreme angles and or pressure.Always hold the cables by the outer coverbelow the crimp.If a cable becomes damaged replace it.Never attempt to repair a damaged cable.

Remote control cables inspection1. Inspect:

• Steering cable• QSTS cable• Shift cable

Frays/kinks/rough movement → Replace.

Steering cable (jet pump end) installation1. Install:

• Steering cable

WARNINGThe steering cable must be screwed in atleast 8 mm (0.31 in).

Steering cable set length a (jet pump end):

14.5 mm (0.57 in)

Steering cable stopper installation1. Install:

• Steering cable stopper

WARNINGBe sure to the steering cable stopper intothe groove in the outer cable as shown inthe illustration.

8-20

EHULLHOOD


QSTS cable (jet pump end) installation1. Install:

• QSTS cable (jet pump end)

WARNINGThe QSTS cable must be screwed in morethan 8 mm (0.31 in).

QSTS cable set length a (jet pump end):

13.6 mm (0.54 in)

QSTS cable stopper installation1. Install:

• QSTS cable stopper

WARNINGBe sure to fit the projection 1 on the QSTScable stopper into the groove in the outercable.

Shift cable (jet pump end) installation1. Install:

• Shift cable (jet pump end)

WARNINGThe shift cable must be screwed in morethan 8 mm (0.31 in).

Shift cable set length a (jet pump end):

13.6 mm (0.54 in)

8-21

EHULLHOOD


Shift cable holder installation1. Install:

• Shift cable holders

NOTE:Install the shift cable holders so that mark aand mark b are in the positions shown in theillustration.

Shift cable stopper installation1. Install:

• Shift cable stopper

WARNINGBe sure to fit the projection 1 on the shiftcable stopper into the groove in the outercable.

Remote control cables adjustmentRefer to “CONTROL SYSTEM” in Chap-ter 3.

8-22

EHULLHOOD FRONT HOOD

FRONT HOODEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsFRONT HOOD REMOVAL Follow the left “Step” for removal.

1 Nut/washer 4/42 Front hood assembly 13 Bolt 44 Bolt 25 Hinge assembly 16 Bolt 27 Hood lock assembly 1

2

76

4

8

9

3

5

1

11 10

6 × 18 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 30 mm

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 4 × 8 mm 1.5 N • m (0.15 kgf • m, 1.1 ft • Ib)

LT

271

LT

242

LT

242

LT

242

6 × 18 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 10 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

8-23

EHULLHOOD

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points8 Bolt 49 Service lid 1 110 Screw 411 Service lid 2 1


2

76

4

8

9

3

5

1

11 10

6 × 18 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 30 mm

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 4 × 8 mm 1.5 N • m (0.15 kgf • m, 1.1 ft • Ib)

LT

271

LT

242

LT

242

LT

242

6 × 18 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 10 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

FRONT HOOD

8-24


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsHINGE DISASSEMBLY Follow the left “Step” for disassembly.

1 Circlip 22 Pin (long) 13 Hinge 14 Pin (short) 15 Damper stay 16 Collar 27 Grommet 2

4

5

1

7 6

10

2

7 6 1

8

9

3

8-25


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points8 Band 19 Damper boots 110 Damper 1


4

5

1

7 6

10

2

7 6 1

8

9

3

8-26

EHULLHOOD

STEERING CONSOLE COVEREXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsMETER AND MIRROR REMOVAL Follow the left “Step” for removal.Handlebar assembly Refer to “HANDLEBAR”.Service lid 1 Refer to “FRONT HOOD”.

1 Band 12 Multifunction meter coupler 43 Bolt 44 Panel 15 Band 1

LT

242

LT

242

5

7

9

5

610

12

1

2

34

5 × 20 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

5 × 20 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)

811

STEERING CONSOLE COVER

8-27

EHULLHOOD STEERING CONSOLE COVER

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points6 Bolt 47 Multifunction meter 18 Hose packing 19 Grommet 110 Nut/washer 4/411 Plate 212 Mirror 2


LT

242

LT

242

5

7

9

5

610

12

1

2

34

5 × 20 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

5 × 20 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)

6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)

811

Not reusable

8-28


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsSIDE COVER REMOVAL Follow the left “Step” for removal.

1 Cup holder 12 Holder 13 Bolt 84 Washer 25 Side cover 2


3

2

3

4

3

5

6 × 22 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

LT

271

3

45

3

1

8-29


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsSTEERING CONSOLE COVER AND GLOVE BOX ASSEMBLY REMOVAL


1 Nut/washer 2/22 Bolt 23 Nut/washer 2/24 Bolt 25 Bolt 26 Shift handle lever 1

6 × 30 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 14 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

4

9

5

6

31 10

12

117

2

6 × 18 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 22 mm8 × 30 mm

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

20 N • m (2.0 kgf • m, 14 ft • Ib)

8

LT

242

LT

271

LT

242

8-30


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points7 Bolt 28 Steering console cover 1 NOTE:

To remove the console cover easily, pull thetilt lever up.

9 Hood lock assembly 110 Nut/washer 2/211 Bolt 212 Glove compartment assembly 1


6 × 30 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 14 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

4

9

5

6

31 10

12

117

2

6 × 18 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 22 mm8 × 30 mm

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

20 N • m (2.0 kgf • m, 14 ft • Ib)

8

LT

242

LT

271

LT

242

8-31


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsGLOVE COMPARTMENT DISASSEMBLY


1 Glove compartment 12 Hinge assembly 23 Lid 14 Gear assembly 25 Screw 26 Latch 1


1

2

4

3

6LT

271

6 × 14 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

2

4

5

8-32


SERVICE POINTSGlove compartment assembly installation

1. Install:• Hinge assembly

NOTE:When installing the hinge assembly, makesure that the springs are in the position shown.

8-33

EHULLHOOD HOSES

HOSESEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsHOSES REMOVAL Follow the left “Step” for removal.Fuel tank Refer to “FUEL TANK AND FUEL PUMP

MODULE” in Chapter 4.

NOTE:When removing the ventilation hose andfuel tank breather hose, it is not necessaryto remove the fuel tank.

1 Band 42 Ventilation hose 23 Fuel tank breather hose 2

(VENT)

(VENT)

(VENT)

1

2

12

7 8

1

64

5

3

54 6

8 7

FWD

4.2 N • m (0.42 kgf • m, 3.0 ft • Ib)4.2 N • m (0.42 kgf • m, 3.0 ft • Ib)

1

3

8-34

EHULLHOOD HOSES

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points4 Clamp 25 Cooling water hose 26 Nut 27 Cooling water pilot outlet 28 Seal 2


(VENT)

(VENT)

(VENT)

1

2

12

7 8

1

64

5

3

54 6

8 7

FWD

4.2 N • m (0.42 kgf • m, 3.0 ft • Ib)4.2 N • m (0.42 kgf • m, 3.0 ft • Ib)

1

3

8-35

EHULLHOOD SHIFT LEVER

SHIFT LEVEREXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsSHIFT LEVER REMOVAL Follow the left “Step” for removal.Side cover Refer to “STEERING CONSOLE COVER”.Shift cable Refer to “REMOTE CONTROL CABLES

AND SPEED SENSOR LEAD”.1 Bolt 22 Shift lever handle 13 Bolt 14 Washer 15 Shift lever 1

8-36


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points6 Screw 37 Base assembly 18 Nut/washer 3/39 Screw 310 Plate 1


8-37


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsBASE DISASSEMBLY Follow the left “Step” for disassembly.

1 Bolt/washer 2/22 Plate 13 Spring 14 Actuator 15 Roller 16 Shaft 17 Shift arm 1


8-38


SERVICE POINTSBase assembly

1. Install:• Shift arm• Shaft

Installation steps:• Install the shift arm 1 so that it comes in

contact with the stopper 2 as shown.• Install the shaft 3 to the base so that it

come in contact with the stopper 4 asshown.

Shift lever1. Install:

• Shift lever

NOTE:To install the shift lever, align the arrow marka on the shift lever with the punch mark b onbase assembly.

a

b

8-39

EHULLHOOD SEATS AND HAND GRIP

SEATS AND HAND GRIPEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsSEATS AND HAND GRIP REMOVAL


1 Rear seat assembly 1 FX High Output2 Rear seat assembly 1 FX Cruiser High Output3 Front seat assembly 14 Bolt 45 Seat lock assembly 26 Seat storage compartment 17 Nut/washer 4/48 Bolt/washer 4/4

31

5

4

22

21

18

19

2017

19

7

8

1014

6

16

15131211

9

54

6 × 25 mm8 × 30 mm8 × 30 mm

18 N • m (1.8 kgf • m, 13 ft • Ib)

5.2 N • m (0.52 kgf • m, 3.8 ft • Ib)

26 N • m (2.6 kgf • m, 19 ft • Ib)

6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

6 × 40 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

15 N • m (1.5 kgf • m, 11 ft • Ib)

26 N • m (2.6 kgf • m, 19 ft • Ib)

LT

271

LT

271

6 × 40 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

2

8-40


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points9 Deck beam 110 Nut 111 Projection 112 Washer 113 Seal 114 Nut 415 Bolt 416 Rear seat stay 217 Nut 1

31

5

4

22

21

18

19

2017

19

7

8

1014

6

16

15131211

9

54

6 × 25 mm8 × 30 mm8 × 30 mm

18 N • m (1.8 kgf • m, 13 ft • Ib)

5.2 N • m (0.52 kgf • m, 3.8 ft • Ib)

26 N • m (2.6 kgf • m, 19 ft • Ib)

6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

6 × 40 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

15 N • m (1.5 kgf • m, 11 ft • Ib)

26 N • m (2.6 kgf • m, 19 ft • Ib)

LT

271

LT

271

6 × 40 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

2

8-41


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points18 Projection 119 Washer 220 Nut/washer 4/421 Bolt 422 Hand grip 1


31

5

4

22

21

18

19

2017

19

7

8

1014

6

16

15131211

9

54

6 × 25 mm8 × 30 mm8 × 30 mm

18 N • m (1.8 kgf • m, 13 ft • Ib)

5.2 N • m (0.52 kgf • m, 3.8 ft • Ib)

26 N • m (2.6 kgf • m, 19 ft • Ib)

6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

6 × 40 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

15 N • m (1.5 kgf • m, 11 ft • Ib)

26 N • m (2.6 kgf • m, 19 ft • Ib)

LT

271

LT

271

6 × 40 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

2

8-42


SERVICE POINTSSeat lock inspection

1. Inspect:• Front seat lock• Rear seat lock


8-43

EHULLHOOD EXHAUST SYSTEM

EXHAUST SYSTEMEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsEXHAUST SYSTEM REMOVAL Follow the left “Step” for removal.Deck beam Refer to “SEATS AND HAND GRIP”.Jet pump unit assembly Refer to “JET PUMP UNIT” in Chapter 6.

NOTE:When removing the water lock and exhaustjoint, it is not necessary to remove the jetpump unit.

1 Band 12 Joint clamp 13 Hose clamp 14 Water lock 1

7

14

3

13

15

18

17

12

11

16

10

5

1

4

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

2.5 N • m (0.25 kgf • m, 1.8 ft • Ib)

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

6

2

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

89

8-44


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points5 Joint clamp 16 Joint 17 Joint clamp 18 Joint 19 Joint clamp 110 Exhaust joint 111 Nut/washer 6/612 Exhaust valve 1 NOTE:

Remove parts 12 to 18 as a set.

13 Hose clamp 114 Rubber hose 1

7

14

3

13

15

18

17

12

11

16

10

5

1

4

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

2.5 N • m (0.25 kgf • m, 1.8 ft • Ib)

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

6

2

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

89

8-45


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points15 Hose clamp 116 Water tank 117 Rubber hose 118 Plate 1


7

14

3

13

15

18

17

12

11

16

10

5

1

4

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

2.5 N • m (0.25 kgf • m, 1.8 ft • Ib)

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

6

2

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

89

8-46


SERVICE POINTSExhaust system inspection

1. Inspect:• Water lock band


2. Inspect:• Rubber hoses

Burns/cracks/damage → Replace.

3. Inspect:• Water lock

Cracks/leaks → Replace.

4. Inspect:• Water tank

Cracks/damage/leaks → Replace.

Exhaust component parts sub-assembly1. Install:

• Rubber hose• Plate

NOTE:Be sure to fit the projections on the rubberhose with the grooves in the plate.

2. Install:• Rubber hoses• Water tank

NOTE:• Be sure to insert the rubber hose to the linea on the water tank.

• Make sure that there is a surface distance of47 mm (1.9 in) b between the parting linesof the water tank and rubber hose.

• Align the parting line c of the rubber hosewith the parting line d of the water tank.

b

a

ac

d

8-47


Exhaust system installation1. Install:

• Exhaust joint

NOTE:Be sure to install the projections a on theexhaust pipe and exhaust joint into the slots bin the joint.

a

b

ba

2. Install:• Water lock

NOTE:Be sure to insert the rubber hose to the line aon the water lock.

a

8-48

EHULLHOOD DECK AND HULL

DECK AND HULLEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsDECK AND HULL DISASSEMBLY Follow the left “Step” for disassembly.

1 Nut 12 Spout 13 Nut 24 Cleat 15 Plate 26 Bolt/collar 10/107 Sponson 28 Nut/washer 4/49 Screw/washer 4/410 Drain plug 2

16

17

18

4 5

3

7

6

1513 14

12 13

1

910

11

8

2

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 45 mm 16 N • m (1.6 kgf • m, 12 ft • Ib)

6 × 22 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

5 × 25 mm2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

LT

271

5

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

15 N • m (1.5 kgf • m, 11 ft • Ib)

13 N • m (1.3 kgf • m, 9.4 ft • Ib)

LT

271

8-49


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points11 Seal 212 Nut 4 NOTE:

To remove the cleat, remove the exhaustsystem first.

13 Plate 414 Cleat 215 Seal 216 Nut/washer 3/317 Bolt 418 Protector 1


16

17

18

4 5

3

7

6

1513 14

12 13

1

910

11

8

2

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 45 mm 16 N • m (1.6 kgf • m, 12 ft • Ib)

6 × 22 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

5 × 25 mm2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

LT

271

5

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

15 N • m (1.5 kgf • m, 11 ft • Ib)

13 N • m (1.3 kgf • m, 9.4 ft • Ib)

LT

271

8-50

EHULLHOOD ENGINE MOUNT

ENGINE MOUNTEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsENGINE MOUNT REMOVAL Follow the left “Step” for removal.Engine unit Refer to “ENGINE UNIT” in Chapter 5.

1 Bolt 42 Damper 1 13 Damper 2 14 Bolt 85 Engine mount 46 Liner 2 Stern side


ETRBLANLS

9

CHAPTER 9TROUBLE ANALYSIS

INTRODUCTION..............................................................................................9-1FEATURES ...............................................................................................9-1

Functions.............................................................................................9-1CONTENTS...............................................................................................9-1HARDWARE REQUIREMENTS................................................................9-2

OPERATING....................................................................................................9-3CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT.........................................................................................9-3

Top view..............................................................................................9-3

TROUBLE ANALYSIS.....................................................................................9-4TROUBLE ANALYSIS CHART..................................................................9-4SELF-DIAGNOSIS ....................................................................................9-8

9-1

ETRBLANLS INTRODUCTION

INTRODUCTIONFEATURESThe newly developed Yamaha Diagnostic System provides quicker detection and analysis of enginemalfunctions for quicker troubleshooting procedures than traditional methods.By connecting your computer to the ECM (Electronic Control Module) of a watercraft using the com-munication cable, this software can be used to display sensor data and data stored in the ECM on acomputer’s monitor.If this software is run on Microsoft Windows® 95, Windows 98, Windows Me, Windows 2000, orWindows XP the information can be displayed in colorful graphics. Also, the software can be oper-ated using either a mouse or a keyboard.In addition, the data for the main functions (Diagnosis, Diagnosis record, Engine monitor, and Datalogger) can be saved on a disk or printed out.

Functions1. Diagnosis: Each sensor’s status and each ECM diagnosis code or item are displayed. This

enables you to find malfunctioning parts and controls quickly.2. Diagnosis record: Sensors that had been activated and ECM diagnostic codes that have been

recorded are displayed. This allows you to check the watercraft’s record of malfunctions.3. Engine monitor: Each sensor’s status and the ECM data are displayed. This enables you to

find malfunctioning parts quickly.4. Stationary test: With the engine off, ignition, fuel injection, and the electric fuel pump are

checked. These tests can be performed quickly.5. Active test: With the engine running, each firing cylinder drops and the engine speed is

checked for changes to determine if the cylinder is malfunctioning. These tests can be per-formed quickly.

6. Data logger: From the data stored in the ECM, at least two items of 78 seconds of recordeddata are displayed on a graph. In addition, the operating time as compared to the engine speedand the total operating time are displayed. This allows you to check the operating status of theengine.

7. Some files: Lets you select and run other applications while continuing to run the diagnosticprogram.

CONTENTS1. Software (1)2. Adapter (1)3. Communication cable (1)4. Instruction Manual (1) 5. Installation Manual (1)

1 2 3 4 5

YAMAHADIAGNOSTIC

SYSTEM

INSTRUCTION MANUAL

YAMAHADIAGNOSTIC

SYSTEM

INSTALLATION MANUAL

9-2

ETRBLANLS INTRODUCTION

HARDWARE REQUIREMENTSMake sure that your computer meets the following requirements before using this software.

Computer: IBM-compatible computer

Operating system: Microsoft (Windows 95), Windows 98, Windows Me, Windows 2000, orWindows XP (English version)

CPU:Windows 95/98: i486X, 100 MHz or higher (Pentium 100 MHz or higher recommended)Windows Me/2000: Pentium, 166 MHz or higher (Pentium 233 MHz or higher recommended)Windows XP: Pentium, 300 MHz or higher (Pentium 500 MHz or higher recommended)

Memory:Windows 95/98: 16 MB or more (32 MB or more recommended)Windows Me: 32 MB or more (64 MB or more recommended)Windows 2000: 64 MB or more (128 MB or more recommended)Windows XP: 128 MB or more (256 MB or more recommended)

Hard disk free space: 20 MB or more (40 MB or more recommended)

Drive: CD-ROM drive

Display: VGA (640 × 480 pixels), (SVGA [800 × 600 pixels] or more recommended) 256 or more colors

Mouse: Compatible with the operating systems mentioned above

Communication port: RS232C (Dsub-9 pin) port, USB port

Printer: Compatible with the operating systems mentioned above

NOTE:• The amount of memory and the amount of free space on the hard disk differs depending on the

computer.• Using this software while there is not enough free space on the hard disk could cause errors and

result in insufficient memory.• This software will not run properly on some computers.• When starting up this program, do not start other software applications.• Do not use the screen saver function or the energy saving feature when using this program.• If the ECM is changed, restart the program.• Windows XP is a multiuser operating system, therefore, be sure to end this program if the login

user is changed.• The USB adapter cannot be used with Windows 95.

For operating instructions of the Yamaha Diagnostic System, refer to the “Yamaha Diagnostic Sys-tem Instruction Manual”.

9-3

ETRBLANLS OPERATING

OPERATINGCONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT

Top view

1 3-pin communication coupler2 Wiring harness coupler3 Meter coupler

NOTE:Be careful not to pinch the communication cable between the hood and the deck or to damage it.

3

1

2

9-4

ETRBLANLS TROUBLE ANALYSIS

TROUBLE ANALYSIS

NOTE:Before consulting the “TROUBLE ANALYSIS CHART,” check the following items.1. Check that the battery is charged and that its specified gravity is within specification.2. Check that there are no incorrect wiring connections.3. Check that all wiring connections are properly secured and that they are not rusty.4. Check that the engine shut-off cord (lanyard) is connect to the engine shut-off switch.5. Check that fuel is reaching the throttle bodies.

TROUBLE ANALYSIS CHART

Trouble mode Check elements

EN

GIN

E W

ILL

NO

T S

TA

RT

HA

RD

ST

AR

TIN

G

RO

UG

H ID

LIN

G

HIG

H ID

LIN

G

EN

GIN

E S

TA

LLS

PO

OR

AC

CE

LER

AT

ION

EN

GIN

E W

ILL

NO

T S

TO

P

PO

OR

PE

RF

OR

MA

NC

E

LIM

ITE

D E

NG

INE

SP

EE

D

OV

ER

HE

AT

ING

LOW

OIL

PR

ES

SU

RE

LOO

SE

ST

EE

RIN

G

BIL

GE

INC

RE

AS

E

IRR

EG

ULA

R W

AR

NIN

G IN

DIC

AT

ION

PO

OR

BA

TT

ER

Y C

HA

RG

ING

Relative partReference

chapter

FUEL SYSTEMFuel tank 4Fuel tank breather hose 4Fuel hose 4Fuel filter 4Fuel pump 4Fuel injectors 4Trolling speed 3Air filter 3

9-5


POWER UNITCompression 5Cylinder head gaskets 5Cylinder block 5Crankcase 5Piston rings 5Pistons 5Bearings 5Thermostat 5Valve(s) and valve seat(s) 5Valve clearance adjusting pad(s)

3

Camshaft(s) 5Timing chain 5Oil pump 5Engine oil 3Oil filter 3Oil pressure switch 7Bearing housing 5Drive couplings 5Rubber coupling 5Pilot water hose 5Water hose 5Water passage 5


EN

GIN

E W

ILL

NO

T S

TA

RT

HA

RD

ST

AR

TIN

G

RO

UG

H ID

LIN

G

HIG

H ID

LIN

G

EN

GIN

E S

TA

LLS

PO

OR

AC

CE

LER

AT

ION

EN

GIN

E W

ILL

NO

T S

TO

P

PO

OR

PE

RF

OR

MA

NC

E

LIM

ITE

D E

NG

INE

SP

EE

D

OV

ER

HE

AT

ING

LOW

OIL

PR

ES

SU

RE

LOO

SE

ST

EE

RIN

G

BIL

GE

INC

RE

AS

E

IRR

EG

ULA

R W

AR

NIN

G IN

DIC

AT

ION

PO

OR

BA

TT

ER

Y C

HA

RG

ING


chapter

9-6


JET PUMP UNITDuct 6Impeller 6Intake grate 6Bearings 6Intake duct 6Water inlet hose 6Bilge hose 6Bilge strainer 3Bilge hose joint 6

ELECTRICALIgnition system, fuel control system• Pickup coils 7• ECM 7• Ignition coils 7• Slant detector switch 7• Engine stop switch 7• Engine shut-off switch 7• Spark plugs 3• Main and fuel pump relay 7• Thermoswitch 7• Sensor assembly 7• Engine temperature

sensor7

• Throttle position sensor 7• Cam position sensor 7


EN

GIN

E W

ILL

NO

T S

TA

RT

HA

RD

ST

AR

TIN

G

RO

UG

H ID

LIN

G

HIG

H ID

LIN

G

EN

GIN

E S

TA

LLS

PO

OR

AC

CE

LER

AT

ION

EN

GIN

E W

ILL

NO

T S

TO

P

PO

OR

PE

RF

OR

MA

NC

E

LIM

ITE

D E

NG

INE

SP

EE

D

OV

ER

HE

AT

ING

LOW

OIL

PR

ES

SU

RE

LOO

SE

ST

EE

RIN

G

BIL

GE

INC

RE

AS

E

IRR

EG

ULA

R W

AR

NIN

G IN

DIC

AT

ION

PO

OR

BA

TT

ER

Y C

HA

RG

ING


chapter

9-7


Starting system• Start switch 7• Starter relay 7• Starter motor 7

Charging system• Lighting coil 7• Rectifier/regulator 7• Fuses 7• Battery leads —• Battery 3

Electric bilge pump• Electric bilge pump 7

Remote control system• Remote control unit 7

HULL AND HOODSteering master 8Water lock 8Exhaust hose 8Muffler 8Drain plugs 8


EN

GIN

E W

ILL

NO

T S

TA

RT

HA

RD

ST

AR

TIN

G

RO

UG

H ID

LIN

G

HIG

H ID

LIN

G

EN

GIN

E S

TA

LLS

PO

OR

AC

CE

LER

AT

ION

EN

GIN

E W

ILL

NO

T S

TO

P

PO

OR

PE

RF

OR

MA

NC

E

LIM

ITE

D E

NG

INE

SP

EE

D

OV

ER

HE

AT

ING

LOW

OIL

PR

ES

SU

RE

LOO

SE

ST

EE

RIN

G

BIL

GE

INC

RE

AS

E

IRR

EG

ULA

R W

AR

NIN

G IN

DIC

AT

ION

PO

OR

BA

TT

ER

Y C

HA

RG

ING


chapter

9-8


SELF-DIAGNOSISWith the engine running, press the select but-ton 1 for 8 seconds and check if an error codeis indicated on the multifunction meter.

If the Yamaha Diagnostic System is not usedto check the symptoms listed in the table, theerror codes can be checked easily with theself-diagnosis in the multifunction meter. How-ever, if there are numerous error codes dis-played, be sure to check them with theYamaha Diagnostic System.

Code Symptom

01 Normal

13 Pickup coil malfunction

15Engine temperature sensor malfunction

18Throttle position sensor malfunction

19 Incorrect battery voltage

23Intake air temperature sensor malfunction

24 Cam position sensor malfunction

29Intake air pressure sensor malfunction

47 Slant detection switch malfunction

48 Incorrect data transmission

54 Bypass valve motor malfunction

55 Steering switch malfunction

63 Intake air system malfunction

1

WIRING DIAGRAMFX High Output, FX Cruiser High Output

1 Fuse (20 A)2 Fuse (3 A)3 Starter relay4 Slant detection switch5 Main and fuel pump relay6 ECM7 Rectifier/regulator8 Noise filter9 Cam position sensor0 Thermoswitch (exhaust)A Oil pressure switchB Thermoswitch (engine)C Engine temperature sensorD Sensor assembly

(intake air pressure, intake air temperature)E Throttle position sensorF Fuel injectorG Bypass valve motorH Ignition coilI Spark plugJ Pickup coilK Lighting coilL BatteryM Starter motorN Electric bilge pumpO Fuel pumpP Fuel senderQ Engine stop switchR Engine shut-off switchS Start switchT Steering switchU Multifunction meterV Speed sensorW BuzzerX Remote control unitY Antenna

È To tachometerÉ To entry box

Color codeB : BlackBr : BrownG : GreenL : BlueO : OrangeP : PinkR : RedW : WhiteY : YellowB/G : Black/greenB/O : Black/orangeB/R : Black/redB/W : Black/whiteB/Y : Black/yellowG/B : Green/blackG/O : Green/orangeG/R : Green/redG/Y : Green/yellowL/B : Blue/blackL/R : Blue/redP/G : Pink/greenP/W : Pink/whitePu/B : Purple/blackPu/G : Purple/greenPu/R : Purple/redPu/Y : Purple/yellowR/Y : Red/yellowR/W : Red/whiteW/B : White/blackW/L : White/blueW/R : White/red

1 3 4 5 6 8 9 10 12 13

14 15 16 17 18

41 42 43 44

35 37 38 39 40

2019 21 22 28

29 3130 33 34

R

FREEPUSH

FREEPUSH

FREEPUSH

B

3 4 6 7 9 10 11

12 13 14 15 16 18B LR Br Y B/L

GyL/Y WB B YL/B

BB

R/Y

GRB

GRB

G/OR/YB/O

P

B/L R/Y

B/Y R/Y

B/W R/Y

B/R R/Y

P

PO

G/BG

Pu/B

G/YG/R

Pu/G

Pu/Y

Pu/B

P

O

B/O

B G

R

B

B

B B

B

L

L P

WB

R

B

Y

Y/BB

R/W

W/LB/OR/Y

Y

R/W

R/W

B/YB/YR/Y

R

R/Y

R

R/Y

B/OB/O

P/W

Br

Br Br

B/Y

P/W

B/Y

B/Y

B

B

R

Br

B/YB/O B/O

B/YB/Y

P

W/BB/O

R/Y

B/O

Pu/Y

G/Y

G/R

G/O

GR

B

G/OB/O

R/Y

R/Y

L/B

B/O

B/O

B/O

L/B

L

R

L/R

Y

B

R/Y

R

B/O

B/O

B/O

B/O

B/O

W/R

P

WB B

PBR

O

P

GGG

G

G

G G

R/Y

B/Y

R/Y

P/G

L/B

L B B P

B

P

Y

W

R

R/Y

B/O

R/Y

B/O

P

W/B

Br

W

Br B

BR/Y

Pu/R

#1 #2 #3 #4

Pu/B Pu/Y

G/Y

R/Y

G

Pu/G

R/Y

B/O

R/Y R/Y R/Y

B

R

R

R R

BB

FX High Output, FX Cruiser High Output

R/Y

P

R/Y

R/Y

R/Y

R/Y

B B/L B/Y B/W

L BW/B G/B G/Y G/R G B/R L/BL/R

B

B/O

B/O

WB

Br

W

W W

B

B B R Br Br Br

Br

WRBB

B

P

Br B

G GG

B R

P/WW B/Y W/R W/BG G/O O B/OP

P B/Y Pu/GW/L YR/Y Pu/Y Pu/RPu/BP/G

1

2

2

3

4

5

6

7

9

0

A

B C

E

F F F F

J

K

M

L

NU

V

A

D

C

B

PO

È

R

H I

PO

Q R S

GB/O

G/R

G/B

W/L

R/YBB/O

8

G

T

P/W

B

R/Y

B

BB

B

#1

#2

#3

#4

D

B/Y O

B/OP/G

R

B/L

BL/R

X

B

W

W

É

L/R L/R

L/Y

L/B

L/BL/RGy

L/BL/RL/Y

B

R

B

Gy

B/L

L/R

R

R R

Pu/R

Pu/RPu/G

P/GR/Y

G

G/B

B GyB

Gy

R/W

Y/B

B

Y

BB

B/O

B/O

R/Y

R

Br

Br

Br

Br

R

R

R

R

R/Y

R/Y

B

B

P

R

G/O

R/YR/YR/YR/Y

R/Y

R RR

R/Y

R/Y

BrB BrB

Y

RR

RR

LB/O

P

P

P

P

P

G

G

LYB

B

O

O

O

L/RL/B

R/Y

R/Y

P/GG/OB/R

W

B/O

G/R

B/LB/Y

G/BG/Y

B/Y

B/Y

B/W

W/B

W/BW/R

W/L

P/W

L/RL/B

Pu/G

Pu/BPu/RPu/Y

R/YR/YR/YR/Y

R

R

B

B

L

R

B/O

B/O

W/L

W/B

R/Y

R/Y

R/YR/Y B/LB/YR/Y

R/YB/R B/W

R/Y

GY

Y

Br

Br

B

B

BB

B/O

GGGB

PP/G

O

BB

B/YPu/R

Pu/BPu/Y

R/YPu/G

B/O

B/OB/O

B/YGGGP

W/BW/RB/OP/W

PR/Y

PP/G

R/YR/Y

O

O

B/YPu/R

Pu/BPu/YB/O

B/O

R/Y R/YR/Y

R/YR/Y

R/YR/Y

B/YP

W/BW/R

B/OP/W

PR/Y

G/OPu/G

R/YPu/Y

Pu/BPu/R

B/YO

P/GP

LW

4

5

6

8

9

0

A

B

C

J

K

123

H

F F FG F

D

ÈÉ

BD

7

CA

B

D

D C

Pu/G

N

O

P

Q

R

S

T

U

V

W

X

B

A

G/RG/Y

G/BG

GG

GG B

G/R

G/BG/Y

G/YG/B

G/RG

E

YAMAHA MOTOR CORPORATION, USA

Printed in USAFeb. 2004 – × 1 CR(E)

SUPPLEMENTARYSERVICE MANUAL

WaveRunner

F1X-28197-1H-1XLIT-18616-02-93*LIT186160293*

FXFX Cruiser

FX High OutputFX Cruiser High Output

E

NOTICEThis Supplementary Service Manual has been prepared to introduce new service and new datainformation for the FX, FX Cruiser, FX High Output, and FX Cruiser High Output which are based onthe 2002 FX140, 2003 FX140/FX Cruiser, and 2004 FX High Output/FX Cruiser High Output. Forcomplete information on service procedures, it is necessary to use this Supplementary ServiceManual together with the following manuals.

FX140 SERVICE MANUAL: F1B-28197-1E-11 (LIT-18616-02-38)FX140/FX Cruiser SUPPLEMENTARY SERVICE MANUAL:

F1B-28197-1F-1X (LIT-18616-02-45)FX High Output/FX Cruiser High Output SERVICE MANUAL:

F1S-28197-1G-11 (LIT-18616-02-83)

A10001-0*

WaveRunner FX/FX Cruiser

FX High Output/FX Cruiser High OutputSUPPLEMENTARY SERVICE MANUAL

©2005 by Yamaha Motor Corporation, USA1st Edition, December 2005

All rights reserved.Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA

is expressly prohibited.Printed in USALIT-18616-02-93

E

HOW TO USE THIS MANUALMANUAL FORMATAll of the procedures in this manual are organized in a sequential, step-by-step format. The informa-tion has been compiled to provide the mechanic with an easy to read, handy reference that containscomprehensive explanations of all disassembly, repair, assembly, and inspection operations.In this revised format, the condition of a faulty component will precede an arrow symbol and thecourse of action required will follow the symbol, e.g.,

• BearingsPitting/scratches → Replace.

To assist you in finding your way through this manual, the section title and major heading is given atthe top of every page.

ILLUSTRATIONSThe illustrations within this service manual represent all of the designated models.

CROSS REFERENCESThe cross references have been kept to a minimum. Cross references will direct you to the appropri-ate section or chapter.

E

IMPORTANT INFORMATIONIn this Supplementary Service Manual particularly important information is distinguished in the fol-lowing ways.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

WARNINGFailure to follow WARNING instructions could result in severe injury or death to the machineoperator, passenger(s), a bystander, or a person inspecting or repairing the watercraft.

CAUTION:A CAUTION indicates special precautions that must be taken to avoid damage to the water-craft.

NOTE:A NOTE provides key information to make procedures easier or clearer.

E

HOW TO USE THIS MANUAL1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

2 Numbers are given in the order of the jobs in the exploded diagram.

3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).

4 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names ofparts, notes in jobs, etc.

5 Dimension figures and the number of parts, are provided for fasteners that require a tighteningtorque.

Example:Bolt or screw size : M10 (D) × 25 mm (L)

6 Jobs requiring more information (such as special service tools and technical data) are describedsequentially.

10 × 25 mm

D

L

E

A50001-1-4

SYMBOLSSymbols 1 to 9 are designed to indicate thecontent of a chapter.

1 General Information2 Specifications3 Periodic Inspection and Adjustment4 Fuel System 5 Power Unit6 Jet Pump Unit7 Electrical System8 Hull and Hood9 Trouble Analysis

Symbols 0 to E indicate specific data.

0 Special service toolA Specified oil or fluidB Specified engine speedC Specified tightening torqueD Specified measurementE Specified electrical value

(resistance, voltage, electric current)

Symbols F to I in an exploded diagram indi-cate the grade of lubricant and the lubricationpoint.

F Apply Yamaha 4-stroke motor oilG Apply water resistant grease

(Yamaha grease A, Yamaha marine grease)H Apply ThreeBond 1104J or ThreeBond 1280BI Apply molybdenum disulfide grease

Symbols J to N in an exploded diagram indi-cate the type of sealant or locking agent andthe application point.

J Apply Gasket MakerK Apply LOCTITE 271 (red)L Apply LOCTITE 242 (blue)M Apply LOCTITE 572N Apply silicone sealant

NOTE:Additional symbols may be used in this man-ual.

1 2

3 4

5 6

7 8

9 0

A B

C D

E F

G H

I J

K L

M N

GENINFO SPEC

INSPADJ FUEL

POWR JETPUMP

– +ELEC HULLHOOD

TRBLANLS

T R..

E

A1280B1104J

M GM

271

LT

242

LT

572

LTSS

E

INDEX

GENERAL INFORMATION 1GEN INFO

SPECIFICATIONS 2SPEC

PERIODIC INSPECTION AND ADJUSTMENT 3INSP

ADJ

FUEL SYSTEM 4FUEL

POWER UNIT 5POWR

JET PUMP UNIT 6JETPUMP

ELECTRICAL SYSTEM 7ELEC

HULL AND HOOD 8HULL HOOD

TROUBLE ANALYSIS 9TRBL ANLS

– +

A30000-0

E

GENERAL INFORMATION

IDENTIFICATION NUMBERS ............................................................................ 1PRIMARY l.D. NUMBER .............................................................................. 1ENGINE SERIAL NUMBER ......................................................................... 1JET PUMP UNIT SERIAL NUMBER ............................................................ 1HULL IDENTIFICATION NUMBER (H.l.N.).................................................. 1

SPECIAL TOOLS ............................................................................................... 2MEASURING................................................................................................ 2

SPECIFICATIONS

GENERAL SPECIFICATIONS ........................................................................... 3

MAINTENANCE SPECIFICATIONS .................................................................. 7ENGINE ....................................................................................................... 7JET PUMP UNIT ....................................................................................... 10HULL AND HOOD ..................................................................................... 10ELECTRICAL ............................................................................................. 11ENGINE ..................................................................................................... 13JET PUMP UNIT ....................................................................................... 16HULL AND HOOD ..................................................................................... 16ELECTRICAL ............................................................................................. 16

TIGHTENING TORQUES ................................................................................. 19SPECIFIED TORQUES.............................................................................. 19GENERAL TORQUE.................................................................................. 20

CABLE AND HOSE ROUTING ........................................................................ 21

CABLE AND HOSE ROUTING (For FX/FX Cruiser) ...................................... 32

CABLE AND HOSE ROUTING (For FX High Output/FX Cruiser High Output)............................................. 37

E

PERIODIC INSPECTION AND ADJUSTMENT

MAINTENANCE INTERVAL CHART............................................................... 41

PERIODIC SERVICE........................................................................................ 42CONTROL SYSTEM .................................................................................. 42

Steering master inspection................................................................... 42Steering cable inspection and adjustment ........................................... 42Throttle cable inspection and adjustment............................................. 43

GENERAL .................................................................................................. 45Drain plug inspection............................................................................ 45Lubrication points ................................................................................. 46

ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS (For FX/FX Cruiser)....................................... 49

ELECTRICAL COMPONENTS (For FX High Output/FX Cruiser High Output)............................................. 50

OFF THROTTLE STEERING SYSTEM............................................................ 52WIRING DIAGRAM .................................................................................... 52STEERING SENSOR ................................................................................. 53

E

INDICATION SYSTEM ..................................................................................... 54WIRING DIAGRAM (For FX Cruiser High Output) ..................................... 54WIRING DIAGRAM (For FX High Output).................................................. 56WIRING DIAGRAM (For FX/FX Cruiser).................................................... 58MULTIFUNCTION METER......................................................................... 59

Multifunction meter............................................................................... 59Operation button .................................................................................. 59

MULTIFUNCTION METER REMOVAL ...................................................... 60OPERATION BUTTON REMOVAL ............................................................ 60

Display function (for FX Cruiser High Output)...................................... 61Display function (for FX High Output) .................................................. 62Display function (for FX/FX Cruiser) .................................................... 63Compass display (for FX Cruiser High Output).................................... 64Air temperature display (for FX Cruiser High Output) .......................... 64Speedometer/average speed/tripmeter display (for FX Cruiser High Output) ............................................................... 65Water temperature display (for FX Cruiser High Output) ..................... 66Trip timer display (for FX Cruiser High Output).................................... 67Fuel consumption per hour, fuel consumption per kilometer/mile display (for FX Cruiser High Output) ........................................... 67Overheat warning indicator .................................................................. 67Check engine warning indicator ........................................................... 68Diagnostic display ................................................................................ 68

REMOTE CONTROL SYSTEM (For FX High Output/FX Cruiser High Output)............................................. 69

WIRING DIAGRAM .................................................................................... 69REMOTE CONTROL SYSTEM.................................................................. 71

Yamaha Security System indicator ...................................................... 71Low-rpm mode indicator....................................................................... 72

E

HULL AND HOOD

HANDLEBAR ................................................................................................... 73EXPLODED DIAGRAM (For FX/FX High Output) ...................................... 73REMOVAL AND INSTALLATION CHART ................................................. 73EXPLODED DIAGRAM (For FX Cruiser/FX Cruiser High Output) ............. 74REMOVAL AND INSTALLATION CHART ................................................. 74EXPLODED DIAGRAM .............................................................................. 75REMOVAL AND INSTALLATION CHART ................................................. 75SERVICE POINTS ..................................................................................... 79

Handlebar assembly installation .......................................................... 79

STEERING MASTER........................................................................................ 82EXPLODED DIAGRAM .............................................................................. 82REMOVAL AND INSTALLATION CHART ................................................. 82SERVICE POINTS ..................................................................................... 87

Steering master components inspection .............................................. 87Rubber seal installation........................................................................ 87

REMOTE CONTROL CABLES AND SPEED SENSOR LEAD ....................... 88EXPLODED DIAGRAM .............................................................................. 88REMOVAL AND INSTALLATION CHART ................................................. 88SERVICE POINTS ..................................................................................... 91

Steering cable removal ........................................................................ 91SERVICE POINTS ..................................................................................... 92

Steering cable installation .................................................................... 92

FRONT HOOD.................................................................................................. 93EXPLODED DIAGRAM .............................................................................. 93REMOVAL AND INSTALLATION CHART ................................................. 93SERVICE POINTS ..................................................................................... 95

Rivet Installation................................................................................... 95SERVICE POINTS ..................................................................................... 98

Ornament disassembly ........................................................................ 98Front hood assembly............................................................................ 98Visor installation ................................................................................... 99Double-sided tape installation .............................................................. 99Ornament installation ......................................................................... 100

MIRROR.......................................................................................................... 101EXPLODED DIAGRAM ............................................................................ 101REMOVAL AND INSTALLATION CHART ............................................... 101

STEERING CONSOLE COVER ..................................................................... 103EXPLODED DIAGRAM ............................................................................ 103REMOVAL AND INSTALLATION CHART ............................................... 103

E

SHIFT LEVER................................................................................................. 111EXPLODED DIAGRAM ............................................................................ 111REMOVAL AND INSTALLATION CHART ............................................... 111

SEATS AND HAND GRIP .............................................................................. 112EXPLODED DIAGRAM ............................................................................ 112REMOVAL AND INSTALLATION CHART ............................................... 112

REBOARDING STEP (For FX Cruiser/FX Cruiser High Output)................ 115EXPLODED DIAGRAM ............................................................................ 115REMOVAL AND INSTALLATION CHART ............................................... 115SERVICE POINTS ................................................................................... 116

Reboarding step installation............................................................... 116

DECK AND HULL........................................................................................... 117EXPLODED DIAGRAM ............................................................................ 117REMOVAL AND INSTALLATION CHART ............................................... 117

CLEAT ASSEMBLY (For FX Cruiser High Output) ..................................... 120EXPLODED DIAGRAM ............................................................................ 120REMOVAL AND INSTALLATION CHART ............................................... 120SERVICE POINTS ................................................................................... 121

Cleat cover installation ....................................................................... 121

TROUBLE ANALYSIS

TROUBLE ANALYSIS.................................................................................... 122SELF-DIAGNOSIS ................................................................................... 122

WIRING DIAGRAM

1

EGENINFO IDENTIFICATION NUMBERS

A60700-0*

IDENTIFICATION NUMBERSPRIMARY l.D. NUMBERThe primary l.D. number is stamped on a labelattached to the inside of the engine compart-ment.

Starting primary l.D. numbers:F1X: 800101F1Y: 800101

ENGINE SERIAL NUMBERThe engine serial number is stamped on alabel attached to the engine unit.

Starting serial numbers:6B6: 101890160E: 1017501

JET PUMP UNIT SERIAL NUMBERThe jet pump unit serial number is stamped ona label attached to the intermediate housing.

HULL IDENTIFICATION NUMBER (H.l.N.)The H.l.N. is stamped on a plate attached tothe aft deck.

2


SPECIAL TOOLSUsing the correct special tools recommendedby Yamaha, will aid the work and enable accu-rate assembly and tune-up. Improvisationsand using improper tools can damage theequipment.

NOTE:• For U.S.A. and Canada, use part numbers

starting with “J-”, “YB-”, “YM-”, “YS-”, “YU-” or“YW-”.

• For other countries, use part numbers start-ing with “90890-”.

MEASURING1 Digital multimeter

P/N. YU-34899-A2 Digital circuit tester

P/N. 90890-03174

2 90890-031741 YU-34899-A

1

3



Item UnitModel

FX High Output FX Cruiser High OutputModel code

Hull F1XEngine/jet 6B6

DimensionsLength mm (in) 3,340 (131.5)Width mm (in) 1,230 (48.4)Height mm (in) 1,160 (45.7) 1,240 (48.8)Dry weight kg (lb) 372 (820) 380 (838)Maximum capacity Person/kg (lb) 3/240 (530)

PerformanceMaximum output kW (PS) @ r/min 117.7 (160) @ 10,000Maximum fuel consumption l/h (US gal/h,

lmp gal/h)45 (11.9, 9.9)


Engine type 4-stroke, L4, DOHCDisplacement cm3 (cu. in) 1,052 (64.2)Bore × stroke mm (in) 76.0 × 58.0 (2.99 × 2.28)Compression ratio 11.9:1Exhaust system Wet exhaustLubrication system Dry sumpCooling system Water cooledStarting system Electric starterIgnition system TCIIgnition timing Degree BTDC 5–BTDC 32Spark plug model (manufacturer)

CR9EB (NGK)



Degree 24 + 24


4

ESPEC




(US gal, Imp gal)70 (18.5, 15.4)



(US qt, Imp qt)4.5 (4.8, 4.0)


2.1 (2.2, 1.8)


2.3 (2.4, 2.0)

Item UnitModel



2

5


Item UnitModel

FX FX CruiserModel code

Hull F1YEngine/jet 60E

DimensionsLength mm (in) 3,340 (131.5)Width mm (in) 1,230 (48.4)Height mm (in) 1,160 (45.7) 1,240 (48.8)Dry weight kg (lb) 384 (847) 392 (864)Maximum capacity Person/kg (lb) 3/240 (530)

PerformanceMaximum output kW (PS) @ r/min 103 (140) @ 10,000Maximum fuel consumption l/h (US gal/h,

lmp gal/h)44 (11.6, 9.7)


Engine type 4-stroke, L4, DOHCDisplacement cm3 (cu. in) 998 (60.9)Bore × stroke mm (in) 74.0 × 58.0 (2.91 × 2.28)Compression ratio 11.4:1Exhaust system Wet exhaustLubrication system Dry sumpCooling system Water cooledStarting system Electric starterIgnition system TCIIgnition timing Degree BTDC 34–ATDC 5Spark plug model (manufacturer)

CR9EB (NGK)



Degree 24 + 24


6





(US gal, Imp gal)70 (18.5, 15.4)



(US qt, Imp qt)4.3 (4.5, 3.8)


2.0 (2.1, 1.8)


2.2 (2.3, 1.9)

Item UnitModel

FX FX Cruiser

7


MAINTENANCE SPECIFICATIONSENGINE

Item UnitModel

FX High Output FX Cruiser High OutputCylinder head



1,150 (11.5, 164)



mm (in) 0.03–0.06 (0.0012–0.0024)


Model/number of links 92RH2015-130/130Tensioning system Automatic







8















Item UnitModel


9


Piston ringTop ring




mm (in) 1.50 × 2.60 (0.06 × 0.10)



Crankshaft


Throttle bodyType/quantity 42EIS/4Manufacturer MikuniID mark 6B601Trolling speed r/min 1,600–1,700


(kgf/cm2, psi)320.8–327.2 (3.2–3.3, 45–47)

Item UnitModel


TB

BT

B

T

B B B

A

10


JET PUMP UNIT

HULL AND HOOD



mm (in) 0.09–0.15 (0.0035–0.0059)


Item UnitModel

FX High Output FX Cruiser High OutputJet pump


Item UnitModel

FX High Output FX Cruiser High OutputFree play


Item UnitModel


11


ELECTRICAL

Item UnitModel

FX High Output FX Cruiser High OutputBattery






Output peak voltage@cranking (unloaded) V 5.2

@cranking (loaded) V 4.7@2,000 r/min (loaded) V 26.1@3,500 r/min (loaded) V 41.3


@cranking (unloaded) V 9.2@2,000 r/min (unloaded) V 38.5@3,500 r/min (unloaded) V 63.2






12






@ 20 °C (68 °F) kΩ 54.2–69.0@ 100 °C (212 °F) kΩ 3.12–3.48

Speed sensorOutput voltage (on pulse) V 11.6 5.0Output pulse/one full turn 2Water temperature sensor resistance (Y – B/Y)

@ 25 °C (77 °F) kΩ — 10Throttle position sensor

Output voltage (P – B/O)@ trolling speed V 0.756 ± 0.016

Cam position sensorOutput voltage (G/O – B/O)

Position A V More than 4.8Position B V Less than 0.8Position C V More than 4.8

Fuel level sensorFuel level sensor resistance



kPa (kgf/cm2, psi)

128–166 (1.28–1.66, 18.2–23.6)


FuseRating

Main V/A 12/20Remote control unit V/A 12/3Electrical bilge pump V/A 12/3

Item UnitModel


13


ENGINE

Item UnitModel

FX FX CruiserCylinder head



1,350 (13.5, 192)



mm (in) 0.05–0.08 (0.002–0.0031)


Model/number of links 92RH2015-130/130Tensioning system Automatic







14















Item UnitModel

FX FX Cruiser

15


Piston ringTop ring




mm (in) 1.50 × 2.60 (0.06 × 0.10)



Crankshaft


Throttle bodyType/quantity 40EIS/4Manufacturer MikuniID mark 60E21Trolling speed r/min 1,600–1,700


(kgf/cm2, psi)320.8–327.2 (3.2–3.3, 45–47)

Item UnitModel

FX FX Cruiser

TB

BT

B

T

B B B

A

16


JET PUMP UNIT

HULL AND HOOD

ELECTRICAL



mm (in) 0.09–0.15 (0.0035–0.0059)


Item UnitModel

FX FX CruiserJet pump


Item UnitModel

FX FX CruiserFree play


Item UnitModel

FX FX CruiserBattery





Item UnitModel

FX FX Cruiser

17



Output peak voltage@cranking (unloaded) V 4



@cranking (unloaded) V 9@2,000 r/min (unloaded) V 11@3,500 r/min (unloaded) V 12









@ 20 °C (68 °F) kΩ 54.2–69.0@ 100 °C (212 °F) kΩ 3.12–3.48

Item UnitModel

FX FX Cruiser

18



Intake air temperature sensorIntake air temperature sensor resistance (B/Y – B/O)

@ 0 °C (32 °F) kΩ 5.4–6.6@ 80 °C (176 °F) kΩ 0.29–0.39

Intake air pressure sensorOutput voltage (P/G – B/O) V @ kPa

(kgf/cm2, psi)4.00 @ 101.3 (1.01, 14.4)

V @ kPa (kgf/cm2, psi)

1.84 @ 47 (0.47, 6.68)

V @ kPa (kgf/cm2, psi)

0.79 @ 20 (0.2, 2.8)

Speed sensorOutput voltage (on pulse) V 11.6Output pulse/one full turn 2

Throttle position sensorOutput voltage (P – B/O)

@ trolling speed V 0.756 ± 0.016Cam position sensor

Output voltage (G/O – B/O)Position A V More than 4.8Position B V Less than 0.8Position C V More than 4.8

Fuel level sensorFuel level sensor resistance



kPa (kgf/cm2, psi)

128–166 (1.28–1.66, 18.2–23.6)


FuseRating

Main V/A 12/20Multifunction meter V/A 12/3Electrical bilge pump V/A 12/3

Item UnitModel

FX FX Cruiser

19


TIGHTENING TORQUESSPECIFIED TORQUES


sizeQ’ty


N•m kgf•m ft•lbHull and hoodHandlebar cover (for FX/FX High Output)

Screw M6 4 1.1 0.11 0.8 242

LT

Handlebar cover stay (for FX/FX High Output)

Bolt M6 2 1.1 0.11 0.8 271

LT

Upper handlebar cover (for FX Cruiser/FX Cruiser High Output)

Screw M5 8 1.1 0.11 0.8

Lower handlebar cover (for FX Cruiser/FX Cruiser High Output)

Screw M6 2 5.4 0.54 3.9 242

LT

Steering pad (for FX Cruiser/FX Cruiser High Output)

Bolt M6 4 1.1 0.11 0.8 271

LT

Handlebar holder Bolt M8 4 20 2.0 14 242

LT

Handle boss cover Screw M6 4 0.9 0.09 0.7 242

LT

QSTS converter Nut — 2 5.4 0.54 3.9QSTS cable 1 locknut Nut — 1 16 1.6 12QSTS cable 2 locknut Nut — 1 16 1.6 12Steering master Nut — 4 20 2.0 14Speed sensor Screw M5 4 5.2 0.52 3.8 24

2

LT

Steering cable joint (jet pump side) Nut — 1 6.4 0.64 4.6Shift cable holder Nut — 2 6.4 0.64 4.6Shift cable bracket Nut — 2 15 1.5 11Steering cable grommet Nut — 1 5.9 0.59 4.3Speed sensor lead grommet Nut — 1 5.9 0.59 4.3QSTS cable end pin Nut — 1 3.8 0.38 2.7QSTS cable grommet Nut — 1 5.9 0.59 4.3QSTS cable locknut (jet pump side) Nut — 1 2.9 0.29 2.1 57

2

LT

Shift cable grommet Nut — 1 5.9 0.59 4.3Shift cable locknut (reverse gate side)

Nut — 1 2.9 0.29 2.1 572

LT

Hinge assembly Nut — 4 6.4 0.64 4.6Front hood assembly Bolt M6 6 5.4 0.54 3.9 24

2

LT

Hood lock assembly Bolt M6 2 5.4 0.54 3.9 242

LT

Front hood Screw M5 8 2.2 0.22 1.6Visor Bolt M5 6 1.1 0.11 0.8

Mirror assemblyBolt M6 4 5.4 0.54 3.9 24

2

LT

Nut — 2 5.4 0.54 3.9Mirror cover Screw M5 12 3.7 0.37 2.7Mirror Screw M5 8 3.7 0.37 2.7Multifunction meter cover Screw M5 4 2.2 0.22 1.6Multifunction meter Bolt M5 4 3.7 0.37 2.7

Side coverBolt M6 8 5.4 0.54 3.9 24

2

LT

Nut — 2 5.4 0.54 3.9

20

ESPEC

Side ornament Screw M5 4 2.2 0.22 1.6Center cover Nut — 4 5.4 0.54 3.9Hood lock Nut — 2 6.4 0.64 4.6Compass sensor and air tempera-ture sensor

Nut — 2 3.8 0.38 2.7

Shift lever assembly Nut — 3 5.4 0.54 3.9Seat lock assembly Bolt M6 4 6.4 0.64 4.6 27

1

LT

Deck beam Nut — 4 18 1.8 13Projection Nut — 2 26 2.6 19Rear seat stay Nut — 4 6.4 0.64 4.6Front seat stay Nut — 2 15 1.5 11Hand grip Nut — 4 5.4 0.54 3.9Spout Nut — 1 5.4 0.54 3.9Cleat Nut — 6 15 1.5 11Sponson Bolt M8 10 16 1.6 12 27

1

LT

Drain plug/screw Screw M5 4 2.0 0.2 1.4Bow eye Bolt M6 2 13 1.3 9.4 57

2

LT

Reboarding step Bolt M8 6 15 1.5 11 271

LT

Front protector 1 Nut — 3 5.4 0.54 3.9Front protector 2/3 Nut — 4 5.4 0.54 3.9Cleat Bolt M6 6 2.4 0.24 1.7


sizeQ’ty



TIGHTENING TORQUES

GENERAL TORQUEThis chart specifies tightening torques for stan-dard fasteners with a standard ISO threadpitch. Tightening torque specifications for spe-cial components or assemblies are provided inapplicable sections of this manual. To avoidwarpage, tighten multi-fastener assemblies ina crisscross fashion and progressive stagesuntil the specified tightening torque is reached.Unless otherwise specified, tightening torquespecifications require clean, dry threads. Components should be at room temperature.

Nut A Bolt B General torque specifications

N•m kgf•m ft•lb8 mm M5 5.0 0.5 3.6

10 mm M6 8.0 0.8 5.812 mm M8 18 1.8 1314 mm M10 36 3.6 2617 mm M12 43 4.3 31

21


CABLE AND HOSE ROUTING

BOW20˚

DOWN

UP

J

H-H

G-G

J

H H

G

G

F

E

A

B-B

A-A

C-C

D-D8

7

9

0

B

1

2

3

4

5

6

0

2

E

9

7

8

D

EC

F

C

1

7 9

0

D

0

C

3

F

H

A

1

1

E-E

F-F

A

D

H H

H H

B

A

G

B B

È

UP

UP

1

I

1 Fuel tank breather hose2 Cooling water pilot outlet hose3 Cooling water pilot outlet4 Negative battery lead5 Positive battery lead6 Battery7 Steering cable8 QSTS cable9 Shift cable0 Speed sensor lead

A Electrical bilge pump leadB Electrical box leadC Throttle cableD Fuel hoseE Handlebar switch leadF Remote control unit lead

(FX High Output/FX Cruiser High Output)

G Compass sensor (FX Cruiser High Output)

H Remote control unit (FX High Output/FX Cruiser High Output)

I Remote control unit antenna (FX High Output/FX Cruiser High Output)

È Fasten the speed sensor leadand electrical box leadsecurely with a plastic band.

22


Ì

Í

Ì

Í

A

B

A

B

A

Ë Ê

Ë

F

1 2

345 6 7

8 9

C B A 0 5A123HJ546

123H

54

6

I

H

G

I H

D

É

È

B

E

1 Buzzer lead2 Steering sensor lead3 Handlebar switch assembly

lead4 Fuel level sensor lead5 Speed sensor lead6 Electrical box lead7 Throttle cable8 Negative battery lead9 Positive battery lead

0 Shift cableA QSTS cableB Steering cableC Electrical bilge pump leadD Remote control unit lead


E Remote control unit (FX High Output/FX Cruiser High Output)

F Remote control unit antenna (FX High Output/FX Cruiser High Output)

G Right operation button lead (FX Cruiser High Output)

H Multifunction meter leadI Left operation button leadJ Compass sensor lead

(FX Cruiser High Output)

23


Ì

Í

Ì

Í

A

B

A

B

A

Ë Ê

Ë

F

1 2

345 6 7

8 9

C B A 0 5A123HJ546

123H

54

6

I

H

G

I H

D

É

È

B

E

È Fasten the handlebar switch assembly lead, fuellevel sensor lead, speed sensor lead, and elec-trical box lead securely with a plastic tie.

É When installing the remote control unit antennaholders, insert the projection on each holder intoa hole in the front storage compartment from theengine compartment side.

Ê Connect the right operation button lead coupler(blue) to the multifunction meter lead coupler(blue). (FX Cruiser High Output)

Ë Connect the left operation button lead coupler(natural) to the multifunction meter lead coupler(natural).

Ì FX Cruiser High OutputÍ FX/FX Cruiser/FX High Output

24


3AAA

S P A R E

20A3A3AMAIN

A

B

È É

Í

3

F

G

GF

A

A A

B

C

C

CD

7

D

D

E

3

A

7

D

C-C

EE

Ì

D-D

12 3 4

A 90 2 9 1

5 6 7

A

21

A

E

3

B

F

É

È

Ë

9

2

A

8

Ê

I

G

H

1 Shift cable2 Steering cable3 Fuel hose4 Throttle cable5 Cooling water pilot outlet hose6 Negative battery lead7 Positive battery lead8 Battery breather hose9 QSTS cable0 Electrical bilge pump leadA Fuel tank breather hose

B Water separatorC Ignition coil leadD Starter motor positive leadE Wiring harnessF Electric fuel pumpG Remote control unit lead

(FX High Output/FX Cruiser High Output)H Remote control unit

(FX High Output/FX Cruiser High Output)I Remote control unit antenna


25


3AAA

S P A R E

20A3A3AMAIN

A

B

È É

Í

3

F

G

GF

A

A A

B

C

C

CD

7

D

D

E

3

A

7

D

C-C

EE

Ì

D-D

12 3 4

A 90 2 9 1

5 6 7

A

21

A

E

3

B

F

É

È

Ë

9

2

A

8

Ê

I

G

H

È To ventilation socketÉ To fuel tankÊ Route the fuel tank breather hose as shown in

the illustration.Ë BowÌ 5–7 mm (0.20–0.28 in)Í Point the arrow on the cover toward the fuel

tank.

26


A

1

23

ÉÊ

È

12 3

È

Ê É

B B C C

B B C C

B-B C-C

25

4

5

4

1

3

9

3

1

2

6

Ë Ì

8

7

A A

Í

DD

1 Throttle cable2 QSTS cable3 Handlebar switch lead4 Grommet5 Hose packing6 Fuel tank breather hose7 Remote control unit lead

(FX High Output/FX Cruiser High Output)8 Remote control unit


9 Remote control unit antenna (FX High Output/FX Cruiser High Output)

È Less than 10 mm (0.39 in)É Position the throttle cable and handlebar switch

lead packing in the opening in the grommet sothat the plastic tie fastened around both thegrommet and the packing.

27


A

1

23

ÉÊ

È

12 3

È

Ê É

B B C C

B B C C

B-B C-C

25

4

5

4

1

3

9

3

1

2

6

Ë Ì

8

7

A A

Í

DD

Ê Position the QSTS cable packing in the openingin the grommet so that the plastic tie is fastenedaround both the grommet and the packing.

Ë FX Cruiser/FX Cruiser High OutputÌ FX/FX High OutputÍ 3–7 mm (0.12–0.28 in)

28


5 BA H

C

D

9

E

F

G

8

2

A

91

2

5

0

2

9

6

7

7

6

54321

È

4

A-A

A

A

8

C

D

1 Cooling water hose (cooling water inlet)2 Bilge hose 13 Electric bilge pump4 Bilge hose 45 Cooling water hose (from thermostat)6 Bilge hose 37 Bilge hose 28 Shift cable9 Cooling water hose (from exhaust pipe)0 Electrical box

A QSTS cableB Positive battery leadC Speed sensor leadD Electric bilge pump leadE Bilge strainerF Negative battery leadG Steering cableH Flushing hose

È Pass the QSTS cable between the bilge hoses.

29


BA

A

A-ACB

34

09

56

7

8

2

1Í

É

Ê

ËC

A

Ì

0 A

4

B

1 1

ÈÈ

È

È

È

ÏÐ

Î

1 Wiring harness2 Ground lead3 Wiring harness coupler4 Noise filter5 Oil pressure switch coupler6 Pickup coil coupler7 Thermoswitch (engine) coupler8 Lighting coil coupler9 Thermoswitch (exhaust)0 Thermoswitch (exhaust) cou-

pler

A Cam position sensor couplerB Oil pressure switch lead

È After connecting the coupler tothe wiring harness, insert theprojection on the coupler intothe hole in the bracket.

É To oil pressure switchÊ To cam position sensorË To electrical box

Ì Fasten the plastic tie with itsend facing downward.

Í To engine temperature sensorÎ 8–12 mm (0.31–0.47 in)Ï 15–25 mm (0.59–0.98 in)Ð 15–20 mm (0.59–0.79 in)

30


A

A

1

2

4

3 75

6

0

98

A-A

Ë ÊÉ

ÌÍ

Î

Ð

Ï

ÑÒÏ

Ð

B

B

È

ÕÔ

Ó

ÑÒÏ

Ð

1 Engine temperature sensor coupler2 Lighting coil coupler3 Pickup coil coupler4 Thermoswitch (engine) coupler5 Thermoswitch (engine)6 Starter motor7 Engine temperature sensor8 Engine temperature sensor lead9 Thermoswitch (engine) lead0 Lighting coil lead

È Fasten the engine temperature sensor lead,thermoswitch lead, and lighting coil lead with aplastic tie. Fasten the engine temperature sen-sor lead 10–20 mm (0.4–0.8 in) from the end ofthe protective cover of the lead.

É To generatorÊ To engine temperature sensorË To thermoswitch (engine)Ì To thermoswitch (engine) couplerÍ To engine temperature sensor coupler

31


A

A

1

2

4

3 75

6

0

98

A-A

Ë ÊÉ

ÌÍ

Î

Ð

Ï

ÑÒÏ

Ð

B

B

È

ÕÔ

Ó

ÑÒÏ

Ð

Î Route the starter motor lead to the outside of theengine temperature sensor lead.

Ï To starter relayÐ To negative battery terminalÑ Route the starter motor and negative battery

leads behind the cooling water hose.Ò Route the starter motor lead over the cooling

water hose.Ó Insert the projection on the plastic tie completely

into the hole in the bracket.

Ô FX High Output/FX Cruiser High OutputÕ FX/FX Cruiser

32

ESPEC CABLE AND HOSE ROUTING (For FX/FX Cruiser)

CABLE AND HOSE ROUTING (For FX/FX Cruiser)

B

D

G F

A

E-E

Ð

Ï

ËËËË

Ê

Ö ×

Ì

Ñ

Ì

Ô

Ø

Ñ

Õ

Ì

Ê

Ó

Ó

Ò

Ú

Ë

D

A

G

F

B

46

7

5

1

E

E

ÍC-C

Î3

2

3

C

C

È

É

1

Ù

1 Thermostat2 Cooling water pilot outlet hose3 Cooling water hose4 Pressure control valve5 Cooling water hose (cooling water inlet)6 Negative battery lead7 Breather hose

È To cooling water pilot outlet on starboard sideÉ To cooling water outlet on starboard side of

sternÊ To pressure control valveË From exhaust manifoldÌ To install the hose, align the white paint mark on

the cooling water hose with the projection of thehose joint.

33


B

D

G F

A

E-E

Ð

Ï

ËËËË

Ê

Ö ×

Ì

Ñ

Ì

Ô

Ø

Ñ

Õ

Ì

Ê

Ó

Ó

Ò

Ú

Ë

D

A

G

F

B

46

7

5

1

E

E

ÍC-C

Î3

2

3

C

C

È

É

1

Ù

Í When installing the cooling water hoses, be sureto push them down until they contact the hosejoint.

Î Bundle the cooling water pilot outlet hose andcooling water hoses, pass a plastic tie throughthe stay hole, and then fasten the tie.Set the tie in the direction shown.

Ï To cooling water pilot outlet on port sideÐ To cooling water outlet at sternÑ From cooling water inlet

Ò To oil tankÓ To exhaust pipeÔ To install the cooling water hose, align the white

paint mark on the hose with the parting line onthe hose joint.

Õ Fasten the cooling water hose, negative batterylead, and breather hose with a plastic tie. Setthe tie in the direction shown.

34


B

D

G F

A

E-E

Ð

Ï

ËËËË

Ê

Ö ×

Ì

Ñ

Ì

Ô

Ø

Ñ

Õ

Ì

Ê

Ó

Ó

Ò

Ú

Ë

D

A

G

F

B

46

7

5

1

E

E

ÍC-C

Î3

2

3

C

C

È

É

1

Ù

Ö Bundle the cooling water hose (cylinder headcover to thermostat) and cooling water hose(starboard cooling water pilot outlet), and thenfasten them with a plastic tie to the oil tank boss.When bundling the hoses, make sure that thecooling water hose (cylinder head cover to ther-mostat) is routed on the deck side and that thecooling water hose (starboard cooling waterpilot outlet) is routed on the engine side.

× Insert the cooling water hose to the paint mark.

Ø Fasten the end of the cooling water hose tubethat is contacting the hose joint with a plastic tie.

Ù Face the ends of the clamps downward.Ú From cooling water passage

35


Ê

AÈ ÉB 1 2

34567

2

8

AB

Ï

Î

Í

Ì

Ë

8

1 Intake air temperature sensor coupler2 Intake air pressure sensor coupler3 Fuel injector #4 coupler4 Fuel injector #3 coupler5 Fuel injector #2 coupler6 Fuel injector #1 coupler7 Throttle position sensor coupler8 Joint coupler

È Route the throttle cable between the sub-wiringharness.

É Route the sub-wiring harness under the intakevacuum hose.

Ê To wiring harnessË To intake air temperature sensor coupler.Ì To fuel injector #3 couplerÍ Fasten the sub-wiring harness to the joint cou-

pler bracket with a plastic tie as shown in theillustration.

36


Ê

AÈ ÉB 1 2

34567

2

8

AB

Ï

Î

Í

Ì

Ë

8

Î Fasten the ring, which is attached to the sub-wiring harness, to the sensor bracket with aplastic tie. Face the end of the plastic tietowards the sensor.

Ï To bypass valve motor coupler.

37

ESPECCABLE AND HOSE ROUTING (For FX High Output/FX Cruiser High Output)

CABLE AND HOSE ROUTING (For FX High Output/FX Cruiser High Output)

B

D

G F

A

E-E

Ð

ÏËËË

Ë

Ê

Õ

Ì

Ñ

Ì

Ó

×

Ñ

Ô

Ì

Ê

Ò

Ò

Ø

Ë

D

A

G

F

B

5

4

1

E

E

ÍC-C

Î3

2

C

C

Ö

Ù

È

É

1

1 Thermostat2 Cooling water pilot outlet hose3 Cooling water hose4 Cooling water hose (cooling water inlet)5 Negative battery lead

È To cooling water pilot outlet on starboard sideÉ To cooling water outlet on starboard side of

sternÊ To cylinder blockË From exhaust manifoldÌ To install the hose, align the white paint mark on

the cooling water hose with the projection of thehose joint.

38


B

D

G F

A

E-E

Ð

ÏËËË

Ë

Ê

Õ

Ì

Ñ

Ì

Ó

×

Ñ

Ô

Ì

Ê

Ò

Ò

Ø

Ë

D

A

G

F

B

5

4

1

E

E

ÍC-C

Î3

2

C

C

Ö

Ù

È

É

1

Í When installing the cooling water hoses, be sureto push them down until they contact the hosejoint.

Î Bundle the cooling water pilot outlet hose andcooling water hoses, pass a plastic tie throughthe stay hole, and then fasten the tie.Set the tie in the direction shown.

Ï To cooling water pilot outlet on port sideÐ To cooling water outlet at sternÑ From cooling water inlet

Ò To exhaust pipeÓ To install the cooling water hose, align the white

paint mark on the hose with the parting line onthe hose joint.

Ô Fasten the cooling water hose and negative bat-tery lead with a plastic tie. Set the tie in thedirection shown.

39


B

D

G F

A

E-E

Ð

ÏËËË

Ë

Ê

Õ

Ì

Ñ

Ì

Ó

×

Ñ

Ô

Ì

Ê

Ò

Ò

Ø

Ë

D

A

G

F

B

5

4

1

E

E

ÍC-C

Î3

2

C

C

Ö

Ù

È

É

1

Õ Bundle the cooling water hose (cylinder headcover to thermostat) and cooling water hose(starboard cooling water pilot outlet), and thenfasten them with a plastic tie to the oil tank boss.When bundling the hoses, make sure that thecooling water hose (cylinder head cover to ther-mostat) is routed on the deck side and that thecooling water hose (starboard cooling waterpilot outlet) is routed on the engine side.

Ö Insert the cooling water hose to the paint mark.× Fasten the end of the cooling water hose tube

that is contacting the hose joint with a plastic tie.Ø From cooling water passageÙ Face the ends of the clamps downward.

40


1 2 3

45678

3

2

2

AB

AÉ Ê

ÈÍ

Ì

Ë

B

1 Bypass valve motor coupler2 Joint coupler3 Sensor assembly coupler4 Fuel injector #4 coupler5 Fuel injector #3 coupler6 Fuel injector #2 coupler7 Fuel injector #1 coupler8 Throttle position sensor cou-

pler

È To wiring harnessÉ Route the throttle cable

between the sub-wiring har-ness.

Ê Route the sub-wiring harnessunder the intake vacuum hose.

Ë To fuel injector #3 coupler

Ì Fasten the sub-wiring harnessto the joint coupler bracket witha plastic tie as shown in theillustration.

Í Fasten the ring, which isattached to the sub-wiring har-ness, to the sensor assemblybracket with a plastic tie. Facethe end of the plastic tietowards the sensor assembly.

41

EINSPADJ MAINTENANCE INTERVAL CHART

MAINTENANCE INTERVAL CHARTThe following chart should be considered strictly as a guide to general maintenance intervals.Depending on operating conditions, the intervals of maintenance should be changed.

*1: Grease quantity: 33.0–35.0 cm3 (1.11–1.18 oz)*2: Grease quantity: 6.0–8.0 cm3 (0.20–0.27 oz)*3: After every use

MAINTENANCE INTERVAL INITIAL THEREAFTER EVERY10 hours 50 hours 100 hours 100 hours 200 hours

ITEM 6 months 12 months 12 months 24 monthsSpark plug Inspect, clean, adjustLubrication points LubricateIntermediate housing Lubricate *1 *2 *2Fuel system InspectFuel tank Inspect, cleanTrolling speed Inspect, adjustThrottle shaft InspectCooling water passages Flush *3Water inlet strainer Inspect, cleanBilge strainer CleanElectric bilge pump strainer Inspect, cleanImpeller InspectJet thrust nozzle angle Inspect, adjustSteering master InspectQSTS mechanism Inspect, adjustShift cable and mechanism Inspect, adjustThrottle cable Inspect, adjustStern drain plugs Inspect, replaceBattery Inspect Rubber coupling InspectEngine mount InspectNuts and bolts InspectAir filter Inspect, replaceEngine oil ReplaceEngine oil filter ReplaceValve clearance Inspect, adjust

42


PERIODIC SERVICECONTROL SYSTEMSteering master inspection

1. Inspect:• Steering master

Excessive play → Replace the steeringmaster.Refer to “STEERING MASTER”.

Inspection steps:• Move the handlebar up and down and

back and forth.• Check the excessive play of the handle-

bar.

Steering cable inspection and adjustment1. Inspect:

• Jet thrust nozzle difference of distancesa and b Out of specification → Adjust.

Difference of distances a and b:Maximum 5 mm (0.2 in)

Inspection steps:• Set the control grip in the neutral position.• Turn the handlebar lock to lock.• Measure distances a and b.• If difference of distances a and b is not

within specification, adjust the cable joint.

3

43


2. Adjust:• Steering cable joint

(steering master end)

NOTE:If the steering cable cannot be properlyadjusted by the cable joint at the steering mas-ter end, adjust the cable joint at the jet pumpend so that the same clearances are obtained.Refer to “REMOTE CONTROL CABLES ANDSPEED SENSOR LEAD”.

Throttle cable inspection and adjustment

NOTE:Before adjusting the throttle lever free play,adjust the trolling speed.

1. Measure:• Throttle lever free play a


Adjustment steps:• Set the control grip in the neutral position.• Loosen the locknut 1.• Disconnect the cable joint 2 from the ball

joint 3.• Turn the cable joint 2 in or out for adjust-

ing the distances a and b.

Turn in Distance a is increased.

Turn out Distance b is increased.



T R.

Locknut:6.4 N • m (0.64 kgf • m, 4.6 ft • lb)

Throttle lever free play:4–7 mm (0.16–0.28 in)

44



Adjustment steps:

NOTE:• When not replacing the throttle cable or

removing the cable from the throttle body,adjust the throttle cable free play by fol-lowing steps (d) through (h).

• When replacing the throttle cable orremoving the cable from the throttle body,adjust the throttle cable free play by fol-lowing steps (a) through (i).

a. Remove the air filter case cover 1 andribbon sub assemblies.

b. Loosen the locknut 2.c. Turn the adjusting nut 3 to adjust the

length a, and then tighten the locknut.

Throttle cable installation length:23.9 ± 1.0 mm (0.94 ± 0.04 in)

NOTE:Apply locking agent (LOCTITE) to thethreads of the adjusting nut 3.

d. Remove the handlebar cover.e. Loosen the locknut 4.f. Turn the adjuster 5 in or out until the

specified free play is obtained.



g. Tighten the locknut.

NOTE:• When adjusting the throttle cable at the

throttle body, fully open the throttle leverand check that the butterfly valve is fullyopen.

• If the throttle cable free play cannot beadjusted properly, replace the throttlecable.

45

EINSPADJ CONTROL SYSTEM/GENERAL

WARNINGAfter adjusting the free play, turn the han-dlebar to the right and left and make surethat the trolling speed does not increase.

h. Install the handlebar cover.

T R.

Handlebar cover screw:1.1 N • m (0.11 kgf • m, 0.8 ft • lb)LOCTITE 242

i. Install the ribbon sub assemblies and airfilter case cover.

T R.

Ribbon sub assembly bolt:6.5 N • m (0.65 kgf • m, 4.7 ft • lb)LOCTITE 242


GENERALDrain plug inspection

1. Inspect:• Drain plugs

Cracks/damage → Replace.• O-rings

Cracks/wear → Replace.• Screw threads


46

EINSPADJ GENERAL

Lubrication points1. Lubricate:

• Throttle cable (handlebar end)

NOTE:Before lubricating the throttle cable, removethe throttle cable 1 from the throttle leverassembly.

Recommended lubricant:Rust inhibitor1

2. Lubricate:• Throttle cable (throttle body end)• Throttle bodies (throttle cable pulley,

throttle cam, and return spring)


3. Lubricate:• QSTS control cables (handlebar end)

NOTE:Before lubricating the QSTS control cables,remove the QSTS cable housing cover. Spraythe rust inhibitor into the outer cables, andapply grease to the inner cables.


47

EINSPADJ GENERAL

4. Lubricate:• QSTS cables (pulley end)


5. Lubricate:• Nozzle pivot shaft • Steering cable (nozzle end)• QSTS cable (nozzle end)


6. Lubricate:• Steering cable • Steering cable joint• Shift cable• Shift cable joint

NOTE:Disconnect the joints and apply a smallamount of grease.


48

EINSPADJ GENERAL

7. Fill:• Intermediate housing

NOTE:Fill the intermediate housing with the recom-mended grease through the grease nipple 1.


Grease quantity:Initial 10 hours:

33.0–35.0 cm3 (1.11–1.18 oz)Every 100 hours or 12 months:

6.0–8.0 cm3 (0.20–0.27 oz)

1

49

E– +ELEC ELECTRICAL COMPONENTS (For FX/FX Cruiser)

ELECTRICAL COMPONENTS (For FX/FX Cruiser)

N

M

L

K

J

H

G

F

E

D

C

B

A

0

98

7

6

5

4

3

2

1I

1 Thermoswitch (engine)2 Starter motor3 Engine temperature sensor4 Spark plugs and ignition coils5 Electrical box6 Battery7 Speed sensor8 Electric bilge pump9 Cam position sensor0 Fuel injectorsA Thermoswitch (exhaust)

B Oil pressure switchC Bypass valve motorD Intake air pressure sensorE Intake air temperature sensorF Throttle position sensorG Lighting coil and pickup coilH Engine stop switch, engine

shut-off switch, and start switch

I Steering sensorJ Buzzer

K Electric fuel pumpL Fuel level sensorM Left operation buttonN Multifunction meter

50

E– +ELEC

ELECTRICAL COMPONENTS (For FX High Output/FX Cruiser High Output)


M

N

L

P

O

K

J

I

G

F

E

D

C

B

A

0

98

7

6

5

4

3

2

1H

1 Thermoswitch (engine)2 Starter motor3 Engine temperature sensor4 Spark plugs and ignition coils5 Electrical box6 Battery7 Speed sensor and water tem-

perature sensor (FX Cruiser High Output) Speed sensor (FX High Output)

8 Electric bilge pump9 Cam position sensor0 Fuel injectorsA Thermoswitch (exhaust)B Oil pressure switchC Sensor assembly (intake air

pressure and intake air tem-perature sensor)

D Bypass valve motorE Throttle position sensorF Lighting coil and pickup coil

G Engine stop switch, engineshut-off switch, and startswitch

H Steering sensorI Buzzer

7

51

E– +ELEC


M

N

L

P

O

K

J

I

G

F

E

D

C

B

A

0

98

7

6

5

4

3

2

1H

J Electric fuel pumpK Fuel level sensorL Left operation buttonM Multifunction meterN Right operation button

(FX Cruiser High Output)O Remote control unitP Compass sensor and air temperature sensor

(FX Cruiser High Output)

52


OFF THROTTLE STEERING SYSTEMWIRING DIAGRAM

PO

G/B

G

Pu/B

G/YG/R

Pu/G

Pu/Y

Pu/B

P

O

R/Y

Pu/Y

G/Y

G/R

B/Y

P/G

Pu/R

Pu/RPu/G

P/GR/Y

G

G/BB/O

GG/Y

WRB

W

B

R

W/BB/O

W/R

B/O

B/O

B/O

B/O

W/BB/O

W/RB/OB/OB/O

B/O

O

PB/O

OP

OB

W/L

W/LB/OR/Y

R/Y

OW/L

OBB/O

B/O

B/O

B/O

B/O

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

G/Y

R/Y

G

G/R

G/B

R/Y

R/Y

G/RG/B

R/YR/Y

R/YR/Y

G/RGW/LR/YP

18 :20 :27 :30 :34 :

OW/RW/BG/BG/Y

8 :12 :13 :16 :17 :

2

3

4

5

P

PO

R R

O

OO

R

W/L

1

1 ECM2 Steering sensor3 Pickup coil4 Throttle position sensor5 Bypass valve motor

B : BlackG : GreenO : OrangeP : PinkR : RedW : WhiteB/O : Black/orangeG/B : Green/blackG/R : Green/red

G/Y : Green/yellowR/Y : Red/yellowW/B : White/blackW/L : White/blueW/R : White/red

53


STEERING SENSOR1. Check:

• Steering sensorMalfunction → Replace the steeringsensor.

Checking steps:• Turn the handlebar all the way to the left

or right, and then release it.• Install a plastic tie 1 loosely around the

center of the handlebar grip as shown.• Hook a spring gauge 2 onto the plastic

tie.• Hold the spring gauge at a 90° angle

from the handlebar, and then pull thespring gauge with a force of 10 kgf(22 lb).

When handlebar pulled

When handlebar not pulled

ON OFF

• Check that the following is displayed inthe “Engine Monitor” window of theYamaha Diagnostic System.

• Use the same procedure to check thatthe steering sensor operates correctlywhen the handlebar is turned to both theleft and right. Replace the steering sen-sor if it is a malfunction.

12

54


INDICATION SYSTEMWIRING DIAGRAM (For FX Cruiser High Output)

G

B B

B

B

B

RL BWG

R

R

3

R L/R

L

Y

R R/Y

R

B

P

R R

P

W/B

R/Y

B/O

R/YR/YR

R/Y

R/Y

R R P P P

1 2 3 4 5 6 7 8

2

7

6

8

5

B/O

P

P

B

P

B/O

P

B

B/O

P

P

B/G

B

W/B

B

P

B/O

P

B

B/Y

B/O B/Y

B/Y

B/YB/O

B/Y

9

B/O

B/OB/O

B/OB/O

B/O

B/O

B/OB/O

B/OB/O

B/O

B/YB/Y

B

B/YR/YY

B/YR/YY

L/R B/L

R

P

B

B

B/GP

A

C

B

R/YW/B

0

B/LL/R

L BW

B R

B

B

B

B

R/Y

1 21 3053515614

P/W

P/W

P/W

D

B/O

R/Y

W/B

B/O

G

4

1

L/BL/YY

L

715 18 16 6

L/R

R/Y

L/R

L/R

L/Y

L/RL/B L/Y

B/O

O

R/Y

R/Y

R

L/B

G

R/Y

Y

E

BR

G

L W

B

RG

B/O

1 ECM2 Main and fuel pump relay3 Fuse (20 A)4 Remote control unit5 Battery6 Tacho pulse7 Thermoswitch (exhaust)8 Thermoswitch (engine)9 Engine temperature sensor

0 Multifunction meterA Fuel level sensorB Speed sensor and water temperature sensorC BuzzerD Oil pressure switchE Compass sensor and air temperature sensor

55


WIRING DIAGRAM (For FX Cruiser High Output)

G

B B

B

B

B

RL BWG

R

R

3

R L/R

L

Y

R R/Y

R

B

P

R R

P

W/B

R/Y

B/O

R/YR/YR

R/Y

R/Y

R R P P P

1 2 3 4 5 6 7 8

2

7

6

8

5

B/O

P

P

B

P

B/O

P

B

B/O

P

P

B/G

B

W/B

B

P

B/O

P

B

B/Y

B/O B/Y

B/Y

B/YB/O

B/Y

9

B/O

B/OB/O

B/OB/O

B/O

B/O

B/OB/O

B/OB/O

B/O

B/YB/Y

B

B/YR/YY

B/YR/YY

L/R B/L

R

P

B

B

B/GP

A

C

B

R/YW/B

0

B/LL/R

L BW

B R

B

B

B

B

R/Y

1 21 3053515614

P/W

P/W

P/W

D

B/O

R/Y

W/B

B/O

G

4

1

L/BL/YY

L

715 18 16 6

L/R

R/Y

L/R

L/R

L/Y

L/RL/B L/Y

B/O

O

R/Y

R/Y

R

L/B

G

R/Y

Y

E

BR

G

L W

B

RG

B/O

B : BlackG : GreenL : BlueO : OrangeP : PinkR : RedW : WhiteY : YellowB/G : Black/green

B/L : Black/blueB/O : Black/orangeB/Y : Black/yellowL/B : Blue/blackL/R : Blue/redL/Y : Blue/yellowP/W : Pink/whiteR/Y : Red/yellowW/B : White/black

56


WIRING DIAGRAM (For FX High Output)

G

B B

B

B

B

R

3

R L/R

L

Y

R R/Y

R

B

P

R R

P

W/B

R/Y

B/O

R/YR/YR

R/Y

R/Y

R R P P P

1 2 3 4 5 6 7 8

2

7

6

8

5

B/O

P

P

B

P

B/O

P

B

B/O

P

P

B/G

B

W

B

P

B/O

P

B

B/Y

B/O B/Y

B/Y

B/YB/O

B/Y

9

B/O

B/OB/O

B/OB/O

B/O

B/O

B/OB/O

B/OB/O

B/O

B/Y

R/Y B/Y

L/R B/L

R

P

B

B

B/G

R/W

P

AB

C

B

RW

0

B/L L/R

B/Y

R/Y

Y

B/Y

R/W

Y

B R

Y

B

B

B

B

R

1 21 3053515614

P/W

P/W

P/W

D

B/O

R/Y

W/B

B/O

G

4

1

L/BL/YY

L

715 18 16 6

L/R

R/Y

L/R

L/Y

L/B

L/RL/B Gy

B/O

O

R/Y

R/Y

R

Gy

L/R

B/O

1 ECM2 Main and fuel pump relay3 Fuse (20 A)4 Remote control unit5 Battery6 Tacho pulse7 Thermoswitch (exhaust)8 Thermoswitch (engine)9 Engine temperature sensor

0 Multifunction meterA Fuel level sensorB Speed sensorC BuzzerD Oil pressure switch

57


WIRING DIAGRAM (For FX High Output)

G

B B

B

B

B

R

3

R L/R

L

Y

R R/Y

R

B

P

R R

P

W/B

R/Y

B/O

R/YR/YR

R/Y

R/Y

R R P P P

1 2 3 4 5 6 7 8

2

7

6

8

5

B/O

P

P

B

P

B/O

P

B

B/O

P

P

B/G

B

W

B

P

B/O

P

B

B/Y

B/O B/Y

B/Y

B/YB/O

B/Y

9

B/O

B/OB/O

B/OB/O

B/O

B/O

B/OB/O

B/OB/O

B/O

B/Y

R/Y B/Y

L/R B/L

R

P

B

B

B/G

R/W

P

AB

C

B

RW

0

B/L L/R

B/Y

R/Y

Y

B/Y

R/W

Y

B R

Y

B

B

B

B

R

1 21 3053515614

P/W

P/W

P/W

D

B/O

R/Y

W/B

B/O

G

4

1

L/BL/YY

L

715 18 16 6

L/R

R/Y

L/R

L/Y

L/B

L/RL/B Gy

B/O

O

R/Y

R/Y

R

Gy

L/R

B/O

B : BlackG : GreenGy : GrayL : BlueO : OrangeP : PinkR : RedW : WhiteY : Yellow

B/G : Black/greenB/L : Black/blueB/O : Black/orangeB/Y : Black/yellowL/B : Blue/blackL/R : Blue/redL/Y : Blue/yellowP/W : Pink/whiteR/W : Red/white

R/Y : Red/yellowW/B : White/black

58


WIRING DIAGRAM (For FX/FX Cruiser)

G

G

R

43

R L/R

Br

L

Y

R/Y R/Y

R

B

P

R

O

R/Y

R/Y

R/YR

P

W/B

R/Y

B/O

R/Y R/Y

R/Y

R/Y

Y YR R P P P

1 2 5 6

2

1

B

BB

7

6

8

5

B/O

B/G

P

B

P

B/O

P

B

B/O

P

P

P

B

W

B

P

B/O

P

B

B/Y

B/O B/Y

B/Y

B/YB/O

B/Y

9

B/O

B/OB/O

B/O

B/O

B/O

B/O

B/OB/O

B/O

B/O

B/Y

R/Y B/Y

L/R L/B

RPB B

B/G

R/W

P

ABC

B

RW

0

L/B L/R

B/Y

R/Y

Y

B/Y

R/W

Y

B R

Y

B

B

BB

R

31 1535156

P/W

P/W

P/W

D

B/O

R/Y

W/B

4 3 2 18 7 6 5

B/O

B/O

1 ECM2 Main and fuel pump

relay3 Fuse (20 A)4 Fuse (3 A)5 Battery6 Tacho pulse7 Thermoswitch

(exhaust)

8 Thermoswitch (engine)

9 Engine temperature sensor

0 Multifunction meterA Fuel level sensorB Speed sensorC BuzzerD Oil pressure switch

B : BlackBr : BrownG : GreenO : OrangeP : PinkR : RedW : WhiteY : YellowB/G : Black/green

B/O : Black/orangeB/Y : Black/yellowL/B : Blue/blackL/R : Blue/redP/W : Pink/whiteR/W : Red/whiteR/Y : Red/yellowW/B : White/black

59

E– +ELEC

MULTIFUNCTION METERMultifunction meter

1. Check:• Multifunction meter

Cracked meter housing → Replace themultifunction meter.Meter is fogged/shows signs of waterintrusion → Replace the multifunctionmeter.

Operation button1. Check:

• Left operation button continuityOut of specification → Replace.

• Right operation button continuity (FX Cruiser High Output)Out of specification → Replace.



Left operation button continuity

Button PositionLeads

Pu/W B G/W

Speed/RPM

Free

Push

Volt/Hour

Free

Push



Right operation button continuity

Button PositionLeads

R/W B Y/W

Start/Stop

Free

Push

Mode/Reset

Free

Push

INDICATION SYSTEM

60


MULTIFUNCTION METER REMOVALRefer to “STEERING CONSOLECOVER”.

OPERATION BUTTON REMOVALRefer to “STEERING CONSOLECOVER”.

61

E– +ELEC

Display function (for FX Cruiser High Output)

1. Check:• Display function

Does not operate → Replace the multi-function meter.

1 Remote control unit2 Buzzer3 Compass sensor4 ECM5 Fuel level sensor6 Left operation button7 Right operation button

B : BlackG : GreenL : BlueP : PinkR : RedW : WhiteB/G : Black/greenB/L : Black/blueG/W : Green/white

L/B : Blue/blackL/R : Blue/redL/Y : Blue/yellowPu/W : Purple/whiteR/W : Red/whiteR/Y : Red/yellowW/B : White/blackY/W : Yellow/white

INDICATION SYSTEM

B/L B

L/R

P

B

P

L/R R

BR

1

2

3

4

5

L/Y

L/B

L/R

L/Y

L/B

B/L

B

R

G

W

L

R/Y

W/B

B

B

R

R/Y

W/B

B/G

B/G

Y/WR/W R/W

Y/W

BB

Y/WB

R/W

Y/WB

R/WPu/W

G/W G/W

Pu/W

BB

G/WB

Pu/W

G/WB

Pu/W

6 7

L W

G

62

E– +ELEC

Display function (for FX High Output)1. Check:

• Display functionDoes not operate → Replace the multi-function meter.

1 Remote control unit2 Buzzer3 Speed sensor4 ECM5 Fuel level sensor6 Left operation button

B : BlackGy : GrayP : PinkR : RedW : WhiteY : YellowB/G : Black/greenB/L : Black/blue

B/Y : Black/yellowG/W : Green/whiteL/B : Blue/blackL/R : Blue/redL/Y : Blue/yellowPu/W : Purple/whiteR/W : Red/white

INDICATION SYSTEM

B/L B

L/R

B/YR/W B/Y

PB/G

R/W

Y Y

R R

W

W

BB

B/G P

L/R R

BR

1

2

3

4

5

Gy

L/B

L/R

L/Y

L/B

B/LPu/W

G/W G/W

Pu/W

BB

G/WB

Pu/W

G/WB

Pu/W

6

63


Display function (for FX/FX Cruiser)1. Check:

• Display functionNot operate → Replace the multifunc-tion meter.

1 Buzzer2 Speed sensor3 ECM4 Fuel level sensor5 Left operation button

B : BlackR : RedW : WhiteY : YellowB/G : Black/greenB/Y : Black/yellow

G/W : Green/whiteL/B : Blue/blackL/R : Blue/redPu/W : Purple/whiteR/W : Red/white

L/B

L/B B

L/R

B/Y R/W B/Y

B/GB/G

R/W

Y Y

R R

W

W

BB

B B

L/R R

BR 1

2

3

4

Pu/WG/W G/W

Pu/W

BB

G/WB

Pu/W

G/WB

Pu/W

5

64


Compass display (for FX Cruiser High Output)

1. Check:• Compass display

Incorrect reading → Replace the com-pass sensor.

Air temperature display (for FX Cruiser High Output)

1. Check:• Air temperature display

Incorrect reading → Replace the com-pass sensor.

Checking steps:• Using a compass for reference, point the

watercraft north.• Turn on the multifunction meter and

check that “NORTH” appears on themeter.

• If “NORTH” does not appear on the multi-function meter, replace the compass sen-sor.

NOTE:Be sure to check the compass display againafter replacing the compass sensor. If thecompass display is still incorrect, replacethe multifunction meter.

Checking steps:• Measure the ambient air temperature.• Turn on the multifunction meter and

check the air temperature displayed onthe meter.

• If the air temperature displayed on themultifunction meter is more than ± 5 °C(9 °F) different from the ambient air tem-perature, replace the compass sensor.

NOTE:Be sure to check the air temperature dis-play again after replacing the compass sen-sor. If the air temperature display is stillincorrect, replace the multifunction meter.

N

65

E– +ELEC

Speedometer/average speed/tripmeter dis-play (for FX Cruiser High Output)

1. Check:• Speedometer/average speed/tripmeter

displayDoes not display → Measure the speedsensor output voltage.

2. Measure: • Speed sensor output voltage

Out of specification → Replace thespeed sensor.Within specification → Replace the mul-tifunction meter.



Speed sensor output voltage(dependant on the paddle wheel position):

Less than 400 mV/More than 5 V

Output pulse:2 pulses/one-full turn

Measuring steps:• Disconnect the coupler between the mul-

tifunction meter and the compass sensor1, and then connect it to a 12 V batteryas shown in the illustration.

• Rotate the paddle wheel and check theoutput voltage and output pulses.

NOTE:As the paddle wheel is rotated, a square-wave voltage signal a is produced.

• If within specification, replace the multi-function meter. If out of specification,replace the speed sensor 2.

NOTE:Be sure to check the output voltage andoutput pulses again after replacing thespeed sensor. If still out of specification,replace the compass sensor.

N

S

S

N

DC V

R

G

B

12

INDICATION SYSTEM

66


Water temperature display (for FX Cruiser High Output)

1. Check:• Water temperature display

Incorrect reading → Measure the speedsensor (water temperature sensor)resistance.

2. Measure:• Speed sensor (water temperature sen-

sor) resistance.Out of specification → Replace thespeed sensor.Within specification → Replace the com-pass sensor.

Checking steps:• Measure the ambient water temperature.• Turn on the multifunction meter and

check the water temperature displayedon the meter.

• If the water temperature displayed on themultifunction meter is more than ± 5 °C(9 °F) different from the ambient watertemperature, measure the speed sensor(water temperature sensor) resistance.



Speed sensor (water temperature sensor) resistance:

10 kΩ at 25 °C (77 °F)

Measuring steps:• Disconnect the coupler, and then mea-

sure the resistance between the yellowand black/yellow leads as shown in theillustration.

• If the speed sensor (water temperaturesensor) resistance is within specification,replace the compass sensor. If out ofspecification, replace the speed sensor.

NOTE:Be sure to check the water temperature dis-play again after replacing the compass sen-sor. If the water temperature display is stillincorrect, replace the multifunction meter.

N

S

S

N

R/Y

Y

B/Y

67

E– +ELEC

Trip timer display (for FX Cruiser High Output)

1. Check:• Trip timer display

Does not display → Replace the multi-function meter.

Fuel consumption per hour, fuel consump-tion per kilometer/mile display (for FX Cruiser High Output)

1. Check:• Fuel consumption per hour, fuel con-

sumption per kilometer/mile displayDoes not display → Check the fuel injec-tion duration using the “Engine monitor”of the Yamaha Diagnostic System.Replace the multifunction meter.

Overheat warning indicator1. Check:

• Overheat warning indicatorDoes not operate → Replace the multi-function meter.

Checking steps:• Start the engine.• Disconnect the thermoswitch (engine)

coupler 1 (blue), engine temperaturesensor coupler 2 (black) or ther-moswitch (exhaust) 3 coupler.

• Connect the jumper lead to the femaleterminal of the disconnected coupler.

• Check that the multifunction meter over-heat warning indicator comes on and thebuzzer sounds.

INDICATION SYSTEM

68


Check engine warning indicator1. Check:

• Check the engine warning indicatorDoes not operate → Replace the multi-function meter.

Checking steps:• Start the engine.• Disconnect the coupler of a sensor (e.g.,

engine temperature sensor) that normallyactivates the check engine warning indi-cator when a malfunction occurs.

• Check that the warning light and checkengine warning indicator blink and thatthe buzzer sounds intermittently.

Diagnostic display1. Check:

• Diagnostic displayDoes not display → Replace the multi-function meter.

Checking steps:• Start the engine.• Disconnect the coupler of a sensor (e.g,.

engine temperature sensor) that is nor-mally displayed when a malfunctionoccurs. Refer to “SELF-DIAGNOSIS”.

• Check that the check engine warningindicator is displayed and that the buzzersounds.

• Simultaneously press the two buttons 1for 8 seconds and check the error codeindicated on the multifunction meter.

1

69

E– +ELEC

REMOTE CONTROL SYSTEM (For FX High Output/FX Cruiser High Output)

REMOTE CONTROL SYSTEM (For FX High Output/FX Cruiser High Output)WIRING DIAGRAM

16 7 6 11 15 14 18 12 3 4 13 10

1234567890ABCDEFGH

L

R/YR/Y

1431 21 1530R/Y

L/R

L

Y

R R/Y

B

R/Y

R/Y

R/Y

L/R

Y

Br

Br

B

B

R

4

73

2

1

6

R/Y

R/Y R

P

P

O

R

R

R

R R

R

1 2 3 4 5 6 7 8

5

B

B

B

B

Y

B

BB

B

W/BW

B

R

R

B

B/L

L/R

B/L

L/YL/B

#4

#3

#2

#1

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

Pu/G

Pu/Y

Pu/B

Pu/R

R/Y

0

0

0

0 Pu/G

R/Y

Pu/Y

R/Y

Pu/B

R/Y

Pu/R

R/Y

R/YR/Y

9

8

W/B

W

W

W A

14 : L15 : W/B21 : L/R30 : R/Y 31 : Y

37 : Pu/G38 : Pu/Y39 : Pu/B40 : Pu/R

W

L/R

L/B Gy

L/R

L/B

L/YL/R

L/R

P

O

G/B

G

Pu/B

G/YG/R

Pu/G

Pu/Y

Pu/B

P

O

R/Y

Pu/Y

G/Y

G/R

B/Y

P/G

Pu/R

Pu/RPu/G

P/GR/Y

G

G/BB/O

B

Gy

B

W/B(*)

W/B(*)

L/Y(*)L/Y(*)

1 ECM2 Main and fuel pump relay3 Fuse (20 A)4 Starter relay5 Starter motor6 Battery7 Fuse (3 A)8 Remote control unit9 Multifunction meter

0 Fuel injectorA AntennaB Buzzer

70

E– +ELEC


WIRING DIAGRAM

16 7 6 11 15 14 18 12 3 4 13 10

1234567890ABCDEFGH

L

R/YR/Y

1431 21 1530R/Y

L/R

L

Y

R R/Y

B

R/Y

R/Y

R/Y

L/R

Y

Br

Br

B

B

R

4

73

2

1

6

R/Y

R/Y R

P

P

O

R

R

R

R R

R

1 2 3 4 5 6 7 8

5

B

B

B

B

Y

B

BB

B

W/BW

B

R

R

B

B/L

L/R

B/L

L/YL/B

#4

#3

#2

#1

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

Pu/G

Pu/Y

Pu/B

Pu/R

R/Y

0

0

0

0 Pu/G

R/Y

Pu/Y

R/Y

Pu/B

R/Y

Pu/R

R/Y

R/YR/Y

9

8

W/B

W

W

W A

14 : L15 : W/B21 : L/R30 : R/Y 31 : Y

37 : Pu/G38 : Pu/Y39 : Pu/B40 : Pu/R

W

L/R

L/B Gy

L/R

L/B

L/YL/R

L/R

P

O

G/B

G

Pu/B

G/YG/R

Pu/G

Pu/Y

Pu/B

P

O

R/Y

Pu/Y

G/Y

G/R

B/Y

P/G

Pu/R

Pu/RPu/G

P/GR/Y

G

G/BB/O

B

Gy

B

W/B(*)

W/B(*)

L/Y(*)L/Y(*)

B : BlackBr : BrownGy : GrayL : BlueR : RedW : WhiteY : Yellow

B/L : Black/blueL/B : Blue/blackL/R : Blue/redL/Y : Blue/yellowPu/B : Purple/blackPu/G : Purple/greenPu/R : Purple/red

Pu/Y : Purple/yellowR/Y : Red/yellowW/B : White/black

* : FX Cruiser High Output

71

E– +ELEC

REMOTE CONTROL SYSTEMYamaha Security System indicator

1. Check:• Yamaha Security System indicator

Check that the “SECURITY” indicatorlight 1 comes on when the YamahaSecurity System is deactivated (i.e., theengine can be started).Does not come on → Measure theremote control unit output voltage.

2. Measure:• Remote control unit output voltage

Within specification → Replace the mul-tifunction meter.Out of specification → Replace theremote control unit.



Remote control unit output voltage:

Blue/yellow (L/Y) – ground11–13 V

Measurement steps:• Disconnect the remote control unit 1

coupler from the multifunction meter.• Measure the remote control unit output

voltage while pushing the unlock buttonof the remote control transmitter.

1

1

L/Y

1


72

E– +ELEC


Low-rpm mode indicator1. Check:

• Low-rpm mode indicatorDoes not come on → Replace the multi-function meter.

Checking steps:• Press the unlock button 1 of remote con-

trol transmitter for more than four sec-onds to select the low-rpm mode.

• Check that the beeper sounds threetimes and the “L-MODE” indicator light 2comes on.

1

2

73

EHULLHOOD HANDLEBAR

HANDLEBAREXPLODED DIAGRAM (For FX/FX High Output)


Step Procedure/Part name Q’ty Service pointsSTEERING PAD REMOVAL Follow the left “Step” for removal.

1 Screw 42 Handlebar cover 13 Pad 14 Bolt 25 Handlebar cover stay 1


74

EHULLHOOD HANDLEBAR

EXPLODED DIAGRAM (For FX Cruiser/FX Cruiser High Output)


Step Procedure/Part name Q’ty Service pointsSTEERING PAD REMOVAL Follow the left “Step” for removal.

1 Screw 82 Screw (black) 23 Lower handlebar cover 14 Upper handlebar cover 1 NOTE:

Be sure to insert the projection on the upperhandlebar cover completely into the grom-met.

5 Bolt 46 Steering pad 17 Grommet 1


8

75

EHULLHOOD HANDLEBAR

EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsHANDLEBAR HOLDER REMOVAL


1 Throttle cable 1 NOTE:Be sure to remove the throttle cable seal asshown in the illustration.

2 Bolt 43 Upper handlebar holder 2


76

EHULLHOOD HANDLEBAR

EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsHANDLEBAR REMOVAL Follow the left “Step” for removal.QSTS cable (to jet thrust nozzle) Refer to “REMOTE CONTROL CABLES

AND SPEED SENSOR LEAD”.1 Nut/washer 2/22 QSTS converter 13 QSTS cable 2 1 With white tape a4 QSTS cable 1 1 NOTE:

• Route the QSTS cables through the star-board side in the steering console.

• Route the handlebar switch lead, and throt-tle cable through the port side in the steer-ing console.

5 Handlebar switch coupler 2

77

EHULLHOOD HANDLEBAR

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points6 Screw 47 Handle boss cover 18 Plastic tie 29 Hose packing 110 Throttle cable 1 NOTE:

Position the corrugated tube for the throttlecable as shown in the illustration so that thetube attaches to the end of the outer throttlecable.

Not reusable

78

EHULLHOOD HANDLEBAR

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points11 Handlebar assembly 1 NOTE:

• Pass the QSTS cable and handlebar switchlead through the handle boss cover, andthen install the handlebar assembly.

• Install the sponges of the QSTS cables asshown and make sure that the grommet isinstalled to the deck securely.

12 Handlebar switch lead 113 Grommet 2


79

EHULLHOOD HANDLEBAR

SERVICE POINTSHandlebar assembly installation

1. Install:• Plastic ties 1 • QSTS cables 2 • Handlebar switch lead 3 • Throttle cable 4

NOTE:After inserting the QSTS cables, handlebarswitch lead and throttle cable into the grom-mets, tie the end of grommets with the plasticties.

È FX/FX High OutputÉ FX Cruiser/FX Cruiser High Output

23

4

1 1

È

1

4

1

2

3

É

2. Install:• Upper handlebar holder 1

NOTE:• Align the punch marks a on the handlebar

with the top surface of the handlebar holder.• The upper handlebar holder should be

installed with the punch mark b facing for-ward.

CAUTION:Clearance c should be narrower thanclearance d.

T R.

Handlebar holder bolt:20 N • m (2.0 kgf • m, 14 ft • lb)LOCTITE 242

Reference clearance:c: 1.5 mm (0.06 in)d: 3.5 mm (0.14 in)

80

EHULLHOOD HANDLEBAR

3. Connect:• Throttle cable

Installing steps (for FX/FX High Output):• Route the throttle cable 1 over the han-

dlebar 2, and then install the throttlecable end into the throttle lever.

• Make sure that the throttle cable, QSTScable 3, and handlebar switch lead 4pass through the opening a in the centerof the steering boss cover. Reroute thecables and lead if they are not routed cor-rectly.

• Make sure that there is slack in the throt-tle cable, QSTS cable, and handlebarswitch lead when the handlebar is turnedto the left and right. Reroute the cablesand lead if there is no slack.

Installing steps (for FX Cruiser/FX Cruiser High Output):• Route the throttle cable 1 under the han-

dlebar 2, and then install the throttlecable end into the throttle lever.

• Make sure that the throttle cable, QSTScable 3, and handlebar switch lead 4pass through the opening a in the centerof the steering boss cover. Reroute thecables and lead if they are not routed cor-rectly.

• Make sure that there is slack in the throt-tle cable, QSTS cable, and handlebarswitch lead when the handlebar is turnedto the left and right. Reroute the cablesand lead if there is no slack.

41

23

a

1

23

4

a

81

EHULLHOOD HANDLEBAR

4. Install:• Throttle cable seal

Installing steps:• Install the throttle cable end into the throt-

tle lever.• Fit the seal 1 into the groove in the

bracket as shown.• Pull the throttle cable 2 in the direction of

the arrow shown in the illustration, andthen fit the end of the seal 3 aroundinner cable.

• Turn the adjuster 4 in/out until the speci-fied free play is obtained.

Throttle lever free play a:4–7mm (0.16–0.28 in)



• Tighten the lock nut 5.

1

32

82


STEERING MASTEREXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsSTEERING MASTER REMOVAL Follow the left “Step” for removal.Mirror assembly Refer to “MIRROR”.Center cover assembly Refer to “STEERING CONSOLE COVER”.Steering cable end Refer to “REMOTE CONTROL CABLES

AND SPEED SENSOR LEAD”.1 Bolt 12 Steering arm assembly 13 Ball joint 14 Nut 15 Bolt/washer/nut 1/1/16 Cable stopper assembly 1

8

6

8

7

56

4

2

1

5

2

9

8

3

8 × 30 mm

8 × 35 mm

6 × 60 mm

20 N • m (2.0 kgf • m, 14 ft • Ib)

LT

271

83

EHULLHOOD

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points7 Nut/washer 4/48 Steering master assembly 19 Bolt 4


8

6

8

7

56

4

2

1

5

2

9

8

3

8 × 30 mm

8 × 35 mm

6 × 60 mm

20 N • m (2.0 kgf • m, 14 ft • Ib)

LT

271

STEERING MASTER

84


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsSTEERING MASTER DISASSEMBLY


1 Steering shaft 1 FX Cruiser/FX Cruiser High Output2 Steering shaft 1 FX/FX High Output3 Bushing 14 Bushing 15 Buzzer 16 Bolt 47 Bracket 1 18 Steering sensor 1

FWD

12

7

8

6

6

3

2121

9

10

16

1522

204

5

1

2

6 × 25 mm

5 × 16 mm

8 × 30 mm

8 × 30 mm

AA

AA

AA

AA

LT

572

LT

LT

271

11

11

11

LT

572

LT

11

1111

11

18

19

17

14

13

AA

11

85


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points9 Bolt 110 Bracket 2 111 Bolt/nut 5/512 Left housing 113 Spring holder 114 Spring 1 115 Lever 116 Lock 117 Spring 2 118 Right housing 1

FWD

12

7

8

6

6

3

2121

9

10

16

1522

204

5

1

2

6 × 25 mm

5 × 16 mm

8 × 30 mm

8 × 30 mm

AA

AA

AA

AA

LT

572

LT

LT

271

11

11

11

LT

572

LT

11

1111

11

18

19

17

14

13

AA

11

86

EHULLHOOD

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points19 Steering tube 120 Rubber seal 121 Bushing 222 Steering master assembly 1


FWD

12

7

8

6

6

3

2121

9

10

16

1522

204

5

1

2

6 × 25 mm

5 × 16 mm

8 × 30 mm

8 × 30 mm

AA

AA

AA

AA

LT

572

LT

LT

271

11

11

11

LT

572

LT

11

1111

11

18

19

17

14

13

AA

11

STEERING MASTER

87

EHULLHOOD

SERVICE POINTSSteering master components inspection

1. Inspect:• Each component part


Rubber seal installation1. Apply:

• Instant adhesive(onto the mating surfaces of the rubberseal 1 and steering master assembly2)

NOTE:After assembling the steering master assem-bly 2, apply instant adhesive onto the matingsurfaces of the rubber seal 1 and steeringmaster assembly 2 in the area a shown inthe illustration.

FW

D

a

1

2

STEERING MASTER

88

EHULLHOOD


REMOTE CONTROL CABLES AND SPEED SENSOR LEADEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsREMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL


Service lid 1 Refer to “FRONT HOOD”.Front seat assembly Refer to “SEATS AND HAND GRIP”.

1 Steering cable end 12 Nut 13 Steering cable 14 Seal 15 Speed sensor coupler 16 Nut 1

89

EHULLHOOD


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points7 Cap 18 Screw 49 Speed sensor

Speed sensor and water temperature sensor

11

FX/FX Cruiser/FX High OutputFX Cruiser High Output

10 Shift cable end 111 Plastic tie 112 Grommet 113 Nut 214 Shift cable holder 215 Nut 216 Bolt 1

90

EHULLHOOD


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points17 Shift cable bracket 118 Nut 119 Shift cable 120 Seal 121 Nut 122 Pin 123 QSTS cable end 124 Nut 125 QSTS cable 126 Packing 1


91

EHULLHOOD


SERVICE POINTSSteering cable removal

1. Remove:• Steering cable

Removal steps:• Rotate the steering stopper plate 1 on

the steering stopper clockwise andremove it from the steering stopper plate2.

• Rotate the steering stopper plate 2

counterclockwise.• Remove the steering cable 3 from the

steering stopper 4.• Disconnect the cable joint 5 to the ball

joint 6.

2

1

1

2

3

4

92

EHULLHOOD


SERVICE POINTSSteering cable installation

1. Install:• Steering cable

Installing steps:• Connect the cable joint 1 to the ball joint

2.• Insert the projection 3 on the steering

cable completely into the indentation 4in the steering stopper.

• Slightly lift up the steering stopper plate5 on the steering stopper, and thenrotate it clockwise.

• Rotate the steering stopper plate 6 onthe steering stopper counterclockwise,making sure to fit the hole in the stopperplate 6 onto the projection 7 on theother steering stopper plate 5.

3

4

6

5

5

7

6

93


FRONT HOODEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsFRONT HOOD REMOVAL Follow the left “Step” for removal.

1 Nut/washer 4/42 Front hood assembly 13 Bolt 44 Bolt 25 Hinge assembly 16 Bolt 27 Hood lock assembly 18 Rivet 49 Service lid 1 1

2

7

6

4

8

9

3

5

111

10

6 × 30 mm

6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

LT

242

LT

242

6 × 18 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 18 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

LT

242

94


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points10 Rivet 411 Service lid 2 1


2

7

6

4

8

9

3

5

111

10

6 × 30 mm

6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

LT

242

LT

242

6 × 18 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 18 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

LT

242

95


SERVICE POINTSRivet Installation

1. Install:• Rivets

Installing steps:• Insert a rivet completely in the holes in

both the service lid 1 and inner hull.• Push in the rivet pin 2 until it clicks and

is flush with the top of the rivet.

NOTE:• To remove a rivet, push the rivet pin in

until it clicks and is below the top of therivet.

• Before reinstalling a rivet, hold the rivetflange a with both hands and push therivet pin perpendicularly against a hardflat surface until the pin protrudes from thetop of the rivet.

21

a

96


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsFRONT HOOD DISASSEMBLY Follow the left “Step” for disassembly.

1 Screw 82 Front hood 1 13 Front hood 2 14 Nut 45 Center ornament 1 NOTE:

• Be careful not to scratch the ornaments.• Install the center ornament after installing

the left and right ornaments.

6 Left ornament 17 Right ornament 1

8 Double-sided tape 29 Bolt 6

2

1

4

9

5 × 16 mm 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib)

5 × 16 mm 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib)

5 × 17 mm 1.1 N • m (0.11 kgf • m, 0.8 ft • Ib)

10

9 10

5 × 17 mm 1.1 N • m (0.11 kgf • m, 0.8 ft • Ib)9

10

9

10

1

11

78 12

12

5

1212

3

6

8

11

Not reusable

97


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points10 Bushing 611 Visor 112 Nut 6 NOTE:

Apply soapy water to the nuts to make theirinstallation easier.


2

1

4

9

5 × 16 mm 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib)

5 × 16 mm 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib)

5 × 17 mm 1.1 N • m (0.11 kgf • m, 0.8 ft • Ib)

10

9 10

5 × 17 mm 1.1 N • m (0.11 kgf • m, 0.8 ft • Ib)9

10

9

10

1

11

78 12

12

5

1212

3

6

8

11

98


SERVICE POINTSOrnament disassembly

1. Disassembly:• Center ornament• Left ornament• Right ornament

Removal steps:• From the bottom side of the front hood

1, push the projections 2 on the centerornament shown in the illustration andremove the ornament from the double-sided tape.

• From the bottom side of the front hood1, push the projections 3 on the leftornament shown in the illustration andremove the ornament from the double-sided tape.

• Remove the right ornament in the sameway as the left ornament.

NOTE:• When removing the ornaments, be sure to

remove the center ornament first.• Be careful not to break the front hood pro-

jections and ornament projections whenremoving the ornaments.

22

1

31

Front hood assembly1. Install:

• Front hood 1 • Front hood 2

NOTE:Fit the end of the front hood 1 under the pro-jection 3 on the front hood 2.

1

2

3

99


Visor installation1. Install:

• Visor

Installing steps:• Install the bushings 1 onto the screws 2

as shown in the illustration.• Install the visor and tighten the screws,

making sure to hold the nuts so that theydo not turn.

T R.

Screw:1.1 N • m (0.11 kgf • m, 0.8 ft • lb)

2 1

Double-sided tape installation1. Install:

• Double-sided tape 1

NOTE:Before affixing the double-sided tape 1, besure to clean the areas on the front hoodwhere the tape will be affixed to remove anydirt.

1

1

100


Ornament installation1. Install:

• Left ornament• Right ornament• Center ornament

Installing steps:• Peel off the backing of the double-sided

tape 1 on the watercraft.• Install the left and right ornaments from

the sides as shown in the illustration.• Install the center ornament from above as

shown in the illustration.

NOTE:Be sure to install the left and right orna-ments before installing the center orna-ment. The left and right ornaments cannotbe installed if the center ornament isinstalled first.

1

1

101

EHULLHOOD

MIRROREXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsMIRROR REMOVAL Follow the left “Step” for removal.

1 Nut 2 2 Washer 23 Bolt 24 Bolt 45 Left mirror assembly 16 Right mirror assembly 1


4

6

4

2

1

5

3

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6 × 23 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

LT

242

LT

LT

242

LT

6 × 23 mm

6 × 22 mm

MIRROR

102

EHULLHOOD MIRROR

EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsMIRROR DISASSEMBLY Follow the left “Step” for disassembly.

1 Screw 122 Left mirror upper cover 13 Screw 84 Left mirror 15 Nut 26 Left mirror lower cover 17 Right mirror upper cover 18 Right mirror 19 Right mirror lower cover 1


1

1

1

2

3

4

5

6

7

38

9

5

1

5 × 15 mm 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

5 × 15 mm 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

5 × 15 mm 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

1

1

103


STEERING CONSOLE COVEREXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsMETER AND METER COVER REMOVAL


Handlebar assembly Refer to “HANDLEBAR”.Service lid 1 Refer to “FRONT HOOD”.

1 Band 12 Multifunction meter coupler 43 Screw 44 Multifunction meter cover 1

2

1

10

7

9

13

5

5

6

14 15

4

3

12

11

12

11

8

5 × 15 mm 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib)

3

5 × 12 mm 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

3

6

5

104


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points5 Left operation button coupler 16 Right operation button coupler 1 FX Cruiser High Output7 Left operation button 18 Right operation button 1 FX Cruiser High Output9 Bolt 410 Washer 411 Band 112 Grommet 113 Multifunction meter 1 FX Cruiser High Output14 Cover 1 FX/FX Cruiser/FX High Output15 Multifunction meter 1 FX/FX Cruiser/FX High Output


2

1

10

7

9

13

5

5

6

14 15

4

3

12

11

12

11

8

5 × 15 mm 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib)

3

5 × 12 mm 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

3

6

5

105


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsSIDE COVER REMOVAL Follow the left “Step” for removal.

1 Bolt 22 Nut/washer 2/23 Bolt 84 Left side cover 15 Left inner side pad 26 Nut 67 Screw 48 Left side ornament 19 Right side cover 1

3

9

11

6

6

1

73

3

1

7

3

6

8

6

1

5

510

10

6

2

2

4

5 × 15 mm 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib)

6 × 23 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

3 3

5 × 15 mm 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib)

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

LT

242

LT

LT

242

LT

LT

242

LT

LT

242

LT

6

6 × 22 mm

LT

242

LT

6 × 22 mm

6 × 23 mm

6 × 23 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

106

EHULLHOOD

EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service points10 Right inner side pad 211 Right side ornament 1


3

9

11

6

6

1

73

3

1

7

3

6

8

6

1

5

510

10

6

2

2

4

5 × 15 mm 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib)

6 × 23 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

3 3

5 × 15 mm 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib)

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

LT

242

LT

LT

242

LT

LT

242

LT

LT

242

LT

6

6 × 22 mm

LT

242

LT

6 × 22 mm

6 × 23 mm

6 × 23 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

STEERING CONSOLE COVER

107


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsCENTER COVER REMOVAL Follow the left “Step” for removal.

1 Nut/washer 2/22 Bolt 23 Nut/washer 2/24 Center cover assembly 1 NOTE:

To remove the center cover assembly easily,pull the tilt lever up.

5 Nut/washer 2/26 Bolt 27 Hood lock 18 Nut/washer 2/2 FX Cruiser High Output

FWD

4

3

3

2

11

12

9

10

6

7

1 5 8

5 × 24 mm

6 × 22 mm

6 × 30 mm

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

3.8 N • m (0.38 kgf • m, 2.7 ft • Ib)

108


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points9 Screw 2 FX Cruiser High Output10 Compass sensor and air

temperature sensor1 FX Cruiser High Output

11 Case cap 112 Inner pad 1


FWD

4

3

3

2

11

12

9

10

6

7

1 5 8

5 × 24 mm

6 × 22 mm

6 × 30 mm

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

3.8 N • m (0.38 kgf • m, 2.7 ft • Ib)

109


EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsCENTER COVER DISASSEMBLY Follow the left “Step” for disassembly.

1 Damper 22 Nut 43 Grommet 44 Damper 65 Damper 16 Hinge assembly 27 Gear assembly 28 Lid 19 Lid lock 1

9

8

76

76

10

5

4

11

1

3

1

2

2

110


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points10 Plug 111 Center cover 1


9

8

76

76

10

5

4

11

1

3

1

2

2

111


SHIFT LEVEREXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsSHIFT LEVER REMOVAL Follow the left “Step” for removal.Front hood assembly Refer to “FRONT HOOD”.Mirror assembly Refer to “MIRROR”.Right side cover Refer to “STEERING CONSOLE COVER”.Shift cable Disconnect.

1 Nut/washer 3/32 Bolt 33 Shift lever assembly 1


1

2

2

2

3

16 × 30 mm

6 × 30 mm

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

AA1

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

112


SEATS AND HAND GRIPEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsSEATS AND HAND GRIP REMOVAL


1 Rear seat assembly 1 FX/FX High Output2 Rear seat assembly 1 FX Cruiser/FX Cruiser High Output3 Front seat assembly 1 FX/FX High Output4 Front seat assembly 1 FX Cruiser/FX Cruiser High Output5 Bolt 46 Seat lock assembly 27 Seat storage compartment 18 Nut/washer 4/49 Bolt/washer 4/410 Deck beam 1

3

1

6

5

23

22

19

20

2118

20

8

9

11 15

7

1716

141312

10

6

56 × 25 mm

8 × 30 mm8 × 30 mm

18 N • m (1.8 kgf • m, 13 ft • Ib)

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

26 N • m (2.6 kgf • m, 19 ft • Ib)

6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

6 × 40 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

15 N • m (1.5 kgf • m, 11 ft • Ib) 26 N • m (2.6 kgf • m, 19 ft • Ib)

LT

271

LT

271

2

4

24

26

25

113


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points11 Nut 112 Projection 113 Washer 114 Seal 115 Nut 416 Bolt 417 Rear seat stay 218 Nut 119 Projection 120 Washer 2

3

1

6

5

23

22

19

20

2118

20

8

9

11 15

7

1716

141312

10

6

56 × 25 mm

8 × 30 mm8 × 30 mm

18 N • m (1.8 kgf • m, 13 ft • Ib)

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

26 N • m (2.6 kgf • m, 19 ft • Ib)

6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

6 × 40 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)


LT

271

LT

271

2

4

24

26

25

114


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points21 Nut/washer 4/422 Bolt 423 Hand grip 1 FX/FX High Output24 Hand grip 1 FX Cruiser/FX Cruiser High Output25 Nut/washer 2/126 Seat holder 1


3

1

6

5

23

22

19

20

2118

20

8

9

11 15

7

1716

141312

10

6

56 × 25 mm

8 × 30 mm8 × 30 mm

18 N • m (1.8 kgf • m, 13 ft • Ib)

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

26 N • m (2.6 kgf • m, 19 ft • Ib)

6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)

6 × 40 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib)


LT

271

LT

271

2

4

24

26

25

115

EHULLHOOD

REBOARDING STEP (For FX Cruiser/FX Cruiser High Output)

REBOARDING STEP (For FX Cruiser/FX Cruiser High Output)EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsREBOARDING STEP REMOVAL Follow the left “Step” for removal.

1 Bolt 62 Reboarding step 1


1

1

2

LT

271

8 × 42 mm 15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 42 mm 15 N • m (1.5 kgf • m, 11 ft • Ib)

116

EHULLHOOD

REBOARDING STEP (For FX Cruiser/FX Cruiser High Output)

SERVICE POINTSReboarding step installation

1. Install:• Reboarding step

Installing steps:• Fasten the brackets on both sides of the

reboarding step in the down position witha plastic tie 1 as shown in the illustra-tions so that they will not return to the upposition.

• Finger tighten all of the bolts, and thentighten them to specification.

T R.

Bolt:15 N • m (1.5 kgf • m, 11 ft • lb)

11

117


DECK AND HULLEXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsDECK AND HULL DISASSEMBLY Follow the left “Step” for disassembly.

1 Nut 12 Spout 13 Nut 24 Cleat 15 Plate 26 Bolt/collar 10/107 Sponson 28 Nut/washer 4/49 Screw 410 Drain plug 2

16

16

19

4 53

7

6

1513 14

12 13

1

9

10

11

2

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 40 mm 16 N • m (1.6 kgf • m, 12 ft • Ib)

6 × 25 mm 2.4 N • m (0.24 kgf • m, 1.7 ft • Ib)

5

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

15 N • m (1.5 kgf • m, 11 ft • Ib)

13 N • m (1.3 kgf • m, 9.4 ft • Ib)

LT

271

16

17

18

8

23 2323

22

24

2021

LT

572

LT

6 × 20 mm

2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

5 × 25 mm

118


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points11 Seal 212 Nut 4 NOTE:

To remove the cleat, remove the exhaustsystem first.

13 Plate 414 Cleat 215 Seal 216 Nut/washer 7/717 Front protector 1 1 NOTE:

Install the front protector 1 and 2 after install-ing the front protector 3.

18 Front protector 2 119 Front protector 3 1

16

16

19

4 53

7

6

1513 14

12 13

1

9

10

11

2

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 40 mm 16 N • m (1.6 kgf • m, 12 ft • Ib)

6 × 25 mm 2.4 N • m (0.24 kgf • m, 1.7 ft • Ib)

5

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

15 N • m (1.5 kgf • m, 11 ft • Ib)

13 N • m (1.3 kgf • m, 9.4 ft • Ib)

LT

271

16

17

18

8

23 2323

22

24

2021

LT

572

LT

6 × 20 mm

2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

5 × 25 mm

119


EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points20 Bolt 221 Bow eye 122 Cleat cover 2 FX Cruiser High Output23 Screw 6 FX Cruiser High Output24 Cleat assembly 2 FX Cruiser High Output


16

16

19

4 53

7

6

1513 14

12 13

1

9

10

11

2

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

15 N • m (1.5 kgf • m, 11 ft • Ib)

8 × 40 mm 16 N • m (1.6 kgf • m, 12 ft • Ib)

6 × 25 mm 2.4 N • m (0.24 kgf • m, 1.7 ft • Ib)

5

5.4 N • m (0.54 kgf • m, 3.9 ft • Ib)

15 N • m (1.5 kgf • m, 11 ft • Ib)

13 N • m (1.3 kgf • m, 9.4 ft • Ib)

LT

271

16

17

18

8

23 2323

22

24

2021

LT

572

LT

6 × 20 mm

2.0 N • m (0.2 kgf • m, 1.4 ft • Ib)

5 × 25 mm

120

EHULLHOOD CLEAT ASSEMBLY (For FX Cruiser High Output)

CLEAT ASSEMBLY (For FX Cruiser High Output)EXPLODED DIAGRAM


Step Procedure/Part name Q’ty Service pointsCLEAT DISASSEMBLY Follow the left “Step” for disassembly.

The following procedure applies to both of the cleat assembly.

1 Circlip 22 Spring 23 Cleat 14 O-ring 25 Plate 16 Packing 1


2

12

1

5

4

4

3

6

Not reusable

Not reusable

121

EHULLHOOD CLEAT ASSEMBLY (For FX Cruiser High Output)

SERVICE POINTSCleat cover installation

1. Install:• Cleat cover

NOTE:Make sure that the word “YAMAHA” a on thecleat covers faces outward as shown in theillustration.

a

122


TROUBLE ANALYSISSELF-DIAGNOSISWith the engine running, simultaneously pressthe two buttons 1 for 8 seconds and check ifan error code is indicated on the multifunctionmeter.

If the Yamaha Diagnostic System is not usedto check the symptoms listed in the table, theerror codes can be checked easily with theself-diagnosis in the multifunction meter. How-ever, if there are numerous error codes dis-played, be sure to check them with theYamaha Diagnostic System.

Code Symptom

01 Normal

13 Pickup coil malfunction

15Engine temperature sensor malfunction

18Throttle position sensor malfunction

19 Incorrect battery voltage

23Intake air temperature sensor malfunction

24 Cam position sensor malfunction

29Intake air pressure sensor malfunction

47 Slant detection switch malfunction

48 Incorrect data transmission

54 Bypass valve motor malfunction

55 Steering sensor malfunction

63 Intake air system malfunction

1

9

FX/FX Cruiser

10987654321

654321

87654321

1234567891011121314151617181920212223242526272829303132333435363738394041424344

10987654321

21

3 2 1

2 3 4 16 5 6 7 15 1 8 12 11 10 9 13 14

1 21

12

12

321

231

1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 1 2

1 3 4 6 2 5 2 12 12 12 1

123

123

21

21

21

21

6 5 4 3 2 1 1 2 3 4 5 6 7 810 9 8 7 6 5 4 3 2 12 1

1 2 1 2

B W

FREE

PUSH

Br Br

FREE

PUSH

W BrB R

FREE

PUSH

321

321

213

123

12

21

2 1 2 1

WR

B

R/Y

R/Y

R

L/R

L/B

B/O

B/RR/Y

G/OB/O

R/YB/W

R/YB/Y

R/YB/L

B/WB/YB/L

Pu/RPu/BPu/YPu/G

B/Y

P/GB/O

R/Y

W/LL/B

B/RL/R

G/RG/YG/BW/B

W/BW/R

B/O

B/YP/W

G/O

L/BB/O

R/YR/YR/Y

R/YR/YR/YR/YR/Y

R/Y

B/OW/BW/R

B/YB/O

B/YB/Y

B/O B

RWB

GGG

GGG

PP

R/Y

R/Y

R/Y

R

RB

R

BGGG

B

P

BB

R

R

BGR R

Y

GB

OO

PW

G

BYBr

L

RRR

PPPOOO

B

Br

RRR

R

B

RBr

Br R

R/Y

B/O

B/O

B/O

B/O

B/O

B/O

R/Y

B/O

B/O

B/O

B/O

B/O

B/O

B/O

B/O

BBBBB BB

B/Y Y Br

BrB

B

B

BB

P

B

B

B/G PLB

B PLB

R

BrR

BrRB

WW

B/O

PB/Y

B/Y

GG

O R/Y

R/Y

R/Y

G/R

G/Y

G/B

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

B/O

B/O

B/O

B/O

B/O

B/O

B/Y

P/G

O G/B

G/Y

G/R

Pu/

GR

/YB

/OP

u/Y

Pu/

BP

u/R

B/Y

P/G

P G/B

BPP

GO

B/O

P/W

P/W

G/Y

G/R

Pu/

GR

/YB

/OP

u/Y

Pu/

BP

u/R

B/Y

P/G

ORGB

B/O

B/O

G/O

WB

BR

GG

G

B/OPO

Pu/

G

Pu/

Y

Pu/

B

Pu/

R BW

Br

B

B

G

O OB

Y

B/GP

B

L/BL/R

R/W

Pu/W

W/LW/L

B/O

B/O

G/W

B

R

Y

R/Y

R/Y

B/OW/B

Pu/WG/W

B/Y

WIRING DIAGRAMFX/FX Cruiser

1 Fuse (20 A)2 Fuse (3 A)3 Starter relay4 Noise filter5 Cam position sensor6 Oil pressure switch7 Thermoswitch (exhaust)8 Intake air pressure9 Intake air temperature0 Bypass valve motorA Fuel injectorB Throttle position sensorC Pickup coilD Lighting coilE Engine stop switchF Engine shut-off switchG Start switchH Multifunction meterI BuzzerJ Left operation buttonK Steering sensorL Fuel level sensorM Fuel pumpN Thermoswitch (engine)O Starter motorP Engine temperature sensorQ Ignition coilR Spark plugS Rectifier/regulatorT BatteryU Electric bilge pumpV Speed sensorW ECMX Slant detection switchY Main and fuel pump relay

È To tachometer

Color codeB : BlackBr : BrownG : GreenL : BlueO : OrangeP : PinkR : RedW : WhiteY : YellowB/G : Black/greenB/L : Black/blueB/O : Black/orangeB/R : Black/redB/W : Black/whiteB/Y : Black/yellowG/B : Green/blackG/O : Green/orangeG/R : Green/redG/W : Green/whiteG/Y : Green/yellowL/B : Blue/blackL/R : Blue/redP/G : Pink/greenP/W : Pink/whitePu/B : Purple/blackPu/G : Purple/greenPu/R : Purple/redPu/W : Purple/whitePu/Y : Purple/yellowR/Y : Red/yellowR/W : Red/whiteW/B : White/blackW/L : White/blueW/R : White/red

FX High Output/FX Cruiser High Output

213

321

321

123456

123

123

10987654321

654321

87654321

1234567891011121314151617181920212223242526272829303132333435363738394041424344

10987654321

21

3 2 1

2 3 4 16 5 6 7 15 1 8 12 11 10 9 13 14

1 21

12

12

321

231

1 2 3 4 5 6 3 2 1 4

1 3 4 6 2 5 2 12 12 12 1

123

123

21

21

21

21

6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 110 9 8 7 6 5 4 3 2 1 2 1

1 2 13 14 12 18 15 11 3 4 7 616 9 10 1 2

B W

FREE

PUSH

Br Br

FREE

PUSH

W BrB R

FREE

PUSH

321

321

321

123456

123

12

12

12

2 1 2 18 4 2 6 9 5 3 1

1

3412

3 2 1

BR/WY/W

BR/WY/W

BB

B

B/G

G

BR

LW

G

BR

LW

P

L/BL/RL/Y

L/BL/RL/Y

Y

R/YB/Y

Y R/Y

R/YR/Y

B/OW/BW/B

B/Y

Pu/WPu/WG/WG/W

Pu/WG/W

Pu/WG/W

WR

B B

B

R/Y

R R

R

L/R

L/B

B/O

B/RR/Y

R/YB/W

R/YB/Y

R/YB/L

B/WB/YB/L

Pu/RPu/BPu/YPu/G

B/Y

P/GB/O

R/Y

W/LL/B

B/RL/R

G/RG/YG/BW/B

W/BW/R

B/O

B/YP/W

G/O

L/BB/O

R/YR/YR/Y

R/YR/YR/YR/YR/Y

R/Y

B/OW/BW/R

B/YB/O

B/YB/Y

B/O B

RWB

GGG

GGG

PP

R/Y

R/Y

R

RB

R

BGGG

B

P

BB

R

R

BGR

GB

R

Y

GB

O

L

O

PW

G

B

Y

L

RRR

PPPOOO

B

Br

RRR

R

Br

BrR R

Br

Br

B/O

B/O

B/O

B/O

B/O

B/O

R/Y

B/O

B/O

B/O

B/O

B/O

B/O

B/O

B/O BBBBBBBB B

Br

BrB

B

B

BB

P

B

B

B/G B/L

L/Y

L/BP WGyBBYYLBBrRLB

B PLB

R

BrR

BrRB

WW

B/O

PB/Y

B/Y

GG

O R/Y

R/Y

R/Y

G/R

G/Y

G/B

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

B/O

B/Y

P/G

O G/B

G/Y

G/R

Pu/

GR

/YB

/OP

u/Y

Pu/

BP

u/R

B/Y

P/G

P G/B

BPP

GO

B/O

P/W

P/W

G/Y

G/R

Pu/

GR

/YB

/OP

u/Y

Pu/

BP

u/R

B/Y

P/G

ORGB

B/O B

/OG

/O

WB

BR

GG

G

B/OPO

Pu/

G

Pu/

Y

Pu/

B

Pu/

R

BW

Br

G

BGy

BGy

BR

B/LL/R

O OB

Y

B/GP

L/BL/RL/Y

L/BL/RGy

R/W

W/LW/L

B/O

B/O

Y

R/Y

R/Y

B/OW/B

B/Y B/Y

RBR/Y

R/Y R R

RBR/Y

R/Y

BB

B/O

W

WIRING DIAGRAMFX High Output/FX Cruiser High Output

1 Fuse (20 A)2 Fuse (3 A)3 Starter relay4 Noise filter5 Cam position sensor6 Oil pressure switch7 Thermoswitch (exhaust)8 Sensor assembly

(intake air pressure, intake air temperature)9 Bypass valve motor0 Fuel injectorA Throttle position sensorB Pickup coilC Lighting coilD Remote control unitE AntennaF Engine stop switchG Engine shut-off switchH Start switchI Left operation buttonJ Multifunction meterK Right operation button

(FX Cruiser High Output)L Steering sensorM Compass sensor and air temperature sensor

(FX Cruiser High Output)N Speed sensor (FX High Output)

Speed sensor and water temperature sensor (FX Cruiser High Output)

O BuzzerP Fuel level sensorQ Fuel pumpR Thermoswitch (engine)S Starter motorT Engine temperature sensorU Ignition coilV Spark plugW Rectifier/regulatorX BatteryY Electric bilge pumpZ ECM[ Slant detection switch\ Main and fuel pump relay

È To tachometerÉ To entry boxÊ FX Cruiser High Output model

Color codeB : BlackBr : BrownG : GreenGy : GrayL : BlueO : OrangeP : PinkR : RedW : WhiteY : YellowB/G : Black/greenB/L : Black/blueB/O : Black/orangeB/R : Black/redB/W : Black/whiteB/Y : Black/yellowG/B : Green/blackG/O : Green/orangeG/R : Green/redG/W : Green/whiteG/Y : Green/yellowL/B : Blue/blackL/R : Blue/redL/Y : Blue/yellowP/G : Pink/greenP/W : Pink/whitePu/B : Purple/blackPu/G : Purple/greenPu/R : Purple/redPu/W : Purple/whitePu/Y : Purple/yellowR/Y : Red/yellowR/W : Red/whiteW/B : White/blackW/L : White/blueW/R : White/redY/W : Yellow/white

YAMAHA MOTOR CORPORATION, USA

Printed in USADec. 2005 – 0.0 × 1 CR(E)

Yamaha FX HO Service Manual

Documents

Transcript of Yamaha FX HO Service Manual