Service manual

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SERVICE MANUAL

GP1300R

WaveRunner

F1G-28197-1F-11LIT-18616-02-44

*LIT186160244*

Summary of content (279 pages)

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WaveRunner GP1300R SERVICE MANUAL *LIT186160244* LIT-18616-02-44 F1G-28197-1F-11
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E NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
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E HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.
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E IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, passenger(s), a bystander, or a person inspecting or repairing the watercraft. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the watercraft.
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E HOW TO USE THIS MANUAL 1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 2 Numbers are given in the order of the jobs in the exploded diagram. 3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”). 4 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.
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E 1 A50001-1-4 2 GEN INFO SYMBOLS Symbols 1 to 9 are designed to indicate the content of a chapter. SPEC 3 1 2 3 4 5 6 7 8 9 4 INSP ADJ FUEL 5 6 JET PUMP POWR 7 General Information Specifications Periodic Inspection and Adjustment Fuel System Power Unit Jet Pump Unit Electrical System Hull and Hood Trouble Analysis 8 – ELEC 9 + HULL HOOD Symbols 0 to E indicate specific data.
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E A30000-0 INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT FUEL SYSTEM POWER UNIT JET PUMP UNIT GEN INFO SPEC INSP ADJ FUEL POWR JET PUMP – ELECTRICAL SYSTEM HULL AND HOOD TROUBLE ANALYSIS + ELEC HULL HOOD TRBL ANLS 1 2 3 4 5 6 7 8 9
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GEN INFO E CHAPTER 1 GENERAL INFORMATION IDENTIFICATION NUMBERS ......................................................................... 1-1 PRIMARY l.D. NUMBER ...........................................................................1-1 ENGINE SERIAL NUMBER ...................................................................... 1-1 JET PUMP UNIT SERIAL NUMBER .........................................................1-1 HULL IDENTIFICATION NUMBER (H.l.N.)...............................................
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GEN INFO IDENTIFICATION NUMBERS E A60700-0* IDENTIFICATION NUMBERS 1 PRIMARY l.D. NUMBER The primary l.D. number is stamped on a label 1 attached inside the engine compartment. Starting primary l.D. number: F1G: 800301 ENGINE SERIAL NUMBER The engine serial number is stamped on a label 1 attached to the engine unit. Starting serial number: 60T: 1000001 JET PUMP UNIT SERIAL NUMBER The jet pump unit serial number is stamped on a label attached to the intermediate housing.
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GEN INFO SAFETY WHILE WORKING E SAFETY WHILE WORKING To prevent and accident or injury and to ensure quality service, follow the safety procedures provided below. FIRE PREVENTION Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. VENTILATION Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If inhaled in large quantities they may cause loss of consciousness and death within a short time.
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GEN INFO SAFETY WHILE WORKING E Under normal conditions, the lubricants mentioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants. 1. Maintain good standards of personal and industrial hygiene. 2. Change and wash clothing as soon as possible if soiled with lubricants. 3. Avoid contact with skin. Do not, for example, place a soiled rag in your pocket. 4.
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GEN INFO SAFETY WHILE WORKING E 3. Non-reusable parts Always use new gaskets, seals, O-rings, oil seals, cotter pins, circlips, etc., when installing or assembling parts. DISASSEMBLY AND ASSEMBLY 1. 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 identification mark in the direction indication in the installation procedure.
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GEN INFO SPECIAL SERVICE TOOLS E SPECIAL SERVICE TOOLS Using the special service tools recommended by Yamaha will aid service and enable accurate assembly and tune-up. Improvisations and using improper tools can damage the equipment. 1 YU-34899-A 2 NOTE: • For USA and Canada, use the special service tools starting with part numbers “J-,” “YB-,” “YM-,” “YS-,” “YU-,” or “YW-.” • For all other countries, use the special service tools starting with part number “90890-.
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GEN INFO SPECIAL SERVICE TOOLS 9 YU-39991 0 90890-03172 A YM-34487 B 90890-06754 C YB-06870 D YB-06869 E YB-06848 F YB-06849 90890-06870 90890-06848 9 Peak volt meter adapter YU-39991 0 Peak voltage adapter B 90890-03172 A Spark gap tester YM-34487 B Ignition tester 90890-06754 C Lighting coil tester (3 pins) YB-06870 Test harness SMT250-3 (3 pins) 90890-06870 D Air pressure sensor tester (3 pins) YB-06869 Test harness EJ-II-3 (3 pins) 90890-06869 E Test harness (6 pins) YB-06848 Test harness FS
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GEN INFO SPECIAL SERVICE TOOLS E REMOVAL AND INSTALLATION 1 YW-06551 2 1 Coupler wrench YW-06551 90890-06551 2 Flywheel holder YW-06550 90890-06550 3 Universal puller YB-06117 4 Flywheel puller 90890-06521 5 Drive shaft holder (impeller) YB-06151 Drive shaft holder 5 (impeller) 90890-06519 6 Slide hammer and adapters (jet pump bearing) YB-06096 7 Stopper guide plate (jet pump bearing) 90890-06501 8 Bearing puller assembly (jet pump bearing) 90890-06535 9 Stopper guide stand (jet pump bearing) 90890-065
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GEN INFO SPECIAL SERVICE TOOLS C YB-06085 D 90890-06634 E YB-06071 F 90890-06606 G YB-34474 H E C Outer race installer—forward gear (jet pump oil seal) YB-06085 D Ball bearing attachment (jet pump oil seal) 90890-06634 E Driver handle—large (intermediate shaft and jet pump) YB-06071 F Driver rod LS (intermediate shaft and jet pump) 90890-06606 G Drive shaft needle bearing depth stop (jet pump bearing) YB-34474 H Shaft holder (intermediate shaft) YB-06552 Crankshaft holder 20 (intermediate shaft)
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SPEC E CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ....................................................................... 2-1 MAINTENANCE SPECIFICATIONS ............................................................... 2-3 ENGINE .................................................................................................... 2-3 JET PUMP UNIT ......................................................................................2-4 HULL AND HOOD ......................................................
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SPEC GENERAL SPECIFICATIONS E GENERAL SPECIFICATIONS Item Model code Hull Engine/jet Dimensions Length Width Height Dry weight Maximum capacity Performance Maximum output Maximum fuel consumption Cruising range Engine Engine type Number of cylinders Displacement Bore × stroke Compression ratio #1, #2 #3 Intake system Scavenging system Exhaust system Lubrication system Cooling system Starting system Ignition system Spark plug model (manufacturer) Spark plug gap Battery Voltage, capacity Generator output
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SPEC GENERAL SPECIFICATIONS Item Drive unit Propulsion system Jet pump type Impeller rotation Transmission Jet thrust nozzle horizontal angle Jet thrust nozzle trim angle Trim system Reverse system Fuel and oil Fuel Minimum fuel rating Oil Fuel-oil ratio (wide open throttle) Fuel tank capacity Oil tank quantity *1 *2 *3 E Model GP1300R Unit Jet pump Axial flow, single stage Counterclockwise (viewed from rear) Direct drive from engine 23 + 23 Degree Degree –5, 0, 5, 10, 15 Manual 5 positions NA Regula
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SPEC MAINTENANCE SPECIFICATIONS E MAINTENANCE SPECIFICATIONS ENGINE Item Cylinder head Warpage limit Minimum compression pressure*1 Cylinders Bore size Taper limit Out-of-round limit Wear limit Pistons Piston diameter Measuring point* Piston-to-cylinder clearance Wear limit Piston pin boss inside diameter Piston rings Top Type Dimension (B) Dimension (T) End gap Ring groove clearance 2nd Type Dimension (B) Dimension (T) End gap Ring groove clearance Piston pins Outside diameter Wear limit Connecting rod
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SPEC MAINTENANCE SPECIFICATIONS Item Crankshaft assembly Crank width A Deflection limit B Deflection limit C Big end side clearance D Maximum small end axial play E Throttle body Model/quantity Manufacturer ID mark Trolling speed Reed valves Thickness Reed valve stopper height Reed valve warpage limit Fuel pump Pump type Output pressure Coupling clearance Vertical Horizontal E Unit Model GP1300R mm (in) mm (in) mm (in) mm (in) mm (in) 72.95–73.00 (2.872–2.874) 0.05 (0.002) 0.15 (0.006) 0.250–0.
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SPEC MAINTENANCE SPECIFICATIONS E HULL AND HOOD Item Free play YPVS cable slack Throttle lever free play Unit Model GP1300R mm (in) mm (in) 0.5–1.5 (0.02–0.06) 4–7 (0.16–0.
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SPEC MAINTENANCE SPECIFICATIONS Item Ignition coil Minimum spark gap Primary coil resistance (B/W – body) Secondary coil resistance (B/W – spark plug lead terminal) Spark plug lead resistance #1 #2 #3 Rectifier/regulator (R – B) Output peak voltage (unloaded) at 3,500 r/min Starter motor Type Output Rating Brush length Wear limit Commutator undercut Limit Commutator diameter Limit Starter relay Rating Engine temperature sensor Engine temperature sensor resistance (B/Y – B/Y) at 20 °C (68 °F) at 100 °C (21
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SPEC MAINTENANCE SPECIFICATIONS Item Exhaust temperature sensor resistance at 300 °C (572 °F) at 600 °C (1,112 °F) at 900 °C (1,652 °F) Cooling water temperature sensor resistance at 0 °C (32 °F) at 100 °C (212 °F) at 200 °C (392 °F) Speed sensor Output voltage (on pulse) Output pulse/one full turn Throttle position sensor Output voltage (P – B/O) at trolling speed Fuel sender Fuel sender resistance Position A Position B Fuel injector Fuel injector resistance*1 Oil level sensor Oil level sensor resistance
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SPEC TIGHTENING TORQUES E TIGHTENING TORQUES SPECIFIED TORQUES 2 Bolt M8 2 — — 1 11 1.1 8.0 — — 1 7.5 0.75 5.4 Tapping screw ø6 13 1.8 0.18 1.3 Screw M5 6 0.8 0.08 0.6 Bolt M6 3 Bolt M5 1 8.8 2.2 4.4 0.88 0.22 0.44 6.4 1.6 3.2 — — 1 11 1.1 8.0 Bolt M6 1 7.6 0.76 5.5 Bolt M6 2 — — 1 3.8 7.6 3.4 0.38 0.76 0.34 2.7 5.5 2.5 — Bolt — — — Nut Bolt Bolt — M6 — — — M10 M10 M10 3 3 2 2 2 2 4 2 25 12 2.5 1.5 2.5 39 39 39 2.5 1.2 0.25 0.15 0.25 3.9 3.
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TIGHTENING TORQUES 4 39 3.9 28 Bolt M10 2 39 3.9 28 Bolt M10 6 39 3.9 28 Bolt M6 1 7.9 0.79 5.7 Bolt M8 4 Bolt M10 10 Nut M10 2 17 22 39 22 39 1.7 2.2 3.9 2.2 3.9 12 16 28 16 28 Bolt M6 6 12 1.2 8.7 3.8 0.38 2.7 Bolt M6 4 7.6 0.76 5.5 3.8 0.38 2.7 7.6 0.76 5.5 3.8 0.38 2.7 7.6 0.76 5.5 4 LT 271 271 LT LT 572 572 LT LT 271 24 1.0 0.1 0.7 Bolt M6 2 9.8 0.98 7.1 LT 572 Bolt Bolt — M6 M4 M5 10 3 3 9.8 2.8 3.8 0.98 0.28 0.38 7.
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TIGHTENING TORQUES M10 1 Bolt M10 Bolt Bolt Bolt Drive coupling LT Bolt 4 39 3.9 28 M6 M5 M6 2 6 3 14 4.9 14 1.4 0.49 1.4 10 3.5 10 — 1 36 3.6 25 Bolt M10 1 74 7.4 53 Bolt M8 1 Bolt M8 1 Bolt M8 6 M8 17 M6 10 9.0 18 9.0 18 15 27 15 27 11 0.9 1.8 0.9 1.8 1.5 2.7 1.5 2.7 1.1 6.5 13 6.5 13 11 19 11 19 8.0 Nut — 1 6.8 0.68 4.9 Bolt Bolt Bolt Screw M8 M8 M6 M5 M10 M6 M8 4 4 4 4 4 1 2 17 17 7.4 3.7 40 7.8 15 1.7 1.7 0.74 0.37 4.0 0.78 1.5 12 12 5.4 2.7 29 5.
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TIGHTENING TORQUES 6.6 0.66 4.8 Nut — 1 74 7.4 53 Impeller M22 1 75 7.5 54 Nut Bolt Driven coupling — M8 4 3 26 17 2.6 1.7 19 12 M24 1 36 3.6 25 Nipple — 1 5.4 0.54 3.9 Screw M6 4 1.1 0.11 0.8 Screw M6 4 2.9 0.29 2.1 Bolt M8 4 16 1.6 11 Nut — M6 — 2 2 5.4 16 0.54 1.6 3.9 11 Screw M5 2 3.4 0.34 2.5 Screw M5 2 3.4 0.34 2.5 Screw Bolt Screw M6 M5 M4 1 2 1 3.4 1.2 1.0 0.34 0.12 0.1 2.5 0.9 0.7 Nut M8 2 16 1.
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TIGHTENING TORQUES Multifunction meter – holder Steering console cover – side cover Steering console cover – glove compartment Steering cable bracket – deck Buzzer bracket/deck – steering cable bracket Hood lock assembly – deck Seat lock assembly – seat Bracket/deck – projection Bracket/deck – handgrip Handgrip – deck Seat bracket – deck Battery box/stay – holder Battery box – deck/bracket Battery box – electrical box Battery box/stay – electrical box Extension bolt – negative battery terminal Exhaust outl
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SPEC TIGHTENING TORQUES Part to be tightened Part name E Thread Q’ty size Tightening torques N•m kgf•m ft•lb Electrical Cover – electrical box Lead retainer – electrical box Positive battery lead – starter relay Starter motor lead – starter relay Rectifier/regulator – electrical box Coupler bracket – electrical box Wire harness retainer – electrical box Ignition coil #1, # 2, #3 – electrical box Fuse holder stay – electrical box Main and fuel pump relay – electrical box Ground leads – electrical box
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SPEC TIGHTENING TORQUES Nut A Bolt B 8 mm 10 mm 12 mm 14 mm 17 mm M5 M6 M8 M10 M12 E GENERAL TORQUE General torque specifications N•m kgf•m ft•lb 5.0 0.5 3.6 8.0 0.8 5.8 18 1.8 13 36 3.6 25 43 4.3 31 This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this manual.
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SPEC CABLE AND HOSE ROUTING E CABLE AND HOSE ROUTING L È A E M K 7 H M É D D K B E L M-M Ê 20˚ Í Î C J L 3 I E 4 I I A 1 H G 7 H H G D-D F F 0 J-J 7 H F E-E 9 G 8 I-I 5 6 A B 7 H-H 1 2 3 4 5 6 7 8 9 C J K-K C 1 Ë J I B K F D 1 Ì Ì 2 2 VENT 5 A 1 CB Fuel tank breather hose Cooling water pilot outlet YPVS servomotor Throttle cable QSTS cable Steering cable Speed sensor lead Positive battery lead Cooling water temperature sensor lead 0 Exhaust tempera
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SPEC CABLE AND HOSE ROUTING E L È A E M K 7 H M É D D K Ê 20˚ Í Î C J L 3 I C E 4 I I J A K-K 1 H G 7 H H G D-D F F 0 J-J 7 H C Ë J I B K F D 1 Ì Ì 2 B E L M-M 2 VENT 5 A 1 CB F E-E 9 G 8 I-I 5 6 A B 7 H-H È Align the parting line on the fuel filler neck with the lot mark on the fuel filler hose.
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SPEC CABLE AND HOSE ROUTING E 8 C D E N M 8 F G O H C B-B L I J A K 1 2 A 34 5 6 7 B E 8 9 D C B B 0 ÈÉÊ A 5 P B 7 A ÌË F F-F F 7 P Î Í D E 1 2 3 4 5 6 7 8 9 0 Buzzer lead Throttle cable YPVS servomotor YPVS cables Positive battery lead Battery breather hose Electrical bilge pump lead Steering cable QSTS cable Speed sensor lead A B C D E F G H I J Negative battery lead Starter motor lead Speed sensor coupler Oil level sensor coupler Buzzer coupler Engine stop switch cou
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SPEC CABLE AND HOSE ROUTING E 8 C D E N M 8 F G O H C B-B L I J A K 1 2 A 34 5 6 7 B E 8 9 D C B B 0 ÈÉÊ A 5 P B 7 A ÌË F F-F F 7 P Î Í D E È É Ê Ë Ì Í Î To cylinder #3 To cylinder #2 To cylinder #1 Cooling water temperature sensor Exhaust temperature sensor To positive battery terminal To starter motor 2-18
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SPEC CABLE AND HOSE ROUTING 1 B 2 E 3 4 4 5 0 A 6 9 A 6 6 4 8 B È 7 8 5 1 7 8 3 A 2 9 0 6 2 8 9 C C C-C 0 3 1 2 3 4 5 6 7 8 9 0 1 7 5 A Electrical bilge pump lead Bilge hose 1 Bilge hose 2 Steering cable Bilge hose 3 QSTS cable Bilge hose 4 Cooling water hose (cooling water inlet) Flushing hose Speed sensor lead Cooling water hose (cooling water outlet) È Contact the corrugated tube (bilge hose 1) to the hose screw clamp.
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SPEC CABLE AND HOSE ROUTING 1 C È E Ê 2 C 3 4 C-C B É Ë B A A Ò Ó Ì Ñ D Ð 3 4 D Ï 1 2 3 4 Í Î 1 Ê Fasten the sub-wire harness with the plastic tie on the rib of the fuel rail. Be sure to position the plastic tie so that the fastener is visible from the outside. Ë Pass the oil bleed hose on the inside of the oil pump cable. Ì To ECM Í Pass the oil return hose on the outside of the oil pump cable.
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SPEC CABLE AND HOSE ROUTING 1 C È E Ê 2 C 3 4 C-C B É Ë B A A Ò Ó Ì Ñ D Ð 3 Í 4 D Ï Î 1 Ó Pass the bleed hose under the exhaust chamber bracket. Be sure to install the L-shaped bleed hose toward the oil pump. Î Push the corrugated tube toward the oil pump, and then tape it. Ï To oil tank Ð To check valve Ñ Install the oil hoses into the hose holders so that the holders do not cover the check valve clips. Ò Pass the intake air temperature sensor lead over the fuel hose.
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SPEC CABLE AND HOSE ROUTING E Ð Ê B Ë É A È B 2 Ì 3 1 Ñ A Ï Í ÎÏ Î Ò Ö Õ Ó Ô C D Ï Û Ú × Ù Ü15˚ Ø 15˚ Ï 20˚ D C 1 Cooling water hose (cooling water pilot outlet on port side) 2 Fuel hose 3 Oil return hose Ë To cooling water pilot outlet on starboard side Ì To electrical box Í Install the exhaust joint so that it contacts the stoppers on the muffler assembly. Î Face the red mark end of the cooling hose toward the cylinder head cover, and then install the hose.
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SPEC CABLE AND HOSE ROUTING E Ð Ê B Ë É A È B 2 Ì 3 1 Ñ A Ï Í ÎÏ Î Ò Ö Õ Ó Ô C D Ï Û Ú × Ù Ü15˚ Ø 15˚ Ï 20˚ D C Ø Install the white tape end of the negative battery lead to the battery. Ù Fasten the sub-wire harness and wire harness (generator). Ú Fasten the wire harness (generator). Û Route the sub-wire harness under the cooling water hose. Ü Install the oil pump cable to the angle shown in the illustration.
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INSP ADJ E CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART .............................................................. 3-1 PERIODIC SERVICE .......................................................................................3-2 CONTROL SYSTEM ................................................................................. 3-2 Steering column inspection .................................................................3-2 Steering cable inspection and adjustment ..............
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INSP ADJ MAINTENANCE INTERVAL CHART E MAINTENANCE INTERVAL CHART Use the following chart as a guide to general maintenance. Adjust the maintenance intervals according to the operating conditions of the watercraft.
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INSP ADJ CONTROL SYSTEM E PERIODIC SERVICE CONTROL SYSTEM Steering column inspection 1. Check: • Steering column Excessive play → Replace the steering column. Refer to “STEERING COLUMN” in Chapter 8. Checking steps: • Move the handlebar up and down and back and forth. • Check the excessive play of the handlebar. Steering cable inspection and adjustment 1. Measure: • Jet thrust nozzle distances a and b Difference → Adjust. Difference of distances a and b: Maximum 5 mm (0.
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INSP ADJ CONTROL SYSTEM E WARNING The cable joint must be screwed in a minimum of 8 mm (0.31 in). • Connect the cable joint, and then tighten the locknut. T. R. Locknut: 6.8 N • m (0.68 kgf • m, 4.9 ft • lb) NOTE: If the steering cable cannot be properly adjusted by the cable joint at the steering column end, adjust the cable joint at the jet pump end so that the specified distance is obtained. Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD” in Chapter 8.
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INSP ADJ CONTROL SYSTEM E QSTS cable inspection and adjustment 1. Measure: • Jet thrust nozzle set lengths a and b Out of specification → Adjust. Measurement steps: • Set the control grip to the neutral position. • Set the jet thrust nozzle in the center position. • Measure jet thrust nozzle set lengths a and b. • If lengths a and b are not even, adjust the cable joint. 2. Adjust: • QSTS cable Adjustment steps: • Set the control grip to the neutral position. • Loosen the locknut 1.
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INSP ADJ CONTROL SYSTEM E NOTE: If the QSTS cable cannot be properly adjusted by the cable joint at the QSTS converter end, adjust the cable joint at the jet pump end so that the same lengths are obtained. Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD” in Chapter 8. Trolling speed check NOTE: The trolling speed of this model is adjusted automatically by the ECM according to the operating conditions of the watercraft. Therefore, it is not necessary to adjust the trolling speed. 1.
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INSP ADJ CONTROL SYSTEM E • Check the exhaust passages. Refer to “MUFFLER ASSEMBLY” in Chapter 5. Refer to “EXHAUST CHAMBER ASSEMBLY” in Chapter 5. Refer to “EXHAUST MANIFOLD” in Chapter 5. Refer to “EXHAUST SYSTEM” in Chapter 8. • Measure the fuel pressure. Refer to “Fuel pressure measurement” in Chapter 4. • Check the fuel for deterioration, the fuel tank for water accumulation, the fuel lines for clogs or kinks, and the fuel injectors for clogs. Refer to “FUEL SYSTEM.
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INSP ADJ FUEL SYSTEM E FUEL SYSTEM WARNING When removing fuel system parts, wrap them in a cloth and take care that no fuel spills into the engine compartment. Fuel line inspection 1. Check: • Fuel pump filter Clog/contaminants → Clean. Refer to “FUEL TANK AND FUEL PUMP MODULE” in Chapter 4. • Fuel hoses Cracks/damage → Replace. • O-rings (quick connector) Cracks/damage → Replace the quick connector. • Fuel pipe Cracks/damage → Replace the fuel pump. Refer to “FUEL INJECTION SYSTEM” in Chapter 4.
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INSP ADJ OIL INJECTION SYSTEM E OIL INJECTION SYSTEM Oil line inspection 1. Check: • Oil filter Contaminants → Clean. Frays/tears → Replace. • Rubber seal Cracks/wear → Replace. • Oil hoses • Oil tank • Oil filler cap Cracks/damage → Replace. • Check valve Malfunction → Replace. CAUTION: Do not allow the oil tank to become completely empty. If the oil tank becomes empty the oil injection pump must be bled to ensure proper oil flow, otherwise engine damage may occur. Refer to “OIL PUMP” in Chapter 4.
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INSP ADJ POWER UNIT E POWER UNIT Spark plug inspection 1. Check: • Electrodes 1 Damage/wear → Replace. • Insulator color 2 Distinctly different color → Check the condition of the engine. Color guide: Medium-to-light tan color: Normal Whitish color: Lean air-fuel mixture Air leakage Incorrect settings Blackish color: Overly rich air-fuel mixture Electrical malfunction Excessive oil use Defective spark plug 2. Clean: • Spark plug (using a spark plug cleaner or wire brush) 3.
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INSP ADJ POWER UNIT E 4. Tighten: • Spark plugs T. R. Spark plug: 25 N • m (2.5 kgf • m, 18 ft • lb) NOTE: • Before installing a spark plug, clean the gasket surface and spark plug surface. Also, it is suggested to apply a thin coat of anti-seize compound to the spark plug threads to prevent thread seizure.
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INSP ADJ POWER UNIT E 2. Measure: • YPVS cable slack a Out of specification → Adjust. YPVS cable slack: 0.5–1.5 mm (0.02–0.06 in) 3. Adjust: • YPVS cables 1 and 2 4 1 3 2 Adjustment steps: • Loosen locknuts 1 and 2. • Turn adjusters 3 and 4 in until there is slack in the cables. • Align the hole a in the pulley with the hole in the cylinder. • Insert a 4 mm (0.16 in) diameter pin through the pulley and cylinder holes. • Turn adjusters 3 and 4 in or out until the specified slack is obtained.
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INSP ADJ ELECTRICAL E ELECTRICAL Battery inspection WARNING • Battery electrolyte is poisonous and dangerous, causing severe burns, etc. Electrolyte contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidotes External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases.
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INSP ADJ ELECTRICAL E 1. Remove: • Battery bands • Negative battery lead 1 • Positive battery lead 2 • Battery • Battery breather hose 3 WARNING • When removing the battery, disconnect the negative lead first. • Remove the battery to prevent acid loss before turning the watercraft on its side to service the impeller, etc. 2. Check: • Electrolyte level Low → Add distilled water. The electrolyte level should be between the maximum a and minimum b level marks. Filling steps: • Remove the filler caps.
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INSP ADJ ELECTRICAL E 3. Check: • Specific gravity Out of specification → Charge. Specific gravity at 20 °C (68 °F): 1.28 Charging current: 1.9 A × 10 h (68.4 kC) 4. Install: • Filler caps CAUTION: Before installing the battery, rinse off any electrolyte from the battery box or battery and make sure that the battery is dry. 5.
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INSP ADJ JET PUMP UNIT E JET PUMP UNIT a Impeller inspection 1. Check: • Impeller 1 Damage/wear → Replace. Nicks/scratches → File or grind. 1 2. Measure: • Impeller-to-housing clearance a Out of specification → Replace. Maximum impeller-to-housing clearance: 0.9 mm (0.035 in) Measurement steps: • Disconnect the battery leads. • Remove the intake grate and intake duct. Refer to “JET PUMP UNIT” in Chapter 6. • Measure the clearance at each impeller blade as shown (a total of four measurements).
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INSP ADJ BILGE PUMP E BILGE PUMP Bilge strainer inspection 1. Check: • Bilge strainer Contaminants → Clean. Cracks/damage → Replace. 1 Checking steps: • Remove the bilge strainer case 1 from the bilge strainer. • Check the bilge strainer and bilge strainer case. • Install the bilge strainer case. Electric bilge pump strainer inspection 1. Check: • Cap • Strainer Contaminants → Clean. 1 Checking steps: • Remove the battery box. Refer to “BATTERY BOX” in Chapter 8. • Remove the band 1.
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INSP ADJ GENERAL E GENERAL Drain plug inspection 1. Check: • Drain plugs Cracks/damage → Replace. • O-rings Cracks/wear → Replace. • Screw threads Contaminants → Clean. Lubrication points 1. Lubricate: • Throttle cable (handlebar end) Recommended lubricant: Rust inhibitor NOTE: Before lubricating the throttle cable, squeeze the throttle lever and remove the rubber seal 1. 2.
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INSP ADJ GENERAL E 3. Lubricate: • QSTS cables (pulley end) • YPVS cables Recommended grease: Yamaha marine grease, Yamaha grease A (water-resistant grease) 4. Lubricate: • Nozzle pivot shaft • Steering cable (jet thrust nozzle end) • QSTS cable (jet thrust nozzle end) Recommended grease: Yamaha marine grease, Yamaha grease A (water-resistant grease) 5. Lubricate: • Steering cable • Steering cable joint NOTE: Disconnect the steering cable joint, and then apply a small amount of grease to it.
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INSP ADJ GENERAL E 6. Fill: • Intermediate housing Recommended grease: Yamaha marine grease, Yamaha grease A (water-resistant grease) Grease quantity: 33.0–35.0 cm3 (1.11–1.18 oz) NOTE: Using a grease gun, fill the intermediate housing with the recommended grease through the grease nipples.
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FUEL E CHAPTER 4 FUEL SYSTEM OIL TANK ........................................................................................................ 4-1 EXPLODED DIAGRAM .............................................................................4-1 REMOVAL AND INSTALLATION CHART ................................................ 4-1 SERVICE POINTS .................................................................................... 4-3 Oil line inspection .........................................................
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FUEL OIL PUMP...................................................................................................... 4-24 EXPLODED DIAGRAM ...........................................................................4-24 REMOVAL AND INSTALLATION CHART .............................................. 4-24 SERVICE POINTS .................................................................................. 4-27 Oil pump inspection...........................................................................
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FUEL OIL TANK E OIL TANK EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name OIL TANK REMOVAL Engine unit Steering console cover assembly Q’ty 1 2 Oil level sensor coupler Plastic tie 1 1 3 4 5 Nut Oil filler neck Rubber seal 1 1 1 4-1 Service points Follow the left “Step” for removal. Refer to “ENGINE UNIT” in Chapter 5. Refer to “STEERING CONSOLE COVER” in Chapter 8. Not reusable Disconnect the oil filler hose from the oil filler neck.
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FUEL OIL TANK E EXPLODED DIAGRAM Step 6 7 8 9 10 11 12 13 Procedure/Part name Breather hose Oil hose Bolt Strap Oil tank Hose screw clamp Oil filler hose Oil level sensor Q’ty 1 1 2 2 1 1 1 1 Service points Reverse the removal steps for installation.
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FUEL OIL TANK E SERVICE POINTS Oil line inspection 1. Check: • Oil filter Contaminants → Clean. Frays/tears → Replace. • Rubber seal Cracks/wear → Replace. • Oil hoses • Oil filler cap Cracks/damage → Replace. • Check valve Faulty → Replace. Oil level sensor inspection Refer to “INDICATION SYSTEM” in Chapter 7. Oil tank inspection 1. Check: • Oil tank Cracks/damage → Replace.
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FUEL FUEL TANK AND FUEL PUMP MODULE E FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM 8 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 1st 4 5 (VENT) 3 6 9 2 7 1 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 10 12 16 17 15 11 13 13 14 5.9 N • m (0.59 kgf • m, 4.3 ft • Ib) 18 1.3 N • m (0.13 kgf • m, 0.9 ft • Ib) 19 20 LT 16 N • m (1.
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FUEL FUEL TANK AND FUEL PUMP MODULE E EXPLODED DIAGRAM 8 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 1st 4 5 (VENT) 3 6 9 2 7 1 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 10 12 16 17 15 11 13 13 14 5.9 N • m (0.59 kgf • m, 4.3 ft • Ib) 18 1.3 N • m (0.13 kgf • m, 0.9 ft • Ib) 19 20 LT 16 N • m (1.
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FUEL FUEL TANK AND FUEL PUMP MODULE E EXPLODED DIAGRAM 8 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 1st 4 5 (VENT) 3 6 9 2 7 1 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 10 12 16 17 15 11 13 13 14 5.9 N • m (0.59 kgf • m, 4.3 ft • Ib) 18 1.3 N • m (0.13 kgf • m, 0.9 ft • Ib) 19 20 LT 16 N • m (1.
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FUEL FUEL TANK AND FUEL PUMP MODULE E SERVICE POINTS Fuel hose disconnection 1. Disconnect: • Fuel hose Refer to “FUEL INJECTION SYSTEM.” 8 7 3 2 Fuel pump module removal 1. Remove: • Nuts • Retainer 5 NOTE: Loosen the nuts in the sequence shown. 1 6 9 4 2. Remove: • Fuel pump module 1 1 NOTE: Remove the float 2 at an angle to avoid catching it on the fuel tank. 2 Fuel sender disassembly 1. Disconnect: • Fuel sender coupler a 2.
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FUEL FUEL TANK AND FUEL PUMP MODULE A B A B E Check valve inspection 1. Check: • Check valve Faulty → Replace. Checking steps: • Connect a hose to end “A” of the check valve, and then blow into the hose. Air should come out from end “B.” • Connect the hose to end “B” of the check valve, and then blow into the hose. Air should not come out from end “A.” 1 Fuel pump filter inspection 1. Check: • Fuel pump filter 1 Clog/contaminants → Wash the fuel pump filter in kerosene or gasoline. 2 3 7 5 T.
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FUEL INTAKE DUCT AND INTAKE SILENCER E INTAKE DUCT AND INTAKE SILENCER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name INTAKE DUCT AND INTAKE SILENCER REMOVAL Exhaust chamber assembly Intake silencer screw clamp Intake silencer Intake silencer pipe screw clamp Intake silencer pipe Plastic tie Q’ty Service points Follow the left “Step” for removal. Refer to “EXHAUST CHAMBER ASSEMBLY” in Chapter 5.
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FUEL INTAKE DUCT AND INTAKE SILENCER E EXPLODED DIAGRAM Step 6 7 Procedure/Part name Bolt/collar/grommet Intake duct Q’ty 1/1/1 1 Service points Reverse the removal steps for installation.
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FUEL INTAKE DUCT AND INTAKE SILENCER E SERVICE POINTS 55˚ Intake silencer installation 1. Install: • Intake silencer pipe • Intake silencer pipe screw clamps 1 • Intake silencer • Intake silencer screw clamp 2 2 1 NOTE: Set the screw clamps in the direction shown.
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FUEL FUEL INJECTION SYSTEM E FUEL INJECTION SYSTEM EXPLODED DIAGRAM 11 N • m (1.1 kgf • m, 8.0 ft • Ib) 1 2 10 8 3 4 7 LT 242 LT 242 8 9 5 8 × 30 mm 1st 9.0 N • m (0.9 kgf • m, 6.5 ft • Ib) 2nd 18 N • m (1.
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FUEL FUEL INJECTION SYSTEM E EXPLODED DIAGRAM 11 N • m (1.1 kgf • m, 8.0 ft • Ib) 1 2 10 8 3 4 7 LT 242 LT 242 8 9 5 8 × 30 mm 1st 9.0 N • m (0.9 kgf • m, 6.5 ft • Ib) 2nd 18 N • m (1.8 kgf • m, 13 ft • Ib) 6 Step 4 Procedure/Part name Plastic tie Q’ty 1 5 6 7 Cover Fuel hose Throttle bodies screw clamp 1 1 3 8 9 10 Bolt Throttle bodies assembly Throttle cable 2 1 1 Service points NOTE: Fasten the sub-wire harness and oil delivery hoses together with the plastic tie.
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FUEL FUEL INJECTION SYSTEM E EXPLODED DIAGRAM 4 2 2 1 3 REMOVAL AND INSTALLATION CHART Step 2 Procedure/Part name INTAKE SILENCER CASE AND THROTTLE BODIES REMOVAL Intake air temperature sensor coupler Intake silencer case screw clamp 3 4 Throttle bodies Intake silencer case 1 Q’ty Service points Follow the left “Step” for removal. 1 3 Tighten the screw clamp until there is no clearance between the spacer and the screw clamp. 1 1 Reverse the removal steps for installation.
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FUEL FUEL INJECTION SYSTEM E EXPLODED DIAGRAM 7 7 0.8 N • m (0.08 kgf • m, 0.6 ft • Ib) 5 × 12 mm 5 8 6 6 4 3 7.5 N • m (0.75 kgf • m, 5.4 ft • Ib) 1 2 LT 6 × 30 mm 1.8 N • m (0.18 kgf • m, 1.
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FUEL FUEL INJECTION SYSTEM E EXPLODED DIAGRAM 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 6 × 60 mm 6 7 6 5 6 9 A 10 9 1 A 10 3 9 2 A 10 8 1 4 REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name THROTTLE BODIES DISASSEMBLY Hose clamp Fuel hose Grommet Quick connector Sub-wire harness Bolt Fuel rail Spacer Q’ty 2 1 1 1 1 3 1 3 4-16 Service points Follow the left “Step” for disassembly.
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FUEL FUEL INJECTION SYSTEM E EXPLODED DIAGRAM 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 6 × 60 mm 6 7 6 5 6 9 A 10 9 1 A 10 3 9 2 A 10 8 1 4 Step 9 10 11 Procedure/Part name Fuel injector O-ring Throttle bodies Q’ty 3 3 1 Service points Not reusable Reverse the disassembly steps for assembly.
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FUEL FUEL INJECTION SYSTEM E SERVICE POINTS Hose clamp removal 1. Remove: • Hose clamps CAUTION: If the hose clamps are removed without cutting the crimp first, the fuel hose can be damaged. Hose clamp installation 1. Install: • Hose clamps WARNING Do not reuse the hose clamps, always replace them with new ones. NOTE: Crimp the hose clamps properly to securely fasten them.
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FUEL FUEL INJECTION SYSTEM CAUTION: 1 2 E • Do not rotate the quick connector tab 1 past the stopper position a, otherwise the tab can be damaged. • When the fuel hoses are disconnected, quickly remove the retainer 2 from the quick connector, otherwise the retainer can be lost. a 2. Disconnect the fuel hose 1 from the fuel pipe 2 directly. 1 WARNING Always reduce the fuel pressure in the fuel line before servicing the line or the fuel pipe.
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FUEL FUEL INJECTION SYSTEM E Fuel injector inspection CAUTION: The throttle bodies should not be disassembled unnecessarily. 1. Check: • Fuel injector Dirt/residue → Clean. Damage → Replace. 2. Measure: • Fuel injector resistance Out of specification → Replace. Digital multimeter: YU-34899-A Digital circuit tester: 90890-03174 Fuel injector resistance (reference data): 13.8 Ω at 21 °C (70 °F) 3. Check the operation of the fuel injector using the “Stationary Test” of the Yamaha Diagnostic System.
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FUEL FUEL INJECTION SYSTEM 2 Fuel hose installation (replacing with new fuel hose) 1. Install: • Quick connector 1 b a E NOTE: To install the fuel hose, be sure to align the lot mark a on the fuel hose and the checker tab 2 on the quick connector with the crimped section b of the clamp. 1 2. Install: • Fuel hose 1 2 NOTE: • Install the checker tab 2 of the fuel hose in the position shown in the illustration in relation to the throttle bodies.
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FUEL FUEL INJECTION SYSTEM E Fuel hose connection 1. Apply a thin coat of engine oil to the contact surfaces of the fuel pipe. 2. Insert the quick connector into the fuel pipe until you hear a “click.” 3. To check the connection of the quick connector, push and pull on the quick connector several times until there is free play of 2–3 mm (0.08–0.12 in). NOTE: If free play cannot be obtained, disconnect the fuel hose and check the O-ring for damage and that it is properly installed.
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FUEL FUEL INJECTION SYSTEM E 3. Start the engine and warm it up for several minutes. 4. Measure: • Fuel pressure Out of specification → Replace the fuel pump module. Fuel pressure: 320.8–327.2 kPa (3.21–3.27 kgf/cm2, 45.62–46.53 psi) 5. Remove: • Fuel pressure gauge • Fuel pressure gauge adapter NOTE: To disconnect the fuel pressure gauge adapter, follow the procedures for disconnecting a fuel hose. (Refer to “Fuel hose disconnection.”) 6. Connect: • Fuel hose Refer to “Fuel hose connection.
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FUEL OIL PUMP E OIL PUMP EXPLODED DIAGRAM 6 5 4 3 3 3 7 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 12 mm 8 13 11 11 N • m (1.1 kgf • m, 8.0 ft • Ib) LT 5 × 10 mm 1st 572 1 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib) 10 2 9 12 6 × 20 mm 1st 3.8 N • m (0.38 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 4.4 N • m (0.44 kgf • m, 3.
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FUEL OIL PUMP E EXPLODED DIAGRAM 6 5 4 3 3 3 7 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 12 mm 8 13 11 11 N • m (1.1 kgf • m, 8.0 ft • Ib) LT 5 × 10 mm 1st 572 1 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib) 10 2 9 12 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib) Step 7 8 9 10 11 12 13 Procedure/Part name Bolt Bleed hose stay Bolt Oil pump assembly Gasket Oil suction hose Oil return hose 6 × 20 mm 1st 3.8 N • m (0.38 kgf • m, 2.
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FUEL OIL PUMP E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 Procedure/Part name OIL PUMP HOSES AND CABLE REMOVAL Bleed hose Air bleed screw Gasket Bleed hose stay Oil delivery hose Oil delivery hose #1 Oil delivery hose #2 Oil delivery hose #3 Check valve Q’ty Service points Follow the left “Step” for removal. 1 1 1 1 3 1 1 1 3 Reverse the removal steps for installation.
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FUEL OIL PUMP E SERVICE POINTS Oil pump inspection 1. Check: • Oil pump Contaminants → Clean. Damage/wear → Replace. • Oil pump joint piece Damage/wear → Replace the oil pump. Oil hose inspection 1. Check: • Oil hoses Cracks/damage → Replace. CAUTION: • If the oil delivery hoses and the oil suction hose are not full of oil, fill them up. • Bleed the oil pump, delivery hoses, and oil suction hose after installing them. Check valve inspection 1. Check: • Check valve Faulty → Replace.
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FUEL OIL PUMP E Oil pump lever position adjustment 1. Check: • Oil pump lever position Incorrect → Adjust. a Checking steps: • Remove the intake duct. Refer to “INTAKE DUCT AND INTAKE SILENCER.” • Squeeze the throttle lever to fully open the throttle valve lever. • Check that the gap of the oil pump lever is 0–0.5 mm (0–0.0197 in) a. • Install the intake duct. Refer to “INTAKE DUCT AND INTAKE SILENCER.” 1 2. Adjust: • Oil pump lever position 2 Adjustment steps: • Remove the intake duct.
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FUEL OIL PUMP E Oil pump bleeding 1. Bleed: • Oil pump 1 Bleeding steps: • Place rags around the air bleed screw 1 to catch any oil that might spill. • Fill the oil tank with the recommended oil. NOTE: If the oil pump is replaced or when the oil suction hose and oil delivery hoses are disconnected from the oil pump, fill the hoses with oil, and then connect them to the oil pump. After connecting the oil suction hose, be sure to it fasten it with a locking tie.
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POWR E CHAPTER 5 POWER UNIT COMPRESSION PRESSURE MEASUREMENT ............................................5-1 SERVICE POINTS .................................................................................... 5-1 MUFFLER ASSEMBLY ................................................................................... 5-3 EXPLODED DIAGRAM .............................................................................5-3 REMOVAL AND INSTALLATION CHART ................................................
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POWR CYLINDER HEAD.......................................................................................... 5-25 EXPLODED DIAGRAM ...........................................................................5-25 REMOVAL AND INSTALLATION CHART ............................................. 5-25 SERVICE POINTS .................................................................................. 5-27 Cylinder head inspection................................................................... 5-27 CYLINDERS .........
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POWR COMPRESSION PRESSURE MEASUREMENT E COMPRESSION PRESSURE MEASUREMENT SERVICE POINTS The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Start the engine and warm it up until the engine temperature is 48 °C (118 °F). 2. Remove: • Seat 3. Disconnect: • Spark plug caps 4.
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POWR COMPRESSION PRESSURE MEASUREMENT E 6. Measure: • Compression pressure Out of specification → Refer to steps (b) and (c). Minimum compression pressure (reference data): 640 kPa (6.4 kgf/cm2, 91 psi) Measurement steps: a. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. WARNING To prevent sparking, ground all spark plug leads before cranking the engine. b.
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POWR MUFFLER ASSEMBLY E MUFFLER ASSEMBLY EXPLODED DIAGRAM 5 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 6 × 22 mm 4 É 7 LT 242 2 3 1 6 È REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name MUFFLER REMOVAL YPVS servomotor and YPVS servomotor bracket Battery box Spark plug cap Exhaust temperature sensor coupler Cooling water temperature sensor coupler Cap/bolt Cover Q’ty 3 1 1 3/3 1 5-3 Service points Follow the left “Step” for removal. Refer to “YPVS SERVOMOTOR” in Chapter 7.
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POWR MUFFLER ASSEMBLY E EXPLODED DIAGRAM 5 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 6 × 22 mm 4 É 7 LT 242 2 1 6 È Step 6 Procedure/Part name Screw clamp/cooling water hose Q’ty 1/1 7 Screw clamp/cooling water hose 1/1 5-4 Service points È To cooling water pilot outlet (port) Route the cooling hose under the exhaust chamber assembly. É To cooling water outlet (stern) Contact the corrugated tube to the hose screw clamp (muffler assembly end).
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POWR MUFFLER ASSEMBLY E EXPLODED DIAGRAM Step 8 9 10 11 12 13 14 15 Procedure/Part name Outer exhaust joint screw clamp Inner exhaust joint screw clamp Exhaust joint screw clamp Water lock band Nut Bolt Intermediate housing grease hose Eye Q’ty 2 2 1 1 2 4 1 2 5-5 Service points Slide the outer exhaust joint off. Slide the water lock off. NOTE: To ease removal of the muffler assembly, remove the spark plugs before removing the eye, remove the muffler, and then reinstall the spark plugs.
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POWR MUFFLER ASSEMBLY E EXPLODED DIAGRAM Step 16 17 18 19 20 21 22 23 Procedure/Part name Bolt Bolt Bolt Bolt Muffler stay 2 Muffler assembly Outer exhaust joint Inner exhaust joint Q’ty 2 1 1 1 1 1 Service points NOTE: Remove the cylinder head if it is difficult to remove the muffler assembly. 1 1 Reverse the removal steps for installation.
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POWR MUFFLER ASSEMBLY E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 10 Procedure/Part name MUFFLER DISASSEMBLY Exhaust temperature sensor Cooling water temperature sensor Bolt Muffler stay Dowel pin Bolt Cover Gasket Catalytic converter housing Gasket Q’ty 1 1 2 1 1 6 1 1 1 1 5-7 Service points Follow the left “Step” for disassembly.
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POWR MUFFLER ASSEMBLY E EXPLODED DIAGRAM Step 11 12 13 14 15 16 17 Procedure/Part name Catalytic converter Gasket Pin Bolt Mixing joint Gasket Muffler Q’ty 1 1 2 6 1 1 1 Service points Not reusable Not reusable Reverse the disassembly steps for assembly.
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POWR MUFFLER ASSEMBLY E SERVICE POINTS Catalytic converter inspection 1. Check: • Catalytic converter Cracks/damage → Replace. Muffler installation 1. Install: • Inner exhaust joint • Outer exhaust joint • Muffler assembly • Inner exhaust joint screw clamp • Outer exhaust joint screw clamp 6˚) (8 45˚ 45˚ b (21˚) NOTE: • Align the projection a on the exhaust joint with the muffler assembly boss. • Use the angles shown in the illustration as reference to Install the exhaust joint screw clamps.
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POWR EXHAUST CHAMBER ASSEMBLY E EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name EXHAUST CHAMBER ASSEMBLY REMOVAL Muffler assembly Screw clamp/cooling water hose Screw clamp/cooling water hose Bolt Bolt Bolt Bolt Exhaust chamber stay Q’ty 1/1 2/2 3 1 2 2 1 5-10 Service points Follow the left “Step” for removal. Refer to “MUFFLER ASSEMBLY.
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POWR EXHAUST CHAMBER ASSEMBLY E EXPLODED DIAGRAM Step 8 9 10 11 Procedure/Part name Screw clamp/cooling water hose Exhaust chamber assembly Gasket Pin Q’ty 1/1 1 1 2 Service points Ê From exhaust manifold NOTE: Before installing the exhaust chamber assembly, connect the cooling water hose and fasten it with the screw clamp to the exhaust chamber (part 8) and place the bolts (part 3) in the bolt holes in the exhaust chamber assembly. Not reusable Reverse the removal steps for installation.
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POWR EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name EXHAUST CHAMBER DISASSEMBLY Bolt Bolt Exhaust chamber joint Gasket Pin Exhaust chamber Q’ty 5 1 1 1 2 1 Service points Follow the left “Step” for disassembly. Not reusable Reverse the disassembly steps for assembly.
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POWR ENGINE UNIT E ENGINE UNIT EXPLODED DIAGRAM 7.9 N • m (0.79 kgf • m, 5.7 ft • Ib) 6 × 25 mm 5 LT 572 17 N • m (1.
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POWR ENGINE UNIT E EXPLODED DIAGRAM 7.9 N • m (0.79 kgf • m, 5.7 ft • Ib) 6 × 25 mm 5 LT 572 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 40 mm 7 6 8 4 a LT 572 3 1 4 2 9 4 4 4 4 Step 3 4 5 6 7 8 9 Procedure/Part name Oil return hose Coupler Bolt/collar Coupling cover Bolt/washer Engine unit Shim Q’ty 1 9 1/1 1 4/4 1 — Service points As required NOTE: Install shims in their original positions. Reverse the removal steps for installation.
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POWR ENGINE UNIT E SERVICE POINTS Shim removal 1. Remove: • Shims NOTE: To ease reassembly and coupling alignment, remove the shims and organize them in their respective groups (e.g., front right, rear left) prior to removing the mounting bolts. Engine mount inspection 1. Check: • Engine mounts Cracks/damage → Replace. Refer to “ENGINE MOUNTS” in Chapter 8. Coupling clearance inspection 1. Measure: • Clearance a • Clearance b (with the rubber damper) Out of specification → Adjust.
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POWR EXHAUST MANIFOLD E EXHAUST MANIFOLD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name EXHAUST MANIFOLD REMOVAL Engine unit Bolt Bolt Nut Exhaust manifold Gasket Pin Q’ty 4 6 2 1 1 2 Service points Follow the left “Step” for removal. Refer to “ENGINE UNIT.” Not reusable Reverse the removal steps for installation.
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POWR EXHAUST MANIFOLD E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name EXHAUST MANIFOLD DISASSEMBLY Screw clamp/cooling water hose Bolt Cooling water joint O-ring Exhaust manifold Q’ty 1/1 6 1 3 1 Service points Follow the left “Step” for disassembly. Not reusable Reverse the disassembly steps for assembly.
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POWR REED VALVES E REED VALVES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name REED VALVE REMOVAL Throttle bodies assembly Oil delivery hoses Grease hose Bolt Throttle bodies bracket 1 Throttle bodies bracket 2 Throttle bodies joint Bolt Q’ty 1 18 1 1 3 4 5-18 Service points Follow the left “Step” for removal. Refer to “FUEL INJECTION SYSTEM” in Chapter 4. Refer to “OIL PUMP” in Chapter 4.
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POWR REED VALVES E EXPLODED DIAGRAM Step 7 8 9 10 11 12 13 Procedure/Part name Balance plate Gasket Reed valve plate Reed valve assembly Screw Valve stopper Reed valve Q’ty 1 1 1 3 24 6 6 Service points Not reusable Reverse the removal steps for installation.
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POWR REED VALVES E SERVICE POINTS Reed valve inspection 1. Check: • Reed valves Cracks/damage → Replace. 2. Measure: • Valve warpage a Out of specification → Replace. Valve warpage limit: 1.5 mm (0.059 in) 3. Measure: • Valve stopper height b Out of specification → Replace. Valve stopper height: 10.5–10.9 mm (0.413–0.
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POWR YPVS E YPVS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name YPVS REMOVAL Exhaust chamber assembly Q’ty Bolt YPVS valve cover Gasket Spacer Link joint/cover Circlip Washer 12 3 3 2 2/2 5 5 5-21 Service points Follow the left “Step” for removal. Refer to “EXHAUST CHAMBER ASSEMBLY.
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POWR YPVS E EXPLODED DIAGRAM Step 8 9 10 11 12 13 Procedure/Part name Bolt Shaft 3 Shaft 2 Shaft 1 YPVS valve arm Bolt Q’ty 3 1 1 1 3 3 5-22 Service points NOTE: For installation, align the hole a in the YPVS shaft with the bolt.
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POWR YPVS E EXPLODED DIAGRAM Step 14 15 Procedure/Part name YPVS valve assembly Oil seal Q’ty 3 Service points NOTE: Install the YPVS valves with the recess b facing toward the stern. 6 NOTE: If the YPVS shaft is removed, the oil seal must be replaced. Reverse the removal steps for installation.
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POWR YPVS E SERVICE POINTS YPVS valve inspection 1. Eliminate: • Carbon deposits (using a rounded scraper 1) CAUTION: Do not use a sharp instrument to avoid damaging or scratching the surfaces. 1 2. Check: • YPVS valve assembly Cracks/damage/wear → Replace. YPVS valve installation 1. Install: • Oil seals Distance a: 1.0–1.5 mm (0.039–0.059 in) NOTE: Install the oil seal with the marks b facing inward.
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POWR CYLINDER HEAD E CYLINDER HEAD EXPLODED DIAGRAM 1st 3.8 N • m (0.38 kgf • m, 2.7 ft • Ib) 1st 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 1st 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 3rd 35 N • m (3.5 kgf • m, 25 ft • Ib) 8 × 65 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 25 N • m (2.5 kgf • m, 18 ft • Ib) 2nd 35 N • m (3.
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POWR CYLINDER HEAD E EXPLODED DIAGRAM 1st 3.8 N • m (0.38 kgf • m, 2.7 ft • Ib) 1st 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 1st 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 3rd 35 N • m (3.5 kgf • m, 25 ft • Ib) 8 × 65 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 25 N • m (2.5 kgf • m, 18 ft • Ib) 2nd 35 N • m (3.
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POWR CYLINDER HEAD E SERVICE POINTS Cylinder head inspection 1. Eliminate: • Carbon deposits (using a rounded scraper 1) CAUTION: Do not use a sharp instrument to avoid damaging or scratching the cylinder head or spark plug bore threads. 2. Check: • Cylinder head water jacket Corrosion/mineral deposits → Clean or replace. 3. Measure: • Cylinder head warpage (using a straightedge and thickness gauge) Out of specification/score marks → Resurface. Warpage limit: 0.05 mm (0.
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POWR CYLINDERS E CYLINDERS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 Procedure/Part name CYLINDER REMOVAL YPVS Cylinder head Engine temperature sensor Bolt 3 Cylinder Q’ty 1 12 3 5-28 Service points Follow the left “Step” for removal. Refer to “YPVS.” Refer to “CYLINDER HEAD.” NOTE: Tighten the bolts in a crisscross pattern and in two stages. NOTE: Install the cylinders in their original positions.
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POWR CYLINDERS E EXPLODED DIAGRAM Step 4 5 Procedure/Part name Cylinder gasket Pin Q’ty 3 6 Service points Not reusable Reverse the removal steps for installation.
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POWR CYLINDERS E SERVICE POINTS Cylinder inspection 1. Eliminate: • Carbon deposits (using a rounded scraper 1) 2. Check: • Cylinder water jacket Corrosion/mineral deposits → Clean or replace. • Cylinder inner surface Score marks → Replace. 3. Measure: • Cylinder bore “D” (using a cylinder gauge) Out of specification → Replace cylinder and piston as a set. NOTE: Measure the cylinder bore parallel to and at a right angle to the crankshaft. Then, average the measurements. Standard Limit 84.000– 84.
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POWR PISTONS E PISTONS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 Procedure/Part name PISTON REMOVAL Cylinders Piston pin clip Q’ty 2 Service points Follow the left “Step” for removal. Refer to “CYLINDERS.” Not reusable CAUTION: Do not align the open end of the clip with the piston pin slot a. 2 3 4 Piston pin Piston Washer 1 1 2 5-31 NOTE: Install the piston with the arrow b facing towards the exhaust port.
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POWR PISTONS E EXPLODED DIAGRAM Step 5 6 Procedure/Part name Bearing Piston ring Q’ty 1 2 Service points CAUTION: Align each end gap with its respective locating pin. Reverse the removal steps for installation.
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POWR PISTONS E SERVICE POINTS Piston pin clip removal and installation 1. Remove and install: • Piston pin clip NOTE: Before removing or installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. Piston inspection 1. Eliminate: • Carbon deposits (from the piston crown and piston ring grooves) 2. Check: • Piston wall Score marks → Repair with 600–800 grit wet sandpaper or replace.
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POWR PISTONS E 4. Calculate: • Piston-to-cylinder clearance Out of specification → Replace the piston, piston rings, and cylinder as a set. PISTON CYLINDER PISTON – = DIAMETER BORE CLEARANCE Piston-to-cylinder clearance: 0.100–0.105 mm (0.0039–0.0041 in) Cylinder and piston combination Select the appropriate piston to match the cylinder size from the table as follows. Cylinder size indication a Piston color mark 00–05 Red 06–10 Orange 11–15 Green 16–18 Purple NOTE: New cylinder bore size = 84.
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POWR PISTONS E 2. Measure: • End gap (using a thickness gauge 1) Out of specification → Replace the piston rings as a set. End gap: 0.45–0.60 mm (0.018–0.024 in) NOTE: Push the piston ring into the cylinder with the piston crown. Piston pin and bearing inspection 1. Check: • Piston pins • Bearings Signs of heat discoloration → Replace. 2. Measure: • Piston pin outside diameter (using a micrometer 1) Out of specification → Replace. Piston pin outside diameter: Standard: 21.995–22.000 mm (0.8659–0.
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POWR PISTONS E 4. Check: • Piston-pin-to-small-end-bearing-toconnecting-rod free play (at the small end of the connecting rod as shown) Free play/wear at the small end → Replace the piston pin, connecting rod, small end bearing, or all parts. Piston installation 1. Install: • Top ring • 2nd ring NOTE: Install the piston rings with the manufacturer’s marks or numbers facing up.
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POWR GENERATOR AND STARTER MOTOR E GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 Procedure/Part name GENERATOR COVER REMOVAL Oil pump Bolt Bolt 3 4 5 6 7 Ground lead Generator cover Washer Spring Seal Q’ty 1 7 1 1 2 1 1 5-37 Service points Follow the left “Step” for removal. Refer to “OIL PUMP” in Chapter 4. NOTE: Do not apply locking agent to the bolt that is used to install the ground lead.
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POWR GENERATOR AND STARTER MOTOR E EXPLODED DIAGRAM Step 8 9 10 11 Procedure/Part name Pin Bolt Bolt Exhaust chamber bracket Q’ty 2 2 2 1 Service points Reverse the removal steps for installation.
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POWR GENERATOR AND STARTER MOTOR E EXPLODED DIAGRAM 5 × 14 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 2 6 LT 242 5 × 14 mm 5 2 6 LT 242 1 10 5 14 N • m (1.4 kgf • m, 10 ft • Ib) 6 × 35 mm 9 LT 8 242 2 6 7 LT 242 4 5 × 14 mm 3 5 5 × 14 mm LT 242 5 × 14 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 14 mm 14 N • m (1.
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POWR GENERATOR AND STARTER MOTOR E EXPLODED DIAGRAM 5 × 14 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 2 6 LT 242 5 × 14 mm 5 2 6 LT 242 1 10 5 14 N • m (1.4 kgf • m, 10 ft • Ib) 6 × 35 mm 9 LT 8 242 6 7 LT 242 4 5 × 14 mm 3 Procedure/Part name Ground lead Bolt Lighting coil 5 5 × 14 mm LT 242 5 × 14 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 14 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) Step 8 9 10 2 Q’ty 2 3 1 Service points Reverse the removal steps for installation.
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POWR GENERATOR AND STARTER MOTOR E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name GENERATOR ROTOR AND STARTER MOTOR REMOVAL Drive coupling Flywheel magneto bolt Flywheel magneto Woodruff key Starter clutch assembly 6 Bolt Q’ty 1 1 1 1 1 2 5-41 Service points Follow the left “Step” for removal. NOTE: Degrease the flywheel magneto where it is coupled to the crankshaft.
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POWR GENERATOR AND STARTER MOTOR E EXPLODED DIAGRAM Step 7 8 9 10 Procedure/Part name Negative battery lead Nut/washer Starter motor lead Starter motor Q’ty 1 1/1 1 1 Service points Reverse the removal steps for installation.
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POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name STARTER CLUTCH DISASSEMBLY Clip Clip stopper Spring seat Spring Washer Idle gear Circlip Plate Q’ty 1 1 1 1 1 1 1 1 5-43 Service points Follow the left “Step” for disassembly.
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POWR GENERATOR AND STARTER MOTOR E EXPLODED DIAGRAM Step 9 10 11 Procedure/Part name Weight Spring ring Pinion gear Q’ty 3 1 Service points NOTE: Install the spring ring after installing the weights, plate, and circlip. 1 Reverse the disassembly steps for assembly.
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POWR GENERATOR AND STARTER MOTOR E SERVICE POINTS Drive coupling removal and installation 1. Remove: • Drive coupling Coupler wrench: YW-06551/90890-06551 Flywheel holder: YW-06550/90890-06550 T. R. Drive coupling: 36 N • m (3.6 kgf • m, 25 ft • lb) LOCTITE 572 NOTE: Install the drive coupling with the same special service tools that were used for removal. Flywheel magneto removal and installation 1. Remove: • Flywheel magneto bolt Flywheel holder: YW-06550/90890-06550 T.
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POWR GENERATOR AND STARTER MOTOR E 2. Remove: • Generator rotor È Universal puller: YB-06117 Flywheel puller: 90890-06521 Set bolt: M8 × 60 mm È For USA and Canada É For Worldwide É CAUTION: To prevent damage to the engine or special service tools, screw in the flywheel puller set bolts evenly and completely so that the puller plate is parallel to the generator rotor. Drive coupling inspection 1. Check: • Drive coupling Damage/wear → Replace. Flywheel magneto inspection 1.
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POWR CRANKCASE E CRANKCASE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name CRANKCASE DISASSEMBLY Pistons Generator cover and starter motor Bolt Mount bracket Pin Bolt Bolt Bolt Bolt Q’ty 6 2 4 4 6 1 16 5-47 Service points Follow the left “Step” for disassembly. Refer to “PISTONS.” Refer to “GENERATOR AND STARTER MOTOR.” NOTE: Tighten the bolts in the sequences shown and in two stages if specified.
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POWR CRANKCASE E EXPLODED DIAGRAM Step 8 9 10 11 Procedure/Part name Lower crankcase Pin Crankshaft assembly Upper crankcase Q’ty 1 2 1 1 Service points Reverse the disassembly steps for assembly.
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POWR CRANKCASE E SERVICE POINTS Crankcase inspection 1. Check: • Mating surfaces Scratches → Replace the crankcase. • Crankcase Cracks/damage → Replace. Crankcase installation 1. Apply: • Gasket Maker (to the crankcase mating surfaces) NOTE: Before applying Gasket Maker, clean the crankcase mating surfaces. 2. Check: • Crankshaft Rough movement → Recheck. NOTE: Make sure that the crankshaft rotates smoothly after installing it.
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POWR CRANKSHAFT E CRANKSHAFT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 Procedure/Part name CRANKSHAFT REMOVAL Crankcase Oil seal Bearing Oil seal 1 Oil seal 2 5 Crankshaft assembly Q’ty 1 1 1 1 1 Service points Follow the left “Step” for removal. Refer to “CRANKCASE.” Not reusable Not reusable Not reusable CAUTION: Install the bearing locating pins into the grooves in the crankcase body. Reverse the removal steps for installation.
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POWR CRANKSHAFT E SERVICE POINTS Crankshaft inspection 1. Measure: • Crank width A Out of specification → Replace the crankshaft. Crank width: 72.95–73.00 mm (2.872–2.874 in) 2. Measure: • Deflection B (using a dial gauge) Out of specification → Replace. Maximum deflection: B 0.05 mm (0.002 in) C 0.15 mm (0.006 in) 3. Measure: • Big end side clearance D (using a thickness gauge) Out of specification → Replace. Big end side clearance: 0.250–0.750 mm (0.0098–0.0295 in) 4.
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POWR CRANKSHAFT E 5. Check: • Bearings Damage/pitting → Replace. NOTE: • Before checking bearings, thoroughly clean them. • Immediately after checking the bearings, lubricate them to prevent rust. 6. Check: • Oil seals Damage/wear → Replace.
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JET PUMP E CHAPTER 6 JET PUMP UNIT JET PUMP UNIT.............................................................................................. 6-1 EXPLODED DIAGRAM .............................................................................6-1 REMOVAL AND INSTALLATION CHART ................................................ 6-1 JET THRUST NOZZLE AND NOZZLE RING ................................................. 6-5 EXPLODED DIAGRAM ............................................................................
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JET PUMP JET PUMP UNIT E JET PUMP UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name JET PUMP UNIT REMOVAL Bolt Bolt Intake grate Bolt Intake duct Felt seal Screw Speed sensor Q’ty 2 2 1 4 1 1 4 1 6-1 Service points Follow the left “Step” for removal. NOTE: Route the speed sensor lead between the jet pump unit and bilge hose 5.
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JET PUMP JET PUMP UNIT E EXPLODED DIAGRAM Step 9 10 11 12 13 14 15 16 17 Procedure/Part name Bolt Ride plate QSTS cable joint Plastic tie/bilge hose 5 Nut/washer Steering cable joint Screw clamp/spout hose Bolt Bolt Q’ty 4 1 1 1/1 1/2 1 1/1 1 4 6-2 Service points
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JET PUMP JET PUMP UNIT E EXPLODED DIAGRAM Step 18 19 20 21 Procedure/Part name Jet pump unit assembly Dowel pin Impeller housing 2 Dowel pin Q’ty 1 2 1 2 Service points NOTE: Clean the mating surfaces before applying Yamabond No. 4. Reverse the removal steps for installation.
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JET PUMP JET PUMP UNIT E EXPLODED DIAGRAM 1 2 FWD REMOVAL AND INSTALLATION CHART Step 1 2 Procedure/Part name SPEED SENSOR DISASSEMBLY Paddle wheel set Speed sensor Q’ty 1 1 Service points Follow the left “Step” for disassembly. Not reusable Reverse the disassembly steps for assembly.
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JET PUMP JET THRUST NOZZLE AND NOZZLE RING E JET THRUST NOZZLE AND NOZZLE RING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name JET THRUST NOZZLE AND NOZZLE RING REMOVAL Jet pump unit Bolt Collar Jet thrust nozzle Bolt Collar Nozzle ring Q’ty Service points Follow the left “Step” for removal. Refer to “JET PUMP UNIT.” 2 2 1 2 2 1 Reverse the removal steps for installation.
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JET PUMP IMPELLER DUCT AND IMPELLER HOUSING 1 E IMPELLER DUCT AND IMPELLER HOUSING 1 EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name IMPELLER DUCT AND IMPELLER HOUSING 1 REMOVAL Nozzle ring Bolt Nozzle Pin Impeller duct assembly Impeller housing 1 Pin Q’ty Service points Follow the left “Step” for removal. Refer to “JET THRUST NOZZLE AND NOZZLE RING.” 4 1 2 1 1 2 6-6 NOTE: Clean the mating surfaces before applying Yamabond No. 4.
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JET PUMP IMPELLER DUCT AND IMPELLER HOUSING 1 E EXPLODED DIAGRAM Step 7 8 9 10 11 Procedure/Part name Bolt Water inlet cover Seal Water inlet strainer Seal Q’ty 4 1 1 1 1 Service points Reverse the removal steps for installation.
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JET PUMP IMPELLER DUCT AND DRIVE SHAFT IMPELLER DUCT AND DRIVE SHAFT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 *1 Procedure/Part name IMPELLER DUCT AND DRIVE SHAFT DISASSEMBLY Impeller Spacer Bolt Cap O-ring Nut Washer Q’ty 1 1 3 1 1 1 1 EPNOC grease AP #0 6-8 Service points Follow the left “Step” for disassembly.
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JET PUMP IMPELLER DUCT AND DRIVE SHAFT EXPLODED DIAGRAM Step 8 9 10 11 12 13 14 Procedure/Part name Drive shaft Rear bearing Spacer Front bearing Oil seal Oil seal Impeller duct Q’ty 1 1 1 1 1 1 1 Service points Not reusable Not reusable Not reusable Not reusable Reverse the disassembly steps for assembly.
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JET PUMP IMPELLER DUCT AND DRIVE SHAFT E SERVICE POINTS Drive shaft removal 1. Remove: • Impeller Drive shaft holder: YB-06151 Drive shaft holder 5: 90890-06519 NOTE: The impeller has left-hand threads. Turn the impeller clockwise to loosen it. 2. Remove: • Nut 1 Drive shaft holder: YB-06151 Drive shaft holder 5: 90890-06519 3. Remove: • Drive shaft 1 NOTE: Remove the drive shaft using a press. 4.
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JET PUMP IMPELLER DUCT AND DRIVE SHAFT E 5. Remove: • Front bearing Driver handle—large: YB-06071 Driver rod L3: 90890-06652 Bearing housing needle bearing remover: YB-06112 Needle bearing attachment: 90890-06614 NOTE: Remove the front bearing using a press. 6. Remove: • Oil seal Driver handle—large: YB-06071 Driver rod L3: 90890-06652 Drive shaft needle bearing installer and remover: YB-06196 Needle bearing attachment: 90890-06653 NOTE: Remove the oil seals using a press.
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JET PUMP IMPELLER DUCT AND DRIVE SHAFT E Drive shaft installation 1. Install: • Oil seals Driver handle—large: YB-06071 Driver rod LS: 90890-06606 Outer race installer—forward gear: YB-06085 Ball bearing attachment: 90890-06634 Distance a: 14.2 ± 0.2 mm (0.56 ± 0.01 in) Distance b: 4.7 ± 0.2 mm (0.19 ± 0.01 in) 2. Install: • Front bearing • Drive shaft NOTE: Install the front bearing and drive shaft using a press. a Distance a: 23.0 ± 0.1 mm (0.906 ± 0.004 in) 3.
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JET PUMP IMPELLER DUCT AND DRIVE SHAFT E 5. Install: • Rear bearing Drive shaft needle bearing depth stop: YB-34474 NOTE: • Press the bearing inner/outer race at the same time holding the drive shaft and impeller duct. • If a bearing inner/outer race attachment is not available, use a washer or pipe with an outer diameter of 47–50 mm (1.85–1.97 in) and an inner diameter of 21–25 mm (0.83– 0.98 in). 6. Add: • EPNOC grease AP #0 (into the cap) Quantity: Approximately 1/3 of capacity 7.
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JET PUMP TRANSOM PLATE AND HOSES E TRANSOM PLATE AND HOSES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 Procedure/Part name TRANSOM PLATE AND HOSE REMOVAL Exhaust system Jet pump unit assembly Hose screw clamp Cooling water hose Bilge hose 2 4 5 Cooling water hose Hose clamp Q’ty Service points Follow the left “Step” for removal. Refer to “EXHAUST SYSTEM” in Chapter 8. Refer to “JET PUMP UNIT.
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JET PUMP TRANSOM PLATE AND HOSES E EXPLODED DIAGRAM Step 6 7 8 9 10 11 12 13 14 Procedure/Part name Bilge hose 4 Band Electric bilge pump assembly Hose clamp Bilge hose 3 Bilge strainer Nut/washer Transom plate Plastic tie/bilge hose 5 Q’ty 1 1 1 1 1 1 4/4 1 1/1 Service points Reverse the removal steps for installation.
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JET PUMP TRANSOM PLATE AND HOSES E SERVICE POINTS Bilge strainer inspection Refer to “JET PUMP UNIT” in Chapter 3. Electric bilge pump inspection Refer to “BILGE PUMP” in Chapter 3. Refer to “ELECTRIC BILGE PUMP” in Chapter 7. Bilge hose inspection 1. Check: • Bilge hoses Cracks/damage/wear → Replace. Cooling water hose inspection 1. Check: • Cooling water hoses Cracks/damage/wear → Replace.
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JET PUMP BEARING HOUSING E BEARING HOUSING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name BEARING HOUSING REMOVAL Engine unit Rubber coupling Bolt Intermediate housing assembly Pin Shim Q’ty 1 3 1 2 — Service points Follow the left “Step” for removal. Refer to “ENGINE UNIT” in Chapter 5. As required NOTE: Install shims in their original positions. Reverse the removal steps for installation.
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JET PUMP BEARING HOUSING E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name BEARING HOUSING DISASSEMBLY Grease hose Grease nipple Grease nipple stay Nipple Driven coupling Washer Intermediate drive shaft O-ring Q’ty 1 1 1 2 1 1 1 2 6-18 Service points Follow the left “Step” for disassembly.
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JET PUMP BEARING HOUSING E EXPLODED DIAGRAM Step 9 10 11 12 13 14 Procedure/Part name Oil seal Oil seal Oil seal Circlip Bearing Circlip Q’ty 1 1 1 1 1 1 Service points Not reusable Not reusable Not reusable Not reusable Reverse the disassembly steps for assembly.
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JET PUMP BEARING HOUSING E SERVICE POINTS Driven coupling removal and installation 1. Remove and install: • Driven coupling T. R. Driven coupling: 36 N • m (3.6 kgf • m, 25 ft • lb) LOCTITE 572 Coupler wrench: YW-06551/90890-06551 Shaft holder: YB-06552 Crankshaft holder 20: 90890-06552 NOTE: Install the driven coupling with the same special service tools that were used for removal. Intermediate drive shaft removal 1.
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JET PUMP BEARING HOUSING E Bearing removal 1. Remove: • Bearing Driver handle—large: YB-06071 Driver rod LS: 90890-06606 Drive shaft taper roller bearing cup installer: YB-06156 Bearing outer race attachment: 90890-06626 NOTE: • Install the bearing with the same special service tools that were used for removal. • Support the intermediate housing with steel blocks 1 and remove the bearing using a press. Bearing, intermediate drive shaft, and grease hose inspection 1.
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JET PUMP BEARING HOUSING E 2. Install: • Bearing Driver handle—large: YB-06071 Driver rod LS: 90890-06606 Drive shaft taper roller bearing cup installer: YB-06156 Bearing outer race attachment: 90890-06626 NOTE: Support the intermediate housing with steel blocks 1 and install the bearing using a press. Oil seal installation 1.
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JET PUMP a BEARING HOUSING E 3. Install: • Oil seal 1 [8 mm (0.31 in)] • Oil seal 2 [10 mm (0.39 in)] b Distance a: 10.3–10.7 mm (0.41–0.42 in) Distance b: 1.6–2.0 mm (0.06–0.08 in) 2 1 Intermediate housing installation 1. Install: • Intermediate housing • Shim(s) • Bolts 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) Not needed 0.3–0.7 mm (0.
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ELEC – + E CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS........................................................................ 7-1 ELECTRICAL BOX.......................................................................................... 7-2 EXPLODED DIAGRAM .............................................................................7-2 REMOVAL AND INSTALLATION CHART ................................................ 7-2 ECM AND SLANT DETECTION SWITCH .................................................
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ELEC – + FUEL CONTROL SYSTEM ...........................................................................7-23 WIRING DIAGRAM ................................................................................. 7-23 FUEL PUMP ............................................................................................ 7-25 FUEL SENDER ....................................................................................... 7-25 FUEL INJECTOR .......................................................................
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ELEC – + YPVS SERVOMOTOR...................................................................................7-39 EXPLODED DIAGRAM ...........................................................................7-39 REMOVAL AND INSTALLATION CHART .............................................. 7-39 SERVICE POINTS .................................................................................. 7-41 YPVS cable removal and installation ................................................ 7-41 YPVS cable inspection...
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ELEC – + ELECTRICAL COMPONENTS E ELECTRICAL COMPONENTS Q 1 P 2 O 3 N M 4 5 L K 6 7 8 9 0 8 A 8 J I H G F E B C D 1 2 3 4 5 6 7 8 9 0 A Slant detection switch Fuel pump Atmospheric pressure sensor Multifunction meter Steering switch Intake air temperature sensor Throttle position sensor Fuel injectors Engine temperature sensor Throttle switch Stepping motor B C D E F G H I J K Rectifier/regulator Electric bilge pump Speed sensor Battery Electrical box Cooling water temperature sensor Exh
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ELEC – + ELECTRICAL BOX E ELECTRICAL BOX EXPLODED DIAGRAM 2 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 6 × 10 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 30 mm 15 13 12 7 14 16 17 11 10 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 30 mm 9 8 27 21 26 25 21 23 21 22 28 24 3 20 30 29 30 29 5 4 19 18 6 31 32 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 6 × 16 mm 28 1 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 25 mm 1 1 33 4.9 N • m (0.49 kgf • m, 3.
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ELEC – + ELECTRICAL BOX E EXPLODED DIAGRAM 2 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 6 × 10 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 30 mm 15 13 12 7 14 16 17 11 10 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 30 mm 9 8 27 21 26 25 21 23 21 22 28 24 3 20 30 29 30 29 5 4 19 18 6 31 32 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 6 × 16 mm 28 1 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 25 mm 1 1 33 4.9 N • m (0.49 kgf • m, 3.
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ELEC – + ELECTRICAL BOX E EXPLODED DIAGRAM 2 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 6 × 10 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 30 mm 15 13 12 7 14 16 17 11 10 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 30 mm 9 8 27 21 26 25 21 23 21 22 28 24 3 20 30 29 30 29 5 4 19 18 6 31 32 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 6 × 16 mm 28 1 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 25 mm 1 1 33 4.9 N • m (0.49 kgf • m, 3.
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ELEC – + ELECTRICAL BOX E EXPLODED DIAGRAM 2 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 6 × 10 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 30 mm 15 13 12 7 14 16 17 11 10 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 30 mm 9 8 27 21 26 25 21 23 21 22 28 24 3 20 30 29 30 29 5 4 19 18 6 31 32 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 6 × 16 mm 28 1 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 25 mm 1 1 33 4.9 N • m (0.49 kgf • m, 3.
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ELEC – + ELECTRICAL BOX E 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 25 mm 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 6 × 16 mm 1 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 25 mm 2 3 5 4 3 2 1 R Br B B B A 1 2 B Ë 3 A 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm B B A B Br B B B Ë Ê É È 7.6 N • m (0.76 kgf • m, 5.
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ELEC – + ECM AND SLANT DETECTION SWITCH E ECM AND SLANT DETECTION SWITCH EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name ECM AND SLANT DETECTION SWITCH REMOVAL Nut/washer ECM ECM coupler Nut/washer Slant detection switch Slant detection switch coupler Q’ty Service points Follow the left “Step” for removal. 2/2 1 1 2/2 1 1 Reverse the removal steps for installation.
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ELEC – + ELECTRICAL ANALYSIS E ELECTRICAL ANALYSIS INSPECTION CAUTION: • All measuring instruments should be handled with special care. Damaged or mishandled instruments will not measure properly. • On instruments powered by dry batteries, check the battery voltage periodically and replace the batteries if necessary. Digital tester NOTE: Throughout this chapter the part numbers of the specified digital testers have been omitted. Refer to the following part numbers.
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ELEC – + ELECTRICAL ANALYSIS E Low resistance measurement NOTE: • When measuring a resistance of 10 Ω or less with the digital tester, the correct measurement cannot be obtained because of the tester’s internal resistance. • To obtain the correct value, subtract the internal resistance from the displayed measurement. • The internal resistance of the tester can be obtained by connecting both of its terminals.
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ELEC – + ELECTRICAL ANALYSIS E Peak voltage adapter NOTE: • Throughout this chapter the part number of the peak voltage adapters have been omitted. Refer to the following part numbers. • The peak voltage adapter should be used with the digital tester. Peak volt meter adapter: YU-39991 Peak voltage adapter B: 90890-03172 È • When measuring the peak voltage, connect the peak voltage adapter to the digital circuit tester and switch the selector to the DC voltage mode.
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– ELEC + IGNITION SYSTEM E IGNITION SYSTEM WIRING DIAGRAM Y 2: 3: 5: 6: 7: 8: 10 : 11 : 12 : 13 : 14 : Y W B/Y B/G B/O B/L O W/Y W/B W/R L/R 19 : 20 : 27 : 28 : 29 : 30 : 31 : 33 : 34 : 35 : B/R O R/Y L/B B P/G P B B/Y B/W 1 Br L/R B R R L 20 21 22 23 24 25 26 27 28 29 30 31 2 3 4 5 6 7 8 9 1 32 33 34 35 10 11 12 13 14 15 16 17 18 19 R/Y R/Y R/Y R R/Y 3 2 B Br R R/Y 4 R/Y 76 3 2 R/Y 4 5 18 R/Y Y L/R 7 FREE PUSH H B/Y B L/B A L/B B B/W B #2 B B W W W B #1
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– ELEC + IGNITION SYSTEM E WIRING DIAGRAM Y 2: 3: 5: 6: 7: 8: 10 : 11 : 12 : 13 : 14 : Y W B/Y B/G B/O B/L O W/Y W/B W/R L/R 19 : 20 : 27 : 28 : 29 : 30 : 31 : 33 : 34 : 35 : B/R O R/Y L/B B P/G P B B/Y B/W 1 Br L/R B R R L 20 21 22 23 24 25 26 27 28 29 30 31 2 3 4 5 6 7 8 9 1 32 33 34 35 10 11 12 13 14 15 16 17 18 19 R/Y R/Y R/Y R R/Y 3 2 B Br R R/Y 4 R/Y 76 3 2 R/Y 4 5 18 R/Y Y L/R 7 FREE PUSH H B/Y B L/B A L/B B B/W R B B B/R W W W B #1 B/O G L/B G
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ELEC – + IGNITION SYSTEM E IGNITION SPARK GAP WARNING • When checking the spark gap, do not touch any of the connections of the spark gap tester lead wires. • When performing the spark gap test, take special care not to let sparks leak out of the removed spark plug cap. • When performing the spark gap check, keep flammable gas or liquids away, since this test can produce sparks. È 1. Check: • Ignition spark gap Below specification → Check the ECM output peak voltage.
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ELEC – + IGNITION SYSTEM E IGNITION SYSTEM PEAK VOLTAGE WARNING When checking the electrical components, do not touch any of the connections of the digital tester lead wires. NOTE: • If there is no spark, or the spark is weak, continue with the ignition system test. • If a good spark is obtained, the problem is not with the ignition system, but possibly with the spark plug(s) or another component. 1. Measure: • ECM output peak voltage Below specification → Measure the pickup coil output peak voltage.
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ELEC – + IGNITION SYSTEM E 2. Measure: • Pickup coil output peak voltage Below specification → Replace the pickup coil. Above specification → Replace the ECM. Test harness (6 pins): YB-06849 Test harness SM6195021-6 (6 pins): 90890-06849 Pickup coil output peak voltage: White/red (W/R) – Black (B) White/black (W/B) – Black (B) White/yellow (W/Y) – Black (B) r/min V Unloaded Loaded Cranking 6.0 6.
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ELEC – + IGNITION SYSTEM E 4. Measure: • Rectifier/regulator output peak voltage Below specification → Replace the rectifier/regulator. Test harness (6 pins): YB-06848 Test harness FSW-6A (6 pins): 90890-06848 Rectifier/regulator output peak voltage: Red (R) – Black (B) Unloaded r/min 3,500 V 14.5 NOTE: • Do not use the peak voltage adapter to measure the output voltage. • Disconnect the output lead of the tester harness. BATTERY Refer to “ELECTRICAL” in Chapter 3. FUSE Refer to “STARTING SYSTEM.
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ELEC – + IGNITION SYSTEM E IGNITION COIL 1. Measure: • Primary coil resistance Out of specification → Replace. Primary coil resistance: Black/white (B/W) – Body 0.26–0.36 Ω at 20 °C (68 °F) NOTE: When measuring a resistance of 10 Ω or less with the digital tester, the correct measurement cannot be obtained because of the tester’s internal resistance. Refer to “Low resistance measurement.” 2. Measure: • Secondary coil resistance Out of specification → Replace.
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ELEC – + IGNITION SYSTEM E ENGINE TEMPERATURE SENSOR 1. Measure: • Engine temperature sensor resistance (at the specified temperatures) Out of specifications → 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 specified temperatures are reached. INTAKE AIR TEMPERATURE SENSOR 1.
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ELEC – + IGNITION SYSTEM E COOLING WATER TEMPERATURE SENSOR 1. Measure: • Cooling water temperature sensor resistance (at the specified temperatures) Out of specifications → Replace. Cooling water temperature sensor resistance: 0 °C (32 °F): 24.0–37.1 kΩ 100 °C (212 °F): 0.87–1.18 kΩ 200 °C (392 °F): 104–153 Ω Measurement steps: • Ice the cooling water temperature sensor and measure the resistance when the specified temperature is reached.
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ELEC – + IGNITION SYSTEM E MAIN AND FUEL PUMP RELAY 1. Check: • Main and fuel pump relay continuity Out of specification → Replace. 1234 5678 Checking steps: • Connect the tester leads between main and fuel pump relay terminals 5, 6, and 7. • Connect terminal 2 or 3 to the positive battery terminal. • Connect terminal 1 to the negative battery terminal. • Check that there is continuity between the main and fuel pump relay terminals.
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ELEC – + IGNITION SYSTEM E ATMOSPHERIC PRESSURE SENSOR 1. Measure: • Atmospheric pressure sensor output voltage Out of specification → Replace. Air pressure sensor tester (3 pins): YB-06869 Test harness EJ-II-3 (3 pins): 90890-06869 Lower unit pressure/vacuum tester: YB-35956-A Vacuum/pressure pump gauge set: 90890-06756 B/O P/G Atmospheric pressure sensor output voltage: Pink/green (P/G) – Black/orange (B/O) 1 101.3 kPa (1.01 kgf/cm2, 14.4 psi): a 4.00 V 2 50 kPa (0.5 kgf/cm2, 7.1 psi): b 1.
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ELEC – + IGNITION SYSTEM E SLANT DETECTION SWITCH È 1. Check: • Slant detection switch continuity Out of specification → Replace.
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ELEC – + FUEL CONTROL SYSTEM E FUEL CONTROL SYSTEM WIRING DIAGRAM Y 2: 5: 6: 7: 8: 10 : 14 : 20 : 23 : Y B/Y B/G B/O B/L O L/R O P 24 : 25 : 26 : 27 : 28 : 29 : 30 : 31 : 33 : Pu/Y Pu/B Pu/R R/Y L/B B P/G P B 1 Br L/R B R R L 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 32 33 34 35 10 11 12 13 14 15 16 17 18 19 R/Y R/Y R/Y R R/Y B 2 R R/Y 4 R/Y 76 3 2 R/Y R 3 4 5 18 R/Y Y L/R B/O B/O B/O B B B/O B B B B/O B/O B B/O B/O L/B L/B B B/O O B/O B B B O B Pu/Y
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ELEC – + FUEL CONTROL SYSTEM E WIRING DIAGRAM Y 2: 5: 6: 7: 8: 10 : 14 : 20 : 23 : Y B/Y B/G B/O B/L O L/R O P 24 : 25 : 26 : 27 : 28 : 29 : 30 : 31 : 33 : Pu/Y Pu/B Pu/R R/Y L/B B P/G P B 1 Br L/R B R R L 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 32 33 34 35 10 11 12 13 14 15 16 17 18 19 R/Y R/Y R/Y R R/Y B 2 R R/Y 4 R/Y 76 3 2 R/Y R 3 4 5 18 R/Y Y L/R B/O B/O B/O B B B/O B B B B/O B/O B B/O B/O L/B L/B B B/O O B/O B B B O B Pu/Y Pu/R B/G Pu/R Pu/
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ELEC – + FUEL CONTROL SYSTEM E FUEL PUMP 1. Check: • Fuel pump operating sound No sound → Measure the fuel pressure. Refer to “FUEL INJECTION SYSTEM” in Chapter 4. FUEL SENDER 1. Measure: • Fuel sender resistance Out of specification → Replace. Float position 7-25 Resistance (Ω) A 133.5–136.
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ELEC – + FUEL CONTROL SYSTEM E FUEL INJECTOR Refer to “FUEL INJECTION SYSTEM” in Chapter 4. ENGINE TEMPERATURE SENSOR Refer to “IGNITION SYSTEM.” INTAKE AIR TEMPERATURE SENSOR Refer to “IGNITION SYSTEM.” COOLING WATER TEMPERATURE SENSOR Refer to “IGNITION SYSTEM.” EXHAUST TEMPERATURE SENSOR Refer to “IGNITION SYSTEM.” MAIN AND FUEL PUMP RELAY Refer to “IGNITION SYSTEM.” THROTTLE POSITION SENSOR Refer to “IGNITION SYSTEM.” ATMOSPHERIC PRESSURE SENSOR Refer to “IGNITION SYSTEM.
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ELEC – + STARTING SYSTEM E STARTING SYSTEM WIRING DIAGRAM 2: Y 27 : R/Y 33 : B 1 Y 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 2 Br L/R 32 33 34 35 10 11 12 13 14 15 16 17 18 19 R/Y R/Y R/Y B L R R/Y R/Y R/Y 76 3 2 R/Y 4 5 18 R/Y Y R R 3 R B B B B B B 4 R R Br R Br Br B 8 7 W B R Br FREE PUSH R B Br Br B FREE PUSH R 6 Br 5 Br Br Br Br R R R 1 2 3 4 5 6 7 8 R ECM Main and fuel pump relay Fuse (20 A) Starter relay Battery Starter motor Start s
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ELEC – + STARTING SYSTEM E BATTERY Refer to “ELECTRICAL” in Chapter 3. WIRING CONNECTIONS 1. Check: • Wiring connections Poor connections → Properly connect. FUSES 1. Check: • Fuses Broken → Replace. Fuse rating: 20 A × 1, 3 A × 2 NOTE: The 20 A fuse is for the main relay, engine shut-off switch, and rectifier/regulator. The 3 A fuses are for the multifunction meter and electric bilge pump. START SWITCH 1. Check: • Continuity Out of specification → Replace.
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ELEC – + STARTING SYSTEM E STARTER RELAY 1. Check: • Brown lead terminal • Black lead terminal Loose → Tighten. 2. Check: • Starter relay continuity Out of specification → 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.
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ELEC – + STARTER MOTOR E STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name STARTER MOTOR DISASSEMBLY Starter motor O-ring Bolt Starter motor front cover O-ring Oil seal retainer Washer Shim Q’ty 1 2 1 1 1 1 — 7-30 Service points Follow the left “Step” for disassembly. Refer to “GENERATOR AND STARTER MOTOR” in Chapter 5. Not reusable Not reusable As required Thickness = 0.2 mm, 0.
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ELEC – + STARTER MOTOR E EXPLODED DIAGRAM Step 8 9 10 11 12 13 14 15 16 17 Procedure/Part name Starter motor rear cover O-ring Shim Q’ty 1 1 — Armature assembly Nut/spring washer/washer O-ring Brush holder Brush spring Bolt Brush assembly 1 1/1/4 1 1 4 1 1 7-31 Service points Not reusable As required Thickness = 0.2 mm, 0.
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ELEC – + STARTER MOTOR E EXPLODED DIAGRAM Step 18 19 20 Procedure/Part name Spacer Holder Starter motor yoke Q’ty 1 1 1 Service points Reverse the disassembly steps for assembly.
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ELEC – + STARTER MOTOR E SERVICE POINTS Armature inspection 1. Check: • Armature shaft 1 Damage/wear → Replace. 1 2. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 3. Measure: • Commutator diameter Out of specification → Replace. Minimum commutator diameter: 27.0 mm (1.06 in) 4. Check: • Commutator undercut Contaminants → Clean. NOTE: Use compressed air to remove all mica and metal particles. 5. Measure: • Commutator undercut Out of specification → Replace.
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ELEC – + STARTER MOTOR E 6. Check: • Armature coil continuity Out of specification → Replace. Armature coil continuity: Commutator segments 1 Continuity Segment – laminations 2 No continuity Segment – armature shaft No continuity Brush holder inspection 1. Measure: • Brush length a Out of specification → Replace. Minimum brush length: 6.5 mm (0.26 in) 2. Check: • Brush holder continuity Out of specification → Replace.
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ELEC – + CHARGING SYSTEM E CHARGING SYSTEM WIRING DIAGRAM 1 B R G G B G G G R 2 R R R G G G R G B G G G G G 3 4 1 2 3 4 Rectifier/regulator Fuse (20 A) Battery Lighting coil B G R 7-35 : Black : Green : Red
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ELEC – + CHARGING SYSTEM E FUSE Refer to “STARTING SYSTEM.” BATTERY Refer to “ELECTRICAL” in Chapter 3. LIGHTING COIL Refer to “IGNITION SYSTEM.” RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM.
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– ELEC + YPVS E YPVS WIRING DIAGRAM 7: 10 : 11 : 12 : 13 : B/O O W/Y W/B W/R 21 : 22 : 23 : 29 : 33 : L G P B B 1 B/O 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 32 33 34 35 10 11 12 13 14 15 16 17 18 19 B/O O O B/O B/O O B/O O B/O O B/O B/O 2 B R B B B R B B R 5 B R G G B G G G R B R 3 B B B B W/B B/O W/R W/Y G G G B B B/O B O L P G B/O G W/R W/Y W/B B B P G B/O O G W/R B L G G G G B W/R W/Y B W/B O B P 6 G L B PO 7 4 1 2 3 4 5 6
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ELEC – + YPVS E FUSE Refer to “STARTING SYSTEM.” BATTERY Refer to “ELECTRICAL” in Chapter 3. PICKUP COIL Refer to “IGNITION SYSTEM.” LIGHTING COIL Refer to “IGNITION SYSTEM.” RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM.
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ELEC – + YPVS SERVOMOTOR E YPVS SERVOMOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name YPVS SERVOMOTOR REMOVAL Bolt Cable holder YPVS servomotor coupler Nut/washer YPVS servomotor Throttle cable plastic tie bracket YPVS cable Q’ty 2 1 1 2/2 1 1 2 7-39 Service points Follow the left “Step” for removal. Slide the cover. Cable 2 is identifiable by its white paint mark a.
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ELEC – + YPVS SERVOMOTOR E EXPLODED DIAGRAM Step 8 9 10 Procedure/Part name Cover Nut/washer YPVS servomotor bracket Q’ty 1 3/3 1 Service points Reverse the removal steps for installation.
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ELEC – + YPVS SERVOMOTOR E SERVICE POINTS YPVS cable removal and installation 1. Remove: • YPVS cables 1 and 2 Removal steps: • Remove the YPVS cable holder 1. • Remove the YPVS cables 2 from both drums. NOTE: • YPVS cable 2 is identifiable by its white paint mark a. • When installing the YPVS cable, make sure that the YPVS cable locknuts 3 are fully turned in. YPVS cable inspection 1. Check: • YPVS cables 1 and 2 Frays/kinks/rough movement → Replace. YPVS servomotor inspection 1.
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– ELEC + OFF THROTTLE STEERING SYSTEM E OFF THROTTLE STEERING SYSTEM WIRING DIAGRAM 4: 7: 9: 10 : 11 : 12 : 13 : W/L B/O W/L O W/Y W/B W/R 15 : 16 : 17 : 18 : 27 : 29 : 31 : G/B G/R G G/Y R/Y B P 2 1 R/W Y/B B 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 10 11 12 13 14 15 16 17 18 19 Y/B R/Y R/Y 2 3 4 5 6 7 8 9 1 R/Y R/W B R/Y R/Y R/Y R/Y W/L B B W/L W/L B B R/Y B B B R/Y B W/L B R/Y B W/L B W/L R/Y B W/L R/Y B R/W O R/Y R/Y O Y/B O Y/B R/W B R/Y O R/Y
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ELEC – + OFF THROTTLE STEERING SYSTEM E STEERING SWITCH 1. Check: • Steering switch Refer to “SELF-DIAGNOSIS” in Chapter 9. Malfunction → Check that the steering switch switches on and off when the handlebar is turned to the right and to the left using the “Engine monitor” of the Yamaha Diagnostic System. Does not operate → Replace. STEPPING MOTOR 1. Check: • Check the operation of the stepping motor using the “Stationary test” of the Yamaha Diagnostic System. THROTTLE SWITCH 1.
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ELEC – + ELECTRIC BILGE PUMP E ELECTRIC BILGE PUMP WIRING DIAGRAM 2: Y 27 : R/Y Y 1 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 Br L/R 32 33 34 35 10 11 12 13 14 15 16 17 18 19 R/Y R/Y B L R R/Y R/Y 2 R/Y R/Y 76 3 2 R/Y 4 5 18 R/Y R R/Y Y 3 R/Y B Br B B B B B Br B B B R R 5 B B B B Br R/Y Br R/Y 4 1 2 3 4 5 R ECM Main and fuel pump relay Fuse (3 A) Battery Electric bilge pump B Br R Y R/Y 7-44 : Black : Brown : Red : Yellow : Red/yellow R
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ELEC – + ELECTRIC BILGE PUMP E ELECTRIC BILGE PUMP Br 1. Check: • Electric bilge pump operation Does not operate → Replace. B – Checking steps: • Suspend the electric bilge pump in a container filled with water. • Connect the brown lead terminal to the positive battery terminal. • Connect the black lead terminal to the negative battery terminal. • Check that the water flows from the electric bilge pump hose. + FUSE Refer to “STARTING SYSTEM.” BATTERY Refer to “ELECTRICAL” in Chapter 3.
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– ELEC + INDICATION SYSTEM E INDICATION SYSTEM WIRING DIAGRAM Y 1: 2: 5: 7: 8: G Y B/Y B/O B/L 20 : 27 : 29 : 32 : 33 : O R/Y B W/B B 1 Br L/R B R R 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 32 33 34 35 10 11 12 13 14 15 16 17 18 19 R/Y R/Y L R R/Y R/Y 2 R/Y 3 B R R R/Y 76 3 2 4 5 18 R/Y 5 4 R/Y R/Y R/Y R/Y Y B B B B B B B B B B B/Y B/O B 9 B B/O B/O Pu/R B R/Y W/B B P P P G/R B/Y G/Y O G/B B/O B/O R/Y G/Y B/Y G/R Pu/Y B/G R Pu/R
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– ELEC + INDICATION SYSTEM E WIRING DIAGRAM Y 1: 2: 5: 7: 8: G Y B/Y B/O B/L 20 : 27 : 29 : 32 : 33 : O R/Y B W/B B 1 Br L/R B R R 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 32 33 34 35 10 11 12 13 14 15 16 17 18 19 R/Y R/Y L R R/Y R/Y 2 R/Y 3 B R R R/Y 76 3 2 4 5 18 R/Y 5 4 R/Y R/Y R/Y R/Y Y B B B B B B B B B B B/Y B/O B 9 B B/O B/O Pu/R B R/Y W/B B P P P G/R B/Y G/Y O G/B B/O B/O R/Y G/Y B/Y G/R Pu/Y B/G R Pu/R Pu/B P B/O B
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ELEC – + INDICATION SYSTEM E FUSE Refer to “STARTING SYSTEM.” BATTERY Refer to “ELECTRICAL” in Chapter 3. ENGINE TEMPERATURE SENSOR Refer to “IGNITION SYSTEM.” COOLING WATER TEMPERATURE SENSOR Refer to “IGNITION SYSTEM.” EXHAUST TEMPERATURE SENSOR Refer to “IGNITION SYSTEM.” MAIN AND FUEL PUMP RELAY Refer to “IGNITION SYSTEM.” OIL LEVEL SENSOR 1. Measure: • Oil level sensor resistance Out of specification → Replace.
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ELEC – + INDICATION SYSTEM E BUZZER 1. Check: • Buzzer Buzzer does not sound → Replace. Checking steps: • Connect a 12 V battery to the buzzer coupler as shown. Positive battery terminal → Red (R) terminal 1 Negative battery terminal → Black (B) terminal 2 MULTIFUNCTION METER Multifunction meter 1. Check: • Multifunction meter Cracked meter housing → Replace the multifunction meter. Meter is fogged/shows signs of water intrusion → Replace the multifunction meter.
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ELEC – + INDICATION SYSTEM E Display function 1. Check: • Display function Does not operate → Replace the multifunction meter.
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ELEC – + INDICATION SYSTEM E Speedometer display 1. Check: • Speedometer display Does not display → Measure the speed sensor output voltage and pulses. 2. Measure: • Speed sensor output voltage and pulses Out of specification → Replace the speed sensor. Within specification → Replace the multifunction meter. Speed sensor output voltage (dependant on the paddle wheel position): Less than 400 mV More than 11.
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ELEC – + INDICATION SYSTEM E Hour meter display 1. Check: • Hour meter display Does not display → Replace the multifunction meter. Voltage meter display 1. Check: • Voltage meter display Does not display → Check the battery voltage using the “Engine monitor” of the Yamaha Diagnostic System. If there is no malfunction, replace the multifunction meter. Fuel level meter display and fuel warning indicator 1.
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ELEC – + INDICATION SYSTEM E Engine overheat warning indicator 1. Check: • Engine overheat warning indicator Does not operate → Replace the multifunction meter. 1 Checking steps: • Start the engine. • Disconnect the cooling water temperature sensor coupler 1. • Check that the warning light comes on and that the engine overheat warning indicator is displayed. Exhaust temperature warning indicator 1. Check: • Exhaust temperature warning indicator Does not operate → Replace the multifunction meter.
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ELEC – + INDICATION SYSTEM E Check engine warning indicator 1. Check: • Check engine warning indicator Does not operate → Replace the multifunction meter. Checking steps: • Start the engine. • Disconnect the coupler of a sensor (e.g., atmospheric pressure sensor) that normally activates the check engine warning indicator when a malfunction occurs. • Check that the warning light and check engine warning indicator blink and that the buzzer sounds intermittently. Diagnostic display 1.
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HULL HOOD E CHAPTER 8 HULL AND HOOD HANDLEBAR ..................................................................................................8-1 EXPLODED DIAGRAM .............................................................................8-1 REMOVAL AND INSTALLATION CHART ................................................ 8-1 SERVICE POINTS .................................................................................... 8-6 Handlebar inspection .......................................................
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HULL HOOD HOSES ..........................................................................................................8-27 EXPLODED DIAGRAM ...........................................................................8-27 REMOVAL AND INSTALLATION CHART .............................................. 8-27 SERVICE POINTS .................................................................................. 8-28 Check valve inspection .....................................................................
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HULL HOOD HANDLEBAR E HANDLEBAR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 10 Procedure/Part name HANDLEBAR COVER REMOVAL Screw Handlebar cover Screw Handlebar cover stay Plastic tie Throttle cable Bolt Upper handlebar holder Handlebar assembly Lower handlebar holder Q’ty Service points Follow the left “Step” for removal. 4 1 4 1 1 1 4 2 1 2 Reverse the removal steps for installation.
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HULL HOOD HANDLEBAR E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name HANDLEBAR REMOVAL QSTS cable (to jet thrust nozzle) Q’ty 1 Grommet 1 2 3 Handlebar switch coupler QSTS cable 2 2 1 4 QSTS cable 1 1 8-2 Service points Follow the left “Step” for removal. Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD.” NOTE: To ease installation, apply soapy water to the grommet. Cable 2 is identifiable by the white tape a wrapped around it.
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HULL HOOD HANDLEBAR E EXPLODED DIAGRAM Step 5 6 7 8 Procedure/Part name Handlebar assembly Nut/washer QSTS converter Throttle cable Q’ty 1 2/2 1 1 Service points Reverse the removal steps for installation.
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HULL HOOD HANDLEBAR E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 10 Procedure/Part name HANDLEBAR DISASSEMBLY Plastic tie Bolt Grip end Spacer Screw/spring washer/washer QSTS grip assembly Screw Handlebar switch assembly Spacer 1 Screw Q’ty 1 2 2 1 1/1/1 1 2 1 1 2 8-4 Service points Follow the left “Step” for disassembly.
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HULL HOOD HANDLEBAR E EXPLODED DIAGRAM Step 11 12 13 14 Procedure/Part name Throttle lever assembly Handlebar grip Spacer 2 Handlebar Q’ty 1 1 Service points NOTE: Apply adhesive to the handlebar and the inner surface of the handlebar grip. 1 1 Reverse the disassembly steps for assembly.
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HULL HOOD HANDLEBAR E SERVICE POINTS Handlebar inspection 1. Check: • Handlebar Bends/cracks/damage → Replace. Handlebar switch inspection Refer to “IGNITION SYSTEM” and “STARTING SYSTEM” in Chapter 7. Handlebar assembly installation 1. Adjust: • QSTS cable length a QSTS cable length: 72 ± 0.5 mm (2.83 ± 0.02 in) NOTE: • Before adjusting the QSTS cables, set the control grip to the neutral position. • Adjust the QSTS cables to the specified length a and be sure to take up any slack if necessary. 2.
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HULL HOOD HANDLEBAR E 3. Install: • Throttle cable NOTE: Fit the seal into the groove in the bracket. 4. Install: • Plastic tie 1 NOTE: After inserting the QSTS cables and throttle cable into the grommet, fasten the end of grommet with the plastic tie. 5. Install: • Handlebar cover 1 NOTE: When the handlebar cover is in contact with the steering console cover, adjust the handlebar mounting angle so that clearances a and b are equal. 6.
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HULL HOOD QSTS GRIP E QSTS GRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name QSTS GRIP DISASSEMBLY QSTS grip assembly Screw/washer Cover Ball Spring QSTS cable 1 QSTS cable 2 Q’ty 1/1 1 2 2 1 1 8-8 Service points Follow the left “Step” for disassembly. Refer to “HANDLEBAR.” Cable 2 is identifiable by the white tape a wrapped around it.
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HULL HOOD QSTS GRIP E EXPLODED DIAGRAM Step 7 8 9 10 11 12 13 Procedure/Part name Screw/washer Collar QSTS shift lock lever Spring Spacer QSTS cable housing cover QSTS shift grip Q’ty 2/2 1 1 1 1 1 1 Service points Reverse the disassembly steps for assembly.
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HULL HOOD QSTS GRIP E SERVICE POINTS QSTS cable inspection 1. Check: • QSTS cables Frays/kinks/rough movement → Replace. QSTS grip inspection 1. Check: • QSTS grip Damage/wear → Replace.
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HULL HOOD STEERING COLUMN E STEERING COLUMN EXPLODED DIAGRAM 16 N • m (1.6 kgf • m, 11 ft • Ib) 2 3 4 1 5 REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name STEERING COLUMN REMOVAL Steering console cover assembly Steering cable end Steering switch coupler Nut Plate Steering column assembly Rubber seal Q’ty Service points Follow the left “Step” for removal. Refer to “STEERING CONSOLE COVER.” Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD.
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HULL HOOD STEERING COLUMN E EXPLODED DIAGRAM 26 N • m (2.6 kgf • m, 19 ft • Ib) 13 8 1 11 10 12 9 8 × 60 mm 7 4 9 2 LT 242 6 5 16 N • m (1.6 kgf • m, 11 ft • Ib) 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 3 5.0 N • m (0.5 kgf • m, 3.
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HULL HOOD STEERING COLUMN E EXPLODED DIAGRAM 26 N • m (2.6 kgf • m, 19 ft • Ib) 13 8 1 11 10 12 9 8 × 60 mm 7 4 9 2 LT 242 6 5 16 N • m (1.6 kgf • m, 11 ft • Ib) 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 3 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib) 2 Step 9 10 11 12 13 Procedure/Part name Bushing Plastic tie Screw clamp Steering switch Steering column housing Q’ty 2 1 1 1 1 Service points Reverse the disassembly steps for assembly.
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HULL HOOD STEERING COLUMN E SERVICE POINTS Steering column bushing inspection 1. Check: • Bushings Damage/wear → Replace. 2. Check: • Steering column Refer to “CONTROL SYSTEM” in Chapter 3. Steering column assembly 1. Install: • Steering switch 1 • Screw clamp 2 • Plastic tie 3 2 1 3 4 NOTE: Fasten the steering switch lead 4 with the plastic tie 3 as shown in the illustration. 2.
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HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 Procedure/Part name REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL Speed sensor coupler Cap Nut Screw Speed sensor Steering cable end Bolt Steering cable holder Nut Q’ty 1 1 1 4 1 1 1 1 1 8-15 Service points Follow the left “Step” for removal.
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HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD E EXPLODED DIAGRAM Step 10 11 12 13 14 15 16 17 Procedure/Part name Seal Steering cable Nut Pin QSTS cable end Nut Seal QSTS cable Q’ty 1 1 1 1 1 1 1 1 Service points Reverse the removal steps for installation.
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REMOTE CONTROL CABLES AND SPEED SENSOR LEAD HULL HOOD E SERVICE POINTS WARNING When routing the cables, do not grasp the cable by the outer crimped sheath or steel end. This could deform or loosen the cable end due to extreme angles and or pressure. Always hold the cables by the bracket or outer cover below the crimp. If a cable becomes damaged, replace it. Never attempt to repair a damaged cable. Remote control cable inspection 1.
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HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD E QSTS cable installation 1. Install: • QSTS cable (jet pump end) QSTS cable set length a (jet pump end): 12.0–14.0 mm (0.47–0.55 in) WARNING The QSTS cable must be screwed in a minimum of 8 mm (0.31 in). QSTS cable stopper installation 1. Install: • QSTS cable stopper WARNING Be sure to fit the projection 1 on the QSTS cable stopper into the groove in the outer cable.
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HULL HOOD HOOD E HOOD EXPLODED DIAGRAM 6 × 14 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 7 6 × 14 mm 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 1 11 2 3 4 5 8 5 × 20 mm 1.0 N • m (0.1 kgf • m, 0.7 ft • Ib) 10 9 16 N • m (1.6 kgf • m, 11 ft • Ib) REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name HOOD REMOVAL Bolt Screw Seal washer Visor Pop nut Bolt Hood lock Hood Q’ty 2 8 8 1 8 2 1 1 8-19 Service points Follow the left “Step” for removal.
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HULL HOOD HOOD E EXPLODED DIAGRAM 6 × 14 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 7 6 × 14 mm 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 1 11 2 3 4 5 8 5 × 20 mm 1.0 N • m (0.1 kgf • m, 0.7 ft • Ib) 10 9 16 N • m (1.6 kgf • m, 11 ft • Ib) Step 9 10 11 Procedure/Part name Nut Plate Hinge assembly Q’ty 2 1 1 Service points Reverse the removal steps for installation.
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HULL HOOD STEERING CONSOLE COVER E STEERING CONSOLE COVER EXPLODED DIAGRAM 8 × 25 mm 8 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 5 × 19 mm 5 9 6 4 2 2.9 N • m (0.29 kgf • m, 2.1 ft • Ib) 6 × 25 mm 3 1 7 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 16 N • m (1.
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HULL HOOD STEERING CONSOLE COVER E EXPLODED DIAGRAM 8 × 25 mm 8 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 5 × 19 mm 5 9 6 4 2 2.9 N • m (0.29 kgf • m, 2.1 ft • Ib) 6 × 25 mm 3 1 7 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) Step 7 8 9 Procedure/Part name Nut/washer Bolt/square ring Steering console cover assembly 16 N • m (1.6 kgf • m, 11 ft • Ib) Q’ty 2/2 2/2 1 Service points NOTE: To ease removal, remove the oil filler cap. Reverse the removal steps for installation.
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HULL HOOD STEERING CONSOLE COVER E EXPLODED DIAGRAM 1.3 N • m (0.13 kgf • m, 0.9 ft • Ib) 5 × 20 mm 5 6 2 9 1 8 2.9 N • m (0.29 kgf • m, 2.1 ft • Ib) 6 × 18 mm 2 7 4 3 1.8 N • m (0.18 kgf • m, 1.3 ft • Ib) REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name STEERING CONSOLE COVER DISASSEMBLY Screw Side cover Nut Holder Multifunction meter Screw Q’ty 4 2 2 1 1 4 8-23 Service points Follow the left “Step” for disassembly.
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HULL HOOD STEERING CONSOLE COVER E EXPLODED DIAGRAM 1.3 N • m (0.13 kgf • m, 0.9 ft • Ib) 5 × 20 mm 5 6 2 9 1 8 2.9 N • m (0.29 kgf • m, 2.1 ft • Ib) 6 × 18 mm 2 7 4 3 Step 7 8 9 1.8 N • m (0.18 kgf • m, 1.3 ft • Ib) Procedure/Part name Glove compartment Pop nut Steering console cover Q’ty 1 4 1 Service points Reverse the disassembly steps for assembly.
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HULL HOOD BUZZER AND HOOD LOCK E BUZZER AND HOOD LOCK EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name BUZZER AND HOOD LOCK REMOVAL Steering console cover assembly Steering cable Ring nut Buzzer Bolt Bracket Bracket Nut Q’ty Service points Follow the left “Step” for removal. Refer to “STEERING CONSOLE COVER.” Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD.
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HULL HOOD BUZZER AND HOOD LOCK E EXPLODED DIAGRAM Step 7 8 9 10 11 Procedure/Part name Bolt Hood lock assembly Grommet Atmospheric pressure sensor coupler Atmospheric pressure sensor Q’ty 2 1 1 1 Service points 1 Reverse the removal steps for installation.
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HULL HOOD HOSES E HOSES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name HOSE REMOVAL Engine unit Steering console cover assembly Plastic tie Ventilation hose Ventilation duct Plastic tie Check valve Oil tank breather hose Fuel tank breather hose Q’ty Service points Follow the left “Step” for removal. Refer to “ENGINE UNIT” in Chapter 5. Refer to “STEERING CONSOLE COVER.” 4 2 2 1 1 1 2 Reverse the removal steps for installation.
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HULL HOOD HOSES E SERVICE POINTS Check valve inspection 1. Check: • Check valve Faulty → Replace. Checking steps: • Connect a hose to end “A” of the check valve, and then blow into the hose. Air should come out from end “B.” • Connect the hose to end “B” of the check valve, and then blow into the hose. Air should not come out from end “A.” Ventilation hose installation 1.
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HULL HOOD SEAT AND HANDGRIP E SEAT AND HANDGRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name SEAT AND HANDGRIP REMOVAL Seat Bolt Seat lock Nut Projection Washer Rubber ring Nut/washer Q’ty 1 2 1 1 1 1 1 2/2 8-29 Service points Follow the left “Step” for removal.
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HULL HOOD SEAT AND HANDGRIP E EXPLODED DIAGRAM Step 9 10 11 12 Procedure/Part name Bolt Bolt Handgrip Bracket Q’ty 2 2 1 1 Service points Reverse the removal steps for installation.
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HULL HOOD SEAT AND HANDGRIP SERVICE POINTS Seat lock inspection 1. Check: • Seat lock Damage/wear → Replace.
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HULL HOOD BATTERY BOX E BATTERY BOX EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 10 11 Procedure/Part name BATTERY BOX REMOVAL Battery band Fire extinguisher container Battery band Bolt Negative battery lead Terminal extension Bolt Positive battery lead Clip/breather hose Battery Bolt Q’ty 1 1 1 1 1 1 1 1 1/1 1 1 8-32 Service points Follow the left “Step” for removal.
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HULL HOOD BATTERY BOX E EXPLODED DIAGRAM Step 12 13 14 15 16 17 18 19 Procedure/Part name Cap nut/washer/bolt Electrical box Cap nut/washer Holder Holder Cap nut/washer Battery box Stay Q’ty 2/2/2 1 2/2 1 1 2/2 1 Service points NOTE: Before installing the battery box, route the battery leads and battery breather hose through the holes in the battery box. 1 Reverse the removal steps for installation.
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HULL HOOD EXHAUST SYSTEM E EXHAUST SYSTEM EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 30 mm 11 5 7 10 4 8 6 8 1 4 9 13 2.5 N • m (0.25 kgf • m, 1.
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HULL HOOD EXHAUST SYSTEM E EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 30 mm 11 5 7 10 4 8 6 8 1 4 9 13 2.5 N • m (0.25 kgf • m, 1.8 ft • Ib) 3 2 12 Step 8 9 10 11 12 13 Procedure/Part name Hose screw clamp Water tank Rubber hose Exhaust outlet Water lock band Water lock Q’ty 2 1 1 1 1 1 Service points NOTE: Remove parts 8 to 11 as a set. Reverse the removal steps for installation.
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HULL HOOD EXHAUST SYSTEM E SERVICE POINTS Exhaust system inspection 1. Check: • Water lock band Cracks/damage → Replace. 2. Check: • Rubber hoses Burns/cracks/damage → Replace. 3. Check: • Water lock Cracks/leaks → Replace. 4. Check: • Water tank Cracks/damage/leaks → Replace. Water lock installation 1. Install: • Water lock 1 • Water lock band a 1 2 NOTE: Install the water lock so that it is 0–5 mm (0– 0.2 in) a high in relation to the bulkhead 2.
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HULL HOOD EXHAUST SYSTEM E Exhaust component parts assembly 1. Install: • Exhaust outlet • Rubber hose • Water tank NOTE: • Insert the exhaust outlet 45–50 mm (1.77– 1.97 in) a into the rubber hose. • Make sure that there is a distance of 10 mm (0.39 in) b between the parting lines of the exhaust outlet and the rubber hose. • Insert the water tank 45–50 mm (1.77–1.97 in) c into the rubber hose. • Make sure that there is a distance of 45 mm (1.
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HULL HOOD DECK AND HULL E DECK AND HULL EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name DECK AND HULL DISASSEMBLY Bolt Bow eye Nut Rope hole fitting Nut Spout Bolt Sponson Q’ty 2 1 2 2 1 1 6 2 8-38 Service points Follow the left “Step” for disassembly. NOTE: Install the starboard and port side sponsons at the same position.
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HULL HOOD DECK AND HULL E EXPLODED DIAGRAM Step 9 10 11 12 13 14 Procedure/Part name Bolt Flap Nut/washer Screw/washer Drain plug Seal Q’ty 8 2 4/4 4/4 2 2 Service points Reverse the disassembly steps for assembly.
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HULL HOOD ENGINE MOUNTS E ENGINE MOUNTS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name ENGINE MOUNT REMOVAL Engine unit Bolt Damper 1 Damper 2 Bolt Engine mount Liner Q’ty Service points Follow the left “Step” for removal. Refer to “ENGINE UNIT” in Chapter 5. 4 1 1 8 4 4 Reverse the removal steps for installation.
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TRBL ANLS E CHAPTER 9 TROUBLE ANALYSIS INTRODUCTION.............................................................................................. 9-1 FEATURES ............................................................................................... 9-1 Functions............................................................................................. 9-1 CONTENTS............................................................................................... 9-1 HARDWARE REQUIREMENTS...............
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TRBL ANLS INTRODUCTION E INTRODUCTION FEATURES The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ECM (Electronic Control Module) of a watercraft using the communication cable, this software can be used to display sensor data and data stored in the ECM on a computer’s monitor.
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TRBL ANLS INTRODUCTION E HARDWARE REQUIREMENTS Make sure that your computer meets the following requirements before using this software.
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TRBL ANLS OPERATING E OPERATING CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT Model: GP1300R Top view 1 2 3 1 3-pin communication coupler 2 Wire harness coupler 3 Multifunction meter coupler NOTE: Be careful not to pinch the communication cable between the hood and the deck or to damage it.
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TRBL ANLS TROUBLE ANALYSIS E 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 connected to the engine shut-off switch. 5. Check that fuel is reaching the throttle bodies.
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TRBL ANLS TROUBLE ANALYSIS YPVS SERVOMOTOR DOES NOT OPERATE POOR BATTERY CHARGING IRREGULAR WARNING INDICATION BILGE WATER ACCUMULATION LOOSE STEERING Check items OVERHEATING LIMITED ENGINE SPEED POOR PERFORMANCE ENGINE WILL NOT STOP POOR ACCELERATION ENGINE STALLS HIGH IDLING ROUGH IDLING HARD STARTING ENGINE WILL NOT START Symptom E Applicable part Chapter JET PUMP UNIT Impeller duct Impeller Intake grate Bearings Intake duct Water inlet hose Bilge hoses Bilge strainer Bilge hose joi
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TRBL ANLS TROUBLE ANALYSIS YPVS SERVOMOTOR DOES NOT OPERATE POOR BATTERY CHARGING IRREGULAR WARNING INDICATION BILGE WATER ACCUMULATION LOOSE STEERING Check items OVERHEATING LIMITED ENGINE SPEED POOR PERFORMANCE ENGINE WILL NOT STOP POOR ACCELERATION ENGINE STALLS HIGH IDLING ROUGH IDLING HARD STARTING ENGINE WILL NOT START Symptom E Applicable part Starting system • Start switch • Starter relay • Starter motor YPVS • YPVS unit Charging system • Lighting coil • Rectifier/regulator • Fu
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TRBL ANLS TROUBLE ANALYSIS E SELF-DIAGNOSIS With the engine running, press the select button 1 for 8 seconds and check if an error code is indicated on the multifunction meter.
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GP1300R 3 O P B L P 2 È B B B/O B/O B G L G L 5 5 #2 R/Y = B R R R B/R B/O B/O B/O B/O B/O B/O B/O B/O B/O B/O B/Y B/W A B B B B B O 6 77 B/O G P L B B B B G B B/R Y W 35 34 33 19 18 17 16 15 14 B/Y B/W B B B B B W/L B/Y B/G B/O B/L W/L R/Y R R/Y B B Br R 9 B R G G B Br Br R 32 O W/Y W/B W/R B RGGG L/R G/B G/R G G/Y B/R O L G P Pu/Y Pu/B Pu/R R/Y 9 8 7 6 5 4 3 2 B P/G P W/B L/B B 1 31 30 29 28 27 26 25 24 23 22 21 20 13 12 11 10 1 R/Y R R R O P B/O
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WIRING DIAGRAM GP1300R 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R S T U V W X ECM Atmospheric pressure sensor YPVS servomotor Spark plugs Ignition coils Fuse (20 A) Fuses (3 A) Main and fuel pump relay Starter relay Starter motor Battery Rectifier/regulator Throttle switch Electrical bilge pump Exhaust temperature sensor Cooling water temperature sensor Throttle position sensor Fuel injectors Engine temperature sensor Stepping motor Intake air temperature sensor Lighting coil Pickup coil Steer
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YAMAHA MOTOR CORPORATION, USA Printed in USA Feb. 2003 – 0.