WaveRunnerGP1200R SERVICE MANUAL *LIT186160215* LIT-18616-02-15 F0X-28197-ZA-11
E NOTICE This manual has been prepared by the Yamaha Motor Company Ltd. 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.
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.
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, a bystander, or a person inspecting or repairing the water vehicle. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the water vehicle.
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.
E 1 A50001-1-4 2 GEN INFO SYMBOLS Symbols 1 to 9 are designed as thumbtabs to indicate the content of a chapter.
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
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.)..............................................
GEN INFO IDENTIFICATION NUMBERS E A60700-0* IDENTIFICATION NUMBERS PRIMARY l.D. NUMBER The primary l.D. number is stamped on a label attached to the inside of the engine compartment. Starting primary l.D. number: F0X: 800101 ~ ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the cylinder head. Starting serial number: 67X: 000101 ~ JET PUMP UNIT SERIAL NUMBER The jet pump unit serial number is stamped on a label attached to the intermediate housing.
GEN INFO SAFETY WHILE WORKING E SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be followed by Yamaha dealers and their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling gasoline (petrol) and keep it away from heat, sparks, and open flames. VENTILATION Petroleum vapor is heavier than air and is deadly if inhaled in large quantities.
GEN INFO SAFETY WHILE WORKING E Under normal conditions of use there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all-important, and by adopting good safety practises any risk is minimized. A summary of the most important precautions is as follows: 1. While working, maintain good standards of personal and industrial hygiene. 2. Clothing which has become contaminated with lubricants should be changed as soon as practicable and laundered before further use. 3.
GEN INFO SAFETY WHILE WORKING E 3. Non-reusable items Always use new gaskets, packings, Orings, oil seals, split-pins, circlips, etc., on reassembly. DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed air when disassembling. 2. Oil the contact surfaces of moving parts during assembly. 3. After assembly, check that moving parts operate normally. 4. Install bearings with the manufacturer’s markings on the side exposed to view and liberally oil the bearings.
GEN INFO SPECIAL TOOLS E SPECIAL TOOLS Using the correct special tools recommended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvisations and using improper tools can damage the equipment. 1 YU-08036-A NOTE: ● For U.S.A. and Canada, use part numbers starting with “J-”, “YB-”, “YM-”, “YU-” or “YW-”. ● For other countries, use part numbers starting with “90890-”. 90890-06760 MEASURING 2 YU-03097 1. Engine tachometer P/N. YU-08036-A 90890-06760 2.
GEN INFO 1 SPECIAL TOOLS 2 YW-06551 E REMOVAL AND INSTALLATION YW-06550 90890-06550 1. Coupler wrench P/N. YW-06551 90890-06551 2. Flywheel holder P/N. YW-06550 90890-06550 3. Flywheel puller P/N. YB-06117 90890-06521 4. Drive shaft holder (impeller) P/N. YB-06151 90890-06519 5. Slide hammer set (jet pump bearing) P/N. YB-06096 6. Stopper guide plate (jet pump bearing) P/N. 90890-06501 7. Bearing puller (jet pump bearing) P/N. 90890-06535 8. Bearing puller claw 1 (jet pump bearing) P/N. 90890-06536 9.
SPEC E CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ......................................................................... 2-1 MAINTENANCE SPECIFICATIONS................................................................ 2-3 ENGINE .................................................................................................... 2-3 JET PUMP UNIT ...................................................................................... 2-4 HULL AND HOOD ...................................................
SPEC GENERAL SPECIFICATIONS E GENERAL SPECIFICATIONS Item MODEL CODE Hull Engine DIMENSIONS Length Width Height Dry weight Vehicle capacity PERFORMANCE Maximum output Maximum fuel consumption Cruising range ENGINE Engine type Number of cylinders Displacement Bore × stroke Compression ratio Intake system Carburetor model (manufacturer) × quantity Enrichment control Scavenging system Lubrication system Cooling system Starting system Ignition system Ignition timing Spark plug model (manufacturer) Battery ca
SPEC GENERAL SPECIFICATIONS Item FUEL AND OIL Fuel Minimum fuel rating Oil Fuel/oil mixing ratio (wide open throttle) Fuel tank capacity Fuel tank reserve capacity Oil tank capacity E Model GP1200R Unit Regular unleaded gasoline 86 90 YAMALUBE 2-W* 30:1 PON* RON* R(US gal, Imp gal) R(US gal, Imp gal) R(US gal, Imp gal) 60 (15.9, 13.2) 10 (2.6, 2.2) 5.5 (1.45, 1.
SPEC MAINTENANCE SPECIFICATIONS E MAINTENANCE SPECIFICATIONS ENGINE Item CYLINDER HEAD Warpage limit Compression pressure*1 CYLINDERS Bore size Taper limit Out-of-round limit Wear limit PISTONS Diameter Measuring point* Piston-to-cylinder clearance Wear limit Piston pin bore inside diameter PISTON RINGS Top Type Dimensions (B) Dimensions (T) End gap Ring groove clearance 2nd Type Dimensions (B) Dimensions (T) End gap Ring groove clearance PISTON PINS Diameter Wear limit Unit Model GP1200R mm (in) KPa
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 CARBURETORS Type Identification mark Main nozzle Main jet Pilot jet Throttle valve Valve seat size Trolling speed REED VALVES Thickness Reed valve stopper height Reed valve warpage limit E Unit Model GP1200R 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) 0.25 ~ 0.75 (0.010 ~ 0.030) 2.0 (0.
SPEC MAINTENANCE SPECIFICATIONS E ELECTRICAL Item BATTERY Type Capacity CDI UNIT (B/O – B for cylinder #1) (B/W – B for cylinder #2) (B/Y – B for cylinder #3) Output peak voltage lower limit @cranking 1 @cranking 2 @2,000 r/min @3,500 r/min STATOR Pickup coil (W/R – B/O) Output peak voltage lower limit @cranking 1 @cranking 2 @2,000 r/min @3,500 r/min Lighting coil (G – G) Output peak voltage lower limit @cranking 1 @cranking 2 @2,000 r/min @3,500 r/min Pickup coil resistance Lighting coil resistance Min
SPEC MAINTENANCE SPECIFICATIONS Item RECTIFIER/REGULATOR (R – B) Output peak voltage lower limit (unloaded) @cranking @2,000 r/min @3,500 r/min STARTER MOTOR Brush length Wear limit Commutator undercut Limit Commutator diameter Limit FUSE Rating E Unit Model GP1200R V V V 7 12.6 12.6 mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) 12.5 (0.49) 6.5 (0.26) 0.7 (0.03) 0.2 (0.01) 28.0 (1.10) 27.0 (1.
SPEC TIGHTENING TORQUES E TIGHTENING TORQUES SPECIFIED TORQUES 28 Bolt M8 4 Bolt M10 10 Nut M10 2 Bolt M6 6 17 22 39 15 39 12 1.7 2.2 3.9 1.5 3.9 1.2 12 16 28 11 28 8.7 Bolt M6 18 12 1.2 8.7 Screw M4 24 1 0.1 0.7 Bolt M6 2 10 1.0 7.2 Bolt Bolt Bolt Bolt M6 M4 M5 M14 10 3 3 3 Bolt M8 22 10 3 4 25 22 22 35 1.0 0.3 0.4 2.5 2.2 2.2 3.5 7.2 2.2 2.9 18 16 16 25 2-7 LT 3.9 242 39 LT 6 271 M10 LT Bolt 271 2 28 11 25 LT M8 3.9 1.5 3.
TIGHTENING TORQUES 12 12 5.1 11 11 5.1 53 Impeller — 1 18 1.8 13 Nut Bolt Coupling Screw — M8 — — 4 3 1 4 26 17 36 4 2.6 1.7 3.6 0.4 19 12 25 2.9 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 — 2 5 0.5 3.6 Screw M5 2 3 0.3 2.2 Screw M5 2 3 0.3 2.2 Screw M6 1 3 0.3 2.2 2-8 LT 1.7 1.7 0.7 1.5 1.5 0.7 7.4 572 17 17 7 15 15 7 74 LT 4 4 4 2 2 4 1 271 M8 M8 M6 M8 M8 M6 — LT Bolt Bolt Bolt Bolt Bolt Bolt Nut 271 5.
SPEC TIGHTENING TORQUES Part to tightened Grip end – handlebar Choke lever assembly – handlebar QSTS cable housing – cover Plate/steering column assembly – deck Steering column – deck Steering arm – steering column QSTS cable locknut (nozzle ring side) – hull QSTS cable – hull QSTS cable – QSTS converter Steering cable locknut (nozzle deflector side) – hull Steering cable – hull Steering cable holder – bracket Speed sensor lead – hull Hinge assembly – front hood Wind shield – front hood Hood lock – front
TIGHTENING TORQUES Nut A Bolt B 8 mm 10 mm 12 mm 14 mm 17 mm M5 M6 M8 M10 M12 Tightening torque Nm m•kgf ft•lb 17 1.7 12 17 1.7 12 5 0.5 3.6 Remarks LT Bolt Bolt Bolt Thread Q’ty size M8 6 M8 2 M6 4 572 Engine mount – hull Engine mount/plate – hull Engine damper – hull Part name LT Part to tightened E 572 SPEC GENERAL TORQUE General torque specifications Nm m•kgf ft•lb 5.0 0.5 3.6 8.0 0.8 5.8 18 1.8 13 36 3.6 25 43 4.
SPEC CABLE AND HOSE ROUTING E CABLE AND HOSE ROUTING 2 A C A B 2 C GE D G 1 B D D E E J 20˚ E 2 I 2 C A G 2 G 3 B J I D-D I 4 6 7 A I-I H H G H G F E-E 5 I 0 E 9 6 6 7 C H-H Fuel filter Fuel breather hose Fuel hose Pilot water hose Bilge hose Speed sensor lead Electrical box lead Starter motor lead F-F F 8 1 2 3 4 5 6 7 8 F G-G 9 0 A B C D E F Generator lead Battery negative lead YPVS cable Pilot water outlet QSTS cable Choke cable Battery Steering cable 2-
SPEC CABLE AND HOSE ROUTING E 6 E E B A 1 2 C I 2 F F D 3 4 5 E-E 1 A H J B G D C G F H G D F G D F I-I 1 2 3 4 5 6 7 8 Choke cable Steering cable Cooling water hose QSTS cable Speed sensor lead Bilge hose Flushing hose Electrical box 4 H 9 2 5 8 8 I I I I I A B 9 C K0 D 7 I FE H 9 0 A B C D E To stator assembly To water temperature sensor To cylinder #1 To cylinder #2 To cylinder #3 To meter To battery positive terminal 2-12 G 5 F-F F To starter motor positive
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 ...............
INSP ADJ MAINTENANCE INTERVAL CHART E MAINTENANCE INTERVAL CHART The following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the intervals of maintenance should be changed.
INSP ADJ CONTROL SYSTEM E PERIODIC SERVICE CONTROL SYSTEM Steering column inspection 1. Inspect: ● Steering column Excessive play → Replace the steering column. Refer to “STEERING COLUMN” in chapter 8. Inspection steps: ● Move the handlebar up and down and back and forth. ● Check the excessive play of the handlebar. Steering cable inspection and adjustment 1. Inspect: ● Distance a, b Out of specification → Adjust. Inspection steps: ● Turn the handlebar from lock to lock. ● Measure distances a and b.
INSP ADJ CONTROL SYSTEM E WARNING The cable joint must be screwed in more than 8 mm (0.31 in). ● Connect the cable joint and tighten the locknut. T. Locknut: 6 Nm (0.6 m • kgf, 4.3 ft • lb) R NOTE: If the steering cable cannot be properly adjusted at the steering column side, make sure the steering cable at the jet pump side is set to the specified length. Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD” in chapter 8.
INSP ADJ CONTROL SYSTEM E WARNING After adjusting the free play, turn the handlebar to the right and left and make sure that the trolling speed does not increase. Choke cable inspection and adjustment 1. Check: ● Choke lever operation Incorrect operation → Adjust. Checking steps: ● Check that the choke lever moves back slightly when it is fully opened. ● Check that the inner cable has some slack when the choke lever is completely closed. 2.
INSP ADJ CONTROL SYSTEM E QSTS cable inspection and adjustment 1. Measure: ● Nozzle deflector set length a, b Difference → Adjust. Measurement steps: ● Set the control grip in the neutral position. ● Measure the nozzle deflector set length a and b. ● If a and b length are not even, adjust the cable joint. 2. Adjust: ● QSTS cable Adjustment steps: ● Set the control grip in the neutral position. ● Loosen the locknut 1. ● Remove the nut 2 and pivot pin 3. ● Set the jet nozzle in the center position.
INSP ADJ CONTROL SYSTEM E NOTE: If correct adjustment by using the cable joint at the wheel end is not obtained, adjust the cable joint on the trim nozzle end. Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD” in chapter 8. YPVS cable adjustment 1. Check: ● YPVS valve position Incorrect position → Adjust the YPVS cable. Checking steps: ● Start the engine and then stop it. NOTE: When the engine has been stopped for 3 seconds, the YPVS valve assembly will extend and retract one time.
INSP ADJ CONTROL SYSTEM/FUEL SYSTEM E 3. Adjust: ● YPVS cables 1 and 2 4 1 3 2 Adjustment steps: Loosen locknuts 1 and 2. ● Turn in the adjuster 3 and 4 until there is slack in the cable. ● Align the hole a in the pulley with the hole in the cylinder. ● Insert a 4-mm-diameter pin through the holes in the pulley and cylinder. ● Turn the adjuster 3 and 4 in or out until the specified slack is obtained. ● Turn in Slack is increased. Turn out Slack is decreased.
INSP ADJ FUEL SYSTEM E 2. Inspect: ● Water separator 1 Water accumulation → Drain. NOTE: If need the water draining, remove the drain plug 2. Trolling speed check and adjustment 1. Check: ● Trolling speed Out of specification → Adjust. Trolling speed: 1,350 ± 50 r/min Checking steps (with the vehicle in the water): ● Start the engine and allow it to warm up for several minutes. ● Attach the engine tachometer to the spark plug lead.
INSP ADJ OIL INJECTION SYSTEM/POWER UNIT E OIL INJECTION SYSTEM Oil line inspection Refer to “OIL TANK” in chapter 4. POWER UNIT Spark plug inspection 1. Inspect: ● Electrodes 1 Damage/wear → Replace. ● Insulator color 2 Distinctly different color → Check the engine condition. Color guide: Medium to light tan color: Normal Whitish color: Lean fuel mixture Air leak Incorrect settings Blackish color: Overly rich mixture Electrical malfunction Excessive oil use Defective spark plug 2.
INSP ADJ POWER UNIT/ELECTRICAL E 4. Tighten: ● Spark plug T. Spark plug: 25 Nm (2.5 m • kgf, 18 ft • lb) R NOTE: ● Before installing the spark plug, clean the gasket surface and spark plug surface. Also, it is suggested to apply a thin film of anti-seize compound to the spark plug threads to prevent thread seizure.
INSP ADJ ELECTRICAL E Batteries generate explosive, hydrogen gas. Always follow these preventive measures: ● Charge batteries in a well-ventilated area. ● Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). ● DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. CAUTION: ● Do not place the battery on its side. adding electrolyte or recharging, be sure to remove the battery from the battery box.
INSP ADJ ELECTRICAL E 2. Inspect: ● Electrolyte level Low → Add distilled water. The electrolyte level should be between the upper a and lower b level marks. Filling steps: Remove each filler cap. ● Add distilled water. ● When the electrolyte level reaches the upper level mark, allow the cell to stand for 20 minutes. If the electrolyte level drops, add more distilled water so the level reaches the upper level mark. ● CAUTION: Use only distilled water.
INSP ADJ ELECTRICAL/JET PUMP UNIT E 5. Install: ● Battery breather hose 1 ● Battery ● Battery positive lead 2 ● Battery negative lead 3 ● Band 3 2 CAUTION: 1 ● Connect the positive lead to the battery terminal first. ● Make sure the battery leads are connected properly. Reversing the leads can seriously damage the electrical system. ● Make sure that the battery breather hose is properly connected and is not obstructed.
INSP ADJ JET PUMP UNIT/GENERAL E Water inlet strainer inspection 1. Inspect: ● Water inlet strainer Contaminants → Clean. Cracks/damage → Replace. a Inspection steps: Remove the water inlet cover 1. ● Inspect the water inlet strainer mesh a. ● Install the water inlet cover. ● 1 Bilge strainer inspection 1. Inspect: ● Bilge strainer Contaminants → Clean. Cracks/damage → Replace. Inspection steps: ● Disconnect the bilge strainer 1 from the bilge strainer holder. ● Inspect the bilge strainer.
INSP ADJ GENERAL E Lubrication points 1. Lubricate: ● Throttle cable (handlebar side) Recommended lubricant: Rust inhibitor NOTE: Before lubricating the throttle cable, squeeze the throttle lever and remove the rubber seal 1. 2. Lubricate: ● QSTS control cables (handlebar side) Recommended lubricant: Yamaha marine grease, Yamaha grease A (Water resistant grease) NOTE: Before lubricating the QSTS control cables, remove the QSTS cable housing cover.
INSP ADJ GENERAL E 4. Lubricate: ● Throttle cable (carburetor side) ● Oil pump cable ● QSTS cables (pulley side) ● YPVS cables Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) 5.
INSP ADJ GENERAL E 6. Lubricate: ● Steering cable ● Steering cable joint NOTE: Disconnect the joints and apply a small amount of grease. Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) 7. Fill: ● Intermediate housing Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) NOTE: Fill the intermediate housing with the recommended grease through the grease nipples.
FUEL E CHAPTER 4 FUEL SYSTEM FUEL COCK AND FUEL FILTER ..................................................................... 4-1 EXPLODED DIAGRAM ............................................................................. 4-1 REMOVAL AND INSTALLATION CHART ............................................... 4-1 SERVICE POINTS ..................................................................................... 4-2 Fuel filter inspection .......................................................................
FUEL E CARBURETOR .............................................................................................. 4-18 EXPLODED DIAGRAM ........................................................................... 4-18 REMOVAL AND INSTALLATION CHART ............................................. 4-18 SERVICE POINTS ................................................................................... 4-21 Diaphragm inspection ....................................................................
FUEL FUEL COCK AND FUEL FILTER E FUEL COCK AND FUEL FILTER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name FUEL COCK AND FUEL FILTER REMOVAL Screw Knob Nut Fuel cock assembly Fuel hose Holder Fuel filter Fuel hose Q’ty Service points Follow the left “Step” for removal. 1 1 1 1 3 1 1 1 Reverse the removal steps for installation.
FUEL FUEL COCK AND FUEL FILTER E SERVICE POINTS Fuel filter inspection Refer to “FUEL SYSTEM” in chapter 3. Fuel cock inspection 1. Check: ● Fuel cock Contaminants → Clean. Rough movement → Replace.
FUEL OIL TANK E OIL TANK EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name OIL TANK REMOVAL Engine unit Steering console cover assembly Oil level sensor coupler Band Nut Oil filler neck Rubber seal Q’ty 1 1 1 1 1 4-3 Service points Follow the left “Step” for removal. Refer to “ENGINE UNIT” in chapter 5. Refer to “STEERING CONSOLE COVER” in chapter 8.
FUEL OIL TANK E EXPLODED DIAGRAM Step 6 7 8 9 10 11 12 13 Procedure/Part name Breather hose Oil hose Bolt Tank belt Oil tank assembly Hose 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.
FUEL OIL TANK E SERVICE POINTS Oil line inspection 1. Inspect: ● Oil filter Contaminants → Clean. Frays/tears → Replace. ● Rubber seal Cracks/wear → Replace. ● Oil hose ● Oil tank ● Oil filler cap Cracks/damage → Replace. ● Check valve Malfunction → Replace. Oil level switch inspection Refer to “INDICATION SYSTEM” in chapter 7. Oil tank inspection 1. Inspect: ● Oil tank Cracks/damage → Replace.
FUEL FUEL TANK E FUEL TANK EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name FUEL TANK REMOVAL Oil tank Fuel level sensor coupler Hose clamp Nut Fuel filler neck Rubber seal Fuel reserve hose Q’ty 1 1 1 1 1 1 4-6 Service points Follow the left “Step” for removal. Refer to “OIL TANK”.
FUEL FUEL TANK E EXPLODED DIAGRAM Step 7 8 9 10 11 12 13 14 Procedure/Part name Fuel hose Fuel return hose Fuel breather hose Fuel tank assembly Hose clamp Fuel filler hose Hose clamp Fuel sensor assembly Q’ty 1 1 1 1 1 1 1 1 4-7 Service points Red mark a
FUEL FUEL TANK E EXPLODED DIAGRAM Step 15 16 17 18 19 20 21 22 Procedure/Part name One way valve Screw/washer Filter Screw/washer Sleeve Floatation Bolt Tank bolt Q’ty 1 1/1 1 1/1 1 1 2 2 Service points Reverse the removal steps for installation.
FUEL FUEL TANK E SERVICE POINTS A B A B Check valve inspection 1. Check: ● Check valve Faulty → Replace. Checking steps: ● Connect a hose to the end of check valve “A” and blow into it. Air should come out from end “B”. ● Connect the hose to the end of check valve “B” and blow into it. Air should not come out from end “A”. Fuel level switch inspection Refer to “INDICATION SYSTEM” in chapter 7. Fuel tank inspection 1. Inspect: ● Fuel tank Cracks/damage → Replace. Pipe joint inspection 1.
FUEL INTAKE DUCT AND SILENCER E INTAKE DUCT AND SILENCER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name INTAKE DUCT AND SILENCER REMOVAL Exhaust chamber assembly Hose clamp Silencer Hose clamp Joint hose Band Q’ty Service points Follow the left “Step” for removal. Refer to “EXHAUST CHAMBER ASSEMBLY” in chapter 5. 1 1 2 1 1 4-10 NOTE: Tie the fuel suction hose, fuel return hose, throttle cable and pilot water hose (port side) together with the band.
FUEL INTAKE DUCT AND SILENCER E EXPLODED DIAGRAM Step 6 7 8 9 10 11 12 Procedure/Part name Bolt/collar/grommet Intake duct Silencer case Bolt Spark arrester Silencer plate O-ring Q’ty 1/1/1 1 1 6 1 1 3 Service points Reverse the removal steps for installation.
FUEL CARBURETOR UNIT E CARBURETOR UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 Procedure/Part name CARBURETOR UNIT REMOVAL Silencer plate Oil pump cable 2 3 4 Throttle cable Choke cable Fuel suction hose Q’ty 1 1 1 1 4-12 Service points Follow the left “Step” for removal. Refer to “INTAKE DUCT AND SILENCER”. NOTE: Before removing the oil pump cable, mark the cable’s installation position for reference when installing the oil pump cable.
FUEL CARBURETOR UNIT E EXPLODED DIAGRAM Step 5 6 7 8 9 10 11 12 Procedure/Part name Fuel return hose Oil delivery hose Clamp/fuel pump vacuum hose Remote throttle stop screw Bolt Bolt Carburetor assembly Gasket Q’ty 1 3 3/3 1 6 4 1 1 4-13 Service points Red mark a Not reusable Reverse the removal steps for installation.
FUEL CARBURETOR UNIT E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name CARBURETOR UNIT SEPARATION Hose Hose Accelerator pump hose Remote throttle stop screw assembly Throttle link Choke link Q’ty 2 2 1 1 1 1 4-14 Service points Follow the left “Step” for removal.
FUEL CARBURETOR UNIT E EXPLODED DIAGRAM Step 7 8 9 10 11 12 Procedure/Part name Bolt Cable holder Bolt Carburetor Gasket Plate Q’ty 3 1 6 3 3 1 Service points Not reusable Reverse the removal steps for installation.
FUEL CARBURETOR UNIT E SERVICE POINTS Throttle valve synchronization inspection and adjustment 1. Check: ● Throttle valve synchronization Not synchronized → Adjust. Checking steps: ● Loosen the remote throttle stop screw 1 until untouched the screw end from the throttle lever. ● Check the each throttle valve is fully closed. 2. Adjust: ● Throttle valve synchronization Adjustment steps: ● Loosen the remote throttle stop screw 1 until untouched the screw end from the throttle lever. ● Loosen the screws 2.
FUEL CARBURETOR UNIT E Choke cable and throttle cable installation 1. Install: ● Choke cable 1 ● Throttle cable 2 Choke cable guide installation position a: 16 ~ 18 mm (0.63 ~ 0.71 in) Throttle cable guide installation position b: 18 ~ 20 mm (0.71 ~ 0.79 in) 2. Adjust: ● Throttle lever free play Refer to “CONTROL SYSTEM” in chapter 3. Oil pump cable installation 1. Adjust: ● Oil pump cable Refer to “OIL PUMP”. Carburetor assembly 1. Adjust: ● Trolling speed Refer to “FUEL SYSTEM” in chapter 3.
FUEL CARBURETOR E CARBURETOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 Procedure/Part name CARBURETOR DISASSEMBLY Accelerator pump delivery hose Accelerator pump fuel hose Screw Accelerator pump/carburetor cover Diaphragm Screw Regulator body Gasket Main jet Q’ty 2 1 4 1/1 1 2 1 1 1 4-18 Service points Follow the left “Step” for disassembly.
FUEL CARBURETOR E EXPLODED DIAGRAM Step 10 11 12 13 14 15 16 17 18 19 Procedure/Part name Pilot jet Screw Arm Arm pin Spring Screw Needle valve seat holder Needle valve Needle valve seat O-ring Q’ty 1 1 1 1 1 1 1 1 1 1 Service points Reverse the disassembly steps for assembly.
FUEL CARBURETOR E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 Procedure/Part name ACCELERATOR PUMP DISASSEMBLY Screw Stay Spring Spring seat Screw Accelerator pump cover assembly Spring Diaphragm Accelerator pump body Q’ty Service points Follow the left “Step” for disassembly. 1 1 1 1 4 1 1 1 1 Reverse the disassembly steps for assembly.
FUEL CARBURETOR E SERVICE POINTS CAUTION: Do not use steel wire for cleaning the jets. This may enlarge the jet diameters and seriously affect performance. Diaphragm inspection 1. Inspect: ● Diaphragm Damage → Replace. Accelerator pump body inspection 1. Inspect: ● One way valve Crack/damage → Replace the accelerator pump body. ● Fuel passage Clog → Clean or replace. Arm inspection 1. Inspect: ● Arm 1 Bends/damage → Repair or replace. 2. Measure: ● Arm height a Arm height: 0 ~ 0.2 mm (0 ~ 0.
FUEL CARBURETOR E Regulator body inspection 1. Inspect: ● Regulator body Contaminants → Clean. Damage → Replace. ● Valve (clear film) 1 Damage → Replace. Needle valve inspection 1. Inspect: ● Needle valve ● Needle valve seat Contaminants a → Clean. Wear b → Replace. NOTE: Always replace the needle valve and needle valve seat as a set. Jet and carburetor body inspection 1. Inspect: ● Main jet ● Pilot jet ● Carburetor body Clog/contaminants → Clean. Damage/wear → Replace.
FUEL FUEL PUMP E FUEL PUMP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name FUEL PUMP DISASSEMBLY Carburetors Screw Fuel pump cover Gasket Diaphragm O-ring Diaphragm body Q’ty 4 1 1 1 1 1 4-23 Service points Follow the left “Step” for disassembly. Refer to “CARBURETOR”.
FUEL FUEL PUMP E EXPLODED DIAGRAM Step 7 8 9 10 Procedure/Part name Rubber diaphragm Diaphragm Packing Fuel filter Q’ty 1 1 1 1 Service points Reverse the disassembly steps for assembly.
FUEL FUEL PUMP E SERVICE POINTS Fuel pump inspection 1. Inspect: ● Diaphragm ● Rubber diaphragm ● Diaphragm body Damage → Replace. Fuel filter inspection 1. Inspect: ● Fuel filter Clog/contaminants → Clean. Damage → Replace.
FUEL OIL PUMP E OIL PUMP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name OIL PUMP REMOVAL Engine unit Bolt Bleed hose stay Bolt Oil pump assembly Gasket Oil suction hose Oil return hose Q’ty 1 1 2 1 1 1 1 Service points Follow the left “Step” for removal. Refer to “ENGINE UNIT” in chapter 5. Not reusable Reverse the removal steps for installation.
FUEL OIL PUMP E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name OIL PUMP HOSES AND CABLE REMOVAL Bleed hose Air bleed screw Gasket Bleed hose stay Oil delivery hose 1 Oil delivery hose 2 Check valve Oil pump cable Q’ty Service points Follow the left “Step” for removal. 1 1 1 1 3 3 3 1 Reverse the removal steps for installation.
FUEL OIL PUMP E SERVICE POINTS Oil pump inspection 1. Inspect: ● Oil pump Contaminants → Clean. Damage/wear → Replace. ● Oil pump joint piece Damage/wear → Replace. Oil hose inspection 1. Inspect: ● Oil hose Cracks/damage → Replace. CAUTION: ● If the oil delivery hoses are not full of oil, fill them up. ● After installing the oil injection system, bleed the system of any air. Check valve inspection 1. Check: ● Check valve Faulty → Replace.
FUEL OIL PUMP E Oil pump cable adjustment 1. Check: ● Oil pump lever position Incorrect → Adjust. Checking steps: Fully close the carburetor throttle valves. ● Check that the mark a on the oil pump lever is aligned with the mark b on the oil pump body. ● 2. Adjust: ● Oil pump cable Adjustment steps: ● Loosen the locknut 1 and the adjusting nut 2. ● Fully close the carburetor throttle valves.
FUEL OIL PUMP E Oil injection pump air bleeding 1. Bleed: ● Air Air 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 the oil suction hose is reinstalled, bleed air from the oil suction hose by removing it from the oil pump. After bleeding the air, reconnect the hose with a locking tie.
POWR E CHAPTER 5 POWER UNIT MUFFLER ASSEMBLY ................................................................................... 5-1 EXPLODED DIAGRAM ............................................................................. 5-1 REMOVAL AND INSTALLATION CHART ............................................... 5-1 SERVICE POINT........................................................................................ 5-7 Catalyst inspection......................................................................
POWR E CYLINDERS ................................................................................................... 5-25 EXPLODED DIAGRAM ........................................................................... 5-25 REMOVAL AND INSTALLATION CHART ............................................. 5-25 SERVICE POINTS ................................................................................... 5-26 Cylinder inspection .........................................................................
POWR MUFFLER ASSEMBLY E MUFFLER ASSEMBLY EXPLODED DIAGRAM 6 12 Nm (1.2 m • kgf, 8.7 ft • Ib) 6 × 22 mm 5 LT 7 242 1 4 2 3 7 Å REMOVAL AND INSTALLATION CHART Step 1 2 3 Procedure/Part name WATER HOSES AND LEADS REMOVAL YPVS servomotor Battery box Spark plug cap Exhaust temperature sensor coupler Water temperature sensor coupler Q’ty Service points Follow the left “Step” for removal. Refer to “YPVS SERVOMOTOR” in chapter 7. Refer to “BATTERY BOX” in chapter 8.
POWR MUFFLER ASSEMBLY E EXPLODED DIAGRAM 6 12 Nm (1.2 m • kgf, 8.
POWR MUFFLER ASSEMBLY E EXPLODED DIAGRAM Step 8 9 10 11 12 13 14 15 Procedure/Part name Hose clamp Hose clamp Hose clamp Water lock band Bolt Intermediate housing grease hose Nut Eye Q’ty 2 2 1 1 4 1 2 2 5-3 Service points Slide the outer exhaust joint. Slide the water lock. NOTE: Remove the spark plug before removing the eye, and reinstall it to make removing the muffler assembly easier.
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.
POWR MUFFLER ASSEMBLY E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name MUFFLER DISASSEMBLY Exhaust temperature sensor Water temperature sensor Bolt Muffler stay Bolt Cover Gasket Catalyst housing Q’ty 1 1 2 1 6 1 1 1 5-5 Service points Follow the left “Step” for disassembly.
POWR MUFFLER ASSEMBLY E EXPLODED DIAGRAM Step 9 10 11 12 13 14 15 16 Procedure/Part name Gasket Catalyst Gasket Pin Bolt Mixing joint Gasket Muffler Q’ty 1 1 1 2 6 1 1 1 Service points Not reusable Not reusable Not reusable Reverse the disassembly steps for assembly.
POWR MUFFLER ASSEMBLY E SERVICE POINT Catalyst inspection 1. Inspect: ● Catalyst Cracks/damage → Replace.
POWR EXHAUST CHAMBER ASSEMBLY EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Q’ty 1 Procedure/Part name EXHAUST CHAMBER ASSEMBLY REMOVAL Muffler assembly Clamp/hose 2 3 4 5 6 7 Bolt Bolt Bolt Bolt Exhaust chamber stay Clamp/hose 3 1 2 2 1 1/1 3/3 5-8 Service points Follow the left “Step” for removal. Refer to “MUFFLER ASSEMBLY”.
POWR EXHAUST CHAMBER ASSEMBLY E EXPLODED DIAGRAM Step 8 9 10 Procedure/Part name Exhaust chamber assembly Gasket Pin Q’ty 1 1 2 Service points NOTE: Before installing the exhaust chamber assembly, install the clamp/hose (step No.7) and place the bolts (step No.2) in the bolts holes of the exhaust chamber assembly. Not reusable Reverse the removal steps for installation.
POWR EXHAUST CHAMBER ASSEMBLY E 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.
POWR ENGINE UNIT E ENGINE UNIT EXPLODED DIAGRAM 6 × 25 mm 5 LT 572 17 Nm (1.7 m • kgf, 12 ft • Ib) 8 × 40 mm 7 6 8 LT 572 a 3 1 2 9 4 REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name ENGINE UNIT REMOVAL Carburetor unit Q’ty Clamp/water hose Oil suction hose Oil return hose Multi-function meter coupler Bolt/collar 1/1 1 1 3 1/1 5-11 Service points Follow the left “Step” for removal. Refer to “CARBURETOR UNIT” in chapter 4.
POWR ENGINE UNIT E EXPLODED DIAGRAM 6 × 25 mm 5 LT 572 17 Nm (1.7 m • kgf, 12 ft • Ib) 8 × 40 mm 7 6 8 LT 572 a 3 1 2 9 4 Step 6 7 8 9 Procedure/Part name Coupling cover Bolt/washer Engine assembly Shim Q’ty 1 4/4 1 * *: As required 5-12 Service points Install the shims original position. Reverse the removal steps for installation.
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. Inspect: ● Engine mounts Cracks/damage → Replace. Coupling clearance inspection 1. Measure: ● Clearance a ● Clearance b (with the rubber damper) Out of specification → Adjust.
POWR EXHAUST MANIFOLD E EXHAUST MANIFOLD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name EXHAUST MANIFOLD AND LEADS REMOVAL Engine unit Bolt Bolt Nut Exhaust manifold Gasket Pin Q’ty Service points Follow the left “Step” for removal. Refer to “ENGINE UNIT”. 4 6 2 1 1 2 Not reusable Reverse the removal steps for installation.
POWR EXHAUST MANIFOLD E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name EXHAUST MANIFOLD DISASSEMBLY Clamp/hose Bolt Water pipe O-ring Exhaust manifold Q’ty Service points Follow the left “Step” for disassembly. 1/1 6 1 3 1 Reverse the disassembly steps for assembly.
POWR REED VALVES E REED VALVES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name REED VALVE REMOVAL Carburetor unit Q’ty 1 2 Bolt Reed valve plate 18 1 3 4 5 6 Reed valve assembly Screw Valve stopper Reed valve 3 24 6 6 Service points Follow the left “Step” for removal. Refer to “CARBURETOR UNIT” in chapter 4. NOTE: Tighten the bolts in the proper sequence as shown. Reverse the removal steps for installation.
POWR REED VALVES E SERVICE POINTS Reed valve inspection 1. Inspect: ● Reed valves Cracks/damage → Replace. 2. Measure: ● Valve bending a Out of specification → Replace. Max. valve bending: 0.2 mm (0.01 in) 3. Measure: ● Valve stopper height b Out of specification → Adjust or replace. Valve stopper height: 10.4 ~ 11.0 mm (0.41 ~ 0.
POWR YPVS E YPVS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name YPVS REMOVAL Exhaust chamber assembly Q’ty Bolt YPVS valve cover Gasket Spacer Link joint/cover Circlip 12 3 3 2 2/2 5 5-18 Service points Follow the left “Step” for removal. Refer to “EXHAUST CHAMBER ASSEMBLY”.
POWR YPVS E EXPLODED DIAGRAM Step 7 8 9 10 11 12 Procedure/Part name Washer Bolt Shaft 3 Shaft 2 Shaft 1 YPVS valve arm Q’ty 5 3 1 1 1 3 5-19 Service points NOTE: During installation, align the hole a in the YPVS shaft with the bolt.
POWR YPVS E EXPLODED DIAGRAM Step 13 14 15 Procedure/Part name Bolt YPVS valve assembly Oil seal Q’ty 3 3 6 Service points NOTE: If the YPVS shaft is removed, the oil seal must be replaced. Reverse the removal steps for installation.
POWR YPVS E SERVICE POINTS YPVS valve inspection 1. Eliminate: ● Carbon deposits (with a rounded scraper 1) CAUTION: Do not use a sharp instrument to avoid damaging or scratching the surfaces. 2. Inspect: ● YPVS valve assembly Crack/damage/wear → Replace. YPVS valve installation 1. Install: ● Oil seal Distance a: 1.0 ~ 1.5 mm (0.04 ~ 0.
POWR CYLINDER HEAD E CYLINDER HEAD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name CYLINDER HEAD REMOVAL Exhaust chamber assembly Spark plug Bolt Ground lead Bolt Bolt Bolt Q’ty 3 1 1 2 6 16 5-22 Service points Follow the left “Step” for removal. Refer to “EXHAUST CHAMBER ASSEMBLY”. NOTE: Tighten the bolts in the proper sequence as shown and in three stages. (No.
POWR CYLINDER HEAD E EXPLODED DIAGRAM Step 7 8 9 10 11 Procedure/Part name Cylinder head cover Gasket Cylinder head Gasket Clamp/hose Q’ty 1 1 1 1 2/2 5-23 Service points Not reusable Not reusable a white mark Reverse the removal steps for installation.
POWR CYLINDER HEAD E SERVICE POINTS Cylinder head inspection 1. Eliminate: ● Carbon deposits (with 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. Inspect: ● Cylinder head water jacket Corrosion/mineral deposits → Clean or replace. 3. Measure: ● Cylinder head warpage (with a straightedge and thickness gauge) Out of specification/score marks → Resurface. Warpage limit: 0.1 mm (0.
POWR CYLINDERS E CYLINDERS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 Procedure/Part name CYLINDER REMOVAL YPVS Cylinder head Bolt Q’ty 2 Cylinder 3 NOTE: Install the original position. 3 4 Cylinder gasket Pin 3 6 Not reusable 12 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. Reverse the removal steps for installation.
POWR CYLINDERS E SERVICE POINTS Cylinder inspection 1. Eliminate: ● Carbon deposits (with a rounded scraper 1) 2. Inspect: ● Cylinder water jacket Corrosion/mineral deposits → Clean or replace. ● Cylinder inner surface Score marks → Replace. 3. Measure: ● Cylinder bore “D” (with a cylinder gauge) Out of specification → Replace cylinder and piston as a set. NOTE: Measure the cylinder bore in parallel and at a right angle to the crankshaft. Then, average the measurements.
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”. 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 5-27 NOTE: Make sure that the arrow b faces towards the exhaust side.
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.
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 gloves) 2. Inspect: ● Piston wall Score marks → Repair with 600 ~ 800 grit wet sandpaper or replace.
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 CLEARANCE BORE 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 by the table as follows.
POWR PISTONS E 2. Measure: ● End gap (with 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. Inspect: ● Piston pins ● Bearings Signs of heat discoloration → Replace. 2. Measure: ● Piston pin outside diameter (with a micrometer 1) Out of specification → Replace. Piston pin outside diameter: Standard 21.995 ~ 22.000 mm (0.8659 ~ 0.
POWR PISTONS E 4. Check: ● Piston-pin-to-connecting-rod free play (with the piston pin in the small end of the connecting rod as shown) Free play/small end wear → Replace the piston pin, connecting rod or both.
POWR GENERATOR AND STARTER MOTOR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name GENERATOR COVER REMOVAL Oil pump Bolt Bolt Ground lead Generator cover Washer Q’ty 1 7 1 1 2 5-33 Service points Follow the left “Step” for removal. Refer to “OIL PUMP” in chapter 4.
POWR GENERATOR AND STARTER MOTOR E EXPLODED DIAGRAM Step 6 7 8 9 10 11 Procedure/Part name Spring Packing Pin Bolt Bolt Bracket Q’ty 1 1 2 2 2 1 Service points Reverse the removal steps for installation.
POWR GENERATOR AND STARTER MOTOR E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name STATOR COIL AND PICKUP COIL REMOVAL Bolt Washer Cable holder Bolt Pickup coil Bolt Stator coil Q’ty 3 1 1 2 1 3 1 Service points Follow the left “Step” for removal. NOTE: This washer holds the pickup coil lead. Make sure to not pinch the lead between the projection and the washer when installing the bolt. Reverse the removal steps for installation.
POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name GENERATOR ROTOR AND STARTER MOTOR REMOVAL Drive coupling Flywheel magneto bolt Flywheel magneto Woodruff key Starter clutch assembly Bolt Battery negative lead Q’ty 1 1 1 1 1 2 1 5-36 Service points Follow the left “Step” for removal.
POWR GENERATOR AND STARTER MOTOR E EXPLODED DIAGRAM Step 8 9 10 Procedure/Part name Nut/washer Starter motor lead Starter motor Q’ty 1/1 1 1 Service points Reverse the removal steps for installation.
POWR GENERATOR AND STARTER MOTOR E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name STARTER CLUTCH DISASSEMBLY Clip Clip stopper Spring seat Spring Idle gear Circlip Plate Q’ty 1 1 1 1 1 1 1 5-38 Service points Follow the left “Step” for disassembly.
POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step 8 9 10 Procedure/Part name Weight Spring ring Pinion gear Q’ty 3 1 1 Service points Reverse the disassembly steps for assembly.
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 NOTE: Install the drive coupling with the same special tools that were used for removal. Flywheel magneto removal and installation 1. Remove: ● Flywheel magneto bolt Flywheel holder: YW-06550/90890-06550 NOTE: Install the bolt with the same special tool that was used for removal. Å 2.
POWR GENERATOR AND STARTER MOTOR Drive coupling inspection 1. Inspect: ● Drive coupling Damage/wear → Replace. Flywheel magneto inspection 1. Inspect: ● Ring gear Damage/wear → Replace. Starter clutch assembly inspection 1. Inspect: ● Pinion gear 1 ● Idle gear 2 Damage/wear → Replace. 2. Check: ● Gear movement Rough movement → Replace the defective part(s).
POWR CRANKCASE E CRANKCASE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name CRANKCASE DISASSEMBLY Pistons Generator cover and starter motor Bolt Mount bracket Pin Bolt Bolt Bolt Q’ty 6 2 4 3 1 6 5-42 Service points Follow the left “Step” for disassembly. Refer to “PISTONS”. Refer to “GENERATOR AND STARTER MOTOR”.
POWR CRANKCASE E EXPLODED DIAGRAM Step 7 8 9 10 11 12 Procedure/Part name Bolt Bolt Lower crankcase Pin Crankshaft assembly Upper crankcase Q’ty 1 16 1 2 1 1 Service points NOTE: Tighten the bolts in sequence as shown. Reverse the disassembly steps for assembly.
POWR CRANKCASE E SERVICE POINTS Crankcase inspection 1. Inspect: ● Mating surfaces Scratches → Replace the crankcase. ● Crankcase Cracks/damage → Replace. Crankcase installation 1. Apply: ● Gasket Maker® (onto 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.
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 Crankshaft assembly Q’ty 1 1 2 1 Service points Follow the left “Step” for removal. Refer to “CRANKCASE”. CAUTION: Install the bearing locating pins into the gloves in the crankcase body. Reverse the removal steps for installation.
POWR CRANKSHAFT E SERVICE POINTS Crankshaft inspection 1. Measure: ● Crank width A Out of specification → Replace. Crank width: 72.95 ~ 73.00 mm (2.872 ~ 2.874 in) 2. Measure: ● Deflection B (with a dial gauge) Out of specification → Replace. Max. deflection: B 0.05 mm (0.002 in) C 0.15 mm (0.006 in) 3. Measure: ● Big end side clearance D (with a thickness gauge) Out of specification → Replace. Big end side clearance: 0.25 ~ 0.75 mm (0.010 ~ 0.030 in) 4.
POWR CRANKSHAFT E 5. Inspect: ● Bearings Damage/pitting → Replace. NOTE: ● Before inspection, thoroughly clean the bearings. ● Immediately after inspection, lubricate the bearings to prevent rust. 6. Inspect: ● Oil seals Damage/wear → Replace.
JET PUMP E CHAPTER 6 JET PUMP UNIT JET PUMP UNIT ............................................................................................. 6-1 EXPLODED DIAGRAM ............................................................................. 6-1 REMOVAL AND INSTALLATION CHART ............................................... 6-1 NOZZLE DEFLECTOR AND NOZZLE RING ................................................... 6-4 EXPLODED DIAGRAM ...........................................................................
JET PUMP JET PUMP UNIT E JET PUMP UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name JET PUMP UNIT REMOVAL Bolt Bolt Intake grate Bolt Intake duct Screw Speed sensor Q’ty 2 2 1 4 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 the bilge hose.
JET PUMP JET PUMP UNIT E EXPLODED DIAGRAM Step 8 9 10 11 12 13 14 15 16 Procedure/Part name Bolt Ride plate QSTS cable joint Bilge hose Nut/washer Steering cable joint Clamp/spout hose Bolt Bolt Q’ty 4 1 1 1 1/2 1 1/1 1 4 6-2 Service points
JET PUMP JET PUMP UNIT E EXPLODED DIAGRAM Step 17 18 Procedure/Part name Jet pump unit assembly Dowel pin Q’ty 1 2 Service points NOTE: ● Pull the jet pump unit straight back. ● When installing the jet pump unit, align the drive shaft spline (male) with the intermediate drive shaft spline (female). Reverse the removal steps for installation.
JET PUMP NOZZLE DEFLECTOR AND NOZZLE RING E NOZZLE DEFLECTOR AND NOZZLE RING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name NOZZLE DEFLECTOR AND NOZZLE RING REMOVAL Jet pump unit Bolt Collar Nozzle deflector 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.
JET PUMP IMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCT E IMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name IMPELLER DUCT AND IMPELLER HOUSING REMOVAL Nozzle ring Bolt Nozzle Pin Impeller duct assembly Impeller housing Pin Q’ty Service points Follow the left “Step” for removal. Refer to “NOZZLE DEFLECTOR AND NOZZLE RING”. 4 1 2 1 1 2 6-5 NOTE: Clean the matching surfaces before applying the Gasket Maker®.
JET PUMP IMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCT E EXPLODED DIAGRAM Step 7 8 9 10 11 Procedure/Part name Bolt Water inlet cover Packing Water inlet strainer Packing Q’ty 4 1 1 1 1 Service points Reverse the removal steps for installation.
JET PUMP IMPELLER DUCT AND DRIVE SHAFT E 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 6-7 Service points Follow the left “Step” for disassembly.
JET PUMP IMPELLER DUCT AND DRIVE SHAFT EXPLODED DIAGRAM Step 8 9 10 11 12 13 *1: Procedure/Part name Drive shaft Rear bearing Spacer Front bearing Oil seal Oil seal Q’ty 1 1 1 1 1 1 EPNOC grease AP #0 6-8 Service points Not reusable Not reusable Not reusable Not reusable Reverse the disassembly steps for assembly.
JET PUMP IMPELLER DUCT AND DRIVE SHAFT E SERVICE POINTS Drive shaft removal 1. Remove: ● Impeller Drive shaft holder: YB-06151/90890-06519 NOTE: The impeller has left-hand threads. Turn the impeller clockwise to loosen it. 2. Remove: ● Nut 1 Drive shaft holder: YB-06151/90890-06519 3. Remove: ● Drive shaft 1 NOTE: Remove the drive shaft with a press. 4.
JET PUMP IMPELLER DUCT AND DRIVE SHAFT 5. Remove: ● Front bearing Driver rod L3: YB-06071/90890-06652 Needle bearing attachment: YB-06112/90890-06614 NOTE: Remove the front bearing with a press. 6. Remove: ● Oil seal Driver rod L3: YB-06071/90890-06652 Needle bearing attachment: YB-06196/90890-06653 NOTE: Remove the oil seal with press. Impeller inspection Refer to “JET PUMP UNIT” in chapter 3. Drive shaft inspection 1. Inspect: ● Drive shaft Damage/wear → Replace. Drive shaft installation 1.
JET PUMP IMPELLER DUCT AND DRIVE SHAFT E 2. Install: ● Front bearing ● Drive shaft NOTE: Install the front bearing and drive shaft with a press. a Distance a: 23 ± 0.1 mm (0.91 ± 0.004 in) 3. Install: ● Drive shaft (with front bearing) ● Spacer ● Impeller duct NOTE: Press the spacer and the front bearing with a 36-mm deep socket. 4. Add: ● EPNOC grease AP #0 (between the drive shaft and spacer) Quantity: Approximately 1/3 of capacity 5.
JET PUMP IMPELLER DUCT AND DRIVE SHAFT E 6. Add: ● EPNOC grease AP #0 (into the cap) Quantity: Approximately 1/3 of capacity 7.
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 HOSES REMOVAL Exhaust system Jet pump unit Hose clamp Hose Bilge hose 1 Q’ty Service points Follow the left “Step” for removal. Refer to “EXHAUST SYSTEM” in chapter 8. Refer to “JET PUMP UNIT”. 3 1 1 6-13 Cooling water outlet NOTE: Route the bilge hose 1 under the drive shaft tube.
JET PUMP TRANSOM PLATE AND HOSES E EXPLODED DIAGRAM Step 4 5 6 7 8 9 10 Procedure/Part name Hose Nut/washer Transom plate Clamp/bilge hose 2 Screw Bilge strainer holder Bilge strainer Q’ty 1 4/4 1 1/1 1 1 1 Service points Cooling water inlet Reverse the removal steps for installation.
JET PUMP TRANSOM PLATE AND HOSES SERVICE POINTS Bilge strainer inspection Refer to “JET PUMP UNIT” in chapter 3. Bilge hose inspection 1. Inspect: ● Bilge hose Cracks/damage/wear → Replace.
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. NOTE: Install the shims in their original locations. Reverse the removal steps for installation.
JET PUMP BEARING HOUSING E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name BEARING HOUSING DISASSEMBLY Grease hose Grease nipple Grease nipple stay Nipple Driven coupling Washer Intermediate drive shaft Q’ty 1 1 1 2 1 1 1 6-17 Service points Follow the left “Step” for disassembly.
JET PUMP BEARING HOUSING E EXPLODED DIAGRAM Step 8 9 10 11 12 13 14 Procedure/Part name O-ring Oil seal Oil seal Oil seal Circlip Bearing Circlip Q’ty 2 1 1 1 1 1 1 Service points Not reusable Not reusable Not reusable Not reusable Reverse the disassembly steps for assembly.
JET PUMP BEARING HOUSING E SERVICE POINTS Driven coupling removal and installation 1. Remove and install: ● Driven coupling Coupler wrench: YW-06551/90890-06551 Shaft holder: YB-06552/90890-06552 NOTE: Install the driven coupling with the same special tools that were used for removal. Intermediate drive shaft removal 1. Remove: ● Intermediate drive shaft Removal steps: Temporarily install the driven coupling to the intermediate drive shaft. ● Insert the long rod to the driven coupling shaft.
JET PUMP BEARING HOUSING E Bearing, driven coupling shaft, and grease hose inspection 1. Inspect: ● Bearing Rotate the inner race by hand. Damage/rough movement → Replace. ● Intermediate drive shaft Damage/pitting → Replace. ● Grease hose Cracks/wear → Replace. Driven coupling inspection 1. Inspect: ● Driven coupling ● Driven coupling damper Damage/wear → Replace. Bearing installation 1. Install: ● Circlip (rear) 2.
JET PUMP BEARING HOUSING E 2. Install: ● Intermediate drive shaft Distance a: 9.5 ~ 10.5 mm (0.37 ~ 0.41 in) NOTE: Support the intermediate housing with steel blocks 1 and press the driven coupling shaft. 3. Install: ● Oil seal 1 [8 mm (0.31 in)] ● Oil seal 2 [10 mm (0.39 in)] Distance a: 10.3 ~ 10.7 mm (0.41 ~ 0.42 in) Distance b: 1.6 ~ 2.0 mm (0.06 ~ 0.08 in) Intermediate housing installation 1. Install: ● Intermediate housing ● Shim Installation steps: Install the intermediate housing.
ELEC – + E CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS......................................................................... 7-1 ELECTRICAL BOX ........................................................................................... 7-2 EXPLODED DIAGRAM ............................................................................. 7-2 REMOVAL AND INSTALLATION CHART ............................................... 7-2 ELECTRICAL ANALYSIS .........................................................
ELEC – + E CHARGING SYSTEM.................................................................................... 7-25 WIRING DIAGRAM................................................................................. 7-25 FUSE ....................................................................................................... 7-26 BATTERY ................................................................................................ 7-26 LIGHTING COIL .....................................................
ELEC – + ELECTRICAL COMPONENTS E ELECTRICAL COMPONENTS 1 D 2 C 3 B A 4 5 6 > 9 7 8 1 2 3 4 5 6 7 8 Buzzer Fuel level sensor Multi-function meter YPVS servomotor Spark plugs Exhaust temperature sensor Electrical box Speed sensor Battery Water temperature sensor Starter motor Stator coil and pickup coil Engine stop switch, engine stop lanyard switch and starter switch D Oil level sensor 9 0 A B C 7-1
ELEC – + ELECTRICAL BOX E ELECTRICAL BOX EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 Procedure/Part name ELECTRICAL BOX REMOVAL Engine unit Battery negative lead Starter motor lead Nut/washer Bracket Electrical box Q’ty Service points Follow the left “Step” for removal. Refer to “ENGINE UNIT” in chapter 5. Refer to “GENERATOR AND STARTER MOTOR” in chapter 5. 4/4 2 1 Reverse the removal steps for installation.
ELEC – + ELECTRICAL BOX E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 Procedure/Part name ELECTRICAL BOX DISASSEMBLY Clamp Coupler 3 4 5 6 7 8 9 10 Screw Rectifier/regulator Screw Cover Packing Spark plug lead holder Screw Ground lead Q’ty 5 3 2 1 10 1 1 3 6 3 7-3 Service points Follow the left “Step” for disassembly.
ELEC – + ELECTRICAL BOX E EXPLODED DIAGRAM Step 11 12 13 14 15 16 17 18 19 20 21 22 Procedure/Part name Ignition coil Ignition coil lead Spark plug lead/cap Bolt Ground lead Lead Nut Starter motor lead Battery positive lead Fuse lead Starter relay lead Starter relay Q’ty 3 3 3/3 3 6 3 2 1 1 1 1 1 7-4 Service points Black/orange
ELEC – + ELECTRICAL BOX E EXPLODED DIAGRAM Step 23 24 25 26 27 28 29 30 31 32 Procedure/Part name Lead holder Fuse lead Screw Fuse holder Lead/coupler Screw Coupler bracket CDI unit Screw Lead holder plate Q’ty 1 5 2 1 1/6 2 1 1 8 2 Service points Reverse the disassembly steps for assembly.
ELEC 1 2 3 4 5 6 7 8 9 – + Ignition coil CDI unit Rectifier/regulator Fuse holder Starter relay Tape Clear tube Red tube White tape ELECTRICAL BOX E Å To battery positive terminal ı To starter motor Ç Affix the ignition coil connector to the electrical box holder. Î Pass the 8 pin coupler leads behind the CDI unit and insert them into the bracket.
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 an instrument powered by dry batteries, check the battery’s voltage periodically and replace the batteries if necessary. Digital circuit tester NOTE: Throughout this chapter the digital circuit tester’s part number has been omitted. Refer to the following part number.
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.
ELEC – + ELECTRICAL ANALYSIS Å ● E When measuring the peak voltage, connect the peak voltage adaptor to the digital tester and switch the selector to the DC voltage mode. NOTE: ● Make sure that the adaptor leads are properly installed in the digital circuit tester. ● Make sure that the positive pin (the “+” mark facing up as shown) on the adaptor is installed into the positive terminal of the tester. ● The test harness is needed for the following tests.
ELEC – + IGNITION SYSTEM E IGNITION SYSTEM WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 Engine stop switch Engine stop lanyard switch Lighting coil Pickup coil CDI unit Ignition coil Spark plug Fuse (20A) Battery 0 Rectifier/regulator A Exhaust temperature sensor B Water temperature sensor 7-10 B O R W B/O B/W B/Y W/R : Black : Orange : Red : White : Black/orange : Black/white : Black/yellow : White/red
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. Å 1. Check: ● Ignition spark gap Below specification → Check the CDI unit output peak voltage.
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.
ELEC – + IGNITION SYSTEM E 2. Measure: ● Pickup coil output peak voltage Below specification → Replace the pickup coil. Pickup coil output peak voltage: White/red (W/R) – Black/orange (B/O) r/min V Unloaded Loaded Cranking 5 2.8 2,000 3,500 7.9 11 NOTE: The starter motor will not operate when the test harness on the output side coupler is disconnected to measure the unloaded peak voltage for the pickup coil(s). Therefore, connect the black lead of the test harness to the ground with a lead. 3.
ELEC – + IGNITION SYSTEM E 4. Measure: ● Rectifier/regulator output peak voltage Below specification → Replace the rectifier/regulator. Rectifier/regulator output peak voltage: Red (R) – Black (B) r/min Unloaded Cranking 2,000 3,500 7 12.6 12.6 V NOTE: Make sure the output lead (red lead) of the rectifier/regulator is disconnected when measuring the output peak voltage. BATTERY Refer to “ELECTRICAL” in chapter 3. FUSE Refer to “STARTING SYSTEM”. SPARK PLUGS Refer to “ELECTRICAL” in chapter 3.
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.
ELEC – + IGNITION SYSTEM E WATER TEMPERATURE SENSOR 1. Measure: ● Water temperature sensor resistance (at the specified temperature) Out of specification → Replace. 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): 0.104 ~ 0.153 kΩ Measurement steps: Ice the water temperature sensor and measure the resistance. ● Suspend the water temperature sensor in a container filled with oil. ● Slowly heat the oil.
ELEC – + STARTING SYSTEM E STARTING SYSTEM WIRING DIAGRAM 1 2 3 4 5 6 7 8 CDI unit Engine stop lanyard switch Starter switch Fuse (10A) Fuse (20A) Starter relay Starter motor Battery B Br R R/Y 7-17 : Black : Brown : Red : Red/yellow
ELEC – + STARTING SYSTEM E BATTERY Refer to “ELECTRICAL” in chapter 3. WIRING CONNECTIONS 1. Check: ● Wiring connections Poor connections → Properly connect. FUSE 1. Check: ● Fuse holder continuity No continuity → Check the fuse or replace the fuse holder. Fuse holder continuity: Between 1 and 2 Between 2 and 3 2. Check: ● Fuse broken Broken → Replace. Fuse rating: 10A, 20A NOTE: 20A fuse is for CDI unit and rectifier/regulator. 10A fuse is for multi-function meter, YPVS motor and start switch.
ELEC – + STARTING SYSTEM E STARTER SWITCH 1. Check: ● Continuity Out of specification → Replace. Starter continuity (natural color coupler) Lock plate Installed Removed Position Leads Red Brown Free Push Free Push STARTER RELAY 1. Inspect: ● Brown lead terminal ● Black lead terminal Loose → Tighten. 2. Check: ● Starter relay Faulty → Replace. Checking steps: Connect the tester leads between the starter relay terminals as shown. ● Connect the brown lead terminal to the positive battery terminal.
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 * *: As required 7-20 Service points Follow the left “Step” for disassembly. Refer to “GENERATOR AND STARTER MOTOR” in chapter 5. Not reusable Not reusable t = 0.2 mm, 0.
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 Armature assembly Nut/spring washer/washer O-ring Brush holder Brush spring Bolt Brush assembly Q’ty 1 1 * 1 1/1/4 1 1 4 1 1 *: As required 7-21 Service points Not reusable t = 0.2 mm, 0.
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.
ELEC – + STARTER MOTOR E SERVICE POINTS Armature inspection 1. Inspect: ● Armature shaft 1 Damage/wear → Replace. 1 2. Inspect: ● Commutator Dirt → Clean with 600 grit sandpaper. 3. Measure: ● Commutator diameter Out of specification → Replace. Min. commutator diameter: 27.0 mm (1.06 in) 4. Check: ● Commutator undercut Contaminants → Clean. NOTE: Remove all mica and metal particles with compressed air. 5. Measure: ● Commutator undercut Out of specification → Replace. Min. commutator undercut: 0.
ELEC – + STARTER MOTOR E 6. Inspect: ● 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. Min. brush length: 6.5 mm (0.26 in) 2. Check: ● Brush holder continuity Out of specification → Replace.
ELEC – + CHARGING SYSTEM E CHARGING SYSTEM WIRING DIAGRAM 1 2 3 4 Lighting coil Battery Fuse (20A) Rectifier/regulator B G R G/W 7-25 : Black : Green : Red : Green/white
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”.
ELEC – + YPVS E YPVS WIRING DIAGRAM 1 2 3 4 5 6 7 8 Lighting coil Pickup coil CDI unit YPVS servomotor Fuse (10A) Fuse (20A) Battery Rectifier/regulator B Gy R B/O R/L R/W W/R 7-27 : Black : Gray : Red : Black/orange : Red/blue : Red/white : White/red
ELEC – + YPVS E FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in chapter 3. PICKUP COIL Refer to “IGNITION SYSTEM”. CDI UNIT Refer to “IGNITION SYSTEM”. LIGHTING COIL Refer to “IGNITION SYSTEM”. RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM”.
ELEC – + YPVS SERVOMOTOR E YPVS SERVOMOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Q’ty 1 2 3 4 5 6 Procedure/Part name YPVS SERVOMOTOR REMOVAL Bolt Cable holder YPVS servomotor coupler Nut/washer YPVS servomotor YPVS cable 7 8 9 Cover Nut/washer YPVS servomotor bracket 1 3/3 1 2 1 1 2/2 1 2 Service points Follow the left “Step” for removal. Slide the cover. White paint mark a is for No. 2 cable. Reverse the removal steps for installation.
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 the both drams. NOTE: ● There is a white paint mark a on YPVS cable 2. ● When installing the YPVS cable, make sure that the YPVS cable locknuts 3 are fully turned in. YPVS cable inspection 1. Inspect: ● YPVS cables 1 and 2 Frays/kinks/rough movement → Replace. YPVS servomotor inspection 1.
ELEC – + YPVS SERVOMOTOR E ● Make sure the servomotor operates properly. NOTE: Make sure the pulley operates three seconds after the jumper lead is removed. CAUTION: Do not disassemble the YPVS servomotor unit. It is a sealed unit and if it is faulty it must be replaced. YPVS cable adjustment Refer to “CONTROL SYSTEM” in chapter 3.
ELEC – + INDICATION SYSTEM E INDICATION SYSTEM WIRING DIAGRAM CDI unit Fuel level sensor Oil level sensor Buzzer Multi-function meter Speed sensor Engine stop lanyard switch 8 Starter switch 9 Battery 0 Fuse (10A) 1 2 3 4 5 6 7 A Fuse (20A) B Exhaust temperature sensor C Water temperature sensor 7-32 B Br Ch G Gy L O R W Y B/O : Black : Brown : Chocolate : Green : Gray : Blue : Orange : Red : White : Yellow : Black/orange B/Y Gy/B Gy/R Gy/Y L/B L/R R/W R/Y W/L : Black/yellow : Gray/black : Gray/
ELEC – + INDICATION 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”. CDI UNIT Refer to “IGNITION SYSTEM”. WATER TEMPERATURE SENSOR Refer to “IGNITION SYSTEM”. EXHAUST TEMPERATURE SENSOR Refer to “IGNITION SYSTEM”. BUZZER 1. Check: ● Buzzer Buzzer does not sound → Replace. Checking steps: Connect the battery (12 V) to the buzzer coupler as shown.
ELEC – + INDICATION SYSTEM E FUEL LEVEL SENSOR 1. Measure: ● Fuel level sensor resistance Out of specification → Replace. White/blue (W/L) – Black (B) Float position Resistance (Ω) A 757 ~ 803 B 0~8 MULTI-FUNCTION METER Multi-function meter 1. Check: ● Multi-function meter Cracked meter housing → Replace the multi-function meter. Meter is fogged/shows signs of water intrusion → Replace the multi-function meter. MULTI-FUNCTION METER REMOVAL Refer to “STEERING COVER” in chapter 8.
ELEC – + INDICATION SYSTEM E Display function 1. Check: ● Display function Not operate → Replace the multifunction meter.
– ELEC + INDICATION SYSTEM E Fuel level gauge 1. Check: ● Fuel level gauge Not operating → Replace the multifunction meter. Checking steps: ● Supply DC 12 voltage to the natural color six-pin connector (+: red, –: black) with a battery. ● Disconnect the green two-pin connector (white/blue and black leads). ● Connect the white/blue and black terminals with a jumper lead 1. ● Connect the green and red terminals with a jumper lead 2.
ELEC – + INDICATION SYSTEM E Oil level gauge 1. Check: ● Oil level gauge Not operating → Replace the multifunction meter. Checking steps: ● Supply DC 12 voltage to the natural color six-pin connector (+: red, –: black) with a battery. ● Disconnect the white two-pin connector (blue and black leads). ● Connect the blue and black terminals with a jumper lead 1. ● Connect the green and red terminals with a jumper lead 2.
ELEC – + INDICATION SYSTEM E Overheat warning indicator 1. Check: ● Overheat 1 warning indicator Not operating → Replace the multifunction meter. Checking steps: ● Supply DC 12 voltage to the natural color six-pin connector (+: red, –: black) with a battery. ● Connect the gray/black and black terminals with a jumper lead 1. ● Connect the green and red terminals with a jumper lead 2. ● Make sure the water temperature symbol 3 and “WARNING” lamp 4 blinks, and the buzzer sounds intermittently.
ELEC – + INDICATION SYSTEM E ● YAMAHA 8 7 MPH FUEL HOUR 6 5 4 Make sure the water temperature symbol 3 display and “WARNING” lamp 4 on, and the buzzer sounds continuity. MULTI D SPLAY 3 2 WARNING 1 x1000r/min 3 4 3. Check: ● Exhaust temperature warning indicator Not operating → Replace the multifunction meter. Checking steps: ● Supply DC 12 voltage to the natural color six-pin connector (+: red, –: black) with a battery. ● Connect the gray/yellow and black terminals with a jumper lead 1.
ELEC – + INDICATION SYSTEM E Speed meter 1. Check: ● Speed meter output voltage Within specification → Check the speed sensor output voltage and pulses. Out of specification → Replace. Speed meter output voltage: 10.5 V Checking steps: Supply DC 12 voltage to the natural color six-pin connector (+: red, –: black) with a battery. ● Connect the green and red terminals with a jumper lead 1.
HULL HOOD E CHAPTER 8 HULL AND HOOD HANDLEBAR ................................................................................................... 8-1 EXPLODED DIAGRAM ............................................................................. 8-1 REMOVAL AND INSTALLATION CHART ............................................... 8-1 SERVICE POINTS ..................................................................................... 8-7 Handlebar inspection.....................................................
HULL HOOD E BUZZER AND HOOD LOCK ......................................................................... 8-27 EXPLODED DIAGRAM ........................................................................... 8-27 REMOVAL AND INSTALLATION CHART ............................................. 8-27 HOSES........................................................................................................... 8-30 EXPLODED DIAGRAM ...........................................................................
HULL HOOD HANDLEBAR E HANDLEBAR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name HANDLEBAR COVER REMOVAL Screw Handlebar cover Screw Handlebar cover stay Spiral tube Band Q’ty 4 1 4 1 1 1 8-1 Service points Follow the left “Step” for removal.
HULL HOOD HANDLEBAR E EXPLODED DIAGRAM Step 7 8 9 10 11 12 Procedure/Part name Throttle cable Choke cable Bolt Upper handlebar holder Handlebar assembly Lower handlebar holder Q’ty 1 1 4 2 1 2 Service points Reverse the removal steps for installation.
HULL HOOD HANDLEBAR E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name HANDLEBAR REMOVAL QSTS cable (to jet nozzle) Q’ty 1 Grommet 1 2 3 Handlebar switch coupler QSTS cable 2 3 1 8-3 Service points Follow the left “Step” for removal. Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”. NOTE: Apply soapy water to the grommet for easier installation.
HULL HOOD HANDLEBAR E EXPLODED DIAGRAM Step 4 5 6 7 8 Procedure/Part name QSTS cable 1 Q’ty 1 Nut/washer QSTS converter Throttle cable Choke cable 2/2 1 1 1 Service points NOTE: Route the QSTS cables behind of the oil filler hose. Reverse the removal steps for installation.
HULL HOOD HANDLEBAR E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 Procedure/Part name HANDLEBAR DISASSEMBLY Band Bolt Grip end Spacer Screw/washer/spring washer QSTS grip assembly Screw Handlebar switch assembly Cable holder Q’ty 1 2 2 1 1/1/1 1 2 1 1 8-5 Service points Follow the left “Step” for disassembly.
HULL HOOD HANDLEBAR E EXPLODED DIAGRAM Step 10 11 12 13 14 15 Procedure/Part name Screw Throttle lever assembly Screw Choke lever assembly Handlebar grip Handlebar Q’ty 2 1 2 1 1 Service points NOTE: Apply adhesive to the handlebar and the inner surface of the handlebar grip. 1 Reverse the disassembly steps for assembly.
HULL HOOD HANDLEBAR E SERVICE POINTS Handlebar inspection 1. Inspect: ● Handlebar Bends/cracks/damage → Replace. Handlebar switch inspection Refer to “STARTING SYSTEM” in chapter 7. Handlebar assembly installation 1. Adjust: ● QSTS cable length a QSTS cable length: 77 ± 0.5 mm (3.03 ± 0.02 in) NOTE: ● Before adjusting the QSTS cables, set the control grip to the neutral position. ● Adjust the QSTS cable lengths a to the specified length and be sure to take up any slack. 2.
HULL HOOD HANDLEBAR E 3. Install: ● Throttle cable NOTE: Fit the seal into the glove in the bracket. 4. Install: ● Band 1 NOTE: After inserting the QSTS cables into the grommet, tie the end of grommet with the band. 5. Install: ● Spiral tube 1 NOTE: Be sure to install the spiral tube, containing the throttle cable, choke cable and handlebar switch lead, at least 50 mm (1.97 in) a into the steering column. 6.
HULL HOOD HANDLEBAR E 7. Adjust: ● Choke lever operation Refer to “CONTROL SYSTEM” in chapter 3. 8. Adjust: ● Throttle cable free play Refer to “CONTROL SYSTEM” in chapter 3. 9. Adjust: ● QSTS cable free play Refer to “CONTROL SYSTEM” in chapter 3.
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 8-10 Service points Follow the left “Step” for disassembly. Refer to “HANDLEBAR”.
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.
HULL HOOD QSTS GRIP E SERVICE POINTS QSTS cable inspection 1. Inspect: ● QSTS cables Frays/kinks/rough movement → Replace. QSTS grip inspection 1. Inspect: ● QSTS grip Damage/wear → Replace.
HULL HOOD STEERING COLUMN E STEERING COLUMN EXPLODED DIAGRAM 16 Nm (1.6 m • kgf, 11 ft • Ib) 1 2 3 4 REMOVAL AND INSTALLATION CHART Step 1 2 3 4 Procedure/Part name STEERING COLUMN REMOVAL Steering console cover assembly Nut/washer Plate Steering column assembly Rubber seal Q’ty Service points Follow the left “Step” for removal. Refer to “STEERING CONSOLE COVER”. 4/4 1 1 1 Reverse the removal steps for installation.
HULL HOOD STEERING COLUMN E EXPLODED DIAGRAM 6 8 1 7 2 5 7 4 16 Nm (1.6 m • kgf, 11 ft • Ib) 8 × 60 mm 26 Nm (2.6 m • kgf, 19 ft • Ib) 3 5 Nm (0.5 m • kgf, 3.6 ft • Ib) 2 REMOVAL AND INSTALLATION CHART Step 1 2 3 4 Procedure/Part name STEERING COLUMN DISASSEMBLY Grommet Bolt/washer/nut Steering arm Shim Q’ty Service points Follow the left “Step” for disassembly. 1 1/2/1 1 * *: Be sure to install the same number of shim(s) as installed originally at factory.
HULL HOOD STEERING COLUMN E EXPLODED DIAGRAM 6 8 1 7 2 5 7 4 16 Nm (1.6 m • kgf, 11 ft • Ib) 8 × 60 mm 26 Nm (2.6 m • kgf, 19 ft • Ib) 3 5 Nm (0.5 m • kgf, 3.6 ft • Ib) 2 Step 5 6 7 8 Procedure/Part name Washer Steering column Bushing Steering column housing Q’ty 1 1 2 1 Service points Reverse the disassembly steps for assembly.
HULL HOOD STEERING COLUMN E SERVICE POINTS Steering column bushing inspection 1. Inspect: ● Bushings Damage/wear → Replace. 2. Inspect: ● Steering column inspection Refer to “CONTROL SYSTEM” in chapter 3.
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 Procedure/Part name REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL Speed sensor coupler Cap Nut Speed sensor Steering cable end Bolt Steering cable holder Q’ty 1 1 1 1 1 1 1 8-17 Service points Follow the left “Step” for removal.
HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD E EXPLODED DIAGRAM Step 8 9 10 11 12 13 14 15 16 Procedure/Part name Cap Nut Steering cable Nut Pin QSTS cable end Cap Nut QSTS cable Q’ty 1 1 1 1 1 1 1 1 1 Service points Reverse the removal steps for installation.
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 cables inspection 1.
HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD E QSTS cable (jet pump side) installation 1. Install: ● QSTS cable (jet pump side) a QSTS cable set length (jet pump side): 12.0 ~ 14.0 mm (0.47 ~ 0.55 in) WARNING The QSTS cable must be screwed in more than 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 glove in the outer cable.
HULL HOOD FRONT HOOD E FRONT HOOD EXPLODED DIAGRAM 6 × 14 mm 5 Nm (0.5 m • kgf, 3.6 ft • Ib) 6 7 6 × 14 mm 6 Nm (0.6 m • kgf, 4.3 ft • Ib) 1 11 3 2 5 8 4 5 × 10 mm 1 Nm (0.1 m • kgf, 0.7 ft • Ib) 10 9 16 Nm (1.6 m • kgf, 11 ft • Ib) REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name FRONT HOOD REMOVAL Bolt Screw Seal washer Wind shield Pop nut Bolt Q’ty 2 8 8 1 8 2 8-21 Service points Follow the left “Step” for removal.
HULL HOOD FRONT HOOD E EXPLODED DIAGRAM 6 × 14 mm 5 Nm (0.5 m • kgf, 3.6 ft • Ib) 6 7 6 × 14 mm 6 Nm (0.6 m • kgf, 4.3 ft • Ib) 1 11 2 3 5 8 4 5 × 10 mm 1 Nm (0.1 m • kgf, 0.7 ft • Ib) 10 9 16 Nm (1.6 m • kgf, 11 ft • Ib) Step 7 8 9 10 11 Procedure/Part name Hood lock Front hood Nut Plate Hinge assembly Q’ty 1 1 2 1 1 Service points Reverse the removal steps for installation.
HULL HOOD STEERING CONSOLE COVER E STEERING CONSOLE COVER EXPLODED DIAGRAM 8 × 25 mm 8 2 Nm (0.2 m • kgf, 1.4 ft • Ib) 5 × 19 mm 5 9 6 4 2 3 Nm (0.3 m • kgf, 2.2 ft • Ib) 6 × 24 mm 3 1 7 5 Nm (0.5 m • kgf, 3.6 ft • Ib) 16 Nm (1.
HULL HOOD STEERING CONSOLE COVER E EXPLODED DIAGRAM 8 × 25 mm 8 2 Nm (0.2 m • kgf, 1.4 ft • Ib) 5 × 19 mm 5 9 6 4 2 3 Nm (0.3 m • kgf, 2.2 ft • Ib) 6 × 24 mm 3 1 7 5 Nm (0.5 m • kgf, 3.6 ft • Ib) 16 Nm (1.6 m • kgf, 11 ft • Ib) Step 6 7 8 9 Procedure/Part name Plate Nut/washer Bolt/square-ring Steering console cover assembly Q’ty 1 2/2 2/2 1 Service points NOTE: Remove the oil filler cap to remove the steering console cover assembly easier. Reverse the removal steps for installation.
HULL HOOD STEERING CONSOLE COVER E EXPLODED DIAGRAM 1 Nm (0.1 m • kgf, 0.7 ft • Ib) 5 × 20 mm 5 6 2 9 1 8 3 Nm (0.3 m • kgf, 2.2 ft • Ib) 6 × 18 mm 2 7 4 3 2 Nm (0.2 m • kgf, 1.4 ft • Ib) REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name STEERING CONSOLE COVER DISASSEMBLY Screw Side cover Nut Holder Multifunction meter Q’ty 4 2 2 1 1 8-25 Service points Follow the left “Step” for disassembly.
HULL HOOD STEERING CONSOLE COVER E EXPLODED DIAGRAM 1 Nm (0.1 m • kgf, 0.7 ft • Ib) 5 × 20 mm 5 6 2 9 1 8 3 Nm (0.3 m • kgf, 2.2 ft • Ib) 6 × 18 mm 2 7 4 3 2 Nm (0.2 m • kgf, 1.4 ft • Ib) Step 6 7 8 9 Procedure/Part name Screw Glove compartment Pop nut Steering console cover Q’ty 4 1 4 1 Service points Reverse the disassembly steps for assembly.
HULL HOOD BUZZER AND HOOD LOCK E BUZZER AND HOOD LOCK EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name BUZZER AND HOOD LOCK REMOVAL Steering console cover assembly Steering cable Ring nut Buzzer Bolt Bracket Bracket Q’ty Service points Follow the left “Step” for removal. Refer to “STEERING CONSOLE COVER”. Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”.
HULL HOOD BUZZER AND HOOD LOCK E EXPLODED DIAGRAM Step 6 7 8 9 Procedure/Part name Nut Bolt Hood lock assembly Grommet Q’ty 2 2 1 1 Service points Reverse the removal steps for installation.
HULL HOOD BUZZER AND HOOD LOCK E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name HOOD LOCK DISASSEMBLY Screw Hood lock button assembly Circlip Washer Pin Hook lever Spring Hood lock body Q’ty Service points Follow the left “Step” for disassembly. 2 1 1 1 1 1 1 1 Reverse the disassembly steps for assembly.
HULL HOOD HOSES E HOSES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 Procedure/Part name HOSES REMOVAL Engine unit Steering console cover assembly Band Ventilation hose (stern side) Ventilation hose (bow side) Q’ty 2 1 1 8-30 Service points Follow the left “Step” for removal. Refer to “ENGINE UNIT” in chapter 5. Refer to “STEERING CONSOLE COVER”. NOTE: ● Route the ventilation hose (bow side) in front of the fuel level sensor lead.
HULL HOOD HOSES E EXPLODED DIAGRAM Step 4 5 6 7 Procedure/Part name Band Check valve Oil tank breather hose Fuel tank breather hose Q’ty 1 1 1 2 Service points Reverse the removal steps for installation.
HULL HOOD HOSES E SERVICE POINTS Check valve inspection 1. Check: ● Check valve Faulty → Replace. Checking steps: Connect a hose to the end of check valve “A” and blow into it. Air should come out from end “B”. ● Connect the hose to the end of check valve “B” and blow into it. Air should not come out from end “A”. ● Ventilation hose installation 1. Install: ● Ventilation hose a NOTE: Insert the ventilation hose into the ventilation fitting until it reaches the bend a in the fitting.
HULL HOOD SEATS AND HAND GRIP SEATS AND HAND GRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name SEATS AND HAND GRIP REMOVAL Seat assembly Bolt Seat lock assembly Nut Notch Washer Q’ty 1 2 1 1 1 1 8-33 Service points Follow the left “Step” for removal.
HULL HOOD SEATS AND HAND GRIP E EXPLODED DIAGRAM Step 7 8 9 10 11 12 Procedure/Part name Rubber ring Nut/washer Bolt Bolt Hand grip Bracket Q’ty 1 2/2 2 2 1 1 Service points Reverse the removal steps for installation.
HULL HOOD SEATS AND HAND GRIP SERVICE POINTS Seat lock inspection 1. Inspect: ● Seat lock Damage/wear → Replace.
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 Band Fire extinguisher container Band Bolt Battery negative lead Bolt Battery positive lead Clip/breather hose Battery Cap nut/washer Holder Q’ty 1 1 1 1 1 1 1 1/1 1 2/2 1 8-36 Service points Follow the left “Step” for removal.
HULL HOOD BATTERY BOX E EXPLODED DIAGRAM Step 12 13 14 15 16 17 Procedure/Part name Holder Cap nut/washer Nut/washer Electrical box Battery box Stay Q’ty 1 2/2 4/4 1 1 Service points NOTE: Before installing the battery box, route the battery leads and battery breather hose through the holes of the battery box. 1 Reverse the removal steps for installation.
HULL HOOD EXHAUST SYSTEM E EXHAUST SYSTEM EXPLODED DIAGRAM 4 Nm (0.4 m • kgf, 2.9 ft • Ib) 4 Nm (0.4 m • kgf, 2.9 ft • Ib) 6 Nm (0.6 m • kgf, 4.3 ft • Ib) 6 × 30 mm 5 12 8 11 4 9 7 9 4 10 6 1 2 13 3 REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name EXHAUST SYSTEM REMOVAL Exhaust chamber assembly Floatation Hose clamp Exhaust joint Hose clamp Rubber hose Water lock Bolt Packing Q’ty 1 1 1 2 1 1 3 1 8-38 Service points Follow the left “Step” for removal.
HULL HOOD EXHAUST SYSTEM E EXPLODED DIAGRAM 4 Nm (0.4 m • kgf, 2.9 ft • Ib) 4 Nm (0.4 m • kgf, 2.9 ft • Ib) 6 Nm (0.6 m • kgf, 4.3 ft • Ib) 6 × 30 mm 5 12 8 11 4 9 7 9 4 10 6 1 2 13 3 Step 9 10 11 12 13 Procedure/Part name Hose clamp Water tank Rubber hose Exhaust outlet Floatation Q’ty 2 1 1 1 1 Service points NOTE: Remove parts 9 to 12 as a set. Reverse the removal steps for installation.
HULL HOOD EXHAUST SYSTEM E SERVICE POINTS Exhaust system inspection 1. Inspect: ● Water lock band Cracks/damage → Replace. 2. Inspect: ● Rubber hoses Burns/cracks/damage → Replace. 3. Inspect: ● Water lock Cracks/leaks → Replace. 4. Inspect: ● Water tank Cracks/damage/leaks → Replace. Exhaust component parts sub-assembly 1. Install: ● Exhaust outlet ● Rubber hose ● Water tank NOTE: the exhaust outlet 45 mm (1.8 in) a into the rubber hose. ● Make sure that there is a surface distance of 10 mm (0.
HULL HOOD DECK AND HULL E DECK AND HULL EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name DECK AND HULL DISASSEMBLY Bolt Bow eye Nut Rope hole fitting Nut Spout Bolt Q’ty 2 1 2 2 1 1 6 8-41 Service points Follow the left “Step” for disassembly.
HULL HOOD DECK AND HULL E EXPLODED DIAGRAM Step 8 9 10 11 12 13 14 Procedure/Part name Sponson Q’ty 2 Bolt Flap Nut/washer Screw/washer Drain plug Packing 8 2 4/4 4/4 2 2 Service points NOTE: Make sure install the starboard and port side sponsons to the same position. Reverse the disassembly steps for assembly.
HULL HOOD ENGINE MOUNT E ENGINE MOUNT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name ENGINE MOUNT REMOVAL Engine assembly Bolt Damper 1 Damper 2 Bolt Engine mount Liner Q’ty 4 1 1 8 4 2 8-43 Service points Follow the left “Step” for removal. Refer to “ENGINE UNIT” in chapter 5. Starboard side Reverse the removal steps for installation.
HULL HOOD ENGINE MOUNT E HULL REPAIR Shallow scratches 1. Sand the scratches with 400 grit sandpaper (either wet or dry) until the scratches are smooth. Then, sand the scratches once again with 600 grit sandpaper (either wet or dry). Deep scratches 1. Remove any sharp or rough edges from the hull surface. 2. Sand the scratches and a 1-inch circumference around them with 80 grit sandpaper (either wet or dry). 3. Clean the entire area with acetone and let it completely dry. 4.
HULL HOOD ENGINE MOUNT E Cracks and punctures NOTE: Before attempting to repair any cracks or punctures, refer to “WATER VEHICLE FRP REPAIR MANUAL”. 1. Remove any damaged fiberglass. 2. Cut the damaged area and separate it approximately 0.25 inch. 3. On the outside of the hull, grind the separated edge of the area to less than 5˚ as shown. 4. Working from inside the hull, grind the damaged area approximately 4 inches beyond the damage. 5.
HULL HOOD ENGINE MOUNT E Insert nut NOTE: Use the insert nut when: ● A pop nut which was attached to the hull slipped off or, ● When a bolt which was fastened to an insert nut or pop nut broke. Part No. Part name Remarks EW2-62733-09 Nut Stainless steel, M6 ● ● ● Nut 1 Thread direction 2 Slot to be threaded 3 NOTE: Drilling size Material Pilot hole diameter FRP or SMC 9.1 ~ 9.2 mm (0.36 in) Brass 9.4 mm (0.
HULL HOOD ENGINE MOUNT E 4. First, apply tape 1 to the inner surface of the hull and then laminate fiberglass mats over the tape with resin. NOTE: When it is possible to work inside the hull, laminate the mats from the inside. 5. Sand the outer surface of the hull until it is smooth. 6. Install the ride plate. 7. Drill a 20 mm (0.79 in) deep hole in the center of the laminated fiberglass layers with a 9.2 mm (0.36 in) diameter drill bit. 8.
HULL HOOD ENGINE MOUNT E 2. To prevent water from entering the urethane foam, apply silicone sealant to the inside of the hole as shown. 3. Install the insert nut as explained in “Example 1”. ● Brass insert nut 1 ● Hull 2 ● Urethane foam 3 ● Silicone sealant 4 Graphic removal 1. Hold a hair dryer approximately 1.5 inches above the graphic 1. 2. Apply heat to one corner of the graphic. 3.
TRBL ANLS E CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS ..................................................................................... 9-1 TROUBLE ANALYSIS CHART .................................................................
TRBL ANLS TROUBLE ANALYSIS E TROUBLE ANALYSIS NOTE: The following items should be checked before the “Trouble analysis” chart is consulted. 1. The battery is charged and its specified gravity is within specification. 2. There are no incorrect wiring connections. 3. Wiring connections are properly secured and not rusty. 4. The lock plate is attached to the engine stop lanyard switch. 5. Fuel is reaching the carburetors.
TRBL ANLS TROUBLE ANALYSIS YPVS SERVOMOTOR DOES NOT MOVE POOR BATTERY CHARGING IRREGULAR WARNING INDICATION Items to be checked BILGE INCREASE LOOSE STEERING OVERHEATING POOR PERFORMANCE ENGINE WILL NOT STOP ENGINE STALLS ROUGH IDLING ENGINE WILL NOT START Problems E Items Rubber coupling Pilot water hose Water hose Water passage JET PUMP UNIT Duct Impeller Intake screen Bearings Intake duct Water inlet hose Bilge hose Bilge strainer Bilge hose joint Valve body ELECTRICAL CDI unit Lighting
YAMAHA MOTOR CO., LTD. Printed in USA Feb.
WIRING DIAGRAM COLOR CODE B Br Ch G Gy L O R W Y B/O B/W GP1200R 1 Lighting coil 2 Pickup coil G G W/R B/O 3 CDI unit : : : : : : : : : : : : Black Brown Chocolate Green Gray Blue Orange Red White Yellow Black/orange Black/white B/Y : Black/yellow Gy/B : Gray/black Gy/R : Gray/red Gy/Y : Gray/yellow L/B : Blue/black L/R : Blue/red R/L : Red/blue R/W : Red/white R/Y : Red/yellow W/L : White/blue W/R : White/red B Gy/B B/O W/R G Gy/Y Gy Br B/Y B/W B O B/O B/O B W G Gy/R W/R L B/Y
