Service manual

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LIT186160198

LIT-18616-01-98 F0D-28197-Z9-11

SERVICE

MANUAL

WaveRunner

XL1200Ltd

Summary of content (244 pages)

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WaveRunner XL1200Ltd SERVICE MANUAL LIT186160198 LIT-18616-01-98 F0D-28197-Z9-11
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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.
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E HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.
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E IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, 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.
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E HOW TO USE THIS MANUAL 1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 2 Numbers are given in the order of the jobs in the exploded diagram. 3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”). 4 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.
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E 1 A50001-1-4 2 GEN INFO SYMBOLS Symbols 1 to 9 are designed as thumbtabs to indicate the content of a chapter.
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E A30000-0 INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT FUEL SYSTEM POWER UNIT JET PUMP UNIT GEN INFO SPEC INSP ADJ FUEL POWR JET PUMP – ELECTRICAL SYSTEM HULL AND HOOD TROUBLE-ANALYSIS + ELEC HULL HOOD TRBL ANLS 1 2 3 4 5 6 7 8 9
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GEN INFO E CHAPTER 1 GENERAL INFORMATION IDENTIFICATION NUMBERS ......................................................................... 1-1 PRIMARY l.D. NUMBER........................................................................... 1-1 ENGINE SERIAL NUMBER ...................................................................... 1-1 JET PUMP UNIT SERIAL NUMBER ........................................................ 1-1 HULL IDENTIFICATION NUMBER (H.l.N.)..............................................
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GEN INFO IDENTIFICATION NUMBERS E A60700-0* IDENTIFICATION NUMBERS 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: F0D: 800101 ~ ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the cylinder head. Starting serial number: 66V: 000101 ~ JET PUMP UNIT SERIAL NUMBER The jet pump unit serial number is stamped on a label attached to the intermediate housing.
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GEN INFO SAFETY WHILE WORKING E SAFETY WHILE WORKING 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.
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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.
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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.
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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 NOTE: ● For U.S.A. and Canada, use part numbers starting with “YB-”, “YM-”, “YU-” or “YW-”. ● For other countries, use part numbers starting with “90890-”.
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GEN INFO SPECIAL TOOLS E REMOVAL AND INSTALLATION 1 2 YW-06551 YW-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. Shaft holder (intermediate shaft) P/N. YB-06552 90890-06552 5. Driver rod (intermediate shaft and jet pump) P/N. YB-06071, YB-06229 90890-06602, 90890-06605, 90890-06606 6. Bearing outer race attachment (intermediate shaft) P/N. YB-06016 90890-06626 7. Drive shaft holder (impeller) P/N.
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SPEC E CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS.......................................................................... 2-1 MAINTENANCE SPECIFICATIONS................................................................ 2-3 ENGINE..................................................................................................... 2-3 JET PUMP UNIT....................................................................................... 2-4 HULL AND HOOD ...................................................
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SPEC GENERAL SPECIFICATIONS E GENERAL SPECIFICATIONS Item MODEL CODE Hull Engine 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
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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 XL1200Ltd 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) 70 (18.5, 15.4) 12 (3.17, 2.64) 5.5 (1.45, 1.
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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 XL1200Ltd mm (in) K
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SPEC MAINTENANCE SPECIFICATIONS Item CRANKSHAFT ASSEMBLY Crank width A Deflection limit B Deflection limit C Big end side clearance D Maximum small end axial play E 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 XL1200Ltd 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.
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SPEC MAINTENANCE SPECIFICATIONS E ELECTRICAL Item BATTERY Type Capacity CDI UNIT (B/W – B) 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 Minimum charging current IGNITION COIL Minimum spark gap Primary coil r
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SPEC MAINTENANCE SPECIFICATIONS Item RECTIFIER/REGULATOR (R – B) Output peak voltage lower limit @cranking 1 @cranking 2 @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 XL1200Ltd V 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.
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SPEC TIGHTENING TORQUES E TIGHTENING TORQUES SPECIFIED TORQUES 20 2.0 14 Nut M10 2 Bolt M10 10 Nut M10 2 Bolt Bolt Bolt Screw M6 M8 M8 M4 6 4 4 24 40 23 40 15 40 12 17 17 1 4.0 2.3 4.0 1.5 4.0 1.2 1.7 1.7 0.1 29 17 29 11 29 8.7 12 12 0.7 Bolt M6 2 10 1.0 7.2 Bolt Bolt Bolt M6 M5 M14 10 3 3 Bolt M8 22 Bolt M10 12 Bolt M10 8 10 4 25 23 23 36 22 40 15 51 1.0 0.4 2.5 2.3 2.3 3.6 2.2 4.0 1.5 5.1 7.2 2.9 18 17 17 26 16 29 11 37 2-7 LT 1 271 — LT — 271 29 LT 4.
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TIGHTENING TORQUES Bolt M6 Bolt LT 4 12 23 12 1.2 2.3 1.2 8.7 17 8.7 M20 1 18 1.8 13 Coupling Bolt Bolt Bolt Bolt Bolt Bolt Nut Nut M27 M8 M6 M8 M8 M8 M8 M16 M10 1 3 4 4 4 2 2 1 4 37 17 8 17 17 16 16 70 27 3.7 1.7 0.8 1.7 1.7 1.6 1.6 7.0 2.7 27 12 5.8 12 12 12 12 51 20 Bolt M8 4 17 1.7 12 LT Bolt M8 4 16 1.6 12 Nut Bolt Nut Nut Nut Bolt M8 M6 M10 M8 M8 M8 4 4 2 2 2 8 20 7 26 16 16 17 2.0 0.7 2.6 1.6 1.6 1.7 14 5.1 19 12 12 12 LT LT LT LT LT LT LT LT LT LT 8.
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SPEC TIGHTENING TORQUES Nut A Bolt B 8 mm 10 mm 12 mm 14 mm 17 mm M5 M6 M8 M10 M12 E GENERAL TORQUE General torque specifications Nm m•kg ft•lb 5.0 0.5 3.6 8.0 0.8 5.8 18 1.8 13 36 3.6 25 43 4.3 31 This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this manual.
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SPEC CABLE AND HOSE ROUTING E CABLE AND HOSE ROUTING 1 2 3 4 5 6 7 8 Fuel breather hose Pilot water hose QSTS cable Fuel hose Shift cable Steering cable Fuel filter Ventilation hose 9 0 A B C D E F Ground lead Starter motor lead Electrical box lead Generator lead Pickup coil lead YPVS cable Speed sensor lead Pilot water outlet 2-10 G H I J K L M Battery Battery breather hose Battery positive lead Battery negative lead Choke knob Fuel cock Choke cable
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SPEC 1 2 3 4 5 6 7 8 CABLE AND HOSE ROUTING Throttle cable Switch box lead QSTS cable Buzzer lead To pickup coil To battery positive terminal To starter motor To multi-function meter 9 To water/exhaust temperature sensor 0 To generator A Battery breather hose B Battery negative lead C Water hose D Speed sensor lead E Fuel breather hose 2-11 E F G H I J To fuel filter Choke cable Fuel return hose Shift cable Steering cable
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INSP ADJ E CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART .............................................................. 3-1 PERIODIC SERVICE ........................................................................................ 3-2 CONTROL SYSTEM ................................................................................. 3-2 Steering master inspection .............................................................. 3-2 Steering cable inspection and adjustment ..............
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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.
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INSP ADJ CONTROL SYSTEM E PERIODIC SERVICE CONTROL SYSTEM Steering master inspection 1. Inspect: ● Steering master Excessive play → Replace the steering master. Refer to “STEERING MASTER” 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: ● Jet nozzle clearance a, b Difference → Adjust. Inspection steps: ● Turn the handlebar from lock to lock. ● Measure clearances a and b.
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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: 7 Nm (0.7 m • kg, 5.1 ft • lb) R. NOTE: If the steering cable cannot be properly adjusted at the steering column side, make adjustments at the jet pump side. Throttle cable inspection and adjustment NOTE: Before adjusting the throttle lever free play, adjust the trolling speed. 1.
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INSP ADJ CONTROL SYSTEM E Choke cable inspection and adjustment 1. Inspect: ● Choke knob (pull the choke knob all the way out) Choke knob automatically returns → Adjust. Adjustment steps: ● Turn in the adjusting nut 1 until the choke knob does not automatically return. 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. ● Set the jet nozzle in the center position.
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INSP ADJ CONTROL SYSTEM E 2. Adjust: ● QSTS cable Adjustment steps: ● Set the control grip in the neutral position. ● Set the jet nozzle in the center position. ● Remove the nut 1 and pivot pin 2. ● Loosen the locknut 3. ● Turn the cable joint 4 for adjusting. Turn in Length b is increased. Turn out Length a is increased. WARNING The cable joint must be screwed in more than 8 mm (0.31 in). ● Connect the cable joint 4 and pivot pin 2 and tighten the nut 1. T. Nut: 4 Nm (0.4 m • kg, 2.9 ft • lb) R.
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INSP ADJ CONTROL SYSTEM E Shift cable inspection and adjustment 1. Check: ● Reverse gate stopper lever position Incorrect → Adjust. Checking steps: Set the shift lever to the reverse position. ● Check to make sure the reverse gate 1 contacts the stopper 2 on the bracket and the lever 3 contacts the reverse gate. ● 2. Adjust: ● Shift cable joint Adjustment steps: ● Loosen the locknut 1. ● Disconnect the cable joint 2 from the ball joint 3. ● Turn the cable joint to align it with the ball joint.
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INSP ADJ CONTROL SYSTEM E YPVS cable adjustment 1. Check: ● YPVS valve position Incorrect position → Adjust the YPVS cable. Checking steps: Initiate the multi-function meter “START” mode so the display comes on. ● 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. ● ● Check that the hole a in the pulley is aligned with the hole in the cylinder when the YPVS valve is fully closed. 2.
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INSP ADJ CONTROL SYSTEM/FUEL SYSTEM E 3. Adjust: ● YPVS cables 1 and 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. ● ● ● ● ● ● Finger tighten the locknut 1 and 2.
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INSP ADJ FUEL SYSTEM E Fuel line inspection 1. Inspect: ● Fuel filter 1 Contaminants → Replace. Cracks/damage → Replace. Water contamination → Replace and check the fuel tank. ● Fuel hose ● Fuel tank ● Fuel hoses through part ● Fuel filler cap Cracks/damage → Replace. 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.
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INSP ADJ FUEL SYSTEM/OIL INJECTION SYSTEM E 2. Adjust: ● Trolling speed Adjustment steps: Start the engine and allow it to warm up for several minutes. ● Attach the engine tachometer to the spark plug lead. ● Engine tachometer: YU-8036-A/90890-06760 ● Turn the remote throttle stop screw 1 in or out until the specified trolling speed is obtain. OIL INJECTION SYSTEM Oil filter inspection 1. Inspect: ● Oil filter Contaminants → Clean. Frays/tears → Replace. ● Rubber seal Cracks/wear → Replace.
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INSP ADJ OIL INJECTION SYSTEM/POWER UNIT E 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 oil. ● Recommended engine oil: YAMALUBE 2-W oil only ● ● ● Loosen the air bleed screw 1 two full turns and make sure that both the oil and air bubbles flow out. When there are no air bubbles left, tighten the air bleed screw. Wipe up any spilt oil. T. Screw: 5 Nm (0.5 m • kg, 3.6 ft • lb) R.
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INSP ADJ POWER UNIT/ELECTRICAL E 3. Measure: ● Spark plug gap a Out of specification → Regap. Spark plug gap: 1.0 ~ 1.1 mm (0.039 ~ 0.043 in) 4. Tighten: ● Spark plug T. Spark plug: 25 Nm (2.5 m • kg, 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.
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INSP ADJ ELECTRICAL E Antidote (EXTERNAL): ● SKIN - Wash with water. ● EYES - Flush with water for 15 minutes and get immediate medical attention. Antidote (INTERNAL): ● Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention. 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.
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INSP ADJ ELECTRICAL E 2. Inspect: ● Electrolyte level Low → Add distilled water. The electrolyte level should be between the upper 1 and lower 2 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.
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INSP ADJ ELECTRICAL/JET PUMP UNIT E 5. Install: ● Battery breather hose 1 ● Battery ● Positive lead 2 ● Negative lead 3 ● Battery band CAUTION: ● 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. ● Coat the terminals with a water resistant grease to minimize terminal corrosion.
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INSP ADJ JET PUMP UNIT/GENERAL E Water inlet filter inspection 1. Inspect: ● Water inlet filter Contaminants → Clean. Cracks/damage → Replace. Inspection steps: Remove the water inlet cover 1. ● Inspect the water inlet filter mesh a. ● Reinstall the removed parts. ● Bilge strainer inspection 1. Inspect: ● Bilge strainer Contaminants → Clean. Cracks/damage → Replace. Inspection steps: ● Remove the coupling cover. ● Disconnect the bilge strainer 1 from the bilge strainer holder.
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INSP ADJ GENERAL E Lubrication points 1. Lubricate: ● Throttle cable (handlebar side) ● QSTS control cables (handlebar side) Recommended lubricant: Rust inhibitor NOTE: ● Before lubricating the throttle cable, squeeze the throttle lever and remove the rubber seal 1. ● Before lubricating the QSTS control cables, remove the trim grip guide. 2.
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INSP ADJ GENERAL E 3. Lubricate: ● Nozzle pivot shaft ● Steering cable (nozzle side) ● QSTS cable (nozzle side) Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) 4. Lubricate: ● Steering cable ● Steering cable joint ● Shift cable ● Shift cable joint NOTE: Disconnect the joints and apply a small amount of grease. Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) 5.
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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 .......................................................................
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FUEL CARBURETOR .............................................................................................. 4-18 EXPLODED DIAGRAM ........................................................................... 4-18 REMOVAL AND INSTALLATION CHART ............................................. 4-18 SERVICE POINTS ................................................................................... 4-21 Diaphragm inspection ....................................................................
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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 9 Procedure/Part name FUEL COCK AND FUEL FILTER REMOVAL Screw Knob Nut Washer Fuel cock assembly Fuel hose Holder Fuel filter Fuel hose Q’ty Service points Follow the left “Step” for removal. 1 1 1 1 1 3 1 1 1 Reverse the removal steps for installation.
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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.
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FUEL CHOKE CABLE E CHOKE CABLE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name CHOKE CABLE REMOVAL Screw Knob Friction adjusting nut Nut Choke cable Q’ty Service points Follow the left “Step” for removal. 1 1 1 1 1 Reverse the removal steps for installation.
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FUEL OIL TANK E OIL TANK EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name OIL TANK REMOVAL Exhaust chamber assembly Intake duct Hose clamp Oil filler cap Screw Oil filler neck Rubber seal Oil level sensor coupler Q’ty 1 1 6 1 1 1 4-4 Service points Follow the left “Step” for removal. Refer to “EXHAUST CHAMBER ASSEMBLY” in chapter 5. Refer to “INTAKE DUCT AND SILENCER”.
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FUEL OIL TANK E EXPLODED DIAGRAM Step 7 8 9 10 11 12 13 14 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.
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FUEL OIL TANK E SERVICE POINTS Oil filter inspection Refer to “OIL INJECTION SYSTEM” in chapter 3. Oil level switch inspection Refer to “INDICATION SYSTEM” in chapter 7. Oil tank inspection 1. Inspect: ● Oil tank Cracks/damage → Replace.
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FUEL FUEL TANK E FUEL TANK EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name FUEL TANK REMOVAL Engine unit Oil tank Hose clamp Fuel filler cap Nut Fuel filler neck Rubber seal Fuel level sensor coupler Fuel reserve hose Q’ty 1 1 1 1 1 1 1 4-7 Service points Follow the left “Step” for removal. Refer to “ENGINE UNIT” in chapter 5. Refer to “OIL TANK”.
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FUEL FUEL TANK E EXPLODED DIAGRAM Step 8 9 10 11 12 13 14 15 16 17 Procedure/Part name Fuel hose Fuel breather hose Fuel tank assembly Hose clamp Fuel filler hose Hose clamp Fuel sensor assembly One way valve Screw Filter Q’ty 1 1 1 1 1 1 1 1 1 1 Service points Reverse the removal steps for installation.
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FUEL FUEL TANK 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”. ● 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.
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FUEL INTAKE DUCT AND SILENCER INTAKE DUCT AND SILENCER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name INTAKE DUCT AND SILENCER REMOVAL Exhaust chamber assembly Q’ty Refer to “EXHAUST CHAMBER ASSEMBLY” in chapter 5. Refer to “MUFFLER ASSEMBLY” in chapter 5. Muffler assembly 1 2 3 4 Hose clamp Joint hose Bolt Intake duct Service points Follow the left “Step” for removal.
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FUEL INTAKE DUCT AND SILENCER E EXPLODED DIAGRAM Step 5 6 7 8 9 10 Procedure/Part name Hook Silencer case Bolt Filter Silencer plate O-ring Q’ty 5 1 6 1 1 3 Service points Reverse the removal steps for installation.
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FUEL CARBURETOR UNIT E CARBURETOR UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name CARBURETOR UNIT REMOVAL Silencer Oil pump cable Throttle cable Choke cable Fuel delivery hose Fuel return hose Oil delivery hose Q’ty 1 1 1 1 1 3 4-12 Service points Follow the left “Step” for removal. Refer to “INTAKE DUCT AND SILENCER”.
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FUEL CARBURETOR UNIT E EXPLODED DIAGRAM Step 7 8 9 10 11 Procedure/Part name Fuel pump vacuum hose Bolt Bolt Carburetor assembly Gasket Q’ty 3 6 4 1 1 4-13 Service points Not reusable Reverse the removal steps for installation.
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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 3 1 1 1 4-14 Service points Follow the left “Step” for removal.
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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.
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FUEL CARBURETOR UNIT E SERVICE POINTS Throttle valve synchronization inspection and adjustment 1. Check: ● Throttle valve synchronization Different clearances → 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.
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FUEL CARBURETOR UNIT E Choke cable and throttle cable installation 1. Install: ● Choke cable 1 ● Throttle cable 2 Choke cable guide installation position a: 13 ~ 15 mm (0.51 ~ 0.59 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.
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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 3 1 4 1/1 1 2 1 1 1 4-18 Service points Follow the left “Step” for disassembly.
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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.
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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.
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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.
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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.
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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”.
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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.
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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.
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FUEL OIL PUMP E OIL PUMP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name OIL PUMP REMOVAL Exhaust chamber assembly Intake duct Oil pump cable Oil delivery hose Bolt Bleed hose stay Bolt Q’ty 1 3 1 1 2 4-26 Service points Follow the left “Step” for removal. Refer to “EXHAUST CHAMBER ASSEMBLY” in chapter 5. Refer to “INTAKE DUCT AND SILENCER”.
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FUEL OIL PUMP E EXPLODED DIAGRAM Step 6 7 8 9 Procedure/Part name Oil pump assembly Gasket Oil hose 1 Oil hose 2 Q’ty 1 1 1 1 Service points Not reusable Reverse the removal steps for installation.
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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.
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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 → Clean. 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. Refer to “OIL INJECTION SYSTEM” in chapter 3. Check valve inspection 1. Check: ● Check valve Faulty → Replace.
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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.
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POWR E CHAPTER 5 POWER UNIT EXHAUST CHAMBER ASSEMBLY ................................................................ 5-1 EXPLODED DIAGRAM ............................................................................. 5-1 REMOVAL AND INSTALLATION CHART ............................................... 5-1 MUFFLER ASSEMBLY ................................................................................... 5-4 EXPLODED DIAGRAM .............................................................................
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POWR CYLINDERS ................................................................................................... 5-25 EXPLODED DIAGRAM ........................................................................... 5-25 REMOVAL AND INSTALLATION CHART ............................................. 5-25 SERVICE POINTS ................................................................................... 5-26 Cylinder inspection ......................................................................... 5-26 PISTONS .
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POWR EXHAUST CHAMBER ASSEMBLY EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name EXHAUST CHAMBER ASSEMBLY REMOVAL Exhaust temperature sensor coupler Cap/bolt Cover Clamp/hose Hose clamp Hose clamp Bolt Bolt Q’ty 1 3/3 1 4/4 2 2 2 2 5-1 Service points Follow the left “Step” for removal.
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POWR EXHAUST CHAMBER ASSEMBLY E EXPLODED DIAGRAM Step 9 10 11 12 13 14 15 16 17 Procedure/Part name Exhaust chamber stay Bolt Bolt Exhaust chamber assembly Clamp/hose Gasket Pin Outer exhaust joint Inner exhaust joint Q’ty 1 3 1 1 1/1 1 2 1 1 Service points Not reusable Reverse the removal steps for installation.
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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.
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POWR MUFFLER ASSEMBLY E MUFFLER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name MUFFLER ASSEMBLY REMOVAL Exhaust chamber assembly Cylinder head Band Ventilation hose Screw Ventilation duct Water temperature sensor coupler Clamp/hose Q’ty 1 1 4 1 1 1/1 5-4 Service points Follow the left “Step” for removal. Refer to “EXHAUST CHAMBER ASSEMBLY”. Refer to “CYLINDER HEAD”.
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POWR MUFFLER ASSEMBLY E EXPLODED DIAGRAM Step 7 8 9 10 11 12 13 14 15 Procedure/Part name Hose clamp Water lock band Bolt Gear case grease hose Bolt Bolt Bolt Muffler stay 2 Muffler assembly Q’ty 1 1 Service points Slide the water lock toward back to disconnect the muffler assembly. 4 1 2 2 1 1 1 Reverse the removal steps for installation.
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POWR MUFFLER ASSEMBLY E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 Procedure/Part name MUFFLER DISASSEMBLY Exhaust temperature sensor Water temperature sensor Nut Hanger Bolt Muffler stay Bolt Cover Gasket Q’ty 1 1 2 2 2 1 6 1 1 5-6 Service points Follow the left “Step” for disassembly.
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POWR MUFFLER ASSEMBLY E EXPLODED DIAGRAM Step 10 11 12 13 14 15 16 17 18 Procedure/Part name Catalyst housing Gasket Catalyst Gasket Pin Bolt Mixing joint Gasket Muffler Q’ty 1 1 1 1 2 6 1 1 1 Service points Not reusable Not reusable Not reusable Reverse the disassembly steps for assembly.
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POWR MUFFLER ASSEMBLY E SERVICE POINT Catalyst inspection 1. Inspect: ● Catalyst Cracks/damage → Replace.
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POWR EXHAUST MANIFOLD AND LEADS E EXHAUST MANIFOLD AND LEADS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name EXHAUST MANIFOLD AND LEADS REMOVAL Battery lead (negative and positive) Exhaust chamber assembly Q’ty AC magneto coupler Bolt YPVS cable holder YPVS cable Clamp/hose 1 2 1 2 1/1 Service points Follow the left “Step” for removal. Refer to “ELECTRICAL BOX” in chapter 7. Refer to “EXHAUST CHAMBER ASSEMBLY”.
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POWR EXHAUST MANIFOLD AND LEADS E EXPLODED DIAGRAM Step 6 7 8 9 10 11 12 13 14 15 Procedure/Part name Bolt Bolt Nut Exhaust manifold Gasket Pin Bolt Battery negative lead Nut/washer Starter motor lead Q’ty 4 6 2 1 1 2 1 1 1/1 1 Service points Not reusable Reverse the removal steps for installation.
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POWR EXHAUST MANIFOLD AND LEADS E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name EXHAUST MANIFOLD DISASSEMBLY Clamp/hose Bolt Joint 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.
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POWR ENGINE UNIT E ENGINE UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 Procedure/Part name ENGINE UNIT REMOVAL Exhaust chamber assembly Muffler assembly Carburetor Oil pump Spark plug lead Bolt Collar Q’ty 3 1 1 5-12 Service points Follow the left “Step” for removal. Refer to “EXHAUST CHAMBER ASSEMBLY”. Refer to “MUFFLER ASSEMBLY”. Refer to “CARBURETOR” in chapter 4. Refer to “OIL PUMP” in chapter 4.
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POWR ENGINE UNIT E EXPLODED DIAGRAM Step 4 5 6 7 Procedure/Part name Coupling cover Bolt/washer Engine assembly Shim Q’ty 1 4/4 1 * *: As required 5-13 Service points Install the shims original position. Reverse the removal steps for installation.
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POWR ENGINE UNIT E SERVICE POINTS Shim removal 1. Remove: ● Shims NOTE: To ease reassembly and coupling alignment, remove the shims and organize them in their respective groups (e.g., front right, rear left) prior to removing the mounting bolts. Engine mount inspection 1. Inspect: ● Engine mounts Cracks/damage → Replace. Coupling clearance inspection 1. Measure: ● Clearance a ● Clearance b (with a straightedge and thickness gauge) Out of specification → Adjust with the shims.
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POWR REED VALVES E REED VALVES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name REED VALVE REMOVAL Exhaust chamber assembly Q’ty Muffler assembly Carburetor unit 1 2 Bolt Reed valve plate 18 1 5-15 Service points Follow the left “Step” for removal. Refer to “EXHAUST CHAMBER ASSEMBLY”. Refer to “MUFFLER ASSEMBLY”. Refer to “CARBURETOR UNIT” in chapter 4. NOTE: Tighten the bolts in the proper sequence as shown.
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POWR REED VALVES E EXPLODED DIAGRAM Step 3 4 5 6 Procedure/Part name Reed valve assembly Screw Valve stopper Reed valve Q’ty 3 24 6 6 Service points Reverse the removal steps for installation.
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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.
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POWR YPVS E YPVS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name YPVS REMOVAL YPVS cable 1 and 2 Q’ty Exhaust chamber assembly 1 2 3 4 5 6 Bolt YPVS cable bracket YPVS valve cover Gasket Spacer Link joint/cover 12 1 3 3 2 2/2 5-18 Service points Follow the left “Step” for removal. Refer to “EXHAUST MANIFOLD AND LEADS”. Refer to “EXHAUST CHAMBER ASSEMBLY”.
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POWR YPVS E EXPLODED DIAGRAM Step 7 8 9 10 11 12 13 Procedure/Part name Bolt (M4) Circlip Shaft 3 Shaft 2 Shaft 1 Washer YPVS valve lever Q’ty 3 5 1 1 1 5 3 5-19 Service points NOTE: During installation, align the hole a in the YPVS shaft with the screw.
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POWR YPVS E EXPLODED DIAGRAM Step 14 15 16 Procedure/Part name Bolt (M5) 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.
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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.
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POWR CYLINDER HEAD E CYLINDER HEAD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name CYLINDER HEAD REMOVAL Exhaust chamber assembly Spark plug Bolt Bolt Bolt Bolt Q’ty 3 2 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.
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POWR CYLINDER HEAD E EXPLODED DIAGRAM Step 6 7 8 9 Procedure/Part name Cylinder head cover Gasket Cylinder head Gasket Q’ty 1 1 1 1 5-23 Service points Not reusable Not reusable Reverse the removal steps for installation.
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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.
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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.
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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.
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POWR PISTONS E PISTONS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 Procedure/Part name PISTON REMOVAL Cylinders Piston pin clip Q’ty 6 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 3 3 6 5-27 NOTE: Make sure that the arrow b faces towards the exhaust side.
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POWR PISTONS E EXPLODED DIAGRAM Step 5 6 Procedure/Part name Bearing Piston ring Q’ty 3 6 Service points CAUTION: Align each end gap with its respective locating pin. Reverse the removal steps for installation.
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POWR PISTONS E SERVICE POINTS Piston pin clip removal and installation 1. Remove and install: ● Piston pin clip NOTE: Before removing or installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. Piston inspection 1. Eliminate: ● Carbon deposits (from the piston crown and piston ring grooves) 2. Inspect: ● Piston wall Score marks → Repair with 600 ~ 800 grit wet sandpaper or replace.
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POWR PISTONS E 4. Calculate: ● Piston-to-cylinder clearance Out of specification → Replace the piston, piston rings and cylinder as a set. PISTON CYLINDER PISTON = – CLEARANCE BORE DIAMETER 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.
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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.
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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.
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POWR GENERATOR AND STARTER MOTOR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name GENERATOR COVER REMOVAL Engine unit Oil pump Band Bolt Bolt Ground lead Generator cover Washer Q’ty 1 1 7 1 1 2 5-33 Service points Follow the left “Step” for removal. Refer to “ENGINE UNIT”. Refer to “OIL PUMP” in chapter 4.
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POWR GENERATOR AND STARTER MOTOR E EXPLODED DIAGRAM Step 7 8 9 10 11 12 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.
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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.
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POWR GENERATOR AND STARTER MOTOR E 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 Starter motor Q’ty Service points Follow the left “Step” for removal. 1 1 1 1 1 2 1 Reverse the removal steps for installation.
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POWR GENERATOR AND STARTER MOTOR E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 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 5-37 Service points Follow the left “Step” for disassembly.
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POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step 8 9 10 Procedure/Part name Weight Spring Pinion gear Q’ty 3 1 1 Service points Reverse the disassembly steps for assembly.
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POWR GENERATOR AND STARTER MOTOR E SERVICE POINTS Drive coupling removal and installation 1. Remove: ● Drive coupling Coupler wrench: YW-06551/90890-06551 Flywheel holder: YW-06550/90890-06550 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.
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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).
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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 5-41 Service points Follow the left “Step” for disassembly. Refer to “PISTONS”. Refer to “GENERATOR AND STARTER MOTOR”.
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POWR CRANKCASE E EXPLODED DIAGRAM Step 7 8 9 10 11 12 13 Procedure/Part name Bolt Bolt Bolt Lower crankcase Pin Crankshaft assembly Upper crankcase Q’ty 1 12 4 1 2 1 1 Service points NOTE: Tighten the bolts in sequence as shown. Reverse the disassembly steps for assembly.
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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: After installation, make sure that the crankshaft rotates smoothly.
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POWR CRANKSHAFT E CRANKSHAFT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 Procedure/Part name CRANKSHAFT REMOVAL Crankcase Oil seal Bearing Oil seal 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 grooves in the crankcase body. Reverse the removal steps for installation.
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POWR CRANKSHAFT E SERVICE POINTS Crankshaft inspection 1. Measure: ● Crank width A Out of specification → Replace. Crank width: 72.95 ~ 73.00 mm (2.872 ~ 2.835 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.
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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.
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JET PUMP E CHAPTER 6 JET PUMP UNIT JET PUMP UNIT ............................................................................................. 6-1 EXPLODED DIAGRAM ............................................................................. 6-1 REMOVAL AND INSTALLATION CHART ............................................... 6-1 REVERSE GATE.............................................................................................. 6-3 EXPLODED DIAGRAM .....................................................
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JET PUMP BEARING HOUSING..................................................................................... 6-15 EXPLODED DIAGRAM ........................................................................... 6-15 REMOVAL AND INSTALLATION CHART ............................................. 6-15 SERVICE POINTS ................................................................................... 6-18 Driven coupling removal and installation..................................... 6-18 Driven coupling shaft removal.
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JET PUMP JET PUMP UNIT E JET PUMP UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 10 11 Procedure/Part name JET PUMP UNIT REMOVAL Bolt Bolt Intake screen Bolt Intake duct Screw Speed sensor Bolt Jet pump cover Shift cable joint QSTS cable joint Q’ty 2 2 1 4 1 4 1 4 1 1 1 6-1 Service points Follow the left “Step” for removal.
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JET PUMP JET PUMP UNIT E EXPLODED DIAGRAM Step 12 13 14 15 16 17 18 19 Procedure/Part name Clamp/bilge hose Nut/washer Steering cable joint Clamp/spout hose Bolt Bolt Jet pump unit assembly Dowel pin Q’ty 1/1 1/2 1 1/1 1 4 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 shaft spline (female). Reverse the removal steps for installation.
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JET PUMP REVERSE GATE E REVERSE GATE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name REVERSE GATE REMOVAL Clamp/spout hose Bolt Washer Collar Reverse gate assembly Nut Bolt Washer Q’ty 1/1 2 2 2 1 1 1 2 6-3 Service points Follow the left “Step” for removal.
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JET PUMP REVERSE GATE E EXPLODED DIAGRAM Step 9 10 11 12 13 14 15 16 17 Procedure/Part name Roller Bolt Reverse gate stay Nut Washer Bolt Lever Spacer Nut Q’ty 1 6 2 1 1 1 1 1 1 6-4 Service points
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JET PUMP REVERSE GATE E EXPLODED DIAGRAM Step 18 19 20 21 22 23 Procedure/Part name Washer Collar Spring Lever Bolt Washer Q’ty 1 1 1 1 1 2 Service points Reverse the removal steps for installation.
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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 Reverse gate Bolt/washer Spacer Nozzle deflector Bolt/washer Spacer Nozzle ring Q’ty Service points Follow the left “Step” for removal. Refer to “JET PUMP UNIT”. Refer to “REVERSE GATE”. 2/2 2 1 2/2 2 1 Reverse the removal steps for installation.
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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 Pin Impeller housing Q’ty Service points Follow the left “Step” for removal. Refer to “NOZZLE DEFLECTOR AND NOZZLE RING”. 4 1 2 1 2 1 6-7 NOTE: Clean the contacting surfaces before applying the Gasket Maker.
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IMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCT JET PUMP E EXPLODED DIAGRAM Step 7 8 9 10 11 Procedure/Part name Bolt Cover Packing Filter Packing Q’ty 4 1 1 1 1 Service points Reverse the removal steps for installation.
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JET PUMP IMPELLER DUCT AND DRIVE SHAFT 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/washer Cap O-ring Nut Washer Q’ty Service points Follow the left “Step” for disassembly.
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JET PUMP IMPELLER DUCT AND DRIVE SHAFT EXPLODED DIAGRAM Step 8 9 10 11 12 13 Procedure/Part name Drive shaft Rear bearing Spacer Front bearing Oil seal Oil seal Q’ty 1 1 1 1 1 1 Service points Not reusable Not reusable Reverse the disassembly steps for assembly.
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JET PUMP IMPELLER DUCT AND DRIVE SHAFT E SERVICE POINTS Drive shaft removal 1. Remove: ● Impeller Drive shaft holder: YB-06151/90890-06519 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. Remove: ● Rear bearing ● Front bearing Slide hammer set: 90890-06523 YB-06096/90890-06531 Impeller inspection Refer to “JET chapter 3.
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JET PUMP IMPELLER DUCT AND DRIVE SHAFT E Drive shaft installation 1. Install: ● Oil seal Driver rod: YB-06071/90890-06606 Ball bearing attachment: YB-06156/90890-06634 2. Install: ● Front bearing ● Drive shaft NOTE: Install the front bearing and drive shaft with a press. Distance a: 23 ± 0.1 mm (0.91 ± 0.004 in) 3. Add: ● EPNOC grease AP #0 (between the drive shaft and spacer) Quantity: Approximately 1/3 of capacity 4. Install: ● Rear bearing Bearing inner race attachment: YB-34474/90890-06662 5.
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JET PUMP TRANSOM PLATE AND HOSES E TRANSOM PLATE AND HOSES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 Procedure/Part name TRANSOM PLATE AND HOSES REMOVAL Hose clamp Hose Bilge hose 1 Hose Nut/washer Transom plate Clamp/bilge hose 2 Holder Bilge filter Q’ty 3 1 1 1 4/4 1 1/1 1 1 Service points Follow the left “Step” for removal. Cooling water outlet Cooling water inlet Reverse the removal steps for installation.
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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.
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JET PUMP BEARING HOUSING E BEARING HOUSING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name BEARING HOUSING REMOVAL Engine unit Rubber coupling Bolt/washer Bearing housing assembly Pin Shim Q’ty 1 3/3 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.
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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 Driven coupling shaft Q’ty 1 1 1 2 1 1 1 6-16 Service points Follow the left “Step” for disassembly.
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JET PUMP BEARING HOUSING E EXPLODED DIAGRAM Step 8 9 10 11 12 13 Procedure/Part name O-ring Oil seal Oil seal Circlip Bearing Circlip Q’ty 2 2 1 1 1 1 Service points Reverse the disassembly steps for assembly.
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JET PUMP BEARING HOUSING E SERVICE POINTS Driven coupling removal and installation 1. Remove and install: ● Driven coupling 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. Driven coupling shaft removal 1. Remove: ● Driven coupling shaft Removal steps: Temporarily install the driven coupling to the driven coupling shaft. ● Insert the long rod to the driven coupling shaft.
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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. ● Driven coupling 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.
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JET PUMP BEARING HOUSING E 2. Install: ● Driven coupling shaft Distance a: 9.5 ~ 10.5 mm (0.37 ~ 0.41 in) 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 ~ 0.07 in) Bearing housing installation 1. Install: ● Bearing housing ● Shim Installation steps: Install the bearing housing. ● Measure the clearance a at each bolt hole. ● Install the suitable shim from the table below.
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ELEC – + E CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS......................................................................... 7-1 ELECTRICAL BOX ........................................................................................... 7-2 EXPLODED DIAGRAM ............................................................................. 7-2 REMOVAL AND INSTALLATION CHART ............................................... 7-2 ELECTRICAL ANALYSIS .........................................................
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ELEC – + CHARGING SYSTEM.................................................................................... 7-26 WIRING DIAGRAM................................................................................. 7-26 FUSE ....................................................................................................... 7-27 BATTERY ................................................................................................ 7-27 LIGHTING COIL ........................................................
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ELEC – + ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 YPVS servomotor Multi-function meter Fuel level sensor Buzzer Oil level sensor Stator coil and pickup coil Spark plugs Exhaust temperature sensor 9 0 A B C D 7-1 Battery Speed sensor Electrical box Water temperature sensor Starter motor Engine stop switch, engine stop lanyard switch and starter switch E
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ELEC – + ELECTRICAL BOX E ELECTRICAL BOX EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name ELECTRICAL BOX REMOVAL Exhaust chamber assembly Q’ty Exhaust manifold 1 2 3 4 5 Spark plug lead Battery negative lead Battery positive lead Breather hose Band Battery 1 1 1 2 1 7-2 Service points Follow the left “Step” for removal. Refer to “EXHAUST CHAMBER ASSEMBLY” in chapter 5. Refer to “EXHAUST MANIFOLD” in chapter 5.
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ELEC – + ELECTRICAL BOX E EXPLODED DIAGRAM Step 6 7 8 9 10 11 Procedure/Part name Damper Bolt Battery box Coupler Bolt Electrical box Q’ty 1 4 1 4 4 1 Service points For multi-function meter Reverse the removal steps for installation.
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ELEC – + ELECTRICAL BOX E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Q’ty 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 Spark plug lead/cap Screw 2 1 10 1 1 3 3/3 6 5 3 7-4 Service points Follow the left “Step” for disassembly.
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ELEC – + ELECTRICAL BOX E EXPLODED DIAGRAM Step 11 12 13 14 15 16 17 18 19 20 21 22 Procedure/Part name Ground lead Ignition coil Ignition coil lead Bolt Ground lead Lead Nut Starter motor lead Battery positive lead Fuse lead Starter relay lead Starter relay Q’ty 3 3 3 3 6 3 2 1 1 1 1 1 7-5 Service points Black/Orange
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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.
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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.
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ELEC – + ELECTRICAL ANALYSIS E ELECTRICAL ANALYSIS INSPECTION CAUTION: ● All measuring instruments should be handled with special care. Damaged or mishandled instruments will not measure properly. ● On 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.
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ELEC – + ELECTRICAL ANALYSIS E Low resistance measurement NOTE: ● When measuring a resistance of 10 Ω or less with the digital tester, the correct measurement cannot be obtained because of the tester’s internal resistance. ● To obtain the correct value, subtract the internal resistance from the displayed measurement. ● The internal resistance of the tester can be obtained by connecting both of its terminals.
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ELEC – + ELECTRICAL ANALYSIS 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.
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ELEC – + IGNITION SYSTEM E IGNITION SYSTEM WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 0 A B O R W B/O B/W B/Y W/R Engine stop switch Engine stop lanyard switch Lighting coil Pickup coil CDI unit Ignition coil Spark plug Battery Rectifier/regulator Exhaust temperature sensor Water temperature sensor 7-11 : Black : Orange : Red : White : Black/Orange : Black/White : Black/Yellow : White/Red
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ELEC – + IGNITION SYSTEM E IGNITION SPARK GAP WARNING ● When checking the spark gap, do not touch any of the connections of the spark gap tester lead wires. ● When performing the spark gap test, take special care not to let sparks leak out of the removed spark plug cap. ● When performing the spark gap check, keep flammable gas or liquids away, since this test can produce sparks. Å 1. Check: ● Ignition spark gap Below specification → Continue to check the CDI unit output. Spark gap: 10 mm (0.
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ELEC – + IGNITION SYSTEM E IGNITION SYSTEM PEAK VOLTAGE WARNING When checking the CDI unit do not touch any of the connections of the digital tester lead wires. NOTE: ● If there is no spark, or the spark is weak, continue with the ignition system test. ● If a good spark is obtained, the problem is not with the ignition system, but possibly with the spark plug(-s) or another component. 1. Measure: ● CDI unit output peak voltage Above specification → Replace the ignition coil.
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ELEC – + IGNITION SYSTEM E 2. Measure: ● Pick-up coil output peak voltage Below specification → Replace the pick-up coil. Pick-up coil output peak voltage: White/Red (W/R) – Black/Orange (B/O): 5 V @ cranking 1 2.8 V @ cranking 2 7.9 V @ 2,000 r/min 11 V @ 3,500 r/min 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) and lighting coil.
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ELEC – + IGNITION SYSTEM E BATTERY Refer to “ELECTRICAL” in chapter 3. FUSE Refer to “STARTING SYSTEM”. SPARK PLUGS Refer to “ELECTRICAL” in chapter 3. SPARK PLUG LEAD ASSEMBLY 1. Inspect: ● Spark plug lead assembly Cracks/damage → Replace. 2. Measure: ● Spark plug lead resistance Out of specification → Replace. Spark plug lead resistance: #1: 6.1 ~ 14.3 kΩ #2: 4.6 ~ 11.1 kΩ #3: 3.1 ~ 7.7 kΩ IGNITION COIL 1. Measure: ● Primary coil resistance Out of specification → Replace.
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ELEC – + IGNITION SYSTEM E 2. Measure: ● Secondary coil resistance Out of specification → Replace. Secondary coil resistance: Black/White (B/W) – Spark plug lead terminal 3.5 ~ 4.7 kΩ at 20 ˚C (68 ˚F) ENGINE STOP SWITCH 1. Check: ● Engine stop switch continuity Out of specification → Replace. Engine stop switch continuity (black coupler) Lock plate Installed Removed Position Lead color White Black Free Push Free Push WATER TEMPERATURE SENSOR 1.
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ELEC – + IGNITION SYSTEM E EXHAUST TEMPERATURE SENSOR 1. Measure: ● Exhaust temperature sensor resistance (at the specified temperature) Out of specification → Replace. Exhaust temperature sensor resistance: 300 ˚C (572 ˚F): 73 ~ 241 kΩ 600 ˚C (1,112 ˚F): 0.86 ~ 1.58 kΩ 900 ˚C (1,652 ˚F): 64 ~ 90 Ω Measurement steps: Heat the exhaust temperature sensor using an electric furnace or equivalent. ● Measure the resistance when the specified temperature.
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ELEC – + STARTING SYSTEM E STARTING SYSTEM WIRING DIAGRAM 1 2 3 4 5 6 7 8 CDI unit Engine stop lanyard switch Starter switch Multi-function meter Fuse Starter relay Starter motor Battery B Br R R/Y 7-18 : Black : Brown : Red : Red/Yellow
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ELEC – + STARTING SYSTEM E BATTERY Refer to “ELECTRICAL” in chapter 3. WIRING CONNECTIONS 1. Check: ● Wiring connections Poor connections → Properly connect. FUSE 1. Check: ● Fuse holder continuity No continuity → Check the fuse or replace the fuse holder. Fuse holder continuity: Between 1 and 2 Between 3 and 4 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.
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ELEC – + STARTING SYSTEM E STARTER SWITCH 1. Check: ● Continuity Out of specification → Replace. Starter continuity (red 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.
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ELEC – + STARTER MOTOR E STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name STARTER MOTOR DISASSEMBLY Starter motor O-ring Bolt Starter motor front cover O-ring Oil seal retainer Washer Shim Q’ty Service points Follow the left “Step” for disassembly. Refer to “GENERATOR AND STARTER MOTOR” in chapter 5. 1 2 1 1 1 1 * *: As required 7-21 t = 0.2 mm, 0.
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ELEC – + STARTER MOTOR E EXPLODED DIAGRAM Step 8 9 10 11 12 13 14 15 16 17 Procedure/Part name Starter motor rear cover O-ring Shim 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 7-22 Service points t = 0.2 mm, 0.
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ELEC – + STARTER MOTOR E EXPLODED DIAGRAM Step 18 19 20 Procedure/Part name Spacer Holder Starter motor yoke Q’ty 1 1 1 Service points Reverse the disassembly steps for assembly.
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ELEC – + STARTER MOTOR E SERVICE POINTS Armature inspection 1. Inspect: ● Armature shaft 1 Damage/wear → Replace. 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.
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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.
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ELEC – + CHARGING SYSTEM E CHARGING SYSTEM WIRING DIAGRAM 1 2 3 4 Lighting coil Battery Fuse (20A) Rectifier/regulator B G R G/W 7-26 : Black : Green : Red : Green/White
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ELEC – + CHARGING SYSTEM E FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in chapter 3. LIGHTING COIL Refer to “IGNITION SYSTEM”. RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM”.
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ELEC – + YPVS E YPVS WIRING DIAGRAM 1 2 3 4 5 6 7 B Gy R B/O R/L R/W W/R Lighting coil Pickup coil CDI unit YPVS servomotor Fuse Battery Rectifier/regulator 7-28 : Black : Gray : Red : Black/Orange : Red/Blue : Red/White : White/Red
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ELEC – + YPVS E FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in chapter 3. PICKUP COIL Refer to “IGNITION SYSTEM”. CDI UNIT Refer to “IGNITION SYSTEM”. LIGHTING COIL Refer to “IGNITION SYSTEM”. RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM”.
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ELEC – + YPVS SERVOMOTOR E YPVS SERVOMOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name YPVS SERVOMOTOR REMOVAL Bolt Cable holder YPVS servomotor coupler Bolt YPVS servomotor Spacer YPVS cable Cover Q’ty 2 1 1 2 1 2 2 1 Service points Follow the left “Step” for removal. White tape is for No. 2 cable. Reverse the removal steps for installation.
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ELEC – + YPVS SERVOMOTOR E SERVICE POINTS YPVS cable removal and installation 1. Remove: ● YPVS cables 1 and 2 Removal steps: ● Remove the YPVS cable holder 1. ● Remove the YPVS cables 2 from the both drams. NOTE: There is a white paint mark a on YPVS cable 2. YPVS cable inspection 1. Inspect: ● YPVS cables 1 and 2 Frays/kinks/rough movement → Replace. YPVS servomotor inspection 1. Check: ● YPVS servomotor YPVS servomotor does not move → Replace.
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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.
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ELEC – + INDICATION SYSTEM E INDICATION SYSTEM WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 0 A B CDI unit Fuel level sensor Oil level sensor Buzzer Multi-function meter Speed sensor Engine stop lanyard switch Starter switch Battery Fuse Exhaust temperature sensor Water temperature sensor B Br Ch G Gy L O R Y B/O B/Y : Black : Brown : Chocolate : Green : Gray : Blue : Orange : Red : Yellow : Black/Orange : Black/Yellow 7-33 Gy/B Gy/R Gy/Y L/B L/R R/B R/W R/Y W/L : Gray/Black : Gray/Red : Gray/Yellow : Blue/
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ELEC – + INDICATION SYSTEM E FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in chapter 3. LIGHTING COIL Refer to “CHARGING SYSTEM”. RECTIFIER/REGULATOR Refer to “CHARGING 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.
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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.
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ELEC – + INDICATION SYSTEM E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 Procedure/Part name MULTI-FUNCTION METER REMOVAL Multi-function meter coupler Nut/washer Holder Multi-function meter Q’ty Service points Follow the left “Step” for removal. 8 2/2 1 1 Reverse the removal steps for installation.
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ELEC – + INDICATION SYSTEM E Display function 1. Check: ● Display function Not operate → Replace the multifunction meter.
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ELEC – + INDICATION SYSTEM E Checking steps: ● Connect the battery terminals to the white six-pin connector as shown. NOTE: If the multi-function meter has been removed from the water vehicle, supply DC 12 voltage to the connector (+: red, –: black) with a battery. Disconnect the blue one-pin connector 1 and make sure the “WARNING” lamp 2 lights. NOTE: If the “WARNING” lamp does not light, disconnect the battery and then reconnect it. ● Press the “A/SET” 3 and “C” 5 buttons at the same time.
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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 white sixpin 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.
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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 white sixpin 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.
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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 white sixpin 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.
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ELEC – + INDICATION SYSTEM E ● Make sure the water temperature warning indicator display 3 and the “ ” message 4 display, the “WARNING” lamp 5 operates properly, and the buzzer sounds continuity. 3. Check: ● Exhaust temperature warning indicator Not operating → Replace the multifunction meter. Checking steps: ● Supply DC 12 voltage to the white sixpin connector (+: red, –: black) with a battery. ● Connect the gray/yellow and black terminals with a jumper lead 1.
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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 white sixpin connector (+: red, –: black) with a battery. ● Disconnect the blue one-pin connector 1 and make sure the “WARNING” lamp lights 2. NOTE: If the “WARNING” lamp does not light, disconnect the battery and then reconnect it.
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ELEC – + INDICATION SYSTEM E Speed sensor 1. Check: ● Speed sensor output voltage and pulses Out of specification → Replace. Speed sensor output voltage (dependant on the paddle wheel position): Less than 400 mV/11.6 - 12 V Output pulse: 2 pulses/one-full turn Checking steps: ● Apply DC 12 voltage to the white three-pin connector (between the red/ white and black leads). ● Rotate the paddle wheel by hand and measure the voltage between the black and yellow leads.
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HULL HOOD E CHAPTER 8 HULL AND HOOD HANDLEBAR ................................................................................................... 8-1 EXPLODED DIAGRAM ............................................................................. 8-1 REMOVAL AND INSTALLATION CHART ............................................... 8-1 SERVICE POINTS ..................................................................................... 8-6 Handlebar inspection.....................................................
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HULL HOOD HOSES........................................................................................................... 8-24 EXPLODED DIAGRAM ........................................................................... 8-24 REMOVAL AND INSTALLATION CHART ............................................. 8-24 SERVICE POINTS ................................................................................... 8-26 Check valve inspection ...................................................................
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HULL HOOD HANDLEBAR E HANDLEBAR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 Procedure/Part name HANDLEBAR COVER REMOVAL Screw Handlebar cover Band Pad Bolt Handlebar cover stay Throttle cable Bolt Upper handlebar holder Q’ty Service points Follow the left “Step” for removal. 4 1 2 1 2 1 1 4 2 Reverse the removal steps for installation.
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HULL HOOD HANDLEBAR E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name HANDLEBAR REMOVAL QSTS cable (to jet nozzle) Bolt QSTS converter QSTS cable 2 QSTS cable 1 Handlebar switch coupler Q’ty 2 1 1 1 3 8-2 Service points Follow the left “Step” for removal. Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”.
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HULL HOOD HANDLEBAR E EXPLODED DIAGRAM Step 6 7 8 9 10 11 Procedure/Part name Buzzer coupler Screw Handle boss cover Band Handlebar assembly Buzzer Q’ty 1 4 1 2 1 1 Service points Reverse the removal steps for installation.
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HULL HOOD HANDLEBAR E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name HANDLEBAR DISASSEMBLY Bolt Grip end Spacer Screw/washer/spring washer QSTS grip assembly Screw Q’ty 2 2 1 1/1/1 1 2 8-4 Service points Follow the left “Step” for disassembly.
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HULL HOOD HANDLEBAR E EXPLODED DIAGRAM Step 7 8 9 10 11 Procedure/Part name Handlebar switch assembly Screw Throttle lever assembly Handlebar grip Handlebar Q’ty 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.
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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. Install: ● QSTS cables ● Buzzer lead ● Handlebar switch lead ● Throttle cable NOTE: After inserting the cables and leads into the grommets, tie the end of grommets with the bands 1. 2. Install: ● Upper handlebar holder 1 CAUTION: Clearance a should be narrower than clearance b.
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HULL HOOD HANDLEBAR E 3. 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 trim grip to the neutral position. ● Adjust the QSTS cable lengths a to the specified length and be sure to take up any slack. 4. Adjust: ● Throttle cable free play Refer to “CONTROL SYSTEM” in chapter 3. 5. Adjust: ● QSTS cable free play Refer to “CONTROL SYSTEM” in chapter 3.
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HULL HOOD QSTS GRIP E QSTS GRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name QSTS GRIP DISASSEMBLY QSTS grip assembly Screw/washer Cover Ball Spring QSTS cable 1 QSTS cable 2 Q’ty 1/1 1 2 2 1 1 8-8 Service points Follow the left “Step” for disassembly. Refer to “HANDLEBAR”. NOTE: QSTS cable 2 has white tape a on its end.
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HULL HOOD QSTS GRIP E EXPLODED DIAGRAM Step 7 8 9 10 11 12 13 Procedure/Part name Screw/washer Spacer QSTS grip position locator Spring Spacer Cable housing QSTS grip Q’ty 2/2 1 1 1 1 1 1 Service points Reverse the disassembly steps for assembly.
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HULL HOOD QSTS GRIP E SERVICE POINTS QSTS cable inspection 1. Inspect: ● QSTS cables Frays/kinks/rough movement → Replace. QSTS grip inspection 1. Inspect: ● QSTS grip Damage/wear → Replace.
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HULL HOOD STEERING MASTER E STEERING MASTER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name STEERING MASTER REMOVAL Handlebar assembly Steering master cover Bolt/washer Steering arm Nut/washer Steering master assembly Bolt Grommet Q’ty Service points Follow the left “Step” for removal. Refer to “HANDLEBAR”. Refer to “STEERING MASTER COVER”. 1/1 1 4/4 1 4 2 Reverse the removal steps for installation.
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HULL HOOD STEERING MASTER E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 10 Procedure/Part name STEERING MASTER DISASSEMBLY Bolt/washer Stay Spring Bolt/washer Lower housing Spring Bushing Bushing Upper housing Tilt lever Q’ty 2/2 1 1 6/6 1 1 1 1 1 1 8-12 Service points Follow the left “Step” for disassembly.
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HULL HOOD STEERING MASTER E EXPLODED DIAGRAM Step 11 12 13 14 15 16 17 18 19 Procedure/Part name Tilt stopper Bolt/nut Retainer Steering shaft assembly Steering tube Bolt/washer/spring washer Cap Shaft 1 Cross piece Q’ty 1 4/4 2 1 1 2/2/2 1 1 1 Service points Reverse the disassembly steps for assembly.
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HULL HOOD STEERING MASTER E SERVICE POINTS Steering master components inspection 1. Inspect: ● Each component part Damage/wear → Replace the steering master.
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HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL Speed sensor coupler Cap Nut Speed sensor Steering cable end Nut/washer Bracket Q’ty 1 1 1 1 1 3/3 1 8-15 Service points Follow the left “Step” for removal.
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HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD E EXPLODED DIAGRAM Step 8 9 10 11 12 13 14 15 16 Procedure/Part name Nut Steering cable holder Cap Nut Steering cable Shift cable end Bolt Shift cable holder Cap Q’ty 2 1 1 1 1 1 2 1 1 8-16 Service points
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HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD E EXPLODED DIAGRAM Step 17 18 19 20 21 22 23 24 Procedure/Part name Nut Shift cable Nut Pin QSTS cable end Cap Nut QSTS cable Q’ty 1 1 1 1 1 1 1 1 Service points Reverse the removal steps for installation.
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HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD E SERVICE POINTS Remote control cables inspection 1. Inspect: ● Steering cable ● QSTS cable ● Shift cable Frays/kinks/rough movement → Replace. Steering cable (jet pump side) installation 1. Install: ● Steering cable a Steering cable set length (jet pump side): 13.5 ~ 15.5 mm (0.53 ~ 0.61 in) WARNING The steering cable must be screwed in at least 8 mm (0.31 in). Steering cable stopper installation 1.
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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 groove in the outer cable. Shift cable (jet pump side) installation 1.
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HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD E Shift cable stopper installation 1. Install: ● Shift cable stopper WARNING Be sure to fit the projection 1 on the shift cable stopper into the groove in the outer cable. Remote control cables adjustment Refer to “CONTROL SYSTEM” in chapter 3.
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HULL HOOD FRONT HOOD E FRONT HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name FRONT HOOD REMOVAL Nut/washer Front hood assembly Circlip Pin Damper Bolt Hood lock assembly Q’ty 4/4 1 4 2 2 2 1 8-21 Service points Follow the left “Step” for removal.
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HULL HOOD FRONT HOOD E EXPLODED DIAGRAM Step 8 9 10 11 12 13 14 15 Procedure/Part name Nut Notch Washer Damper Bolt Plate Mirror Packing Q’ty 1 1 2 1 4 2 2 2 Service points Reverse the removal steps for installation.
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HULL HOOD STEERING MASTER COVER E STEERING MASTER COVER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name STEERING MASTER COVER REMOVAL Handlebar assembly Fuel cock Choke knob Bolt Shift lever handle Nut/washer Bolt Bolt Steering master cover Q’ty Service points Follow the left “Step” for removal. Refer to “HANDLEBAR”. Refer to “FUEL COCK AND FUEL FILTER” in chapter 4. Refer to “CHOKE CABLE” in chapter 4. 2 1 2/2 2 2 1 Reverse the removal steps for installation.
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HULL HOOD HOSES E HOSES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name HOSES REMOVAL Steering master cover Band Ventilation hose Screw Ventilation duct Band Check valve Q’ty 2 2 4 1 1 1 8-24 Service points Follow the left “Step” for removal. Refer to “STEERING MASTER COVER”.
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HULL HOOD HOSES E EXPLODED DIAGRAM Step 7 8 9 10 11 12 Procedure/Part name Oil tank breather hose Fuel tank breather hose Clamp/pilot water hose Nut/washer Pilot water outlet Packing Q’ty 1 2 2/2 2/2 2 2 Service points Reverse the removal steps for installation.
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HULL HOOD HOSES E SERVICE POINTS Check valve inspection 1. Check: ● Check valve Faulty → Replace. Checking steps: Connect a hose to 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”.
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HULL HOOD SHIFT LEVER E SHIFT LEVER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 Procedure/Part name SHIFT LEVER REMOVAL Steering master cover Shift cable Ventilation duct Bolt Washer Shift lever Q’ty 1 1 1 8-27 Service points Follow the left “Step” for removal. Refer to “STEERING MASTER COVER”. Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”. Refer to “HOSES”.
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HULL HOOD SHIFT LEVER E SHIFT LEVER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 4 5 6 7 8 Procedure/Part name Screw Base assembly Nut/washer Screw Plate Q’ty 3 1 3/3 3 1 Service points Reverse the removal steps for installation.
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HULL HOOD SHIFT LEVER E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name BASE DISASSEMBLY Bolt/washer Plate Spring Actuator Roller Shaft Shift arm Q’ty Service points Follow the left “Step” for disassembly. 2/2 1 1 1 1 1 1 Reverse the disassembly steps for assembly.
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HULL HOOD SHIFT LEVER E SERVICE POINTS Base assembly 1. Install: ● Shift arm ● Shaft Installation steps: Install the shift arm 1 so that it comes in contact with the stopper 2 as shown. ● Install the shaft 3 to the base so that it come in contact with the stopper 4 as shown.
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HULL HOOD SEATS AND HAND GRIP SEATS AND HAND GRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name SEATS AND HAND GRIP REMOVAL Rear seat assembly Front seat assembly Bolt Seat lock assembly Nut/washer Notch Bolt Q’ty 1 1 4 2 4/5 2 2 8-31 Service points Follow the left “Step” for removal.
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HULL HOOD SEATS AND HAND GRIP E EXPLODED DIAGRAM Step 8 9 10 11 12 13 Procedure/Part name Rear seat stay Nut/washer Front seat stay Nut/washer Bolt Hand grip Q’ty 1 4/4 2 4/4 4 1 Service points Reverse the removal steps for installation.
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HULL HOOD SEATS AND HAND GRIP SERVICE POINTS Seat lock inspection 1. Inspect: ● Front seat lock ● Rear seat lock Damage/wear → Replace.
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HULL HOOD EXHAUST SYSTEM E EXHAUST SYSTEM EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name EXHAUST SYSTEM REMOVAL Hose clamp Band Rubber joint Hose clamp Rubber hose Water lock Hose clamp Resonator assembly Q’ty 2 1 1 2 1 1 1 1 8-34 Service points Follow the left “Step” for removal.
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HULL HOOD EXHAUST SYSTEM E EXPLODED DIAGRAM Step 9 10 11 12 13 14 15 16 17 Procedure/Part name Hose clamp Rubber hose Hose clamp Water tank Hose clamp Rubber hose Bolt Exhaust outlet Packing Q’ty 1 1 1 1 1 1 Service points Align hose parting line with tank mark Align hose parting line with tank parting line 3 1 1 Reverse the removal steps for installation.
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HULL HOOD EXHAUST SYSTEM E SERVICE POINTS Exhaust system inspection 1. Inspect: ● Water lock band Cracks → Replace. 2. Inspect: ● Rubber hoses Burns/cracks/damage → Replace. 3. Inspect: ● Water lock Cracks/leaks → Replace. Water → Drain. 4. Inspect: ● Resonator ● Water tank Cracks/damage → Replace.
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HULL HOOD DECK AND HULL E DECK AND HULL EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 Procedure/Part name DECK AND HULL DISASSEMBLY Nut Rope hole bolt Nut/washer Bow eye Nut Rope hole bolt Nut Spout Nut Q’ty 1 1 2/2 1 1 1 1 1 2 8-37 Service points Follow the left “Step” for disassembly.
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HULL HOOD DECK AND HULL E EXPLODED DIAGRAM Step 10 11 12 13 14 15 16 17 18 Procedure/Part name Plate Cleat Nut Sponson Spacer Nut/washer Screw/washer Drain plug Packing Q’ty 1 1 8 2 8 4/4 4/4 2 2 Service points Reverse the disassembly steps for assembly.
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HULL HOOD ENGINE MOUNT E ENGINE MOUNT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name ENGINE MOUNT REMOVAL Engine assembly Bolt Damper 1 Damper 2 Bolt Engine mount Q’ty Service points Follow the left “Step” for removal. Refer to “ENGINE UNIT” in chapter 5. 6 1 1 8 4 Reverse the removal steps for installation.
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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.
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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.
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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.
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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.
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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.
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TRBL ANLS E CHAPTER 9 TROUBLE-ANALYSIS TROUBLE-ANALYSIS ..................................................................................... 9-1 TROUBLE-ANALYSIS CHART .................................................................
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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.
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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
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WIRING DIAGRAM 1 3 G G W/R L L 2 d e 4 B/O B B B E D C B f g W/L B A B B/O B/Y W/R B/O Gy/B Br O Gy/R Gy G Gy/Y B/W W B/O B Br R W/L 5 B/Y B/O B B/O G G W/R W F G B/Y B/O W L M Gy/Y Gy Gy Gy/Y G G Gy/B Gy/B N O G Gy/B B/Y B/O B/O O Gy/R P Q Gy/R 20 7 G Gy/R R B B R S B/O 19 O O T U B/O B/O 17 Br Br Br Br R R R/W R/W R/W R R R/L R/Y R/W l m R/W Y B 8 R/W Y B 10 9 W B R W B B/O p q B Br B 17 R/W 14 #2 B/W Br R Br R/
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YAMAHA MOTOR CO., LTD. Printed in USA Mar. 1999 – ?.