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Yamaha FX Cruiser High Output, Service Manual

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Yamaha FX Cruiser High Output Service Manual Download Page 16

1-8

E

GEN

INFO

SPECIAL TOOLS

5

Universal magneto and rotor holder
P/N. YU-01235
Rotor holder
P/N. 90890-01235

6

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

7

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

8

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

9

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

0

Valve spring compressor
P/N. YM-01253

90890-04019

A

Valve spring compressor attachment
P/N. YM-4114 (ø19 mm)

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

B

Valve guide remover
P/N. YM-04111 (ø4.0 mm)

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

C

Valve guide installer
P/N. YM-04112 (ø4.0 mm)

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

D

Valve guide reamer
P/N. YM-04113 (ø4.0 mm)

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

5

6

A

B

YU-01235
90890-01235

YB-06111

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

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

7

8

90890-06631

YB-06726-B

9

0

90890-06657

YM-01253
90890-04019

C

D

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

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

Summary of Contents for FX Cruiser High Output

Page 1: ...SERVICE MANUAL FX High Output WaveRunner F1S 28197 1G 11 LIT 18616 02 83 LIT186160283 FX Cruiser High Output ...

Page 2: ...licy of continuously improving its products models may differ in detail from the descriptions and illustrations given in this publication Use only the latest edition of this manual Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual A10001 0 WaveRunner FX High ...

Page 3: ...evised format the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol e g Bearings Pitting scratches Replace To assist you in finding your way through this manual the section title and major heading is given at the top of every page ILLUSTRATIONS The illustrations within this service manual represent all of the designated models CRO...

Page 4: ...low WARNING instructions could result in severe injury or death to the machine operator passenger s a bystander or a person inspecting or repairing the watercraft CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the water craft NOTE A NOTE provides key information to make procedures easier or clearer IMPORTANT This part has been subjected to change of specifica...

Page 5: ...s 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 5 Dimension figures and the number of parts are provided for fasteners that require a tightening torque Example Bolt or screw size M10 D 25 mm L 6 Jobs requiring more information such as special tools and technical data ar...

Page 6: ...mbols F to H in an exploded diagram indi cate the grade of lubricant and the lubrication point F Apply Yamaha 4 stroke motor oil G Apply water resistant grease Yamaha grease A Yamaha marine grease H Apply molybdenum disulfide grease Symbols I to N in an exploded diagram indi cate the type of sealant or locking agent and the application point I Apply Gasket Maker J Apply Yamabond No 4 K Apply LOCTI...

Page 7: ...1 GEN INFO SPECIFICATIONS 2 SPEC PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR JET PUMP UNIT 6 JET PUMP ELECTRICAL SYSTEM 7 ELEC HULL AND HOOD 8 HULL HOOD TROUBLE ANALYSIS 9 TRBL ANLS A30000 0 ...

Page 8: ...UMBER 1 1 JET PUMP UNIT SERIAL NUMBER 1 1 HULL IDENTIFICATION NUMBER H l N 1 1 SAFETY WHILE WORKING 1 2 FIRE PREVENTION 1 2 VENTILATION 1 2 SELF PROTECTION 1 2 PARTS LUBRICANTS AND SEALANTS 1 2 GOOD WORKING PRACTICES 1 3 DISASSEMBLY AND ASSEMBLY 1 4 SPECIAL TOOLS 1 5 MEASURING 1 5 REMOVAL AND INSTALLATION 1 7 ...

Page 9: ...ent Starting primary l D number F1S 800101 ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the engine unit Starting serial number 6B6 1000001 JET PUMP UNIT SERIAL NUMBER The jet pump unit serial number is stamped on a label attached to the intermediate housing HULL IDENTIFICATION NUMBER H l N The H l N is stamped on a plate attached to the aft deck ...

Page 10: ...tities they may cause loss of con sciousness and death within a short time When test running an engine indoors e g in a water tank be sure to do so where adequate ventilation can be maintained SELF PROTECTION Protect your eyes by wearing safety glasses or safety goggles during all operation involving drilling and grinding or when using an air com pressor Protect your hands and feet by wearing prot...

Page 11: ...part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made 5 To protect your skin apply a protective cream to your hands before working on the watercraft 6 Keep a supply of clean lint free cloths for wiping up spills etc GOOD WORKING PRACTICES 1 The right tools Use the recommended special service tools to protect parts from damage ...

Page 12: ...t during disassembly 2 Apply engine oil to the contact surfaces of moving parts during assembly 3 Install bearings with the manufacture iden tification mark in the direction indication in the installation procedure In addition be sure to lubricate the bearings liberally 4 Apply a thin coat of water resistant grease to the lip and periphery of an oil seal before installation 5 Check that moving par...

Page 13: ...auge stand P N 90890 06583 3 Dial gauge needle P N 90890 06584 4 Dial gauge stand set P N YW 06585 90890 06585 5 Pocket tester P N YU 03112 90890 03112 6 Digital multimeter P N YU 34899 A 7 Digital circuit tester P N 90890 03174 8 Carburetor synchronizer P N YU 08030 9 Vacuum gauge P N 90890 03094 0 Test connector P N YW 06862 Test connector FMY 8 P N 90890 06862 A Fuel pressure gauge adapter P N ...

Page 14: ...YB 06767 Test harness FWY 2 2 pins P N New 90890 06867 Current 90890 06767 K Test harness 3 pins P N New YB 06870 Current YB 06770 Test harness SMT250 3 3 pins P N New 90890 06870 Current 90890 06770 L Test harness 6 pins P N YB 06848 Test harness FSW 6A 6 pins P N 90890 06848 M Test harness 3 pins P N YB 06793 Test harness SMHW099 3 3 pins P N 90890 06793 B C D E F H J K L M YB 06766 90890 06786 ...

Page 15: ...N 60V 85300 02 Q Yamaha diagnostic system P N 60V WS853 02 N O YB 06877 06777 90890 06877 06777 YB 35956 A 90890 06756 Q 60V WS853 02 YAMAHA DIAGNOSTIC SYSTEM INSTALLATION MANUAL P 60V 85300 02 REMOVAL AND INSTALLATION 1 Oil filter wrench P N YU 38411 90890 01426 2 Coupler wrench P N YW 06551 90890 06551 3 Sheave holder P N YS 01880 A 90890 01701 4 Rotor puller P N YM 01082 90890 01080 1 2 3 4 YU ...

Page 16: ...22 mm 90890 04108 ø22 mm B Valve guide remover P N YM 04111 ø4 0 mm 90890 04111 ø4 0 mm YM 04116 ø4 5 mm 90890 04116 ø4 5 mm C Valve guide installer P N YM 04112 ø4 0 mm 90890 04112 ø4 0 mm YM 04117 ø4 5 mm 90890 04117 ø4 5 mm D Valve guide reamer P N YM 04113 ø4 0 mm 90890 04113 ø4 0 mm YM 04118 ø4 5 mm 90890 04118 ø4 5 mm 5 6 A B YU 01235 90890 01235 YB 06111 YM 4114 ø19 mm 90890 04114 ø19 mm YM...

Page 17: ...mer and adapters jet pump bearing and reduction drive gear P N YB 06096 K Stopper guide plate jet pump bearing P N 90890 06501 L Bearing puller assembly jet pump bearing and reduction drive gear P N 90890 06535 M Stopper guide stand jet pump bearing and reduction drive gear P N 90890 06538 N Drive rod L3 jet pump bearing and reduction drive gear P N 90890 06652 90890 06315 60 90890 06312 45 90890 ...

Page 18: ...ermediate shaft jet pump and reduction drive gear P N YB 06071 T Driver rod LS intermediate shaft jet pump and reduction drive gear P N 90890 06606 U Bearing inner outer race attachment jet pump bearing P N YB 34474 V Shaft holder intermediate shaft P N YB 06552 Crankshaft holder 20 intermediate shaft P N 90890 06552 W Drive shaft taper roller bearing cup installer intermediate shaft and reduction...

Page 19: ...CIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 ENGINE 2 3 JET PUMP UNIT 2 6 HULL AND HOOD 2 6 ELECTRICAL 2 7 TIGHTENING TORQUES 2 9 SPECIFIED TORQUES 2 9 GENERAL TORQUE 2 17 CABLE AND HOSE ROUTING 2 18 ...

Page 20: ...2 Bore stroke mm in 76 0 58 0 2 99 2 28 Compression ratio 11 9 1 Exhaust system Wet exhaust Lubrication system Dry sump Cooling system Water cooled Starting system Electric starter Ignition system TCI Ignition timing Degree BTDC 5 BTDC 32 Spark plug model manufacturer CR9EB NGK Spark plug gap mm in 0 7 0 8 0 028 0 031 Battery capacity V Ah 12 19 Generator output A r min 14 16 6 000 Drive unit Prop...

Page 21: ...86 RON 90 Fuel tank capacity L US gal Imp gal 70 18 5 15 4 Engine oil type 4 stroke motor oil Engine oil grade API SE SF SG SH SJ SL SAE 10W 30 Engine oil quantity L US qt Imp qt 4 5 4 8 4 0 without oil filter replacement L US qt Imp qt 2 1 2 2 1 8 with oil filter replacement L US qt Imp qt 2 3 2 4 2 0 Item Unit Model FX High Output FX Cruiser High Output GENERAL SPECIFICATIONS ...

Page 22: ...646 Camshaft journal diameter mm in 24 46 24 47 0 9630 0 9634 Camshaft journal to camshaft cap clearance mm in 0 03 0 06 0 0012 0 0024 Maximum camshaft runout mm in 0 03 0 0012 Timing chain Model number of links DID SCR 0412SV 130 Tensioning system Automatic Valves valve seats valve guides Valve clearance cold Intake mm in 0 11 0 20 0 0043 0 0079 Exhaust mm in 0 25 0 34 0 0098 0 0134 Valve dimensi...

Page 23: ...0004 0 0015 Exhaust mm in 0 020 0 047 0 0008 0 0019 Valve stem runout mm in 0 01 0 0004 Valve spring Free length Intake mm in 38 90 1 53 Exhaust mm in 40 67 1 60 Installed length Intake mm in 34 50 1 36 Exhaust mm in 35 00 1 38 Spring limit Intake Degree mm in 2 5 1 7 0 067 Exhaust Degree mm in 2 5 1 8 0 071 Piston Piston to cylinder clearance mm in 0 10 0 11 0 0039 0 0043 Piston diameter mm in 75...

Page 24: ...rance mm in 0 040 0 160 0 0016 0 0063 Connecting rod Big end oil clearance mm in 0 016 0 040 0 0006 0 0016 Bearing color code 1 Brown 2 Black 3 Blue 4 Green Small end inside diameter mm in 17 005 17 018 0 6694 0 6699 Crankshaft Crank width A mm in 304 8 306 0 12 00 12 05 Deflection limit B mm in 0 03 0 0012 Crankshaft journal oil clearance mm in 0 004 0 028 0 0002 0 0011 Bearing color code 1 Brown...

Page 25: ...15 0 0035 0 0059 Item Unit Model FX High Output FX Cruiser High Output Jet pump Impeller material Stainless steel Number of impeller blades 3 Impeller pitch angle Degree 16 8 Impeller clearance mm in 0 35 0 45 0 0138 0 0177 Impeller clearance limit mm in 0 6 0 0236 Drive shaft runout limit mm in 0 3 0 0118 Nozzle diameter mm in 86 5 87 1 3 41 3 43 Item Unit Model FX High Output FX Cruiser High Out...

Page 26: ... Output peak voltage cranking unloaded V 9 2 2 000 r min unloaded V 38 5 3 500 r min unloaded V 63 2 Pickup coil resistance W B Ω color 459 561 Pickup coil resistance R B Ω color 459 561 Lighting coil resistance G G Ω color 0 54 0 66 Minimum charging current A r min 14 6 000 Ignition coil Primary coil resistance Ω 1 19 1 61 Secondary coil resistance kΩ 8 5 11 5 Rectifier regulator R B Output peak ...

Page 27: ...voltage on pulse V 11 6 Output pulse one full turn 2 Throttle position sensor Output voltage P B O trolling speed V 0 756 0 016 Cam position sensor Output voltage G O B O Position A V More than 4 8 Position B V Less than 0 8 Position C V More than 4 8 Fuel sender Fuel sender resistance Position A Ω 133 5 136 5 Position B Ω 5 7 Oil pressure switch Oil pressure switch continuity pressure kPa kgf cm2...

Page 28: ... 8 22 2 2 16 E Air filter case air filter case stay 1 air filter case stay 2 1st Bolt M8 3 8 8 0 88 6 4 242 LT 2nd 18 1 8 13 Wire harness bracket 1 sub wire harness air filter case Bolt M6 2 7 6 0 76 5 5 572 LT Fuel hose bracket wire harness bracket 2 air filter case Bolt M6 2 7 6 0 76 5 5 242 LT Wire harness bracket 2 air filter case Screw M5 1 1 3 0 13 0 9 572 LT Air filter case stay 1 exhaust p...

Page 29: ...lt M10 1 15 1 5 11 242 LT 2nd 42 4 2 30 Exhaust pipe 2 exhaust pipe 1 1 1st Nut 5 39 3 9 28 E 2nd 39 3 9 28 Exhaust pipe 1 exhaust manifold 1 exhaust manifold 2 1st Bolt M8 10 22 2 2 16 242 LT 2nd 22 2 2 16 3rd 35 3 5 25 Exhaust manifold 1 cylinder head 1st Bolt M8 6 22 2 2 16 242 LT 2nd 22 2 2 16 3rd 35 3 5 25 Exhaust manifold 2 cylinder head 1st Bolt M8 5 22 2 2 16 242 LT 2nd 22 2 2 16 3rd 35 3 ...

Page 30: ...cover oil tank 1st Bolt M6 24 3 7 0 37 2 7 572 LT 2nd 7 6 0 76 5 5 Anode oil tank Screw M4 1 3 7 0 37 2 7 E Oil pump assembly reduction drive gear case Bolt M6 5 10 1 0 7 2 572 LT 1st M8 4 15 1 5 11 2nd 28 2 8 20 Drain plug engine oil Bolt M8 1 20 2 0 14 Strainer reduction drive gear case 1st Bolt M6 2 3 7 0 37 2 7 2nd 7 6 0 76 5 5 Oil pump housing cover 1 oil seal housing 1 Bolt M8 1 20 2 0 14 Oi...

Page 31: ... M6 1 3 7 0 37 2 7 572 LT 2nd 7 6 0 76 5 5 Cylinder head cover cylinder head Bolt M6 6 12 1 2 8 7 E Timing chain tensioner cap bolt Bolt M6 1 10 1 0 7 2 Timing chain tensioner cylinder head Bolt M6 2 10 1 0 7 2 Exhaust camshaft cap cylinder head Bolt M6 10 10 1 0 7 2 E Intake camshaft cap cylinder head Bolt M6 18 10 1 0 7 2 E Exhaust camshaft sprocket exhaust camshaft Bolt M7 2 24 2 4 17 E Intake ...

Page 32: ...cable joint jet thrust nozzle Nut 1 6 8 0 68 4 9 242 LT Ride plate hull Bolt M8 4 17 1 7 12 572 LT Intake duct hull Bolt M8 4 17 1 7 12 242 LT Intake grate hull Bolt M6 4 7 6 0 76 5 5 242 LT Speed sensor ride plate Screw M5 4 3 7 0 37 2 7 242 LT Jet pump unit assembly impeller housing 2 transom plate Bolt M10 4 40 4 0 29 572 LT Bolt M6 1 7 8 0 78 5 6 Rubber plate bracket Bolt M6 6 6 8 0 68 4 9 Bra...

Page 33: ...r steering master Screw M6 4 0 9 0 09 0 7 242 LT QSTS converter hull Nut 2 5 4 0 54 3 9 Throttle lever assembly handlebar Screw M5 2 3 5 0 35 2 5 Handlebar switch assembly handlebar Screw M5 2 3 4 0 34 2 5 QSTS grip assembly handlebar Screw M6 1 3 4 0 34 2 5 Grip end handlebar Bolt M5 2 1 2 0 12 0 9 242 LT Cable housing QSTS grip assembly Screw M4 1 1 0 1 0 7 Steering master deck Nut 4 20 2 0 14 S...

Page 34: ... Nut 4 5 4 0 54 3 9 Service lid 1 deck Bolt M6 4 5 4 0 54 3 9 271 LT Service lid 2 deck Screw M4 4 1 5 0 15 1 1 Panel steering console cover Bolt M5 4 3 9 0 39 2 8 242 LT Multifunction meter steering console cover Bolt M5 4 3 9 0 39 2 8 242 LT Mirror steering console cover Nut 4 6 9 0 69 5 0 Side cover deck Bolt M6 8 5 4 0 54 3 9 271 LT Steering console cover glove box Bolt M6 2 5 4 0 54 3 9 242 L...

Page 35: ... Cleat deck Nut 2 15 1 5 11 Cleat hull Nut 4 15 1 5 11 Spout hull Nut 1 5 4 0 54 3 9 Protector bow hull Bolt M6 4 5 4 0 54 3 9 271 LT Nut 3 5 4 0 54 3 9 Bow eye hull Nut 2 13 1 3 9 4 Drain plug packing hull Screw M5 4 2 0 0 2 1 4 Engine mount hull Bolt M8 8 17 1 7 12 572 LT Engine damper hull Bolt M6 4 6 4 0 64 4 6 271 LT Electrical Battery box hull Bolt M6 2 5 4 0 54 3 9 572 LT Battery box spacer...

Page 36: ...01 0 07 Part to tightened Part name Thread size Q ty Tightening torque Remarks N m kgf m ft lb GENERAL TORQUE This chart specifies tightening torques for stan dard fasteners with a standard ISO thread pitch Tightening torque specifications for spe cial components or assemblies are provided in applicable sections of this manual To avoid warpage tighten multi fastener assemblies in a crisscross fash...

Page 37: ...eering switch lead 2 Fuel tank breather hose 3 QSTS cable 4 Steering cable 5 Shift cable 6 Speed sensor lead 7 Electrical box lead 8 Cooling water pilot outlet 9 Cooling water pilot outlet hose 0 Cooling water pilot outlet A Negative battery lead B Positive battery lead C Battery D Throttle cable E Fuel hose F Handlebar switch lead G Electrical bilge pump lead H Remote control unit lead I Remote c...

Page 38: ...3 Handlebar switch lead 4 QSTS cable 5 Buzzer lead 6 Fuel tank breather hose 7 Ignition coil lead 8 Positive battery lead 9 Starter motor lead 0 Wire harness A Fuel hose B Shift cable C Steering cable D Electrical box lead E Cooling water pilot outlet hose F Negative battery lead G Battery breather hose H Speed sensor lead I Electrical bilge pump lead J Remote control unit lead K Remote control un...

Page 39: ...ectric bilge pump 4 Bilge hose 4 5 Cooling water hose from thermostat 6 Bilge hose 3 7 Bilge hose 2 8 Shift cable 9 Cooling water hose from exhaust pipe 0 Electrical box A QSTS cable B Positive battery lead C Speed sensor lead D Electric bilge pump lead E Bilge strainer F Negative battery lead G Steering cable H Flushing hose È Pass the QSTS cable between the bilge hoses ...

Page 40: ...ter hose cooling water inlet 5 Negative battery lead È To cooling water pilot outlet on starboard side É To cooling water outlet on star board side of stern Ê To cylinder block Ë From exhaust manifold Ì To install the hose align the white paint mark on the cooling water hose with the projection of the hose joint Í When installing the cooling water hoses be sure to push them down until they contact...

Page 41: ...ough the stay hole and then fasten the tie Set the tie in the direction shown Ï To cooling water pilot outlet on port side Ð To cooling water outlet at stern Ñ Cooling water inlet Ò To exhaust pipe Ó To install the cooling water hose align the white paint mark on the hose with the parting line on the hose joint Ô Fasten the cooling water hose and negative bat tery lead with a plastic tie Set the t...

Page 42: ...let and then fasten them with a plastic tie to the oil tank boss When bundling the hoses make sure that the cooling water hose cylinder head cover to thermostat is routed on the deck side and that the cooling water hose starboard cooling water pilot outlet is routed on the engine side Ö Insert the cooling water hose to the paint mark Fasten the end of the cooling water hose tube that is contacting...

Page 43: ...Oil pressure switch coupler 6 Pickup coil coupler 7 Thermoswitch engine coupler 8 Lighting coil coupler 9 Thermoswitch exhaust 0 Thermoswitch exhaust coupler A Cam position sensor coupler B Oil pressure switch lead È To electrical box É To cam position sensor Ê Fasten the plastic tie with its end facing down ward Ë To oil pressure switch Ì To engine temperature sensor ...

Page 44: ...Ð Ï Ñ Ò Ï Ð B B È 1 Engine temperature sensor coupler 2 Lighting coil coupler 3 Pickup coil coupler 4 Thermoswitch engine coupler 5 Thermoswitch engine 6 Starter motor 7 Engine temperature sensor 8 Engine temperature sensor lead 9 Thermoswitch engine lead 0 Lighting coil lead ...

Page 45: ...m the end of the protec tive cover of the lead É To generator Ê To engine temperature sensor Ë To thermoswitch engine Ì To thermoswitch engine coupler Í To engine temperature sensor coupler Î Route the starter motor lead to the outside of the engine temperature sensor lead Ï To starter relay Ð To negative battery terminal Ñ Route the starter motor and negative battery leads behind the cooling wate...

Page 46: ... check and adjustment 3 8 FUEL SYSTEM 3 9 Fuel line inspection 3 9 Water separator inspection 3 10 POWER UNIT 3 10 Valve clearance adjustment 3 10 Engine oil level check 3 16 Engine oil change using oil changer 3 18 Air filter element clean 3 20 Spark plug inspection 3 21 ELECTRICAL 3 24 Battery inspection 3 24 JET PUMP UNIT 3 27 Impeller inspection 3 27 Water inlet strainer inspection 3 27 BILGE ...

Page 47: ...ate 3 29 Intermediate housing Lubricate 1 2 2 3 31 Fuel system Inspect 3 9 Fuel tank Inspect clean 3 9 Trolling speed Inspect adjust 3 8 Throttle shaft Inspect Cooling water passages Flush 3 Water inlet strainer Inspect clean 3 27 Bilge strainer Clean 3 28 Electric bilge pump strainer Inspect clean 3 28 Impeller Inspect 3 27 Jet thrust nozzle angle Inspect adjust 3 2 Steering master Inspect 3 2 QS...

Page 48: ...pect Jet thrust nozzle clearance a b Difference Adjust 2 Adjust Steering cable joint steering master end Inspection steps Set the control grip in the neutral position Turn the handlebar from lock to lock Measure clearances a and b If clearances a and b are not the same adjust them Adjustment steps Set the control grip in the neutral position Loosen the locknut 1 Disconnect the cable joint 2 from t...

Page 49: ... CONTROL CABLES AND SPEED SENSOR LEAD in Chapter 8 WARNING The cable joint must be screwed in more than 8 mm 0 31 in Connect the cable joint and tighten the locknut T R Locknut 6 4 N m 0 64 kgf m 4 6 ft lb Throttle cable inspection and adjustment NOTE Before adjusting the throttle lever free play adjust the trolling speed 1 Measure Throttle lever free play a Out of specification Adjust Throttle le...

Page 50: ...ies b Loosen the locknut 2 c Turn the adjusting nut 3 to adjust the length a Throttle cable installation length 24 4 1 0 mm 0 96 0 04 in NOTE Apply locking agent LOCTITE to the threads of the adjusting nut 3 d Remove the handlebar cover e Loosen the locknut 4 f Turn the adjuster 5 in or out until the specified free play is obtained Turn in Free play is increased Turn out Free play is decreased g T...

Page 51: ...assemblies and air filter case cover T R Ribbon sub assembly bolt 6 5 N m 0 65 kgf m 4 7 ft lb LOCTITE 242 Air filter case cover screw 2 5 N m 0 25 kgf m 1 8 ft lb LOCTITE 572 QSTS cable inspection and adjustment 1 Measure Jet thrust nozzle set length a b Difference Adjust Measurement steps Set the control grip in the neutral position Set the jet thrust nozzle in the center position Measure the je...

Page 52: ... 8 Adjustment steps Set the control grip in the neutral position Loosen the locknut 1 Remove the nut 2 and pivot pin 3 Set the jet thrust nozzle in the center position Turn the cable joint 4 for adjusting Turn in Length a is increased Turn out Length b is increased WARNING The cable joint must be screwed in more than 8 mm 0 31 in Connect the cable joint 4 and pivot pin 3 and tighten the nut 2 T R ...

Page 53: ...ted over the bracket 5 4 5 2 Adjust Shift cable joint Adjustment steps Loosen the locknut 1 Disconnect the cable joint 2 from the ball joint 3 Situate the reverse gate to the stopper on the bracket and the lever to the reverse gate Turn the cable joint to align it with the ball joint Turn in Shortens Turn out Lengthens Turn out the cable joint nine times a to extend cable 7 mm 0 28 in from the ali...

Page 54: ... engine trolling speed using the tachometer of the multifunction meter or using the Yamaha Diagnostic System 2 Adjust Trolling speed Adjustment steps Remove the air filter case cover 1 Start the engine Turn the throttle stop screw 2 in or out until the specified speed is obtained Turn in a Increase trolling speed Turn out b Decrease trolling speed Install the air filter case cover T R Air filter c...

Page 55: ... in Chapter 4 Fuel hose Damage cracks Replace O rings quick connector Damage cracks Replace the quick connector Fuel pipe Damage cracks Replace the fuel pump Refer to FUEL INJECTION SYSTEM in Chapter 4 Fuel filler hose Fuel tank Fuel filler cap Cracks damage Replace 2 Inspect Fuel tank Cracks damage Replace Water accumulation Remove NOTE To remove water from the fuel tank remove the cap 1 and use ...

Page 56: ...om temperature When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove Air filter case Refer to FUEL INJECTION SYSTEM in Chapter 4 2 Remove Ignition coils Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS in Chapter 5 3 Install Dial gauge needle Dial gauge stand 1 into spark plug hole 1 Dial gau...

Page 57: ...e turned away from each other Measure the valve clearance with a thick ness gauge 1 NOTE If the valve clearance is incorrect record the measured reading Measure the valve clearance in the follow ing sequence Valve clearance measuring sequence Cylinder 1 2 4 3 È Bow side To measure the valve clearances of the other cylinders starting with cylinder 1 at TDC turn the drive coupling counter clockwise ...

Page 58: ... NOTE Make sure that the tensioner rod has been fully set clockwise 1 7 Remove Intake camshaft caps Exhaust camshaft caps Timing chain from the camshaft sprockets Intake camshaft Exhaust camshaft NOTE Refer to CAMSHAFTS in Chapter 5 When removing the timing chain and cam shafts fasten the timing chain with a wire to prevent it from falling into the crankcase ...

Page 59: ... 05 mm increments NOTE The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter Since valve pads of various sizes are orig inally installed the valve pad number must be rounded in order to reach the closest equivalent to the original Round off the original valve pad number according to the following table Last digit Rounded value 0 or 2 0 5...

Page 60: ...the valve lifter and the valve pad in the correct place Install the exhaust and intake camshafts timing chain and camshaft caps T R Camshaft cap bolt 10 N m 1 0 kgf m 7 2 ft lb NOTE Refer to Camshaft installation CAM SHAFTS in Chapter 5 Lubricate the camshafts camshaft lobes and camshaft journals First install the exhaust camshaft Align the camshaft marks with the cam shaft cap marks Turn the cran...

Page 61: ...RANCE ORIGINAL VALVE PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 0 02 0 06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 0 07 0 11 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 22...

Page 62: ...can cause the watercraft to move and lead to a colli sion When checking the engine oil level on land supply water to the cooling water passages Make sure that engine has enough oil but do not overfill If there is too little oil the engine can be damaged if there is too much oil the air filter can become saturated with oil perma nently damaging the filter and reduc ing engine performance Follow the...

Page 63: ...stick is securely fitted into the oil tank NOTE The engine cannot be started if the Yamaha Security System is in the lock mode For information on the Yamaha Security System see the owner s manual Run the engine at trolling speed for 6 minutes or more and then stop the engine CAUTION When checking the oil level on land be sure to connect a garden hose to the watercraft for proper water supply NOTE ...

Page 64: ...the reading on the dipstick will be high Engine oil change using oil changer WARNING Avoid changing the engine oil immediately after turning the engine off The oil is hot and should be handled with care to avoid burns CAUTION Do not run the engine with too much or not enough oil in the oil tank Oil could spray out or the engine could be dam aged Do not run the engine for more than 15 seconds witho...

Page 65: ...f the recom mended engine oil into the oil filler hole Replacing steps Place a rag under the oil filter Remove the oil filter 1 with an oil filter wrench Oil filter wrench YU 38411 90890 01426 Lubricate the O ring 2 of the new oil filter with a thin coat of engine oil CAUTION Make sure the O ring 2 is positioned correctly in the groove of the oil filter Tighten the new oil filter to specification ...

Page 66: ...he dipstick is securely fitted into the oil tank 8 Install Oil filler cap Recommended oil SAE 10W 30 API SE SF SG SH SJ SL Oil quantity Total amount 4 5 L 4 8 US qt 4 0 Imp qt Without oil filter replacement 2 1 L 2 2 US qt 1 8 Imp qt With oil filter replacement 2 3 L 2 4 US qt 2 0 Imp qt Air filter element clean 1 Remove Air filter case cover 1 ...

Page 67: ...f cleaning the air filter element use cold or lukewarm water and let it air dry com pletely Do not use detergent or an sol vent to clean the air filter element or dry it with heat or compressed air otherwise it could be damaged 3 Install Air filter case cover T R Air filter case cover screw 2 5 N m 0 25 kgf m 1 8 ft lb LOCTITE 572 Spark plug inspection 1 Remove Air filter case cover 1 2 Remove Air...

Page 68: ...on Color guide Medium to light tan color Normal Whitish color Lean fuel mixture Air leak Incorrect settings Blackish color Overly rich mixture Electrical malfunction Defective spark plug 4 Clean Spark plug with a spark plug cleaner or wire brush 5 Measure Spark plug gap a Out of specification Regap Spark plug gap 0 7 0 8 mm 0 028 0 031 in ...

Page 69: ... seizure If a torque wrench is not available a good estimate of the correct tightening torque for a new spark plug is to finger tighten a the spark plug and then tighten it another 1 4 to 1 2 of a turn b T R Spark plug 13 N m 1 3 kgf m 9 4 ft lb 7 Install Ignition coils Air filter element Air filter case cover T R Ignition coil bolt 7 6 N m 0 76 kgf m 5 5 ft lb LOCTITE 572 Air filter case cover sc...

Page 70: ...Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc well away If using or charging the battery in an enclosed space make sure that it is well ventilated Always shield your eyes when working near batteries KEEP OUT OF THE REACH OF CHILDREN CAUTION Be careful not to place the battery on its side Make sure to remove the b...

Page 71: ...rvice 2 3 1 2 Inspect Electrolyte level Low Add distilled water The electrolyte level should be between the upper a and lower b level marks CAUTION Use only distilled water Other types of water contain minerals which are harmful to batteries 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...

Page 72: ... Charging current 1 9 amps 10 hrs 5 Install Battery breather hose 1 Battery Battery positive lead 2 Battery negative lead 3 Bands CAUTION Connect the positive lead to the battery terminal first Make sure the battery leads are con nected properly Reversing the leads can seriously damage the electrical system Make sure that the battery breather hose is properly connected and is not obstructed Coat t...

Page 73: ... a total of three measure ments Install the intake duct and intake grate Refer to INTAKE GRATE RIDE PLATE AND INTAKE DUCT in Chapter 6 Install the battery leads Water inlet strainer inspection 1 Inspect Water inlet strainer Contaminants Clean Cracks damage Replace Inspection steps Remove the ride plate Refer to INTAKE GRATE RIDE PLATE AND INTAKE DUCT in Chapter 6 Remove the rubber plate Refer to J...

Page 74: ...oupling cover Disconnect the bilge strainer case 1 from the bilge strainer Inspect the bilge strainer Install the coupling cover Install the deck beam Refer to SEATS AND HAND GRIP in Chapter 8 1 Electric bilge pump strainer inspection 1 Inspect Cap Strainer Contaminants Clean Inspection steps Remove the band 1 Remove the cap 2 and strainer 3 Inspect the cap and strainer Install the strainer and ca...

Page 75: ... and remove the rubber seal 1 2 Lubricate Throttle cable throttle body end Recommended lubricant Rust inhibitor Recommended lubricant Yamaha marine grease Yamaha grease A Water resistant grease 3 Lubricate QSTS control cables handlebar end NOTE Before lubricating the QSTS control cables remove the QSTS cable housing cover Spray the rust inhibitor into the outer cables and apply grease to the inner...

Page 76: ... pivot shaft Steering cable nozzle end QSTS cable nozzle end Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease 6 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 ...

Page 77: ...termediate housing with the recom mended grease through the grease nipple 1 Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease Grease quantity Initial 10 hours 33 0 35 0 cm3 1 11 1 18 oz Every 100 hours or 12 months 6 0 8 0 cm3 0 20 0 27 oz 1 ...

Page 78: ...mp filter inspection 4 6 Fuel pump module installation 4 7 Fuel hose connect 4 7 FUEL INJECTION SYSTEM 4 8 EXPLODED DIAGRAM 4 8 REMOVAL AND INSTALLATION CHART 4 8 SERVICE POINTS 4 17 Hose clamps removal 4 17 Hose clamps installation 4 17 Fuel hose disconnection 4 17 Fuel line inspection 4 18 Fuel hose installation replacing with new fuel hose 4 19 Fuel hose connection 4 19 Throttle body removal 4 ...

Page 79: ...osition sensor coupler È To wiring harness É Route the throttle cable between the sub wiring har ness Ê Route the sub wiring harness under the intake vacuum hose Ë To fuel injector 3 Ì Fasten the sub wiring harness to the joint coupler bracket with a plastic tie as shown in the illustration Í Fasten the ring which is attached to the sub wiring har ness to the sensor assembly bracket with a plastic...

Page 80: ...e From ventilation fitting Engine unit Refer to ENGINE UNIT in Chapter 5 NOTE When removing the pump module only it is not necessary to remove the engine unit 1 Rollover valve 1 2 Fuel tank breather hose 2 3 Check valve 1 1 3 N m 0 13 kgf m 0 9 ft Ib 8 18 mm 16 N m 1 6 kgf m 11 ft Ib 5 9 N m 0 59 kgf m 4 3 ft Ib 4 2 N m 0 42 kgf m 3 0 ft Ib 16 17 15 3 2 2 1 7 10 9 4 5 11 8 18 19 20 21 13 12 13 LT ...

Page 81: ...g the coupler 5 Fuel sender coupler 1 6 Fuel pump module coupler 1 7 Cover 1 8 Fuel hose 1 9 Nut 9 10 Retainer 1 11 Fuel pump module 1 12 Packing 1 1 3 N m 0 13 kgf m 0 9 ft Ib 8 18 mm 16 N m 1 6 kgf m 11 ft Ib 5 9 N m 0 59 kgf m 4 3 ft Ib 4 2 N m 0 42 kgf m 3 0 ft Ib 16 17 15 3 2 2 1 7 10 9 4 5 11 8 18 19 20 21 13 12 13 LT 572 LT 572 LT 572 LT 572 2nd 6 4 N m 0 64 kgf m 4 6 ft Ib 1st 3 2 N m 0 32...

Page 82: ...eal 1 18 Bolt 2 19 Fuel tank assembly 1 20 Bolt 2 21 Fuel tank belt 2 Reverse the removal steps for installation 1 3 N m 0 13 kgf m 0 9 ft Ib 8 18 mm 16 N m 1 6 kgf m 11 ft Ib 5 9 N m 0 59 kgf m 4 3 ft Ib 4 2 N m 0 42 kgf m 3 0 ft Ib 16 17 15 3 2 2 1 7 10 9 4 5 11 8 18 19 20 21 13 12 13 LT 572 LT 572 LT 572 LT 572 2nd 6 4 N m 0 64 kgf m 4 6 ft Ib 1st 3 2 N m 0 32 kgf m 2 3 ft Ib 14 6 ...

Page 83: ...the sequence shown 1 4 9 6 2 3 8 7 5 2 Remove Fuel pump module 1 NOTE Remove the float 2 at an angle because it could catch on the fuel tank 2 1 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 come out from end ...

Page 84: ...acks damage Replace Fuel hose inspection Refer to FUEL INJECTION SYSTEM Checking steps Connect a hose to the end of rollover valve A and blow into it Air should come out from end B Connect the hose to the end of rollover valve B and blow into it Air should not come out from end A A B A B Fuel pump filter inspection 1 Inspect Fuel pump filter 1 Clog contaminants Wash the fuel pump filter in kerosen...

Page 85: ...uel pump module installation 1 Tighten Nuts NOTE Tighten the nuts in the sequence shown Fuel hose connect Refer to FUEL INJECTION SYSTEM T R Fuel pump module nut 1st 3 2 N m 0 32 kgf m 2 3 ft lb 2nd 6 4 N m 0 64 kgf m 4 6 ft lb 9 6 1 4 8 7 2 3 5 ...

Page 86: ... case cover 1 3 Air filter 1 4 Bolt 4 5 Ribbon sub assembly 2 6 Holder 2 7 Throttle cable 1 8 Bolt 2 9 Throttle cable holder 1 10 Cover 1 LT 572 LT LT 242 LT E A A LT 572 LT LT 572 LT 7 8 9 15 14 12 13 11 10 5 70 mm 2 5 N m 0 25 kgf m 1 8 ft Ib 6 7 mm 6 5 N m 0 65 kgf m 4 7 ft Ib 8 50 mm 22 N m 2 2 kgf m 16 ft Ib 19 19 22 20 21 18 23 17 4 8 mm 3 3 N m 0 33 kgf m 2 4 ft Ib 6 14 mm 7 6 N m 0 76 kgf ...

Page 87: ...18 Sensor assembly coupler 1 19 Fuel injector coupler 4 20 Throttle position sensor coupler 1 LT 572 LT LT 242 LT E A A LT 572 LT LT 572 LT 7 8 9 15 14 12 13 11 10 5 70 mm 2 5 N m 0 25 kgf m 1 8 ft Ib 6 7 mm 6 5 N m 0 65 kgf m 4 7 ft Ib 8 50 mm 22 N m 2 2 kgf m 16 ft Ib 19 19 22 20 21 18 23 17 4 8 mm 3 3 N m 0 33 kgf m 2 4 ft Ib 6 14 mm 7 6 N m 0 76 kgf m 5 5 ft Ib 3 2 16 6 5 6 4 1 Not reusable ...

Page 88: ...r 1 23 Ring 1 Reverse the removal steps for installation LT 572 LT LT 242 LT E A A LT 572 LT LT 572 LT 7 8 9 15 14 12 13 11 10 5 70 mm 2 5 N m 0 25 kgf m 1 8 ft Ib 6 7 mm 6 5 N m 0 65 kgf m 4 7 ft Ib 8 50 mm 22 N m 2 2 kgf m 16 ft Ib 19 19 22 20 21 18 23 17 4 8 mm 3 3 N m 0 33 kgf m 2 4 ft Ib 6 14 mm 7 6 N m 0 76 kgf m 5 5 ft Ib 3 2 16 6 5 6 4 1 ...

Page 89: ...2 6 Thermoswitch coupler exhaust 1 From wiring harness bracket 1 7 Cam position sensor coupler 1 From wiring harness bracket 1 3 16 5 15 14 24 23 25 10 18 17 9 7 6 13 12 8 11 22 21 4 19 20 LT 271 LT 242 LT 271 1 2 LT 572 LT LT 242 8 30 mm 2nd 18 N m 1 8 kgf m 13 ft Ib 1st 8 8 N m 0 88 kgf m 6 4 ft Ib 1 8 N m 0 18 kgf m 1 3 ft Ib 5 14 mm 1 3 N m 0 13 kgf m 0 9 ft Ib 5 14 mm 1 3 N m 0 13 kgf m 0 9 f...

Page 90: ...15 14 24 23 25 10 18 17 9 7 6 13 12 8 11 22 21 4 19 20 LT 271 LT 242 LT 271 1 2 LT 572 LT LT 242 8 30 mm 2nd 18 N m 1 8 kgf m 13 ft Ib 1st 8 8 N m 0 88 kgf m 6 4 ft Ib 1 8 N m 0 18 kgf m 1 3 ft Ib 5 14 mm 1 3 N m 0 13 kgf m 0 9 ft Ib 5 14 mm 1 3 N m 0 13 kgf m 0 9 ft Ib 5 14 mm 8 16 mm 2nd 39 N m 3 9 kgf m 28 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 16 mm 2nd 39 N m 3 9 kgf m 28 ft Ib 1st 15 N m 1 5 ...

Page 91: ...23 25 10 18 17 9 7 6 13 12 8 11 22 21 4 19 20 LT 271 LT 242 LT 271 1 2 LT 572 LT LT 242 8 30 mm 2nd 18 N m 1 8 kgf m 13 ft Ib 1st 8 8 N m 0 88 kgf m 6 4 ft Ib 1 8 N m 0 18 kgf m 1 3 ft Ib 5 14 mm 1 3 N m 0 13 kgf m 0 9 ft Ib 5 14 mm 1 3 N m 0 13 kgf m 0 9 ft Ib 5 14 mm 8 16 mm 2nd 39 N m 3 9 kgf m 28 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 16 mm 2nd 39 N m 3 9 kgf m 28 ft Ib 1st 15 N m 1 5 kgf m 11 ...

Page 92: ...ypass valve motor 1 5 Holder 1 6 Holder 1 7 Hose 4 1 8 Hose 3 1 9 Hose 2 1 10 Hose 1 1 5 0 N m 0 5 kgf m 3 6 ft Ib 6 10 mm 5 0 N m 0 5 kgf m 3 6 ft Ib 6 9 mm 24 25 26 27 28 29 30 31 32 21 20 15 16 19 17 2 0 N m 0 2 kgf m 1 4 ft Ib 4 12 mm 5 0 N m 0 5 kgf m 3 6 ft Ib 6 9 mm 15 18 23 24 22 3 5 N m 0 35 kgf m 2 5 ft Ib 5 15 mm 13 N m 1 3 kgf m 9 4 ft Ib 5 0 N m 0 5 kgf m 3 6 ft Ib 6 10 mm 8 18 mm 13 ...

Page 93: ...ommet 4 20 Screw 2 21 Throttle stop guide 1 22 Screw 2 5 0 N m 0 5 kgf m 3 6 ft Ib 6 10 mm 5 0 N m 0 5 kgf m 3 6 ft Ib 6 9 mm 24 25 26 27 28 29 30 31 32 21 20 15 16 19 17 2 0 N m 0 2 kgf m 1 4 ft Ib 4 12 mm 5 0 N m 0 5 kgf m 3 6 ft Ib 6 9 mm 15 18 23 24 22 3 5 N m 0 35 kgf m 2 5 ft Ib 5 15 mm 13 N m 1 3 kgf m 9 4 ft Ib 5 0 N m 0 5 kgf m 3 6 ft Ib 6 10 mm 8 18 mm 13 14 11 12 1 3 10 5 6 9 8 4 7 2 3 ...

Page 94: ...1 31 O ring 1 32 Throttle bodies 1 Reverse the disassembly steps for assembly 5 0 N m 0 5 kgf m 3 6 ft Ib 6 10 mm 5 0 N m 0 5 kgf m 3 6 ft Ib 6 9 mm 24 25 26 27 28 29 30 31 32 21 20 15 16 19 17 2 0 N m 0 2 kgf m 1 4 ft Ib 4 12 mm 5 0 N m 0 5 kgf m 3 6 ft Ib 6 9 mm 15 18 23 24 22 3 5 N m 0 35 kgf m 2 5 ft Ib 5 15 mm 13 N m 1 3 kgf m 9 4 ft Ib 5 0 N m 0 5 kgf m 3 6 ft Ib 6 10 mm 8 18 mm 13 14 11 12 ...

Page 95: ...o securely fasten them Fuel hose disconnection WARNING Before disconnecting the hose remove the fuel tank filler cap to reduce any pressure inside the fuel tank and then disconnect the battery negative lead to cut off the elec tric current to the electrical systems 1 Wrap the quick connector with a cloth and then rotate the quick connector tab 1 to the stopper position a WARNING If the quick conne...

Page 96: ... 2 directly WARNING Always reduce the fuel pressure in the fuel line before servicing the line or the fuel pipe If the fuel pressure is not released pressurized fuel could spray out 2 1 1 2 3 Cover the quick connector and fuel pipe with a plastic bag to prevent damage and to protect them from dirt Fuel line inspection 1 Inspect Fuel hose Damage cracks Replace O rings quick connector Damage cracks ...

Page 97: ...connector is completely installed to the fuel pipe it is removable 2 1 a 2 Fuel hose connection 1 Apply a thin coat of engine oil to the con tact surfaces of the fuel pipe 2 Insert the quick connector into the fuel pipe until you hear a click 3 To check the connection of the quick con nector push and pull on the quick connec tor several times until there is free play of 2 3 mm 0 08 0 12 in NOTE If...

Page 98: ...tor using the Stationary Test of the Yamaha Diagnostic System Digital multimeter YU 34899 A Digital circuit tester 90890 03174 Fuel injector resistance reference data 11 5 12 5 Ω at 20 C 68 F Throttle body inspection 1 Check Throttle body Cracks damage Replace the throttle bodies 2 Check Fuel passages Obstruction Clean Checking steps Wash the throttle body in a petroleum based solvent Do not use a...

Page 99: ...valve motor operation using the Yamaha Diagnostic System Throttle body installation 1 Install Throttle body CAUTION Do not bend the fuel pipe 1 1 2 Install Fuel hose 1 throttle body side Clamp NOTE Install the fuel hose with the white mark a fac ing up 1 a 3 Adjust Throttle lever free play Refer to CONTROL SYSTEM in Chap ter 3 ...

Page 100: ...tion CAUTION Do not start the engine when removing the fuel hose Fuel can spurt out when the fuel pump is operated a Loosen the throttle stop screw 2 and synchronizing screws 1 3 2 4 and 3 5 until released from the levers NOTE Only butterfly valve 2 should be fully closed and the other valves should be halfway closed Check the valve for light leaks with a flashlight If there are no light leaks the...

Page 101: ... 4 should be fully closed Butterfly valves 1 2 and 3 open if the screw is turned more than 7 times If all butterfly valves are not fully closed close the valves by adjusting synchroniz ing screw 3 5 e Check that all butterfly valves are fully closed and that they open simulta neously NOTE If all butterfly valves are not fully closed close the valves by repeating steps a d f Turn the throttle stop ...

Page 102: ...onnect it to the throttle bodies and main wiring harness m Connect the test harness 3 pin to the throttle position sensor A Test harness 3 pins YB 06793 Test harness SMHW099 3 3 pins 90890 06793 n To start the ECM normally start the Yamaha Diagnostic System CAUTION If the Yamaha Diagnostic System and ECM are started fuel can spurt out Be sure to connect the fuel hoses and throt tle bodies when adj...

Page 103: ...E Warm the engine up in the water While checking the engine temperature with the Yamaha Diagnostic System warm the engine up until the engine tem perature is 50 C 122 F q Adjust the throttle stop screw until trolling speed is within specification Trolling speed Season Temperature Specified engine speed Summer 30 C 86 F or more 1 650 r min Winter 10 C 50 F or less 1 720 r min Spring Fall 20 C 68 F ...

Page 104: ...3 kPa 0 5 0 4 inHg 223 10 mmHg 29 76 1 33 kPa 8 8 0 4 inHg 4 1 0 10 mmHg 0 04 1 33 kPa 0 0 4 inHg 211 10 mmHg 28 19 1 33 kPa 8 3 0 4 inHg Standard When setting the specified engine speed the value is zero NOTE Always maintain the specified trolling speed when making this adjustment s Measure the throttle position sensor out put voltage Adjust the throttle position sensor position if out of specifi...

Page 105: ...e engine and arrow it to warm up for several minutes 4 Measure Fuel pressure Out of specification Replace the fuel pump module 5 Remove Fuel pressure gauge Fuel pressure gauge adapter NOTE To disconnect the fuel pressure gauge adapter follow the procedures for disconnect ing a fuel hose Refer to Fuel hose discon nection 6 Connect Fuel hose Refer to Fuel hose connection Fuel pressure gauge adapter ...

Page 106: ...pection 5 7 Coupling clearance inspection 5 7 EXHAUST PIPE 3 5 8 EXPLODED DIAGRAM 5 8 REMOVAL AND INSTALLATION CHART 5 8 EXHAUST PIPES 1 AND 2 5 11 EXPLODED DIAGRAM 5 11 REMOVAL AND INSTALLATION CHART 5 11 EXHAUST MANIFOLD 5 13 EXPLODED DIAGRAM 5 13 REMOVAL AND INSTALLATION CHART 5 13 OIL TANK 5 15 EXPLODED DIAGRAM 5 15 REMOVAL AND INSTALLATION CHART 5 15 SERVICE POINTS 5 21 Oil tank removal 5 21 ...

Page 107: ...ump drive shaft inspection 5 37 Drive shaft inspection 5 37 Bearing installing 5 38 Drive shaft installation 5 40 Drive coupling installation 5 40 GENERATOR AND STARTER MOTOR 5 41 EXPLODED DIAGRAM 5 41 REMOVAL AND INSTALLATION CHART 5 41 SERVICE POINTS 5 46 Flywheel magneto removal 5 46 Starter clutch inspection 5 46 Flywheel magneto installation 5 48 CAMSHAFTS 5 49 EXPLODED DIAGRAM 5 49 REMOVAL A...

Page 108: ...ide replacement 5 73 Valve seat inspection 5 75 Valve seat reface 5 76 Valve installation 5 78 CRANKCASE 5 80 EXPLODED DIAGRAM 5 80 REMOVAL AND INSTALLATION CHART 5 80 SERVICE POINTS 5 85 Crankcase disassembly 5 85 Crankcase inspection 5 86 Timing chain inspection 5 86 Crankcase assembly 5 87 CONNECTING RODS AND PISTONS 5 90 EXPLODED DIAGRAM 5 90 REMOVAL AND INSTALLATION CHART 5 90 SERVICE POINTS ...

Page 109: ...ft removal 5 104 Crankshaft inspection 5 104 Crankshaft installation 5 107 THERMOSTAT 5 108 EXPLODED DIAGRAM 5 108 REMOVAL AND INSTALLATION CHART 5 108 SERVICE POINTS 5 110 Thermostat inspection 5 110 Thermostat installation 5 110 COOLING WATER HOSE 5 111 EXPLODED DIAGRAM 5 111 REMOVAL AND INSTALLATION CHART 5 111 ...

Page 110: ...NT HOOD in Chapter 8 Battery negative and positive lead Refer to ELECTRICAL BOX in Chapter 7 Throttle cable and fuel hose Refer to FUEL INJECTION SYSTEM in Chapter 4 Water lock and exhaust joint Refer to EXHAUST SYSTEM in Chapter 8 1 Oil filter 1 2 Bolt 4 4 10 11 12 6 3 7 2 8 1 9 5 9 14 9 13 15 LT 271 LT LT 572 LT 7 8 N m 0 78 kgf m 5 6 ft Ib 6 25 mm 8 28 mm 17 N m 1 7 kgf m 12 ft Ib 17 N m 1 7 kg...

Page 111: ...Clamp cooling water hose 1 1 Cooling water outlet 7 Clamp cooling water hose 1 1 Cooling water outlet 8 Clamp cooling water hose 1 1 Cooling water inlet 9 Coupler 10 10 Grease hose 1 11 Bolt collar 1 1 12 Coupling cover 1 4 10 11 12 6 3 7 2 8 1 9 5 9 14 9 13 15 LT 271 LT LT 572 LT 7 8 N m 0 78 kgf m 5 6 ft Ib 6 25 mm 8 28 mm 17 N m 1 7 kgf m 12 ft Ib 17 N m 1 7 kgf m 12 ft Ib 8 40 mm 17 N m 1 7 kg...

Page 112: ...ints 13 Bolt washer 4 4 14 Shim 15 Engine unit 1 Reverse the removal steps for installation 4 10 11 12 6 3 7 2 8 1 9 5 9 14 9 13 15 LT 271 LT LT 572 LT 7 8 N m 0 78 kgf m 5 6 ft Ib 6 25 mm 8 28 mm 17 N m 1 7 kgf m 12 ft Ib 17 N m 1 7 kgf m 12 ft Ib 8 40 mm 17 N m 1 7 kgf m 12 ft Ib LT 572 LT E ...

Page 113: ...T in Chapter 3 2 Warm the engine up and then put the watercraft in a horizontal position 3 Remove Air filter case cover 1 Air filter element Ignition coils Spark plugs CAUTION Before removing the spark plugs use com pressed air to blow away any dirt accumu lated in the spark plug wells to prevent it from falling into the cylinders 4 Install Compression gauge extension 1 Compression gauge 2 Compres...

Page 114: ...kPa 1 kgf cm2 14 psi b If the compression pressure is extremely high check the cylinder head valve sur faces and piston crown for carbon depos its Carbon deposits Eliminate c If the compression pressure is below the minimum specification squirt a few drops of oil into the cylinder and measure again Refer to the following table Compression pressure with oil applied into the cylinder Reading Diagnos...

Page 115: ...r case cover screw 2 5 N m 0 25 kgf m 1 8 ft lb LOCTITE 572 Oil filter wrench YU 38411 90890 01426 T R Oil filter 17 N m 1 7 kgf m 12 ft lb Removal steps CAUTION Lift the engine unit carefully trying not to hit it on the deck or letting it fall hard on the hull Suspend the engine unit using all three engine hangers and then separate the unit from the engine mount Remove the hoist cable from the fr...

Page 116: ...pect Engine mounts Cracks damage Replace Refer to ENGINE MOUNT in Chapter 8 Coupling clearance inspection 1 Measure Clearance a Clearance b Out of specification Adjust NOTE Measure the clearances with a straightedge and thickness gauge Clearance a 0 0 5 mm 0 0 020 in Clearance b 2 4 mm 0 079 0 157 in 2 Adjust Clearance a and b Adjustment steps Adjust the clearance a by adding or removing shims Adj...

Page 117: ...oswitch exhaust 1 3 6 18 2 7 17 16 10 12 11 8 9 13 14 15 5 4 1 LT 572 LT 572 LT 572 LT 572 LT 242 LT 242 7th 15 N m 1 5 kgf m 11 ft Ib 3rd 2 0 N m 0 2 kgf m 1 4 ft Ib 10 40 mm 11th 39 N m 3 9 kgf m 28 ft Ib LT 242 8th 15 N m 1 5 kgf m 11 ft Ib 4th 2 0 N m 0 2 kgf m 1 4 ft Ib 10 45 mm 12th 39 N m 3 9 kgf m 28 ft Ib 7 6 N m 0 76 kgf m 5 5 ft Ib 6 16 mm 5th 15 N m 1 5 kgf m 11 ft Ib 1st 2 0 N m 0 2 k...

Page 118: ...T 242 LT 242 7th 15 N m 1 5 kgf m 11 ft Ib 3rd 2 0 N m 0 2 kgf m 1 4 ft Ib 10 40 mm 11th 39 N m 3 9 kgf m 28 ft Ib LT 242 8th 15 N m 1 5 kgf m 11 ft Ib 4th 2 0 N m 0 2 kgf m 1 4 ft Ib 10 45 mm 12th 39 N m 3 9 kgf m 28 ft Ib 7 6 N m 0 76 kgf m 5 5 ft Ib 6 16 mm 5th 15 N m 1 5 kgf m 11 ft Ib 1st 2 0 N m 0 2 kgf m 1 4 ft Ib 10 35 mm 9th 39 N m 3 9 kgf m 28 ft Ib 6th 15 N m 1 5 kgf m 11 ft Ib 2nd 2 0 ...

Page 119: ... 1 4 ft Ib 10 40 mm 11th 39 N m 3 9 kgf m 28 ft Ib LT 242 8th 15 N m 1 5 kgf m 11 ft Ib 4th 2 0 N m 0 2 kgf m 1 4 ft Ib 10 45 mm 12th 39 N m 3 9 kgf m 28 ft Ib 7 6 N m 0 76 kgf m 5 5 ft Ib 6 16 mm 5th 15 N m 1 5 kgf m 11 ft Ib 1st 2 0 N m 0 2 kgf m 1 4 ft Ib 10 35 mm 9th 39 N m 3 9 kgf m 28 ft Ib 6th 15 N m 1 5 kgf m 11 ft Ib 2nd 2 0 N m 0 2 kgf m 1 4 ft Ib 10 35 mm 10th 39 N m 3 9 kgf m 28 ft Ib ...

Page 120: ... 13 6 7 5 4 4 4 2 3 11 È È 6th 39 N m 3 9 kgf m 28 ft Ib 1st 39 N m 3 9 kgf m 28 ft Ib 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 8 75 mm 3rd 35 N m 3 5 kgf m 25 ft Ib 8 45 mm 2nd 42 N m 4 2 kgf m 30 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 10 35 mm 2nd 42 N m 4 2 kgf m 30 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 9th 39 N m 3 9 kgf m 28 ft Ib 4th 39 N m 3 9 kgf m 28 ft Ib 7th 39 N m 3 9 kgf...

Page 121: ...8 ft Ib 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 8 75 mm 3rd 35 N m 3 5 kgf m 25 ft Ib 8 45 mm 2nd 42 N m 4 2 kgf m 30 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 10 35 mm 2nd 42 N m 4 2 kgf m 30 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 9th 39 N m 3 9 kgf m 28 ft Ib 4th 39 N m 3 9 kgf m 28 ft Ib 7th 39 N m 3 9 kgf m 28 ft Ib 2nd 39 N m 3 9 kgf m 28 ft Ib 10th 39 N m 3 9 kgf m 28 ft Ib 5th 39...

Page 122: ...the white mark a facing up 2 Bolt 2 3 Bolt 4 4 Exhaust manifold 1 1 5 Dowel pin 2 4 3 2 5 6 7 10 10 9 8 5 LT 242 LT 242 LT 242 LT 242 1 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 8 70 mm 3rd 35 N m 3 5 kgf m 25 ft Ib a È 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 8 95 mm 3rd 35 N m 3 5 kgf m 25 ft Ib 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 8 55...

Page 123: ... LT 242 LT 242 LT 242 1 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 8 70 mm 3rd 35 N m 3 5 kgf m 25 ft Ib a È 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 8 95 mm 3rd 35 N m 3 5 kgf m 25 ft Ib 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 8 55 mm 3rd 35 N m 3 5 kgf m 25 ft Ib 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 8 95 mm 3rd 35 N m...

Page 124: ...LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 25 21 27 26 28 27 23 19 16 17 18 1514 20 12 22 24 5 3 4 11 1 10 6 8 9 5 7 2 E 6 A A 6 35 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 30 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 2nd 15 N m 1 5 kgf m 11 ft Ib 1st 2 0 N m 0 2 kgf m 1 4 ft Ib 3rd 39 N m 3 9 kgf m 28 ft Ib 2nd 39 N m 3 9 kgf m 28 ft ...

Page 125: ... 21 27 26 28 27 23 19 16 17 18 1514 20 12 22 24 5 3 4 11 1 10 6 8 9 5 7 2 E 6 A A 6 35 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 30 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 2nd 15 N m 1 5 kgf m 11 ft Ib 1st 2 0 N m 0 2 kgf m 1 4 ft Ib 3rd 39 N m 3 9 kgf m 28 ft Ib 2nd 39 N m 3 9 kgf m 28 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 85 mm 2nd 15 N m...

Page 126: ... 11 1 10 6 8 9 5 7 2 E 6 A A 6 35 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 30 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 2nd 15 N m 1 5 kgf m 11 ft Ib 1st 2 0 N m 0 2 kgf m 1 4 ft Ib 3rd 39 N m 3 9 kgf m 28 ft Ib 2nd 39 N m 3 9 kgf m 28 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 85 mm 2nd 15 N m 1 5 kgf m 11 ft Ib 1st 2 0 N m 0 2 kgf m 1 4 ft Ib 1...

Page 127: ...LT 572 LT LT 572 LT LT 572 LT LT 572 LT 6 25 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 5 14 mm 2nd 4 4 N m 0 44 kgf m 3 2 ft Ib 1st 1 9 N m 0 19 kgf m 1 4 ft Ib 6 20 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 20 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 14 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m ...

Page 128: ...25 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 5 14 mm 2nd 4 4 N m 0 44 kgf m 3 2 ft Ib 1st 1 9 N m 0 19 kgf m 1 4 ft Ib 6 20 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 20 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 14 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 5 35 mm 2nd 4 4 N m 0 44 kgf m 3...

Page 129: ... 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 5 14 mm 2nd 4 4 N m 0 44 kgf m 3 2 ft Ib 1st 1 9 N m 0 19 kgf m 1 4 ft Ib 6 20 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 20 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 14 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 5 35 mm 2nd 4 4 N m 0 44 kgf m 3 2 ft Ib 1st 1 9 N m 0 19 kgf ...

Page 130: ...bolts and nuts in the sequence shown 3 5 6 8 9 4 2 1 7 2 Remove Oil tank cover Gasket NOTE Loosen the oil tank cover bolts in the sequence shown 1 2 6 7 3 4 8 5 3 Remove Oil breather plate 1 Oil breather plate 2 Gasket NOTE Loosen the oil breather plate bolts in the sequence shown 3 4 5 6 1 2 7 8 ...

Page 131: ... 10 3 4 2 Oil strainer inspection 1 Check Oil strainer 1 Damage Replace Contaminants Clean Oil tank installation 1 Install Gaskets Oil cooler covers NOTE Tighten the oil cooler bolts in the sequence shown T R Oil cooler cover bolt 1st 3 7 N m 0 37 kgf m 2 7 ft lb 2nd 7 6 N m 0 76 kgf m 5 5 ft lb LOCTITE 572 5 12 4 1 6 7 8 2 3 10 9 11 ...

Page 132: ...own T R Oil breather plate bolt 1st 1 9 N m 0 19 kgf m 1 4 ft lb 2nd 4 4 N m 0 44 kgf m 3 2 ft lb 6 5 4 3 8 7 2 1 3 Install Gasket Oil tank cover NOTE Tighten the oil tank cover bolts in the sequence shown T R Oil tank cover bolt 1st 3 7 N m 0 37 kgf m 2 7 ft lb 2nd 7 6 N m 0 76 kgf m 5 5 ft lb LOCTITE 572 8 7 3 2 6 5 1 4 OIL TANK ...

Page 133: ...nk nuts and bolts in the sequence shown T R Bolt 1 1st 15 N m 1 5 kgf m 11 ft lb 2nd 39 N m 3 9 kgf m 28 ft lb LOCTITE 572 Nut 2 bolt 3 1st 2 0 N m 0 2 kgf m 1 4 ft lb 2nd 15 N m 1 5 kgf m 11 ft lb 3rd 39 N m 3 9 kgf m 28 ft lb LOCTITE 572 7 5 1 3 4 6 8 9 2 1 2 2 3 ...

Page 134: ...olt 1 5 Bolt 2 6 Oil pump assembly 1 7 Gasket 1 8 Pin 2 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 130 mm 6 25 mm 10 N m 1 0 kgf m 7 2 ft Ib 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 100 mm 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 80 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 16 mm LT 572 LT LT 572 LT 18 N m 1 ...

Page 135: ... Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 130 mm 6 25 mm 10 N m 1 0 kgf m 7 2 ft Ib 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 100 mm 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 80 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 16 mm LT 572 LT LT 572 LT 18 N m 1 8 kgf m 13 ft Ib 8 12 mm LT 572 LT 1 6 8 8 3 4 5 2 7 9 9 10 ...

Page 136: ... Bolt 3 3 Oil pump housing cover 1 1 4 Gasket 1 5 Oil pump housing 1 1 6 Check valve assembly 1 7 Oil pump housing 2 1 8 Gasket 1 9 Outer rotor scavenge 2 10 Inner rotor scavenge 2 E 8 70 mm 20 N m 2 0 kgf m 14 ft Ib 8 20 mm 20 N m 2 0 kgf m 14 ft Ib 4 12 mm 2 0 N m 0 2 kgf m 1 4 ft Ib E E E 2 1 3 20 18 21 22 4 5 23 17 9 10 8 7 10 11 9 19 6 16 15 14 13 12 Not reusable Not reusable ...

Page 137: ...ng cover 2 1 14 Gasket 1 15 Spring 1 16 Plunger 1 17 Pin 1 18 Pin 1 19 Oil pump shaft 1 20 Inner rotor feed 1 21 Outer rotor feed 1 E 8 70 mm 20 N m 2 0 kgf m 14 ft Ib 8 20 mm 20 N m 2 0 kgf m 14 ft Ib 4 12 mm 2 0 N m 0 2 kgf m 1 4 ft Ib E E E 2 1 3 20 18 21 22 4 5 23 17 9 10 8 7 10 11 9 19 6 16 15 14 13 12 Not reusable ...

Page 138: ... points 22 Check valve seat 1 23 Oil seal 1 Reverse the disassembly steps for assembly E 8 70 mm 20 N m 2 0 kgf m 14 ft Ib 8 20 mm 20 N m 2 0 kgf m 14 ft Ib 4 12 mm 2 0 N m 0 2 kgf m 1 4 ft Ib E E E 2 1 3 20 18 21 22 4 5 23 17 9 10 8 7 10 11 9 19 6 16 15 14 13 12 Not reusable ...

Page 139: ...tion Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance a 0 09 0 15 mm 0 0035 0 0059 in Outer rotor to oil pump housing clearance b scavenge pump 0 09 0 15 mm 0 0035 0 0059 in Outer rotor to oil pump housing clearance b feed pump 0 09 0 17 mm 0 0035 0 0067 in 3 Check Oil pump operation Rough movement Replace the defec tive part s Check valv...

Page 140: ...n 1 Oil pump installation 1 Install Oil pump assembly NOTE Align the projection a on the oil pump shaft with the slit b on the oil pump driven gear shaft T R Oil pump assembly bolt M6 10 N m 1 0 kgf m 7 2 ft lb LOCTITE 572 M8 1st 15 N m 1 5 kgf m 11 ft lb 2nd 28 N m 2 8 kgf m 20 ft lb LOCTITE 572 a b ...

Page 141: ... Bolt 1 3 Bolt 1 4 Bolt 3 5 Bolt 1 8 8 9 11 10 11 9 7 3 2 4 12 5 4 6 E LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT 6 55 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 28 N m 2 8 kgf m 20 ft Ib 6 35 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 8 40 mm 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 70 mm 2nd 28 N m 2 8 kgf m 20 ft Ib...

Page 142: ...11 9 7 3 2 4 12 5 4 6 E LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT 6 55 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 28 N m 2 8 kgf m 20 ft Ib 6 35 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 8 40 mm 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 70 mm 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 1 8 100 mm 2nd 2...

Page 143: ...e Part name Q ty Service points REDUCTION DRIVE GEAR DISASSEMBLY Follow the left Step for disassembly 1 Oil pump drive shaft 1 2 Drive shaft 1 3 Collar 1 4 Oil seal 2 5 Circlip 1 6 Bearing 1 7 Collar 1 8 Bearing 1 E E E E 3 4 8 6 5 10 9 1 1 A A 1 5 10 mm E 2 11 7 Not reusable Not reusable Not reusable Not reusable ...

Page 144: ...AGRAM 1 EPNOC grease AP 0 Step Procedure Part name Q ty Service points 9 Circlip 1 10 Bearing 1 11 Reduction drive gear case 1 Reverse the disassembly steps for assembly E E E E 3 4 8 6 5 10 9 1 1 A A 1 5 10 mm E 2 11 7 Not reusable Not reusable ...

Page 145: ...551 Universal magneto and rotor holder YU 01235 Rotor holder 90890 01235 1 4 2 3 Drive shaft removal 1 Remove Drive shaft NOTE Press in the direction of the arrow Bearing removal 1 Remove Circlip Rear bearing Collar Front bearing NOTE Remove the front bearing spacer and rear bearing using a press È For USA and Canada É For worldwide Driver handle large YB 06071 Driver rod L3 90890 06652 Bearing ho...

Page 146: ...ldwide Slide hammer and adapters YB 06096 Stopper guide plate 90890 06501 Bearing puller assembly 90890 06535 Stopper guide stand 90890 06538 È É Oil pump drive shaft inspection 1 Check Oil pump drive shaft 1 Cracks damage wear Replace 1 Drive shaft inspection 1 Check Drive shaft 1 Cracks damage wear Replace 1 ...

Page 147: ... Driver handle large YB 06071 Driver rod LS 90890 06606 Outer race installer forward gear YB 06085 Ball bearing attachment 90890 06631 2 Install Front bearing NOTE Install the front bearing using a press È For USA and Canada É For worldwide Driver rod LS 90890 06606 Forward gear bearing cup installer YB 06726 B Ball bearing attachment 90890 06657 È É ...

Page 148: ...er of 70 mm 2 76 in and an inner diame ter of 30 mm 1 18 in È For USA and Canada É For worldwide Driver rod LS 90890 06606 Outer race installer forward gear YB 06085 Bearing outer race attachment 90890 06624 È É 4 Install Oil seals È For USA and Canada É For worldwide Driver handle large YB 06071 Driver rod LS 90890 06606 Outer race installer forward gear YB 06085 Bearing outer race attachment 908...

Page 149: ...er of approximately 35 mm 1 97 in and an inner diameter of approximately 28 0 5 mm 1 10 0 02 in Drive coupling installation 1 Install Drive coupling 1 NOTE While holding the drive shaft 2 with the rotor holder 3 tighten the drive coupling with the coupler wrench 4 2 Install Reduction drive gear housing Coupler wrench YW 06551 90890 06551 Universal magneto and rotor holder YU 01235 Rotor holder 908...

Page 150: ...asher 1 1 2 Starter motor lead 1 3 Bolt 2 4 Battery negative lead 1 5 Starter motor 1 6 Band 1 7 Lighting coil coupler 1 4 3 2 1 5 6 8 7 9 10 11 13 12 18 16 17 19 20 21 15 14 A A E E E LT 572 LT 572 A A A A 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 4 9 N m 0 49 kgf m 3 5 ft Ib 10 47 mm 75 N m 7 5 kgf m 54 ft Ib 8 20 mm 24 N m 2 4 kgf m 17 ft Ib 10 60 mm 2nd 50 N m 5 0 kgf m 36 ft Ib 1st 15 N m 1 5 kgf m 1...

Page 151: ...olt washer 1 1 17 Flywheel magneto 1 18 Bolt 6 4 3 2 1 5 6 8 7 9 10 11 13 12 18 16 17 19 20 21 15 14 A A E E E LT 572 LT 572 A A A A 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 4 9 N m 0 49 kgf m 3 5 ft Ib 10 47 mm 75 N m 7 5 kgf m 54 ft Ib 8 20 mm 24 N m 2 4 kgf m 17 ft Ib 10 60 mm 2nd 50 N m 5 0 kgf m 36 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib LT 572 LT 572 2nd 50 N m 5 0 kgf m 36 ft Ib 1st 15 N m 1 5 kgf m 1...

Page 152: ...eps for installation 4 3 2 1 5 6 8 7 9 10 11 13 12 18 16 17 19 20 21 15 14 A A E E E LT 572 LT 572 A A A A 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 4 9 N m 0 49 kgf m 3 5 ft Ib 10 47 mm 75 N m 7 5 kgf m 54 ft Ib 8 20 mm 24 N m 2 4 kgf m 17 ft Ib 10 60 mm 2nd 50 N m 5 0 kgf m 36 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib LT 572 LT 572 2nd 50 N m 5 0 kgf m 36 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib ...

Page 153: ...mbly 1 Bolt washer 3 3 2 Bolt 4 3 Pickup coil 2 NOTE There washers holds the pickup coil lead Make sure to not pitch the lead between the projection and the washer when installing the bolt 4 Bolt 2 1 7 6 3 2 4 5 LT 242 LT 242 LT 242 LT 242 14 N m 1 4 kgf m 10 ft Ib 6 14 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 5 14 mm 14 N m 1 4 kgf m 10 ft Ib 6 33 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 5 10 mm 1 1 2 3 ...

Page 154: ... Service points 5 Holder 1 6 Bolt 3 7 Lighting coil 1 Reverse the disassembly steps for assembly 1 7 6 3 2 4 5 LT 242 LT 242 LT 242 LT 242 14 N m 1 4 kgf m 10 ft Ib 6 14 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 5 14 mm 14 N m 1 4 kgf m 10 ft Ib 6 33 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 5 10 mm 1 1 2 3 ...

Page 155: ... with the sheave holder 3 loosen the flywheel magneto bolt Sheave holder YS 01880 A 90890 01701 2 Remove Flywheel magneto 1 Woodruff key NOTE While holding the flywheel magneto with sheave holder 2 remove the flywheel mag neto with the rotor puller 3 Rotor puller YM 01082 90890 01080 Starter clutch inspection 1 Check Starter clutch rollers 1 Damage wear Replace ...

Page 156: ...utch gear 1 2 a 4 Check Starter clutch operation Checking steps Install the starter gear 1 onto the starter clutch 2 and hold the starter clutch When turning the starter gear clockwise È it should turn freely otherwise the starter clutch is faulty and must be replaced When turning the starter gear counter clockwise É the starter clutch and the starter gear should engage otherwise the starter clutc...

Page 157: ...ake sure the woodruff key is properly seated in the keyway of the crankshaft Lubricate the flywheel magneto bolt and washer with engine oil 2 Tighten Flywheel magneto bolt 1 NOTE While holding the flywheel magneto 2 with the sheave holder 3 tighten the flywheel mag neto bolt CAUTION Do not reuse the flywheel magneto bolt and washer always replace them with new ones T R Flywheel magneto bolt 75 N m...

Page 158: ... Chapter 4 1 Bolt 4 2 Ignition coil 4 3 Spark plug 4 4 Clamp breather hose 1 1 È To oil tank Paint mark a 5 Bolt 1 6 Cam position sensor 1 E 4 6 5 7 8 10 11 15 16 9 LT 572 LT 17 19 18 3 13 N m 1 3 kgf m 9 4 ft Ib 10 N m 1 0 kgf m 7 2 ft Ib 6 16 mm 6 16 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 12 N m 1 2 kgf m 8 7 ft Ib 6 22 mm a È É 6 16 mm 12 14 13 1 2 7 6 N m 0 76 kgf...

Page 159: ...2 Bolt 1 13 Band 1 14 Collar 1 15 Bolt 6 16 Rubber mount 6 17 Cylinder head cover 1 E 4 6 5 7 8 10 11 15 16 9 LT 572 LT 17 19 18 3 13 N m 1 3 kgf m 9 4 ft Ib 10 N m 1 0 kgf m 7 2 ft Ib 6 16 mm 6 16 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 12 N m 1 2 kgf m 8 7 ft Ib 6 22 mm a È É 6 16 mm 12 14 13 1 2 7 6 N m 0 76 kgf m 5 5 ft Ib 6 16 mm LT 572 LT GM GM Not reusable ...

Page 160: ...everse the removal steps for installation E 4 6 5 7 8 10 11 15 16 9 LT 572 LT 17 19 18 3 13 N m 1 3 kgf m 9 4 ft Ib 10 N m 1 0 kgf m 7 2 ft Ib 6 16 mm 6 16 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 12 N m 1 2 kgf m 8 7 ft Ib 6 22 mm a È É 6 16 mm 12 14 13 1 2 7 6 N m 0 76 kgf m 5 5 ft Ib 6 16 mm LT 572 LT GM GM Not reusable ...

Page 161: ...When removing camshafts it is not neces sary to remove the reduction drive gear case 1 Cap bolt 1 2 Gasket 1 3 Bolt 2 4 Timing chain tensioner 1 E E E E E E M M 10 11 10 11 10 11 12 16 17 8 18 8 8 13 9 14 7 15 6 20 19 1 2 3 4 5 10 N m 1 0 kgf m 7 2 ft Ib 6 35 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 35 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 25 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 8 mm 24 N m 2 4 kgf m 17 ft Ib 7 11 mm...

Page 162: ...be connected to the camshaft caps 10 Bolt 10 11 Exhaust camshaft cap 3 12 Dowel pin 6 13 Intake camshaft 1 14 Bolt 2 15 Intake camshaft sprocket 1 E E E E E E M M 10 11 10 11 10 11 12 16 17 8 18 8 8 13 9 14 7 15 6 20 19 1 2 3 4 5 10 N m 1 0 kgf m 7 2 ft Ib 6 35 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 35 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 25 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 8 mm 24 N m 2 4 kgf m 17 ft Ib 7 11 ...

Page 163: ...ming chain guide intake side 1 Reverse the removal steps for installation E E E E E E M M 10 11 10 11 10 11 12 16 17 8 18 8 8 13 9 14 7 15 6 20 19 1 2 3 4 5 10 N m 1 0 kgf m 7 2 ft Ib 6 35 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 35 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 25 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 8 mm 24 N m 2 4 kgf m 17 ft Ib 7 11 mm 24 N m 2 4 kgf m 17 ft Ib 7 11 mm ...

Page 164: ...at TDC of the compression stroke with a dial gauge NOTE TDC on the compression stroke can be found when the camshaft lobes are turned away from each other Dial gauge stand 90890 06583 Dial gauge needle 90890 06584 Dial gauge stand set YW 06585 90890 06585 Dial gauge YU 03097 90890 01252 2 1 IN EX 3 Make the alignment marks a on the timing chain and camshaft sprockets a 4 Remove Timing chain tensio...

Page 165: ...case fasten it with a wire 3 7 Remove Exhaust camshaft sprocket 1 Intake camshaft sprocket 2 with the special tool 3 Universal magneto and rotor holder YU 01235 Rotor holder 90890 01235 Camshaft inspection 1 Check Camshaft lobes Blue discoloration pitting scratches Replace the camshaft 2 Measure Camshaft lobe dimensions a and b Out of specification Replace the cam shaft Cam lobe dimensions Intake ...

Page 166: ...nto the cylinder head without the dowel pins and camshaft caps Position a strip of Plastigauge 1 onto the camshaft journal as shown Install the dowel pins and camshaft caps NOTE Tighten the intake and exhaust camshaft cap bolts in the sequence shown Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge T R Camshaft cap bolt 10 N m 1 0 kgf m 7 2...

Page 167: ...n as a set a 1 4 of a tooth b Correct 1 Timing chain 2 Camshaft sprocket Timing chain tensioner inspection 1 Check Timing chain tensioner Cracks damage rough movement Replace Checking steps While lightly pressing the timing chain tensioner rod by hand turn the tensioner rod fully clockwise with a thin screwdriver 1 Remove the screwdriver and slowly release the timing chain tensioner rod Make sure ...

Page 168: ... camshaft Exhaust camshaft caps Intake camshaft caps Installation steps Turn the drive coupling counterclockwise and then check if cylinder 1 is at TDC of the compression stroke with a dial gauge Install the timing chain onto both cam shaft sprockets and then install the cam shaft CAUTION Do not turn the crankshaft when install ing the camshaft to avoid damage or improper valve timing NOTE Make su...

Page 169: ...2 6 13 11 10 16 3 Install Timing chain tensioner Installation steps While lightly pressing the timing chain tensioner rod by hand turn the tensioner rod fully clockwise with a thin screwdriver 1 NOTE Make sure that the tensioner rod has been fully set clockwise With the timing chain tensioner rod turned all the way into the timing chain tensioner housing with the thin screw driver still installed ...

Page 170: ...Turn Drive coupling several turns counterclockwise 5 Check Turn the drive coupling counterclock wise and then check if cylinder 1 is at TDC of the compression stroke with a dial gauge Camshaft punch marks a Make sure that the camshaft punch marks are aligned with the arrow marks b on the camshaft caps Out of alignment Adjust Refer to the installation steps above 6 Measure Valve clearance Out of sp...

Page 171: ...sket Cylinder head cover NOTE Apply Gasket Maker onto the mating sur faces of the cylinder head cover gasket and cylinder head Tighten the cylinder head cover bolts stages and in a crisscross pattern T R Cylinder head cover bolt 12 N m 1 2 kgf m 8 7 ft lb ...

Page 172: ...ipe 3 Refer to EXHAUST PIPE 3 Exhaust pipes 1 and 2 Refer to EXHAUST PIPES 1 AND 2 Oil tank Refer to OIL TANK Intake and exhaust camshaft Refer to CAMSHAFTS 1 Bolt 2 2 Hunger 1 3 Bolt 3 E E E E E E 2 4 1 8 5 5 7 9 3 5 5 6 LT 271 2nd 121 5 1st 20 N m 2 0 kgf m 14 ft Ib 2nd 140 5 1st 20 N m 2 0 kgf m 14 ft Ib 10 N m 1 0 kgf m 7 2 ft Ib 6 12 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 55 mm 10 N m 1 0 kgf m 7 2 ...

Page 173: ...t 1 9 Dowel pin 2 Reverse the removal steps for installation E E E E E E 2 4 1 8 5 5 7 9 3 5 5 6 LT 271 2nd 121 5 1st 20 N m 2 0 kgf m 14 ft Ib 2nd 140 5 1st 20 N m 2 0 kgf m 14 ft Ib 10 N m 1 0 kgf m 7 2 ft Ib 6 12 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 55 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 12 mm 40 N m 4 0 kgf m 29 ft Ib 8 20 mm 5 2nd 105 5 1st 20 N m 2 0 kgf m 14 ft Ib E Not reusable ...

Page 174: ...inder head nuts in the sequence shown Cylinder head inspection 1 Eliminate Combustion chamber carbon deposits with a rounded scraper NOTE Do not use a sharp instrument to avoid damag ing or scratching spark plug bore threads valve seats 2 Check Cylinder head Damage scratches Replace Cylinder head water jacket Mineral deposits rust Eliminate ...

Page 175: ...arpage If the limit is exceeded replace the cylin der head Cylinder head installation 1 Install Cylinder head NOTE Pass the timing chain through the timing chain cavity Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts in the sequence shown T R Cylinder head nut 1 1st 20 N m 2 0 kgf m 14 ft lb 2nd 121 5 Cylinder head nut 2 1st 20 N m 2 0 kgf m 14 ft lb 2nd 105 5 Cylin...

Page 176: ...5 67 E POWR CYLINDER HEAD 2 Tighten Cylinder head bolts 1 NOTE Lubricate the cylinder head bolts with engine oil T R Cylinder head bolt 10 N m 1 0 kgf m 7 2 ft lb ...

Page 177: ...Follow the left Step for removal Cylinder head Refer to CYLINDER HEAD 1 Intake valve lifter 12 2 Intake valve pad 12 3 Intake valve cotter 24 4 Intake valve upper spring seat 12 5 Intake valve spring 12 6 Intake valve oil seal 12 7 Intake valve lower spring seat 12 8 Intake valve 12 9 Intake valve guide 12 E E E 8 9 17 18 16 15 14 13 10 11 12 1 2 3 4 5 6 7 3 12 Not reusable Not reusable ...

Page 178: ... valve pad 8 12 Exhaust valve cotter 16 13 Exhaust valve upper spring seat 8 14 Exhaust valve spring 8 15 Exhaust valve oil seal 8 16 Exhaust valve lower spring seat 8 17 Exhaust valve 8 18 Exhaust valve guide 8 Reverse the removal steps for installation E E E 8 9 17 18 16 15 14 13 10 11 12 1 2 3 4 5 6 7 3 12 Not reusable Not reusable ...

Page 179: ...move the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 Valve spring compressor YM 01253 90890 04019 Valve spring compressor attachment for the intake valve YM 4114 90890 04114 for the exhaust valve YM 4108 90890 04108 3 Remove Upper spring seat 1 Valve spring 2 Valve 3 Oil seal 4 Lower spring seat 5 NOTE Identify the position of each part very ca...

Page 180: ... free length Intake valve spring 38 90 mm 1 53 in Exhaust valve spring 40 67 mm 1 60 in Valve spring tilt Intake valve spring 1 7 mm 0 067 in Exhaust valve spring 1 8 mm 0 071 in Valve inspection 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve face Pitting wear Replace the valve 3 Measure Valve margin thickness a Out of specification Replace the valve Valve margin thic...

Page 181: ...e 4 465 4 480 mm 0 1758 0 1764 in 5 Measure Valve stem runout Out of specification Replace the valve NOTE When installing a new valve always replace the valve guide If the valve is removed or replaced always replace the oil seal Valve stem runout 0 01 mm 0 0004 in Valve guide inspection NOTE Before checking the valve guide make sure that the valve stem diameter is within specifi cation ...

Page 182: ... 0 1575 0 1580 in Exhaust 4 500 4 512 mm 0 1772 0 1776 in Valve stem to valve guide clearance valve guide inside diameter valve stem diameter Intake 0 010 0 037 mm 0 0004 0 0015 in Exhaust 0 020 0 047 mm 0 0008 0 0019 in a Valve guide replacement 1 Remove the valve guide 1 by striking the special service tool from the combustion chamber side Valve guide remover Intake ø4 0 mm YM 04111 90890 04111 ...

Page 183: ...de installer Intake ø4 0 mm YM 04112 90890 04112 Exhaust ø4 5 mm YM 04117 90890 04117 3 E 2 3 Insert the special service tool into the valve guide 2 and then ream the valve guide NOTE Turn the valve guide reamer clockwise to ream the valve guide Do not turn the reamer counterclockwise when removing the reamer 4 Measure Valve guide inside diameter Valve guide reamer Intake ø4 0 mm YM 04113 90890 04...

Page 184: ...valve slowly on the valve seat with a valve lapper commercially obtainable as shown 4 Measure the valve seat contact width a where the blueing dye is adhered to the valve face Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification Replace the valve guide if the valve seat contact is uneven Valve seat contact width a 0 9 1 1 mm 0 0354 0 ...

Page 185: ...seat Be sure to turn the cutter evenly downward at a pres sure of 40 50 N 4 5 kgf 8 8 11 lbf to pre vent chatter marks Valve seat cutter holder Intake ø4 0 mm 90890 06811 Exhaust ø4 5 mm 90890 06812 Valve seat cutter 30 intake 90890 06815 45 intake 90890 06814 60 intake 90890 06813 30 exhaust 90890 06328 45 exhaust 90890 06312 60 exhaust 90890 06315 Valve seat cutter set YM 91043 C 3 Use a 30 cutt...

Page 186: ...p edge of the valve seat a 60 cutter to cut the bottom edge to center the area and set its width b Previous contact width 7 If the valve seat contact area is too narrow and situated near the top edge of the valve face use a 30 cutter to cut the top edge of the valve seat If necessary use a 45 cutter to center the area and set its width b Previous contact width 8 If the valve seat contact area is t...

Page 187: ... remaining lapping compound from the cylinder head and the valve 11 Check the valve seat contact area of the valve again Valve installation 1 Install Lower spring seat 1 Oil seal 2 Valve 3 Valve spring 4 Upper spring seat 5 into the cylinder head NOTE Make sure that each valve is installed in its original place Refer to the following embossed marks Right and left intake valve s 4XV Middle intake v...

Page 188: ...ase applied to it Valve spring compressor YM 01253 90890 04019 Valve spring compressor attachment for the intake valve YM 4114 90890 04114 for the exhaust valve YM 4108 90890 04108 3 Lightly tap the valve spring retainer with a plastic hammer to set the valve cotter securely NOTE Apply engine oil to the valve pads and valve lifters before installation ...

Page 189: ...UST MANIFOLD Generator cover Refer to GENERATOR AND STARTER MOTOR Loosen completely 6 21 20 20 11 10 9 8 7 2 3 4 5 16 15 17 18 13 14 12 19 1 LT 271 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT E E A A 12 N m 1 2 kgf m 8 7 ft Ib 6 70 mm 12 N m 1 2 kgf m 8 7 ft Ib 6 20 mm 20 N m 2 0 kgf m 14 ft Ib 8 40 mm 2nd 3rd 15 N m 1 5 kgf m 11 ft Ib 1st 7 8 N m 0 78 kgf m 5 6 ft Ib 9 105 mm 4th 49 5 8 ...

Page 190: ...re switch 1 6 21 20 20 11 10 9 8 7 2 3 4 5 16 15 17 18 13 14 12 19 1 LT 271 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT E E A A 12 N m 1 2 kgf m 8 7 ft Ib 6 70 mm 12 N m 1 2 kgf m 8 7 ft Ib 6 20 mm 20 N m 2 0 kgf m 14 ft Ib 8 40 mm 2nd 3rd 15 N m 1 5 kgf m 11 ft Ib 1st 7 8 N m 0 78 kgf m 5 6 ft Ib 9 105 mm 4th 49 5 8 4 N m 0 84 kgf m 6 1 ft Ib 12 N m 1 2 kgf m 8 7 ft Ib 6 55 mm 12 N m 1 2...

Page 191: ...1 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT E E A A 12 N m 1 2 kgf m 8 7 ft Ib 6 70 mm 12 N m 1 2 kgf m 8 7 ft Ib 6 20 mm 20 N m 2 0 kgf m 14 ft Ib 8 40 mm 2nd 3rd 15 N m 1 5 kgf m 11 ft Ib 1st 7 8 N m 0 78 kgf m 5 6 ft Ib 9 105 mm 4th 49 5 8 4 N m 0 84 kgf m 6 1 ft Ib 12 N m 1 2 kgf m 8 7 ft Ib 6 55 mm 12 N m 1 2 kgf m 8 7 ft Ib 6 55 mm 7 6 N m 0 76 kgf m 5 5 ft Ib 6 16 mm 15 N m 1 5 k...

Page 192: ...T 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT E E A A 12 N m 1 2 kgf m 8 7 ft Ib 6 70 mm 12 N m 1 2 kgf m 8 7 ft Ib 6 20 mm 20 N m 2 0 kgf m 14 ft Ib 8 40 mm 2nd 3rd 15 N m 1 5 kgf m 11 ft Ib 1st 7 8 N m 0 78 kgf m 5 6 ft Ib 9 105 mm 4th 49 5 8 4 N m 0 84 kgf m 6 1 ft Ib 12 N m 1 2 kgf m 8 7 ft Ib 6 55 mm 12 N m 1 2 kgf m 8 7 ft Ib 6 55 mm 7 6 N m 0 76 kgf m 5 5 ft Ib 6 16 mm 15 N m 1 5 kgf m 1...

Page 193: ...nts OIL PIPE AND OIL FILTER BOLT REMOVAL Follow the left Step for removal Crankshaft Refer to CRANKSHAFT 1 Bolt 1 2 Oil pipe 1 3 O ring 2 4 Oil filter bolt 1 5 Lower crankcase 1 Reverse the removal steps for installation E E 5 1 2 3 4 A A 6 10 mm 12 N m 1 2 kgf m 8 7 ft Ib 35 N m 3 5 kgf m 25 ft Ib Not reusable ...

Page 194: ... 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them Loosen the bolts in decreasing numerical order refer to the numbers in the illustra tion The numbers embossed on the crankcase indicate the crankcase tightening sequence 3 Remove Lower crankcase CAUTION Tap on one side of the crankcase with a soft face hammer Tap only on reinforced ...

Page 195: ...ild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with com pressed air Timing chain inspection 1 Check Timing chain 1 Damage stiffness Replace the timing chain and camshaft sprockets as a set ...

Page 196: ...to come into contact with the oil gallery or crankshaft journal bearings Recommended lubricant Engine oil 3 Install Dowel pins 1 O ring 2 GM 1 12 1 4 Install Crankcase bolts NOTE Lubricate the bolt 1 0 threads and wash ers with engine oil Finger tighten the crankcase bolts M9 105 mm bolts 1 0 M6 55 mm bolts A F M6 55 mm bolts G H M6 70 mm bolts I M6 55 mm bolts J 1 5 3 9 7 I C A E G 8 6 2 4 0 H F ...

Page 197: ... 5 6 ft lb Loosen and retighten the crankcase bolts in the proper tightening sequence as shown T R Crankcase bolt 1 0 2nd Loosen completely 3rd 15 N m 1 5 kgf m 11 ft lb Tighten the crankcase bolts further to reach the specified angle 49 in the proper tightening sequence as shown T R Crankcase bolt 1 0 Final Specified angle 49 5 WARNING When the bolts are tightened more than the specified angle do...

Page 198: ...rom one corner to another is 60 6 Tighten Crankcase bolts A J NOTE Tighten the bolts in the tightening sequence cast on the crankcase T R Crankcase bolt A J 12 N m 1 2 kgf m 8 7 ft lb 1 5 3 9 7 I C A E G 8 6 2 4 0 H F B D J 7 Tighten Oil pan bolts NOTE Tighten the bolts in the tightening sequence cast on the oil pan T R Oil pan bolt 12 N m 1 2 kgf m 8 7 ft lb LOCTITE 572 10 6 2 4 8 12 15 11 7 3 1 ...

Page 199: ...rvice points CONNECTING RODS AND PISTONS REMOVAL Follow the left Step for removal Crankcase Separate Refer to CRANKCASE 1 Nut 8 2 Connecting rod cap 4 3 Big end lower bearing 4 4 Piston pin clip 8 5 Piston pin 4 6 Piston 4 7 Connecting rod 4 E E E E 1 2 3 10 11 12 4 5 6 8 7 9 2nd 120 5 1st 20 N m 2 0 kgf m 14 ft Ib M M M M Not reusable Not reusable ...

Page 200: ...tep Procedure Part name Q ty Service points 8 Bolt 8 9 Big end upper bearing 4 10 Top ring 4 11 2nd ring 4 12 Oil ring 4 Reverse the removal steps for installation E E E E 1 2 3 10 11 12 4 5 6 8 7 9 2nd 120 5 1st 20 N m 2 0 kgf m 14 ft Ib M M M M Not reusable ...

Page 201: ... its original place 1 2 Remove Piston pin clips 1 Piston pin 2 Piston 3 Connecting rod 4 CAUTION Do not use a hammer to drive the piston pin out NOTE For reference during installation put an iden tification number a on the piston crown Before removing the piston pin deburr the piston pin clip s groove and the piston s pin bore area 3 Remove Top ring 2nd ring Oil ring NOTE When removing a piston ri...

Page 202: ...e cylin der bore gauge Cylinder bore C 76 000 76 015 mm 2 9921 2 9927 in Taper limit T 0 08 mm 0 003 in Out of round R 0 05 mm 0 002 in C maximum of D1 D6 T maximum of D1 D5 direction d and D2 D6 direction e R maximum of D2 D1 measuring point a and D6 D5 measuring point c If out of specification replace the cylin der and the piston and piston rings as a set Measure piston skirt diameter P with the...

Page 203: ... 0 0043 in Limit 0 17 mm 0 0067 in If out of specification replace the piston and piston rings as a set Piston ring inspection 1 Measure Piston ring side clearance Out of specification Replace the pis ton and piston rings as a set NOTE Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings Side clearance Top ring 0 030 0 065 mm ...

Page 204: ...0 2 in 3 Measure Piston ring end gap Out of specification Replace the pis ton ring NOTE The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring end gap Top ring 0 32 0 44 mm 0 0126 0 0173 in 2nd ring 0 43 0 58 mm 0 0169 0 0228 in Oil ring 0 10 0 35 mm 0 0039 0 0138 in ...

Page 205: ...n pin Piston pin outside diameter 16 991 17 000 mm 0 6689 0 6693 in Limit 16 98 mm 0 67 in 3 Measure Piston pin bore diameter in the piston b Out of specification Replace the pis ton 4 Calculate Piston pin to piston clearance Out of specification Replace the pis ton pin Piston pin bore diameter in the piston 17 002 17 013 mm 0 6693 0 6698 in Piston pin to piston clearance Piston pin bore diameter ...

Page 206: ...nnecting rods To obtain the cor rect crankshaft pin to big end bearing clearance and prevent engine damage the big end bearings must be installed in their original positions Clean the big end bearings crankshaft pins and the inside of the connecting rod halves Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap NOTE Align the projecti...

Page 207: ...ten the connecting rod nuts Refer to Connecting rod and piston installation Remove the connecting rod and big end bearings Refer to Connecting rod and piston removal Measure the compressed Plastigauge width e on the crankshaft pin If the crankshaft pin to big end bearing clearance is out of specification select replacement big end bearings c d e 2 Select Big end bearings P1 P4 NOTE The numbers sta...

Page 208: ... of the pistons and connecting rods 1 Install Oil ring 2nd ring Top ring NOTE Be sure to install the piston rings so that the manufacturer s marks or numbers face up 2 Install Piston 1 Connecting rod 2 Piston pin 3 Piston pin clips 4 NOTE Apply engine oil onto the piston pin When installing the connecting rod to the pis ton make sure that the Y mark a on the connecting rod faces towards the left w...

Page 209: ... b c a È 90 45 90 4 Lubricate Piston Piston rings Cylinder with the recommended lubricant Recommended lubricant Engine oil 5 Lubricate Bolt threads Nut seats with the recommended lubricant Recommended lubricant Molybdenum disulfide grease 6 Lubricate Crankshaft pins Big end bearings Connecting rod inner surface with the recommended lubricant Recommended lubricant Engine oil ...

Page 210: ...ing rod caps Be sure to reinstall each big end bearing in its original place While compressing the piston rings with pis ton ring compressor 2 install the connecting rod assembly into the cylinder with the other hand Make sure the Y marks a on the connect ing rods face towards the front side of the crankshaft Make sure the characters b on both the con necting rod and connecting rod cap are aligned...

Page 211: ...orque T R Connecting rod nut 1st 20 N m 2 0 kgf m 14 ft lb Tighten the connecting rod nuts further to reach the specified angle 120 T R Connecting rod nut Final Specified angle 120 5 WARNING When the nuts are tightened more than the specified angle do not loosen the nut and then retighten it Replace the bolt and nut with a new one and perform the procedure again CAUTION Do not use a torque wrench ...

Page 212: ...Q ty Service points CRANKSHAFT REMOVAL Follow the left Step for removal Crankcase Separate Refer to CRANKCASE Connecting rod caps Refer to CONNECTING RODS AND PISTONS 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearing 5 Reverse the removal steps for installation 2 2 1 3 3 E ...

Page 213: ...haft inspection 1 Measure Crankshaft runout Out of specification Replace the crankshaft Maximum crankshaft runout 0 03 mm 0 0012 in 2 Check Crankshaft journal surfaces Crankshaft pin surfaces Scratches wear Replace the crank shaft Bearing surfaces Scratches wear Replace the crank shaft journal bearing 3 Measure crankshaft journal to crankshaft journal bearing clearance Out of specification Replace...

Page 214: ...all the crankshaft journal upper bear ings 1 and the crankshaft into the upper crankcase NOTE Align the projections a of the crankshaft journal upper bearings with the notches b in the upper crankcase Put a piece of Plastigauge 2 on each crankshaft journal NOTE Do not put the Plastigauge over the oil hole in the crankshaft journal Install the crankshaft journal lower bear ings into the lower crank...

Page 215: ... 4 Select Crankshaft journal bearings J1 J5 NOTE The numbers stamped into the crankshaft web and the numbers stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the crankshaft illustration If J1 J5 are the same use the same size for all of the bearings For example if the crankcase J1 and crank shaft web J1 num...

Page 216: ...bearings into the lower crankcase NOTE Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase Be sure to install each crankshaft journal bearing in its original place a b 2 Lubricate Crankshaft pins Connecting rod inner surface with the recommended lubricant Recommended lubricant Engine oil ...

Page 217: ... on stern side 3 Clamp cooling water hose 2 1 4 Clamp cooling water hose 1 1 É For cooling water pilot outlet on starboard side 5 Band grease hose 1 1 6 Bolt 2 7 Thermostat housing cover 1 8 Thermostat 1 3 1 3 10 8 7 4 6 5 2 LT 572 LT 572 6 35 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib È É 6 70 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib LT 572 LT...

Page 218: ...llar 2 13 Thermostat housing holder 1 Reverse the removal steps for installation 3 1 3 10 8 7 4 6 5 2 LT 572 LT 572 6 35 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib È É 6 70 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib LT 572 LT 572 13 12 11 12 5 9 N m 0 59 kgf m 4 3 ft Ib 9 Not reusable ...

Page 219: ...eri ous overheating or over cooling Checking steps Suspend the thermostat in a container filled with water Slowly heat the water Place a thermometer in the water While stirring the water observe the ther mostat and thermometer s indicated tem perature 1 3 2 4 2 Check Thermostat housing cover Thermostat housing Cracks damage Replace 3 Check Cooling system Leaks Repair or replace any faulty part The...

Page 220: ...anifold Refer to EXHAUST MANIFOLD 1 Clamp cooling water hose 1 1 È From exhaust manifold É To cylinder block 2 Clamp cooling water hose 2 2 Ê To exhaust pipe 3 Clamp cooling water hose 2 1 Ë To cylinder block 4 Clamp cooling water hose 2 1 5 Joint 1 6 Clamp cooling water hose 1 1 Ì To oil tank 7 Joint 1 Í From cooling water inlet Reverse the removal steps for installation 1 6 7 4 4 5 3 3 2 2 È È È...

Page 221: ...ERVICE POINTS 6 9 Lever 1 installation 6 9 Lever 2 installation 6 9 JET THRUST NOZZLE AND NOZZLE RING 6 10 EXPLODED DIAGRAM 6 10 REMOVAL AND INSTALLATION CHART 6 10 IMPELLER DUCT AND IMPELLER HOUSING 1 6 11 EXPLODED DIAGRAM 6 11 REMOVAL AND INSTALLATION CHART 6 11 IMPELLER DUCT AND DRIVE SHAFT 6 13 EXPLODED DIAGRAM 6 13 REMOVAL AND INSTALLATION CHART 6 13 SERVICE POINTS 6 15 Drive shaft removal 6 ...

Page 222: ...g water hose inspection 6 23 BEARING HOUSING 6 24 EXPLODED DIAGRAM 6 24 REMOVAL AND INSTALLATION CHART 6 24 SERVICE POINTS 6 27 Driven coupling removal and installation 6 27 Intermediate drive shaft removal 6 27 Bearing removal 6 28 Bearing intermediate drive shaft and grease hose inspection 6 28 Driven coupling inspection 6 28 Bearing installation 6 29 Oil seal installation 6 29 Intermediate hous...

Page 223: ...Procedure Part name Q ty Service points INTAKE GRATE RIDE PLATE AND INTAKE DUCT REMOVAL Follow the left Step for removal 1 Bolt 2 2 Bolt 2 3 Intake grate 1 4 Screw 4 5 Speed sensor 1 NOTE Route the speed sensor lead between the jet pump unit and the bilge hose 6 Bolt 4 INTAKE GRATE RIDE PLATE AND INTAKE DUCT ...

Page 224: ... INTAKE GRATE RIDE PLATE AND INTAKE DUCT EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Ride plate 1 8 Bolt 4 9 Intake duct 1 10 Felt packing 1 Reverse the removal steps for installation Not reusable ...

Page 225: ...ED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points SPEED SENSOR DISASSEMBLY Follow the left Step for disassembly 1 Holder 1 2 Paddle wheel set 1 3 Speed sensor 1 Reverse the disassembly steps for assembly FWD 2 3 1 Not reusable ...

Page 226: ...1 NOTE Route the speed sensor lead between the jet pump unit and the bilge hose 4 Nut washer 1 2 5 Steering cable joint 1 6 Clamp spout hose 1 1 7 Bolt 6 8 24 mm 14 N m 1 4 kgf m 10 ft Ib 6 22 mm 6 8 N m 0 68 kgf m 4 9 ft Ib 6 80 mm 7 8 N m 0 78 kgf m 5 6 ft Ib 2 2 N m 0 22 kgf m 1 6 ft Ib 6 8 N m 0 68 kgf m 4 9 ft Ib 10 95 mm 40 N m 4 0 kgf m 29 ft Ib 9 8 7 6 5 2 4 11 13 4 3 10 1 12 15 14 4 4 LT ...

Page 227: ... 2 14 Impeller housing 2 1 15 Dowel pin 2 Reverse the removal steps for installation 8 24 mm 14 N m 1 4 kgf m 10 ft Ib 6 22 mm 6 8 N m 0 68 kgf m 4 9 ft Ib 6 80 mm 7 8 N m 0 78 kgf m 5 6 ft Ib 2 2 N m 0 22 kgf m 1 6 ft Ib 6 8 N m 0 68 kgf m 4 9 ft Ib 10 95 mm 40 N m 4 0 kgf m 29 ft Ib 9 8 7 6 5 2 4 11 13 4 3 10 1 12 15 14 4 4 LT 572 LT 572 LT 572 LT 572 LT 242 A A M M LT 271 LT ...

Page 228: ...AGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points REVERSE GATE REMOVAL Follow the left Step for removal 1 Clamp spout hose 1 1 2 Bolt 2 3 Washer 2 4 Collar 2 5 Reverse gate assembly 1 6 Nut 1 7 Bolt 1 8 Washer 2 9 Roller 1 ...

Page 229: ... JET PUMP REVERSE GATE EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 10 Bolt 6 11 Bracket 1 12 Reverse gate stay 2 13 Nut 1 14 Washer 1 15 Bolt 1 16 Lever 1 1 17 Spacer 1 18 Nut 1 19 Washer 1 ...

Page 230: ...ET PUMP REVERSE GATE EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 20 Collar 1 21 Bolt 1 22 Washer 1 23 Collar 1 24 Spring 1 25 Lever 2 1 26 Washer 1 Reverse the removal steps for installation ...

Page 231: ...llar 3 Spring 4 Lever 2 5 Washer 6 Collar 7 NOTE When installing the spring hook the spring end a to lever 2 and spring end b to the reverse gate as shown in the illustration When installing the lever 2 hook the lever 2 end c to lever 1 end d as shown in the illustration 4 a c d b 2 Install Washer 1 Nut 2 3 Check Lever 1 and lever 2 movements Stick Reassemble lever 1 and lever 2 ...

Page 232: ...TION CHART Step Procedure Part name Q ty Service points JET THRUST NOZZLE AND NOZZLE RING REMOVAL Follow the left Step for removal Jet pump unit Refer to JET PUMP UNIT Reverse gate Refer to REVERSE GATE 1 Bolt 2 2 Collar 2 3 Jet thrust nozzle 1 4 Bolt 2 5 Collar 2 6 Nozzle ring 1 Reverse the removal steps for installation ...

Page 233: ...ure Part name Q ty Service points IMPELLER DUCT AND IMPELLER HOUSING 1 REMOVAL Follow the left Step for removal Nozzle ring Refer to JET THRUST NOZZLE AND NOZZLE RING 1 Bolt 4 2 Nozzle 1 NOTE Clean the contacting surfaces before apply ing the Yamabond 4 Yamaha bond num ber 4 3 Pin 2 4 Impeller duct assembly 1 5 Impeller housing 1 1 6 Pin 2 7 Bolt 4 ...

Page 234: ...P IMPELLER DUCT AND IMPELLER HOUSING 1 EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Water inlet cover 1 9 Packing 1 10 Water inlet strainer 1 11 Packing 1 Reverse the removal steps for installation ...

Page 235: ...GRAM REMOVAL AND INSTALLATION CHART 1 EPNOC grease AP 0 Step Procedure Part name Q ty Service points IMPELLER DUCT AND DRIVE SHAFT DISASSEMBLY Follow the left Step for disassembly 1 Impeller 1 Left hand threads 2 Spacer 1 3 Bolt washer 3 3 4 Cap 1 5 O ring 1 6 Nut 1 7 Washer 1 Not reusable ...

Page 236: ...PNOC grease AP 0 Step Procedure Part name Q ty Service points 8 Drive shaft 1 9 Rear bearing 1 10 Spacer 1 11 Front bearing 1 12 Oil seal 1 13 Oil seal 1 14 Impeller duct 1 Reverse the disassembly steps for assembly Not reusable Not reusable Not reusable Not reusable ...

Page 237: ... Impeller NOTE The impeller has left hand threads Turn the impeller clockwise to loosen it Drive shaft holder YB 06151 Drive shaft holder 5 90890 06519 2 Remove Nut 1 Drive shaft holder YB 06151 Drive shaft holder 5 90890 06519 3 Remove Drive shaft 1 NOTE Remove the drive shaft with a press ...

Page 238: ...apters YB 06096 Stopper guide plate 90890 06501 Bearing puller assembly 90890 06535 Stopper guide stand 90890 06538 È É 5 Remove Front bearing NOTE Remove the front bearing with a press Driver handle large YB 06071 Driver rod L3 90890 06652 Bearing housing needle bearing remover YB 06112 Needle bearing attachment 90890 06614 ...

Page 239: ...196 Needle bearing attachment 90890 06614 Impeller inspection Refer to JET PUMP UNIT in Chapter 3 Drive shaft inspection 1 Inspect Drive shaft Damage wear Replace Drive shaft installation 1 Install Oil seals Driver handle large YB 06071 Driver rod LS 90890 06606 Outer race installer forward gear YB 06085 Ball bearing attachment 90890 06631 Distance a 14 2 0 2 mm 0 56 0 01 in Distance b 4 7 0 2 mm ...

Page 240: ... which has an inner diameter of 25 mm 0 98 in Distance a 23 0 1 mm 0 91 0 004 in a 3 Install Drive shaft with front bearing Spacer Impeller duct NOTE Press the spacer and the front bearing with a pipe that is more than 33 mm 1 30 in long and which has an outer diameter less than 50 mm 1 97 in and an inner diameter more than 26 mm 1 02 in 4 Add EPNOC grease AP 0 between the drive shaft and spacer Q...

Page 241: ...achment is not available use a washer or pipe with an outer diameter of 46 mm 1 81 in and an inner diameter of 20 mm 0 79 in Bearing inner outer race attachment YB 34474 6 Add EPNOC grease AP 0 into the cap Quantity 20 g 0 7 oz 7 Install Nut Impeller T R Drive shaft nut 69 N m 6 9 kgf m 50 ft lb Impeller 75 N m 7 5 kgf m 54 ft lb LOCTITE 572 Drive shaft holder YB 06151 Drive shaft holder 5 90890 0...

Page 242: ...NSOM PLATE AND HOSES REMOVAL Follow the left Step for removal Exhaust system Refer to EXHAUST SYSTEM in Chapter 8 Jet pump unit assembly Refer to JET PUMP UNIT 1 Hose clamp 2 2 Cooling water hose 1 Cooling water outlet exhaust pipe 3 Bilge hose 1 1 NOTE Route the bilge hose 1 under the drive shaft tube 4 Hose clamp 1 5 Cooling water hose 1 Cooling water inlet ...

Page 243: ...ep Procedure Part name Q ty Service points 6 Hose clamp 2 7 Cooling water hose 1 Cooling water outlet thermostat 8 Bilge hose 2 1 9 Hose clamp 1 10 Bilge hose 3 1 11 Band 1 12 Electric bilge pump assembly 1 13 Hose clamp 1 14 Bilge hose 4 1 15 Bilge strainer 1 ...

Page 244: ...6 22 E JET PUMP TRANSOM PLATE AND HOSES EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 16 Nut washer 4 4 17 Transom plate 1 18 Bilge hose 5 1 Reverse the removal steps for installation ...

Page 245: ... JET PUMP UNIT in Chapter 3 Electric bilge pump inspection Refer to BILGE PUMP in Chapter 3 Refer to ELECTRIC BILGE PUMP in Chapter 7 Bilge hose inspection 1 Inspect Bilge hoses Cracks damage wear Replace Cooling water hose inspection 1 Inspect Cooling water hoses Cracks damage wear Replace ...

Page 246: ...Procedure Part name Q ty Service points BEARING HOUSING REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT in Chapter 5 1 Rubber coupling 1 2 Bolt 3 3 Intermediate housing assembly 1 4 Pin 2 5 Shim NOTE Install the shims in their original locations Reverse the removal steps for installation ...

Page 247: ...REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points BEARING HOUSING DISASSEMBLY Follow the left Step for disassembly 1 Grease hose 1 2 Nipple 1 3 Driven coupling 1 4 Washer 1 5 Intermediate drive shaft 1 6 O ring 2 Not reusable ...

Page 248: ...RAM Step Procedure Part name Q ty Service points 7 Oil seal 1 8 Oil seal 1 9 Oil seal 1 10 Circlip 1 11 Bearing 1 12 Circlip 1 Reverse the disassembly steps for assembly Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable ...

Page 249: ...0 06551 Shaft holder YB 06552 Crankshaft holder 20 90890 06552 Intermediate drive shaft removal 1 Remove Intermediate drive shaft NOTE Support the intermediate housing with steel blocks 1 and press the driven coupling shaft with a rod that is more than 210 mm 8 27 in long and which has an outer diameter less than 16 mm 0 63 in Removal steps Temporarily install the driven coupling to the intermedia...

Page 250: ... 06071 Driver rod LS 90890 06606 Drive shaft taper roller bearing cup installer YB 06156 Bearing outer race attachment 90890 06626 Bearing intermediate drive shaft and grease hose inspection 1 Inspect Bearing Rotate the inner race by hand Damage rough movement Replace Intermediate drive shaft Damage pitting Replace Grease hose Cracks wear Replace Driven coupling inspection 1 Inspect Driven couplin...

Page 251: ...0 06606 Driveshaft taper roller bearing cup installer YB 06156 Bearing outer race attachment 90890 06626 Oil seal installation 1 Install Oil seal NOTE Before installing the oil seal lubricate the clip glove with water resistant grease Driver handle large YB 06071 Driver rod LS 90890 06606 Driveshaft taper roller bearing cup installer YB 06156 Bearing outer race attachment 90890 06626 Distance a 7 ...

Page 252: ...lation 1 Install Intermediate housing Shim NOTE Install the shim s to the original position if the intermediate housing is not replaced Distance a 46 0 0 5 mm 1 81 0 02 in Distance a 10 5 0 2 mm 0 41 0 01 in Distance b 0 8 0 2 mm 0 03 0 01 in Installation steps Install the intermediate housing Measure the clearance a at each bolt hole Install the suitable shim from the table below Clearance a Shim...

Page 253: ... VOLTAGE 7 15 BATTERY 7 17 FUSE 7 17 SPARK PLUGS 7 17 IGNITION COIL 7 18 ENGINE STOP SWITCH 7 18 ENGINE TEMPERATURE SENSOR 7 19 SENSOR ASSEMBLY 7 19 THERMOSWITCH ENGINE 7 20 THERMOSWITCH EXHAUST 7 20 MAIN AND FUEL PUMP RELAY 7 21 THROTTLE POSITION SENSOR 7 22 CAM POSITION SENSOR 7 23 NOISE FILTER 7 24 SLANT DETECTION SWITCH 7 24 FUEL CONTROL SYSTEM 7 25 WIRING DIAGRAM 7 25 FUEL PUMP 7 27 FUEL SEND...

Page 254: ...Brush holder inspection 7 36 Starter motor front cover inspection 7 36 CHARGING SYSTEM 7 37 WIRING DIAGRAM 7 37 FUSE 7 38 BATTERY 7 38 LIGHTING COIL 7 38 RECTIFIER REGULATOR 7 38 ELECTRIC BILGE PUMP 7 39 WIRING DIAGRAM 7 39 ELECTRIC BILGE PUMP 7 40 FUSE 7 40 BATTERY 7 40 MAIN AND FUEL PUMP RELAY 7 40 REMOTE CONTROL UNIT 7 40 OFF THROTTLE STEERING SYSTEM 7 41 WIRING DIAGRAM 7 41 STEERING SWITCH 7 4...

Page 255: ...n 7 47 Speedometer display 7 48 Tachometer display 7 49 Hour meter display 7 49 Voltage meter display 7 49 Low oil pressure warning indicator 7 49 Fuel level meter display and fuel warning indicator 7 49 Overheat warning indicator 7 50 Check the engine warning indicator 7 50 REMOTE CONTROL SYSTEM 7 51 WIRING DIAGRAM 7 51 REMOTE CONTROL SYSTEM 7 52 Yamaha Security System indicator 7 52 Low rpm mode...

Page 256: ... Electrical box 6 Battery 7 Speed sensor 8 Electric bilge pump 9 Cam position sensor 0 Fuel injectors A Thermoswitch exhaust B Oil pressure switch C Sensor assembly D Bypass valve motor E Throttle position sensor F Lighting coil and pickup coil G Engine stop switch engine shut off switch and start switch H Steering switch I Buzzer J Fuel pump K Fuel sender L Multifunction meter M Remote control un...

Page 257: ...ther hose 1 1 4 Band 2 5 Battery 1 6 Damper 1 7 Bolt 2 8 Bolt 2 A A A A 22 11 14 13 12 1516 21 20 19 22 22 22 17 18 22 10 1 9 7 8 6 5 2 3 4 VENT LT 572 LT LT 271 LT LT 572 LT A A LT 572 LT E 7 6 N m 0 76 kgf m 5 5 ft Ib 6 12 mm 7 6 N m 0 76 kgf m 5 5 ft Ib 6 16 mm 7 6 N m 0 76 kgf m 5 5 ft Ib 6 10 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 30 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 16 mm 8 28 mm 17 N m 1 7 kgf m...

Page 258: ... 18 Cover 1 A A A A 22 11 14 13 12 1516 21 20 19 22 22 22 17 18 22 10 1 9 7 8 6 5 2 3 4 VENT LT 572 LT LT 271 LT LT 572 LT A A LT 572 LT E 7 6 N m 0 76 kgf m 5 5 ft Ib 6 12 mm 7 6 N m 0 76 kgf m 5 5 ft Ib 6 16 mm 7 6 N m 0 76 kgf m 5 5 ft Ib 6 10 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 30 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 16 mm 8 28 mm 17 N m 1 7 kgf m 12 ft Ib 4 9 N m 0 49 kgf m 3 5 ft Ib 5 20 mm 22 22...

Page 259: ...ation A A A A 22 11 14 13 12 1516 21 20 19 22 22 22 17 18 22 10 1 9 7 8 6 5 2 3 4 VENT LT 572 LT LT 271 LT LT 572 LT A A LT 572 LT E 7 6 N m 0 76 kgf m 5 5 ft Ib 6 12 mm 7 6 N m 0 76 kgf m 5 5 ft Ib 6 16 mm 7 6 N m 0 76 kgf m 5 5 ft Ib 6 10 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 30 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 16 mm 8 28 mm 17 N m 1 7 kgf m 12 ft Ib 4 9 N m 0 49 kgf m 3 5 ft Ib 5 20 mm 22 22 4 Not...

Page 260: ...8 2 Cover 1 3 Gasket 1 4 Clamp 3 5 Wiring harness 1 6 Tapping screw 1 7 Fuse holder stay 1 8 Wiring harness 1 9 Fuse 6 2 3 1 19 20 18 17 16 14 11 15 13 12 6 7 8 5 4 22 21 6 20 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 6 30 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 6 16 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 3 9 N m 0 39 kgf m 2 8 ft Ib 6 30 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 6 16 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 5 30 mm 4 4 9 1...

Page 261: ...int connector 2 17 Tapping screw 2 18 Slant detection switch 1 19 Tapping screw 1 20 Main and fuel pump relay 1 2 3 1 19 20 18 17 16 14 11 15 13 12 6 7 8 5 4 22 21 6 20 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 6 30 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 6 16 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 3 9 N m 0 39 kgf m 2 8 ft Ib 6 30 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 6 16 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 5 30 mm 4 4 9 10 ...

Page 262: ...r 1 Reverse the disassembly steps for assembly 2 3 1 19 20 18 17 16 14 11 15 13 12 6 7 8 5 4 22 21 6 20 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 6 30 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 6 16 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 3 9 N m 0 39 kgf m 2 8 ft Ib 6 30 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 6 16 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 5 30 mm 4 4 9 10 ...

Page 263: ... 4 5 6 7 8 1 Ê É È 1 Starter relay 2 Fuse holder 3 ECM 4 Joint connector 5 Joint connector 6 Main and fuel pump relay 7 Rectifier regulator 8 Slant detection switch È To ignition coil É To battery positive terminal Ê To starter motor ...

Page 264: ...wered by dry batter ies check the battery s voltage periodi cally and replace the batteries if necessary Digital tester NOTE Throughout this chapter the part numbers of the specified digital testers have been omitted Refer to the following part numbers NOTE indicates a continuity of electricity i e a closed circuit at the respective switch position Digital multimeter YU 34899 A Digital circuit tes...

Page 265: ...be obtained by connecting both of its terminals Correct value Displayed measurement Internal resistance Peak voltage measurement NOTE When checking the condition of the ignition system it is vital to know the peak voltage Cranking speed is dependant on many fac tors e g fouled or weak spark plugs a weak battery If one of these is defective the peak voltage will be lower than specifica tion If the ...

Page 266: ...ircuit 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 È Voltage measurement É Peak voltage measurement Peak volt meter adapter YU 39991 Peak voltage adapter B 90890 03172 È É Test harness NOTE If the lighting coil and pickup coil s are mea sured unloaded disco...

Page 267: ... 4 W 5 P 6 P W 9 O 12 W R 13 W B 21 L R 22 B R 28 L B 30 R Y 33 P G 34 P 35 B Y 42 B L 43 B Y 44 B W 1 2 3 4 5 6 7 8 B B B B O Br B Y O B O P G R Y B B B R Y R Y B B G B O R Y R Y R K 1 P O G B G Pu B G Y G R Pu G Pu Y Pu B P O R Y Pu Y G Y G R B Y P G Pu R Pu R Pu G P G R Y G G B B O 1 ECM 2 Main and fuel pump relay 3 Fuse 20A 4 Battery 5 Engine shut off switch 6 Engine stop switch 7 Start switch...

Page 268: ... 3 2 B H H D I I F G E E 8 5 6 7 9 0 4 R P P O R R R R R P P O O B O L B 3 G O 4 W 5 P 6 P W 9 O 12 W R 13 W B 21 L R 22 B R 28 L B 30 R Y 33 P G 34 P 35 B Y 42 B L 43 B Y 44 B W 1 2 3 4 5 6 7 8 B B B B O Br B Y O B O P G R Y B B B R Y R Y B B G B O R Y R Y R K 1 P O G B G Pu B G Y G R Pu G Pu Y Pu B P O R Y Pu Y G Y G R B Y P G Pu R Pu R Pu G P G R Y G G B B O B Black Br Brown G Green L Blue O Or...

Page 269: ... cap When performing the spark gap check keep flammable gas or liquids away since this test can produce sparks 1 Check Ignition spark Weak Check the ECM output peak voltage Check the ignition coil for resistance È For USA and Canada É For worldwide Checking steps Connect the spark plug cap to the spark gap tester Spark gap tester YM 34487 Ignition tester 90890 06754 Crank the engine and observe th...

Page 270: ...n Measure the pickup coil output peak voltage NOTE When measuring the ECM output peak volt age while cranking the engine disconnect the ignition coil couplers for all cylinders except for the cylinder being measured To crank the engine connect the engine shut off cord lanyard to the engine shut off switch and then press the start switch Test harness 2 pins New YB 06867 Current YB 06767 Test harnes...

Page 271: ... pins New YB 06877 Current YB 06777 Test harness HM090 3 3 pins New 90890 06877 Current 90890 06777 Pickup coil output peak voltage White W Black B Red R Black B r min Unloaded Loaded Cranking 2 000 3 500 V 5 2 4 7 26 1 41 3 3 Measure Lighting coil output peak voltage Below specification Replace the light ing coil Test harness 3 pins New YB 06870 Current YB 06770 Test harness SMT250 3 3 pins New 9...

Page 272: ...cation Replace the recti fier regulator NOTE Do not use the peak voltage adapter to mea sure the output voltage Disconnect the output lead of the tester har ness Test harness 6 pins YB 06848 Test harness FSW 6A 6 pins 90890 06848 Rectifier regulator output voltage Red R Black B r min Unloaded 3 500 V 15 0 BATTERY Refer to ELECTRICAL in Chapter 3 FUSE Refer to STARTING SYSTEM SPARK PLUGS Refer to P...

Page 273: ...nal resistance Refer to Low resistance measurement Primary coil resistance 1 19 1 61 Ω at 20 C 68 F 2 Measure Secondary coil resistance Out of specification Replace Secondary coil resistance 8 5 11 5 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 Clip Position Lead color White Black Installed Free Pu...

Page 274: ...a container filled with water Slowly heat the water Measure the resistance when the speci fied temperature is reached SENSOR ASSEMBLY 1 Check Intake air temperature sensor Out of specification Replace the sen sor assembly Checking steps Measure the ambient temperature Connect a computer to the watercraft and use the Yamaha Diagnostic System to display the intake air temperature If the ambient temp...

Page 275: ...ermoswitch engine continuity temperature a 84 90 C 183 194 F b 70 84 C 158 183 F Checking steps Suspend the thermoswitch engine in a container filled with water Place a thermometer in the water Slowly heat the water Measure the continuity when the speci fied temperature is reached Thermoswitch exhaust continuity temperature a 94 100 C 201 212 F b 80 94 C 176 201 F Checking steps Suspend the thermo...

Page 276: ...n and fuel pump relay terminals Check that there is no continuity between the main and fuel pump relay terminals after disconnecting terminals 2 3 or 1 Connect the tester leads between the main and fuel pump relay terminals 7 and 8 Connect the terminals 4 to the negative battery terminal Connect the terminal 6 to the positive battery terminal Check that there is continuity between the main and fue...

Page 277: ...3 pins 90890 06793 Test connector YW 06862 Test connector FMY 8 90890 06862 Throttle position sensor output voltage Pink P Black orange B O 0 756 0 016 V Measurement steps Connect the test harness 3 pins to the throttle position sensor 1 To start the ECM normally use the Yamaha Diagnostic System Use the test connector 2 to start the ECM normally only if the Yamaha Diagnostic System is not availabl...

Page 278: ... Yamaha Diagnostic Sys tem electric power is supplied to the cam position sensor Test harness 3 pins New YB 06877 Current YB 06777 Test harness HM090 3 3 pins New 90890 06877 Current 90890 06777 Cam position sensor output voltage Green orange G O Black orange B O Position Voltage V A More than 4 8 B Less than 0 8 C More than 4 8 Measurement steps Remove the cam position sensor Connect the test har...

Page 279: ...t of specification Replace Noise filter continuity Black B Red R No continuity B G G R B R SLANT DETECTION SWITCH 1 Check Slant detection switch continuity Out of specification Replace Position Lead color Blue black L B Black orange B O Normal operation È OverturnedÉ UP UP È É ...

Page 280: ... 1 2 3 4 5 6 7 8 Pu G R Y Pu Y R Y Pu B R Y Pu R R Y R Y R Y B L B P B A B O L B Y L B B O B O P P B P B O B P B O P B P B 8 9 P P O P W P W P W E 15 18 L F B Y O B O P G P O G B G Pu B G Y G R Pu G Pu Y Pu B P O R Y Pu Y G Y G R B Y P G Pu R Pu R Pu G P G R Y G G B B O B B B O B O B O 5 7 R Y R Y R Y R 1 1 ECM 2 Main and fuel pump relay 3 Fuse 20A 4 Battery 5 Fuel pump 6 Multifunction meter 7 Fue...

Page 281: ...u R 1 2 3 4 5 6 7 8 Pu G R Y Pu Y R Y Pu B R Y Pu R R Y R Y R Y B L B P B A B O L B Y L B B O B O P P B P B O B P B O P B P B 8 9 P P O P W P W P W E 15 18 L F B Y O B O P G P O G B G Pu B G Y G R Pu G Pu Y Pu B P O R Y Pu Y G Y G R B Y P G Pu R Pu R Pu G P G R Y G G B B O B B B O B O B O 5 7 R Y R Y R Y R 1 B Black Br Brown G Green L Blue O Orange P Pink R Red W White Y Yellow B O Black orange B ...

Page 282: ...mp does not sound Measure the fuel pressure Refer to FUEL INJECTION SYSTEM in Chapter 4 NOTE After the engine is stopped the fuel pump will operate for 10 seconds FUEL SENDER 1 Measure Fuel sender resistance Out of specification Replace Float position Resistance Ω A 133 5 136 5 B 5 7 ...

Page 283: ...4 MAIN AND FUEL PUMP RELAY Refer to IGNITION SYSTEM OIL PRESSURE SWITCH Refer to INDICATION SYSTEM THERMOSWITCH ENGINE Refer to IGNITION SYSTEM THERMOSWITCH EXHAUST Refer to IGNITION SYSTEM SLANT DETECTION SWITCH Refer to IGNITION SYSTEM REMOTE CONTROL UNIT Refer to REMOTE CONTROL SYS TEM ...

Page 284: ...r R Br R B B R 4 9 3 2 1 8 7 6 R P P O R R R R R R R 1 2 3 4 5 6 7 8 5 Br B B B B B B L L Y L L B B A B B B B R Y B R Y R 123456789 0ABCDEFGH 1 ECM 2 Main and fuel pump relay 3 Fuse 20A 4 Starter relay 5 Starter motor 6 Battery 7 Start switch 8 Engine shut off switch 9 Fuse 3A 0 Remote control unit A Fuel pump B Black Br Brown L Blue R Red Y Yellow L R Blue red R Y Red yellow ...

Page 285: ... broken Broken Replace NOTE 20A fuse is for main relay engine shut off switch and rectifier regulator 3A fuse is for multifunction meter electric bilge pump and remote control unit Fuse rating 3A 20A START SWITCH 1 Check Continuity Out of specification Replace Start continuity natural color coupler Clip Position Leads Red Brown Installed Free Push Removed Free Push ...

Page 286: ...leads between the starter relay terminals as shown Connect the brown lead terminal to the positive battery terminal Connect the black lead terminal to the negative battery terminal Check that there is continuity between the starter relay terminals Check that there is no continuity after the brown or black lead is removed Br B REMOTE CONTROL UNIT Refer to REMOTE CONTROL SYS TEM ...

Page 287: ...rocedure Part name Q ty Service points STARTER MOTOR DISASSEMBLY Follow the left Step for disassembly Starter motor Refer to GENERATOR AND STARTER MOTOR in Chapter 5 1 O ring 1 2 Bolt 2 3 Starter motor front cover 1 4 O ring 1 5 Oil seal retainer 1 6 Washer 1 7 Shim t 0 2 mm 0 5 mm Not reusable Not reusable ...

Page 288: ...rocedure Part name Q ty Service points 8 Starter motor rear cover 1 9 O ring 1 10 Shim t 0 2 mm 0 8 mm 11 Armature assembly 1 12 Nut spring washer washer 1 1 4 13 O ring 1 14 Brush holder 1 15 Brush spring 4 16 Bolt 1 17 Brush assembly 1 Not reusable Not reusable ...

Page 289: ...7 34 E ELEC STARTER MOTOR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 18 Spacer 1 19 Holder 1 20 Starter motor yoke 1 Reverse the disassembly steps for assembly ...

Page 290: ...ean with 600 grit sandpaper 3 Measure Commutator diameter Below specification Replace Minimum commutator diameter 27 0 mm 1 06 in 4 Check Commutator undercut Contaminants Clean NOTE Remove all mica and metal particles with com pressed air 5 Measure Commutator undercut Below specification Replace Minimum commutator undercut 0 2 mm 0 01 in ...

Page 291: ...t Armature shaft No continuity Brush holder inspection 1 Measure Brush length a Below specification Replace Minimum brush length 6 5 mm 0 26 in 2 Check Brush holder continuity Out of specification Replace Brush holder continuity Brush holder Base No continuity Starter motor front cover inspection 1 Inspect Starter motor front cover oil seal Damage wear Replace the starter motor front cover ...

Page 292: ...7 37 E ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM B R R 1 2 3 R R R G G G G G G B G B G G G G G 4 1 Rectifier regulator 2 Fuse 20A 3 Battery 4 Lighting coil B Black G Green R Red ...

Page 293: ...7 38 E ELEC CHARGING SYSTEM FUSE Refer to STARTING SYSTEM BATTERY Refer to ELECTRICAL in Chapter 3 LIGHTING COIL Refer to IGNITION SYSTEM RECTIFIER REGULATOR Refer to IGNITION SYSTEM ...

Page 294: ... R Y Br B B B B B R R 3 7 2 4 5 R P P O R B R R R 1 2 3 4 5 6 7 8 R Y R Y B Br R Y R Y R R Y R Y R R Y 6 15 B B B B L R R Y B 1 1 ECM 2 Main and fuel pump relay 3 Fuse 3A 4 Battery 5 Electric bilge pump 6 Remote control unit 7 Fuse 20A B Black Br Brown R Red Y Yellow L R Blue red R Y Red yellow ...

Page 295: ...ed with water Connect the brown lead terminal to the positive battery terminal Connect the black lead terminal to the negative battery terminal Check the water flows from the electric bilge pump hose B Br FUSE Refer to STARTING SYSTEM BATTERY Refer to ELECTRICAL in Chapter 3 MAIN AND FUEL PUMP RELAY Refer to IGNITION SYSTEM REMOTE CONTROL UNIT Refer to REMOTE CONTROL SYS TEM ...

Page 296: ... R Y R Y R Y W L R Y B B O B O B O B O B O R Y R Y R Y R Y R Y R Y G Y R Y G G R G B R Y R Y G R G B R Y R Y R Y R Y G R G W L R Y P 18 20 29 30 34 O W R W B G B G Y 9 12 13 16 17 2 3 4 5 P P O R R R W O O R Y B 1 1 ECM 2 Steering switch 3 Pickup coil 4 Throttle position sensor 5 Bypass valve motor B Black G Green O Orange P Pink W White B O Black orange G B Green black G R Green red G Y Green yel...

Page 297: ...e Engine monitor of the Yamaha Diagnostic System to check that the steering switch switches on and off when the handlebar is turned to the right and to the left Does not operate Replace ECM Refer to IGNITION SYSTEM PICKUP COIL Refer to IGNITION SYSTEM THROTTLE POSITION SENSOR Refer to IGNITION SYSTEM BYPASS VALVE MOTOR Refer to FUEL INJECTION SYSTEM in Chapter 4 ...

Page 298: ...B O B O B O R W B Y R Y L R B L R P B B B B Y P A B C B R W 0 B L L R B Y R Y Y B Y R W Y B R Y B B B B R 1 21 30 5 35 15 6 14 P W P W P W D B O R Y W B B O G 4 1 L B L Y Y L 7 15 18 16 6 L R R Y L R L R L Y L B L R L B Gy B O O R Y R Y R Gy 1 ECM 2 Main and fuel pump relay 3 Fuse 20A 4 Remote control unit 5 Battery 6 Tacho pulse 7 Thermoswitch exhaust 8 Thermoswitch engine 9 Engine temperature se...

Page 299: ...O B O B O R W B Y R Y L R B L R P B B B B Y P A B C B R W 0 B L L R B Y R Y Y B Y R W Y B R Y B B B B R 1 21 30 5 35 15 6 14 P W P W P W D B O R Y W B B O G 4 1 L B L Y Y L 7 15 18 16 6 L R R Y L R L R L Y L B L R L B Gy B O O R Y R Y R Gy B Black Br Brown G Green Gy Gray L Blue O Orange P Pink R Red W White Y Yellow B L Black blue B O Black orange B Y Black yellow L B Blue black L R Blue red L Y ...

Page 300: ...ERATURE SENSOR Refer to IGNITION SYSTEM THERMOSWITCH ENGINE Refer to IGNITION SYSTEM THERMOSWITCH EXHAUST Refer to IGNITION SYSTEM REMOTE CONTROL UNIT Refer to REMOTE CONTROL SYS TEM BUZZER 1 Check Buzzer Buzzer does not sound Replace Checking steps Connect the battery 12 V to the buzzer coupler as shown Battery positive terminal Red R terminal 1 Battery negative terminal Black B terminal 2 ...

Page 301: ...e set 90890 06756 Oil pressure switch continuity pressure 128 kPa 1 28 kgf cm2 18 2 psi 166 kPa 1 66 kgf cm2 23 6 psi MULTIFUNCTION METER Multifunction meter 1 Check Multifunction meter Cracked meter housing Replace the multifunction meter Meter is fogged shows signs of water intrusion Replace the multifunction meter MULTIFUNCTION METER REMOVAL Refer to STEERING CONSOLE COVER in Chapter 8 ...

Page 302: ...function meter B L B L R B Y B Y R W P B R W Y Y R R W W B B B P L R R B R 1 2 3 4 5 Gy L B L R L Y L B B L 1 Remote control unit 2 Buzzer 3 Speed sensor 4 ECM 5 Fuel sender B Black Gy Gray P Pink R Red W White Y Yellow B G Black green B L Black blue B Y Black yellow L B Blue black L R Blue red R W Red white ...

Page 303: ...ensor output voltage dependant on the paddle wheel position Less than 400 mV More than 11 6 V Output pulse 2 pulses one full turn Measurement steps Apply DC 12 voltage to the natural color three pin connector between the red yel low and black yellow leads Rotate the paddle wheel by hand and measure the voltage between the black yellow and yellow leads NOTE As the paddle wheel is rotated a square w...

Page 304: ...he Engine monitor of the Yamaha Diagnostic System Replace the multifunction meter Low oil pressure warning indicator 1 Check Low oil pressure warning indicator No operating Check the oil pressure switch using the Engine monitor of the Yamaha Diagnostic System Replace the multifunction meter Fuel level meter display and fuel warning indicator 1 Check Fuel level meter display and fuel warn ing indic...

Page 305: ...inal of the disconnected connector Check that the multifunction meter over heat warning indicator comes on and the buzzer sounds Check the engine warning indicator 1 Check Check the engine warning indicator Does not operate Replace the multi function meter Checking steps Start the engine Disconnect the coupler of a sensor e g engine temperature sensor that normally activates the check engine warni...

Page 306: ...Y R Y 9 8 W B W W W A 14 L 15 W B 21 L R 30 R Y 31 Y 37 Pu G 38 Pu Y 39 Pu B 40 Pu R W L R L B Gy L R L B L Y L R L R P O G B G Pu B G Y G R Pu G Pu Y Pu B P O R Y Pu Y G Y G R B Y P G Pu R Pu R Pu G P G R Y G G B B O B Gy B 1 ECM 2 Main and fuel pump relay 3 Fuse 20A 4 Starter relay 5 Starter motor 6 Battery 7 Fuse 3A 8 Remote control unit 9 Multifunction meter 0 Fuel injector A Antenna B Buzzer ...

Page 307: ...ication Replace the remote control unit Remote control unit output voltage Blue yellow L Y ground 11 13 V Measurement steps Disconnect the remote control unit 1 coupler from the multifunction meter Measure the remote control unit output voltage while pushing the unlock button of the remote control transmitter 1 1 L Y 1 Low rpm mode indicator 1 Check Low rpm mode indicator Does not come on Replace ...

Page 308: ...ndicated on the multifunction meter 1 Checking the remote control transmitter 1 Check Remote control transmitter Does not operate Replace the remote control transmitter Checking steps CAUTION If the buttons on the remote control transmitter are pushed but the transmit ter does not operate the battery may be low Press the lock button 1 of the remote control transmitter The beeper sounds once Check ...

Page 309: ... Check that the beeper sounds three times and the L MODE indicator light comes on NOTE If the start switch or the remote control transmitter is not operated for more than 25 seconds the multifunction meter dis play and the L MODE indicator light will go off To change the modes again press the lock button for a short time and then start the procedures from the lock mode While the engine is running ...

Page 310: ...is time the system enters the regis tration mode to register the first code All existing ID codes will be deleted from the EEPROM The SECURITY indicator light flashes when the registration of the ID code has been completed If the registration could not be completed the SECURITY indi cator light comes on Re transmit the ID code After confirming that the registration of the ID code has been complete...

Page 311: ... trapped between the upper case and lower case of the remote control transmit ter during assembly 1 Remove Cover NOTE Loosen the transmitter cover screws in the sequence shown 4 1 5 3 2 6 2 Install Battery 1 NOTE Install the battery CR2016 with the positive side facing down 1 3 Install Cover NOTE Tighten the transmitter cover screws in the sequence shown T R Transmitter cover screw 0 1 N m 0 01 kg...

Page 312: ...ATION CHART 8 11 SERVICE POINTS 8 15 Steering master components inspection 8 15 REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 8 16 EXPLODED DIAGRAM 8 16 REMOVAL AND INSTALLATION CHART 8 16 SERVICE POINTS 8 19 Remote control cables inspection 8 19 Steering cable jet pump end installation 8 19 Steering cable stopper installation 8 19 QSTS cable jet pump end installation 8 20 QSTS cable stopper install...

Page 313: ...8 38 Base assembly 8 38 Shift lever 8 38 SEATS AND HAND GRIP 8 39 EXPLODED DIAGRAM 8 39 REMOVAL AND INSTALLATION CHART 8 39 SERVICE POINTS 8 42 Seat lock inspection 8 42 EXHAUST SYSTEM 8 43 EXPLODED DIAGRAM 8 43 REMOVAL AND INSTALLATION CHART 8 43 SERVICE POINTS 8 46 Exhaust system inspection 8 46 Exhaust component parts sub assembly 8 46 Exhaust system installation 8 47 DECK AND HULL 8 48 EXPLODE...

Page 314: ... Follow the left Step for removal 1 Screw 4 2 Handlebar cover 1 3 Pad 1 4 Bolt 2 NOTE Position the corrugated tube for the throttle cable as shown in the illustration so that the tube attaches to the end of the outer throttle cable 5 Handlebar cover stay 1 6 Throttle cable 1 7 Bolt 4 8 Upper handlebar holder 2 Reverse the removal steps for installation ...

Page 315: ...nts HANDLEBAR REMOVAL Follow the left Step for removal QSTS cable to jet thrust nozzle Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Nut washer 2 2 2 QSTS converter 1 3 QSTS cable 2 1 with white tape a 4 QSTS cable 1 1 5 Handlebar switch coupler 2 6 Buzzer coupler 1 7 Screw 4 8 Handle boss cover 1 9 Band 2 ...

Page 316: ...Handlebar assembly 1 NOTE Pass the QSTS cable and handlebar switch lead through the handle boss cover and then install the handlebar assembly Install the sponges of the QSTS cables as shown and make sure that the grommet is installed to the deck securely 13 Grommet 2 Reverse the removal steps for installation Not reusable ...

Page 317: ...Step Procedure Part name Q ty Service points HANDLEBAR DISASSEMBLY Follow the left Step for disassembly 1 Bolt 2 2 Grip end 2 3 Spacer 1 4 Screw spring washer washer 1 1 1 5 QSTS grip assembly 1 6 Special nut 1 7 Screw 2 NOTE Tighten the screw from the engine stop switch side ...

Page 318: ... Part name Q ty Service points 8 Handlebar switch assembly 1 9 Screw 2 10 Throttle lever assembly 1 11 Handlebar grip 1 NOTE Apply adhesive to the handlebar and the inner surface of the handlebar grip 12 Handlebar 1 Reverse the disassembly steps for assembly ...

Page 319: ...dlebar switch lead and throttle cable into the grommets tie the end of grommets with the bands 2 Install Upper handlebar holder 1 NOTE Align the punch marks a on the handlebar with the top surface of the handlebar holder The upper handlebar holder should be installed with the punch mark b facing for ward CAUTION Clearance c should be narrower than clearance d T R Handlebar holder bolt 20 N m 2 0 k...

Page 320: ... Install Handlebar cover 1 NOTE When the handlebar cover is in contact with the steering boss cover adjust the handlebar mount angle so that the clearance a and b are equal 5 Adjust Throttle cable free play Refer to CONTROL SYSTEM in Chap ter 3 6 Adjust QSTS cable Refer to CONTROL SYSTEM in Chap ter 3 ...

Page 321: ...ND INSTALLATION CHART Step Procedure Part name Q ty Service points QSTS GRIP DISASSEMBLY Follow the left Step for disassembly QSTS grip assembly Refer to HANDLEBAR 1 Screw washer 1 1 2 Cover 1 3 Ball 2 4 Spring 2 5 QSTS cable 1 1 6 QSTS cable 2 1 with white tape a ...

Page 322: ...GRIP EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Screw washer 2 2 8 Spacer 1 9 QSTS shift lock lever 1 10 Spring 1 11 Spacer 1 12 Cable housing 1 13 QSTS grip 1 Reverse the disassembly steps for assembly ...

Page 323: ...h movement Replace 2 Adjust QSTS cable length a NOTE Before adjusting the QSTS cables set the trim grip to the neutral position Adjust the QSTS cable lengths a to the specified length and be sure to take up any slack QSTS cable length 72 0 5 mm 2 83 0 02 in QSTS grip inspection 1 Inspect QSTS grip Damage wear Replace ...

Page 324: ...dure Part name Q ty Service points STEERING MASTER REMOVAL Follow the left Step for removal Steering console cover Refer to STEERING CONSOLE COVER Steering cable end Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Bolt washer 1 1 2 Steering arm 1 3 Nut washer 4 4 4 Steering master assembly 1 5 Bolt 4 ...

Page 325: ...8 12 E HULL HOOD STEERING MASTER EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Bolt 3 7 Magnet 1 8 Steering switch 1 Reverse the removal steps for installation ...

Page 326: ...ALLATION CHART Step Procedure Part name Q ty Service points STEERING MASTER DISASSEMBLY Follow the left Step for disassembly 1 Bolt washer 2 2 2 Stay 1 3 Spring 1 4 Bolt washer 6 6 5 Lower housing 1 6 Spring 1 7 Bushing 1 8 Bushing 1 9 Upper housing 1 10 Tilt lever 1 ...

Page 327: ...D DIAGRAM Step Procedure Part name Q ty Service points 11 Tilt stopper 1 12 Bolt nut holder 4 4 4 13 Retainer 2 14 Steering shaft 1 15 Steering tube 1 16 Bolt 2 17 Cap 1 18 Shaft 1 1 19 Cross piece 1 Reverse the disassembly steps for assembly ...

Page 328: ...8 15 E HULL HOOD STEERING MASTER SERVICE POINTS Steering master components inspection 1 Inspect Each component part Damage wear Replace the steering master ...

Page 329: ...RT Step Procedure Part name Q ty Service points REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL Follow the left Step for removal Service lid 1 Refer to FRONT HOOD Front seat assembly Refer to SEATS AND HAND GRIP Glove compartment Refer to STEERING CONSOLE COVER 1 Steering cable end 1 2 Nut washer 2 2 3 Bracket 1 4 Nut 2 5 Steering cable holder 1 ...

Page 330: ...OL CABLES AND SPEED SENSOR LEAD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Nut 1 7 Steering cable 1 8 Seal 1 9 Speed sensor coupler 1 10 Nut 1 11 Cap 1 12 Screw 4 13 Speed sensor 1 14 Shift cable end 1 15 Nut 2 ...

Page 331: ...ENSOR LEAD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 16 Shift cable holder 2 17 Nut 1 18 Shift cable 1 19 Seal 1 20 Nut 1 21 Pin 1 22 QSTS cable end 1 23 Nut 1 24 QSTS cable 1 25 Packing 1 Reverse the removal steps for installation ...

Page 332: ... replace it Never attempt to repair a damaged cable Remote control cables inspection 1 Inspect Steering cable QSTS cable Shift cable Frays kinks rough movement Replace Steering cable jet pump end installation 1 Install Steering cable WARNING The steering cable must be screwed in at least 8 mm 0 31 in Steering cable set length a jet pump end 14 5 mm 0 57 in Steering cable stopper installation 1 Ins...

Page 333: ... cable set length a jet pump end 13 6 mm 0 54 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 end installation 1 Install Shift cable jet pump end WARNING The shift cable must be screwed in more than 8 mm 0 31 in Shift cable set length a jet pump end 13 6 mm 0 54...

Page 334: ...ll the shift cable holders so that mark a and mark b are in the positions shown in the illustration 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 Chap ter 3 ...

Page 335: ...moval 1 Nut washer 4 4 2 Front hood assembly 1 3 Bolt 4 4 Bolt 2 5 Hinge assembly 1 6 Bolt 2 7 Hood lock assembly 1 2 7 6 4 8 9 3 5 1 11 10 6 18 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 30 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 4 8 mm 1 5 N m 0 15 kgf m 1 1 ft Ib LT 271 LT 242 LT 242 LT 242 6 18 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 10 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib ...

Page 336: ...e lid 2 1 Reverse the removal steps for installation 2 7 6 4 8 9 3 5 1 11 10 6 18 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 30 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 4 8 mm 1 5 N m 0 15 kgf m 1 1 ft Ib LT 271 LT 242 LT 242 LT 242 6 18 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 10 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib FRONT HOOD ...

Page 337: ... REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points HINGE DISASSEMBLY Follow the left Step for disassembly 1 Circlip 2 2 Pin long 1 3 Hinge 1 4 Pin short 1 5 Damper stay 1 6 Collar 2 7 Grommet 2 4 5 1 7 6 10 2 7 6 1 8 9 3 ...

Page 338: ...8 25 E HULL HOOD FRONT HOOD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Band 1 9 Damper boots 1 10 Damper 1 Reverse the disassembly steps for assembly 4 5 1 7 6 10 2 7 6 1 8 9 3 ...

Page 339: ... REMOVAL Follow the left Step for removal Handlebar assembly Refer to HANDLEBAR Service lid 1 Refer to FRONT HOOD 1 Band 1 2 Multifunction meter coupler 4 3 Bolt 4 4 Panel 1 5 Band 1 LT 242 LT 242 5 7 9 5 6 10 12 1 2 3 4 5 20 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 5 20 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 6 9 N m 0 69 kgf m 5 0 ft Ib 8 11 STEERING CONSOLE COVER ...

Page 340: ...6 Bolt 4 7 Multifunction meter 1 8 Hose packing 1 9 Grommet 1 10 Nut washer 4 4 11 Plate 2 12 Mirror 2 Reverse the removal steps for installation LT 242 LT 242 5 7 9 5 6 10 12 1 2 3 4 5 20 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 5 20 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 6 9 N m 0 69 kgf m 5 0 ft Ib 8 11 Not reusable ...

Page 341: ...ATION CHART Step Procedure Part name Q ty Service points SIDE COVER REMOVAL Follow the left Step for removal 1 Cup holder 1 2 Holder 1 3 Bolt 8 4 Washer 2 5 Side cover 2 Reverse the removal steps for installation 3 2 3 4 3 5 6 22 mm 5 4 N m 0 54 kgf m 3 9 ft Ib LT 271 3 4 5 3 1 ...

Page 342: ...BOX ASSEMBLY REMOVAL Follow the left Step for removal 1 Nut washer 2 2 2 Bolt 2 3 Nut washer 2 2 4 Bolt 2 5 Bolt 2 6 Shift handle lever 1 6 30 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 14 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 4 9 5 6 3 1 10 12 11 7 2 6 18 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 22 mm 8 30 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 20 N m 2 0 kgf m 14 ft Ib 8 LT 242 LT 271 LT 242 ...

Page 343: ... pull the tilt lever up 9 Hood lock assembly 1 10 Nut washer 2 2 11 Bolt 2 12 Glove compartment assembly 1 Reverse the removal steps for installation 6 30 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 14 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 4 9 5 6 3 1 10 12 11 7 2 6 18 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 22 mm 8 30 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 20 N m 2 0 kgf m 14 ft Ib 8 LT 242 LT 271 LT 242 ...

Page 344: ...rocedure Part name Q ty Service points GLOVE COMPARTMENT DISASSEMBLY Follow the left Step for disassembly 1 Glove compartment 1 2 Hinge assembly 2 3 Lid 1 4 Gear assembly 2 5 Screw 2 6 Latch 1 Reverse the disassembly steps for assembly 1 2 4 3 6 LT 271 6 14 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 2 4 5 ...

Page 345: ...E HULL HOOD STEERING CONSOLE COVER SERVICE POINTS Glove compartment assembly installation 1 Install Hinge assembly NOTE When installing the hinge assembly make sure that the springs are in the position shown ...

Page 346: ...for removal Fuel tank Refer to FUEL TANK AND FUEL PUMP MODULE in Chapter 4 NOTE When removing the ventilation hose and fuel tank breather hose it is not necessary to remove the fuel tank 1 Band 4 2 Ventilation hose 2 3 Fuel tank breather hose 2 VENT VENT VENT 1 2 1 2 7 8 1 6 4 5 3 5 4 6 8 7 FW D 4 2 N m 0 42 kgf m 3 0 ft Ib 4 2 N m 0 42 kgf m 3 0 ft Ib 1 3 ...

Page 347: ...name Q ty Service points 4 Clamp 2 5 Cooling water hose 2 6 Nut 2 7 Cooling water pilot outlet 2 8 Seal 2 Reverse the removal steps for installation VENT VENT VENT 1 2 1 2 7 8 1 6 4 5 3 5 4 6 8 7 FW D 4 2 N m 0 42 kgf m 3 0 ft Ib 4 2 N m 0 42 kgf m 3 0 ft Ib 1 3 ...

Page 348: ...ON CHART Step Procedure Part name Q ty Service points SHIFT LEVER REMOVAL Follow the left Step for removal Side cover Refer to STEERING CONSOLE COVER Shift cable Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Bolt 2 2 Shift lever handle 1 3 Bolt 1 4 Washer 1 5 Shift lever 1 ...

Page 349: ...8 36 E HULL HOOD SHIFT LEVER EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Screw 3 7 Base assembly 1 8 Nut washer 3 3 9 Screw 3 10 Plate 1 Reverse the removal steps for installation ...

Page 350: ...L AND INSTALLATION CHART Step Procedure Part name Q ty Service points BASE DISASSEMBLY Follow the left Step for disassembly 1 Bolt washer 2 2 2 Plate 1 3 Spring 1 4 Actuator 1 5 Roller 1 6 Shaft 1 7 Shift arm 1 Reverse the disassembly steps for assembly ...

Page 351: ...l 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 Shift lever 1 Install Shift lever NOTE To install the shift lever align the arrow mark a on the shift lever with the punch mark b on base assembly a b ...

Page 352: ...Cruiser High Output 3 Front seat assembly 1 4 Bolt 4 5 Seat lock assembly 2 6 Seat storage compartment 1 7 Nut washer 4 4 8 Bolt washer 4 4 3 1 5 4 22 21 18 19 20 17 19 7 8 10 14 6 16 15 13 12 11 9 5 4 6 25 mm 8 30 mm 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 5 2 N m 0 52 kgf m 3 8 ft Ib 26 N m 2 6 kgf m 19 ft Ib 6 4 N m 0 64 kgf m 4 6 ft Ib 6 40 mm 6 4 N m 0 64 kgf m 4 6 ft Ib 15 N m 1 5 kgf m 11 ft Ib 2...

Page 353: ...Bolt 4 16 Rear seat stay 2 17 Nut 1 3 1 5 4 22 21 18 19 20 17 19 7 8 10 14 6 16 15 13 12 11 9 5 4 6 25 mm 8 30 mm 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 5 2 N m 0 52 kgf m 3 8 ft Ib 26 N m 2 6 kgf m 19 ft Ib 6 4 N m 0 64 kgf m 4 6 ft Ib 6 40 mm 6 4 N m 0 64 kgf m 4 6 ft Ib 15 N m 1 5 kgf m 11 ft Ib 26 N m 2 6 kgf m 19 ft Ib LT 271 LT 271 6 40 mm 6 4 N m 0 64 kgf m 4 6 ft Ib 2 ...

Page 354: ...rse the removal steps for installation 3 1 5 4 22 21 18 19 20 17 19 7 8 10 14 6 16 15 13 12 11 9 5 4 6 25 mm 8 30 mm 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 5 2 N m 0 52 kgf m 3 8 ft Ib 26 N m 2 6 kgf m 19 ft Ib 6 4 N m 0 64 kgf m 4 6 ft Ib 6 40 mm 6 4 N m 0 64 kgf m 4 6 ft Ib 15 N m 1 5 kgf m 11 ft Ib 26 N m 2 6 kgf m 19 ft Ib LT 271 LT 271 6 40 mm 6 4 N m 0 64 kgf m 4 6 ft Ib 2 ...

Page 355: ...8 42 E HULL HOOD SEATS AND HAND GRIP SERVICE POINTS Seat lock inspection 1 Inspect Front seat lock Rear seat lock Damage wear Replace ...

Page 356: ...P Jet pump unit assembly Refer to JET PUMP UNIT in Chapter 6 NOTE When removing the water lock and exhaust joint it is not necessary to remove the jet pump unit 1 Band 1 2 Joint clamp 1 3 Hose clamp 1 4 Water lock 1 7 14 3 13 15 18 17 12 11 16 10 5 1 4 3 7 N m 0 37 kgf m 2 7 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 2 5 N m 0 25 kgf m 1 8 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 6 2 3 7 N m 0 37 kgf m 2 7 ft I...

Page 357: ...t clamp 1 10 Exhaust joint 1 11 Nut washer 6 6 12 Exhaust valve 1 NOTE Remove parts 12 to 18 as a set 13 Hose clamp 1 14 Rubber hose 1 7 14 3 13 15 18 17 12 11 16 10 5 1 4 3 7 N m 0 37 kgf m 2 7 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 2 5 N m 0 25 kgf m 1 8 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 6 2 3 7 N m 0 37 kgf m 2 7 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 8 9 ...

Page 358: ... 1 16 Water tank 1 17 Rubber hose 1 18 Plate 1 Reverse the removal steps for installation 7 14 3 13 15 18 17 12 11 16 10 5 1 4 3 7 N m 0 37 kgf m 2 7 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 2 5 N m 0 25 kgf m 1 8 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 6 2 3 7 N m 0 37 kgf m 2 7 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 8 9 ...

Page 359: ...aust component parts sub assembly 1 Install Rubber hose Plate NOTE Be sure to fit the projections on the rubber hose with the grooves in the plate 2 Install Rubber hoses Water tank NOTE Be sure to insert the rubber hose to the line a on the water tank Make sure that there is a surface distance of 47 mm 1 9 in b between the parting lines of the water tank and rubber hose Align the parting line c of...

Page 360: ...installation 1 Install Exhaust joint NOTE Be sure to install the projections a on the exhaust pipe and exhaust joint into the slots b in the joint a b b a 2 Install Water lock NOTE Be sure to insert the rubber hose to the line a on the water lock a ...

Page 361: ... 3 Nut 2 4 Cleat 1 5 Plate 2 6 Bolt collar 10 10 7 Sponson 2 8 Nut washer 4 4 9 Screw washer 4 4 10 Drain plug 2 16 17 18 4 5 3 7 6 15 13 14 12 13 1 9 10 11 8 2 5 4 N m 0 54 kgf m 3 9 ft Ib 15 N m 1 5 kgf m 11 ft Ib 8 45 mm 16 N m 1 6 kgf m 12 ft Ib 6 22 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 5 25 mm 2 0 N m 0 2 kgf m 1 4 ft Ib LT 271 5 5 4 N m 0 54 kgf m 3 9 ft Ib 15 N m 1 5 kgf m 11 ft Ib 13 N m 1 3 kg...

Page 362: ...al 2 16 Nut washer 3 3 17 Bolt 4 18 Protector 1 Reverse the disassembly steps for assembly 16 17 18 4 5 3 7 6 15 13 14 12 13 1 9 10 11 8 2 5 4 N m 0 54 kgf m 3 9 ft Ib 15 N m 1 5 kgf m 11 ft Ib 8 45 mm 16 N m 1 6 kgf m 12 ft Ib 6 22 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 5 25 mm 2 0 N m 0 2 kgf m 1 4 ft Ib LT 271 5 5 4 N m 0 54 kgf m 3 9 ft Ib 15 N m 1 5 kgf m 11 ft Ib 13 N m 1 3 kgf m 9 4 ft Ib LT 271 ...

Page 363: ...ATION CHART Step Procedure Part name Q ty Service points ENGINE MOUNT REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT in Chapter 5 1 Bolt 4 2 Damper 1 1 3 Damper 2 1 4 Bolt 8 5 Engine mount 4 6 Liner 2 Stern side Reverse the removal steps for installation ...

Page 364: ...YSIS INTRODUCTION 9 1 FEATURES 9 1 Functions 9 1 CONTENTS 9 1 HARDWARE REQUIREMENTS 9 2 OPERATING 9 3 CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT 9 3 Top view 9 3 TROUBLE ANALYSIS 9 4 TROUBLE ANALYSIS CHART 9 4 SELF DIAGNOSIS 9 8 ...

Page 365: ... been activated and ECM diagnostic codes that have been recorded are displayed This allows you to check the watercraft s record of malfunctions 3 Engine monitor Each sensor s status and the ECM data are displayed This enables you to find malfunctioning parts quickly 4 Stationary test With the engine off ignition fuel injection and the electric fuel pump are checked These tests can be performed qui...

Page 366: ...ay VGA 640 480 pixels SVGA 800 600 pixels or more recommended 256 or more colors Mouse Compatible with the operating systems mentioned above Communication port RS232C Dsub 9 pin port USB port Printer Compatible with the operating systems mentioned above NOTE The amount of memory and the amount of free space on the hard disk differs depending on the computer Using this software while there is not e...

Page 367: ...CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT Top view 1 3 pin communication coupler 2 Wiring harness coupler 3 Meter coupler NOTE Be careful not to pinch the communication cable between the hood and the deck or to damage it 3 1 2 ...

Page 368: ...off cord lanyard is connect to the engine shut off switch 5 Check that fuel is reaching the throttle bodies TROUBLE ANALYSIS CHART Trouble mode Check elements ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDLING ENGINE STALLS POOR ACCELERATION ENGINE WILL NOT STOP POOR PERFORMANCE LIMITED ENGINE SPEED OVERHEATING LOW OIL PRESSURE LOOSE STEERING BILGE INCREASE IRREGULAR WARNING INDICATION P...

Page 369: ...e oil 3 Oil filter 3 Oil pressure switch 7 Bearing housing 5 Drive couplings 5 Rubber coupling 5 Pilot water hose 5 Water hose 5 Water passage 5 Trouble mode Check elements ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDLING ENGINE STALLS POOR ACCELERATION ENGINE WILL NOT STOP POOR PERFORMANCE LIMITED ENGINE SPEED OVERHEATING LOW OIL PRESSURE LOOSE STEERING BILGE INCREASE IRREGULAR WARNIN...

Page 370: ...h 7 Engine shut off switch 7 Spark plugs 3 Main and fuel pump relay 7 Thermoswitch 7 Sensor assembly 7 Engine temperature sensor 7 Throttle position sensor 7 Cam position sensor 7 Trouble mode Check elements ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDLING ENGINE STALLS POOR ACCELERATION ENGINE WILL NOT STOP POOR PERFORMANCE LIMITED ENGINE SPEED OVERHEATING LOW OIL PRESSURE LOOSE STEER...

Page 371: ...ol system Remote control unit 7 HULL AND HOOD Steering master 8 Water lock 8 Exhaust hose 8 Muffler 8 Drain plugs 8 Trouble mode Check elements ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDLING ENGINE STALLS POOR ACCELERATION ENGINE WILL NOT STOP POOR PERFORMANCE LIMITED ENGINE SPEED OVERHEATING LOW OIL PRESSURE LOOSE STEERING BILGE INCREASE IRREGULAR WARNING INDICATION POOR BATTERY CHA...

Page 372: ...w ever if there are numerous error codes dis played be sure to check them with the Yamaha Diagnostic System Code Symptom 01 Normal 13 Pickup coil malfunction 15 Engine temperature sensor malfunction 18 Throttle position sensor malfunction 19 Incorrect battery voltage 23 Intake air temperature sensor malfunction 24 Cam position sensor malfunction 29 Intake air pressure sensor malfunction 47 Slant d...

Page 373: ...L Battery M Starter motor N Electric bilge pump O Fuel pump P Fuel sender Q Engine stop switch R Engine shut off switch S Start switch T Steering switch U Multifunction meter V Speed sensor W Buzzer X Remote control unit Y Antenna È To tachometer É To entry box Color code B Black Br Brown G Green L Blue O Orange P Pink R Red W White Y Yellow B G Black green B O Black orange B R Black red B W Black...

Page 374: ...B O W R P W B B P B R O P G G G G G G G R Y B Y R Y P G L B L B B P B P Y W R R Y B O R Y B O P W B Br W Br B B R Y Pu R 1 2 3 4 Pu B Pu Y G Y R Y G Pu G R Y B O R Y R Y R Y B R R R R B B FX High Output FX Cruiser High Output R Y P R Y R Y R Y R Y B B L B Y B W L B W B G B G Y G R G B R L B L R B B O B O W B Br W W W B B B R Br Br Br Br W R B B B P Br B G G G B R P W W B Y W R W B G G O O B O P P ...

Page 375: ...B R Y R Y R Y R Y B L B Y R Y R Y B R B W R Y G Y Y Br Br B B B B B O G G G B P P G O B B B Y Pu R Pu B Pu Y R Y Pu G B O B O B O B Y G G G P W B W R B O P W P R Y P P G R Y R Y O O B Y Pu R Pu B Pu Y B O B O R Y R Y R Y R Y R Y R Y R Y B Y P W B W R B O P W P R Y G O Pu G R Y Pu Y Pu B Pu R B Y O P G P L W 4 5 6 8 9 0 A B C J K 123 H F F F G F D È É B D 7 C A B D D C Pu G N O P Q R S T U V W X B ...

Page 376: ...YAMAHA MOTOR CORPORATION USA Printed in USA Feb 2004 1 CR E ...

Page 377: ...SUPPLEMENTARY SERVICE MANUAL WaveRunner F1X 28197 1H 1X LIT 18616 02 93 LIT186160293 FX FX Cruiser FX High Output FX Cruiser High Output ...

Page 378: ...gether with the following manuals FX140 SERVICE MANUAL F1B 28197 1E 11 LIT 18616 02 38 FX140 FX Cruiser SUPPLEMENTARY SERVICE MANUAL F1B 28197 1F 1X LIT 18616 02 45 FX High Output FX Cruiser High Output SERVICE MANUAL F1S 28197 1G 11 LIT 18616 02 83 A10001 0 WaveRunner FX FX Cruiser FX High Output FX Cruiser High Output SUPPLEMENTARY SERVICE MANUAL 2005 by Yamaha Motor Corporation USA 1st Edition ...

Page 379: ...evised format the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol e g Bearings Pitting scratches Replace To assist you in finding your way through this manual the section title and major heading is given at the top of every page ILLUSTRATIONS The illustrations within this service manual represent all of the designated models CRO...

Page 380: ...RT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator passenger s a bystander or a person inspecting or repairing the watercraft CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the water craft NOTE A NOTE provides key information to make procedures easier or clearer ...

Page 381: ...dicate 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 5 Dimension figures and the number of parts are provided for fasteners that require a tightening torque Example Bolt or screw size M10 D 25 mm L 6 Jobs requiring more information such as special service tools and technical dat...

Page 382: ... in an exploded diagram indi cate the grade of lubricant and the lubrication point F Apply Yamaha 4 stroke motor oil G Apply water resistant grease Yamaha grease A Yamaha marine grease H Apply ThreeBond 1104J or ThreeBond 1280B I Apply molybdenum disulfide grease Symbols J to N in an exploded diagram indi cate the type of sealant or locking agent and the application point J Apply Gasket Maker K Ap...

Page 383: ...1 GEN INFO SPECIFICATIONS 2 SPEC PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR JET PUMP UNIT 6 JET PUMP ELECTRICAL SYSTEM 7 ELEC HULL AND HOOD 8 HULL HOOD TROUBLE ANALYSIS 9 TRBL ANLS A30000 0 ...

Page 384: ...2 SPECIFICATIONS GENERAL SPECIFICATIONS 3 MAINTENANCE SPECIFICATIONS 7 ENGINE 7 JET PUMP UNIT 10 HULL AND HOOD 10 ELECTRICAL 11 ENGINE 13 JET PUMP UNIT 16 HULL AND HOOD 16 ELECTRICAL 16 TIGHTENING TORQUES 19 SPECIFIED TORQUES 19 GENERAL TORQUE 20 CABLE AND HOSE ROUTING 21 CABLE AND HOSE ROUTING For FX FX Cruiser 32 CABLE AND HOSE ROUTING For FX High Output FX Cruiser High Output 37 ...

Page 385: ...ering cable inspection and adjustment 42 Throttle cable inspection and adjustment 43 GENERAL 45 Drain plug inspection 45 Lubrication points 46 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS For FX FX Cruiser 49 ELECTRICAL COMPONENTS For FX High Output FX Cruiser High Output 50 OFF THROTTLE STEERING SYSTEM 52 WIRING DIAGRAM 52 STEERING SENSOR 53 ...

Page 386: ... Cruiser High Output 64 Air temperature display for FX Cruiser High Output 64 Speedometer average speed tripmeter display for FX Cruiser High Output 65 Water temperature display for FX Cruiser High Output 66 Trip timer display for FX Cruiser High Output 67 Fuel consumption per hour fuel consumption per kilometer mile display for FX Cruiser High Output 67 Overheat warning indicator 67 Check engine ...

Page 387: ...on 87 Rubber seal installation 87 REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 88 EXPLODED DIAGRAM 88 REMOVAL AND INSTALLATION CHART 88 SERVICE POINTS 91 Steering cable removal 91 SERVICE POINTS 92 Steering cable installation 92 FRONT HOOD 93 EXPLODED DIAGRAM 93 REMOVAL AND INSTALLATION CHART 93 SERVICE POINTS 95 Rivet Installation 95 SERVICE POINTS 98 Ornament disassembly 98 Front hood assembly 98...

Page 388: ... 115 EXPLODED DIAGRAM 115 REMOVAL AND INSTALLATION CHART 115 SERVICE POINTS 116 Reboarding step installation 116 DECK AND HULL 117 EXPLODED DIAGRAM 117 REMOVAL AND INSTALLATION CHART 117 CLEAT ASSEMBLY For FX Cruiser High Output 120 EXPLODED DIAGRAM 120 REMOVAL AND INSTALLATION CHART 120 SERVICE POINTS 121 Cleat cover installation 121 TROUBLE ANALYSIS TROUBLE ANALYSIS 122 SELF DIAGNOSIS 122 WIRING...

Page 389: ...rimary l D numbers F1X 800101 F1Y 800101 ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the engine unit Starting serial numbers 6B6 1018901 60E 1017501 JET PUMP UNIT SERIAL NUMBER The jet pump unit serial number is stamped on a label attached to the intermediate housing HULL IDENTIFICATION NUMBER H l N The H l N is stamped on a plate attached to the aft deck ...

Page 390: ...assembly and tune up Improvisations and using improper tools can damage the equipment NOTE For U S A and Canada use part numbers starting with J YB YM YS YU or YW For other countries use part numbers start ing with 90890 MEASURING 1 Digital multimeter P N YU 34899 A 2 Digital circuit tester P N 90890 03174 2 90890 03174 1 YU 34899 A 1 ...

Page 391: ... 052 64 2 Bore stroke mm in 76 0 58 0 2 99 2 28 Compression ratio 11 9 1 Exhaust system Wet exhaust Lubrication system Dry sump Cooling system Water cooled Starting system Electric starter Ignition system TCI Ignition timing Degree BTDC 5 BTDC 32 Spark plug model manufacturer CR9EB NGK Spark plug gap mm in 0 7 0 8 0 028 0 031 Battery capacity V Ah 12 19 Generator output A r min 14 16 6 000 Drive u...

Page 392: ... RON 90 Fuel tank capacity L US gal Imp gal 70 18 5 15 4 Engine oil type 4 stroke motor oil Engine oil grade API SE SF SG SH SJ SL SAE 10W 30 Engine oil quantity L US qt Imp qt 4 5 4 8 4 0 without oil filter replacement L US qt Imp qt 2 1 2 2 1 8 with oil filter replacement L US qt Imp qt 2 3 2 4 2 0 Item Unit Model FX High Output FX Cruiser High Output GENERAL SPECIFICATIONS 2 ...

Page 393: ...in 74 0 58 0 2 91 2 28 Compression ratio 11 4 1 Exhaust system Wet exhaust Lubrication system Dry sump Cooling system Water cooled Starting system Electric starter Ignition system TCI Ignition timing Degree BTDC 34 ATDC 5 Spark plug model manufacturer CR9EB NGK Spark plug gap mm in 0 7 0 8 0 028 0 031 Battery capacity V Ah 12 19 Generator output A r min 14 16 6 000 Drive unit Propulsion system Jet...

Page 394: ... gasoline Minimum fuel rating PON 86 RON 90 Fuel tank capacity L US gal Imp gal 70 18 5 15 4 Engine oil type 4 stroke motor oil Engine oil grade API SE SF SG SH SJ SL SAE 10W 30 Engine oil quantity L US qt Imp qt 4 3 4 5 3 8 without oil filter replacement L US qt Imp qt 2 0 2 1 1 8 with oil filter replacement L US qt Imp qt 2 2 2 3 1 9 Item Unit Model FX FX Cruiser ...

Page 395: ...646 Camshaft journal diameter mm in 24 46 24 47 0 9630 0 9634 Camshaft journal to camshaft cap clearance mm in 0 03 0 06 0 0012 0 0024 Maximum camshaft runout mm in 0 03 0 0012 Timing chain Model number of links 92RH2015 130 130 Tensioning system Automatic Valves valve seats valve guides Valve clearance cold Intake mm in 0 11 0 20 0 0043 0 0079 Exhaust mm in 0 25 0 34 0 0098 0 0134 Valve dimension...

Page 396: ... 0004 0 0015 Exhaust mm in 0 020 0 047 0 0008 0 0019 Valve stem runout mm in 0 01 0 0004 Valve spring Free length Intake mm in 38 90 1 53 Exhaust mm in 40 67 1 60 Installed length Intake mm in 34 50 1 36 Exhaust mm in 35 00 1 38 Spring limit Intake Degree mm in 2 5 1 7 0 067 Exhaust Degree mm in 2 5 1 8 0 071 Piston Piston to cylinder clearance mm in 0 10 0 11 0 0039 0 0043 Piston diameter mm in 7...

Page 397: ...ce mm in 0 040 0 160 0 0016 0 0063 Connecting rod Big end oil clearance mm in 0 016 0 040 0 0006 0 0016 Bearing color code 1 Brown 2 Black 3 Blue 4 Green Small end inside diameter mm in 17 005 17 018 0 6694 0 6699 Crankshaft Crank width A mm in 304 8 306 0 12 00 12 05 Deflection limit B mm in 0 03 0 0012 Crankshaft journal oil clearance mm in 0 004 0 028 0 0002 0 0011 Bearing color code 1 Brown 2 ...

Page 398: ...5 0 0035 0 0059 Item Unit Model FX High Output FX Cruiser High Output Jet pump Impeller material Stainless steel Number of impeller blades 3 Impeller pitch angle Degree 16 8 Impeller clearance mm in 0 35 0 45 0 0138 0 0177 Impeller clearance limit mm in 0 6 0 0236 Drive shaft runout limit mm in 0 3 0 0118 Nozzle diameter mm in 86 5 87 1 3 41 3 43 Item Unit Model FX High Output FX Cruiser High Outp...

Page 399: ... Output peak voltage cranking unloaded V 9 2 2 000 r min unloaded V 38 5 3 500 r min unloaded V 63 2 Pickup coil resistance W B Ω color 459 561 Pickup coil resistance R B Ω color 459 561 Lighting coil resistance G G Ω color 0 54 0 66 Minimum charging current A r min 14 6 000 Ignition coil Primary coil resistance Ω 1 19 1 61 Secondary coil resistance kΩ 8 5 11 5 Rectifier regulator R B Output peak ...

Page 400: ...se one full turn 2 Water temperature sensor resistance Y B Y 25 C 77 F kΩ 10 Throttle position sensor Output voltage P B O trolling speed V 0 756 0 016 Cam position sensor Output voltage G O B O Position A V More than 4 8 Position B V Less than 0 8 Position C V More than 4 8 Fuel level sensor Fuel level sensor resistance Position A Ω 133 5 136 5 Position B Ω 5 7 Oil pressure switch Oil pressure sw...

Page 401: ...meter mm in 24 44 24 45 0 9622 0 9626 Camshaft journal to camshaft cap clearance mm in 0 05 0 08 0 002 0 0031 Maximum camshaft runout mm in 0 03 0 0012 Timing chain Model number of links 92RH2015 130 130 Tensioning system Automatic Valves valve seats valve guides Valve clearance cold Intake mm in 0 11 0 20 0 0043 0 0079 Exhaust mm in 0 25 0 34 0 0098 0 0134 Valve dimensions Valve head diameter A I...

Page 402: ... 010 0 037 0 0004 0 0015 Exhaust mm in 0 020 0 047 0 0008 0 0019 Valve stem runout mm in 0 01 0 0004 Valve spring Free length Intake mm in 38 90 1 53 Exhaust mm in 40 67 1 60 Installed length Intake mm in 34 50 1 36 Exhaust mm in 35 00 1 38 Spring limit Intake Degree mm in 2 5 1 7 0 067 Exhaust Degree mm in 2 5 1 8 0 071 Piston Piston to cylinder clearance mm in 0 10 0 11 0 0039 0 0043 Piston diam...

Page 403: ...oove clearance mm in 0 040 0 160 0 0016 0 0063 Connecting rod Big end oil clearance mm in 0 016 0 040 0 0006 0 0016 Bearing color code 1 Brown 2 Black 3 Blue 4 Green Small end inside diameter mm in 17 005 17 018 0 6694 0 6699 Crankshaft Crank width A mm in 304 8 306 0 12 00 12 05 Deflection limit B mm in 0 03 0 0012 Crankshaft journal oil clearance mm in 0 004 0 028 0 0002 0 0011 Bearing color cod...

Page 404: ...ainless steel Number of impeller blades 3 Impeller pitch angle Degree 16 3 Impeller clearance mm in 0 35 0 45 0 0138 0 0177 Impeller clearance limit mm in 0 6 0 0236 Drive shaft runout limit mm in 0 3 0 0118 Nozzle diameter mm in 86 5 87 1 3 41 3 43 Item Unit Model FX FX Cruiser Free play Throttle lever free play mm in 4 7 0 16 0 28 Item Unit Model FX FX Cruiser Battery Type Fluid Capacity V Ah 12...

Page 405: ...1 61 Secondary coil resistance kΩ 8 5 11 5 Rectifier regulator R B Output peak voltage 3 500 r min unloaded V 15 0 Starter motor Type Constant mesh Output kW 0 8 Rating Seconds 30 Brush length mm in 12 5 0 49 Wear limit mm in 6 5 0 26 Commutator undercut mm in 0 7 0 03 Limit mm in 0 2 0 01 Commutator diameter mm in 28 0 1 10 Limit mm in 27 0 1 06 Starter relay Rating Seconds 30 Thermoswitch ON tem...

Page 406: ... 11 6 Output pulse one full turn 2 Throttle position sensor Output voltage P B O trolling speed V 0 756 0 016 Cam position sensor Output voltage G O B O Position A V More than 4 8 Position B V Less than 0 8 Position C V More than 4 8 Fuel level sensor Fuel level sensor resistance Position A Ω 133 5 136 5 Position B Ω 5 7 Oil pressure switch Oil pressure switch continuity pressure kPa kgf cm2 psi 1...

Page 407: ...20 2 0 14 Speed sensor Screw M5 4 5 2 0 52 3 8 242 LT Steering cable joint jet pump side Nut 1 6 4 0 64 4 6 Shift cable holder Nut 2 6 4 0 64 4 6 Shift cable bracket Nut 2 15 1 5 11 Steering cable grommet Nut 1 5 9 0 59 4 3 Speed sensor lead grommet Nut 1 5 9 0 59 4 3 QSTS cable end pin Nut 1 3 8 0 38 2 7 QSTS cable grommet Nut 1 5 9 0 59 4 3 QSTS cable locknut jet pump side Nut 1 2 9 0 29 2 1 572...

Page 408: ...3 9 Front protector 2 3 Nut 4 5 4 0 54 3 9 Cleat Bolt M6 6 2 4 0 24 1 7 Part to tightened Part name Thread size Q ty Tightening torque Remarks N m kgf m ft lb TIGHTENING TORQUES GENERAL TORQUE This chart specifies tightening torques for stan dard fasteners with a standard ISO thread pitch Tightening torque specifications for spe cial components or assemblies are provided in applicable sections of ...

Page 409: ...ttery lead 5 Positive battery lead 6 Battery 7 Steering cable 8 QSTS cable 9 Shift cable 0 Speed sensor lead A Electrical bilge pump lead B Electrical box lead C Throttle cable D Fuel hose E Handlebar switch lead F Remote control unit lead FX High Output FX Cruiser High Output G Compass sensor FX Cruiser High Output H Remote control unit FX High Output FX Cruiser High Output I Remote control unit ...

Page 410: ...hrottle cable 8 Negative battery lead 9 Positive battery lead 0 Shift cable A QSTS cable B Steering cable C Electrical bilge pump lead D Remote control unit lead FX High Output FX Cruiser High Output E Remote control unit FX High Output FX Cruiser High Output F Remote control unit antenna FX High Output FX Cruiser High Output G Right operation button lead FX Cruiser High Output H Multifunction met...

Page 411: ...lastic tie É When installing the remote control unit antenna holders insert the projection on each holder into a hole in the front storage compartment from the engine compartment side Ê Connect the right operation button lead coupler blue to the multifunction meter lead coupler blue FX Cruiser High Output Ë Connect the left operation button lead coupler natural to the multifunction meter lead coup...

Page 412: ...g water pilot outlet hose 6 Negative battery lead 7 Positive battery lead 8 Battery breather hose 9 QSTS cable 0 Electrical bilge pump lead A Fuel tank breather hose B Water separator C Ignition coil lead D Starter motor positive lead E Wiring harness F Electric fuel pump G Remote control unit lead FX High Output FX Cruiser High Output H Remote control unit FX High Output FX Cruiser High Output I ...

Page 413: ... A B C C C D 7 D D E 3 A 7 D C C E E Ì D D 1 2 3 4 A 9 0 2 9 1 5 6 7 A 2 1 A E 3 B F É È Ë 9 2 A 8 Ê I G H È To ventilation socket É To fuel tank Ê Route the fuel tank breather hose as shown in the illustration Ë Bow Ì 5 7 mm 0 20 0 28 in Í Point the arrow on the cover toward the fuel tank ...

Page 414: ...uel tank breather hose 7 Remote control unit lead FX High Output FX Cruiser High Output 8 Remote control unit FX High Output FX Cruiser High Output 9 Remote control unit antenna FX High Output FX Cruiser High Output È Less than 10 mm 0 39 in É Position the throttle cable and handlebar switch lead packing in the opening in the grommet so that the plastic tie fastened around both the grommet and the...

Page 415: ... C C B B C C 2 5 4 5 4 1 3 9 3 1 2 6 Ë Ì 8 7 A A Í D D Ê Position the QSTS cable packing in the opening in the grommet so that the plastic tie is fastened around both the grommet and the packing Ë FX Cruiser FX Cruiser High Output Ì FX FX High Output Í 3 7 mm 0 12 0 28 in ...

Page 416: ...ctric bilge pump 4 Bilge hose 4 5 Cooling water hose from thermostat 6 Bilge hose 3 7 Bilge hose 2 8 Shift cable 9 Cooling water hose from exhaust pipe 0 Electrical box A QSTS cable B Positive battery lead C Speed sensor lead D Electric bilge pump lead E Bilge strainer F Negative battery lead G Steering cable H Flushing hose È Pass the QSTS cable between the bilge hoses ...

Page 417: ...ng coil coupler 9 Thermoswitch exhaust 0 Thermoswitch exhaust cou pler A Cam position sensor coupler B Oil pressure switch lead È After connecting the coupler to the wiring harness insert the projection on the coupler into the hole in the bracket É To oil pressure switch Ê To cam position sensor Ë To electrical box Ì Fasten the plastic tie with its end facing downward Í To engine temperature senso...

Page 418: ...ine temperature sensor 8 Engine temperature sensor lead 9 Thermoswitch engine lead 0 Lighting coil lead È Fasten the engine temperature sensor lead thermoswitch lead and lighting coil lead with a plastic tie Fasten the engine temperature sen sor lead 10 20 mm 0 4 0 8 in from the end of the protective cover of the lead É To generator Ê To engine temperature sensor Ë To thermoswitch engine Ì To ther...

Page 419: ...ngine temperature sensor lead Ï To starter relay Ð To negative battery terminal Ñ Route the starter motor and negative battery leads behind the cooling water hose Ò Route the starter motor lead over the cooling water hose Ó Insert the projection on the plastic tie completely into the hole in the bracket Ô FX High Output FX Cruiser High Output Õ FX FX Cruiser ...

Page 420: ...ng water pilot outlet hose 3 Cooling water hose 4 Pressure control valve 5 Cooling water hose cooling water inlet 6 Negative battery lead 7 Breather hose È To cooling water pilot outlet on starboard side É To cooling water outlet on starboard side of stern Ê To pressure control valve Ë From exhaust manifold Ì To install the hose align the white paint mark on the cooling water hose with the project...

Page 421: ...e and cooling water hoses pass a plastic tie through the stay hole and then fasten the tie Set the tie in the direction shown Ï To cooling water pilot outlet on port side Ð To cooling water outlet at stern Ñ From cooling water inlet Ò To oil tank Ó To exhaust pipe Ô To install the cooling water hose align the white paint mark on the hose with the parting line on the hose joint Õ Fasten the cooling...

Page 422: ...en fasten them with a plastic tie to the oil tank boss When bundling the hoses make sure that the cooling water hose cylinder head cover to ther mostat is routed on the deck side and that the cooling water hose starboard cooling water pilot outlet is routed on the engine side Insert the cooling water hose to the paint mark Ø Fasten the end of the cooling water hose tube that is contacting the hose...

Page 423: ...r 5 Fuel injector 2 coupler 6 Fuel injector 1 coupler 7 Throttle position sensor coupler 8 Joint coupler È Route the throttle cable between the sub wiring harness É Route the sub wiring harness under the intake vacuum hose Ê To wiring harness Ë To intake air temperature sensor coupler Ì To fuel injector 3 coupler Í Fasten the sub wiring harness to the joint cou pler bracket with a plastic tie as s...

Page 424: ... FX Cruiser Ê A È É B 1 2 3 4 5 6 7 2 8 A B Ï Î Í Ì Ë 8 Î Fasten the ring which is attached to the sub wiring harness to the sensor bracket with a plastic tie Face the end of the plastic tie towards the sensor Ï To bypass valve motor coupler ...

Page 425: ... C C Î 3 2 C C Ö Ù È É 1 1 Thermostat 2 Cooling water pilot outlet hose 3 Cooling water hose 4 Cooling water hose cooling water inlet 5 Negative battery lead È To cooling water pilot outlet on starboard side É To cooling water outlet on starboard side of stern Ê To cylinder block Ë From exhaust manifold Ì To install the hose align the white paint mark on the cooling water hose with the projection ...

Page 426: ...water pilot outlet hose and cooling water hoses pass a plastic tie through the stay hole and then fasten the tie Set the tie in the direction shown Ï To cooling water pilot outlet on port side Ð To cooling water outlet at stern Ñ From cooling water inlet Ò To exhaust pipe Ó To install the cooling water hose align the white paint mark on the hose with the parting line on the hose joint Ô Fasten the...

Page 427: ...t and then fasten them with a plastic tie to the oil tank boss When bundling the hoses make sure that the cooling water hose cylinder head cover to ther mostat is routed on the deck side and that the cooling water hose starboard cooling water pilot outlet is routed on the engine side Ö Insert the cooling water hose to the paint mark Fasten the end of the cooling water hose tube that is contacting ...

Page 428: ...ler 8 Throttle position sensor cou pler È To wiring harness É Route the throttle cable between the sub wiring har ness Ê Route the sub wiring harness under the intake vacuum hose Ë To fuel injector 3 coupler Ì Fasten the sub wiring harness to the joint coupler bracket with a plastic tie as shown in the illustration Í Fasten the ring which is attached to the sub wiring har ness to the sensor assemb...

Page 429: ...clean adjust Lubrication points Lubricate Intermediate housing Lubricate 1 2 2 Fuel system Inspect Fuel tank Inspect clean Trolling speed Inspect adjust Throttle shaft Inspect Cooling water passages Flush 3 Water inlet strainer Inspect clean Bilge strainer Clean Electric bilge pump strainer Inspect clean Impeller Inspect Jet thrust nozzle angle Inspect adjust Steering master Inspect QSTS mechanism...

Page 430: ...and forth Check the excessive play of the handle bar Steering cable inspection and adjustment 1 Inspect Jet thrust nozzle difference of distances a and b Out of specification Adjust Difference of distances a and b Maximum 5 mm 0 2 in Inspection steps Set the control grip in the neutral position Turn the handlebar lock to lock Measure distances a and b If difference of distances a and b is not with...

Page 431: ... throttle lever free play adjust the trolling speed 1 Measure Throttle lever free play a Out of specification Adjust Adjustment steps Set the control grip in the neutral position Loosen the locknut 1 Disconnect the cable joint 2 from the ball joint 3 Turn the cable joint 2 in or out for adjust ing the distances a and b Turn in Distance a is increased Turn out Distance b is increased WARNING The ca...

Page 432: ...e locknut 2 c Turn the adjusting nut 3 to adjust the length a and then tighten the locknut Throttle cable installation length 23 9 1 0 mm 0 94 0 04 in NOTE Apply locking agent LOCTITE to the threads of the adjusting nut 3 d Remove the handlebar cover e Loosen the locknut 4 f Turn the adjuster 5 in or out until the specified free play is obtained Turn in Free play is increased Turn out Free play is...

Page 433: ... T R Handlebar cover screw 1 1 N m 0 11 kgf m 0 8 ft lb LOCTITE 242 i Install the ribbon sub assemblies and air filter case cover T R Ribbon sub assembly bolt 6 5 N m 0 65 kgf m 4 7 ft lb LOCTITE 242 Air filter case cover screw 2 5 N m 0 25 kgf m 1 8 ft lb LOCTITE 572 GENERAL Drain plug inspection 1 Inspect Drain plugs Cracks damage Replace O rings Cracks wear Replace Screw threads Contaminants Cl...

Page 434: ...tle body end Throttle bodies throttle cable pulley throttle cam and return spring Recommended lubricant Yamaha marine grease Yamaha grease A Water resistant grease 3 Lubricate QSTS control cables handlebar end NOTE Before lubricating the QSTS control cables remove the QSTS cable housing cover Spray the rust inhibitor into the outer cables and apply grease to the inner cables Recommended lubricant ...

Page 435: ...pivot shaft Steering cable nozzle end QSTS cable nozzle end Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease 6 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 ...

Page 436: ...ermediate housing with the recom mended grease through the grease nipple 1 Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease Grease quantity Initial 10 hours 33 0 35 0 cm3 1 11 1 18 oz Every 100 hours or 12 months 6 0 8 0 cm3 0 20 0 27 oz 1 ...

Page 437: ... box 6 Battery 7 Speed sensor 8 Electric bilge pump 9 Cam position sensor 0 Fuel injectors A Thermoswitch exhaust B Oil pressure switch C Bypass valve motor D Intake air pressure sensor E Intake air temperature sensor F Throttle position sensor G Lighting coil and pickup coil H Engine stop switch engine shut off switch and start switch I Steering sensor J Buzzer K Electric fuel pump L Fuel level s...

Page 438: ...ion coils 5 Electrical box 6 Battery 7 Speed sensor and water tem perature sensor FX Cruiser High Output Speed sensor FX High Output 8 Electric bilge pump 9 Cam position sensor 0 Fuel injectors A Thermoswitch exhaust B Oil pressure switch C Sensor assembly intake air pressure and intake air tem perature sensor D Bypass valve motor E Throttle position sensor F Lighting coil and pickup coil G Engine...

Page 439: ...M N L P O K J I G F E D C B A 0 9 8 7 6 5 4 3 2 1 H J Electric fuel pump K Fuel level sensor L Left operation button M Multifunction meter N Right operation button FX Cruiser High Output O Remote control unit P Compass sensor and air temperature sensor FX Cruiser High Output ...

Page 440: ...W L W L B O R Y R Y O W L O B B O B O B O B O B O R Y R Y R Y R Y R Y R Y G Y R Y G G R G B R Y R Y G R G B R Y R Y R Y R Y G R G W L R Y P 18 20 27 30 34 O W R W B G B G Y 8 12 13 16 17 2 3 4 5 P P O R R O O O R W L 1 1 ECM 2 Steering sensor 3 Pickup coil 4 Throttle position sensor 5 Bypass valve motor B Black G Green O Orange P Pink R Red W White B O Black orange G B Green black G R Green red G ...

Page 441: ...a spring gauge 2 onto the plastic tie Hold the spring gauge at a 90 angle from the handlebar and then pull the spring gauge with a force of 10 kgf 22 lb When handlebar pulled When handlebar not pulled ON OFF Check that the following is displayed in the Engine Monitor window of the Yamaha Diagnostic System Use the same procedure to check that the steering sensor operates correctly when the handleba...

Page 442: ... R Y Y L R B L R P B B B G P A C B R Y W B 0 B L L R L B W B R B B B B R Y 1 21 30 5 35 15 6 14 P W P W P W D B O R Y W B B O G 4 1 L B L Y Y L 7 15 18 16 6 L R R Y L R L R L Y L R L B L Y B O O R Y R Y R L B G R Y Y E B R G L W B R G B O 1 ECM 2 Main and fuel pump relay 3 Fuse 20 A 4 Remote control unit 5 Battery 6 Tacho pulse 7 Thermoswitch exhaust 8 Thermoswitch engine 9 Engine temperature sens...

Page 443: ...O B O B O B O B O B O B Y B Y B B Y R Y Y B Y R Y Y L R B L R P B B B G P A C B R Y W B 0 B L L R L B W B R B B B B R Y 1 21 30 5 35 15 6 14 P W P W P W D B O R Y W B B O G 4 1 L B L Y Y L 7 15 18 16 6 L R R Y L R L R L Y L R L B L Y B O O R Y R Y R L B G R Y Y E B R G L W B R G B O B Black G Green L Blue O Orange P Pink R Red W White Y Yellow B G Black green B L Black blue B O Black orange B Y Bl...

Page 444: ...O B O B Y R Y B Y L R B L R P B B B G R W P A B C B R W 0 B L L R B Y R Y Y B Y R W Y B R Y B B B B R 1 21 30 5 35 15 6 14 P W P W P W D B O R Y W B B O G 4 1 L B L Y Y L 7 15 18 16 6 L R R Y L R L Y L B L R L B Gy B O O R Y R Y R Gy L R B O 1 ECM 2 Main and fuel pump relay 3 Fuse 20 A 4 Remote control unit 5 Battery 6 Tacho pulse 7 Thermoswitch exhaust 8 Thermoswitch engine 9 Engine temperature s...

Page 445: ... B O B O B O B Y R Y B Y L R B L R P B B B G R W P A B C B R W 0 B L L R B Y R Y Y B Y R W Y B R Y B B B B R 1 21 30 5 35 15 6 14 P W P W P W D B O R Y W B B O G 4 1 L B L Y Y L 7 15 18 16 6 L R R Y L R L Y L B L R L B Gy B O O R Y R Y R Gy L R B O B Black G Green Gy Gray L Blue O Orange P Pink R Red W White Y Yellow B G Black green B L Black blue B O Black orange B Y Black yellow L B Blue black L...

Page 446: ... W 0 L B L R B Y R Y Y B Y R W Y B R Y B B B B R 31 1 5 35 15 6 P W P W P W D B O R Y W B 4 3 2 1 8 7 6 5 B O B O 1 ECM 2 Main and fuel pump relay 3 Fuse 20 A 4 Fuse 3 A 5 Battery 6 Tacho pulse 7 Thermoswitch exhaust 8 Thermoswitch engine 9 Engine temperature sensor 0 Multifunction meter A Fuel level sensor B Speed sensor C Buzzer D Oil pressure switch B Black Br Brown G Green O Orange P Pink R Re...

Page 447: ... of specification Replace Right operation button continuity FX Cruiser High Output Out of specification Replace Digital multimeter YU 34899 A Digital circuit tester 90890 03174 Left operation button continuity Button Position Leads Pu W B G W Speed RPM Free Push Volt Hour Free Push Digital multimeter YU 34899 A Digital circuit tester 90890 03174 Right operation button continuity Button Position Le...

Page 448: ...60 E ELEC INDICATION SYSTEM MULTIFUNCTION METER REMOVAL Refer to STEERING CONSOLE COVER OPERATION BUTTON REMOVAL Refer to STEERING CONSOLE COVER ...

Page 449: ...ration button B Black G Green L Blue P Pink R Red W White B G Black green B L Black blue G W Green white L B Blue black L R Blue red L Y Blue yellow Pu W Purple white R W Red white R Y Red yellow W B White black Y W Yellow white INDICATION SYSTEM B L B L R P B P L R R B R 1 2 3 4 5 L Y L B L R L Y L B B L B R G W L R Y W B B B R R Y W B B G B G Y W R W R W Y W B B Y W B R W Y W B R W Pu W G W G W ...

Page 450: ...evel sensor 6 Left operation button B Black Gy Gray P Pink R Red W White Y Yellow B G Black green B L Black blue B Y Black yellow G W Green white L B Blue black L R Blue red L Y Blue yellow Pu W Purple white R W Red white INDICATION SYSTEM B L B L R B Y R W B Y P B G R W Y Y R R W W B B B G P L R R B R 1 2 3 4 5 Gy L B L R L Y L B B L Pu W G W G W Pu W B B G W B Pu W G W B Pu W 6 ...

Page 451: ...1 Buzzer 2 Speed sensor 3 ECM 4 Fuel level sensor 5 Left operation button B Black R Red W White Y Yellow B G Black green B Y Black yellow G W Green white L B Blue black L R Blue red Pu W Purple white R W Red white L B L B B L R B Y R W B Y B G B G R W Y Y R R W W B B B B L R R B R 1 2 3 4 Pu W G W G W Pu W B B G W B Pu W G W B Pu W 5 ...

Page 452: ...tion meter replace the compass sen sor NOTE Be sure to check the compass display again after replacing the compass sensor If the compass display is still incorrect replace the multifunction meter Checking steps Measure the ambient air temperature Turn on the multifunction meter and check the air temperature displayed on the meter If the air temperature displayed on the multifunction meter is more ...

Page 453: ...00 mV More than 5 V Output pulse 2 pulses one full turn Measuring steps Disconnect the coupler between the mul tifunction meter and the compass sensor 1 and then connect it to a 12 V battery as shown in the illustration Rotate the paddle wheel and check the output voltage and output pulses NOTE As the paddle wheel is rotated a square wave voltage signal a is produced If within specification replac...

Page 454: ...s more than 5 C 9 F different from the ambient water temperature measure the speed sensor water temperature sensor resistance Digital multimeter YU 34899 A Digital circuit tester 90890 03174 Speed sensor water temperature sensor resistance 10 kΩ at 25 C 77 F Measuring steps Disconnect the coupler and then mea sure the resistance between the yellow and black yellow leads as shown in the illustratio...

Page 455: ...duration using the Engine monitor of the Yamaha Diagnostic System Replace the multifunction meter Overheat warning indicator 1 Check Overheat warning indicator Does not operate Replace the multi function meter Checking steps Start the engine Disconnect the thermoswitch engine coupler 1 blue engine temperature sensor coupler 2 black or ther moswitch exhaust 3 coupler Connect the jumper lead to the ...

Page 456: ...ight and check engine warning indicator blink and that the buzzer sounds intermittently Diagnostic display 1 Check Diagnostic display Does not display Replace the multi function meter Checking steps Start the engine Disconnect the coupler of a sensor e g engine temperature sensor that is nor mally displayed when a malfunction occurs Refer to SELF DIAGNOSIS Check that the check engine warning indic...

Page 457: ...W B W B R R B B L L R B L L Y L B 4 3 2 1 R Y R Y R Y R Y R Y R Y Pu G Pu Y Pu B Pu R R Y 0 0 0 0 Pu G R Y Pu Y R Y Pu B R Y Pu R R Y R Y R Y 9 8 W B W W W A 14 L 15 W B 21 L R 30 R Y 31 Y 37 Pu G 38 Pu Y 39 Pu B 40 Pu R W L R L B Gy L R L B L Y L R L R P O G B G Pu B G Y G R Pu G Pu Y Pu B P O R Y Pu Y G Y G R B Y P G Pu R Pu R Pu G P G R Y G G B B O B Gy B W B W B L Y L Y 1 ECM 2 Main and fuel p...

Page 458: ... Y Pu G Pu Y Pu B Pu R R Y 0 0 0 0 Pu G R Y Pu Y R Y Pu B R Y Pu R R Y R Y R Y 9 8 W B W W W A 14 L 15 W B 21 L R 30 R Y 31 Y 37 Pu G 38 Pu Y 39 Pu B 40 Pu R W L R L B Gy L R L B L Y L R L R P O G B G Pu B G Y G R Pu G Pu Y Pu B P O R Y Pu Y G Y G R B Y P G Pu R Pu R Pu G P G R Y G G B B O B Gy B W B W B L Y L Y B Black Br Brown Gy Gray L Blue R Red W White Y Yellow B L Black blue L B Blue black L...

Page 459: ...utput voltage Within specification Replace the mul tifunction meter Out of specification Replace the remote control unit Digital multimeter YU 34899 A Digital circuit tester 90890 03174 Remote control unit output voltage Blue yellow L Y ground 11 13 V Measurement steps Disconnect the remote control unit 1 coupler from the multifunction meter Measure the remote control unit output voltage while pus...

Page 460: ...r 1 Check Low rpm mode indicator Does not come on Replace the multi function meter Checking steps Press the unlock button 1 of remote con trol transmitter for more than four sec onds to select the low rpm mode Check that the beeper sounds three times and the L MODE indicator light 2 comes on 1 2 ...

Page 461: ... FX High Output REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points STEERING PAD REMOVAL Follow the left Step for removal 1 Screw 4 2 Handlebar cover 1 3 Pad 1 4 Bolt 2 5 Handlebar cover stay 1 Reverse the removal steps for installation ...

Page 462: ...ame Q ty Service points STEERING PAD REMOVAL Follow the left Step for removal 1 Screw 8 2 Screw black 2 3 Lower handlebar cover 1 4 Upper handlebar cover 1 NOTE Be sure to insert the projection on the upper handlebar cover completely into the grom met 5 Bolt 4 6 Steering pad 1 7 Grommet 1 Reverse the removal steps for installation 8 ...

Page 463: ...tep Procedure Part name Q ty Service points HANDLEBAR HOLDER REMOVAL Follow the left Step for removal 1 Throttle cable 1 NOTE Be sure to remove the throttle cable seal as shown in the illustration 2 Bolt 4 3 Upper handlebar holder 2 Reverse the removal steps for installation ...

Page 464: ... cable to jet thrust nozzle Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Nut washer 2 2 2 QSTS converter 1 3 QSTS cable 2 1 With white tape a 4 QSTS cable 1 1 NOTE Route the QSTS cables through the star board side in the steering console Route the handlebar switch lead and throt tle cable through the port side in the steer ing console 5 Handlebar switch coupler 2 ...

Page 465: ...Q ty Service points 6 Screw 4 7 Handle boss cover 1 8 Plastic tie 2 9 Hose packing 1 10 Throttle cable 1 NOTE Position the corrugated tube for the throttle cable as shown in the illustration so that the tube attaches to the end of the outer throttle cable Not reusable ...

Page 466: ...TE Pass the QSTS cable and handlebar switch lead through the handle boss cover and then install the handlebar assembly Install the sponges of the QSTS cables as shown and make sure that the grommet is installed to the deck securely 12 Handlebar switch lead 1 13 Grommet 2 Reverse the removal steps for installation ...

Page 467: ...he plastic ties È FX FX High Output É FX Cruiser FX Cruiser High Output 2 3 4 1 1 È 1 4 1 2 3 É 2 Install Upper handlebar holder 1 NOTE Align the punch marks a on the handlebar with the top surface of the handlebar holder The upper handlebar holder should be installed with the punch mark b facing for ward CAUTION Clearance c should be narrower than clearance d T R Handlebar holder bolt 20 N m 2 0 ...

Page 468: ...ch lead when the handlebar is turned to the left and right Reroute the cables and lead if there is no slack Installing steps for FX Cruiser FX Cruiser High Output Route the throttle cable 1 under the han dlebar 2 and then install the throttle cable end into the throttle lever Make sure that the throttle cable QSTS cable 3 and handlebar switch lead 4 pass through the opening a in the center of the ...

Page 469: ...the bracket as shown Pull the throttle cable 2 in the direction of the arrow shown in the illustration and then fit the end of the seal 3 around inner cable Turn the adjuster 4 in out until the speci fied free play is obtained Throttle lever free play a 4 7mm 0 16 0 28 in Turn in Free play is increased Turn out Free play is decreased Tighten the lock nut 5 1 3 2 ...

Page 470: ...e left Step for removal Mirror assembly Refer to MIRROR Center cover assembly Refer to STEERING CONSOLE COVER Steering cable end Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Bolt 1 2 Steering arm assembly 1 3 Ball joint 1 4 Nut 1 5 Bolt washer nut 1 1 1 6 Cable stopper assembly 1 8 6 8 7 5 6 4 2 1 5 2 9 8 3 8 30 mm 8 35 mm 6 60 mm 20 N m 2 0 kgf m 14 ft Ib LT 271 ...

Page 471: ...Procedure Part name Q ty Service points 7 Nut washer 4 4 8 Steering master assembly 1 9 Bolt 4 Reverse the removal steps for installation 8 6 8 7 5 6 4 2 1 5 2 9 8 3 8 30 mm 8 35 mm 6 60 mm 20 N m 2 0 kgf m 14 ft Ib LT 271 STEERING MASTER ...

Page 472: ...he left Step for disassembly 1 Steering shaft 1 FX Cruiser FX Cruiser High Output 2 Steering shaft 1 FX FX High Output 3 Bushing 1 4 Bushing 1 5 Buzzer 1 6 Bolt 4 7 Bracket 1 1 8 Steering sensor 1 FWD 12 7 8 6 6 3 21 21 9 10 16 15 22 20 4 5 1 2 6 25 mm 5 16 mm 8 30 mm 8 30 mm A A A A A A A A LT 572 LT LT 271 11 11 11 LT 572 LT 11 11 11 11 18 19 17 14 13 A A 11 ...

Page 473: ... 10 Bracket 2 1 11 Bolt nut 5 5 12 Left housing 1 13 Spring holder 1 14 Spring 1 1 15 Lever 1 16 Lock 1 17 Spring 2 1 18 Right housing 1 FWD 12 7 8 6 6 3 21 21 9 10 16 15 22 20 4 5 1 2 6 25 mm 5 16 mm 8 30 mm 8 30 mm A A A A A A A A LT 572 LT LT 271 11 11 11 LT 572 LT 11 11 11 11 18 19 17 14 13 A A 11 ...

Page 474: ...tube 1 20 Rubber seal 1 21 Bushing 2 22 Steering master assembly 1 Reverse the disassembly steps for assembly FWD 12 7 8 6 6 3 21 21 9 10 16 15 22 20 4 5 1 2 6 25 mm 5 16 mm 8 30 mm 8 30 mm A A A A A A A A LT 572 LT LT 271 11 11 11 LT 572 LT 11 11 11 11 18 19 17 14 13 A A 11 STEERING MASTER ...

Page 475: ...nstallation 1 Apply Instant adhesive onto the mating surfaces of the rubber seal 1 and steering master assembly 2 NOTE After assembling the steering master assem bly 2 apply instant adhesive onto the mating surfaces of the rubber seal 1 and steering master assembly 2 in the area a shown in the illustration FWD a 1 2 STEERING MASTER ...

Page 476: ... AND INSTALLATION CHART Step Procedure Part name Q ty Service points REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL Follow the left Step for removal Service lid 1 Refer to FRONT HOOD Front seat assembly Refer to SEATS AND HAND GRIP 1 Steering cable end 1 2 Nut 1 3 Steering cable 1 4 Seal 1 5 Speed sensor coupler 1 6 Nut 1 ...

Page 477: ...Step Procedure Part name Q ty Service points 7 Cap 1 8 Screw 4 9 Speed sensor Speed sensor and water temperature sensor 1 1 FX FX Cruiser FX High Output FX Cruiser High Output 10 Shift cable end 1 11 Plastic tie 1 12 Grommet 1 13 Nut 2 14 Shift cable holder 2 15 Nut 2 16 Bolt 1 ...

Page 478: ...NSOR LEAD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 17 Shift cable bracket 1 18 Nut 1 19 Shift cable 1 20 Seal 1 21 Nut 1 22 Pin 1 23 QSTS cable end 1 24 Nut 1 25 QSTS cable 1 26 Packing 1 Reverse the removal steps for installation ...

Page 479: ...ring cable Removal steps Rotate the steering stopper plate 1 on the steering stopper clockwise and remove it from the steering stopper plate 2 Rotate the steering stopper plate 2 counterclockwise Remove the steering cable 3 from the steering stopper 4 Disconnect the cable joint 5 to the ball joint 6 2 1 1 2 3 4 ...

Page 480: ... the projection 3 on the steering cable completely into the indentation 4 in the steering stopper Slightly lift up the steering stopper plate 5 on the steering stopper and then rotate it clockwise Rotate the steering stopper plate 6 on the steering stopper counterclockwise making sure to fit the hole in the stopper plate 6 onto the projection 7 on the other steering stopper plate 5 3 4 6 5 5 7 6 ...

Page 481: ...llow the left Step for removal 1 Nut washer 4 4 2 Front hood assembly 1 3 Bolt 4 4 Bolt 2 5 Hinge assembly 1 6 Bolt 2 7 Hood lock assembly 1 8 Rivet 4 9 Service lid 1 1 2 7 6 4 8 9 3 5 1 11 10 6 30 mm 6 4 N m 0 64 kgf m 4 6 ft Ib LT 242 LT 242 6 18 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 18 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib LT 242 ...

Page 482: ... Service points 10 Rivet 4 11 Service lid 2 1 Reverse the removal steps for installation 2 7 6 4 8 9 3 5 1 11 10 6 30 mm 6 4 N m 0 64 kgf m 4 6 ft Ib LT 242 LT 242 6 18 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 18 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib LT 242 ...

Page 483: ... hull Push in the rivet pin 2 until it clicks and is flush with the top of the rivet NOTE To remove a rivet push the rivet pin in until it clicks and is below the top of the rivet Before reinstalling a rivet hold the rivet flange a with both hands and push the rivet pin perpendicularly against a hard flat surface until the pin protrudes from the top of the rivet 2 1 a ...

Page 484: ... 4 5 Center ornament 1 NOTE Be careful not to scratch the ornaments Install the center ornament after installing the left and right ornaments 6 Left ornament 1 7 Right ornament 1 8 Double sided tape 2 9 Bolt 6 2 1 4 9 5 16 mm 2 2 N m 0 22 kgf m 1 6 ft Ib 5 16 mm 2 2 N m 0 22 kgf m 1 6 ft Ib 5 17 mm 1 1 N m 0 11 kgf m 0 8 ft Ib 10 9 10 5 17 mm 1 1 N m 0 11 kgf m 0 8 ft Ib 9 10 9 10 1 1 1 7 8 12 12 ...

Page 485: ...6 NOTE Apply soapy water to the nuts to make their installation easier Reverse the disassembly steps for assembly 2 1 4 9 5 16 mm 2 2 N m 0 22 kgf m 1 6 ft Ib 5 16 mm 2 2 N m 0 22 kgf m 1 6 ft Ib 5 17 mm 1 1 N m 0 11 kgf m 0 8 ft Ib 10 9 10 5 17 mm 1 1 N m 0 11 kgf m 0 8 ft Ib 9 10 9 10 1 1 1 7 8 12 12 5 12 12 3 6 8 11 ...

Page 486: ...ront hood 1 push the projections 3 on the left ornament shown in the illustration and remove the ornament from the double sided tape Remove the right ornament in the same way as the left ornament NOTE When removing the ornaments be sure to remove the center ornament first Be careful not to break the front hood pro jections and ornament projections when removing the ornaments 2 2 1 3 1 Front hood a...

Page 487: ...ion Install the visor and tighten the screws making sure to hold the nuts so that they do not turn T R Screw 1 1 N m 0 11 kgf m 0 8 ft lb 2 1 Double sided tape installation 1 Install Double sided tape 1 NOTE Before affixing the double sided tape 1 be sure to clean the areas on the front hood where the tape will be affixed to remove any dirt 1 1 ...

Page 488: ... tape 1 on the watercraft Install the left and right ornaments from the sides as shown in the illustration Install the center ornament from above as shown in the illustration NOTE Be sure to install the left and right orna ments before installing the center orna ment The left and right ornaments cannot be installed if the center ornament is installed first 1 1 ...

Page 489: ... points MIRROR REMOVAL Follow the left Step for removal 1 Nut 2 2 Washer 2 3 Bolt 2 4 Bolt 4 5 Left mirror assembly 1 6 Right mirror assembly 1 Reverse the removal steps for installation 4 6 4 2 1 5 3 5 4 N m 0 54 kgf m 3 9 ft Ib 6 23 mm 5 4 N m 0 54 kgf m 3 9 ft Ib LT 242 LT LT 242 LT 6 23 mm 6 22 mm MIRROR ...

Page 490: ...embly 1 Screw 12 2 Left mirror upper cover 1 3 Screw 8 4 Left mirror 1 5 Nut 2 6 Left mirror lower cover 1 7 Right mirror upper cover 1 8 Right mirror 1 9 Right mirror lower cover 1 Reverse the disassembly steps for assembly 1 1 1 2 3 4 5 6 7 3 8 9 5 1 5 15 mm 3 7 N m 0 37 kgf m 2 7 ft Ib 5 15 mm 3 7 N m 0 37 kgf m 2 7 ft Ib 5 15 mm 3 7 N m 0 37 kgf m 2 7 ft Ib 1 1 ...

Page 491: ... points METER AND METER COVER REMOVAL Follow the left Step for removal Handlebar assembly Refer to HANDLEBAR Service lid 1 Refer to FRONT HOOD 1 Band 1 2 Multifunction meter coupler 4 3 Screw 4 4 Multifunction meter cover 1 2 1 10 7 9 13 5 5 6 14 15 4 3 12 11 12 11 8 5 15 mm 2 2 N m 0 22 kgf m 1 6 ft Ib 3 5 12 mm 3 7 N m 0 37 kgf m 2 7 ft Ib 3 6 5 ...

Page 492: ...utton 1 8 Right operation button 1 FX Cruiser High Output 9 Bolt 4 10 Washer 4 11 Band 1 12 Grommet 1 13 Multifunction meter 1 FX Cruiser High Output 14 Cover 1 FX FX Cruiser FX High Output 15 Multifunction meter 1 FX FX Cruiser FX High Output Reverse the removal steps for installation 2 1 10 7 9 13 5 5 6 14 15 4 3 12 11 12 11 8 5 15 mm 2 2 N m 0 22 kgf m 1 6 ft Ib 3 5 12 mm 3 7 N m 0 37 kgf m 2 7...

Page 493: ...t 8 4 Left side cover 1 5 Left inner side pad 2 6 Nut 6 7 Screw 4 8 Left side ornament 1 9 Right side cover 1 3 9 11 6 6 1 7 3 3 1 7 3 6 8 6 1 5 5 10 10 6 2 2 4 5 15 mm 2 2 N m 0 22 kgf m 1 6 ft Ib 6 23 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 3 3 5 15 mm 2 2 N m 0 22 kgf m 1 6 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib LT 242 LT LT 242 LT LT 242 LT LT 242 LT 6 6 22 mm LT 242 LT 6 22 mm 6 23 mm 6 23 mm 5 4 N m 0 5...

Page 494: ...e the removal steps for installation 3 9 11 6 6 1 7 3 3 1 7 3 6 8 6 1 5 5 10 10 6 2 2 4 5 15 mm 2 2 N m 0 22 kgf m 1 6 ft Ib 6 23 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 3 3 5 15 mm 2 2 N m 0 22 kgf m 1 6 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib LT 242 LT LT 242 LT LT 242 LT LT 242 LT 6 6 22 mm LT 242 LT 6 22 mm 6 23 mm 6 23 mm 5 4 N m 0 54 kgf m 3 9 ft Ib STEERING CONSOLE COVER ...

Page 495: ...ut washer 2 2 2 Bolt 2 3 Nut washer 2 2 4 Center cover assembly 1 NOTE To remove the center cover assembly easily pull the tilt lever up 5 Nut washer 2 2 6 Bolt 2 7 Hood lock 1 8 Nut washer 2 2 FX Cruiser High Output FW D 4 3 3 2 11 12 9 10 6 7 1 5 8 5 24 mm 6 22 mm 6 30 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 6 4 N m 0 64 kgf m 4 6 ft Ib 3 8 N m 0 38 kgf m 2 7 ft Ib ...

Page 496: ...gh Output 10 Compass sensor and air temperature sensor 1 FX Cruiser High Output 11 Case cap 1 12 Inner pad 1 Reverse the removal steps for installation FW D 4 3 3 2 11 12 9 10 6 7 1 5 8 5 24 mm 6 22 mm 6 30 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 6 4 N m 0 64 kgf m 4 6 ft Ib 3 8 N m 0 38 kgf m 2 7 ft Ib ...

Page 497: ... INSTALLATION CHART Step Procedure Part name Q ty Service points CENTER COVER DISASSEMBLY Follow the left Step for disassembly 1 Damper 2 2 Nut 4 3 Grommet 4 4 Damper 6 5 Damper 1 6 Hinge assembly 2 7 Gear assembly 2 8 Lid 1 9 Lid lock 1 9 8 7 6 7 6 10 5 4 11 1 3 1 2 2 ...

Page 498: ...10 E HULL HOOD STEERING CONSOLE COVER EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 10 Plug 1 11 Center cover 1 Reverse the disassembly steps for assembly 9 8 7 6 7 6 10 5 4 11 1 3 1 2 2 ...

Page 499: ...ow the left Step for removal Front hood assembly Refer to FRONT HOOD Mirror assembly Refer to MIRROR Right side cover Refer to STEERING CONSOLE COVER Shift cable Disconnect 1 Nut washer 3 3 2 Bolt 3 3 Shift lever assembly 1 Reverse the removal steps for installation 1 2 2 2 3 1 6 30 mm 6 30 mm 5 4 N m 0 54 kgf m 3 9 ft Ib A A 1 5 4 N m 0 54 kgf m 3 9 ft Ib ...

Page 500: ... seat assembly 1 FX FX High Output 4 Front seat assembly 1 FX Cruiser FX Cruiser High Output 5 Bolt 4 6 Seat lock assembly 2 7 Seat storage compartment 1 8 Nut washer 4 4 9 Bolt washer 4 4 10 Deck beam 1 3 1 6 5 23 22 19 20 21 18 20 8 9 11 15 7 17 16 14 13 12 10 6 5 6 25 mm 8 30 mm 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 26 N m 2 6 kgf m 19 ft Ib 6 4 N m 0 64 kgf m 4 6 ft Ib...

Page 501: ... Rear seat stay 2 18 Nut 1 19 Projection 1 20 Washer 2 3 1 6 5 23 22 19 20 21 18 20 8 9 11 15 7 17 16 14 13 12 10 6 5 6 25 mm 8 30 mm 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 26 N m 2 6 kgf m 19 ft Ib 6 4 N m 0 64 kgf m 4 6 ft Ib 6 40 mm 6 4 N m 0 64 kgf m 4 6 ft Ib 15 N m 1 5 kgf m 11 ft Ib 26 N m 2 6 kgf m 19 ft Ib LT 271 LT 271 2 4 24 26 25 ...

Page 502: ...gh Output 25 Nut washer 2 1 26 Seat holder 1 Reverse the removal steps for installation 3 1 6 5 23 22 19 20 21 18 20 8 9 11 15 7 17 16 14 13 12 10 6 5 6 25 mm 8 30 mm 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 26 N m 2 6 kgf m 19 ft Ib 6 4 N m 0 64 kgf m 4 6 ft Ib 6 40 mm 6 4 N m 0 64 kgf m 4 6 ft Ib 15 N m 1 5 kgf m 11 ft Ib 26 N m 2 6 kgf m 19 ft Ib LT 271 LT 271 2 4 24 26 25...

Page 503: ...High Output EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points REBOARDING STEP REMOVAL Follow the left Step for removal 1 Bolt 6 2 Reboarding step 1 Reverse the removal steps for installation 1 1 2 LT 271 8 42 mm 15 N m 1 5 kgf m 11 ft Ib 8 42 mm 15 N m 1 5 kgf m 11 ft Ib ...

Page 504: ...ll Reboarding step Installing steps Fasten the brackets on both sides of the reboarding step in the down position with a plastic tie 1 as shown in the illustra tions so that they will not return to the up position Finger tighten all of the bolts and then tighten them to specification T R Bolt 15 N m 1 5 kgf m 11 ft lb 1 1 ...

Page 505: ...1 5 Plate 2 6 Bolt collar 10 10 7 Sponson 2 8 Nut washer 4 4 9 Screw 4 10 Drain plug 2 16 16 19 4 5 3 7 6 15 13 14 12 13 1 9 10 11 2 5 4 N m 0 54 kgf m 3 9 ft Ib 15 N m 1 5 kgf m 11 ft Ib 8 40 mm 16 N m 1 6 kgf m 12 ft Ib 6 25 mm 2 4 N m 0 24 kgf m 1 7 ft Ib 5 5 4 N m 0 54 kgf m 3 9 ft Ib 15 N m 1 5 kgf m 11 ft Ib 13 N m 1 3 kgf m 9 4 ft Ib LT 271 16 17 18 8 23 23 23 22 24 20 21 LT 572 LT 6 20 mm ...

Page 506: ... front protector 1 and 2 after install ing the front protector 3 18 Front protector 2 1 19 Front protector 3 1 16 16 19 4 5 3 7 6 15 13 14 12 13 1 9 10 11 2 5 4 N m 0 54 kgf m 3 9 ft Ib 15 N m 1 5 kgf m 11 ft Ib 8 40 mm 16 N m 1 6 kgf m 12 ft Ib 6 25 mm 2 4 N m 0 24 kgf m 1 7 ft Ib 5 5 4 N m 0 54 kgf m 3 9 ft Ib 15 N m 1 5 kgf m 11 ft Ib 13 N m 1 3 kgf m 9 4 ft Ib LT 271 16 17 18 8 23 23 23 22 24 ...

Page 507: ... Cruiser High Output Reverse the disassembly steps for assembly 16 16 19 4 5 3 7 6 15 13 14 12 13 1 9 10 11 2 5 4 N m 0 54 kgf m 3 9 ft Ib 15 N m 1 5 kgf m 11 ft Ib 8 40 mm 16 N m 1 6 kgf m 12 ft Ib 6 25 mm 2 4 N m 0 24 kgf m 1 7 ft Ib 5 5 4 N m 0 54 kgf m 3 9 ft Ib 15 N m 1 5 kgf m 11 ft Ib 13 N m 1 3 kgf m 9 4 ft Ib LT 271 16 17 18 8 23 23 23 22 24 20 21 LT 572 LT 6 20 mm 2 0 N m 0 2 kgf m 1 4 f...

Page 508: ...NSTALLATION CHART Step Procedure Part name Q ty Service points CLEAT DISASSEMBLY Follow the left Step for disassembly The following procedure applies to both of the cleat assembly 1 Circlip 2 2 Spring 2 3 Cleat 1 4 O ring 2 5 Plate 1 6 Packing 1 Reverse the disassembly steps for assembly 2 1 2 1 5 4 4 3 6 Not reusable Not reusable ...

Page 509: ... HOOD CLEAT ASSEMBLY For FX Cruiser High Output SERVICE POINTS Cleat cover installation 1 Install Cleat cover NOTE Make sure that the word YAMAHA a on the cleat covers faces outward as shown in the illustration a ...

Page 510: ...ction meter How ever if there are numerous error codes dis played be sure to check them with the Yamaha Diagnostic System Code Symptom 01 Normal 13 Pickup coil malfunction 15 Engine temperature sensor malfunction 18 Throttle position sensor malfunction 19 Incorrect battery voltage 23 Intake air temperature sensor malfunction 24 Cam position sensor malfunction 29 Intake air pressure sensor malfunct...

Page 511: ... B O R Y W L L B B R L R G R G Y G B W B W B W R B O B Y P W G O L B B O R Y R Y R Y R Y R Y R Y R Y R Y R Y B O W B W R B Y B O B Y B Y B O B R W B G G G G G G P P R Y R Y R Y R R B R B G G G B P B B R R B G R R Y G B O O P W G B Y Br L R R R P P P O O O B Br R R R R B R Br Br R R Y B O B O B O B O B O B O R Y B O B O B O B O B O B O B O B O B B B B B B B B Y Y Br Br B B B B B P B B B G P L B B P...

Page 512: ...ter motor P Engine temperature sensor Q Ignition coil R Spark plug S Rectifier regulator T Battery U Electric bilge pump V Speed sensor W ECM X Slant detection switch Y Main and fuel pump relay È To tachometer Color code B Black Br Brown G Green L Blue O Orange P Pink R Red W White Y Yellow B G Black green B L Black blue B O Black orange B R Black red B W Black white B Y Black yellow G B Green bla...

Page 513: ...W G W W R B B B R Y R R R L R L B B O B R R Y R Y B W R Y B Y R Y B L B W B Y B L Pu R Pu B Pu Y Pu G B Y P G B O R Y W L L B B R L R G R G Y G B W B W B W R B O B Y P W G O L B B O R Y R Y R Y R Y R Y R Y R Y R Y R Y B O W B W R B Y B O B Y B Y B O B R W B G G G G G G P P R Y R Y R R B R B G G G B P B B R R B G R G B R Y G B O L O P W G B Y L R R R P P P O O O B Br R R R R Br Br R R Br Br B O B O...

Page 514: ...rature sensor FX Cruiser High Output O Buzzer P Fuel level sensor Q Fuel pump R Thermoswitch engine S Starter motor T Engine temperature sensor U Ignition coil V Spark plug W Rectifier regulator X Battery Y Electric bilge pump Z ECM Slant detection switch Main and fuel pump relay È To tachometer É To entry box Ê FX Cruiser High Output model Color code B Black Br Brown G Green Gy Gray L Blue O Oran...

Page 515: ...YAMAHA MOTOR CORPORATION USA Printed in USA Dec 2005 0 0 1 CR E ...

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