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Yamaha GP1200R WaveRunner 2001, Service Manual

The Yamaha GP1200R WaveRunner 2001 Owner's/Operator's Manual is a comprehensive guide that provides detailed instructions on how to operate and maintain this powerful watercraft. You can conveniently download this manual for free from our website, ensuring that you have all the essential information at your fingertips.

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3-1

INSP

ADJ

 

E

 

MAINTENANCE INTERVAL CHART

MAINTENANCE INTERVAL CHART

 

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

*1: After every ride
*2: Inspect fluid level before every ride
*3: Grease capacity 33.0 ~ 35.0 cm

 

3

 

 (1.11 ~ 1.18 oz.)

*4: Grease capacity 6.0 ~ 8.0 cm

 

3

 

 (0.20 ~ 0.27 oz.)

Item

Remarks

Initial

Every

Refer to 

page

 

10 hours 

(Break-in)

50 hours 

(3 months)

100 hours 

(6 months)

200 hours 

(1 year)

 

CONTROL SYSTEM

Steering cable

Inspect/adjust

3-2

Steering column

Inspect

3-2

Throttle cable

Inspect/adjust

3-3

Carburetor throttle shaft

Inspect/adjust

—

Choke cable

Inspect/adjust

3-4

QSTS cable

Inspect/adjust

3-5

YPVS cable

Inspect/adjust

3-6

FUEL SYSTEM

Fuel tank

Clean

4-9

Fuel filter

Clean/replace

3-7

Fuel line

Inspect

3-7

Trolling speed

Check/adjust

3-8

Carburetor setting

Inspect/adjust

4-16

OIL INJECTION SYSTEM

Oil injection system

Check/clean

4-30

Oil pump cable

Inspect/adjust

4-29

POWER UNIT

Spark plugs

Inspect/clean/adjust

3-9

Cooling-water passage

Inspect/clean

 

*1

 

 

—

Rubber coupling

Inspect

—

ELECTRICAL

Battery

Inspect

 

*2

 

 3-10

JET PUMP UNIT

Impeller

Inspect

3-13

Water inlet strainer

Clean

3-14

Bilge strainer

Clean

3-14

GENERAL

Bolts and nuts

Retighten

—

Drain plugs

Inspect/replace

3-14

Lubrication points

Grease

3-15

Intermediate housing

Grease

 

*3

 

 

 

*4

 

 3-17

Summary of Contents for GP1200R WaveRunner 2001

Page 1: ... LIT186160215 SERVICE MANUAL LIT 18616 02 15 F0X 28197 ZA 11 WaveRunnerGP1200R ...

Page 2: ...may differ in detail from the descriptions and illustrations given in this publica tion 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 GP1200R SERVICE MANUAL 2000 Yamaha Motor Co Ltd 1st Editio...

Page 3: ...revised format the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol e g 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 CR...

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

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 tight ening torque Example Bolt or screw size M10 D 25 mm L 6 Jobs requiring more information such as special tools and technical data a...

Page 6: ...cate the grade of lubricant and the loca tion of lubrication point F Apply YAMALUBE 2 W 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 indicate the grade of the sealing or locking agent and the location of the application point I Apply Gasket Maker J Apply Yamabond 4 Yamaha bond number 4 K Apply LOCT...

Page 7: ...1 SPECIFICATIONS 2 SPEC PERIODIC INSPECTION AND ADJUSTMENT 3 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 GEN INFO INSP ADJ TRBL ANLS A30000 0 ...

Page 8: ...MBER 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 OILS GREASES AND SEALING FLUIDS 1 2 GOOD WORKING PRACTICES 1 3 DISASSEMBLY AND ASSEMBLY 1 4 SPECIAL TOOLS 1 5 MEASURING 1 5 REMOVAL AND INSTALLATION 1 6 ...

Page 9: ...ry l D number F0X 800101 ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the cylinder head Starting serial number 67X 000101 JET PUMP UNIT SERIAL NUMBER The jet pump unit serial number is stamped on a label attached to the intermediate housing Starting serial number 67X 800101 HULL IDENTIFICATION NUMBER H l N The H l N is stamped on a plate attached to the aft deck ...

Page 10: ...N Petroleum vapor is heavier than air and is deadly if inhaled in large quantities Engine exhaust gases are harmful to breathe When test running an engine indoors maintain good ventilation SELF PROTECTION Protect your eyes with suitable safety spec tacles or safety goggles when grinding or doing any operation which may cause parti cles to fly off Protect hands and feet by wearing safety gloves or ...

Page 11: ...oiled rag in your pocket 4 Hands and any other part of the body which have been in contact with lubri cants or lubricant contaminated cloth ing should be thoroughly washed with hot water and soap as soon as practica ble 5 To protect the skin the application of a suitable barrier cream to the hands before working is recommended 6 A supply of clean lint free cloths should be available for wiping pur...

Page 12: ...bling 2 Oil the contact surfaces of moving parts during assembly 3 After assembly check that moving parts operate normally 4 Install bearings with the manufacturer s markings on the side exposed to view and liberally oil the bearings CAUTION Do not spin bearings with compressed air because this will damage their surfaces 5 When installing oil seals apply a light coat of water resistant grease to t...

Page 13: ...0 06760 2 Dial gauge and stand P N YU 03097 YU 01256 90890 01252 3 Pocket tester P N YU 03112 90890 03112 4 Cylinder gauge set P N YU 03017 90890 06759 5 Compression gauge P N YU 33223 90890 03160 6 Digital multimeter P N J 39299 90890 06752 7 Peak voltage adapter P N YU 39991 90890 03169 8 Peak voltage test harness P N YW 06780 90890 06780 9 Spark gap tester P N YM 34487 90890 06754 4 3 1 2 5 6 8...

Page 14: ... bearing attachment jet pump bearing and oil seal P N YB 06112 YB 06196 90890 06614 90890 06653 12 Ball bearing attachment jet pump oil seal P N YB 06156 90890 06634 13 Driver rod intermediate shaft and jet pump P N YB 06071 90890 06606 14 Bearing inner outer race attachment jet pump bearing P N YB 34474 15 Shaft holder intermediate shaft P N YB 06552 90890 06552 16 Bearing outer race attachment i...

Page 15: ...CIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 ENGINE 2 3 JET PUMP UNIT 2 4 HULL AND HOOD 2 4 ELECTRICAL 2 5 TIGHTENING TORQUES 2 7 SPECIFIED TORQUES 2 7 GENERAL TORQUE 2 10 CABLE AND HOSE ROUTING 2 11 ...

Page 16: ... ratio 5 9 1 Intake system Reed valve Carburetor model manufacturer quantity BN44 MIKUNI 3 Enrichment control Choke valve Scavenging system Loop charge Lubrication system Variable oil injection Cooling system Water cooled Starting system Electric starter Ignition system Digital CDI Ignition timing Degree 18 BTDC 24 BTDC Spark plug model manufacturer BR8ES 11 NGK Battery capacity V Ah kC 12 19 68 4...

Page 17: ...BE 2 W oil Using another oil can seriously damage the catalytic converter and other engine components FUEL AND OIL Fuel Regular unleaded gasoline Minimum fuel rating PON 86 RON 90 Oil YAMALUBE 2 W Fuel oil mixing ratio wide open throttle 30 1 Fuel tank capacity R US gal Imp gal 60 15 9 13 2 Fuel tank reserve capacity R US gal Imp gal 10 2 6 2 2 Oil tank capacity R US gal Imp gal 5 5 1 45 1 21 Item...

Page 18: ...1 3 1462 Measuring point mm in 22 0 87 Piston to cylinder clearance mm in 0 100 0 105 0 0039 0 0041 Wear limit mm in Cylinder bore 0 105 0 0041 Piston pin bore inside diameter mm in 22 004 22 025 0 8663 0 8671 PISTON RINGS Top Type Keystone Dimensions B mm in 1 47 1 49 0 058 0 059 Dimensions T mm in 2 8 2 9 0 110 0 114 End gap mm in 0 45 0 60 0 018 0 024 Ring groove clearance mm in 0 03 0 05 0 001...

Page 19: ...tle valve 150 Valve seat size mm in 1 2 0 05 Trolling speed r min 1 350 50 REED VALVES Thickness mm in 0 6 0 024 Reed valve stopper height mm in 10 4 11 0 0 41 0 43 Reed valve warpage limit mm in 0 2 0 01 Item Unit Model GP1200R JET PUMP Impeller material Stainless steel Number of impeller blades 3 Impeller pitch angle Degree 13 5 Impeller clearance mm in 0 35 0 45 0 014 0 018 Impeller clearance l...

Page 20: ...nking 2 V 2 8 2 000 r min V 7 9 3 500 r min V 11 Lighting coil G G Output peak voltage lower limit cranking 1 V 9 cranking 2 V 9 2 000 r min V 14 3 500 r min V 14 Pickup coil resistance Ω color 445 545 W R B O Lighting coil resistance Ω color 0 49 0 59 G G Minimum charging current A r min 9 6 000 IGNITION COIL Minimum spark gap mm in 10 0 39 Primary coil resistance Ω color 0 26 0 36 B W Body Secon...

Page 21: ... unloaded cranking V 7 2 000 r min V 12 6 3 500 r min V 12 6 STARTER MOTOR 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 FUSE Rating V A 12 10 12 20 Item Unit Model GP1200R ...

Page 22: ...xhaust chamber joint exhaust manifold Bolt M10 4 39 3 9 28 271 LT Exhaust chamber stay bracket Bolt M10 2 39 3 9 28 271 LT Exhaust chamber stay cylinder head cylinder 1st Bolt M8 2 15 1 5 11 2nd 35 3 5 25 Exhaust chamber exhaust chamber joint Bolt M10 6 39 3 9 28 271 LT Engine engine mount Bolt M8 4 17 1 7 12 572 LT Exhaust manifold cylinder 1st Bolt M10 10 22 2 2 16 271 LT 2nd 39 3 9 28 1st Nut M...

Page 23: ...7 12 572 LT Intake grate hull Bolt M6 4 7 0 7 5 1 572 LT Nozzle ring nozzle Bolt M8 2 15 1 5 11 271 LT Nozzle deflector nozzle ring Bolt M8 2 15 1 5 11 271 LT Strainer cover impeller duct Bolt M6 4 7 0 7 5 1 572 LT Drive shaft nut drive shaft Nut 1 74 7 4 53 Impeller left hand threads drive shaft Impeller 1 18 1 8 13 572 LT Transom plate hull Nut 4 26 2 6 19 Intermediate housing bulkhead Bolt M8 3...

Page 24: ...eering console cover assembly deck Nut 2 5 0 5 3 6 Bolt M6 4 3 0 3 2 2 Screw M5 2 2 0 2 1 4 Nut M8 2 16 1 6 11 Multifunction meter holder Nut 2 2 0 2 1 4 Steering console cover side cover Screw M6 4 3 0 3 2 2 Steering console cover glove compartment Screw M5 4 1 0 1 0 7 Steering cable bracket deck Bolt M6 3 5 0 5 3 6 Hood lock assembly deck Nut M6 2 5 0 5 3 6 Seat lock assembly seat Bolt M6 2 6 0 ...

Page 25: ...tch Tightening torque specifica tions for special components or assemblies are provided in applicable sections of this manual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached Unless other wise specified tightening torque specifica tions require clean dry threads Components should be at room tempera tu...

Page 26: ... 6 7 8 9 0 1 2 2 3 2 4 5 6 7 1 Fuel filter 2 Fuel breather hose 3 Fuel hose 4 Pilot water hose 5 Bilge hose 6 Speed sensor lead 7 Electrical box lead 8 Starter motor lead 9 Generator lead 0 Battery negative lead A YPVS cable B Pilot water outlet C QSTS cable D Choke cable E Battery F Steering cable G Battery breather hose H Battery positive lead I YPVS servomotor ...

Page 27: ...le 3 Cooling water hose 4 QSTS cable 5 Speed sensor lead 6 Bilge hose 7 Flushing hose 8 Electrical box 9 To stator assembly 0 To water temperature sensor A To cylinder 1 B To cylinder 2 C To cylinder 3 D To meter E To battery positive terminal F To starter motor positive terminal G Battery positive lead H Battery negative lead I Buzzer lead J Battery breather hose K Exhaust temperature sensor ...

Page 28: ... and adjustment 3 4 QSTS cable inspection and adjustment 3 5 YPVS cable adjustment 3 6 FUEL SYSTEM 3 7 Fuel line inspection 3 7 Trolling speed check and adjustment 3 8 OIL INJECTION SYSTEM 3 9 Oil line inspection 3 9 POWER UNIT 3 9 Spark plug inspection 3 9 ELECTRICAL 3 10 Battery inspection 3 10 JET PUMP UNIT 3 13 Impeller inspection 3 13 Water inlet strainer inspection 3 14 Bilge strainer inspec...

Page 29: ...rottle cable Inspect adjust 3 3 Carburetor throttle shaft Inspect adjust Choke cable Inspect adjust 3 4 QSTS cable Inspect adjust 3 5 YPVS cable Inspect adjust 3 6 FUEL SYSTEM Fuel tank Clean 4 9 Fuel filter Clean replace 3 7 Fuel line Inspect 3 7 Trolling speed Check adjust 3 8 Carburetor setting Inspect adjust 4 16 OIL INJECTION SYSTEM Oil injection system Check clean 4 30 Oil pump cable Inspect...

Page 30: ...ck and forth Check the excessive play of the han dlebar Inspection steps Turn the handlebar from lock to lock Measure distances a and b If the difference is not within specifica tion adjust the cable joint Difference of distances a and b Maximum 5 mm 0 2 in 2 Adjust Steering cable joint steering column side Adjustment steps Loosen the locknut 1 Disconnect the steering cable joint 2 from the ball j...

Page 31: ...tle lever free play adjust the trolling speed 1 Measure Throttle lever free play a Out of specification Adjust 2 Adjust Throttle lever free play 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 Nm 0 6 m kgf 4 3 ft lb Throttle lever free play 4 7 mm 0 16 0 28 in Adjustment steps Loosen the locknut 1 Turn the adjuster 2 i...

Page 32: ...hen it is fully opened Check that the inner cable has some slack when the choke lever is com pletely closed Adjustment steps Loosen the locknut 1 Screw the adjuster 2 fully into the bracket Align the choke lever end a within the line marks b Turn out the adjuster 2 until the inner cable is taut NOTE If the inner cable is difficult to make taut using the adjuster 2 adjust the choke lever so that th...

Page 33: ...Adjust QSTS cable Adjustment steps Set the control grip in the neutral posi tion Loosen the locknut 1 Remove the nut 2 and pivot pin 3 Set the jet nozzle in the center posi tion Turn the cable joint 4 for adjusting Turn in Length b is increased Turn out Length a is increased WARNING The cable joint must be screwed in more than 8 mm 0 31 in Connect the cable joint 4 and pivot pin 3 and tighten the ...

Page 34: ...stment 1 Check YPVS valve position Incorrect position Adjust the YPVS cable Checking steps Start the engine and then stop it NOTE When the engine has been stopped for 3 seconds the YPVS valve assembly will extend and retract one time Check that the hole a in the pulley is aligned with the hole in the cylinder when the YPVS valve is fully closed 2 Measure YPVS cable slack a Out of specification Adj...

Page 35: ...hoses through part Fuel filler cap Cracks damage Replace Adjustment steps Loosen locknuts 1 and 2 Turn in the adjuster 3 and 4 until there is slack in the cable Align the hole a in the pulley with the hole in the cylinder Insert a 4 mm diameter pin through the holes in the pulley and cylinder Turn the adjuster 3 and 4 in or out until the specified slack is obtained Turn in Slack is increased Turn ...

Page 36: ...in the water Start the engine and allow it to warm up for several minutes Attach the engine tachometer to the spark plug lead Engine tachometer YU 8036 A 90890 06760 Measure the engine trolling speed 2 Adjust Trolling speed Adjustment steps Start the engine and allow it to warm up for several minutes Attach the engine tachometer to the spark plug lead Engine tachometer YU 8036 A 90890 06760 Turn t...

Page 37: ... 2 Distinctly different color Check the engine condition 2 Clean Spark plug with a spark plug cleaner or wire brush Color guide Medium to light tan color Normal Whitish color Lean fuel mixture Air leak Incorrect settings Blackish color Overly rich mixture Electrical malfunction Excessive oil use Defective spark plug 3 Measure Spark plug gap a Out of specification Regap Spark plug gap 1 0 1 1 mm 0 ...

Page 38: ... of a turn b T R Spark plug 25 Nm 2 5 m kgf 18 ft lb ELECTRICAL Battery inspection WARNING Battery electrolyte is dangerous it contains sulfuric acid which is poisonous and highly caustic Always follow these preventive measures Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury Wear protective eye gear when handling or working near batteries Antidote EXTERNA...

Page 39: ...g batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN CAUTION Do not place the battery on its side Before adding electrolyte or recharging be sure to remove the battery from the battery box Make sure that the battery breather hose is properly connected and is not pinched or damaged 1 Remove Battery WARNING When removing the battery disconnect the negative lead first Remove the batter...

Page 40: ...istilled water When the electrolyte level reaches the upper level mark allow the cell to stand for 20 minutes If the electrolyte level drops add more distilled water so the level reaches the upper level mark 3 Inspect Specific gravity Out of specification Charge Specific gravity at 20 C 68 F 1 28 Charging current 1 9 amps 10 hrs 68 4 kC 4 Install Filler caps CAUTION Before installation rinse off a...

Page 41: ...the terminals with a water resistant grease to minimize terminal corrosion 3 1 2 JET PUMP UNIT Impeller inspection 1 Check Impeller 1 Damage wear Replace Nicks scratches File or grind 2 Measure Impeller to housing clearance a Out of specification Replace Max impeller to housing clearance 0 6 mm 0 02 in Measurement steps Remove the battery leads Remove the intake grate 1 and intake duct 2 Measure t...

Page 42: ...the water inlet strainer mesh a Install the water inlet cover 1 a Bilge strainer inspection 1 Inspect Bilge strainer Contaminants Clean Cracks damage Replace Inspection steps Disconnect the bilge strainer 1 from the bilge strainer holder Inspect the bilge strainer 1 GENERAL Drain plug inspection 1 Inspect Drain plug Cracks damage Replace O ring Cracks wear Replace Screw threads Contaminants Clean ...

Page 43: ...lubricant Rust inhibitor 2 Lubricate QSTS control cables handlebar side 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 Yamaha marine grease Yamaha grease A Water resistant grease 3 Lubricate Choke cable handlebar side Recommended lubricant Rust inhibitor ...

Page 44: ...able QSTS cables pulley side YPVS cables Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease 5 Lubricate Nozzle pivot shaft Steering cable nozzle side QSTS cable nozzle side Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease ...

Page 45: ...ply a small amount of grease Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease 7 Fill Intermediate housing NOTE Fill the intermediate housing with the rec ommended grease through the grease nip ples Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease ...

Page 46: ...FUEL TANK 4 6 EXPLODED DIAGRAM 4 6 REMOVAL AND INSTALLATION CHART 4 6 SERVICE POINTS 4 9 Check valve inspection 4 9 Fuel level switch inspection 4 9 Fuel tank inspection 4 9 Pipe joint inspection 4 9 INTAKE DUCT AND SILENCER 4 10 EXPLODED DIAGRAM 4 10 REMOVAL AND INSTALLATION CHART 4 10 CARBURETOR UNIT 4 12 EXPLODED DIAGRAM 4 12 REMOVAL AND INSTALLATION CHART 4 12 SERVICE POINTS 4 16 Throttle valv...

Page 47: ...Jet and carburetor body inspection 4 22 Carburetor assembly 4 22 FUEL PUMP 4 23 EXPLODED DIAGRAM 4 23 REMOVAL AND INSTALLATION CHART 4 23 SERVICE POINTS 4 25 Fuel pump inspection 4 25 Fuel filter inspection 4 25 OIL PUMP 4 26 EXPLODED DIAGRAM 4 26 REMOVAL AND INSTALLATION CHART 4 26 SERVICE POINTS 4 28 Oil pump inspection 4 28 Oil hose inspection 4 28 Check valve inspection 4 28 Oil pump cable adj...

Page 48: ...VAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points FUEL COCK AND FUEL FILTER REMOVAL Follow the left Step for removal 1 Screw 1 2 Knob 1 3 Nut 1 4 Fuel cock assembly 1 5 Fuel hose 3 6 Holder 1 7 Fuel filter 1 8 Fuel hose 1 Reverse the removal steps for installation ...

Page 49: ...4 2 FUEL E FUEL COCK AND FUEL FILTER SERVICE POINTS Fuel filter inspection Refer to FUEL SYSTEM in chapter 3 Fuel cock inspection 1 Check Fuel cock Contaminants Clean Rough movement Replace ...

Page 50: ...dure Part name Q ty Service points OIL TANK REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT in chapter 5 Steering console cover assembly Refer to STEERING CONSOLE COVER in chapter 8 1 Oil level sensor coupler 1 2 Band 1 3 Nut 1 4 Oil filler neck 1 5 Rubber seal 1 ...

Page 51: ...DIAGRAM Step Procedure Part name Q ty Service points 6 Breather hose 1 7 Oil hose 1 8 Bolt 2 9 Tank belt 2 10 Oil tank assembly 1 11 Hose clamp 1 12 Oil filler hose 1 13 Oil level sensor 1 Reverse the removal steps for installation ...

Page 52: ...aminants Clean Frays tears Replace Rubber seal Cracks wear Replace Oil hose Oil tank Oil filler cap Cracks damage Replace Check valve Malfunction Replace Oil level switch inspection Refer to INDICATION SYSTEM in chapter 7 Oil tank inspection 1 Inspect Oil tank Cracks damage Replace ...

Page 53: ...AND INSTALLATION CHART Step Procedure Part name Q ty Service points FUEL TANK REMOVAL Follow the left Step for removal Oil tank Refer to OIL TANK 1 Fuel level sensor coupler 1 2 Hose clamp 1 3 Nut 1 4 Fuel filler neck 1 5 Rubber seal 1 6 Fuel reserve hose 1 ...

Page 54: ...ED DIAGRAM Step Procedure Part name Q ty Service points 7 Fuel hose 1 8 Fuel return hose 1 Red mark a 9 Fuel breather hose 1 10 Fuel tank assembly 1 11 Hose clamp 1 12 Fuel filler hose 1 13 Hose clamp 1 14 Fuel sensor assembly 1 ...

Page 55: ...LODED DIAGRAM Step Procedure Part name Q ty Service points 15 One way valve 1 16 Screw washer 1 1 17 Filter 1 18 Screw washer 1 1 19 Sleeve 1 20 Floatation 1 21 Bolt 2 22 Tank bolt 2 Reverse the removal steps for installation ...

Page 56: ...pter 7 Fuel tank inspection 1 Inspect Fuel tank Cracks damage Replace Pipe joint inspection 1 Inspect Pipe Contaminants Clean Bends damage Replace Checking steps Connect a hose to the end of check valve A and blow into it Air should come out from end B Connect the hose to the end of check valve B and blow into it Air should not come out from end A A A B B ...

Page 57: ...ty Service points INTAKE DUCT AND SILENCER REMOVAL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY in chapter 5 1 Hose clamp 1 2 Silencer 1 3 Hose clamp 2 4 Joint hose 1 5 Band 1 NOTE Tie the fuel suction hose fuel return hose throttle cable and pilot water hose port side together with the band ...

Page 58: ...ENCER EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Bolt collar grommet 1 1 1 7 Intake duct 1 8 Silencer case 1 9 Bolt 6 10 Spark arrester 1 11 Silencer plate 1 12 O ring 3 Reverse the removal steps for installation ...

Page 59: ...Service points CARBURETOR UNIT REMOVAL Follow the left Step for removal Silencer plate Refer to INTAKE DUCT AND SILENCER 1 Oil pump cable 1 NOTE Before removing the oil pump cable mark the cable s installation position for reference when installing the oil pump cable 2 Throttle cable 1 3 Choke cable 1 4 Fuel suction hose 1 ...

Page 60: ... Part name Q ty Service points 5 Fuel return hose 1 Red mark a 6 Oil delivery hose 3 7 Clamp fuel pump vacuum hose 3 3 8 Remote throttle stop screw 1 9 Bolt 6 10 Bolt 4 11 Carburetor assembly 1 12 Gasket 1 Reverse the removal steps for installation Not reusable ...

Page 61: ...TALLATION CHART Step Procedure Part name Q ty Service points CARBURETOR UNIT SEPARATION Follow the left Step for removal 1 Hose 2 Fuel suction 2 Hose 2 Fuel return 3 Accelerator pump hose 1 4 Remote throttle stop screw assembly 1 5 Throttle link 1 6 Choke link 1 ...

Page 62: ... E CARBURETOR UNIT EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Bolt 3 8 Cable holder 1 9 Bolt 6 10 Carburetor 3 11 Gasket 3 12 Plate 1 Reverse the removal steps for installation Not reusable ...

Page 63: ...rew end from the throttle lever Check the each throttle valve is fully closed 2 Adjust Throttle valve synchronization Adjustment steps Loosen the remote throttle stop screw 1 until untouched the screw end from the throttle lever Loosen the screws 2 NOTE Make sure that the throttle valves are in the fully closed position Tighten the screws 2 T R Screw 2 Nm 0 2 m kgf 1 4 ft lb Turn in the remote thr...

Page 64: ... installation position a 16 18 mm 0 63 0 71 in Throttle cable guide installation position b 18 20 mm 0 71 0 79 in 2 Adjust Throttle lever free play Refer to CONTROL SYSTEM in chapter 3 Oil pump cable installation 1 Adjust Oil pump cable Refer to OIL PUMP Carburetor assembly 1 Adjust Trolling speed Refer to FUEL SYSTEM in chapter 3 ...

Page 65: ... ty Service points CARBURETOR DISASSEMBLY Follow the left Step for disassembly 1 Accelerator pump delivery hose 2 For carburetor 3 2 Accelerator pump fuel hose 1 3 Screw 4 4 Accelerator pump carburetor cover 1 1 Carburetor 3 carburetor 1 and 2 5 Diaphragm 1 6 Screw 2 7 Regulator body 1 8 Gasket 1 9 Main jet 1 ...

Page 66: ...Step Procedure Part name Q ty Service points 10 Pilot jet 1 11 Screw 1 12 Arm 1 13 Arm pin 1 14 Spring 1 15 Screw 1 16 Needle valve seat holder 1 17 Needle valve 1 18 Needle valve seat 1 19 O ring 1 Reverse the disassembly steps for assembly ...

Page 67: ...re Part name Q ty Service points ACCELERATOR PUMP DISASSEMBLY Follow the left Step for disassembly 1 Screw 1 2 Stay 1 3 Spring 1 4 Spring seat 1 5 Screw 4 6 Accelerator pump cover assembly 1 7 Spring 1 8 Diaphragm 1 9 Accelerator pump body 1 Reverse the disassembly steps for assembly ...

Page 68: ...rator pump body inspection 1 Inspect One way valve Crack damage Replace the acceler ator pump body Fuel passage Clog Clean or replace Arm inspection 1 Inspect Arm 1 Bends damage Repair or replace 2 Measure Arm height a NOTE Measure the distance between the surface of the carburetor body b and the top sur face of the arm The arm should be resting on the needle valve but not compressing it Arm heigh...

Page 69: ...an Wear b Replace NOTE Always replace the needle valve and needle valve seat as a set Jet and carburetor body inspection 1 Inspect Main jet Pilot jet Carburetor body Clog contaminants Clean Damage wear Replace CAUTION Do not use a steel wire to clean the jets This may enlarge the jet diameters and seriously affect performance Carburetor assembly 1 Adjust Trolling speed Refer to FUEL SYSTEM in chap...

Page 70: ... AND INSTALLATION CHART Step Procedure Part name Q ty Service points FUEL PUMP DISASSEMBLY Follow the left Step for disassembly Carburetors Refer to CARBURETOR 1 Screw 4 2 Fuel pump cover 1 3 Gasket 1 4 Diaphragm 1 5 O ring 1 6 Diaphragm body 1 Not reusable ...

Page 71: ...4 24 FUEL E FUEL PUMP EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Rubber diaphragm 1 8 Diaphragm 1 9 Packing 1 10 Fuel filter 1 Reverse the disassembly steps for assembly ...

Page 72: ...5 FUEL E FUEL PUMP SERVICE POINTS Fuel pump inspection 1 Inspect Diaphragm Rubber diaphragm Diaphragm body Damage Replace Fuel filter inspection 1 Inspect Fuel filter Clog contaminants Clean Damage Replace ...

Page 73: ... Part name Q ty Service points OIL PUMP REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT in chapter 5 1 Bolt 1 2 Bleed hose stay 1 3 Bolt 2 4 Oil pump assembly 1 5 Gasket 1 6 Oil suction hose 1 7 Oil return hose 1 Reverse the removal steps for installation Not reusable ...

Page 74: ...art name Q ty Service points OIL PUMP HOSES AND CABLE REMOVAL Follow the left Step for removal 1 Bleed hose 1 2 Air bleed screw 1 3 Gasket 1 4 Bleed hose stay 1 5 Oil delivery hose 1 3 6 Oil delivery hose 2 3 7 Check valve 3 8 Oil pump cable 1 Reverse the removal steps for installation ...

Page 75: ...e Replace CAUTION If the oil delivery hoses are not full of oil fill them up After installing the oil injection system bleed the system of any air Check valve inspection 1 Check Check valve Faulty Replace Checking steps Connect a hose to the end of check valve A and blow into it Air should come out from end B Connect the hose to the end of check valve B and blow into it Air should not come out fro...

Page 76: ...pump cable NOTE If the installation position has been marked for reference on the inner cable at the car buretor end while marks a and b are aligned adjusting the cable at the carbure tor end is easier Adjustment steps Loosen the locknut 1 and the adjust ing nut 2 Fully close the carburetor throttle valves Adjust the oil pump cable so that the mark a on the oil pump lever is aligned with the mark ...

Page 77: ...with a locking tie Recommended engine oil YAMALUBE 2 W oil only Loosen the air bleed screw 1 two full turns and make sure that both the oil and air bubbles flow out When there are no air bubbles left tighten the air bleed screw Wipe up any spilt oil T R Air bleed screw 3 Nm 0 3 m kgf 2 2 ft lb CAUTION Do not run the engine if oil does not flow out of the air bleed screw Inspect the oil pump hoses ...

Page 78: ...5 13 Engine mount inspection 5 13 Coupling clearance inspection 5 13 EXHAUST MANIFOLD 5 14 EXPLODED DIAGRAM 5 14 REMOVAL AND INSTALLATION CHART 5 14 REED VALVES 5 16 EXPLODED DIAGRAM 5 16 REMOVAL AND INSTALLATION CHART 5 16 SERVICE POINTS 5 17 Reed valve inspection 5 17 YPVS 5 18 EXPLODED DIAGRAM 5 18 REMOVAL AND INSTALLATION CHART 5 18 SERVICE POINTS 5 21 YPVS valve inspection 5 21 YPVS valve ins...

Page 79: ...ion 5 31 GENERATOR AND STARTER MOTOR 5 33 EXPLODED DIAGRAM 5 33 REMOVAL AND INSTALLATION CHART 5 33 SERVICE POINTS 5 40 Drive coupling removal and installation 5 40 Flywheel magneto removal and installation 5 40 Drive coupling inspection 5 41 Flywheel magneto inspection 5 41 Starter clutch assembly inspection 5 41 CRANKCASE 5 42 EXPLODED DIAGRAM 5 42 REMOVAL AND INSTALLATION CHART 5 42 SERVICE POI...

Page 80: ... HOSES AND LEADS REMOVAL Follow the left Step for removal YPVS servomotor Refer to YPVS SERVOMOTOR in chapter 7 Battery box Refer to BATTERY BOX in chapter 8 1 Spark plug cap 3 2 Exhaust temperature sensor coupler 1 3 Water temperature sensor coupler 1 6 22 mm 12 Nm 1 2 m kgf 8 7 ft Ib 5 LT 242 7 6 7 1 2 3 4 Å MUFFLER ASSEMBLY ...

Page 81: ...ODED DIAGRAM Step Procedure Part name Q ty Service points 4 AC magneto coupler 1 5 Cap bolt 3 3 6 Cover 1 7 Water hose clamp 2 2 Å For cooling water pilot outlet on port side 6 22 mm 12 Nm 1 2 m kgf 8 7 ft Ib 5 LT 242 7 6 7 1 2 3 4 Å ...

Page 82: ...Hose clamp 2 Slide the outer exhaust joint 9 Hose clamp 2 10 Hose clamp 1 11 Water lock band 1 Slide the water lock 12 Bolt 4 13 Intermediate housing grease hose 1 14 Nut 2 15 Eye 2 NOTE Remove the spark plug before removing the eye and reinstall it to make removing the muffler assembly easier ...

Page 83: ... ty Service points 16 Bolt 2 17 Bolt 1 18 Bolt 1 19 Bolt 1 20 Muffler stay 2 1 21 Muffler assembly 1 NOTE Remove the cylinder head if it is difficult to remove the muffler assembly 22 Outer exhaust joint 1 23 Inner exhaust joint 1 Reverse the removal steps for installation ...

Page 84: ...LATION CHART Step Procedure Part name Q ty Service points MUFFLER DISASSEMBLY Follow the left Step for disassembly 1 Exhaust temperature sensor 1 2 Water temperature sensor 1 3 Bolt 2 4 Muffler stay 1 5 Bolt 6 6 Cover 1 7 Gasket 1 8 Catalyst housing 1 Not reusable ...

Page 85: ...ED DIAGRAM Step Procedure Part name Q ty Service points 9 Gasket 1 10 Catalyst 1 11 Gasket 1 12 Pin 2 13 Bolt 6 14 Mixing joint 1 15 Gasket 1 16 Muffler 1 Reverse the disassembly steps for assembly Not reusable Not reusable Not reusable ...

Page 86: ...5 7 POWR E MUFFLER ASSEMBLY SERVICE POINT Catalyst inspection 1 Inspect Catalyst Cracks damage Replace ...

Page 87: ...CHART Step Procedure Part name Q ty Service points EXHAUST CHAMBER ASSEMBLY REMOVAL Follow the left Step for removal Muffler assembly Refer to MUFFLER ASSEMBLY 1 Clamp hose 3 3 Å For cooling water pilot outlet on starboard side 2 Bolt 3 3 Bolt 1 4 Bolt 2 5 Bolt 2 6 Exhaust chamber stay 1 7 Clamp hose 1 1 ...

Page 88: ...Service points 8 Exhaust chamber assembly 1 NOTE Before installing the exhaust chamber assembly install the clamp hose step No 7 and place the bolts step No 2 in the bolts holes of the exhaust chamber assembly 9 Gasket 1 10 Pin 2 Reverse the removal steps for installation Not reusable ...

Page 89: ...INSTALLATION CHART Step Procedure Part name Q ty Service points EXHAUST CHAMBER DISASSEMBLY Follow the left Step for disassembly 1 Bolt 5 2 Bolt 1 3 Exhaust chamber joint 1 4 Gasket 1 5 Pin 2 6 Exhaust chamber 1 Reverse the disassembly steps for assembly Not reusable ...

Page 90: ...s ENGINE UNIT REMOVAL Follow the left Step for removal Carburetor unit Refer to CARBURETOR UNIT in chapter 4 1 Clamp water hose 1 1 Should be white mark a up side 2 Oil suction hose 1 3 Oil return hose 1 4 Multi function meter coupler 3 5 Bolt collar 1 1 LT 572 LT 572 8 40 mm 17 Nm 1 7 m kgf 12 ft Ib 8 3 6 5 6 25 mm 7 1 9 2 4 a ...

Page 91: ...art name Q ty Service points 6 Coupling cover 1 7 Bolt washer 4 4 8 Engine assembly 1 9 Shim Install the shims original position Reverse the removal steps for installation As required LT 572 LT 572 8 40 mm 17 Nm 1 7 m kgf 12 ft Ib 8 3 6 5 6 25 mm 7 1 9 2 4 a ...

Page 92: ...spection 1 Inspect Engine mounts Cracks damage Replace Coupling clearance inspection 1 Measure Clearance a Clearance b with the rubber damper 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 A...

Page 93: ...LLATION CHART Step Procedure Part name Q ty Service points EXHAUST MANIFOLD AND LEADS REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT 1 Bolt 4 2 Bolt 6 3 Nut 2 4 Exhaust manifold 1 5 Gasket 1 6 Pin 2 Reverse the removal steps for installation Not reusable ...

Page 94: ...AL AND INSTALLATION CHART Step Procedure Part name Q ty Service points EXHAUST MANIFOLD DISASSEMBLY Follow the left Step for disassembly 1 Clamp hose 1 1 2 Bolt 6 3 Water pipe 1 4 O ring 3 5 Exhaust manifold 1 Reverse the disassembly steps for assembly ...

Page 95: ...ervice points REED VALVE REMOVAL Follow the left Step for removal Carburetor unit Refer to CARBURETOR UNIT in chapter 4 1 Bolt 18 NOTE Tighten the bolts in the proper sequence as shown 2 Reed valve plate 1 3 Reed valve assembly 3 4 Screw 24 5 Valve stopper 6 6 Reed valve 6 Reverse the removal steps for installation ...

Page 96: ...ction 1 Inspect Reed valves Cracks damage Replace 2 Measure Valve bending a Out of specification Replace 3 Measure Valve stopper height b Out of specification Adjust or replace Max valve bending 0 2 mm 0 01 in Valve stopper height 10 4 11 0 mm 0 41 0 43 in ...

Page 97: ...ART Step Procedure Part name Q ty Service points YPVS REMOVAL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY 1 Bolt 12 2 YPVS valve cover 3 3 Gasket 3 4 Spacer 2 5 Link joint cover 2 2 6 Circlip 5 Not reusable Not reusable ...

Page 98: ...VS EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Washer 5 8 Bolt 3 NOTE During installation align the hole a in the YPVS shaft with the bolt 9 Shaft 3 1 10 Shaft 2 1 11 Shaft 1 1 12 YPVS valve arm 3 ...

Page 99: ... EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 13 Bolt 3 14 YPVS valve assembly 3 15 Oil seal 6 NOTE If the YPVS shaft is removed the oil seal must be replaced Reverse the removal steps for installation ...

Page 100: ...Carbon deposits with a rounded scraper 1 CAUTION Do not use a sharp instrument to avoid damaging or scratching the surfaces 2 Inspect YPVS valve assembly Crack damage wear Replace YPVS valve installation 1 Install Oil seal Distance a 1 0 1 5 mm 0 04 0 06 in YPVS ...

Page 101: ...rt name Q ty Service points CYLINDER HEAD REMOVAL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY 1 Spark plug 3 2 Bolt 1 NOTE Tighten the bolts in the proper sequence as shown and in three stages No 23 24 in two stages 3 Ground lead 1 4 Bolt 2 5 Bolt 6 6 Bolt 16 ...

Page 102: ... EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Cylinder head cover 1 8 Gasket 1 9 Cylinder head 1 10 Gasket 1 11 Clamp hose 2 2 a white mark Reverse the removal steps for installation Not reusable Not reusable ...

Page 103: ...cylinder head or spark plug bore threads 2 Inspect Cylinder head water jacket Corrosion mineral deposits Clean or replace 3 Measure Cylinder head warpage with a straightedge and thickness gauge Out of specification score marks Resurface NOTE Place a 400 600 grit wet sandpaper on a surface plate and resurface the cylinder head using a figure eight sanding pattern Warpage limit 0 1 mm 0 004 in ...

Page 104: ...points CYLINDER REMOVAL Follow the left Step for removal YPVS Refer to YPVS Cylinder head Refer to CYLINDER HEAD 1 Bolt 12 NOTE Tighten the bolts in a crisscross pattern and in two stages 2 Cylinder 3 NOTE Install the original position 3 Cylinder gasket 3 4 Pin 6 Reverse the removal steps for installation Not reusable ...

Page 105: ... D with a cylinder gauge Out of specification Replace cylin der and piston as a set NOTE Measure the cylinder bore in parallel and at a right angle to the crankshaft Then aver age the measurements Standard Limit Cylinder bore D 80 000 80 018 mm 3 1496 3 1503 in Original cylinder bore 0 04 mm 0 0016 in Taper T 0 08 mm 0 003 in Out of round R 0 05 mm 0 002 in D Maximum D1 D6 T Maximum D1 or D2 Maxim...

Page 106: ...t name Q ty Service points PISTON REMOVAL Follow the left Step for removal Cylinders Refer to CYLINDERS 1 Piston pin clip 2 CAUTION Do not align the open end of the clip with the piston pin slot a 2 Piston pin 1 3 Piston 1 NOTE Make sure that the arrow b faces towards the exhaust side 4 Washer 2 ...

Page 107: ...POWR E PISTONS EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 5 Bearing 1 6 Piston ring 2 CAUTION Align each end gap with its respective locating pin Reverse the removal steps for installation ...

Page 108: ...ston pin clip from falling into the crankcase Piston inspection 1 Eliminate Carbon deposits from the piston crown and piston ring gloves 2 Inspect Piston wall Score marks Repair with 600 800 grit wet sandpaper or replace NOTE Lightly sand the piston wall in a crisscross pattern 3 Measure Piston skirt diameter with a micrometer Out of specification Replace Piston diameter Distance a 79 899 79 914 m...

Page 109: ...ws NOTE New cylinder bore size 80 000 a 1 000 Example a 12 80 012 mm PISTON CLEARANCE CYLINDER BORE PISTON DIAMETER Piston to cylinder clearance 0 100 0 105 mm 0 0039 0 0041 in Cylinder size indication a Piston color mark 0 5 Red 6 10 Orange 11 15 Green 16 18 Purple Piston ring inspection 1 Measure Side clearance with a thickness gauge 1 Out of specification Replace the piston and piston rings as ...

Page 110: ... in Piston pin and bearing inspection 1 Inspect Piston pins Bearings Signs of heat discoloration Replace 2 Measure Piston pin outside diameter with a micrometer 1 Out of specification Replace Piston pin outside diameter Standard 21 995 22 000 mm 0 8659 0 8661 in Limit 21 990 mm 0 8657 in 3 Check Piston pin to piston free play with the piston pin in the piston as shown Free play Replace the piston ...

Page 111: ...32 POWR E PISTONS 4 Check Piston pin to connecting rod free play with the piston pin in the small end of the connecting rod as shown Free play small end wear Replace the piston pin connecting rod or both ...

Page 112: ...R MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points GENERATOR COVER REMOVAL Follow the left Step for removal Oil pump Refer to OIL PUMP in chapter 4 1 Bolt 1 2 Bolt 7 3 Ground lead 1 4 Generator cover 1 5 Washer 2 ...

Page 113: ...4 POWR E GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Spring 1 7 Packing 1 8 Pin 2 9 Bolt 2 10 Bolt 2 11 Bracket 1 Reverse the removal steps for installation ...

Page 114: ...EMOVAL Follow the left Step for removal 1 Bolt 3 NOTE This washer holds the pickup coil lead Make sure to not pinch the lead between the projection and the washer when installing the bolt 2 Washer 1 3 Cable holder 1 4 Bolt 2 5 Pickup coil 1 6 Bolt 3 7 Stator coil 1 Reverse the removal steps for installation GENERATOR AND STARTER MOTOR ...

Page 115: ...ATION CHART Step Procedure Part name Q ty Service points GENERATOR ROTOR AND STARTER MOTOR REMOVAL Follow the left Step for removal 1 Drive coupling 1 2 Flywheel magneto bolt 1 3 Flywheel magneto 1 4 Woodruff key 1 5 Starter clutch assembly 1 6 Bolt 2 7 Battery negative lead 1 ...

Page 116: ... 37 POWR E GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Nut washer 1 1 9 Starter motor lead 1 10 Starter motor 1 Reverse the removal steps for installation ...

Page 117: ... DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points STARTER CLUTCH DISASSEMBLY Follow the left Step for disassembly 1 Clip 1 2 Clip stopper 1 3 Spring seat 1 4 Spring 1 5 Idle gear 1 6 Circlip 1 7 Plate 1 Not reusable ...

Page 118: ...5 39 POWR E GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Weight 3 9 Spring ring 1 10 Pinion gear 1 Reverse the disassembly steps for assembly ...

Page 119: ...and installation 1 Remove Flywheel magneto bolt NOTE Install the bolt with the same special tool that was used for removal 2 Remove Generator rotor Å For USA and Canada ı For worldwide CAUTION To prevent damage to the engine or tools screw in the flywheel puller set bolts evenly and completely so that the puller plate is parallel to the generator rotor Flywheel holder YW 06550 90890 06550 Flywheel...

Page 120: ... Inspect Drive coupling Damage wear Replace Flywheel magneto inspection 1 Inspect Ring gear Damage wear Replace Starter clutch assembly inspection 1 Inspect Pinion gear 1 Idle gear 2 Damage wear Replace 2 Check Gear movement Rough movement Replace the defective part s ...

Page 121: ...ION CHART Step Procedure Part name Q ty Service points CRANKCASE DISASSEMBLY Follow the left Step for disassembly Pistons Refer to PISTONS Generator cover and starter motor Refer to GENERATOR AND STARTER MOTOR 1 Bolt 6 2 Mount bracket 2 3 Pin 4 4 Bolt 3 5 Bolt 1 6 Bolt 6 ...

Page 122: ...DIAGRAM Step Procedure Part name Q ty Service points 7 Bolt 1 NOTE Tighten the bolts in sequence as shown 8 Bolt 16 9 Lower crankcase 1 10 Pin 2 11 Crankshaft assembly 1 12 Upper crankcase 1 Reverse the disassembly steps for assembly ...

Page 123: ...e crankcase Crankcase Cracks damage Replace Crankcase installation 1 Apply Gasket Maker onto the crankcase mating surfaces NOTE Before applying Gasket Maker clean the crankcase mating surfaces 2 Check Crankshaft Rough movement Recheck NOTE Make sure that the crankshaft rotates smoothly after installing it ...

Page 124: ...e Part name Q ty Service points CRANKSHAFT REMOVAL Follow the left Step for removal Crankcase Refer to CRANKCASE 1 Oil seal 1 2 Bearing 1 3 Oil seal 2 4 Crankshaft assembly 1 CAUTION Install the bearing locating pins into the gloves in the crankcase body Reverse the removal steps for installation ...

Page 125: ... Deflection B with a dial gauge Out of specification Replace Max deflection B 0 05 mm 0 002 in C 0 15 mm 0 006 in 3 Measure Big end side clearance D with a thickness gauge Out of specification Replace Big end side clearance 0 25 0 75 mm 0 010 0 030 in 4 Measure Small end free play E with a dial gauge Out of specification Replace Small end free play 2 0 mm 0 08 in ...

Page 126: ...CRANKSHAFT 5 Inspect Bearings Damage pitting Replace NOTE Before inspection thoroughly clean the bearings Immediately after inspection lubricate the bearings to prevent rust 6 Inspect Oil seals Damage wear Replace ...

Page 127: ...6 9 Impeller inspection 6 10 Drive shaft inspection 6 10 Drive shaft installation 6 10 TRANSOM PLATE AND HOSES 6 13 EXPLODED DIAGRAM 6 13 REMOVAL AND INSTALLATION CHART 6 13 SERVICE POINTS 6 15 Bilge strainer inspection 6 15 Bilge hose inspection 6 15 BEARING HOUSING 6 16 EXPLODED DIAGRAM 6 16 REMOVAL AND INSTALLATION CHART 6 16 SERVICE POINTS 6 19 Driven coupling removal and installation 6 19 Int...

Page 128: ...LLATION CHART Step Procedure Part name Q ty Service points JET PUMP UNIT REMOVAL Follow the left Step for removal 1 Bolt 2 2 Bolt 2 3 Intake grate 1 4 Bolt 4 5 Intake duct 1 6 Screw 4 7 Speed sensor 1 NOTE Route the speed sensor lead between the jet pump unit and the bilge hose ...

Page 129: ...PUMP UNIT EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Bolt 4 9 Ride plate 1 10 QSTS cable joint 1 11 Bilge hose 1 12 Nut washer 1 2 13 Steering cable joint 1 14 Clamp spout hose 1 1 15 Bolt 1 16 Bolt 4 ...

Page 130: ...name Q ty Service points 17 Jet pump unit assembly 1 NOTE Pull the jet pump unit straight back When installing the jet pump unit align the drive shaft spline male with the intermediate drive shaft spline female 18 Dowel pin 2 Reverse the removal steps for installation ...

Page 131: ...OVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points NOZZLE DEFLECTOR AND NOZZLE RING REMOVAL Follow the left Step for removal Jet pump unit Refer to JET PUMP UNIT 1 Bolt 2 2 Collar 2 3 Nozzle deflector 1 4 Bolt 2 5 Collar 2 6 Nozzle ring 1 Reverse the removal steps for installation ...

Page 132: ...STALLATION CHART Step Procedure Part name Q ty Service points IMPELLER DUCT AND IMPELLER HOUSING REMOVAL Follow the left Step for removal Nozzle ring Refer to NOZZLE DEFLECTOR AND NOZZLE RING 1 Bolt 4 2 Nozzle 1 NOTE Clean the matching surfaces before applying the Gasket Maker 3 Pin 2 4 Impeller duct assembly 1 5 Impeller housing 1 6 Pin 2 ...

Page 133: ... DUCT IMPELLER HOUSING AND INTAKE DUCT EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Bolt 4 8 Water inlet cover 1 9 Packing 1 10 Water inlet strainer 1 11 Packing 1 Reverse the removal steps for installation ...

Page 134: ...PLODED DIAGRAM 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 3 4 Cap 1 5 O ring 1 6 Nut 1 7 Washer 1 ...

Page 135: ...AGRAM 1 EPNOC 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 Reverse the disassembly steps for assembly Not reusable Not reusable Not reusable Not reusable ...

Page 136: ... it 2 Remove Nut 1 Drive shaft holder YB 06151 90890 06519 Drive shaft holder YB 06151 90890 06519 3 Remove Drive shaft 1 NOTE Remove the drive shaft with a press 4 Remove Rear bearing Å For USA and Canada ı For worldwide Slide hammer set YB 06096 Stopper guide plate 90890 06501 Bearing puller 90890 06535 Bearing puller claw 1 90890 06536 Stopper guide stand 90890 06538 Å ı ...

Page 137: ... Refer to JET PUMP UNIT in chapter 3 Drive shaft inspection 1 Inspect Drive shaft Damage wear Replace Driver rod L3 YB 06071 90890 06652 Needle bearing attachment YB 06112 90890 06614 Driver rod L3 YB 06071 90890 06652 Needle bearing attachment YB 06196 90890 06653 Drive shaft installation 1 Install Oil seal Driver rod YB 06071 90890 06606 Ball bearing attachment YB 06156 90890 06634 ...

Page 138: ... socket 4 Add EPNOC grease AP 0 between the drive shaft and spacer Distance a 23 0 1 mm 0 91 0 004 in Quantity Approximately 1 3 of capacity a 5 Install Rear bearing NOTE Press the bearing inner outer race at the same time holding the drive shaft and impeller duct If a bearing inner outer race attachment is not available use a washer or pipe with an outer diameter of 46 mm 1 81 in and an inner dia...

Page 139: ...6 12 E JET PUMP IMPELLER DUCT AND DRIVE SHAFT 6 Add EPNOC grease AP 0 into the cap Quantity Approximately 1 3 of capacity 7 Install Nut Impeller Drive shaft holder YB 06151 90890 06519 ...

Page 140: ...tep Procedure Part name Q ty Service points TRANSOM PLATE AND HOSES REMOVAL Follow the left Step for removal Exhaust system Refer to EXHAUST SYSTEM in chapter 8 Jet pump unit Refer to JET PUMP UNIT 1 Hose clamp 3 2 Hose 1 Cooling water outlet 3 Bilge hose 1 1 NOTE Route the bilge hose 1 under the drive shaft tube ...

Page 141: ...ODED DIAGRAM Step Procedure Part name Q ty Service points 4 Hose 1 Cooling water inlet 5 Nut washer 4 4 6 Transom plate 1 7 Clamp bilge hose 2 1 1 8 Screw 1 9 Bilge strainer holder 1 10 Bilge strainer 1 Reverse the removal steps for installation ...

Page 142: ...6 15 E JET PUMP TRANSOM PLATE AND HOSES SERVICE POINTS Bilge strainer inspection Refer to JET PUMP UNIT in chapter 3 Bilge hose inspection 1 Inspect Bilge hose Cracks damage wear Replace ...

Page 143: ...rt 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 As required ...

Page 144: ...ND INSTALLATION CHART Step Procedure Part name Q ty Service points BEARING HOUSING DISASSEMBLY Follow the left Step for disassembly 1 Grease hose 1 2 Grease nipple 1 3 Grease nipple stay 1 4 Nipple 2 5 Driven coupling 1 6 Washer 1 7 Intermediate drive shaft 1 ...

Page 145: ...D DIAGRAM Step Procedure Part name Q ty Service points 8 O ring 2 9 Oil seal 1 10 Oil seal 1 11 Oil seal 1 12 Circlip 1 13 Bearing 1 14 Circlip 1 Reverse the disassembly steps for assembly Not reusable Not reusable Not reusable Not reusable ...

Page 146: ...ven cou pling shaft Bearing removal 1 Remove Bearing NOTE Install the bearing with the same special tools that were used for removal Support the intermediate housing with steel blocks 1 and press the bearing Coupler wrench YW 06551 90890 06551 Shaft holder YB 06552 90890 06552 Removal steps Temporarily install the driven coupling to the intermediate drive shaft Insert the long rod to the driven co...

Page 147: ...ection 1 Inspect Driven coupling Driven coupling damper Damage wear Replace Bearing installation 1 Install Circlip rear 2 Install Bearing Oil seal installation 1 Install Oil seal NOTE Before installing the oil seal lubricate the clip glove with water resistant grease Driver rod YB 06071 90890 06606 Bearing outer race attachment YB 06016 90890 06626 Driver rod YB 06071 90890 06606 Bearing outer rac...

Page 148: ...n Distance b 1 6 2 0 mm 0 06 0 08 in Intermediate housing installation 1 Install Intermediate housing Shim NOTE Install the shim s to the original position if the intermediate housing is not replaced Installation steps Install the intermediate housing Measure the clearance a at each bolt hole Install the suitable shim from the table below Clearance a Shim thickness 0 0 2 mm 0 0 008 in No need 0 3 ...

Page 149: ...ITION SPARK GAP 7 11 IGNITION SYSTEM PEAK VOLTAGE 7 12 BATTERY 7 14 FUSE 7 14 SPARK PLUGS 7 14 SPARK PLUG LEAD ASSEMBLY 7 14 IGNITION COIL 7 15 ENGINE STOP SWITCH 7 15 WATER TEMPERATURE SENSOR 7 16 EXHAUST TEMPERATURE SENSOR 7 16 STARTING SYSTEM 7 17 WIRING DIAGRAM 7 17 BATTERY 7 18 WIRING CONNECTIONS 7 18 FUSE 7 18 STARTER SWITCH 7 19 STARTER RELAY 7 19 STARTER MOTOR 7 20 EXPLODED DIAGRAM 7 20 RE...

Page 150: ...d installation 7 30 YPVS cable inspection 7 30 YPVS servomotor inspection 7 30 YPVS cable adjustment 7 31 INDICATION SYSTEM 7 32 WIRING DIAGRAM 7 32 FUSE 7 33 BATTERY 7 33 LIGHTING COIL 7 33 RECTIFIER REGULATOR 7 33 CDI UNIT 7 33 WATER TEMPERATURE SENSOR 7 33 EXHAUST TEMPERATURE SENSOR 7 33 BUZZER 7 33 OIL LEVEL SENSOR 7 33 FUEL LEVEL SENSOR 7 34 MULTI FUNCTION METER 7 34 Multi function meter 7 34...

Page 151: ... level sensor 3 Multi function meter 4 YPVS servomotor 5 Spark plugs 6 Exhaust temperature sensor 7 Electrical box 8 Speed sensor 9 Battery 0 Water temperature sensor A Starter motor B Stator coil and pickup coil C Engine stop switch engine stop lanyard switch and starter switch D Oil level sensor ...

Page 152: ... name Q ty Service points ELECTRICAL BOX REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT in chapter 5 Battery negative lead Starter motor lead Refer to GENERATOR AND STARTER MOTOR in chapter 5 1 Nut washer 4 4 2 Bracket 2 3 Electrical box 1 Reverse the removal steps for installation ...

Page 153: ...Part name Q ty Service points ELECTRICAL BOX DISASSEMBLY Follow the left Step for disassembly 1 Clamp 5 2 Coupler 3 For water exhaust temperature sensor and lighting coil 3 Screw 2 4 Rectifier regulator 1 5 Screw 10 6 Cover 1 7 Packing 1 8 Spark plug lead holder 3 9 Screw 6 10 Ground lead 3 ...

Page 154: ... name Q ty Service points 11 Ignition coil 3 12 Ignition coil lead 3 13 Spark plug lead cap 3 3 14 Bolt 3 15 Ground lead 6 16 Lead 3 Black orange 17 Nut 2 18 Starter motor lead 1 19 Battery positive lead 1 20 Fuse lead 1 21 Starter relay lead 1 22 Starter relay 1 ...

Page 155: ...tep Procedure Part name Q ty Service points 23 Lead holder 1 24 Fuse lead 5 25 Screw 2 26 Fuse holder 1 27 Lead coupler 1 6 28 Screw 2 29 Coupler bracket 1 30 CDI unit 1 31 Screw 8 32 Lead holder plate 2 Reverse the disassembly steps for assembly ...

Page 156: ...y positive terminal ı To starter motor Ç Affix the ignition coil connector to the electrical box holder Î Pass the 8 pin coupler leads behind the CDI unit and insert them into the bracket Br Brown G Green Gy Gray O Orange R Red W White B O Black orange B W Black white B Y Black yellow Gy B Gray black Gy R Gray red Gy Y Gray yellow R W Red white R Y Red yellow ...

Page 157: ...nstrument powered by dry batter ies check the battery s voltage periodi cally and replace the batteries if necessary Digital circuit tester NOTE Throughout this chapter the digital circuit tester s part number has been omitted Refer to the following part number NOTE indicates a continuity of electric ity i e a closed circuit at the respective switch position Digital circuit tester J 39299 90890 06...

Page 158: ... NOTE When checking the condition of the igni tion system it is vital to know the peak voltage Cranking speed is dependant on many factors e g fouled or weak spark plugs a weak battery If one of these is defected the peak voltage will be lower than speci fication If the peak voltage measurement is not within specification the engine will not operate properly A low peak voltage will also cause comp...

Page 159: ...ow ing tests Å Voltage measurement ı Peak voltage measurement Å ı Test harness NOTE Make sure the output lead red lead of the rectifier regulator is disconnected when measuring the peak voltage of the lighting coil and rectifier regulator If the lighting coil and pickup coil s are measured unloaded disconnect the test harness on the output side coupler YW 90890 Pin Usage 06780 06780 6 Pickup coil ...

Page 160: ...ine stop lanyard switch 3 Lighting coil 4 Pickup coil 5 CDI unit 6 Ignition coil 7 Spark plug 8 Fuse 20A 9 Battery 0 Rectifier regulator A Exhaust temperature sensor B Water temperature sensor B Black O Orange R Red W White B O Black orange B W Black white B Y Black yellow W R White red ...

Page 161: ...mmable gas or liquids away since this test can produce sparks 1 Check Ignition spark gap Below specification Check the CDI unit output peak voltage Check the ignition coil for resistance Å For USA and Canada ı For worldwide Spark gap 10 mm 0 39 in Checking steps Connect the spark plug cap to the spark gap tester Set the spark gap length on the adjust ing knob Spark gap tester YM 34487 90890 06754 ...

Page 162: ...is obtained the problem is not with the ignition system but possibly with the spark plug s or another compo nent 1 Measure CDI unit output peak voltage Below specification Measure the rectifier regulator output peak volt age Replace the CDI unit NOTE B O B for cylinder 1 B W B for cylinder 2 B Y B for cylinder 3 CDI unit output peak voltage Black orange B O Black B Black white B W Black B Black ye...

Page 163: ...ation Replace the lighting coil NOTE Make sure the output lead red lead of the rectifier regulator is disconnected when measuring the output peak voltage The starter motor will not operate when the test harness on the output side cou pler is disconnected to measure the unloaded peak voltage for the lighting coil Therefore connect the black lead of the test harness to the ground with a lead Pickup ...

Page 164: ... voltage Rectifier regulator output peak voltage Red R Black B r min Unloaded Cranking 2 000 3 500 V 7 12 6 12 6 BATTERY Refer to ELECTRICAL in chapter 3 FUSE Refer to STARTING SYSTEM SPARK PLUGS Refer to ELECTRICAL in chapter 3 SPARK PLUG LEAD ASSEMBLY 1 Inspect Spark plug lead assembly Cracks damage Replace 2 Measure Spark plug lead resistance Out of specification Replace Spark plug lead resista...

Page 165: ...tance measurement Primary coil resistance Black white B W Body 0 26 0 36 Ω at 20 C 68 F 2 Measure Secondary coil resistance Out of specification Replace Secondary coil resistance Black white B W Spark plug lead terminal 3 5 4 7 kΩ at 20 C 68 F ENGINE STOP SWITCH 1 Check Engine stop switch continuity Out of specification Replace Engine stop switch continuity black coupler Lock plate Position Lead c...

Page 166: ...r temperature sen sor in a container filled with oil Slowly heat the oil Measure the resistance when the spec ified temperature is reached EXHAUST TEMPERATURE SENSOR 1 Measure Exhaust temperature sensor resis tance at the specified temperature Out of specification Replace Exhaust temperature sensor resistance 300 C 572 F 73 241 kΩ 600 C 1 112 F 0 86 1 58 kΩ 900 C 1 652 F 64 90 Ω Measurement steps ...

Page 167: ...LEC STARTING SYSTEM STARTING SYSTEM WIRING DIAGRAM 1 CDI unit 2 Engine stop lanyard switch 3 Starter switch 4 Fuse 10A 5 Fuse 20A 6 Starter relay 7 Starter motor 8 Battery B Black Br Brown R Red R Y Red yellow ...

Page 168: ...operly connect FUSE 1 Check Fuse holder continuity No continuity Check the fuse or replace the fuse holder Fuse holder continuity Between 1 and 2 Between 2 and 3 2 Check Fuse broken Broken Replace NOTE 20A fuse is for CDI unit and rectifier regula tor 10A fuse is for multi function meter YPVS motor and start switch Fuse rating 10A 20A ...

Page 169: ...ad terminal Black lead terminal Loose Tighten 2 Check Starter relay Faulty Replace Checking steps Connect the tester leads between the starter relay terminals as shown Connect the brown lead terminal to the positive battery terminal Connect the black lead terminal to the negative battery terminal Check that there is continuity between the starter relay terminals Check that there is no continuity a...

Page 170: ...t 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 As required Not reusable Not reusable ...

Page 171: ...t 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 As required Not reusable Not reusable ...

Page 172: ...7 22 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 173: ...t Clean with 600 grit sandpaper 3 Measure Commutator diameter Out of specification Replace Min commutator diameter 27 0 mm 1 06 in 4 Check Commutator undercut Contaminants Clean NOTE Remove all mica and metal particles with compressed air 5 Measure Commutator undercut Out of specification Replace Min commutator undercut 0 2 mm 0 01 in ...

Page 174: ...ent Armature shaft No continuity Brush holder inspection 1 Measure Brush length a Out of specification Replace Min brush length 6 5 mm 0 26 in 2 Check Brush holder continuity Out of specification Replace Brush holder continuity Brush holder Base No continuity Starter motor front cover inspection 1 Inspect Starter motor front cover bushing Damage wear Replace the starter motor front cover ...

Page 175: ...7 25 E ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM 1 Lighting coil 2 Battery 3 Fuse 20A 4 Rectifier regulator B Black G Green R Red G W Green white ...

Page 176: ...7 26 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 177: ...VS YPVS WIRING DIAGRAM 1 Lighting coil 2 Pickup coil 3 CDI unit 4 YPVS servomotor 5 Fuse 10A 6 Fuse 20A 7 Battery 8 Rectifier regulator B Black Gy Gray R Red B O Black orange R L Red blue R W Red white W R White red ...

Page 178: ...E Refer to STARTING SYSTEM BATTERY Refer to ELECTRICAL in chapter 3 PICKUP COIL Refer to IGNITION SYSTEM CDI UNIT Refer to IGNITION SYSTEM LIGHTING COIL Refer to IGNITION SYSTEM RECTIFIER REGULATOR Refer to IGNITION SYSTEM ...

Page 179: ...rvice points YPVS SERVOMOTOR REMOVAL Follow the left Step for removal 1 Bolt 2 2 Cable holder 1 3 YPVS servomotor coupler 1 4 Nut washer 2 2 5 YPVS servomotor 1 6 YPVS cable 2 Slide the cover White paint mark a is for No 2 cable 7 Cover 1 8 Nut washer 3 3 9 YPVS servomotor bracket 1 Reverse the removal steps for installation ...

Page 180: ...from the both drams YPVS cable inspection 1 Inspect YPVS cables 1 and 2 Frays kinks rough movement Replace YPVS servomotor inspection 1 Check YPVS servomotor YPVS servomotor does not move Replace Checking steps Connect the battery 12 V to the YPVS servomotor coupler as shown Battery positive terminal Red R terminal 1 Battery negative terminal Black B terminal 2 Install a jumper lead 4 between the ...

Page 181: ...VS servomotor unit It is a sealed unit and if it is faulty it must be replaced YPVS cable adjustment Refer to CONTROL SYSTEM in chapter 3 Make sure the servomotor operates properly NOTE Make sure the pulley operates three sec onds after the jumper lead is removed ...

Page 182: ...gine stop lanyard switch 8 Starter switch 9 Battery 0 Fuse 10A A Fuse 20A B Exhausttemperature sensor C Water temperature sensor B Black Br Brown Ch Chocolate G Green Gy Gray L Blue O Orange R Red W White Y Yellow B O Black orange B Y Black yellow Gy B Gray black Gy R Gray red Gy Y Gray yellow L B Blue black L R Blue red R W Red white R Y Red yellow W L White blue ...

Page 183: ...OR Refer to IGNITION SYSTEM EXHAUST TEMPERATURE SENSOR Refer to IGNITION SYSTEM BUZZER 1 Check Buzzer Buzzer does not sound Replace OIL LEVEL SENSOR 1 Measure Oil level sensor resistance Out of specification 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 Blue L Black B Float posi...

Page 184: ...Black B Float position Resistance Ω A 757 803 B 0 8 MULTI FUNCTION METER Multi function meter 1 Check Multi function meter Cracked meter housing Replace the multi function meter Meter is fogged shows signs of water intrusion Replace the multi func tion meter MULTI FUNCTION METER REMOVAL Refer to STEERING CONSOLE COVER in chapter 8 ...

Page 185: ...rate Replace the multi function meter 1 Oil level sensor 2 Fuel level sensor 3 Buzzer 4 Battery 5 Start switch 6 Speed sensor B Black Ch Chocolate G Green L Blue R Red Y Yellow Gy B Gray black Gy R Gray red Gy Y Gray yellow L B Blue black L R Blue red R W Red white W L White blue ...

Page 186: ...inals with a jumper lead 2 NOTE If the jumper lead is installed for more than 30 seconds the display will auto matically turn off Check the fuel level segments is full indicated Remove the jumper lead 1 from the green two pin connector Disconnect the jumper lead 2 and then connect it to green and red ter minal again Make sure the fuel level segment 3 fuel symbol 4 and WARNING lamp 5 blinks and the...

Page 187: ...black terminals with a jumper lead 1 Connect the green and red terminals with a jumper lead 2 NOTE If the jumper lead is installed for more than 30 seconds the display will auto matically turn off Remove the jumper lead 1 from the white two pin connector Disconnect the jumper lead 2 and then connect it to green and red ter minal again Make sure the oil symbol 3 and WARNING lamp 4 blinks and the bu...

Page 188: ...n and red terminals with a jumper lead 2 Make sure the water temperature sym bol 3 and WARNING lamp 4 blinks and the buzzer sounds intermit tently WARNING YAMAHA 8 7 6 5 4 3 2 1 MPH FUEL HOUR x1000r min MULTI D SPLAY 4 3 2 Check Overheat 2 warning indicator Not operating Replace the multi function meter Checking steps Supply DC 12 voltage to the natural color six pin connector red black with a bat...

Page 189: ...tor Not operating Replace the multi function meter Checking steps Supply DC 12 voltage to the natural color six pin connector red black with a battery Connect the gray yellow and black ter minals with a jumper lead 1 Connect the green and red terminals with a jumper lead 2 Make sure the exhaust temperature symbol 3 and WARNING lamp 4 blinks and the buzzer sounds intermit tently WARNING YAMAHA 8 7 ...

Page 190: ... with a jumper lead 1 Measure the voltage on the speed sen sor connector white color three pin connector between the red white and black leads Speed sensor output voltage dependant on the paddle wheel position Less than 400 mV More than 11 6 V Output pulse 2 pulses one full turn Checking steps Apply DC 12 voltage to the white color three pin connector between the red yellow and black yellow leads ...

Page 191: ...GRAM 8 13 REMOVAL AND INSTALLATION CHART 8 13 SERVICE POINTS 8 16 Steering column bushing inspection 8 16 REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 8 17 EXPLODED DIAGRAM 8 17 REMOVAL AND INSTALLATION CHART 8 17 SERVICE POINTS 8 19 Remote control cables inspection 8 19 Steering cable jet pump side installation 8 19 Steering cable stopper installation 8 19 QSTS cable jet pump side installation 8 2...

Page 192: ... inspection 8 35 BATTERY BOX 8 36 EXPLODED DIAGRAM 8 36 REMOVAL AND INSTALLATION CHART 8 36 EXHAUST SYSTEM 8 38 EXPLODED DIAGRAM 8 38 REMOVAL AND INSTALLATION CHART 8 38 SERVICE POINTS 8 40 Exhaust system inspection 8 40 Exhaust component parts sub assembly 8 40 DECK AND HULL 8 41 EXPLODED DIAGRAM 8 41 REMOVAL AND INSTALLATION CHART 8 41 ENGINE MOUNT 8 43 EXPLODED DIAGRAM 8 43 REMOVAL AND INSTALLA...

Page 193: ...XPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points HANDLEBAR COVER REMOVAL Follow the left Step for removal 1 Screw 4 2 Handlebar cover 1 3 Screw 4 4 Handlebar cover stay 1 5 Spiral tube 1 6 Band 1 ...

Page 194: ...EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Throttle cable 1 8 Choke cable 1 9 Bolt 4 10 Upper handlebar holder 2 11 Handlebar assembly 1 12 Lower handlebar holder 2 Reverse the removal steps for installation ...

Page 195: ...t name Q ty Service points HANDLEBAR REMOVAL Follow the left Step for removal QSTS cable to jet nozzle Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Grommet 1 NOTE Apply soapy water to the grommet for easier installation 2 Handlebar switch coupler 3 3 QSTS cable 2 1 with white tape a ...

Page 196: ...AGRAM Step Procedure Part name Q ty Service points 4 QSTS cable 1 1 NOTE Route the QSTS cables behind of the oil filler hose 5 Nut washer 2 2 6 QSTS converter 1 7 Throttle cable 1 8 Choke cable 1 Reverse the removal steps for installation ...

Page 197: ...N CHART Step Procedure Part name Q ty Service points HANDLEBAR DISASSEMBLY Follow the left Step for disassembly 1 Band 1 2 Bolt 2 3 Grip end 2 4 Spacer 1 5 Screw washer spring washer 1 1 1 6 QSTS grip assembly 1 7 Screw 2 8 Handlebar switch assembly 1 9 Cable holder 1 ...

Page 198: ...t name Q ty Service points 10 Screw 2 11 Throttle lever assembly 1 12 Screw 2 13 Choke lever assembly 1 14 Handlebar grip 1 NOTE Apply adhesive to the handlebar and the inner surface of the handlebar grip 15 Handlebar 1 Reverse the disassembly steps for assembly ...

Page 199: ...g the QSTS cables set the control grip to the neutral position Adjust the QSTS cable lengths a to the specified length and be sure to take up any slack QSTS cable length 77 0 5 mm 3 03 0 02 in 2 Install Upper handlebar holder 1 NOTE Align the punch marks a on the handle bar with the top surface of the handlebar holder The upper handlebar holder should be installed with the punch mark b facing forw...

Page 200: ...f grommet with the band 5 Install Spiral tube 1 NOTE Be sure to install the spiral tube containing the throttle cable choke cable and handle bar switch lead at least 50 mm 1 97 in a into the steering column 6 Install Handlebar cover 1 NOTE When the handlebar cover is in contact with the steering console cover adjust the han dlebar mount angle so that the clearance a and b are equal ...

Page 201: ... HANDLEBAR 7 Adjust Choke lever operation Refer to CONTROL SYSTEM in chapter 3 8 Adjust Throttle cable free play Refer to CONTROL SYSTEM in chapter 3 9 Adjust QSTS cable free play Refer to CONTROL SYSTEM in chapter 3 ...

Page 202: ...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 203: ...LODED DIAGRAM Step Procedure Part name Q ty Service points 7 Screw washer 2 2 8 Collar 1 9 QSTS shift lock lever 1 10 Spring 1 11 Spacer 1 12 QSTS cable housing cover 1 13 QSTS shift grip 1 Reverse the disassembly steps for assembly ...

Page 204: ...8 12 E HULL HOOD QSTS GRIP SERVICE POINTS QSTS cable inspection 1 Inspect QSTS cables Frays kinks rough movement Replace QSTS grip inspection 1 Inspect QSTS grip Damage wear Replace ...

Page 205: ...ocedure Part name Q ty Service points STEERING COLUMN REMOVAL Follow the left Step for removal Steering console cover assembly Refer to STEERING CONSOLE COVER 1 Nut washer 4 4 2 Plate 1 3 Steering column assembly 1 4 Rubber seal 1 Reverse the removal steps for installation 1 2 3 4 16 Nm 1 6 m kgf 11 ft Ib ...

Page 206: ...of shim s as installed originally at factory Step Procedure Part name Q ty Service points STEERING COLUMN DISASSEMBLY Follow the left Step for disassembly 1 Grommet 1 2 Bolt washer nut 1 2 1 3 Steering arm 1 4 Shim 8 60 mm 16 Nm 1 6 m kgf 11 ft Ib 5 Nm 0 5 m kgf 3 6 ft Ib 26 Nm 2 6 m kgf 19 ft Ib 2 7 5 4 3 2 1 8 6 7 ...

Page 207: ...Procedure Part name Q ty Service points 5 Washer 1 6 Steering column 1 7 Bushing 2 8 Steering column housing 1 Reverse the disassembly steps for assembly 8 60 mm 16 Nm 1 6 m kgf 11 ft Ib 5 Nm 0 5 m kgf 3 6 ft Ib 26 Nm 2 6 m kgf 19 ft Ib 2 7 5 4 3 2 1 8 6 7 ...

Page 208: ...8 16 E HULL HOOD STEERING COLUMN SERVICE POINTS Steering column bushing inspection 1 Inspect Bushings Damage wear Replace 2 Inspect Steering column inspection Refer to CONTROL SYSTEM in chapter 3 ...

Page 209: ...R LEAD EXPLODED DIAGRAM REMOVAL 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 1 Speed sensor coupler 1 2 Cap 1 3 Nut 1 4 Speed sensor 1 5 Steering cable end 1 6 Bolt 1 7 Steering cable holder 1 ...

Page 210: ...ES AND SPEED SENSOR LEAD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Cap 1 9 Nut 1 10 Steering cable 1 11 Nut 1 12 Pin 1 13 QSTS cable end 1 14 Cap 1 15 Nut 1 16 QSTS cable 1 Reverse the removal steps for installation ...

Page 211: ...becomes damaged replace it Never attempt to repair a damaged cable Remote control cables inspection 1 Inspect Steering cable QSTS cable Frays kinks rough movement Replace Steering cable jet pump side installation 1 Install Steering cable a WARNING The steering cable must be screwed in at least 8 mm 0 31 in Steering cable set length jet pump side 13 5 15 5 mm 0 53 0 61 in Steering cable stopper ins...

Page 212: ...TS cable jet pump side a WARNING The QSTS cable must be screwed in more than 8 mm 0 31 in QSTS cable set length jet pump side 12 0 14 0 mm 0 47 0 55 in QSTS cable stopper installation 1 Install QSTS cable stopper WARNING Be sure to fit the projection 1 on the QSTS cable stopper into the glove in the outer cable ...

Page 213: ... Part name Q ty Service points FRONT HOOD REMOVAL Follow the left Step for removal 1 Bolt 2 2 Screw 8 3 Seal washer 8 4 Wind shield 1 5 Pop nut 8 6 Bolt 2 10 9 1 11 2 3 5 8 4 16 Nm 1 6 m kgf 11 ft Ib 6 14 mm 5 Nm 0 5 m kgf 3 6 ft Ib 6 14 mm 6 Nm 0 6 m kgf 4 3 ft Ib 5 10 mm 1 Nm 0 1 m kgf 0 7 ft Ib 6 7 ...

Page 214: ...oints 7 Hood lock 1 8 Front hood 1 9 Nut 2 10 Plate 1 11 Hinge assembly 1 Reverse the removal steps for installation 10 9 1 11 2 3 5 8 4 16 Nm 1 6 m kgf 11 ft Ib 6 14 mm 5 Nm 0 5 m kgf 3 6 ft Ib 6 14 mm 6 Nm 0 6 m kgf 4 3 ft Ib 5 10 mm 1 Nm 0 1 m kgf 0 7 ft Ib 6 7 FRONT HOOD ...

Page 215: ...COVER REMOVAL Follow the left Step for removal Handlebar assembly Refer to HANDLEBAR Knob fuel cock Refer to FUEL COCK AND FUEL FILTER in chapter 4 1 Band 1 2 Multifunction meter coupler 6 3 Nut washer 2 2 4 Bolt washer 4 4 5 Screw 2 5 19 mm 2 Nm 0 2 m kgf 1 4 ft Ib 8 25 mm 16 Nm 1 6 m kgf 11 ft Ib 5 Nm 0 5 m kgf 3 6 ft Ib 1 7 2 9 8 5 6 4 6 24 mm 3 Nm 0 3 m kgf 2 2 ft Ib 3 ...

Page 216: ...2 8 Bolt square ring 2 2 9 Steering console cover assembly 1 NOTE Remove the oil filler cap to remove the steering console cover assembly easier Reverse the removal steps for installation 5 19 mm 2 Nm 0 2 m kgf 1 4 ft Ib 8 25 mm 16 Nm 1 6 m kgf 11 ft Ib 5 Nm 0 5 m kgf 3 6 ft Ib 1 7 2 9 8 5 6 4 6 24 mm 3 Nm 0 3 m kgf 2 2 ft Ib 3 ...

Page 217: ...p Procedure Part name Q ty Service points STEERING CONSOLE COVER DISASSEMBLY Follow the left Step for disassembly 1 Screw 4 2 Side cover 2 3 Nut 2 4 Holder 1 5 Multifunction meter 1 6 8 7 2 Nm 0 2 m kgf 1 4 ft Ib 6 18 mm 3 Nm 0 3 m kgf 2 2 ft Ib 4 3 1 9 2 2 5 5 20 mm 1 Nm 0 1 m kgf 0 7 ft Ib ...

Page 218: ...Procedure Part name Q ty Service points 6 Screw 4 7 Glove compartment 1 8 Pop nut 4 9 Steering console cover 1 Reverse the disassembly steps for assembly 6 8 7 2 Nm 0 2 m kgf 1 4 ft Ib 6 18 mm 3 Nm 0 3 m kgf 2 2 ft Ib 4 3 1 9 2 2 5 5 20 mm 1 Nm 0 1 m kgf 0 7 ft Ib ...

Page 219: ... CHART Step Procedure Part name Q ty Service points BUZZER AND HOOD LOCK REMOVAL Follow the left Step for removal Steering console cover assembly Refer to STEERING CONSOLE COVER Steering cable Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Ring nut 1 2 Buzzer 1 3 Bolt 3 4 Bracket 1 5 Bracket 1 ...

Page 220: ...8 28 E HULL HOOD BUZZER AND HOOD LOCK EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Nut 2 7 Bolt 2 8 Hood lock assembly 1 9 Grommet 1 Reverse the removal steps for installation ...

Page 221: ...LATION CHART Step Procedure Part name Q ty Service points HOOD LOCK DISASSEMBLY Follow the left Step for disassembly 1 Screw 2 2 Hood lock button assembly 1 3 Circlip 1 4 Washer 1 5 Pin 1 6 Hook lever 1 7 Spring 1 8 Hood lock body 1 Reverse the disassembly steps for assembly ...

Page 222: ...val Engine unit Refer to ENGINE UNIT in chapter 5 Steering console cover assembly Refer to STEERING CONSOLE COVER 1 Band 2 2 Ventilation hose stern side 1 NOTE Route the ventilation hose bow side in front of the fuel level sensor lead Route the ventilation hose stern side between the oil level sensor lead and the oil tank breather hose 3 Ventilation hose bow side 1 ...

Page 223: ...1 E HULL HOOD HOSES EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 4 Band 1 5 Check valve 1 6 Oil tank breather hose 1 7 Fuel tank breather hose 2 Reverse the removal steps for installation ...

Page 224: ... end of check valve A and blow into it Air should come out from end B Connect the hose to the end of check valve B and blow into it Air should not come out from end A Ventilation hose installation 1 Install Ventilation hose NOTE Insert the ventilation hose into the ventila tion fitting until it reaches the bend a in the fitting a a ...

Page 225: ...ND HAND GRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points SEATS AND HAND GRIP REMOVAL Follow the left Step for removal 1 Seat assembly 1 2 Bolt 2 3 Seat lock assembly 1 4 Nut 1 5 Notch 1 6 Washer 1 ...

Page 226: ...L HOOD SEATS AND HAND GRIP EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Rubber ring 1 8 Nut washer 2 2 9 Bolt 2 10 Bolt 2 11 Hand grip 1 12 Bracket 1 Reverse the removal steps for installation ...

Page 227: ...8 35 E HULL HOOD SEATS AND HAND GRIP SERVICE POINTS Seat lock inspection 1 Inspect Seat lock Damage wear Replace ...

Page 228: ... Step Procedure Part name Q ty Service points BATTERY BOX REMOVAL Follow the left Step for removal 1 Band 1 2 Fire extinguisher container 1 3 Band 1 4 Bolt 1 5 Battery negative lead 1 6 Bolt 1 7 Battery positive lead 1 8 Clip breather hose 1 1 9 Battery 1 10 Cap nut washer 2 2 11 Holder 1 ...

Page 229: ...rvice points 12 Holder 1 13 Cap nut washer 2 2 14 Nut washer 4 4 15 Electrical box 1 16 Battery box 1 NOTE Before installing the battery box route the battery leads and battery breather hose through the holes of the battery box 17 Stay 1 Reverse the removal steps for installation ...

Page 230: ...YSTEM REMOVAL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY in chapter 5 1 Floatation 1 2 Hose clamp 1 3 Exhaust joint 1 4 Hose clamp 2 5 Rubber hose 1 6 Water lock 1 7 Bolt 3 8 Packing 1 4 Nm 0 4 m kgf 2 9 ft Ib 6 30 mm 6 Nm 0 6 m kgf 4 3 ft Ib 4 Nm 0 4 m kgf 2 9 ft Ib 7 4 5 8 12 9 11 9 1 13 4 2 3 6 10 ...

Page 231: ...e points 9 Hose clamp 2 NOTE Remove parts 9 to 12 as a set 10 Water tank 1 11 Rubber hose 1 12 Exhaust outlet 1 13 Floatation 1 Reverse the removal steps for installation 4 Nm 0 4 m kgf 2 9 ft Ib 6 30 mm 6 Nm 0 6 m kgf 4 3 ft Ib 4 Nm 0 4 m kgf 2 9 ft Ib 7 4 5 8 12 9 11 9 1 13 4 2 3 6 10 ...

Page 232: ...ce Exhaust component parts sub assembly 1 Install Exhaust outlet Rubber hose Water tank NOTE Insert the exhaust outlet 45 mm 1 8 in a into the rubber hose Make sure that there is a surface distance of 10 mm 0 4 in b between the parting lines of the exhaust outlet and the rubber hose Insert the water tank 45 mm 1 8 in c into the rubber hose Make sure that there is a surface distance of 45 mm 1 8 in...

Page 233: ...D HULL EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points DECK AND HULL DISASSEMBLY Follow the left Step for disassembly 1 Bolt 2 2 Bow eye 1 3 Nut 2 4 Rope hole fitting 2 5 Nut 1 6 Spout 1 7 Bolt 6 ...

Page 234: ...cedure Part name Q ty Service points 8 Sponson 2 NOTE Make sure install the starboard and port side sponsons to the same position 9 Bolt 8 10 Flap 2 11 Nut washer 4 4 12 Screw washer 4 4 13 Drain plug 2 14 Packing 2 Reverse the disassembly steps for assembly ...

Page 235: ...N CHART Step Procedure Part name Q ty Service points ENGINE MOUNT REMOVAL Follow the left Step for removal Engine assembly 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 Starboard side Reverse the removal steps for installation ...

Page 236: ...an the entire area with acetone and let it completely dry 4 Mix gel coat and gel coat thickener to form a putty and then add the catalyst to the putty 5 Apply the putty spread it with a squee gee and then cover the putty with wax paper 6 When the putty has set sand it Smooth the area with 80 400 grit sandpaper either wet or dry and a sanding block 7 Clean the area with a dry cloth and then polish ...

Page 237: ...P 1 or an equivalent primer onto both sides of the damaged area and then allow it to cure for approximately 30 minutes 6 Cover a piece of cardboard with wax paper 1 and then cover the damaged area with it 7 Combine the polyester resin and the catalyst and then apply the mixture onto the hull 8 Install a glass mat 2 2 inches smaller than the ground area 9 Apply the resin 10 Install a 20 oz fibergla...

Page 238: ...2 62733 09 Nut Stainless steel M6 Material Pilot hole diameter FRP or SMC 9 1 9 2 mm 0 36 in Brass 9 4 mm 0 37 in Example 1 NOTE Before attempting to install the insert nut refer to WATER VEHICLE FRP REPAIR MANUAL The insert nut is used to repair the pop nut designed for the ride plate By repairing the FRP portion the insert nut can be used for all models 1 Remove Pop nut 2 Clean the surface to be...

Page 239: ...ert nut and lock the bolt with the nut 3 as shown 9 Screw in the insert nut so that the top is flush with the FRP surface 10 Loosen the locknut and remove the bolt CAUTION Only use a steel bolt with a tensile strength of 8T or more If the bolt is inferior in strength or is made of stainless steel it may break Bolt 2 Locknut 3 Example 2 The brass insert nut which is designed for the Super Jet ride ...

Page 240: ...th isopropyl alcohol to remove any residual adhesive Graphic installation 1 Mix 1 tablespoon of liquid detergent and water in a 1 quart spray bottle 2 Remove the backing from the new graphic 3 Spray the soap and water mixture onto both sides of the graphic and also onto the hull area where the graphic will be installed NOTE Spraying the front of the graphic with the soap and water mixture will pro...

Page 241: ...E 9 TRBL ANLS CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS 9 1 TROUBLE ANALYSIS CHART 9 1 ...

Page 242: ...etors TROUBLE ANALYSIS CHART Problems Items to be checked ENGINE WILL NOT START ROUGH IDLING ENGINE STALLS ENGINE WILL NOT STOP POOR PERFORMANCE OVERHEATING LOOSE STEERING BILGE INCREASE IRREGULAR WARNING INDICATION POOR BATTERY CHARGING YPVS SERVOMOTOR DOES NOT MOVE Items Reference chapter FUEL SYSTEM Fuel tank 4 Air vent hose 4 Fuel hose 4 Fuel filter 4 Fuel pump 4 Carburetors 4 Carburetor synch...

Page 243: ... coil 7 Ignition coil 7 Rectifier regulator 7 Electrical sender s 7 Starter relay starter motor 7 YPVS unit 7 Battery 3 Fuse s 7 Wire harness electrical coupler s 7 HULL AND HOOD Steering column 8 Water lock 8 Exhaust hose 8 Muffler 8 Drain plugs 8 Problems Items to be checked ENGINE WILL NOT START ROUGH IDLING ENGINE STALLS ENGINE WILL NOT STOP POOR PERFORMANCE OVERHEATING LOOSE STEERING BILGE IN...

Page 244: ...Printed on recycled paper Printed in USA Feb 2000 1 CR F0X 28197 ZA 11 GP1200AY YAMAHA MOTOR CO LTD ...

Page 245: ...B O B Y O O B O B Y B Y B O B O B O W O B B W B O 1 2 3 B B B W B W B B B B B B B B W B Y B B B Br R R R R R R B R W R L R R Y Br Gy B Gy B R Br B W B W Br Br R R R W R W R W Br Br R R R L R Y R W R R B W Br Br Br Ch R Y B Y Y R W Gy R Gy B Gy Y G R B Y B L B L R R B Gy Y G R W Gy B Gy R B W Gy G Gy B Gy R Gy Y Gy R Gy B G Gy Gy Y W W R Gy R Gy B B W Gy Y B O B Y O G Gy W B Br R B O Br B Y B O W L...

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