Yamaha GP800R WaveRunner 2003 Service Manual Download Page 197

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8-6

HULL

HOOD

HANDLEBAR

EXPLODED DIAGRAM

Step

Procedure/Part name

Q’ty

Service points

Screw

Throttle lever assembly

Screw

Choke lever assembly

Handlebar grip

NOTE:

Apply adhesive to the handlebar and the
inner surface of the handlebar grip.

Handlebar

Reverse the disassembly steps for
assembly.

Summary of Contents for GP800R WaveRunner 2003

Page 1: ... LIT186160226 WaveRunner GP800R SERVICEMANUAL F0W 28197 1A 11 LIT 18616 02 26 ...

Page 2: ...Yamaha has a policy of continuously improving its products models may differ in detail from the descriptions and illustrations given in this publication Use only the latest edi tion of this manual Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures and these are incorporated in succes sive editions of this manual A10001 0 Wa...

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: ...to follow WARNING instructions could result in severe injury or deathto the machine operator 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 specification du...

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: ...lubricant and the loca tion of lubrication point F Apply YAMALUBE 2 W oil or TC W3 cirtified outboard 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 ...

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 ...

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Page 9: ...ERIAL NUMBER 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 10: ...ry l D number F0W 800101 ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the cylinder head Starting serial number 68A 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 68A 800101 HULL IDENTIFICATION NUMBER H l N The H l N is stamped on a plate attached to the aft deck ...

Page 11: ...N Gasoline 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 p...

Page 12: ...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 13: ...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 14: ...890 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 tester P N J 39299 90890 06752 7 Peak voltage adapter P N YU 39991 90890 03169 8 Peak voltage test harness P N YW 06779 90890 06779 9 Spark gap tester P N YM 34487 90890 06754 4 3 1 2 5 6 8 7...

Page 15: ...le bearing attachment jet pump bearing and oil seal P N YB 06112 YB 06196 90890 06614 90890 06653 B Ball bearing attachment jet pump oil seal P N YB 06156 90890 06634 C Driver rod intermediate shaft and jet pump P N YB 06071 90890 06606 D Bearing inner outer race attachment jet pump bearing P N YB 34474 E Shaft holder intermediate shaft P N YB 06552 90890 06552 F Bearing outer race attachment inte...

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Page 17: ...ER 2 SPECIFICATIONS 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 18: ... 3 07 Compression ratio 6 6 1 Intake system Reed valve Carburetor model manufacturer quantity BN44 Mikuni 2 Enrichment control Choke valve Scavenging system Loop charge Lubrication system Oil injection Cooling system Water Starting system Electric Ignition system Digital CDI Ignition timing Degree 15 BTDC 20 BTDC Spark plug model manufacturer BR8ES NGK Battery capacity V Ah kC 12 19 68 4 Lighting ...

Page 19: ...gasoline Fuel rating PON 86 RON 90 Oil YAMALUBE 2 W or an equivalent TC W3 certified outboard oil 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 Unit Model GP800R GENERAL SPECIFICATIONS ...

Page 20: ...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 2 0 05 Dimensions T mm in 2 85 0 112 End gap mm in 0 30 0 45 0 012 0 018 Ring groove clearance mm in 0 03 0 05 0 001 0 002 2nd 2 Type Keystone...

Page 21: ...t size mm in 1 2 0 05 Trolling speed r min 1 300 50 REED VALVES Thickness mm in 0 52 0 020 Reed valve stopper height mm in 10 8 11 4 0 43 0 45 Reed valve warpage limit mm in 0 2 0 01 Item Unit Model GP800R JET PUMP Impeller material Stainless steel Number of impeller blades 3 Impeller pitch angle Degree 13 2 Impeller clearance mm in 0 35 0 45 0 014 0 018 Impeller clearance limit mm in 0 6 0 024 Dr...

Page 22: ...eak voltage lower limit cranking 1 V 5 cranking 2 V 3 2 000 r min V 7 3 500 r min V 11 Lighting coil G G Output peak voltage lower limit cranking 1 V 8 5 cranking 2 V 8 5 2 000 r min V 13 3 500 r min V 13 Charge coil resistance Ω color 299 365 Br L Pickup coil resistance Ω color 446 545 W R W B Lighting coil resistance Ω color 0 86 1 06 G G Minimum charging current A r min 9 6 000 IGNITION COIL Mi...

Page 23: ...r min V 12 5 3 500 r min V 12 5 THERMO SWITCH On temperature C F 80 177 Off temperature C F 70 159 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 Item Unit Model GP800R ...

Page 24: ...t exhaust manifold 1st Bolt M8 5 17 1 7 12 271 LT 2nd 34 3 4 24 Exhaust chamber joint muffler stay 1st Bolt M10 1 2 0 2 1 4 271 LT 3rd 49 4 9 35 2nd Bolt M8 2 2 0 2 1 4 271 LT 4th 37 3 7 27 Exhaust manifold cylinder 1st Bolt M10 8 23 2 3 17 271 LT 2nd 51 5 1 37 Reed valve reed valve seat Screw M3 16 0 8 0 08 0 58 242 LT YPVS cable bracket YPVS cover cylinder Bolt M6 2 10 1 0 7 2 572 LT YPVS cover ...

Page 25: ...lt M8 2 15 1 5 11 271 LT Nozzle deflector nozzle ring Bolt M8 2 15 1 5 11 271 LT Water inlet cover water inlet strainer impeller duct Bolt M6 4 7 0 7 5 1 572 LT Drive shaft nut drive shaft Nut M16 1 74 7 4 53 Impeller left hand threads drive shaft Impeller M22 1 18 1 8 13 572 LT Transom plate hull Nut M10 4 26 2 6 19 Bilge strainer holder bulkhead Screw M5 1 4 0 4 2 9 Intermediate housing bulkhead...

Page 26: ...3 Steering cable hull Nut 1 6 0 6 4 3 Steering cable holder bracket Bolt M6 1 6 0 6 4 3 Speed sensor lead hull Nut 1 6 0 6 4 3 Hinge assembly front hood Bolt M6 2 12 1 2 8 7 Wind shield front hood Screw M5 8 1 0 1 0 7 Hood lock front hood Bolt M6 2 5 0 5 3 6 Hinge assembly deck Nut M8 2 16 1 6 11 Steering console cover assembly deck Nut M6 2 5 0 5 3 6 Bolt M6 4 3 0 3 2 2 Screw M5 2 2 0 2 1 4 Nut M...

Page 27: ...gine damper hull Bolt M6 2 6 0 6 4 3 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 standard fasteners with a standard ISO thread pitch Tightening torque specifica tions for special components or assemblies are provided in applicable sections of this manual To avoid warpage tighten multi fastener ass...

Page 28: ... F K G H I J A F 1 Fuel filter 2 Fuel tank breather hose 3 Fuel hose 4 Cooling water hose 5 Choke cable 6 Throttle cable 7 Oil return hose 8 Bilge hose 9 Speed sensor lead 0 Electrical box lead A YPVS cables B Cooling water pilot outlet C Battery negative lead D Battery E Steering cable F QSTS cable G Battery breather hose H Battery positive lead I Starter motor lead J Generator lead K YPVS servom...

Page 29: ...suction hose 4 Speed sensor lead 5 QSTS cable 6 Cooling water hose 7 Steering cable 8 Flushing hose 9 Bilge hoses 0 To multifunction meter A To stator assembly B To cylinder 1 C To cylinder 2 D To battery positive terminal E To starter motor positive terminal F To thermoswitch G Battery negative lead H Buzzer lead I Choke cable J YPVS servomotor K YPVS cables L Battery positive lead M Battery brea...

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Page 31: ...spection 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 straine...

Page 32: ...hrottle 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 18 OIL INJECTION SYSTEM Oil injection system Check clean 3 9 Oil pump cable Inspect...

Page 33: ...tion steps Move the handlebar up and down and back and forth Check the excessive play of the han dlebar Inspection steps Set the control grip in the neutral posi tion 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 Adjustment steps Loosen the locknut 1 Disconnect...

Page 34: ...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 N m 0 6 kgf m 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 ...

Page 35: ...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 36: ...st 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 nozzle deflector in the center position 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 37: ...S cable adjustment 1 Check YPVS valve position Incorrect position Adjust the YPVS cable Checking steps Start the engine and then stop it NOTE When the engine has been stopped for 3 seconds the YPVS valve assembly will retract and extend 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 speci...

Page 38: ...uel hoses through part Fuel filler cap Cracks damage Replace Adjustment steps Loosen locknuts 1 and 2 Turn in adjusters 3 and 4 until there is slack in the cables 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 adjusters 3 and 4 in or out until the specified slack is obtained Turn in Slack is increased Turn o...

Page 39: ...aft 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 Tu...

Page 40: ...ecomes empty the oil injection pump must be bled to ensure proper oil flow otherwise engine damage may occur Refer to OIL PUMP in chapter 4 POWER UNIT Spark plug inspection 1 Inspect Electrodes 1 Damage wear Replace Insulator color 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 ...

Page 41: ...orrect 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 25 N m 2 5 kgf m 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 c...

Page 42: ... NOT SMOKE when charging or han dling 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 Band Battery negative lead 1 Battery positive lead 2 Batte...

Page 43: ...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 44: ...d and is not obstructed Coat the terminals with a water resistant grease to minimize terminal corrosion 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 ...

Page 45: ...he 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 plugs Cracks damage Replace O rings Cracks wear Replace Screw threads Contaminants Clean...

Page 46: ...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 47: ...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 48: ...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 ...

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Page 50: ... 4 5 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 sensor inspection 4 9 Fuel tank inspection 4 9 Pipe joint inspection 4 9 INTAKE SILENCER 4 10 EXPLODED DIAGRAM 4 10 REMOVAL AND INSTALLATION CHART 4 10 CARBURETOR UNIT 4 11 EXPLODED DIAGRAM 4 11 REMOVAL AND INSTALLATION CHART 4 11 SERVICE POINTS 4 18 Throttle valve sy...

Page 51: ...on 4 24 Jet and carburetor body inspection 4 24 Carburetor assembly 4 24 FUEL PUMP 4 25 EXPLODED DIAGRAM 4 25 REMOVAL AND INSTALLATION CHART 4 25 SERVICE POINTS 4 27 Fuel pump inspection 4 27 Fuel filter inspection 4 27 OIL PUMP 4 28 EXPLODED DIAGRAM 4 28 REMOVAL AND INSTALLATION CHART 4 28 SERVICE POINTS 4 30 Oil pump inspection 4 30 Oil hose inspection 4 30 Check valve inspection 4 30 Oil pump c...

Page 52: ...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 53: ...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 54: ...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 Disconnect the oil filler hose from the oil filler neck 3 Nut 1 4 Oil filler neck 1 5 Rubber seal 1 Not reusable ...

Page 55: ...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 56: ...minants Clean Frays tears Replace Rubber seal Cracks wear Replace Oil hoses Oil tank Oil filler cap Cracks damage Replace Check valve Malfunction Replace Oil level sensor inspection Refer to INDICATION SYSTEM in chapter 7 Oil tank inspection 1 Inspect Oil tank Cracks damage Replace ...

Page 57: ...rocedure 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 Disconnect the fuel filler hose from the fuel filler neck 3 Nut 1 4 Fuel filler neck 1 5 Rubber seal 1 6 Fuel reserve hose 1 ...

Page 58: ...LODED DIAGRAM Step Procedure Part name Q ty Service points 7 Fuel hose 1 8 Fuel return hose 1 9 Fuel tank 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 59: ...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 belt 2 Reverse the removal steps for installation ...

Page 60: ...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 61: ...OVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points INTAKE SILENCER REMOVAL Follow the left Step for removal 1 Bolt 3 2 Intake silencer cover 1 3 Bolt 4 4 Spark arrester 1 5 Intake silencer 1 6 O ring 2 Reverse the removal steps for installation ...

Page 62: ...X in chapter 8 Intake silencer Refer to INTAKE SILENCER 1 Bolt 2 NOTE When removing the carburetor the exhaust chamber assembly does not need to be removed if the engine unit has already been removed 2 Thermoswitch 1 3 Clamp cooling water hose 1 1 4 Grease hose 1 5 Clamp cooling water hose 1 1 Å For cooling water pilot outlet on starboard side 6 Clamp cooling water hose 1 1 ı For cooling water pil...

Page 63: ...T EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Hose clamp 2 Slide the outer exhaust joint 8 Hose clamp 2 9 Floatation 1 10 Water lock band 1 11 Bolt 1 12 Bolt 1 13 Muffler stay 3 1 14 Bolt 4 15 Nut washer 2 2 ...

Page 64: ...ame Q ty Service points 16 Muffler stay 1 2 NOTE Make sure to remove spark plugs before removing the muffler stay 1 17 Bolt 2 18 Hose clamp 2 19 Exhaust chamber assembly 1 20 Rubber joint 1 Slide the water lock to back 21 Outer exhaust joint 1 22 Inner exhaust joint 1 ...

Page 65: ... DIAGRAM Step Procedure Part name Q ty Service points 23 Fuel hose 2 Å suction ı return NOTE Use the white marks a on the fuel hoses to distinguish the hose ends 24 Oil feed hose 2 25 Choke cable 1 26 Throttle cable 1 27 Oil pump cable 1 ...

Page 66: ...RBURETOR UNIT EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 28 Pulse hose 2 29 Bolt 2 30 Bolt 4 31 Carburetor unit 1 32 Gasket 1 33 Dowel pin 2 Reverse the removal steps for installation Not reusable ...

Page 67: ...ND INSTALLATION CHART Step Procedure Part name Q ty Service points CARBURETOR UNIT SEPARATION Follow the left Step for removal 1 Pulse hose 2 2 Fuel hose 4 Å suction ı return 3 Oil feed hose 2 4 Accelerator pump fuel hose 3 5 Throttle link 1 6 Choke link 1 ...

Page 68: ...D DIAGRAM Step Procedure Part name Q ty Service points 7 Bolt 3 8 Cable bracket 1 9 Bolt 4 10 Carburetor 2 11 Gasket 2 12 Carburetor joint 1 13 Bolt washer 2 2 14 Fuel hose guide 1 Reverse the removal steps for installation Not reusable ...

Page 69: ...screw end from the throttle lever Check the each throttle valve is fully closed a a a 2 Adjust Throttle valve synchronization Adjustment steps Loosen the 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 N m 0 2 kgf m 1 4 ft lb Turn in the throttle...

Page 70: ... play Choke lever operation Refer to CONTROL SYSTEM in chapter 3 Choke cable guide installation position a 13 15 mm 0 51 0 59 in Throttle cable guide installation position a 18 20 mm 0 71 0 79 in 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 71: ...ure Part name Q ty Service points CARBURETOR DISASSEMBLY Follow the left Step for disassembly 1 Accelerator pump fuel hose 1 Carburetor 1 2 Screw 4 3 Accelerator pump carburetor cover 1 1 Carburetor 1 carburetor 2 4 Diaphragm 1 5 Screw 2 6 Regulator body 1 7 Gasket 1 8 Main jet 1 9 Pilot jet 1 ...

Page 72: ...DIAGRAM Step Procedure Part name Q ty Service points 10 Screw 1 11 Arm 1 12 Arm pin 1 13 Spring 1 14 Screw 1 15 Needle valve seat holder 1 16 Needle valve 1 17 Needle valve seat 1 18 O ring 1 Reverse the disassembly steps for assembly ...

Page 73: ...ocedure 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 1 7 Spring 1 8 Diaphragm 1 9 Accelerator pump body 1 Reverse the disassembly steps for assembly ...

Page 74: ...ct performance Diaphragm inspection 1 Inspect Diaphragm Damage Replace Accelerator 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 T...

Page 75: ...t 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 NOTE Before assembling the carburetor make sure to turn out the pilot screw the same number of times as noted before disassem bly from the s...

Page 76: ...ND INSTALLATION CHART Step Procedure Part name Q ty Service points FUEL PUMP DISASSEMBLY Follow the left Step for disassembly Carburetors Refer to CARBURETOR UNIT 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 77: ...4 26 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 78: ...7 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 79: ...assembly Refer to CARBURETOR UNIT Oil pump cable and oil feed hoses Refer to CARBURETOR UNIT 1 Oil return hose 1 NOTE When removing the oil pump the exhaust chamber assembly does not need to be removed if the engine unit has already been removed 2 Oil hose 1 3 Bolt 2 4 Oil pump assembly 1 5 Gasket 1 Reverse the removal steps for installation 4 2 6 20 mm LT LT LT 572 572 3 5 1 Not reusable ...

Page 80: ...t name Q ty Service points OIL PUMP HOSES AND CABLE REMOVAL Follow the left Step for removal 1 Air bleed screw 1 2 Gasket 1 3 Oil feed hose 1 2 4 Check valve 2 5 Oil feed hose 2 2 6 Hose joint 1 7 Oil return hose 2 8 Oil pump cable 1 9 Oil pump 1 Reverse the removal steps for installation ...

Page 81: ...eck valve inspection 1 Check Check valve Faulty Replace Oil pump cable adjustment 1 Check Oil pump lever position Incorrect Adjust 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 Checking steps Fully close the carburetor throttle valves Check th...

Page 82: ...rags around the air bleed screw 1 to catch any oil that might spill Fill the oil tank with the recommended oil NOTE If the oil pump is replaced or the oil suc tion hose is removed bleed air from the oil suction hose by removing it from the oil pump After bleeding the air reconnect the hose with a locking tie Recommended engine oil YAMALUBE 2 W or an equivalent TC W3 certified outboard oil Loosen t...

Page 83: ... T R Air bleed screw 5 N m 0 5 kgf m 3 6 ft lb CAUTION Do not run the engine if oil does not flow out of the air bleed screw Inspect the oil pump hoses for proper routing and make sure there are no restrictions in the line ...

Page 84: ...DIAGRAM 5 10 REMOVAL AND INSTALLATION CHART 5 10 EXHAUST MANIFOLD 5 12 EXPLODED DIAGRAM 5 12 REMOVAL AND INSTALLATION CHART 5 12 REED VALVES 5 13 EXPLODED DIAGRAM 5 13 REMOVAL AND INSTALLATION CHART 5 13 SERVICE POINTS 5 14 Reed valve inspection 5 14 YPVS 5 15 EXPLODED DIAGRAM 5 15 REMOVAL AND INSTALLATION CHART 5 15 SERVICE POINTS 5 17 YPVS valve inspection 5 17 YPVS valve installation 5 17 CYLIN...

Page 85: ...28 EXPLODED DIAGRAM 5 28 REMOVAL AND INSTALLATION CHART 5 28 FLYWHEEL MAGNETO 5 29 EXPLODED DIAGRAM 5 29 REMOVAL AND INSTALLATION CHART 5 29 SERVICE POINTS 5 34 Drive coupling removal and installation 5 34 Flywheel magneto removal and installation 5 34 Drive coupling inspection 5 35 Flywheel magneto inspection 5 35 Starter clutch assembly inspection 5 35 CRANKCASE 5 36 EXPLODED DIAGRAM 5 36 REMOVA...

Page 86: ...low the left Step for removal Battery box Refer to BATTERY BOX in chapter 8 YPVS cables and YPVS servomotor Refer to YPVS SERVOMOTOR in chapter 7 Intake silencer Refer to INTAKE SILENCER in chapter 4 Choke cable throttle cable and fuel hoses Refer to CARBURETOR UNIT in chapter 4 1 Coupler 3 2 Band 6 3 Clamp Cooling water hose 1 ENGINE UNIT ...

Page 87: ...ame Q ty Service points 4 Grease hose 1 5 Clamp cooling water hose 1 1 6 Clamp cooling water hose 1 1 Å For cooling water pilot outlet on starboard side 7 Clamp cooling water hose 1 1 ı For cooling water pilot outlet on port side 8 Oil hose 1 9 Oil return hose 1 ...

Page 88: ...ine unit fix the choke valves to the choke link with a plastic band etc to the fully closed position When lifting the engine unit hook the hoister on the bow side of muffler stay 1 Lift the engine unit carefully trying not hit it on the deck 11 Coupling cover 1 12 Floatation 1 13 Water lock band 1 14 Hose clamp 2 15 Bolt washer 4 4 ...

Page 89: ...OWR E ENGINE UNIT EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 16 Shim 17 Engine unit 1 18 Rubber joint 1 Slide the water lock to back Reverse the removal steps for installation As required ...

Page 90: ...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 91: ...NSTALLATION CHART Step Procedure Part name Q ty Service points EXHAUST CHAMBER ASSEMBLY REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT 1 Bolt 2 2 Thermoswitch 1 3 Hose clamp 2 Slide the outer exhaust joint 4 Hose clamp 2 5 Bolt 1 6 Bolt 1 7 Muffler stay 3 1 8 Bolt 4 ...

Page 92: ...art name Q ty Service points 9 Nut washer 2 2 10 Muffler stay 1 2 NOTE Make sure to remove spark plugs before removing the muffler stay 1 11 Bolt 2 12 Exhaust chamber assembly 1 13 Outer exhaust joint 1 14 Inner exhaust joint 1 Reverse the removal steps for installation ...

Page 93: ...D DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points EXHAUST CHAMBER DISASSEMBLY Follow the left Step for disassembly 1 Nut washer 1 1 2 Bolt 3 3 Nut washer 2 2 4 Exhaust chamber 1 5 Gasket 1 6 Pin 2 Not reusable ...

Page 94: ...5 9 POWR E EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Muffler 1 8 Screw 3 9 Plate 1 10 Gasket 1 Reverse the disassembly steps for assembly Not reusable ...

Page 95: ...AL AND INSTALLATION CHART Step Procedure Part name Q ty Service points EXHAUST CHAMBER JOINT REMOVAL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY 1 Clamp cooling water hose 2 1 a white mark 2 Bolt 2 3 Bolt 1 4 Muffler stay 1 5 Bolt 1 ...

Page 96: ...WR E EXHAUST CHAMBER JOINT EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Bolt 2 7 Bolt 2 8 Exhaust chamber joint 1 9 Gasket 1 10 Pin 2 Reverse the removal steps for installation Not reusable ...

Page 97: ...Part name Q ty Service points EXHAUST MANIFOLD REMOVAL Follow the left Step for removal Exhaust chamber joint Refer to EXHAUST CHAMBER JOINT 1 Bolt 4 2 Bolt 4 3 Wire harness bracket 2 4 Exhaust manifold 1 5 Gasket 1 6 Pin 2 7 Clamp cooling water hose 2 2 Reverse the removal steps for installation Not reusable ...

Page 98: ...ervice points REED VALVE REMOVAL Follow the left Step for removal Carburetor unit Refer to CARBURETOR UNIT in chapter 4 1 Bolt 12 NOTE Tighten the bolts in the proper sequence as shown 2 Reed valve plate 1 3 Reed valve assembly 2 4 Screw 16 5 Valve stopper 4 6 Reed valve 4 Reverse the removal steps for installation ...

Page 99: ...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 8 11 4 mm 0 43 0 45 in ...

Page 100: ... CHART Step Procedure Part name Q ty Service points YPVS REMOVAL Follow the left Step for removal Exhaust manifold Refer to EXHAUST MANIFOLD 1 Bolt 8 2 YPVS valve cover 2 3 Gasket 2 4 Spacer 1 5 Link joint cover 1 1 6 Circlip 3 7 Washer 3 Not reusable Not reusable ...

Page 101: ...Bolt 2 NOTE During installation align the hole a in the YPVS shaft with the bolt 9 Shaft 2 1 10 Shaft 1 1 11 YPVS valve lever 2 12 Bolt 2 13 YPVS valve assembly 2 14 Oil seal 4 NOTE If the YPVS shaft is removed the oil seal must be replaced Reverse the removal steps for installation ...

Page 102: ...nate 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 ...

Page 103: ...dure Part name Q ty Service points CYLINDER HEAD REMOVAL Follow the left Step for removal Exhaust manifold Refer to EXHAUST MANIFOLD 1 Bolt 10 NOTE Tighten the bolts in the proper sequence as shown and in two stages 2 Cylinder head 1 3 Gasket 1 Reverse the removal steps for installation Not reusable ...

Page 104: ...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 105: ... points CYLINDER REMOVAL Follow the left Step for removal YPVS Refer to YPVS Cylinder head Refer to CYLINDER HEAD 1 Bolt 8 NOTE Tighten the bolts in a crisscross pattern and in two stages 2 Cylinder 2 NOTE Install the original position 3 Cylinder gasket 2 4 Pin 4 Reverse the removal steps for installation Not reusable ...

Page 106: ... 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 107: ...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 108: ...POWR E 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 PISTONS ...

Page 109: ...ton pin clip from falling into the crankcase Piston inspection 1 Eliminate Carbon deposits from the piston crown and piston ring grooves 2 Inspect Piston wall Score marks Repair with 600 800 grit wet sandpaper or replace 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 110: ...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 111: ... 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 3 Check Piston pin to piston free play with the piston pin in the piston as shown Free play Replace the piston pin piston or both Piston pin outside diameter Standard 21 995 22 000 mm 0 8659 0 8661 in Limit 2...

Page 112: ... E PISTONS 4 Check Piston pin to small end bearing to connecting rod free play at the small end of the connecting rod as shown Free play small end wear Replace the piston pin connecting rod or small end bearing ...

Page 113: ...TION CHART Step Procedure Part name Q ty Service points STARTER MOTOR REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT 1 Nut washer 1 1 2 Starter motor lead 1 3 Bolt 2 4 Battery negative lead 1 5 Starter motor 1 Reverse the removal steps for installation ...

Page 114: ...REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points FLYWHEEL MAGNETO REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT Oil pump Refer to OIL PUMP in chapter 4 1 Bolt 2 2 Bolt 6 3 Generator cover 1 4 Packing 1 5 Pin 2 ...

Page 115: ...LYWHEEL MAGNETO EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Drive coupling 1 7 Bolt 1 8 Flywheel magneto 1 9 Woodruff key 1 10 Starter clutch assembly 1 Reverse the removal steps for installation ...

Page 116: ...ble holder 1 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 5 Bolt washer 1 1 6 Bolt 1 7 Pickup coil 1 8 Generator cover 1 Reverse the disassembly steps for assembly 6 14 mm 14 N m 1 4 kgf m 10 ft Ib 5 14 mm 5 N m 0 5 kgf m 3 6 ft Ib 6 30 mm 14 N m 1 4 kgf m 10 ft Ib 3 LT LT LT 242 242 1 5 6 LT LT LT 242 24...

Page 117: ...AM 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 Washer 1 6 Idle gear 1 7 Circlip 1 Not reusable ...

Page 118: ...PLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Plate 1 9 Weight 3 10 Spring ring 1 NOTE Install the spring ring after installing the weights plate and circlip 11 Pinion gear 1 Reverse the disassembly steps for assembly ...

Page 119: ...heel magneto removal and installation 1 Remove Flywheel magneto bolt NOTE Install the bolt with the same special tool that was used for removal 2 Remove Flywheel magneto 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 flywheel magneto Flywheel holder YW 065...

Page 120: ...ect 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: ... Procedure Part name Q ty Service points CRANKCASE DISASSEMBLY Follow the left Step for disassembly Pistons Refer to PISTONS Starter motor Refer to STARTER MOTOR Generator cover Refer to FLYWHEEL MAGNETO 1 Bolt 3 2 Mount bracket 1 1 3 Pin 2 4 Bolt 3 5 Pin 2 6 Mount bracket 2 1 7 Bolt 4 ...

Page 122: ...e Part name Q ty Service points 8 Bolt 3 NOTE Tighten the bolts in sequence as shown 9 Bolt 1 10 Bolt 10 11 Bolt 2 12 Lower crankcase 1 13 Pin 2 14 Crankshaft assembly 1 15 Upper crankcase 1 Reverse the disassembly steps for assembly CRANKCASE ...

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: ... 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 Bearing clip 1 5 Bearing 1 6 Crankshaft 1 CAUTION Install the bearing locating pins into the grooves in the crankcase body Reverse the removal steps for installation ...

Page 125: ...n 2 Measure Deflection B with a dial gauge Out of specification Replace Max deflection 0 05 mm 0 002 in 3 Measure Big end side clearance C 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 D 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: ...removal 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 ...

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: ...n 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 seals 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: ...cedure 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 Cooling water hose 1 Cooling water outlet 3 Bilge hose 1 1 NOTE Route the bilge hose 1 under the drive shaft tube ...

Page 141: ...AGRAM Step Procedure Part name Q ty Service points 4 Cooling water 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 hoses 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: ... 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 7 Oil seal 1 Not reusable ...

Page 145: ...RING HOUSING EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 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 ...

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: ......

Page 150: ...SYSTEM 7 9 WIRING DIAGRAM 7 9 IGNITION SPARK GAP 7 10 IGNITION SYSTEM PEAK VOLTAGE 7 11 SPARK PLUGS 7 12 SPARK PLUG CAPS 7 12 IGNITION COIL 7 12 ENGINE STOP SWITCH 7 13 THERMOSWITCH 7 13 STARTING SYSTEM 7 14 WIRING DIAGRAM 7 14 BATTERY 7 15 WIRING CONNECTIONS 7 15 FUSE 7 15 STARTER SWITCH 7 15 STARTER RELAY 7 16 STARTER MOTOR 7 17 EXPLODED DIAGRAM 7 17 REMOVAL AND INSTALLATION CHART 7 17 SERVICE P...

Page 151: ...7 YPVS cable removal and installation 7 27 YPVS cable inspection 7 27 YPVS servomotor inspection 7 27 YPVS cable adjustment 7 28 INDICATION SYSTEM 7 29 WIRING DIAGRAM 7 29 FUSE 7 30 BATTERY 7 30 LIGHTING COIL 7 30 RECTIFIER REGULATOR 7 30 CDI UNIT 7 30 THERMOSWITCH 7 30 BUZZER 7 30 OIL LEVEL SENSOR 7 30 FUEL LEVEL SENSOR 7 31 MULTIFUNCTION METER 7 31 Multifunction meter 7 31 MULTIFUNCTION METER RE...

Page 152: ... 9 7 1 Buzzer 2 Fuel level sensor 3 Multifunction meter 4 YPVS servomotor 5 Spark plugs 6 Electrical box 7 Speed sensor 8 Battery 9 Thermoswitch 0 Starter motor A Stator coil and pickup coil B Engine stop switch engine stop lanyard switch and starter switch C Oil level sensor ...

Page 153: ...EMBLY Follow the left Step for disassembly Electrical box Refer to BATTERY BOX in chapter 8 1 Plastic locking tie 2 2 Bolt collar 1 1 NOTE To separate the battery box from the engine unit refer to ENGINE UNIT STARTER MOTOR and FLYWHEEL MAGNETO in Chapter 5 to disconnect the leads 3 Plastic clamp 1 4 Bolt 14 5 Electrical box cover 1 6 Gasket 1 Not reusable ...

Page 154: ...X EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Nut 2 8 Starter motor lead battery positive lead 1 1 9 Fuse 1 10 Plastic locking tie 1 11 Screw 2 12 Ignition coil 1 13 Screw 2 14 Starter relay 1 Not reusable ...

Page 155: ... BOX EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 15 Bolt 1 16 Rectifier regulator 1 17 Thermoswitch 1 18 Wire harness 2 19 CDI unit 1 20 Electrical box housing 1 Reverse the disassembly steps for assembly ...

Page 156: ...7 5 E ELEC ELECTRICAL BOX 1 CDI unit 2 Starter relay 3 Fuse 10A 4 Ignition coil 5 Rectifier regulator 6 Spark plug caps B Black Br Brown G Green P Pink R Red W White ...

Page 157: ...n omitted Refer to the following part number NOTE indicates a continuity of electric ity i e a closed circuit at the respective switch position Low resistance measurement NOTE When measuring a resistance of 10 Ω or less with the digital tester the correct measurement cannot be obtained because of the tester s internal resistance To obtain the correct value subtract the internal resistance from the...

Page 158: ...ltage adaptor NOTE Throughout this chapter the peak voltage adaptor s part number has been omitted Refer to the following part number The peak voltage adaptor should be used with the digital tester When measuring the peak voltage con nect the peak voltage adaptor to the digi tal tester and switch the selector to the DC voltage mode NOTE Make sure that the adaptor leads are properly installed in th...

Page 159: ...regulator If the charge coil and pickup coil are mea sured unloaded disconnect the test har ness on the output side coupler YW 90890 Pin Usage 06779 06779 8 Charge coil and pickup coil Checking steps Disconnect the coupler connections Connect the test harness between the couplers Connect the tester terminals to the ter minals which are being checked Run the engine and observe the mea surement ...

Page 160: ...6 8 7 4 5 B B O O P P B P W B B W B W B Br L W B W R 3 B B L Br W R W B O W P W B R Br W B 1 Pickup coil 2 Charge coil 3 CDI unit 4 Engine stop switch 5 Engine stop lanyard switch 6 Thermoswitch 7 Ignition coil 8 Spark plugs B Black Br Brown L Blue O Orange P Pink R Red W White W B White black W R White red ...

Page 161: ...keep flammable 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 9089...

Page 162: ...stem but possibly with the spark plug s or another compo nent 1 Measure CDI unit output peak voltage Below specification Measure the charge coil output peak voltage or replace the CDI unit CDI unit output peak voltage Orange O Black B r min Unloaded Loaded Cranking 2 000 3 500 V 85 110 205 200 2 Measure Charge coil output peak voltage Below specification Replace the charge coil Charge coil output ...

Page 163: ...779 SPARK PLUGS Refer to POWER UNIT in chapter 3 SPARK PLUG CAPS 1 Inspect Spark plug cap Loose Tighten Cracks damage Replace IGNITION COIL 1 Measure Primary coil resistance Out of specification Replace NOTE When measuring a resistance of 10 Ω or less with the digital tester the correct mea surement cannot be obtained because of the tester s internal resistance Refer to Low resistance measurement ...

Page 164: ...black coupler Lock plate Position Lead color White Black Installed Free Push Removed Free Push THERMOSWITCH 1 Measure Thermoswitch continuity Out of specification Replace 1 No continuity Å Temperature 2 Continuity ı Time Thermoswitch continuity temperature Pink P Black B a 80 C 177 F b 70 C 159 F Measurement steps Suspend the thermostat in a container filled with water Place a thermometer in the w...

Page 165: ...TARTING SYSTEM WIRING DIAGRAM SET PULL 2 3 R Br R Br Br W B R Br M 1 R B 4 5 6 B R Br Br R R B R R Br 1 Starter motor 2 Engine stop lanyard switch 3 Starter switch 4 Fuse 10A 5 Starter relay 6 Battery B Black Br Brown R Red W White ...

Page 166: ...continuity No continuity Check the fuse holder leads 2 Check Fuse holder lead continuity No continuity Replace the fuse holder Continuity Check the fuse 3 Check Fuse broken Broken Replace Fuse rating 10A STARTER SWITCH 1 Check Continuity Out of specification Replace Starter continuity natural coupler Lock plate Position Leads Red Brown Installed Free Push Removed Free Push ...

Page 167: ...ng 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 after the brown or black lead is removed ...

Page 168: ...Q ty Service points STARTER MOTOR DISASSEMBLY Follow the left Step for disassembly Starter motor Refer to 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 STARTER MOTOR ...

Page 169: ...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 170: ...7 19 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 171: ...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 172: ...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 173: ...7 22 E ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM 3 2 R R M B 1 G G 4 B G G B R R R G G 1 Lighting coil 2 Battery 3 Fuse 10A 4 Rectifier regulator B Black G Green R Red G W Green white ...

Page 174: ...rectifier regulator is disconnected when measuring the output peak voltage Rectifier regulator output peak voltage Red R Black B r min Unloaded Cranking 2 000 3 500 V 7 5 12 5 12 5 1 LIGHTING COIL PEAK VOLTAGE 1 Measure Lighting coil output peak voltage Below specification Replace the lighting coil NOTE Make sure the output lead red lead 1 of the rectifier regulator is disconnected when measuring ...

Page 175: ...B 3 R B B Gy B M 5 4 R R R B 2 Gy B R Gy P W B W R W O P O Br Br L L B B W B G Gy 1 Pickup coil 2 CDI unit 3 YPVS servomotor 4 Fuse 10A 5 Battery B Black Br Brown G Green Gy Gray L Blue O Orange P Pink R Red W White W B White black W R White red YPVS ...

Page 176: ...7 25 E ELEC YPVS FUSE Refer to STARTING SYSTEM BATTERY Refer to ELECTRICAL in chapter 3 PICKUP COIL Refer to IGNITION SYSTEM CDI UNIT Refer to IGNITION SYSTEM ...

Page 177: ...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 178: ...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 179: ...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 180: ...P W B W R W O P O Br Br L L B B W B G Gy 3 B B W L W L 4 L L B L B B B W L B L 1 Lighting coil 2 CDI unit 3 Fuel level sensor 4 Oil level sensor 5 Buzzer 6 Multifunction meter 7 Speed sensor 8 Thermoswitch 9 Rectifier regulator 0 Fuse 10A A Battery B Black Br Brown G Green Gy Gray L Blue O Orange P Pink R Red W White Y Yellow B Y Black yellow L B Blue black L R Blue red R B Red black R W Red white...

Page 181: ...ON SYSTEM THERMOSWITCH 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 position Resistance Ω A 292 308 B 97...

Page 182: ...W L Black B Float position Resistance Ω A 757 803 B 0 8 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 183: ...n 1 Check Display function Not operate Replace the multifunc tion meter 1 Oil level sensor 2 Fuel level sensor 3 Buzzer 4 Battery 5 Speed sensor B Black G Green L Blue P Pink R Red Y Yellow L B Blue black L R Blue red R W Red white W L White blue ...

Page 184: ...ack leads Connect the white blue and black ter minals with a jumper lead 2 Connect the green and red terminals with a jumper lead 3 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 2 from the green two pin connector Disconnect the jumper lead 3 and then connect it to green a...

Page 185: ...r red black with a battery Disconnect the white two pin connec tor blue and black leads Connect the blue and black terminals with a jumper lead 2 Connect the green and red terminals with a jumper lead 3 NOTE If the jumper lead is installed for more than 30 seconds the display will auto matically turn off Remove the jumper lead 2 from the white two pin connector Disconnect the jumper lead 3 and the...

Page 186: ...he multifunction meter unit or emptying the oil tank connect the blue and black terminals white two pin connector with a jumper lead 2 to pre vent the oil warning indicator from being activated Checking steps Supply DC 12 voltage to the white four pin connector red black with a battery Connect the green and red terminals with a jumper lead 3 Connect the pink and black terminals with a jumper lead ...

Page 187: ... fuel warning indicator from being activated When inspecting the multifunction meter unit or emptying the oil tank connect the blue and black terminals white two pin connector with a jumper lead 2 to pre vent the oil warning indicator from being activated Speed meter output voltage 10 5 V Checking steps Supply DC 12 voltage to the white four pin connector red black with a battery Connect the green...

Page 188: ...e than 11 6 V Output pulse 2 pulses one full turn Checking steps Apply DC 12 voltage to the white three pin connector between the red yellow and black yellow leads Rotate the paddle wheel by hand and measure the voltage between the yel low and black yellow leads NOTE As the paddle wheel is rotated a square wave voltage signal a is produced Two pulses occur every time the pad dle wheel makes one fu...

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Page 190: ...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 20 Remote control cables inspection 8 20 Steering cable jet pump side installation 8 20 Steering cable stopper installation 8 20 QSTS cable jet pump side installation 8 2...

Page 191: ...eat lock inspection 8 36 BATTERY BOX 8 37 EXPLODED DIAGRAM 8 37 REMOVAL AND INSTALLATION CHART 8 37 EXHAUST SYSTEM 8 39 EXPLODED DIAGRAM 8 39 REMOVAL AND INSTALLATION CHART 8 39 SERVICE POINTS 8 41 Exhaust system inspection 8 41 Exhaust component parts sub assembly 8 41 DECK AND HULL 8 42 EXPLODED DIAGRAM 8 42 REMOVAL AND INSTALLATION CHART 8 42 ENGINE MOUNT 8 44 EXPLODED DIAGRAM 8 44 REMOVAL AND ...

Page 192: ...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 193: ...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 194: ...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 2 3 QSTS cable 2 1 with white tape a ...

Page 195: ...Procedure Part name Q ty Service points 4 QSTS cable 1 1 NOTE Route the QSTS cables behind of the oil filler hose 5 Handlebar assembly 1 6 Nut washer 2 2 7 QSTS converter 1 8 Throttle cable 1 9 Choke cable 1 Reverse the removal steps for installation ...

Page 196: ...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 197: ...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 198: ...e adjusting the QSTS cables set the control grip to the neutral position Adjust the QSTS cable lengths a to the specified length and be sure to take up any slack 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 f...

Page 199: ...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 200: ... HOOD HANDLEBAR 7 Adjust Choke lever operation Refer to CONTROL SYSTEM in chapter 3 8 Adjust Throttle lever free play Refer to CONTROL SYSTEM in chapter 3 9 Adjust QSTS cable Refer to CONTROL SYSTEM in chapter 3 ...

Page 201: ...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 202: ...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 203: ...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 204: ...oints STEERING COLUMN REMOVAL Follow the left Step for removal Steering console cover assembly Refer to STEERING CONSOLE COVER Steering cable end Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Nut 4 2 Plate 1 3 Steering column assembly 1 4 Rubber seal 1 Reverse the removal steps for installation 1 2 3 4 16 N m 1 6 kgf m 11 ft Ib ...

Page 205: ...f 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 N m 1 6 kgf m 11 ft Ib 5 N m 0 5 kgf m 3 6 ft Ib 26 N m 2 6 kgf m 19 ft Ib 2 7 5 4 3 2 1 8 6 7 ...

Page 206: ...rocedure 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 N m 1 6 kgf m 11 ft Ib 5 N m 0 5 kgf m 3 6 ft Ib 26 N m 2 6 kgf m 19 ft Ib 2 7 5 4 3 2 1 8 6 7 ...

Page 207: ...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 208: ...D 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 Screw 4 5 Speed sensor 1 6 Steering cable end 1 7 Bolt 1 8 Steering cable holder 1 ...

Page 209: ...ES AND SPEED SENSOR LEAD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 9 Cap 1 10 Nut 1 11 Steering cable 1 12 Nut 1 13 Pin 1 14 QSTS cable end 1 15 Cap 1 16 Nut 1 17 QSTS cable 1 Reverse the removal steps for installation ...

Page 210: ...XPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points SPEED SENSOR DISASSEMBLY Follow the left Step for disassembly 1 Paddle wheel set 1 2 Speed sensor housing 1 Reverse the disassembly steps for assembly FWD 1 2 Not reusable ...

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: ...e 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 Visor 1 5 Pop nut 8 6 Bolt 2 10 9 1 11 2 3 5 8 4 16 N m 1 6 kgf m 11 ft Ib 6 14 mm 5 N m 0 5 kgf m 3 6 ft Ib 6 14 mm 12 N m 1 2 kgf m 8 7 ft Ib 5 20 mm 1 N m 0 1 kgf m 0 7 ft Ib 6 7 ...

Page 214: ...ts 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 N m 1 6 kgf m 11 ft Ib 6 14 mm 5 N m 0 5 kgf m 3 6 ft Ib 6 14 mm 12 N m 1 2 kgf m 8 7 ft Ib 5 20 mm 1 N m 0 1 kgf m 0 7 ft Ib 6 7 FRONT HOOD ...

Page 215: ...VER 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 5 3 Nut washer 2 2 4 Bolt washer 4 4 5 Screw 2 5 19 mm 2 N m 0 2 kgf m 1 4 ft Ib 8 25 mm 16 N m 1 6 kgf m 11 ft Ib 5 N m 0 5 kgf m 3 6 ft Ib 1 7 2 9 8 5 6 4 6 25 mm 3 N m 0 3 kgf m 2 2 ft Ib 3 ...

Page 216: ...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 N m 0 2 kgf m 1 4 ft Ib 8 25 mm 16 N m 1 6 kgf m 11 ft Ib 5 N m 0 5 kgf m 3 6 ft Ib 1 7 2 9 8 5 6 4 6 25 mm 3 N m 0 3 kgf m 2 2 ft Ib 3 ...

Page 217: ... 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 N m 0 2 kgf m 1 4 ft Ib 6 18 mm 3 N m 0 3 kgf m 2 2 ft Ib 4 3 1 9 2 2 5 5 20 mm 1 N m 0 1 kgf m 0 7 ft Ib ...

Page 218: ...ocedure 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 N m 0 2 kgf m 1 4 ft Ib 6 18 mm 3 N m 0 3 kgf m 2 2 ft Ib 4 3 1 9 2 2 5 5 20 mm 1 N m 0 1 kgf m 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 29 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: ...oval 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 front the oil level sensor lead and the oil tank breather hose 3 Ventilation hose bow side 1 ...

Page 223: ...2 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 36 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 Terminal extension 1 7 Bolt 1 8 Battery positive lead 1 9 Clip breather hose 1 1 10 Battery 1 11 Bolt 3 ...

Page 229: ...ints 12 Electrical box 1 13 Cap nut washer 2 2 14 Holder 1 15 Holder 1 16 Cap nut washer 2 2 17 Battery box 1 NOTE Before installing the battery box route the battery leads and battery breather hose through the holes of the battery box 18 Stay 1 Reverse the removal steps for installation ...

Page 230: ... Procedure Part name Q ty Service points EXHAUST SYSTEM REMOVAL Follow the left Step for removal Battery box Refer to BATTERY BOX Jet pump unit assembly Refer to JET PUMP UNIT in chapter 6 1 Floatation 1 2 Floatation 1 3 Water lock band 1 4 Hose clamp 2 5 Rubber joint 1 6 Hose clamp 2 7 Rubber hose 1 ...

Page 231: ...ED DIAGRAM Step Procedure Part name Q ty Service points 8 Water lock 1 9 Bolt 3 10 Packing 1 11 Hose clamp 2 NOTE Remove parts 11 to 14 as a set 12 Water tank 1 13 Rubber hose 1 14 Exhaust outlet 1 Reverse the removal steps for installation ...

Page 232: ... 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 d...

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: ...EMOVAL AND INSTALLATION 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 2 2 Damper 1 3 Bolt 8 4 Engine mount 4 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: ...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 fiberglass...

Page 238: ...W2 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 WATERCRAFT FRP REPAIR MAN UAL 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: ...with 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 p...

Page 241: ...E 1 2 3 4 5 6 7 8 9 TRBL ANLS CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS 9 1 TROUBLE ANALYSIS CHART 9 1 ...

Page 242: ...LYSIS 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 Fuel tank breather hose 4 Fuel hose 4 Fuel filter 4 Fuel pump 4 Carburetors 4 Carburetor synchronizat...

Page 243: ...il 7 Ignition coil 7 Rectifier regulator 7 Electrical sensor 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 INCRE...

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Page 246: ...YAMAHA MOTOR CORPORATION USA Printed in USA Nov 2000 1 CR F0W 28197 1A 11 GP800A ...

Page 247: ... regulator B YPVS servomotor C Oil level sensor D Fuel level sensor E Multifunction meter F Speed sensor J Buzzer B B B P P O G G G G Br G L B G O B P P P W B W R Br Br Br Br L B B B R R B R B B B W W Gy P R B B B B B B B L L Gy R R Br Br R B B B W W W W B Y B R R P P B Gy R R R R R R R R R R G G G W B W R Br L W P B O W B R Y B Y Y R B R W L B L R W L W L W R W R W R W B B B Br Br O O P W G G Gy ...

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Yamaha GP800R WaveRunner 2003, Service Manual

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Summary of Contents for GP800R WaveRunner 2003

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