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Yamaha GX1800A, Service Manual

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Yamaha GX1800A Service Manual Download Page 2

Preface

This Service Guide has been prepared to provide Yamaha dealers with information about a new
model (e.g., product concept, features, technical details).

The information contained in this guide is essential to Yamaha dealer service staff for their daily cus-
tomer service.
It is our hope that you will use this guide to train your dealer service staff about this model and that it
will help answer questions about this new model.

TIP:

• The descriptions herein are based on the latest specifications available at the time when this guide

has issued.

• For detailed service information, refer to the appropriate service manual.

WaveRunner

FZR, FZS

SERVICE GUIDE

©2013 by Yamaha Motor Co., Ltd.

1st Edition, November 2013

All rights reserved.

Any reprinting or unauthorized use 

without the written permission of 

Yamaha Motor Corporation, U.S.A. 

is expressly prohibited.

Printed in U.S.A.

Summary of Contents for GX1800A

Page 1: ...SERVICE GUIDE 90894 64631 02 WaveRunner FZR GX1800 F3L FZS GX1800A F3K ...

Page 2: ...aler service staff about this model and that it will help answer questions about this new model TIP The descriptions herein are based on the latest specifications available at the time when this guide has issued For detailed service information refer to the appropriate service manual WaveRunner FZR FZS SERVICE GUIDE 2013 by Yamaha Motor Co Ltd 1st Edition November 2013 All rights reserved Any repr...

Page 3: ...son table 3 Technical tips 4 Engine control 4 ECM circuit diagram 6 ECM coupler layout 8 Engine control system 10 Self diagnosis 13 Diagnostic code table 13 Power unit 15 Jet pump unit 16 Hull and hood 17 Lubrication system 18 Hose routing 19 Cooling water flow 20 Service information 21 Maintenance interval chart 21 Specifications 23 Model data 23 Wiring diagram 25 How to use the wiring diagram 25...

Page 4: ...umber H I N The H I N is stamped on a plate attached to the boarding platform 1 Model name 2 Hull type 3 Primary I D number Starting primary I D number F3K 800101 F3L 800101 1 Engine name 2 Engine type 3 Engine serial number MODEL F3K PRI I D YAMAHA MOTOR CO LTD ASSEMBLED IN U S A FROM AMERICAN AND JAPANESE COMPONENTS ASSEMBLÉ AUX ÉTATS UNIS DE PIÈCES AMÉRICAINES ET JAPONAISES 1 2 3 YAMAHA MOTOR C...

Page 5: ...gn to improve the straight running stability a Power unit 4 stroke L4 DOHC 16 valve 1812 cm engine with electronic fuel injection Supercharged Single throttle body 4 in 1 exhaust system Wet sump lubrication b Jet pump Stainless steel 3 blade ø160 mm 17 0 pitched impeller Impeller turning direction counterclock wise when viewed from the rear Aluminum jet thrust nozzle Q S T S c Electrical Electroni...

Page 6: ...ble Model FZR FZS Total length 3 37 m 132 7 in Width 1 23 m 48 4 in Dry weight 375 kg 827 lb 377 kg 831 lb Seats 1 2 seater 3 seater 1 The rear seats 1 and handgrips 2 for the FZR and FZS have different shape 1 1 2 2 A B A FZR B FZS ...

Page 7: ...me opening angle of the ETV and fail safe function with information received from the sensors and switches 4 Thermo sensor Detects the temperature of the exhaust cooling water 5 Oil pressure switch Detects the pressure of the engine oil 6 Thermo switch Detects engine overheating 7 Intake air temperature sen sor Detects the temperature of the intake air 8 Knock sensor Detects engine knocking 9 TPS ...

Page 8: ...pening angle of the throttle lever 14 Steering sensor Detects when the handlebar is turned all the way to the right or left and a load is applied 15 Reverse sensor Detects the R position of the shift lever Part name Function ...

Page 9: ...e sensor 15 Reverse sensor 16 Intake air temperature sensor 17 Engine temperature sensor 18 Thermo sensor 19 Steering sensor 41 ETV relay 39 Dual analog meter 38 YDIS 37 Fuel pump relay 36 Fuel pump module 35 Ignition coil 4 34 Ignition coil 3 33 Ignition coil 2 32 Ignition coil 1 28 Fuel injector 1 29 Fuel injector 2 30 Fuel injector 3 31 Fuel injector 4 20 Slant detection switch 40 Fuse 10 A 2 S...

Page 10: ...temperature sensor 17 Engine temperature sensor 18 Thermo sensor 19 Steering sensor 20 Slant detection switch 21 Knock sensor 22 Oil pressure switch 23 Thermo switch 24 Engine shut off switch 25 APS 26 APS 1 27 APS 2 28 Fuel injector 1 29 Fuel injector 2 30 Fuel injector 3 31 Fuel injector 4 32 Ignition coil 1 33 Ignition coil 2 34 Ignition coil 3 35 Ignition coil 4 36 Fuel pump module 37 Fuel pum...

Page 11: ...n 2 3 Cam position sensor Green Orange 4 5 Slant detection switch Blue Black 6 7 Battery power source Red Yellow 8 Pickup coil White Black 9 10 11 12 13 Thermo sensor Black Blue 14 Main relay drive signal Yellow White 15 Intake air tempera ture sensor Black Red 16 Intake air pressure sensor Pink Green 17 Steering sensor White Blue 18 Reverse sensor Green White 19 20 Main and fuel pump relay main r...

Page 12: ...55 56 57 58 Fuel injector 1 Purple Red 59 Fuel injector 2 Purple Black 60 Ignition coil 4 Black Green 61 Ignition coil 3 Black Yellow 62 ETV ground Black 63 64 Thermo switch Pink 65 66 67 Ground Black 68 69 70 ETV ground Black 71 No Connecting part Color 72 Engine shut off switch White 73 74 75 76 77 78 ETV motor positive Green 79 Oil pressure switch Pink White 80 ETV relay power source coil Yello...

Page 13: ...ssure switch is on ETV is open Engine speed exceeds 4500 r min Opening angle of the ETV is regulated Maximum engine speed is limited to approximately 2100 2300 r min Cancel Stop the engine and wait for 30 seconds or more Engine is restarted and the oil pressure switch is off If the engine is stopped during oil pressure warning control it can be restarted Cam position sensor failure control Control...

Page 14: ...ed exceeds 7800 r min Ignition is controlled Condi tion Action Normal None Level 1 Ignition is cut off to 1 cylinder Level 2 Ignition is cut off to 2 cylinders Level 3 Ignition is cut off to 3 cylinders Level 4 Ignition is cut off to all cylinders High intake air pressure control In a state where engine speed has exceeded 7550 r min and intake pressure is higher than 177 kPa 25 7 psi has lasted lo...

Page 15: ...ns are present Slant detection switch is on Engine speed is 3000 r min or less Ignition and fuel injection are cut to all cylinders and the engine is stopped Cancel Engine is stopped The check engine warning indicator does not come on and the buzzer does not sound L MODE con trol L MODE is activated Opening angle of the ETV is regulated Ignition timing is con trolled Maximum engine speed is limite...

Page 16: ...d Diagnostic code table Indicated Not indicated Code No Item Diagnostic code output Multifunction meter YDIS Diagnosis Diagnosis record 01 Normal 13 Pulser coil 1 15 Engine temperature sensor 17 Knock sensor 19 Battery voltage 23 Air temperature sensor 2 24 Cam position sensor 29 Air pressure sensor 3 47 Slant detection switch 55 Steering sensor 65 EX manifold water temp sensor 4 78 Reverse switch...

Page 17: ... air temperature sensor 3 Intake air pressure sensor 4 Thermo sensor 5 Reverse sensor 124 125 126 127 128 TPS 131 132 133 134 135 APS 251 low octane fuel Code No Item Diagnostic code output Multifunction meter YDIS Diagnosis Diagnosis record ...

Page 18: ... 7 fins to increase supercharged pressure 2 Large sized air cooler Enlarged internal core improves cooling efficiency and increases air density 3 High efficiency oil cooler Regulates the engine temperature increase due to higher out put 4 Forged piston Improved strength Shape of piston head has been changed to improve combus tion efficiency and to reduce pollutants in the exhaust gases 5 Piston pi...

Page 19: ...higher output 8 Thermostat Thermostat valve opening temperature has been changed to optimize engine temperature and to reduce pollutants in the exhaust gases 9 Cooling water passage Cooling passages through exhaust manifold and exhaust man ifold gasket have been optimized to reduce thermal load 10 Premium gasoline Provides better anti knock property to correspond to higher engine output Major chan...

Page 20: ...e the number of recti fying fins has been increased from 6 fins to 8 fins The number of oil seals has also been increased for better sealing property 4 Jet intake Fins are added to improve water supply efficiency 5 Jet nozzle To correspond to the higher output engine the nozzle diame ter a has been reduced from 86 8 mm 3 42 in to 85 0 mm 3 35 in and the nozzle angle b has also been reduced from 5 ...

Page 21: ...ngine temperature increase due to higher output A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B 1 Intake camshaft 2 Exhaust camshaft 3 Cylinder block 4 Crankshaft 5 Oil separator tank 6 Oil pan 7 Oil strainer 8 Oil pipe 9 Oil pump feed pump 10 Relief valve 11 Oil cooler ASSY 12 Oil filter 13 Oil pump drive gear 14 Supercharger A To air intake pipe B Oil flow ...

Page 22: ...nsom plate C To cooling water pilot outlet on port side D To drain joint transom plate E To drain joint F To drain joint G To cooling water pilot outlet on starboard side H For water draining when engine is stopped I Cooling water flow J Blowby gas flow K Bilge water flow L Fuel flow ...

Page 23: ... F D B C E G A From flushing hose connector B From transom plate C To cooling water pilot outlet on port side D To drain joint E To exhaust valve F To cooling water pilot outlet on star board side G For water draining when engine is stopped ...

Page 24: ... strainer Check for clogs and damage Cooling water hoses Check for damage and leakage and check clamps Engine oil Replace Oil filter Replace Intermediate housing Lubricate Spark plugs Check Battery Check specific gravity of electrolyte terminals bands and breather hose Battery leads Check terminals Steering master Check operation and for looseness Steering cable Check exterior and con nections and...

Page 25: ...Check hoses for clogs and damage check clamps and clean bilge strainer Electric bilge draining system Check operation check hoses for damage check clamps and clean bilge pump strainer Stern drain plugs Check O rings Anode Check for corrosion and clean 2 Valve clearance Check and adjust 2 Rubber coupling Check for cracks inden tations looseness and noise Engine mount Check for damage and peeling It...

Page 26: ...min Maximum fuel consumption 83 4 L h 22 0 US gal h 18 3 Imp gal h Cruising range at full throttle 0 84 hour Power unit Engine type Liquid cooled 4 stroke DOHC Cylinder quantity 4 Total displacement 1812 cm Bore stroke 86 0 78 0 mm 3 39 3 07 in Compression ratio 8 5 1 Exhaust system Wet exhaust Lubrication system Wet sump Cooling system Water cooled Starting system Electric Camshaft drive system C...

Page 27: ...stem Reverse gate Fuel and oil Recommended fuel Premium unleaded gasoline Minimum octane rating PON 91 Minimum octane rating RON 95 Fuel tank capacity 70 L 18 5 US gal 15 4 Imp gal Recommended engine oil 4 stroke motor oil Engine oil grade API SE SF SG SH SJ SL Engine oil type SAE 10W 30 10W 40 20W 40 20W 50 Engine oil total quantity 5 3 L 5 60 US qt 4 66 Imp qt With oil filter replacement 3 6 L 3...

Page 28: ...range B R Black Red B W Black White B Y Black Yellow G Green Gy Gray G O Green Orange G W Green White L Blue L B Blue Black L R Blue Red L Y Blue Yellow O Orange O R Orange Red O W Orange White P Pink P B Pink Black P G Pink Green P R Pink Red P W Pink White Pu B Purple Black Pu G Purple Green Pu R Purple Red Pu Y Purple Yellow R Red R Y Red Yellow W White W B White Black W L White Blue Y Yellow Y...

Page 29: ......

Page 30: ...Nov 2013 ABE E ...

Page 31: ...O W O W R R W W W Br Br Br Br B W B B B B B B B B R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y B O B O B O B O B O B O B O B O B O B O B O Y Y Y Y B R R R R R R R R R Br Br Br L L B O B O B O B O B O B O B B O B O B O O R O R B B B B B B B O B B R Y R Y R Y R Y R Y R Y R R W W W W Gy Gy Gy P Y Y L Y G Y W Y W L R L R L R L R L B L B L B L Y L Y B G B L B L B Y R W W B R ...

Page 32: ...S A To entry box B Antenna a Fuse 30 A battery b Fuse 20 A main and fuel pump relay c Fuse 10 A ETV relay d Fuse 10 A main and fuel pump relay e Fuse 3 A remote control receiver f Fuse 3 A electric bilge pump ...

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