Page 1: ...ENT Use Genuine YAMAHA Parts And Accessories LIT 18616 00 77 Service Manual SUPER JET SJ650Q LIT 18616 00 77 Service Manual YAMAHA MOTOR CORPORATION U S A PRINTED IN U S A SJ650Q 18616 00 77 CVR_R 8 1...
Page 2: ...YAMAHA SUPER JET SJ650Q...
Page 3: ...may differ in detail from the descriptions and illustrations given in this publication Use only the latest edition of this manual Authorized Yamaha dealers are notified periodically of modifications a...
Page 4: ...e model you have This is because a procedure described may relate to several models though only one may be illustrated The name of model described will be mentioned in the description REFERENCES These...
Page 5: ...N REED VALVE CYLINDER HEAD CYLINDER AND PISTON PREPARA110N FOR REMOVAL J RernowetM cartlureiOf 2 Remarks 0 Removal point Extent of removal Symbol mark Exploded diagram I REED VALVE CYLINDER HEAD CYLIN...
Page 6: ...lue Service limit Resistance J Voltage V Electric current A Symbol to in an exploded diagram indicate grade of lubricant and location of lubrication point Apply Yamaha two cycle outboard oil Yamalube...
Page 7: ...ELECTRICAL SYSTEM HULL AND HOOD TROUBLE SHOOTING ELEC HULL HOOD TRBL SHTG...
Page 8: ...MBER 1 1 HULL IDENTIFICATION NUMBER H I N 1 1 DIMENSIONS 1 2 SAFETY WHILE WORKING 1 3 FIRE PREVENTION 1 3 VENTILATION 1 3 SELF PROTECTION 1 3 OILS GREASES AND SEALING FLUIDS 1 3 GOOD WORKING PRACTICES...
Page 9: ...ting Primary J D Number 811701 ENGINE SERIAL NUMBER The engine serial number is stamped on a plate attached to the intake manifold Starting serial number 016911 PUMP SERIAL NUMBER The jet pump unit se...
Page 10: ...I I DIMENSIONS A60750 0 DIMENSIONS 1 525 mm 60 0 in 90mm 3 54 in 660 mm 26 0 in 1 2 c N X E E 0 N N 680 mm 26 8 in __ I I...
Page 11: ...are doing OILS GREASES AND SEALING FLUIDS Use only genuine Yamaha oils greases and sealing fluids or those recommended by Yamaha Under normal conditions of use there should be no hazards from the use...
Page 12: ...fixings before outer positioned ones 3 Non reusable items Always use new gaskets packings 0 rings split pins and circlips etc on reassembly DISASSEMBLY AND ASSEMBLY 1 Clean parts with compressed air...
Page 13: ...and enable accurate assembly and tune up Improvisa tions and use of improper tools can cause damage to the equipment NOTE For U S A and Canada use part number starting with VB YU or YW For others use...
Page 14: ...117 90890 06521 p Ppp YB 6139 90890 06522 1 6 4 Compression gauge P N YU 33223 1 90890 06751 5 Cylinder gauge set P N YU 3017 90890 06759 6 Tachometer P N YU 8036 A 90890 06760 FOR POWER UNIT SERVICE...
Page 15: ...B 6049 90890 06518 YB 6096 1 7 3 Bearing separater P N YU 35557 90890 06534 FOR JET UNIT SERVICE 1 Shaft holder P N YW 38742 90890 6069 2 Coupler wrench P N YW 38741 90890 06425 3 Drive shaft holder P...
Page 16: ...890 06606 90890 06626 90890 06662 90890 06634 1 8 5 Driver rod PIN YB 6071 YB 6229 90890 06606 6 Bearing outer race attachment P N YB 6016 90890 06626 7 Bearing inner race attachment P N YB 34474 9089...
Page 17: ...CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 2 1 Engine 2 2 2 Electrical 2 4 TIGHTENING TORQUE 2 5 GENERAL TORQUE SPECIFICATIONS 2 5 PIPE ROUTING DIAGRAM 2 6 CABLE...
Page 18: ...pulsion system Jet pump type Impeller rotation Transmission Steering nozzle angle Fuel and oil Fuel Recommended engine oil Gasoline and oil mixing ratio Fuel tank capacity I Unit mm in mm in mm in kg...
Page 19: ...ut limit B A Connecting rod big end side clearance C Small end free play limit D Unit SUPER JET SJ650Q kPa kg cm2 psi 940 9 4 134 mm in 0 1 0 0039 mm in mm in mm in mm in mm in mm in mm in mm in mm in...
Page 20: ...pass 2 B P 2 mm in 0 6 0 024 Bypass 3 B P 3 mm in 0 9 0 035 Bypass 4 B P 4 mm in 0 7 0 028 Low speed screw 1 1 8 114 Throttle valve Th V 120 Valve seat V S mm in 1 5 0 059 High speed screw 1 3 8 114 R...
Page 21: ...rol rpm 3 400 400 Ignition coil Model Manufacturer F6T43281 MITSUBISHI Minimum spark gap mm in 8 0 31 Primary winding resistance 0 0 092 0 014 at 20 C 68 F Secondary winding resistance kO 4 1 0 6 at 2...
Page 22: ...semblies are given in applicable sections of this manual To avoid causing warpage tighten multifastener assemblies in criss cross fashion in progressive stages until the specified torque is reached 2...
Page 23: ...Ecl I __P_IP_E_R_o_u_T_IN_G __ D_IA_G_R_A_M _______________ G Breather hose Fuel hose 2 Fuel hose 1 Air vent hose 1 Breather hose c 2 Fuel hose 4 J Fuel hose 3 Air vent hose 2 Air vent hose 3 A A 8 8...
Page 24: ...ISPEC I I CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM CD Choke cable Throttle cable Steering cable 2 7 C C _ 4 A A B B...
Page 25: ...LE ADJUSTMENT 3 6 STEERING SYSTEM INSPECTION ADJUSTMENT 3 6 STEERING COLUMN 3 6 STEERING POLE 3 7 STEERING CABLE 3 7 STEERING NOZZLE ANGLE ADJUSTMENT 3 9 IMPELLER INSPECTION 3 10 RIDE PLATE ANGLE ADJU...
Page 26: ...ction Impeller housing clearance inspection Rubber coupling inspection Electrical Wire inspection Starting switch inspection Stop switch inspection Starting motor operation Battery maintenance Hull an...
Page 27: ...PARATION FOR MAINTENANCE 3 2 020710 0 PREPARATION FOR MAINTENANCE 1 Support Steering pole 2 Remove Engine hood NOTE Turn the latch knob to the open position Then lift upward on the latch hook and un l...
Page 28: ...250 50 rpm using the throttle stop screw 4 Screw the low speed screw in or out 1 4 of a turn and adjust for maximum stable engine speed 5 Readjust the throttle stop screw to obtain a 1 250 50 rpm idl...
Page 29: ...1 Remove Hose tie CD Hose Holder Fuel filter assembly 2 1nspect Filter element Contamination Replace as a filter as sembly Filter body Crack Damage Replace as a filter as sembly Filter assembly Water...
Page 30: ...nstall Fuel tank filler cap Fuel filler lid 034700 0 THROTTLE LEVER ADJUSTMENT NOTE Before adjusting the throttle lever free play trolling speed should be adjusted 1 Measure Throttle lever free play O...
Page 31: ...ion Fully closed the choke valve and tighten the screw 3 Inspect Pull knob farthest toward Knob automatically return Adjust 4 Adjust Adjust nut Turn in to stop automatic return STEERING SYSTEM INSPEC...
Page 32: ...ustment steps Remove the bow cover Loosen the lock nut G Tighten the adjusting nut Adjusting nut 15 Nm 1 5 m kg 11 ft lb Hold the adjusting nut with one wrench while tightening the lock nut Lock nut 7...
Page 33: ...ck nut Turn the barrel for adjusting Tum in Increase the clearance Tum out Increase the clearance Tighten the lock nut X Lock nut 3 Nm 0 3 m kg 2 2 ft lb Connect the cable joint it WARNING The cable j...
Page 34: ...elect the nozzle angle refering to the following table Nozzle angle Handle stopper CD and steering cable pivot bolt position 18 5 s o P1 20 5 s P1 22 5 s o P2 24 5 S2 1J 8 P2 Tighten the steering cabl...
Page 35: ...Remove battery to prevent acid loss dur ing impeller service Fill charge battery as required while performing impeller service 2 Remove Bolt Intake screen 3 Check Impeller CD Wear Damage Replace Scra...
Page 36: ...I I _ IMPELLER INSPECTION D 35 70M7 o 3 11 RUBBER COUPLING 1 Remove Engine unit Refer to CHAPTER 5 POWER UNIT 2 Inspect Rubber coupling CD Wear Clack Replace 3 Install and adjust Refer to CHAPTER 5 PO...
Page 37: ...lling them NOTE Rear end height changes 1 0 mm 0 04 in per turn of the jack bolt Add shim washers to achieve the desired amount of rear end height Rear end height Counter measure 0 1 0 mm 0 0 04 in 1...
Page 38: ...e lock plate is released the switch for starter and stop is open oon Install the lock plate to the switch box and inspect the following steps Starter switch Engine stop switch inspec tion steps Discon...
Page 39: ...INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beat en egg or vegetable oil Call physician im mediately Eyes Flush with water for 15 minutes and get prompt medical atte...
Page 40: ...ses After the acid is filled up to the UPPER LEVEL allow the cell to stand for 20 minutes If the acid level has dropped add the same acid up to the UPPER LEVEL once again Acid filling nozzle CD Filler...
Page 41: ...minals with a water resistant grease to minimize terminal corrosion 03673 0 SPARK PLUG 1 Remove Spark plug 2 Inspect Electrode CD Wear Damage Replace Insulator color Normal condition is a medium to li...
Page 42: ...ighten Spark plug NOTE Before installing a spark plug clean the gasket surface and plug surface Also it is suggested to apply a thin film of Anti Seize Compound to the spark plug threads to pre vent f...
Page 43: ...e engine and check torque of the cylinder head 2 Remove Spark plugs 3 Set Compression gauge 4 Cranking Cranking the engine until compression gauge stops rising Compression pressure 940 kPa 9 4 kg cm2...
Page 44: ...R 1 Inspect Seal rubber CD Wear Crack Replace 037740 0 RUBBER MOUNT 1 1nspect Rubber mount CD Crack Separate Replace 03775 0 BILGE STRAINER 1 Remove Bilge strainer CD Located under the coupling Strain...
Page 45: ...ase Engine control cables G Throttle cable inner NOT Squeeze the throttle lever and remove the seal G Spray a rush inhibitor into the outer cable Cable joint G Steering cable NOT Remove cable joint an...
Page 46: ...ing column pivot shaft Choke knob shaft Bearing housing NOTE Full in the bearing housing from nipple with water resistant grease Fill in the grease slowly and carefully because they can damage the hos...
Page 47: ...DIAGRAM 4 1 FUEL SYSTEM 4 2 PREPARATION FOR REMOVAL 4 2 INSPECTION 4 3 Fuel filter water separator 4 3 Fuel cock 4 3 Fuel tank 4 3 ASSEMBLY AND INSTALLATION 4 4 CARBURETOR 4 6 PREPARATION FOR REMOVAL...
Page 48: ...l tank ON Fuel cock ON 1 000 mm 39 4 in Gray with Yellow paint ring 2 Fuel tank RES Fuel cock RES 890 mm 35 0 in Gray 3 Fuel cock OUT Fuel filter IN 180 mm 7 1 in Gray 4 Fuel filter OUT Carburetor cov...
Page 49: ...L SYSTEM PREPARATION FOR REMOVAL Lift the steering pole up and support it Remove the engine hood Turn the fuel cock to OFF Loosen the fuel filler cap Release the fuel line pressure Drain the fuel Remo...
Page 50: ...joint assembly 7 Band 8 Fuel tank I 4 3 Q ty Remarks 1 Loosen the screw 1 3 1 1 Loosen the screw 1 2 1 INSPECTION FUEL FILTER WATER SEPARATOR Refer to page 3 4 FUEL COCK 1 Check Smoothness Leakage Cl...
Page 51: ...242 Bolt 7 Nm 0 7 m kg 5 1 ft lb 2 Install Pipe joint G Pipe Hose Clamp NOTE Connect the hose for RES pipeside Install the pipe with the pipe bending as shown 3 Install Pipe joint assembly G Sleeve Pi...
Page 52: ...IFUEL I 0 I__ F U EL S Y ST EM v_ s lnstall _ embly Gl Pipe jomt ass CD Clamp 4 5 Clamp 0 1 m kg 0 7 ft lb 1 Nm 6 Connect Fuel hose Breather hose 4 1 Refer to page NOTE t re new Always use a...
Page 53: ...N FOR REMOVAL Turn the fuel cock to OFF Disconnect the fuel hose Disconnect the throttle cable at carburetor side Disconnect the choke cable at carburetor side 4 6 A 1 Nm 0 1 m kg 0 7 ft lb B 2 Nm 0 2...
Page 54: ...at arm 1 Screw 1 Plate 1 Needle valve assembly 1 Screw 2 Body assembly 1 Main jet 1 Pilot jet 1 Screw 4 Pump cover 1 Diaphragm body assembly 1 Filter High speed screw Low speed screw 1 1 1 INSPECTION...
Page 55: ...height Measure the distance between the sur face of the carburetor body and the top surface of the float arm Float arm height 0 0 2 mm 0 0 008 in NOTE The float arm should be resting on the needle val...
Page 56: ...n Ciean Damage Replace ASSEMBLY AND INSTALLATION 1 Install 0 ring Waster Spring High speed screw CD Low speed screw Note the following installation points Screw in the screw CD and until they are ligh...
Page 57: ...n s_crews in a diagonal pattern Screw 4 Nm 0 4 m kg 2 9 ft lb 3 Install Pilot jet CD Main jet Gasket Body assembly Screw 9 Screw 2 Nm 0 2 m kg 1 5 ft lb 4 Install 0 ring CD Needle valve assembly Clip...
Page 58: ...retor Washer Nut Gasket Plate Cover 2 j Flame arrester Cover 1 NOTE Tighten bolts in a diagonal pattern Bolt Plate 1 st 15 Nm 1 5 m kg 11 ft lb 2 nd 30 Nm 3 0 m kg 22 ft lb 7 Install Fuel hose Hose ti...
Page 59: ...de set position 17 mm 0 67 in Between cable guide top and plate top 10 Tighten Cable guide nut Throttle and choke cables Cable guide nut 9 Nm 0 9 m kg 6 5 ft lb 11 Adjust Throttle lever free play Chok...
Page 60: ...5 10 Piston 5 10 Reed valve 5 11 Cylinder head and cylinder 5 11 Muffler 5 12 Intake manifold 5 16 ENGINE UNIT INTERMEDIATE SHAFT AND HOUSING 5 17 PREPARATION FOR REMOVAL 5 17 NOTE ON REMOVAL AND REA...
Page 61: ...Turn the fuel cock to OFF Remove the carburetor a A 242 A B c D E 1 Nm 0 1 m kg 0 7 ft lb 2 Nm 0 2 m kg 1 4 ft lb 4 Nm 0 4 m kg 2 9 ft lb 20 Nm 2 0 m kg 14 ft lb 1 st j15 Nm 1 5 m kg 11 ft lb 2 nd I3...
Page 62: ...assembly the removed parts should be cleaned with solvent and apply the two cycle outboard oil onto the sliding surface Extent of removal Extent of removal Order 9 1 2 3 4 5 2 6 7 8 9 10 3 11 12 4 13...
Page 63: ..._c_v_u_N_o_ER_H_EA_o _c_v_L_IN_o_E_R_ 5 3 2 Disconnect Hose Spark plug cap 3 Disconnect Hose CD Clamp Exhaust hose 4 Remove Clamp 5 Loosen Clamp NOTE Loosen a hose clamp at muffler side 6 Remove Muff...
Page 64: ...r 1 8 Remove Bolt CD Thermo switch assembly 9 Remove Spark plug Bolt Cylinder head 10 Remove Bolt Cylinder 11 Remove Piston pin clip CD Piston pin Piston Bearing NOTE Before removing the piston pin cl...
Page 65: ...to scratch the piston and damage the piston ring G60700 0 INSPECTION AND REPAIR REED VALVE 1 Measure Clearance Out of specification Replace Reed valve bending limit vA 0 2 mm 0 008 in 2 Measure Valve...
Page 66: ...eral deposits Corrosion Ciean 3 Measure Cylinder head warpage Out of specification Resurface Warpage limit 0 1 mm 0 004 in Warpage measurement and resurface ment steps Attach a straight edge and a thi...
Page 67: ...er bore 0 Use cylinder gauge Out of limit Replace NOTE Measure the cylinder bore 0 in parallel Then find the average of the measurements Standard Wear limit Cylinder 77 00 77 02 mm 77 1 mm bore D 3 03...
Page 68: ...pecification Replace I Distance Piston diameter 10 mm 76 915 76 940 mm 0 4 in 3 028 3 029 in 4 Calculate Piston clearance Out of limit Replace piston piston rings as a set PISTON CYLINDER CLEARANCE BO...
Page 69: ...m End ga 2nd 0 008 0 016 in PISTON PIN AND BEARING 1 Inspect Piston pin Bearing Signs of heat discoloration Replace 2 Measure Piston pin outside diameter Use micrometer G Out of limit Replace l Piston...
Page 70: ...p with the locating pin Top and 2nd rings are same ring Take care not to scrach the piston and damage the piston ring 2 Install Bearing NOTE Apply the two cycle outboard oil onto the bearing 3 Install...
Page 71: ...1 Apply Two cycle outboard oil To piston piston rings and cylinder surface 2 Install Gasket Cylinder NOTE Aiways use a new gasket After installing check the smooth move ment of the piston Tighten the...
Page 72: ...nd 30 Nm 3 0 m kg 22 ft lb Thermo switch assembly Stay Spark plug NOTE Apply the water resistant grease into the thermo sensor hole Spark plug 20 Nm 2 0 m kg 14 ft lb MUFFLER 1 Install Muffler stay N...
Page 73: ...________ Coat the bolt with blue LOCTITE 242 3 Install Muffler 2 CD Silencer assembly Gasket Outer cover Bolt Bolt NOTE Aiways use a new gasket Tighten bolts to the outer cover first then to the sile...
Page 74: ...b 5 Install Gasket CD Ring Bolt NOTE Aiways use a new gasket lllll llil________ Coat the bolt with blue LOCTITE 242 6 Install Joint 2 CD Clamp Joint 1 Clamp NOTE Temporarily tighten the clamps 7 Insta...
Page 75: ...H_E_A_o _c_v_L_IN_o_E_R_ 5 15 8 Tighten Clamp Clamp 2 Nm 0 2 m kg 1 4 ft lb 9 Tighten Clamp Clamp 2 Nm 0 2 m kg 1 4 ft lb 10 Install Exhaust hose CD Clamp Hose Clamp 4 Nm 0 4 m kg 2 9 ft lb 11 Connect...
Page 76: ...ed valve assembly CD Gasket Reed valve plate Screw IIII It l 111_________ Coat the screw with blue LOCTITE 242 NOTE Aiways use a new gasket 2 Install Gasket Reed valve plate Gasket Intake manifold Pla...
Page 77: ...NIT INTERMEDIATE SHAFT AND HOUSING PREPARATION FOR REMOVAL Open the engine hood and support it Turn the fuel cock to OFF A 1 Nm 0 1 m kg 0 7 ft lb B 17 Nm 1 7 m kg 12 ft lb c 10 Nm 1 0 m kg 7 2 fHb D...
Page 78: ...nd bearing removal Extent of removal Order Part name 1 Bolt 2 Plate 3 Bolt 4 Coupling cover 5 Bolt 6 Engine unit 7 Coupling rubber 2 8 Bolt 9 Housing 10 Ring nut 11 Coupling 12 Washer 13 Shaft 14 Oil...
Page 79: ..._ N_r_e_R_M_E_o_rA_r_E_s_H_A_FT_A_N_o_ 5 19 4 Disconnect Fuel hose G Breather hose 5 Disconnect Choke cable G Throttle cable 6 Remove Bolt G Plate 7 Remove Bolt G Coupling cover 8 Disconnect Cooling w...
Page 80: ...o mounting bolt removal for ease of reassem bly and coupling alignment 10 Remove Coupling rubber Bolt CD Housing Clamp Hose 11 Remove Ring nut Coupling CD Washer Coupler wrench YW 38741 90890 06425 Sh...
Page 81: ...Shaft Pitting Damage Replace Hose Wear Crack Replace 2 Inspect Coupling flange Coupling rubber Wear Damage Replace 3 1nspect Mount bracket Refer to page 3 11 G7 712 o INSTALLATION 1 Install Clip CD B...
Page 82: ...TE Apply the water resistant grease on the oil seal lip when shaft installing 4 Check Distance Out of specification Adjust Distance 19 5 20 5 mm 0 77 0 81 in 5 Install Oil seal CD 0 ring Install the h...
Page 83: ...ust Distance 10 3 10 7 mm 0 41 0 42 in Distance 1 6 2 0 mm 0 063 0 079 in 7 Install Washer Coupling Coupler wrench YW 38741 90890 06425 Shaft holder YW 38742 90890 06069 l li _________ Coat the shaft...
Page 84: ...iginal location Seal the housing fitting plane with silicone Coat the bolt with blue LOCTITE 242 P Bolt 17 Nm 1 7 m kg 12 ft lb 10 Fill Grease Recommended grease Water resistant grease Grease capacity...
Page 85: ...ft lb 13 Install Engine unit Engine mounting bolt G Shim NOTE Install the bolts temporarily Install the previously marked shims back into their original location Coat the bolts with blue LOCTITE 242 1...
Page 86: ...1 7 m kg 12 ft lb Install the shims thick between the 0 mm 0 in and 4 mm 0 157 in 16 Connect Exhaust hose CD Cooling water hose Clamp 4 Nm 0 4 m kg 2 9 ft lb NOTE Pass the cooling water hose under the...
Page 87: ...TE 572 19 Connect Choke cable Throttle cable Refer to page 4 11 20 Adjust Choke cable Throttle cable Refer to page 3 6 21 Connect Breather hose CD Fuel hose 22 Tighten Hose tie NOT Aiways use a new ti...
Page 88: ...IPOWR IWI_ G_u _Gu_N_Ir_ _ _Nr_e_R_M_e_o_IA_r_e_s_H_A_FT_A_N_o_ 5 28 24 Connect Wire clamp CD Coupler 25 Install Battery CD Breather pipe Band Positive lead Negative lead...
Page 89: ...Dismount the engine unit Remove the following parts Muffler 1 2 Muffler stay Cylinder head Cylinder A 2 Nm 0 2 m kg 1 4 ft lb B 37 Nm 3 7 m kg 27 ft lb C 70 Nm 7 0 m kg 50 ft lb 0 1 st 14 Nm 1 4 m kg...
Page 90: ...11 12 13 14 G Starter motor removal Base assembly removal Separating crankcase Crankshaft removal Part name Bolt Starter motor Bolt Flywheel cover Coupling flange Bolt Flywheel magneto Idle gear asse...
Page 91: ...Ring nut Coupling flange Coupler wrench YW 38741 90890 06425 Flywheel holder YB 6139 90890 06522 4 Remove Bolt Flywheel magneto Flywheel puller YB 6117 90890 06521 Flywheel holder YB 6139 90890 06522...
Page 92: ...eplace or repair Maximum deflection 0 03 mm 0 0012 in 2 Measure Small end free play Use a Dial gauge Out of specification Replace the defec tive parts Small end free play 2 0 mm 0 08 in 3 Measure Big...
Page 93: ...ANKCASE 1 Inspect Contacting surface Scratch Replace Crankcase Crack Damage Replace IDLE GEAR ASSEMBLY 1 Inspect Pinion Inner cogs Wear Damage Replace 2 Check Clutch movement Unsmooth movement Replace...
Page 94: ...assembly CD Crankcase Dowel pin Pin NOTE After installing check the smooth movement of the crankshaft Place the locating pins on the bearing into the crankcase body grove Do not allow the bearing clip...
Page 95: ...ith blue LOCTITE 242 Bolt 6 Install 1 st 23 Nm 2 3 m kg 17 ft lb 2 nd 47 Nm 4 7 m kg 34 ft lb Base assembly Screw Align the punch mark on the crankcase with punch mark on the base assembly Coat the sc...
Page 96: ...b 9 Install Coupling flange O ring Ring nut Coupler wrench YW 38741 90890 06425 Flywheel holder YB 6139 90890 06522 NOTE ____________ Always use a new o ring Apply the water resistant grease on the o...
Page 97: ..._E_A_N_D_C_R_A_N_K_S_H_A_F_T____ 5 37 11 Install Flywheel cover Bolt Coat the bolt with blue LOCTITE 242 12 Install Starter motor Bolt Positive lead NOTE Apply the Yamaha Marine Grease to the oil seal...
Page 98: ...MP UNIT JET PUMP 6 1 PREPARATION FOR REMOVAL 6 1 REMOVAL POINTS 6 2 Jet pump unit 6 2 Impeller 6 2 Drive shaft 6 3 Houging 6 3 INSPECTION 6 4 ASSEMBLY AND INSTALLATION 6 4 BILGE SYSTEM 6 10 PREPARATIO...
Page 99: ...he fuel cock to OFF Remove the battery A B c D 2 Nm 0 2 m kg 1 4 ft lb E 15 Nm 1 5 m kg 11 ft lb 5 Nm 0 5 m kg 3 6 ft lb F 18 Nm 1 8 m kg 13 ft lb 7 Nm 0 7 m kg 5 1 ft lb G 1 st 117 Nm 1 7 m kg 12 ft...
Page 100: ...il seal 6 2 Q ty Remarks 2 6 1 1 1 Disconnect the cable joint 4 1 Refer to REMOVAL POINTS 4 1 1 1 3 1 1 2 Refer to REMOVAL 2 POINTS 020710 0 REMOVAL POINTS JET PUMP UNIT 1 Remove Bolt CD Jet pump unit...
Page 101: ...________ 6 3 DRIVE SHAFT 1 Remove Drive shaft and bearing rear NOTE Use a press 2 Remove Bearing rear NOTE Use a press 020731 o HOUSING 1 Remove Bearing front Slide hammer set 90890 06523 YB 6096 9089...
Page 102: ...ller Refer to page 3 10 3 Inspect Bearing front and rear Rotate inner race with a finger Rough spot Seizure Replace 040712 0 ASSEMBLY AND INSTALLATION 1 Install Oil seal CD Duct Driver rod YB 6071 908...
Page 103: ...haft and duct Recommended grease Water resistant grease Grease capacity 23 7 cm3 1 45 cu in 5 Install Bearing rear CD Bearing inner race attachment YB 34474 90890 06662 NOTE Use a press Install the be...
Page 104: ...asket llllllll ________ Coat the bolt with LOCTITE 572 9 Install Washer CD Impeller Drive shaft holder YB 6049 90890 06518 NOTE Be sure the plane side is impeller side Apply the water resistant grease...
Page 105: ...duct G NOTE Ciean the connecting surface of housing duct and nozzle before applying the bond 11 Install Houging CD Pin Duct Nozzle Bolt NOTE Tighten the bolt temporalily lj l lQN r ________ Coat the...
Page 106: ...ed shims back into their original location Original shim thickness is indicated at the back of mounting bolts llitiMii l ________ Coat the bolt with blue LOCTITE 242 14 Tighten Bolt CD Bolt Bolt NOTE...
Page 107: ...6 9 15 Install Cable joint Ride plate CD Bolt i liliil 1 Coat the bolt with blue LOCTITE 242 Bolt Ride plate 7 Nm 0 7 m kg 5 1 ft lb Bolt Valve body 5 Nm 0 5 m kg 3 6 ft lb...
Page 108: ...kg 1 4 ft lb C 5 Nm 0 5 m kg 3 6 ft lb Extent of removal CD Bilge strainer removal Body valve removal Cooling water hose removal Extent of removal Order Part name Q ty Remarks 1 Bilge strainer 1 2 Hos...
Page 109: ...strainer Refer to page 3 19 2 Inspect Body valve Hose Connecter Wear Clack Replace INSTALLATION Refer to EXPLODED DIAGRAM NOTE When connecting a hose be sure to use a new tie Tighten the throught hull...
Page 110: ...L WIRE 7 3 STARTER SWITCH ENGINE STOP SWITCH 7 3 BATTERY 7 3 SPARK PLUG 7 3 THERMO SWITCH 7 3 FUSE 7 4 ELECTRICAL BOX 7 4 STARTER RELAY 7 4 RECTIFIRE REGULATOR 7 5 IGNITION COIL 7 5 COl UNIT 7 6 BASE...
Page 111: ...gneto base assembly COl unit Ignition coil Rectifire regulator A 4 Nm 0 4 m kg 2 9 ft lb B 5 Nm 0 5 m kg 3 6 ft lb C 13 Nm 1 3 m kg 9 4 ft lb D 20 Nm 2 0 m kg 14 ft lb __ I q I I o I J l d I l r 572 S...
Page 112: ...EO E IJ tJCi mm a r ii3 r CD m a iii o O _ CD O CDfO CD J E CD r8 CD r I I I I 1 Ignition coil Rectifier regulator B COl magneto B Br Starter relay Starting motor Engine stop switch Battery m a g r z...
Page 113: ...mmerse the thermo switch CD in the coolant Check the thermo switch for continuity Note temperatures while heating the coolant with the temperature gauge Test Coolant temperature Good step condition 1...
Page 114: ...Inspect Box Crack Damage Replace STARTER RELAY 1 Remove Electrical box CD Starter relay 2 Inspect Starter relay Inspection steps Connect the tester to relay terminals Connect the 12V battery CD Brown...
Page 115: ...00 00 B 2 20 1 10 1 10 G1 1 10 2 15 3 30 G2 1 10 2 15 3 30 oo No continuity R Red lead IGNITION COIL 1 Remove Electrical box G Ignition coil 2 Measure B Black lead G1 Green lead G2 Green lead Primary...
Page 116: ...ove Electrical box COl unit 2 Measure COl unit lead resistance Out of specification Replace Following chart Tester range 0 x 1k B Black W White 0 Orange W R White Red P Pink Br W Brown White co No con...
Page 117: ...t of specification Replace Charge coil resistance Brown White Black 3650 36 50 at 20 oc 68 F 3 Measure Pulser coil resistance Out of specification Replace Pulser coil resistance White Red Black 140 1...
Page 118: ...OR CD Front bracket assembly Washer kit Armature assembly Gasket 7 8 Yoke assembly Brush holder assembly 0 Rear bracket assembly REMOVAL 1 Remove Refer to page 5 28 5 29 DISASSEMBLY 1 Remove Through b...
Page 119: ...___ Replace Diameter limit 31 mm 1 22 in 3 Measure Mica under cut Out of specification Cut it until speci fied depth is obtained Under cut 0 5 0 8 mm 0 02 0 03 in 4 Inspect Armature coil Defects Repla...
Page 120: ...one for the positive terminal another lead for the starter body G Continuity Replace Connect pocket tester leads to each segment of the commutator Discontinuity Replace 7 Inspect Brush holder Defect R...
Page 121: ...o front bracket oil seal lip 3 Install Gasket CD Rear bracket Front bracket Through bolt NOTE Aiign the match mark on the front bracket with the mark on the yoke assembly INSTALLATION 1 Install Starte...
Page 122: ...8 14 Inspection 8 15 Installation 8 15 TH ROTILE CABLE 8 17 Removal 8 17 Inspection 8 18 Installation 8 18 CHOKE CABLE 8 19 Removal 8 19 Inspection 8 20 Installation 8 20 GUNWALE AND MAT 8 21 INSPECTI...
Page 123: ...following parts Engine hood Battery Fuel tank A 3 Nm 0 3 m kg 2 2 ft lb 8 5 Nm 0 5 m kg 3 6 ft lb 5 Extent of removal CD Water lock removal Extent of removal Order Part name 1 Clamp 2 Hose 3 Clame 1...
Page 124: ...ack Leak Replace Hose Crack Wear Burn Replace Clamp Wear Replace Band Crack Replace INSTALLATION 1 Install Hook Bolt Coat the bolt with LOCTITE 572 Bolt 5 Nm 0 5 m kg 3 6 ft lb 2 Install Water lock Ba...
Page 125: ...8 3 A 1 Nm 0 1 m kg 0 7 ft lb B 2 Nm 0 2 m kg 1 4 ft lb C 3 Nm 0 3 m kg 2 2 ft lb D 4 Nm 0 4 m kg 2 9 ft lb E 15 Nm 1 5 m kg 11 ft lb F 16 Nm 1 6 m kg 11 ft lb G 17 Nm 1 7 m kg 12 ft lb H 29 Nm 2 9 m...
Page 126: ...tch assembly 1 5 Bolt 6 Handle cover 7 Handle holder 8 Handlebar 9 Clamp 10 Band 11 Lock nut 12 Nut 13 Handle column 14 Screw 15 Bow cover 16 Lock nut 17 Nut 18 Shaft bolt 19 Steering pole 20 Pin 21 S...
Page 127: ...h assembly Bolt Handle cover Handle holder Handlebar 5 Remove Cable joint CD Band Clamp Cable clamp 6 Remove Lock nut Nut Handle column CD 7 Remove Wire clamp CD Coupler 8 Remove Clamp CD Steering cab...
Page 128: ...g pole 11 Remove Pin CD Stopper pin Bolt Pole pivot Damper INSPECTION 1 Inspect Throttle lever Handlebar Shaft bolt Handle column Pivot springs Stopper pin Bend Clack Damage Replace 2 Inspect Steering...
Page 129: ...Install the damper CD as shown 11111 1111111 _______ Coat the screw and bolt with blue LOCTITE 242 Screw 6 Nm 0 6 m kg 4 3 ft lb Bolt 6 Nm 0 6 m kg 4 3 ft lb 2 Install Pole pivot CD Plate Holder Washe...
Page 130: ...he bush inner circumference Hold the nut with one wrench while tight ening the lock nut 1 i J jfli Coat the shaft bolt with LOCTITE 572 Nut 15 Nm 1 5 m kg 11 ft lb Lock nut 70 Nm 7 0 m kg 50 ft lb 4 I...
Page 131: ...the handle column pivot Hold the nut with one wrench while tight ening the lock nut Coat the handle column bolt with LOCTITE 572 Nut 1 Nm 0 1 m kg 0 7 ft lb Lock nut 29 Nm 2 9 m kg 21 fNb 7 Connect C...
Page 132: ...2 ft lb 9 Install Throttle lever assembly G Screw Collar Handle grip Left and Right Washer Screw ll l l li lllll__________ Coat the screws with blue LOCTITE 242 Apply adhesive to handlebar and inner s...
Page 133: ...side of handle holder Bolt Handle holder 17 Nm 1 7 m kg 12 ft lb NOT Tighten the screw firstly stop button side Screw 4 Nm 0 4 m kg 2 9 ft lb 11 Connect Throttle cable 12 Adjust Throttle cable free p...
Page 134: ...STEERING SYSTEM 14 Install 8 12 Wire clamp G Coupler...
Page 135: ..._c_H_O_K_E_C_A_B_L_E ___________ R31707 0 STEERING CABLE THROTTLE CABLE AND CHOKE CABLE PREPARATION FOR REMOVAL Open the engine hood and support it Drain the fuel Disconnect the battery leads 8 13 A 3...
Page 136: ...pper Seal Bolt Steering pad Steering cable Lock nut Seal Adjuster Clamp Band Clamp Lock nut Throttle cable Choke knob Adjuster Lock nut Lock nut Choke cable 8 14 Q ty Remarks 8 1 1 Disconnect and remo...
Page 137: ..._C_H_O_K_E_C_A_B_L_E___________ 8 15 4 Remove Bolt CD Steering pad 5 Disconnect Cable joint CD Band Cable clamp 6 Remove Clamp CD Steering cable INSPECTION 1 Inspect Steering cable Kink Fray Stick Rep...
Page 138: ...at the handlebar end is impossible adjust the cable joint on the steering nozzle end Coat the lock nut and cable joint nut with LOCTITE 572 Cap 5 Nm 0 5 m kg 3 6 ft lb Lock nut 3 Nm 0 3 m kg 2 2 ft lb...
Page 139: ...E CABLE 8 17 6 Install Ride plate Refer to page 6 8 7 Install Steering pad Refer to page 8 11 THROTTLE CABLE REMOVAL 1 Remove Bolt CD Steering pad 2 Remove Seal CD Lock nut Adjuster Throttle cable 3 R...
Page 140: ...C_H_O_K_E_C_A_B_LE ___________ CD 8 18 5 Disconnect Clamp G 6 Loosen Lock nut G 7 Disconnect Throttle cable INSPECTION 1 Inspect Throttle cable Kink Fray Stick Replace INSTALLATION 1 Install Throttle...
Page 141: ...tle cable into the pipe of steering pole 4 Install Clamp CD Band 5 Connect Throttle cable 6 Adjust Throttle cable free play Refer to page 3 5 7 Install Steering pad Refer to page 8 11 CHOKE CABLE REMO...
Page 142: ...ct Choke cable Kink Fray Stick Replace INSTALLATION 1 Install Choke cable CD Lock nut Adjuster Choke knob Screw Lock nut 5 Nm 0 5 m kg 3 6 fHb 2 Tighten Nut CD Screw Refer to page 4 11 4 12 3 Adjust C...
Page 143: ...6 I GUNWALE AND MAT GUNWALE AND MAT 8 21 A 3 Nm 0 3 m kg 2 2 ft lb B 5 Nm 0 5 m kg 3 6 ft lb a 572...
Page 144: ...t removal Part name Nut Rope hole bolt Cap nut Plain washer Spring washer Screw Bow gunwale Cap nut Screw Cap nut Screw Cover Stern gunwale Screw Side gunwale Nut Rope hole bolt Mat lower Mat Left Mat...
Page 145: ...s 2 Install Side gunwale CD Screw Rope hole bolt Nut Nut 5 Nm 0 5 m kg 3 6 ft lb 3 Install Stern gunwale CD Plain washer Cap nut Coat the nuts with LOCTITE 572 Cap nut 5 Nm 0 5 m kg 3 6 ft lb 4 Instal...
Page 146: ...WALE AND MAT 8 24 3 Install Bow gunwale G 4 Install Rope hole bolt G Nut Screw Plain washer Spring washer Cap nut Coat the screw with LOCTITE 572 Screw 5 Nm 0 5 m kg 3 6 ft lb Nut 5 Nm 0 5 m kg 3 6 ft...
Page 147: ...85 1 ENGINE HOOD ENGINE HOOD a 572 8 25 A 1 Nm 0 1 m kg 0 7 ft lb B 3 Nm 0 3 m kg 2 2 ft lb C 5 Nm 0 5 m kg 3 6 ft lb...
Page 148: ...Lock removal Band removal Part name Bolt Stopper Nut Plate Nut Base Bolt Hook Band Ventilator hose 1 Ventilator hose 2 Engine hood Nut Lock Nut Bracket Nut Band 8 26 Q ty 4 2 2 1 4 2 2 1 2 1 1 1 4 1 2...
Page 149: ...crylate adhesive on the seal rubber 2 Install Band G Bracket Screw Collar Washer Nut NOTE Apply the silicone sealant on the screw Nut 3 Nm 0 3 m kg 2 2 ft lb 3 Install Lock G Hook Packing Collar Plate...
Page 150: ...rew Washer Nut Nut 3 Nm 0 3 m kg 2 2 ft lb 6 Install Stopper CD Bolt Collar Plate Coat the bolt with LOCTITE 572 Bolt 5 Nm 0 5 m kg 3 6 ft lb 7 Install Ventilator hose 1 Short CD Ventilator hose 2 Lon...
Page 151: ...oat thickener and make gel coat putty and then mix the catalyst catalyzed putty 5 Apply and spread the catalyzed putty with a squeegee then cover the putty with a piece of waxed paper 6 After stiffen...
Page 152: ...n and catalyst and apply to the hull 8 Apply a glass mat 2 in smaller than grind ed area 9 Apply catalyzed resin 10 Apply a 20 oz fiber glass cloth 1 in smaller than the glass mat 11 Apply catalyzed r...
Page 153: ...ol IPA and dry it for 15 minutes 4 Mix adhesive agent NOTE Recommend CIBY GEIGY Araldite AW 2104 RTU using for adhesive agent 5 Fill up the hole with adhesive agent 6 Apply adhesive tape to prevent th...
Page 154: ...any adhesive left behind INSTALLATION 1 Preparation In a spray bottle 1qt mix in 1 tablespoon liquid dishwashing detergent with water Next is to remove the backing of the new graphic and spray both si...
Page 155: ...733 09 Nut Stainless steel M6 Nut G Turning in direction of screw Slot to be threaded NOTE Drilling size Material FRP or SMC Brass R37710 Q OPERATION Example 1 Pilot hold diameter 9 1 9 2 mm 0 36 in 9...
Page 156: ...lock the bolt with the nut Screw in the insert nut so that its top is flush with the FRP surface Loosen the lock nut and remove the bolt The bolt should be made of steel and its strength should be 8T...
Page 157: ...7 in drill at the final stage of drilling 3 Apply silicone sealant to the inside of the hole so that no water can enter the urethane foam 4 As Example 1 above screw in the insert nut Brass insert G Hu...
Page 158: ...010700 0 CHAPTER 9 TROUBLE SHOOTING TROUBLE SHOOTING 9 1 ENGINE DOES NOT START 9 1 ENGINE RUNS IRREGULARLY OR STALLS 9 4 ENGINE DOES NOT SHUT OFF 9 7...
Page 159: ...t out J 1Replace IBattery I I Run down I l lr _ 1 Charge Check charging circuit IWire harness I Lead connection l Secure I I loose IStarter switch I LFaulty l Replace I I I IStarter relay I 1Faulty 1...
Page 160: ...l line j No fuel in the line Supply fuel Carburetor Diaphragm defective Replace I Clogged j Clean 032700 0 No spark IGNITION t J Faulty 1 1 Replace L 1 1 Faulty 1 1 Replace r _IC_D_I_un_it ____ t 1 Di...
Page 161: ...ng but weak L r _o_ef_e_ct_iv_e________ 1 _Re_p_la_c_e________ 0337000 ICOMPRES ION _Re_e_d_v_a_lv_e r _Fa_u_lt_Y___________ _j_Re_p_l_ac_e________ Piston cylinder wall 1 J Scuffed worn piston ring 9...
Page 162: ...EL lFuel I Empty stale or j Syphon Refill I I contaminated j Fuel hose l Leakage kinked Replace IFuel filter I IClogged 1 Clean I ICarburetor I IDiaphragm defective I Replace I j Clogged iClean I H Id...
Page 163: ...ure Defective Replace 033730 0 ICOMPRESSION Warpage IRepair Replace Leakage IReplace IWorn 1 Replace 1 Faulty j Replace Piston cylinder wall 1 Scuffed Worn 1 Replace piston ring Woodruff key lFaulty I...
Page 164: ...1 Replace Repair J Clearance impeller case 1 i r_o_o_m_u_c_h___ ir 1_R_ep_l_ac_e ____ J J_e_t_p_u_m_p ____ ___ 1 Clogged r _ C_l_e_an ___________ 033750 0 IFUEL j Fuel tank r 1 Deteriorated fuel 1 J...
Page 165: ...CDI unil IThermo switch jlgnition coil 034700 0 TROUBLE SHOOTING I Defective I Replace I I Short circuited Replace j Defective Replace ENGINE DOES NOT SHUT OFF f Faulty f j Replace Disonnected CDI uni...
