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Yamaha VX110 Sport, Service Manual

The Yamaha VX110 Sport is a versatile watercraft designed for sport and leisure. Enhance your experience with the comprehensive Service Manual, essential for maintenance and repairs. Download this manual for free from manualshive.com and unlock the full potential of your Yamaha VX110 Sport, ensuring years of thrilling water adventures.

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2-14

E

SPEC

TIGHTENING TORQUES

Shift cable locknut 
(Deluxe model only)

Nut

—

1

3.8

0.38

2.7

572

LT

8-23

Steering cable locknut 
(steering column side)

Nut

—

1

6.5

0.65

4.7

8-23

Steering cable locknut 
(jet pump side)

Nut

—

1

6.8

0.68

4.9

572

LT

8-23

Steering cable seal

Nut

—

1

5.9

0.59

4.3

8-23

Steering cable bracket

Bolt

M6

1

6.9

0.69

5.0

572

LT

8-23

Speed sensor lead grommet

Nut

—

1

5.9

0.59

4.3

8-23

Hinge assembly

Bolt

M6

2

6.9

0.69

5.0

8-8

Hood lock assembly

Bolt

M5

2

1.9

0.19

1.4

572

LT

8-8

Hinge assembly

Bolt

M6

4

6.9

0.69

5.0

242

LT

8-8

Lid lock hook

Bolt

M6

2

6.9

0.69

5.0

242

LT

8-8

Mirror (Deluxe model only)

Nut

—

4

15

1.5

11

8-8

Shift handle lever 
(Deluxe model only)

Screw

M5

2

3.7

0.37

2.7

572

LT

8-11

Multifunction meter

Bolt

M5

4

3.9

0.39

2.8

572

LT

8-11

Engine hatch cover 
(Deluxe model only)

Bolt

M6

1

6.9

0.69

5.0

572

LT

8-11

Engine hatch cover

Bolt

M6

8

6.9

0.69

5.0

572

LT

8-11

Detent plate

Bolt

M6

2

8.0

0.8

5.8

572

LT

8-16

Shift lever bracket 
(Deluxe model only)

Nut

—

2

15

1.5

11

8-16

Pilot water outlet

Nut

—

1

4.2

0.42

3.0

8-17

Hand grip

Nut

—

4

6.9

0.69

5.0

8-28

Seat bracket

Nut

—

2

15

1.5

11

8-28

Seat lock projection

Bolt

—

1

26

2.6

19

8-28

Seat lock assembly

Bolt

M6

2

6.4

0.64

4.6

271

LT

8-28

Plate/rubber hose/exhaust 
valve

Nut

—

6

5.4

0.54

3.9

8-31

Hose clamp 1

—

—

2

3.7

0.37

2.7

8-31

Hose clamp 2

—

—

1

3.7

0.37

2.7

8-31

Joint clamp 1 and 4

—

—

2

3.7

0.37

2.7

8-31

Joint clamp 2 and 3

1st

—

—

2

2.4

0.24

1.7

8-31

2nd

2.4

0.24

1.7

Sponson

Bolt

M8

10

16

1.6

12

572

LT

8-36

Cleat

Nut

—

2

15

1.5

11

8-36

4

Spout

Nut

—

1

5.4

0.54

3.9

8-36

Protector (bow)

Nut

—

5

6.9

0.69

5.0

8-36

Bow eye

Bolt

M6

2

13

1.3

9.4

8-36

Drain plug/packing

Screw

M5

4

2.0

0.2

1.4

8-36

Engine mount

Bolt

M8

8

17

1.7

12

572

LT

8-38

Engine damper

Bolt

M6

2

6.6

0.66

4.8

271

LT

8-38

Part to tightened

Part 

name

Thread 

size

Q’ty

Tightening torque

Remarks

Refer to 

page

N•m kgf•m

ft•lb

Summary of Contents for VX110 Sport

Page 1: ...SERVICE MANUAL VX110 Sport WaveRunner F1K 28197 1H 11 LIT 18616 02 91 LIT186160291 VX110 Deluxe ...

Page 2: ...as 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 edition of this manual Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual A10001 0 WaveRunner V...

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

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

Page 5: ...s indicate parts to be lubricated or replaced see SYMBOLS 4 A job instruction chart accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc 5 Dimension figures and the number of parts are provided for fasteners that require a tightening torque Example Bolt or screw size M10 D 25 mm L 6 Jobs requiring more information such as special tools and technical data ar...

Page 6: ... in an exploded diagram indi cate the grade of lubricant and the lubrication point F Apply Yamaha 4 stroke motor oil G Apply water resistant grease Yamaha grease A Yamaha marine grease H Apply ThreeBond 1104J or ThreeBond 1280B I Apply molybdenum disulfide grease Symbols J to N in an exploded diagram indi cate the type of sealant or locking agent and the application point J Apply Gasket Maker K Ap...

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

Page 8: ......

Page 9: ...AL 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 PARTS LUBRICANTS AND SEALANTS 1 2 GOOD WORKING PRACTICES 1 3 DISASSEMBLY AND ASSEMBLY 1 4 SPECIAL SERVICE TOOLS 1 5 MEASURING 1 5 REMOVAL AND INSTALLATION 1 7 ...

Page 10: ...ent Starting primary l D number F1K 800101 ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the engine unit Starting serial number 6D3 1000001 JET PUMP UNIT SERIAL NUMBER The jet pump unit serial number is stamped on a label attached to the intermediate housing HULL IDENTIFICATION NUMBER H l N The H l N is stamped on a plate attached to the aft deck ...

Page 11: ...tities they may cause loss of con sciousness and death within a short time When test running an engine indoors e g in a water tank be sure to do so where adequate ventilation can be maintained SELF PROTECTION Protect your eyes by wearing safety glasses or safety goggles during all operation involving drilling and grinding or when using an air com pressor Protect your hands and feet by wearing prot...

Page 12: ...part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made 5 To protect your skin apply a protective cream to your hands before working on the watercraft 6 Keep a supply of clean lint free cloths for wiping up spills etc GOOD WORKING PRACTICES 1 The right tools Use the recommended special service tools to protect parts from damage ...

Page 13: ...t during disassembly 2 Apply engine oil to the contact surfaces of moving parts during assembly 3 Install bearings with the manufacture iden tification mark in the direction indication in the installation procedure In addition be sure to lubricate the bearings liberally 4 Apply a thin coat of water resistant grease to the lip and periphery of an oil seal before installation 5 Check that moving par...

Page 14: ...MEASURING 1 Dial gauge stand P N 90890 06583 2 Dial gauge needle P N 90890 06584 3 Dial gauge stand set P N YB 06585 90890 06585 4 Dial indicator gauge P N YU 03097 Dial gauge set P N 90890 01252 5 Pocket tester P N YU 03112 90890 03112 6 Digital multimeter P N YU 34899 A 7 Digital circuit tester P N 90890 03174 8 Fuel pressure gauge adapter P N YW 06842 90890 06842 9 Fuel pressure gauge P N YB 06...

Page 15: ... New YB 06870 Current YB 06770 Test harness SMT250 3 3 pins P N New 90890 06870 Current 90890 06770 H Test harness 6 pins P N YB 06848 Test harness FSW 6A 6 pins P N 90890 06848 I Test harness 3 pins P N New YB 06877 Current YB 06777 Test harness HM090 3 3 pins P N New 90890 06877 Current 90890 06777 J Lower unit pressure vacuum tester P N YB 35956 A Vacuum pressure pump gauge set P N 90890 06756 ...

Page 16: ...90890 01426 2 Coupler wrench P N YW 06551 90890 06551 3 Sheave holder P N YS 01880 A 90890 01701 4 Rotor puller P N YM 01082 90890 01080 5 Universal magneto and rotor holder P N YU 01235 Rotor holder P N 90890 01235 6 Bearing housing needle bearing installer reduction drive gear P N YB 06111 1 2 3 4 YB 01426 90890 01426 YW 06551 90890 06551 YS 01880 A 90890 01701 YM 01082 90890 01080 5 6 YU 01235 ...

Page 17: ...4117 ø4 5 mm 90890 04117 ø4 5 mm C Valve guide reamer P N YM 04113 ø4 0 mm 90890 04113 ø4 0 mm YM 04118 ø4 5 mm 90890 04118 ø4 5 mm D Valve seat cutter Intake P N 90890 06813 60 90890 06814 45 90890 06815 30 Exhaust P N 90890 06315 60 90890 06312 45 90890 06328 30 0 A YM 04114 ø19 mm 90890 04114 ø19 mm YM 04108 ø22 mm 90890 04108 ø22 mm YM 04111 ø4 0 mm 90890 04111 ø4 0 mm YM 04116 ø4 5 mm 90890 0...

Page 18: ... pump bearing and reduction drive gear P N 90890 06535 L Stopper guide stand jet pump bearing and reduction drive gear P N 90890 06538 M Driver rod L3 jet pump bearing and reduction drive gear P N 90890 06652 N Bearing housing needle bearing remover jet pump bearing P N YB 06112 O Needle bearing attachment jet pump bearing oil seal and reduction drive gear P N 90890 06614 90890 06653 Ball bearing ...

Page 19: ...S Driver rod LS intermediate shaft jet pump and reduction drive gear P N 90890 06606 T Crankshaft holder intermediate shaft P N YB 06552 Crankshaft holder 20 intermediate shaft P N 90890 06552 U Bearing outer race attachment intermediate shaft and reduction drive gear P N 90890 06624 90890 06628 V Roller bearing installer remover intermediate shaft bearing and oil seals P N YB 06432 YB 06071 90890...

Page 20: ......

Page 21: ...R 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 ENGINE 2 3 JET PUMP UNIT 2 6 HULL AND HOOD 2 6 ELECTRICAL 2 7 TIGHTENING TORQUES 2 10 SPECIFIED TORQUES 2 10 GENERAL TORQUE 2 15 CABLE AND HOSE ROUTING 2 16 ...

Page 22: ... in 1 052 64 2 Bore stroke mm in 76 0 58 0 2 99 2 28 Compression ratio 11 4 1 Exhaust system Wet exhaust Lubrication system Dry sump Cooling system Water cooled Starting system Electric starter Ignition system TCI Ignition timing Degree BTDC 5 BTDC 35 Spark plug model manufacturer CR9EB NGK Spark plug gap mm in 0 7 0 8 0 028 0 031 Battery capacity V Ah 12 19 Generator output A r min 12 21 6 000 Dr...

Page 23: ...86 RON 90 Fuel tank capacity L US gal Imp gal 60 15 9 13 2 Engine oil type 4 stroke motor oil Engine oil grade API SE SF SG SH SJ SL SAE 10W 30 20W 40 20W 50 Engine oil quantity L US qt Imp qt 4 3 4 5 3 8 without oil filter replacement L US qt Imp qt 2 0 2 1 1 8 with oil filter replacement L US qt Imp qt 2 2 2 3 1 9 Item Unit Model VX110 Sport VX110 Deluxe GENERAL SPECIFICATIONS ...

Page 24: ...ter mm in 24 5 0 9646 Camshaft journal diameter Intake mm in 24 46 24 47 0 9630 0 9634 Exhaust mm in 24 44 24 45 0 9622 0 9626 Camshaft journal to camshaft cap clearance mm in 0 05 0 06 0 0020 0 0024 Maximum camshaft runout mm in 0 03 0 0012 Timing chain Model number of links 92RH2015 130 130 Tensioning system Automatic Valves valve seats valve guides Valve clearance cold Intake mm in 0 11 0 20 0 ...

Page 25: ...Exhaust mm in 4 500 4 512 0 1772 0 1776 Valve stem to valve guide clearance Intake mm in 0 010 0 037 0 0004 0 0015 Exhaust mm in 0 020 0 047 0 0008 0 0019 Valve stem runout mm in 0 01 0 0004 Valve spring Free length Intake mm in 38 90 1 53 Exhaust mm in 40 67 1 60 Installed length Intake mm in 34 50 1 36 Exhaust mm in 35 00 1 38 Tilt limit Intake Degree mm in 2 5 1 7 0 067 Exhaust Degree mm in 2 5...

Page 26: ...n 1 50 2 60 0 06 0 10 End gap installed mm in 0 10 0 35 0 0039 0 0138 Ring groove clearance mm in 0 040 0 160 0 0016 0 0063 Connecting rod Big end oil clearance mm in 0 016 0 040 0 0006 0 0016 Bearing color code 1 Brown 2 Black 3 Blue 4 Green Small end inside diameter mm in 17 005 17 018 0 6695 0 6700 Crankshaft Crank width A mm in 304 8 306 0 12 00 12 05 Deflection limit B mm in 0 03 0 0012 Crank...

Page 27: ...ce Rotor feed pump mm in 0 09 0 17 0 0035 0 0067 Rotor scavenge pump mm in 0 09 0 15 0 0035 0 0059 Item Unit Model VX110 Sport VX110 Deluxe Jet pump Impeller material Stainless steel Number of impeller blades 3 Impeller pitch angle Degree 21 2 Impeller clearance mm in 0 35 0 45 0 0138 0 0177 Impeller clearance limit mm in 0 6 0 0236 Drive shaft runout limit mm in 0 3 0 0118 Item Unit Model VX110 S...

Page 28: ...ltage cranking unloaded V 8 0 cranking loaded V 6 9 2 000 r min loaded V 19 4 3 500 r min loaded V 25 1 Lighting coil G G Output peak voltage cranking unloaded V 7 8 2 000 r min unloaded V 24 5 3 500 r min unloaded V 41 6 Pickup coil resistance W B B O Ω color 459 561 Lighting coil resistance G G Ω color 0 23 0 29 Minimum charging current A r min 14 6 000 Ignition coil Primary coil resistance 20 C...

Page 29: ...aust C F 80 86 176 187 OFF temperature exhaust C F 66 80 151 176 Engine temperature sensor Engine temperature sensor resistance B Y B Y 20 C 68 F kΩ 54 2 69 0 100 C 212 F kΩ 3 12 3 48 Speed sensor Output voltage on pulse V 11 6 Output pulse one full turn 2 Throttle position sensor Output voltage throttle valve fully closed Sensor 1 V 0 45 0 95 throttle valve fully opened Sensor 2 V 4 60 4 70 Accel...

Page 30: ... Position B V Less than 0 8 Position C V More than 4 8 Fuel sender Fuel sender resistance Position A Ω 133 5 136 5 Position B Ω 5 7 Oil pressure switch Oil pressure switch continuity pressure kPa kgf cm2 psi 128 1 28 18 2 167 1 67 23 8 Fuel injector Fuel injector resistance 1 20 C 68 F Ω 11 5 12 5 Fuse Rating Main V A 12 30 Main and fuel pump relay V A 12 20 Main and fuel pump relay V A 12 10 Elec...

Page 31: ...8 0 88 6 4 242 LT 4 7 2nd 18 1 8 13 Intake manifold bracket wiring harness bracket 1 1st Bolt M8 2 15 1 5 11 271 LT 4 7 2nd 39 3 9 28 Fuel rail Bolt M8 2 13 1 3 9 4 4 10 Sensor assembly Screw M5 2 3 5 0 35 2 5 4 10 Engine Engine unit Bolt M8 4 17 1 7 12 271 LT 5 1 Oil filter 1 17 1 7 12 E 3 17 Coupling cover Bolt M6 1 7 8 0 78 5 6 572 LT 5 1 Thermoswitch exhaust Bolt M6 2 7 6 0 76 5 5 572 LT 5 8 O...

Page 32: ...5 2nd 4 4 0 44 3 2 Oil strainer 1st Bolt M6 2 3 7 0 37 2 7 E 5 15 2nd 7 6 0 76 5 5 Oil cooler cover 1st Bolt M6 24 3 7 0 37 2 7 572 LT 5 15 2nd 7 6 0 76 5 5 Anode Screw M4 1 3 8 0 38 2 7 E 5 15 Oil pump assembly Bolt M6 6 10 1 0 7 2 572 LT 5 21 1st M8 4 15 1 5 11 2nd 28 2 8 20 Drain plug engine oil Bolt M8 1 13 1 3 9 4 5 21 Strainer 1st Bolt M6 2 3 7 0 37 2 7 5 21 2nd 7 6 0 76 5 5 Drive coupling 1...

Page 33: ...t camshaft sprocket Bolt M7 2 24 2 4 17 E 5 43 Intake camshaft sprocket Bolt M7 2 24 2 4 17 E 5 43 Cylinder head 1 Bolt M6 3 10 1 0 7 2 E 5 54 1st Nut 2 20 2 0 14 E 5 54 2nd 140 5 1st Nut 3 20 2 0 14 E 5 54 2nd 121 5 1st Nut 5 20 2 0 14 E 5 54 2nd 105 5 Engine temperature sensor 1 15 1 5 11 5 71 Thermoswitch engine Bolt M6 2 7 6 0 76 5 5 572 LT 5 71 Oil pressure switch 1 8 4 0 84 6 1 572 LT 5 71 A...

Page 34: ...mpeller Impeller M22 1 75 7 5 54 572 LT 6 8 Transom plate Nut 4 26 2 6 19 6 15 Intermediate housing cover Bolt M8 4 17 1 7 12 271 LT 6 18 Driven coupling Driven coupling M24 1 36 3 6 26 572 LT 6 19 Clamp 2 4 2 0 42 3 0 6 18 Hull and hood Handlebar holder Bolt M8 4 20 2 0 14 572 LT 8 1 Upper handlebar cover Screw M4 2 1 1 0 11 0 8 8 1 M5 4 1 1 0 11 0 8 Lower handlebar cover Screw M6 4 3 7 0 37 2 7 ...

Page 35: ...72 LT 8 11 Engine hatch cover Bolt M6 8 6 9 0 69 5 0 572 LT 8 11 Detent plate Bolt M6 2 8 0 0 8 5 8 572 LT 8 16 Shift lever bracket Deluxe model only Nut 2 15 1 5 11 8 16 Pilot water outlet Nut 1 4 2 0 42 3 0 8 17 Hand grip Nut 4 6 9 0 69 5 0 8 28 Seat bracket Nut 2 15 1 5 11 8 28 Seat lock projection Bolt 1 26 2 6 19 8 28 Seat lock assembly Bolt M6 2 6 4 0 64 4 6 271 LT 8 28 Plate rubber hose exh...

Page 36: ...Q ty Tightening torque Remarks Refer to page N m kgf m ft lb GENERAL TORQUE This chart specifies tightening torques for stan dard fasteners with a standard ISO thread pitch Tightening torque specifications for spe cial components or assemblies are provided in applicable sections of this manual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and progressive stages until t...

Page 37: ...3 Throttle cable 4 Fuse box 5 Starter motor lead 6 Positive battery lead 7 Negative battery lead 8 Battery 9 Cooling water outlet hose 0 Shift cable Deluxe model only A Speed sensor lead B Cooling water inlet hose C Fuel hose D Electric fuel pump E Accelerator position sensor F Antenna lead Deluxe model only G Remote control unit lead Deluxe model only H Bilge hose joint I Cooling water hose joint...

Page 38: ... B B È Fasten the speed sensor lead fuel sender lead wiring harness and antenna lead Deluxe model only with plastic tie 1 at the white tape on the wiring harness É Fasten the steering sensor lead handlebar switch lead multifunction meter lead and buzzer lead with plastic tie 2 Ê To install the cooling water inlet hose align the white paint mark on the hose with the parting line on the hose joint ...

Page 39: ...witch lead 3 Buzzer 4 Shift cable Deluxe model only 5 Fuel hose 6 Relay assembly 7 Fuse box 8 ECM 9 Positive battery lead 0 Flushing hose A Cooling water outlet hose B Bilge hose C Battery breather hose D Battery E Negative battery lead F Starter motor lead G Speed sensor lead H Steering cable I Remote control unit lead Deluxe model only J Fuel tank breather hose K Antenna lead Deluxe model only L...

Page 40: ... water inlet hose È Fasten the steering sensor lead handlebar switch lead multifunction meter lead and buzzer lead with plastic tie 2 É Fasten the speed sensor lead fuel sender lead wiring harness and antenna lead Deluxe model only with plastic tie 1 at the white tape on the wiring harness Ê Deluxe model Ë Sport model Ì To remote control unit Deluxe model only Í Fasten the antenna lead and wiring ...

Page 41: ... E F G H I P G G G A B D F C E J J M C F I I E D B A A Ï Ð H H G G J K 0 Q L Ê Ë Ï To ventilation socket Ð To fuel tank Ñ Point the arrow on the cover toward the fuel tank Ò Fasten the fuel hose with a plastic tie Ó To fuse box Ô Fasten the wiring harness with a plastic tie at the white tape Õ To ECM ...

Page 42: ...hose 6 Oil separator breather hose to oil tank 7 Oil separator breather hose to air intake duct 8 Cooling water pilot outlet hose È To install the cooling water outlet hose align the white paint mark on the cooling water hose with the projection of the hose joint É To transom plate Ê Fasten the cooling water outlet hose with a plas tic tie Ë 25 45 mm 0 98 1 77 in Ì Fasten the oil separator breathe...

Page 43: ...tercraft Ï Insert the cooling water hose to the paint mark Ð To install the cooling water hose align the white paint mark on the cooling water hose with the arrow mark of the hose joint Ñ Install the cooling water hose with the white paint mark facing up Ò To cooling water pilot outlet Ó Face the ends of the hose clamp towards the bow Ô Install the hose onto the cooling water pipe until the pipe r...

Page 44: ...ion coil lead 3 6 Ignition coil lead 4 7 Cam position sensor 8 Ignition coil 9 ECM 0 Rectifier regulator A Oil pressure switch coupler B Thermoswitch exhaust coupler C Ground lead plate D Wiring harness E Thermoswitch exhaust lead F Oil pressure switch lead È Fasten the oil separator breather hose to air intake duct at the paint mark with a holder É 15 25 mm 0 59 0 98 in Ê To fuse box Ë To multifu...

Page 45: ... 6 7 2 E D F È É Í Ê Ë Ì A A A A Î Ì To generator Í Fasten the thermoswitch exhaust lead at the protective sleeve the oil pressure switch lead at the corrugated tube and the wiring harness at the tape on the harness with a plastic tie Î 60 80 mm 2 36 3 15 in ...

Page 46: ...intake air pressure and intake air temperature 8 Cam position sensor coupler 9 Cam position sensor lead 0 Oil pressure switch È To engine temperature sensor É To thermoswitch engine Ê Route the engine thermoswitch lead and engine temperature sensor lead through the corrugated tube Ë More than 10 mm 0 39 in Ì Do not leave any slack in the lead Í Attach the thermoswitch engine coupler to the bracket...

Page 47: ...the fuel rail with a plastic tie Ò Fasten the wiring harness and cam position sensor within the range shown in the illustration with a plastic tie Ó Split in wiring harness Ô To cam position sensor Õ Pass fuel injector lead 4 under the sensor assembly intake air pressure and intake air temperature lead Ö To oil pressure switch To thermoswitch exhaust Ø To ground lead plate Ù Bow end Ú Make sure th...

Page 48: ......

Page 49: ...l only 3 5 Trolling speed inspection 3 6 FUEL SYSTEM 3 7 Fuel line inspection 3 7 Water separator inspection 3 8 POWER UNIT 3 8 Valve clearance adjustment 3 8 Engine oil level check 3 14 Engine oil change using oil changer 3 16 Air filter element clean 3 18 Spark plug inspection 3 20 ELECTRICAL 3 22 Battery inspection 3 22 JET PUMP UNIT 3 25 Impeller inspection 3 25 Water inlet strainer inspection...

Page 50: ...Lubrication points Lubricate 3 26 Fuel system Inspect 3 7 Fuel tank Inspect clean 3 7 Trolling speed Inspect 3 6 Throttle shaft Inspect Cooling water passages Flush 1 Water inlet strainer Inspect clean Bilge strainer Clean 3 26 Impeller Inspect 3 25 Jet thrust nozzle angle Inspect adjust 3 2 Shift cable and mechanism Deluxe model only Inspect adjust 3 5 Throttle cable Inspect adjust 3 4 Stern drai...

Page 51: ...wn and back and forth Check the excessive play of the handle bar Steering cable inspection and adjustment 1 Inspect Jet thrust nozzle distances a and b Out of specification Adjust Difference of distances a and b Maximum 5 mm 0 2 in Measurement steps Set the control grip to the neutral posi tion Turn the handlebar lock to lock Measure distances a and b If the difference of distances a and b is not ...

Page 52: ...le joint 2 from the ball joint 3 Turn the cable joint 2 in or out to adjust the steering cable length c Steering cable length c 218 8 mm 8 61 in NOTE Check that the sum of lengths c and d is 581 8 1 mm 22 91 0 04 in If the sum of lengths c and d is out of specification adjust length d and then check the jet thrust nozzle distances again WARNING The cable joint must be screwed in more than 8 mm 0 3...

Page 53: ...ecessary Adjust the throttle lever free play at the throt tle lever end of the throttle cable Throttle lever free play a 4 7 mm 0 16 0 28 in Throttle cable length b 18 4 1 mm 0 72 0 04 in b 2 Adjust Throttle lever free play a Adjustment steps a Remove the handlebar cover b Loosen the locknut 1 c Turn the adjuster 2 in or out until the specified free play is obtained Turn in Free play is increased ...

Page 54: ... 8 ft lb Shift cable inspection and adjustment Deluxe model only 1 Check Reverse gate stopper lever position Incorrect Adjust 2 Adjust Shift cable joint Checking steps Set the shift lever to the reverse position Check that the reverse gate 1 contacts the stopper 2 Adjustment steps Loosen the locknut 1 Disconnect the cable joint 2 from the ball joint 3 Situate the reverse gate to the stopper Turn t...

Page 55: ... 31 in Connect the cable joint and tighten the locknut T R Locknut 3 8 N m 0 38 kgf m 2 7 ft lb Trolling speed inspection 1 Inspect Trolling speed Trolling speed 1 550 1 750 r min Checking steps watercraft in water Start the engine and allow it to warm up for 15 minutes Check the engine trolling speed using the tachometer of the multifunction meter or using the Yamaha Diagnostic System ...

Page 56: ...MP MODULE in Chapter 4 Fuel hose Cracks damage Replace O rings quick connector Cracks damage Replace the quick connector Fuel rail Cracks damage Replace Refer to FUEL INJECTION SYSTEM in Chapter 4 Fuel filler hose Fuel filler cap Cracks damage Replace 2 Inspect Fuel tank Cracks damage Replace Water accumulation Remove NOTE To remove water from the fuel tank remove the fuel filler hose 1 and use a ...

Page 57: ...d engine at room temperature When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC of the compression stroke 1 Remove Ignition coils Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS in Chapter 5 2 Install Dial gauge needle Dial gauge stand 1 into spark plug hole 1 Dial gauge 2 Dial gauge stand 90890 06583 Dial gauge needle 908...

Page 58: ...e turned away from each other Measure the valve clearance with a thick ness gauge 1 NOTE If the valve clearance is incorrect record the measured reading Measure the valve clearance in the follow ing sequence Valve clearance measuring sequence Cylinder 1 2 4 3 È Bow end To measure the valve clearances of the other cylinders starting with cylinder 1 at TDC turn the drive coupling counter clockwise a...

Page 59: ...OTE Make sure that the tensioner rod has been fully turned clockwise 1 6 Remove Intake camshaft caps Exhaust camshaft caps Timing chain from the camshaft sprockets Intake camshaft Exhaust camshaft NOTE Refer to CAMSHAFTS in Chapter 5 When removing the timing chain and cam shafts fasten the timing chain with a wire to prevent it from falling into the crankcase ...

Page 60: ...m increments NOTE The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter Since valve pads of various sizes are orig inally installed the valve pad number must be rounded in order to reach the closest equivalent to the original Round off the original valve pad number according to the following table Last digit Rounded value 0 or 2 0 5 5 8 ...

Page 61: ...the valve lifter and the valve pad in the correct place Install the exhaust and intake camshafts timing chain and camshaft caps T R Camshaft cap bolt 10 N m 1 0 kgf m 7 2 ft lb NOTE Refer to Camshaft installation CAM SHAFTS in Chapter 5 Lubricate the camshafts camshaft lobes and camshaft journals Install the exhaust camshaft first Align the camshaft marks with the cam shaft cap marks Turn the cran...

Page 62: ...RANCE ORIGINAL VALVE PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 0 02 0 06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 0 07 0 11 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 22...

Page 63: ...an cause the watercraft to move and lead to a colli sion When checking the engine oil level on land supply water to the cooling water passages Make sure that engine has enough oil but do not overfill If there is too little oil the engine can be damaged If there is too much oil the air filter can become saturated with oil perma nently damaging the filter and reduc ing engine performance Follow the ...

Page 64: ...o the oil tank NOTE The engine cannot be started if the Yamaha Security System is in the lock mode Deluxe model only For information on the Yamaha Security System see the owner s manual Deluxe model only Run the engine at trolling speed for 6 minutes or more and then turn the engine off CAUTION When checking the oil level on land be sure to connect a garden hose to the watercraft for proper water ...

Page 65: ...high the reading on the dipstick will be high Engine oil change using oil changer WARNING Avoid changing the engine oil immediately after turning the engine off The oil is hot and should be handled with care to avoid burns CAUTION Do not run the engine with too much or not enough oil in the oil tank Oil could spray out or the engine could be dam aged Do not run the engine for more than 15 seconds ...

Page 66: ...of the recom mended engine oil into the oil filler hole Replacing steps Place a rag under the oil filter Remove the oil filter 1 with an oil filter wrench Oil filter wrench YB 01426 90890 01426 Lubricate the O ring 2 of the new oil filter with a thin coat of engine oil CAUTION Make sure the O ring 2 is positioned correctly in the groove of the oil filter Tighten the new oil filter to specification...

Page 67: ...commended oil SAE 10W 30 20W 40 20W 50 API SE SF SG SH SJ SL Oil quantity Total amount 4 3 L 4 5 US qt 3 8 Imp qt Without oil filter replacement 2 0 L 2 1 US qt 1 8 Imp qt With oil filter replacement 2 2 L 2 3 US qt 1 9 Imp qt Air filter element clean 1 Disconnect Fuel hose 1 Air intake hose 2 Oil separator breather hose 3 2 Remove Plastic ties 4 Bolts 5 1 2 4 4 5 4 3 3 Remove Air filter case 4 Re...

Page 68: ...ly Do not use detergent or a solvent to clean the air filter element or dry it with heat or compressed air otherwise it could be damaged 6 Install Air filter element NOTE Install the air filter element with its projections a facing away from the projections b on the air filter case 7 Install Air filter case cover 8 Install Air filter case T R Air filter case cover screw short 1 5 N m 0 15 kgf m 1 ...

Page 69: ...ator color 2 Distinctly different color Check the engine condition Color guide Medium to light tan color Normal Whitish color Lean fuel mixture Air leak Incorrect settings Blackish color Overly rich mixture Electrical malfunction Defective spark plug 3 Clean Spark plug with a spark plug cleaner or wire brush 4 Measure Spark plug gap a Out of specification Regap Spark plug gap 0 7 0 8 mm 0 028 0 03...

Page 70: ...ze compound to the spark plug threads to prevent thread seizure If a torque wrench is not available a good estimate of the correct tightening torque for a new spark plug is to finger tighten a the spark plug and then tighten it another 1 4 to 1 2 of a turn b T R Spark plug 13 N m 1 3 kgf m 9 4 ft lb 6 Install Ignition coils T R Ignition coil bolt 7 6 N m 0 76 kgf m 5 5 ft lb LOCTITE 572 ...

Page 71: ...Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc well away If using or charging the battery in an enclosed space make sure that it is well ventilated Always shield your eyes when working near batteries KEEP OUT OF THE REACH OF CHILDREN CAUTION Be careful not to place the battery on its side Make sure to remove the b...

Page 72: ... Electrolyte level Low Add distilled water The electrolyte level should be between the maximum a and minimum b level marks CAUTION Use only distilled water Other types of water contain minerals which are harmful to batteries Filling steps Remove each filler cap Add distilled water to the maximum level mark When the electrolyte level reaches the maximum level mark allow the cell to stand for 20 min...

Page 73: ...F 1 28 Charging current 1 9 A 10 h 5 Install Battery breather hose 1 Battery Battery positive lead 2 Battery negative lead 3 Bands CAUTION Connect the positive lead to the battery terminal first Make sure the battery leads are con nected properly Reversing the leads can seriously damage the electrical system Make sure that the battery breather hose is properly connected and is not obstructed Coat ...

Page 74: ...e as shown a total of three measure ments Install the intake duct and intake grate Refer to INTAKE GRATE AND RIDE PLATE in Chapter 6 Install the battery leads Water inlet strainer inspection 1 Inspect Water inlet strainer Contaminants Clean Cracks damage Replace Inspection steps Remove the ride plate Refer to INTAKE GRATE AND RIDE PLATE in Chapter 6 Remove the rubber plate Refer to JET PUMP UNIT i...

Page 75: ...lace 1 GENERAL Drain plug inspection 1 Inspect Drain plugs Cracks damage Replace O rings Cracks wear Replace Screw threads Contaminants Clean Lubrication points 1 Lubricate Throttle cable handlebar end NOTE Before lubricating the throttle cable squeeze the throttle lever and remove the rubber seal 1 Recommended lubricant Rust inhibitor ...

Page 76: ...cable joint NOTE Disconnect the joints and apply a small amount of grease Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease 4 Lubricate Deluxe model only Shift cable shift lever end Shift cable reverse gate end Shift cable joint NOTE Disconnect the joints and apply a small amount of grease Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease ...

Page 77: ...TION SYSTEM 4 7 EXPLODED DIAGRAM 4 7 REMOVAL AND INSTALLATION CHART 4 7 THROTTLE BODY ASSEMBLY AND INTAKE MANIFOLD 4 10 EXPLODED DIAGRAM 4 10 REMOVAL AND INSTALLATION CHART 4 10 SERVICE POINTS 4 12 Fuel hose clamps removal 4 12 Hose clamps installation 4 12 Fuel hose disconnection 4 12 Fuel line inspection 4 13 Fuel hose installation replacing with new fuel hose 4 14 Fuel hose connection 4 14 Fuel...

Page 78: ... in Chapter 8 Ventilation hose From ventilation fitting Engine unit Refer to ENGINE UNIT in Chapter 5 NOTE When removing the pump module only it is not necessary to remove the engine unit 1 Fuel tank breather hose 1 2 Check valve 1 NOTE Make sure the arrow direction pointed toward fuel tank 7 10 11 3 2 1 18 17 12 13 15 16 14 12 6 5 4 8 9 2nd 6 4 N m 0 64 kgf m 4 6 ft Ib 1st 3 2 N m 0 32 kgf m 2 3 ...

Page 79: ...f the coupler is installed properly before connecting the coupler 4 Fuel sender coupler 1 5 Fuel pump module coupler 1 6 Cover 1 7 Fuel hose 1 8 Nut 9 9 Retainer 1 10 Fuel pump module 1 11 Packing 1 7 10 11 3 2 1 18 17 12 13 15 16 14 12 6 5 4 8 9 2nd 6 4 N m 0 64 kgf m 4 6 ft Ib 1st 3 2 N m 0 32 kgf m 2 3 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 5 9 N m 0 59 kgf m 4 3 ft Ib ...

Page 80: ...Fuel filler hose 1 14 Nut 1 15 Fuel filler neck 1 16 Rubber seal 1 17 Fuel tank belt 2 18 Fuel tank assembly 1 Reverse the removal steps for installation 7 10 11 3 2 1 18 17 12 13 15 16 14 12 6 5 4 8 9 2nd 6 4 N m 0 64 kgf m 4 6 ft Ib 1st 3 2 N m 0 32 kgf m 2 3 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 5 9 N m 0 59 kgf m 4 3 ft Ib ...

Page 81: ...ence shown 2 3 8 7 5 1 2 3 8 7 5 1 4 4 9 6 6 2 Remove Fuel pump module 1 NOTE Remove the float 2 at an angle because it could catch on the fuel tank 1 2 Check valve inspection 1 Check Check valve Faulty Replace Checking steps Connect a hose to the end of check valve A and blow into it Air should come out from end B Connect the hose to the end of check valve B and blow into it Air should come out f...

Page 82: ... FUEL CONTROL SYSTEM in Chapter 7 Fuel tank inspection 1 Inspect Fuel tank Cracks damage Replace Fuel hose inspection Refer to FUEL INJECTION SYSTEM Fuel pump filter inspection 1 Inspect Fuel pump filter 1 Clog contaminants Wash the fuel pump filter in kerosene or gasoline 1 ...

Page 83: ...Nuts NOTE Tighten the nuts in the sequence shown Fuel hose connect Refer to FUEL INJECTION SYSTEM T R Fuel pump module nut 1st 3 2 N m 0 32 kgf m 2 3 ft lb 2nd 6 4 N m 0 64 kgf m 4 6 ft lb 2 3 8 7 5 1 8 7 2 3 5 9 4 6 1 6 4 FUEL TANK AND FUEL PUMP MODULE ...

Page 84: ...upler 2 7 Joint connector 4 From fuel rail 8 Throttle body assembly coupler 1 9 Cover 1 17 N m 1 7 kgf m 12 ft Ib 5 75 mm 1 2 N m 0 12 kgf m 0 9 ft Ib 5 25 mm 1 5 N m 0 15 kgf m 1 1 ft Ib 8 35 mm 17 N m 1 7 kgf m 12 ft Ib 2nd 18 N m 1 8 kgf m 13 ft Ib 1st 8 8 N m 0 88 kgf m 6 4 ft Ib 8 30 mm 2nd 39 N m 3 9 kgf m 28 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 20 mm LT 242 LT 242 LT 271 LT 572 LT LT 572 L...

Page 85: ...kgf m 12 ft Ib 5 75 mm 1 2 N m 0 12 kgf m 0 9 ft Ib 5 25 mm 1 5 N m 0 15 kgf m 1 1 ft Ib 8 35 mm 17 N m 1 7 kgf m 12 ft Ib 2nd 18 N m 1 8 kgf m 13 ft Ib 1st 8 8 N m 0 88 kgf m 6 4 ft Ib 8 30 mm 2nd 39 N m 3 9 kgf m 28 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 20 mm LT 242 LT 242 LT 271 LT 572 LT LT 572 LT 22 23 20 19 21 18 15 13 16 14 17 12 1 7 3 2 2 2 5 4 6 24 24 25 8 26 27 28 29 11 10 9 2 5 N m 0 25...

Page 86: ...tallation 17 N m 1 7 kgf m 12 ft Ib 5 75 mm 1 2 N m 0 12 kgf m 0 9 ft Ib 5 25 mm 1 5 N m 0 15 kgf m 1 1 ft Ib 8 35 mm 17 N m 1 7 kgf m 12 ft Ib 2nd 18 N m 1 8 kgf m 13 ft Ib 1st 8 8 N m 0 88 kgf m 6 4 ft Ib 8 30 mm 2nd 39 N m 3 9 kgf m 28 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 20 mm LT 242 LT 242 LT 271 LT 572 LT LT 572 LT 22 23 20 19 21 18 15 13 16 14 17 12 1 7 3 2 2 2 5 4 6 24 24 25 8 26 27 28 29...

Page 87: ...ty Service points THROTTLE BODY ASSEMBLY AND INTAKE MANIFOLD DISASSEMBLY Follow the left Step for disassembly 1 Bolt 4 2 Washer 4 3 Throttle body assembly 1 4 Gasket 1 5 Intake manifold 1 6 Bolt 2 7 Fuel rail 1 8 17 mm 13 N m 1 3 kgf m 9 4 ft Ib 5 15 mm 3 5 N m 0 35 kgf m 2 5 ft Ib 8 65 mm 13 N m 1 3 kgf m 9 4 ft Ib 1 2 3 4 14 15 16 8 9 10 7 6 6 11 11 12 13 5 Not reusable ...

Page 88: ...or 4 10 O ring 4 11 Screw 2 12 Sensor assembly 1 13 O ring 1 14 Clamp 4 15 Clamp 4 16 Intake manifold joint 4 Reverse the disassembly steps for assembly 8 17 mm 13 N m 1 3 kgf m 9 4 ft Ib 5 15 mm 3 5 N m 0 35 kgf m 2 5 ft Ib 8 65 mm 13 N m 1 3 kgf m 9 4 ft Ib 1 2 3 4 14 15 16 8 9 10 7 6 6 11 11 12 13 5 Not reusable Not reusable Not reusable ...

Page 89: ...fuel hose clamps properly to securely fasten them Fuel hose disconnection WARNING Before disconnecting the hose remove the fuel tank filler cap to reduce any pressure inside the fuel tank and then disconnect the battery negative lead to cut off the elec tric current to the electrical systems 1 Wrap the quick connector with a cloth and then rotate the quick connector tab 1 to the stopper position a...

Page 90: ...ARNING Always reduce the fuel pressure in the fuel line before servicing the line or the fuel pipe If the fuel pressure is not released pressurized fuel could spray out 2 1 1 2 3 Cover the quick connector and fuel pipe with a plastic bag 3 to prevent damage and to protect them from dirt 3 Fuel line inspection 1 Inspect Fuel hose Damage cracks Replace O rings quick connector Damage cracks Replace t...

Page 91: ...ed to the quick con nector of the hose If the quick connector is completely installed to the fuel pipe it is removable 2 1 a 2 Fuel hose connection 1 Apply a thin coat of engine oil to the con tact surfaces of the fuel pipe 2 Insert the quick connector into the fuel pipe until you hear a click 3 To check the connection of the quick con nector push and pull on the quick connec tor several times unt...

Page 92: ...sing the Stationary Test of the Yamaha Diagnostic System Digital multimeter YU 34899 A Digital circuit tester 90890 03174 Fuel injector resistance reference data 11 5 12 5 Ω at 20 C 68 F Throttle body assembly inspection CAUTION The throttle body assembly should not be disassembled 1 Check Throttle body assembly Cracks damage Replace the throttle body assembly Accelerator position sensor inspectio...

Page 93: ...e projec tion a on the intake manifold joint Tighten the clamp screw until both ends of the intake screw clamp contact the spacer 1 around the screw a 1 1 2 Install Fuel hose 2 fuel rail side Fuel hose clamps WARNING Do not reuse the fuel hose clamps always replace them with new ones NOTE Install the fuel hose with the white mark a facing up Install the fuel hose clamps at the locations shown in t...

Page 94: ... Chap ter 3 a b a b 2 1 Fuel pressure measurement 1 Disconnect Fuel hose Refer to Fuel hose disconnection 2 Install Fuel pressure gauge adapter 1 Fuel pressure gauge 2 NOTE To connect the fuel pressure gauge adapter follow the procedures for connecting a fuel hose Refer to Fuel hose connection 3 Start the engine and arrow it to warm up for several minutes 4 Measure Fuel pressure Out of specificati...

Page 95: ...ssure gauge adapter NOTE To disconnect the fuel pressure gauge adapter follow the procedures for disconnect ing a fuel hose Refer to Fuel hose discon nection 6 Connect Fuel hose Refer to Fuel hose connection THROTTLE BODY ASSEMBLY AND INTAKE MANIFOLD ...

Page 96: ......

Page 97: ... TANK 5 12 EXPLODED DIAGRAM 5 12 REMOVAL AND INSTALLATION CHART 5 12 SERVICE POINTS 5 17 Oil tank removal 5 17 Oil strainer inspection 5 18 Oil tank installation 5 18 OIL PUMP 5 21 EXPLODED DIAGRAM 5 21 REMOVAL AND INSTALLATION CHART 5 21 SERVICE POINTS 5 23 Oil strainer inspection 5 23 Oil pump installation 5 23 REDUCTION DRIVE GEAR 5 24 EXPLODED DIAGRAM 5 24 REMOVAL AND INSTALLATION CHART 5 24 S...

Page 98: ... EXPLODED DIAGRAM 5 54 REMOVAL AND INSTALLATION CHART 5 54 SERVICE POINTS 5 56 Cylinder head removal 5 56 Cylinder head inspection 5 56 Cylinder head installation 5 57 VALVES AND VALVE SPRINGS 5 59 EXPLODED DIAGRAM 5 59 REMOVAL AND INSTALLATION CHART 5 59 SERVICE POINTS 5 61 Valve removal 5 61 Valve spring inspection 5 62 Valve inspection 5 62 Valve guide inspection 5 64 Valve guide replacement 5 ...

Page 99: ...5 83 Piston ring inspection 5 84 Piston pin inspection 5 86 Connecting rod inspection 5 87 Connecting rod and piston installation 5 89 CRANKSHAFT 5 93 EXPLODED DIAGRAM 5 93 REMOVAL AND INSTALLATION CHART 5 93 SERVICE POINTS 5 94 Crankshaft removal 5 94 Crankshaft inspection 5 94 Crankshaft installation 5 97 COOLING WATER HOSE 5 98 EXPLODED DIAGRAM 5 98 REMOVAL AND INSTALLATION CHART 5 98 ...

Page 100: ...8 Battery negative and positive lead Refer to FUSE BOX in Chapter 7 Fuel hose Refer to FUEL INJECTION SYSTEM in Chapter 4 Water lock and exhaust joint Refer to EXHAUST SYSTEM in Chapter 8 1 Bolt washer 2 2 2 Fuse box 1 14 10 10 2 1 13 3 4 11 15 12 8 7 9 6 5 2nd 18 N m 1 8 kgf m 13 ft Ib 1st 8 8 N m 0 88 kgf m 6 4 ft Ib 8 35 mm 6 25 mm 7 8 N m 0 78 kgf m 5 6 ft Ib 8 35 mm 17 N m 1 7 kgf m 12 ft Ib ...

Page 101: ...et 8 Clamp cooling water hose 1 1 Cooling water inlet 9 Clamp cooling water hose 1 1 Cooling water outlet 10 Coupler 10 11 Bolt collar 1 1 12 Coupling cover 1 14 10 10 2 1 13 3 4 11 15 12 8 7 9 6 5 2nd 18 N m 1 8 kgf m 13 ft Ib 1st 8 8 N m 0 88 kgf m 6 4 ft Ib 8 35 mm 6 25 mm 7 8 N m 0 78 kgf m 5 6 ft Ib 8 35 mm 17 N m 1 7 kgf m 12 ft Ib 17 N m 1 7 kgf m 12 ft Ib 8 40 mm 17 N m 1 7 kgf m 12 ft Ib ...

Page 102: ... Engine unit 1 Reverse the removal steps for installation 14 10 10 2 1 13 3 4 11 15 12 8 7 9 6 5 2nd 18 N m 1 8 kgf m 13 ft Ib 1st 8 8 N m 0 88 kgf m 6 4 ft Ib 8 35 mm 6 25 mm 7 8 N m 0 78 kgf m 5 6 ft Ib 8 35 mm 17 N m 1 7 kgf m 12 ft Ib 17 N m 1 7 kgf m 12 ft Ib 8 40 mm 17 N m 1 7 kgf m 12 ft Ib 10 LT 242 LT LT 572 LT LT 271 ...

Page 103: ...st Refer to POWER UNIT in Chapter 3 2 Warm the engine up and then put the watercraft in a horizontal position 3 Remove Ignition coils Spark plugs CAUTION Before removing the spark plugs use com pressed air to blow away any dirt accumu lated in the spark plug wells to prevent it from falling into the cylinders 4 Install Compression gauge extension 1 Compression gauge 2 Compression gauge extension 9...

Page 104: ...kPa 1 kgf cm2 14 psi b If the compression pressure is extremely high check the cylinder head valve sur faces and piston crown for carbon depos its Carbon deposits Eliminate c If the compression pressure is below the minimum specification squirt a few drops of oil into the cylinder and measure again Refer to the following table Compression pressure with oil applied into the cylinder Reading Diagnos...

Page 105: ...r letting it fall hard on the hull Suspend the engine unit using all three engine hangers and then separate the unit from the engine mount Shim removal 1 Remove Shims NOTE To ease reassembly and coupling alignment remove the shims and organize them in their respective groups e g front right rear left prior to removing the mounting bolts Engine mount inspection 1 Inspect Engine mounts Cracks damage...

Page 106: ...ication 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 Adjust the clearance b by moving the engine unit position ...

Page 107: ...T È For cooling water pilot outlet on port side É From water jacket 1 Clamp cooling water hose 1 1 2 Clamp cooling water hose 1 1 3 Bolt 2 4 Thermoswitch exhaust 1 5 Exhaust joint clamp 2 Slide the outer exhaust joint for exhaust manifold side 6 Exhaust joint clamp 2 6 6 4 3 É 5 2 È 6 16 mm 7 6 N m 0 76 kgf m 5 5 ft Ib 2nd 3 4 N m 0 34 kgf m 2 5 ft Ib 1st 3 4 N m 0 34 kgf m 2 5 ft Ib LT 242 LT 242...

Page 108: ...d 2 0 N m 0 2 kgf m 1 4 ft Ib 10th 39 N m 3 9 kgf m 28 ft Ib 10 35 mm 5th 15 N m 1 5 kgf m 11 ft Ib 1st 2 0 N m 0 2 kgf m 1 4 ft Ib 9th 39 N m 3 9 kgf m 28 ft Ib 10 35 mm 8th 15 N m 1 5 kgf m 11 ft Ib 4th 2 0 N m 0 2 kgf m 1 4 ft Ib 12th 39 N m 3 9 kgf m 28 ft Ib 10 45 mm 7th 15 N m 1 5 kgf m 11 ft Ib 3rd 2 0 N m 0 2 kgf m 1 4 ft Ib 11th 39 N m 3 9 kgf m 28 ft Ib 10 40 mm LT 242 LT 242 LT 572 LT L...

Page 109: ...se the removal steps for installation 14 17 20 16 11 12 13 14 É 18 19 È 22 21 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 3rd 35 N m 3 5 kgf m 25 ft Ib 8 75 mm 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 3rd 35 N m 3 5 kgf m 25 ft Ib 8 125 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 16 mm LT 242 19 18 LT 242 LT 572 LT LT 572 LT LT 242 LT 2...

Page 110: ...er to EXHAUST PIPES 1 AND 2 1 Clamp cooling hose 2 1 È To cylinder block 2 Bolt 5 3 Bolt 6 4 Exhaust manifold 1 5 Gasket 1 6 Dowel pin 2 Reverse the removal steps for installation 6 5 3 È 6 2 4 1 1 1 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 3rd 35 N m 3 5 kgf m 25 ft Ib 8 75 mm 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 3rd 35 N m 3 5 kgf m 25 ft Ib 8 155 mm LT ...

Page 111: ...r 2 Ì LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 23 19 25 24 26 25 21 16 17 1514 12 20 22 3 4 6 8 9 7 2 6 A A 6 30 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 2nd 15 N m 1 5 kgf m 11 ft Ib 1st 2 0 N m 0 2 kgf m 1 4 ft Ib 3rd 39 N m 3 9 kgf m 28 ft Ib 2nd 39 N m 3 9 kgf m 28 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 10 85 mm 2nd 15 N m 1 5 kgf m 11 ft Ib 1st 2 0 N m 0 2 kgf m 1 4 ...

Page 112: ... 572 23 19 25 24 26 25 21 16 17 1514 12 20 22 3 4 6 8 9 7 2 6 A A 6 30 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 2nd 15 N m 1 5 kgf m 11 ft Ib 1st 2 0 N m 0 2 kgf m 1 4 ft Ib 3rd 39 N m 3 9 kgf m 28 ft Ib 2nd 39 N m 3 9 kgf m 28 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 10 85 mm 2nd 15 N m 1 5 kgf m 11 ft Ib 1st 2 0 N m 0 2 kgf m 1 4 ft Ib 10 70 mm 3rd 39 N m 3 9 kgf m 28 ft I...

Page 113: ... mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 2nd 15 N m 1 5 kgf m 11 ft Ib 1st 2 0 N m 0 2 kgf m 1 4 ft Ib 3rd 39 N m 3 9 kgf m 28 ft Ib 2nd 39 N m 3 9 kgf m 28 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 10 85 mm 2nd 15 N m 1 5 kgf m 11 ft Ib 1st 2 0 N m 0 2 kgf m 1 4 ft Ib 10 70 mm 3rd 39 N m 3 9 kgf m 28 ft Ib 7 6 N m 0 76 kgf m 5 5 ft Ib 6 35 mm È É Ì 13 LT 572 LT 572 LT 572 L...

Page 114: ... 16 14 12 15 11 13 5 6 4 3 LT 572 LT LT 572 LT LT 572 LT 6 25 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 5 14 mm 2nd 4 4 N m 0 44 kgf m 3 2 ft Ib 1st 1 9 N m 0 19 kgf m 1 4 ft Ib 6 20 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 20 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 14 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 ...

Page 115: ...LT 572 LT LT 572 LT LT 572 LT 6 25 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 5 14 mm 2nd 4 4 N m 0 44 kgf m 3 2 ft Ib 1st 1 9 N m 0 19 kgf m 1 4 ft Ib 6 20 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 20 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 14 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib ...

Page 116: ...e oil tank bolts and nuts in the sequence shown 3 5 9 7 6 4 2 1 8 2 Remove Oil tank cover Gasket NOTE Loosen the oil tank cover bolts in the sequence shown 1 2 6 7 3 4 8 5 3 Remove Oil breather plate Gasket NOTE Loosen the oil breather plate bolts in the sequence shown 2 1 7 6 5 4 3 8 9 ...

Page 117: ... 10 3 4 2 Oil strainer inspection 1 Check Oil strainer 1 Damage Replace Contaminants Clean Oil tank installation 1 Install Gaskets Oil cooler covers NOTE Tighten the oil cooler bolts in the sequence shown T R Oil cooler cover bolt 1st 3 7 N m 0 37 kgf m 2 7 ft lb 2nd 7 6 N m 0 76 kgf m 5 5 ft lb LOCTITE 572 5 12 4 1 6 7 8 2 3 10 9 11 ...

Page 118: ...breather plate bolt 1st 1 9 N m 0 19 kgf m 1 4 ft lb 2nd 4 4 N m 0 44 kgf m 3 2 ft lb 8 9 3 4 5 6 7 2 1 3 Install Gasket Oil tank cover NOTE Tighten the oil tank cover bolts in the sequence shown T R Oil tank cover bolt 1st 3 7 N m 0 37 kgf m 2 7 ft lb 2nd 7 6 N m 0 76 kgf m 5 5 ft lb LOCTITE 572 8 7 3 2 6 5 1 4 OIL TANK ...

Page 119: ...nk nuts and bolts in the sequence shown T R Bolt 1 1st 15 N m 1 5 kgf m 11 ft lb 2nd 39 N m 3 9 kgf m 28 ft lb LOCTITE 572 Nut 2 bolt 3 1st 2 0 N m 0 2 kgf m 1 4 ft lb 2nd 15 N m 1 5 kgf m 11 ft lb 3rd 39 N m 3 9 kgf m 28 ft lb LOCTITE 572 7 5 1 3 4 6 8 9 2 2 3 2 1 ...

Page 120: ...1 Drain engine oil 2 Bolt 6 3 Bolt 2 4 Bolt 2 5 Oil pump assembly 1 6 Gasket 1 7 Pin 2 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 112 mm 6 25 mm 10 N m 1 0 kgf m 7 2 ft Ib 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 16 mm LT 572 LT LT 572 LT 13 N m 1 3 kgf m 9 4 ft Ib 8 12 mm LT 572 LT 1 5 7 7 3 4 2 6 8 8 9 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf...

Page 121: ...allation 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 112 mm 6 25 mm 10 N m 1 0 kgf m 7 2 ft Ib 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 16 mm LT 572 LT LT 572 LT 13 N m 1 3 kgf m 9 4 ft Ib 8 12 mm LT 572 LT 1 5 7 7 3 4 2 6 8 8 9 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 95 mm ...

Page 122: ...nts Clean 1 Oil pump installation 1 Install Oil pump assembly NOTE Align the projection a on the oil pump shaft with the slit b on the oil pump driven gear shaft T R Oil pump assembly bolt M6 10 N m 1 0 kgf m 7 2 ft lb LOCTITE 572 M8 1st 15 N m 1 5 kgf m 11 ft lb 2nd 28 N m 2 8 kgf m 20 ft lb LOCTITE 572 a b ...

Page 123: ...olt 1 3 Bolt 1 4 Bolt 3 5 Bolt 1 8 8 9 11 10 11 9 7 3 2 4 12 5 4 6 E LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT 6 55 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 28 N m 2 8 kgf m 20 ft Ib 6 35 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 8 40 mm 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 70 mm 2nd 28 N m 2 8 kgf m 20 ft Ib 1...

Page 124: ... 9 7 3 2 4 12 5 4 6 E LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT 6 55 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 28 N m 2 8 kgf m 20 ft Ib 6 35 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 8 40 mm 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 70 mm 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 1 8 100 mm 2nd 28 ...

Page 125: ...dure Part name Q ty Service points REDUCTION DRIVE GEAR DISASSEMBLY Follow the left Step for disassembly 1 Oil pump drive shaft 1 2 Drive shaft 1 3 Collar 1 4 Oil seal 2 5 Circlip 1 6 Bearing 1 7 Collar 1 8 Bearing 1 E E E E 3 4 8 6 5 10 9 1 1 A A 1 E 2 11 7 1 Not reusable Not reusable Not reusable Not reusable ...

Page 126: ... DIAGRAM 1 EPNOC grease AP 0 Step Procedure Part name Q ty Service points 9 Circlip 1 10 Bearing 1 11 Reduction drive gear case 1 Reverse the disassembly steps for assembly E E E E 3 4 8 6 5 10 9 1 1 A A 1 E 2 11 7 1 Not reusable Not reusable ...

Page 127: ...551 Universal magneto and rotor holder YU 01235 Rotor holder 90890 01235 1 4 2 3 Drive shaft removal 1 Remove Drive shaft NOTE Press in the direction of the arrow Bearing removal 1 Remove Circlip Rear bearing Collar Front bearing NOTE Remove the front bearing spacer and rear bearing using a press È For USA and Canada É For worldwide Driver handle large YB 06071 Driver rod L3 90890 06652 Bearing ho...

Page 128: ...ldwide Slide hammer and adapters YB 06096 Stopper guide plate 90890 06501 Bearing puller assembly 90890 06535 Stopper guide stand 90890 06538 È É Oil pump drive shaft inspection 1 Check Oil pump drive shaft 1 Cracks damage wear Replace 1 Drive shaft inspection 1 Check Drive shaft 1 Cracks damage wear Replace 1 ...

Page 129: ... Driver handle large YB 06071 Driver rod LS 90890 06606 Outer race installer forward gear YB 06085 Ball bearing attachment 90890 06631 2 Install Front bearing NOTE Install the front bearing using a press È For USA and Canada É For worldwide Driver rod LS 90890 06606 Forward gear bearing cup installer YB 06276 B Ball bearing attachment 90890 06657 È É ...

Page 130: ...er of 70 mm 2 76 in and an inner diame ter of 30 mm 1 18 in È For USA and Canada É For worldwide Driver rod LS 90890 06606 Outer race installer forward gear YB 06085 Bearing outer race attachment 90890 06624 È É 4 Install Oil seals È For USA and Canada É For worldwide Driver handle large YB 06071 Driver rod LS 90890 06606 Outer race installer forward gear YB 06085 Bearing outer race attachment 908...

Page 131: ...97 in and an inner diameter of approximately 28 0 5 mm 1 10 0 02 in Drive coupling installation 1 Install Drive coupling 1 NOTE While holding the drive shaft 2 with the rotor holder 3 tighten the drive coupling with the coupler wrench 4 2 Install Reduction drive gear housing Coupler wrench YW 06551 90890 06551 Universal magneto and rotor holder YU 01235 Rotor holder 90890 01235 T R Drive coupling ...

Page 132: ... 1 1 2 Starter motor lead 1 3 Bolt 2 4 Battery negative lead 1 5 Starter motor 1 6 Band 1 7 Lighting coil coupler 1 4 3 2 1 5 7 8 9 11 13 12 18 16 17 19 20 21 15 14 A A E E E LT 572 LT 572 A A A A 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 4 9 N m 0 49 kgf m 3 5 ft Ib 10 47 mm 75 N m 7 5 kgf m 54 ft Ib 8 20 mm 24 N m 2 4 kgf m 17 ft Ib 10 60 mm 2nd 50 N m 5 0 kgf m 36 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 6 ...

Page 133: ...washer 1 1 17 Flywheel magneto 1 18 Bolt 6 4 3 2 1 5 7 8 9 11 13 12 18 16 17 19 20 21 15 14 A A E E E LT 572 LT 572 A A A A 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 4 9 N m 0 49 kgf m 3 5 ft Ib 10 47 mm 75 N m 7 5 kgf m 54 ft Ib 8 20 mm 24 N m 2 4 kgf m 17 ft Ib 10 60 mm 2nd 50 N m 5 0 kgf m 36 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 6 2nd 50 N m 5 0 kgf m 36 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 10 135 mm 10 ...

Page 134: ...or installation 4 3 2 1 5 7 8 9 11 13 12 18 16 17 19 20 21 15 14 A A E E E LT 572 LT 572 A A A A 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 4 9 N m 0 49 kgf m 3 5 ft Ib 10 47 mm 75 N m 7 5 kgf m 54 ft Ib 8 20 mm 24 N m 2 4 kgf m 17 ft Ib 10 60 mm 2nd 50 N m 5 0 kgf m 36 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 6 2nd 50 N m 5 0 kgf m 36 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 10 135 mm 10 LT 572 LT 572 ...

Page 135: ...sassembly 1 Bolt washer 1 1 2 Bolt 2 3 Pickup coil 1 NOTE There washer hold the pickup coil lead Make sure to not pitch the lead between the projection and the washer when installing the bolt 4 Bolt 2 1 7 6 3 2 4 5 LT 242 LT 242 LT 242 LT 242 14 N m 1 4 kgf m 10 ft Ib 6 14 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 5 14 mm 14 N m 1 4 kgf m 10 ft Ib 6 35 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 5 10 mm ...

Page 136: ...Q ty Service points 5 Holder 1 6 Bolt 3 7 Lighting coil 1 Reverse the disassembly steps for assembly 1 7 6 3 2 4 5 LT 242 LT 242 LT 242 LT 242 14 N m 1 4 kgf m 10 ft Ib 6 14 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 5 14 mm 14 N m 1 4 kgf m 10 ft Ib 6 35 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 5 10 mm ...

Page 137: ... with the sheave holder 3 loosen the flywheel magneto bolt Sheave holder YS 01880 A 90890 01701 2 Remove Flywheel magneto 1 Woodruff key NOTE While holding the flywheel magneto with sheave holder 2 remove the flywheel mag neto with the rotor puller 3 Rotor puller YM 01082 90890 01080 Starter clutch inspection 1 Check Starter clutch rollers 1 Damage wear Replace ...

Page 138: ...utch gear 1 2 a 4 Check Starter clutch operation Checking steps Install the starter gear 1 onto the starter clutch 2 and hold the starter clutch When turning the starter gear clockwise È it should turn freely otherwise the starter clutch is faulty and must be replaced When turning the starter gear counter clockwise É the starter clutch and the starter gear should engage otherwise the starter clutc...

Page 139: ...ake sure the woodruff key is properly seated in the keyway of the crankshaft Lubricate the flywheel magneto bolt and washer with engine oil 2 Tighten Flywheel magneto bolt 1 NOTE While holding the flywheel magneto 2 with the sheave holder 3 tighten the flywheel mag neto bolt CAUTION Do not reuse the flywheel magneto bolt and washer always replace them with new ones T R Flywheel magneto bolt 75 N m...

Page 140: ...p breather hose 1 1 È To oil tank Paint mark a 5 Bolt 1 6 Cam position sensor 1 7 Clamp cooling water hose 1 1 É To transom plate 8 Rubber seal 1 E 4 6 5 7 8 10 11 12 13 9 LT 572 LT 14 16 15 3 13 N m 1 3 kgf m 9 4 ft Ib 10 N m 1 0 kgf m 7 2 ft Ib 6 16 mm 6 16 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 12 N m 1 2 kgf m 8 7 ft Ib 6 22 mm a È É 1 2 7 6 N m 0 76 kgf m 5 5 ft ...

Page 141: ...er gasket 1 16 Timing chain guide top side 1 Reverse the removal steps for installation E 4 6 5 7 8 10 11 12 13 9 LT 572 LT 14 16 15 3 13 N m 1 3 kgf m 9 4 ft Ib 10 N m 1 0 kgf m 7 2 ft Ib 6 16 mm 6 16 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 12 N m 1 2 kgf m 8 7 ft Ib 6 22 mm a È É 1 2 7 6 N m 0 76 kgf m 5 5 ft Ib 6 16 mm LT 572 LT A A 1280B 1280B Not reusable Not reus...

Page 142: ... sary to remove the reduction drive gear case 1 Thermoswitch engine coupler 1 2 Engine temperature sensor coupler 1 3 Cap bolt 1 4 Gasket 1 5 Bolt 2 M E E E E E E M 12 13 12 13 12 13 14 18 19 10 20 10 10 15 11 16 9 17 8 22 21 3 4 5 6 7 10 N m 1 0 kgf m 7 2 ft Ib 6 35 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 35 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 25 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 8 mm 24 N m 2 4 kgf m 17 ft Ib...

Page 143: ...0 13 Exhaust camshaft cap 3 14 Dowel pin 6 15 Intake camshaft 1 16 Bolt 2 17 Intake camshaft sprocket 1 M E E E E E E M 12 13 12 13 12 13 14 18 19 10 20 10 10 15 11 16 9 17 8 22 21 3 4 5 6 7 10 N m 1 0 kgf m 7 2 ft Ib 6 35 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 35 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 25 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 8 mm 24 N m 2 4 kgf m 17 ft Ib 7 11 mm 24 N m 2 4 kgf m 17 ft Ib 7 11 mm 23...

Page 144: ...25 Gasket 1 26 Pipe 1 27 O ring 1 Reverse the removal steps for installation M E E E E E E M 12 13 12 13 12 13 14 18 19 10 20 10 10 15 11 16 9 17 8 22 21 3 4 5 6 7 10 N m 1 0 kgf m 7 2 ft Ib 6 35 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 35 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 25 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 8 mm 24 N m 2 4 kgf m 17 ft Ib 7 11 mm 24 N m 2 4 kgf m 17 ft Ib 7 11 mm 23 24 25 26 27 1 2 6 16 mm A ...

Page 145: ... compression stroke with a dial gauge NOTE TDC on the compression stroke can be found when the camshaft lobes are turned away from each other Dial gauge stand 90890 06583 Dial gauge needle 90890 06584 Dial gauge stand set YB 06585 90890 06585 Dial indicator gauge YU 03097 Dial gauge set 90890 01252 2 1 IN EX 3 Make the alignment marks a on the timing chain and camshaft sprockets a 4 Remove Timing ...

Page 146: ...e fasten it with a wire 3 7 Remove Exhaust camshaft sprocket 1 Intake camshaft sprocket 2 with the special service tool 3 Universal magneto and rotor holder YU 01235 Rotor holder 90890 01235 Camshaft inspection 1 Check Camshaft lobes Bluediscoloration pitting scratches Replace the camshaft 2 Measure Camshaft lobe dimensions a and b Out of specification Replace the cam shaft Cam lobe dimensions Int...

Page 147: ...nto the cylinder head without the dowel pins and camshaft caps Position a strip of Plastigauge 1 onto the camshaft journal as shown Install the dowel pins and camshaft caps NOTE Tighten the intake and exhaust camshaft cap bolts in the sequence shown Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge T R Camshaft cap bolt 10 N m 1 0 kgf m 7 2...

Page 148: ...rockets and timing chain as a set a 1 4 of a tooth b Correct 1 Timing chain 2 Camshaft sprocket Timing chain tensioner inspection 1 Check Timing chain tensioner Cracks damage rough movement Replace Checking steps While lightly pressing the timing chain tensioner rod by hand turn the tensioner rod fully clockwise with a thin screwdriver 1 Remove the screwdriver and slowly release the timing chain t...

Page 149: ...take camshaft Exhaust camshaft caps Intake camshaft caps Installation steps Turn the drive coupling counterclockwise and then check if cylinder 1 is at TDC of the compression stroke with a dial gauge Install the timing chain onto both cam shaft sprockets and then install the cam shaft CAUTION Do not turn the crankshaft when install ing the camshaft to avoid damage or improper valve timing NOTE Mak...

Page 150: ...2 6 13 11 10 16 3 Install Timing chain tensioner Installation steps While lightly pressing the timing chain tensioner rod by hand turn the tensioner rod fully clockwise with a thin screwdriver 1 NOTE Make sure that the tensioner rod has been fully set clockwise With the timing chain tensioner rod turned all the way into the timing chain tensioner housing with the thin screw driver still installed ...

Page 151: ...Turn Drive coupling several turns counterclockwise 5 Check Turn the drive coupling counterclock wise and then check if cylinder 1 is at TDC of the compression stroke with a dial gauge Camshaft punch marks a Make sure that the camshaft punch marks are aligned with the arrow marks b on the camshaft caps Out of alignment Adjust Refer to the installation steps above 6 Measure Valve clearance Out of sp...

Page 152: ... gasket Cylinder head cover NOTE Apply sealant onto the mating surfaces of the cylinder head cover gasket and cylinder head Tighten the cylinder head cover bolts stages and in a crisscross pattern T R Cylinder head cover bolt 12 N m 1 2 kgf m 8 7 ft lb ...

Page 153: ... Refer to EXHAUST PIPES 1 AND 2 Oil tank Refer to OIL TANK Intake and exhaust camshaft Refer to CAMSHAFTS 1 Bolt 2 2 Hunger 1 3 Bolt 3 E E E E 2 4 1 8 5 5 7 9 3 6 6 LT 271 2nd 121 5 1st 20 N m 2 0 kgf m 14 ft Ib 2nd 140 5 1st 20 N m 2 0 kgf m 14 ft Ib 10 N m 1 0 kgf m 7 2 ft Ib 6 12 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 55 mm 8 20 mm 6 2nd 105 5 1st 20 N m 2 0 kgf m 14 ft Ib 2nd 105 5 1st 20 N m 2 0 kgf...

Page 154: ...emoval steps for installation E E E E 2 4 1 8 5 5 7 9 3 6 6 LT 271 2nd 121 5 1st 20 N m 2 0 kgf m 14 ft Ib 2nd 140 5 1st 20 N m 2 0 kgf m 14 ft Ib 10 N m 1 0 kgf m 7 2 ft Ib 6 12 mm 10 N m 1 0 kgf m 7 2 ft Ib 6 55 mm 8 20 mm 6 2nd 105 5 1st 20 N m 2 0 kgf m 14 ft Ib 2nd 105 5 1st 20 N m 2 0 kgf m 14 ft Ib 2nd 105 5 1st 20 N m 2 0 kgf m 14 ft Ib 2nd 105 5 1st 20 N m 2 0 kgf m 14 ft Ib E 6 4 6 6 6 N...

Page 155: ...inder head nuts in the sequence shown Cylinder head inspection 1 Eliminate Combustion chamber carbon deposits with a rounded scraper NOTE Do not use a sharp instrument to avoid damag ing or scratching spark plug bore threads valve seats 2 Check Cylinder head Damage scratches Replace Cylinder head water jacket Mineral deposits rust Eliminate ...

Page 156: ...arpage If the limit is exceeded replace the cylin der head Cylinder head installation 1 Install Cylinder head NOTE Pass the timing chain through the timing chain cavity Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts in the sequence shown T R Cylinder head nut 1 1st 20 N m 2 0 kgf m 14 ft lb 2nd 121 5 Cylinder head nut 2 1st 20 N m 2 0 kgf m 14 ft lb 2nd 105 5 Cylin...

Page 157: ...5 58 E POWR CYLINDER HEAD 2 Tighten Cylinder head bolts 1 NOTE Lubricate the cylinder head bolts with engine oil T R Cylinder head bolt 10 N m 1 0 kgf m 7 2 ft lb ...

Page 158: ...Follow the left Step for removal Cylinder head Refer to CYLINDER HEAD 1 Intake valve lifter 12 2 Intake valve pad 12 3 Intake valve cotter 24 4 Intake valve upper spring seat 12 5 Intake valve spring 12 6 Intake valve stem seal 12 7 Intake valve lower spring seat 12 8 Intake valve 12 9 Intake valve guide 12 E E E 8 9 17 18 16 15 14 13 10 11 12 1 2 3 4 5 6 7 3 12 Not reusable Not reusable ...

Page 159: ... valve pad 8 12 Exhaust valve cotter 16 13 Exhaust valve upper spring seat 8 14 Exhaust valve spring 8 15 Exhaust valve stem seal 8 16 Exhaust valve lower spring seat 8 17 Exhaust valve 8 18 Exhaust valve guide 8 Reverse the removal steps for installation E E E 8 9 17 18 16 15 14 13 10 11 12 1 2 3 4 5 6 7 3 12 Not reusable Not reusable ...

Page 160: ...ove the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 Valve spring compressor YM 01253 90890 04019 Valve spring compressor attachment for the intake valve YM 04114 90890 04114 for the exhaust valve YM 04108 90890 04108 3 Remove Upper spring seat 1 Valve spring 2 Valve 3 Stem seal 4 Lower spring seat 5 NOTE Identify the position of each part very ...

Page 161: ...ngth Intake valve spring 38 90 mm 1 53 in Exhaust valve spring 40 67 mm 1 60 in Valve spring tilt limit Intake valve spring 2 5 1 7 mm 0 067 in Exhaust valve spring 2 5 1 8 mm 0 071 in Valve inspection 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve face Pitting wear Replace the valve 3 Measure Valve margin thickness a Out of specification Replace the valve Valve margi...

Page 162: ...er a Intake valve 3 975 3 990 mm 0 1565 0 1571 in Exhaust valve 4 465 4 480 mm 0 1758 0 1764 in 5 Measure Valve stem runout Out of specification Replace the valve NOTE When installing a new valve always replace the valve guide If the valve is removed or replaced always replace the stem seal Valve stem runout 0 01 mm 0 0004 in ...

Page 163: ...pecification Valve guide inside diameter Intake 4 000 4 012 mm 0 1575 0 1580 in Exhaust 4 500 4 512 mm 0 1772 0 1776 in Valve stem to valve guide clearance valve guide inside diameter valve stem diameter Intake 0 010 0 037 mm 0 0004 0 0015 in Exhaust 0 020 0 047 mm 0 0008 0 0019 in a Valve guide replacement 1 Remove the valve guide 1 by striking the special service tool from the combustion chamber...

Page 164: ...de installer Intake ø4 0 mm YM 04112 90890 04112 Exhaust ø4 5 mm YM 04117 90890 04117 3 E 2 3 Insert the special service tool into the valve guide 2 and then ream the valve guide NOTE Turn the valve guide reamer clockwise to ream the valve guide Do not turn the reamer counterclockwise when removing the reamer 4 Measure Valve guide inside diameter Valve guide reamer Intake ø4 0 mm YM 04113 90890 04...

Page 165: ...alve slowly on the valve seat with a valve lapper commercially available as shown 4 Measure the valve seat contact width a where the blueing dye is adhered to the valve face Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification Replace the valve guide if the valve seat contact is uneven Valve seat contact width a 0 90 1 10 mm 0 0354 0 ...

Page 166: ...at Be sure to turn the cutter evenly downward at a pres sure of 40 50 N 4 5 kgf 8 8 11 lbf to pre vent chatter marks Valve seat cutter holder Intake ø4 0 mm 90890 06811 Exhaust ø4 5 mm 90890 06812 Valve seat cutter 30 intake 90890 06815 45 intake 90890 06814 60 intake 90890 06813 30 exhaust 90890 06328 45 exhaust 90890 06312 60 exhaust 90890 06315 Neway valve seat cutter kit YM 91044 3 Use a 30 cu...

Page 167: ...p edge of the valve seat a 60 cutter to cut the bottom edge to center the area and set its width b Previous contact width 7 If the valve seat contact area is too narrow and situated near the top edge of the valve face use a 30 cutter to cut the top edge of the valve seat If necessary use a 45 cutter to center the area and set its width b Previous contact width 8 If the valve seat contact area is t...

Page 168: ...remaining lapping compound from the cylinder head and the valve 11 Check the valve seat contact area of the valve again Valve installation 1 Install Lower spring seat 1 Stem seal 2 Valve 3 Valve spring 4 Upper spring seat 5 into the cylinder head NOTE Make sure that each valve is installed in its original place Refer to the following embossed marks Right and left intake valve s 4XV Middle intake v...

Page 169: ...se applied to it Valve spring compressor YM 01253 90890 04019 Valve spring compressor attachment for the intake valve YM 04114 90890 04114 for the exhaust valve YM 04108 90890 04108 3 Lightly tap the valve spring retainer with a plastic hammer to set the valve cotter securely NOTE Apply engine oil to the valve pads and valve lifters before installation ...

Page 170: ...AND STARTER MOTOR Oil tank Refer to OIL TANK Oil pump Refer to OIL PUMP Loosen completely 6 21 20 20 11 10 9 8 7 2 3 4 5 16 15 17 18 13 14 12 19 1 LT 271 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT E E A A 12 N m 1 2 kgf m 8 7 ft Ib 6 70 mm 12 N m 1 2 kgf m 8 7 ft Ib 6 20 mm 20 N m 2 0 kgf m 14 ft Ib 8 40 mm 2nd 3rd 15 N m 1 5 kgf m 11 ft Ib 1st 7 8 N m 0 78 kgf m 5 6 ft Ib 9 105 mm 4th 4...

Page 171: ...mmet 1 6 21 20 20 11 10 9 8 7 2 3 4 5 16 15 17 18 13 14 12 19 1 LT 271 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT E E A A 12 N m 1 2 kgf m 8 7 ft Ib 6 70 mm 12 N m 1 2 kgf m 8 7 ft Ib 6 20 mm 20 N m 2 0 kgf m 14 ft Ib 8 40 mm 2nd 3rd 15 N m 1 5 kgf m 11 ft Ib 1st 7 8 N m 0 78 kgf m 5 6 ft Ib 9 105 mm 4th 49 5 8 4 N m 0 84 kgf m 6 1 ft Ib 12 N m 1 2 kgf m 8 7 ft Ib 6 55 mm 12 N m 1 2 kgf ...

Page 172: ...7 18 13 14 12 19 1 LT 271 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT E E A A 12 N m 1 2 kgf m 8 7 ft Ib 6 70 mm 12 N m 1 2 kgf m 8 7 ft Ib 6 20 mm 20 N m 2 0 kgf m 14 ft Ib 8 40 mm 2nd 3rd 15 N m 1 5 kgf m 11 ft Ib 1st 7 8 N m 0 78 kgf m 5 6 ft Ib 9 105 mm 4th 49 5 8 4 N m 0 84 kgf m 6 1 ft Ib 12 N m 1 2 kgf m 8 7 ft Ib 6 55 mm 12 N m 1 2 kgf m 8 7 ft Ib 6 55 mm 7 6 N m 0 76 kgf m 5 5 ft...

Page 173: ...nts OIL PIPE AND OIL FILTER BOLT REMOVAL Follow the left Step for removal Crankshaft Refer to CRANKSHAFT 1 Bolt 1 2 Oil pipe 1 3 O ring 2 4 Oil filter bolt 1 5 Lower crankcase 1 Reverse the removal steps for installation E E 5 1 2 3 4 A A 6 10 mm 12 N m 1 2 kgf m 8 7 ft Ib 35 N m 3 5 kgf m 25 ft Ib Not reusable ...

Page 174: ... Loosen each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them Loosen the bolts in decreasing numerical order refer to the numbers in the illustra tion The numbers embossed on the crankcase indicate the crankcase tightening sequence 3 Remove Lower crankcase CAUTION Tap on one side of the crankcase with a soft face hammer Tap on...

Page 175: ...ild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with com pressed air Timing chain inspection 1 Check Timing chain 1 Damage stiffness Replace the timing chain and camshaft sprockets as a set ...

Page 176: ...w any sealant to come into contact with the oil gallery or crankshaft journal bear ings Recommended lubricant Engine oil 3 Install Dowel pins 1 O ring 2 1 12 1 1280B 4 Install Crankcase bolts NOTE Lubricate the bolt 1 0 threads and wash ers with engine oil Finger tighten the crankcase bolts M9 105 mm bolts 1 0 M6 55 mm bolts A H J M6 70 mm bolts I 1 5 3 9 7 I C A E G 8 6 2 4 0 H F B D J ...

Page 177: ... 6 ft lb Loosen and retighten the crankcase bolts in the proper tightening sequence as shown T R Crankcase bolt 1 0 2nd Loosen completely 3rd 15 N m 1 5 kgf m 11 ft lb Tighten the crankcase bolts further to reach the specified angle 49 in the proper tightening sequence as shown T R Crankcase bolt 1 0 Final Specified angle 49 5 WARNING When the bolts are tightened more than the specified angle do n...

Page 178: ...m one corner to another is 60 6 Tighten Crankcase bolts A J NOTE Tighten the bolts in the order of the numbers on the crankcase 7 Tighten Oil pan bolts NOTE Tighten the bolts in the order of the numbers on the oil pan T R Crankcase bolt A J 12 N m 1 2 kgf m 8 7 ft lb LOCTITE 572 T R Oil pan bolt 12 N m 1 2 kgf m 8 7 ft lb LOCTITE 572 1 5 3 9 7 I C A E G 8 6 2 4 0 H F B D J 10 6 2 4 8 12 15 11 7 3 ...

Page 179: ...vice points CONNECTING RODS AND PISTONS REMOVAL Follow the left Step for removal Crankcase Separate Refer to CRANKCASE 1 Nut 8 2 Connecting rod cap 4 3 Big end lower bearing 4 4 Piston pin clip 8 5 Piston pin 4 6 Piston 4 7 Connecting rod 4 E E E E 1 2 3 10 11 12 4 5 6 8 7 9 2nd 120 5 1st 20 N m 2 0 kgf m 14 ft Ib M M M M 4 Not reusable Not reusable ...

Page 180: ...ep Procedure Part name Q ty Service points 8 Bolt 8 9 Big end upper bearing 4 10 Top ring 4 11 2nd ring 4 12 Oil ring 4 Reverse the removal steps for installation E E E E 1 2 3 10 11 12 4 5 6 8 7 9 2nd 120 5 1st 20 N m 2 0 kgf m 14 ft Ib M M M M 4 Not reusable ...

Page 181: ... its original place 1 2 Remove Piston pin clips 1 Piston pin 2 Piston 3 Connecting rod 4 CAUTION Do not use a hammer to drive the piston pin out NOTE For reference during installation put an iden tification number a on the piston crown Before removing the piston pin deburr the piston pin clip s groove and the piston s pin bore area 3 Remove Top ring 2nd ring Oil ring NOTE When removing a piston ri...

Page 182: ...he cylin der bore gauge Cylinder bore C 76 000 76 015 mm 2 9921 2 9927 in Taper limit T 0 08 mm 0 003 in Out of round R 0 05 mm 0 002 in C maximum of D1 D6 T maximum of D1 D5 direction c and D2 D6 direction d R maximum of D2 D1 measuring point a and D6 D5 measuring point b If out of specification replace the cylin der and the piston and piston rings as a set Measure piston skirt diameter P with th...

Page 183: ... 0 0043 in Limit 0 17 mm 0 0067 in If out of specification replace the piston and piston rings as a set Piston ring inspection 1 Measure Piston ring side clearance Out of specification Replace the pis ton and piston rings as a set NOTE Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings Side clearance Top ring 0 030 0 065 mm ...

Page 184: ...0 2 in 3 Measure Piston ring end gap Out of specification Replace the pis ton ring NOTE The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring end gap Top ring 0 32 0 44 mm 0 0126 0 0173 in 2nd ring 0 43 0 58 mm 0 0169 0 0228 in Oil ring 0 10 0 35 mm 0 0039 0 0138 in ...

Page 185: ...n pin Piston pin outside diameter 16 991 17 000 mm 0 6689 0 6693 in Limit 16 98 mm 0 67 in 3 Measure Piston pin bore diameter in the piston b Out of specification Replace the pis ton 4 Calculate Piston pin to piston clearance Out of specification Replace the pis ton pin Piston pin bore diameter in the piston 17 002 17 013 mm 0 6694 0 6698 in Piston pin to piston clearance Piston pin bore diameter ...

Page 186: ...s To obtain the cor rect big end oil clearance and prevent engine damage the big end bearings must be installed in their original posi tions Clean the big end bearings crankshaft pins and the inside of the connecting rod halves Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap NOTE Align the projections a on the big end bear ings wi...

Page 187: ...rod and connecting rod cap are aligned Tighten the connecting rod nuts Refer to Connecting rod and piston installation Remove the connecting rod and big end bearings Refer to Connecting rod and piston removal Measure the compressed Plastigauge width e on the crankshaft pin If the big end oil clearance is out of speci fication select replacement big end bear ings c d e 2 Select Big end bearings P1 ...

Page 188: ... of the pistons and connecting rods 1 Install Oil ring 2nd ring Top ring NOTE Be sure to install the piston rings so that the manufacturer s marks or numbers face up 2 Install Piston 1 Connecting rod 2 Piston pin 3 Piston pin clips 4 NOTE Apply engine oil onto the piston pin When installing the connecting rod to the pis ton make sure that the Y mark a on the connecting rod faces towards the left w...

Page 189: ...È Exhaust side b c a È 90 45 90 4 Lubricate Piston Piston rings Cylinder with the recommended lubricant Recommended lubricant Engine oil 5 Lubricate Bolt threads Nut seats with the recommended lubricant Recommended lubricant Molybdenum disulfide grease 6 Lubricate Crankshaft pins Big end bearings with the recommended lubricant Recommended lubricant Engine oil ...

Page 190: ...ng rod caps Be sure to reinstall each big end bearing in its original place While compressing the piston rings with pis ton ring compressor 2 install the connecting rod assembly into the cylinder with the other hand Make sure the Y marks a on the connect ing rods face towards the front side of the crankshaft Make sure the characters b on both the con necting rod and connecting rod cap are aligned ...

Page 191: ...rque T R Connecting rod nut 1st 20 N m 2 0 kgf m 14 ft lb Tighten the connecting rod nuts further to reach the specified angle 120 T R Connecting rod nut Final Specified angle 120 5 WARNING When the nuts are tightened more than the specified angle do not loosen the nut and then retighten it Replace the bolt and nut with a new one and perform the procedure again CAUTION Do not use a torque wrench t...

Page 192: ... ty Service points CRANKSHAFT REMOVAL Follow the left Step for removal Crankcase Separate Refer to CRANKCASE Connecting rod caps Refer to CONNECTING RODS AND PISTONS 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearing 5 Reverse the removal steps for installation 2 2 1 3 3 E ...

Page 193: ... origi nal place 1 Crankshaft inspection 1 Measure Crankshaft runout Out of specification Replace the crankshaft Maximum crankshaft runout 0 03 mm 0 0012 in 2 Check Crankshaft journal surfaces Crankshaft pin surfaces Scratches wear Replace the crank shaft Bearing surfaces Scratches wear Replace the crank shaft journal bearing 3 Measure Crankshaft journal oil clearance Out of specification Replace ...

Page 194: ...haft journal upper bear ings 1 and the crankshaft into the upper crankcase NOTE Align the projections a of the crankshaft journal upper bearings with the notches b in the upper crankcase Put a piece of Plastigauge 2 on each crankshaft journal NOTE Do not put the Plastigauge over the oil hole in the crankshaft journal Install the crankshaft journal lower bear ings into the lower crankcase and assem...

Page 195: ...earings J1 J5 NOTE The numbers stamped into the crankshaft web and the numbers stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the crankshaft illustration If J1 J5 are the same use the same size for all of the bearings For example if the crankcase J1 and crank shaft web J1 numbers are 8 and 2 respec tively...

Page 196: ...arings into the lower crankcase NOTE Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase Be sure to install each crankshaft journal bearing in its original place a b 2 Lubricate Crankshaft journals Crankshaft journal bearings with the recommended lubricant Recommended lubricant Engine oil ...

Page 197: ...OVAL Follow the left Step for removal Exhaust manifold Refer to EXHAUST MANIFOLD 1 Clamp cooling water hose 1 1 È To cylinder block NOTE To install the cooling water hose align the white paint mark a water hose with the pro jection of the hose joint 2 Clamp cooling water hose 1 1 É To exhaust manifold 3 Clamp cooling water hose 2 1 1 4 3 2 3 7 5 6 È É Ê Ë a 2 3 4 1 ...

Page 198: ...AGRAM Step Procedure Part name Q ty Service points 4 Joint 1 5 Clamp cooling water hose 1 1 Ê To oil tank 6 Clamp cooling water hose 1 1 Ë From transom plate 7 Joint 1 Reverse the removal steps for installation 1 4 3 2 3 7 5 6 È É Ê Ë a 2 3 4 1 ...

Page 199: ...RT 6 8 SERVICE POINTS 6 10 Drive shaft removal 6 10 Impeller inspection 6 11 Drive shaft inspection 6 11 Drive shaft installation 6 12 TRANSOM PLATE AND HOSES 6 15 EXPLODED DIAGRAM 6 15 REMOVAL AND INSTALLATION CHART 6 15 SERVICE POINTS 6 17 Bilge strainer inspection 6 17 Bilge hose inspection 6 17 Cooling water hose inspection 6 17 BEARING HOUSING 6 18 EXPLODED DIAGRAM 6 18 REMOVAL AND INSTALLATI...

Page 200: ...Step Procedure Part name Q ty Service points INTAKE GRATE RIDE PLATE AND INTAKE DUCT REMOVAL Follow the left Step for removal 1 Bolt 2 2 Bolt 2 3 Intake grate 1 4 Screw 4 5 Speed sensor 1 NOTE Route the speed sensor lead between the jet pump unit and the bilge hose INTAKE GRATE AND RIDE PLATE ...

Page 201: ...6 2 E JET PUMP INTAKE GRATE AND RIDE PLATE EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Bolt 4 7 Ride plate 1 Reverse the removal steps for installation ...

Page 202: ...her 1 2 4 Steering cable joint 1 5 Hose clamp spout hose 1 1 6 Bolt 4 7 Collar 4 8 Nut 2 8 24 mm 14 N m 1 4 kgf m 10 ft Ib 6 22 mm 6 8 N m 0 68 kgf m 4 9 ft Ib 2 2 N m 0 22 kgf m 1 6 ft Ib 6 8 N m 0 68 kgf m 4 9 ft Ib 10 45 mm 40 N m 4 0 kgf m 29 ft Ib 11 7 6 5 3 16 3 12 1 15 LT 572 LT 572 LT 572 LT 572 LT 242 A A LT 271 LT 4 14 2 10 13 6 8 N m 0 68 kgf m 4 9 ft Ib 8 9 6 30 mm 7 8 N m 0 78 kgf m 5...

Page 203: ...erse the removal steps for installation 8 24 mm 14 N m 1 4 kgf m 10 ft Ib 6 22 mm 6 8 N m 0 68 kgf m 4 9 ft Ib 2 2 N m 0 22 kgf m 1 6 ft Ib 6 8 N m 0 68 kgf m 4 9 ft Ib 10 45 mm 40 N m 4 0 kgf m 29 ft Ib 11 7 6 5 3 16 3 12 1 15 LT 572 LT 572 LT 572 LT 572 LT 242 A A LT 271 LT 4 14 2 10 13 6 8 N m 0 68 kgf m 4 9 ft Ib 8 9 6 30 mm 7 8 N m 0 78 kgf m 5 6 ft Ib 8 18 mm 17 N m 1 7 kgf m 12 ft Ib 6 25 m...

Page 204: ...OVAL Follow the left Step for removal 1 Hose clamp spout hose 1 1 2 Bolt 2 3 Collar 2 4 Reverse gate 1 5 Spring 1 6 Nut 1 7 Washer 1 8 Bolt 1 9 Collar 1 Reverse the removal steps for installation 7 8 N m 0 78 kgf m 5 6 ft Ib 1 2 N m 0 12 kgf m 0 9 ft Ib 6 35 mm 8 20 mm 15 N m 1 5 kgf m 11 ft Ib A A LT 271 LT 242 LT 242 LT 271 A A 3 2 7 6 2 3 5 9 8 1 4 8 20 mm 15 N m 1 5 kgf m 11 ft Ib ...

Page 205: ... 1 REMOVAL Follow the left Step for removal 1 Bolt 2 2 Collar 2 3 Jet thrust nozzle 1 4 Bolt 4 5 Bracket 1 6 Nozzle 1 NOTE Clean the contacting surfaces before apply ing the sealant 7 Impeller duct assembly 1 8 Impeller housing 1 1 9 Pin 2 10 125 mm 40 N m 4 0 kgf m 29 ft Ib 6 35 mm 6 6 N m 0 66 kgf m 4 8 ft Ib 10 11 12 13 14 9 9 7 LT 572 LT LT 572 LT LT 572 LT 8 10 125 mm 40 N m 4 0 kgf m 29 ft I...

Page 206: ...Water inlet cover 1 12 Packing 1 13 Water inlet strainer 1 14 Packing 1 Reverse the removal steps for installation 10 125 mm 40 N m 4 0 kgf m 29 ft Ib 6 35 mm 6 6 N m 0 66 kgf m 4 8 ft Ib 10 11 12 13 14 9 9 7 LT 572 LT LT 572 LT LT 572 LT 8 10 125 mm 40 N m 4 0 kgf m 29 ft Ib 1 2 3 4 4 6 5 8 20 mm 15 N m 1 5 kgf m 11 ft Ib LT 271 A A 1104J 1104J ...

Page 207: ...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 Bolt 3 2 Cap 1 3 O ring 1 4 Cap 1 5 Impeller 1 6 Drive shaft 1 7 Oil seal 1 Not reusable Not reusable ...

Page 208: ...T EXPLODED DIAGRAM 1 EPNOC grease AP 0 Step Procedure Part name Q ty Service points 8 Oil seal 1 9 Rear bearing 1 10 Spacer 1 11 Front bearing 1 12 Impeller duct 1 Reverse the disassembly steps for assembly Not reusable Not reusable Not reusable ...

Page 209: ...en two aluminum plates a Crankshaft holder YB 06552 Crankshaft holder 20 90890 06552 a a 2 Remove Drive shaft 1 NOTE Remove the drive shaft using a press 1 3 Remove Rear bearing È For USA and Canada É For worldwide Slide hammer and adapters YB 06096 Stopper guide plate 90890 06501 Bearing puller assembly 90890 06535 Stopper guide stand 90890 06538 È É ...

Page 210: ...Remove Front bearing NOTE Remove the front bearing using a press Driver handle large YB 06071 Driver rod L3 90890 06652 Bearing housing needle bearing remover YB 06112 Needle bearing attachment 90890 06614 Impeller inspection Refer to JET PUMP UNIT in Chapter 3 Drive shaft inspection 1 Inspect Drive shaft Damage wear Replace ...

Page 211: ... 06085 Ball bearing attachment 90890 06634 Distance a 4 6 0 2 mm 0 18 0 01 in 2 Install Rear bearing NOTE Install the rear bearing onto the drive shaft using a press Press the rear bearing using a pipe that is more than 140 mm 5 51 in long and that has an inner diameter of 26 mm 1 02 in 3 Install Spacer 4 Add EPNOC grease AP 0 between the drive shaft and spacer Quantity 20 g 0 7 oz ...

Page 212: ...in long and that has an inner diameter more than 26 mm 1 02 in 6 Install Drive shaft with front bearing spacer and rear bearing NOTE Press the rear bearing using a washer or pipe that has an outer diameter of 50 mm 1 97 in and an inner diameter of 33 mm 1 30 in Distance a 11 7 0 2 mm 0 46 0 01 in a 7 Add EPNOC grease AP 0 into the cap Quantity 20 g 0 7 oz ...

Page 213: ...mpeller NOTE Hold the impeller duct assembly in a vise between two aluminum plates a T R Impeller 75 N m 7 5 kgf m 54 ft lb LOCTITE 572 Crankshaft holder YB 06552 Crankshaft holder 20 90890 06552 a a IMPELLER DUCT AND DRIVE SHAFT ...

Page 214: ...ame 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 assembly Refer to JET PUMP UNIT 1 Hose clamp 2 2 Cooling water hose 1 Cooling water outlet cylinder head 3 Bilge hose 1 1 4 Hose clamp 1 5 Cooling water hose 1 Cooling water inlet ...

Page 215: ...TRANSOM PLATE AND HOSES EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Bilge strainer 1 7 Nut washer 2 2 8 Nut washer 2 2 9 Transom plate 1 10 Bilge hose 2 1 Reverse the removal steps for installation ...

Page 216: ...SES SERVICE POINTS Bilge strainer inspection Refer to JET PUMP UNIT in Chapter 3 Bilge hose inspection 1 Inspect Bilge hoses Cracks damage wear Replace Cooling water hose inspection 1 Inspect Cooling water hoses Cracks damage wear Replace ...

Page 217: ...ING HOUSING REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT in Chapter 5 1 Rubber coupling 1 2 Bolt 4 3 Intermediate housing cover 1 4 Clamp 2 5 Intermediate drive shaft assembly 1 6 Rubber hose 1 Reverse the removal steps for installation 2 3 4 6 5 1 LT 271 8 48 mm 17 N m 1 7 kgf m 12 ft Ib 4 2 N m 0 42 kgf m 3 0 ft Ib ...

Page 218: ...IAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points BEARING HOUSING DISASSEMBLY Follow the left Step for disassembly 1 Driven coupling 1 2 Washer 1 3 Damper 1 4 Intermediate drive shaft 1 5 Circlip 1 Not reusable ...

Page 219: ...NG EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Oil seal 1 7 Bearing 1 8 Oil seal 1 9 Oil seal 1 10 Bearing housing 1 Reverse the disassembly steps for assembly Not reusable Not reusable Not reusable Not reusable ...

Page 220: ...using the same special tools that were used for removal Check that the drive shaft holder and inter mediate drive shaft are properly engaged Coupler wrench YW 06551 90890 06551 Drive shaft holder YB 06151 Drive shaft holder 5 90890 06519 Intermediate drive shaft removal 1 Remove Intermediate drive shaft NOTE Remove the intermediate drive shaft using a press ...

Page 221: ... YB 06071 Driver rod LS 90890 06606 Roller bearing installer remover YB 06432 Bearing outer race attachment 90890 06628 È É Bearing and intermediate drive shaft inspection 1 Inspect Bearing Rotate the inner race by hand Damage rough movement Replace Intermediate drive shaft Damage pitting Replace Driven coupling inspection 1 Inspect Driven coupling Driven coupling damper Damage wear Replace ...

Page 222: ... large YB 06071 Driver rod LS 90890 06606 Outer race installer forward gear YB 06085 Ball bearing attachment 90890 06631 Distance a 14 2 0 2 mm 0 56 0 01 in a 2 Install Oil seal Driver handle large YB 06071 Driver rod LS 90890 06606 Outer race installer forward gear YB 06085 Ball bearing attachment 90890 06631 Distance a 6 2 0 2 mm 0 24 0 01 in a ...

Page 223: ...6 24 E JET PUMP BEARING HOUSING Intermediate drive shaft installation 1 Install Intermediate drive shaft NOTE Install the intermediate drive shaft using a press Distance a 56 8 0 2 mm 2 24 0 01 in a ...

Page 224: ......

Page 225: ...age measurement 7 10 Peak voltage adapter 7 11 Test harness 7 11 IGNITION SYSTEM 7 12 WIRING DIAGRAM 7 12 IGNITION SPARK 7 14 IGNITION SYSTEM PEAK VOLTAGE 7 15 BATTERY 7 17 FUSE 7 17 SPARK PLUGS 7 17 IGNITION COIL 7 18 ENGINE STOP SWITCH 7 18 ENGINE TEMPERATURE SENSOR 7 19 SENSOR ASSEMBLY 7 19 THERMOSWITCH ENGINE 7 20 THERMOSWITCH EXHAUST 7 21 MAIN AND FUEL PUMP RELAY 7 22 ELECTRONIC CONTROL THROT...

Page 226: ...S 7 37 FUSES 7 37 START SWITCH 7 37 STARTER RELAY 7 38 REMOTE CONTROL UNIT DELUXE MODEL ONLY 7 38 THROTTLE POSITION SENSOR 7 38 ACCELERATOR POSITION SENSOR 7 38 STARTER MOTOR 7 39 EXPLODED DIAGRAM 7 39 REMOVAL AND INSTALLATION CHART 7 39 SERVICE POINTS 7 41 Armature inspection 7 41 Brush holder inspection 7 42 Starter motor front cover inspection 7 42 CHARGING SYSTEM 7 43 WIRING DIAGRAM 7 43 FUSE ...

Page 227: ...play function Deluxe model only 7 53 Speedometer display 7 54 Tachometer display 7 55 Hour meter display 7 55 Voltage meter display 7 55 Low oil pressure warning indicator 7 55 Fuel level meter display and fuel warning indicator 7 55 Overheat warning indicator 7 56 Check engine warning indicator 7 56 Diagnostic display 7 57 REMOTE CONTROL SYSTEM DELUXE MODEL ONLY 7 58 WIRING DIAGRAM 7 58 REMOTE CO...

Page 228: ...ensor 8 Battery 9 Speed sensor 0 Sensor assembly intake air pressure and intake air tem perature A Oil pressure switch B Fuel injectors C Thermoswitch exhaust D Rectifier regulator E ECM F Throttle body assembly G Lighting coil and pickup coil H Engine stop switch engine shut off switch and start switch I Steering sensor J Buzzer K Accelerator position sensor L Electric fuel pump M Fuel sender N M...

Page 229: ... couplers 3 Fuse box 1 4 Fuse box cap 1 5 Gasket 1 6 Fuse 10 7 Tapping screw 2 8 Washer 2 30 3 10 10 20 30 3 10 10 20 6 25 mm 6 20 mm 6 10 mm 6 8 mm 6 20 mm A A A A 33 32 31 VENT 22 22 21 21 27 27 27 30 29 28 24 23 13 13 19 19 26 25 17 3 4 5 6 2 10 9 8 7 7 8 11 12 15 16 18 14 20 1 1 17 N m 1 7 kgf m 12 ft Ib 15 N m 1 5 kgf m 11 ft Ib 36 35 35 34 35 17 N m 1 7 kgf m 12 ft Ib 31 6 20 mm 3 9 N m 0 39...

Page 230: ...ion switch 1 15 Bolt 6 16 Fuse box cover 1 17 Nut 6 18 Gasket 1 19 Tapping screw 2 30 3 10 10 20 30 3 10 10 20 6 25 mm 6 20 mm 6 10 mm 6 8 mm 6 20 mm A A A A 33 32 31 VENT 22 22 21 21 27 27 27 30 29 28 24 23 13 13 19 19 26 25 17 3 4 5 6 2 10 9 8 7 7 8 11 12 15 16 18 14 20 1 1 17 N m 1 7 kgf m 12 ft Ib 15 N m 1 5 kgf m 11 ft Ib 36 35 35 34 35 17 N m 1 7 kgf m 12 ft Ib 31 6 20 mm 3 9 N m 0 39 kgf m ...

Page 231: ... 26 Grommet 1 27 Bolt 3 28 Wiring harness 1 Red 29 Wiring harness 1 Brown 30 3 10 10 20 30 3 10 10 20 6 25 mm 6 20 mm 6 10 mm 6 8 mm 6 20 mm A A A A 33 32 31 VENT 22 22 21 21 27 27 27 30 29 28 24 23 13 13 19 19 26 25 17 3 4 5 6 2 10 9 8 7 7 8 11 12 15 16 18 14 20 1 1 17 N m 1 7 kgf m 12 ft Ib 15 N m 1 5 kgf m 11 ft Ib 36 35 35 34 35 17 N m 1 7 kgf m 12 ft Ib 31 6 20 mm 3 9 N m 0 39 kgf m 2 8 ft Ib...

Page 232: ...lder 1 Reverse the removal steps for installation 30 3 10 10 20 30 3 10 10 20 6 25 mm 6 20 mm 6 10 mm 6 8 mm 6 20 mm A A A A 33 32 31 VENT 22 22 21 21 27 27 27 30 29 28 24 23 13 13 19 19 26 25 17 3 4 5 6 2 10 9 8 7 7 8 11 12 15 16 18 14 20 1 1 17 N m 1 7 kgf m 12 ft Ib 15 N m 1 5 kgf m 11 ft Ib 36 35 35 34 35 17 N m 1 7 kgf m 12 ft Ib 31 6 20 mm 3 9 N m 0 39 kgf m 2 8 ft Ib ...

Page 233: ...7 6 E ELEC FUSE BOX 1 2 6 5 4 3 1 Positive battery lead 2 Starter motor lead white tape 3 Starter relay 4 Wiring harness black 5 Wiring harness brown 6 Wiring harness red ...

Page 234: ... REMOVAL Follow the left Step for removal 1 Wiring harness 1 NOTE Disconnect all couplers 2 Bolt 2 3 Rectifier regulator 1 4 Bolt 4 5 ECM 1 6 Grommet 4 7 Collar 4 2nd 18 N m 1 8 kgf m 13 ft Ib 1st 8 8 N m 0 88 kgf m 6 4 ft Ib 8 35 mm 6 30 mm 4 0 N m 0 4 kgf m 2 9 ft Ib 6 30 mm 4 0 N m 0 4 kgf m 2 9 ft Ib LT 572 LT LT 242 LT LT 242 LT LT 572 LT LT 572 LT 4 6 5 1 2 2 3 9 10 8 10 8 11 11 7 ...

Page 235: ... 2 9 Bracket 1 10 Grommet 2 11 Collar 2 Reverse the removal steps for installation 2nd 18 N m 1 8 kgf m 13 ft Ib 1st 8 8 N m 0 88 kgf m 6 4 ft Ib 8 35 mm 6 30 mm 4 0 N m 0 4 kgf m 2 9 ft Ib 6 30 mm 4 0 N m 0 4 kgf m 2 9 ft Ib LT 572 LT LT 242 LT LT 242 LT LT 572 LT LT 572 LT 4 6 5 1 2 2 3 9 10 8 10 8 11 11 7 ...

Page 236: ...wered by dry batter ies check the battery s voltage periodi cally and replace the batteries if necessary Digital tester NOTE Throughout this chapter the part numbers of the specified digital testers have been omitted Refer to the following part numbers NOTE indicates a continuity of electricity i e a closed circuit at the respective switch position Digital multimeter YU 34899 A Digital circuit tes...

Page 237: ...e obtained by connecting both of its terminals Correct value Displayed measurement Internal resistance Peak voltage measurement NOTE When checking the condition of the ignition system it is vital to know the peak voltage Cranking speed is dependant on many fac tors e g fouled or weak spark plugs a weak battery If one of these is defective the peak voltage will be lower than specifica tion If the p...

Page 238: ... digital circuit tester Make sure that the positive pin the mark facing up as shown on the adapter is installed into the positive terminal of the tester The test harness is needed for the following tests È Voltage measurement É Peak voltage measurement Test harness NOTE If the lighting coil and pickup coil s are mea sured unloaded disconnect the test harness on the output side coupler Peak voltage...

Page 239: ...Br R B O B Br B W Y Br L R B R G B R Y B Br 4 0 9 8 B B B B H I J K L M N O Q P R 3 5 6 7 2 1 A A A A C D E F G 1 Battery 2 Fuse 30 A 3 Fuse 20 A 4 Fuse 3 A 5 Fuse 10 A 6 Fuse 10 A 7 Starter relay 8 Main and fuel pump relay 9 Electronic control throttle valve relay 0 Slant detection switch A Ignition coil B Spark plug C Cam position sensor D Engine temperature sensor E Thermoswitch engine F Thermo...

Page 240: ...R Y B O L B B O L B B G G O B O G O P W B O B Y B Y R Y R Y R Y R Y B Y R Y R Y B O B R R Y R Y R Y Y W Y G L R Y P P O O R R R B B Br R B O B Br B W Y Br L R B R G B R Y B Br 4 0 9 8 B B B B H I J K L M N O Q P R 3 5 6 7 2 1 A A A A C D E F G B Black Br Brown G Green L Blue O Orange P Pink R Red W White Y Yellow B G Black green B O Black orange B R Black red B W Black white B Y Black yellow G O G...

Page 241: ...of the removed spark plug cap When performing the spark gap check keep flammable gas or liquids away since this test can produce sparks 1 Check Ignition spark Weak Check the ECM output peak voltage Check the ignition coil for resistance Checking steps Connect the spark plug cap to the special service tool Spark checker YM 34487 Ignition tester 90890 06754 Crank the engine and observe the igni tion...

Page 242: ... Measure the pickup coil output peak voltage NOTE When measuring the ECM output peak volt age while cranking the engine disconnect the ignition coil couplers for all cylinders except for the cylinder being measured To crank the engine connect the engine shut off cord lanyard to the engine shut off switch and then press the start switch Test harness 2 pins New YB 06867 Current YB 06767 Test harness...

Page 243: ...ins New YB 06877 Current YB 06777 Test harness HM090 3 3 pins New 90890 06877 Current 90890 06777 Pickup coil output peak voltage White black W B Black orange B O r min Unloaded Loaded Cranking 2 000 3 500 V 8 0 6 9 19 4 25 1 3 Measure Lighting coil output peak voltage Below specification Replace the light ing coil Test harness 3 pins New YB 06870 Current YB 06770 Test harness SMT250 3 3 pins New ...

Page 244: ...cation Replace the recti fier regulator NOTE Do not use the peak voltage adapter to mea sure the output voltage Disconnect the output lead of the tester har ness Test harness 6 pins YB 06848 Test harness FSW 6A 6 pins 90890 06848 Rectifier regulator output voltage Red R Black B r min Unloaded 3 500 V 13 0 BATTERY Refer to ELECTRICAL in Chapter 3 FUSE Refer to STARTING SYSTEM SPARK PLUGS Refer to P...

Page 245: ...al resistance Refer to Low resistance measurement Primary coil resistance 1 19 1 61 Ω at 20 C 68 F 2 Measure Secondary coil resistance Out of specification Replace Secondary coil resistance 8 5 11 5 kΩ at 20 C 68 F ENGINE STOP SWITCH 1 Check Engine stop switch continuity Out of specification Replace Engine stop switch continuity black coupler Clip Position Lead color White Black Installed Free Pus...

Page 246: ...d with water Place a thermometer in the water Slowly heat the water Measure the resistance when the speci fied temperature is reached SENSOR ASSEMBLY 1 Check Intake air temperature sensor Out of specification Replace the sen sor assembly Checking steps Measure the ambient temperature Connect a computer to the watercraft and use the Yamaha Diagnostic System to display the intake air temperature If ...

Page 247: ... Temperature 2 Continuity É Time NOTE The thermoswitch engine connector is blue Thermoswitch engine continuity temperature a 84 90 C 183 194 F b 70 84 C 158 183 F Checking steps Suspend the thermoswitch engine in a container filled with water Place a thermometer in the water Slowly heat the water Measure the continuity when the speci fied temperature is reached ...

Page 248: ...ntinuity É Time NOTE The thermoswitch exhaust connector is black Thermoswitch exhaust continuity temperature a 80 86 C 176 187 F b 66 80 C 151 176 F Checking steps Suspend the thermoswitch exhaust in a container filled with water Place a thermometer in the water Slowly heat the water Measure the continuity when the speci fied temperature is reached IGNITION SYSTEM ...

Page 249: ...ain and fuel pump relay terminals Check that there is no continuity between the main and fuel pump relay terminals after disconnecting terminals 1 2 or 3 Connect the tester leads between main and fuel pump relay terminals 7 and 8 Connect terminals 4 to the negative bat tery terminal Connect terminal 6 to the positive bat tery terminal Check that there is continuity between the main and fuel pump r...

Page 250: ...valve relay terminals 4 or 5 and 6 Connect terminals 2 or 3 to the positive battery terminal Connect terminal 1 to the negative bat tery terminal Check that there is continuity between the electronic control throttle valve relay ter minals Check that there is no continuity between the electronic control throttle valve relay terminals after disconnecting terminals 1 2 or 3 6 5 4 3 2 1 IGNITION SYST...

Page 251: ...e the throttle lever to the fully closed position Check the output voltage of throttle posi tion sensor 1 and the throttle valve open ing angle 1 Throttle position sensor 1 2 Throttle position sensor 2 È Throttle position sensor output voltage É Throttle valve opening angle Ê Fully closed Ë Fully open NOTE The actual throttle position sensor output voltage and throttle valve opening angle may vary...

Page 252: ...le Hold the throttle lever when the output voltage of throttle position sensor 2 is below 4 5 V and the throttle valve open ing angle is above 10 Calculate the difference of the output voltage of throttle position sensor 1 and the output voltage of throttle position sen sor 2 Throttle position sensor 2 output voltage throttle position sensor 1 output voltage 1 9 2 1 V Example If the output voltage...

Page 253: ...hat the accelerator position sen sor 1 and 2 output voltage NOTE The actual accelerator position sensor out put voltage and throttle valve opening angle may vary according to environmental condi tions Accelerator position sensor 1 output voltage at throttle lever fully closed position 0 50 0 90 V Accelerator position sensor 2 output voltage at throttle lever fully closed position 0 35 1 05 V Throt...

Page 254: ...tor position sensor 1 output voltage and accelerator position sensor 2 output volt age at fully opened position Accelerator position sensor 1 output voltage Accelerator position sensor 2 output voltage at fully opened position below 0 75 V Example If accelerator position sensor 1 output volt age is 4 009 V and accelerator position sen sor 2 output voltage is 3 896 V then 4 009 3 896 0 113 V Operat...

Page 255: ...on sensor 2 resistance at fully closed position 0 35 1 05 kΩ Move the accelerator position cam to the fully opened position Connect the tester leads accelerator position sensor terminals 1 3 Measure the resistance when the fully opened position Accelerator position sensor 1 resistance at fully opened position 3 75 4 35 kΩ Connect the tester leads accelerator position sensor terminals 6 7 Measure t...

Page 256: ...gnostic Sys tem electric power is supplied to the cam position sensor Test harness 3 pins New YB 06877 Current YB 06777 Test harness HM090 3 3 pins New 90890 06877 Current 90890 06777 Cam position sensor output voltage Green orange G O Black orange B O Position Voltage V A More than 4 8 B Less than 0 8 C More than 4 8 Measurement steps Remove the cam position sensor Connect the test harness to the...

Page 257: ... specification Replace NOTE When checking the slant detection switch be sure to turn the switch over to both the left and right as shown in the illustration Position Lead color Blue black L B Black orange B O Normal operation È 4 18 5 10 kΩ OverturnedÉ UP UP UP È É É IGNITION SYSTEM ...

Page 258: ... O P P O R R L R R B B L B L B B G P P B W B R Y B R W 9 8 7 E E E E F G H I 3 4 5 6 2 1 0 A B C D J K 1 Battery 2 Fuse 30 A 3 Fuse 20 A 4 Fuse 10 A 5 Fuse 10 A 6 Starter relay 7 Main and fuel pump relay 8 Electronic control throttle valve relay 9 Slant detection switch 0 Sensor assembly intake air pressure and intake air temperature A Engine temperature sensor B Thermoswitch engine C Thermoswitch...

Page 259: ...R Y R Y Pu G Pu Y Pu B Pu R R Y R Y R Y R Y R Y Y W Y G L R O P P O R R L R R B B L B L B B G P P B W B R Y B R W 9 8 7 E E E E F G H I 3 4 5 6 2 1 0 A B C D J K B Black G Green L Blue O Orange P Pink R Red W White B G Black green B O Black orange B R Black red B W Black white L B Blue black L R Blue red P G Pink green P R Pink red P W Pink white Pu B Purple black Pu G Purple green Pu R Purple red...

Page 260: ... 1 Check Fuel pump operating sound Fuel pump does not sound Measure the fuel pressure Refer to FUEL INJECTION SYSTEM in Chapter 4 FUEL SENDER 1 Measure Fuel sender resistance Out of specification Replace Float position Resistance Ω A 133 5 136 5 B 5 7 ...

Page 261: ...CH Refer to INDICATION SYSTEM THERMOSWITCH ENGINE Refer to IGNITION SYSTEM THERMOSWITCH EXHAUST Refer to IGNITION SYSTEM SLANT DETECTION SWITCH Refer to IGNITION SYSTEM REMOTE CONTROL UNIT DELUXE MODEL ONLY Refer to REMOTE CONTROL SYS TEM DELUXE MODEL ONLY THROTTLE POSITION SENSOR Refer to IGNITION SYSTEM ACCELERATOR POSITION SENSOR Refer to IGNITION SYSTEM ...

Page 262: ... R B B G O B O G O R Y B O R Y R Y R Y Y W Y G L R Y O O R R L R B B L B L Y Br L R B Br W 0 9 B C D E F G 5 4 6 7 8 3 I H J 1 2 A 1 Battery 2 Starter motor 3 Fuse 30 A 4 Fuse 20 A 5 Fuse 3 A 6 Fuse 10 A 7 Fuse 10 A 8 Starter relay 9 Main and fuel pump relay 0 Electronic control throttle valve relay A Cam position sensor B Remote control unit C Antenna D ECM E Throttle body assembly F Accelerator ...

Page 263: ...G O W O O L G W Y W G O R Y Y G B O L B W R Y Y W L R B B G O B O G O R Y B O R Y R Y R Y Y W Y G L R Y O O R R L R B B L B L Y Br L R B Br W 0 9 B C D E F G 5 4 6 7 8 3 I H J 1 2 A B Black Br Brown G Green L Blue O Orange R Red W White Y Yellow B O Black orange B R Black red B W Black white G O Green orange L R Blue red P R Pink red P W Pink white R Y Red yellow Y G Yellow green Y W Yellow white ...

Page 264: ...e control unit Deluxe model only The 10 A fuse is for the main and fuel pump relay and the electronic control throttle valve relay The 20 A fuse is for main and fuel pump relay The 30 A fuse is for the main relay Fuse ratings 3 A 10 A 20 A 30 A START SWITCH 1 Check Continuity Out of specification Replace Start switch continuity natural color coupler Clip Position Leads Red Brown Installed Free Pus...

Page 265: ...ead terminal to the positive battery terminal Connect the black lead terminal to the negative battery terminal Check that there is continuity between the starter relay terminals Check that there is no continuity after the brown or black lead is removed Br B REMOTE CONTROL UNIT DELUXE MODEL ONLY Refer to REMOTE CONTROL SYS TEM DELUXE MODEL ONLY THROTTLE POSITION SENSOR Refer to IGNITION SYSTEM ACCE...

Page 266: ...OTOR DISASSEMBLY Follow the left Step for disassembly Starter motor Refer to GENERATOR AND STARTER MOTOR in Chapter 5 1 O ring 1 2 Bolt 2 3 Starter motor front cover assembly 1 4 O ring 2 5 Washer set 1 6 Armature assembly 1 A A 5 114 mm 6 4 N m 0 64 kgf m 4 6 ft Ib 5 7 2 9 4 4 6 5 3 1 8 8 8 N m 0 88 kgf m 6 4 ft Ib Not reusable Not reusable ...

Page 267: ...ocedure Part name Q ty Service points 7 Starter motor rear cover 1 8 Brush holder assembly 1 9 Starter motor yoke 1 Reverse the disassembly steps for assembly A A 5 114 mm 6 4 N m 0 64 kgf m 4 6 ft Ib 5 7 2 9 4 4 6 5 3 1 8 8 8 N m 0 88 kgf m 6 4 ft Ib ...

Page 268: ...grit sandpaper 3 Measure Commutator diameter Below specification Replace Commutator diameter 28 0 mm 1 10 in Limit 27 0 mm 1 06 in 4 Check Commutator undercut Contaminants Clean NOTE Remove all mica and metal particles with com pressed air 5 Measure Commutator undercut Below specification Replace Commutator undercut 0 7 mm 0 03 in Limit 0 2 mm 0 01 in ...

Page 269: ... shaft No continuity Brush holder inspection 1 Measure Brush length a Below specification Replace Brush length 12 5 mm 0 49 in Wear limit 6 5 mm 0 26 in 2 Check Brush holder continuity Out of specification Replace Brush holder continuity Brush holder Base No continuity Starter motor front cover inspection 1 Inspect Starter motor front cover oil seal Damage wear Replace the starter motor front cove...

Page 270: ...LEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM 10A 10A 3A 30A 20A R R B B R G G G G G G R G G G B R B 4 5 3 2 1 1 Battery 2 Fuse 30 A 3 Fuse 20 A 4 Rectifier regulator 5 Lighting coil B Black G Green R Red ...

Page 271: ...7 44 E ELEC CHARGING SYSTEM FUSE Refer to STARTING SYSTEM BATTERY Refer to ELECTRICAL in Chapter 3 LIGHTING COIL Refer to IGNITION SYSTEM RECTIFIER REGULATOR Refer to IGNITION SYSTEM ...

Page 272: ...Pu R Pu B Pu G Pu Y R Y Y W L R R Y R Y R Y R Y Pu G Pu Y Pu B Pu R R Y R Y R Y R Y Y W Y G L R R R R B W L B O W L B O O R 9 8 0 0 0 0 A B C D E 1 4 5 6 7 3 2 1 Battery 2 Starter motor 3 Fuse 30 A 4 Fuse 20 A 5 Fuse 10 A 6 Fuse 10 A 7 Starter relay 8 Main and fuel pump relay 9 Electronic control throttle valve relay 0 Fuel injector A ECM B Throttle body assembly C Accelerator position sensor D Pi...

Page 273: ... Pu Y Pu B Pu R R Y R Y R Y R Y Y W Y G L R R R R B W L B O W L B O O R 9 8 0 0 0 0 A B C D E 1 4 5 6 7 3 2 B Black G Green L Blue O Orange R Red W White B O Black orange B R Black red B W Black white L R Blue red 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 Y Red yellow W B White black W L White blue Y G Yellow green Y W Yellow white OFF THR...

Page 274: ...andlebar and then pull the spring gauge with a force of 10 kgf 22 lb When handlebar pulled When handlebar not pulled ON OFF Check that the following is displayed in the Engine Monitor window of the Yamaha Diagnostic System Use the same procedure to check that the steering sensor operates correctly when the handlebar is turned to both the left and right Replace the steering sen sor if it is a malfu...

Page 275: ... R B G B R Y B Y R W B R W P P B B L L R L R L B B W R B W BR Y L R L YL B Gy B G Y B Y R Y 9 8 A A A A G G G G H I J K 4 3 5 6 7 2 1 0 0 0 0 B C D E F L M N 1 Battery 2 Fuse 30 A 3 Fuse 20 A 4 Fuse 3 A 5 Fuse 10 A 6 Fuse 10 A 7 Starter relay 8 Main and fuel pump relay 9 Electronic control throttle valve relay 0 Ignition coil A Spark plug B Cam position sensor C Engine temperature sensor D Thermos...

Page 276: ... P P O O R R R B G B R Y B Y R W B R W P P B B L L R L R L B B W R B W BR Y L R L YL B Gy B G Y B Y R Y 9 8 A A A A G G G G H I J K 4 3 5 6 7 2 1 0 0 0 0 B C D E F L M N B Black Br Brown G Green Gy Gray O Orange P Pink R Red W White Y Yellow B G Black green B L Black blue B O Black orange B R Black red B W Black white B Y Black yellow G O Green orange L B Blue black L R Blue red L Y Blue yellow P ...

Page 277: ...er to IGNITION SYSTEM THERMOSWITCH ENGINE Refer to IGNITION SYSTEM THERMOSWITCH EXHAUST Refer to IGNITION SYSTEM REMOTE CONTROL UNIT DELUXE MODEL ONLY Refer to REMOTE CONTROL SYS TEM DELUXE MODEL ONLY BUZZER 1 Check Buzzer Buzzer does not sound Replace Checking steps Connect the battery 12 V to the buzzer coupler as shown Battery positive terminal Red R terminal 1 Battery negative terminal Black B...

Page 278: ...uge set 90890 06756 Oil pressure switch continuity pressure 128 kPa 1 28 kgf cm2 18 6 psi 167 kPa 1 67 kgf cm2 24 2 psi MULTIFUNCTION METER Multifunction meter 1 Check Multifunction meter Cracked meter housing Replace the multifunction meter Meter is fogged shows signs of water intrusion Replace the multifunction meter MULTIFUNCTION METER REMOVAL Refer to ENGINE HATCH COVER in Chapter 8 ...

Page 279: ...te Replace the multi function meter L B B B Y R W B Y P B G R W Y Y R R W W B B B G P L R R B R 1 2 3 4 L B L R 1 Buzzer 2 Speed sensor 3 ECM 4 Fuel sender B Black P Pink R Red W White Y Yellow B G Black green B Y Black yellow L B Blue black L R Blue red R W Red white INDICATION SYSTEM ...

Page 280: ...mote control unit 2 Buzzer 3 Speed sensor 4 ECM 5 Fuel sender B Black Gy Gray P Pink R Red W White Y Yellow B G Black green B L Black blue B Y Black yellow L B Blue black L R Blue red L Y Blue yellow R W Red white INDICATION SYSTEM B L B L R B Y R W B Y P B G R W Y Y R R W W B B B G P L R R B R 1 2 3 4 5 Gy L B L R L Y L B B L ...

Page 281: ...sensor output voltage dependant on the paddle wheel position Less than 400 mV More than 11 6 V Output pulse 2 pulses one full turn Measurement steps Apply DC 12 volts to the natural color three pin connector between the red yel low and black yellow leads Rotate the paddle wheel by hand and measure the voltage between the black yellow and yellow leads NOTE As the paddle wheel is rotated a square wa...

Page 282: ...e Engine monitor of the Yamaha Diagnostic System Replace the multifunction meter Low oil pressure warning indicator 1 Check Low oil pressure warning indicator Does not come on Check the oil pres sure switch using the Engine monitor of the Yamaha Diagnostic System Replace the multifunction meter Fuel level meter display and fuel warning indicator 1 Check Fuel level meter display and fuel warn ing i...

Page 283: ...or Check that the multifunction meter over heat warning indicator blinks then comes on The buzzer also begins to sound intermittently then sounds continuously 3 1 2 Check engine warning indicator 1 Check Check engine warning indicator Does not come on Replace the multi function meter Checking steps Start the engine Disconnect the coupler of a sensor e g engine temperature sensor that normally acti...

Page 284: ...t the coupler of a sensor e g engine temperature sensor that is nor mally displayed when a malfunction occurs Refer to SELF DIAGNOSIS in Chapter 9 Check that the check engine warning indicator comes on and that the buzzer sounds Press the select switch 1 for 8 seconds and check the error code indicated on the multifunction meter 1 INDICATION SYSTEM ...

Page 285: ...R Y R Y Y Y L R B B B B B R B Gy R W B L L R L R L B L YL B W B Br Gy Br L R 6 6 6 6 7 8 9 0 4 3 5 2 C B D 1 A È 1 Battery 2 Fuse 30 A 3 Fuse 20 A 4 Fuse 3 A 5 Starter relay 6 Fuel injector 7 Remote control unit 8 Antenna 9 ECM 0 Buzzer A Multifunction meter B Start switch C Engine stop switch D Engine shut off switch È To entry box B Black Br Brown Gy Gray L Blue R Red W White Y Yellow B L Black ...

Page 286: ...specification Replace the remote control unit Remote control unit output voltage Blue yellow L Y ground 11 13 V Measurement steps Disconnect the remote control unit 1 coupler from the multifunction meter Measure the remote control unit output voltage while pushing the unlock button of the remote control transmitter 1 1 L Y 1 Low rpm mode indicator 1 Check Low rpm mode indicator Does not come on Re...

Page 287: ... once Check that the SECURITY indicator light goes off and that the engine cannot be started Press the unlock button 2 of the remote control transmitter for a short time The beeper sounds two or three times Check that the SECURITY indicator light comes on and that the engine can be started Press the unlock button for more than 4 seconds to select the low rpm mode Check that the beeper sounds three...

Page 288: ... not operated for more than 25 seconds the multifunction meter dis play and the L MODE indicator light will go off To change the modes again press the lock button for a short time and then start the procedures from the lock mode While the engine is running input is not received from the remote control transmit ter ...

Page 289: ...ers At this time the system enters the regis tration mode to register the first code All existing ID codes will be deleted from the EEPROM The SECURITY indicator light flashes when the registration of the ID code has been completed If the registration could not be completed the SECURITY indi cator light comes on Re transmit the ID code After confirming that the registration of the ID code has been...

Page 290: ...terial is trapped between the upper case and lower case of the remote control transmit ter during assembly 1 Remove Cover NOTE Loosen the transmitter cover screws in the sequence shown 4 1 5 3 2 6 2 Install Battery 1 NOTE Install the battery CR2016 with the positive side facing down 1 3 Install Cover NOTE Tighten the transmitter cover screws in the sequence shown T R Transmitter cover screw 0 1 N ...

Page 291: ......

Page 292: ...ERVICE POINTS 8 13 Damper stopper inspection Deluxe model only 8 13 EXPLODED DIAGRAM 8 14 REMOVAL AND INSTALLATION CHART 8 14 SERVICE POINTS 8 15 Glove compartment assembly installation 8 15 SHIFT LEVER DELUXE MODEL ONLY 8 16 EXPLODED DIAGRAM 8 16 REMOVAL AND INSTALLATION CHART 8 16 HOSES 8 17 EXPLODED DIAGRAM 8 17 REMOVAL AND INSTALLATION CHART 8 17 SERVICE POINTS 8 19 Cooling water pilot outlet ...

Page 293: ...nd installation Deluxe model only 8 27 Remote control cables adjustment 8 27 SEAT AND HAND GRIP 8 28 EXPLODED DIAGRAM 8 28 REMOVAL AND INSTALLATION CHART 8 28 SERVICE POINTS 8 30 Seat lock assembly inspection 8 30 EXHAUST SYSTEM 8 31 EXPLODED DIAGRAM 8 31 REMOVAL AND INSTALLATION CHART 8 31 SERVICE POINTS 8 34 Exhaust system inspection 8 34 Exhaust component parts sub assembly 8 34 Exhaust system ...

Page 294: ...4 2 Screw 4 3 Screw 2 4 Upper handlebar cover 1 5 Pad 1 6 Throttle cable 1 7 Bolt 4 8 Upper handlebar holder 2 9 Handlebar assembly 1 10 Lower handlebar cover 1 Reverse the removal steps for installation LT 242 8 48 mm 20 N m 2 0 kgf m 14 ft Ib 6 13 mm 3 7 N m 0 37 kgf m 2 7 ft Ib 4 9 mm 1 1 N m 0 11 kgf m 0 8 ft Ib 5 15 mm 1 1 N m 0 11 kgf m 0 8 ft Ib 8 7 1 2 9 10 5 4 3 6 FWD A A LT 572 ...

Page 295: ...vice points HANDLEBAR REMOVAL Follow the left Step for removal 1 Handlebar switch coupler 2 2 Plastic tie 1 NOTE Fasten the buzzer lead steering sensor lead start switch lead engine shut off switch lead and multifunction meter lead with a plastic tie 3 Corrugated tube 1 4 Grommet 1 4 5 3 4 3 7 2 FW D 6 1 1 6 ...

Page 296: ...y Service points 5 Throttle cable 1 NOTE Pass the throttle cable and wiring harness through the grommet and then fit the grom met into the steering column 6 Handlebar switch lead 1 7 Handlebar assembly 1 Reverse the removal steps for installation 4 5 3 4 3 7 2 FW D 6 1 1 6 ...

Page 297: ...ND INSTALLATION CHART Step Procedure Part name Q ty Service points HANDLEBAR DISASSEMBLY Follow the left Step for disassembly 1 Bolt 2 2 Grip end 2 3 Screw 2 NOTE Tighten the screw from the engine stop switch side 4 Handlebar switch assembly 1 5 Screw 2 ...

Page 298: ... Step Procedure Part name Q ty Service points 6 Throttle lever assembly 1 7 Handlebar grip 2 NOTE Apply adhesive to the handlebar and the inner surface of the handlebar grip 8 End plate 2 9 Handlebar 1 Reverse the disassembly steps for assembly ...

Page 299: ...dlebar switch lead 1 NOTE Be sure to leave some slack in the handlebar switch lead 1 in the area a shown in the illus tration 2 Install Upper handlebar holder 1 NOTE The upper handlebar holder should be installed with the punch mark a facing forward CAUTION Clearance b should be narrower than clearance c T R Handlebar holder bolt 20 N m 2 0 kgf m 14 ft lb LOCTITE 572 Reference clearance b 1 5 mm 0...

Page 300: ...l into the groove in the bracket 4 Install Pad 1 NOTE Make sure that the handlebar switch lead 2 and throttle cable 3 are routed behind the pad 1 when installing the pad 1 onto the steering column 5 Adjust Throttle cable free play Refer to CONTROL SYSTEM in Chap ter 3 ...

Page 301: ... 2 2 2 2 Front hood assembly 1 3 Bolt 2 4 Hood lock assembly 1 5 Hinge assembly 1 6 Bolt 4 7 Nut washer 4 4 Deluxe model only 8 Left mirror seal 1 1 Deluxe model only 4 3 10 11 13 8 7 1 9 5 2 12 6 5 20 mm 1 9 N m 0 19 kgf m 1 4 ft Ib 6 18 mm 6 9 N m 0 69 kgf m 5 0 ft Ib LT 242 LT 6 18 mm 6 9 N m 0 69 kgf m 5 0 ft Ib LT 242 LT 15 N m 1 5 kgf m 11 ft Ib LT 572 LT 6 95 mm 6 9 N m 0 69 kgf m 5 0 ft Ib...

Page 302: ... 4 11 Storage compartment panel 1 12 Bolt 2 13 Lid lock hook 1 Reverse the removal steps for installation 4 3 10 11 13 8 7 1 9 5 2 12 6 5 20 mm 1 9 N m 0 19 kgf m 1 4 ft Ib 6 18 mm 6 9 N m 0 69 kgf m 5 0 ft Ib LT 242 LT 6 18 mm 6 9 N m 0 69 kgf m 5 0 ft Ib LT 242 LT 15 N m 1 5 kgf m 11 ft Ib LT 572 LT 6 95 mm 6 9 N m 0 69 kgf m 5 0 ft Ib 1 ...

Page 303: ...nd inner hull Push in the rivet pin 2 until it clicks and is flush with the top of the rivet NOTE To remove a rivet push the rivet pin in until it clicks and is below the top of the rivet Before reinstalling a rivet hold the rivet flange a with both hands and push the rivet pin perpendicularly against a hard flat surface until the pin protrudes from the top of the rivet 2 1 a ...

Page 304: ...nly 6 Damper stopper 1 Deluxe model only 7 Screw 2 Deluxe model only 5 10 11 8 7 6 2 9 4 3 3 3 4 3 1 6 23 mm 6 9 N m 0 69 kgf m 5 0 ft Ib 5 14 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 5 16 mm 3 7 N m 0 37 kgf m 2 7 ft Ib 3 3 3 10 7 6 23 mm 6 9 N m 0 69 kgf m 5 0 ft Ib 6 23 mm 6 9 N m 0 69 kgf m 5 0 ft Ib 6 23 mm 6 9 N m 0 69 kgf m 5 0 ft Ib LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572...

Page 305: ...nstallation 5 10 11 8 7 6 2 9 4 3 3 3 4 3 1 6 23 mm 6 9 N m 0 69 kgf m 5 0 ft Ib 5 14 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 5 16 mm 3 7 N m 0 37 kgf m 2 7 ft Ib 3 3 3 10 7 6 23 mm 6 9 N m 0 69 kgf m 5 0 ft Ib 6 23 mm 6 9 N m 0 69 kgf m 5 0 ft Ib 6 23 mm 6 9 N m 0 69 kgf m 5 0 ft Ib LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT 4 LT 572 LT LT 572 LT LT 572 LT 6 23 mm 6 9 N m 0 69 ...

Page 306: ...per stopper inspection Deluxe model only 1 Install Damper stopper 1 Shift lever handle 2 NOTE To install the damper stopper insert it into the hole in the shift lever handle from the bottom and then slide it upward 2 1 ENGINE HATCH COVER ...

Page 307: ...D INSTALLATION CHART Step Procedure Part name Q ty Service points GLOVE COMPARTMENT REMOVAL Follow the left Step for removal 1 Hinge assembly 2 2 Lid 1 3 Latch 1 4 Cap holder 1 5 Hood bumper 2 6 Drain plug 1 Reverse the removal steps for installation 4 3 2 1 5 5 6 ...

Page 308: ...5 E HULL HOOD SERVICE POINTS Glove compartment assembly installation 1 Install Hinge assembly NOTE When installing the hinge assembly make sure that the springs are in the position shown ENGINE HATCH COVER ...

Page 309: ...ts SHIFT LEVER REMOVAL Follow the left Step for removal Engine hatch cover Refer to ENGINE HATCH COVER Shift cable Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Bolt 2 2 Detent plate 1 3 Shift lever 1 4 Nut 2 5 Bracket 1 Reverse the removal steps for installation 5 4 3 2 1 6 18 mm 8 0 N m 0 8 kgf m 5 8 ft Ib 4 1 LT 572 LT LT 572 LT 15 N m 1 5 kgf m 11 ft Ib ...

Page 310: ...l Fuel tank Refer to FUEL TANK AND FUEL PUMP MODULE in Chapter 4 Accelerator position sensor Refer to Throttle cable inspection and adjustment in Chapter 3 NOTE When removing the ventilation hose and fuel tank breather hose it is not necessary to remove the fuel tank 1 Band 8 2 Grommet 2 4 1 7 9 8 5 6 1 1 1 3 1 1 2 3 2 1 1 4 4 2 N m 0 42 kgf m 3 0 ft Ib VENT VENT FWD ...

Page 311: ...y Service points 3 Ventilation hose 2 4 Fuel tank breather hose 2 5 Clamp 1 6 Cooling water hose 1 7 Nut 1 8 Cooling water pilot outlet 1 9 Seal 1 Reverse the removal steps for installation 4 1 7 9 8 5 6 1 1 1 3 1 1 2 3 2 1 1 4 4 2 N m 0 42 kgf m 3 0 ft Ib VENT VENT FWD ...

Page 312: ...n place 30 FWD 3 1 2 Grommet installation 1 Install Ventilation hose 1 Grommet 2 NOTE Install the grommet on the ventilation hose making sure that the end of the hose protrudes the specified length a from the groove around the outside of the grommet as shown in the illustration Specified length a 30 40 mm 1 18 1 57 in 1 2 a Ventilation hose assembly installation 1 Install Ventilation hose assembly...

Page 313: ...Step for removal Engine hatch cover Refer to ENGINE HATCH COVER Steering cable end Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Bolt 1 2 Steering arm 1 3 Joint ball 1 4 Bolt 4 5 Steering column assembly 1 Reverse the removal steps for installation 5 4 2 3 1 6 9 N m 0 69 kgf m 5 0 ft Ib 8 30 mm 17 N m 1 7 kgf m 12 ft Ib LT 572 LT LT 242 LT 8 18 mm 20 N m 2 0 kgf m 14 ft Ib ...

Page 314: ...ice points STEERING COLUMN DISASSEMBLY Follow the left Step for disassembly 1 Steering column 1 2 Seal rubber 1 3 Bolt 4 4 Steering sensor 1 5 Bolt 3 6 Spacer 1 7 Buzzer 1 8 Steering housing assembly 1 Reverse the disassembly steps for assembly 6 LT 572 LT LT 572 LT 3 4 1 8 2 7 5 7 8 25 mm 16 N m 1 6 kgf m 12 ft Ib ...

Page 315: ...8 22 E HULL HOOD STEERING COLUMN SERVICE POINTS Steering column inspection 1 Inspect Seal rubber Steering housing assembly Cracks damage wear Replace the steering column ...

Page 316: ...ART Step Procedure Part name Q ty Service points REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL Follow the left Step for removal Service lid 1 Refer to FRONT HOOD Seat assembly Refer to SEAT AND HAND GRIP Engine hatch cover Refer to ENGINE HATCH COVER Shift lever Refer to SHIFT LEVER DELUXE MODEL ONLY 1 Steering cable end 1 2 Bolt 1 3 Bracket 1 ...

Page 317: ... SENSOR LEAD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 4 Nut 1 5 Steering cable 1 6 Seal 1 7 Speed sensor coupler 1 8 Nut 1 9 Cap 1 10 Screw 4 11 Speed sensor 1 12 Bolt 2 Deluxe model only 13 Shift cable holder 1 Deluxe model only ...

Page 318: ...XPLODED DIAGRAM Step Procedure Part name Q ty Service points 14 Shift cable end 1 Deluxe model only 15 Grommet 1 Deluxe model only 16 Nut 1 Deluxe model only 17 Shift cable 1 Deluxe model only 18 Seal 1 Deluxe model only Reverse the removal steps for installation ...

Page 319: ...place it Never attempt to repair a damaged cable Remote control cables inspection 1 Inspect Steering cable Shift cable Deluxe model only Frays kinks rough movement Replace Steering cable jet pump end installation 1 Install Steering cable WARNING The steering cable must be screwed in at least 8 mm 0 31 in Steering cable set length a jet pump end 14 5 mm 0 57 in Steering cable stopper installation 1...

Page 320: ...shift cable must be screwed in more than 8 mm 0 31 in Shift cable set length a jet pump end 13 6 mm 0 54 in Shift cable shift lever end installation Deluxe model only 1 Install Shift cable shift lever end NOTE Install the shift cable 1 before securing the shift lever assembly 2 to the deck 1 2 Remote control cables adjustment Refer to CONTROL SYSTEM in Chap ter 3 ...

Page 321: ...P REMOVAL Follow the left Step for removal 1 Seat assembly 1 2 Bolt 2 3 Seat lock assembly 1 4 Nut washer 4 4 5 Bolt 4 6 Hand grip 1 7 Bolt 1 10 11 10 12 8 4 2 3 9 7 5 6 1 6 40 mm 6 4 N m 0 64 kgf m 4 6 ft Ib 2 6 30 mm 6 9 N m 0 69 kgf m 5 0 ft Ib 6 23 mm 6 9 N m 0 69 kgf m 5 0 ft Ib 15 N m 1 5 kgf m 11 ft Ib 10 20 mm 26 N m 2 6 kgf m 19 ft Ib LT 271 LT 271 LT 271 ...

Page 322: ... Projection 1 10 Nut washer 2 2 11 Bolt 2 12 Seat bracket 1 Reverse the removal steps for installation 10 11 10 12 8 4 2 3 9 7 5 6 1 6 40 mm 6 4 N m 0 64 kgf m 4 6 ft Ib 2 6 30 mm 6 9 N m 0 69 kgf m 5 0 ft Ib 6 23 mm 6 9 N m 0 69 kgf m 5 0 ft Ib 15 N m 1 5 kgf m 11 ft Ib 10 20 mm 26 N m 2 6 kgf m 19 ft Ib LT 271 LT 271 LT 271 ...

Page 323: ...8 30 E HULL HOOD SEAT AND HAND GRIP SERVICE POINTS Seat lock assembly inspection 1 Inspect Seat lock assembly Damage wear Replace ...

Page 324: ...P UNIT in Chapter 6 NOTE When removing the water lock and exhaust joint it is not necessary to remove the jet pump unit 1 Band 1 2 Joint clamp 1 1 3 Hose clamp 1 1 4 Water lock 1 3 1 2 6 7 9 8 5 4 14 13 15 18 17 12 11 16 10 F1K 3 7 N m 0 37 kgf m 2 7 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 2nd 2 4 N m 0 24 kgf m 1 7 ft Ib 1st 2 4 N m 0 24 kgf m ...

Page 325: ...t joint 1 11 Nut washer 6 6 12 Exhaust valve 1 13 Hose clamp 1 1 14 Rubber hose 1 3 1 2 6 7 9 8 5 4 14 13 15 18 17 12 11 16 10 F1K 3 7 N m 0 37 kgf m 2 7 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 2nd 2 4 N m 0 24 kgf m 1 7 ft Ib 1st 2 4 N m 0 24 kgf m 1 7 ft Ib 2nd 2 4 N m 0 24 kgf m 1 7 ft Ib 1st 2 4 N m 0 24 kgf m 1 7 ft Ib ...

Page 326: ... Plate 1 Reverse the removal steps for installation 3 1 2 6 7 9 8 5 4 14 13 15 18 17 12 11 16 10 F1K 3 7 N m 0 37 kgf m 2 7 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 2nd 2 4 N m 0 24 kgf m 1 7 ft Ib 1st 2 4 N m 0 24 kgf m 1 7 ft Ib 2nd 2 4 N m 0 24 kgf m 1 7 ft Ib 1st 2 4 N m 0 24 kgf m 1 7 ft Ib ...

Page 327: ...aks Replace Exhaust component parts sub assembly 1 Install Rubber hose Plate NOTE Be sure to fit the projections a on the rubber hose with the grooves in the plate 2 Install Rubber hoses Water tank NOTE Be sure to insert the rubber hose to the line b on the water tank Align the parting line c of the water tank with the parting line d of the rubber hose Align the parting line e of the rubber hose w...

Page 328: ...8 35 E HULL HOOD EXHAUST SYSTEM Exhaust system installation 1 Install Exhaust joint NOTE Be sure to install the projections a on the exhaust pipe and exhaust joint into the slots b in the joint b a a ...

Page 329: ...t 1 3 Nut 2 4 Cleat 1 5 Plate 2 6 Bolt collar 10 10 7 Sponson 2 8 Nut washer 4 4 9 Screw washer 4 4 10 Drain plug 2 11 Seal 2 4 5 3 7 6 1 2 5 LT 572 16 16 19 17 18 9 10 11 13 15 14 12 6 20 mm 13 N m 1 3 kgf m 9 4 ft Ib 6 9 N m 0 69 kgf m 5 0 ft Ib 8 45 mm 16 N m 1 6 kgf m 12 ft Ib 15 N m 1 5 kgf m 11 ft Ib 5 25 mm 2 0 N m 0 2 kgf m 1 4 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib LT 572 LT 8 14 20 15 N m 1 ...

Page 330: ...Nut washer 5 5 17 Bolt 2 18 Protector 1 19 Bolt 2 20 Bow eye 1 Reverse the disassembly steps for assembly 4 5 3 7 6 1 2 5 LT 572 16 16 19 17 18 9 10 11 13 15 14 12 6 20 mm 13 N m 1 3 kgf m 9 4 ft Ib 6 9 N m 0 69 kgf m 5 0 ft Ib 8 45 mm 16 N m 1 6 kgf m 12 ft Ib 15 N m 1 5 kgf m 11 ft Ib 5 25 mm 2 0 N m 0 2 kgf m 1 4 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib LT 572 LT 8 14 20 15 N m 1 5 kgf m 11 ft Ib ...

Page 331: ...STALLATION 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 1 3 Damper 2 1 4 Bolt 8 5 Engine mount 4 6 Liner 4 Reverse the removal steps for installation ...

Page 332: ......

Page 333: ...BLE ANALYSIS INTRODUCTION 9 1 FEATURES 9 1 Functions 9 1 CONTENTS 9 1 HARDWARE REQUIREMENTS 9 2 OPERATING 9 3 CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT 9 3 Top view 9 3 TROUBLE ANALYSIS 9 4 TROUBLE ANALYSIS CHART 9 4 SELF DIAGNOSIS 9 8 ...

Page 334: ... Sensors that had been activated and ECM diagnostic codes that have been recorded are displayed This allows you to check the watercraft s record of malfunctions 3 Engine monitor Each sensor s status and the ECM data are displayed This enables you to find malfunctioning parts quickly In addition the data displayed using the Engine Monitor func tion can be displayed in a graph 4 Stationary test Oper...

Page 335: ... Display VGA 640 480 pixels SVGA 800 600 pixels or more recommended 256 or more colors Mouse Compatible with the operating systems mentioned above Communication port RS232C Dsub 9 pin port USB port Printer Compatible with the operating systems mentioned above NOTE The amount of memory and the amount of free space on the hard disk differs depending on the computer Using this software while there is...

Page 336: ...CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT Top view 1 3 pin communication coupler 2 Wiring harness coupler 3 Meter coupler NOTE Be careful not to pinch the communication cable between the hood and the deck or to damage it 1 3 2 ...

Page 337: ... cord lanyard is connect to the engine shut off switch 5 Check that fuel is reaching the fuel rail TROUBLE ANALYSIS CHART Trouble mode Check elements ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDLING ENGINE STALLS POOR ACCELERATION ENGINE WILL NOT STOP POOR PERFORMANCE LIMITED ENGINE SPEED OVERHEATING LOW OIL PRESSURE LOOSE STEERING BILGE INCREASE IRREGULAR WARNING INDICATION POOR BATTE...

Page 338: ...3 Oil filter 3 Oil pressure switch 7 Bearing housing 5 Drive couplings 5 Rubber coupling 5 Pilot water hose 5 Water hose 5 Water passage 5 Trouble mode Check elements ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDLING ENGINE STALLS POOR ACCELERATION ENGINE WILL NOT STOP POOR PERFORMANCE LIMITED ENGINE SPEED OVERHEATING LOW OIL PRESSURE LOOSE STEERING BILGE INCREASE IRREGULAR WARNING INDI...

Page 339: ...el pump relay 7 Electronic control throttle valve relay 7 Thermoswitch 7 Sensor assembly 7 Engine temperature sensor 7 Throttle body assembly throttle position sensor 7 Accelerator position sensor 7 Cam position sensor 7 Trouble mode Check elements ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDLING ENGINE STALLS POOR ACCELERATION ENGINE WILL NOT STOP POOR PERFORMANCE LIMITED ENGINE SPEED...

Page 340: ...mote control unit 7 HULL AND HOOD Steering column 8 Water lock 8 Exhaust hose 8 Muffler 8 Drain plugs 8 Trouble mode Check elements ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDLING ENGINE STALLS POOR ACCELERATION ENGINE WILL NOT STOP POOR PERFORMANCE LIMITED ENGINE SPEED OVERHEATING LOW OIL PRESSURE LOOSE STEERING BILGE INCREASE IRREGULAR WARNING INDICATION POOR BATTERY CHARGING Relati...

Page 341: ...System Code Symptom 01 Normal 13 Pickup coil malfunction 15 Engine temperature sensor malfunction 19 Incorrect battery voltage 23 Intake air temperature sensor malfunction 24 Cam position sensor malfunction 29 Intake air pressure sensor malfunction 47 Slant detection switch malfunction 48 Incorrect data transmission 55 Steering switch malfunction 112 123 Electronic control throttle system malfunct...

Page 342: ...sembly N Accelerator position sensor O Pickup coil P Lighting coil Q Buzzer R Electric fuel pump S Steering sensor T Fuel sender U Speed sensor V Multifunction meter W Start switch X Engine stop switch Y Engine shut off switch È To tachometer Color code B Black Br Brown G Green Gy Gray L Blue O Orange P Pink R Red W White Y Yellow B G Black green B O Black orange B R Black red B W Black white B Y ...

Page 343: ... P Accelerator position sensor Q Pickup coil R Lighting coil S Buzzer T Electric fuel pump U Steering sensor V Fuel sender W Speed sensor X Multifunction meter Y Start switch Z Engine stop switch Engine shut off switch È To entry box É To tachometer Color code B Black Br Brown G Green Gy Gray L Blue O Orange P Pink R Red W White Y Yellow B G Black green B O Black orange B R Black red B W Black whi...

Page 344: ......

Page 345: ...YAMAHA MOTOR CORPORATION USA Printed in USA Jan 2005 0 0 1 CR E_4 ...

Page 346: ...0212223242526 1 2 B B W W Br Br Br R W B W B O B O B O B R P P B O W B P W P W B O B O B O B O B O B O B O B O B O B O L B B W B R B O B O P P W P P W G G O O O W O G G B W G G G G O O L G R G G G B W Y Y G O W B R Y B Y P G W L Y G B Y R Y B O O L P B B B B W B Pu R Pu B Pu G Pu Y P W B G R Y R Y W B B Y Y W L R B R B W B B B B B B B B B B P P B B P R R B B B R Y Br R Y B O L B B O L B B G G O B ...

Page 347: ...2526 1 2 B B W W Br Br Br R W B W B O B O B O B R P P B O W B P W P W B O B O B O B O B O B O B O B O B O B O L B B W B R B O B O P P W P P W W W W L R Y Y G G O O O W O G G B W G G G G O O L G R G G G B W Y Y W G O W B R Y R Y P G W L Y G R Y R Y B O O L P B B B B W B Pu R Pu B Pu G Pu Y P W B G R Y R Y W B B Y Y W L R B R B W Gy B B B B B B B B B B B B B B P P B B P R R B B B R R Y Br R Y B O L ...

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