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Yamaha WaveRunner FX SHO, Service Manual

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Yamaha WaveRunner FX SHO Service Manual Download Page 153

5-28

E

POWR

1

2

3

4

5

6

7

8

9

Electrical box and starter motor

Electrical box and starter motor removal

Step

Procedure/Part name

Q

’

ty

Service points

1

Ignition coil coupler

4

2

Plastic tie

1

3

Injector coupler

4

4

Knock sensor coupler

1

5

Thermoswitch coupler

1

6

Plastic tie

1

7

Cam position sensor coupler

1

8

Intake air temperature sensor 
coupler

1

9

Engine temperature sensor coupler

1

10

Plastic tie

1

SG

SG

19

18

20

21

23

24

27

28

25

26

22

11

10

2

16

13

15

17

8

12

6

9

7

4

5

1

3

14

26

12

24

28

25

A

A

B

B

a

A

A

18 N 

·

 m (1.8 m 

·

 kg, 13.3 ft 

·

 Ib)

5 N 

·

 m (0.5 kgf 

·

 m, 3.7 ft 

·

 Ib)

8 

×

  30 mm 

Electrical box and starter motor

Summary of Contents for WaveRunner FX SHO

Page 1: ...SERVICE MANUAL FX SHO WaveRunner F1W 28197 1K 11 FX Cruiser SHO LIT 18616 03 12 LIT186160312 ...

Page 2: ...t changes in specifications and procedures and these are incorporated in successive editions of this manual Important information Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machin...

Page 3: ...formation GEN INFO Specification SPEC Periodic check and adjustment CHK ADJ Fuel system FUEL Power unit POWR Jet pump unit JET PUMP Electrical system ELEC Hull and hood HULL HOOD Trouble analysis TRBL ANLS 1 2 3 4 5 6 7 8 9 ...

Page 4: ...N 1 6 Special service tool 1 7 Measuring 1 7 Removal and installation 1 9 Feature and benefit 1 14 Watercraft overview 1 14 Engine overview 1 15 Air filter case and air filter element 1 16 Supercharger assembly 1 16 Air cooler assembly 1 17 Intake system 1 17 Electronic control throttle valve ETV system 1 18 Cylinder head assembly 1 19 Hydraulic timing chain tensioner 1 19 Ignition coil 1 20 Pisto...

Page 5: ...1 39 L MODE low rpm mode and yamaha security system 1 39 Remote control transmitter 1 41 Technical tips 1 42 Engine control 1 42 Cruise assist control 1 43 No wake mode control 1 44 Reverse with traction control 1 45 Idle speed control 1 45 Over revolution control 1 45 L MODE LOW RPM MODE control 1 45 Slant detection control 1 45 High intake air pressure control 1 46 Knock control 1 46 Off throttl...

Page 6: ...re used to indicate important aspects of a procedure such as the grade of lubricant and lubrication point refer to 3 in the figure below Tightening torque specifications are provided in the exploded diagrams refer to 4 in the figure below for an example and in the related detailed instructions Some torque specifications are listed in stages as torque figures or angles in degrees Separate procedure...

Page 7: ...ols F to I in an exploded diagram indi cate the grade of lubricant and the lubrication point F Apply 4 stroke motor oil G Apply water resistant grease Yamaha grease A 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 Apply LOCTITE 271 re...

Page 8: ...ic Control Module ETV Electronic throttle valve EX Exhaust IN Intake OL Overload OTS Off throttle steering system PORT Port side QSTS Quick Shift Trim System RPM Revolutions Per Minute SAE Society of Automotive Engineers STBD Starboard side STERN Stern end TCI Transistor Controlled Ignition TDC Top Dead Center TPS Throttle Position Sensor UP Upside YDIS Yamaha Diagnostic System YEMS Yamaha Engine ...

Page 9: ...grinding or when using an air com pressor Protect your hands and feet by wearing protec tive gloves and safety shoes when necessary Parts lubricants and sealants Use only genuine Yamaha parts lubricants and sealants or those recommended by Yamaha when servicing or repairing the watercraft Under normal conditions the lubricants men tioned in this manual should not harm or be hazardous to your skin ...

Page 10: ...steners starting in the cen ter and moving outward Non reusable parts Always use new gaskets seals O rings cotter pins circlips etc when installing or assem bling parts Disassembly and assembly 1 Use compressed air to remove dust and dirt during disassembly 2 Apply oil or fluid to the contact surfaces of moving parts before assembly 3 Install bearings with the manufacture iden tification mark in t...

Page 11: ...e unit NOTE The label stamped with the engine serial number is located on the cylinder head cover Remove the engine cover to check the engine serial number Slide the engine cover rearward and then lift the cover to remove it Starting serial number 6S5 1000001 Jet pump unit serial number The jet pump unit serial number is stamped on a label attached to the intermediate housing Hull identification n...

Page 12: ... USA and Canada use part numbers starting with YB YM YU or YW For other countries use part numbers start ing with 90890 Measuring 1 Gauge stand 90890 06725 2 Dial gauge stand set use needle only YB 06585 3 Dial gauge needle 90890 06584 4 Dial gauge YU 03097 90890 01252 5 Compression gauge extension 90890 06582 6 Compression gauge YU 33223 90890 03160 7 Fuel pressure gauge adapter YW 06842 90890 06...

Page 13: ...cooler attachment 90890 06731 A YDIS connecting kit 60V 85300 04 B YDIS CD ROM Ver 1 30 60V WS853 04 C Digital multimeter YU 34899 A D Peak voltage adapter YU 39991 E Digital circuit tester 90890 03174 F Peak voltage adapter B 90890 03172 G Spark checker YM 34487 Ignition tester 90890 06754 Special service tool ...

Page 14: ...0890 06756 K Test harness 3 pins YB 06870 Test harness SMT250 3 3 pins 90890 06870 L Test harness 2 pins 90890 06850 Removal and installation 1 Oil filter wrench 90890 06830 2 Exhaust pipe wrench 90890 06726 3 Bearing separator 90890 06534 4 Slide hammer and adapters YB 06096 5 Bearing puller assembly 90890 06535 6 Stopper guide plate 90890 06501 Special service tool ...

Page 15: ...hment 90890 06661 A Coupler wrench 90890 06729 B Camshaft wrench 90890 06724 C Valve spring compressor YM 04019 90890 04019 D Compressor adapter YM 04114 Valve spring compressor attachment 90890 04114 E Valve guide remover YB 06801 90890 06801 F Valve guide installer YB 06810 90890 06810 G Valve guide reamer YM 01196 90890 06804 Special service tool ...

Page 16: ...0890 06818 30 90890 06555 45 90890 06323 60 K Crankshaft holder YB 06562 90890 06562 L Flywheel puller 90890 06723 M Rotor puller 90890 01080 N Driver handle small YB 06229 O Driver rod LS 90890 06606 P Bearing and seal installer YW 06356 Q Bearing outer race attachment 90890 06623 90890 06627 90890 06628 R Forward bearing race installer YB 06258 Special service tool ...

Page 17: ...YB 41446 V Ball bearing attachment 90890 06657 W Piston ring compressor YM 08037 90890 05158 X Drive shaft holder YB 06201 Drive shaft holder 6 90890 06520 Y Driver rod L3 90890 06652 Z Drive shaft needle bearing installer and remover YB 06194 Needle bearing attachment 90890 06609 Bearing attachment 90890 06728 C Special service tool ...

Page 18: ...1 13 E GEN INFO Bearing cup installer YB 06167 _ Shaft holder 90890 06730 a Needle bearing installer YB 06434 b Bearing puller legs YB 06523 c Bearing attachment 90890 06727 Special service tool ...

Page 19: ...1 Handlebar 2 Rear seat assembly 3 Front seat assembly 4 Foot well 5 Sponson 6 Gunwale 7 Pull up cleat FX Cruiser SHO 8 Cooling water pilot outlet 9 Bow eye 0 Front hood assembly A Fuel filler cap B Intake grate C Speed sensor FX SHO Speed and water temperature sensor FX Cruiser SHO D Stern eye E Drain plug F Reverse gate G Ride plate H Jet thrust nozzle I Reboarding step assembly J Boarding platf...

Page 20: ...ed using regular unleaded gasoline The engine meets environmental regulations and complies with the 2006 U S EPA Environmental Protection Agency emission regulations and the 2008 CARB California Air Resources Board 3 star emission regulations 1 Air cooler assembly 2 Oil level gauge 3 Oil filler cap 4 Ignition coil 5 Rectifier regulator 6 4 in 1 exhaust system 7 Oil filter 8 Oil cooler assembly 9 O...

Page 21: ...arging The impeller uses a step up gear with 2 steps to transmit the rotation of the crankshaft The impeller rotates about 10 times faster than the crankshaft The impeller drive gear is equipped with a one way clutch therefore even if the engine stops when the impeller is rotating at high speed the structure of the impeller allows it alone to continue rotating The super charger has excellent durab...

Page 22: ...r 1 Air cooler assembly 2 Supercharger assembly È Compressed air É Cooled air Intake system The intake system has incorporated an electronic control throttle valve ETV By using the ETV the intake system itself is compact and is able to perform various engine controls Furthermore the intake air that passes through the ETV is balanced in the intake manifold before it is supplied to each cylinder 1 I...

Page 23: ...e output voltage of the APS accordingly This voltage is then transmitted from the APS to the ECM In accordance with the volt age input from the APS the ECM operates the DC motor which is installed on the ETV and sets the throttle valve to the opening angle that corresponds to the changes in operation of the throttle lever At the same time the throttle position sensor TPS which is located on the sa...

Page 24: ...pe 1 Valve lifter 2 Valve pad 3 Valve spring 4 Intake valve 5 Exhaust valve Hydraulic timing chain tensioner A hydraulic timing chain tensioner has been adopted in order to ensure that the tension on timing chain is maintained When the engine is started and engine oil is supplied to the timing chain ten sioner the structure of the tensioner ensures that the rod is maintained in the proper position...

Page 25: ...lt 3 Ignition coil Piston and connecting rod The pistons and connecting rods have been newly designed The shape of the piston crown has been designed to achieve the optimum compression ratio and the shape of the connecting rod has been designed to handle the high output Furthermore a mark to indicate the installation direction has been placed on the piston crown 1 Piston 2 Drive coupling 3 Transfe...

Page 26: ...r deck structure in order to achieve high rigidity 1 Cylinder block 2 Crankcase Knock sensor The knock sensor is installed directly to the cylinder block The knock sensor detects vibration that is generated by knocking in the combustion chambers and transmits the information to the ECM If the ECM determines that knocking is occurring it adjusts the ignition timing to control the knocking and prote...

Page 27: ... oil pan at the bottom of the engine to drawn in and pressure feed the engine oil 1 Intake camshaft 2 Exhaust camshaft 3 Cylinder block 4 Crankshaft 5 Oil separator tank 6 Oil pan 7 Oil strainer 8 Oil pipe 9 Oil pump assembly feed pump 0 Relief valve A Oil pump assembly scavenge pump B Oil cooler assembly C Oil filter D Drive gear assembly E Supercharger assembly C B 0 E D 8 9 7 5 6 4 3 1 2 A Feat...

Page 28: ...eed pump The scavenge pump pressure feeds engine oil from the oil pan to the oil separator tank The feed pump supplies engine oil from the oil pan to the various engine components 1 Oil separator tank 2 Oil pump assembly feed pump 3 Oil pump assembly scavenge pump 4 Oil pump assembly 2 1 3 4 Feature and benefit ...

Page 29: ...il in the outer oil pan is sent to the oil separator tank by the scavenge pump and then it flows into the inner oil pan By using 2 internal compartments a stable supply of engine oil is possible even under the harsh operating conditions of watercraft 1 Baffle plate 2 Strainer feed 3 Strainer scavenge 4 Oil pan 5 Outer oil pan 6 Inner oil pan È To feed pump É To scavenge pump 1 2 4 5 3 6 È É 5 Feat...

Page 30: ... oil flows into the inner oil pan at the center of the oil pan È From scavenge pump É To cylinder head Ê To inner oil pan Oil cooler assembly The mounting location for the oil filter is integrated into the oil cooler assembly Cooling water flows on both sides of the engine oil to effectively cool the oil 1 Engine oil 2 Cooling water È From jet pump unit É To cooling water pilot outlet on port side...

Page 31: ...em features a compact design that uses double pipe construction and a 4 in 1 sys tem to collect the exhaust gas before it is routed through the exhaust pipe 1 In addition exhaust pipe 3 is connected to the rear end of the exhaust pipe 1 in order to extend the exhaust outlet into the water lock This prevents back flow of water into the exhaust passage 1 Exhaust manifold 2 Exhaust pipe 1 3 Exhaust p...

Page 32: ...ol the engine oil with cooling water at the same temperature as the cooling water for the air cooler assembly The cooling water for the engine first cools the exhaust system which is at the highest temperature The cooling water then flows to the cylinder head where the thermostat which is installed to the cylinder head maintains the cooling water at a fixed temperature 1 Thermostat housing 2 Air c...

Page 33: ...system a water cooled rectifier regulator has been adopted for the first time in a WaveRunner By changing to a water cooled system a more stable supply of electrical output has been achieved 1 Rectifier regulator È From exhaust manifold É To cylinder block Ê To exhaust pipe 1 1 È Ê É 1 È Ê É Feature and benefit ...

Page 34: ...el pump inlet nearby With the suction generated at this time fuel in the fuel tank is fed into the fuel pump module As a result fuel is supplied to the fuel pump inlet without interruption for reliable fuel pressure 1 Fuel pump module assembly 2 Pressure regulator 3 Fuel pump È From pressure regulator É From fuel tank Ê To fuel pump module 1 Fuel pump module assembly 2 Fuel pump module 3 Pressure ...

Page 35: ...terproofing 1 Oil seal 2 Intermediate housing 3 Driven coupling Intake grate The grate of the intake grate has been changed to 3 bars and the components have been combined into a single part This improves serviceability In addition the transom plate and spacer have been combined into a single part which improves the rigidity and serviceability of the part 1 Intake grate 2 Transom plate 3 1 2 1 2 F...

Page 36: ...ating in reverse which improves reverse performance by acti vating the reverse with traction control 1 Shift lever 2 Reverse sensor 3 Reverse gate assembly QSTS The shape and installation location of the QSTS converter assembly have been changed from those of conventional models in order to improve operability 1 QSTS grip 2 QSTS converter 3 1 2 2 1 Feature and benefit ...

Page 37: ...unction display and operation buttons FX Cruiser SHO The analog speedometer tachometer and indicator lights have the following functions 1 Analog speedometer tachometer 2 SPEED indicator light 3 WARNING indicator light 4 RPM indicator light 5 UNLOCK indicator light 6 L MODE indicator light The analog speedometer tachometer can be used as a speedometer or a tachometer however both cannot be selecte...

Page 38: ...times in the following instances The analog speedometer tachometer is switched to the speedometer function when miles are selected as the display units The display units of the multifunction meter are switched to miles from kilometers Miles are selected as the display units when the multifunction meter starts operating 1 SPEED indicator light The RPM indicator light comes on when the analog tachom...

Page 39: ...s significantly high HI is displayed The left multifunction display indicates the following warnings Fuel level warning If the fuel remaining in the fuel tank drops to about 18 L the lowest 2 fuel level segments the fuel level warning indicator and the WARNING indicator light begin to blink The buzzer also starts sounding intermittently Oil pressure warning If the oil pressure does not rise to spe...

Page 40: ...g the 8 major compass points 5 Fuel consumption per hour This display shows the cur rent fuel consumption in gallons per hour G HR or liters per hour L HR 2 Average speed This display shows the average speed in miles per hour AV MPH or kilome ters per hour AV KMH since it was reset 6 Fuel consumption per kilometer mile This display shows the cur rent fuel consumption in gallons per mile G MILE or ...

Page 41: ...op button for less than 1 second The beeper sounds 1 time To restart the measurements push the Start Stop button for less than 1 second The beeper sounds 1 time To reset the displays push the Mode Reset button for at least 2 seconds while the measurements are stopped The beeper sounds 2 times The displays can be reset only when the measurements are stopped The mea surements are not saved if the en...

Page 42: ...ake mode The cruise assist and no wake mode are new functions Both functions can be operated easily using the buttons on the right handlebar switch assembly Cruise assist The cruise assist is a function for maintaining a set engine speed between approxi mately 3 000 r min and approximately 7 000 r min No wake mode The no wake mode is a function for operating the watercraft at a low speed to limit ...

Page 43: ...to protect the engine If engine speed is less than 3 000 r min the engine is turned off However if engine speed exceeds 3 000 r min the engine is not turned off to prevent improper operation of the switch Normal position of watercraft No circuit continuity Overturned watercraft Circuit continuity 1 Fuse box 2 Slant detection switch 2 1 Feature and benefit ...

Page 44: ...ngine speed is maintained above 4 000 r min for a few seconds The throttle lever is released completely The handlebar is turned sharply to the right or left and is applied load Some steering will be available with this system but the watercraft will turn more sharply if throttle is applied For the best steering and turning performance apply throttle while turning the handle bar L MODE low rpm mode...

Page 45: ... Lock Unlock Ê L MODE START Security Unlock mode START Security Lock mode START Security Unlock mode 1 Push the lock button 1 time 1 Push the unlock button 1 time 1 Push the unlock button for at least 4 seconds A Buzzer sound 1 time 0 3 sec onds B UNLOCK indicator light flashes 1 time and then goes off A Buzzer sound 2 times 0 3 seconds 2 B UNLOCK indicator light flashes 2 times and then remains o...

Page 46: ... codes can be added or re registered by connecting the entry box to the receiver ID codes from up to 5 remote control transmitters can be registered 1 Remote control transmitter 2 Remote control receiver 3 Entry box È Transmission É Power supply connection to the battery É È 2 1 3 Feature and benefit ...

Page 47: ...r slant detection switch thermoswitch oil pressure switch engine stop switch engine start switch NO WAKE MODE switch right handlebar switch SET up and down and reverse sensor APS Steering sensor Cam position sensor Engine temperature sensor TPS Pickup coil Intake air temperature sensor Intake air pressure sensor Knock sensor Thermo sensor Slant detection switch Thermoswitch Oil pressure switch Eng...

Page 48: ...e assist activated be sure to keep the throttle lever squeezed further than the position at which the cruise assist was set Once the cruise assist is activated the engine speed can be increased by pushing the up switch or decreased by pushing the down switch Each time a switch is pushed the beeper will sound 1 time quickly and the engine speed will change However the adjustment is limited to a max...

Page 49: ...ating the mode To activate the no wake mode Push and hold the NO WAKE MODE switch When the no wake mode is activated the beeper sounds 3 times quickly and 5 when miles are selected or 8 when kilometers are selected starts flashing in the digital speedometer display Keep the throttle lever in the idle position when the no wake mode is activated To deactivate the no wake mode Perform one of the foll...

Page 50: ...rpm mode control In the L MODE the ETV regulates the opening angle of the throttle valve and controls ignition tim ing Maximum engine speed is limited to approximately 5 400 r min Slant detection control The slant detection control is activated under the following conditions If the engine speed is below 3 000 r min If the slant detection switch is on If the slant detection control is activated ign...

Page 51: ...he throttle valve is closed until the above conditions are no longer present The throttle valve doesn t open until the high intake air pressure control is canceled Cancel The throttle lever is released to the fully closed position Knock control The knock control system retards the ignition timing to prevent the occurrence of engine knock The knock control is activated under the following condition...

Page 52: ... The ETV is operated and air is introduced into the intake manifold 6 The ECM controls the opening of the ETV to provide forward thrust and steering 1 Steering sensor 2 Steering shaft 3 TPS 4 Throttle body assembly 5 DC motor 6 Pickup coil 7 Flywheel magneto 8 ECM 9 Handlebar Start the engine and operate it for several seconds with the engine speed above 4 000 r min Release the throttle lever and ...

Page 53: ...nable disable starting of the engine 2 ECM engine startability control The ECM prevents the engine from being started until the ID code from the remote control trans mitter is verified and the signal to enable the engine to be started is received 3 Normal mode L MODE If the unlock button on the remote control transmitter is pressed continuously for more than 4 seconds the transmitter sends a mode ...

Page 54: ...ditions If the engine speed exceeds 4 500 r min If the ETV is open If the oil pressure switch is on If the oil pressure warning control is activated the oil pressure indicator on the multifunction meter comes on and the buzzer sounds In addition the opening angle of the ETV is regulated and the maximum engine speed is limited to approximately 3 500 3 800 r min by the ECM If the engine is turned of...

Page 55: ...ve conditions are maintained for 10 seconds Meter buzzer No indication or buzzer sounds ECM The opening angle of the ETV is regulated and the engine speed is limited to 3 500 3 800 r min If the engine speed exceeds 5 000 r min the ECM cuts the ignition and fuel injection Cancel The engine is turned off Battery disconnection warning The ETV failure control is activated when a battery cable is disco...

Page 56: ... air tempera ture Incorrect intake air temperature sensor signal Normal control using pseudo intake air tem perature Normal control using pseudo intake air temperature Pseudo intake air tem perature is 40 C 104 F Incorrect intake air pressure sensor sig nal Normal control using pseudo intake air pres sure Normal control using pseudo intake air pressure Pseudo intake air pres sure is set according ...

Page 57: ...mperature sensor signal Normal control Normal control Pseudo cooling water temperature is set to 50 C 122 F ETV system malfunction ETV failure control ETV failure control ETV failure control Symptom Ignition control Fuel injection control Function Technical tips ...

Page 58: ...1 53 E GEN INFO MEMO Technical tips ...

Page 59: ...ation 2 1 Maintenance specifications 2 3 Engine 2 3 Fuel system 2 6 Jet pump unit 2 7 Hull and hood 2 7 Electrical 2 7 Tightening torques 2 11 Specified torques 2 11 General torque 2 17 Cable and hose routing 2 18 Starboard bow view 2 18 Top view 2 19 Port view 2 21 ...

Page 60: ... 0 3 39 3 07 Compression ratio 8 6 1 Exhaust system Wet exhaust Lubrication system Wet sump Cooling system Water cooled Starting system Electric starter Ignition system TCI Maximum ignition timing advance Degree BTDC 20 Spark plug manufacturer LFR6A NGK Spark plug gap mm in 0 8 0 9 0 031 0 035 Generator output A r min 23 3 25 3 6 000 Drive unit Propulsion system Jet pump Jet pump type Axial flow s...

Page 61: ... gal 70 18 5 15 4 Engine oil type 4 stroke motor oil Engine oil grade API SE SF SG SH SJ or SL SAE 10W 30 10W 40 20W 40 or 20W 50 Engine oil quantity Total amount L US qt Imp qt 4 3 4 55 3 78 Without oil filter replacement L US qt Imp qt 3 0 3 17 2 64 With oil filter replacement L US qt Imp qt 3 1 3 28 2 73 Battery Type Fluid Capacity V Ah 12 19 Specific gravity 20 C 68 F 1 265 Item Unit Model FX ...

Page 62: ...ge position mm in 0 1 0 004 Camshaft cap inside diameter mm in 25 000 25 021 0 9843 0 9851 Camshaft Drive system Chain drive Intake A mm in 40 9 1 610 Intake B mm in 32 0 1 260 Exhaust A mm in 41 0 1 614 Exhaust B mm in 32 2 1 268 Camshaft journal diameter mm in 24 960 24 980 0 9827 0 9835 Camshaft journal to camshaft cap clearance mm in 0 020 0 061 0 0008 0 0024 Camshaft runout limit mm in 0 015 ...

Page 63: ...1 40 1 60 0 055 0 063 Exhaust mm in 1 50 1 70 0 059 0 067 Valve margin thickness D Intake and exhaust mm in 0 80 1 20 0 031 0 047 Valve stem diameter Intake mm in 5 477 5 492 0 2156 0 2162 Exhaust mm in 5 464 5 479 0 2151 0 2157 Valve guide inside diameter Intake and exhaust mm in 5 504 5 522 0 2167 0 2174 Valve stem to valve guide clearance Intake mm in 0 012 0 045 0 0005 0 0018 Exhaust mm in 0 0...

Page 64: ...utside diameter mm in 21 991 22 000 0 8658 0 8661 Piston ring Top ring Type Barrel Dimension B mm in 1 17 1 19 0 0461 0 0469 Dimension T mm in 2 85 3 05 0 112 0 120 End gap installed 1 mm in 0 30 0 45 0 012 0 018 Side clearance mm in 0 02 0 06 0 0008 0 0024 2nd ring Type Taper Dimension B mm in 1 17 1 19 0 0461 0 0469 Dimension T mm in 2 60 2 80 0 102 0 110 End gap installed 1 mm in 0 45 0 60 0 01...

Page 65: ... 0009 0 0021 Bearing color code 1 Brown 2 Black 3 Blue 4 Green 5 Yellow Oil filter Oil filter type Cartridge type Oil pump Oil pump type Trochoid Thermostat Opening temperature 0 05 mm 0 002 in C F 48 52 118 126 Fully open temperature C F 60 140 Valve open lower limit mm in More than 4 3 0 17 Item Unit Model FX SHO FX Cruiser SHO Throttle body Type quantity IM54 3D04 1 Manufacturer Mikuni ID mark ...

Page 66: ...limit mm in 0 3 0 012 Nozzle diameter mm in 82 2 82 8 3 24 3 26 Item Unit Model FX SHO FX Cruiser SHO Throttle lever Free play mm in 2 0 5 0 0 08 0 20 Item Unit Model FX SHO FX Cruiser SHO Ignition system ECM unit B R B B W B B Y B B G B Output peak voltage cranking loaded V 2 5 2 000 r min loaded V 2 6 3 500 r min loaded V 2 6 Pickup coil W B Output peak voltage cranking unloaded V 5 4 cranking l...

Page 67: ...6 Thermoswitch Thermoswitch continuity temperature C F 94 100 201 212 Thermoswitch no continuity temperature C F 80 94 176 201 Thermo sensor Thermo sensor resistance 1 B B 0 C 32 F kΩ 24 0 37 1 100 C 212 F kΩ 0 87 1 18 Engine temperature sensor Engine temperature sensor resistance 1 B Y B Y 20 C 68 F kΩ 54 2 69 0 100 C 212 F kΩ 3 12 3 48 Intake air temperature sensor Intake air temperature sensor ...

Page 68: ...ottle lever fully closed APS 1 V 0 50 0 90 APS 2 V 0 35 1 05 with throttle lever fully open APS 1 V 3 75 4 35 APS 2 V 3 60 4 50 APS resistance 1 20 C 68 F with APS pully fully closed APS 1 kΩ 0 50 0 90 APS 2 kΩ 0 35 1 05 with APS pully fully open APS 1 kΩ 3 75 4 35 APS 2 kΩ 3 60 4 50 Cam position sensor Output voltage G O B O Position a c V More than 4 8 Position b V Less than 0 8 1 The figures ar...

Page 69: ...otor Type Constant mesh Output kW 0 6 Cranking time limit Seconds 30 Brush length mm in 5 0 12 5 0 20 0 49 Commutator undercut 1 mm in 0 2 0 7 0 008 0 028 Commutator diameter mm in 27 0 28 0 1 06 1 10 Remote control system Remote control receiver Output voltage 1 L Y Ground V 11 0 12 0 Indication system Speed sensor Output voltage on pulse Y B Y mV Less than 400 V More than 11 6 G B mV Less than 4...

Page 70: ... 5 6 Rectifier regulator bolt M8 26 2 6 19 2 5 6 Pipe clamp 2 0 2 1 5 5 6 Exhaust pipe 1 stay bolt 1st M8 M10 23 2 3 17 0 5 6 2nd 42 4 2 31 0 Exhaust manifold bolt 1st M8 20 2 0 14 8 5 6 2nd 35 3 5 25 8 Electrical box bolt M8 17 1 7 12 5 5 9 Coupling cover bolt M6 8 0 8 5 9 5 9 Engine mounting bolt M8 17 1 7 12 5 5 9 Damper 1 bolt M6 6 0 6 4 4 5 10 Damper 2 bolt M6 6 0 6 4 4 5 10 Engine mount bolt...

Page 71: ...lt M8 13 1 3 9 6 5 36 Throttle body assembly nut 13 1 3 9 6 5 36 Supercharger oil filler hole bolt 4 0 4 3 0 5 39 Oil filter bolt 18 1 8 13 3 5 42 Oil cooler assembly bolt M8 19 1 9 14 0 5 42 Oil pipe holder bolt M6 8 0 8 5 9 5 42 Oil pipe bolt M10 21 2 1 15 5 5 42 Oil pump assembly bolt M6 11 1 1 8 1 5 42 Drive gear assembly bolt M12 80 8 0 59 0 5 44 Ignition coil bolt M6 8 0 8 5 9 5 52 Spark plu...

Page 72: ...olt M6 10 1 0 7 4 5 90 Baffle plate bolt M6 12 1 2 8 9 5 94 Oil pipe 1 and 2 bolt M6 9 0 9 6 6 5 94 Bracket 1 and 2 bolt M10 50 5 0 36 9 5 96 Baffle plate bolt M6 10 1 0 7 4 5 96 Crankcase bolt M6 10 1 0 7 4 5 96 1st M10 30 3 0 22 1 2nd 90 Connecting rod cap nut 1st 51 5 1 37 6 5 96 2nd 90 Thermostat housing bolt M6 8 0 8 5 9 5 116 Jet pump unit Intake grate bolt M6 8 0 8 5 9 6 1 M8 17 1 7 12 5 Ri...

Page 73: ...M30 36 3 6 26 6 6 23 Hull and hood Upper handlebar cover screw M4 1 0 1 0 7 8 1 Lower handlebar cover screw M5 1 0 1 0 7 8 1 M6 5 0 5 3 7 Steering pad bolt M6 1 0 1 0 7 8 2 Upper handlebar holder bolt M8 21 2 1 15 5 8 3 QSTS grip assembly screw M6 3 0 3 2 2 8 4 Left handlebar switch assembly screw M5 3 0 3 2 2 8 4 Right handlebar switch assembly bolt M5 3 0 3 2 2 8 4 Handle boss cover screw M6 1 0...

Page 74: ...7 0 7 5 2 8 36 Shift cable bracket nut 16 1 6 11 8 8 36 Shift cable grommet nut 5 9 0 59 4 4 8 36 Shift cable locknut jet pump end 2 9 0 29 2 1 8 36 Cooling water pilot outlet nut 4 0 4 3 0 8 41 Seat lock assembly bolt M6 6 0 6 4 4 8 43 Deck beam nut 18 1 8 13 3 8 43 Projection nut 26 2 6 19 2 8 43 Rear seat stay nut 6 0 6 4 4 8 43 Seat holder nut 16 1 6 11 8 8 43 Hand grip nut 5 0 5 3 7 8 43 Rubb...

Page 75: ...6 7 4 Slant detection switch screw M6 4 0 4 3 0 7 4 ECM bolt M6 5 0 5 3 7 7 4 Lead bolt red brown and black M6 10 1 0 7 4 7 6 Starter motor terminal nut 9 0 9 6 6 7 53 Starter motor cover bolt M6 6 0 6 4 4 7 53 Transmitter cover screw 0 1 0 01 0 1 7 62 Part to tightened Thread size Tightening torque Refer to page N m kgf m ft lb Tightening torques ...

Page 76: ...avoid warpage tighten multi fastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Components should be at room temperature Nut A Bolt B General torque specifications N m kgf m ft lb 8 mm M5 5 0 5 3 7 10 mm M6 8 0 8 5 9 12 mm M8 18 1 8 13 3 14 mm M10 36...

Page 77: ...y to intake pipe 4 Right handlebar switch lead 5 Throttle cable 6 Left handlebar switch lead 7 QSTS cable 8 Fuel tank breather hose water separator to fuel tank 9 Cooling water pilot outlet hose 0 Speed sensor lead A Remote control receiver antenna B Fuel tank breather hose ventilation socket to water separator C Wiring harness D Steering cable E Shift cable F Fuel hose fuel tank to fuel rail G Co...

Page 78: ...ottle cable 6 Left handlebar switch lead 7 QSTS cable 8 Fuel tank breather hose water separator to fuel tank 9 Cooling water pilot outlet hose 0 Speed sensor lead A Remote control receiver antenna B Fuel tank breather hose ventilation socket to water separator C Wiring harness D Steering cable E Shift cable F Fuel hose fuel tank to fuel rail G Cooling water hose hose joint 1 to hose joint 4 H Reve...

Page 79: ...bilge pump coupler J Negative battery cable K Positive battery cable L Battery breather hose M Cooling water hose jet pump to hose joint 1 N Flushing hose O Cooling water hose hose joint 1 to hose joint 3 P Buzzer lead Q Compass and air temperature sensor lead FX Cruiser SHO Cable and hose routing ...

Page 80: ... Left handlebar switch lead 7 QSTS cable 8 Fuel tank breather hose water separator to fuel tank 9 Cooling water pilot outlet hose 0 Speed sensor lead A Remote control receiver antenna B Fuel tank breather hose ventilation socket to water separator C Wiring harness D Steering cable E Shift cable F Fuel hose fuel tank to fuel rail G Cooling water hose hose joint 1 to hose joint 4 H Reverse sensor le...

Page 81: ...L Battery breather hose M Steering sensor lead N Bilge hose hose joint to drain joint O Bilge hose electric bilge pump to hose joint P Buzzer lead Q Bilge hose hose joint to pilot outlet R Electric bilge pump lead È Fasten the wiring harness with the plastic tie making sure to align the tie with the gray tape on the harness Cable and hose routing ...

Page 82: ...2 23 E SPEC MEMO Cable and hose routing ...

Page 83: ... and adjustment 3 7 Fuel system 3 9 Fuel line check 3 9 Water separator check 3 10 Power unit 3 10 Valve clearance measurement 3 10 Compression pressure measurement 3 12 Engine oil level check 3 13 Engine oil change 3 14 Oil filter replacement 3 15 Air filter element check 3 16 Spark plug check 3 17 Electrical 3 19 Battery check 3 19 Jet pump unit 3 21 Jet pump unit check 3 21 Bilge pump 3 22 Bilg...

Page 84: ...Lubricate 50 hours or 6 months 5 39 QSTS cables Lubricate 3 24 Intermediate housing Lubricate 2 3 3 3 24 Fuel system Check 3 9 Fuel tank Check clean 3 9 Trolling speed Check 3 7 Throttle shaft Check 5 38 Cooling water passages Flush 4 Water inlet strainer Check clean 3 22 Bilge strainer Clean 3 22 Electric bilge pump strainer Check clean 3 23 Impeller Check 3 21 Jet thrust nozzle angle Check adjus...

Page 85: ...dlebar lock to lock and push it back and forth 2 Check for excessive play of the handlebar Jet thrust nozzle steering angle check and adjustment 1 Check Jet thrust nozzle distances a and b Difference above specification Adjust the steering cable joint Checking steps 1 Set the QSTS grip to the neutral position 2 Turn the handlebar lock to lock 3 Measure distances a and b Difference of distances a a...

Page 86: ...an 8 mm 0 31 in c 6 Connect the steering cable joint 2 and then tighten the locknut 1 to the specified torque 7 Check the jet thrust nozzle angle differ ence of distances a and b again 8 If the steering cable cannot be properly adjusted using the cable joint at the steer ing master end adjust the cable joint at the jet pump end so that the difference of distances a and b is within specification Re...

Page 87: ...t distances a and b a b DOWN UP 2 Adjust QSTS rod joint Adjustment steps 1 Set the QSTS grip to the neutral position 2 Loosen the locknut 1 3 Disconnect the QSTS rod joint 2 4 Adjust the QSTS rod joint 2 until the upper and lower set distances a and b for the jet thrust nozzle are equal WARNING The QSTS rod joint must be screwed in more than 8 mm 0 31 in c 5 Connect the QSTS rod joint 2 to the bal...

Page 88: ... lever free play Adjustment steps NOTE Follow all the steps if the throttle cable has been replaced or if it has been disconnected from the APS Follow only steps 6 13 if the throttle cable has not been disconnected from the APS 1 Face the handlebar straight ahead 2 Remove the service lid Refer to Front hood removal in Chapter 8 3 Slide the boot 1 4 Check that the throttle cable installation length...

Page 89: ... or out until the specified free play is obtained 10 Tighten the locknut 5 11 Squeeze the throttle lever to the fully open position and check that the APS pulley stopper c contacts the fully open stopper d on the APS 12 Release the throttle lever and check that the APS pulley stopper e contacts the fully closed stopper f on the APS NOTE If the throttle cable free play cannot be adjusted properly r...

Page 90: ... steps 1 Place the watercraft in the water 2 Start the engine and allow it to warm up for 5 minutes 3 Check the engine trolling speed using the tachometer of the multifunction meter or using the YDIS Trolling speed 1 150 1 350 r min Shift cable check and adjustment 1 Check Reverse gate position Incorrect Adjust the shift cable joint Checking steps 1 Set the shift lever to the reverse position 2 Ch...

Page 91: ...able joint 2 in or out until the specified distance a between the cen ter of the joint and the center of the ball joint 3 is obtained WARNING The shift cable joint must be screwed in more than 8 mm 0 31 in b 6 Connect the shift cable joint 2 to the ball joint 3 and then tighten the locknut 1 to the specified torque Turn in Distance is decreased Turn out Distance is increased Distance a 7 mm 0 28 i...

Page 92: ... spray out When removing fuel system parts wrap them in a cloth and take care that no fuel spills into the engine compartment Fuel line check 1 Check Fuel pump filter 1 Clog contaminants Clean the fuel pump filter Fuel hose 2 Quick connectors 3 Cracks damage Replace the fuel hose Fuel filler hose Damage Replace the fuel filler hose Fuel filler neck Cracks damage Replace the fuel filler neck Fuel r...

Page 93: ... check 1 Check Water separator 1 Water accumulation Drain the water NOTE To drain water from the water separator 1 remove the drain plug 2 1 2 Power unit Valve clearance measurement 1 Measure Valve clearance Out of specification Adjust the valve clearance Refer to Valve clearance adjustment in Chapter 5 NOTE Measure the valve clearance when the engine is cold Valve clearance cold Intake a 0 14 0 2...

Page 94: ... with the thick ness gauge 3 6 Position piston 2 at TDC by turning the exhaust camshaft sprocket an additional 90 clockwise and then measure the intake and exhaust valve clearances for cylinder 2 7 Position piston 4 at TDC by turning the exhaust camshaft sprocket an additional 90 clockwise and then measure the intake and exhaust valve clearances for cylinder 4 8 Position piston 3 at TDC by turning...

Page 95: ...s 4 Install the special service tools 5 and 6 5 Crank the engine until the reading on the compression gauge stabilizes 6 Measure the compression pressure for all cylinders according to steps 4 5 7 If the compression pressure is below spec ification squirt a few drops of engine oil into the cylinder and measure again Compression pressure reference data 610 kPa 6 1 kgf cm2 86 8 psi Compression gauge...

Page 96: ...T 572 LT Engine oil level check 1 Check Engine oil level Below the minimum level mark a Add the engine oil Above the maximum level mark b Extract the excess engine oil Checking steps CAUTION Make sure that debris or water does not en ter the oil filler hole 1 Place the watercraft in a precisely level position on land with the engine stopped Recommended engine oil API SE SF SG SH SJ or SL SAE 10W 3...

Page 97: ...he oil level gauge 1 b a Engine oil change WARNING Be careful when handling the engine oil to avoid burns The engine oil is hot immedi ately after the engine is turned off CAUTION When checking the oil level on land be sure to connect a garden hose to the water craft for proper water supply 1 Change Engine oil Changing steps 1 Place the watercraft in a precisely level position on land with the eng...

Page 98: ...ttles Recommended engine oil API SE SF SG SH SJ or SL SAE 10W 30 10W 40 20W 40 or 20W 50 Engine oil quantity Total amount 4 3 L 4 55 US qt 3 78 Imp qt Without oil filter replacement 3 0 L 3 17 US qt 2 64 Imp qt With oil filter replacement 3 1 L 3 28 US qt 2 73 Imp qt PORT STBD 1 2 4 5 3 Oil filter replacement 1 Replace Oil filter Replacing steps 1 Remove the engine cover 2 Place a rag under the oi...

Page 99: ... m 13 3 ft lb Air filter element check 1 Remove Intake pipe 1 Air filter case cover 2 Screws 3 Air filter element 4 3 1 2 4 2 Check Air filter element Damage dirt Replace the air filter ele ment 3 Install Air filter element Screws Air filter case cover Intake pipe NOTE Make sure that the screws are installed securely Make sure that the air filter case cover is installed in the filter case properly...

Page 100: ...remove it Be careful not to get water or any other for eign substances in the spark plug holes 1 3 4 2 2 Check Electrodes 1 Spark plug Carbon deposits Clean the spark plug Damage wear Replace the spark plug 3 Measure Spark plug gap a Out of specification Replace the spark plug Specified spark plug manufacturer LFR6A NGK Spark plug gap a 0 8 0 9 mm 0 031 0 035 in Power unit ...

Page 101: ...g clean the gasket surface and spark plug surface 5 Install Ignition coils 2 Ignition coil bolts 3 Engine cover 4 T R Spark plug 25 N m 2 5 kgf m 18 4 ft lb T R Ignition coil bolt 3 8 N m 0 8 kgf m 5 9 ft lb LOCTITE 572 Engine cover bolt 5 N m 0 5 kgf m 3 7 ft lb 4 2 1 3 LT 572 LT Power unit ...

Page 102: ...r 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 en closed space make sure that it is well ven tilated 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 battery from t...

Page 103: ...s 1 Remove each filler cap 2 Add distilled water 3 When the electrolyte level reaches the upper level mark a allow the cell to stand for 20 minutes If the electrolyte level drops add more distilled water so the level reaches the upper level mark NOTE The electrolyte level should be between the upper a and lower b level marks Use only distilled water 3 Check Specific gravity Out of specification Ch...

Page 104: ...minals with water resistant grease to minimize terminal corrosion 4 5 3 2 1 A A A A Jet pump unit Jet pump unit check WARNING Be sure to remove the battery before checking the jet pump unit 1 Check Impeller 1 Damage Replace the impeller 2 Measure Impeller to housing clearance a Out of specification Measure the impeller housing inside diameter Refer to Impeller duct and impeller housing removal in ...

Page 105: ...hand grip removal in Chapter 8 Electrical box Coupling cover Refer to Engine unit removal 3 in Chapter 5 2 Remove Bilge strainer case 1 NOTE Remove the bilge strainer case 1 by pushing the hooks a on the bilge strainer inward 3 Check Bilge strainer Contaminants Clean the bilge strainer Cracks damage Replace the bilge strainer 1 a 1 4 Install Bilge strainer case Coupling cover Electrical box Deck b...

Page 106: ...p Band Negative battery cable 2 1 4 3 General Drain plug check 1 Check Drain plugs O rings Cracks damage Replace the O ring Throttle valve and engine internal compo nents 1 Lubricate Throttle valve Engine internal components Lubricating steps 1 Remove the engine cover 2 Disconnect the breather hose 1 from the breather assembly 2 side 3 Start the engine and then spray a rust inhibitor through the b...

Page 107: ...speed will drop 4 Connect the breather hose 5 Install the engine cover Lubrication points 1 Lubricate Throttle cable handlebar end NOTE Before lubricating the throttle cable discon nect it from the throttle lever assembly After lubricating the throttle cable be sure to adjust the throttle lever free play Refer to Throttle lever free play check and adjust ment Recommended lubricant Rust inhibitor 2...

Page 108: ...pray the rust inhibitor into the outer cables and apply grease to the inner cables Recommended lubricant Yamaha grease A Rust inhibitor 4 Lubricate QSTS cables pulley end QSTS rod joint pulley end Recommended lubricant Yamaha grease A 5 Lubricate Nozzle pivot shaft Steering cable nozzle end Steering cable end nozzle end QSTS rod joint nozzle end Recommended lubricant Yamaha grease A General ...

Page 109: ...Disconnect the joints and apply a small amount of grease Recommended lubricant Yamaha grease A 7 Lubricate Intermediate housing through the grease nipple 1 Recommended lubricant Yamaha grease A Grease quantity Initial 10 hours 33 0 35 0 cm3 1 12 1 18 US oz 1 16 1 23 Imp oz Every 100 hours or 12 months 6 0 8 0 cm3 0 20 0 27 US oz 0 21 0 28 Imp oz 1 General ...

Page 110: ...3 27 E CHK ADJ MEMO General ...

Page 111: ...removal 4 5 Fuel sender removal 4 6 Rollover valve check 4 7 Check valve check 4 7 Fuel line check 4 8 Fuel pump module check 4 8 Fuel filler neck and hose check 4 8 Fuel tank check 4 8 Fuel injector check 4 9 Fuel injector installation 4 9 Fuel sender installation 4 9 Fuel pump module installation 4 10 Fuel hose connection 4 10 Fuel pressure measurement 4 11 ...

Page 112: ...reusable 3 Band 2 Not reusable 4 Fuel tank breather hose 1 5 Rollover valve 1 6 Fuel tank breather hose 1 8 18 mm 16 N m 1 6 kgf m 11 8 ft Ib 6 N m 0 6 kgf m 4 4 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 8 18 mm 16 N m 1 6 kgf m 11 8 ft Ib 2nd 6 N m 0 6 kgf m 4 4 ft Ib 1st 3 N m 0 3 kgf m 2 2 ft Ib 31 31 24 26 25 20 21 18 18 14 4 1 6 8 7 2 5 3 22 17 19 LT 572 LT LT 572 LT LT 242 LT...

Page 113: ...uel hose assembly 12 Nut 9 13 Retainer 1 8 18 mm 16 N m 1 6 kgf m 11 8 ft Ib 6 N m 0 6 kgf m 4 4 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 8 18 mm 16 N m 1 6 kgf m 11 8 ft Ib 2nd 6 N m 0 6 kgf m 4 4 ft Ib 1st 3 N m 0 3 kgf m 2 2 ft Ib 31 31 24 26 25 20 21 18 18 14 4 1 6 8 7 2 5 3 22 17 19 LT 572 LT LT 572 LT LT 242 LT 9 10 13 12 11 27 27 28 29 30 29 24 23 16 15 8 17 mm 13 N m 1 3 k...

Page 114: ...mp cap 1 1 8 18 mm 16 N m 1 6 kgf m 11 8 ft Ib 6 N m 0 6 kgf m 4 4 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 8 18 mm 16 N m 1 6 kgf m 11 8 ft Ib 2nd 6 N m 0 6 kgf m 4 4 ft Ib 1st 3 N m 0 3 kgf m 2 2 ft Ib 31 31 24 26 25 20 21 18 18 14 4 1 6 8 7 2 5 3 22 17 19 LT 572 LT LT 572 LT LT 242 LT 9 10 13 12 11 27 27 28 29 30 29 24 23 16 15 8 17 mm 13 N m 1 3 kgf m 9 6 ft Ib 24 E 2 È a a b ...

Page 115: ...oval steps for installation 8 18 mm 16 N m 1 6 kgf m 11 8 ft Ib 6 N m 0 6 kgf m 4 4 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 8 18 mm 16 N m 1 6 kgf m 11 8 ft Ib 2nd 6 N m 0 6 kgf m 4 4 ft Ib 1st 3 N m 0 3 kgf m 2 2 ft Ib 31 31 24 26 25 20 21 18 18 14 4 1 6 8 7 2 5 3 22 17 19 LT 572 LT LT 572 LT LT 242 LT 9 10 13 12 11 27 27 28 29 30 29 24 23 16 15 8 17 mm 13 N m 1 3 kgf m 9 6 ft I...

Page 116: ...tor with a cloth 2 Spread apart the ends of the locking slider red plastic 1 with your fingers as shown and then pull up on the slider NOTE If the quick connector is removed suddenly pressurized fuel could spray out To gradually release the fuel pressure be sure to remove the quick connector slowly 3 Disconnect the quick connector 2 from the fuel pipe 3 directly 4 Cover the quick connector and fue...

Page 117: ... not come off when removing the fuel pump mod ule assembly 1 2 1 3 Fuel sender removal 1 Remove Fuel sender 1 Removal steps 1 Disconnect the fuel sender coupler 2 2 Squeeze the hooks a on the retaining clip 3 and then slide the clip in direction È to remove it 3 Push the tabs b on the fuel sender 1 and then slide the sender in direction É to remove it a 3 3 1 2 È b É 1 Fuel tank fuel pump module a...

Page 118: ...o the end b of the rollover valve and make sure that air does not come out from the end a a b Check valve check 1 Check Check valve Does not function properly Replace the check valve Checking steps 1 Blow into the end a of the check valve and make sure that airflow from the end b is restricted 2 Blow into the end b of the check valve and make sure that airflow from the end a is unrestricted a b Fu...

Page 119: ...4 Cracks damage Replace the fuel rail 2 3 1 2 4 Fuel pump module check 1 Check Fuel pump filter 1 Clog contaminants Clean the fuel pump filter with kerosene or gasoline CAUTION Do not disassemble the fuel pump module 1 Fuel filler neck and hose check 1 Check Fuel filler neck 1 Cracks damage Replace the fuel filler neck Fuel filler hose 2 Cracks damage Replace the fuel filler hose 2 1 Fuel tank che...

Page 120: ...gine oil to the O ring before installing the fuel injector to the fuel rail otherwise the O ring could twist and break causing fuel leakage Fuel sender installation 1 Install Fuel sender 1 Installation steps 1 Install the fuel sender 1 NOTE Make sure that the tabs a on the fuel sender 1 are securely seated into the slots b in the fuel pump module 2 Install the retaining clip 2 NOTE Make sure that ...

Page 121: ...el pipe 1 2 Connect the quick connector 2 onto the fuel pipe 1 3 Push down on the locking slider 3 until it clicks NOTE If the fuel hose quick connector 2 is not installed completely onto the fuel pipe 1 the locking slider 3 cannot be pushed down 4 Confirm that the fuel hose quick connector is correctly installed by making sure there is a small amount of free play when the quick connector is pulle...

Page 122: ...connector from the fuel rail 2 Install the special service tools 1 and 2 as shown 3 Start the engine and allow it to warm up for 5 minutes 4 Measure the fuel pressure Fuel pressure gauge adapter 1 YW 06842 90890 06842 Fuel pressure gauge 2 YB 06766 90890 06786 Fuel pressure 345 370 kPa 3 45 3 70 kgf cm2 49 1 52 6 psi 2 1 Fuel tank fuel pump module and fuel hose ...

Page 123: ...Muffler check 5 27 Pipe check 5 27 Thermo sensor check 5 27 Exhaust pipe 3 installation 5 27 Electrical box and starter motor 5 28 Electrical box and starter motor removal 5 28 Air cooler supercharger and throttle body assembly 5 31 Air cooler and supercharger removal 5 31 Intake assembly removal 5 34 Intake disassembly 5 36 Air cooler check 5 37 Supercharger check 5 38 Throttle body assembly chec...

Page 124: ...emoval 5 52 Camshaft and timing chain removal 5 53 Camshaft removal 5 56 Camshaft check 5 58 Camshaft sprocket check 5 60 Timing chain check 5 60 Timing chain tensioner check 5 60 Camshaft installation 5 61 Cylinder head cover installation 5 63 Valve clearance adjustment 5 64 Cylinder head 5 67 Cylinder head assembly removal 5 67 Cylinder head disassembly 5 68 Cylinder head assembly removal 5 69 V...

Page 125: ...parator tank and oil pan removal 5 90 Oil pan disassembly 5 94 Oil pan check 5 95 Crankcase connecting rod and piston 5 96 Crankcase connecting rod and piston disassembly 5 96 Crankcase disassembly 5 99 Connecting rod and piston removal 5 99 Crankcase check 5 100 Anode check 5 100 Piston check 5 101 Piston ring check 5 102 Piston pin check 5 103 Connecting rod check 5 104 Cylinder check 5 104 Cran...

Page 126: ...ck beam Refer to Seat and hand grip removal in Chapter 8 Shift cable bracket Refer to Remote control cables and speed sensor lead removal in Chapter 8 1 Negative battery cable 1 2 Positive battery cable 1 3 Bolt grommet 2 2 4 Engine cover 1 5 Nut 2 1 3 3 8 4 2 9 11 12 13 14 14 14 14 a a 11 10 15 16 14 a 11 a 7 17 N m 1 7 kgf m 12 5 ft Ib 5 6 A A A A 6 12 mm 5 N m 0 5 kgf m 3 7 ft Ib Engine unit ...

Page 127: ...e plastic ties with the gray tape a on the wiring harness assembly 9 Plastic tie 1 10 Plastic tie 1 11 Coupler 8 NOTE Disconnect the multifunction meter sensor and switch couplers 1 3 3 8 4 2 9 11 12 13 14 14 14 14 a a 11 10 15 16 14 a 11 a 7 17 N m 1 7 kgf m 12 5 ft Ib 5 6 A A A A 6 12 mm 5 N m 0 5 kgf m 3 7 ft Ib Engine unit ...

Page 128: ...ol receiver coupler 1 14 Plastic tie 5 15 Fuel pump module coupler 1 16 Electric bilge pump coupler 1 Reverse the removal steps for installation 1 3 3 8 4 2 9 11 12 13 14 14 14 14 a a 11 10 15 16 14 a 11 a 7 17 N m 1 7 kgf m 12 5 ft Ib 5 6 A A A A 6 12 mm 5 N m 0 5 kgf m 3 7 ft Ib Engine unit ...

Page 129: ...he connection with the mark b on the intake pipe 5 Clamp intake pipe 2 1 6 Air filter case cover 1 7 Screw 3 8 Air filter element 1 9 Bolt 4 A 15 16 17 18 1 14 4 a b 7 9 9 11 11 8 6 5 5 13 12 3 3 10 19 18 16 17 2 È É É Ê Ë 10 N m 1 0 kgf m 7 4 ft Ib 6 12 mm 13 N m 1 3 kgf m 9 6 ft Ib 8 35 mm 6 15 mm 18 N m 1 8 kgf m 13 3 ft Ib LT 242 LT 242 LT 242 6 10 mm 6 N m 0 6 kgf m 4 4 ft Ib A E 3 N m 0 3 kg...

Page 130: ...er pilot outlet on starboard side 15 Clamp cooling water hose 1 1 Ë To cooling water outlet on starboard side of stern 16 Bolt grommet 4 4 17 Bolt 4 18 Stay 4 19 Oil filter 1 Reverse the removal steps for installation A 15 16 17 18 1 14 4 a b 7 9 9 11 11 8 6 5 5 13 12 3 3 10 19 18 16 17 2 È É É Ê Ë 10 N m 1 0 kgf m 7 4 ft Ib 6 12 mm 13 N m 1 3 kgf m 9 6 ft Ib 8 35 mm 6 15 mm 18 N m 1 8 kgf m 13 3 ...

Page 131: ...È LT 572 LT 572 LT 242 LT 242 LT 242 LT 242 A B 6 30 mm 8 N m 0 8 kgf m 5 9 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 8 35 mm 26 N m 2 6 kgf m 19 2 ft Ib 2nd 42 N m 4 2 kgf m 31 0 ft Ib 1st 23 N m 2 3 kgf m 17 0 ft Ib 8 47 mm 2nd 35 N m 3 5 kgf m 25 8 ft Ib 1st 20 N m 2 0 kgf m 14 8 ft Ib 8 120 mm 2nd 42 N m 4 2 kgf m 31 0 ft Ib 1st 23 N m 2 3 kgf m 17 0 ft Ib 10 50 mm 2nd 35 N m 3 5 kgf m 25 8 ft Ib 1st 20...

Page 132: ...LT 572 LT 242 LT 242 LT 242 LT 242 A B 6 30 mm 8 N m 0 8 kgf m 5 9 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 8 35 mm 26 N m 2 6 kgf m 19 2 ft Ib 2nd 42 N m 4 2 kgf m 31 0 ft Ib 1st 23 N m 2 3 kgf m 17 0 ft Ib 8 47 mm 2nd 35 N m 3 5 kgf m 25 8 ft Ib 1st 20 N m 2 0 kgf m 14 8 ft Ib 8 120 mm 2nd 42 N m 4 2 kgf m 31 0 ft Ib 1st 23 N m 2 3 kgf m 17 0 ft Ib 10 50 mm 2nd 35 N m 3 5 kgf m 25 8 ft Ib 1st 20 N m 2 0 ...

Page 133: ...2 N m 0 2 kgf m 1 5 ft Ib 8 35 mm 26 N m 2 6 kgf m 19 2 ft Ib 2nd 42 N m 4 2 kgf m 31 0 ft Ib 1st 23 N m 2 3 kgf m 17 0 ft Ib 8 47 mm 2nd 35 N m 3 5 kgf m 25 8 ft Ib 1st 20 N m 2 0 kgf m 14 8 ft Ib 8 120 mm 2nd 42 N m 4 2 kgf m 31 0 ft Ib 1st 23 N m 2 3 kgf m 17 0 ft Ib 10 50 mm 2nd 35 N m 3 5 kgf m 25 8 ft Ib 1st 20 N m 2 0 kgf m 14 8 ft Ib 11 18 2 1 17 16 24 3 25 19 26 28 22 28 21 12 9 15 11 23 ...

Page 134: ...t 4 2 Electrical box 1 3 Bolt collar 1 1 4 Coupling cover 1 5 Engine mounting bolt 4 6 Shim 7 Engine unit 1 Reverse the removal steps for installation LT 572 LT 271 8 28 mm 17 N m 1 7 kgf m 12 5 ft Ib 8 37 mm 17 N m 1 7 kgf m 12 5 ft Ib 6 25 mm 8 N m 0 8 kgf m 5 9 ft Ib 6 5 3 4 1 7 2 Engine unit ...

Page 135: ...f each engine mount so that it can be installed in its origi nal place Be sure to adjust the coupling clearance 3 Liner 4 4 Bolt 2 5 Damper 1 1 NOTE Install the damper 1 with the mark a toward the bow 4 6 1 5 7 3 2 a LT 572 LT 572 LT 572 6 20 mm 6 N m 0 6 kgf m 4 4 ft Ib 6 12 mm 6 N m 0 6 kgf m 4 4 ft Ib 8 35 mm 17 N m 1 7 kgf m 12 5 ft Ib BOW Engine unit ...

Page 136: ... ty Service points 6 Bolt 2 7 Damper 2 1 Reverse the removal steps for installation 4 6 1 5 7 3 2 a LT 572 LT 572 LT 572 6 20 mm 6 N m 0 6 kgf m 4 4 ft Ib 6 12 mm 6 N m 0 6 kgf m 4 4 ft Ib 8 35 mm 17 N m 1 7 kgf m 12 5 ft Ib BOW Engine unit ...

Page 137: ...he service lid 1 3 Remove the deck beam bolts 2 and nuts and then remove the deck beam 3 1 3 2 4 Disconnect the negative battery cable 4 and positive battery cable 5 from the bat tery 5 4 5 Disconnect the shift cable joint 6 and then remove the shift cable bracket nuts 7 6 Remove the shift cable bracket 8 6 8 7 7 Remove the engine cover bolts 9 and then remove the engine cover 0 NOTE Slide the eng...

Page 138: ...E E 12 Disconnect the fuel pump module coupler F and electric bilge pump coupler G 13 Remove the fuel tank filler cap to reduce the fuel pressure 14 Wrap the quick connector H with a cloth and then disconnect it from the fuel rail Refer to Fuel tank removal in Chapter 4 WARNING Always reduce the fuel pressure in the fuel line before servicing the line or the fuel pipe If the fuel pressure is not r...

Page 139: ... the cooling water hoses O from the oil cooler assembly O O 18 Disconnect the cooling water hose P from the air cooler and cooling water hose Q from the thermostat housing Q P 19 Place a cloth under the oil filter R and then remove it with the special service tool NOTE Be sure to clean up any oil spills Oil filter wrench 90890 06830 R 20 Disconnect the thermo sensor coupler S 21 Remove the breathe...

Page 140: ...sconnect cooling water hose from the hose joint 1 Z 27 Disconnect the cooling water hoses from the hose joint 3 a 28 Remove the stay bolts b and then remove the stay c b c a 29 Remove the clamp d from the pipe e d e 30 Remove the muffler assembly bolts f and then remove the muffler assembly g NOTE When removing the muffler assembly move it forward and separate it from the water lock f g Engine uni...

Page 141: ...ounting bolts l 34 Lift the engine unit slightly remove the shims m and then lower the engine NOTE Make a note of the position of each removed shim so that it can be installed in its original position 35 Remove the engine mounting bolts l l m m l 36 Suspend the engine unit using all 3 engine hangers and then separate the unit from the engine mounts and move it forward to disconnect the coupling En...

Page 142: ... causing damage to the hull and deck opening 38 Lift the engine unit out vertically Breather assembly check CAUTION The breather assembly should not be dis assembled 1 Check Breather assembly Breather hoses Cracks damage Replace the breather assembly Engine mount check 1 Check Engine mounts Cracks damage Replace the engine mounts NOTE When replacing the engine mounts be sure to check the coupling ...

Page 143: ...cally CAUTION When installing the engine unit take care to avoid causing damage to the hull and deck opening 4 Lift the front of the engine unit slightly and lower the unit Repeat this step until the drive and driven couplings are aligned 5 Move the engine unit rearward to connect the coupling 1 and lower the unit onto the engine mounts NOTE Do not install the rubber damper until the cou pling cle...

Page 144: ... coupling clearance a and if necessary add or remove shims 3 so that the clearance is within specification 9 Install the rubber damper 4 10 Adjust the position of the engine unit so that the coupling clearances a and b are within specification Available shim thicknesses 0 10 0 30 0 50 1 00 and 2 00 mm Clearance a Less than 1 0 mm 0 039 in without rubber damper Clearance b 2 0 4 0 mm 0 079 0 157 in...

Page 145: ...d then tighten the electrical box bolts 8 to the specified torque 15 Install the muffler assembly 9 into the water lock and then tighten the muffler assembly bolts 0 to the specified torque in the seguence shown CAUTION Do not reuse the muffler gasket always re place it with a new one Clearance a Less than 0 5 mm 0 020 in with rubber damper Clearance b 2 0 4 0 mm 0 079 0 157 in T R Coupling cover ...

Page 146: ...f m 17 0 ft lb 2nd 42 N m 4 2 kgf m 31 0 ft lb LOCTITE 242 D C B E LT 242 I F H G 21 Install the rectifier regulator J and then tighten the rectifier regulator bolts K to the specified torque 22 Connect the cooling water hoses L 23 Install the breather assembly M and then tighten the breather assembly bolts N to the specified torque 24 Connect the breather hose O and the thermo sensor coupler P T ...

Page 147: ...all the oil filter R with the special ser vice tool Oil filter wrench 90890 06830 T R Oil filter 18 N m 1 8 kgf m 13 3 ft lb R 27 Connect the cooling water hose S to the air cooler and cooling water hose T to the thermostat housing T S 28 Connect the cooling water hoses U to the oil cooler assembly U U Engine unit ...

Page 148: ...r case bolt 13 N m 1 3 kgf m 9 6 ft lb T R Intake pipe clamp 3 N m 0 3 kgf m 2 2 ft lb Z X W Y V 33 Connect the fuel pump module coupler and electric bilge pump coupler 34 Connect the quick connector a to the fuel rail Refer to Fuel tank removal in Chapter 4 a 35 Clamp the wiring harness assembly with 5 plastic ties NOTE Align the plastic ties with the gray tape c on the wiring harness assembly c ...

Page 149: ...t the shift cable joint j NOTE Apply grease to the shift cable joint and shift cable 42 Connect the positive battery cable k and negative battery cable l to the battery NOTE After connecting the battery cables to the bat tery coat the battery cable terminals and bat tery terminals with a water resistance grease to minimize terminal corrosion 43 Install the deck beam m and tighten the deck beam nut...

Page 150: ...pin 2 10 Clamp cooling water hose 1 1 1 2 5 12 11 15 14 16 13 9 8 7 7 9 10 4 3 6 LT 572 LT 242 2 N m 0 2 kgf m 1 5 ft Ib 2nd 35 N m 3 5 kgf m 25 8 ft Ib 1st 20 N m 2 0 kgf m 14 8 ft Ib 8 120 mm 2nd 29 N m 2 9 kgf m 21 4 ft Ib 1st 15 N m 1 5 kgf m 11 1 ft Ib 8 35 mm 2nd 35 N m 3 5 kgf m 25 8 ft Ib 1st 20 N m 2 0 kgf m 14 8 ft Ib 8 70 mm 20 N m 2 0 kgf m 14 8 ft Ib 60 N m 6 0 kgf m 44 3 ft Ib LT 242...

Page 151: ...steps for assembly 1 2 5 12 11 15 14 16 13 9 8 7 7 9 10 4 3 6 LT 572 LT 242 2 N m 0 2 kgf m 1 5 ft Ib 2nd 35 N m 3 5 kgf m 25 8 ft Ib 1st 20 N m 2 0 kgf m 14 8 ft Ib 8 120 mm 2nd 29 N m 2 9 kgf m 21 4 ft Ib 1st 15 N m 1 5 kgf m 11 1 ft Ib 8 35 mm 2nd 35 N m 3 5 kgf m 25 8 ft Ib 1st 20 N m 2 0 kgf m 14 8 ft Ib 8 70 mm 20 N m 2 0 kgf m 14 8 ft Ib 60 N m 6 0 kgf m 44 3 ft Ib LT 242 LT 242 LT 242 Muff...

Page 152: ...st pipe 2 3 Exhaust pipe 3 4 Cracks damage Replace 3 1 4 2 Pipe check 1 Check Pipe Cracks damage Replace the pipe Thermo sensor check 1 Check Thermo sensor tube 1 Bends damage Replace the thermo sensor Exhaust pipe 3 installation 1 Install Exhaust pipe 3 1 Exhaust pipe wrench 90890 06726 T R Exhaust pipe 3 60 N m 6 0 kgf m 44 3 ft lb LOCTITE 242 1 1 Muffler ...

Page 153: ...upler 4 4 Knock sensor coupler 1 5 Thermoswitch coupler 1 6 Plastic tie 1 7 Cam position sensor coupler 1 8 Intake air temperature sensor coupler 1 9 Engine temperature sensor coupler 1 10 Plastic tie 1 SG SG 19 18 20 21 23 24 27 28 25 26 22 11 10 2 16 13 15 17 8 12 6 9 7 4 5 1 3 14 26 12 24 28 25 A A B B a A A 18 N m 1 8 m kg 13 3 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 8 30 mm Electrical box and starter...

Page 154: ...ntake air pressure sensor coupler 1 14 Clamp 3 15 Earth plate coupler 1 1 16 Earth plate coupler 2 1 17 Oil pressure switch coupler 1 18 Nut washer 1 1 19 Starter motor cable 1 SG SG 19 18 20 21 23 24 27 28 25 26 22 11 10 2 16 13 15 17 8 12 6 9 7 4 5 1 3 14 26 12 24 28 25 A A B B a A A 18 N m 1 8 m kg 13 3 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 8 30 mm Electrical box and starter motor ...

Page 155: ...stic tie 1 25 Rectifier regulator coupler 1 26 Stator coil coupler 1 27 Rectifier regulator 1 28 Pick up coil coupler 1 Reverse the removal steps for installation SG SG 19 18 20 21 23 24 27 28 25 26 22 11 10 2 16 13 15 17 8 12 6 9 7 4 5 1 3 14 26 12 24 28 25 A A B B a A A 18 N m 1 8 m kg 13 3 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 8 30 mm Electrical box and starter motor ...

Page 156: ... 15 10 13 16 25 20 21 22 23 24 20 N m 2 0 kgf m 14 8 ft Ib 8 35 mm 20 N m 2 0 kgf m 14 8 ft Ib 8 65 mm 4 N m 0 4 kgf m 3 0 ft Ib 2nd 42 N m 4 2 kgf m 31 0 ft Ib 1st 23 N m 2 3 kgf m 17 0 ft Ib LT 242 LT 242 LT 242 LT 242 42 N m 4 2 kgf m 31 0 ft Ib 10 80 mm 42 N m 4 2 kgf m 31 0 ft Ib 10 50 mm 3 N m 0 3 kgf m 2 2 ft Ib 10 N m 1 0 kgf m 7 4 ft Ib 6 65 mm LT 242 2nd 20 N m 2 0 kgf m 14 8 ft Ib 1st 1...

Page 157: ...Ib 8 35 mm 20 N m 2 0 kgf m 14 8 ft Ib 8 65 mm 4 N m 0 4 kgf m 3 0 ft Ib 2nd 42 N m 4 2 kgf m 31 0 ft Ib 1st 23 N m 2 3 kgf m 17 0 ft Ib LT 242 LT 242 LT 242 LT 242 42 N m 4 2 kgf m 31 0 ft Ib 10 80 mm 42 N m 4 2 kgf m 31 0 ft Ib 10 50 mm 3 N m 0 3 kgf m 2 2 ft Ib 10 N m 1 0 kgf m 7 4 ft Ib 6 65 mm LT 242 2nd 20 N m 2 0 kgf m 14 8 ft Ib 1st 10 N m 1 0 kgf m 7 4 ft Ib 2nd 42 N m 4 2 kgf m 31 0 ft I...

Page 158: ...4 8 ft Ib 8 35 mm 20 N m 2 0 kgf m 14 8 ft Ib 8 65 mm 4 N m 0 4 kgf m 3 0 ft Ib 2nd 42 N m 4 2 kgf m 31 0 ft Ib 1st 23 N m 2 3 kgf m 17 0 ft Ib LT 242 LT 242 LT 242 LT 242 42 N m 4 2 kgf m 31 0 ft Ib 10 80 mm 42 N m 4 2 kgf m 31 0 ft Ib 10 50 mm 3 N m 0 3 kgf m 2 2 ft Ib 10 N m 1 0 kgf m 7 4 ft Ib 6 65 mm LT 242 2nd 20 N m 2 0 kgf m 14 8 ft Ib 1st 10 N m 1 0 kgf m 7 4 ft Ib 2nd 42 N m 4 2 kgf m 31...

Page 159: ... 9 15 17 16 5 N m 0 5 kgf m 3 7 ft Ib 6 25 mm 3 5 N m 0 35 kgf m 2 6 ft Ib 5 15 mm LT 572 15 N m 1 5 kgf m 11 1 ft Ib 6 12 mm 8 N m 0 8 kgf m 5 9 ft Ib 1st 23 N m 2 3 kgf m 17 0 ft Ib 2nd 42 N m 4 2 kgf m 31 0 ft Ib 8 40 mm 1st 23 N m 2 3 kgf m 17 0 ft Ib 2nd 42 N m 4 2 kgf m 31 0 ft Ib 8 25 mm 2nd 20 N m 2 0 kgf m 14 8 ft Ib 1st 10 N m 1 0 kgf m 7 4 ft Ib 8 35 mm 2nd 20 N m 2 0 kgf m 14 8 ft Ib 1...

Page 160: ... 35 kgf m 2 6 ft Ib 5 15 mm LT 572 15 N m 1 5 kgf m 11 1 ft Ib 6 12 mm 8 N m 0 8 kgf m 5 9 ft Ib 1st 23 N m 2 3 kgf m 17 0 ft Ib 2nd 42 N m 4 2 kgf m 31 0 ft Ib 8 40 mm 1st 23 N m 2 3 kgf m 17 0 ft Ib 2nd 42 N m 4 2 kgf m 31 0 ft Ib 8 25 mm 2nd 20 N m 2 0 kgf m 14 8 ft Ib 1st 10 N m 1 0 kgf m 7 4 ft Ib 8 35 mm 2nd 20 N m 2 0 kgf m 14 8 ft Ib 1st 10 N m 1 0 kgf m 7 4 ft Ib 2nd 20 N m 2 0 kgf m 14 8...

Page 161: ...Throttle body assembly 1 3 Gasket 1 Not reusable 4 Bolt 4 5 Joint 1 6 O ring 1 Not reusable 7 Ribbon 1 8 Holder 1 9 Intake manifold 1 Reverse the disassembly steps for assembly 8 7 6 5 3 2 1 9 4 13 N m 1 3 kgf m 9 6 ft Ib 8 20 mm 13 N m 1 3 kgf m 9 6 ft Ib LT 242 Air cooler supercharger and throttle body assembly ...

Page 162: ... water pas sage 2 Cover the other end a of the water pas sage with a finger 3 Apply the specified positive pressure and check that the pressure is maintained 4 Connect the special service tools 2 and 3 to the inlet and outlet of the air cooler air passage 5 Apply the specified positive pressure and check that the pressure is maintained Leakage tester 2 90890 06840 Specified positive pressure water...

Page 163: ... Replace the super charger assembly 1 2 Throttle body assembly check CAUTION The throttle body assembly should not be disassembled 1 Check Throttle shaft 1 Cracks damage Replace the throttle body assembly Throttle valve opening Refer to Throttle position sensor in Chapter 7 1 Intake manifold check 1 Check Intake manifold Cracks damage Replace the intake manifold Air cooler supercharger and throttl...

Page 164: ...e the gasket 2 always replace it with a new one 2 Lubricate the supercharger impeller shaft with engine oil through the oil filler hole a NOTE Turn the supercharger impeller while lubricat ing the supercharger impeller shaft through the hole a 3 Tighten the bolt 1 to the specified torque T R Intake manifold bolt 1st 10 N m 1 0 kgf m 7 4 ft lb 2nd 20 N m 2 0 kgf m 14 8 ft lb LOCTITE 242 Recommended...

Page 165: ...l the air cooler intake hose 1 between the supercharger and air cooler NOTE Make sure that the arrow mark a on the air cooler intake hose 1 is pointing up Make sure that the hose 1 contacts the pro jection b on the air cooler 2 Tighten each clamp 2 to the specified torque NOTE Fit each hose clamp 2 over the white paint mark c on each end of the air cooler intake hose 1 making sure that the fastene...

Page 166: ...mbly between the air cooler assembly 5 and the throttle body assembly 6 NOTE Fit the lip e on the air cooler assembly 5 into the groove f in the hose 2 Fit the lip g on the throttle body assembly 5 into the groove h in the joint 3 4 Tighten the hose clamps 4 to the speci fied torque 5 Tighten the boost pipe bolt 7 to the speci fied torque T R Hose clamp 3 N m 0 3 kgf m 2 2 ft lb T R Hose clamp 3 N...

Page 167: ...cooler assembly 1 6 Connector 2 7 O ring 4 Not reusable 8 Bolt 1 9 Bolt 2 10 Gasket 4 Not reusable 3 4 9 8 11 9 10 10 2 13 16 17 17 15 14 12 7 1 6 7 6 12 mm 8 N m 0 8 kgf m 5 9 ft Ib 11 N m 1 1 kgf m 8 1 ft Ib 6 20 mm 19 N m 1 9 kgf m 14 0 ft Ib 8 70 mm 19 N m 1 9 kgf m 14 0 ft Ib 8 55 mm 18 N m 1 8 kgf m 13 3 ft Ib LT 572 LT 572 LT 572 LT 572 A A A A 10 21 mm 21 N m 2 1 kgf m 15 5 ft Ib 5 Oil coo...

Page 168: ... 2 Reverse the removal steps for installation 3 4 9 8 11 9 10 10 2 13 16 17 17 15 14 12 7 1 6 7 6 12 mm 8 N m 0 8 kgf m 5 9 ft Ib 11 N m 1 1 kgf m 8 1 ft Ib 6 20 mm 19 N m 1 9 kgf m 14 0 ft Ib 8 70 mm 19 N m 1 9 kgf m 14 0 ft Ib 8 55 mm 18 N m 1 8 kgf m 13 3 ft Ib LT 572 LT 572 LT 572 LT 572 A A A A 10 21 mm 21 N m 2 1 kgf m 15 5 ft Ib 5 Oil cooler oil pump assembly and drive gear ...

Page 169: ...t 1 2 Circlip 2 3 Washer 1 4 Bearing 2 5 Collar 1 6 Idle gear 1 7 Washer 1 8 Collar 1 9 Bolt 1 Left hand threads 10 Circlip 1 11 Oil pump drive gear 1 12 Bearing 1 14 15 a 17 16 13 12 11 10 9 8 1 3 2 4 5 6 7 2 80 N m 8 0 kgf m 59 0 ft Ib 12 58 mm E E E E E E Oil cooler oil pump assembly and drive gear ...

Page 170: ...utch is installed so that the side a is facing to ward the supercharger drive gear as shown Check the drive gear clutch operation after installation 17 Supercharger drive gear 1 Reverse the removal steps for installation 14 15 a 17 16 13 12 11 10 9 8 1 3 2 4 5 6 7 2 80 N m 8 0 kgf m 59 0 ft Ib 12 58 mm E E E E E E Oil cooler oil pump assembly and drive gear ...

Page 171: ...t has left hand threads Turn the bolt clockwise to loosen it 4 Remove the drive gear assembly 5 with the special service tools Drive gear disassembly 1 Remove Circlip 1 Oil pump drive gear 2 Bearing 3 Washer 4 Circlip 5 Washer 6 Drive gear clutch 7 Supercharger drive gear 8 Shaft holder 2 90890 06721 Driver handle 3 90890 06722 Bearing puller assembly 6 90890 06535 Stopper guide plate 7 90890 0650...

Page 172: ...r connect the hoses 1 to the oil cooler 1 Connect the special service tool 2 to the inlet of the oil cooler water passage a 2 Cover the outlet of the oil cooler water passage b with a finger 3 Apply the specified positive pressure and check that the pressure is maintained 4 Repeat steps 1 3 to check the oil cooler water passage between c and d Leakage tester 2 90890 06840 Specified positive pressu...

Page 173: ...racks damage Replace the oil pump assembly Oil pump operation Rough movement Replace the oil pump assembly 1 Idle gear check 1 Check Idle gear 1 Cracks damage Replace the idle gear Shaft 2 Bends wear Replace the shaft 1 2 Drive gear check 1 Check Oil pump drive gear 1 Supercharger drive gear 2 Cracks damage Replace 1 2 Oil cooler oil pump assembly and drive gear ...

Page 174: ...ger drive gear 1 2 Install the oil pump drive gear 2 onto the supercharger drive gear 1 3 Hold the oil pump drive gear 2 4 Turn the supercharger drive gear 1 coun terclockwise È and check that it does not turn 5 Turn the supercharger drive gear 1 clock wise É and check that it turns smoothly a 1 2 È É Oil pump drive gear assembly 1 Install Bearing NOTE Use a pipe that is at least 22 mm 0 87 in lon...

Page 175: ... Apply engine oil to the threads of the drive gear assembly bolt The drive gear assembly bolt has left hand threads Turn the bolt counterclockwise to tighten it 3 Install the generator cover and drive cou pling Refer to Generator cover and flywheel magneto removal Shaft holder 2 90890 06721 Driver handle 3 90890 06722 T R Drive gear assembly bolt 80 N m 8 0 kgf m 59 0 ft lb 1 2 3 4 Oil cooler oil ...

Page 176: ...avenge port b NOTE The oil level should be up to the brim 2 Turn the driven gear 1 of the oil pump clockwise while filling the oil pump assem bly 3 Continue filling the oil pump assembly until engine oil comes out of the ports c 2 Install Oil pump assembly Recommended engine oil SAE 10W 30 10W 40 20W 40 or 20W 50 API SE SF SG SH SJ or SL T R Oil pump assembly bolt 11 N m 1 1 kgf m 8 1 ft lb LOCTIT...

Page 177: ...t 8 5 Ignition coil 4 6 Spark plug 4 7 Bolt 1 8 Cam position sensor 1 9 Bolt 8 10 Cylinder head cover 1 11 Gasket 1 Not reusable 12 Timing chain guide upper 1 Reverse the removal steps for installation 4 10 2 5 3 12 9 6 11 7 8 1 1 È LT 572 LT 572 LT 572 1280B 8 N m 0 8 kgf m 5 9 ft Ib 6 20 mm 8 N m 0 8 kgf m 5 9 ft Ib 6 30 mm A A A A 25 N m 2 5 kgf m 18 4 ft lb 6 15 mm 10 N m 1 0 kgf m 7 4 ft lb C...

Page 178: ... Yellow paint 9 Bolt 2 NOTE Loosen the timing chain tensioner bolts evenly d 16 19 18 17 19 18 23 22 21 20 12 24 9 6 7 8 7 a 10 11 1 2 4 13 13 15 14 15 15 14 15 5 3 E E E E c 6 14 mm 8 N m 0 8 kgf m 5 9 ft Ib 10 N m 1 0 kgf m 7 4 ft Ib 6 25 mm 10 N m 1 0 kgf m 7 4 ft Ib 6 30 mm LT 572 LT 572 E E 7 11 mm 24 N m 2 4 kgf m 17 7 ft Ib 7 45 mm 16 N m 1 6 kgf m 11 8 ft Ib 20 N m 2 0 kgf m 14 8 ft Ib 10 ...

Page 179: ...l low paint c Install each camshaft sprocket with the punch mark d facing outward 15 Camshaft cap 4 16 Intake camshaft 1 17 Exhaust camshaft 1 18 Bolt 4 19 Camshaft sprocket 2 d 16 19 18 17 19 18 23 22 21 20 12 24 9 6 7 8 7 a 10 11 1 2 4 13 13 15 14 15 15 14 15 5 3 E E E E c 6 14 mm 8 N m 0 8 kgf m 5 9 ft Ib 10 N m 1 0 kgf m 7 4 ft Ib 6 25 mm 10 N m 1 0 kgf m 7 4 ft Ib 6 30 mm LT 572 LT 572 E E 7 ...

Page 180: ...se the removal steps for installation d 16 19 18 17 19 18 23 22 21 20 12 24 9 6 7 8 7 a 10 11 1 2 4 13 13 15 14 15 15 14 15 5 3 E E E E c 6 14 mm 8 N m 0 8 kgf m 5 9 ft Ib 10 N m 1 0 kgf m 7 4 ft Ib 6 25 mm 10 N m 1 0 kgf m 7 4 ft Ib 6 30 mm LT 572 LT 572 E E 7 11 mm 24 N m 2 4 kgf m 17 7 ft Ib 7 45 mm 16 N m 1 6 kgf m 11 8 ft Ib 20 N m 2 0 kgf m 14 8 ft Ib 10 21 mm M M b Camshaft ...

Page 181: ... reached TDC 3 Check that the punch marks a on the camshafts are aligned with the marks b on the camshaft caps Gauge stand 1 90890 06725 Dial gauge stand set YB 06585 Dial gauge 2 YU 03097 90890 01252 Dial gauge needle 90890 06584 Coupler wrench 4 90890 06729 1 2 3 4 1 2 3 4 b a 4 Make alignment marks c on the camshaft sprockets and camshafts c 5 Remove the timing chain tensioner 5 and gasket NOTE...

Page 182: ... 4 6 0 0 1 5 8 3 A B B A EX IN d 8 Remove the intake camshaft 7 and exhaust camshaft 8 NOTE To prevent the timing chain from falling into the crankcase secure it with a wire 9 7 8 9 IN EX 9 Hold each camshaft sprocket with the spe cial service tool 0 and then loosen the bolts A 10 Remove the exhaust camshaft sprocket B and intake camshaft sprocket C Camshaft wrench 0 90890 06724 BC 0 A Camshaft ...

Page 183: ...am shaft Camshaft lobe dimensions Intake a 40 9 mm 1 610 in b 32 0 mm 1 260 in Exhaust a 41 0 mm 1 614 in b 32 2 mm 1 268 in 3 Measure Camshaft runout Out of specification Replace the cam shaft Camshaft runout limit 0 015 mm 0 0006 in 4 Measure Camshaft journal diameter a Out of specification Replace the cam shaft Camshaft journal diameter a 24 960 24 980 mm 0 9827 0 9835 in Camshaft ...

Page 184: ... the oil hole in the camshaft journal 4 Install the camshaft caps and bolts 5 Gradually tighten the camshaft cap bolts to the specified torque in the sequence shown NOTE Apply engine oil to the threads of the cam shaft cap bolts Make sure to keep the camshafts level Do not turn the camshafts when measuring the camshaft journal to camshaft cap clear ance with the Plastigauge 6 Remove the camshaft c...

Page 185: ...ing the timing chain tensioner rod 1 turn the timing chain tensioner housing 2 in direction È until the groove a in the tensioner rod is aligned with the snap ring 3 2 While squeezing the end of the snap ring 3 so that it fits into the groove a in the timing chain tensioner rod 1 slowly release the tensioner rod until it is locked in place NOTE Make sure that the timing chain tensioner rod 1 is lo...

Page 186: ...t marks b made during removal Apply engine oil to the threads of the cam shaft sprocket bolts 3 Install the exhaust camshaft 3 and then intake camshaft 4 NOTE Make sure that the punch marks c on the camshafts face up When installing the exhaust camshaft 3 make sure that the exhaust side d of the timing chain is taut Apply molybdenum disulfide grease to the camshaft journals camshaft journal bear i...

Page 187: ...n tensioner housing 6 in direction È until the groove f in the tensioner rod is aligned with the snap ring 10 While squeezing the end of the snap ring 7 so that it fits into the groove f in the timing chain tensioner rod 5 slowly release the tensioner rod until it is locked in place 11 Install a new gasket and the timing chain tensioner 8 onto the cylinder block and then tighten the timing chain t...

Page 188: ...hain is taut again g 14 Position piston 1 at TDC Refer to Camshaft removal 15 Check that the punch marks c of the cam shaft are aligned with the alignment marks e on the camshaft caps If the punch marks are not aligned reinstall the cam shafts e c Cylinder head cover installation 1 Install Cylinder head cover gasket 1 Cylinder head cover 2 NOTE Apply sealant onto the locations a of the new cylinde...

Page 189: ...ct the proper valve pad from the fol lowing table NOTE The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter 4 Round off the original valve pad number according to the following table 5 Select the new valve pad number from the valve pad selection table 6 Apply the valve pad and valve lifter with engine oil 7 Install the selected valve pa...

Page 190: ... Position piston 2 at TDC by turning the drive coupling an additional 180 counter clockwise and then measure the intake and exhaust valve clearances for cylinder 2 15 Position piston 4 at TDC by turning the drive coupling an additional 180 counter clockwise and then measure the intake and exhaust valve clearances for cylinder 4 16 Position piston 3 at TDC by turning the drive coupling an additiona...

Page 191: ...0 MEASURED CLEARANCE 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 0 00 0 01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 0 02 0 04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 0 05 0 09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 0 10 0 14 120 125 130 135 1...

Page 192: ...ead bolt 10 Not reusable 5 Washer 10 6 Cylinder head assembly 1 7 Gasket 1 Not reusable 8 Dowel pin 2 Reverse the removal steps for installation 7 6 8 8 4 5 10 N m 1 0 kgf m 7 4 ft Ib 6 55 mm LT 242 LT 242 E E 12 N m 1 2 kgf m 8 9 ft Ib 6 12 mm 2nd 90 1st 48 N m 4 8 kgf m 35 4 ft Ib 12 140 mm 12 N m 1 2 kgf m 8 9 ft Ib 6 12 mm 1 2 2 1 3 Cylinder head ...

Page 193: ...alve pad 16 3 Valve cotter 32 4 Upper spring seat 16 5 Valve spring 16 6 Lower spring seat 16 7 Intake valve 8 8 Exhaust valve 8 9 Valve seal 16 Not reusable 10 Valve guide 16 Not reusable 11 Cylinder head 1 Reverse the disassembly steps for assembly E E E E 8 9 9 1 1 2 2 3 3 3 4 4 5 5 6 6 7 3 10 10 11 M M M Cylinder head ...

Page 194: ...eir original positions 1 2 2 Remove Valve cotters 1 Upper spring seat 2 Valve spring 3 Lower spring seat 4 Valve 5 Valve seal 6 NOTE Make a note of the position of each valve spring and other part so that they can be installed in their original positions Valve spring compressor 7 YM 04019 90890 04019 Compressor adapter 8 YM 04114 Valve spring compressor attachment 8 90890 04114 8 7 5 6 4 3 2 1 Cyl...

Page 195: ...head warpage limit 0 1 mm 0 004 in 1 2 Valve spring check 1 Measure Valve spring free length a Out of specification Replace the valve spring Valve spring free length a Intake and exhaust 45 58 mm 1 794 in a 2 Measure Valve spring tilt a Out of specification Replace the valve spring Valve spring tilt limit a Intake and exhaust 2 0 mm 0 08 in Valve check NOTE To ensure accurate measurements be sure ...

Page 196: ...ce the valve Valve margin thickness b Intake and exhaust 0 80 1 20 mm 0 031 0 047 in b 3 Measure Valve stem diameter a Out of specification Replace the valve Valve stem diameter a Intake 5 477 5 492 mm 0 2156 0 2162 in Exhaust 5 464 5 479 mm 0 2151 0 2157 in 4 Measure Valve stem runout Out of specification Replace the valve Valve stem runout limit Intake and exhaust 0 01 mm 0 0004 in Cylinder head...

Page 197: ...lve guide Valve stem to valve guide clearance valve guide inside diameter valve stem diameter Intake 0 012 0 045 mm 0 0005 0 0018 in Exhaust 0 025 0 058 mm 0 0010 0 0023 in Valve guide removal 1 Remove Valve guide 1 Removal steps 1 Insert the special service tool 2 into the combustion chamber end of the valve guide 1 2 Strike the special service tool to drive the valve guide out of the cylinder he...

Page 198: ...ve guide and surface of the special ser vice tool 4 Turn the valve guide reamer clockwise to ream the valve guide Do not turn the special service tool 4 coun terclockwise when removing the tool 4 Clean the valve guide inner surface 5 Measure the valve guide inside diameter Valve guide remover 2 YB 06801 90890 06801 Valve guide installer 3 YB 06810 90890 06810 Valve guide installation height a Inta...

Page 199: ...at 3 Press the valve lightly against the valve seat with a valve lapper commercially available 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 Intake 1 ...

Page 200: ... refacing the valve seat 1 Reface Valve seats Neway valve seat kit YB 91044 Valve seat cutter holder 90890 06812 Valve seat cutter 30 intake 90890 06720 45 intake 90890 06325 60 intake 90890 06324 30 exhaust 90890 06818 45 exhaust 90890 06555 60 exhaust 90890 06323 Refacing steps 1 Cut the surface of the valve seat with a 45 cutter by turning the cutter clockwise until the valve seat face has beco...

Page 201: ...e valve seat contact area of the valve Refer to Valve seat check 45 b c Example If the valve seat contact width is too wide and situated in the center of the valve face use a 30 cutter to cut the top edge of the valve seat and then use a 60 cutter to cut the bot tom edge to center the area and set its width b Previous contact width 30 60 b If the valve seat contact width is too narrow and situated...

Page 202: ...layer of lapping compound onto the valve seat and then lap the valve using a valve lapper commercially available CAUTION Do not get the lapping compound on the valve stem and valve guide 7 After every lapping procedure be sure to clean off any remaining lapping compound from the cylinder head and the valves 8 Check the valve seat contact area of the valve again Refer to Valve seat check NOTE After...

Page 203: ...equence shown and then attach the special service tools 7 and 8 NOTE When installing a new valve always replace the valve guide and valve seal with new ones Install the valve spring with the larger pitch a toward the camshaft and the smaller pitch b toward the combustion chamber The end c of the valve spring with the larger pitch is painted red Valve spring compressor 7 YM 04019 90890 04019 Compre...

Page 204: ...ation steps 1 Pass the timing chain 1 through the tim ing chain cavity 2 Apply engine oil to the cylinder head bolts 3 Tighten the cylinder head bolts 2 and 3 to the specified torques in the sequence shown NOTE Use a commercially available angle gauge to tighten the bolts to the specified angle T R Cylinder head bolt M12 140 mm 2 1st 48 N m 4 8 kgf m 35 4 ft lb 2nd 90 Cylinder head bolt M6 55 mm 3...

Page 205: ...sher 2 2 7 Bracket 2 8 Clamp hose 1 1 9 Bolt 9 10 Clamp 1 11 Generator cover assembly 1 12 O ring 1 Not reusable 13 Dowel pin 2 13 2 8 7 6 3 1 4 5 9 8 6 6 10 9 7 12 19 18 14 16 a 15 21 11 20 LT 572 LT 242 E 120 N m 12 0 kgf m 88 5 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 6 20 mm 80 N m 8 0 kgf m 59 0 ft Ib 26 N m 2 6 kgf m 19 2 ft Ib 8 50 mm LT 572 LT 572 24 N m 2 4 kgf m 17 7 ft Ib 8 20 mm E E A A 17 17 G...

Page 206: ...side a is facing toward the flywheel mag neto as shown 19 Starter gear 1 20 Idle gear 1 21 Shaft 1 Reverse the removal steps for installation 13 2 8 7 6 3 1 4 5 9 8 6 6 10 9 7 12 19 18 14 16 a 15 21 11 20 LT 572 LT 242 E 120 N m 12 0 kgf m 88 5 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 6 20 mm 80 N m 8 0 kgf m 59 0 ft Ib 26 N m 2 6 kgf m 19 2 ft Ib 8 50 mm LT 572 LT 572 24 N m 2 4 kgf m 17 7 ft Ib 8 20 mm E...

Page 207: ...sembly 1 8 Oil seal 1 Not reusable 9 Circlip 1 10 Bearing 1 Not reusable 11 Generator cover 1 Reverse the disassembly steps for assembly 8 9 10 11 3 2 1 7 4 6 5 LT 242 A A A A E LT 242 15 N m 1 5 kgf m 11 1 ft lb 6 15 mm 5 N m 0 5 kgf m 3 7 ft Ib 5 15 mm LT 242 5 N m 0 5 kgf m 3 7 ft Ib 5 10 mm 15 N m 1 5 kgf m 11 1 ft lb 6 30 mm LT 242 EP Generator cover and flywheel magneto ...

Page 208: ...vice tool 3 Crankshaft holder 2 YB 06562 90890 06562 Coupler wrench 3 90890 06729 1 3 2 Flywheel magneto removal 1 Remove Transfer shaft 1 Removal step 1 Hold the flywheel magneto 2 with the spe cial service tools 3 and 4 and then remove the transfer shaft 1 with the spe cial service tool 5 Shaft holder 3 90890 06721 Driver handle 4 90890 06722 Crankshaft holder 5 YB 06562 90890 06562 5 3 1 2 4 Ge...

Page 209: ... 1 2 3 4 1 5 Bearing removal 1 Remove Oil seal1 Circlip 2 Bearing 3 NOTE Be sure to remove the circlip before removing the bearing È For USA and Canada É For worldwide Idle gear and shaft check 1 Check Shaft 1 Bends wear Replace the idle gear shaft Idle gear 2 Cracks damage Replace the idle gear Driver handle small YB 06229 Bearing and seal installer YW 06356 Driver rod LS 90890 06606 Bearing oute...

Page 210: ...amage Replace the starter gear 3 Check Starter clutch operation Does not operate properly Replace the starter clutch assembly Checking steps 1 Install the starter clutch assembly 1 onto the starter gear 2 and hold the starter clutch assembly 2 Turn the starter gear clockwise È and check that it turns smoothly 3 Turn the starter gear counterclockwise É and check that it does not turn 1 2 È É Genera...

Page 211: ...6071 Forward gear outer race installer YB 41446 Driver rod LS 90890 06606 Ball bearing attachment 90890 06657 A A E 2 1 È 2 1 A A E É Oil seal installation CAUTION Do not reuse the oil seal always replace it with a new one 1 Install Oil seal 1 È For USA and Canada É For worldwide Forward bearing race installer YB 06258 Bearing pressure C 90890 02393 1 A A EP È EP 1 A A É Generator cover and flywhe...

Page 212: ...ickup coil bolt 7 5 N m 0 5 kgf m 3 7 ft lb LOCTITE 242 7 a 1 5 4 2 2 3 6 Flywheel magneto installation 1 Install Starter clutch assembly 1 Flywheel magneto 2 Bolts 3 CAUTION Make sure that the starter clutch is in stalled into the outer flange so that the side a is facing toward the flywheel magneto as shown NOTE Apply engine oil to the starter clutch rollers before installation T R Flywheel magn...

Page 213: ... and the inner surface b of the flywheel magneto 3 2 Hold the flywheel magneto 3 with the spe cial service tools 5 and 6 and then tighten the transfer shaft 4 with the spe cial service tool 7 NOTE Apply engine oil the threads of the crankshaft before installing the transfer shaft Shaft holder 5 90890 06721 Driver handle 6 90890 06722 Crankshaft holder 7 YB 06562 90890 06562 T R Transfer shaft 120 ...

Page 214: ...the transfer shaft with the special ser vice tool 2 and then tighten the drive cou pling 1 with the special service tool 3 Crankshaft holder 2 YB 06562 90890 06562 Coupler wrench 3 90890 06729 T R Drive coupling 80 N m 8 0 kgf m 59 0 ft lb LOCTITE 572 3 2 1 Generator cover and flywheel magneto ...

Page 215: ...6 5 4 1 2 3 8 40 mm 20 N m 2 0 kgf m 14 8 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 6 20 mm LT 572 LT 8 N m 0 8 kgf m 5 9 ft Ib 6 35 mm 8 N m 0 8 kgf m 5 9 ft Ib 6 25 mm 8 N m 0 8 kgf m 5 9 ft Ib A A A A LT 242 LT 10 N m 1 0 kgf m 7 4 ft Ib 6 35 mm 10 N m 1 0 kgf m 7 4 ft Ib 6 20 mm 10 N m 1 0 kgf m 7 4 ft Ib 6 30 mm 2 N m 0 2 kgf m 1 5 ft Ib 4 8 mm 15 N m 1 5 kgf m 11 1 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 8 ...

Page 216: ...4 1 2 3 8 40 mm 20 N m 2 0 kgf m 14 8 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 6 20 mm LT 572 LT 8 N m 0 8 kgf m 5 9 ft Ib 6 35 mm 8 N m 0 8 kgf m 5 9 ft Ib 6 25 mm 8 N m 0 8 kgf m 5 9 ft Ib A A A A LT 242 LT 10 N m 1 0 kgf m 7 4 ft Ib 6 35 mm 10 N m 1 0 kgf m 7 4 ft Ib 6 20 mm 10 N m 1 0 kgf m 7 4 ft Ib 6 30 mm 2 N m 0 2 kgf m 1 5 ft Ib 4 8 mm 15 N m 1 5 kgf m 11 1 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 8 N m ...

Page 217: ...mm 20 N m 2 0 kgf m 14 8 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 6 20 mm LT 572 LT 8 N m 0 8 kgf m 5 9 ft Ib 6 35 mm 8 N m 0 8 kgf m 5 9 ft Ib 6 25 mm 8 N m 0 8 kgf m 5 9 ft Ib A A A A LT 242 LT 10 N m 1 0 kgf m 7 4 ft Ib 6 35 mm 10 N m 1 0 kgf m 7 4 ft Ib 6 20 mm 10 N m 1 0 kgf m 7 4 ft Ib 6 30 mm 2 N m 0 2 kgf m 1 5 ft Ib 4 8 mm 15 N m 1 5 kgf m 11 1 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 8 N m 0 8 kgf m 5 9...

Page 218: ...kgf m 5 9 ft Ib 6 20 mm LT 572 LT 8 N m 0 8 kgf m 5 9 ft Ib 6 35 mm 8 N m 0 8 kgf m 5 9 ft Ib 6 25 mm 8 N m 0 8 kgf m 5 9 ft Ib A A A A LT 242 LT 10 N m 1 0 kgf m 7 4 ft Ib 6 35 mm 10 N m 1 0 kgf m 7 4 ft Ib 6 20 mm 10 N m 1 0 kgf m 7 4 ft Ib 6 30 mm 2 N m 0 2 kgf m 1 5 ft Ib 4 8 mm 15 N m 1 5 kgf m 11 1 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 6 20 mm 8 N m 0 8 kgf m 5 9 ft Ib ...

Page 219: ...3 6 Oil pipe 1 1 7 Oil pipe 2 1 8 Gasket 1 1 Not reusable 9 Gasket 2 1 Not reusable 10 Grommet 1 11 Oil pan 1 Reverse the disassembly steps for assembly 5 5 10 1 2 8 4 3 3 6 11 9 7 12 N m 1 2 kgf m 8 9 ft Ib 6 14 mm 12 N m 1 2 kgf m 8 9 ft Ib 6 14 mm 6 60 mm 9 N m 0 9 kgf m 6 6 ft Ib 9 N m 0 9 kgf m 6 6 ft Ib 6 35 mm 3 3 LT 271 LT 271 Oil separator tank and oil pan ...

Page 220: ...1 Clog contaminants Clean the baffle plate Cracks damage Replace the baffle plate Oil pan 2 Cracks damage Replace the oil pan 1 2 2 Check Oil pipe Clog contaminants Clean the oil pipe Cracks damage Replace the oil pipe Oil separator tank and oil pan ...

Page 221: ...ate 1 7 Bolt 12 8 Bolt 10 Not reusable 9 Crankcase 1 10 Dowel 1 20 1T Y 2T 21 22 19 18 17 24 23 15 15 1 14 13 10 11 2 1 4 4 9 8 6 5 3 12 12 25 4 7 1 2 16 3 1 4 1280B 10 30 mm 50 N m 5 0 kgf m 36 9 ft Ib 10 N m 1 0 kgf m 7 4 ft Ib 6 12 mm 10 N m 1 0 kgf m 7 4 ft Ib 6 70 mm E E E E E E E 2nd 90 1st 51 N m 5 1 kgf m 37 6 ft Ib 2nd 90 1st 30 N m 3 0 kgf m 22 1 ft Ib 10 85 mm A A LT 271 E M M M M M Cra...

Page 222: ... 8 Not reusable 18 Piston pin 4 19 Piston 4 20 1T Y 2T 21 22 19 18 17 24 23 15 15 1 14 13 10 11 2 1 4 4 9 8 6 5 3 12 12 25 4 7 1 2 16 3 1 4 1280B 10 30 mm 50 N m 5 0 kgf m 36 9 ft Ib 10 N m 1 0 kgf m 7 4 ft Ib 6 12 mm 10 N m 1 0 kgf m 7 4 ft Ib 6 70 mm E E E E E E E 2nd 90 1st 51 N m 5 1 kgf m 37 6 ft Ib 2nd 90 1st 30 N m 3 0 kgf m 22 1 ft Ib 10 85 mm A A LT 271 E M M M M M Crankcase connecting ro...

Page 223: ...assembly steps for assembly 20 1T Y 2T 21 22 19 18 17 24 23 15 15 1 14 13 10 11 2 1 4 4 9 8 6 5 3 12 12 25 4 7 1 2 16 3 1 4 1280B 10 30 mm 50 N m 5 0 kgf m 36 9 ft Ib 10 N m 1 0 kgf m 7 4 ft Ib 6 12 mm 10 N m 1 0 kgf m 7 4 ft Ib 6 70 mm E E E E E E E 2nd 90 1st 51 N m 5 1 kgf m 37 6 ft Ib 2nd 90 1st 30 N m 3 0 kgf m 22 1 ft Ib 10 85 mm A A LT 271 E M M M M M Crankcase connecting rod and piston ...

Page 224: ...Remove Crankcase NOTE Insert a flat head screwdriver between the reinforced portions a of the cylinder block 1 and the crankcase 2 to separate them Work carefully and make sure the crankcase halves separate evenly a 1 2 a Connecting rod and piston removal 1 Remove Nuts 1 Connecting rod caps 2 Big end bearings 3 NOTE For reference during installation put identifica tion marks a on the connecting ro...

Page 225: ...on crown and con necting rod 3 Remove Top ring 2nd ring Oil ring a a 4 5 Crankcase check 1 Check Crankcase Cracks damage Replace the crank case assembly Oil delivery passage a Oil spray passage b Obstruction Blow out with com pressed air a b Anode check 1 Check Anode 1 Eroded Replace the anode CAUTION Do not oil or grease the anode otherwise it will be ineffective 1 Crankcase connecting rod and pi...

Page 226: ...iston outside diameter a 85 915 85 930 mm 3 3825 3 3831 in Measuring point b 10 0 mm 0 39 in a b 3 Measure Piston pin boss bore diameter a Out of specification Replace the pis ton NOTE When measuring the piston pin boss bore do not measure it at the oil grooves b or ring groove c Piston pin boss bore diameter a 22 004 22 015 mm 0 8663 0 8667 in c b b a Crankcase connecting rod and piston ...

Page 227: ... 112 0 120 in 2nd ring b B 1 17 1 19 mm 0 0461 0 0469 in T 2 60 2 80 mm 0 102 0 110 in Oil ring c B 2 37 2 47 mm 0 093 0 097 in T reference data 2 50 mm 0 098 in c B T T B b a T B 2 Measure Piston ring end gap a Piston ring end gap a reference data Top ring 0 30 0 45 mm 0 012 0 018 in 2nd ring 0 45 0 60 mm 0 018 0 024 in Oil ring 0 10 0 35 mm 0 004 0 014 in Measuring point b 5 mm 0 2 in a b Crankc...

Page 228: ...ide 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 Piston ring side clearance Top ring a 0 02 0 06 mm 0 0008 0 0024 in 2nd ring b 0 02 0 06 mm 0 0008 0 0024 in Oil ring c 0 04 0 16 mm 0 0016 0 0063 in Piston pin check 1 Measure Piston pin o...

Page 229: ... der block 2 Measure Cylinder bore D1 D6 Out of specification Replace the cyl inder block Measurement step 1 Measure the cylinder bore D1 D6 at mea suring points a b and c and in direc tions D1 D3 and D5 which are parallel to the crankshaft and directions D2 D4 and D6 which are at a right angle to the crank shaft Cylinder bore D1 D6 86 000 86 015 mm 3 3858 3 3864 in Measuring points a 20 mm 0 8 in...

Page 230: ...nkshaft pin b diameter 41 976 42 000 mm 1 6526 1 6535 in a b 2 Measure Crankshaft runout Out of specification Replace the crankshaft Crankshaft runout limit 0 03 mm 0 0012 in Crankshaft pin oil clearance check 1 Measure Crankshaft pin oil clearance Out of specification Replace the con necting rod bearings Measurement steps 1 Clean the bearings and connecting rod big end Crankcase connecting rod an...

Page 231: ...gine oil to the connecting rod bolts threads and nut seats Make sure that the Y mark b on the con necting rod faces towards the timing chain drive gear c of the crankshaft Make sure that the characters d on both the connecting rod and connecting rod cap are aligned 5 Tighten the connecting rod nuts to the specified torques in 2 stages NOTE Do not turn the connecting rod until the crank shaft pin o...

Page 232: ...or the con necting rod bearing from the table Example P1 connecting rod size number 5 P1 crankshaft pin size number 1 5 1 4 Select the size 4 green connecting rod bearing Calculation formula Connecting rod bearing size number connecting rod size number a crankshaft pin size number b Bearing size number Bearing color c 1 Brown 2 Black 3 Blue 4 Green 5 F a b P3 P4 P2 P1 P3 P4 P2 P1 P J Crankcase con...

Page 233: ...ft journal bearings in their original positions Insert the projection a of each bearing into the slots in the cylinder block 4 Install the crankshaft 5 Put a piece of Plastigauge 2 on each crankshaft journal parallel to the crank shaft NOTE Do not put the Plastigauge over the oil hole in the main journals of the crankshaft 6 Install the remaining half of the main bear ings into the crankcase NOTE ...

Page 234: ...l oil clearance measurement has been completed 9 Remove the crankcase and measure the width b of the compressed Plastigauge on each crankshaft journal T R Crankcase bolt 1 0 1st 30 N m 3 0 kgf m 22 1 ft lb 2nd 90 Crankcase bolt A L 10 N m 1 0 kgf m 7 4 ft lb Crankshaft journal oil clearance 0 024 0 053 mm 0 0009 0 0021 in EX IN 7 5 1 3 9 0 4 2 6 8 J L D B F H G K E A C I E b Crankcase connecting r...

Page 235: ...t journal size number b on crankshaft web 3 Select the suitable color c for main bear ing Example J1 crankcase journal size number 5 J1 crankshaft journal size number 2 5 2 3 Select the size 3 blue main bearing Calculation formula Main bearing size number crankcase journal size number a crankshaft journal size number b Bearing size number Bearing color c 1 Brown 2 Black 3 Blue 4 Green 5 Yellow J1 ...

Page 236: ...e that the Y mark a on the connecting rod faces towards the front mark b on the piston crown Do not allow the piston pin clip ends to align with the piston pin slot c M 1 4 c 4 3 b 5 2 Install Oil ring 1 2nd ring 2 Top ring 3 CAUTION Do not scratch the pistons or break the pis ton rings NOTE Be sure to install the piston rings so that the 1T mark on the top ring and the 2T mark on the 2nd ring fac...

Page 237: ...cap 2 NOTE Install the connecting rod bearings in their original positions Insert the projections a of the bearings into the slots in the connecting rod cap and con necting rod Align the characters b on the connecting rod cap and connecting rod 3 While compressing the piston rings with the special service tool install the con necting rod assembly into the cylinder 5 Tighten Connecting rod nuts 1 N...

Page 238: ...pply engine oil to the threads of the crank case bolts and flange surface of the crankcase bolts Installing steps 1 Tighten the crankcase bolts 1 0 to the specified torque in 2 stages in the sequence shown NOTE Use a commercially available angle gauge to tighten the bolts to the specified angle 2 Tighten the bolts A L to the specified torques in the sequence shown T R Crankcase bolt 1 0 1st 30 N m...

Page 239: ... POWR 1 2 3 4 5 6 7 8 9 3 Tighten Bracket bolts NOTE Tighten the bolts a and then tighten the bolts b T R Bracket bolt 50 N m 5 0 kgf m 36 9 ft lb LOCTITE 271 a b a b LT 271 Crankcase connecting rod and piston ...

Page 240: ...WR Cooling water Cooling water hose routing 1 Hose joint 2 2 Hose joint 3 È To hose joint 1 É To cooling water pilot outlet on port side Ê To cooling water pilot outlet on starboard side 1 2 È Ê É É Cooling water ...

Page 241: ...tep Procedure Part name Q ty Service points 1 Clamp cooling water hose 1 1 È To drain joint 2 Bolt 2 3 Thermostat housing 1 4 Thermostat 1 NOTE Install the thermostat so that the hole a is positioned as shown Reverse the removal steps for installation UP È É Ê 2 1 1 3 4 2 4 a 2 3 6 35 mm 8 N m 0 8 kgf m 5 9 ft Ib LT 572 Cooling water ...

Page 242: ... specification Replace the ther mostat Checking steps 1 Suspend the thermostat 1 in a container of water 2 Place a thermometer in the water and slowly heat the water 3 Measure the thermostat valve opening a at the specified water temperatures Water temperature Valve opening 48 52 C 118 126 F 0 05 mm 0 002 in valve begins to open above 60 C 140 F more than 4 3 mm 0 17 in 1 Cooling water ...

Page 243: ...5 118 E POWR 1 2 3 4 5 6 7 8 9 MEMO Cooling water ...

Page 244: ...nozzle and nozzle ring removal 6 8 Impeller duct and impeller housing 6 9 Impeller duct and impeller housing removal 6 9 Impeller duct and drive shaft 6 10 Impeller duct and drive shaft disassembly 6 10 Drive shaft removal 6 12 Impeller check 6 14 Impeller housing check 6 14 Drive shaft check 6 14 Drive shaft installation 6 15 Impeller duct and impeller housing installation 6 17 Transom plate and ...

Page 245: ...emoval 6 25 Driven coupling removal 6 25 Intermediate drive shaft removal 6 25 Oil seal removal 6 26 Bearing removal 6 26 Intermediate drive shaft and grease hose check 6 26 Driven coupling and intermediate housing check 6 27 Bearing installation 6 27 Oil seal installation 6 28 Driven coupling installation 6 29 Intermediate housing installation 6 29 ...

Page 246: ...Screw 4 5 Speed sensor 1 FX SHO Speed and water temperature sensor 1 FX Cruiser SHO 6 Ride plate 1 7 Spacer 1 Reverse the removal steps for installation 2 5 4 2 1 3 6 2 7 LT 572 LT LT 572 LT LT 242 LT LT 242 LT LT 242 LT 6 30 mm 8 N m 0 8 kgf m 5 9 ft Ib 8 35 mm 17 N m 1 7 kgf m 12 5 ft Ib 5 12 mm 4 N m 0 4 kgf m 3 0 ft Ib LT 572 LT Intake grate and ride plate ...

Page 247: ...nt 1 5 Clamp bilge hose 1 1 6 Clamp spout hose 1 1 7 Bolt collar 6 6 8 Rubber plate 2 9 Bolt 1 10 Bolt 4 8 13 mm 15 N m 1 5 kgf m 11 1 ft Ib 6 22 mm 7 N m 0 7 kgf m 5 2 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 6 30 mm 2 N m 0 2 kgf m 1 5 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 10 45 mm 40 N m 4 0 kgf m 29 5 ft Ib 4 15 2 3 10 12 3 5 9 1 11 LT 572 LT 5 LT 572 LT LT 572 LT LT 242 M LT 572 LT...

Page 248: ... removal steps for installation 8 13 mm 15 N m 1 5 kgf m 11 1 ft Ib 6 22 mm 7 N m 0 7 kgf m 5 2 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 6 30 mm 2 N m 0 2 kgf m 1 5 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 10 45 mm 40 N m 4 0 kgf m 29 5 ft Ib 4 15 2 3 10 12 3 5 9 1 11 LT 572 LT 5 LT 572 LT LT 572 LT LT 242 M LT 572 LT 7 7 13 14 1194E A A A A 6 8 Jet pump unit ...

Page 249: ...d water temperature sensor 2 FX Cruiser SHO Ride plate 3 2 1 3 2 Remove Steering cable joint 1 Shift cable joint 2 QSTS rod joint 3 Spout hose 4 Rubber plats 5 2 1 3 5 4 3 Remove Bolt M6 30 mm 1 Bolts M10 45 mm 2 1 2 2 4 Remove Jet pump unit 1 NOTE Insert a flat head screwdriver into the gap a between the jet pump unit 1 and the transom plate 2 to separate them 2 1 a Jet pump unit ...

Page 250: ...int 5 Steering cable joint 6 NOTE When installing the rubber plate 1 pass the shift cable 5 through the hole a in the plate 3 Check Steering operation Shift operation QSTS operation Do not operate correctly Reinstall T R Jet pump unit assembly bolt M10 45 mm 40 N m 4 0 kgf m 29 5 ft lb LOCTITE 572 M6 30 mm 8 N m 0 8 kgf m 5 9 ft lb LOCTITE 572 T R Rubber plate bolt 7 N m 0 7 kgf m 5 2 ft lb LOCTIT...

Page 251: ...oint washer 1 1 6 Bolt 1 7 Collar 1 8 Spring 1 NOTE Install the spring as shown 9 Bolt 1 10 Bolt 6 2 7 9 11 8 1 5 4 4 10 10 12 3 14 10 2 13 12 6 6 9 8 1 N m 0 1 kgf m 0 7 ft Ib 8 14 mm 20 N m 2 0 kgf m 14 8 ft Ib 6 25 mm 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 6 20 mm 8 25 mm 20 N m 2 0 kgf m 14 8 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib A A LT 242 A A LT 242 LT 242 LT 242 6 35 mm LT 242 LT 242...

Page 252: ...l steps for installation 2 7 9 11 8 1 5 4 4 10 10 12 3 14 10 2 13 12 6 6 9 8 1 N m 0 1 kgf m 0 7 ft Ib 8 14 mm 20 N m 2 0 kgf m 14 8 ft Ib 6 25 mm 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 6 20 mm 8 25 mm 20 N m 2 0 kgf m 14 8 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib A A LT 242 A A LT 242 LT 242 LT 242 6 35 mm LT 242 LT 242 A A Reverse gate ...

Page 253: ... Reverse gate Refer to Reverse gate 1 Bolt collar 2 2 2 Jet thrust nozzle 1 3 Bolt collar 2 2 4 Nozzle ring 1 5 Nut washer 1 1 6 Ball joint washer 1 1 Reverse the removal steps for installation 16 N m 1 6 kgf m 11 8 ft Ib 8 20 mm 16 N m 1 6 kgf m 11 8 ft Ib 16 N m 1 6 kgf m 11 8 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 8 20 mm 2 6 3 5 3 1 1 4 LT 271 LT 271 LT 271 LT 271 A A Jet thrust nozzle and nozzle rin...

Page 254: ...ing 1 Bolt 4 2 Nozzle 1 3 Dowel pin 2 4 Impeller duct assembly 1 5 Impeller housing 1 6 Dowel pin 2 7 Bolt 4 8 Water inlet cover 1 9 Packing 2 Not reusable 10 Water inlet strainer 1 Reverse the removal steps for installation LT 572 LT LT 572 LT 1194E 2 3 4 6 6 9 9 3 10 8 5 1 10 125 mm 40 N m 4 0 kgf m 29 5 ft Ib 6 35 mm 7 N m 0 7 kgf m 5 2 ft Ib 7 1194E Impeller duct and impeller housing ...

Page 255: ...t name Q ty Service points 1 Impeller 1 NOTE The impeller has left hand threads 2 Spacer 1 3 Bolt 3 4 Cap 1 5 O ring 1 Not reusable 6 Nut 1 7 Washer 1 EP A A A A A A 69 N m 6 9 kgf m 50 9 ft Ib 110 N m 11 0 kgf m 81 1 ft Ib EP 13 12 11 LT 572 LT LT 572 LT 3 8 N m 0 8 kgf m 5 9 ft Ib 6 20 mm 1 14 Impeller duct and drive shaft ...

Page 256: ...1 Oil seal 1 Not reusable 12 Oil seal 1 Not reusable 13 Front bearing 1 Not reusable Inside diameter 30 mm 1 18 in 14 Impeller duct 1 Reverse the disassembly steps for assembly EP A A A A A A 69 N m 6 9 kgf m 50 9 ft Ib 110 N m 11 0 kgf m 81 1 ft Ib EP 13 12 11 LT 572 LT LT 572 LT 3 8 N m 0 8 kgf m 5 9 ft Ib 6 20 mm 1 14 Impeller duct and drive shaft ...

Page 257: ... 2 Cap 3 Nut 4 NOTE The impeller has left hand threads Turn the impeller clockwise to loosen it Drive shaft holder 5 YB 06201 Drive shaft holder 6 5 90890 06520 1 2 4 3 5 1 4 5 2 Remove Drive shaft 1 NOTE Do not press the drive shaft threads directry 1 Impeller duct and drive shaft ...

Page 258: ...90890 06501 Bearing puller assembly 3 90890 06535 Stopper guide stand 4 90890 06538 È 3 4 4 2 É 4 Remove Oil seals È For USA and Canada É For worldwide Slide hammer and adapters 1 YB 06096 Stopper guide plate 2 90890 06501 Bearing puller assembly 3 90890 06535 Stopper guide stand 4 90890 06538 1 È 2 3 4 É Impeller duct and drive shaft ...

Page 259: ...g attachment 4 90890 06609 1 1 2 2 È 2 3 4 É 3 3 4 4 É Impeller check 1 Check Impeller Refer to Jet pump unit check in Chap ter 3 Impeller housing check 1 Measure Impeller housing inside diameter a Out of specification Replace the impeller housing Impeller housing inside diameter a 155 35 155 45 mm 6 116 6 120 in Drive shaft check 1 Check Drive shaft spline Cracks damage Replace the drive shaft Im...

Page 260: ...1 halfway into the impeller duct and then install the oil seal 2 È For USA and Canada É For worldwide Driver handle large 3 YB 06071 Bearing cup installer 4 YB 06167 Driver rod LS 5 90890 06606 Bearing outer race attachment 6 90890 06628 Distance a 7 0 0 2 mm 0 28 0 008 in A A 4 3 2 1 a È A A 6 5 a 2 1 É 2 Install Front bearing to the drive shaft Bearing attachment 1 90890 06728 Distance a 23 0 0 ...

Page 261: ... drive shaft and spacer Quantity 20 g 0 04 lb EP EP 5 Install Rear bearing 1 Bearing attachment 2 90890 06728 1 2 A A 6 Apply EPNOC grease AP 0 into the cap 7 Install Nut 1 O ring 2 Cap 3 Quantity 20 g 0 04 lb Drive shaft holder 4 YB 06201 Drive shaft holder 6 4 90890 06520 T R Drive shaft nut 69 N m 6 9 kgf m 50 9 ft lb EP 1 2 3 4 A A 4 Impeller duct and drive shaft ...

Page 262: ... 06520 T R Impeller 110 N m 11 0 kgf m 81 1 ft lb LOCTITE 572 2 1 LT 572 LT A A 3 Impeller duct and impeller housing installation 1 Install Dowel pins 1 Impeller duct assembly 2 Dowel pins 3 Nozzle 4 Bolts 5 NOTE Clean the contacting surfaces before applying sealant T R Impeller duct bolt 40 N m 4 0 kgf m 29 5 ft lb LOCTITE 572 1 1 2 3 4 5 3 1194E 1194E LT 572 LT Impeller duct and drive shaft ...

Page 263: ...ter hose 2 1 2 Cap 1 3 Nut 1 4 Clamp flushing hose 1 1 5 Clamp cooling water hose 2 1 6 Clamp cooling water hose 1 1 7 Hose joint 1 1 8 Band 1 Not reusable 9 Bilge strainer assembly 1 10 Plastic tie 1 13 10 30 28 21 23 24 22 22 12 1 24 23 29 15 6 9 27 26 25 15 19 20 17 18 7 27 4 3 2 SS 8 11 5 N m 0 5 kgf m 3 7 ft Ib 6 N m 0 6 kgf m 4 4 ft Ib 26 N m 2 6 kgf m 19 2 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 11...

Page 264: ...e pump assembly 1 17 Clamp bilge hose 2 1 18 Nut 1 19 Gasket 1 Not reusable 20 Pilot outlet 1 21 Clamp bilge hose 2 1 22 Nut 2 13 10 30 28 21 23 24 22 22 12 1 24 23 29 15 6 9 27 26 25 15 19 20 17 18 7 27 4 3 2 SS 8 11 5 N m 0 5 kgf m 3 7 ft Ib 6 N m 0 6 kgf m 4 4 ft Ib 26 N m 2 6 kgf m 19 2 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 11 12 17 21 5 4 1 5 16 14 b a Transom plate and hoses ...

Page 265: ... Hose joint 1 27 Clamp cooling water hose 2 1 28 Clamp bilge hose 1 1 29 Nut washer 4 4 30 Transom plate 1 Reverse the removal steps for installation 13 10 30 28 21 23 24 22 22 12 1 24 23 29 15 6 9 27 26 25 15 19 20 17 18 7 27 4 3 2 SS 8 11 5 N m 0 5 kgf m 3 7 ft Ib 6 N m 0 6 kgf m 4 4 ft Ib 26 N m 2 6 kgf m 19 2 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 11 12 17 21 5 4 1 5 16 14 b a Transom plate and hoses...

Page 266: ...ge hoses Cooling water hoses Cracks damage Replace Transom plate installation 1 install Transom plate NOTE Clean the contacting surfaces before applying silicone sealant T R Transom plate nut 26 N m 2 6 kgf m 19 2 ft lb SS Transom plate and hoses ...

Page 267: ... Engine unit Refer to Engine unit in Chapter 5 1 Rubber damper 1 2 Band 1 Not reusable 3 Grease hose 1 4 Bolt 3 5 Intermediate housing assembly 1 6 Dowel pin 2 7 Shim NOTE Install the shims in their original positions Reverse the removal steps for installation 17 N m 1 7 kgf m 12 5 ft Ib 8 48 mm LT 572 LT 4 7 5 2 3 1 6 Intermediate housing ...

Page 268: ... 1 4 Driven coupling 1 5 Washer 1 6 Intermediate drive shaft 1 7 O ring 2 Not reusable 8 Thrust washer 1 Not reusable 9 Oil seal 1 Not reusable 10 Oil seal 2 Not reusable 11 Circlip 2 Not reusable LT 572 LT 1 2 3 10 11 A A A A 12 13 8 9 11 10 LT 572 LT A A 4 5 6 7 36 N m 3 6 kgf m 26 6 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib M Intermediate housing ...

Page 269: ... Q ty Service points 12 Bearing 1 Not reusable 13 Intermediate housing 1 Reverse the disassembly steps for assembly LT 572 LT 1 2 3 10 11 A A A A 12 13 8 9 11 10 LT 572 LT A A 4 5 6 7 36 N m 3 6 kgf m 26 6 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib M Intermediate housing ...

Page 270: ...position 2 1 Driven coupling removal 1 Remove Driven coupling 1 NOTE Make sure that the special service tool 2 is inserted completely into the intermediate drive shaft Shaft holder 2 90890 06730 Coupler wrench 3 90890 06729 3 1 2 Intermediate drive shaft removal 1 Remove Intermediate drive shaft 1 Thrust washer 2 NOTE Do not press the intermediate drive shaft directry 1 2 Intermediate housing ...

Page 271: ...e stand 5 90890 06538 1 2 È 3 4 5 É Bearing removal 1 Remove Circlips 1 Bearing 2 NOTE Remove the circlips 1 before removing the bearing 2 È For USA and Canada É For worldwide Driver handle large 3 YB 06071 Needle bearing installer 4 YB 06434 Driver rod LS 5 90890 06606 Bearing outer race attachment 6 90890 06623 1 1 4 2 3 È 1 1 6 2 5 É Intermediate drive shaft and grease hose check 1 Check Interm...

Page 272: ...the bearing always replace it with a new one 1 Install Circlip 1 Bearing 2 Installing step 1 Install the circlip 1 and then install the bearing 2 until it contacts the circlip È For USA and Canada É For worldwide Driver handle large 3 YB 06071 Needle bearing installer 4 YB 06434 Driver rod LS 5 90890 06606 Bearing outer race attachment 6 90890 06623 3 4 1 2 A A È 5 6 1 2 A A É Intermediate housing...

Page 273: ...g outer race attachment 5 90890 06623 Distance a 6 5 0 2 mm 0 26 0 01 in 2 3 A A A A 1 a È 4 5 A A A A 1 a É 2 Install Intermediate drive shaft 1 Bearing attachment 2 90890 06728 Distance a 46 0 0 5 mm 1 81 0 02 in 1 a 2 3 Install Circlip 1 Oil seal 2 Bearing attachment 3 90890 06728 1 3 2 1 A A 4 Install Oil seal 1 Bearing attachment 2 90890 06727 Distance a 1 6 0 2 mm 0 06 0 01 in 2 1 a A A Inte...

Page 274: ...ure that the special service tool 2 is inserted completely into the intermediate drive shaft Shaft holder 2 90890 06730 Coupler wrench 3 90890 06729 T R Driven coupling 36 N m 3 6 kgf m 26 6 ft lb LOCTITE 572 3 2 1 Intermediate housing installation 1 Install Intermediate housing assembly 1 Shims 2 NOTE Be sure to install the shims in their original positions 1 2 Intermediate housing ...

Page 275: ...6 30 E JET PUMP 1 2 3 4 5 6 7 8 9 MEMO Intermediate housing ...

Page 276: ...ectifier regulator 7 17 Control system 7 19 Oil pressure switch 7 19 Thermoswitch 7 20 Thermo sensor 7 22 Engine temperature sensor 7 23 Intake air temperature sensor 7 24 Intake air pressure sensor 7 26 Knock sensor 7 28 Throttle position sensor 7 28 Accelerator position sensor 7 31 Electronic throttle valve relay 7 35 Cam position sensor 7 36 Slant detection switch 7 37 Steering sensor 7 38 Reve...

Page 277: ...e control transmitter 7 60 Remote control receiver 7 63 Indication system 7 64 Multifunction meter 7 64 Operation button assembly 7 65 Compass display FX Cruiser SHO 7 67 Air temperature display FX Cruiser SHO 7 68 Water temperature display FX Cruiser SHO 7 68 Speed sensor 7 69 Digital speedometer display FX SHO 7 70 Digital speedometer display FX Cruiser SHO 7 71 Fuel level meter display and fuel...

Page 278: ...utton assembly FX Cruiser SHO 4 Steering sensor 5 Buzzer 6 Reverse sensor 7 Right handlebar switch assembly 8 Fuel injectors 9 Thermoswitch 0 Knock sensor A TPS B Intake air temperature sensor C Intake air pressure sensor D Engine temperature sensor E Earth plate F Stator coil and pickup coil G Electrical box H Electric bilge pump I Battery Electrical components ...

Page 279: ...ture sensor FX Cruiser SHO K Thermo sensor L Starter motor M Rectifier regulator N Cam position sensor O Spark plugs and ignition coils P Oil pressure switch Q Left handlebar switch assembly R Fuel pump module and fuel sender S Left operation button assembly T Compass and air temperature sensor FX Cruiser SHO U APS Electrical components ...

Page 280: ... 3 2 1 5 1 Starter relay 2 Main and fuel pump relay 3 ETV relay 4 Slant detection switch 5 ECM 6 Fuse 30 A battery 7 Fuse 10 A main and fuel pump relay 8 Fuse 10 A ETV relay 9 Fuse 3 A remote control receiver 0 Fuse 20 A main and fuel pump relay Electrical box ...

Page 281: ...ay coupler 1 3 ETV relay coupler 1 4 Slant detection switch coupler 1 5 Fuse box coupler 2 6 Wiring harness assembly 1 7 Bolt 4 8 ECM 1 9 Collar grommet 4 4 10 Screw 2 UP 4 N m 0 4 kgf m 3 0 ft Ib 13 N m 1 3 kgf m 9 6 ft Ib LT 242 LT 242 A A 7 2 9 11 8 1 5 4 6 12 14 6 18 mm 8 25 mm 9 3 a 13 10 6 25 mm 5 N m 0 5 kgf m 3 7 ft Ib Electrical box ...

Page 282: ... switch with the UP mark a facing upward 12 Bolt 2 13 Fuse box assembly 1 14 Electrical box case 1 Reverse the disassembly steps for assembly UP 4 N m 0 4 kgf m 3 0 ft Ib 13 N m 1 3 kgf m 9 6 ft Ib LT 242 LT 242 A A 7 2 9 11 8 1 5 4 6 12 14 6 18 mm 8 25 mm 9 3 a 13 10 6 25 mm 5 N m 0 5 kgf m 3 7 ft Ib Electrical box ...

Page 283: ... fuel pump relay 1 4 ETV relay 1 5 Damper 1 6 Cap 1 7 Packing 1 Not reusable 8 Fuse puller 1 9 Bolt 6 10 Cover 1 11 Gasket 1 Not reusable 12 Screw 3 A A 8 12 14 20 23 12 13 7 6 6 25 mm 6 20 mm 6 10 mm 6 10 mm 6 7 mm 24 È É 18 22 21 17 23 b a 10 N m 1 0 kgf m 7 4 ft Ib 22 20 A A 1 3 4 5 2 11 19 17 16 15 10 9 16 15 18 21 Electrical box ...

Page 284: ...starter motor 18 Positive battery cable 1 b Gray tape É To battery 19 Starter relay 1 CAUTION The starter motor will not function if the cables are reversed A A 8 12 14 20 23 12 13 7 6 6 25 mm 6 20 mm 6 10 mm 6 10 mm 6 7 mm 24 È É 18 22 21 17 23 b a 10 N m 1 0 kgf m 7 4 ft Ib 22 20 A A 1 3 4 5 2 11 19 17 16 15 10 9 16 15 18 21 Electrical box ...

Page 285: ... Red lead 22 Lead 1 Brown lead 23 Lead 1 Black lead 24 Housing 1 Reverse the disassembly steps for assembly A A 8 12 14 20 23 12 13 7 6 6 25 mm 6 20 mm 6 10 mm 6 10 mm 6 7 mm 24 È É 18 22 21 17 23 b a 10 N m 1 0 kgf m 7 4 ft Ib 22 20 A A 1 3 4 5 2 11 19 17 16 15 10 9 16 15 18 21 Electrical box ...

Page 286: ...he engine otherwise the diagnostic codes will not be cleared from the ECM NOTE Before checking the electrical components make sure that the battery is fully charged If the tester leads are connected while using the YDIS diagnostic codes will be detected If a diagnosis record is displayed and it is caused by the checking steps delete the record by using the Diagnosis record func tion of the YDIS Th...

Page 287: ...cked by measuring the peak voltage The specified engine speed when measuring the peak voltage is affected by many factors such as fouled spark plugs or a weak battery If one of these factors is present the peak volt age cannot be measured properly WARNING When checking the peak voltage do not touch any of the connections of the digital tester leads CAUTION When testing the voltage between the ter ...

Page 288: ... digital circuit tester to the DC voltage mode È For USA and Canada É For worldwide Digital multimeter 1 YU 34899 A Peak voltage adapter 2 YU 39991 Digital circuit tester 3 90890 03174 Peak voltage adapter B 4 90890 03172 V 1 2 È DC V 3 4 É Ignition system Ignition coil 1 Check Ignition spark No spark Measure the ignition coil input voltage Checking steps 1 Connect a computer to the watercraft and...

Page 289: ...he spark gap check keep flammable gas or liquids away since this test can produce sparks 2 Measure Ignition coil input voltage from the battery Out of specification Check the wiring harness Measurement steps 1 Disconnect the ignition coil couplers 1 2 Push the unlock button and then measure the input voltage at the ignition coil coupler terminals wiring harness end Ignition coil input voltage from...

Page 290: ...e ECM output peak voltage as shown NOTE If measuring the ECM output peak voltage under the Cranking condition disconnect the fuel injector couplers for all cylinders To crank the engine connect the engine shut off cord lanyard to the engine shut off switch and then push the engine start switch ECM output peak voltage 1 Black red B R Black B 2 Black white B W Black B 3 Black yellow B Y Black B 4 Bl...

Page 291: ... To crank the engine connect the engine shut off cord lanyard to the engine shut off switch and then push the engine start switch and engine stop switch simultaneously If measuring the pickup coil output peak volt age under the Cranking and Unloaded conditions disconnect the coupler 3 Test harness 3 pins YB 06877 Test harness HM090 3 3 pins 90890 06877 Pickup coil output peak voltage White W Black...

Page 292: ... reference data White W Black B 459 561 Ω B W 1 Charging system Stator coil 1 Measure Stator coil output peak voltage Below specification Measure the sta tor coil resistance Measurement steps 1 Disconnect the stator coil coupler 1 2 Connect the test harness 3 pins 2 to the stator coil coupler 1 Test harness 3 pins YB 06870 Test harness SMT250 3 3 pins 90890 06870 G G G W R B G G G B R W G G G 1 2 ...

Page 293: ...ngine stop switch simultaneously Stator coil output peak voltage Green G Green G r min Unloaded Cranking 2 000 3 500 V 8 4 42 7 74 0 2 Measure Stator coil resistance Out of specification Replace the sta tor coil assembly Measurement steps 1 Disconnect the stator coil coupler 1 2 Measure the stator coil resistance Stator coil resistance at 20 C 68 F reference data Green G Green G 0 31 0 38 Ω G G G ...

Page 294: ...ctifier regulator coupler 1 2 Connect the test harness 2 pins 2 to the rectifier regulator coupler 1 3 Measure the rectifier regulator output peak voltage NOTE Do not use the peak voltage adapter to mea sure the output voltage Test harness 2 pins 90890 06850 Rectifier regulator output peak voltage Red R Black B r min Loaded 2 000 3 500 V 13 13 R B R G G G B R B 2 1 Charging system ...

Page 295: ...ure to set the measurement range a when checking the rectifier regulator continu ity È For USA and Canada É For worldwide OL overload Rectifier regulator continuity testing diode Tester lead Display value V reference data 1 R 2 G OL 1 R 3 G 1 R 4 G 1 R 5 B 5 B 2 G 0 43 0 51 5 B 3 G 0 43 0 51 5 B 4 G 0 43 0 51 5 B 1 R 0 66 0 74 2 G 1 R 0 43 0 51 3 G 1 R 0 43 0 51 4 G 1 R 0 43 0 51 2 G 5 B OL 3 G 5 ...

Page 296: ...ss end and ground Oil pressure switch input voltage reference data Pink white P W Ground 11 0 12 0 V P W 1 2 Check Oil pressure switch continuity Out of specification Replace the oil pressure switch Checking steps 1 Remove the oil pressure switch Refer to Oil separator tank and oil pan removal in Chapter 5 2 Connect the tester leads to the terminal thread 1 and body 2 of the oil pressure switch as...

Page 297: ... 6 psi Continuity Above 128 166 kPa 1 28 1 66 kgf cm2 18 2 23 6 psi No continuity Thermoswitch 1 Measure Thermoswitch input voltage Out of specification Check the wiring harness Measurement steps 1 Disconnect the thermoswitch coupler 1 2 Push the unlock button and then measure the input voltage at the thermoswitch cou pler terminals wiring harness end Thermoswitch input voltage reference data Pink...

Page 298: ...er 3 Slowly heat the water 4 Check the continuity when the specified temperatures are reached a 94 100 C 201 212 F b 80 94 C 176 201 F c No continuity d Continuity È Temperature É Time Thermoswitch continuity Pink P Black orange B O Temperature reference data Pink P Black orange B O Increasing Below 94 100 C 201 212 F No continuity Above 94 100 C 201 212 F Continuity Decreasing Above 80 94 C 176 2...

Page 299: ...rence data Black blue B L Black orange B O 4 75 5 25 V 1 B O B L 2 Measure Thermo sensor resistance at the speci fied temperatures Out of specification Replace the thermo sensor Measurement steps 1 Remove the thermo sensor Refer to Muffler disassembly in Chapter 5 2 Suspend the thermo sensor in a container filled with water 3 Slowly heat the water 4 Measure the resistance when the specified temper...

Page 300: ...minals wiring har ness end Engine temperature sensor input voltage reference data Black yellow B Y Black orange B O 4 75 5 25 V 1 B Y B O 2 Measure Engine temperature sensor resistance at the specified temperatures Out of specification Replace the engine temperature sensor Measurement steps 1 Remove the engine temperature sensor Refer to Oil separator tank and oil pan removal in Chapter 5 2 Suspen...

Page 301: ...take air temperature Incorrect reading Measure the intake air temperature sensor input voltage Checking steps 1 Measure the ambient temperature 2 Connect a computer to the watercraft and use the YDIS to display the intake air tem perature NOTE Check the intake air temperature sensor when the engine is cold 3 If the ambient temperature and the dis played intake air temperature differ by more than 5...

Page 302: ...ke air tempera ture sensor coupler wiring harness end Intake air temperature sensor input voltage reference data Black red B R Black orange B O 4 75 5 25 V B R B O 1 3 Measure Intake air temperature sensor resistance at the specified temperatures Out of specification Replace the intake air temperature sensor Measurement steps 1 Remove the intake air temperature sensor Refer to Intake assembly remo...

Page 303: ...essure sensor 1 Measure Intake air pressure sensor input voltage Out of specification Check the wiring harness Measurement steps 1 Disconnect the intake air pressure sensor coupler 1 2 Push the unlock button and then measure the input voltage at the intake air pressure sensor coupler terminals wiring harness end Intake air pressure sensor input voltage reference data Orange O Black orange B O 4 75...

Page 304: ...intake air pressure sensor 2 Connect a computer to the watercraft and use the YDIS to display the intake air pres sure 3 Push the unlock button 4 Apply negative pressure to the intake air pressure sensor slowly and check that the displayed intake air pressure decreases Lower unit pressure vacuum tester YB 35956 A Vacuum pressure pump gauge set 90890 06756 Control system ...

Page 305: ...f specification Replace the knock sensor Measurement steps 1 Remove the knock sensor Refer to Oil separator tank and oil pan removal in Chapter 5 2 Measure the knock sensor resistance Knock sensor resistance at 20 C 68 F reference data 504 616 kΩ Throttle position sensor CAUTION Do not loosen the throttle stop screw nut 1 and do not turn the throttle stop screw 2 Do not disconnect the throttle bod...

Page 306: ...s sembled 2 Squeeze the throttle lever slowly and check that the displayed throttle valve opening increases 3 Check that the APS pulley stopper a con tacts the fully closed stopper b when the throttle lever 1 is at the fully closed posi tion È NOTE To adjust the throttle cable refer to Throttle lever free play check and adjustment in Chap ter 3 4 Push the unlock button and then check the TPS 1 out...

Page 307: ... TPS 2 Example If the TPS 1 output voltage is 2 5 V and the TPS 2 output voltage is 4 5 V then 4 5 2 5 2 0 V 2 Measure TPS input voltage Out of specification Check the TPS circuit Measurement steps 1 Disconnect the throttle body assembly coupler 1 2 Push the unlock button and then measure the input voltage at the throttle body assembly coupler terminals wiring har ness end TPS 2 output voltage wit...

Page 308: ...pler 1 2 Disconnect the ECM couplers 2 and 3 3 Check the wiring harness for continuity Wiring harness continuity Terminal No Color Coupler 1 Coupler 2 3 1 42 P 2 44 O 3 78 G 4 43 P B 5 41 B O 6 52 L 1 2 3 1 d 2 3 Accelerator position sensor 1 Check APS output voltage Out of specification Measure the APS input voltage Checking steps NOTE When checking the APS using the YDIS do not start the engine ...

Page 309: ...check and adjustment in Chap ter 3 3 Push the unlock button operate the throt tle lever 1 and then check the output volt ages of APS 1 and APS 2 at the fully closed position È and fully open position É NOTE The actual APS output voltage may vary according to environmental conditions 4 Squeeze the throttle lever 1 to the fully open position and then check the voltage difference between APS 1 and AP...

Page 310: ...s wiring harness end APS 1 input voltage reference data Orange red O R Black red B R 4 75 5 25 V APS 2 input voltage reference data Orange white O W Black white B W 4 75 5 25 V 1 O R B R O W B W 3 Measure APS resistance Out of specification Replace the APS Measurement steps 1 Disconnect the APS coupler 2 Check that the APS pulley stopper a con tacts the fully closed stopper b when the APS pulley i...

Page 311: ...the wiring har ness assembly Checking steps 1 Disconnect the APS coupler 1 2 Disconnect the ECM coupler 2 3 Check the wiring harness for continuity APS resistance at 20 C 68 F reference data Item Termi nal APS pulley position Fully closed È Fully open É APS 1 1 3 0 50 0 90 kΩ 3 75 4 35 kΩ APS 2 6 7 0 35 1 05 kΩ 3 60 4 50 kΩ Wiring harness continuity Terminal No Color Coupler 1 Coupler 2 1 34 B R 2...

Page 312: ...ck ETV relay continuity Out of specification Replace the ETV relay Checking steps 1 Remove the ETV relay Refer to Fuse box disassembly 2 Connect the tester leads to the ETV relay terminals 4 and 5 or to the terminals 4 and 6 3 Connect the positive battery lead to the ETV relay terminal 1 or 2 4 Connect the negative battery lead to the ETV relay terminal 3 5 Check the continuity between terminals 4...

Page 313: ... Measurement steps 1 Remove the cam position sensor Refer to Cylinder head cover removal in Chapter 5 2 Connect the test harness 3 pins to the cam position sensor 3 Push the unlock button and then measure the output voltage when a screwdriver is passed under the cam position sensor in direction È as shown Cam position sensor input voltage reference data Orange O Black orange B O 4 75 5 25 V Test h...

Page 314: ...tinuity Out of specification Replace the slant detection switch Checking steps 1 Remove the slant detection switch Refer to Electrical box disassembly 2 Check the slant detection switch continu ity NOTE Be sure to turn the switch over to both the left and right as shown Slant detection switch input voltage reference data Blue black L B Black orange B O 4 75 5 25 V Slant detection switch continuity...

Page 315: ...astic tie 1 5 Push the unlock button 6 Hold the spring gauge 2 at a 90 angle from the handlebar grip and then pull the spring gauge in direction È as shown with a force of 10 kgf 22 lb NOTE At this time the button 3 in the steering sen sor will be pushed in direction É 7 Check that the following is displayed in the Engine monitor window of the YDIS 8 Use the same procedure to check that the steeri...

Page 316: ...s end Reverse sensor 1 Check Reverse sensor operation Does not operate Measure the reverse sensor input voltage Checking steps 1 Connect a computer to the watercraft to use the YDIS 2 Push the unlock button 3 Operate the shift lever 1 and check that the following is displayed in the Engine monitor window of the YDIS Steering sensor input voltage reference data Orange red O R Black orange B O 4 75 ...

Page 317: ...ensor input voltage reference data Orange O Black orange B O 4 75 5 25 V O B O 1 Right handlebar switch assembly 1 Check Right handlebar switch operation Does not operate Measure the right handlebar switch input voltage Checking steps 1 Connect a computer to the watercraft to use the YDIS 2 Push the unlock button 3 Operate the switches 1 4 and check that the following is displayed in the Engine mo...

Page 318: ...ent steps 1 Disconnect the right handlebar switch cou pler 1 2 Push the unlock button and then measure the input voltage at the right handlebar switch coupler terminals wiring harness end Right handlebar switch input voltage reference data Terminal Color Voltage V 1 4 L R B 4 75 5 25 2 4 Y B B 4 75 5 25 3 4 Y R B 11 0 12 0 6 4 Y G B 11 0 12 0 1 L R Y B Y R Y G B Control system ...

Page 319: ...rminal wiring harness end and ground NOTE Do not disconnect the coupler 2 or coupler 3 when measuring the ECM input voltage ECM input voltage Red yellow R Y Ground 12 V battery voltage R Y 2 1 3 2 Check ECM circuit continuity No continuity Replace the wiring har ness assembly Checking steps 1 Disconnect the ECM couplers 1 and 2 2 Check the continuity between the ECM coupler terminals 3 wiring harn...

Page 320: ...ach termi nal 1 and the housing 2 1 2 Electric bilge pump 1 Measure Electric bilge pump input voltage Out of specification Check the wiring harness Measurement steps 1 Disconnect the electric bilge pump coupler 1 2 Push the unlock button and then measure the input voltage at the electric bilge pump coupler wiring harness end Electric bilge pump input voltage Red yellow R Y Black B 12 V battery vol...

Page 321: ...h water 3 Connect the positive battery lead to the terminal 1 and the negative battery lead to the terminal 2 4 Check that water flows from the electric bilge pump hose 3 3 Br 1 2B Fuel system Fuel injector 1 Check Fuel injector operation sound Does not sound Measure the fuel injector input voltage Checking steps 1 Connect a computer to the watercraft to use the YDIS 2 Using the Stationary test of...

Page 322: ...the fuel injector coupler terminals wiring harness end and ground Fuel injector input voltage Red yellow R Y Ground 12 V battery voltage R Y 1 3 Measure Fuel injector resistance Out of specification Replace the fuel injector Measurement steps 1 Remove the fuel injector Refer to Fuel tank removal in Chapter 4 2 Measure the fuel injector resistance Fuel injector resistance at 20 C 68 F reference dat...

Page 323: ...module operation sound 2 Measure Fuel pump module input voltage Out of specification Check the wiring harness Measurement steps 1 Disconnect the fuel pump module coupler 1 2 Push the unlock button and then measure the input voltage at the fuel pump module coupler terminals wiring harness end NOTE After the unlock button is pushed voltage will only be applied to the fuel pump module for 3 seconds F...

Page 324: ...emove the fuel pump module Refer to Fuel tank removal in Chapter 4 2 Measure the fuel sender resistance Fuel sender resistance at 20 C 68 F reference data Float position Yellow Y Black B Lower position È 133 5 136 5 Ω Upper position É 5 0 7 0 Ω Y B È É Starting system Fuse 1 Check Fuse continuity No continuity Replace the fuse Fuel system Starting system ...

Page 325: ...8 2 Check the engine start switch continuity Engine start switch continuity Clip 1 Enginestart switch 2 Red R Brown Br Installed È Free No continuity Pushed Continuity Removed É Free No continuity Pushed No continuity R Br 1 2 È É 2 2 Check Engine stop switch continuity Out of specification Replace the left handlebar switch assembly Checking steps 1 Disconnect the left handlebar switch cou pler Re...

Page 326: ...inuity Main and fuel pump relay 1 Measure Main and fuel pump relay input voltage Out of specification Check the wiring harness Measurement steps 1 Disconnect the main and fuel pump relay coupler 1 2 Measure the input voltage between the main and fuel pump relay coupler termi nals 2 or 3 wring harness end and ground Main and fuel pump relay input voltage Red R Ground 12 V battery voltage 1 R R 2 3 ...

Page 327: ...d fuel pump relay terminal 2 or 3 4 Connect the negative battery lead to the main and fuel pump relay terminal 1 5 Check the continuity between the termi nals 5 and 6 or the terminals 5 and 7 Main relay continuity Battery lead 2 or 3 1 Terminal 5 Terminal 6 or 7 Disconnected No continuity Connected Continuity 1 2 3 4 5 6 7 8 7 8 6 5 3 4 2 1 3 Check Fuel pump relay continuity Out of specification R...

Page 328: ...tarter relay 1 Measure Starter relay input voltage Out of specification Check the wiring harness Measurement steps 1 Slide the boot away from the starter relay terminal 1 NOTE The positive battery cable is marked with gray tape a 2 Measure the input voltage between the starter relay terminal 1 and ground Fuel pump relay continuity Battery lead 6 4 Terminal 7 Terminal 8 Disconnected No continuity C...

Page 329: ...mbly 2 Connect the tester leads between the starter relay terminals 1 and 2 3 Connect the positive battery lead to the terminal 3 and the negative battery lead to the terminal 4 4 Check the continuity between the starter relay terminals 1 and 2 Starter relay continuity Battery lead 3 4 Terminal 1 Terminal 2 Disconnected No continuity Connected Continuity Br B 1 2 3 4 Starting system ...

Page 330: ...embly 1 3 Circlip 1 4 Drive gear 1 5 O ring 1 Not reusable 6 Front cover 1 7 Packing 1 Not reusable 8 Dowel pin 1 9 Planetary gear 2 10 Ring gear 1 11 Bracket 1 3 4 5 1 6 7 8 2 9 10 11 12 13 14 15 18 19 20 21 22 23 24 25 27 26 28 29 6 N m 0 6 kgf m 4 4 ft Ib 6 120 mm M M M M 17 16 16 9 N m 0 9 kgf m 6 6 ft Ib Starter motor ...

Page 331: ... Shim 15 Packing 1 Not reusable 16 Brush spring 4 17 Armature 1 18 Brush holder stay 1 19 Nut 1 20 Spring washer 1 21 Washer 1 22 Insulator washer 1 1 3 4 5 1 6 7 8 2 9 10 11 12 13 14 15 18 19 20 21 22 23 24 25 27 26 28 29 6 N m 0 6 kgf m 4 4 ft Ib 6 120 mm M M M M 17 16 16 9 N m 0 9 kgf m 6 6 ft Ib Starter motor ...

Page 332: ... 25 Terminal bolt 1 26 Lead plate 1 27 Terminal insulator 1 28 Plate cover 1 29 Starter motor yoke 1 Reverse the disassembly steps for assembly 3 4 5 1 6 7 8 2 9 10 11 12 13 14 15 18 19 20 21 22 23 24 25 27 26 28 29 6 N m 0 6 kgf m 4 4 ft Ib 6 120 mm M M M M 17 16 16 9 N m 0 9 kgf m 6 6 ft Ib Starter motor ...

Page 333: ...motor terminal bolt 2 3 Connect the negative battery cable 3 to the starter motor body 4 4 Check the starter motor operation NOTE Check the starter motor operation for a few seconds If the starter motor is disassembled be sure to check the operation again after assem bling it 1 3 2 4 Armature 1 Check Armature shaft 1 Wear damage Replace the armature Commutator 2 Dirt Clean with 600 grit sandpaper ...

Page 334: ...r undercut a Out of specification Replace the armature Commutator undercut a reference data 0 2 0 7 mm 0 008 0 028 in 4 Check Armature coil continuity Out of specification Replace the armature Armature coil continuity Commutator segments a Continuity Segment a Armature core b No continuity Segment a Armature shaft c No continuity b c a Starter motor ...

Page 335: ...the brush holder assembly Brush holder continuity Brush 1 Brush 2 Brush 3 Brush 4 Brush 3 Terminal 5 Brush 4 Terminal 5 Continuity For all brush and terminal combinations not listed above No continuity 5 1 3 4 5 3 1 4 2 2 Gear cover 1 Check Drive shaft 1 Bearing 2 Rough movement wear Replace the gear cover assembly 1 2 2 Check Planetary gears 1 Ring gear 2 Broken gear teeth Replace the gear cover ...

Page 336: ...he notch a in the ring gear is aligned with the projection b on the starter motor yoke 4 a b 2 4 1 3 M Remote control system Transmitter registration 1 Register ID code NOTE The remote control transmitter 1 can be added or re registered with the remote con trol receiver 2 by connecting the entry box 3 The entry box is necessary to register the ID code of a remote control transmitter Registration s...

Page 337: ...it the ID code 3 After confirming that the registration of the ID code has been completed using the UNLOCK indicator light 7 transmit the next ID code NOTE Up to 5 remote control transmitters can be registered in any sequence regardless of whether they are original equipment or addi tional transmitters The same ID code cannot be registered twice in the remote control receiver 4 After ID code regis...

Page 338: ... UNLOCK indicator light 2 goes off NOTE While the engine is running input from the remote control transmitter is not received Number of beeps Yamaha Security System mode 1 beep Lock 2 beeps Unlock normal mode 3 beeps L MODE low rpm mode 4 1 2 3 2 Measure Remote control transmitter battery voltage Below specification Replace the remote control transmitter battery Measurement steps 1 Remove the tran...

Page 339: ...NOTE Refer to local hazardous waste regulations when disposing of transmitter batteries 4 Install the battery 3 and transmitter cover 2 NOTE Install the battery CR2016 3 with the posi tive side a facing down 5 Install the transmitter cover screws 1 NOTE Tighten the transmitter cover screws 1 in the sequence shown Remote control transmitter battery voltage 3 0 V T R Transmitter cover screw 0 1 N m ...

Page 340: ...oltage Red R Black B 12 V battery voltage 1 R B 2 Measure Remote control receiver output voltage Out of specification Replace the remote control receiver Measurement steps 1 Disconnect the multifunction meter coupler 1 from the remote control receiver 2 Push the unlock button and then measure the remote control receiver output voltage at the multifunction meter coupler terminal wiring harness end ...

Page 341: ...meter No display Measure the multifunction meter input voltage Checking step 1 Push the unlock button and then check that all indicator lights and display ele ments on the multifunction meter light up 1 Indicator lights 2 Left multifunction display 3 Analog speedometer tachometer 4 Right multifunction display FX Cruiser SHO NOTE When pushing the unlock button the analog speedometer tachometer make...

Page 342: ...then measure the input voltage at the multifunction meter coupler terminals wiring harness end Multifunction meter input voltage Red yellow R Y Black B 12 V battery voltage B R Y 1 Operation button assembly 1 Check Left operation button continuity Out of specification Replace the left operation button assembly Checking steps 1 Disconnect the left operation button cou pler Refer to Multifunction me...

Page 343: ...on button continuity FX Cruiser SHO Out of specification Replace the right operation button assembly Checking steps 1 Disconnect the right operation button cou pler Refer to Multifunction meter and cover removal in Chapter 8 2 Check the right operation button assembly continuity NOTE indicates a continuity of electricity Right operation button continuity Button Position Leads R W B Y W Start Stop ...

Page 344: ... 2 Select the compass display mode of the multifunction meter and check that NORTH appears on the meter N 2 Check Compass and air temperature sensor installation condition Installed correctly Replace the com pass and air temperature sensor Checking steps 1 Remove the center cover Refer to Center cover removal in Chapter 8 2 Check that the arrow a on the compass and air temperature sensor is facing...

Page 345: ...s less than 5 C 9 F different from the ambient air tem perature NOTE Check the air temperature display when the engine is cold Water temperature display FX Cruiser SHO 1 Check Water temperature display Incorrect reading Measure the speed and water temperature sensor resis tance Checking steps 1 Measure the ambient water temperature 2 Select the water temperature display mode of the multifunction m...

Page 346: ... and water tempera ture sensor coupler 2 Refer to Steering master removal in Chapter 8 2 Measure the resistance of the water tem perature sensor 1 Speed and water temperature sensor resistance at 25 C 77 F reference data Yellow Y Black yellow B Y 10 kΩ 1 B Y Y 2 1 Speed sensor 1 Check Speed sensor paddle wheel 1 Cracks damage rough movement Replace the speed sensor FX SHO or speed and water temper...

Page 347: ...teering master removal in Chapter 8 2 Connect the positive battery lead to the terminal 2 and the negative battery lead to the terminal 3 3 Connect the tester leads between the ter minal 4 and terminal 3 4 Rotate the paddle wheel 5 by hand and measure the output voltage between the terminal 4 and terminal 3 Speed sensor output voltage dependant on the paddle wheel position Yellow Y Black yellow B ...

Page 348: ...nect the positive battery lead to the terminal 2 and the negative battery lead to the terminal 3 3 Connect the tester leads between the ter minal 4 and terminal 3 4 Rotate the paddle wheel 5 by hand and measure the output voltage between the terminal 4 and terminal 3 5 Check the output voltage again after replacing the speed and water tempera ture sensor If still out of specification replace the c...

Page 349: ...sition É 7 Check that the fuel level warning indicator 2 the lowest 2 fuel level segments 4 and the WARNING indicator light 5 blink Check engine warning indicator 1 Check Check engine warning indicator Does not come on Check the Diag nosis record of the YDIS Checking steps 1 Disconnect the engine temperature sensor coupler 1 2 Push the unlock button 3 Check that the WARNING indicator light 2 and t...

Page 350: ...s replace the multifunction meter Oil pressure warning indicator 1 Check Oil pressure warning indicator Does not come on Check the Diag nosis record of the YDIS Checking steps 1 Disconnect the oil pressure switch coupler 1 and then ground the terminal 2 2 Start the engine 3 Increase the engine speed to 4 500 r min or more 4 Check that the WARNING indicator light 3 and the oil pressure warning indi...

Page 351: ...ator 4 blink and then come on and the buzzer begins to sound intermittently and then it sounds continuously 5 If the light and indicator do not blink check the Diagnosis record of the YDIS If a diagnosis record is available and it is caused by the checking steps replace the multifunction meter 1 B O P 2 3 4 Buzzer 1 Measure Buzzer input voltage Out of specification Check the wiring harness Measure...

Page 352: ...ace the buzzer Checking steps 1 Remove the buzzer Refer to Steering master disassembly in Chapter 8 2 Connect the positive battery lead to the terminal 1 and the negative battery lead to the terminal 2 3 Check that the buzzer sounds 1R 2 B Indication system ...

Page 353: ...E ELEC 1 2 3 4 5 6 7 8 9 7 76 MEMO Indication system ...

Page 354: ...Mirror assembly installation 8 20 Rivet removal 8 21 Rivet installation 8 21 Steering console cover 8 22 Multifunction meter and cover removal 8 22 Side cover removal 8 24 Center cover removal 8 25 Center cover disassembly 8 27 Side cover removal 8 28 Shift lever removal 8 28 Steering master 8 29 Steering master removal 8 29 Steering master disassembly 8 31 Steering master component check 8 34 Spr...

Page 355: ... check 8 45 Exhaust system 8 46 Exhaust system and battery removal 8 46 Exhaust system check 8 49 Deck and hull 8 50 Deck and hull disassembly 1 8 50 Deck and hull disassembly 2 8 52 Drain plug check 8 54 Front protector 1 installation 8 54 Pull up cleat cover installation FX Cruiser SHO 8 54 Reboarding step installation 8 54 ...

Page 356: ...ervice points 1 Screw 2 2 Screw 6 3 Upper handlebar cover 1 4 Steering pad 1 5 Screw 3 6 Lower handlebar cover 1 Reverse the removal steps for installation 4 6 5 2 1 3 4 10 mm 1 N m 0 1 kgf m 0 7 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 6 14 mm 5 N m 0 5 kgf m 3 7 ft Ib LT 242 5 15 mm Handlebar ...

Page 357: ...cover 1 4 Upper handlebar cover 1 NOTE Be sure to insert the projection a on the upper handlebar cover completely into the grommet 5 Bolt 4 6 Steering pad 1 7 Grommet 1 Reverse the removal steps for installation 7 4 6 5 2 1 6 7 5 4 3 1 N m 0 1 kgf m 0 7 ft Ib 6 14 mm a LT 271 1 N m 0 1 kgf m 0 7 ft Ib 5 15 mm 5 N m 0 5 kgf m 3 7 ft Ib 6 14 mm Handlebar ...

Page 358: ...rt name Q ty Service points 1 Throttle cable 1 NOTE Be sure to remove the throttle cable seal as shown 2 Bolt 4 3 Upper handlebar holder 2 a Punch mark Reverse the removal steps for installation 8 48 mm 21 N m 2 1 kgf m 15 5 ft Ib A A a 1 2 3 LT 242 Handlebar ...

Page 359: ...ive to the handlebar and the inner surface of the handlebar grip 9 Screw 2 A LT 242 LT 242 12 11 13 14 12 4 10 5 6 7 3 2 1 6 10 mm 1 N m 0 1 kgf m 0 7 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 5 35 mm 3 N m 0 3 kgf m 2 2 ft Ib 6 70 mm 3 N m 0 3 kgf m 2 2 ft Ib 5 35 mm 3 N m 0 3 kgf m 2 2 ft Ib 5 25 mm 1 2 15 1 2 8 3 16 10 9 18 15 14 14 14 21 22 20 17 A 19 21 19 20 b a 5 35 mm 1 N m 0 1 kgf m 0 7 ft Ib LT 24...

Page 360: ...andlebar switch assembly 12 Right handlebar switch assembly 1 13 Handlebar 1 14 Screw 4 A LT 242 LT 242 12 11 13 14 12 4 10 5 6 7 3 2 1 6 10 mm 1 N m 0 1 kgf m 0 7 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 5 35 mm 3 N m 0 3 kgf m 2 2 ft Ib 6 70 mm 3 N m 0 3 kgf m 2 2 ft Ib 5 35 mm 3 N m 0 3 kgf m 2 2 ft Ib 5 25 mm 1 2 15 1 2 8 3 16 10 9 18 15 14 14 14 21 22 20 17 A 19 21 19 20 b a 5 35 mm 1 N m 0 1 kgf m 0 ...

Page 361: ...7 Left handlebar switch coupler 2 18 Right handlebar switch coupler 1 19 Plastic tie 2 20 Grommet 1 21 Grommet 1 22 Throttle cable 1 Reverse the removal steps for installation A LT 242 LT 242 12 11 13 14 12 4 10 5 6 7 3 2 1 6 10 mm 1 N m 0 1 kgf m 0 7 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 5 35 mm 3 N m 0 3 kgf m 2 2 ft Ib 6 70 mm 3 N m 0 3 kgf m 2 2 ft Ib 5 35 mm 3 N m 0 3 kgf m 2 2 ft Ib 5 25 mm 1 2 15...

Page 362: ... points 1 Left handlebar switch assembly 1 2 Engine shut off cord 1 3 Stop button assembly 1 4 Start button assembly 1 5 Screw 2 6 Right handlebar switch assembly 1 7 E ring 1 8 Washer 2 9 Shaft 1 10 Lever 1 11 Spring 1 Reverse the disassembly steps for assembly 2 3 1 4 5 6 8 10 8 11 7 9 Handlebar ...

Page 363: ...itch assembly NOTE To check the operation and continuity of the left hand right handlebar switches refer to Left handlebar switch assembly and Right handlebar switch assembly in Chapter 7 Handlebar assembly installation 1 Install Packings 1 Grommet 2 Grommet 3 QSTS cables 4 Throttle cable 5 Left handlebar switch lead 6 Right handlebar switch lead 7 Plastic ties 8 Handlebar 9 Corrugated tube thrott...

Page 364: ... from the upper edge d of the grommet 4 Fasten the end of each grommet with the plastic tie 8 NOTE Position the corrugated tube 0 for the throttle cable so that the end of the tube makes con tact with the packing 1 as shown È STBD É PORT Marking tape b FX SHO Throttle cable White QSTS cable White Handlebar switch leads Blue FX Cruiser SHO Throttle cable Gray QSTS cable Blue Handlebar switch leads ...

Page 365: ...1 QSTS cables 2 and handlebar switch leads 3 and 4 when the handlebar 5 is turned to the left and right Reroute the cables and lead if there is no slack È FX SHO É FX Cruiser SHO 3 Install Handlebar 1 Upper handlebar holders 2 Installation steps 1 Align the punch marks a on the handlebar 1 with the top surface of the steering shaft 3 2 Install the upper handlebar holders 2 with the punch marks b f...

Page 366: ...al 1 into the groove in the bracket 3 Pull the throttle cable 2 in the direction of the arrow shown and then fit the end of the seal 1 around the inner cable 4 Adjust the throttle lever free play Refer to Throttle lever free play check and adjustment in Chapter 3 Throttle lever free play a 2 0 5 0 mm 0 08 0 20 in 1 1 2 a Handlebar ...

Page 367: ...efer to Exhaust system and battery removal QSTS grip assembly Refer to Handlebar assembly removal 1 Cover 1 2 Cable end 2 3 Grip 1 4 Housing 1 5 Bolt washer 4 4 6 Washer 4 7 QSTS rod 1 STERN 7 13 10 7 12 13 11 5 3 4 1 2 9 15 2 1 4 3 8 15 14 3 mm 0 12 in 6 mm 0 24 in a 6 14 mm 7 N m 0 7 kgf m 5 2 ft Ib 5 9 N m 0 59 kgf m 4 4 ft Ib 6 33 mm 5 N m 0 5 kgf m 3 7 ft Ib a b A A A 6 A A A A A QSTS grip an...

Page 368: ...mbly make identification mark near the pulley STBD hole b 13 QSTS converter 1 14 Nut 1 15 QSTS cable 2 Reverse the disassembly steps for assembly STERN 7 13 10 7 12 13 11 5 3 4 1 2 9 15 2 1 4 3 8 15 14 3 mm 0 12 in 6 mm 0 24 in a 6 14 mm 7 N m 0 7 kgf m 5 2 ft Ib 5 9 N m 0 59 kgf m 4 4 ft Ib 6 33 mm 5 N m 0 5 kgf m 3 7 ft Ib a b A A A 6 A A A A A QSTS grip and converter ...

Page 369: ...Remove QSTS cable ends 1 QSTS check 1 Check QSTS grip Cracks damage wear Replace the QSTS grip 2 Check QSTS cables Damage kinks Replace the QSTS cables QSTS rod Bends damage Replace the QSTS rod 3 Check Pulley 1 Rough movement stiffness Clean the pulley Damage Replace the pulley QSTS converter Cracks damage wear Replace the QSTS converter 1 QSTS grip and converter ...

Page 370: ... must be screwed in more than 8 mm 0 31 in c QSTS rod set length b 176 0 5 mm 6 93 0 02 in T R QSTS rod locknut 4 N m 0 4 kgf m 3 0 ft lb LOCTITE 572 b 1 a c LT 572 LT 3 Install QSTS cables handlebar end Installation steps 1 Pass the QSTS cables 1 through the cover 2 and housing 3 as shown NOTE Pass the cable with the thin end a into the hole of the narrow groove b side and the cable with the thic...

Page 371: ... cable with the thin end a into the open ing with the narrow groove b and the cable with the thick end c into the opening with the wide groove d 5 Fit the cover 2 into the housing 3 and grip 4 4 Check QSTS nozzle angle Refer to Jet thrust nozzle steering angle check and adjustment in Chapter 3 d b 3 2 4 QSTS grip and converter ...

Page 372: ...Band 1 Not reusable 8 Boot 1 9 Damper 1 10 Nut 4 5 N m 0 5 kgf m 3 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 4 9 3 5 6 8 2 26 10 1 7 25 6 N m 0 6 kgf m 4 4 ft Ib 11 LT 242 LT 242 LT 242 23 22 14 17 16 15 12 6 30 mm 14 13 19 20 21 18 8 25 mm 13 N m 1 3 kgf m 9 6 ft Ib 17 5 N m 0 5 kgf m 3 7 ft Ib 24 24 5 N m 0 5 kgf m 3 7 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 4 13 mm Front hood ...

Page 373: ...asher 2 2 18 Left mirror 1 19 Right mirror 1 20 Left mirror cover 1 5 N m 0 5 kgf m 3 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 4 9 3 5 6 8 2 26 10 1 7 25 6 N m 0 6 kgf m 4 4 ft Ib 11 LT 242 LT 242 LT 242 23 22 14 17 16 15 12 6 30 mm 14 13 19 20 21 18 8 25 mm 13 N m 1 3 kgf m 9 6 ft Ib 17 5 N m 0 5 kgf m 3 7 ft Ib 24 24 5 N m 0 5 kgf m 3 7 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 4 13 mm Front hood ...

Page 374: ...26 Service lid 1 Reverse the removal steps for installation 5 N m 0 5 kgf m 3 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 4 9 3 5 6 8 2 26 10 1 7 25 6 N m 0 6 kgf m 4 4 ft Ib 11 LT 242 LT 242 LT 242 23 22 14 17 16 15 12 6 30 mm 14 13 19 20 21 18 8 25 mm 13 N m 1 3 kgf m 9 6 ft Ib 17 5 N m 0 5 kgf m 3 7 ft Ib 24 24 5 N m 0 5 kgf m 3 7 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 4 13 mm Front hood ...

Page 375: ...e mirror orna ment 1 shown and remove the ornament from the mirror cover 2 NOTE Be careful not to break the mirror ornament projections when removing the ornaments a a 1 2 Mirror assembly installation 1 Install Mirror assembly 1 NOTE When installing a mirror assembly be sure to hook the projection a on the mirror onto the front hood T R Mirror assembly bolt 13 N m 1 3 kgf m 9 6 ft lb LOCTITE 242 a...

Page 376: ... Install Rivets Installation steps NOTE Before reinstalling a rivet hold the rivet flange a with both hands and push the rivet pin per pendicularly against a hard flat surface until the pin protrudes from the top of the rivet 1 Insert a rivet completely in the holes in both the service lid 1 and inner hull 2 2 Push in the rivet pin 3 until it clicks and is flush with the top of the rivet a 3 1 2 F...

Page 377: ...bar assembly removal Service lid Refer to Front hood removal 1 Rivet 2 2 Cover 1 3 Plastic tie 1 4 Multifunction meter coupler 4 5 Screw 4 6 Multifunction meter cover 1 7 Left operation button coupler 1 8 Right operation button coupler 1 FX Cruiser SHO 11 10 14 4 1 2 5 8 12 3 7 9 6 2 N m 0 2 kgf m 1 5 ft Ib 5 15 mm 4 N m 0 4 kgf m 3 0 ft Ib 5 12 mm 13 Steering console cover ...

Page 378: ...embly 1 10 Cover 1 FX SHO 11 Right operation button assembly 1 FX Cruiser SHO 12 Bolt 4 13 Plastic tie 1 14 Multifunction meter 1 Reverse the removal steps for installation 11 10 14 4 1 2 5 8 12 3 7 9 6 2 N m 0 2 kgf m 1 5 ft Ib 5 15 mm 4 N m 0 4 kgf m 3 0 ft Ib 5 12 mm 13 Steering console cover ...

Page 379: ... 2 Left side cover 1 3 Right side cover 1 4 Nut 6 5 Rivet 2 Not reusable 6 Nut 6 7 Bolt 6 8 Left side ornament 1 9 Right side ornament 1 Reverse the removal steps for installation 1 7 5 1 1 8 2 3 1 1 5 7 4 4 9 1 1 6 6 6 20 mm 5 N m 0 5 kgf m 3 7 ft Ib 6 28 mm 5 N m 0 5 kgf m 3 7 ft Ib Steering console cover ...

Page 380: ...r 1 2 Nut 3 3 Bolt 3 4 Shift lever assembly 1 5 Bolt 2 6 Reverse sensor 1 7 Nut washer 2 2 8 Nut washer 6 6 9 Bolt 4 11 9 9 13 4 3 6 7 14 10 15 12 14 2 8 1 5 6 30 mm 6 28 mm 5 N m 0 5 kgf m 3 7 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 5 16 mm Steering console cover ...

Page 381: ... Left induction box 1 13 Right induction box 1 14 Rivet 3 Not reusable 15 Box 1 Reverse the removal steps for installation 11 9 9 13 4 3 6 7 14 10 15 12 14 2 8 1 5 6 30 mm 6 28 mm 5 N m 0 5 kgf m 3 7 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 5 16 mm Steering console cover ...

Page 382: ...name Q ty Service points 1 Bolt 2 2 Lid lock hook 1 3 Bracket 1 4 Nut 2 5 Grommet 4 6 Hinge pin 2 7 Center console box lid 1 8 Gear 2 9 Lock 1 Reverse the disassembly steps for assembly 1 2 4 3 4 8 5 8 6 7 9 5 20 mm 4 N m 0 4 kgf m 3 0 ft Ib Steering console cover ...

Page 383: ...e side cover 1 push down on the cover near the tab a to release the raised portion on the tab a 1 1 Shift lever removal 1 Remove Nut 1 Bolt 2 Shift lever assembly 3 Bolt 4 Reverse sensor 5 CAUTION Do not disassemble the shift lever assem bly except the reverse sensor 1 4 5 2 3 Steering console cover ...

Page 384: ...pler 1 2 Buzzer coupler 1 3 Bolt 1 4 Plate 1 NOTE Bend a tab a along a flat side of the bolt 5 Steering arm assembly 1 6 Nut 1 7 Steering cable ball joint 1 8 Arm 1 NOTE Align the rounded portions b and c 14 12 7 5 9 16 3 8 13 14 6 8 4 8 35 mm 5 25 mm 6 60 mm LT 271 21 N m 2 1 kgf m 15 5 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 4 N m 0 4kgf m 3 0 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib a a 8 25 mm 16 N m 1 6 kgf m...

Page 385: ...16 Nut washer 2 2 FX Cruiser SHO 17 Screw 2 FX Cruiser SHO 18 Compass and air temperature sensor 1 FX Cruiser SHO 19 Grommet 1 Reverse the removal steps for installation 14 12 7 5 9 16 3 8 13 14 6 8 4 8 35 mm 5 25 mm 6 60 mm LT 271 21 N m 2 1 kgf m 15 5 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 4 N m 0 4kgf m 3 0 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib a a 8 25 mm 16 N m 1 6 kgf m 11 8 ft Ib 11 1 2 17 15 19 18 10 b...

Page 386: ...ing a otherwise the OTS does not function properly 4 Pipe seal 1 Not reusable 5 Bolt 1 6 Bracket 2 1 7 Bushing 1 É È 2 10 9 1 7 24 17 24 5 6 19 18 23 22 8 11 11 14 12 3 3 4 A A A A A A A A A A LT 572 LT A A 20 16 15 12 12 13 12 21 LT 572 LT a a 6 25 mm 7 N m 0 7 kgf m 5 2 ft Ib 5 16 mm 4 N m 0 4 kgf m 3 0 ft Ib 6 25 mm 7 N m 0 7 kgf m 5 2 ft Ib 5 16 mm 4 N m 0 4 kgf m 3 0 ft Ib A A Steering master...

Page 387: ...ng 1 15 Spring holder 1 16 Spring 1 1 17 Spring 2 1 18 Lever 1 19 Lock 1 20 Right housing 1 É È 2 10 9 1 7 24 17 24 5 6 19 18 23 22 8 11 11 14 12 3 3 4 A A A A A A A A A A LT 572 LT A A 20 16 15 12 12 13 12 21 LT 572 LT a a 6 25 mm 7 N m 0 7 kgf m 5 2 ft Ib 5 16 mm 4 N m 0 4 kgf m 3 0 ft Ib 6 25 mm 7 N m 0 7 kgf m 5 2 ft Ib 5 16 mm 4 N m 0 4 kgf m 3 0 ft Ib A A Steering master ...

Page 388: ...g 2 Reverse the disassembly steps for assembly É È 2 10 9 1 7 24 17 24 5 6 19 18 23 22 8 11 11 14 12 3 3 4 A A A A A A A A A A LT 572 LT A A 20 16 15 12 12 13 12 21 LT 572 LT a a 6 25 mm 7 N m 0 7 kgf m 5 2 ft Ib 5 16 mm 4 N m 0 4 kgf m 3 0 ft Ib 6 25 mm 7 N m 0 7 kgf m 5 2 ft Ib 5 16 mm 4 N m 0 4 kgf m 3 0 ft Ib A A Steering master ...

Page 389: ...g shaft CAUTION 3 Do not disassemble the board spring a otherwise the OTS does not function prop erly a Spring installation 1 Install Spring 2 1 NOTE Before installing the spring 2 1 install the steering tube 2 to the right housing 3 Installation steps 1 Angle the steering tube 2 as shown 2 While compressing the spring 2 1 install it into the steering tube 2 2 3 1 Steering master ...

Page 390: ... spring 1 1 install it into the lever 4 3 2 1 4 Rubber seal installation 1 Install Rubber seal 1 Steering master assembly 2 CAUTION Do not reuse the rubber seal always re place it with a new one Installation step 1 Apply instant adhesive onto the mating surfaces of the rubber seal 1 and steering master assembly 2 in the area a shown and then install the seal a 1 2 Steering master ...

Page 391: ...sable 5 Nut 1 6 Screw 4 7 Speed sensor Speed and water temperature sen sor 1 1 È To multifunction meter FX SHO È To compass and air temperature sensor FX Cruiser SHO 8 Shift cable joint 1 15 1 14 9 10 8 12 11 16 13 18 19 17 2 4 3 6 5 7 A A LT 572 LT LT 572 LT LT 242 16 N m 1 6 kgf m 11 8 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 5 9 N m 0 59 kgf m 4 4 ft Ib 5 9 N m 0 59 kgf m 4 4 f...

Page 392: ...18 Shift cable 1 19 Seal 1 Not reusable Reverse the removal steps for installation 15 1 14 9 10 8 12 11 16 13 18 19 17 2 4 3 6 5 7 A A LT 572 LT LT 572 LT LT 242 16 N m 1 6 kgf m 11 8 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 5 9 N m 0 59 kgf m 4 4 ft Ib 5 9 N m 0 59 kgf m 4 4 ft Ib 2 9 N m 0 29 kgf m 2 1 ft Ib 5 9 N m 0 59 kgf m 4 4 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 5 12 mm È Remote...

Page 393: ... tion rotate the drum nut 1 counterclock wise a maximum of 90 for proper alignment CAUTION Do not attempt to twist the steering cable to align it Be sure to turn the drum nut 1 to install the steering cable 3 Slightly pull out the clamp plate 2 on the cable stopper assembly and then rotate it clockwise to lock it in place securely 1 a b 3 2 4 Rotate the clamp plate 3 on the cable stopper assembly ...

Page 394: ... Steering cable locknut jet pump end 7 N m 0 7 kgf m 5 2 ft lb LOCTITE 572 a LT 572 LT Shift cable installation shift lever end 1 Install Shift cable holders Installation steps 1 Install the shift cable holder 1 so that the projection a on the holder fits into the groove b in the outer cable 2 Slide the shift cable holder 2 onto the shift cable holder 1 so that the marks c and d are positioned as ...

Page 395: ... cable NOTE To adjust the shift cable Refer to Shift cable check and adjustment in Chapter 3 Shift cable set length a jet pump end 13 0 0 8 mm 0 51 0 03 in T R Shift cable locknut jet pump end 2 9 N m 0 29 kgf m 2 1 ft lb LOCTITE 572 a LT 572 LT Remote control cables and speed sensor lead ...

Page 396: ...ter 5 1 Band 4 Not reusable 2 Ventilation hose 2 3 Fuel tank breather hose 1 1 4 Fuel tank breather hose 2 1 5 Rivet 2 Not reusable 6 Water separator 1 7 Nut 3 8 Seal 3 Not reusable 9 Clamp 3 2 1 2 7 1 8 11 11 11 10 9 7 4 N m 0 4 kgf m 3 0 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 1 4 3 12 15 14 13 9 10 10 8 b a 7 1 È ÉÉ 6 5 Hoses ...

Page 397: ...a with the slits b 11 Cooling water hose 3 È To air cooler É To oil cooler 12 Rivet 2 Not reusable 13 Ventilation socket 1 14 Band 1 Not reusable 15 Ventilation pipe 1 Reverse the removal steps for installation 2 1 2 7 1 8 11 11 11 10 9 7 4 N m 0 4 kgf m 3 0 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 1 4 3 12 15 14 13 9 10 10 8 b a 7 1 È ÉÉ 6 5 Hoses ...

Page 398: ...ble 7 Seat storage compartment 1 8 Nut washer 4 4 9 Bolt washer 4 4 10 Deck beam 1 11 Nut 1 12 Projection washer 1 1 6 N m 0 6 kgf m 4 4 ft Ib 6 40 mm 6 40 mm 6 25 mm 8 30 mm LT 271 4 3 6 6 2 2 5 1 LT 271 4 3 LT 271 4 23 22 7 8 22 23 3 É È 5 LT 271 4 3 É É È È 18 9 10 12 13 14 14 11 16 15 16 17 15 16 N m 1 6 kgf m 11 8 ft Ib 26 N m 2 6 kgf m 19 2 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib 20 21 19 5 N m 0 ...

Page 399: ...grip 1 È FX SHO É FX Cruiser SHO Reverse the removal steps for installation 6 N m 0 6 kgf m 4 4 ft Ib 6 40 mm 6 40 mm 6 25 mm 8 30 mm LT 271 4 3 6 6 2 2 5 1 LT 271 4 3 LT 271 4 23 22 7 8 22 23 3 É È 5 LT 271 4 3 É É È È 18 9 10 12 13 14 14 11 16 15 16 17 15 16 N m 1 6 kgf m 11 8 ft Ib 26 N m 2 6 kgf m 19 2 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib 20 21 19 5 N m 0 5 kgf m 3 7 ft Ib 6 N m 0 6 kgf m 4 4 ft ...

Page 400: ...8 45 E HULL HOOD Seat lock check 1 Check Seat lock assembly 1 Does not lock Replace the seat lock assembly Projection 2 Damage Replace the projection 2 2 1 1 Seats and hand grip ...

Page 401: ...ter 6 1 Negative battery cable 1 2 Positive battery cable 1 3 Clip battery breather hose 1 1 4 Band 2 5 Battery 1 6 Damper 1 7 Bolt 2 8 Bolt 2 9 Battery box 1 10 Spacer 2 23 22 21 3 7 N m 0 37 kgf m 2 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 6 16 mm 6 30 mm a a b 11 15 13 14 16 8 10 17 12 18 20 1 19 3 7 N m 0 37 kgf m 2 7 ft Ib 3 7 N m 0 37 kgf m ...

Page 402: ...ark b on the water tank 16 Band 1 17 Water lock 1 18 Clamp 1 19 Water tank 1 20 Nut washer 6 6 23 22 21 3 7 N m 0 37 kgf m 2 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 6 16 mm 6 30 mm a a b 11 15 13 14 16 8 10 17 12 18 20 1 19 3 7 N m 0 37 kgf m 2 7 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 21 23 22 2 3 5 6 9 7 4 b 572 LT 572 LT A A A A Exhaust system ...

Page 403: ...everse the removal steps for installation 23 22 21 3 7 N m 0 37 kgf m 2 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 6 16 mm 6 30 mm a a b 11 15 13 14 16 8 10 17 12 18 20 1 19 3 7 N m 0 37 kgf m 2 7 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 21 23 22 2 3 5 6 9 7 4 b 572 LT 572 LT A A A A Exhaust system ...

Page 404: ...8 49 E HULL HOOD Exhaust system check 1 Check Rubber hoses Burns cracks damage Replace the rubber hoses 2 Check Water lock 1 Water tank 2 Cracks damage leaks Replace 2 1 Exhaust system ...

Page 405: ...s before installing the projec tions b of the front protectors 6 Grommet 4 7 Front protector 2 1 8 Rivet 9 Not reusable 9 Rear protector 2 10 Rivet 10 Not reusable 13 N m 1 3 kgf m 9 6 ft Ib 6 20 mm 5 12 mm 6 15 mm 5 N m 0 5 kgf m 3 7 ft Ib 6 25 mm 2 N m 0 2 kgf m 1 5 ft Ib 16 N m 1 6 kgf m 11 8 ft Ib 8 40 mm 1 2 3 4 17 15 16 5 7 572 LT 6 3 LT 242 12 14 13 b 8 8 9 18 19 10 11 LT 271 5 N m 0 5 kgf ...

Page 406: ...ll up cleat assembly 2 FX Cruiser SHO 18 Bolt collar 10 10 19 Sponson 2 Reverse the disassembly steps for assembly 13 N m 1 3 kgf m 9 6 ft Ib 6 20 mm 5 12 mm 6 15 mm 5 N m 0 5 kgf m 3 7 ft Ib 6 25 mm 2 N m 0 2 kgf m 1 5 ft Ib 16 N m 1 6 kgf m 11 8 ft Ib 8 40 mm 1 2 3 4 17 15 16 5 7 572 LT 6 3 LT 242 12 14 13 b 8 8 9 18 19 10 11 LT 271 5 N m 0 5 kgf m 3 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib a Deck and ...

Page 407: ...out 1 NOTE Face the mark a toward the bow 6 Nut 4 7 Plate 4 8 Packing 2 Not reusable 9 Stern eye 2 10 Nut washer 4 4 11 Screw 4 2 2 1 3 a 5 25 mm 8 48 mm 5 N m 0 5 kgf m 3 7 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 16 N m 1 6 kgf m 11 8 ft Ib 16 N m 1 6 kgf m 11 8 ft Ib 14 16 14 15 16 9 7 8 10 13 12 11 6 7 5 4 LT 271 16 N m 1 6 kgf m 11 8 ft Ib Deck and hull ...

Page 408: ...t 6 15 Reboarding step assembly 1 16 Spacer 2 Reverse the disassembly steps for assembly 2 2 1 3 a 5 25 mm 8 48 mm 5 N m 0 5 kgf m 3 7 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 16 N m 1 6 kgf m 11 8 ft Ib 16 N m 1 6 kgf m 11 8 ft Ib 14 16 14 15 16 9 7 8 10 13 12 11 6 7 5 4 LT 271 16 N m 1 6 kgf m 11 8 ft Ib Deck and hull ...

Page 409: ...nstall Pull up cleat covers NOTE Make sure that the word YAMAHA a on each pull up cleat cover can be read correctly from the side of the watercraft as shown a Reboarding step installation 1 Install Reboarding step Installation steps 1 Fasten the brackets in both sides of the reboarding step in the down position with plastic ties 1 as shown so that they will not return to the up position 2 Finger t...

Page 410: ...8 55 E HULL HOOD MEMO Deck and hull ...

Page 411: ...erating 9 5 Connecting the communication cable to the watercraft 9 5 Engine unit trouble analysis 9 6 Using the YDIS for engine unit trouble analysis 9 6 Self diagnosis 9 7 Diagnostic code table 9 8 Diagnostic code and checking step 9 9 Engine unit trouble analysis diagnostic code not detected 9 15 Trouble analysis chart 9 15 ...

Page 412: ...sis Diagnosis record Engine monitor Data log ger and Record of engine oil exchange can be saved on a disk or printed out NOTE Be sure to use YDIS Ver 1 30 with this model Functions Scan tool 1 Diagnosis Each sensor s status and each ECM diagnostic code or item is displayed This enables you to find malfunctioning parts and controls quickly The diagnostic codes displayed are the same as those descri...

Page 413: ...and fuel pump relay 1 Engine speed 11 Fuel injection duration 21 No Wake mode switch 11 2 Intake pressure 1 12 Engine temperature 22 Cruise assist switch 12 3 Throttle position sensor 1 2 13 Intake temperature 6 23 Cruise assist up switch 13 4 Throttle valve opening 0 90 14 Ex manifold water temp sensor 7 24 Cruise assist down switch 14 5 Throttle position sensor 2 3 15 Engine stop lanyard switch ...

Page 414: ...recorded data are displayed on a graph In addition the operating time as compared to the engine speed and the total operating time are displayed This allows you to check the operating status of the engine For FX SHO FX Cruiser SHO models you can also save the ECM record data in a file so that you can read and display the graph later Items For FX SHO FX Cruiser SHO 1 Intake air pressure 2 Oil press...

Page 415: ...tage of the APS This value is used to detect the APS output voltage when the throttle lever is opened 9 Target TPS voltage for Idle Speed Control ECM controls the engine idle speed by using the throttle valve attached to the TPS This target voltage is used by the ECM to achieve the target opening angle of the throttle valve at the engine idle speed 10 Engine stop mode with switch 11 Engine shut of...

Page 416: ...CD ROM software instruction manual 2 Adapter 3 Communication cable Operating Connecting the communication cable to the watercraft 1 Wiring harness coupler 2 Meter coupler 3 3 pin communication coupler NOTE Be careful not to pinch the communication cable between the front hood and the deck or to damage it 1 2 3 B R Y W B 1 2 3 YDIS ...

Page 417: ...e not rusty or corroded Check that the engine shut off cord lanyard is connect to the engine shut off switch When deleting the diagnosis record on the YDIS be sure to check the time that the diagnostic codes were detected When checking the input voltage of a part the coupler or connector must be disconnected As a result the ECM determines that the part is disconnected and a diagnostic code is dete...

Page 418: ... meter If the YDIS is not used to check the symptoms listed in the Diagnostic code table the diag nostic codes can be checked easily with the self diagnosis in the multifunction meter How ever because the multifunction meter cannot display more than 1 diagnostic code even if there are multiple diagnostic codes using the YDIS is recommended 1 Engine unit trouble analysis ...

Page 419: ...function 19 Battery voltage malfunction 23 Intake temp sensor 3 malfunction 24 Cam position sensor malfunction 29 Intake press sensor 4 malfunction 47 Slant detection switch malfunction 55 Steering sensor malfunction 65 EX manifold water temp sensor 5 malfunction 68 No Wake mode switch 6 malfunction 78 Reverse switch 7 malfunction 112 113 114 115 116 117 118 119 121 122 123 129 136 137 138 139 141...

Page 420: ...or wiring harness leads for continuity WD 4 Measure the engine temperature sen sor resistance 7 23 17 Knock sensor malfunction Normal operation 1 Check that the knock sensor is installed correctly 5 90 2 Measure the knock sensor resistance 7 28 3 Check the green G knock sensor wir ing harness lead for continuity WD 19 Batteryvoltage malfunction Trolling speed is unstable 3 1 Check the battery volt...

Page 421: ...gine stalls Trolling speed is unstable 3 1 Check the intake air pressure using the YDIS 9 1 2 Measure the intake air pressure sen sor input voltage 7 26 3 Check the orange pink green and black orange O P G and B O intake air pressure sensor wiring harness leads for continuity WD 4 Check the intake air pressure sensor operation 7 26 47 Slant detection switch malfunction Normal operation 1 Check the...

Page 422: ...mo sensor resis tance 7 22 68 No Wake mode switch malfunction Normal operation 1 Check the right handlebar switch oper ation using the YDIS 7 40 2 Measure the right handlebar switch input voltage 7 40 3 Check the blue red yellow black yel low red yellow green and black L R Y B Y R Y G and B right handlebar switch assembly wiring harness leads for continuity WD 78 Reverse switch 2 malfunction Norma...

Page 423: ... orange pink black and black orange P O P B and B O throttle body assembly wiring harness leads for continuity WD 2 Check the TPS output voltage and throttle valve opening using the YDIS 7 28 3 Check the throttle shaft and throttle inner surface for wear or damage 5 38 117 118 119 Electronic throttle system 1 malfunction Engine speed is limited 1 Check the throttle body assembly cou pler terminals...

Page 424: ...YDIS 7 28 2 Check the ECM circuit for continuity 7 42 129 Electronic throttle system 1 malfunction Engine speed is limited 1 Check the TPS output voltage using the YDIS 7 28 2 Check the ETV relay and fuse ETV relay for continuity 7 35 7 3 131 132 133 134 Accelerator position sensor malfunction Engine speed is limited 1 Check the APS output voltage using the YDIS 7 31 2 Check the APS circuit for co...

Page 425: ...e TPS output voltage and throttle valve opening using the YDIS 7 28 2 Check the throttle shaft and throttle inner surface for wear or damage 5 38 143 144 Electronic throttle system 1 malfunction Engine speed is limited 1 Check the ECM circuit for continuity 7 42 2 Check the ETV relay for continuity 7 35 3 Check the charging system Stator coil output peak voltage Stator coil resistance Rectifier re...

Page 426: ...GINE STALLS POOR ACCELERATION ENGINE WILL NOT STOP POOR PERFORMANCE LIMITED ENGINE SPEED OVERHEATING LOW OIL PRESSURE LOOSE STEERING BILGE INCREASE IRREGULAR WARNING INDICATION Relative item Reference chapter FUEL SYSTEM Fuel tank breather hose 4 Check valve 4 Fuel hose 4 Fuel pump 4 7 Fuel filter 4 Fuel tank 4 Fuel sender 4 7 Fuel rail 4 Fuel injectors 4 7 Engine unit trouble analysis ...

Page 427: ...er head gasket 5 Cylinder block 5 Crankcase 5 Crankshaft 5 Piston rings 5 Pistons 5 Bearings 5 Thermostat 5 Pilot water hose 5 Water hose 5 Trouble mode Check items 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 INDICA...

Page 428: ...e shut off switch 7 Main and fuel pump relay 7 Starter relay 7 Starter motor 7 Remote control receiver 7 HULL AND HOOD Steering master 8 Water lock 8 Exhaust hose 8 Drain plugs 8 Trouble mode Check items 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 ...

Page 429: ...9 18 E TRBL ANLS 1 2 3 4 5 6 7 8 9 MEMO Engine unit trouble analysis ...

Page 430: ...eter _ Compass and air temperature sensor FX Cruiser SHO a Speed sensor FX SHO Speed and water temperature sensor FX Cruiser SHO b Left operation button assembly c Right operation button assembly FX Cruiser SHO d Engine start switch e Engine stop switch f Engine shut off switch È To entry box É To tachometer Ê FX Cruiser SHO Color code B Black Br Brown G Green Gy Gray L Blue O Orange P Pink R Red ...

Page 431: ......

Page 432: ...YAMAHA MOTOR CORPORATION USA Printed in USA Jan 2008 0 0 1 CR E ...

Page 433: ...B P B W Pu R Pu B Pu G Pu Y P W B G R Y R Y W B B Y Y G Y R Y W L R B R B W Y Y Y Gy B B B R R B R R Br Y B O L B L B B O B G G O B O G O B O P W P W R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y B Y B Y B Y R Y B O B R B O B O B O B O B L P G R Y R Y R Y R Y R Y R Y R Y R Y R Y R Y B L L Y L B Y W Pu G Pu Y Pu B Pu R R Y B Y B W B R R Y R Y R Y R Y R Y R Y Y W Y G R Y R Y L R P B B R R O O B B B R Y B ...

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