Yamaha WaveRunner GP800R Service Manual Download

Page: 105 / 247

5-20

POWR

CYLINDERS

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step

Procedure/Part name

Q’ty

Service points

CYLINDER REMOVAL

Follow the left “Step” for removal.

YPVS

Refer to “YPVS”.

Cylinder head

Refer to “CYLINDER HEAD”.

Bolt

NOTE:

Tighten the bolts in a crisscross pattern
and in two stages.

Cylinder

NOTE:

Install the original position.

Cylinder gasket

Reverse the removal steps for installation.

Not reusable

Summary of Contents for WaveRunner GP800R

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

Page 2: ...amaha has a policy of continuously improving its products models may differ in detail from the descriptions and illustrations given in this publication Use only the latest edi tion of this manual Auth...

Page 3: ...evised format the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol e g Bearings Pitting scratches Replace To assist you in finding...

Page 4: ...o follow WARNING instructions could result in severe injury or deathto the machine operator a bystander or a person inspecting or repairing the watercraft CAUTION A CAUTION indicates special precautio...

Page 5: ...indicate parts to be lubricated or replaced see SYMBOLS 4 A job instruction chart accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc 5 Dimension figures and...

Page 6: ...bricant and the loca tion of lubrication point F Apply YAMALUBE 2 W oil or TC W3 cirtified outboard oil G Apply water resistant grease Yamaha grease A Yamaha marine grease H Apply molybdenum disulfide...

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

Page 8: ......

Page 9: ...RIAL NUMBER 1 1 JET PUMP UNIT SERIAL NUMBER 1 1 HULL IDENTIFICATION NUMBER H l N 1 1 SAFETY WHILE WORKING 1 2 FIRE PREVENTION 1 2 VENTILATION 1 2 SELF PROTECTION 1 2 OILS GREASES AND SEALING FLUIDS 1...

Page 10: ...y l D number F0W 800101 ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the cylinder head Starting serial number 68A 000101 JET PUMP UNIT SERIAL NUMBER The jet pump uni...

Page 11: ...Gasoline vapor is heavier than air and is deadly if inhaled in large quantities Engine exhaust gases are harmful to breathe When test running an engine indoors maintain good ventilation SELF PROTECTI...

Page 12: ...iled rag in your pocket 4 Hands and any other part of the body which have been in contact with lubri cants or lubricant contaminated cloth ing should be thoroughly washed with hot water and soap as so...

Page 13: ...ling 2 Oil the contact surfaces of moving parts during assembly 3 After assembly check that moving parts operate normally 4 Install bearings with the manufacturer s markings on the side exposed to vie...

Page 14: ...90 06760 2 Dial gauge and stand P N YU 03097 YU 01256 90890 01252 3 Pocket tester P N YU 03112 90890 03112 4 Cylinder gauge set P N YU 03017 90890 06759 5 Compression gauge P N YU 33223 90890 03160 6...

Page 15: ...e bearing attachment jet pump bearing and oil seal P N YB 06112 YB 06196 90890 06614 90890 06653 B Ball bearing attachment jet pump oil seal P N YB 06156 90890 06634 C Driver rod intermediate shaft an...

Page 16: ......

Page 17: ...R 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 ENGINE 2 3 JET PUMP UNIT 2 4 HULL AND HOOD 2 4 ELECTRICAL 2 5 TIGHTENING TORQUES 2 7 SPECIFIED TORQUES 2 7 GENERAL TORQUE 2...

Page 18: ...3 07 Compression ratio 6 6 1 Intake system Reed valve Carburetor model manufacturer quantity BN44 Mikuni 2 Enrichment control Choke valve Scavenging system Loop charge Lubrication system Oil injection...

Page 19: ...asoline Fuel rating PON 86 RON 90 Oil YAMALUBE 2 W or an equivalent TC W3 certified outboard oil Fuel oil mixing ratio wide open throttle 30 1 Fuel tank capacity R US gal Imp gal 60 15 9 13 2 Fuel tan...

Page 20: ...462 Measuring point mm in 22 0 87 Piston to cylinder clearance mm in 0 100 0 105 0 0039 0 0041 Wear limit mm in Cylinder bore 0 105 0 0041 Piston pin bore inside diameter mm in 22 004 22 025 0 8663 0...

Page 21: ...size mm in 1 2 0 05 Trolling speed r min 1 300 50 REED VALVES Thickness mm in 0 52 0 020 Reed valve stopper height mm in 10 8 11 4 0 43 0 45 Reed valve warpage limit mm in 0 2 0 01 Item Unit Model GP...

Page 22: ...t peak voltage lower limit cranking 1 V 5 cranking 2 V 3 2 000 r min V 7 3 500 r min V 11 Lighting coil G G Output peak voltage lower limit cranking 1 V 8 5 cranking 2 V 8 5 2 000 r min V 13 3 500 r m...

Page 23: ...min V 12 5 3 500 r min V 12 5 THERMO SWITCH On temperature C F 80 177 Off temperature C F 70 159 STARTER MOTOR Brush length mm in 12 5 0 49 Wear limit mm in 6 5 0 26 Commutator undercut mm in 0 7 0 0...

Page 24: ...exhaust manifold 1st Bolt M8 5 17 1 7 12 271 LT 2nd 34 3 4 24 Exhaust chamber joint muffler stay 1st Bolt M10 1 2 0 2 1 4 271 LT 3rd 49 4 9 35 2nd Bolt M8 2 2 0 2 1 4 271 LT 4th 37 3 7 27 Exhaust man...

Page 25: ...t M8 2 15 1 5 11 271 LT Nozzle deflector nozzle ring Bolt M8 2 15 1 5 11 271 LT Water inlet cover water inlet strainer impeller duct Bolt M6 4 7 0 7 5 1 572 LT Drive shaft nut drive shaft Nut M16 1 74...

Page 26: ...Steering cable hull Nut 1 6 0 6 4 3 Steering cable holder bracket Bolt M6 1 6 0 6 4 3 Speed sensor lead hull Nut 1 6 0 6 4 3 Hinge assembly front hood Bolt M6 2 12 1 2 8 7 Wind shield front hood Scre...

Page 27: ...ine damper hull Bolt M6 2 6 0 6 4 3 Part to tightened Part name Thread size Q ty Tightening torque Remarks N m kgf m ft lb GENERAL TORQUE This chart specifies tightening torques for standard fasteners...

Page 28: ...F K G H I J A F 1 Fuel filter 2 Fuel tank breather hose 3 Fuel hose 4 Cooling water hose 5 Choke cable 6 Throttle cable 7 Oil return hose 8 Bilge hose 9 Speed sensor lead 0 Electrical box lead A YPVS...

Page 29: ...uction hose 4 Speed sensor lead 5 QSTS cable 6 Cooling water hose 7 Steering cable 8 Flushing hose 9 Bilge hoses 0 To multifunction meter A To stator assembly B To cylinder 1 C To cylinder 2 D To batt...

Page 30: ......

Page 31: ...pection and adjustment 3 4 QSTS cable inspection and adjustment 3 5 YPVS cable adjustment 3 6 FUEL SYSTEM 3 7 Fuel line inspection 3 7 Trolling speed check and adjustment 3 8 OIL INJECTION SYSTEM 3 9...

Page 32: ...rottle cable Inspect adjust 3 3 Carburetor throttle shaft Inspect adjust Choke cable Inspect adjust 3 4 QSTS cable Inspect adjust 3 5 YPVS cable Inspect adjust 3 6 FUEL SYSTEM Fuel tank Clean 4 9 Fuel...

Page 33: ...ion steps Move the handlebar up and down and back and forth Check the excessive play of the han dlebar Inspection steps Set the control grip in the neutral posi tion Turn the handlebar from lock to lo...

Page 34: ...le lever free play adjust the trolling speed 1 Measure Throttle lever free play a Out of specification Adjust 2 Adjust Throttle lever free play WARNING The cable joint must be screwed in more than 8 m...

Page 35: ...en it is fully opened Check that the inner cable has some slack when the choke lever is com pletely closed Adjustment steps Loosen the locknut 1 Screw the adjuster 2 fully into the bracket Align the c...

Page 36: ...t QSTS cable Adjustment steps Set the control grip in the neutral posi tion Loosen the locknut 1 Remove the nut 2 and pivot pin 3 Set the nozzle deflector in the center position Turn the cable joint 4...

Page 37: ...cable adjustment 1 Check YPVS valve position Incorrect position Adjust the YPVS cable Checking steps Start the engine and then stop it NOTE When the engine has been stopped for 3 seconds the YPVS val...

Page 38: ...el hoses through part Fuel filler cap Cracks damage Replace Adjustment steps Loosen locknuts 1 and 2 Turn in adjusters 3 and 4 until there is slack in the cables Align the hole a in the pulley with th...

Page 39: ...ft in the water Start the engine and allow it to warm up for several minutes Attach the engine tachometer to the spark plug lead Engine tachometer YU 8036 A 90890 06760 Measure the engine trolling spe...

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

Page 41: ...rrect tightening torque for a new spark plug is to finger tighten a the spark plug and then tighten it another 1 4 to 1 2 of a turn b T R Spark plug 25 N m 2 5 kgf m 18 ft lb ELECTRICAL Battery inspec...

Page 42: ...NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN CAUTION Do not place the battery on its side Before adding electrolyte or recharging be sure to r...

Page 43: ...stilled water When the electrolyte level reaches the upper level mark allow the cell to stand for 20 minutes If the electrolyte level drops add more distilled water so the level reaches the upper leve...

Page 44: ...and is not obstructed Coat the terminals with a water resistant grease to minimize terminal corrosion JET PUMP UNIT Impeller inspection 1 Check Impeller 1 Damage wear Replace Nicks scratches File or...

Page 45: ...e water inlet strainer mesh a Install the water inlet cover 1 a Bilge strainer inspection 1 Inspect Bilge strainer Contaminants Clean Cracks damage Replace Inspection steps Disconnect the bilge strain...

Page 46: ...ubricant Rust inhibitor 2 Lubricate QSTS control cables handlebar side NOTE Before lubricating the QSTS control cables remove the QSTS cable housing cover Spray the rust inhibitor into the outer cable...

Page 47: ...ble QSTS cables pulley side YPVS cables Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease 5 Lubricate Nozzle pivot shaft Steering cable nozzle side QSTS cable nozzle side...

Page 48: ...ly a small amount of grease Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease 7 Fill Intermediate housing NOTE Fill the intermediate housing with the rec ommended grease t...

Page 49: ......

Page 50: ...4 5 FUEL TANK 4 6 EXPLODED DIAGRAM 4 6 REMOVAL AND INSTALLATION CHART 4 6 SERVICE POINTS 4 9 Check valve inspection 4 9 Fuel level sensor inspection 4 9 Fuel tank inspection 4 9 Pipe joint inspection...

Page 51: ...n 4 24 Jet and carburetor body inspection 4 24 Carburetor assembly 4 24 FUEL PUMP 4 25 EXPLODED DIAGRAM 4 25 REMOVAL AND INSTALLATION CHART 4 25 SERVICE POINTS 4 27 Fuel pump inspection 4 27 Fuel filt...

Page 52: ...AL AND INSTALLATION CHART Step Procedure Part name Q ty Service points FUEL COCK AND FUEL FILTER REMOVAL Follow the left Step for removal 1 Screw 1 2 Knob 1 3 Nut 1 4 Fuel cock assembly 1 5 Fuel hose...

Page 53: ...4 2 FUEL E FUEL COCK AND FUEL FILTER SERVICE POINTS Fuel filter inspection Refer to FUEL SYSTEM in chapter 3 Fuel cock inspection 1 Check Fuel cock Contaminants Clean Rough movement Replace...

Page 54: ...IL TANK REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT in chapter 5 Steering console cover assembly Refer to STEERING CONSOLE COVER in chapter 8 1 Oil level sensor coupler 1...

Page 55: ...IAGRAM Step Procedure Part name Q ty Service points 6 Breather hose 1 7 Oil hose 1 8 Bolt 2 9 Tank belt 2 10 Oil tank assembly 1 11 Hose clamp 1 12 Oil filler hose 1 13 Oil level sensor 1 Reverse the...

Page 56: ...inants Clean Frays tears Replace Rubber seal Cracks wear Replace Oil hoses Oil tank Oil filler cap Cracks damage Replace Check valve Malfunction Replace Oil level sensor inspection Refer to INDICATION...

Page 57: ...ocedure Part name Q ty Service points FUEL TANK REMOVAL Follow the left Step for removal Oil tank Refer to OIL TANK 1 Fuel level sensor coupler 1 2 Hose clamp 1 Disconnect the fuel filler hose from th...

Page 58: ...ODED DIAGRAM Step Procedure Part name Q ty Service points 7 Fuel hose 1 8 Fuel return hose 1 9 Fuel tank breather hose 1 10 Fuel tank assembly 1 11 Hose clamp 1 12 Fuel filler hose 1 13 Hose clamp 1 1...

Page 59: ...ODED DIAGRAM Step Procedure Part name Q ty Service points 15 One way valve 1 16 Screw washer 1 1 17 Filter 1 18 Screw washer 1 1 19 Sleeve 1 20 Floatation 1 21 Bolt 2 22 Tank belt 2 Reverse the remova...

Page 60: ...ter 7 Fuel tank inspection 1 Inspect Fuel tank Cracks damage Replace Pipe joint inspection 1 Inspect Pipe Contaminants Clean Bends damage Replace Checking steps Connect a hose to the end of check valv...

Page 61: ...VAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points INTAKE SILENCER REMOVAL Follow the left Step for removal 1 Bolt 3 2 Intake silencer cover 1 3 Bolt 4 4 Spark arrester 1 5 Intake...

Page 62: ...OX in chapter 8 Intake silencer Refer to INTAKE SILENCER 1 Bolt 2 NOTE When removing the carburetor the exhaust chamber assembly does not need to be removed if the engine unit has already been removed...

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

Page 64: ...me Q ty Service points 16 Muffler stay 1 2 NOTE Make sure to remove spark plugs before removing the muffler stay 1 17 Bolt 2 18 Hose clamp 2 19 Exhaust chamber assembly 1 20 Rubber joint 1 Slide the w...

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

Page 66: ...BURETOR UNIT EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 28 Pulse hose 2 29 Bolt 2 30 Bolt 4 31 Carburetor unit 1 32 Gasket 1 33 Dowel pin 2 Reverse the removal steps for installatio...

Page 67: ...AND INSTALLATION CHART Step Procedure Part name Q ty Service points CARBURETOR UNIT SEPARATION Follow the left Step for removal 1 Pulse hose 2 2 Fuel hose 4 suction return 3 Oil feed hose 2 4 Accelera...

Page 68: ...DIAGRAM Step Procedure Part name Q ty Service points 7 Bolt 3 8 Cable bracket 1 9 Bolt 4 10 Carburetor 2 11 Gasket 2 12 Carburetor joint 1 13 Bolt washer 2 2 14 Fuel hose guide 1 Reverse the removal...

Page 69: ...crew end from the throttle lever Check the each throttle valve is fully closed a a a 2 Adjust Throttle valve synchronization Adjustment steps Loosen the throttle stop screw 1 until untouched the screw...

Page 70: ...play Choke lever operation Refer to CONTROL SYSTEM in chapter 3 Choke cable guide installation position a 13 15 mm 0 51 0 59 in Throttle cable guide installation position a 18 20 mm 0 71 0 79 in Oil p...

Page 71: ...re Part name Q ty Service points CARBURETOR DISASSEMBLY Follow the left Step for disassembly 1 Accelerator pump fuel hose 1 Carburetor 1 2 Screw 4 3 Accelerator pump carburetor cover 1 1 Carburetor 1...

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

Page 73: ...cedure Part name Q ty Service points ACCELERATOR PUMP DISASSEMBLY Follow the left Step for disassembly 1 Screw 1 2 Stay 1 3 Spring 1 4 Spring seat 1 5 Screw 4 6 Accelerator pump cover 1 7 Spring 1 8 D...

Page 74: ...t performance Diaphragm inspection 1 Inspect Diaphragm Damage Replace Accelerator pump body inspection 1 Inspect One way valve Crack damage Replace the acceler ator pump body Fuel passage Clog Clean o...

Page 75: ...and carburetor body inspection 1 Inspect Main jet Pilot jet Carburetor body Clog contaminants Clean Damage wear Replace CAUTION Do not use a steel wire to clean the jets This may enlarge the jet diam...

Page 76: ...D INSTALLATION CHART Step Procedure Part name Q ty Service points FUEL PUMP DISASSEMBLY Follow the left Step for disassembly Carburetors Refer to CARBURETOR UNIT 1 Screw 4 2 Fuel pump cover 1 3 Gasket...

Page 77: ...4 26 FUEL E FUEL PUMP EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Rubber diaphragm 1 8 Diaphragm 1 9 Packing 1 10 Fuel filter 1 Reverse the disassembly steps for assembly...

Page 78: ...FUEL E FUEL PUMP SERVICE POINTS Fuel pump inspection 1 Inspect Diaphragm Rubber diaphragm Diaphragm body Damage Replace Fuel filter inspection 1 Inspect Fuel filter Clog contaminants Clean Damage Rep...

Page 79: ...ssembly Refer to CARBURETOR UNIT Oil pump cable and oil feed hoses Refer to CARBURETOR UNIT 1 Oil return hose 1 NOTE When removing the oil pump the exhaust chamber assembly does not need to be removed...

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

Page 81: ...ck valve inspection 1 Check Check valve Faulty Replace Oil pump cable adjustment 1 Check Oil pump lever position Incorrect Adjust Checking steps Connect a hose to the end of check valve A and blow int...

Page 82: ...ags around the air bleed screw 1 to catch any oil that might spill Fill the oil tank with the recommended oil NOTE If the oil pump is replaced or the oil suc tion hose is removed bleed air from the oi...

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

Page 84: ...IAGRAM 5 10 REMOVAL AND INSTALLATION CHART 5 10 EXHAUST MANIFOLD 5 12 EXPLODED DIAGRAM 5 12 REMOVAL AND INSTALLATION CHART 5 12 REED VALVES 5 13 EXPLODED DIAGRAM 5 13 REMOVAL AND INSTALLATION CHART 5...

Page 85: ...8 EXPLODED DIAGRAM 5 28 REMOVAL AND INSTALLATION CHART 5 28 FLYWHEEL MAGNETO 5 29 EXPLODED DIAGRAM 5 29 REMOVAL AND INSTALLATION CHART 5 29 SERVICE POINTS 5 34 Drive coupling removal and installation...

Page 86: ...ow the left Step for removal Battery box Refer to BATTERY BOX in chapter 8 YPVS cables and YPVS servomotor Refer to YPVS SERVOMOTOR in chapter 7 Intake silencer Refer to INTAKE SILENCER in chapter 4 C...

Page 87: ...name Q ty Service points 4 Grease hose 1 5 Clamp cooling water hose 1 1 6 Clamp cooling water hose 1 1 For cooling water pilot outlet on starboard side 7 Clamp cooling water hose 1 1 For cooling water...

Page 88: ...ne unit fix the choke valves to the choke link with a plastic band etc to the fully closed position When lifting the engine unit hook the hoister on the bow side of muffler stay 1 Lift the engine unit...

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

Page 90: ...pection 1 Inspect Engine mounts Cracks damage Replace Coupling clearance inspection 1 Measure Clearance a Clearance b with the rubber damper Out of specification Adjust NOTE Measure the clearances wit...

Page 91: ...STALLATION CHART Step Procedure Part name Q ty Service points EXHAUST CHAMBER ASSEMBLY REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT 1 Bolt 2 2 Thermoswitch 1 3 Hose clamp...

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

Page 93: ...DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points EXHAUST CHAMBER DISASSEMBLY Follow the left Step for disassembly 1 Nut washer 1 1 2 Bolt 3 3 Nut washer 2 2 4 Exhau...

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

Page 95: ...L AND INSTALLATION CHART Step Procedure Part name Q ty Service points EXHAUST CHAMBER JOINT REMOVAL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY 1 Clamp...

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

Page 97: ...art name Q ty Service points EXHAUST MANIFOLD REMOVAL Follow the left Step for removal Exhaust chamber joint Refer to EXHAUST CHAMBER JOINT 1 Bolt 4 2 Bolt 4 3 Wire harness bracket 2 4 Exhaust manifol...

Page 98: ...rvice points REED VALVE REMOVAL Follow the left Step for removal Carburetor unit Refer to CARBURETOR UNIT in chapter 4 1 Bolt 12 NOTE Tighten the bolts in the proper sequence as shown 2 Reed valve pla...

Page 99: ...tion 1 Inspect Reed valves Cracks damage Replace 2 Measure Valve bending a Out of specification Replace 3 Measure Valve stopper height b Out of specification Adjust or replace Max valve bending 0 2 mm...

Page 100: ...CHART Step Procedure Part name Q ty Service points YPVS REMOVAL Follow the left Step for removal Exhaust manifold Refer to EXHAUST MANIFOLD 1 Bolt 8 2 YPVS valve cover 2 3 Gasket 2 4 Spacer 1 5 Link j...

Page 101: ...olt 2 NOTE During installation align the hole a in the YPVS shaft with the bolt 9 Shaft 2 1 10 Shaft 1 1 11 YPVS valve lever 2 12 Bolt 2 13 YPVS valve assembly 2 14 Oil seal 4 NOTE If the YPVS shaft i...

Page 102: ...ate Carbon deposits with a rounded scraper 1 CAUTION Do not use a sharp instrument to avoid damaging or scratching the surfaces 2 Inspect YPVS valve assembly Crack damage wear Replace YPVS valve insta...

Page 103: ...ure Part name Q ty Service points CYLINDER HEAD REMOVAL Follow the left Step for removal Exhaust manifold Refer to EXHAUST MANIFOLD 1 Bolt 10 NOTE Tighten the bolts in the proper sequence as shown and...

Page 104: ...ylinder head or spark plug bore threads 2 Inspect Cylinder head water jacket Corrosion mineral deposits Clean or replace 3 Measure Cylinder head warpage with a straightedge and thickness gauge Out of...

Page 105: ...points CYLINDER REMOVAL Follow the left Step for removal YPVS Refer to YPVS Cylinder head Refer to CYLINDER HEAD 1 Bolt 8 NOTE Tighten the bolts in a crisscross pattern and in two stages 2 Cylinder 2...

Page 106: ...D with a cylinder gauge Out of specification Replace cylin der and piston as a set NOTE Measure the cylinder bore in parallel and at a right angle to the crankshaft Then aver age the measurements Stan...

Page 107: ...name Q ty Service points PISTON REMOVAL Follow the left Step for removal Cylinders Refer to CYLINDERS 1 Piston pin clip 2 CAUTION Do not align the open end of the clip with the piston pin slot a 2 Pi...

Page 108: ...OWR E EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 5 Bearing 1 6 Piston ring 2 CAUTION Align each end gap with its respective locating pin Reverse the removal steps for installation P...

Page 109: ...on pin clip from falling into the crankcase Piston inspection 1 Eliminate Carbon deposits from the piston crown and piston ring grooves 2 Inspect Piston wall Score marks Repair with 600 800 grit wet s...

Page 110: ...s NOTE New cylinder bore size 80 000 a 1 000 Example a 12 80 012 mm PISTON CLEARANCE CYLINDER BORE PISTON DIAMETER Piston to cylinder clearance 0 100 0 105 mm 0 0039 0 0041 in Cylinder size indication...

Page 111: ...in Piston pin and bearing inspection 1 Inspect Piston pins Bearings Signs of heat discoloration Replace 2 Measure Piston pin outside diameter with a micrometer 1 Out of specification Replace 3 Check P...

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

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

Page 114: ...EMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points FLYWHEEL MAGNETO REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT Oil pump Refer to OIL PUMP in chap...

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

Page 116: ...le holder 1 NOTE This washer holds the pickup coil lead Make sure to not pinch the lead between the projection and the washer when installing the bolt 5 Bolt washer 1 1 6 Bolt 1 7 Pickup coil 1 8 Gene...

Page 117: ...M REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points STARTER CLUTCH DISASSEMBLY Follow the left Step for disassembly 1 Clip 1 2 Clip stopper 1 3 Spring seat 1 4 Spring 1 5 Was...

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

Page 119: ...lywheel magneto removal and installation 1 Remove Flywheel magneto bolt NOTE Install the bolt with the same special tool that was used for removal 2 Remove Flywheel magneto For USA and Canada For worl...

Page 120: ...ct Drive coupling Damage wear Replace Flywheel magneto inspection 1 Inspect Ring gear Damage wear Replace Starter clutch assembly inspection 1 Inspect Pinion gear 1 Idle gear 2 Damage wear Replace 2 C...

Page 121: ...Procedure Part name Q ty Service points CRANKCASE DISASSEMBLY Follow the left Step for disassembly Pistons Refer to PISTONS Starter motor Refer to STARTER MOTOR Generator cover Refer to FLYWHEEL MAGNE...

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

Page 123: ...crankcase Crankcase Cracks damage Replace Crankcase installation 1 Apply Gasket Maker onto the crankcase mating surfaces NOTE Before applying Gasket Maker clean the crankcase mating surfaces 2 Check...

Page 124: ...Q ty Service points CRANKSHAFT REMOVAL Follow the left Step for removal Crankcase Refer to CRANKCASE 1 Oil seal 1 2 Bearing 1 3 Oil seal 2 4 Bearing clip 1 5 Bearing 1 6 Crankshaft 1 CAUTION Install t...

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

Page 126: ...RANKSHAFT 5 Inspect Bearings Damage pitting Replace NOTE Before inspection thoroughly clean the bearings Immediately after inspection lubricate the bearings to prevent rust 6 Inspect Oil seals Damage...

Page 127: ...emoval 6 9 Impeller inspection 6 10 Drive shaft inspection 6 10 Drive shaft installation 6 10 TRANSOM PLATE AND HOSES 6 13 EXPLODED DIAGRAM 6 13 REMOVAL AND INSTALLATION CHART 6 13 SERVICE POINTS 6 15...

Page 128: ...LATION CHART Step Procedure Part name Q ty Service points JET PUMP UNIT REMOVAL Follow the left Step for removal 1 Bolt 2 2 Bolt 2 3 Intake grate 1 4 Bolt 4 5 Intake duct 1 6 Screw 4 7 Speed sensor 1...

Page 129: ...UMP UNIT EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Bolt 4 9 Ride plate 1 10 QSTS cable joint 1 11 Bilge hose 1 12 Nut washer 1 2 13 Steering cable joint 1 14 Clamp spout hose 1 1...

Page 130: ...ame Q ty Service points 17 Jet pump unit assembly 1 NOTE Pull the jet pump unit straight back When installing the jet pump unit align the drive shaft spline male with the intermediate drive shaft spli...

Page 131: ...VAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points NOZZLE DEFLECTOR AND NOZZLE RING REMOVAL Follow the left Step for removal Jet pump unit Refer to JET PUMP UNIT 1 Bolt 2 2 Collar...

Page 132: ...TALLATION CHART Step Procedure Part name Q ty Service points IMPELLER DUCT AND IMPELLER HOUSING REMOVAL Follow the left Step for removal Nozzle ring Refer to NOZZLE DEFLECTOR AND NOZZLE RING 1 Bolt 4...

Page 133: ...DUCT IMPELLER HOUSING AND INTAKE DUCT EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Bolt 4 8 Water inlet cover 1 9 Packing 1 10 Water inlet strainer 1 11 Packing 1 Reverse the remova...

Page 134: ...LODED DIAGRAM REMOVAL AND INSTALLATION CHART 1 EPNOC grease AP 0 Step Procedure Part name Q ty Service points IMPELLER DUCT AND DRIVE SHAFT DISASSEMBLY Follow the left Step for disassembly 1 Impeller...

Page 135: ...GRAM 1 EPNOC grease AP 0 Step Procedure Part name Q ty Service points 8 Drive shaft 1 9 Rear bearing 1 10 Spacer 1 11 Front bearing 1 12 Oil seal 1 13 Oil seal 1 Reverse the disassembly steps for asse...

Page 136: ...sen it 2 Remove Nut 1 Drive shaft holder YB 06151 90890 06519 Drive shaft holder YB 06151 90890 06519 3 Remove Drive shaft 1 NOTE Remove the drive shaft with a press 4 Remove Rear bearing For USA and...

Page 137: ...Refer to JET PUMP UNIT in chapter 3 Drive shaft inspection 1 Inspect Drive shaft Damage wear Replace Driver rod L3 YB 06071 90890 06652 Needle bearing attachment YB 06112 90890 06614 Driver rod L3 YB...

Page 138: ...socket 4 Add EPNOC grease AP 0 between the drive shaft and spacer Distance a 23 0 1 mm 0 91 0 004 in Quantity Approximately 1 3 of capacity a 5 Install Rear bearing NOTE Press the bearing inner outer...

Page 139: ...6 12 E JET PUMP IMPELLER DUCT AND DRIVE SHAFT 6 Add EPNOC grease AP 0 into the cap Quantity Approximately 1 3 of capacity 7 Install Nut Impeller Drive shaft holder YB 06151 90890 06519...

Page 140: ...edure Part name Q ty Service points TRANSOM PLATE AND HOSES REMOVAL Follow the left Step for removal Exhaust system Refer to EXHAUST SYSTEM in chapter 8 Jet pump unit Refer to JET PUMP UNIT 1 Hose cla...

Page 141: ...GRAM Step Procedure Part name Q ty Service points 4 Cooling water hose 1 Cooling water inlet 5 Nut washer 4 4 6 Transom plate 1 7 Clamp bilge hose 2 1 1 8 Screw 1 9 Bilge strainer holder 1 10 Bilge st...

Page 142: ...6 15 E JET PUMP TRANSOM PLATE AND HOSES SERVICE POINTS Bilge strainer inspection Refer to JET PUMP UNIT in chapter 3 Bilge hose inspection 1 Inspect Bilge hoses Cracks damage wear Replace...

Page 143: ...t name Q ty Service points BEARING HOUSING REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT in chapter 5 1 Rubber coupling 1 2 Bolt 3 3 Intermediate housing assembly 1 4 Pin 2...

Page 144: ...AND INSTALLATION CHART Step Procedure Part name Q ty Service points BEARING HOUSING DISASSEMBLY Follow the left Step for disassembly 1 Grease hose 1 2 Nipple 1 3 Driven coupling 1 4 Washer 1 5 Interme...

Page 145: ...ING HOUSING EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Oil seal 1 9 Oil seal 1 10 Circlip 1 11 Bearing 1 12 Circlip 1 Reverse the disassembly steps for assembly Not reusable Not r...

Page 146: ...en cou pling shaft Bearing removal 1 Remove Bearing NOTE Install the bearing with the same special tools that were used for removal Support the intermediate housing with steel blocks 1 and press the b...

Page 147: ...ction 1 Inspect Driven coupling Driven coupling damper Damage wear Replace Bearing installation 1 Install Circlip rear 2 Install Bearing Oil seal installation 1 Install Oil seal NOTE Before installing...

Page 148: ...Distance b 1 6 2 0 mm 0 06 0 08 in Intermediate housing installation 1 Install Intermediate housing Shim NOTE Install the shim s to the original position if the intermediate housing is not replaced I...

Page 149: ......

Page 150: ...YSTEM 7 9 WIRING DIAGRAM 7 9 IGNITION SPARK GAP 7 10 IGNITION SYSTEM PEAK VOLTAGE 7 11 SPARK PLUGS 7 12 SPARK PLUG CAPS 7 12 IGNITION COIL 7 12 ENGINE STOP SWITCH 7 13 THERMOSWITCH 7 13 STARTING SYSTE...

Page 151: ...YPVS cable removal and installation 7 27 YPVS cable inspection 7 27 YPVS servomotor inspection 7 27 YPVS cable adjustment 7 28 INDICATION SYSTEM 7 29 WIRING DIAGRAM 7 29 FUSE 7 30 BATTERY 7 30 LIGHTI...

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

Page 153: ...MBLY Follow the left Step for disassembly Electrical box Refer to BATTERY BOX in chapter 8 1 Plastic locking tie 2 2 Bolt collar 1 1 NOTE To separate the battery box from the engine unit refer to ENGI...

Page 154: ...EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Nut 2 8 Starter motor lead battery positive lead 1 1 9 Fuse 1 10 Plastic locking tie 1 11 Screw 2 12 Ignition coil 1 13 Screw 2 14 Star...

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

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

Page 157: ...n omitted Refer to the following part number NOTE indicates a continuity of electric ity i e a closed circuit at the respective switch position Low resistance measurement NOTE When measuring a resista...

Page 158: ...voltage adaptor NOTE Throughout this chapter the peak voltage adaptor s part number has been omitted Refer to the following part number The peak voltage adaptor should be used with the digital tester...

Page 159: ...egulator If the charge coil and pickup coil are mea sured unloaded disconnect the test har ness on the output side coupler YW 90890 Pin Usage 06779 06779 8 Charge coil and pickup coil Checking steps D...

Page 160: ...8 7 4 5 B B O O P P B P W B B W B W B Br L W B W R 3 B B L Br W R W B O W P W B R Br W B 1 Pickup coil 2 Charge coil 3 CDI unit 4 Engine stop switch 5 Engine stop lanyard switch 6 Thermoswitch 7 Igni...

Page 161: ...heck keep flammable gas or liquids away since this test can produce sparks 1 Check Ignition spark gap Below specification Check the CDI unit output peak voltage Check the ignition coil for resistance...

Page 162: ...tem but possibly with the spark plug s or another compo nent 1 Measure CDI unit output peak voltage Below specification Measure the charge coil output peak voltage or replace the CDI unit CDI unit out...

Page 163: ...6779 SPARK PLUGS Refer to POWER UNIT in chapter 3 SPARK PLUG CAPS 1 Inspect Spark plug cap Loose Tighten Cracks damage Replace IGNITION COIL 1 Measure Primary coil resistance Out of specification Repl...

Page 164: ...black coupler Lock plate Position Lead color White Black Installed Free Push Removed Free Push THERMOSWITCH 1 Measure Thermoswitch continuity Out of specification Replace 1 No continuity Temperature...

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

Page 166: ...ontinuity No continuity Check the fuse holder leads 2 Check Fuse holder lead continuity No continuity Replace the fuse holder Continuity Check the fuse 3 Check Fuse broken Broken Replace Fuse rating 1...

Page 167: ...g steps Connect the tester leads between the starter relay terminals as shown Connect the brown lead terminal to the positive battery terminal Connect the black lead terminal to the negative battery t...

Page 168: ...ty Service points STARTER MOTOR DISASSEMBLY Follow the left Step for disassembly Starter motor Refer to STARTER MOTOR in chapter 5 1 O ring 1 2 Bolt 2 3 Starter motor front cover 1 4 O ring 1 5 Oil s...

Page 169: ...name Q ty Service points 8 Starter motor rear cover 1 9 O ring 1 10 Shim t 0 2 mm 0 8 mm 11 Armature assembly 1 12 Nut spring washer washer 1 1 4 13 O ring 1 14 Brush holder 1 15 Brush spring 4 16 Bo...

Page 170: ...7 19 E ELEC STARTER MOTOR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 18 Spacer 1 19 Holder 1 20 Starter motor yoke 1 Reverse the disassembly steps for assembly...

Page 171: ...Clean with 600 grit sandpaper 3 Measure Commutator diameter Out of specification Replace Min commutator diameter 27 0 mm 1 06 in 4 Check Commutator undercut Contaminants Clean NOTE Remove all mica an...

Page 172: ...nt Armature shaft No continuity Brush holder inspection 1 Measure Brush length a Out of specification Replace Min brush length 6 5 mm 0 26 in 2 Check Brush holder continuity Out of specification Repla...

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

Page 174: ...ectifier regulator is disconnected when measuring the output peak voltage Rectifier regulator output peak voltage Red R Black B r min Unloaded Cranking 2 000 3 500 V 7 5 12 5 12 5 1 LIGHTING COIL PEAK...

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

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

Page 177: ...vice points YPVS SERVOMOTOR REMOVAL Follow the left Step for removal 1 Bolt 2 2 Cable holder 1 3 YPVS servomotor coupler 1 4 Nut washer 2 2 5 YPVS servomotor 1 6 YPVS cable 2 Slide the cover White pai...

Page 178: ...rom the both drams YPVS cable inspection 1 Inspect YPVS cables 1 and 2 Frays kinks rough movement Replace YPVS servomotor inspection 1 Check YPVS servomotor YPVS servomotor does not move Replace Check...

Page 179: ...S servomotor unit It is a sealed unit and if it is faulty it must be replaced YPVS cable adjustment Refer to CONTROL SYSTEM in chapter 3 Make sure the servomotor operates properly NOTE Make sure the p...

Page 180: ...W B W R W O P O Br Br L L B B W B G Gy 3 B B W L W L 4 L L B L B B B W L B L 1 Lighting coil 2 CDI unit 3 Fuel level sensor 4 Oil level sensor 5 Buzzer 6 Multifunction meter 7 Speed sensor 8 Thermosw...

Page 181: ...ON SYSTEM THERMOSWITCH Refer to IGNITION SYSTEM BUZZER 1 Check Buzzer Buzzer does not sound Replace OIL LEVEL SENSOR 1 Measure Oil level sensor resistance Out of specification Replace Checking steps C...

Page 182: ...W L Black B Float position Resistance A 757 803 B 0 8 MULTIFUNCTION METER Multifunction meter 1 Check Multifunction meter Cracked meter housing Replace the multifunction meter Meter is fogged shows si...

Page 183: ...1 Check Display function Not operate Replace the multifunc tion meter 1 Oil level sensor 2 Fuel level sensor 3 Buzzer 4 Battery 5 Speed sensor B Black G Green L Blue P Pink R Red Y Yellow L B Blue bl...

Page 184: ...ck leads Connect the white blue and black ter minals with a jumper lead 2 Connect the green and red terminals with a jumper lead 3 NOTE If the jumper lead is installed for more than 30 seconds the dis...

Page 185: ...red black with a battery Disconnect the white two pin connec tor blue and black leads Connect the blue and black terminals with a jumper lead 2 Connect the green and red terminals with a jumper lead...

Page 186: ...e multifunction meter unit or emptying the oil tank connect the blue and black terminals white two pin connector with a jumper lead 2 to pre vent the oil warning indicator from being activated Checkin...

Page 187: ...fuel warning indicator from being activated When inspecting the multifunction meter unit or emptying the oil tank connect the blue and black terminals white two pin connector with a jumper lead 2 to p...

Page 188: ...than 11 6 V Output pulse 2 pulses one full turn Checking steps Apply DC 12 voltage to the white three pin connector between the red yellow and black yellow leads Rotate the paddle wheel by hand and m...

Page 189: ......

Page 190: ...RAM 8 13 REMOVAL AND INSTALLATION CHART 8 13 SERVICE POINTS 8 16 Steering column bushing inspection 8 16 REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 8 17 EXPLODED DIAGRAM 8 17 REMOVAL AND INSTALLATION...

Page 191: ...at lock inspection 8 36 BATTERY BOX 8 37 EXPLODED DIAGRAM 8 37 REMOVAL AND INSTALLATION CHART 8 37 EXHAUST SYSTEM 8 39 EXPLODED DIAGRAM 8 39 REMOVAL AND INSTALLATION CHART 8 39 SERVICE POINTS 8 41 Exh...

Page 192: ...PLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points HANDLEBAR COVER REMOVAL Follow the left Step for removal 1 Screw 4 2 Handlebar cover 1 3 Screw 4 4 Handlebar...

Page 193: ...XPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Throttle cable 1 8 Choke cable 1 9 Bolt 4 10 Upper handlebar holder 2 11 Handlebar assembly 1 12 Lower handlebar holder 2 Reverse the rem...

Page 194: ...name Q ty Service points HANDLEBAR REMOVAL Follow the left Step for removal QSTS cable to jet nozzle Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Grommet 1 NOTE Apply soapy water to the gro...

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

Page 196: ...CHART Step Procedure Part name Q ty Service points HANDLEBAR DISASSEMBLY Follow the left Step for disassembly 1 Band 1 2 Bolt 2 3 Grip end 2 4 Spacer 1 5 Screw washer spring washer 1 1 1 6 QSTS grip...

Page 197: ...name Q ty Service points 10 Screw 2 11 Throttle lever assembly 1 12 Screw 2 13 Choke lever assembly 1 14 Handlebar grip 1 NOTE Apply adhesive to the handlebar and the inner surface of the handlebar g...

Page 198: ...adjusting the QSTS cables set the control grip to the neutral position Adjust the QSTS cable lengths a to the specified length and be sure to take up any slack QSTS cable length 77 0 5 mm 3 03 0 02 i...

Page 199: ...grommet with the band 5 Install Spiral tube 1 NOTE Be sure to install the spiral tube containing the throttle cable choke cable and handle bar switch lead at least 50 mm 1 97 in a into the steering c...

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

Page 201: ...D INSTALLATION CHART Step Procedure Part name Q ty Service points QSTS GRIP DISASSEMBLY Follow the left Step for disassembly QSTS grip assembly Refer to HANDLEBAR 1 Screw washer 1 1 2 Cover 1 3 Ball 2...

Page 202: ...ODED DIAGRAM Step Procedure Part name Q ty Service points 7 Screw washer 2 2 8 Collar 1 9 QSTS shift lock lever 1 10 Spring 1 11 Spacer 1 12 QSTS cable housing cover 1 13 QSTS shift grip 1 Reverse the...

Page 203: ...8 12 E HULL HOOD QSTS GRIP SERVICE POINTS QSTS cable inspection 1 Inspect QSTS cables Frays kinks rough movement Replace QSTS grip inspection 1 Inspect QSTS grip Damage wear Replace...

Page 204: ...ints STEERING COLUMN REMOVAL Follow the left Step for removal Steering console cover assembly Refer to STEERING CONSOLE COVER Steering cable end Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1...

Page 205: ...shim s as installed originally at factory Step Procedure Part name Q ty Service points STEERING COLUMN DISASSEMBLY Follow the left Step for disassembly 1 Grommet 1 2 Bolt washer nut 1 2 1 3 Steering...

Page 206: ...ocedure Part name Q ty Service points 5 Washer 1 6 Steering column 1 7 Bushing 2 8 Steering column housing 1 Reverse the disassembly steps for assembly 8 60 mm 16 N m 1 6 kgf m 11 ft Ib 5 N m 0 5 kgf...

Page 207: ...8 16 E HULL HOOD STEERING COLUMN SERVICE POINTS Steering column bushing inspection 1 Inspect Bushings Damage wear Replace 2 Inspect Steering column inspection Refer to CONTROL SYSTEM in chapter 3...

Page 208: ...EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL Follow the left Step for removal 1 Speed sensor couple...

Page 209: ...S AND SPEED SENSOR LEAD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 9 Cap 1 10 Nut 1 11 Steering cable 1 12 Nut 1 13 Pin 1 14 QSTS cable end 1 15 Cap 1 16 Nut 1 17 QSTS cable 1 Rever...

Page 210: ...PLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points SPEED SENSOR DISASSEMBLY Follow the left Step for disassembly 1 Paddle wheel set 1 2 Speed sensor housing 1 R...

Page 211: ...ecomes damaged replace it Never attempt to repair a damaged cable Remote control cables inspection 1 Inspect Steering cable QSTS cable Frays kinks rough movement Replace Steering cable jet pump side i...

Page 212: ...S cable jet pump side a WARNING The QSTS cable must be screwed in more than 8 mm 0 31 in QSTS cable set length jet pump side 12 0 14 0 mm 0 47 0 55 in QSTS cable stopper installation 1 Install QSTS ca...

Page 213: ...Part name Q ty Service points FRONT HOOD REMOVAL Follow the left Step for removal 1 Bolt 2 2 Screw 8 3 Seal washer 8 4 Visor 1 5 Pop nut 8 6 Bolt 2 10 9 1 11 2 3 5 8 4 16 N m 1 6 kgf m 11 ft Ib 6 14...

Page 214: ...s 7 Hood lock 1 8 Front hood 1 9 Nut 2 10 Plate 1 11 Hinge assembly 1 Reverse the removal steps for installation 10 9 1 11 2 3 5 8 4 16 N m 1 6 kgf m 11 ft Ib 6 14 mm 5 N m 0 5 kgf m 3 6 ft Ib 6 14 mm...

Page 215: ...ER REMOVAL Follow the left Step for removal Handlebar assembly Refer to HANDLEBAR Knob fuel cock Refer to FUEL COCK AND FUEL FILTER in chapter 4 1 Band 1 2 Multifunction meter coupler 5 3 Nut washer 2...

Page 216: ...Bolt square ring 2 2 9 Steering console cover assembly 1 NOTE Remove the oil filler cap to remove the steering console cover assembly easier Reverse the removal steps for installation 5 19 mm 2 N m 0...

Page 217: ...Procedure Part name Q ty Service points STEERING CONSOLE COVER DISASSEMBLY Follow the left Step for disassembly 1 Screw 4 2 Side cover 2 3 Nut 2 4 Holder 1 5 Multifunction meter 1 6 8 7 2 N m 0 2 kgf...

Page 218: ...cedure Part name Q ty Service points 6 Screw 4 7 Glove compartment 1 8 Pop nut 4 9 Steering console cover 1 Reverse the disassembly steps for assembly 6 8 7 2 N m 0 2 kgf m 1 4 ft Ib 6 18 mm 3 N m 0 3...

Page 219: ...CHART Step Procedure Part name Q ty Service points BUZZER AND HOOD LOCK REMOVAL Follow the left Step for removal Steering console cover assembly Refer to STEERING CONSOLE COVER Steering cable Refer to...

Page 220: ...8 29 E HULL HOOD BUZZER AND HOOD LOCK EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Nut 2 7 Bolt 2 8 Hood lock assembly 1 9 Grommet 1 Reverse the removal steps for installation...

Page 221: ...ATION CHART Step Procedure Part name Q ty Service points HOOD LOCK DISASSEMBLY Follow the left Step for disassembly 1 Screw 2 2 Hood lock button assembly 1 3 Circlip 1 4 Washer 1 5 Pin 1 6 Hook lever...

Page 222: ...val Engine unit Refer to ENGINE UNIT in chapter 5 Steering console cover assembly Refer to STEERING CONSOLE COVER 1 Band 2 2 Ventilation hose stern side 1 NOTE Route the ventilation hose bow side in f...

Page 223: ...E HULL HOOD HOSES EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 4 Band 1 5 Check valve 1 6 Oil tank breather hose 1 7 Fuel tank breather hose 2 Reverse the removal steps for installat...

Page 224: ...end of check valve A and blow into it Air should come out from end B Connect the hose to the end of check valve B and blow into it Air should not come out from end A Ventilation hose installation 1 In...

Page 225: ...D HAND GRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points SEATS AND HAND GRIP REMOVAL Follow the left Step for removal 1 Seat assembly 1 2 Bolt 2 3 Seat...

Page 226: ...HOOD SEATS AND HAND GRIP EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Rubber ring 1 8 Nut washer 2 2 9 Bolt 2 10 Bolt 2 11 Hand grip 1 12 Bracket 1 Reverse the removal steps for in...

Page 227: ...8 36 E HULL HOOD SEATS AND HAND GRIP SERVICE POINTS Seat lock inspection 1 Inspect Seat lock Damage wear Replace...

Page 228: ...Step Procedure Part name Q ty Service points BATTERY BOX REMOVAL Follow the left Step for removal 1 Band 1 2 Fire extinguisher container 1 3 Band 1 4 Bolt 1 5 Battery negative lead 1 6 Terminal extens...

Page 229: ...nts 12 Electrical box 1 13 Cap nut washer 2 2 14 Holder 1 15 Holder 1 16 Cap nut washer 2 2 17 Battery box 1 NOTE Before installing the battery box route the battery leads and battery breather hose th...

Page 230: ...Procedure Part name Q ty Service points EXHAUST SYSTEM REMOVAL Follow the left Step for removal Battery box Refer to BATTERY BOX Jet pump unit assembly Refer to JET PUMP UNIT in chapter 6 1 Floatation...

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

Page 232: ...Exhaust component parts sub assembly 1 Install Exhaust outlet Rubber hose Water tank NOTE Insert the exhaust outlet 45 mm 1 8 in a into the rubber hose Make sure that there is a surface distance of 10...

Page 233: ...HULL EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points DECK AND HULL DISASSEMBLY Follow the left Step for disassembly 1 Bolt 2 2 Bow eye 1 3 Nut 2 4 Rope ho...

Page 234: ...edure Part name Q ty Service points 8 Sponson 2 NOTE Make sure install the starboard and port side sponsons to the same position 9 Bolt 8 10 Flap 2 11 Nut washer 4 4 12 Screw washer 4 4 13 Drain plug...

Page 235: ...MOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points ENGINE MOUNT REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT in chapter 5 1 Bolt 2 2 Damper 1 3 Bolt...

Page 236: ...n the entire area with acetone and let it completely dry 4 Mix gel coat and gel coat thickener to form a putty and then add the catalyst to the putty 5 Apply the putty spread it with a squee gee and t...

Page 237: ...or an equivalent primer onto both sides of the damaged area and then allow it to cure for approximately 30 minutes 6 Cover a piece of cardboard with wax paper 1 and then cover the damaged area with i...

Page 238: ...2 62733 09 Nut Stainless steel M6 Material Pilot hole diameter FRP or SMC 9 1 9 2 mm 0 36 in Brass 9 4 mm 0 37 in Example 1 NOTE Before attempting to install the insert nut refer to WATERCRAFT FRP REP...

Page 239: ...rt nut and lock the bolt with the nut 3 as shown 9 Screw in the insert nut so that the top is flush with the FRP surface 10 Loosen the locknut and remove the bolt CAUTION Only use a steel bolt with a...

Page 240: ...ith isopropyl alcohol to remove any residual adhesive Graphic installation 1 Mix 1 tablespoon of liquid detergent and water in a 1 quart spray bottle 2 Remove the backing from the new graphic 3 Spray...

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

Page 242: ...YSIS CHART Problems Items to be checked ENGINE WILL NOT START ROUGH IDLING ENGINE STALLS ENGINE WILL NOT STOP POOR PERFORMANCE OVERHEATING LOOSE STEERING BILGE INCREASE IRREGULAR WARNING INDICATION PO...

Page 243: ...l 7 Ignition coil 7 Rectifier regulator 7 Electrical sensor s 7 Starter relay starter motor 7 YPVS unit 7 Battery 3 Fuse s 7 Wire harness electrical coupler s 7 HULL AND HOOD Steering column 8 Water l...

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Page 245: ......

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

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

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Yamaha WaveRunner GP800R, Service Manual

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