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Yamaha WaveRunner VX 700, Service Manual

The Yamaha WaveRunner VX 700 is a top-notch watercraft built for exhilarating adventures on the waves. For thorough maintenance and repairs, make sure to acquire the comprehensive Service Manual. Easily downloadable for free from manualshive.com, this indispensable manual guarantees optimal performance and longevity for your WaveRunner VX 700.

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HULL

HOOD

Hull and hood

8-11

Multifunction meter and engine hatch cover

No.

Part name

Q’ty

Remarks

Seat assy.

See “Seat and handgrip” (8-18).

1

Glove  box

1

2

Lock

1

3

Hinge pin

2

4

Center console box lid

1

5

Damper

2

6

Nut

6

7

Bolt

4

M6 

×

 18 mm

8

Bolt

4

M6 

×

 29 mm

9

Bolt

4

M6 

×

 29 mm

10

Plastic tie

1

11

Multifunction meter coupler

4

12

Engine hatch cover

1

13

Screw

4

ø5 

×

 15 mm

14

Multifunction meter

1

15

Spring nut

4

6

6

6

9

8

19

18

14

13

11

15

7

12

5

5

7

3

3

2

4

17

16

8

1

10

5 N·m (0.5 kgf·m, 3.7 ft·Ib)

5 N·m (0.5 kgf·m, 3.7 ft·Ib)

4 N·m (0.4 kgf·m, 3.0 ft·Ib)

Summary of Contents for WaveRunner VX 700

Page 1: ...SERVICE MANUAL WaveRunner F2V 28197 ZN 11 VX 700 VX 700 F2V ...

Page 2: ...ions and procedures and these are incorporated in successive editions of this manual Also up to date parts information is available on YPEC web Additional information and up to date information on Yamaha products and services are available on Yamaha Service Portal Important information Particularly important information is distinguished in this manual by the following notations The Safety Alert Sy...

Page 3: ...al information GEN INFO Specification SPEC Maintenance MNT Fuel system FUEL Power unit POWR Jet pump unit JET PUMP Electrical system ELEC Hull and hood HULL HOOD Troubleshooting TRBL SHTG Appendix 1 2 3 4 5 6 7 8 9 A ...

Page 4: ......

Page 5: ...ith crane 1 2 Handling of heat gun 1 3 Part lubricant and sealant 1 3 Handling of sealant 1 3 Special service tool 1 3 Tightening torque 1 3 Non reusable part 1 3 Disassembly and assembly 1 4 How to use this manual 1 5 Manual format 1 5 Abbreviation 1 6 Adhesive lubricant sealant and thread locking agent 1 7 Symbol 1 7 Special service tool 1 8 Model feature 1 10 Identification number 1 10 ...

Page 6: ...resulting in severe injury Hot part During and after operation engine parts are hot enough to cause burns Do not touch any parts in the engine compartment until the engine has cooled Electric shock Do not touch any electrical parts while start ing or operating the engine Otherwise shock or electrocution could result Impeller Do not hold the impeller with your hands when loosening or tightening the...

Page 7: ...eet by wearing protective gloves and safety shoes when necessary Working with crane When moving the watercraft or when lifting the engine during removal or installation make sure to use a crane with a lifting capacity that is equal to or more than the weight of the watercraft or engine respec tively When lifting the watercraft use the water craft lift harness and make sure that the watercraft is i...

Page 8: ...n servicing or repairing the watercraft Handling of sealant Wear protective gloves to protect your skin when using the sealants See the material safety data sheet issued by the manufacturer Some of the sealants may be harmful to human health Special service tool Use the recommended special service tools to work safely and to protect parts from dam age Tightening torque Follow the tightening torque...

Page 9: ... Install bearings so that the bearing identifi cation mark is facing in the direction indi cated in the installation procedure In addition make sure to lubricate the bear ings liberally Apply a thin coat of water resistant grease to the lip and periphery of an oil seal before installation Check that moving parts operate normally after assembly Safety while working ...

Page 10: ...ain the details of removal checking and installation where necessary see 5 in the following figure for an example page TIP For troubleshooting procedures see Chapter 9 Troubleshooting 6 6 Impeller duct and drive shaft EPNOC grease AP 0 No Part name Q ty Remarks 1 Bolt 3 M6 20 mm 2 Cap 1 3 O ring 1 Not reusable 4 Cap 1 5 Impeller 1 6 Drive shaft 1 7 Oil seal 1 Not reusable 8 Oil seal 1 Not reusable...

Page 11: ...Abbreviation Description BOW Bow end CDI Capacitor discharge ignition EX Exhaust IN Intake NMMA National Marine Manufacturers Association PON Pump Octane Number PORT Port side RON Research Octane Number STBD Starboard side STERN Stern end TDC Top Dead Center How to use this manual ...

Page 12: ...thread lock ing agent and the application points Symbol Name Application Yamaha 2 stroke motor oil Lubricant Water resistant grease Yamaha grease A Lubricant Molybdenum disulfide grease Lubricant Epnoc grease AP 0 Lubricant Symbol Name Application Gasket Maker Sealant LOCTITE 271 red Thread locking agent LOCTITE 242 blue Thread locking agent LOCTITE 572 white Sealant Silicone sealant Sealant Three...

Page 13: ...ompression gauge 90890 03160 Flywheel holder 90890 06522 Flywheel puller 90890 06521 Coupler wrench 90890 06425 Driver rod L3 90890 06652 Needle bearing attachment 90890 06614 Ball bearing attachment 90890 06634 Stopper guide plate 90890 06501 Bearing puller assembly 90890 06535 Adhesive lubricant sealant and thread locking agent Special service tool ...

Page 14: ...d LS 90890 06606 Ball bearing attachment 90890 06631 Crankshaft holder 20 90890 06552 Bearing outer race attachment 90890 06628 Drive shaft holder 5 90890 06519 Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 Ignition tester Spark gap tester 90890 06754 ...

Page 15: ...serial number The jet pump unit serial number is stamped on a label attached to the intermediate hous ing 1 Jet pump unit name 2 Jet pump unit type 3 Jet pump unit serial number Hull identification number H I N The H I N is stamped on a plate attached to the boarding platform Starting primary I D number F2V 800101 MODEL F2V PRI I D YAMAHA MOTOR CO LTD ASSEMBLED IN U S A FROM AMERICAN AND JAPANESE ...

Page 16: ...1 11 GEN INFO General information MEMO ...

Page 17: ...t 2 3 Cylinder head assy 2 3 Crank case assy 2 4 Jet pump unit technical data 2 5 Jet pump unit 2 5 Electrical technical data 2 5 Ignition system 2 5 Charging system 2 6 Control system 2 6 Starting system 2 7 Meter system 2 7 Specified tightening torque 2 8 Fuel system 2 8 Power unit 2 8 Jet pump unit 2 10 Electrical system 2 10 Hull and hood 2 11 General tightening torque 2 12 Cooling system 2 13...

Page 18: ...aximum fuel consumption L h US gal h lmp gal h 34 0 9 0 7 5 Cruising range h 1 47 Item Unit Model VX 700 Type 2 stroke L2 Cylinder quantity 2 Total displacement cm3 cu in 701 42 8 Bore stroke mm in 81 0 68 0 3 19 2 68 Compression ratio 7 2 1 Intake system Reed valve Starting enrichment Choke valve Scavenging system Loop charge Exhaust system Wet exhaust Lubrication system Oil injection Cooling sys...

Page 19: ...m Jet thrust nozzle trim angle Degree 3 Item Unit Model VX 700 Fuel type Regular unleaded gasoline Fuel minimum rating PON 86 RON 90 Fuel tank capacity Total L US gal Imp gal 50 13 2 11 0 Reserve L US gal Imp gal 12 3 2 2 6 Engine oil type YAMALUBE 2 W Fuel and oil mixing ratio Wide open throttle 50 1 Engine oil grade NMMA certified TC W3 Oil tank capacity L US gal Imp gal 3 8 1 0 0 8 Item Unit Mo...

Page 20: ...Low speed screw turns out 5 8 1 4 Throttle valve 190 Valve seat size mm in 1 5 0 06 Arm height mm in 0 0 2 0 0 008 High speed screw turns out 5 8 1 4 front 1 1 8 1 4 rear Throttle lever free play mm in 4 0 7 0 0 16 0 28 Item Unit Model VX 700 Cylinder Minimum compression pressure 1 kPa kgf cm2 psi 590 5 9 84 1 Measuring conditions Ambient temperature 20 C 68 F with spark plugs removed from all cyl...

Page 21: ...imension height B mm in 1 170 1 190 0 0461 0 0469 Dimension width T mm in 2 750 2 950 0 1083 0 1161 End gap 1 mm in 0 20 0 40 0 008 0 015 Side clearance mm in 0 03 0 05 0 001 0 002 2nd ring Type Keystone Dimension height B mm in 1 170 1 190 0 0461 0 0469 Dimension width T mm in 2 750 2 950 0 1083 0 1161 End gap 1 mm in 0 20 0 40 0 008 0 015 Side clearance mm in 0 03 0 05 0 001 0 002 Connecting rod...

Page 22: ... 13 2 Drive shaft Runout limit mm in 0 01 0 0004 Intermediate drive shaft Runout limit mm in 0 30 0 012 Nozzle Diameter mm in 86 80 87 40 3 417 3 441 maximum difference of jet thrust nozzle distances mm in 5 0 2 Item Unit Model VX 700 CDI unit Output peak voltage at cranking loaded V 10 at 1500 r min loaded V 200 at 3500 r min loaded V 130 Pickup coil Output peak voltage at cranking unloaded V 5 2...

Page 23: ...d V 47 3 Resistance 1 at 20 C 68 F Ω 1 143 1 397 Minimum charging current A at r min 14 at 6000 Rectifier regulator Output peak voltage at 3500 r min loaded V 13 0 1 The figures are for reference only Item Unit Model VX 700 Ignition coil Primary coil resistance at 20 C 68 F Ω 0 078 0 106 Secondary coil resistance at 20 C 68 F kΩ 14 336 30 464 Thermoswitch engine Input voltage 1 V 11 0 12 0 Continu...

Page 24: ...it Seconds 30 Commutator diameter mm in 27 0 28 0 1 06 1 10 Commutator undercut 1 mm in 0 2 0 7 0 008 0 028 Brush length mm in 6 5 12 5 0 26 0 49 1 The figures are for reference only Item Unit Model VX 700 Fuel level sensor Resistance at 20 C 68 F Empty position Ω 757 0 803 0 Full position Ω 0 8 0 Oil level sensor Float distance for continuity mm 37 0 41 0 1 46 1 61 ...

Page 25: ...11 Cover carburetor 1 screw ø5 4 4 0 44 3 2 4 11 Cover carburetor 2 screw ø5 3 4 0 34 2 5 4 11 Diaphragm cover screw ø5 3 4 0 34 2 5 4 11 Body assy screw ø4 2 0 2 1 5 4 11 Main jet 1 8 0 18 1 3 4 11 Pilot jet 0 7 0 07 0 5 4 11 Air bleed screw ø6 5 0 5 3 7 4 17 Oil pump bolt M6 8 0 8 5 9 4 17 Part to tightened Screw size Tightening torque See page N m kgf m ft lb Coupling cover bolt M6 8 0 8 5 9 5 ...

Page 26: ...e screw ø4 3 0 3 2 2 5 18 Starter motor bolt M8 18 1 8 13 3 5 25 Starter motor positive lead nut 5 0 5 3 7 5 25 Flywheel cover bolt M6 8 0 8 5 9 5 25 Flywheel magneto bolt M10 74 7 4 54 6 5 25 Drive coupling 36 3 6 26 6 5 25 Base assy screw ø6 8 0 8 5 9 5 25 Engine bracket lower crankcase bolt 1st M10 23 2 3 17 0 5 30 2nd 52 5 2 38 4 5 30 Upper crankcase lower crankcase bolt 1st M8 15 1 5 11 1 5 3...

Page 27: ... M6 7 0 7 5 2 6 5 Cap bolt M6 8 0 8 5 9 6 6 Impeller M22 75 7 5 55 3 6 6 Transom plate nut 26 2 6 19 2 6 10 Flushing hose nut 5 5 0 55 4 1 6 10 Intermediate housing cover bolt M8 17 1 7 12 5 6 12 Rubber hose clamp 4 0 4 3 0 6 12 Joint bolt M6 7 0 7 5 2 6 12 Driven coupling M24 36 3 6 26 6 6 13 Intermediate drive shaft extension M24 36 3 6 26 6 6 13 Part to tightened Screw size Tightening torque Se...

Page 28: ...olt M6 7 0 7 5 2 8 13 Steering master assy bolt M8 17 1 7 12 5 8 13 Steering arm assy bolt M8 16 1 6 11 8 8 13 Ball joint nut 7 0 7 5 2 8 14 Ball joint 7 0 7 5 2 8 14 Buzzer bracket bolt M5 4 0 4 3 0 8 14 Case assy bolt M6 7 0 7 5 2 8 14 Steering cable locknut 7 0 7 5 2 8 16 Packing nut 5 9 0 59 4 4 8 16 Seat lock assy bolt M6 6 0 6 4 4 8 18 Projection nut 26 2 6 19 2 8 18 Handgrip nut 5 0 5 3 7 8...

Page 29: ...vent warpage tighten multi fastener assemblies in a crisscross fashion and progressive stages until the specified torque is reached Unless otherwise indi cated torque specifications require clean dry threads Components should be at room temperature Width across flats A Screw size 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 30: ...3 Cylinder head 6 Exhaust outer cover 1 Flushing hose Jet pump 7 Water lock Exhaust outlet 5 Exhaust chamber Water To stern outlet To exhaust outlet To pilot outlet 4 Exhaust ring 2 Cylinder block Pilot outlet Stern outlet From flushing hose From jet pump cooling water flow ...

Page 31: ...ke cable 7 Oil tank breather hose 8 Buzzer lead 9 Multifunction meter lead 0 Left handlebar switch lead A Fuel level sensor lead B Fuel tank breather hose C Oil level sensor lead D Throttle cable E Oil hose F Steering cable G Wiring harness H Spark plug lead 1 I Spark plug lead 2 J Cooling water outlet hose 7 8 6 5 4 3 2 1 J I H G F E D C B A 0 9 Cooling system Cable and hose routing ...

Page 32: ...eather hose 8 Buzzer lead 9 Multifunction meter lead 0 Left handlebar switch lead A Fuel level sensor lead B Fuel tank breather hose C Oil level sensor lead D Throttle cable E Oil hose F Steering cable G Wiring harness H Spark plug lead 1 I Spark plug lead 2 J Cooling water outlet hose K Fuel inlet hose L Fuel return hose 8 A 6 C 7 D G I H 1 2 J F 4 O 5 E L 0 M K N 9 3 B ...

Page 33: ...2 16 1 2 3 4 5 6 7 8 9 A M Fuel hose N Fuel reservoir hose O Negative battery cable 8 A 6 C 7 D G I H 1 2 J F 4 O 5 E L 0 M K N 9 3 B Cable and hose routing ...

Page 34: ...reather hose 8 Buzzer lead 9 Multifunction meter lead 0 Left handlebar switch lead A Fuel level sensor lead B Fuel tank breather hose C Oil level sensor lead D Throttle cable E Oil hose F Steering cable G Wiring harness H Spark plug lead 1 I Spark plug lead 2 J Cooling water outlet hose K Fuel inlet hose L Fuel return hose 9 0 8 7 6 5 G L H I 1 2 4 3 J O K E F B M N D A C ...

Page 35: ...2 18 1 2 3 4 5 6 7 8 9 A M Fuel hose N Fuel reservoir hose O Negative battery cable 9 0 8 7 6 5 G L H I 1 2 4 3 J O K E F B M N D A C Cable and hose routing ...

Page 36: ...2 19 SPEC Specification MEMO ...

Page 37: ...seal check 3 4 Oil tank check 3 4 Check valve check 3 4 Power unit 3 4 Spark plug check 3 4 Compression pressure measurement 3 5 Engine oil level check 3 6 Trolling speed check 3 6 Trolling speed adjustment 3 6 Engine mount check 3 6 Nut and bolt check 3 7 Jet pump unit 3 7 Impeller check 3 7 Water inlet strainer check 3 7 Jet thrust nozzle steering angle check 3 7 Jet thrust nozzle steering angle...

Page 38: ... 4 Lubrication points Lubricate 3 10 Fuel system Check 3 3 Fuel filter Check 3 3 Check replace 3 3 Fuel tank Check clean 3 3 Oil injection system Check adjust 3 4 Carburetor Check adjust 4 15 Engine idling speed Check adjust 3 6 Carburetor throttle shaft Check 4 14 Water inlet strainer Check clean 3 7 Bilge strainer Clean 3 9 Impeller Check 3 7 Jet thrust nozzle angle Check adjust 3 7 Throttle cab...

Page 39: ...e play make sure that the throttle cable is not pulled when the handlebar is turned to the right and left 1 Face the handlebar straight ahead 2 Slide the throttle cable end boot 1 to the carburetor pulley end 3 Check that the throttle cable installation length a is within specification 4 If the throttle cable installation length a is out of specification loosen the locknut 2 and then turn the adju...

Page 40: ...ut When removing fuel system parts wrap them in a cloth and take care that no fuel spills into the engine compartment Fuel filter check 1 Check the fuel filter 1 Replace the fuel filter if cracked or damaged 2 Replace the fuel filter if there are water contaminants and check for water in the fuel tank See Fuel tank check 3 3 Fuel hose check 1 Check the fuel hose Replace if cracked or damaged Fuel ...

Page 41: ...mpty If the oil tank becomes empty the oil injection pump must be bled to ensure proper oil flow otherwise engine damage may occur See Oil pump air bleeding 4 18 Oil filter check 1 Check the oil filter Clean if there are con taminants Replace if frayed or torn Oil hose oil filler cap and rubber seal check 1 Check the oil hose or oil filler cap Replace if cracked or damaged 2 Check the rubber seal ...

Page 42: ...top the engine 4 Remove the spark plug caps and then remove the plugs 5 Install the special service tool 1 6 Fully open the throttle lever 7 Crank the engine until the reading on the compression gauge stabilizes 8 Measure the compression pressure for all cylinders according to steps 5 7 9 If the compression pressure is below specification squirt a few drops of engine oil into the cylinder and meas...

Page 43: ...e is 20 C 68 F or less 3 Connect the special service tool 1 to the spark plug wire 4 Check the trolling speed Trolling speed adjustment 1 Turn the low speed screws 1 until they are lightly seated and then turn out the low speed screws 1 to the specified number of turns 2 Start the engine 3 Turn the throttle stop screw 2 in or out until the specified speed is obtained Engine mount check 1 Check the...

Page 44: ... installation 6 4 Water inlet strainer check 1 Remove the water inlet strainer cover 1 and water inlet strainer See Jet thrust nozzle impeller duct and impeller hous ing 6 5 2 Check the water inlet strainer mesh a Clean if contaminated Replace if cracked or damaged 3 Install the water inlet strainer mesh a and water inlet strainer cover 1 See Jet thrust nozzle impeller duct and impeller housing 6 ...

Page 45: ...mp end 8 17 8 Install the service lid See Front hood 8 8 Electrical Battery check Battery electrolyte is poisonous and dan gerous causing severe burns etc Elec trolyte contains sulfuric acid Avoid contact with skin eyes or clothing Antidotes External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physi cian immediatel...

Page 46: ...ed water until the level is between the maximum level mark b and minimum level mark a 4 Check the specific gravity of the electro lyte Charge the battery if below specifi cation 5 Install the battery 5 and then install the bands 4 6 Connect the battery breather hose 3 NOTICE Make sure that the battery breather hose 3 is properly con nected and is not obstructed 7 Connect the positive battery cable...

Page 47: ...le handlebar end TIP Before lubricating the throttle cable squeeze the throttle lever and then remove the rubber seal 1 2 Lubricate the throttle cable carburetor end 3 Lubricate the choke cable carburetor end Nozzle pivot shaft and steering cable lubrication 1 Lubricate the nozzle pivot shaft and steering cable Steering cable and steering cable joint lubrication 1 Lubricate the steering cable and ...

Page 48: ...3 11 MNT Maintenance TIP Disconnect the joint and apply a small amount of grease Recommended lubricant Yamaha grease A ...

Page 49: ...able and throttle cable installation 4 10 Carburetor assy check 4 10 Carburetor and fuel pump 4 11 Diaphragm check 4 14 Arm check 4 14 Body assy check 4 14 Needle valve check 4 14 Jet and carburetor body check 4 14 Fuel pump check 4 15 Fuel filter check 4 15 High and low speed screw adjustment 4 15 Throttle valve synchronization check and adjustment 4 15 Choke valve synchronization check and adjus...

Page 50: ...ilter No Part name Q ty Remarks 1 Screw 1 M4 7 mm 2 Fuel cock knob 1 3 Nut 1 4 Washer 1 5 Fuel cock assy 1 6 Fuel hose 3 7 Holder 1 8 Fuel filter 1 9 Fuel hose 1 1 2 7 8 9 3 4 5 6 OUT ON RES 2 N m 0 2 kgf m 1 5 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib ...

Page 51: ... Fuel system 3 3 Fuel cock check Before checking the fuel system remove the battery and then remove the fuel filler cap to reduce any pressure inside the fuel tank 1 Check the fuel cock Replace if there is rough movement Fuel cock and fuel filter ...

Page 52: ...4 3 FUEL Fuel system Choke cable No Part name Q ty Remarks 1 Screw 1 M3 6 mm 2 Knob 1 3 Friction adjusting nut 1 4 Nut 1 5 Choke cable 1 2 3 5 4 1 2 N m 0 2 kgf m 1 5 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib ...

Page 53: ...r seal 1 5 Tank belt 1 6 Oil level sensor coupler 1 7 Oil level sensor 1 8 Oil filter 1 9 Damper 1 10 Clamp 1 11 Oil filler hose 1 12 Breather hose 1 13 Oil hose 1 14 Oil tank 1 15 Damper 1 2 1 3 4 11 12 14 13 15 10 6 7 8 9 3 7 N m 0 37 kgf m 2 7 ft Ib 5 VENT 6 N m 0 6 kgf m 4 4 ft Ib Choke cable Oil tank ...

Page 54: ... if frayed or teared 2 Check the rubber seal Replace if cracked or worn 3 Check the hoses Replace if cracked or damaged 4 Check the oil tank filler cap Replace if cracked or damaged Oil level sensor check See Indication system 7 15 Oil tank check 1 Check the oil tank Replace if cracked or damaged ...

Page 55: ...ler hose 1 6 Fuel tank breather hose 1 7 Check valve 1 8 Fuel tank breather hose 1 9 Fuel level sensor coupler 1 10 Fuel hose 3 11 Tank belt 1 12 Fuel tank 1 13 Clamp 1 14 Fuel level sensor assy 1 ON RETURN RES VENT VENT 6 8 10 7 5 4 3 2 1 14 13 12 1 9 3 7 N m 0 37 kgf m 2 7 ft Ib 6 N m 0 6 kgf m 4 4 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 11 Oil tank Fuel tank ...

Page 56: ...nd a is restricted Replace if the air flow is unrestricted È Upright É Inverted Fuel level sensor check See Indication system 7 15 Fuel tank check 1 Check the fuel tank Replace if cracked or damaged Fuel filler cap check 1 Install the fuel filler cap 1 onto the fuel filler neck 2 and then hold the fuel filler neck 2 2 Turn the fuel filler cap 1 clockwise È and check that it clicks when tightened c...

Page 57: ... Bolt 1 M6 14 mm 7 Bolt 1 M6 12 mm 8 Holder 1 9 Washer 1 10 Bolt 6 M6 20 mm 11 Flame arrester holder 1 12 Gasket 1 Not reusable 13 Plate 1 14 Gasket 1 Not reusable 15 Choke cable 1 a 13 15 mm 0 51 0 59 in 1 N m 0 1 kgf m 0 7 ft Ib 7 9 8 6 5 4 14 17 19 18 17 22 17 20 23 16 21 15 3 3 2 1 10 11 4 5 12 13 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib Fuel tank Carbure...

Page 58: ... Not reusable 18 Fuel hose 1 19 Pulse hose 1 20 Fuel reservoir hose 1 21 Nut 4 22 Carburetor assy 1 23 Gasket 1 Not reusable 1 N m 0 1 kgf m 0 7 ft Ib 7 9 8 6 5 4 14 17 19 18 17 22 17 20 23 16 21 15 3 3 2 1 10 11 4 5 12 13 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib ...

Page 59: ... specified torque 2 Adjust the throttle lever free play See Steering system 3 2 Carburetor assy check 1 Adjust the trolling speed See Power unit 3 4 Choke cable and throttle cable guide installation position a 14 0 1 0 mm 0 55 0 04 in Choke cable nut b 8 N m 0 8 kgf m 5 9 ft lb Throttle cable nut c 8 N m 0 8 kgf m 5 9 ft lb 1 b c 2 a Carburetor unit ...

Page 60: ...ve seat 2 9 Diaphragm 1 10 Packing 1 11 Fuel filter 1 12 Screw 4 M5 18 mm 13 Cover 1 14 Packing 1 15 Fuel filter 1 1 8 N m 0 18 kgf m 1 3 ft Ib 0 7 N m 0 07 kgf m 0 5 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 3 4 N m 0 34 kgf m 2 5 ft Ib 2 0 N m 0 2 kgf m 1 5 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 3 4 N m 0 34 kgf m 2 5 ft Ib 4 4 N m 0 44 kgf m 3 2 ft Ib 43 32 34 35 33 36 42 19 21 22 20 11 10 31 28 29 30 37 38 39 ...

Page 61: ...7 Washer 2 28 Screw 8 M5 12 mm 29 Cover 2 30 Diaphragm 2 31 Screw 2 M3 6 mm 1 8 N m 0 18 kgf m 1 3 ft Ib 0 7 N m 0 07 kgf m 0 5 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 3 4 N m 0 34 kgf m 2 5 ft Ib 2 0 N m 0 2 kgf m 1 5 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 3 4 N m 0 34 kgf m 2 5 ft Ib 4 4 N m 0 44 kgf m 3 2 ft Ib 43 32 34 35 33 36 42 19 21 22 20 11 10 31 28 29 30 37 38 39 40 41 24 25 26 27 23 9 6 8 7 5 4 3 2 1 ...

Page 62: ...or 2 F 120 41 Pilot jet 2 67 5 42 Carburetor assy 1 1 43 Carburetor assy 2 1 1 8 N m 0 18 kgf m 1 3 ft Ib 0 7 N m 0 07 kgf m 0 5 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 3 4 N m 0 34 kgf m 2 5 ft Ib 2 0 N m 0 2 kgf m 1 5 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 3 4 N m 0 34 kgf m 2 5 ft Ib 4 4 N m 0 44 kgf m 3 2 ft Ib 43 32 34 35 33 36 42 19 21 22 20 11 10 31 28 29 30 37 38 39 40 41 24 25 26 27 23 9 6 8 7 5 4 3 2 1...

Page 63: ...ged 2 Check the valve clear film 1 Replace if damaged TIP Always replace the body assy and valve clear film as a set Needle valve check 1 Clean the needle valve assy and then check the needle valve assy Replace if worn a TIP Always replace the needle valve and needle valve seat as a set Jet and carburetor body check Do not use a steel wire to clean the jets This may enlarge the jet diameters and s...

Page 64: ...he opening angle of both throttle valves is the same 2 Turn out the idle adjusting screw 1 until its tips are no longer touching the throttle cable pulley 2 TIP Record the set position of the idle adjusting screw 3 Check that the throttle valve of the Car buretor 1 rear 3 is fully closed 4 Turn the synchronization screw 4 in or out until the throttle valve of the Carbure tor 2 front 5 is fully clo...

Page 65: ...4 16 1 2 3 4 5 6 7 8 9 A Carburetor assy check 1 Adjust the trolling speed See Power unit 3 4 Carburetor and fuel pump ...

Page 66: ...3 35 in 5 Oil delivery hose 1 1 70 mm 2 76 in 6 Bolt 2 M6 35 mm 7 Oil pump 1 8 Gasket 1 Not reusable 9 Hose clamp 4 10 Check valve 2 11 Oil delivery hose 2 1 210 mm 8 27 in 12 Oil delivery hose 2 1 450 mm 17 72 in 7 1 2 9 9 9 9 8 6 5 4 3 3 10 10 12 11 6 LT 572 LT LT 572 LT 8 N m 0 8 kgf m 5 9 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib ...

Page 67: ...flow from the end a is restricted Replace if the airflow is unrestricted Oil pump air bleeding Do not run the engine if oil does not flow out of the air bleed screw Inspect the oil hose for proper routing and make sure there are no restrictions in the line 1 Place rags around the air bleed screw 1 to catch any oil that might spill 2 Fill the oil tank with the recommended oil TIP If the oil pump is...

Page 68: ...nstallation 5 17 Cylinder 5 18 Cylinder check 5 19 Cylinder installation 5 19 Pistons 5 21 Piston pin clip removal and installation 5 22 Piston check 5 22 Piston ring check 5 22 Piston pin and bearing check 5 23 Piston installation 5 23 Flywheel magneto and base assy 5 25 Starter clutch assy 5 27 Drive coupling removal and installation 5 28 Flywheel magneto removal and installation 5 28 Drive coup...

Page 69: ...1 2 3 4 5 6 7 8 9 A Crankcase 5 30 Crankcase check 5 32 Crankcase installation 5 32 Crankshaft 5 33 Crankshaft check 5 34 ...

Page 70: ...x 1 6 Band cooling water hose 1 1 È Cooling water pilot outlet 7 Band cooling water hose 1 1 8 Clamp cooling water hose 1 1 É Cooling water outlet 9 Clamp 1 10 Band oil hose 1 1 11 Band fuel hose 2 2 12 Choke cable 1 13 Throttle cable 1 11 7 9 18 11 12 13 10 2 17 1 6 16 8 15 14 5 4 3 14 LT 572 LT LT 271 5 N m 0 5 kgf m 3 7 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 17 N m 1 7 kgf m ...

Page 71: ...mm 15 Coupling cover 1 16 Bolt washer 4 4 M8 35 mm 17 Shim 18 Engine unit 1 11 7 9 18 11 12 13 10 2 17 1 6 16 8 15 14 5 4 3 14 LT 572 LT LT 271 5 N m 0 5 kgf m 3 7 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib Engine unit ...

Page 72: ...r unit Engine mount No Part name Q ty Remarks 1 Bolt 8 M8 35 mm 2 Engine mount 4 3 Bolt 4 4 Bracket 1 5 Bracket 1 6 Bracket 2 BOW 17 N m 1 7 kgf m 12 5 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib 1 1 2 4 6 2 2 6 1 3 1 2 3 5 1 ...

Page 73: ...cou plers 1 and then remove the plastic ties 2 4 Remove the wiring harness from the plastic ties 3 5 Remove the electrical box 4 and plastic ties 5 6 Remove the band 6 and then discon nect the cooling water hose 7 7 Remove the band 8 and then discon nect the cooling water hose 9 8 Disconnect the cooling water hose 0 from hose joint A 9 Disconnect the exhaust hose B from the water lock 10 Remove th...

Page 74: ... H 13 Remove the fuel hose H from the plastic ties I 14 Disconnect the throttle cable J and choke cable K 15 Remove the coupling cover L 16 Loosen the engine mounting bolts M 17 Lift the engine unit slightly remove the shims N and then lower the unit TIP Make a note of the position of each removed shim so that it can be installed in its original position 18 Remove the engine mounting bolts M and w...

Page 75: ...sure to check the coupling clearance Engine unit installation When installing the engine unit take care to avoid causing damage to the hull liner and deck opening 1 Move the engine unit rearward to con nect the coupling 1 and then lower the unit onto the engine mounts TIP Do not install the rubber damper until the coupling clearance adjustment has been made 2 Temporarily install the engine mountin...

Page 76: ...thin specification Readjust if out of specification 12 Install the coupling cover 6 and collar 7 and then tighten the bolt 8 to the specified torque 13 Connect the throttle cable 9 and choke cable 0 14 Check the throttle cable installation length c and choke cable installation length c is within specification and then tighten the nuts to the specified torque Clearance a Less than 1 0 mm 0 039 in w...

Page 77: ...t the cooling water hose H to hose joint I 20 Connect the exhaust hose J 21 Connect the cooling water hose K and then install the band L 22 Connect the cooling water hose M and then install the band N Choke cable and throttle cable guide installation position c 14 0 1 0 mm 0 55 0 04 in Choke cable nut d 8 N m 0 8 kgf m 5 9 ft lb Throttle cable nut e 8 N m 0 8 kgf m 5 9 ft lb 0 d e 9 c A C B D E G ...

Page 78: ... ties R 26 Connect the multifunction meter couplers S and then install the plastic ties T 27 Install the service lid 28 Connect the positive battery cable and then connect the negative battery cable 29 Coat the battery cable terminals and bat tery terminals with water resistance grease Electrical box nut P 15 N m 1 5 kgf m 11 1 ft lb O Q P R T T S ...

Page 79: ...3 Clamp 1 4 Bolt 2 M8 75 mm 5 Bolt 2 M8 115 mm 6 Exhaust ring 1 7 Dowel pin 2 8 Gasket 1 Not reusable 9 Clamp 1 10 Joint 1 11 Exhaust joint 1 2 N m 0 2 kgf m 1 5 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 29 N m 2 9 kgf m 21 4 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 11 2 2 1 1 1 5 4 8 7 6 9 10 3 Engine mount Exhaust ring ...

Page 80: ...ot reusable 3 Joint 1 4 Hose 1 5 Hose 1 6 Bolt 2 M10 35 mm 7 Bolt 4 M10 45 mm 8 Muffler stay 1 9 Bolt 2 M10 35 mm 10 Exhaust chamber assy 1 2 N m 0 2 kgf m 1 5 ft Ib 46 N m 4 6 kgf m 33 9 ft Ib 2 5 2 N m 0 2 kgf m 1 5 ft Ib 39 N m 3 9 kgf m 28 8 ft Ib 3 6 2 N m 0 2 kgf m 1 5 ft Ib 39 N m 3 9 kgf m 28 8 ft Ib 1 4 6 7 8 5 2 2 3 2 4 2 9 10 1 ...

Page 81: ...Exhaust outer cover 1 1 3 Gasket 1 Not reusable 4 Exhaust inner cover 1 5 Rubber seal 1 6 Gasket 1 Not reusable 7 Bolt 6 M6 25 mm 8 Exhaust outer cover 2 1 9 Gasket 1 Not reusable 10 Exhaust chamber 1 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib Exhaust chamber assy Exhaust chamber ...

Page 82: ...y Remarks Exhaust chamber See Exhaust chamber assy 5 11 1 Clamp cooling water hose 1 1 È Cooling water inlet 2 Bolt 8 M10 35 mm 3 Muffler 1 4 Gasket 1 Not reusable LT 271 LT 271 4 3 1 2 È 21 N m 2 1 kgf m 15 5 ft Ib 39 N m 3 9 kgf m 28 8 ft Ib 1 2 ...

Page 83: ...mm 2 Plate 1 3 Bolt 8 M6 25 mm 4 Bolt 3 M6 35 mm 5 Intake manifold 1 6 Screw 4 M5 15 mm 7 Reed valve assy 2 8 Plate 1 9 Gasket 2 Not reusable 10 Screw 16 M3 8 mm 11 Valve stopper 8 12 Reed valve 8 1 N m 0 1 kgf m 0 7 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib Muffler Reed valves ...

Page 84: ...reed valves Replace if cracked or damaged 2 Measure the valve warpage a Replace if out of specification 3 Measure the valve stopper height b Replace if out of specification Valve warpage limit 0 2 mm 0 01 in Valve stopper height 8 8 9 2 mm 0 35 0 36 in ...

Page 85: ... assy See Exhaust chamber assy 5 11 1 Bolt 2 M6 16 mm 2 Thermoswitch 1 3 Spark plug 2 4 Bolt 10 M8 50 mm 5 Cylinder head 1 6 Gasket 1 25 N m 2 5 kgf m 18 4 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 29 N m 2 9 kgf m 21 4 ft Ib 1 2 4 3 5 6 8 N m 0 8 kgf m 5 9 ft Ib Reed valves Cylinder head ...

Page 86: ...mineral deposits 3 Measure the cylinder head warpage Resurface if out of specification or if there are score marks TIP Place 400 600 grit wet sandpaper on a sur face plate and resurface the cylinder head using a figure eight sanding pattern Cylinder head installation 1 Install the cylinder head and then tighten the bolts to the specified torque in the order 1 2 and so on Warpage limit 0 1 mm 0 004...

Page 87: ...ylinder head See Cylinder head 5 16 1 Bolt 4 M10 40 mm 2 Bolt 2 M10 55 mm 3 Cylinder 1 4 Gasket 1 Not reusable 5 Dowel pin 2 6 Screw 1 M4 12 mm 7 Anode 1 3 N m 0 3 kgf m 2 2 ft Ib 22 N m 2 2 kgf m 16 2 ft Ib 39 N m 3 9 kgf m 28 8 ft Ib 1 2 Cylinder head Cylinder ...

Page 88: ...the cylinder and piston as a set if out of specification TIP Measure the cylinder bore parallel to and at a right angle to the crankshaft Then average the measurements Cylinder installation 1 Install the cylinder and then tighten the bolts to the specified torque in the order 1 2 and so on Standard Limit Cylinder bore D 81 000 81 020 mm 3 1890 3 1898 in 81 100 mm 3 1929 in Taper T 0 080 mm 0 0031 ...

Page 89: ...5 20 1 2 3 4 5 6 7 8 9 A Cylinder bolt 1st 22 N m 2 2 kgf m 16 2 ft lb 2nd 39 N m 3 9 kgf m 28 8 ft lb 6 2 3 5 1 4 Cylinder ...

Page 90: ...5 21 POWR Power unit Pistons No Part name Q ty Remarks Cylinder See Cylinder 5 18 1 Piston pin clip 4 Not reusable 2 Piston pin 2 3 Piston 2 a Arrow mark 4 Washer 4 5 Bearing 2 6 Piston ring 4 ...

Page 91: ... piston wall in a crisscross pattern 3 Measure the piston skirt diameter Replace if out of specification Piston ring check 1 Measure the side clearance using a thickness gauge 1 Replace the piston and piston rings as a set if out of specifi cation 2 Measure the end gap using a thickness gauge 1 Replace the piston rings as a set if out of specification TIP Push the piston ring into the cylinder wit...

Page 92: ...free play at the small end of the connecting rod as shown Replace the piston pin crank shaft assy small end bearing or all parts if there is free play or wear at the small end Piston installation Align each end gap with its respective locating pin 1 Install the top ring and 2nd ring TIP Install the piston rings with the recess for the locating pin facing up toward the piston crown 2 Assemble the b...

Page 93: ...5 24 1 2 3 4 5 6 7 8 9 A TIP Install the piston with the arrow a facing towards the exhaust port Do not align the open end of the clip with the piston pin slot b Pistons ...

Page 94: ...et 1 Not reusable 4 Dowel pin 2 5 Drive coupling 1 6 Bolt 1 M10 32 mm 7 Flywheel magneto 1 8 Woodruff key 1 9 Starter clutch assy 1 10 Screw 2 M6 16 mm 11 Base assy 1 12 Nut washer 1 1 13 Starter motor lead 1 5 N m 0 5 kgf m 3 7 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib 36 N m 3 6 kgf m 26 6 ft Ib 74 N m 7 4 kgf m 54 6 ft Ib 1207D 1207D ...

Page 95: ...arks 14 Bolt 2 M6 16 mm 15 Starter motor 1 5 N m 0 5 kgf m 3 7 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib 36 N m 3 6 kgf m 26 6 ft Ib 74 N m 7 4 kgf m 54 6 ft Ib 1207D 1207D Flywheel magneto and base assy ...

Page 96: ...ower unit Starter clutch assy No Part name Q ty Remarks 1 Clip 1 Not reusable 2 Clip stopper 1 3 Spring seat 1 4 Spring 1 5 Washer 1 6 Idle gear 1 7 Circlip 1 8 Plate 1 9 Weight 3 10 Spring ring 1 11 Pinion gear 1 ...

Page 97: ...ecial service tools screw in the fly wheel puller set bolts evenly and com pletely so that the puller plate is parallel to the flywheel magneto TIP When installing the flywheel magneto degrease the flywheel magneto where it is coupled to the crankshaft Drive coupling check 1 Check the drive coupling Replace if damaged or worn Flywheel magneto check 1 Check the ring gear Replace if damaged or worn ...

Page 98: ... damaged or worn 2 Check the idle gear 2 Replace if dam aged or worn 3 Check the gear movement Replace the defective part s if there is rough move ment Base assy installation 1 Install the base assy 1 Distance a 0 1 mm 0 0 04 in Base assy screw 2 8 N m 0 8 kgf m 5 9 ft lb 2 1 a 1207D ...

Page 99: ...3 Bolt 1 M10 70 mm 4 Bolt 1 M10 80 mm 5 Engine bracket 1 6 Bolt 3 M10 70 mm 7 Engine bracket 1 8 Bolt 4 M8 83 mm 9 Rubber mount 1 10 Bolt 4 M8 85 mm 11 Lower crankcase 1 12 Dowel pin 2 23 N m 2 3 kgf m 17 0 ft Ib 52 N m 5 2 kgf m 38 4 ft Ib 1 2 15 N m 1 5 kgf m 11 1 ft Ib 27 N m 2 7 kgf m 19 9 ft Ib 1 2 23 N m 2 3 kgf m 17 0 ft Ib 52 N m 5 2 kgf m 38 4 ft Ib 1 2 Starter clutch assy Crankcase ...

Page 100: ... Q ty Remarks 13 Crankshaft assy 1 14 Upper crankcase 1 23 N m 2 3 kgf m 17 0 ft Ib 52 N m 5 2 kgf m 38 4 ft Ib 1 2 15 N m 1 5 kgf m 11 1 ft Ib 27 N m 2 7 kgf m 19 9 ft Ib 1 2 23 N m 2 3 kgf m 17 0 ft Ib 52 N m 5 2 kgf m 38 4 ft Ib 1 2 ...

Page 101: ...faces 2 Install the crankshaft TIP Install the bearing location pins into the grooves in the crankcase body Make sure that the crankshaft rotates smoothly after installing it 3 Install the crankcase and rubber mount and then tighten the bolts to the specified torque in the order 1 2 and so on TIP Be sure that the F mark a is on the fly wheel magneto side Crankcase bolt 1st 15 N m 1 5 kgf m 11 1 ft...

Page 102: ...unit Crankshaft No Part name Q ty Remarks Crankcase See Crankcase 5 30 1 Oil seal 1 Not reusable 2 Bearing 1 3 Oil seal 1 2 Not reusable 4 Drive shaft collar 1 5 Bearing clip 1 6 Bearing 2 1 7 Crankshaft assy 1 7 5 6 4 ...

Page 103: ...ee play d using a dial gauge Replace if out of specifica tion 5 Check the bearings Replace if damaged or pitted TIP Before checking the bearings thoroughly clean them Immediately after checking the bearings lubricate them to prevent rust 6 Check the oil seals Replace if damaged or worn Crank width a 61 950 62 000 mm 2 4390 2 4409 in Deflection limit b 0 050 mm 0 0020 in Big end side clearance c 0 ...

Page 104: ...5 35 POWR Power unit MEMO ...

Page 105: ...aft installation 6 8 Transom plate and hoses 6 10 Bilge strainer check 6 11 Bilge hose check 6 11 Cooling water hose check 6 11 Bearing housing 6 12 Intermediate drive shaft assy 6 13 Joint removal 6 14 Joint installation 6 14 Driven coupling removal and installation 6 15 Intermediate drive shaft extension removal 6 15 Intermediate drive shaft removal 6 15 Bearing removal 6 15 Driven coupling chec...

Page 106: ...ate No Part name Q ty Remarks 1 Bolt 2 M6 30 mm 2 Bolt 2 M10 25 mm 3 Intake grate 1 4 Screw 4 M5 12 mm 5 Cover 1 6 Bolt 4 M8 35 mm 7 Ride plate 1 4 N m 0 4 kgf m 3 0 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib 40 N m 4 0 kgf m 29 5 ft Ib ...

Page 107: ...2 Bolt 2 M8 18 mm 13 Bolt 4 M10 45 mm 14 Jet pump unit 1 15 Dowel pin 2 16 Bolt 2 M8 24 mm 10 6 5 4 2 15 2 11 LT 572 LT 572 LT 572 LT 572 LT 242 LT 271 LT 3 16 17 18 16 17 18 19 13 1 9 12 7 8 14 4 1 N m 0 1 kgf m 0 7 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 6 8 N m 0 68 kgf m 4 9 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 14 N m 1 4 kgf m 10 3 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib 40 N m 4 0 kgf...

Page 108: ... 11 LT 572 LT 572 LT 572 LT 572 LT 242 LT 271 LT 3 16 17 18 16 17 18 19 13 1 9 12 7 8 14 4 1 N m 0 1 kgf m 0 7 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 6 8 N m 0 68 kgf m 4 9 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 14 N m 1 4 kgf m 10 3 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib 40 N m 4 0 kgf m 29 5 ft Ib ...

Page 109: ...e the battery before installing the jet pump unit 1 Clean the mating surfaces of the jet pump unit 1 and transom plate 2 2 Apply sealant to the mating surfaces of the jet pump unit 1 and transom plate 2 3 Install the jet pump unit 1 and then tighten the bolts 3 4 and 5 to the specified torques 2 a 1 a a 2 1 2 1 È É Jet pump unit assy bolt M10 45 mm 3 40 N m 4 0 kgf m 29 5 ft lb Jet pump unit assy ...

Page 110: ...10 125 mm 5 Bracket 1 6 Nozzle 1 7 Impeller duct assy 1 8 Impeller housing 1 1 9 Pin 2 10 Bolt 4 M6 35 mm 11 Water inlet cover 1 12 Packing 1 13 Water inlet strainer 1 14 Packing 1 10 11 12 13 14 9 9 7 LT 572 LT LT 572 LT LT 572 LT 8 1 2 3 4 4 6 5 LT 271 A A 7 N m 0 7 kgf m 5 2 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 40 N m 4 0 kgf m 29 5 ft Ib 40 N m 4 0 kgf m 29 5 ft Ib ...

Page 111: ...3 M6 20 mm 2 Cap 1 3 O ring 1 Not reusable 4 Cap 1 5 Impeller 1 6 Drive shaft 1 7 Oil seal 1 Not reusable 8 Oil seal 1 Not reusable 9 Rear bearing 1 Not reusable 10 Spacer 1 11 Front bearing 1 Not reusable 12 Impeller duct 1 Jet thrust nozzle impeller duct and impeller housing Impeller duct and drive shaft ...

Page 112: ...e rear bearing 4 Remove the oil seals TIP Remove the oil seals using a flat head screw driver 5 Remove the front bearing TIP Remove the front bearing using a press Impeller check 1 Check the impeller Replace if damaged Crankshaft holder 20 90890 06552 a a 1 Stopper guide plate 90890 06501 Bearing puller assembly 90890 06535 Stopper guide stand 90890 06538 Driver rod L3 90890 06652 Needle bearing a...

Page 113: ...rear bearing TIP Install the rear bearing onto the drive shaft using a press Press the rear bearing using a pipe of the proper size more than 140 mm 5 51 in long and that has an inner diameter of 26 mm 1 02 in 3 Install the spacer 4 Add a EPNOC grease AP 0 between the drive shaft and spacer Impeller housing inside diameter a 155 35 155 45 mm 6 116 6 120 in Drive shaft runout limit 0 01 mm 0 0004 i...

Page 114: ...ng spacer and rear bearing TIP Press the rear bearing using a washer or pipe of the proper size outer diameter of 50 mm 1 97 in and an inner diameter of 33 mm 1 30 in 7 Add a EPNOC grease AP 0 into the cap 8 Install the impeller TIP Hold the impeller duct assembly in a vise between two aluminum plates a Quantity 20 g 0 7 oz Distance a 11 7 0 2 mm 0 46 0 01 in a Quantity 20 g 0 7 oz Impeller 75 N m...

Page 115: ...t pump unit assy See Jet pump unit 6 2 1 Clamp 1 2 Bilge hose 1 1 3 Clamp 1 4 Cooling water hose 1 Cooling water inlet 5 Bilge strainer 1 6 Nut washer 2 2 7 Nut washer 2 2 8 Transom plate 1 9 Bilge hose 2 1 5 5 N m 0 55 kgf m 4 0 ft Ib 26 N m 2 6 kgf m 19 2 ft Ib Impeller duct and drive shaft Transom plate and hoses ...

Page 116: ... Jet pump unit Bilge strainer check See Hull and hood 3 9 Bilge hose check 1 Check the bilge hoses Replace if cracked or damaged Cooling water hose check 1 Check the cooling water hoses Replace if cracked or damage ...

Page 117: ... Rubber coupling 1 2 Bolt 4 M8 48 mm 3 Intermediate housing cover 1 4 Clamp 2 5 Intermediate drive shaft assy 1 6 Rubber hose 1 7 Bolt 3 M6 14 mm 8 Joint 1 2 3 4 6 5 1 LT 271 7 7 7 8 4 N m 0 4 kgf m 3 0 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib Transom plate and hoses Bearing housing ...

Page 118: ...Q ty Remarks 1 Driven coupling 1 2 Washer 1 3 Damper 1 4 Intermediate drive shaft extension 1 5 Intermediate drive shaft 1 6 Circlip 1 Not reusable 7 Oil seal 1 Not reusable 8 Bearing 1 Not reusable 9 Oil seal 1 Not reusable 10 Oil seal 1 Not reusable 11 Bearing housing 1 ...

Page 119: ... TIP When using the heat gun be careful not to direct the heat towards any hoses or rubber parts After removing the joint clean off any adhe sive remaining on the hull Joint installation 1 Apply urethane adhesive 1 MWV GLUET UB to the hull in the area shown in the illustration using the glue gun 2 MWV GLUEG UN and then install the joint TIP Before installing the joint clean the contact surfaces of...

Page 120: ...aft holder and inter mediate drive shaft are properly engaged Intermediate drive shaft extension removal 1 Remove the intermediate drive shaft extension TIP Fit a wrench into the notches in the inter mediate drive shaft extension Check that the drive shaft holder and inter mediate drive shaft are properly engaged Intermediate drive shaft removal 1 Remove the intermediate drive shaft TIP Remove the...

Page 121: ...termediate drive shaft TIP Install the intermediate drive shaft using a press Intermediate drive shaft extension installation 1 Install the intermediate drive shaft exten sion Driver rod LS 90890 06606 Bearing outer race attachment 90890 06628 Driver rod LS 90890 06606 Ball bearing attachment 90890 06631 Distance a 14 2 0 2 mm 0 56 0 01 in Driver rod LS 90890 06606 Ball bearing attachment 90890 06...

Page 122: ...6 17 JET PUMP Jet pump unit TIP Fit a wrench into the notches in the interme diate drive shaft extension Intermediate drive shaft extension 36 N m 3 6 kgf m 26 6 ft lb ...

Page 123: ...tem 7 9 Lighting coil 7 9 Rectifier regulator 7 9 Starting system 7 10 Fuse 7 10 Left handlebar switch assy 7 10 Starter relay 7 11 Starter motor 7 12 Starter motor operation 7 13 Armature 7 13 Front and rear cover 7 14 Brush holder 7 14 Starter motor assembly 7 14 Indication system 7 15 Multifunction meter 7 15 Oil level sensor and oil level warning indicator 7 15 Fuel level meter display and fue...

Page 124: ...s 4 Electrical box rectifier regulator CDI unit starter relay and ignition coil 5 Battery 6 Starter motor 7 Thermoswitch 8 Lighting coil pickup coil and charge coil 9 Fuel level sensor 0 Left handlebar switch assy Engine stop switch engine shut off switch and start switch A Buzzer 5 4 2 3 1 A 0 9 8 7 6 ...

Page 125: ...multifunction meter and handlebar switch 9 Wiring harness 1 Electrical box to base assy 10 Fuse holder fuse spare fuse 1 1 1 11 Screw 2 ø6 16 mm 12 Holder 1 13 CDI unit 1 14 Bolt 2 M6 10 mm 15 Starter motor cable 1 Starter relay to starter motor 3 N m 0 3 kgf m 2 2 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 15 N m 1 5 kgf m 11 1 ft...

Page 126: ...ø6 30 mm 22 Spark plug wire 1 spark plug cap 1 1 23 Spark plug wire 2 spark plug cap 1 1 24 Ignition coil assy 1 25 Electrical box case 1 26 Nut 4 27 Bracket 1 28 Band 2 29 Battery breather hose 1 30 Battery 1 31 Battery box 1 3 N m 0 3 kgf m 2 2 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 17 N m 1 7 kgf ...

Page 127: ...r È To base assy É To multifunction meter engine start switch and engine stop switch Ê To thermoswitch Ë To positive battery terminal Ì To starter motor B Black Br Brown G Green O Orange P Pink R Red W White Br W Brown White W R White Red 1 2 5 4 3 È É Ê Ë Ì 5 1 4 6 1 Br W W R B R O P W G B B R Br O G P B Electrical box ...

Page 128: ...ction and corro sion and check that the battery is fully charged Use the peak voltage adapter with the rec ommended digital circuit tester Connect the positive pin of the peak voltage adapter to the positive terminal of the digital circuit tester and the negative pin to the negative terminal When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode Ignit...

Page 129: ... the engine connect the engine shut off cord to the engine shut off switch and then push the engine start switch and engine stop switch simultaneously CDI unit resistance 1 Measure the CDI unit resistance 2 Replace the CDI unit if out of specifica tion Ignition tester Spark gap tester 90890 06754 Primary coil resistance at 20 C 68 F reference data Connector Connector 0 078 0 106 Ω Secondary coil r...

Page 130: ...he engine shut off switch and then push the engine start switch and engine stop switch simultaneously If measuring the charge coil output peak voltage under the Cranking and Unloaded conditions disconnect the charge coil terminals Charge coil resistance 1 Measure the charge coil resistance 2 Replace the charge coil if out of specifi cation È B W O B W R P Br W É B 10 40 0 150 600 3 11 2 6 W O B 0 ...

Page 131: ... 1 Measure the pickup coil resistance 2 Replace the pickup coil if out of specifica tion Thermoswitch 1 Suspend the thermoswitch in a container filled with water and then slowly heat the water 2 Check the thermoswitch for continuity when the specified temperatures are reached 3 Replace if out of specification c No continuity d Continuity È Temperature É Time Pickup coil output peak voltage White R...

Page 132: ...tance 1 Measure the lighting coil resistance 2 Replace the lighting coil if out of specifi cation Rectifier regulator Rectifier regulator output peak voltage 1 Disconnect the rectifier regulator connec tors 2 Measure the rectifier regulator output peak voltage 3 Measure the rectifier regulator resistance if below specification Lighting coil output peak voltage Green G Green G r min Unloaded Cranki...

Page 133: ...handlebar switch assy if out of specification Engine stop switch continuity 1 Disconnect the left handlebar switch cou pler black coupler See Handlebar and handlebar switch assy 8 2 2 Check the engine stop switch for continu ity 3 Replace the left handlebar switch assy if out of specification È R B G1 G2 É R B 2 20 1 10 1 10 G1 1 10 2 15 3 30 G2 1 10 2 15 3 30 Engine start switch continuity Clip 1...

Page 134: ...he positive battery lead to the terminal a and the negative battery lead to the terminal b 3 Check the continuity between the starter relay terminals 1 and 2 4 Replace the starter relay if out of specifi cation Starter relay continuity Battery lead a b Terminal 1 2 Disconnected No continuity Connected Continuity Br B 1 2 a b ...

Page 135: ...t reusable 2 Bolt 2 M5 114 mm 3 Front cover assy 1 4 O ring 2 Not reusable 5 Washer set 1 6 Rear cover assy 1 7 Armature 1 8 Brush holder assy 1 9 Starter motor yoke 1 6 N m 0 6 kgf m 4 4 ft Ib A A A A 6 5 2 9 4 4 7 8 5 3 1 5 N m 0 5 kgf m 3 7 ft Ib Starting system Starter motor ...

Page 136: ...sembling it 4 Disconnect the negative battery cable and then the positive battery cable from the battery terminals Armature Armature appearance 1 Check the armature Replace if damaged or worn 2 Check the commutator Clean with 600 grit sandpaper and compressed air if dirty Commutator diameter 1 Measure the commutator diameter a Replace the armature if below specifica tion Commutator undercut 1 Meas...

Page 137: ...eplace if out specification Starter motor assembly Do not reuse an O ring always replace it with a new one 1 Install the brush holder assy 1 and then tighten the nut a to the specified torque Armature continuity Commutator segments a Continuity Segment a Armature core b No continuity Segment a Armature shaft c No continuity Brush length a 6 5 12 5 mm 0 26 0 49 in a Brush holder assy continuity Bru...

Page 138: ...re is no continuity 6 Replace the multifunction meter if there is continuity Hour meter operation 1 Check the hour meter display 2 Replace the multifunction meter if it does not operate correctly Oil level sensor and oil level warning indicator 1 Check the oil level sensor if oil level warning indicator does not come on 2 Replace the oil level sensor if out of specification 3 Replace the multifunc...

Page 139: ...art the engine 3 Disconnect the thermoswitch connectors 1 and then connect the jumper lead to the disconnected connector 4 Check that the WARNING indicator light and the engine overheat warning indicator blink and the buzzer begins to sound intermittently Buzzer 1 Connect the positive battery lead to the terminal 1 and the negative battery lead to the terminal 2 2 Check that the buzzer sounds Repl...

Page 140: ...ion meter and engine hatch cover 8 11 Steering master assy 8 13 Steering master 8 14 Shift lever assy check 8 15 Bushing check 8 15 Steering arm assy installation 8 15 Steering cable 8 16 Steering cable installation steering master end 8 17 Steering cable installation jet pump end 8 17 Seat and handgrip 8 18 Ventilation hose and water separator 8 19 Seat lock check 8 21 Check valve check 8 21 Wate...

Page 141: ...1 2 3 4 5 6 7 8 9 A Deck and hull 8 25 Rear section 8 27 Drain plug check 8 29 Spout installation 8 29 ...

Page 142: ...bar cover No Part name Q ty Remarks 1 Screw 2 ø4 10 mm 2 Screw 4 ø5 16 mm 3 Upper handlebar cover 1 4 Steering pad 1 5 Screw 4 ø6 14 mm 6 Lower handlebar cover 1 5 2 6 4 1 1 3 1 N m 0 1 kgf m 0 7 ft Ib 1 N m 0 1 kgf m 0 7 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib ...

Page 143: ...tch assy 1 8 Bolt 2 M5 25 mm 9 Throttle lever assy 1 10 Bolt 4 M8 45 mm 11 Handlebar holder 2 a Punch mark 12 Handlebar 1 13 Grommet 1 14 Plastic tie 1 15 Left handlebar switch coupler 2 15 13 14 11 1 N m 0 1 kgf m 0 7 ft Ib 3 N m 0 3 kgf m 2 2 ft Ib 3 N m 0 3 kgf m 2 2 ft Ib 20 N m 2 0 kgf m 14 8 ft Ib 1 2 3 7 7 6 4 9 1 2 3 10 10 11 5 8 9 12 a Steering pad and handlebar cover Handlebar and handle...

Page 144: ...throttle lever assy No Part name Q ty Remarks 1 Left handlebar switch assy 1 2 Engine shut off cord 1 3 Stop button assy 1 4 Start button assy 1 5 Screw 2 6 Throttle lever assy 1 7 E ring 1 8 Washer 2 9 Shaft 1 10 Lever 1 11 Spring 1 6 1 9 8 10 11 7 8 4 2 5 5 3 ...

Page 145: ...r assy make sure that the throttle cable and left han dlebar switch lead are not pulled when the handlebar is turned to the right and left 1 Install the left handlebar switch lead 1 into the opening a in the grommet 2 and then install the throttle cable 3 into the opening a TIP Face the chamfered end b of the grommet 2 down with the opening a facing forward 2 Install the grommet 2 into the steerin...

Page 146: ...fied torque TIP Align the projection f on the throttle lever assy with the handlebar hole g 5 Install the left handlebar switch assy 0 and then tighten the screws A to the specified torque TIP Align the projection h on the handlebar switch assy with the handlebar hole k 6 Install the throttle cable end into the throttle lever 7 Fit the seal m into the groove in the bracket 8 Pull the throttle cabl...

Page 147: ...and then tighten the bolts G to the specified torque Steering pad and handlebar cover installation After installing the handlebar upper cover make sure that the throttle cable is not pulled when the handlebar is turned to right and left 1 Install the lower handlebar cover 1 and then tighten the screws 2 to the speci fied torque 2 Push the steering pad 3 into the upper handlebar cover 4 until it is...

Page 148: ... lower handlebar cover 3 Install the upper handlebar cover 4 and then tighten the screws 5 and 6 to the specified torque TIP Align the portions a on the upper handlebar cover with the portions b on the lower han dlebar cover Upper handlebar cover screw ø5 16 mm 5 Upper handlebar cover screw ø4 10 mm 6 1 N m 0 1 kgf m 0 7 ft lb 3 4 5 4 6 a b b a ...

Page 149: ...assy 1 9 Screw 8 ø5 15 mm 10 Front hood 1 11 Nut 2 12 Washer 2 13 Bolt 2 M6 95 mm 14 Ventilator cover 1 15 Packing 1 Not reusable 16 Bolt 4 M6 18 mm 12 17 11 13 18 19 15 7 9 16 5 2 2 1 1 6 8 10 3 4 14 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 7 N m 0 7 kgf m 5 2 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib Left handlebar switch assy and throttle lever assy Front hood ...

Page 150: ...e Q ty Remarks 17 Hinge assy 1 18 Rivet 5 19 Service lid 1 12 17 11 13 18 19 15 7 9 16 5 2 2 1 1 6 8 10 3 4 14 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 7 N m 0 7 kgf m 5 2 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib ...

Page 151: ...rivet hold the rivet flange a with both hands and push the rivet pin perpendicularly against a hard flat surface until the pin protrudes from the top of the rivet Hinge assy check 1 Fully open the front hood and check that it remains in the open position If the front hood cannot remain in the open position replace the hinge assy Hood lock check 1 Fully close the front hood and check that it latche...

Page 152: ... 4 Center console box lid 1 5 Damper 2 6 Nut 6 7 Bolt 4 M6 18 mm 8 Bolt 4 M6 29 mm 9 Bolt 4 M6 29 mm 10 Plastic tie 1 11 Multifunction meter coupler 4 12 Engine hatch cover 1 13 Screw 4 ø5 15 mm 14 Multifunction meter 1 15 Spring nut 4 6 6 6 9 8 19 18 14 13 11 15 7 12 5 5 7 3 3 2 4 17 16 8 1 10 5 N m 0 5 kgf m 3 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib ...

Page 153: ... ty Remarks 16 Lid lock hook 1 17 Nut 2 18 Revet 1 19 Plug 1 6 6 6 9 8 19 18 14 13 11 15 7 12 5 5 7 3 3 2 4 17 16 8 1 10 5 N m 0 5 kgf m 3 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib Multifunction meter and engine hatch cover ...

Page 154: ... Remarks 1 Buzzer coupler 1 2 Steering cable joint 1 3 Bolt 1 M6 18 mm 4 Cable stopper 1 5 Bolt 4 M8 30 mm 6 Steering master assy 1 7 Rivet 2 Not reusable 8 Cable stopper bracket 1 9 Grommet 1 5 6 7 N m 0 7 kgf m 5 2 ft Ib 17 N m 1 7 kgf m 12 5 ft Ib 1 9 2 8 7 7 8 4 3 ...

Page 155: ...assy 1 8 Bushing 1 9 Band 2 Not reusable 10 Buzzer 1 11 Bolt 2 M5 16 mm 12 Bracket 1 13 Bolt 4 M6 25 mm 14 Case assy 1 15 Packing 1 Not reusable 16 Housing assy 1 1 2 3 4 5 6 4 N m 0 4 kgf m 3 0 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 16 N m 1 6 kgf m 11 8 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 7 8 16 11 10 15 9 13 14 12 10 7 N m 0 7 kgf m 5 2 ft Ib Steering master assy Steering master ...

Page 156: ...amaged or worn Steering arm assy installation 1 Install the steering arm assy 1 nut 2 and plate 3 and then tighten the bolt 4 to the specified torque TIP Align the projection on the steering shaft assy with the slot on the arm Align the tab a on the plate 3 with the por tion b on the steering arm assy 1 Bend a tab c along a flat side of the bolt Steering arm assy bolt 4 16 N m 1 6 kgf m 11 8 ft lb...

Page 157: ... 8 18 Ride plate rubber plate See Intake grate and ride plate 6 1 1 Steering cable joint 1 2 Bolt 1 M6 18 mm 3 Steering cable stopper 1 4 Plastic tie 3 5 Nut 1 6 Steering cable 1 7 Packing 1 Not reusable 5 4 7 6 1 2 3 7 N m 0 7 kgf m 5 2 ft Ib 5 9 N m 0 59 kgf m 4 4 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib Steering master Steering cable ...

Page 158: ...the groove a in the outer cable 2 Connect the steering cable joint 4 to the ball joint 5 3 Adjust the steering cable See Jet thrust nozzle steering angle check 3 7 Steering cable installation jet pump end 1 Adjust the steering cable set length a and then tighten the locknut 1 to the specified torque jet pump end Steering cable stopper bolt 3 7 N m 0 7 kgf m 5 2 ft lb 1 2 3 a 4 5 Steering cable set...

Page 159: ...2 M6 40 mm 3 Seat lock assy 1 4 Packing 1 Not reusable 5 Nut 1 6 Washer 1 7 Projection 1 8 Washer 1 9 Nut 4 10 Washer 4 11 Bolt 4 M8 30 mm 12 Handgrip 1 3 1 11 2 4 7 8 12 10 9 6 5 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 Steering cable Seat and handgrip ...

Page 160: ...tion box 2 3 Band 2 Not reusable 4 Ventilation hose 2 5 Grommet 2 6 Nut 2 7 Seat holder 1 8 Band 3 Not reusable 9 Fuel tank breather hose 1 1 10 Fuel tank breather hose 2 1 11 Rivet 2 Not reusable 12 Water separator 1 13 Rivet 1 Not reusable 14 Filter bracket 1 19 20 22 21 23 18 6 9 12 10 3 4 3 4 8 2 1 15 1 16 17 5 5 7 14 2 13 11 24 26 27 25 8 8 È 15 N m 1 5 kgf m 11 1 ft Ib 4 N m 0 4 kgf m 3 0 ft...

Page 161: ...t reusable 21 Clamp 1 22 Cooling water pilot outlet 1 23 Cooling water hose 1 È To exhaust joint 24 Plastic tie 1 25 Band 1 Not reusable 26 Check valve 1 27 Oil tank breather hose 1 19 20 22 21 23 18 6 9 12 10 3 4 3 4 8 2 1 15 1 16 17 5 5 7 14 2 13 11 24 26 27 25 8 8 È 15 N m 1 5 kgf m 11 1 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib Ventilation hose and water separator ...

Page 162: ...e fuel tank breather hose 1 1 2 Disconnect fuel tank breather hose 1 1 and fuel tank breather hose 2 2 Water separator check 1 Check the water separator 1 O ring 2 and drain plug 3 Replace if cracked or damaged Water separator assy installation 1 Connect fuel tank breather hose 1 1 and fuel tank breather hose 2 2 onto the water separator 3 TIP Connect fuel tank breather hose 1 1 which is identifie...

Page 163: ...ll the ventilation hoses 3 TIP Make sure to route the ventilation hose PORT in front of the ventilation hose STBD Make sure that the end of the ventilation hose 3 is the specified distance a from the groove around the outside of the grom met 1 Cooling water pilot outlet nut 3 4 N m 0 4 kgf m 3 0 ft lb 3 1 2 b a 1 1 2 2 Installation distance a 30 40 mm 1 18 1 57 in 3 2 2 a 1 3 Ventilation hose and ...

Page 164: ...e Intake grate and ride plate 6 1 1 Band 1 2 Clamp 3 3 Water lock 1 4 Band 1 Not reusable 5 Rubber hose 1 6 Bolt 3 M5 20 mm 7 Exhaust outlet 1 8 Band 1 Not reusable 9 Hose 1 10 Seal 1 Not reusable 5 4 10 2 7 9 8 2 3 1 2 6 6 LT 572 LT 5 N m 0 5 kgf m 3 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib ...

Page 165: ...8 24 1 2 3 4 5 6 7 8 9 A Exhaust system check 1 Check the rubber hoses Replace if burned cracked or damaged 2 Check the water lock Replace if cracked damaged or leaked Exhaust system ...

Page 166: ... mm 2 Bow eye 1 3 Nut 4 4 Washer 4 5 Bolt 2 M6 25 mm 6 Front protector 1 7 Bolt 2 M6 25 mm 8 Rivet 9 Not reusable 9 Rear protector 2 10 Inner gunwale 2 11 Rivet 30 Not reusable 12 Washer 30 13 Side gunwale 2 14 Bolt 10 M8 40 mm 1 2 7 5 19 6 11 4 4 3 12 3 13 17 10 16 15 14 8 9 8 7 N m 0 7 kgf m 5 2 ft Ib 13 N m 1 3 kgf m 9 6 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 20 18 ...

Page 167: ...llar 10 16 Sponson 2 17 Rivet 2 Not reusable 18 Fuel cock cover 1 19 Rivet 2 Not reusable 20 Choke cover 1 1 2 7 5 19 6 11 4 4 3 12 3 13 17 10 16 15 14 8 9 8 7 N m 0 7 kgf m 5 2 ft Ib 13 N m 1 3 kgf m 9 6 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 20 18 Deck and hull ...

Page 168: ... 1 Nut 2 2 Bracket 1 3 Plate 2 4 Ski tow 1 5 Clamp 1 6 Spout hose 1 7 Nut 1 8 Spout 1 9 Nut 4 10 Plate 4 11 Packing 2 Not reusable 12 Stern eye 2 13 Nut 4 14 Washer 4 5 8 7 15 9 10 12 10 11 4 3 1 2 3 17 16 14 13 2 N m 0 2 kgf m 1 5 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 6 BOW ...

Page 169: ...Screw 4 ø5 25 mm 16 Packing 2 Not reusable 17 Drain plug 2 5 8 7 15 9 10 12 10 11 4 3 1 2 3 17 16 14 13 2 N m 0 2 kgf m 1 5 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 15 N m 1 5 kgf m 11 1 ft Ib 6 BOW Rear section ...

Page 170: ...amaged Spout installation 1 Install the spout 1 and then tighten the nut 2 to the specified torque 2 Install the hose 3 and then tighten the clamp 4 to the specified torque TIP Face the mark a toward the bow Spout nut 2 5 N m 0 5 kgf m 3 7 ft lb Spout hose clamp 4 2 N m 0 2 kgf m 1 5 ft lb 1 2 4 1 a 2 3 BOW ...

Page 171: ...TRBL SHTG 1 2 3 4 5 6 7 8 9 A Troubleshooting Engine unit troubleshooting 9 1 Troubleshooting engine unit jet pump unit charging system 9 1 ...

Page 172: ...cking step See page Starter motor does not operate Discharged battery Check the battery voltage and spe cific gravity 3 8 Loose connection of bat tery terminal Check the battery cable and termi nal for proper connection 7 2 Blown fuse Check the fuse for continuity 7 10 Starter relay malfunction Check the starter relay 7 11 Engine start switch mal function Check the engine start switch left handleb...

Page 173: ...k the wiring harness WD Spark plug does not spark all cylinders Engine shut off cord clip not installed Check that the engine shut off cord clip is installed properly 7 10 Engine stop switch mal function Check the engine stop switch left handlebar switch 7 10 Pickup coil malfunction Measure the pickup coil output peak voltage 7 8 Measure the pickup coil resistance 7 8 Short open or loose con necti...

Page 174: ...ymptom 2 Cause Checking step See page Throttle valve does not move properly Throttle cable installed incorrectly Adjust the throttle lever free play 3 2 Throttle valve malfunction Check the throttle valve synchroni zation 4 15 Improper throttle stop screw setting Adjust the throttle stop screw 3 6 Spark plug does not spark some cylin ders Spark plug malfunction Check the spark plug 3 4 Ignition co...

Page 175: ...ng water passage Check the cooling water pilot outlet for water discharge Check the cooling water passage 2 13 Thermoswitch malfunction Check the thermoswitch 7 8 Symptom 2 Cause Checking step See page Battery performance decrease Check the battery voltage and spe cific gravity 3 8 Loose connection of bat tery terminal Check the battery cable and termi nal for proper connection 7 2 Short open or l...

Page 176: ... pump unit malfunction Check the impeller impeller duct and intake grate 6 6 Water entered hull Check the drain plugs and O rings for damage 8 29 Check the cooling water hoses for damage 2 13 Check the water lock and rubber hoses for damage 8 24 Check the exterior of the hull for damage Check the bilge hose bilge strainer and joint 3 9 ...

Page 177: ...1 2 3 4 5 6 7 8 9 A Appendix Wiring diagram A 1 ...

Page 178: ...level sensor L Blue 5 Fuel level sensor O Orange 6 Multifunction meter P Pink 7 Buzzer R Red 8 Engine start switch W White 9 Engine shut off switch Br W Brown White 0 Engine stop switch L B Blue Black A Battery L R Blue Red B Starter relay W L White Blue C Fuse 10 A W R White Red D CDI unit E Rectifier regulator F Ignition coil G Spark plug A 1 ...

Page 179: ......

Page 180: ...YAMAHA MOTOR CO LTD Sep 2010 1 CR E ...

Page 181: ... B W L B W L B L R L B W L B B G R P B Br B W B W R G R P B P B O B R B G G B P P G G G P P O B O B B P B Br W W R G G B Br W W R G G B B W W W P O B B B B B B B B B B Br W W R Br W W R G G B R R Br B W R R R B R R R Br Br R R R R R R Br B B W Br R B W Br Br L R L B B R 10A ...

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