Yamaha WaveRunner XL1200Ltd Service Manual Download Page 201

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8-6

HULL

HOOD

HANDLEBAR

SERVICE POINTS

Handlebar inspection

1. Inspect:

●

Handlebar
Bends/cracks/damage

→

Replace.

Handlebar switch inspection

Refer to “STARTING SYSTEM” in
chapter 7.

Handlebar assembly installation

1. Install:

●

QSTS cables

●

Buzzer lead

●

Handlebar switch lead

●

Throttle cable

NOTE:

After inserting the cables and leads into the
grommets, tie the end of grommets with

the bands

2. Install:

●

Upper handlebar holder

CAUTION:

Clearance

should be narrower than

clearance

NOTE:

●

Align the punch mark

on the handlebar

with the top surface of the handlebar
holder.

●

The upper handlebar holder should be
installed with the punch mark

facing

forward.

Reference clearance:

: 1.5 mm (0.06 in)

: 3.5 mm (0.14 in)

Summary of Contents for WaveRunner XL1200Ltd

Page 1: ...LIT186160198 LIT 18616 01 98 F0D 28197 Z9 11 SERVICE MANUAL WaveRunner XL1200Ltd ...

Page 2: ... may differ in detail from the descriptions and illustrations given in this publica tion Use only the latest edition of this manual Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual A10001 0 WaveRunner XL1200Ltd SERVICE MANUAL 1999 Yamaha Motor Co Ltd 1st Edi...

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

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

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

Page 6: ...te the grade of lubricant and the loca tion of lubrication point F Apply YAMALUBE 2 W oil G Apply water resistant grease Yamaha grease A Yamaha marine grease H Apply molybdenum disulfide grease Symbols I to N in an exploded diagram indicate the grade of the sealing or locking agent and the location of the application point I Apply Gasket Maker J Apply Yamabond 4 Yamaha bond number 4 K Apply LOCTIT...

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

Page 8: ...ERIAL 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 2 GOOD WORKING PRACTICES 1 3 DISASSEMBLY AND ASSEMBLY 1 4 SPECIAL TOOLS 1 5 MEASURING 1 5 REMOVAL AND INSTALLATION 1 6 ...

Page 9: ...ry l D number F0D 800101 ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the cylinder head Starting serial number 66V 000101 JET PUMP UNIT SERIAL NUMBER The jet pump unit serial number is stamped on a label attached to the intermediate housing Starting serial number 66V 800101 HULL IDENTIFICATION NUMBER H l N The H l N is stamped on a plate attached to the aft deck ...

Page 10: ...N Petroleum 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 PROTECTION Protect your eyes with suitable safety spec tacles or safety goggles when grinding or doing any operation which may cause parti cles to fly off Protect hands and feet by wearing safety gloves or ...

Page 11: ...oiled 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 soon as practica ble 5 To protect the skin the application of a suitable barrier cream to the hands before working is recommended 6 A supply of clean lint free cloths should be available for wiping pur...

Page 12: ...bling 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 view and liberally oil the bearings CAUTION Do not spin bearings with compressed air because this will damage their surfaces 5 When installing oil seals apply a light coat of water resistant grease to t...

Page 13: ...gauge and stand P N YU 03097 YU 01256 90890 01252 2 Digital multimeter P N YU 34899 A 90890 06752 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 Engine tachometer P N YU 08036 A 90890 06760 7 Spark gap tester P N YM 34487 90890 06754 8 Peak voltage test harness P N YW 06780 90890 06780 1 7 6 4 5 3 2 YU 03097 YU ...

Page 14: ...ediate shaft P N YB 06016 90890 06626 7 Drive shaft holder impeller P N YB 06151 90890 06519 8 Slide hammer set jet pump bearing P N YB 06096 90890 06523 90890 06531 9 Ball bearing attachment jet pump oil seal P N YB 06156 90890 06634 10 Bearing inner race attachment jet pump bearing P N YB 34474 90890 06662 1 2 3 4 5 6 7 8 9 0 YW 06551 90890 06551 YW 06550 90890 06550 YB 06117 90890 06521 YB 0655...

Page 15: ...ER 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 9 CABLE AND HOSE ROUTING 2 10 ...

Page 16: ... 5 9 1 Intake system Reed valve Carburetor model manufacturer quantity BN44 MIKUNI 3 Enrichment control Choke valve Scavenging system Loop charge Lubrication system Variable oil injection Cooling system Water cooled Starting system Electric starter Ignition system Digital CDI Ignition timing Degree 18 BTDC 24 BTDC Spark plug model manufacturer BR8ES 11 NGK Battery capacity V Ah kC 12 19 68 4 Light...

Page 17: ...oil can seriously damage the catalytic converter and other engine components FUEL AND OIL Fuel Regular unleaded gasoline Minimum fuel rating PON 86 RON 90 Oil YAMALUBE 2 W Fuel oil mixing ratio wide open throttle 30 1 Fuel tank capacity R US gal Imp gal 70 18 5 15 4 Fuel tank reserve capacity R US gal Imp gal 12 3 17 2 64 Oil tank capacity R US gal Imp gal 5 5 1 45 1 21 Item Unit Model XL1200Ltd G...

Page 18: ...61 3 1462 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 8671 PISTON RINGS Top Type Keystone Dimensions B mm in 1 47 1 49 0 058 0 059 Dimensions T mm in 2 8 2 9 0 110 0 114 End gap mm in 0 45 0 60 0 018 0 024 Ring groove clearance mm in 0 02 0 07 0 00...

Page 19: ...hrottle valve 180 Valve seat size mm in 1 2 0 05 Trolling speed r min 1 350 50 REED VALVES Thickness mm in 0 6 0 024 Reed valve stopper height mm in 10 4 11 0 0 41 0 43 Reed valve warpage limit mm in 0 2 0 01 Item Unit Model XL1200Ltd JET PUMP Impeller material Stainless steel Number of impeller blades 3 Impeller pitch angle Degree 15 6 Impeller clearance mm in 0 8 0 031 Impeller clearance limit m...

Page 20: ...7 9 3 500 r min V 11 Lighting coil G G Output peak voltage lower limit cranking 1 V 9 cranking 2 V 9 2 000 r min V 14 3 500 r min V 14 Pickup coil resistance Ω color 445 545 W R B O Lighting coil resistance Ω color 0 49 0 59 G G Minimum charging current A r min 9 6 000 IGNITION COIL Minimum spark gap mm in 10 0 39 Primary coil resistance Ω color 0 26 0 36 B W Ground Secondary coil resistance kΩ co...

Page 21: ...2 V 7 2 000 r min V 12 6 3 500 r min V 12 6 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 03 Limit mm in 0 2 0 01 Commutator diameter mm in 28 0 1 10 Limit mm in 27 0 1 06 FUSE Rating V A 12 10 12 20 Item Unit Model XL1200Ltd Cranking 1 unloaded Cranking 2 loaded ...

Page 22: ...t Bolt M8 6 12 1 2 8 8 271 LT 2nd 23 2 3 17 Exhaust temperature sensor muffler 1 40 4 0 29 572 LT Water temperature sensor mixing joint 1 20 2 0 14 572 LT Muffler hanger Nut M10 2 40 4 0 29 271 LT Exhaust manifold cylinder 1st Bolt M10 10 23 2 3 17 271 LT 2nd 40 4 0 29 1st Nut M10 2 15 1 5 11 271 LT 2nd 40 4 0 29 Joint pipe exhaust manifold Bolt M6 6 12 1 2 8 7 242 LT Electrical box hull Bolt M8 4...

Page 23: ...7 1 37 3 7 27 572 LT Bearing housing hull Bolt M8 3 17 1 7 12 271 LT Intake screen hull Bolt M6 4 8 0 8 5 8 572 LT Intake duct hull Bolt M8 4 17 1 7 12 572 LT Jet pump cover hull Bolt M8 4 17 1 7 12 572 LT Nozzle deflector nozzle ring Bolt M8 2 16 1 6 12 271 LT Nozzle ring nozzle Bolt M8 2 16 1 6 12 271 LT Drive shaft nut drive shaft Nut M16 1 70 7 0 51 Transom plate hull Nut M10 4 27 2 7 20 HULL ...

Page 24: ... of this manual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached Unless other wise specified tightening torque specifica tions require clean dry threads Components should be at room tempera ture Nut A Bolt B General torque specifications Nm m kg ft lb 8 mm M5 5 0 0 5 3 6 10 mm M6 8 0 0 8 5 8 12 mm M8 ...

Page 25: ...hift cable 6 Steering cable 7 Fuel filter 8 Ventilation hose 9 Ground lead 0 Starter motor lead A Electrical box lead B Generator lead C Pickup coil lead D YPVS cable E Speed sensor lead F Pilot water outlet G Battery H Battery breather hose I Battery positive lead J Battery negative lead K Choke knob L Fuel cock M Choke cable ...

Page 26: ...l 6 To battery positive terminal 7 To starter motor 8 To multi function meter 9 To water exhaust temperature sensor 0 To generator A Battery breather hose B Battery negative lead C Water hose D Speed sensor lead E Fuel breather hose F To fuel filter G Choke cable H Fuel return hose I Shift cable J Steering cable ...

Page 27: ...spection and adjustment 3 4 Shift cable inspection and adjustment 3 6 YPVS cable adjustment 3 7 FUEL SYSTEM 3 8 Fuel line inspection 3 9 Trolling speed check and adjustment 3 9 OIL INJECTION SYSTEM 3 10 Oil filter inspection 3 10 Oil injection pump air bleeding 3 10 POWER UNIT 3 11 Spark plug inspection 3 11 ELECTRICAL 3 12 Battery inspection 3 12 JET PUMP UNIT 3 15 Impeller inspection 3 15 Water ...

Page 28: ...le cable Inspect adjust 3 3 Carburetor throttle shaft Inspect adjust Choke cable Inspect adjust 3 4 Shift cable Inspect adjust 3 6 QSTS Inspect adjust 3 4 YPVS Inspect adjust 3 7 FUEL SYSTEM Fuel tank Clean 4 7 Fuel filter Clean replace 3 9 Fuel line Inspect Trolling speed Check adjust 3 9 Carburetor setting Inspect adjust 4 16 OIL INJECTION SYSTEM Oil injection system Check clean 3 10 Oil pump ca...

Page 29: ...bar Steering cable inspection and adjustment 1 Inspect Jet nozzle clearance a b Difference Adjust 2 Adjust Steering cable joint steering column side Inspection steps Turn the handlebar from lock to lock Measure clearances a and b If clearances a and b are not the same adjust them Adjustment steps Loosen the locknut 1 Disconnect the steering cable joint 2 from the ball joint 3 Turn the cable joint ...

Page 30: ...E Before adjusting the throttle 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 After adjusting the free play turn the han dlebar to the right and left and make sure that the trolling speed does not increase Throttle lever free play 4 7 mm 0 16 0 28 in Adjustment steps Loosen the locknut 1 Turn the...

Page 31: ...Turn in the adjusting nut 1 until the choke knob does not automatically return QSTS cable inspection and adjustment 1 Measure Nozzle deflector set length a b Difference Adjust Measurement steps Set the control grip in the neutral posi tion Set the jet nozzle in the center posi tion Measure the nozzle deflector set length a and b If a and b length are not even adjust the cable joint ...

Page 32: ...utral posi tion Set the jet nozzle in the center posi tion Remove the nut 1 and pivot pin 2 Loosen the locknut 3 Turn the cable joint 4 for adjusting Turn in Length b is increased Turn out Length a is increased Connect the cable joint 4 and pivot pin 2 and tighten the nut 1 T R Nut 4 Nm 0 4 m kg 2 9 ft lb Tighten the locknut 3 T R Locknut 4 Nm 0 4 m kg 2 9 ft lb WARNING The cable joint must be scr...

Page 33: ...ket and the lever 3 contacts the reverse gate 2 Adjust Shift cable joint Adjustment steps Loosen the locknut 1 Disconnect the cable joint 2 from the ball joint 3 Turn the cable joint to align it with the ball joint Turn in Shortens Turn out Lengthens Turn out the cable joint nine times from the aligned position Connect the cable joint and tighten the locknut T R Locknut 3 Nm 0 3 m kg 2 2 ft lb WAR...

Page 34: ...de so the display comes on Start the engine and then stop it Check that the hole a in the pulley is aligned with the hole in the cylinder when the YPVS valve is fully closed NOTE When the engine has been stopped for 3 seconds the YPVS valve assembly will extend and retract one time 2 Measure YPVS cable slack a Out of specification Adjust YPVS cable slack 0 5 1 5 mm 0 02 0 06 in ...

Page 35: ...ntil the specified slack is obtained Turn in Slack is increased Turn out Slack is decreased Finger tighten the locknut 1 and 2 Remove the pin Start and stop the engine Recheck the hole alignment If the hole alignment is correctly tighten the locknut If the hole alignment is incorrect repeat the above steps FUEL SYSTEM WARNING Stop the engine set the fuel cock to OFF and loosen the fuel filler cap ...

Page 36: ...nspect Water separator 1 Water accumulation Drain NOTE If need the water draining remove the drain plug 2 Trolling speed check and adjustment 1 Check Trolling speed Out of specification Adjust Trolling speed 1 350 50 r min Checking steps with the vehicle 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 Y...

Page 37: ...meter YU 8036 A 90890 06760 Turn the remote throttle stop screw 1 in or out until the specified trolling speed is obtain OIL INJECTION SYSTEM Oil filter inspection 1 Inspect Oil filter Contaminants Clean Frays tears Replace Rubber seal Cracks wear Replace Oil injection pump air bleeding NOTE Bleed the oil injection system if the system has been disassembled or the oil has been completely depleted ...

Page 38: ...When there are no air bubbles left tighten the air bleed screw Wipe up any spilt oil T R Screw 5 Nm 0 5 m kg 3 6 ft lb POWER UNIT Spark plug inspection 1 Inspect Electrodes 1 Damage wear Replace Insulator color 2 Distinctly different color Check the engine condition 2 Clean Spark plug with a spark plug cleaner or wire brush Color guide Medium to light tan color Normal Whitish color Lean fuel mixtu...

Page 39: ...a torque wrench is not available a good estimate of the correct tightening torque for a new spark plug is to finger tighten a the spark plug and then tighten it another 1 4 to 1 2 of a turn b T R Spark plug 25 Nm 2 5 m kg 18 ft lb ELECTRICAL Battery inspection WARNING Battery electrolyte is dangerous it contains sulfuric acid which is poisonous and highly caustic Always follow these preventive mea...

Page 40: ...l ventilated area Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes DO 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 remove the battery from the battery box Make sure that the battery breather hose is pro...

Page 41: ...istilled 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 level mark 3 Inspect Specific gravity Out of specification Charge Specific gravity at 20 C 68 F 1 28 Charging current 1 9 amps 10 hrs 68 4 kC 4 Install Filler caps CAUTION Before installation rinse off a...

Page 42: ...cted 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 grind 2 Measure Impeller to housing clearance a Out of specification Replace Max impeller to housing clearance 0 9 mm 0 035 in Measurement steps Remove the battery leads Remove the intake screen 1 and duct 2 Measure th...

Page 43: ...inlet filter mesh a Reinstall the removed parts Bilge strainer inspection 1 Inspect Bilge strainer Contaminants Clean Cracks damage Replace Inspection steps Remove the coupling cover Disconnect the bilge strainer 1 from the bilge strainer holder Inspect the bilge strainer GENERAL Drain plug inspection 1 Inspect Drain plug Cracks damage Replace O ring Cracks wear Replace Screw threads Contaminants ...

Page 44: ...throttle cable squeeze the throttle lever and remove the rubber seal 1 Before lubricating the QSTS control cables remove the trim grip guide Recommended lubricant Rust inhibitor 2 Lubricate Throttle cable carburetor side Oil pump cable QSTS cables pulley side YPVS cables Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease ...

Page 45: ...ble joint NOTE Disconnect the joints and apply a small amount of grease Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease 5 Fill Bearing housing NOTE Fill the bearing housing with water resis tant grease through the grease nipples Add the grease slowly and carefully or it could damage the hose and the joints Refer to MAINTENANCE INTERVAL CHART Recommended grease Yamaha...

Page 46: ...spection 4 6 Oil tank inspection 4 6 FUEL TANK 4 7 EXPLODED DIAGRAM 4 7 REMOVAL AND INSTALLATION CHART 4 7 SERVICE POINTS 4 9 Check valve inspection 4 9 Fuel level switch inspection 4 9 Fuel tank inspection 4 9 Pipe joint inspection 4 9 INTAKE DUCT AND SILENCER 4 10 EXPLODED DIAGRAM 4 10 REMOVAL AND INSTALLATION CHART 4 10 CARBURETOR UNIT 4 12 EXPLODED DIAGRAM 4 12 REMOVAL AND INSTALLATION CHART 4...

Page 47: ...dle valve inspection 4 22 Jet and carburetor body inspection 4 22 Carburetor assembly 4 22 FUEL PUMP 4 23 EXPLODED DIAGRAM 4 23 REMOVAL AND INSTALLATION CHART 4 23 SERVICE POINTS 4 25 Fuel pump inspection 4 25 Fuel filter inspection 4 25 OIL PUMP 4 26 EXPLODED DIAGRAM 4 26 REMOVAL AND INSTALLATION CHART 4 26 SERVICE POINTS 4 29 Oil pump inspection 4 29 Oil hose inspection 4 29 Check valve inspecti...

Page 48: ...D 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 Washer 1 5 Fuel cock assembly 1 6 Fuel hose 3 7 Holder 1 8 Fuel filter 1 9 Fuel hose 1 Reverse the removal steps for installation ...

Page 49: ...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 50: ...AGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points CHOKE CABLE REMOVAL Follow the left Step for removal 1 Screw 1 2 Knob 1 3 Friction adjusting nut 1 4 Nut 1 5 Choke cable 1 Reverse the removal steps for installation ...

Page 51: ...ame Q ty Service points OIL TANK REMOVAL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY in chapter 5 Intake duct Refer to INTAKE DUCT AND SILENCER 1 Hose clamp 1 2 Oil filler cap 1 3 Screw 6 4 Oil filler neck 1 5 Rubber seal 1 6 Oil level sensor coupler 1 ...

Page 52: ...IAGRAM Step Procedure Part name Q ty Service points 7 Breather hose 1 8 Oil hose 1 9 Bolt 2 10 Tank belt 2 11 Oil tank assembly 1 12 Hose clamp 1 13 Oil filler hose 1 14 Oil level sensor 1 Reverse the removal steps for installation ...

Page 53: ...L TANK SERVICE POINTS Oil filter inspection Refer to OIL INJECTION SYSTEM in chapter 3 Oil level switch inspection Refer to INDICATION SYSTEM in chapter 7 Oil tank inspection 1 Inspect Oil tank Cracks damage Replace ...

Page 54: ...dure Part name Q ty Service points FUEL TANK REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT in chapter 5 Oil tank Refer to OIL TANK 1 Hose clamp 1 2 Fuel filler cap 1 3 Nut 1 4 Fuel filler neck 1 5 Rubber seal 1 6 Fuel level sensor coupler 1 7 Fuel reserve hose 1 ...

Page 55: ...Part name Q ty Service points 8 Fuel hose 1 9 Fuel breather hose 1 10 Fuel tank assembly 1 11 Hose clamp 1 12 Fuel filler hose 1 13 Hose clamp 1 14 Fuel sensor assembly 1 15 One way valve 1 16 Screw 1 17 Filter 1 Reverse the removal steps for installation ...

Page 56: ... chapter 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 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 ...

Page 57: ...ON CHART Step Procedure Part name Q ty Service points INTAKE DUCT AND SILENCER REMOVAL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY in chapter 5 Muffler assembly Refer to MUFFLER ASSEMBLY in chapter 5 1 Hose clamp 2 2 Joint hose 1 3 Bolt 1 4 Intake duct 1 ...

Page 58: ... E INTAKE DUCT AND SILENCER EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 5 Hook 5 6 Silencer case 1 7 Bolt 6 8 Filter 1 9 Silencer plate 1 10 O ring 3 Reverse the removal steps for installation ...

Page 59: ...ALLATION CHART Step Procedure Part name Q ty Service points CARBURETOR UNIT REMOVAL Follow the left Step for removal Silencer Refer to INTAKE DUCT AND SILENCER 1 Oil pump cable 1 2 Throttle cable 1 3 Choke cable 1 4 Fuel delivery hose 1 5 Fuel return hose 1 6 Oil delivery hose 3 ...

Page 60: ...CARBURETOR UNIT EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Fuel pump vacuum hose 3 8 Bolt 6 9 Bolt 4 10 Carburetor assembly 1 11 Gasket 1 Reverse the removal steps for installation Not reusable ...

Page 61: ...OVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points CARBURETOR UNIT SEPARATION Follow the left Step for removal 1 Hose 2 2 Hose 2 3 Accelerator pump hose 3 4 Remote throttle stop screw assembly 1 5 Throttle link 1 6 Choke link 1 ...

Page 62: ... E CARBURETOR UNIT EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Bolt 3 8 Cable holder 1 9 Bolt 6 10 Carburetor 3 11 Gasket 3 12 Plate 1 Reverse the removal steps for installation Not reusable ...

Page 63: ... screw end from the throttle lever Check the each throttle valve is fully closed 2 Adjust Throttle valve synchronization Adjustment steps Loosen the remote throttle stop screw 1 until untouched the screw end from the throttle lever Loosen the screws 2 Tighten the screws 2 T R Screw 2 Nm 0 2 m kg 1 4 ft lb Turn in the remote throttle stop screw to the original position NOTE Make sure that the throt...

Page 64: ... installation position a 13 15 mm 0 51 0 59 in Throttle cable guide installation position b 18 20 mm 0 71 0 79 in 2 Adjust Throttle lever free play Refer to CONTROL SYSTEM in chapter 3 Oil pump cable installation 1 Adjust Oil pump cable Refer to OIL PUMP Carburetor assembly 1 Adjust Trolling speed Refer to FUEL SYSTEM in chapter 3 ...

Page 65: ...ervice points CARBURETOR DISASSEMBLY Follow the left Step for disassembly 1 Accelerator pump delivery hose 3 Carburetor 3 2 Accelerator pump fuel hose 1 Carburetor 3 3 Screw 4 4 Accelerator pump carburetor cover 1 1 Carburetor 3 carburetor 1 and 2 5 Diaphragm 1 6 Screw 2 7 Regulator body 1 8 Gasket 1 9 Main jet 1 ...

Page 66: ...Step Procedure Part name Q ty Service points 10 Pilot jet 1 11 Screw 1 12 Arm 1 13 Arm pin 1 14 Spring 1 15 Screw 1 16 Needle valve seat holder 1 17 Needle valve 1 18 Needle valve seat 1 19 O ring 1 Reverse the disassembly steps for assembly ...

Page 67: ...re 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 assembly 1 7 Spring 1 8 Diaphragm 1 9 Accelerator pump body 1 Reverse the disassembly steps for assembly ...

Page 68: ...rator pump body inspection 1 Inspect One way valve Crack damage Replace the acceler ator pump body Fuel passage Clog Clean or replace Arm inspection 1 Inspect Arm 1 Bends damage Repair or replace 2 Measure Arm height a NOTE Measure the distance between the surface of the carburetor body b and the top sur face of the arm The arm should be resting on the needle valve but not compressing it Arm heigh...

Page 69: ...an Wear b Replace NOTE Always replace the needle valve and needle valve seat as a set Jet 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 diameters and seriously affect performance Carburetor assembly 1 Adjust Trolling speed Refer to FUEL SYSTEM in chap...

Page 70: ... AND INSTALLATION CHART Step Procedure Part name Q ty Service points FUEL PUMP DISASSEMBLY Follow the left Step for disassembly Carburetors Refer to CARBURETOR 1 Screw 4 2 Fuel pump cover 1 3 Gasket 1 4 Diaphragm 1 5 O ring 1 6 Diaphragm body 1 Not reusable ...

Page 71: ...4 24 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 72: ...5 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 Replace ...

Page 73: ...rocedure Part name Q ty Service points OIL PUMP REMOVAL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY in chapter 5 Intake duct Refer to INTAKE DUCT AND SILENCER 1 Oil pump cable 1 2 Oil delivery hose 3 3 Bolt 1 4 Bleed hose stay 1 5 Bolt 2 ...

Page 74: ...4 27 FUEL E OIL PUMP EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Oil pump assembly 1 7 Gasket 1 8 Oil hose 1 1 9 Oil hose 2 1 Reverse the removal steps for installation Not reusable ...

Page 75: ...art name Q ty Service points OIL PUMP HOSES AND CABLE REMOVAL Follow the left Step for removal 1 Bleed hose 1 2 Air bleed screw 1 3 Gasket 1 4 Bleed hose stay 1 5 Oil delivery hose 1 3 6 Oil delivery hose 2 3 7 Check valve 3 8 Oil pump cable 1 Reverse the removal steps for installation ...

Page 76: ...he oil delivery hoses are not full of oil fill them up After installing the oil injection system bleed the system of any air Refer to OIL INJECTION SYSTEM in chapter 3 Check valve inspection 1 Check Check valve Faulty Replace Checking steps Connect a hose to the end of check valve A and blow into it Air should come out from end B Connect the hose to the end of check valve B and blow into it Air sh...

Page 77: ...t the mark a on the oil pump lever is aligned with the mark b on the oil pump body 2 Adjust Oil pump cable Adjustment steps Loosen the locknut 1 and the adjust ing nut 2 Fully close the carburetor throttle valves Adjust the oil pump cable so that the mark a on the oil pump lever is aligned with the mark b on the oil pump body Tighten the adjusting nut and locknut ...

Page 78: ...T 5 12 EXPLODED DIAGRAM 5 12 REMOVAL AND INSTALLATION CHART 5 12 SERVICE POINTS 5 14 Shim removal 5 14 Engine mount inspection 5 14 Coupling clearance inspection 5 14 REED VALVES 5 15 EXPLODED DIAGRAM 5 15 REMOVAL AND INSTALLATION CHART 5 15 SERVICE POINTS 5 17 Reed valve inspection 5 17 YPVS 5 18 EXPLODED DIAGRAM 5 18 REMOVAL AND INSTALLATION CHART 5 18 SERVICE POINTS 5 21 YPVS valve inspection 5...

Page 79: ... inspection 5 31 GENERATOR AND STARTER MOTOR 5 33 EXPLODED DIAGRAM 5 33 REMOVAL AND INSTALLATION CHART 5 33 SERVICE POINTS 5 39 Drive coupling removal and installation 5 39 Flywheel magneto removal and installation 5 39 Drive coupling inspection 5 40 Flywheel magneto inspection 5 40 Starter clutch assembly inspection 5 40 CRANKCASE 5 41 EXPLODED DIAGRAM 5 41 REMOVAL AND INSTALLATION CHART 5 41 SER...

Page 80: ...GRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points EXHAUST CHAMBER ASSEMBLY REMOVAL Follow the left Step for removal 1 Exhaust temperature sensor coupler 1 2 Cap bolt 3 3 3 Cover 1 4 Clamp hose 4 4 5 Hose clamp 2 6 Hose clamp 2 7 Bolt 2 8 Bolt 2 ...

Page 81: ...Procedure Part name Q ty Service points 9 Exhaust chamber stay 1 10 Bolt 3 11 Bolt 1 12 Exhaust chamber assembly 1 13 Clamp hose 1 1 14 Gasket 1 15 Pin 2 16 Outer exhaust joint 1 17 Inner exhaust joint 1 Reverse the removal steps for installation Not reusable ...

Page 82: ...INSTALLATION CHART Step Procedure Part name Q ty Service points EXHAUST CHAMBER DISASSEMBLY Follow the left Step for disassembly 1 Bolt 5 2 Bolt 1 3 Exhaust chamber joint 1 4 Gasket 1 5 Pin 2 6 Exhaust chamber 1 Reverse the disassembly steps for assembly Not reusable ...

Page 83: ...edure Part name Q ty Service points MUFFLER ASSEMBLY REMOVAL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY Cylinder head Refer to CYLINDER HEAD 1 Band 1 2 Ventilation hose 1 3 Screw 4 4 Ventilation duct 1 5 Water temperature sensor coupler 1 6 Clamp hose 1 1 ...

Page 84: ... ty Service points 7 Hose clamp 1 8 Water lock band 1 Slide the water lock toward back to disconnect the muffler assembly 9 Bolt 4 10 Gear case grease hose 1 11 Bolt 2 12 Bolt 2 13 Bolt 1 14 Muffler stay 2 1 15 Muffler assembly 1 Reverse the removal steps for installation ...

Page 85: ...LLATION CHART Step Procedure Part name Q ty Service points MUFFLER DISASSEMBLY Follow the left Step for disassembly 1 Exhaust temperature sensor 1 2 Water temperature sensor 1 3 Nut 2 4 Hanger 2 5 Bolt 2 6 Muffler stay 1 7 Bolt 6 8 Cover 1 9 Gasket 1 Not reusable ...

Page 86: ...tep Procedure Part name Q ty Service points 10 Catalyst housing 1 11 Gasket 1 12 Catalyst 1 13 Gasket 1 14 Pin 2 15 Bolt 6 16 Mixing joint 1 17 Gasket 1 18 Muffler 1 Reverse the disassembly steps for assembly Not reusable Not reusable Not reusable ...

Page 87: ...5 8 POWR E MUFFLER ASSEMBLY SERVICE POINT Catalyst inspection 1 Inspect Catalyst Cracks damage Replace ...

Page 88: ...ocedure Part name Q ty Service points EXHAUST MANIFOLD AND LEADS REMOVAL Follow the left Step for removal Battery lead negative and positive Refer to ELECTRICAL BOX in chapter 7 Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY 1 AC magneto coupler 1 2 Bolt 2 3 YPVS cable holder 1 4 YPVS cable 2 5 Clamp hose 1 1 ...

Page 89: ...GRAM Step Procedure Part name Q ty Service points 6 Bolt 4 7 Bolt 6 8 Nut 2 9 Exhaust manifold 1 10 Gasket 1 11 Pin 2 12 Bolt 1 13 Battery negative lead 1 14 Nut washer 1 1 15 Starter motor lead 1 Reverse the removal steps for installation Not reusable ...

Page 90: ...REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points EXHAUST MANIFOLD DISASSEMBLY Follow the left Step for disassembly 1 Clamp hose 1 1 2 Bolt 6 3 Joint pipe 1 4 O ring 3 5 Exhaust manifold 1 Reverse the disassembly steps for assembly ...

Page 91: ... name Q ty Service points ENGINE UNIT REMOVAL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY Muffler assembly Refer to MUFFLER ASSEMBLY Carburetor Refer to CARBURETOR in chapter 4 Oil pump Refer to OIL PUMP in chapter 4 1 Spark plug lead 3 2 Bolt 1 3 Collar 1 ...

Page 92: ...UNIT EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 4 Coupling cover 1 5 Bolt washer 4 4 6 Engine assembly 1 7 Shim Install the shims original position Reverse the removal steps for installation As required ...

Page 93: ...t rear left prior to removing the mounting bolts Engine mount inspection 1 Inspect Engine mounts Cracks damage Replace Coupling clearance inspection 1 Measure Clearance a Clearance b with a straightedge and thickness gauge Out of specification Adjust with the shims NOTE Before measuring the clearance remove the rubber damper Clearance a 0 1 0 mm 0 0 039 in Clearance b 2 4 mm 0 079 0 157 in ...

Page 94: ... ty Service points REED VALVE REMOVAL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY Muffler assembly Refer to MUFFLER ASSEMBLY Carburetor unit Refer to CARBURETOR UNIT in chapter 4 1 Bolt 18 2 Reed valve plate 1 NOTE Tighten the bolts in the proper sequence as shown ...

Page 95: ...5 16 POWR E REED VALVES EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 3 Reed valve assembly 3 4 Screw 24 5 Valve stopper 6 6 Reed valve 6 Reverse the removal steps for installation ...

Page 96: ...ction 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 0 01 in Valve stopper height 10 4 11 0 mm 0 41 0 43 in ...

Page 97: ...me Q ty Service points YPVS REMOVAL Follow the left Step for removal YPVS cable 1 and 2 Refer to EXHAUST MANIFOLD AND LEADS Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY 1 Bolt 12 2 YPVS cable bracket 1 3 YPVS valve cover 3 4 Gasket 3 5 Spacer 2 6 Link joint cover 2 2 Not reusable ...

Page 98: ...RAM Step Procedure Part name Q ty Service points 7 Bolt M4 3 8 Circlip 5 9 Shaft 3 1 10 Shaft 2 1 11 Shaft 1 1 12 Washer 5 13 YPVS valve lever 3 NOTE During installation align the hole a in the YPVS shaft with the screw Not reusable ...

Page 99: ...XPLODED DIAGRAM Step Procedure Part name Q ty Service points 14 Bolt M5 3 15 YPVS valve assembly 3 16 Oil seal 6 Reverse the removal steps for installation NOTE If the YPVS shaft is removed the oil seal must be replaced ...

Page 100: ...INTS YPVS valve inspection 1 Eliminate 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 ...

Page 101: ...edure Part name Q ty Service points CYLINDER HEAD REMOVAL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY 1 Spark plug 3 2 Bolt 2 3 Bolt 2 4 Bolt 6 5 Bolt 16 NOTE Tighten the bolts in the proper sequence as shown and in three stages No 23 24 in two stages ...

Page 102: ... E CYLINDER HEAD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Cylinder head cover 1 7 Gasket 1 8 Cylinder head 1 9 Gasket 1 Reverse the removal steps for installation Not reusable Not reusable ...

Page 103: ...cylinder 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 specification score marks Resurface NOTE Place a 400 600 grit wet sandpaper on a surface plate and resurface the cylinder head using a figure eight sanding pattern Warpage limit 0 1 mm 0 004 in ...

Page 104: ...points CYLINDER REMOVAL Follow the left Step for removal YPVS Refer to YPVS Cylinder head Refer to CYLINDER HEAD 1 Bolt 12 2 Cylinder 3 3 Cylinder gasket 3 4 Pin 6 Reverse the removal steps for installation NOTE Tighten the bolts in a crisscross pattern and in two stages NOTE Install the original position Not reusable ...

Page 105: ... 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 Standard Limit Cylinder bore D 80 000 80 018 mm 3 1496 3 1503 in Original cylinder bore 0 04 mm 0 0016 in Taper T 0 08 mm 0 003 in Out of round R 0 05 mm 0 002 in D Maximum D1 D6 T Maximum D1 or D2 Maxim...

Page 106: ...t name Q ty Service points PISTON REMOVAL Follow the left Step for removal Cylinders Refer to CYLINDERS 1 Piston pin clip 6 2 Piston pin 3 3 Piston 3 4 Washer 6 CAUTION Do not align the open end of the clip with the piston pin slot a NOTE Make sure that the arrow b faces towards the exhaust side ...

Page 107: ...POWR E PISTONS EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 5 Bearing 3 6 Piston ring 6 Reverse the removal steps for installation CAUTION Align each end gap with its respective locating pin ...

Page 108: ...ton 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 sandpaper or replace NOTE Lightly sand the piston wall in a crisscross pattern 3 Measure Piston skirt diameter with a micrometer Out of specification Replace Piston diameter Distance a 79 899 79 914 m...

Page 109: ...ws 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 a Piston color mark 0 5 Red 6 10 Orange 11 15 Green 16 18 Purple Piston ring inspection 1 Measure Side clearance with a thickness gauge 1 Out of specification Replace the piston and piston rings as ...

Page 110: ... 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 Piston pin outside diameter Standard 21 995 22 000 mm 0 8659 0 8661 in Limit 21 990 mm 0 8657 in 3 Check Piston pin to piston free play with the piston pin in the piston as shown Free play Replace the piston ...

Page 111: ...32 POWR E PISTONS 4 Check Piston pin to connecting rod free play with the piston pin in the small end of the connecting rod as shown Free play small end wear Replace the piston pin connecting rod or both ...

Page 112: ...RAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points GENERATOR COVER REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT Oil pump Refer to OIL PUMP in chapter 4 1 Band 1 2 Bolt 1 3 Bolt 7 4 Ground lead 1 5 Generator cover 1 6 Washer 2 ...

Page 113: ...4 POWR E GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Spring 1 8 Packing 1 9 Pin 2 10 Bolt 2 11 Bolt 2 12 Bracket 1 Reverse the removal steps for installation ...

Page 114: ...EMOVAL Follow the left Step for removal 1 Bolt 3 2 Washer 1 3 Cable holder 1 4 Bolt 2 5 Pickup coil 1 6 Bolt 3 7 Stator coil 1 Reverse the removal steps for installation 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 GENERATOR AND STARTER MOTOR ...

Page 115: ...Procedure Part name Q ty Service points GENERATOR ROTOR AND STARTER MOTOR REMOVAL Follow the left Step for removal 1 Drive coupling 1 2 Flywheel magneto bolt 1 3 Flywheel magneto 1 4 Woodruff key 1 5 Starter clutch assembly 1 6 Bolt 2 7 Starter motor 1 Reverse the removal steps for installation ...

Page 116: ... DIAGRAM 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 Idle gear 1 6 Circlip 1 7 Plate 1 Not reusable ...

Page 117: ...5 38 POWR E GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Weight 3 9 Spring 1 10 Pinion gear 1 Reverse the disassembly steps for assembly ...

Page 118: ...and installation 1 Remove Flywheel magneto bolt NOTE Install the bolt with the same special tool that was used for removal 2 Remove Generator rotor Å For USA and CANADA ı For worldwide CAUTION To prevent damage to the engine or tools screw in the flywheel puller set bolts evenly and completely so that the puller plate is parallel to the generator rotor Flywheel holder YW 06550 90890 06550 Flywheel...

Page 119: ... Inspect 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 Check Gear movement Rough movement Replace the defective part s ...

Page 120: ...ION CHART Step Procedure Part name Q ty Service points CRANKCASE DISASSEMBLY Follow the left Step for disassembly Pistons Refer to PISTONS Generator cover and starter motor Refer to GENERATOR AND STARTER MOTOR 1 Bolt 6 2 Mount bracket 2 3 Pin 4 4 Bolt 3 5 Bolt 1 6 Bolt 6 ...

Page 121: ...AM Step Procedure Part name Q ty Service points 7 Bolt 1 8 Bolt 12 9 Bolt 4 10 Lower crankcase 1 11 Pin 2 12 Crankshaft assembly 1 13 Upper crankcase 1 Reverse the disassembly steps for assembly NOTE Tighten the bolts in sequence as shown ...

Page 122: ...e 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 Crankshaft Rough movement Recheck NOTE After installation make sure that the crank shaft rotates smoothly ...

Page 123: ... Part name 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 Crankshaft assembly 1 Reverse the removal steps for installation CAUTION Install the bearing locating pins into the grooves in the crankcase body ...

Page 124: ... Deflection B with a dial gauge Out of specification Replace Max deflection B 0 05 mm 0 002 in C 0 15 mm 0 006 in 3 Measure Big end side clearance D with a thickness gauge Out of specification Replace Big end side clearance 0 25 0 75 mm 0 010 0 030 in 4 Measure Small end free play E with a dial gauge Out of specification Replace Small end free play 2 0 mm 0 08 in ...

Page 125: ...CRANKSHAFT 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 wear Replace ...

Page 126: ...LLER HOUSING AND INTAKE DUCT 6 7 EXPLODED DIAGRAM 6 7 REMOVAL AND INSTALLATION CHART 6 7 IMPELLER DUCT AND DRIVE SHAFT 6 9 EXPLODED DIAGRAM 6 9 REMOVAL AND INSTALLATION CHART 6 9 SERVICE POINTS 6 11 Drive shaft removal 6 11 Impeller inspection 6 11 Drive shaft inspection 6 11 Bearing inspection 6 11 Drive shaft installation 6 12 TRANSOM PLATE AND HOSES 6 13 EXPLODED DIAGRAM 6 13 REMOVAL AND INSTAL...

Page 127: ... 15 SERVICE POINTS 6 18 Driven coupling removal and installation 6 18 Driven coupling shaft removal 6 18 Bearing removal 6 18 Bearing driven coupling shaft and grease hose inspection 6 19 Driven coupling inspection 6 19 Bearing installation 6 19 Oil seal installation 6 19 Bearing housing installation 6 20 ...

Page 128: ...TALLATION 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 screen 1 4 Bolt 4 5 Intake duct 1 6 Screw 4 7 Speed sensor 1 8 Bolt 4 9 Jet pump cover 1 10 Shift cable joint 1 11 QSTS cable joint 1 ...

Page 129: ...ut washer 1 2 14 Steering cable joint 1 15 Clamp spout hose 1 1 16 Bolt 1 17 Bolt 4 18 Jet pump unit assembly 1 19 Dowel pin 2 Reverse the removal steps for installation NOTE Pull the jet pump unit straight back When installing the jet pump unit align the drive shaft spline male with the intermediate shaft spline female ...

Page 130: ...ED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points REVERSE GATE REMOVAL Follow the left Step for removal 1 Clamp spout hose 1 1 2 Bolt 2 3 Washer 2 4 Collar 2 5 Reverse gate assembly 1 6 Nut 1 7 Bolt 1 8 Washer 2 ...

Page 131: ...6 4 E JET PUMP REVERSE GATE EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 9 Roller 1 10 Bolt 6 11 Reverse gate stay 2 12 Nut 1 13 Washer 1 14 Bolt 1 15 Lever 1 16 Spacer 1 17 Nut 1 ...

Page 132: ...6 5 E JET PUMP REVERSE GATE EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 18 Washer 1 19 Collar 1 20 Spring 1 21 Lever 1 22 Bolt 1 23 Washer 2 Reverse the removal steps for installation ...

Page 133: ... 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 Reverse gate Refer to REVERSE GATE 1 Bolt washer 2 2 2 Spacer 2 3 Nozzle deflector 1 4 Bolt washer 2 2 5 Spacer 2 6 Nozzle ring 1 Reverse the removal steps for installation ...

Page 134: ...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 2 Nozzle 1 3 Pin 2 4 Impeller duct assembly 1 5 Pin 2 6 Impeller housing 1 NOTE Clean the contacting surfaces before applying the Gasket Maker ...

Page 135: ...PUMP IMPELLER DUCT IMPELLER HOUSING AND INTAKE DUCT EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Bolt 4 8 Cover 1 9 Packing 1 10 Filter 1 11 Packing 1 Reverse the removal steps for installation ...

Page 136: ...ED 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 1 Left hand threads 2 Spacer 1 3 Bolt washer 3 3 4 Cap 1 5 O ring 1 6 Nut 1 7 Washer 1 ...

Page 137: ...FT EXPLODED DIAGRAM 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 assembly Not reusable Not reusable ...

Page 138: ...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 Front bearing Impeller inspection Refer to JET PUMP UNIT in chapter 3 Drive shaft inspection 1 Inspect Drive shaft Damage wear Replace Bearing inspection 1 Inspect Front and rear bearings rotate each inner race by hand Damage rough movement Replace Slide hammer set 90...

Page 139: ...NOTE Install the front bearing and drive shaft with a press 3 Add EPNOC grease AP 0 between the drive shaft and spacer 4 Install Rear bearing 5 Add EPNOC grease AP 0 into the cap Distance a 23 0 1 mm 0 91 0 004 in Quantity Approximately 1 3 of capacity Bearing inner race attachment YB 34474 90890 06662 Quantity Approximately 1 3 of capacity 6 Install Nut Impeller Drive shaft holder YB 06151 90890 ...

Page 140: ...edure Part name Q ty Service points TRANSOM PLATE AND HOSES REMOVAL Follow the left Step for removal 1 Hose clamp 3 2 Hose 1 Cooling water outlet 3 Bilge hose 1 1 4 Hose 1 Cooling water inlet 5 Nut washer 4 4 6 Transom plate 1 7 Clamp bilge hose 2 1 1 8 Holder 1 9 Bilge filter 1 Reverse the removal steps for installation ...

Page 141: ...6 14 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 hose Cracks damage wear Replace ...

Page 142: ... 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 washer 3 3 3 Bearing housing assembly 1 4 Pin 2 5 Shim Reverse the removal steps for installation As required NOTE Install the shims in their original locations ...

Page 143: ... 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 Grease nipple 1 3 Grease nipple stay 1 4 Nipple 2 5 Driven coupling 1 6 Washer 1 7 Driven coupling shaft 1 ...

Page 144: ... JET PUMP BEARING HOUSING EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 O ring 2 9 Oil seal 2 10 Oil seal 1 11 Circlip 1 12 Bearing 1 13 Circlip 1 Reverse the disassembly steps for assembly ...

Page 145: ...ling shaft Coupler wrench YW 06551 90890 06551 Shaft holder YB 06552 90890 06552 Removal steps Temporarily install the driven coupling to the driven coupling shaft Insert the long rod to the driven cou pling shaft Press out the driven coupling shaft by pushing the rod Bearing removal 1 Remove Bearing NOTE Install the bearing with the same special tools that were used for removal Driver rod YB 0607...

Page 146: ...pling inspection 1 Inspect Driven coupling Driven coupling damper Damage wear Replace Bearing installation 1 Install Bearing Driver rod YB 06071 90890 06606 Bearing outer race attachment YB 06016 90890 06626 Oil seal installation 1 Install Oil seal NOTE Before installing the oil seal lubricate the clip groove with water resistant grease Driver rod YB 06071 90890 06606 Bearing outer race attachment...

Page 147: ...aring housing installation 1 Install Bearing housing Shim NOTE Install the shim s to the original position if the bearing housing is not replaced Installation steps Install the bearing housing Measure the clearance a at each bolt hole Install the suitable shim from the table below Clearance a Shim thickness 0 0 2 mm 0 0 010 in No need 0 3 0 7 mm 0 011 0 030 in 0 5 mm 0 8 1 2 mm 0 031 0 050 in 1 0 ...

Page 148: ...NITION SPARK GAP 7 12 IGNITION SYSTEM PEAK VOLTAGE 7 13 BATTERY 7 15 FUSE 7 15 SPARK PLUGS 7 15 SPARK PLUG LEAD ASSEMBLY 7 15 IGNITION COIL 7 15 ENGINE STOP SWITCH 7 16 WATER TEMPERATURE SENSOR 7 16 EXHAUST TEMPERATURE SENSOR 7 17 STARTING SYSTEM 7 18 WIRING DIAGRAM 7 18 BATTERY 7 19 WIRING CONNECTIONS 7 19 FUSE 7 19 STARTER SWITCH 7 20 STARTER RELAY 7 20 STARTER MOTOR 7 21 EXPLODED DIAGRAM 7 21 R...

Page 149: ...stallation 7 31 YPVS cable inspection 7 31 YPVS servomotor inspection 7 31 YPVS cable adjustment 7 32 INDICATION SYSTEM 7 33 WIRING DIAGRAM 7 33 FUSE 7 34 BATTERY 7 34 LIGHTING COIL 7 34 RECTIFIER REGULATOR 7 34 CDI UNIT 7 34 WATER TEMPERATURE SENSOR 7 34 EXHAUST TEMPERATURE SENSOR 7 34 BUZZER 7 34 OIL LEVEL SENSOR 7 34 FUEL LEVEL SENSOR 7 35 MULTI FUNCTION METER 7 35 Multi function meter 7 35 EXP...

Page 150: ...nction meter 3 Fuel level sensor 4 Buzzer 5 Oil level sensor 6 Stator coil and pickup coil 7 Spark plugs 8 Exhaust temperature sensor 9 Battery 0 Speed sensor A Electrical box B Water temperature sensor C Starter motor D Engine stop switch engine stop lanyard switch and starter switch ...

Page 151: ...me Q ty Service points ELECTRICAL BOX REMOVAL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY in chapter 5 Exhaust manifold Refer to EXHAUST MANIFOLD in chapter 5 Spark plug lead 1 Battery negative lead 1 2 Battery positive lead 1 3 Breather hose 1 4 Band 2 5 Battery 1 ...

Page 152: ...RICAL BOX EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Damper 1 7 Bolt 4 8 Battery box 1 9 Coupler 4 For multi function meter 10 Bolt 4 11 Electrical box 1 Reverse the removal steps for installation ...

Page 153: ...me Q ty Service points ELECTRICAL BOX DISASSEMBLY Follow the left Step for disassembly 1 Clamp 5 2 Coupler 3 For overheat exhaust temperature sensor and lighting coil 3 Screw 2 4 Rectifier regulator 1 5 Screw 10 6 Cover 1 7 Packing 1 8 Spark plug lead holder 3 9 Spark plug lead cap 3 3 10 Screw 6 ...

Page 154: ... Part name Q ty Service points 11 Ground lead 3 12 Ignition coil 3 13 Ignition coil lead 3 14 Bolt 3 15 Ground lead 6 16 Lead 3 Black Orange 17 Nut 2 18 Starter motor lead 1 19 Battery positive lead 1 20 Fuse lead 1 21 Starter relay lead 1 22 Starter relay 1 ...

Page 155: ...tep Procedure Part name Q ty Service points 23 Lead holder 1 24 Fuse lead 5 25 Screw 2 26 Fuse holder 1 27 Lead coupler 1 6 28 Screw 2 29 Coupler bracket 1 30 CDI unit 1 31 Screw 8 32 Lead holder plate 2 Reverse the disassembly steps for assembly ...

Page 156: ...y positive terminal ı To starter motor Ç Affix the ignition coil connector to the electrical box holder Î Pass the 8 pin coupler leads behind the CDI unit and insert them into the bracket Br Brown G Green Gy Gray O Orange R Red W White B O Black Orange B W Black White B Y Black Yellow Gy B Gray Black Gy R Gray Red Gy Y Gray Yellow R W Red White R Y Red Yellow ...

Page 157: ...nstrument powered by dry batter ies check the battery s voltage periodi cally and replace the batteries if necessary Digital circuit tester NOTE Throughout this chapter the digital circuit tester s part number has been omitted Refer to the following part number NOTE indicates a continuity of electric ity i e a closed circuit at the respective switch position Digital circuit tester J 39299 90890 06...

Page 158: ... NOTE When checking the condition of the igni tion system it is vital to know the peak voltage Cranking speed is dependant on many factors e g fouled or weak spark plugs a weak battery If one of these is defected the peak voltage will be lower than speci fication If the peak voltage measurement is not within specification the engine will not operate properly A low peak voltage will also cause comp...

Page 159: ...ow ing tests Å Voltage measurement ı Peak voltage measurement Å ı Test harness NOTE Make sure the output lead red lead of the rectifier regulator is disconnected when measuring the peak voltage of the lighting coil and rectifier regulator If the lighting coil and pickup coil s are measured unloaded disconnect the test harness on the output side coupler YW 90890 Pin Usage 06780 06780 6 Pick up coil...

Page 160: ...2 Engine stop lanyard switch 3 Lighting coil 4 Pickup coil 5 CDI unit 6 Ignition coil 7 Spark plug 8 Battery 9 Rectifier regulator 0 Exhaust temperature sensor A Water temperature sensor B Black O Orange R Red W White B O Black Orange B W Black White B Y Black Yellow W R White Red ...

Page 161: ...ck keep flammable gas or liquids away since this test can produce sparks 1 Check Ignition spark gap Below specification Continue to check the CDI unit output Å For USA and CANADA ı For worldwide Spark gap 10 mm 0 39 in Checking steps Remove the spark plugs from the engine Connect the spark plug cap to the spark gap tester Set the spark gap length on the adjust ing knob Spark gap tester YM 34487 90...

Page 162: ...n system but possibly with the spark plug s or another compo nent 1 Measure CDI unit output peak voltage Above specification Replace the ignition coil Below specification Measure the rectifier output peak voltage Replace the CDI unit Cranking 1 unloaded Cranking 2 loaded NOTE B O B for cylinder 1 B W B for cylinder 2 B Y B for cylinder 3 CDI unit output peak voltage Black Orange B O Black B Black ...

Page 163: ...h a lead 3 Measure Lighting coil output peak voltage Below specification Replace the lighting coil 4 Measure Rectifier output peak voltage Below specification Replace the rectifier regulator Cranking 1 unloaded Cranking 2 loaded Pick up coil output peak voltage White Red W R Black Orange B O 5 V cranking 1 2 8 V cranking 2 7 9 V 2 000 r min 11 V 3 500 r min Lighting coil output peak voltage Green ...

Page 164: ... resistance Out of specification Replace Spark plug lead resistance 1 6 1 14 3 kΩ 2 4 6 11 1 kΩ 3 3 1 7 7 kΩ IGNITION COIL 1 Measure Primary coil resistance Out of specification Replace NOTE When measuring a resistance of 10 Ω or less with the digital tester the correct mea surement cannot be obtained because of the tester s internal resistance Refer to Low resistance measurement Primary coil resi...

Page 165: ...te Black Installed Free Push Removed Free Push WATER TEMPERATURE SENSOR 1 Measure Water temperature sensor resistance at the specified temperature Out of specification Replace Water temperature sensor resistance 0 C 32 F 24 0 37 1 kΩ 100 C 212 F 0 87 1 18 kΩ 200 C 392 F 0 104 0 153 kΩ Measurement steps Ice the water temperature sensor and measure the resistance Suspend the water temperature sen so...

Page 166: ...erature Out of specification Replace Exhaust temperature sensor resistance 300 C 572 F 73 241 kΩ 600 C 1 112 F 0 86 1 58 kΩ 900 C 1 652 F 64 90 Ω Measurement steps Heat the exhaust temperature sensor using an electric furnace or equivalent Measure the resistance when the spec ified temperature IGNITION SYSTEM ...

Page 167: ...STARTING SYSTEM STARTING SYSTEM WIRING DIAGRAM 1 CDI unit 2 Engine stop lanyard switch 3 Starter switch 4 Multi function meter 5 Fuse 6 Starter relay 7 Starter motor 8 Battery B Black Br Brown R Red R Y Red Yellow ...

Page 168: ...operly connect FUSE 1 Check Fuse holder continuity No continuity Check the fuse or replace the fuse holder Fuse holder continuity Between 1 and 2 Between 3 and 4 2 Check Fuse broken Broken Replace NOTE 20A fuse is for CDI unit and rectifier regula tor 10A fuse is for multi function meter YPVS motor and start switch Fuse rating 10A 20A ...

Page 169: ...rminal Black lead terminal Loose Tighten 2 Check Starter relay Faulty Replace Checking 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 terminal Check that there is continuity between the starter relay terminals Check that there is no continuity after ...

Page 170: ...Procedure Part name Q ty Service points STARTER MOTOR DISASSEMBLY Follow the left Step for disassembly Starter motor Refer to GENERATOR AND STARTER MOTOR in chapter 5 1 O ring 1 2 Bolt 2 3 Starter motor front cover 1 4 O ring 1 5 Oil seal retainer 1 6 Washer 1 7 Shim t 0 2 mm 0 5 mm As required ...

Page 171: ...Procedure Part 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 Bolt 1 17 Brush assembly 1 As required ...

Page 172: ...7 23 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 173: ... 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 and metal particles with compressed air 5 Measure Commutator undercut Out of specification Replace Min commutator undercut 0 2 mm 0 01 in ...

Page 174: ...ent 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 Replace Brush holder continuity Brush holder Base No continuity Starter motor front cover inspection 1 Inspect Starter motor front cover bushing Damage wear Replace the starter motor front cover ...

Page 175: ...7 26 E ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM 1 Lighting coil 2 Battery 3 Fuse 20A 4 Rectifier regulator B Black G Green R Red G W Green White ...

Page 176: ...7 27 E ELEC CHARGING SYSTEM FUSE Refer to STARTING SYSTEM BATTERY Refer to ELECTRICAL in chapter 3 LIGHTING COIL Refer to IGNITION SYSTEM RECTIFIER REGULATOR Refer to IGNITION SYSTEM ...

Page 177: ... ELEC YPVS YPVS WIRING DIAGRAM 1 Lighting coil 2 Pickup coil 3 CDI unit 4 YPVS servomotor 5 Fuse 6 Battery 7 Rectifier regulator B Black Gy Gray R Red B O Black Orange R L Red Blue R W Red White W R White Red ...

Page 178: ...E Refer to STARTING SYSTEM BATTERY Refer to ELECTRICAL in chapter 3 PICKUP COIL Refer to IGNITION SYSTEM CDI UNIT Refer to IGNITION SYSTEM LIGHTING COIL Refer to IGNITION SYSTEM RECTIFIER REGULATOR Refer to IGNITION SYSTEM ...

Page 179: ... Step Procedure Part name Q ty Service points YPVS SERVOMOTOR REMOVAL Follow the left Step for removal 1 Bolt 2 2 Cable holder 1 3 YPVS servomotor coupler 1 4 Bolt 2 5 YPVS servomotor 1 6 Spacer 2 7 YPVS cable 2 White tape is for No 2 cable 8 Cover 1 Reverse the removal steps for installation ...

Page 180: ...spect YPVS cables 1 and 2 Frays kinks rough movement Replace YPVS servomotor inspection 1 Check YPVS servomotor YPVS servomotor does not move Replace Checking steps Connect the battery 12 V to the YPVS servomotor coupler as shown Battery positive terminal Red R terminal 1 Battery negative terminal Black B terminal 2 Install a jumper lead 4 between the black 2 and gray 3 terminals as shown Only ins...

Page 181: ...VS 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 pulley operates three sec onds after the jumper lead is removed ...

Page 182: ...7 Engine stop lanyard switch 8 Starter switch 9 Battery 0 Fuse A Exhaust temperature sensor B Water temperature sensor B Black Br Brown Ch Chocolate G Green Gy Gray L Blue O Orange R Red Y Yellow B O Black Orange B Y Black Yellow Gy B Gray Black Gy R Gray Red Gy Y Gray Yellow L B Blue Black L R Blue Red R B Red Black R W Red White R Y Red Yellow W L White Blue ...

Page 183: ...OR Refer to IGNITION SYSTEM EXHAUST TEMPERATURE SENSOR 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 Connect the battery 12 V to the buzzer coupler as shown Battery positive terminal Red R terminal 1 Battery negative terminal Black B terminal 2 Blue L Black B Float posi...

Page 184: ...specification Replace White blue W L Black B Float position Resistance Ω A 757 803 B 0 8 MULTI FUNCTION METER Multi function meter 1 Check Multi function meter Cracked meter housing Replace the multi function meter Meter is fogged shows signs of water intrusion Replace the multi func tion meter ...

Page 185: ...ND INSTALLATION CHART Step Procedure Part name Q ty Service points MULTI FUNCTION METER REMOVAL Follow the left Step for removal 1 Multi function meter coupler 8 2 Nut washer 2 2 3 Holder 1 4 Multi function meter 1 Reverse the removal steps for installation ...

Page 186: ...1 Oil level sensor 2 Fuel level sensor 3 Buzzer 4 Electrical box 5 Start switch 6 Battery 7 Speed sensor Disconnected B Black Br Brown Ch Chocolate G Green Gy Gray L Blue R Red Y Yellow Gy B Gray Black Gy R Gray Red Gy Y Gray Yellow L B Blue Black L R Blue Red R B Red Black R W Red White R Y Red Yellow W L White Blue ...

Page 187: ...s turn on 4 is displayed 5 is displayed 6 is displayed 7 is displayed 8 is displayed 9 is displayed 10 is displayed 11 is displayed 12 is displayed 13 is displayed 14 is displayed 15 is displayed Press either button 3 4 5 or 6 The self indicating function will then stop and the WARNING lamp 2 will light Reconnect the blue one pin connector The WARNING lamp 2 will turn off NOTE If the multi functio...

Page 188: ... jumper lead 1 Connect the green and red terminals with a jumper lead 2 Check the fuel level segments is full indicated Remove the jumper lead from the green two pin connector Disconnect the jumper lead 2 and then connect it to green and red ter minal again Make sure the fuel low level segment 3 fuel level warning indicator 4 and message 5 blinks and the WARNING lamp 6 operates properly and the bu...

Page 189: ... lead 1 Connect the green and red terminals with a jumper lead 2 Check the oil level segments is full indicated Remove the jumper lead from the white two pin connector Disconnect the jumper lead 2 and then connect it to green and red ter minal again Make sure the oil low level segment 3 oil level warning indicator 4 and message 5 blinks and the WARNING lamp 6 operates prop erly and the buzzer soun...

Page 190: ...Connect the green and red terminals with a jumper lead 2 Make sure the water temperature warning indicator blinks 3 and the message 4 blinks the WARNING lamp 5 blinks and the buzzer sounds intermittently 2 Check Overheat 2 warning indicator Not operating Replace the multi function meter Checking steps Supply DC 12 voltage to the white six pin connector red black with a battery Connect the gray red...

Page 191: ...cator Not operating Replace the multi function meter Checking steps Supply DC 12 voltage to the white six pin connector red black with a battery Connect the gray yellow and black ter minals with a jumper lead 1 Connect the green and red terminals with a jumper lead 2 Make sure the exhaust temperature warning indicator blinks 3 and the message 4 blinks the WARNING lamp 5 operates prop erly and the ...

Page 192: ...tput voltage 10 5 V Checking steps Supply DC 12 voltage to the white six pin connector red black with a battery Disconnect the blue one pin connector 1 and make sure the WARNING lamp lights 2 Measure the voltage on the speed meter connector white three pin con nector between the red white and black leads NOTE If the WARNING lamp does not light disconnect the battery and then recon nect it ...

Page 193: ...n 400 mV 11 6 12 V Output pulse 2 pulses one full turn Checking steps Apply DC 12 voltage to the white three pin connector between the red white and black leads Rotate the paddle wheel by hand and measure the voltage between the black and yellow leads Two pulses occur every time the pad dle wheel makes one full turn NOTE As the paddle wheel is rotated a square wave voltage signal a is produced ...

Page 194: ... 14 Steering master components inspection 8 14 REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 8 15 EXPLODED DIAGRAM 8 15 REMOVAL AND INSTALLATION CHART 8 15 SERVICE POINTS 8 18 Remote control cables inspection 8 18 Steering cable jet pump side installation 8 18 Steering cable stopper installation 8 18 QSTS cable jet pump side installation 8 19 QSTS cable stopper installation 8 19 Shift cable jet pump...

Page 195: ...AND GRIP 8 31 EXPLODED DIAGRAM 8 31 REMOVAL AND INSTALLATION CHART 8 31 SERVICE POINTS 8 33 Seat lock inspection 8 33 EXHAUST SYSTEM 8 34 EXPLODED DIAGRAM 8 34 REMOVAL AND INSTALLATION CHART 8 34 SERVICE POINTS 8 36 Exhaust system inspection 8 36 DECK AND HULL 8 37 EXPLODED DIAGRAM 8 37 REMOVAL AND INSTALLATION CHART 8 37 ENGINE MOUNT 8 39 EXPLODED DIAGRAM 8 39 REMOVAL AND INSTALLATION CHART 8 39 ...

Page 196: ...RT 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 Band 2 4 Pad 1 5 Bolt 2 6 Handlebar cover stay 1 7 Throttle cable 1 8 Bolt 4 9 Upper handlebar holder 2 Reverse the removal steps for installation ...

Page 197: ...ep Procedure Part 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 Bolt 2 2 QSTS converter 1 3 QSTS cable 2 1 with white tape 4 QSTS cable 1 1 5 Handlebar switch coupler 3 ...

Page 198: ...OOD HANDLEBAR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Buzzer coupler 1 7 Screw 4 8 Handle boss cover 1 9 Band 2 10 Handlebar assembly 1 11 Buzzer 1 Reverse the removal steps for installation ...

Page 199: ...GRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points HANDLEBAR DISASSEMBLY Follow the left Step for disassembly 1 Bolt 2 2 Grip end 2 3 Spacer 1 4 Screw washer spring washer 1 1 1 5 QSTS grip assembly 1 6 Screw 2 ...

Page 200: ...e Part name Q ty Service points 7 Handlebar switch assembly 1 8 Screw 2 9 Throttle lever assembly 1 10 Handlebar grip 1 11 Handlebar 1 Reverse the disassembly steps for assembly NOTE Apply adhesive to the handlebar and the inner surface of the handlebar grip ...

Page 201: ...bar switch lead Throttle cable NOTE After inserting the cables and leads into the grommets tie the end of grommets with the bands 1 2 Install Upper handlebar holder 1 CAUTION Clearance a should be narrower than clearance b NOTE Align the punch mark c on the handlebar with the top surface of the handlebar holder The upper handlebar holder should be installed with the punch mark d facing forward Ref...

Page 202: ... trim 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 in 4 Adjust Throttle cable free play Refer to CONTROL SYSTEM in chapter 3 5 Adjust QSTS cable free play Refer to CONTROL SYSTEM in chapter 3 ...

Page 203: ...N 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 4 Spring 2 5 QSTS cable 1 1 6 QSTS cable 2 1 NOTE QSTS cable 2 has white tape a on its end ...

Page 204: ...P EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Screw washer 2 2 8 Spacer 1 9 QSTS grip position locator 1 10 Spring 1 11 Spacer 1 12 Cable housing 1 13 QSTS grip 1 Reverse the disassembly steps for assembly ...

Page 205: ...8 10 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 206: ... name Q ty Service points STEERING MASTER REMOVAL Follow the left Step for removal Handlebar assembly Refer to HANDLEBAR Steering master cover Refer to STEERING MASTER COVER 1 Bolt washer 1 1 2 Steering arm 1 3 Nut washer 4 4 4 Steering master assembly 1 5 Bolt 4 6 Grommet 2 Reverse the removal steps for installation ...

Page 207: ...ALLATION CHART Step Procedure Part name Q ty Service points STEERING MASTER DISASSEMBLY Follow the left Step for disassembly 1 Bolt washer 2 2 2 Stay 1 3 Spring 1 4 Bolt washer 6 6 5 Lower housing 1 6 Spring 1 7 Bushing 1 8 Bushing 1 9 Upper housing 1 10 Tilt lever 1 ...

Page 208: ...p Procedure Part name Q ty Service points 11 Tilt stopper 1 12 Bolt nut 4 4 13 Retainer 2 14 Steering shaft assembly 1 15 Steering tube 1 16 Bolt washer spring washer 2 2 2 17 Cap 1 18 Shaft 1 1 19 Cross piece 1 Reverse the disassembly steps for assembly ...

Page 209: ...8 14 E HULL HOOD STEERING MASTER SERVICE POINTS Steering master components inspection 1 Inspect Each component part Damage wear Replace the steer ing master ...

Page 210: ...NSOR LEAD 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 coupler 1 2 Cap 1 3 Nut 1 4 Speed sensor 1 5 Steering cable end 1 6 Nut washer 3 3 7 Bracket 1 ...

Page 211: ...ROL CABLES AND SPEED SENSOR LEAD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Nut 2 9 Steering cable holder 1 10 Cap 1 11 Nut 1 12 Steering cable 1 13 Shift cable end 1 14 Bolt 2 15 Shift cable holder 1 16 Cap 1 ...

Page 212: ... CABLES AND SPEED SENSOR LEAD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 17 Nut 1 18 Shift cable 1 19 Nut 1 20 Pin 1 21 QSTS cable end 1 22 Cap 1 23 Nut 1 24 QSTS cable 1 Reverse the removal steps for installation ...

Page 213: ...Replace Steering cable jet pump side installation 1 Install Steering cable a WARNING The steering cable must be screwed in at least 8 mm 0 31 in Steering cable set length jet pump side 13 5 15 5 mm 0 53 0 61 in Steering cable stopper installation 1 Install Steering cable stopper WARNING Be sure to fit the projection 1 on the steer ing cable stopper into the groove in the outer cable ...

Page 214: ...t length jet pump side 12 0 14 0 mm 0 47 0 55 in QSTS cable stopper installation 1 Install QSTS cable stopper WARNING Be sure to fit the projection 1 on the QSTS cable stopper into the groove in the outer cable Shift cable jet pump side installation 1 Install Shift cable jet pump side a WARNING The shift cable must be screwed in more than 8 mm 0 31 in Shift cable set length jet pump side 12 2 13 8...

Page 215: ...D SENSOR LEAD Shift cable stopper installation 1 Install Shift cable stopper WARNING Be sure to fit the projection 1 on the shift cable stopper into the groove in the outer cable Remote control cables adjustment Refer to CONTROL SYSTEM in chapter 3 ...

Page 216: ...ODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points FRONT HOOD REMOVAL Follow the left Step for removal 1 Nut washer 4 4 2 Front hood assembly 1 3 Circlip 4 4 Pin 2 5 Damper 2 6 Bolt 2 7 Hood lock assembly 1 ...

Page 217: ...LL HOOD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Nut 1 9 Notch 1 10 Washer 2 11 Damper 1 12 Bolt 4 13 Plate 2 14 Mirror 2 15 Packing 2 Reverse the removal steps for installation FRONT HOOD ...

Page 218: ... points STEERING MASTER COVER REMOVAL Follow the left Step for removal Handlebar assembly Refer to HANDLEBAR Fuel cock Refer to FUEL COCK AND FUEL FILTER in chapter 4 Choke knob Refer to CHOKE CABLE in chapter 4 1 Bolt 2 2 Shift lever handle 1 3 Nut washer 2 2 4 Bolt 2 5 Bolt 2 6 Steering master cover 1 Reverse the removal steps for installation ...

Page 219: ... AND INSTALLATION CHART Step Procedure Part name Q ty Service points HOSES REMOVAL Follow the left Step for removal Steering master cover Refer to STEERING MASTER COVER 1 Band 2 2 Ventilation hose 2 3 Screw 4 4 Ventilation duct 1 5 Band 1 6 Check valve 1 ...

Page 220: ...DIAGRAM Step Procedure Part name Q ty Service points 7 Oil tank breather hose 1 8 Fuel tank breather hose 2 9 Clamp pilot water hose 2 2 10 Nut washer 2 2 11 Pilot water outlet 2 12 Packing 2 Reverse the removal steps for installation ...

Page 221: ...e inspection 1 Check Check valve Faulty Replace Checking steps Connect a hose to the end of check valve A and blow into it Air should come out from end B Connect the hose to the end of check valve B and blow into it Air should not come out from end A ...

Page 222: ...dure Part name Q ty Service points SHIFT LEVER REMOVAL Follow the left Step for removal Steering master cover Refer to STEERING MASTER COVER Shift cable Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD Ventilation duct Refer to HOSES 1 Bolt 1 2 Washer 1 3 Shift lever 1 Mark its original position ...

Page 223: ...FT LEVER SHIFT LEVER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points 4 Screw 3 5 Base assembly 1 6 Nut washer 3 3 7 Screw 3 8 Plate 1 Reverse the removal steps for installation ...

Page 224: ...L AND INSTALLATION CHART Step Procedure Part name Q ty Service points BASE DISASSEMBLY Follow the left Step for disassembly 1 Bolt washer 2 2 2 Plate 1 3 Spring 1 4 Actuator 1 5 Roller 1 6 Shaft 1 7 Shift arm 1 Reverse the disassembly steps for assembly ...

Page 225: ...CE POINTS Base assembly 1 Install Shift arm Shaft Installation steps Install the shift arm 1 so that it comes in contact with the stopper 2 as shown Install the shaft 3 to the base so that it come in contact with the stopper 4 as shown ...

Page 226: ...DED 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 Rear seat assembly 1 2 Front seat assembly 1 3 Bolt 4 4 Seat lock assembly 2 5 Nut washer 4 5 6 Notch 2 7 Bolt 2 ...

Page 227: ...TS AND HAND GRIP EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Rear seat stay 1 9 Nut washer 4 4 10 Front seat stay 2 11 Nut washer 4 4 12 Bolt 4 13 Hand grip 1 Reverse the removal steps for installation ...

Page 228: ...8 33 E HULL HOOD SEATS AND HAND GRIP SERVICE POINTS Seat lock inspection 1 Inspect Front seat lock Rear seat lock Damage wear Replace ...

Page 229: ... Procedure Part name Q ty Service points EXHAUST SYSTEM REMOVAL Follow the left Step for removal 1 Hose clamp 2 2 Band 1 3 Rubber joint 1 Slide the water lock to back 4 Hose clamp 2 5 Rubber hose 1 Align mark with weld line 6 Water lock 1 Mark a should be upside 7 Hose clamp 1 8 Resonator assembly 1 ...

Page 230: ...ervice points 9 Hose clamp 1 10 Rubber hose 1 Align hose parting line with tank mark 11 Hose clamp 1 12 Water tank 1 13 Hose clamp 1 14 Rubber hose 1 Align hose parting line with tank parting line 15 Bolt 3 16 Exhaust outlet 1 17 Packing 1 Reverse the removal steps for installation ...

Page 231: ...VICE POINTS Exhaust system inspection 1 Inspect Water lock band Cracks Replace 2 Inspect Rubber hoses Burns cracks damage Replace 3 Inspect Water lock Cracks leaks Replace Water Drain 4 Inspect Resonator Water tank Cracks damage Replace ...

Page 232: ...DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points DECK AND HULL DISASSEMBLY Follow the left Step for disassembly 1 Nut 1 2 Rope hole bolt 1 3 Nut washer 2 2 4 Bow eye 1 5 Nut 1 6 Rope hole bolt 1 7 Nut 1 8 Spout 1 9 Nut 2 ...

Page 233: ...LL EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 10 Plate 1 11 Cleat 1 12 Nut 8 13 Sponson 2 14 Spacer 8 15 Nut washer 4 4 16 Screw washer 4 4 17 Drain plug 2 18 Packing 2 Reverse the disassembly steps for assembly ...

Page 234: ... INSTALLATION CHART Step Procedure Part name Q ty Service points ENGINE MOUNT REMOVAL Follow the left Step for removal Engine assembly Refer to ENGINE UNIT in chapter 5 1 Bolt 6 2 Damper 1 1 3 Damper 2 1 4 Bolt 8 5 Engine mount 4 Reverse the removal steps for installation ...

Page 235: ...an 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 then cover the putty with wax paper 6 When the putty has set sand it Smooth the area with 80 400 grit sandpaper either wet or dry and a sanding block 7 Clean the area with a dry cloth and then polish ...

Page 236: ...P 1 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 it 7 Combine the polyester resin and the catalyst and then apply the mixture onto the hull 8 Install a glass mat 2 2 inches smaller than the ground area 9 Apply the resin 10 Install a 20 oz fibergla...

Page 237: ...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 WATER VEHICLE FRP REPAIR MANUAL The insert nut is used to repair the pop nut designed for the ride plate By repairing the FRP portion the insert nut can be used for all models 1 Remove Pop nut 2 Clean the surface to be...

Page 238: ...ert 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 tensile strength of 8T or more If the bolt is inferior in strength or is made of stainless steel it may break Bolt 2 Locknut 3 Example 2 The brass insert nut which is designed for the Super Jet ride ...

Page 239: ...th 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 the soap and water mixture onto both sides of the graphic and also onto the hull area where the graphic will be installed NOTE Spraying the front of the graphic with the soap and water mixture will pro...

Page 240: ...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 241: ...etors TROUBLE ANALYSIS 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 POOR BATTERY CHARGING YPVS SERVOMOTOR DOES NOT MOVE Items Reference chapter FUEL SYSTEM Fuel tank 4 Air vent hose 4 Fuel hose 4 Fuel filter 4 Fuel pump 4 Carburetors 4 Carburetor synch...

Page 242: ... coil 7 Ignition coil 7 Rectifier regulator 7 Electrical sender 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 master 8 Water lock 8 Exhaust hose 8 Muffler 8 Drain plugs 8 Problems Items to be checked ENGINE WILL NOT START ROUGH IDLING ENGINE STALLS ENGINE WILL NOT STOP POOR PERFORMANCE OVERHEATING LOOSE STEERING BILGE IN...

Page 243: ...R Y Br R Gy B Gy B 12 o n m l Br R Y R Br 8 9 10 11 Br Br Br Ch R W Y B R W R Y Gy R Gy B Gy Y G R B L B L R R B R B R Gy Y B 6 1 2 G G B W R B O A B F G H I M L O N Q P S R J K C D E B G G B O B O B O W R B O B O B Y Gy R Gy B B W Gy Y B O B Y O O O B O B Y B Y B O B O B Y B O B O Br W Gy G Br R R R W Gy B Gy R Gy Y R W G Gy W B Br R B O Br B Y W R 3 21 20 B G G R U T O O B O B 1 19 17 18 B W B O...

Page 244: ...YAMAHA MOTOR CO LTD Printed in USA Mar 1999 1 CR XA1200X Printed on recycled paper ...

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Yamaha WaveRunner XL1200Ltd, Service Manual

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