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Yamaha WaveRunner, Service Manual

The IBM WaveRunner manual is available for free download on our website. This comprehensive user manual provides detailed instructions on how to maximize the performance of your IBM WaveRunner device. Simply visit manualshive.com to download your manual and unlock the full potential of your product.

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5-35

E

POWR

REDUCTION DRIVE GEAR

EXPLODED DIAGRAM

*1

: EPNOC grease AP #0

Step

Procedure/Part name

Q’ty

Service points

9

Circlip

1

10

Bearing

1

11

Reduction drive gear case

1

Reverse the disassembly steps for 
assembly.

E

E

E

E

3

4

8

6

5

10

9

1

*

1

A

A

*

1

5 

×

 10 mm

E

2

11

7

Not reusable

Not reusable

Summary of Contents for WaveRunner

Page 1: ...SERVICE MANUAL FX High Output WaveRunner F1S 28197 1G 11 LIT 18616 02 83 LIT186160283 FX Cruiser High Output...

Page 2: ...icy of continuously improving its products models may differ in detail from the descriptions and illustrations given in this publication Use only the latest edition of this manual Authorized Yamaha de...

Page 3: ...vised 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 y...

Page 4: ...ow WARNING instructions could result in severe injury or death to the machine operator passenger s a bystander or a person inspecting or repairing the watercraft CAUTION A CAUTION indicates special pr...

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

Page 6: ...bols F to H in an exploded diagram indi cate the grade of lubricant and the lubrication point F Apply Yamaha 4 stroke motor oil G Apply water resistant grease Yamaha grease A Yamaha marine grease H Ap...

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

Page 8: ...MBER 1 1 JET PUMP UNIT SERIAL NUMBER 1 1 HULL IDENTIFICATION NUMBER H l N 1 1 SAFETY WHILE WORKING 1 2 FIRE PREVENTION 1 2 VENTILATION 1 2 SELF PROTECTION 1 2 PARTS LUBRICANTS AND SEALANTS 1 2 GOOD WO...

Page 9: ...nt Starting primary l D number F1S 800101 ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the engine unit Starting serial number 6B6 1000001 JET PUMP UNIT SERIAL NUMBER...

Page 10: ...ities they may cause loss of con sciousness and death within a short time When test running an engine indoors e g in a water tank be sure to do so where adequate ventilation can be maintained SELF PRO...

Page 11: ...art of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made 5 To protect your skin apply a protective cream to your hands before workin...

Page 12: ...during disassembly 2 Apply engine oil to the contact surfaces of moving parts during assembly 3 Install bearings with the manufacture iden tification mark in the direction indication in the installat...

Page 13: ...uge stand P N 90890 06583 3 Dial gauge needle P N 90890 06584 4 Dial gauge stand set P N YW 06585 90890 06585 5 Pocket tester P N YU 03112 90890 03112 6 Digital multimeter P N YU 34899 A 7 Digital cir...

Page 14: ...B 06767 Test harness FWY 2 2 pins P N New 90890 06867 Current 90890 06767 K Test harness 3 pins P N New YB 06870 Current YB 06770 Test harness SMT250 3 3 pins P N New 90890 06870 Current 90890 06770 L...

Page 15: ...60V 85300 02 Q Yamaha diagnostic system P N 60V WS853 02 N O YB 06877 06777 90890 06877 06777 YB 35956 A 90890 06756 Q 60V WS853 02 YAMAHA DIAGNOSTIC SYSTEM INSTALLATION MANUAL P 60V 85300 02 REMOVAL...

Page 16: ...mm YM 4108 22 mm 90890 04108 22 mm B Valve guide remover P N YM 04111 4 0 mm 90890 04111 4 0 mm YM 04116 4 5 mm 90890 04116 4 5 mm C Valve guide installer P N YM 04112 4 0 mm 90890 04112 4 0 mm YM 04...

Page 17: ...er and adapters jet pump bearing and reduction drive gear P N YB 06096 K Stopper guide plate jet pump bearing P N 90890 06501 L Bearing puller assembly jet pump bearing and reduction drive gear P N 90...

Page 18: ...rmediate shaft jet pump and reduction drive gear P N YB 06071 T Driver rod LS intermediate shaft jet pump and reduction drive gear P N 90890 06606 U Bearing inner outer race attachment jet pump bearin...

Page 19: ...IFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 ENGINE 2 3 JET PUMP UNIT 2 6 HULL AND HOOD 2 6 ELECTRICAL 2 7 TIGHTENING TORQUES 2 9 SPECIFIED TORQUES 2 9 GENERAL TORQUE 2 17 CABL...

Page 20: ...Bore stroke mm in 76 0 58 0 2 99 2 28 Compression ratio 11 9 1 Exhaust system Wet exhaust Lubrication system Dry sump Cooling system Water cooled Starting system Electric starter Ignition system TCI...

Page 21: ...6 RON 90 Fuel tank capacity L US gal Imp gal 70 18 5 15 4 Engine oil type 4 stroke motor oil Engine oil grade API SE SF SG SH SJ SL SAE 10W 30 Engine oil quantity L US qt Imp qt 4 5 4 8 4 0 without oi...

Page 22: ...46 Camshaft journal diameter mm in 24 46 24 47 0 9630 0 9634 Camshaft journal to camshaft cap clearance mm in 0 03 0 06 0 0012 0 0024 Maximum camshaft runout mm in 0 03 0 0012 Timing chain Model numbe...

Page 23: ...004 0 0015 Exhaust mm in 0 020 0 047 0 0008 0 0019 Valve stem runout mm in 0 01 0 0004 Valve spring Free length Intake mm in 38 90 1 53 Exhaust mm in 40 67 1 60 Installed length Intake mm in 34 50 1 3...

Page 24: ...ance mm in 0 040 0 160 0 0016 0 0063 Connecting rod Big end oil clearance mm in 0 016 0 040 0 0006 0 0016 Bearing color code 1 Brown 2 Black 3 Blue 4 Green Small end inside diameter mm in 17 005 17 01...

Page 25: ...5 0 0035 0 0059 Item Unit Model FX High Output FX Cruiser High Output Jet pump Impeller material Stainless steel Number of impeller blades 3 Impeller pitch angle Degree 16 8 Impeller clearance mm in 0...

Page 26: ...G G Output peak voltage cranking unloaded V 9 2 2 000 r min unloaded V 38 5 3 500 r min unloaded V 63 2 Pickup coil resistance W B color 459 561 Pickup coil resistance R B color 459 561 Lighting coil...

Page 27: ...voltage on pulse V 11 6 Output pulse one full turn 2 Throttle position sensor Output voltage P B O trolling speed V 0 756 0 016 Cam position sensor Output voltage G O B O Position A V More than 4 8 P...

Page 28: ...8 22 2 2 16 E Air filter case air filter case stay 1 air filter case stay 2 1st Bolt M8 3 8 8 0 88 6 4 242 LT 2nd 18 1 8 13 Wire harness bracket 1 sub wire harness air filter case Bolt M6 2 7 6 0 76 5...

Page 29: ...t M10 1 15 1 5 11 242 LT 2nd 42 4 2 30 Exhaust pipe 2 exhaust pipe 1 1 1st Nut 5 39 3 9 28 E 2nd 39 3 9 28 Exhaust pipe 1 exhaust manifold 1 exhaust manifold 2 1st Bolt M8 10 22 2 2 16 242 LT 2nd 22 2...

Page 30: ...over oil tank 1st Bolt M6 24 3 7 0 37 2 7 572 LT 2nd 7 6 0 76 5 5 Anode oil tank Screw M4 1 3 7 0 37 2 7 E Oil pump assembly reduction drive gear case Bolt M6 5 10 1 0 7 2 572 LT 1st M8 4 15 1 5 11 2n...

Page 31: ...M6 1 3 7 0 37 2 7 572 LT 2nd 7 6 0 76 5 5 Cylinder head cover cylinder head Bolt M6 6 12 1 2 8 7 E Timing chain tensioner cap bolt Bolt M6 1 10 1 0 7 2 Timing chain tensioner cylinder head Bolt M6 2 1...

Page 32: ...able joint jet thrust nozzle Nut 1 6 8 0 68 4 9 242 LT Ride plate hull Bolt M8 4 17 1 7 12 572 LT Intake duct hull Bolt M8 4 17 1 7 12 242 LT Intake grate hull Bolt M6 4 7 6 0 76 5 5 242 LT Speed sens...

Page 33: ...steering master Screw M6 4 0 9 0 09 0 7 242 LT QSTS converter hull Nut 2 5 4 0 54 3 9 Throttle lever assembly handlebar Screw M5 2 3 5 0 35 2 5 Handlebar switch assembly handlebar Screw M5 2 3 4 0 34...

Page 34: ...Nut 4 5 4 0 54 3 9 Service lid 1 deck Bolt M6 4 5 4 0 54 3 9 271 LT Service lid 2 deck Screw M4 4 1 5 0 15 1 1 Panel steering console cover Bolt M5 4 3 9 0 39 2 8 242 LT Multifunction meter steering c...

Page 35: ...Cleat deck Nut 2 15 1 5 11 Cleat hull Nut 4 15 1 5 11 Spout hull Nut 1 5 4 0 54 3 9 Protector bow hull Bolt M6 4 5 4 0 54 3 9 271 LT Nut 3 5 4 0 54 3 9 Bow eye hull Nut 2 13 1 3 9 4 Drain plug packin...

Page 36: ...07 Part to tightened Part name Thread size Q ty Tightening torque Remarks N m kgf m ft lb GENERAL TORQUE This chart specifies tightening torques for stan dard fasteners with a standard ISO thread pit...

Page 37: ...ering switch lead 2 Fuel tank breather hose 3 QSTS cable 4 Steering cable 5 Shift cable 6 Speed sensor lead 7 Electrical box lead 8 Cooling water pilot outlet 9 Cooling water pilot outlet hose 0 Cooli...

Page 38: ...Handlebar switch lead 4 QSTS cable 5 Buzzer lead 6 Fuel tank breather hose 7 Ignition coil lead 8 Positive battery lead 9 Starter motor lead 0 Wire harness A Fuel hose B Shift cable C Steering cable...

Page 39: ...ctric bilge pump 4 Bilge hose 4 5 Cooling water hose from thermostat 6 Bilge hose 3 7 Bilge hose 2 8 Shift cable 9 Cooling water hose from exhaust pipe 0 Electrical box A QSTS cable B Positive battery...

Page 40: ...er inlet 5 Negative battery lead To cooling water pilot outlet on starboard side To cooling water outlet on star board side of stern To cylinder block From exhaust manifold To install the hose align t...

Page 41: ...d then fasten the tie Set the tie in the direction shown To cooling water pilot outlet on port side To cooling water outlet at stern Cooling water inlet To exhaust pipe To install the cooling water ho...

Page 42: ...with a plastic tie to the oil tank boss When bundling the hoses make sure that the cooling water hose cylinder head cover to thermostat is routed on the deck side and that the cooling water hose starb...

Page 43: ...il pressure switch coupler 6 Pickup coil coupler 7 Thermoswitch engine coupler 8 Lighting coil coupler 9 Thermoswitch exhaust 0 Thermoswitch exhaust coupler A Cam position sensor coupler B Oil pressur...

Page 44: ...B B 1 Engine temperature sensor coupler 2 Lighting coil coupler 3 Pickup coil coupler 4 Thermoswitch engine coupler 5 Thermoswitch engine 6 Starter motor 7 Engine temperature sensor 8 Engine temperatu...

Page 45: ...end of the protec tive cover of the lead To generator To engine temperature sensor To thermoswitch engine To thermoswitch engine coupler To engine temperature sensor coupler Route the starter motor l...

Page 46: ...check and adjustment 3 8 FUEL SYSTEM 3 9 Fuel line inspection 3 9 Water separator inspection 3 10 POWER UNIT 3 10 Valve clearance adjustment 3 10 Engine oil level check 3 16 Engine oil change using oi...

Page 47: ...te 3 29 Intermediate housing Lubricate 1 2 2 3 31 Fuel system Inspect 3 9 Fuel tank Inspect clean 3 9 Trolling speed Inspect adjust 3 8 Throttle shaft Inspect Cooling water passages Flush 3 Water inle...

Page 48: ...ect Jet thrust nozzle clearance a b Difference Adjust 2 Adjust Steering cable joint steering master end Inspection steps Set the control grip in the neutral position Turn the handlebar from lock to lo...

Page 49: ...CONTROL CABLES AND SPEED SENSOR LEAD in Chapter 8 WARNING The cable joint must be screwed in more than 8 mm 0 31 in Connect the cable joint and tighten the locknut T R Locknut 6 4 N m 0 64 kgf m 4 6 f...

Page 50: ...es b Loosen the locknut 2 c Turn the adjusting nut 3 to adjust the length a Throttle cable installation length 24 4 1 0 mm 0 96 0 04 in NOTE Apply locking agent LOCTITE to the threads of the adjusting...

Page 51: ...ssemblies and air filter case cover T R Ribbon sub assembly bolt 6 5 N m 0 65 kgf m 4 7 ft lb LOCTITE 242 Air filter case cover screw 2 5 N m 0 25 kgf m 1 8 ft lb LOCTITE 572 QSTS cable inspection and...

Page 52: ...8 Adjustment steps Set the control grip in the neutral position Loosen the locknut 1 Remove the nut 2 and pivot pin 3 Set the jet thrust nozzle in the center position Turn the cable joint 4 for adjust...

Page 53: ...ed over the bracket 5 4 5 2 Adjust Shift cable joint Adjustment steps Loosen the locknut 1 Disconnect the cable joint 2 from the ball joint 3 Situate the reverse gate to the stopper on the bracket and...

Page 54: ...engine trolling speed using the tachometer of the multifunction meter or using the Yamaha Diagnostic System 2 Adjust Trolling speed Adjustment steps Remove the air filter case cover 1 Start the engine...

Page 55: ...in Chapter 4 Fuel hose Damage cracks Replace O rings quick connector Damage cracks Replace the quick connector Fuel pipe Damage cracks Replace the fuel pump Refer to FUEL INJECTION SYSTEM in Chapter 4...

Page 56: ...m temperature When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove Air filter case Refer to FUEL INJECTION SYSTEM in Chap...

Page 57: ...lobes are turned away from each other Measure the valve clearance with a thick ness gauge 1 NOTE If the valve clearance is incorrect record the measured reading Measure the valve clearance in the fol...

Page 58: ...NOTE Make sure that the tensioner rod has been fully set clockwise 1 7 Remove Intake camshaft caps Exhaust camshaft caps Timing chain from the camshaft sprockets Intake camshaft Exhaust camshaft NOTE...

Page 59: ...05 mm increments NOTE The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter Since valve pads of various sizes are orig inally installed the...

Page 60: ...he valve lifter and the valve pad in the correct place Install the exhaust and intake camshafts timing chain and camshaft caps T R Camshaft cap bolt 10 N m 1 0 kgf m 7 2 ft lb NOTE Refer to Camshaft i...

Page 61: ...ANCE ORIGINAL VALVE PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190...

Page 62: ...an cause the watercraft to move and lead to a colli sion When checking the engine oil level on land supply water to the cooling water passages Make sure that engine has enough oil but do not overfill...

Page 63: ...tick is securely fitted into the oil tank NOTE The engine cannot be started if the Yamaha Security System is in the lock mode For information on the Yamaha Security System see the owner s manual Run t...

Page 64: ...he reading on the dipstick will be high Engine oil change using oil changer WARNING Avoid changing the engine oil immediately after turning the engine off The oil is hot and should be handled with car...

Page 65: ...the recom mended engine oil into the oil filler hole Replacing steps Place a rag under the oil filter Remove the oil filter 1 with an oil filter wrench Oil filter wrench YU 38411 90890 01426 Lubricat...

Page 66: ...e dipstick is securely fitted into the oil tank 8 Install Oil filler cap Recommended oil SAE 10W 30 API SE SF SG SH SJ SL Oil quantity Total amount 4 5 L 4 8 US qt 4 0 Imp qt Without oil filter replac...

Page 67: ...cleaning the air filter element use cold or lukewarm water and let it air dry com pletely Do not use detergent or an sol vent to clean the air filter element or dry it with heat or compressed air oth...

Page 68: ...n Color guide Medium to light tan color Normal Whitish color Lean fuel mixture Air leak Incorrect settings Blackish color Overly rich mixture Electrical malfunction Defective spark plug 4 Clean Spark...

Page 69: ...seizure If a torque wrench is not available a good estimate of the correct tightening torque for a new spark plug is to finger tighten a the spark plug and then tighten it another 1 4 to 1 2 of a turn...

Page 70: ...lush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc well away If using or charging the battery in an enclosed space make...

Page 71: ...vice 2 3 1 2 Inspect Electrolyte level Low Add distilled water The electrolyte level should be between the upper a and lower b level marks CAUTION Use only distilled water Other types of water contain...

Page 72: ...Charging current 1 9 amps 10 hrs 5 Install Battery breather hose 1 Battery Battery positive lead 2 Battery negative lead 3 Bands CAUTION Connect the positive lead to the battery terminal first Make su...

Page 73: ...a total of three measure ments Install the intake duct and intake grate Refer to INTAKE GRATE RIDE PLATE AND INTAKE DUCT in Chapter 6 Install the battery leads Water inlet strainer inspection 1 Inspec...

Page 74: ...upling cover Disconnect the bilge strainer case 1 from the bilge strainer Inspect the bilge strainer Install the coupling cover Install the deck beam Refer to SEATS AND HAND GRIP in Chapter 8 1 Electr...

Page 75: ...and remove the rubber seal 1 2 Lubricate Throttle cable throttle body end Recommended lubricant Rust inhibitor Recommended lubricant Yamaha marine grease Yamaha grease A Water resistant grease 3 Lubri...

Page 76: ...pivot shaft Steering cable nozzle end QSTS cable nozzle end Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease 6 Lubricate Steering cable Steering cable joint Shift cable S...

Page 77: ...ermediate housing with the recom mended grease through the grease nipple 1 Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease Grease quantity Initial 10 hours 33 0 35 0 cm3...

Page 78: ...p filter inspection 4 6 Fuel pump module installation 4 7 Fuel hose connect 4 7 FUEL INJECTION SYSTEM 4 8 EXPLODED DIAGRAM 4 8 REMOVAL AND INSTALLATION CHART 4 8 SERVICE POINTS 4 17 Hose clamps remova...

Page 79: ...Throttle position sensor coupler To wiring harness Route the throttle cable between the sub wiring har ness Route the sub wiring harness under the intake vacuum hose To fuel injector 3 Fasten the sub...

Page 80: ...From ventilation fitting Engine unit Refer to ENGINE UNIT in Chapter 5 NOTE When removing the pump module only it is not necessary to remove the engine unit 1 Rollover valve 1 2 Fuel tank breather ho...

Page 81: ...the coupler 5 Fuel sender coupler 1 6 Fuel pump module coupler 1 7 Cover 1 8 Fuel hose 1 9 Nut 9 10 Retainer 1 11 Fuel pump module 1 12 Packing 1 1 3 N m 0 13 kgf m 0 9 ft Ib 8 18 mm 16 N m 1 6 kgf m...

Page 82: ...al 1 18 Bolt 2 19 Fuel tank assembly 1 20 Bolt 2 21 Fuel tank belt 2 Reverse the removal steps for installation 1 3 N m 0 13 kgf m 0 9 ft Ib 8 18 mm 16 N m 1 6 kgf m 11 ft Ib 5 9 N m 0 59 kgf m 4 3 ft...

Page 83: ...he sequence shown 1 4 9 6 2 3 8 7 5 2 Remove Fuel pump module 1 NOTE Remove the float 2 at an angle because it could catch on the fuel tank 2 1 Check valve inspection 1 Check Check valve Faulty Replac...

Page 84: ...cks damage Replace Fuel hose inspection Refer to FUEL INJECTION SYSTEM Checking steps Connect a hose to the end of rollover valve A and blow into it Air should come out from end B Connect the hose to...

Page 85: ...el pump module installation 1 Tighten Nuts NOTE Tighten the nuts in the sequence shown Fuel hose connect Refer to FUEL INJECTION SYSTEM T R Fuel pump module nut 1st 3 2 N m 0 32 kgf m 2 3 ft lb 2nd 6...

Page 86: ...case cover 1 3 Air filter 1 4 Bolt 4 5 Ribbon sub assembly 2 6 Holder 2 7 Throttle cable 1 8 Bolt 2 9 Throttle cable holder 1 10 Cover 1 LT 572 LT LT 242 LT E A A LT 572 LT LT 572 LT 7 8 9 15 14 12 13...

Page 87: ...8 Sensor assembly coupler 1 19 Fuel injector coupler 4 20 Throttle position sensor coupler 1 LT 572 LT LT 242 LT E A A LT 572 LT LT 572 LT 7 8 9 15 14 12 13 11 10 5 70 mm 2 5 N m 0 25 kgf m 1 8 ft Ib...

Page 88: ...1 23 Ring 1 Reverse the removal steps for installation LT 572 LT LT 242 LT E A A LT 572 LT LT 572 LT 7 8 9 15 14 12 13 11 10 5 70 mm 2 5 N m 0 25 kgf m 1 8 ft Ib 6 7 mm 6 5 N m 0 65 kgf m 4 7 ft Ib 8...

Page 89: ...6 Thermoswitch coupler exhaust 1 From wiring harness bracket 1 7 Cam position sensor coupler 1 From wiring harness bracket 1 3 16 5 15 14 24 23 25 10 18 17 9 7 6 13 12 8 11 22 21 4 19 20 LT 271 LT 24...

Page 90: ...5 14 24 23 25 10 18 17 9 7 6 13 12 8 11 22 21 4 19 20 LT 271 LT 242 LT 271 1 2 LT 572 LT LT 242 8 30 mm 2nd 18 N m 1 8 kgf m 13 ft Ib 1st 8 8 N m 0 88 kgf m 6 4 ft Ib 1 8 N m 0 18 kgf m 1 3 ft Ib 5 14...

Page 91: ...3 25 10 18 17 9 7 6 13 12 8 11 22 21 4 19 20 LT 271 LT 242 LT 271 1 2 LT 572 LT LT 242 8 30 mm 2nd 18 N m 1 8 kgf m 13 ft Ib 1st 8 8 N m 0 88 kgf m 6 4 ft Ib 1 8 N m 0 18 kgf m 1 3 ft Ib 5 14 mm 1 3 N...

Page 92: ...pass valve motor 1 5 Holder 1 6 Holder 1 7 Hose 4 1 8 Hose 3 1 9 Hose 2 1 10 Hose 1 1 5 0 N m 0 5 kgf m 3 6 ft Ib 6 10 mm 5 0 N m 0 5 kgf m 3 6 ft Ib 6 9 mm 24 25 26 27 28 29 30 31 32 21 20 15 16 19 1...

Page 93: ...mmet 4 20 Screw 2 21 Throttle stop guide 1 22 Screw 2 5 0 N m 0 5 kgf m 3 6 ft Ib 6 10 mm 5 0 N m 0 5 kgf m 3 6 ft Ib 6 9 mm 24 25 26 27 28 29 30 31 32 21 20 15 16 19 17 2 0 N m 0 2 kgf m 1 4 ft Ib 4...

Page 94: ...31 O ring 1 32 Throttle bodies 1 Reverse the disassembly steps for assembly 5 0 N m 0 5 kgf m 3 6 ft Ib 6 10 mm 5 0 N m 0 5 kgf m 3 6 ft Ib 6 9 mm 24 25 26 27 28 29 30 31 32 21 20 15 16 19 17 2 0 N m...

Page 95: ...securely fasten them Fuel hose disconnection WARNING Before disconnecting the hose remove the fuel tank filler cap to reduce any pressure inside the fuel tank and then disconnect the battery negative...

Page 96: ...2 directly WARNING Always reduce the fuel pressure in the fuel line before servicing the line or the fuel pipe If the fuel pressure is not released pressurized fuel could spray out 2 1 1 2 3 Cover the...

Page 97: ...onnector is completely installed to the fuel pipe it is removable 2 1 a 2 Fuel hose connection 1 Apply a thin coat of engine oil to the con tact surfaces of the fuel pipe 2 Insert the quick connector...

Page 98: ...tor using the Stationary Test of the Yamaha Diagnostic System Digital multimeter YU 34899 A Digital circuit tester 90890 03174 Fuel injector resistance reference data 11 5 12 5 at 20 C 68 F Throttle b...

Page 99: ...alve motor operation using the Yamaha Diagnostic System Throttle body installation 1 Install Throttle body CAUTION Do not bend the fuel pipe 1 1 2 Install Fuel hose 1 throttle body side Clamp NOTE Ins...

Page 100: ...ion CAUTION Do not start the engine when removing the fuel hose Fuel can spurt out when the fuel pump is operated a Loosen the throttle stop screw 2 and synchronizing screws 1 3 2 4 and 3 5 until rele...

Page 101: ...lve 4 should be fully closed Butterfly valves 1 2 and 3 open if the screw is turned more than 7 times If all butterfly valves are not fully closed close the valves by adjusting synchroniz ing screw 3...

Page 102: ...nnect it to the throttle bodies and main wiring harness m Connect the test harness 3 pin to the throttle position sensor A Test harness 3 pins YB 06793 Test harness SMHW099 3 3 pins 90890 06793 n To s...

Page 103: ...Warm the engine up in the water While checking the engine temperature with the Yamaha Diagnostic System warm the engine up until the engine tem perature is 50 C 122 F q Adjust the throttle stop screw...

Page 104: ...kPa 0 5 0 4 inHg 223 10 mmHg 29 76 1 33 kPa 8 8 0 4 inHg 4 1 0 10 mmHg 0 04 1 33 kPa 0 0 4 inHg 211 10 mmHg 28 19 1 33 kPa 8 3 0 4 inHg Standard When setting the specified engine speed the value is z...

Page 105: ...engine and arrow it to warm up for several minutes 4 Measure Fuel pressure Out of specification Replace the fuel pump module 5 Remove Fuel pressure gauge Fuel pressure gauge adapter NOTE To disconnec...

Page 106: ...ection 5 7 Coupling clearance inspection 5 7 EXHAUST PIPE 3 5 8 EXPLODED DIAGRAM 5 8 REMOVAL AND INSTALLATION CHART 5 8 EXHAUST PIPES 1 AND 2 5 11 EXPLODED DIAGRAM 5 11 REMOVAL AND INSTALLATION CHART...

Page 107: ...mp drive shaft inspection 5 37 Drive shaft inspection 5 37 Bearing installing 5 38 Drive shaft installation 5 40 Drive coupling installation 5 40 GENERATOR AND STARTER MOTOR 5 41 EXPLODED DIAGRAM 5 41...

Page 108: ...de replacement 5 73 Valve seat inspection 5 75 Valve seat reface 5 76 Valve installation 5 78 CRANKCASE 5 80 EXPLODED DIAGRAM 5 80 REMOVAL AND INSTALLATION CHART 5 80 SERVICE POINTS 5 85 Crankcase dis...

Page 109: ...t removal 5 104 Crankshaft inspection 5 104 Crankshaft installation 5 107 THERMOSTAT 5 108 EXPLODED DIAGRAM 5 108 REMOVAL AND INSTALLATION CHART 5 108 SERVICE POINTS 5 110 Thermostat inspection 5 110...

Page 110: ...T HOOD in Chapter 8 Battery negative and positive lead Refer to ELECTRICAL BOX in Chapter 7 Throttle cable and fuel hose Refer to FUEL INJECTION SYSTEM in Chapter 4 Water lock and exhaust joint Refer...

Page 111: ...lamp cooling water hose 1 1 Cooling water outlet 7 Clamp cooling water hose 1 1 Cooling water outlet 8 Clamp cooling water hose 1 1 Cooling water inlet 9 Coupler 10 10 Grease hose 1 11 Bolt collar 1 1...

Page 112: ...nts 13 Bolt washer 4 4 14 Shim 15 Engine unit 1 Reverse the removal steps for installation 4 10 11 12 6 3 7 2 8 1 9 5 9 14 9 13 15 LT 271 LT LT 572 LT 7 8 N m 0 78 kgf m 5 6 ft Ib 6 25 mm 8 28 mm 17 N...

Page 113: ...in Chapter 3 2 Warm the engine up and then put the watercraft in a horizontal position 3 Remove Air filter case cover 1 Air filter element Ignition coils Spark plugs CAUTION Before removing the spark...

Page 114: ...Pa 1 kgf cm2 14 psi b If the compression pressure is extremely high check the cylinder head valve sur faces and piston crown for carbon depos its Carbon deposits Eliminate c If the compression pressur...

Page 115: ...case cover screw 2 5 N m 0 25 kgf m 1 8 ft lb LOCTITE 572 Oil filter wrench YU 38411 90890 01426 T R Oil filter 17 N m 1 7 kgf m 12 ft lb Removal steps CAUTION Lift the engine unit carefully trying n...

Page 116: ...ect Engine mounts Cracks damage Replace Refer to ENGINE MOUNT in Chapter 8 Coupling clearance inspection 1 Measure Clearance a Clearance b Out of specification Adjust NOTE Measure the clearances with...

Page 117: ...switch exhaust 1 3 6 18 2 7 17 16 10 12 11 8 9 13 14 15 5 4 1 LT 572 LT 572 LT 572 LT 572 LT 242 LT 242 7th 15 N m 1 5 kgf m 11 ft Ib 3rd 2 0 N m 0 2 kgf m 1 4 ft Ib 10 40 mm 11th 39 N m 3 9 kgf m 28...

Page 118: ...LT 242 LT 242 7th 15 N m 1 5 kgf m 11 ft Ib 3rd 2 0 N m 0 2 kgf m 1 4 ft Ib 10 40 mm 11th 39 N m 3 9 kgf m 28 ft Ib LT 242 8th 15 N m 1 5 kgf m 11 ft Ib 4th 2 0 N m 0 2 kgf m 1 4 ft Ib 10 45 mm 12th...

Page 119: ...m 1 4 ft Ib 10 40 mm 11th 39 N m 3 9 kgf m 28 ft Ib LT 242 8th 15 N m 1 5 kgf m 11 ft Ib 4th 2 0 N m 0 2 kgf m 1 4 ft Ib 10 45 mm 12th 39 N m 3 9 kgf m 28 ft Ib 7 6 N m 0 76 kgf m 5 5 ft Ib 6 16 mm 5...

Page 120: ...2 13 6 7 5 4 4 4 2 3 11 6th 39 N m 3 9 kgf m 28 ft Ib 1st 39 N m 3 9 kgf m 28 ft Ib 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 8 75 mm 3rd 35 N m 3 5 kgf m 25 ft Ib 8 45 mm 2nd 42 N m...

Page 121: ...Ib 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 8 75 mm 3rd 35 N m 3 5 kgf m 25 ft Ib 8 45 mm 2nd 42 N m 4 2 kgf m 30 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 10 35 mm 2nd 42 N m 4 2 kgf m...

Page 122: ...he white mark a facing up 2 Bolt 2 3 Bolt 4 4 Exhaust manifold 1 1 5 Dowel pin 2 4 3 2 5 6 7 10 10 9 8 5 LT 242 LT 242 LT 242 LT 242 1 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 8 70...

Page 123: ...LT 242 LT 242 LT 242 1 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 8 70 mm 3rd 35 N m 3 5 kgf m 25 ft Ib a 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 8 95 mm 3rd 35 N...

Page 124: ...LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 LT 572 25 21 27 26 28 27 23 19 16 17 18 1514 20 12 22 24 5 3 4 11 1 10 6 8 9 5 7 2 E 6 A A 6 35 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2...

Page 125: ...21 27 26 28 27 23 19 16 17 18 1514 20 12 22 24 5 3 4 11 1 10 6 8 9 5 7 2 E 6 A A 6 35 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 30 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st...

Page 126: ...3 4 11 1 10 6 8 9 5 7 2 E 6 A A 6 35 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 30 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 2nd 15 N m 1 5 kgf m...

Page 127: ...T 572 LT LT 572 LT LT 572 LT LT 572 LT 6 25 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 5 14 mm 2nd 4 4 N m 0 44 kgf m 3 2 ft Ib 1st 1 9 N m 0 19 kgf m 1 4 ft Ib 6 20 mm 2nd 7...

Page 128: ...5 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 5 14 mm 2nd 4 4 N m 0 44 kgf m 3 2 ft Ib 1st 1 9 N m 0 19 kgf m 1 4 ft Ib 6 20 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0...

Page 129: ...5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 5 14 mm 2nd 4 4 N m 0 44 kgf m 3 2 ft Ib 1st 1 9 N m 0 19 kgf m 1 4 ft Ib 6 20 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 20 mm 2nd...

Page 130: ...olts and nuts in the sequence shown 3 5 6 8 9 4 2 1 7 2 Remove Oil tank cover Gasket NOTE Loosen the oil tank cover bolts in the sequence shown 1 2 6 7 3 4 8 5 3 Remove Oil breather plate 1 Oil breath...

Page 131: ...10 3 4 2 Oil strainer inspection 1 Check Oil strainer 1 Damage Replace Contaminants Clean Oil tank installation 1 Install Gaskets Oil cooler covers NOTE Tighten the oil cooler bolts in the sequence sh...

Page 132: ...wn T R Oil breather plate bolt 1st 1 9 N m 0 19 kgf m 1 4 ft lb 2nd 4 4 N m 0 44 kgf m 3 2 ft lb 6 5 4 3 8 7 2 1 3 Install Gasket Oil tank cover NOTE Tighten the oil tank cover bolts in the sequence s...

Page 133: ...k nuts and bolts in the sequence shown T R Bolt 1 1st 15 N m 1 5 kgf m 11 ft lb 2nd 39 N m 3 9 kgf m 28 ft lb LOCTITE 572 Nut 2 bolt 3 1st 2 0 N m 0 2 kgf m 1 4 ft lb 2nd 15 N m 1 5 kgf m 11 ft lb 3rd...

Page 134: ...lt 1 5 Bolt 2 6 Oil pump assembly 1 7 Gasket 1 8 Pin 2 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 130 mm 6 25 mm 10 N m 1 0 kgf m 7 2 ft Ib 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m...

Page 135: ...Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 130 mm 6 25 mm 10 N m 1 0 kgf m 7 2 ft Ib 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11 ft Ib 8 100 mm 2nd 28 N m 2 8 kgf m 20 ft Ib 1st 15 N m 1 5 kgf m 11...

Page 136: ...Bolt 3 3 Oil pump housing cover 1 1 4 Gasket 1 5 Oil pump housing 1 1 6 Check valve assembly 1 7 Oil pump housing 2 1 8 Gasket 1 9 Outer rotor scavenge 2 10 Inner rotor scavenge 2 E 8 70 mm 20 N m 2 0...

Page 137: ...g cover 2 1 14 Gasket 1 15 Spring 1 16 Plunger 1 17 Pin 1 18 Pin 1 19 Oil pump shaft 1 20 Inner rotor feed 1 21 Outer rotor feed 1 E 8 70 mm 20 N m 2 0 kgf m 14 ft Ib 8 20 mm 20 N m 2 0 kgf m 14 ft Ib...

Page 138: ...points 22 Check valve seat 1 23 Oil seal 1 Reverse the disassembly steps for assembly E 8 70 mm 20 N m 2 0 kgf m 14 ft Ib 8 20 mm 20 N m 2 0 kgf m 14 ft Ib 4 12 mm 2 0 N m 0 2 kgf m 1 4 ft Ib E E E 2...

Page 139: ...ion Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance a 0 09 0 15 mm 0 0035 0 0059 in Outer rotor to oil pump housing clearance b scavenge pu...

Page 140: ...1 Oil pump installation 1 Install Oil pump assembly NOTE Align the projection a on the oil pump shaft with the slit b on the oil pump driven gear shaft T R Oil pump assembly bolt M6 10 N m 1 0 kgf m...

Page 141: ...Bolt 1 3 Bolt 1 4 Bolt 3 5 Bolt 1 8 8 9 11 10 11 9 7 3 2 4 12 5 4 6 E LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT 6 55 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 28 N m...

Page 142: ...1 9 7 3 2 4 12 5 4 6 E LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT 6 55 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 28 N m 2 8 kgf m 20 ft Ib 6 35 mm 2nd 7 6 N m 0 76 kg...

Page 143: ...Part name Q ty Service points REDUCTION DRIVE GEAR DISASSEMBLY Follow the left Step for disassembly 1 Oil pump drive shaft 1 2 Drive shaft 1 3 Collar 1 4 Oil seal 2 5 Circlip 1 6 Bearing 1 7 Collar 1...

Page 144: ...GRAM 1 EPNOC grease AP 0 Step Procedure Part name Q ty Service points 9 Circlip 1 10 Bearing 1 11 Reduction drive gear case 1 Reverse the disassembly steps for assembly E E E E 3 4 8 6 5 10 9 1 1 A A...

Page 145: ...06551 Universal magneto and rotor holder YU 01235 Rotor holder 90890 01235 1 4 2 3 Drive shaft removal 1 Remove Drive shaft NOTE Press in the direction of the arrow Bearing removal 1 Remove Circlip R...

Page 146: ...dwide Slide hammer and adapters YB 06096 Stopper guide plate 90890 06501 Bearing puller assembly 90890 06535 Stopper guide stand 90890 06538 Oil pump drive shaft inspection 1 Check Oil pump drive shaf...

Page 147: ...ess Driver handle large YB 06071 Driver rod LS 90890 06606 Outer race installer forward gear YB 06085 Ball bearing attachment 90890 06631 2 Install Front bearing NOTE Install the front bearing using a...

Page 148: ...diam eter of 70 mm 2 76 in and an inner diame ter of 30 mm 1 18 in For USA and Canada For worldwide Driver rod LS 90890 06606 Outer race installer forward gear YB 06085 Bearing outer race attachment 9...

Page 149: ...r of approximately 35 mm 1 97 in and an inner diameter of approximately 28 0 5 mm 1 10 0 02 in Drive coupling installation 1 Install Drive coupling 1 NOTE While holding the drive shaft 2 with the roto...

Page 150: ...sher 1 1 2 Starter motor lead 1 3 Bolt 2 4 Battery negative lead 1 5 Starter motor 1 6 Band 1 7 Lighting coil coupler 1 4 3 2 1 5 6 8 7 9 10 11 13 12 18 16 17 19 20 21 15 14 A A E E E LT 572 LT 572 A...

Page 151: ...lt washer 1 1 17 Flywheel magneto 1 18 Bolt 6 4 3 2 1 5 6 8 7 9 10 11 13 12 18 16 17 19 20 21 15 14 A A E E E LT 572 LT 572 A A A A 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 4 9 N m 0 49 kgf m 3 5 ft Ib 10 47...

Page 152: ...ps for installation 4 3 2 1 5 6 8 7 9 10 11 13 12 18 16 17 19 20 21 15 14 A A E E E LT 572 LT 572 A A A A 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 4 9 N m 0 49 kgf m 3 5 ft Ib 10 47 mm 75 N m 7 5 kgf m 54 ft...

Page 153: ...bly 1 Bolt washer 3 3 2 Bolt 4 3 Pickup coil 2 NOTE There washers holds the pickup coil lead Make sure to not pitch the lead between the projection and the washer when installing the bolt 4 Bolt 2 1 7...

Page 154: ...Service points 5 Holder 1 6 Bolt 3 7 Lighting coil 1 Reverse the disassembly steps for assembly 1 7 6 3 2 4 5 LT 242 LT 242 LT 242 LT 242 14 N m 1 4 kgf m 10 ft Ib 6 14 mm 4 9 N m 0 49 kgf m 3 5 ft Ib...

Page 155: ...with the sheave holder 3 loosen the flywheel magneto bolt Sheave holder YS 01880 A 90890 01701 2 Remove Flywheel magneto 1 Woodruff key NOTE While holding the flywheel magneto with sheave holder 2 rem...

Page 156: ...lutch gear 1 2 a 4 Check Starter clutch operation Checking steps Install the starter gear 1 onto the starter clutch 2 and hold the starter clutch When turning the starter gear clockwise it should turn...

Page 157: ...ke sure the woodruff key is properly seated in the keyway of the crankshaft Lubricate the flywheel magneto bolt and washer with engine oil 2 Tighten Flywheel magneto bolt 1 NOTE While holding the flyw...

Page 158: ...in Chapter 4 1 Bolt 4 2 Ignition coil 4 3 Spark plug 4 4 Clamp breather hose 1 1 To oil tank Paint mark a 5 Bolt 1 6 Cam position sensor 1 E 4 6 5 7 8 10 11 15 16 9 LT 572 LT 17 19 18 3 13 N m 1 3 kgf...

Page 159: ...2 Bolt 1 13 Band 1 14 Collar 1 15 Bolt 6 16 Rubber mount 6 17 Cylinder head cover 1 E 4 6 5 7 8 10 11 15 16 9 LT 572 LT 17 19 18 3 13 N m 1 3 kgf m 9 4 ft Ib 10 N m 1 0 kgf m 7 2 ft Ib 6 16 mm 6 16 mm...

Page 160: ...Reverse the removal steps for installation E 4 6 5 7 8 10 11 15 16 9 LT 572 LT 17 19 18 3 13 N m 1 3 kgf m 9 4 ft Ib 10 N m 1 0 kgf m 7 2 ft Ib 6 16 mm 6 16 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7...

Page 161: ...hen removing camshafts it is not neces sary to remove the reduction drive gear case 1 Cap bolt 1 2 Gasket 1 3 Bolt 2 4 Timing chain tensioner 1 E E E E E E M M 10 11 10 11 10 11 12 16 17 8 18 8 8 13 9...

Page 162: ...e connected to the camshaft caps 10 Bolt 10 11 Exhaust camshaft cap 3 12 Dowel pin 6 13 Intake camshaft 1 14 Bolt 2 15 Intake camshaft sprocket 1 E E E E E E M M 10 11 10 11 10 11 12 16 17 8 18 8 8 13...

Page 163: ...ing chain guide intake side 1 Reverse the removal steps for installation E E E E E E M M 10 11 10 11 10 11 12 16 17 8 18 8 8 13 9 14 7 15 6 20 19 1 2 3 4 5 10 N m 1 0 kgf m 7 2 ft Ib 6 35 mm 10 N m 1...

Page 164: ...t TDC of the compression stroke with a dial gauge NOTE TDC on the compression stroke can be found when the camshaft lobes are turned away from each other Dial gauge stand 90890 06583 Dial gauge needle...

Page 165: ...ase fasten it with a wire 3 7 Remove Exhaust camshaft sprocket 1 Intake camshaft sprocket 2 with the special tool 3 Universal magneto and rotor holder YU 01235 Rotor holder 90890 01235 Camshaft inspec...

Page 166: ...to the cylinder head without the dowel pins and camshaft caps Position a strip of Plastigauge 1 onto the camshaft journal as shown Install the dowel pins and camshaft caps NOTE Tighten the intake and...

Page 167: ...as a set a 1 4 of a tooth b Correct 1 Timing chain 2 Camshaft sprocket Timing chain tensioner inspection 1 Check Timing chain tensioner Cracks damage rough movement Replace Checking steps While light...

Page 168: ...camshaft Exhaust camshaft caps Intake camshaft caps Installation steps Turn the drive coupling counterclockwise and then check if cylinder 1 is at TDC of the compression stroke with a dial gauge Insta...

Page 169: ...6 13 11 10 16 3 Install Timing chain tensioner Installation steps While lightly pressing the timing chain tensioner rod by hand turn the tensioner rod fully clockwise with a thin screwdriver 1 NOTE M...

Page 170: ...urn Drive coupling several turns counterclockwise 5 Check Turn the drive coupling counterclock wise and then check if cylinder 1 is at TDC of the compression stroke with a dial gauge Camshaft punch ma...

Page 171: ...ket Cylinder head cover NOTE Apply Gasket Maker onto the mating sur faces of the cylinder head cover gasket and cylinder head Tighten the cylinder head cover bolts stages and in a crisscross pattern T...

Page 172: ...pe 3 Refer to EXHAUST PIPE 3 Exhaust pipes 1 and 2 Refer to EXHAUST PIPES 1 AND 2 Oil tank Refer to OIL TANK Intake and exhaust camshaft Refer to CAMSHAFTS 1 Bolt 2 2 Hunger 1 3 Bolt 3 E E E E E E 2 4...

Page 173: ...1 9 Dowel pin 2 Reverse the removal steps for installation E E E E E E 2 4 1 8 5 5 7 9 3 5 5 6 LT 271 2nd 121 5 1st 20 N m 2 0 kgf m 14 ft Ib 2nd 140 5 1st 20 N m 2 0 kgf m 14 ft Ib 10 N m 1 0 kgf m...

Page 174: ...nder head nuts in the sequence shown Cylinder head inspection 1 Eliminate Combustion chamber carbon deposits with a rounded scraper NOTE Do not use a sharp instrument to avoid damag ing or scratching...

Page 175: ...rpage If the limit is exceeded replace the cylin der head Cylinder head installation 1 Install Cylinder head NOTE Pass the timing chain through the timing chain cavity Lubricate the cylinder head nuts...

Page 176: ...5 67 E POWR CYLINDER HEAD 2 Tighten Cylinder head bolts 1 NOTE Lubricate the cylinder head bolts with engine oil T R Cylinder head bolt 10 N m 1 0 kgf m 7 2 ft lb...

Page 177: ...ollow the left Step for removal Cylinder head Refer to CYLINDER HEAD 1 Intake valve lifter 12 2 Intake valve pad 12 3 Intake valve cotter 24 4 Intake valve upper spring seat 12 5 Intake valve spring 1...

Page 178: ...valve pad 8 12 Exhaust valve cotter 16 13 Exhaust valve upper spring seat 8 14 Exhaust valve spring 8 15 Exhaust valve oil seal 8 16 Exhaust valve lower spring seat 8 17 Exhaust valve 8 18 Exhaust val...

Page 179: ...ove the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 Valve spring compressor YM 01253 90890 04019 Valve spring compressor attachment for the intake...

Page 180: ...free length Intake valve spring 38 90 mm 1 53 in Exhaust valve spring 40 67 mm 1 60 in Valve spring tilt Intake valve spring 1 7 mm 0 067 in Exhaust valve spring 1 8 mm 0 071 in Valve inspection 1 Eli...

Page 181: ...4 465 4 480 mm 0 1758 0 1764 in 5 Measure Valve stem runout Out of specification Replace the valve NOTE When installing a new valve always replace the valve guide If the valve is removed or replaced...

Page 182: ...0 1575 0 1580 in Exhaust 4 500 4 512 mm 0 1772 0 1776 in Valve stem to valve guide clearance valve guide inside diameter valve stem diameter Intake 0 010 0 037 mm 0 0004 0 0015 in Exhaust 0 020 0 047...

Page 183: ...de installer Intake 4 0 mm YM 04112 90890 04112 Exhaust 4 5 mm YM 04117 90890 04117 3 E 2 3 Insert the special service tool into the valve guide 2 and then ream the valve guide NOTE Turn the valve gui...

Page 184: ...alve slowly on the valve seat with a valve lapper commercially obtainable as shown 4 Measure the valve seat contact width a where the blueing dye is adhered to the valve face Reface the valve seat if...

Page 185: ...seat Be sure to turn the cutter evenly downward at a pres sure of 40 50 N 4 5 kgf 8 8 11 lbf to pre vent chatter marks Valve seat cutter holder Intake 4 0 mm 90890 06811 Exhaust 4 5 mm 90890 06812 Val...

Page 186: ...edge of the valve seat a 60 cutter to cut the bottom edge to center the area and set its width b Previous contact width 7 If the valve seat contact area is too narrow and situated near the top edge o...

Page 187: ...remaining lapping compound from the cylinder head and the valve 11 Check the valve seat contact area of the valve again Valve installation 1 Install Lower spring seat 1 Oil seal 2 Valve 3 Valve spring...

Page 188: ...se applied to it Valve spring compressor YM 01253 90890 04019 Valve spring compressor attachment for the intake valve YM 4114 90890 04114 for the exhaust valve YM 4108 90890 04108 3 Lightly tap the va...

Page 189: ...ST MANIFOLD Generator cover Refer to GENERATOR AND STARTER MOTOR Loosen completely 6 21 20 20 11 10 9 8 7 2 3 4 5 16 15 17 18 13 14 12 19 1 LT 271 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT...

Page 190: ...e switch 1 6 21 20 20 11 10 9 8 7 2 3 4 5 16 15 17 18 13 14 12 19 1 LT 271 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT E E A A 12 N m 1 2 kgf m 8 7 ft Ib 6 70 mm 12 N m 1 2 kgf m 8 7 ft Ib 6...

Page 191: ...LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT E E A A 12 N m 1 2 kgf m 8 7 ft Ib 6 70 mm 12 N m 1 2 kgf m 8 7 ft Ib 6 20 mm 20 N m 2 0 kgf m 14 ft Ib 8 40 mm 2nd 3rd 15 N m 1 5 kgf m 11 ft Ib...

Page 192: ...572 LT LT 572 LT LT 572 LT LT 572 LT LT 572 LT E E A A 12 N m 1 2 kgf m 8 7 ft Ib 6 70 mm 12 N m 1 2 kgf m 8 7 ft Ib 6 20 mm 20 N m 2 0 kgf m 14 ft Ib 8 40 mm 2nd 3rd 15 N m 1 5 kgf m 11 ft Ib 1st 7...

Page 193: ...ts OIL PIPE AND OIL FILTER BOLT REMOVAL Follow the left Step for removal Crankshaft Refer to CRANKSHAFT 1 Bolt 1 2 Oil pipe 1 3 O ring 2 4 Oil filter bolt 1 5 Lower crankcase 1 Reverse the removal ste...

Page 194: ...1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them Loosen the bolts in decreasing numerical order refer to the numbers in the illustra...

Page 195: ...ld solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with com pressed air Timing chain...

Page 196: ...o come into contact with the oil gallery or crankshaft journal bearings Recommended lubricant Engine oil 3 Install Dowel pins 1 O ring 2 GM 1 12 1 4 Install Crankcase bolts NOTE Lubricate the bolt 1 0...

Page 197: ...5 6 ft lb Loosen and retighten the crankcase bolts in the proper tightening sequence as shown T R Crankcase bolt 1 0 2nd Loosen completely 3rd 15 N m 1 5 kgf m 11 ft lb Tighten the crankcase bolts fur...

Page 198: ...om one corner to another is 60 6 Tighten Crankcase bolts A J NOTE Tighten the bolts in the tightening sequence cast on the crankcase T R Crankcase bolt A J 12 N m 1 2 kgf m 8 7 ft lb 1 5 3 9 7 I C A E...

Page 199: ...vice points CONNECTING RODS AND PISTONS REMOVAL Follow the left Step for removal Crankcase Separate Refer to CRANKCASE 1 Nut 8 2 Connecting rod cap 4 3 Big end lower bearing 4 4 Piston pin clip 8 5 Pi...

Page 200: ...ep Procedure Part name Q ty Service points 8 Bolt 8 9 Big end upper bearing 4 10 Top ring 4 11 2nd ring 4 12 Oil ring 4 Reverse the removal steps for installation E E E E 1 2 3 10 11 12 4 5 6 8 7 9 2n...

Page 201: ...its original place 1 2 Remove Piston pin clips 1 Piston pin 2 Piston 3 Connecting rod 4 CAUTION Do not use a hammer to drive the piston pin out NOTE For reference during installation put an iden tific...

Page 202: ...cylin der bore gauge Cylinder bore C 76 000 76 015 mm 2 9921 2 9927 in Taper limit T 0 08 mm 0 003 in Out of round R 0 05 mm 0 002 in C maximum of D1 D6 T maximum of D1 D5 direction d and D2 D6 direc...

Page 203: ...0 0043 in Limit 0 17 mm 0 0067 in If out of specification replace the piston and piston rings as a set Piston ring inspection 1 Measure Piston ring side clearance Out of specification Replace the pis...

Page 204: ...2 in 3 Measure Piston ring end gap Out of specification Replace the pis ton ring NOTE The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all th...

Page 205: ...pin Piston pin outside diameter 16 991 17 000 mm 0 6689 0 6693 in Limit 16 98 mm 0 67 in 3 Measure Piston pin bore diameter in the piston b Out of specification Replace the pis ton 4 Calculate Piston...

Page 206: ...necting rods To obtain the cor rect crankshaft pin to big end bearing clearance and prevent engine damage the big end bearings must be installed in their original positions Clean the big end bearings...

Page 207: ...en the connecting rod nuts Refer to Connecting rod and piston installation Remove the connecting rod and big end bearings Refer to Connecting rod and piston removal Measure the compressed Plastigauge...

Page 208: ...of the pistons and connecting rods 1 Install Oil ring 2nd ring Top ring NOTE Be sure to install the piston rings so that the manufacturer s marks or numbers face up 2 Install Piston 1 Connecting rod 2...

Page 209: ...b c a 90 45 90 4 Lubricate Piston Piston rings Cylinder with the recommended lubricant Recommended lubricant Engine oil 5 Lubricate Bolt threads Nut seats with the recommended lubricant Recommended lu...

Page 210: ...ng rod caps Be sure to reinstall each big end bearing in its original place While compressing the piston rings with pis ton ring compressor 2 install the connecting rod assembly into the cylinder with...

Page 211: ...rque T R Connecting rod nut 1st 20 N m 2 0 kgf m 14 ft lb Tighten the connecting rod nuts further to reach the specified angle 120 T R Connecting rod nut Final Specified angle 120 5 WARNING When the n...

Page 212: ...ty Service points CRANKSHAFT REMOVAL Follow the left Step for removal Crankcase Separate Refer to CRANKCASE Connecting rod caps Refer to CONNECTING RODS AND PISTONS 1 Crankshaft 1 2 Crankshaft journa...

Page 213: ...aft inspection 1 Measure Crankshaft runout Out of specification Replace the crankshaft Maximum crankshaft runout 0 03 mm 0 0012 in 2 Check Crankshaft journal surfaces Crankshaft pin surfaces Scratches...

Page 214: ...ll the crankshaft journal upper bear ings 1 and the crankshaft into the upper crankcase NOTE Align the projections a of the crankshaft journal upper bearings with the notches b in the upper crankcase...

Page 215: ...4 Select Crankshaft journal bearings J1 J5 NOTE The numbers stamped into the crankshaft web and the numbers stamped into the lower crankcase are used to determine the replacement crankshaft journal be...

Page 216: ...earings into the lower crankcase NOTE Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase Be sure to install each crankshaft journal bearing in i...

Page 217: ...t on stern side 3 Clamp cooling water hose 2 1 4 Clamp cooling water hose 1 1 For cooling water pilot outlet on starboard side 5 Band grease hose 1 1 6 Bolt 2 7 Thermostat housing cover 1 8 Thermostat...

Page 218: ...ollar 2 13 Thermostat housing holder 1 Reverse the removal steps for installation 3 1 3 10 8 7 4 6 5 2 LT 572 LT 572 6 35 mm 2nd 7 6 N m 0 76 kgf m 5 5 ft Ib 1st 3 7 N m 0 37 kgf m 2 7 ft Ib 6 70 mm 2...

Page 219: ...ous overheating or over cooling Checking steps Suspend the thermostat in a container filled with water Slowly heat the water Place a thermometer in the water While stirring the water observe the ther...

Page 220: ...moval Exhaust manifold Refer to EXHAUST MANIFOLD 1 Clamp cooling water hose 1 1 From exhaust manifold To cylinder block 2 Clamp cooling water hose 2 2 To exhaust pipe 3 Clamp cooling water hose 2 1 To...

Page 221: ...RVICE POINTS 6 9 Lever 1 installation 6 9 Lever 2 installation 6 9 JET THRUST NOZZLE AND NOZZLE RING 6 10 EXPLODED DIAGRAM 6 10 REMOVAL AND INSTALLATION CHART 6 10 IMPELLER DUCT AND IMPELLER HOUSING 1...

Page 222: ...water hose inspection 6 23 BEARING HOUSING 6 24 EXPLODED DIAGRAM 6 24 REMOVAL AND INSTALLATION CHART 6 24 SERVICE POINTS 6 27 Driven coupling removal and installation 6 27 Intermediate drive shaft re...

Page 223: ...rocedure Part name Q ty Service points INTAKE GRATE RIDE PLATE AND INTAKE DUCT REMOVAL Follow the left Step for removal 1 Bolt 2 2 Bolt 2 3 Intake grate 1 4 Screw 4 5 Speed sensor 1 NOTE Route the spe...

Page 224: ...INTAKE GRATE RIDE PLATE AND INTAKE DUCT EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Ride plate 1 8 Bolt 4 9 Intake duct 1 10 Felt packing 1 Reverse the removal steps for installati...

Page 225: ...D DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points SPEED SENSOR DISASSEMBLY Follow the left Step for disassembly 1 Holder 1 2 Paddle wheel set 1 3 Speed sensor 1 Rev...

Page 226: ...NOTE Route the speed sensor lead between the jet pump unit and the bilge hose 4 Nut washer 1 2 5 Steering cable joint 1 6 Clamp spout hose 1 1 7 Bolt 6 8 24 mm 14 N m 1 4 kgf m 10 ft Ib 6 22 mm 6 8 N...

Page 227: ...2 14 Impeller housing 2 1 15 Dowel pin 2 Reverse the removal steps for installation 8 24 mm 14 N m 1 4 kgf m 10 ft Ib 6 22 mm 6 8 N m 0 68 kgf m 4 9 ft Ib 6 80 mm 7 8 N m 0 78 kgf m 5 6 ft Ib 2 2 N m...

Page 228: ...GRAM 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 g...

Page 229: ...JET PUMP REVERSE GATE EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 10 Bolt 6 11 Bracket 1 12 Reverse gate stay 2 13 Nut 1 14 Washer 1 15 Bolt 1 16 Lever 1 1 17 Spacer 1 18 Nut 1 19 Wa...

Page 230: ...T PUMP REVERSE GATE EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 20 Collar 1 21 Bolt 1 22 Washer 1 23 Collar 1 24 Spring 1 25 Lever 2 1 26 Washer 1 Reverse the removal steps for insta...

Page 231: ...lar 3 Spring 4 Lever 2 5 Washer 6 Collar 7 NOTE When installing the spring hook the spring end a to lever 2 and spring end b to the reverse gate as shown in the illustration When installing the lever...

Page 232: ...ION CHART Step Procedure Part name Q ty Service points JET THRUST NOZZLE AND NOZZLE RING REMOVAL Follow the left Step for removal Jet pump unit Refer to JET PUMP UNIT Reverse gate Refer to REVERSE GAT...

Page 233: ...re Part name Q ty Service points IMPELLER DUCT AND IMPELLER HOUSING 1 REMOVAL Follow the left Step for removal Nozzle ring Refer to JET THRUST NOZZLE AND NOZZLE RING 1 Bolt 4 2 Nozzle 1 NOTE Clean the...

Page 234: ...IMPELLER DUCT AND IMPELLER HOUSING 1 EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Water inlet cover 1 9 Packing 1 10 Water inlet strainer 1 11 Packing 1 Reverse the removal steps f...

Page 235: ...RAM 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 han...

Page 236: ...NOC 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 14 Impeller duct 1 Reverse the disassembly step...

Page 237: ...Impeller NOTE The impeller has left hand threads Turn the impeller clockwise to loosen it Drive shaft holder YB 06151 Drive shaft holder 5 90890 06519 2 Remove Nut 1 Drive shaft holder YB 06151 Drive...

Page 238: ...pters YB 06096 Stopper guide plate 90890 06501 Bearing puller assembly 90890 06535 Stopper guide stand 90890 06538 5 Remove Front bearing NOTE Remove the front bearing with a press Driver handle large...

Page 239: ...96 Needle bearing attachment 90890 06614 Impeller inspection Refer to JET PUMP UNIT in Chapter 3 Drive shaft inspection 1 Inspect Drive shaft Damage wear Replace Drive shaft installation 1 Install Oil...

Page 240: ...which has an inner diameter of 25 mm 0 98 in Distance a 23 0 1 mm 0 91 0 004 in a 3 Install Drive shaft with front bearing Spacer Impeller duct NOTE Press the spacer and the front bearing with a pipe...

Page 241: ...chment is not available use a washer or pipe with an outer diameter of 46 mm 1 81 in and an inner diameter of 20 mm 0 79 in Bearing inner outer race attachment YB 34474 6 Add EPNOC grease AP 0 into th...

Page 242: ...SOM PLATE AND HOSES REMOVAL Follow the left Step for removal Exhaust system Refer to EXHAUST SYSTEM in Chapter 8 Jet pump unit assembly Refer to JET PUMP UNIT 1 Hose clamp 2 2 Cooling water hose 1 Coo...

Page 243: ...p Procedure Part name Q ty Service points 6 Hose clamp 2 7 Cooling water hose 1 Cooling water outlet thermostat 8 Bilge hose 2 1 9 Hose clamp 1 10 Bilge hose 3 1 11 Band 1 12 Electric bilge pump assem...

Page 244: ...6 22 E JET PUMP TRANSOM PLATE AND HOSES EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 16 Nut washer 4 4 17 Transom plate 1 18 Bilge hose 5 1 Reverse the removal steps for installation...

Page 245: ...JET PUMP UNIT in Chapter 3 Electric bilge pump inspection Refer to BILGE PUMP in Chapter 3 Refer to ELECTRIC BILGE PUMP in Chapter 7 Bilge hose inspection 1 Inspect Bilge hoses Cracks damage wear Repl...

Page 246: ...rocedure Part name Q ty Service points BEARING HOUSING REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT in Chapter 5 1 Rubber coupling 1 2 Bolt 3 3 Intermediate housing assemb...

Page 247: ...EMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points BEARING HOUSING DISASSEMBLY Follow the left Step for disassembly 1 Grease hose 1 2 Nipple 1 3 Driven coupling 1 4 Washer 1 5...

Page 248: ...AM Step Procedure Part name Q ty Service points 7 Oil seal 1 8 Oil seal 1 9 Oil seal 1 10 Circlip 1 11 Bearing 1 12 Circlip 1 Reverse the disassembly steps for assembly Not reusable Not reusable Not r...

Page 249: ...06551 Shaft holder YB 06552 Crankshaft holder 20 90890 06552 Intermediate drive shaft removal 1 Remove Intermediate drive shaft NOTE Support the intermediate housing with steel blocks 1 and press the...

Page 250: ...06071 Driver rod LS 90890 06606 Drive shaft taper roller bearing cup installer YB 06156 Bearing outer race attachment 90890 06626 Bearing intermediate drive shaft and grease hose inspection 1 Inspect...

Page 251: ...06606 Driveshaft taper roller bearing cup installer YB 06156 Bearing outer race attachment 90890 06626 Oil seal installation 1 Install Oil seal NOTE Before installing the oil seal lubricate the clip...

Page 252: ...ation 1 Install Intermediate housing Shim NOTE Install the shim s to the original position if the intermediate housing is not replaced Distance a 46 0 0 5 mm 1 81 0 02 in Distance a 10 5 0 2 mm 0 41 0...

Page 253: ...VOLTAGE 7 15 BATTERY 7 17 FUSE 7 17 SPARK PLUGS 7 17 IGNITION COIL 7 18 ENGINE STOP SWITCH 7 18 ENGINE TEMPERATURE SENSOR 7 19 SENSOR ASSEMBLY 7 19 THERMOSWITCH ENGINE 7 20 THERMOSWITCH EXHAUST 7 20 M...

Page 254: ...rush holder inspection 7 36 Starter motor front cover inspection 7 36 CHARGING SYSTEM 7 37 WIRING DIAGRAM 7 37 FUSE 7 38 BATTERY 7 38 LIGHTING COIL 7 38 RECTIFIER REGULATOR 7 38 ELECTRIC BILGE PUMP 7...

Page 255: ...7 47 Speedometer display 7 48 Tachometer display 7 49 Hour meter display 7 49 Voltage meter display 7 49 Low oil pressure warning indicator 7 49 Fuel level meter display and fuel warning indicator 7...

Page 256: ...Electrical box 6 Battery 7 Speed sensor 8 Electric bilge pump 9 Cam position sensor 0 Fuel injectors A Thermoswitch exhaust B Oil pressure switch C Sensor assembly D Bypass valve motor E Throttle posi...

Page 257: ...her hose 1 1 4 Band 2 5 Battery 1 6 Damper 1 7 Bolt 2 8 Bolt 2 A A A A 22 11 14 13 12 1516 21 20 19 22 22 22 17 18 22 10 1 9 7 8 6 5 2 3 4 VENT LT 572 LT LT 271 LT LT 572 LT A A LT 572 LT E 7 6 N m 0...

Page 258: ...18 Cover 1 A A A A 22 11 14 13 12 1516 21 20 19 22 22 22 17 18 22 10 1 9 7 8 6 5 2 3 4 VENT LT 572 LT LT 271 LT LT 572 LT A A LT 572 LT E 7 6 N m 0 76 kgf m 5 5 ft Ib 6 12 mm 7 6 N m 0 76 kgf m 5 5 ft...

Page 259: ...tion A A A A 22 11 14 13 12 1516 21 20 19 22 22 22 17 18 22 10 1 9 7 8 6 5 2 3 4 VENT LT 572 LT LT 271 LT LT 572 LT A A LT 572 LT E 7 6 N m 0 76 kgf m 5 5 ft Ib 6 12 mm 7 6 N m 0 76 kgf m 5 5 ft Ib 6...

Page 260: ...2 Cover 1 3 Gasket 1 4 Clamp 3 5 Wiring harness 1 6 Tapping screw 1 7 Fuse holder stay 1 8 Wiring harness 1 9 Fuse 6 2 3 1 19 20 18 17 16 14 11 15 13 12 6 7 8 5 4 22 21 6 20 mm 3 9 N m 0 39 kgf m 2 8...

Page 261: ...nt connector 2 17 Tapping screw 2 18 Slant detection switch 1 19 Tapping screw 1 20 Main and fuel pump relay 1 2 3 1 19 20 18 17 16 14 11 15 13 12 6 7 8 5 4 22 21 6 20 mm 3 9 N m 0 39 kgf m 2 8 ft Ib...

Page 262: ...1 Reverse the disassembly steps for assembly 2 3 1 19 20 18 17 16 14 11 15 13 12 6 7 8 5 4 22 21 6 20 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 6 30 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 6 16 mm 3 9 N m 0 39 kgf m 2...

Page 263: ...P 2 3 4 5 6 7 8 1 1 Starter relay 2 Fuse holder 3 ECM 4 Joint connector 5 Joint connector 6 Main and fuel pump relay 7 Rectifier regulator 8 Slant detection switch To ignition coil To battery positive...

Page 264: ...ered by dry batter ies check the battery s voltage periodi cally and replace the batteries if necessary Digital tester NOTE Throughout this chapter the part numbers of the specified digital testers ha...

Page 265: ...obtained by connecting both of its terminals Correct value Displayed measurement Internal resistance Peak voltage measurement NOTE When checking the condition of the ignition system it is vital to kn...

Page 266: ...l circuit tester Make sure that the positive pin the mark facing up as shown on the adaptor is installed into the positive terminal of the tester The test harness is needed for the following tests Vol...

Page 267: ...4 W 5 P 6 P W 9 O 12 W R 13 W B 21 L R 22 B R 28 L B 30 R Y 33 P G 34 P 35 B Y 42 B L 43 B Y 44 B W 1 2 3 4 5 6 7 8 B B B B O Br B Y O B O P G R Y B B B R Y R Y B B G B O R Y R Y R K 1 P O G B G Pu B...

Page 268: ...3 2 B H H D I I F G E E 8 5 6 7 9 0 4 R P P O R R R R R P P O O B O L B 3 G O 4 W 5 P 6 P W 9 O 12 W R 13 W B 21 L R 22 B R 28 L B 30 R Y 33 P G 34 P 35 B Y 42 B L 43 B Y 44 B W 1 2 3 4 5 6 7 8 B B B...

Page 269: ...lug cap When performing the spark gap check keep flammable gas or liquids away since this test can produce sparks 1 Check Ignition spark Weak Check the ECM output peak voltage Check the ignition coil...

Page 270: ...Measure the pickup coil output peak voltage NOTE When measuring the ECM output peak volt age while cranking the engine disconnect the ignition coil couplers for all cylinders except for the cylinder...

Page 271: ...pins New YB 06877 Current YB 06777 Test harness HM090 3 3 pins New 90890 06877 Current 90890 06777 Pickup coil output peak voltage White W Black B Red R Black B r min Unloaded Loaded Cranking 2 000 3...

Page 272: ...ation Replace the recti fier regulator NOTE Do not use the peak voltage adapter to mea sure the output voltage Disconnect the output lead of the tester har ness Test harness 6 pins YB 06848 Test harne...

Page 273: ...al resistance Refer to Low resistance measurement Primary coil resistance 1 19 1 61 at 20 C 68 F 2 Measure Secondary coil resistance Out of specification Replace Secondary coil resistance 8 5 11 5 k a...

Page 274: ...container filled with water Slowly heat the water Measure the resistance when the speci fied temperature is reached SENSOR ASSEMBLY 1 Check Intake air temperature sensor Out of specification Replace t...

Page 275: ...witch engine continuity temperature a 84 90 C 183 194 F b 70 84 C 158 183 F Checking steps Suspend the thermoswitch engine in a container filled with water Place a thermometer in the water Slowly heat...

Page 276: ...and fuel pump relay terminals Check that there is no continuity between the main and fuel pump relay terminals after disconnecting terminals 2 3 or 1 Connect the tester leads between the main and fue...

Page 277: ...pins 90890 06793 Test connector YW 06862 Test connector FMY 8 90890 06862 Throttle position sensor output voltage Pink P Black orange B O 0 756 0 016 V Measurement steps Connect the test harness 3 pi...

Page 278: ...Yamaha Diagnostic Sys tem electric power is supplied to the cam position sensor Test harness 3 pins New YB 06877 Current YB 06777 Test harness HM090 3 3 pins New 90890 06877 Current 90890 06777 Cam po...

Page 279: ...Out of specification Replace Noise filter continuity Black B Red R No continuity B G G R B R SLANT DETECTION SWITCH 1 Check Slant detection switch continuity Out of specification Replace Position Lead...

Page 280: ...1 2 3 4 5 6 7 8 Pu G R Y Pu Y R Y Pu B R Y Pu R R Y R Y R Y B L B P B A B O L B Y L B B O B O P P B P B O B P B O P B P B 8 9 P P O P W P W P W E 15 18 L F B Y O B O P G P O G B G Pu B G Y G R Pu G Pu...

Page 281: ...R 1 2 3 4 5 6 7 8 Pu G R Y Pu Y R Y Pu B R Y Pu R R Y R Y R Y B L B P B A B O L B Y L B B O B O P P B P B O B P B O P B P B 8 9 P P O P W P W P W E 15 18 L F B Y O B O P G P O G B G Pu B G Y G R Pu G...

Page 282: ...mp does not sound Measure the fuel pressure Refer to FUEL INJECTION SYSTEM in Chapter 4 NOTE After the engine is stopped the fuel pump will operate for 10 seconds FUEL SENDER 1 Measure Fuel sender res...

Page 283: ...MAIN AND FUEL PUMP RELAY Refer to IGNITION SYSTEM OIL PRESSURE SWITCH Refer to INDICATION SYSTEM THERMOSWITCH ENGINE Refer to IGNITION SYSTEM THERMOSWITCH EXHAUST Refer to IGNITION SYSTEM SLANT DETEC...

Page 284: ...R Br R B B R 4 9 3 2 1 8 7 6 R P P O R R R R R R R 1 2 3 4 5 6 7 8 5 Br B B B B B B L L Y L L B B A B B B B R Y B R Y R 123456789 0ABCDEFGH 1 ECM 2 Main and fuel pump relay 3 Fuse 20A 4 Starter relay...

Page 285: ...broken Broken Replace NOTE 20A fuse is for main relay engine shut off switch and rectifier regulator 3A fuse is for multifunction meter electric bilge pump and remote control unit Fuse rating 3A 20A S...

Page 286: ...eads 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...

Page 287: ...ocedure 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...

Page 288: ...ocedure 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 sp...

Page 289: ...7 34 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 290: ...an with 600 grit sandpaper 3 Measure Commutator diameter Below specification Replace Minimum commutator diameter 27 0 mm 1 06 in 4 Check Commutator undercut Contaminants Clean NOTE Remove all mica and...

Page 291: ...Armature shaft No continuity Brush holder inspection 1 Measure Brush length a Below specification Replace Minimum brush length 6 5 mm 0 26 in 2 Check Brush holder continuity Out of specification Repl...

Page 292: ...7 37 E ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM B R R 1 2 3 R R R G G G G G G B G B G G G G G 4 1 Rectifier regulator 2 Fuse 20A 3 Battery 4 Lighting coil B Black G Green R Red...

Page 293: ...7 38 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 294: ...R Y Br B B B B B R R 3 7 2 4 5 R P P O R B R R R 1 2 3 4 5 6 7 8 R Y R Y B Br R Y R Y R R Y R Y R R Y 6 15 B B B B L R R Y B 1 1 ECM 2 Main and fuel pump relay 3 Fuse 3A 4 Battery 5 Electric bilge pum...

Page 295: ...d with water Connect the brown lead terminal to the positive battery terminal Connect the black lead terminal to the negative battery terminal Check the water flows from the electric bilge pump hose B...

Page 296: ...R Y R Y R Y W L R Y B B O B O B O B O B O R Y R Y R Y R Y R Y R Y G Y R Y G G R G B R Y R Y G R G B R Y R Y R Y R Y G R G W L R Y P 18 20 29 30 34 O W R W B G B G Y 9 12 13 16 17 2 3 4 5 P P O R R R W...

Page 297: ...Engine monitor of the Yamaha Diagnostic System to check that the steering switch switches on and off when the handlebar is turned to the right and to the left Does not operate Replace ECM Refer to IG...

Page 298: ...O B O B O R W B Y R Y L R B L R P B B B B Y P A B C B R W 0 B L L R B Y R Y Y B Y R W Y B R Y B B B B R 1 21 30 5 35 15 6 14 P W P W P W D B O R Y W B B O G 4 1 L B L Y Y L 7 15 18 16 6 L R R Y L R L...

Page 299: ...B O B O R W B Y R Y L R B L R P B B B B Y P A B C B R W 0 B L L R B Y R Y Y B Y R W Y B R Y B B B B R 1 21 30 5 35 15 6 14 P W P W P W D B O R Y W B B O G 4 1 L B L Y Y L 7 15 18 16 6 L R R Y L R L R...

Page 300: ...RATURE SENSOR Refer to IGNITION SYSTEM THERMOSWITCH ENGINE Refer to IGNITION SYSTEM THERMOSWITCH EXHAUST Refer to IGNITION SYSTEM REMOTE CONTROL UNIT Refer to REMOTE CONTROL SYS TEM BUZZER 1 Check Buz...

Page 301: ...set 90890 06756 Oil pressure switch continuity pressure 128 kPa 1 28 kgf cm2 18 2 psi 166 kPa 1 66 kgf cm2 23 6 psi MULTIFUNCTION METER Multifunction meter 1 Check Multifunction meter Cracked meter h...

Page 302: ...unction meter B L B L R B Y B Y R W P B R W Y Y R R W W B B B P L R R B R 1 2 3 4 5 Gy L B L R L Y L B B L 1 Remote control unit 2 Buzzer 3 Speed sensor 4 ECM 5 Fuel sender B Black Gy Gray P Pink R Re...

Page 303: ...nsor output voltage dependant on the paddle wheel position Less than 400 mV More than 11 6 V Output pulse 2 pulses one full turn Measurement steps Apply DC 12 voltage to the natural color three pin co...

Page 304: ...e Engine monitor of the Yamaha Diagnostic System Replace the multifunction meter Low oil pressure warning indicator 1 Check Low oil pressure warning indicator No operating Check the oil pressure switc...

Page 305: ...nal of the disconnected connector Check that the multifunction meter over heat warning indicator comes on and the buzzer sounds Check the engine warning indicator 1 Check Check the engine warning indi...

Page 306: ...R Y 9 8 W B W W W A 14 L 15 W B 21 L R 30 R Y 31 Y 37 Pu G 38 Pu Y 39 Pu B 40 Pu R W L R L B Gy L R L B L Y L R L R P O G B G Pu B G Y G R Pu G Pu Y Pu B P O R Y Pu Y G Y G R B Y P G Pu R Pu R Pu G P...

Page 307: ...cation Replace the remote control unit Remote control unit output voltage Blue yellow L Y ground 11 13 V Measurement steps Disconnect the remote control unit 1 coupler from the multifunction meter Mea...

Page 308: ...dicated on the multifunction meter 1 Checking the remote control transmitter 1 Check Remote control transmitter Does not operate Replace the remote control transmitter Checking steps CAUTION If the bu...

Page 309: ...Check that the beeper sounds three times and the L MODE indicator light comes on NOTE If the start switch or the remote control transmitter is not operated for more than 25 seconds the multifunction m...

Page 310: ...s time the system enters the regis tration mode to register the first code All existing ID codes will be deleted from the EEPROM The SECURITY indicator light flashes when the registration of the ID co...

Page 311: ...trapped between the upper case and lower case of the remote control transmit ter during assembly 1 Remove Cover NOTE Loosen the transmitter cover screws in the sequence shown 4 1 5 3 2 6 2 Install Bat...

Page 312: ...TION CHART 8 11 SERVICE POINTS 8 15 Steering master components inspection 8 15 REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 8 16 EXPLODED DIAGRAM 8 16 REMOVAL AND INSTALLATION CHART 8 16 SERVICE POINTS...

Page 313: ...38 Base assembly 8 38 Shift lever 8 38 SEATS AND HAND GRIP 8 39 EXPLODED DIAGRAM 8 39 REMOVAL AND INSTALLATION CHART 8 39 SERVICE POINTS 8 42 Seat lock inspection 8 42 EXHAUST SYSTEM 8 43 EXPLODED DI...

Page 314: ...Follow the left Step for removal 1 Screw 4 2 Handlebar cover 1 3 Pad 1 4 Bolt 2 NOTE Position the corrugated tube for the throttle cable as shown in the illustration so that the tube attaches to the e...

Page 315: ...ts HANDLEBAR REMOVAL Follow the left Step for removal QSTS cable to jet thrust nozzle Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Nut washer 2 2 2 QSTS converter 1 3 QSTS cable 2 1 with whi...

Page 316: ...andlebar assembly 1 NOTE Pass the QSTS cable and handlebar switch lead through the handle boss cover and then install the handlebar assembly Install the sponges of the QSTS cables as shown and make su...

Page 317: ...tep 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 spring washer washer 1 1 1 5 QSTS grip assembly 1 6 Spec...

Page 318: ...Part name Q ty Service points 8 Handlebar switch assembly 1 9 Screw 2 10 Throttle lever assembly 1 11 Handlebar grip 1 NOTE Apply adhesive to the handlebar and the inner surface of the handlebar grip...

Page 319: ...lebar switch lead and throttle cable into the grommets tie the end of grommets with the bands 2 Install Upper handlebar holder 1 NOTE Align the punch marks a on the handlebar with the top surface of t...

Page 320: ...Install Handlebar cover 1 NOTE When the handlebar cover is in contact with the steering boss cover adjust the handlebar mount angle so that the clearance a and b are equal 5 Adjust Throttle cable free...

Page 321: ...D INSTALLATION CHART Step Procedure Part name Q ty Service points QSTS GRIP DISASSEMBLY Follow the left Step for disassembly QSTS grip assembly Refer to HANDLEBAR 1 Screw washer 1 1 2 Cover 1 3 Ball 2...

Page 322: ...RIP EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Screw washer 2 2 8 Spacer 1 9 QSTS shift lock lever 1 10 Spring 1 11 Spacer 1 12 Cable housing 1 13 QSTS grip 1 Reverse the disassem...

Page 323: ...movement Replace 2 Adjust QSTS cable length a NOTE Before adjusting the QSTS cables set the trim grip to the neutral position Adjust the QSTS cable lengths a to the specified length and be sure to ta...

Page 324: ...ure Part name Q ty Service points STEERING MASTER REMOVAL Follow the left Step for removal Steering console cover Refer to STEERING CONSOLE COVER Steering cable end Refer to REMOTE CONTROL CABLES AND...

Page 325: ...8 12 E HULL HOOD STEERING MASTER EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Bolt 3 7 Magnet 1 8 Steering switch 1 Reverse the removal steps for installation...

Page 326: ...LLATION 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...

Page 327: ...DIAGRAM Step Procedure Part name Q ty Service points 11 Tilt stopper 1 12 Bolt nut holder 4 4 4 13 Retainer 2 14 Steering shaft 1 15 Steering tube 1 16 Bolt 2 17 Cap 1 18 Shaft 1 1 19 Cross piece 1 R...

Page 328: ...8 15 E HULL HOOD STEERING MASTER SERVICE POINTS Steering master components inspection 1 Inspect Each component part Damage wear Replace the steering master...

Page 329: ...T Step Procedure Part name Q ty Service points REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL Follow the left Step for removal Service lid 1 Refer to FRONT HOOD Front seat assembly Refer to SEATS...

Page 330: ...L CABLES AND SPEED SENSOR LEAD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Nut 1 7 Steering cable 1 8 Seal 1 9 Speed sensor coupler 1 10 Nut 1 11 Cap 1 12 Screw 4 13 Speed sensor 1...

Page 331: ...NSOR LEAD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 16 Shift cable holder 2 17 Nut 1 18 Shift cable 1 19 Seal 1 20 Nut 1 21 Pin 1 22 QSTS cable end 1 23 Nut 1 24 QSTS cable 1 25 Pa...

Page 332: ...replace it Never attempt to repair a damaged cable Remote control cables inspection 1 Inspect Steering cable QSTS cable Shift cable Frays kinks rough movement Replace Steering cable jet pump end insta...

Page 333: ...cable set length a jet pump end 13 6 mm 0 54 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 ou...

Page 334: ...l the shift cable holders so that mark a and mark b are in the positions shown in the illustration Shift cable stopper installation 1 Install Shift cable stopper WARNING Be sure to fit the projection...

Page 335: ...oval 1 Nut washer 4 4 2 Front hood assembly 1 3 Bolt 4 4 Bolt 2 5 Hinge assembly 1 6 Bolt 2 7 Hood lock assembly 1 2 7 6 4 8 9 3 5 1 11 10 6 18 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 30 mm 5 4 N m 0 54 kgf...

Page 336: ...lid 2 1 Reverse the removal steps for installation 2 7 6 4 8 9 3 5 1 11 10 6 18 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 30 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 4 8 mm 1 5 N m 0 15 kgf m 1 1 ft Ib LT 271 LT 242...

Page 337: ...REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points HINGE DISASSEMBLY Follow the left Step for disassembly 1 Circlip 2 2 Pin long 1 3 Hinge 1 4 Pin short 1 5 Damper stay 1 6 Co...

Page 338: ...8 25 E HULL HOOD FRONT HOOD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Band 1 9 Damper boots 1 10 Damper 1 Reverse the disassembly steps for assembly 4 5 1 7 6 10 2 7 6 1 8 9 3...

Page 339: ...REMOVAL Follow the left Step for removal Handlebar assembly Refer to HANDLEBAR Service lid 1 Refer to FRONT HOOD 1 Band 1 2 Multifunction meter coupler 4 3 Bolt 4 4 Panel 1 5 Band 1 LT 242 LT 242 5 7...

Page 340: ...Bolt 4 7 Multifunction meter 1 8 Hose packing 1 9 Grommet 1 10 Nut washer 4 4 11 Plate 2 12 Mirror 2 Reverse the removal steps for installation LT 242 LT 242 5 7 9 5 6 10 12 1 2 3 4 5 20 mm 3 9 N m 0...

Page 341: ...TION CHART Step Procedure Part name Q ty Service points SIDE COVER REMOVAL Follow the left Step for removal 1 Cup holder 1 2 Holder 1 3 Bolt 8 4 Washer 2 5 Side cover 2 Reverse the removal steps for i...

Page 342: ...OX ASSEMBLY REMOVAL Follow the left Step for removal 1 Nut washer 2 2 2 Bolt 2 3 Nut washer 2 2 4 Bolt 2 5 Bolt 2 6 Shift handle lever 1 6 30 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 14 mm 5 4 N m 0 54 kgf m...

Page 343: ...pull the tilt lever up 9 Hood lock assembly 1 10 Nut washer 2 2 11 Bolt 2 12 Glove compartment assembly 1 Reverse the removal steps for installation 6 30 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 6 14 mm 5 4 N...

Page 344: ...ocedure Part name Q ty Service points GLOVE COMPARTMENT DISASSEMBLY Follow the left Step for disassembly 1 Glove compartment 1 2 Hinge assembly 2 3 Lid 1 4 Gear assembly 2 5 Screw 2 6 Latch 1 Reverse...

Page 345: ...HULL HOOD STEERING CONSOLE COVER SERVICE POINTS Glove compartment assembly installation 1 Install Hinge assembly NOTE When installing the hinge assembly make sure that the springs are in the position...

Page 346: ...or removal Fuel tank Refer to FUEL TANK AND FUEL PUMP MODULE in Chapter 4 NOTE When removing the ventilation hose and fuel tank breather hose it is not necessary to remove the fuel tank 1 Band 4 2 Ven...

Page 347: ...ame Q ty Service points 4 Clamp 2 5 Cooling water hose 2 6 Nut 2 7 Cooling water pilot outlet 2 8 Seal 2 Reverse the removal steps for installation VENT VENT VENT 1 2 1 2 7 8 1 6 4 5 3 5 4 6 8 7 FW D...

Page 348: ...N CHART Step Procedure Part name Q ty Service points SHIFT LEVER REMOVAL Follow the left Step for removal Side cover Refer to STEERING CONSOLE COVER Shift cable Refer to REMOTE CONTROL CABLES AND SPEE...

Page 349: ...8 36 E HULL HOOD SHIFT LEVER EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Screw 3 7 Base assembly 1 8 Nut washer 3 3 9 Screw 3 10 Plate 1 Reverse the removal steps for installation...

Page 350: ...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 Sh...

Page 351: ...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 Shift lever 1 Install Shift lever NOTE T...

Page 352: ...ruiser High Output 3 Front seat assembly 1 4 Bolt 4 5 Seat lock assembly 2 6 Seat storage compartment 1 7 Nut washer 4 4 8 Bolt washer 4 4 3 1 5 4 22 21 18 19 20 17 19 7 8 10 14 6 16 15 13 12 11 9 5 4...

Page 353: ...olt 4 16 Rear seat stay 2 17 Nut 1 3 1 5 4 22 21 18 19 20 17 19 7 8 10 14 6 16 15 13 12 11 9 5 4 6 25 mm 8 30 mm 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 5 2 N m 0 52 kgf m 3 8 ft Ib 26 N m 2 6 kgf m 19 ft I...

Page 354: ...se the removal steps for installation 3 1 5 4 22 21 18 19 20 17 19 7 8 10 14 6 16 15 13 12 11 9 5 4 6 25 mm 8 30 mm 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 5 2 N m 0 52 kgf m 3 8 ft Ib 26 N m 2 6 kgf m 19 f...

Page 355: ...8 42 E HULL HOOD SEATS AND HAND GRIP SERVICE POINTS Seat lock inspection 1 Inspect Front seat lock Rear seat lock Damage wear Replace...

Page 356: ...Jet pump unit assembly Refer to JET PUMP UNIT in Chapter 6 NOTE When removing the water lock and exhaust joint it is not necessary to remove the jet pump unit 1 Band 1 2 Joint clamp 1 3 Hose clamp 1...

Page 357: ...clamp 1 10 Exhaust joint 1 11 Nut washer 6 6 12 Exhaust valve 1 NOTE Remove parts 12 to 18 as a set 13 Hose clamp 1 14 Rubber hose 1 7 14 3 13 15 18 17 12 11 16 10 5 1 4 3 7 N m 0 37 kgf m 2 7 ft Ib...

Page 358: ...1 16 Water tank 1 17 Rubber hose 1 18 Plate 1 Reverse the removal steps for installation 7 14 3 13 15 18 17 12 11 16 10 5 1 4 3 7 N m 0 37 kgf m 2 7 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 2 5 N m 0 25 kgf...

Page 359: ...ust component parts sub assembly 1 Install Rubber hose Plate NOTE Be sure to fit the projections on the rubber hose with the grooves in the plate 2 Install Rubber hoses Water tank NOTE Be sure to inse...

Page 360: ...nstallation 1 Install Exhaust joint NOTE Be sure to install the projections a on the exhaust pipe and exhaust joint into the slots b in the joint a b b a 2 Install Water lock NOTE Be sure to insert th...

Page 361: ...3 Nut 2 4 Cleat 1 5 Plate 2 6 Bolt collar 10 10 7 Sponson 2 8 Nut washer 4 4 9 Screw washer 4 4 10 Drain plug 2 16 17 18 4 5 3 7 6 15 13 14 12 13 1 9 10 11 8 2 5 4 N m 0 54 kgf m 3 9 ft Ib 15 N m 1 5...

Page 362: ...l 2 16 Nut washer 3 3 17 Bolt 4 18 Protector 1 Reverse the disassembly steps for assembly 16 17 18 4 5 3 7 6 15 13 14 12 13 1 9 10 11 8 2 5 4 N m 0 54 kgf m 3 9 ft Ib 15 N m 1 5 kgf m 11 ft Ib 8 45 mm...

Page 363: ...TION CHART Step Procedure Part name Q ty Service points ENGINE MOUNT REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT in Chapter 5 1 Bolt 4 2 Damper 1 1 3 Damper 2 1 4 Bolt 8...

Page 364: ...SIS INTRODUCTION 9 1 FEATURES 9 1 Functions 9 1 CONTENTS 9 1 HARDWARE REQUIREMENTS 9 2 OPERATING 9 3 CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT 9 3 Top view 9 3 TROUBLE ANALYSIS 9 4 TROUBLE...

Page 365: ...been activated and ECM diagnostic codes that have been recorded are displayed This allows you to check the watercraft s record of malfunctions 3 Engine monitor Each sensor s status and the ECM data ar...

Page 366: ...y VGA 640 480 pixels SVGA 800 600 pixels or more recommended 256 or more colors Mouse Compatible with the operating systems mentioned above Communication port RS232C Dsub 9 pin port USB port Printer C...

Page 367: ...ONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT Top view 1 3 pin communication coupler 2 Wiring harness coupler 3 Meter coupler NOTE Be careful not to pinch the communication cable between the hoo...

Page 368: ...ff cord lanyard is connect to the engine shut off switch 5 Check that fuel is reaching the throttle bodies TROUBLE ANALYSIS CHART Trouble mode Check elements ENGINE WILL NOT START HARD STARTING ROUGH...

Page 369: ...oil 3 Oil filter 3 Oil pressure switch 7 Bearing housing 5 Drive couplings 5 Rubber coupling 5 Pilot water hose 5 Water hose 5 Water passage 5 Trouble mode Check elements ENGINE WILL NOT START HARD S...

Page 370: ...7 Engine shut off switch 7 Spark plugs 3 Main and fuel pump relay 7 Thermoswitch 7 Sensor assembly 7 Engine temperature sensor 7 Throttle position sensor 7 Cam position sensor 7 Trouble mode Check el...

Page 371: ...l system Remote control unit 7 HULL AND HOOD Steering master 8 Water lock 8 Exhaust hose 8 Muffler 8 Drain plugs 8 Trouble mode Check elements ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDL...

Page 372: ...ever if there are numerous error codes dis played be sure to check them with the Yamaha Diagnostic System Code Symptom 01 Normal 13 Pickup coil malfunction 15 Engine temperature sensor malfunction 18...

Page 373: ...L Battery M Starter motor N Electric bilge pump O Fuel pump P Fuel sender Q Engine stop switch R Engine shut off switch S Start switch T Steering switch U Multifunction meter V Speed sensor W Buzzer...

Page 374: ...B O W R P W B B P B R O P G G G G G G G R Y B Y R Y P G L B L B B P B P Y W R R Y B O R Y B O P W B Br W Br B B R Y Pu R 1 2 3 4 Pu B Pu Y G Y R Y G Pu G R Y B O R Y R Y R Y B R R R R B B FX High Out...

Page 375: ...B R Y R Y R Y R Y B L B Y R Y R Y B R B W R Y G Y Y Br Br B B B B B O G G G B P P G O B B B Y Pu R Pu B Pu Y R Y Pu G B O B O B O B Y G G G P W B W R B O P W P R Y P P G R Y R Y O O B Y Pu R Pu B Pu...

Page 376: ...YAMAHA MOTOR CORPORATION USA Printed in USA Feb 2004 1 CR E...

Page 377: ...SUPPLEMENTARY SERVICE MANUAL WaveRunner F1X 28197 1H 1X LIT 18616 02 93 LIT186160293 FX FX Cruiser FX High Output FX Cruiser High Output...

Page 378: ...ether with the following manuals FX140 SERVICE MANUAL F1B 28197 1E 11 LIT 18616 02 38 FX140 FX Cruiser SUPPLEMENTARY SERVICE MANUAL F1B 28197 1F 1X LIT 18616 02 45 FX High Output FX Cruiser High Outpu...

Page 379: ...vised 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 y...

Page 380: ...T YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator passenger s a bystander or a person inspecting or repairing the...

Page 381: ...icate 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...

Page 382: ...in an exploded diagram indi cate the grade of lubricant and the lubrication point F Apply Yamaha 4 stroke motor oil G Apply water resistant grease Yamaha grease A Yamaha marine grease H Apply ThreeBon...

Page 383: ...GEN INFO SPECIFICATIONS 2 SPEC PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR JET PUMP UNIT 6 JET PUMP ELECTRICAL SYSTEM 7 ELEC HULL AND HOOD 8 HULL HOOD TROUBLE A...

Page 384: ...SPECIFICATIONS GENERAL SPECIFICATIONS 3 MAINTENANCE SPECIFICATIONS 7 ENGINE 7 JET PUMP UNIT 10 HULL AND HOOD 10 ELECTRICAL 11 ENGINE 13 JET PUMP UNIT 16 HULL AND HOOD 16 ELECTRICAL 16 TIGHTENING TORQ...

Page 385: ...ring cable inspection and adjustment 42 Throttle cable inspection and adjustment 43 GENERAL 45 Drain plug inspection 45 Lubrication points 46 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS For FX FX Cruiser...

Page 386: ...Cruiser High Output 64 Air temperature display for FX Cruiser High Output 64 Speedometer average speed tripmeter display for FX Cruiser High Output 65 Water temperature display for FX Cruiser High Out...

Page 387: ...n 87 Rubber seal installation 87 REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 88 EXPLODED DIAGRAM 88 REMOVAL AND INSTALLATION CHART 88 SERVICE POINTS 91 Steering cable removal 91 SERVICE POINTS 92 Stee...

Page 388: ...115 EXPLODED DIAGRAM 115 REMOVAL AND INSTALLATION CHART 115 SERVICE POINTS 116 Reboarding step installation 116 DECK AND HULL 117 EXPLODED DIAGRAM 117 REMOVAL AND INSTALLATION CHART 117 CLEAT ASSEMBLY...

Page 389: ...imary l D numbers F1X 800101 F1Y 800101 ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the engine unit Starting serial numbers 6B6 1018901 60E 1017501 JET PUMP UNIT SE...

Page 390: ...ssembly and tune up Improvisations and using improper tools can damage the equipment NOTE For U S A and Canada use part numbers starting with J YB YM YS YU or YW For other countries use part numbers s...

Page 391: ...052 64 2 Bore stroke mm in 76 0 58 0 2 99 2 28 Compression ratio 11 9 1 Exhaust system Wet exhaust Lubrication system Dry sump Cooling system Water cooled Starting system Electric starter Ignition sys...

Page 392: ...RON 90 Fuel tank capacity L US gal Imp gal 70 18 5 15 4 Engine oil type 4 stroke motor oil Engine oil grade API SE SF SG SH SJ SL SAE 10W 30 Engine oil quantity L US qt Imp qt 4 5 4 8 4 0 without oil...

Page 393: ...n 74 0 58 0 2 91 2 28 Compression ratio 11 4 1 Exhaust system Wet exhaust Lubrication system Dry sump Cooling system Water cooled Starting system Electric starter Ignition system TCI Ignition timing D...

Page 394: ...gasoline Minimum fuel rating PON 86 RON 90 Fuel tank capacity L US gal Imp gal 70 18 5 15 4 Engine oil type 4 stroke motor oil Engine oil grade API SE SF SG SH SJ SL SAE 10W 30 Engine oil quantity L U...

Page 395: ...46 Camshaft journal diameter mm in 24 46 24 47 0 9630 0 9634 Camshaft journal to camshaft cap clearance mm in 0 03 0 06 0 0012 0 0024 Maximum camshaft runout mm in 0 03 0 0012 Timing chain Model numbe...

Page 396: ...0004 0 0015 Exhaust mm in 0 020 0 047 0 0008 0 0019 Valve stem runout mm in 0 01 0 0004 Valve spring Free length Intake mm in 38 90 1 53 Exhaust mm in 40 67 1 60 Installed length Intake mm in 34 50 1...

Page 397: ...e mm in 0 040 0 160 0 0016 0 0063 Connecting rod Big end oil clearance mm in 0 016 0 040 0 0006 0 0016 Bearing color code 1 Brown 2 Black 3 Blue 4 Green Small end inside diameter mm in 17 005 17 018 0...

Page 398: ...0 0035 0 0059 Item Unit Model FX High Output FX Cruiser High Output Jet pump Impeller material Stainless steel Number of impeller blades 3 Impeller pitch angle Degree 16 8 Impeller clearance mm in 0...

Page 399: ...G G Output peak voltage cranking unloaded V 9 2 2 000 r min unloaded V 38 5 3 500 r min unloaded V 63 2 Pickup coil resistance W B color 459 561 Pickup coil resistance R B color 459 561 Lighting coil...

Page 400: ...ulse one full turn 2 Water temperature sensor resistance Y B Y 25 C 77 F k 10 Throttle position sensor Output voltage P B O trolling speed V 0 756 0 016 Cam position sensor Output voltage G O B O Posi...

Page 401: ...eter mm in 24 44 24 45 0 9622 0 9626 Camshaft journal to camshaft cap clearance mm in 0 05 0 08 0 002 0 0031 Maximum camshaft runout mm in 0 03 0 0012 Timing chain Model number of links 92RH2015 130 1...

Page 402: ...010 0 037 0 0004 0 0015 Exhaust mm in 0 020 0 047 0 0008 0 0019 Valve stem runout mm in 0 01 0 0004 Valve spring Free length Intake mm in 38 90 1 53 Exhaust mm in 40 67 1 60 Installed length Intake mm...

Page 403: ...ove clearance mm in 0 040 0 160 0 0016 0 0063 Connecting rod Big end oil clearance mm in 0 016 0 040 0 0006 0 0016 Bearing color code 1 Brown 2 Black 3 Blue 4 Green Small end inside diameter mm in 17...

Page 404: ...inless steel Number of impeller blades 3 Impeller pitch angle Degree 16 3 Impeller clearance mm in 0 35 0 45 0 0138 0 0177 Impeller clearance limit mm in 0 6 0 0236 Drive shaft runout limit mm in 0 3...

Page 405: ...1 Secondary coil resistance k 8 5 11 5 Rectifier regulator R B Output peak voltage 3 500 r min unloaded V 15 0 Starter motor Type Constant mesh Output kW 0 8 Rating Seconds 30 Brush length mm in 12 5...

Page 406: ...V 11 6 Output pulse one full turn 2 Throttle position sensor Output voltage P B O trolling speed V 0 756 0 016 Cam position sensor Output voltage G O B O Position A V More than 4 8 Position B V Less t...

Page 407: ...0 2 0 14 Speed sensor Screw M5 4 5 2 0 52 3 8 242 LT Steering cable joint jet pump side Nut 1 6 4 0 64 4 6 Shift cable holder Nut 2 6 4 0 64 4 6 Shift cable bracket Nut 2 15 1 5 11 Steering cable grom...

Page 408: ...9 Front protector 2 3 Nut 4 5 4 0 54 3 9 Cleat Bolt M6 6 2 4 0 24 1 7 Part to tightened Part name Thread size Q ty Tightening torque Remarks N m kgf m ft lb TIGHTENING TORQUES GENERAL TORQUE This cha...

Page 409: ...tery lead 5 Positive battery lead 6 Battery 7 Steering cable 8 QSTS cable 9 Shift cable 0 Speed sensor lead A Electrical bilge pump lead B Electrical box lead C Throttle cable D Fuel hose E Handlebar...

Page 410: ...ble 8 Negative battery lead 9 Positive battery lead 0 Shift cable A QSTS cable B Steering cable C Electrical bilge pump lead D Remote control unit lead FX High Output FX Cruiser High Output E Remote c...

Page 411: ...tie When installing the remote control unit antenna holders insert the projection on each holder into a hole in the front storage compartment from the engine compartment side Connect the right operat...

Page 412: ...ilot outlet hose 6 Negative battery lead 7 Positive battery lead 8 Battery breather hose 9 QSTS cable 0 Electrical bilge pump lead A Fuel tank breather hose B Water separator C Ignition coil lead D St...

Page 413: ...G F A A A B C C C D 7 D D E 3 A 7 D C C E E D D 1 2 3 4 A 9 0 2 9 1 5 6 7 A 2 1 A E 3 B F 9 2 A 8 I G H To ventilation socket To fuel tank Route the fuel tank breather hose as shown in the illustratio...

Page 414: ...breather hose 7 Remote control unit lead FX High Output FX Cruiser High Output 8 Remote control unit FX High Output FX Cruiser High Output 9 Remote control unit antenna FX High Output FX Cruiser High...

Page 415: ...C C B B C C 2 5 4 5 4 1 3 9 3 1 2 6 8 7 A A D D Position the QSTS cable packing in the opening in the grommet so that the plastic tie is fastened around both the grommet and the packing FX Cruiser FX...

Page 416: ...tric bilge pump 4 Bilge hose 4 5 Cooling water hose from thermostat 6 Bilge hose 3 7 Bilge hose 2 8 Shift cable 9 Cooling water hose from exhaust pipe 0 Electrical box A QSTS cable B Positive battery...

Page 417: ...il coupler 9 Thermoswitch exhaust 0 Thermoswitch exhaust cou pler A Cam position sensor coupler B Oil pressure switch lead After connecting the coupler to the wiring harness insert the projection on t...

Page 418: ...sensor 8 Engine temperature sensor lead 9 Thermoswitch engine lead 0 Lighting coil lead Fasten the engine temperature sensor lead thermoswitch lead and lighting coil lead with a plastic tie Fasten th...

Page 419: ...re sensor lead To starter relay To negative battery terminal Route the starter motor and negative battery leads behind the cooling water hose Route the starter motor lead over the cooling water hose I...

Page 420: ...ose 3 Cooling water hose 4 Pressure control valve 5 Cooling water hose cooling water inlet 6 Negative battery lead 7 Breather hose To cooling water pilot outlet on starboard side To cooling water outl...

Page 421: ...es pass a plastic tie through the stay hole and then fasten the tie Set the tie in the direction shown To cooling water pilot outlet on port side To cooling water outlet at stern From cooling water in...

Page 422: ...tic tie to the oil tank boss When bundling the hoses make sure that the cooling water hose cylinder head cover to ther mostat is routed on the deck side and that the cooling water hose starboard cooli...

Page 423: ...Fuel injector 2 coupler 6 Fuel injector 1 coupler 7 Throttle position sensor coupler 8 Joint coupler Route the throttle cable between the sub wiring harness Route the sub wiring harness under the int...

Page 424: ...NG For FX FX Cruiser A B 1 2 3 4 5 6 7 2 8 A B 8 Fasten the ring which is attached to the sub wiring harness to the sensor bracket with a plastic tie Face the end of the plastic tie towards the sensor...

Page 425: ...1 1 Thermostat 2 Cooling water pilot outlet hose 3 Cooling water hose 4 Cooling water hose cooling water inlet 5 Negative battery lead To cooling water pilot outlet on starboard side To cooling water...

Page 426: ...and cooling water hoses pass a plastic tie through the stay hole and then fasten the tie Set the tie in the direction shown To cooling water pilot outlet on port side To cooling water outlet at stern...

Page 427: ...th a plastic tie to the oil tank boss When bundling the hoses make sure that the cooling water hose cylinder head cover to ther mostat is routed on the deck side and that the cooling water hose starbo...

Page 428: ...er 8 Throttle position sensor cou pler To wiring harness Route the throttle cable between the sub wiring har ness Route the sub wiring harness under the intake vacuum hose To fuel injector 3 coupler F...

Page 429: ...lean adjust Lubrication points Lubricate Intermediate housing Lubricate 1 2 2 Fuel system Inspect Fuel tank Inspect clean Trolling speed Inspect adjust Throttle shaft Inspect Cooling water passages Fl...

Page 430: ...nd forth Check the excessive play of the handle bar Steering cable inspection and adjustment 1 Inspect Jet thrust nozzle difference of distances a and b Out of specification Adjust Difference of dista...

Page 431: ...throttle lever free play adjust the trolling speed 1 Measure Throttle lever free play a Out of specification Adjust Adjustment steps Set the control grip in the neutral position Loosen the locknut 1 D...

Page 432: ...locknut 2 c Turn the adjusting nut 3 to adjust the length a and then tighten the locknut Throttle cable installation length 23 9 1 0 mm 0 94 0 04 in NOTE Apply locking agent LOCTITE to the threads of...

Page 433: ...T R Handlebar cover screw 1 1 N m 0 11 kgf m 0 8 ft lb LOCTITE 242 i Install the ribbon sub assemblies and air filter case cover T R Ribbon sub assembly bolt 6 5 N m 0 65 kgf m 4 7 ft lb LOCTITE 242 A...

Page 434: ...le body end Throttle bodies throttle cable pulley throttle cam and return spring Recommended lubricant Yamaha marine grease Yamaha grease A Water resistant grease 3 Lubricate QSTS control cables handl...

Page 435: ...ivot shaft Steering cable nozzle end QSTS cable nozzle end Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease 6 Lubricate Steering cable Steering cable joint Shift cable Sh...

Page 436: ...rmediate housing with the recom mended grease through the grease nipple 1 Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease Grease quantity Initial 10 hours 33 0 35 0 cm3...

Page 437: ...box 6 Battery 7 Speed sensor 8 Electric bilge pump 9 Cam position sensor 0 Fuel injectors A Thermoswitch exhaust B Oil pressure switch C Bypass valve motor D Intake air pressure sensor E Intake air te...

Page 438: ...on coils 5 Electrical box 6 Battery 7 Speed sensor and water tem perature sensor FX Cruiser High Output Speed sensor FX High Output 8 Electric bilge pump 9 Cam position sensor 0 Fuel injectors A Therm...

Page 439: ...N L P O K J I G F E D C B A 0 9 8 7 6 5 4 3 2 1 H J Electric fuel pump K Fuel level sensor L Left operation button M Multifunction meter N Right operation button FX Cruiser High Output O Remote contr...

Page 440: ...L W L B O R Y R Y O W L O B B O B O B O B O B O R Y R Y R Y R Y R Y R Y G Y R Y G G R G B R Y R Y G R G B R Y R Y R Y R Y G R G W L R Y P 18 20 27 30 34 O W R W B G B G Y 8 12 13 16 17 2 3 4 5 P P O...

Page 441: ...spring gauge 2 onto the plastic tie Hold the spring gauge at a 90 angle from the handlebar and then pull the spring gauge with a force of 10 kgf 22 lb When handlebar pulled When handlebar not pulled...

Page 442: ...R Y Y L R B L R P B B B G P A C B R Y W B 0 B L L R L B W B R B B B B R Y 1 21 30 5 35 15 6 14 P W P W P W D B O R Y W B B O G 4 1 L B L Y Y L 7 15 18 16 6 L R R Y L R L R L Y L R L B L Y B O O R Y R...

Page 443: ...B O B O B O B O B O B Y B Y B B Y R Y Y B Y R Y Y L R B L R P B B B G P A C B R Y W B 0 B L L R L B W B R B B B B R Y 1 21 30 5 35 15 6 14 P W P W P W D B O R Y W B B O G 4 1 L B L Y Y L 7 15 18 16 6...

Page 444: ...B O B Y R Y B Y L R B L R P B B B G R W P A B C B R W 0 B L L R B Y R Y Y B Y R W Y B R Y B B B B R 1 21 30 5 35 15 6 14 P W P W P W D B O R Y W B B O G 4 1 L B L Y Y L 7 15 18 16 6 L R R Y L R L Y L...

Page 445: ...B O B O B O B Y R Y B Y L R B L R P B B B G R W P A B C B R W 0 B L L R B Y R Y Y B Y R W Y B R Y B B B B R 1 21 30 5 35 15 6 14 P W P W P W D B O R Y W B B O G 4 1 L B L Y Y L 7 15 18 16 6 L R R Y L...

Page 446: ...W 0 L B L R B Y R Y Y B Y R W Y B R Y B B B B R 31 1 5 35 15 6 P W P W P W D B O R Y W B 4 3 2 1 8 7 6 5 B O B O 1 ECM 2 Main and fuel pump relay 3 Fuse 20 A 4 Fuse 3 A 5 Battery 6 Tacho pulse 7 Therm...

Page 447: ...of specification Replace Right operation button continuity FX Cruiser High Output Out of specification Replace Digital multimeter YU 34899 A Digital circuit tester 90890 03174 Left operation button co...

Page 448: ...60 E ELEC INDICATION SYSTEM MULTIFUNCTION METER REMOVAL Refer to STEERING CONSOLE COVER OPERATION BUTTON REMOVAL Refer to STEERING CONSOLE COVER...

Page 449: ...ation button B Black G Green L Blue P Pink R Red W White B G Black green B L Black blue G W Green white L B Blue black L R Blue red L Y Blue yellow Pu W Purple white R W Red white R Y Red yellow W B W...

Page 450: ...vel sensor 6 Left operation button B Black Gy Gray P Pink R Red W White Y Yellow B G Black green B L Black blue B Y Black yellow G W Green white L B Blue black L R Blue red L Y Blue yellow Pu W Purple...

Page 451: ...Buzzer 2 Speed sensor 3 ECM 4 Fuel level sensor 5 Left operation button B Black R Red W White Y Yellow B G Black green B Y Black yellow G W Green white L B Blue black L R Blue red Pu W Purple white R...

Page 452: ...ion meter replace the compass sen sor NOTE Be sure to check the compass display again after replacing the compass sensor If the compass display is still incorrect replace the multifunction meter Check...

Page 453: ...0 mV More than 5 V Output pulse 2 pulses one full turn Measuring steps Disconnect the coupler between the mul tifunction meter and the compass sensor 1 and then connect it to a 12 V battery as shown i...

Page 454: ...more than 5 C 9 F different from the ambient water temperature measure the speed sensor water temperature sensor resistance Digital multimeter YU 34899 A Digital circuit tester 90890 03174 Speed sens...

Page 455: ...uration using the Engine monitor of the Yamaha Diagnostic System Replace the multifunction meter Overheat warning indicator 1 Check Overheat warning indicator Does not operate Replace the multi functi...

Page 456: ...ght and check engine warning indicator blink and that the buzzer sounds intermittently Diagnostic display 1 Check Diagnostic display Does not display Replace the multi function meter Checking steps St...

Page 457: ...B W B R R B B L L R B L L Y L B 4 3 2 1 R Y R Y R Y R Y R Y R Y Pu G Pu Y Pu B Pu R R Y 0 0 0 0 Pu G R Y Pu Y R Y Pu B R Y Pu R R Y R Y R Y 9 8 W B W W W A 14 L 15 W B 21 L R 30 R Y 31 Y 37 Pu G 38 P...

Page 458: ...Y Pu G Pu Y Pu B Pu R R Y 0 0 0 0 Pu G R Y Pu Y R Y Pu B R Y Pu R R Y R Y R Y 9 8 W B W W W A 14 L 15 W B 21 L R 30 R Y 31 Y 37 Pu G 38 Pu Y 39 Pu B 40 Pu R W L R L B Gy L R L B L Y L R L R P O G B G...

Page 459: ...tput voltage Within specification Replace the mul tifunction meter Out of specification Replace the remote control unit Digital multimeter YU 34899 A Digital circuit tester 90890 03174 Remote control...

Page 460: ...1 Check Low rpm mode indicator Does not come on Replace the multi function meter Checking steps Press the unlock button 1 of remote con trol transmitter for more than four sec onds to select the low...

Page 461: ...FX High Output REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points STEERING PAD REMOVAL Follow the left Step for removal 1 Screw 4 2 Handlebar cover 1 3 Pad 1 4 Bolt 2 5 Handle...

Page 462: ...me Q ty Service points STEERING PAD REMOVAL Follow the left Step for removal 1 Screw 8 2 Screw black 2 3 Lower handlebar cover 1 4 Upper handlebar cover 1 NOTE Be sure to insert the projection on the...

Page 463: ...ep Procedure Part name Q ty Service points HANDLEBAR HOLDER REMOVAL Follow the left Step for removal 1 Throttle cable 1 NOTE Be sure to remove the throttle cable seal as shown in the illustration 2 Bo...

Page 464: ...cable to jet thrust nozzle Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Nut washer 2 2 2 QSTS converter 1 3 QSTS cable 2 1 With white tape a 4 QSTS cable 1 1 NOTE Route the QSTS cables throu...

Page 465: ...ty Service points 6 Screw 4 7 Handle boss cover 1 8 Plastic tie 2 9 Hose packing 1 10 Throttle cable 1 NOTE Position the corrugated tube for the throttle cable as shown in the illustration so that th...

Page 466: ...E Pass the QSTS cable and handlebar switch lead through the handle boss cover and then install the handlebar assembly Install the sponges of the QSTS cables as shown and make sure that the grommet is...

Page 467: ...h the plastic ties FX FX High Output FX Cruiser FX Cruiser High Output 2 3 4 1 1 1 4 1 2 3 2 Install Upper handlebar holder 1 NOTE Align the punch marks a on the handlebar with the top surface of the...

Page 468: ...h lead when the handlebar is turned to the left and right Reroute the cables and lead if there is no slack Installing steps for FX Cruiser FX Cruiser High Output Route the throttle cable 1 under the h...

Page 469: ...he bracket as shown Pull the throttle cable 2 in the direction of the arrow shown in the illustration and then fit the end of the seal 3 around inner cable Turn the adjuster 4 in out until the speci f...

Page 470: ...left Step for removal Mirror assembly Refer to MIRROR Center cover assembly Refer to STEERING CONSOLE COVER Steering cable end Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Bolt 1 2 Steering...

Page 471: ...rocedure Part name Q ty Service points 7 Nut washer 4 4 8 Steering master assembly 1 9 Bolt 4 Reverse the removal steps for installation 8 6 8 7 5 6 4 2 1 5 2 9 8 3 8 30 mm 8 35 mm 6 60 mm 20 N m 2 0...

Page 472: ...e left Step for disassembly 1 Steering shaft 1 FX Cruiser FX Cruiser High Output 2 Steering shaft 1 FX FX High Output 3 Bushing 1 4 Bushing 1 5 Buzzer 1 6 Bolt 4 7 Bracket 1 1 8 Steering sensor 1 FWD...

Page 473: ...10 Bracket 2 1 11 Bolt nut 5 5 12 Left housing 1 13 Spring holder 1 14 Spring 1 1 15 Lever 1 16 Lock 1 17 Spring 2 1 18 Right housing 1 FWD 12 7 8 6 6 3 21 21 9 10 16 15 22 20 4 5 1 2 6 25 mm 5 16 mm...

Page 474: ...ube 1 20 Rubber seal 1 21 Bushing 2 22 Steering master assembly 1 Reverse the disassembly steps for assembly FWD 12 7 8 6 6 3 21 21 9 10 16 15 22 20 4 5 1 2 6 25 mm 5 16 mm 8 30 mm 8 30 mm A A A A A A...

Page 475: ...stallation 1 Apply Instant adhesive onto the mating surfaces of the rubber seal 1 and steering master assembly 2 NOTE After assembling the steering master assem bly 2 apply instant adhesive onto the m...

Page 476: ...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 Service lid 1 Refer to FRONT HOOD Front seat as...

Page 477: ...tep Procedure Part name Q ty Service points 7 Cap 1 8 Screw 4 9 Speed sensor Speed sensor and water temperature sensor 1 1 FX FX Cruiser FX High Output FX Cruiser High Output 10 Shift cable end 1 11 P...

Page 478: ...SOR LEAD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 17 Shift cable bracket 1 18 Nut 1 19 Shift cable 1 20 Seal 1 21 Nut 1 22 Pin 1 23 QSTS cable end 1 24 Nut 1 25 QSTS cable 1 26 Pa...

Page 479: ...ing cable Removal steps Rotate the steering stopper plate 1 on the steering stopper clockwise and remove it from the steering stopper plate 2 Rotate the steering stopper plate 2 counterclockwise Remov...

Page 480: ...the projection 3 on the steering cable completely into the indentation 4 in the steering stopper Slightly lift up the steering stopper plate 5 on the steering stopper and then rotate it clockwise Rota...

Page 481: ...low the left Step for removal 1 Nut washer 4 4 2 Front hood assembly 1 3 Bolt 4 4 Bolt 2 5 Hinge assembly 1 6 Bolt 2 7 Hood lock assembly 1 8 Rivet 4 9 Service lid 1 1 2 7 6 4 8 9 3 5 1 11 10 6 30 mm...

Page 482: ...Service points 10 Rivet 4 11 Service lid 2 1 Reverse the removal steps for installation 2 7 6 4 8 9 3 5 1 11 10 6 30 mm 6 4 N m 0 64 kgf m 4 6 ft Ib LT 242 LT 242 6 18 mm 5 4 N m 0 54 kgf m 3 9 ft Ib...

Page 483: ...hull Push in the rivet pin 2 until it clicks and is flush with the top of the rivet NOTE To remove a rivet push the rivet pin in until it clicks and is below the top of the rivet Before reinstalling a...

Page 484: ...4 5 Center ornament 1 NOTE Be careful not to scratch the ornaments Install the center ornament after installing the left and right ornaments 6 Left ornament 1 7 Right ornament 1 8 Double sided tape 2...

Page 485: ...NOTE Apply soapy water to the nuts to make their installation easier Reverse the disassembly steps for assembly 2 1 4 9 5 16 mm 2 2 N m 0 22 kgf m 1 6 ft Ib 5 16 mm 2 2 N m 0 22 kgf m 1 6 ft Ib 5 17...

Page 486: ...ont hood 1 push the projections 3 on the left ornament shown in the illustration and remove the ornament from the double sided tape Remove the right ornament in the same way as the left ornament NOTE...

Page 487: ...on Install the visor and tighten the screws making sure to hold the nuts so that they do not turn T R Screw 1 1 N m 0 11 kgf m 0 8 ft lb 2 1 Double sided tape installation 1 Install Double sided tape...

Page 488: ...tape 1 on the watercraft Install the left and right ornaments from the sides as shown in the illustration Install the center ornament from above as shown in the illustration NOTE Be sure to install th...

Page 489: ...points MIRROR REMOVAL Follow the left Step for removal 1 Nut 2 2 Washer 2 3 Bolt 2 4 Bolt 4 5 Left mirror assembly 1 6 Right mirror assembly 1 Reverse the removal steps for installation 4 6 4 2 1 5 3...

Page 490: ...mbly 1 Screw 12 2 Left mirror upper cover 1 3 Screw 8 4 Left mirror 1 5 Nut 2 6 Left mirror lower cover 1 7 Right mirror upper cover 1 8 Right mirror 1 9 Right mirror lower cover 1 Reverse the disasse...

Page 491: ...points METER AND METER COVER REMOVAL Follow the left Step for removal Handlebar assembly Refer to HANDLEBAR Service lid 1 Refer to FRONT HOOD 1 Band 1 2 Multifunction meter coupler 4 3 Screw 4 4 Multi...

Page 492: ...tton 1 8 Right operation button 1 FX Cruiser High Output 9 Bolt 4 10 Washer 4 11 Band 1 12 Grommet 1 13 Multifunction meter 1 FX Cruiser High Output 14 Cover 1 FX FX Cruiser FX High Output 15 Multifun...

Page 493: ...8 4 Left side cover 1 5 Left inner side pad 2 6 Nut 6 7 Screw 4 8 Left side ornament 1 9 Right side cover 1 3 9 11 6 6 1 7 3 3 1 7 3 6 8 6 1 5 5 10 10 6 2 2 4 5 15 mm 2 2 N m 0 22 kgf m 1 6 ft Ib 6 2...

Page 494: ...the removal steps for installation 3 9 11 6 6 1 7 3 3 1 7 3 6 8 6 1 5 5 10 10 6 2 2 4 5 15 mm 2 2 N m 0 22 kgf m 1 6 ft Ib 6 23 mm 5 4 N m 0 54 kgf m 3 9 ft Ib 3 3 5 15 mm 2 2 N m 0 22 kgf m 1 6 ft I...

Page 495: ...t washer 2 2 2 Bolt 2 3 Nut washer 2 2 4 Center cover assembly 1 NOTE To remove the center cover assembly easily pull the tilt lever up 5 Nut washer 2 2 6 Bolt 2 7 Hood lock 1 8 Nut washer 2 2 FX Crui...

Page 496: ...h Output 10 Compass sensor and air temperature sensor 1 FX Cruiser High Output 11 Case cap 1 12 Inner pad 1 Reverse the removal steps for installation FW D 4 3 3 2 11 12 9 10 6 7 1 5 8 5 24 mm 6 22 mm...

Page 497: ...INSTALLATION CHART Step Procedure Part name Q ty Service points CENTER COVER DISASSEMBLY Follow the left Step for disassembly 1 Damper 2 2 Nut 4 3 Grommet 4 4 Damper 6 5 Damper 1 6 Hinge assembly 2 7...

Page 498: ...0 E HULL HOOD STEERING CONSOLE COVER EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 10 Plug 1 11 Center cover 1 Reverse the disassembly steps for assembly 9 8 7 6 7 6 10 5 4 11 1 3 1 2...

Page 499: ...w the left Step for removal Front hood assembly Refer to FRONT HOOD Mirror assembly Refer to MIRROR Right side cover Refer to STEERING CONSOLE COVER Shift cable Disconnect 1 Nut washer 3 3 2 Bolt 3 3...

Page 500: ...seat assembly 1 FX FX High Output 4 Front seat assembly 1 FX Cruiser FX Cruiser High Output 5 Bolt 4 6 Seat lock assembly 2 7 Seat storage compartment 1 8 Nut washer 4 4 9 Bolt washer 4 4 10 Deck beam...

Page 501: ...Rear seat stay 2 18 Nut 1 19 Projection 1 20 Washer 2 3 1 6 5 23 22 19 20 21 18 20 8 9 11 15 7 17 16 14 13 12 10 6 5 6 25 mm 8 30 mm 8 30 mm 18 N m 1 8 kgf m 13 ft Ib 5 4 N m 0 54 kgf m 3 9 ft Ib 26 N...

Page 502: ...h Output 25 Nut washer 2 1 26 Seat holder 1 Reverse the removal steps for installation 3 1 6 5 23 22 19 20 21 18 20 8 9 11 15 7 17 16 14 13 12 10 6 5 6 25 mm 8 30 mm 8 30 mm 18 N m 1 8 kgf m 13 ft Ib...

Page 503: ...igh Output EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points REBOARDING STEP REMOVAL Follow the left Step for removal 1 Bolt 6 2 Reboarding step 1 Reverse th...

Page 504: ...l Reboarding step Installing steps Fasten the brackets on both sides of the reboarding step in the down position with a plastic tie 1 as shown in the illustra tions so that they will not return to the...

Page 505: ...5 Plate 2 6 Bolt collar 10 10 7 Sponson 2 8 Nut washer 4 4 9 Screw 4 10 Drain plug 2 16 16 19 4 5 3 7 6 15 13 14 12 13 1 9 10 11 2 5 4 N m 0 54 kgf m 3 9 ft Ib 15 N m 1 5 kgf m 11 ft Ib 8 40 mm 16 N...

Page 506: ...front protector 1 and 2 after install ing the front protector 3 18 Front protector 2 1 19 Front protector 3 1 16 16 19 4 5 3 7 6 15 13 14 12 13 1 9 10 11 2 5 4 N m 0 54 kgf m 3 9 ft Ib 15 N m 1 5 kgf...

Page 507: ...Cruiser High Output Reverse the disassembly steps for assembly 16 16 19 4 5 3 7 6 15 13 14 12 13 1 9 10 11 2 5 4 N m 0 54 kgf m 3 9 ft Ib 15 N m 1 5 kgf m 11 ft Ib 8 40 mm 16 N m 1 6 kgf m 12 ft Ib 6...

Page 508: ...STALLATION CHART Step Procedure Part name Q ty Service points CLEAT DISASSEMBLY Follow the left Step for disassembly The following procedure applies to both of the cleat assembly 1 Circlip 2 2 Spring...

Page 509: ...HOOD CLEAT ASSEMBLY For FX Cruiser High Output SERVICE POINTS Cleat cover installation 1 Install Cleat cover NOTE Make sure that the word YAMAHA a on the cleat covers faces outward as shown in the ill...

Page 510: ...tion meter How ever if there are numerous error codes dis played be sure to check them with the Yamaha Diagnostic System Code Symptom 01 Normal 13 Pickup coil malfunction 15 Engine temperature sensor...

Page 511: ...B O R Y W L L B B R L R G R G Y G B W B W B W R B O B Y P W G O L B B O R Y R Y R Y R Y R Y R Y R Y R Y R Y B O W B W R B Y B O B Y B Y B O B R W B G G G G G G P P R Y R Y R Y R R B R B G G G B P B B...

Page 512: ...ter motor P Engine temperature sensor Q Ignition coil R Spark plug S Rectifier regulator T Battery U Electric bilge pump V Speed sensor W ECM X Slant detection switch Y Main and fuel pump relay To tac...

Page 513: ...G W W R B B B R Y R R R L R L B B O B R R Y R Y B W R Y B Y R Y B L B W B Y B L Pu R Pu B Pu Y Pu G B Y P G B O R Y W L L B B R L R G R G Y G B W B W B W R B O B Y P W G O L B B O R Y R Y R Y R Y R Y...

Page 514: ...perature sensor FX Cruiser High Output O Buzzer P Fuel level sensor Q Fuel pump R Thermoswitch engine S Starter motor T Engine temperature sensor U Ignition coil V Spark plug W Rectifier regulator X B...

Page 515: ...YAMAHA MOTOR CORPORATION USA Printed in USA Dec 2005 0 0 1 CR E...

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