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8-40

E

HULL

HOOD

ENGINE MOUNTS

ENGINE MOUNTS

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step

Procedure/Part name

Q’ty

Service points

ENGINE MOUNT REMOVAL

Follow the left “Step” for removal.

Engine unit

Refer to “ENGINE UNIT” in Chapter 5.

1

Bolt

4

2

Damper 1

1

3

Damper 2

1

4

Bolt

8

5

Engine mount

4

6

Liner

4

Reverse the removal steps for installation.

Содержание WaveRunner GP1300R

Страница 1: ...SUPPLEMENTARY SERVICE MANUAL GP1300R WaveRunner F1G 28197 1G 1X LIT 18616 02 90 LIT186160290...

Страница 2: ...to use this Supplementary Service Manual together with the fol lowing manual GP1300R SERVICE MANUAL F1G 28197 1F 11 LIT 18616 02 44 A10001 0 WaveRunner GP1300R SUPPLEMENTARY SERVICE MANUAL 2004 by Ya...

Страница 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...

Страница 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...

Страница 5: ...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...

Страница 6: ...Symbols F to H in an exploded diagram indi cate the grade of lubricant and the lubrication point F Apply Yamaha 2 stroke motor oil G Apply water resistant grease Yamaha grease A Yamaha marine grease...

Страница 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...

Страница 8: ...NUMBER H l N 1 SPECIAL SERVICE TOOLS 2 REMOVAL AND INSTALLATION 3 SPECIFICATIONS GENERAL SPECIFICATIONS 4 MAINTENANCE SPECIFICATIONS 6 ENGINE 6 JET PUMP UNIT 7 HULL AND HOOD 8 ELECTRICAL 8 TIGHTENING...

Страница 9: ...33 Drive shaft inspection 33 Drive shaft installation 33 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 36 IGNITION SYSTEM 37 WIRING DIAGRAM 37 SENSOR ASSEMBLY 39 SLANT DETECTION SWITCH 39 OFF THROTTLE STEE...

Страница 10: ...E TROUBLE ANALYSIS TROUBLE ANALYSIS 48 SELF DIAGNOSIS 48 WIRING DIAGRAM...

Страница 11: ...number F1G 809601 1 ENGINE SERIAL NUMBER The engine serial number is stamped on a label 1 attached to the engine unit Starting serial number 60T 1009801 JET PUMP UNIT SERIAL NUMBER The jet pump unit...

Страница 12: ...ervice and enable accu rate assembly and tune up Improvisations and using improper tools can damage the equipment NOTE For USA and Canada use the special ser vice tools starting with part numbers J YB...

Страница 13: ...g YB 06112 Drive shaft needle bearing installer jet pump oil seal YB 06196 8 Needle bearing attachment jet pump bearing and oil seal 90890 06614 9 Outer race installer forward gear jet pump oil seal Y...

Страница 14: ...0 15 1 12 5 Cruising range h 1 05 Engine Engine type 2 stroke Number of cylinders 3 Displacement cm3 cu in 1 297 79 1 Bore stroke mm in 84 78 3 31 3 07 Compression ratio 1 2 3 6 0 1 Intake system Ree...

Страница 15: ...Jet pump type Axial flow single stage Impeller rotation Counterclockwise viewed from rear Transmission Direct drive from engine Jet thrust nozzle horizontal angle Degree 23 23 Jet thrust nozzle trim a...

Страница 16: ...45 Wear limit mm in 0 165 0 0065 Piston pin boss inside diameter mm in 22 008 22 020 0 8665 0 8669 Piston rings Top Type Keystone Dimension B mm in 1 47 1 49 0 058 0 059 Dimension T mm in 3 0 3 2 0 11...

Страница 17: ...0 024 Reed valve stopper height mm in 10 5 10 9 0 413 0 429 Reed valve warpage limit mm in 0 2 0 079 Fuel pump Pump type Electrical Output pressure kPa kgf cm2 psi 320 8 327 2 3 21 3 27 45 62 46 53 C...

Страница 18: ...k voltage lower limit at cranking V 0 8 at 2 000 r min V 174 at 3 500 r min V 156 Stator Pickup coil W R W B W Y B Output peak voltage at cranking 1 V 6 0 at cranking 2 V 6 0 at 2 000 r min V 24 at 3...

Страница 19: ...onds 30 Brush length mm in 12 5 0 49 Wear limit mm in 6 5 0 26 Commutator undercut mm in 0 7 0 03 Limit mm in 0 2 0 01 Commutator diameter mm in 28 0 1 10 Limit mm in 27 0 1 06 Starter relay Rating Se...

Страница 20: ...ut voltage P B O at trolling speed V 0 793 0 807 Fuel sender Fuel sender resistance Position A 133 5 136 5 Position B 5 7 Fuel injector Fuel injector resistance 1 13 8 Oil level sensor Oil level senso...

Страница 21: ...locknut and adjuster throttle bodies end 1 11 1 1 8 0 Intake silencer case cover Tapping screw 6 13 1 8 0 18 1 3 Flame arrester Screw M5 6 0 8 0 08 0 6 Fuel rail Bolt M6 3 8 8 0 88 6 4 Oil pump cable...

Страница 22: ...t Bolt M6 4 3 8 0 38 2 7 572 LT 2nd 7 6 0 76 5 5 Throttle bodies joint balance plate plate reed valve assembly 1st Bolt M6 14 3 8 0 38 2 7 572 LT 2nd 7 6 0 76 5 5 Balance plate plate reed valve assemb...

Страница 23: ...impeller housing 2 Bolt M10 4 40 4 0 29 572 LT M6 1 7 8 0 78 5 6 Nozzle ring Bolt M8 2 15 1 5 11 271 LT Jet thrust nozzle Bolt M8 2 15 1 5 11 271 LT Spout hose screw clamp 1 1 2 0 12 0 9 Nozzle impel...

Страница 24: ...7 Hood lock Bolt M6 2 5 4 0 54 3 9 Hinge assembly Nut M8 2 16 1 6 11 Steering console cover assembly Nut M6 2 5 4 0 54 3 9 Bolt M6 4 2 9 0 29 2 1 Screw M5 2 2 0 0 2 1 4 Nut M8 2 16 1 6 11 Multifuncti...

Страница 25: ...6 1 3 4 0 34 2 5 Rectifier regulator Tapping screw 6 2 3 9 0 39 2 8 Coupler bracket Tapping screw 6 2 3 4 0 34 2 5 Wire harness retainer Tapping screw 6 2 4 9 0 49 3 5 Ignition coil 1 2 3 Tapping scre...

Страница 26: ...of this manual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening...

Страница 27: ...let 3 Throttle cable 4 QSTS cable 5 Steering cable 6 Speed sensor lead 7 Positive battery lead 8 Cooling water temperature sensor lead 9 Exhaust temperature sensor lead 0 Negative battery lead A Start...

Страница 28: ...I B D D A E E D D F F 1 D E F F M M C E E J J G G B C A J J L 4 6 F 2 I D H F 6 6 F 0 A 6 F G 1 1 B A 0 9 8 7 6 5 4 3 2 1 J C Align the parting line on the fuel filler neck with the lot mark on the fu...

Страница 29: ...le 7 QSTS cable 8 Speed sensor lead 9 Negative battery lead 0 Starter motor lead A Speed sensor coupler B Oil level sensor coupler C Buzzer coupler D Engine stop switch coupler E Multifunction meter c...

Страница 30: ...D E F G H I 6 K J A L M 6 C D E B B F F B B C F F E D A 1 2 3 4 5 6 7 8 9 0 5 9 3 N 0 5 N To cylinder 3 To cylinder 2 To cylinder 1 Cooling water temperature sensor Exhaust temperature sensor To posi...

Страница 31: ...7 1 A 1 Bilge hose 1 2 Bilge hose 2 3 Steering cable 4 Bilge hose 3 5 QSTS cable 6 Bilge hose 4 7 Cooling water hose cooling water inlet 8 Flushing hose 9 Speed sensor lead 0 Cooling water hose coolin...

Страница 32: ...on the fuel rail Fasten oil delivery hoses 2 and 3 and the engine temperature sensor lead with a plastic tie Fasten the sub wire harness with the plastic tie on the rib of the fuel rail Be sure to po...

Страница 33: ...tube toward the oil pump and then tape it To oil tank To check valve Install the oil hoses into the hose holders so that the holders do not cover the check valve clips Pass the bleed hose under the e...

Страница 34: ...the corrugated tube of the fuel hose to the intake silencer slide it toward the fuel pump and then tighten it with a plastic tie To cooling water pilot outlet on starboard side To electrical box Inst...

Страница 35: ...exhaust temperature sensor lead To cylinder 1 To cylinder 2 To cylinder 3 Cooling water inlet Install the white tape end of the negative battery lead to the battery Fasten the sub wire harness and wi...

Страница 36: ...s 200 hours ITEM 6 months 12 months 12 months 24 months Spark plug Inspect clean adjust Lubrication points Lubricate Intermediate housing Lubricate 1 2 2 Fuel system Inspect Fuel tank Clean Oil inject...

Страница 37: ...Procedure 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 in the base manual 1 Bolt...

Страница 38: ...CT AND IMPELLER HOUSING 1 EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Bolt 4 8 Water inlet cover 1 9 Seal 1 10 Water inlet strainer 1 11 Seal 1 Reverse the removal steps for instal...

Страница 39: ...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...

Страница 40: ...OC 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 steps...

Страница 41: ...mpeller 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 s...

Страница 42: ...ters 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...

Страница 43: ...attachment 90890 06614 Impeller inspection Refer to JET PUMP UNIT in Chapter 3 in the base manual Drive shaft inspection 1 Inspect Drive shaft Damage wear Replace Drive shaft installation 1 Install O...

Страница 44: ...hich has an inner diameter of 25 mm 0 98 in Distance a 23 5 0 1 mm 0 93 0 004 in a 3 Install Drive shaft with front bearing Spacer NOTE Press the spacer and the front bearing with a pipe that is more...

Страница 45: ...ment 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 Drive shaft needle bearing depth stop YB 34474 6 Add EPNOC grease AP 0 into th...

Страница 46: ...or 6 Throttle position sensor 7 Fuel injectors 8 Engine temperature sensor 9 Throttle switch 0 Stepping motor A Rectifier regulator B Electric bilge pump C Speed sensor D Battery E Electrical box F Co...

Страница 47: ...B O P O B O B Y B Y B Y Pu R W L Pu B B O B O P Pu Y G R R Y O G R Y G B G Y B Y Pu R B Y R Y G Y B O B O Pu B W L Pu Y P G R O O O W Y W B W R W R B B G G G B O B O B O B O B O L B B L B G G R B B B...

Страница 48: ...B O O P B O B Y B Y B Y B Y B O B B Y B W B R B Y B W B R B O P O B O B Y B Y B Y Pu R W L Pu B B O B O P Pu Y G R R Y O G R Y G B G Y B Y Pu R B Y R Y G Y B O B O Pu B W L Pu Y P G R O O O W Y W B W...

Страница 49: ...System to display the intake air temperature If the ambient temperature and the dis played intake air temperature differ by more than 5 C 9 F replace the sensor assembly SLANT DETECTION SWITCH 1 Chec...

Страница 50: ...O B O B O B O B O B O B O B O B O O O O O O O O G B G B B Y B Y G Y G Y R Y R Y G R G R G R R Y G B R Y G Y R Y R Y R Y R Y G R G G B G Y R Y R Y R Y R Y R Y B O B W L O O W L O O B W L B O W L R W B...

Страница 51: ...ing 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 100 N 10 kgf 22 lb Check that the following is displayed in the E...

Страница 52: ...AL Follow the left Step for removal Steering console cover assembly Refer to STEERING CONSOLE COVER in the base manual Steering cable end Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD in the ba...

Страница 53: ...43 E HULL HOOD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Plate 1 7 Rivet 1 Reverse the removal steps for installation 3 4 5 6 2 7 2 1 16 N m 1 6 kgf m 11 ft Ib STEERING COLUMN...

Страница 54: ...SASSEMBLY Follow the left Step for disassembly 1 Grommet 1 2 Bolt washer nut 3 2 3 3 Steering arm 1 4 Shim Install the same number of shims installed originally at the factory 5 Steering column 1 16 N...

Страница 55: ...ice points 6 Bushing 2 7 Spacer 1 8 Steering sensor 1 9 Bolt 2 10 Steering column housing 1 Reverse the disassembly steps for assembly 16 N m 1 6 kgf m 11 ft Ib 16 N m 1 6 kgf m 11 ft Ib 2 1 4 3 6 2 1...

Страница 56: ...COLUMN SERVICE POINTS Steering column assembly 1 Install Spacer 1 Bolt 2 Bolt 3 Steering sensor 4 Nut 5 NOTE Tighten the nut while pushing the steering sen sor against the spacer T R Nut 16 N m 1 6 k...

Страница 57: ...ter tank 45 50 mm 1 77 1 97 in c into the rubber hose Make sure that there is a distance of 30 mm 1 18 in d between the parting lines of the water tank and rubber hose Bow b d 2 Install Rubber hose NO...

Страница 58: ...m with the Yamaha Diagnostic System Code Symptom 01 Normal 13 Pickup coil malfunction 15 Engine temperature sensor malfunction 18 Throttle position sensor TPS malfunction 19 Incorrect battery voltage...

Страница 59: ...1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 22 B B B B B O B O B O B O B O B O B O B O B O B O P G O B B B B B B O O O O Br Br Br W W L B B Y B Y L R R W R Y B...

Страница 60: ...ickup coil L Steering sensor M Oil level sensor N Buzzer O Speed sensor P Multifunction meter Q Fuel pump R Fuel sender S Engine stop switch T Engine shut off switch U Start switch V Slant detection s...

Страница 61: ...YAMAHA MOTOR CORPORATION USA Printed in USA Dec 2004 0 0 1 CR E...

Страница 62: ...SERVICE MANUAL GP1300R WaveRunner F1G 28197 1F 11 LIT 18616 02 44 LIT186160244...

Страница 63: ...amaha has a policy of continuously improving its products models may differ in detail from the descriptions and illustrations given in this publication Use only the latest edition of this manual Autho...

Страница 64: ...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...

Страница 65: ...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...

Страница 66: ...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...

Страница 67: ...Symbols F to H in an exploded diagram indi cate the grade of lubricant and the lubrication point F Apply Yamaha 2 stroke motor oil G Apply water resistant grease Yamaha grease A Yamaha marine grease...

Страница 68: ...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...

Страница 69: ...R 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 WORKI...

Страница 70: ...D number F1G 800301 1 ENGINE SERIAL NUMBER The engine serial number is stamped on a label 1 attached to the engine unit Starting serial number 60T 1000001 JET PUMP UNIT SERIAL NUMBER The jet pump unit...

Страница 71: ...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...

Страница 72: ...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...

Страница 73: ...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...

Страница 74: ...he special ser vice tools starting with part number 90890 MEASURING AND DIAGNOSIS 1 Digital multimeter YU 34899 A 2 Digital circuit tester 90890 03174 3 Dial gauge YU 03097 90890 01252 4 Pocket tester...

Страница 75: ...69 E Test harness 6 pins YB 06848 Test harness FSW 6A 6 pins 90890 06848 F Test harness 6 pins YB 06849 Test harness SM6195021 6 6 pins 90890 06849 G Lower unit pressure vacuum tester YB 35956 A Vacuu...

Страница 76: ...8 Bearing puller assembly jet pump bearing 90890 06535 9 Stopper guide stand jet pump bearing 90890 06538 0 Driver rod L3 jet pump bearing 90890 06652 A Bearing housing needle bearing remover jet pump...

Страница 77: ...diate shaft and jet pump 90890 06606 G Drive shaft needle bearing depth stop jet pump bearing YB 34474 H Shaft holder intermediate shaft YB 06552 Crankshaft holder 20 intermediate shaft 90890 06552 I...

Страница 78: ...R 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 ENGINE 2 3 JET PUMP UNIT 2 4 HULL AND HOOD 2 5 ELECTRICAL 2 5 TIGHTENING TORQUES 2 8 SPECIFIED TORQUES 2 8 GENERAL TORQUE 2...

Страница 79: ...h 63 0 16 6 13 9 Cruising range h 0 95 Engine Engine type 2 stroke Number of cylinders 3 Displacement cm3 cu in 1 297 79 1 Bore stroke mm in 84 78 3 31 3 07 Compression ratio 1 2 5 9 1 3 5 7 1 Intake...

Страница 80: ...p Jet pump type Axial flow single stage Impeller rotation Counterclockwise viewed from rear Transmission Direct drive from engine Jet thrust nozzle horizontal angle Degree 23 23 Jet thrust nozzle trim...

Страница 81: ...041 Wear limit mm in 0 155 0 0061 Piston pin boss inside diameter mm in 22 008 22 020 0 8665 0 8669 Piston rings Top Type Keystone Dimension B mm in 1 47 1 49 0 058 0 059 Dimension T mm in 3 0 3 2 0 1...

Страница 82: ...ness mm in 0 6 0 024 Reed valve stopper height mm in 10 5 10 9 0 413 0 429 Reed valve warpage limit mm in 1 5 0 059 Fuel pump Pump type Electrical Output pressure kPa kgf cm2 psi 320 8 327 2 3 21 3 27...

Страница 83: ...cylinder 3 Output peak voltage lower limit at cranking V 0 8 at 2 000 r min V 174 at 3 500 r min V 156 Stator Pickup coil W R W B W Y B Output peak voltage at cranking 1 V 6 0 at cranking 2 V 6 0 at 2...

Страница 84: ...5 0 49 Wear limit mm in 6 5 0 26 Commutator undercut mm in 0 7 0 03 Limit mm in 0 2 0 01 Commutator diameter mm in 28 0 1 10 Limit mm in 27 0 1 06 Starter relay Rating Seconds 30 Engine temperature se...

Страница 85: ...392 F 104 153 Speed sensor Output voltage on pulse V 11 6 Output pulse one full turn 2 Throttle position sensor Output voltage P B O at trolling speed V 0 793 0 807 Fuel sender Fuel sender resistance...

Страница 86: ...Throttle cable locknut and adjuster throttle bodies end 1 11 1 1 8 0 Intake air temperature sensor intake silencer case cover 1 7 5 0 75 5 4 572 LT Intake silencer case cover intake silencer case Tapp...

Страница 87: ...ngine unit engine mount Bolt M8 4 17 1 7 12 572 LT Exhaust manifold cylinder 1st Bolt M10 10 22 2 2 16 271 LT 2nd 39 3 9 28 1st Nut M10 2 22 2 2 16 2nd 39 3 9 28 Cooling water joint exhaust manifold B...

Страница 88: ...er Bolt M6 3 14 1 4 10 242 LT Drive coupling crankshaft assembly Drive coupling 1 36 3 6 25 572 LT Flywheel magneto crankshaft assembly Bolt M10 1 74 7 4 53 E Starter motor negative battery lead crank...

Страница 89: ...ebar holder lower handlebar holder steering column Bolt M8 4 16 1 6 11 QSTS converter hull Nut M6 2 5 4 0 54 3 9 QSTS cable 1 2 locknut 2 16 1 6 11 Throttle lever assembly handlebar Screw M5 2 3 4 0 3...

Страница 90: ...4 4 6 Hood lock assembly deck Nut M6 2 6 4 0 64 4 6 Seat lock assembly seat Bolt M6 2 6 4 0 64 4 6 572 LT Bracket deck projection Nut M10 1 26 2 6 19 Bracket deck handgrip Bolt M8 2 5 2 0 52 3 8 Handg...

Страница 91: ...Tapping screw 6 6 3 9 0 39 2 8 Fuse holder stay electrical box Tapping screw 6 1 3 4 0 34 2 5 Main and fuel pump relay electrical box Tapping screw 6 1 3 9 0 39 2 8 Ground leads electrical box Bolt M...

Страница 92: ...of this manual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening...

Страница 93: ...ot outlet 3 YPVS servomotor 4 Throttle cable 5 QSTS cable 6 Steering cable 7 Speed sensor lead 8 Positive battery lead 9 Cooling water temperature sensor lead 0 Exhaust temperature sensor lead A Negat...

Страница 94: ...B D D A E E D D F F 1 F G F F M M C E E J J G G B C A J J L 5 7 H 2 K F J H 7 7 H C A B 7 H I 1 1 D C B A 0 9 8 7 6 5 4 3 2 1 L E Align the parting line on the fuel filler neck with the lot mark on th...

Страница 95: ...al bilge pump lead 8 Steering cable 9 QSTS cable 0 Speed sensor lead A Negative battery lead B Starter motor lead C Speed sensor coupler D Oil level sensor coupler E Buzzer coupler F Engine stop switc...

Страница 96: ...F G H I J K 8 M L A N O 8 C D E B B F F B B C F F E D A 1 2 3 4 5 6 7 8 9 0 A B 7 A 5 P B 7 P To cylinder 3 To cylinder 2 To cylinder 1 Cooling water temperature sensor Exhaust temperature sensor To p...

Страница 97: ...7 1 A 1 Bilge hose 1 2 Bilge hose 2 3 Steering cable 4 Bilge hose 3 5 QSTS cable 6 Bilge hose 4 7 Cooling water hose cooling water inlet 8 Flushing hose 9 Speed sensor lead 0 Cooling water hose cooli...

Страница 98: ...b on the fuel rail Fasten oil delivery hoses 2 and 3 and the engine temperature sensor lead with a plastic tie Fasten the sub wire harness with the plastic tie on the rib of the fuel rail Be sure to p...

Страница 99: ...hen tape it To oil tank To check valve Install the oil hoses into the hose holders so that the holders do not cover the check valve clips Pass the intake air temperature sensor lead over the fuel hose...

Страница 100: ...g the corrugated tube of the fuel hose to the intake silencer slide it toward the fuel pump and then tighten it with a plastic tie To cooling water pilot outlet on starboard side To electrical box Ins...

Страница 101: ...ten the throttle cable Fasten the exhaust temperature sensor lead To cylinder 1 To cylinder 2 To cylinder 3 Cooling water inlet Install the white tape end of the negative battery lead to the battery F...

Страница 102: ...ent 3 4 Trolling speed check 3 5 FUEL SYSTEM 3 7 Fuel line inspection 3 7 Water separator inspection 3 7 OIL INJECTION SYSTEM 3 8 Oil line inspection 3 8 POWER UNIT 3 9 Spark plug inspection 3 9 YPVS...

Страница 103: ...12 months 12 months 24 months Spark plug Inspect clean adjust 3 9 Lubrication points Lubricate 3 17 Intermediate housing Lubricate 1 2 2 3 19 Fuel system Inspect 3 7 Fuel tank Clean 3 7 Oil injection...

Страница 104: ...ce Adjust 2 Adjust Steering cable joint steering column end Difference of distances a and b Maximum 5 mm 0 2 in Measurement steps Set the control grip to the neutral position Turn the handlebar lock t...

Страница 105: ...then tighten the locknut T R Locknut 6 8 N m 0 68 kgf m 4 9 ft lb Throttle cable inspection and adjustment 1 Measure Throttle lever free play a Out of specification Adjust 2 Adjust Throttle lever fre...

Страница 106: ...e joint 2 Adjust QSTS cable Adjustment steps Set the control grip to the neutral posi tion Loosen the locknut 1 Remove the nut 2 and pivot pin 3 Set the jet thrust nozzle in the center position Turn t...

Страница 107: ...of specification Proceed to step 2 2 If the trolling speed is out of specification check the following If no malfunctions are found after perform ing all of the checks replace the throttle bodies Chec...

Страница 108: ...ter accumulation the fuel lines for clogs or kinks and the fuel injectors for clogs Refer to FUEL SYSTEM Refer to FUEL TANK AND FUEL PUMP MODULE in Chapter 4 Refer to FUEL INJECTION SYSTEM in Chapter...

Страница 109: ...r Cracks damage Replace the quick connector Fuel pipe Cracks damage Replace the fuel pump Refer to FUEL INJECTION SYSTEM in Chapter 4 Fuel filler hose Fuel filler cap Cracks damage Replace 2 Check Fue...

Страница 110: ...bber seal Cracks wear Replace Oil hoses Oil tank Oil filler cap Cracks damage Replace Check valve Malfunction Replace CAUTION Do not allow the oil tank to become com pletely empty If the oil tank beco...

Страница 111: ...ne 2 Clean Spark plug using a spark plug cleaner or wire brush Color guide Medium to light tan color Normal Whitish color Lean air fuel mixture Air leakage Incorrect settings Blackish color Overly ric...

Страница 112: ...o 1 2 of a turn b T R Spark plug 25 N m 2 5 kgf m 18 ft lb YPVS cable adjustment 1 Check YPVS valve position Incorrect position Adjust YPVS cables 1 and 2 Checking steps Start the engine and then turn...

Страница 113: ...ey with the hole in the cylinder Insert a 4 mm 0 16 in diameter pin through the pulley and cylinder holes Turn adjusters 3 and 4 in or out until the specified slack is obtained Turn in Slack is increa...

Страница 114: ...roduce explosive gases Keep sparks flame cigarettes etc well away If using or charging the battery in an enclosed space make sure that it is well ventilated Always shield your eyes when working near b...

Страница 115: ...service the impeller etc 2 Check Electrolyte level Low Add distilled water The electrolyte level should be between the maximum a and minimum b level marks CAUTION Use only distilled water Other types...

Страница 116: ...5 Install Battery breather hose 1 Battery Positive battery lead 2 Negative battery lead 3 with terminal extension at negative battery terminal Battery bands CAUTION Connect the positive lead to the b...

Страница 117: ...the clearance at each impeller blade as shown a total of four measure ments Install the intake duct and intake grate Refer to JET PUMP UNIT in Chapter 6 Connect the battery leads a 1 Water inlet stra...

Страница 118: ...ilge strainer and bilge strainer case Install the bilge strainer case 1 Electric bilge pump strainer inspection 1 Check Cap Strainer Contaminants Clean Checking steps Remove the battery box Refer to B...

Страница 119: ...fore lubricating the throttle cable squeeze the throttle lever and remove the rubber seal 1 Recommended lubricant Rust inhibitor 2 Lubricate QSTS control cables handlebar end NOTE Before lubricating t...

Страница 120: ...ot shaft Steering cable jet thrust nozzle end QSTS cable jet thrust nozzle end Recommended grease Yamaha marine grease Yamaha grease A water resistant grease 5 Lubricate Steering cable Steering cable...

Страница 121: ...e housing NOTE Using a grease gun fill the intermediate hous ing with the recommended grease through the grease nipples Recommended grease Yamaha marine grease Yamaha grease A water resistant grease G...

Страница 122: ...spection 4 8 Fuel pump module installation 4 8 Fuel hose connection 4 8 INTAKE DUCT AND INTAKE SILENCER 4 9 EXPLODED DIAGRAM 4 9 REMOVAL AND INSTALLATION CHART 4 9 SERVICE POINTS 4 11 Intake silencer...

Страница 123: ...PUMP 4 24 EXPLODED DIAGRAM 4 24 REMOVAL AND INSTALLATION CHART 4 24 SERVICE POINTS 4 27 Oil pump inspection 4 27 Oil hose inspection 4 27 Check valve inspection 4 27 Oil pump lever position adjustment...

Страница 124: ...VAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT in Chapter 5 Steering console cover assembly Refer to STEERING CONSOLE COVER in Chapter 8 1 Oil level sensor coupler 1 2 Plastic t...

Страница 125: ...D DIAGRAM Step Procedure Part name Q ty Service points 6 Breather hose 1 7 Oil hose 1 8 Bolt 2 9 Strap 2 10 Oil tank 1 11 Hose screw clamp 1 12 Oil filler hose 1 13 Oil level sensor 1 Reverse the remo...

Страница 126: ...Contaminants Clean Frays tears Replace Rubber seal Cracks wear Replace Oil hoses Oil filler cap Cracks damage Replace Check valve Faulty Replace Oil level sensor inspection Refer to INDICATION SYSTEM...

Страница 127: ...r hose 1 2 Check valve 1 3 Fuel tank breather hose 1 4 Fuel sender coupler 1 NOTE Make sure that the inner seal of the coupler is installed properly before connecting the coupler 5 Fuel pump module co...

Страница 128: ...1 11 Seal 1 12 Fuel sender assembly 1 13 Hose screw clamp 2 14 Fuel filler hose 1 15 Nut 1 16 Fuel filler neck 1 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 f...

Страница 129: ...tank 1 19 Bolt 2 20 Strap 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 Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 16 17 1...

Страница 130: ...6 2 3 8 7 5 2 Remove Fuel pump module 1 NOTE Remove the float 2 at an angle to avoid catch ing it on the fuel tank 2 1 Fuel sender disassembly 1 Disconnect Fuel sender coupler 2 Remove Retainer 1 NOTE...

Страница 131: ...f the check valve and then blow into the hose Air should come out from end B Connect the hose to end B of the check valve and then blow into the hose Air should not come out from end A A A B B 1 Fuel...

Страница 132: ...AL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY in Chapter 5 1 Intake silencer screw clamp 1 2 Intake silencer 1 3 Intake silencer pipe screw clamp 2 4 I...

Страница 133: ...4 10 E FUEL INTAKE DUCT AND INTAKE SILENCER EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Bolt collar grommet 1 1 1 7 Intake duct 1 Reverse the removal steps for installation...

Страница 134: ...NTAKE SILENCER SERVICE POINTS Intake silencer installation 1 Install Intake silencer pipe Intake silencer pipe screw clamps 1 Intake silencer Intake silencer screw clamp 2 NOTE Set the screw clamps in...

Страница 135: ...ke silencer pipe Refer to INTAKE DUCT AND INTAKE SILENCER 1 Plastic tie 1 NOTE Fasten the wire harness lighting coil pickup coil ground lead and sub wire harness together with the plastic tie 2 Sub wi...

Страница 136: ...tic tie 5 Cover 1 6 Fuel hose 1 7 Throttle bodies screw clamp 3 Tighten the screw clamp until there is no clearance between the spacer and the screw clamp 8 Bolt 2 9 Throttle bodies assembly 1 10 Thro...

Страница 137: ...NCER CASE AND THROTTLE BODIES REMOVAL Follow the left Step for removal 1 Intake air temperature sensor coupler 1 2 Intake silencer case screw clamp 3 Tighten the screw clamp until there is no clearanc...

Страница 138: ...Step for disassembly 1 Intake air temperature sensor 1 2 Tapping screw 13 3 Intake silencer case cover 1 4 Gasket 1 5 Screw 6 6 Flame arrester 3 7 Intake silencer case joint 3 8 Intake silencer case 1...

Страница 139: ...e Q ty Service points THROTTLE BODIES DISASSEMBLY Follow the left Step for disassembly 1 Hose clamp 2 2 Fuel hose 1 3 Grommet 1 4 Quick connector 1 5 Sub wire harness 1 6 Bolt 3 7 Fuel rail 1 8 Spacer...

Страница 140: ...GRAM Step Procedure Part name Q ty Service points 9 Fuel injector 3 10 O ring 3 11 Throttle bodies 1 Reverse the disassembly steps for assembly 6 6 6 7 5 2 3 1 9 10 9 10 9 10 11 4 1 8 8 N m 0 88 kgf m...

Страница 141: ...urely fasten them Fuel hose disconnection WARNING Before disconnecting the fuel hoses remove the fuel tank filler cap to reduce any pressure inside the fuel tank and then disconnect the negative batte...

Страница 142: ...e 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 can spray out 1 2 a 1 2 3 Cover t...

Страница 143: ...njector using the Stationary Test of the Yamaha Diagnostic System Digital multimeter YU 34899 A Digital circuit tester 90890 03174 Fuel injector resistance reference data 13 8 at 21 C 70 F Throttle bo...

Страница 144: ...2 1 a b 2 Install Fuel hose 1 NOTE Install the checker tab 2 of the fuel hose in the position shown in the illustration in rela tion to the throttle bodies Install the clamp with the crimped section a...

Страница 145: ...t the fuel hose and check the O ring for damage and that it is properly installed Throttle cable installation 1 Adjust Oil pump lever position Refer to OIL PUMP 2 Adjust Throttle lever free play Refer...

Страница 146: ...place the fuel pump module 5 Remove Fuel pressure gauge Fuel pressure gauge adapter NOTE To disconnect the fuel pressure gauge adapter follow the procedures for disconnect ing a fuel hose Refer to Fue...

Страница 147: ...D INTAKE SILENCER 1 Bolt 1 2 Oil pump cable 1 Route the oil pump cable outside of the bleed hose and the oil delivery hoses 3 Plastic tie 3 4 Oil delivery hose 1 1 5 Oil delivery hose 2 1 6 Oil delive...

Страница 148: ...12 Oil suction hose 1 13 Oil return hose 1 Reverse the removal steps for installation 5 3 3 3 7 8 10 12 9 11 6 20 mm 13 4 6 6 12 mm 7 6 N m 0 76 kgf m 5 5 ft Ib 5 10 mm 2 1 LT 572 LT 2nd 4 4 N m 0 44...

Страница 149: ...oints OIL PUMP HOSES AND CABLE REMOVAL Follow the left Step for removal 1 Bleed hose 1 2 Air bleed screw 1 3 Gasket 1 4 Bleed hose stay 1 5 Oil delivery hose 3 6 Oil delivery hose 1 1 7 Oil delivery h...

Страница 150: ...e oil delivery hoses and the oil suc tion hose are not full of oil fill them up Bleed the oil pump delivery hoses and oil suction hose after installing them Check valve inspection 1 Check Check valve...

Страница 151: ...s Remove the intake duct Refer to INTAKE DUCT AND INTAKE SILENCER Loosen the locknut 1 and adjusting nut 2 of the throttle cable Adjust the throttle cable length to 18 5 1 0 mm 0 728 0 039 in a Tighte...

Страница 152: ...e to it fasten it with a locking tie Recommended engine oil YAMALUBE 2 W oil only Loosen the air bleed screw 1 two full turns and check that both the oil and air bubbles flow out When there are no air...

Страница 153: ...10 ENGINE UNIT 5 13 EXPLODED DIAGRAM 5 13 REMOVAL AND INSTALLATION CHART 5 13 SERVICE POINTS 5 15 Shim removal 5 15 Engine mount inspection 5 15 Coupling clearance inspection 5 15 EXHAUST MANIFOLD 5 1...

Страница 154: ...Piston ring inspection 5 34 Piston pin and bearing inspection 5 35 Piston installation 5 36 GENERATOR AND STARTER MOTOR 5 37 EXPLODED DIAGRAM 5 37 REMOVAL AND INSTALLATION CHART 5 37 SERVICE POINTS 5...

Страница 155: ...esult in a loss of performance 1 Start the engine and warm it up until the engine temperature is 48 C 118 F 2 Remove Seat 3 Disconnect Spark plug caps 4 Remove Spark plugs CAUTION Before removing the...

Страница 156: ...e compression pressure is extremely high check the cylinder head and piston crown for carbon deposits Carbon deposits Eliminate c If the compression pressure is below specification and the compression...

Страница 157: ...OVAL Follow the left Step for removal YPVS servomotor and YPVS servomotor bracket Refer to YPVS SERVOMOTOR in Chapter 7 Battery box Refer to BATTERY BOX in Chapter 8 1 Spark plug cap 3 2 Exhaust tempe...

Страница 158: ...ing water hose 1 1 To cooling water pilot outlet port Route the cooling hose under the exhaust chamber assembly 7 Screw clamp cooling water hose 1 1 To cooling water outlet stern Contact the corrugate...

Страница 159: ...exhaust joint off 9 Inner exhaust joint screw clamp 2 10 Exhaust joint screw clamp 1 11 Water lock band 1 Slide the water lock off 12 Nut 2 13 Bolt 4 14 Intermediate housing grease hose 1 15 Eye 2 NOT...

Страница 160: ...ty Service points 16 Bolt 2 17 Bolt 1 18 Bolt 1 19 Bolt 1 20 Muffler stay 2 1 21 Muffler assembly 1 NOTE Remove the cylinder head if it is difficult to remove the muffler assembly 22 Outer exhaust joi...

Страница 161: ...rt name Q ty Service points MUFFLER DISASSEMBLY Follow the left Step for disassembly 1 Exhaust temperature sensor 1 2 Cooling water temperature sensor 1 3 Bolt 2 4 Muffler stay 1 5 Dowel pin 1 6 Bolt...

Страница 162: ...XPLODED DIAGRAM Step Procedure Part name Q ty Service points 11 Catalytic converter 1 12 Gasket 1 13 Pin 2 14 Bolt 6 15 Mixing joint 1 16 Gasket 1 17 Muffler 1 Reverse the disassembly steps for assemb...

Страница 163: ...ust joint Muffler assembly Inner exhaust joint screw clamp Outer exhaust joint screw clamp NOTE Align the projection a on the exhaust joint with the muffler assembly boss Use the angles shown in the i...

Страница 164: ...t name Q ty Service points EXHAUST CHAMBER ASSEMBLY REMOVAL Follow the left Step for removal Muffler assembly Refer to MUFFLER ASSEMBLY 1 Screw clamp cooling water hose 1 1 To cooling water pilot outl...

Страница 165: ...aust manifold 9 Exhaust chamber assembly 1 NOTE Before installing the exhaust chamber assembly connect the cooling water hose and fasten it with the screw clamp to the exhaust chamber part 8 and place...

Страница 166: ...NSTALLATION CHART Step Procedure Part name Q ty Service points EXHAUST CHAMBER DISASSEMBLY Follow the left Step for disassembly 1 Bolt 5 2 Bolt 1 3 Exhaust chamber joint 1 4 Gasket 1 5 Pin 2 6 Exhaust...

Страница 167: ...T CHAMBER ASSEMBLY Silencer pipe and intake duct Refer to INTAKE DUCT AND INTAKE SILENCER in Chapter 4 Throttle bodies assembly Refer to FUEL INJECTION SYSTEM in Chapter 4 Oil pump cable Refer to OIL...

Страница 168: ...oupler 9 5 Bolt collar 1 1 6 Coupling cover 1 7 Bolt washer 4 4 8 Engine unit 1 9 Shim As required NOTE Install shims in their original positions Reverse the removal steps for installation 4 8 3 6 5 7...

Страница 169: ...gine mounts Cracks damage Replace Refer to ENGINE MOUNTS in Chapter 8 Coupling clearance inspection 1 Measure Clearance a Clearance b with the rubber damper Out of specification Adjust NOTE Measure th...

Страница 170: ...NSTALLATION CHART Step Procedure Part name Q ty Service points EXHAUST MANIFOLD REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT 1 Bolt 4 2 Bolt 6 3 Nut 2 4 Exhaust manifold 1...

Страница 171: ...ART Step Procedure Part name Q ty Service points EXHAUST MANIFOLD DISASSEMBLY Follow the left Step for disassembly 1 Screw clamp cooling water hose 1 1 2 Bolt 6 3 Cooling water joint 1 4 O ring 3 5 Ex...

Страница 172: ...ty Service points REED VALVE REMOVAL Follow the left Step for removal Throttle bodies assembly Refer to FUEL INJECTION SYSTEM in Chapter 4 Oil delivery hoses Refer to OIL PUMP in Chapter 4 1 Grease h...

Страница 173: ...DIAGRAM Step Procedure Part name Q ty Service points 7 Balance plate 1 8 Gasket 1 9 Reed valve plate 1 10 Reed valve assembly 3 11 Screw 24 12 Valve stopper 6 13 Reed valve 6 Reverse the removal step...

Страница 174: ...heck Reed valves Cracks damage Replace 2 Measure Valve warpage a Out of specification Replace 3 Measure Valve stopper height b Out of specification Replace Valve warpage limit 1 5 mm 0 059 in Valve st...

Страница 175: ...ep Procedure Part name Q ty Service points YPVS REMOVAL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY 1 Bolt 12 2 YPVS valve cover 3 3 Gasket 3 4 Spacer 2...

Страница 176: ...PVS EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Bolt 3 NOTE For installation align the hole a in the YPVS shaft with the bolt 9 Shaft 3 1 10 Shaft 2 1 11 Shaft 1 1 12 YPVS valve ar...

Страница 177: ...Part name Q ty Service points 14 YPVS valve assembly 3 NOTE Install the YPVS valves with the recess b facing toward the stern 15 Oil seal 6 NOTE If the YPVS shaft is removed the oil seal must be repl...

Страница 178: ...nded scraper 1 CAUTION Do not use a sharp instrument to avoid damaging or scratching the surfaces 1 2 Check YPVS valve assembly Cracks damage wear Replace YPVS valve installation 1 Install Oil seals N...

Страница 179: ...roper sequence as shown and in three stages Tighten bolts G and H in two stages 5 Bolt 12 6 Bolt 4 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 3rd 35 N m 3 5 kgf m 25 ft Ib 2nd 35 N m...

Страница 180: ...1 Anode 2 Reverse the removal steps for installation 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 3rd 35 N m 3 5 kgf m 25 ft Ib 2nd 35 N m 3 5 kgf m 25 ft Ib 1st 15 N m 1 5 kgf m 11 ft...

Страница 181: ...cylinder head or spark plug bore threads 2 Check Cylinder head water jacket Corrosion mineral deposits Clean or replace 3 Measure Cylinder head warpage using a straightedge and thickness gauge Out of...

Страница 182: ...me Q ty Service points CYLINDER REMOVAL Follow the left Step for removal YPVS Refer to YPVS Cylinder head Refer to CYLINDER HEAD 1 Engine temperature sensor 1 2 Bolt 12 NOTE Tighten the bolts in a cri...

Страница 183: ...5 29 E POWR CYLINDERS EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 4 Cylinder gasket 3 5 Pin 6 Reverse the removal steps for installation Not reusable...

Страница 184: ...der bore D using a cylinder gauge Out of specification Replace cylinder and piston as a set NOTE Measure the cylinder bore parallel to and at a right angle to the crankshaft Then average the measureme...

Страница 185: ...ervice points PISTON REMOVAL Follow the left Step for removal Cylinders Refer to CYLINDERS 1 Piston pin clip 2 CAUTION Do not align the open end of the clip with the piston pin slot a 2 Piston pin 1 3...

Страница 186: ...POWR PISTONS EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 5 Bearing 1 6 Piston ring 2 CAUTION Align each end gap with its respective locating pin Reverse the removal steps for instal...

Страница 187: ...on pin clip from falling into the crankcase Piston inspection 1 Eliminate Carbon deposits from the piston crown and piston ring grooves 2 Check Piston wall Score marks Repair with 600 800 grit wet san...

Страница 188: ...OTE New cylinder bore size 84 000 a 1 000 Example a 12 84 012 mm PISTON CLEARANCE CYLINDER BORE PISTON DIAMETER Piston to cylinder clearance 0 100 0 105 mm 0 0039 0 0041 in Cylinder size indication a...

Страница 189: ...in Piston pin and bearing inspection 1 Check Piston pins Bearings Signs of heat discoloration Replace 2 Measure Piston pin outside diameter using a micrometer 1 Out of specification Replace Piston pi...

Страница 190: ...play at the small end of the connecting rod as shown Free play wear at the small end Replace the piston pin connecting rod small end bearing or all parts Piston installation 1 Install Top ring 2nd rin...

Страница 191: ...RT Step Procedure Part name Q ty Service points GENERATOR COVER REMOVAL Follow the left Step for removal Oil pump Refer to OIL PUMP in Chapter 4 1 Bolt 1 2 Bolt 7 NOTE Do not apply locking agent to th...

Страница 192: ...5 38 E POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Pin 2 9 Bolt 2 10 Bolt 2 11 Exhaust chamber bracket 1 Reverse the removal steps for installation...

Страница 193: ...ese washers hold the pickup coil leads Be sure not to pinch the leads between the projections and the washers when installing the bolts 3 Bolt 2 4 Cable holder 1 5 Bolt 6 6 Pickup coil 3 7 Bolt 1 4 9...

Страница 194: ...lead 2 9 Bolt 3 10 Lighting coil 1 Reverse the removal steps for installation 4 9 N m 0 49 kgf m 3 5 ft Ib 5 14 mm 14 N m 1 4 kgf m 10 ft Ib 6 35 mm 14 N m 1 4 kgf m 10 ft Ib 6 14 mm 1 2 2 6 6 5 5 10...

Страница 195: ...re Part name Q ty Service points GENERATOR ROTOR AND STARTER MOTOR REMOVAL Follow the left Step for removal 1 Drive coupling 1 2 Flywheel magneto bolt 1 3 Flywheel magneto 1 NOTE Degrease the flywheel...

Страница 196: ...ERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Negative battery lead 1 8 Nut washer 1 1 9 Starter motor lead 1 10 Starter motor 1 Reverse the removal steps fo...

Страница 197: ...M REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points STARTER CLUTCH DISASSEMBLY Follow the left Step for disassembly 1 Clip 1 2 Clip stopper 1 3 Spring seat 1 4 Spring 1 5 Was...

Страница 198: ...MOTOR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 9 Weight 3 10 Spring ring 1 NOTE Install the spring ring after installing the weights plate and circlip 11 Pinion gear 1 Reverse th...

Страница 199: ...re used for removal Coupler wrench YW 06551 90890 06551 Flywheel holder YW 06550 90890 06550 T R Drive coupling 36 N m 3 6 kgf m 25 ft lb LOCTITE 572 Flywheel magneto removal and installation 1 Remove...

Страница 200: ...so that the puller plate is parallel to the generator rotor Universal puller YB 06117 Flywheel puller 90890 06521 Set bolt M8 60 mm Drive coupling inspection 1 Check Drive coupling Damage wear Replac...

Страница 201: ...ice points CRANKCASE DISASSEMBLY Follow the left Step for disassembly Pistons Refer to PISTONS Generator cover and starter motor Refer to GENERATOR AND STARTER MOTOR 1 Bolt 6 2 Mount bracket 2 3 Pin 4...

Страница 202: ...5 48 E POWR CRANKCASE EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Lower crankcase 1 9 Pin 2 10 Crankshaft assembly 1 11 Upper crankcase 1 Reverse the disassembly steps for assembly...

Страница 203: ...crankcase Crankcase Cracks damage Replace Crankcase installation 1 Apply Gasket Maker to the crankcase mating surfaces NOTE Before applying Gasket Maker clean the crankcase mating surfaces 2 Check Cr...

Страница 204: ...FT REMOVAL Follow the left Step for removal Crankcase Refer to CRANKCASE 1 Oil seal 1 2 Bearing 1 3 Oil seal 1 1 4 Oil seal 2 1 5 Crankshaft assembly 1 CAUTION Install the bearing locating pins into t...

Страница 205: ...lection B using a dial gauge Out of specification Replace Maximum deflection B 0 05 mm 0 002 in C 0 15 mm 0 006 in 3 Measure Big end side clearance D using a thickness gauge Out of specification Repla...

Страница 206: ...CRANKSHAFT 5 Check Bearings Damage pitting Replace NOTE Before checking bearings thoroughly clean them Immediately after checking the bearings lubricate them to prevent rust 6 Check Oil seals Damage w...

Страница 207: ...e shaft inspection 6 11 Drive shaft installation 6 12 TRANSOM PLATE AND HOSES 6 14 EXPLODED DIAGRAM 6 14 REMOVAL AND INSTALLATION CHART 6 14 SERVICE POINTS 6 16 Bilge strainer inspection 6 16 Electric...

Страница 208: ...CHART Step Procedure Part name Q ty Service points JET PUMP UNIT REMOVAL Follow the left Step for removal 1 Bolt 2 2 Bolt 2 3 Intake grate 1 4 Bolt 4 5 Intake duct 1 6 Felt seal 1 7 Screw 4 8 Speed s...

Страница 209: ...LODED DIAGRAM Step Procedure Part name Q ty Service points 9 Bolt 4 10 Ride plate 1 11 QSTS cable joint 1 12 Plastic tie bilge hose 5 1 1 13 Nut washer 1 2 14 Steering cable joint 1 15 Screw clamp spo...

Страница 210: ...DIAGRAM Step Procedure Part name Q ty Service points 18 Jet pump unit assembly 1 NOTE Clean the mating surfaces before applying Yamabond No 4 19 Dowel pin 2 20 Impeller housing 2 1 21 Dowel pin 2 Reve...

Страница 211: ...AM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points SPEED SENSOR DISASSEMBLY Follow the left Step for disassembly 1 Paddle wheel set 1 2 Speed sensor 1 Reverse the disassemb...

Страница 212: ...VAL AND INSTALLATION 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 1 Bolt 2 2 Colla...

Страница 213: ...CHART Step Procedure 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 Nozzl...

Страница 214: ...MPELLER DUCT AND IMPELLER HOUSING 1 EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Bolt 4 8 Water inlet cover 1 9 Seal 1 10 Water inlet strainer 1 11 Seal 1 Reverse the removal steps...

Страница 215: ...LODED DIAGRAM REMOVAL AND INSTALLATION CHART 1 EPNOC grease AP 0 Step Procedure Part name Q ty Service points IMPELLER DUCT AND DRIVE SHAFT DISASSEMBLY Follow the left Step for disassembly 1 Impeller...

Страница 216: ...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...

Страница 217: ...ve Nut 1 3 Remove Drive shaft 1 NOTE Remove the drive shaft using a press Drive shaft holder YB 06151 Drive shaft holder 5 90890 06519 Drive shaft holder YB 06151 Drive shaft holder 5 90890 06519 4 Re...

Страница 218: ...bearing remover YB 06112 Needle bearing attachment 90890 06614 6 Remove Oil seal NOTE Remove the oil seals using a press Impeller inspection Refer to JET PUMP UNIT in Chapter 3 Drive shaft inspection...

Страница 219: ...n 2 Install Front bearing Drive shaft NOTE Install the front bearing and drive shaft using a press 3 Install Drive shaft with front bearing Spacer Impeller duct NOTE Press the spacer and the front bea...

Страница 220: ...lable use a washer or pipe with an outer diameter of 47 50 mm 1 85 1 97 in and an inner diameter of 21 25 mm 0 83 0 98 in Drive shaft needle bearing depth stop YB 34474 6 Add EPNOC grease AP 0 into th...

Страница 221: ...ANSOM PLATE AND HOSE 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 screw clamp 3 2 Cooling water hos...

Страница 222: ...rocedure Part name Q ty Service points 6 Bilge hose 4 1 7 Band 1 8 Electric bilge pump assembly 1 9 Hose clamp 1 10 Bilge hose 3 1 11 Bilge strainer 1 12 Nut washer 4 4 13 Transom plate 1 14 Plastic t...

Страница 223: ...o 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 Check Bilge hoses Cracks damage wear Repl...

Страница 224: ...art name Q ty Service points BEARING HOUSING REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT in Chapter 5 1 Rubber coupling 1 2 Bolt 3 3 Intermediate housing assembly 1 4 Pin...

Страница 225: ...ON CHART Step Procedure Part name Q ty Service points BEARING HOUSING DISASSEMBLY Follow the left Step for disassembly 1 Grease hose 1 2 Grease nipple 1 3 Grease nipple stay 1 4 Nipple 2 5 Driven coup...

Страница 226: ...PLODED DIAGRAM Step Procedure Part name Q ty Service points 9 Oil seal 1 10 Oil seal 1 11 Oil seal 1 12 Circlip 1 13 Bearing 1 14 Circlip 1 Reverse the disassembly steps for assembly Not reusable Not...

Страница 227: ...ft 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 intermedi...

Страница 228: ...t and grease hose inspection 1 Check Bearing Rotate the inner race by hand Damage rough movement Replace Intermediate drive shaft Damage pitting Replace Grease hose Cracks wear Replace Driven coupling...

Страница 229: ...ive shaft NOTE Support the intermediate housing with steel blocks 1 and install the intermediate drive shaft using a press Driver handle large YB 06071 Driver rod LS 90890 06606 Drive shaft taper roll...

Страница 230: ...Install shims in their original positions if the intermediate housing is not replaced Installation steps Install the intermediate housing Measure the clearance a at each bolt hole Install the suitabl...

Страница 231: ...voltage measurement 7 9 Peak voltage adapter 7 10 Test harness 7 10 IGNITION SYSTEM 7 11 WIRING DIAGRAM 7 11 IGNITION SPARK GAP 7 13 IGNITION SYSTEM PEAK VOLTAGE 7 14 BATTERY 7 16 FUSE 7 16 SPARK PLU...

Страница 232: ...ING SYSTEM 7 27 WIRING DIAGRAM 7 27 BATTERY 7 28 WIRING CONNECTIONS 7 28 FUSES 7 28 START SWITCH 7 28 STARTER RELAY 7 29 MAIN AND FUEL PUMP RELAY 7 29 STARTER MOTOR 7 30 EXPLODED DIAGRAM 7 30 REMOVAL...

Страница 233: ...AIN AND FUEL PUMP RELAY 7 45 INDICATION SYSTEM 7 46 WIRING DIAGRAM 7 46 FUSE 7 48 BATTERY 7 48 ENGINE TEMPERATURE SENSOR 7 48 COOLING WATER TEMPERATURE SENSOR 7 48 EXHAUST TEMPERATURE SENSOR 7 48 MAIN...

Страница 234: ...or 7 Throttle position sensor 8 Fuel injectors 9 Engine temperature sensor 0 Throttle switch A Stepping motor B Rectifier regulator C Electric bilge pump D Speed sensor E Battery F Electrical box G Co...

Страница 235: ...sket 1 5 Tapping screw 2 6 Lead holder 1 7 Bolt 2 8 Positive battery lead 1 9 Stator motor lead 1 3 9 N m 0 39 kgf m 2 8 ft Ib 6 30 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 6 25 mm 3 4 N m 0 34 kgf m 2 5 ft Ib...

Страница 236: ...screw 2 17 Rectifier regulator 1 18 Tapping screw 2 19 Coupler bracket 1 20 Bolt 2 3 9 N m 0 39 kgf m 2 8 ft Ib 6 30 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 6 25 mm 3 4 N m 0 34 kgf m 2 5 ft Ib 6 16 mm 4 9 N...

Страница 237: ...ead 1 28 Spark plug lead 1 cap 1 1 29 Spark plug lead 2 cap 1 1 30 Spark plug lead 3 cap 1 1 31 Fuse 3 A 2 3 9 N m 0 39 kgf m 2 8 ft Ib 6 30 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 6 25 mm 3 4 N m 0 34 kgf m...

Страница 238: ...mbly steps for assembly 3 9 N m 0 39 kgf m 2 8 ft Ib 6 30 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 6 25 mm 3 4 N m 0 34 kgf m 2 5 ft Ib 6 16 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 6 30 mm 3 4 N m 0 34 kgf m 2 5 ft Ib...

Страница 239: ...m 5 5 ft Ib 6 16 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 6 25 mm 2 3 4 5 1 1 Ignition coils 2 Starter relay 3 Fuse holders 4 Main and fuel pump relay 5 Rectifier regulator White tape To starter motor To posi...

Страница 240: ...D INSTALLATION CHART Step Procedure Part name Q ty Service points ECM AND SLANT DETECTION SWITCH REMOVAL Follow the left Step for removal 1 Nut washer 2 2 2 ECM 1 3 ECM coupler 1 4 Nut washer 2 2 5 Sl...

Страница 241: ...wered by dry batteries check the battery voltage periodically and replace the batteries if necessary Digital tester NOTE Throughout this chapter the part numbers of the specified digital testers have...

Страница 242: ...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 kno...

Страница 243: ...l circuit tester Make sure that the positive pin the mark facing up as shown on the adapter is installed into the positive terminal of the tester The test harness is needed for the following tests Vol...

Страница 244: ...B W B R B Y B W B R B O P O B O B Y B Y B Y Pu R Pu B B O B O P Pu Y G R R Y O G B G G B G Y B Y Pu R B Y B G G Y B O B O Pu B Pu Y P G R O O O W Y W B W R W R B B G G G B O B O B O B O B O L B B L B...

Страница 245: ...L B O O O P B O O P B G B O B Y B G B O B Y B Y B Y B O B B Y B W B R B Y B W B R B O P O B O B Y B Y B Y Pu R Pu B B O B O P Pu Y G R R Y O G B G G B G Y B Y Pu R B Y B G G Y B O B O Pu B Pu Y P G R...

Страница 246: ...le gas or liquids away since this test can produce sparks 1 Check Ignition spark gap Below specification Check the ECM output peak voltage Check the ignition coil for resistance For USA and Canada For...

Страница 247: ...nition system but possibly with the spark plug s or another component 1 Measure ECM output peak voltage Below specification Measure the pickup coil output peak voltage NOTE To crank the engine connect...

Страница 248: ...ng coil NOTE To crank the engine connect the engine shut off cord lanyard to the engine shut off switch and then press the start switch and engine stop switch simultaneously Test harness 6 pins YB 068...

Страница 249: ...in Chapter 3 FUSE Refer to STARTING SYSTEM SPARK PLUGS Refer to POWER UNIT in Chapter 3 SPARK PLUG LEAD ASSEMBLY 1 Check Spark plug lead assembly Cracks damage Replace Test harness 6 pins YB 06848 Tes...

Страница 250: ...istance measurement Primary coil resistance Black white B W Body 0 26 0 36 at 20 C 68 F 2 Measure Secondary coil resistance Out of specification Replace Secondary coil resistance Black white B W Spark...

Страница 251: ...esistance when the speci fied temperatures are reached INTAKE AIR TEMPERATURE SENSOR 1 Measure Intake air temperature sensor resistance at the specified temperatures Out of specifications Replace Inta...

Страница 252: ...temperature is reached Suspend the cooling water temperature sensor in a container filled with oil Slowly heat the oil Measure the resistance when the speci fied temperatures are reached EXHAUST TEMPE...

Страница 253: ...sconnecting terminal 1 2 or 3 Connect the tester leads between main and fuel pump relay terminals 6 and 8 Connect terminal 7 to the positive bat tery terminal Connect terminal 4 to the negative bat te...

Страница 254: ...06869 Lower unit pressure vacuum tester YB 35956 A Vacuum pressure pump gauge set 90890 06756 Atmospheric pressure sensor output voltage Pink green P G Black orange B O 1 101 3 kPa 1 01 kgf cm2 14 4...

Страница 255: ...E ELEC IGNITION SYSTEM SLANT DETECTION SWITCH 1 Check Slant detection switch continuity Out of specification Replace Position Lead color Blue black L B Black orange B O Normal operation Overturned UP...

Страница 256: ...B O B Y B Y B Y Pu R Pu B B O B O P Pu Y G R R Y O G B G G B G Y B Y Pu R B Y B G G Y B O B O Pu B Pu Y P G R O R Y R Y B G B O B O L B B L B O O O B B B R Y R Y R Y R Y R Y R Br B L R Y L R Y B L B O...

Страница 257: ...O P B G B O B O B Y B Y B Y B O B O B Y B Y B Y Pu R Pu B B O B O P Pu Y G R R Y O G B G G B G Y B Y Pu R B Y B G G Y B O B O Pu B Pu Y P G R O R Y R Y B G B O B O L B B L B O O O B B B R Y R Y R Y R...

Страница 258: ...PUMP 1 Check Fuel pump operating sound No sound Measure the fuel pressure Refer to FUEL INJECTION SYSTEM in Chapter 4 FUEL SENDER 1 Measure Fuel sender resistance Out of specification Replace Float po...

Страница 259: ...EMPERATURE SENSOR Refer to IGNITION SYSTEM COOLING WATER TEMPERATURE SENSOR Refer to IGNITION SYSTEM EXHAUST TEMPERATURE SENSOR Refer to IGNITION SYSTEM MAIN AND FUEL PUMP RELAY Refer to IGNITION SYST...

Страница 260: ...23 22 21 1 4 9 15 16 17 18 Y R Y B 2 27 33 R Br R Br 1 2 3 4 5 6 7 8 Y B B B B R Y R Y B B R Y R Y R Y R Y R Y R Br B L R Y L R Y R Br R Br Br R R R R R B B R R B Br Br Br R 1 2 3 4 5 6 7 8 1 ECM 2 Ma...

Страница 261: ...s Broken Replace NOTE The 20 A fuse is for the main relay engine shut off switch and rectifier regulator The 3 A fuses are for the multifunction meter and electric bilge pump Fuse rating 20 A 1 3 A 2...

Страница 262: ...e tester leads between the starter relay terminals as shown Connect the brown lead terminal to the positive battery terminal Connect the black lead terminal to the negative battery terminal Check that...

Страница 263: ...e Q ty Service points STARTER MOTOR DISASSEMBLY Follow the left Step for disassembly Starter motor Refer to GENERATOR AND STARTER MOTOR in Chapter 5 1 O ring 1 2 Bolt 2 3 Starter motor front cover 1 4...

Страница 264: ...e Q ty Service points 8 Starter motor rear cover 1 9 O ring 1 10 Shim As required Thickness 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 Brus...

Страница 265: ...7 32 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...

Страница 266: ...with 600 grit sandpaper 3 Measure Commutator diameter Out of specification Replace Minimum commutator diameter 27 0 mm 1 06 in 4 Check Commutator undercut Contaminants Clean NOTE Use compressed air to...

Страница 267: ...armature shaft No continuity Brush holder inspection 1 Measure Brush length a Out of specification Replace Minimum brush length 6 5 mm 0 26 in 2 Check Brush holder continuity Out of specification Repl...

Страница 268: ...7 35 E ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM B R B G G G G G G G G G G G G G G R B R R R R 1 2 3 4 1 Rectifier regulator 2 Fuse 20 A 3 Battery 4 Lighting coil B Black G Green R Red...

Страница 269: ...7 36 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...

Страница 270: ...B B B O B O B O W B W R W Y B W Y W R W B B O B R B G G G G G G G G G B W Y W B W R W R B B G G G P B O G O L G G R B B B B B P R R R B B B O O O G L O P B G L O P B O B O B O B O B B B B R 1 5 4 3 2...

Страница 271: ...E ELEC YPVS FUSE Refer to STARTING SYSTEM BATTERY Refer to ELECTRICAL in Chapter 3 PICKUP COIL Refer to IGNITION SYSTEM LIGHTING COIL Refer to IGNITION SYSTEM RECTIFIER REGULATOR Refer to IGNITION SY...

Страница 272: ...dure Part name Q ty Service points YPVS SERVOMOTOR REMOVAL Follow the left Step for removal 1 Bolt 2 2 Cable holder 1 3 YPVS servomotor coupler 1 4 Nut washer 2 2 5 YPVS servomotor 1 6 Throttle cable...

Страница 273: ...7 40 E ELEC YPVS SERVOMOTOR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Cover 1 9 Nut washer 3 3 10 YPVS servomotor bracket 1 Reverse the removal steps for installation...

Страница 274: ...rned in Removal steps Remove the YPVS cable holder 1 Remove the YPVS cables 2 from both drums YPVS cable inspection 1 Check YPVS cables 1 and 2 Frays kinks rough movement Replace YPVS servomotor inspe...

Страница 275: ...B O B O B O B O B O B O B O O O O O O O G B G B B Y B Y G Y G Y R Y R Y G R G R G R R Y G B R Y G Y R Y R Y R Y R Y G R G G B G Y R Y R Y R Y R Y R Y R Y W L B R W Y B B B R W Y B R Y W L B R Y W L B...

Страница 276: ...to the left using the Engine monitor of the Yamaha Diagnostic System Does not operate Replace STEPPING MOTOR 1 Check Check the operation of the stepping motor using the Stationary test of the Yamaha D...

Страница 277: ...13 14 32 26 25 24 23 22 21 1 4 9 15 16 17 18 Y R Y 2 27 1 2 3 4 5 6 7 8 Br R R Y R Y B B B R Y R Y R Y R Y R Y R Br B L R Y L R Y Y Br B B R Y R Y B R Y R R B B B Br B B B R B R Y Br R 1 2 3 4 5 1 ECM...

Страница 278: ...r to ELECTRICAL in Chapter 3 MAIN AND FUEL PUMP RELAY Refer to IGNITION SYSTEM Checking steps Suspend the electric bilge pump in a con tainer filled with water Connect the brown lead terminal to the p...

Страница 279: ...u R B Y B G G Y B O B O Pu B Pu Y P G R W B B O B O B O B O B R Y R Y R Y R Y R Y R Br B L R Y L R Y O G B L B B B O B O B O B O B O B R Y R Y B L R L B R B B Y B Y B Y Y B R L L B Y R Y Y B Y R W L B...

Страница 280: ...B G G B G Y B Y Pu R B Y B G G Y B O B O Pu B Pu Y P G R W B B O B O B O B O B R Y R Y R Y R Y R Y R Br B L R Y L R Y O G B L B B B O B O B O B O B O B R Y R Y B L R L B R B B Y B Y B Y Y B R L L B Y...

Страница 281: ...r to IGNITION SYSTEM COOLING WATER TEMPERATURE SENSOR Refer to IGNITION SYSTEM EXHAUST TEMPERATURE SENSOR Refer to IGNITION SYSTEM MAIN AND FUEL PUMP RELAY Refer to IGNITION SYSTEM OIL LEVEL SENSOR 1...

Страница 282: ...ive battery terminal Red R terminal 1 Negative battery terminal Black B terminal 2 MULTIFUNCTION METER Multifunction meter 1 Check Multifunction meter Cracked meter housing Replace the multifunction m...

Страница 283: ...ce the multi function meter R W B R B Y P B L B W R Y Y W B Y R W L R P B L R L B R B B R B L B L R B R 1 5 4 3 2 1 Buzzer 2 Speed sensor 3 ECM 4 Oil level sensor 5 Fuel sender B Black L Blue P Pink R...

Страница 284: ...put pulse 2 pulses 1 full turn Measurement steps Connect a 12 volt battery to the white three pin connector between the red yel low and black yellow leads Rotate the paddle wheel by hand and measure t...

Страница 285: ...splay and fuel warning indicator 1 Check Fuel level meter display and fuel warn ing indicator Do not display Measure the fuel sender resistance If the fuel sender resistance is within specification re...

Страница 286: ...and that the engine overheat warning indicator is displayed 1 Exhaust temperature warning indicator 1 Check Exhaust temperature warning indicator Does not operate Replace the multi function meter Che...

Страница 287: ...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 Start...

Страница 288: ...11 SERVICE POINTS 8 14 Steering column bushing inspection 8 14 Steering column assembly 8 14 REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 8 15 EXPLODED DIAGRAM 8 15 REMOVAL AND INSTALLATION CHART 8 15...

Страница 289: ...ICE POINTS 8 31 Seat lock inspection 8 31 BATTERY BOX 8 32 EXPLODED DIAGRAM 8 32 REMOVAL AND INSTALLATION CHART 8 32 EXHAUST SYSTEM 8 34 EXPLODED DIAGRAM 8 34 REMOVAL AND INSTALLATION CHART 8 34 SERVI...

Страница 290: ...Q ty Service points HANDLEBAR COVER REMOVAL Follow the left Step for removal 1 Screw 4 2 Handlebar cover 1 3 Screw 4 4 Handlebar cover stay 1 5 Plastic tie 1 6 Throttle cable 1 7 Bolt 4 8 Upper handl...

Страница 291: ...Step for removal QSTS cable to jet thrust nozzle Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Grommet 1 NOTE To ease installation apply soapy water to the grommet 2 Handlebar switch coupler...

Страница 292: ...E HULL HOOD HANDLEBAR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 5 Handlebar assembly 1 6 Nut washer 2 2 7 QSTS converter 1 8 Throttle cable 1 Reverse the removal steps for installa...

Страница 293: ...Step Procedure Part name Q ty Service points HANDLEBAR DISASSEMBLY Follow the left Step for disassembly 1 Plastic tie 1 2 Bolt 2 3 Grip end 2 4 Spacer 1 5 Screw spring washer washer 1 1 1 6 QSTS grip...

Страница 294: ...ep Procedure Part name Q ty Service points 11 Throttle lever assembly 1 12 Handlebar grip 1 NOTE Apply adhesive to the handlebar and the inner surface of the handlebar grip 13 Spacer 2 1 14 Handlebar...

Страница 295: ...djusting the QSTS cables set the control grip to the neutral position Adjust the QSTS cables to the specified length a and be sure to take up any slack if necessary QSTS cable length 72 0 5 mm 2 83 0...

Страница 296: ...ble into the grommet fasten the end of grommet with the plastic tie 5 Install Handlebar cover 1 NOTE When the handlebar cover is in contact with the steering console cover adjust the handle bar mounti...

Страница 297: ...tep Procedure Part name Q ty Service points QSTS GRIP DISASSEMBLY Follow the left Step for disassembly QSTS grip assembly Refer to HANDLEBAR 1 Screw washer 1 1 2 Cover 1 3 Ball 2 4 Spring 2 5 QSTS cab...

Страница 298: ...DED DIAGRAM Step Procedure Part name Q ty Service points 7 Screw washer 2 2 8 Collar 1 9 QSTS shift lock lever 1 10 Spring 1 11 Spacer 1 12 QSTS cable housing cover 1 13 QSTS shift grip 1 Reverse the...

Страница 299: ...8 10 E HULL HOOD QSTS GRIP SERVICE POINTS QSTS cable inspection 1 Check QSTS cables Frays kinks rough movement Replace QSTS grip inspection 1 Check QSTS grip Damage wear Replace...

Страница 300: ...OLUMN REMOVAL Follow the left Step for removal Steering console cover assembly Refer to STEERING CONSOLE COVER Steering cable end Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Steering switch...

Страница 301: ...left Step for disassembly 1 Grommet 1 2 Bolt washer nut 1 2 1 3 Steering arm 1 4 Screw 1 5 Magnet 1 6 Shim Install the same number of shims installed originally at the factory 7 Washer 1 8 Steering c...

Страница 302: ...9 Bushing 2 10 Plastic tie 1 11 Screw clamp 1 12 Steering switch 1 13 Steering column housing 1 Reverse the disassembly steps for assembly 2 9 11 7 6 3 2 1 13 8 9 12 10 4 5 16 N m 1 6 kgf m 11 ft Ib 2...

Страница 303: ...ering column assembly 1 Install Steering switch 1 Screw clamp 2 Plastic tie 3 NOTE Fasten the steering switch lead 4 with the plastic tie 3 as shown in the illustration 2 Install Bushings Steering col...

Страница 304: ...LODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL Follow the left Step for removal 1 Speed sensor coupler 1...

Страница 305: ...BLES AND SPEED SENSOR LEAD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 10 Seal 1 11 Steering cable 1 12 Nut 1 13 Pin 1 14 QSTS cable end 1 15 Nut 1 16 Seal 1 17 QSTS cable 1 Reverse...

Страница 306: ...ecomes damaged replace it Never attempt to repair a damaged cable Remote control cable inspection 1 Check Steering cable QSTS cable Frays kinks rough movement Replace Steering cable installation 1 Ins...

Страница 307: ...jet pump end WARNING The QSTS cable must be screwed in a mini mum of 8 mm 0 31 in QSTS cable set length a jet pump end 12 0 14 0 mm 0 47 0 55 in QSTS cable stopper installation 1 Install QSTS cable st...

Страница 308: ...ervice points HOOD REMOVAL Follow the left Step for removal 1 Bolt 2 2 Screw 8 3 Seal washer 8 4 Visor 1 5 Pop nut 8 6 Bolt 2 7 Hood lock 1 8 Hood 1 10 9 1 11 2 3 5 8 4 6 7 5 4 N m 0 54 kgf m 3 9 ft I...

Страница 309: ...y Service points 9 Nut 2 10 Plate 1 11 Hinge assembly 1 Reverse the removal steps for installation 10 9 1 11 2 3 5 8 4 6 7 5 4 N m 0 54 kgf m 3 9 ft Ib 6 14 mm 12 N m 1 2 kgf m 8 7 ft Ib 6 14 mm 5 20...

Страница 310: ...EMOVAL Follow the left Step for removal Handlebar assembly Refer to HANDLEBAR 1 Plastic tie 1 2 Multifunction meter coupler 5 3 Nut washer 2 2 4 Bolt washer 4 4 5 Screw 2 6 Plate 1 1 7 2 9 8 5 6 4 3 5...

Страница 311: ...her 2 2 8 Bolt square ring 2 2 9 Steering console cover assembly 1 NOTE To ease removal remove the oil filler cap Reverse the removal steps for installation 1 7 2 9 8 5 6 4 3 5 4 N m 0 54 kgf m 3 9 ft...

Страница 312: ...Part name Q ty Service points STEERING CONSOLE COVER DISASSEMBLY Follow the left Step for disassembly 1 Screw 4 2 Side cover 2 3 Nut 2 4 Holder 1 5 Multifunction meter 1 6 Screw 4 6 8 7 4 3 1 9 2 2 5...

Страница 313: ...ocedure Part name Q ty Service points 7 Glove compartment 1 8 Pop nut 4 9 Steering console cover 1 Reverse the disassembly steps for assembly 6 8 7 4 3 1 9 2 2 5 5 20 mm 6 18 mm 2 9 N m 0 29 kgf m 2 1...

Страница 314: ...T Step Procedure Part name Q ty Service points BUZZER AND HOOD LOCK REMOVAL Follow the left Step for removal Steering console cover assembly Refer to STEERING CONSOLE COVER Steering cable Refer to REM...

Страница 315: ...OD LOCK EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Bolt 2 8 Hood lock assembly 1 9 Grommet 1 10 Atmospheric pressure sensor coupler 1 11 Atmospheric pressure sensor 1 Reverse the...

Страница 316: ...L Follow the left Step for removal Engine unit Refer to ENGINE UNIT in Chapter 5 Steering console cover assembly Refer to STEERING CONSOLE COVER 1 Plastic tie 4 2 Ventilation hose 2 3 Ventilation duct...

Страница 317: ...heck valve and then blow into the hose Air should come out from end B Connect the hose to end B of the check valve and then blow into the hose Air should not come out from end A Ventilation hose insta...

Страница 318: ...EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points SEAT AND HANDGRIP REMOVAL Follow the left Step for removal 1 Seat 1 2 Bolt 2 3 Seat lock 1 4 Nut 1 5 Proje...

Страница 319: ...8 30 E HULL HOOD SEAT AND HANDGRIP EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 9 Bolt 2 10 Bolt 2 11 Handgrip 1 12 Bracket 1 Reverse the removal steps for installation...

Страница 320: ...8 31 E HULL HOOD SEAT AND HANDGRIP SERVICE POINTS Seat lock inspection 1 Check Seat lock Damage wear Replace...

Страница 321: ...cedure Part name Q ty Service points BATTERY BOX REMOVAL Follow the left Step for removal 1 Battery band 1 2 Fire extinguisher container 1 3 Battery band 1 4 Bolt 1 5 Negative battery lead 1 6 Termina...

Страница 322: ...washer bolt 2 2 2 13 Electrical box 1 14 Cap nut washer 2 2 15 Holder 1 16 Holder 1 17 Cap nut washer 2 2 18 Battery box 1 NOTE Before installing the battery box route the battery leads and battery br...

Страница 323: ...YSTEM REMOVAL Follow the left Step for removal Battery box Refer to BATTERY BOX 1 Flotation 1 2 Exhaust joint clamp 1 3 Exhaust joint 1 4 Hose screw clamp 2 5 Rubber hose 1 6 Bolt 3 7 Seal 1 6 4 5 8 1...

Страница 324: ...Remove parts 8 to 11 as a set 9 Water tank 1 10 Rubber hose 1 11 Exhaust outlet 1 12 Water lock band 1 13 Water lock 1 Reverse the removal steps for installation 6 4 5 8 10 8 4 2 3 13 9 7 11 1 12 3 7...

Страница 325: ...e Replace 2 Check Rubber hoses Burns cracks damage Replace 3 Check Water lock Cracks leaks Replace 4 Check Water tank Cracks damage leaks Replace Water lock installation 1 Install Water lock 1 Water l...

Страница 326: ...97 in c into the rubber hose Make sure that there is a distance of 45 mm 1 77 in d between the parting lines of the water tank and rubber hose b d 2 Install Rubber hose NOTE Install the rubber hose 45...

Страница 327: ...ATION CHART Step Procedure Part name Q ty Service points DECK AND HULL DISASSEMBLY Follow the left Step for disassembly 1 Bolt 2 2 Bow eye 1 3 Nut 2 4 Rope hole fitting 2 5 Nut 1 6 Spout 1 7 Bolt 6 8...

Страница 328: ...LL HOOD DECK AND HULL EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 9 Bolt 8 10 Flap 2 11 Nut washer 4 4 12 Screw washer 4 4 13 Drain plug 2 14 Seal 2 Reverse the disassembly steps for...

Страница 329: ...STALLATION 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 B...

Страница 330: ...TROUBLE ANALYSIS 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 TROUBLE ANALYSIS 9 4 TROUBLE...

Страница 331: ...ave 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 are displayed while the engine is run ning This...

Страница 332: ...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...

Страница 333: ...COMMUNICATION CABLE TO THE WATERCRAFT Model GP1300R Top view 1 3 pin communication coupler 2 Wire harness coupler 3 Multifunction meter coupler NOTE Be careful not to pinch the communication cable be...

Страница 334: ...S CHART Symptom Check items ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDLING ENGINE STALLS POOR ACCELERATION ENGINE WILL NOT STOP POOR PERFORMANCE LIMITED ENGINE SPEED OVERHEATING LOOSE ST...

Страница 335: ...lugs 3 Main and fuel pump relay 7 Exhaust temperature sensor 7 Atmospheric pressure sensor 7 Intake air temperature sensor 7 Engine temperature sensor 7 Throttle position sensor 7 Cooling water temper...

Страница 336: ...bilge pump 7 HULL AND HOOD Steering column 8 Water lock 8 Exhaust hose 8 Muffler 8 Drain plugs 8 Symptom Check items ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDLING ENGINE STALLS POOR ACC...

Страница 337: ...hem with the Yamaha Diagnostic System Code Symptom 01 Normal 13 Pickup coil malfunction 15 Engine temperature sensor malfunction 18 Throttle position sensor TPS malfunction 19 Incorrect battery voltag...

Страница 338: ...13 14 15 16 17 18 19 20 21 22 25 26 27 28 29 30 31 32 33 34 35 23 24 B B B B B O B O B O B O B O B O B O B O B O B O P G B O O B B B B B B B O O O O Br Br Br W W L B B Y B Y L R R W R Y B R W R W B B...

Страница 339: ...oil M Pickup coil N Steering switch O Oil level sensor P Buzzer Q Speed sensor R Multifunction meter S Fuel pump T Fuel sender U Engine stop switch V Engine shut off switch W Start switch X Slant dete...

Страница 340: ...YAMAHA MOTOR CORPORATION USA Printed in USA Feb 2003 0 0 1 CR E...

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