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IMPORTANT INFORMATION

In this Service Manual particularly important information is distinguished in the following
ways.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine

operator, a bystander, or a person inspecting or repairing the watercraft.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the water-

craft.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

IMPORTANT:

This part has been subjected to change of specification during production.

Содержание WaveRunner GP800R

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

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

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

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

Страница 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...

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

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: ......

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

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

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

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

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

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

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

Страница 16: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 30: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 49: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 149: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 189: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 244: ......

Страница 245: ......

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

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

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