Yamaha FX HO Service Manual

WaveRunner FX High Output FX Cruiser High Output
SERVICE MANUAL
*LIT186160283*
LIT-18616-02-83 F1S-28197-1G-11
NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use. Because Yamaha 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. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual.
A10001-0*
WaveRunner FX High Output, FX Cruiser High Output SERVICE MANUAL 2004 by Yamaha Motor Corporation, USA 1st Edition, February 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited. Printed in USA LIT-18616-02-83
HOW TO USE THIS MANUAL

MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., Bearings Pitting/scratches Replace. To assist you in finding your way through this manual, the section title and major heading is given at the top of every page.
ILLUSTRATIONS
The illustrations within this service manual represent all of the designated models.
CROSS REFERENCES
The cross references have been kept to a minimum. Cross references will direct you to the appropriate section or chapter.
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, passenger(s), 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 watercraft. NOTE: A NOTE provides key information to make procedures easier or clearer. IMPORTANT: This part has been subjected to change of specification during production.

1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 2 Numbers are given in the order of the jobs in the exploded diagram. 3 Symbols indicate parts to be lubricated or replaced (see SYMBOLS). 4 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5 Dimension figures and the number of parts, are provided for fasteners that require a tightening torque. Example: Bolt or screw size 10 25 mm : M10 (D) 25 mm (L)
D L
6 Jobs requiring more information (such as special tools and technical data) are described sequentially.
E
1 2
A50001-1-4
GEN INFO
3
SYMBOLS
Symbols 1 to 9 are designed to indicate the content of a chapter.
1 2 3 4 5 6 7 8 9 General Information Specifications Periodic Inspection and Adjustment Fuel System Power Unit Jet Pump Unit Electrical System Hull and Hood Trouble Analysis
SPEC
4
INSP ADJ
5
FUEL
6
POWR
7
JET PUMP
8
+
ELEC
9
HULL HOOD
0
Symbols 0 to E indicate specific data.

0 A B C D E Special tool Specified oil or fluid Specified engine speed Specified tightening torque Specified measurement Specified electrical value (resistance, voltage, electric current)
TRBL ANLS
A B
T.
R.
Symbols F to H in an exploded diagram indicate the grade of lubricant and the lubrication point.
E
F Apply Yamaha 4-stroke motor oil G Apply water resistant grease (Yamaha grease A, Yamaha marine grease) H Apply molybdenum disulfide grease
G
A
H
M
I
GM
4
L
Symbols I to N in an exploded diagram indicate the type of sealant or locking agent and the application point.
I J K L M N Apply Gasket Maker Apply Yamabond No. 4 Apply LOCTITE 271 (red) Apply LOCTITE 242 (blue) Apply LOCTITE 572 Apply silicone sealant
K
LT
LT
271
242
M
LT
N
SS
572
NOTE: Additional symbols may be used in this manual.
E
A30000-0
INDEX
GEN INFO
GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT FUEL SYSTEM POWER UNIT JET PUMP UNIT ELECTRICAL SYSTEM HULL AND HOOD TROUBLE ANALYSIS
SPEC
INSP ADJ
FUEL
POWR
JET PUMP
+
ELEC
HULL HOOD
TRBL ANLS
1 2 3 4 5 6 7 8 9
GEN INFO
CHAPTER 1 GENERAL INFORMATION
IDENTIFICATION NUMBERS ......................................................................... 1-1 PRIMARY l.D. NUMBER ...........................................................................1-1 ENGINE SERIAL 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 PARTS, LUBRICANTS, AND SEALANTS ................................................ 1-2 GOOD WORKING PRACTICES ............................................................... 1-3 DISASSEMBLY AND ASSEMBLY ............................................................ 1-4 SPECIAL TOOLS ............................................................................................ 1-5 MEASURING............................................................................................. 1-5 REMOVAL AND INSTALLATION.............................................................. 1-7
GEN INFO
IDENTIFICATION NUMBERS
A60700-0*
PRIMARY l.D. NUMBER
The primary l.D. number is stamped on a label attached to the inside of the engine compartment. Starting primary l.D. number: F1S: 800101
ENGINE SERIAL NUMBER

The engine serial number is stamped on a label attached to the engine unit. Starting serial number: 6B6: 1000001
JET PUMP UNIT SERIAL NUMBER

The jet pump unit serial number is stamped on a label attached to the intermediate housing.
HULL IDENTIFICATION NUMBER (H.l.N.)

The H.l.N. is stamped on a plate attached to the aft deck.
1-1
GEN INFO
SAFETY WHILE WORKING SAFETY WHILE WORKING
To prevent and accident or injury and to ensure quality service, follow the safety procedures provided below.
FIRE PREVENTION
Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames.
VENTILATION
Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If inhaled in large quantities they may cause loss of consciousness 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-PROTECTION
Protect your eyes by wearing safety glasses or safety goggles during all operation involving drilling and grinding, or when using an air compressor. Protect your hands and feet by wearing protective gloves or safety shoes when necessary.
PARTS, LUBRICANTS, AND SEALANTS

Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the watercraft.
1-2
GEN INFO
SAFETY WHILE WORKING
Under normal conditions, the lubricants mentioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants. 1. Maintain good standards of personal and industrial hygiene. 2. Change and wash clothing as soon as possible if soiled with lubricants. 3. Avoid contact with skin. Do not, for example, place a soiled rag in your pocket. 4. Wash hands and any other part 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 working on the watercraft. 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc.
GOOD WORKING PRACTICES

1. The right tools Use the recommended special service tools to protect parts from damage. Use the right tool in the right mannerdo not improvise. 2. Tightening torques Follow the tightening torque specifications provided throughout the manual. When tightening nuts, bolts, and screws, tighten the large sizes first, and tighten fasteners starting in the center and moving outward.
1-3
GEN INFO
SAFETY WHILE WORKING
3. Non-reusable parts Always use new gaskets, seals, O-rings, oil seals, cotter pins, circlips, etc., when installing or assembling parts.
DISASSEMBLY AND ASSEMBLY

1. Use compressed air to remove dust and dirt during disassembly. 2. Apply engine oil to the contact surfaces of moving parts during assembly.
3. Install bearings with the manufacture identification mark in the direction indication in the installation procedure. In addition, be sure to lubricate the bearings liberally. 4. Apply a thin coat of water-resistant grease to the lip and periphery of an oil seal before installation. 5. Check that moving parts operate normally after assembly.
1-4
GEN INFO
SPECIAL TOOLS SPECIAL TOOLS
Using the correct special tools recommended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvisations and using improper tools can damage the equipment. NOTE: For U.S.A. and Canada, use part numbers starting with J-, YB-, YM-, YS-, YU- or YW-. For other countries, use part numbers starting with 90890-.
1 YU-03097
90890-01252
MEASURING
2 90890-06583 3 1 Dial gauge P/N. YU-03097 90890-01252 2 Dial gauge stand P/N. 90890-06583 3 Dial gauge needle P/N. 90890-06584 4 Dial gauge stand set P/N. YW-06585 90890-06585 5 Pocket tester P/N. YU-03112 90890-03112 6 Digital multimeter P/N. YU-34899-A 7 Digital circuit tester P/N. 90890-03174 8 Carburetor synchronizer P/N. YU-08030 9 Vacuum gauge P/N. 90890-03094 0 Test connector P/N. YW-06862 Test connector FMY-8 P/N. 90890-06862 A Fuel pressure gauge adapter P/N. YW-06842 90890-06842
90890-06584
4 YW-06585
90890-06585
5 YU-03112
90890-03112
YU-34899-A
7 90890-03174
YU-08030
9 90890-03094
0 YW-06862
90890-06862
A YW-06842
90890-06842
1-5
GEN INFO
B YB-06766
SPECIAL TOOLS
90890-06786
E B Fuel pressure gauge P/N. YB-06766 90890-06786 C Compression gauge extension P/N. 90890-06582 D Cylinder gauge set P/N. YU-03017 90890-06759 E Compression gauge P/N. YU-33223-1 90890-03160 F Peak volt meter adapter P/N. YU-39991 G Peak voltage adapter B P/N. 90890-03172 H Spark gap tester P/N. YM-34487 I Ignition tester P/N. 90890-06754 J Test harness (2 pins) P/N. New: YB-06867 Current: YB-06767 Test harness FWY-2 (2 pins) P/N. New: 90890-06867 Current: 90890-06767 K Test harness (3 pins) P/N. New: YB-06870 Current: YB-06770 Test harness SMT250-3 (3 pins) P/N. New: 90890-06870 Current: 90890-06770 L Test harness (6 pins) P/N. YB-06848 Test harness FSW-6A (6 pins) P/N. 90890-06848 M Test harness (3 pins) P/N. YB-06793 Test harness SMHW099-3 (3 pins) P/N. 90890-06793
C 90890-06582
D YU-03017
90890-06759
E YU-33223-1
90890-03160
F YU-39991
G 90890-03172
H YM-34487
I 90890-06754
J YB-06867 (-06767)
90890-06867 (-06767)
K YB-06870 (-06770)
90890-06870 (-06770)
L YB-06848
90890-06848
M YB-06793
90890-06793
1-6
GEN INFO
N YB-06877 (-06777)
90890-06877 (-06777)
SPECIAL TOOLS
O YB-35956-A N Test harness (3 pins) P/N. New: YB-06877 Current: YB-06777 Test harness HM090-3 (3 pins) P/N. New: 90890-06877 Current: 90890-06777 O Lower unit pressure/vacuum tester P/N. YB-35956-A Vacuum/pressure pump gauge set P/N. 90890-06756 P Yamaha diagnostic system P/N. 60V-85300-02 Q Yamaha diagnostic system P/N. 60V-WS853-02
90890-06756
P 60V-85300-02
Q 60V-WS853-02
YAMAHA DIAGNOSTIC SYSTEM

INSTALLATION MANUAL
REMOVAL AND INSTALLATION

1 YU-38411
90890-01426
2 YW-06551
90890-06551
3 YS-01880-A
90890-01701
4 YM-01082
90890-01080
1 Oil filter wrench P/N. YU-38411 90890-01426 2 Coupler wrench P/N. YW-06551 90890-06551 3 Sheave holder P/N. YS-01880-A 90890-01701 4 Rotor puller P/N. YM-01082 90890-01080
1-7
GEN INFO
5 YU-01235
90890-01235
SPECIAL TOOLS
6 YB-06111
E 5 Universal magneto and rotor holder P/N. YU-01235 Rotor holder P/N. 90890-01235 6 Bearing housing needle bearing installer (reduction drive gear) P/N. YB-06111 7 Ball bearing attachment (reduction drive gear) P/N. 90890-06631 8 Forward gear bearing cup installer (reduction drive gear) P/N. YB-06726-B 9 Ball bearing attachment (reduction drive gear) P/N. 90890-06657 0 Valve spring compressor P/N. YM-01253 90890-04019 A Valve spring compressor attachment P/N. YM-4114 (19 mm) 90890-04114 (19 mm) YM-4108 (22 mm) 90890-04108 (22 mm) B Valve guide remover P/N. YM-04111 (4.0 mm) 90890-04111 (4.0 mm) YM-04116 (4.5 mm) 90890-04116 (4.5 mm) C Valve guide installer P/N. YM-04112 (4.0 mm) 90890-04112 (4.0 mm) YM-04117 (4.5 mm) 90890-04117 (4.5 mm) D Valve guide reamer P/N. YM-04113 (4.0 mm) 90890-04113 (4.0 mm) YM-04118 (4.5 mm) 90890-04118 (4.5 mm)
7 90890-06631
8 YB-06726-B
9 90890-06657
0 YM-01253
90890-04019
A YM-4114 (19 mm)
90890-04114 (19 mm) YM-4108 (22 mm) 90890-04108 (22 mm)
B YM-04111 (4.0 mm)
90890-04111 (4.0 mm) YM-04116 (4.5 mm) 90890-04116 (4.5 mm)
C YM-04112 (4.0 mm)
90890-04112 (4.0 mm) YM-04117 (4.5 mm) 90890-04117 (4.5 mm)
D YM-04113 (4.0 mm)
90890-04113 (4.0 mm) YM-04118 (4.5 mm) 90890-04118 (4.5 mm)
1-8
GEN INFO
E
90890-06813 (60) 90890-06814 (45) 90890-06815 (30)
SPECIAL TOOLS
90890-06315 (60) 90890-06312 (45) 90890-06328 (30)
E E Valve seat cutter Intake P/N. 90890-06813 (60) 90890-06814 (45) 90890-06815 (30) Exhaust P/N. 90890-06315 (60) 90890-06312 (45) 90890-06328 (30) F Valve seat cutter holder P/N. 90890-06811 (4.0 mm) 90890-06812 (4.5 mm) G Valve seat cutter set P/N. YM-91043-C H Piston ring compressor P/N. YM-08037 90890-05158 I Drive shaft holder (impeller) P/N. YB-06151 Drive shaft holder 5 (impeller) P/N. 90890-06519 J Slide hammer and adapters (jet pump bearing and reduction drive gear) P/N. YB-06096 K Stopper guide plate (jet pump bearing) P/N. 90890-06501 L Bearing puller assembly (jet pump bearing and reduction drive gear) P/N. 90890-06535 M Stopper guide stand (jet pump bearing and reduction drive gear) P/N. 90890-06538 N Drive rod L3 (jet pump bearing and reduction drive gear) P/N. 90890-06652
90890-06811 (4.0 mm) 90890-06812 (4.5 mm)
YM-91043-C
H YM-08037
90890-05158
YB-06151 90890-06519
YB-06096
K 90890-06501
90890-06535
M 90890-06538
90890-06652
1-9
GEN INFO
O YB-06112
YB-06196
SPECIAL TOOLS
P
90890-06614 90890-06653
E O Bearing housing needle bearing remover (jet pump bearing) P/N. YB-06112 Drive shaft needle bearing installer and remover (jet pump oil seal) P/N. YB-06196 P Needle bearing attachment (jet pump bearing, oil seal, and reduction drive gear) P/N. 90890-06614, 90890-06653 Q Outer race installerforward gear (jet pump oil seal and reduction drive gear) P/N. YB-06085 R Ball bearing attachment (jet pump oil seal and reduction drive gear) P/N. 90890-06631 S Driver handlelarge (intermediate shaft, jet pump, and reduction drive gear) P/N. YB-06071 T Driver rod LS (intermediate shaft, jet pump, and reduction drive gear) P/N. 90890-06606 U Bearing inner/outer race attachment (jet pump bearing) P/N. YB-34474 V Shaft holder (intermediate shaft) P/N. YB-06552 Crankshaft holder 20 (intermediate shaft) P/N. 90890-06552 W Drive shaft taper roller bearing cup installer (intermediate shaft and reduction drive gear) P/N. YB-06156 Bearing outer race attachment (intermediate shaft and reduction drive gear) P/N. 90890-06624, 90890-06626
Q YB-06085
90890-06631
S YB-06071
90890-06606
U YB-34474
V YB-06552
90890-06552
W YB-06156
90890-06624 90890-06626
1-10
SPEC
CHAPTER 2 SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................................... 2-1 MAINTENANCE SPECIFICATIONS ............................................................... 2-3 ENGINE .................................................................................................... 2-3 JET PUMP UNIT ......................................................................................2-6 HULL AND HOOD .................................................................................... 2-6 ELECTRICAL ............................................................................................ 2-7 TIGHTENING TORQUES ................................................................................ 2-9 SPECIFIED TORQUES.............................................................................2-9 GENERAL TORQUE ............................................................................... 2-17 CABLE AND HOSE ROUTING ..................................................................... 2-18
SPEC
GENERAL SPECIFICATIONS
Item Model code Hull Engine/jet Dimensions Length Width Height Dry weight Maximum capacity Performance Maximum output Maximum fuel consumption Cruising range Engine Engine type Displacement Bore stroke Compression ratio Exhaust system Lubrication system Cooling system Starting system Ignition system Ignition timing Spark plug model (manufacturer) Spark plug gap Battery capacity Generator output Drive unit Propulsion system Jet pump type Impeller rotation Transmission Jet thrust nozzle horizontal angle Jet thrust nozzle trim angle Trim system Reverse system Unit Model FX High Output FX Cruiser High Output F1S 6B6 mm (in) mm (in) mm (in) kg (lb) Person/kg (lb) kW (PS) @ r/min l/h (US gal/h, lmp gal/h) h 3,340 (131.5) 1,230 (48.4) 1,160 (45.7) 350 (772) 3/240 (530) 117.7 (160) @ 10,000 45 (11.9, 9.9) 1.56 4-stroke, L4, DOHC 1,052 (64.2) 76.0 58.0 (2.99 2.28) 11.9:1 Wet exhaust Dry sump Water cooled Electric starter TCI BTDC 5BTDC 32 CR9EB (NGK) 0.70.8 (0.0280.031) 12/19 1416 @ 6,000 Jet pump Axial flow, single stage Counterclockwise (viewed from rear) Constant mesh 1-speed 24 + 24 10, 5, 0, 5, 10 Manual 5 positions Reverse gate
cm (cu. in) mm (in)
Degree
mm (in) V/Ah A @ r/min
Degree Degree
2-1
SPEC
Item Fuel and oil Fuel type Minimum fuel rating Fuel tank capacity Engine oil type Engine oil grade Engine oil quantity
Unit
Model FX High Output FX Cruiser High Output Regular unleaded gasoline 86 90 70 (18.5, 15.4) 4-stroke motor oil SE, SF, SG, SH, SJ, SL 10W-30 4.5 (4.8, 4.0) 2.1 (2.2, 1.8) 2.3 (2.4, 2.0)
PON* RON* L (US gal, Imp gal) API SAE L (US qt, Imp qt) L (US qt, Imp qt) L (US qt, Imp qt)
(without oil filter replacement) (with oil filter replacement)
PON*: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2 RON*: Research Octane Number
2-2
SPEC
ENGINE
Item Cylinder head Warpage limit
MAINTENANCE SPECIFICATIONS
Unit mm (in) Model FX Cruiser High Output
FX High Output
0.1 (0.004)
Compression pressure*1 Cylinder Bore size Taper limit Out-of-round limit Wear limit Camshaft Drive system Intake A Exhaust A Intake and exhaust B Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaftcap clearance Maximum camshaft runout Timing chain Model/number of links Tensioning system Valves, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions Valve head diameter A Intake Exhaust Valve face width B Intake Exhaust
kPa (kgf/cm2, psi) mm (in) mm (in) mm (in) mm (in)
1,150 (11.5, 164)
76.00076.015 (2.99212.9927) 0.08 (0.003) 0.05 (0.002) 76.100 (2.9961) Chain drive 32.55 (1.281) 33.00 (1.299) 25.00 (0.984) 24.5 (0.9646) 24.4624.47 (0.96300.9634) 0.030.06 (0.00120.0024) 0.03 (0.0012) DID SCR-0412SV/130 Automatic
mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
mm (in) mm (in)
0.110.20 (0.00430.0079) 0.250.34 (0.00980.0134)
mm (in) mm (in)
22.923.1 (0.90160.9094) 24.424.6 (0.96060.9685)
mm (in) mm (in)
1.762.90 (0.06930.1142) 1.762.90 (0.06930.1142)
*1 Measuring conditions: Ambient temperature 20 C (68 F), wide open throttle, with spark plugs removed from all cylinders. The figures are for reference only.
2-3
SPEC
Item
Unit mm (in) mm (in) mm (in) mm (in)
Model FX High Output FX Cruiser High Output 0.91.1 (0.03540.0433) 0.91.1 (0.03540.0433) 0.50.9 (0.01970.0354) 0.50.9 (0.01970.0354)
Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve-stem-to-valve-guide clearance Intake Exhaust Valve stem runout
mm (in) mm (in) mm (in) mm (in)
3.9753.990 (0.15650.1571) 4.4654.480 (0.17580.1764) 4.0004.012 (0.15750.1580) 4.5004.512 (0.17720.1776)
mm (in) mm (in) mm (in)
0.0100.037 (0.00040.0015) 0.0200.047 (0.00080.0019) 0.01 (0.0004)
Valve spring Free length Intake mm (in) Exhaust mm (in) Installed length Intake mm (in) Exhaust mm (in) Spring limit Intake Degree/mm (in) Exhaust Degree/mm (in) Piston Piston-to-cylinder clearance mm (in) Piston diameter mm (in) Measuring point H* mm (in) Wear limit mm (in) Piston pin boss inside diameter mm (in) Piston pins Outside diameter mm (in) Wear limit mm (in)
38.90 (1.53) 40.67 (1.60) 34.50 (1.36) 35.00 (1.38) 2.5/1.7 (0.067) 2.5/1.8 (0.071) 0.100.11 (0.00390.0043) 75.89575.910 (2.98802.9886) 5 (0.2) 0.17 (0.0067) 17.00217.013 (0.66930.6698) 16.99117.000 (0.66890.6693) 16.98 (0.67)
2-4
SPEC
Item
Unit
Model FX High Output FX Cruiser High Output
Piston ring Top ring T Type Dimension (B T) End gap (installed) Ring groove clearance 2nd ring Type T Dimensions (B T) End gap (installed) Ring groove clearance Oil ring Dimensions T (B T) End gap (installed) Ring groove clearance Connecting rod Big end oil clearance Bearing color code Small end inside diameter Crankshaft
B B B

B
Barrel 0.90 2.75 (0.04 0.11) 0.320.44 (0.01260.0173) 0.0300.065 (0.00120.0026) Taper 0.80 2.80 (0.03 0.11) 0.430.58 (0.01690.0228) 0.0200.055 (0.00080.0022) 1.50 2.60 (0.06 0.10) 0.100.35 (0.00390.0138) 0.0400.160 (0.00160.0063) 0.0160.040 (0.00060.0016) 1. Brown 2. Black 3. Blue 4. Green 17.00517.018 (0.66940.6699)

B
mm (in) mm (in) mm (in) mm (in) mm (in)
Crank width A Deflection limit B Crankshaft journal oil clearance Bearing color code Throttle body Type/quantity Manufacturer ID mark Trolling speed Fuel pump Pump type Fuel pressure
304.8306.0 (12.0012.05) 0.03 (0.0012) 0.0040.028 (0.00020.0011) 1. Brown 2. Black 3. Blue 4. Green 5. Yellow 42EIS/4 Mikuni 6B600 1,5501,750 Electrical 310330 (3.13.3, 4547)
r/min
kPa (kgf/cm2, psi)
2-5
SPEC
Item
Unit
Model FX High Output FX Cruiser High Output Cartridge type Trochoid 0.090.15 (0.00350.0059)
Oil filter Oil filter type Oil pump Oil pump type Rotor tip clearance (scavenge pump) Oil pump housing clearance Rotor (feed pump) Rotor (scavenge pump)
mm (in)
mm (in) mm (in)
0.090.17 (0.00350.0067) 0.090.15 (0.00350.0059)
JET PUMP UNIT

Item Jet pump Impeller material Number of impeller blades Impeller pitch angle Impeller clearance Impeller clearance limit Drive shaft runout limit Nozzle diameter Unit Model FX High Output FX Cruiser High Output Stainless steel 3 16.8 0.350.45 (0.01380.0177) 0.6 (0.0236) 0.3 (0.0118) 86.587.1 (3.413.43)
Degree mm (in) mm (in) mm (in) mm (in)
HULL AND HOOD

Item Free play Throttle lever free play Unit mm (in) FX High Output Model FX Cruiser High Output
47 (0.160.28)
2-6
SPEC
ELECTRICAL
Item
Unit
FX High Output
Model FX Cruiser High Output Fluid 12/19 1.28
Battery Type Capacity Specific gravity ECM unit (B/R R/Y, B/W R/Y, B/Y R/Y, B/L R/Y) Output peak voltage lower limit @cranking (loaded) @2,000 r/min (loaded) @3,500 r/min (loaded) Stator Pickup coil (W B, R B) Output peak voltage @cranking (unloaded) @cranking (loaded) @2,000 r/min (loaded) @3,500 r/min (loaded) Lighting coil (G G) Output peak voltage @cranking (unloaded) @2,000 r/min (unloaded) @3,500 r/min (unloaded) Pickup coil resistance (W B) Pickup coil resistance (R B) Lighting coil resistance (G G) Minimum charging current Ignition coil Primary coil resistance Secondary coil resistance Rectifier/regulator (R B) Output peak voltage @3,500 r/min (unloaded) Starter motor Type Output Rating Brush length Wear limit Commutator undercut Limit Commutator diameter Limit
V/Ah
V V V
87 86 85
V V V V
5.2 4.7 26.1 41.3
V V V (color) (color) (color) A @ r/min k
9.2 38.5 63.2 459561 459561 0.540.66 14 @ 6,000 1.191.61 8.511.5
15.0 Constant mesh 0.8 30 12.5 (0.49) 6.5 (0.26) 0.7 (0.03) 0.2 (0.01) 28.0 (1.10) 27.0 (1.06)
2-7
kW Seconds mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
SPEC
Item
Unit Seconds C (F) C (F) C (F) C (F)
Model FX High Output FX Cruiser High Output 30 8490 (183194) 7084 (158183) 94100 (201212) 8094 (176201)
Starter relay Rating Thermoswitch ON temperature (engine) OFF temperature (engine) ON temperature (exhaust) OFF temperature (exhaust) Engine temperature sensor Engine temperature sensor resistance (B/Y B/Y) @ 20 C (68 F) @ 100 C (212 F) Speed sensor Output voltage (on pulse) Output pulse/one full turn Throttle position sensor Output voltage (P B/O) @ trolling speed Cam position sensor Output voltage (G/O B/O) Position A Position B Position C Fuel sender Fuel sender resistance Position A Position B Oil pressure switch Oil pressure switch continuity pressure Fuel injector Fuel injector resistance*1 Fuse Rating Main Remote control unit Electrical bilge pump *1 The figures are for reference only.
k k V
54.269.0 3.123.48 11.6 2
0.756 0.016
V V V
More than 4.8 Less than 0.8 More than 4.8
kPa (kgf/cm2, psi)
133.5136.5 57 128 (1.28, 18.2)166 (1.66, 23.6)
11.512.5
V/A V/A V/A
12/20 12/3 12/3
2-8
SPEC
TIGHTENING TORQUES
TIGHTENING TORQUES
SPECIFIED TORQUES
Part to tightened Fuel system 1st Retainer/fuel pump module fuel tank 2nd Fuel filler neck/rubber seal deck Fuel tank belt/fuel tank hull Fuel tank cap screw clamp fuel tank cap/fuel tank Fuel filter hose clamp fuel filter hose/fuel tank/fuel filter neck Air filter case cover air filter case Ribbon sub assembly throttle bodies Throttle cable holder air filter case Fuel hose holder fuel hose bracket Throttle bodies throttle body joint Air filter case 1st air filter case stay 1/ 2nd air filter case stay 2 Wire harness bracket 1/sub wire harness air filter case Fuel hose bracket/wire harness bracket 2 air filter case Wire harness bracket 2 air filter case 1st Air filter case stay 1 exhaust pipe 3 2nd 1st Air filter case stay 2 cylinder head 2nd Band air filter case Breather cover air filter case Fuel rail throttle bodies Sensor assembly fuel rail Bracket throttle bodies Bracket bypass valve motor Throttle stop guide throttle bodies Throttle stop screw bracket throttle bodies Throttle position sensor throttle bodies Part name Thread Qty size Tightening torque Nm kgfm ftlb 3.2 6.4 5.9 16 1.3 4.2 2.5 6.5 7.6 3.3 22 8.8 Bolt Bolt Bolt Screw Bolt Bolt Screw Screw Bolt Screw Screw Nut Screw Screw Screw M8 M6 M6 M5 M8 M8 M5 M5 M6 M5 M6 M6 M6 M4 3 2 2 1 2 1 1 3 4 2 3 2 2 2 2 18 7.6 7.6 1.3 15 39 15 39 1.3 1.8 5.0 3.5 5.0 13 5.0 5.0 2.0 0.32 0.64 0.59 1.6 0.13 0.42 0.25 0.65 0.76 0.33 2.2 0.88 1.8 0.76 0.76 0.13 1.5 3.9 1.5 3.9 0.13 0.18 0.5 0.35 0.5 1.3 0.5 0.5 0.2 2.3 4.6 4.3 11 0.9 3.0 1.8 4.7 5.5 2.4 16 6.4 13 5.5 5.5 0.9 11 28 11 28 0.9 1.3 3.6 2.5 3.6 9.4 3.6 3.6 1.4
572
LT
Remarks
Nut Nut Bolt Screw Bolt Bolt Bolt Bolt
M8 M5 M6 M6 M4 M8
9 1 4 1 2 2 4 2 2 8
2-9
271
LT
271
LT
572
LT
242
LT
242
LT
572
LT
572
LT
242
LT
572
LT
572
LT
SPEC
TIGHTENING TORQUES
Part name Bolt Bolt Bolt Thread Qty size M8 M6 M6 4 1 1 2 2 Tightening torque Nm kgfm ftlb 17 17 7.8 7.6 4.4 4.4 4.4 2 4.4 2.0 15 39 3.7 7.6 15 42 15 42 39 39 22 22 35 22 22 35 22 22 35 3.7 7.6 3.7 Bolt Bolt Bolt Bolt M6 M6 M6 M8 3 3 2 5 7.6 7.6 7.6 15 39 1.7 1.7 0.78 0.76 0.44 0.44 0.44 0.44 0.2 1.5 3.9 0.37 0.76 1.5 4.2 1.5 4.2 3.9 3.9 2.2 2.2 3.5 2.2 2.2 3.5 2.2 2.2 3.5 0.37 0.76 0.37 0.76 0.76 0.76 1.5 3.9 12 12 5.6 5.5 3.2 3.2 3.2 3.2 1.4 11 28 2.7 5.5 11 30 11 30 28 28 16 16 25 16 16 25 16 16 25 2.7 5.5 2.7 5.5 5.5 5.5 11 28
E Remarks
Part to tightened Engine Engine unit engine mount Oil filter Coupling cover intermediate housing Thermoswitch (exhaust) exhaust pipe 3 Outer exhaust joint clamp 1st exhaust pipe 3/exhaust 2nd pipe 2 Inner exhaust joint clamp 1st exhaust pipe 3/exhaust 2nd pipe 2 1st Exhaust pipe 3 2nd crankcase*1 3rd 1st Exhaust pipe end exhaust pipe 3 2nd 1st Exhaust pipe stay crankcase 2nd 1st Exhaust pipe 1 exhaust pipe stay 2nd 1st Exhaust pipe 2 *1 exhaust pipe 1 2nd 1st Exhaust pipe 1 2nd exhaust manifold 1/ exhaust manifold 2 3rd 1st Exhaust manifold 1 2nd cylinder head 3rd 1st Exhaust manifold 2 2nd cylinder head 3rd 1st Water jacket oil tank 2nd Oil tank stay/reduction 1st drive gear case 2nd oil separator Cover (ground lead) oil tank Ground lead oil tank 1st Oil tank reduction drive gear case 2nd
Bolt Bolt Bolt Bolt Nut Bolt
M10 M6 M8 M10 M8
4 3 2 1 5 10
Bolt
M8
Bolt Bolt
M8 M6
5 4
*1 For details, refer to the tightening procedures in this manual.
2-10
572
LT
572
LT
572
LT
572
LT
242
LT
242
LT
242
LT
242
LT
242
LT
572
LT
242
LT
572
LT
572
LT
271
LT
SPEC
TIGHTENING TORQUES
Part name 1st 2nd 3rd 1st 2nd 3rd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd Bolt Bolt Bolt Bolt Screw 1st 2nd Bolt Bolt Bolt Bolt Bolt Screw Bolt Bolt Nut Bolt M5 M5 M6 M6 M4 M6 M8 M8 M6 M8 M8 M4 M6 M8 M8 10 3 2 24 1 5 4 1 2 1 3 1 1 2 5 1 2 Nut Thread Qty size 2 Tightening torque Nm kgfm ftlb 2.0 0.2 1.4 15 1.5 11 39 3.9 28 2.0 0.2 1.4 15 1.5 11 39 3.9 28 7.6 0.76 5.5 3.7 0.37 2.7 7.6 0.76 5.5 3.7 0.37 2.7 7.6 0.76 5.5 3.7 0.37 2.7 7.6 0.76 5.5 1.9 4.4 1.9 4.4 3.7 7.6 3.7 7.6 3.7 10 15 28 20 3.7 7.6 20 20 2.0 28 3.7 7.6 15 28 4.9 18 0.19 0.44 0.19 0.44 0.37 0.76 0.37 0.76 0.37 1.0 1.5 2.8 2.0 0.37 0.76 2.0 2.0 0.2 2.8 0.37 0.76 1.5 2.8 0.49 1.8 1.4 3.2 1.4 3.2 2.7 5.5 2.7 5.5 2.7 7.2 11 20 14 2.7 5.5 14 14 1.4 20 2.7 5.5 11 20 3.5 13
E Remarks
Part to tightened Oil tank oil tank stay
Oil tank stay cylinder head Band/collar oil tank Bracket (coupling cover) oil tank Hanger oil tank cover Oil tank cover oil tank Oil breather plate 1/ oil breather plate 2 oil tank cover Baffle plate oil tank Oil strainer oil tank Oil cooler cover oil tank Anode oil tank Oil pump assembly reduction drive gear case
Bolt Bolt Bolt Bolt Bolt
M10 M6 M6 M6 M6
2 1 2 4 8
Drain plug (engine oil) 1st Strainer reduction drive gear case 2nd Oil pump housing cover 1 oil seal housing 1 Oil pump housing cover 1/oil seal housing 1/oil pump housing cover 2 oil pump housing 2 Oil pump housing cover 2 oil seal housing 1 Drive coupling drive shaft 1st 2nd Reduction drive gear case crankcase 1st 2nd Starter motor lead starter motor Starter motor crankcase
2-11
572
LT
572
LT
572
LT
572
LT
572
LT
572
LT
572
LT
572
LT
572
LT
572
LT
572
LT
SPEC
TIGHTENING TORQUES
Part name 1st 2nd 1st 2nd Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Nut Nut Bolt Thread Qty size M10 M10 M8 M5 M5 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M7 M7 M8 M6 M6 2 8 1 6 3 4 2 3 4 4 1 1 6 1 2 10 18 2 2 2 3 2 2 6 4 1 Tightening torque Nm kgfm ftlb 15 1.5 11 50 5.0 36 15 1.5 11 50 5.0 36 75 7.5 54 24 2.4 17 4.9 4.9 14 14 13 7.6 10 3.7 7.6 12 10 10 10 10 24 24 40 10 20 20 20 10 15 0.49 0.49 1.4 1.4 1.3 0.76 1.0 0.37 0.76 1.2 1.0 1.0 1.0 1.0 2.4 2.4 4.0 1.0 2.0 140 5 2.0 121 5 2.0 105 5 1.0 1.5 3.5 3.5 10 10 9.4 5.5 7.2 2.7 5.5 8.7 7.2 7.2 7.2 7.2 17 17 29 7.2 14 14 14 7.2 11
LT
E Remarks
572
LT LT
Part to tightened
Rotor crankshaft Rotor starter clutch Washer/pickup coil lead and lighting coil lead generator cover Pickup coil generator cover Holder (wire harness) generator cover Lighting coil generator cover Spark plug Ignition coil cylinder head cover Cam position sensor cylinder head cover 1st Cooling water pipe cylinder head 2nd Cylinder head cover cylinder head Timing chain tensioner cap bolt Timing chain tensioner cylinder head Exhaust camshaft cap cylinder head Intake camshaft cap cylinder head Exhaust camshaft sprocket exhaust camshaft Intake camshaft sprocket intake camshaft Hanger cylinder head 1st 2nd 1st 2nd 1st 2nd
Cylinder head upper crankcase*1
Plug (vacuum pressure) Engine temperature sensor crankcase
*1 For details, refer to the tightening procedures in this manual.
2-12
271
572
LT
572
LT
572
LT
242
LT
242
LT
242
LT
242
LT
572
Generator cover crankcase
SPEC
TIGHTENING TORQUES
Part name Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Bolt Bolt Thread Qty size M6 M6 M8 M6 M6 M9 M6 M6 M6 2 1 1 1 13 10 10 1 1 8 2 2 1 Tightening torque Nm kgfm ftlb 7.6 0.76 5.5
E Remarks
572
LT LT
Part to tightened Thermoswitch (engine) crankcase Oil pressure switch Anode cover anode Anode cover upper crankcase Oil pan lower crankcase 1st 2nd 3rd 4th
Lower crankcase upper crankcase
Oil pipe lower crankcase Oil filter bolt lower crankcase 1st Connecting rod cap 2nd 1st Thermostat housing cover Thermostat housing 2nd 1st Thermostat housing holder oil tank 2nd Grease nipple thermostat housing cover Jet pump unit Steering cable joint jet thrust nozzle Ride plate hull Intake duct hull Intake grate hull Speed sensor ride plate Jet pump unit assembly/impeller housing 2 transom plate Rubber plate bracket Bracket hull Roller reverse gate stay Reverse gate stay jet pump Reverse gate reverse gate stay Lever 1 Reverse gate stay Lever 2 Reverse gate stay Shift cable ball joint lever 1 Spout hose clamp spout hose/nozzle Nozzle ring nozzle Jet thrust nozzle nozzle ring
8.4 0.84 6.1 12 1.2 8.7 20 2.0 14 12 1.2 8.7 12 1.2 8.7 7.8 0.78 5.6 Loosen completely 15 1.5 11 5 49 12 1.2 8.7 35 3.5 25 20 2.0 14 5 120 3.7 0.37 2.7 7.6 0.76 5.5 3.7 0.37 2.7 7.6 0.76 5.5 5.9 0.59 4.3
Nut Bolt Bolt Bolt Screw Bolt Bolt Bolt Bolt Bolt Nut Bolt Bolt Bolt Nut Nut Bolt Bolt
M8 M8 M6 M5 M10 M6 M6 M8 M8 M6 M8 M6 M8 M8
1 4 4 4 4 4 1 6 2 1 1 6 2 1 1 1 1 2 2
6.8 17 17 7.6 3.7 40 7.8 6.8 14 8.3 26 7.8 20 7.8 7.8 7.8 1.2 15 15
0.68 1.7 1.7 0.76 0.37 4.0 0.78 0.68 1.4 0.83 2.6 0.78 2.0 0.78 0.78 0.78 0.12 1.5 1.5
4.9 12 12 5.5 2.7 29 5.6 4.9 10 6.0 19 5.6 14 5.6 5.6 5.6 0.9 11 11
2-13
271
LT
271
LT
242
LT
242
LT
242
LT
242
LT
242
LT
271
LT
271
LT
572
LT
242
LT
242
LT
242
LT
572
LT
242
LT
572
LT
572
LT
572
LT
572
LT
572
LT
271
LT
572
SPEC
TIGHTENING TORQUES
Part name Nut Bolt Bolt Nut Impeller Nut Bolt Driven coupling Nipple Bolt Bolt Screw Screw Nut Screw Screw Screw Bolt Screw Nut Nut Bolt Bolt Bolt Nut Nut Bolt Bolt Bolt Nut Thread Qty size 1 M10 M6 M22 M8 M24 M8 M6 M6 M6 M5 M5 M6 M5 M4 M8 M5 M5 M5 M6 M6 4 4 1 1 4 3 1 1 4 2 4 4 2 2 2 1 2 1 4 1 1 2 1 1 1 2 4 4 1 Tightening torque Nm kgfm ftlb 7.8 0.78 5.6 40 6.6 69 75 26 17 36 5.4 20 1.1 1.1 0.9 5.4 3.5 3.4 3.4 1.2 1 20 6.8 18 2.8 2.8 3 2.9 6.8 6.8 6.8 5.9 4.0 0.66 6.9 7.5 2.6 1.7 3.6 0.54 2.0 0.11 0.11 0.09 0.54 0.35 0.34 0.34 0.12 0.1 2.0 0.68 1.8 0.28 0.28 0.3 0.29 0.68 0.68 0.68 0.59 29 4.8 50 54 19 12 25 3.9 14 0.8 0.8 0.7 3.9 2.5 2.5 2.5 0.9 0.7 14 4.9 13 2.1 2.1 2.2 2.1 4.9 4.9 4.9 4.3
E Remarks
Part to tightened QSTS cable ball joint nozzle ring Nozzle/impeller duct assembly impeller housing 1 Water inlet cover/water inlet strainer impeller duct Drive shaft nut drive shaft Impeller (left-hand threads) drive shaft Transom plate hull Intermediate housing bulkhead Driven coupling shaft Grease nipple intermediate housing Hull and hood Handlebar holder steering master Handlebar cover stay steering master Handlebar cover handlebar cover stay Handle boss cover steering master QSTS converter hull Throttle lever assembly handlebar Handlebar switch assembly handlebar QSTS grip assembly handlebar Grip end handlebar Cable housing QSTS grip assembly Steering master deck Steering cable ball joint steering arm Steering arm steering master Steering switch steering master Magneto steering arm QSTS cable locknut (QSTS converter side) QSTS cable locknut (jet pump side) Steering shaft 1 cap Upper housing lower housing Retainer steering tube QSTS cable grommet hull
2-14
271
LT
572
LT
271
LT
242
LT
242
LT
242
LT
271
LT
242
LT
572
LT
572
LT
572
LT
572
LT
572
LT
572
LT
SPEC
TIGHTENING TORQUES
Part name Nut Nut Nut Nut Nut Nut Nut Nut Nut Nut Nut Nut Bolt Bolt Nut Bolt Screw Bolt Bolt Nut Bolt Bolt Bolt Nut Nut Bolt Screw Nut Nut Screw Bolt Nut Thread Qty size M6 M6 M6 M4 M5 M5 M6 M6 M6 M6 M6 M6 M6 1 1 1 2 1 1 1 1 1 2 2 1 6 2 4 4 4 4 4 4 8 2 2 2 2 2 2 2 3 3 1 1 Tightening torque Nm kgfm ftlb 3.8 2.9 5.9 5.4 6.4 6.5 5.9 16 16 6.4 5.4 5.9 5.4 5.4 5.4 5.4 1.5 3.9 3.9 6.9 5.4 5.4 5.4 5.4 20 5.4 5.4 4.2 5.4 5.4 5.4 6.8 0.38 0.29 0.59 0.54 0.64 0.65 0.59 1.6 1.6 0.64 0.54 0.59 0.54 0.54 0.54 0.54 0.15 0.39 0.39 0.69 0.54 0.54 0.54 0.54 2.0 0.54 0.54 0.42 0.54 0.54 0.54 0.68 2.7 2.1 4.3 3.9 4.6 4.7 4.3 11 11 4.6 3.9 4.3 3.9 3.9 3.9 3.9 1.1 2.8 2.8 5.0 3.9 3.9 3.9 3.9 14 3.9 3.9 3.0 3.9 3.9 3.9 4.9
E Remarks
Part to tightened QSTS cable end pin QSTS converter Shift cable locknut (reverse gate side) Shift cable grommet hull Shift cable holder shift lever base Steering cable locknut (steering master side) Steering cable locknut (jet pump side) Steering cable grommet hull QSTS cable 1 locknut QSTS cable 2 locknut Steering cable bracket steering cable holder Steering cable bracket deck Speed sensor lead grommet hull Hinge assembly front hood assembly Hood lock assembly front hood assembly Hinge assembly deck Service lid 1 deck Service lid 2 deck Panel steering console cover Multifunction meter steering console cover Mirror steering console cover Side cover deck Steering console cover glove box Hood lock assembly Steering console cover deck Glove compartment deck Shift lever handle shift lever Latch glove compartment Pilot water outlet hull Shift lever plate deck Shift lever plate deck/shift lever base assembly Shift lever base assembly Shift cable ball joint base assembly
2-15
271
LT
242
LT
271
LT
271
LT
242
LT
271
LT
242
LT
242
LT
271
LT
242
LT
242
LT
572
LT
572
LT
SPEC
TIGHTENING TORQUES
Part name Nut Nut Nut Nut Nut Nut Bolt Bolt Nut Bolt Nut Nut Nut Bolt Nut Nut Screw Bolt Bolt Bolt Bolt Bolt Screw Tapping screw Screw Screw Tapping screw Tapping screw Thread Qty size 4 2 1 1 4 4 M6 2 M6 2 M8 M6 M5 M8 M6 M6 M6 M8 M5 5 M6 M6 6 6 6 1 2 1 1 2 10 2 4 1 4 3 2 4 8 4 2 2 4 4 18 1 1 1 4 Tightening torque Nm kgfm ftlb 5.2 0.52 3.8 15 1.5 11 26 2.6 19 26 2.6 19 6.4 0.64 4.6 18 1.8 13 6.4 0.64 4.6 6.4 0.64 4.6 5.4 3.7 3.7 3.7 3.7 2.5 16 15 15 5.4 5.4 5.4 13 2.0 17 6.4 5.4 5.4 17 4.9 4.9 7.6 7.6 3.9 3.9 0.54 0.37 0.37 0.37 0.37 0.25 1.6 1.5 1.5 0.54 0.54 0.54 1.3 0.2 1.7 0.64 0.54 0.54 1.7 0.49 0.49 0.76 0.76 0.39 0.39 3.9 2.7 2.7 2.7 2.7 1.8 12 11 11 3.9 3.9 3.9 9.4 1.4 12 4.6 3.9 3.9 12 3.5 3.5 5.5 5.5 2.8 2.8
A A
E Remarks
Part to tightened Hand grip deck Front seat stay deck Seat lock projection deck beam Seat lock projection deck Rear seat stay deck beam Deck beam deck Seat lock assembly front seat Seat lock assembly rear seat Plate/rubber hose/exhaust valve hull Hose clamp rubber hose/water lock Hose clamp rubber hose/water tank Joint clamp joint/water lock Joint clamp joint/exhaust pipe 3 Joint clamp joint/exhaust joint Sponson hull Cleat deck Cleat hull Spout hull Protector (bow) hull Bow eye hull Drain plug/packing hull Engine mount hull Engine damper hull Electrical Battery box hull Battery box/spacer hull Electrical box bulk head Terminal cover electrical box Cover electrical box Starter motor lead electrical box Battery positive lead electrical box Fuse holder stay electrical box ECM electrical box
2-16
572
LT
271
LT
572
LT
271
LT
572
LT
271
LT
242
LT
271
LT
271
LT
SPEC
TIGHTENING TORQUES
Part name Tapping screw Tapping screw Tapping screw Tapping screw Bolt Nut Bolt Tapping screw Thread Qty size 6 6 6 6 M6 M5 2 1 2 1 2 4 1 2 6 Tightening torque Nm kgfm ftlb 3.9 3.9 3.9 3.9 7.6 8.8 6.4 0.1 0.39 0.39 0.39 0.39 0.76 0.88 0.64 0.01 2.8 2.8 2.8 2.8 5.5 6.4 4.6 0.07
E Remarks
Part to tightened Bracket (coupler) electrical box Slant detection switch electrical box Main and fuel pump relay electrical box Rectifier/regulator electrical box Ignition coil cylinder head cover Brush assembly/spacer starter motor yoke Starter motor rear cover starter motor front cover Cover remote control transmitter
Nut A 8 mm 10 mm 12 mm 14 mm 17 mm
Bolt B M5 M6 M8 M10 M12
General torque specifications Nm kgfm ftlb 5.0 0.5 3.6 8.0 0.8 5.8 18 1.8 13 36 3.6 25 43 4.3 31
GENERAL TORQUE
This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections 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 torque specifications require clean, dry threads. Components should be at room temperature.
2-17
572
LT
SPEC
CABLE AND HOSE ROUTING
H F 9
UP DOWN
DOWN
1 1 2 A-A
9 4
I A B B H H D C C D A
BOW
20
0 B-B 3
8 I
2 C-C A
6 E
E E
7 H-H D
G F G
2 D-D
6
F
7
+
B C 4 E-E 5 5
G-G 6 6
G F-F 3
1 2 3 4 5 6 7 8 9 0 Steering switch lead Fuel tank breather hose QSTS cable Steering cable Shift cable Speed sensor lead Electrical box lead Cooling water pilot outlet Cooling water pilot outlet hose Cooling water pilot outlet A B C D E F G H I
Negative battery lead Positive battery lead Battery Throttle cable Fuel hose Handlebar switch lead Electrical bilge pump lead Remote control unit lead Remote control unit antenna
2-18
SPEC
2 1 3 4 5 A
B
K
A
B C A 2 D E
C D
I C
MAIN
A 6 1 6 A B 6 C
E
3A
A
3A
3A
20A
3A
SPARE
7 8 9 E 0
D 9
F
1 2 3 4 5 6 7 8 9 0 Steering switch lead Throttle cable Handlebar switch lead QSTS cable Buzzer lead Fuel tank breather hose Ignition coil lead Positive battery lead Starter motor lead Wire harness A B C D E F G H I Fuel hose Shift cable Steering cable Electrical box lead Cooling water pilot outlet hose Negative battery lead Battery breather hose Speed sensor lead Electrical bilge pump lead
E-E
J Remote control unit lead K Remote control unit antenna
2-19
SPEC
4 5 6
9 7 2
8 6
0 H 5 2
A C
1 A 2 8 G A-A
A
9 C D
F E
1 2 3 4 5 6 7 8 9 0 Cooling water hose (cooling water inlet) Bilge hose 1 Electric bilge pump Bilge hose 4 Cooling water hose (from thermostat) Bilge hose 3 Bilge hose 2 Shift cable Cooling water hose (from exhaust pipe) Electrical box
A B C D E F G H
QSTS cable Positive battery lead Speed sensor lead Electric bilge pump lead Bilge strainer Negative battery lead Steering cable Flushing hose
Pass the QSTS cable between the bilge hoses.

2-20
SPEC
1 1
A C D B C E
3 C-C D
4 5 G
F E-E
1 2 3 4
Thermostat Cooling water pilot outlet hose Cooling water hose Cooling water hose (cooling water inlet) 5 Negative battery lead
To cooling water pilot outlet on starboard side To cooling water outlet on starboard side of stern To cylinder block From exhaust manifold To install the hose, align the white paint mark on the cooling water hose with the projection of the hose joint.
When installing the cooling water hoses, be sure to push them down until they contact the hose joint.
2-21
SPEC
1 1
A C D B C E
3 C-C D
4 5 G
F E-E
Bundle the cooling water pilot outlet hose and cooling water hoses, pass a plastic tie through the stay hole, and then fasten the tie. Set the tie in the direction shown. To cooling water pilot outlet on port side To cooling water outlet at stern Cooling water inlet To exhaust pipe
To install the cooling water hose, align the white paint mark on the hose with the parting line on the hose joint. Fasten the cooling water hose and negative battery lead with a plastic tie. Set the tie in the direction shown.
2-22
SPEC
1 1
A C D B C E
3 C-C D
4 5 G
F E-E
Bundle the cooling water hose (cylinder head cover to thermostat) and cooling water hose (starboard cooling water pilot outlet), and then fasten them with a plastic tie to the oil tank boss. When bundling the hoses, make sure that the cooling water hose (cylinder head cover to thermostat) is routed on the deck side and that the cooling water hose (starboard cooling water pilot outlet) is routed on the engine side. Insert the cooling water hose to the paint mark.
Fasten the end of the cooling water hose tube that is contacting the hose joint with a plastic tie. Cooling water passage
2-23
SPEC
8 7
A B C
1 2
A
5 4 3
0 B
1 4 A-A B C
1 2 3 4 5 6 7 8 9 0
Wiring harness Ground lead Wiring harness coupler Noise filter Oil pressure switch coupler Pickup coil coupler Thermoswitch (engine) coupler Lighting coil coupler Thermoswitch (exhaust) Thermoswitch (exhaust) coupler
A Cam position sensor coupler B Oil pressure switch lead To electrical box To cam position sensor Fasten the plastic tie with its end facing downward. To oil pressure switch To engine temperature sensor
2-24
SPEC
1 2
A
4 3
6 8
9 0
A-A
1 2 3 4 5 6 7 8 9 0
Engine temperature sensor coupler Lighting coil coupler Pickup coil coupler Thermoswitch (engine) coupler Thermoswitch (engine) Starter motor Engine temperature sensor Engine temperature sensor lead Thermoswitch (engine) lead Lighting coil lead
2-25
SPEC
1 2
A
4 3
6 8
9 0
A-A
Route the starter motor lead to the outside of the engine temperature sensor lead. To starter relay To negative battery terminal Route the starter motor and negative battery leads behind the cooling water hose. Route the starter motor lead over the cooling water hose.
Fasten the engine temperature sensor lead, thermoswitch lead, and lighting coil lead with a plastic tie. Fasten the engine temperature sensor lead 1020 mm (0.40.8 in) from the end of the protective cover of the lead. To generator To engine temperature sensor To thermoswitch (engine) To thermoswitch (engine) coupler To engine temperature sensor coupler
2-26
INSP ADJ
CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT
MAINTENANCE INTERVAL CHART .............................................................. 3-1 PERIODIC SERVICE .......................................................................................3-2 CONTROL SYSTEM ................................................................................. 3-2 Steering master inspection..................................................................3-2 Steering cable inspection and adjustment .......................................... 3-2 Throttle cable inspection and adjustment............................................3-3 QSTS cable inspection and adjustment ..............................................3-5 Shift cable inspection and adjustment................................................. 3-7 Trolling speed check and adjustment.................................................. 3-8 FUEL SYSTEM.......................................................................................... 3-9 Fuel line inspection .............................................................................3-9 Water separator inspection ...............................................................3-10 POWER UNIT.......................................................................................... 3-10 Valve clearance adjustment ..............................................................3-10 Engine oil level check........................................................................3-16 Engine oil change using oil changer............................................. 3-18 Air filter element clean....................................................................... 3-20 Spark plug inspection........................................................................3-21 ELECTRICAL .......................................................................................... 3-24 Battery inspection.............................................................................. 3-24 JET PUMP UNIT .....................................................................................3-27 Impeller inspection ............................................................................3-27 Water inlet strainer inspection........................................................... 3-27 BILGE PUMP........................................................................................... 3-28 Bilge strainer inspection .................................................................... 3-28 Electric bilge pump strainer inspection.............................................. 3-28 GENERAL ...............................................................................................3-29 Drain plug inspection.........................................................................3-29 Lubrication points .............................................................................. 3-29
INSP ADJ
MAINTENANCE INTERVAL CHART

The following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the intervals of maintenance should be changed.
MAINTENANCE INTERVAL THEREAFTER PAGE EVERY 10 hours 50 hours 100 hours 100 hours 200 hours 6 12 12 24 months months months months Inspect, clean, adjust 3-21 Lubricate 3-29 Lubricate *1 *2 *2 3-31 Inspect 3-9 Inspect, clean 3-9 Inspect, adjust 3-8 Inspect Flush *3 Inspect, clean 3-27 Clean 3-28 INITIAL Inspect, clean Inspect Inspect, adjust Inspect Inspect, adjust Inspect, adjust Inspect, adjust Inspect, replace Inspect Inspect Inspect Inspect Inspect Replace Replace Inspect, adjust 3-28 3-27 3-2 3-2 3-5 3-7 3-3 3-29 3-24 5-7 3-20 3-16 3-18 3-10
ITEM Spark plug Lubrication points Intermediate housing Fuel system Fuel tank Trolling speed Throttle shaft Cooling water passages Water inlet strainer Bilge strainer Electric bilge pump strainer Impeller Jet thrust nozzle angle Steering master QSTS mechanism Shift cable and mechanism Throttle cable Stern drain plugs Battery Rubber coupling Engine mount Nuts and bolts Air filter Engine oil Engine oil filter Valve clearance
*1: Grease quantity: 33.035.0 cm3 (1.111.18 oz) *2: Grease quantity: 6.08.0 cm3 (0.200.27 oz) *3: After every use
3-1
INSP ADJ
CONTROL SYSTEM PERIODIC SERVICE

CONTROL SYSTEM
Steering master inspection 1. Inspect: Steering master Excessive play Replace the steering master. Refer to STEERING MASTER in Chapter 8. Inspection steps: Move the handlebar up and down and back and forth. Check the excessive play of the handlebar.
Steering cable inspection and adjustment 1. Inspect: Jet thrust nozzle clearance a, b Difference Adjust. Inspection steps: Set the control grip in the neutral position. Turn the handlebar from lock to lock. Measure clearances a and b. If clearances a and b are not the same, adjust them. 2. Adjust: Steering cable joint (steering master end) Adjustment steps: Set the control grip in the neutral position. Loosen the locknut 1. Disconnect the cable joint 2 from the ball joint 3. Turn the cable joint 2 in or out for adjusting the clearances a and b. Turn in Turn out Clearance a is increased. Clearance b is increased.
3-2
INSP ADJ
CONTROL SYSTEM
WARNING
The cable joint must be screwed in more than 8 mm (0.31 in). Connect the cable joint and tighten the locknut. Locknut: 6.4 N m (0.64 kgf m, 4.6 ft lb)
NOTE: If the steering cable cannot be properly adjusted by the cable joint at the steering master end, adjust the cable joint at the jet pump end so that the same clearances are obtained. Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD in Chapter 8.
Throttle cable inspection and adjustment NOTE: Before adjusting the throttle lever free play, adjust the trolling speed. 1. Measure: Throttle lever free play a Out of specification Adjust. Throttle lever free play: 47 mm (0.160.28 in)
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3-3
INSP ADJ
CONTROL SYSTEM
2. Adjust: Throttle lever free play Adjustment steps:
NOTE: When not replacing the throttle cable or removing the cable from the throttle body, adjust the throttle cable free play by following steps (f) through (j). When replacing the throttle cable or removing the cable from the throttle body, adjust the throttle cable free play by following steps (a) through (k). a. Remove the air filter case cover 1 and ribbon sub assemblies. b. Loosen the locknut 2. c. Turn the adjusting nut 3 to adjust the length a. Throttle cable installation length: 24.4 1.0 mm (0.96 0.04 in) NOTE: Apply locking agent (LOCTITE) to the threads of the adjusting nut 3. d. Remove the handlebar cover. e. Loosen the locknut 4. f. Turn the adjuster 5 in or out until the specified free play is obtained. Turn in Turn out Free play is increased. Free play is decreased.
g. Tighten the locknut. NOTE: When adjusting the throttle cable at the throttle body, fully open the throttle lever and check that the butterfly valve is fully open. If the throttle cable free play cannot be adjusted properly, replace the throttle cable.
3-4
INSP ADJ
CONTROL SYSTEM
h. Install the handlebar cover.
Handlebar cover screw: 1.1 N m (0.11 kgf m, 0.8 ft lb) LOCTITE 242
i. Install the ribbon sub assemblies and air filter case cover. Ribbon sub assembly bolt: 6.5 N m (0.65 kgf m, 4.7 ft lb) LOCTITE 242 Air filter case cover screw: 2.5 N m (0.25 kgf m, 1.8 ft lb) LOCTITE 572
WARNING
After adjusting the free play, turn the handlebar to the right and left and make sure that the trolling speed does not increase.
QSTS cable inspection and adjustment 1. Measure: Jet thrust nozzle set length a, b Difference Adjust. Measurement steps: Set the control grip in the neutral position. Set the jet thrust nozzle in the center position. Measure the jet thrust nozzle set length a and b. If a and b lengths are not even, adjust the cable joint.
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INSP ADJ
CONTROL SYSTEM
2. Adjust: QSTS cable
Adjustment steps: Set the control grip in the neutral position. Loosen the locknut 1. Remove the nut 2 and pivot pin 3. Set the jet thrust nozzle in the center position. Turn the cable joint 4 for adjusting. Turn in Turn out Length a is increased. Length b is increased.
WARNING
The cable joint must be screwed in more than 8 mm (0.31 in). Connect the cable joint 4 and pivot pin 3 and tighten the nut 2. Nut: 3.8 N m (0.38 kgf m, 2.7 ft lb)
Tighten the locknut 1. Locknut: 3 N m (0.3 kgf m, 2.2 ft lb)
NOTE: If the QSTS cable cannot be properly adjusted by the cable joint at the QSTS converter end, adjust the cable joint at the jet pump end so that the same lengths are obtained. Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD in Chapter 8.
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3-6
INSP ADJ
CONTROL SYSTEM
Shift cable inspection and adjustment 1. Check: Reverse gate stopper lever position Incorrect Adjust.
Checking steps: Set the shift lever to the reverse position. Check that the reverse gate 1 contacts the stopper 2 on the bracket and the lever 3 contacts the reverse gate. Set the shift lever to the forward position. Check that the lever 4 has been shifted over the bracket 5.
5 4
2. Adjust: Shift cable joint Adjustment steps: Loosen the locknut 1. Disconnect the cable joint 2 from the ball joint 3. Situate the reverse gate to the stopper on the bracket and the lever to the reverse gate. Turn the cable joint to align it with the ball joint. Turn in Turn out Shortens. Lengthens.
Turn out the cable joint nine times a to extend cable 7 mm (0.28 in) from the aligned position.
WARNING
The cable joint must be screwed in more than 8 mm (0.31 in). Connect the cable joint and tighten the locknut. Locknut: 2.9 N m (0.29 kgf m, 2.1 ft lb) LOCTITE 572
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3-7
INSP ADJ
CONTROL SYSTEM
Trolling speed check and adjustment 1. Measure: Trolling speed Out of specification Adjust. Trolling speed: 1,5501,750 r/min
Checking steps: (Watercraft on water) Start the engine and allow it to warm up for a 15 minutes. Check the engine trolling speed using the tachometer of the multifunction meter or using the Yamaha Diagnostic System.
2. Adjust: Trolling speed Adjustment steps: Remove the air filter case cover 1. Start the engine. Turn the throttle stop screw 2 in or out until the specified speed is obtained. Turn in a Turn out b Increase trolling speed. Decrease trolling speed.
Install the air filter case cover. Air filter case cover screw: 2.5 N m (0.25 kgf m, 1.8 ft lb) LOCTITE 572
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3-8
INSP ADJ
FUEL SYSTEM
FUEL SYSTEM
WARNING
When removing fuel system parts, wrap them in a cloth and take care that no fuel spills into the engine compartment. Fuel line inspection 1. Inspect: Fuel pump filter Clog/contaminants Clean. Refer to FUEL TANK AND FUEL PUMP MODULE in Chapter 4. Fuel hose Damage/cracks Replace. O-rings (quick connector) Damage/cracks Replace the quick connector. Fuel pipe Damage/cracks Replace the fuel pump. Refer to FUEL INJECTION SYSTEM in Chapter 4. Fuel filler hose Fuel tank Fuel filler cap Cracks/damage Replace.
2. Inspect: Fuel tank Cracks/damage Replace. Water accumulation Remove. NOTE: To remove water from the fuel tank, remove the cap 1 and use a siphon pump. Fuel tank cap screw clamp: 1.3 N m (0.13 kgf m, 0.9 ft lb)
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3-9
INSP ADJ
FUEL SYSTEM/POWER UNIT

Water separator inspection 1. Inspect: Water separator 1 Water accumulation Drain.
1 2
NOTE: If need the water draining, remove the drain plug 2.
POWER UNIT
Valve clearance adjustment The following procedure applies to all of the valves. NOTE: Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: Air filter case Refer to FUEL INJECTION SYSTEM in Chapter 4. 2. Remove: Ignition coils Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS in Chapter 5. 3. Install: Dial gauge needle Dial gauge stand 1 (into spark plug hole #1) Dial gauge 2 Dial gauge stand: 90890-06583 Dial gauge needle: 90890-06584 Dial gauge stand set: YW-06585/90890-06585 Dial gauge: YU-03097/90890-01252
2 1
3-10
INSP ADJ
POWER UNIT
4. Measure: Valve clearance Out of specification Adjust. Valve clearance (cold): Intake valve: 0.110.20 mm (0.00430.0079 in) Exhaust valve: 0.250.34 mm (0.00980.0134 in)
IN EX
Measurement steps: Turn the drive coupling counterclockwise, and then check if cylinder #1 is at TDC of the compression stroke with a dial gauge. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. Measure the valve clearance with a thickness gauge 1. NOTE: If the valve clearance is incorrect, record the measured reading. Measure the valve clearance in the following sequence. Valve clearance measuring sequence Cylinder #1 #2 #4 #3
Bow side
To measure the valve clearances of the other cylinders, starting with cylinder #1 at TDC, turn the drive coupling counterclockwise as specified in the following table.
Degrees that the crankshaft is turned clockwise Cylinder Combustion cycle
180
360
540
720
Cylinder #2 Cylinder #4 Cylinder #3
180 360 540
#1
#2 #3 #4
3-11
INSP ADJ
POWER UNIT
5. Remove: Timing chain tensioner cap bolt 1 Gasket
6. Turn the timing chain tensioner rod fully clockwise with a thin screwdriver 1. NOTE: Make sure that the tensioner rod has been fully set clockwise.
7. Remove: Intake camshaft caps Exhaust camshaft caps Timing chain (from the camshaft sprockets) Intake camshaft Exhaust camshaft NOTE: Refer to CAMSHAFTS in Chapter 5. When removing the timing chain and camshafts, fasten the timing chain with a wire to prevent it from falling into the crankcase.
3-12
INSP ADJ
POWER UNIT
8. Adjust: Valve clearance
1 2
Adjustment steps: Remove the valve lifter 1 and the valve pad 2. NOTE: Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. Make a note of the position of each valve lifter 3 and valve pad 4 so that they can be installed in the correct place. Select the proper valve pad from the following table. Valve pad thickness range Nos. 120240 Available valve pads
1.20 25 thicknesses in 2.40 mm 0.05 mm increments
a
148
NOTE: The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. Since valve pads of various sizes are originally installed, the valve pad number must be rounded in order to reach the closest equivalent to the original. Round off the original valve pad number according to the following table. Last digit 0 or 2 5 8 Rounded value 0 5 10
EXAMPLE: Original valve pad number = 148 (thickness = 1.48 mm) Rounded value = 150 Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number.
3-13
INSP ADJ
POWER UNIT
6 5
NOTE: The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect. Install the new valve pad 5 and the valve lifter 6. NOTE: Lubricate the valve pad with molybdenum disulfide grease. Lubricate the valve lifter with molybdenum disulfide oil. The valve lifter must turn smoothly when rotated by hand. Install the valve lifter and the valve pad in the correct place. Install the exhaust and intake camshafts, timing chain and camshaft caps. Camshaft cap bolt: 10 N m (1.0 kgf m, 7.2 ft lb)
NOTE: Refer to Camshaft installation CAMSHAFTS in Chapter 5. Lubricate the camshafts, camshaft lobes and camshaft journals. First, install the exhaust camshaft. Align the camshaft marks with the camshaft cap marks. Turn the crankshaft clockwise several full turns to seat the parts. Measure the valve clearance again. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained.
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3-14
INSP ADJ
Intake
MEASURED CLEARANCE 0.000.02 0.030.07 0.080.10 0.110.20 0.210.22 0.230.27 0.280.32 0.330.37 0.380.42 0.430.47 0.480.52 0.530.57 0.580.62 0.630.67 0.680.72 0.730.77 0.780.82 0.830.87 0.880.92 0.930.97 0.981.02 1.031.07 1.081.12 1.131.17 1.181.22 1.231.27 1.281.32 1.331.37
POWER UNIT
ORIGINAL VALVE PAD NUMBER 165 170 175 180 185 190 195 200 205 210 150 155 160 165 170 175 180 185 190 195 155 160 165 170 175 180 185 190 195 200 160 165 170 175 180 185 190 195 200 205 STANDARD CLEARANCE 165 170 175 180 185 190 195 200 205 210 215 170 175 180 185 190 195 200 205 210 215 220 175 180 185 190 195 200 205 210 215 220 225 180 185 190 195 200 205 210 215 220 225 230 185 190 195 200 205 210 215 220 225 230 235 190 195 200 205 210 215 220 225 230 235 240 195 200 205 210 215 220 225 230 235 240 200 205 210 215 220 225 230 235 240 205 210 215 220 225 230 235 240 210 215 220 225 230 235 240 215 220 225 230 235 240 220 225 230 235 240 225 230 235 240 230 235 240 235 240 Example: 240 Intake valve clearance (cold) 160 145 150 155
120 125 130 135 120 120 125 120 125 130 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
140 125 130 135 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
145 130 135 140 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
150 135 140 145 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
155 140 145 150 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
215 200 205 210 220 225 230 235 240
220 205 210 215
225 210 215 220
230 215 220 225
235 220 225 230
240 225 230 235
225 230 235 240 230 235 240 235 240 240
0.110.20 mm (0.00430.0079 in) Rounded value 150 Measured valve clearance is 0.24 mm (0.0094 in) Replace pad 150 with pad 160 Pad No. 150 = 1.50 mm (0.0591 in) Pad No. 160 = 1.60 mm (0.0630 in)
Exhaust
MEASURED CLEARANCE 0.000.01 0.020.06 0.070.11 0.120.16 0.170.21 0.220.24 0.250.34 0.350.37 0.380.42 0.430.47 0.480.52 0.530.57 0.580.62 0.630.67 0.680.72 0.730.77 0.780.82 0.830.87 0.880.92 0.930.97 0.981.02 1.031.07 1.081.12 1.131.17 1.181.22 1.231.27 1.281.32 1.331.37 1.381.42 1.431.47 1.481.52 120 125 130 135 140 145 150 120 120 125 120 125 130 120 125 130 135 120 125 130 135 140 120 125 130 135 140 145 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 155 125 130 135 140 145 150 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 ORIGINAL VALVE PAD NUMBER 165 170 175 180 185 190 195 200 205 210 215 135 140 145 150 155 160 165 170 175 180 185 140 145 150 155 160 165 170 175 180 185 190 145 150 155 160 165 170 175 180 185 190 195 150 155 160 165 170 175 180 185 190 195 200 155 160 165 170 175 180 185 190 195 200 205 160 165 170 175 180 185 190 195 200 205 210 STANDARD CLEARANCE 165 170 175 180 185 190 195 200 205 210 215 220 170 175 180 185 190 195 200 205 210 215 220 225 175 180 185 190 195 200 205 210 215 220 225 230 180 185 190 195 200 205 210 215 220 225 230 235 185 190 195 200 205 210 215 220 225 230 235 240 190 195 200 205 210 215 220 225 230 235 240 195 200 205 210 215 220 225 230 235 240 200 205 210 215 220 225 230 235 240 205 210 215 220 225 230 235 240 210 215 220 225 230 235 240 215 220 225 230 235 240 220 225 230 235 240 225 230 235 240 230 235 240 235 240 Example: 240 Exhaust valve clearance (cold) 160 130 135 140 145 150 155 220 190 195 200 205 210 215 225 195 200 205 210 215 220 230 200 205 210 215 220 225 235 205 210 215 220 225 230 240 210 215 220 225 230 235
225 230 235 240 230 235 240 235 240 240
0.250.34 mm (0.00980.0134 in) Rounded value 170 Measured valve clearance is 0.44 mm (0.0173 in) Replace pad 170 with pad 185 Pad No. 170 = 1.70 mm (0.0669 in) Pad No. 185 = 1.85 mm (0.0728 in)
3-15
INSP ADJ
POWER UNIT
9. Remove: Dial gauge Dial gauge stand Dial gauge needle 10. Install: All removed parts
NOTE: For installation, reverse the removal procedure.
Engine oil level check 1. Check: Engine oil level Checking steps:
CAUTION:
When checking the engine oil level on water, be careful of other watercraft, boats, swimmers, or obstacles. The water current or wind can cause the watercraft to move and lead to a collision. When checking the engine oil level on land, supply water to the cooling water passages. Make sure that engine has enough oil but do not overfill. If there is too little oil, the engine can be damaged. if there is too much oil, the air filter can become saturated with oil, permanently damaging the filter and reducing engine performance. Follow the checking procedure carefully. Make sure that debris or water does not enter the oil tank filler hole. Debris or water in the engine oil can cause serious engine damage.
3-16
INSP ADJ
POWER UNIT
Place the watercraft in a horizontal position or launch the watercraft. Remove the rear and front seats. Remove the oil tank filler cap 1 and check for oil on the dipstick 2. If there is no oil on the dipstick, pour enough oil so that the tip of the dipstick comes into contact with the oil, and then install the filler cap. Start the engine.
CAUTION:
When starting the engine make sure the dipstick is securely fitted into the oil tank. NOTE: The engine cannot be started if the Yamaha Security System is in the lock mode. For information on the Yamaha Security System, see the owners manual. Run the engine at trolling speed for 6 minutes or more, and then stop the engine.
CAUTION:
When checking the oil level on land, be sure to connect a garden hose to the watercraft for proper water supply. NOTE: If the ambient temperature is 20 C (68 F) or less, warm up the engine for an additional 5 minutes. Remove the oil tank filler cap 1, wipe the dipstick 2 clean, and then screw the filler cap into the filler hole completely.
3-17
INSP ADJ
POWER UNIT
Remove the filler cap again and check that the oil level is between the minimum level mark a and maximum level mark b on the dipstick. If the engine oil is below the minimum level mark a, add sufficient oil of the recommended type to raise it to the correct level. If the engine oil is above the maximum level mark b, extract sufficient oil using an oil changer to lower it to the correct level. NOTE: If the oil temperature is low, the reading on the dipstick will be low, and if the temperature is high, the reading on the dipstick will be high.
Engine oil change using oil changer
WARNING
Avoid changing the engine oil immediately after turning the engine off. The oil is hot and should be handled with care to avoid burns.
CAUTION:
Do not run the engine with too much or not enough oil in the oil tank. Oil could spray out or the engine could be damaged. Do not run the engine for more than 15 seconds without supplying water, when checking the oil level on land. The engine could overheat. Be sure to change the engine oil after the first 10 hours of operation, and every 100 hours thereafter or at the start of a new season, otherwise the engine will wear quickly. 1. Warm the engine up, and then put the watercraft in a horizontal position.
3-18
INSP ADJ
POWER UNIT
2. Remove: Oil filler cap 1
3. Insert the tube of an oil changer into the oil filler hole. 4. Operate the oil changer to extract the oil.
5. If the oil filter is also to be replaced, perform the following procedure. Replacing steps: Place a rag under the oil filter. Remove the oil filter 1 with an oil filter wrench.
Oil filter wrench: YU-38411/90890-01426 Lubricate the O-ring 2 of the new oil filter with a thin coat of engine oil.
CAUTION:
Make sure the O-ring 2 is positioned correctly in the groove of the oil filter. Tighten the new oil filter to specification with an oil filter wrench. Oil filter: 17 N m (1.7 kgf m, 12 ft lb)
6. Pour the specified amount of the recommended engine oil into the oil filler hole.
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3-19
INSP ADJ
POWER UNIT
E 7. Fill: Oil tank (with the specified amount of the recommended engine oil) Recommended oil: SAE 10W-30 API SE, SF, SG, SH, SJ, SL Oil quantity: Total amount: 4.5 L (4.8 US qt, 4.0 Imp qt) Without oil filter replacement: 2.1 L (2.2 US qt, 1.8 Imp qt) With oil filter replacement: 2.3 L (2.4 US qt, 2.0 Imp qt)
CAUTION:
When starting the engine make sure the dipstick is securely fitted into the oil tank. 8. Install: Oil filler cap
Air filter element clean 1. Remove: Air filter case cover 1
3-20
INSP ADJ
POWER UNIT
E 2. Remove the air filter element and check it for dirt and oil. Replace the air filter element if there is any oil buildup.
CAUTION:
Make sure that the air filter element is installed in the filter case properly. Do not start the engine with the air filter element removed, otherwise the engine could be damaged. If cleaning the air filter element, use cold or lukewarm water and let it air dry completely. Do not use detergent or an solvent to clean the air filter element, or dry it with heat or compressed air, otherwise it could be damaged.
3. Install: Air filter case cover Air filter case cover screw: 2.5 N m (0.25 kgf m, 1.8 ft lb) LOCTITE 572
Spark plug inspection 1. Remove: Air filter case cover 1
2. Remove: Air filter element Ignition coils
CAUTION:
Be careful not to get any foreign substances or water in the air intake port and spark plug hole.
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3-21
INSP ADJ
POWER UNIT
E 3. Inspect: Electrodes 1 Damage/wear Replace. Insulator color 2 Distinctly different color Check the engine condition. Color guide: Medium to light tan color: Normal Whitish color: Lean fuel mixture Air leak Incorrect settings Blackish color: Overly rich mixture Electrical malfunction Defective spark plug
4. Clean: Spark plug (with a spark plug cleaner or wire brush)
5. Measure: Spark plug gap a Out of specification Regap. Spark plug gap: 0.70.8 mm (0.0280.031 in)
3-22
INSP ADJ
POWER UNIT
6. Tighten: Spark plug
Spark plug: 13 N m (1.3 kgf m, 9.4 ft lb)
NOTE: Before installing the spark plug, clean the gasket surface and spark plug surface. Also, it is suggested to apply a thin film of antiseize compound to the spark plug threads to prevent thread seizure. If a torque wrench is not available, a good estimate of the correct tightening torque for a new spark plug is to finger tighten a the spark plug and then tighten it another 1/4 to 1/2 of a turn b.
7. Install: Ignition coils Air filter element Air filter case cover Ignition coil bolt: 7.6 N m (0.76 kgf m, 5.5 ft lb) LOCTITE 572 Air filter case cover screw: 2.5 N m (0.25 kgf m, 1.8 ft lb) LOCTITE 572
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3-23
INSP ADJ
ELECTRICAL
ELECTRICAL
Battery inspection
WARNING
Battery electrolyte is poisonous and dangerous, causing severe burns, etc. Electrolyte contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidotes External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc., well away. If using or charging the battery in an enclosed space, make sure that it is well ventilated. Always shield your eyes when working near batteries. KEEP OUT OF THE REACH OF CHILDREN.
CAUTION:
Be careful not to place the battery on its side. Make sure to remove the battery from the battery compartment when adding battery electrolyte or charging the battery. When checking the battery, make sure the breather hose is connected to the battery and not obstructed.
3-24
INSP ADJ
ELECTRICAL
1. Remove: Bands Battery negative lead 1 Battery positive lead 2 Battery Battery breather hose 3
2 3
WARNING
When removing the battery, disconnect the negative lead first. Remove the battery to prevent acid loss during turning the machine on its side for the impeller service.
2. Inspect: Electrolyte level Low Add distilled water. The electrolyte level should be between the upper a and lower b level marks. Filling steps: Remove each filler cap. Add distilled water. When the electrolyte level reaches the upper level mark, allow the cell to stand for 20 minutes. If the electrolyte level drops, add more distilled water so the level reaches the upper level mark.
CAUTION:
Use only distilled water. Other types of water contain minerals which are harmful to batteries.
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INSP ADJ
ELECTRICAL
3. Inspect: Specific gravity Out of specification Charge.
Specific gravity at 20 C (68 F): 1.28 Charging current: 1.9 amps 10 hrs 4. Install: Filler caps
CAUTION:
Before installation, rinse off any fluid from the battery box and battery and make sure that the battery is dry before installing it.
2 1
5. Install: Battery breather hose 1 Battery Battery positive lead 2 Battery negative lead 3 Bands
CAUTION:
Connect the positive lead to the battery terminal first. Make sure the battery leads are connected properly. Reversing the leads can seriously damage the electrical system. Make sure that the battery breather hose is properly connected and is not obstructed. Coat the terminals with a water resistant grease to minimize terminal corrosion.
3-26
INSP ADJ
JET PUMP UNIT

JET PUMP UNIT
Impeller inspection 1. Check: Impeller 1 Damage/wear Replace. Nicks/scratches File or grind. 2. Measure: Impeller-to-housing clearance a Out of specification Replace.
Maximum impeller-to-housing clearance: 0.350.45 mm (0.01380.0177 in) Measurement steps: Remove the battery leads. Remove the intake grate and intake duct. Refer to INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT in Chapter 6. Measure the clearance at each impeller blade as shown (a total of three measurements). Install the intake duct and intake grate. Refer to INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT in Chapter 6. Install the battery leads.
Water inlet strainer inspection 1. Inspect: Water inlet strainer Contaminants Clean. Cracks/damage Replace. Inspection steps: Remove the ride plate. Refer to INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT in Chapter 6. Remove the rubber plate. Refer to JET PUMP UNIT in Chapter 6. Remove the water inlet cover 1. Inspect the water inlet strainer mesh a. Install the water inlet cover. Install the rubber plate. Refer to JET PUMP UNIT in Chapter 6. Install the ride plate. Refer to INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT in Chapter 6.
3-27
INSP ADJ
BILGE PUMP
BILGE PUMP
Bilge strainer inspection 1. Inspect: Bilge strainer Contaminants Clean. Cracks/damage Replace.
Inspection steps: Remove the deck beam. Refer to SEATS AND HAND GRIP in Chapter 8. Remove the coupling cover. Disconnect the bilge strainer case 1 from the bilge strainer. Inspect the bilge strainer. Install the coupling cover. Install the deck beam. Refer to SEATS AND HAND GRIP in Chapter 8.
Electric bilge pump strainer inspection 1. Inspect: Cap Strainer Contaminants Clean.
Inspection steps: Remove the band 1. Remove the cap 2 and strainer 3. Inspect the cap and strainer. Install the strainer and cap. Install the band.
3 2
3-28
INSP ADJ
GENERAL
GENERAL
Drain plug inspection 1. Inspect: Drain plugs Cracks/damage Replace. O-rings Cracks/wear Replace. Screw threads Contaminants Clean. Lubrication points 1. Lubricate: Throttle cable (handlebar end) Recommended lubricant: Rust inhibitor
NOTE: Before lubricating the throttle cable, squeeze the throttle lever and remove the rubber seal 1. 2. Lubricate: Throttle cable (throttle body end) Recommended lubricant: Yamaha marine grease, Yamaha grease A (Water resistant grease)
3. Lubricate: QSTS control cables (handlebar end) Recommended lubricant: Yamaha marine grease, Yamaha grease A (Water resistant grease) NOTE: Before lubricating the QSTS control cables, remove the QSTS cable housing cover. Spray the rust inhibitor into the outer cables, and apply grease to the inner cables.
3-29
INSP ADJ
GENERAL
4. Lubricate: QSTS cables (pulley end) Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease)
5. Lubricate: Nozzle pivot shaft Steering cable (nozzle end) QSTS cable (nozzle end) Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease)
6. Lubricate: Steering cable Steering cable joint Shift cable Shift cable joint NOTE: Disconnect the joints and apply a small amount of grease. Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease)
3-30
INSP ADJ
1
GENERAL
7. Fill: Intermediate housing
Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) Grease quantity: Initial 10 hours: 33.035.0 cm3 (1.111.18 oz) Every 100 hours or 12 months: 6.08.0 cm3 (0.200.27 oz) NOTE: Fill the intermediate housing with the recommended grease through the grease nipple 1.
3-31
FUEL
CHAPTER 4 FUEL SYSTEM
ARRANGEMENT OF THE THROTTLE BODY COMPONENTS COUPLERS .................................................................................................... 4-1 FUEL TANK AND FUEL PUMP MODULE......................................................4-2 EXPLODED DIAGRAM .............................................................................4-2 REMOVAL AND INSTALLATION CHART ................................................ 4-2 SERVICE POINTS .................................................................................... 4-5 Fuel hose disconnection ..................................................................... 4-5 Fuel pump module removal.................................................................4-5 Check valve inspection ....................................................................... 4-5 Rollover valve inspection .................................................................... 4-6 Fuel sender inspection ........................................................................ 4-6 Fuel tank inspection ............................................................................4-6 Fuel hose inspection ...........................................................................4-6 Fuel pump filter inspection ..................................................................4-6 Fuel pump module installation ............................................................ 4-7 Fuel hose connect............................................................................... 4-7 FUEL INJECTION SYSTEM............................................................................4-8 EXPLODED DIAGRAM .............................................................................4-8 REMOVAL AND INSTALLATION CHART ................................................ 4-8 SERVICE POINTS .................................................................................. 4-17 Hose clamps removal........................................................................4-17 Hose clamps installation ................................................................... 4-17 Fuel hose disconnection ................................................................... 4-17 Fuel line inspection ...........................................................................4-18 Fuel hose installation (replacing with new fuel hose)........................ 4-19 Fuel hose connection ........................................................................4-19 Throttle body removal ....................................................................... 4-19 Fuel injector inspection ..................................................................... 4-20 Throttle body inspection .................................................................... 4-20 Bypass valve motor inspection.......................................................... 4-21 Throttle body installation ................................................................... 4-21 Throttle bodies synchronization ........................................................ 4-22 Fuel pressure measurement ............................................................. 4-27
FUEL
ARRANGEMENT OF THE THROTTLE BODY COMPONENTS COUPLERS
ARRANGEMENT OF THE THROTTLE BODY COMPONENTS COUPLERS
3
A
8 3
2 A B
1 2 3 4 5 6 7 8
Bypass valve motor coupler Joint coupler Sensor assembly coupler Fuel injector #4 coupler Fuel injector #3 coupler Fuel injector #2 coupler Fuel injector #1 coupler Throttle position sensor coupler
To wiring harness Route the throttle cable between the sub-wiring harness. Route the sub-wiring harness under the intake vacuum hose. To fuel injector #3 Fasten the sub-wiring harness to the joint coupler bracket with a plastic tie as shown in the illustration.
Fasten the ring, which is attached to the sub-wiring harness, to the sensor assembly bracket with a plastic tie. Face the end of the plastic tie towards the sensor assembly.
4-1
FUEL
FUEL TANK AND FUEL PUMP MODULE

EXPLODED DIAGRAM
4 3 2 16 17 15 1 2
1st
3.2 N m (0.32 kgf m, 2.3 ft Ib)
2nd 6.4 N m (0.64 kgf m, 4.6 ft Ib)
6
1.3 N m (0.13 kgf m, 0.9 ft Ib)
10 8 11
13
5.9 N m (0.59 kgf m, 4.3 ft Ib)
12 14 13 18
20
4.2 N m (0.42 kgf m, 3.0 ft Ib)
LT
572
19 21
LT
572
16 N m (1.6 kgf m, 11 ft Ib) 8 18 mm
REMOVAL AND INSTALLATION CHART

Step Procedure/Part name FUEL TANK REMOVAL Service lid 1 Service lid 2 Ventilation hose Engine unit Qty Service points Follow the left Step for removal. Refer to FRONT HOOD in Chapter 8. From ventilation fitting Refer to ENGINE UNIT in Chapter 5. NOTE: When removing the pump module only, it is not necessary to remove the engine unit. 1 2 1
1 2 3
Rollover valve Fuel tank breather hose Check valve
4-2
FUEL
EXPLODED DIAGRAM
4 3 2 16 17 15 1 2
1st
3.2 N m (0.32 kgf m, 2.3 ft Ib)
2nd 6.4 N m (0.64 kgf m, 4.6 ft Ib)
6
1.3 N m (0.13 kgf m, 0.9 ft Ib)
10 8 11
13
5.9 N m (0.59 kgf m, 4.3 ft Ib)
12 14 13 18
20
4.2 N m (0.42 kgf m, 3.0 ft Ib)
LT
572
19 21
LT
572
16 N m (1.6 kgf m, 11 ft Ib) 8 18 mm
Step 4 5
Procedure/Part name Fuel tank breather hose Fuel sender coupler
Qty 1 1
Service points NOTE: Make sure that the inner seal of the coupler is installed properly before connecting the coupler.
6 7 8 9 10 11 12
Fuel pump module coupler Cover Fuel hose Nut Retainer Fuel pump module Packing
1 1 1 9 1 1 1
4-3
FUEL
EXPLODED DIAGRAM
4 3 2 16 17 15 1 2
1st
3.2 N m (0.32 kgf m, 2.3 ft Ib)
2nd 6.4 N m (0.64 kgf m, 4.6 ft Ib)
6
1.3 N m (0.13 kgf m, 0.9 ft Ib)
10 8 11
13
5.9 N m (0.59 kgf m, 4.3 ft Ib)
12 14 13 18
20
4.2 N m (0.42 kgf m, 3.0 ft Ib)
LT
572
19 21
LT
572
16 N m (1.6 kgf m, 11 ft Ib) 8 18 mm
Step 13 14 15 16 17 18 19 20 21
Procedure/Part name Hose clamp Fuel filler hose Nut Fuel filler neck Rubber seal Bolt Fuel tank assembly Bolt Fuel tank belt
Qty 2 1 1 1 1 2 1 2 2
Service points
Reverse the removal steps for installation.
4-4
FUEL

SERVICE POINTS
Fuel hose disconnection 1. Disconnect: Fuel hose Refer to FUEL INJECTION SYSTEM.
8 3 2 6 9 4
5 1
Fuel pump module removal 1. Remove: Nuts Retainer NOTE: Loosen the nuts in the sequence shown.
1 2
2. Remove: Fuel pump module 1 NOTE: Remove the float 2 at an angle because it could catch on the fuel tank.
Check valve inspection 1. Check: Check valve Faulty Replace. Checking steps: Connect a hose to the end of check valve A and blow into it. Air should come out from end B. Connect the hose to the end of check valve B and blow into it. Air should come out from end A.
4-5
FUEL
A

Rollover valve inspection 1. Check: Rollover valve Faulty Replace.
Checking steps: Connect a hose to the end of rollover valve A and blow into it. Air should come out from end B. Connect the hose to the end of rollover valve B and blow into it. Air should not come out from end A. Fuel sender inspection Refer to FUEL CONTROL SYSTEM in Chapter 7. Fuel tank inspection 1. Inspect: Fuel tank Cracks/damage Replace. Fuel hose inspection Refer to FUEL INJECTION SYSTEM.
Fuel pump filter inspection 1. Inspect: Fuel pump filter 1 Clog/contaminants Wash the fuel pump filter in kerosene or gasoline.
4-6
FUEL

Fuel pump module installation 1. Tighten: Nuts
5
T.
2 7 8 4 1 6
Fuel pump module nut: 1st: 3.2 N m (0.32 kgf m, 2.3 ft lb) 2nd: 6.4 N m (0.64 kgf m, 4.6 ft lb)
NOTE: Tighten the nuts in the sequence shown. Fuel hose connect Refer to FUEL INJECTION SYSTEM.
4-7
FUEL
FUEL INJECTION SYSTEM

EXPLODED DIAGRAM
2.5 N m (0.25 kgf m, 1.8 ft Ib) 5 70 mm
6.5 N m (0.65 kgf m, 4.7 ft Ib) 6 7 mm
4 2
LT LT
5 6
572
242
16 3
E
18 21
17 22 20 19 19
23
22 N m (2.2 kgf m, 16 ft Ib) 8 50 mm
12
LT
7 13 14 11 15
A
572
8
LT
10
4 8 mm 3.3 N m (0.33 kgf m, 2.4 ft Ib)
572
6 14 mm 7.6 N m (0.76 kgf m, 5.5 ft Ib)

Step 1 2 3 4 5 6 7 8 9 10 Procedure/Part name THROTTLE BODIES REMOVAL Screw Air filter case cover Air filter Bolt Ribbon sub assembly Holder Throttle cable Bolt Throttle cable holder Cover Qty 2 1 1 4 2 2 1 2 1 1 Service points Follow the left Step for removal.
4-8
FUEL
EXPLODED DIAGRAM
2.5 N m (0.25 kgf m, 1.8 ft Ib) 5 70 mm
6.5 N m (0.65 kgf m, 4.7 ft Ib) 6 7 mm
4 2
LT LT
5 6
572
242
16 3
E
18 21
17 22 20 19 19
23
22 N m (2.2 kgf m, 16 ft Ib) 8 50 mm
12
LT
7 13 14 11 15
A
572
8
LT
10
4 8 mm 3.3 N m (0.33 kgf m, 2.4 ft Ib)
572
6 14 mm 7.6 N m (0.76 kgf m, 5.5 ft Ib)
Step 11 12 13 14 15 16 17 18 19 20
Procedure/Part name Fuel hose Bolt Fuel hose holder Clamp Clamp Bolt Throttle bodies Sensor assembly coupler Fuel injector coupler Throttle position sensor coupler
Qty 1 2 1 1 1 8 1 1 4 1
Service points
Not reusable
4-9
FUEL
EXPLODED DIAGRAM
2.5 N m (0.25 kgf m, 1.8 ft Ib) 5 70 mm
6.5 N m (0.65 kgf m, 4.7 ft Ib) 6 7 mm
4 2
LT LT
5 6
572
242
16 3
E
18 21
17 22 20 19 19
23
22 N m (2.2 kgf m, 16 ft Ib) 8 50 mm
12
LT
7 13 14 11 15
A
572
8
LT
10
4 8 mm 3.3 N m (0.33 kgf m, 2.4 ft Ib)
572
6 14 mm 7.6 N m (0.76 kgf m, 5.5 ft Ib)
Step 21 22 23
Procedure/Part name Joint connector Bypass valve motor coupler Ring
Qty 1 1 1
Service points
4-10
FUEL
EXPLODED DIAGRAM
1st
8.8 N m (0.88 kgf m, 6.4 ft Ib)
7 13
LT
2nd 18 N m (1.8 kgf m, 13 ft Ib) 8 30 mm 9 1st 15 N m (1.5 kgf m, 11 ft Ib)

242
6 8 12
2nd 39 N m (3.9 kgf m, 28 ft Ib) 8 16 mm
9
LT
11
572
25 23 10 24 4
LT
17
271
18 2 1
LT
6 16 mm 7.6 N m (0.76 kgf m, 5.5 ft Ib)
5 15
LT
22 20
5 14 mm 1.8 N m (0.18 kgf m, 1.3 ft Ib)
14
242
16
21
572
LT
271
8 16 mm 1st 15 N m (1.5 kgf m, 11 ft Ib) 2nd 39 N m (3.9 kgf m, 28 ft Ib)
19
6 16 mm 7.6 N m (0.76 kgf m, 5.5 ft Ib)
1.3 N m (0.13 kgf m, 0.9 ft Ib) 5 14 mm 5 14 mm 1.3 N m (0.13 kgf m, 0.9 ft Ib)

Step Procedure/Part name AIR FILTER CASE REMOVAL Throttle bodies Clamp/breather hose Band Lighting coil coupler Thermoswitch coupler (engine) Pickup coil coupler Thermoswitch coupler (exhaust) Cam position sensor coupler Qty Service points Follow the left Step for removal.
1 2 3 4 5 6 7
1/1 1 1 1 1 1 1
Unfasten the wiring harness. From wiring harness bracket 2 From wiring harness bracket 2 From wiring harness bracket 2 From wiring harness bracket 1 From wiring harness bracket 1
4-11
FUEL
EXPLODED DIAGRAM
1st
8.8 N m (0.88 kgf m, 6.4 ft Ib)
7 13
LT

242
6 8 12
2nd 39 N m (3.9 kgf m, 28 ft Ib) 8 16 mm
9
LT
11
572
25 23 10 24 4
LT
17
271
18 2 1
LT
6 16 mm 7.6 N m (0.76 kgf m, 5.5 ft Ib)
5 15
LT
22 20
5 14 mm 1.8 N m (0.18 kgf m, 1.3 ft Ib)
14
242
16
21
572
LT
271
19
6 16 mm 7.6 N m (0.76 kgf m, 5.5 ft Ib)
Step 8 9 10 11 12 13 14 15 16 17
Procedure/Part name Wiring harness coupler Bolt Air filter case Bolt Wiring harness bracket 1 Sub wiring harness Bolt Fuel hose bracket Screw Wiring harness bracket 2
Qty 1 3 1 2 1 1 2 1 1 1
Service points
4-12
FUEL
EXPLODED DIAGRAM
1st
8.8 N m (0.88 kgf m, 6.4 ft Ib)
7 13
LT

242
6 8 12
2nd 39 N m (3.9 kgf m, 28 ft Ib) 8 16 mm
9
LT
11
572
25 23 10 24 4
LT
17
271
18 2 1
LT
6 16 mm 7.6 N m (0.76 kgf m, 5.5 ft Ib)
5 15
LT
22 20
5 14 mm 1.8 N m (0.18 kgf m, 1.3 ft Ib)
14
242
16
21
572
LT
271
19
6 16 mm 7.6 N m (0.76 kgf m, 5.5 ft Ib)
Step 18 19 20 21 22 23 24 25
Procedure/Part name Grommet Throttle body joint Band Bolt Air filter case stay 1 Band Bolt Air filter case stay 2
Qty 1 4 2 2 2 1 1 1
Service points
4-13
FUEL
EXPLODED DIAGRAM
6 9
8 7 4
3.5 N m (0.35 kgf m, 2.5 ft Ib) 5 15 mm
13
11
14
5 10 3
8 18 mm
12
22 1
24
5.0 N m (0.5 kgf m, 3.6 ft Ib) 6 10 mm 5.0 N m (0.5 kgf m, 3.6 ft Ib) 6 9 mm
5.0 N m (0.5 kgf m, 3.6 ft Ib) 6 10 mm 13 N m (1.3 kgf m, 9.4 ft Ib)
3 24
23
19 17
18
25 26 27 28 15 29 30 31 32 21 20 16
15

Step Procedure/Part name THROTTLE BODY DISASSEMBLY Screw Bracket Bolt/nut Bypass valve motor Holder Holder Hose #4 Hose #3 Hose #2 Hose #1 Qty Service points Follow the left Step for disassembly.
1 2 3 4 5 6 7 8 9 10
3 1 2/2 1 1 1 1 1 1 1
4-14
FUEL
EXPLODED DIAGRAM
6 9
8 7 4
3.5 N m (0.35 kgf m, 2.5 ft Ib) 5 15 mm
13
11
14
5 10 3
8 18 mm
12
22 1
24
3 24
23
19 17
18
25 26 27 28 15 29 30 31 32 21 20 16
15
Step 11 12 13 14 15 16 17 18 19 20 21 22
Procedure/Part name Bolt Fuel rail Screw Sensor assembly Intake vacuum hose Joint Fuel injector O-ring Grommet Screw Throttle stop guide Screw
Qty 4 1 2 1 3 1 4 4 4 2 1 2
4-15
Service points
Not reusable Not reusable
FUEL
EXPLODED DIAGRAM
6 9
8 7 4
3.5 N m (0.35 kgf m, 2.5 ft Ib) 5 15 mm
13
11
14
5 10 3
8 18 mm
12
22 1
24
3 24
23
19 17
18
25 26 27 28 15 29 30 31 32 21 20 16
15
Step 23 24 25 26 27 28 29 30 31 32
Procedure/Part name Throttle stop screw bracket Screw/spring Bypass air screw Spring Washer O-ring Screw Throttle position sensor O-ring Throttle bodies
Qty 1 4/4 4 4 4 4 2 1 1 1
Service points
Not reusable
Not reusable Reverse the disassembly steps for assembly.
4-16
FUEL

SERVICE POINTS
Hose clamps removal 1. Remove: Hose clamps
CAUTION:
If the hose clamps are removed without cutting the joint first, the fuel hose will be damaged. Hose clamps installation 1. Install: Hose clamps
WARNING
Do not reuse the hose clamps, always replace them with new ones. NOTE: Crimp the hose clamps properly to securely fasten them.
Fuel hose disconnection
WARNING
Before disconnecting the hose, remove the fuel tank filler cap to reduce any pressure inside the fuel tank, and then disconnect the battery negative lead to cut off the electric current to the electrical systems. 1. Wrap the quick connector with a cloth, and then rotate the quick connector tab 1 to the stopper position a.
WARNING
If the quick connector is removed suddenly, pressurized fuel could spray out. To gradually release the fuel pressure, be sure to remove the quick connector slowly.
4-17
FUEL
1 2

CAUTION:
Do not rotate the quick connector tab 1 past the stopper position a, otherwise it could be damaged. When the fuel hoses are disconnected, quickly remove the retainer 2 from the quick connector, otherwise the retainer could be lost. 2. Disconnect the fuel hose 1 from the fuel pipe 2 directly.
WARNING
Always reduce the fuel pressure in the fuel line before servicing the line or the fuel pipe. If the fuel pressure is not released, pressurized fuel could spray out.
3. Cover the quick connector and fuel pipe with a plastic bag to prevent damage and to protect them from dirt.
Fuel line inspection 1. Inspect: Fuel hose Damage/cracks Replace. O-rings (quick connector) Damage/cracks Replace the quick connector. Fuel pipe Damage/cracks Replace the fuel pump.
4-18
FUEL
Fuel hose installation (replacing with new fuel hose) 1. Install: Fuel hose 1 NOTE: To install the fuel hose, be sure to align the white mark a of the fuel hose with the checker tab 2 of the quick connector. When replacing the fuel hose with a new one, a checker tab 2 that has half engagement prevention is attached to the quick connector of the hose. If the quick connector is completely installed to the fuel pipe, it is removable.
Fuel hose connection 1. Apply a thin coat of engine oil to the contact surfaces of the fuel pipe. 2. Insert the quick connector into the fuel pipe until you hear a click. 3. To check the connection of the quick connector, push and pull on the quick connector several times until there is free play of 23 mm (0.080.12 in). NOTE: If free is not obtained, disconnect the fuel hose and check the O-ring for damage and that it is properly installed.
Throttle body removal 1. Remove: Throttle body
CAUTION:
Do not bend the fuel pipe 1.
4-19
FUEL

Fuel injector inspection
CAUTION:
The throttle bodies should not be disassembled unnecessarily. 1. Check: Injector Dirt/residue Clean. Damage Replace. 2. Measure: Fuel injectors resistance Out of specification Replace. Digital multimeter: YU-34899-A Digital circuit tester: 90890-03174 Fuel injector resistance: (reference data) 11.512.5 at 20 C (68 F) 3. Check the operation of the fuel injector using the Stationary Test of the Yamaha Diagnostic System.
Throttle body inspection 1. Check: Throttle body Cracks/damage Replace the throttle bodies. 2. Check: Fuel passages Obstruction Clean. Checking steps: Wash the throttle body in a petroleum based solvent. Do not use any caustic carburetor cleaning solution. Blow out all of passages with compressed air.
4-20
FUEL

Bypass valve motor inspection 1. Inspect: Hoses Damage/cracks Replace.
2. Check: Check the bypass valve motor operation using the Yamaha Diagnostic System.
Throttle body installation 1. Install: Throttle body
CAUTION:
Do not bend the fuel pipe 1.
2. Install: Fuel hose 1 (throttle body side) Clamp NOTE: Install the fuel hose with the white mark a facing up.
1
3. Adjust: Throttle lever free play Refer to CONTROL SYSTEM in Chapter 3.
4-21
FUEL

Throttle bodies synchronization 1. Remove: Throttle bodies Air filter case 2. Adjust: Throttle bodies synchronization Adjustment steps:
#4
#3
#2
#1
1 #1
1 #2 2 #3 #4
NOTE: The bypass air screws 1 should not be adjusted. However, if it is necessary to remove the bypass air screw, be sure to note the number of times the screw is turned from its set position. When installing the screw, be sure to tighten the screw the same number of turns as noted at removal. If the number of turns is not known, turn the screw approximately 2.5 times counterclockwise from the fully closed position.
CAUTION:
Do not start the engine when removing the fuel hose. Fuel can spurt out when the fuel pump is operated. a. Loosen the throttle stop screw 2 and synchronizing screws #1 3, #2 4, and #3 5 until released from the levers. NOTE: Only butterfly valve #2 should be fully closed and the other valves should be halfway closed. Check the valve for light leaks with a flashlight. If there are no light leaks, the valve is fully closed. b. Turn synchronizing screw #2 4 clockwise approximately 7 times until it starts to contact the lever. NOTE: Butterfly valves #2 and #3 should be fully closed. Butterfly valve #2 opens if the screw is turned more than 7 times. If butterfly valves #2 and #3 are not fully closed, close the valves by adjusting synchronizing screw #2 4.
4-22
FUEL
c. Turn synchronizing screw #1 3 clockwise approximately 7 times until it starts to contact the lever. NOTE: Butterfly valve #1 should be fully closed. Butterfly valves #2 and #3 open if the screw is turned more than 7 times. If butterfly valves #1, #2, and #3 are not fully closed, close the valves by adjusting synchronizing screw #1 3. d. Turn synchronizing screw #3 5 clockwise approximately 7 times until it starts to contact the lever. NOTE: Butterfly valve #4 should be fully closed. Butterfly valves #1, #2, and #3 open if the screw is turned more than 7 times. If all butterfly valves are not fully closed, close the valves by adjusting synchronizing screw #3 5. e. Check that all butterfly valves are fully closed and that they open simultaneously.
#1 #2 #3 #4
NOTE: If all butterfly valves are not fully closed, close the valves by repeating steps ad. f. Turn the throttle stop screw 2 clockwise approximately 1.5 times until it starts to contact the throttle lever. g. Remove the plugs 6. h. Install the carburetor synchronizer 7 or vacuum gauge 8.
For USA and Canada For worldwide
Carburetor synchronizer: YU-08030 Vacuum gauge: 90890-03094
4-23
FUEL
0 9
NOTE: For best results, use a vacuum gauge (commercially obtainable), like 9 or 0 shown in the illustration, that has four adapters. i. Install the throttle bodies. NOTE: Adjust the throttle body synchronization with the air filter case uninstalled. j. Connect the fuel hose and clamp. k. Connect the Yamaha Diagnostic System. l. Remove the sub wiring harness from the air filter case, and then connect it to the throttle bodies and main wiring harness. m. Connect the test harness (3 pin) to the throttle position sensor A. Test harness (3 pins): YB-06793 Test harness SMHW099-3 (3 pins): 90890-06793 n. To start the ECM normally, start the Yamaha Diagnostic System.
B/O
CAUTION:
If the Yamaha Diagnostic System and ECM are started, fuel can spurt out. Be sure to connect the fuel hoses and throttle bodies when adjusting the throttle position sensor. NOTE: Use the test connector B to start the ECM normally only if the Yamaha Diagnostic System is not available. Test connector: YW-06862 Test connector FMY-8: 90890-06862
4-24
FUEL
o. Measure the throttle position sensor output voltage (DC). Adjust the throttle position sensor A position if out of specification. Throttle position sensor output voltage: Pink (P) Black/orange (B/O) 0.756 0.016 V NOTE: To decrease the output voltage, turn the throttle position sensor clockwise. Slightly tighten the throttle position screw. p. Start the engine and let it run at trolling speed for 20 minutes. NOTE: Warm the engine up in the water. While checking the engine temperature with the Yamaha Diagnostic System, warm the engine up until the engine temperature is 50 C (122 F).
1,740 1,720 1,700
q. Adjust the throttle stop screw until trolling speed is within specification. Trolling speed: Season
0 5 10 15 20 25 30 35 40 45 50
r/min
1,680 1,660 1,640 1,620 1,600
Temperature 30 C (86 F) or more 10 C (50 F) or less 20 C (68 F)
Specified engine speed 1,650 r/min 1,720 r/min 1,680 r/min
Summer Winter Spring/ Fall
r. Adjust each cylinder to the cylinder differences shown in the table using synchronizing screws 35 and using cylinder #2 as the standard.
4-25
FUEL

Vacuum pressure at trolling speed: Cylinder Cylinder difference Example
#1
18 10 mmHg 230 10 mmHg (2.45 (30.68 1.33 kPa, 1.33 kPa, 0.8 0.4 inHg) 9.1 0.4 inHg) Standard*0 212 mmHg (28.23 kPa, 8.3 inHg)
#2
#3
11 10 mmHg 223 10 mmHg (1.53 (29.76 1.33 kPa, 1.33 kPa, 0.5 0.4 inHg) 8.8 0.4 inHg) +1.0 10 mmHg 211 10 mmHg (+0.04 (28.19 1.33 kPa, 1.33 kPa, 0 0.4 inHg) 8.3 0.4 inHg)
#4
Standard*: When setting the specified engine speed, the value is zero. NOTE: Always maintain the specified trolling speed when making this adjustment. s. Measure the throttle position sensor output voltage. Adjust the throttle position sensor position if out of specification. Throttle position sensor output voltage: Pink (P) Black/orange (B/O) 0.756 0.016 V 3. Remove: Throttle bodies 4. Remove: Carburetor synchronizer or vacuum gauge 5. Install: Plugs Plug (vacuum pressure): 10 N m (1.0 kgf m, 7.2 ft lb)
6. Install: Air filter case Throttle bodies

4-26
T.
FUEL

Fuel pressure measurement 1. Disconnect: Fuel hose Refer to Fuel hose disconnection.
2 1
2. Install: Fuel pressure gauge adapter 1 Fuel pressure gauge 2 Fuel pressure gauge adapter: YW-06842/90890-06842 Fuel pressure gauge: YB-06766/90890-06786 NOTE: To connect the fuel pressure gauge adapter, follow the procedures for connecting a fuel hose. (Refer to Fuel hose connection.) 3. Start the engine and arrow it to warm up for several minutes. 4. Measure: Fuel pressure Out of specification Replace the fuel pump module. Fuel pressure: 310330 kPa (3.13.3 kgf/cm2, 4547 psi) 5. Remove: Fuel pressure gauge Fuel pressure gauge adapter NOTE: To disconnect the fuel pressure gauge adapter, follow the procedures for disconnecting a fuel hose. (Refer to Fuel hose disconnection.) 6. Connect: Fuel hose Refer to Fuel hose connection.
4-27
POWR
CHAPTER 5 POWER UNIT
ENGINE UNIT ..................................................................................................5-1 EXPLODED DIAGRAM .............................................................................5-1 REMOVAL AND INSTALLATION CHART ................................................ 5-1 SERVICE POINTS .................................................................................... 5-4 Compression pressure measurement ................................................. 5-4 Oil filter removal and installation .........................................................5-6 Engine unit removal ............................................................................5-6 Shim removal ......................................................................................5-7 Engine mount inspection..................................................................... 5-7 Coupling clearance inspection ............................................................ 5-7 EXHAUST PIPE 3............................................................................................ 5-8 EXPLODED DIAGRAM .............................................................................5-8 REMOVAL AND INSTALLATION CHART ................................................ 5-8 EXHAUST PIPES 1 AND 2............................................................................5-11 EXPLODED DIAGRAM ...........................................................................5-11 REMOVAL AND INSTALLATION CHART .............................................. 5-11 EXHAUST MANIFOLD .................................................................................. 5-13 EXPLODED DIAGRAM ...........................................................................5-13 REMOVAL AND INSTALLATION CHART .............................................. 5-13 OIL TANK ...................................................................................................... 5-15 EXPLODED DIAGRAM ...........................................................................5-15 REMOVAL AND INSTALLATION CHART .............................................. 5-15 SERVICE POINTS .................................................................................. 5-21 Oil tank removal ................................................................................ 5-21 Oil strainer inspection........................................................................5-22 Oil tank installation ............................................................................5-22
POWR
OIL PUMP...................................................................................................... 5-25 EXPLODED DIAGRAM ...........................................................................5-25 REMOVAL AND INSTALLATION CHART .............................................. 5-25 SERVICE POINTS .................................................................................. 5-30 Oil pump inspection...........................................................................5-30 Check valve inspection ..................................................................... 5-30 Oil strainer inspection........................................................................5-31 Oil pump installation..........................................................................5-31 REDUCTION DRIVE GEAR ..........................................................................5-32 EXPLODED DIAGRAM ...........................................................................5-32 REMOVAL AND INSTALLATION CHART .............................................. 5-32 SERVICE POINTS .................................................................................. 5-36 Drive coupling removal...................................................................... 5-36 Drive shaft removal ...........................................................................5-36 Bearing removal ................................................................................ 5-36 Oil pump drive shaft inspection ......................................................... 5-37 Drive shaft inspection........................................................................5-37 Bearing installing............................................................................... 5-38 Drive shaft installation ....................................................................... 5-40 Drive coupling installation .................................................................5-40 GENERATOR AND STARTER MOTOR .......................................................5-41 EXPLODED DIAGRAM ...........................................................................5-41 REMOVAL AND INSTALLATION CHART ............................................. 5-41 SERVICE POINTS .................................................................................. 5-46 Flywheel magneto removal ...............................................................5-46 Starter clutch inspection.................................................................... 5-46 Flywheel magneto installation ........................................................... 5-48 CAMSHAFTS.................................................................................................5-49 EXPLODED DIAGRAM ...........................................................................5-49 REMOVAL AND INSTALLATION CHART .............................................. 5-49 SERVICE POINTS .................................................................................. 5-55 Camshaft removal ............................................................................. 5-55 Camshaft inspection..........................................................................5-56 Camshaft sprockets inspection ......................................................... 5-58 Timing chain tensioner inspection.....................................................5-58 Camshaft installation.........................................................................5-59
POWR
CYLINDER HEAD.......................................................................................... 5-63 EXPLODED DIAGRAM ...........................................................................5-63 REMOVAL AND INSTALLATION CHART ............................................. 5-63 SERVICE POINTS .................................................................................. 5-65 Cylinder head removal ...................................................................... 5-65 Cylinder head inspection................................................................... 5-65 Cylinder head installation .................................................................. 5-66 VALVES AND VALVE SPRINGS.................................................................. 5-68 EXPLODED DIAGRAM ...........................................................................5-68 REMOVAL AND INSTALLATION CHART ............................................. 5-68 SERVICE POINTS .................................................................................. 5-70 Valve removal ...................................................................................5-70 Valve spring inspection ..................................................................... 5-71 Valve inspection ................................................................................ 5-71 Valve guide inspection ...................................................................... 5-72 Valve guide replacement................................................................... 5-73 Valve seat inspection ........................................................................5-75 Valve seat reface .............................................................................. 5-76 Valve installation ............................................................................... 5-78 CRANKCASE ................................................................................................5-80 EXPLODED DIAGRAM ...........................................................................5-80 REMOVAL AND INSTALLATION CHART .............................................. 5-80 SERVICE POINTS .................................................................................. 5-85 Crankcase disassembly .................................................................... 5-85 Crankcase inspection........................................................................5-86 Timing chain inspection..................................................................... 5-86 Crankcase assembly.........................................................................5-87 CONNECTING RODS AND PISTONS .......................................................... 5-90 EXPLODED DIAGRAM ...........................................................................5-90 REMOVAL AND INSTALLATION CHART .............................................. 5-90 SERVICE POINTS .................................................................................. 5-92 Connecting rod and piston removal .................................................. 5-92 Cylinder and piston inspection .......................................................... 5-93 Piston ring inspection ........................................................................5-94 Piston pin inspection .........................................................................5-96 Connecting rod inspection.................................................................5-97 Connecting rod and piston installation .............................................. 5-99
POWR
CRANKSHAFT ............................................................................................5-103 EXPLODED DIAGRAM .........................................................................5-103 REMOVAL AND INSTALLATION CHART ............................................ 5-103 SERVICE POINTS ................................................................................ 5-104 Crankshaft removal .........................................................................5-104 Crankshaft inspection......................................................................5-104 Crankshaft installation..................................................................... 5-107 THERMOSTAT ............................................................................................5-108 EXPLODED DIAGRAM .........................................................................5-108 REMOVAL AND INSTALLATION CHART ............................................ 5-108 SERVICE POINTS ................................................................................ 5-110 Thermostat inspection..................................................................... 5-110 Thermostat installation .................................................................... 5-110 COOLING WATER HOSE ........................................................................... 5-111 EXPLODED DIAGRAM .........................................................................5-111 REMOVAL AND INSTALLATION CHART ............................................ 5-111
POWR
ENGINE UNIT
ENGINE UNIT
EXPLODED DIAGRAM
7.8 N m (0.78 kgf m, 5.6 ft Ib) 6 25 mm
4
LT
11 12
572
10
17 N m (1.7 kgf m, 12 ft Ib) 8 40 mm
17 N m (1.7 kgf m, 12 ft Ib) 8 28 mm
7 15
LT
13
LT
271
572
9 1 5 14 9
E
17 N m (1.7 kgf m, 12 ft Ib)

Step Procedure/Part name ENGINE UNIT REMOVAL Engine oil Service lid 1 Battery negative and positive lead Throttle cable and fuel hose Water lock and exhaust joint Oil filter Bolt Qty Service points Follow the left Step for removal. Drain. Refer to POWER UNIT in Chapter 3. Refer to FRONT HOOD in Chapter 8. Refer to ELECTRICAL BOX in Chapter 7. Refer to FUEL INJECTION SYSTEM in Chapter 4. Refer to EXHAUST SYSTEM in Chapter 8.
1 2
1 4
5-1
POWR
ENGINE UNIT
EXPLODED DIAGRAM
7.8 N m (0.78 kgf m, 5.6 ft Ib) 6 25 mm
4
LT
11 12
572
10
17 N m (1.7 kgf m, 12 ft Ib) 8 40 mm
17 N m (1.7 kgf m, 12 ft Ib) 8 28 mm
7 15
LT
13
LT
271
572
9 1 5 14 9
E
17 N m (1.7 kgf m, 12 ft Ib)
Step 3 4 5 6 7 8 9 10 11 12
Procedure/Part name Electrical box Clamp/cooling water hose Clamp/cooling water hose Clamp/cooling water hose Clamp/cooling water hose Clamp/cooling water hose Coupler Grease hose Bolt/collar Coupling cover
Qty 1 1/1 1/1 1/1 1/1 1/1 10 1 1/1 1
Service points Cooling water pilot outlet Cooling water pilot outlet Cooling water outlet Cooling water outlet Cooling water inlet
5-2
POWR
ENGINE UNIT
EXPLODED DIAGRAM
7.8 N m (0.78 kgf m, 5.6 ft Ib) 6 25 mm
4
LT
11 12
572
10
17 N m (1.7 kgf m, 12 ft Ib) 8 40 mm
17 N m (1.7 kgf m, 12 ft Ib) 8 28 mm
7 15
LT
13
LT
271
572
9 1 5 14 9
E
17 N m (1.7 kgf m, 12 ft Ib)
Step 13 14 15
Procedure/Part name Bolt/washer Shim Engine unit
Qty 4/4 * 1
Service points
Reverse the removal steps for installation. *: As required.
5-3
POWR
ENGINE UNIT
SERVICE POINTS
Compression pressure measurement The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: Valve clearance Out of specification Adjust. Refer to POWER UNIT in Chapter 3. 2. Warm the engine up, and then put the watercraft in a horizontal position.
3. Remove: Air filter case cover 1 Air filter element Ignition coils Spark plugs
CAUTION:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from falling into the cylinders.
4. Install: Compression gauge extension 1 Compression gauge 2 Compression gauge extension: 90890-06582 Compression gauge: YU-33223-1/90890-03160
5-4
POWR
ENGINE UNIT
E 5. Measure: Compression pressure Out of specification Refer to steps (b) and (c). Minimum compression pressure (reference data): 1,150 kPa (11.5 kgf/cm2, 164 psi) Measurement steps: a. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. NOTE: The difference in compression pressure between cylinders should not exceed 100 kPa (1 kgf/cm2, 14 psi). b. If the compression pressure is extremely high, check the cylinder head, valve surfaces and piston crown for carbon deposits. Carbon deposits Eliminate. c. If the compression pressure is below the minimum specification, squirt a few drops of oil into the cylinder and measure again. Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Higher than without oil Same as without oil 6. Install: Spark plug Spark plug: 13 N m (1.3 kgf m, 9.4 ft lb) Diagnosis Piston ring wear, piston wear or damage Repair. Valves, cylinder head gasket or piston possibly defective Repair.
T.
5-5
POWR
ENGINE UNIT
7. Install: Ignition coils Air filter element Air filter case cover
Ignition coils bolt: 7.6 N m (0.76 kgf m, 5.5 ft lb) LOCTITE 572 Air filter case cover screw: 2.5 N m (0.25 kgf m, 1.8 ft lb) LOCTITE 572
Oil filter removal and installation 1. Remove: Oil filter 1 Oil filter wrench: YU-38411/90890-01426
T.
1
T.
Oil filter: 17 N m (1.7 kgf m, 12 ft lb)
NOTE: Install the oil filter with the same special tool that was used for removal. Engine unit removal 1. Remove: Engine unit Removal steps:
CAUTION:
Lift the engine unit carefully trying not to hit it on the deck or letting it fall hard on the hull. Suspend the engine unit using all three engine hangers, and then separate the unit from the engine mount. Remove the hoist cable from the front engine hanger and use the two rear engine hangers to suspend the engine unit. Lift the engine unit out vertically while turning it clockwise.
5-6
POWR
ENGINE UNIT
Shim removal 1. Remove: Shims
NOTE: To ease reassembly and coupling alignment, remove the shims and organize them in their respective groups (e.g., front right, rear left) prior to removing the mounting bolts. Engine mount inspection 1. Inspect: Engine mounts Cracks/damage Replace. Refer to ENGINE MOUNT in Chapter 8.
Coupling clearance inspection 1. Measure: Clearance a Clearance b Out of specification Adjust. NOTE: Measure the clearances with a straightedge and thickness gauge. Clearance a: 00.5 mm (00.020 in) Clearance b: 24 mm (0.0790.157 in)
2. Adjust: Clearance a and b Adjustment steps: Adjust the clearance a by adding or removing shims. Adjust the clearance b by moving the engine unit position.
5-7
POWR
EXHAUST PIPE 3
EXHAUST PIPE 3
EXPLODED DIAGRAM
1st
2.0 N m (0.2 kgf m, 1.4 ft Ib) 5th 15 N m (1.5 kgf m, 11 ft Ib) 9th 39 N m (3.9 kgf m, 28 ft Ib) 10 35 mm
2nd 2.0 N m (0.2 kgf m, 1.4 ft Ib) 6th 15 N m (1.5 kgf m, 11 ft Ib) 10th 39 N m (3.9 kgf m, 28 ft Ib) 10 35 mm 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm
6 17 16
10
4 5
LT
18
1
LT
572
15 14
13
242
7
1st 4.4 N m (0.44 kgf m, 3.2 ft Ib) 2nd 4.4 N m (0.44 kgf m, 3.2 ft Ib)
LT
572
12 11
LT
3.7 N m (0.37 kgf m, 2.7 ft Ib) 2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm 1st
8
LT
9
242
242
4th 2.0 N m (0.2 kgf m, 1.4 ft Ib) 8th 15 N m (1.5 kgf m, 11 ft Ib) 12th 39 N m (3.9 kgf m, 28 ft Ib) 10 45 mm
3rd 2.0 N m (0.2 kgf m, 1.4 ft Ib) 7th 15 N m (1.5 kgf m, 11 ft Ib) 11th 39 N m (3.9 kgf m, 28 ft Ib) 10 40 mm

Step Procedure/Part name EXHAUST PIPE 3 REMOVAL Engine unit Air filter case Clamp/cooling water hose Clamp/cooling water hose Clamp/cooling water hose Bolt Thermoswitch (exhaust) Qty Service points Follow the left Step for removal. Refer to ENGINE UNIT. Refer to FUEL INJECTION SYSTEM in Chapter 4. For cooling water outlet on stern side For cooling water pilot outlet on port side From water jacket
1 2 3 4 5
1/1 2/1 2/1 2 1
5-8
POWR
EXHAUST PIPE 3
EXPLODED DIAGRAM
1st
6 17 16
10
4 5
LT
18
1
LT
572
15 14
13
242
7
LT
572
12 11
LT
8
LT
9
242
242
Step 6 7 8 9 10 11 12 13 14
Procedure/Part name Exhaust joint clamp Exhaust joint clamp Bolt Bolt Bolt Collar Exhaust pipe 3 Bolt Exhaust pipe end
Qty 2 2 1 1 2 1 1 3 1
Service points Slide the outer exhaust joint for exhaust manifold side NOTE: Tighten the bolts in the sequence indicated.
5-9
POWR
EXHAUST PIPE 3
EXPLODED DIAGRAM
1st
6 17 16
10
4 5
LT
18
1
LT
572
15 14
13
242
7
LT
572
12 11
LT
8
LT
9
242
242
Step 15 16 17 18
Procedure/Part name Gasket Inner exhaust joint Exhaust joint seal Outer exhaust joint
Qty 1 1 1 1
Service points Not reusable
5-10
POWR
EXHAUST PIPES 1 AND 2

EXPLODED DIAGRAM
4th 39 N m (3.9 kgf m, 28 ft Ib) 9th 39 N m (3.9 kgf m, 28 ft Ib) 3rd 39 N m (3.9 kgf m, 28 ft Ib) 8th 39 N m (3.9 kgf m, 28 ft Ib)
4
1st
22 N m (2.2 kgf m, 16 ft Ib) 2nd 22 N m (2.2 kgf m, 16 ft Ib) 3rd 35 N m (3.5 kgf m, 25 ft Ib) 8 75 mm 1st 39 N m (3.9 kgf m, 28 ft Ib) 6th 39 N m (3.9 kgf m, 28 ft Ib)
5 7 6
13 12 8
E
5th 39 N m (3.9 kgf m, 28 ft Ib) 10th 39 N m (3.9 kgf m, 28 ft Ib) 2nd 39 N m (3.9 kgf m, 28 ft Ib) 7th 39 N m (3.9 kgf m, 28 ft Ib) 15 N m (1.5 kgf m, 11 ft Ib) 2nd 42 N m (4.2 kgf m, 30 ft Ib) 10 35 mm 1st 1st
2 11
LT
4
LT
242
242
3
E
LT
10
242
15 N m (1.5 kgf m, 11 ft Ib) 2nd 42 N m (4.2 kgf m, 30 ft Ib) 8 45 mm
22 N m (2.2 kgf m, 16 ft Ib) 2nd 22 N m (2.2 kgf m, 16 ft Ib) 3rd 35 N m (3.5 kgf m, 25 ft Ib) 8 125 mm 1st

Step Procedure/Part name EXHAUST PIPES 1 AND 2 REMOVAL Exhaust pipe 3 Generator cover Bolt Bolt Exhaust pipe stay Nut Exhaust pipe 2 Qty Service points Follow the left Step for removal. Refer to EXHAUST PIPE 3. Refer to GENERATOR AND STARTER MOTOR. 2 1 1 5 1
1 2 3 4 5
NOTE: Tighten the nuts in the sequence indicated.
5-11
POWR
EXPLODED DIAGRAM
4th 39 N m (3.9 kgf m, 28 ft Ib) 9th 39 N m (3.9 kgf m, 28 ft Ib) 3rd 39 N m (3.9 kgf m, 28 ft Ib) 8th 39 N m (3.9 kgf m, 28 ft Ib)
4
1st
22 N m (2.2 kgf m, 16 ft Ib) 2nd 22 N m (2.2 kgf m, 16 ft Ib) 3rd 35 N m (3.5 kgf m, 25 ft Ib) 8 75 mm 1st 39 N m (3.9 kgf m, 28 ft Ib) 6th 39 N m (3.9 kgf m, 28 ft Ib)
5 7 6
13 12 8
E
5th 39 N m (3.9 kgf m, 28 ft Ib) 10th 39 N m (3.9 kgf m, 28 ft Ib) 2nd 39 N m (3.9 kgf m, 28 ft Ib) 7th 39 N m (3.9 kgf m, 28 ft Ib) 15 N m (1.5 kgf m, 11 ft Ib) 2nd 42 N m (4.2 kgf m, 30 ft Ib) 10 35 mm 1st 1st
2 11
LT
4
LT
242
242
3
E
LT
10
242
15 N m (1.5 kgf m, 11 ft Ib) 2nd 42 N m (4.2 kgf m, 30 ft Ib) 8 45 mm
22 N m (2.2 kgf m, 16 ft Ib) 2nd 22 N m (2.2 kgf m, 16 ft Ib) 3rd 35 N m (3.5 kgf m, 25 ft Ib) 8 125 mm 1st
Step 6 7 8 9 10 11 12 13
Procedure/Part name Gasket Dowel pin Clamp/cooling water hose Bolt Bolt Exhaust pipe 1 Gasket Dowel pin
Qty 1 2 2/2 4 6 1 1 2
Service points Not reusable From cooling water inlet
Not reusable Reverse the removal steps for installation.
5-12
POWR
EXHAUST MANIFOLD
EXHAUST MANIFOLD
EXPLODED DIAGRAM
a 1
5
LT
242
8 10
LT
4 6
242
LT
5 7 2
LT
10
242
242
22 N m (2.2 kgf m, 16 ft Ib) 2nd 22 N m (2.2 kgf m, 16 ft Ib) 3rd 35 N m (3.5 kgf m, 25 ft Ib) 8 55 mm 1st 22 N m (2.2 kgf m, 16 ft Ib) 2nd 22 N m (2.2 kgf m, 16 ft Ib) 3rd 35 N m (3.5 kgf m, 25 ft Ib) 8 95 mm 1st 1st
22 N m (2.2 kgf m, 16 ft Ib) 2nd 22 N m (2.2 kgf m, 16 ft Ib) 3rd 35 N m (3.5 kgf m, 25 ft Ib) 8 70 mm 1st 22 N m (2.2 kgf m, 16 ft Ib) 2nd 22 N m (2.2 kgf m, 16 ft Ib) 3rd 35 N m (3.5 kgf m, 25 ft Ib) 8 95 mm

Step Procedure/Part name EXHAUST MANIFOLD REMOVAL Exhaust pipes 1 and 2 Joint assembly Qty Service points Follow the left Step for removal. Refer to EXHAUST PIPES 1 AND 2. To cylinder block NOTE: Install the cooling water hose with the white mark a facing up. 2 3 4 5 Bolt Bolt Exhaust manifold 1 Dowel pin 2 4 1 2
5-13
POWR
EXHAUST MANIFOLD
EXPLODED DIAGRAM
a 1
5
LT
242
8 10
LT
4 6
242
LT
5 7 2
LT
10
242
242
22 N m (2.2 kgf m, 16 ft Ib) 2nd 22 N m (2.2 kgf m, 16 ft Ib) 3rd 35 N m (3.5 kgf m, 25 ft Ib) 8 55 mm 1st 22 N m (2.2 kgf m, 16 ft Ib) 2nd 22 N m (2.2 kgf m, 16 ft Ib) 3rd 35 N m (3.5 kgf m, 25 ft Ib) 8 95 mm 1st 1st
22 N m (2.2 kgf m, 16 ft Ib) 2nd 22 N m (2.2 kgf m, 16 ft Ib) 3rd 35 N m (3.5 kgf m, 25 ft Ib) 8 70 mm 1st 22 N m (2.2 kgf m, 16 ft Ib) 2nd 22 N m (2.2 kgf m, 16 ft Ib) 3rd 35 N m (3.5 kgf m, 25 ft Ib) 8 95 mm
Step 6 7 8 9 10
Procedure/Part name Bolt Bolt Exhaust manifold 2 Gasket Dowel pin
Qty 1 4 1 1 2
Service points
5-14
POWR
OIL TANK
OIL TANK
EXPLODED DIAGRAM
1st
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 35 mm

LT
24
2.0 N m (0.2 kgf m, 1.4 ft Ib) 2nd 15 N m (1.5 kgf m, 11 ft Ib) 3rd 39 N m (3.9 kgf m, 28 ft Ib) 1st 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 20 mm
572
4 5
22
LT
11
15 14
572
13 5 8
LT
LT
572
a 12 21 25
LT
18 26 27 28 27
A
17 16
572
20
19
LT
10 6
572
LT
572
572
23
3.7 N m (0.37 kgf m, 2.7 ft Ib) 2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 30 mm 10 70 mm 1st 2.0 N m (0.2 kgf m, 1.4 ft Ib) 1st 2nd 15 N m (1.5 kgf m, 11 ft Ib) 3rd 39 N m (3.9 kgf m, 28 ft Ib)
6 12 mm 7.6 N m (0.76 kgf m, 5.5 ft Ib) 15 N m (1.5 kgf m, 11 ft Ib) 2nd 39 N m (3.9 kgf m, 28 ft Ib) 6 16 mm 8 85 mm 7.6 N m (0.76 kgf m, 5.5 ft Ib) 1st

Step Procedure/Part name OIL TANK REMOVAL Engine unit Air filter case Thermostat housing Clamp/cooling water hose Bolt Water jacket Gasket Clamp/breather hose Clamp/breather hose Qty Service points Follow the left Step for removal. Refer to ENGINE UNIT. Refer to FUEL INJECTION SYSTEM in Chapter 4. Refer to THERMOSTAT. To exhaust joint
1 2 3 4 5 6
1/1 4 1 1 2/1 2/1
Not reusable To oil pump
5-15
POWR
OIL TANK
EXPLODED DIAGRAM
1st
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 35 mm

LT
24
572
4 5
22
LT
11
15 14
572
13 5 8
LT
LT
572
a 12 21 25
LT
18 26 27 28 27
A
17 16
572
20
19
LT
10 6
572
LT
572
572
23
Step 7 8 9 10 11 12 13 14 15 16 17
Procedure/Part name Bolt Collar Oil separator Clamp/breather hose Clamp/breather hose Clamp/cooling water hose Bolt Collar Band Bolt Cover
Qty 2 2 1 1/1 1/1 1/1 1 1 1 3 1

5-16
Service points
To air filter case Mark a From cylinder head cover From cooling water inlet
POWR
OIL TANK
EXPLODED DIAGRAM
1st
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 35 mm

LT
24
572
4 5
22
LT
11
15 14
572
13 5 8
LT
LT
572
a 12 21 25
LT
18 26 27 28 27
A
17 16
572
20
19
LT
10 6
572
LT
572
572
23
Step 18 19 20 21 22 23 24 25 26 27 28
Procedure/Part name Gasket Bolt Ground lead Bolt Nut Bolt Oil tank Oil tank stay Pin O-ring Connector
Qty 1 2 2 2 2 5 1 1 2 4 2
5-17
POWR
OIL TANK
EXPLODED DIAGRAM
5
3.7 N m (0.37 kgf m, 2.7 ft Ib) 2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm 3 1st
3.7 N m (0.37 kgf m, 2.7 ft Ib) 2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 25 mm 1st 1.9 N m (0.19 kgf m, 1.4 ft Ib) 2nd 4.4 N m (0.44 kgf m, 3.2 ft Ib) 5 14 mm 1st
LT
6 8
7
572
LT
4 9 13 12 11 10 14
572
18
E
15
LT
572
5 35 mm 1st
16 17
E
1.9 N m (0.19 kgf m, 1.4 ft Ib) 2nd 4.4 N m (0.44 kgf m, 3.2 ft Ib) 3.7 N m (0.37 kgf m, 2.7 ft Ib) 2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 14 mm 1st
19 22 20 21 1
E
23
LT
572
20
1st
LT
572
6 20 mm 1st
18
3.7 N m (0.37 kgf m, 2.7 ft Ib) 2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
3.7 N m (0.37 kgf m, 2.7 ft Ib) 19 2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 4 12 mm 6 20 mm 3.7 N m (0.37 kgf m, 2.7 ft Ib)

Step 1 2 3 4 5 6 7 8 9 10 Procedure/Part name OIL TANK DISASSEMBLY Bolt/washer Bracket/grommet Bolt Hunger Oil tank filler cap Packing Bolt Oil tank cover Gasket Bolt Qty 2/2 2/2 4 2 1 1 8 1 1 10 Service points Follow the left Step for disassembly.
Not reusable
5-18
POWR
OIL TANK
EXPLODED DIAGRAM
5
LT
6 8
7
572
LT
4 9 13 12 11 10 14
572
18
E
15
LT
572
5 35 mm 1st
16 17
E
19 22 20 21 1
E
23
LT
572
20
1st
LT
572
6 20 mm 1st
18
Step 11 12 13 14 15 16 17 18 19 20
Procedure/Part name Oil breather plate 1 Oil breather plate 2 Gasket Bolt Baffle plate Bolt Oil strainer Bolt Oil cooler cover Gasket
Qty 1 1 1 3 1 2 1 24 2 2
Service points
Not reusable
Not reusable
5-19
POWR
OIL TANK
EXPLODED DIAGRAM
5
LT
6 8
7
572
LT
4 9 13 12 11 10 14
572
18
E
15
LT
572
5 35 mm 1st
16 17
E
19 22 20 21 1
E
23
LT
572
20
1st
LT
572
6 20 mm 1st
18
Step 21 22 23
Procedure/Part name Screw Anode Oil tank
Qty 1 1 1
Service points
Reverse the disassembly steps for assembly.
5-20
POWR
OIL TANK
SERVICE POINTS
Oil tank removal 1. Remove: Oil tank
3 1 2 4
NOTE: Loosen the oil tank bolts and nuts in the sequence shown.
5 6 7 8 9
5 1
8 4
2. Remove: Oil tank cover Gasket NOTE: Loosen the oil tank cover bolts in the sequence shown.
2 6 7
3 8 4 5 7 6
3. Remove: Oil breather plate 1 Oil breather plate 2 Gasket NOTE: Loosen the oil breather plate bolts in the sequence shown.
5-21
POWR
OIL TANK
4. Remove: Oil cooler covers Gaskets
1 2
12
NOTE: Loosen the oil cooler cover bolts in the sequence shown.
7 6
5 10 11
Oil strainer inspection 1. Check: Oil strainer 1 Damage Replace. Contaminants Clean.
Oil tank installation 1. Install: Gaskets Oil cooler covers
12 11
NOTE: Tighten the oil cooler bolts in the sequence shown. Oil cooler cover bolt: 1st: 3.7 N m (0.37 kgf m, 2.7 ft lb) 2nd: 7.6 N m (0.76 kgf m, 5.5 ft lb) LOCTITE 572
6
T.
10
8 3 2
5-22
POWR
OIL TANK
2. Install: Gasket Oil breather plate 2 Oil breather plate 1
6 1 5 4 2 3
NOTE: Tighten the oil breather plate bolts in the sequence shown. Oil breather plate bolt: 1st: 1.9 N m (0.19 kgf m, 1.4 ft lb) 2nd: 4.4 N m (0.44 kgf m, 3.2 ft lb)
4 8
1 5
3. Install: Gasket Oil tank cover NOTE: Tighten the oil tank cover bolts in the sequence shown. Oil tank cover bolt: 1st: 3.7 N m (0.37 kgf m, 2.7 ft lb) 2nd: 7.6 N m (0.76 kgf m, 5.5 ft lb) LOCTITE 572
T.
7 3 2
T.
5-23
POWR
OIL TANK
4. Install: Oil tank
2 7 9 8 6 3 2
NOTE: Tighten the oil tank nuts and bolts in the sequence shown. Bolt 1: 1st: 15 N m (1.5 kgf m, 11 ft lb) 2nd: 39 N m (3.9 kgf m, 28 ft lb) LOCTITE 572 Nut 2, bolt 3: 1st: 2.0 N m (0.2 kgf m, 1.4 ft lb) 2nd: 15 N m (1.5 kgf m, 11 ft lb) 3rd: 39 N m (3.9 kgf m, 28 ft lb) LOCTITE 572
T.
5 1 2 1 3 4
5-24
POWR
OIL PUMP
OIL PUMP
EXPLODED DIAGRAM
1st 1st 15 N m (1.5 kgf m, 11 ft Ib)
2nd 28 N m (2.8 kgf m, 20 ft Ib) 8 100 mm 15 N m (1.5 kgf m, 11 ft Ib)
2nd 28 N m (2.8 kgf m, 20 ft Ib) 8 80 mm 10 N m (1.0 kgf m, 7.2 ft Ib) 6 25 mm
3 4 5
LT
572
LT
572
1st
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm
8
LT
572
7 9 1 6 8
18 N m (1.8 kgf m, 13 ft Ib) 8 12 mm
9 10
1st 15 N m (1.5 kgf m, 11 ft Ib) 2nd 28 N m (2.8 kgf m, 20 ft Ib) 8 130 mm

Step Procedure/Part name OIL PUMP ASSEMBLY REMOVAL Oil tank Drain plug/washer Bolt Bolt Bolt Bolt Oil pump assembly Gasket Pin Qty Service points Follow the left Step for removal. Refer to OIL TANK. Drain engine oil.
1 2 3 4 5 6 7 8
1/1 6 1 1 2 1 1 2
Not reusable
5-25
POWR
OIL PUMP
EXPLODED DIAGRAM
1st 1st 15 N m (1.5 kgf m, 11 ft Ib)
2nd 28 N m (2.8 kgf m, 20 ft Ib) 8 100 mm 15 N m (1.5 kgf m, 11 ft Ib)
2nd 28 N m (2.8 kgf m, 20 ft Ib) 8 80 mm 10 N m (1.0 kgf m, 7.2 ft Ib) 6 25 mm
3 4 5
LT
572
LT
572
1st
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm
8
LT
572
7 9 1 6 8
18 N m (1.8 kgf m, 13 ft Ib) 8 12 mm
9 10
1st 15 N m (1.5 kgf m, 11 ft Ib) 2nd 28 N m (2.8 kgf m, 20 ft Ib) 8 130 mm
Step 9 10
Procedure/Part name Bolt Strainer
Qty 2 1
Service points
5-26
POWR
OIL PUMP
EXPLODED DIAGRAM
13 14 12 15 16 6
E
2.0 N m (0.2 kgf m, 1.4 ft Ib) 4 12 mm
19 10
20 N m (2.0 kgf m, 14 ft Ib) 8 70 mm
9 10 11
22 23 5
9 17
4
E
3 2 18 20 21
20 N m (2.0 kgf m, 14 ft Ib) 8 20 mm

Step 1 2 3 4 5 6 7 8 9 10 Procedure/Part name OIL PUMP DISASSEMBLY Bolt Bolt Oil pump housing cover 1 Gasket Oil pump housing 1 Check valve assembly Oil pump housing 2 Gasket Outer rotor (scavenge) Inner rotor (scavenge) Qty 1 3 1 1 1 1 1 1 2 2 Service points Follow the left Step for disassembly.
Not reusable
Not reusable
5-27
POWR
OIL PUMP
EXPLODED DIAGRAM
13 14 12 15 16 6
E
2.0 N m (0.2 kgf m, 1.4 ft Ib) 4 12 mm
19 10
20 N m (2.0 kgf m, 14 ft Ib) 8 70 mm
9 10 11
22 23 5
9 17
4
E
3 2 18 20 21
20 N m (2.0 kgf m, 14 ft Ib) 8 20 mm
Step 11 12 13 14 15 16 17 18 19 20 21
Procedure/Part name Pin Screw Oil pump housing cover 2 Gasket Spring Plunger Pin Pin Oil pump shaft Inner rotor (feed) Outer rotor (feed)
Qty 1 1 1 1 1 1 1 1 1 1 1
Service points
Not reusable
5-28
POWR
OIL PUMP
EXPLODED DIAGRAM
13 14 12 15 16 6
E
2.0 N m (0.2 kgf m, 1.4 ft Ib) 4 12 mm
19 10
20 N m (2.0 kgf m, 14 ft Ib) 8 70 mm
9 10 11
22 23 5
9 17
4
E
3 2 18 20 21
20 N m (2.0 kgf m, 14 ft Ib) 8 20 mm
Step 22 23
Procedure/Part name Check valve seat Oil seal
Qty 1 1
Service points Not reusable Reverse the disassembly steps for assembly.
5-29
POWR
OIL PUMP
SERVICE POINTS
Oil pump inspection 1. Check: Oil pump housing cover 1 1 Oil pump housing cover 2 2 Oil pump housing 1 3 Oil pump housing 2 4 Cracks/damage/wear Replace the defective part(s). 2. Measure: Inner-rotor-to-outer-rotor-tip clearance a Outer-rotor-to-oil-pump-housing clearance b Out of specification Replace the oil pump.
1 Inner rotor 2 Outer rotor 3 Oil pump housing
Inner-rotor-to-outer-rotor-tip clearance a: 0.090.15 mm (0.00350.0059 in) Outer-rotor-to-oil-pump-housing clearance b (scavenge pump): 0.090.15 mm (0.00350.0059 in) Outer-rotor-to-oil-pump-housing clearance b (feed pump): 0.090.17 mm (0.00350.0067 in)
3. Check: Oil pump operation Rough movement Replace the defective part(s).
Check valve inspection 1. Check: Check valve seat 1 Check valve body 2 Check valve 3 Spring 4 Damage/wear Replace the defective part(s).
5-30
POWR
OIL PUMP
1
Oil strainer inspection 1. Check: Oil strainer 1 Damage Replace. Contaminants Clean.
Oil pump installation 1. Install: Oil pump assembly
b a
NOTE: Align the projection a on the oil pump shaft with the slit b on the oil pump driven gear shaft. Oil pump assembly bolt: M6: 10 N m (1.0 kgf m, 7.2 ft lb) LOCTITE 572 M8: 1st: 15 N m (1.5 kgf m, 11 ft lb) 2nd: 28 N m (2.8 kgf m, 20 ft lb) LOCTITE 572
T.
5-31
POWR
REDUCTION DRIVE GEAR

EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib) 2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 55 mm 1st 1st 15 N m (1.5 kgf m, 11 ft Ib) 2nd 28 N m (2.8 kgf m, 20 ft Ib) 8 40 mm
LT
8 7 9 8
572
11 3
LT
1 9 11
E 572
10
2 6
LT
572
4
LT
572
LT
12
572
15 N m (1.5 kgf m, 11 ft Ib) 2nd 28 N m (2.8 kgf m, 20 ft Ib) 8 70 mm 1st
28 N m (2.8 kgf m, 20 ft Ib)

Step Procedure/Part name REDUCTION DRIVE GEAR REMOVAL Generator cover Oil pump Bolt Bolt Bolt Bolt Bolt Qty Service points Follow the left Step for removal. Refer to GENERATOR AND STARTER MOTOR. Refer to OIL PUMP. 1 1 1 3 1
1 2 3 4 5
5-32
POWR
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib) 2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 55 mm 1st 1st 15 N m (1.5 kgf m, 11 ft Ib) 2nd 28 N m (2.8 kgf m, 20 ft Ib) 8 40 mm
LT
8 7 9 8
572
11 3
LT
1 9 11
E 572
10
2 6
LT
572
4
LT
572
LT
12
572
28 N m (2.8 kgf m, 20 ft Ib)
Step 6 7 8 9 10 11 12
Procedure/Part name Reduction drive gear case assembly Gasket Pin Circlip Reduction drive gear Washer Drive coupling
Qty 1 1 2 2 1 2 1 Not reusable Not reusable
Service points
5-33
POWR
EXPLODED DIAGRAM
*1 3
E
4 8 7
5 10 mm
6 5
11
2 *1
10 9
E E
1
E

Step Procedure/Part name REDUCTION DRIVE GEAR DISASSEMBLY Oil pump drive shaft Drive shaft Collar Oil seal Circlip Bearing Collar Bearing Qty Service points Follow the left Step for disassembly.
1 2 3 4 5 6 7 8
*1
1 1 1 2 1 1 1 1
Not reusable Not reusable Not reusable Not reusable
: EPNOC grease AP #0
5-34
POWR
EXPLODED DIAGRAM
*1 3
E
4 8 7
5 10 mm
6 5
11
2 *1
10 9
E E
1
E
Step 9 10 11
Procedure/Part name Circlip Bearing Reduction drive gear case
Qty 1 1 1
Service points Not reusable Not reusable Reverse the disassembly steps for assembly.
*1
5-35
POWR

SERVICE POINTS
Drive coupling removal 1. Remove: Reduction drive gear housing 2. Remove: Drive coupling 1
1 4
NOTE: While holding the drive shaft 2 with the rotor holder 3, loosen the drive coupling with the coupler wrench 4.
3 2
Coupler wrench: YW-06551/90890-06551 Universal magneto and rotor holder: YU-01235 Rotor holder: 90890-01235 Drive shaft removal 1. Remove: Drive shaft NOTE: Press in the direction of the arrow. Bearing removal 1. Remove: Circlip Rear bearing Collar Front bearing NOTE: Remove the front bearing, spacer, and rear bearing using a press. Driver handlelarge: YB-06071 Driver rod L3: 90890-06652 Bearing housing needle bearing installer: YB-06111 Needle bearing attachment: 90890-06653
5-36
POWR

2. Remove: Circlip Reduction drive gear bearing Slide hammer and adapters: YB-06096 Stopper guide plate: 90890-06501 Bearing puller assembly: 90890-06535 Stopper guide stand: 90890-06538
Oil pump drive shaft inspection 1. Check: Oil pump drive shaft 1 Cracks/damage/wear Replace.
Drive shaft inspection 1. Check: Drive shaft 1 Cracks/damage/wear Replace.
5-37
POWR

Bearing installing 1. Install: Reduction drive gear bearing
NOTE: Install the reduction driver gear bearing using a press. Driver handlelarge: YB-06071 Driver rod LS: 90890-06606 Outer race installerforward gear: YB-06085 Ball bearing attachment: 90890-06631
2. Install: Front bearing NOTE: Install the front bearing using a press. Driver rod LS: 90890-06606 Forward gear bearing cup installer: YB-06726-B Ball bearing attachment: 90890-06657
5-38
POWR

3. Install: Collar Rear bearing
NOTE: Install the front bearing using a press. Before installing the rear bearing, hold both the inner and outer races of the front bearing in place as shown with a pipe that is at least 40 mm (1.57 in) long and has an outer diameter of 70 mm (2.76 in) and an inner diameter of 30 mm (1.18 in). Driver rod LS: 90890-06606 Outer race installerforward gear: YB-06085 Bearing outer race attachment: 90890-06624
4. Install: Oil seals Driver handlelarge: YB-06071 Driver rod LS: 90890-06606 Outer race installerforward gear: YB-06085 Bearing outer race attachment: 90890-06624
Distance a: 17.9 0.2 mm (0.70 0.01 in) Distance b: 9.3 0.2 mm (0.37 0.01 in)
5-39
POWR

Drive shaft installation 1. Install: Drive shaft Collar
NOTE: Press the into the reduction drive gear case with a pipe that is more than 30 mm (1.18 in) long, and which has an outer diameter of approximately 35 mm (1.97 in) and an inner diameter of approximately 28 0.5 mm (1.10 0.02 in).
1 4
Drive coupling installation 1. Install: Drive coupling 1 NOTE: While holding the drive shaft 2 with the rotor holder 3, tighten the drive coupling with the coupler wrench 4. Coupler wrench: YW-06551/90890-06551 Universal magneto and rotor holder: YU-01235 Rotor holder: 90890-01235 2. Install: Reduction drive gear housing
3 2
5-40
POWR
GENERATOR AND STARTER MOTOR

EXPLODED DIAGRAM
3
18 N m (1.8 kgf m, 13 ft Ib) 8 30 mm A 4.9 N m (0.49 kgf m, 3.5 ft Ib) 15 N m (1.5 kgf m, 11 ft Ib) 2nd 50 N m (5.0 kgf m, 36 ft Ib) 1st
1 2 14 5 21 15
E
6
75 N m (7.5 kgf m, 54 ft Ib) 10 47 mm
20
19 17
12 8
16
A E
LT
572
7
E
18
24 N m (2.4 kgf m, 17 ft Ib) 8 20 mm
9
LT
10
572
11
13

Step Procedure/Part name GENERATOR COVER AND FLYWHEEL MAGNETO REMOVAL Engine unit Nut/washer Starter motor lead Bolt Battery negative lead Starter motor Band Lighting coil coupler Qty Service points Follow the left Step for removal.
Refer to ENGINE UNIT. 1/1 1 2 1 1 1 1
1 2 3 4 5 6 7
5-41
POWR
EXPLODED DIAGRAM
3
1 2 14 5 21 15
E
6
75 N m (7.5 kgf m, 54 ft Ib) 10 47 mm
20
19 17
12 8
16
A E
LT
572
7
E
18
24 N m (2.4 kgf m, 17 ft Ib) 8 20 mm
9
LT
10
572
11
13
Step 8 9 10 11 12 13 14 15 16 17 18
Procedure/Part name Pulser coil coupler Nut Bolt Generator cover Dowel pin Gasket Idle gear shaft Idle gear Bolt/washer Flywheel magneto Bolt
Qty 1 2 8 1 2 1 1 1 1/1 1 6
Service points
Not reusable
Not reusable
5-42
POWR
EXPLODED DIAGRAM
3
1 2 14 5 21 15
E
6
75 N m (7.5 kgf m, 54 ft Ib) 10 47 mm
20
19 17
12 8
16
A E
LT
572
7
E
18
24 N m (2.4 kgf m, 17 ft Ib) 8 20 mm
9
LT
10
572
11
13
Step 19 20 21
Procedure/Part name Starter clutch Starter gear Woodruff key
Qty 1 1 1
Service points
5-43
POWR
EXPLODED DIAGRAM
4.9 N m (0.49 kgf m, 3.5 ft Ib) 5 10 mm
LT
242
7 1
LT
242
6 3 5
LT
3 2
242
LT
242
6 33 mm 14 N m (1.4 kgf m, 10 ft Ib)
5 14 mm 4.9 N m (0.49 kgf m, 3.5 ft Ib)
6 14 mm 14 N m (1.4 kgf m, 10 ft Ib)

Step 1 2 3 Procedure/Part name GENERATOR DISASSEMBLY Bolt/washer Bolt Pickup coil Qty 3/3 4 2 Service points Follow the left Step for disassembly.
NOTE: There washers holds the pickup coil lead. Make sure to not pitch the lead between the projection and the washer when installing the bolt.
Bolt
5-44
POWR
EXPLODED DIAGRAM
4.9 N m (0.49 kgf m, 3.5 ft Ib) 5 10 mm
LT
242
7 1
LT
242
6 3 5
LT
3 2
242
LT
242
6 33 mm 14 N m (1.4 kgf m, 10 ft Ib)
5 14 mm 4.9 N m (0.49 kgf m, 3.5 ft Ib)
6 14 mm 14 N m (1.4 kgf m, 10 ft Ib)
Step 5 6 7
Procedure/Part name Holder Bolt Lighting coil
Qty 1 3 1
Service points
5-45
POWR

SERVICE POINTS
Flywheel magneto removal 1. Remove: Flywheel magneto bolt 1 Washer
NOTE: While holding the flywheel magneto 2 with the sheave holder 3, loosen the flywheel magneto bolt. Sheave holder: YS-01880-A/90890-01701
2. Remove: Flywheel magneto 1 Woodruff key NOTE: While holding the flywheel magneto with sheave holder 2, remove the flywheel magneto with the rotor puller 3. Rotor puller: YM-01082/90890-01080
Starter clutch inspection 1. Check: Starter clutch rollers 1 Damage/wear Replace.
5-46
POWR

2 a
2. Check: Starter clutch 1 Starter gear 2 Burrs/chips/roughness/wear Replace the defective part(s). 3. Check: Starter clutch gears contacting surfaces a Damage/pitting/wear Replace the starter clutch gear.
4. Check: Starter clutch operation Checking steps: Install the starter gear 1 onto the starter clutch 2 and hold the starter clutch. When turning the starter gear clockwise , it should turn freely, otherwise the starter clutch is faulty and must be replaced. When turning the starter gear counterclockwise , the starter clutch and the starter gear should engage, otherwise the starter clutch is faulty and must be replaced.
5-47
POWR

Flywheel magneto installation 1. Install: Woodruff key Flywheel magneto Washer Flywheel magneto bolt
NOTE: Clean the tapered portion of the crankshaft and the flywheel magneto hub. When installing the flywheel magneto, make sure the woodruff key is properly seated in the keyway of the crankshaft. Lubricate the flywheel magneto bolt and washer with engine oil.
2. Tighten: Flywheel magneto bolt 1 NOTE: While holding the flywheel magneto 2 with the sheave holder 3, tighten the flywheel magneto bolt. Flywheel magneto bolt: 75 N m (7.5 kgf m, 54 ft lb) Sheave holder: YS-01880-A/90890-01701
CAUTION:
Do not reuse the flywheel magneto bolt and washer, always replace them with new ones.
T.
5-48
POWR
CAMSHAFTS
CAMSHAFTS
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib) 2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm 1st 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm
7 5
LT
10 N m (1.0 kgf m, 7.2 ft Ib) 6 16 mm 6 16 mm
a 4
12 14 13
1
LT
9 10 11 15 16
E 572
17
572
19
GM
18
12 N m (1.2 kgf m, 8.7 ft Ib) 6 22 mm
GM
13 N m (1.3 kgf m, 9.4 ft Ib)

Step Procedure/Part name CYLINDER HEAD COVER REMOVAL Air filter case Bolt Ignition coil Spark plug Clamp/breather hose Bolt Cam position sensor Qty Service points Follow the left Step for removal. Refer to FUEL INJECTION SYSTEM in Chapter 4. 4 4 4 1/1 1 1
1 2 3 4 5 6
To oil tank Paint mark a
5-49
POWR
CAMSHAFTS
EXPLODED DIAGRAM
7 5
LT
10 N m (1.0 kgf m, 7.2 ft Ib) 6 16 mm 6 16 mm
a 4
12 14 13
1
LT
9 10 11 15 16
E 572
17
572
19
GM
18
12 N m (1.2 kgf m, 8.7 ft Ib) 6 22 mm
GM
13 N m (1.3 kgf m, 9.4 ft Ib)
Step 7 8 9 10 11 12 13 14 15 16 17
Procedure/Part name Clamp/cooling water hose Rubber seal Bolt Cooling water pipe O-ring Bolt Band Collar Bolt Rubber mount Cylinder head cover
Qty 1/1 1 1 1 1 1 1 1 6 6 1
Service points To thermostat
Not reusable
5-50
POWR
CAMSHAFTS
EXPLODED DIAGRAM
7 5
LT
10 N m (1.0 kgf m, 7.2 ft Ib) 6 16 mm 6 16 mm
a 4
12 14 13
1
LT
9 10 11 15 16
E 572
17
572
19
GM
18
12 N m (1.2 kgf m, 8.7 ft Ib) 6 22 mm
GM
13 N m (1.3 kgf m, 9.4 ft Ib)
Step 18 19
Procedure/Part name Cylinder head cover gasket Timing chain guide (top side)
Qty 1 1
Service points Not reusable Reverse the removal steps for installation.
5-51
POWR
CAMSHAFTS
EXPLODED DIAGRAM
6 35 mm 10 N m (1.0 kgf m, 7.2 ft Ib)
10 10 10 11
E E
11 11
E
24 N m (2.4 kgf m, 17 ft Ib) 7 11 mm 10 N m (1.0 kgf m, 7.2 ft Ib) 6 35 mm
17 16
7 8 8 18
E
8 9
24 N m (2.4 kgf m, 17 ft Ib) 7 11 mm
12
14 20 15
E
13 6
19
10 N m (1.0 kgf m, 7.2 ft Ib) 6 8 mm
2 5 4
6 25 mm 10 N m (1.0 kgf m, 7.2 ft Ib)
1 3

Step Procedure/Part name CAMSHAFT REMOVAL Cylinder head cover Reduction drive gear case Qty Service points Follow the left Step for removal. Refer to REDUCTION DRIVE GEAR. NOTE: When removing camshafts it is not necessary to remove the reduction drive gear case. 1 1 2 1 Not reusable
1 2 3 4
Cap bolt Gasket Bolt Timing chain tensioner
5-52
POWR
CAMSHAFTS
EXPLODED DIAGRAM
6 35 mm 10 N m (1.0 kgf m, 7.2 ft Ib)
10 10 10 11
E E
11 11
E
17 16
7 8 8 18
E
8 9
24 N m (2.4 kgf m, 17 ft Ib) 7 11 mm
12
14 20 15
E
13 6
19
10 N m (1.0 kgf m, 7.2 ft Ib) 6 8 mm
2 5 4
6 25 mm 10 N m (1.0 kgf m, 7.2 ft Ib)
1 3
Step 5 6 7 8 9 10 11 12 13 14 15
Procedure/Part name Timing chain tensioner gasket Timing chain guide (exhaust side) Bolt Intake camshaft cap Dowel pin Bolt Exhaust camshaft cap Dowel pin Intake camshaft Bolt Intake camshaft sprocket
Qty 1 1 18 3 6 10 3 6 1 2 1
NOTE: During removal, the dowel pins may still be connected to the camshaft caps.
5-53
POWR
CAMSHAFTS
EXPLODED DIAGRAM
6 35 mm 10 N m (1.0 kgf m, 7.2 ft Ib)
10 10 10 11
E E
11 11
E
17 16
7 8 8 18
E
8 9
24 N m (2.4 kgf m, 17 ft Ib) 7 11 mm
12
14 20 15
E
13 6
19
10 N m (1.0 kgf m, 7.2 ft Ib) 6 8 mm
2 5 4
6 25 mm 10 N m (1.0 kgf m, 7.2 ft Ib)
1 3
Step 16 17 18 19 20
Procedure/Part name Exhaust camshaft Bolt Exhaust camshaft sprocket Pin Timing chain guide (intake side)
Qty 1 2 1 1 1
Service points
5-54
POWR
CAMSHAFTS
SERVICE POINTS
Camshaft removal 1. Install: Dial gauge needle Dial gauge stand 1 (into spark plug hole #1) Dial gauge 2 Dial gauge stand: 90890-06583 Dial gauge needle: 90890-06584 Dial gauge stand set: YW-06585/90890-06585 Dial gauge: YU-03097/90890-01252
2 1
2. Turn the drive coupling counterclockwise, and then check if cylinder #1 is at TDC of the compression stroke with a dial gauge. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.
IN
EX
3. Make the alignment marks a on the timing chain and camshaft sprockets.
4. Remove: Timing chain tensioner 1 Gasket
5-55
POWR
3 5 3 9 6 4 8 6
CAMSHAFTS
7 9 13 17 10 1
5. Remove: Camshaft caps Dowel pins
8 2 16 12 1
NOTE: Loosen the intake and exhaust camshaft cap bolts in the sequence shown.
5 7
10 4
1115
1814 2
6. Remove: Intake camshaft 1 Exhaust camshaft 2 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire 3.
7. Remove: Exhaust camshaft sprocket 1 Intake camshaft sprocket 2 (with the special tool 3) Universal magneto and rotor holder: YU-01235 Rotor holder: 90890-01235 Camshaft inspection 1. Check: Camshaft lobes Blue discoloration/pitting/scratches Replace the camshaft. 2. Measure: Camshaft lobe dimensions a and b Out of specification Replace the camshaft. Cam lobe dimensions: Intake camshaft: a 32.55 mm (1.281 in) b 25.00 mm (0.984 in) Exhaust camshaft: a 33.00 mm (1.299 in) b 25.00 mm (0.984 in)
5-56
POWR
CAMSHAFTS
3. Measure: Camshaft runout Out of specification Replace. Maximum camshaft runout: 0.03 mm (0.0012 in)
8 6 16 10
5 7 11 13
4 2 6 2
10
3 9 3 7 18
4. Measure: Camshaft-journal-to-camshaft-cap clearance Out of specification Measure the camshaft journal diameter. Camshaft-journal-to-camshaftcap clearance: 0.030.06 mm (0.00120.0024 in) Measurement steps: Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). Position a strip of Plastigauge 1 onto the camshaft journal as shown. Install the dowel pins and camshaft caps. NOTE: Tighten the intake and exhaust camshaft cap bolts in the sequence shown. Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the Plastigauge. Camshaft cap bolt: 10 N m (1.0 kgf m, 7.2 ft lb)
14 12
9 15
8 4
1 5 17
Remove the camshaft caps and then measure the width of the Plastigauge 1.
T.
5-57
POWR
CAMSHAFTS
E 5. Measure: Camshaft journal diameter a Out of specification Replace the camshaft. Within specification Replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter: 24.4624.47 mm (0.96300.9634 in)
Camshaft sprockets inspection 1. Check: Camshaft sprocket Wear/damage Replace the camshaft sprockets and timing chain as a set.
a b 1 2 1/4 of a tooth Correct Timing chain Camshaft sprocket
Timing chain tensioner inspection 1. Check: Timing chain tensioner Cracks/damage/rough movement Replace. Checking steps: While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1. Remove the screwdriver and slowly release the timing chain tensioner rod. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough movement, replace the timing chain tensioner.
5-58
POWR
CAMSHAFTS
Camshaft installation 1. Install: Exhaust camshaft sprocket 1 Intake camshaft sprocket 2 (with the special tool 3) Universal magneto and rotor holder: YU-01235 Rotor holder: 90890-01235
NOTE: Install the camshaft sprocket with the punch mark a facing outside. Camshaft sprocket bolt: 24 N m (2.4 kgf m, 17 ft lb)
2. Install: Exhaust camshaft Intake camshaft Exhaust camshaft caps Intake camshaft caps Installation steps: Turn the drive coupling counterclockwise, and then check if cylinder #1 is at TDC of the compression stroke with a dial gauge. Install the timing chain onto both camshaft sprockets, and then install the camshaft.
CAUTION:
Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. NOTE: Make sure that the punch marks a on the camshafts face up. Be sure to align the alignment marks b made during removal to install the timing chain and camshaft sprockets.
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8 6 16 10 5 7 11 13
CAMSHAFTS
4 2 6 2 1 10
Install the exhaust and intake camshaft caps. NOTE: Gradually tighten the intake and exhaust camshaft cap bolts in 23 steps in the sequence shown. Camshaft cap bolt: 10 N m (1.0 kgf m, 7.2 ft lb)
3 9 3 7 18
14 12
9 15
8 4
1 5 17
NOTE: Make sure that the punch marks c on the camshafts are aligned with the arrow marks d on the camshaft caps. Out of alignment Reinstall. Remove the wire from the timing chain. 3. Install: Timing chain tensioner Installation steps: While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1. NOTE: Make sure that the tensioner rod has been fully set clockwise. With the timing chain tensioner rod turned all the way into the timing chain tensioner housing (with the thin screwdriver still installed), install the gasket and the timing chain tensioner 2 onto the cylinder block.
T.
3 2
WARNING
Always use a new gasket. Tighten the timing chain tensioner bolts 3 to the specified torque. NOTE: The UP mark on the timing chain tensioner should face up.
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CAMSHAFTS
Timing chain tensioner bolt: 10 N m (1.0 kgf m, 7.2 ft lb)
Remove the screwdriver, make sure the timing chain tensioner rod releases, and then tighten the cap bolt to the specified torque. Cap bolt: 10 N m (1.0 kgf m, 7.2 ft lb)
4. Turn: Drive coupling (several turns counterclockwise)
5. Check: Turn the drive coupling counterclockwise, and then check if cylinder #1 is at TDC of the compression stroke with a dial gauge. Camshaft punch marks a Make sure that the camshaft punch marks are aligned with the arrow marks b on the camshaft caps. Out of alignment Adjust. Refer to the installation steps above. 6. Measure: Valve clearance Out of specification Adjust. Refer to POWER UNIT in Chapter 3.
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T.
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CAMSHAFTS
7. Install: Cylinder head cover gasket Cylinder head cover
NOTE: Apply Gasket Maker onto the mating surfaces of the cylinder head cover gasket and cylinder head. Tighten the cylinder head cover bolts stages and in a crisscross pattern. Cylinder head cover bolt: 12 N m (1.2 kgf m, 8.7 ft lb)
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CYLINDER HEAD
CYLINDER HEAD
EXPLODED DIAGRAM
1st
20 N m (2.0 kgf m, 14 ft Ib) 10 N m (1.0 kgf m, 7.2 ft Ib) 6 12 mm 10 N m (1.0 kgf m, 7.2 ft Ib) 6 55 mm
E
2nd 121 5 1st 20 N m (2.0 kgf m, 14 ft Ib) 2nd 140 5
3 5 5
E E E
1st
20 N m (2.0 kgf m, 14 ft Ib)
2nd 105 5
5
E
6
E
4 2
E
1
LT
7 8
10 N m (1.0 kgf m, 7.2 ft Ib) 6 12 mm
271
40 N m (4.0 kgf m, 29 ft Ib) 8 20 mm

Step Procedure/Part name CYLINDER HEAD REMOVAL Engine unit Air filter case Exhaust pipe 3 Exhaust pipes 1 and 2 Oil tank Intake and exhaust camshaft Bolt Hunger Bolt Qty Service points Follow the left Step for removal. Refer to ENGINE UNIT. Refer to FUEL INJECTION SYSTEM in Chapter 4. Refer to EXHAUST PIPE 3. Refer to EXHAUST PIPES 1 AND 2. Refer to OIL TANK. Refer to CAMSHAFTS.
1 2 3
2 1 3
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CYLINDER HEAD
EXPLODED DIAGRAM
1st
20 N m (2.0 kgf m, 14 ft Ib) 10 N m (1.0 kgf m, 7.2 ft Ib) 6 12 mm 10 N m (1.0 kgf m, 7.2 ft Ib) 6 55 mm
E
2nd 121 5 1st 20 N m (2.0 kgf m, 14 ft Ib) 2nd 140 5
3 5 5
E E E
1st
20 N m (2.0 kgf m, 14 ft Ib)
2nd 105 5
5
E
6
E
4 2
E
1
LT
7 8
10 N m (1.0 kgf m, 7.2 ft Ib) 6 12 mm
271
40 N m (4.0 kgf m, 29 ft Ib) 8 20 mm
Step 4 5 6 7 8 9
Procedure/Part name Nut/washer Nut/washer Nut/washer Cylinder head Cylinder head gasket Dowel pin
Qty 2/2 6/6 2/2 1 1 2
Service points
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CYLINDER HEAD
SERVICE POINTS
Cylinder head removal 1. Remove: Cylinder head bolts 1
2. Remove: Cylinder head nuts NOTE: Loosen the cylinder head nuts in the sequence shown.
Cylinder head inspection 1. Eliminate: Combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: spark plug bore threads valve seats 2. Check: Cylinder head Damage/scratches Replace. Cylinder head water jacket Mineral deposits/rust Eliminate.
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CYLINDER HEAD
E 3. Measure: Cylinder head warpage Out of specification Replace the cylinder head. Cylinder head warpage limit: 0.1 mm (0.004 in) Measurement steps: Place a straightedge 1 and a thickness gauge 2 across the cylinder head. Measure the warpage. If the limit is exceeded, replace the cylinder head.
Cylinder head installation 1. Install: Cylinder head NOTE: Pass the timing chain through the timing chain cavity. Lubricate the cylinder head nuts with engine oil. Tighten the cylinder head nuts in the sequence shown. Cylinder head nut 1: 1st: 20 N m (2.0 kgf m, 14 ft lb) 2nd: 121 5 Cylinder head nut 2: 1st: 20 N m (2.0 kgf m, 14 ft lb) 2nd: 105 5 Cylinder head nut 3: 1st: 20 N m (2.0 kgf m, 14 ft lb) 2nd: 140 5
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CYLINDER HEAD
2. Tighten: Cylinder head bolts 1
NOTE: Lubricate the cylinder head bolts with engine oil. Cylinder head bolt: 10 N m (1.0 kgf m, 7.2 ft lb)
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VALVES AND VALVE SPRINGS

EXPLODED DIAGRAM
10 11 12 13 14 15 16
3 12
E
1 2 3 4 5 6 7
9 8
18
17
E

Step Procedure/Part name VALVES AND VALVE SPRINGS REMOVAL Cylinder head Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve oil seal Intake valve lower spring seat Intake valve Intake valve guide Qty Service points Follow the left Step for removal. Refer to CYLINDER HEAD. 12 12 24 12 12 12 12 12 12
5-68
1 2 3 4 5 6 7 8 9
Not reusable
Not reusable
POWR
EXPLODED DIAGRAM
10 11 12 13 14 15 16
3 12
E
1 2 3 4 5 6 7
9 8
18
17
E
Step 10 11 12 13 14 15 16 17 18
Procedure/Part name Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide
Qty 8 8 16 8 8 8 8 8 8
Service points
Not reusable
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SERVICE POINTS
Valve removal 1. Remove: Valve lifter 1 Valve pad 2
NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place. 2. Remove: Valve cotters 1 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3. Valve spring compressor: YM-01253/90890-04019 Valve spring compressor attachment: (for the intake valve) YM-4114/90890-04114 (for the exhaust valve) YM-4108/90890-04108
3. Remove: Upper spring seat 1 Valve spring 2 Valve 3 Oil seal 4 Lower spring seat 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
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Valve spring inspection 1. Measure: Valve spring free length a Out of specification Replace the valve spring. Valve spring free length: Intake valve spring: 38.90 mm (1.53 in) Exhaust valve spring: 40.67 mm (1.60 in) 2. Measure: Valve spring tilt a Out of specification Replace the valve spring. Valve spring tilt: Intake valve spring: 1.7 mm (0.067 in) Exhaust valve spring: 1.8 mm (0.071 in)
Valve inspection 1. Eliminate: Carbon deposits (from the valve face and valve seat) 2. Check: Valve face Pitting/wear Replace the valve.
3. Measure: Valve margin thickness a Out of specification Replace the valve. Valve margin thickness: 0.50.9 mm (0.01970.0354 in)
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4. Measure: Valve stem diameter a Out of specification Replace the valve. Valve stem diameter a: Intake valve: 3.9753.990 mm (0.15650.1571 in) Exhaust valve: 4.4654.480 mm (0.17580.1764 in)
5. Measure: Valve stem runout Out of specification Replace the valve. NOTE: When installing a new valve, always replace the valve guide. If the valve is removed or replaced, always replace the oil seal. Valve stem runout: 0.01 mm (0.0004 in)
Valve guide inspection NOTE: Before checking the valve guide make sure that the valve stem diameter is within specification.
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1. Measure: Valve guide inside diameter a Valve guide inside diameter: Intake: 4.0004.012 mm (0.15750.1580 in) Exhaust: 4.5004.512 mm (0.17720.1776 in)
2. Calculate the valve stem-to-valve guide clearance as follows. Replace the valve guide if out of specification. Valve stem-to-valve guide clearance = valve guide inside diameter valve stem diameter: Intake: 0.0100.037 mm (0.00040.0015 in) Exhaust: 0.0200.047 mm (0.00080.0019 in)
Valve guide replacement 1. Remove the valve guide 1 by striking the special service tool from the combustion chamber side. Valve guide remover: Intake (4.0 mm): YM-04111/90890-04111 Exhaust (4.5 mm): YM-04116/90890-04116
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2. Install the new valve guide 2 by striking the special service tool from the camshaft side until the valve guide clip 3 contacts the cylinder head. NOTE: Apply engine oil to the surface of the new valve guide. Valve guide remover: Intake (4.0 mm): YM-04111/90890-04111 Exhaust (4.5 mm): YM-04116/90890-04116 Valve guide installer: Intake (4.0 mm): YM-04112/90890-04112 Exhaust (4.5 mm): YM-04117/90890-04117
3. Insert the special service tool into the valve guide 2, and then ream the valve guide. NOTE: Turn the valve guide reamer clockwise to ream the valve guide. Do not turn the reamer counterclockwise when removing the reamer. Valve guide reamer: Intake (4.0 mm): YM-04113/90890-04113 Exhaust (4.5 mm): YM-04118/90890-04118 4. Measure: Valve guide inside diameter Valve guide inside diameter: Intake: 4.0004.012 mm (0.15750.1580 in) Exhaust: 4.5004.512 mm (0.17720.1776 in)
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Valve seat inspection 1. Eliminate carbon deposits from the valve with a scraper. 2. Apply a thin, even layer of Mechanics blueing dye (Dykem) onto the valve seat.
3. Lap the valve slowly on the valve seat with a valve lapper (commercially obtainable) as shown.
4. Measure the valve seat contact width a where the blueing dye is adhered to the valve face. Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification. Replace the valve guide if the valve seat contact is uneven. Valve seat contact width a: 0.91.1 mm (0.03540.0433 in)
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Valve seat reface 1. Reface the valve seat with the valve seat cutter. Valve seat cutter holder: Intake (4.0 mm): 90890-06811 Exhaust (4.5 mm): 90890-06812 Valve seat cutter: 30 (intake): 90890-06815 45 (intake): 90890-06814 60 (intake): 90890-06813 30 (exhaust): 90890-06328 45 (exhaust): 90890-06312 60 (exhaust): 90890-06315 Valve seat cutter set: YM-91043-C 2. Cut the surface of the valve seat with a 45 cutter by turning the cutter clockwise until the valve seat face has become smooth.
a Slag or rough surface
CAUTION:
Do not over cut the valve seat. Be sure to turn the cutter evenly downward at a pressure of 4050 N (45 kgf, 8.811 lbf) to prevent chatter marks.
3. Use a 30 cutter to adjust the contact width of the top edge of the valve seat.
b Previous contact width
30
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b
4. Use a 60 cutter to adjust the contact width of the bottom edge of the valve seat.
60
b c
5. Use a 45 cutter to adjust the contact width of the valve seat to specification.
b Previous contact width c Specified contact width
45
6. If the valve seat contact area is too wide and situated in the center of the valve face, use a 30 cutter to cut the top edge of the valve seat, a 60 cutter to cut the bottom edge to center the area and set its width.
7. If the valve seat contact area is too narrow and situated near the top edge of the valve face, use a 30 cutter to cut the top edge of the valve seat. If necessary, use a 45 cutter to center the area and set its width.
8. If the valve seat contact area is too narrow and situated near the bottom edge of the valve face, use a 60 cutter to cut the bottom edge of the valve seat. If necessary, use a 45 cutter to center the area and set its width.
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9. Apply a thin, even layer of lapping compound onto the valve seat, and then lap the valve using a valve lapper (commercially obtainable).
CAUTION:
Do not get the lapping compound on the valve stem and valve guide. 10. After every lapping procedure, be sure to clean off any remaining lapping compound from the cylinder head and the valve. 11. Check the valve seat contact area of the valve again.
Valve installation 1. Install: Lower spring seat 1 Oil seal 2 Valve 3 Valve spring 4 Upper spring seat 5 (into the cylinder head) NOTE: Make sure that each valve is installed in its original place. Refer to the following embossed marks. Right and left intake valve(s): 4XV: Middle intake valve(s): 4XV. Exhaust valve(s): 5LV Install the valve spring with the larger pitch a facing up.
b Smaller pitch
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2. Compress the valve spring, and then install the valve cotter 1 using a thin screwdriver with a small amount of grease applied to it. Valve spring compressor: YM-01253/90890-04019 Valve spring compressor attachment: (for the intake valve) YM-4114/90890-04114 (for the exhaust valve) YM-4108/90890-04108
3. Lightly tap the valve spring retainer with a plastic hammer to set the valve cotter securely. NOTE: Apply engine oil to the valve pads and valve lifters before installation.
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CRANKCASE
CRANKCASE
EXPLODED DIAGRAM
12 N m (1.2 kgf m, 8.7 ft Ib) 6 20 mm

LT
20 N m (2.0 kgf m, 14 ft Ib) 8 40 mm

A
LT
8.4 N m (0.84 kgf m, 6.1 ft Ib)
271
9 10 11 8
15 N m (1.5 kgf m, 11 ft Ib)
572
1 6
A
2 4 5
LT
3 20 21
19
GM
572
20 18
E
7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm

LT
1st
7.8 N m (0.78 kgf m, 5.6 ft Ib)
6 70 mm 12 N m (1.2 kgf m, 8.7 ft Ib)
572
16 18
E
LT
572
2nd * 3rd 15 N m (1.5 kgf m, 11 ft Ib) 4th 49 5
15
17
9 105 mm
14 13
12 N m (1.2 kgf m, 8.7 ft Ib) 6 55 mm 12 N m (1.2 kgf m, 8.7 ft Ib) 6 55 mm
LT
572
12
12 N m (1.2 kgf m, 8.7 ft Ib) 6 20 mm

Step Procedure/Part name OIL PAN AND CRANKCASE REMOVAL Engine unit Air filter case Exhaust pipe 3 Exhaust pipes 1 and 2 Exhaust manifold Generator cover *: Loosen completely Qty Service points Follow the left Step for removal. Refer to ENGINE UNIT. Refer to FUEL INJECTION SYSTEM in Chapter 4. Refer to EXHAUST PIPE 3. Refer to EXHAUST PIPES 1 AND 2. Refer to EXHAUST MANIFOLD. Refer to GENERATOR AND STARTER MOTOR.
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CRANKCASE
EXPLODED DIAGRAM
12 N m (1.2 kgf m, 8.7 ft Ib) 6 20 mm

LT
20 N m (2.0 kgf m, 14 ft Ib) 8 40 mm

A
LT
8.4 N m (0.84 kgf m, 6.1 ft Ib)
271
9 10 11 8
15 N m (1.5 kgf m, 11 ft Ib)
572
1 6
A
2 4 5
LT
3 20 21
19
GM
572
20 18
E
7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm

LT
1st
7.8 N m (0.78 kgf m, 5.6 ft Ib)
6 70 mm 12 N m (1.2 kgf m, 8.7 ft Ib)
572
16 18
E
LT
572
15
17
9 105 mm
14 13
LT
572
12
12 N m (1.2 kgf m, 8.7 ft Ib) 6 20 mm
Step
1 2 3 4 5 6
Procedure/Part name Oil tank Oil pump Reduction drive gear case Cylinder head Timing chain Engine temperature sensor Washer Bolt Thermoswitch (engine) Oil pressure switch
Qty
Service points Refer to OIL TANK. Refer to OIL PUMP. Refer to REDUCTION DRIVE GEAR. Refer to CAMSHAFTS.
1 1 1 2 1 1
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CRANKCASE
EXPLODED DIAGRAM
12 N m (1.2 kgf m, 8.7 ft Ib) 6 20 mm

LT
20 N m (2.0 kgf m, 14 ft Ib) 8 40 mm

A
LT
8.4 N m (0.84 kgf m, 6.1 ft Ib)
271
9 10 11 8
15 N m (1.5 kgf m, 11 ft Ib)
572
1 6
A
2 4 5
LT
3 20 21
19
GM
572
20 18
E
7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm

LT
1st
7.8 N m (0.78 kgf m, 5.6 ft Ib)
6 70 mm 12 N m (1.2 kgf m, 8.7 ft Ib)
572
16 18
E
LT
572
15
17
9 105 mm
14 13
LT
572
12
12 N m (1.2 kgf m, 8.7 ft Ib) 6 20 mm
Step 7 8 9 10 11 12 13 14 15 16 17
Procedure/Part name Bolt Bolt Anode cover Grommet Anode Bolt Oil pan Gasket Bolt Bolt Bolt
Qty 1 1 1 1 1 15 1 1 2 1 7
Service points
Not reusable
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CRANKCASE
EXPLODED DIAGRAM
12 N m (1.2 kgf m, 8.7 ft Ib) 6 20 mm

LT
20 N m (2.0 kgf m, 14 ft Ib) 8 40 mm

A
LT
8.4 N m (0.84 kgf m, 6.1 ft Ib)
271
9 10 11 8
15 N m (1.5 kgf m, 11 ft Ib)
572
1 6
A
2 4 5
LT
3 20 21
19
GM
572
20 18
E
7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm

LT
1st
7.8 N m (0.78 kgf m, 5.6 ft Ib)
6 70 mm 12 N m (1.2 kgf m, 8.7 ft Ib)
572
16 18
E
LT
572
15
17
9 105 mm
14 13
LT
572
12
12 N m (1.2 kgf m, 8.7 ft Ib) 6 20 mm
Step 18 19 20 21
Procedure/Part name Bolt/washer Lower crankcase Dowel pin Dowel pin/O-ring
Qty 10/10 1 2 1/1
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CRANKCASE
EXPLODED DIAGRAM
6 10 mm 12 N m (1.2 kgf m, 8.7 ft Ib)
1 2
E A
3 5
E
4
35 N m (3.5 kgf m, 25 ft Ib)

Step Procedure/Part name OIL PIPE AND OIL FILTER BOLT REMOVAL Crankshaft Bolt Oil pipe O-ring Oil filter bolt Lower crankcase Qty Service points Follow the left Step for removal. Refer to CRANKSHAFT. 1 1 2 1 1
1 2 3 4 5
Not reusable
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CRANKCASE
SERVICE POINTS
Crankcase disassembly 1. Remove: Oil pan bolts
10 14 13 9
6 5
2 1
4 3
8 7
12 15 11
NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration). The numbers embossed on the oil pan indicate the oil pan tightening sequence.
H 8
F 6
B 2
D 4
J 0
2. Remove: Crankcase bolts NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration). The numbers embossed on the crankcase indicate the crankcase tightening sequence. 3. Remove: Lower crankcase
9 I
3 C
1 A
5 E
7 G
CAUTION:
Tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced portions of the crankcase, not on he crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves separate evenly.
M9 105 mm bolts: 10 M6 55 mm bolts: AF M6 55 mm bolts: G, H M6 70 mm bolts: I M6 55 mm bolts: J
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CRANKCASE
4. Remove: Dowel pins
Crankcase inspection 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: Crankcase Cracks/damage Replace. Oil delivery passages Obstruction Blow out with compressed air.
Timing chain inspection 1. Check: Timing chain 1 Damage/stiffness Replace the timing chain and camshaft sprockets as a set.
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CRANKCASE
Crankcase assembly 1. Lubricate: Crankshaft journal bearings (with the recommended lubricant) Recommended lubricant: Engine oil
2. Apply: Gasket Maker (onto the crankcase mating surfaces) NOTE: Do not allow any Gasket Maker to come into contact with the oil gallery or crankshaft journal bearings.
GM
3. Install: Dowel pins 1 O-ring 2
12
H 8
F 6
B 2
D 4
J 0
4. Install: Crankcase bolts NOTE: Lubricate the bolt 10 threads and washers with engine oil. Finger tighten the crankcase bolts.
M9 105 mm bolts: 10 M6 55 mm bolts: AF M6 55 mm bolts: G, H M6 70 mm bolts: I M6 55 mm bolts: J
9 I
3 C
1 A
5 E
7 G
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H 8 F 6
CRANKCASE
B 2 D 4 J 0
5. Tighten: Crankcase bolts 10
9 I
3 C
1 A
5 E
7 G
NOTE: Do not reuse crankcase bolts 10. The tightening procedure of crankcase bolts 10 is angle controlled, therefore tighten the bolts using the following procedure. Tightening steps: Tighten the bolts in the tightening sequence cast on the crankcase. Crankcase bolt 10: 1st: 7.8 N m (0.78 kgf m, 5.6 ft lb)
Loosen and retighten the crankcase bolts in the proper tightening sequence as shown. Crankcase bolt 10: 2nd: Loosen completely 3rd: 15 N m (1.5 kgf m, 11 ft lb)
Tighten the crankcase bolts further to reach the specified angle 49 in the proper tightening sequence as shown. Crankcase bolt 10: Final: Specified angle 49 5
When the bolts are tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one and perform the procedure again.
T.
R
T.
R
T.
WARNING
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CRANKCASE
CAUTION:
Do not use a torque wrench to tighten the bolt to the specified angle. Tighten the bolt until it is at the specified angle. NOTE: When using a hexagonal bolt, note that the angle from one corner to another is 60.
H 8
F 6
B 2
D 4
J 0
6. Tighten: Crankcase bolts AJ NOTE: Tighten the bolts in the tightening sequence cast on the crankcase. Crankcase bolt AJ: 12 N m (1.2 kgf m, 8.7 ft lb)
9 I
3 C
1 A
5 E
7 G
T.
7. Tighten: Oil pan bolts
10 14 13 9
6 5
2 1
4 3
8 7
12 15 11
NOTE: Tighten the bolts in the tightening sequence cast on the oil pan. Oil pan bolt: 12 N m (1.2 kgf m, 8.7 ft lb) LOCTITE 572
T.
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CONNECTING RODS AND PISTONS

EXPLODED DIAGRAM
10 11 12
E
4 5 6 8 7
M
3 2
E M
1st
20 N m (2.0 kgf m, 14 ft Ib)
2nd 120 5

Step Procedure/Part name CONNECTING RODS AND PISTONS REMOVAL Crankcase Nut Connecting rod cap Big end lower bearing Piston pin clip Piston pin Piston Connecting rod Qty Service points Follow the left Step for removal. Separate Refer to CRANKCASE. Not reusable
1 2 3 4 5 6 7
8 4 4 8 4 4 4
Not reusable
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POWR
EXPLODED DIAGRAM
10 11 12
E
4 5 6 8 7
M
3 2
E M
1st
20 N m (2.0 kgf m, 14 ft Ib)
2nd 120 5
Step 8 9 10 11 12
Procedure/Part name Bolt Big end upper bearing Top ring 2nd ring Oil ring
Qty 8 4 4 4 4
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1

SERVICE POINTS
Connecting rod and piston removal The following procedure applies to all of the connecting rods and pistons. 1. Remove: Connecting rod cap 1 Big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.
2. Remove: Piston pin clips 1 Piston pin 2 Piston 3 Connecting rod 4
CAUTION:
Do not use a hammer to drive the piston pin out. NOTE: For reference during installation, put an identification number a on the piston crown. Before removing the piston pin, deburr the piston pin clips groove and the pistons pin bore area.
3. Remove: Top ring 2nd ring Oil ring NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown.
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Cylinder and piston inspection The following procedure applies to all of the cylinders and pistons. 1. Check: Piston wall Cylinder wall Vertical scratches Replace the cylinder, and the piston and piston rings as a set. 2. Measure: Piston-to-cylinder clearance
D2 D4 D6
D1 D3 D5
d e
Measurement steps: Measure cylinder bore C with the cylinder bore gauge. Cylinder bore C Taper limit T Out of round R 76.00076.015 mm (2.99212.9927 in) 0.08 mm (0.003 in) 0.05 mm (0.002 in)
C = maximum of D1D6 T = maximum of D1D5 (direction d) and D2D6 (direction e) R = maximum of D2D1 (measuring point a) and D6D5 (measuring point c) If out of specification, replace the cylinder, and the piston and piston rings as a set. Measure piston skirt diameter P with the micrometer.
a 5 mm (0.2 in) from the bottom edge of the piston
Piston size P Standard 75.89575.910 mm (2.98802.9986 in)
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POWR
If out of specification, replace the piston and piston rings as a set. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore C Piston skirt diameter P Piston-to-cylinder clearance: 0.100.11 mm (0.00390.0043 in) <Limit>: 0.17 mm (0.0067 in) If out of specification, replace the piston and piston rings as a set.
Piston ring inspection 1. Measure: Piston ring side clearance Out of specification Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Side clearance: Top ring: 0.0300.065 mm (0.00120.0026 in) 2nd ring: 0.0200.055 mm (0.00080.0022 in) Oil ring: 0.0400.160 mm (0.00160.0063 in)
5-94
POWR

2. Install: Piston ring (into the cylinder)
NOTE: Level the piston ring in the cylinder with the piston crown.
a 5 mm (0.2 in)
3. Measure: Piston ring end gap Out of specification Replace the piston ring. NOTE: The oil ring expander spacers end gap cannot be measured. If the oil ring rails gap is excessive, replace all three piston rings. Piston ring end gap: Top ring: 0.320.44 mm (0.01260.0173 in) 2nd ring: 0.430.58 mm (0.01690.0228 in) Oil ring: 0.100.35 mm (0.00390.0138 in)
5-95
POWR
Piston pin inspection The following procedure applies to all of the piston pins. 1. Check: Piston pin Blue discoloration/grooves Replace the piston pin and then check the lubrication system.
2. Measure: Piston pin outside diameter a Out of specification Replace the piston pin. Piston pin outside diameter: 16.99117.000 mm (0.66890.6693 in) <Limit>: 16.98 mm (0.67 in)
3. Measure: Piston pin bore diameter (in the piston) b Out of specification Replace the piston. Piston pin bore diameter (in the piston): 17.00217.013 mm (0.66930.6698 in) 4. Calculate: Piston-pin-to-piston clearance Out of specification Replace the piston pin. Piston-pin-to-piston clearance = Piston pin bore diameter (in the piston) b Piston pin outside diameter a Piston-pin-to-piston clearance: 0.0020.022 mm (0.00010.0009 in)
5-96
POWR
Connecting rod inspection 1. Measure: Crankshaft-pin-to-big-end-bearing clearance Out of specification Replace the big end bearings. Crankshaft-pin-to-big-endbearing clearance: 0.0160.040 mm (0.00060.0016 in) Measurement steps: The following procedure applies to all of the connecting rods.
CAUTION:
Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clearance and prevent engine damage, the big end bearings must be installed in their original positions. Clean the big end bearings, crankshaft pins, and the inside of the connecting rod halves. Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap. NOTE: Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap. Put a piece of Plastigauge 1 on the crankshaft pin. Assemble the connecting rod halves.
5-97
POWR

d
NOTE: Do not move the connecting rod or crankshaft until the clearance measurement has been completed. Lubricate the bolts threads and nut seats with molybdenum disulfide grease. Make sure the Y mark c on the connecting rod faces towards the front side of the crankshaft. Make sure the characters d on both the connecting rod and connecting rod cap are aligned.
Tighten the connecting rod nuts. Refer to Connecting rod and piston installation. Remove the connecting rod and big end bearings. Refer to Connecting rod and piston removal. Measure the compressed Plastigauge width e on the crankshaft pin. If the crankshaft-pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings.
2. Select: Big end bearings (P1P4) NOTE: The numbers stamped into the crankshaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes. P1P4 refer to the bearings shown in the crankshaft illustration.
P1 P2 P3
P4
5-98
POWR
For example, if the connecting rod P1 and the crankshaft web P1 numbers are 5 and 1 respectively, then the bearing size for P1 is: Bearing size of P1: P1 (connecting rod) P1 (crankshaft web) 5 1 = 4 (green) BEARING COLOR CODE 1
P1 P2 P3 P4
5G
brown black blue green
2 3 4
Connecting rod and piston installation The following procedure applies to all of the pistons and connecting rods. 1. Install: Oil ring 2nd ring Top ring NOTE: Be sure to install the piston rings so that the manufacturers marks or numbers face up. 2. Install: Piston 1 Connecting rod 2 Piston pin 3 Piston pin clips 4 NOTE: Apply engine oil onto the piston pin. When installing the connecting rod to the piston, make sure that the Y mark a on the connecting rod faces towards the left when the exhaust valve recesses b on the piston face upward. Refer to the illustration. Reinstall each piston into its original cylinder (numbering order starting from the front: #1 to #4).
5-99
POWR
b

90 c 90
3. Offset: Piston ring end gaps
a b c Top ring, oil ring expander spacer 2nd ring, lower oil ring rail Upper oil ring rail Exhaust side
45
a
4. Lubricate: Piston Piston rings Cylinder (with the recommended lubricant) Recommended lubricant: Engine oil
5. Lubricate: Bolt threads Nut seats (with the recommended lubricant) Recommended lubricant: Molybdenum disulfide grease
6. Lubricate: Crankshaft pins Big end bearings Connecting rod inner surface (with the recommended lubricant) Recommended lubricant: Engine oil
5-100
POWR

7. Install: Big end bearings Connecting rod assembly 1 (into the cylinder and onto the crankshaft pin) Connecting rod cap (onto the crankshaft pin)
NOTE: Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps. Be sure to reinstall each big end bearing in its original place. While compressing the piston rings with piston ring compressor 2, install the connecting rod assembly into the cylinder with the other hand. Make sure the Y marks a on the connecting rods face towards the front side of the crankshaft. Make sure the characters b on both the connecting rod and connecting rod cap are aligned. Piston ring compressor: YM-08037/90890-05158 8. Align: Bolt heads (with the connecting rod)
5-101
POWR

9. Tighten: Connecting rod nuts
WARNING
Replace the connecting rod bolts and nuts with new ones. Clean the connecting rod bolts and nuts. NOTE: The tightening procedure of the connecting rod nuts is angle controlled, therefore tighten the nuts using the following procedure. Tightening steps: Tighten the connecting rod nuts to the specified torque. Connecting rod nut: 1st: 20 N m (2.0 kgf m, 14 ft lb)
Tighten the connecting rod nuts further to reach the specified angle 120. Connecting rod nut: Final: Specified angle 120 5
When the nuts are tightened more than the specified angle, do not loosen the nut and then retighten it. Replace the bolt and nut with a new one and perform the procedure again.
CAUTION:
Do not use a torque wrench to tighten the nut to the specified angle. Tighten the nut until it is at the specified angle. NOTE: When using a hexagonal nut, note that the angle from one corner to another is 60.
T.
R
T.
WARNING
5-102
POWR
CRANKSHAFT
CRANKSHAFT
EXPLODED DIAGRAM
3 3 1
2
E

Step Procedure/Part name CRANKSHAFT REMOVAL Crankcase Connecting rod caps 1 2 3 Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing 1 5 5 Reverse the removal steps for installation. Qty Service points Follow the left Step for removal. Separate Refer to CRANKCASE. Refer to CONNECTING RODS AND PISTONS.
5-103
POWR
1
CRANKSHAFT
SERVICE POINTS
Crankshaft removal 1. Remove: Crankshaft 1 Crankshaft journal lower bearings (from the lower crankcase) Crankshaft journal upper bearings (from the upper crankcase)
NOTE: Identify the position of each crankshaft journal bearing so that it can be reinstalled in its original place.
Crankshaft inspection 1. Measure: Crankshaft runout Out of specification Replace the crankshaft. Maximum crankshaft runout: 0.03 mm (0.0012 in)
2. Check: Crankshaft journal surfaces Crankshaft pin surfaces Scratches/wear Replace the crankshaft. Bearing surfaces Scratches/wear Replace the crankshaft journal bearing. 3. Measure: crankshaft-journal-to-crankshaft-journalbearing clearance Out of specification Replace the crankshaft journal bearings. Crankshaft-journal-to-crankshaftjournal-bearing clearance: 0.0040.028 mm (0.00020.0011 in)
5-104
POWR
CRANKSHAFT
CAUTION:
Do not interchange the crankshaft journal bearings. To obtain the correct crankshaftjournal-to-crankshaft-journal-bearing clearance and prevent engine damage, the crankshaft journal bearings must be installed in their original positions. Measurement steps: Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase. Place the upper crankcase upside down on a bench. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crankcase. NOTE: Align the projections a of the crankshaft journal upper bearings with the notches b in the upper crankcase.
a b
Put a piece of Plastigauge 2 on each crankshaft journal. NOTE: Do not put the Plastigauge over the oil hole in the crankshaft journal. Install the crankshaft journal lower bearings into the lower crankcase and assemble the crankcase halves. NOTE: Align the projections a of the crankshaft journal lower bearings with the notches b in the lower crankcase. Do not move the crankshaft until the clearance measurement has been completed.
5-105
POWR
CRANKSHAFT
Tighten the bolts to specification in the tightening sequence cast on the crankcase. Refer to Crankcase assembly CRANKCASE. Remove the lower crankcase and the crankshaft journal lower bearings. Measure the compressed Plastigauge width c on each crankshaft journal. If the crankshaft-journal-to-crankshaftjournal-bearing clearance is out of specification, select replacement crankshaft journal bearings.
4. Select: Crankshaft journal bearings (J1J5) NOTE: The numbers stamped into the crankshaft web and the numbers stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. J1J5 refer to the bearings shown in the crankshaft illustration. If J1J5 are the same, use the same size for all of the bearings. For example, if the crankcase J1 and crankshaft web J1 numbers are 5 and 2 respectively, then the bearing size for J1 is:
J5 J4 J3 J2 J1
J1
J2
J3
J4
J5
Bearing size of J1: J1 (crankcase) J1 (crankshaft web) 5 2 = 3 (blue) BEARING COLOR CODE 1 2 3 4 5 brown black blue green yellow
J1 J2 J3 J4 J5
5-106
POWR
CRANKSHAFT
Crankshaft installation 1. Install: Crankshaft journal upper bearings (into the upper crankcase) Crankshaft journal lower bearings (into the lower crankcase)
a b
NOTE: Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase. Be sure to install each crankshaft journal bearing in its original place.
2. Lubricate: Crankshaft pins Connecting rod inner surface (with the recommended lubricant) Recommended lubricant: Engine oil
5-107
POWR
THERMOSTAT
THERMOSTAT
EXPLODED DIAGRAM
1st
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 35 mm 5.9 N m (0.59 kgf m, 4.3 ft Ib)
4 8 7 9
LT
12 13
1
11
10
12
LT
572 572
6 5 2

Step 1 2 3 4 5 6 7 8 Procedure/Part name THERMOSTAT REMOVAL Band Clamp/cooling water hose Clamp/cooling water hose Clamp/cooling water hose Band/grease hose Bolt Thermostat housing cover Thermostat Qty 1 1/1 2/1 1/1 1/1 2 1 1 Service points Follow the left Step for removal. For cooling water outlet on stern side. For cooling water pilot outlet on starboard side.
5-108
POWR
THERMOSTAT
EXPLODED DIAGRAM
1st
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 35 mm 5.9 N m (0.59 kgf m, 4.3 ft Ib)
4 8 7 9
LT
12 13
1
11
10
12
LT
572 572
6 5 2
Step 9 10 11 12 13
Procedure/Part name Gasket Thermostat housing Bolt Collar Thermostat housing holder
Qty 1 1 2 2 1
5-109
POWR
THERMOSTAT
SERVICE POINTS
Thermostat inspection 1. Check: Thermostat 1 Does not open at 5060 C (123 141 F) Replace. Checking steps: Suspend the thermostat in a container filled with water. Slowly heat the water. Place a thermometer in the water. While stirring the water, observe the thermostat and thermometers indicated temperature.
3 1 4
1 2 3 4
Thermostat Thermometer Water Container Fully closed Fully open
NOTE: If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious overheating or over cooling.
2. Check: Thermostat housing cover Thermostat housing Cracks/damage Replace. 3. Check: Cooling system Leaks Repair or replace any faulty part.
Thermostat installation 1. Install: Thermostat housing 1 Thermostat 2 Gasket Thermostat housing cover
5-110
POWR
COOLING WATER HOSE
COOLING WATER HOSE

EXPLODED DIAGRAM
3 2
6 4 4 7 5
3 2

Step Procedure/Part name COOLING WATER HOSE REMOVAL Exhaust manifold Clamp/cooling water hose Clamp/cooling water hose Clamp/cooling water hose Clamp/cooling water hose Joint Clamp/cooling water hose Joint Qty Service points Follow the left Step for removal. Refer to EXHAUST MANIFOLD. From exhaust manifold To cylinder block To exhaust pipe To cylinder block
1 2 3 4 5 6 7
1/1 2/2 2/1 2/1 1 1/1 1
To oil tank From cooling water inlet Reverse the removal steps for installation.
5-111
JET PUMP
CHAPTER 6 JET PUMP UNIT
INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT....................................6-1 EXPLODED DIAGRAM .............................................................................6-1 REMOVAL AND INSTALLATION CHART ................................................ 6-1 JET PUMP UNIT.............................................................................................. 6-4 EXPLODED DIAGRAM .............................................................................6-4 REMOVAL AND INSTALLATION CHART ................................................ 6-4 REVERSE GATE ............................................................................................. 6-6 EXPLODED DIAGRAM .............................................................................6-6 REMOVAL AND INSTALLATION CHART ................................................ 6-6 SERVICE POINTS .................................................................................... 6-9 Lever 1 installation ..............................................................................6-9 Lever 2 installation ..............................................................................6-9 JET THRUST NOZZLE AND NOZZLE RING ............................................... 6-10 EXPLODED DIAGRAM ...........................................................................6-10 REMOVAL AND INSTALLATION CHART .............................................. 6-10 IMPELLER DUCT AND IMPELLER HOUSING 1 .........................................6-11 EXPLODED DIAGRAM ...........................................................................6-11 REMOVAL AND INSTALLATION CHART .............................................. 6-11 IMPELLER DUCT AND DRIVE SHAFT ........................................................ 6-13 EXPLODED DIAGRAM ...........................................................................6-13 REMOVAL AND INSTALLATION CHART .............................................. 6-13 SERVICE POINTS .................................................................................. 6-15 Drive shaft removal ...........................................................................6-15 Impeller inspection ............................................................................6-17 Drive shaft inspection........................................................................6-17 Drive shaft installation ....................................................................... 6-17
JET PUMP
TRANSOM PLATE AND HOSES.................................................................. 6-20 EXPLODED DIAGRAM ...........................................................................6-20 REMOVAL AND INSTALLATION CHART .............................................. 6-20 SERVICE POINTS .................................................................................. 6-23 Bilge strainer inspection .................................................................... 6-23 Electric bilge pump inspection........................................................... 6-23 Bilge hose inspection ........................................................................6-23 Cooling water hose inspection .......................................................... 6-23 BEARING HOUSING.....................................................................................6-24 EXPLODED DIAGRAM ...........................................................................6-24 REMOVAL AND INSTALLATION CHART .............................................. 6-24 SERVICE POINTS .................................................................................. 6-27 Driven coupling removal and installation...........................................6-27 Intermediate drive shaft removal.......................................................6-27 Bearing removal ................................................................................ 6-28 Bearing, intermediate drive shaft, and grease hose inspection ........ 6-28 Driven coupling inspection ................................................................6-28 Bearing installation............................................................................6-29 Oil seal installation ............................................................................6-29 Intermediate housing installation.......................................................6-30
JET PUMP
INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT

EXPLODED DIAGRAM

Step Procedure/Part name INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT REMOVAL Bolt Bolt Intake grate Screw Speed sensor Qty Service points Follow the left Step for removal.
1 2 3 4 5
2 2 1 4 1
NOTE: Route the speed sensor lead between the jet pump unit and the bilge hose.
Bolt
6-1
JET PUMP
EXPLODED DIAGRAM
Step 7 8 9 10
Procedure/Part name Ride plate Bolt Intake duct Felt packing
Qty 1 4 1 1
Service points
6-2
JET PUMP
EXPLODED DIAGRAM
2 3
FWD

Step 1 2 3 Procedure/Part name SPEED SENSOR DISASSEMBLY Holder Paddle wheel set Speed sensor Qty 1 1 1 Service points Follow the left Step for disassembly. Not reusable Reverse the disassembly steps for assembly.
6-3
JET PUMP
JET PUMP UNIT
JET PUMP UNIT
EXPLODED DIAGRAM
14 N m (1.4 kgf m, 10 ft Ib) 8 24 mm
6.8 N m (0.68 kgf m, 4.9 ft Ib) 6 22 mm
9
LT
7 8
271
2.2 N m (0.22 kgf m, 1.6 ft Ib)
5
LT
6
A
242
2 11
40 N m (4.0 kgf m, 29 ft Ib) 10 95 mm
12
LT
1 10
572
14 13
4
LT
572
6.8 N m (0.68 kgf m, 4.9 ft Ib)
15
M 4
6 80 mm 7.8 N m (0.78 kgf m, 5.6 ft Ib)

Step 1 2 3 Procedure/Part name JET PUMP UNIT REMOVAL Shift cable joint QSTS cable joint Bilge hose Qty 1 1 1 Service points Follow the left Step for removal.
NOTE: Route the speed sensor lead between the jet pump unit and the bilge hose.
4 5 6 7
Nut/washer Steering cable joint Clamp/spout hose Bolt
1/2 1 1/1 6
6-4
JET PUMP
JET PUMP UNIT
EXPLODED DIAGRAM
14 N m (1.4 kgf m, 10 ft Ib) 8 24 mm
6.8 N m (0.68 kgf m, 4.9 ft Ib) 6 22 mm
9
LT
7 8
271
2.2 N m (0.22 kgf m, 1.6 ft Ib)
5
LT
6
A
242
2 11
40 N m (4.0 kgf m, 29 ft Ib) 10 95 mm
12
LT
1 10
572
14 13
4
LT
572
6.8 N m (0.68 kgf m, 4.9 ft Ib)
15
M 4
6 80 mm 7.8 N m (0.78 kgf m, 5.6 ft Ib)
Step 8 9 10 11 12 13 14 15
Procedure/Part name Collar Rubber plate Bolt Bolt Jet pump unit assembly Dowel pin Impeller housing 2 Dowel pin
Qty 4 2 1 4 1 2 1 2
Service points
6-5
JET PUMP
REVERSE GATE
REVERSE GATE
EXPLODED DIAGRAM

Step 1 2 3 4 5 6 7 8 9 Procedure/Part name REVERSE GATE REMOVAL Clamp/spout hose Bolt Washer Collar Reverse gate assembly Nut Bolt Washer Roller Qty 1/1 2 2 2 1 1 1 2 1 Service points Follow the left Step for removal.
6-6
JET PUMP
REVERSE GATE
EXPLODED DIAGRAM
Step 10 11 12 13 14 15 16 17 18 19
Procedure/Part name Bolt Bracket Reverse gate stay Nut Washer Bolt Lever 1 Spacer Nut Washer
Qty 6 1 2 1 1 1 1 1 1 1
Service points
6-7
JET PUMP
REVERSE GATE
EXPLODED DIAGRAM
Step 20 21 22 23 24 25 26
Procedure/Part name Collar Bolt Washer Collar Spring Lever 2 Washer
Qty 1 1 1 1 1 1 1
Service points
6-8
JET PUMP
REVERSE GATE
SERVICE POINTS
Lever 1 installation 1. Install: Bolt 1 Lever 1 2 Spacer 3 Reverse gate 4 Washer 5 Nut 6 Lever 2 installation 1. Install: Bolt 1 Washer 2 Collar 3 Spring 4 Lever 2 5 Washer 6 Collar 7
NOTE: When installing the spring, hook the spring end a to lever 2 and spring end b to the reverse gate, as shown in the illustration. When installing the lever 2, hook the lever 2 end c to lever 1 end d, as shown in the illustration.
d c
2. Install: Washer 1 Nut 2
3. Check: Lever 1 and lever 2 movements Stick Reassemble lever 1 and lever 2.
6-9
JET PUMP
JET THRUST NOZZLE AND NOZZLE RING
JET THRUST NOZZLE AND NOZZLE RING

EXPLODED DIAGRAM

Step Procedure/Part name JET THRUST NOZZLE AND NOZZLE RING REMOVAL Jet pump unit Reverse gate Bolt Collar Jet thrust nozzle Bolt Collar Nozzle ring Qty Service points Follow the left Step for removal. Refer to JET PUMP UNIT. Refer to REVERSE GATE. 2 2 1 2 2 1 Reverse the removal steps for installation.
1 2 3 4 5 6
6-10
JET PUMP
IMPELLER DUCT AND IMPELLER HOUSING 1

EXPLODED DIAGRAM

Step Procedure/Part name IMPELLER DUCT AND IMPELLER HOUSING 1 REMOVAL Nozzle ring Bolt Nozzle Pin Impeller duct assembly Impeller housing 1 Pin Bolt Qty Service points Follow the left Step for removal. Refer to JET THRUST NOZZLE AND NOZZLE RING. 4 1 2 1 1 2 4 NOTE: Clean the contacting surfaces before applying the Yamabond #4 (Yamaha bond number 4).
1 2 3 4 5 6 7
6-11
JET PUMP
EXPLODED DIAGRAM
Step 8 9 10 11
Procedure/Part name Water inlet cover Packing Water inlet strainer Packing
Qty 1 1 1 1
Service points
6-12
JET PUMP
IMPELLER DUCT AND DRIVE SHAFT

EXPLODED DIAGRAM

Step Procedure/Part name IMPELLER DUCT AND DRIVE SHAFT DISASSEMBLY Impeller Spacer Bolt/washer Cap O-ring Nut Washer Qty Service points Follow the left Step for disassembly. Left-hand threads
1 2 3 4 5 6 7
*1
1 1 3/3 1 1 1 1
Not reusable
6-13
JET PUMP
EXPLODED DIAGRAM
Step 8 9 10 11 12 13 14
Procedure/Part name Drive shaft Rear bearing Spacer Front bearing Oil seal Oil seal Impeller duct
Qty 1 1 1 1 1 1 1
Service points Not reusable Not reusable Not reusable Not reusable Reverse the disassembly steps for assembly.
*1
6-14
JET PUMP

SERVICE POINTS
Drive shaft removal 1. Remove: Impeller Drive shaft holder: YB-06151 Drive shaft holder 5: 90890-06519
NOTE: The impeller has left-hand threads. Turn the impeller clockwise to loosen it.
2. Remove: Nut 1 Drive shaft holder: YB-06151 Drive shaft holder 5: 90890-06519
3. Remove: Drive shaft 1 NOTE: Remove the drive shaft with a press.
6-15
JET PUMP

4. Remove: Rear bearing Slide hammer and adapters: YB-06096 Stopper guide plate: 90890-06501 Bearing puller assembly: 90890-06535 Stopper guide stand: 90890-06538
5. Remove: Front bearing Driver handlelarge: YB-06071 Driver rod L3: 90890-06652 Bearing housing needle bearing remover: YB-06112 Needle bearing attachment: 90890-06614 NOTE: Remove the front bearing with a press.
6-16
JET PUMP

6. Remove: Oil seal Driver handlelarge: YB-06071 Driver rod L3: 90890-06652 Drive shaft needle bearing installer and remover: YB-06196 Needle bearing attachment: 90890-06614 NOTE: Remove the oil seals with press.
Impeller inspection Refer to JET PUMP UNIT in Chapter 3. Drive shaft inspection 1. Inspect: Drive shaft Damage/wear Replace.
Drive shaft installation 1. Install: Oil seals Driver handlelarge: YB-06071 Driver rod LS: 90890-06606 Outer race installerforward gear: YB-06085 Ball bearing attachment: 90890-06631 Distance a: 14.2 0.2 mm (0.56 0.01 in) Distance b: 4.7 0.2 mm (0.19 0.01 in)
6-17
JET PUMP

2. Install: Front bearing Drive shaft
NOTE: Install the front bearing and drive shaft with a press. Press the front bearing with a pipe that is more than 85 mm (3.35 in) long, and which has an inner diameter of 25 mm (0.98 in). Distance a: 23 0.1 mm (0.91 0.004 in)
3. Install: Drive shaft (with front bearing) Spacer Impeller duct NOTE: Press the spacer and the front bearing with a pipe that is more than 33 mm (1.30 in) long, and which has an outer diameter less than 50 mm (1.97 in) and an inner diameter more than 26 mm (1.02 in).
4. Add: EPNOC grease AP #0 (between the drive shaft and spacer) Quantity: 20 g (0.7 oz)
6-18
JET PUMP

5. Install: Rear bearing Bearing inner/outer race attachment: YB-34474
NOTE: Press the bearing inner/outer race at the same time holding the drive shaft and impeller duct. If a bearing inner/outer race attachment 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).
6. Add: EPNOC grease AP #0 (into the cap) Quantity: 20 g (0.7 oz)
7. Install: Nut Impeller Drive shaft nut: 69 N m (6.9 kgf m, 50 ft lb) Impeller: 75 N m (7.5 kgf m, 54 ft lb) LOCTITE 572 Drive shaft holder: YB-06151 Drive shaft holder 5: 90890-06519
T.
6-19
JET PUMP
TRANSOM PLATE AND HOSES

EXPLODED DIAGRAM

Step Procedure/Part name TRANSOM PLATE AND HOSES REMOVAL Exhaust system Jet pump unit assembly Hose clamp Cooling water hose Bilge hose 1 Qty Service points Follow the left Step for removal. Refer to EXHAUST SYSTEM in Chapter 8. Refer to JET PUMP UNIT. 2 1 1 Cooling water outlet (exhaust pipe) NOTE: Route the bilge hose 1 under the drive shaft tube. Cooling water inlet
1 2 3
4 5
Hose clamp Cooling water hose
1 1
6-20
JET PUMP
EXPLODED DIAGRAM
Step 6 7 8 9 10 11 12 13 14 15
Procedure/Part name Hose clamp Cooling water hose Bilge hose 2 Hose clamp Bilge hose 3 Band Electric bilge pump assembly Hose clamp Bilge hose 4 Bilge strainer
Qty 2 1 1 1 1 1 1 1 1 1
Service points Cooling water outlet (thermostat)
6-21
JET PUMP
EXPLODED DIAGRAM
Step 16 17 18
Procedure/Part name Nut/washer Transom plate Bilge hose 5
Qty 4/4 1 1
Service points
6-22
JET PUMP

SERVICE POINTS
Bilge strainer inspection Refer to JET PUMP UNIT in Chapter 3.
Electric bilge pump inspection Refer to BILGE PUMP in Chapter 3. Refer to ELECTRIC BILGE PUMP in Chapter 7. Bilge hose inspection 1. Inspect: Bilge hoses Cracks/damage/wear Replace. Cooling water hose inspection 1. Inspect: Cooling water hoses Cracks/damage/wear Replace.
6-23
JET PUMP
BEARING HOUSING
BEARING HOUSING
EXPLODED DIAGRAM

Step Procedure/Part name BEARING HOUSING REMOVAL Engine unit Rubber coupling Bolt Intermediate housing assembly Pin Shim Qty Service points Follow the left Step for removal. Refer to ENGINE UNIT in Chapter 5.
1 2 3 4 5
1 3 1 2 *
NOTE: Install the shims in their original locations. Reverse the removal steps for installation.
*: As required
6-24
JET PUMP
BEARING HOUSING
EXPLODED DIAGRAM

Step Procedure/Part name BEARING HOUSING DISASSEMBLY Grease hose Nipple Driven coupling Washer Intermediate drive shaft O-ring Qty Service points Follow the left Step for disassembly.
1 2 3 4 5 6
1 1 1 1 1 2
Not reusable
6-25
JET PUMP
BEARING HOUSING
EXPLODED DIAGRAM
Step 7 8 9 10 11 12
Procedure/Part name Oil seal Oil seal Oil seal Circlip Bearing Circlip
Qty 1 1 1 1 1 1
Service points Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Reverse the disassembly steps for assembly.
6-26
JET PUMP
BEARING HOUSING
SERVICE POINTS
Driven coupling removal and installation 1. Remove and install: Driven coupling Coupler wrench: YW-06551/90890-06551 Shaft holder: YB-06552 Crankshaft holder 20: 90890-06552 NOTE: Install the driven coupling with the same special tools that were used for removal. Check that the shaft holder and intermediate drive shaft are properly engaged.
Intermediate drive shaft removal 1. Remove: Intermediate drive shaft Removal steps: Temporarily install the driven coupling to the intermediate drive shaft. Insert a long rod to the driven coupling shaft. Press out the intermediate drive shaft by pushing the rod.
NOTE: Support the intermediate housing with steel blocks 1 and press the driven coupling shaft with a rod that is more than 210 mm (8.27 in) long, and which has an outer diameter less than 16 mm (0.63 in).
6-27
JET PUMP
BEARING HOUSING
Bearing removal 1. Remove: Bearing Driver handlelarge: YB-06071 Driver rod LS: 90890-06606 Drive shaft taper roller bearing cup installer: YB-06156 Bearing outer race attachment: 90890-06626
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 bearing.
Bearing, intermediate drive shaft, and grease hose inspection 1. Inspect: Bearing Rotate the inner race by hand. Damage/rough movement Replace. Intermediate drive shaft Damage/pitting Replace. Grease hose Cracks/wear Replace. Driven coupling inspection 1. Inspect: Driven coupling Driven coupling damper Damage/wear Replace.
6-28
JET PUMP
BEARING HOUSING
Bearing installation 1. Install: Circlip (front) 2. Install: Bearing Driver handlelarge: YB-06071 Driver rod LS: 90890-06606 Driveshaft taper roller bearing cup installer: YB-06156 Bearing outer race attachment: 90890-06626
NOTE: Support the intermediate housing with steel blocks 1 and press the bearing. Oil seal installation 1. Install: Oil seal
Driver handlelarge: YB-06071 Driver rod LS: 90890-06606 Driveshaft taper roller bearing cup installer: YB-06156 Bearing outer race attachment: 90890-06626 NOTE: Before installing the oil seal, lubricate the clip glove with water resistant grease. Distance a: 7.0 0.2 mm (0.28 0.01 in)
6-29
JET PUMP
BEARING HOUSING
2. Install: Intermediate drive shaft Circlip (rear)
NOTE: Hold the bearing in place as shown with a pipe that is more than 80 mm (3.15 in) long, and which has an outer diameter of 51 mm (2.00 in) and an inner diameter of 26 mm (1.02 in). Distance a: 46.0 0.5 mm (1.81 0.02 in) 3. Install: Oil seal 1 [8 mm (0.31 in)] Oil seal 2 [11 mm (0.43 in)] Distance a: 10.5 0.2 mm (0.41 0.01 in) Distance b: 0.8 0.2 mm (0.03 0.01 in) Intermediate housing installation 1. Install: Intermediate housing Shim Installation steps: Install the intermediate housing. Measure the clearance a at each bolt hole. Install the suitable shim from the table below. Clearance a 00.2 mm (00.008 in) 0.30.7 mm (0.0120.028 in) 0.81.2 mm (0.0310.047 in) 1.32.0 mm (0.0510.079 in) Shim thickness No need 0.5 mm 1.0 mm 1.5 mm
b 2 1
NOTE: Install the shim(s) to the original position if the intermediate housing is not replaced.
6-30
ELEC
CHAPTER 7 ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS........................................................................ 7-1 ELECTRICAL BOX.......................................................................................... 7-2 EXPLODED DIAGRAM .............................................................................7-2 REMOVAL AND INSTALLATION CHART ................................................ 7-2 ELECTRICAL ANALYSIS ............................................................................... 7-9 INSPECTION............................................................................................. 7-9 Digital tester ........................................................................................7-9 Low resistance measurement ........................................................... 7-10 Peak voltage measurement ..............................................................7-10 Peak voltage adapter ........................................................................7-11 Test harness ....................................................................................7-11 IGNITION SYSTEM ....................................................................................... 7-12 WIRING DIAGRAM ................................................................................. 7-12 IGNITION SPARK ...................................................................................7-14 IGNITION SYSTEM PEAK VOLTAGE ....................................................7-15 BATTERY ................................................................................................7-17 FUSE ....................................................................................................... 7-17 SPARK PLUGS ....................................................................................... 7-17 IGNITION COIL ....................................................................................... 7-18 ENGINE STOP SWITCH.........................................................................7-18 ENGINE TEMPERATURE SENSOR ......................................................7-19 SENSOR ASSEMBLY ............................................................................. 7-19 THERMOSWITCH (ENGINE).................................................................. 7-20 THERMOSWITCH (EXHAUST) ..............................................................7-20 MAIN AND FUEL PUMP RELAY............................................................. 7-21 THROTTLE POSITION SENSOR ........................................................... 7-22 CAM POSITION SENSOR ...................................................................... 7-23 NOISE FILTER ........................................................................................ 7-24 SLANT DETECTION SWITCH ................................................................7-24 FUEL CONTROL SYSTEM ...........................................................................7-25 WIRING DIAGRAM ................................................................................. 7-25 FUEL PUMP ............................................................................................ 7-27 FUEL SENDER ....................................................................................... 7-27 FUEL INJECTOR ....................................................................................7-28 MAIN AND FUEL PUMP RELAY............................................................. 7-28 OIL PRESSURE SWITCH....................................................................... 7-28 THERMOSWITCH (ENGINE).................................................................. 7-28 THERMOSWITCH (EXHAUST) ..............................................................7-28 SLANT DETECTION SWITCH ................................................................7-28 REMOTE CONTROL UNIT ..................................................................... 7-28
ELEC
STARTING SYSTEM .....................................................................................7-29 WIRING DIAGRAM ................................................................................. 7-29 BATTERY ................................................................................................7-30 WIRING CONNECTIONS........................................................................7-30 FUSE ....................................................................................................... 7-30 START SWITCH......................................................................................7-30 STARTER RELAY ...................................................................................7-31 REMOTE CONTROL UNIT ..................................................................... 7-31 STARTER MOTOR........................................................................................ 7-32 EXPLODED DIAGRAM ...........................................................................7-32 REMOVAL AND INSTALLATION CHART ............................................. 7-32 SERVICE POINTS .................................................................................. 7-35 Armature inspection ..........................................................................7-35 Brush holder inspection..................................................................... 7-36 Starter motor front cover inspection .................................................. 7-36 CHARGING SYSTEM....................................................................................7-37 WIRING DIAGRAM ................................................................................. 7-37 FUSE ....................................................................................................... 7-38 BATTERY ................................................................................................7-38 LIGHTING COIL ......................................................................................7-38 RECTIFIER/REGULATOR ...................................................................... 7-38 ELECTRIC BILGE PUMP.............................................................................. 7-39 WIRING DIAGRAM ................................................................................. 7-39 ELECTRIC BILGE PUMP........................................................................7-40 FUSE ....................................................................................................... 7-40 BATTERY ................................................................................................7-40 MAIN AND FUEL PUMP RELAY............................................................. 7-40 REMOTE CONTROL UNIT ..................................................................... 7-40 OFF THROTTLE STEERING SYSTEM......................................................... 7-41 WIRING DIAGRAM ................................................................................. 7-41 STEERING SWITCH ............................................................................... 7-42 ECM.........................................................................................................7-42 PICKUP COIL.......................................................................................... 7-42 THROTTLE POSITION SENSOR ........................................................... 7-42 BYPASS VALVE MOTOR ....................................................................... 7-42
ELEC
INDICATION SYSTEM .................................................................................. 7-43 WIRING DIAGRAM ................................................................................. 7-43 FUSE ....................................................................................................... 7-45 BATTERY ................................................................................................7-45 MAIN AND FUEL PUMP RELAY............................................................. 7-45 ECM.........................................................................................................7-45 ENGINE TEMPERATURE SENSOR ......................................................7-45 THERMOSWITCH (ENGINE).................................................................. 7-45 THERMOSWITCH (EXHAUST) ..............................................................7-45 REMOTE CONTROL UNIT ..................................................................... 7-45 BUZZER .................................................................................................. 7-45 OIL PRESSURE SWITCH....................................................................... 7-46 MULTIFUNCTION METER...................................................................... 7-46 Multifunction meter............................................................................7-46 MULTIFUNCTION METER REMOVAL ...................................................7-46 Display function................................................................................. 7-47 Speedometer display ........................................................................7-48 Tachometer display...........................................................................7-49 Hour meter display ............................................................................7-49 Voltage meter display........................................................................7-49 Low oil pressure warning indicator....................................................7-49 Fuel level meter display and fuel warning indicator .......................... 7-49 Overheat warning indicator ...............................................................7-50 Check the engine warning indicator .................................................. 7-50 REMOTE CONTROL SYSTEM ..................................................................... 7-51 WIRING DIAGRAM ................................................................................. 7-51 REMOTE CONTROL SYSTEM...............................................................7-52 Yamaha Security System indicator ...................................................7-52 Low-rpm mode indicator.................................................................... 7-52 Diagnostic display ............................................................................. 7-53 Checking the remote control transmitter ...........................................7-53 Transmitter registration ..................................................................... 7-55 Replacing of the transmitter battery .................................................. 7-56
ELEC
ELECTRICAL COMPONENTS
ELECTRICAL COMPONENTS
M L K J I H G F E D C B A 0 9 8 7 5 6 1
2 3 4
1 2 3 4 5 6 7 8 9 0 A
Thermoswitch (engine) Starter motor Engine temperature sensor Spark plugs and ignition coils Electrical box Battery Speed sensor Electric bilge pump Cam position sensor Fuel injectors Thermoswitch (exhaust)
B C D E F G
Oil pressure switch Sensor assembly Bypass valve motor Throttle position sensor Lighting coil and pickup coil Engine stop switch, engine shut-off switch, and start switch H Steering switch I Buzzer J Fuel pump
K Fuel sender L Multifunction meter M Remote control unit
7-1
ELEC
ELECTRICAL BOX
ELECTRICAL BOX
EXPLODED DIAGRAM
17 N m (1.7 kgf m, 12 ft Ib) 8 28 mm 5 20 mm 4.9 N m (0.49 kgf m, 3.5 ft Ib)
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 16 mm 4

A A
11
3
LT
572
7
LT
(VENT)
572
22
A
5 6 9 1
1516
LT
271 4
12
10
14 22 13
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 30 mm
22 22
E
21 20
19 18
17 22
7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 10 mm

LT
572
7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm
22 22
7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 12 mm

Step 1 2 3 4 5 6 7 8 Procedure/Part name ELECTRICAL BOX REMOVAL Battery negative lead Battery positive lead Clip/breather hose Band Battery Damper Bolt Bolt Qty 1 1 1/1 2 1 1 2 2 Service points Follow the left Step for removal.
7-2
ELEC
ELECTRICAL BOX
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 16 mm 4

A A
11
3
LT
572
7
LT
(VENT)
572
22
A
5 6 9 1
1516
LT
271 4
12
10
14 22 13
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 30 mm
22 22
E
21 20
19 18
17 22
7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 10 mm

LT
572
7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm
22 22
7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 12 mm
Step 9 10 11 12 13 14 15 16 17 18
Procedure/Part name Battery box Spacer Bolt Screw Terminal cover Gasket Screw Starter motor lead Bolt Cover
Qty 1 2 4 4 1 1 2 1 3 1
Service points
Not reusable
7-3
ELEC
ELECTRICAL BOX
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 16 mm 4

A A
11
3
LT
572
7
LT
(VENT)
572
22
A
5 6 9 1
1516
LT
271 4
12
10
14 22 13
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 30 mm
22 22
E
21 20
19 18
17 22
7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 10 mm

LT
572
7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm
22 22
7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 12 mm
Step 19 20 21 22
Procedure/Part name Gasket Bolt Ground lead Coupler
Qty 1 2 2 22
NOTE: Disconnect all couplers. Reverse the removal steps for installation.
7-4
ELEC
ELECTRICAL BOX
EXPLODED DIAGRAM
4.9 N m (0.49 kgf m, 3.5 ft Ib) 5 30 mm
3.9 N m (0.39 kgf m, 2.8 ft Ib) 6 20 mm
20
19
16 17 15 14 11 18 13 12
3.9 N m (0.39 kgf m, 2.8 ft Ib) 6 16 mm 6 30 mm 3.9 N m (0.39 kgf m, 2.8 ft Ib) 3.9 N m (0.39 kgf m, 2.8 ft Ib) 6 16 mm 6
21
7 22
3.9 N m (0.39 kgf m, 2.8 ft Ib) 6 30 mm
4
10
9 8
5 4
4

Step Procedure/Part name ELECTRICAL BOX DISASSEMBLY Tapping screw Cover Gasket Clamp Wiring harness Tapping screw Fuse holder stay Wiring harness Fuse Qty Service points Follow the left Step for disassembly.
1 2 3 4 5 6 7 8 9
18 1 1 3 1 1 1 1 6
7-5
ELEC
ELECTRICAL BOX
EXPLODED DIAGRAM
4.9 N m (0.49 kgf m, 3.5 ft Ib) 5 30 mm
3.9 N m (0.39 kgf m, 2.8 ft Ib) 6 20 mm
20
19
16 17 15 14 11 18 13 12
21
7 22
3.9 N m (0.39 kgf m, 2.8 ft Ib) 6 30 mm
4
10
9 8
5 4
4
Step 10 11 12 13 14 15 16 17 18 19 20
Procedure/Part name Starter relay Clamp Tapping screw/washer ECM Tapping screw Bracket Joint connector Tapping screw Slant detection switch Tapping screw Main and fuel pump relay
Qty 1 2 4/4 1 1 1 2 2 1 1 1
Service points
7-6
ELEC
ELECTRICAL BOX
EXPLODED DIAGRAM
4.9 N m (0.49 kgf m, 3.5 ft Ib) 5 30 mm
3.9 N m (0.39 kgf m, 2.8 ft Ib) 6 20 mm
20
19
16 17 15 14 11 18 13 12
21
7 22
3.9 N m (0.39 kgf m, 2.8 ft Ib) 6 30 mm
4
10
9 8
5 4
4
Step 21 22
Procedure/Part name Tapping screw Rectifier/regulator
Qty 2 1
Service points
7-7
ELEC
ELECTRICAL BOX
7 1
UP
1 2 3 4 5 6 7 8
Starter relay Fuse holder ECM Joint connector Joint connector Main and fuel pump relay Rectifier/regulator Slant detection switch
To ignition coil To battery positive terminal To starter motor
7-8
ELEC
ELECTRICAL ANALYSIS ELECTRICAL ANALYSIS

INSPECTION
CAUTION:
All measuring instruments should be handled with special care. Damaged or mishandled instruments will not measure properly. On an instrument powered by dry batteries, check the batterys voltage periodically and replace the batteries if necessary.
Digital tester NOTE: Throughout this chapter the part numbers of the specified digital testers have been omitted. Refer to the following part numbers. Digital multimeter: YU-34899-A Digital circuit tester: 90890-03174 NOTE: indicates a continuity of electricity; i.e., a closed circuit at the respective switch position.
7-9
ELEC
ELECTRICAL ANALYSIS
Low resistance measurement
NOTE: When measuring a resistance of 10 or less with the digital tester, the correct measurement cannot be obtained because of the testers internal resistance. To obtain the correct value, subtract the internal resistance from the displayed measurement. The internal resistance of the tester can be 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 know the peak voltage. Cranking speed is dependant on many factors (e.g., fouled or weak spark plugs, a weak battery). If one of these is defective, the peak voltage will be lower than specification. If the peak voltage measurement is not within specification the engine will not operate properly. A low peak voltage will also cause components to prematurely wear.
7-10
ELEC
ELECTRICAL ANALYSIS
Peak voltage adapter
NOTE: Throughout this chapter the peak voltage adapters part number has been omitted. Refer to the following part number. The peak voltage adapter should be used with the digital tester. Peak volt meter adapter: YU-39991 Peak voltage adapter B: 90890-03172 When measuring the peak voltage, connect the peak voltage adapter to the digital circuit tester and switch the selector to the DC voltage mode. NOTE: Make sure that the adapter leads are properly installed in the digital circuit tester. Make sure that the positive pin (the + mark facing up as shown) on the adaptor is installed into the positive terminal of the tester. The test harness is needed for the following tests.
Voltage measurement Peak voltage measurement
Test harness Checking steps: Disconnect the coupler connections. Connect the test harness between the couplers. Connect the tester terminals to the terminals which are being checked. Run the engine and observe the measurement. NOTE: If the lighting coil and pickup coil(s) are measured unloaded, disconnect the test harness on the output side coupler.
7-11
ELEC
IGNITION SYSTEM
IGNITION SYSTEM
WIRING DIAGRAM
Y
3 : G/O 4 :W 5 :P 6 : P/W 9 :O 12 : W/R 13 : W/B 21 : L/R 22 : B/R
28 : L/B 30 : R/Y 33 : P/G 34 : P 35 : B/Y 42 : B/L 43 : B/Y 44 : B/W
L/R
B R R
1
R R/Y R/Y R/Y R/Y R/Y
3
R R/Y R P R P Br B O R R
R/Y R/Y
12 3 456
7 8 O O P P R R R
P/W
L/R P
P/G O
R/Y Pu/B Pu/R B FREE PUSH
P/W
5
W B R Br
6
W B FREE PUSH
Pu/Y Pu/G G/R G/Y
P/W
G/Y
G B/Y B/O G/B G/B G Pu/R Pu/B R/Y P/G P
R B
B R W B W B/O B/O W B B FREE 7 PUSH
Br
G/R Pu/G Pu/Y O
B/O
R/Y
K
R R B B G G
G/O
Br Br
R R R Br P
R Br Br
B/R
R/Y
#1
H
B/W
B/O
R/Y
L/B
B/O P B/O P B B/O P B
I
G/O R/Y
B
W/R W B R R G R G
P B/O B/O B/O B/O B/Y B/Y B/Y B/Y B/Y B/O B
P B
#2
H
B/Y
I
R/Y B/Y
C
O B/O W/B B W B R G G G
G G B G
0
B/O
#3
I
P/G B/L R/Y O B/O P
F D E G
G G G G B/O B/O B/O B/O B/O B/O B/O
#4
B/O
1 2 3 4 5 6 7 8 9
ECM Main and fuel pump relay Fuse (20A) Battery Engine shut-off switch Engine stop switch Start switch Thermoswitch (exhaust) Thermoswitch (engine)
0 A B C D E F
Engine temperature sensor Slant detection switch Cam position sensor Rectifier/regulator Lighting coil Pickup coil Sensor assembly (intake air temperature, intake air pressure)
7-12
G H I J K
Throttle position sensor Spark plug Ignition coil Oil pressure switch Noise filter
ELEC
IGNITION SYSTEM
WIRING DIAGRAM
Y
3 : G/O 4 :W 5 :P 6 : P/W 9 :O 12 : W/R 13 : W/B 21 : L/R 22 : B/R
28 : L/B 30 : R/Y 33 : P/G 34 : P 35 : B/Y 42 : B/L 43 : B/Y 44 : B/W
L/R
B R R
1
3
R R/Y R P R P Br B O R R
R/Y R/Y
12 3 456
7 8 O O P P R R R
P/W
L/R P
P/G O
R/Y Pu/B Pu/R B FREE PUSH
P/W
5
W B R Br
6
W B FREE PUSH
Pu/Y Pu/G G/R G/Y
P/W
G/Y
G B/Y B/O G/B G/B G Pu/R Pu/B R/Y P/G P
R B
B R W B W B/O B/O W B B FREE 7 PUSH
Br
G/R Pu/G Pu/Y O
B/O
R/Y
K
R R B B G G
G/O
Br Br
R R R Br P
R Br Br
B/R
R/Y
#1
H
B/W
B/O
R/Y
L/B
B/O P B/O P B B/O P B
I
G/O R/Y
B
W/R W B R R G R G
P B/O B/O B/O B/O B/Y B/Y B/Y B/Y B/Y B/O B
P B
#2
H
B/Y
I
R/Y B/Y
C
O B/O W/B B W B R G G G
G G B G
0
B/O
#3
I
P/G B/L R/Y O B/O P
F D E G
G G G G B/O B/O B/O B/O B/O B/O B/O
#4
B/O
B Br G L O P R W Y
: Black : Brown : Green : Blue : Orange : Pink : Red : White : Yellow
B/L B/O B/R B/W B/Y G/O L/B L/R P/G
: Black/blue : Black/orange : Black/red : Black/white : Black/yellow : Green/orange : Blue/black : Blue/red : Pink/green

7-13
P/W R/Y W/B W/R
: Pink/white : Red/yellow : White/black : White/red
ELEC
IGNITION SYSTEM
IGNITION SPARK
WARNING
When checking the spark gap, do not touch any of the connections of the spark gap tester lead wires. When performing the spark gap test, take special care not to let sparks leak out of the removed spark plug cap. When performing the spark gap check, keep flammable gas or liquids away, since this test can produce sparks.
1. Check: Ignition spark Weak Check the ECM output peak voltage. Check the ignition coil for resistance. Checking steps: Connect the spark plug cap to the spark gap tester.
Spark gap tester: YM-34487 Ignition tester: 90890-06754 Crank the engine and observe the ignition system spark through the discharge window.
7-14
ELEC
IGNITION SYSTEM
IGNITION SYSTEM PEAK VOLTAGE

WARNING
When checking the electrical components, do not touch any of the connections of the digital tester lead wires. NOTE: If there is no spark, or the spark is weak, continue with the ignition system test. If a good spark is obtained, the problem is not with the ignition 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. Test harness (2 pins): New: YB-06867 Current: YB-06767 Test harness FWY-2 (2 pins): New: 90890-06867 Current: 90890-06767 ECM output peak voltage: Black/red (B/R) Red/yellow (R/Y) Black/white (B/W) Red/yellow (R/Y) Black/yellow (B/Y) Red/yellow (R/Y) Black/blue (B/L) Red/yellow (R/Y) r/min V Loaded Cranking 87 2,000 86 3,500 85
NOTE: When measuring the ECM output peak voltage while cranking the engine, disconnect the ignition coil couplers for all cylinders except for the cylinder being measured. To crank the engine, connect the engine shut-off cord (lanyard) to the engine shut-off switch, and then press the start switch.
7-15
ELEC
IGNITION SYSTEM
E 2. Measure: Pickup coil output peak voltage Below specification Replace the pickup coil. Above specification Replace the ECM. Test harness (3 pins): New: YB-06877 Current: YB-06777 Test harness HM090-3 (3 pins): New: 90890-06877 Current: 90890-06777 Pickup coil output peak voltage: White (W) Black (B) Red (R) Black (B) r/min V Unloaded Cranking 5.2 4.7 Loaded 2,000 26.1 3,500 41.3
NOTE: To crank the engine, connect the engine shutoff cord (lanyard) to the engine shut-off switch, and then press the start switch and engine stop switch simultaneously.
3. Measure: Lighting coil output peak voltage Below specification Replace the lighting coil. Test harness (3 pins): New: YB-06870 Current: YB-06770 Test harness SMT250-3 (3 pins): New: 90890-06870 Current: 90890-06770 Lighting coil output peak voltage: Green (G) Green (G) r/min V Unloaded Cranking 9.2 2,000 38.5 3,500 63.2
7-16
ELEC
IGNITION SYSTEM
E NOTE: To crank the engine, connect the engine shutoff cord (lanyard) to the engine shut-off switch, and then press the start switch and engine stop switch simultaneously.
4. Measure: Rectifier/regulator output voltage Below specification Replace the rectifier/regulator. Test harness (6 pins): YB-06848 Test harness FSW-6A (6 pins): 90890-06848 Rectifier/regulator output voltage: Red (R) Black (B) r/min V Unloaded 3,500 15.0
NOTE: Do not use the peak voltage adapter to measure the output voltage. Disconnect the output lead of the tester harness.
BATTERY
Refer to ELECTRICAL in Chapter 3.
FUSE
Refer to STARTING SYSTEM.
SPARK PLUGS
Refer to POWER UNIT in Chapter 3.
7-17
ELEC
IGNITION SYSTEM
IGNITION COIL
1. Measure: Primary coil resistance Out of specification Replace. Primary coil resistance: 1.191.61 at 20 C (68 F)
NOTE: When measuring a resistance of 10 or less with the digital tester, the correct measurement cannot be obtained because of the testers internal resistance. Refer to Low resistance measurement.
2. Measure: Secondary coil resistance Out of specification Replace. Secondary coil resistance: 8.511.5 k at 20 C (68 F)
ENGINE STOP SWITCH

1. Check: Engine stop switch continuity Out of specification Replace. Engine stop switch continuity (black coupler) Clip Installed Removed Position Free Push Free Push Lead color White Black
7-18
ELEC
IGNITION SYSTEM
ENGINE TEMPERATURE SENSOR
1. Measure: Engine temperature sensor resistance (at the specified temperature) Out of specification Replace. Engine temperature sensor resistance: 20 C (68 F): 54.269.0 k 100 C (212 F): 3.123.48 k Measurement steps: Suspend the engine temperature sensor in a container filled with water. Slowly heat the water. Measure the resistance when the specified temperature is reached.
SENSOR ASSEMBLY
1. Check: Intake air temperature sensor Out of specification Replace the sensor assembly. Checking steps: Measure the ambient temperature. Connect a computer to the watercraft and use the Yamaha Diagnostic System to display the intake air temperature. If the ambient temperature and the displayed intake air temperature differ by more than 5 C ( 9 F), replace the sensor assembly.
7-19
ELEC
IGNITION SYSTEM
THERMOSWITCH (ENGINE)
1. Check: Thermoswitch (engine) continuity (at the specified temperature) Out of specification Replace.
Thermoswitch (engine) continuity temperature: a 8490 C (183194 F) b 7084 C (158183 F)

1 No continuity 2 Continuity Temperature Time
Checking steps: Suspend the thermoswitch (engine) in a container filled with water. Place a thermometer in the water. Slowly heat the water. Measure the continuity when the specified temperature is reached.
THERMOSWITCH (EXHAUST)
1. Check: Thermoswitch (exhaust) continuity (at the specified temperature) Out of specification Replace. Thermoswitch (exhaust) continuity temperature: a 94100 C (201212 F) b 8094 C (176201 F)
1 No continuity 2 Continuity Temperature Time
Checking steps: Suspend the thermoswitch (exhaust) in a container filled with water. Place a thermometer in the water. Slowly heat the water. Measure the continuity when the specified temperature is reached.
7-20
ELEC
IGNITION SYSTEM
MAIN AND FUEL PUMP RELAY
1. Check: Main and fuel pump relay continuity Faulty Replace.
UP
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
Checking steps: Connect the tester leads between the main and fuel pump relay terminals 5, 6 and 7. Connect the terminals 2 or 3 to the positive battery terminal. Connect the terminal 1 to the negative battery terminal. Check that there is continuity between the main and fuel pump relay terminals. Check that there is no continuity between the main and fuel pump relay terminals after disconnecting terminals 2, 3 or 1. Connect the tester leads between the main and fuel pump relay terminals 7 and 8. Connect the terminals 4 to the negative battery terminal. Connect the terminal 6 to the positive battery terminal. Check that there is continuity between the main and fuel pump relay terminals. Check that there is no continuity between the main and fuel pump relay terminals after disconnecting terminals 4 or 6.
7-21
ELEC
IGNITION SYSTEM
THROTTLE POSITION SENSOR
1. Measure: Throttle position sensor output voltage Out of specification Adjust the throttle bodies synchronization. Refer to FUEL INJECTION SYSTEM in Chapter 4. Test harness (3 pins): YB-06793 Test harness SMHW099-3 (3 pins): 90890-06793 Test connector: YW-06862 Test connector FMY-8: 90890-06862 Throttle position sensor output voltage: Pink (P) Black/orange (B/O) 0.756 0.016 V
B/O
Measurement steps: Connect the test harness (3 pins) to the throttle position sensor 1. To start the ECM normally, use the Yamaha Diagnostic System. Use the test connector 2 to start the ECM normally only if the Yamaha Diagnostic System is not available. Measure the throttle position sensor output voltage.
7-22
ELEC
IGNITION SYSTEM
CAM POSITION SENSOR
1. Measure: Cam position sensor output voltage Out of specification Replace. Test harness (3 pins): New: YB-06877 Current: YB-06777 Test harness HM090-3 (3 pins): New: 90890-06877 Current: 90890-06777 Cam position sensor output voltage: Green/orange (G/O) Black/orange (B/O) Position A B C Voltage (V) More than 4.8 Less than 0.8 More than 4.8
A B C
Measurement steps: Remove the cam position sensor. Connect the test harness (3 pins) to the cam position sensor. Operate the Yamaha Diagnostic System. Measure the output voltage when a screwdriver is passed under the cam position sensor in the direction shown. NOTE: The cam position sensor contains two individual sensors as shown in the illustration: sensor 1 1 and sensor 2 2. To measure the output voltage, pass the screwdriver under the measuring positions A, B (center), and C of the cam position sensor in order. When operating the Yamaha Diagnostic System, electric power is supplied to the cam position sensor.
7-23
ELEC
B
IGNITION SYSTEM
NOISE FILTER
R
1. Check: Noise filter continuity Out of specification Replace. Noise filter continuity:
Black (B) Red (R)

R
No continuity
SLANT DETECTION SWITCH
UP
1. Check: Slant detection switch continuity Out of specification Replace.
UP
7-24
Lead color Position Blue/black (L/B) Normal operation Overturned Black/ orange (B/O)
ELEC
FUEL CONTROL SYSTEM
FUEL CONTROL SYSTEM

WIRING DIAGRAM
Br
Y B R R
5 :P 6 : P/W 8 : B/Y 9 :O 14 : L 28 : L/B 30 : R/Y
33 : P/G 35 : B/Y 37 : Pu/G 38 : Pu/Y 39 : Pu/B 40 : Pu/R
L/R
1
R/Y
R P
3
R R
P O
2
R/Y R/Y R 12 3 456 7 8 P O O P R R
L/B Y
P/W
18 15
L/R
P/W
P/G O Pu/Y P R/Y Pu/B Pu/R L B G B/Y G/Y G/R Pu/G Pu/Y O P/G P B/O G/B G/B G Pu/R L/B Pu/B R/Y B B B B P R/Y R/Y R/Y B/Y R/Y R/Y B/Y P/G B/O O P B/O B/O P B B P P P/G B/O P B/O B/O B/O B/Y B/Y B/Y B/Y B/O O O P Pu/B B/O B/O R/Y B P B B B/O P B P B P B B B B B L L B
P/W
Pu/G G/R G/Y
5 7
P B
8 9 0
Pu/R
O Pu/R
#1
R/Y Pu/B
R/Y
B/O B/Y
#2
R/Y Pu/Y
Pu/Y
B/O
#3
R/Y
B/O B/O
B/O B/O
R/Y Pu/G
B/O Pu/G B/O B/O
#4
R/Y
R/Y
B/O
1 2 3 4 5 6 7 8 9
ECM Main and fuel pump relay Fuse (20A) Battery Fuel pump Multifunction meter Fuel sender Thermoswitch (exhaust) Thermoswitch (engine)
0 A B C D E F
Engine temperature sensor Slant detection switch Sensor assembly Throttle position sensor Fuel injector Oil pressure switch Remote control unit
7-25
ELEC
FUEL CONTROL SYSTEM
WIRING DIAGRAM
Br
Y B R R
5 :P 6 : P/W 8 : B/Y 9 :O 14 : L 28 : L/B 30 : R/Y
33 : P/G 35 : B/Y 37 : Pu/G 38 : Pu/Y 39 : Pu/B 40 : Pu/R
L/R
1
R/Y
R P
3
R R
P O
2
R/Y R/Y R 12 3 456 7 8 P O O P R R
L/B Y
P/W
18 15
L/R
P/W
P/G O Pu/Y P R/Y Pu/B Pu/R L B G B/Y G/Y G/R Pu/G Pu/Y O P/G P B/O G/B G/B G Pu/R L/B Pu/B R/Y B B B B P R/Y R/Y R/Y B/Y R/Y R/Y B/Y P/G B/O O P B/O B/O P B B P P P/G B/O P B/O B/O B/O B/Y B/Y B/Y B/Y B/O O O P Pu/B B/O B/O R/Y B P B B B/O P B P B P B B B B B L L B
P/W
Pu/G G/R G/Y
5 7
P B
8 9 0
Pu/R
O Pu/R
#1
R/Y Pu/B
R/Y
B/O B/Y
#2
R/Y Pu/Y
Pu/Y
B/O
#3
R/Y
B/O B/O
B/O B/O
R/Y Pu/G
B/O Pu/G B/O B/O
#4
R/Y
R/Y
B/O
B Br G L O P R W Y
: Black : Brown : Green : Blue : Orange : Pink : Red : White : Yellow
B/O B/Y G/O L/B L/R P/G P/W Pu/B Pu/G
: Black/orange : Black/yellow : Green/orange : Blue/black : Blue/red : Pink/green : Pink/white : Purple/black : Purple/green

7-26
Pu/R Pu/Y R/Y W/R
: Purple/red : Purple/yellow : Red/yellow : White/red
ELEC
FUEL CONTROL SYSTEM

FUEL PUMP
1. Check: Fuel pump operating sound Fuel pump does not sound Measure the fuel pressure. Refer to FUEL INJECTION SYSTEM in Chapter 4. NOTE: After the engine is stopped, the fuel pump will operate for 10 seconds.
FUEL SENDER
1. Measure: Fuel sender resistance Out of specification Replace. Float position A B Resistance () 133.5136.5 57
7-27
ELEC
FUEL CONTROL SYSTEM

FUEL INJECTOR
Refer to FUEL INJECTION SYSTEM in Chapter 4.

Refer to IGNITION SYSTEM.
OIL PRESSURE SWITCH

Refer to INDICATION SYSTEM.
SLANT DETECTION SWITCH

REMOTE CONTROL UNIT

Refer to REMOTE CONTROL SYSTEM.
7-28
ELEC
STARTING SYSTEM
STARTING SYSTEM
WIRING DIAGRAM
Y L/R L B R
1
R R R/Y R/Y R/Y O R/Y R/Y R P P R
12 3 456 7 8 31 14 21 30 L/R R/Y R Y R R R
L Y B B L R B L B B B B B B B B B Br L R
A
B
L B
4
Br
8
W B FREE PUSH R Br
7
Br Br FREE PUSH
5
Br R B Br R
Br
Br
R 11 15 14 18 12 3 4 13
123456789 0ABCDEFGH
1 2 3 4 5 6 7 8 9
ECM Main and fuel pump relay Fuse (20A) Starter relay Starter motor Battery Start switch Engine shut-off switch Fuse (3A)
0 Remote control unit A Fuel pump
B Br L R Y L/R R/Y
: Black : Brown : Blue : Red : Yellow : Blue/red : Red/yellow
7-29
ELEC
STARTING SYSTEM
BATTERY
WIRING CONNECTIONS
1. Check: Wiring connections Poor connections Properly connect.
FUSE
1. Check: Fuse broken Broken Replace. Fuse rating: 3A, 20A NOTE: 20A fuse is for main relay, engine shut-off switch and rectifier/regulator. 3A fuse is for multifunction meter, electric bilge pump, and remote control unit.
START SWITCH
1. Check: Continuity Out of specification Replace. Start continuity (natural color coupler) Clip Installed Removed Position Free Push Free Push Leads Red Brown
7-30
ELEC
STARTING SYSTEM
STARTER RELAY
1. Inspect: Brown lead terminal Black lead terminal Loose Tighten.
2. Check: Starter relay Faulty Replace. Checking steps: Connect the tester leads between the starter relay terminals as shown. Connect the brown lead terminal to the positive battery terminal. Connect the black lead terminal to the negative battery terminal. Check that there is continuity between the starter relay terminals. Check that there is no continuity after the brown or black lead is removed.
Br B
REMOTE CONTROL UNIT

7-31
ELEC
STARTER MOTOR
STARTER MOTOR
EXPLODED DIAGRAM

Step Procedure/Part name STARTER MOTOR DISASSEMBLY Starter motor O-ring Bolt Starter motor front cover O-ring Oil seal retainer Washer Shim Qty Service points Follow the left Step for disassembly. Refer to GENERATOR AND STARTER MOTOR in Chapter 5. Not reusable
1 2 3 4 5 6 7
1 2 1 1 1 1 *
Not reusable
t = 0.2 mm, 0.5 mm
*: As required
7-32
ELEC
STARTER MOTOR
EXPLODED DIAGRAM
Step 8 9 10 11 12 13 14 15 16 17
Procedure/Part name Starter motor rear cover O-ring Shim Armature assembly Nut/spring washer/washer O-ring Brush holder Brush spring Bolt Brush assembly
Qty 1 1 * 1 1/1/4 1 1 4 1 1
Service points Not reusable t = 0.2 mm, 0.8 mm
Not reusable
*: As required
7-33
ELEC
STARTER MOTOR
EXPLODED DIAGRAM
Step 18 19 20
Procedure/Part name Spacer Holder Starter motor yoke
Qty 1 1 1
Service points
7-34
ELEC
STARTER MOTOR
SERVICE POINTS
Armature inspection 1. Inspect: Armature shaft 1 Damage/wear Replace.
2. Inspect: Commutator Dirt Clean with 600 grit sandpaper.
3. Measure: Commutator diameter Below specification Replace. Minimum commutator diameter: 27.0 mm (1.06 in)
4. Check: Commutator undercut Contaminants Clean. NOTE: Remove all mica and metal particles with compressed air.
5. Measure: Commutator undercut Below specification Replace. Minimum commutator undercut: 0.2 mm (0.01 in)
7-35
ELEC
STARTER MOTOR
6. Inspect: Armature coil continuity Out of specification Replace. Armature coil continuity: Commutator segments 1 Segment - Laminations 2 Continuity
No continuity
Segment - Armature shaft No continuity
Brush holder inspection 1. Measure: Brush length a Below specification Replace. Minimum brush length: 6.5 mm (0.26 in)
2. Check: Brush holder continuity Out of specification Replace. Brush holder continuity: Brush holder - Base No continuity
Starter motor front cover inspection 1. Inspect: Starter motor front cover oil seal Damage/wear Replace the starter motor front cover.
7-36
ELEC
CHARGING SYSTEM
CHARGING SYSTEM
WIRING DIAGRAM
1
B R
B G G G R
G G G R R
G G G G
1 2 3 4
Rectifier/regulator Fuse (20A) Battery Lighting coil
B G R
: Black : Green : Red
7-37
ELEC
CHARGING SYSTEM
FUSE
BATTERY
LIGHTING COIL
RECTIFIER/REGULATOR
7-38
ELEC
ELECTRIC BILGE PUMP
ELECTRIC BILGE PUMP

WIRING DIAGRAM
Y L/R B R L
1
R R/Y R/Y R/Y
R/Y
R P
R/Y
R/Y
12 3 456 7 8 21 30 R R
R/Y
Y R/Y
L/R
3
B B R/Y R
B B B
5
B Br
Br
R/Y B
R/Y B 15 R R
1 2 3 4 5 6 7
ECM Main and fuel pump relay Fuse (3A) Battery Electric bilge pump Remote control unit Fuse (20A)
B Br R Y L/R R/Y
: Black : Brown : Red : Yellow : Blue/red : Red/yellow
7-39
ELEC
ELECTRIC BILGE PUMP

Br B
ELECTRIC BILGE PUMP

1. Check: Electric bilge pump operation Incorrect Replace.
+
Checking steps: Suspend the electric bilge pump in a container filled with water. Connect the brown lead terminal to the positive battery terminal. Connect the black lead terminal to the negative battery terminal. Check the water flows from the electric bilge pump hose.
FUSE
BATTERY

REMOTE CONTROL UNIT

7-40
ELEC
OFF THROTTLE STEERING SYSTEM

WIRING DIAGRAM
9 :O 12 : W/R 13 : W/B 16 : G/B 17 : G/Y
18 : G/R 20 : G 29 : W/L 30 : R/Y 34 : P
1
R P B/O B/O O P B/O R
B/O O R/Y R R/Y R/Y R/Y R/Y R/Y R/Y R/Y W/L B/O R/Y W/L Y/B O R/Y R/W B Y/B B R/W
B/O
P/G O Pu/Y Pu/G G/R G/Y B/Y B/O
R/Y Pu/B Pu/R
B/O B/O B/O
B/O W/R W/B
B/O
B/O B/O W/R W/B
G G/B G/B G Pu/R Pu/B R/Y P/G P
R/Y
G/Y G/R Pu/G Pu/Y O
B/O
B/O
W B
R/Y
B R/Y R/Y R W
3
G R/Y G/R G/Y R/Y G/B
R/Y G/Y G R/Y
G/R B/O P O
B/O
G/B
1 2 3 4 5
ECM Steering switch Pickup coil Throttle position sensor Bypass valve motor
B G O P W B/O G/B G/R G/Y
: Black : Green : Orange : Pink : White : Black/orange : Green/black : Green/red : Green/yellow

7-41
R/Y R/W W/B W/L W/R Y/B
: Red/yellow : Red/white : White/black : White/blue : White/red : Yellow/black
ELEC

STEERING SWITCH
1. Check: Steering switch For checking instructions, refer to SELF-DIAGNOSIS in Chapter 9. Malfunction Use the Engine monitor of the Yamaha Diagnostic System to check that the steering switch switches on and off when the handlebar is turned to the right and to the left. Does not operate Replace.
ECM
PICKUP COIL
THROTTLE POSITION SENSOR

BYPASS VALVE MOTOR

Refer to FUEL INJECTION SYSTEM in Chapter 4.
7-42
ELEC
INDICATION SYSTEM
INDICATION SYSTEM
WIRING DIAGRAM
Y L/R B R R P P O R/Y R R R/Y R/Y R/Y R/Y R
L R
R/Y
1 2 3456 7 8 14 6 15 35 5 1 21 30 L/R P P P R R
R R/Y
R/Y
P/W
B P/W B W
R/Y R W/B W/B R/Y
5
B/O G B/O B/O P G P B/O B/O B
B B
6
P B
P/W
B
W B R
0
P
4
L/R
P L/R L/B Gy Gy B/Y L/B L/Y B/O Y B/Y R/W R/W P B B/O B/Y B/Y B/Y B/Y P B/Y B/L L/R L/R B/L B/Y R/Y Y P B B/O B/O B/O B/O R B R B B/O R/Y B B/O Y B/O B/O B
P B
15 18 16 7 6 Y L L/Y L/B
L/R
B/Y
B/O B/O
A
B/O B/O B/O
B/O
C
1 2 3 4 5 6 7 8 9 ECM Main and fuel pump relay Fuse (20A) Remote control unit Battery Tacho pulse Thermoswitch (exhaust) Thermoswitch (engine) Engine temperature sensor
7-43
B/O
0 A B C D
Multifunction meter Fuel sender Speed sensor Buzzer Oil pressure switch
ELEC
INDICATION SYSTEM
WIRING DIAGRAM
L R
R/Y
1 2 3456 7 8 14 6 15 35 5 1 21 30 L/R P P P R R
R R/Y
R/Y
P/W
B P/W B W
R/Y R W/B W/B R/Y
5
B/O G B/O B/O P G P B/O B/O B
B B
6
P B
P/W
B
W B R
0
P
4
L/R
P L/R L/B Gy Gy B/Y L/B L/Y B/O Y B/Y R/W R/W P B B/O B/Y B/Y B/Y B/Y P B/Y B/L L/R L/R B/L B/Y R/Y Y P B B/O B/O B/O B/O R B R B B/O R/Y B B/O Y B/O B/O B
P B
15 18 16 7 6 Y L L/Y L/B
L/R
B/Y
B/O B/O
A
B/O B/O B/O
B/O
C
B Br G Gy L O P : Black : Brown : Green : Gray : Blue : Orange : Pink R W Y B/L B/O B/Y L/B : Red : White : Yellow : Black/blue : Black/orange : Black/yellow : Blue/black L/R L/Y P/W R/W R/Y W/B : Blue/red : Blue/yellow : Pink/white : Red/white : Red/yellow : White/black
B/O
7-44
ELEC
INDICATION SYSTEM
FUSE
BATTERY

ECM
ENGINE TEMPERATURE SENSOR

REMOTE CONTROL UNIT

BUZZER
1. Check: Buzzer Buzzer does not sound Replace. Checking steps: Connect the battery (12 V) to the buzzer coupler as shown. Battery positive terminal Red (R) terminal 1 Battery negative terminal Black (B) terminal 2
7-45
ELEC
INDICATION SYSTEM
OIL PRESSURE SWITCH
1. Measure: Oil pressure switch continuity Out of specification Replace. Lower unit pressure/vacuum tester: YB-35956-A Vacuum/pressure pump gauge set: 90890-06756
Oil pressure switch continuity pressure: 128 kPa (1.28 kgf/cm2, 18.2 psi) 166 kPa (1.66 kgf/cm2, 23.6 psi)
MULTIFUNCTION METER
Multifunction meter 1. Check: Multifunction meter Cracked meter housing Replace the multifunction meter. Meter is fogged/shows signs of water intrusion Replace the multifunction meter.
MULTIFUNCTION METER REMOVAL

Refer to STEERING COVER in Chapter 8. CONSOLE
7-46
ELEC
INDICATION SYSTEM
E Display function 1. Check: Display function Does not operate Replace the multifunction meter.
L/Y L/B B/L
Gy L/B L/R L/R
B/L
B B R
2
R/W
L/R
R B/Y
B/Y R/W Y Y W R W B B R
P B
5
P
1 2 3 4 5
Remote control unit Buzzer Speed sensor ECM Fuel sender
B Gy P R W Y
: Black : Gray : Pink : Red : White : Yellow
B/G B/L B/Y L/B L/R R/W
: Black/green : Black/blue : Black/yellow : Blue/black : Blue/red : Red/white
7-47
ELEC
INDICATION SYSTEM
E Speedometer display 1. Check: Speedometer display Does not display Measure the speed sensor output voltage and pulses. 2. Measure: Speed sensor output voltage and pulses Out of specification Repair or replace. Within specification Replace the multifunction meter. Speed sensor output voltage (dependant on the paddle wheel position): Less than 400 mV/ More than 11.6 V Output pulse: 2 pulses/one-full turn Measurement steps: Apply DC 12 voltage to the natural color three-pin connector (between the red/yellow and black/yellow leads). Rotate the paddle wheel by hand and measure the voltage between the black/ yellow and yellow leads. NOTE: As the paddle wheel is rotated, a squarewave voltage signal a is produced. Two pulses occur every time the paddle wheel makes one-full turn.
7-48
ELEC
INDICATION SYSTEM
E Tachometer display 1. Check: Tachometer display Does not display Check the engine speed using the Engine monitor of the Yamaha Diagnostic System. Replace the multifunction meter. Hour meter display 1. Check: Hour meter display Does not display Replace the multifunction meter. Voltage meter display 1. Check: Voltage meter display Does not display Check the battery voltage using the Engine monitor of the Yamaha Diagnostic System. Replace the multifunction meter. Low oil pressure warning indicator 1. Check: Low oil pressure warning indicator No operating Check the oil pressure switch using the Engine monitor of the Yamaha Diagnostic System. Replace the multifunction meter. Fuel level meter display and fuel warning indicator 1. Check: Fuel level meter display and fuel warning indicator Does not display Measure the fuel sender resistance. If the fuel sender resistance is within specification, replace the multifunction meter. 2. Measure: Fuel sender resistance Refer to FUEL CONTROL SYSTEM.
7-49
ELEC
INDICATION SYSTEM
E Overheat warning indicator 1. Check: Overheat warning indicator Does not operate Replace the multifunction meter. Checking steps: Start the engine. Disconnect the thermoswitch (engine) connector 1 (blue), engine temperature sensor connector 2 (black) or thermoswitch (exhaust) 3 connector. Connect the jumper lead to the female terminal of the disconnected connector. Check that the multifunction meter overheat warning indicator comes on and the buzzer sounds.
Check the engine warning indicator 1. Check: Check the engine warning indicator Does not operate Replace the multifunction meter. Checking steps: Start the engine. Disconnect the coupler of a sensor (e.g., engine temperature sensor) that normally activates the check engine warning indicator when a malfunction occurs. Check that the warning light and check engine warning indicator blink and that the buzzer sounds intermittently.
7-50
ELEC
REMOTE CONTROL SYSTEM

WIRING DIAGRAM
Y L/R L B R
1
R R R/Y R/Y R/Y O R/Y R/Y R P P R
14 : L 15 : W/B 21 : L/R 30 : R/Y 31 : Y
37 : Pu/G 38 : Pu/Y 39 : Pu/B 40 : Pu/R
12 3 456 7 8 31 14 21 30 15 R/Y R R/Y Y R R
L/R
L Y
P/G O Pu/Y Pu/G G/R G/Y B/Y G/Y G/R Pu/G Pu/Y O P/G P B/O P R/Y Pu/B Pu/R
3
R B B R
B
G G/B G/B G Pu/R Pu/B R/Y
Br
B B B B B B B
4
Br
R/Y W R W/B W/B B

R
R/Y
R/Y R/Y
B/O W
5 9
B
R/Y R/Y
0
#1
Pu/R
Pu/R R/Y
6
L/R L/B Gy L/R Gy W
16 7 6 11 15 14 18 12 3 4 13 10
R/Y
0
#2
Pu/B
Pu/B R/Y
R/Y
0
#3
Pu/Y
Pu/Y R/Y
L/B
L/Y
A
W
123456789 0ABCDEFGH
R L/R L/R B/L B B/L L/R L/Y L/B
R/Y
0
#4
Pu/G
Pu/G R/Y
B R
R/Y
1 ECM 2 Main and fuel pump relay 3 Fuse (20A) 4 Starter relay 5 Starter motor 6 Battery 7 Fuse (3A) 8 Remote control unit
9 0 A B
Multifunction meter Fuel injector Antenna Buzzer
B Br Gy L R W Y B/L L/B
7-51
: Black : Brown : Gray : Blue : Red : White : Yellow : Black/blue : Blue/black
L/R L/Y Pu/B Pu/G Pu/R Pu/Y R/Y W/B
: Blue/red : Blue/yellow : Purple/black : Purple/green : Purple/red : Purple/yellow : Red/yellow : White/black
ELEC
1

Yamaha Security System indicator 1. Check: Yamaha Security System indicator Check that the SECURITY indicator light 1 comes on when the Yamaha Security System is deactivated (i.e., the engine can be started). Does not come on Measure the remote control unit output voltage. 2. Measure: Remote control unit output voltage Within specification Replace the multifunction meter. Out of specification Replace the remote control unit. Remote control unit output voltage: Blue/yellow (L/Y) ground 1113 V
Measurement steps: Disconnect the remote control unit 1 coupler from the multifunction meter. Measure the remote control unit output voltage while pushing the unlock button of the remote control transmitter.
L/Y
Low-rpm mode indicator 1. Check: Low-rpm mode indicator Does not come on Replace the multifunction meter. Checking steps: Press the unlock button 1 of remote control transmitter for more than four seconds to select the low-rpm mode. Check that the beeper sounds three times and the L-MODE indicator light 2 comes on.
7-52
ELEC
1
Diagnostic display 1. Check: Diagnostic display Does not display Replace the multifunction meter. Checking steps: Start the engine. Disconnect the coupler of a sensor (e.g,. engine temperature sensor) that is normally displayed when a malfunction occurs. Refer to SELF-DIAGNOSIS in Chapter 9. Check that the check engine warning indicator is displayed and that the buzzer sounds. Press the select switch 1 for 8 seconds and check the error code indicated on the multifunction meter.
Checking the remote control transmitter 1. Check: Remote control transmitter Does not operate Replace the remote control transmitter. Checking steps:
CAUTION:
If the buttons on the remote control transmitter are pushed but the transmitter does not operate, the battery may be low. Press the lock button 1 of the remote control transmitter. The beeper sounds once. Check that the SECURITY indicator light goes off and the engine cannot be started. Press the unlock button 2 of the remote control transmitter for a short time. The beeper sounds two or three times. Check that the SECURITY indicator light comes on and the engine can be started.
7-53
ELEC

Yamaha Security System mode Lock Unlock (normal mode) Unlock (low-rpm mode)
Number of beeps 1 beep 2 beeps 3 beeps
Engine startability Unable Able Able
Press the unlock button for more than 4 seconds to select the low-rpm mode. Check that the beeper sounds three times and the L-MODE indicator light comes on. NOTE: If the start switch or the remote control transmitter is not operated for more than 25 seconds, the multifunction meter display and the L-MODE indicator light will go off. To change the modes again, press the lock button for a short time, and then start the procedures from the lock mode. While the engine is running, input from the remote control transmitter is not received.
7-54
ELEC
2
Gy
Transmitter registration 1. Register: Remote control transmitter 1 ID codes can be added or re-registered by connecting the entry box 2. Registration steps: Connect the entry box. Transmit the ID code from the remote control transmitter to be registered. NOTE: The remote control transmitters can be registered in any sequence, regardless of whether they are original equipment or additional transmitters. At this time, the system enters the registration mode to register the first code. All existing ID codes will be deleted from the EEPROM. The SECURITY indicator light flashes when the registration of the ID code has been completed. (If the registration could not be completed, the SECURITY indicator light comes on. Re-transmit the ID code.) After confirming that the registration of the ID code has been completed using the SECURITY indicator light, transmit the next ID code. Register the ID codes for up to five remote control transmitters. After ID code registration has been completed, disconnect the entry box to exit the registration mode.
7-55
ELEC

Replacing of the transmitter battery
CAUTION:
Do not allow any water, dust, or dirt to enter the remote control transmitter case when replacing the battery. Make sure that no foreign material is trapped between the upper case and lower case of the remote control transmitter during assembly.
1. Remove: Cover NOTE: Loosen the transmitter cover screws in the sequence shown.
2. Install: Battery 1 NOTE: Install the battery (CR2016) with the positive side facing down.
3. Install: Cover NOTE: Tighten the transmitter cover screws in the sequence shown. Transmitter cover screw: 0.1 N m (0.01 kgf m, 0.07 ft lb)
4
T.
7-56
HULL HOOD
CHAPTER 8 HULL AND HOOD
HANDLEBAR ..................................................................................................8-1 EXPLODED DIAGRAM .............................................................................8-1 REMOVAL AND INSTALLATION CHART ................................................ 8-1 SERVICE POINTS .................................................................................... 8-6 Handlebar inspection ..........................................................................8-6 Handlebar switch inspection ............................................................... 8-6 Handlebar assembly installation .........................................................8-6 QSTS GRIP ..................................................................................................... 8-8 EXPLODED DIAGRAM .............................................................................8-8 REMOVAL AND INSTALLATION CHART ................................................ 8-8 SERVICE POINTS .................................................................................. 8-10 QSTS cable inspection and adjustment ............................................8-10 QSTS grip inspection ........................................................................8-10 STEERING MASTER.....................................................................................8-11 EXPLODED DIAGRAM ...........................................................................8-11 REMOVAL AND INSTALLATION CHART .............................................. 8-11 SERVICE POINTS .................................................................................. 8-15 Steering master components inspection ...........................................8-15 REMOTE CONTROL CABLES AND SPEED SENSOR LEAD ....................8-16 EXPLODED DIAGRAM ...........................................................................8-16 REMOVAL AND INSTALLATION CHART .............................................. 8-16 SERVICE POINTS .................................................................................. 8-19 Remote control cables inspection .....................................................8-19 Steering cable (jet pump end) installation .........................................8-19 Steering cable stopper installation ....................................................8-19 QSTS cable (jet pump end) installation............................................. 8-20 QSTS cable stopper installation........................................................ 8-20 Shift cable (jet pump end) installation ............................................... 8-20 Shift cable holder installation ............................................................ 8-21 Shift cable stopper installation .......................................................... 8-21 Remote control cables adjustment....................................................8-21 FRONT HOOD ...............................................................................................8-22 EXPLODED DIAGRAM ...........................................................................8-22 REMOVAL AND INSTALLATION CHART .............................................. 8-22
HULL HOOD
STEERING CONSOLE COVER .................................................................... 8-26 EXPLODED DIAGRAM ...........................................................................8-26 REMOVAL AND INSTALLATION CHART .............................................. 8-26 SERVICE POINTS .................................................................................. 8-32 Glove compartment assembly installation.........................................8-32 HOSES ..........................................................................................................8-33 EXPLODED DIAGRAM ...........................................................................8-33 REMOVAL AND INSTALLATION CHART .............................................. 8-33 SHIFT LEVER................................................................................................8-35 EXPLODED DIAGRAM ...........................................................................8-35 REMOVAL AND INSTALLATION CHART .............................................. 8-35 SERVICE POINTS .................................................................................. 8-38 Base assembly.................................................................................. 8-38 Shift lever .......................................................................................... 8-38 SEATS AND HAND GRIP ............................................................................. 8-39 EXPLODED DIAGRAM ...........................................................................8-39 REMOVAL AND INSTALLATION CHART .............................................. 8-39 SERVICE POINTS .................................................................................. 8-42 Seat lock inspection ..........................................................................8-42 EXHAUST SYSTEM ......................................................................................8-43 EXPLODED DIAGRAM ...........................................................................8-43 REMOVAL AND INSTALLATION CHART .............................................. 8-43 SERVICE POINTS .................................................................................. 8-46 Exhaust system inspection................................................................8-46 Exhaust component parts sub-assembly ..........................................8-46 Exhaust system installation...............................................................8-47 DECK AND HULL.......................................................................................... 8-48 EXPLODED DIAGRAM ...........................................................................8-48 REMOVAL AND INSTALLATION CHART .............................................. 8-48 ENGINE MOUNT ........................................................................................... 8-50 EXPLODED DIAGRAM ...........................................................................8-50 REMOVAL AND INSTALLATION CHART .............................................. 8-50
HULL HOOD
HANDLEBAR
HANDLEBAR
EXPLODED DIAGRAM

Step 1 2 3 4 5 6 7 8 Procedure/Part name HANDLEBAR COVER REMOVAL Screw Handlebar cover Pad Bolt Handlebar cover stay Throttle cable Bolt Upper handlebar holder Qty 4 1 1 2 1 1 4 2 Service points Follow the left Step for removal.
NOTE: Position the corrugated tube for the throttle cable as shown in the illustration so that the tube attaches to the end of the outer throttle cable. Reverse the removal steps for installation.
8-1
HULL HOOD
HANDLEBAR
EXPLODED DIAGRAM

Step Procedure/Part name HANDLEBAR REMOVAL QSTS cable (to jet thrust nozzle) Nut/washer QSTS converter QSTS cable 2 QSTS cable 1 Handlebar switch coupler Buzzer coupler Screw Handle boss cover Band Qty Service points Follow the left Step for removal. Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD.
1 2 3 4 5 6 7 8 9
2/2 1 1 1 2 1 4 1 2
8-2
with white tape a
HULL HOOD
HANDLEBAR
EXPLODED DIAGRAM
Step 10 11 12
Procedure/Part name Hose packing Buzzer Handlebar assembly
Qty 1 1 1
Service points Not reusable NOTE: Pass the QSTS cable and handlebar switch lead through the handle boss cover, and then install the handlebar assembly. Install the sponges of the QSTS cables as shown and make sure that the grommet is installed to the deck securely. Reverse the removal steps for installation.
13
Grommet
8-3
HULL HOOD
HANDLEBAR
EXPLODED DIAGRAM

Step 1 2 3 4 5 6 7 Procedure/Part name HANDLEBAR DISASSEMBLY Bolt Grip end Spacer Screw/spring washer/washer QSTS grip assembly Special nut Screw Qty 2 2 1 1/1/1 1 1 2 Service points Follow the left Step for disassembly.
NOTE: Tighten the screw from the engine stop switch side.
8-4
HULL HOOD
HANDLEBAR
EXPLODED DIAGRAM
Step 8 9 10 11
Procedure/Part name Handlebar switch assembly Screw Throttle lever assembly Handlebar grip
Qty 1 2 1 1
Service points
NOTE: Apply adhesive to the handlebar and the inner surface of the handlebar grip. Reverse the disassembly steps for assembly.
12
Handlebar
8-5
HULL HOOD
HANDLEBAR
SERVICE POINTS
Handlebar inspection 1. Inspect: Handlebar Bends/cracks/damage Replace.
Handlebar switch inspection Refer to STARTING SYSTEM in Chapter 7. Handlebar assembly installation 1. Install: Bands 1 NOTE: After inserting the QSTS cables, buzzer lead, handlebar switch lead and throttle cable into the grommets, tie the end of grommets with the bands. 2. Install: Upper handlebar holder 1 NOTE: Align the punch marks a on the handlebar with the top surface of the handlebar holder. The upper handlebar holder should be installed with the punch mark b facing forward.
CAUTION:
Clearance c should be narrower than clearance d. Handlebar holder bolt: 20 N m (2.0 kgf m, 14 ft lb) LOCTITE 242 Reference clearance: c: 1.5 mm (0.06 in) d: 3.5 mm (0.14 in)
T.
8-6
HULL HOOD
HANDLEBAR
3. Install: Throttle cable NOTE: Fit the seal into the groove in the bracket.
4. Install: Handlebar cover 1 NOTE: When the handlebar cover is in contact with the steering boss cover, adjust the handlebar mount angle so that the clearance a and b are equal.
5. Adjust: Throttle cable free play Refer to CONTROL SYSTEM in Chapter 3. 6. Adjust: QSTS cable Refer to CONTROL SYSTEM in Chapter 3.
8-7
HULL HOOD
QSTS GRIP
QSTS GRIP
EXPLODED DIAGRAM

Step Procedure/Part name QSTS GRIP DISASSEMBLY QSTS grip assembly Screw/washer Cover Ball Spring QSTS cable 1 QSTS cable 2 Qty Service points Follow the left Step for disassembly. Refer to HANDLEBAR.
1 2 3 4 5 6
1/1 1 2 2 1 1
with white tape a
8-8
HULL HOOD
QSTS GRIP
EXPLODED DIAGRAM
Step 7 8 9 10 11 12 13
Procedure/Part name Screw/washer Spacer QSTS shift lock lever Spring Spacer Cable housing QSTS grip
Qty 2/2 1 1 1 1 1 1
Service points
8-9
HULL HOOD
QSTS GRIP
SERVICE POINTS
QSTS cable inspection and adjustment 1. Inspect: QSTS cables Frays/kinks/rough movement Replace.
2. Adjust: QSTS cable length a QSTS cable length: 72 0.5 mm (2.83 0.02 in) NOTE: Before adjusting the QSTS cables, set the trim grip to the neutral position. Adjust the QSTS cable lengths a to the specified length and be sure to take up any slack.
QSTS grip inspection 1. Inspect: QSTS grip Damage/wear Replace.
8-10
HULL HOOD
STEERING MASTER
STEERING MASTER
EXPLODED DIAGRAM

Step Procedure/Part name STEERING MASTER REMOVAL Steering console cover Steering cable end Bolt/washer Steering arm Nut/washer Steering master assembly Bolt Qty Service points Follow the left Step for removal. Refer to STEERING CONSOLE COVER. Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD.
1 2 3 4 5
1/1 1 4/4 1 4
8-11
HULL HOOD
STEERING MASTER
EXPLODED DIAGRAM
Step 6 7 8
Procedure/Part name Bolt Magnet Steering switch
Qty 3 1 1
Service points
8-12
HULL HOOD
STEERING MASTER
EXPLODED DIAGRAM

Step Procedure/Part name STEERING MASTER DISASSEMBLY Bolt/washer Stay Spring Bolt/washer Lower housing Spring Bushing Bushing Upper housing Tilt lever Qty Service points Follow the left Step for disassembly.
1 2 3 4 5 6 7 8 9 10
2/2 1 1 6/6 1 1 1 1 1 1
8-13
HULL HOOD
STEERING MASTER
EXPLODED DIAGRAM
Step 11 12 13 14 15 16 17 18 19
Procedure/Part name Tilt stopper Bolt/nut/holder Retainer Steering shaft Steering tube Bolt Cap Shaft 1 Cross piece
Qty 1 4/4/4 2 1 1 2 1 1 1
Service points
8-14
HULL HOOD
STEERING MASTER
SERVICE POINTS
Steering master components inspection 1. Inspect: Each component part Damage/wear Replace the steering master.
8-15
HULL HOOD
REMOTE CONTROL CABLES AND SPEED SENSOR LEAD

EXPLODED DIAGRAM

Step Procedure/Part name REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL Service lid 1 Front seat assembly Glove compartment Steering cable end Nut/washer Bracket Nut Steering cable holder Qty Service points Follow the left Step for removal.
Refer to FRONT HOOD. Refer to SEATS AND HAND GRIP. Refer to STEERING CONSOLE COVER. 1 2/2 1 2 1
1 2 3 4 5
8-16
HULL HOOD
EXPLODED DIAGRAM
Step 6 7 8 9 10 11 12 13 14 15
Procedure/Part name Nut Steering cable Seal Speed sensor coupler Nut Cap Screw Speed sensor Shift cable end Nut
Qty 1 1 1 1 1 1 4 1 1 2
Service points
8-17
HULL HOOD
EXPLODED DIAGRAM
Step 16 17 18 19 20 21 22 23 24 25
Procedure/Part name Shift cable holder Nut Shift cable Seal Nut Pin QSTS cable end Nut QSTS cable Packing
Qty 2 1 1 1 1 1 1 1 1 1
Service points
8-18
HULL HOOD

SERVICE POINTS
WARNING
When routing the cables, do not grasp the cable by the outer crimped sheath or steel end. This could deform or loosen the cable end due to extreme angles and or pressure. Always hold the cables by the outer cover below the crimp. If a cable becomes damaged replace it. Never attempt to repair a damaged cable. Remote control cables inspection 1. Inspect: Steering cable QSTS cable Shift cable Frays/kinks/rough movement Replace. Steering cable (jet pump end) installation 1. Install: Steering cable Steering cable set length a (jet pump end): 14.5 mm (0.57 in)
WARNING
The steering cable must be screwed in at least 8 mm (0.31 in).
Steering cable stopper installation 1. Install: Steering cable stopper
WARNING
Be sure to the steering cable stopper into the groove in the outer cable as shown in the illustration.
8-19
HULL HOOD

QSTS cable (jet pump end) installation 1. Install: QSTS cable (jet pump end) QSTS cable set length a (jet pump end): 13.6 mm (0.54 in)
WARNING
The QSTS cable must be screwed in more than 8 mm (0.31 in).
QSTS cable stopper installation 1. Install: QSTS cable stopper
WARNING
Be sure to fit the projection 1 on the QSTS cable stopper into the groove in the outer cable.
Shift cable (jet pump end) installation 1. Install: Shift cable (jet pump end) Shift cable set length a (jet pump end): 13.6 mm (0.54 in)
WARNING
The shift cable must be screwed in more than 8 mm (0.31 in).
8-20
HULL HOOD

Shift cable holder installation 1. Install: Shift cable holders
NOTE: Install the shift cable holders so that mark a and mark b are in the positions shown in the illustration.
Shift cable stopper installation 1. Install: Shift cable stopper
WARNING
Be sure to fit the projection 1 on the shift cable stopper into the groove in the outer cable. Remote control cables adjustment Refer to CONTROL SYSTEM in Chapter 3.
8-21
HULL HOOD
FRONT HOOD
FRONT HOOD
EXPLODED DIAGRAM
7 2 6
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 10 mm
LT
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 18 mm
242
8
LT
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 18 mm
4
LT
242
242
LT
271
5
6 30 mm 5.4 N m (0.54 kgf m, 3.9 ft Ib)
11 10
1
5.4 N m (0.54 kgf m, 3.9 ft Ib)
1.5 N m (0.15 kgf m, 1.1 ft Ib) 4 8 mm

Step 1 2 3 4 5 6 7 Procedure/Part name FRONT HOOD REMOVAL Nut/washer Front hood assembly Bolt Bolt Hinge assembly Bolt Hood lock assembly Qty 4/4 1 4 2 1 2 1 Service points Follow the left Step for removal.
8-22
HULL HOOD
FRONT HOOD
EXPLODED DIAGRAM
7 2 6
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 10 mm
LT
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 18 mm
242
8
LT
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 18 mm
4
LT
242
242
LT
271
5
6 30 mm 5.4 N m (0.54 kgf m, 3.9 ft Ib)
11 10
1
5.4 N m (0.54 kgf m, 3.9 ft Ib)
1.5 N m (0.15 kgf m, 1.1 ft Ib) 4 8 mm
Step 8 9 10 11
Procedure/Part name Bolt Service lid 1 Screw Service lid 2
Qty 4 1 4 1
Service points
8-23
HULL HOOD
FRONT HOOD
EXPLODED DIAGRAM
4 1
6 10
2 7 6
8 9

Step 1 2 3 4 5 6 7 Procedure/Part name HINGE DISASSEMBLY Circlip Pin (long) Hinge Pin (short) Damper stay Collar Grommet Qty 2 1 1 1 1 2 2 Service points Follow the left Step for disassembly.
8-24
HULL HOOD
FRONT HOOD
EXPLODED DIAGRAM
4 1
6 10
2 7 6
8 9
Step 8 9 10
Procedure/Part name Band Damper boots Damper
Qty 1 1 1
Service points
8-25
HULL HOOD
STEERING CONSOLE COVER

EXPLODED DIAGRAM
3.9 N m (0.39 kgf m, 2.8 ft Ib) 5 20 mm 6.9 N m (0.69 kgf m, 5.0 ft Ib)
5 6
11 10
LT
9 4 3 5
242
12
LT
242
1 2
3.9 N m (0.39 kgf m, 2.8 ft Ib) 5 20 mm

Step Procedure/Part name METER AND MIRROR REMOVAL Handlebar assembly Service lid 1 Band Multifunction meter coupler Bolt Panel Band Qty Service points Follow the left Step for removal. Refer to HANDLEBAR. Refer to FRONT HOOD.
1 2 3 4 5
1 4 4 1 1
8-26
HULL HOOD
EXPLODED DIAGRAM
5 6
11 10
LT
9 4 3 5
242
12
LT
242
1 2
3.9 N m (0.39 kgf m, 2.8 ft Ib) 5 20 mm
Step 6 7 8 9 10 11 12
Procedure/Part name Bolt Multifunction meter Hose packing Grommet Nut/washer Plate Mirror
Qty 4 1 1 1 4/4 2 2
Service points
Not reusable
8-27
HULL HOOD
EXPLODED DIAGRAM
2 1 5 4 3 3 4 3
3 3 5
LT
271
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 22 mm

Step 1 2 3 4 5 Procedure/Part name SIDE COVER REMOVAL Cup holder Holder Bolt Washer Side cover Qty 1 1 8 2 2 Reverse the removal steps for installation. Service points Follow the left Step for removal.
8-28
HULL HOOD
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 30 mm
6 22 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 18 mm
2
LT
7
242
11
8 30 mm
LT
242
8
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 14 mm
6 5
12
LT
271
10
20 N m (2.0 kgf m, 14 ft Ib) 5.4 N m (0.54 kgf m, 3.9 ft Ib)

Step Procedure/Part name STEERING CONSOLE COVER AND GLOVE BOX ASSEMBLY REMOVAL Nut/washer Bolt Nut/washer Bolt Bolt Shift handle lever Qty Service points Follow the left Step for removal.
1 2 3 4 5 6
2/2 2 2/2 2 2 1
8-29
HULL HOOD
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 30 mm
6 22 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 18 mm
2
LT
7
242
11
8 30 mm
LT
242
8
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 14 mm
6 5
12
LT
271
10
20 N m (2.0 kgf m, 14 ft Ib) 5.4 N m (0.54 kgf m, 3.9 ft Ib)
Step 7 8
Procedure/Part name Bolt Steering console cover
Qty 2 1
Service points NOTE: To remove the console cover easily, pull the tilt lever up.
9 10 11 12
Hood lock assembly Nut/washer Bolt Glove compartment assembly
1 2/2 2 1 Reverse the removal steps for installation.
8-30
HULL HOOD
EXPLODED DIAGRAM
3
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 14 mm
5 2 2 6
LT
271

Step Procedure/Part name GLOVE COMPARTMENT DISASSEMBLY Glove compartment Hinge assembly Lid Gear assembly Screw Latch Qty Service points Follow the left Step for disassembly.
1 2 3 4 5 6
1 2 1 2 2 1 Reverse the disassembly steps for assembly.
8-31
HULL HOOD

SERVICE POINTS
Glove compartment assembly installation 1. Install: Hinge assembly NOTE: When installing the hinge assembly, make sure that the springs are in the position shown.
8-32
HULL HOOD
HOSES
HOSES
EXPLODED DIAGRAM
(VENT)
1 2 7 8 3
(VENT)
FW
1 2
1 1 6 4 5 5
(VENT)
4 6 8 7
4.2 N m (0.42 kgf m, 3.0 ft Ib)
4.2 N m (0.42 kgf m, 3.0 ft Ib)

Step Procedure/Part name HOSES REMOVAL Fuel tank Qty Service points Follow the left Step for removal. Refer to FUEL TANK AND FUEL PUMP MODULE in Chapter 4. NOTE: When removing the ventilation hose and fuel tank breather hose, it is not necessary to remove the fuel tank. 1 2 3 Band Ventilation hose Fuel tank breather hose 4 2 2
8-33
HULL HOOD
HOSES
EXPLODED DIAGRAM
(VENT)
1 2 7 8 3
(VENT)
FW
1 2
1 1 6 4 5 5
(VENT)
4 6 8 7
4.2 N m (0.42 kgf m, 3.0 ft Ib)
4.2 N m (0.42 kgf m, 3.0 ft Ib)
Step 4 5 6 7 8
Procedure/Part name Clamp Cooling water hose Nut Cooling water pilot outlet Seal
Qty 2 2 2 2 2
Service points
8-34
HULL HOOD
SHIFT LEVER
SHIFT LEVER
EXPLODED DIAGRAM

Step Procedure/Part name SHIFT LEVER REMOVAL Side cover Shift cable Bolt Shift lever handle Bolt Washer Shift lever Qty Service points Follow the left Step for removal. Refer to STEERING CONSOLE COVER. Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD.
1 2 3 4 5
2 1 1 1 1
8-35
HULL HOOD
SHIFT LEVER
EXPLODED DIAGRAM
Step 6 7 8 9 10
Procedure/Part name Screw Base assembly Nut/washer Screw Plate
Qty 3 1 3/3 3 1
Service points
8-36
HULL HOOD
SHIFT LEVER
EXPLODED DIAGRAM

Step 1 2 3 4 5 6 7 Procedure/Part name BASE DISASSEMBLY Bolt/washer Plate Spring Actuator Roller Shaft Shift arm Qty 2/2 1 1 1 1 1 1 Reverse the disassembly steps for assembly. Service points Follow the left Step for disassembly.
8-37
HULL HOOD
SHIFT LEVER
SERVICE POINTS
Base assembly 1. Install: Shift arm Shaft
Installation steps: Install the shift arm 1 so that it comes in contact with the stopper 2 as shown. Install the shaft 3 to the base so that it come in contact with the stopper 4 as shown.
a b
Shift lever 1. Install: Shift lever NOTE: To install the shift lever, align the arrow mark a on the shift lever with the punch mark b on base assembly.
8-38
HULL HOOD
SEATS AND HAND GRIP
SEATS AND HAND GRIP

EXPLODED DIAGRAM
6.4 N m (0.64 kgf m, 4.6 ft Ib) 6 40 mm
1 2 5 4
LT
271
5 11 12 13
8
LT
6.4 N m (0.64 kgf m, 4.6 ft Ib) 6 40 mm
8 30 mm
271
6 25 mm
21
15 16 22
8 30 mm
10
9 14 19 6
18 19
26 N m (2.6 kgf m, 19 ft Ib)
20 7 17
5.2 N m (0.52 kgf m, 3.8 ft Ib) 18 N m (1.8 kgf m, 13 ft Ib) 15 N m (1.5 kgf m, 11 ft Ib) 26 N m (2.6 kgf m, 19 ft Ib) 6.4 N m (0.64 kgf m, 4.6 ft Ib)

Step Procedure/Part name SEATS AND HAND GRIP REMOVAL Rear seat assembly Rear seat assembly Front seat assembly Bolt Seat lock assembly Seat storage compartment Nut/washer Bolt/washer Qty Service points Follow the left Step for removal. FX High Output FX Cruiser High Output
1 2 3 4 5 6 7 8
1 1 1 4 2 1 4/4 4/4
8-39
HULL HOOD
SEATS AND HAND GRIP
EXPLODED DIAGRAM
6.4 N m (0.64 kgf m, 4.6 ft Ib) 6 40 mm
1 2 5 4
LT
271
5 11 12 13
8
LT
6.4 N m (0.64 kgf m, 4.6 ft Ib) 6 40 mm
8 30 mm
271
6 25 mm
21
15 16 22
8 30 mm
10
9 14 19 6
18 19
26 N m (2.6 kgf m, 19 ft Ib)
20 7 17
Step 9 10 11 12 13 14 15 16 17
Procedure/Part name Deck beam Nut Projection Washer Seal Nut Bolt Rear seat stay Nut
Qty 1 1 1 1 1 4 4 2 1
Service points
8-40
HULL HOOD
SEATS AND HAND GRIP
EXPLODED DIAGRAM
6.4 N m (0.64 kgf m, 4.6 ft Ib) 6 40 mm
1 2 5 4
LT
271
5 11 12 13
8
LT
6.4 N m (0.64 kgf m, 4.6 ft Ib) 6 40 mm
8 30 mm
271
6 25 mm
21
15 16 22
8 30 mm
10
9 14 19 6
18 19
26 N m (2.6 kgf m, 19 ft Ib)
20 7 17
Step 18 19 20 21 22
Procedure/Part name Projection Washer Nut/washer Bolt Hand grip
Qty 1 2 4/4 4 1
Service points
8-41
HULL HOOD
SEATS AND HAND GRIP

SERVICE POINTS
Seat lock inspection 1. Inspect: Front seat lock Rear seat lock Damage/wear Replace.
8-42
HULL HOOD
EXHAUST SYSTEM
EXHAUST SYSTEM
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib)
14 13 16
3.7 N m (0.37 kgf m, 2.7 ft Ib)
3 15 18 17 12 4
11
5.4 N m (0.54 kgf m, 3.9 ft Ib) 3.7 N m (0.37 kgf m, 2.7 ft Ib)
1 2 6 5 10

Step Procedure/Part name EXHAUST SYSTEM REMOVAL Deck beam Jet pump unit assembly Qty Service points Follow the left Step for removal. Refer to SEATS AND HAND GRIP. Refer to JET PUMP UNIT in Chapter 6. NOTE: When removing the water lock and exhaust joint, it is not necessary to remove the jet pump unit. 1 2 3 4 Band Joint clamp Hose clamp Water lock 1 1 1 1
8-43
HULL HOOD
EXHAUST SYSTEM
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib)
14 13 16
3.7 N m (0.37 kgf m, 2.7 ft Ib)
3 15 18 17 12 4
11
1 2 6 5 10
Step 5 6 7 8 9 10 11 12 13 14
Procedure/Part name Joint clamp Joint Joint clamp Joint Joint clamp Exhaust joint Nut/washer Exhaust valve Hose clamp Rubber hose
Qty 1 1 1 1 1 1 6/6 1 1 1
Service points
NOTE: Remove parts 12 to 18 as a set.
8-44
HULL HOOD
EXHAUST SYSTEM
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib)
14 13 16
3.7 N m (0.37 kgf m, 2.7 ft Ib)
3 15 18 17 12 4
11
1 2 6 5 10
Step 15 16 17 18
Procedure/Part name Hose clamp Water tank Rubber hose Plate
Qty 1 1 1 1
Service points
8-45
HULL HOOD
EXHAUST SYSTEM
SERVICE POINTS
Exhaust system inspection 1. Inspect: Water lock band Cracks/damage Replace. 2. Inspect: Rubber hoses Burns/cracks/damage Replace. 3. Inspect: Water lock Cracks/leaks Replace. 4. Inspect: Water tank Cracks/damage/leaks Replace.
Exhaust component parts sub-assembly 1. Install: Rubber hose Plate NOTE: Be sure to fit the projections on the rubber hose with the grooves in the plate.
2. Install: Rubber hoses Water tank NOTE: Be sure to insert the rubber hose to the line a on the water tank. Make sure that there is a surface distance of 47 mm (1.9 in) b between the parting lines of the water tank and rubber hose. Align the parting line c of the rubber hose with the parting line d of the water tank.
b a
c d
8-46
HULL HOOD
EXHAUST SYSTEM
Exhaust system installation 1. Install: Exhaust joint
a b
NOTE: Be sure to install the projections a on the exhaust pipe and exhaust joint into the slots b in the joint.
b a
2. Install: Water lock NOTE: Be sure to insert the rubber hose to the line a on the water lock.
8-47
HULL HOOD
DECK AND HULL
DECK AND HULL

EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib) 13 N m (1.3 kgf m, 9.4 ft Ib) 5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 22 mm
17
LT
16
271
16 N m (1.6 kgf m, 12 ft Ib) 8 45 mm 15 N m (1.5 kgf m, 11 ft Ib)
5 3 4 5
18 12 13 7
6 8
5.4 N m (0.54 kgf m, 3.9 ft Ib)
1 11 10
15 13
14
LT
271
9 5 25 mm 2.0 N m (0.2 kgf m, 1.4 ft Ib)
15 N m (1.5 kgf m, 11 ft Ib)

Step 1 2 3 4 5 6 7 8 9 10 Procedure/Part name Qty Service points DECK AND HULL DISASSEMBLY Follow the left Step for disassembly. Nut 1 Spout 1 Nut 2 Cleat 1 Plate 2 Bolt/collar 10/10 Sponson 2 Nut/washer 4/4 Screw/washer 4/4 Drain plug 2
8-48
HULL HOOD
DECK AND HULL
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib) 13 N m (1.3 kgf m, 9.4 ft Ib) 5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 22 mm
17
LT
16
271
16 N m (1.6 kgf m, 12 ft Ib) 8 45 mm 15 N m (1.5 kgf m, 11 ft Ib)
5 3 4 5
18 12 13 7
6 8
5.4 N m (0.54 kgf m, 3.9 ft Ib)
1 11 10
15 13
14
LT
271
9 5 25 mm 2.0 N m (0.2 kgf m, 1.4 ft Ib)
15 N m (1.5 kgf m, 11 ft Ib)
Step 11 12
Procedure/Part name Seal Nut
Qty 2 4
Service points NOTE: To remove the cleat, remove the exhaust system first.
13 14 15 16 17 18
Plate Cleat Seal Nut/washer Bolt Protector
4 2 2 3/3 4 1 Reverse the disassembly steps for assembly.

8-49
HULL HOOD
ENGINE MOUNT
ENGINE MOUNT
EXPLODED DIAGRAM

Step Procedure/Part name ENGINE MOUNT REMOVAL Engine unit Bolt Damper 1 Damper 2 Bolt Engine mount Liner Qty Service points Follow the left Step for removal. Refer to ENGINE UNIT in Chapter 5.
1 2 3 4 5 6
4 1 1 8 4 2
Stern side Reverse the removal steps for installation.
8-50
TRBL ANLS
CHAPTER 9 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 Top view.............................................................................................. 9-3 TROUBLE ANALYSIS.....................................................................................9-4 TROUBLE ANALYSIS CHART..................................................................9-4 SELF-DIAGNOSIS .................................................................................... 9-8
TRBL ANLS
INTRODUCTION
FEATURES
INTRODUCTION
The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ECM (Electronic Control Module) of a watercraft using the communication cable, this software can be used to display sensor data and data stored in the ECM on a computers monitor. If this software is run on Microsoft Windows 95, Windows 98, Windows Me, Windows 2000, or Windows XP the information can be displayed in colorful graphics. Also, the software can be operated using either a mouse or a keyboard. In addition, the data for the main functions (Diagnosis, Diagnosis record, Engine monitor, and Data logger) can be saved on a disk or printed out. Functions 1. Diagnosis: Each sensors status and each ECM diagnosis code or item are displayed. This enables you to find malfunctioning parts and controls quickly. 2. Diagnosis record: Sensors that had been activated and ECM diagnostic codes that have been recorded are displayed. This allows you to check the watercrafts record of malfunctions. 3. Engine monitor: Each sensors status and the ECM data are displayed. This enables you to find malfunctioning parts quickly. 4. Stationary test: With the engine off, ignition, fuel injection, and the electric fuel pump are checked. These tests can be performed quickly. 5. Active test: With the engine running, each firing cylinder drops and the engine speed is checked for changes to determine if the cylinder is malfunctioning. These tests can be performed quickly. 6. Data logger: From the data stored in the ECM, at least two items of 78 seconds of recorded data are displayed on a graph. In addition, the operating time as compared to the engine speed and the total operating time are displayed. This allows you to check the operating status of the engine. 7. Some files: Lets you select and run other applications while continuing to run the diagnostic program.
CONTENTS
1. Software (1) 2. Adapter (1) 3. Communication cable (1) 4. Instruction Manual (1) 5. Installation Manual (1)
INSTRUCTION MANUAL

INSTALLATION MANUAL
9-1
TRBL ANLS
INTRODUCTION
HARDWARE REQUIREMENTS
Make sure that your computer meets the following requirements before using this software. Computer: Operating system: CPU: Windows 95/98: Windows Me/2000: Windows XP: Memory: Windows 95/98: Windows Me: Windows 2000: Windows XP: Hard disk free space: Drive: Display: Mouse: Communication port: Printer: IBM-compatible computer Microsoft (Windows 95), Windows 98, Windows Me, Windows 2000, or Windows XP (English version) i486X, 100 MHz or higher (Pentium 100 MHz or higher recommended) Pentium, 166 MHz or higher (Pentium 233 MHz or higher recommended) Pentium, 300 MHz or higher (Pentium 500 MHz or higher recommended) 16 MB or more (32 MB or more recommended) 32 MB or more (64 MB or more recommended) 64 MB or more (128 MB or more recommended) 128 MB or more (256 MB or more recommended) 20 MB or more (40 MB or more recommended) CD-ROM drive VGA (640 480 pixels), (SVGA [800 600 pixels] or more recommended) 256 or more colors Compatible with the operating systems mentioned above RS232C (Dsub-9 pin) port, USB port Compatible with the operating systems mentioned above
NOTE: The amount of memory and the amount of free space on the hard disk differs depending on the computer. Using this software while there is not enough free space on the hard disk could cause errors and result in insufficient memory. This software will not run properly on some computers. When starting up this program, do not start other software applications. Do not use the screen saver function or the energy saving feature when using this program. If the ECM is changed, restart the program. Windows XP is a multiuser operating system, therefore, be sure to end this program if the login user is changed. The USB adapter cannot be used with Windows 95. For operating instructions of the Yamaha Diagnostic System, refer to the Yamaha Diagnostic System Instruction Manual.
9-2
TRBL ANLS
OPERATING
OPERATING
CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT

Top view
1 2
1 3-pin communication coupler 2 Wiring harness coupler 3 Meter coupler
NOTE: Be careful not to pinch the communication cable between the hood and the deck or to damage it.
9-3
TRBL ANLS
TROUBLE ANALYSIS
TROUBLE ANALYSIS
NOTE: Before consulting the TROUBLE ANALYSIS CHART, check the following items. 1. Check that the battery is charged and that its specified gravity is within specification. 2. Check that there are no incorrect wiring connections. 3. Check that all wiring connections are properly secured and that they are not rusty. 4. Check that the engine shut-off cord (lanyard) is connect to the engine shut-off switch. 5. Check that fuel is reaching the throttle bodies.
TROUBLE ANALYSIS CHART

Trouble mode IRREGULAR WARNING INDICATION Check elements
POOR BATTERY CHARGING
ENGINE WILL NOT START
ENGINE WILL NOT STOP
LIMITED ENGINE SPEED
POOR ACCELERATION
POOR PERFORMANCE
LOW OIL PRESSURE
LOOSE STEERING
BILGE INCREASE
HARD STARTING
Relative part
ENGINE STALLS
Reference chapter
ROUGH IDLING
OVERHEATING
HIGH IDLING
FUEL SYSTEM Fuel tank Fuel tank breather hose Fuel hose Fuel filter Fuel pump Fuel injectors Trolling speed Air filter
4 4 4 4 4 4 3 3
9-4
TRBL ANLS
TROUBLE ANALYSIS
POOR ACCELERATION
POOR PERFORMANCE
LOW OIL PRESSURE
LOOSE STEERING
BILGE INCREASE
HARD STARTING
Relative part
ENGINE STALLS
Reference chapter
ROUGH IDLING
OVERHEATING
HIGH IDLING
POWER UNIT Compression Cylinder head gaskets Cylinder block Crankcase Piston rings Pistons Bearings Thermostat Valve(s) and valve seat(s) Valve clearance adjusting pad(s) Camshaft(s) Timing chain Oil pump Engine oil Oil filter Oil pressure switch Bearing housing Drive couplings Rubber coupling Pilot water hose Water hose Water passage
5 5 5 5 5 5 5 5 5 3 5 5 5 3 3 7 5 5 5 5 5 5
9-5
TRBL ANLS
TROUBLE ANALYSIS
POOR ACCELERATION
POOR PERFORMANCE
LOW OIL PRESSURE
LOOSE STEERING
BILGE INCREASE
HARD STARTING
Relative part
ENGINE STALLS
Reference chapter
ROUGH IDLING
OVERHEATING
HIGH IDLING
JET PUMP UNIT Duct Impeller Intake grate Bearings Intake duct Water inlet hose Bilge hose Bilge strainer Bilge hose joint ELECTRICAL Ignition system, fuel control system Pickup coils ECM Ignition coils Slant detector switch Engine stop switch Engine shut-off switch Spark plugs Main and fuel pump relay Thermoswitch Sensor assembly Engine temperature sensor Throttle position sensor Cam position sensor
6 6 6 6 6 6 6 3 6
7 7 7 7 7 7 3 7 7 7 7 7 7
9-6
TRBL ANLS
TROUBLE ANALYSIS
POOR ACCELERATION
POOR PERFORMANCE
LOW OIL PRESSURE
LOOSE STEERING
BILGE INCREASE
HARD STARTING
Relative part
ENGINE STALLS
Reference chapter
ROUGH IDLING
OVERHEATING
HIGH IDLING
Starting system Start switch Starter relay Starter motor Charging system Lighting coil Rectifier/regulator Fuses Battery leads Battery Electric bilge pump Electric bilge pump Remote control system Remote control unit HULL AND HOOD Steering master Water lock Exhaust hose Muffler Drain plugs
7 7 7 7 7 7 3 7 7 8 8 8 8 8
9-7
TRBL ANLS
1
TROUBLE ANALYSIS
SELF-DIAGNOSIS
With the engine running, press the select button 1 for 8 seconds and check if an error code is indicated on the multifunction meter. Code 01 13 15 18 19 23 24 29 47 48 54 55 63 Normal Pickup coil malfunction Engine temperature sensor malfunction Throttle position sensor malfunction Incorrect battery voltage Intake air temperature sensor malfunction Cam position sensor malfunction Intake air pressure sensor malfunction Slant detection switch malfunction Incorrect data transmission Bypass valve motor malfunction Steering switch malfunction Intake air system malfunction Symptom
If the Yamaha Diagnostic System is not used to check the symptoms listed in the table, the error codes can be checked easily with the self-diagnosis in the multifunction meter. However, if there are numerous error codes displayed, be sure to check them with the Yamaha Diagnostic System.
9-8
WIRING DIAGRAM FX High Output, FX Cruiser High Output

1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R S T U V W X Y Fuse (20 A) Fuse (3 A) Starter relay Slant detection switch Main and fuel pump relay ECM Rectifier/regulator Noise filter Cam position sensor Thermoswitch (exhaust) Oil pressure switch Thermoswitch (engine) Engine temperature sensor Sensor assembly (intake air pressure, intake air temperature) Throttle position sensor Fuel injector Bypass valve motor Ignition coil Spark plug Pickup coil Lighting coil Battery Starter motor Electric bilge pump Fuel pump Fuel sender Engine stop switch Engine shut-off switch Start switch Steering switch Multifunction meter Speed sensor Buzzer Remote control unit Antenna
Color code
B Br G L O P R W Y B/G B/O B/R B/W B/Y G/B G/O G/R G/Y L/B L/R P/G P/W Pu/B Pu/G Pu/R Pu/Y R/Y R/W W/B W/L W/R : Black : Brown : Green : Blue : Orange : Pink : Red : White : Yellow : Black/green : Black/orange : Black/red : Black/white : Black/yellow : Green/black : Green/orange : Green/red : Green/yellow : Blue/black : Blue/red : Pink/green : Pink/white : Purple/black : Purple/green : Purple/red : Purple/yellow : Red/yellow : Red/white : White/black : White/blue : White/red
To tachometer To entry box
FX High Output, FX Cruiser High Output

B B/O B/O B B B B/O B B/O G/O B/O R/Y B R Br R R B B/O P B/O P/W B/O B
B
P/W B/O W/R W/B B/O P B/O B/Y G
1
R R
3 8
P/G O R/Y Pu/Y Pu/G G/R G/Y B/Y G/Y G/R B/O G/B G Pu/R Pu/B R/Y P/G R/Y L R R/Y R B L/R Y R R R/Y Br Br B R O P P R/Y Pu/B Pu/R G G/B
2
R
R G B G B P R B P
B/O B/O P/W R B W B B P P B/Y B/Y B/Y B/Y
2
R/Y
A
G B B R G
0
R
Br Br B
B/O
R/Y G/O B/O R/Y G/O
4
B/O L/B
B/O
B/O Br R/Y R R L/B L/B B Br
Pu/G Pu/Y O
3 4 6 7 9 10 11
X
R/Y
L/Y L/B Gy
Y B
B R W B GGG
9
R/Y B/Y O
12 13 14 15 16 18
B R Br Y B/L L
J E C
B P B/O Pu/R Pu/B R/Y G/Y G/R Pu/Y Pu/G P/G B/O B
A
G R/Y R/Y R/Y G/B R/Y R/Y
K Q R
B FREE PUSH B W B B W FREE PUSH W Br W B R Br FREE PUSH
R P
D
W
S
Br Br
Y
B/O W
R R/Y
P R/Y B/R R/Y
H
#1
F I
#1
#2
#3
#4
F
Br R Br
R/Y R/Y R/Y R/Y B/W R/Y
R Br
O
#2
B/O
L B B P R/Y W/B W R B W R R/Y B/Y R/W Y B/Y R/W Y L P L/Y L/R L/B Br B L/R R/Y L/B L/R B P R/W B Y/B B R/W W/L L/R L/R B/L B B R/Y B B Gy B B/L Gy B R R B Y/B L/Y Gy Gy L/R L/B B/O B B
B/Y
R/Y
#3
B/L
R/Y
#4
Y B/Y R/Y
1 3 4 5 6 8 9 10 12 13
G G/O W P P/W B/Y O B/O W/R W/B
L
Br B B/O B B W/L B/O R/Y
B/O
14 15 16 17 18 19 20 21 22 28
L W/B G/B G/Y G/R B G L/R B/R L/B
29 30 31 33 34 35 37 38 39 40
W/L R/Y Y P/G P B/Y Pu/G Pu/Y Pu/B Pu/R
41 42 43 44
B B/L B/Y B/W
D
B R
B/O
7
G G G
123
C B
4 5
R/Y B L B/O Y L/R L/B R R R R O P R P P O R R/Y R/Y R/Y R/Y R/Y R/Y R/Y R/Y R/Y L/B L/R P O R/Y B/W Pu/G B Pu/B Pu/R Pu/Y W/B B/Y P P/G G/O B/R W/B W/R B/O B/Y W G P/W G G/R G/B G/Y W/L L Y B B/L B/Y
R/Y R R R B Br R/Y Br
P Pu/B G/R G G/B Pu/G B/Y Pu/R O G/Y B/O Pu/Y P/G R/Y
R/Y R/Y R/Y R/Y R/Y R/Y
O B/O
R/Y R/Y
H
G/B B G B/Y W/B B/O P G/O R/Y Pu/B B/Y P/G B/O G/Y G G P W/R P/W R/Y Pu/G Pu/Y Pu/R O P B
D B
B/Y G G G P W/B W/R B/O P/W P R/Y G/O B/R B/W R/Y B/Y R/Y R/Y R/Y B/L
G G/R
B/O B/O B B
8 9 0 A B C J K 7
P B G G G
B/O B W/L R/Y R R/Y L R/Y W/B
O Pu/R Pu/Y Pu/G P/G B/Y Pu/B R/Y B/O
G/Y G/R G/B G
Y G L W B Br R B B B B/O Br Y
N O P Q R S T U V W X
YAMAHA MOTOR CORPORATION, USA
Printed in USA Feb. 2004 1 CR (E)
WaveRunner FX FX Cruiser FX High Output FX Cruiser High Output
SUPPLEMENTARY SERVICE MANUAL

*LIT186160293*
LIT-18616-02-93 F1X-28197-1H-1X
NOTICE
This Supplementary Service Manual has been prepared to introduce new service and new data information for the FX, FX Cruiser, FX High Output, and FX Cruiser High Output which are based on the 2002 FX140, 2003 FX140/FX Cruiser, and 2004 FX High Output/FX Cruiser High Output. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manuals. FX140 SERVICE MANUAL: F1B-28197-1E-11 (LIT-18616-02-38) FX140/FX Cruiser SUPPLEMENTARY SERVICE MANUAL: F1B-28197-1F-1X (LIT-18616-02-45) FX High Output/FX Cruiser High Output SERVICE MANUAL: F1S-28197-1G-11 (LIT-18616-02-83)
A10001-0*
WaveRunner FX/FX Cruiser FX High Output/FX Cruiser High Output SUPPLEMENTARY SERVICE MANUAL 2005 by Yamaha Motor Corporation, USA 1st Edition, December 2005 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited. Printed in USA LIT-18616-02-93

MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., Bearings Pitting/scratches Replace. To assist you in finding your way through this manual, the section title and major heading is given at the top of every page.
ILLUSTRATIONS
The illustrations within this service manual represent all of the designated models.
CROSS REFERENCES
The cross references have been kept to a minimum. Cross references will direct you to the appropriate section or chapter.
IMPORTANT INFORMATION
In this Supplementary 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, passenger(s), 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 watercraft. NOTE: A NOTE provides key information to make procedures easier or clearer.

1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 2 Numbers are given in the order of the jobs in the exploded diagram. 3 Symbols indicate parts to be lubricated or replaced (see SYMBOLS). 4 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5 Dimension figures and the number of parts, are provided for fasteners that require a tightening torque. Example: Bolt or screw size 10 25 mm : M10 (D) 25 mm (L)
D L
6 Jobs requiring more information (such as special service tools and technical data) are described sequentially.
E
1 2
A50001-1-4
GEN INFO
3
SYMBOLS
Symbols 1 to 9 are designed to indicate the content of a chapter.
1 2 3 4 5 6 7 8 9 General Information Specifications Periodic Inspection and Adjustment Fuel System Power Unit Jet Pump Unit Electrical System Hull and Hood Trouble Analysis
SPEC
4
INSP ADJ
5
FUEL
6
POWR
7
JET PUMP
8
+
ELEC
9
HULL HOOD
0
Symbols 0 to E indicate specific data.

0 A B C D E Special service tool Specified oil or fluid Specified engine speed Specified tightening torque Specified measurement Specified electrical value (resistance, voltage, electric current)
TRBL ANLS
A B
T.
R.
Symbols F to I in an exploded diagram indicate the grade of lubricant and the lubrication point.
E
F Apply Yamaha 4-stroke motor oil G Apply water resistant grease (Yamaha grease A, Yamaha marine grease) H Apply ThreeBond 1104J or ThreeBond 1280B I Apply molybdenum disulfide grease
G
A
H
1104J 1280B
I
M
J
GM
Symbols J to N in an exploded diagram indicate the type of sealant or locking agent and the application point.
J K L M N Apply Gasket Maker Apply LOCTITE 271 (red) Apply LOCTITE 242 (blue) Apply LOCTITE 572 Apply silicone sealant
K
LT
L
LT
271
242
M
LT
N
SS
572
NOTE: Additional symbols may be used in this manual.
E
A30000-0
INDEX
GEN INFO
GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT FUEL SYSTEM POWER UNIT JET PUMP UNIT ELECTRICAL SYSTEM HULL AND HOOD TROUBLE ANALYSIS
SPEC
INSP ADJ
FUEL
POWR
JET PUMP
+
ELEC
HULL HOOD
TRBL ANLS
1 2 3 4 5 6 7 8 9
GENERAL INFORMATION
IDENTIFICATION NUMBERS ............................................................................ 1 PRIMARY l.D. NUMBER .............................................................................. 1 ENGINE SERIAL NUMBER ......................................................................... 1 JET PUMP UNIT SERIAL NUMBER ............................................................ 1 HULL IDENTIFICATION NUMBER (H.l.N.).................................................. 1 SPECIAL TOOLS ............................................................................................... 2 MEASURING................................................................................................ 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................... 3 MAINTENANCE SPECIFICATIONS .................................................................. 7 ENGINE ....................................................................................................... 7 JET PUMP UNIT ....................................................................................... 10 HULL AND HOOD ..................................................................................... 10 ELECTRICAL ............................................................................................. 11 ENGINE ..................................................................................................... 13 JET PUMP UNIT ....................................................................................... 16 HULL AND HOOD ..................................................................................... 16 ELECTRICAL ............................................................................................. 16 TIGHTENING TORQUES ................................................................................. 19 SPECIFIED TORQUES.............................................................................. 19 GENERAL TORQUE .................................................................................. 20 CABLE AND HOSE ROUTING ........................................................................ 21 CABLE AND HOSE ROUTING (For FX/FX Cruiser) ...................................... 32 CABLE AND HOSE ROUTING (For FX High Output/FX Cruiser High Output)............................................. 37
PERIODIC INSPECTION AND ADJUSTMENT

MAINTENANCE INTERVAL CHART ............................................................... 41 PERIODIC SERVICE ........................................................................................ 42 CONTROL SYSTEM .................................................................................. 42 Steering master inspection................................................................... 42 Steering cable inspection and adjustment ........................................... 42 Throttle cable inspection and adjustment............................................. 43 GENERAL .................................................................................................. 45 Drain plug inspection............................................................................ 45 Lubrication points ................................................................................. 46
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS (For FX/FX Cruiser)....................................... 49 ELECTRICAL COMPONENTS (For FX High Output/FX Cruiser High Output)............................................. 50 OFF THROTTLE STEERING SYSTEM............................................................ 52 WIRING DIAGRAM .................................................................................... 52 STEERING SENSOR ................................................................................. 53
E INDICATION SYSTEM ..................................................................................... 54 WIRING DIAGRAM (For FX Cruiser High Output) ..................................... 54 WIRING DIAGRAM (For FX High Output).................................................. 56 WIRING DIAGRAM (For FX/FX Cruiser).................................................... 58 MULTIFUNCTION METER......................................................................... 59 Multifunction meter............................................................................... 59 Operation button .................................................................................. 59 MULTIFUNCTION METER REMOVAL ...................................................... 60 OPERATION BUTTON REMOVAL ............................................................ 60 Display function (for FX Cruiser High Output)...................................... 61 Display function (for FX High Output) .................................................. 62 Display function (for FX/FX Cruiser) .................................................... 63 Compass display (for FX Cruiser High Output).................................... 64 Air temperature display (for FX Cruiser High Output) .......................... 64 Speedometer/average speed/tripmeter display (for FX Cruiser High Output) ............................................................... 65 Water temperature display (for FX Cruiser High Output) ..................... 66 Trip timer display (for FX Cruiser High Output).................................... 67 Fuel consumption per hour, fuel consumption per kilometer/ mile display (for FX Cruiser High Output) ........................................... 67 Overheat warning indicator .................................................................. 67 Check engine warning indicator ........................................................... 68 Diagnostic display ................................................................................ 68 REMOTE CONTROL SYSTEM (For FX High Output/FX Cruiser High Output)............................................. 69 WIRING DIAGRAM .................................................................................... 69 REMOTE CONTROL SYSTEM.................................................................. 71 Yamaha Security System indicator ...................................................... 71 Low-rpm mode indicator....................................................................... 72
HULL AND HOOD

HANDLEBAR ................................................................................................... 73 EXPLODED DIAGRAM (For FX/FX High Output) ...................................... 73 REMOVAL AND INSTALLATION CHART ................................................. 73 EXPLODED DIAGRAM (For FX Cruiser/FX Cruiser High Output)............. 74 REMOVAL AND INSTALLATION CHART ................................................. 74 EXPLODED DIAGRAM .............................................................................. 75 REMOVAL AND INSTALLATION CHART ................................................. 75 SERVICE POINTS ..................................................................................... 79 Handlebar assembly installation .......................................................... 79 STEERING MASTER........................................................................................ 82 EXPLODED DIAGRAM .............................................................................. 82 REMOVAL AND INSTALLATION CHART ................................................. 82 SERVICE POINTS ..................................................................................... 87 Steering master components inspection .............................................. 87 Rubber seal installation........................................................................ 87 REMOTE CONTROL CABLES AND SPEED SENSOR LEAD ....................... 88 EXPLODED DIAGRAM .............................................................................. 88 REMOVAL AND INSTALLATION CHART ................................................. 88 SERVICE POINTS ..................................................................................... 91 Steering cable removal ........................................................................ 91 SERVICE POINTS ..................................................................................... 92 Steering cable installation .................................................................... 92 FRONT HOOD .................................................................................................. 93 EXPLODED DIAGRAM .............................................................................. 93 REMOVAL AND INSTALLATION CHART ................................................. 93 SERVICE POINTS ..................................................................................... 95 Rivet Installation................................................................................... 95 SERVICE POINTS ..................................................................................... 98 Ornament disassembly ........................................................................ 98 Front hood assembly............................................................................ 98 Visor installation ................................................................................... 99 Double-sided tape installation .............................................................. 99 Ornament installation ......................................................................... 100 MIRROR.......................................................................................................... 101 EXPLODED DIAGRAM ............................................................................ 101 REMOVAL AND INSTALLATION CHART ............................................... 101 STEERING CONSOLE COVER ..................................................................... 103 EXPLODED DIAGRAM ............................................................................ 103 REMOVAL AND INSTALLATION CHART ............................................... 103
E SHIFT LEVER................................................................................................. 111 EXPLODED DIAGRAM ............................................................................ 111 REMOVAL AND INSTALLATION CHART ............................................... 111 SEATS AND HAND GRIP .............................................................................. 112 EXPLODED DIAGRAM ............................................................................ 112 REMOVAL AND INSTALLATION CHART ............................................... 112 REBOARDING STEP (For FX Cruiser/FX Cruiser High Output)................ 115 EXPLODED DIAGRAM ............................................................................ 115 REMOVAL AND INSTALLATION CHART ............................................... 115 SERVICE POINTS ................................................................................... 116 Reboarding step installation............................................................... 116 DECK AND HULL........................................................................................... 117 EXPLODED DIAGRAM ............................................................................ 117 REMOVAL AND INSTALLATION CHART ............................................... 117 CLEAT ASSEMBLY (For FX Cruiser High Output) ..................................... 120 EXPLODED DIAGRAM ............................................................................ 120 REMOVAL AND INSTALLATION CHART ............................................... 120 SERVICE POINTS ................................................................................... 121 Cleat cover installation ....................................................................... 121
TROUBLE ANALYSIS
TROUBLE ANALYSIS.................................................................................... 122 SELF-DIAGNOSIS ................................................................................... 122 WIRING DIAGRAM
GEN INFO
A60700-0*
PRIMARY l.D. NUMBER
The primary l.D. number is stamped on a label attached to the inside of the engine compartment. Starting primary l.D. numbers: F1X: 800101 F1Y: 800101
ENGINE SERIAL NUMBER

The engine serial number is stamped on a label attached to the engine unit. Starting serial numbers: 6B6: 1018901 60E: 1017501
JET PUMP UNIT SERIAL NUMBER

The jet pump unit serial number is stamped on a label attached to the intermediate housing.
HULL IDENTIFICATION NUMBER (H.l.N.)

The H.l.N. is stamped on a plate attached to the aft deck.
GEN INFO
SPECIAL TOOLS SPECIAL TOOLS
Using the correct special tools recommended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvisations and using improper tools can damage the equipment. NOTE: For U.S.A. and Canada, use part numbers starting with J-, YB-, YM-, YS-, YU- or YW-. For other countries, use part numbers starting with 90890-.
MEASURING
1
YU-34899-A
2 90890-03174
1 Digital multimeter P/N. YU-34899-A 2 Digital circuit tester P/N. 90890-03174
SPEC
Item Model code Hull Engine/jet Dimensions Length Width Height Dry weight Maximum capacity Performance Maximum output Maximum fuel consumption Cruising range Engine Engine type Displacement Bore stroke Compression ratio Exhaust system Lubrication system Cooling system Starting system Ignition system Ignition timing Spark plug model (manufacturer) Spark plug gap Battery capacity Generator output Drive unit Propulsion system Jet pump type Impeller rotation Transmission Jet thrust nozzle horizontal angle Jet thrust nozzle trim angle Trim system Reverse system Unit Model FX High Output FX Cruiser High Output F1X 6B6 mm (in) mm (in) mm (in) kg (lb) Person/kg (lb) kW (PS) @ r/min l/h (US gal/h, lmp gal/h) h 3,340 (131.5) 1,230 (48.4) 1,160 (45.7) 1,240 (48.8) 372 (820) 380 (838) 3/240 (530) 117.7 (160) @ 10,000 45 (11.9, 9.9) 1.56 4-stroke, L4, DOHC 1,052 (64.2) 76.0 58.0 (2.99 2.28) 11.9:1 Wet exhaust Dry sump Water cooled Electric starter TCI BTDC 5BTDC 32 CR9EB (NGK) 0.70.8 (0.0280.031) 12/19 1416 @ 6,000 Jet pump Axial flow, single stage Counterclockwise (viewed from rear) Constant mesh 1-speed 24 + 24 10, 5, 0, 5, 10 Manual 5 positions Reverse gate
cm (cu. in) mm (in)
Degree
Degree Degree
SPEC
Unit
Model FX High Output FX Cruiser High Output Regular unleaded gasoline 86 90 70 (18.5, 15.4) 4-stroke motor oil SE, SF, SG, SH, SJ, SL 10W-30 4.5 (4.8, 4.0) 2.1 (2.2, 1.8) 2.3 (2.4, 2.0)
SPEC
Item
Unit Model FX F1Y 60E mm (in) mm (in) mm (in) kg (lb) Person/kg (lb) kW (PS) @ r/min l/h (US gal/h, lmp gal/h) h 3,340 (131.5) 1,230 (48.4) 1,160 (45.7) 1,240 (48.8) 384 (847) 392 (864) 3/240 (530) 103 (140) @ 10,000 44 (11.6, 9.7) 1.59 4-stroke, L4, DOHC 998 (60.9) 74.0 58.0 (2.91 2.28) 11.4:1 Wet exhaust Dry sump Water cooled Electric starter TCI BTDC 34ATDC 5 CR9EB (NGK) 0.70.8 (0.0280.031) 12/19 1416 @ 6,000 Jet pump Axial flow, single stage Counterclockwise (viewed from rear) Constant mesh 1-speed 24 + 24 10, 5, 0, 5, 10 Manual 5 positions Reverse gate FX Cruiser
Model code Hull Engine/jet Dimensions Length Width Height Dry weight Maximum capacity Performance Maximum output Maximum fuel consumption Cruising range Engine Engine type Displacement Bore stroke Compression ratio Exhaust system Lubrication system Cooling system Starting system Ignition system Ignition timing Spark plug model (manufacturer) Spark plug gap Battery capacity Generator output Drive unit Propulsion system Jet pump type Impeller rotation Transmission Jet thrust nozzle horizontal angle Jet thrust nozzle trim angle Trim system Reverse system
cm (cu. in) mm (in)
Degree
Degree Degree
SPEC
Unit Model FX FX Cruiser
Regular unleaded gasoline 86 90 70 (18.5, 15.4) 4-stroke motor oil SE, SF, SG, SH, SJ, SL 10W-30 4.3 (4.5, 3.8) 2.0 (2.1, 1.8) 2.2 (2.3, 1.9)
SPEC
ENGINE
Unit mm (in) Model FX Cruiser High Output
FX High Output
0.1 (0.004)
1,150 (11.5, 164)
76.00076.015 (2.99212.9927) 0.08 (0.003) 0.05 (0.002) 76.100 (2.9961) Chain drive 33.00 (1.299) 33.00 (1.299) 25.00 (0.984) 24.5 (0.9646) 24.4624.47 (0.96300.9634) 0.030.06 (0.00120.0024) 0.03 (0.0012) 92RH2015-130/130 Automatic
mm (in) mm (in)
0.110.20 (0.00430.0079) 0.250.34 (0.00980.0134)
mm (in) mm (in)
22.923.1 (0.90160.9094) 24.424.6 (0.96060.9685)
mm (in) mm (in)
1.912.64 (0.07520.1039) 1.912.64 (0.07520.1039)
7
SPEC
Item
Unit mm (in) mm (in) mm (in) mm (in)
Model FX High Output FX Cruiser High Output 0.91.1 (0.03540.0433) 0.91.1 (0.03540.0433) 0.851.15 (0.03350.0453) 0.851.15 (0.03350.0453)
3.9753.990 (0.15650.1571) 4.4654.480 (0.17580.1764) 4.0004.012 (0.15750.1580) 4.5004.512 (0.17720.1776)
0.0100.037 (0.00040.0015) 0.0200.047 (0.00080.0019) 0.01 (0.0004)
38.90 (1.53) 40.67 (1.60) 34.50 (1.36) 35.00 (1.38) 2.5/1.7 (0.067) 2.5/1.8 (0.071) 0.100.11 (0.00390.0043) 75.89575.910 (2.98802.9886) 5 (0.2) 0.17 (0.0067) 17.00217.013 (0.66930.6698) 16.99117.000 (0.66890.6693) 16.98 (0.67)
SPEC
Item
Unit
Model FX High Output FX Cruiser High Output
B B B

B

B
304.8306.0 (12.0012.05) 0.03 (0.0012) 0.0040.028 (0.00020.0011) 1. Brown 2. Black 3. Blue 4. Green 5. Yellow 42EIS/4 Mikuni 6B601 1,6001,700 Electrical 320.8327.2 (3.23.3, 4547)
r/min
kPa (kgf/cm2, psi)
SPEC
Item
Unit
Model FX High Output FX Cruiser High Output Cartridge type Trochoid 0.090.15 (0.00350.0059)
mm (in)
mm (in) mm (in)
0.090.17 (0.00350.0067) 0.090.15 (0.00350.0059)
JET PUMP UNIT

Item Jet pump Impeller material Number of impeller blades Impeller pitch angle Impeller clearance Impeller clearance limit Drive shaft runout limit Nozzle diameter Unit Model FX High Output FX Cruiser High Output Stainless steel 3 16.8 0.350.45 (0.01380.0177) 0.6 (0.0236) 0.3 (0.0118) 86.587.1 (3.413.43)
HULL AND HOOD

Item Free play Throttle lever free play Unit mm (in) FX High Output Model FX Cruiser High Output
47 (0.160.28)
10
SPEC
ELECTRICAL
Item
Unit
FX High Output
Model FX Cruiser High Output Fluid 12/19 1.28
Battery Type Capacity Specific gravity ECM unit (B/R R/Y, B/W R/Y, B/Y R/Y, B/L R/Y) Output peak voltage lower limit @cranking (loaded) @2,000 r/min (loaded) @3,500 r/min (loaded) Stator Pickup coil (W B, R B) Output peak voltage @cranking (unloaded) @cranking (loaded) @2,000 r/min (loaded) @3,500 r/min (loaded) Lighting coil (G G) Output peak voltage @cranking (unloaded) @2,000 r/min (unloaded) @3,500 r/min (unloaded) Pickup coil resistance (W B) Pickup coil resistance (R B) Lighting coil resistance (G G) Minimum charging current Ignition coil Primary coil resistance Secondary coil resistance Rectifier/regulator (R B) Output peak voltage @3,500 r/min (unloaded) Starter motor Type Output Rating Brush length Wear limit Commutator undercut Limit Commutator diameter Limit
V/Ah
V V V
87 86 85
V V V V
5.2 4.7 26.1 41.3
9.2 38.5 63.2 459561 459561 0.540.66 14 @ 6,000 1.191.61 8.511.5
15.0 Constant mesh 0.8 30 12.5 (0.49) 6.5 (0.26) 0.7 (0.03) 0.2 (0.01) 28.0 (1.10) 27.0 (1.06)
11
kW Seconds mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
SPEC
Item
Unit Seconds C (F) C (F) C (F) C (F)
Model FX High Output FX Cruiser High Output 30 8490 (183194) 7084 (158183) 94100 (201212) 8094 (176201)
Starter relay Rating Thermoswitch ON temperature (engine) OFF temperature (engine) ON temperature (exhaust) OFF temperature (exhaust) Engine temperature sensor Engine temperature sensor resistance (B/Y B/Y) @ 20 C (68 F) @ 100 C (212 F) Speed sensor Output voltage (on pulse) Output pulse/one full turn Water temperature sensor resistance (Y B/Y) @ 25 C (77 F) Throttle position sensor Output voltage (P B/O) @ trolling speed Cam position sensor Output voltage (G/O B/O) Position A Position B Position C Fuel level sensor Fuel level sensor resistance Position A Position B Oil pressure switch Oil pressure switch continuity pressure Fuel injector Fuel injector resistance*1 Fuse Rating Main Remote control unit Electrical bilge pump *1 The figures are for reference only.
k k V 11.6
54.269.0 3.123.48 5.0 2
10
0.756 0.016
V V V
kPa (kgf/cm2, psi)
133.5136.5 57 128166 (1.281.66, 18.223.6)
11.512.5
V/A V/A V/A
12/20 12/3 12/3
12
SPEC
ENGINE
Model FX 0.1 (0.004) FX Cruiser
Unit mm (in)
1,350 (13.5, 192)
74.06074.075 (2.91572.9163) 0.08 (0.003) 0.05 (0.002) 74.200 (2.9213) Chain drive 32.25 (1.270) 32.65 (1.285) 25.00 (0.984) 24.5 (0.9646) 24.4424.45 (0.96220.9626) 0.050.08 (0.0020.0031) 0.03 (0.0012) 92RH2015-130/130 Automatic
mm (in) mm (in)
0.110.20 (0.00430.0079) 0.250.34 (0.00980.0134)
mm (in) mm (in)
22.923.1 (0.90160.9094) 24.424.6 (0.96060.9685)
mm (in) mm (in)
1.912.64 (0.07520.1039) 1.912.64 (0.07520.1039)
13
SPEC
Item
Unit mm (in) mm (in) mm (in) mm (in) Model FX FX Cruiser
0.91.1 (0.03540.0433) 0.91.1 (0.03540.0433) 0.851.15 (0.03350.0453) 0.851.15 (0.03350.0453)
3.9753.990 (0.15650.1571) 4.4654.480 (0.17580.1764) 4.0004.012 (0.15750.1580) 4.5004.512 (0.17720.1776)
0.0100.037 (0.00040.0015) 0.0200.047 (0.00080.0019) 0.01 (0.0004)
38.90 (1.53) 40.67 (1.60) 34.50 (1.36) 35.00 (1.38) 2.5/1.7 (0.067) 2.5/1.8 (0.071) 0.100.11 (0.00390.0043) 73.95573.970 (2.91162.9121) 5 (0.2) 0.17 (0.0067) 17.00217.013 (0.66930.6698) 16.99117.000 (0.66890.6693) 16.98 (0.67)
14
SPEC
Item
B B B

B

B
304.8306.0 (12.0012.05) 0.03 (0.0012) 0.0040.028 (0.00020.0011) 1. Brown 2. Black 3. Blue 4. Green 5. Yellow 40EIS/4 Mikuni 60E21 1,6001,700 Electrical 320.8327.2 (3.23.3, 4547)
r/min
kPa (kgf/cm2, psi)
15
SPEC
Item
Unit Model FX FX Cruiser Cartridge type Trochoid 0.090.15 (0.00350.0059)
mm (in)
mm (in) mm (in)
0.090.17 (0.00350.0067) 0.090.15 (0.00350.0059)
JET PUMP UNIT

Item Jet pump Impeller material Number of impeller blades Impeller pitch angle Impeller clearance Impeller clearance limit Drive shaft runout limit Nozzle diameter Unit Model FX FX Cruiser
Stainless steel 3 16.3 0.350.45 (0.01380.0177) 0.6 (0.0236) 0.3 (0.0118) 86.587.1 (3.413.43)
HULL AND HOOD

Item Free play Throttle lever free play Unit mm (in) Model FX FX Cruiser 47 (0.160.28)
ELECTRICAL
Item Battery Type Capacity Specific gravity ECM unit (B/R R/Y, B/W R/Y, B/Y R/Y, B/L R/Y) Output peak voltage lower limit @cranking (loaded) @2,000 r/min (loaded) @3,500 r/min (loaded) Unit Model FX Fluid 12/19 1.28 FX Cruiser
V/Ah
V V V
87 86 85
16
SPEC
Item
Stator Pickup coil (W B, R B) Output peak voltage @cranking (unloaded) @cranking (loaded) @2,000 r/min (loaded) @3,500 r/min (loaded) Lighting coil (G G) Output peak voltage @cranking (unloaded) @2,000 r/min (unloaded) @3,500 r/min (unloaded) Pickup coil resistance (W B) Pickup coil resistance (R B) Lighting coil resistance (G G) Minimum charging current Ignition coil Primary coil resistance Secondary coil resistance Rectifier/regulator (R B) Output peak voltage @3,500 r/min (unloaded) Starter motor Type Output Rating Brush length Wear limit Commutator undercut Limit Commutator diameter Limit Starter relay Rating Thermoswitch ON temperature (engine) OFF temperature (engine) ON temperature (exhaust) OFF temperature (exhaust) Engine temperature sensor Engine temperature sensor resistance (B/Y B/Y) @ 20 C (68 F) @ 100 C (212 F)
V V V V
4 4 23 38
9 11 12 459561 459561 0.540.66 14 @ 6,000 1.191.61 8.511.5
15.0 Constant mesh 0.8 30 12.5 (0.49) 6.5 (0.26) 0.7 (0.03) 0.2 (0.01) 28.0 (1.10) 27.0 (1.06) 30 8490 (183194) 7084 (158183) 94100 (201212) 8094 (176201)
kW Seconds mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) Seconds C (F) C (F) C (F) C (F)
k k
17
54.269.0 3.123.48
SPEC
Item
Intake air temperature sensor Intake air temperature sensor resistance (B/Y B/O) @ 0 C (32 F) @ 80 C (176 F) Intake air pressure sensor Output voltage (P/G B/O)
k k V @ kPa (kgf/cm2, psi) V @ kPa (kgf/cm2, psi) V @ kPa (kgf/cm2, psi) V
5.46.6 0.290.39 4.00 @ 101.3 (1.01, 14.4) 1.84 @ 47 (0.47, 6.68) 0.79 @ 20 (0.2, 2.8)
Speed sensor Output voltage (on pulse) Output pulse/one full turn Throttle position sensor Output voltage (P B/O) @ trolling speed Cam position sensor Output voltage (G/O B/O) Position A Position B Position C Fuel level sensor Fuel level sensor resistance Position A Position B Oil pressure switch Oil pressure switch continuity pressure Fuel injector Fuel injector resistance*1 Fuse Rating Main Multifunction meter Electrical bilge pump *1 The figures are for reference only.
11.6 2
0.756 0.016
V V V
kPa (kgf/cm2, psi)
133.5136.5 57 128166 (1.281.66, 18.223.6)
11.512.5
V/A V/A V/A
12/20 12/3 12/3
18
SPEC
TIGHTENING TORQUES
TIGHTENING TORQUES
SPECIFIED TORQUES
Part to tightened Hull and hood Handlebar cover (for FX/FX High Output) Handlebar cover stay (for FX/FX High Output) Upper handlebar cover (for FX Cruiser/FX Cruiser High Output) Lower handlebar cover (for FX Cruiser/FX Cruiser High Output) Steering pad (for FX Cruiser/FX Cruiser High Output) Handlebar holder Handle boss cover QSTS converter QSTS cable 1 locknut QSTS cable 2 locknut Steering master Speed sensor Steering cable joint (jet pump side) Shift cable holder Shift cable bracket Steering cable grommet Speed sensor lead grommet QSTS cable end pin QSTS cable grommet QSTS cable locknut (jet pump side) Shift cable grommet Shift cable locknut (reverse gate side) Hinge assembly Front hood assembly Hood lock assembly Front hood Visor Mirror assembly Mirror cover Mirror Multifunction meter cover Multifunction meter Side cover Part name Thread Qty size M6 M6 M5 M6 M6 M8 M6 M5 M6 M6 M5 M5 M6 M5 M5 M5 M5 M6 4 2 8 2 4 4 4 2 1 1 4 4 1 2 2 1 1 1 1 1 1 1 4 6 2 8 6 4 2 12 8 4 4 8 2 Tightening torque Nm kgfm ftlb 1.1 1.1 1.1 5.4 1.1 20 0.9 5.4 16 16 20 5.2 6.4 6.4 15 5.9 5.9 3.8 5.9 2.9 5.9 2.9 6.4 5.4 5.4 2.2 1.1 5.4 5.4 3.7 3.7 2.2 3.7 5.4 5.4 0.11 0.11 0.11 0.54 0.11 2.0 0.09 0.54 1.6 1.6 2.0 0.52 0.64 0.64 1.5 0.59 0.59 0.38 0.59 0.29 0.59 0.29 0.64 0.54 0.54 0.22 0.11 0.54 0.54 0.37 0.37 0.22 0.37 0.54 0.54 0.8 0.8 0.8 3.9 0.8 14 0.7 3.9 12 12 14 3.8 4.6 4.6 11 4.3 4.3 2.7 4.3 2.1 4.3 2.1 4.6 3.9 3.9 1.6 0.8 3.9 3.9 2.7 2.7 1.6 2.7 3.9 3.9
242 242 242 242 242
572 572
LT LT LT LT LT LT LT LT
LT LT
Remarks
Screw Bolt Screw Screw Bolt Bolt Screw Nut Nut Nut Nut Screw Nut Nut Nut Nut Nut Nut Nut Nut Nut Nut Nut Bolt Bolt Screw Bolt Bolt Nut Screw Screw Screw Bolt Bolt Nut
19
242
LT
242
242
271
271
LT
242
LT
SPEC
TIGHTENING TORQUES
Part name Screw Nut Nut Nut Nut Bolt Nut Nut Nut Nut Nut Nut Nut Bolt Screw Bolt Bolt Nut Nut Bolt Thread Qty size M5 4 4 2 M6 M8 M5 M6 M8 M6 2 3 4 4 2 4 2 4 1 6 10 4 2 6 3 4 6 Tightening torque Nm kgfm ftlb 2.2 0.22 1.6 5.4 0.54 3.9 6.4 0.64 4.6 3.8 5.4 6.4 18 26 6.4 15 5.4 5.4 15 16 2.0 13 15 5.4 5.4 2.4 0.38 0.54 0.64 1.8 2.6 0.64 1.5 0.54 0.54 1.5 1.6 0.2 1.3 1.5 0.54 0.54 0.24 2.7 3.9 4.6 13 19 4.6 11 3.9 3.9 11 12 1.4 9.4 11 3.9 3.9 1.7
E Remarks
Part to tightened Side ornament Center cover Hood lock Compass sensor and air temperature sensor Shift lever assembly Seat lock assembly Deck beam Projection Rear seat stay Front seat stay Hand grip Spout Cleat Sponson Drain plug/screw Bow eye Reboarding step Front protector 1 Front protector 2/3 Cleat
Nut A 8 mm 10 mm 12 mm 14 mm 17 mm
Bolt B M5 M6 M8 M10 M12
General torque specifications Nm kgfm ftlb 5.0 0.5 3.6 8.0 0.8 5.8 18 1.8 13 36 3.6 26 43 4.3 31
GENERAL TORQUE
This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections 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 torque specifications require clean, dry threads. Components should be at room temperature.
20
271
LT
572
LT
271
LT
271
LT
SPEC

H G F E 2 2
UP DOWN BOW
20
1 A-A
A B D H H E D B
A C CE
3 1 B-B 1
3 J
0
UP
0
H H F F
C-C 4 7 9
B H-H B 0 A A G-G 0 C
H G G H
D-D
UP
5 6 E-E
7 9 7 9 F-F
8
1 2 3 4 5 6 7 8 9 0 A B C D E F H Remote control unit (FX High Output/FX Cruiser High Output) I Remote control unit antenna (FX High Output/FX Cruiser High Output) Fasten the speed sensor lead and electrical box lead securely with a plastic band.
Fuel tank breather hose Cooling water pilot outlet hose Cooling water pilot outlet Negative battery lead Positive battery lead Battery Steering cable QSTS cable Shift cable Speed sensor lead
Electrical bilge pump lead Electrical box lead Throttle cable Fuel hose Handlebar switch lead Remote control unit lead (FX High Output/FX Cruiser High Output) G Compass sensor (FX Cruiser High Output)
21
SPEC
1 2 A
8 3 45 6 7
D 1 2 3 H J 5 4 6 B 1 2 3 H 5 4 6 B
1 Buzzer lead 2 Steering sensor lead 3 Handlebar switch assembly lead 4 Fuel level sensor lead 5 Speed sensor lead 6 Electrical box lead 7 Throttle cable 8 Negative battery lead 9 Positive battery lead 0 A B C D Shift cable QSTS cable Steering cable Electrical bilge pump lead Remote control unit lead (FX High Output/FX Cruiser High Output) E Remote control unit (FX High Output/FX Cruiser High Output)
A 0
H I A G
H A
F Remote control unit antenna (FX High Output/FX Cruiser High Output) G Right operation button lead (FX Cruiser High Output) H Multifunction meter lead I Left operation button lead J Compass sensor lead (FX Cruiser High Output)
22
SPEC
1 2 A
8 3 45 6 7
D 1 2 3 H J 5 4 6 B 1 2 3 H 5 4 6 B
Fasten the handlebar switch assembly lead, fuel level sensor lead, speed sensor lead, and electrical box lead securely with a plastic tie. When installing the remote control unit antenna holders, insert the projection on each holder into a hole in the front storage compartment from the engine compartment side. Connect the right operation button lead coupler (blue) to the multifunction meter lead coupler (blue). (FX Cruiser High Output)
A 0
H I A G
H A
Connect the left operation button lead coupler (natural) to the multifunction meter lead coupler (natural). FX Cruiser High Output FX/FX Cruiser/FX High Output
23
SPEC
I A 1 2 3
A F
A B A 4 5 6 7 8
H G
E
A 3 9 2
9 A
G
A 3
1 2 A G
F F E
MAIN
3A
A
3A
A
20A
3A
SPARE
C 7 D C
1 2 3 4 5 6 7 8 9 0 A
C-C
D
B C D E F G
D-D
Shift cable Steering cable Fuel hose Throttle cable Cooling water pilot outlet hose Negative battery lead Positive battery lead Battery breather hose QSTS cable Electrical bilge pump lead Fuel tank breather hose
24
Water separator Ignition coil lead Starter motor positive lead Wiring harness Electric fuel pump Remote control unit lead (FX High Output/FX Cruiser High Output) H Remote control unit (FX High Output/FX Cruiser High Output) I Remote control unit antenna (FX High Output/FX Cruiser High Output)
SPEC
I A 1 2 3
A F
A B A 4 5 6 7 8
H G
E
A 3 9 2
9 A
G
A 3
1 2 A G
F F E
MAIN
3A
A
3A
A
20A
3A
SPARE
C 7 D C
C-C
D
D-D
To ventilation socket To fuel tank Route the fuel tank breather hose as shown in the illustration. Bow 57 mm (0.200.28 in) Point the arrow on the cover toward the fuel tank.
25
SPEC
3 2 1 2 3

B B C C
B B C C
A 5 4 B-B 6 3 9
A
A 2 5 4 C-C 1 3
D
D
8 7
1 2 3 4 5 6 7
Throttle cable QSTS cable Handlebar switch lead Grommet Hose packing Fuel tank breather hose Remote control unit lead (FX High Output/FX Cruiser High Output) 8 Remote control unit (FX High Output/FX Cruiser High Output)
9 Remote control unit antenna (FX High Output/FX Cruiser High Output) Less than 10 mm (0.39 in) Position the throttle cable and handlebar switch lead packing in the opening in the grommet so that the plastic tie fastened around both the grommet and the packing.
26
SPEC
3 2 1 2 3

B B C C
B B C C
A 5 4 B-B 6 3 9
A
A 2 5 4 C-C 1 3
D
D
8 7
Position the QSTS cable packing in the opening in the grommet so that the plastic tie is fastened around both the grommet and the packing. FX Cruiser/FX Cruiser High Output FX/FX High Output 37 mm (0.120.28 in)
27
SPEC
4 5 6
9 7 2
8 6
0 H 5 2
A C
1 A 2 8 G A-A
A
9 C D
F E
1 2 3 4 5 6 7 8 9 0 Cooling water hose (cooling water inlet) Bilge hose 1 Electric bilge pump Bilge hose 4 Cooling water hose (from thermostat) Bilge hose 3 Bilge hose 2 Shift cable Cooling water hose (from exhaust pipe) Electrical box
A B C D E F G H
QSTS cable Positive battery lead Speed sensor lead Electric bilge pump lead Bilge strainer Negative battery lead Steering cable Flushing hose
Pass the QSTS cable between the bilge hoses.

28
SPEC
9 0 A
8 7
A B C
1 2
5 4 A 3
0 B
1 A-A B 4 C
1 2 3 4 5 6 7 8 9 0
Wiring harness Ground lead Wiring harness coupler Noise filter Oil pressure switch coupler Pickup coil coupler Thermoswitch (engine) coupler Lighting coil coupler Thermoswitch (exhaust) Thermoswitch (exhaust) coupler
A Cam position sensor coupler B Oil pressure switch lead After connecting the coupler to the wiring harness, insert the projection on the coupler into the hole in the bracket. To oil pressure switch To cam position sensor To electrical box
29
Fasten the plastic tie with its end facing downward. To engine temperature sensor 812 mm (0.310.47 in) 1525 mm (0.590.98 in) 1520 mm (0.590.79 in)
SPEC
1 2
A
9 0
A-A
A
4 3
1 2 3 4 5 6 7 8 9 0
Engine temperature sensor coupler Lighting coil coupler Pickup coil coupler Thermoswitch (engine) coupler Thermoswitch (engine) Starter motor Engine temperature sensor Engine temperature sensor lead Thermoswitch (engine) lead Lighting coil lead
Fasten the engine temperature sensor lead, thermoswitch lead, and lighting coil lead with a plastic tie. Fasten the engine temperature sensor lead 1020 mm (0.40.8 in) from the end of the protective cover of the lead. To generator To engine temperature sensor To thermoswitch (engine) To thermoswitch (engine) coupler To engine temperature sensor coupler
30
SPEC
1 2
A
9 0
A-A
A
4 3
Route the starter motor lead to the outside of the engine temperature sensor lead. To starter relay To negative battery terminal Route the starter motor and negative battery leads behind the cooling water hose. Route the starter motor lead over the cooling water hose. Insert the projection on the plastic tie completely into the hole in the bracket.
FX High Output/FX Cruiser High Output FX/FX Cruiser
31
SPEC
CABLE AND HOSE ROUTING (For FX/FX Cruiser)
2 1 1
A
3 C-C
C D
A
E
B C
7 G 5 6
F 4 E-E
1 2 3 4 5 6 7
Thermostat Cooling water pilot outlet hose Cooling water hose Pressure control valve Cooling water hose (cooling water inlet) Negative battery lead Breather hose
To cooling water pilot outlet on starboard side To cooling water outlet on starboard side of stern To pressure control valve From exhaust manifold To install the hose, align the white paint mark on the cooling water hose with the projection of the hose joint.
32
SPEC
2 1 1
A
3 C-C
C D
A
E
B C
7 G 5 6
F 4 E-E
When installing the cooling water hoses, be sure to push them down until they contact the hose joint. Bundle the cooling water pilot outlet hose and cooling water hoses, pass a plastic tie through the stay hole, and then fasten the tie. Set the tie in the direction shown. To cooling water pilot outlet on port side To cooling water outlet at stern From cooling water inlet
33
To oil tank To exhaust pipe To install the cooling water hose, align the white paint mark on the hose with the parting line on the hose joint. Fasten the cooling water hose, negative battery lead, and breather hose with a plastic tie. Set the tie in the direction shown.
SPEC
2 1 1
A
3 C-C
C D
A
E
B C
7 G 5 6
F 4 E-E
Bundle the cooling water hose (cylinder head cover to thermostat) and cooling water hose (starboard cooling water pilot outlet), and then fasten them with a plastic tie to the oil tank boss. When bundling the hoses, make sure that the cooling water hose (cylinder head cover to thermostat) is routed on the deck side and that the cooling water hose (starboard cooling water pilot outlet) is routed on the engine side. Insert the cooling water hose to the paint mark.
34
Fasten the end of the cooling water hose tube that is contacting the hose joint with a plastic tie. Face the ends of the clamps downward. From cooling water passage
SPEC
2 8
8 A B
1 2 3 4 5 6 7 8
Intake air temperature sensor coupler Intake air pressure sensor coupler Fuel injector #4 coupler Fuel injector #3 coupler Fuel injector #2 coupler Fuel injector #1 coupler Throttle position sensor coupler Joint coupler
Route the throttle cable between the sub-wiring harness. Route the sub-wiring harness under the intake vacuum hose. To wiring harness To intake air temperature sensor coupler. To fuel injector #3 coupler Fasten the sub-wiring harness to the joint coupler bracket with a plastic tie as shown in the illustration.
35
SPEC
2 8
8 A B
Fasten the ring, which is attached to the subwiring harness, to the sensor bracket with a plastic tie. Face the end of the plastic tie towards the sensor. To bypass valve motor coupler.
36
SPEC
CABLE AND HOSE ROUTING (For FX High Output/ FX Cruiser High Output)
CABLE AND HOSE ROUTING (For FX High Output/FX Cruiser High Output)
1 1
A
3 C-C
C D B C E
4 5 G
F E-E
1 2 3 4 5
Thermostat Cooling water pilot outlet hose Cooling water hose Cooling water hose (cooling water inlet) Negative battery lead
To cooling water pilot outlet on starboard side To cooling water outlet on starboard side of stern To cylinder block From exhaust manifold To install the hose, align the white paint mark on the cooling water hose with the projection of the hose joint.
37
SPEC
1 1
A
3 C-C
C D B C E
4 5 G
F E-E
When installing the cooling water hoses, be sure to push them down until they contact the hose joint. Bundle the cooling water pilot outlet hose and cooling water hoses, pass a plastic tie through the stay hole, and then fasten the tie. Set the tie in the direction shown. To cooling water pilot outlet on port side To cooling water outlet at stern From cooling water inlet
38
To exhaust pipe To install the cooling water hose, align the white paint mark on the hose with the parting line on the hose joint. Fasten the cooling water hose and negative battery lead with a plastic tie. Set the tie in the direction shown.
SPEC
1 1
A
3 C-C
C D B C E
4 5 G
F E-E
Bundle the cooling water hose (cylinder head cover to thermostat) and cooling water hose (starboard cooling water pilot outlet), and then fasten them with a plastic tie to the oil tank boss. When bundling the hoses, make sure that the cooling water hose (cylinder head cover to thermostat) is routed on the deck side and that the cooling water hose (starboard cooling water pilot outlet) is routed on the engine side.
Insert the cooling water hose to the paint mark. Fasten the end of the cooling water hose tube that is contacting the hose joint with a plastic tie. From cooling water passage Face the ends of the clamps downward.
39
SPEC
3
A
8 3
2 A B
1 2 3 4 5 6 7 8
Bypass valve motor coupler Joint coupler Sensor assembly coupler Fuel injector #4 coupler Fuel injector #3 coupler Fuel injector #2 coupler Fuel injector #1 coupler Throttle position sensor coupler
To wiring harness Route the throttle cable between the sub-wiring harness. Route the sub-wiring harness under the intake vacuum hose. To fuel injector #3 coupler
Fasten the sub-wiring harness to the joint coupler bracket with a plastic tie as shown in the illustration. Fasten the ring, which is attached to the sub-wiring harness, to the sensor assembly bracket with a plastic tie. Face the end of the plastic tie towards the sensor assembly.
40
INSP ADJ

The following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the intervals of maintenance should be changed.
MAINTENANCE INTERVAL 10 hours ITEM Spark plug Lubrication points Intermediate housing Fuel system Fuel tank Trolling speed Throttle shaft Cooling water passages Water inlet strainer Bilge strainer Electric bilge pump strainer Impeller Jet thrust nozzle angle Steering master QSTS mechanism Shift cable and mechanism Throttle cable Stern drain plugs Battery Rubber coupling Engine mount Nuts and bolts Air filter Engine oil Engine oil filter Valve clearance Inspect, clean, adjust Lubricate Lubricate Inspect Inspect, clean Inspect, adjust Inspect Flush Inspect, clean Clean Inspect, clean Inspect Inspect, adjust Inspect Inspect, adjust Inspect, adjust Inspect, adjust Inspect, replace Inspect Inspect Inspect Inspect Inspect, replace Replace Replace Inspect, adjust INITIAL THEREAFTER EVERY 50 hours 100 hours 100 hours 200 hours 6 months 12 months 12 months 24 months
*1
*2
*2
*3
*1: Grease quantity: 33.035.0 cm3 (1.111.18 oz) *2: Grease quantity: 6.08.0 cm3 (0.200.27 oz) *3: After every use
41
INSP ADJ
CONTROL SYSTEM PERIODIC SERVICE

CONTROL SYSTEM
Steering master inspection 1. Inspect: Steering master Excessive play Replace the steering master. Refer to STEERING MASTER. Inspection steps: Move the handlebar up and down and back and forth. Check the excessive play of the handlebar.
3
Steering cable inspection and adjustment 1. Inspect: Jet thrust nozzle difference of distances a and b Out of specification Adjust. Difference of distances a and b: Maximum 5 mm (0.2 in) Inspection steps: Set the control grip in the neutral position. Turn the handlebar lock to lock. Measure distances a and b. If difference of distances a and b is not within specification, adjust the cable joint.
42
INSP ADJ
CONTROL SYSTEM
2. Adjust: Steering cable joint (steering master end)
Adjustment steps: Set the control grip in the neutral position. Loosen the locknut 1. Disconnect the cable joint 2 from the ball joint 3. Turn the cable joint 2 in or out for adjusting the distances a and b. Turn in Turn out Distance a is increased. Distance b is increased.
WARNING
The cable joint must be screwed in more than 8 mm (0.31 in). Connect the cable joint and tighten the locknut. Locknut: 6.4 N m (0.64 kgf m, 4.6 ft lb)
NOTE: If the steering cable cannot be properly adjusted by the cable joint at the steering master end, adjust the cable joint at the jet pump end so that the same clearances are obtained. Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD.
Throttle cable inspection and adjustment NOTE: Before adjusting the throttle lever free play, adjust the trolling speed. 1. Measure: Throttle lever free play a Out of specification Adjust. Throttle lever free play: 47 mm (0.160.28 in)
43
T.
INSP ADJ
CONTROL SYSTEM
2. Adjust: Throttle lever free play Adjustment steps:
NOTE: When not replacing the throttle cable or removing the cable from the throttle body, adjust the throttle cable free play by following steps (d) through (h). When replacing the throttle cable or removing the cable from the throttle body, adjust the throttle cable free play by following steps (a) through (i). a. Remove the air filter case cover 1 and ribbon sub assemblies. b. Loosen the locknut 2. c. Turn the adjusting nut 3 to adjust the length a, and then tighten the locknut. Throttle cable installation length: 23.9 1.0 mm (0.94 0.04 in) NOTE: Apply locking agent (LOCTITE) to the threads of the adjusting nut 3. d. Remove the handlebar cover. e. Loosen the locknut 4. f. Turn the adjuster 5 in or out until the specified free play is obtained. Turn in Turn out Free play is increased. Free play is decreased.
g. Tighten the locknut. NOTE: When adjusting the throttle cable at the throttle body, fully open the throttle lever and check that the butterfly valve is fully open. If the throttle cable free play cannot be adjusted properly, replace the throttle cable.
44
INSP ADJ
CONTROL SYSTEM/GENERAL
h. Install the handlebar cover.
Handlebar cover screw: 1.1 N m (0.11 kgf m, 0.8 ft lb) LOCTITE 242
i. Install the ribbon sub assemblies and air filter case cover. Ribbon sub assembly bolt: 6.5 N m (0.65 kgf m, 4.7 ft lb) LOCTITE 242 Air filter case cover screw: 2.5 N m (0.25 kgf m, 1.8 ft lb) LOCTITE 572
WARNING
After adjusting the free play, turn the handlebar to the right and left and make sure that the trolling speed does not increase.
GENERAL
Drain plug inspection 1. Inspect: Drain plugs Cracks/damage Replace. O-rings Cracks/wear Replace. Screw threads Contaminants Clean.
T.
R
T.
45
INSP ADJ
GENERAL
Lubrication points 1. Lubricate: Throttle cable (handlebar end) Recommended lubricant: Rust inhibitor
NOTE: Before lubricating the throttle cable, remove the throttle cable 1 from the throttle lever assembly.
2. Lubricate: Throttle cable (throttle body end) Throttle bodies (throttle cable pulley, throttle cam, and return spring) Recommended lubricant: Yamaha marine grease, Yamaha grease A (Water resistant grease)
3. Lubricate: QSTS control cables (handlebar end) Recommended lubricant: Yamaha marine grease, Yamaha grease A (Water resistant grease) NOTE: Before lubricating the QSTS control cables, remove the QSTS cable housing cover. Spray the rust inhibitor into the outer cables, and apply grease to the inner cables.
46
INSP ADJ
GENERAL
4. Lubricate: QSTS cables (pulley end) Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease)
5. Lubricate: Nozzle pivot shaft Steering cable (nozzle end) QSTS cable (nozzle end) Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease)
6. Lubricate: Steering cable Steering cable joint Shift cable Shift cable joint NOTE: Disconnect the joints and apply a small amount of grease. Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease)
47
INSP ADJ
1
GENERAL
7. Fill: Intermediate housing
Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) Grease quantity: Initial 10 hours: 33.035.0 cm3 (1.111.18 oz) Every 100 hours or 12 months: 6.08.0 cm3 (0.200.27 oz) NOTE: Fill the intermediate housing with the recommended grease through the grease nipple 1.
48
ELEC
ELECTRICAL COMPONENTS (For FX/FX Cruiser)
ELECTRICAL COMPONENTS (For FX/FX Cruiser)
N M L K J I H G F E D C B 5 A 0 9 8 6 2 3 4 1
1 2 3 4 5 6 7 8 9 0 A
Thermoswitch (engine) Starter motor Engine temperature sensor Spark plugs and ignition coils Electrical box Battery Speed sensor Electric bilge pump Cam position sensor Fuel injectors Thermoswitch (exhaust)
B C D E F G H
Oil pressure switch Bypass valve motor Intake air pressure sensor Intake air temperature sensor Throttle position sensor Lighting coil and pickup coil Engine stop switch, engine shut-off switch, and start switch I Steering sensor J Buzzer
K L M N
Electric fuel pump Fuel level sensor Left operation button Multifunction meter
49
ELEC
ELECTRICAL COMPONENTS (For FX High Output/ FX Cruiser High Output)
ELECTRICAL COMPONENTS (For FX High Output/FX Cruiser High Output)
O N M L K J I H G F E D C B
2 3 4
5 A 0 9 8 6
1 2 3 4 5 6 7
Thermoswitch (engine) Starter motor Engine temperature sensor Spark plugs and ignition coils Electrical box Battery Speed sensor and water temperature sensor (FX Cruiser High Output) Speed sensor (FX High Output)
8 9 0 A B C
Electric bilge pump Cam position sensor Fuel injectors Thermoswitch (exhaust) Oil pressure switch Sensor assembly (intake air pressure and intake air temperature sensor) D Bypass valve motor E Throttle position sensor F Lighting coil and pickup coil
G Engine stop switch, engine shut-off switch, and start switch H Steering sensor I Buzzer
50
ELEC
ELECTRICAL COMPONENTS (For FX High Output/ FX Cruiser High Output)
O N M L K J I H G F E D C B
2 3 4
5 A 0 9 8 6
J K L M N
Electric fuel pump Fuel level sensor Left operation button Multifunction meter Right operation button (FX Cruiser High Output) O Remote control unit P Compass sensor and air temperature sensor (FX Cruiser High Output)
51
ELEC

WIRING DIAGRAM
8 :O 12 : W/R 13 : W/B 16 : G/B 17 : G/Y
18 : G/R 20 : G 27 : W/L 30 : R/Y 34 : P
1
R P B/O B/O O P B/O R
B/O O R/Y R R/Y R/Y R/Y R/Y R/Y R/Y W/L B/O O W/L W/L O O O B O B W/L
B/O
P/G O Pu/Y Pu/G G/R G/Y B/Y B/O
R/Y Pu/B Pu/R
B/O B/O B/O
B/O W/R W/B
B/O
B/O B/O W/R W/B
G G/B G/B G Pu/R Pu/B R/Y P/G P
R/Y
G/Y G/R Pu/G Pu/Y O
B/O
B/O
W B
R/Y
B R/Y R/Y R W
3
G R/Y G/R G/Y R/Y G/B
R/Y G/Y G R/Y
G/R B/O P O
B/O
G/B
1 2 3 4 5
ECM Steering sensor Pickup coil Throttle position sensor Bypass valve motor
B G O P R W B/O G/B G/R
: Black : Green : Orange : Pink : Red : White : Black/orange : Green/black : Green/red

52
G/Y R/Y W/B W/L W/R
: Green/yellow : Red/yellow : White/black : White/blue : White/red
ELEC

STEERING SENSOR
1. Check: Steering sensor Malfunction Replace the steering sensor. Checking steps: Turn the handlebar all the way to the left or right, and then release it. Install a plastic tie 1 loosely around the center of the handlebar grip as shown. Hook a spring gauge 2 onto the plastic tie. Hold the spring gauge at a 90 angle from the handlebar, and then pull the spring gauge with a force of 10 kgf (22 lb). When handlebar pulled ON When handlebar not pulled OFF
Check that the following is displayed in the Engine Monitor window of the Yamaha Diagnostic System. Use the same procedure to check that the steering sensor operates correctly when the handlebar is turned to both the left and right. Replace the steering sensor if it is a malfunction.
53
ELEC
INDICATION SYSTEM
INDICATION SYSTEM
WIRING DIAGRAM (For FX Cruiser High Output)
L R
R/Y
1 2 3456 7 8 14 6 15 35 5 1 21 30 L/R P P P R R
R R/Y
R/Y
P/W
B P/W B W/B
R/Y R/Y W/B W/B R/Y
5
B/O G B/O G P P B/O B/O B B/O B/O
B B
6
P B
P/W
B
W/B B R/Y
0
P
4
L/R
P L/R L/B L/Y R G L/Y L/B L W B P B/G B/O B/O B/Y G B R B/O B/L L G R W B P B B/O B/O B/O B/O B/O B/Y R/Y Y Y B/Y P B B/Y B/Y B/Y L G R W B B/O B/O B
P B
B/G
15 18 16 7 6 Y L B/L L/R L/Y L/B L/R
L/R
E
R B R B/Y R/Y Y B B/Y R/Y B/Y
B/O B/O
A
B/O B/O B/O
B/O
C
1 2 3 4 5 6 7 8 9
B/O
ECM Main and fuel pump relay Fuse (20 A) Remote control unit Battery Tacho pulse Thermoswitch (exhaust) Thermoswitch (engine) Engine temperature sensor
54
0 A B C D E
Multifunction meter Fuel level sensor Speed sensor and water temperature sensor Buzzer Oil pressure switch Compass sensor and air temperature sensor
ELEC
INDICATION SYSTEM
WIRING DIAGRAM (For FX Cruiser High Output)
L R
R/Y
1 2 3456 7 8 14 6 15 35 5 1 21 30 L/R P P P R R
R R/Y
R/Y
P/W
B P/W B W/B
R/Y R/Y W/B W/B R/Y
5
B B
6
P B
P/W
B
W/B B R/Y
0
P
4
L/R
P L/R L/B L/Y R G L/Y L/B L W B P B/G B/O B/O B/Y G B R B/O B/L L G R W B P B B/O B/O B/O B/O B/O B/Y R/Y Y Y B/Y P B B/Y B/Y B/Y L G R W B B/O B/O B
P B
B/G
15 18 16 7 6 Y L B/L L/R L/Y L/B L/R
L/R
E
R B R B/Y R/Y Y B B/Y R/Y B/Y
B/O B/O
A
B/O B/O B/O
B/O
C
B G L O P R W Y B/G : Black : Green : Blue : Orange : Pink : Red : White : Yellow : Black/green
B/O
B/L B/O B/Y L/B L/R L/Y P/W R/Y W/B

55
: Black/blue : Black/orange : Black/yellow : Blue/black : Blue/red : Blue/yellow : Pink/white : Red/yellow : White/black
ELEC
INDICATION SYSTEM
WIRING DIAGRAM (For FX High Output)
L R
R/Y
1 2 3456 7 8 14 6 15 35 5 1 21 30 L/R P P P R R
R R/Y
R/Y
P/W
B P/W B W
R/Y R W/B W/B R/Y
5
B B
6
P B
P/W
B
W B R
0
P
4
L/R Gy
P L/R L/B Gy B/Y R/W R/W L/B B/Y P B/G B/O B/O L/Y L/R Y B/Y B/Y P R/Y B/L L/R L/R B/L B/Y R/Y Y P B B/O B/O B/O B/O R B R B B/O B/Y B B/O B/Y B/Y B/Y Y B/O B/O B
P B
B/G
15 18 16 7 6 Y L L/Y L/B
B/O B/O
A
B/O B/O B/O
B/O
C
1 2 3 4 5 6 7 8 9 ECM Main and fuel pump relay Fuse (20 A) Remote control unit Battery Tacho pulse Thermoswitch (exhaust) Thermoswitch (engine) Engine temperature sensor
56
B/O
0 A B C D
Multifunction meter Fuel level sensor Speed sensor Buzzer Oil pressure switch
ELEC
INDICATION SYSTEM
WIRING DIAGRAM (For FX High Output)
L R
R/Y
1 2 3456 7 8 14 6 15 35 5 1 21 30 L/R P P P R R
R R/Y
R/Y
P/W
B P/W B W
R/Y R W/B W/B R/Y
5
B B
6
P B
P/W
B
W B R
0
P
4
L/R Gy
P L/R L/B Gy B/Y R/W R/W L/B B/Y P B/G B/O B/O L/Y L/R Y B/Y B/Y P R/Y B/L L/R L/R B/L B/Y R/Y Y P B B/O B/O B/O B/O R B R B B/O B/Y B B/O B/Y B/Y B/Y Y B/O B/O B
P B
B/G
15 18 16 7 6 Y L L/Y L/B
B/O B/O
A
B/O B/O B/O
B/O
C
B G Gy L O P R W Y : Black : Green : Gray : Blue : Orange : Pink : Red : White : Yellow B/G B/L B/O B/Y L/B L/R L/Y P/W R/W : Black/green : Black/blue : Black/orange : Black/yellow : Blue/black : Blue/red : Blue/yellow : Pink/white : Red/white
57
B/O
R/Y : Red/yellow W/B : White/black
ELEC
INDICATION SYSTEM
WIRING DIAGRAM (For FX/FX Cruiser)
Br L/R
Y B R R P P O R/Y R/Y R R/Y R/Y R/Y R
L R/Y
4 3 2 1 8 7 6 5
R/Y
12 6 15 35 5 31 1 Y
56 P P P R R Y
R/Y
R/Y
P/W
B P/W B B P/W B B W R/Y R W/B W/B R/Y B B/O P B/O B/O B/O G B/O
B/O
5 6
G P P B B
W B R
P B/O B/O B
P B
B/Y L/B L/R R/W L/R L/B Y R/W
B/G B/O
B/O
B/Y B/Y B/Y B/Y
B/Y P B/G B/Y
B/O R B R/Y B R B/Y R/Y Y B/Y P B B/O B/O B/O P B B/O B/O B/O
B/O B/O
B/O B/O
1 ECM 2 Main and fuel pump relay 3 Fuse (20 A) 4 Fuse (3 A) 5 Battery 6 Tacho pulse 7 Thermoswitch (exhaust)
8 Thermoswitch (engine) 9 Engine temperature sensor 0 Multifunction meter A Fuel level sensor B Speed sensor C Buzzer D Oil pressure switch
58
B Br G O P R W Y B/G
: Black : Brown : Green : Orange : Pink : Red : White : Yellow : Black/green
B/O B/Y L/B L/R P/W R/W R/Y W/B
: Black/orange : Black/yellow : Blue/black : Blue/red : Pink/white : Red/white : Red/yellow : White/black
ELEC
INDICATION SYSTEM
MULTIFUNCTION METER
Multifunction meter 1. Check: Multifunction meter Cracked meter housing Replace the multifunction meter. Meter is fogged/shows signs of water intrusion Replace the multifunction meter. Operation button 1. Check: Left operation button continuity Out of specification Replace. Digital multimeter: YU-34899-A Digital circuit tester: 90890-03174 Left operation button continuity Button Speed/ RPM Volt/ Hour Position Free Push Free Push Leads Pu/W B G/W
Right operation button continuity (FX Cruiser High Output) Out of specification Replace. Digital multimeter: YU-34899-A Digital circuit tester: 90890-03174 Right operation button continuity Button Start/ Stop Mode/ Reset Position Free Push Free Push Leads R/W B Y/W
59
ELEC
INDICATION SYSTEM
Refer to COVER. STEERING
MULTIFUNCTION METER REMOVAL

CONSOLE
OPERATION BUTTON REMOVAL

Refer to COVER. STEERING CONSOLE
60
ELEC
INDICATION SYSTEM
E Display function (for FX Cruiser High Output) 1. Check: Display function Does not operate Replace the multifunction meter.
G/W Pu/W Pu/W B G/W B
R/W Y/W R/W B Y/W B
R/W Y/W R/W B Y/W B L/Y L/B B/L
L/Y L/B L/R L/R
B/L
B B R
2
R B
L/R
R
G
B R G W L R/Y W/B B
W/B R/Y
4
B B/G
P B/G
5
P
1 2 3 4 5 6 7
Remote control unit Buzzer Compass sensor ECM Fuel level sensor Left operation button Right operation button
B G L P R W B/G B/L G/W
: Black : Green : Blue : Pink : Red : White : Black/green : Black/blue : Green/white
L/B L/R L/Y Pu/W R/W R/Y W/B Y/W
: Blue/black : Blue/red : Blue/yellow : Purple/white : Red/white : Red/yellow : White/black : Yellow/white
61
ELEC
INDICATION SYSTEM
E Display function (for FX High Output) 1. Check: Display function Does not operate Replace the multifunction meter.

Gy L/B L/R L/R
L/Y L/B B/L
B/L
B B R
2
B/Y
L/R
R R/W
B/Y R/W Y Y W R W B B R
P B/G
B/G
5
P
1 2 3 4 5 6
Remote control unit Buzzer Speed sensor ECM Fuel level sensor Left operation button
B Gy P R W Y B/G B/L
: Black : Gray : Pink : Red : White : Yellow : Black/green : Black/blue
B/Y G/W L/B L/R L/Y Pu/W R/W
: Black/yellow : Green/white : Blue/black : Blue/red : Blue/yellow : Purple/white : Red/white
62
ELEC
INDICATION SYSTEM
E Display function (for FX/FX Cruiser) 1. Check: Display function Not operate Replace the multifunction meter.

L/B L/R L/R R L/B B B R
B/Y R/W Y
R/W
B/Y Y W
R W B
3
B
B/G B
B/G
4
B
1 2 3 4 5
Buzzer Speed sensor ECM Fuel level sensor Left operation button
B R W Y B/G B/Y
: Black : Red : White : Yellow : Black/green : Black/yellow
G/W L/B L/R Pu/W R/W
: Green/white : Blue/black : Blue/red : Purple/white : Red/white
63
ELEC
INDICATION SYSTEM
N
E Compass display (for FX Cruiser High Output) 1. Check: Compass display Incorrect reading Replace the compass sensor. Checking steps: Using a compass for reference, point the watercraft north. Turn on the multifunction meter and check that NORTH appears on the meter. If NORTH does not appear on the multifunction meter, replace the compass sensor. NOTE: Be sure to check the compass display again after replacing the compass sensor. If the compass display is still incorrect, replace the multifunction meter.
Air temperature display (for FX Cruiser High Output) 1. Check: Air temperature display Incorrect reading Replace the compass sensor. Checking steps: Measure the ambient air temperature. Turn on the multifunction meter and check the air temperature displayed on the meter. If the air temperature displayed on the multifunction meter is more than 5 C (9 F) different from the ambient air temperature, replace the compass sensor. NOTE: Be sure to check the air temperature display again after replacing the compass sensor. If the air temperature display is still incorrect, replace the multifunction meter.
64
ELEC
INDICATION SYSTEM
R G
E Speedometer/average speed/tripmeter display (for FX Cruiser High Output) 1. Check: Speedometer/average speed/tripmeter display Does not display Measure the speed sensor output voltage.
S N
N S
DC V
2. Measure: Speed sensor output voltage Out of specification Replace the speed sensor. Within specification Replace the multifunction meter. Digital multimeter: YU-34899-A Digital circuit tester: 90890-03174 Speed sensor output voltage (dependant on the paddle wheel position): Less than 400 mV/ More than 5 V Output pulse: 2 pulses/one-full turn Measuring steps: Disconnect the coupler between the multifunction meter and the compass sensor 1, and then connect it to a 12 V battery as shown in the illustration. Rotate the paddle wheel and check the output voltage and output pulses. NOTE: As the paddle wheel is rotated, a squarewave voltage signal a is produced. If within specification, replace the multifunction meter. If out of specification, replace the speed sensor 2. NOTE: Be sure to check the output voltage and output pulses again after replacing the speed sensor. If still out of specification, replace the compass sensor.
65
ELEC
INDICATION SYSTEM
E Water temperature display (for FX Cruiser High Output) 1. Check: Water temperature display Incorrect reading Measure the speed sensor (water temperature sensor) resistance. Checking steps: Measure the ambient water temperature. Turn on the multifunction meter and check the water temperature displayed on the meter. If the water temperature displayed on the multifunction meter is more than 5 C (9 F) different from the ambient water temperature, measure the speed sensor (water temperature sensor) resistance. 2. Measure: Speed sensor (water temperature sensor) resistance. Out of specification Replace the speed sensor. Within specification Replace the compass sensor. Digital multimeter: YU-34899-A Digital circuit tester: 90890-03174 Speed sensor (water temperature sensor) resistance: 10 k at 25 C (77 F) Measuring steps: Disconnect the coupler, and then measure the resistance between the yellow and black/yellow leads as shown in the illustration. If the speed sensor (water temperature sensor) resistance is within specification, replace the compass sensor. If out of specification, replace the speed sensor. NOTE: Be sure to check the water temperature display again after replacing the compass sensor. If the water temperature display is still incorrect, replace the multifunction meter.
S N
R/Y Y
N S
B/Y
66
ELEC
INDICATION SYSTEM
E Trip timer display (for FX Cruiser High Output) 1. Check: Trip timer display Does not display Replace the multifunction meter. Fuel consumption per hour, fuel consumption per kilometer/mile display (for FX Cruiser High Output) 1. Check: Fuel consumption per hour, fuel consumption per kilometer/mile display Does not display Check the fuel injection duration using the Engine monitor of the Yamaha Diagnostic System. Replace the multifunction meter.
Overheat warning indicator 1. Check: Overheat warning indicator Does not operate Replace the multifunction meter. Checking steps: Start the engine. Disconnect the thermoswitch (engine) coupler 1 (blue), engine temperature sensor coupler 2 (black) or thermoswitch (exhaust) 3 coupler. Connect the jumper lead to the female terminal of the disconnected coupler. Check that the multifunction meter overheat warning indicator comes on and the buzzer sounds.
67
ELEC
INDICATION SYSTEM
E Check engine warning indicator 1. Check: Check the engine warning indicator Does not operate Replace the multifunction meter. Checking steps: Start the engine. Disconnect the coupler of a sensor (e.g., engine temperature sensor) that normally activates the check engine warning indicator when a malfunction occurs. Check that the warning light and check engine warning indicator blink and that the buzzer sounds intermittently.
Diagnostic display 1. Check: Diagnostic display Does not display Replace the multifunction meter. Checking steps: Start the engine. Disconnect the coupler of a sensor (e.g,. engine temperature sensor) that is normally displayed when a malfunction occurs. Refer to SELF-DIAGNOSIS. Check that the check engine warning indicator is displayed and that the buzzer sounds. Simultaneously press the two buttons 1 for 8 seconds and check the error code indicated on the multifunction meter.
68
ELEC
REMOTE CONTROL SYSTEM (For FX High Output/ FX Cruiser High Output)
REMOTE CONTROL SYSTEM (For FX High Output/FX Cruiser High Output)

WIRING DIAGRAM
Y L/R L B R
1
R R/Y R/Y R/Y R/Y O R/Y R/Y R P P R
14 : L 15 : W/B 21 : L/R 30 : R/Y 31 : Y
37 : Pu/G 38 : Pu/Y 39 : Pu/B 40 : Pu/R
12 3 456 7 8 31 14 21 30 15 R/Y R/Y R/Y Y R R
L/R
L Y
3
R B B R
B
Br
B B B B B B B
4
Br
W/B( ) W
W/B W/B
R
R/Y
R/Y R/Y
W/B( ) W
5 9
B
R/Y R/Y
0
#1
Pu/R
Pu/R R/Y
6
L/Y( ) Gy
R/Y
0
#2
Pu/B
Pu/B R/Y
L/Y( ) L/B Gy L/R L/R
W R/Y L/B
Pu/Y R/Y
16 7 6 11 15 14 18 12 3 4 13 10 W
0
#3
Pu/Y L/Y R L/R

Pu/G R/Y
A
W
L/R
123456789 0ABCDEFGH
R/Y
0
#4
Pu/G
B R
L/R B/L B B/L
L/Y L/B
R/Y
1 2 3 4 5 6 7 8 9
ECM Main and fuel pump relay Fuse (20 A) Starter relay Starter motor Battery Fuse (3 A) Remote control unit Multifunction meter
69
0 Fuel injector A Antenna B Buzzer
ELEC
WIRING DIAGRAM
Y L/R L B R
1
R R/Y R/Y R/Y R/Y O R/Y R/Y R P P R
14 : L 15 : W/B 21 : L/R 30 : R/Y 31 : Y
37 : Pu/G 38 : Pu/Y 39 : Pu/B 40 : Pu/R
12 3 456 7 8 31 14 21 30 15 R/Y R/Y R/Y Y R R
L/R
L Y
3
R B B R
B
Br
B B B B B B B
4
Br
W/B( ) W
W/B W/B
R
R/Y
R/Y R/Y
W/B( ) W
5 9
B
R/Y R/Y
0
#1
Pu/R
Pu/R R/Y
6
L/Y( ) Gy
R/Y
0
#2
Pu/B
Pu/B R/Y
L/Y( ) L/B Gy L/R L/R
W R/Y L/B
Pu/Y R/Y
16 7 6 11 15 14 18 12 3 4 13 10 W
0
#3
Pu/Y L/Y R L/R

Pu/G R/Y
A
W
L/R
123456789 0ABCDEFGH
R/Y
0
#4
Pu/G
B R
L/R B/L B B/L
L/Y L/B
R/Y
B Br Gy L R W Y
: Black : Brown : Gray : Blue : Red : White : Yellow
B/L L/B L/R L/Y Pu/B Pu/G Pu/R
: Black/blue : Blue/black : Blue/red : Blue/yellow : Purple/black : Purple/green : Purple/red
Pu/Y : Purple/yellow R/Y : Red/yellow W/B : White/black * : FX Cruiser High Output
70
ELEC

Yamaha Security System indicator 1. Check: Yamaha Security System indicator Check that the SECURITY indicator light 1 comes on when the Yamaha Security System is deactivated (i.e., the engine can be started). Does not come on Measure the remote control unit output voltage. 2. Measure: Remote control unit output voltage Within specification Replace the multifunction meter. Out of specification Replace the remote control unit. Digital multimeter: YU-34899-A Digital circuit tester: 90890-03174
Remote control unit output voltage: Blue/yellow (L/Y) ground 1113 V Measurement steps: Disconnect the remote control unit 1 coupler from the multifunction meter. Measure the remote control unit output voltage while pushing the unlock button of the remote control transmitter.
L/Y
71
ELEC
Low-rpm mode indicator 1. Check: Low-rpm mode indicator Does not come on Replace the multifunction meter. Checking steps: Press the unlock button 1 of remote control transmitter for more than four seconds to select the low-rpm mode. Check that the beeper sounds three times and the L-MODE indicator light 2 comes on.
72
HULL HOOD
HANDLEBAR
HANDLEBAR
EXPLODED DIAGRAM (For FX/FX High Output)

Step 1 2 3 4 5 Procedure/Part name STEERING PAD REMOVAL Screw Handlebar cover Pad Bolt Handlebar cover stay Qty 4 1 1 2 1 Reverse the removal steps for installation. Service points Follow the left Step for removal.
73
HULL HOOD
HANDLEBAR
EXPLODED DIAGRAM (For FX Cruiser/FX Cruiser High Output)

Step 1 2 3 4 Procedure/Part name STEERING PAD REMOVAL Screw Screw (black) Lower handlebar cover Upper handlebar cover Qty 8 2 1 1 Service points Follow the left Step for removal.
NOTE: Be sure to insert the projection on the upper handlebar cover completely into the grommet.
5 6 7
Bolt Steering pad Grommet
4 1 1 Reverse the removal steps for installation.

74
HULL HOOD
HANDLEBAR
EXPLODED DIAGRAM

Step Procedure/Part name HANDLEBAR HOLDER REMOVAL Throttle cable Qty Service points Follow the left Step for removal. NOTE: Be sure to remove the throttle cable seal as shown in the illustration.
2 3
Bolt Upper handlebar holder
4 2 Reverse the removal steps for installation.
75
HULL HOOD
HANDLEBAR
EXPLODED DIAGRAM

Step Procedure/Part name HANDLEBAR REMOVAL QSTS cable (to jet thrust nozzle) Nut/washer QSTS converter QSTS cable 2 QSTS cable 1 Handlebar switch coupler Qty Service points Follow the left Step for removal. Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD.
1 2 3 4 5
2/2 1 1 1 2
With white tape a NOTE: Route the QSTS cables through the starboard side in the steering console. Route the handlebar switch lead, and throttle cable through the port side in the steering console.
76
HULL HOOD
HANDLEBAR
EXPLODED DIAGRAM
Step 6 7 8 9 10
Procedure/Part name Screw Handle boss cover Plastic tie Hose packing Throttle cable
Qty Service points 4 1 2 1 Not reusable NOTE: 1 Position the corrugated tube for the throttle cable as shown in the illustration so that the tube attaches to the end of the outer throttle cable.
77
HULL HOOD
HANDLEBAR
EXPLODED DIAGRAM
Step Procedure/Part name 11 Handlebar assembly 12 Handlebar switch lead 13 Grommet
Qty Service points NOTE: 1 Pass the QSTS cable and handlebar switch 1 lead through the handle boss cover, and 2 then install the handlebar assembly. Install the sponges of the QSTS cables as shown and make sure that the grommet is installed to the deck securely. Reverse the removal steps for installation.
78
HULL HOOD
HANDLEBAR
SERVICE POINTS
Handlebar assembly installation 1. Install: Plastic ties 1 QSTS cables 2 Handlebar switch lead 3 Throttle cable 4
4 2
NOTE: After inserting the QSTS cables, handlebar switch lead and throttle cable into the grommets, tie the end of grommets with the plastic ties.
4 2 1
FX/FX High Output FX Cruiser/FX Cruiser High Output
2. Install: Upper handlebar holder 1 NOTE: Align the punch marks a on the handlebar with the top surface of the handlebar holder. The upper handlebar holder should be installed with the punch mark b facing forward.
CAUTION:
Clearance c should be narrower than clearance d. Handlebar holder bolt: 20 N m (2.0 kgf m, 14 ft lb) LOCTITE 242 Reference clearance: c: 1.5 mm (0.06 in) d: 3.5 mm (0.14 in)
T.
79
HULL HOOD
HANDLEBAR
3. Connect: Throttle cable
3 4
2 1 a
Installing steps (for FX/FX High Output): Route the throttle cable 1 over the handlebar 2, and then install the throttle cable end into the throttle lever. Make sure that the throttle cable, QSTS cable 3, and handlebar switch lead 4 pass through the opening a in the center of the steering boss cover. Reroute the cables and lead if they are not routed correctly. Make sure that there is slack in the throttle cable, QSTS cable, and handlebar switch lead when the handlebar is turned to the left and right. Reroute the cables and lead if there is no slack. Installing steps (for FX Cruiser/FX Cruiser High Output): Route the throttle cable 1 under the handlebar 2, and then install the throttle cable end into the throttle lever. Make sure that the throttle cable, QSTS cable 3, and handlebar switch lead 4 pass through the opening a in the center of the steering boss cover. Reroute the cables and lead if they are not routed correctly. Make sure that there is slack in the throttle cable, QSTS cable, and handlebar switch lead when the handlebar is turned to the left and right. Reroute the cables and lead if there is no slack.
3 4
2 1 a
80
HULL HOOD
HANDLEBAR
4. Install: Throttle cable seal
Installing steps: Install the throttle cable end into the throttle lever. Fit the seal 1 into the groove in the bracket as shown. Pull the throttle cable 2 in the direction of the arrow shown in the illustration, and then fit the end of the seal 3 around inner cable. Turn the adjuster 4 in/out until the specified free play is obtained. Throttle lever free play a: 47mm (0.160.28 in)
2 3
Turn in Turn out
Free play is increased. Free play is decreased.
Tighten the lock nut 5.
81
HULL HOOD
STEERING MASTER
STEERING MASTER
EXPLODED DIAGRAM
8 6 9
8
8 35 mm
2 5 7
20 N m (2.0 kgf m, 14 ft Ib)
6 4
LT
6 60 mm
271
8 30 mm

Step Procedure/Part name STEERING MASTER REMOVAL Mirror assembly Center cover assembly Steering cable end Bolt Steering arm assembly Ball joint Nut Bolt/washer/nut Cable stopper assembly Qty Service points Follow the left Step for removal. Refer to MIRROR. Refer to STEERING CONSOLE COVER. Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD.
1 2 3 4 5 6
1 1 1 1 1/1/1 1
82
HULL HOOD
STEERING MASTER
EXPLODED DIAGRAM
8 6 9
8
8 35 mm
2 5 7
20 N m (2.0 kgf m, 14 ft Ib)
6 4
LT
6 60 mm
271
8 30 mm
Step Procedure/Part name 7 Nut/washer 8 Steering master assembly 9 Bolt
Qty 4/4 1 4
Service points
83
HULL HOOD
STEERING MASTER
EXPLODED DIAGRAM
8 30 mm
7
LT
8 11 11
572
6 1
A A
11 13
9 3 16
5 16 mm
10
A
LT
572
18 11 14
A
21 19 20 4
A
21 17
15 11
22
11 12 11 11
6 25 mm
8 30 mm
LT
271
FW

Step Procedure/Part name STEERING MASTER DISASSEMBLY Steering shaft Steering shaft Bushing Bushing Buzzer Bolt Bracket 1 Steering sensor Qty Service points Follow the left Step for disassembly. FX Cruiser/FX Cruiser High Output FX/FX High Output
1 2 3 4 5 6 7 8
1 1 1 1 1 4 1 1
84
HULL HOOD
STEERING MASTER
EXPLODED DIAGRAM
8 30 mm
7
LT
8 11 11
572
6 1
A A
11 13
9 3 16
5 16 mm
10
A
LT
572
18 11 14
A
21 19 20 4
A
21 17
15 11
22
11 12 11 11
6 25 mm
8 30 mm
LT
271
FW
Step 9 10 11 12 13 14 15 16 17 18
Procedure/Part name Bolt Bracket 2 Bolt/nut Left housing Spring holder Spring 1 Lever Lock Spring 2 Right housing
Qty 1 1 5/5 1 1 1 1 1 1 1
Service points
85
HULL HOOD
STEERING MASTER
EXPLODED DIAGRAM
8 30 mm
7
LT
8 11 11
572
6 1
A A
11 13
9 3 16
5 16 mm
10
A
LT
572
18 11 14
A
21 19 20 4
A
21 17
15 11
22
11 12 11 11
6 25 mm
8 30 mm
LT
271
FW
Step 19 20 21 22
Procedure/Part name Steering tube Rubber seal Bushing Steering master assembly
Qty 1 1 2 1
Service points
86
HULL HOOD
STEERING MASTER
SERVICE POINTS
Steering master components inspection 1. Inspect: Each component part Damage/wear Replace.
Rubber seal installation 1. Apply: Instant adhesive (onto the mating surfaces of the rubber seal 1 and steering master assembly 2) NOTE: After assembling the steering master assembly 2, apply instant adhesive onto the mating surfaces of the rubber seal 1 and steering master assembly 2 in the area a shown in the illustration.
FWD
87
HULL HOOD

EXPLODED DIAGRAM

Step Procedure/Part name REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL Service lid 1 Front seat assembly Steering cable end Nut Steering cable Seal Speed sensor coupler Nut Qty Service points Follow the left Step for removal.
Refer to FRONT HOOD. Refer to SEATS AND HAND GRIP. 1 1 1 1 1 1
1 2 3 4 5 6
88
HULL HOOD
EXPLODED DIAGRAM
Step Procedure/Part name 7 Cap 8 Screw 9 Speed sensor Speed sensor and water temperature sensor 10 Shift cable end 11 Plastic tie 12 Grommet 13 Nut 14 Shift cable holder 15 Nut 16 Bolt
Qty Service points 1 4 1 FX/FX Cruiser/FX High Output 1 FX Cruiser High Output 1 1 1 2 2 2 1
89
HULL HOOD
EXPLODED DIAGRAM
Step 17 18 19 20 21 22 23 24 25 26
Procedure/Part name Shift cable bracket Nut Shift cable Seal Nut Pin QSTS cable end Nut QSTS cable Packing
Qty 1 1 1 1 1 1 1 1 1 1
Service points
90
HULL HOOD

SERVICE POINTS
Steering cable removal 1. Remove: Steering cable
2 1
2 1
Removal steps: Rotate the steering stopper plate 1 on the steering stopper clockwise and remove it from the steering stopper plate 2. Rotate the steering stopper plate 2 counterclockwise. Remove the steering cable 3 from the steering stopper 4. Disconnect the cable joint 5 to the ball joint 6.
4 3
91
HULL HOOD

SERVICE POINTS
Steering cable installation 1. Install: Steering cable
4 3
Installing steps: Connect the cable joint 1 to the ball joint 2. Insert the projection 3 on the steering cable completely into the indentation 4 in the steering stopper. Slightly lift up the steering stopper plate 5 on the steering stopper, and then rotate it clockwise. Rotate the steering stopper plate 6 on the steering stopper counterclockwise, making sure to fit the hole in the stopper plate 6 onto the projection 7 on the other steering stopper plate 5.
5 6
7 5 6
92
HULL HOOD
FRONT HOOD
FRONT HOOD
EXPLODED DIAGRAM
LT
242
6 7
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 18 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 18 mm
8
LT
4
LT
242
242
9 3
5
6 30 mm 5.4 N m (0.54 kgf m, 3.9 ft Ib)
10
11 1
6.4 N m (0.64 kgf m, 4.6 ft Ib)

Step 1 2 3 4 5 6 7 8 9 Procedure/Part name FRONT HOOD REMOVAL Nut/washer Front hood assembly Bolt Bolt Hinge assembly Bolt Hood lock assembly Rivet Service lid 1 Qty 4/4 1 4 2 1 2 1 4 1 Service points Follow the left Step for removal.
93
HULL HOOD
FRONT HOOD
EXPLODED DIAGRAM
LT
242
6 7
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 18 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 18 mm
8
LT
4
LT
242
242
9 3
5
6 30 mm 5.4 N m (0.54 kgf m, 3.9 ft Ib)
10
11 1
6.4 N m (0.64 kgf m, 4.6 ft Ib)
Step Procedure/Part name 10 Rivet 11 Service lid 2
Qty 4 1
Service points
94
HULL HOOD
2
FRONT HOOD
SERVICE POINTS
1
Rivet Installation 1. Install: Rivets
Installing steps: Insert a rivet completely in the holes in both the service lid 1 and inner hull. Push in the rivet pin 2 until it clicks and is flush with the top of the rivet. NOTE: To remove a rivet, push the rivet pin in until it clicks and is below the top of the rivet. Before reinstalling a rivet, hold the rivet flange a with both hands and push the rivet pin perpendicularly against a hard flat surface until the pin protrudes from the top of the rivet.
95
HULL HOOD
FRONT HOOD
EXPLODED DIAGRAM
9
1.1 N m (0.11 kgf m, 0.8 ft Ib) 5 17 mm
10 9 10
1.1 N m (0.11 kgf m, 0.8 ft Ib) 5 17 mm
11 9 10
2.2 N m (0.22 kgf m, 1.6 ft Ib) 5 16 mm
12 9 10 7 3 8 12
12 8
6 12 1
5 4
1 1 1
2.2 N m (0.22 kgf m, 1.6 ft Ib) 5 16 mm

Step 1 2 3 4 5 6 7 8 9 Procedure/Part name FRONT HOOD DISASSEMBLY Screw Front hood 1 Front hood 2 Nut Center ornament Left ornament Right ornament Double-sided tape Bolt Qty 8 1 1 4 1 1 1 2 6 Service points Follow the left Step for disassembly.
NOTE: Be careful not to scratch the ornaments. Install the center ornament after installing the left and right ornaments. Not reusable
96
HULL HOOD
FRONT HOOD
EXPLODED DIAGRAM
9
1.1 N m (0.11 kgf m, 0.8 ft Ib) 5 17 mm
10 9 10
1.1 N m (0.11 kgf m, 0.8 ft Ib) 5 17 mm
11 9 10
2.2 N m (0.22 kgf m, 1.6 ft Ib) 5 16 mm
12 9 10 7 3 8 12
12 8
6 12 1
5 4
1 1 1
2.2 N m (0.22 kgf m, 1.6 ft Ib) 5 16 mm
Step Procedure/Part name 10 Bushing 11 Visor 12 Nut
Qty Service points 6 1 NOTE: 6 Apply soapy water to the nuts to make their installation easier. Reverse the disassembly steps for assembly.
97
HULL HOOD
FRONT HOOD
SERVICE POINTS
Ornament disassembly 1. Disassembly: Center ornament Left ornament Right ornament
3 1
Removal steps: From the bottom side of the front hood 1, push the projections 2 on the center ornament shown in the illustration and remove the ornament from the doublesided tape. From the bottom side of the front hood 1, push the projections 3 on the left ornament shown in the illustration and remove the ornament from the doublesided tape. Remove the right ornament in the same way as the left ornament. NOTE: When removing the ornaments, be sure to remove the center ornament first. Be careful not to break the front hood projections and ornament projections when removing the ornaments.
1 2 3
Front hood assembly 1. Install: Front hood 1 Front hood 2 NOTE: Fit the end of the front hood 1 under the projection 3 on the front hood 2.
98
HULL HOOD
2
FRONT HOOD
1
Visor installation 1. Install: Visor
Installing steps: Install the bushings 1 onto the screws 2 as shown in the illustration. Install the visor and tighten the screws, making sure to hold the nuts so that they do not turn. Screw: 1.1 N m (0.11 kgf m, 0.8 ft lb)
Double-sided tape installation 1. Install: Double-sided tape 1
T.
NOTE: Before affixing the double-sided tape 1, be sure to clean the areas on the front hood where the tape will be affixed to remove any dirt.
99
HULL HOOD
FRONT HOOD
Ornament installation 1. Install: Left ornament Right ornament Center ornament
Installing steps: Peel off the backing of the double-sided tape 1 on the watercraft. Install the left and right ornaments from the sides as shown in the illustration. Install the center ornament from above as shown in the illustration. NOTE: Be sure to install the left and right ornaments before installing the center ornament. The left and right ornaments cannot be installed if the center ornament is installed first.
100
HULL HOOD
MIRROR
MIRROR
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 23 mm 6 22 mm
3 6
LT
242
5 2 1
4
LT
242
6 23 mm 5.4 N m (0.54 kgf m, 3.9 ft Ib)

Step 1 2 3 4 5 6 Procedure/Part name MIRROR REMOVAL Nut Washer Bolt Bolt Left mirror assembly Right mirror assembly Qty 2 2 2 4 1 1 Reverse the removal steps for installation. Service points Follow the left Step for removal.
101
HULL HOOD
MIRROR
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib) 5 15 mm
8 3
9 2 5
1 1 6
3.7 N m (0.37 kgf m, 2.7 ft Ib) 5 15 mm
1 1
3.7 N m (0.37 kgf m, 2.7 ft Ib) 5 15 mm

Step 1 2 3 4 5 6 7 8 9 Procedure/Part name MIRROR DISASSEMBLY Screw Left mirror upper cover Screw Left mirror Nut Left mirror lower cover Right mirror upper cover Right mirror Right mirror lower cover Qty 12 1 8 1 2 1 1 1 1 Reverse the disassembly steps for assembly.
102
Service points Follow the left Step for disassembly.
HULL HOOD

EXPLODED DIAGRAM
14
2.2 N m (0.22 kgf m, 1.6 ft Ib) 5 15 mm
15
3 8 6 4 6 3 3
7 5 13 5
5 12
12 11 11 9 1 10
2
3.7 N m (0.37 kgf m, 2.7 ft Ib) 5 12 mm

Step Procedure/Part name METER AND METER COVER REMOVAL Handlebar assembly Service lid 1 Band Multifunction meter coupler Screw Multifunction meter cover Qty Service points Follow the left Step for removal. Refer to HANDLEBAR. Refer to FRONT HOOD. 1 4 4 1
1 2 3 4
103
HULL HOOD
EXPLODED DIAGRAM
14
2.2 N m (0.22 kgf m, 1.6 ft Ib) 5 15 mm
15
3 8 6 4 6 3 3
7 5 13 5
5 12
12 11 11 9 1 10
2
3.7 N m (0.37 kgf m, 2.7 ft Ib) 5 12 mm
Step 5 6 7 8 9 10 11 12 13 14 15
Procedure/Part name Left operation button coupler Right operation button coupler Left operation button Right operation button Bolt Washer Band Grommet Multifunction meter Cover Multifunction meter
Qty Service points 1 1 FX Cruiser High Output 1 1 FX Cruiser High Output 4 4 1 1 1 FX Cruiser High Output 1 FX/FX Cruiser/FX High Output 1 FX/FX Cruiser/FX High Output Reverse the removal steps for installation.
104
HULL HOOD
EXPLODED DIAGRAM
11
6 23 mm
LT
6 3
LT
6 1
242
242
7 3 9 6 10 10
LT
LT
3 1
242
5
242
6 8 6
6 22 mm
5 2 2
LT
6 22 mm
242
1
6 23 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)

Step 1 2 3 4 5 6 7 8 9 Procedure/Part name SIDE COVER REMOVAL Bolt Nut/washer Bolt Left side cover Left inner side pad Nut Screw Left side ornament Right side cover Qty 2 2/2 8 1 2 6 4 1 1 Service points Follow the left Step for removal.
105
HULL HOOD
EXPLODED DIAGRAM
11
6 23 mm
LT
6 3
LT
6 1
242
242
7 3 9 6 10 10
LT
LT
3 1
242
5
242
6 8 6
6 22 mm
5 2 2
LT
6 22 mm
242
1
6 23 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)

Step Procedure/Part name 10 Right inner side pad 11 Right side ornament Qty 2 1 Service points
106
HULL HOOD
EXPLODED DIAGRAM
6 22 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)
3 3
11 9
5 24 mm
10 6
6 30 mm
12
FW
8
5.4 N m (0.54 kgf m, 3.9 ft Ib)

Step 1 2 3 4 Procedure/Part name CENTER COVER REMOVAL Nut/washer Bolt Nut/washer Center cover assembly Qty 2/2 2 2/2 1 Service points Follow the left Step for removal.
NOTE: To remove the center cover assembly easily, pull the tilt lever up.
5 6 7 8
Nut/washer Bolt Hood lock Nut/washer
2/2 2 1 2/2
FX Cruiser High Output
107
HULL HOOD
EXPLODED DIAGRAM
6 22 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)
3 3
11 9
5 24 mm
10 6
6 30 mm
12
FW
8
5.4 N m (0.54 kgf m, 3.9 ft Ib)
Step Procedure/Part name 9 Screw 10 Compass sensor and air temperature sensor 11 Case cap 12 Inner pad
Qty Service points 2 FX Cruiser High Output 1 FX Cruiser High Output 1 1 Reverse the removal steps for installation.
108
HULL HOOD
EXPLODED DIAGRAM
7 6 5 4 6 7 10
11
2 1 3 1 2

Step 1 2 3 4 5 6 7 8 9 Procedure/Part name CENTER COVER DISASSEMBLY Damper Nut Grommet Damper Damper Hinge assembly Gear assembly Lid Lid lock Qty 2 4 4 6 1 2 2 1 1 Service points Follow the left Step for disassembly.
109
HULL HOOD
EXPLODED DIAGRAM
7 6 5 4 6 7 10
11
2 1 3 1 2
Step Procedure/Part name 10 Plug 11 Center cover
Qty 1 1
Service points
110
HULL HOOD
SHIFT LEVER
SHIFT LEVER
EXPLODED DIAGRAM
6 30 mm
2
5.4 N m (0.54 kgf m, 3.9 ft Ib) 6 30 mm
A
1 1
2 1
5.4 N m (0.54 kgf m, 3.9 ft Ib)

Step Procedure/Part name SHIFT LEVER REMOVAL Front hood assembly Mirror assembly Right side cover Shift cable Nut/washer Bolt Shift lever assembly Qty Service points Follow the left Step for removal. Refer to FRONT HOOD. Refer to MIRROR. Refer to STEERING CONSOLE COVER. Disconnect.
1 2 3
3/3 3 1 Reverse the removal steps for installation.
111
HULL HOOD
SEATS AND HAND GRIP
SEATS AND HAND GRIP

EXPLODED DIAGRAM
4 1 3 6 5 6 12 13 14
9
LT
271
5
LT
6.4 N m (0.64 kgf m, 4.6 ft Ib) 6 40 mm 8 30 mm
8 30 mm
271
6 25 mm
24
26
16 17 11 15 10 20
7 19
22
20
23
26 N m (2.6 kgf m, 19 ft Ib)
21 8 18
5.4 N m (0.54 kgf m, 3.9 ft Ib) 18 N m (1.8 kgf m, 13 ft Ib)
25
15 N m (1.5 kgf m, 11 ft Ib)

Step Procedure/Part name SEATS AND HAND GRIP REMOVAL Rear seat assembly Rear seat assembly Front seat assembly Front seat assembly Bolt Seat lock assembly Seat storage compartment Nut/washer Bolt/washer Deck beam Qty Service points Follow the left Step for removal. FX/FX High Output FX Cruiser/FX Cruiser High Output FX/FX High Output FX Cruiser/FX Cruiser High Output
1 2 3 4 5 6 7 8 9 10
1 1 1 1 4 2 1 4/4 4/4 1
112
HULL HOOD
SEATS AND HAND GRIP
EXPLODED DIAGRAM
4 1 3 6 5 6 12 13 14
9
LT
271
5
LT
6.4 N m (0.64 kgf m, 4.6 ft Ib) 6 40 mm 8 30 mm
8 30 mm
271
6 25 mm
24
26
16 17 11 15 10 20
7 19
22
20
23
26 N m (2.6 kgf m, 19 ft Ib)
21 8 18
25
15 N m (1.5 kgf m, 11 ft Ib)
Step 11 12 13 14 15 16 17 18 19 20
Procedure/Part name Nut Projection Washer Seal Nut Bolt Rear seat stay Nut Projection Washer
Qty 1 1 1 1 4 4 2 1 1 2
Service points
113
HULL HOOD
SEATS AND HAND GRIP
EXPLODED DIAGRAM
4 1 3 6 5 6 12 13 14
9
LT
271
5
LT
6.4 N m (0.64 kgf m, 4.6 ft Ib) 6 40 mm 8 30 mm
8 30 mm
271
6 25 mm
24
26
16 17 11 15 10 20
7 19
22
20
23
26 N m (2.6 kgf m, 19 ft Ib)
21 8 18
25
15 N m (1.5 kgf m, 11 ft Ib)
Step 21 22 23 24 25 26
Procedure/Part name Nut/washer Bolt Hand grip Hand grip Nut/washer Seat holder
Qty Service points 4/4 4 1 FX/FX High Output 1 FX Cruiser/FX Cruiser High Output 2/1 1 Reverse the removal steps for installation.
114
HULL HOOD
REBOARDING STEP (For FX Cruiser/FX Cruiser High Output)

EXPLODED DIAGRAM
2 1
15 N m (1.5 kgf m, 11 ft Ib) 8 42 mm
LT
271
15 N m (1.5 kgf m, 11 ft Ib) 8 42 mm

Step 1 2 Procedure/Part name REBOARDING STEP REMOVAL Bolt Reboarding step Qty 6 1 Reverse the removal steps for installation. Service points Follow the left Step for removal.
115
HULL HOOD
1

1
SERVICE POINTS
Reboarding step installation 1. Install: Reboarding step Installing steps: Fasten the brackets on both sides of the reboarding step in the down position with a plastic tie 1 as shown in the illustrations so that they will not return to the up position. Finger tighten all of the bolts, and then tighten them to specification. Bolt: 15 N m (1.5 kgf m, 11 ft lb)
T.
116
HULL HOOD
DECK AND HULL
DECK AND HULL

EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib) 13 N m (1.3 kgf m, 9.4 ft Ib) 6 20 mm
2.4 N m (0.24 kgf m, 1.7 ft Ib) 6 25 mm
22 23 23 23 24 16
16
18
16
15 N m (1.5
16 N m (1.6 kgf m, 12 ft Ib) 8 40 mm kgf m, 11 ft Ib)
21 20
LT
5 3
572
19
17 2 8 12 13
5.4 N m (0.54 kgf m, 3.9 ft Ib) 2.0 N m (0.2 kgf m, 1.4 ft Ib) 5 25 mm
11 10 9
15 13
14
LT
271
15 N m (1.5 kgf m, 11 ft Ib)

Step 1 2 3 4 5 6 7 8 9 10 Procedure/Part name DECK AND HULL DISASSEMBLY Nut Spout Nut Cleat Plate Bolt/collar Sponson Nut/washer Screw Drain plug Qty 1 1 2 1 2 10/10 2 4/4 4 2 Service points Follow the left Step for disassembly.
117
HULL HOOD
DECK AND HULL
EXPLODED DIAGRAM
2.4 N m (0.24 kgf m, 1.7 ft Ib) 6 25 mm
22 23 23 23 24 16
16
18
16
15 N m (1.5
21 20
LT
5 3
572
19
17 2 8 12 13
11 10 9
15 13
14
LT
271
15 N m (1.5 kgf m, 11 ft Ib)
Step 11 Seal 12 Nut
Procedure/Part name
Qty Service points 2 NOTE: 4 To remove the cleat, remove the exhaust system first. 4 2 2 7/7 1 1 1
13 14 15 16 17 18 19
Plate Cleat Seal Nut/washer Front protector 1 Front protector 2 Front protector 3
NOTE: Install the front protector 1 and 2 after installing the front protector 3.
118
HULL HOOD
DECK AND HULL
EXPLODED DIAGRAM
2.4 N m (0.24 kgf m, 1.7 ft Ib) 6 25 mm
22 23 23 23 24 16
16
18
16
15 N m (1.5
21 20
LT
5 3
572
19
17 2 8 12 13
11 10 9
15 13
14
LT
271
15 N m (1.5 kgf m, 11 ft Ib)
Step 20 21 22 23 24
Procedure/Part name Bolt Bow eye Cleat cover Screw Cleat assembly
Qty Service points 2 1 2 FX Cruiser High Output 6 FX Cruiser High Output 2 FX Cruiser High Output Reverse the disassembly steps for assembly.
119
HULL HOOD
CLEAT ASSEMBLY (For FX Cruiser High Output)

EXPLODED DIAGRAM
4 4
2 6 1 2

Step Procedure/Part name CLEAT DISASSEMBLY Qty Service points Follow the left Step for disassembly. The following procedure applies to both of the cleat assembly.
1 2 3 4 5 6
Circlip Spring Cleat O-ring Plate Packing
2 2 1 2 1 1
Not reusable Not reusable Reverse the disassembly steps for assembly.
120
HULL HOOD

SERVICE POINTS
Cleat cover installation 1. Install: Cleat cover
NOTE: Make sure that the word YAMAHA a on the cleat covers faces outward as shown in the illustration.
121
TRBL ANLS
1
TROUBLE ANALYSIS TROUBLE ANALYSIS

SELF-DIAGNOSIS
With the engine running, simultaneously press the two buttons 1 for 8 seconds and check if an error code is indicated on the multifunction meter. Code 01 13 15 18 19 23 24 29 47 48 54 55 63 Normal Pickup coil malfunction Engine temperature sensor malfunction Throttle position sensor malfunction Incorrect battery voltage Intake air temperature sensor malfunction Cam position sensor malfunction Intake air pressure sensor malfunction Slant detection switch malfunction Incorrect data transmission Bypass valve motor malfunction Steering sensor malfunction Intake air system malfunction Symptom
If the Yamaha Diagnostic System is not used to check the symptoms listed in the table, the error codes can be checked easily with the self-diagnosis in the multifunction meter. However, if there are numerous error codes displayed, be sure to check them with the Yamaha Diagnostic System.
122
FX/FX Cruiser
R R
R R Br B
P/W
R/Y
R/Y
1
P/W
12
P B/O
P B
R/Y
R/Y
B/O W/B W/R
2 3 1 3 2 1
B W R
Br Br
R R
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
B/O
R R R B/O B B B/O G/O O
P P/G O B/Y Pu/R Pu/B Pu/Y B/O R/Y Pu/G G/R G/Y G/B G
O O O P P P
G G G
G G G
B/Y B/O
1 2
P B
B/Y B/Y W B
2 3 4 16 5 6 7 15 1 8 121110 9 1314
P B/O
1 2
B G R
L R/Y R/Y R L/R Br Y B
321
G G R B
R/Y R/Y R/Y R/Y R/Y R/Y R/Y R/Y
123
O B/O P/G
12
B/Y B/O
123456
B/O B/O B/O B/O
123456
R/Y R/Y R/Y R/Y R/Y R/Y B/O P O
R R B B
1 2 3
FREE PUSH
W FREE PUSH
Br FREE PUSH
Br
Br
Pu/G R/Y
Pu/R R/Y
Pu/Y R/Y
Pu/B R/Y
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
G G/O W P P/W B/Y O O B/O W/R W/B W/B G/B G/Y G/R B G L/R B/R B/R R/Y
134625
R G B
G/R G/Y G/B G R/Y R/Y
L/B
2 1
B/O L/B
W B
Br
21
21
21
21 21
W B/O R Br W B
1 2 3
R G/O B/O
21
R Br B/O W/B R/Y
2 1
3 2 1 3 2 1
B W R
B/Y
B/Y
B/W R/Y L/B W/L R/Y Y B/O P/G P B/Y Pu/G Pu/Y Pu/B Pu/R B B/L B/Y B/W
2 1
Y B/Y R/Y
Y B R/W
B/Y R/Y
2 1
R B
B R
2 1
L/B L/R
B L
B/L R/Y
2 1 12
B L
P B/G
12
B/G P
G/W Pu/W B
2 1 3
G/W Pu/W B
6 5 4 3 2 1
G G G B R B R
G B/O
1 2
B/O O W/L
1 2 3
B O W/L
B/O B/O B/O
B/O B/O
B/O B/O B/O
B/O B/O B/O B/O B/O B/O
B B B B B B B
R/Y B/Y Y
109 8 7 6 5 4 3 2 1
Br B
654321
12345678
B Br
B R/Y
21
WIRING DIAGRAM FX/FX Cruiser

1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R S T U V W X Y Fuse (20 A) Fuse (3 A) Starter relay Noise filter Cam position sensor Oil pressure switch Thermoswitch (exhaust) Intake air pressure Intake air temperature Bypass valve motor Fuel injector Throttle position sensor Pickup coil Lighting coil Engine stop switch Engine shut-off switch Start switch Multifunction meter Buzzer Left operation button Steering sensor Fuel level sensor Fuel pump Thermoswitch (engine) Starter motor Engine temperature sensor Ignition coil Spark plug Rectifier/regulator Battery Electric bilge pump Speed sensor ECM Slant detection switch Main and fuel pump relay
Color code
B Br G L O P R W Y B/G B/L B/O B/R B/W B/Y G/B G/O G/R G/W G/Y L/B L/R P/G P/W Pu/B Pu/G Pu/R Pu/W Pu/Y R/Y R/W W/B W/L W/R : Black : Brown : Green : Blue : Orange : Pink : Red : White : Yellow : Black/green : Black/blue : Black/orange : Black/red : Black/white : Black/yellow : Green/black : Green/orange : Green/red : Green/white : Green/yellow : Blue/black : Blue/red : Pink/green : Pink/white : Purple/black : Purple/green : Purple/red : Purple/white : Purple/yellow : Red/yellow : Red/white : White/black : White/blue : White/red
To tachometer
FX High Output/FX Cruiser High Output

R R Br P B B P/W R R R
W B
G B G G FREE PUSH W FREE PUSH W B B W R W B R Br FREE PUSH Br Br
1
P/W
12
P B/O
R B B/O W/B W/R
R/Y
R/Y
84269 531
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
B/O Pu/G R/Y Pu/R R/Y Pu/Y R/Y Pu/B R/Y L/B O O O P P P R R R G G G
3 2 1
G G G
21
W B/O
R/Y R/Y B R R
R Br Br
B B B/O
L R/Y R/Y R L/R Y B
B/O
B/O G/O O
3 4 1 2
B/Y B/O
1 2
P B
B/Y B/Y
2 3 4 16 5 6 7 15 1 8 121110 9 1314
P B/O
1 2
321
G/W Pu/W B
1 2 3 3 2 1
B G R
R/Y R/Y R/Y R/Y R/Y R/Y R/Y R/Y
R R B B
3214
O B/O P/G B/Y
123456
R/Y R/Y R/Y R/Y R/Y R/Y
B/O W/B R/Y
321
B/O L/B R G B R/Y B/Y Y G R B L W
Y B/Y R/Y
B/O P O
1 2 3
2 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
G G/O W P P/W B/Y O O B/O W/R W/B L W/B G/B G/Y G/R B G L/R B/R
1 2 3
R G B
134625
21
21
21
21
L/B L/R L/Y
1 2 3 4 5 6 3 2 1
R Br G/W Pu/W B B W/B R/Y G R B L W L/B L/R L/Y P B/G Y/W R/W B
B/R R/Y
2 1
G/R G/Y G/B G R/Y R/Y
B/W R/Y
2 1 1
B/Y B/Y P B W
2 1 3
B/Y R/Y L/B W/L R/Y Y B/O P/G P B/Y Pu/G Pu/Y Pu/B Pu/R B B/L B/Y B/W
2 1
G/W Pu/W B
1 2 3 3 2 1 3 2 1
B/L R/Y
2 1 12
B L
B/O W/B R/Y
B L
12
B/G P
13 14 12 18
R Br B L
15 11 3 4 7 616 9 10
Y B B L/B L/Y B/L Gy W Y
Y B/Y R/Y
L/B L/R L/Y
3 2 1
6 5 4 3 2 1
G G G B R G B/O
1 2
R B/O O W/L B/O B/O B/O B/O B/O B/O B/O B/O B/O B/O B/O B/O B/O B/O B R/Y B B B B B B B B B
1 2 3 1 2 1 2 3 4 5 6
Br B
109 8 7 6 5 4 3 2 1
654321
109 8 7 6 5 4 3 2 1
21
L/R B/L
B Br
Gy B
1 2
Gy B
R Br
W B
2 3 1
Br
R/Y R/Y B R R
R Br Br
21
Y/W R/W B
G/W Pu/W B
B W R
Y B/Y R/W
L/B L/R Gy P B/G
B O W/L
R B
WIRING DIAGRAM FX High Output/FX Cruiser High Output

1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z [ \ Fuse (20 A) Fuse (3 A) Starter relay Noise filter Cam position sensor Oil pressure switch Thermoswitch (exhaust) Sensor assembly (intake air pressure, intake air temperature) Bypass valve motor Fuel injector Throttle position sensor Pickup coil Lighting coil Remote control unit Antenna Engine stop switch Engine shut-off switch Start switch Left operation button Multifunction meter Right operation button (FX Cruiser High Output) Steering sensor Compass sensor and air temperature sensor (FX Cruiser High Output) Speed sensor (FX High Output) Speed sensor and water temperature sensor (FX Cruiser High Output) Buzzer Fuel level sensor Fuel pump Thermoswitch (engine) Starter motor Engine temperature sensor Ignition coil Spark plug Rectifier/regulator Battery Electric bilge pump ECM Slant detection switch Main and fuel pump relay
Color code
B Br G Gy L O P R W Y B/G B/L B/O B/R B/W B/Y G/B G/O G/R G/W G/Y L/B L/R L/Y P/G P/W Pu/B Pu/G Pu/R Pu/W Pu/Y R/Y R/W W/B W/L W/R Y/W : Black : Brown : Green : Gray : Blue : Orange : Pink : Red : White : Yellow : Black/green : Black/blue : Black/orange : Black/red : Black/white : Black/yellow : Green/black : Green/orange : Green/red : Green/white : Green/yellow : Blue/black : Blue/red : Blue/yellow : Pink/green : Pink/white : Purple/black : Purple/green : Purple/red : Purple/white : Purple/yellow : Red/yellow : Red/white : White/black : White/blue : White/red : Yellow/white
To tachometer To entry box FX Cruiser High Output model
YAMAHA MOTOR CORPORATION, USA
Printed in USA Dec. 2005 0.0 1 CR (E)

Yamaha FX HO Service Manual

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Yamaha FX HO Service Manual

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Yamaha FX HO Service Manual

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How should the manual be used?

WaveRunner FX High Output FX Cruiser High Output

HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

Symbols 0 to E indicate specific data.

NOTE: Additional symbols may be used in this manual.

ENGINE SERIAL NUMBER

JET PUMP UNIT SERIAL NUMBER

HULL IDENTIFICATION NUMBER (H.l.N.)

SAFETY WHILE WORKING SAFETY WHILE WORKING

PARTS, LUBRICANTS, AND SEALANTS

SAFETY WHILE WORKING

GOOD WORKING PRACTICES

SAFETY WHILE WORKING

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOLS SPECIAL TOOLS

YAMAHA DIAGNOSTIC SYSTEM

REMOVAL AND INSTALLATION

A YM-4114 (19 mm)

90890-04114 (19 mm) YM-4108 (22 mm) 90890-04108 (22 mm)

B YM-04111 (4.0 mm)

90890-04111 (4.0 mm) YM-04116 (4.5 mm) 90890-04116 (4.5 mm)

C YM-04112 (4.0 mm)

90890-04112 (4.0 mm) YM-04117 (4.5 mm) 90890-04117 (4.5 mm)

D YM-04113 (4.0 mm)

90890-04113 (4.0 mm) YM-04118 (4.5 mm) 90890-04118 (4.5 mm)

90890-06811 (4.0 mm) 90890-06812 (4.5 mm)

cm (cu. in) mm (in)

mm (in) V/Ah A @ r/min

(without oil filter replacement) (with oil filter replacement)

kPa (kgf/cm2, psi) mm (in) mm (in) mm (in) mm (in)

1,150 (11.5, 164)

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

0.110.20 (0.00430.0079) 0.250.34 (0.00980.0134)

22.923.1 (0.90160.9094) 24.424.6 (0.96060.9685)

1.762.90 (0.06930.1142) 1.762.90 (0.06930.1142)

mm (in) mm (in) mm (in) mm (in)

3.9753.990 (0.15650.1571) 4.4654.480 (0.17580.1764) 4.0004.012 (0.15750.1580) 4.5004.512 (0.17720.1776)

mm (in) mm (in) mm (in)

0.0100.037 (0.00040.0015) 0.0200.047 (0.00080.0019) 0.01 (0.0004)

Model FX High Output FX Cruiser High Output

mm (in) mm (in) mm (in)

mm (in) mm (in) mm (in)

mm (in) mm (in) mm (in) mm (in) mm (in)

mm (in) mm (in) mm (in)

kPa (kgf/cm2, psi)

0.090.17 (0.00350.0067) 0.090.15 (0.00350.0059)

JET PUMP UNIT

Degree mm (in) mm (in) mm (in) mm (in)

HULL AND HOOD

Model FX Cruiser High Output Fluid 12/19 1.28

5.2 4.7 26.1 41.3

V V V (color) (color) (color) A @ r/min k

9.2 38.5 63.2 459561 459561 0.540.66 14 @ 6,000 1.191.61 8.511.5

kW Seconds mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

54.269.0 3.123.48 11.6 2

More than 4.8 Less than 0.8 More than 4.8