Yamaha WaveRunner FX SHO Service Manual
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Yamaha WaveRunner FX SHO Service Manual

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Table of Contents

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WaveRunner
FX SHO
FX Cruiser SHO
SERVICE MANUAL
*LIT186160312*
LIT-18616-03-12
F1W-28197-1K-11

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Summary of Contents for Yamaha WaveRunner FX SHO

  • Page 1 WaveRunner FX SHO FX Cruiser SHO SERVICE MANUAL *LIT186160312* LIT-18616-03-12 F1W-28197-1K-11...

  • Page 2: Lit-18616

    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.

  • Page 3: Table Of Contents

    Contents General information INFO Specification SPEC Periodic check and adjustment Fuel system FUEL Power unit POWR Jet pump unit PUMP – Electrical system ELEC Hull and hood HULL HOOD Trouble analysis TRBL ANLS...
  • Page 4 INFO Chapter 1 General information How to use this manual ................. 1-1 Manual format.................... 1-1 Symbols..................... 1-2 Abbreviation....................1-3 Grease table ....................1-3 Safety while working..................1-4 Fire prevention................... 1-4 Ventilation....................1-4 Self-protection ................... 1-4 Parts, lubricants, and sealants ..............1-4 Good working practices ................
  • Page 5 Yamaha diagnostic system (YDIS) ........... 1-37 Cruise assist and no-wake mode ............1-37 Slant detection switch ............... 1-38 Off-throttle steering (OTS) system ............ 1-39 L-MODE (low-rpm mode) and yamaha security system ....1-39 Remote control transmitter..............1-41 Technical tips ....................1-42 Engine control..................1-42 Cruise assist control................

  • Page 6: How To Use This Manual

    INFO How to use this manual How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. •...

  • Page 7: Symbols

    Symbols F to I in an exploded diagram indi- cate the grade of lubricant and the lubrication point. F Apply 4-stroke motor oil G Apply water resistant grease (Yamaha grease A) H Apply ThreeBond 1104J or ThreeBond 1280B I Apply molybdenum disulfide grease 1104J 1280B...

  • Page 8: Abbreviation

    Top Dead Center Throttle Position Sensor Upside YDIS Yamaha Diagnostic System YEMS Yamaha Engine Management System Grease table The following table contains sealants, locking agents, and lubricants used in this service manual that are not listed on the “Symbols” page. Symbol Name...

  • Page 9: Safety While Working

    Protect your hands and feet by wearing protec- tive gloves and 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. Under normal conditions, the lubricants men- tioned in this manual should not harm or be hazardous to your skin.

  • Page 10: Good Working Practices

    INFO Safety while working 5. Keep a supply of clean, lint-free cloths for wiping up spills, etc. 6. Maintain good standards of personal and industrial hygiene. Good working practices Special service tool Use the recommended special service tools to protect parts from damage. Use the right tool in the right manner;...

  • Page 11: Identification Number

    INFO Identification number Identification number Primary l.D. number The primary l.D. number is stamped on a label attached to the inside of the engine compart- ment. Starting primary l.D. number: F1W: 800101 Engine serial number The engine serial number is stamped on a label attached to the engine unit.

  • Page 12: Special Service Tool

    Special service tool 4 Dial gauge Special service tool YU-03097 Using the correct special tools recommended by Yamaha will aid the work and enable accu- rate assembly and tune-up. Improvisations and using improper tools can damage the equipment. NOTE: • For USA and Canada, use part numbers 90890-01252 starting with “YB-”, “YM-”, “YU-”, or “YW-.”...
  • Page 13 INFO Special service tool 8 Fuel pressure gauge C Digital multimeter YB-06766 YU-34899-A D Peak voltage adapter 90890-06786 YU-39991 9 Leakage tester 90890-06840 E Digital circuit tester 90890-03174 0 Air cooler attachment F Peak voltage adapter B 90890-06731 90890-03172 A YDIS (connecting kit) 60V-85300-04 G Spark checker YM-34487...

  • Page 14: Removal And Installation

    INFO Special service tool H Test harness (3 pins) Removal and installation YB-06877 1 Oil filter wrench Test harness HM090-3 (3 pins) 90890-06830 90890-06877 2 Exhaust pipe wrench I Lower unit pressure/vacuum tester 90890-06726 YB-35956-A 3 Bearing separator J Vacuum/pressure pump gauge set 90890-06534 90890-06756 4 Slide hammer and adapters...
  • Page 15 INFO Special service tool 7 Stopper guide stand C Valve spring compressor 90890-06538 YM-04019 90890-04019 8 Shaft holder 90890-06721 D Compressor adapter YM-04114 Valve spring compressor attachment 90890-04114 9 Driver handle 90890-06722 E Valve guide remover YB-06801 90890-06801 0 Bearing inner race attachment 90890-06661 F Valve guide installer YB-06810...
  • Page 16 INFO Special service tool H Neway valve seat kit M Rotor puller YB-91044 90890-01080 I Valve seat cutter holder N Driver handle (small) 90890-06812 YB-06229 J Valve seat cutter O Driver rod LS 90890-06606 Intake 90890-06720 (30°) 90890-06325 (45°) 90890-06324 (60°) Exhaust 90890-06818 (30°) 90890-06555 (45°)
  • Page 17 INFO Special service tool S Bearing pressure C X Drive shaft holder 90890-02393 YB-06201 Drive shaft holder 6 90890-06520 T Driver handle (large) YB-06071 Y Driver rod L3 90890-06652 U Forward gear outer race installer YB-41446 Z Drive shaft needle bearing installer and remover YB-06194 V Ball bearing attachment...
  • Page 18 INFO Special service tool ] Bearing cup installer YB-06167 _ Shaft holder 90890-06730 a Needle bearing installer YB-06434 b Bearing puller legs YB-06523 c Bearing attachment 90890-06727 1-13...

  • Page 19: Feature And Benefit

    INFO Feature and benefit Feature and benefit Watercraft overview The FX SHO series features a newly designed deck, while keeping the popular hull design of the FX. Both the deck and hull are made of NanoXcel, which is 25% lighter compared to conventional materials.

  • Page 20: Engine Overview

    INFO Feature and benefit Engine overview The FX SHO series features a newly designed 1.8 L in-line 4-cylinder supercharged engine. Because of its light and compact design, this engine is roughly the same size as the MR-1 engine used on the FX series watercraft. Both high output and low fuel consumption are achieved using regular unleaded gasoline.

  • Page 21: Air Filter Case And Air Filter Element

    INFO Feature and benefit Air filter case and air filter element The air filter case and air filter element have been newly designed to handle the increased intake air volume. The air filter element itself is made of water-repellent material, which prevents water from entering the engine.

  • Page 22: Air Cooler Assembly

    INFO Feature and benefit Air cooler assembly The air cooler assembly uses cooling water to cool the intake air that has been compressed in the supercharger. While the air cooler assembly has an extremely compact design, it functions as a highly efficient heat exchanger to cool the intake air.

  • Page 23: Electronic Control Throttle Valve (Etv) System

    INFO Feature and benefit Electronic control throttle valve (ETV) system The flow chart shows a typical ETV system. The ETV system consists of a throttle lever, a throttle cable, an accelerator position sensor, elec- tronic control throttle bodies, and an electronic control module (ECM). A throttle cable connects the throttle lever and the APS.

  • Page 24: Cylinder Head Assembly

    INFO Feature and benefit Cylinder head assembly The newly designed cylinder head has 4 valves per cylinder: 2 intake valves and 2 exhaust valves. The shapes of the combustion chamber and piston have been designed to obtain the optimum com- pression ratio.

  • Page 25: Ignition Coil

    INFO Feature and benefit Ignition coil The ignition coils are a direct-ignition type with a coil installed to each cylinder. The coils are installed to the cylinder head cover using 2 bolts each, which ensures a secure installation and waterproofing of the spark plug holes. 1 Engine cover 2 Bolt 3 Ignition coil...

  • Page 26: Cylinder Block And Crankcase

    INFO Feature and benefit Cylinder block and crankcase The cylinder block and crankcase have been newly designed. Cast-in iron sleeves, which offer the same high reliability of conventional sleeves, have been adopted. The crankshaft journal portions of the crankcase use a ladder-deck structure in order to achieve high rigidity. 1 Cylinder block 2 Crankcase Knock sensor...

  • Page 27: Lubrication System

    INFO Feature and benefit Lubrication system The FX SHO employs a wet sump lubrication system, which is different from conventional models. There are 2 oil pumps, the scavenge pump and feed pump, located in the oil pan at the bottom of the engine to drawn in and pressure feed the engine oil.

  • Page 28: Oil Pump Assembly

    INFO Feature and benefit Oil pump assembly The oil pump assembly is comprised of 2 oil pumps: the scavenge pump and the feed pump. The scavenge pump pressure feeds engine oil from the oil pan to the oil separator tank. The feed pump supplies engine oil from the oil pan to the various engine components.

  • Page 29: Oil Pan

    INFO Feature and benefit Oil pan The wet-sump type oil pan is divided into 2 internal compartments. Engine oil in the inner oil pan is pressure-fed to the various engine components by the feed pump. Engine oil in the outer oil pan is sent to the oil separator tank by the scavenge pump, and then it flows into the inner oil pan.

  • Page 30: Oil Separator Tank

    INFO Feature and benefit Oil separator tank The scavenge pump pressure feeds the engine oil to the oil separator tank. The oil saparator tank separates the gas from the engine oil. The gas is routed to the cylinder head cover as blow-by gas and the engine oil flows into the inner oil pan at the center of the oil pan.

  • Page 31: Oil Filter

    INFO Feature and benefit Oil filter The oil filter has been changed from the conventional 5GH type to the 69J type. The 69J type oil fil- ter is also used on large outboard motors. 1 Oil filter Exhaust system The exhaust system features a compact design that uses double-pipe construction and a 4-in-1 sys- tem to collect the exhaust gas before it is routed through the exhaust pipe 1.

  • Page 32: Cooling System

    INFO Feature and benefit Cooling system The cooling water is divided into cooling water for the engine and cooling water for the air cooler assembly. The cooling water for the air cooler assembly is at the lowest temperature and it cools the intake air.

  • Page 33: Water Cooled Rectifier Regulator

    INFO Feature and benefit Water cooled rectifier regulator To improve the reliability of the charging system, a water cooled rectifier regulator has been adopted for the first time in a WaveRunner. By changing to a water-cooled system, a more stable supply of electrical output has been achieved.

  • Page 34: In-Tank Fuel Pump Module

    INFO Feature and benefit In-tank fuel pump module A fuel pump module is integrated in the fuel tank. A fuel sender is installed to the side of the pump module. A pressure regulator at the fuel pump outlet controls pressure to the fuel line. Remaining fuel returns to the bottom of the fuel pump, and then re-enters the fuel pump inlet nearby.

  • Page 35: Large Intermediate Housing And Oil Seal

    INFO Feature and benefit Large intermediate housing and oil seal In order to handle the high output, the intermediate housing has been strengthened. Furthermore, lipped oil seals have been adopted to improve waterproofing. 1 Oil seal 2 Intermediate housing 3 Driven coupling Intake grate The grate of the intake grate has been changed to 3 bars and the components have been combined into a single part.

  • Page 36: Reverse Gate Assembly

    INFO Feature and benefit Reverse gate assembly A reverse gate assembly shape has been adopted. In addition, a reverse sensor has been adopted to detect when the watercraft is operating in reverse, which improves reverse performance by acti- vating the “reverse with traction control.” 1 Shift lever 2 Reverse sensor 3 Reverse gate assembly...

  • Page 37: Multifunction Meter

    INFO Feature and benefit Multifunction meter A multifunction meter with an analog speedometer/tachometer located in the center has been adopted. This meter is basically comprised of 3 types of meters. When the multifunction meter starts operating, the analog speedometer/tachometer makes 1 sweep, all displays light up for 2 seconds, and then the meter starts to operate normally.
  • Page 38 INFO Feature and benefit The analog speedometer shows the watercraft speed against water. The large inner numbers on the meter show the watercraft speed in miles per hour (mph) and the small outer numbers show the speed in kilometers per hour (km/h) when the speedometer function is selected. To switch the speedometer display between kilometers and miles, push the “Volt/Hour”...
  • Page 39 INFO Feature and benefit The “UNLOCK” indicator light comes on when the unlock mode of the Yamaha Security System is selected. The watercraft can be ridden normally when this light is on. The “L-MODE” indicator light comes on when the L-MODE is selected.

  • Page 40: Right Multifunction Display (Fx Cruiser Sho)

    INFO Feature and benefit Right multifunction display (FX Cruiser SHO) The display mode of the right multifunction display changes in the following order each time the “Mode/Reset” button is pushed briefly. Compass → Average speed → Tripmeter → Trip timer → Fuel consumption per hour → Fuel con- sumption per kilometer/mile →...

  • Page 41: Average Speed, Tripmeter, And Trip Time Measurements

    INFO Feature and benefit Average speed, tripmeter, and trip time measurements Average speed, tripmeter (distance traveled), and trip time are recorded once measurements have started, regardless of the current display. To start the measurements, push the “Start/Stop” button for less than 1 second. The beeper sounds 1 time. To stop the measurements, push the “Start/Stop” button for less than 1 second.

  • Page 42: Electrical System

    Electrical system Yamaha diagnostic system (YDIS) This model is equipped with the Yamaha Diagnostic System (YDIS). By connecting a computer to the ECM, quick detection of malfunctions and parts that are difficult to check such as the fuel injectors and fuel pump module can be checked easily.

  • Page 43: Slant Detection Switch

    INFO Feature and benefit Slant detection switch When the watercraft is overturned, the slant detection switch turns on and the ECM stops the engine to protect the engine. If engine speed is less than 3,000 r/min, the engine is turned off. However, if engine speed exceeds 3,000 r/min, the engine is not turned off to prevent improper operation of the switch.

  • Page 44: Off-Throttle Steering (Ots) System

    • Some steering will be available with this system, but the watercraft will turn more sharply if throttle is applied. For the best steering and turning performance, apply throttle while turning the handle- bar. L-MODE (low-rpm mode) and Yamaha Security System L-MODE: The user can select the normal mode or the L-MODE.
  • Page 45 Yamaha Security System: The user can set the Yamaha Security System to the lock mode using the remote control transmitter to prevent the engine from starting. To start the engine, the Yamaha Security System must be set to the unlock mode.

  • Page 46: Remote Control Transmitter

    INFO Feature and benefit Remote control transmitter Transmitter registration function (performed by dealers): ID codes can be added or re-registered by connecting the entry box to the receiver. ID codes from up to 5 remote control transmitters can be registered. È...

  • Page 47: Technical Tips

    Thermo sensor Multifunction meter Slant detection switch YDIS Thermoswitch Oil pressure switch Fuel pump relay Engine stop switch Engine start switch Main relay “NO-WAKE MODE” switch “SET” switch Up switch Down switch Reverse sensor Throttle body assembly Yamaha Security System 1-42...

  • Page 48: Cruise Assist Control

    INFO Technical tips Cruise assist control The cruise assist has been added as a new function. The cruise assist is a function for maintaining a set engine speed while cruising. Activation of the cruise assist will be confirmed by the beeper and the digital speedometer display.

  • Page 49: No-Wake Mode Control

    INFO Technical tips No-wake mode control The no-wake mode has been added as a new function. The no-wake mode is a function for operat- ing the watercraft at a low speed to limit the watercraft's wake. In this mode, the ECM automatically maintains the engine speed at approximately 2,100 r/min.

  • Page 50: Reverse With Traction Control

    INFO Technical tips Reverse with traction control The reverse with traction control is activated when the shift lever is in the reverse position and the reverse sensor operates. The reverse with traction control limits the engine speed to 3,000 r/min so that an efficient water flow is produced when the watercraft is operating in reverse.

  • Page 51: High Intake Air Pressure Control

    INFO Technical tips High intake air pressure control The high intake air pressure control is activated under the following conditions. • If the engine speed exceeds 7,550 r/min. • If the intake air pressure exceeds 145 kPa. • If the above conditions are maintained for 1.5 seconds. Meter &...

  • Page 52: Off-Throttle Steering (Ots) Control

    INFO Technical tips Off-throttle steering (OTS) control Off-throttle steering (OTS) system operates as follows: 1. The engine speed is maintained above 4,000 r/min for a few seconds. 2. The APS detects when the throttle lever is completely released. 3. The steering sensor detects on when the handlebar is turned sharply to the right or left and is applied load.

  • Page 53: Remote Control Transmitter Control

    To set the Yamaha Security System, the user aims the remote control transmitter at the watercraft and presses the lock or unlock button to remotely turn the Yamaha Security System relay ON or OFF. The unlock button can also be used to remotely select the normal mode or L-MODE.

  • Page 54: Warning Control

    INFO Technical tips Warning control Overheat warning control The overheat warning control is activated under the following conditions. • If the engine temperature rises rapidly within several seconds. • If the thermoswitch is on. • If the exhaust cooling water temperature exceed 75°C (167 °F) If the overheat warning control is activated, the overheat warning indicator comes on and the buzzer sounds.

  • Page 55: Cam Position Sensor Failure Control

    INFO Technical tips Cam position sensor failure control The cam position sensor failure control is activated under the following conditions. • If the cam position sensor failed. • If the engine speed exceeds about 1,000 r/min. • If the above conditions are maintained for 10 seconds. Meter &...

  • Page 56: Fail-Safe Function Table

    INFO Technical tips Fail-safe function table Symptom Ignition control Fuel injection control Function Incorrect pickup coil None None None signal malfunction Incorrect cam posi- Sensor malfunction Sensor malfunction When Fail-safe is active, tion sensor signal occurs after cylinder occurs after cylinder engine speed is identification: normal identification: normal...
  • Page 57 INFO Technical tips Symptom Ignition control Fuel injection control Function Incorrect cooling Normal control Normal control Pseudo cooling water water temperature temperature is set to 50 sensor signal °C (122 °F). ETV system ETV failure control ETV failure control ETV failure control malfunction 1-52...
  • Page 58 INFO Technical tips — MEMO — 1-53...
  • Page 59 SPEC Chapter 2 Specification General specification..................2-1 Maintenance specifications ................2-3 Engine ...................... 2-3 Fuel system ....................2-6 Jet pump unit .................... 2-7 Hull and hood ................... 2-7 Electrical ....................2-7 Tightening torques..................2-11 Specified torques..................2-11 General torque..................2-17 Cable and hose routing ................

  • Page 60: General Specification

    SPEC General specification General specification Model Item Unit FX SHO FX Cruiser SHO Model code Hull Engine/jet 6S5/6S5 Dimensions Length mm (in) 3,370 (132.7) Width mm (in) 1,230 (48.4) Height mm (in) 1,160 (45.7) 1,240 (48.8) Weight Dry weight kg (lb) 376 (829) 381 (840) Maximum capacity...
  • Page 61 SPEC General specification Model Item Unit FX SHO FX Cruiser SHO Fuel and oil Fuel type Regular unleaded gasoline Minimum fuel rating PON* RON* Fuel tank capacity 70 (18.5, 15.4) (US gal, Imp.gal) Engine oil type 4-stroke motor oil Engine oil grade SE, SF, SG, SH, SJ, or SL 10W-30, 10W-40, 20W-40, or 20W-50 Engine oil quantity...

  • Page 62: Maintenance Specifications

    SPEC Maintenance specifications Maintenance specifications Engine Model Item Unit FX SHO FX Cruiser SHO Power unit Compression pressure 610 (6.1, 86.8) (kgf/cm , psi) Air cooler Holding pressure Water passage 200 (2.0, 28.5) (kgf/cm , psi) Air passage 100 (1.0, 14.2) (kgf/cm , psi) Oil cooler...
  • Page 63 SPEC Maintenance specifications Model Item Unit FX SHO FX Cruiser SHO Timing chain Model/number of links 97RH2015–152PX/152 Tensioning system Automatic Valve Valve clearance (cold) Intake mm (in) 0.14–0.23 (0.006–0.009) Exhaust mm (in) 0.28–0.37 (0.011–0.015) Valve dimensions Valve head diameter A Intake mm (in) 33.9–34.1 (1.335–1.343)
  • Page 64 SPEC Maintenance specifications Model Item Unit FX SHO FX Cruiser SHO Valve spring Free length Intake and exhaust mm (in) 45.58 (1.794) Installed length Intake and exhaust mm (in) 34.00 (1.339) Tilt limit Intake and exhaust mm (in) 2.0 (0.08) Cylinder Bore size mm (in)

  • Page 65: Fuel System

    SPEC Maintenance specifications Model Item Unit FX SHO FX Cruiser SHO Connecting rod Bearing color code 1. Brown 2. Black 3. Blue 4. Green Small end inside diameter mm (in) 22.015–22.028 (0.8667–0.8672) Crankshaft Crankshaft journal diameter mm (in) 39.976–40.000 (1.5739–1.5748) Crankshaft pin diameter mm (in) 41.976–42.000 (1.6526–1.6535)

  • Page 66: Jet Pump Unit

    SPEC Maintenance specifications Jet pump unit Model Item Unit FX SHO FX Cruiser SHO Jet pump Impeller housing inside mm (in) 155.35–155.45 (6.116–6.120) diameter Impeller material Stainless steel Number of impeller blades Impeller pitch angle Degree 16.0 Impeller-to-housing clearance mm (in) 0.35–0.45 (0.014–0.018) Impeller clearance limit mm (in)
  • Page 67 SPEC Maintenance specifications Model Item Unit FX SHO FX Cruiser SHO Charging system Stator coil (G – G) Output peak voltage @cranking (unloaded) @2,000 r/min (unloaded) 42.7 @3,500 r/min (unloaded) 74.0 Ω Stator coil resistance 0.31–0.38 (G – G) @ 20 °C (68 °F) Rectifier regulator (R –...
  • Page 68 SPEC Maintenance specifications Model Item Unit FX SHO FX Cruiser SHO TPS output voltage with throttle lever fully closed TPS 1 0.6–0.9 with throttle lever fully open TPS 2 4.6–4.7 Throttle valve opening angle with throttle lever fully degree 2.0–8.0 closed with throttle lever fully open degree...
  • Page 69 SPEC Maintenance specifications Model Item Unit FX SHO FX Cruiser SHO Fuel system Fuel injector Ω Fuel injector resistance 11.5–12.5 @ 20 °C (68 °F) Fuel sender Fuel sender resistance (Y– B) @ 20 °C (68 °F) Ω Lower position 133.5–136.5 Ω...

  • Page 70: Tightening Torques

    SPEC Tightening torques Tightening torques Specified torques Tightening torque Thread Refer to Part to tightened size page N·m kgf·m ft·lb Fuel system Fuel pump module assembly nut — Strap bolt 11.8 Fuel rail bolt Fuel tank cap clamp — Fuel filler neck nut —...
  • Page 71 SPEC Tightening torques Tightening torque Thread Refer to Part to tightened size page N·m kgf·m ft·lb 17.0 Air cooler assembly nut — 5-31 31.0 Stud bolt 5-31 14.8 17.0 Air cooler assembly bolt 5-31 31.0 Air cooler stay bolt 31.0 5-31 Supercharger assembly bolt 5-31...
  • Page 72 SPEC Tightening torques Tightening torque Thread Refer to Part to tightened size page N·m kgf·m ft·lb Grommet bracket bolt 5-80 Generator cover assembly bolt 19.2 5-80 Transfer shaft — 12.0 88.5 5-80 Flywheel magneto bolt 17.7 5-80 Pickup coil bolt 5-82 Washer bolt 5-82...
  • Page 73 SPEC Tightening torques Tightening torque Thread Refer to Part to tightened size page N·m kgf·m ft·lb Spring nut — Spring bolt 14.8 Shift cable ball joint nut — Reverse gate stay bolt Bracket 1 and 2 bolt Jet thrust nozzle bolt 11.8 Nozzle ring bolt 11.8...
  • Page 74 SPEC Tightening torques Tightening torque Thread Refer to Part to tightened size page N·m kgf·m ft·lb Multifunction meter bolt 8-22 Side cover bolt 8-24 Side ornament nut — 8-24 Center cover nut — 8-25 Shift lever assembly nut — 8-25 Box cap —...
  • Page 75 SPEC Tightening torques Tightening torque Thread Refer to Part to tightened size page N·m kgf·m ft·lb Drain plug nut — 8-52 Reboarding step assembly bolt 11.8 8-52 Electrical Fuse box bolt Slant detection switch screw ECM bolt Lead bolt (red, brown, and black) Starter motor terminal nut —...

  • Page 76: General Torque

    SPEC Tightening torques General torque General torque This chart specifies tightening torques for stan- specifications Nut (A) Bolt (B) dard fasteners with a standard ISO thread · · · pitch. Tightening torque specifications for spe- 8 mm cial components or assemblies are provided in 10 mm applicable sections of this manual.

  • Page 77: Cable And Hose Routing

    SPEC Cable and hose routing Cable and hose routing Starboard bow view 1 Breather hose (head cover to breather 9 Cooling water pilot outlet hose 0 Speed sensor lead assembly) 2 Cooling water hose (exhaust manifold to rectifier A Remote control receiver antenna regulator) B Fuel tank breather hose (ventilation socket to 3 Breather hose (breather assembly to intake pipe)

  • Page 78: Top View

    SPEC Cable and hose routing Top view 1 Breather hose (head cover to breather 9 Cooling water pilot outlet hose assembly) 0 Speed sensor lead 2 Multifunction meter lead A Remote control receiver antenna 3 Breather hose (breather assembly to intake B Fuel tank breather hose (ventilation socket to pipe) water separator)
  • Page 79 SPEC Cable and hose routing I Electric bilge pump coupler J Negative battery cable K Positive battery cable L Battery breather hose M Cooling water hose (jet pump to hose joint 1) N Flushing hose O Cooling water hose (hose joint 1 to hose joint 3) P Buzzer lead Q Compass and air temperature sensor lead (FX Cruiser SHO)

  • Page 80: Port View

    SPEC Cable and hose routing Port view 1 3 H P M 5 6 4 8 È 1 Multifunction meter lead 0 Speed sensor lead 2 Cooling water hose (exhaust manifold to rectifier A Remote control receiver antenna B Fuel tank breather hose (ventilation socket to regulator) 3 Left operation button lead water separator)
  • Page 81 SPEC Cable and hose routing 1 3 H P M 5 6 4 8 È È Fasten the wiring harness with the plastic tie, J Negative battery cable K Positive battery cable making sure to align the tie with the gray tape on L Battery breather hose the harness.
  • Page 82 SPEC Cable and hose routing — MEMO — 2-23...
  • Page 83 Chapter 3 Periodic check and adjustment Maintenance interval chart................3-1 Periodic service ..................... 3-2 Control system................... 3-2 Steering system check ................ 3-2 Jet thrust nozzle steering angle check and adjustment ...... 3-2 Jet thrust nozzle QSTS angle check and adjustment ......3-4 Throttle lever free play check and adjustment ........

  • Page 84: Maintenance Interval Chart

    Maintenance interval chart Maintenance interval chart The following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the maintenance intervals should be changed. THEREAFTER MAINTENANCE INTERVAL INITIAL EVERY 10 hours 50 hours PAGE hours hours hours...

  • Page 85: Periodic Service

    Control system Periodic service Control system Steering system check 1. Check: • Steering system Excessive play → Check the bushings, bolts, and nuts. Refer to “Handlebar assembly removal” in Chapter 8. Checking steps: 1. Turn the handlebar lock to lock and push it back and forth.
  • Page 86 Control system 2. Adjust: • Steering cable joint (steering master end) Adjustment steps: 1. Set the QSTS grip to the neutral position. 2. Remove the service lid. Refer to “Front hood removal” in Chapter 3. Loosen the locknut 1. 4. Disconnect the steering cable joint 2 from the ball joint 3.

  • Page 87: Jet Thrust Nozzle Qsts Angle Check And Adjustment

    Control system Jet thrust nozzle QSTS angle check and adjustment 1. Check: • Jet thrust nozzle angle set distances a and b Difference → Adjust the QSTS rod joint. NOTE: Before measuring the jet thrust nozzle QSTS DOWN angle make sure that the steering position of the jet thrust nozzle is centered.

  • Page 88: Throttle Lever Free Play Check And Adjustment

    Control system 6. If the QSTS rod cannot be properly adjusted using the rod joint at the jet pump end, check the rod joint at the QSTS con- verter end. Refer to “QSTS grip and converter disas- sembly” in Chapter 8. Throttle lever free play check and adjustment 1.
  • Page 89 Control system 5. If the throttle cable installation length a is out of specification, loosen the locknut 2, turn the adjusting nut 3 to adjust the length, and then tighten the locknut 2 to the specified torque. NOTE: Apply locking agent to the threads of the adjusting nut 3.

  • Page 90: Trolling Speed Check

    Control system 14. Install the service lid. NOTE: Make sure that the throttle cable is not pulled when the handlebar is turned to the right and left. Trolling speed check 1. Check: • Trolling speed Out of specification → Check the throttle cable or throttle body assembly.
  • Page 91 Control system 2. Adjust: • Shift cable joint (jet pump end) Adjustment steps: 1. Set the shift lever to the reverse position. 2. Loosen the locknut 1. 3. Disconnect the shift cable joint 2 from the ball joint 3. 4. Situate the reverse gate 4 to the stopper 5.

  • Page 92: Fuel System

    Fuel system Fuel system WARNING • Before checking the fuel system, remove the battery and then remove the fuel tank filler cap to reduce any pressure inside the fuel tank. • Always reduce the fuel pressure in the fuel line before checking the line or the fuel pipe.

  • Page 93: Water Separator Check

    Fuel system / Power unit 2. Check: • Fuel tank Water accumulation → Extract the water and fuel. Cracks/damage → Replace the fuel tank. NOTE: To extract water and fuel from the fuel tank, remove the cap 1 and use a siphon pump. Fuel tank cap clamp: 1 N·m (0.1 kgf·m, 0.7 ft·lb) Water separator check...
  • Page 94 Power unit Measurement steps: 1. Remove the spark plugs and cylinder head cover. Refer to “Cylinder head cover removal” in Chapter 5. 2. Install the dial gauge needle and special service tools 1 and 2 into spark plug hole Gauge stand: 90890-06725 Dial gauge stand set: YB-06585...

  • Page 95: Compression Pressure Measurement

    Power unit Compression pressure measurement 1. Measure: • Compression pressure NOTE: Make sure that the battery voltage is more than 12 V. Compression pressure (reference data): 610 kPa (6.1 kgf/cm , 86.8 psi) Measurement steps: 1. Place the watercraft in the water. 2.

  • Page 96: Engine Oil Level Check

    Power unit 8. Install the spark plugs 4, ignition coils 3, bolts 2, and engine cover 1. Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb) Ignition coil bolt: 8 N·m (0.8 kgf·m, 5.9 ft·lb) LOCTITE 572 Engine cover bolt: 5 N·m (0.5 kgf·m, 3.7 ft·lb) Engine oil level check 1.

  • Page 97: Engine Oil Change

    Power unit 2. Remove the oil level gauge 1, wipe the gauge clean, and then install the gauge into the oil level pipe completely. 3. Remove the oil level gauge 1 again to check that the oil level is between the min- imum level mark a and maximum level mark b on the gauge.

  • Page 98: Oil Filter Replacement

    Power unit 3. Remove the oil filler cap 1 and oil level PORT gauge 2. 4. Insert the tube 3 of an oil changer into the oil level pipe 4. 5. Operate the oil changer to extract the oil. 6. Fill the crankcase with the specified amount of the recommended engine oil through the oil filler hole 5.

  • Page 99: Air Filter Element Check

    Power unit 5. Tighten a new oil filter to the specified torque with the special service tool. NOTE: Be sure to clean up any oil spills. Oil filter: 18 N·m (1.8 kgf·m, 13.3 ft·lb) 6. Install the engine cover. Air filter element check 1.

  • Page 100: Spark Plug Check

    Power unit Spark plug check 1. Remove: • Engine cover 1 • Ignition coil bolts 2 • Ignition coils 3 • Spark plugs 4 NOTE: • Slide the engine cover rearward, and then lift the cover to remove it. • Be careful not to get water or any other for- eign substances in the spark plug holes.
  • Page 101 Power unit 4. Install: • Spark plugs 1 NOTE: Before installing a spark plug, clean the gasket surface and spark plug surface. Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb) 5. Install: • Ignition coils 2 • Ignition coil bolts 3 •...

  • Page 102: Electrical

    Electrical Electrical Battery check WARNING Battery electrolyte is poisonous and dan- gerous, causing severe burns, etc. Electro- lyte contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidotes External: Flush with water. Internal: Drink large quantities of water or milk.
  • Page 103 Electrical 1. Remove: • Negative battery cable 1 • Positive battery cable 2 • Battery breather hose 3 • Bands 4 • Battery 5 CAUTION: When removing the battery, disconnect the negative battery cable first. 2. Check: • Electrolyte level Low →...

  • Page 104: Jet Pump Unit

    Electrical / Jet pump unit 4. Install: • Battery 1 • Bands 2 • Battery breather hose 3 • Positive battery cable 4 • Negative battery cable 5 CAUTION: Connect the positive battery cable 4 to the battery terminal first. NOTE: •...

  • Page 105: Bilge Pump

    Jet pump unit / Bilge pump 3. Check: • Water inlet strainer a Contaminants → Clean the water inlet strainer. Cracks/damage → Replace the water inlet strainer. Bilge pump Bilge strainer check 1. Remove: • Deck beam Refer to “Seat and hand grip removal” in Chapter 8.

  • Page 106: Electric Bilge Pump Strainer Check

    Bilge pump / General Electric bilge pump strainer check 1. Remove: • Negative battery cable 1 • Band 2 • Electric bilge pump cap 3 • Electric bilge pump strainer 4 2. Check: • Electric bilge pump strainer Contaminants → Clean the cap and strainer.

  • Page 107: Lubrication Points

    • After lubricating the throttle cable, be sure to adjust the throttle lever free play. Refer to “Throttle lever free play check and adjust- ment.” Recommended lubricant: Rust inhibitor 2. Lubricate: • Throttle cable (APS end) • Return spring Recommended lubricant: Yamaha grease A 3-24...
  • Page 108 Refer to “Handlebar assembly removal” in Chapter 8. • Spray the rust inhibitor into the outer cables, and apply grease to the inner cables. Recommended lubricant: Yamaha grease A Rust inhibitor 4. Lubricate: • QSTS cables (pulley end) • QSTS rod joint (pulley end)
  • Page 109 • Shift cable • Shift cable joint NOTE: Disconnect the joints and apply a small amount of grease. Recommended lubricant: Yamaha grease A 7. Lubricate: • Intermediate housing (through the grease nipple 1) Recommended lubricant: Yamaha grease A Grease quantity: Initial 10 hours: 33.0–35.0 cm...
  • Page 110 General — MEMO — 3-27...
  • Page 111 FUEL Chapter 4 Fuel system Fuel tank, fuel pump module, and fuel hose ..........4-1 Fuel tank removal ..................4-1 Fuel hose disconnection................4-5 Fuel pump module removal ............... 4-5 Fuel sender removal.................. 4-6 Rollover valve check.................. 4-7 Check valve check..................4-7 Fuel line check...................

  • Page 112: Fuel Tank, Fuel Pump Module, And Fuel Hose

    FUEL Fuel tank, fuel pump module, and fuel hose Fuel tank, fuel pump module, and fuel hose Fuel tank removal · · · 13 N m (1.3 kgf m, 9.6 ft m (0.3 kgf m, 2.2 ft · · · 8 ×...
  • Page 113 FUEL Fuel tank, fuel pump module, and fuel hose 13 N · m (1.3 kgf · m, 9.6 ft · · m (0.3 kgf · m, 2.2 ft · 8 × 17 mm · m (0.6 kgf · m, 4.4 ft ·...
  • Page 114 FUEL Fuel tank, fuel pump module, and fuel hose · · · 13 N m (1.3 kgf m, 9.6 ft m (0.3 kgf m, 2.2 ft · · · 8 × 17 mm · m (0.6 kgf · m, 4.4 ft ·...
  • Page 115 FUEL Fuel tank, fuel pump module, and fuel hose 13 N · m (1.3 kgf · m, 9.6 ft · · m (0.3 kgf · m, 2.2 ft · 8 × 17 mm · m (0.6 kgf · m, 4.4 ft ·...

  • Page 116: Fuel Hose Disconnection

    FUEL Fuel tank, fuel pump module, and fuel hose Fuel hose disconnection WARNING • Before checking the fuel system, remove the battery and then remove the fuel tank filler cap to reduce any pressure inside the fuel tank. • Always reduce the fuel pressure in the fuel line before servicing the line or the fuel pipe.

  • Page 117: Fuel Sender Removal

    FUEL Fuel tank, fuel pump module, and fuel hose 2. Remove: • Fuel pump module assembly 1 NOTE: • Remove the fuel pump module assembly 1 at an angle so that the float 2 does not catch on the fuel tank. •...

  • Page 118: Rollover Valve Check

    FUEL Fuel tank, fuel pump module, and fuel hose Rollover valve check 1. Check: • Rollover valve Does not function properly → Replace the rollover valve. Checking steps: 1. Blow into the end a of the rollover valve, and make sure that airflow from the end b is unrestricted.

  • Page 119: Fuel Line Check

    FUEL Fuel tank, fuel pump module, and fuel hose Fuel line check 1. Check: • Fuel hose 1 • Quick connectors 2 Cracks/damage → Replace the fuel hose assembly. CAUTION: Do not remove the quick connectors from the fuel hose assembly. •...

  • Page 120: Fuel Injector Check

    FUEL Fuel tank, fuel pump module, and fuel hose Fuel injector check 1. Check: • Fuel injector Dirt/residue → Clean the fuel injector. Damage → Replace the fuel injector. Fuel injector installation 1. Install: • Fuel injector Installation steps: 1. Apply a thin coat of engine oil to the O-ring 2.

  • Page 121: Fuel Pump Module Installation

    FUEL Fuel tank, fuel pump module, and fuel hose Fuel pump module installation 1. Install: • Fuel pump module assembly NOTE: Tighten the nuts to the specified torques in the sequence shown. Fuel pump module nut: 1st: 3 N·m (0.3 kgf·m, 2.2 ft·lb) 2nd: 6 N·m (0.6 kgf·m, 4.4 ft·lb) Fuel hose connection...

  • Page 122: Fuel Pressure Measurement

    FUEL Fuel tank, fuel pump module, and fuel hose Fuel pressure measurement 1. Measure: • Fuel pressure Out of specification → Replace the fuel pump module assembly. Measurement steps: 1. Disconnect the quick connector from the fuel rail. 2. Install the special service tools 1 and 2 as shown.

  • Page 123: Powr

    POWR Chapter 5 Power unit Engine unit...................... 5-1 Engine unit removal 1................5-1 Engine unit removal 2................5-4 Engine unit removal 3................5-6 Engine unit removal 4................5-9 Engine mount removal................5-10 Engine unit removal................. 5-12 Breather assembly check ................ 5-17 Engine mount check ................

  • Page 124: Pump

    POWR Oil cooler, oil pump assembly, and drive gear.......... 5-42 Oil cooler and oil pump assembly removal..........5-42 Drive gear removal .................. 5-44 Drive gear assembly removal ..............5-46 Drive gear disassembly ................5-46 Oil cooler assembly check............... 5-47 Oil pump assembly check................ 5-48 Idle gear check ..................
  • Page 125 POWR Generator cover and flywheel magneto............. 5-80 Generator cover and flywheel magneto removal........5-80 Generator cover disassembly..............5-82 Drive coupling removal ................5-83 Flywheel magneto removal..............5-83 Bearing removal ..................5-84 Idle gear and shaft check ................ 5-84 Transfer shaft check ................5-85 Starter clutch check .................

  • Page 126: Engine Unit

    POWR Engine unit Engine unit Engine unit removal 1 · · · m (0.5 kgf m, 3.7 ft 6 × 12 mm · · · 17 N m (1.7 kgf m, 12.5 ft Step Q’ty Service points Procedure/Part name Engine oil Refer to “Engine oil change”...
  • Page 127 POWR Engine unit · · · m (0.5 kgf m, 3.7 ft 6 × 12 mm 17 N · m (1.7 kgf · m, 12.5 ft · Step Q’ty Service points Procedure/Part name APS coupler Plastic tie NOTE: Align the plastic ties with the gray tape a on Plastic tie the wiring harness assembly.
  • Page 128 POWR Engine unit · · · m (0.5 kgf m, 3.7 ft 6 × 12 mm · · · 17 N m (1.7 kgf m, 12.5 ft Step Q’ty Service points Procedure/Part name Antenna holder Remote control receiver coupler Plastic tie Fuel pump module coupler Electric bilge pump coupler Reverse the removal steps for installation.
  • Page 129 POWR Engine unit Engine unit removal 2 · · · m (0.3 kgf m, 2.2 ft · m (0.6 kgf · m, 4.4 ft · 6 × 10 mm È Ê É · · · 18 N m (1.8 kgf m, 13.3 ft É...
  • Page 130 POWR Engine unit · · · m (0.3 kgf m, 2.2 ft · m (0.6 kgf · m, 4.4 ft · 6 × 10 mm È Ê É · · · 18 N m (1.8 kgf m, 13.3 ft É ·...
  • Page 131 POWR Engine unit Engine unit removal 3 · · · m (0.8 kgf m, 5.9 ft 23 N · m (2.3 kgf · m, 17.0 ft · 6 × 30 mm 2nd 42 N · m (4.2 kgf · m, 31.0 ft ·...
  • Page 132 POWR Engine unit · · · · · · m (0.8 kgf m, 5.9 ft 23 N m (2.3 kgf m, 17.0 ft 6 × 30 mm · · · 2nd 42 N m (4.2 kgf m, 31.0 ft 8 × 47 mm ·...
  • Page 133 POWR Engine unit · · · m (0.8 kgf m, 5.9 ft 23 N · m (2.3 kgf · m, 17.0 ft · 6 × 30 mm 2nd 42 N · m (4.2 kgf · m, 31.0 ft · 8 × 47 mm 26 N ·...
  • Page 134 POWR Engine unit Engine unit removal 4 · · · 17 N m (1.7 kgf m, 12.5 ft 8 × 28 mm · · · m (0.8 kgf m, 5.9 ft 6 × 25 mm · · · 17 N m (1.7 kgf m, 12.5 ft 8 ×...
  • Page 135 POWR Engine unit Engine mount removal · · · m (0.6 kgf m, 4.4 ft 6 × 20 mm · m (0.6 kgf · m, 4.4 ft · 6 × 12 mm · · · 17 N m (1.7 kgf m, 12.5 ft 8 ×...
  • Page 136 POWR Engine unit · · · m (0.6 kgf m, 4.4 ft 6 × 20 mm · · · m (0.6 kgf m, 4.4 ft 6 × 12 mm · · · 17 N m (1.7 kgf m, 12.5 ft 8 ×...
  • Page 137 POWR Engine unit Engine unit removal 1. Remove: • Engine unit CAUTION: Before removing the engine, be sure to take adequate measures to protect the deck opening from damage. Removal steps: 1. Extract the engine oil. Refer to “Engine oil change” in Chapter 3. 2.
  • Page 138 POWR Engine unit 8. Disconnect the APS coupler A, and the 8 multifunction meter, sensor, and switch couplers B. 9. Remove the antenna holders C. 10. Disconnect the remote control receiver coupler D. 11. Remove the wiring harness from the 5 plastic ties E.
  • Page 139 POWR Engine unit 15. Disconnect the breather hose I from the intake pipe J, and then remove the intake pipe J from the supercharger. 16. Unhook the fasteners K, and then remove the air filter case cover L. Remove the air filter case bolts M, and then remove the air filter case N.
  • Page 140 POWR Engine unit 23. Remove the cooling water hoses W. 24. Remove the rectifier regulator bolts X, and then remove the rectifier regulator Y. 25. Remove the plastic tie Z from the hose joint 4 [. 26. Disconnect cooling water hose \ from the hose joint 1 ].
  • Page 141 POWR Engine unit 31. Remove the electrical box bolts h, and then remove the electrical box i. 32. Remove the coupling cover bolt j, and then remove the coupling cover k. 33. Loosen the engine mounting bolts l. 34. Lift the engine unit slightly, remove the shims m, and then lower the engine.

  • Page 142: Breather Assembly Check

    POWR Engine unit 37. Lift the engine unit slightly, and then lower the front of the unit. Repeat this step until the engine unit can be removed from the engine compartment. CAUTION: When removing the engine unit, take care to avoid causing damage to the hull and deck opening.

  • Page 143: Engine Unit Installation

    POWR Engine unit Engine unit installation 1. Install: • Engine unit Installation steps: 1. Suspend the engine unit using all 3 engine hangers. 2. Lower the front of the engine unit. 3. Lower the engine unit into the engine com- partment vertically.
  • Page 144 POWR Engine unit 6. Temporarily install the engine mounting bolts 2. 7. Lift the engine unit slightly, install the shims 3, and then lower the engine. NOTE: Install the shims in their original positions. 8. Measure the coupling clearance a, and if necessary, add or remove shims 3 so that the clearance is within specification.
  • Page 145 POWR Engine unit 11. Tighten the engine mounting bolts 2 to the specified torque. Engine mounting bolt: 17 N·m (1.7 kgf·m, 12.5 ft·lb) LOCTITE 271 12. Check that the coupling clearances a and b are within specification. If the clear- ances are out of specification, adjust them again.
  • Page 146 POWR Engine unit 16. Tighten the pipe clamp A to the specified torque. Pipe clamp: 2 N·m (0.2 kgf·m, 1.5 ft·lb) 17. Install the stay B, and then tighten the stay bolts C to the specified torque. Stay bolt: 1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb)
  • Page 147 POWR Engine unit 25. Apply a thin coat of engine oil to the O-ring Q of the oil filter R. 26. Install the oil filter R with the special ser- vice tool. Oil filter wrench: 90890-06830 Oil filter: 18 N·m (1.8 kgf·m, 13.3 ft·lb) 27.
  • Page 148 POWR Engine unit 29. Install the air filter case V, and then tighten the air filter case bolts W to the specified torque. Air filter case bolt: 13 N·m (1.3 kgf·m, 9.6 ft·lb) 30. Install the air filter case cover X, and then hook the fasteners Y.
  • Page 149 POWR Engine unit 38. Connect the APS coupler d, and the 8 multifunction meter, sensor, and switch couplers e. 39. Install the engine cover f, and then tighten the engine cover bolts g to the specified torque. NOTE: Hold the engine cover down, and slide the cover forward to install it.

  • Page 150: Muffler

    POWR Muffler Muffler Muffler disassembly · · · m (0.2 kgf m, 1.5 ft 20 N · m (2.0 kgf · m, 14.8 ft · · · · 60 N m (6.0 kgf m, 44.3 ft 15 N · m (1.5 kgf ·...
  • Page 151 POWR Muffler · · · m (0.2 kgf m, 1.5 ft · · · 20 N m (2.0 kgf m, 14.8 ft 60 N · m (6.0 kgf · m, 44.3 ft · · · · 15 N m (1.5 kgf m, 11.1 ft ·...

  • Page 152: Exhaust Pipe 3 Removal

    POWR Muffler Exhaust pipe 3 removal 1. Remove: • Exhaust pipe 3 1 Exhaust pipe wrench: 90890-06726 Muffler check 1. Check: • Exhaust manifold 1 • Exhaust pipe 1 2 • Exhaust pipe 2 3 • Exhaust pipe 3 4 Cracks/damage →...

  • Page 153: Electrical Box And Starter Motor

    POWR Electrical box and starter motor Electrical box and starter motor Electrical box and starter motor removal · · · m (0.5 kgf m, 3.7 ft · m (1.8 m · kg, 13.3 ft · 18 N 8 × 30 mm Step Procedure/Part name Q’ty...
  • Page 154 POWR Electrical box and starter motor · · · m (0.5 kgf m, 3.7 ft m (1.8 m kg, 13.3 ft 18 N · · · 8 × 30 mm Step Q’ty Service points Procedure/Part name Plastic tie Throttle body assembly coupler CAUTION: Do not disconnect the throttle body as- sembly coupler a.
  • Page 155 POWR Electrical box and starter motor · · · m (0.5 kgf m, 3.7 ft · m (1.8 m · kg, 13.3 ft · 18 N 8 × 30 mm Step Q’ty Service points Procedure/Part name Bolt Negative battery cable Starter motor Electrical box cover Plastic tie...

  • Page 156: Air Cooler, Supercharger, And Throttle Body Assembly

    POWR Air cooler, supercharger, and throttle body assembly Air cooler, supercharger, and throttle body assembly Air cooler and supercharger removal · · · 10 N m (1.0 kgf m, 7.4 ft 10 N · m (1.0 kgf · m, 7.4 ft ·...
  • Page 157 POWR Air cooler, supercharger, and throttle body assembly · · · · · · 10 N m (1.0 kgf m, 7.4 ft 10 N m (1.0 kgf m, 7.4 ft 6 × 65 mm · · · 2nd 20 N m (2.0 kgf m, 14.8 ft ·...
  • Page 158 POWR Air cooler, supercharger, and throttle body assembly · · · 10 N m (1.0 kgf m, 7.4 ft 10 N · m (1.0 kgf · m, 7.4 ft · 6 × 65 mm · · · 2nd 20 N m (2.0 kgf m, 14.8 ft ·...

  • Page 159: Intake Assembly Removal

    POWR Air cooler, supercharger, and throttle body assembly Intake assembly removal · m (0.5 kgf · m, 3.7 ft · · · · 10 N m (1.0 kgf m, 7.4 ft 6 × 25 mm · m (0.35 kgf · m, 2.6 ft ·...
  • Page 160 POWR Air cooler, supercharger, and throttle body assembly · m (0.5 kgf · m, 3.7 ft · 10 N · m (1.0 kgf · m, 7.4 ft · 6 × 25 mm · m (0.35 kgf · m, 2.6 ft ·...

  • Page 161: Intake Disassembly

    POWR Air cooler, supercharger, and throttle body assembly Intake disassembly 13 N · m (1.3 kgf · m, 9.6 ft · 8 × 20 mm 13 N · m (1.3 kgf · m, 9.6 ft · Step Q’ty Service points Procedure/Part name Nut/washer Throttle body assembly...

  • Page 162: Air Cooler Check

    POWR Air cooler, supercharger, and throttle body assembly Air cooler check CAUTION: The air cooler assembly should not be dis- assembled. 1. Check: • Air cooler assembly Cracks/damage → Replace the air cooler assembly. • Air cooler holding pressure Cannot be maintained → Replace the air cooler assembly.

  • Page 163: Supercharger Check

    POWR Air cooler, supercharger, and throttle body assembly Supercharger check CAUTION: The supercharger should not be disassem- bled. 1. Check: • Impeller 1 • Gear 2 Cracks/damage → Replace the super- charger assembly. • Supercharger operation Rough movement → Replace the super- charger assembly.

  • Page 164: Intake Manifold Installation

    POWR Air cooler, supercharger, and throttle body assembly Intake manifold installation ± & 1. Install: • Intake manifold NOTE: Tighten the bolts to the specified torques in the ² sequence shown. Intake manifold bolt: 1st: 10 N·m (1.0 kgf·m, 7.4 ft·lb) 2nd: 20 N·m (2.0 kgf·m, 14.8 ft·lb) LOCTITE 242 Supercharger installation...

  • Page 165: Air Cooler Intake Hose Installation

    POWR Air cooler, supercharger, and throttle body assembly 2. Install: • Supercharger Installation step: 1. Tighten the supercharger bolts 1, and then bolts 2 to the specified torque. Supercharger bolt (M8 × 65 mm) 1: 20 N·m (2.0 kgf·m, 14.8 ft·lb) LOCTITE 242 Supercharger bolt (M6 ×...

  • Page 166: Boost Pipe Installation

    POWR Air cooler, supercharger, and throttle body assembly Boost pipe installation 1. Install: • Boost pipe 1 • Hose 2 • Joint 3 Installation steps: 1. Install the hose 2 and joint 3 to the boost pipe 1. NOTE: • Fit the projection a on the boost pipe 1 between the projections b on the hose 2.

  • Page 167: Oil Cooler, Oil Pump Assembly, And Drive Gear

    POWR Oil cooler, oil pump assembly, and drive gear Oil cooler, oil pump assembly, and drive gear Oil cooler and oil pump assembly removal 11 N · m (1.1 kgf · m, 8.1 ft · 6 × 20 mm 19 N ·...
  • Page 168 POWR Oil cooler, oil pump assembly, and drive gear · m (1.1 kgf · m, 8.1 ft · 11 N 6 × 20 mm 19 N · m (1.9 kgf · m, 14.0 ft · 8 × 70 mm m (1.8 kgf m, 13.3 ft 18 N ·...
  • Page 169 POWR Oil cooler, oil pump assembly, and drive gear Drive gear removal · · · 80 N m (8.0 kgf m, 59.0 ft 12 × 58 mm Step Q’ty Service points Procedure/Part name Shaft Circlip Washer Bearing Collar Idle gear Washer Collar Bolt...
  • Page 170 POWR Oil cooler, oil pump assembly, and drive gear 80 N · m (8.0 kgf · m, 59.0 ft · 12 × 58 mm Step Q’ty Service points Procedure/Part name Washer Circlip Washer Drive gear clutch CAUTION: • Make sure that the drive gear clutch is installed so that the side a is facing to- ward the supercharger drive gear as shown.

  • Page 171: Drive Gear Assembly Removal

    POWR Oil cooler, oil pump assembly, and drive gear Drive gear assembly removal 1. Remove: • Drive gear assembly Removal steps: 1. Remove the drive coupling and generator cover. Refer to “Generator cover and flywheel magneto removal.” 2. Hold the flywheel magneto 1 with the spe- cial service tools 2 and 3.

  • Page 172: Oil Cooler Assembly Check

    POWR Oil cooler, oil pump assembly, and drive gear Oil cooler assembly check CAUTION: The oil cooler assembly should not be dis- assembled. 1. Check: • Oil cooler assembly Cracks/damage → Replace the oil cooler assembly. • Oil cooler holding pressure Cannot be maintained →...

  • Page 173: Oil Pump Assembly Check

    POWR Oil cooler, oil pump assembly, and drive gear Oil pump assembly check CAUTION: The oil pump assembly should not be dis- assembled. 1. Check: • Oil pump assembly • Oil pump driven gear 1 Cracks/damage → Replace the oil pump assembly.

  • Page 174: Drive Gear Clutch Check

    POWR Oil cooler, oil pump assembly, and drive gear Drive gear clutch check 1. Check: • Drive gear clutch Cracks/damage → Replace the drive gear clutch. • Drive gear clutch operation Does not operate properly → Replace the drive gear clutch. CAUTION: Make sure that the drive gear clutch is in- È...

  • Page 175: Drive Gear Assembly Installation

    POWR Oil cooler, oil pump assembly, and drive gear Drive gear assembly installation 1. Install: • Drive gear assembly Installation steps: 1. Hold the flywheel magneto 1 with the spe- cial service tools 2 and 3. Shaft holder 2: 90890-06721 Driver handle 3: 90890-06722 2.

  • Page 176: Oil Pump Assembly Installation

    POWR Oil cooler, oil pump assembly, and drive gear Oil pump assembly installation 1. Fill: • Oil pump assembly CAUTION: Be sure to fill the oil pump assembly with engine oil through the scavenge and feed ports. Filling steps: 1. Fill the oil pump assembly with engine oil through the feed port a and scavenge port b.

  • Page 177: Camshaft

    POWR Camshaft Camshaft Cylinder head cover removal · m (0.8 kgf · m, 5.9 ft · 6 × 20 mm · m (0.8 kgf · m, 5.9 ft · 6 × 30 mm 25 N · m (2.5 kgf · m, 18.4 ft ·...

  • Page 178: Camshaft And Timing Chain Removal

    POWR Camshaft Camshaft and timing chain removal · · · · m (0.8 kgf · m, 5.9 ft · 16 N m (1.6 kgf m, 11.8 ft 7 × 45 mm 6 × 14 mm · · · 24 N m (2.4 kgf m, 17.7 ft 7 ×...
  • Page 179 POWR Camshaft m (0.8 kgf m, 5.9 ft 16 N · m (1.6 kgf · m, 11.8 ft · · · · 7 × 45 mm 6 × 14 mm · · · 24 N m (2.4 kgf m, 17.7 ft 7 ×...
  • Page 180 POWR Camshaft · · · · m (0.8 kgf · m, 5.9 ft · 16 N m (1.6 kgf m, 11.8 ft 7 × 45 mm 6 × 14 mm · · · 24 N m (2.4 kgf m, 17.7 ft 7 ×...

  • Page 181: Camshaft Removal

    POWR Camshaft Camshaft removal 1. Remove: • Camshafts Removal steps: 1. Install the special service tools 1 and 2 into spark plug hole #1. Gauge stand 1: 90890-06725 Dial gauge stand set: YB-06585 Dial gauge 2: YU-03097/90890-01252 Dial gauge needle: 90890-06584 2.
  • Page 182 POWR Camshaft 7. Loosen the intake and exhaust camshaft cap bolts in the sequence shown. NOTE: For reference during installation, put identifica- tion marks d on the camshaft caps. 8. Remove the intake camshaft 7 and exhaust camshaft 8. NOTE: To prevent the timing chain from falling into the crankcase, secure it with a wire 9.

  • Page 183: Camshaft Check

    POWR Camshaft Camshaft check 1. Check: • Camshaft lobes Pitting/scratches → Replace the cam- shaft. 2. Measure: • Camshaft lobe dimensions a and b Out of specification → Replace the cam- shaft. Camshaft lobe dimensions: Intake: a 40.9 mm (1.610 in) b 32.0 mm (1.260 in) Exhaust: a 41.0 mm (1.614 in)
  • Page 184 POWR Camshaft 5. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification → Replace the cyl- inder head assembly. Camshaft-journal-to-camshaft-cap clearance: 0.020–0.061 mm (0.0008–0.0024 in) Measurement steps: 1. Remove the valve lifters 1 and valve pads NOTE: Make a note of the position of each valve lifter and valve pad so that they can be installed in their original positions.

  • Page 185: Camshaft Sprocket Check

    POWR Camshaft Camshaft sprocket check 1. Check: • Camshaft sprockets Damage/wear → Replace the camshaft sprockets and timing chain as a set. Timing chain check 1. Check: • Timing chain Damage/stiffness/wear → Replace the timing chain and camshaft sprockets as a set.

  • Page 186: Camshaft Installation

    POWR Camshaft Camshaft installation 1. Install: • Camshafts Installation steps: 1. Position piston #1 at TDC. Refer to “Camshaft removal.” 2. Install the exhaust camshaft sprocket 1 and intake camshaft sprocket 2. NOTE: • Install each camshaft sprocket with the punch mark a facing outward.
  • Page 187 POWR Camshaft 4. Install the exhaust camshaft caps, intake camshaft caps, and bolts. 5. Gradually tighten the camshaft cap bolts to the specified torque in the sequence shown. NOTE: • Apply engine oil to the threads of the cam- shaft cap bolts. •...

  • Page 188: Cylinder Head Cover Installation

    POWR Camshaft 12. Turn the drive coupling 0 counterclock- wise 2 turns. NOTE: Make sure that the camshafts turn smoothly. If the camshafts do not turn smoothly, reinstall camshafts. Refer to the installation steps. 13. Check that the portion g of the timing chain is taut.

  • Page 189: Valve Clearance Adjustment

    POWR Camshaft Valve clearance adjustment NOTE: To measure the valve clearance, refer to “Valve clearance measurement” in Chapter 3. 1. Adjust: • Valve clearance Adjustment steps: 1. Remove the camshaft. Refer to “Camshaft removal.” 2. Remove the valve lifter 1 and valve pad NOTE: Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be...
  • Page 190 POWR Camshaft 8. Rotate the valve lifter and check that it turns smoothly. 9. Install the camshafts, timing chain, and camshaft caps. Refer to “Camshaft installation.” Camshaft cap bolt: 16 N·m (1.6 kgf·m, 11.8 ft·lb) 10. Install the special service tools 3 and 4 into spark plug hole #1.
  • Page 191 POWR Camshaft Intake MEASURED ORIGINAL VALVE PAD NUMBER CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.00–0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 0.03–0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 0.07–0.10...

  • Page 192: Cylinder Head

    POWR Cylinder head Cylinder head Cylinder head assembly removal 12 N · m (1.2 kgf · m, 8.9 ft · · · · 48 N m (4.8 kgf m, 35.4 ft 6 × 12 mm 2nd 90˚ 12 × 140 mm ·...
  • Page 193 POWR Cylinder head Cylinder head disassembly Step Q’ty Service points Procedure/Part name Valve lifter Valve pad Valve cotter Upper spring seat Valve spring Lower spring seat Intake valve Exhaust valve Valve seal Not reusable Valve guide Not reusable Cylinder head Reverse the disassembly steps for assembly.

  • Page 194: Cylinder Head Assembly Removal

    POWR Cylinder head Cylinder head assembly removal 1. Remove: × • Cylinder head bolts (M6 55 mm) 1 × 140 mm) 2 • Cylinder head bolts (M12 NOTE: Loosen the cylinder head bolts 2 in the sequence shown. Valve removal 1.

  • Page 195: Valve Spring Check

    POWR Cylinder head 2. Measure: • Cylinder head warpage Out of specification → Replace the cyl- inder head. Measurement steps: 1. Eliminate carbon deposits from the com- bustion chambers. 2. Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in the directions shown.
  • Page 196 POWR Cylinder head 2. Measure: • Valve face width a Out of specification → Replace the valve. Valve face width a: Intake and exhaust: 2.26–2.83 mm (0.089–0.111 in) • Valve margin thickness b Out of specification → Replace the valve. Valve margin thickness b: Intake and exhaust: 0.80–1.20 mm (0.031–0.047 in)

  • Page 197: Valve Guide Check

    POWR Cylinder head Valve guide check 1. Measure: • Valve guide inside diameter a Valve guide inside diameter: Intake and exhaust: 5.504–5.522 mm (0.2167–0.2174 in) 2. Calculate: • Valve stem-to-valve guide clearance Out of specification → Replace the valve and valve guide. Valve stem-to-valve guide clearance = valve guide inside diameter –...

  • Page 198: Valve Guide Installation

    POWR Cylinder head Valve guide installation 1. Install: • New valve guide 1 Installation steps: 1. Insert the special service tools 2 and 3 into the camshaft end of a new valve guide Valve guide remover 2: YB-06801/90890-06801 Valve guide installer 3: YB-06810/90890-06810 2.

  • Page 199: Valve Seat Check

    POWR Cylinder head Valve seat check 1. Measure: • Valve seat contact Does not seat properly → Reface the valve seat. Measurement steps: 1. Eliminate carbon deposits from the valves and valve seats. 2. Apply a thin, even layer of Mechanic’s blueing dye (Dykem) onto the valve seat.

  • Page 200: Valve Seat Refacing

    POWR Cylinder head Valve seat refacing CAUTION: Do not over cut the valve seat. Be sure to turn the cutter evenly downward at a pres- sure of 40–50 N (4–5 kgf, 8.8–11 lbf) to pre- vent chatter marks. NOTE: Does not turn the special service tool counter- clockwise when refacing the valve seat.
  • Page 201 POWR Cylinder head 2. Use a 30° cutter to adjust the contact width 30˚ of the top edge of the valve seat. b Previous contact width 3. Use a 60° cutter to adjust the contact width of the bottom edge of the valve seat. b Previous contact width 60˚...
  • Page 202 POWR Cylinder head • If the valve seat contact width 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, and then use a 45° cutter to center the area and set its width.

  • Page 203: Valve Installation

    POWR Cylinder head Valve installation 1. Install: • Valve seal 1 • Valve 2 • Lower spring seat 3 • Valve spring 4 • Upper spring seat 5 • Valve cotters 6 Installation steps: 1. Install a new valve seal 1 onto the valve guide.

  • Page 204: Cylinder Head Installation

    POWR Cylinder head 4. Lightly tap the upper spring seat with a plastic hammer to set the valve cotters 6 securely. Cylinder head installation 1. Install: • Cylinder head CAUTION: Do not reuse the cylinder head bolts 1 and the cylinder head gasket, always replace them with new ones.
  • Page 205 POWR Generator cover and flywheel magneto Generator cover and flywheel magneto Generator cover and flywheel magneto removal · · · m (0.8 kgf m, 5.9 ft 6 × 20 mm 26 N · m (2.6 kgf · m, 19.2 ft ·...
  • Page 206 POWR Generator cover and flywheel magneto · · · m (0.8 kgf m, 5.9 ft 6 × 20 mm · · · 26 N m (2.6 kgf m, 19.2 ft 8 × 50 mm 80 N · m (8.0 kgf ·...
  • Page 207 POWR Generator cover and flywheel magneto Generator cover disassembly · · · 15 N m (1.5 kgf m, 11.1 ft 6 × 15 mm · m (0.5 kgf · m, 3.7 ft · 5 × 10 mm · · · 15 N m (1.5 kgf m, 11.1 ft...

  • Page 208: Drive Coupling Removal

    POWR Generator cover and flywheel magneto Drive coupling removal 1. Remove: • Drive coupling 1 Removal steps: 1. Remove the plug from the drive coupling. 2. Hold the transfer shaft with the special ser- vice tool 2, and then remove the drive coupling 1 with the special service tool 3.

  • Page 209: Bearing Removal

    POWR Generator cover and flywheel magneto 2. Remove: • Flywheel magneto 1 Removal steps: 1. Remove the flywheel magneto 1 with the special service tools 2 and 3. Flywheel puller 2: 90890-06723 Rotor puller 3: 90890-01080 2. Remove the flywheel magneto bolts 4, and then remove the starter clutch assem- bly 5.

  • Page 210: Transfer Shaft Check

    POWR Generator cover and flywheel magneto Transfer shaft check 1. Check: • Transfer shaft Cracks/damage → Replace the transfer shaft. Starter clutch check 1. Check: • Starter clutch rollers Cracks/damage → Replace the starter clutch assembly. 2. Check: • Starter gear Cracks/damage →...

  • Page 211: Bearing Installation

    POWR Generator cover and flywheel magneto Bearing installation È CAUTION: Do not reuse the bearing, always replace it with a new one. 1. Install: • Bearing 1 • Circlip 2 Driver handle (large): É YB-06071 Forward gear outer race installer: YB-41446 Driver rod LS: 90890-06606...

  • Page 212: Generator Cover Assembly

    POWR Generator cover and flywheel magneto Generator cover assembly 1. Install: • Stator coil assembly 1 NOTE: Pass the pickup coil lead 2 between the cover and the bolt hole a, and then hold the washer Clamp bolt 4: 15 N·m (1.5 kgf·m, 11.1 ft·lb) Stator coil bolt 5: 15 N·m (1.5 kgf·m, 11.1 ft·lb) Washer bolt 6:...
  • Page 213 POWR Generator cover and flywheel magneto 2. Install: • Starter gear 1 • Woodruff key 2 • Flywheel magneto 3 • Transfer shaft 4 Installation steps: 1. Install the starter gear 1, woodruff key 2, flywheel magneto 3, and transfer shaft 4. NOTE: Be sure to remove any grease from the tapered portion a of the crankshaft and the...

  • Page 214: Drive Coupling Installation

    POWR Generator cover and flywheel magneto Drive coupling installation 1. Install: • Drive coupling 1 Installation step: 1. Hold the transfer shaft with the special ser- vice tool 2, and then tighten the drive cou- pling 1 with the special service tool 3. Crankshaft holder 2: YB-06562/90890-06562 Coupler wrench 3:...

  • Page 215: Oil Separator Tank And Oil Pan

    POWR Oil separator tank and oil pan Oil separator tank and oil pan Oil separator tank and oil pan removal · · · · · · 15 N m (1.5 kgf m, 11.1 ft m (0.8 kgf m, 5.9 ft 6 ×...
  • Page 216 POWR Oil separator tank and oil pan · · · · · · 15 N m (1.5 kgf m, 11.1 ft m (0.8 kgf m, 5.9 ft 6 × 20 mm 20 N · m (2.0 kgf · m, 14.8 ft ·...
  • Page 217 POWR Oil separator tank and oil pan · · · · · · 15 N m (1.5 kgf m, 11.1 ft m (0.8 kgf m, 5.9 ft 6 × 20 mm 20 N · m (2.0 kgf · m, 14.8 ft ·...
  • Page 218 POWR Oil separator tank and oil pan · · · · · · 15 N m (1.5 kgf m, 11.1 ft m (0.8 kgf m, 5.9 ft 6 × 20 mm 20 N · m (2.0 kgf · m, 14.8 ft ·...

  • Page 219: Oil Pan Disassembly

    POWR Oil separator tank and oil pan Oil pan disassembly · · · 12 N m (1.2 kgf m, 8.9 ft 6 × 14 mm · · · 12 N m (1.2 kgf m, 8.9 ft 6 × 14 mm ·...

  • Page 220: Oil Pan Check

    POWR Oil separator tank and oil pan Oil pan check 1. Check: • Baffle plate 1 Clog/contaminants → Clean the baffle plate. Cracks/damage → Replace the baffle plate. • Oil pan 2 Cracks/damage → Replace the oil pan. 2. Check: •...
  • Page 221 POWR Crankcase, connecting rod, and piston Crankcase, connecting rod, and piston Crankcase, connecting rod, and piston disassembly · m (5.0 kgf · m, 36.9 ft · 50 N 10 × 30 mm 1280B 10 N · m (1.0 kgf · m, 7.4 ft ·...

  • Page 222: Crankcase, Connecting Rod, And Piston

    POWR Crankcase, connecting rod, and piston · m (5.0 kgf · m, 36.9 ft · 50 N 10 × 30 mm 1280B m (1.0 kgf m, 7.4 ft 10 N · · · 6 × 70 mm · · · 1st 51 N m (5.1 kgf m, 37.6 ft...
  • Page 223 POWR Crankcase, connecting rod, and piston · m (5.0 kgf · m, 36.9 ft · 50 N 10 × 30 mm 1280B 10 N · m (1.0 kgf · m, 7.4 ft · 6 × 70 mm · · · 1st 51 N m (5.1 kgf m, 37.6 ft...

  • Page 224: Crankcase Disassembly

    POWR Crankcase, connecting rod, and piston Crankcase disassembly 1. Remove: • Crankcase bolts (M6 × 70 mm) 1–B • Crankcase bolts (M8 × 85 mm) C–L NOTE: • Place the crankcase upside down on a bench. • The numbers embossed on the crankcase indicate the crankcase tightening sequence.

  • Page 225: Crankcase Check

    POWR Crankcase, connecting rod, and piston 2. Remove: • Piston pin clips 1 • Piston pin 2 • Piston 3 • Connecting rod 4 • Connecting rod cap bolts 5 NOTE: For reference during installation, put identifica- tion marks a on the piston crown and con- necting rod.

  • Page 226: Piston Check

    POWR Crankcase, connecting rod, and piston Piston check 1. Check: • Piston wall Vertical scratches → Replace the piston and piston rings as a set. 2. Measure: • Piston outside diameter a Out of specification → Replace the pis- ton. Piston outside diameter a: 85.915–85.930 mm (3.3825–3.3831 in)

  • Page 227: Piston Ring Check

    POWR Crankcase, connecting rod, and piston Piston ring check 1. Measure: • Piston ring dimensions B and T Out of specification → Replace the pis- ton rings as a set. Piston ring dimensions: Top ring B: 1.17–1.19 mm (0.0461–0.0469 in) T: 2.85–3.05 mm (0.112–0.120 in) 2nd ring...

  • Page 228: Piston Pin Check

    POWR Crankcase, connecting rod, and piston 3. Measure: • Piston ring grooves Out of specification → Replace the pis- ton. NOTE: Before measuring the piston ring grooves, eliminate any carbon deposits from the piston ring grooves. Piston ring groove: Top ring 1.21–1.23 mm (0.0476–0.0484 in) 2nd ring 1.21–1.23 mm (0.0476–0.0484 in)

  • Page 229: Connecting Rod Check

    POWR Crankcase, connecting rod, and piston Connecting rod check 1. Measure: • Connecting rod small end inside diameter a Out of specification → Replace the con- necting rod assembly. Connecting rod small end inside diameter a: 22.015–22.028 mm (0.8667–0.8672 in) Cylinder check 1.

  • Page 230: Crankshaft Check

    POWR Crankcase, connecting rod, and piston Crankshaft check 1. Measure: • Crankshaft journal a diameter • Crankshaft pin b diameter Out of specification → Replace the crankshaft. Crankshaft journal a diameter: 39.976–40.000 mm (1.5739–1.5748 in) Crankshaft pin b diameter: 41.976–42.000 mm (1.6526–1.6535 in) 2.
  • Page 231 POWR Crankcase, connecting rod, and piston 2. Install the upper bearing into the connect- ing rod and lower bearing into the connect- ing rod cap. NOTE: • Install the connecting rod bearings in their original positions. • Insert the projection a of each bearing into the slots in the connecting rod cap and con- necting rod.
  • Page 232 POWR Crankcase, connecting rod, and piston 2. Select: • Connecting rod bearing Selecting steps: 1. Check the connecting rod size number a on the connecting rod. 2. Check the crankshaft pin size number b on the crankshaft web. 3. Select the suitable color c for the con- necting rod bearing from the table.

  • Page 233: Crankshaft Journal Oil Clearance Check

    POWR Crankcase, connecting rod, and piston Crankshaft journal oil clearance check 1. Measure: • Crankshaft journal oil clearance Out of specification → Replace the crankshaft journal bearings. Measurement steps: 1. Clean the bearings, crankshaft journals, and bearing portions of the crankcase and cylinder block.
  • Page 234 POWR Crankcase, connecting rod, and piston 8. Tighten the crankcase bolts to the speci- fied torques in 2 stages in the sequence shown. NOTE: • Apply engine oil to the crankcase bolts threads. • Do not turn the crankshaft until the crank- shaft journal oil clearance measurement has been completed.
  • Page 235 POWR Crankcase, connecting rod, and piston 2. Select: • Crankshaft main journal bearing Selecting steps: 1. Check the crankcase journal size number a on the crankcase. NOTE: If the crankcase journal sizes are the same at all positions, the size number a is stamped only at the “J1”...

  • Page 236: Connecting Rod And Piston Installation

    POWR Crankcase, connecting rod, and piston Connecting rod and piston installation 1. Install: • Piston 1 • Connecting rod 2 • Piston pin 3 • Piston pin clips 4 • Connecting rod cap bolts 5 CAUTION: Do not reuse the piston pin clips 4 and connecting rod cap bolts 5, always replace them with new ones.
  • Page 237 POWR Crankcase, connecting rod, and piston 3. Offset: • Piston ring end gap È a Top ring, oil ring expander spacer b 2nd ring c Upper oil ring rail d Lower oil ring rail È Intake side 90˚ 4. Install: •...

  • Page 238: Crankcase Assembly

    POWR Crankcase, connecting rod, and piston Crankcase assembly 1280B 1. Install • Dowel pin 1 • O-ring 2 NOTE: • Thoroughly clean all the gasket surfaces and crankcase mating surfaces. • Apply sealant to the mating surface of the 1280B crankcase.
  • Page 239 POWR Crankcase, connecting rod, and piston 3. Tighten: • Bracket bolts NOTE: Tighten the bolts a, and then tighten the bolts Bracket bolt: 50 N·m (5.0 kgf·m, 36.9 ft·lb) LOCTITE 271 5-114...

  • Page 240: Cooling Water

    POWR Cooling water Cooling water Cooling water hose routing È Ê É É 1 Hose joint 2 2 Hose joint 3 È To hose joint 1 É To cooling water pilot outlet on port side Ê To cooling water pilot outlet on starboard side 5-115...

  • Page 241: Thermostat Removal

    POWR Cooling water Thermostat removal · · · m (0.8 kgf m, 5.9 ft 6 × 35 mm È Ê É Step Q’ty Service points Procedure/Part name È To drain joint Clamp/cooling water hose Bolt Thermostat housing Thermostat NOTE: Install the thermostat so that the hole a is positioned as shown.

  • Page 242: Cooling Water Line Check

    POWR Cooling water Cooling water line check 1. Check: • Thermostat housing 1 • Hose joints 2 • Cooling water hoses Cracks/damage → Replace. Thermostat check 1. Check: • Thermostat valve opening a Out of specification → Replace the ther- mostat.
  • Page 243 POWR Cooling water — MEMO — 5-118...
  • Page 244 PUMP Chapter 6 Jet pump unit Intake grate and ride plate................6-1 Intake grate and ride plate removal ............6-1 Jet pump unit....................6-2 Jet pump unit removal ................6-2 Jet pump unit removal ................6-4 Jet pump unit installation ................6-5 Reverse gate....................
  • Page 245 PUMP Intermediate housing................... 6-22 Intermediate housing removal ..............6-22 Intermediate housing disassembly ............6-23 Intermediate housing removal ..............6-25 Driven coupling removal ................6-25 Intermediate drive shaft removal ............. 6-25 Oil seal removal..................6-26 Bearing removal ..................6-26 Intermediate drive shaft and grease hose check........6-26 Driven coupling and intermediate housing check ........

  • Page 246: Intake Grate And Ride Plate

    PUMP Intake grate and ride plate Intake grate and ride plate Intake grate and ride plate removal · m (0.4 kgf · m, 3.0 ft · 5 × 12 mm 17 N · m (1.7 kgf · m, 12.5 ft ·...

  • Page 247: Jet Pump Unit Removal

    PUMP Jet pump unit Jet pump unit Jet pump unit removal · m (1.5 kgf · m, 11.1 ft · · m (0.7 kgf · m, 5.2 ft · 15 N 6 × 22 mm 8 × 13 mm · m (0.2 kgf ·...
  • Page 248 PUMP Jet pump unit m (0.7 kgf m, 5.2 ft · m (1.5 kgf · m, 11.1 ft · · · · 15 N 6 × 22 mm 8 × 13 mm · m (0.2 kgf · m, 1.5 ft ·...
  • Page 249 PUMP Jet pump unit Jet pump unit removal WARNING Be sure to remove the battery before re- moving the jet pump unit. 1. Remove: • Intake grate 1 • Speed sensor 2 (FX SHO) Speed and water temperature sensor 2 (FX Cruiser SHO) •...

  • Page 250: Jet Pump Unit Installation

    PUMP Jet pump unit Jet pump unit installation 1194E WARNING Be sure to remove the battery before in- stalling the jet pump unit. 1. Install: • Jet pump unit 1 NOTE: Rotate the drive shaft 2 to align the splines on the drive shaft with the splines on the inside of the intermediate drive shaft.

  • Page 251: Reverse Gate

    PUMP Reverse gate Reverse gate Reverse gate removal · · · m (0.8 kgf m, 5.9 ft · m (0.1 kgf · m, 0.7 ft · 6 × 25 mm · m (0.8 kgf · m, 5.9 ft · 6 × 20 mm 20 N ·...
  • Page 252 PUMP Reverse gate · · · m (0.8 kgf m, 5.9 ft · m (0.1 kgf · m, 0.7 ft · 6 × 25 mm · m (0.8 kgf · m, 5.9 ft · 6 × 20 mm · · ·...

  • Page 253: Jet Thrust Nozzle And Nozzle Ring

    PUMP Jet thrust nozzle and nozzle ring Jet thrust nozzle and nozzle ring Jet thrust nozzle and nozzle ring removal · · · 16 N m (1.6 kgf m, 11.8 ft 8 × 20 mm · · · m (0.8 kgf m, 5.9 ft 16 N ·...

  • Page 254: Impeller Duct And Impeller Housing

    PUMP Impeller duct and impeller housing Impeller duct and impeller housing Impeller duct and impeller housing removal 40 N · m (4.0 kgf · m, 29.5 ft · 10 × 125 mm 1194E 1194E · · · m (0.7 kgf m, 5.2 ft 6 ×...

  • Page 255: Impeller Duct And Drive Shaft

    PUMP Impeller duct and drive shaft Impeller duct and drive shaft Impeller duct and drive shaft disassembly · · · · m (0.8 kgf · m, 5.9 ft · 69 N m (6.9 kgf m, 50.9 ft 6 × 20 mm ·...
  • Page 256 PUMP Impeller duct and drive shaft · · · · · · 69 N m (6.9 kgf m, 50.9 ft m (0.8 kgf m, 5.9 ft 6 × 20 mm · · · 110 N m (11.0 kgf m, 81.1 ft Step Q’ty Service points...

  • Page 257: Drive Shaft Removal

    PUMP Impeller duct and drive shaft Drive shaft removal 1. Remove: • Impeller 1 • Spacer 2 • Cap 3 • Nut 4 NOTE: The impeller has left-hand threads. Turn the impeller clockwise to loosen it. Drive shaft holder 5: YB-06201 Drive shaft holder 6 5: 90890-06520...
  • Page 258 PUMP Impeller duct and drive shaft 3. Remove: È • Rear bearing Slide hammer and adapters 1: YB-06096 Stopper guide plate 2: 90890-06501 Bearing puller assembly 3: 90890-06535 Stopper guide stand 4: 90890-06538 É È For USA and Canada É For worldwide 4.

  • Page 259: Impeller Check

    PUMP Impeller duct and drive shaft 5. Remove: È • Front bearing Driver handle (large) 1: YB-06071 Drive shaft needle bearing installer and remover 2: YB-06194 Driver rod L3 3: 90890-06652 Needle bearing attachment 4: 90890-06609 É É È For USA and Canada É...

  • Page 260: Drive Shaft Installation

    PUMP Impeller duct and drive shaft 2. Measure: • Drive shaft runout Out of specification → Replace the drive shaft. Drive shaft runout limit: 0.3 mm (0.012 in) Measuring point a: 310 mm (12.20 in) Drive shaft installation È 1. Install: •...
  • Page 261 PUMP Impeller duct and drive shaft 3. Install: • Drive shaft assembly (with front bearing) • Spacer Bearing attachment 1: 90890-06728 4. Apply: • EPNOC grease AP #0 (between the drive shaft and spacer) Quantity: 20 g (0.04 lb) 5. Install: •...

  • Page 262: Impeller Duct And Impeller Housing Installation

    PUMP Impeller duct and drive shaft 8. Install: • Spacer 1 • Impeller 2 NOTE: The impeller has left-hand threads. Turn the impeller counterclockwise to tighten it. Drive shaft holder 3: YB-06201 Drive shaft holder 6 3: 90890-06520 Impeller: 110 N·m (11.0 kgf·m, 81.1 ft·lb) LOCTITE 572 Impeller duct and impeller housing installation...
  • Page 263 PUMP Transom plate and hoses Transom plate and hoses Transom plate and hose removal · · · m (0.5 kgf m, 3.7 ft · · · 26 N m (2.6 kgf m, 19.2 ft · · · m (0.6 kgf m, 4.4 ft ·...

  • Page 264: Transom Plate And Hoses

    PUMP Transom plate and hoses · · · m (0.5 kgf m, 3.7 ft · · · 26 N m (2.6 kgf m, 19.2 ft · · · m (0.6 kgf m, 4.4 ft · · · m (0.7 kgf m, 5.2 ft Step Q’ty...
  • Page 265 PUMP Transom plate and hoses · · · m (0.5 kgf m, 3.7 ft · · · 26 N m (2.6 kgf m, 19.2 ft · · · m (0.6 kgf m, 4.4 ft · m (0.7 kgf · m, 5.2 ft ·...

  • Page 266: Water Hose Check

    PUMP Transom plate and hoses Water hose check 1. Check: • Bilge hoses • Cooling water hoses Cracks/damage → Replace. Transom plate installation 1. install: • Transom plate NOTE: Clean the contacting surfaces before applying silicone sealant. Transom plate nut: 26 N·m (2.6 kgf·m, 19.2 ft·lb) 6-21...
  • Page 267 PUMP Intermediate housing Intermediate housing Intermediate housing removal · · · 17 N m (1.7 kgf m, 12.5 ft 8 × 48 mm Step Q’ty Service points Procedure/Part name Engine unit Refer to “Engine unit” in Chapter 5. Rubber damper Band Not reusable Grease hose...
  • Page 268 PUMP Intermediate housing Intermediate housing disassembly · · · m (0.5 kgf m, 3.7 ft · · · 36 N m (3.6 kgf m, 26.6 ft Step Q’ty Service points Procedure/Part name Band Not reusable Grease hose Nipple Driven coupling Washer Intermediate drive shaft O-ring...
  • Page 269 PUMP Intermediate housing · m (0.5 kgf · m, 3.7 ft · · · · 36 N m (3.6 kgf m, 26.6 ft Step Q’ty Service points Procedure/Part name Bearing Not reusable Intermediate housing Reverse the disassembly steps for assembly. 6-24...

  • Page 270: Intermediate Housing

    PUMP Intermediate housing Intermediate housing removal 1. Remove: • Intermediate housing assembly 1 • Shims 2 NOTE: Make a note of the position of each removed shim 2 so that it can be installed in its original position. Driven coupling removal 1.

  • Page 271: Oil Seal Removal

    PUMP Intermediate housing Oil seal removal È 1. Remove: • Oil seal (front) • Oil seals (rear) Slide hammer and adapters 1: YB-06096 Bearing puller legs 2: YB-06523 Stopper guide plate 3: 90890-06501 Bearing puller assembly 4: É 90890-06535 Stopper guide stand 5: 90890-06538 È...

  • Page 272: Driven Coupling And Intermediate Housing Check

    PUMP Intermediate housing Driven coupling and intermediate housing check 1. Check: • Driven coupling 1 • Rubber damper 2 • Intermediate housing 3 Cracks/damage → Replace. Bearing installation È CAUTION: Do not reuse the bearing, always replace it with a new one. 1.

  • Page 273: Oil Seal Installation

    PUMP Intermediate housing Oil seal installation È 1. Install: • Oil seal 1 Driver handle (large) 2: YB-06071 Needle bearing installer 3: YB-06434 Driver rod LS 4: 90890-06606 Bearing outer race attachment 5: 90890-06623 É Distance a: 6.5 ± 0.2 mm (0.26 ± 0.01 in) È...

  • Page 274: Driven Coupling Installation

    PUMP Intermediate housing 5. Install: • Thrust washer 1 Bearing attachment 2: 90890-06727 Distance a: 4.4 ± 0.3 mm (0.17 ± 0.01 in) Driven coupling installation 1. Install: • Driven coupling 1 NOTE: Make sure that the special service tool 2 is inserted completely into the intermediate drive shaft.
  • Page 275 PUMP Intermediate housing — MEMO — 6-30...
  • Page 276 – ELEC Chapter 7 Electrical system Electrical components................... 7-1 Electrical box....................7-3 Electrical components ................7-3 Electrical box disassembly ................ 7-4 Fuse box disassembly ................7-6 Electrical analysis ..................7-9 Check using the YDIS ................7-9 Input voltage measurement ..............7-10 Peak voltage measurement..............
  • Page 277 – ELEC Starting system .................... 7-47 Fuse......................7-47 Left handlebar switch assembly .............. 7-48 Main and fuel pump relay ................ 7-49 Starter relay ..................... 7-51 Starter motor ....................7-53 Starter motor disassembly............... 7-53 Starter motor operation................7-56 Armature....................7-56 Brush holder .................... 7-58 Gear cover....................

  • Page 278: Electrical Components

    – ELEC Electrical components Electrical components 1 Remote control receiver A TPS 2 Multifunction meter B Intake air temperature sensor 3 Right operation button assembly C Intake air pressure sensor D Engine temperature sensor (FX Cruiser SHO) 4 Steering sensor E Earth plate 5 Buzzer F Stator coil and pickup coil...
  • Page 279 – ELEC Electrical components J Speed sensor (FX SHO) S Left operation button assembly T Compass and air temperature sensor Speed and water temperature sensor (FX Cruiser SHO) (FX Cruiser SHO) K Thermo sensor U APS L Starter motor M Rectifier regulator N Cam position sensor O Spark plugs and ignition coils P Oil pressure switch...

  • Page 280: Electrical Box

    – ELEC Electrical box Electrical box Electrical components 1 Starter relay 2 Main and fuel pump relay 3 ETV relay 4 Slant detection switch 5 ECM 6 Fuse (30 A) (battery) 7 Fuse (10 A) (main and fuel pump relay) 8 Fuse (10 A) (ETV relay) 9 Fuse (3 A) (remote control receiver) 0 Fuse (20 A) (main and fuel pump relay)
  • Page 281 – ELEC Electrical box Electrical box disassembly · · · m (0.4 kgf m, 3.0 ft 6 × 18 mm · · · 13 N m (1.3 kgf m, 9.6 ft 8 × 25 mm · m (0.5 kgf · m, 3.7 ft ·...
  • Page 282 – ELEC Electrical box · · · m (0.4 kgf m, 3.0 ft 6 × 18 mm · · · 13 N m (1.3 kgf m, 9.6 ft 8 × 25 mm · · · m (0.5 kgf m, 3.7 ft 6 ×...

  • Page 283: Fuse Box Disassembly

    – ELEC Electrical box Fuse box disassembly 6 × 25 mm É 6 × 10 mm È 16 15 6 × 10 mm · · · 10 N m (1.0 kgf m, 7.4 ft 6 × 20 mm 6 × 7 mm Step Q’ty Service points...
  • Page 284 – ELEC Electrical box 6 × 25 mm É 6 × 10 mm È 16 15 6 × 10 mm · · · 10 N m (1.0 kgf m, 7.4 ft 6 × 20 mm 6 × 7 mm Step Q’ty Service points Procedure/Part name...
  • Page 285 – ELEC Electrical box 6 × 25 mm É 6 × 10 mm È 16 15 6 × 10 mm · · · 10 N m (1.0 kgf m, 7.4 ft 6 × 20 mm 6 × 7 mm Step Q’ty Service points Procedure/Part name...

  • Page 286: Electrical Analysis

    – ELEC Electrical analysis Electrical analysis Check using the YDIS When checking the TPS, APS, or other sen- sors, use the YDIS. When deleting the diagnosis record in the YDIS, be sure to check the time that the diag- nostic codes were detected. When checking the input voltage of a part, the coupler or connector must be disconnected.

  • Page 287: Input Voltage Measurement

    – ELEC Electrical analysis Input voltage measurement Push the unlock button 1 on the remote con- trol transmitter so that power is supplied to the ECM. NOTE: To check that the remote control transmitter is working correctly, refer to “Remote control transmitter.”...

  • Page 288: Ignition System

    – ELEC Electrical analysis / Ignition system È NOTE: • Before measuring the peak voltage, check all wiring for proper connection and corrosion, and check that the battery is fully charged. • Use the peak voltage adapter with the rec- ommended digital circuit tester.
  • Page 289 – ELEC Ignition system 4. Using the “Stationary test” of the YDIS, observe the ignition spark through the dis- charge window in the special service tool. WARNING • When checking the spark gap, do not touch any of the connections of the spe- cial service tool leads.
  • Page 290 – ELEC Ignition system 3. Measure: • ECM output peak voltage Within specification → Replace the igni- tion coil. Below specification → Check the pickup coil. Refer to “Pickup coil.” WARNING When checking the electrical components, do not touch any of the connections of the digital tester leads.

  • Page 291: Pickup Coil

    – ELEC Ignition system Pickup coil 1. Measure: • Pickup coil output peak voltage Below specification → Measure the pickup coil resistance. Measurement steps: 1. Disconnect the pickup coil coupler 1. 2. Connect the test harness (3 pins) 2 to the pickup coil coupler 1.

  • Page 292: Charging System

    – ELEC Ignition system / Charging system 2. Measure: • Pickup coil resistance Out of specification → Replace the sta- tor coil assembly. Measurement steps: 1. Disconnect the pickup coil coupler 1. 2. Measure the pickup coil resistance. Pickup coil resistance at 20 °C (68 °F) (reference data): White (W) –...
  • Page 293 – ELEC Charging system 3. Measure the stator coil output peak volt- age. NOTE: To crank the engine, connect the engine shut- off cord (lanyard) to the engine shut-off switch, and then push the engine start switch and engine stop switch simultaneously. Stator coil output peak voltage: Green (G) –...

  • Page 294: Rectifier Regulator

    – ELEC Charging system Rectifier regulator 1. Measure: • Rectifier regulator output peak voltage Below specification → Check the recti- fier regulator continuity. Measurement steps: 1. Disconnect the rectifier regulator coupler 2. Connect the test harness (2 pins) 2 to the rectifier regulator coupler 1.
  • Page 295 – ELEC Charging system 2. Check: È • Rectifier regulator continuity Out of specification → Replace the recti- fier regulator. Checking steps: 1. Remove the rectifier regulator. Refer to “Engine unit removal 3” in Chap- ter 5. 2. Check the rectifier regulator continuity. É...

  • Page 296: Control System

    – ELEC Control system Control system Oil pressure switch 1. Measure: • Oil pressure switch input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the oil pressure switch coupler 2. Push the unlock button, and then measure the input voltage between the oil pressure switch coupler terminal (wiring harness end) and ground.

  • Page 297: Thermoswitch

    – ELEC Control system 4. Check the oil pressure switch continuity. NOTE: Use a commercially available vacuum/pres- sure pump gauge and meter. Oil pressure switch continuity: Terminal thread 1 – Pressure Body 2 Below 128–166 kPa (1.28–1.66 kgf/cm Continuity 18.2–23.6 psi) Above 128–166 kPa (1.28–1.66 kgf/cm No continuity...
  • Page 298 – ELEC Control system 2. Check: • Thermoswitch continuity (at the specified temperatures) Out of specification → Replace the ther- moswitch. Checking steps: 1. Remove the thermoswitch. Refer to “Oil separator tank and oil pan removal” in Chapter 5. 2. Suspend the thermoswitch in a container filled with water.

  • Page 299: Thermo Sensor

    – ELEC Control system Thermo sensor 1. Measure: • Thermo sensor input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the thermo sensor coupler 1. 2. Push the unlock button, and then measure the input voltage at the thermo sensor cou- pler terminals (wiring harness end).

  • Page 300: Engine Temperature Sensor

    – ELEC Control system Engine temperature sensor 1. Measure: • Engine temperature sensor input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the engine temperature sensor coupler 1. 2. Push the unlock button, and then measure the input voltage at the engine tempera- ture sensor coupler terminals (wiring har- ness end).

  • Page 301: Intake Air Temperature Sensor

    – ELEC Control system 4. Measure the resistance when the specified temperatures are reached. Engine temperature sensor resistance (reference data): Black/yellow (B/Y) – Black/yellow (B/Y) 20 °C (68 °F): 54.2–69.0 kΩ 100 °C (212 °F): 3.12–3.48 kΩ Intake air temperature sensor 1.
  • Page 302 – ELEC Control system 2. Measure: • Intake air temperature sensor input voltage Within specification → Measure the intake air temperature sensor resis- tance. Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the intake air temperature sen- sor coupler 1.

  • Page 303: Intake Air Pressure Sensor

    – ELEC Control system 4. Measure the resistance when the specified temperatures are reached. Intake air temperature sensor resistance (reference data): Black (B) – Black (B) 0 °C (32 °F): 5.4–6.6 kΩ 80 °C (176 °F): 0.29–0.39 kΩ Intake air pressure sensor 1.
  • Page 304 – ELEC Control system 2. Check: • Intake air pressure sensor operation Does not operate → Replace the intake air pressure sensor. Checking steps: 1. Connect the special service tool to the intake air pressure sensor. 2. Connect a computer to the watercraft and use the YDIS to display the intake air pres- sure.

  • Page 305: Knock Sensor

    – ELEC Control system Knock sensor 1. Check: • Knock sensor ground connection Knock sensor not grounded when installed → Install the knock sensor cor- rectly. Refer to “Oil separator tank and oil pan removal” in Chapter 5. 2. Measure: •...
  • Page 306 – ELEC Control system 1. Check: • Throttle valve opening • TPS output voltage Out of specification → Measure the TPS input voltage. Checking steps: NOTE: When checking the TPS using the YDIS, do not start the engine. 1. Connect a computer to the watercraft and use the YDIS to display “Throttle position sensor 1,”...
  • Page 307 – ELEC Control system 5. Operate the throttle lever 1, and then check the TPS 2 output voltage and throt- tle valve opening angle at the fully open position É. NOTE: The actual TPS output voltage and throttle valve opening angle may vary according to environmental conditions and engine tempera- ture.

  • Page 308: Accelerator Position Sensor

    – ELEC Control system 3. Check: • TPS circuit No continuity → Replace the wiring har- ness assembly. Wiring harness is correct → Replace the throttle body assembly. Checking steps: 1. Disconnect the throttle body assembly coupler 1. 2. Disconnect the ECM couplers 2 and 3. 3.
  • Page 309 – ELEC Control system 1. Connect a computer to the watercraft and use the YDIS to display the “Accelerator position sensor 1” and “Accelerator posi- tion sensor 2.” NOTE: APS 1 and APS 2 are a single unit, which can- not be disassembled.
  • Page 310 – ELEC Control system 2. Measure: • APS input voltage Within specification → Measure the APS resistance. Out of specification → Check the APS circuit. Measurement steps: 1. Disconnect the APS coupler 1. 2. Push the unlock button, and then measure the input voltage at the APS coupler termi- nals (wiring harness end).
  • Page 311 – ELEC Control system 3. Check that the APS pulley stopper c con- tacts the fully open stopper d when the APS pulley is at the fully open position É. 4. Measure the resistance of the APS at the fully closed position and fully open posi- 1 2 3 4 5 6 7 8 tion.

  • Page 312: Electronic Throttle Valve Relay

    – ELEC Control system Electronic throttle valve relay 1. Measure: • ETV relay input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the ETV relay coupler 1. 2. Push the unlock button, and then measure the input voltage between the ETV relay coupler terminals and ground.

  • Page 313: Cam Position Sensor

    – ELEC Control system Cam position sensor 1. Measure: • Cam position sensor input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the cam position sensor cou- pler 1. 2. Push the unlock button, and then measure the input voltage at the cam position sen- sor coupler terminals (wiring harness end).

  • Page 314: Slant Detection Switch

    – ELEC Control system Slant detection switch 1. Measure: • Slant detection switch input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the slant detection switch cou- pler 1. 2. Push the unlock button, and then measure the input voltage at the slant detection switch coupler (wiring harness end).

  • Page 315: Steering Sensor

    – ELEC Control system Steering sensor 1. Check: • Steering sensor operation Does not operate → Measure the steer- ing sensor input voltage. Checking steps: 1. Connect a computer to the watercraft to use the YDIS. 2. Turn the handlebar all the way to the left or right.

  • Page 316: Reverse Sensor

    – ELEC Control system 2. Measure: • Steering sensor input voltage Within specification → Replace the steering sensor. Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the steering sensor coupler 1. 2. Push the unlock button, and then measure the input voltage at the steering sensor coupler terminals (wiring harness end).

  • Page 317: Right Handlebar Switch Assembly

    – ELEC Control system 2. Measure: • Reverse sensor input voltage Within specification → Replace the reverse sensor. Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the reverse sensor coupler 1. 2. Push the unlock button, and then measure the input voltage at the reverse sensor coupler terminals (wiring harness end).
  • Page 318 – ELEC Control system 2. Measure: • Right handlebar switch input voltage Within specification → Replace the right handlebar switch assembly. Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the right handlebar switch cou- pler 1. 2.

  • Page 319: Ecm Circuit

    – ELEC Control system ECM circuit 1. Measure: • ECM input voltage Out of specification → Check the ECM circuit. Measurement steps: 1. Disconnect the ECM coupler 1. 2. Push the unlock button, and then measure the input voltage between the ECM cou- pler terminal (wiring harness end) and ground.

  • Page 320: Earth Plate

    – ELEC Control system Earth plate 1. Check: • Earth plate continuity No continuity → Replace the earth plate. Checking steps: 1. Remove the earth plate. Refer to “Oil separator tank and oil pan removal” in Chapter 5. 2. Check the continuity between each termi- nal 1 and the housing 2.

  • Page 321: Fuel System

    – ELEC Control system / Fuel system 2. Check: • Electric bilge pump operation Does not operate → Replace the elec- tric bilge pump. Checking steps: 1. Remove the electrical bilge pump. Refer “Transom plate hose removal” in Chapter 6. 2.
  • Page 322 – ELEC Fuel system 2. Measure: • Fuel injector input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the fuel injector couplers 1. 2. Push the unlock button, and then measure the input voltage between the fuel injector coupler terminals (wiring harness end) and ground.

  • Page 323: Fuel Pump Module

    – ELEC Fuel system Fuel pump module 1. Check: • Fuel pump module operation sound Does not sound → Measure the fuel pump module input voltage. Checking steps: 1. Connect a computer to the watercraft to use the YDIS. 2. Using the “Stationary test” of the YDIS, lis- ten for the fuel pump module operation sound.

  • Page 324: Starting System

    – ELEC Fuel system / Starting system 3. Measure: • Fuel sender resistance É Out of specification → Replace the fuel sender. Refer to “Fuel sender removal” in Chap- ter 4. È Measurement steps: 1. Remove the fuel pump module. Refer to “Fuel tank removal”...

  • Page 325: Left Handlebar Switch Assembly

    – ELEC Starting system Left handlebar switch assembly 1. Check: È • Engine start switch continuity Out of specification → Replace the left handlebar switch assembly. Checking steps: É 1. Disconnect the left handlebar switch cou- pler. Refer to “Handlebar assembly removal” in Chapter 8.

  • Page 326: Main And Fuel Pump Relay

    – ELEC Starting system 2. Check the engine stop switch continuity. Engine stop switch continuity: Engine stop White (W) – Clip 1 switch 2 Black (B) Free No continuity Installed È Pushed Continuity Free Continuity Removed É Pushed Continuity Main and fuel pump relay 1.
  • Page 327 – ELEC Starting system 2. Check: • Main relay continuity Out of specification → Replace the main and fuel pump relay. Checking steps: 1. Remove the main and fuel pump relay. Refer to “Fuse box disassembly.” 2. Connect the tester leads to the main and fuel pump relay terminals 5 and 6 or to the terminals 5 and 7.

  • Page 328: Starter Relay

    – ELEC Starting system Checking steps: 1. Connect the tester leads to the main and fuel pump relay terminals 7 and 8. 2. Connect the positive battery lead to the main and fuel pump relay terminal 6. 3. Connect the negative battery lead to the main and fuel pump relay terminal 4.
  • Page 329 – ELEC Starting system 2. Check: • Starter relay continuity Out of specification → Replace the starter relay. Checking steps: 1. Remove the starter relay. Refer to “Electrical box disassembly.” 2. Connect the tester leads between the starter relay terminals 1 and 2. 3.

  • Page 330: Starter Motor

    – ELEC Starter motor Starter motor Starter motor disassembly · · · m (0.9 kgf m, 6.6 ft · m (0.6 kgf · m, 4.4 ft · 6 × 120 mm Step Q’ty Service points Procedure/Part name Bolt Gear cover assembly Circlip Drive gear O-ring...
  • Page 331 – ELEC Starter motor · · · m (0.9 kgf m, 6.6 ft · · · m (0.6 kgf m, 4.4 ft 6 × 120 mm Step Q’ty Service points Procedure/Part name Shim Rear cover Shim Packing Not reusable Brush spring Armature Brush holder stay Spring washer...
  • Page 332 – ELEC Starter motor · · · m (0.9 kgf m, 6.6 ft · m (0.6 kgf · m, 4.4 ft · 6 × 120 mm Step Q’ty Service points Procedure/Part name Insulator washer 2 O-ring Not reusable Terminal bolt Lead plate Terminal insulator Plate cover...

  • Page 333: Starter Motor Operation

    – ELEC Starter motor Starter motor operation 1. Check: • Starter motor operation Does not operate → Check the starter motor. Checking steps: 1. Hold the starter motor in a vise using alu- minum plates on both sides. 2. Connect the positive battery cable 1 to the starter motor terminal bolt 2.
  • Page 334 – ELEC Starter motor 2. Measure: • Commutator diameter Out of specification → Replace the armature. Commutator diameter: 27.0–28.0 mm (1.06–1.10 in) 3. Measure: • Commutator undercut a Out of specification → Replace the armature. Commutator undercut a (reference data): 0.2–0.7 mm (0.008–0.028 in) 4.

  • Page 335: Brush Holder

    – ELEC Starter motor Brush holder 1. Measure: • Brush length a Out of specification → Replace the brush holder assembly. Brush length a: 5.0–12.5 mm (0.20–0.49 in) 2. Check: • Brush holder continuity Out of specification → Replace the brush holder assembly.

  • Page 336: Rear Cover

    – ELEC Starter motor / Remote control system Rear cover 1. Check: • Rear cover 1 • Metal 2 Cracks/damage → Replace the rear cover assembly. Starter motor assembly 1. Install: • Gear cover assembly Installation steps: 1. Install the ring gear 1, planetary gears 2, and dowel pin to the front cover 3.

  • Page 337: Remote Control Transmitter

    – ELEC Remote control system 2. Push the lock button 5 or unlock button 6 to transmit the ID code from the remote control transmitter to be registered. NOTE: • At this time, the system enters the registra- tion mode to register the first code. All exist- ing ID codes will be deleted from the remote control receiver.
  • Page 338 6. Check that the “UNLOCK” indicator light 2 goes off. NOTE: While the engine is running, input from the remote control transmitter is not received. Yamaha Security Number of beeps System mode 1 beep Lock Unlock 2 beeps...
  • Page 339 – ELEC Remote control system 2. Remove the battery 3. 3. Measure the battery voltage. CAUTION: • Do not touch the internal parts except the battery. • Do not touch the battery directly with your hands. Use a pair of non-conductive tweezers to replace the battery.

  • Page 340: Remote Control Receiver

    – ELEC Remote control system Remote control receiver 1. Measure: • Remote control receiver input voltage Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the remote control receiver coupler 1. 2. Measure the input voltage at the remote control receiver coupler terminals (wiring harness end).

  • Page 341: Indication System

    – ELEC Indication system Indication system Multifunction meter 1. Check: • Multifunction meter external appearance Cracked meter housing/meter is fogged/ shows signs of water intrusion → Replace the multifunction meter. 2. Check: • Multifunction meter display Intermittent or missing segment a → Replace the multifunction meter.

  • Page 342: Operation Button Assembly

    – ELEC Indication system 3. Measure: • Multifunction meter input voltage Within specification → Replace the mul- tifunction meter. Out of specification → Check the wiring harness. Measurement steps: 1. Disconnect the multifunction meter coupler 2. Push the unlock button, and then measure the input voltage at the multifunction meter coupler terminals (wiring harness end).
  • Page 343 – ELEC Indication system 2. Check the left operation button continuity. Left operation button continuity: Leads Pu/W Button Position Pu/W “Speed/ Free RPM” button Pushed Free “Volt/Hour” button 2 Pushed NOTE: “ ” indicates a continuity of electricity. 2. Check: •...

  • Page 344: Compass Display (Fx Cruiser Sho)

    – ELEC Indication system Compass display (FX Cruiser SHO) 1. Check: • Compass display Incorrect reading → Check the installa- tion condition of the compass and air temperature sensor. Checking steps: 1. Using a compass for reference, point the watercraft north. 2.

  • Page 345: Air Temperature Display (Fx Cruiser Sho)

    – ELEC Indication system Air temperature display (FX Cruiser SHO) 1. Check: • Air temperature display Incorrect reading → Replace the com- pass and air temperature sensor. Checking steps: 1. Measure the ambient air temperature. 2. Select the air temperature display mode of the multifunction meter and check the air temperature displayed on the meter.

  • Page 346: Speed Sensor

    – ELEC Indication system 2. Measure: • Speed and water temperature sensor 1 resistance Within specification → Replace the com- pass and air temperature sensor. Out of specification → Replace the speed and water temperature sensor. Measurement steps: 1. Disconnect the speed and water tempera- ture sensor coupler 2.

  • Page 347: Digital Speedometer Display (Fx Sho)

    – ELEC Indication system Digital speedometer display (FX SHO) 1. Measure: • Speed sensor output voltage Within specification → Replace the mul- tifunction meter. Out of specification → Replace the speed sensor. Measurement steps: 1. Disconnect the speed sensor coupler 1. Refer to “Steering master removal”...

  • Page 348: Digital Speedometer Display (Fx Cruiser Sho)

    – ELEC Indication system Digital speedometer display (FX Cruiser SHO) 1. Measure: • Speed and water temperature sensor output voltage Within specification → Replace the mul- tifunction meter. Out of specification → Replace the speed and water temperature sensor or compass and air temperature sensor.

  • Page 349: Fuel Level Meter Display And Fuel Level Warning Indicator

    – ELEC Indication system Fuel level meter display and fuel level warning indicator 1. Check: • Fuel level meter display 1 and fuel level warning indicator 2 Do not come on → Replace the multi- function meter. Checking steps: 1. Remove the fuel pump module assembly. Refer to “Fuel tank removal”...

  • Page 350: Diagnostic Display

    – ELEC Indication system Diagnostic display 1. Check: • Diagnostic display Does not come on → Check the “Diag- nosis record” of the YDIS. Checking steps: 1. Create a condition so that a diagnostic code is recorded. 2. Push the unlock button. 3.

  • Page 351: Engine Overheat Warning Indicator

    – ELEC Indication system Engine overheat warning indicator 1. Check: • Engine overheat warning indicator Does not come on → Check the “Diag- nosis record” of the YDIS. Checking steps: 1. Disconnect the thermoswitch coupler 1. 2. Connect the jumper lead 2 to the ther- moswitch coupler terminals (wiring har- ness end).
  • Page 352 – ELEC Indication system 2. Check: • Buzzer operation Does not sound → Replace the buzzer. Checking steps: 1. Remove the buzzer. Refer to “Steering master disassembly” in Chapter 8. 2. Connect the positive battery lead to the terminal 1 and the negative battery lead to the terminal 2.
  • Page 353 – ELEC Indication system — MEMO — 7-76...
  • Page 354 HULL HOOD Chapter 8 Hull and hood Handlebar ....................... 8-1 Steering pad removal (FX SHO)..............8-1 Steering pad removal (FX Cruiser SHO) ........... 8-2 Handlebar holder removal ................. 8-3 Handlebar assembly removal ..............8-4 Left and right handlebar switch disassembly..........8-7 Handlebar check..................
  • Page 355 HULL HOOD Hoses ......................8-41 Hose removal ..................8-41 Seats and hand grip..................8-43 Seat and hand grip removal ..............8-43 Seat lock check ..................8-45 Exhaust system.................... 8-46 Exhaust system and battery removal ............8-46 Exhaust system check................8-49 Deck and hull....................

  • Page 356: Handlebar

    HULL HOOD Handlebar Handlebar Steering pad removal (FX SHO) · m (0.1 kgf · m, 0.7 ft · 4 × 10 mm · · · m (0.1 kgf m, 0.7 ft 5 × 15 mm · · · m (0.5 kgf m, 3.7 ft 6 ×...

  • Page 357: Steering Pad Removal (Fx Cruiser Sho)

    HULL HOOD Handlebar Steering pad removal (FX Cruiser SHO) · · · m (0.1 kgf m, 0.7 ft 5 × 15 mm · · · m (0.5 kgf m, 3.7 ft 6 × 14 mm · · · m (0.1 kgf m, 0.7 ft 6 ×...

  • Page 358: Handlebar Holder Removal

    HULL HOOD Handlebar Handlebar holder removal 21 N · m (2.1 kgf · m, 15.5 ft · 8 × 48 mm Step Q’ty Service points Procedure/Part name Throttle cable NOTE: Be sure to remove the throttle cable seal as shown. Bolt a Punch mark Upper handlebar holder...

  • Page 359: Handlebar Assembly Removal

    HULL HOOD Handlebar Handlebar assembly removal · · · m (0.3 kgf m, 2.2 ft 5 × 35 mm · · · m (0.1 kgf m, 0.7 ft 5 × 35 mm · · · m (0.1 kgf m, 0.7 ft 6 ×...
  • Page 360 HULL HOOD Handlebar · · · m (0.3 kgf m, 2.2 ft 5 × 35 mm · · · m (0.1 kgf m, 0.7 ft 5 × 35 mm · · · m (0.1 kgf m, 0.7 ft 6 × 10 mm ·...
  • Page 361 HULL HOOD Handlebar · · · m (0.3 kgf m, 2.2 ft 5 × 35 mm · · · m (0.1 kgf m, 0.7 ft 5 × 35 mm · · · m (0.1 kgf m, 0.7 ft 6 × 10 mm ·...
  • Page 362 HULL HOOD Handlebar Left and right handlebar switch disassembly Step Q’ty Service points Procedure/Part name Left handlebar switch assembly Engine shut-off cord Stop button assembly Start button assembly Screw Right handlebar switch assembly E-ring Washer Shaft Lever Spring Reverse the disassembly steps for assembly.

  • Page 363: Handlebar Check

    HULL HOOD Handlebar Handlebar check 1. Check: • Handlebar Bends/cracks/damage → Replace the handlebar. Handlebar switch assembly check 1. Check: • Left handlebar switch assembly • Right handlebar switch assembly Cracks/damage → Replace the handle- bar switch assembly. NOTE: To check the operation and continuity of the left hand right handlebar switches, refer to “Left handlebar switch assembly”...
  • Page 364 HULL HOOD Handlebar È Installation steps: 1. Wrap the packings 1, making sure to align the upper edge a of the packing with the upper edge of the marking tape b on the lead and cable. Marking tape b: FX SHO: Throttle cable –...
  • Page 365 HULL HOOD Handlebar 2. Route: È • Throttle cable 1 • QSTS cable 2 • Right handlebar switch lead 3 • Left handlebar switch lead 4 Routing steps: 1. Route the throttle cable 1 as shown. 2. Make sure that the throttle cable 1, QSTS cables 2, and handlebar switch leads 3 É...
  • Page 366 HULL HOOD Handlebar 4. Install: • Throttle cable Installation steps: 1. Install the throttle cable end into the throt- tle lever. 2. Fit the seal 1 into the groove in the bracket. 3. Pull the throttle cable 2 in the direction of the arrow shown, and then fit the end of the seal 1 around the inner cable.

  • Page 367: Qsts Grip And Converter

    HULL HOOD QSTS grip and converter QSTS grip and converter QSTS grip and converter disassembly STERN 3 mm (0.12 in) 6 mm (0.24 in) · · · m (0.5 kgf m, 3.7 ft 6 × 33 mm · · · 5.9 N m (0.59 kgf m, 4.4 ft...
  • Page 368 HULL HOOD QSTS grip and converter STERN 3 mm (0.12 in) 6 mm (0.24 in) · · · m (0.5 kgf m, 3.7 ft 6 × 33 mm · · · 5.9 N m (0.59 kgf m, 4.4 ft · ·...

  • Page 369: Qsts Cable Removal

    HULL HOOD QSTS grip and converter QSTS cable removal 1. Remove: • QSTS converter 2. Remove: • Cable guide 1 NOTE: Remove the cable guide 1 with needlenose pliers as shown. 3. Remove: • QSTS cable ends QSTS check 1. Check: •...

  • Page 370: Qsts Cable Installation

    HULL HOOD QSTS grip and converter QSTS cable installation 1. Install: • QSTS cable ends NOTE: • Be sure to fit the QSTS cable end with yellow paint mark a into the STBD hole b of the pulley. • Be careful not to twist the QSTS cables. STERN 2.
  • Page 371 HULL HOOD QSTS grip and converter 3. Fit the grip 4 into the housing 3. 4. Fit the QSTS cables 1 into the housing NOTE: Fit the cable with the thin end a into the open- ing with the narrow groove b and the cable with the thick end c into the opening with the wide groove d.

  • Page 372: Front Hood

    HULL HOOD Front hood Front hood Front hood removal · · · · · · · · · 13 N m (1.3 kgf m, 9.6 ft m (0.5 kgf m, 3.7 ft m (0.5 kgf m, 3.7 ft 8 × 25 mm ·...
  • Page 373 HULL HOOD Front hood · · · · · · · · · 13 N m (1.3 kgf m, 9.6 ft m (0.5 kgf m, 3.7 ft m (0.5 kgf m, 3.7 ft 8 × 25 mm · · · m (0.1 kgf m, 0.7 ft 4 ×...
  • Page 374 HULL HOOD Front hood · · · · · · · · · 13 N m (1.3 kgf m, 9.6 ft m (0.5 kgf m, 3.7 ft m (0.5 kgf m, 3.7 ft 8 × 25 mm · · · m (0.1 kgf m, 0.7 ft 4 ×...

  • Page 375: Damper Check

    HULL HOOD Front hood Damper check 1. Check: • Damper assembly Does not hold front hood open → Replace the damper assembly. Mirror disassembly 1. Remove: • Mirror ornament 1 Removal step: 1. Push the projections a on the mirror orna- ment 1 shown and remove the ornament from the mirror cover 2.

  • Page 376: Rivet Removal

    HULL HOOD Front hood Rivet removal 1. Remove: • Rivets Removal step: 1. Push in the rivet pin 1 until it clicks and is below the top of the rivet. 2. Check: • Rivets Cracks/damage → Replace the rivets. Rivet installation 1.
  • Page 377 HULL HOOD Steering console cover Steering console cover Multifunction meter and cover removal · · · m (0.2 kgf m, 1.5 ft 5 × 15 mm · · · m (0.4 kgf m, 3.0 ft 5 × 12 mm Step Q’ty Service points Procedure/Part name...
  • Page 378 HULL HOOD Steering console cover · · · m (0.2 kgf m, 1.5 ft 5 × 15 mm · · · m (0.4 kgf m, 3.0 ft 5 × 12 mm Step Q’ty Service points Procedure/Part name Left operation button assembly Cover FX SHO Right operation button assembly...
  • Page 379 HULL HOOD Steering console cover Side cover removal · m (0.5 kgf · m, 3.7 ft · 6 × 28 mm 6 × 20 mm · · · m (0.5 kgf m, 3.7 ft Step Q’ty Service points Procedure/Part name Bolt Left side cover Right side cover...

  • Page 380: Center Cover Removal

    HULL HOOD Steering console cover Center cover removal 6 × 28 mm · m (0.5 kgf · m, 3.7 ft · · · · m (0.2 kgf m, 1.5 ft 5 × 16 mm 6 × 30 mm · · ·...
  • Page 381 HULL HOOD Steering console cover 6 × 28 mm · · · m (0.5 kgf m, 3.7 ft · m (0.2 kgf · m, 1.5 ft · 5 × 16 mm 6 × 30 mm · m (0.5 kgf · m, 3.7 ft ·...
  • Page 382 HULL HOOD Steering console cover Center cover disassembly · · · m (0.4 kgf m, 3.0 ft 5 × 20 mm Step Q’ty Service points Procedure/Part name Bolt Lid lock hook Bracket Grommet Hinge pin Center console box lid Gear Lock Reverse the disassembly steps for assembly.
  • Page 383 HULL HOOD Steering console cover Side cover removal 1. Remove: • Side cover 1 NOTE: While removing the side cover 1, push down on the cover near the tab a to release the raised portion on the tab. Shift lever removal 1.

  • Page 384: Steering Master

    HULL HOOD Steering master Steering master Steering master removal 5 × 25 mm 8 × 35 mm · · · 21 N m (2.1 kgf m, 15.5 ft · · · m (0.4kgf m, 3.0 ft · · · 16 N m (1.6 kgf m, 11.8 ft ·...
  • Page 385 HULL HOOD Steering master 5 × 25 mm 8 × 35 mm · · · 21 N m (2.1 kgf m, 15.5 ft · · · m (0.4kgf m, 3.0 ft · · · 16 N m (1.6 kgf m, 11.8 ft ·...
  • Page 386 HULL HOOD Steering master Steering master disassembly · · · m (0.4 kgf m, 3.0 ft 5 × 16 mm È · · · m (0.7 kgf m, 5.2 ft 6 × 25 mm É · · · m (0.4 kgf m, 3.0 ft 5 ×...
  • Page 387 HULL HOOD Steering master · · · m (0.4 kgf m, 3.0 ft 5 × 16 mm È · m (0.7 kgf · m, 5.2 ft · 6 × 25 mm É · · · m (0.4 kgf m, 3.0 ft 5 ×...
  • Page 388 HULL HOOD Steering master · · · m (0.4 kgf m, 3.0 ft 5 × 16 mm È · · · m (0.7 kgf m, 5.2 ft 6 × 25 mm É · · · m (0.4 kgf m, 3.0 ft 5 ×...

  • Page 389: Steering Master Component Check

    HULL HOOD Steering master Steering master component check 1. Check: • Bushings 1 • Lock 2 Cracks/damage/wear → Replace. 2. Check: • Steering shaft Cracks/damage → Replace the steering shaft. CAUTION: Do not disassemble the board spring a, otherwise the OTS does not function prop- erly.

  • Page 390: Rubber Seal Installation

    HULL HOOD Steering master 2. Install: • Spring 1 1 Installation steps: 1. Install the spring 1 1 into the spring holder 2, and then install the holder to the right housing 3. 2. While compressing the spring 1 1, install it into the lever 4.

  • Page 391: Remote Control Cables And Speed Sensor Lead

    HULL HOOD Remote control cables and speed sensor lead Remote control cables and speed sensor lead Remote control cables and speed sensor lead removal · · · 16 N m (1.6 kgf m, 11.8 ft 5.9 N · m (0.59 kgf ·...
  • Page 392 HULL HOOD Remote control cables and speed sensor lead · · · 16 N m (1.6 kgf m, 11.8 ft · · · 5.9 N m (0.59 kgf m, 4.4 ft · · · 2.9 N m (0.29 kgf m, 2.1 ft ·...

  • Page 393: Steering Cable Installation (Steering Master End)

    HULL HOOD Remote control cables and speed sensor lead Steering cable installation (steering master end) WARNING If a cable becomes damaged, replace it. Never attempt to repair a damaged cable. 1. Install: • Steering cable Installation steps: 1. Insert the projection a on the steering cable completely into the indentation b in the cable stopper assembly.

  • Page 394: Steering Cable Installation (Jet Pump End)

    HULL HOOD Remote control cables and speed sensor lead Steering cable installation (jet pump end) 1. Install: • Steering cable NOTE: To adjust the steering cable. Refer to “Jet thrust nozzle steering angle check and adjust- ment” in Chapter 3. Steering cable set length a (jet pump end): 14.5 ±...

  • Page 395: Shift Cable Installation (Jet Pump End)

    HULL HOOD Remote control cables and speed sensor lead Shift cable installation (jet pump end) 1. Install: • Shift cable NOTE: To adjust the shift cable. Refer to “Shift cable check and adjustment” in Chapter 3. Shift cable set length a (jet pump end): 13.0 ±...
  • Page 396 HULL HOOD Hoses Hoses Hose removal · · · m (0.4 kgf m, 3.0 ft È ÉÉ · · · m (0.4 kgf m, 3.0 ft Step Q’ty Service points Procedure/Part name Engine unit Refer to “Engine unit” in Chapter 5. Band Not reusable Ventilation hose...
  • Page 397 HULL HOOD Hoses · · · m (0.4 kgf m, 3.0 ft È ÉÉ · m (0.4 kgf · m, 3.0 ft · Step Q’ty Service points Procedure/Part name Cooling water pilot outlet NOTE: Align each projection a with the slits b. È...

  • Page 398: Seats And Hand Grip

    HULL HOOD Seats and hand grip Seats and hand grip Seat and hand grip removal È È É · m (0.6 kgf · m, 4.4 ft · 6 × 40 mm · m (0.6 kgf · m, 4.4 ft · 6 ×...
  • Page 399 HULL HOOD Seats and hand grip È È É · · · m (0.6 kgf m, 4.4 ft 6 × 40 mm · m (0.6 kgf · m, 4.4 ft · 6 × 25 mm 6 × 40 mm 8 × 30 mm É...

  • Page 400: Seat Lock Check

    HULL HOOD Seats and hand grip Seat lock check 1. Check: • Seat lock assembly 1 Does not lock → Replace the seat lock assembly. • Projection 2 Damage → Replace the projection. 8-45...

  • Page 401: Exhaust System

    HULL HOOD Exhaust system Exhaust system Exhaust system and battery removal 3.7 N · m (0.37 kgf · m, 2.7 ft · 3.7 N · m (0.37 kgf · m, 2.7 ft · 23 22 21 · · · m (0.5 kgf m, 3.7 ft ·...
  • Page 402 HULL HOOD Exhaust system · · · · · · 3.7 N m (0.37 kgf m, 2.7 ft 3.7 N m (0.37 kgf m, 2.7 ft 23 22 21 · · · m (0.5 kgf m, 3.7 ft · · ·...
  • Page 403 HULL HOOD Exhaust system 3.7 N · m (0.37 kgf · m, 2.7 ft · 3.7 N · m (0.37 kgf · m, 2.7 ft · 23 22 21 · · · m (0.5 kgf m, 3.7 ft · · ·...

  • Page 404: Exhaust System Check

    HULL HOOD Exhaust system Exhaust system check 1. Check: • Rubber hoses Burns/cracks/damage → Replace the rubber hoses. 2. Check: • Water lock 1 • Water tank 2 Cracks/damage/leaks → Replace. 8-49...

  • Page 405: Deck And Hull

    HULL HOOD Deck and hull Deck and hull Deck and hull disassembly 1 · · · m (0.2 kgf m, 1.5 ft 6 × 25 mm · · · m (0.5 kgf m, 3.7 ft · · · 16 N m (1.6 kgf m, 11.8 ft 8 ×...
  • Page 406 HULL HOOD Deck and hull · · · m (0.2 kgf m, 1.5 ft 6 × 25 mm · · · m (0.5 kgf m, 3.7 ft · · · 16 N m (1.6 kgf m, 11.8 ft 8 × 40 mm 5 ×...
  • Page 407 HULL HOOD Deck and hull Deck and hull disassembly 2 · · · 16 N m (1.6 kgf m, 11.8 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.5 kgf m, 3.7 ft 5 × 25 mm 16 N ·...
  • Page 408 HULL HOOD Deck and hull 16 N · m (1.6 kgf · m, 11.8 ft · · m (0.2 kgf · m, 1.5 ft · · m (0.5 kgf · m, 3.7 ft · 5 × 25 mm · · ·...

  • Page 409: Drain Plug Check

    Pull-up cleat cover installation (FX Cruiser SHO) 1. Install: • Pull-up cleat covers NOTE: Make sure that the word “YAMAHA” a on each pull-up cleat cover can be read correctly from the side of the watercraft as shown. Reboarding step installation 1. Install: •...
  • Page 410 HULL HOOD Deck and hull — MEMO — 8-55...
  • Page 411 TRBL ANLS Chapter 9 Trouble analysis YDIS......................... 9-1 Introduction....................9-1 Features ....................9-1 Functions..................... 9-1 Contents....................9-5 Operating....................9-5 Connecting the communication cable to the watercraft ...... 9-5 Engine unit trouble analysis ................. 9-6 Using the YDIS for engine unit trouble analysis ........9-6 Self-diagnosis..................

  • Page 412: Ydis

    TRBL ANLS YDIS YDIS Introduction Features The newly developed YDIS provides quicker detection and analysis of engine malfunctions. By connecting your computer to the ECM of a watercraft using the communication cable, this soft- ware can be used to display sensor data and data stored in the ECM on a computer’s monitor. ®...
  • Page 413 TRBL ANLS YDIS 3. Engine monitor: Each sensor status and the ECM data are displayed. This enables you to find malfunctioning parts quickly. In addition, the data displayed using the Engine Monitor function can be displayed in a graph. Items: For FX SHO, FX Cruiser SHO (*11) 1 Engine speed 11 Fuel injection duration...
  • Page 414 TRBL ANLS YDIS 4. Stationary test: Operation tests can be performed with the engine off. Items: For FX SHO, FX Cruiser SHO 1 Ignite ignition coil (#1–#4) 2 Operate injector (#1–#4) 3 Operate electric fuel (*1) pump (*1) : Operate fuel pump module 5.
  • Page 415 TRBL ANLS YDIS 7. ECM record data graph: When a malfunction occurs in the ETV system, 4 seconds (2 seconds before and after the malfunction) of recorded data are saved in the ECM. This data can be dis- played on a graph using the “ECM record data graph” of the Data logger function. When the communication cable is used to connect a computer to the ECM, the ECM record data can be saved and viewed on the computer.
  • Page 416 TRBL ANLS YDIS 8. Some files: Other applications can be selected and run while continuing to run the diagnostic program. Contents 1. CD-ROM (software + instruction manual) 2. Adapter 3. Communication cable Operating Connecting the communication cable to the watercraft 1 Wiring harness coupler 2 Meter coupler 3 3-pin communication coupler...

  • Page 417: Engine Unit Trouble Analysis

    TRBL ANLS Engine unit trouble analysis Engine unit trouble analysis NOTE: • Before troubleshooting the engine unit, make sure that fresh fuel of the specified type has been used. • Check that the battery is charged and that its specific gravity is within specification. •...

  • Page 418: Self-Diagnosis

    TRBL ANLS Engine unit trouble analysis Self-diagnosis With the engine running, press the 2 buttons 1 simultaneously for 8 seconds and check if a diagnostic code is indicated on the multifunc- tion meter. If the YDIS is not used to check the symptoms listed in the “Diagnostic code table,”...

  • Page 419: Diagnostic Code Table

    TRBL ANLS Engine unit trouble analysis Diagnostic code table Diagnostic code output YDIS Code No. Symptom Multifunc- Diagnosis tion meter Diagnosis record Normal — — (*1) Pulser coil malfunction (*2) Engine temp sensor malfunction Knock sensor malfunction Battery voltage malfunction (*3) Intake temp sensor malfunction...

  • Page 420: Diagnostic Code And Checking Step

    TRBL ANLS Engine unit trouble analysis Diagnostic code and checking step Refer Diagnos- Item Symptom Checking steps tic code page 1. Measure the pickup coil output peak 7-14 voltage. (*1) 2. Measure the pickup coil resistance. 7-14 Pulser coil Engine will not malfunction start 3.
  • Page 421 TRBL ANLS Engine unit trouble analysis Refer Diagnos- Item Symptom Checking steps tic code page 1. Check the intake air temperature using 7-24 the YDIS. 2. Measure the intake air temperature 7-24 sensor input voltage. Intake temp Trolling speed 3. Check the black/red and black/orange (*1) sensor (*3)
  • Page 422 TRBL ANLS Engine unit trouble analysis Refer Diagnos- Item Symptom Checking steps tic code page 1. Check the steering sensor operation 7-38 using the YDIS. 2. Measure the steering sensor input 7-38 Steering voltage. Normal sensor operation 3. Check the orange/red, white/blue, and malfunction black/orange (O/R, W/L, and B/O) steering sensor wiring harness leads...
  • Page 423 TRBL ANLS Engine unit trouble analysis Refer Diagnos- Item Symptom Checking steps tic code page 1. Check the TPS output voltage and 7-28 throttle valve opening using the YDIS. 2. Check the ECM circuit for continuity. 7-42 3. Check the ETV relay for continuity. 7-35 4.
  • Page 424 TRBL ANLS Engine unit trouble analysis Refer Diagnos- Item Symptom Checking steps tic code page Electronic 1. Check the ETV relay and fuse (ETV 7-35 throttle Engine speed relay) for continuity. (*1) system is limited 2. Check the ECM circuit for continuity. 7-42 malfunction 1.
  • Page 425 TRBL ANLS Engine unit trouble analysis Refer Diagnos- Item Symptom Checking steps tic code page 1. Check the ECM circuit for continuity. 7-42 2. Check the ETV relay for continuity. 7-35 3. Check the charging system. • Stator coil output peak voltage 7-15 •...

  • Page 426: Engine Unit Trouble Analysis (Diagnostic Code Not Detected)

    TRBL ANLS Engine unit trouble analysis Engine unit trouble analysis (diagnostic code not detected) Trouble analysis chart Trouble mode Check items Reference Relative item chapter FUEL SYSTEM Fuel tank breather hose Check valve Fuel hose Fuel pump 4, 7 Fuel filter Fuel tank Fuel sender 4, 7...
  • Page 427 TRBL ANLS Engine unit trouble analysis Trouble mode Check items Reference Relative item chapter POWER UNIT Water passage Compression pressure Engine oil Oil filter Air filter Air cooler Supercharger Oil cooler Oil pump Valves and valve seats Valve pads Camshafts Timing chain Drive coupling Cylinder head gasket...
  • Page 428 TRBL ANLS Engine unit trouble analysis Trouble mode Check items Reference Relative item chapter JET PUMP UNIT Bilge strainer Impeller duct Impeller Intake grate Bearings Water inlet hose Bilge hose Bilge hose joint Rubber damper ELECTRICAL Spark plugs Ignition coils Oil pressure switch Electric bilge pump Engine start switch...
  • Page 429 TRBL ANLS Engine unit trouble analysis — MEMO — 9-18...
  • Page 430 Wiring diagram FX SHO/FX Cruiser SHO 1 Battery Color code 2 Starter motor : Black 3 Fuse (30 A) : Brown 4 Fuse (20 A) : Green 5 Fuse (3 A) : Gray 6 Fuse (10 A) : Blue 7 Fuse (10 A) : Orange 8 Starter relay : Pink...
  • Page 432 YAMAHA MOTOR CORPORATION, USA Printed in USA × 1 CR Jan. 2008 –...
  • Page 433 FX SHO, FX Cruiser SHO 5 6 7 8 4 5 1 3 2 7 6 4 2 1 3 5 6 1 2 3 4 5 6 7 8 3 2 1 3 2 1 3 2 1 3 2 1 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3...

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