Preface 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.
Contents General information INFO Specification SPEC Maintenance Fuel system FUEL Power unit POWR Jet pump unit PUMP – Electrical system ELEC Hull and hood HULL HOOD Troubleshooting TRBL SHTG Appendix...
INFO General information Safety while working ............. 1-1 Rotating part................1-1 Hot part..................1-1 Electric shock ................1-1 Impeller..................1-1 Handling of gasoline..............1-1 Ventilation................... 1-2 Self-protection ................1-2 Working with crane..............1-2 Handling of heat gun ..............1-3 Part, lubricant, and sealant............1-3 Handling of sealant..............
INFO General information Safety while working To prevent an accident or injury and to pro- vide quality service, observe the following safety procedures. Rotating part • Hands, feet, hair, jewelry, clothing, per- sonal flotation device straps, and so on, can become entangled with internal rotating parts of the engine or jet pump unit, result- ing in serious injury or death.
Safety while working Ventilation Working with crane • Gasoline vapor and exhaust gas are • When moving the watercraft, or when lifting heavier than air and extremely poisonous. the engine during removal or installation, If gasoline vapor or exhaust gas is inhaled make sure to use a crane with a lifting in large quantities, it may cause loss of con- capacity that is equal to or more than the...
Part, lubricant, and sealant Non-reusable part Use only genuine Yamaha parts, lubricants, Always use new gaskets, seals, O-rings, cot- and sealants, or those recommended by ter pins, and so on, when installing or assem- Yamaha, when servicing or repairing the bling parts.
Safety while working Disassembly and assembly • Use compressed air to remove dust and dirt during disassembly. • Apply engine oil to the contact surfaces of moving parts before assembly. • Install bearings so that the bearing identifi- cation mark is facing in the direction indi- cated in the installation procedure.
INFO General information 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. •...
How to use this manual Abbreviation The following abbreviations are used in this service manual. Abbreviation Description Bow end Capacitor discharge ignition Exhaust Intake NMMA National Marine Manufacturers Association Pump Octane Number PORT Port side Research Octane Number STBD Starboard side STERN Stern end Top Dead Center...
Adhesive, lubricant, sealant, and thread locking agent Symbol Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points. Symbol Name Application Yamaha 2-stroke motor oil Lubricant Water resistant grease Lubricant (Yamaha grease A) Molybdenum disulfide grease Lubricant...
Adhesive, lubricant, sealant, and thread locking agent / Special service tool Special service tool Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division. Digital tachometer Driver rod L3 90890-06760 90890-06652 Compression gauge Needle bearing attachment...
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INFO General information Stopper guide stand Drive shaft holder 5 90890-06538 90890-06519 Driver rod LS Digital circuit tester 90890-06606 90890-03174 Ball bearing attachment Peak voltage adapter B 90890-06631 90890-03172 Crankshaft holder 20 Ignition tester (Spark gap tester) 90890-06552 90890-06754 Bearing outer race attachment 90890-06628...
The jet pump unit serial number is stamped compartment. on a label attached to the intermediate hous- ing. PRI-I.D. MODEL YAMAHA MOTOR CO., LTD. ASSEMBLED IN U.S.A. FROM AMERICAN AND JAPANESE COMPONENTS. ASSEMBLÉ AUX ÉTATS-UNIS DE PIÈCES AMÉRICAINES ET JAPONAISES. 1 Model name...
SPEC Specification Model data ................2-1 Model code................. 2-1 Dimension and weight ..............2-1 Performance................2-1 Power unit .................. 2-1 Drive unit ..................2-2 Fuel and oil requirement............. 2-2 Battery requirement..............2-2 Fuel system technical data ..........2-3 Fuel system ................2-3 Power unit technical data ..........
SPEC Specification Model data Model code Model Item Unit VX 700 Hull Engine/jet 6CP/6CP Dimension and weight Model Item Unit VX 700 Length mm (in) 3220 (126.8) Width mm (in) 1170 (46.1) Height mm (in) 1160 (45.7) Dry weight kg (lb) 283 (624) Person/ Maximum capacity...
Model data Drive unit Model Item Unit VX 700 Jet pump type Axial flow, single stage Impeller rotation Counterclockwise (viewed from rear) Transmission Constant mesh 1-speed Jet thrust nozzle horizontal Degree 24 + 24 angle Trim system — Jet thrust nozzle trim angle Degree Fuel and oil requirement Model...
SPEC Specification Fuel system technical data Fuel system Model Item Unit VX 700 Carburetor Manufacturer Mikuni Model × quantity BN38 × 2 Type Floatless ID mark 62T03F/03R Main jet (MJ) 120 (front), 130 (rear) Main nozzle (MN) mm (in) 2.5 (0.10) Pilot jet (PJ) 67.5 5/8 ±...
Fuel system technical data / Power unit technical data Crank case assy. Model Item Unit VX 700 Cylinder Bore mm (in) 81.000–81.020 (3.1890–3.1898) Bore wear limit mm (in) 81.100 (3.1929) Taper limit mm (in) 0.080 (0.0031) Out-of-round limit mm (in) 0.050 (0.0020) Piston Diameter...
SPEC Specification Jet pump unit technical data Jet pump unit Model Item Unit VX 700 Impeller housing Inside diameter mm (in) 155.35–155.45 (6.116–6.120) Impeller-to-housing mm (in) 0.35–0.45 (0.014–0.018) clearance Clearance limit mm (in) 0.60 (0.024) Impeller Material Stainless steel Blades number Pitch angle Degree 13.2...
Jet pump unit technical data / Electrical technical data Charging system Model Item Unit VX 700 Charge coil Output peak voltage at cranking (unloaded) at cranking (loaded) at 1500 r/min (loaded) at 3500 r/min (loaded) Resistance (*1) Ω at 20 °C (68 °F) 497.7–608.3 Lighting coil Output peak voltage...
SPEC Specification Starting system Model Item Unit VX 700 Fuse Rating Main 12/10 Starter motor Type Constant mesh Output Cranking time limit Seconds Commutator diameter mm (in) 27.0–28.0 (1.06–1.10) Commutator undercut (*1) mm (in) 0.2–0.7 (0.008–0.028) Brush length mm (in) 6.5–12.5 (0.26–0.49) (*1) The figures are for reference only.
Specified tightening torque / General tightening torque General tightening torque This chart indicates the tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components and assemblies are provided in the applicable sections of this manual.
SPEC Specification Cooling system To exhaust To stern outlet outlet To pilot outlet From flushing hose From jet pump cooling water flow Water lock Exhaust outer cover 1 Exhaust chamber Exhaust ring Cylinder head Cylinder block Stern outlet Exhaust manifold Exhaust outlet Pilot outlet Flushing hose...
Cooling system / Cable and hose routing Cable and hose routing Starboard bow view 1 Positive battery cable B Fuel tank breather hose 2 Battery breather hose C Oil level sensor lead 3 Flushing hose D Throttle cable 4 Bilge hose E Oil hose 5 Cooling water pilot outlet hose F Steering cable...
SPEC Specification Top view 1 Positive battery cable B Fuel tank breather hose 2 Battery breather hose C Oil level sensor lead 3 Flushing hose D Throttle cable 4 Bilge hose E Oil hose 5 Cooling water pilot outlet hose F Steering cable 6 Choke cable G Wiring harness...
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Cable and hose routing M Fuel hose N Fuel reservoir hose O Negative battery cable 2-16...
SPEC Specification Port view 1 Positive battery cable B Fuel tank breather hose 2 Battery breather hose C Oil level sensor lead 3 Flushing hose D Throttle cable 4 Bilge hose E Oil hose 5 Cooling water pilot outlet hose F Steering cable 6 Choke cable G Wiring harness...
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Cable and hose routing M Fuel hose N Fuel reservoir hose O Negative battery cable 2-18...
Maintenance 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. MAINTENANCE INTERVAL INITIAL THEREAFTER EVERY hours hours hours hours PAGE ITEM months months months months...
Maintenance interval chart / Periodic service Periodic service Throttle lever free play adjustment Follow all the steps if the throttle cable has Steering system been replaced. Steering master check 1. Turn the handlebar lock to lock and push it back and forth. After adjusting the throttle lever free play, make sure that the throttle cable is not pulled when the handlebar is turned to the...
Maintenance 7. Remove the upper handlebar cover. See Fuel filter check 1. Check the fuel filter 1. Replace the fuel “Steering pad and handlebar cover” (8- filter if cracked or damaged. 8. Slide the rubber cover 4 away from the 2.
Periodic service Water separator check 1. Check the water separator 1. Drain the water if water has accumulated. 2. Check the O-ring of the drain plug. Replace the O-ring if cracked or dam- aged. See “Water separator check” (8- 21). Oil hose, oil filler cap and rubber seal check 1.
Maintenance 4. Measure the spark plug gap b. Replace 3. Stop the engine. if out of specification. 4. Remove the spark plug caps, and then remove the plugs. 5. Install the special service tool 1. Specified spark plug (manufacturer): BR8HS (NGK) Spark plug gap b: 0.6–0.7 mm (0.024–0.028 in) Compression gauge 1: 90890-03160...
Periodic service Engine oil level check Digital tachometer 1: 90890-06760 Do not allow the oil tank to become com- Trolling speed: 1250–1350 r/min pletely empty. If the oil tank becomes empty the oil injection pump must be bled Trolling speed adjustment to ensure proper oil flow, otherwise 1.
Maintenance Nut and bolt check 1. Check the engine, deck, and hull for loose bolts and nuts. Tighten if loose. See “Specified tightening torque” (2-8). Jet pump unit Impeller check Make sure to remove the battery before checking the jet pump unit. 3.
Periodic service 3. Disconnect the steering cable joint 2 from the ball joint 3. 4. Turn the steering cable joint 2 in or out adjust distances WARNING! The steering cable joint must be screwed in more than 8 mm (0.31 in) c. 7.
Maintenance 5. Install the battery 5, and then install the bands 4. Be careful not to place the battery on its side. 6. Connect the battery breather hose 3. Make sure to remove the battery from the NOTICE: Make sure that the battery battery compartment when adding battery breather hose 3 is properly con- electrolyte or charging the battery.
Drain plug check 1. Check the O-ring of each drain plug. Replace if cracked or damaged. See “Drain plug check” (8-29). Recommended lubricant: Yamaha grease A Nozzle pivot shaft and steering cable lubrication 1. Lubricate the nozzle pivot shaft and steering cable.
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Maintenance Recommended lubricant: Yamaha grease A TIP: Disconnect the joint and apply a small amount of grease. 3-11...
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FUEL Fuel system Fuel cock and fuel filter ............. 4-1 Fuel filter check ................4-2 Fuel cock check................4-2 Choke cable ................ 4-3 Oil tank ................4-4 Oil line check ................4-5 Oil level sensor check ..............4-5 Oil tank check................4-5 Fuel tank ................
FUEL Fuel system Fuel cock and fuel filter (RES) 2 N • m (0.2 kgf • m, 1.5 ft • Ib) (OUT) (ON) 5 N • m (0.5 kgf • m, 3.7 ft • Ib) Part name Q’ty Remarks M4 × 7 mm Screw Fuel cock knob Washer...
Fuel cock and fuel filter Fuel filter check See “Fuel system” (3-3). Fuel cock check Before checking the fuel system, remove the battery, and then remove the fuel filler cap to reduce any pressure inside the fuel tank. 1. Check the fuel cock. Replace if there is rough movement.
FUEL Fuel system Choke cable 2 N • m (0.2 kgf • m, 1.5 ft • Ib) 2 N • m (0.2 kgf • m, 1.5 ft • Ib) Part name Q’ty Remarks M3 × 6 mm Screw Knob Friction adjusting nut Choke cable...
Choke cable / Oil tank Oil tank (VENT) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 6 N • m (0.6 kgf • m, 4.4 ft • Ib) Part name Q’ty Remarks Clamp Oil filler neck Rubber seal Tank belt Oil level sensor coupler...
FUEL Fuel system Oil line check 1. Clean the oil filter, and then check the oil filter. Replace if frayed or teared. 2. Check the rubber seal. Replace if cracked or worn. 3. Check the hoses. Replace if cracked or damaged.
Oil tank / Fuel tank Fuel tank (RETURN) (RES) (VENT) (ON) (VENT) 6 N • m (0.6 kgf • m, 4.4 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 1 N •...
FUEL Fuel system Check valve check 1. Blow into the end a of the check valve, and make sure that airflow from the end b is unrestricted. Replace if the air flow is restricted. 2. Blow into the end b of the check valve, and make sure that airflow from the end a is restricted.
Fuel tank / Carburetor unit Carburetor unit 1 N·m (0.1 kgf·m, 0.7 ft·Ib) 18 N·m (1.8 kgf·m, 13.3 ft·Ib) 8 N·m (0.8 kgf·m, 5.9 ft·Ib) 8 N·m (0.8 kgf·m, 5.9 ft·Ib) Part name Q’ty Remarks Fuel cock knob Turn the fuel cock knob to “OFF”. M5 ×...
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FUEL Fuel system 1 N · m (0.1 kgf · m, 0.7 ft · Ib) 18 N · m (1.8 kgf · m, 13.3 ft · Ib) 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 8 N · m (0.8 kgf · m, 5.9 ft · Ib) Part name Q’ty Remarks...
Carburetor unit Choke cable and throttle cable installation 1. Install the choke cable 1 and throttle cable 2, and then tighten the nuts to the specified torque. Choke cable and throttle cable guide installation position a: 14.0 ± 1.0 mm (0.55 ± 0.04 in) Choke cable nut b: 8 N·m (0.8 kgf·m, 5.9 ft·lb) Throttle cable nut c:...
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FUEL Fuel system Carburetor and fuel pump 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 1 N • m (0.1 kgf • m, 0.7 ft • Ib) 1 N • m (0.1 kgf • m, 0.7 ft • Ib) 1.8 N •...
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Carburetor and fuel pump 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 1 N • m (0.1 kgf • m, 0.7 ft • Ib) 1 N • m (0.1 kgf • m, 0.7 ft • Ib) 1.8 N •...
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FUEL Fuel system 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 1 N • m (0.1 kgf • m, 0.7 ft • Ib) 1 N • m (0.1 kgf • m, 0.7 ft • Ib) 1.8 N • m (0.18 kgf • m, 1.3 ft • Ib) 4.4 N •...
Carburetor and fuel pump Diaphragm check 1. Check the diaphragm. Replace if dam- aged. Arm check 1. Check the arm 1. Repair if bent. Replace if damaged. 2. Measure the arm height a. TIP: Always replace the body assy. and valve (clear film) as a set.
FUEL Fuel system TIP: Before disassembling the carburetor, make sure to note the number of times the speed screw is turned in from its set position to the seated position. Fuel pump check 1. Check the fuel pump gasket, diaphragm, fuel pump diaphragm, fuel pump dia- phragm body, and valve seat.
FUEL Fuel system Oil pump 5 N · m (0.5 kgf · m, 3.7 ft · Ib) 8 N · m (0.8 kgf · m, 5.9 ft · Ib) Part name Q’ty Remarks Band Oil hose Hose clamp Oil delivery hose 1 85 mm (3.35 in) Oil delivery hose 1 70 mm (2.76 in)
Oil pump Oil pump check 1. Place rags around the air bleed screw 1 to catch any oil that might spill. • If the oil delivery hoses are not full of oil, 2. Fill the oil tank with the recommended oil. fill them up.
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POWR Power unit Engine unit................5-1 Engine mount ..............5-3 Engine unit removal..............5-4 Engine mount check..............5-6 Engine unit installation ............... 5-6 Exhaust ring ..............5-10 Exhaust chamber assy............ 5-11 Exhaust chamber ............. 5-12 Muffler ................5-13 Reed valves ..............5-14 Reed valve check ..............
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POWR Power unit Engine unit 15 N · m (1.5 kgf · m, 11.1 ft · Ib) 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 5 N ·...
POWR Power unit Engine mount 17 N · m (1.7 kgf · m, 12.5 ft · Ib) 17 N · m (1.7 kgf · m, 12.5 ft · Ib) Part name Q’ty Remarks M8 × 35 mm Bolt Engine mount Bolt Bracket Bracket...
Engine mount Engine unit removal 6. Remove the band 6, and then discon- nect the cooling water hose 7. Before removing the engine, make sure to take adequate measures to protect the deck opening from damage. 1. Disconnect the negative battery cable, and then disconnect the positive battery cable.
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POWR Power unit 11. Remove the band E, and then discon- 15. Remove the coupling cover L. nect the fuel hose F. 16. Loosen the engine mounting bolts M. TIP: 17. Lift the engine unit slightly, remove the When removing the fuel hose, remove the shims N, and then lower the unit.
Engine mount 19. Suspend the engine unit using an engine hangers, and then separate the unit from the engine mounts and move it forward to disconnect the coupling. NOTICE: When removing the engine unit, take care to avoid causing damage to the hull liner and deck opening.
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POWR Power unit 11. Check that the coupling clearances a Clearance a: and b are within specification. Readjust Less than 1.0 mm (0.039 in) (without if out of specification. rubber damper) Clearance b: 2.0–4.0 mm (0.079–0.157 in) Available shim thicknesses: 0.10, 0.30, 0.50, 1.00, and 2.00 mm 5.
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Engine mount 19. Connect the cooling water hose H to Choke cable and throttle cable guide hose joint I. installation position c: 14.0 ± 1.0 mm (0.55 ± 0.04 in) 20. Connect the exhaust hose J. Choke cable nut d: 8 N·m (0.8 kgf·m, 5.9 ft·lb) Throttle cable nut e: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
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POWR Power unit 23. Install the fuse box assy. O, and then tighten the nuts P to the specified torque. 24. Install the band Q. Electrical box nut P: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 25. Install the plastic ties R. 26.
POWR Power unit Exhaust chamber assy. 2 N · m (0.2 kgf · m, 1.5 ft · Ib) 46 N · m (4.6 kgf · m, 33.9 ft · Ib) 2 N · m (0.2 kgf · m, 1.5 ft · Ib) 39 N ·...
POWR Power unit Muffler 21 N · m (2.1 kgf · m, 15.5 ft · Ib) 39 N · m (3.9 kgf · m, 28.8 ft · Ib) È Part name Q’ty Remarks Exhaust chamber See “Exhaust chamber assy.” (5-11). È...
POWR Power unit Reed valve check 1. Check the reed valves. Replace if cracked or damaged. 2. Measure the valve warpage a. Replace if out of specification. Valve warpage limit: 0.2 mm (0.01 in) 3. Measure the valve stopper height b. Replace if out of specification.
POWR Power unit Cylinder head check TIP: Place 400–600 grit wet sandpaper on a sur- face plate and resurface the cylinder head Do not use a sharp instrument to avoid using a figure-eight sanding pattern. damaging or scratching the cylinder head or spark plug bore threads.
POWR Power unit Cylinder check 1. Eliminate the carbon deposits (using a rounded scraper 1). 2. Check the cylinder water jacket. Clean or replace the cylinder if there is corrosion or mineral deposits. 3. Check cylinder inner surface. Replace if there are score marks. Standard Limit 81.000–...
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POWR Power unit Pistons Part name Q’ty Remarks Cylinder See “Cylinder” (5-18). Piston pin clip Not reusable Piston pin a Arrow mark Piston Washer Bearing Piston ring 5-21...
Pistons Piston pin clip removal and Piston ring check installation 1. Measure the side clearance (using a thickness gauge 1). Replace the piston TIP: and piston rings as a set if out of specifi- Before removing or installing the piston pin cation.
POWR Power unit Piston pin and bearing check 1. Check the piston pins and bearings. Replace if there are signs of heat discol- oration. 2. Measure the piston pin outside diameter (using a micrometer 1). Replace if out of specification. Piston installation Align each end gap with its respective locating pin.
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Pistons TIP: • Install the piston with the arrow a facing towards the exhaust port. • Do not align the open end of the clip with the piston pin slot b. 5-24...
POWR Power unit Flywheel magneto and base assy. 36 N · m (3.6 kgf · m, 26.6 ft · Ib) 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 74 N · m (7.4 kgf · m, 54.6 ft · Ib) 1207D 1207D 18 N ·...
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POWR Power unit Starter clutch assy. Part name Q’ty Remarks Clip Not reusable Clip stopper Spring seat Spring Washer Idle gear Circlip Plate Weight Spring ring Pinion gear 5-27...
Starter clutch assy. Drive coupling removal and Flywheel magneto bolt: installation 74 N·m (7.4 kgf·m, 54.6 ft·lb) 1. Remove the drive coupling. TIP: Install the bolt with the same special service tool that was used for removal. 2. Remove the flywheel magneto. NOTICE: To prevent damage to the engine or special service tools, screw in the fly- wheel puller set bolts evenly and com-...
POWR Power unit Starter clutch assy. check 1. Check the pinion gear 1. Replace if damaged or worn. 2. Check the idle gear 2. Replace if dam- aged or worn. 3. Check the gear movement. Replace the defective part(s) if there is rough move- ment.
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POWR Power unit 23 N · m (2.3 kgf · m, 17.0 ft · Ib) 52 N · m (5.2 kgf · m, 38.4 ft · Ib) 23 N · m (2.3 kgf · m, 17.0 ft · Ib) 52 N · m (5.2 kgf · m, 38.4 ft · Ib) 15 N ·...
Crankcase Crankcase check TIP: 1. Check the mating surfaces. Replace the Be sure that the “F” mark a is on the fly- crankcase if scratched. wheel magneto side. Crankcase installation 1. Apply the Gasket Maker (to the crank- case mating surfaces). TIP: Before applying Gasket Maker, clean the crankcase mating surfaces.
POWR Power unit Crankshaft Part name Q’ty Remarks Crankcase See “Crankcase” (5-30). Oil seal Not reusable Bearing Oil seal 1 Not reusable Drive shaft collar Bearing clip Bearing 2 Crankshaft assy. 5-33...
Crankshaft 4. Measure small end free play d (using a Crankshaft check 1. Measure the crank width a. Replace if dial gauge). Replace if out of specifica- tion. out of specification. Maximum small end axial play d: Crank width a: 2.000 mm (0.0787 in) 61.950–62.000 mm (2.4390–2.4409 5.
PUMP Jet pump unit Intake grate and ride plate 17 N · m (1.7 kgf · m, 12.5 ft · Ib) 4 N · m (0.4 kgf · m, 3.0 ft · Ib) 40 N · m (4.0 kgf · m, 29.5 ft · Ib) 8 N ·...
Jet pump unit Jet pump unit removal Make sure to remove the battery before removing the jet pump unit. 1. Remove the jet pump unit 1. 3. Install the jet pump unit 1, and then tighten the bolts 3, 4, and 5 to the specified torques.
PUMP Jet pump unit Jet thrust nozzle, impeller duct, and impeller housing 40 N · m (4.0 kgf · m, 29.5 ft · Ib) 15 N · m (1.5 kgf · m, 11.1 ft · Ib) 40 N · m (4.0 kgf · m, 29.5 ft · Ib) 7 N ·...
Jet thrust nozzle, impeller duct, and impeller housing / Impeller duct and drive shaft Impeller duct and drive shaft Part name Q’ty Remarks M6 × 20 mm Bolt O-ring Not reusable Impeller Drive shaft Oil seal Not reusable Oil seal Not reusable Rear bearing Not reusable...
PUMP Jet pump unit Drive shaft removal 1. Remove the impeller. Stopper guide plate: 90890-06501 Bearing puller assembly: 90890-06535 Stopper guide stand: 90890-06538 4. Remove the oil seals. Crankshaft holder 20: 90890-06552 TIP: Hold the impeller duct assy. in a vise between two aluminum plates a.
Impeller duct and drive shaft Impeller housing check Driver rod LS: 90890-06606 1. Measure the impeller housing inside Ball bearing attachment: 90890-06634 diameter a. Replace if out of specifica- tion. Distance a: 4.6 ± 0.2 mm (0.18 ± 0.01 in) 2.
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PUMP Jet pump unit Quantity: 20 g (0.7 oz) 5. Install the front bearing. Quantity: 20 g (0.7 oz) 8. Install the impeller. TIP: Press the spacer and the front bearing using a pipe of the proper size [more than 60 mm (2.36 in) long and that has an inner diameter more than 24 mm (0.94 in)].
Impeller duct and drive shaft / Transom plate and hoses Transom plate and hoses 26 N·m (2.6 kgf·m, 19.2 ft·Ib) 5.5 N·m (0.55 kgf·m, 4.0 ft·Ib) Part name Q’ty Remarks Exhaust system See “Exhaust system” (8-23). Jet pump unit assy. See “Jet pump unit”...
PUMP Jet pump unit Bilge strainer check See “Hull and hood” (3-9). Bilge hose check 1. Check the bilge hoses. Replace if cracked or damaged. Cooling water hose check 1. Check the cooling water hoses. Replace if cracked or damage. 6-11...
PUMP Jet pump unit Intermediate drive shaft assy. Part name Q’ty Remarks Driven coupling Washer Damper Intermediate drive shaft extension Intermediate drive shaft Circlip Not reusable Oil seal Not reusable Bearing Not reusable Oil seal Not reusable Oil seal Not reusable Bearing housing 6-13...
Intermediate drive shaft assy. Joint removal Do not touch the joint or adhesive that was heated by the heat gun with your bare hands; they will be very hot and could cause burns. 1. Set a heat gun 1 to 350 °C (662 °F) and use it for about 20 minutes to heat the joint and adhesive.
PUMP Jet pump unit TIP: Drive shaft holder 5: 90890-06519 • Remove any adhesive that is protruding in or around the hole for the intermediate Width a: 27 mm (1.06 in) drive shaft. • After installing the joint, allow the adhesive TIP: to harden for at least 24 hours before plac- •...
Intermediate drive shaft assy. Distance a: Driver rod LS: 90890-06606 6.2 ± 0.2 mm (0.24 ± 0.01 in) Bearing outer race attachment: 90890-06628 Intermediate drive shaft installation 1. Install the intermediate drive shaft. TIP: Remove the bearing and oil seals using a press.
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PUMP Jet pump unit Intermediate drive shaft extension: 36 N·m (3.6 kgf·m, 26.6 ft·lb) TIP: Fit a wrench into the notches in the interme- diate drive shaft extension. 6-17...
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– ELEC Electrical system Electrical components ............7-1 Electrical box ..............7-2 Electrical analysis .............. 7-5 To measure the peak voltage............. 7-5 Ignition system ..............7-5 Ignition coil ................. 7-5 CDI unit ..................7-6 CDI unit resistance ..............7-6 Charge coil ................. 7-7 Pickup coil ..................
Electrical box Br/W È É Ì Ë Ê Ì To starter motor 1 CDI unit 2 Rectifier regulator 3 Spark plug wires : Black 4 Ignition coil : Brown 5 Starter relay : Green 6 Fuse holder : Orange : Pink È...
– ELEC Electrical system Electrical analysis TIP: To measure the peak voltage • Before measuring the peak voltage, check all wiring for proper connection and corro- sion, and check that the battery is fully When measuring the peak voltage, do not charged.
Electrical analysis / Ignition system Secondary coil resistance at 20 °C (68 °F) (reference data): Spark plug cap – Spark plug cap 14.336–30.464 kΩ CDI unit CDI unit output peak voltage 1. Measure the CDI unit output peak volt- age. 2.
Charging system / Starting system [kΩ] È È ∞ ∞ ∞ 2–20 1–10 1–10 É É 1–10 2–15 3–30 1–10 2–15 3–30 Engine start switch continuity: È Tester lead + Engine start Red (R) – É Tester lead - Clip 1 switch 2 Brown (Br) Free...
– ELEC Electrical system Starter relay 1. Connect the tester leads between the starter relay terminals 1 and 2. 2. Connect the positive battery lead to the terminal a, and the negative battery lead to the terminal b. 3. Check the continuity between the starter relay terminals 1 and 2.
Starting system / Starter motor Starter motor 5 N·m (0.5 kgf·m, 3.7 ft·Ib) 6 N·m (0.6 kgf·m, 4.4 ft·Ib) Part name Q’ty Remarks O-ring Not reusable M5 × 114 mm Bolt Front cover assy. O-ring Not reusable Washer set Rear cover assy. Armature Brush holder assy.
– ELEC Electrical system Starter motor operation 1. Hold the starter motor in a vise using alu- minum plates on both sides. 2. Connect the positive battery cable to the starter motor terminal bolt. 3. Connect the negative battery cable to the starter motor body, and then check the starter motor operation.
Starter motor Armature continuity: Commutator Continuity segments a Segment a – No continuity Armature core b Segment a – No continuity Armature shaft c Front and rear cover 1. Check the front cover oil seal. Replace the front cover if damaged or worn. 2.
– ELEC Electrical system 5. Replace or repair the wiring harness if there is no continuity. 6. Replace the multifunction meter if there is continuity. Hour meter operation 1. Check the hour meter display. 2. Replace the multifunction meter if it does not operate correctly.
Indication system 3. Replace the fuel level sensor if out of specification. Buzzer 1. Connect the positive battery lead to the terminal 1 and the negative battery lead Float position Resistance (Ω) to the terminal 2. 757.0–803.0 0–8 2. Check that the buzzer sounds. Replace the buzzer if does not sound.
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HULL HOOD Hull and hood Steering pad and handlebar cover ........8-1 Handlebar and handlebar switch assy......8-2 Left handlebar switch assy. and throttle lever assy..8-3 Throttle cable removal..............8-4 Handlebar check ................ 8-4 Left handlebar switch assy. check..........8-4 Handlebar assy.
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HULL HOOD Hull and hood Steering pad and handlebar cover 1 N · m (0.1 kgf · m, 0.7 ft · Ib) 1 N · m (0.1 kgf · m, 0.7 ft · Ib) 4 N · m (0.4 kgf · m, 3.0 ft · Ib) Part name Q’ty Remarks...
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Steering pad and handlebar cover / Handlebar and handlebar switch assy. Handlebar and handlebar switch assy. 1 N·m (0.1 kgf·m, 0.7 ft·Ib) 3 N·m (0.3 kgf·m, 2.2 ft·Ib) 20 N·m (2.0 kgf·m, 14.8 ft·Ib) 3 N·m (0.3 kgf·m, 2.2 ft·Ib) Part name Q’ty Remarks...
HULL HOOD Hull and hood Left handlebar switch assy. and throttle lever assy. Part name Q’ty Remarks Left handlebar switch assy. Engine shut-off cord Stop button assy. Start button assy. Screw Throttle lever assy. E-ring Washer Shaft Lever Spring...
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Left handlebar switch assy. and throttle lever assy. Throttle cable removal 1. Remove the corrugated tube 1. TIP: Face the chamfered end b of the grommet 2. Remove the throttle cable 2. NOTICE: 2 down, with the opening a facing forward. Make sure to remove the throttle cable seal a.
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HULL HOOD Hull and hood 5. Install the left handlebar switch assy. 0, and then tighten the screws A to the specified torque. < Handlebar holder bolt 7: 20 N·m (2.0 kgf·m, 14.8 ft·lb) TIP: Left handlebar switch screw A: •...
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Left handlebar switch assy. and throttle lever assy. 10. Tighten the locknut B, and then slide the rubber cover C to its original position. Grip end bolt G: 1 N·m (0.1 kgf·m, 0.7 ft·lb) Throttle lever free play p: Steering pad and handlebar cover 4.0–7.0 mm (0.16–0.28 in) installation 11.
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HULL HOOD Hull and hood TIP: If the steering pad 3 is not installed securely, the upper handlebar cover 4 cannot be installed properly onto the lower handlebar cover. 3. Install the upper handlebar cover 4, and then tighten the screws 5 and 6 to the specified torque.
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Left handlebar switch assy. and throttle lever assy. / Front hood Front hood 7 N·m (0.7 kgf·m, 5.2 ft·Ib) 4 N·m (0.4 kgf·m, 3.0 ft·Ib) 2 N·m (0.2 kgf·m, 1.5 ft·Ib) 7 N·m (0.7 kgf·m, 5.2 ft·Ib) 7 N·m (0.7 kgf·m, 5.2 ft·Ib) Part name Q’ty Remarks...
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HULL HOOD Hull and hood 7 N · m (0.7 kgf · m, 5.2 ft · Ib) 4 N · m (0.4 kgf · m, 3.0 ft · Ib) 2 N · m (0.2 kgf · m, 1.5 ft · Ib) 7 N ·...
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Front hood Service lid installation Hinge assy. check 1. Install the service lid 1, and then insert a 1. Fully open the front hood and check that rivet completely in the holes in both the it remains in the open position. If the front service lid 1 and inner hull 2.
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HULL HOOD Hull and hood Multifunction meter and engine hatch cover 4 N · m (0.4 kgf · m, 3.0 ft · Ib) 5 N · m (0.5 kgf · m, 3.7 ft · Ib) 5 N · m (0.5 kgf · m, 3.7 ft · Ib) Part name Q’ty Remarks...
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Multifunction meter and engine hatch cover 4 N·m (0.4 kgf·m, 3.0 ft·Ib) 5 N·m (0.5 kgf·m, 3.7 ft·Ib) 5 N·m (0.5 kgf·m, 3.7 ft·Ib) Part name Q’ty Remarks Lid lock hook Revet Plug 8-12...
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HULL HOOD Hull and hood Steering master assy. 17 N · m (1.7 kgf · m, 12.5 ft · Ib) 7 N · m (0.7 kgf · m, 5.2 ft · Ib) Part name Q’ty Remarks Buzzer coupler Steering cable joint M6 ×...
HULL HOOD Hull and hood Shift lever assy. check 1. Check the shift lever assy. Replace if cracked or damaged. NOTICE: Do not disassemble the shift lever assy. Bushing check 1. Check the bushing. Replace if cracked, damaged, or worn. Steering arm assy.
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Steering master / Steering cable Steering cable 5.9 N·m (0.59 kgf·m, 4.4 ft·Ib) 7 N·m (0.7 kgf·m, 5.2 ft·Ib) 7 N·m (0.7 kgf·m, 5.2 ft·Ib) Part name Q’ty Remarks Service lid See “Front hood” (8-8). Seat assy. See “Seat and handgrip” (8-18). Ride plate/rubber plate See “Intake grate and ride plate”...
HULL HOOD Hull and hood Steering cable installation (steering master end) If a cable becomes damaged, replace it. Never attempt to repair damaged cable. 1. Install the steering cable 1 and steering cable stopper 2, and then tighten the bolt 3 to the specified torque. Steering cable set length a (jet pump end): 14.5 ±...
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Steering cable / Seat and handgrip Seat and handgrip 6 N·m (0.6 kgf·m, 4.4 ft·Ib) 26 N·m (2.6 kgf·m, 19.2 ft·Ib) 5 N·m (0.5 kgf·m, 3.7 ft·Ib) Part name Q’ty Remarks Seat assy. M6 × 40 mm Bolt Seat lock assy. Packing Not reusable Washer...
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HULL HOOD Hull and hood Ventilation hose and water separator È 4 N · m (0.4 kgf · m, 3.0 ft · Ib) 15 N · m (1.5 kgf · m, 11.1 ft · Ib) Part name Q’ty Remarks Oil filler neck See “Oil tank”...
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Ventilation hose and water separator È 4 N·m (0.4 kgf·m, 3.0 ft·Ib) 15 N·m (1.5 kgf·m, 11.1 ft·Ib) Part name Q’ty Remarks Rivet Not reusable Ventilation socket Ventilation pipe Plastic tie Seal Not reusable Clamp Cooling water pilot outlet È To exhaust joint Cooling water hose Plastic tie Band...
HULL HOOD Hull and hood Seat lock check 1. Check the seat lock assy. Replace if cracked, damaged, or worn. 2. Check the projection. Replace if dam- aged. Check valve check 1. Blow into the end “A” of the check valve, and make sure that airflow from the end “B”...
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Ventilation hose and water separator Cooling water pilot outlet nut 3: 4 N·m (0.4 kgf·m, 3.0 ft·lb) TIP: Align the projection a with the slit b. Installation distance a: 30–40 mm (1.18–1.57 in) Ventilation hose installation TIP: 1. Install the grommets 1. •...
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HULL HOOD Hull and hood Exhaust system 5 N · m (0.5 kgf · m, 3.7 ft · Ib) 5 N · m (0.5 kgf · m, 3.7 ft · Ib) Part name Q’ty Remarks Ride plate See “Intake grate and ride plate” (6-1). Band Clamp Water lock...
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Exhaust system Exhaust system check 1. Check the rubber hoses. Replace if burned, cracked, or damaged. 2. Check the water lock. Replace if cracked, damaged, or leaked. 8-24...
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HULL HOOD Hull and hood Deck and hull 15 N · m (1.5 kgf · m, 11.1 ft · Ib) 7 N · m (0.7 kgf · m, 5.2 ft · Ib) 13 N · m (1.3 kgf · m, 9.6 ft · Ib) Part name Q’ty Remarks...
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Deck and hull 15 N·m (1.5 kgf·m, 11.1 ft·Ib) 7 N·m (0.7 kgf·m, 5.2 ft·Ib) 13 N·m (1.3 kgf·m, 9.6 ft·Ib) Part name Q’ty Remarks Collar Sponson Rivet Not reusable Fuel cock cover Rivet Not reusable Choke cover 8-26...
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HULL HOOD Hull and hood Rear section 15 N · m (1.5 kgf · m, 11.1 ft · Ib) 5 N · m (0.5 kgf · m, 3.7 ft · Ib) 2 N · m (0.2 kgf · m, 1.5 ft · Ib) 15 N ·...
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HULL HOOD Hull and hood Drain plug check 1. Check the drain plug 1 and O-ring 2. Replace if cracked or damaged. Spout installation 1. Install the spout 1, and then tighten the nut 2 to the specified torque. 2. Install the hose 3, and then tighten the clamp 4 to the specified torque.
TRBL SHTG Troubleshooting Engine unit troubleshooting ..........9-1 Troubleshooting (engine unit, jet pump unit, charging system)......9-1...
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TRBL SHTG Troubleshooting Engine unit troubleshooting TIP: • Before troubleshooting the engine unit, make sure that fresh fuel of the specified type has been used. • Check that all wiring connections are properly secured and that they are not rusty or corroded. •...
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Engine unit troubleshooting Symptom 1: Engine will not start (engine cranks). Symptom 2 Cause Checking step page Throttle valve does Throttle cable installed Adjust the throttle lever free play. not move properly incorrectly Throttle valve malfunction Check the carburetor. 4-14 Discharged battery Battery performance Check the battery voltage and spe-...
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TRBL SHTG Troubleshooting Symptom 2 Cause Checking step page Fuel not supplied (all Fuel leakage Check the fuel hose. cylinders) Clogged fuel filter Replace the fuel filter. Fuel pump malfunction Check the fuel pump onto the car- 4-14 buretor. Improper low speed screw Adjust the low speed screw.
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Engine unit troubleshooting Symptom 2 Cause Checking step page Compression pres- Compression leakage Measure the compression pres- sure is low sure. Check the cylinder head gasket 5-17 and cylinder head warpage. Check the piston and piston ring for 5-22 damage. Check the cylinder for damage.
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TRBL SHTG Troubleshooting Symptom 1: Poor performance Symptom 2 Cause Checking step page Watercraft cannot Jet pump unit malfunction Check the impeller, impeller duct, reach high speeds and intake grate. Water entered hull Check the drain plugs and O-rings 8-29 for damage.