Page 1 WaveRunner VX110 Sport VX110 Deluxe SERVICE MANUAL *LIT186160291* LIT-18616-02-91 F1K-28197-1H-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: How To Use This Manual
HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
Page 4 IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, passenger(s), a bystander, or a person inspecting or repairing the watercraft.
Page 5 HOW TO USE THIS MANUAL 1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 2 Numbers are given in the order of the jobs in the exploded diagram. 3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
Page 6: Periodic Inspection And
Symbols F to I in an exploded diagram indi- cate the grade of lubricant and the lubrication point. F Apply Yamaha 4-stroke motor oil G Apply water resistant grease (Yamaha grease A, Yamaha marine grease) H Apply ThreeBond 1104J or ThreeBond 1280B...
Page 7 INDEX A30000-0 GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND ADJUSTMENT INSP FUEL SYSTEM FUEL POWER UNIT POWR JET PUMP UNIT PUMP – ELECTRICAL SYSTEM ELEC HULL AND HOOD HULL HOOD TROUBLE ANALYSIS TRBL ANLS...
Page 9: Table Of Contents
INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION NUMBERS ................. 1-1 PRIMARY l.D. NUMBER ................1-1 ENGINE SERIAL NUMBER ..............1-1 JET PUMP UNIT SERIAL NUMBER ............1-1 HULL IDENTIFICATION NUMBER (H.l.N.)..........1-1 SAFETY WHILE WORKING..............1-2 FIRE PREVENTION .................. 1-2 VENTILATION ................... 1-2 SELF-PROTECTION.................
Page 10: Identification Numbers
IDENTIFICATION NUMBERS INFO A60700-0* IDENTIFICATION NUMBERS 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: F1K: 800101 ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the engine unit.
Page 11: Safety While Working
Protect your hands and feet by wearing protec- tive gloves or safety shoes when necessary. PARTS, LUBRICANTS, AND SEALANTS Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the watercraft.
Page 12: Good Working Practices
SAFETY WHILE WORKING INFO Under normal conditions, the lubricants men- tioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants. 1. Maintain good standards of personal and industrial hygiene.
Page 13: Disassembly And Assembly
SAFETY WHILE WORKING INFO 3. Non-reusable parts Always use new gaskets, seals, O-rings, oil seals, cotter pins, circlips, etc., when installing or assembling parts. DISASSEMBLY AND ASSEMBLY 1. Use compressed air to remove dust and dirt during disassembly. 2. Apply engine oil to the contact surfaces of moving parts during assembly.
Page 14: Special Service Tools
SPECIAL SERVICE TOOLS INFO SPECIAL SERVICE TOOLS Using the correct special service tools recom- mended by Yamaha, will aid the work and enable accurate assembly and tune-up. Impro- visations and using improper tools can dam- age the equipment. NOTE: • For U.S.A. and Canada, use part numbers starting with “J-”, “YB-”, “YM-”, “YS-”, “YU-”...
Page 15 SPECIAL SERVICE TOOLS INFO 0 Compression gauge extension P/N. 90890-06582 90890-06582 YU-03017 A Cylinder gauge set 90890-06759 P/N. YU-03017 90890-06759 B Compression gauge P/N. YU-33223-1 90890-03160 C Peak voltage adapter P/N. YU-39991 YU-33223-1 90890-03160 D Peak voltage adapter B P/N. 90890-03172 E Spark checker P/N.
Page 16: Removal And Installation
SPECIAL SERVICE TOOLS INFO K Yamaha diagnostic system 60V-85300-02-00 P/N. 60V-85300-02-00 L Yamaha diagnostic system P/N. 60V-WS853-03 60V-WS853-03 REMOVAL AND INSTALLATION 1 Oil filter wrench YB-01426 YW-06551 P/N. YB-01426 90890-01426 90890-01426 90890-06551 2 Coupler wrench P/N. YW-06551 90890-06551 3 Sheave holder P/N.
Page 17 SPECIAL SERVICE TOOLS INFO 7 Forward gear bearing cup installer (reduction drive gear) P/N. YB-06276-B YB-06276-B 90890-06657 8 Ball bearing attachment (reduction drive gear) P/N. 90890-06657 9 Valve spring compressor P/N. YM-01253 90890-04019 0 Valve spring compressor attachment P/N. YM-04114 (ø19 mm) 90890-04114 (ø19 mm) YM-01253 YM-04114 (ø19 mm)
Page 18 SPECIAL SERVICE TOOLS INFO E Valve seat cutter holder P/N. 90890-06811 (ø4.0 mm) 90890-06811 (ø4.0 mm) YM-91044 90890-06812 (ø4.5 mm) 90890-06812 (ø4.5 mm) F Neway valve seat cutter kit P/N. YM-91044 G Piston ring compressor P/N. YM-08037 90890-05158 H Drive shaft holder (impeller) P/N.
Page 19 SPECIAL SERVICE TOOLS INFO P Outer race installer—forward gear (jet pump oil seal and reduction drive gear) YB-06085 90890-06631 P/N. YB-06085 Q Ball bearing attachment (jet pump oil seal and reduction drive gear) P/N. 90890-06631 R Driver handle—large (intermediate shaft, jet pump, and YB-06071 90890-06606 reduction drive gear)
Page 21 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ............... 2-1 MAINTENANCE SPECIFICATIONS ............... 2-3 ENGINE ....................2-3 JET PUMP UNIT ..................2-6 HULL AND HOOD ..................2-6 ELECTRICAL .................... 2-7 TIGHTENING TORQUES ................2-10 SPECIFIED TORQUES................2-10 GENERAL TORQUE ................2-15 CABLE AND HOSE ROUTING ..............2-16...
Page 22 SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Item Unit VX110 Sport VX110 Deluxe Model code Hull Engine/jet Dimensions Length mm (in) 3,220 (126.8) Width mm (in) 1,170 (46.1) Height mm (in) 1,150 (45.3) Dry weight kg (lb) 325 (716) Maximum capacity...
Page 23: General Specifications
SPEC GENERAL SPECIFICATIONS Model Item Unit VX110 Sport VX110 Deluxe Fuel and oil Fuel type Regular unleaded gasoline Minimum fuel rating PON* RON* Fuel tank capacity 60 (15.9, 13.2) (US gal, Imp gal) Engine oil type 4-stroke motor oil Engine oil grade...
Page 24: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model Item Unit VX110 Sport VX110 Deluxe Cylinder head Warpage limit mm (in) 0.1 (0.004) Compression pressure 1,150 (11.5, 164) (kgf/cm , psi) Cylinder Bore size mm (in) 76.000–76.015 (2.9921–2.9927) Taper limit mm (in) 0.08 (0.003)
Page 25 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit VX110 Sport VX110 Deluxe Valve face width B Intake mm (in) 1.91–2.64 (0.0752–0.1039) Exhaust mm (in) 1.91–2.64 (0.0752–0.1039) Valve seat width C Intake mm (in) 0.90–1.10 (0.0354–0.0433) Exhaust mm (in) 0.90–1.10 (0.0354–0.0433) Valve margin thickness D...
Page 26 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit VX110 Sport VX110 Deluxe Piston pins Outside diameter mm (in) 16.991–17.000 (0.6689–0.6693) Wear limit mm (in) 16.986 (0.6687) Piston ring Top ring Type Barrel Dimension (B × T) 0.90 × 2.75 (0.04 × 0.11)
Page 27: Jet Pump Unit
SPEC MAINTENANCE SPECIFICATIONS Model Item Unit VX110 Sport VX110 Deluxe Fuel pump Pump type Electrical Fuel pressure 320–327 (3.2–3.3, 46–47) (kgf/cm , psi) Oil filter Oil filter type Cartridge type Oil pump Oil pump type Trochoid Rotor tip clearance mm (in) 0.09–0.15 (0.0035–0.0059)
Page 28: Electrical
SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model Item Unit VX110 Sport VX110 Deluxe Battery Type Fluid Capacity V/Ah 12/19 Specific gravity 1.28 ECM unit (B/R – R/Y, B/W – R/Y, B/Y – R/Y, B/G – R/Y) Output peak voltage lower limit @cranking (loaded)
Page 29 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit VX110 Sport VX110 Deluxe Starter motor Type Constant mesh Output Rating Seconds Brush length mm (in) 12.5 (0.49) Wear limit mm (in) 6.5 (0.26) Commutator undercut mm (in) 0.7 (0.03) Limit mm (in) 0.2 (0.01)
Page 30 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit VX110 Sport VX110 Deluxe Accelerator position sensor resis- tance @ throttle lever fully closed Sensor 1 kΩ 0.50–0.90 Sensor 2 kΩ 0.35–10.50 @ throttle lever fully opened Sensor 1 kΩ 3.75–4.35 Sensor 2 kΩ...
Page 31: Tightening Torques
SPEC TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Tightening torque Part Thread Refer to Part to tightened Q’ty Remarks name size page N•m kgf•m ft•lb Fuel system 0.32 Retainer/fuel pump — module 0.64 Fuel filler neck/rubber seal — 0.59 Fuel filter hose clamp —...
Page 32 SPEC TIGHTENING TORQUES Tightening torque Part Thread Refer to Part to tightened Q’ty Remarks name size page N•m kgf•m ft•lb 0.37 Oil separator Bolt 5-12 0.76 Ground lead box Bolt 0.76 5-12 Oil tank Bolt 5-12 0.37 Plastic tie/collar Bolt 5-12 0.76 Oil tank...
Page 33 SPEC TIGHTENING TORQUES Tightening torque Part Thread Refer to Part to tightened Q’ty Remarks name size page N•m kgf•m ft•lb Washer/pickup coil lead and Bolt 0.49 5-36 lighting coil lead Pickup coil Bolt 0.49 5-36 Holder (wiring harness) Bolt 5-36 Lighting coil Bolt 5-36...
Page 34 SPEC TIGHTENING TORQUES Tightening torque Part Thread Refer to Part to tightened Q’ty Remarks name size page N•m kgf•m ft•lb Jet pump unit Steering cable joint — 0.68 Ride plate Bolt 0.76 Intake grate Bolt Speed sensor Screw 0.37 0.78 Jet pump unit assembly Bolt Bolt...
Page 35 SPEC TIGHTENING TORQUES Tightening torque Part Thread Refer to Part to tightened Q’ty Remarks name size page N•m kgf•m ft•lb Shift cable locknut — 0.38 8-23 (Deluxe model only) Steering cable locknut — 0.65 8-23 (steering column side) Steering cable locknut —...
Page 36: General Torque
SPEC TIGHTENING TORQUES Tightening torque Part Thread Refer to Part to tightened Q’ty Remarks name size page N•m kgf•m ft•lb Electrical Fuse box — Fuse box bracket — Bolt 0.88 Bracket Bolt Tapping Slant detection switch ø6 0.39 screw Rectifier/regulator Bolt Brush assembly/spacer —...
Page 37: Cable And Hose Routing
SPEC CABLE AND HOSE ROUTING CABLE AND HOSE ROUTING È É Ê 1 Fuel tank breather hose B Cooling water inlet hose 2 Steering cable C Fuel hose 3 Throttle cable D Electric fuel pump 4 Fuse box E Accelerator position sensor 5 Starter motor lead F Antenna lead (Deluxe model only) 6 Positive battery lead...
Page 38 SPEC CABLE AND HOSE ROUTING È É Ê È Fasten the speed sensor lead, fuel sender lead, wiring harness, and antenna lead (Deluxe model only) with plastic tie 1 at the white tape on the wiring harness. É Fasten the steering sensor lead, handlebar switch lead, multifunction meter lead, and buzzer lead with plastic tie 2.
Page 39 SPEC CABLE AND HOSE ROUTING Ï Ð Ó Ô Ð È Ê Ò É Õ È Ë Ñ Î É Í Ì 1 Multifunction meter B Bilge hose 2 Handlebar switch lead C Battery breather hose 3 Buzzer D Battery 4 Shift cable (Deluxe model only) E Negative battery lead 5 Fuel hose...
Page 40 SPEC CABLE AND HOSE ROUTING Ï Ð Ó Ô Ð È Ê Ò É Õ È Ë Ñ Î É Í Ì M Water separator É Fasten the speed sensor lead, fuel sender lead, N Electric fuel pump wiring harness, and antenna lead (Deluxe O Oil separator breather hose (to air intake duct) model only) with plastic tie 1 at the white tape on P Wiring harness...
Page 41 SPEC CABLE AND HOSE ROUTING Ï Ð Ó Ô Ð È Ê Ò É Õ È Ë Ñ Î É Í Ì Ï To ventilation socket Ð To fuel tank Ñ Point the arrow on the cover toward the fuel tank.
Page 42 SPEC CABLE AND HOSE ROUTING Ñ Ò Ê Ó Ê Ì Î Ï Í Ê É Ë Ô È Ð Õ 1 Cooling water inlet hose È To install the cooling water outlet hose, align the 2 Cooling water hose white paint mark on the cooling water hose with 3 Cooling water outlet hose the projection of the hose joint.
Page 43 SPEC CABLE AND HOSE ROUTING Ñ Ò Ê Ó Ê Ì Î Ï Í Ê É Ë Ô È Ð Õ Í Fasten the oil separator breather hose (to air Ñ Install the cooling water hose with the white intake duct) and cooling water hose with a paint mark facing up.
Page 44 SPEC CABLE AND HOSE ROUTING È É Í Ê Ë Î Ì 1 Oil separator breather hose (to air intake duct) B Thermoswitch (exhaust) coupler 2 Wiring harness C Ground lead plate 3 Ignition coil lead #1 D Wiring harness 4 Ignition coil lead #2 E Thermoswitch (exhaust) lead 5 Ignition coil lead #3...
Page 45 SPEC CABLE AND HOSE ROUTING È É Í Ê Ë Î Ì Ì To generator Í Fasten the thermoswitch (exhaust) lead at the protective sleeve, the oil pressure switch lead at the corrugated tube, and the wiring harness at the tape on the harness with a plastic tie. Î...
Page 46 SPEC CABLE AND HOSE ROUTING Ð Ú Ï Î Ì Ù Í Ì Ë Ë Ê É È Ò Ô Ñ Ì Ñ ÌÑ Ó Õ Ö × Ø 1 Ignition coil È To engine temperature sensor 2 Fuel rail É...
Page 47 SPEC CABLE AND HOSE ROUTING Ð Ú Ï Î Ì Ù Í Ì Ë Ë Ê É È Ò Ô Ñ Ì Ñ ÌÑ Ó Õ Ö × Ø Ð Insert the plastic tie completely into the hole in Õ Pass fuel injector lead #4 under the sensor the engine hanger.
Page 49 INSP CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART .............. 3-1 PERIODIC SERVICE ..................3-2 CONTROL SYSTEM ................. 3-2 Steering column inspection ..............3-2 Steering cable inspection and adjustment .......... 3-2 Throttle cable inspection and adjustment..........3-4 Shift cable inspection and adjustment (Deluxe model only)....3-5 Trolling speed inspection ..............
Page 50: Maintenance Interval Chart
INSP 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 intervals of maintenance should be changed. THEREAFTER MAINTENANCE INTERVAL INITIAL PAGE EVERY 10 hours 50 hours 100 hours 100 hours 200 hours ITEM months months...
Page 51: Periodic Service
INSP CONTROL SYSTEM PERIODIC SERVICE CONTROL SYSTEM Steering column inspection 1. Inspect: • Steering column Excessive play → Replace the steering column. Refer to “STEERING COLUMN” in Chapter 8. Inspection steps: • Move the handlebar up and down and back and forth. •...
Page 52 INSP CONTROL SYSTEM 2. Adjust: • Steering cable joint (steering column end) Adjustment steps: • Set the control grip to the neutral posi- tion. • Loosen the locknut 1. • Disconnect the cable joint 2 from the ball joint 3. •...
Page 53: Throttle Cable Inspection And Adjustment
INSP CONTROL SYSTEM Throttle cable inspection and adjustment NOTE: Before adjusting the throttle lever free play, check the trolling speed. 1. Measure: • Throttle lever free play a Out of specification → Adjust. Throttle lever free play a: 4–7 mm (0.16–0.28 in) •...
Page 54: Shift Cable Inspection And Adjustment (Deluxe Model Only)
INSP CONTROL SYSTEM e. Install the handlebar cover. Lower handlebar cover screw: 3.7 N • m (0.37 kgf • m, 2.7 ft • lb) LOCTITE 242 Upper handlebar cover screw: 1.1 N • m (0.11 kgf • m, 0.8 ft • lb) WARNING After adjusting the free play, turn the han- dlebar to the right and left and make sure...
Page 55: Trolling Speed Inspection
Trolling speed: 1,550–1,750 r/min Checking steps (watercraft in water): • Start the engine and allow it to warm up for 15 minutes. • Check the engine trolling speed using the tachometer of the multifunction meter or using the Yamaha Diagnostic System.
Page 56: Fuel System
INSP FUEL SYSTEM FUEL SYSTEM WARNING When removing fuel system parts, wrap them in a cloth and take care that no fuel spills into the engine compartment. Fuel line inspection 1. Inspect: • Fuel pump filter Clog/contaminants → Clean. Refer to “FUEL TANK AND FUEL PUMP MODULE”...
Page 57: Water Separator Inspection
INSP FUEL SYSTEM/POWER UNIT Water separator inspection 1. Inspect: • Water separator 1 Water accumulation → Drain. NOTE: To drain the water, remove the drain plug. POWER UNIT Valve clearance adjustment The following procedure applies to all of the valves. NOTE: •...
Page 58 INSP POWER UNIT 3. Measure: • Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake valve: 0.11–0.20 mm (0.0043–0.0079 in) Exhaust valve: 0.25–0.34 mm (0.0098–0.0134 in) Measurement steps: • Turn the drive coupling counterclockwise, and then check if cylinder #1 is at TDC of the compression stroke with a dial gauge.
Page 59 INSP POWER UNIT 4. Remove: • Timing chain tensioner cap bolt 1 • Gasket 5. Turn the timing chain tensioner rod fully clockwise with a thin screwdriver 1. NOTE: Make sure that the tensioner rod has been fully turned clockwise. 6.
Page 60 INSP POWER UNIT 7. Adjust: • Valve clearance Adjustment steps: • Remove the valve lifter 1 and the valve pad 2. NOTE: • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. •...
Page 61 INSP POWER UNIT NOTE: The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect. • Install the new valve pad 5 and the valve lifter 6.
Page 62 INSP POWER UNIT Intake MEASURED ORIGINAL VALVE PAD NUMBER CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00–0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03–0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.08–0.10...
Page 63: Engine Oil Level Check
INSP POWER UNIT 8. Remove: • Dial gauge • Dial gauge stand • Dial gauge needle 9. Install: • All removed parts NOTE: For installation, reverse the removal proce- dure. Engine oil level check 1. Check: • Engine oil level Checking steps: CAUTION: •...
Page 64 NOTE: • The engine cannot be started if the Yamaha Security System is in the lock mode. (Deluxe model only) • For information on the Yamaha Security System, see the owner’s manual. (Deluxe model only) •...
Page 65: Engine Oil Change - Using Oil Changer
INSP POWER UNIT • Remove the oil tank filler cap again and check that the oil level is between the minimum level mark a and maximum level mark b on the dipstick. • If the engine oil is below the minimum level mark b, add sufficient oil of the rec- ommended type to raise it to the correct level.
Page 66 INSP POWER UNIT 2. Remove: • Oil tank filler cap 1 3. Insert the tube of an oil changer into the oil filler hole. 4. Operate the oil changer to extract the oil. 5. If the oil filter is also to be replaced, per- form the following procedure.
Page 67: Air Filter Element Clean
INSP POWER UNIT 7. Fill: • Oil tank (with the specified amount of the recom- mended engine oil) Recommended oil: SAE 10W-30, 20W-40, 20W-50 API SE, SF, SG, SH, SJ, SL Oil quantity: Total amount: 4.3 L (4.5 US qt, 3.8 Imp qt) Without oil filter replacement: 2.0 L (2.1 US qt, 1.8 Imp qt) With oil filter replacement:...
Page 68 INSP POWER UNIT 5. Remove the air filter element and check it for dirt and oil. Replace the air filter ele- ment if there is any oil buildup. CAUTION: • Do not start the engine with the air filter case removed, otherwise the engine could be damaged.
Page 69: Spark Plug Inspection
INSP POWER UNIT Spark plug inspection 1. Remove: • Ignition coils CAUTION: Be careful not to get any foreign sub- stances or water in spark plug hole. 2. Inspect: • Electrodes 1 Damage/wear → Replace. • Insulator color 2 Distinctly different color → Check the engine condition.
Page 70 INSP POWER UNIT 5. Tighten: • Spark plug Spark plug: 13 N • m (1.3 kgf • m, 9.4 ft • lb) NOTE: • Before installing the spark plug, clean the gasket surface and spark plug surface. Also, it is suggested to apply a thin film of anti- seize compound to the spark plug threads to prevent thread seizure.
Page 71: Electrical
INSP ELECTRICAL ELECTRICAL Battery inspection 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 72 INSP ELECTRICAL 1. Remove: • Bands • Battery negative lead 1 • Battery positive lead 2 • Battery • Battery breather hose 3 WARNING • When removing the battery, disconnect the negative lead first. • Remove the battery to prevent acid loss during turning the watercraft on its side for the impeller, etc.
Page 73 INSP ELECTRICAL 3. Inspect: • Specific gravity Out of specification → Charge. Specific gravity at 20 °C (68 °F): 1.28 Charging current: 1.9 A × 10 h 4. Install: • Filler caps CAUTION: Before installation, rinse off any fluid from the battery box and battery and make sure that the battery is dry before installing it.
Page 74: Jet Pump Unit
INSP JET PUMP UNIT JET PUMP UNIT Impeller inspection 1. Check: • Impeller 1 Damage/wear → Replace. Nicks/scratches → File or grind. 2. Measure: • Impeller-to-housing clearance a Out of specification → Replace. Maximum impeller-to-housing clearance: 0.35–0.45 mm (0.0138–0.0177 in) Measurement steps: •...
Page 75: Bilge Pump
INSP BILGE PUMP/GENERAL BILGE PUMP Bilge strainer inspection 1. Inspect: • Bilge strainer 1 Contaminants → Clean. Cracks/damage → Replace. GENERAL Drain plug inspection 1. Inspect: • Drain plugs Cracks/damage → Replace. • O-rings Cracks/wear → Replace. • Screw threads Contaminants →...
Page 76 INSP GENERAL 2. Lubricate: • Nozzle pivot shaft • Steering cable (nozzle end) Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) 3. Lubricate: • Steering cable • Steering cable joint NOTE: Disconnect the joints and apply a small amount of grease.
Page 77 FUEL CHAPTER 4 FUEL SYSTEM FUEL TANK AND FUEL PUMP MODULE............4-1 EXPLODED DIAGRAM ................4-1 REMOVAL AND INSTALLATION CHART ..........4-1 SERVICE POINTS ..................4-4 Fuel hose disconnection ..............4-4 Fuel pump module removal..............4-4 Check valve inspection ............... 4-4 Fuel sender inspection ................ 4-5 Fuel tank inspection ................4-5 Fuel hose inspection ................4-5 Fuel pump filter inspection ..............4-5...
Page 78: Fuel Tank And Fuel Pump Module
FUEL FUEL TANK AND FUEL PUMP MODULE FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 5.9 N •...
Page 79 FUEL FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 5.9 N • m (0.59 kgf • m, 4.3 ft • Ib) 3.7 N •...
Page 80 FUEL FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 5.9 N • m (0.59 kgf • m, 4.3 ft • Ib) 3.7 N •...
Page 81: Service Points
FUEL FUEL TANK AND FUEL PUMP MODULE SERVICE POINTS Fuel hose disconnection 1. Disconnect: • Fuel hose Refer to “FUEL INJECTION SYSTEM”. Fuel pump module removal 1. Remove: • Nuts • Retainer NOTE: Loosen the nuts in the sequence shown. 2.
Page 82: Fuel Sender Inspection
FUEL FUEL TANK AND FUEL PUMP MODULE Fuel sender inspection Refer to “FUEL CONTROL SYSTEM” in Chapter 7. Fuel tank inspection 1. Inspect: • Fuel tank Cracks/damage → Replace. Fuel hose inspection Refer to “FUEL INJECTION SYSTEM”. Fuel pump filter inspection 1.
Page 83: Fuel Pump Module Installation
FUEL FUEL TANK AND FUEL PUMP MODULE Fuel pump module installation 1. Tighten: • Nuts Fuel pump module nut: 1st: 3.2 N • m (0.32 kgf • m, 2.3 ft • lb) 2nd: 6.4 N • m (0.64 kgf • m, 4.6 ft • lb) NOTE: Tighten the nuts in the sequence shown.
Page 84: Fuel Injection System
FUEL FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM EXPLODED DIAGRAM 1.2 N • m (0.12 kgf • m, 0.9 ft • Ib) 2.5 N • m (0.25 kgf • m, 1.8 ft • Ib) 5 × 75 mm 1.5 N • m (0.15 kgf • m, 1.1 ft • Ib) 5 ×...
Page 85 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 1.2 N • m (0.12 kgf • m, 0.9 ft • Ib) 2.5 N • m (0.25 kgf • m, 1.8 ft • Ib) 5 × 75 mm 1.5 N • m (0.15 kgf • m, 1.1 ft • Ib) 5 ×...
Page 86 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 1.2 N • m (0.12 kgf • m, 0.9 ft • Ib) 2.5 N • m (0.25 kgf • m, 1.8 ft • Ib) 5 × 75 mm 1.5 N • m (0.15 kgf • m, 1.1 ft • Ib) 5 ×...
Page 87: Throttle Body Assembly And Intake Manifold
THROTTLE BODY ASSEMBLY AND INTAKE FUEL MANIFOLD THROTTLE BODY ASSEMBLY AND INTAKE MANIFOLD EXPLODED DIAGRAM 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 5 × 15 mm 13 N • m (1.3 kgf • m, 9.4 ft • Ib) 8 ×...
Page 88 THROTTLE BODY ASSEMBLY AND INTAKE FUEL MANIFOLD EXPLODED DIAGRAM 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 5 × 15 mm 13 N • m (1.3 kgf • m, 9.4 ft • Ib) 8 × 17 mm 13 N •...
Page 89: Service Points
THROTTLE BODY ASSEMBLY AND INTAKE FUEL MANIFOLD SERVICE POINTS Fuel hose clamps removal 1. Remove: • Fuel hose clamps CAUTION: If the fuel hose clamps are removed with- out cutting the joint first, the fuel hose will be damaged. Hose clamps installation 1.
Page 90: Fuel Line Inspection
THROTTLE BODY ASSEMBLY AND INTAKE FUEL MANIFOLD CAUTION: • Do not rotate the quick connector tab 1 past the stopper position, otherwise it could be damaged. • When the fuel hoses are disconnected, quickly remove the retainer 2 from the quick connector, otherwise the retainer could be lost.
Page 91: Fuel Hose Installation (Replacing With New Fuel Hose)
THROTTLE BODY ASSEMBLY AND INTAKE FUEL MANIFOLD Fuel hose installation (replacing with new fuel hose) 1. Install: • Fuel hose 1 NOTE: • To install the fuel hose, be sure to align the white mark a of the fuel hose with the checker tab 2 of the quick connector.
Page 92: Fuel Injectors Inspection
Fuel injector resistance: (reference data) 11.5–12.5 Ω at 20 °C (68 °F) 3. Check the operation of the fuel injector using the “Stationary Test” of the Yamaha Diagnostic System. Throttle body assembly inspection CAUTION: The throttle body assembly should not be disassembled.
Page 93: Intake Assembly Installation
THROTTLE BODY ASSEMBLY AND INTAKE FUEL MANIFOLD Intake assembly installation 1. Install: • Intake screw clamp • Intake manifold joint • Intake assembly NOTE: • Install the intake screw clamp in the direction shown in the illustration, making sure to align the indentation in the clamp with the projec- tion a on the intake manifold joint.
Page 94: Air Filter Case Assembly Installation
THROTTLE BODY ASSEMBLY AND INTAKE FUEL MANIFOLD Air filter case assembly installation 1. Install: • Air intake duct 1 • Air intake hose 2 • Air filter case cover NOTE: Align the projections a on the air intake duct and air intake hose with the projections b on the air filter case cover as shown in the illustra- tion.
Page 95 THROTTLE BODY ASSEMBLY AND INTAKE FUEL MANIFOLD 5. Remove: • Fuel pressure gauge • Fuel pressure gauge adapter NOTE: To disconnect the fuel pressure gauge adapter, follow the procedures for disconnect- ing a fuel hose. (Refer to “Fuel hose discon- nection”.) 6.
Page 97 POWR CHAPTER 5 POWER UNIT ENGINE UNIT ....................5-1 EXPLODED DIAGRAM ................5-1 REMOVAL AND INSTALLATION CHART ..........5-1 SERVICE POINTS ..................5-4 Compression pressure measurement ..........5-4 Engine unit removal ................5-6 Shim removal ..................5-6 Engine mount inspection..............5-6 Coupling clearance inspection ............5-7 EXHAUST PIPES 1 AND 2................5-8 EXPLODED DIAGRAM ................5-8 REMOVAL AND INSTALLATION CHART ..........
Page 98 POWR GENERATOR AND STARTER MOTOR ............5-33 EXPLODED DIAGRAM ................5-33 REMOVAL AND INSTALLATION CHART ..........5-33 SERVICE POINTS .................. 5-38 Flywheel magneto removal ...............5-38 Starter clutch inspection..............5-38 Flywheel magneto installation ............5-40 CAMSHAFTS....................5-41 EXPLODED DIAGRAM ................5-41 REMOVAL AND INSTALLATION CHART ..........5-41 SERVICE POINTS ..................
Page 99 POWR CONNECTING RODS AND PISTONS ............5-80 EXPLODED DIAGRAM ................5-80 REMOVAL AND INSTALLATION CHART ..........5-80 SERVICE POINTS .................. 5-82 Connecting rod and piston removal ..........5-82 Cylinder and piston inspection ............5-83 Piston ring inspection ................5-84 Piston pin inspection .................5-86 Connecting rod inspection..............5-87 Connecting rod and piston installation ..........
Page 100: Engine Unit
POWR ENGINE UNIT ENGINE UNIT EXPLODED DIAGRAM 17 N • m (1.7 kgf • m, 12 ft • Ib) 17 N • m (1.7 kgf • m, 12 ft • Ib) 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 8 ×...
Page 101 POWR ENGINE UNIT EXPLODED DIAGRAM 17 N • m (1.7 kgf • m, 12 ft • Ib) 17 N • m (1.7 kgf • m, 12 ft • Ib) 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 8 ×...
Page 102 POWR ENGINE UNIT EXPLODED DIAGRAM 17 N • m (1.7 kgf • m, 12 ft • Ib) 17 N • m (1.7 kgf • m, 12 ft • Ib) 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 8 ×...
Page 103: Service Points
POWR ENGINE UNIT SERVICE POINTS Compression pressure measurement The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: • Valve clearance Out of specification → Adjust. Refer to “POWER UNIT” in Chapter 3. 2.
Page 104 POWR ENGINE UNIT 5. Measure: • Compression pressure Out of specification → Refer to steps (b) and (c). Minimum compression pressure (reference data): 1,150 kPa (11.5 kgf/cm , 164 psi) Measurement steps: a. With the throttle wide open, crank the engine until the reading on the compres- sion gauge stabilizes.
Page 105: Engine Unit Removal
POWR ENGINE UNIT 7. Install: • Ignition coils Ignition coils bolt: 7.6 N • m (0.76 kgf • m, 5.5 ft • lb) LOCTITE 572 Engine unit removal 1. Remove: • Engine unit Removal steps: CAUTION: Lift the engine unit carefully trying not to hit it on the deck or letting it fall hard on the hull.
Page 106: Coupling Clearance Inspection
POWR ENGINE UNIT Coupling clearance inspection 1. Measure: • Clearance a • Clearance b Out of specification → Adjust. NOTE: Measure the clearances with a straightedge and thickness gauge. Clearance a: 0–0.5 mm (0–0.020 in) Clearance b: 2–4 mm (0.079–0.157 in) 2.
Page 107: Exhaust Pipes 1 And 2
POWR EXHAUST PIPES 1 AND 2 EXHAUST PIPES 1 AND 2 EXPLODED DIAGRAM É 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm È 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 2nd 3.4 N •...
Page 108 POWR EXHAUST PIPES 1 AND 2 EXPLODED DIAGRAM 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 15 N • m (1.5 kgf • m, 11 ft • Ib) 39 N • m (3.9 kgf • m, 28 ft • Ib) 10 ×...
Page 109 POWR EXHAUST PIPES 1 AND 2 EXPLODED DIAGRAM 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 35 N • m (3.5 kgf • m, 25 ft • Ib) 8 ×...
Page 110: Exhaust Manifold
POWR EXHAUST MANIFOLD EXHAUST MANIFOLD EXPLODED DIAGRAM 22 N • m (2.2 kgf • m, 16 ft • Ib) 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N •...
Page 111: Oil Tank
POWR OIL TANK OIL TANK EXPLODED DIAGRAM 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 6 × 35 mm 2nd 15 N • m (1.5 kgf • m, 11 ft • Ib) 39 N • m (3.9 kgf • m, 28 ft • Ib) 3.7 N •...
Page 112 POWR OIL TANK EXPLODED DIAGRAM 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 6 × 35 mm 2nd 15 N • m (1.5 kgf • m, 11 ft • Ib) 39 N • m (3.9 kgf • m, 28 ft • Ib) 3.7 N •...
Page 113 POWR OIL TANK EXPLODED DIAGRAM 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 6 × 35 mm 2nd 15 N • m (1.5 kgf • m, 11 ft • Ib) 39 N • m (3.9 kgf • m, 28 ft • Ib) 3.7 N •...
Page 114 POWR OIL TANK EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 25 mm 1.9 N • m (0.19 kgf • m, 1.4 ft • Ib) 2nd 4.4 N •...
Page 115 POWR OIL TANK EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 25 mm 1.9 N • m (0.19 kgf • m, 1.4 ft • Ib) 2nd 4.4 N •...
Page 116 POWR OIL TANK SERVICE POINTS Oil tank removal 1. Remove: • Oil tank NOTE: Loosen the oil tank bolts and nuts in the sequence shown. 2. Remove: • Oil tank cover • Gasket NOTE: Loosen the oil tank cover bolts in the sequence shown.
Page 117: Oil Strainer Inspection
POWR OIL TANK 4. Remove: • Oil cooler covers • Gaskets NOTE: Loosen the oil cooler cover bolts in the sequence shown. Oil strainer inspection 1. Check: • Oil strainer 1 Damage → Replace. Contaminants → Clean. Oil tank installation 1.
Page 118 POWR OIL TANK 2. Install: • Gasket • Oil breather plate NOTE: Tighten the oil breather plate bolts in the sequence shown. Oil breather plate bolt: 1st: 1.9 N • m (0.19 kgf • m, 1.4 ft • lb) 2nd: 4.4 N •...
Page 119 POWR OIL TANK 4. Install: • Oil tank NOTE: Tighten the oil tank nuts and bolts in the sequence shown. Bolt 1: 1st: 15 N • m (1.5 kgf • m, 11 ft • lb) 2nd: 39 N • m (3.9 kgf • m, 28 ft • lb) LOCTITE 572 Nut 2, bolt 3: 1st:...
Page 120: Oil Pump
POWR OIL PUMP OIL PUMP EXPLODED DIAGRAM 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N • m (2.8 kgf • m, 20 ft • Ib) 8 × 95 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 ×...
Page 121 POWR OIL PUMP EXPLODED DIAGRAM 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N • m (2.8 kgf • m, 20 ft • Ib) 8 × 95 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 ×...
Page 122: Service Points
POWR OIL PUMP SERVICE POINTS Oil strainer inspection 1. Check: • Oil strainer 1 Damage → Replace. Contaminants → Clean. Oil pump installation 1. Install: • Oil pump assembly NOTE: Align the projection a on the oil pump shaft with the slit b on the oil pump driven gear shaft.
Page 123: Reduction Drive Gear
POWR REDUCTION DRIVE GEAR REDUCTION DRIVE GEAR EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 55 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N •...
Page 124 POWR REDUCTION DRIVE GEAR EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 55 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N •...
Page 125 POWR REDUCTION DRIVE GEAR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REDUCTION DRIVE GEAR Follow the left “Step” for disassembly. DISASSEMBLY Oil pump drive shaft Drive shaft Collar Oil seal Not reusable Circlip Not reusable Bearing Not reusable Collar...
Page 126 POWR REDUCTION DRIVE GEAR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Circlip Not reusable Bearing Not reusable Reduction drive gear case Reverse the disassembly steps for assembly. : EPNOC grease AP #0 5-27...
Page 127: Service Points
POWR REDUCTION DRIVE GEAR SERVICE POINTS Drive coupling removal 1. Remove: • Reduction drive gear housing 2. Remove: • Drive coupling 1 NOTE: While holding the drive shaft 2 with the rotor holder 3, loosen the drive coupling with the coupler wrench 4.
Page 128: Oil Pump Drive Shaft Inspection
POWR REDUCTION DRIVE GEAR 2. Remove: È • Circlip • Reduction drive gear bearing Slide hammer and adapters: YB-06096 Stopper guide plate: 90890-06501 Bearing puller assembly: 90890-06535 Stopper guide stand: 90890-06538 É È For USA and Canada É For worldwide Oil pump drive shaft inspection 1.
Page 129: Bearing Installing
POWR REDUCTION DRIVE GEAR Bearing installing 1. Install: • Reduction drive gear bearing NOTE: Install the reduction driver gear bearing using a press. Driver handle—large: YB-06071 Driver rod LS: 90890-06606 Outer race installer—forward gear: YB-06085 Ball bearing attachment: 90890-06631 2. Install: È...
Page 130 POWR REDUCTION DRIVE GEAR 3. Install: È • Collar • Rear bearing NOTE: • Install the front bearing using a press. • Before installing the rear bearing, hold both the inner and outer races of the front bearing in place as shown with a pipe that is at least 40 mm (1.57 in) long and has an outer diam- eter of 70 mm (2.76 in) and an inner diame- É...
Page 131: Drive Shaft Installation
POWR REDUCTION DRIVE GEAR Drive shaft installation 1. Install: • Drive shaft • Collar NOTE: Press the into the reduction drive gear case using a pipe that is more than 30 mm (1.18 in) long, and which has an outer diameter of approximately 35 mm (1.97 in) and an inner diameter of approximately 28 ±...
Page 132: Generator And Starter Motor
POWR GENERATOR AND STARTER MOTOR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 30 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 50 N •...
Page 133 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 30 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 50 N •...
Page 134 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 30 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 50 N •...
Page 135 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 10 mm 6 × 14 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) 5 × 14 mm 4.9 N •...
Page 136 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 10 mm 6 × 14 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) 5 × 14 mm 4.9 N •...
Page 137: Service Points
POWR GENERATOR AND STARTER MOTOR SERVICE POINTS Flywheel magneto removal 1. Remove: • Flywheel magneto bolt 1 • Washer NOTE: While holding the flywheel magneto 2 with the sheave holder 3, loosen the flywheel magneto bolt. Sheave holder: YS-01880-A/90890-01701 2. Remove: •...
Page 138 POWR GENERATOR AND STARTER MOTOR 2. Check: • Starter clutch 1 • Starter gear 2 Burrs/chips/roughness/wear → Replace the defective part(s). 3. Check: • Starter clutch gear’s contacting surfaces Damage/pitting/wear → Replace the starter clutch gear. 4. Check: • Starter clutch operation Checking steps: •...
Page 139: Flywheel Magneto Installation
POWR GENERATOR AND STARTER MOTOR Flywheel magneto installation 1. Install: • Woodruff key • Flywheel magneto • Washer • Flywheel magneto bolt NOTE: • Clean the tapered portion of the crankshaft and the flywheel magneto hub. • When installing the flywheel magneto, make sure the woodruff key is properly seated in the keyway of the crankshaft.
Page 140: Camshafts
POWR CAMSHAFTS CAMSHAFTS EXPLODED DIAGRAM È 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 ×...
Page 141 POWR CAMSHAFTS EXPLODED DIAGRAM È 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 ×...
Page 142: Removal And Installation Chart
POWR CAMSHAFTS EXPLODED DIAGRAM 6 × 35 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 24 N • m (2.4 kgf • m, 17 ft • Ib) 7 × 11 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 ×...
Page 143 POWR CAMSHAFTS EXPLODED DIAGRAM 6 × 35 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 24 N • m (2.4 kgf • m, 17 ft • Ib) 7 × 11 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 ×...
Page 144 POWR CAMSHAFTS EXPLODED DIAGRAM 6 × 35 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 24 N • m (2.4 kgf • m, 17 ft • Ib) 7 × 11 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 ×...
Page 145 POWR CAMSHAFTS SERVICE POINTS Camshaft removal 1. Install: • Dial gauge needle • Dial gauge stand 1 (into spark plug hole #1) • Dial gauge 2 Dial gauge stand: 90890-06583 Dial gauge needle: 90890-06584 Dial gauge stand set: YB-06585/90890-06585 Dial indicator gauge: YU-03097 Dial gauge set: 90890-01252...
Page 146: Camshaft Inspection
POWR CAMSHAFTS 5. Remove: • Camshaft caps • Dowel pins NOTE: Loosen the intake and exhaust camshaft cap bolts in the sequence shown. 6. Remove: • Intake camshaft 1 • Exhaust camshaft 2 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire 3.
Page 147 POWR CAMSHAFTS 3. Measure: • Camshaft runout Out of specification → Replace. Maximum camshaft runout: 0.03 mm (0.0012 in) 4. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance: 0.05–0.06 mm (0.0020–0.0024 in) Measurement steps: •...
Page 148: Camshaft Sprockets Inspection
POWR CAMSHAFTS 5. Measure: • Camshaft journal diameter a Out of specification → Replace the cam- shaft. Within specification → Replace the cyl- inder head and the camshaft caps as a set. Camshaft journal diameter: Intake: 24.46–24.47 mm (0.9630–0.9634 in) Exhaust: 24.44–24.45 mm (0.9622–0.9626 in)
Page 149: Camshaft Installation
POWR CAMSHAFTS Camshaft installation 1. Install: • Exhaust camshaft sprocket 1 • Intake camshaft sprocket 2 (with the special service tool 3) Universal magneto and rotor holder: YU-01235 Rotor holder: 90890-01235 NOTE: Install the camshaft sprocket with the punch mark a facing outside. Camshaft sprocket bolt: 24 N •...
Page 150 POWR CAMSHAFTS • Install the exhaust and intake camshaft caps. NOTE: Gradually tighten the intake and exhaust camshaft cap bolts in 2–3 steps in the sequence shown. Camshaft cap bolt: 10 N • m (1.0 kgf • m, 7.2 ft • lb) NOTE: Make sure that the punch marks c on the camshafts are aligned with the arrow marks...
Page 151 POWR CAMSHAFTS Timing chain tensioner bolt: 10 N • m (1.0 kgf • m, 7.2 ft • lb) • Remove the screwdriver, make sure the timing chain tensioner rod releases, and then tighten the cap bolt to the specified torque. Cap bolt: 10 N •...
Page 152 POWR CAMSHAFTS 7. Install: • Cylinder head cover gasket • Cylinder head cover NOTE: • Apply sealant onto the mating surfaces of the cylinder head cover gasket and cylinder head. • Tighten the cylinder head cover bolts stages and in a crisscross pattern. Cylinder head cover bolt: 12 N •...
Page 153: Cylinder Head
POWR CYLINDER HEAD CYLINDER HEAD EXPLODED DIAGRAM 20 N • m (2.0 kgf • m, 14 ft • Ib) 2nd 105 ± 5˚ 20 N • m (2.0 kgf • m, 14 ft • Ib) 2nd 121 ± 5˚ 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 ×...
Page 154 POWR CYLINDER HEAD EXPLODED DIAGRAM 20 N • m (2.0 kgf • m, 14 ft • Ib) 2nd 105 ± 5˚ 20 N • m (2.0 kgf • m, 14 ft • Ib) 2nd 121 ± 5˚ 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 ×...
Page 155: Cylinder Head Inspection
POWR CYLINDER HEAD SERVICE POINTS Cylinder head removal 1. Remove: • Cylinder head bolts 1 2. Remove: • Cylinder head nuts NOTE: Loosen the cylinder head nuts in the sequence shown. Cylinder head inspection 1. Eliminate: • Combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag-...
Page 156: Cylinder Head Installation
POWR CYLINDER HEAD 3. Measure: • Cylinder head warpage Out of specification → Replace the cyl- inder head. Cylinder head warpage limit: 0.1 mm (0.004 in) Measurement steps: • Place a straightedge 1 and a thickness gauge 2 across the cylinder head. •...
Page 157 POWR CYLINDER HEAD 2. Tighten: • Cylinder head bolts 1 NOTE: Lubricate the cylinder head bolts with engine oil. Cylinder head bolt: 10 N • m (1.0 kgf • m, 7.2 ft • lb) 5-58...
Page 158: Exploded Diagram
POWR VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points VALVES AND VALVE SPRINGS Follow the left “Step” for removal. REMOVAL Cylinder head Refer to “CYLINDER HEAD”. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat...
Page 159 POWR VALVES AND VALVE SPRINGS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve stem seal Not reusable Exhaust valve lower spring seat Exhaust valve Exhaust valve guide Not reusable...
Page 160: Valve Removal
POWR VALVES AND VALVE SPRINGS SERVICE POINTS Valve removal 1. Remove: • Valve lifter 1 • Valve pad 2 NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place.
Page 161: Valve Spring Inspection
POWR VALVES AND VALVE SPRINGS Valve spring inspection 1. Measure: • Valve spring free length a Out of specification → Replace the valve spring. Valve spring free length: Intake valve spring: 38.90 mm (1.53 in) Exhaust valve spring: 40.67 mm (1.60 in) 2.
Page 162 POWR VALVES AND VALVE SPRINGS 4. Measure: • Valve stem diameter a Out of specification → Replace the valve. Valve stem diameter a: Intake valve: 3.975–3.990 mm (0.1565–0.1571 in) Exhaust valve: 4.465–4.480 mm (0.1758–0.1764 in) 5. Measure: • Valve stem runout Out of specification →...
Page 163: Valve Guide Inspection
POWR VALVES AND VALVE SPRINGS Valve guide inspection NOTE: Before checking the valve guide make sure that the valve stem diameter is within specifi- cation. 1. Measure: • Valve guide inside diameter a Valve guide inside diameter: Intake: 4.000–4.012 mm (0.1575–0.1580 in) Exhaust: 4.500–4.512 mm...
Page 164 POWR VALVES AND VALVE SPRINGS 2. Install the new valve guide 2 by striking the special service tool from the camshaft side until the valve guide clip 3 contacts the cylinder head. NOTE: Apply engine oil to the surface of the new valve guide.
Page 165: Valve Seat Inspection
POWR VALVES AND VALVE SPRINGS Valve seat inspection 1. Eliminate carbon deposits from the valve with a scraper. 2. Apply a thin, even layer of Mechanic’s blueing dye (Dykem) onto the valve seat. 3. Lap the valve slowly on the valve seat with a valve lapper (commercially available) as shown.
Page 166: Valve Seat Reface
POWR VALVES AND VALVE SPRINGS Valve seat reface 1. Reface the valve seat with the valve seat cutter. Valve seat cutter holder: Intake (ø4.0 mm): 90890-06811 Exhaust (ø4.5 mm): 90890-06812 Valve seat cutter: 30° (intake): 90890-06815 45° (intake): 90890-06814 60° (intake): 90890-06813 30°...
Page 167 POWR VALVES AND VALVE SPRINGS 4. Use a 60° cutter to adjust the contact width of the bottom edge of the valve seat. b Previous contact width 60˚ 5. Use a 45° cutter to adjust the contact width of the valve seat to specification. b Previous contact width c Specified contact width 45˚...
Page 168: Valve Installation
POWR VALVES AND VALVE SPRINGS 9. Apply a thin, even layer of lapping com- pound onto the valve seat, and then lap the valve using a valve lapper (commer- cially available). CAUTION: Do not get the lapping compound on the valve stem and valve guide.
Page 169 POWR VALVES AND VALVE SPRINGS 2. Compress the valve spring, and then install the valve cotter 1 using a thin screwdriver with a small amount of grease applied to it. Valve spring compressor: YM-01253/90890-04019 Valve spring compressor attachment: (for the intake valve): YM-04114/90890-04114 (for the exhaust valve): YM-04108/90890-04108...
Page 170: Crankcase
POWR CRANKCASE CRANKCASE EXPLODED DIAGRAM 8.4 N • m (0.84 kgf • m, 6.1 ft • Ib) 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 20 N • m (2.0 kgf • m, 14 ft • Ib) 6 ×...
Page 171 POWR CRANKCASE EXPLODED DIAGRAM 8.4 N • m (0.84 kgf • m, 6.1 ft • Ib) 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 20 N • m (2.0 kgf • m, 14 ft • Ib) 6 ×...
Page 172 POWR CRANKCASE EXPLODED DIAGRAM 8.4 N • m (0.84 kgf • m, 6.1 ft • Ib) 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 20 N • m (2.0 kgf • m, 14 ft • Ib) 6 ×...
Page 173 POWR CRANKCASE EXPLODED DIAGRAM 6 × 10 mm 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 35 N • m (3.5 kgf • m, 25 ft • Ib) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points OIL PIPE AND OIL FILTER BOLT Follow the left “Step”...
Page 174: Service Points
POWR CRANKCASE SERVICE POINTS Crankcase disassembly 1. Remove: • Oil pan bolts NOTE: • Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. •...
Page 175: Crankcase Inspection
POWR CRANKCASE 4. Remove: • Dowel pins Crankcase inspection 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • Crankcase Cracks/damage → Replace. • Oil delivery passages Obstruction →...
Page 176: Crankcase Assembly
POWR CRANKCASE Crankcase assembly 1. Lubricate: Crankshaft journal bearings (with the recommended lubricant) Recommended lubricant: Engine oil 2. Apply: • ThreeBond 1280B (onto the crankcase mating surfaces) NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings.
Page 177 POWR CRANKCASE 5. Tighten: • Crankcase bolts 1–0 NOTE: • Do not reuse crankcase bolts 1–0. • The tightening procedure of crankcase bolts 1–0 is angle controlled, therefore tighten the bolts using the following procedure. Tightening steps: • Tighten the bolts in the order of the num- bers on the crankcase.
Page 178 POWR CRANKCASE CAUTION: • Do not use a torque wrench to tighten the bolt to the specified angle. • Tighten the bolt until it is at the speci- fied angle. NOTE: When using a hexagonal bolt, note that the angle from one corner to another is 60°. 6.
Page 179: Connecting Rods And Pistons
POWR CONNECTING RODS AND PISTONS CONNECTING RODS AND PISTONS EXPLODED DIAGRAM 20 N • m (2.0 kgf • m, 14 ft • Ib) 2nd 120 ± 5˚ REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CONNECTING RODS AND Follow the left “Step”...
Page 180 POWR CONNECTING RODS AND PISTONS EXPLODED DIAGRAM 20 N • m (2.0 kgf • m, 14 ft • Ib) 2nd 120 ± 5˚ Step Procedure/Part name Q’ty Service points Bolt Not reusable Big end upper bearing Top ring 2nd ring Oil ring Reverse the removal steps for installation.
Page 181: Service Points
POWR CONNECTING RODS AND PISTONS SERVICE POINTS Connecting rod and piston removal The following procedure applies to all of the connecting rods and pistons. 1. Remove: • Connecting rod cap 1 • Big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.
Page 182: Cylinder And Piston Inspection
POWR CONNECTING RODS AND PISTONS Cylinder and piston inspection The following procedure applies to all of the cylinders and pistons. 1. Check: • Piston wall • Cylinder wall Vertical scratches → Replace the cylin- der, and the piston and piston rings as a set.
Page 183: Piston Ring Inspection
POWR CONNECTING RODS AND PISTONS • If out of specification, replace the piston and piston rings as a set. • Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance: 0.10–0.11 mm (0.0039–0.0043 in) <Limit>: 0.17 mm (0.0067 in) •...
Page 184 POWR CONNECTING RODS AND PISTONS 2. Install: • Piston ring (into the cylinder) NOTE: Level the piston ring in the cylinder with the piston crown. a 5 mm (0.2 in) 3. Measure: • Piston ring end gap Out of specification → Replace the pis- ton ring.
Page 185: Piston Pin Inspection
POWR CONNECTING RODS AND PISTONS Piston pin inspection The following procedure applies to all of the piston pins. 1. Check: • Piston pin Bluediscoloration/grooves → Replace the piston pin and then check the lubri- cation system. 2. Measure: • Piston pin outside diameter a Out of specification →...
Page 186: Connecting Rod Inspection
POWR CONNECTING RODS AND PISTONS Connecting rod inspection 1. Measure: • Big end oil clearance Out of specification → Replace the big end bearings. Big end oil clearance: 0.016–0.040 mm (0.0006–0.0016 in) Measurement steps: The following procedure applies to all of the connecting rods.
Page 187 POWR CONNECTING RODS AND PISTONS NOTE: • Do not move the connecting rod or crank- shaft until the clearance measurement has been completed. • Lubricate the bolts threads and nut seats with molybdenum disulfide grease. • Make sure the “Y” mark c on the con- necting rod faces towards the front side of the crankshaft.
Page 188: Connecting Rod And Piston Installation
POWR CONNECTING RODS AND PISTONS For example, if the connecting rod “P ” and the crankshaft web “P ” numbers are “5” and “1” respectively, then the bearing size for “P ” is: Bearing size of P “P ” (connecting rod) – “P ”...
Page 189 POWR CONNECTING RODS AND PISTONS 3. Offset: 90˚ • Piston ring end gaps È a Top ring, oil ring expander spacer b 2nd ring, lower oil ring rail c Upper oil ring rail È Exhaust side 4. Lubricate: • Piston •...
Page 190 POWR CONNECTING RODS AND PISTONS 7. Install: • Big end bearings • Connecting rod assembly 1 (into the cylinder and onto the crankshaft pin) • Connecting rod cap (onto the crankshaft pin) NOTE: • Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps.
Page 191 POWR CONNECTING RODS AND PISTONS 9. Tighten: • Connecting rod nuts WARNING • Replace the connecting rod bolts and nuts with new ones. • Clean the connecting rod bolts and nuts. NOTE: The tightening procedure of the connecting rod nuts is angle controlled, therefore tighten the nuts using the following procedure.
Page 192: Crankshaft
POWR CRANKSHAFT CRANKSHAFT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CRANKSHAFT REMOVAL Follow the left “Step” for removal. Crankcase Separate Refer to “CRANKCASE”. Connecting rod caps Refer to “CONNECTING RODS AND PISTONS”. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Reverse the removal steps for installation.
Page 193: Service Points
POWR CRANKSHAFT SERVICE POINTS Crankshaft removal 1. Remove: • Crankshaft 1 • Crankshaft journal lower bearings (from the lower crankcase) • Crankshaft journal upper bearings (from the upper crankcase) NOTE: Identify the position of each crankshaft journal bearing so that it can be reinstalled in its origi- nal place.
Page 194 POWR CRANKSHAFT CAUTION: Do not interchange the crankshaft journal bearings. To obtain the correct crankshaft journal oil clearance and prevent engine damage, the crankshaft journal bearings must be installed in their original positions. Measurement steps: • Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase.
Page 195 POWR CRANKSHAFT • Tighten the bolts to specification in the order of the numbers on the crankcase. Refer “Crankcase assembly”— “CRANKCASE”. • Remove the lower crankcase and the crankshaft journal lower bearings. • Measure the compressed Plastigauge width c on each crankshaft journal. If the crankshaft journal oil clearance is out of specification, select replacement crankshaft journal bearings.
Page 196: Crankshaft Installation
POWR CRANKSHAFT Crankshaft installation 1. Install: • Crankshaft journal upper bearings (into the upper crankcase) • Crankshaft journal lower bearings (into the lower crankcase) NOTE: • Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase.
Page 197: Cooling Water Hose
POWR COOLING WATER HOSE COOLING WATER HOSE EXPLODED DIAGRAM Ê É 3 4 1 Ë È REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points COOLING WATER HOSE Follow the left “Step” for removal. REMOVAL Exhaust manifold Refer to “EXHAUST MANIFOLD”. È...
Page 198 POWR COOLING WATER HOSE EXPLODED DIAGRAM Ê É 3 4 1 Ë È Step Procedure/Part name Q’ty Service points Joint Ê To oil tank Clamp/cooling water hose Ë From transom plate Clamp/cooling water hose Joint Reverse the removal steps for installation. 5-99...
Page 199 PUMP CHAPTER 6 JET PUMP UNIT INTAKE GRATE AND RIDE PLATE ............... 6-1 EXPLODED DIAGRAM ................6-1 REMOVAL AND INSTALLATION CHART ..........6-1 JET PUMP UNIT....................6-3 EXPLODED DIAGRAM ................6-3 REMOVAL AND INSTALLATION CHART ..........6-3 REVERSE GATE (DELUXE MODEL ONLY) ..........6-5 EXPLODED DIAGRAM ................6-5 REMOVAL AND INSTALLATION CHART ..........
Page 200 INTAKE GRATE AND RIDE PLATE PUMP INTAKE GRATE AND RIDE PLATE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points INTAKE GRATE, RIDE PLATE, Follow the left “Step” for removal. AND INTAKE DUCT REMOVAL Bolt Bolt Intake grate Screw NOTE: Speed sensor...
Page 201: Intake Grate And Ride Plate
INTAKE GRATE AND RIDE PLATE PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Ride plate Reverse the removal steps for installation.
Page 202: Removal And Installation Chart
JET PUMP UNIT PUMP JET PUMP UNIT EXPLODED DIAGRAM 6.8 N • m (0.68 kgf • m, 4.9 ft • Ib) 6 × 22 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) 8 × 24 mm 17 N •...
Page 203 JET PUMP UNIT PUMP EXPLODED DIAGRAM 6.8 N • m (0.68 kgf • m, 4.9 ft • Ib) 6 × 22 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) 8 × 24 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 ×...
Page 204: Reverse Gate (Deluxe Model Only)
REVERSE GATE (DELUXE MODEL ONLY) PUMP REVERSE GATE (DELUXE MODEL ONLY) EXPLODED DIAGRAM 1.2 N • m (0.12 kgf • m, 0.9 ft • Ib) 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 6 × 35 mm 15 N •...
Page 205: Jet Thrust Nozzle, Impeller Duct, And Impeller Housing 1
JET THRUST NOZZLE, IMPELLER DUCT, AND IMPELLER HOUSING 1 PUMP JET THRUST NOZZLE, IMPELLER DUCT, AND IMPELLER HOUSING 1 EXPLODED DIAGRAM 40 N • m (4.0 kgf • m, 29 ft • Ib) 15 N • m (1.5 kgf • m, 11 ft • Ib) 10 ×...
Page 206 JET THRUST NOZZLE, IMPELLER DUCT, AND IMPELLER HOUSING 1 PUMP EXPLODED DIAGRAM 40 N • m (4.0 kgf • m, 29 ft • Ib) 15 N • m (1.5 kgf • m, 11 ft • Ib) 10 × 125 mm 8 ×...
Page 207: Impeller Duct And Drive Shaft
IMPELLER DUCT AND DRIVE SHAFT PUMP IMPELLER DUCT AND DRIVE SHAFT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points IMPELLER DUCT AND DRIVE Follow the left “Step” for disassembly. SHAFT DISASSEMBLY Bolt O-ring Not reusable Impeller Drive shaft Not reusable Oil seal...
Page 208 IMPELLER DUCT AND DRIVE SHAFT PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Oil seal Not reusable Rear bearing Not reusable Spacer Front bearing Not reusable Impeller duct Reverse the disassembly steps for assembly. *1: EPNOC grease AP #0...
Page 209: Service Points
IMPELLER DUCT AND DRIVE SHAFT PUMP SERVICE POINTS Drive shaft removal 1. Remove: • Impeller NOTE: Hold the impeller duct assembly in a vise between two aluminum plates a. Crankshaft holder: YB-06552 Crankshaft holder 20: 90890-06552 2. Remove: • Drive shaft 1 NOTE: Remove the drive shaft using a press.
Page 210: Impeller Inspection
IMPELLER DUCT AND DRIVE SHAFT PUMP 4. Remove: • Oil seals NOTE: Remove the oil seals using a flat head screw- driver. 5. Remove: • Front bearing Driver handle—large: YB-06071 Driver rod L3: 90890-06652 Bearing housing needle bearing remover: YB-06112 Needle bearing attachment: 90890-06614 NOTE:...
Page 211: Drive Shaft Installation
IMPELLER DUCT AND DRIVE SHAFT PUMP Drive shaft installation 1. Install: • Oil seals Driver handle—large: YB-06071 Driver rod LS: 90890-06606 Outer race installer—forward gear: YB-06085 Ball bearing attachment: 90890-06634 Distance a: 4.6 ± 0.2 mm (0.18 ± 0.01 in) 2.
Page 212 IMPELLER DUCT AND DRIVE SHAFT PUMP 5. Install: • Front bearing NOTE: Press the spacer and the front bearing using a pipe that is more than 60 mm (2.36 in) long and that has an inner diameter more than 26 mm (1.02 in).
Page 213 IMPELLER DUCT AND DRIVE SHAFT PUMP 8. Install: • Impeller NOTE: Hold the impeller duct assembly in a vise between two aluminum plates a. Impeller: 75 N • m (7.5 kgf • m, 54 ft • lb) LOCTITE 572 Crankshaft holder: YB-06552 Crankshaft holder 20: 90890-06552...
Page 214: Transom Plate And Hoses
TRANSOM PLATE AND HOSES PUMP TRANSOM PLATE AND HOSES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points TRANSOM PLATE AND HOSES Follow the left “Step” for removal. REMOVAL Exhaust system Refer to “EXHAUST SYSTEM” in Chapter 8. Jet pump unit assembly Refer to “JET PUMP UNIT”.
Page 215 TRANSOM PLATE AND HOSES PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bilge strainer Nut/washer Nut/washer Transom plate Bilge hose 2 Reverse the removal steps for installation. 6-16...
Page 216: Service Points
TRANSOM PLATE AND HOSES PUMP SERVICE POINTS Bilge strainer inspection Refer to “JET PUMP UNIT” in Chapter 3. Bilge hose inspection 1. Inspect: • Bilge hoses Cracks/damage/wear → Replace. Cooling water hose inspection 1. Inspect: • Cooling water hoses Cracks/damage/wear → Replace. 6-17...
Page 217: Bearing Housing
BEARING HOUSING PUMP BEARING HOUSING EXPLODED DIAGRAM 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 48 mm 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points...
Page 218: Removal And Installation Chart
BEARING HOUSING PUMP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BEARING HOUSING Follow the left “Step” for disassembly. DISASSEMBLY Driven coupling Washer Damper Intermediate drive shaft Not reusable Circlip 6-19...
Page 219 BEARING HOUSING PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Oil seal Not reusable Bearing Not reusable Oil seal Not reusable Oil seal Not reusable Bearing housing Reverse the disassembly steps for assembly. 6-20...
Page 220: Service Points
BEARING HOUSING PUMP SERVICE POINTS Driven coupling removal and installation 1. Remove and install: • Driven coupling Coupler wrench: YW-06551/90890-06551 Drive shaft holder: YB-06151 Drive shaft holder 5: 90890-06519 NOTE: • Install the driven coupling using the same special tools that were used for removal. •...
Page 221: Bearing Removal
BEARING HOUSING PUMP Bearing removal È 1. Remove: • Circlip • Bearing • Oil seals Driver handle—large: YB-06071 Driver rod LS: 90890-06606 Roller bearing installer/remover: YB-06432 É Bearing outer race attachment: 90890-06628 È For USA and Canada É For worldwide NOTE: Remove the bearing and oil seals using a press.
Page 222: Bearing And Oil Seals Installation
BEARING HOUSING PUMP Bearing and oil seals installation 1. Install: • Oil seals • Bearing NOTE: Install the bearing using a press. Driver handle—large: YB-06071 Driver rod LS: 90890-06606 Outer race installer—forward gear: YB-06085 Ball bearing attachment: 90890-06631 Distance a: 14.2 ±...
Page 223: Intermediate Drive Shaft Installation
BEARING HOUSING PUMP Intermediate drive shaft installation 1. Install: • Intermediate drive shaft NOTE: Install the intermediate drive shaft using a press. Distance a: 56.8 ± 0.2 mm (2.24 ± 0.01 in) 6-24...
Page 225 – ELEC CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS................ 7-1 FUSE BOX....................... 7-2 EXPLODED DIAGRAM ................7-2 REMOVAL AND INSTALLATION CHART ..........7-2 ECM AND RECTIFIER/REGULATOR............. 7-7 EXPLODED DIAGRAM ................7-7 REMOVAL AND INSTALLATION CHART ..........7-7 ELECTRICAL ANALYSIS ................7-9 INSPECTION..................... 7-9 Digital tester ..................7-9 Low resistance measurement ............
Page 226 – ELEC FUEL CONTROL SYSTEM ................7-31 WIRING DIAGRAM ................. 7-31 ELECTRIC FUEL PUMP ................. 7-33 FUEL SENDER ..................7-33 FUEL INJECTOR ..................7-34 MAIN AND FUEL PUMP RELAY............. 7-34 OIL PRESSURE SWITCH............... 7-34 THERMOSWITCH (ENGINE)..............7-34 THERMOSWITCH (EXHAUST) .............. 7-34 SLANT DETECTION SWITCH ..............
Page 227 Diagnostic display ................7-57 REMOTE CONTROL SYSTEM (DELUXE MODEL ONLY) ......7-58 WIRING DIAGRAM ................. 7-58 REMOTE CONTROL SYSTEM............... 7-59 Yamaha Security System indicator ........... 7-59 Low-rpm mode indicator..............7-59 Checking the remote control transmitter ........... 7-60 Transmitter registration ..............7-62...
Page 228: Electrical Components
– ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 1 Thermoswitch (engine) A Oil pressure switch K Accelerator position sensor 2 Fuse box B Fuel injectors L Electric fuel pump 3 Slant detection switch C Thermoswitch (exhaust) M Fuel sender 4 Starter motor D Rectifier/regulator N Multifunction meter 5 Engine temperature sensor...
Page 229: Fuse Box
– ELEC FUSE BOX FUSE BOX EXPLODED DIAGRAM 15 N • m (1.5 kgf • m, 11 ft • Ib) 6 × 25 mm 6 × 20 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 11 (VENT) 17 N •...
Page 230: Exploded Diagram
– ELEC FUSE BOX EXPLODED DIAGRAM 15 N • m (1.5 kgf • m, 11 ft • Ib) 6 × 25 mm 6 × 20 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 11 (VENT) 17 N •...
Page 231 – ELEC FUSE BOX EXPLODED DIAGRAM 15 N • m (1.5 kgf • m, 11 ft • Ib) 6 × 25 mm 6 × 20 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 11 (VENT) 17 N •...
Page 232 – ELEC FUSE BOX EXPLODED DIAGRAM 15 N • m (1.5 kgf • m, 11 ft • Ib) 6 × 25 mm 6 × 20 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 11 (VENT) 17 N •...
Page 233 – ELEC FUSE BOX 1 Positive battery lead 2 Starter motor lead (white tape) 3 Starter relay 4 Wiring harness (black) 5 Wiring harness (brown) 6 Wiring harness (red)
Page 234: Removal And Installation Chart
– ELEC ECM AND RECTIFIER/REGULATOR ECM AND RECTIFIER/REGULATOR EXPLODED DIAGRAM 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 2nd 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 35 mm 4.0 N • m (0.4 kgf • m, 2.9 ft • Ib) 6 ×...
Page 235 – ELEC ECM AND RECTIFIER/REGULATOR EXPLODED DIAGRAM 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 2nd 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 35 mm 4.0 N • m (0.4 kgf • m, 2.9 ft • Ib) 6 ×...
Page 236: Electrical Analysis
– ELEC ELECTRICAL ANALYSIS ELECTRICAL ANALYSIS INSPECTION CAUTION: • All measuring instruments should be han- dled with special care. Damaged or mis- handled instruments will not measure properly. • On an instrument powered by dry batter- ies, check the battery’s voltage periodi- cally replace batteries...
Page 237: Low Resistance Measurement
– ELEC ELECTRICAL ANALYSIS Low resistance measurement NOTE: • When measuring a resistance of 10 Ω or less using a digital tester, the correct measure- ment cannot be obtained because of the tester’s internal resistance. • To obtain the correct value, subtract the internal resistance from the displayed mea- surement.
Page 238: Peak Voltage Adapter
– ELEC ELECTRICAL ANALYSIS Peak voltage adapter NOTE: • Throughout this chapter the part numbers of the specified peak voltage adapters have been omitted. Refer to the following part numbers. • The peak voltage adapter should be used with a digital tester. Peak voltage adapter: È...
Page 239: Ignition System
– ELEC IGNITION SYSTEM IGNITION SYSTEM WIRING DIAGRAM FREE FREE PUSH PUSH FREE PUSH Br R B Br 1 Battery 9 Electronic control F Thermoswitch L Throttle body assem- 2 Fuse (30 A) throttle valve relay (exhaust) 3 Fuse (20 A) 0 Slant detection switch G Oil pressure switch M Accelerator position...
Page 240 – ELEC IGNITION SYSTEM WIRING DIAGRAM FREE FREE PUSH PUSH FREE PUSH Br R B Br : Black : Black/green P/W : Pink/white : Brown : Black/orange : Red/yellow : Green : Black/red W/B : White/black : Blue B/W : Black/white : Yellow/green : Orange : Black/yellow...
Page 241: Ignition Spark
– ELEC IGNITION SYSTEM IGNITION SPARK WARNING • When checking the spark gap, do not touch any of the connections of the spark checker/ignition tester lead wires. • When performing the spark gap test, take special care not to let sparks leak out of the removed spark plug cap.
Page 242: Ignition System Peak Voltage
– ELEC IGNITION SYSTEM IGNITION SYSTEM PEAK VOLTAGE WARNING When checking the electrical components, do not touch any of the connections of the digital tester lead wires. NOTE: • If there is no spark, or the spark is weak, continue with the ignition system test. •...
Page 243 – ELEC IGNITION SYSTEM 2. Measure: • Pickup coil output peak voltage Below specification → Replace the pickup coil. Above specification → Replace the ECM. Test harness (3 pins): New: YB-06877 Current: YB-06777 Test harness HM090-3 (3 pins): New: 90890-06877 Current: 90890-06777 Pickup coil output peak voltage: White/black (W/B) –...
Page 244: Battery
– ELEC IGNITION SYSTEM NOTE: To crank the engine, connect the engine shut- off cord (lanyard) to the engine shut-off switch, and then press the start switch and engine stop switch simultaneously. 4. Measure: • Rectifier/regulator output voltage Below specification → Replace the recti- fier/regulator.
Page 245: Ignition Coil
– ELEC IGNITION SYSTEM IGNITION COIL 1. Measure: • Primary coil resistance Out of specification → Replace. Primary coil resistance: 1.19–1.61 Ω at 20 °C (68 °F) NOTE: When measuring a resistance of 10 Ω or less using a digital tester, the correct measurement cannot be obtained because of the tester’s internal resistance.
Page 246: Engine Temperature Sensor
Checking steps: • Measure the ambient temperature. • Connect a computer to the watercraft and use the Yamaha Diagnostic System to display the intake air temperature. • If the ambient temperature and the dis- played intake air temperature differ by more than ±...
Page 247: Thermoswitch (Engine)
– ELEC IGNITION SYSTEM THERMOSWITCH (ENGINE) 1. Check: • Thermoswitch (engine) continuity (at the specified temperature) Out of specification → Replace. Thermoswitch (engine) continuity temperature: a 84–90 °C (183–194 °F) b 70–84 °C (158–183 °F) 1 No continuity È Temperature 2 Continuity É...
Page 248: Thermoswitch (Exhaust)
– ELEC IGNITION SYSTEM THERMOSWITCH (EXHAUST) 1. Check: • Thermoswitch (exhaust) continuity (at the specified temperature) Out of specification → Replace. Thermoswitch (exhaust) continuity temperature: a 80–86 °C (176–187 °F) b 66–80 °C (151–176 °F) 1 No continuity È Temperature 2 Continuity É...
Page 249: Main And Fuel Pump Relay
– ELEC IGNITION SYSTEM MAIN AND FUEL PUMP RELAY 1. Check: • Main and fuel pump relay continuity Faulty → Replace. Checking steps: • Connect the tester leads to the main and fuel pump relay terminals 5 and 6 or 7. •...
Page 250: Electronic Control Throttle Valve Relay
– ELEC IGNITION SYSTEM ELECTRONIC CONTROL THROTTLE VALVE RELAY 1. Check: • Electronic control throttle valve relay continuity Faulty → Replace. Checking steps: • Connect the tester leads to the electronic control throttle valve relay terminals 4 or 5 and 6. •...
Page 251: Throttle Position Sensor
Do not loosen the throttle stop screw nut and do not turn the throttle stop screw. • Connect a computer to the watercraft and use the Yamaha Diagnostic System to display the “throttle position sensor 1 out- put voltage”, “throttle valve opening angle”, and “throttle position sensor 2...
Page 252 – ELEC IGNITION SYSTEM • Squeeze the throttle lever to the fully open position and hold it. • Check the output voltage of throttle posi- tion sensor 2 and the throttle valve open- ing angle. Throttle position sensor 2 output voltage with throttle lever fully open: 4.60–4.70 V...
Page 253: Accelerator Position Sensor
Out of specification → Replace the accelerator position sensor. Checking steps: • Connect a computer to the watercraft and use the Yamaha Diagnostic System to display the “accelerator position sensor 1” and “accelerator position sensor 2”. • Release the throttle lever to the fully closed position.
Page 254 – ELEC IGNITION SYSTEM Accelerator position sensor 1 output voltage at throttle lever fully opened position: 3.75–4.35 V Accelerator position sensor 2 output voltage at throttle lever fully opened position: 3.50–4.50 V Throttle valve opening angle at throttle lever fully opened position: above 61°...
Page 255 – ELEC IGNITION SYSTEM 2. Measure: • Accelerator position sensor resistance Out of specification → Replace the accelerator position sensor. 45678 Checking steps: • Connect the tester leads accelerator position sensor terminals 1, 3. • Measure the resistance when the fully closed position.
Page 256: Cam Position Sensor
• To measure the output voltage, pass a screwdriver under the cam position sensor at measuring points A, B (center), and C in this order. • When operating the Yamaha Diagnostic Sys- tem, electric power is supplied to the cam position sensor. 7-29...
Page 257: Slant Detection Switch
– ELEC IGNITION SYSTEM SLANT DETECTION SWITCH È 1. Check: • Slant detection switch operation Out of specification → Replace. NOTE: É É When checking the slant detection switch be sure to turn the switch over to both the left and right as shown in the illustration.
Page 258: Fuel Control System
– ELEC FUEL CONTROL SYSTEM FUEL CONTROL SYSTEM WIRING DIAGRAM W/B R/Y Pu/R Pu/R Pu/B Pu/B Pu/Y Pu/G Pu/Y Pu/G 1 Battery 9 Slant detection switch F ECM 2 Fuse (30 A) 0 Sensor assembly G Throttle body assembly 3 Fuse (20 A) H Accelerator position sensor (intake air pressure and intake 4 Fuse (10 A)
Page 259 – ELEC FUEL CONTROL SYSTEM WIRING DIAGRAM W/B R/Y Pu/R Pu/R Pu/B Pu/B Pu/Y Pu/G Pu/Y Pu/G : Black : Black/red Pu/R : Purple/red : Green B/W : Black/white Pu/Y : Purple/yellow : Blue : Blue/black : Red/yellow : Orange : Blue/red W/B : White/black : Pink...
Page 260: Electric Fuel Pump
– ELEC FUEL CONTROL SYSTEM ELECTRIC FUEL PUMP 1. Check: • Fuel pump operating sound Fuel pump does not sound → Measure the fuel pressure. Refer to “FUEL INJECTION SYSTEM” in Chapter 4. FUEL SENDER 1. Measure: • Fuel sender resistance Out of specification →...
Page 261: Fuel Injector
– ELEC FUEL CONTROL SYSTEM FUEL INJECTOR Refer to “FUEL INJECTION SYSTEM” in Chapter 4. MAIN AND FUEL PUMP RELAY Refer to “IGNITION SYSTEM”. OIL PRESSURE SWITCH Refer to “INDICATION SYSTEM”. THERMOSWITCH (ENGINE) Refer to “IGNITION SYSTEM”. THERMOSWITCH (EXHAUST) Refer to “IGNITION SYSTEM”. SLANT DETECTION SWITCH Refer to “IGNITION SYSTEM”.
Page 262: Starting System
– ELEC STARTING SYSTEM STARTING SYSTEM WIRING DIAGRAM FREE FREE PUSH PUSH FREE PUSH B Br 1 Battery 0 Electronic control throttle valve H Start switch 2 Starter motor I Engine stop switch relay 3 Fuse (30 A) A Cam position sensor J Engine shut-off switch 4 Fuse (20 A) B Remote control unit...
Page 263 – ELEC STARTING SYSTEM WIRING DIAGRAM FREE FREE PUSH PUSH FREE PUSH B Br : Black : Black/red : Brown B/W : Black/white : Green G/O : Green/orange : Blue : Blue/red : Orange : Pink/red : Red P/W : Pink/white : White : Red/yellow : Yellow...
Page 264: Battery
– ELEC STARTING SYSTEM BATTERY Refer to “ELECTRICAL” in Chapter 3. WIRING CONNECTIONS 1. Check: • Wiring connections Poor connections → Properly connect. FUSES 1. Check: • Fuses Broken → Replace. Fuse ratings: 3 A, 10 A, 20 A, 30 A NOTE: The 3 A fuse is for the remote control unit (Deluxe model only).
Page 265: Starter Relay
– ELEC STARTING SYSTEM STARTER RELAY 1. Inspect: • Brown lead terminal • Black lead terminal Loose → Tighten. 2. Check: • Starter relay Faulty → Replace. Checking steps: • Connect the tester leads between the starter relay terminals as shown. •...
Page 266: Starter Motor
– ELEC STARTER MOTOR STARTER MOTOR EXPLODED DIAGRAM 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 5 × 114 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty...
Page 267 – ELEC STARTER MOTOR EXPLODED DIAGRAM 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 5 × 114 mm Step Procedure/Part name Q’ty Service points Starter motor rear cover Brush holder assembly Starter motor yoke...
Page 268: Service Points
– ELEC STARTER MOTOR SERVICE POINTS Armature inspection 1. Inspect: • Armature shaft 1 Damage/wear → Replace. 2. Inspect: • Commutator Dirt → Clean with 600-grit sandpaper. 3. Measure: • Commutator diameter Below specification → Replace. Commutator diameter: 28.0 mm (1.10 in) Limit: 27.0 mm (1.06 in) 4.
Page 269: Brush Holder Inspection
– ELEC STARTER MOTOR 6. Inspect: • Armature coil continuity Out of specification → Replace. Armature coil continuity: Commutator segments 1 Continuity Segment - Laminations 2 No continuity Segment - Armature shaft No continuity Brush holder inspection 1. Measure: • Brush length a Below specification →...
Page 270: Charging System
– ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM 1 Battery : Black 2 Fuse (30 A) : Green 3 Fuse (20 A) : Red 4 Rectifier/regulator 5 Lighting coil 7-43...
Page 271: Fuse
– ELEC CHARGING SYSTEM FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in Chapter 3. LIGHTING COIL Refer to “IGNITION SYSTEM”. RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM”. 7-44...
Page 272: Off Throttle Steering System
– ELEC OFF THROTTLE STEERING SYSTEM OFF THROTTLE STEERING SYSTEM WIRING DIAGRAM Pu/R Pu/R Pu/B Pu/B Pu/G Pu/Y Pu/Y Pu/G 1 Battery 0 Fuel injector 2 Starter motor A ECM 3 Fuse (30 A) B Throttle body assembly 4 Fuse (20 A) C Accelerator position sensor 5 Fuse (10 A) D Pickup coil...
Page 273 – ELEC OFF THROTTLE STEERING SYSTEM WIRING DIAGRAM Pu/R Pu/R Pu/B Pu/B Pu/G Pu/Y Pu/Y Pu/G : Black : Blue/red : White/blue : Green : Pink/red : Yellow/green : Blue P/W : Pink/white Y/W : Yellow/white : Orange Pu/B : Purple/black : Red Pu/G : Purple/green : White...
Page 274: Steering Sensor
• Check that the following is displayed in the “Engine Monitor” window of the Yamaha Diagnostic System. • Use the same procedure to check that the steering sensor operates correctly when the handlebar is turned to both the left and right.
Page 275: Indication System
– ELEC INDICATION SYSTEM INDICATION SYSTEM WIRING DIAGRAM B/Y R/Y B/Y R/W B Br L/R L/YL/B W/BR/Y Pu/R Pu/R Pu/B Pu/B Pu/Y Pu/G Pu/G Pu/Y 1 Battery 9 Electronic control throttle valve G Fuel injector 2 Fuse (30 A) H Remote control unit relay 3 Fuse (20 A) 0 Ignition coil...
Page 276 – ELEC INDICATION SYSTEM WIRING DIAGRAM B/Y R/Y B/Y R/W B Br L/R L/YL/B W/BR/Y Pu/R Pu/R Pu/B Pu/B Pu/Y Pu/G Pu/G Pu/Y : Black : Black/blue Pu/B : Purple/black : Brown : Black/orange Pu/G : Purple/green : Green : Black/red Pu/R : Purple/red : Gray B/W : Black/white...
Page 277: Fuse
– ELEC INDICATION SYSTEM FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in Chapter 3. MAIN AND FUEL PUMP RELAY Refer to “IGNITION SYSTEM”. Refer to “IGNITION SYSTEM”. ENGINE TEMPERATURE SENSOR Refer to “IGNITION SYSTEM”. THERMOSWITCH (ENGINE) Refer to “IGNITION SYSTEM”. THERMOSWITCH (EXHAUST) Refer to “IGNITION SYSTEM”.
Page 278: Oil Pressure Switch
– ELEC INDICATION SYSTEM OIL PRESSURE SWITCH 1. Measure: • Oil pressure switch continuity Out of specification → Replace. Lower unit pressure/vacuum tester: YB-35956-A Vacuum/pressure pump gauge set: 90890-06756 Oil pressure switch continuity pressure: 128 kPa (1.28 kgf/cm , 18.6 psi) – 167 kPa (1.67 kgf/cm , 24.2 psi) MULTIFUNCTION METER...
Page 279: Display Function (Sport Model Only)
– ELEC INDICATION SYSTEM Display function (Sport model only) 1. Check: • Display function Does not operate → Replace the multi- function meter. 1 Buzzer : Black : Black/green 2 Speed sensor : Pink : Black/yellow 3 ECM : Red : Blue/black 4 Fuel sender : White...
Page 280: Display Function (Deluxe Model Only)
– ELEC INDICATION SYSTEM Display function (Deluxe model only) 1. Check: • Display function Does not operate → Replace the multi- function meter. 1 Remote control unit : Black : Black/blue 2 Buzzer : Gray : Black/yellow 3 Speed sensor : Pink : Blue/black 4 ECM...
Page 281: Speedometer Display
– ELEC INDICATION SYSTEM Speedometer display 1. Check: • Speedometer display Does not display → Measure the speed sensor output voltage and pulses. 2. Measure: • Speed sensor output voltage and pulses Out of specification → Repair or replace. Within specification → Replace the mul- tifunction meter.
Page 282: Tachometer Display
1. Check: • Low oil pressure warning indicator Does not come on → Check the oil pres- sure switch using the “Engine monitor” of the Yamaha Diagnostic System. Replace the multifunction meter. Fuel level meter display and fuel warning indicator 1.
Page 283: Overheat Warning Indicator
– ELEC INDICATION SYSTEM Overheat warning indicator 1. Check: • Overheat warning indicator Does not come on → Replace the multi- function meter. Checking steps: • Start the engine. • Disconnect the thermoswitch (engine) connector 1 (blue), engine temperature sensor connector 2 (black), or ther- moswitch (exhaust) 3 connector.
Page 284: Diagnostic Display
– ELEC INDICATION SYSTEM Diagnostic display 1. Check: • Diagnostic display Does not display → Replace the multi- function meter. Checking steps: • Start the engine. • Disconnect the coupler of a sensor (e.g,. engine temperature sensor) that is nor- mally displayed when a malfunction occurs.
Page 285: Remote Control System (Deluxe Model Only)
REMOTE CONTROL SYSTEM – ELEC (DELUXE MODEL ONLY) REMOTE CONTROL SYSTEM (DELUXE MODEL ONLY) WIRING DIAGRAM FREE FREE PUSH PUSH FREE PUSH Br Br Br Br L/YL/B B Br Pu/R Pu/B Pu/Y Pu/R Pu/B Pu/G Pu/G Pu/Y È 1 Battery 0 Buzzer : Black : Blue/red...
Page 286: Yamaha Security System Indicator
Yamaha Security System indicator 1. Check: • Yamaha Security System indicator Check that the “SECURITY” indicator light 1 comes on when the Yamaha Security System is deactivated (i.e., the engine can be started). Does not come on → Measure the remote control unit output voltage.
Page 287: Checking The Remote Control Transmitter
• Press the unlock button for more than 4 seconds to select the low-rpm mode. • Check that the beeper sounds three times and that the “L-MODE” indicator light comes on. Yamaha Number of Engine Security beeps startability...
Page 288 REMOTE CONTROL SYSTEM – ELEC (DELUXE MODEL ONLY) NOTE: • If the start switch or the remote control transmitter is not operated for more than 25 seconds, the multifunction meter dis- play and the “L-MODE” indicator light will go off. To change the modes again, press the lock button for a short time, and then start the procedures from the lock mode.
Page 289: Transmitter Registration
REMOTE CONTROL SYSTEM – ELEC (DELUXE MODEL ONLY) Transmitter registration 1. Register: • Remote control transmitter 1 ID codes can be added or re-registered by connecting the entry box 2. Registration steps: • Connect the entry box. • Transmit the ID code from the remote control transmitter to be registered.
Page 290: Replacing Of The Transmitter Battery
REMOTE CONTROL SYSTEM – ELEC (DELUXE MODEL ONLY) Replacing of the transmitter battery CAUTION: • Do not allow any water, dust, or dirt to enter the remote control transmitter case when replacing the battery. • Make sure that no foreign material is trapped between the upper case and lower case of the remote control transmit- ter during assembly.
Page 292 HULL HOOD CHAPTER 8 HULL AND HOOD HANDLEBAR ....................8-1 EXPLODED DIAGRAM ................8-1 REMOVAL AND INSTALLATION CHART ..........8-1 SERVICE POINTS ..................8-6 Handlebar inspection ................8-6 Handlebar switch inspection ............... 8-6 Handlebar assembly installation ............8-6 FRONT HOOD ....................8-8 EXPLODED DIAGRAM ................8-8 REMOVAL AND INSTALLATION CHART ..........
Page 293 HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD ....8-23 EXPLODED DIAGRAM ................8-23 REMOVAL AND INSTALLATION CHART ..........8-23 SERVICE POINTS .................. 8-26 Remote control cables inspection .............8-26 Steering cable (jet pump end) installation .........8-26 Steering cable stopper installation ............8-26 Shift cable (jet pump end) installation (Deluxe model only) ....
Page 294: Handlebar
HULL HANDLEBAR HOOD HANDLEBAR EXPLODED DIAGRAM 1.1 N • m (0.11 kgf • m, 0.8 ft • Ib) 4 × 9 mm 20 N • m (2.0 kgf • m, 14 ft • Ib) 8 × 48 mm 1.1 N • m (0.11 kgf • m, 0.8 ft • Ib) 5 ×...
Page 295 HULL HANDLEBAR HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR REMOVAL Follow the left “Step” for removal. Handlebar switch coupler NOTE: Plastic tie Fasten the buzzer lead, steering sensor lead, start switch lead, engine shut-off switch lead, and multifunction meter lead with a plastic tie.
Page 296 HULL HANDLEBAR HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points NOTE: Throttle cable Pass the throttle cable and wiring harness through the grommet, and then fit the grom- met into the steering column. Handlebar switch lead Handlebar assembly Reverse the removal steps for installation.
Page 297 HULL HANDLEBAR HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR DISASSEMBLY Follow the left “Step” for disassembly. Bolt Grip end Screw NOTE: Tighten the screw from the engine stop switch side. Handlebar switch assembly Screw...
Page 298 HULL HANDLEBAR HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Throttle lever assembly NOTE: Handlebar grip Apply adhesive to the handlebar and the inner surface of the handlebar grip. End plate Handlebar Reverse the disassembly steps for assembly.
Page 299: Service Points
HULL HANDLEBAR HOOD SERVICE POINTS Handlebar inspection 1. Inspect: • Handlebar Bends/cracks/damage → Replace. Handlebar switch inspection Refer to “STARTING SYSTEM” in Chapter 7. Handlebar assembly installation 1. Install: • Handlebar switch lead 1 NOTE: Be sure to leave some slack in the handlebar switch lead 1 in the area a shown in the illus- tration.
Page 300 HULL HANDLEBAR HOOD 3. Install: • Throttle cable NOTE: Fit the seal into the groove in the bracket. 4. Install: • Pad 1 NOTE: Make sure that the handlebar switch lead 2 and throttle cable 3 are routed behind the pad 1 when installing the pad 1 onto the steering column.
Page 301 HULL FRONT HOOD HOOD FRONT HOOD EXPLODED DIAGRAM 1.9 N • m (0.19 kgf • m, 1.4 ft • Ib) 5 × 20 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 6.9 N • m (0.69 kgf • m, 5.0 ft • Ib) 6 ×...
Page 302 HULL FRONT HOOD HOOD EXPLODED DIAGRAM 1.9 N • m (0.19 kgf • m, 1.4 ft • Ib) 5 × 20 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) 6.9 N • m (0.69 kgf • m, 5.0 ft • Ib) 6 ×...
Page 303: Service Points
HULL FRONT HOOD HOOD SERVICE POINTS Rivet Installation 1. Install: • Rivets Installing steps: • Insert a rivet completely in the holes in both the storage compartment panel 1 and inner hull. • Push in the rivet pin 2 until it clicks and is flush with the top of the rivet.
Page 304: Engine Hatch Cover
HULL ENGINE HATCH COVER HOOD ENGINE HATCH COVER EXPLODED DIAGRAM 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 5 × 14 mm 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5 × 16 mm 6.9 N •...
Page 305 HULL ENGINE HATCH COVER HOOD EXPLODED DIAGRAM 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 5 × 14 mm 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5 × 16 mm 6.9 N • m (0.69 kgf • m, 5.0 ft • Ib) 6 ×...
Page 306: Service Points
HULL ENGINE HATCH COVER HOOD SERVICE POINTS Damper stopper inspection (Deluxe model only) 1. Install: • Damper stopper 1 • Shift lever handle 2 NOTE: To install the damper stopper, insert it into the hole in the shift lever handle from the bottom, and then slide it upward.
Page 307: Exploded Diagram
HULL ENGINE HATCH COVER HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points GLOVE COMPARTMENT Follow the left “Step” for removal. REMOVAL Hinge assembly Latch Cap holder Hood bumper Drain plug Reverse the removal steps for installation. 8-14...
Page 308: Service Points
HULL ENGINE HATCH COVER HOOD SERVICE POINTS Glove compartment assembly installation 1. Install: • Hinge assembly NOTE: When installing the hinge assembly, make sure that the springs are in the position shown. 8-15...
Page 309: Shift Lever (Deluxe Model Only)
HULL SHIFT LEVER (DELUXE MODEL ONLY) HOOD SHIFT LEVER (DELUXE MODEL ONLY) EXPLODED DIAGRAM 8.0 N • m (0.8 kgf • m, 5.8 ft • Ib) 6 × 18 mm 15 N • m (1.5 kgf • m, 11 ft • Ib) REMOVAL AND INSTALLATION CHART Step Procedure/Part name...
Page 310: Hoses
HULL HOSES HOOD HOSES EXPLODED DIAGRAM (VENT) 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) (VENT) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HOSES REMOVAL Follow the left “Step” for removal. Fuel tank Refer to “FUEL TANK AND FUEL PUMP MODULE”...
Page 311 HULL HOSES HOOD EXPLODED DIAGRAM (VENT) 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) (VENT) Step Procedure/Part name Q’ty Service points Ventilation hose Fuel tank breather hose Clamp Cooling water hose Cooling water pilot outlet Seal Reverse the removal steps for installation.
Page 312: Service Points
HULL HOSES HOOD SERVICE POINTS Cooling water pilot outlet installation 1. Install: • Cooling water pilot outlet 1 • Seal 2 • Nut 3 NOTE: • When installing the cooling water pilot outlet, face the discharge hole toward the stern and downward at a 30°...
Page 313: Steering Column
HULL STEERING COLUMN HOOD STEERING COLUMN EXPLODED DIAGRAM 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 30 mm 6.9 N • m (0.69 kgf • m, 5.0 ft • Ib) 20 N • m (2.0 kgf • m, 14 ft • Ib) 8 ×...
Page 314 HULL STEERING COLUMN HOOD EXPLODED DIAGRAM 16 N • m (1.6 kgf • m, 12 ft • Ib) 8 × 25 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING COLUMN Follow the left “Step” for disassembly. DISASSEMBLY Steering column Seal rubber...
Page 315: Service Points
HULL STEERING COLUMN HOOD SERVICE POINTS Steering column inspection 1. Inspect: • Seal rubber • Steering housing assembly Cracks/damage/wear → Replace the steering column. 8-22...
Page 316: Remote Control Cables And Speed Sensor Lead
REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REMOTE CONTROL CABLES Follow the left “Step” for removal. AND SPEED SENSOR LEAD REMOVAL Service lid 1 Refer to “FRONT HOOD”.
Page 317 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Steering cable Seal Speed sensor coupler Screw Speed sensor Bolt Deluxe model only Shift cable holder Deluxe model only 8-24...
Page 318 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Shift cable end Deluxe model only Grommet Deluxe model only Deluxe model only Shift cable Deluxe model only Seal Deluxe model only Reverse the removal steps for installation. 8-25...
Page 319: Service Points
REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD SERVICE POINTS WARNING When routing the cables, do not grasp the cable by the outer crimped sheath or steel end. This could deform or loosen the cable end due to extreme angles and or pressure. Always hold the cables by the outer cover below the crimp.
Page 320: Shift Cable (Jet Pump End) Installation (Deluxe Model Only)
REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD Shift cable (jet pump end) installation (Deluxe model only) 1. Install: • Shift cable (jet pump end) Shift cable set length a (jet pump end): 13.6 mm (0.54 in) WARNING The shift cable must be screwed in more than 8 mm (0.31 in).
Page 321: Seat And Hand Grip
HULL SEAT AND HAND GRIP HOOD SEAT AND HAND GRIP EXPLODED DIAGRAM 6 × 30 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 6.9 N • m (0.69 kgf • m, 5.0 ft • Ib) 26 N •...
Page 322 HULL SEAT AND HAND GRIP HOOD EXPLODED DIAGRAM 6 × 30 mm 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 6.9 N • m (0.69 kgf • m, 5.0 ft • Ib) 26 N •...
Page 323: Service Points
HULL SEAT AND HAND GRIP HOOD SERVICE POINTS Seat lock assembly inspection 1. Inspect: • Seat lock assembly Damage/wear → Replace. 8-30...
Page 324: Exhaust System
HULL EXHAUST SYSTEM HOOD EXHAUST SYSTEM EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2.4 N •...
Page 325 HULL EXHAUST SYSTEM HOOD EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2.4 N •...
Page 326 HULL EXHAUST SYSTEM HOOD EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2.4 N •...
Page 327: Service Points
HULL EXHAUST SYSTEM HOOD SERVICE POINTS Exhaust system inspection 1. Inspect: • Water lock band Cracks/damage → Replace. 2. Inspect: • Rubber hoses Burns/cracks/damage → Replace. 3. Inspect: • Water lock Cracks/leaks → Replace. 4. Inspect: • Water tank Cracks/damage/leaks → Replace. Exhaust component parts sub-assembly 1.
Page 328 HULL EXHAUST SYSTEM HOOD Exhaust system installation 1. Install: • Exhaust joint NOTE: Be sure to install the projections a on the exhaust pipe and exhaust joint into the slots b in the joint. 8-35...
Page 329 HULL DECK AND HULL HOOD DECK AND HULL EXPLODED DIAGRAM 6.9 N • m (0.69 kgf • m, 5.0 ft • Ib) 13 N • m (1.3 kgf • m, 9.4 ft • Ib) 6 × 20 mm 16 N • m (1.6 kgf • m, 12 ft • Ib) 8 ×...
Page 330 HULL DECK AND HULL HOOD EXPLODED DIAGRAM 6.9 N • m (0.69 kgf • m, 5.0 ft • Ib) 13 N • m (1.3 kgf • m, 9.4 ft • Ib) 6 × 20 mm 16 N • m (1.6 kgf • m, 12 ft • Ib) 8 ×...
Page 331 HULL ENGINE MOUNT HOOD ENGINE MOUNT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ENGINE MOUNT REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT” in Chapter 5. Bolt Damper 1 Damper 2 Bolt Engine mount Liner...
Page 333 TRBL ANLS CHAPTER 9 TROUBLE ANALYSIS INTRODUCTION....................9-1 FEATURES ....................9-1 Functions..................... 9-1 CONTENTS....................9-1 HARDWARE REQUIREMENTS..............9-2 OPERATING....................9-3 CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT ................9-3 Top view....................9-3 TROUBLE ANALYSIS..................9-4 TROUBLE ANALYSIS CHART..............9-4 SELF-DIAGNOSIS ..................9-8...
Page 334 ANLS INTRODUCTION FEATURES The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions. By connecting your computer to the ECM (Electronic Control Module) of a watercraft using the com- munication cable, this software can be used to display sensor data and data stored in the ECM on a computer’s monitor.
Page 335 • Windows XP is a multiuser operating system, therefore, be sure to end this program if the login user is changed. • The USB adapter cannot be used with Windows 95. For operating instructions of the Yamaha Diagnostic System, refer to “Yamaha Diagnostic System Instruction manual”.
Page 336: Operating
TRBL OPERATING ANLS OPERATING CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT Top view 1 3-pin communication coupler 2 Wiring harness coupler 3 Meter coupler NOTE: Be careful not to pinch the communication cable between the hood and the deck or to damage it.
Page 337: Trouble Analysis
TRBL TROUBLE ANALYSIS ANLS TROUBLE ANALYSIS NOTE: Before consulting the “TROUBLE ANALYSIS CHART,” check the following items. 1. Check that the battery is charged and that its specified gravity is within specification. 2. Check that there are no incorrect wiring connections. 3.
Page 338 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part chapter POWER UNIT Compression Cylinder head gaskets Cylinder block Crankcase Piston rings Pistons Bearings Valve(s) and valve seat(s) Valve clearance adjusting pad(s) Camshaft(s) Timing chain Oil pump Engine oil Oil filter Oil pressure switch Bearing housing...
Page 339 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part chapter JET PUMP UNIT Duct Impeller Intake grate Bearings Water inlet hose Bilge hose Bilge strainer Bilge hose joint ELECTRICAL Ignition system, fuel control system • Pickup coils • ECM •...
Page 340 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part chapter Starting system • Start switch • Starter relay • Starter motor Charging system • Lighting coil • Rectifier/regulator • Fuses • Battery leads — • Battery Remote control system (Deluxe model only) •...
Page 341: Self-Diagnosis
141– Electronic control throttle system malfunction If the Yamaha Diagnostic System is not used to check the symptoms listed in the table, the error codes can be checked easily with the self-diagnosis in the multifunction meter. How- ever, if there are numerous error codes dis- played, be sure to check them with the Yamaha Diagnostic System.
Page 342 WIRING DIAGRAM VX110 Sport 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)
Page 343 WIRING DIAGRAM VX110 Deluxe 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 345 YAMAHA MOTOR CORPORATION, USA Printed in USA × 1 CR Jan. 2005 – (E_4)
Page 346 VX110 Sport 8 1 7 4 2 3 8 4 5 1 3 2 7 6 4 2 1 3 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14...
Page 347 VX110 Deluxe 5 1 6 4 2 3 8 4 5 1 3 2 7 6 4 2 1 3 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 4 2 3 1 1 2 3 5 6 7 4 8 9 10 11 12 13 14 13 14 12 18...

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Waverunner vx110 sport

Yamaha VX110 Sport Service Manual

Table of Contents

Chapter 1

Table of Contents

Chapter 2

Insp Adj

Chapter 3

Table of Contents

Chapter 4

Table of Contents

Chapter 5

Pump Chapter 6 Jet Pump Unit

Chapter 6

Table of Contents

Chapter 7

Quick Links

Chapters

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Summary of Contents for Yamaha VX110 Sport