Yamaha FX High Output Manuals

Manuals and User Guides for Yamaha FX High Output. We have 1 Yamaha FX High Output manual available for free PDF download: Service Manual

Yamaha FX High Output Service Manual (516 pages)

Brand: Yamaha | Category: Boat | Size: 22.52 MB

Lit-18616
2
Important Information
4
How to Use this Manual
5
Symbols
6
Current:
6
Index
7
General Information
8
Primary I.D. Number
9
Engine Serial Number
9
Jet Pump Unit Serial Number
9
Hull Identification Number (H.I.N.)
9
Safety While Working
10
Fire Prevention
10
Ventilation
10
Self-Protection
10
Good Working Practices
11
Disassembly and Assembly
12
Measuring
13
Special Tools
13
Removal and Installation
15
Special Tools
16
Specifications
19
General Specifications
20
Maintenance Specifications
22
Electrical
26
Current:
26
Tightening Torques
28
General Torque
36
Cable and Hose Routing
37
Periodic Inspection and Adjustment
46
Maintenance Interval Chart
47
Control System
48
Periodic Service
48
Steering Master Inspection
48
Steering Cable Inspection and Adjustment
48
Throttle Cable Inspection and Adjustment
49
QSTS Cable Inspection and Adjustment
51
Shift Cable Inspection and Adjustment
53
Trolling Speed Check and Adjustment
54
Fuel Line Inspection
55
Fuel System/Power Unit
56
Water Separator Inspection
56
Valve Clearance Adjustment
56
Intake
61
Exhaust
61
Engine Oil Level Check
62
Engine Oil Change-Using Oil Changer
64
Air Filter Element Clean
66
Spark Plug Inspection
67
Battery Inspection
70
Impeller Inspection
73
Water Inlet Strainer Inspection
73
Bilge Strainer Inspection
74
Electric Bilge Pump Strainer Inspection
74
Drain Plug Inspection
75
Lubrication Points
75
Fuel System
78
Arrangement of the Throttle Body Components Couplers
79
Fuel Tank and Fuel Pump Module
80
Exploded Diagram
80
Removal and Installation Chart
80
Service Points
83
Fuel Hose Disconnection
83
Fuel Pump Module Removal
83
Check Valve Inspection
83
Rollover Valve Inspection
84
Fuel Tank Inspection
84
Fuel Pump Module Installation
85
Fuel Injection System
86
Hose Clamps Removal
95
Hose Clamps Installation
95
Fuel Hose Installation (Replacing with New Fuel Hose)
97
Fuel Hose Connection
97
Throttle Body Removal
97
Fuel Injector Inspection
98
Throttle Body Inspection
98
Bypass Valve Motor Inspection
99
Throttle Body Installation
99
Throttle Bodies Synchronization
100
Fuel Pressure Measurement
105
Power Unit
106
Engine Unit
110
Compression Pressure Measurement
113
Oil Filter Removal and Installation
115
Engine Unit Removal
115
Shim Removal
116
Engine Mount Inspection
116
Coupling Clearance Inspection
116
Exhaust Pipe 3
117
Exhaust Pipes 1 and 2
120
Exhaust Manifold
122
Oil Tank
124
Oil Tank Removal
130
Oil Strainer Inspection
131
Oil Tank Installation
131
Oil Pump
134
Oil Pump Inspection
139
Oil Pump Installation
140
Reduction Drive Gear
141
Drive Coupling Removal
145
Drive Shaft Removal
145
Bearing Removal
145
Oil Pump Drive Shaft Inspection
146
Drive Shaft Inspection
146
Bearing Installing
147
Drive Shaft Installation
149
Drive Coupling Installation
149
Generator and Starter Motor
150
Flywheel Magneto Removal
155
Starter Clutch Inspection
155
Flywheel Magneto Installation
157
Camshafts
158
Camshaft Removal
164
Camshaft Inspection
165
Camshaft Sprockets Inspection
167
Timing Chain Tensioner Inspection
167
Camshaft Installation
168
Cylinder Head
172
Cylinder Head Removal
174
Cylinder Head Inspection
174
Cylinder Head Installation
175
Valves and Valve Springs
177
Valve Removal
179
Valve Spring Inspection
180
Valve Inspection
180
Valve Guide Replacement
182
Valve Seat Inspection
184
Valve Seat Reface
185
Valve Installation
187
Crankcase
189
Crankcase Disassembly
194
Timing Chain Inspection
195
Crankcase Assembly
196
Connecting Rods and Pistons
199
Connecting Rod and Piston Removal
201
Cylinder and Piston Inspection
202
Piston Ring Inspection
203
Piston Pin Inspection
205
Connecting Rod Inspection
206
Connecting Rod and Piston Installation
208
Crankshaft
212
Crankshaft Removal
213
Crankshaft Inspection
213
Crankshaft Installation
216
Thermostat
217
Thermostat Inspection
219
Thermostat Installation
219
Cooling Water Hose
220
Jet Pump Unit
221
Intake Grate, Ride Plate, and Intake Duct
223
Reverse Gate
228
Lever 1, 2 Installation
231
Jet Thrust Nozzle and Nozzle Ring
232
Impeller Duct and Impeller Housing 1
233
Impeller Duct and Drive Shaft
235
Transom Plate and Hoses
242
Electric Bilge Pump Inspection
245
Bilge Hose Inspection
245
Cooling Water Hose Inspection
245
Bearing Housing
246
Driven Coupling Removal and Installation
249
Intermediate Drive Shaft Removal
249
Bearing, Intermediate Drive Shaft, and Grease Hose Inspection
250
Driven Coupling Inspection
250
Bearing Installation
251
Oil Seal Installation
251
Intermediate Housing Installation
252
Electrical System
253
Electrical Components
256
Electrical Box
257
Electrical Analysis
264
Inspection
264
Digital Tester
264
Low Resistance Measurement
265
Peak Voltage Measurement
265
Peak Voltage Adapter
266
Test Harness
266
Ignition System
267
Wiring Diagram
267
Ignition Coil
267
Ignition Spark
269
Ignition System Peak Voltage
270
Ignition Coil
273
Engine Stop Switch
273
Engine Temperature Sensor
274
Sensor Assembly
274
Thermoswitch (Engine)
275
Thermoswitch (Exhaust)
275
Main and Fuel Pump Relay
276
Throttle Position Sensor
277
Cam Position Sensor
278
Noise Filter
279
Slant Detection Switch
279
Fuel Control System
280
Fuel Pump
282
Fuel Sender
282
Starting System
284
Wiring Connections
285
Fuse
285
Start Switch
285
Starter Relay
286
Starter Motor
287
Armature Inspection
290
Brush Holder Inspection
291
Starter Motor Front Cover Inspection
291
Charging System
292
Electric Bilge Pump
294
Off Throttle Steering System
296
Steering Switch
297
Indication System
298
Buzzer
300
Oil Pressure Switch
301
Multifunction Meter
301
Display Function
302
Speedometer Display
303
Tachometer Display
304
Voltage Meter Display
304
Low Oil Pressure Warning Indicator
304
Fuel Level Meter Display and Fuel Warning Indicator
304
Overheat Warning Indicator
305
Check the Engine Warning Indicator
305
Remote Control System
306
Yamaha Security System Indicator
307
Low-Rpm Mode Indicator
307
Diagnostic Display
308
Checking the Remote Control Transmitter
308
Transmitter Registration
310
Replacing of the Transmitter Battery
311
Hull and Hood
312
Handlebar
314
Handlebar Inspection
319
Handlebar Assembly Installation
319
QSTS Grip
321
QSTS Grip Inspection
323
Steering Master
324
Steering Master Components Inspection
328
Remote Control Cables and Speed Sensor Lead
329
Remote Control Cables Inspection
332
Steering Cable (Jet Pump End) Installation
332
Steering Cable Stopper Installation
332
QSTS Cable (Jet Pump End) Installation
333
QSTS Cable Stopper Installation
333
Shift Cable (Jet Pump End) Installation
333
Shift Cable Holder Installation
334
Shift Cable Stopper Installation
334
Front Hood
335
Steering Console Cover
339
Glove Compartment Assembly Installation
345
Hoses
346
Shift Lever
348
Base Assembly
351
Seats and Hand Grip
352
Seat Lock Inspection
355
Exhaust System
356
Exhaust System Inspection
359
Exhaust Component Parts Sub-Assembly
359
Exhaust System Installation
360
Deck and Hull
361
Engine Mount
363
Trouble Analysis
364
Introduction
365
Features
365
Functions
365
Hardware Requirements
366
Operating
367
Connecting the Communication Cable to the Watercraft
367
Trouble Analysis Chart
368
Self-Diagnosis
372
FX High Output, FX Cruiser High Output
373
F1S-28197-1G
378
Specifications
382
Periodic Inspection and
383
Identification Numbers
389
Specified Torques
407
Cable and Hose Routing (for FX/FX Cruiser)
420
Cable and Hose Routing (for FX High Output/Fx Cruiser High Output)
425
Fuel System
429
Electrical Components (for FX/FX Cruiser)
437
Electrical Components (for FX High Output/Fx Cruiser High Output)
438
Steering Sensor
441
Indication System (for FX Cruiser High Output)
442
Wiring Diagram (for FX Cruiser High Output)
443
Wiring Diagram (for FX High Output)
444
Wiring Diagram (for FX/FX Cruiser)
446
Operation Button
447
Display Function (for FX Cruiser High Output)
449
Display Function (for FX High Output)
450
Display Function (for FX/FX Cruiser)
451
Compass Display (for FX Cruiser High Output)
452
Air Temperature Display (for FX Cruiser High Output)
452
Speedometer/Average Speed/Tripmeter Display (for FX Cruiser High Output)
453
Water Temperature Display (for FX Cruiser High Output)
454
Trip Timer Display (for FX Cruiser High Output)
455
Fuel Consumption Per Hour, Fuel Consumption Per Kilometer/Mile Display (for FX Cruiser High Output)
455
Check Engine Warning Indicator
456
Remote Control System (for FX High Output/Fx Cruiser High Output)
457
Exploded Diagram (for FX/FX High Output)
461
Exploded Diagram (for FX Cruiser/Fx Cruiser High Output)
462
Installing Steps (for FX/FX High Output)
468
Installing Steps (for FX Cruiser/Fx Cruiser High Output)
468
Rubber Seal Installation
475
Steering Cable Removal
479
Steering Cable Installation
480
Rivet Installation
483
Ornament Disassembly
486
Front Hood Assembly
486
Visor Installation
487
Double-Sided Tape Installation
487
Ornament Installation
488
Mirror
489
Reboarding Step (for FX Cruiser/Fx Cruiser High Output)
503
Reboarding Step Installation
504
Cleat Assembly (for FX Cruiser High Output)
508
Cleat Cover Installation
509
FX/FX Cruiser
511
FX High Output/Fx Cruiser High Output
513

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Yamaha FX High Output Service Manual (516 pages)

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