Yamaha WaveRunner GP1300R, Supplementary Service Manual

Page 1: ...SUPPLEMENTARY SERVICE MANUAL GP1300R WaveRunner F1G 28197 1G 1X LIT 18616 02 90 LIT186160290...

Page 2: ...to use this Supplementary Service Manual together with the fol lowing manual GP1300R SERVICE MANUAL F1G 28197 1F 11 LIT 18616 02 44 A10001 0 WaveRunner GP1300R SUPPLEMENTARY SERVICE MANUAL 2004 by Ya...

Page 3: ...vised format the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol e g Bearings Pitting scratches Replace To assist you in finding y...

Page 4: ...ow WARNING instructions could result in severe injury or death to the machine operator passenger s a bystander or a person inspecting or repairing the watercraft CAUTION A CAUTION indicates special pr...

Page 5: ...icate parts to be lubricated or replaced see SYMBOLS 4 A job instruction chart accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc 5 Dimension figures and the...

Page 6: ...Symbols F to H in an exploded diagram indi cate the grade of lubricant and the lubrication point F Apply Yamaha 2 stroke motor oil G Apply water resistant grease Yamaha grease A Yamaha marine grease...

Page 7: ...GEN INFO SPECIFICATIONS 2 SPEC PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR JET PUMP UNIT 6 JET PUMP ELECTRICAL SYSTEM 7 ELEC HULL AND HOOD 8 HULL HOOD TROUBLE A...

Page 8: ...NUMBER H l N 1 SPECIAL SERVICE TOOLS 2 REMOVAL AND INSTALLATION 3 SPECIFICATIONS GENERAL SPECIFICATIONS 4 MAINTENANCE SPECIFICATIONS 6 ENGINE 6 JET PUMP UNIT 7 HULL AND HOOD 8 ELECTRICAL 8 TIGHTENING...

Page 9: ...33 Drive shaft inspection 33 Drive shaft installation 33 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 36 IGNITION SYSTEM 37 WIRING DIAGRAM 37 SENSOR ASSEMBLY 39 SLANT DETECTION SWITCH 39 OFF THROTTLE STEE...

Page 10: ...E TROUBLE ANALYSIS TROUBLE ANALYSIS 48 SELF DIAGNOSIS 48 WIRING DIAGRAM...

Page 11: ...number F1G 809601 1 ENGINE SERIAL NUMBER The engine serial number is stamped on a label 1 attached to the engine unit Starting serial number 60T 1009801 JET PUMP UNIT SERIAL NUMBER The jet pump unit...

Page 12: ...ervice and enable accu rate assembly and tune up Improvisations and using improper tools can damage the equipment NOTE For USA and Canada use the special ser vice tools starting with part numbers J YB...

Page 13: ...g YB 06112 Drive shaft needle bearing installer jet pump oil seal YB 06196 8 Needle bearing attachment jet pump bearing and oil seal 90890 06614 9 Outer race installer forward gear jet pump oil seal Y...

Page 14: ...0 15 1 12 5 Cruising range h 1 05 Engine Engine type 2 stroke Number of cylinders 3 Displacement cm3 cu in 1 297 79 1 Bore stroke mm in 84 78 3 31 3 07 Compression ratio 1 2 3 6 0 1 Intake system Ree...

Page 15: ...Jet pump type Axial flow single stage Impeller rotation Counterclockwise viewed from rear Transmission Direct drive from engine Jet thrust nozzle horizontal angle Degree 23 23 Jet thrust nozzle trim a...

Page 16: ...45 Wear limit mm in 0 165 0 0065 Piston pin boss inside diameter mm in 22 008 22 020 0 8665 0 8669 Piston rings Top Type Keystone Dimension B mm in 1 47 1 49 0 058 0 059 Dimension T mm in 3 0 3 2 0 11...

Page 17: ...0 024 Reed valve stopper height mm in 10 5 10 9 0 413 0 429 Reed valve warpage limit mm in 0 2 0 079 Fuel pump Pump type Electrical Output pressure kPa kgf cm2 psi 320 8 327 2 3 21 3 27 45 62 46 53 C...

Page 18: ...k voltage lower limit at cranking V 0 8 at 2 000 r min V 174 at 3 500 r min V 156 Stator Pickup coil W R W B W Y B Output peak voltage at cranking 1 V 6 0 at cranking 2 V 6 0 at 2 000 r min V 24 at 3...

Page 19: ...onds 30 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 Commutator diameter mm in 28 0 1 10 Limit mm in 27 0 1 06 Starter relay Rating Se...

Page 20: ...ut voltage P B O at trolling speed V 0 793 0 807 Fuel sender Fuel sender resistance Position A 133 5 136 5 Position B 5 7 Fuel injector Fuel injector resistance 1 13 8 Oil level sensor Oil level senso...

Page 21: ...locknut and adjuster throttle bodies end 1 11 1 1 8 0 Intake silencer case cover Tapping screw 6 13 1 8 0 18 1 3 Flame arrester Screw M5 6 0 8 0 08 0 6 Fuel rail Bolt M6 3 8 8 0 88 6 4 Oil pump cable...

Page 22: ...t Bolt M6 4 3 8 0 38 2 7 572 LT 2nd 7 6 0 76 5 5 Throttle bodies joint balance plate plate reed valve assembly 1st Bolt M6 14 3 8 0 38 2 7 572 LT 2nd 7 6 0 76 5 5 Balance plate plate reed valve assemb...

Page 23: ...impeller housing 2 Bolt M10 4 40 4 0 29 572 LT M6 1 7 8 0 78 5 6 Nozzle ring Bolt M8 2 15 1 5 11 271 LT Jet thrust nozzle Bolt M8 2 15 1 5 11 271 LT Spout hose screw clamp 1 1 2 0 12 0 9 Nozzle impel...

Page 24: ...7 Hood lock Bolt M6 2 5 4 0 54 3 9 Hinge assembly Nut M8 2 16 1 6 11 Steering console cover assembly Nut M6 2 5 4 0 54 3 9 Bolt M6 4 2 9 0 29 2 1 Screw M5 2 2 0 0 2 1 4 Nut M8 2 16 1 6 11 Multifuncti...

Page 25: ...6 1 3 4 0 34 2 5 Rectifier regulator Tapping screw 6 2 3 9 0 39 2 8 Coupler bracket Tapping screw 6 2 3 4 0 34 2 5 Wire harness retainer Tapping screw 6 2 4 9 0 49 3 5 Ignition coil 1 2 3 Tapping scre...

Page 26: ...of this manual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening...

Page 27: ...let 3 Throttle cable 4 QSTS cable 5 Steering cable 6 Speed sensor lead 7 Positive battery lead 8 Cooling water temperature sensor lead 9 Exhaust temperature sensor lead 0 Negative battery lead A Start...

Page 28: ...I B D D A E E D D F F 1 D E F F M M C E E J J G G B C A J J L 4 6 F 2 I D H F 6 6 F 0 A 6 F G 1 1 B A 0 9 8 7 6 5 4 3 2 1 J C Align the parting line on the fuel filler neck with the lot mark on the fu...

Page 29: ...le 7 QSTS cable 8 Speed sensor lead 9 Negative battery lead 0 Starter motor lead A Speed sensor coupler B Oil level sensor coupler C Buzzer coupler D Engine stop switch coupler E Multifunction meter c...

Page 30: ...D E F G H I 6 K J A L M 6 C D E B B F F B B C F F E D A 1 2 3 4 5 6 7 8 9 0 5 9 3 N 0 5 N To cylinder 3 To cylinder 2 To cylinder 1 Cooling water temperature sensor Exhaust temperature sensor To posi...

Page 31: ...7 1 A 1 Bilge hose 1 2 Bilge hose 2 3 Steering cable 4 Bilge hose 3 5 QSTS cable 6 Bilge hose 4 7 Cooling water hose cooling water inlet 8 Flushing hose 9 Speed sensor lead 0 Cooling water hose coolin...

Page 32: ...on the fuel rail Fasten oil delivery hoses 2 and 3 and the engine temperature sensor lead with a plastic tie Fasten the sub wire harness with the plastic tie on the rib of the fuel rail Be sure to po...

Page 33: ...tube toward the oil pump and then tape it To oil tank To check valve Install the oil hoses into the hose holders so that the holders do not cover the check valve clips Pass the bleed hose under the e...

Page 34: ...the corrugated tube of the fuel hose to the intake silencer slide it toward the fuel pump and then tighten it with a plastic tie To cooling water pilot outlet on starboard side To electrical box Inst...

Page 35: ...exhaust temperature sensor lead To cylinder 1 To cylinder 2 To cylinder 3 Cooling water inlet Install the white tape end of the negative battery lead to the battery Fasten the sub wire harness and wi...

Page 36: ...s 200 hours ITEM 6 months 12 months 12 months 24 months Spark plug Inspect clean adjust Lubrication points Lubricate Intermediate housing Lubricate 1 2 2 Fuel system Inspect Fuel tank Clean Oil inject...

Page 37: ...Procedure Part name Q ty Service points IMPELLER DUCT AND IMPELLER HOUSING 1 REMOVAL Follow the left Step for removal Nozzle ring Refer to JET THRUST NOZZLE AND NOZZLE RING in the base manual 1 Bolt...

Page 38: ...CT AND IMPELLER HOUSING 1 EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Bolt 4 8 Water inlet cover 1 9 Seal 1 10 Water inlet strainer 1 11 Seal 1 Reverse the removal steps for instal...

Page 39: ...RAM REMOVAL AND INSTALLATION CHART 1 EPNOC grease AP 0 Step Procedure Part name Q ty Service points IMPELLER DUCT AND DRIVE SHAFT DISASSEMBLY Follow the left Step for disassembly 1 Impeller 1 Left han...

Page 40: ...OC grease AP 0 Step Procedure Part name Q ty Service points 8 Drive shaft 1 9 Rear bearing 1 10 Spacer 1 11 Front bearing 1 12 Oil seal 1 13 Oil seal 1 14 Impeller duct 1 Reverse the disassembly steps...

Page 41: ...mpeller NOTE The impeller has left hand threads Turn the impeller clockwise to loosen it Drive shaft holder YB 06151 Drive shaft holder 5 90890 06519 2 Remove Nut 1 Drive shaft holder YB 06151 Drive s...

Page 42: ...ters YB 06096 Stopper guide plate 90890 06501 Bearing puller assembly 90890 06535 Stopper guide stand 90890 06538 5 Remove Front bearing NOTE Remove the front bearing with a press Driver handle large...

Page 43: ...attachment 90890 06614 Impeller inspection Refer to JET PUMP UNIT in Chapter 3 in the base manual Drive shaft inspection 1 Inspect Drive shaft Damage wear Replace Drive shaft installation 1 Install O...

Page 44: ...hich has an inner diameter of 25 mm 0 98 in Distance a 23 5 0 1 mm 0 93 0 004 in a 3 Install Drive shaft with front bearing Spacer NOTE Press the spacer and the front bearing with a pipe that is more...

Page 45: ...ment is not available use a washer or pipe with an outer diameter of 46 mm 1 81 in and an inner diameter of 20 mm 0 79 in Drive shaft needle bearing depth stop YB 34474 6 Add EPNOC grease AP 0 into th...

Page 46: ...or 6 Throttle position sensor 7 Fuel injectors 8 Engine temperature sensor 9 Throttle switch 0 Stepping motor A Rectifier regulator B Electric bilge pump C Speed sensor D Battery E Electrical box F Co...

Page 47: ...B O P O B O B Y B Y B Y Pu R W L Pu B B O B O P Pu Y G R R Y O G R Y G B G Y B Y Pu R B Y R Y G Y B O B O Pu B W L Pu Y P G R O O O W Y W B W R W R B B G G G B O B O B O B O B O L B B L B G G R B B B...

Page 48: ...B O O P B O B Y B Y B Y B Y B O B B Y B W B R B Y B W B R B O P O B O B Y B Y B Y Pu R W L Pu B B O B O P Pu Y G R R Y O G R Y G B G Y B Y Pu R B Y R Y G Y B O B O Pu B W L Pu Y P G R O O O W Y W B W...

Page 49: ...System to display the intake air temperature If the ambient temperature and the dis played intake air temperature differ by more than 5 C 9 F replace the sensor assembly SLANT DETECTION SWITCH 1 Chec...

Page 50: ...O B O B O B O B O B O B O B O B O O O O O O O O G B G B B Y B Y G Y G Y R Y R Y G R G R G R R Y G B R Y G Y R Y R Y R Y R Y G R G G B G Y R Y R Y R Y R Y R Y B O B W L O O W L O O B W L B O W L R W B...

Page 51: ...ing gauge 2 onto the plastic tie Hold the spring gauge at a 90 angle from the handlebar and then pull the spring gauge with a force of 100 N 10 kgf 22 lb Check that the following is displayed in the E...

Page 52: ...AL Follow the left Step for removal Steering console cover assembly Refer to STEERING CONSOLE COVER in the base manual Steering cable end Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD in the ba...

Page 53: ...43 E HULL HOOD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Plate 1 7 Rivet 1 Reverse the removal steps for installation 3 4 5 6 2 7 2 1 16 N m 1 6 kgf m 11 ft Ib STEERING COLUMN...

Page 54: ...SASSEMBLY Follow the left Step for disassembly 1 Grommet 1 2 Bolt washer nut 3 2 3 3 Steering arm 1 4 Shim Install the same number of shims installed originally at the factory 5 Steering column 1 16 N...

Page 55: ...ice points 6 Bushing 2 7 Spacer 1 8 Steering sensor 1 9 Bolt 2 10 Steering column housing 1 Reverse the disassembly steps for assembly 16 N m 1 6 kgf m 11 ft Ib 16 N m 1 6 kgf m 11 ft Ib 2 1 4 3 6 2 1...

Page 56: ...COLUMN SERVICE POINTS Steering column assembly 1 Install Spacer 1 Bolt 2 Bolt 3 Steering sensor 4 Nut 5 NOTE Tighten the nut while pushing the steering sen sor against the spacer T R Nut 16 N m 1 6 k...

Page 57: ...ter tank 45 50 mm 1 77 1 97 in c into the rubber hose Make sure that there is a distance of 30 mm 1 18 in d between the parting lines of the water tank and rubber hose Bow b d 2 Install Rubber hose NO...

Page 58: ...m with the Yamaha Diagnostic System Code Symptom 01 Normal 13 Pickup coil malfunction 15 Engine temperature sensor malfunction 18 Throttle position sensor TPS malfunction 19 Incorrect battery voltage...

Page 59: ...1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 22 B B B B B O B O B O B O B O B O B O B O B O B O P G O B B B B B B O O O O Br Br Br W W L B B Y B Y L R R W R Y B...

Page 60: ...ickup coil L Steering sensor M Oil level sensor N Buzzer O Speed sensor P Multifunction meter Q Fuel pump R Fuel sender S Engine stop switch T Engine shut off switch U Start switch V Slant detection s...

Page 61: ...YAMAHA MOTOR CORPORATION USA Printed in USA Dec 2004 0 0 1 CR E...

Page 62: ...SERVICE MANUAL GP1300R WaveRunner F1G 28197 1F 11 LIT 18616 02 44 LIT186160244...

Page 63: ...amaha has a policy of continuously improving its products models may differ in detail from the descriptions and illustrations given in this publication Use only the latest edition of this manual Autho...

Page 64: ...vised format the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol e g Bearings Pitting scratches Replace To assist you in finding y...

Page 65: ...ow WARNING instructions could result in severe injury or death to the machine operator passenger s a bystander or a person inspecting or repairing the watercraft CAUTION A CAUTION indicates special pr...

Page 66: ...icate parts to be lubricated or replaced see SYMBOLS 4 A job instruction chart accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc 5 Dimension figures and the...

Page 67: ...Symbols F to H in an exploded diagram indi cate the grade of lubricant and the lubrication point F Apply Yamaha 2 stroke motor oil G Apply water resistant grease Yamaha grease A Yamaha marine grease...

Page 68: ...GEN INFO SPECIFICATIONS 2 SPEC PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR JET PUMP UNIT 6 JET PUMP ELECTRICAL SYSTEM 7 ELEC HULL AND HOOD 8 HULL HOOD TROUBLE A...

Page 69: ...R 1 1 JET PUMP UNIT SERIAL NUMBER 1 1 HULL IDENTIFICATION NUMBER H l N 1 1 SAFETY WHILE WORKING 1 2 FIRE PREVENTION 1 2 VENTILATION 1 2 SELF PROTECTION 1 2 PARTS LUBRICANTS AND SEALANTS 1 2 GOOD WORKI...

Page 70: ...D number F1G 800301 1 ENGINE SERIAL NUMBER The engine serial number is stamped on a label 1 attached to the engine unit Starting serial number 60T 1000001 JET PUMP UNIT SERIAL NUMBER The jet pump unit...

Page 71: ...ities they may cause loss of con sciousness and death within a short time When test running an engine indoors e g in a water tank be sure to do so where adequate ventilation can be maintained SELF PRO...

Page 72: ...art of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made 5 To protect your skin apply a protective cream to your hands before workin...

Page 73: ...during disassembly 2 Apply engine oil to the contact surfaces of moving parts during assembly 3 Install bearings with the manufacture iden tification mark in the direction indication in the installat...

Page 74: ...he special ser vice tools starting with part number 90890 MEASURING AND DIAGNOSIS 1 Digital multimeter YU 34899 A 2 Digital circuit tester 90890 03174 3 Dial gauge YU 03097 90890 01252 4 Pocket tester...

Page 75: ...69 E Test harness 6 pins YB 06848 Test harness FSW 6A 6 pins 90890 06848 F Test harness 6 pins YB 06849 Test harness SM6195021 6 6 pins 90890 06849 G Lower unit pressure vacuum tester YB 35956 A Vacuu...

Page 76: ...8 Bearing puller assembly jet pump bearing 90890 06535 9 Stopper guide stand jet pump bearing 90890 06538 0 Driver rod L3 jet pump bearing 90890 06652 A Bearing housing needle bearing remover jet pump...

Page 77: ...diate shaft and jet pump 90890 06606 G Drive shaft needle bearing depth stop jet pump bearing YB 34474 H Shaft holder intermediate shaft YB 06552 Crankshaft holder 20 intermediate shaft 90890 06552 I...

Page 78: ...R 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 ENGINE 2 3 JET PUMP UNIT 2 4 HULL AND HOOD 2 5 ELECTRICAL 2 5 TIGHTENING TORQUES 2 8 SPECIFIED TORQUES 2 8 GENERAL TORQUE 2...

Page 79: ...h 63 0 16 6 13 9 Cruising range h 0 95 Engine Engine type 2 stroke Number of cylinders 3 Displacement cm3 cu in 1 297 79 1 Bore stroke mm in 84 78 3 31 3 07 Compression ratio 1 2 5 9 1 3 5 7 1 Intake...

Page 80: ...p Jet pump type Axial flow single stage Impeller rotation Counterclockwise viewed from rear Transmission Direct drive from engine Jet thrust nozzle horizontal angle Degree 23 23 Jet thrust nozzle trim...

Page 81: ...041 Wear limit mm in 0 155 0 0061 Piston pin boss inside diameter mm in 22 008 22 020 0 8665 0 8669 Piston rings Top Type Keystone Dimension B mm in 1 47 1 49 0 058 0 059 Dimension T mm in 3 0 3 2 0 1...

Page 82: ...ness mm in 0 6 0 024 Reed valve stopper height mm in 10 5 10 9 0 413 0 429 Reed valve warpage limit mm in 1 5 0 059 Fuel pump Pump type Electrical Output pressure kPa kgf cm2 psi 320 8 327 2 3 21 3 27...

Page 83: ...cylinder 3 Output peak voltage lower limit at cranking V 0 8 at 2 000 r min V 174 at 3 500 r min V 156 Stator Pickup coil W R W B W Y B Output peak voltage at cranking 1 V 6 0 at cranking 2 V 6 0 at 2...

Page 84: ...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 Commutator diameter mm in 28 0 1 10 Limit mm in 27 0 1 06 Starter relay Rating Seconds 30 Engine temperature se...

Page 85: ...392 F 104 153 Speed sensor Output voltage on pulse V 11 6 Output pulse one full turn 2 Throttle position sensor Output voltage P B O at trolling speed V 0 793 0 807 Fuel sender Fuel sender resistance...

Page 86: ...Throttle cable locknut and adjuster throttle bodies end 1 11 1 1 8 0 Intake air temperature sensor intake silencer case cover 1 7 5 0 75 5 4 572 LT Intake silencer case cover intake silencer case Tapp...

Page 87: ...ngine unit engine mount Bolt M8 4 17 1 7 12 572 LT Exhaust manifold cylinder 1st Bolt M10 10 22 2 2 16 271 LT 2nd 39 3 9 28 1st Nut M10 2 22 2 2 16 2nd 39 3 9 28 Cooling water joint exhaust manifold B...

Page 88: ...er Bolt M6 3 14 1 4 10 242 LT Drive coupling crankshaft assembly Drive coupling 1 36 3 6 25 572 LT Flywheel magneto crankshaft assembly Bolt M10 1 74 7 4 53 E Starter motor negative battery lead crank...

Page 89: ...ebar holder lower handlebar holder steering column Bolt M8 4 16 1 6 11 QSTS converter hull Nut M6 2 5 4 0 54 3 9 QSTS cable 1 2 locknut 2 16 1 6 11 Throttle lever assembly handlebar Screw M5 2 3 4 0 3...

Page 90: ...4 4 6 Hood lock assembly deck Nut M6 2 6 4 0 64 4 6 Seat lock assembly seat Bolt M6 2 6 4 0 64 4 6 572 LT Bracket deck projection Nut M10 1 26 2 6 19 Bracket deck handgrip Bolt M8 2 5 2 0 52 3 8 Handg...

Page 91: ...Tapping screw 6 6 3 9 0 39 2 8 Fuse holder stay electrical box Tapping screw 6 1 3 4 0 34 2 5 Main and fuel pump relay electrical box Tapping screw 6 1 3 9 0 39 2 8 Ground leads electrical box Bolt M...

Page 92: ...of this manual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening...

Page 93: ...ot outlet 3 YPVS servomotor 4 Throttle cable 5 QSTS cable 6 Steering cable 7 Speed sensor lead 8 Positive battery lead 9 Cooling water temperature sensor lead 0 Exhaust temperature sensor lead A Negat...

Page 94: ...B D D A E E D D F F 1 F G F F M M C E E J J G G B C A J J L 5 7 H 2 K F J H 7 7 H C A B 7 H I 1 1 D C B A 0 9 8 7 6 5 4 3 2 1 L E Align the parting line on the fuel filler neck with the lot mark on th...

Page 95: ...al bilge pump lead 8 Steering cable 9 QSTS cable 0 Speed sensor lead A Negative battery lead B Starter motor lead C Speed sensor coupler D Oil level sensor coupler E Buzzer coupler F Engine stop switc...

Page 96: ...F G H I J K 8 M L A N O 8 C D E B B F F B B C F F E D A 1 2 3 4 5 6 7 8 9 0 A B 7 A 5 P B 7 P To cylinder 3 To cylinder 2 To cylinder 1 Cooling water temperature sensor Exhaust temperature sensor To p...

Page 97: ...7 1 A 1 Bilge hose 1 2 Bilge hose 2 3 Steering cable 4 Bilge hose 3 5 QSTS cable 6 Bilge hose 4 7 Cooling water hose cooling water inlet 8 Flushing hose 9 Speed sensor lead 0 Cooling water hose cooli...

Page 98: ...b on the fuel rail Fasten oil delivery hoses 2 and 3 and the engine temperature sensor lead with a plastic tie Fasten the sub wire harness with the plastic tie on the rib of the fuel rail Be sure to p...

Page 99: ...hen tape it To oil tank To check valve Install the oil hoses into the hose holders so that the holders do not cover the check valve clips Pass the intake air temperature sensor lead over the fuel hose...

Page 100: ...g the corrugated tube of the fuel hose to the intake silencer slide it toward the fuel pump and then tighten it with a plastic tie To cooling water pilot outlet on starboard side To electrical box Ins...

Page 101: ...ten the throttle cable Fasten the exhaust temperature sensor lead To cylinder 1 To cylinder 2 To cylinder 3 Cooling water inlet Install the white tape end of the negative battery lead to the battery F...

Page 102: ...ent 3 4 Trolling speed check 3 5 FUEL SYSTEM 3 7 Fuel line inspection 3 7 Water separator inspection 3 7 OIL INJECTION SYSTEM 3 8 Oil line inspection 3 8 POWER UNIT 3 9 Spark plug inspection 3 9 YPVS...

Page 103: ...12 months 12 months 24 months Spark plug Inspect clean adjust 3 9 Lubrication points Lubricate 3 17 Intermediate housing Lubricate 1 2 2 3 19 Fuel system Inspect 3 7 Fuel tank Clean 3 7 Oil injection...

Page 104: ...ce Adjust 2 Adjust Steering cable joint steering column end Difference of distances a and b Maximum 5 mm 0 2 in Measurement steps Set the control grip to the neutral position Turn the handlebar lock t...

Page 105: ...then tighten the locknut T R Locknut 6 8 N m 0 68 kgf m 4 9 ft lb Throttle cable inspection and adjustment 1 Measure Throttle lever free play a Out of specification Adjust 2 Adjust Throttle lever fre...

Page 106: ...e joint 2 Adjust QSTS cable Adjustment steps Set the control grip to the neutral posi tion Loosen the locknut 1 Remove the nut 2 and pivot pin 3 Set the jet thrust nozzle in the center position Turn t...

Page 107: ...of specification Proceed to step 2 2 If the trolling speed is out of specification check the following If no malfunctions are found after perform ing all of the checks replace the throttle bodies Chec...

Page 108: ...ter accumulation the fuel lines for clogs or kinks and the fuel injectors for clogs Refer to FUEL SYSTEM Refer to FUEL TANK AND FUEL PUMP MODULE in Chapter 4 Refer to FUEL INJECTION SYSTEM in Chapter...

Page 109: ...r Cracks damage Replace the quick connector Fuel pipe Cracks damage Replace the fuel pump Refer to FUEL INJECTION SYSTEM in Chapter 4 Fuel filler hose Fuel filler cap Cracks damage Replace 2 Check Fue...

Page 110: ...bber seal Cracks wear Replace Oil hoses Oil tank Oil filler cap Cracks damage Replace Check valve Malfunction Replace CAUTION Do not allow the oil tank to become com pletely empty If the oil tank beco...

Page 111: ...ne 2 Clean Spark plug using a spark plug cleaner or wire brush Color guide Medium to light tan color Normal Whitish color Lean air fuel mixture Air leakage Incorrect settings Blackish color Overly ric...

Page 112: ...o 1 2 of a turn b T R Spark plug 25 N m 2 5 kgf m 18 ft lb YPVS cable adjustment 1 Check YPVS valve position Incorrect position Adjust YPVS cables 1 and 2 Checking steps Start the engine and then turn...

Page 113: ...ey with the hole in the cylinder Insert a 4 mm 0 16 in diameter pin through the pulley and cylinder holes Turn adjusters 3 and 4 in or out until the specified slack is obtained Turn in Slack is increa...

Page 114: ...roduce explosive gases Keep sparks flame cigarettes etc well away If using or charging the battery in an enclosed space make sure that it is well ventilated Always shield your eyes when working near b...

Page 115: ...service the impeller etc 2 Check Electrolyte level Low Add distilled water The electrolyte level should be between the maximum a and minimum b level marks CAUTION Use only distilled water Other types...

Page 116: ...5 Install Battery breather hose 1 Battery Positive battery lead 2 Negative battery lead 3 with terminal extension at negative battery terminal Battery bands CAUTION Connect the positive lead to the b...

Page 117: ...the clearance at each impeller blade as shown a total of four measure ments Install the intake duct and intake grate Refer to JET PUMP UNIT in Chapter 6 Connect the battery leads a 1 Water inlet stra...

Page 118: ...ilge strainer and bilge strainer case Install the bilge strainer case 1 Electric bilge pump strainer inspection 1 Check Cap Strainer Contaminants Clean Checking steps Remove the battery box Refer to B...

Page 119: ...fore lubricating the throttle cable squeeze the throttle lever and remove the rubber seal 1 Recommended lubricant Rust inhibitor 2 Lubricate QSTS control cables handlebar end NOTE Before lubricating t...

Page 120: ...ot shaft Steering cable jet thrust nozzle end QSTS cable jet thrust nozzle end Recommended grease Yamaha marine grease Yamaha grease A water resistant grease 5 Lubricate Steering cable Steering cable...

Page 121: ...e housing NOTE Using a grease gun fill the intermediate hous ing with the recommended grease through the grease nipples Recommended grease Yamaha marine grease Yamaha grease A water resistant grease G...

Page 122: ...spection 4 8 Fuel pump module installation 4 8 Fuel hose connection 4 8 INTAKE DUCT AND INTAKE SILENCER 4 9 EXPLODED DIAGRAM 4 9 REMOVAL AND INSTALLATION CHART 4 9 SERVICE POINTS 4 11 Intake silencer...

Page 123: ...PUMP 4 24 EXPLODED DIAGRAM 4 24 REMOVAL AND INSTALLATION CHART 4 24 SERVICE POINTS 4 27 Oil pump inspection 4 27 Oil hose inspection 4 27 Check valve inspection 4 27 Oil pump lever position adjustment...

Page 124: ...VAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT in Chapter 5 Steering console cover assembly Refer to STEERING CONSOLE COVER in Chapter 8 1 Oil level sensor coupler 1 2 Plastic t...

Page 125: ...D DIAGRAM Step Procedure Part name Q ty Service points 6 Breather hose 1 7 Oil hose 1 8 Bolt 2 9 Strap 2 10 Oil tank 1 11 Hose screw clamp 1 12 Oil filler hose 1 13 Oil level sensor 1 Reverse the remo...

Page 126: ...Contaminants Clean Frays tears Replace Rubber seal Cracks wear Replace Oil hoses Oil filler cap Cracks damage Replace Check valve Faulty Replace Oil level sensor inspection Refer to INDICATION SYSTEM...

Page 127: ...r hose 1 2 Check valve 1 3 Fuel tank breather hose 1 4 Fuel sender coupler 1 NOTE Make sure that the inner seal of the coupler is installed properly before connecting the coupler 5 Fuel pump module co...

Page 128: ...1 11 Seal 1 12 Fuel sender assembly 1 13 Hose screw clamp 2 14 Fuel filler hose 1 15 Nut 1 16 Fuel filler neck 1 1 3 N m 0 13 kgf m 0 9 ft Ib 8 18 mm 16 N m 1 6 kgf m 11 ft Ib 5 9 N m 0 59 kgf m 4 3 f...

Page 129: ...tank 1 19 Bolt 2 20 Strap 2 Reverse the removal steps for installation 1 3 N m 0 13 kgf m 0 9 ft Ib 8 18 mm 16 N m 1 6 kgf m 11 ft Ib 5 9 N m 0 59 kgf m 4 3 ft Ib 3 7 N m 0 37 kgf m 2 7 ft Ib 16 17 1...

Page 130: ...6 2 3 8 7 5 2 Remove Fuel pump module 1 NOTE Remove the float 2 at an angle to avoid catch ing it on the fuel tank 2 1 Fuel sender disassembly 1 Disconnect Fuel sender coupler 2 Remove Retainer 1 NOTE...

Page 131: ...f the check valve and then blow into the hose Air should come out from end B Connect the hose to end B of the check valve and then blow into the hose Air should not come out from end A A A B B 1 Fuel...

Page 132: ...AL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY in Chapter 5 1 Intake silencer screw clamp 1 2 Intake silencer 1 3 Intake silencer pipe screw clamp 2 4 I...

Page 133: ...4 10 E FUEL INTAKE DUCT AND INTAKE SILENCER EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 6 Bolt collar grommet 1 1 1 7 Intake duct 1 Reverse the removal steps for installation...

Page 134: ...NTAKE SILENCER SERVICE POINTS Intake silencer installation 1 Install Intake silencer pipe Intake silencer pipe screw clamps 1 Intake silencer Intake silencer screw clamp 2 NOTE Set the screw clamps in...

Page 135: ...ke silencer pipe Refer to INTAKE DUCT AND INTAKE SILENCER 1 Plastic tie 1 NOTE Fasten the wire harness lighting coil pickup coil ground lead and sub wire harness together with the plastic tie 2 Sub wi...

Page 136: ...tic tie 5 Cover 1 6 Fuel hose 1 7 Throttle bodies screw clamp 3 Tighten the screw clamp until there is no clearance between the spacer and the screw clamp 8 Bolt 2 9 Throttle bodies assembly 1 10 Thro...

Page 137: ...NCER CASE AND THROTTLE BODIES REMOVAL Follow the left Step for removal 1 Intake air temperature sensor coupler 1 2 Intake silencer case screw clamp 3 Tighten the screw clamp until there is no clearanc...

Page 138: ...Step for disassembly 1 Intake air temperature sensor 1 2 Tapping screw 13 3 Intake silencer case cover 1 4 Gasket 1 5 Screw 6 6 Flame arrester 3 7 Intake silencer case joint 3 8 Intake silencer case 1...

Page 139: ...e Q ty Service points THROTTLE BODIES DISASSEMBLY Follow the left Step for disassembly 1 Hose clamp 2 2 Fuel hose 1 3 Grommet 1 4 Quick connector 1 5 Sub wire harness 1 6 Bolt 3 7 Fuel rail 1 8 Spacer...

Page 140: ...GRAM Step Procedure Part name Q ty Service points 9 Fuel injector 3 10 O ring 3 11 Throttle bodies 1 Reverse the disassembly steps for assembly 6 6 6 7 5 2 3 1 9 10 9 10 9 10 11 4 1 8 8 N m 0 88 kgf m...

Page 141: ...urely fasten them Fuel hose disconnection WARNING Before disconnecting the fuel hoses remove the fuel tank filler cap to reduce any pressure inside the fuel tank and then disconnect the negative batte...

Page 142: ...e 2 directly WARNING Always reduce the fuel pressure in the fuel line before servicing the line or the fuel pipe If the fuel pressure is not released pressurized fuel can spray out 1 2 a 1 2 3 Cover t...

Page 143: ...njector using the Stationary Test of the Yamaha Diagnostic System Digital multimeter YU 34899 A Digital circuit tester 90890 03174 Fuel injector resistance reference data 13 8 at 21 C 70 F Throttle bo...

Page 144: ...2 1 a b 2 Install Fuel hose 1 NOTE Install the checker tab 2 of the fuel hose in the position shown in the illustration in rela tion to the throttle bodies Install the clamp with the crimped section a...

Page 145: ...t the fuel hose and check the O ring for damage and that it is properly installed Throttle cable installation 1 Adjust Oil pump lever position Refer to OIL PUMP 2 Adjust Throttle lever free play Refer...

Page 146: ...place the fuel pump module 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 Fue...

Page 147: ...D INTAKE SILENCER 1 Bolt 1 2 Oil pump cable 1 Route the oil pump cable outside of the bleed hose and the oil delivery hoses 3 Plastic tie 3 4 Oil delivery hose 1 1 5 Oil delivery hose 2 1 6 Oil delive...

Page 148: ...12 Oil suction hose 1 13 Oil return hose 1 Reverse the removal steps for installation 5 3 3 3 7 8 10 12 9 11 6 20 mm 13 4 6 6 12 mm 7 6 N m 0 76 kgf m 5 5 ft Ib 5 10 mm 2 1 LT 572 LT 2nd 4 4 N m 0 44...

Page 149: ...oints OIL PUMP HOSES AND CABLE REMOVAL Follow the left Step for removal 1 Bleed hose 1 2 Air bleed screw 1 3 Gasket 1 4 Bleed hose stay 1 5 Oil delivery hose 3 6 Oil delivery hose 1 1 7 Oil delivery h...

Page 150: ...e oil delivery hoses and the oil suc tion hose are not full of oil fill them up Bleed the oil pump delivery hoses and oil suction hose after installing them Check valve inspection 1 Check Check valve...

Page 151: ...s Remove the intake duct Refer to INTAKE DUCT AND INTAKE SILENCER Loosen the locknut 1 and adjusting nut 2 of the throttle cable Adjust the throttle cable length to 18 5 1 0 mm 0 728 0 039 in a Tighte...

Page 152: ...e to it fasten it with a locking tie Recommended engine oil YAMALUBE 2 W oil only Loosen the air bleed screw 1 two full turns and check that both the oil and air bubbles flow out When there are no air...

Page 153: ...10 ENGINE UNIT 5 13 EXPLODED DIAGRAM 5 13 REMOVAL AND INSTALLATION CHART 5 13 SERVICE POINTS 5 15 Shim removal 5 15 Engine mount inspection 5 15 Coupling clearance inspection 5 15 EXHAUST MANIFOLD 5 1...

Page 154: ...Piston ring inspection 5 34 Piston pin and bearing inspection 5 35 Piston installation 5 36 GENERATOR AND STARTER MOTOR 5 37 EXPLODED DIAGRAM 5 37 REMOVAL AND INSTALLATION CHART 5 37 SERVICE POINTS 5...

Page 155: ...esult in a loss of performance 1 Start the engine and warm it up until the engine temperature is 48 C 118 F 2 Remove Seat 3 Disconnect Spark plug caps 4 Remove Spark plugs CAUTION Before removing the...

Page 156: ...e compression pressure is extremely high check the cylinder head and piston crown for carbon deposits Carbon deposits Eliminate c If the compression pressure is below specification and the compression...

Page 157: ...OVAL Follow the left Step for removal YPVS servomotor and YPVS servomotor bracket Refer to YPVS SERVOMOTOR in Chapter 7 Battery box Refer to BATTERY BOX in Chapter 8 1 Spark plug cap 3 2 Exhaust tempe...

Page 158: ...ing water hose 1 1 To cooling water pilot outlet port Route the cooling hose under the exhaust chamber assembly 7 Screw clamp cooling water hose 1 1 To cooling water outlet stern Contact the corrugate...

Page 159: ...exhaust joint off 9 Inner exhaust joint screw clamp 2 10 Exhaust joint screw clamp 1 11 Water lock band 1 Slide the water lock off 12 Nut 2 13 Bolt 4 14 Intermediate housing grease hose 1 15 Eye 2 NOT...

Page 160: ...ty Service points 16 Bolt 2 17 Bolt 1 18 Bolt 1 19 Bolt 1 20 Muffler stay 2 1 21 Muffler assembly 1 NOTE Remove the cylinder head if it is difficult to remove the muffler assembly 22 Outer exhaust joi...

Page 161: ...rt name Q ty Service points MUFFLER DISASSEMBLY Follow the left Step for disassembly 1 Exhaust temperature sensor 1 2 Cooling water temperature sensor 1 3 Bolt 2 4 Muffler stay 1 5 Dowel pin 1 6 Bolt...

Page 162: ...XPLODED DIAGRAM Step Procedure Part name Q ty Service points 11 Catalytic converter 1 12 Gasket 1 13 Pin 2 14 Bolt 6 15 Mixing joint 1 16 Gasket 1 17 Muffler 1 Reverse the disassembly steps for assemb...

Page 163: ...ust joint Muffler assembly Inner exhaust joint screw clamp Outer exhaust joint screw clamp NOTE Align the projection a on the exhaust joint with the muffler assembly boss Use the angles shown in the i...

Page 164: ...t name Q ty Service points EXHAUST CHAMBER ASSEMBLY REMOVAL Follow the left Step for removal Muffler assembly Refer to MUFFLER ASSEMBLY 1 Screw clamp cooling water hose 1 1 To cooling water pilot outl...

Page 165: ...aust manifold 9 Exhaust chamber assembly 1 NOTE Before installing the exhaust chamber assembly connect the cooling water hose and fasten it with the screw clamp to the exhaust chamber part 8 and place...

Page 166: ...NSTALLATION CHART Step Procedure Part name Q ty Service points EXHAUST CHAMBER DISASSEMBLY Follow the left Step for disassembly 1 Bolt 5 2 Bolt 1 3 Exhaust chamber joint 1 4 Gasket 1 5 Pin 2 6 Exhaust...

Page 167: ...T CHAMBER ASSEMBLY Silencer pipe and intake duct Refer to INTAKE DUCT AND INTAKE SILENCER in Chapter 4 Throttle bodies assembly Refer to FUEL INJECTION SYSTEM in Chapter 4 Oil pump cable Refer to OIL...

Page 168: ...oupler 9 5 Bolt collar 1 1 6 Coupling cover 1 7 Bolt washer 4 4 8 Engine unit 1 9 Shim As required NOTE Install shims in their original positions Reverse the removal steps for installation 4 8 3 6 5 7...

Page 169: ...gine mounts Cracks damage Replace Refer to ENGINE MOUNTS in Chapter 8 Coupling clearance inspection 1 Measure Clearance a Clearance b with the rubber damper Out of specification Adjust NOTE Measure th...

Page 170: ...NSTALLATION CHART Step Procedure Part name Q ty Service points EXHAUST MANIFOLD REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT 1 Bolt 4 2 Bolt 6 3 Nut 2 4 Exhaust manifold 1...

Page 171: ...ART Step Procedure Part name Q ty Service points EXHAUST MANIFOLD DISASSEMBLY Follow the left Step for disassembly 1 Screw clamp cooling water hose 1 1 2 Bolt 6 3 Cooling water joint 1 4 O ring 3 5 Ex...

Page 172: ...ty Service points REED VALVE REMOVAL Follow the left Step for removal Throttle bodies assembly Refer to FUEL INJECTION SYSTEM in Chapter 4 Oil delivery hoses Refer to OIL PUMP in Chapter 4 1 Grease h...

Page 173: ...DIAGRAM Step Procedure Part name Q ty Service points 7 Balance plate 1 8 Gasket 1 9 Reed valve plate 1 10 Reed valve assembly 3 11 Screw 24 12 Valve stopper 6 13 Reed valve 6 Reverse the removal step...

Page 174: ...heck Reed valves Cracks damage Replace 2 Measure Valve warpage a Out of specification Replace 3 Measure Valve stopper height b Out of specification Replace Valve warpage limit 1 5 mm 0 059 in Valve st...

Page 175: ...ep Procedure Part name Q ty Service points YPVS REMOVAL Follow the left Step for removal Exhaust chamber assembly Refer to EXHAUST CHAMBER ASSEMBLY 1 Bolt 12 2 YPVS valve cover 3 3 Gasket 3 4 Spacer 2...

Page 176: ...PVS EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Bolt 3 NOTE For installation align the hole a in the YPVS shaft with the bolt 9 Shaft 3 1 10 Shaft 2 1 11 Shaft 1 1 12 YPVS valve ar...

Page 177: ...Part name Q ty Service points 14 YPVS valve assembly 3 NOTE Install the YPVS valves with the recess b facing toward the stern 15 Oil seal 6 NOTE If the YPVS shaft is removed the oil seal must be repl...

Page 178: ...nded scraper 1 CAUTION Do not use a sharp instrument to avoid damaging or scratching the surfaces 1 2 Check YPVS valve assembly Cracks damage wear Replace YPVS valve installation 1 Install Oil seals N...

Page 179: ...roper sequence as shown and in three stages Tighten bolts G and H in two stages 5 Bolt 12 6 Bolt 4 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 3rd 35 N m 3 5 kgf m 25 ft Ib 2nd 35 N m...

Page 180: ...1 Anode 2 Reverse the removal steps for installation 2nd 22 N m 2 2 kgf m 16 ft Ib 1st 22 N m 2 2 kgf m 16 ft Ib 3rd 35 N m 3 5 kgf m 25 ft Ib 2nd 35 N m 3 5 kgf m 25 ft Ib 1st 15 N m 1 5 kgf m 11 ft...

Page 181: ...cylinder head or spark plug bore threads 2 Check Cylinder head water jacket Corrosion mineral deposits Clean or replace 3 Measure Cylinder head warpage using a straightedge and thickness gauge Out of...

Page 182: ...me Q ty Service points CYLINDER REMOVAL Follow the left Step for removal YPVS Refer to YPVS Cylinder head Refer to CYLINDER HEAD 1 Engine temperature sensor 1 2 Bolt 12 NOTE Tighten the bolts in a cri...

Page 183: ...5 29 E POWR CYLINDERS EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 4 Cylinder gasket 3 5 Pin 6 Reverse the removal steps for installation Not reusable...

Page 184: ...der bore D using a cylinder gauge Out of specification Replace cylinder and piston as a set NOTE Measure the cylinder bore parallel to and at a right angle to the crankshaft Then average the measureme...

Page 185: ...ervice points PISTON REMOVAL Follow the left Step for removal Cylinders Refer to CYLINDERS 1 Piston pin clip 2 CAUTION Do not align the open end of the clip with the piston pin slot a 2 Piston pin 1 3...

Page 186: ...POWR PISTONS EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 5 Bearing 1 6 Piston ring 2 CAUTION Align each end gap with its respective locating pin Reverse the removal steps for instal...

Page 187: ...on pin clip from falling into the crankcase Piston inspection 1 Eliminate Carbon deposits from the piston crown and piston ring grooves 2 Check Piston wall Score marks Repair with 600 800 grit wet san...

Page 188: ...OTE New cylinder bore size 84 000 a 1 000 Example a 12 84 012 mm PISTON CLEARANCE CYLINDER BORE PISTON DIAMETER Piston to cylinder clearance 0 100 0 105 mm 0 0039 0 0041 in Cylinder size indication a...

Page 189: ...in Piston pin and bearing inspection 1 Check Piston pins Bearings Signs of heat discoloration Replace 2 Measure Piston pin outside diameter using a micrometer 1 Out of specification Replace Piston pi...

Page 190: ...play at the small end of the connecting rod as shown Free play wear at the small end Replace the piston pin connecting rod small end bearing or all parts Piston installation 1 Install Top ring 2nd rin...

Page 191: ...RT Step Procedure Part name Q ty Service points GENERATOR COVER REMOVAL Follow the left Step for removal Oil pump Refer to OIL PUMP in Chapter 4 1 Bolt 1 2 Bolt 7 NOTE Do not apply locking agent to th...

Page 192: ...5 38 E POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Pin 2 9 Bolt 2 10 Bolt 2 11 Exhaust chamber bracket 1 Reverse the removal steps for installation...

Page 193: ...ese washers hold the pickup coil leads Be sure not to pinch the leads between the projections and the washers when installing the bolts 3 Bolt 2 4 Cable holder 1 5 Bolt 6 6 Pickup coil 3 7 Bolt 1 4 9...

Page 194: ...lead 2 9 Bolt 3 10 Lighting coil 1 Reverse the removal steps for installation 4 9 N m 0 49 kgf m 3 5 ft Ib 5 14 mm 14 N m 1 4 kgf m 10 ft Ib 6 35 mm 14 N m 1 4 kgf m 10 ft Ib 6 14 mm 1 2 2 6 6 5 5 10...

Page 195: ...re Part name Q ty Service points GENERATOR ROTOR AND STARTER MOTOR REMOVAL Follow the left Step for removal 1 Drive coupling 1 2 Flywheel magneto bolt 1 3 Flywheel magneto 1 NOTE Degrease the flywheel...

Page 196: ...ERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Negative battery lead 1 8 Nut washer 1 1 9 Starter motor lead 1 10 Starter motor 1 Reverse the removal steps fo...

Page 197: ...M REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points STARTER CLUTCH DISASSEMBLY Follow the left Step for disassembly 1 Clip 1 2 Clip stopper 1 3 Spring seat 1 4 Spring 1 5 Was...

Page 198: ...MOTOR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 9 Weight 3 10 Spring ring 1 NOTE Install the spring ring after installing the weights plate and circlip 11 Pinion gear 1 Reverse th...

Page 199: ...re used for removal Coupler wrench YW 06551 90890 06551 Flywheel holder YW 06550 90890 06550 T R Drive coupling 36 N m 3 6 kgf m 25 ft lb LOCTITE 572 Flywheel magneto removal and installation 1 Remove...

Page 200: ...so that the puller plate is parallel to the generator rotor Universal puller YB 06117 Flywheel puller 90890 06521 Set bolt M8 60 mm Drive coupling inspection 1 Check Drive coupling Damage wear Replac...

Page 201: ...ice points CRANKCASE DISASSEMBLY Follow the left Step for disassembly Pistons Refer to PISTONS Generator cover and starter motor Refer to GENERATOR AND STARTER MOTOR 1 Bolt 6 2 Mount bracket 2 3 Pin 4...

Page 202: ...5 48 E POWR CRANKCASE EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Lower crankcase 1 9 Pin 2 10 Crankshaft assembly 1 11 Upper crankcase 1 Reverse the disassembly steps for assembly...

Page 203: ...crankcase Crankcase Cracks damage Replace Crankcase installation 1 Apply Gasket Maker to the crankcase mating surfaces NOTE Before applying Gasket Maker clean the crankcase mating surfaces 2 Check Cr...

Page 204: ...FT REMOVAL Follow the left Step for removal Crankcase Refer to CRANKCASE 1 Oil seal 1 2 Bearing 1 3 Oil seal 1 1 4 Oil seal 2 1 5 Crankshaft assembly 1 CAUTION Install the bearing locating pins into t...

Page 205: ...lection B using a dial gauge Out of specification Replace Maximum deflection B 0 05 mm 0 002 in C 0 15 mm 0 006 in 3 Measure Big end side clearance D using a thickness gauge Out of specification Repla...

Page 206: ...CRANKSHAFT 5 Check Bearings Damage pitting Replace NOTE Before checking bearings thoroughly clean them Immediately after checking the bearings lubricate them to prevent rust 6 Check Oil seals Damage w...

Page 207: ...e shaft inspection 6 11 Drive shaft installation 6 12 TRANSOM PLATE AND HOSES 6 14 EXPLODED DIAGRAM 6 14 REMOVAL AND INSTALLATION CHART 6 14 SERVICE POINTS 6 16 Bilge strainer inspection 6 16 Electric...

Page 208: ...CHART Step Procedure Part name Q ty Service points JET PUMP UNIT REMOVAL Follow the left Step for removal 1 Bolt 2 2 Bolt 2 3 Intake grate 1 4 Bolt 4 5 Intake duct 1 6 Felt seal 1 7 Screw 4 8 Speed s...

Page 209: ...LODED DIAGRAM Step Procedure Part name Q ty Service points 9 Bolt 4 10 Ride plate 1 11 QSTS cable joint 1 12 Plastic tie bilge hose 5 1 1 13 Nut washer 1 2 14 Steering cable joint 1 15 Screw clamp spo...

Page 210: ...DIAGRAM Step Procedure Part name Q ty Service points 18 Jet pump unit assembly 1 NOTE Clean the mating surfaces before applying Yamabond No 4 19 Dowel pin 2 20 Impeller housing 2 1 21 Dowel pin 2 Reve...

Page 211: ...AM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points SPEED SENSOR DISASSEMBLY Follow the left Step for disassembly 1 Paddle wheel set 1 2 Speed sensor 1 Reverse the disassemb...

Page 212: ...VAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points JET THRUST NOZZLE AND NOZZLE RING REMOVAL Follow the left Step for removal Jet pump unit Refer to JET PUMP UNIT 1 Bolt 2 2 Colla...

Page 213: ...CHART Step Procedure Part name Q ty Service points IMPELLER DUCT AND IMPELLER HOUSING 1 REMOVAL Follow the left Step for removal Nozzle ring Refer to JET THRUST NOZZLE AND NOZZLE RING 1 Bolt 4 2 Nozzl...

Page 214: ...MPELLER DUCT AND IMPELLER HOUSING 1 EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Bolt 4 8 Water inlet cover 1 9 Seal 1 10 Water inlet strainer 1 11 Seal 1 Reverse the removal steps...

Page 215: ...LODED DIAGRAM REMOVAL AND INSTALLATION CHART 1 EPNOC grease AP 0 Step Procedure Part name Q ty Service points IMPELLER DUCT AND DRIVE SHAFT DISASSEMBLY Follow the left Step for disassembly 1 Impeller...

Page 216: ...NOC grease AP 0 Step Procedure Part name Q ty Service points 8 Drive shaft 1 9 Rear bearing 1 10 Spacer 1 11 Front bearing 1 12 Oil seal 1 13 Oil seal 1 14 Impeller duct 1 Reverse the disassembly step...

Page 217: ...ve Nut 1 3 Remove Drive shaft 1 NOTE Remove the drive shaft using a press Drive shaft holder YB 06151 Drive shaft holder 5 90890 06519 Drive shaft holder YB 06151 Drive shaft holder 5 90890 06519 4 Re...

Page 218: ...bearing remover YB 06112 Needle bearing attachment 90890 06614 6 Remove Oil seal NOTE Remove the oil seals using a press Impeller inspection Refer to JET PUMP UNIT in Chapter 3 Drive shaft inspection...

Page 219: ...n 2 Install Front bearing Drive shaft NOTE Install the front bearing and drive shaft using a press 3 Install Drive shaft with front bearing Spacer Impeller duct NOTE Press the spacer and the front bea...

Page 220: ...lable use a washer or pipe with an outer diameter of 47 50 mm 1 85 1 97 in and an inner diameter of 21 25 mm 0 83 0 98 in Drive shaft needle bearing depth stop YB 34474 6 Add EPNOC grease AP 0 into th...

Page 221: ...ANSOM PLATE AND HOSE REMOVAL Follow the left Step for removal Exhaust system Refer to EXHAUST SYSTEM in Chapter 8 Jet pump unit assembly Refer to JET PUMP UNIT 1 Hose screw clamp 3 2 Cooling water hos...

Page 222: ...rocedure Part name Q ty Service points 6 Bilge hose 4 1 7 Band 1 8 Electric bilge pump assembly 1 9 Hose clamp 1 10 Bilge hose 3 1 11 Bilge strainer 1 12 Nut washer 4 4 13 Transom plate 1 14 Plastic t...

Page 223: ...o JET PUMP UNIT in Chapter 3 Electric bilge pump inspection Refer to BILGE PUMP in Chapter 3 Refer to ELECTRIC BILGE PUMP in Chapter 7 Bilge hose inspection 1 Check Bilge hoses Cracks damage wear Repl...

Page 224: ...art name Q ty Service points BEARING HOUSING REMOVAL Follow the left Step for removal Engine unit Refer to ENGINE UNIT in Chapter 5 1 Rubber coupling 1 2 Bolt 3 3 Intermediate housing assembly 1 4 Pin...

Page 225: ...ON CHART Step Procedure Part name Q ty Service points BEARING HOUSING DISASSEMBLY Follow the left Step for disassembly 1 Grease hose 1 2 Grease nipple 1 3 Grease nipple stay 1 4 Nipple 2 5 Driven coup...

Page 226: ...PLODED DIAGRAM Step Procedure Part name Q ty Service points 9 Oil seal 1 10 Oil seal 1 11 Oil seal 1 12 Circlip 1 13 Bearing 1 14 Circlip 1 Reverse the disassembly steps for assembly Not reusable Not...

Page 227: ...ft holder YB 06552 Crankshaft holder 20 90890 06552 Intermediate drive shaft removal 1 Remove Intermediate drive shaft NOTE Support the intermediate housing with steel blocks 1 and press the intermedi...

Page 228: ...t and grease hose inspection 1 Check Bearing Rotate the inner race by hand Damage rough movement Replace Intermediate drive shaft Damage pitting Replace Grease hose Cracks wear Replace Driven coupling...

Page 229: ...ive shaft NOTE Support the intermediate housing with steel blocks 1 and install the intermediate drive shaft using a press Driver handle large YB 06071 Driver rod LS 90890 06606 Drive shaft taper roll...

Page 230: ...Install shims in their original positions if the intermediate housing is not replaced Installation steps Install the intermediate housing Measure the clearance a at each bolt hole Install the suitabl...

Page 231: ...voltage measurement 7 9 Peak voltage adapter 7 10 Test harness 7 10 IGNITION SYSTEM 7 11 WIRING DIAGRAM 7 11 IGNITION SPARK GAP 7 13 IGNITION SYSTEM PEAK VOLTAGE 7 14 BATTERY 7 16 FUSE 7 16 SPARK PLU...

Page 232: ...ING SYSTEM 7 27 WIRING DIAGRAM 7 27 BATTERY 7 28 WIRING CONNECTIONS 7 28 FUSES 7 28 START SWITCH 7 28 STARTER RELAY 7 29 MAIN AND FUEL PUMP RELAY 7 29 STARTER MOTOR 7 30 EXPLODED DIAGRAM 7 30 REMOVAL...

Page 233: ...AIN AND FUEL PUMP RELAY 7 45 INDICATION SYSTEM 7 46 WIRING DIAGRAM 7 46 FUSE 7 48 BATTERY 7 48 ENGINE TEMPERATURE SENSOR 7 48 COOLING WATER TEMPERATURE SENSOR 7 48 EXHAUST TEMPERATURE SENSOR 7 48 MAIN...

Page 234: ...or 7 Throttle position sensor 8 Fuel injectors 9 Engine temperature sensor 0 Throttle switch A Stepping motor B Rectifier regulator C Electric bilge pump D Speed sensor E Battery F Electrical box G Co...

Page 235: ...sket 1 5 Tapping screw 2 6 Lead holder 1 7 Bolt 2 8 Positive battery lead 1 9 Stator motor lead 1 3 9 N m 0 39 kgf m 2 8 ft Ib 6 30 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 6 25 mm 3 4 N m 0 34 kgf m 2 5 ft Ib...

Page 236: ...screw 2 17 Rectifier regulator 1 18 Tapping screw 2 19 Coupler bracket 1 20 Bolt 2 3 9 N m 0 39 kgf m 2 8 ft Ib 6 30 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 6 25 mm 3 4 N m 0 34 kgf m 2 5 ft Ib 6 16 mm 4 9 N...

Page 237: ...ead 1 28 Spark plug lead 1 cap 1 1 29 Spark plug lead 2 cap 1 1 30 Spark plug lead 3 cap 1 1 31 Fuse 3 A 2 3 9 N m 0 39 kgf m 2 8 ft Ib 6 30 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 6 25 mm 3 4 N m 0 34 kgf m...

Page 238: ...mbly steps for assembly 3 9 N m 0 39 kgf m 2 8 ft Ib 6 30 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 6 25 mm 3 4 N m 0 34 kgf m 2 5 ft Ib 6 16 mm 4 9 N m 0 49 kgf m 3 5 ft Ib 6 30 mm 3 4 N m 0 34 kgf m 2 5 ft Ib...

Page 239: ...m 5 5 ft Ib 6 16 mm 3 9 N m 0 39 kgf m 2 8 ft Ib 6 25 mm 2 3 4 5 1 1 Ignition coils 2 Starter relay 3 Fuse holders 4 Main and fuel pump relay 5 Rectifier regulator White tape To starter motor To posi...

Page 240: ...D INSTALLATION CHART Step Procedure Part name Q ty Service points ECM AND SLANT DETECTION SWITCH REMOVAL Follow the left Step for removal 1 Nut washer 2 2 2 ECM 1 3 ECM coupler 1 4 Nut washer 2 2 5 Sl...

Page 241: ...wered by dry batteries check the battery voltage periodically and replace the batteries if necessary Digital tester NOTE Throughout this chapter the part numbers of the specified digital testers have...

Page 242: ...obtained by connecting both of its terminals Correct value Displayed measurement Internal resistance Peak voltage measurement NOTE When checking the condition of the ignition system it is vital to kno...

Page 243: ...l circuit tester Make sure that the positive pin the mark facing up as shown on the adapter is installed into the positive terminal of the tester The test harness is needed for the following tests Vol...

Page 244: ...B W B R B Y B W B R B O P O B O B Y B Y B Y Pu R Pu B B O B O P Pu Y G R R Y O G B G G B G Y B Y Pu R B Y B G G Y B O B O Pu B Pu Y P G R O O O W Y W B W R W R B B G G G B O B O B O B O B O L B B L B...

Page 245: ...L B O O O P B O O P B G B O B Y B G B O B Y B Y B Y B O B B Y B W B R B Y B W B R B O P O B O B Y B Y B Y Pu R Pu B B O B O P Pu Y G R R Y O G B G G B G Y B Y Pu R B Y B G G Y B O B O Pu B Pu Y P G R...

Page 246: ...le gas or liquids away since this test can produce sparks 1 Check Ignition spark gap Below specification Check the ECM output peak voltage Check the ignition coil for resistance For USA and Canada For...

Page 247: ...nition system but possibly with the spark plug s or another component 1 Measure ECM output peak voltage Below specification Measure the pickup coil output peak voltage NOTE To crank the engine connect...

Page 248: ...ng coil 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 Test harness 6 pins YB 068...

Page 249: ...in Chapter 3 FUSE Refer to STARTING SYSTEM SPARK PLUGS Refer to POWER UNIT in Chapter 3 SPARK PLUG LEAD ASSEMBLY 1 Check Spark plug lead assembly Cracks damage Replace Test harness 6 pins YB 06848 Tes...

Page 250: ...istance measurement Primary coil resistance Black white B W Body 0 26 0 36 at 20 C 68 F 2 Measure Secondary coil resistance Out of specification Replace Secondary coil resistance Black white B W Spark...

Page 251: ...esistance when the speci fied temperatures are reached INTAKE AIR TEMPERATURE SENSOR 1 Measure Intake air temperature sensor resistance at the specified temperatures Out of specifications Replace Inta...

Page 252: ...temperature is reached Suspend the cooling water temperature sensor in a container filled with oil Slowly heat the oil Measure the resistance when the speci fied temperatures are reached EXHAUST TEMPE...

Page 253: ...sconnecting terminal 1 2 or 3 Connect the tester leads between main and fuel pump relay terminals 6 and 8 Connect terminal 7 to the positive bat tery terminal Connect terminal 4 to the negative bat te...

Page 254: ...06869 Lower unit pressure vacuum tester YB 35956 A Vacuum pressure pump gauge set 90890 06756 Atmospheric pressure sensor output voltage Pink green P G Black orange B O 1 101 3 kPa 1 01 kgf cm2 14 4...

Page 255: ...E ELEC IGNITION SYSTEM SLANT DETECTION SWITCH 1 Check Slant detection switch continuity Out of specification Replace Position Lead color Blue black L B Black orange B O Normal operation Overturned UP...

Page 256: ...B O B Y B Y B Y Pu R Pu B B O B O P Pu Y G R R Y O G B G G B G Y B Y Pu R B Y B G G Y B O B O Pu B Pu Y P G R O R Y R Y B G B O B O L B B L B O O O B B B R Y R Y R Y R Y R Y R Br B L R Y L R Y B L B O...

Page 257: ...O P B G B O B O B Y B Y B Y B O B O B Y B Y B Y Pu R Pu B B O B O P Pu Y G R R Y O G B G G B G Y B Y Pu R B Y B G G Y B O B O Pu B Pu Y P G R O R Y R Y B G B O B O L B B L B O O O B B B R Y R Y R Y R...

Page 258: ...PUMP 1 Check Fuel pump operating sound No sound Measure the fuel pressure Refer to FUEL INJECTION SYSTEM in Chapter 4 FUEL SENDER 1 Measure Fuel sender resistance Out of specification Replace Float po...

Page 259: ...EMPERATURE SENSOR Refer to IGNITION SYSTEM COOLING WATER TEMPERATURE SENSOR Refer to IGNITION SYSTEM EXHAUST TEMPERATURE SENSOR Refer to IGNITION SYSTEM MAIN AND FUEL PUMP RELAY Refer to IGNITION SYST...

Page 260: ...23 22 21 1 4 9 15 16 17 18 Y R Y B 2 27 33 R Br R Br 1 2 3 4 5 6 7 8 Y B B B B R Y R Y B B R Y R Y R Y R Y R Y R Br B L R Y L R Y R Br R Br Br R R R R R B B R R B Br Br Br R 1 2 3 4 5 6 7 8 1 ECM 2 Ma...

Page 261: ...s Broken Replace NOTE The 20 A fuse is for the main relay engine shut off switch and rectifier regulator The 3 A fuses are for the multifunction meter and electric bilge pump Fuse rating 20 A 1 3 A 2...

Page 262: ...e tester leads between the starter relay terminals as shown Connect the brown lead terminal to the positive battery terminal Connect the black lead terminal to the negative battery terminal Check that...

Page 263: ...e Q ty Service points STARTER MOTOR DISASSEMBLY Follow the left Step for disassembly Starter motor Refer to GENERATOR AND STARTER MOTOR in Chapter 5 1 O ring 1 2 Bolt 2 3 Starter motor front cover 1 4...

Page 264: ...e Q ty Service points 8 Starter motor rear cover 1 9 O ring 1 10 Shim As required Thickness 0 2 mm 0 8 mm 11 Armature assembly 1 12 Nut spring washer washer 1 1 4 13 O ring 1 14 Brush holder 1 15 Brus...

Page 265: ...7 32 E ELEC STARTER MOTOR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 18 Spacer 1 19 Holder 1 20 Starter motor yoke 1 Reverse the disassembly steps for assembly...

Page 266: ...with 600 grit sandpaper 3 Measure Commutator diameter Out of specification Replace Minimum commutator diameter 27 0 mm 1 06 in 4 Check Commutator undercut Contaminants Clean NOTE Use compressed air to...

Page 267: ...armature shaft No continuity Brush holder inspection 1 Measure Brush length a Out of specification Replace Minimum brush length 6 5 mm 0 26 in 2 Check Brush holder continuity Out of specification Repl...

Page 268: ...7 35 E ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM B R B G G G G G G G G G G G G G G R B R R R R 1 2 3 4 1 Rectifier regulator 2 Fuse 20 A 3 Battery 4 Lighting coil B Black G Green R Red...

Page 269: ...7 36 E 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...

Page 270: ...B B B O B O B O W B W R W Y B W Y W R W B B O B R B G G G G G G G G G B W Y W B W R W R B B G G G P B O G O L G G R B B B B B P R R R B B B O O O G L O P B G L O P B O B O B O B O B B B B R 1 5 4 3 2...

Page 271: ...E ELEC YPVS FUSE Refer to STARTING SYSTEM BATTERY Refer to ELECTRICAL in Chapter 3 PICKUP COIL Refer to IGNITION SYSTEM LIGHTING COIL Refer to IGNITION SYSTEM RECTIFIER REGULATOR Refer to IGNITION SY...

Page 272: ...dure Part name Q ty Service points YPVS SERVOMOTOR REMOVAL Follow the left Step for removal 1 Bolt 2 2 Cable holder 1 3 YPVS servomotor coupler 1 4 Nut washer 2 2 5 YPVS servomotor 1 6 Throttle cable...

Page 273: ...7 40 E ELEC YPVS SERVOMOTOR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 8 Cover 1 9 Nut washer 3 3 10 YPVS servomotor bracket 1 Reverse the removal steps for installation...

Page 274: ...rned in Removal steps Remove the YPVS cable holder 1 Remove the YPVS cables 2 from both drums YPVS cable inspection 1 Check YPVS cables 1 and 2 Frays kinks rough movement Replace YPVS servomotor inspe...

Page 275: ...B O B O B O B O B O B O B O O O O O O O G B G B B Y B Y G Y G Y R Y R Y G R G R G R R Y G B R Y G Y R Y R Y R Y R Y G R G G B G Y R Y R Y R Y R Y R Y R Y W L B R W Y B B B R W Y B R Y W L B R Y W L B...

Page 276: ...to the left using the Engine monitor of the Yamaha Diagnostic System Does not operate Replace STEPPING MOTOR 1 Check Check the operation of the stepping motor using the Stationary test of the Yamaha D...

Page 277: ...13 14 32 26 25 24 23 22 21 1 4 9 15 16 17 18 Y R Y 2 27 1 2 3 4 5 6 7 8 Br R R Y R Y B B B R Y R Y R Y R Y R Y R Br B L R Y L R Y Y Br B B R Y R Y B R Y R R B B B Br B B B R B R Y Br R 1 2 3 4 5 1 ECM...

Page 278: ...r to ELECTRICAL in Chapter 3 MAIN AND FUEL PUMP RELAY Refer to IGNITION SYSTEM Checking steps Suspend the electric bilge pump in a con tainer filled with water Connect the brown lead terminal to the p...

Page 279: ...u R B Y B G G Y B O B O Pu B Pu Y P G R W B B O B O B O B O B R Y R Y R Y R Y R Y R Br B L R Y L R Y O G B L B B B O B O B O B O B O B R Y R Y B L R L B R B B Y B Y B Y Y B R L L B Y R Y Y B Y R W L B...

Page 280: ...B G G B G Y B Y Pu R B Y B G G Y B O B O Pu B Pu Y P G R W B B O B O B O B O B R Y R Y R Y R Y R Y R Br B L R Y L R Y O G B L B B B O B O B O B O B O B R Y R Y B L R L B R B B Y B Y B Y Y B R L L B Y...

Page 281: ...r to IGNITION SYSTEM COOLING WATER TEMPERATURE SENSOR Refer to IGNITION SYSTEM EXHAUST TEMPERATURE SENSOR Refer to IGNITION SYSTEM MAIN AND FUEL PUMP RELAY Refer to IGNITION SYSTEM OIL LEVEL SENSOR 1...

Page 282: ...ive battery terminal Red R terminal 1 Negative battery terminal Black B terminal 2 MULTIFUNCTION METER Multifunction meter 1 Check Multifunction meter Cracked meter housing Replace the multifunction m...

Page 283: ...ce the multi function meter R W B R B Y P B L B W R Y Y W B Y R W L R P B L R L B R B B R B L B L R B R 1 5 4 3 2 1 Buzzer 2 Speed sensor 3 ECM 4 Oil level sensor 5 Fuel sender B Black L Blue P Pink R...

Page 284: ...put pulse 2 pulses 1 full turn Measurement steps Connect a 12 volt battery to the white three pin connector between the red yel low and black yellow leads Rotate the paddle wheel by hand and measure t...

Page 285: ...splay and fuel warning indicator 1 Check Fuel level meter display and fuel warn ing indicator Do not display Measure the fuel sender resistance If the fuel sender resistance is within specification re...

Page 286: ...and that the engine overheat warning indicator is displayed 1 Exhaust temperature warning indicator 1 Check Exhaust temperature warning indicator Does not operate Replace the multi function meter Che...

Page 287: ...and check engine warning indicator blink and that the buzzer sounds intermittently Diagnostic display 1 Check Diagnostic display Does not display Replace the multi function meter Checking steps Start...

Page 288: ...11 SERVICE POINTS 8 14 Steering column bushing inspection 8 14 Steering column assembly 8 14 REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 8 15 EXPLODED DIAGRAM 8 15 REMOVAL AND INSTALLATION CHART 8 15...

Page 289: ...ICE POINTS 8 31 Seat lock inspection 8 31 BATTERY BOX 8 32 EXPLODED DIAGRAM 8 32 REMOVAL AND INSTALLATION CHART 8 32 EXHAUST SYSTEM 8 34 EXPLODED DIAGRAM 8 34 REMOVAL AND INSTALLATION CHART 8 34 SERVI...

Page 290: ...Q ty Service points HANDLEBAR COVER REMOVAL Follow the left Step for removal 1 Screw 4 2 Handlebar cover 1 3 Screw 4 4 Handlebar cover stay 1 5 Plastic tie 1 6 Throttle cable 1 7 Bolt 4 8 Upper handl...

Page 291: ...Step for removal QSTS cable to jet thrust nozzle Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Grommet 1 NOTE To ease installation apply soapy water to the grommet 2 Handlebar switch coupler...

Page 292: ...E HULL HOOD HANDLEBAR EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 5 Handlebar assembly 1 6 Nut washer 2 2 7 QSTS converter 1 8 Throttle cable 1 Reverse the removal steps for installa...

Page 293: ...Step Procedure Part name Q ty Service points HANDLEBAR DISASSEMBLY Follow the left Step for disassembly 1 Plastic tie 1 2 Bolt 2 3 Grip end 2 4 Spacer 1 5 Screw spring washer washer 1 1 1 6 QSTS grip...

Page 294: ...ep Procedure Part name Q ty Service points 11 Throttle lever assembly 1 12 Handlebar grip 1 NOTE Apply adhesive to the handlebar and the inner surface of the handlebar grip 13 Spacer 2 1 14 Handlebar...

Page 295: ...djusting the QSTS cables set the control grip to the neutral position Adjust the QSTS cables to the specified length a and be sure to take up any slack if necessary QSTS cable length 72 0 5 mm 2 83 0...

Page 296: ...ble into the grommet fasten the end of grommet with the plastic tie 5 Install Handlebar cover 1 NOTE When the handlebar cover is in contact with the steering console cover adjust the handle bar mounti...

Page 297: ...tep Procedure Part name Q ty Service points QSTS GRIP DISASSEMBLY Follow the left Step for disassembly QSTS grip assembly Refer to HANDLEBAR 1 Screw washer 1 1 2 Cover 1 3 Ball 2 4 Spring 2 5 QSTS cab...

Page 298: ...DED DIAGRAM Step Procedure Part name Q ty Service points 7 Screw washer 2 2 8 Collar 1 9 QSTS shift lock lever 1 10 Spring 1 11 Spacer 1 12 QSTS cable housing cover 1 13 QSTS shift grip 1 Reverse the...

Page 299: ...8 10 E HULL HOOD QSTS GRIP SERVICE POINTS QSTS cable inspection 1 Check QSTS cables Frays kinks rough movement Replace QSTS grip inspection 1 Check QSTS grip Damage wear Replace...

Page 300: ...OLUMN REMOVAL Follow the left Step for removal Steering console cover assembly Refer to STEERING CONSOLE COVER Steering cable end Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD 1 Steering switch...

Page 301: ...left Step for disassembly 1 Grommet 1 2 Bolt washer nut 1 2 1 3 Steering arm 1 4 Screw 1 5 Magnet 1 6 Shim Install the same number of shims installed originally at the factory 7 Washer 1 8 Steering c...

Page 302: ...9 Bushing 2 10 Plastic tie 1 11 Screw clamp 1 12 Steering switch 1 13 Steering column housing 1 Reverse the disassembly steps for assembly 2 9 11 7 6 3 2 1 13 8 9 12 10 4 5 16 N m 1 6 kgf m 11 ft Ib 2...

Page 303: ...ering column assembly 1 Install Steering switch 1 Screw clamp 2 Plastic tie 3 NOTE Fasten the steering switch lead 4 with the plastic tie 3 as shown in the illustration 2 Install Bushings Steering col...

Page 304: ...LODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL Follow the left Step for removal 1 Speed sensor coupler 1...

Page 305: ...BLES AND SPEED SENSOR LEAD EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 10 Seal 1 11 Steering cable 1 12 Nut 1 13 Pin 1 14 QSTS cable end 1 15 Nut 1 16 Seal 1 17 QSTS cable 1 Reverse...

Page 306: ...ecomes damaged replace it Never attempt to repair a damaged cable Remote control cable inspection 1 Check Steering cable QSTS cable Frays kinks rough movement Replace Steering cable installation 1 Ins...

Page 307: ...jet pump end WARNING The QSTS cable must be screwed in a mini mum of 8 mm 0 31 in QSTS cable set length a jet pump end 12 0 14 0 mm 0 47 0 55 in QSTS cable stopper installation 1 Install QSTS cable st...

Page 308: ...ervice points HOOD REMOVAL Follow the left Step for removal 1 Bolt 2 2 Screw 8 3 Seal washer 8 4 Visor 1 5 Pop nut 8 6 Bolt 2 7 Hood lock 1 8 Hood 1 10 9 1 11 2 3 5 8 4 6 7 5 4 N m 0 54 kgf m 3 9 ft I...

Page 309: ...y Service points 9 Nut 2 10 Plate 1 11 Hinge assembly 1 Reverse the removal steps for installation 10 9 1 11 2 3 5 8 4 6 7 5 4 N m 0 54 kgf m 3 9 ft Ib 6 14 mm 12 N m 1 2 kgf m 8 7 ft Ib 6 14 mm 5 20...

Page 310: ...EMOVAL Follow the left Step for removal Handlebar assembly Refer to HANDLEBAR 1 Plastic tie 1 2 Multifunction meter coupler 5 3 Nut washer 2 2 4 Bolt washer 4 4 5 Screw 2 6 Plate 1 1 7 2 9 8 5 6 4 3 5...

Page 311: ...her 2 2 8 Bolt square ring 2 2 9 Steering console cover assembly 1 NOTE To ease removal remove the oil filler cap Reverse the removal steps for installation 1 7 2 9 8 5 6 4 3 5 4 N m 0 54 kgf m 3 9 ft...

Page 312: ...Part name Q ty Service points STEERING CONSOLE COVER DISASSEMBLY Follow the left Step for disassembly 1 Screw 4 2 Side cover 2 3 Nut 2 4 Holder 1 5 Multifunction meter 1 6 Screw 4 6 8 7 4 3 1 9 2 2 5...

Page 313: ...ocedure Part name Q ty Service points 7 Glove compartment 1 8 Pop nut 4 9 Steering console cover 1 Reverse the disassembly steps for assembly 6 8 7 4 3 1 9 2 2 5 5 20 mm 6 18 mm 2 9 N m 0 29 kgf m 2 1...

Page 314: ...T Step Procedure Part name Q ty Service points BUZZER AND HOOD LOCK REMOVAL Follow the left Step for removal Steering console cover assembly Refer to STEERING CONSOLE COVER Steering cable Refer to REM...

Page 315: ...OD LOCK EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 7 Bolt 2 8 Hood lock assembly 1 9 Grommet 1 10 Atmospheric pressure sensor coupler 1 11 Atmospheric pressure sensor 1 Reverse the...

Page 316: ...L Follow the left Step for removal Engine unit Refer to ENGINE UNIT in Chapter 5 Steering console cover assembly Refer to STEERING CONSOLE COVER 1 Plastic tie 4 2 Ventilation hose 2 3 Ventilation duct...

Page 317: ...heck valve and then blow into the hose Air should come out from end B Connect the hose to end B of the check valve and then blow into the hose Air should not come out from end A Ventilation hose insta...

Page 318: ...EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points SEAT AND HANDGRIP REMOVAL Follow the left Step for removal 1 Seat 1 2 Bolt 2 3 Seat lock 1 4 Nut 1 5 Proje...

Page 319: ...8 30 E HULL HOOD SEAT AND HANDGRIP EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 9 Bolt 2 10 Bolt 2 11 Handgrip 1 12 Bracket 1 Reverse the removal steps for installation...

Page 320: ...8 31 E HULL HOOD SEAT AND HANDGRIP SERVICE POINTS Seat lock inspection 1 Check Seat lock Damage wear Replace...

Page 321: ...cedure Part name Q ty Service points BATTERY BOX REMOVAL Follow the left Step for removal 1 Battery band 1 2 Fire extinguisher container 1 3 Battery band 1 4 Bolt 1 5 Negative battery lead 1 6 Termina...

Page 322: ...washer bolt 2 2 2 13 Electrical box 1 14 Cap nut washer 2 2 15 Holder 1 16 Holder 1 17 Cap nut washer 2 2 18 Battery box 1 NOTE Before installing the battery box route the battery leads and battery br...

Page 323: ...YSTEM REMOVAL Follow the left Step for removal Battery box Refer to BATTERY BOX 1 Flotation 1 2 Exhaust joint clamp 1 3 Exhaust joint 1 4 Hose screw clamp 2 5 Rubber hose 1 6 Bolt 3 7 Seal 1 6 4 5 8 1...

Page 324: ...Remove parts 8 to 11 as a set 9 Water tank 1 10 Rubber hose 1 11 Exhaust outlet 1 12 Water lock band 1 13 Water lock 1 Reverse the removal steps for installation 6 4 5 8 10 8 4 2 3 13 9 7 11 1 12 3 7...

Page 325: ...e Replace 2 Check Rubber hoses Burns cracks damage Replace 3 Check Water lock Cracks leaks Replace 4 Check Water tank Cracks damage leaks Replace Water lock installation 1 Install Water lock 1 Water l...

Page 326: ...97 in c into the rubber hose Make sure that there is a distance of 45 mm 1 77 in d between the parting lines of the water tank and rubber hose b d 2 Install Rubber hose NOTE Install the rubber hose 45...

Page 327: ...ATION CHART Step Procedure Part name Q ty Service points DECK AND HULL DISASSEMBLY Follow the left Step for disassembly 1 Bolt 2 2 Bow eye 1 3 Nut 2 4 Rope hole fitting 2 5 Nut 1 6 Spout 1 7 Bolt 6 8...

Page 328: ...LL HOOD DECK AND HULL EXPLODED DIAGRAM Step Procedure Part name Q ty Service points 9 Bolt 8 10 Flap 2 11 Nut washer 4 4 12 Screw washer 4 4 13 Drain plug 2 14 Seal 2 Reverse the disassembly steps for...

Page 329: ...STALLATION 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 1 Bolt 4 2 Damper 1 1 3 Damper 2 1 4 B...

Page 330: ...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 TROUBLE ANALYSIS 9 4 TROUBLE...

Page 331: ...ave been recorded are displayed This allows you to check the watercraft s record of malfunctions 3 Engine monitor Each sensor s status and the ECM data are displayed while the engine is run ning This...

Page 332: ...y VGA 640 480 pixels SVGA 800 600 pixels or more recommended 256 or more colors Mouse Compatible with the operating systems mentioned above Communication port RS232C Dsub 9 pin port USB port Printer C...

Page 333: ...COMMUNICATION CABLE TO THE WATERCRAFT Model GP1300R Top view 1 3 pin communication coupler 2 Wire harness coupler 3 Multifunction meter coupler NOTE Be careful not to pinch the communication cable be...

Page 334: ...S CHART Symptom Check items ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDLING ENGINE STALLS POOR ACCELERATION ENGINE WILL NOT STOP POOR PERFORMANCE LIMITED ENGINE SPEED OVERHEATING LOOSE ST...

Page 335: ...lugs 3 Main and fuel pump relay 7 Exhaust temperature sensor 7 Atmospheric pressure sensor 7 Intake air temperature sensor 7 Engine temperature sensor 7 Throttle position sensor 7 Cooling water temper...

Page 336: ...bilge pump 7 HULL AND HOOD Steering column 8 Water lock 8 Exhaust hose 8 Muffler 8 Drain plugs 8 Symptom Check items ENGINE WILL NOT START HARD STARTING ROUGH IDLING HIGH IDLING ENGINE STALLS POOR ACC...

Page 337: ...hem with the Yamaha Diagnostic System Code Symptom 01 Normal 13 Pickup coil malfunction 15 Engine temperature sensor malfunction 18 Throttle position sensor TPS malfunction 19 Incorrect battery voltag...

Page 338: ...13 14 15 16 17 18 19 20 21 22 25 26 27 28 29 30 31 32 33 34 35 23 24 B B B B B O B O B O B O B O B O B O B O B O B O P G B O O B B B B B B B O O O O Br Br Br W W L B B Y B Y L R R W R Y B R W R W B B...

Page 339: ...oil M Pickup coil N Steering switch O Oil level sensor P Buzzer Q Speed sensor R Multifunction meter S Fuel pump T Fuel sender U Engine stop switch V Engine shut off switch W Start switch X Slant dete...

Page 340: ...YAMAHA MOTOR CORPORATION USA Printed in USA Feb 2003 0 0 1 CR E...