Service Manual Watercraft VX1100

WaveRunner
VX110 Sport VX110 Deluxe
SERVICE MANUAL
*LIT186160291*
LIT-18616-02-91 F1K-28197-1H-11
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. Because Yamaha 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. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual.
A10001-0*
WaveRunner VX110 Sport, VX110 Deluxe SERVICE MANUAL 2005 by Yamaha Motor Corporation, USA 1st Edition, January 2005 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited. Printed in USA LIT-18616-02-91
HOW TO USE THIS MANUAL

MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information 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. In this revised 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 your way through this manual, the section title and major heading is given at the top of every page.
ILLUSTRATIONS
The illustrations within this service manual represent all of the designated models.
CROSS REFERENCES
The cross references have been kept to a minimum. Cross references will direct you to the appropriate section or chapter.
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.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the watercraft. NOTE: A NOTE provides key information to make procedures easier or clearer. IMPORTANT: This part has been subjected to change of specification during production.
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). 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 number of parts, are provided for fasteners that require a tightening torque. Example: Bolt or screw size 10 25 mm : M10 (D) 25 mm (L)
D L
6 Jobs requiring more information (such as special tools and technical data) are described sequentially.
E
1 2
A50001-1-4
GEN INFO
3
SYMBOLS
Symbols 1 to 9 are designed to indicate the content of a chapter.
1 2 3 4 5 6 7 8 9 General Information Specifications Periodic Inspection and Adjustment Fuel System Power Unit Jet Pump Unit Electrical System Hull and Hood Trouble Analysis
SPEC
4
INSP ADJ
5
FUEL
6
POWR
7
JET PUMP
8
+
ELEC
9
HULL HOOD
0
Symbols 0 to E indicate specific data.

0 A B C D E Special service tool Specified oil or fluid Specified engine speed Specified tightening torque Specified measurement Specified electrical value (resistance, voltage, electric current)
TRBL ANLS
A B
T.
R.
Symbols F to I in an exploded diagram indicate the grade of lubricant and the lubrication point.
E
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 I Apply molybdenum disulfide grease
G
A
H
1104J 1280B
I
M
J
GM
Symbols J to N in an exploded diagram indicate the type of sealant or locking agent and the application point.
J K L M N Apply Gasket Maker Apply LOCTITE 271 (red) Apply LOCTITE 242 (blue) Apply LOCTITE 572 Apply silicone sealant
K
LT
L
LT
271
242
M
LT
N
SS
572
NOTE: Additional symbols may be used in this manual.
E
A30000-0
INDEX
GEN INFO
GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT FUEL SYSTEM POWER UNIT JET PUMP UNIT ELECTRICAL SYSTEM HULL AND HOOD TROUBLE ANALYSIS
SPEC
INSP ADJ
FUEL
POWR
JET PUMP
+
ELEC
HULL HOOD
TRBL ANLS
1 2 3 4 5 6 7 8 9
GEN 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................................................................................. 1-2 PARTS, LUBRICANTS, AND SEALANTS ................................................ 1-2 GOOD WORKING PRACTICES ............................................................... 1-3 DISASSEMBLY AND ASSEMBLY ............................................................ 1-4 SPECIAL SERVICE TOOLS ...........................................................................1-5 MEASURING............................................................................................. 1-5 REMOVAL AND INSTALLATION.............................................................. 1-7
1 2 3 4 5 6 7 8 9
GEN INFO
IDENTIFICATION NUMBERS
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 compartment. Starting primary l.D. number: F1K: 800101
ENGINE SERIAL NUMBER

The engine serial number is stamped on a label attached to the engine unit. Starting serial number: 6D3: 1000001
JET PUMP UNIT SERIAL NUMBER

The jet pump unit serial number is stamped on a label attached to the intermediate housing.
HULL IDENTIFICATION NUMBER (H.l.N.)

The H.l.N. is stamped on a plate attached to the aft deck.
1-1
GEN INFO
SAFETY WHILE WORKING SAFETY WHILE WORKING
To prevent and accident or injury and to ensure quality service, follow the safety procedures provided below.
FIRE PREVENTION
Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames.
VENTILATION
Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If inhaled in large quantities they may cause loss of consciousness 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-PROTECTION
Protect your eyes by wearing safety glasses or safety goggles during all operation involving drilling and grinding, or when using an air compressor. Protect your hands and feet by wearing protective 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.
1-2
GEN INFO
SAFETY WHILE WORKING
Under normal conditions, the lubricants mentioned 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. 2. Change and wash clothing as soon as possible if soiled with lubricants. 3. Avoid contact with skin. Do not, for example, place a soiled rag in your pocket. 4. Wash hands and any other part 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 working on the watercraft. 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc.
GOOD WORKING PRACTICES

1. The right tools Use the recommended special service tools to protect parts from damage. Use the right tool in the right mannerdo not improvise. 2. Tightening torques Follow the tightening torque specifications provided throughout the manual. When tightening nuts, bolts, and screws, tighten the large sizes first, and tighten fasteners starting in the center and moving outward.
1-3
GEN INFO
SAFETY WHILE WORKING
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.
3. Install bearings with the manufacture identification mark in the direction indication in the installation procedure. In addition, be sure to lubricate the bearings liberally. 4. Apply a thin coat of water-resistant grease to the lip and periphery of an oil seal before installation. 5. Check that moving parts operate normally after assembly.
1-4
GEN INFO
SPECIAL SERVICE TOOLS SPECIAL SERVICE TOOLS
Using the correct special service tools recommended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvisations and using improper tools can damage the equipment. NOTE: For U.S.A. and Canada, use part numbers starting with J-, YB-, YM-, YS-, YU- or YW-. For other countries, use part numbers starting with 90890-.
1 90890-06583
90890-06584
MEASURING
3
YB-06585 90890-06585
4 YU-03097
90890-01252
5 YU-03112
90890-03112
YU-34899-A
7 90890-03174
8 YW-06842
90890-06842
1 Dial gauge stand P/N. 90890-06583 2 Dial gauge needle P/N. 90890-06584 3 Dial gauge stand set P/N. YB-06585 90890-06585 4 Dial indicator gauge P/N. YU-03097 Dial gauge set P/N. 90890-01252 5 Pocket tester P/N. YU-03112 90890-03112 6 Digital multimeter P/N. YU-34899-A 7 Digital circuit tester P/N. 90890-03174 8 Fuel pressure gauge adapter P/N. YW-06842 90890-06842 9 Fuel pressure gauge P/N. YB-06766 90890-06786
9 YB-06766
90890-06786
1-5
GEN INFO
0 90890-06582
SPECIAL SERVICE TOOLS

A YU-03017 0 Compression gauge extension P/N. 90890-06582 A Cylinder gauge set P/N. YU-03017 90890-06759 B Compression gauge P/N. YU-33223-1 90890-03160 C Peak voltage adapter P/N. YU-39991 D Peak voltage adapter B P/N. 90890-03172 E Spark checker P/N. YM-34487 Ignition tester P/N. 90890-06754 F Test harness (2 pins) P/N. New: YB-06867 Current: YB-06767 Test harness FWY-2 (2 pins) P/N. New: 90890-06867 Current: 90890-06767 G Test harness (3 pins) P/N. New: YB-06870 Current: YB-06770 Test harness SMT250-3 (3 pins) P/N. New: 90890-06870 Current: 90890-06770 H Test harness (6 pins) P/N. YB-06848 Test harness FSW-6A (6 pins) P/N. 90890-06848 I Test harness (3 pins) P/N. New: YB-06877 Current: YB-06777 Test harness HM090-3 (3 pins) P/N. New: 90890-06877 Current: 90890-06777 J Lower unit pressure/vacuum tester P/N. YB-35956-A Vacuum/pressure pump gauge set P/N. 90890-06756
90890-06759
B YU-33223-1
90890-03160
C YU-39991
D 90890-03172
E YM-34487
90890-06754
F YB-06867 (-06767)
90890-06867 (-06767)
G YB-06870 (-06770)
90890-06870 (-06770)
H YB-06848
90890-06848
I YB-06877 (-06777)
90890-06877 (-06777)
J YB-35956-A
90890-06756
1-6
GEN INFO
K 60V-85300-02-00

K Yamaha diagnostic system P/N. 60V-85300-02-00 L Yamaha diagnostic system P/N. 60V-WS853-03
L 60V-WS853-03
REMOVAL AND INSTALLATION

1 YB-01426
90890-01426
2 YW-06551
90890-06551
3 YS-01880-A
90890-01701
4 YM-01082
90890-01080
5 YU-01235
90890-01235
6 YB-06111
1 Oil filter wrench P/N. YB-01426 90890-01426 2 Coupler wrench P/N. YW-06551 90890-06551 3 Sheave holder P/N. YS-01880-A 90890-01701 4 Rotor puller P/N. YM-01082 90890-01080 5 Universal magneto and rotor holder P/N. YU-01235 Rotor holder P/N. 90890-01235 6 Bearing housing needle bearing installer (reduction drive gear) P/N. YB-06111
1-7
GEN INFO
7 YB-06276-B

7 Forward gear bearing cup installer (reduction drive gear) P/N. YB-06276-B 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 (19 mm) 90890-04114 (19 mm) YM-04108 (22 mm) 90890-04108 (22 mm) A Valve guide remover P/N. YM-04111 (4.0 mm) 90890-04111 (4.0 mm) YM-04116 (4.5 mm) 90890-04116 (4.5 mm) B Valve guide installer P/N. YM-04112 (4.0 mm) 90890-04112 (4.0 mm) YM-04117 (4.5 mm) 90890-04117 (4.5 mm) C Valve guide reamer P/N. YM-04113 (4.0 mm) 90890-04113 (4.0 mm) YM-04118 (4.5 mm) 90890-04118 (4.5 mm) D Valve seat cutter Intake P/N. 90890-06813 (60) 90890-06814 (45) 90890-06815 (30) Exhaust P/N. 90890-06315 (60) 90890-06312 (45) 90890-06328 (30)
8 90890-06657
9 YM-01253
90890-04019
0 YM-04114 (19 mm)
90890-04114 (19 mm) YM-04108 (22 mm) 90890-04108 (22 mm)
A YM-04111 (4.0 mm)
90890-04111 (4.0 mm) YM-04116 (4.5 mm) 90890-04116 (4.5 mm)
B YM-04112 (4.0 mm)
90890-04112 (4.0 mm) YM-04117 (4.5 mm) 90890-04117 (4.5 mm)
C YM-04113 (4.0 mm)
90890-04113 (4.0 mm) YM-04118 (4.5 mm) 90890-04118 (4.5 mm)
D 90890-06813 (60)
90890-06814 (45) 90890-06815 (30)
90890-06315 (60) 90890-06312 (45) 90890-06328 (30)
1-8
GEN INFO
90890-06812 (4.5 mm)
E 90890-06811 (4.0 mm) F YM-91044
G YM-08037
90890-05158
H YB-06151
90890-06519
I YB-06096
J 90890-06501
K 90890-06535
L 90890-06538
M 90890-06652
E Valve seat cutter holder P/N. 90890-06811 (4.0 mm) 90890-06812 (4.5 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. YB-06151 Drive shaft holder 5 (impeller) P/N. 90890-06519 I Slide hammer and adapters (jet pump bearing and reduction drive gear) P/N. YB-06096 J Stopper guide plate (jet pump bearing) P/N. 90890-06501 K Bearing puller assembly (jet pump bearing and reduction drive gear) P/N. 90890-06535 L Stopper guide stand (jet pump bearing and reduction drive gear) P/N. 90890-06538 M Driver rod L3 (jet pump bearing and reduction drive gear) P/N. 90890-06652 N Bearing housing needle bearing remover (jet pump bearing) P/N. YB-06112 O Needle bearing attachment (jet pump bearing, oil seal, and reduction drive gear) P/N. 90890-06614, 90890-06653 Ball bearing attachment (jet pump oil seal) P/N. 90890-06634
N YB-06112
O 90890-06614
90890-06653 90890-06634
1-9
GEN INFO
P YB-06085
Q 90890-06631
R YB-06071
S 90890-06606
T YB-06552
90890-06552
U YB-06156
90890-06624 90890-06626
V YB-06432
P Outer race installerforward gear (jet pump oil seal and reduction drive gear) P/N. YB-06085 Q Ball bearing attachment (jet pump oil seal and reduction drive gear) P/N. 90890-06631 R Driver handlelarge (intermediate shaft, jet pump, and reduction drive gear) P/N. YB-06071 S Driver rod LS (intermediate shaft, jet pump, and reduction drive gear) P/N. 90890-06606 T Crankshaft holder (intermediate shaft) P/N. YB-06552 Crankshaft holder 20 (intermediate shaft) P/N. 90890-06552 U Bearing outer race attachment (intermediate shaft and reduction drive gear) P/N. 90890-06624, 90890-06628 V Roller bearing installer/remover (intermediate shaft bearing and oil seals) P/N. YB-06432
1-10
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
1 2 3 4 5 6 7 8 9
SPEC
GENERAL SPECIFICATIONS
Item Model code Hull Engine/jet Dimensions Length Width Height Dry weight Maximum capacity Performance Maximum output Maximum fuel consumption Cruising range Engine Engine type Displacement Bore stroke Compression ratio Exhaust system Lubrication system Cooling system Starting system Ignition system Ignition timing Spark plug model (manufacturer) Spark plug gap Battery capacity Generator output Drive unit Propulsion system Jet pump type Impeller rotation Transmission Jet thrust nozzle horizontal angle Jet thrust nozzle trim angle Reverse system Unit Model VX110 Sport F1K 6D3 mm (in) mm (in) mm (in) kg (lb) Person/kg (lb) kW (PS) @ r/min l/h (US gal/h, lmp gal/h) h 3,220 (126.8) 1,170 (46.1) 1,150 (45.3) 325 (716) 3/240 (530) 81.0 (110) @ 8,000 28.0 (7.4, 6.2) 2.1 4-stroke, L4, DOHC 1,052 (64.2) 76.0 58.0 (2.99 2.28) 11.4:1 Wet exhaust Dry sump Water cooled Electric starter TCI BTDC 5BTDC 35 CR9EB (NGK) 0.70.8 (0.0280.031) 12/19 1221 @ 6,000 Jet pump Axial flow, single stage Counterclockwise (viewed from rear) Constant mesh 1-speed 24 + 24 3 Reverse gate VX110 Deluxe
cm (cu. in) mm (in)
Degree
mm (in) V/Ah A @ r/min
Degree Degree
2-1
SPEC
Item Fuel and oil Fuel type Minimum fuel rating Fuel tank capacity Engine oil type Engine oil grade Engine oil quantity
Unit Model VX110 Sport VX110 Deluxe
PON* RON* L (US gal, Imp gal) API SAE L (US qt, Imp qt) L (US qt, Imp qt) L (US qt, Imp qt)
Regular unleaded gasoline 86 90 60 (15.9, 13.2) 4-stroke motor oil SE, SF, SG, SH, SJ, SL 10W-30, 20W-40, 20W-50 4.3 (4.5, 3.8) 2.0 (2.1, 1.8) 2.2 (2.3, 1.9)
(without oil filter replacement) (with oil filter replacement)
PON*: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2 RON*: Research Octane Number
2-2
SPEC
ENGINE
Item Cylinder head Warpage limit
MAINTENANCE SPECIFICATIONS
Unit mm (in) Model VX110 Sport VX110 Deluxe
0.1 (0.004)
Compression pressure*1 Cylinder Bore size Taper limit Out-of-round limit Wear limit Camshaft Drive system Intake A Exhaust A Intake and exhaust B Camshaft cap inside diameter Camshaft journal diameter Intake Exhaust Camshaft-journal-to-camshaftcap clearance Maximum camshaft runout Timing chain Model/number of links Tensioning system Valves, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions Valve head diameter A Intake Exhaust
kPa (kgf/cm2, psi) mm (in) mm (in) mm (in) mm (in)
1,150 (11.5, 164)
76.00076.015 (2.99212.9927) 0.08 (0.003) 0.05 (0.002) 76.100 (2.9961) Chain drive 31.15 (1.226) 30.75 (1.211) 25.00 (0.984) 24.5 (0.9646) 24.4624.47 (0.96300.9634) 24.4424.45 (0.96220.9626) 0.050.06 (0.00200.0024) 0.03 (0.0012) 92RH2015-130/130 Automatic
mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
mm (in) mm (in)
0.110.20 (0.00430.0079) 0.250.34 (0.00980.0134)
mm (in) mm (in)
22.923.1 (0.90160.9094) 24.424.6 (0.96060.9685)
*1 Measuring conditions: Ambient temperature 20 C (68 F), wide open throttle, with spark plugs removed from all cylinders. The figures are for reference only.
2-3
SPEC
Item
Unit mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) Model VX110 Sport VX110 Deluxe
Valve face width B Intake Exhaust Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve-stem-to-valve-guide clearance Intake Exhaust Valve stem runout
1.912.64 (0.07520.1039) 1.912.64 (0.07520.1039) 0.901.10 (0.03540.0433) 0.901.10 (0.03540.0433) 0.851.15 (0.03350.0453) 0.851.15 (0.03350.0453)
mm (in) mm (in) mm (in) mm (in)
3.9753.990 (0.15650.1571) 4.4654.480 (0.17580.1764) 4.0004.012 (0.15750.1580) 4.5004.512 (0.17720.1776)
mm (in) mm (in) mm (in)
0.0100.037 (0.00040.0015) 0.0200.047 (0.00080.0019) 0.01 (0.0004)
Valve spring Free length Intake mm (in) Exhaust mm (in) Installed length Intake mm (in) Exhaust mm (in) Tilt limit Intake Degree/mm (in) Exhaust Degree/mm (in) Piston Piston-to-cylinder clearance mm (in) Piston diameter mm (in) Measuring point H* mm (in) Wear limit mm (in) Piston pin boss inside diameter mm (in)
38.90 (1.53) 40.67 (1.60) 34.50 (1.36) 35.00 (1.38) 2.5/1.7 (0.067) 2.5/1.8 (0.071) 0.100.11 (0.00390.0043) 75.89575.910 (2.98802.9886) 5 (0.2) 0.170 (0.0067) 17.00217.013 (0.66940.6698)
2-4
SPEC
Item
Unit mm (in) mm (in)
B
E Model
VX110 Sport
VX110 Deluxe
Piston pins Outside diameter Wear limit Piston ring Top ring T Type Dimension (B T) End gap (installed) Ring groove clearance 2nd ring Type T Dimensions (B T) End gap (installed) Ring groove clearance Oil ring Dimensions T (B T) End gap (installed) Ring groove clearance Connecting rod Big end oil clearance Bearing color code Small end inside diameter Crankshaft
B B B
16.99117.000 (0.66890.6693) 16.986 (0.6687)

B
Barrel 0.90 2.75 (0.04 0.11) 0.320.44 (0.01260.0173) 0.0300.065 (0.00120.0026) Taper 0.80 2.80 (0.03 0.11) 0.430.58 (0.01690.0228) 0.0200.055 (0.00080.0022) 1.50 2.60 (0.06 0.10) 0.100.35 (0.00390.0138) 0.0400.160 (0.00160.0063) 0.0160.040 (0.00060.0016) 1. Brown 2. Black 3. Blue 4. Green 17.00517.018 (0.66950.6700)

B
mm (in) mm (in) mm (in) mm (in) mm (in)
Crank width A Deflection limit B Crankshaft journal oil clearance Bearing color code Throttle body Type/quantity Manufacturer ID mark Trolling speed
304.8306.0 (12.0012.05) 0.03 (0.0012) 0.0040.028 (0.00020.0011) 3. Red/Red 4. Red/Brown 5. Red/Black 6. Red/Blue 7. Red/Green IM-230/1 Mikuni 6D300 1,5501,750
r/min
2-5
SPEC
Item Fuel pump Pump type Fuel pressure
kPa (kgf/cm2, psi)
Electrical 320327 (3.23.3, 4647)
Oil filter Oil filter type Oil pump Oil pump type Rotor tip clearance (scavenge pump) Oil pump housing clearance Rotor (feed pump) Rotor (scavenge pump)
Cartridge type Trochoid 0.090.15 (0.00350.0059)
mm (in)
mm (in) mm (in)
0.090.17 (0.00350.0067) 0.090.15 (0.00350.0059)
JET PUMP UNIT

Item Jet pump Impeller material Number of impeller blades Impeller pitch angle Impeller clearance Impeller clearance limit Drive shaft runout limit Unit Model VX110 Sport VX110 Deluxe
Degree mm (in) mm (in) mm (in)
Stainless steel 3 21.2 0.350.45 (0.01380.0177) 0.6 (0.0236) 0.3 (0.0118)
HULL AND HOOD

Item Free play Throttle lever free play Unit mm (in) Model VX110 Sport VX110 Deluxe
47 (0.160.28)
2-6
SPEC
ELECTRICAL
Item
Model VX110 Sport Fluid 12/19 1.28 VX110 Deluxe
Unit
Battery Type Capacity Specific gravity 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) @2,000 r/min (loaded) @3,500 r/min (loaded) Stator Pickup coil (W/B B/O) Output peak voltage @cranking (unloaded) @cranking (loaded) @2,000 r/min (loaded) @3,500 r/min (loaded) Lighting coil (G G) Output peak voltage @cranking (unloaded) @2,000 r/min (unloaded) @3,500 r/min (unloaded) Pickup coil resistance (W/B B/O) Lighting coil resistance (G G) Minimum charging current Ignition coil Primary coil resistance @20 C (68 F) Secondary coil resistance @20 C (68 F) Rectifier/regulator (R B) Output peak voltage @3,500 r/min (unloaded)
V/Ah
V V V
90 130 140
V V V V
8.0 6.9 19.4 25.1
V V V (color) (color) A @ r/min
7.8 24.5 41.6 459561 0.230.29 14 @ 6,000
1.191.61 8.511.5
13.0
2-7
SPEC
Item
Starter motor Type Output Rating Brush length Wear limit Commutator undercut Limit Commutator diameter Limit Starter relay Rating Thermoswitch ON temperature (engine) OFF temperature (engine) ON temperature (exhaust) OFF temperature (exhaust) Engine temperature sensor Engine temperature sensor resistance (B/Y B/Y) @ 20 C (68 F) @ 100 C (212 F) Speed sensor Output voltage (on pulse) Output pulse/one full turn Throttle position sensor Output voltage @ throttle valve fully closed Sensor 1 @ throttle valve fully opened Sensor 2 Accelerator position sensor Output voltage @ throttle lever fully closed Sensor 1 Sensor 2 @ throttle lever fully opened Sensor 1 Sensor 2
kW Seconds mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) Seconds C (F) C (F) C (F) C (F)
Constant mesh 0.8 30 12.5 (0.49) 6.5 (0.26) 0.7 (0.03) 0.2 (0.01) 28.0 (1.10) 27.0 (1.06) 30 8490 (183194) 7084 (158183) 8086 (176187) 6680 (151176)
k k V
54.269.0 3.123.48 11.6 2
V V
0.450.95 4.604.70
V V V V
0.500.90 0.351.05 3.754.35 3.504.50
2-8
SPEC
Item
Accelerator position sensor resistance*1 @ throttle lever fully closed Sensor 1 Sensor 2 @ throttle lever fully opened Sensor 1 Sensor 2 Cam position sensor Output voltage (G/O B/O) Position A Position B Position C Fuel sender Fuel sender resistance Position A Position B Oil pressure switch Oil pressure switch continuity pressure Fuel injector Fuel injector resistance*1 @ 20 C (68 F) Fuse Rating Main Main and fuel pump relay Main and fuel pump relay Electronic control throttle valve relay Remote control unit (Deluxe model only)
k k k k
0.500.90 0.3510.50 3.754.35 3.604.50
V V V
More than 4.8 Less than 0.8 More than 4.8
kPa (kgf/cm2, psi)
133.5136.5 57 128 (1.28, 18.2)167 (1.67, 23.8)
11.512.5
V/A V/A V/A V/A V/A
12/30 12/20 12/10 12/10 12/3
*1: The figures are for reference only.
2-9
SPEC
TIGHTENING TORQUES
TIGHTENING TORQUES
SPECIFIED TORQUES
Part to tightened Fuel system 1st Retainer/fuel pump module 2nd Fuel filler neck/rubber seal Fuel filter hose clamp Air filter case cover Air filter case Air filter case bracket Air intake hose clamp Throttle cable Accelerator position sensor Throttle body assembly Intake manifold Intake manifold bracket/ wiring harness bracket 1 Fuel rail Sensor assembly Engine Engine unit Oil filter Coupling cover Thermoswitch (exhaust) Outer exhaust joint clamp 1st 2nd 1st 2nd Part name Thread Qty size Tightening torque Nm kgfm ftlb 3.2 6.4 5.9 3.7 1.2 1.5 17 15 2.5 6.5 17 13 8.8 18 15 39 13 3.5 17 17 7.8 7.6 3.4 3.4 3.4 3.4 2.0 15 39 3.7 7.6 22 22 35 22 22 35 0.32 0.64 0.59 0.37 0.12 0.15 1.7 1.5 0.25 0.65 1.7 1.3 0.88 1.8 1.5 3.9 1.3 0.35 1.7 1.7 0.78 0.76 0.34 0.34 0.34 0.34 0.2 1.5 3.9 0.37 0.76 2.2 2.2 3.5 2.2 2.2 3.5 2.3 4.6 4.3 2.7 0.9 1.1 12 11 1.8 4.7 12 9.4 6.4 13 11 28 9.4 2.5 12 12 5.6 5.5 2.5 2.5 2.5 2.5 1.4 11 28 2.7 5.5 16 16 25 16 16 25 Remarks Refer to page
Nut Nut Screw Bolt Nut Nut Nut Bolt Bolt Bolt Bolt Screw Bolt Bolt Bolt Bolt Bolt Bolt
M5 M8 M8 M6 M8 M8 M5 M8 M6 M6 M10 M6 M8
9 1 2 2 4 4 4 1 1 2 4 2 2 2 2 4 1 1 2 2 2 4 3 4
4-1 4-1 4-1 4-7 4-7 4-7 4-7 4-7 4-7 4-10 4-7 4-7 4-10 4-10 5-1 3-17 5-1 5-8 5-8 5-8 5-9 5-10 5-10
271 242
572
LT
LT LT
1st 2nd 1st Inner exhaust joint clamp 2nd 1st *1 2nd Exhaust pipe 2 3rd 1st Exhaust pipe end 2nd 1st Exhaust pipe 1 2nd 3rd 1st Exhaust manifold 2nd 3rd
Bolt
M8
11
LT
LT
242
LT
572
572
271
LT
242
LT
572
LT
5-11
*1: For details, refer to the tightening procedures in this manual.
2-10
242
LT
SPEC
TIGHTENING TORQUES
Part name 1st 2nd 1st 2nd 1st 2nd 1st 2nd 3rd 1st 2nd 3rd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd Bolt Bolt Bolt Bolt Nut Thread Qty size M6 M6 M10 M6 2 3 5 1 2 Tightening torque Nm kgfm ftlb 3.7 0.37 2.7 7.6 0.76 5.5 7.6 0.76 5.5 15 1.5 11 39 3.9 28 3.7 0.37 2.7 7.6 0.76 5.5 2.0 0.2 1.4 15 1.5 11 39 3.9 28 2.0 0.2 1.4 15 1.5 11 39 3.9 28 3.7 0.37 2.7 7.6 0.76 5.5 3.7 0.37 2.7 7.6 0.76 5.5 1.9 0.19 1.4 4.4 0.44 3.2 1.9 0.19 1.4 4.4 0.44 3.2 3.7 0.37 2.7 7.6 0.76 5.5 3.7 0.37 2.7 7.6 0.76 5.5 3.8 0.38 2.7 10 1.0 7.2 15 1.5 11 28 2.8 20 13 1.3 9.4 3.7 0.37 2.7 7.6 0.76 5.5 28 2.8 20 3.7 0.37 2.7 7.6 0.76 5.5 15 1.5 11 28 2.8 20 4.9 0.49 3.5 18 1.8 13 15 1.5 11 50 5.0 36 75 7.5 54 24 2.4 17 Remarks
572
LT
E Refer to page 5-12 5-12 5-12 5-12 5-12
Part to tightened Oil separator Ground lead box Oil tank Plastic tie/collar Oil tank
Oil tank stay Bracket (coupling cover) Oil tank cover Oil breather plate Baffle plate Oil strainer Oil cooler cover Anode Oil pump assembly Drain plug (engine oil) Strainer Drive coupling Reduction drive gear case Starter motor lead Starter motor Generator cover Flywheel magneto Starter clutch
Bolt Bolt Bolt Bolt Bolt Bolt Bolt Screw
M10 M6 M6 M5 M5 M6 M6 M4 M6 M8 M8 M6 M6 M8 M8 M10 M10 M8
2 2 8 9 3 2 24 1 6 4 1 2 1 2 5 1 2 8 1 6
572
LT
572
LT
5-12 5-15 5-15 5-15 5-15 5-15 5-15 5-15 5-21 5-21 5-21 5-24 5-24 5-24 5-33 5-33 5-33 5-33 5-33
1st 2nd 1st 2nd 1st 2nd 1st 2nd
Bolt Bolt Bolt Bolt Bolt Nut Bolt
1st 2nd
Bolt Bolt Bolt
2-11
572
LT
572
LT
572
LT
572
LT
572
LT
572
LT
572
LT
572
LT
572
LT
SPEC
TIGHTENING TORQUES
Part name Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Nut Nut Bolt Bolt Bolt Bolt 1st 2nd 3rd 4th Bolt Bolt 1st 2nd Nut Thread Qty size M5 M5 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M7 M7 M6 M6 M6 M8 M6 M6 M9 M6 1 2 2 3 4 4 1 1 6 1 2 10 18 2 2 3 2 3 5 1 2 1 1 15 10 10 1 1 8 Tightening torque Nm kgfm ftlb 4.9 4.9 14 14 13 7.6 10 3.7 7.6 12 10 10 10 10 24 24 10 20 0.49 3.5 Remarks
242
LT
E Refer to page 5-36 5-36 5-36 5-36 5-41 5-41 5-41 5-41 5-41 5-43 5-43 5-43 5-43 5-43 5-43 5-54 5-54 5-54 5-54 5-71 5-71 5-71 5-71 5-71 5-71 5-71 5-74 5-74 5-80
E
Part to tightened Washer/pickup coil lead and lighting coil lead Pickup coil Holder (wiring harness) Lighting coil Spark plug Ignition coil Cam position sensor 1st Cooling water pipe 2nd Cylinder head cover Timing chain tensioner cap bolt Timing chain tensioner Exhaust camshaft cap Intake camshaft cap Exhaust camshaft sprocket Intake camshaft sprocket 1st 2nd Cylinder head*1 1st 2nd 1st 2nd Engine temperature sensor Thermoswitch (engine) Oil pressure switch Anode cover Oil pan
Lower crankcase
Oil pipe Oil filter bolt Connecting rod cap
0.49 3.5 1.4 10 1.4 10 1.3 9.4 0.76 5.5 1.0 7.2 0.37 2.7 0.76 5.5 1.2 8.7 1.0 7.2 1.0 7.2 1.0 7.2 1.0 7.2 2.4 17 2.4 17 1.0 7.2 2.0 14 140 5 20 2.0 14 121 5 20 2.0 14 105 5 15 1.5 11 7.6 0.76 5.5 8.4 0.84 6.1 12 1.2 8.7 20 2.0 14 12 1.2 8.7 12 1.2 8.7 7.8 0.78 5.6 Loosen completely 15 1.5 11 5 49 12 1.2 8.7 35 3.5 25 20 2.0 14 120 5
*1: For details, refer to the tightening procedures in this manual.
2-12
572
LT
572
LT
271
LT
572
LT
572
LT
572
LT
572
LT
242
LT
242
LT
242
LT
SPEC
TIGHTENING TORQUES
Part name Nut Bolt Bolt Screw Bolt Bolt Nut Bolt Bolt Nut Nut Bolt Bolt Bolt Bolt Impeller Nut Bolt Driven coupling Bolt Screw Screw Screw Screw Bolt Bolt Ball joint Bolt Bolt Bolt Bolt Nut Thread Qty size M8 M6 M10 M5 M6 M10 M6 M8 M8 M8 M10 M6 M6 M22 M8 M24 M8 M4 M5 M6 M5 M5 M5 M8 M8 M8 M8 M6
2-13
E Tightening torque Nm kgfm ftlb 6.8 17 7.6 40 3.7 7.8 40 6.8 17 14 15 7.8 7.8 1.2 2.2 15 40 6.6 7.8 75 26 17 36 4.2 20 1.1 1.1 3.7 3.4 3.4 1.2 17 6.9 6.9 16 16 6.9 5.9 0.68 1.7 0.76 4.0 0.37 0.78 4.0 0.68 1.7 1.4 1.5 0.78 0.78 0.12 0.22 1.5 4.0 0.66 0.78 7.5 2.6 1.7 3.6 0.42 2.0 0.11 0.11 0.37 0.34 0.34 0.12 1.7 0.69 0.69 1.6 1.6 0.69 0.59 4.9 12 5.5 29 2.7 5.6 29 4.9 12 10 11 5.6 5.6 0.9 1.6 11 29 4.8 5.6 54 19 12 26 3.0 14 0.8 0.8 2.7 2.5 2.5 0.9 12 5.0 5.0 12 12 5.0 4.3
572
LT
Part to tightened Jet pump unit Steering cable joint Ride plate Intake grate Speed sensor Jet pump unit assembly Rubber plate Bracket Reverse gate Reverse gate ball joint Reverse gate spring Spout hose clamp Jet thrust nozzle Nozzle/bracket Water inlet cover/water inlet strainer Cap Impeller Transom plate Intermediate housing cover Driven coupling Clamp Hull and hood Handlebar holder Upper handlebar cover Lower handlebar cover Throttle lever assembly Handlebar switch assembly Grip end Steering column Steering cable ball joint Steering arm Steering sensor Spacer Shift cable holder (Deluxe model only) Shift cable seal (Deluxe model only)
Remarks
Refer to page 6-3 6-1 6-1 6-1 6-3 6-3 6-3 6-5 6-5 6-5 6-5 6-3 6-6 6-6 6-6 6-8 6-8 6-15 6-18 6-19 6-18 8-1 8-1 8-1 8-4 8-4 8-4 8-20 8-20 8-20 8-21 8-21 8-23 8-23
1 4 2 4 1 4 4 2 2 2 1 1 1 1 2 4 4 3 1 4 4 1 2 4 2 4 4 2 2 2 4 1 1 4 3 2 1
242
LT
572
LT
572
LT
242
LT
572
LT
242
LT
271
LT
572
LT
271
LT
572
LT
572
LT
572
LT
572
LT
271
LT
242
LT
242
LT
271
LT
271
LT
572
LT
242
LT
242
LT
572
LT
242
LT
SPEC
TIGHTENING TORQUES
Part name Nut Nut Nut Nut Bolt Nut Bolt Bolt Bolt Bolt Nut Screw Bolt Bolt Bolt Bolt Nut Nut Nut Nut Bolt Bolt Nut Bolt Nut Nut Nut Bolt Screw Bolt Bolt Thread Qty size M6 M6 M5 M6 M6 M5 M5 M6 M6 M6 M6 M8 M6 M5 M8 M6 1 1 1 1 1 1 2 2 4 2 4 2 4 1 8 2 2 1 4 2 1 2 6 2 1 2 2 10 2 4 1 5 2 4 8 2 Tightening torque Nm kgfm ftlb 3.8 6.5 6.8 5.9 6.9 5.9 6.9 1.9 6.9 6.9 15 3.7 3.9 6.9 6.9 8.0 15 4.2 6.9 15 26 6.4 5.4 3.7 3.7 3.7 2.4 2.4 16 15 5.4 6.9 13 2.0 17 6.6 0.38 0.65 0.68 0.59 0.69 0.59 0.69 0.19 0.69 0.69 1.5 0.37 0.39 0.69 0.69 0.8 1.5 0.42 0.69 1.5 2.6 0.64 0.54 0.37 0.37 0.37 0.24 0.24 1.6 1.5 0.54 0.69 1.3 0.2 1.7 0.66 2.7 4.7 4.9 4.3 5.0 4.3 5.0 1.4 5.0 5.0 11 2.7 2.8 5.0 5.0 5.8 11 3.0 5.0 11 19 4.6 3.9 2.7 2.7 2.7 1.7 1.7 12 11 3.9 5.0 9.4 1.4 12 4.8
572
LT
E Remarks
572
LT
Part to tightened Shift cable locknut (Deluxe model only) Steering cable locknut (steering column side) Steering cable locknut (jet pump side) Steering cable seal Steering cable bracket Speed sensor lead grommet Hinge assembly Hood lock assembly Hinge assembly Lid lock hook Mirror (Deluxe model only) Shift handle lever (Deluxe model only) Multifunction meter Engine hatch cover (Deluxe model only) Engine hatch cover Detent plate Shift lever bracket (Deluxe model only) Pilot water outlet Hand grip Seat bracket Seat lock projection Seat lock assembly Plate/rubber hose/exhaust valve Hose clamp 1 Hose clamp 2 Joint clamp 1 and 4 1st Joint clamp 2 and 3 2nd Sponson Cleat Spout Protector (bow) Bow eye Drain plug/packing Engine mount Engine damper
Refer to page 8-23 8-23 8-23 8-23 8-23 8-23 8-8 8-8 8-8 8-8 8-8 8-11 8-11 8-11 8-11 8-16 8-16 8-17 8-28 8-28 8-28 8-28 8-31 8-31 8-31 8-31 8-31 8-36 8-36 8-36 8-36 8-36 8-36 8-38 8-38
2-14
271
LT
572
LT
572
LT
271
LT
572
LT
572
LT
572
LT
572
LT
572
LT
242
LT
242
LT
572
LT
572
LT
SPEC
TIGHTENING TORQUES
Part name Nut Nut Bolt 1st 2nd Bolt Tapping screw Bolt Nut Bolt Tapping screw Thread Qty size M6 M8 6 M8 M5 2 2 4 4 2 2 2 1 2 6 Tightening torque Nm kgfm ftlb 17 15 4.0 8.8 18 3.9 4.0 8.8 6.4 0.1 1.7 1.5 0.4 0.88 1.8 0.39 0.4 0.88 0.64 0.01 12 11 2.9 6.4 13 2.8 2.9 6.4 4.6 0.1
572
LT
E Remarks Refer to page 7-2 7-2 7-7 7-7 7-2 7-7 7-39 7-39 7-64
Part to tightened Electrical Fuse box Fuse box bracket ECM Bracket Slant detection switch Rectifier/regulator Brush assembly/spacer Starter motor rear cover Remote control transmitter cover
Nut A 8 mm 10 mm 12 mm 14 mm 17 mm
Bolt B M5 M6 M8 M10 M12
General torque specifications Nm kgfm ftlb 5.0 0.5 3.6 8.0 0.8 5.8 18 1.8 13 36 3.6 26 43 4.3 31
GENERAL TORQUE
This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections 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 torque specifications require clean, dry threads. Components should be at room temperature.
2-15
572
LT
572
LT
SPEC
CABLE AND HOSE ROUTING
G F
K E
J K A B B
2 3
A-A
K-K J
D
J
1 B-B
C J-J A
C I I C B B
2 C-C
I-I
D
A
I I E F E F
5 6
5 6 D-D 0
I H-H H
7
H G G
7 6 E-E
8 7 6 F-F 0 9
A G-G
1 2 3 4 5 6 7 8 9 0 A
Fuel tank breather hose Steering cable Throttle cable Fuse box Starter motor lead Positive battery lead Negative battery lead Battery Cooling water outlet hose Shift cable (Deluxe model only) Speed sensor lead
2-16
B C D E F G H I J K
Cooling water inlet hose Fuel hose Electric fuel pump Accelerator position sensor Antenna lead (Deluxe model only) Remote control unit lead (Deluxe model only) Bilge hose joint Cooling water hose joint Cooling water pilot outlet hose Accelerator position sensor lead
SPEC
G F
K E
J K A B B
2 3
A-A
K-K J
D
J
1 B-B
C J-J A
C I I C B B
2 C-C
I-I
D
A
I I E F E F
5 6
5 6 D-D 0
I H-H H
7
H G G
7 6 E-E
8 7 6 F-F 0 9
A G-G
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. Fasten the steering sensor lead, handlebar switch lead, multifunction meter lead, and buzzer lead with plastic tie 2. To install the cooling water inlet hose, align the white paint mark on the hose with the parting line on the hose joint.
2-17
SPEC
12
A
J 3 4
C D
C 567
J M 890
H
A B C D H-H
I O
G
G P G-G
HGF
E I 0
A I
K L
A 5
F
E
N D
1 2 3 4 5 6 7 8 9 0 A
Multifunction meter Handlebar switch lead Buzzer Shift cable (Deluxe model only) Fuel hose Relay assembly Fuse box ECM Positive battery lead Flushing hose Cooling water outlet hose
2-18
B C D E F G H I J K L
Bilge hose Battery breather hose Battery Negative battery lead Starter motor lead Speed sensor lead Steering cable Remote control unit lead (Deluxe model only) Fuel tank breather hose Antenna lead (Deluxe model only) Ventilation hose
SPEC
12
A
J 3 4
C D
C 567
J M 890
H
A B C D H-H
I O
G
G P G-G
HGF
E I 0
A I
K L
A 5
F
E
N D
M N O P Q
Water separator Electric fuel pump Oil separator breather hose (to air intake duct) Wiring harness Cooling water inlet hose
Fasten the steering sensor lead, handlebar switch lead, multifunction meter lead, and buzzer lead with plastic tie 2.
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. Deluxe model Sport model To remote control unit (Deluxe model only) Fasten the antenna lead and wiring harness with a plastic tie at the white tape. (Deluxe model only) To engine unit (Deluxe model only)
2-19
SPEC
12
A
J 3 4
C D
C 567
J M 890
H
A B C D H-H
I O
G
G P G-G
HGF
E I 0
A I
K L
A 5
F
E
N D
To ventilation socket To fuel tank Point the arrow on the cover toward the fuel tank. Fasten the fuel hose with a plastic tie. To fuse box Fasten the wiring harness with a plastic tie at the white tape. To ECM
2-20
SPEC
2 2 A B 5 6 4 3
F C
2 8
E E
A B
1 2 2 2 2
2 F-F
1 2 3 4 5 6 7 8 Cooling water inlet hose Cooling water hose Cooling water outlet hose Flushing hose Cylinder head breather hose Oil separator breather hose (to oil tank) Oil separator breather hose (to air intake duct) Cooling water pilot outlet hose
2 E-E D
To install the cooling water outlet hose, align the white paint mark on the cooling water hose with the projection of the hose joint. To transom plate Fasten the cooling water outlet hose with a plastic tie. 2545 mm (0.981.77 in) Fasten the oil separator breather (to oil tank) hose and cooling water hose with a holder.
2-21
SPEC
2 2 A B 5 6 4 3
F C
2 8
E E
A B
1 2 2 2 2
2 F-F
Fasten the oil separator breather hose (to air intake duct) and cooling water hose with a holder. Face the ends of the hose clamp towards the starboard (right) side of the watercraft. Insert the cooling water hose to the paint mark. To install the cooling water hose, align the white paint mark on the cooling water hose with the arrow mark of the hose joint.
2 E-E D
Install the cooling water hose with the white paint mark facing up. To cooling water pilot outlet Face the ends of the hose clamp towards the bow. Install the hose onto the cooling water pipe until the pipe reaches the curve in the hose. Insert the plastic tie completely into the hole in the boss on the cylinder block.
2-22
SPEC
1 2
D E F 8 8
A-A
AB
1 2 3 4 5 6 7 8 9 0 A
Oil separator breather hose (to air intake duct) Wiring harness Ignition coil lead #1 Ignition coil lead #2 Ignition coil lead #3 Ignition coil lead #4 Cam position sensor Ignition coil ECM Rectifier/regulator Oil pressure switch coupler
2-23
B C D E F
Thermoswitch (exhaust) coupler Ground lead plate Wiring harness Thermoswitch (exhaust) lead Oil pressure switch lead
Fasten the oil separator breather hose (to air intake duct) at the paint mark with a holder. 1525 mm (0.590.98 in) To fuse box To multifunction meter
SPEC
1 2
D E F 8 8
A-A
AB
To generator 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. 6080 mm (2.363.15 in)
2-24
SPEC
0 D-D
2 5 6 1 A-A
A
8 5 B-B
B
9 5 C-C
C

1 2 3 4 5 6 7 Ignition coil Fuel rail Fuel injector coupler Throttle body assembly coupler Wiring harness Engine temperature sensor lead Sensor assembly (intake air pressure and intake air temperature) 8 Cam position sensor coupler 9 Cam position sensor lead 0 Oil pressure switch
2-25
To engine temperature sensor To thermoswitch (engine) Route the engine thermoswitch lead and engine temperature sensor lead through the corrugated tube. More than 10 mm (0.39 in) Do not leave any slack in the lead. Attach the thermoswitch (engine) coupler to the bracket. Attach a joint connector to the bracket. Pass the fuel injector leads under the fuel rail.
SPEC
0 D-D
2 5 6 1 A-A
A
8 5 B-B
B
9 5 C-C
C

Insert the plastic tie completely into the hole in the engine hanger. Fasten the wiring harness to a bracket on the fuel rail with a plastic tie. Fasten the wiring harness and cam position sensor within the range shown in the illustration with a plastic tie. Split in wiring harness To cam position sensor Pass fuel injector lead #4 under the sensor assembly (intake air pressure and intake air temperature) lead. To oil pressure switch To thermoswitch (exhaust) To ground lead plate Bow end Make sure that the rubber boot is fitted properly without any folds.
2-26
INSP ADJ
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 .................................................................... 3-6 FUEL SYSTEM.......................................................................................... 3-7 Fuel line inspection .............................................................................3-7 Water separator inspection .................................................................3-8 POWER UNIT............................................................................................ 3-8 Valve clearance adjustment ................................................................3-8 Engine oil level check........................................................................3-14 Engine oil change using oil changer............................................. 3-16 Air filter element clean....................................................................... 3-18 Spark plug inspection........................................................................3-20 ELECTRICAL .......................................................................................... 3-22 Battery inspection.............................................................................. 3-22 JET PUMP UNIT .....................................................................................3-25 Impeller inspection ............................................................................3-25 Water inlet strainer inspection........................................................... 3-25 BILGE PUMP........................................................................................... 3-26 Bilge strainer inspection .................................................................... 3-26 GENERAL ...............................................................................................3-26 Drain plug inspection.........................................................................3-26 Lubrication points .............................................................................. 3-26
1 2 3 4 5 6 7 8 9
INSP ADJ
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.
MAINTENANCE INTERVAL THEREAFTER PAGE EVERY 10 hours 50 hours 100 hours 100 hours 200 hours 6 12 12 24 months months months months Inspect, clean, adjust 3-20 Lubricate 3-26 Inspect 3-7 Inspect, clean 3-7 Inspect 3-6 Inspect Flush *1 Inspect, clean Clean 3-26 Inspect 3-25 Inspect, adjust 3-2 INITIAL Inspect, adjust Inspect, adjust Inspect, replace Inspect Inspect Inspect Inspect Inspect, replace Replace Replace Inspect, adjust 3-5 3-4 3-26 3-22 5-7 3-18 3-14 3-16 3-8
ITEM Spark plug Lubrication points Fuel system Fuel tank Trolling speed Throttle shaft Cooling water passages Water inlet strainer Bilge strainer Impeller Jet thrust nozzle angle Shift cable and mechanism (Deluxe model only) Throttle cable Stern drain plugs Battery Rubber coupling Engine mount Nuts and bolts Air filter Engine oil Engine oil filter Valve clearance
*1: After every use
3-1
INSP ADJ
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. Check the excessive play of the handlebar.
Steering cable inspection and adjustment 1. Inspect: Jet thrust nozzle distances a and b Out of specification Adjust. 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 to lock. Measure distances a and b. If the difference of distances a and b is not within specification, adjust the cable joint.
3-2
INSP ADJ
CONTROL SYSTEM
2. Adjust: Steering cable joint (steering column end)
Adjustment steps: Set the control grip to the neutral position. Loosen the locknut 1. Disconnect the cable joint 2 from the ball joint 3. Turn the cable joint 2 in or out to adjust the steering cable length c.
Steering cable length c: 218.8 mm (8.61 in) NOTE: Check that the sum of lengths c and d is 581.8 1 mm (22.91 0.04 in). If the sum of lengths c and d is out of specification, adjust length d, and then check the jet thrust nozzle distances again.
WARNING
The cable joint must be screwed in more than 8 mm (0.31 in). Connect the cable joint and tighten the locknut. Locknut: 6.8 N m (0.68 kgf m, 4.9 ft lb)
NOTE: Adjust the cable joint at the jet pump end. Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD in Chapter 8.
T.
R.
3-3
INSP ADJ
CONTROL SYSTEM
E 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: 47 mm (0.160.28 in) Throttle cable length b Out of specification Adjust. Throttle cable length b: 18.4 1 mm (0.72 0.04 in) NOTE: Check that the throttle cable length b is 18.4 1 mm (0.72 0.04 in). Adjust if necessary. Adjust the throttle lever free play at the throttle lever end of the throttle cable.
2. Adjust: Throttle lever free play a Adjustment steps: a. Remove the handlebar cover. b. Loosen the locknut 1. c. Turn the adjuster 2 in or out until the specified free play is obtained. Turn in Turn out Free play is increased. Free play is decreased.
d. Tighten the locknut 1. NOTE: If the throttle cable free play cannot be adjusted properly, replace the throttle cable.
3-4
INSP ADJ
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 handlebar to the right and left and make sure that the trolling speed does not increase.
Shift cable inspection and adjustment (Deluxe model only) 1. Check: Reverse gate stopper lever position Incorrect Adjust. Checking steps: Set the shift lever to the reverse position. Check that the reverse gate 1 contacts the stopper 2. 2. Adjust: Shift cable joint
T.
R.
3 2
Adjustment steps: Loosen the locknut 1. Disconnect the cable joint 2 from the ball joint 3. Situate the reverse gate to the stopper. Turn the cable joint in or out to align it with the ball joint. Turn in Turn out Length is decreased. Length is increased.
3-5
INSP ADJ
CONTROL SYSTEM
Turn out the cable joint nine times a to extend the cable 7 mm (0.28 in) from the aligned position.
WARNING
The cable joint must be screwed in more than 8 mm (0.31 in). Connect the cable joint and tighten the locknut. Locknut: 3.8 N m (0.38 kgf m, 2.7 ft lb)
Trolling speed inspection 1. Inspect: Trolling speed Trolling speed: 1,5501,750 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.
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3-6
INSP ADJ
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 in Chapter 4. Fuel hose Cracks/damage Replace. O-rings (quick connector) Cracks/damage Replace the quick connector. Fuel rail Cracks/damage Replace. Refer to FUEL INJECTION SYSTEM in Chapter 4. Fuel filler hose Fuel filler cap Cracks/damage Replace.
2. Inspect: Fuel tank Cracks/damage Replace. Water accumulation Remove. NOTE: To remove water from the fuel tank, remove the fuel filler hose 1 and use a siphon pump. Refer to FUEL TANK AND FUEL PUMP MODULE in Chapter 4.
3-7
INSP ADJ
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: Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) of the compression stroke. 1. Remove: Ignition coils Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS in Chapter 5. 2. Install: Dial gauge needle Dial gauge stand 1 (into spark plug hole #1) Dial gauge 2
2 1
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
3-8
INSP ADJ
POWER UNIT
3. Measure: Valve clearance Out of specification Adjust. Valve clearance (cold): Intake valve: 0.110.20 mm (0.00430.0079 in) Exhaust valve: 0.250.34 mm (0.00980.0134 in)
IN EX
Measurement steps: Turn the drive coupling counterclockwise, and then check if cylinder #1 is at TDC of the compression stroke with a dial gauge. NOTE: TDC of the compression stroke can be found when the camshaft lobes are turned away from each other. Measure the valve clearance with a thickness gauge 1. NOTE: If the valve clearance is incorrect, record the measured reading. Measure the valve clearance in the following sequence. Valve clearance measuring sequence: Cylinder #1 #2 #4 #3
Bow end
To measure the valve clearances of the other cylinders, starting with cylinder #1 at TDC, turn the drive coupling counterclockwise as specified in the following table.
Degrees that the crankshaft is turned clockwise Cylinder Combustion cycle
180
360
540
720
Cylinder #2 Cylinder #4 Cylinder #3
180 360 540
#1
#2 #3 #4
3-9
INSP ADJ
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. Remove: Intake camshaft caps Exhaust camshaft caps Timing chain (from the camshaft sprockets) Intake camshaft Exhaust camshaft NOTE: Refer to CAMSHAFTS in Chapter 5. When removing the timing chain and camshafts, fasten the timing chain with a wire to prevent it from falling into the crankcase.
3-10
INSP ADJ
POWER UNIT
7. Adjust: Valve clearance
1 2
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. Note the position of each valve lifter 3 and valve pad 4 so that they can be installed in the correct place. Select the proper valve pad from the following table. Valve pad thickness range Nos. 120240 Available valve pads
1.20 25 thicknesses in 2.40 mm 0.05 mm increments
a
148
NOTE: The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. Since valve pads of various sizes are originally installed, the valve pad number must be rounded in order to reach the closest equivalent to the original. Round off the original valve pad number according to the following table. Last digit 0 or 2 5 8 Rounded value 0 5 10
EXAMPLE: Original valve pad number = 148 (thickness = 1.48 mm) Rounded value = 150 Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number.
3-11
INSP ADJ
POWER UNIT
6 5
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. NOTE: Lubricate the valve pad with molybdenum disulfide grease. Lubricate the valve lifter with molybdenum disulfide oil. The valve lifter must turn smoothly when rotated by hand. Install the valve lifter and the valve pad in the correct place. Install the exhaust and intake camshafts, timing chain, and camshaft caps. Camshaft cap bolt: 10 N m (1.0 kgf m, 7.2 ft lb)
NOTE: Refer to Camshaft installation CAMSHAFTS in Chapter 5. Lubricate the camshafts, camshaft lobes, and camshaft journals. Install the exhaust camshaft first. Align the camshaft marks with the camshaft cap marks. Turn the crankshaft clockwise several full turns to seat the parts. Measure the valve clearance again. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained.
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3-12
INSP ADJ
Intake
MEASURED CLEARANCE 0.000.02 0.030.07 0.080.10 0.110.20 0.210.22 0.230.27 0.280.32 0.330.37 0.380.42 0.430.47 0.480.52 0.530.57 0.580.62 0.630.67 0.680.72 0.730.77 0.780.82 0.830.87 0.880.92 0.930.97 0.981.02 1.031.07 1.081.12 1.131.17 1.181.22 1.231.27 1.281.32 1.331.37
POWER UNIT
ORIGINAL VALVE PAD NUMBER 165 170 175 180 185 190 195 200 205 210 150 155 160 165 170 175 180 185 190 195 155 160 165 170 175 180 185 190 195 200 160 165 170 175 180 185 190 195 200 205 STANDARD CLEARANCE 165 170 175 180 185 190 195 200 205 210 215 170 175 180 185 190 195 200 205 210 215 220 175 180 185 190 195 200 205 210 215 220 225 180 185 190 195 200 205 210 215 220 225 230 185 190 195 200 205 210 215 220 225 230 235 190 195 200 205 210 215 220 225 230 235 240 195 200 205 210 215 220 225 230 235 240 200 205 210 215 220 225 230 235 240 205 210 215 220 225 230 235 240 210 215 220 225 230 235 240 215 220 225 230 235 240 220 225 230 235 240 225 230 235 240 230 235 240 235 240 Example: 240 Intake valve clearance (cold) 160 145 150 155
120 125 130 135 120 120 125 120 125 130 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
140 125 130 135 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
145 130 135 140 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
150 135 140 145 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
155 140 145 150 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
215 200 205 210 220 225 230 235 240
220 205 210 215
225 210 215 220
230 215 220 225
235 220 225 230
240 225 230 235
225 230 235 240 230 235 240 235 240 240
0.110.20 mm (0.00430.0079 in) Rounded value 150 Measured valve clearance is 0.24 mm (0.0094 in) Replace pad 150 with pad 160 Pad No. 150 = 1.50 mm (0.0591 in) Pad No. 160 = 1.60 mm (0.0630 in)
Exhaust
MEASURED CLEARANCE 0.000.01 0.020.06 0.070.11 0.120.16 0.170.21 0.220.24 0.250.34 0.350.37 0.380.42 0.430.47 0.480.52 0.530.57 0.580.62 0.630.67 0.680.72 0.730.77 0.780.82 0.830.87 0.880.92 0.930.97 0.981.02 1.031.07 1.081.12 1.131.17 1.181.22 1.231.27 1.281.32 1.331.37 1.381.42 1.431.47 1.481.52 120 125 130 135 140 145 150 120 120 125 120 125 130 120 125 130 135 120 125 130 135 140 120 125 130 135 140 145 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 155 125 130 135 140 145 150 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 ORIGINAL VALVE PAD NUMBER 165 170 175 180 185 190 195 200 205 210 215 135 140 145 150 155 160 165 170 175 180 185 140 145 150 155 160 165 170 175 180 185 190 145 150 155 160 165 170 175 180 185 190 195 150 155 160 165 170 175 180 185 190 195 200 155 160 165 170 175 180 185 190 195 200 205 160 165 170 175 180 185 190 195 200 205 210 STANDARD CLEARANCE 165 170 175 180 185 190 195 200 205 210 215 220 170 175 180 185 190 195 200 205 210 215 220 225 175 180 185 190 195 200 205 210 215 220 225 230 180 185 190 195 200 205 210 215 220 225 230 235 185 190 195 200 205 210 215 220 225 230 235 240 190 195 200 205 210 215 220 225 230 235 240 195 200 205 210 215 220 225 230 235 240 200 205 210 215 220 225 230 235 240 205 210 215 220 225 230 235 240 210 215 220 225 230 235 240 215 220 225 230 235 240 220 225 230 235 240 225 230 235 240 230 235 240 235 240 Example: 240 Exhaust valve clearance (cold) 160 130 135 140 145 150 155 220 190 195 200 205 210 215 225 195 200 205 210 215 220 230 200 205 210 215 220 225 235 205 210 215 220 225 230 240 210 215 220 225 230 235
225 230 235 240 230 235 240 235 240 240
0.250.34 mm (0.00980.0134 in) Rounded value 170 Measured valve clearance is 0.44 mm (0.0173 in) Replace pad 170 with pad 185 Pad No. 170 = 1.70 mm (0.0669 in) Pad No. 185 = 1.85 mm (0.0728 in)
3-13
INSP ADJ
POWER UNIT
8. Remove: Dial gauge Dial gauge stand Dial gauge needle 9. Install: All removed parts
NOTE: For installation, reverse the removal procedure.
Engine oil level check 1. Check: Engine oil level Checking steps:
CAUTION:
When checking the engine oil level on water, be careful of other watercraft, boats, swimmers, or obstacles. The water current or wind can cause the watercraft to move and lead to a collision. When checking the engine oil level on land, supply water to the cooling water passages. Make sure that engine has enough oil but do not overfill. If there is too little oil, the engine can be damaged. If there is too much oil, the air filter can become saturated with oil, permanently damaging the filter and reducing engine performance. Follow the checking procedure carefully. Make sure that debris or water does not enter the oil tank filler hole. Debris or water in the engine oil can cause serious engine damage.
3-14
INSP ADJ
POWER UNIT
Place the watercraft in a horizontal position or launch the watercraft. Remove the seat. Remove the oil tank filler cap 1 and check for oil on the dipstick 2. If there is no oil on the dipstick, pour enough oil so that the tip of the dipstick comes into contact with the oil, and then install the filler cap. Start the engine.
CAUTION:
When starting the engine make sure the dipstick is securely fitted into the oil tank. 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 owners manual. (Deluxe model only) Run the engine at trolling speed for 6 minutes or more, and then turn the engine off.
CAUTION:
When checking the oil level on land, be sure to connect a garden hose to the watercraft for proper water supply. NOTE: If the ambient temperature is 20 C (68 F) or less, warm up the engine for an additional 5 minutes. Remove the oil tank filler cap 1, wipe the dipstick 2 clean, and then screw the filler cap into the filler hole completely.
3-15
INSP ADJ
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 recommended type to raise it to the correct level. If the engine oil is above the maximum level mark a, extract sufficient oil using an oil changer to lower it to the correct level. NOTE: If the oil temperature is low, the reading on the dipstick will be low, and if the temperature is high, the reading on the dipstick will be high.
Engine oil change using oil changer
WARNING
Avoid changing the engine oil immediately after turning the engine off. The oil is hot and should be handled with care to avoid burns.
CAUTION:
Do not run the engine with too much or not enough oil in the oil tank. Oil could spray out or the engine could be damaged. Do not run the engine for more than 15 seconds without supplying water, when checking the oil level on land. The engine could overheat. Be sure to change the engine oil after the first 10 hours of operation, and every 100 hours thereafter or at the start of a new season, otherwise the engine will wear quickly. 1. Warm the engine up, and then put the watercraft in a horizontal position.
3-16
INSP ADJ
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, perform the following procedure. Replacing steps: Place a rag under the oil filter. Remove the oil filter 1 with an oil filter wrench.
Oil filter wrench: YB-01426/90890-01426 Lubricate the O-ring 2 of the new oil filter with a thin coat of engine oil.
CAUTION:
Make sure the O-ring 2 is positioned correctly in the groove of the oil filter. Tighten the new oil filter to specification with an oil filter wrench. Oil filter: 17 N m (1.7 kgf m, 12 ft lb)
6. Pour the specified amount of the recommended engine oil into the oil filler hole.
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3-17
INSP ADJ
POWER UNIT
E 7. Fill: Oil tank (with the specified amount of the recommended 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: 2.2 L (2.3 US qt, 1.9 Imp qt)
CAUTION:
When starting the engine make sure the dipstick is securely fitted into the oil tank. 8. Install: Oil tank filler cap
1 5
Air filter element clean 1. Disconnect: Fuel hose 1 Air intake hose 2 Oil separator breather hose 3 2. Remove: Plastic ties 4 Bolts 5 3. Remove: Air filter case 4. Remove: Air filter case cover
4 2 3
3-18
INSP ADJ
POWER UNIT
a
E 5. Remove the air filter element and check it for dirt and oil. Replace the air filter element if there is any oil buildup.
CAUTION:
b
Do not start the engine with the air filter case removed, otherwise the engine could be damaged. If cleaning the air filter element, use cold or lukewarm water and let it air dry completely. Do not use detergent or a solvent to clean the air filter element, or dry it with heat or compressed air, otherwise it could be damaged. 6. Install: Air filter element NOTE: Install the air filter element with its projections a facing away from the projections b on the air filter case. 7. Install: Air filter case cover Air filter case cover screw (short): 1.5 N m (0.15 kgf m, 1.1 ft lb) LOCTITE 572 Air filter case cover screw (long): 1.2 N m (0.12 kgf m, 0.9 ft lb) LOCTITE 572
8. Install: Air filter case Air filter case: 17 N m (1.7 kgf m, 12 ft lb)
T.
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T.
R.
3-19
INSP ADJ
POWER UNIT
Spark plug inspection 1. Remove: Ignition coils
CAUTION:
Be careful not to get any foreign substances or water in spark plug hole.
2. Inspect: Electrodes 1 Damage/wear Replace. Insulator color 2 Distinctly different color Check the engine condition. Color guide: Medium to light tan color: Normal Whitish color: Lean fuel mixture Air leak Incorrect settings Blackish color: Overly rich mixture Electrical malfunction Defective spark plug
3. Clean: Spark plug (with a spark plug cleaner or wire brush)
4. Measure: Spark plug gap a Out of specification Regap. Spark plug gap: 0.70.8 mm (0.0280.031 in)
3-20
INSP ADJ
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 antiseize compound to the spark plug threads to prevent thread seizure. If a torque wrench is not available, a good estimate of the correct tightening torque for a new spark plug is to finger tighten a the spark plug and then tighten it another 1/4 to 1/2 of a turn b.
6. Install: Ignition coils Ignition coil bolt: 7.6 N m (0.76 kgf m, 5.5 ft lb) LOCTITE 572
T.
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T.
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3-21
INSP ADJ
ELECTRICAL
ELECTRICAL
Battery inspection
WARNING
Battery electrolyte is poisonous and dangerous, causing severe burns, etc. Electrolyte contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidotes External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce 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 batteries. KEEP OUT OF THE REACH OF CHILDREN.
CAUTION:
Be careful not to place the battery on its side. Make sure to remove the battery from the battery compartment when adding battery electrolyte or charging the battery. When checking the battery, make sure the breather hose is connected to the battery and not obstructed.
3-22
INSP ADJ
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.
2. Inspect: Electrolyte level Low Add distilled water. The electrolyte level should be between the maximum a and minimum b level marks. Filling steps: Remove each filler cap. Add distilled water to the maximum level mark. When the electrolyte level reaches the maximum level mark, allow the cell to stand for 20 minutes. If the electrolyte level drops, add more distilled water so the level reaches the maximum level mark.
CAUTION:
Use only distilled water. Other types of water contain minerals which are harmful to batteries.
3-23
INSP ADJ
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.
5. Install: Battery breather hose 1 Battery Battery positive lead 2 Battery negative lead 3 Bands
CAUTION:
Connect the positive lead to the battery terminal first. Make sure the battery leads are connected properly. Reversing the leads can seriously damage the electrical system. Make sure that the battery breather hose is properly connected and is not obstructed. Coat the terminals with a water resistant grease to minimize terminal corrosion.
3-24
INSP ADJ
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: 0.350.45 mm (0.01380.0177 in) Measurement steps: Remove the battery leads. Remove the intake grate and intake duct. Refer to INTAKE GRATE AND RIDE PLATE in Chapter 6. Measure the clearance at each impeller blade as shown (a total of three measurements). Install the intake duct and intake grate. Refer to INTAKE GRATE AND RIDE PLATE in Chapter 6. Install the battery leads.
Water inlet strainer inspection 1. Inspect: Water inlet strainer Contaminants Clean. Cracks/damage Replace. Inspection steps: Remove the ride plate. Refer to INTAKE GRATE AND RIDE PLATE in Chapter 6. Remove the rubber plate. Refer to JET PUMP UNIT in Chapter 6. Remove the water inlet cover 1. Inspect the water inlet strainer mesh a. Install the water inlet cover. Install the rubber plate. Refer to JET PUMP UNIT in Chapter 6. Install the ride plate. Refer to INTAKE GRATE AND RIDE PLATE in Chapter 6.
3-25
INSP ADJ
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 Clean. Lubrication points 1. Lubricate: Throttle cable (handlebar end) Recommended lubricant: Rust inhibitor NOTE: Before lubricating the throttle cable, squeeze the throttle lever and remove the rubber seal 1.
3-26
INSP ADJ
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. Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease)
4. Lubricate: (Deluxe model only) Shift cable (shift lever end) Shift cable (reverse gate end) Shift cable joint NOTE: Disconnect the joints and apply a small amount of grease. Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease)
3-27
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 Fuel pump module installation ............................................................ 4-6 Fuel hose connect............................................................................... 4-6 FUEL INJECTION SYSTEM............................................................................4-7 EXPLODED DIAGRAM .............................................................................4-7 REMOVAL AND INSTALLATION CHART ................................................ 4-7 THROTTLE BODY ASSEMBLY AND INTAKE MANIFOLD ........................ 4-10 EXPLODED DIAGRAM ...........................................................................4-10 REMOVAL AND INSTALLATION CHART .............................................. 4-10 SERVICE POINTS .................................................................................. 4-12 Fuel hose clamps removal ................................................................4-12 Hose clamps installation ................................................................... 4-12 Fuel hose disconnection ................................................................... 4-12 Fuel line inspection ...........................................................................4-13 Fuel hose installation (replacing with new fuel hose)........................ 4-14 Fuel hose connection ........................................................................4-14 Fuel injectors inspection.................................................................... 4-15 Throttle body assembly inspection....................................................4-15 Accelerator position sensor inspection.............................................. 4-15 Intake assembly installation ..............................................................4-16 Air filter case assembly installation ...................................................4-17 Fuel pressure measurement ............................................................. 4-17
1 2 3 4 5 6 7 8 9
FUEL
FUEL TANK AND FUEL PUMP MODULE

EXPLODED DIAGRAM
8
1st 3.2 N m (0.32 kgf m, 2.3 ft Ib)
5 6
2nd 6.4 N m (0.64 kgf m, 4.6 ft Ib)
7 3 10
2 1 18 11
5.9 N m (0.59 kgf m, 4.3 ft Ib)
15 16 13 12 12 17
3.7 N m (0.37 kgf m, 2.7 ft Ib)
14
REMOVAL AND INSTALLATION CHART

Step Procedure/Part name FUEL TANK REMOVAL Storage compartment panel Ventilation hose Engine unit Qty Service points Follow the left Step for removal. Refer to FRONT HOOD in Chapter 8. From ventilation fitting Refer to ENGINE UNIT in Chapter 5. NOTE: When removing the pump module only, it is not necessary to remove the engine unit. NOTE: Make sure the arrow direction pointed toward fuel tank.
1 2
Fuel tank breather hose Check valve
1 1
4-1
FUEL
EXPLODED DIAGRAM
8
1st 3.2 N m (0.32 kgf m, 2.3 ft Ib)
5 6
2nd 6.4 N m (0.64 kgf m, 4.6 ft Ib)
7 3 10
2 1 18 11
5.9 N m (0.59 kgf m, 4.3 ft Ib)
15 16 13 12 12 17
3.7 N m (0.37 kgf m, 2.7 ft Ib)
14
Step 3 4
Procedure/Part name Fuel tank breather hose Fuel sender coupler
Qty 1 1
Service points NOTE: Make sure that the inner seal of the coupler is installed properly before connecting the coupler.
5 6 7 8 9 10 11
Fuel pump module coupler Cover Fuel hose Nut Retainer Fuel pump module Packing
1 1 1 9 1 1 1
4-2
FUEL
EXPLODED DIAGRAM
8
1st 3.2 N m (0.32 kgf m, 2.3 ft Ib)
5 6
2nd 6.4 N m (0.64 kgf m, 4.6 ft Ib)
7 3 10
2 1 18 11
5.9 N m (0.59 kgf m, 4.3 ft Ib)
15 16 13 12 12 17
3.7 N m (0.37 kgf m, 2.7 ft Ib)
14
Step 12 13 14 15 16 17 18
Procedure/Part name Hose clamp Fuel filler hose Nut Fuel filler neck Rubber seal Fuel tank belt Fuel tank assembly
Qty 2 1 1 1 1 2 1
Service points
Reverse the removal steps for installation.
4-3
FUEL

SERVICE POINTS
Fuel hose disconnection 1. Disconnect: Fuel hose Refer to FUEL INJECTION SYSTEM.
8 3 2 6 9 4
7 5 1
Fuel pump module removal 1. Remove: Nuts Retainer NOTE: Loosen the nuts in the sequence shown.
2. Remove: Fuel pump module 1 NOTE: Remove the float 2 at an angle because it could catch on the fuel tank.
Check valve inspection 1. Check: Check valve Faulty Replace. Checking steps: Connect a hose to the end of check valve A and blow into it. Air should come out from end B. Connect the hose to the end of check valve B and blow into it. Air should come out from end A.
4-4
FUEL
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. Inspect: Fuel pump filter 1 Clog/contaminants Wash the fuel pump filter in kerosene or gasoline.
4-5
FUEL
2 8 7 3 8 2 4 6

Fuel pump module installation 1. Tighten: Nuts
3 7 5 9 1 1 6 4
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. Fuel hose connect Refer to FUEL INJECTION SYSTEM.
T.
R.
4-6
FUEL
FUEL INJECTION SYSTEM

EXPLODED DIAGRAM
1.2 N m (0.12 kgf m, 0.9 ft Ib) 12 5 75 mm 2.5 N m (0.25 kgf m, 1.8 ft Ib)
16
17
7 3 5 2 4 6
13
LT
1.5 N m (0.15 kgf m, 1.1 ft Ib) 5 25 mm
15
LT
572
572
14
10
11
LT
242
8 18 25
15 N m (1.5 kgf m, 11 ft Ib)
LT
24 24
242
26
1st
8.8 N m (0.88 kgf m, 6.4 ft Ib)
19 21
17 N m (1.7 kgf m, 12 ft Ib) 8 35 mm
LT
2nd 18 N m (1.8 kgf m, 13 ft Ib) 8 30 mm 1st

271
15 N m (1.5 kgf m, 11 ft Ib)
20 23 30 22 31 30
6.5 N m (0.65 kgf m, 4.7 ft Ib)
2nd 39 N m (3.9 kgf m, 28 ft Ib) 8 20 mm
27
17 N m (1.7 kgf m, 12 ft Ib)
28
29

Step Procedure/Part name FUEL INJECTION SYSTEM REMOVAL Cam position sensor coupler Fuel injector coupler Sensor assembly coupler Thermoswitch coupler (exhaust) Oil pressure switch coupler Ground lead coupler Joint connector Throttle body assembly coupler Cover Qty Service points Follow the left Step for removal.
1 2 3 4 5 6 7 8 9
1 4 1 1 1 2 4 1 1
From fuel rail
4-7
FUEL
EXPLODED DIAGRAM
16
17
7 3 5 2 4 6
13
LT
1.5 N m (0.15 kgf m, 1.1 ft Ib) 5 25 mm
15
LT
572
572
14
10
11
LT
242
8 18 25
15 N m (1.5 kgf m, 11 ft Ib)
LT
24 24
242
26
1st
8.8 N m (0.88 kgf m, 6.4 ft Ib)
19 21
17 N m (1.7 kgf m, 12 ft Ib) 8 35 mm
LT

271
15 N m (1.5 kgf m, 11 ft Ib)
20 23 30 22 31 30
6.5 N m (0.65 kgf m, 4.7 ft Ib)
2nd 39 N m (3.9 kgf m, 28 ft Ib) 8 20 mm
27
17 N m (1.7 kgf m, 12 ft Ib)
28
29
Step 10 11 12 13 14 15 16 17 18 19 20
Procedure/Part name Fuel hose Clamp Hose screw clamp Screw Screw Air filter case cover Air intake duct Air intake hose Gasket Air filter element Bolt
Qty 1 2 1 2 4 1 1 1 1 1 4
Service points Not reusable
4-8
FUEL
EXPLODED DIAGRAM
16
17
7 3 5 2 4 6
13
LT
1.5 N m (0.15 kgf m, 1.1 ft Ib) 5 25 mm
15
LT
572
572
14
10
11
LT
242
8 18 25
15 N m (1.5 kgf m, 11 ft Ib)
LT
24 24
242
26
1st
8.8 N m (0.88 kgf m, 6.4 ft Ib)
19 21
17 N m (1.7 kgf m, 12 ft Ib) 8 35 mm
LT

271
15 N m (1.5 kgf m, 11 ft Ib)
20 23 30 22 31 30
6.5 N m (0.65 kgf m, 4.7 ft Ib)
2nd 39 N m (3.9 kgf m, 28 ft Ib) 8 20 mm
27
17 N m (1.7 kgf m, 12 ft Ib)
28
29
Step 21 22 23 24 25 26 27 28 29 30 31
Procedure/Part name Air filter case Collar Grommet Bolt Intake assembly Bolt Throttle cable Nut Accelerator position sensor Nut Bracket
Qty 1 4 4 2 1 2 1 2 1 4 2
Service points

4-9
FUEL
THROTTLE BODY ASSEMBLY AND INTAKE MANIFOLD

EXPLODED DIAGRAM
13 N m (1.3 kgf m, 9.4 ft Ib) 8 17 mm
3.5 N m (0.35 kgf m, 2.5 ft Ib) 5 15 mm
11 6 11
6 7
12 13 5
10 9 8 15 16
14
3 2 1
13 N m (1.3 kgf m, 9.4 ft Ib) 8 65 mm

Step Procedure/Part name THROTTLE BODY ASSEMBLY AND INTAKE MANIFOLD DISASSEMBLY Bolt Washer Throttle body assembly Gasket Intake manifold Bolt Fuel rail Qty Service points Follow the left Step for disassembly.
1 2 3 4 5 6 7
4 4 1 1 1 2 1
Not reusable
4-10
FUEL
EXPLODED DIAGRAM
13 N m (1.3 kgf m, 9.4 ft Ib) 8 17 mm
3.5 N m (0.35 kgf m, 2.5 ft Ib) 5 15 mm
11 6 11
6 7
12 13 5
10 9 8 15 16
14
3 2 1
13 N m (1.3 kgf m, 9.4 ft Ib) 8 65 mm
Step 8 9 10 11 12 13 14 15 16
Procedure/Part name Gasket Fuel injector O-ring Screw Sensor assembly O-ring Clamp Clamp Intake manifold joint
Qty 4 4 4 2 1 1 4 4 4
Service points Not reusable Not reusable
Not reusable
Reverse the disassembly steps for assembly.
4-11
FUEL

SERVICE POINTS
Fuel hose clamps removal 1. Remove: Fuel hose clamps
CAUTION:
If the fuel hose clamps are removed without cutting the joint first, the fuel hose will be damaged. Hose clamps installation 1. Install: Fuel hose clamps
WARNING
Do not reuse the fuel hose clamps, always replace them with new ones. NOTE: Crimp the fuel hose clamps properly to securely fasten them.
Fuel hose disconnection
WARNING
Before disconnecting the hose, remove the fuel tank filler cap to reduce any pressure inside the fuel tank, and then disconnect the battery negative lead to cut off the electric current to the electrical systems. 1. Wrap the quick connector with a cloth, and then rotate the quick connector tab 1 to the stopper position a.
WARNING
If the quick connector is removed suddenly, pressurized fuel could spray out. To gradually release the fuel pressure, be sure to remove the quick connector slowly.
4-12
FUEL
1 2

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. 2. Disconnect the fuel hose 1 from the fuel pipe 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 could spray out.
3. Cover the quick connector and fuel pipe with a plastic bag 3 to prevent damage and to protect them from dirt.
Fuel line inspection 1. Inspect: Fuel hose Damage/cracks Replace. O-rings (quick connector) Damage/cracks Replace the quick connector. Fuel pipe Damage/cracks Replace the fuel pump.
4-13
FUEL
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. When replacing the fuel hose with a new one, a checker tab 2 that has half engagement prevention is attached to the quick connector of the hose. If the quick connector is completely installed to the fuel pipe, it is removable.
Fuel hose connection 1. Apply a thin coat of engine oil to the contact surfaces of the fuel pipe. 2. Insert the quick connector into the fuel pipe until you hear a click. 3. To check the connection of the quick connector, push and pull on the quick connector several times until there is free play of 23 mm (0.080.12 in). NOTE: If free is not obtained, disconnect the fuel hose and check the O-ring for damage and that it is properly installed.
4-14
FUEL

Fuel injectors inspection NOTE: Do not remove the throttle body assembly. 1. Check: Fuel injectors Dirt/residue Clean. Damage Replace. 2. Measure: Fuel injectors resistance Out of specification Replace. Digital multimeter: YU-34899-A Digital circuit tester: 90890-03174 Fuel injector resistance: (reference data) 11.512.5 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. 1. Check: Throttle body assembly Cracks/damage Replace the throttle body assembly. Accelerator position sensor inspection 1. Inspect: Accelerator position sensor Damage/cracks Replace the accelerator position sensor.
4-15
FUEL

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 projection a on the intake manifold joint. Tighten the clamp screw until both ends of the intake screw clamp contact the spacer 1 around the screw.
2. Install: Fuel hose 2 (fuel rail side) Fuel hose clamps
a 2
WARNING
Do not reuse the fuel hose clamps, always replace them with new ones. NOTE: Install the fuel hose with the white mark a facing up. Install the fuel hose clamps at the locations shown in the illustration, and then crimp them to securely fasten them.
8 mm (0.31 in)
6 mm (0.24 in)
4-16
FUEL
1 a

2
Air filter case assembly installation 1. Install: Air intake duct 1 Air intake hose 2 Air filter case cover
a b b
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 illustration. 2. Adjust: Throttle lever free play Refer to CONTROL SYSTEM in Chapter 3.
Fuel pressure measurement 1. Disconnect: Fuel hose Refer to Fuel hose disconnection. 2. Install: Fuel pressure gauge adapter 1 Fuel pressure gauge 2 Fuel pressure gauge adapter: YW-06842/90890-06842 Fuel pressure gauge: YB-06766/90890-06786
2
NOTE: To connect the fuel pressure gauge adapter, follow the procedures for connecting a fuel hose. (Refer to Fuel hose connection.) 3. Start the engine and arrow it to warm up for several minutes. 4. Measure: Fuel pressure Out of specification Replace the fuel pump module. Fuel pressure: 320327 kPa (3.23.3 kgf/cm2, 4647 psi)
4-17
FUEL

5. Remove: Fuel pressure gauge Fuel pressure gauge adapter
NOTE: To disconnect the fuel pressure gauge adapter, follow the procedures for disconnecting a fuel hose. (Refer to Fuel hose disconnection.) 6. Connect: Fuel hose Refer to Fuel hose connection.
4-18
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 ................................................ 5-8 EXHAUST MANIFOLD .................................................................................. 5-11 EXPLODED DIAGRAM ...........................................................................5-11 REMOVAL AND INSTALLATION CHART .............................................. 5-11 OIL TANK ...................................................................................................... 5-12 EXPLODED DIAGRAM ...........................................................................5-12 REMOVAL AND INSTALLATION CHART .............................................. 5-12 SERVICE POINTS .................................................................................. 5-17 Oil tank removal ................................................................................ 5-17 Oil strainer inspection........................................................................5-18 Oil tank installation ............................................................................5-18 OIL PUMP...................................................................................................... 5-21 EXPLODED DIAGRAM ...........................................................................5-21 REMOVAL AND INSTALLATION CHART .............................................. 5-21 SERVICE POINTS .................................................................................. 5-23 Oil strainer inspection........................................................................5-23 Oil pump installation..........................................................................5-23 REDUCTION DRIVE GEAR ..........................................................................5-24 EXPLODED DIAGRAM ...........................................................................5-24 REMOVAL AND INSTALLATION CHART .............................................. 5-24 SERVICE POINTS .................................................................................. 5-28 Drive coupling removal...................................................................... 5-28 Drive shaft removal ...........................................................................5-28 Bearing removal ................................................................................ 5-28 Oil pump drive shaft inspection ......................................................... 5-29 Drive shaft inspection........................................................................5-29 Bearing installing............................................................................... 5-30 Drive shaft installation ....................................................................... 5-32 Drive coupling installation .................................................................5-32
1 2 3 4 5 6 7 8 9
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 .................................................................................. 5-46 Camshaft removal ............................................................................. 5-46 Camshaft inspection..........................................................................5-47 Camshaft sprockets inspection ......................................................... 5-49 Timing chain tensioner inspection.....................................................5-49 Camshaft installation.........................................................................5-50 CYLINDER HEAD.......................................................................................... 5-54 EXPLODED DIAGRAM ...........................................................................5-54 REMOVAL AND INSTALLATION CHART ............................................. 5-54 SERVICE POINTS .................................................................................. 5-56 Cylinder head removal ...................................................................... 5-56 Cylinder head inspection................................................................... 5-56 Cylinder head installation .................................................................. 5-57 VALVES AND VALVE SPRINGS.................................................................. 5-59 EXPLODED DIAGRAM ...........................................................................5-59 REMOVAL AND INSTALLATION CHART ............................................. 5-59 SERVICE POINTS .................................................................................. 5-61 Valve removal ...................................................................................5-61 Valve spring inspection ..................................................................... 5-62 Valve inspection ................................................................................ 5-62 Valve guide inspection ...................................................................... 5-64 Valve guide replacement................................................................... 5-64 Valve seat inspection ........................................................................5-66 Valve seat reface .............................................................................. 5-67 Valve installation ............................................................................... 5-69 CRANKCASE ................................................................................................5-71 EXPLODED DIAGRAM ...........................................................................5-71 REMOVAL AND INSTALLATION CHART .............................................. 5-71 SERVICE POINTS .................................................................................. 5-75 Crankcase disassembly .................................................................... 5-75 Crankcase inspection........................................................................5-76 Timing chain inspection..................................................................... 5-76 Crankcase assembly.........................................................................5-77
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 .............................................. 5-89 CRANKSHAFT ..............................................................................................5-93 EXPLODED DIAGRAM ...........................................................................5-93 REMOVAL AND INSTALLATION CHART .............................................. 5-93 SERVICE POINTS .................................................................................. 5-94 Crankshaft removal ...........................................................................5-94 Crankshaft inspection........................................................................5-94 Crankshaft installation....................................................................... 5-97 COOLING WATER HOSE ............................................................................. 5-98 EXPLODED DIAGRAM ...........................................................................5-98 REMOVAL AND INSTALLATION CHART .............................................. 5-98
POWR
ENGINE UNIT
ENGINE UNIT
EXPLODED DIAGRAM
17 N m (1.7 kgf m, 12 ft Ib) 8 35 mm
17 N m (1.7 kgf m, 12 ft Ib) 8 40 mm
7.8 N m (0.78 kgf m, 5.6 ft Ib) 6 25 mm 11
12
LT
3 13 9
572
15
LT
4 2
271
6 5 7 10 1 10 10 14
17 N m (1.7 kgf m, 12 ft Ib) 1st
LT
242
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

Step Procedure/Part name ENGINE UNIT REMOVAL Engine oil Storage compartment panel Battery negative and positive lead Fuel hose Water lock and exhaust joint Bolt/washer Fuse box Qty Service points Follow the left Step for removal. Drain. Refer to POWER UNIT in Chapter 3. Refer to FRONT HOOD in Chapter 8. Refer to FUSE BOX in Chapter 7. Refer to FUEL INJECTION SYSTEM in Chapter 4. Refer to EXHAUST SYSTEM in Chapter 8.
1 2
2/2 1
5-1
POWR
ENGINE UNIT
EXPLODED DIAGRAM
17 N m (1.7 kgf m, 12 ft Ib) 8 35 mm
17 N m (1.7 kgf m, 12 ft Ib) 8 40 mm
7.8 N m (0.78 kgf m, 5.6 ft Ib) 6 25 mm 11
12
LT
3 13 9
572
15
LT
4 2
271
6 5 7 10 1 10 10 14
17 N m (1.7 kgf m, 12 ft Ib) 1st
LT
242
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
Step 3 4 5 6 7 8 9 10 11 12
Procedure/Part name Bolt Air filter case assembly Bolt ECM and rectifier/regulator assembly Clamp/cooling water hose Clamp/cooling water hose Clamp/cooling water hose Coupler Bolt/collar Coupling cover
Qty 2 1 1 1 1/1 1/1 1/1 10 1/1 1
Service points
Cooling water pilot outlet Cooling water inlet Cooling water outlet
5-2
POWR
ENGINE UNIT
EXPLODED DIAGRAM
17 N m (1.7 kgf m, 12 ft Ib) 8 35 mm
17 N m (1.7 kgf m, 12 ft Ib) 8 40 mm
7.8 N m (0.78 kgf m, 5.6 ft Ib) 6 25 mm 11
12
LT
3 13 9
572
15
LT
4 2
271
6 5 7 10 1 10 10 14
17 N m (1.7 kgf m, 12 ft Ib) 1st
LT
242
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
Step 13 14 15
Procedure/Part name Bolt/washer Shim Engine unit
Qty 4/4 * 1
Service points
Reverse the removal steps for installation. *: As required.
5-3
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. Warm the engine up, and then put the watercraft in a horizontal position. 3. Remove: Ignition coils Spark plugs
CAUTION:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from falling into the cylinders.
4. Install: Compression gauge extension 1 Compression gauge 2
Compression gauge extension: 90890-06582 Compression gauge: YU-33223-1/90890-03160
5-4
POWR
ENGINE UNIT
E 5. Measure: Compression pressure Out of specification Refer to steps (b) and (c). Minimum compression pressure (reference data): 1,150 kPa (11.5 kgf/cm2, 164 psi) Measurement steps: a. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. NOTE: The difference in compression pressure between cylinders should not exceed 100 kPa (1 kgf/cm2, 14 psi). b. If the compression pressure is extremely high, check the cylinder head, valve surfaces and piston crown for carbon deposits. Carbon deposits Eliminate. c. If the compression pressure is below the minimum specification, squirt a few drops of oil into the cylinder and measure again. Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Higher than without oil Same as without oil 6. Install: Spark plug Spark plug: 13 N m (1.3 kgf m, 9.4 ft lb) Diagnosis Piston ring wear, piston wear or damage Repair. Valves, cylinder head gasket or piston possibly defective Repair.
T.
R.
5-5
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. Suspend the engine unit using all three engine hangers, and then separate the unit from the engine mount.
Shim removal 1. Remove: Shims NOTE: To ease reassembly and coupling alignment, remove the shims and organize them in their respective groups (e.g., front right, rear left) prior to removing the mounting bolts. Engine mount inspection 1. Inspect: Engine mounts Cracks/damage Replace. Refer to ENGINE MOUNT in Chapter 8.
T.
R.
5-6
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: 00.5 mm (00.020 in) Clearance b: 24 mm (0.0790.157 in)
2. Adjust: Clearance a and b Adjustment steps: Adjust the clearance a by adding or removing shims. Adjust the clearance b by moving the engine unit position.
5-7
POWR
EXHAUST PIPES 1 AND 2

EXPLODED DIAGRAM
2
LT
7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm
242
3 6 6
LT LT LT
572 242
242
LT
572
1st
3.4 N m (0.34 kgf m, 2.5 ft Ib)

LT
LT
2nd 3.4 N m (0.34 kgf m, 2.5 ft Ib)
242
242

Step Procedure/Part name EXHAUST PIPES 1 AND 2 REMOVAL Engine unit Qty Service points Follow the left Step for removal. Refer to ENGINE UNIT. For cooling water pilot outlet on port side From water jacket 1/1 1/1 2 1 2 2
1 2 3 4 5 6
Clamp/cooling water hose Clamp/cooling water hose Bolt Thermoswitch (exhaust) Exhaust joint clamp Exhaust joint clamp
Slide the outer exhaust joint for exhaust manifold side
5-8
POWR
EXPLODED DIAGRAM
1st 2.0 N m (0.2 kgf m, 1.4 ft Ib)
5th 15 N m (1.5 kgf m, 11 ft Ib) 9th 39 N m (3.9 kgf m, 28 ft Ib) 10 35 mm 2nd 2.0 N m (0.2 kgf m, 1.4 ft Ib) 6th 15 N m (1.5 kgf m, 11 ft Ib) 10th 39 N m (3.9 kgf m, 28 ft Ib) 10 35 mm
LT
242
7
LT
572
LT
242
LT
242
LT
572
10 9
LT LT
242
242
4th
2.0 N m (0.2 kgf m, 1.4 ft Ib)
3rd
2.0 N m (0.2 kgf m, 1.4 ft Ib)
8th 15 N m (1.5 kgf m, 11 ft Ib) 12th 39 N m (3.9 kgf m, 28 ft Ib) 10 45 mm
7th 15 N m (1.5 kgf m, 11 ft Ib) 11th 39 N m (3.9 kgf m, 28 ft Ib) 10 40 mm
Step 7 8 9 10
Procedure/Part name Bolt Bolt Bolt Collar
Qty 1 1 2 1
Service points NOTE: Tighten the bolts in the sequence indicated.
5-9
POWR
EXPLODED DIAGRAM
1st
22 N m (2.2 kgf m, 16 ft Ib)
2nd 22 N m (2.2 kgf m, 16 ft Ib) 3rd 35 N m (3.5 kgf m, 25 ft Ib) 8 75 mm

LT
22 21 17 16
LT
12
242
18
20 14 15 14 14 13
12 14 13
19
18
LT
572
LT
242
19
1st
242
15
LT
22 N m (2.2 kgf m, 16 ft Ib)
572
11
1st
3.7 N m (0.37 kgf m, 2.7 ft Ib)
LT LT
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm
242
242
Step 11 12 13 14 15 16 17 18 19 20 21 22
Procedure/Part name Exhaust pipe 2 Bolt Exhaust pipe end Gasket Silencer Inner exhaust joint Outer exhaust joint Bolt Bolt Exhaust pipe 1 Gasket Dowel pin
Qty 1 3 1 2 1 1 1 2 2 1 1 2
5-10
Service points
Not reusable
Not reusable Reverse the removal steps for installation.
POWR
EXHAUST MANIFOLD
EXHAUST MANIFOLD
EXPLODED DIAGRAM
1st
22 N m (2.2 kgf m, 16 ft Ib)
1st
22 N m (2.2 kgf m, 16 ft Ib)
1 1 2
LT
242
6 3
LT
242

Step Procedure/Part name EXHAUST MANIFOLD REMOVAL Exhaust pipes 1 and 2 Clamp/cooling hose Bolt Bolt Exhaust manifold Gasket Dowel pin Qty Service points Follow the left Step for removal. Refer to EXHAUST PIPES 1 AND 2. To cylinder block
1 2 3 4 5 6
2/1 5 6 1 1 2
5-11
POWR
OIL TANK
OIL TANK
EXPLODED DIAGRAM
6 35 mm
2 3 1
10
5 4
22
2.0 N m (0.2 kgf m, 1.4 ft Ib) 2nd 15 N m (1.5 kgf m, 11 ft Ib) 3rd 39 N m (3.9 kgf m, 28 ft Ib) 1st 1st 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 20 mm
20
11 11 5
LT
15 14 13
8
LT
18 17 12 19
LT
572
572
24 25 26 25 21
A
LT LT
6 6
16
572 572
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 30 mm 1st 1st 10 70 mm 2.0 N m (0.2 kgf m, 1.4 ft Ib)
572
23
2nd 15 N m (1.5 kgf m, 11 ft Ib) 3rd 39 N m (3.9 kgf m, 28 ft Ib)
15 N m (1.5 kgf m, 11 ft Ib) 2nd 39 N m (3.9 kgf m, 28 ft Ib) 10 85 mm 6 35 mm 7.6 N m (0.76 kgf m, 5.5 ft Ib) 1st

Step Procedure/Part name OIL TANK REMOVAL Engine unit Intake assembly Clamp/cooling water hose Bolt Water jacket Gasket Clamp/breather hose Clamp/breather hose Bolt Collar Qty Service points Follow the left Step for removal. Refer to ENGINE UNIT. Refer to FUEL INJECTION SYSTEM in Chapter 4. To exhaust pipe 1
1 2 3 4 5 6 7 8
1/1 4 1 1 2/1 2/1 2 2

5-12
Not reusable To oil pump
POWR
OIL TANK
EXPLODED DIAGRAM
6 35 mm
2 3 1
10
5 4
22
20
11 11 5
LT
15 14 13
8
LT
18 17 12 19
LT
572
572
24 25 26 25 21
A
LT LT
6 6
16
572 572
572
23
Step 9 10 11 12 13 14 15 16 17 18 19
Procedure/Part name Oil separator Clamp/breather hose Clamp/breather hose Clamp/cooling water hose Bolt Collar Band Bolt Ground lead box O-ring Bolt
Qty 1 1/1 1/1 1/1 1 1 1 3 1 1 2

5-13
Service points To air intake pipe From cylinder head cover Mark a From cooling water inlet
Not reusable
POWR
OIL TANK
EXPLODED DIAGRAM
6 35 mm
2 3 1
10
5 4
22
20
11 11 5
LT
15 14 13
8
LT
18 17 12 19
LT
572
572
24 25 26 25 21
A
LT LT
6 6
16
572 572
572
23
Step 20 21 22 23 24 25 26
Procedure/Part name Nut Bolt Oil tank Oil tank stay Pin O-ring Connector
Qty 2 5 1 1 2 4 2
Service points
5-14
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 1st 1.9 N m (0.19 kgf m, 1.4 ft Ib) 2nd 4.4 N m (0.44 kgf m, 3.2 ft Ib) 5 14 mm 1st
LT
4 6 7 10 9 5
572
11
E
15 12
LT
572
5 16 mm 1st
13 14
E
1.9 N m (0.19 kgf m, 1.4 ft Ib) 2nd 4.4 N m (0.44 kgf m, 3.2 ft Ib) 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 14 mm 1st
16 19 17 18 1
E
20
LT
572
17
1st
LT
572
6 20 mm 1st
15
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)
3.7 N m (0.37 kgf m, 2.7 ft Ib) 16 2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 4 12 mm 6 20 mm 3.8 N m (0.38 kgf m, 2.7 ft Ib)

Step 1 2 3 4 5 6 7 8 9 10 Procedure/Part name OIL TANK DISASSEMBLY Bolt/washer Bracket/grommet Oil tank filler cap Packing Bolt Oil tank cover Gasket Bolt Oil breather plate Gasket Qty 2/2 2/2 1 1 8 1 1 9 1 1 Service points Follow the left Step for disassembly.
Not reusable
Not reusable
5-15
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 1st 1.9 N m (0.19 kgf m, 1.4 ft Ib) 2nd 4.4 N m (0.44 kgf m, 3.2 ft Ib) 5 14 mm 1st
LT
4 6 7 10 9 5
572
11
E
15 12
LT
572
5 16 mm 1st
13 14
E
1.9 N m (0.19 kgf m, 1.4 ft Ib) 2nd 4.4 N m (0.44 kgf m, 3.2 ft Ib) 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 14 mm 1st
16 19 17 18 1
E
20
LT
572
17
1st
LT
572
6 20 mm 1st
15
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)
3.7 N m (0.37 kgf m, 2.7 ft Ib) 16 2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib) 4 12 mm 6 20 mm 3.8 N m (0.38 kgf m, 2.7 ft Ib)
Step 11 12 13 14 15 16 17 18 19 20
Procedure/Part name Bolt Baffle plate Bolt Oil strainer Bolt Oil cooler cover Gasket Screw Anode Oil tank
Qty 3 1 2 1 24 2 2 1 1 1
Service points
Not reusable

5-16
POWR
OIL TANK
SERVICE POINTS
Oil tank removal 1. Remove: Oil tank
3 1 2 4
NOTE: Loosen the oil tank bolts and nuts in the sequence shown.
5 9 8 7 6
5 1
8 4
2. Remove: Oil tank cover Gasket NOTE: Loosen the oil tank cover bolts in the sequence shown.
2 6 7
9 4 5 6 7
3. Remove: Oil breather plate Gasket
3 2 1
NOTE: Loosen the oil breather plate bolts in the sequence shown.
5-17
POWR
OIL TANK
4. Remove: Oil cooler covers Gaskets
1 2
12
NOTE: Loosen the oil cooler cover bolts in the sequence shown.
7 6
5 10 11
Oil strainer inspection 1. Check: Oil strainer 1 Damage Replace. Contaminants Clean.
Oil tank installation 1. Install: Gaskets Oil cooler covers
12 11
NOTE: Tighten the oil cooler bolts in the sequence shown. Oil cooler cover bolt: 1st: 3.7 N m (0.37 kgf m, 2.7 ft lb) 2nd: 7.6 N m (0.76 kgf m, 5.5 ft lb) LOCTITE 572
6
T.
R.
10
8 3 2
5-18
POWR
OIL TANK
2. Install: Gasket Oil breather plate
1 6 5 4 3
7 8 9
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 m (0.44 kgf m, 3.2 ft lb)
4 8
1 5
3. Install: Gasket Oil tank cover NOTE: Tighten the oil tank cover bolts in the sequence shown. Oil tank cover bolt: 1st: 3.7 N m (0.37 kgf m, 2.7 ft lb) 2nd: 7.6 N m (0.76 kgf m, 5.5 ft lb) LOCTITE 572
T.
R.
7 3 2
T.
R.
5-19
POWR
OIL TANK
4. Install: Oil tank
7 2 9 3 8 2
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: 2.0 N m (0.2 kgf m, 1.4 ft lb) 2nd: 15 N m (1.5 kgf m, 11 ft lb) 3rd: 39 N m (3.9 kgf m, 28 ft lb) LOCTITE 572
T.
R.
5 1 2 1 3 4
5-20
POWR
OIL PUMP
OIL PUMP
EXPLODED DIAGRAM
1st
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 25 mm

LT
2
572
LT
572
1st
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 16 mm
4 7
LT
572
6 8 1 5 7
13 N m (1.3 kgf m, 9.4 ft Ib) 8 12 mm
8 9
1st 15 N m (1.5 kgf m, 11 ft Ib) 2nd 28 N m (2.8 kgf m, 20 ft Ib) 8 112 mm

Step Procedure/Part name OIL PUMP ASSEMBLY REMOVAL Oil tank Drain plug/washer Bolt Bolt Bolt Oil pump assembly Gasket Pin Qty Service points Follow the left Step for removal. Refer to OIL TANK. Drain engine oil.
1 2 3 4 5 6 7
1/1 6 2 2 1 1 2
Not reusable
5-21
POWR
OIL PUMP
EXPLODED DIAGRAM
1st
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 25 mm

LT
2
572
LT
572
1st
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 16 mm
4 7
LT
572
6 8 1 5 7
13 N m (1.3 kgf m, 9.4 ft Ib) 8 12 mm
8 9
1st 15 N m (1.5 kgf m, 11 ft Ib) 2nd 28 N m (2.8 kgf m, 20 ft Ib) 8 112 mm
Step 8 9
Procedure/Part name Bolt Strainer
Qty 2 1
Service points
5-22
POWR
OIL PUMP
SERVICE POINTS
1
Oil strainer inspection 1. Check: Oil strainer 1 Damage Replace. Contaminants Clean.
Oil pump installation 1. Install: Oil pump assembly
b a
NOTE: Align the projection a on the oil pump shaft with the slit b on the oil pump driven gear shaft. Oil pump assembly bolt: M6: 10 N m (1.0 kgf m, 7.2 ft lb) LOCTITE 572 M8: 1st: 15 N m (1.5 kgf m, 11 ft lb) 2nd: 28 N m (2.8 kgf m, 20 ft lb) LOCTITE 572
T.
R.
5-23
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 1st 1st 15 N m (1.5 kgf m, 11 ft Ib) 2nd 28 N m (2.8 kgf m, 20 ft Ib) 8 40 mm
LT
7 9 8
572
11 3
LT
1 9 11
E 572
10
2 6
LT
572
4
LT
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 35 mm 1st
572
LT
12
572
15 N m (1.5 kgf m, 11 ft Ib) 2nd 28 N m (2.8 kgf m, 20 ft Ib) 8 70 mm 1st
28 N m (2.8 kgf m, 20 ft Ib)

Step Procedure/Part name REDUCTION DRIVE GEAR REMOVAL Generator cover Oil pump Bolt Bolt Bolt Bolt Bolt Qty Service points Follow the left Step for removal. Refer to GENERATOR AND STARTER MOTOR. Refer to OIL PUMP. 1 1 1 3 1
1 2 3 4 5
5-24
POWR
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 1st 1st 15 N m (1.5 kgf m, 11 ft Ib) 2nd 28 N m (2.8 kgf m, 20 ft Ib) 8 40 mm
LT
7 9 8
572
11 3
LT
1 9 11
E 572
10
2 6
LT
572
4
LT
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 35 mm 1st
572
LT
12
572
28 N m (2.8 kgf m, 20 ft Ib)
Step 6 7 8 9 10 11 12
Procedure/Part name Reduction drive gear case assembly Gasket Pin Circlip Reduction drive gear Washer Drive coupling
Qty 1 1 2 2 1 2 1 Not reusable Not reusable
Service points
5-25
POWR
EXPLODED DIAGRAM
*1 3
E
4 8 7 *1
6 5
11
2 *1
10 9
E E
1
E

Step Procedure/Part name REDUCTION DRIVE GEAR DISASSEMBLY Oil pump drive shaft Drive shaft Collar Oil seal Circlip Bearing Collar Bearing Qty Service points Follow the left Step for disassembly.
1 2 3 4 5 6 7 8
*1
1 1 1 2 1 1 1 1
Not reusable Not reusable Not reusable Not reusable
: EPNOC grease AP #0
5-26
POWR
EXPLODED DIAGRAM
*1 3
E
4 8 7 *1
6 5
11
2 *1
10 9
E E
1
E
Step 9 10 11
Procedure/Part name Circlip Bearing Reduction drive gear case
Qty 1 1 1
Service points Not reusable Not reusable Reverse the disassembly steps for assembly.
*1
: EPNOC grease AP #0
5-27
POWR

SERVICE POINTS
Drive coupling removal 1. Remove: Reduction drive gear housing 2. Remove: Drive coupling 1
1 4
NOTE: While holding the drive shaft 2 with the rotor holder 3, loosen the drive coupling with the coupler wrench 4.
3 2
Coupler wrench: YW-06551/90890-06551 Universal magneto and rotor holder: YU-01235 Rotor holder: 90890-01235 Drive shaft removal 1. Remove: Drive shaft NOTE: Press in the direction of the arrow. Bearing removal 1. Remove: Circlip Rear bearing Collar Front bearing NOTE: Remove the front bearing, spacer, and rear bearing using a press. Driver handlelarge: YB-06071 Driver rod L3: 90890-06652 Bearing housing needle bearing installer: YB-06111 Needle bearing attachment: 90890-06653
For USA and Canada For worldwide
5-28
POWR

2. Remove: 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
Oil pump drive shaft inspection 1. Check: Oil pump drive shaft 1 Cracks/damage/wear Replace.
Drive shaft inspection 1. Check: Drive shaft 1 Cracks/damage/wear Replace.
5-29
POWR

Bearing installing 1. Install: Reduction drive gear bearing
NOTE: Install the reduction driver gear bearing using a press. Driver handlelarge: YB-06071 Driver rod LS: 90890-06606 Outer race installerforward gear: YB-06085 Ball bearing attachment: 90890-06631
2. Install: Front bearing NOTE: Install the front bearing using a press. Driver rod LS: 90890-06606 Forward gear bearing cup installer: YB-06276-B Ball bearing attachment: 90890-06657
5-30
POWR

3. Install: 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 diameter of 70 mm (2.76 in) and an inner diameter of 30 mm (1.18 in). Driver rod LS: 90890-06606 Outer race installerforward gear: YB-06085 Bearing outer race attachment: 90890-06624
4. Install: Oil seals Driver handlelarge: YB-06071 Driver rod LS: 90890-06606 Outer race installerforward gear: YB-06085 Bearing outer race attachment: 90890-06624
Distance a: 17.9 0.2 mm (0.70 0.01 in) Distance b: 9.3 0.2 mm (0.37 0.01 in)
5-31
POWR

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 0.5 mm (1.10 0.02 in).
1 4
Drive coupling installation 1. Install: Drive coupling 1 NOTE: While holding the drive shaft 2 with the rotor holder 3, tighten the drive coupling with the coupler wrench 4. Coupler wrench: YW-06551/90890-06551 Universal magneto and rotor holder: YU-01235 Rotor holder: 90890-01235 Drive coupling: 28 N m (2.8 kgf m, 20 ft lb) LOCTITE 572
3 2
2. Install: Reduction drive gear housing
T.
R.
5-32
POWR
GENERATOR AND STARTER MOTOR

EXPLODED DIAGRAM
3
18 N m (1.8 kgf m, 13 ft Ib) 8 30 mm A 4.9 N m (0.49 kgf m, 3.5 ft Ib)
2 14 5 21 15
E
20
1st
15 N m (1.5 kgf m, 11 ft Ib) 2nd 50 N m (5.0 kgf m, 36 ft Ib) 10 135 mm
19 17 12
6 9
LT
16
A E
572
18 7 10 8
LT
24 N m (2.4 kgf m, 17 ft Ib) 8 20 mm
572
11
13
75 N m (7.5 kgf m, 54 ft Ib) 10 47 mm
1st
15 N m (1.5 kgf m, 11 ft Ib)
2nd 50 N m (5.0 kgf m, 36 ft Ib) 10 60 mm

Step Procedure/Part name GENERATOR COVER AND FLYWHEEL MAGNETO REMOVAL Engine unit Nut/washer Starter motor lead Bolt Battery negative lead Starter motor Band Lighting coil coupler Qty Service points Follow the left Step for removal.
Refer to ENGINE UNIT. 1/1 1 2 1 1 1 1
1 2 3 4 5 6 7
5-33
POWR
EXPLODED DIAGRAM
3
2 14 5 21 15
E
20
1st
19 17 12
6 9
LT
16
A E
572
18 7 10 8
LT
24 N m (2.4 kgf m, 17 ft Ib) 8 20 mm
572
11
13
75 N m (7.5 kgf m, 54 ft Ib) 10 47 mm
1st
15 N m (1.5 kgf m, 11 ft Ib)
2nd 50 N m (5.0 kgf m, 36 ft Ib) 10 60 mm
Step 8 9 10 11 12 13 14 15 16 17 18
Procedure/Part name Pickup coil coupler Bolt Bolt Generator cover Dowel pin Gasket Idle gear shaft Idle gear Bolt/washer Flywheel magneto Bolt
Qty 1 6 2 1 2 1 1 1 1/1 1 6
Service points
Not reusable
Not reusable
5-34
POWR
EXPLODED DIAGRAM
3
2 14 5 21 15
E
20
1st
19 17 12
6 9
LT
16
A E
572
18 7 10 8
LT
24 N m (2.4 kgf m, 17 ft Ib) 8 20 mm
572
11
13
75 N m (7.5 kgf m, 54 ft Ib) 10 47 mm
1st
15 N m (1.5 kgf m, 11 ft Ib)
2nd 50 N m (5.0 kgf m, 36 ft Ib) 10 60 mm
Step 19 20 21
Procedure/Part name Starter clutch Starter gear Woodruff key
Qty 1 1 1
Service points
5-35
POWR
EXPLODED DIAGRAM
4.9 N m (0.49 kgf m, 3.5 ft Ib) 5 10 mm
LT
242
LT
242
6 3 5
LT
242
LT
242
6 35 mm 14 N m (1.4 kgf m, 10 ft Ib)
5 14 mm 4.9 N m (0.49 kgf m, 3.5 ft Ib)
6 14 mm 14 N m (1.4 kgf m, 10 ft Ib)

Step 1 2 3 Procedure/Part name GENERATOR DISASSEMBLY Bolt/washer Bolt Pickup coil Qty 1/1 2 1 Service points Follow the left Step for disassembly.
NOTE: There washer hold the pickup coil lead. Make sure to not pitch the lead between the projection and the washer when installing the bolt.
Bolt
5-36
POWR
EXPLODED DIAGRAM
4.9 N m (0.49 kgf m, 3.5 ft Ib) 5 10 mm
LT
242
LT
242
6 3 5
LT
242
LT
242
6 35 mm 14 N m (1.4 kgf m, 10 ft Ib)
5 14 mm 4.9 N m (0.49 kgf m, 3.5 ft Ib)
6 14 mm 14 N m (1.4 kgf m, 10 ft Ib)
Step 5 6 7
Procedure/Part name Holder Bolt Lighting coil
Qty 1 3 1
Service points
5-37
POWR

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: Flywheel magneto 1 Woodruff key NOTE: While holding the flywheel magneto with sheave holder 2, remove the flywheel magneto with the rotor puller 3. Rotor puller: YM-01082/90890-01080
Starter clutch inspection 1. Check: Starter clutch rollers 1 Damage/wear Replace.
5-38
POWR

2 a
2. Check: Starter clutch 1 Starter gear 2 Burrs/chips/roughness/wear Replace the defective part(s). 3. Check: Starter clutch gears contacting surfaces a Damage/pitting/wear Replace the starter clutch gear.
4. Check: Starter clutch operation Checking steps: Install the starter gear 1 onto the starter clutch 2 and hold the starter clutch. When turning the starter gear clockwise , it should turn freely, otherwise the starter clutch is faulty and must be replaced. When turning the starter gear counterclockwise , the starter clutch and the starter gear should engage, otherwise the starter clutch is faulty and must be replaced.
5-39
POWR

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. Lubricate the flywheel magneto bolt and washer with engine oil.
2. Tighten: Flywheel magneto bolt 1 NOTE: While holding the flywheel magneto 2 with the sheave holder 3, tighten the flywheel magneto bolt. Flywheel magneto bolt: 75 N m (7.5 kgf m, 54 ft lb) Sheave holder: YS-01880-A/90890-01701
CAUTION:
Do not reuse the flywheel magneto bolt and washer, always replace them with new ones.
T.
R.
5-40
POWR
CAMSHAFTS
CAMSHAFTS
EXPLODED DIAGRAM
10 N m (1.0 kgf m, 7.2 ft Ib) 6 16 mm
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 16 mm 1st 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm
8 5 9 10 7
A
LT
a 4
1
LT
572
14
572
11 12 13
E 1280B
16
15
12 N m (1.2 kgf m, 8.7 ft Ib) 6 22 mm
1280B
13 N m (1.3 kgf m, 9.4 ft Ib)

Step Procedure/Part name CYLINDER HEAD COVER REMOVAL Bolt Ignition coil Spark plug Clamp/breather hose Bolt Cam position sensor Clamp/cooling water hose Rubber seal Qty Service points Follow the left Step for removal.
1 2 3 4 5 6 7 8
4 4 4 1/1 1 1 1/1 1
To oil tank Paint mark a
To transom plate
5-41
POWR
CAMSHAFTS
EXPLODED DIAGRAM
10 N m (1.0 kgf m, 7.2 ft Ib) 6 16 mm
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 16 mm 1st 7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm
8 5 9 10 7
A
LT
a 4
1
LT
572
14
572
11 12 13
E 1280B
16
15
12 N m (1.2 kgf m, 8.7 ft Ib) 6 22 mm
1280B
13 N m (1.3 kgf m, 9.4 ft Ib)
Step 9 10 11 12 13 14 15 16
Procedure/Part name Bolt Cooling water pipe O-ring Bolt Rubber mount Cylinder head cover Cylinder head cover gasket Timing chain guide (top side)
Qty 1 1 1 6 6 1 1 1
Service points
Not reusable
5-42
POWR
CAMSHAFTS
EXPLODED DIAGRAM
6 35 mm 10 N m (1.0 kgf m, 7.2 ft Ib)
12 12 12 13
E E
13 13
E
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 35 mm
19 18
9 10 20
E
10 11
24 N m (2.4 kgf m, 17 ft Ib) 7 11 mm
14 10
M
16 22 17
E
15 23 24 25 26 27 8
6 16 mm
A
21
10 N m (1.0 kgf m, 7.2 ft Ib) 6 8 mm
4 1 7 6
6 25 mm 10 N m (1.0 kgf m, 7.2 ft Ib)

Step Procedure/Part name CAMSHAFT REMOVAL Cylinder head cover Reduction drive gear case Qty Service points Follow the left Step for removal. Refer to REDUCTION DRIVE GEAR. NOTE: When removing camshafts it is not necessary to remove the reduction drive gear case. 1 1 1 1 2
5-43
1 2 3 4 5
Thermoswitch (engine) coupler Engine temperature sensor coupler Cap bolt Gasket Bolt
Not reusable
POWR
CAMSHAFTS
EXPLODED DIAGRAM
6 35 mm 10 N m (1.0 kgf m, 7.2 ft Ib)
12 12 12 13
E E
13 13
E
19 18
9 10 20
E
10 11
24 N m (2.4 kgf m, 17 ft Ib) 7 11 mm
14 10
M
16 22 17
E
15 23 24 25 26 27 8
6 16 mm
A
21
10 N m (1.0 kgf m, 7.2 ft Ib) 6 8 mm
4 1 7 6
6 25 mm 10 N m (1.0 kgf m, 7.2 ft Ib)
Step 6 7 8 9 10 11 12 13 14 15 16 17
Procedure/Part name Timing chain tensioner Timing chain tensioner gasket Timing chain guide (exhaust side) Bolt Intake camshaft cap Dowel pin Bolt Exhaust camshaft cap Dowel pin Intake camshaft Bolt Intake camshaft sprocket
Qty 1 1 1 18 3 6 10 3 6 1 2 1
5-44
NOTE: During removal, the dowel pins may still be connected to the camshaft caps.
POWR
CAMSHAFTS
EXPLODED DIAGRAM
6 35 mm 10 N m (1.0 kgf m, 7.2 ft Ib)
12 12 12 13
E E
13 13
E
19 18
9 10 20
E
10 11
24 N m (2.4 kgf m, 17 ft Ib) 7 11 mm
14 10
M
16 22 17
E
15 23 24 25 26 27 8
6 16 mm
A
21
10 N m (1.0 kgf m, 7.2 ft Ib) 6 8 mm
4 1 7 6
6 25 mm 10 N m (1.0 kgf m, 7.2 ft Ib)
Step 18 19 20 21 22 23 24 25 26 27
Procedure/Part name Exhaust camshaft Bolt Exhaust camshaft sprocket Pin Timing chain guide (intake side) Bolt Plate Gasket Pipe O-ring
Qty 1 2 1 1 1 1 1 1 1 1
Service points
5-45
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
2 1
2. Turn the drive coupling counterclockwise, and then check if cylinder #1 is at TDC of the compression stroke with a dial gauge.
IN EX
NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.
3. Make the alignment marks a on the timing chain and camshaft sprockets.
4. Remove: Timing chain tensioner 1 Gasket
5-46
POWR
3 5 3 9 6 4 8 6
CAMSHAFTS
7 9 13 17 10 1
5. Remove: Camshaft caps Dowel pins
8 2 16 12 1
NOTE: Loosen the intake and exhaust camshaft cap bolts in the sequence shown.
5 7
10 4
1115
1814 2
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.
7. Remove: 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 Camshaft inspection 1. Check: Camshaft lobes Bluediscoloration/pitting/scratches Replace the camshaft.
2. Measure: Camshaft lobe dimensions a and b Out of specification Replace the camshaft. Cam lobe dimensions: Intake camshaft: a 31.15 mm (1.226 in) b 25.00 mm (0.984 in) Exhaust camshaft: a 30.75 mm (1.211 in) b 25.00 mm (0.984 in)
5-47
POWR
CAMSHAFTS
3. Measure: Camshaft runout Out of specification Replace. Maximum camshaft runout: 0.03 mm (0.0012 in)
8 6 16 10
5 7 11 13
4 2 6 2
10
3 9 3 7 18
4. Measure: Camshaft-journal-to-camshaft-cap clearance Out of specification Measure the camshaft journal diameter. Camshaft-journal-to-camshaftcap clearance: 0.050.06 mm (0.00200.0024 in) Measurement steps: Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). Position a strip of Plastigauge 1 onto the camshaft journal as shown. Install the dowel pins and camshaft caps. NOTE: Tighten the intake and exhaust camshaft cap bolts in the sequence shown. Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the Plastigauge. Camshaft cap bolt: 10 N m (1.0 kgf m, 7.2 ft lb)
14 12
9 15
8 4
1 5 17
Remove the camshaft caps and then measure the width of the Plastigauge 1.
T.
R.
5-48
POWR
CAMSHAFTS
E 5. Measure: Camshaft journal diameter a Out of specification Replace the camshaft. Within specification Replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter: Intake: 24.4624.47 mm (0.96300.9634 in) Exhaust: 24.4424.45 mm (0.96220.9626 in)
Camshaft sprockets inspection 1. Check: Camshaft sprocket Wear/damage Replace the camshaft sprockets and timing chain as a set.
a b 1 2 1/4 of a tooth Correct Timing chain Camshaft sprocket
Timing chain tensioner inspection 1. Check: Timing chain tensioner Cracks/damage/rough movement Replace. Checking steps: While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1. Remove the screwdriver and slowly release the timing chain tensioner rod. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough movement, replace the timing chain tensioner.
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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 m (2.4 kgf m, 17 ft lb)
2. Install: Exhaust camshaft Intake camshaft Exhaust camshaft caps Intake camshaft caps Installation steps: Turn the drive coupling counterclockwise, and then check if cylinder #1 is at TDC of the compression stroke with a dial gauge. Install the timing chain onto both camshaft sprockets, and then install the camshaft.
CAUTION:
Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. NOTE: Make sure that the punch marks a on the camshafts face up. Be sure to align the alignment marks b made during removal to install the timing chain and camshaft sprockets.
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8 6 16 10 5 7 11 13
CAMSHAFTS
4 2 6 2 1 10
Install the exhaust and intake camshaft caps. NOTE: Gradually tighten the intake and exhaust camshaft cap bolts in 23 steps in the sequence shown. Camshaft cap bolt: 10 N m (1.0 kgf m, 7.2 ft lb)
3 9 3 7 18
14 12
9 15
8 4
1 5 17
NOTE: Make sure that the punch marks c on the camshafts are aligned with the arrow marks d on the camshaft caps. Out of alignment Reinstall. Remove the wire from the timing chain. 3. Install: Timing chain tensioner Installation steps: While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1. NOTE: Make sure that the tensioner rod has been fully set clockwise.
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3 2
With the timing chain tensioner rod turned all the way into the timing chain tensioner housing (with the thin screwdriver still installed), install the gasket and the timing chain tensioner 2 onto the cylinder block.
WARNING
Always use a new gasket. Tighten the timing chain tensioner bolts 3 to the specified torque. NOTE: The UP mark on the timing chain tensioner should face up.
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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 m (1.0 kgf m, 7.2 ft lb)
4. Turn: Drive coupling (several turns counterclockwise)
5. Check: Turn the drive coupling counterclockwise, and then check if cylinder #1 is at TDC of the compression stroke with a dial gauge. Camshaft punch marks a Make sure that the camshaft punch marks are aligned with the arrow marks b on the camshaft caps. Out of alignment Adjust. Refer to the installation steps above. 6. Measure: Valve clearance Out of specification Adjust. Refer to POWER UNIT in Chapter 3.
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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 m (1.2 kgf m, 8.7 ft lb)
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CYLINDER HEAD
CYLINDER HEAD
EXPLODED DIAGRAM
1st 1st 20 N m (2.0 kgf m, 14 ft Ib) 2nd 121 5
20 N m (2.0 kgf m, 14 ft Ib)
2nd 105 5 10 N m (1.0 kgf m, 7.2 ft Ib) 6 12 mm 1st 20 N m (2.0 kgf m, 14 ft Ib) 2nd 105 5
1st
20 N m (2.0 kgf m, 14 ft Ib)
2nd 105 5
6 6 6
E
6 6
3
E
10 N m (1.0 kgf m, 7.2 ft Ib) 6 55 mm
4
E
5 5
1st
4 1
2 7
LT
20 N m (2.0 kgf m, 14 ft Ib)
2nd 105 5
8 20 mm 1st
271
20 N m (2.0 kgf m, 14 ft Ib)
2nd 140 5

Step Procedure/Part name CYLINDER HEAD REMOVAL Engine unit Intake assembly Exhaust pipes 1 and 2 Oil tank Intake and exhaust camshaft Bolt Hunger Bolt Qty Service points Follow the left Step for removal. Refer to ENGINE UNIT. Refer to FUEL INJECTION SYSTEM in Chapter 4. Refer to EXHAUST PIPES 1 AND 2. Refer to OIL TANK. Refer to CAMSHAFTS.
1 2 3
2 1 3
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CYLINDER HEAD
EXPLODED DIAGRAM
1st 1st 20 N m (2.0 kgf m, 14 ft Ib) 2nd 121 5
20 N m (2.0 kgf m, 14 ft Ib)
2nd 105 5 10 N m (1.0 kgf m, 7.2 ft Ib) 6 12 mm 1st 20 N m (2.0 kgf m, 14 ft Ib) 2nd 105 5
1st
20 N m (2.0 kgf m, 14 ft Ib)
2nd 105 5
6 6 6
E
6 6
3
E
10 N m (1.0 kgf m, 7.2 ft Ib) 6 55 mm
4
E
5 5
1st
4 1
2 7
LT
20 N m (2.0 kgf m, 14 ft Ib)
2nd 105 5
8 20 mm 1st
271
20 N m (2.0 kgf m, 14 ft Ib)
2nd 140 5
Step 4 5 6 7 8 9
Procedure/Part name Nut/washer Nut/washer Nut/washer Cylinder head Cylinder head gasket Dowel pin
Qty 2/2 3/3 5/5 1 1 2
Service points
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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 damaging or scratching: spark plug bore threads valve seats 2. Check: Cylinder head Damage/scratches Replace. Cylinder head water jacket Mineral deposits/rust Eliminate.
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CYLINDER HEAD
E 3. Measure: Cylinder head warpage Out of specification Replace the cylinder 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. Measure the warpage. If the limit is exceeded, replace the cylinder head.
Cylinder head installation 1. Install: Cylinder head NOTE: Pass the timing chain through the timing chain cavity. Lubricate the cylinder head nuts with engine oil. Tighten the cylinder head nuts in the sequence shown. Cylinder head nut 1: 1st: 20 N m (2.0 kgf m, 14 ft lb) 2nd: 121 5 Cylinder head nut 2: 1st: 20 N m (2.0 kgf m, 14 ft lb) 2nd: 105 5 Cylinder head nut 3: 1st: 20 N m (2.0 kgf m, 14 ft lb) 2nd: 140 5
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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)
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VALVES AND VALVE SPRINGS

EXPLODED DIAGRAM
10 11 12 13 14 15 16
3 12
E
1 2 3 4 5 6 7
9 8
18
17
E

Step Procedure/Part name VALVES AND VALVE SPRINGS REMOVAL Cylinder head Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve stem seal Intake valve lower spring seat Intake valve Intake valve guide Qty Service points Follow the left Step for removal. Refer to CYLINDER HEAD. 12 12 24 12 12 12 12 12 12
5-59
1 2 3 4 5 6 7 8 9
Not reusable
Not reusable
POWR
EXPLODED DIAGRAM
10 11 12 13 14 15 16
3 12
E
1 2 3 4 5 6 7
9 8
18
17
E
Step 10 11 12 13 14 15 16 17 18
Procedure/Part name Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve stem seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide
Qty 8 8 16 8 8 8 8 8 8
Service points
Not reusable
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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. 2. Remove: Valve cotters 1 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3. 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
3. Remove: Upper spring seat 1 Valve spring 2 Valve 3 Stem seal 4 Lower spring seat 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
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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. Measure: Valve spring tilt a Out of specification Replace the valve spring. Valve spring tilt limit: Intake valve spring: 2.5/1.7 mm (0.067 in) Exhaust valve spring: 2.5/1.8 mm (0.071 in)
Valve inspection 1. Eliminate: Carbon deposits (from the valve face and valve seat) 2. Check: Valve face Pitting/wear Replace the valve.
3. Measure: Valve margin thickness a Out of specification Replace the valve. Valve margin thickness: 0.851.15 mm (0.03350.0453 in)
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4. Measure: Valve stem diameter a Out of specification Replace the valve. Valve stem diameter a: Intake valve: 3.9753.990 mm (0.15650.1571 in) Exhaust valve: 4.4654.480 mm (0.17580.1764 in)
5. Measure: Valve stem runout Out of specification Replace the valve. NOTE: When installing a new valve, always replace the valve guide. If the valve is removed or replaced, always replace the stem seal. Valve stem runout: 0.01 mm (0.0004 in)
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Valve guide inspection
NOTE: Before checking the valve guide make sure that the valve stem diameter is within specification. 1. Measure: Valve guide inside diameter a Valve guide inside diameter: Intake: 4.0004.012 mm (0.15750.1580 in) Exhaust: 4.5004.512 mm (0.17720.1776 in)
2. Calculate the valve stem-to-valve guide clearance as follows. Replace the valve guide if out of specification. Valve stem-to-valve guide clearance = valve guide inside diameter valve stem diameter: Intake: 0.0100.037 mm (0.00040.0015 in) Exhaust: 0.0200.047 mm (0.00080.0019 in)
Valve guide replacement 1. Remove the valve guide 1 by striking the special service tool from the combustion chamber side. Valve guide remover: Intake (4.0 mm): YM-04111/90890-04111 Exhaust (4.5 mm): YM-04116/90890-04116
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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. Valve guide remover: Intake (4.0 mm): YM-04111/90890-04111 Exhaust (4.5 mm): YM-04116/90890-04116 Valve guide installer: Intake (4.0 mm): YM-04112/90890-04112 Exhaust (4.5 mm): YM-04117/90890-04117
3. Insert the special service tool into the valve guide 2, and then ream the valve guide. NOTE: Turn the valve guide reamer clockwise to ream the valve guide. Do not turn the reamer counterclockwise when removing the reamer. Valve guide reamer: Intake (4.0 mm): YM-04113/90890-04113 Exhaust (4.5 mm): YM-04118/90890-04118 4. Measure: Valve guide inside diameter Valve guide inside diameter: Intake: 4.0004.012 mm (0.15750.1580 in) Exhaust: 4.5004.512 mm (0.17720.1776 in)
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Valve seat inspection 1. Eliminate carbon deposits from the valve with a scraper. 2. Apply a thin, even layer of Mechanics blueing dye (Dykem) onto the valve seat.
3. Lap the valve slowly on the valve seat with a valve lapper (commercially available) as shown.
4. Measure the valve seat contact width a where the blueing dye is adhered to the valve face. Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification. Replace the valve guide if the valve seat contact is uneven. Valve seat contact width a: 0.901.10 mm (0.03540.0433 in)
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Valve seat reface 1. Reface the valve seat with the valve seat cutter. Valve seat cutter holder: Intake (4.0 mm): 90890-06811 Exhaust (4.5 mm): 90890-06812 Valve seat cutter: 30 (intake): 90890-06815 45 (intake): 90890-06814 60 (intake): 90890-06813 30 (exhaust): 90890-06328 45 (exhaust): 90890-06312 60 (exhaust): 90890-06315 Neway valve seat cutter kit: YM-91044 2. Cut the surface of the valve seat with a 45 cutter by turning the cutter clockwise until the valve seat face has become smooth.
a Slag or rough surface
CAUTION:
Do not over cut the valve seat. Be sure to turn the cutter evenly downward at a pressure of 4050 N (45 kgf, 8.811 lbf) to prevent chatter marks.
3. Use a 30 cutter to adjust the contact width of the top edge of the valve seat.
b Previous contact width
30
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b
4. Use a 60 cutter to adjust the contact width of the bottom edge of the valve seat.
60
b c
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
6. If the valve seat contact area is too wide and situated in the center of the valve face, use a 30 cutter to cut the top edge of the valve seat, a 60 cutter to cut the bottom edge to center the area and set its width.
7. If the valve seat contact area is too narrow and situated near the top edge of the valve face, use a 30 cutter to cut the top edge of the valve seat. If necessary, use a 45 cutter to center the area and set its width.
8. If the valve seat contact area is too narrow and situated near the bottom edge of the valve face, use a 60 cutter to cut the bottom edge of the valve seat. If necessary, use a 45 cutter to center the area and set its width.
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9. Apply a thin, even layer of lapping compound onto the valve seat, and then lap the valve using a valve lapper (commercially available).
CAUTION:
Do not get the lapping compound on the valve stem and valve guide. 10. After every lapping procedure, be sure to clean off any remaining lapping compound from the cylinder head and the valve. 11. Check the valve seat contact area of the valve again.
Valve installation 1. Install: Lower spring seat 1 Stem seal 2 Valve 3 Valve spring 4 Upper spring seat 5 (into the cylinder head) NOTE: Make sure that each valve is installed in its original place. Refer to the following embossed marks. Right and left intake valve(s): 4XV: Middle intake valve(s): 4XV. Exhaust valve(s): 5LV Install the valve spring with the larger pitch a facing up.
b Smaller pitch
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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
3. Lightly tap the valve spring retainer with a plastic hammer to set the valve cotter securely. NOTE: Apply engine oil to the valve pads and valve lifters before installation.
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CRANKCASE
CRANKCASE
EXPLODED DIAGRAM
12 N m (1.2 kgf m, 8.7 ft Ib) 6 20 mm

LT
20 N m (2.0 kgf m, 14 ft Ib) 8 40 mm

A
LT
8.4 N m (0.84 kgf m, 6.1 ft Ib)
271
9 10 11 8
15 N m (1.5 kgf m, 11 ft Ib)
572
1 6
A
2 4 5
LT
3 20 21
19
1280B
572
20 18
LT
7.6 N m (0.76 kgf m, 5.5 ft Ib) 6 16 mm 6 70 mm 12 N m (1.2 kgf m, 8.7 ft Ib)

572
1st
7.8 N m (0.78 kgf m, 5.6 ft Ib)
16 18
E
LT
572
2nd * 3rd 15 N m (1.5 kgf m, 11 ft Ib) 4th 49 5
15
17
9 105 mm
14 13
12 N m (1.2 kgf m, 8.7 ft Ib) 6 55 mm 12 N m (1.2 kgf m, 8.7 ft Ib) 6 55 mm
LT
572
12
12 N m (1.2 kgf m, 8.7 ft Ib) 6 20 mm

Step Procedure/Part name OIL PAN AND CRANKCASE REMOVAL Engine unit Intake assembly Exhaust pipes 1 and 2 Exhaust manifold Generator cover Oil tank Oil pump *: Loosen completely
5-71
Qty
Service points Follow the left Step for removal. Refer to ENGINE UNIT. Refer to FUEL INJECTION SYSTEM in Chapter 4. Refer to EXHAUST PIPES 1 AND 2. Refer to EXHAUST MANIFOLD. Refer to GENERATOR AND STARTER MOTOR. Refer to OIL TANK. Refer to OIL PUMP.
POWR
CRANKCASE
EXPLODED DIAGRAM
12 N m (1.2 kgf m, 8.7 ft Ib) 6 20 mm

LT
20 N m (2.0 kgf m, 14 ft Ib) 8 40 mm

A
LT
8.4 N m (0.84 kgf m, 6.1 ft Ib)
271
9 10 11 8
15 N m (1.5 kgf m, 11 ft Ib)
572
1 6
A
2 4 5
LT
3 20 21
19
1280B
572
20 18
LT

572
1st
7.8 N m (0.78 kgf m, 5.6 ft Ib)
16 18
E
LT
572
15
17
9 105 mm
14 13
LT
572
12
12 N m (1.2 kgf m, 8.7 ft Ib) 6 20 mm
Step
1 2 3 4 5 6 7 8 9 10
Procedure/Part name Reduction drive gear case Cylinder head Timing chain Engine temperature sensor Washer Bolt Thermoswitch (engine) Oil pressure switch Bolt Bolt Anode cover Grommet
Qty
Service points Refer to REDUCTION DRIVE GEAR. Refer to CAMSHAFTS.
1 1 1 2 1 1 1 1 1 1
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CRANKCASE
EXPLODED DIAGRAM
12 N m (1.2 kgf m, 8.7 ft Ib) 6 20 mm

LT
20 N m (2.0 kgf m, 14 ft Ib) 8 40 mm

A
LT
8.4 N m (0.84 kgf m, 6.1 ft Ib)
271
9 10 11 8
15 N m (1.5 kgf m, 11 ft Ib)
572
1 6
A
2 4 5
LT
3 20 21
19
1280B
572
20 18
LT

572
1st
7.8 N m (0.78 kgf m, 5.6 ft Ib)
16 18
E
LT
572
15
17
9 105 mm
14 13
LT
572
12
12 N m (1.2 kgf m, 8.7 ft Ib) 6 20 mm
Step 11 12 13 14 15 16 17 18 19 20 21
Procedure/Part name Anode Bolt Oil pan Gasket Bolt Bolt Bolt Bolt/washer Lower crankcase Dowel pin Dowel pin/O-ring
Qty 1 15 1 1 2 1 7 10/10 1 2 1/1
Service points
Not reusable
Not reusable
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CRANKCASE
EXPLODED DIAGRAM
6 10 mm 12 N m (1.2 kgf m, 8.7 ft Ib)
1 2
E A
3 5
E
4
35 N m (3.5 kgf m, 25 ft Ib)

Step Procedure/Part name OIL PIPE AND OIL FILTER BOLT REMOVAL Crankshaft Bolt Oil pipe O-ring Oil filter bolt Lower crankcase Qty Service points Follow the left Step for removal. Refer to CRANKSHAFT. 1 1 2 1 1
1 2 3 4 5
Not reusable
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CRANKCASE
SERVICE POINTS
Crankcase disassembly 1. Remove: Oil pan bolts
10 14 13 9
6 5
2 1
4 3
8 7
12 15 11
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. Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration). The numbers embossed on the oil pan indicate the oil pan tightening sequence.
H 8
F 6
B 2
D 4
J 0
2. Remove: Crankcase 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. Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration). The numbers embossed on the crankcase indicate the crankcase tightening sequence. 3. Remove: Lower crankcase
9 I
3 C
1 A
5 E
7 G
CAUTION:
Tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves separate evenly.
M9 105 mm bolts: 10 M6 55 mm bolts: AH, J M6 70 mm bolts: I
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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 Blow out with compressed air.
Timing chain inspection 1. Check: Timing chain 1 Damage/stiffness Replace the timing chain and camshaft sprockets as a set.
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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 bearings.
1280B
3. Install: Dowel pins 1 O-ring 2
12
H 8
F 6
B 2
D 4
J 0
4. Install: Crankcase bolts NOTE: Lubricate the bolt 10 threads and washers with engine oil. Finger tighten the crankcase bolts.
M9 105 mm bolts: 10 M6 55 mm bolts: AH, J M6 70 mm bolts: I
9 I
3 C
1 A
5 E
7 G
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H 8 F 6
CRANKCASE
B 2 D 4 J 0
5. Tighten: Crankcase bolts 10
9 I
3 C
1 A
5 E
7 G
NOTE: Do not reuse crankcase bolts 10. The tightening procedure of crankcase bolts 10 is angle controlled, therefore tighten the bolts using the following procedure. Tightening steps: Tighten the bolts in the order of the numbers on the crankcase. Crankcase bolt 10: 1st: 7.8 N m (0.78 kgf m, 5.6 ft lb)
Loosen and retighten the crankcase bolts in the proper tightening sequence as shown. Crankcase bolt 10: 2nd: Loosen completely 3rd: 15 N m (1.5 kgf m, 11 ft lb)
Tighten the crankcase bolts further to reach the specified angle 49 in the proper tightening sequence as shown. Crankcase bolt 10: Final: Specified angle 49 5
When the bolts are tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one and perform the procedure again.
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T.
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WARNING
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CRANKCASE
CAUTION:
Do not use a torque wrench to tighten the bolt to the specified angle. Tighten the bolt until it is at the specified angle. NOTE: When using a hexagonal bolt, note that the angle from one corner to another is 60.
H 8
F 6
B 2
D 4
J 0
6. Tighten: Crankcase bolts AJ NOTE: Tighten the bolts in the order of the numbers on the crankcase. Crankcase bolt AJ: 12 N m (1.2 kgf m, 8.7 ft lb) LOCTITE 572
9 I
3 C
1 A
5 E
7 G
T.
7. Tighten: Oil pan bolts
R.
10 14 13 9
6 5
2 1
4 3
8 7
12 15 11
NOTE: Tighten the bolts in the order of the numbers on the oil pan. Oil pan bolt: 12 N m (1.2 kgf m, 8.7 ft lb) LOCTITE 572
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CONNECTING RODS AND PISTONS

EXPLODED DIAGRAM
10 11 12
E
4 5 6 4 7 8
M
3 2
E M
1st
20 N m (2.0 kgf m, 14 ft Ib)
2nd 120 5

Step Procedure/Part name CONNECTING RODS AND PISTONS REMOVAL Crankcase Nut Connecting rod cap Big end lower bearing Piston pin clip Piston pin Piston Connecting rod Qty Service points Follow the left Step for removal. Separate Refer to CRANKCASE. Not reusable
1 2 3 4 5 6 7
8 4 4 8 4 4 4
Not reusable
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EXPLODED DIAGRAM
10 11 12
E
4 5 6 4 7 8
M
3 2
E M
1st
20 N m (2.0 kgf m, 14 ft Ib)
2nd 120 5
Step 8 9 10 11 12
Procedure/Part name Bolt Big end upper bearing Top ring 2nd ring Oil ring
Qty 8 4 4 4 4
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1

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.
2. Remove: Piston pin clips 1 Piston pin 2 Piston 3 Connecting rod 4
CAUTION:
Do not use a hammer to drive the piston pin out. NOTE: For reference during installation, put an identification number a on the piston crown. Before removing the piston pin, deburr the piston pin clips groove and the pistons pin bore area.
3. Remove: Top ring 2nd ring Oil ring NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown.
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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 cylinder, and the piston and piston rings as a set. 2. Measure: Piston-to-cylinder clearance
a b
D2 D4 D6
D1 D3 D5
c d
Measurement steps: Measure cylinder bore C with the cylinder bore gauge. Cylinder bore C Taper limit T Out of round R 76.00076.015 mm (2.99212.9927 in) 0.08 mm (0.003 in) 0.05 mm (0.002 in)
C = maximum of D1D6 T = maximum of D1D5 (direction c) and D2D6 (direction d) R = maximum of D2D1 (measuring point a) and D6D5 (measuring point b) If out of specification, replace the cylinder, and the piston and piston rings as a set. Measure piston skirt diameter P with the micrometer.
a 5 mm (0.2 in) from the bottom edge of the piston
Piston size P Standard 75.89575.910 mm (2.98802.9986 in)
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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: 0.100.11 mm (0.00390.0043 in) <Limit>: 0.17 mm (0.0067 in) If out of specification, replace the piston and piston rings as a set.
Piston ring inspection 1. Measure: Piston ring side clearance Out of specification Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Side clearance: Top ring: 0.0300.065 mm (0.00120.0026 in) 2nd ring: 0.0200.055 mm (0.00080.0022 in) Oil ring: 0.0400.160 mm (0.00160.0063 in)
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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 piston ring. NOTE: The oil ring expander spacers end gap cannot be measured. If the oil ring rails gap is excessive, replace all three piston rings. Piston ring end gap: Top ring: 0.320.44 mm (0.01260.0173 in) 2nd ring: 0.430.58 mm (0.01690.0228 in) Oil ring: 0.100.35 mm (0.00390.0138 in)
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POWR
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 lubrication system.
2. Measure: Piston pin outside diameter a Out of specification Replace the piston pin. Piston pin outside diameter: 16.99117.000 mm (0.66890.6693 in) <Limit>: 16.98 mm (0.67 in)
3. Measure: Piston pin bore diameter (in the piston) b Out of specification Replace the piston. Piston pin bore diameter (in the piston): 17.00217.013 mm (0.66940.6698 in) 4. Calculate: Piston-pin-to-piston clearance Out of specification Replace the piston pin. Piston-pin-to-piston clearance = Piston pin bore diameter (in the piston) b Piston pin outside diameter a Piston-pin-to-piston clearance: 0.0020.022 mm (0.00010.0009 in)
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Connecting rod inspection 1. Measure: Big end oil clearance Out of specification Replace the big end bearings. Big end oil clearance: 0.0160.040 mm (0.00060.0016 in) Measurement steps: The following procedure applies to all of the connecting rods.
CAUTION:
Do not interchange the big end bearings and connecting rods. To obtain the correct big end oil clearance and prevent engine damage, the big end bearings must be installed in their original positions. Clean the big end bearings, crankshaft pins, and the inside of the connecting rod halves. Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap. NOTE: Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap.
Put a piece of Plastigauge 1 on the crankshaft pin. Assemble the connecting rod halves.
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POWR

d
NOTE: Do not move the connecting rod or crankshaft 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 connecting rod faces towards the front side of the crankshaft. Make sure the characters d on both the connecting rod and connecting rod cap are aligned.
Tighten the connecting rod nuts. Refer to Connecting rod and piston installation. Remove the connecting rod and big end bearings. Refer to Connecting rod and piston removal. Measure the compressed Plastigauge width e on the crankshaft pin. If the big end oil clearance is out of specification, select replacement big end bearings.
2. Select: Big end bearings (P1P4) NOTE: The numbers stamped into the crankshaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes. P1P4 refer to the bearings shown in the crankshaft illustration.
P1 P2 P3
P4
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POWR
For example, if the connecting rod P1 and the crankshaft web P1 numbers are 5 and 1 respectively, then the bearing size for P1 is: Bearing size of P1: P1 (connecting rod) P1 (crankshaft web) 5 1 = 4 (green) BEARING COLOR CODE 1
P1 P2 P3 P4
5G
brown black blue green
2 3 4
Connecting rod and piston installation The following procedure applies to all of the pistons and connecting rods. 1. Install: Oil ring 2nd ring Top ring NOTE: Be sure to install the piston rings so that the manufacturers marks or numbers face up. 2. Install: Piston 1 Connecting rod 2 Piston pin 3 Piston pin clips 4 NOTE: Apply engine oil onto the piston pin. When installing the connecting rod to the piston, make sure that the Y mark a on the connecting rod faces towards the left when the exhaust valve recesses b on the piston face upward. Refer to the illustration. Reinstall each piston into its original cylinder (numbering order starting from the front: #1 to #4).
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POWR
b

90 c 90
3. Offset: Piston ring end gaps
a b c Top ring, oil ring expander spacer 2nd ring, lower oil ring rail Upper oil ring rail Exhaust side
45
a
4. Lubricate: Piston Piston rings Cylinder (with the recommended lubricant) Recommended lubricant: Engine oil
5. Lubricate: Bolt threads Nut seats (with the recommended lubricant) Recommended lubricant: Molybdenum disulfide grease
6. Lubricate: Crankshaft pins Big end bearings (with the recommended lubricant) Recommended lubricant: Engine oil
5-90
POWR

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. Be sure to reinstall each big end bearing in its original place. While compressing the piston rings with piston ring compressor 2, install the connecting rod assembly into the cylinder with the other hand. Make sure the Y marks a on the connecting rods face towards the front side of the crankshaft. Make sure the characters b on both the connecting rod and connecting rod cap are aligned. Piston ring compressor: YM-08037/90890-05158 8. Align: Bolt heads (with the connecting rod)
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POWR

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. Tightening steps: Tighten the connecting rod nuts to the specified torque. Connecting rod nut: 1st: 20 N m (2.0 kgf m, 14 ft lb)
Tighten the connecting rod nuts further to reach the specified angle 120. Connecting rod nut: Final: Specified angle 120 5
When the nuts are tightened more than the specified angle, do not loosen the nut and then retighten it. Replace the bolt and nut with a new one and perform the procedure again.
CAUTION:
Do not use a torque wrench to tighten the nut to the specified angle. Tighten the nut until it is at the specified angle. NOTE: When using a hexagonal nut, note that the angle from one corner to another is 60.
T.
R.
T.
R.
WARNING
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POWR
CRANKSHAFT
CRANKSHAFT
EXPLODED DIAGRAM
3 3 1
2
E

Step Procedure/Part name CRANKSHAFT REMOVAL Crankcase Connecting rod caps 1 2 3 Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing 1 5 5 Reverse the removal steps for installation. Qty Service points Follow the left Step for removal. Separate Refer to CRANKCASE. Refer to CONNECTING RODS AND PISTONS.
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POWR
1
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 original place.
Crankshaft inspection 1. Measure: Crankshaft runout Out of specification Replace the crankshaft. Maximum crankshaft runout: 0.03 mm (0.0012 in)
2. Check: Crankshaft journal surfaces Crankshaft pin surfaces Scratches/wear Replace the crankshaft. Bearing surfaces Scratches/wear Replace the crankshaft journal bearing. 3. Measure: Crankshaft journal oil clearance Out of specification Replace the crankshaft journal bearings. Crankshaft journal oil clearance: 0.0040.028 mm (0.00020.0011 in)
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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. Place the upper crankcase upside down on a bench. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crankcase. NOTE: Align the projections a of the crankshaft journal upper bearings with the notches b in the upper crankcase.
a b
Put a piece of Plastigauge 2 on each crankshaft journal. NOTE: Do not put the Plastigauge over the oil hole in the crankshaft journal. Install the crankshaft journal lower bearings into the lower crankcase and assemble the crankcase halves. NOTE: Align the projections a of the crankshaft journal lower bearings with the notches b in the lower crankcase. Do not move the crankshaft until the clearance measurement has been completed.
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POWR
CRANKSHAFT
Tighten the bolts to specification in the order of the numbers on the crankcase. Refer to 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.
4. Select: Crankshaft journal bearings (J1J5) NOTE: The numbers stamped into the crankshaft web and the numbers stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. J1J5 refer to the bearings shown in the crankshaft illustration. If J1J5 are the same, use the same size for all of the bearings. For example, if the crankcase J1 and crankshaft web J1 numbers are 8 and 2 respectively, then the bearing size for J1 is:
J5 J4 J3 J2 J1
J1
J2
J3
J4
J5
Bearing size of J1: J1 (crankcase) J1 (crankshaft web) 1 8 2 1 = 5 (Red/black) BEARING COLOR CODE 3 4 5 6 7 Red/red Red/brown Red/black Red/blue Red/green
J1 J2 J3 J4 J5
5-96
POWR
CRANKSHAFT
Crankshaft installation 1. Install: Crankshaft journal upper bearings (into the upper crankcase) Crankshaft journal lower bearings (into the lower crankcase)
a b
NOTE: Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase. Be sure to install each crankshaft journal bearing in its original place.
2. Lubricate: Crankshaft journals Crankshaft journal bearings (with the recommended lubricant) Recommended lubricant: Engine oil
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POWR
COOLING WATER HOSE
COOLING WATER HOSE

EXPLODED DIAGRAM
a 3 4 1 5
2 7 3
3 4 1

Step Procedure/Part name COOLING WATER HOSE REMOVAL Exhaust manifold Clamp/cooling water hose Qty Service points Follow the left Step for removal. Refer to EXHAUST MANIFOLD. To cylinder block NOTE: To install the cooling water hose, align the white paint mark a water hose with the projection of the hose joint. To exhaust manifold
1/1
2 3
Clamp/cooling water hose Clamp/cooling water hose
1/1 2/1
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POWR
COOLING WATER HOSE
EXPLODED DIAGRAM
a 3 4 1 5
2 7 3
3 4 1
Step 4 5 6 7
Procedure/Part name Joint Clamp/cooling water hose Clamp/cooling water hose Joint
Qty 1 1/1 1/1 1
Service points To oil tank From transom plate Reverse the removal steps for installation.
5-99
JET 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 ................................................ 6-5 JET THRUST NOZZLE, IMPELLER DUCT, AND IMPELLER HOUSING 1 ................................................................................. 6-6 EXPLODED DIAGRAM .............................................................................6-6 REMOVAL AND INSTALLATION CHART ................................................ 6-6 IMPELLER DUCT AND DRIVE SHAFT .......................................................... 6-8 EXPLODED DIAGRAM .............................................................................6-8 REMOVAL AND INSTALLATION CHART ................................................ 6-8 SERVICE POINTS .................................................................................. 6-10 Drive shaft removal ...........................................................................6-10 Impeller inspection ............................................................................6-11 Drive shaft inspection........................................................................6-11 Drive shaft installation ....................................................................... 6-12 TRANSOM PLATE AND HOSES.................................................................. 6-15 EXPLODED DIAGRAM ...........................................................................6-15 REMOVAL AND INSTALLATION CHART .............................................. 6-15 SERVICE POINTS .................................................................................. 6-17 Bilge strainer inspection .................................................................... 6-17 Bilge hose inspection ........................................................................6-17 Cooling water hose inspection .......................................................... 6-17 BEARING HOUSING.....................................................................................6-18 EXPLODED DIAGRAM ...........................................................................6-18 REMOVAL AND INSTALLATION CHART .............................................. 6-18 SERVICE POINTS .................................................................................. 6-21 Driven coupling removal and installation...........................................6-21 Intermediate drive shaft removal.......................................................6-21 Bearing removal ................................................................................ 6-22 Bearing and intermediate drive shaft inspection ...............................6-22 Driven coupling inspection ................................................................6-22 Bearing and oil seals installation.......................................................6-23 Intermediate drive shaft installation...................................................6-24
1 2 3 4 5 6 7 8 9
JET PUMP
INTAKE GRATE AND RIDE PLATE

EXPLODED DIAGRAM

Step Procedure/Part name INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT REMOVAL Bolt Bolt Intake grate Screw Speed sensor Qty Service points Follow the left Step for removal.
1 2 3 4 5
2 2 1 4 1
NOTE: Route the speed sensor lead between the jet pump unit and the bilge hose.
6-1
JET PUMP
EXPLODED DIAGRAM
Step 6 7
Procedure/Part name Bolt Ride plate
Qty 4 1
Service points
6-2
JET PUMP
JET PUMP UNIT
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 m (1.7 kgf m, 12 ft Ib) 8 18 mm
11 6 7 8 9
6.8 N m (0.68 kgf m, 4.9 ft Ib)
4
LT
242
13
LT
2.2 N m (0.22 kgf m, 1.6 ft Ib)
5 2 3
A
271
40 N m (4.0 kgf m, 29 ft Ib) 10 45 mm

LT
15 14 1 12
572
16
LT
1104J
6.8 N m (0.68 kgf m, 4.9 ft Ib) 6 25 mm
10
572
7.8 N m (0.78 kgf m, 5.6 ft Ib) 6 30 mm

Step 1 2 3 4 5 6 7 8 Procedure/Part name JET PUMP UNIT REMOVAL Shift cable joint Bilge hose Nut/washer Steering cable joint Hose clamp/spout hose Bolt Collar Nut Qty 1 1 1/2 1 1/1 4 4 2 Service points Follow the left Step for removal. Deluxe model only
6-3
JET 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 m (1.7 kgf m, 12 ft Ib) 8 18 mm
11 6 7 8 9
6.8 N m (0.68 kgf m, 4.9 ft Ib)
4
LT
242
13
LT
2.2 N m (0.22 kgf m, 1.6 ft Ib)
5 2 3
A
271
40 N m (4.0 kgf m, 29 ft Ib) 10 45 mm

LT
15 14 1 12
572
16
LT
1104J
6.8 N m (0.68 kgf m, 4.9 ft Ib) 6 25 mm
10
572
7.8 N m (0.78 kgf m, 5.6 ft Ib) 6 30 mm
Step 9 10 11 12 13 14 15 16
Procedure/Part name Collar Bolt Rubber plate Bolt Bolt Bolt Jet pump unit assembly Dowel pin
Qty 2 2 2 1 2 4 1 2
Service points
6-4
JET PUMP
REVERSE GATE (DELUXE MODEL ONLY)
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)
LT
3
6 35 mm
LT
271
242
7 2 3
2 6
5 9
A
LT
271
LT
4
15 N m (1.5 kgf m, 11 ft Ib) 8 20 mm
242
15 N m (1.5 kgf m, 11 ft Ib) 8 20 mm

Step 1 2 3 4 5 6 7 8 9 Procedure/Part name REVERSE GATE REMOVAL Hose clamp/spout hose Bolt Collar Reverse gate Spring Nut Washer Bolt Collar Qty 1/1 2 2 1 1 1 1 1 1 Reverse the removal steps for installation. Service points Follow the left Step for removal.
6-5
JET PUMP
JET THRUST NOZZLE, IMPELLER DUCT, AND IMPELLER HOUSING 1

EXPLODED DIAGRAM
40 N m (4.0 kgf m, 29 ft Ib) 10 125 mm
15 N m (1.5 kgf m, 11 ft Ib) 8 20 mm
5 1 4
LT LT
271 A
3 2 4
572
1104J
1104J
LT
572
40 N m (4.0 kgf m, 29 ft Ib) 10 125 mm
10 14 9 13 12 8 11
LT
572
6.6 N m (0.66 kgf m, 4.8 ft Ib) 6 35 mm

Step Procedure/Part name JET THRUST NOZZLE, IMPELLER DUCT, AND IMPELLER HOUSING 1 REMOVAL Bolt Collar Jet thrust nozzle Bolt Bracket Nozzle Impeller duct assembly Impeller housing 1 Pin Qty Service points Follow the left Step for removal.
1 2 3 4 5 6 7 8 9
2 2 1 4 1 1 1 1 2
6-6
NOTE: Clean the contacting surfaces before applying the sealant.
JET PUMP
EXPLODED DIAGRAM
40 N m (4.0 kgf m, 29 ft Ib) 10 125 mm
15 N m (1.5 kgf m, 11 ft Ib) 8 20 mm
5 1 4
LT LT
271 A
3 2 4
572
1104J
1104J
LT
572
40 N m (4.0 kgf m, 29 ft Ib) 10 125 mm
10 14 9 13 12 8 11
LT
572
6.6 N m (0.66 kgf m, 4.8 ft Ib) 6 35 mm
Step 10 11 12 13 14
Procedure/Part name Bolt Water inlet cover Packing Water inlet strainer Packing
Qty 4 1 1 1 1
Service points
6-7
JET PUMP
IMPELLER DUCT AND DRIVE SHAFT

EXPLODED DIAGRAM

Step Procedure/Part name IMPELLER DUCT AND DRIVE SHAFT DISASSEMBLY Bolt Cap O-ring Cap Impeller Drive shaft Oil seal Qty Service points Follow the left Step for disassembly.
1 2 3 4 5 6 7
3 1 1 1 1 1 1
Not reusable
Not reusable
*1: EPNOC grease AP #0
6-8
JET PUMP
EXPLODED DIAGRAM
Step 8 9 10 11 12
Procedure/Part name Oil seal Rear bearing Spacer Front bearing Impeller duct
Qty 1 1 1 1 1
Service points Not reusable Not reusable Not reusable Reverse the disassembly steps for assembly.
*1: EPNOC grease AP #0
6-9
JET 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
a
2. Remove: Drive shaft 1 NOTE: Remove the drive shaft using a press.
3. Remove: Rear bearing Slide hammer and adapters: YB-06096 Stopper guide plate: 90890-06501 Bearing puller assembly: 90890-06535 Stopper guide stand: 90890-06538
6-10
JET PUMP

4. Remove: Oil seals
NOTE: Remove the oil seals using a flat head screwdriver.
5. Remove: Front bearing Driver handlelarge: YB-06071 Driver rod L3: 90890-06652 Bearing housing needle bearing remover: YB-06112 Needle bearing attachment: 90890-06614 NOTE: Remove the front bearing using a press.
Impeller inspection Refer to JET PUMP UNIT in Chapter 3. Drive shaft inspection 1. Inspect: Drive shaft Damage/wear Replace.
6-11
JET PUMP

Drive shaft installation 1. Install: Oil seals Driver handlelarge: YB-06071 Driver rod LS: 90890-06606 Outer race installerforward gear: YB-06085 Ball bearing attachment: 90890-06634 Distance a: 4.6 0.2 mm (0.18 0.01 in)
2. Install: Rear bearing NOTE: Install the rear bearing onto the drive shaft using a press. Press the rear bearing using a pipe that is more than 140 mm (5.51 in) long and that has an inner diameter of 26 mm (1.02 in). 3. Install: Spacer 4. Add: EPNOC grease AP #0 (between the drive shaft and spacer) Quantity: 20 g (0.7 oz)
6-12
JET 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).
6. Install: Drive shaft (with front bearing spacer and rear bearing) Distance a: 11.7 0.2 mm (0.46 0.01 in) NOTE: Press the rear bearing using a washer or pipe that has an outer diameter of 50 mm (1.97 in) and an inner diameter of 33 mm (1.30 in).
7. Add: EPNOC grease AP #0 (into the cap) Quantity: 20 g (0.7 oz)
6-13
JET 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
T.
R.
6-14
JET PUMP
TRANSOM PLATE AND HOSES

EXPLODED DIAGRAM

Step Procedure/Part name TRANSOM PLATE AND HOSES REMOVAL Exhaust system Jet pump unit assembly Hose clamp Cooling water hose Bilge hose 1 Hose clamp Cooling water hose Qty Service points Follow the left Step for removal. Refer to EXHAUST SYSTEM in Chapter 8. Refer to JET PUMP UNIT. 2 1 1 1 1 Cooling water outlet (cylinder head)
1 2 3 4 5
Cooling water inlet
6-15
JET PUMP
EXPLODED DIAGRAM
Step 6 7 8 9 10
Procedure/Part name Bilge strainer Nut/washer Nut/washer Transom plate Bilge hose 2
Qty 1 2/2 2/2 1 1
Service points
6-16
JET 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
JET PUMP
BEARING HOUSING
BEARING HOUSING
EXPLODED DIAGRAM
17 N m (1.7 kgf m, 12 ft Ib) 8 48 mm
6 4
LT
271
5
4.2 N m (0.42 kgf m, 3.0 ft Ib)

Step Procedure/Part name BEARING HOUSING REMOVAL Engine unit Rubber coupling Bolt Intermediate housing cover Clamp Intermediate drive shaft assembly Rubber hose Qty Service points Follow the left Step for removal. Refer to ENGINE UNIT in Chapter 5.
1 2 3 4 5 6
1 4 1 2 1 1 Reverse the removal steps for installation.
6-18
JET PUMP
BEARING HOUSING
EXPLODED DIAGRAM

Step Procedure/Part name BEARING HOUSING DISASSEMBLY Driven coupling Washer Damper Intermediate drive shaft Circlip Qty Service points Follow the left Step for disassembly.
1 2 3 4 5
1 1 1 1 1
Not reusable
6-19
JET PUMP
BEARING HOUSING
EXPLODED DIAGRAM
Step 6 7 8 9 10
Procedure/Part name Oil seal Bearing Oil seal Oil seal Bearing housing
Qty 1 1 1 1 1
Service points Not reusable Not reusable Not reusable Not reusable Reverse the disassembly steps for assembly.
6-20
JET PUMP
BEARING HOUSING
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. Check that the drive shaft holder and intermediate drive shaft are properly engaged.
Intermediate drive shaft removal 1. Remove: Intermediate drive shaft NOTE: Remove the intermediate drive shaft using a press.
6-21
JET PUMP
BEARING HOUSING
Bearing removal 1. Remove: Circlip Bearing Oil seals
Driver handlelarge: YB-06071 Driver rod LS: 90890-06606 Roller bearing installer/remover: YB-06432 Bearing outer race attachment: 90890-06628
NOTE: Remove the bearing and oil seals using a press.
Bearing and intermediate drive shaft inspection 1. Inspect: Bearing Rotate the inner race by hand. Damage/rough movement Replace. Intermediate drive shaft Damage/pitting Replace.
Driven coupling inspection 1. Inspect: Driven coupling Driven coupling damper Damage/wear Replace.
6-22
JET PUMP
BEARING HOUSING
Bearing and oil seals installation 1. Install: Oil seals Bearing
a
NOTE: Install the bearing using a press. Driver handlelarge: YB-06071 Driver rod LS: 90890-06606 Outer race installerforward gear: YB-06085 Ball bearing attachment: 90890-06631 Distance a: 14.2 0.2 mm (0.56 0.01 in)
2. Install: Oil seal
Driver handlelarge: YB-06071 Driver rod LS: 90890-06606 Outer race installerforward gear: YB-06085 Ball bearing attachment: 90890-06631 Distance a: 6.2 0.2 mm (0.24 0.01 in)
6-23
JET PUMP
BEARING HOUSING
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
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 ........................................................... 7-10 Peak voltage measurement ..............................................................7-10 Peak voltage adapter ........................................................................7-11 Test harness ....................................................................................7-11 IGNITION SYSTEM ....................................................................................... 7-12 WIRING DIAGRAM ................................................................................. 7-12 IGNITION SPARK ...................................................................................7-14 IGNITION SYSTEM PEAK VOLTAGE ....................................................7-15 BATTERY ................................................................................................7-17 FUSE ....................................................................................................... 7-17 SPARK PLUGS ....................................................................................... 7-17 IGNITION COIL ....................................................................................... 7-18 ENGINE STOP SWITCH.........................................................................7-18 ENGINE TEMPERATURE SENSOR ......................................................7-19 SENSOR ASSEMBLY ............................................................................. 7-19 THERMOSWITCH (ENGINE).................................................................. 7-20 THERMOSWITCH (EXHAUST) ..............................................................7-21 MAIN AND FUEL PUMP RELAY............................................................. 7-22 ELECTRONIC CONTROL THROTTLE VALVE RELAY ......................... 7-23 THROTTLE POSITION SENSOR ........................................................... 7-24 ACCELERATOR POSITION SENSOR ...................................................7-26 CAM POSITION SENSOR ...................................................................... 7-29 SLANT DETECTION SWITCH ................................................................7-30
1 2 3 4 5 6 7 8 9
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 ................................................................7-34 REMOTE CONTROL UNIT (DELUXE MODEL ONLY)........................... 7-34 THROTTLE POSITION SENSOR ........................................................... 7-34 ACCELERATOR POSITION SENSOR ...................................................7-34 STARTING SYSTEM .....................................................................................7-35 WIRING DIAGRAM ................................................................................. 7-35 BATTERY ................................................................................................7-37 WIRING CONNECTIONS........................................................................7-37 FUSES..................................................................................................... 7-37 START SWITCH......................................................................................7-37 STARTER RELAY ...................................................................................7-38 REMOTE CONTROL UNIT (DELUXE MODEL ONLY)........................... 7-38 THROTTLE POSITION SENSOR ........................................................... 7-38 ACCELERATOR POSITION SENSOR ...................................................7-38 STARTER MOTOR........................................................................................ 7-39 EXPLODED DIAGRAM ...........................................................................7-39 REMOVAL AND INSTALLATION CHART ............................................. 7-39 SERVICE POINTS .................................................................................. 7-42 Armature inspection ..........................................................................7-42 Brush holder inspection..................................................................... 7-43 Starter motor front cover inspection .................................................. 7-43 CHARGING SYSTEM....................................................................................7-44 WIRING DIAGRAM ................................................................................. 7-44 FUSE ....................................................................................................... 7-45 BATTERY ................................................................................................7-45 LIGHTING COIL ......................................................................................7-45 RECTIFIER/REGULATOR ...................................................................... 7-45 OFF THROTTLE STEERING SYSTEM......................................................... 7-46 WIRING DIAGRAM ................................................................................. 7-46 STEERING SENSOR .............................................................................. 7-48 ECM.........................................................................................................7-48 PICKUP COIL.......................................................................................... 7-48 THROTTLE POSITION SENSOR ........................................................... 7-48 ACCELERATOR POSITION SENSOR ...................................................7-48
ELEC
INDICATION SYSTEM .................................................................................. 7-49 WIRING DIAGRAM ................................................................................. 7-49 FUSE ....................................................................................................... 7-51 BATTERY ................................................................................................7-51 MAIN AND FUEL PUMP RELAY............................................................. 7-51 ECM.........................................................................................................7-51 ENGINE TEMPERATURE SENSOR ......................................................7-51 THERMOSWITCH (ENGINE).................................................................. 7-51 THERMOSWITCH (EXHAUST) ..............................................................7-51 REMOTE CONTROL UNIT (DELUXE MODEL ONLY)........................... 7-51 BUZZER .................................................................................................. 7-51 OIL PRESSURE SWITCH....................................................................... 7-52 MULTIFUNCTION METER...................................................................... 7-52 Multifunction meter............................................................................7-52 MULTIFUNCTION METER REMOVAL ...................................................7-52 Display function (Sport model only) .................................................. 7-53 Display function (Deluxe model only)................................................ 7-54 Speedometer display ........................................................................7-55 Tachometer display...........................................................................7-56 Hour meter display ............................................................................7-56 Voltage meter display........................................................................7-56 Low oil pressure warning indicator....................................................7-56 Fuel level meter display and fuel warning indicator .......................... 7-56 Overheat warning indicator ...............................................................7-57 Check engine warning indicator ........................................................ 7-57 Diagnostic display ............................................................................. 7-58 REMOTE CONTROL SYSTEM (DELUXE MODEL ONLY) .......................... 7-59 WIRING DIAGRAM ................................................................................. 7-59 REMOTE CONTROL SYSTEM...............................................................7-60 Yamaha Security System indicator ...................................................7-60 Low-rpm mode indicator.................................................................... 7-60 Checking the remote control transmitter ...........................................7-61 Transmitter registration ..................................................................... 7-63 Replacing of the transmitter battery .................................................. 7-64
ELEC
ELECTRICAL COMPONENTS
ELECTRICAL COMPONENTS
O N M L K J I H G F E D C B A 0
2 3 4 5 6 7
1 2 3 4 5 6 7 8 9 0
Thermoswitch (engine) Fuse box Slant detection switch Starter motor Engine temperature sensor Spark plugs and ignition coils Cam position sensor Battery Speed sensor Sensor assembly (intake air pressure and intake air temperature)
A B C D E F G H
Oil pressure switch Fuel injectors Thermoswitch (exhaust) Rectifier/regulator ECM Throttle body assembly Lighting coil and pickup coil Engine stop switch, engine shut-off switch, and start switch I Steering sensor J Buzzer
7-1
K L M N O
Accelerator position sensor Electric fuel pump Fuel sender Multifunction meter Remote control unit (Deluxe model only)
ELEC
FUSE BOX
FUSE BOX
EXPLODED DIAGRAM
6 25 mm
6 20 mm
15 N m (1.5 kgf m, 11 ft Ib)
17 N m (1.7 kgf m, 12 ft Ib)
15 35
36
31
31
A
7 8 9 10
7 8 11
32 35 35
A
12
(VENT) 33
34
18 1 21 22 28
16
17 N m (1.7 kgf m, 12 ft Ib) 6 10 mm
30 10 10 3 20
30 10 10 3 20
26 25
23 27
17 4 5
22
21 24
29 20 19 14 2 6 13 13 19 30
6 20 mm
27 27
6 8 mm
3.9 N m (0.39 kgf m, 2.8 ft Ib) 6 20 mm

Step 1 2 3 4 5 6 7 8 Procedure/Part name FUSE BOX REMOVAL Nut/washer Wiring harness Fuse box Fuse box cap Gasket Fuse Tapping screw Washer Qty 2/2 1 1 1 1 10 2 2 Service points Follow the left Step for removal. NOTE: Disconnect all couplers.
Not reusable
7-2
ELEC
FUSE BOX
EXPLODED DIAGRAM
6 25 mm
6 20 mm
15 N m (1.5 kgf m, 11 ft Ib)
17 N m (1.7 kgf m, 12 ft Ib)
15 35
36
31
31
A
7 8 9 10
7 8 11
32 35 35
A
12
(VENT) 33
34
18 1 21 22 28
16
17 N m (1.7 kgf m, 12 ft Ib) 6 10 mm
30 10 10 3 20
30 10 10 3 20
26 25
23 27
17 4 5
22
21 24
29 20 19 14 2 6 13 13 19 30
6 20 mm
27 27
6 8 mm
3.9 N m (0.39 kgf m, 2.8 ft Ib) 6 20 mm
Step 9 10 11 12 13 14 15 16 17 18 19
Procedure/Part name Bracket Rubber mount Main and fuel pump relay Electronic control throttle valve relay Tapping screw Slant detection switch Bolt Fuse box cover Nut Gasket Tapping screw
Qty 1 1 1 1 2 1 6 1 6 1 2
7-3
Service points
Not reusable
ELEC
FUSE BOX
EXPLODED DIAGRAM
6 25 mm
6 20 mm
15 N m (1.5 kgf m, 11 ft Ib)
17 N m (1.7 kgf m, 12 ft Ib)
15 35
36
31
31
A
7 8 9 10
7 8 11
32 35 35
A
12
(VENT) 33
34
18 1 21 22 28
16
17 N m (1.7 kgf m, 12 ft Ib) 6 10 mm
30 10 10 3 20
30 10 10 3 20
26 25
23 27
17 4 5
22
21 24
29 20 19 14 2 6 13 13 19 30
6 20 mm
27 27
6 8 mm
3.9 N m (0.39 kgf m, 2.8 ft Ib) 6 20 mm
Step 20 21 22 23 24 25 26 27 28 29
Procedure/Part name Plate Bolt Cover Positive battery lead Starter motor lead Starter relay Grommet Bolt Wiring harness Wiring harness
Qty 1 2 2 1 1 1 1 3 1 1
Service points
With white tape
Red Brown
7-4
ELEC
FUSE BOX
EXPLODED DIAGRAM
6 25 mm
6 20 mm
15 N m (1.5 kgf m, 11 ft Ib)
17 N m (1.7 kgf m, 12 ft Ib)
15 35
36
31
31
A
7 8 9 10
7 8 11
32 35 35
A
12
(VENT) 33
34
18 1 21 22 28
16
17 N m (1.7 kgf m, 12 ft Ib) 6 10 mm
30 10 10 3 20
30 10 10 3 20
26 25
23 27
17 4 5
22
21 24
29 20 19 14 2 6 13 13 19 30
6 20 mm
27 27
6 8 mm
3.9 N m (0.39 kgf m, 2.8 ft Ib) 6 20 mm
Step 30 31 32 33 34 35 36
Procedure/Part name Wiring harness Holder Pipe Battery Battery box Nut Holder
Qty 1 2 1 1 1 4 1
Service points Black
7-5
ELEC
FUSE BOX
1 2 3 4 5 6
Positive battery lead Starter motor lead (white tape) Starter relay Wiring harness (black) Wiring harness (brown) Wiring harness (red)
7-6
ELEC
ECM AND RECTIFIER/REGULATOR

EXPLODED DIAGRAM
1st
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 30 mm
11 10 8
LT
242
LT
8 10 4
LT
242
11
7 5 9
572
LT
572
2
4.0 N m (0.4 kgf m, 2.9 ft Ib) 6 30 mm
LT
572

Step Procedure/Part name ECM AND RECTIFIER/ REGULATOR REMOVAL Wiring harness Bolt Rectifier/regulator Bolt ECM Grommet Collar Qty Service points Follow the left Step for removal. NOTE: Disconnect all couplers.
1 2 3 4 5 6 7
1 2 1 4 1 4 4
7-7
ELEC
EXPLODED DIAGRAM
1st
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 30 mm
11 10 8
LT
242
LT
8 10 4
LT
242
11
7 5 9
572
LT
572
2
4.0 N m (0.4 kgf m, 2.9 ft Ib) 6 30 mm
LT
572
Step 8 9 10 11
Procedure/Part name Bolt Bracket Grommet Collar
Qty 2 1 2 2
Service points
7-8
ELEC
ELECTRICAL ANALYSIS ELECTRICAL ANALYSIS

INSPECTION
CAUTION:
All measuring instruments should be handled with special care. Damaged or mishandled instruments will not measure properly. On an instrument powered by dry batteries, check the batterys voltage periodically and replace the batteries if necessary.
Digital tester NOTE: Throughout this chapter the part numbers of the specified digital testers have been omitted. Refer to the following part numbers. Digital multimeter: YU-34899-A Digital circuit tester: 90890-03174 NOTE: indicates a continuity of electricity; i.e., a closed circuit at the respective switch position.
7-9
ELEC
ELECTRICAL ANALYSIS
Low resistance measurement
NOTE: When measuring a resistance of 10 or less using a digital tester, the correct measurement cannot be obtained because of the testers internal resistance. To obtain the correct value, subtract the internal resistance from the displayed measurement. The internal resistance of the tester can be 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 know the peak voltage. Cranking speed is dependant on many factors (e.g., fouled or weak spark plugs, a weak battery). If one of these is defective, the peak voltage will be lower than specification. If the peak voltage measurement is not within specification the engine will not operate properly. A low peak voltage will also cause components to prematurely wear.
7-10
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: YU-39991 Peak voltage adapter B: 90890-03172 When measuring the peak voltage, connect the peak voltage adapter to the digital circuit tester and switch the selector to the DC voltage mode. NOTE: Make sure that the adapter leads are properly installed in the digital 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.
Voltage measurement Peak voltage measurement
Test harness Checking steps: Disconnect the coupler connections. Connect the test harness between the couplers. Connect the tester terminals to the terminals which are being checked. Run the engine and observe the measurement. NOTE: If the lighting coil and pickup coil(s) are measured unloaded, disconnect the test harness on the output side coupler.
7-11
ELEC
IGNITION SYSTEM
IGNITION SYSTEM
WIRING DIAGRAM
Q P
B FREE PUSH
W FREE PUSH
Br
B R B
W B
Br FREE PUSH Br
Br Br
Br
Br R W B
R
20A
3 2
30A
3A
G G G
Br R G
W B/O
R L Br Y
10A
W B
W/B B/O L/R Y/G R R/Y
10A
4 5 6
B Br
RR
7
B Br
N M
B/R P/R B/W P/W O B/O W
8 9
L/B B/O
R Y/W R/Y
B/O P/R P/W O L G
L/B B/O
R/Y O Y
B/O
R/Y B/R R/Y B/W R/Y B/Y R/Y B/G
R B G
A A A A
R/Y G/O B/O
G/O L/B W R/Y W/B Y Y/G O
O G/O B/O
B B B B C
R/Y
W B/R B/W P/W R/Y B/O P/R B O L
R/Y B/O
B/Y B/Y
D
P B
P B
E F G
P B B/G B/Y P B W G P/W Y/W L/R B/R B/W
P B
P/W
B R L W Y B W
H I
L Throttle body assembly M Accelerator position sensor N Pickup coil O Lighting coil P Start switch Q Engine stop switch R Engine shut-off switch
1 2 3 4 5 6 7 8
Battery Fuse (30 A) Fuse (20 A) Fuse (3 A) Fuse (10 A) Fuse (10 A) Starter relay Main and fuel pump relay
9 Electronic control throttle valve relay 0 Slant detection switch A Ignition coil B Spark plug C Cam position sensor D Engine temperature sensor E Thermoswitch (engine)
F Thermoswitch (exhaust) G Oil pressure switch H Remote control unit (Deluxe model only) I Antenna (Deluxe model only) J ECM K Rectifier/regulator
7-12
ELEC
IGNITION SYSTEM
WIRING DIAGRAM
Q P
B FREE PUSH
W FREE PUSH
Br
B R B
W B
Br FREE PUSH Br
Br Br
Br
Br R W B
R
20A
3 2
30A
3A
G G G
Br R G
W B/O
R L Br Y
10A
W B
W/B B/O L/R Y/G R R/Y
10A
4 5 6
B Br
RR
7
B Br
N M
8 9
L/B B/O
R Y/W R/Y
B/O P/R P/W O L G
L/B B/O
R/Y O Y
B/O
R/Y B/R R/Y B/W R/Y B/Y R/Y B/G
R B G
A A A A
R/Y G/O B/O
G/O L/B W R/Y W/B Y Y/G O
O G/O B/O
B B B B C
R/Y
W B/R B/W P/W R/Y B/O P/R B O L
R/Y B/O
B/Y B/Y
D
P B
P B
E F G
P B B/G B/Y P B W G P/W Y/W L/R B/R B/W
P B
P/W
B R L W Y B W
H I
B Br G L O P R W Y
: Black : Brown : Green : Blue : Orange : Pink : Red : White : Yellow
B/G B/O B/R B/W B/Y G/O L/B L/R P/R
: Black/green : Black/orange : Black/red : Black/white : Black/yellow : Green/orange : Blue/black : Blue/red : Pink/red

7-13
P/W R/Y W/B Y/G Y/W
: Pink/white : Red/yellow : White/black : Yellow/green : Yellow/white
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. When performing the spark gap check, keep flammable gas or liquids away, since this test can produce sparks.
OK
1. Check: Ignition spark Weak Check the ECM output peak voltage. Check the ignition coil for resistance. Checking steps: Connect the spark plug cap to the special service tool. Spark checker: YM-34487 Ignition tester: 90890-06754 Crank the engine and observe the ignition system spark through the discharge window.
7-14
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. If a good spark is obtained, the problem is not with the ignition 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. Test harness (2 pins): New: YB-06867 Current: YB-06767 Test harness FWY-2 (2 pins): New: 90890-06867 Current: 90890-06767 ECM output peak voltage: Black/red (B/R) Red/yellow (R/Y) Black/white (B/W) Red/yellow (R/Y) Black/yellow (B/Y) Red/yellow (R/Y) Black/green (B/G) Red/yellow (R/Y) r/min V Loaded Cranking 90 2,000 130 3,500 140
NOTE: When measuring the ECM output peak voltage while cranking the engine, disconnect the ignition coil couplers for all cylinders except for the cylinder being measured. To crank the engine, connect the engine shut-off cord (lanyard) to the engine shut-off switch, and then press the start switch.
7-15
ELEC
IGNITION SYSTEM
E 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) Black/orange (B/O) r/min V Unloaded Cranking 8.0 6.9 Loaded 2,000 19.4 3,500 25.1
NOTE: To crank the engine, connect the engine shutoff cord (lanyard) to the engine shut-off switch, and then press the start switch and engine stop switch simultaneously.
3. Measure: Lighting coil output peak voltage Below specification Replace the lighting coil. Test harness (3 pins): New: YB-06870 Current: YB-06770 Test harness SMT250-3 (3 pins): New: 90890-06870 Current: 90890-06770 Lighting coil output peak voltage: Green (G) Green (G) r/min V Unloaded Cranking 7.8 2,000 24.5 3,500 41.6
7-16
ELEC
IGNITION SYSTEM
E NOTE: To crank the engine, connect the engine shutoff 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 rectifier/regulator. Test harness (6 pins): YB-06848 Test harness FSW-6A (6 pins): 90890-06848 Rectifier/regulator output voltage: Red (R) Black (B) r/min V Unloaded 3,500 13.0
NOTE: Do not use the peak voltage adapter to measure the output voltage. Disconnect the output lead of the tester harness.
BATTERY
Refer to ELECTRICAL in Chapter 3.
FUSE
Refer to STARTING SYSTEM.
SPARK PLUGS
Refer to POWER UNIT in Chapter 3.
7-17
ELEC
IGNITION SYSTEM
IGNITION COIL
1. Measure: Primary coil resistance Out of specification Replace. Primary coil resistance: 1.191.61 at 20 C (68 F)
NOTE: When measuring a resistance of 10 or less using a digital tester, the correct measurement cannot be obtained because of the testers internal resistance. Refer to Low resistance measurement.
2. Measure: Secondary coil resistance Out of specification Replace. Secondary coil resistance: 8.511.5 k at 20 C (68 F)
ENGINE STOP SWITCH

1. Check: Engine stop switch continuity Out of specification Replace. Engine stop switch continuity (black coupler) Clip Installed Removed Position Free Push Free Push Lead color White Black
7-18
ELEC
IGNITION SYSTEM
ENGINE TEMPERATURE SENSOR
1. Measure: Engine temperature sensor resistance (at the specified temperature) Out of specification Replace. Engine temperature sensor resistance: 20 C (68 F): 54.269.0 k 100 C (212 F): 3.123.48 k Measurement steps: Suspend the engine temperature sensor in a container filled with water. Place a thermometer in the water. Slowly heat the water. Measure the resistance when the specified temperature is reached.
SENSOR ASSEMBLY
1. Check: Intake air temperature sensor Out of specification Replace the sensor assembly. 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 displayed intake air temperature differ by more than 5 C ( 9 F), replace the sensor assembly.
7-19
ELEC
IGNITION SYSTEM
THERMOSWITCH (ENGINE)
1. Check: Thermoswitch (engine) continuity (at the specified temperature) Out of specification Replace.
Thermoswitch (engine) continuity temperature: a 8490 C (183194 F) b 7084 C (158183 F)

1 No continuity 2 Continuity Temperature Time
Checking steps: Suspend the thermoswitch (engine) in a container filled with water. Place a thermometer in the water. Slowly heat the water. Measure the continuity when the specified temperature is reached. NOTE: The thermoswitch (engine) connector is blue.
7-20
ELEC
IGNITION SYSTEM
THERMOSWITCH (EXHAUST)
1. Check: Thermoswitch (exhaust) continuity (at the specified temperature) Out of specification Replace. Thermoswitch (exhaust) continuity temperature: a 8086 C (176187 F) b 6680 C (151176 F)
1 No continuity 2 Continuity Temperature Time
Checking steps: Suspend the thermoswitch (exhaust) in a container filled with water. Place a thermometer in the water. Slowly heat the water. Measure the continuity when the specified temperature is reached. NOTE: The thermoswitch (exhaust) connector is black.
7-21
ELEC
IGNITION SYSTEM
MAIN AND FUEL PUMP RELAY
1. Check: Main and fuel pump relay continuity Faulty Replace.
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
Checking steps: Connect the tester leads to the main and fuel pump relay terminals 5 and 6 or 7. Connect terminals 2 or 3 to the positive battery terminal. Connect terminal 1 to the negative battery terminal. Check that there is continuity between the main and fuel pump relay terminals. Check that there is no continuity between the main and fuel pump relay terminals after disconnecting terminals 1, 2, or 3. Connect the tester leads between main and fuel pump relay terminals 7 and 8. Connect terminals 4 to the positive battery terminal. Connect terminal 6 to the negative battery terminal. Check that there is continuity between the main and fuel pump relay terminals. Check that there is no continuity between the main and fuel pump relay terminals after disconnecting terminals 4 or 6.
7-22
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. Connect terminals 2 or 3 to the positive battery terminal. Connect terminal 1 to the negative battery terminal. Check that there is continuity between the electronic control throttle valve relay terminals. Check that there is no continuity between the electronic control throttle valve relay terminals after disconnecting terminals 1, 2, or 3.
6 5 4 3 2 1
7-23
ELEC
IGNITION SYSTEM
THROTTLE POSITION SENSOR
1. Measure: Throttle position sensor output voltage Out of specification Replace the throttle body assembly. Checking steps:
CAUTION:
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 output voltage, throttle valve opening angle, and throttle position sensor 2 output voltage. Release the throttle lever to the fully closed position. Check the output voltage of throttle position sensor 1 and the throttle valve opening angle.
1 2 Throttle position sensor 1 Throttle position sensor 2 Throttle position sensor output voltage Throttle valve opening angle Fully closed Fully open
NOTE: The actual throttle position sensor output voltage and throttle valve opening angle may vary according to environmental conditions.
4.65 0.05 V (4.5 V)
2
2 0.1 V
Throttle position sensor 1 output voltage with throttle lever fully closed: 0.450.95 V (reference data) Throttle valve opening angle with throttle lever fully closed: 1.19.4 (reference data)
0.5 0.05 V (10)
7-24
ELEC
IGNITION SYSTEM
Squeeze the throttle lever to the fully open position and hold it. Check the output voltage of throttle position sensor 2 and the throttle valve opening angle. Throttle position sensor 2 output voltage with throttle lever fully open: 4.604.70 V Throttle valve opening angle with throttle lever fully open: above 80 (reference data) Release the throttle lever from the fully open position to the fully closed position slowly and check the output voltage of throttle position sensor 2 and the throttle valve opening angle. Hold the throttle lever when the output voltage of throttle position sensor 2 is below 4.5 V and the throttle valve opening angle is above 10. Calculate the difference of the output voltage of throttle position sensor 1 and the output voltage of throttle position sensor 2. Throttle position sensor 2 output voltage throttle position sensor 1 output voltage = 1.92.1 V Example: If the output voltage of throttle position sensor 1 is 2.5 V and the output voltage of throttle position sensor 2 is 4.5 V, then 4.5 2.5 = 2.0 V Operate the throttle lever and check that the output voltage of throttle position sensors 1 and 2 changes continuously. NOTE: The maximum output voltage of throttle position sensor 2 is 4.65 0.05 V at the half open position.
7-25
ELEC
IGNITION SYSTEM
ACCELERATOR POSITION SENSOR

1. Measure: Accelerator position sensor output voltage 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. Check that the accelerator position sensor 1 and 2 output voltage. NOTE: The actual accelerator position sensor output voltage and throttle valve opening angle may vary according to environmental conditions. Accelerator position sensor 1 output voltage at throttle lever fully closed position: 0.500.90 V Accelerator position sensor 2 output voltage at throttle lever fully closed position: 0.351.05 V Throttle valve opening angle at throttle lever fully closed position: 2.74.8 Squeeze the throttle lever to the fully open position and hold it. Check that the accelerator position sensor 1 and 2 output voltage.
7-26
ELEC
IGNITION SYSTEM
Accelerator position sensor 1 output voltage at throttle lever fully opened position: 3.754.35 V Accelerator position sensor 2 output voltage at throttle lever fully opened position: 3.504.50 V Throttle valve opening angle at throttle lever fully opened position: above 61
Calculate the difference of the accelerator position sensor 1 output voltage and accelerator position sensor 2 output voltage at fully opened position. Accelerator position sensor 1 output voltage Accelerator position sensor 2 output voltage at fully opened position = below 0.75 V Example: If accelerator position sensor 1 output voltage is 4.009 V and accelerator position sensor 2 output voltage is 3.896 V, then 4.009 3.896 = 0.113 V Operate the throttle lever, and check that the accelerator position sensor 1 and 2 output voltage changes continuously.
7-27
ELEC
IGNITION SYSTEM
E 2. Measure: Accelerator position sensor resistance Out of specification Replace the accelerator position sensor. Checking steps: Connect the tester leads accelerator position sensor terminals 1, 3. Measure the resistance when the fully closed position. Accelerator position sensor 1 resistance at fully closed position: 0.500.90 k Connect the tester leads accelerator position sensor terminals 6, 7. Measure the resistance when the fully closed position. Accelerator position sensor 2 resistance at fully closed position: 0.3510.50 k
1 23 45678
1 23 45678
Move the accelerator position cam to the fully opened position. Connect the tester leads accelerator position sensor terminals 1, 3. Measure the resistance when the fully opened position. Accelerator position sensor 1 resistance at fully opened position: 3.754.35 k Connect the tester leads accelerator position sensor terminals 6, 7. Measure the resistance when the fully opened position. Accelerator position sensor 2 resistance at fully opened position: 3.604.50 k Operate the accelerator cam, and check that the accelerator position sensor 1 and 2 resistance changes continuously.
7-28
ELEC
IGNITION SYSTEM
CAM POSITION SENSOR
1. Measure: Cam position sensor output voltage Out of specification Replace. Test harness (3 pins): New: YB-06877 Current: YB-06777 Test harness HM090-3 (3 pins): New: 90890-06877 Current: 90890-06777 Cam position sensor output voltage: Green/orange (G/O) Black/orange (B/O) Position A B C Voltage (V) More than 4.8 Less than 0.8 More than 4.8
A B C
Measurement steps: Remove the cam position sensor. Connect the test harness to the cam position sensor. Operate the Yamaha Diagnostic System. Pass a screwdriver under the cam position sensor in the direction shown and measure the output voltage. NOTE: The cam position sensor consists of two individual sensors as shown in the illustration: sensor 1 1 and sensor 2 2. 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 System, electric power is supplied to the cam position sensor.
7-29
ELEC
IGNITION SYSTEM
UP
SLANT DETECTION SWITCH

1. Check: Slant detection switch operation Out of specification Replace.
UP UP
NOTE: When checking the slant detection switch be sure to turn the switch over to both the left and right as shown in the illustration. Lead color Position Blue/black (L/B) Normal operation Overturned Black/ orange (B/O)
4.185.10 k
7-30
ELEC
FUEL CONTROL SYSTEM
FUEL CONTROL SYSTEM

WIRING DIAGRAM
1
R B W
B R B
J I
L B L B
P B
P B/G
K
R
R
20A
3 2
30A
3A
RR
10A
10A
4 5
W/B R/Y B B/R P/R O B/W P/W B/O W L L/R Y/G R R/Y
7 8
L/B B/O
R Y/W R/Y
B/O P/R P/W O L G
L/B B/O
R/Y O B/O
R/Y P
L/B W R/Y P/G Y/G O
P/G O B/O R/Y
0
B/Y B/Y
R/Y B/O
A
P B
P B
B C D
B/R B/W P/R P/W R/Y B/O B W/B O L
P B
P B
P/W
R/Y Pu/R
E E E E
B
Pu/R Pu/B P B G P/W Y/W L/R Pu/G Pu/Y
R/Y Pu/B
R/Y Pu/Y
R/Y Pu/G B
1 2 3 4 5 6 7 8
Battery Fuse (30 A) Fuse (20 A) Fuse (10 A) Fuse (10 A) Starter relay Main and fuel pump relay Electronic control throttle valve relay
9 Slant detection switch 0 Sensor assembly (intake air pressure and intake air temperature) A Engine temperature sensor B Thermoswitch (engine) C Thermoswitch (exhaust) D Oil pressure switch E Fuel injector
7-31
F G H I J K
ECM Throttle body assembly Accelerator position sensor Electric fuel pump Fuel sender Multifunction meter
ELEC
FUEL CONTROL SYSTEM
WIRING DIAGRAM
1
R B W
B R B
J I
L B L B
P B
P B/G
K
R
R
20A
3 2
30A
3A
RR
10A
10A
4 5
W/B R/Y B B/R P/R O B/W P/W B/O W L L/R Y/G R R/Y
7 8
L/B B/O
R Y/W R/Y
B/O P/R P/W O L G
L/B B/O
R/Y O B/O
R/Y P
L/B W R/Y P/G Y/G O
P/G O B/O R/Y
0
B/Y B/Y
R/Y B/O
A
P B
P B
B C D
B/R B/W P/R P/W R/Y B/O B W/B O L
P B
P B
P/W
R/Y Pu/R
E E E E
B
Pu/R Pu/B P B G P/W Y/W L/R Pu/G Pu/Y
R/Y Pu/B
R/Y Pu/Y
R/Y Pu/G B
B G L O P R W B/G B/O
: Black : Green : Blue : Orange : Pink : Red : White : Black/green : Black/orange
B/R B/W L/B L/R P/G P/R P/W Pu/B Pu/G
: Black/red : Black/white : Blue/black : Blue/red : Pink/green : Pink/red : Pink/white : Purple/black : Purple/green

7-32
Pu/R Pu/Y R/Y W/B Y/G Y/W
: Purple/red : Purple/yellow : Red/yellow : White/black : Yellow/green : Yellow/white
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 Replace. Float position A B Resistance () 133.5136.5 57
7-33
ELEC
FUEL CONTROL SYSTEM

FUEL INJECTOR
Refer to FUEL INJECTION SYSTEM in Chapter 4.

Refer to IGNITION SYSTEM.
OIL PRESSURE SWITCH

Refer to INDICATION SYSTEM.
SLANT DETECTION SWITCH

REMOTE CONTROL UNIT (DELUXE MODEL ONLY)

Refer to REMOTE CONTROL SYSTEM (DELUXE MODEL ONLY).


7-34
ELEC
STARTING SYSTEM
STARTING SYSTEM
WIRING DIAGRAM
I G
L B L B
B FREE PUSH
W FREE PUSH
Br
B R B
W B
Br FREE PUSH Br
Br
2
B R
20A
Br
Br
Br R W B
4 3
30A
3A
Br R
W B/O
R L Br Y
10A
10A
5 6 7
B Br
RR
8
B Br B
B/R P/R O B/W P/W B/O W
L L/R R Y/G R/Y R Y/W R/Y
9 0
B/O P/R P/W O L G R/Y O Y
B/O
O G/O B/O G/O W R/Y Y/G Y O
R/Y G/O B/O
W B/R B/W P/R P/W R/Y B/O B O L
B W G Y/W L/R
R Y L W B W
B C
H Start switch I Engine stop switch J Engine shut-off switch
1 2 3 4 5 6 7 8 9
Battery Starter motor Fuse (30 A) Fuse (20 A) Fuse (3 A) Fuse (10 A) Fuse (10 A) Starter relay Main and fuel pump relay
0 Electronic control throttle valve relay A Cam position sensor B Remote control unit C Antenna D ECM E Throttle body assembly F Accelerator position sensor G Electric fuel pump
7-35
ELEC
STARTING SYSTEM
WIRING DIAGRAM
I G
L B L B
B FREE PUSH
W FREE PUSH
Br
B R B
W B
Br FREE PUSH Br
Br
2
B R
20A
Br
Br
Br R W B
4 3
30A
3A
Br R
W B/O
R L Br Y
10A
10A
5 6 7
B Br
RR
8
B Br B
B/R P/R O B/W P/W B/O W
L L/R R Y/G R/Y R Y/W R/Y
9 0
B/O P/R P/W O L G R/Y O Y
B/O
O G/O B/O G/O W R/Y Y/G Y O
R/Y G/O B/O
W B/R B/W P/R P/W R/Y B/O B O L
B W G Y/W L/R
R Y L W B W
B C
B Br G L O R W Y B/O
: Black : Brown : Green : Blue : Orange : Red : White : Yellow : Black/orange

7-36
B/R B/W G/O L/R P/R P/W R/Y Y/G Y/W
: Black/red : Black/white : Green/orange : Blue/red : Pink/red : Pink/white : Red/yellow : Yellow/green : Yellow/white
ELEC
STARTING SYSTEM
BATTERY
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). The 10 A fuse is for the main and fuel pump relay and the electronic control throttle valve relay. The 20 A fuse is for main and fuel pump relay. The 30 A fuse is for the main relay.
START SWITCH
1. Check: Continuity Out of specification Replace. Start switch continuity (natural color coupler) Clip Installed Removed Position Free Push Free Push Leads Red Brown
7-37
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. Connect the brown lead terminal to the positive battery terminal. Connect the black lead terminal to the negative battery terminal. Check that there is continuity between the starter relay terminals. Check that there is no continuity after the brown or black lead is removed.
Br B



7-38
ELEC
STARTER MOTOR
STARTER MOTOR
EXPLODED DIAGRAM
11 7 5 3 1 19 18 16
A
6 14 17
15
9
8.8 N m (0.88 kgf m, 6.4 ft Ib)
13 20 4 2 10
6.4 N m (0.64 kgf m, 4.6 ft Ib) 5 114 mm
A
12

Step Procedure/Part name STARTER MOTOR DISASSEMBLY Starter motor O-ring Bolt Starter motor front cover O-ring Oil seal retainer Washer Shim Qty Service points Follow the left Step for disassembly. Refer to GENERATOR AND STARTER MOTOR in Chapter 5. Not reusable
1 2 3 4 5 6 7
1 2 1 1 1 1 *
Not reusable
t = 0.2 mm, 0.5 mm
*: As required
7-39
ELEC
STARTER MOTOR
EXPLODED DIAGRAM
11 7 5 3 1 19 18 16
A
6 14 17
15
9
8.8 N m (0.88 kgf m, 6.4 ft Ib)
13 20 4 2 10
6.4 N m (0.64 kgf m, 4.6 ft Ib) 5 114 mm
A
12
Step 8 9 10 11 12 13 14 15 16 17
Procedure/Part name Starter motor rear cover O-ring Shim Armature assembly Nut/spring washer/washer O-ring Brush holder Brush spring Bolt Brush assembly
Qty 1 1 * 1 1/1/4 1 1 4 1 1
Service points Not reusable t = 0.2 mm, 0.8 mm
Not reusable
*: As required
7-40
ELEC
STARTER MOTOR
EXPLODED DIAGRAM
11 7 5 3 1 19 18 16
A
6 14 17
15
9
8.8 N m (0.88 kgf m, 6.4 ft Ib)
13 20 4 2 10
6.4 N m (0.64 kgf m, 4.6 ft Ib) 5 114 mm
A
12
Step 18 19 20
Procedure/Part name Spacer Holder Starter motor yoke
Qty 1 1 1
Service points
7-41
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. Check: Commutator undercut Contaminants Clean. NOTE: Remove all mica and metal particles with compressed air.
5. Measure: Commutator undercut Below specification Replace. Commutator undercut: 0.7 mm (0.03 in) Limit: 0.2 mm (0.01 in)
7-42
ELEC
STARTER MOTOR
6. Inspect: Armature coil continuity Out of specification Replace. Armature coil continuity: Commutator segments 1 Segment - Laminations 2 Continuity
No continuity
Segment - Armature shaft No continuity
Brush holder inspection 1. Measure: Brush length a Below specification Replace. Brush length: 12.5 mm (0.49 in) Wear limit: 6.5 mm (0.26 in)
2. Check: Brush holder continuity Out of specification Replace. Brush holder continuity: Brush holder - Base No continuity
Starter motor front cover inspection 1. Inspect: Starter motor front cover oil seal Damage/wear Replace the starter motor front cover.
7-43
ELEC
CHARGING SYSTEM
CHARGING SYSTEM
WIRING DIAGRAM
5
G G G G G G
B
R
20A
2
30A
R R
3A
10A
10A
R B G G G
1 2 3 4 5
Battery Fuse (30 A) Fuse (20 A) Rectifier/regulator Lighting coil
B G R
: Black : Green : Red
7-44
ELEC
CHARGING SYSTEM
FUSE
BATTERY
LIGHTING COIL
RECTIFIER/REGULATOR
7-45
ELEC
OFF THROTTLE STEERING SYSTEM

WIRING DIAGRAM
B W/L O
B/O W/L O
B R B
2
20A
4 3
30A
R RR
3A
10A
R W B W/B B/O L/R R Y/G R/Y R Y/W R/Y

10A
5 6
D C
8 9
B/O P/R P/W O L G R/Y
B/O
W R/Y W/B W/L Y/G O R/Y
R/Y B/R B/W P/R P/W R/Y B/O B O L R/Y Pu/R Pu/R Pu/B B G Y/W L/R Pu/G Pu/Y
0 0 0 0
R/Y Pu/B
R/Y Pu/Y
R/Y Pu/G B
1 2 3 4 5 6 7 8 9
Battery Starter motor Fuse (30 A) Fuse (20 A) Fuse (10 A) Fuse (10 A) Starter relay Main and fuel pump relay Electronic control throttle valve relay
7-46
0 A B C D E
Fuel injector ECM Throttle body assembly Accelerator position sensor Pickup coil Steering sensor
ELEC
WIRING DIAGRAM
B W/L O
B/O W/L O
B R B
2
20A
4 3
30A
R RR
3A
10A
R W B W/B B/O L/R R Y/G R/Y R Y/W R/Y

10A
5 6
D C
8 9
B/O P/R P/W O L G R/Y
B/O
W R/Y W/B W/L Y/G O R/Y
R/Y B/R B/W P/R P/W R/Y B/O B O L R/Y Pu/R Pu/R Pu/B B G Y/W L/R Pu/G Pu/Y
0 0 0 0
R/Y Pu/B
R/Y Pu/Y
R/Y Pu/G B
B G L O R W B/O B/R B/W
: Black : Green : Blue : Orange : Red : White : Black/orange : Black/red : Black/white
L/R P/R P/W Pu/B Pu/G Pu/R Pu/Y R/Y W/B
: Blue/red : Pink/red : Pink/white : Purple/black : Purple/green : Purple/red : Purple/yellow : Red/yellow : White/black

7-47
W/L : White/blue Y/G : Yellow/green Y/W : Yellow/white
ELEC

STEERING SENSOR
1. Check: Steering sensor Malfunction Replace the steering sensor. Checking steps: Turn the handlebar all the way to the left or right, and then release it. Install a plastic tie 1 loosely around the center of the handlebar grip as shown. Hook a spring 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 10 kgf (22 lb). When handlebar pulled ON When handlebar not pulled OFF
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. Replace the steering sensor if it is a malfunction.
ECM
PICKUP COIL


7-48
ELEC
INDICATION SYSTEM
INDICATION SYSTEM
WIRING DIAGRAM
L
B P
M
B/Y Y R/Y
B R B
R
20A
3 2
30A
B/G P
B/Y Y R/W
N
L/R Gy L/B RB W R
3A
10A
10A
4 5 6
B Br
RR
7
B Br
R B
L/R B/L
L/R Y/G R R/Y L/R L/YL/B W/BR/Y B R
8 9
W B
W/B B/O
Y/W R/Y
J
B/O R/Y B/R R/Y B/W R/Y B/Y R/Y B/G
R/Y O Y
0 0 0 0
O G/O B/O
A A A A
R/Y G/O B/O
G/O W/B Y Y/G R/Y O R/Y B/O P B W B/Y B/Y P R/Y
C
P B P B
D F
R/Y B/O B W/B
P B P/W R/Y Pu/R
E
P
G
R/Y Pu/B
Pu/R Pu/B B/G B/Y P B P/W Y/W L/R G Pu/G Pu/Y B/R B/W
G G G
R/Y Pu/Y R/Y Pu/G
R W G Y B L/B L/Y B/L
1 2 3 4 5 6 7 8
Battery Fuse (30 A) Fuse (20 A) Fuse (3 A) Fuse (10 A) Fuse (10 A) Starter relay Main and fuel pump relay
9 Electronic control throttle valve relay 0 Ignition coil A Spark plug B Cam position sensor C Engine temperature sensor D Thermoswitch (engine) E Thermoswitch (exhaust) F Oil pressure switch
7-49
G Fuel injector H Remote control unit (Deluxe model only) I ECM J Pickup coil K Buzzer L Fuel sender M Speed sensor N Multifunction meter
ELEC
INDICATION SYSTEM
WIRING DIAGRAM
L
B P
M
B/Y Y R/Y
B R B
R
20A
3 2
30A
B/G P
B/Y Y R/W
N
L/R Gy L/B RB W R
3A
10A
10A
4 5 6
B Br
RR
7
B Br
R B
L/R B/L
L/R Y/G R R/Y L/R L/YL/B W/BR/Y B R
8 9
W B
W/B B/O
Y/W R/Y
J
B/O R/Y B/R R/Y B/W R/Y B/Y R/Y B/G
R/Y O Y
0 0 0 0
O G/O B/O
A A A A
R/Y G/O B/O
G/O W/B Y Y/G R/Y O R/Y B/O P B W B/Y B/Y P R/Y
C
P B P B
D F
R/Y B/O B W/B
P B P/W R/Y Pu/R
E
P
G
R/Y Pu/B
Pu/R Pu/B B/G B/Y P B P/W Y/W L/R G Pu/G Pu/Y B/R B/W
G G G
R/Y Pu/Y R/Y Pu/G
R W G Y B L/B L/Y B/L
B Br G Gy O P R W Y B/G
: Black : Brown : Green : Gray : Orange : Pink : Red : White : Yellow : Black/green
B/L B/O B/R B/W B/Y G/O L/B L/R L/Y P/W
: Black/blue : Black/orange : Black/red : Black/white : Black/yellow : Green/orange : Blue/black : Blue/red : Blue/yellow : Pink/white
7-50
Pu/B Pu/G Pu/R Pu/Y R/W R/Y W/B Y/G Y/W
: Purple/black : Purple/green : Purple/red : Purple/yellow : Red/white : Red/yellow : White/black : Yellow/green : Yellow/white
ELEC
INDICATION SYSTEM
FUSE
BATTERY

ECM
ENGINE TEMPERATURE SENSOR


BUZZER
1. Check: Buzzer Buzzer does not sound Replace. Checking steps: Connect the battery (12 V) to the buzzer coupler as shown. Battery positive terminal Red (R) terminal 1 Battery negative terminal Black (B) terminal 2
7-51
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/cm2, 18.6 psi) 167 kPa (1.67 kgf/cm2, 24.2 psi)
MULTIFUNCTION METER
Multifunction meter 1. Check: Multifunction meter Cracked meter housing Replace the multifunction meter. Meter is fogged/shows signs of water intrusion Replace the multifunction meter.
MULTIFUNCTION METER REMOVAL

Refer to ENGINE HATCH COVER in Chapter 8.
7-52
ELEC
INDICATION SYSTEM
E Display function (Sport model only) 1. Check: Display function Does not operate Replace the multifunction meter.
L/B L/B L/R L/R
B B R R R/W B/Y
B/Y R/W Y Y W R W B B R
P B/G
B/G
4
P
1 2 3 4
Buzzer Speed sensor ECM Fuel sender
B P R W Y
: Black : Pink : Red : White : Yellow
B/G B/Y L/B L/R R/W
: Black/green : Black/yellow : Blue/black : Blue/red : Red/white
7-53
ELEC
INDICATION SYSTEM
E Display function (Deluxe model only) 1. Check: Display function Does not operate Replace the multifunction meter.
L/Y L/B B/L
Gy L/B L/R L/R
B/L
B B R
2
B/Y
L/R
R R/W
B/Y R/W Y Y W R W B B R
P B/G
B/G
5
P
1 2 3 4 5
Remote control unit Buzzer Speed sensor ECM Fuel sender
B Gy P R W Y B/G
: Black : Gray : Pink : Red : White : Yellow : Black/green
B/L B/Y L/B L/R L/Y R/W
: Black/blue : Black/yellow : Blue/black : Blue/red : Blue/yellow : Red/white
7-54
ELEC
INDICATION SYSTEM
E 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 multifunction meter. Speed sensor output voltage (dependant on the paddle wheel position): Less than 400 mV/ More than 11.6 V Output pulse: 2 pulses/one-full turn Measurement steps: Apply DC 12 volts to the natural color three-pin connector (between the red/yellow and black/yellow leads). Rotate the paddle wheel by hand and measure the voltage between the black/ yellow and yellow leads. NOTE: As the paddle wheel is rotated, a squarewave voltage signal a is produced. Two pulses occur every time the paddle wheel makes one-full turn.
7-55
ELEC
INDICATION SYSTEM
E Tachometer display 1. Check: Tachometer display Does not display Check the engine speed using the Engine monitor of the Yamaha Diagnostic System. Replace the multifunction meter. Hour meter display 1. Check: Hour meter display Does not display Replace the multifunction meter. Voltage meter display 1. Check: Voltage meter display Does not display Check the battery voltage using the Engine monitor of the Yamaha Diagnostic System. Replace the multifunction meter. Low oil pressure warning indicator 1. Check: Low oil pressure warning indicator Does not come on Check the oil pressure switch using the Engine monitor of the Yamaha Diagnostic System. Replace the multifunction meter. Fuel level meter display and fuel warning indicator 1. Check: Fuel level meter display and fuel warning indicator Do not display Measure the fuel sender resistance. If the fuel sender resistance is within specification, replace the multifunction meter. 2. Measure: Fuel sender resistance Refer to FUEL CONTROL SYSTEM.
7-56
ELEC
INDICATION SYSTEM
E Overheat warning indicator 1. Check: Overheat warning indicator Does not come on Replace the multifunction meter.
2 1
Checking steps: Start the engine. Disconnect the thermoswitch (engine) connector 1 (blue), engine temperature sensor connector 2 (black), or thermoswitch (exhaust) 3 connector. Connect the jumper lead to the female terminal of the disconnected connector. Check that the multifunction meter overheat warning indicator blinks, then comes on. The buzzer also begins to sound intermittently, then sounds continuously.
Check engine warning indicator 1. Check: Check engine warning indicator Does not come on Replace the multifunction meter. Checking steps: Start the engine. Disconnect the coupler of a sensor (e.g., engine temperature sensor) that normally activates the check engine warning indicator when a malfunction occurs. Check that the warning light and check engine warning indicator begin to blink and the buzzer sounds intermittently.
7-57
ELEC
1
INDICATION SYSTEM
E Diagnostic display 1. Check: Diagnostic display Does not display Replace the multifunction meter. Checking steps: Start the engine. Disconnect the coupler of a sensor (e.g,. engine temperature sensor) that is normally displayed when a malfunction occurs. Refer to SELF-DIAGNOSIS in Chapter 9. Check that the check engine warning indicator comes on and that the buzzer sounds. Press the select switch 1 for 8 seconds and check the error code indicated on the multifunction meter.
7-58
ELEC
REMOTE CONTROL SYSTEM (DELUXE MODEL ONLY)

WIRING DIAGRAM
L/R Gy L/B
R BW
C B
B FREE PUSH
W FREE PUSH
Br
W B
Br FREE PUSH Br
B R B
Br
Br R
R B
L/R B/L
20A
3 2
30A
L/R L/YL/B W/B Br R R R L Br Y

3A
RR
10A
5
B Br B Br
10A
Y Y
R/Y R/Y R/Y R/Y R/Y
R/Y W B W/B
R/Y Pu/R
6 6 6 6
B B B B B B R Y L W Y B B L/B L/Y B/L Gy W W
R/Y Pu/B
R/Y Pu/Y Pu/R Pu/B B Pu/G Pu/Y R/Y Pu/G
B Gy
7 8
L/R L/Y Pu/B Pu/G Pu/R Pu/Y R/Y W/B : Blue/red : Blue/yellow : Purple/black : Purple/green : Purple/red : Purple/yellow : Red/yellow : White/black
1 2 3 4 5 6 7 8 9 Battery Fuse (30 A) Fuse (20 A) Fuse (3 A) Starter relay Fuel injector Remote control unit Antenna ECM 0 A B C D Buzzer Multifunction meter Start switch Engine stop switch Engine shut-off switch B Br Gy L R W Y B/L L/B
7-59
To entry box
: Black : Brown : Gray : Blue : Red : White : Yellow : Black/blue : Blue/black
ELEC
1

REMOTE CONTROL SYSTEM
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. 2. Measure: Remote control unit output voltage Within specification Replace the multifunction meter. Out of specification Replace the remote control unit. Remote control unit output voltage: Blue/yellow (L/Y) ground 1113 V
Measurement steps: Disconnect the remote control unit 1 coupler from the multifunction meter. Measure the remote control unit output voltage while pushing the unlock button of the remote control transmitter.
L/Y
Low-rpm mode indicator 1. Check: Low-rpm mode indicator Does not come on Replace the multifunction meter. Checking steps: Press the unlock button 1 of the remote control transmitter 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 2 comes on.
7-60
ELEC
Checking the remote control transmitter 1. Check: Remote control transmitter Does not operate Replace the remote control transmitter. Checking steps:
CAUTION:
If the buttons on the remote control transmitter are pushed but the transmitter does not operate, the battery may be low. Press the lock button 1 of the remote control transmitter. The beeper sounds once. Check that the SECURITY indicator light goes off and that the engine cannot be started. Press the unlock button 2 of the remote control transmitter for a short time. The beeper sounds two or three times. Check that the SECURITY indicator light comes on and that the engine can be started. 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. Number of beeps 1 beep 2 beeps 3 beeps Yamaha Security System mode Lock Unlock (normal mode) Unlock (low-rpm mode) Engine startability Unable Able Able
7-61
ELEC
NOTE: If the start switch or the remote control transmitter is not operated for more than 25 seconds, the multifunction meter display 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. While the engine is running, input is not received from the remote control transmitter.
7-62
ELEC
2
Gy
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. NOTE: The remote control transmitters can be registered in any sequence, regardless of whether they are original equipment or additional transmitters. At this time, the system enters the registration mode to register the first code. All existing ID codes will be deleted from the EEPROM. The SECURITY indicator light flashes when the registration of the ID code has been completed. (If the registration could not be completed, the SECURITY indicator light comes on. Re-transmit the ID code.) After confirming that the registration of the ID code has been completed using the SECURITY indicator light, transmit the next ID code. Register the ID codes for up to five remote control transmitters. After ID code registration has been completed, disconnect the entry box to exit the registration mode.
7-63
ELEC

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 transmitter during assembly.
1. Remove: Cover NOTE: Loosen the transmitter cover screws in the sequence shown.
2. Install: Battery 1 NOTE: Install the battery (CR2016) with the positive side facing down.
3. Install: Cover NOTE: Tighten the transmitter cover screws in the sequence shown. Transmitter cover screw: 0.1 N m (0.01 kgf m, 0.1 ft lb)
4
T.
R.
7-64
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 ................................................ 8-8 SERVICE POINTS .................................................................................. 8-10 Rivet Installation................................................................................ 8-10 ENGINE HATCH COVER .............................................................................. 8-11 EXPLODED DIAGRAM ...........................................................................8-11 REMOVAL AND INSTALLATION CHART .............................................. 8-11 SERVICE POINTS .................................................................................. 8-13 Damper stopper inspection (Deluxe model only) ..............................8-13 EXPLODED DIAGRAM ...........................................................................8-14 REMOVAL AND INSTALLATION CHART .............................................. 8-14 SERVICE POINTS .................................................................................. 8-15 Glove compartment assembly installation.........................................8-15 SHIFT LEVER (DELUXE MODEL ONLY).....................................................8-16 EXPLODED DIAGRAM ...........................................................................8-16 REMOVAL AND INSTALLATION CHART .............................................. 8-16 HOSES ..........................................................................................................8-17 EXPLODED DIAGRAM ...........................................................................8-17 REMOVAL AND INSTALLATION CHART .............................................. 8-17 SERVICE POINTS .................................................................................. 8-19 Cooling water pilot outlet installation................................................. 8-19 Grommet installation .........................................................................8-19 Ventilation hose assembly installation .............................................. 8-19 STEERING COLUMN ....................................................................................8-20 EXPLODED DIAGRAM ...........................................................................8-20 REMOVAL AND INSTALLATION CHART .............................................. 8-20 SERVICE POINTS .................................................................................. 8-22 Steering column inspection ...............................................................8-22
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) .............. 8-27 Shift cable (shift lever end) installation (Deluxe model only)............. 8-27 Remote control cables adjustment....................................................8-27 SEAT AND HAND GRIP................................................................................ 8-28 EXPLODED DIAGRAM ...........................................................................8-28 REMOVAL AND INSTALLATION CHART .............................................. 8-28 SERVICE POINTS .................................................................................. 8-30 Seat lock assembly inspection .......................................................... 8-30 EXHAUST SYSTEM ......................................................................................8-31 EXPLODED DIAGRAM ...........................................................................8-31 REMOVAL AND INSTALLATION CHART .............................................. 8-31 SERVICE POINTS .................................................................................. 8-34 Exhaust system inspection................................................................8-34 Exhaust component parts sub-assembly ..........................................8-34 Exhaust system installation...............................................................8-35 DECK AND HULL.......................................................................................... 8-36 EXPLODED DIAGRAM ...........................................................................8-36 REMOVAL AND INSTALLATION CHART .............................................. 8-36 ENGINE MOUNT ........................................................................................... 8-38 EXPLODED DIAGRAM ...........................................................................8-38 REMOVAL AND INSTALLATION CHART .............................................. 8-38
1 2 3 4 5 6 7 8 9
HULL HOOD
HANDLEBAR
HANDLEBAR
EXPLODED DIAGRAM
4
20 N m (2.0 kgf m, 14 ft Ib) 8 48 mm
FWD
1.1 N m (0.11 kgf m, 0.8 ft Ib) 4 9 mm
7 8
LT
1.1 N m (0.11 kgf m, 0.8 ft Ib) 5 15 mm
572
1 5
10
6
A
LT
242
3.7 N m (0.37 kgf m, 2.7 ft Ib) 6 13 mm

Step 1 2 3 4 5 6 7 8 9 10 Procedure/Part name HANDLEBAR REMOVAL Screw Screw Screw Upper handlebar cover Pad Throttle cable Bolt Upper handlebar holder Handlebar assembly Lower handlebar cover Qty 4 4 2 1 1 1 4 2 1 1 Reverse the removal steps for installation.
8-1
Service points Follow the left Step for removal.
HULL HOOD
HANDLEBAR
EXPLODED DIAGRAM
3 7 3 4 5
6 6 4 2
1 1
FW D

Step 1 2 Procedure/Part name HANDLEBAR REMOVAL Handlebar switch coupler Plastic tie Qty 2 1 Service points Follow the left Step for removal. NOTE: Fasten the buzzer lead, steering sensor lead, start switch lead, engine shut-off switch lead, and multifunction meter lead with a plastic tie.
3 4
Corrugated tube Grommet
1 1
8-2
HULL HOOD
HANDLEBAR
EXPLODED DIAGRAM
3 7 3 4 5
6 6 4 2
1 1
FW D
Step 5
Procedure/Part name Throttle cable
Qty 1
Service points NOTE: Pass the throttle cable and wiring harness through the grommet, and then fit the grommet into the steering column.
6 7
Handlebar switch lead Handlebar assembly
1 1 Reverse the removal steps for installation.
8-3
HULL HOOD
HANDLEBAR
EXPLODED DIAGRAM

Step 1 2 3 Procedure/Part name HANDLEBAR DISASSEMBLY Bolt Grip end Screw Qty 2 2 2 Service points Follow the left Step for disassembly.
NOTE: Tighten the screw from the engine stop switch side.
4 5
Handlebar switch assembly Screw
1 2
8-4
HULL HOOD
HANDLEBAR
EXPLODED DIAGRAM
Step 6 7
Procedure/Part name Throttle lever assembly Handlebar grip
Qty 1 2
Service points NOTE: Apply adhesive to the handlebar and the inner surface of the handlebar grip.
8 9
End plate Handlebar
2 1 Reverse the disassembly steps for assembly.
8-5
HULL HOOD
HANDLEBAR
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 illustration.
2. Install: Upper handlebar holder 1 NOTE: The upper handlebar holder should be installed with the punch mark a facing forward.
CAUTION:
Clearance b should be narrower than clearance c. Handlebar holder bolt: 20 N m (2.0 kgf m, 14 ft lb) LOCTITE 572 Reference clearance: b: 1.5 mm (0.06 in) c: 3.5 mm (0.14 in)
T.
R.
8-6
HULL HOOD
HANDLEBAR
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.
5. Adjust: Throttle cable free play Refer to CONTROL SYSTEM in Chapter 3.
8-7
HULL HOOD
FRONT HOOD
FRONT HOOD
EXPLODED DIAGRAM
1.9 N m (0.19 kgf m, 1.4 ft Ib) 5 20 mm
10 3 2
LT
11
572
1
15 N m (1.5 kgf m, 11 ft Ib)
1 9
13
LT
5 12
242
6
6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 95 mm
6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 18 mm
LT
6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 18 mm
242

Step 1 2 3 4 5 6 7 8 Procedure/Part name FRONT HOOD REMOVAL Bolt/washer/nut Front hood assembly Bolt Hood lock assembly Hinge assembly Bolt Nut/washer Left mirror/seal Qty 2/2/2 1 2 1 1 4 4/4 1/1 Service points Follow the left Step for removal.
Deluxe model only Deluxe model only
8-8
HULL HOOD
FRONT HOOD
EXPLODED DIAGRAM
1.9 N m (0.19 kgf m, 1.4 ft Ib) 5 20 mm
10 3 2
LT
11
572
1
15 N m (1.5 kgf m, 11 ft Ib)
1 9
13
LT
5 12
242
6
6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 95 mm
6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 18 mm
LT
6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 18 mm
242
Step 9 10 11 12 13
Procedure/Part name Right mirror/seal Rivet Storage compartment panel Bolt Lid lock hook
Qty 1/1 4 1 2 1
Service points Deluxe model only
8-9
HULL HOOD
2
FRONT HOOD
SERVICE POINTS
1
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. NOTE: To remove a rivet, push the rivet pin in until it clicks and is below the top of the rivet. Before reinstalling a rivet, hold the rivet flange a with both hands and push the rivet pin perpendicularly against a hard flat surface until the pin protrudes from the top of the rivet.
8-10
HULL HOOD
ENGINE HATCH COVER
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) LT 7 5 16 mm 10 572
FWD
10 5
LT
6
6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 23 mm 6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 23 mm
LT
8 3
572
11
LT
572
LT
572
6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 23 mm 6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 23 mm 9
LT
572
572
3
LT
LT
572
572
2 1
LT
572
3 3 3
LT LT
4
6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 23 mm
572
572

Step Procedure/Part name ENGINE HATCH COVER REMOVAL Band Grommet Bolt/washer/nut Bolt Bolt Damper stopper Screw Qty Service points Follow the left Step for removal.
1 2 3 4 5 6 7
1 1 4/4/4 4 1 1 2
Deluxe model only Deluxe model only Deluxe model only
8-11
HULL 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) LT 7 5 16 mm 10 572
FWD
10 5
LT
6
6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 23 mm 6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 23 mm
LT
8 3
572
11
LT
572
LT
572
6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 23 mm 6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 23 mm 9
LT
572
572
3
LT
LT
572
572
2 1
LT
572
3 3 3
LT LT
4
6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 23 mm
572
572
Step 8 9 10 11
Procedure/Part name Shift lever handle Engine hatch cover Bolt Multifunction meter
Qty 1 1 4 1
Service points Deluxe model only
8-12
HULL HOOD
2 1
ENGINE HATCH COVER

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.
8-13
HULL HOOD
ENGINE HATCH COVER
EXPLODED DIAGRAM
3 2 4 6

Step Procedure/Part name GLOVE COMPARTMENT REMOVAL Hinge assembly Lid Latch Cap holder Hood bumper Drain plug Qty Service points Follow the left Step for removal.
1 2 3 4 5 6
8-14
HULL HOOD
ENGINE HATCH COVER

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
HULL HOOD
SHIFT LEVER (DELUXE MODEL ONLY)
SHIFT LEVER (DELUXE MODEL ONLY)

EXPLODED DIAGRAM
15 N m (1.5 kgf m, 11 ft Ib)
8.0 N m (0.8 kgf m, 5.8 ft Ib) 6 18 mm
4 4
3
LT
1
572
2 5
LT
572

Step Procedure/Part name SHIFT LEVER REMOVAL Engine hatch cover Shift cable Bolt Detent plate Shift lever Nut Bracket Qty Service points Follow the left Step for removal. Refer to ENGINE HATCH COVER. Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD.
1 2 3 4 5
2 1 1 2 1 Reverse the removal steps for installation.
8-16
HULL HOOD
HOSES
HOSES
EXPLODED DIAGRAM
(VENT)
2
4.2 N m (0.42 kgf m, 3.0 ft Ib)
1
FW D
1 2
4
(VENT)
1 1
3 1
9 8 5 1 1 6 4 1

Step Procedure/Part name HOSES REMOVAL Fuel tank Accelerator position sensor Qty Service points Follow the left Step for removal. Refer to FUEL TANK AND FUEL PUMP MODULE in Chapter 4. Refer to Throttle cable inspection and adjustment in Chapter 3. NOTE: When removing the ventilation hose and fuel tank breather hose, it is not necessary to remove the fuel tank. 1 2 Band Grommet 8 2
8-17
HULL HOOD
HOSES
EXPLODED DIAGRAM
(VENT)
2
4.2 N m (0.42 kgf m, 3.0 ft Ib)
1
FW D
1 2
4
(VENT)
1 1
3 1
9 8 5 1 1 6 4 1
Step 3 4 5 6 7 8 9
Procedure/Part name Ventilation hose Fuel tank breather hose Clamp Cooling water hose Nut Cooling water pilot outlet Seal
Qty 2 2 1 1 1 1 1
Service points
8-18
HULL HOOD
FWD
HOSES
SERVICE POINTS
3 2
Cooling water pilot outlet installation 1. Install: Cooling water pilot outlet 1 Seal 2 Nut 3
30
NOTE: When installing the cooling water pilot outlet, face the discharge hole toward the stern and downward at a 30 angle from the horizontal line as shown in the illustration. Tighten the nut while holding the cooling water pilot outlet in place.
Grommet installation 1. Install: Ventilation hose 1 Grommet 2 NOTE: Install the grommet on the ventilation hose, making sure that the end of the hose protrudes the specified length a from the groove around the outside of the grommet as shown in the illustration. Specified length a: 3040 mm (1.181.57 in)
Ventilation hose assembly installation 1. Install: Ventilation hose assembly NOTE: When installing the ventilation hose assembly, make sure that the grommet is properly seated in the hole in the inner hull as shown in the illustration.
8-19
HULL HOOD
STEERING COLUMN
STEERING COLUMN
EXPLODED DIAGRAM
LT
572
17 N m (1.7 kgf m, 12 ft Ib) 8 30 mm
1
LT
572
6.9 N m (0.69 kgf m, 5.0 ft Ib) 8 18 mm
6.9 N m (0.69 kgf m, 5.0 ft Ib)

Step Procedure/Part name STEERING COLUMN REMOVAL Engine hatch cover Steering cable end Bolt Steering arm Joint ball Bolt Steering column assembly Qty Service points Follow the left Step for removal. Refer to ENGINE HATCH COVER. Refer to REMOTE CONTROL CABLES AND SPEED SENSOR LEAD.
1 2 3 4 5
1 1 1 4 1 Reverse the removal steps for installation.
8-20
HULL HOOD
STEERING COLUMN
EXPLODED DIAGRAM
1 3 4
LT
16 N m (1.6 kgf m, 12 ft Ib) 8 25 mm
572
LT
572
6 7

Step Procedure/Part name STEERING COLUMN DISASSEMBLY Steering column Seal rubber Bolt Steering sensor Bolt Spacer Buzzer Steering housing assembly Qty Service points Follow the left Step for disassembly.
1 2 3 4 5 6 7 8
1 1 4 1 3 1 1 1 Reverse the disassembly steps for assembly.

8-21
HULL HOOD
STEERING COLUMN
SERVICE POINTS
Steering column inspection 1. Inspect: Seal rubber Steering housing assembly Cracks/damage/wear Replace the steering column.
8-22
HULL HOOD
REMOTE CONTROL CABLES AND SPEED SENSOR LEAD

EXPLODED DIAGRAM

Step Procedure/Part name REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL Service lid 1 Seat assembly Engine hatch cover Shift lever Steering cable end Bolt Bracket Qty Service points Follow the left Step for removal.
Refer to FRONT HOOD. Refer to SEAT AND HAND GRIP. Refer to ENGINE HATCH COVER. Refer to SHIFT LEVER (DELUXE MODEL ONLY). 1 1 1
1 2 3
8-23
HULL HOOD
EXPLODED DIAGRAM
Step 4 5 6 7 8 9 10 11 12 13
Procedure/Part name Nut Steering cable Seal Speed sensor coupler Nut Cap Screw Speed sensor Bolt Shift cable holder
Qty 1 1 1 1 1 1 4 1 2 1
Service points
Deluxe model only Deluxe model only
8-24
HULL HOOD
EXPLODED DIAGRAM
Step 14 15 16 17 18
Procedure/Part name Shift cable end Grommet Nut Shift cable Seal
Qty 1 1 1 1 1
Service points Deluxe model only Deluxe model only Deluxe model only Deluxe model only Deluxe model only Reverse the removal steps for installation.
8-25
HULL 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. If a cable becomes damaged replace it. Never attempt to repair a damaged cable. Remote control cables inspection 1. Inspect: Steering cable Shift cable (Deluxe model only) Frays/kinks/rough movement Replace. Steering cable (jet pump end) installation 1. Install: Steering cable Steering cable set length a (jet pump end): 14.5 mm (0.57 in)
WARNING
The steering cable must be screwed in at least 8 mm (0.31 in).
Steering cable stopper installation 1. Install: Steering cable stopper
WARNING
Be sure to the steering cable stopper into the groove in the outer cable as shown in the illustration.
8-26
HULL 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).
Shift cable (shift lever end) installation (Deluxe model only) 1. Install: Shift cable (shift lever end) NOTE: Install the shift cable 1 before securing the shift lever assembly 2 to the deck.
Remote control cables adjustment Refer to CONTROL SYSTEM in Chapter 3.
8-27
HULL HOOD
SEAT AND HAND GRIP
SEAT AND HAND GRIP

EXPLODED DIAGRAM
6 30 mm
5 6
3
LT
271
2 2 9
LT
271
6.4 N m (0.64 kgf m, 4.6 ft Ib) 6 40 mm
12
4 8 7
LT
6.9 N m (0.69 kgf m, 5.0 ft Ib)
271
26 N m (2.6 kgf m, 19 ft Ib) 10 20 mm 6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 23 mm
10 10 11
15 N m (1.5 kgf m, 11 ft Ib)

Step Procedure/Part name SEAT AND HAND GRIP REMOVAL Seat assembly Bolt Seat lock assembly Nut/washer Bolt Hand grip Bolt Qty Service points Follow the left Step for removal.
1 2 3 4 5 6 7
1 2 1 4/4 4 1 1
8-28
HULL HOOD
SEAT AND HAND GRIP
EXPLODED DIAGRAM
6 30 mm
5 6
3
LT
271
2 2 9
LT
271
6.4 N m (0.64 kgf m, 4.6 ft Ib) 6 40 mm
12
4 8 7
LT
6.9 N m (0.69 kgf m, 5.0 ft Ib)
271
26 N m (2.6 kgf m, 19 ft Ib) 10 20 mm 6.9 N m (0.69 kgf m, 5.0 ft Ib) 6 23 mm
10 10 11
15 N m (1.5 kgf m, 11 ft Ib)
Step 8 9 10 11 12
Procedure/Part name Spring washer/washer Projection Nut/washer Bolt Seat bracket
Qty 1/1 1 2/2 2 1
Service points
8-29
HULL HOOD
SEAT AND HAND GRIP

SERVICE POINTS
Seat lock assembly inspection 1. Inspect: Seat lock assembly Damage/wear Replace.
8-30
HULL HOOD
EXHAUST SYSTEM
EXHAUST SYSTEM
EXPLODED DIAGRAM
14 13
3.7 N m (0.37 kgf m, 2.7 ft Ib)
F1K
18
17 12 3
16 15
11 6 5
5.4 N m (0.54 kgf m, 3.9 ft Ib)
10
1 4
3.7 N m (0.37 kgf m, 2.7 ft Ib) 1st 2.4 N m (0.24 kgf m, 1.7 ft Ib)
2nd 2.4 N m (0.24 kgf m, 1.7 ft Ib) 1st 2.4 N m (0.24 kgf m, 1.7 ft Ib)
2nd 2.4 N m (0.24 kgf m, 1.7 ft Ib) 3.7 N m (0.37 kgf m, 2.7 ft Ib)

Step Procedure/Part name EXHAUST SYSTEM REMOVAL Deck beam Jet pump unit assembly Qty Service points Follow the left Step for removal. Refer to SEAT AND HAND GRIP. Refer to JET PUMP UNIT in Chapter 6. NOTE: When removing the water lock and exhaust joint, it is not necessary to remove the jet pump unit. 1 2 3 4 Band Joint clamp 1 Hose clamp 1 Water lock 1 1 1 1
8-31
HULL HOOD
EXHAUST SYSTEM
EXPLODED DIAGRAM
14 13
3.7 N m (0.37 kgf m, 2.7 ft Ib)
F1K
18
17 12 3
16 15
11 6 5
5.4 N m (0.54 kgf m, 3.9 ft Ib)
10
1 4
Step 5 6 7 8 9 10 11 12 13 14
Procedure/Part name Joint clamp 2 Joint Joint clamp 3 Joint clamp 4 Joint Exhaust joint Nut/washer Exhaust valve Hose clamp 1 Rubber hose
Qty 1 1 1 1 1 1 6/6 1 1 1
Service points
8-32
HULL HOOD
EXHAUST SYSTEM
EXPLODED DIAGRAM
14 13
3.7 N m (0.37 kgf m, 2.7 ft Ib)
F1K
18
17 12 3
16 15
11 6 5
5.4 N m (0.54 kgf m, 3.9 ft Ib)
10
1 4
Step 15 16 17 18
Procedure/Part name Hose clamp 2 Water tank Rubber hose Plate
Qty 1 1 1 1
Service points
8-33
HULL HOOD
EXHAUST SYSTEM
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. Install: Rubber hose Plate NOTE: Be sure to fit the projections a on the rubber hose with the grooves in the plate.
2. Install: Rubber hoses Water tank NOTE: Be sure to insert the rubber hose to the line b on the water tank. Align the parting line c of the water tank with the parting line d of the rubber hose. Align the parting line e of the rubber hose with the parting line f of the water tank.
cb
e b f
8-34
HULL HOOD
EXHAUST SYSTEM
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
HULL HOOD
DECK AND HULL
DECK AND HULL

EXPLODED DIAGRAM
13 N m (1.3 kgf m, 9.4 ft Ib) 6 20 mm
6.9 N m (0.69 kgf m, 5.0 ft Ib)
16 16
16 N m (1.6 kgf m, 12 ft Ib) 8 45 mm 15 N m (1.5 kgf m, 11 ft Ib)
20 4 19
18
LT
5 5 3
572
17 2 14
12
7 6
1 11
5.4 N m (0.54 kgf m, 3.9 ft Ib)
10
2.0 N m (0.2 kgf m, 1.4 ft Ib) 5 25 mm
8 15 14 13
LT
572
15 N m (1.5 kgf m, 11 ft Ib)

Step 1 2 3 4 5 6 7 8 9 10 11 Procedure/Part name Qty Service points DECK AND HULL DISASSEMBLY Follow the left Step for disassembly. Nut 1 Spout 1 Nut 2 Cleat 1 Plate 2 Bolt/collar 10/10 Sponson 2 Nut/washer 4/4 Screw/washer 4/4 Drain plug 2 Seal 2
8-36
HULL HOOD
DECK AND HULL
EXPLODED DIAGRAM
13 N m (1.3 kgf m, 9.4 ft Ib) 6 20 mm
6.9 N m (0.69 kgf m, 5.0 ft Ib)
16 16
16 N m (1.6 kgf m, 12 ft Ib) 8 45 mm 15 N m (1.5 kgf m, 11 ft Ib)
20 4 19
18
LT
5 5 3
572
17 2 14
12
7 6
1 11
5.4 N m (0.54 kgf m, 3.9 ft Ib)
10
2.0 N m (0.2 kgf m, 1.4 ft Ib) 5 25 mm
8 15 14 13
LT
572
15 N m (1.5 kgf m, 11 ft Ib)
Step 12
Procedure/Part name Nut
Qty 4
Service points NOTE: To remove the cleat, remove the exhaust system first.
13 14 15 16 17 18 19 20
Cleat Plate Seal Nut/washer Bolt Protector Bolt Bow eye
2 4 2 5/5 2 1 2 1 Reverse the disassembly steps for assembly.

8-37
HULL HOOD
ENGINE MOUNT
ENGINE MOUNT
EXPLODED DIAGRAM

Step Procedure/Part name ENGINE MOUNT REMOVAL Engine unit Bolt Damper 1 Damper 2 Bolt Engine mount Liner Qty Service points Follow the left Step for removal. Refer to ENGINE UNIT in Chapter 5.
1 2 3 4 5 6
8-38
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
1 2 3 4 5 6 7 8 9
TRBL ANLS
INTRODUCTION
FEATURES
INTRODUCTION
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 communication cable, this software can be used to display sensor data and data stored in the ECM on a computers monitor. If this software is run on Microsoft Windows 95, Windows 98, Windows Me, Windows 2000, or Windows XP the information can be displayed in colorful graphics. Also, the software can be operated using either a mouse or a keyboard. In addition, the data for the main functions (Diagnosis, Diagnosis record, Engine monitor, and Data logger) can be saved on a disk or printed out. Functions 1. Diagnosis: Each sensors status and each ECM diagnosis code or item are displayed. This enables you to find malfunctioning parts and controls quickly. 2. Diagnosis record: Sensors that had been activated and ECM diagnostic codes that have been recorded are displayed. This allows you to check the watercrafts record of malfunctions. 3. Engine monitor: Each sensors status and the ECM data are displayed. This enables you to find malfunctioning parts quickly. In addition, the data displayed using the Engine Monitor function can be displayed in a graph. 4. Stationary test: Operation tests can be performed with the engine off. 5. Active test: Operation tests can be performed with the engine running. 6. Data logger: From the data stored in the ECM, at least two items of 78 seconds of recorded data are displayed on a graph. In addition, the operating time as compared to the engine speed and the total operating time are displayed. This allows you to check the operating status of the engine. For some models, you can also save the ECM record data in a file so that you can read and display the graph later. 7. Some files: Lets you select and run other applications while continuing to run the diagnostic program.
CONTENTS
1. CD-ROM (software + instruction manual) (1) 2. Adapter (1) 3. Communication cable (1)
9-1
TRBL ANLS
INTRODUCTION
HARDWARE REQUIREMENTS
Make sure that your computer meets the following requirements before using this software. Computer: Operating system: CPU: Windows 95/98: Windows Me/2000: Windows XP: Memory: Windows 95/98: Windows Me: Windows 2000: Windows XP: Hard disk free space: Drive: Display: Mouse: Communication port: Printer: IBM PC/AT compatible computer Microsoft Windows 95, Windows 98, Windows Me, Windows 2000, or Windows XP (English version) i486X, 100 MHz or higher (Pentium 100 MHz or higher recommended) Pentium, 166 MHz or higher (Pentium 233 MHz or higher recommended) Pentium, 300 MHz or higher (Pentium 500 MHz or higher recommended) 16 MB or more (32 MB or more recommended) 32 MB or more (64 MB or more recommended) 64 MB or more (128 MB or more recommended) 128 MB or more (256 MB or more recommended) 20 MB or more (40 MB or more recommended) CD-ROM drive VGA (640 480 pixels), (SVGA [800 600 pixels] or more recommended) 256 or more colors Compatible with the operating systems mentioned above RS232C (Dsub-9 pin) port, USB port Compatible with the operating systems mentioned above
NOTE: The amount of memory and the amount of free space on the hard disk differs depending on the computer. Using this software while there is not enough free space on the hard disk could cause errors and result in insufficient memory. This software will not run properly on some computers. When starting up this program, do not start other software applications. Do not use the screen saver function or the energy saving feature when using this program. If the ECM is changed, restart the program. 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.
9-2
TRBL ANLS
OPERATING
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.
9-3
TRBL ANLS
TROUBLE ANALYSIS
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. Check that all wiring connections are properly secured and that they are not rusty. 4. Check that the engine shut-off cord (lanyard) is connect to the engine shut-off switch. 5. Check that fuel is reaching the fuel rail.
TROUBLE ANALYSIS CHART

Trouble mode IRREGULAR WARNING INDICATION Check elements
POOR BATTERY CHARGING
ENGINE WILL NOT START
ENGINE WILL NOT STOP
LIMITED ENGINE SPEED
POOR ACCELERATION
POOR PERFORMANCE
LOW OIL PRESSURE
LOOSE STEERING
BILGE INCREASE
HARD STARTING
Relative part
ENGINE STALLS
Reference chapter
ROUGH IDLING
OVERHEATING
HIGH IDLING
FUEL SYSTEM Fuel tank Fuel tank breather hose Fuel hose Fuel filter Fuel pump Fuel rail Fuel injectors Trolling speed Air filter
4 4 4 4 4 4 4 3 3
9-4
TRBL ANLS
TROUBLE ANALYSIS
POOR ACCELERATION
POOR PERFORMANCE
LOW OIL PRESSURE
LOOSE STEERING
BILGE INCREASE
HARD STARTING
Relative part
ENGINE STALLS
Reference chapter
ROUGH IDLING
OVERHEATING
HIGH IDLING
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 Drive couplings Rubber coupling Pilot water hose Water hose Water passage
5 5 5 5 5 5 5 5 3 5 5 5 3 3 7 5 5 5 5 5 5
9-5
TRBL ANLS
TROUBLE ANALYSIS
POOR ACCELERATION
POOR PERFORMANCE
LOW OIL PRESSURE
LOOSE STEERING
BILGE INCREASE
HARD STARTING
Relative part
ENGINE STALLS
Reference chapter
ROUGH IDLING
OVERHEATING
HIGH IDLING
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 Ignition coils Slant detection switch Engine stop switch Engine shut-off switch Spark plugs Main and fuel pump relay Electronic control throttle valve relay Thermoswitch Sensor assembly Engine temperature sensor Throttle body assembly (throttle position sensor) Accelerator position sensor Cam position sensor
6 6 6 6 6 6 3 6
7 7 7 7 7 7 3 7 7 7 7 7 7 7 7
9-6
TRBL ANLS
TROUBLE ANALYSIS
POOR ACCELERATION
POOR PERFORMANCE
LOW OIL PRESSURE
LOOSE STEERING
BILGE INCREASE
HARD STARTING
Relative part
ENGINE STALLS
Reference chapter
ROUGH IDLING
OVERHEATING
HIGH IDLING
Starting system Start switch 7 Starter relay 7 Starter motor 7 Charging system Lighting coil 7 Rectifier/regulator 7 Fuses 7 Battery leads Battery 3 Remote control system (Deluxe model only) Remote control unit 7 HULL AND HOOD Steering column 8 Water lock 8 Exhaust hose 8 Muffler 8 Drain plugs 8
9-7
TRBL ANLS
1
TROUBLE ANALYSIS
SELF-DIAGNOSIS
With the engine running, press the select button 1 for 8 seconds and check if an error code is indicated on the multifunction meter. Code 01 13 15 19 23 24 29 47 48 55 112 123 124 128 129 131 135 136 139 141 145 Normal Pickup coil malfunction Engine temperature sensor malfunction Incorrect battery voltage Intake air temperature sensor malfunction Cam position sensor malfunction Intake air pressure sensor malfunction Slant detection switch malfunction Incorrect data transmission Steering switch malfunction Electronic control throttle system malfunction Throttle position sensor malfunction Electronic control throttle system malfunction Accelerator position sensor malfunction Electronic control throttle system malfunction Electronic control throttle system malfunction Symptom
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. However, if there are numerous error codes displayed, be sure to check them with the Yamaha Diagnostic System.
9-8
VX110 Sport
B B B R R Br B 30A R B
20A
10A
10A
3A
Br
R/Y G/O B/O
1
R
2
R
8 1 7
R
6
R
5
R
4 2 3
Br B Y
8451 3276
L L/R R Y/G R/Y R/Y R
421
R/Y R
356
Y/W R/Y R/Y
1 2
B/O L/B
1 2 3 4 5 6 7 8 9 1011121314
R/Y R/Y R/Y R/Y R/Y R/Y R/Y O O O Y Y Y
1 2
R/Y B/R
1 2
B/W R/Y
1 2
R/Y B/Y
1 2
B/G R/Y
123
O G/O B/O
1 2 3 4 5 6 7 8 9 1011121314
R/Y R/Y R/Y R/Y R/Y R/Y R/Y P P P
4231
P/G O B/O B/Y
1 2
B/O B/Y
1 2
P B
1 2
P B
P/W
B/O
B/Y
B/Y
L/B
1
P/W
1 2
Pu/R R/Y
1 2
Pu/B R/Y
1 2
Pu/Y R/Y
1 2
Pu/G R/Y
1 2 3 5 6 7 4 8 9 1011121314
B B B B B B B B
B FREE PUSH
W FREE PUSH W B
Br
Br FREE PUSH
Br
B W
1 2
B/O W
Br Br
R Br
2 1 3 2 1
R Br G B B R/Y W/B
R/Y Y B/Y
3 2 1
R/W Y B/Y
W B R
1 2
L/B L/R P B
2 1
P B/G
B W/L O
3 2 1
B/O W/L O
L B
2 1
L B
B B B B
1 2 3 4 5 6 7 8
R B
2 1
L/R B/L
B B B B
B B G P/W Y/W L/R G Pu/G Pu/Y B/R B/W Pu/R Pu/B B/G B/Y B B/R P O B/W P/W O B/O P/W O B/R B/W P P/W R/Y B/O B/O P P/W O R/Y B W/B W/B L/B W R/Y W/B G/O Y B/Y P/G W/L B/O B/O P B/O B/O B/O B/O B/O B/O B/O B/O B/O B/O B/O Y/G Y R/Y B/Y W W G G G G B G G G O O O O R P B B B L L
1 2
123
132
W
1327685 4
34
65
1 2 3 5 6 7 4 8 9 1011121314
123456
1 2 3 4 5 6 7 8 9 10111213 14151617181920212223242526
1 2 3 4 5 6 7 8 9 10111213 14151617181920212223242526
1 2 3 4 5 6 7 8 9 10111213 141516171819202122232425262728293031323334
G G G
WIRING DIAGRAM VX110 Sport

1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R S T U V W X Y Battery Starter motor Fuse (30 A) Fuse (20 A) Fuse (3 A) Fuse (10 A) Fuse (10 A) Starter relay Main and fuel pump relay Electronic control throttle valve relay Slant detection switch Ignition coil Spark plug Cam position sensor Sensor assembly (intake air pressure and intake air temperature) Engine temperature sensor Thermoswitch (engine) Thermoswitch (exhaust) Oil pressure switch Fuel injector ECM Rectifier/regulator Throttle body assembly Accelerator position sensor Pickup coil Lighting coil Buzzer Electric fuel pump Steering sensor Fuel sender Speed sensor Multifunction meter Start switch Engine stop switch Engine shut-off switch
Color code
B Br G Gy L O P R W Y B/G B/O B/R B/W B/Y G/B G/O G/R G/Y L/R P/G P/W Pu/B Pu/G Pu/R Pu/Y R/W R/Y W/B W/L W/R Y/G Y/W : Black : Brown : Green : Gray : Blue : Orange : Pink : Red : White : Yellow : Black/green : Black/orange : Black/red : Black/white : Black/yellow : Green/black : Green/orange : Green/red : Green/yellow : Blue/red : Pink/green : Pink/white : Purple/black : Purple/green : Purple/red : Purple/yellow : Red/white : Red/yellow : White/black : White/blue : White/red : Yellow/green : Yellow/white
To tachometer
VX110 Deluxe
B B B R R Br B 30A R B
20A
10A
10A
3A
Br
B/O
R/Y G/O B/O
1
R
2
R
5 1 6
R R
7
R
8
R
4 2 3
Br Y L
8451 3276
L L/R R Y/G R/Y R/Y R
421
R/Y R
356
Y/W R/Y R/Y
1 2
B/O L/B
1 2 3 4 5 6 7 8 9 1011121314
R/Y R/Y R/Y R/Y R/Y R/Y R/Y O O O Y Y Y
1 2
R/Y B/R
1 2
B/W R/Y
1 2
R/Y B/Y
1 2
B/G R/Y
123
O G/O B/O
1 2 3 4 5 6 7 8 9 1011121314
R/Y R/Y R/Y R/Y R/Y R/Y R/Y P P P
4231
P/G O B/O R/Y
1 2
B/O R/Y
1 2
P B
1 2
P B
P/W
B/Y
B/Y
L/B
1
P/W
1 2
Pu/R R/Y
1 2
Pu/B R/Y
1 2
Pu/Y R/Y
1 2
Pu/G R/Y
1 2 3 5 6 7 4 8 9 1011121314
B B B B B B B B B B
13141218
R Y L W
15 11 3 4 7 6 16 910
B B L/B L/Y B/L Gy W Y
1
W
B FREE PUSH
W FREE PUSH W B
Br
Gy B B W
1 2
Br FREE PUSH
Br
1 2
B/O W
Br Br
R Br
2 1 3 2 1 3 1 2
R Br G B B R/Y W/B L/B L/Y L/R
R/Y Y B/Y
3 2 1
R/W Y B/Y
W B R L/B Gy L/R
1 2
P B
2 1
P B/G
B W/L O
3 2 1
B/O W/L O
L B
2 1
L B
B B B B
1 2 3 4 5 6 7 8
R B
2 1
L/R B/L
B B B B
B B G P/W Y/W L/R G Pu/G Pu/Y B/R B/W Pu/R Pu/B B/G B/Y B B/R P O B/W P/W O B/O P/W O B/R B/W P P/W R/Y B/O B/O P P/W O R/Y B W/B W/B L/B W R/Y W/B G/O Y R/Y P/G W/L B/O B/O P B/O B/O B/O B/O B/O B/O B/O B/O B/O B/O B/O Y/G Y R/Y R/Y W W W G G G G B G G G O O O O R P B B B L L
1 2
123
132
W
1327685 4
34
65
1 2 3 5 6 7 4 8 9 1011121314
123456
1 2 3 4 5 6 7 8 9 10111213 14151617181920212223242526
1 2 3 4 5 6 7 8 9 10111213 14151617181920212223242526
1 2 3 4 5 6 7 8 9 10111213 141516171819202122232425262728293031323334
G G G
WIRING DIAGRAM VX110 Deluxe

1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z [ Battery Starter motor Fuse (30 A) Fuse (20 A) Fuse (3 A) Fuse (10 A) Fuse (10 A) Starter relay Main and fuel pump relay Electronic control throttle valve relay Slant detection switch Ignition coil Spark plug Cam position sensor Sensor assembly (intake air pressure and intake air temperature) Engine temperature sensor Thermoswitch (engine) Thermoswitch (exhaust) Oil pressure switch Fuel injector Remote control unit Antenna ECM Rectifier/regulator Throttle body assembly Accelerator position sensor Pickup coil Lighting coil Buzzer Electric fuel pump Steering sensor Fuel sender Speed sensor Multifunction meter Start switch Engine stop switch Engine shut-off switch
Color code
B Br G Gy L O P R W Y B/G B/O B/R B/W B/Y G/B G/O G/R G/Y L/B L/R L/Y P/G P/W Pu/B Pu/G Pu/R Pu/Y R/W R/Y W/B W/L W/R Y/G Y/W : Black : Brown : Green : Gray : Blue : Orange : Pink : Red : White : Yellow : Black/green : Black/orange : Black/red : Black/white : Black/yellow : Green/black : Green/orange : Green/red : Green/yellow : Blue/black : Blue/red : Blue/yellow : Pink/green : Pink/white : Purple/black : Purple/green : Purple/red : Purple/yellow : Red/white : Red/yellow : White/black : White/blue : White/red : Yellow/green : Yellow/white
To entry box To tachometer
YAMAHA MOTOR CORPORATION, USA
Printed in USA Jan. 2005 0.0 1 CR (E)

Service Manual Watercraft VX1100

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Service Manual Watercraft VX1100

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WaveRunner

VX110 Sport VX110 Deluxe

HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

Symbols 0 to E indicate specific data.

NOTE: Additional symbols may be used in this manual.

ENGINE SERIAL NUMBER

JET PUMP UNIT SERIAL NUMBER

HULL IDENTIFICATION NUMBER (H.l.N.)

SAFETY WHILE WORKING SAFETY WHILE WORKING

PARTS, LUBRICANTS, AND SEALANTS

SAFETY WHILE WORKING

GOOD WORKING PRACTICES

SAFETY WHILE WORKING

DISASSEMBLY AND ASSEMBLY

SPECIAL SERVICE TOOLS SPECIAL SERVICE TOOLS

SPECIAL SERVICE TOOLS

SPECIAL SERVICE TOOLS

REMOVAL AND INSTALLATION

SPECIAL SERVICE TOOLS

0 YM-04114 (19 mm)

90890-04114 (19 mm) YM-04108 (22 mm) 90890-04108 (22 mm)

A YM-04111 (4.0 mm)

90890-04111 (4.0 mm) YM-04116 (4.5 mm) 90890-04116 (4.5 mm)

B YM-04112 (4.0 mm)

90890-04112 (4.0 mm) YM-04117 (4.5 mm) 90890-04117 (4.5 mm)

C YM-04113 (4.0 mm)

90890-04113 (4.0 mm) YM-04118 (4.5 mm) 90890-04118 (4.5 mm)

90890-06315 (60) 90890-06312 (45) 90890-06328 (30)

SPECIAL SERVICE TOOLS

E 90890-06811 (4.0 mm) F YM-91044

SPECIAL SERVICE TOOLS

cm (cu. in) mm (in)

mm (in) V/Ah A @ r/min

(without oil filter replacement) (with oil filter replacement)

kPa (kgf/cm2, psi) mm (in) mm (in) mm (in) mm (in)

1,150 (11.5, 164)

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

0.110.20 (0.00430.0079) 0.250.34 (0.00980.0134)

22.923.1 (0.90160.9094) 24.424.6 (0.96060.9685)

mm (in) mm (in) mm (in) mm (in)

3.9753.990 (0.15650.1571) 4.4654.480 (0.17580.1764) 4.0004.012 (0.15750.1580) 4.5004.512 (0.17720.1776)

mm (in) mm (in) mm (in)

0.0100.037 (0.00040.0015) 0.0200.047 (0.00080.0019) 0.01 (0.0004)

16.99117.000 (0.66890.6693) 16.986 (0.6687)

mm (in) mm (in) mm (in)

mm (in) mm (in) mm (in)

mm (in) mm (in) mm (in) mm (in) mm (in)

mm (in) mm (in) mm (in)

kPa (kgf/cm2, psi)

Electrical 320327 (3.23.3, 4647)

Cartridge type Trochoid 0.090.15 (0.00350.0059)

0.090.17 (0.00350.0067) 0.090.15 (0.00350.0059)

JET PUMP UNIT

Degree mm (in) mm (in) mm (in)

Stainless steel 3 21.2 0.350.45 (0.01380.0177) 0.6 (0.0236) 0.3 (0.0118)

HULL AND HOOD

8.0 6.9 19.4 25.1

V V V (color) (color) A @ r/min