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Yamaha FX Cruiser High Output Service Manual

Summary of FX Cruiser High Output

  • Page 1

    Service manual fx high output waverunner f1s-28197-1g-11 lit-18616-02-83 *lit186160283* fx cruiser high output.

  • Page 2: Notice

    E 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 co...

  • Page 3: How to Use This Manual

    E how to use this manual manual format all of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assem...

  • Page 4

    E 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 machi...

  • Page 5

    E how to use this manual 1 to help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 2 numbers are given in the order of the jobs in the exploded diagram. 3 symbols indicate parts to be lubricated or replaced (see “symbols”)...

  • Page 6: Gen

    E a50001-1-4 symbols symbols 1 to 9 are designed to indicate the content of a chapter. 1 general information 2 specifications 3 periodic inspection and adjustment 4 fuel system 5 power unit 6 jet pump unit 7 electrical system 8 hull and hood 9 trouble analysis symbols 0 to e indicate specific data. ...

  • Page 7: Index

    E index general information 1 gen info specifications 2 spec periodic inspection and adjustment 3 insp adj fuel system 4 fuel power unit 5 powr jet pump unit 6 jet pump electrical system 7 elec hull and hood 8 hull hood trouble analysis 9 trbl anls – + a30000-0

  • Page 8: Gen

    E gen info 1 chapter 1 general information identification numbers ......................................................................... 1-1 primary l.D. Number ........................................................................... 1-1 engine serial number ......................................

  • Page 9: Gen

    1-1 e 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 compart- ment. Starting primary l.D. Number: f1s: 800101 engine serial number the engine serial number is stamped on a label a...

  • Page 10: Gen

    1-2 e gen info safety while working safety while working to prevent and accident or injury and to ensure quality service, follow the safety proce- dures provided below. Fire prevention gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. Ven...

  • Page 11: Gen

    1-3 e gen info safety while working under normal conditions, the lubricants men- tioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants. 1. Maintain good standards of personal and industrial h...

  • Page 12: Gen

    1-4 e 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...

  • Page 13: Gen

    1-5 e gen info special tools special tools using the correct special tools recommended by yamaha, will aid the work and enable accu- rate 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-”,...

  • Page 14: Gen

    1-6 e gen info special tools b fuel pressure gauge p/n. Yb-06766 90890-06786 c compression gauge extension p/n. 90890-06582 d cylinder gauge set p/n. Yu-03017 90890-06759 e compression gauge p/n. Yu-33223-1 90890-03160 f peak volt meter adapter p/n. Yu-39991 g peak voltage adapter b p/n. 90890-03172...

  • Page 15: Gen

    1-7 e gen info special tools n 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 o lower unit pressure/vacuum tester p/n. Yb-35956-a vacuum/pressure pump gauge set p/n. 90890-06756 p yamaha diagnostic system p/n. 60v-8...

  • Page 16: Gen

    1-8 e gen info special tools 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 7 ball bearing attachment (reduction drive gear) p/n. 90890-06631 8 forward gear bearing cup installer (reduct...

  • Page 17: Gen

    1-9 e gen info special tools e 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°) f valve seat cutter holder p/n. 90890-06811 (ø4.0 mm) 90890-06812 (ø4.5 mm) g valve seat cutter set p/n. Ym-91043-c h ...

  • Page 18: Gen

    1-10 e gen info special tools o bearing housing needle bearing remover (jet pump bearing) p/n. Yb-06112 drive shaft needle bearing installer and remover (jet pump oil seal) p/n. Yb-06196 p needle bearing attachment (jet pump bearing, oil seal, and reduction drive gear) p/n. 90890-06614, 90890-06653 ...

  • Page 19: Spec

    E spec 2 chapter 2 specifications general specifications ....................................................................... 2-1 maintenance specifications ............................................................... 2-3 engine ....................................................................

  • Page 20: Spec

    2-1 e spec general specifications general specifications item unit model fx high output fx cruiser high output model code hull f1s engine/jet 6b6 dimensions length mm (in) 3,340 (131.5) width mm (in) 1,230 (48.4) height mm (in) 1,160 (45.7) dry weight kg (lb) 350 (772) maximum capacity person/kg (lb...

  • Page 21: Spec

    2-2 e spec pon*: pump octane number = (motor octane number + research octane number)/2 ron*: research octane number fuel and oil fuel type regular unleaded gasoline minimum fuel rating pon* 86 ron* 90 fuel tank capacity l (us gal, imp gal) 70 (18.5, 15.4) engine oil type 4-stroke motor oil engine oi...

  • Page 22: Spec

    2-3 e spec maintenance specifications maintenance specifications engine item unit model fx high output fx cruiser high output cylinder head warpage limit mm (in) 0.1 (0.004) compression pressure *1 kpa (kgf/cm 2 , psi) 1,150 (11.5, 164) cylinder bore size mm (in) 76.000–76.015 (2.9921–2.9927) taper ...

  • Page 23: Spec

    2-4 e spec maintenance specifications valve seat width c intake mm (in) 0.9–1.1 (0.0354–0.0433) exhaust mm (in) 0.9–1.1 (0.0354–0.0433) valve margin thickness d intake mm (in) 0.5–0.9 (0.0197–0.0354) exhaust mm (in) 0.5–0.9 (0.0197–0.0354) valve stem diameter intake mm (in) 3.975–3.990 (0.1565–0.157...

  • Page 24: Spec

    2-5 e spec maintenance specifications piston ring top ring type barrel dimension (b × t) mm (in) 0.90 × 2.75 (0.04 × 0.11) end gap (installed) mm (in) 0.32–0.44 (0.0126–0.0173) ring groove clearance mm (in) 0.030–0.065 (0.0012–0.0026) 2nd ring type taper dimensions (b × t) mm (in) 0.80 × 2.80 (0.03 ...

  • Page 25: Spec

    2-6 e spec maintenance specifications jet pump unit hull and hood oil filter oil filter type cartridge type oil pump oil pump type trochoid rotor tip clearance (scavenge pump) mm (in) 0.09–0.15 (0.0035–0.0059) oil pump housing clearance rotor (feed pump) mm (in) 0.09–0.17 (0.0035–0.0067) rotor (scav...

  • Page 26: Spec

    2-7 e spec maintenance specifications electrical item unit model fx high output fx cruiser high output battery type fluid capacity v/ah 12/19 specific gravity 1.28 ecm unit (b/r – r/y, b/w – r/y, b/y – r/y, b/l – r/y) output peak voltage lower limit @cranking (loaded) v 87 @2,000 r/min (loaded) v 86...

  • Page 27: Spec

    2-8 e spec maintenance specifications *1 the figures are for reference only. Starter relay rating seconds 30 thermoswitch on temperature (engine) °c (°f) 84–90 (183–194) off temperature (engine) °c (°f) 70–84 (158–183) on temperature (exhaust) °c (°f) 94–100 (201–212) off temperature (exhaust) °c (°...

  • Page 28: Spec

    2-9 e spec tightening torques tightening torques specified torques part to tightened part name thread size q’ty tightening torque remarks n•m kgf•m ft•lb fuel system retainer/fuel pump module – fuel tank 1st nut — 9 3.2 0.32 2.3 2nd 6.4 0.64 4.6 fuel filler neck/rubber seal – deck nut — 1 5.9 0.59 4...

  • Page 29: Spec

    2-10 e spec tightening torques engine engine unit – engine mount bolt m8 4 17 1.7 12 271 lt oil filter — — 1 17 1.7 12 e coupling cover – intermediate housing bolt m6 1 7.8 0.78 5.6 572 lt thermoswitch (exhaust) – exhaust pipe 3 bolt m6 2 7.6 0.76 5.5 572 lt outer exhaust joint clamp – exhaust pipe ...

  • Page 30: Spec

    2-11 e spec tightening torques oil tank – oil tank stay 1st nut — 2 2.0 0.2 1.4 572 lt 2nd 15 1.5 11 3rd 39 3.9 28 oil tank stay – cylinder head 1st bolt m10 2 2.0 0.2 1.4 572 lt 2nd 15 1.5 11 3rd 39 3.9 28 band/collar – oil tank bolt m6 1 7.6 0.76 5.5 572 lt bracket (coupling cover) – oil tank 1st ...

  • Page 31: Spec

    2-12 e spec tightening torques generator cover – crankcase 1st nut — 2 15 1.5 11 572 lt 2nd 50 5.0 36 1st bolt m10 8 15 1.5 11 572 lt 2nd 50 5.0 36 rotor – crankshaft bolt m10 1 75 7.5 54 e rotor – starter clutch bolt m8 6 24 2.4 17 washer/pickup coil lead and lighting coil lead – generator cover bo...

  • Page 32: Spec

    2-13 e spec tightening torques thermoswitch (engine) – crankcase bolt m6 2 7.6 0.76 5.5 572 lt oil pressure switch — — 1 8.4 0.84 6.1 572 lt anode cover – anode bolt m6 1 12 1.2 8.7 271 lt anode cover – upper crankcase bolt m8 1 20 2.0 14 oil pan – lower crankcase bolt m6 13 12 1.2 8.7 572 lt lower ...

  • Page 33: Spec

    2-14 e spec tightening torques qsts cable ball joint – nozzle ring nut — 1 7.8 0.78 5.6 nozzle/impeller duct assembly – impeller housing 1 bolt m10 4 40 4.0 29 572 lt water inlet cover/water inlet strainer – impeller duct bolt m6 4 6.6 0.66 4.8 572 lt drive shaft nut – drive shaft nut — 1 69 6.9 50 ...

  • Page 34: Spec

    2-15 e spec tightening torques qsts cable end pin – qsts converter nut — 1 3.8 0.38 2.7 shift cable locknut (reverse gate side) nut — 1 2.9 0.29 2.1 572 lt shift cable grommet – hull nut — 1 5.9 0.59 4.3 shift cable holder – shift lever base nut — 2 5.4 0.54 3.9 steering cable locknut (steering mast...

  • Page 35: Spec

    2-16 e spec tightening torques hand grip – deck nut — 4 5.2 0.52 3.8 front seat stay – deck nut — 2 15 1.5 11 seat lock projection – deck beam nut — 1 26 2.6 19 seat lock projection – deck nut — 1 26 2.6 19 rear seat stay – deck beam nut — 4 6.4 0.64 4.6 deck beam – deck nut — 4 18 1.8 13 seat lock ...

  • Page 36: Spec

    2-17 e spec tightening torques bracket (coupler) – electrical box tapping screw ø6 1 3.9 0.39 2.8 slant detection switch – electrical box tapping screw ø6 2 3.9 0.39 2.8 main and fuel pump relay – electrical box tapping screw ø6 1 3.9 0.39 2.8 rectifier/regulator – electrical box tapping screw ø6 2 ...

  • Page 37: Spec

    2-18 e spec cable and hose routing cable and hose routing down bow 20˚ down up + i h-h g-g f-f i h h g g e b d a a b-b a-a c-c e-e d-d 2 3 2 5 4 6 7 6 7 2 9 0 a b c 6 9 f 5 4 3 f f b d c e c 1 1 2 4 5 6 g e d 8 h i 1 steering switch lead 2 fuel tank breather hose 3 qsts cable 4 steering cable 5 shif...

  • Page 38: Spec

    2-19 e spec cable and hose routing 3a 3a a s p a r e 20a 3a 3a main a b c d b c f d 8 7 2 3 4 5 6 6 e e a b c a 2 d e f g b 4 c h 9 9 8 a 6 a 6 c b 6 e-e f 1 i 1 0 k j 1 steering switch lead 2 throttle cable 3 handlebar switch lead 4 qsts cable 5 buzzer lead 6 fuel tank breather hose 7 ignition coil...

  • Page 39: Spec

    2-20 e spec cable and hose routing 5 b a h c d 9 e f g 8 2 a 9 1 2 5 0 2 9 6 7 7 6 5 4 3 2 1 È 4 a-a a a 8 c d 1 cooling water hose (cooling water inlet) 2 bilge hose 1 3 electric bilge pump 4 bilge hose 4 5 cooling water hose (from thermostat) 6 bilge hose 3 7 bilge hose 2 8 shift cable 9 cooling w...

  • Page 40: Spec

    2-21 e spec cable and hose routing b d g f a e-e Ð Ï Ë Ë Ë Ë Ê È É Õ Ì Ñ Ì Ó × Ñ Ô Ì Ê Ò Ò Ø Ë d a g f b 5 4 1 1 e e Í c-c Î 3 2 c c Ö 1 thermostat 2 cooling water pilot outlet hose 3 cooling water hose 4 cooling water hose (cooling water inlet) 5 negative battery lead È to cooling water pilot outle...

  • Page 41: Spec

    2-22 e spec cable and hose routing b d g f a e-e Ð Ï Ë Ë Ë Ë Ê È É Õ Ì Ñ Ì Ó × Ñ Ô Ì Ê Ò Ò Ø Ë d a g f b 5 4 1 1 e e Í c-c Î 3 2 c c Ö Î bundle the cooling water pilot outlet hose and cooling water hoses, pass a plastic tie through the stay hole, and then fasten the tie. Set the tie in the direction...

  • Page 42: Spec

    2-23 e spec cable and hose routing b d g f a e-e Ð Ï Ë Ë Ë Ë Ê È É Õ Ì Ñ Ì Ó × Ñ Ô Ì Ê Ò Ò Ø Ë d a g f b 5 4 1 1 e e Í c-c Î 3 2 c c Ö Õ bundle the cooling water hose (cylinder head cover to thermostat) and cooling water hose (star- board cooling water pilot outlet), and then fasten them with a plas...

  • Page 43: Spec

    2-24 e spec cable and hose routing b a a a-a c b 3 4 0 9 5 6 7 8 2 1 Ì Ë É È c a Ê 0 a 4 b 1 1 1 wiring harness 2 ground lead 3 wiring harness coupler 4 noise filter 5 oil pressure switch coupler 6 pickup coil coupler 7 thermoswitch (engine) coupler 8 lighting coil coupler 9 thermoswitch (exhaust) 0...

  • Page 44: Spec

    2-25 e spec cable and hose routing a a 1 2 4 3 7 5 6 0 9 8 a-a Ë Ê É Ì Í Î Ð Ï Ñ Ò Ï Ð b b È 1 engine temperature sensor coupler 2 lighting coil coupler 3 pickup coil coupler 4 thermoswitch (engine) coupler 5 thermoswitch (engine) 6 starter motor 7 engine temperature sensor 8 engine temperature sens...

  • Page 45: Spec

    2-26 e spec cable and hose routing a a 1 2 4 3 7 5 6 0 9 8 a-a Ë Ê É Ì Í Î Ð Ï Ñ Ò Ï Ð b b È È fasten the engine temperature sensor lead, ther- moswitch lead, and lighting coil lead with a plastic tie. Fasten the engine temperature sensor lead 10–20 mm (0.4–0.8 in) from the end of the protec- tive c...

  • Page 46: Insp

    E insp adj 3 chapter 3 periodic inspection and adjustment maintenance interval chart .............................................................. 3-1 periodic service ....................................................................................... 3-2 control system ...........................

  • Page 47: Insp

    3-1 e 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. *1: grease quantity: 33.0–35.0 cm 3 (1.11–1.18 oz) *2...

  • Page 48: Insp

    3-2 e insp adj control system periodic service control system steering master inspection 1. Inspect: • steering master excessive play → replace the steering master. Refer to “steering master” in chapter 8. Inspection steps: • move the handlebar up and down and back and forth. • check the excessive p...

  • Page 49: Insp

    3-3 e insp adj control system note: if the steering cable cannot be properly adjusted by the cable joint at the steering mas- ter end, adjust the cable joint at the jet pump end so that the same clearances are obtained. Refer to “remote control cables and speed sensor lead” in chapter 8. Warning the...

  • Page 50: Insp

    3-4 e insp adj control system 2. Adjust: • throttle lever free play adjustment steps: note: • when not replacing the throttle cable or removing the cable from the throttle body, adjust the throttle cable free play by fol- lowing steps (f) through (j). • when replacing the throttle cable or removing ...

  • Page 51: Insp

    3-5 e insp adj control system warning after adjusting the free play, turn the han- dlebar to the right and left and make sure that the trolling speed does not increase. H. Install the handlebar cover. T r . Handlebar cover screw: 1.1 n • m (0.11 kgf • m, 0.8 ft • lb) loctite 242 i. Install the ribbo...

  • Page 52: Insp

    3-6 e insp adj control system 2. Adjust: • qsts cable note: if the qsts cable cannot be properly adjusted by the cable joint at the qsts converter end, adjust the cable joint at the jet pump end so that the same lengths are obtained. Refer to “remote control cables and speed sensor lead” in chapter ...

  • Page 53: Insp

    3-7 e insp adj control system shift cable inspection and adjustment 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 on the bracket and the lever 3 contacts the re...

  • Page 54: Insp

    3-8 e insp adj control system trolling speed check and adjustment 1. Measure: • trolling speed out of specification → adjust. Trolling speed: 1,550–1,750 r/min checking steps: (watercraft on water) • start the engine and allow it to warm up for a 15 minutes. • check the engine trolling speed using t...

  • Page 55: Insp

    3-9 e 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. •...

  • Page 56: Insp

    3-10 e insp adj fuel system/power unit water separator inspection 1. Inspect: • water separator 1 water accumulation → drain. Note: if need the water draining, remove the drain plug 2. 1 2 power unit valve clearance adjustment the following procedure applies to all of the valves. Note: • valve clear...

  • Page 57: Insp

    3-11 e insp adj power unit 4. Measure: • valve clearance out of specification → adjust. Valve clearance (cold): intake valve: 0.11–0.20 mm (0.0043–0.0079 in) exhaust valve: 0.25–0.34 mm (0.0098–0.0134 in) measurement steps: • turn the drive coupling counterclockwise, and then check if cylinder #1 is...

  • Page 58: Insp

    3-12 e insp adj power unit 5. Remove: • timing chain tensioner cap bolt 1 • gasket 1 6. Turn the timing chain tensioner rod fully clockwise with a thin screwdriver 1. Note: make sure that the tensioner rod has been fully set clockwise. 1 7. Remove: • intake camshaft caps • exhaust camshaft caps • ti...

  • Page 59: Insp

    3-13 e insp adj power unit 8. Adjust: • valve clearance adjustment steps: • remove the valve lifter 1 and the valve pad 2. Note: • cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. • make a note of the position of each valve lifter 3 and valve pad 4 ...

  • Page 60: Insp

    3-14 e insp adj power unit note: the new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect. • install the new valve pad 5 and the valve lifter 6. Note: • lubricate the valve pad with moly...

  • Page 61: Insp

    3-15 e insp adj power unit intake exhaust measured clearance original valve pad number 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00–0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03–0.07 120 1...

  • Page 62: Insp

    3-16 e insp adj power unit 9. Remove: • dial gauge • dial gauge stand • dial gauge needle 10. Install: • all removed parts note: for installation, reverse the removal proce- dure. Engine oil level check 1. Check: • engine oil level checking steps: caution: • when checking the engine oil level on wat...

  • Page 63: Insp

    3-17 e insp adj power unit • place the watercraft in a horizontal posi- tion or launch the watercraft. • remove the rear and front seats. • 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 come...

  • Page 64: Insp

    3-18 e insp adj power unit • remove the 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 a, add sufficient oil of the rec- ommended type to raise it to the correct level. • ...

  • Page 65: Insp

    3-19 e insp adj power unit 2. Remove: • oil filler cap 1 1 3. Insert the tube of an oil changer into the oil filler hole. 4. Operate the oil changer to extract the oil. 5. If the oil filter is also to be replaced, per- form the following procedure. 6. Pour the specified amount of the recom- mended e...

  • Page 66: Insp

    3-20 e insp adj power unit 7. Fill: • oil tank (with the specified amount of the recom- mended engine oil) caution: when starting the engine make sure the dipstick is securely fitted into the oil tank. 8. Install: • oil filler cap recommended oil: sae 10w-30 api se, sf, sg, sh, sj, sl oil quantity: ...

  • Page 67: Insp

    3-21 e insp adj power unit 2. Remove the air filter element and check it for dirt and oil. Replace the air filter ele- ment if there is any oil buildup. Caution: • make sure that the air filter element is installed in the filter case properly. • do not start the engine with the air filter element re...

  • Page 68: Insp

    3-22 e insp adj power unit 3. 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 el...

  • Page 69: Insp

    3-23 e insp adj power unit 6. Tighten: • spark plug note: • before installing the spark plug, clean the gasket surface and spark plug surface. Also, it is suggested to apply a thin film of anti- seize compound to the spark plug threads to prevent thread seizure. • if a torque wrench is not available...

  • Page 70: Insp

    3-24 e insp adj electrical electrical battery inspection warning battery electrolyte is poisonous and dan- gerous, causing severe burns, etc. Electro- lyte contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidotes external: flush with water. Internal: drink large quantities of wat...

  • Page 71: Insp

    3-25 e 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 machine on its side for the impe...

  • Page 72: Insp

    3-26 e insp adj electrical 3. Inspect: • specific gravity out of specification → charge. 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. Specific gravity at 20 °c (68 °f): 1.28 ch...

  • Page 73: Insp

    3-27 e 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: 0.35–0.45 mm (0.0138–0.0177 in) measurem...

  • Page 74: Insp

    3-28 e insp adj bilge pump bilge pump bilge strainer inspection 1. Inspect: • bilge strainer contaminants → clean. Cracks/damage → replace. Inspection steps: • remove the deck beam. Refer to “seats and hand grip” in chapter 8. • remove the coupling cover. • disconnect the bilge strainer case 1 from ...

  • Page 75: Insp

    3-29 e insp adj general 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) note: before lubricating the throttle cable, squeeze the t...

  • Page 76: Insp

    3-30 e insp adj general 4. Lubricate: • qsts cables (pulley end) recommended grease: yamaha marine grease, yamaha grease a (water resistant grease) 5. Lubricate: • nozzle pivot shaft • steering cable (nozzle end) • qsts cable (nozzle end) recommended grease: yamaha marine grease, yamaha grease a (wa...

  • Page 77: Insp

    3-31 e insp adj general 7. Fill: • intermediate housing note: fill the intermediate housing with the recom- mended grease through the grease nipple 1. Recommended grease: yamaha marine grease, yamaha grease a (water resistant grease) grease quantity: initial 10 hours: 33.0–35.0 cm 3 (1.11–1.18 oz) e...

  • Page 78: Fuel

    E fuel 4 chapter 4 fuel system arrangement of the throttle body components couplers .................................................................................................... 4-1 fuel tank and fuel pump module...................................................... 4-2 exploded diagram ........

  • Page 79: Fuel

    4-1 e fuel arrangement of the throttle body components couplers arrangement of the throttle body components couplers 1 bypass valve motor coupler 2 joint coupler 3 sensor assembly coupler 4 fuel injector #4 coupler 5 fuel injector #3 coupler 6 fuel injector #2 coupler 7 fuel injector #1 coupler 8 th...

  • Page 80: Fuel

    4-2 e fuel fuel tank and fuel pump module fuel tank and fuel pump module exploded diagram removal and installation chart step procedure/part name q’ty service points fuel tank removal follow the left “step” for removal. Service lid 1 refer to “front hood” in chapter 8. Service lid 2 ventilation hose...

  • Page 81: Fuel

    4-3 e fuel fuel tank and fuel pump module exploded diagram step procedure/part name q’ty service points 4 fuel tank breather hose 1 note: make sure that the inner seal of the coupler is installed properly before connecting the coupler. 5 fuel sender coupler 1 6 fuel pump module coupler 1 7 cover 1 8...

  • Page 82: Fuel

    4-4 e fuel fuel tank and fuel pump module exploded diagram step procedure/part name q’ty service points 13 hose clamp 2 14 fuel filler hose 1 15 nut 1 16 fuel filler neck 1 17 rubber seal 1 18 bolt 2 19 fuel tank assembly 1 20 bolt 2 21 fuel tank belt 2 reverse the removal steps for installation. 1....

  • Page 83: Fuel

    4-5 e fuel fuel tank and fuel pump module service points fuel hose disconnection 1. Disconnect: • fuel hose refer to “fuel injection system”. Fuel pump module removal 1. Remove: • nuts • retainer note: loosen the nuts in the sequence shown. 1 4 9 6 2 3 8 7 5 2. Remove: • fuel pump module 1 note: rem...

  • Page 84: Fuel

    4-6 e fuel fuel tank and fuel pump module rollover valve inspection 1. Check: • rollover valve faulty → replace. 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 sys...

  • Page 85: Fuel

    4-7 e fuel fuel tank and fuel pump module fuel pump module installation 1. Tighten: • nuts note: tighten the nuts in the sequence shown. Fuel hose connect refer to “fuel injection system”. T r . 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 • l...

  • Page 86: Fuel

    4-8 e fuel fuel injection system fuel injection system exploded diagram removal and installation chart step procedure/part name q’ty service points throttle bodies removal follow the left “step” for removal. 1 screw 2 2 air filter case cover 1 3 air filter 1 4 bolt 4 5 ribbon sub assembly 2 6 holder...

  • Page 87: Fuel

    4-9 e fuel fuel injection system exploded diagram step procedure/part name q’ty service points 11 fuel hose 1 12 bolt 2 13 fuel hose holder 1 14 clamp 1 15 clamp 1 16 bolt 8 17 throttle bodies 1 18 sensor assembly coupler 1 19 fuel injector coupler 4 20 throttle position sensor coupler 1 lt 572 lt l...

  • Page 88: Fuel

    4-10 e fuel fuel injection system exploded diagram step procedure/part name q’ty service points 21 joint connector 1 22 bypass valve motor coupler 1 23 ring 1 reverse the removal steps for installation. Lt 572 lt lt 242 lt e a a lt 572 lt lt 572 lt 7 8 9 15 14 12 13 11 10 5 × 70 mm 2.5 n • m (0.25 k...

  • Page 89: Fuel

    4-11 e fuel fuel injection system exploded diagram removal and installation chart step procedure/part name q’ty service points air filter case removal follow the left “step” for removal. Throttle bodies 1 clamp/breather hose 1/1 2 band 1 unfasten the wiring harness. 3 lighting coil coupler 1 from wi...

  • Page 90: Fuel

    4-12 e fuel fuel injection system exploded diagram step procedure/part name q’ty service points 8 wiring harness coupler 1 9 bolt 3 10 air filter case 1 11 bolt 2 12 wiring harness bracket 1 1 13 sub wiring harness 1 14 bolt 2 15 fuel hose bracket 1 16 screw 1 17 wiring harness bracket 2 1 3 16 5 15...

  • Page 91: Fuel

    4-13 e fuel fuel injection system exploded diagram step procedure/part name q’ty service points 18 grommet 1 19 throttle body joint 4 20 band 2 21 bolt 2 22 air filter case stay 1 2 23 band 1 24 bolt 1 25 air filter case stay 2 1 reverse the removal steps for installation. 3 16 5 15 14 24 23 25 10 1...

  • Page 92: Fuel

    4-14 e fuel fuel injection system exploded diagram removal and installation chart step procedure/part name q’ty service points throttle body disassembly follow the left “step” for disassembly. 1 screw 3 2 bracket 1 3 bolt/nut 2/2 4 bypass valve motor 1 5 holder 1 6 holder 1 7 hose #4 1 8 hose #3 1 9...

  • Page 93: Fuel

    4-15 e fuel fuel injection system exploded diagram step procedure/part name q’ty service points 11 bolt 4 12 fuel rail 1 13 screw 2 14 sensor assembly 1 15 intake vacuum hose 3 16 joint 1 17 fuel injector 4 18 o-ring 4 19 grommet 4 20 screw 2 21 throttle stop guide 1 22 screw 2 5.0 n • m (0.5 kgf • ...

  • Page 94: Fuel

    4-16 e fuel fuel injection system exploded diagram step procedure/part name q’ty service points 23 throttle stop screw bracket 1 24 screw/spring 4/4 25 bypass air screw 4 26 spring 4 27 washer 4 28 o-ring 4 29 screw 2 30 throttle position sensor 1 31 o-ring 1 32 throttle bodies 1 reverse the disasse...

  • Page 95: Fuel

    4-17 e fuel fuel injection system service points hose clamps removal 1. Remove: • hose clamps caution: if the hose clamps are removed without cutting the joint first, the fuel hose will be damaged. Hose clamps installation 1. Install: • hose clamps warning do not reuse the hose clamps, always replac...

  • Page 96: Fuel

    4-18 e fuel caution: • do not rotate the quick connector tab 1 past the stopper position a, 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...

  • Page 97: Fuel

    4-19 e fuel fuel injection system 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 check...

  • Page 98: Fuel

    4-20 e fuel fuel injection system fuel injector inspection caution: the throttle bodies should not be disas- sembled unnecessarily. 1. Check: • injector dirt/residue → clean. Damage → replace. 2. Measure: • fuel injectors resistance out of specification → replace. 3. Check the operation of the fuel ...

  • Page 99: Fuel

    4-21 e fuel fuel injection system bypass valve motor inspection 1. Inspect: • hoses damage/cracks → replace. 2. Check: • check the bypass valve motor operation using the yamaha diagnostic system. Throttle body installation 1. Install: • throttle body caution: do not bend the fuel pipe 1. 1 2. Instal...

  • Page 100: Fuel

    4-22 e fuel fuel injection system throttle bodies synchronization 1. Remove: • throttle bodies • air filter case 2. Adjust: • throttle bodies synchronization adjustment steps: note: the bypass air screws 1 should not be adjusted. However, if it is necessary to remove the bypass air screw, be sure to...

  • Page 101: Fuel

    4-23 e fuel fuel injection system c. Turn synchronizing screw #1 3 clock- wise approximately 7 times until it starts to contact the lever. Note: • butterfly valve #1 should be fully closed. Butterfly valves #2 and #3 open if the screw is turned more than 7 times. • if butterfly valves #1, #2, and #3...

  • Page 102: Fuel

    4-24 e fuel fuel injection system note: for best results, use a vacuum gauge (commercially obtainable), like 9 or 0 shown in the illustration, that has four adapters. I. Install the throttle bodies. Note: adjust the throttle body synchronization with the air filter case uninstalled. J. Connect the f...

  • Page 103: Fuel

    4-25 e fuel fuel injection system o. Measure the throttle position sensor out- put voltage (dc). Adjust the throttle posi- tion sensor a position if out of specification. Throttle position sensor output voltage: pink (p) – black/orange (b/o) 0.756 ± 0.016 v note: • to decrease the output voltage, tu...

  • Page 104: Fuel

    4-26 e fuel 3. Remove: • throttle bodies 4. Remove: • carburetor synchronizer or vacuum gauge 5. Install: • plugs 6. Install: • air filter case • throttle bodies vacuum pressure at trolling speed: cylinder cylinder difference example #1 –18 ± 10 mmhg (–2.45 ± 1.33 kpa, –0.8 ± 0.4 inhg) –230 ± 10 mmh...

  • Page 105: Fuel

    4-27 e fuel fuel injection system fuel pressure measurement 1. Disconnect: • fuel hose refer to “fuel hose disconnection”. 2. Install: • fuel pressure gauge adapter 1 • fuel pressure gauge 2 note: to connect the fuel pressure gauge adapter, follow the procedures for connecting a fuel hose. (refer to...

  • Page 106: Powr

    E powr chapter 5 power unit engine unit .................................................................................................. 5-1 exploded diagram ............................................................................. 5-1 removal and installation chart ..............................

  • Page 107: Powr

    E powr 5 oil pump...................................................................................................... 5-25 exploded diagram ........................................................................... 5-25 removal and installation chart .................................................

  • Page 108: Powr

    E powr cylinder head.......................................................................................... 5-63 exploded diagram ........................................................................... 5-63 removal and installation chart ............................................. 5-63 serv...

  • Page 109: Powr

    E powr crankshaft ............................................................................................ 5-103 exploded diagram ......................................................................... 5-103 removal and installation chart ............................................ 5-103 serv...

  • Page 110: Powr

    5-1 e powr engine unit engine unit exploded diagram removal and installation chart step procedure/part name q’ty service points engine unit removal follow the left “step” for removal. Engine oil drain. Refer to “power unit” in chapter 3. Service lid 1 refer to “front hood” in chapter 8. Battery nega...

  • Page 111: Powr

    5-2 e powr engine unit exploded diagram step procedure/part name q’ty service points 3 electrical box 1 4 clamp/cooling water hose 1/1 cooling water pilot outlet 5 clamp/cooling water hose 1/1 cooling water pilot outlet 6 clamp/cooling water hose 1/1 cooling water outlet 7 clamp/cooling water hose 1...

  • Page 112: Powr

    5-3 e powr engine unit exploded diagram *: as required. Step procedure/part name q’ty service points 13 bolt/washer 4/4 14 shim * 15 engine unit 1 reverse the removal steps for installation. 4 10 11 12 6 3 7 2 8 1 9 5 9 14 9 13 15 lt 271 lt lt 572 lt 7.8 n • m (0.78 kgf • m, 5.6 ft • ib) 6 × 25 mm 8...

  • Page 113: Powr

    5-4 e 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 ...

  • Page 114: Powr

    5-5 e powr engine unit 5. Measure: • compression pressure out of specification → refer to steps (b) and (c). 6. Install: • spark plug minimum compression pressure (reference data): 1,150 kpa (11.5 kgf/cm 2 , 164 psi) measurement steps: a. With the throttle wide open, crank the engine until the readi...

  • Page 115: Powr

    5-6 e powr engine unit 7. Install: • ignition coils • air filter element • air filter case cover oil filter removal and installation 1. Remove: • oil filter 1 note: install the oil filter with the same special tool that was used for removal. Engine unit removal 1. Remove: • engine unit t r . Ignitio...

  • Page 116: Powr

    5-7 e powr engine unit 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...

  • Page 117: Powr

    5-8 e powr exhaust pipe 3 exhaust pipe 3 exploded diagram removal and installation chart step procedure/part name q’ty service points exhaust pipe 3 removal follow the left “step” for removal. Engine unit refer to “engine unit”. Air filter case refer to “fuel injection system” in chapter 4. 1 clamp/...

  • Page 118: Powr

    5-9 e powr exhaust pipe 3 exploded diagram step procedure/part name q’ty service points 6 exhaust joint clamp 2 slide the outer exhaust joint for exhaust manifold side 7 exhaust joint clamp 2 8 bolt 1 note: tighten the bolts in the sequence indicated. 9 bolt 1 10 bolt 2 11 collar 1 12 exhaust pipe 3...

  • Page 119: Powr

    5-10 e powr exhaust pipe 3 exploded diagram step procedure/part name q’ty service points 15 gasket 1 16 inner exhaust joint 1 17 exhaust joint seal 1 18 outer exhaust joint 1 reverse the removal steps for installation. 3 6 18 2 7 17 16 10 12 11 8 9 13 14 15 5 4 1 lt 572 lt 572 lt 572 lt 572 lt 242 l...

  • Page 120: Powr

    5-11 e powr exhaust pipes 1 and 2 exhaust pipes 1 and 2 exploded diagram removal and installation chart step procedure/part name q’ty service points exhaust pipes 1 and 2 removal follow the left “step” for removal. Exhaust pipe 3 refer to “exhaust pipe 3”. Generator cover refer to “generator and sta...

  • Page 121: Powr

    5-12 e powr exhaust pipes 1 and 2 exploded diagram step procedure/part name q’ty service points 6 gasket 1 7 dowel pin 2 8 clamp/cooling water hose 2/2 È from cooling water inlet 9 bolt 4 10 bolt 6 11 exhaust pipe 1 1 12 gasket 1 13 dowel pin 2 reverse the removal steps for installation. E e e lt 24...

  • Page 122: Powr

    5-13 e powr exhaust manifold exhaust manifold exploded diagram removal and installation chart step procedure/part name q’ty service points exhaust manifold removal follow the left “step” for removal. Exhaust pipes 1 and 2 refer to “exhaust pipes 1 and 2”. 1 joint assembly 1 È to cylinder block note:...

  • Page 123: Powr

    5-14 e powr exhaust manifold exploded diagram step procedure/part name q’ty service points 6 bolt 1 7 bolt 4 8 exhaust manifold 2 1 9 gasket 1 10 dowel pin 2 reverse the removal steps for installation. 4 3 2 5 6 7 10 10 9 8 5 lt 242 lt 242 lt 242 lt 242 1 2nd 22 n • m (2.2 kgf • m, 16 ft • ib) 1st 2...

  • Page 124: Powr

    5-15 e powr oil tank oil tank exploded diagram removal and installation chart step procedure/part name q’ty service points oil tank removal follow the left “step” for removal. Engine unit refer to “engine unit”. Air filter case refer to “fuel injection system” in chapter 4. Thermostat housing refer ...

  • Page 125: Powr

    5-16 e powr oil tank exploded diagram step procedure/part name q’ty service points 7 bolt 2 8 collar 2 9 oil separator 1 10 clamp/breather hose 1/1 Ê to air filter case mark a 11 clamp/breather hose 1/1 Ë from cylinder head cover 12 clamp/cooling water hose 1/1 Ì from cooling water inlet 13 bolt 1 1...

  • Page 126: Powr

    5-17 e powr oil tank exploded diagram step procedure/part name q’ty service points 18 gasket 1 19 bolt 2 20 ground lead 2 21 bolt 2 22 nut 2 23 bolt 5 24 oil tank 1 25 oil tank stay 1 26 pin 2 27 o-ring 4 28 connector 2 reverse the removal steps for installation. Ì lt 572 lt 572 lt 572 lt 572 lt 572...

  • Page 127: Powr

    5-18 e powr oil tank exploded diagram removal and installation chart step procedure/part name q’ty service points oil tank disassembly follow the left “step” for disassembly. 1 bolt/washer 2/2 2 bracket/grommet 2/2 3 bolt 4 4 hunger 2 5 oil tank filler cap 1 6 packing 1 7 bolt 8 8 oil tank cover 1 9...

  • Page 128: Powr

    5-19 e powr oil tank exploded diagram step procedure/part name q’ty service points 11 oil breather plate 1 1 12 oil breather plate 2 1 13 gasket 1 14 bolt 3 15 baffle plate 1 16 bolt 2 17 oil strainer 1 18 bolt 24 19 oil cooler cover 2 20 gasket 2 e e e e 3 4 9 13 12 11 10 18 19 20 23 2 1 22 20 21 1...

  • Page 129: Powr

    5-20 e powr oil tank exploded diagram step procedure/part name q’ty service points 21 screw 1 22 anode 1 23 oil tank 1 reverse the disassembly steps for assembly. E e e e 3 4 9 13 12 11 10 18 19 20 23 2 1 22 20 21 19 17 15 18 14 16 7 8 6 5 lt 572 lt lt 572 lt lt 572 lt lt 572 lt lt 572 lt 6 × 25 mm ...

  • Page 130: Powr

    5-21 e powr oil tank service points oil tank removal 1. Remove: • oil tank note: loosen the oil tank bolts and nuts in the sequence shown. 3 5 6 8 9 4 2 1 7 2. Remove: • oil tank cover • gasket note: loosen the oil tank cover bolts in the sequence shown. 1 2 6 7 3 4 8 5 3. Remove: • oil breather pla...

  • Page 131: Powr

    5-22 e powr oil tank 4. Remove: • oil cooler covers • gaskets note: loosen the oil cooler cover bolts in the sequence shown. 8 1 9 12 7 6 5 11 10 3 4 2 oil strainer inspection 1. Check: • oil strainer 1 damage → replace. Contaminants → clean. Oil tank installation 1. Install: • gaskets • oil cooler ...

  • Page 132: Powr

    5-23 e powr 2. Install: • gasket • oil breather plate 2 • oil breather plate 1 note: tighten the oil breather plate bolts in the sequence shown. T r . 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) 6 5 4 3 8 7 2 1 3. Install: • gasket •...

  • Page 133: Powr

    5-24 e powr oil tank 4. Install: • oil tank note: tighten the oil tank nuts and bolts in the sequence shown. T r . 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, ...

  • Page 134: Powr

    5-25 e powr oil pump oil pump exploded diagram removal and installation chart step procedure/part name q’ty service points oil pump assembly removal follow the left “step” for removal. Oil tank refer to “oil tank”. 1 drain plug/washer 1/1 drain engine oil. 2 bolt 6 3 bolt 1 4 bolt 1 5 bolt 2 6 oil p...

  • Page 135: Powr

    5-26 e powr oil pump exploded diagram step procedure/part name q’ty service points 9 bolt 2 10 strainer 1 reverse the removal steps for installation. 2nd 28 n • m (2.8 kgf • m, 20 ft • ib) 1st 15 n • m (1.5 kgf • m, 11 ft • ib) 8 × 130 mm 6 × 25 mm 10 n • m (1.0 kgf • m, 7.2 ft • ib) 2nd 28 n • m (2...

  • Page 136: Powr

    5-27 e powr oil pump exploded diagram removal and installation chart step procedure/part name q’ty service points oil pump disassembly follow the left “step” for disassembly. 1 bolt 1 2 bolt 3 3 oil pump housing cover 1 1 4 gasket 1 5 oil pump housing 1 1 6 check valve assembly 1 7 oil pump housing ...

  • Page 137: Powr

    5-28 e powr oil pump exploded diagram step procedure/part name q’ty service points 11 pin 1 12 screw 1 13 oil pump housing cover 2 1 14 gasket 1 15 spring 1 16 plunger 1 17 pin 1 18 pin 1 19 oil pump shaft 1 20 inner rotor (feed) 1 21 outer rotor (feed) 1 e 8 × 70 mm 20 n • m (2.0 kgf • m, 14 ft • i...

  • Page 138: Powr

    5-29 e powr oil pump exploded diagram step procedure/part name q’ty service points 22 check valve seat 1 23 oil seal 1 reverse the disassembly steps for assembly. E 8 × 70 mm 20 n • m (2.0 kgf • m, 14 ft • ib) 8 × 20 mm 20 n • m (2.0 kgf • m, 14 ft • ib) 4 × 12 mm 2.0 n • m (0.2 kgf • m, 1.4 ft • ib...

  • Page 139: Powr

    5-30 e powr oil pump service points oil pump inspection 1. Check: • oil pump housing cover 1 1 • oil pump housing cover 2 2 • oil pump housing 1 3 • oil pump housing 2 4 cracks/damage/wear → replace the defective part(s). 1 2 3 4 2. Measure: • inner-rotor-to-outer-rotor-tip clearance a • outer-rotor...

  • Page 140: Powr

    5-31 e powr oil pump oil strainer inspection 1. Check: • oil strainer 1 damage → replace. Contaminants → clean. 1 oil pump installation 1. Install: • oil pump assembly note: align the projection a on the oil pump shaft with the slit b on the oil pump driven gear shaft. T r . Oil pump assembly bolt: ...

  • Page 141: Powr

    5-32 e powr reduction drive gear reduction drive gear exploded diagram removal and installation chart step procedure/part name q’ty service points reduction drive gear removal follow the left “step” for removal. Generator cover refer to “generator and starter motor”. Oil pump refer to “oil pump”. 1 ...

  • Page 142: Powr

    5-33 e powr reduction drive gear exploded diagram step procedure/part name q’ty service points 6 reduction drive gear case assembly 1 7 gasket 1 8 pin 2 9 circlip 2 10 reduction drive gear 1 11 washer 2 12 drive coupling 1 reverse the removal steps for installation. 8 8 9 11 10 11 9 7 3 2 4 12 5 4 6...

  • Page 143: Powr

    5-34 e powr reduction drive gear exploded diagram removal and installation chart *1 : epnoc grease ap #0 step procedure/part name q’ty service points reduction drive gear disassembly follow the left “step” for disassembly. 1 oil pump drive shaft 1 2 drive shaft 1 3 collar 1 4 oil seal 2 5 circlip 1 ...

  • Page 144: Powr

    5-35 e powr reduction drive gear exploded diagram *1 : epnoc grease ap #0 step procedure/part name q’ty service points 9 circlip 1 10 bearing 1 11 reduction drive gear case 1 reverse the disassembly steps for assembly. E e e e 3 4 8 6 5 10 9 1 * 1 a a * 1 5 × 10 mm e 2 11 7 not reusable not reusable.

  • Page 145: Powr

    5-36 e powr reduction drive gear service points drive coupling removal 1. Remove: • reduction drive gear housing 2. Remove: • drive coupling 1 note: while holding the drive shaft 2 with the rotor holder 3, loosen the drive coupling with the coupler wrench 4. Coupler wrench: yw-06551/90890-06551 univ...

  • Page 146: Powr

    5-37 e powr reduction drive gear 2. Remove: • circlip • reduction drive gear bearing È for usa and canada É for worldwide slide hammer and adapters: yb-06096 stopper guide plate: 90890-06501 bearing puller assembly: 90890-06535 stopper guide stand: 90890-06538 È É oil pump drive shaft inspection 1. ...

  • Page 147: Powr

    5-38 e powr reduction drive gear bearing installing 1. Install: • reduction drive gear bearing note: install the reduction driver gear bearing using a press. Driver handle—large: yb-06071 driver rod ls: 90890-06606 outer race installer—forward gear: yb-06085 ball bearing attachment: 90890-06631 2. I...

  • Page 148: Powr

    5-39 e powr reduction drive gear 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 di...

  • Page 149: Powr

    5-40 e powr reduction drive gear drive shaft installation 1. Install: • drive shaft • collar note: press the into the reduction drive gear case with 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 ...

  • Page 150: Powr

    5-41 e powr generator and starter motor generator and starter motor exploded diagram removal and installation chart step procedure/part name q’ty service points generator cover and flywheel magneto removal follow the left “step” for removal. Engine unit refer to “engine unit”. 1 nut/washer 1/1 2 sta...

  • Page 151: Powr

    5-42 e powr generator and starter motor exploded diagram step procedure/part name q’ty service points 8 pulser coil coupler 1 9 nut 2 10 bolt 8 11 generator cover 1 12 dowel pin 2 13 gasket 1 14 idle gear shaft 1 15 idle gear 1 16 bolt/washer 1/1 17 flywheel magneto 1 18 bolt 6 4 3 2 1 5 6 8 7 9 10 ...

  • Page 152: Powr

    5-43 e powr generator and starter motor exploded diagram step procedure/part name q’ty service points 19 starter clutch 1 20 starter gear 1 21 woodruff key 1 reverse the removal steps for installation. 4 3 2 1 5 6 8 7 9 10 11 13 12 18 16 17 19 20 21 15 14 a a e e e lt 572 lt 572 a a a a 8 × 30 mm 18...

  • Page 153: Powr

    5-44 e powr generator and starter motor exploded diagram removal and installation chart step procedure/part name q’ty service points generator disassembly follow the left “step” for disassembly. 1 bolt/washer 3/3 2 bolt 4 3 pickup coil 2 note: there washers holds the pickup coil lead. Make sure to n...

  • Page 154: Powr

    5-45 e powr generator and starter motor exploded diagram step procedure/part name q’ty service points 5 holder 1 6 bolt 3 7 lighting coil 1 reverse the disassembly steps for assembly. 1 7 6 3 2 4 5 lt 242 lt 242 lt 242 lt 242 14 n • m (1.4 kgf • m, 10 ft • ib) 6 × 14 mm 4.9 n • m (0.49 kgf • m, 3.5 ...

  • Page 155: Powr

    5-46 e powr generator and starter motor service points flywheel magneto removal 1. Remove: • flywheel magneto bolt 1 • washer note: while holding the flywheel magneto 2 with the sheave holder 3, loosen the flywheel magneto bolt. Sheave holder: ys-01880-a/90890-01701 2. Remove: • flywheel magneto 1 •...

  • Page 156: Powr

    5-47 e powr generator and starter motor 2. Check: • starter clutch 1 • starter gear 2 burrs/chips/roughness/wear → replace the defective part(s). 3. Check: • starter clutch gear’s contacting surfaces a damage/pitting/wear → replace the starter clutch gear. 1 2 a 4. Check: • starter clutch operation ...

  • Page 157: Powr

    5-48 e powr generator and starter motor flywheel magneto installation 1. Install: • woodruff key • flywheel magneto • washer • flywheel magneto bolt note: • clean the tapered portion of the crankshaft and the flywheel magneto hub. • when installing the flywheel magneto, make sure the woodruff key is...

  • Page 158: Powr

    5-49 e powr camshafts camshafts exploded diagram removal and installation chart step procedure/part name q’ty service points cylinder head cover removal follow the left “step” for removal. Air filter case refer to “fuel injection system” in chapter 4. 1 bolt 4 2 ignition coil 4 3 spark plug 4 4 clam...

  • Page 159: Powr

    5-50 e powr camshafts exploded diagram step procedure/part name q’ty service points 7 clamp/cooling water hose 1/1 É to thermostat 8 rubber seal 1 9 bolt 1 10 cooling water pipe 1 11 o-ring 1 12 bolt 1 13 band 1 14 collar 1 15 bolt 6 16 rubber mount 6 17 cylinder head cover 1 e 4 6 5 7 8 10 11 15 16...

  • Page 160: Powr

    5-51 e powr camshafts exploded diagram step procedure/part name q’ty service points 18 cylinder head cover gasket 1 19 timing chain guide (top side) 1 reverse the removal steps for installation. E 4 6 5 7 8 10 11 15 16 9 lt 572 lt 17 19 18 3 13 n • m (1.3 kgf • m, 9.4 ft • ib) 10 n • m (1.0 kgf • m,...

  • Page 161: Powr

    5-52 e powr camshafts exploded diagram removal and installation chart step procedure/part name q’ty service points camshaft removal follow the left “step” for removal. Cylinder head cover reduction drive gear case refer to “reduction drive gear”. Note: when removing camshafts it is not neces- sary t...

  • Page 162: Powr

    5-53 e powr camshafts exploded diagram step procedure/part name q’ty service points 5 timing chain tensioner gasket 1 6 timing chain guide (exhaust side) 1 7 bolt 18 8 intake camshaft cap 3 9 dowel pin 6 note: during removal, the dowel pins may still be connected to the camshaft caps. 10 bolt 10 11 ...

  • Page 163: Powr

    5-54 e powr camshafts exploded diagram step procedure/part name q’ty service points 16 exhaust camshaft 1 17 bolt 2 18 exhaust camshaft sprocket 1 19 pin 1 20 timing chain guide (intake side) 1 reverse the removal steps for installation. E e e e e e m m 10 11 10 11 10 11 12 16 17 8 18 8 8 13 9 14 7 ...

  • Page 164: Powr

    5-55 e powr camshafts service points camshaft removal 1. Install: • dial gauge needle • dial gauge stand 1 (into spark plug hole #1) • dial gauge 2 2. Turn the drive coupling counterclockwise, and then check if cylinder #1 is at tdc of the compression stroke with a dial gauge. Note: tdc on the compr...

  • Page 165: Powr

    5-56 e powr camshafts 5. Remove: • camshaft caps • dowel pins note: loosen the intake and exhaust camshaft cap bolts in the sequence shown. 1 10 7 6 3 2 14 18 15 11 4 10 7 5 2 8 9 4 5 1 12 16 17 13 6 8 9 3 6. Remove: • intake camshaft 1 • exhaust camshaft 2 note: to prevent the timing chain from fal...

  • Page 166: Powr

    5-57 e powr camshafts 3. Measure: • camshaft runout out of specification → replace. Maximum camshaft runout: 0.03 mm (0.0012 in) 4. Measure: • camshaft-journal-to-camshaft-cap clearance out of specification → measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance: 0.03–0....

  • Page 167: Powr

    5-58 e powr camshafts 5. Measure: • camshaft journal diameter a out of specification → replace the cam- shaft. Within specification → replace the cyl- inder head and the camshaft caps as a set. Camshaft journal diameter: 24.46–24.47 mm (0.9630–0.9634 in) camshaft sprockets inspection 1. Check: • cam...

  • Page 168: Powr

    5-59 e powr camshafts camshaft installation 1. Install: • exhaust camshaft sprocket 1 • intake camshaft sprocket 2 (with the special tool 3) note: install the camshaft sprocket with the punch mark a facing outside. Universal magneto and rotor holder: yu-01235 rotor holder: 90890-01235 t r . Camshaft...

  • Page 169: Powr

    5-60 e powr camshafts • install the exhaust and intake camshaft caps. Note: gradually tighten the intake and exhaust camshaft cap bolts in 2–3 steps in the sequence shown. T r . Camshaft cap bolt: 10 n • m (1.0 kgf • m, 7.2 ft • lb) note: make sure that the punch marks c on the camshafts are aligned...

  • Page 170: Powr

    5-61 e powr camshafts t r . 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. T r . Cap bolt: 10 n • m (1.0 kgf • m, 7.2 ft • lb) 4. Turn: • drive coupli...

  • Page 171: Powr

    5-62 e powr camshafts 7. Install: • cylinder head cover gasket • cylinder head cover note: • apply gasket maker onto the mating sur- faces of the cylinder head cover gasket and cylinder head. • tighten the cylinder head cover bolts stages and in a crisscross pattern. T r . Cylinder head cover bolt: ...

  • Page 172: Powr

    5-63 e powr cylinder head cylinder head exploded diagram removal and installation chart step procedure/part name q’ty service points cylinder head removal follow the left “step” for removal. Engine unit refer to “engine unit”. Air filter case refer to “fuel injection system” in chapter 4. Exhaust pi...

  • Page 173: Powr

    5-64 e powr cylinder head exploded diagram step procedure/part name q’ty service points 4 nut/washer 2/2 5 nut/washer 6/6 6 nut/washer 2/2 7 cylinder head 1 8 cylinder head gasket 1 9 dowel pin 2 reverse the removal steps for installation. E e e e e e 2 4 1 8 5 5 7 9 3 5 5 6 lt 271 2nd 121 ± 5˚ 1st ...

  • Page 174: Powr

    5-65 e powr cylinder head service points cylinder head removal 1. Remove: • cylinder head bolts 1 2. Remove: • cylinder head nuts note: loosen the cylinder head nuts in the sequence shown. Cylinder head inspection 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) note: do n...

  • Page 175: Powr

    5-66 e powr cylinder head 3. Measure: • cylinder head warpage out of specification → replace the cyl- inder head. Cylinder head warpage limit: 0.1 mm (0.004 in) measurement steps: • place a straightedge 1 and a thickness gauge 2 across the cylinder head. • measure the warpage. • if the limit is exce...

  • Page 176: Powr

    5-67 e powr cylinder head 2. Tighten: • cylinder head bolts 1 note: lubricate the cylinder head bolts with engine oil. T r . Cylinder head bolt: 10 n • m (1.0 kgf • m, 7.2 ft • lb).

  • Page 177: Powr

    5-68 e powr valves and valve springs valves and valve springs exploded diagram removal and installation chart step procedure/part name q’ty service points valves and valve springs removal follow the left “step” for removal. Cylinder head refer to “cylinder head”. 1 intake valve lifter 12 2 intake va...

  • Page 178: Powr

    5-69 e powr valves and valve springs exploded diagram step procedure/part name q’ty service points 10 exhaust valve lifter 8 11 exhaust valve pad 8 12 exhaust valve cotter 16 13 exhaust valve upper spring seat 8 14 exhaust valve spring 8 15 exhaust valve oil seal 8 16 exhaust valve lower spring seat...

  • Page 179: Powr

    5-70 e powr valves and valve springs service points valve removal 1. Remove: • valve lifter 1 • valve pad 2 note: make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place. 2. Remove: • valve cotters 1 note: remove the valve cotters by com...

  • Page 180: Powr

    5-71 e powr valves and valve springs valve spring inspection 1. Measure: • valve spring free length a out of specification → replace the valve spring. 2. Measure: • valve spring tilt a out of specification → replace the valve spring. Valve spring free length: intake valve spring: 38.90 mm (1.53 in) ...

  • Page 181: Powr

    5-72 e powr valves and valve springs 4. Measure: • valve stem diameter a out of specification → replace the valve. Valve stem diameter a: intake valve: 3.975–3.990 mm (0.1565–0.1571 in) exhaust valve: 4.465–4.480 mm (0.1758–0.1764 in) 5. Measure: • valve stem runout out of specification → replace th...

  • Page 182: Powr

    5-73 e powr valves and valve springs 1. Measure: • valve guide inside diameter a 2. Calculate the valve stem-to-valve guide clearance as follows. Replace the valve guide if out of specification. Valve guide inside diameter: intake: 4.000–4.012 mm (0.1575–0.1580 in) exhaust: 4.500–4.512 mm (0.1772–0....

  • Page 183: Powr

    5-74 e powr valves and valve springs 2. Install the new valve guide 2 by striking the special service tool from the camshaft side until the valve guide clip 3 contacts the cylinder head. Note: apply engine oil to the surface of the new valve guide. Valve guide remover: intake (ø4.0 mm): ym-04111/908...

  • Page 184: Powr

    5-75 e powr valves and valve springs valve seat inspection 1. Eliminate carbon deposits from the valve with a scraper. 2. Apply a thin, even layer of mechanic’s blueing dye (dykem) onto the valve seat. 3. Lap the valve slowly on the valve seat with a valve lapper (commercially obtainable) as shown. ...

  • Page 185: Powr

    5-76 e powr valves and valve springs valve seat reface 1. Reface the valve seat with the valve seat cutter. 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 s...

  • Page 186: Powr

    5-77 e powr valves and valve springs 4. Use a 60° cutter to adjust the contact width of the bottom edge of the valve seat. B previous contact width 60˚ b 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˚ b c 6. ...

  • Page 187: Powr

    5-78 e powr valves and valve springs 9. Apply a thin, even layer of lapping com- pound onto the valve seat, and then lap the valve using a valve lapper (commer- cially obtainable). Caution: do not get the lapping compound on the valve stem and valve guide. 10. After every lapping procedure, be sure ...

  • Page 188: Powr

    5-79 e powr valves and valve springs 2. Compress the valve spring, and then install the valve cotter 1 using a thin screwdriver with a small amount of grease applied to it. Valve spring compressor: ym-01253/90890-04019 valve spring compressor attachment: (for the intake valve) ym-4114/90890-04114 (f...

  • Page 189: Powr

    5-80 e powr crankcase crankcase exploded diagram removal and installation chart step procedure/part name q’ty service points oil pan and crankcase removal follow the left “step” for removal. Engine unit refer to “engine unit”. Air filter case refer to “fuel injection system” in chapter 4. Exhaust pi...

  • Page 190: Powr

    5-81 e powr crankcase exploded diagram step procedure/part name q’ty service points oil tank refer to “oil tank”. Oil pump refer to “oil pump”. Reduction drive gear case refer to “reduction drive gear”. Cylinder head refer to “camshafts”. 1 timing chain 1 2 engine temperature sensor 1 3 washer 1 4 b...

  • Page 191: Powr

    5-82 e powr crankcase exploded diagram step procedure/part name q’ty service points 7 bolt 1 8 bolt 1 9 anode cover 1 10 grommet 1 11 anode 1 12 bolt 15 13 oil pan 1 14 gasket 1 15 bolt 2 16 bolt 1 17 bolt 7 6 21 20 20 11 10 9 8 7 2 3 4 5 16 15 17 18 13 14 12 19 1 lt 271 lt lt 572 lt lt 572 lt lt 57...

  • Page 192: Powr

    5-83 e powr crankcase exploded diagram step procedure/part name q’ty service points 18 bolt/washer 10/10 19 lower crankcase 1 20 dowel pin 2 21 dowel pin/o-ring 1/1 reverse the removal steps for installation. 6 21 20 20 11 10 9 8 7 2 3 4 5 16 15 17 18 13 14 12 19 1 lt 271 lt lt 572 lt lt 572 lt lt 5...

  • Page 193: Powr

    5-84 e powr crankcase exploded diagram removal and installation chart step procedure/part name q’ty service points oil pipe and oil filter bolt removal follow the left “step” for removal. Crankshaft refer to “crankshaft”. 1 bolt 1 2 oil pipe 1 3 o-ring 2 4 oil filter bolt 1 5 lower crankcase 1 rever...

  • Page 194: Powr

    5-85 e powr crankcase service points crankcase disassembly 1. Remove: • oil pan bolts note: • loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • loosen the bolts in decreasing numerical order (refer to the number...

  • Page 195: Powr

    5-86 e powr crankcase 4. Remove: • dowel pins crankcase inspection 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • crankcase cracks/damage → replace. • oil delivery passages obstruction → blow out with ...

  • Page 196: Powr

    5-87 e powr crankcase crankcase assembly 1. Lubricate: crankshaft journal bearings (with the recommended lubricant) 2. Apply: • gasket maker (onto the crankcase mating surfaces) note: do not allow any gasket maker to come into contact with the oil gallery or crankshaft journal bearings. Recommended ...

  • Page 197: Powr

    5-88 e powr crankcase 5. Tighten: • crankcase bolts 1–0 note: • do not reuse crankcase bolts 1–0. • the tightening procedure of crankcase bolts 1–0 is angle controlled, therefore tighten the bolts using the following procedure. Tightening steps: • tighten the bolts in the tightening sequence cast on...

  • Page 198: Powr

    5-89 e powr crankcase caution: • do not use a torque wrench to tighten the bolt to the specified angle. • tighten the bolt until it is at the speci- fied angle. Note: when using a hexagonal bolt, note that the angle from one corner to another is 60°. 6. Tighten: • crankcase bolts a–j note: tighten t...

  • Page 199: Powr

    5-90 e powr connecting rods and pistons connecting rods and pistons exploded diagram removal and installation chart step procedure/part name q’ty service points connecting rods and pistons removal follow the left “step” for removal. Crankcase separate refer to “crankcase”. 1 nut 8 2 connecting rod c...

  • Page 200: Powr

    5-91 e powr connecting rods and pistons exploded diagram step procedure/part name q’ty service points 8 bolt 8 9 big end upper bearing 4 10 top ring 4 11 2nd ring 4 12 oil ring 4 reverse the removal steps for installation. E e e e 1 2 3 10 11 12 4 5 6 8 7 9 2nd 120 ± 5˚ 1st 20 n • m (2.0 kgf • m, 14...

  • Page 201: Powr

    5-92 e powr connecting rods and pistons service points connecting rod and piston removal the following procedure applies to all of the connecting rods and pistons. 1. Remove: • connecting rod cap 1 • big end bearings note: identify the position of each big end bearing so that it can be reinstalled i...

  • Page 202: Powr

    5-93 e powr connecting rods and pistons cylinder and piston inspection the following procedure applies to all of the cylinders and pistons. 1. Check: • piston wall • cylinder wall vertical scratches → replace the cylin- der, and the piston and piston rings as a set. 2. Measure: • piston-to-cylinder ...

  • Page 203: Powr

    5-94 e powr connecting rods and pistons • if out of specification, replace the piston and piston rings as a set. • calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = cylinder bore “c” – piston skirt diameter “p” piston-to-cylinder clearance: 0.10–0....

  • Page 204: Powr

    5-95 e powr connecting rods and pistons 2. Install: • piston ring (into the cylinder) note: level the piston ring in the cylinder with the piston crown. A 5 mm (0.2 in) 3. Measure: • piston ring end gap out of specification → replace the pis- ton ring. Note: the oil ring expander spacer’s end gap ca...

  • Page 205: Powr

    5-96 e powr connecting rods and pistons piston pin inspection the following procedure applies to all of the piston pins. 1. Check: • piston pin blue discoloration/grooves → replace the piston pin and then check the lubri- cation system. 2. Measure: • piston pin outside diameter a out of specificatio...

  • Page 206: Powr

    5-97 e powr connecting rods and pistons connecting rod inspection 1. Measure: • crankshaft-pin-to-big-end-bearing clearance out of specification → replace the big end bearings. Crankshaft-pin-to-big-end- bearing clearance: 0.016–0.040 mm (0.0006–0.0016 in) measurement steps: the following procedure ...

  • Page 207: Powr

    5-98 e powr connecting rods and pistons note: • do not move the connecting rod or crank- shaft until the clearance measurement has been completed. • lubricate the bolts threads and nut seats with molybdenum disulfide grease. • make sure the “y” mark c on the con- necting rod faces towards the front ...

  • Page 208: Powr

    5-99 e powr connecting rods and pistons for example, if the connecting rod “p 1 ” and the crankshaft web “p 1 ” numbers are “5” and “1” respectively, then the bearing size for “p 1 ” is: bearing size of p 1 : “p 1 ” (connecting rod) – “p 1 ” (crankshaft web) 5 – 1 = 4 (green) bearing color code 1 br...

  • Page 209: Powr

    5-100 e powr connecting rods and pistons 3. Offset: • piston ring end gaps a top ring, oil ring expander spacer b 2nd ring, lower oil ring rail c upper oil ring rail È exhaust side b c a È 90 ˚ 45˚ 90˚ 4. Lubricate: • piston • piston rings • cylinder (with the recommended lubricant) recommended lubr...

  • Page 210: Powr

    5-101 e powr connecting rods and pistons 7. Install: • big end bearings • connecting rod assembly 1 (into the cylinder and onto the crankshaft pin) • connecting rod cap (onto the crankshaft pin) note: • align the projections on the big end bearings with the notches in the connecting rods and connect...

  • Page 211: Powr

    5-102 e powr connecting rods and pistons 9. Tighten: • connecting rod nuts warning • replace the connecting rod bolts and nuts with new ones. • clean the connecting rod bolts and nuts. Note: the tightening procedure of the connecting rod nuts is angle controlled, therefore tighten the nuts using the...

  • Page 212: Powr

    5-103 e powr crankshaft crankshaft exploded diagram removal and installation chart step procedure/part name q’ty service points crankshaft removal follow the left “step” for removal. Crankcase separate refer to “crankcase”. Connecting rod caps refer to “connecting rods and pistons”. 1 crankshaft 1 2...

  • Page 213: Powr

    5-104 e powr crankshaft service points crankshaft removal 1. Remove: • crankshaft 1 • crankshaft journal lower bearings (from the lower crankcase) • crankshaft journal upper bearings (from the upper crankcase) note: identify the position of each crankshaft journal bearing so that it can be reinstall...

  • Page 214: Powr

    5-105 e powr crankshaft caution: do not interchange the crankshaft journal bearings. To obtain the correct crankshaft- journal-to-crankshaft-journal-bearing clear- ance and prevent engine damage, the crankshaft journal bearings must be installed in their original positions. Measurement steps: • clea...

  • Page 215: Powr

    5-106 e powr crankshaft • tighten the bolts to specification in the tightening sequence cast on the crank- case. 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...

  • Page 216: Powr

    5-107 e powr crankshaft crankshaft installation 1. Install: • crankshaft journal upper bearings (into the upper crankcase) • crankshaft journal lower bearings (into the lower crankcase) note: • align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase...

  • Page 217: Powr

    5-108 e powr thermostat thermostat exploded diagram removal and installation chart step procedure/part name q’ty service points thermostat removal follow the left “step” for removal. 1 band 1 2 clamp/cooling water hose 1/1 È for cooling water outlet on stern side. 3 clamp/cooling water hose 2/1 4 cl...

  • Page 218: Powr

    5-109 e powr thermostat exploded diagram step procedure/part name q’ty service points 9 gasket 1 10 thermostat housing 1 11 bolt 2 12 collar 2 13 thermostat housing holder 1 reverse the removal steps for installation. 3 1 3 10 8 7 4 6 5 2 lt 572 lt 572 6 × 35 mm 2nd 7.6 n • m (0.76 kgf • m, 5.5 ft •...

  • Page 219: Powr

    5-110 e powr thermostat service points thermostat inspection 1. Check: • thermostat 1 does not open at 50–60 °c (123– 141 °f) → replace. 1 thermostat 2 thermometer 3 water 4 container È fully closed É fully open note: if the accuracy of the thermostat is in doubt, replace it. A faulty thermostat cou...

  • Page 220: Powr

    5-111 e powr cooling water hose cooling water hose exploded diagram removal and installation chart step procedure/part name q’ty service points cooling water hose removal follow the left “step” for removal. Exhaust manifold refer to “exhaust manifold”. 1 clamp/cooling water hose 1/1 È from exhaust m...

  • Page 221: Jet

    E jet pump chapter 6 jet pump unit intake grate, ride plate, and intake duct.................................... 6-1 exploded diagram ............................................................................. 6-1 removal and installation chart ................................................ 6-1 ...

  • Page 222: Jet

    E jet pump 6 transom plate and hoses.................................................................. 6-20 exploded diagram ........................................................................... 6-20 removal and installation chart .............................................. 6-20 service poi...

  • Page 223: Jet

    6-1 e jet pump intake grate, ride plate, and intake duct exploded diagram removal and installation chart step procedure/part name q’ty service points intake grate, ride plate, and intake duct removal follow the left “step” for removal. 1 bolt 2 2 bolt 2 3 intake grate 1 4 screw 4 5 speed sensor 1 no...

  • Page 224: Jet

    6-2 e jet pump intake grate, ride plate, and intake duct exploded diagram step procedure/part name q’ty service points 7 ride plate 1 8 bolt 4 9 intake duct 1 10 felt packing 1 reverse the removal steps for installation. Not reusable.

  • Page 225: Jet

    6-3 e jet pump intake grate, ride plate, and intake duct exploded diagram removal and installation chart step procedure/part name q’ty service points speed sensor disassembly follow the left “step” for disassembly. 1 holder 1 2 paddle wheel set 1 3 speed sensor 1 reverse the disassembly steps for as...

  • Page 226: Jet

    6-4 e jet pump jet pump unit jet pump unit exploded diagram removal and installation chart step procedure/part name q’ty service points jet pump unit removal follow the left “step” for removal. 1 shift cable joint 1 2 qsts cable joint 1 3 bilge hose 1 note: route the speed sensor lead between the je...

  • Page 227: Jet

    6-5 e jet pump jet pump unit exploded diagram step procedure/part name q’ty service points 8 collar 4 9 rubber plate 2 10 bolt 1 11 bolt 4 12 jet pump unit assembly 1 13 dowel pin 2 14 impeller housing 2 1 15 dowel pin 2 reverse the removal steps for installation. 8 × 24 mm 14 n • m (1.4 kgf • m, 10...

  • Page 228: Jet

    6-6 e jet pump reverse gate reverse gate exploded diagram removal and installation chart step procedure/part name q’ty service points reverse gate removal follow the left “step” for removal. 1 clamp/spout hose 1/1 2 bolt 2 3 washer 2 4 collar 2 5 reverse gate assembly 1 6 nut 1 7 bolt 1 8 washer 2 9...

  • Page 229: Jet

    6-7 e jet pump reverse gate exploded diagram step procedure/part name q’ty service points 10 bolt 6 11 bracket 1 12 reverse gate stay 2 13 nut 1 14 washer 1 15 bolt 1 16 lever 1 1 17 spacer 1 18 nut 1 19 washer 1.

  • Page 230: Jet

    6-8 e jet pump reverse gate exploded diagram step procedure/part name q’ty service points 20 collar 1 21 bolt 1 22 washer 1 23 collar 1 24 spring 1 25 lever 2 1 26 washer 1 reverse the removal steps for installation..

  • Page 231: Jet

    6-9 e jet pump reverse gate service points lever 1 installation 1. Install: • bolt 1 • lever 1 2 • spacer 3 • reverse gate 4 • washer 5 • nut 6 lever 2 installation 1. Install: • bolt 1 • washer 2 • collar 3 • spring 4 • lever 2 5 • washer 6 • collar 7 note: • when installing the spring, hook the sp...

  • Page 232: Jet

    6-10 e jet pump jet thrust nozzle and nozzle ring jet thrust nozzle and nozzle ring exploded diagram removal and installation chart step procedure/part name q’ty service points jet thrust nozzle and nozzle ring removal follow the left “step” for removal. Jet pump unit refer to “jet pump unit”. Rever...

  • Page 233: Jet

    6-11 e jet pump impeller duct and impeller housing 1 impeller duct and impeller housing 1 exploded diagram removal and installation chart step procedure/part name q’ty service points impeller duct and impeller housing 1 removal follow the left “step” for removal. Nozzle ring refer to “jet thrust noz...

  • Page 234: Jet

    6-12 e jet pump impeller duct and impeller housing 1 exploded diagram step procedure/part name q’ty service points 8 water inlet cover 1 9 packing 1 10 water inlet strainer 1 11 packing 1 reverse the removal steps for installation..

  • Page 235: Jet

    6-13 e jet pump impeller duct and drive shaft impeller duct and drive shaft exploded diagram removal and installation chart *1 : epnoc grease ap #0 step procedure/part name q’ty service points impeller duct and drive shaft disassembly follow the left “step” for disassembly. 1 impeller 1 left-hand th...

  • Page 236: Jet

    6-14 e jet pump impeller duct and drive shaft exploded diagram *1 : epnoc grease ap #0 step procedure/part name q’ty service points 8 drive shaft 1 9 rear bearing 1 10 spacer 1 11 front bearing 1 12 oil seal 1 13 oil seal 1 14 impeller duct 1 reverse the disassembly steps for assembly. Not reusable ...

  • Page 237: Jet

    6-15 e jet pump impeller duct and drive shaft service points drive shaft removal 1. Remove: • impeller note: the impeller has left-hand threads. Turn the impeller clockwise to loosen it. Drive shaft holder: yb-06151 drive shaft holder 5: 90890-06519 2. Remove: • nut 1 drive shaft holder: yb-06151 dr...

  • Page 238: Jet

    6-16 e jet pump impeller duct and drive shaft 4. Remove: • rear bearing È for usa and canada É for worldwide slide hammer and adapters: yb-06096 stopper guide plate: 90890-06501 bearing puller assembly: 90890-06535 stopper guide stand: 90890-06538 È É 5. Remove: • front bearing note: remove the fron...

  • Page 239: Jet

    6-17 e jet pump impeller duct and drive shaft 6. Remove: • oil seal note: remove the oil seals with press. Driver handle—large: yb-06071 driver rod l3: 90890-06652 drive shaft needle bearing installer and remover: yb-06196 needle bearing attachment: 90890-06614 impeller inspection refer to “jet pump...

  • Page 240: Jet

    6-18 e jet pump impeller duct and drive shaft 2. Install: • front bearing • drive shaft note: • install the front bearing and drive shaft with a press. • press the front bearing with a pipe that is more than 85 mm (3.35 in) long, and which has an inner diameter of 25 mm (0.98 in). Distance a: 23 ± 0...

  • Page 241: Jet

    6-19 e jet pump impeller duct and drive shaft 5. Install: • rear bearing note: • press the bearing inner/outer race at the same time holding the drive shaft and impel- ler duct. • if a bearing inner/outer race attachment is not available, use a washer or pipe with an outer diameter of 46 mm (1.81 in...

  • Page 242: Jet

    6-20 e jet pump transom plate and hoses transom plate and hoses exploded diagram removal and installation chart step procedure/part name q’ty service points transom plate and hoses removal follow the left “step” for removal. Exhaust system refer to “exhaust system” in chapter 8. Jet pump unit assemb...

  • Page 243: Jet

    6-21 e jet pump transom plate and hoses exploded diagram step procedure/part name q’ty service points 6 hose clamp 2 7 cooling water hose 1 cooling water outlet (thermostat) 8 bilge hose 2 1 9 hose clamp 1 10 bilge hose 3 1 11 band 1 12 electric bilge pump assembly 1 13 hose clamp 1 14 bilge hose 4 ...

  • Page 244: Jet

    6-22 e jet pump transom plate and hoses exploded diagram step procedure/part name q’ty service points 16 nut/washer 4/4 17 transom plate 1 18 bilge hose 5 1 reverse the removal steps for installation..

  • Page 245: Jet

    6-23 e jet pump transom plate and hoses service points bilge strainer inspection refer to “jet pump unit” in chapter 3. Electric bilge pump inspection refer to “bilge pump” in chapter 3. Refer to “electric bilge pump” in chapter 7. Bilge hose inspection 1. Inspect: • bilge hoses cracks/damage/wear →...

  • Page 246: Jet

    6-24 e jet pump bearing housing bearing housing exploded diagram removal and installation chart *: as required step procedure/part name q’ty service points bearing housing removal follow the left “step” for removal. Engine unit refer to “engine unit” in chapter 5. 1 rubber coupling 1 2 bolt 3 3 inte...

  • Page 247: Jet

    6-25 e jet pump bearing housing exploded diagram removal and installation chart step procedure/part name q’ty service points bearing housing disassembly follow the left “step” for disassembly. 1 grease hose 1 2 nipple 1 3 driven coupling 1 4 washer 1 5 intermediate drive shaft 1 6 o-ring 2 not reusa...

  • Page 248: Jet

    6-26 e jet pump bearing housing exploded diagram step procedure/part name q’ty service points 7 oil seal 1 8 oil seal 1 9 oil seal 1 10 circlip 1 11 bearing 1 12 circlip 1 reverse the disassembly steps for assembly. Not reusable not reusable not reusable not reusable not reusable not reusable.

  • Page 249: Jet

    6-27 e jet pump bearing housing service points driven coupling removal and installation 1. Remove and install: • driven coupling note: • install the driven coupling with the same spe- cial tools that were used for removal. • check that the shaft holder and intermediate drive shaft are properly engag...

  • Page 250: Jet

    6-28 e jet pump bearing housing bearing removal 1. Remove: • bearing note: • install the bearing with the same special tools that were used for removal. • support the intermediate housing with steel blocks 1 and press the bearing. Driver handle—large: yb-06071 driver rod ls: 90890-06606 drive shaft ...

  • Page 251: Jet

    6-29 e jet pump bearing housing bearing installation 1. Install: • circlip (front) 2. Install: • bearing note: support the intermediate housing with steel blocks 1 and press the bearing. Driver handle—large: yb-06071 driver rod ls: 90890-06606 driveshaft taper roller bearing cup installer: yb-06156 ...

  • Page 252: Jet

    6-30 e jet pump bearing housing 2. Install: • intermediate drive shaft • circlip (rear) note: hold the bearing in place as shown with a pipe that is more than 80 mm (3.15 in) long, and which has an outer diameter of 51 mm (2.00 in) and an inner diameter of 26 mm (1.02 in). 3. Install: • oil seal 1 [...

  • Page 253: Elec

    E – + elec 7 chapter 7 electrical system electrical components........................................................................ 7-1 electrical box.......................................................................................... 7-2 exploded diagram ......................................

  • Page 254: Elec

    E – + elec starting system ..................................................................................... 7-29 wiring diagram ................................................................................. 7-29 battery ...........................................................................

  • Page 255: Elec

    E – + elec indication system .................................................................................. 7-43 wiring diagram ................................................................................. 7-43 fuse ...............................................................................

  • Page 256: Elec

    7-1 e – + elec electrical components electrical components l m k j i g f e d c b a 0 9 8 7 6 5 4 3 2 1 h 1 thermoswitch (engine) 2 starter motor 3 engine temperature sensor 4 spark plugs and ignition coils 5 electrical box 6 battery 7 speed sensor 8 electric bilge pump 9 cam position sensor 0 fuel i...

  • Page 257: Elec

    7-2 e – + elec electrical box electrical box exploded diagram removal and installation chart step procedure/part name q’ty service points electrical box removal follow the left “step” for removal. 1 battery negative lead 1 2 battery positive lead 1 3 clip/breather hose 1/1 4 band 2 5 battery 1 6 dam...

  • Page 258: Elec

    7-3 e – + elec electrical box exploded diagram step procedure/part name q’ty service points 9 battery box 1 10 spacer 2 11 bolt 4 12 screw 4 13 terminal cover 1 14 gasket 1 15 screw 2 16 starter motor lead 1 17 bolt 3 18 cover 1 a a a a 22 11 14 13 12 1516 21 20 19 22 22 22 17 18 22 10 1 9 7 8 6 5 2...

  • Page 259: Elec

    7-4 e – + elec electrical box exploded diagram step procedure/part name q’ty service points 19 gasket 1 20 bolt 2 21 ground lead 2 22 coupler 22 note: disconnect all couplers. Reverse the removal steps for installation. A a a a 22 11 14 13 12 1516 21 20 19 22 22 22 17 18 22 10 1 9 7 8 6 5 2 3 4 (ven...

  • Page 260: Elec

    7-5 e – + elec electrical box exploded diagram removal and installation chart step procedure/part name q’ty service points electrical box disassembly follow the left “step” for disassembly. 1 tapping screw 18 2 cover 1 3 gasket 1 4 clamp 3 5 wiring harness 1 6 tapping screw 1 7 fuse holder stay 1 8 ...

  • Page 261: Elec

    7-6 e – + elec electrical box exploded diagram step procedure/part name q’ty service points 10 starter relay 1 11 clamp 2 12 tapping screw/washer 4/4 13 ecm 1 14 tapping screw 1 15 bracket 1 16 joint connector 2 17 tapping screw 2 18 slant detection switch 1 19 tapping screw 1 20 main and fuel pump ...

  • Page 262: Elec

    7-7 e – + elec electrical box exploded diagram step procedure/part name q’ty service points 21 tapping screw 2 22 rectifier/regulator 1 reverse the disassembly steps for assembly. 2 3 1 19 20 18 17 16 14 11 15 13 12 6 7 8 5 4 22 21 6 × 20 mm 3.9 n • m (0.39 kgf • m, 2.8 ft • ib) 6 × 30 mm 3.9 n • m ...

  • Page 263: Elec

    7-8 e – + elec electrical box up 2 3 4 5 6 7 8 1 Ê É È 1 starter relay 2 fuse holder 3 ecm 4 joint connector 5 joint connector 6 main and fuel pump relay 7 rectifier/regulator 8 slant detection switch È to ignition coil É to battery positive terminal Ê to starter motor.

  • Page 264: Elec

    7-9 e – + elec electrical analysis electrical analysis inspection caution: • all measuring instruments should be han- dled with special care. Damaged or mis- handled instruments will not measure properly. • on an instrument powered by dry batter- ies, check the battery’s voltage periodi- cally and r...

  • Page 265: Elec

    7-10 e – + elec electrical analysis low resistance measurement note: • when measuring a resistance of 10 Ω or less with the digital tester, the correct measure- ment cannot be obtained because of the tester’s internal resistance. • to obtain the correct value, subtract the internal resistance from t...

  • Page 266: Elec

    7-11 e – + elec electrical analysis peak voltage adapter note: • throughout this chapter the peak voltage adapter’s part number has been omitted. Refer to the following part number. • the peak voltage adapter should be used with the digital tester. • when measuring the peak voltage, connect the peak...

  • Page 267: Elec

    7-12 e – + elec ignition system ignition system wiring diagram free push w b free push br br free push w b r br p/w p/w p/w j r r r/y r/y b/l l/r r/y r r/y b/o b/o b/y b/o b/o b/o b/o b b r g b b/o r/y g/o b/o r r/y l/r l y r r/y b g g/o r/y r/y b/y b/y b/y b/o b/y b/o w/r w/b w b r o p p r g g g g ...

  • Page 268: Elec

    7-13 e – + elec ignition system wiring diagram free push w b free push br br free push w b r br p/w p/w p/w j r r r/y r/y b/l l/r r/y r r/y b/o b/o b/y b/o b/o b/o b/o b b r g b b/o r/y g/o b/o r r/y l/r l y r r/y b g g/o r/y r/y b/y b/y b/y b/o b/y b/o w/r w/b w b r o p p r g g g g r b w g g b p r ...

  • Page 269: Elec

    7-14 e – + elec ignition system ignition spark warning • when checking the spark gap, do not touch any of the connections of the spark gap 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 ...

  • Page 270: Elec

    7-15 e – + 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 obtaine...

  • Page 271: Elec

    7-16 e – + elec ignition system 2. Measure: • pickup coil output peak voltage below specification → replace the pickup coil. Above specification → replace the ecm. Note: to crank the engine, connect the engine shut- off cord (lanyard) to the engine shut-off switch, and then press the start switch an...

  • Page 272: Elec

    7-17 e – + elec note: to crank the engine, connect the engine shut- off cord (lanyard) to the engine shut-off switch, and then press the start switch and engine stop switch simultaneously. 4. Measure: • rectifier/regulator output voltage below specification → replace the recti- fier/regulator. Note:...

  • Page 273: Elec

    7-18 e – + elec ignition coil 1. Measure: • primary coil resistance out of specification → replace. Note: when measuring a resistance of 10 Ω or less with the digital tester, the correct measurement cannot be obtained because of the tester’s internal resistance. Refer to “low resistance measurement”...

  • Page 274: Elec

    7-19 e – + 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): 54.2–69.0 k Ω 100 °c (212 °f): 3.12–3.48 k Ω measurement steps: • suspend t...

  • Page 275: Elec

    7-20 e – + elec ignition system thermoswitch (engine) 1. Check: • thermoswitch (engine) continuity (at the specified temperature) out of specification → replace. 1 no continuity È temperature 2 continuity É time thermoswitch (exhaust) 1. Check: • thermoswitch (exhaust) continuity (at the specified t...

  • Page 276: Elec

    7-21 e – + elec ignition system main and fuel pump relay 1. Check: • main and fuel pump relay continuity faulty → replace. Checking steps: • connect the tester leads between the main and fuel pump relay terminals 5, 6 and 7. • connect the terminals 2 or 3 to the pos- itive battery terminal. • connec...

  • Page 277: Elec

    7-22 e – + elec ignition system throttle position sensor 1. Measure: • throttle position sensor output voltage out of specification → adjust the throttle bodies synchronization. Refer to “fuel injection system” in chapter 4. Test harness (3 pins): yb-06793 test harness smhw099-3 (3 pins): 90890-0679...

  • Page 278: Elec

    7-23 e – + elec ignition system cam position sensor 1. Measure: • cam position sensor output voltage out of specification → replace. Note: • the cam position sensor contains two indi- vidual sensors as shown in the illustration: sensor 1 1 and sensor 2 2. • to measure the output voltage, pass the sc...

  • Page 279: Elec

    7-24 e – + elec ignition system noise filter 1. Check: • noise filter continuity out of specification → replace. Noise filter continuity: black (b) – red (r) no continuity b g g r b r slant detection switch 1. Check: • slant detection switch continuity out of specification → replace. Position lead c...

  • Page 280: Elec

    7-25 e – + elec fuel control system fuel control system wiring diagram #4 #3 #2 #1 l/r p/g b/y b/o b/o r/y r/y r/y r/y r/y r/y pu/g pu/y pu/b pu/r o o p r/y r/y r b/o b/o b/o b/o b/y b/o p p l/r br l y r r/y r b r/y r/y b/y b/y b/y b/o b/y o p p b/o r r r b/o b/o b/o b b b r/y b b l b l b b b b 6 3 ...

  • Page 281: Elec

    7-26 e – + elec fuel control system wiring diagram #4 #3 #2 #1 l/r p/g b/y b/o b/o r/y r/y r/y r/y r/y r/y pu/g pu/y pu/b pu/r o o p r/y r/y r b/o b/o b/o b/o b/y b/o p p l/r br l y r r/y r b r/y r/y b/y b/y b/y b/o b/y o p p b/o r r r b/o b/o b/o b b b r/y b b l b l b b b b 6 3 2 d d d d b c 0 4 r ...

  • Page 282: Elec

    7-27 e – + elec fuel control system 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. Note: after the engine is stopped, the fuel pump will operate for 10 seconds. Fuel sender 1. Measure: • fuel sender...

  • Page 283: Elec

    7-28 e – + elec fuel control system fuel injector refer to “fuel injection system” in chapter 4. Main and fuel pump relay refer to “ignition system”. Oil pressure switch refer to “indication system”. Thermoswitch (engine) refer to “ignition system”. Thermoswitch (exhaust) refer to “ignition system”....

  • Page 284: Elec

    7-29 e – + elec starting system starting system wiring diagram free push br br free push w b r br 0 11 15 14 18 12 3 4 13 l r/y 14 31 21 30 r l/r l y r r/y b r/y r/y l/r y r br br br br r br r b b r 4 9 3 2 1 8 7 6 r p p o r r r r r r r 1 2 3 4 5 6 7 8 5 br b b b b b b l l y l l b b a b b b b r/y b ...

  • Page 285: Elec

    7-30 e – + elec starting system battery refer to “electrical” in chapter 3. Wiring connections 1. Check: • wiring connections poor connections → properly connect. Fuse 1. Check: • fuse broken broken → replace. Note: 20a fuse is for main relay, engine shut-off switch and rectifier/regulator. 3a fuse ...

  • Page 286: Elec

    7-31 e – + 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 positiv...

  • Page 287: Elec

    7-32 e – + elec starter motor starter motor exploded diagram removal and installation chart *: as required step procedure/part name q’ty service points starter motor disassembly follow the left “step” for disassembly. Starter motor refer to “generator and starter motor” in chapter 5. 1 o-ring 1 2 bo...

  • Page 288: Elec

    7-33 e – + elec starter motor exploded diagram *: as required step procedure/part name q’ty service points 8 starter motor rear cover 1 9 o-ring 1 10 shim * t = 0.2 mm, 0.8 mm 11 armature assembly 1 12 nut/spring washer/washer 1/1/4 13 o-ring 1 14 brush holder 1 15 brush spring 4 16 bolt 1 17 brush ...

  • Page 289: Elec

    7-34 e – + elec starter motor exploded diagram step procedure/part name q’ty service points 18 spacer 1 19 holder 1 20 starter motor yoke 1 reverse the disassembly steps for assembly..

  • Page 290: Elec

    7-35 e – + elec starter motor service points armature inspection 1. Inspect: • armature shaft 1 damage/wear → replace. 1 2. Inspect: • commutator dirt → clean with 600 grit sandpaper. 3. Measure: • commutator diameter below specification → replace. Minimum commutator diameter: 27.0 mm (1.06 in) 4. C...

  • Page 291: Elec

    7-36 e – + elec starter motor 6. Inspect: • armature coil continuity out of specification → replace. Armature coil continuity: commutator segments 1 continuity segment - laminations 2 no continuity segment - armature shaft no continuity brush holder inspection 1. Measure: • brush length a below spec...

  • Page 292: Elec

    7-37 e – + elec charging system charging system wiring diagram b r r 1 2 3 r r r g g g g g g b g b g g g g g 4 1 rectifier/regulator 2 fuse (20a) 3 battery 4 lighting coil b : black g : green r : red.

  • Page 293: Elec

    7-38 e – + elec charging system fuse refer to “starting system”. Battery refer to “electrical” in chapter 3. Lighting coil refer to “ignition system”. Rectifier/regulator refer to “ignition system”..

  • Page 294: Elec

    7-39 e – + elec electric bilge pump electric bilge pump wiring diagram 21 30 l/r l y r r/y r/y r/y r y br b b b b b r r 3 7 2 4 5 r p p o r b r r r 1 2 3 4 5 6 7 8 r/y r/y b br r/y r/y r r/y r/y r r/y 6 15 b b b b l/r r/y b 1 1 ecm 2 main and fuel pump relay 3 fuse (3a) 4 battery 5 electric bilge pu...

  • Page 295: Elec

    7-40 e – + elec electric bilge pump electric bilge pump 1. Check: • electric bilge pump operation incorrect → replace. Checking steps: • suspend the electric bilge pump in a con- tainer filled with water. • connect the brown lead terminal to the positive battery terminal. • connect the black lead te...

  • Page 296: Elec

    7-41 e – + elec off throttle steering system off throttle steering system wiring diagram p o g/b g pu/b g/y g/r pu/g pu/y pu/b p o r/y pu/y g/y g/r b/y p/g pu/r pu/r pu/g p/g r/y g g/b b/o g g/y w r b w b r w/b b/o w/r b/o b/o b/o b/o w/b b/o w/r b/o b/o b/o b/o o p b/o o p y/b b r/w w/l b/o r/y r/y...

  • Page 297: Elec

    7-42 e – + elec off throttle steering system steering switch 1. Check: • steering switch for checking instructions, refer to “self-diagnosis” in chapter 9. Malfunction → use the “engine monitor” of the yamaha diagnostic system to check that the steering switch switches on and off when the handlebar ...

  • Page 298: Elec

    7-43 e – + elec indication system indication system wiring diagram g b b b b b r 3 r l/r l y r r/y r b p r r p w/b r/y b/o r/y r/y r r/y r/y r r p p p 1 2 3 4 5 6 7 8 2 7 6 8 5 b/o p p b p b/o p b b/o p p b b w b p b/o p b b/y b/o b/y b/y b/y b/o b/y 9 b/o b/o b/o b/o b/o b/o b/o b/o b/o b/o b/o b/o...

  • Page 299: Elec

    7-44 e – + elec indication system wiring diagram g b b b b b r 3 r l/r l y r r/y r b p r r p w/b r/y b/o r/y r/y r r/y r/y r r p p p 1 2 3 4 5 6 7 8 2 7 6 8 5 b/o p p b p b/o p b b/o p p b b w b p b/o p b b/y b/o b/y b/y b/y b/o b/y 9 b/o b/o b/o b/o b/o b/o b/o b/o b/o b/o b/o b/o r/w b/y r/y l/r b...

  • Page 300: Elec

    7-45 e – + elec indication system fuse refer to “starting system”. Battery refer to “electrical” in chapter 3. Main and fuel pump relay refer to “ignition system”. Ecm refer to “ignition system”. Engine temperature sensor refer to “ignition system”. Thermoswitch (engine) refer to “ignition system”. ...

  • Page 301: Elec

    7-46 e – + elec indication system oil pressure switch 1. Measure: • oil pressure switch continuity out of specification → replace. Lower unit pressure/vacuum tester: yb-35956-a vacuum/pressure pump gauge set: 90890-06756 oil pressure switch continuity pressure: 128 kpa (1.28 kgf/cm 2 , 18.2 psi) – 1...

  • Page 302: Elec

    7-47 e – + elec indication system display function 1. Check: • display function does not operate → replace the multi- function meter. B/l b l/r b/y b/y r/w p b r/w y y r r w w b b b p l/r r b r 1 2 3 4 5 gy l/b l/r l/y l/b b/l 1 remote control unit 2 buzzer 3 speed sensor 4 ecm 5 fuel sender b : bla...

  • Page 303: Elec

    7-48 e – + elec indication system speedometer display 1. Check: • speedometer display does not display → measure the speed sensor output voltage and pulses. 2. Measure: • speed sensor output voltage and pulses out of specification → repair or replace. Within specification → replace the mul- tifuncti...

  • Page 304: Elec

    7-49 e – + elec indication system 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 ...

  • Page 305: Elec

    7-50 e – + elec indication system overheat warning indicator 1. Check: • overheat warning indicator does not operate → replace the multi- function meter. Checking steps: • start the engine. • disconnect the thermoswitch (engine) connector 1 (blue), engine temperature sensor connector 2 (black) or th...

  • Page 306: Elec

    7-51 e – + elec remote control system remote control system wiring diagram 16 7 6 11 15 14 18 12 3 4 13 10 123456789 0abcdefgh l r/y r/y 14 31 21 15 30 r l/r l y r r/y b r/y r/y r/y l/r y br br b b r 4 7 3 2 1 6 r/y r r p p o r r r r r r 1 2 3 4 5 6 7 8 5 b b b b y b b b b w/b r/y b/o b r w b r r b ...

  • Page 307: Elec

    7-52 e – + elec remote control system 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 ...

  • Page 308: Elec

    7-53 e – + elec remote control system diagnostic display 1. Check: • diagnostic display does not display → replace the multi- function meter. Checking steps: • start the engine. • disconnect the coupler of a sensor (e.G,. Engine temperature sensor) that is nor- mally displayed when a malfunction occ...

  • Page 309: Elec

    7-54 e – + elec remote control system number of beeps yamaha security system mode engine startability 1 beep lock unable 2 beeps unlock (normal mode) able 3 beeps unlock (low-rpm mode) able • press the unlock button for more than 4 seconds to select the low-rpm mode. • check that the beeper sounds t...

  • Page 310: Elec

    7-55 e – + elec remote control system 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. N...

  • Page 311: Elec

    7-56 e – + elec remote control system 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 con...

  • Page 312: Hull

    E hull hood chapter 8 hull and hood handlebar .................................................................................................. 8-1 exploded diagram ............................................................................. 8-1 removal and installation chart ........................

  • Page 313: Hull

    E hull hood 8 steering console cover .................................................................... 8-26 exploded diagram ........................................................................... 8-26 removal and installation chart .............................................. 8-26 service ...

  • Page 314: Hull

    8-1 e hull hood handlebar handlebar exploded diagram removal and installation chart step procedure/part name q’ty service points handlebar cover removal follow the left “step” for removal. 1 screw 4 2 handlebar cover 1 3 pad 1 4 bolt 2 note: position the corrugated tube for the throttle cable as sho...

  • Page 315: Hull

    8-2 e hull hood handlebar exploded diagram removal and installation chart step procedure/part name q’ty service points handlebar removal follow the left “step” for removal. Qsts cable (to jet thrust nozzle) refer to “remote control cables and speed sensor lead”. 1 nut/washer 2/2 2 qsts converter 1 3...

  • Page 316: Hull

    8-3 e hull hood handlebar exploded diagram step procedure/part name q’ty service points 10 hose packing 1 11 buzzer 1 12 handlebar assembly 1 note: • pass the qsts cable and handlebar switch lead through the handle boss cover, and then install the handlebar assembly. • install the sponges of the qst...

  • Page 317: Hull

    8-4 e hull hood handlebar exploded diagram removal and installation chart step procedure/part name q’ty service points handlebar disassembly follow the left “step” for disassembly. 1 bolt 2 2 grip end 2 3 spacer 1 4 screw/spring washer/washer 1/1/1 5 qsts grip assembly 1 6 special nut 1 7 screw 2 no...

  • Page 318: Hull

    8-5 e hull hood handlebar exploded diagram step procedure/part name q’ty service points 8 handlebar switch assembly 1 9 screw 2 10 throttle lever assembly 1 11 handlebar grip 1 note: apply adhesive to the handlebar and the inner surface of the handlebar grip. 12 handlebar 1 reverse the disassembly s...

  • Page 319: Hull

    8-6 e 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: • bands 1 note: after inserting the qsts cables, buzzer lead, handleba...

  • Page 320: Hull

    8-7 e hull hood handlebar 3. Install: • throttle cable note: fit the seal into the groove in the bracket. 4. Install: • handlebar cover 1 note: when the handlebar cover is in contact with the steering boss cover, adjust the handlebar mount angle so that the clearance a and b are equal. 5. Adjust: • ...

  • Page 321: Hull

    8-8 e hull hood qsts grip qsts grip exploded diagram removal and installation chart step procedure/part name q’ty service points qsts grip disassembly follow the left “step” for disassembly. Qsts grip assembly refer to “handlebar”. 1 screw/washer 1/1 2 cover 1 3 ball 2 4 spring 2 5 qsts cable 1 1 6 ...

  • Page 322: Hull

    8-9 e hull hood qsts grip exploded diagram step procedure/part name q’ty service points 7 screw/washer 2/2 8 spacer 1 9 qsts shift lock lever 1 10 spring 1 11 spacer 1 12 cable housing 1 13 qsts grip 1 reverse the disassembly steps for assembly..

  • Page 323: Hull

    8-10 e hull hood qsts grip service points qsts cable inspection and adjustment 1. Inspect: • qsts cables frays/kinks/rough movement → replace. 2. Adjust: • qsts cable length a note: • before adjusting the qsts cables, set the trim grip to the neutral position. • adjust the qsts cable lengths a to th...

  • Page 324: Hull

    8-11 e hull hood steering master steering master exploded diagram removal and installation chart step procedure/part name q’ty service points steering master removal follow the left “step” for removal. Steering console cover refer to “steering console cover”. Steering cable end refer to “remote cont...

  • Page 325: Hull

    8-12 e hull hood steering master exploded diagram step procedure/part name q’ty service points 6 bolt 3 7 magnet 1 8 steering switch 1 reverse the removal steps for installation..

  • Page 326: Hull

    8-13 e hull hood steering master exploded diagram removal and installation chart step procedure/part name q’ty service points steering master disassembly follow the left “step” for disassembly. 1 bolt/washer 2/2 2 stay 1 3 spring 1 4 bolt/washer 6/6 5 lower housing 1 6 spring 1 7 bushing 1 8 bushing...

  • Page 327: Hull

    8-14 e hull hood steering master exploded diagram step procedure/part name q’ty service points 11 tilt stopper 1 12 bolt/nut/holder 4/4/4 13 retainer 2 14 steering shaft 1 15 steering tube 1 16 bolt 2 17 cap 1 18 shaft 1 1 19 cross piece 1 reverse the disassembly steps for assembly..

  • Page 328: Hull

    8-15 e hull hood steering master service points steering master components inspection 1. Inspect: • each component part damage/wear → replace the steering master..

  • Page 329: Hull

    8-16 e hull hood remote control cables and speed sensor lead remote control cables and speed sensor lead exploded diagram removal and installation chart step procedure/part name q’ty service points remote control cables and speed sensor lead removal follow the left “step” for removal. Service lid 1 ...

  • Page 330: Hull

    8-17 e hull hood remote control cables and speed sensor lead exploded diagram step procedure/part name q’ty service points 6 nut 1 7 steering cable 1 8 seal 1 9 speed sensor coupler 1 10 nut 1 11 cap 1 12 screw 4 13 speed sensor 1 14 shift cable end 1 15 nut 2.

  • Page 331: Hull

    8-18 e hull hood remote control cables and speed sensor lead exploded diagram step procedure/part name q’ty service points 16 shift cable holder 2 17 nut 1 18 shift cable 1 19 seal 1 20 nut 1 21 pin 1 22 qsts cable end 1 23 nut 1 24 qsts cable 1 25 packing 1 reverse the removal steps for installatio...

  • Page 332: Hull

    8-19 e hull hood remote control cables and speed sensor lead 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 bel...

  • Page 333: Hull

    8-20 e hull hood remote control cables and speed sensor lead qsts cable (jet pump end) installation 1. Install: • qsts cable (jet pump end) warning the qsts cable must be screwed in more than 8 mm (0.31 in). Qsts cable set length a (jet pump end): 13.6 mm (0.54 in) qsts cable stopper installation 1....

  • Page 334: Hull

    8-21 e hull hood remote control cables and speed sensor lead shift cable holder installation 1. Install: • shift cable holders note: install the shift cable holders so that mark a and mark b are in the positions shown in the illustration. Shift cable stopper installation 1. Install: • shift cable st...

  • Page 335: Hull

    8-22 e hull hood front hood front hood exploded diagram removal and installation chart step procedure/part name q’ty service points front hood removal follow the left “step” for removal. 1 nut/washer 4/4 2 front hood assembly 1 3 bolt 4 4 bolt 2 5 hinge assembly 1 6 bolt 2 7 hood lock assembly 1 2 7...

  • Page 336: Hull

    8-23 e hull hood exploded diagram step procedure/part name q’ty service points 8 bolt 4 9 service lid 1 1 10 screw 4 11 service lid 2 1 reverse the removal steps for installation. 2 7 6 4 8 9 3 5 1 11 10 6 × 18 mm 5.4 n • m (0.54 kgf • m, 3.9 ft • ib) 6 × 30 mm 5.4 n • m (0.54 kgf • m, 3.9 ft • ib) ...

  • Page 337: Hull

    8-24 e hull hood front hood exploded diagram removal and installation chart step procedure/part name q’ty service points hinge disassembly follow the left “step” for disassembly. 1 circlip 2 2 pin (long) 1 3 hinge 1 4 pin (short) 1 5 damper stay 1 6 collar 2 7 grommet 2 4 5 1 7 6 10 2 7 6 1 8 9 3.

  • Page 338: Hull

    8-25 e hull hood front hood exploded diagram step procedure/part name q’ty service points 8 band 1 9 damper boots 1 10 damper 1 reverse the disassembly steps for assembly. 4 5 1 7 6 10 2 7 6 1 8 9 3.

  • Page 339: Hull

    8-26 e hull hood steering console cover exploded diagram removal and installation chart step procedure/part name q’ty service points meter and mirror removal follow the left “step” for removal. Handlebar assembly refer to “handlebar”. Service lid 1 refer to “front hood”. 1 band 1 2 multifunction met...

  • Page 340: Hull

    8-27 e hull hood steering console cover exploded diagram step procedure/part name q’ty service points 6 bolt 4 7 multifunction meter 1 8 hose packing 1 9 grommet 1 10 nut/washer 4/4 11 plate 2 12 mirror 2 reverse the removal steps for installation. Lt 242 lt 242 5 7 9 5 6 10 12 1 2 3 4 5 × 20 mm 3.9...

  • Page 341: Hull

    8-28 e hull hood steering console cover exploded diagram removal and installation chart step procedure/part name q’ty service points side cover removal follow the left “step” for removal. 1 cup holder 1 2 holder 1 3 bolt 8 4 washer 2 5 side cover 2 reverse the removal steps for installation. 3 2 3 4...

  • Page 342: Hull

    8-29 e hull hood steering console cover exploded diagram removal and installation chart step procedure/part name q’ty service points steering console cover and glove box assembly removal follow the left “step” for removal. 1 nut/washer 2/2 2 bolt 2 3 nut/washer 2/2 4 bolt 2 5 bolt 2 6 shift handle l...

  • Page 343: Hull

    8-30 e hull hood steering console cover exploded diagram step procedure/part name q’ty service points 7 bolt 2 8 steering console cover 1 note: to remove the console cover easily, pull the tilt lever up. 9 hood lock assembly 1 10 nut/washer 2/2 11 bolt 2 12 glove compartment assembly 1 reverse the r...

  • Page 344: Hull

    8-31 e hull hood steering console cover exploded diagram removal and installation chart step procedure/part name q’ty service points glove compartment disassembly follow the left “step” for disassembly. 1 glove compartment 1 2 hinge assembly 2 3 lid 1 4 gear assembly 2 5 screw 2 6 latch 1 reverse th...

  • Page 345: Hull

    8-32 e hull hood steering console 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..

  • Page 346: Hull

    8-33 e hull hood hoses hoses exploded diagram removal and installation chart step procedure/part name q’ty service points hoses removal follow the left “step” for removal. Fuel tank refer to “fuel tank and fuel pump module” in chapter 4. Note: when removing the ventilation hose and fuel tank breathe...

  • Page 347: Hull

    8-34 e hull hood hoses exploded diagram step procedure/part name q’ty service points 4 clamp 2 5 cooling water hose 2 6 nut 2 7 cooling water pilot outlet 2 8 seal 2 reverse the removal steps for installation. (vent) (vent) (vent) 1 2 1 2 7 8 1 6 4 5 3 5 4 6 8 7 fwd 4.2 n • m (0.42 kgf • m, 3.0 ft •...

  • Page 348: Hull

    8-35 e hull hood shift lever shift lever exploded diagram removal and installation chart step procedure/part name q’ty service points shift lever removal follow the left “step” for removal. Side cover refer to “steering console cover”. Shift cable refer to “remote control cables and speed sensor lea...

  • Page 349: Hull

    8-36 e hull hood shift lever exploded diagram step procedure/part name q’ty service points 6 screw 3 7 base assembly 1 8 nut/washer 3/3 9 screw 3 10 plate 1 reverse the removal steps for installation..

  • Page 350: Hull

    8-37 e hull hood shift lever exploded diagram removal and installation chart step procedure/part name q’ty service points base disassembly follow the left “step” for disassembly. 1 bolt/washer 2/2 2 plate 1 3 spring 1 4 actuator 1 5 roller 1 6 shaft 1 7 shift arm 1 reverse the disassembly steps for ...

  • Page 351: Hull

    8-38 e hull hood shift lever service points base assembly 1. Install: • shift arm • shaft installation steps: • install the shift arm 1 so that it comes in contact with the stopper 2 as shown. • install the shaft 3 to the base so that it come in contact with the stopper 4 as shown. Shift lever 1. In...

  • Page 352: Hull

    8-39 e hull hood seats and hand grip seats and hand grip exploded diagram removal and installation chart step procedure/part name q’ty service points seats and hand grip removal follow the left “step” for removal. 1 rear seat assembly 1 fx high output 2 rear seat assembly 1 fx cruiser high output 3 ...

  • Page 353: Hull

    8-40 e hull hood seats and hand grip exploded diagram step procedure/part name q’ty service points 9 deck beam 1 10 nut 1 11 projection 1 12 washer 1 13 seal 1 14 nut 4 15 bolt 4 16 rear seat stay 2 17 nut 1 3 1 5 4 22 21 18 19 20 17 19 7 8 10 14 6 16 15 13 12 11 9 5 4 6 × 25 mm 8 × 30 mm 8 × 30 mm ...

  • Page 354: Hull

    8-41 e hull hood seats and hand grip exploded diagram step procedure/part name q’ty service points 18 projection 1 19 washer 2 20 nut/washer 4/4 21 bolt 4 22 hand grip 1 reverse the removal steps for installation. 3 1 5 4 22 21 18 19 20 17 19 7 8 10 14 6 16 15 13 12 11 9 5 4 6 × 25 mm 8 × 30 mm 8 × ...

  • Page 355: Hull

    8-42 e hull hood seats and hand grip service points seat lock inspection 1. Inspect: • front seat lock • rear seat lock damage/wear → replace..

  • Page 356: Hull

    8-43 e hull hood exhaust system exhaust system exploded diagram removal and installation chart step procedure/part name q’ty service points exhaust system removal follow the left “step” for removal. Deck beam refer to “seats and hand grip”. Jet pump unit assembly refer to “jet pump unit” in chapter ...

  • Page 357: Hull

    8-44 e hull hood exhaust system exploded diagram step procedure/part name q’ty service points 5 joint clamp 1 6 joint 1 7 joint clamp 1 8 joint 1 9 joint clamp 1 10 exhaust joint 1 11 nut/washer 6/6 12 exhaust valve 1 note: remove parts 12 to 18 as a set. 13 hose clamp 1 14 rubber hose 1 7 14 3 13 1...

  • Page 358: Hull

    8-45 e hull hood exhaust system exploded diagram step procedure/part name q’ty service points 15 hose clamp 1 16 water tank 1 17 rubber hose 1 18 plate 1 reverse the removal steps for installation. 7 14 3 13 15 18 17 12 11 16 10 5 1 4 3.7 n • m (0.37 kgf • m, 2.7 ft • ib) 5.4 n • m (0.54 kgf • m, 3....

  • Page 359: Hull

    8-46 e 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 c...

  • Page 360: Hull

    8-47 e 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. A b b a 2. Install: • water lock note: be sure to insert the rubber hose to the line a on the water ...

  • Page 361: Hull

    8-48 e hull hood deck and hull deck and hull exploded diagram removal and installation chart step procedure/part name q’ty service points deck and hull disassembly follow the left “step” for disassembly. 1 nut 1 2 spout 1 3 nut 2 4 cleat 1 5 plate 2 6 bolt/collar 10/10 7 sponson 2 8 nut/washer 4/4 9...

  • Page 362: Hull

    8-49 e hull hood deck and hull exploded diagram step procedure/part name q’ty service points 11 seal 2 12 nut 4 note: to remove the cleat, remove the exhaust system first. 13 plate 4 14 cleat 2 15 seal 2 16 nut/washer 3/3 17 bolt 4 18 protector 1 reverse the disassembly steps for assembly. 16 17 18 ...

  • Page 363: Hull

    8-50 e hull hood engine mount engine mount exploded diagram removal and installation chart step procedure/part name q’ty service points engine mount removal follow the left “step” for removal. Engine unit refer to “engine unit” in chapter 5. 1 bolt 4 2 damper 1 1 3 damper 2 1 4 bolt 8 5 engine mount...

  • Page 364: Trbl

    E trbl anls 9 chapter 9 trouble analysis introduction.............................................................................................. 9-1 features ............................................................................................... 9-1 functions.................................

  • Page 365: Trbl

    9-1 e trbl anls introduction introduction features the newly developed yamaha diagnostic system provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ecm (electronic control module) of a wate...

  • Page 366: Trbl

    9-2 e trbl anls introduction hardware requirements make sure that your computer meets the following requirements before using this software. Computer: ibm-compatible computer operating system: microsoft (windows 95), windows 98, windows me, windows 2000, or windows xp (english version) cpu: windows ...

  • Page 367: Trbl

    9-3 e 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. 3 1 2.

  • Page 368: Trbl

    9-4 e 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 w...

  • Page 369: Trbl

    9-5 e trbl anls trouble analysis power unit compression 5 cylinder head gaskets 5 cylinder block 5 crankcase 5 piston rings 5 pistons 5 bearings 5 thermostat 5 valve(s) and valve seat(s) 5 valve clearance adjusting pad(s) 3 camshaft(s) 5 timing chain 5 oil pump 5 engine oil 3 oil filter 3 oil pressu...

  • Page 370: Trbl

    9-6 e trbl anls trouble analysis jet pump unit duct 6 impeller 6 intake grate 6 bearings 6 intake duct 6 water inlet hose 6 bilge hose 6 bilge strainer 3 bilge hose joint 6 electrical ignition system, fuel control system • pickup coils 7 • ecm 7 • ignition coils 7 • slant detector switch 7 • engine ...

  • Page 371: Trbl

    9-7 e trbl anls trouble analysis 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 electric bilge pump • electric bilge pump 7 remote control system • remote control unit 7 hull and h...

  • Page 372: Trbl

    9-8 e trbl anls trouble analysis self-diagnosis with the engine running, press the select but- ton 1 for 8 seconds and check if an error code is indicated on the multifunction meter. If the yamaha diagnostic system is not used to check the symptoms listed in the table, the error codes can be checked...

  • Page 373

    Wiring diagram fx high output, fx cruiser high output 1 fuse (20 a) 2 fuse (3 a) 3 starter relay 4 slant detection switch 5 main and fuel pump relay 6 ecm 7 rectifier/regulator 8 noise filter 9 cam position sensor 0 thermoswitch (exhaust) a oil pressure switch b thermoswitch (engine) c engine temper...

  • Page 374

    1 3 4 5 6 8 9 10 12 13 14 15 16 17 18 41 42 43 44 35 37 38 39 40 20 19 21 22 28 29 31 30 33 34 r free push free push free push b 3 4 6 7 9 10 11 12 13 14 15 16 18 b l r br y b/l gy l/y w b b y l/b b b r/y g r b g r b g/o r/y b/o p b/l r/y b/y r/y b/w r/y b/r r/y p p o g/b g pu/b g/y g/r pu/g pu/y pu...

  • Page 375

    P r g/o r/y r/y r/y r/y r/y r r r r/y r/y br b br b y r r r r l b/o p p p p p g g l y b b o o o l/r l/b r/y r/y p/g g/o b/r w b/o g/r b/l b/y g/b g/y b/y b/y b/w w/b w/b w/r w/l p/w l/r l/b pu/g pu/b pu/r pu/y r/y r/y r/y r/y r r b b l r b/o b/o w/l w/b r/y r/y r/y r/y b/l b/y r/y r/y b/r b/w r/y g ...

  • Page 376

    Yamaha motor corporation, usa printed in usa feb. 2004 – × 1 cr (e).

  • Page 377: Supplementary

    Supplementary service manual waverunner f1x-28197-1h-1x lit-18616-02-93 *lit186160293* fx fx cruiser fx high output fx cruiser high output.

  • Page 378: Notice

    E notice this supplementary service manual has been prepared to introduce new service and new data information for the fx, fx cruiser, fx high output, and fx cruiser high output which are based on the 2002 fx140, 2003 fx140/fx cruiser, and 2004 fx high output/fx cruiser high output. For complete inf...

  • Page 379: How to Use This Manual

    E how to use this manual manual format all of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assem...

  • Page 380

    E important information in this supplementary service manual particularly important information is distinguished in the fol- lowing 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 de...

  • Page 381

    E how to use this manual 1 to help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 2 numbers are given in the order of the jobs in the exploded diagram. 3 symbols indicate parts to be lubricated or replaced (see “symbols”)...

  • Page 382: Gen

    E a50001-1-4 symbols symbols 1 to 9 are designed to indicate the content of a chapter. 1 general information 2 specifications 3 periodic inspection and adjustment 4 fuel system 5 power unit 6 jet pump unit 7 electrical system 8 hull and hood 9 trouble analysis symbols 0 to e indicate specific data. ...

  • Page 383: Index

    E index general information 1 gen info specifications 2 spec periodic inspection and adjustment 3 insp adj fuel system 4 fuel power unit 5 powr jet pump unit 6 jet pump electrical system 7 elec hull and hood 8 hull hood trouble analysis 9 trbl anls – + a30000-0

  • Page 384: General Information

    E general information identification numbers ............................................................................ 1 primary l.D. Number .............................................................................. 1 engine serial number .........................................................

  • Page 385: Electrical System

    E periodic inspection and adjustment maintenance interval chart ............................................................... 41 periodic service ........................................................................................ 42 control system ................................................

  • Page 386

    E indication system ..................................................................................... 54 wiring diagram (for fx cruiser high output) ..................................... 54 wiring diagram (for fx high output).................................................. 56 wiring diagram (f...

  • Page 387: Hull And Hood

    E hull and hood handlebar ................................................................................................... 73 exploded diagram (for fx/fx high output) ...................................... 73 removal and installation chart ................................................. 73 expl...

  • Page 388: Trouble Analysis

    E shift lever................................................................................................. 111 exploded diagram ............................................................................ 111 removal and installation chart ............................................... 111 seat...

  • Page 389: Gen

    1 e 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 compart- ment. Starting primary l.D. Numbers: f1x: 800101 f1y: 800101 engine serial number the engine serial number is stamped o...

  • Page 390: Gen

    2 e gen info special tools special tools using the correct special tools recommended by yamaha, will aid the work and enable accu- rate 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-”, “...

  • Page 391: Spec

    3 e spec general specifications general specifications item unit model fx high output fx cruiser high output model code hull f1x engine/jet 6b6 dimensions length mm (in) 3,340 (131.5) width mm (in) 1,230 (48.4) height mm (in) 1,160 (45.7) 1,240 (48.8) dry weight kg (lb) 372 (820) 380 (838) maximum c...

  • Page 392: Spec

    4 e spec pon*: pump octane number = (motor octane number + research octane number)/2 ron*: research octane number fuel and oil fuel type regular unleaded gasoline minimum fuel rating pon* 86 ron* 90 fuel tank capacity l (us gal, imp gal) 70 (18.5, 15.4) engine oil type 4-stroke motor oil engine oil ...

  • Page 393: Spec

    5 e spec general specifications item unit model fx fx cruiser model code hull f1y engine/jet 60e dimensions length mm (in) 3,340 (131.5) width mm (in) 1,230 (48.4) height mm (in) 1,160 (45.7) 1,240 (48.8) dry weight kg (lb) 384 (847) 392 (864) maximum capacity person/kg (lb) 3/240 (530) performance ...

  • Page 394: Spec

    6 e spec general specifications pon*: pump octane number = (motor octane number + research octane number)/2 ron*: research octane number fuel and oil fuel type regular unleaded gasoline minimum fuel rating pon* 86 ron* 90 fuel tank capacity l (us gal, imp gal) 70 (18.5, 15.4) engine oil type 4-strok...

  • Page 395: Spec

    7 e spec maintenance specifications maintenance specifications engine item unit model fx high output fx cruiser high output cylinder head warpage limit mm (in) 0.1 (0.004) compression pressure *1 kpa (kgf/cm 2 , psi) 1,150 (11.5, 164) cylinder bore size mm (in) 76.000–76.015 (2.9921–2.9927) taper li...

  • Page 396: Spec

    8 e spec maintenance specifications valve seat width c intake mm (in) 0.9–1.1 (0.0354–0.0433) exhaust mm (in) 0.9–1.1 (0.0354–0.0433) valve margin thickness d intake mm (in) 0.85–1.15 (0.0335–0.0453) exhaust mm (in) 0.85–1.15 (0.0335–0.0453) valve stem diameter intake mm (in) 3.975–3.990 (0.1565–0.1...

  • Page 397: Spec

    9 e spec maintenance specifications piston ring top ring type barrel dimension (b × t) mm (in) 0.90 × 2.75 (0.04 × 0.11) end gap (installed) mm (in) 0.32–0.44 (0.0126–0.0173) ring groove clearance mm (in) 0.030–0.065 (0.0012–0.0026) 2nd ring type taper dimensions (b × t) mm (in) 0.80 × 2.80 (0.03 × ...

  • Page 398: Spec

    10 e spec maintenance specifications jet pump unit hull and hood oil filter oil filter type cartridge type oil pump oil pump type trochoid rotor tip clearance (scavenge pump) mm (in) 0.09–0.15 (0.0035–0.0059) oil pump housing clearance rotor (feed pump) mm (in) 0.09–0.17 (0.0035–0.0067) rotor (scave...

  • Page 399: Spec

    11 e spec maintenance specifications electrical item unit model fx high output fx cruiser high output battery type fluid capacity v/ah 12/19 specific gravity 1.28 ecm unit (b/r – r/y, b/w – r/y, b/y – r/y, b/l – r/y) output peak voltage lower limit @cranking (loaded) v 87 @2,000 r/min (loaded) v 86 ...

  • Page 400: Spec

    12 e spec maintenance specifications *1 the figures are for reference only. Starter relay rating seconds 30 thermoswitch on temperature (engine) °c (°f) 84–90 (183–194) off temperature (engine) °c (°f) 70–84 (158–183) on temperature (exhaust) °c (°f) 94–100 (201–212) off temperature (exhaust) °c (°f...

  • Page 401: Spec

    13 e spec maintenance specifications engine item unit model fx fx cruiser cylinder head warpage limit mm (in) 0.1 (0.004) compression pressure *1 kpa (kgf/cm 2 , psi) 1,350 (13.5, 192) cylinder bore size mm (in) 74.060–74.075 (2.9157–2.9163) taper limit mm (in) 0.08 (0.003) out-of-round limit mm (in...

  • Page 402: Spec

    14 e spec maintenance specifications valve seat width c intake mm (in) 0.9–1.1 (0.0354–0.0433) exhaust mm (in) 0.9–1.1 (0.0354–0.0433) valve margin thickness d intake mm (in) 0.85–1.15 (0.0335–0.0453) exhaust mm (in) 0.85–1.15 (0.0335–0.0453) valve stem diameter intake mm (in) 3.975–3.990 (0.1565–0....

  • Page 403: Spec

    15 e spec maintenance specifications piston ring top ring type barrel dimension (b × t) mm (in) 0.90 × 2.75 (0.04 × 0.11) end gap (installed) mm (in) 0.19–0.31 (0.0075–0.0122) ring groove clearance mm (in) 0.030–0.065 (0.0012–0.0026) 2nd ring type taper dimensions (b × t) mm (in) 0.80 × 2.80 (0.03 ×...

  • Page 404: Spec

    16 e spec maintenance specifications jet pump unit hull and hood electrical oil filter oil filter type cartridge type oil pump oil pump type trochoid rotor tip clearance (scavenge pump) mm (in) 0.09–0.15 (0.0035–0.0059) oil pump housing clearance rotor (feed pump) mm (in) 0.09–0.17 (0.0035–0.0067) r...

  • Page 405: Spec

    17 e spec maintenance specifications stator pickup coil (w – b, r – b) output peak voltage @cranking (unloaded) v 4 @cranking (loaded) v 4 @2,000 r/min (loaded) v 23 @3,500 r/min (loaded) v 38 lighting coil (g – g) output peak voltage @cranking (unloaded) v 9 @2,000 r/min (unloaded) v 11 @3,500 r/mi...

  • Page 406: Spec

    18 e spec maintenance specifications *1 the figures are for reference only. Intake air temperature sensor intake air temperature sensor resistance (b/y – b/o) @ 0 °c (32 °f) k Ω 5.4–6.6 @ 80 °c (176 °f) k Ω 0.29–0.39 intake air pressure sensor output voltage (p/g – b/o) v @ kpa (kgf/cm 2 , psi) 4.00...

  • Page 407: Spec

    19 e spec tightening torques tightening torques specified torques part to tightened part name thread size q’ty tightening torque remarks n•m kgf•m ft•lb hull and hood handlebar cover (for fx/fx high output) screw m6 4 1.1 0.11 0.8 242 lt handlebar cover stay (for fx/fx high output) bolt m6 2 1.1 0.1...

  • Page 408: Spec

    20 e spec side ornament screw m5 4 2.2 0.22 1.6 center cover nut — 4 5.4 0.54 3.9 hood lock nut — 2 6.4 0.64 4.6 compass sensor and air tempera- ture sensor nut — 2 3.8 0.38 2.7 shift lever assembly nut — 3 5.4 0.54 3.9 seat lock assembly bolt m6 4 6.4 0.64 4.6 271 lt deck beam nut — 4 18 1.8 13 pro...

  • Page 409: Spec

    21 e spec cable and hose routing cable and hose routing bow 20˚ down up j h-h g-g j h h g g f e a b-b a-a c-c d-d 8 7 9 0 b 1 2 3 4 5 6 0 2 e 9 7 8 d e c f c 1 7 9 0 d 0 c 3 f h a 1 1 e-e f-f a d h h h h b a g b b È up up 1 i 1 fuel tank breather hose 2 cooling water pilot outlet hose 3 cooling wate...

  • Page 410: Spec

    22 e spec cable and hose routing Ì Í Ì Í a b a b a Ë Ê Ë f 1 2 3 4 5 6 7 8 9 c b a 0 5 a 1 2 3 h j 5 4 6 1 2 3 h 5 4 6 i h g i h d É È b e 1 buzzer lead 2 steering sensor lead 3 handlebar switch assembly lead 4 fuel level sensor lead 5 speed sensor lead 6 electrical box lead 7 throttle cable 8 negat...

  • Page 411: Spec

    23 e spec cable and hose routing Ì Í Ì Í a b a b a Ë Ê Ë f 1 2 3 4 5 6 7 8 9 c b a 0 5 a 1 2 3 h j 5 4 6 1 2 3 h 5 4 6 i h g i h d É È b e È fasten the handlebar switch assembly lead, fuel level sensor lead, speed sensor lead, and elec- trical box lead securely with a plastic tie. É when installing ...

  • Page 412: Spec

    24 e spec cable and hose routing 3a a a s p a r e 20a 3a 3a main a b È É Í 3 f g g f a a a b c c c d 7 d d e 3 a 7 d c-c e e Ì d-d 1 2 3 4 a 9 0 2 9 1 5 6 7 a 2 1 a e 3 b f É È Ë 9 2 a 8 Ê i g h 1 shift cable 2 steering cable 3 fuel hose 4 throttle cable 5 cooling water pilot outlet hose 6 negative ...

  • Page 413: Spec

    25 e spec cable and hose routing 3a a a s p a r e 20a 3a 3a main a b È É Í 3 f g g f a a a b c c c d 7 d d e 3 a 7 d c-c e e Ì d-d 1 2 3 4 a 9 0 2 9 1 5 6 7 a 2 1 a e 3 b f É È Ë 9 2 a 8 Ê i g h È to ventilation socket É to fuel tank Ê route the fuel tank breather hose as shown in the illustration. ...

  • Page 414: Spec

    26 e spec cable and hose routing a 1 2 3 É Ê È 1 2 3 È Ê É b b c c b b c c b-b c-c 2 5 4 5 4 1 3 9 3 1 2 6 Ë Ì 8 7 a a Í d d 1 throttle cable 2 qsts cable 3 handlebar switch lead 4 grommet 5 hose packing 6 fuel tank breather hose 7 remote control unit lead (fx high output/fx cruiser high output) 8 r...

  • Page 415: Spec

    27 e spec cable and hose routing a 1 2 3 É Ê È 1 2 3 È Ê É b b c c b b c c b-b c-c 2 5 4 5 4 1 3 9 3 1 2 6 Ë Ì 8 7 a a Í d d Ê position the qsts cable packing in the opening in the grommet so that the plastic tie is fastened around both the grommet and the packing. Ë fx cruiser/fx cruiser high outpu...

  • Page 416: Spec

    28 e spec cable and hose routing 5 b a h c d 9 e f g 8 2 a 9 1 2 5 0 2 9 6 7 7 6 5 4 3 2 1 È 4 a-a a a 8 c d 1 cooling water hose (cooling water inlet) 2 bilge hose 1 3 electric bilge pump 4 bilge hose 4 5 cooling water hose (from thermostat) 6 bilge hose 3 7 bilge hose 2 8 shift cable 9 cooling wat...

  • Page 417: Spec

    29 e spec cable and hose routing b a a a-a c b 3 4 0 9 5 6 7 8 2 1 Í É Ê Ë c a Ì 0 a 4 b 1 1 È È È È È Ï Ð Î 1 wiring harness 2 ground lead 3 wiring harness coupler 4 noise filter 5 oil pressure switch coupler 6 pickup coil coupler 7 thermoswitch (engine) coupler 8 lighting coil coupler 9 thermoswit...

  • Page 418: Spec

    30 e spec cable and hose routing a a 1 2 4 3 7 5 6 0 9 8 a-a Ë Ê É Ì Í Î Ð Ï Ñ Ò Ï Ð b b È Õ Ô Ó Ñ Ò Ï Ð 1 engine temperature sensor coupler 2 lighting coil coupler 3 pickup coil coupler 4 thermoswitch (engine) coupler 5 thermoswitch (engine) 6 starter motor 7 engine temperature sensor 8 engine temp...

  • Page 419: Spec

    31 e spec cable and hose routing a a 1 2 4 3 7 5 6 0 9 8 a-a Ë Ê É Ì Í Î Ð Ï Ñ Ò Ï Ð b b È Õ Ô Ó Ñ Ò Ï Ð Î route the starter motor lead to the outside of the engine temperature sensor lead. Ï to starter relay Ð to negative battery terminal Ñ route the starter motor and negative battery leads behind ...

  • Page 420: Spec

    32 e spec cable and hose routing (for fx/fx cruiser) cable and hose routing (for fx/fx cruiser) b d g f a e-e Ð Ï Ë Ë Ë Ë Ê Ö × Ì Ñ Ì Ô Ø Ñ Õ Ì Ê Ó Ó Ò Ú Ë d a g f b 4 6 7 5 1 e e Í c-c Î 3 2 3 c c È É 1 Ù 1 thermostat 2 cooling water pilot outlet hose 3 cooling water hose 4 pressure control valve 5...

  • Page 421: Spec

    33 e spec cable and hose routing (for fx/fx cruiser) b d g f a e-e Ð Ï Ë Ë Ë Ë Ê Ö × Ì Ñ Ì Ô Ø Ñ Õ Ì Ê Ó Ó Ò Ú Ë d a g f b 4 6 7 5 1 e e Í c-c Î 3 2 3 c c È É 1 Ù Í when installing the cooling water hoses, be sure to push them down until they contact the hose joint. Î bundle the cooling water pilot ...

  • Page 422: Spec

    34 e spec cable and hose routing (for fx/fx cruiser) b d g f a e-e Ð Ï Ë Ë Ë Ë Ê Ö × Ì Ñ Ì Ô Ø Ñ Õ Ì Ê Ó Ó Ò Ú Ë d a g f b 4 6 7 5 1 e e Í c-c Î 3 2 3 c c È É 1 Ù Ö bundle the cooling water hose (cylinder head cover to thermostat) and cooling water hose (starboard cooling water pilot outlet), and th...

  • Page 423: Spec

    35 e spec cable and hose routing (for fx/fx cruiser) Ê a È É b 1 2 3 4 5 6 7 2 8 a b Ï Î Í Ì Ë 8 1 intake air temperature sensor coupler 2 intake air pressure sensor coupler 3 fuel injector #4 coupler 4 fuel injector #3 coupler 5 fuel injector #2 coupler 6 fuel injector #1 coupler 7 throttle positio...

  • Page 424: Spec

    36 e spec cable and hose routing (for fx/fx cruiser) Ê a È É b 1 2 3 4 5 6 7 2 8 a b Ï Î Í Ì Ë 8 Î fasten the ring, which is attached to the sub- wiring harness, to the sensor bracket with a plastic tie. Face the end of the plastic tie towards the sensor. Ï to bypass valve motor coupler..

  • Page 425: Spec

    37 e spec cable and hose routing (for fx high output/ fx cruiser high output) cable and hose routing (for fx high output/fx cruiser high output) b d g f a e-e Ð Ï Ë Ë Ë Ë Ê Õ Ì Ñ Ì Ó × Ñ Ô Ì Ê Ò Ò Ø Ë d a g f b 5 4 1 e e Í c-c Î 3 2 c c Ö Ù È É 1 1 thermostat 2 cooling water pilot outlet hose 3 cool...

  • Page 426: Spec

    38 e spec cable and hose routing (for fx high output/ fx cruiser high output) b d g f a e-e Ð Ï Ë Ë Ë Ë Ê Õ Ì Ñ Ì Ó × Ñ Ô Ì Ê Ò Ò Ø Ë d a g f b 5 4 1 e e Í c-c Î 3 2 c c Ö Ù È É 1 Í when installing the cooling water hoses, be sure to push them down until they contact the hose joint. Î bundle the coo...

  • Page 427: Spec

    39 e spec cable and hose routing (for fx high output/ fx cruiser high output) b d g f a e-e Ð Ï Ë Ë Ë Ë Ê Õ Ì Ñ Ì Ó × Ñ Ô Ì Ê Ò Ò Ø Ë d a g f b 5 4 1 e e Í c-c Î 3 2 c c Ö Ù È É 1 Õ bundle the cooling water hose (cylinder head cover to thermostat) and cooling water hose (starboard cooling water pilo...

  • Page 428: Spec

    40 e spec cable and hose routing (for fx high output/ fx cruiser high output) 1 2 3 4 5 6 7 8 3 2 2 a b a É Ê È Í Ì Ë b 1 bypass valve motor coupler 2 joint coupler 3 sensor assembly coupler 4 fuel injector #4 coupler 5 fuel injector #3 coupler 6 fuel injector #2 coupler 7 fuel injector #1 coupler 8...

  • Page 429: Insp

    41 e 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. *1: grease quantity: 33.0–35.0 cm 3 (1.11–1.18 oz) *2:...

  • Page 430: Insp

    42 e insp adj control system periodic service control system steering master inspection 1. Inspect: • steering master excessive play → replace the steering master. Refer to “steering master”. Inspection steps: • move the handlebar up and down and back and forth. • check the excessive play of the han...

  • Page 431: Insp

    43 e insp adj control system 2. Adjust: • steering cable joint (steering master end) note: if the steering cable cannot be properly adjusted by the cable joint at the steering mas- ter end, adjust the cable joint at the jet pump end so that the same clearances are obtained. Refer to “remote control ...

  • Page 432: Insp

    44 e insp adj control system 2. Adjust: • throttle lever free play adjustment steps: note: • when not replacing the throttle cable or removing the cable from the throttle body, adjust the throttle cable free play by fol- lowing steps (d) through (h). • when replacing the throttle cable or removing t...

  • Page 433: Insp

    45 e insp adj control system/general warning after adjusting the free play, turn the han- dlebar to the right and left and make sure that the trolling speed does not increase. H. Install the handlebar cover. T r . Handlebar cover screw: 1.1 n • m (0.11 kgf • m, 0.8 ft • lb) loctite 242 i. Install th...

  • Page 434: Insp

    46 e insp adj general lubrication points 1. Lubricate: • throttle cable (handlebar end) note: before lubricating the throttle cable, remove the throttle cable 1 from the throttle lever assembly. Recommended lubricant: rust inhibitor 1 2. Lubricate: • throttle cable (throttle body end) • throttle bod...

  • Page 435: Insp

    47 e insp adj general 4. Lubricate: • qsts cables (pulley end) recommended grease: yamaha marine grease, yamaha grease a (water resistant grease) 5. Lubricate: • nozzle pivot shaft • steering cable (nozzle end) • qsts cable (nozzle end) recommended grease: yamaha marine grease, yamaha grease a (wate...

  • Page 436: Insp

    48 e insp adj general 7. Fill: • intermediate housing note: fill the intermediate housing with the recom- mended grease through the grease nipple 1. Recommended grease: yamaha marine grease, yamaha grease a (water resistant grease) grease quantity: initial 10 hours: 33.0–35.0 cm 3 (1.11–1.18 oz) eve...

  • Page 437: Elec

    49 e – + elec electrical components (for fx/fx cruiser) electrical components (for fx/fx cruiser) n m l k j h g f e d c b a 0 9 8 7 6 5 4 3 2 1 i 1 thermoswitch (engine) 2 starter motor 3 engine temperature sensor 4 spark plugs and ignition coils 5 electrical box 6 battery 7 speed sensor 8 electric ...

  • Page 438: Elec

    50 e – + elec electrical components (for fx high output/ fx cruiser high output) electrical components (for fx high output/fx cruiser high output) m n l p o k j i g f e d c b a 0 9 8 7 6 5 4 3 2 1 h 1 thermoswitch (engine) 2 starter motor 3 engine temperature sensor 4 spark plugs and ignition coils ...

  • Page 439: Elec

    51 e – + elec electrical components (for fx high output/ fx cruiser high output) m n l p o k j i g f e d c b a 0 9 8 7 6 5 4 3 2 1 h j electric fuel pump k fuel level sensor l left operation button m multifunction meter n right operation button (fx cruiser high output) o remote control unit p compas...

  • Page 440: Elec

    52 e – + elec off throttle steering system off throttle steering system wiring diagram p o g/b g pu/b g/y g/r pu/g pu/y pu/b p o r/y pu/y g/y g/r b/y p/g pu/r pu/r pu/g p/g r/y g g/b b/o g g/y w r b w b r w/b b/o w/r b/o b/o b/o b/o w/b b/o w/r b/o b/o b/o b/o o p b/o o p o b w/l w/l b/o r/y r/y o w...

  • Page 441: Elec

    53 e – + elec off throttle steering system 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 s...

  • Page 442: Elec

    54 e – + elec indication system indication system wiring diagram (for fx cruiser high output) g b b b b b r l b w g r r 3 r l/r l y r r/y r b p r r p w/b r/y b/o r/y r/y r r/y r/y r r p p p 1 2 3 4 5 6 7 8 2 7 6 8 5 b/o p p b p b/o p b b/o p p b/g b w/b b p b/o p b b/y b/o b/y b/y b/y b/o b/y 9 b/o ...

  • Page 443: Elec

    55 e – + elec indication system wiring diagram (for fx cruiser high output) g b b b b b r l b w g r r 3 r l/r l y r r/y r b p r r p w/b r/y b/o r/y r/y r r/y r/y r r p p p 1 2 3 4 5 6 7 8 2 7 6 8 5 b/o p p b p b/o p b b/o p p b/g b w/b b p b/o p b b/y b/o b/y b/y b/y b/o b/y 9 b/o b/o b/o b/o b/o b/...

  • Page 444: Elec

    56 e – + elec indication system wiring diagram (for fx high output) g b b b b b r 3 r l/r l y r r/y r b p r r p w/b r/y b/o r/y r/y r r/y r/y r r p p p 1 2 3 4 5 6 7 8 2 7 6 8 5 b/o p p b p b/o p b b/o p p b/g b w b p b/o p b b/y b/o b/y b/y b/y b/o b/y 9 b/o b/o b/o b/o b/o b/o b/o b/o b/o b/o b/o ...

  • Page 445: Elec

    57 e – + elec indication system wiring diagram (for fx high output) g b b b b b r 3 r l/r l y r r/y r b p r r p w/b r/y b/o r/y r/y r r/y r/y r r p p p 1 2 3 4 5 6 7 8 2 7 6 8 5 b/o p p b p b/o p b b/o p p b/g b w b p b/o p b b/y b/o b/y b/y b/y b/o b/y 9 b/o b/o b/o b/o b/o b/o b/o b/o b/o b/o b/o ...

  • Page 446: Elec

    58 e – + elec indication system wiring diagram (for fx/fx cruiser) g g r 4 3 r l/r br l y r/y r/y r b p r o r/y r/y r/y r p w/b r/y b/o r/y r/y r/y r/y y y r r p p p 1 2 5 6 2 1 b b b 7 6 8 5 b/o b/g p b p b/o p b b/o p p p b w b p b/o p b b/y b/o b/y b/y b/y b/o b/y 9 b/o b/o b/o b/o b/o b/o b/o b/...

  • Page 447: Elec

    59 e – + elec 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. Operation button 1. Check: • left operation button continuity out of specif...

  • Page 448: Elec

    60 e – + elec indication system multifunction meter removal refer to “steering console cover”. Operation button removal refer to “steering console cover”..

  • Page 449: Elec

    61 e – + elec display function (for fx cruiser high output) 1. Check: • display function does not operate → replace the multi- function meter. 1 remote control unit 2 buzzer 3 compass sensor 4 ecm 5 fuel level sensor 6 left operation button 7 right operation button b : black g : green l : blue p : p...

  • Page 450: Elec

    62 e – + elec display function (for fx high output) 1. Check: • display function does not operate → replace the multi- function meter. 1 remote control unit 2 buzzer 3 speed sensor 4 ecm 5 fuel level sensor 6 left operation button b : black gy : gray p : pink r : red w : white y : yellow b/g : black...

  • Page 451: Elec

    63 e – + elec indication system display function (for fx/fx cruiser) 1. Check: • display function not operate → replace the multifunc- tion meter. 1 buzzer 2 speed sensor 3 ecm 4 fuel level sensor 5 left operation button b : black r : red w : white y : yellow b/g : black/green b/y : black/yellow g/w...

  • Page 452: Elec

    64 e – + elec indication system compass display (for fx cruiser high output) 1. Check: • compass display incorrect reading → replace the com- pass sensor. Air temperature display (for fx cruiser high output) 1. Check: • air temperature display incorrect reading → replace the com- pass sensor. Checki...

  • Page 453: Elec

    65 e – + elec speedometer/average speed/tripmeter dis- play (for fx cruiser high output) 1. Check: • speedometer/average speed/tripmeter display does not display → measure the speed sensor output voltage. 2. Measure: • speed sensor output voltage out of specification → replace the speed sensor. With...

  • Page 454: Elec

    66 e – + elec indication system water temperature display (for fx cruiser high output) 1. Check: • water temperature display incorrect reading → measure the speed sensor (water temperature sensor) resistance. 2. Measure: • speed sensor (water temperature sen- sor) resistance. Out of specification → ...

  • Page 455: Elec

    67 e – + elec trip timer display (for fx cruiser high output) 1. Check: • trip timer display does not display → replace the multi- function meter. Fuel consumption per hour, fuel consump- tion per kilometer/mile display (for fx cruiser high output) 1. Check: • fuel consumption per hour, fuel con- su...

  • Page 456: Elec

    68 e – + elec indication system check engine warning indicator 1. Check: • check the engine warning indicator does not operate → replace the multi- function meter. Checking steps: • start the engine. • disconnect the coupler of a sensor (e.G., engine temperature sensor) that normally activates the c...

  • Page 457: Elec

    69 e – + elec remote control system (for fx high output/ fx cruiser high output) remote control system (for fx high output/fx cruiser high output) wiring diagram 16 7 6 11 15 14 18 12 3 4 13 10 123456789 0abcdefgh l r/y r/y 14 31 21 15 30 r/y l/r l y r r/y b r/y r/y r/y l/r y br br b b r 4 7 3 2 1 6...

  • Page 458: Elec

    70 e – + elec remote control system (for fx high output/ fx cruiser high output) wiring diagram 16 7 6 11 15 14 18 12 3 4 13 10 123456789 0abcdefgh l r/y r/y 14 31 21 15 30 r/y l/r l y r r/y b r/y r/y r/y l/r y br br b b r 4 7 3 2 1 6 r/y r/y r p p o r r r r r r 1 2 3 4 5 6 7 8 5 b b b b y b b b b w...

  • Page 459: Elec

    71 e – + elec 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 ...

  • Page 460: Elec

    72 e – + elec remote control system (for fx high output/ fx cruiser high output) low-rpm mode indicator 1. Check: • low-rpm mode indicator does not come on → replace the multi- function meter. Checking steps: • press the unlock button 1 of remote con- trol transmitter for more than four sec- onds to...

  • Page 461: Hull

    73 e hull hood handlebar handlebar exploded diagram (for fx/fx high output) removal and installation chart step procedure/part name q’ty service points steering pad removal follow the left “step” for removal. 1 screw 4 2 handlebar cover 1 3 pad 1 4 bolt 2 5 handlebar cover stay 1 reverse the removal...

  • Page 462: Hull

    74 e hull hood handlebar exploded diagram (for fx cruiser/fx cruiser high output) removal and installation chart step procedure/part name q’ty service points steering pad removal follow the left “step” for removal. 1 screw 8 2 screw (black) 2 3 lower handlebar cover 1 4 upper handlebar cover 1 note:...

  • Page 463: Hull

    75 e hull hood handlebar exploded diagram removal and installation chart step procedure/part name q’ty service points handlebar holder removal follow the left “step” for removal. 1 throttle cable 1 note: be sure to remove the throttle cable seal as shown in the illustration. 2 bolt 4 3 upper handleb...

  • Page 464: Hull

    76 e hull hood handlebar exploded diagram removal and installation chart step procedure/part name q’ty service points handlebar removal follow the left “step” for removal. Qsts cable (to jet thrust nozzle) refer to “remote control cables and speed sensor lead”. 1 nut/washer 2/2 2 qsts converter 1 3 ...

  • Page 465: Hull

    77 e hull hood handlebar exploded diagram step procedure/part name q’ty service points 6 screw 4 7 handle boss cover 1 8 plastic tie 2 9 hose packing 1 10 throttle cable 1 note: position the corrugated tube for the throttle cable as shown in the illustration so that the tube attaches to the end of t...

  • Page 466: Hull

    78 e hull hood handlebar exploded diagram step procedure/part name q’ty service points 11 handlebar assembly 1 note: • pass the qsts cable and handlebar switch lead through the handle boss cover, and then install the handlebar assembly. • install the sponges of the qsts cables as shown and make sure...

  • Page 467: Hull

    79 e hull hood handlebar service points handlebar assembly installation 1. Install: • plastic ties 1 • qsts cables 2 • handlebar switch lead 3 • throttle cable 4 note: after inserting the qsts cables, handlebar switch lead and throttle cable into the grom- mets, tie the end of grommets with the plas...

  • Page 468: Hull

    80 e hull hood handlebar 3. Connect: • throttle cable installing steps (for fx/fx high output): • route the throttle cable 1 over the han- dlebar 2, and then install the throttle cable end into the throttle lever. • make sure that the throttle cable, qsts cable 3, and handlebar switch lead 4 pass th...

  • Page 469: Hull

    81 e hull hood handlebar 4. Install: • throttle cable seal installing steps: • install the throttle cable end into the throt- tle lever. • fit the seal 1 into the groove in the bracket as shown. • pull the throttle cable 2 in the direction of the arrow shown in the illustration, and then fit the end...

  • Page 470: Hull

    82 e hull hood steering master steering master exploded diagram removal and installation chart step procedure/part name q’ty service points steering master removal follow the left “step” for removal. Mirror assembly refer to “mirror”. Center cover assembly refer to “steering console cover”. Steering...

  • Page 471: Hull

    83 e hull hood exploded diagram step procedure/part name q’ty service points 7 nut/washer 4/4 8 steering master assembly 1 9 bolt 4 reverse the removal steps for installation. 8 6 8 7 5 6 4 2 1 5 2 9 8 3 8 × 30 mm 8 × 35 mm 6 × 60 mm 20 n • m (2.0 kgf • m, 14 ft • ib) lt 271 steering master.

  • Page 472: Hull

    84 e hull hood steering master exploded diagram removal and installation chart step procedure/part name q’ty service points steering master disassembly follow the left “step” for disassembly. 1 steering shaft 1 fx cruiser/fx cruiser high output 2 steering shaft 1 fx/fx high output 3 bushing 1 4 bush...

  • Page 473: Hull

    85 e hull hood steering master exploded diagram step procedure/part name q’ty service points 9 bolt 1 10 bracket 2 1 11 bolt/nut 5/5 12 left housing 1 13 spring holder 1 14 spring 1 1 15 lever 1 16 lock 1 17 spring 2 1 18 right housing 1 fwd 12 7 8 6 6 3 21 21 9 10 16 15 22 20 4 5 1 2 6 × 25 mm 5 × ...

  • Page 474: Hull

    86 e hull hood exploded diagram step procedure/part name q’ty service points 19 steering tube 1 20 rubber seal 1 21 bushing 2 22 steering master assembly 1 reverse the disassembly steps for assembly. Fwd 12 7 8 6 6 3 21 21 9 10 16 15 22 20 4 5 1 2 6 × 25 mm 5 × 16 mm 8 × 30 mm 8 × 30 mm a a a a a a ...

  • Page 475: Hull

    87 e hull hood service points steering master components inspection 1. Inspect: • each component part damage/wear → replace. Rubber seal installation 1. Apply: • instant adhesive (onto the mating surfaces of the rubber seal 1 and steering master assembly 2) note: after assembling the steering master...

  • Page 476: Hull

    88 e hull hood remote control cables and speed sensor lead remote control cables and speed sensor lead exploded diagram removal and installation chart step procedure/part name q’ty service points remote control cables and speed sensor lead removal follow the left “step” for removal. Service lid 1 re...

  • Page 477: Hull

    89 e hull hood remote control cables and speed sensor lead exploded diagram step procedure/part name q’ty service points 7 cap 1 8 screw 4 9 speed sensor speed sensor and water temperature sensor 1 1 fx/fx cruiser/fx high output fx cruiser high output 10 shift cable end 1 11 plastic tie 1 12 grommet...

  • Page 478: Hull

    90 e hull hood remote control cables and speed sensor lead exploded diagram step procedure/part name q’ty service points 17 shift cable bracket 1 18 nut 1 19 shift cable 1 20 seal 1 21 nut 1 22 pin 1 23 qsts cable end 1 24 nut 1 25 qsts cable 1 26 packing 1 reverse the removal steps for installation...

  • Page 479: Hull

    91 e hull hood remote control cables and speed sensor lead service points steering cable removal 1. Remove: • steering cable removal steps: • rotate the steering stopper plate 1 on the steering stopper clockwise and remove it from the steering stopper plate 2. • rotate the steering stopper plate 2 c...

  • Page 480: Hull

    92 e hull hood remote control cables and speed sensor lead service points steering cable installation 1. Install: • steering cable installing steps: • connect the cable joint 1 to the ball joint 2. • insert the projection 3 on the steering cable completely into the indentation 4 in the steering stop...

  • Page 481: Hull

    93 e hull hood front hood front hood exploded diagram removal and installation chart step procedure/part name q’ty service points front hood removal follow the left “step” for removal. 1 nut/washer 4/4 2 front hood assembly 1 3 bolt 4 4 bolt 2 5 hinge assembly 1 6 bolt 2 7 hood lock assembly 1 8 riv...

  • Page 482: Hull

    94 e hull hood front hood exploded diagram step procedure/part name q’ty service points 10 rivet 4 11 service lid 2 1 reverse the removal steps for installation. 2 7 6 4 8 9 3 5 1 11 10 6 × 30 mm 6.4 n • m (0.64 kgf • m, 4.6 ft • ib) lt 242 lt 242 6 × 18 mm 5.4 n • m (0.54 kgf • m, 3.9 ft • ib) 6 × ...

  • Page 483: Hull

    95 e hull hood front hood service points rivet installation 1. Install: • rivets installing steps: • insert a rivet completely in the holes in both the service lid 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 ...

  • Page 484: Hull

    96 e hull hood front hood exploded diagram removal and installation chart step procedure/part name q’ty service points front hood disassembly follow the left “step” for disassembly. 1 screw 8 2 front hood 1 1 3 front hood 2 1 4 nut 4 5 center ornament 1 note: • be careful not to scratch the ornament...

  • Page 485: Hull

    97 e hull hood front hood exploded diagram step procedure/part name q’ty service points 10 bushing 6 11 visor 1 12 nut 6 note: apply soapy water to the nuts to make their installation easier. Reverse the disassembly steps for assembly. 2 1 4 9 5 × 16 mm 2.2 n • m (0.22 kgf • m, 1.6 ft • ib) 5 × 16 m...

  • Page 486: Hull

    98 e hull hood front hood service points ornament disassembly 1. Disassembly: • center ornament • left ornament • right ornament removal steps: • from the bottom side of the front hood 1, push the projections 2 on the center ornament shown in the illustration and remove the ornament from the double-...

  • Page 487: Hull

    99 e hull hood front hood visor installation 1. Install: • visor installing steps: • install the bushings 1 onto the screws 2 as shown in the illustration. • install the visor and tighten the screws, making sure to hold the nuts so that they do not turn. T r . Screw: 1.1 n • m (0.11 kgf • m, 0.8 ft ...

  • Page 488: Hull

    100 e hull hood front hood ornament installation 1. Install: • left ornament • right ornament • center ornament installing steps: • peel off the backing of the double-sided tape 1 on the watercraft. • install the left and right ornaments from the sides as shown in the illustration. • install the cen...

  • Page 489: Hull

    101 e hull hood mirror exploded diagram removal and installation chart step procedure/part name q’ty service points mirror removal follow the left “step” for removal. 1 nut 2 2 washer 2 3 bolt 2 4 bolt 4 5 left mirror assembly 1 6 right mirror assembly 1 reverse the removal steps for installation. 4...

  • Page 490: Hull

    102 e hull hood mirror exploded diagram removal and installation chart step procedure/part name q’ty service points mirror disassembly follow the left “step” for disassembly. 1 screw 12 2 left mirror upper cover 1 3 screw 8 4 left mirror 1 5 nut 2 6 left mirror lower cover 1 7 right mirror upper cov...

  • Page 491: Hull

    103 e hull hood steering console cover steering console cover exploded diagram removal and installation chart step procedure/part name q’ty service points meter and meter cover removal follow the left “step” for removal. Handlebar assembly refer to “handlebar”. Service lid 1 refer to “front hood”. 1...

  • Page 492: Hull

    104 e hull hood steering console cover exploded diagram step procedure/part name q’ty service points 5 left operation button coupler 1 6 right operation button coupler 1 fx cruiser high output 7 left operation button 1 8 right operation button 1 fx cruiser high output 9 bolt 4 10 washer 4 11 band 1 ...

  • Page 493: Hull

    105 e hull hood steering console cover exploded diagram removal and installation chart step procedure/part name q’ty service points side cover removal follow the left “step” for removal. 1 bolt 2 2 nut/washer 2/2 3 bolt 8 4 left side cover 1 5 left inner side pad 2 6 nut 6 7 screw 4 8 left side orna...

  • Page 494: Hull

    106 e hull hood exploded diagram removal and installation chart step procedure/part name q’ty service points 10 right inner side pad 2 11 right side ornament 1 reverse the removal steps for installation. 3 9 11 6 6 1 7 3 3 1 7 3 6 8 6 1 5 5 10 10 6 2 2 4 5 × 15 mm 2.2 n • m (0.22 kgf • m, 1.6 ft • i...

  • Page 495: Hull

    107 e hull hood steering console cover exploded diagram removal and installation chart step procedure/part name q’ty service points center cover removal follow the left “step” for removal. 1 nut/washer 2/2 2 bolt 2 3 nut/washer 2/2 4 center cover assembly 1 note: to remove the center cover assembly ...

  • Page 496: Hull

    108 e hull hood steering console cover exploded diagram step procedure/part name q’ty service points 9 screw 2 fx cruiser high output 10 compass sensor and air temperature sensor 1 fx cruiser high output 11 case cap 1 12 inner pad 1 reverse the removal steps for installation. Fwd 4 3 3 2 11 12 9 10 ...

  • Page 497: Hull

    109 e hull hood steering console cover exploded diagram removal and installation chart step procedure/part name q’ty service points center cover disassembly follow the left “step” for disassembly. 1 damper 2 2 nut 4 3 grommet 4 4 damper 6 5 damper 1 6 hinge assembly 2 7 gear assembly 2 8 lid 1 9 lid...

  • Page 498: Hull

    110 e hull hood steering console cover exploded diagram step procedure/part name q’ty service points 10 plug 1 11 center cover 1 reverse the disassembly steps for assembly. 9 8 7 6 7 6 10 5 4 11 1 3 1 2 2.

  • Page 499: Hull

    111 e hull hood shift lever shift lever exploded diagram removal and installation chart step procedure/part name q’ty service points shift lever removal follow the left “step” for removal. Front hood assembly refer to “front hood”. Mirror assembly refer to “mirror”. Right side cover refer to “steeri...

  • Page 500: Hull

    112 e hull hood seats and hand grip seats and hand grip exploded diagram removal and installation chart step procedure/part name q’ty service points seats and hand grip removal follow the left “step” for removal. 1 rear seat assembly 1 fx/fx high output 2 rear seat assembly 1 fx cruiser/fx cruiser h...

  • Page 501: Hull

    113 e hull hood seats and hand grip exploded diagram step procedure/part name q’ty service points 11 nut 1 12 projection 1 13 washer 1 14 seal 1 15 nut 4 16 bolt 4 17 rear seat stay 2 18 nut 1 19 projection 1 20 washer 2 3 1 6 5 23 22 19 20 21 18 20 8 9 11 15 7 17 16 14 13 12 10 6 5 6 × 25 mm 8 × 30...

  • Page 502: Hull

    114 e hull hood seats and hand grip exploded diagram step procedure/part name q’ty service points 21 nut/washer 4/4 22 bolt 4 23 hand grip 1 fx/fx high output 24 hand grip 1 fx cruiser/fx cruiser high output 25 nut/washer 2/1 26 seat holder 1 reverse the removal steps for installation. 3 1 6 5 23 22...

  • Page 503: Hull

    115 e hull hood reboarding step (for fx cruiser/fx cruiser high output) reboarding step (for fx cruiser/fx cruiser high output) exploded diagram removal and installation chart step procedure/part name q’ty service points reboarding step removal follow the left “step” for removal. 1 bolt 6 2 reboardi...

  • Page 504: Hull

    116 e hull hood reboarding step (for fx cruiser/fx cruiser high output) service points reboarding step installation 1. Install: • reboarding step installing steps: • fasten the brackets on both sides of the reboarding step in the down position with a plastic tie 1 as shown in the illustra- tions so ...

  • Page 505: Hull

    117 e hull hood deck and hull deck and hull exploded diagram removal and installation chart step procedure/part name q’ty service points deck and hull disassembly follow the left “step” for disassembly. 1 nut 1 2 spout 1 3 nut 2 4 cleat 1 5 plate 2 6 bolt/collar 10/10 7 sponson 2 8 nut/washer 4/4 9 ...

  • Page 506: Hull

    118 e hull hood deck and hull exploded diagram step procedure/part name q’ty service points 11 seal 2 12 nut 4 note: to remove the cleat, remove the exhaust system first. 13 plate 4 14 cleat 2 15 seal 2 16 nut/washer 7/7 17 front protector 1 1 note: install the front protector 1 and 2 after install-...

  • Page 507: Hull

    119 e hull hood deck and hull exploded diagram step procedure/part name q’ty service points 20 bolt 2 21 bow eye 1 22 cleat cover 2 fx cruiser high output 23 screw 6 fx cruiser high output 24 cleat assembly 2 fx cruiser high output reverse the disassembly steps for assembly. 16 16 19 4 5 3 7 6 15 13...

  • Page 508: Hull

    120 e hull hood cleat assembly (for fx cruiser high output) cleat assembly (for fx cruiser high output) exploded diagram removal and installation chart step procedure/part name q’ty service points cleat disassembly follow the left “step” for disassembly. The following procedure applies to both of th...

  • Page 509: Hull

    121 e hull hood cleat assembly (for fx cruiser high output) service points cleat cover installation 1. Install: • cleat cover note: make sure that the word “yamaha” a on the cleat covers faces outward as shown in the illustration. A.

  • Page 510: Trbl

    122 e trbl anls trouble analysis trouble analysis self-diagnosis with the engine running, simultaneously press the two buttons 1 for 8 seconds and check if an error code is indicated on the multifunction meter. If the yamaha diagnostic system is not used to check the symptoms listed in the table, th...

  • Page 511

    Fx/fx cruiser 10 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 10 9 8 7 6 5 4 3 2 1 2 1 3 2 1 2 3 4 16 5 6 7 15 1 8 12 11 10 9 13 14 1 2 1 1 2 1 2 3 2 1 2 3 1 1 2 3 4 5 6 1 2 3 ...

  • Page 512

    Wiring diagram fx/fx cruiser 1 fuse (20 a) 2 fuse (3 a) 3 starter relay 4 noise filter 5 cam position sensor 6 oil pressure switch 7 thermoswitch (exhaust) 8 intake air pressure 9 intake air temperature 0 bypass valve motor a fuel injector b throttle position sensor c pickup coil d lighting coil e e...

  • Page 513

    Fx high output/fx cruiser high output 2 1 3 3 2 1 3 2 1 1 2 3 4 5 6 1 2 3 1 2 3 10 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 10 9 8 7 6 5 4 3 2 1 2 1 3 2 1 2 3 4 16 5 6 7 15...

  • Page 514

    Wiring diagram fx high output/fx cruiser high output 1 fuse (20 a) 2 fuse (3 a) 3 starter relay 4 noise filter 5 cam position sensor 6 oil pressure switch 7 thermoswitch (exhaust) 8 sensor assembly (intake air pressure, intake air temperature) 9 bypass valve motor 0 fuel injector a throttle position...

  • Page 515

    Yamaha motor corporation, usa printed in usa dec. 2005 – 0.0 × 1 cr (e).