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Yamaha FX140 Service Manual

Manual is about: WaveRunner FX140

Summary of FX140

  • Page 1

    Waverunner fx140 f1b-28197-1e-11 *lit186160238* lit-18616-02-38 service manual.

  • 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 as thumb-tabs 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 s...

  • 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 9: Gen

    E gen info 1 2 3 4 5 6 7 8 9 chapter 1 general information identification numbers ......................................................................... 1-1 primary l.D. Number ........................................................................... 1-1 engine serial number ......................

  • Page 10: 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: f1b: 800101 engine serial number the engine serial number is stamped on a label a...

  • Page 11: Gen

    1-2 e gen info safety while working safety while working the procedures given in this manual are those recommended by yamaha to be followed by yamaha dealers and their mechanics. Fire prevention gasoline (petrol) is highly flammable. Gasoline vapor is explosive if ignited. Do not smoke while handlin...

  • Page 12: Gen

    1-3 e gen info safety while working under normal conditions of use there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all- important, and by adopting good safety prac- tises any risk is minimized. A summary of the most important precautions is as follow...

  • Page 13: Gen

    1-4 e gen info safety while working 3. Non-reusable items always use new gaskets, packings, o- rings, oil seals, split-pins, circlips, etc., on reassembly. Disassembly and assembly 1. Clean parts with compressed air when dis- assembling. 2. Oil the contact surfaces of moving parts during assembly. 3...

  • Page 14: 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 15: Gen

    1-6 e gen info special tools a fuel pressure gauge p/n. Yb-06766 90890-06786 b compression gauge extension p/n. 90890-06582 c cylinder gauge set p/n. Yu-03017 90890-06759 d compression gauge p/n. Yu-33223-1 90890-03160 e peak voltage adapter p/n. Yu-39991 90890-03172 f spark gap tester p/n. Ym-34487...

  • Page 16: Gen

    1-7 e gen info special tools m test harness (3 pins) p/n. Yb-06769 90890-06769 n vacuum/pressure pump gauge set p/n. Yb-35956-a 90890-06756 o yamaha diagnostic system for watercraft p/n. 60e-85300-01 p yamaha diagnostic system for watercraft (cd-rom only) p/n. 60e-ws853-00 m p n yb-06769 90890-06769...

  • Page 17: Gen

    1-8 e gen info special tools removal and installation 1 oil filter wrench p/n. Yu-38411 90890-01426 2 coupler wrench p/n. Yw-06551 90890-06551 3 sheave holder p/n. Ys-01880-a 90890-01701 4 rotor puller p/n. Ym-01082 90890-01080 5 rotor holder p/n. Yu-01235 90890-01235 6 valve spring compressor p/n. ...

  • Page 18: Gen

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

  • Page 19: Gen

    1-10 e gen info special tools m ball bearing attachment (jet pump oil seal) p/n. Yb-06085 90890-06634 n driver rod (intermediate shaft and jet pump) p/n. Yb-06071 90890-06606 o bearing inner/outer race attachment (jet pump bearing) p/n. Yb-34474 p shaft holder (intermediate shaft) p/n. Yb-06552 9089...

  • Page 21: Spec

    E spec 1 2 3 4 5 6 7 8 9 chapter 2 specifications general specifications ....................................................................... 2-1 maintenance specifications ............................................................... 2-3 engine ....................................................

  • Page 22: Spec

    2-1 e spec general specifications general specifications item unit model fx140 model code hull f1b 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) dry weight kg (lb) 362 (798) maximum capacity person/kg (lb) 3/240 (530) performance maximu...

  • Page 23: 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 24: Spec

    2-3 e spec maintenance specifications maintenance specifications engine item unit model fx140 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-o...

  • Page 25: 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 26: 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) 0.38–0.55 (0.0150–0.0217) 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 27: Spec

    2-6 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 mm (in) 0.09–0.15 (0.004–0.006) oil pump housing clearance rotor (feed pump) mm (in) 0.09–0.17 (0.0035–0.0067) rotor (scavenge pu...

  • Page 28: Spec

    2-7 e spec maintenance specifications stator pulser coil (w – b, r – b) output peak voltage @cranking 1 v 4 @cranking 2 v 4 @2,000 r/min v 23 @3,500 r/min v 38 lighting coil (g – g) output peak voltage @cranking 1 v 9 @cranking 2 v 8 @2,000 r/min v 11 @3,500 r/min v 12 pulser coil resistance Ω (colo...

  • Page 29: Spec

    2-8 e spec maintenance specifications 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) 80–94 (176–201) engine temperature sensor engine temperature sensor ...

  • Page 30: 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 31: 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 coupling cover 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 3/exhaust pipe 2 1st — — ...

  • Page 32: Spec

    2-11 e spec tightening torques exhaust manifold 1 – cylinder head 1st bolt m8 6 22 2.2 16 242 lt 2nd 22 2.2 16 3rd 35 3.5 25 exhaust manifold 2 – cylinder head 1st bolt m8 5 22 2.2 16 242 lt 2nd 22 2.2 16 3rd 35 3.5 25 water jacket – oil tank 1st bolt m6 4 3.7 0.37 2.7 572 lt 2nd 7.6 0.76 5.5 oil ta...

  • Page 33: Spec

    2-12 e spec tightening torques reduction drive gear case – crankcase 1st bolt m6 2 3.7 0.37 2.7 572 lt 2nd 7.6 0.76 5.5 1st bolt m8 7 15 1.5 11 572 lt 2nd 28 2.8 20 holder (relief valve) – reduction drive gear case bolt m6 1 10 1.0 7.2 e bearing housing – reduction drive gear case 1st bolt m8 4 15 1...

  • Page 34: Spec

    2-13 e spec tightening torques plug (vacuum pressure) bolt m6 4 10 1.0 7.2 engine temperature sensor – crankcase — — 1 15 1.5 11 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 –...

  • Page 35: Spec

    2-14 e spec tightening torques 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 impeller (left-hand threads) – drive shaft impeller m22 1 27 2.7 19 572 lt transom plate – hull nut — 4 26 2.6 19 bilge strainer holder ...

  • Page 36: Spec

    2-15 e spec tightening torques steering cable locknut (jet thrust nozzle side) nut — 1 6.5 0.65 4.7 steering cable grommet – hull nut — 1 5.9 0.59 4.3 steering cable bracket – steering cable holder nut — 2 5.4 0.54 3.9 steering cable bracket – deck nut — 2 5.4 0.54 3.9 speed sensor lead grommet – hu...

  • Page 37: Spec

    2-16 e spec tightening torques bow eye – hull bolt m6 2 13 1.3 9.4 drain plug/packing – hull bolt m5 4 2.0 0.2 1.4 engine mount – hull bolt m8 8 17 1.7 12 572 lt engine damper – hull bolt m6 4 6.4 0.64 4.6 271 lt electrical battery box – hull bolt m6 2 5.4 0.54 3.9 572 lt battery box/spacer – hull b...

  • Page 38: Spec

    2-17 e spec tightening torques general torque this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided in applicable sections of this manual. To avoid warpage, tighten multi...

  • Page 39: Spec

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

  • Page 40: Spec

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

  • Page 41: Spec

    2-20 e spec cable and hose routing 5 2 a 0 h b c 8 d e f g 2 0 8 1 2 5 9 2 8 6 7 4 6 5 4 3 2 1 È 7 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 cooling water hose (from exhaust pi...

  • Page 42: Spec

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

  • Page 43: Spec

    2-22 e spec cable and hose routing b c f e a d-d Î Ï Ë Ë Ë Ë Ê È É Õ Ö × Ì Ð Ì Ó Ø Ð Ô Ì Ê Ò Ò Ñ Ð Ë c a f e b 2 4 5 3 1 1 d d Í Ò to exhaust pipe Ó to install the hose, align the white paint mark on the cooling water hose with the parting line on the hose joint. Ô fasten the cooling water hose and ...

  • Page 44: Spec

    2-23 e spec cable and hose routing b a a a-a b 3 4 5 6 a 1 1 7 8 9 0 2 1 Ë Ê É È 1 wire harness 2 ground lead 3 wire harness coupler 4 cam position sensor coupler 5 thermoswitch (exhaust) 6 thermoswitch (exhaust) coupler 7 oil pressure switch coupler 8 pulser coil coupler 9 thermoswitch (engine) cou...

  • Page 45: Spec

    2-24 e spec cable and hose routing b d a a 1 2 4 3 7 5 6 0 9 8 a-a Ê É È Ë Ì Í Î Ï Ð Ñ Î Ï 1 engine temperature sensor coupler 2 lighting coil coupler 3 pulser coil coupler 4 thermoswitch (engine) coupler 5 thermoswitch (engine) 6 starter motor 7 engine temperature sensor 8 engine temperature sensor...

  • Page 46: Spec

    2-25 e spec cable and hose routing b d a a 1 2 4 3 7 5 6 0 9 8 a-a Ê É È Ë Ì Í Î Ï Ð Ñ Î Ï È to generator É to engine temperature sensor Ê to thermoswitch (engine) Ë to thermoswitch (engine) coupler Ì to engine temperature sensor coupler Í route the starter motor lead to the outside of the engine te...

  • Page 47: Insp

    E insp adj 1 2 3 4 5 6 7 8 9 chapter 3 periodic inspection and adjustment maintenance interval chart .............................................................. 3-1 periodic service ....................................................................................... 3-2 control system ...........

  • Page 48: 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. ( ● ) this mark indicates maintenance that you may do...

  • Page 49: 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 50: 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 51: 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 52: 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. J. Install the handlebar cover. T r . . Handlebar cover screw: 1.1 n • m (0.11 kgf • m, 0.8 ft • lb) loctite ® 242 k. Install the f...

  • Page 53: 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 54: 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 55: Insp

    3-8 e insp adj control system trolling speed check and adjustment 1. Measure: • trolling speed out of specification → adjust. Trolling speed: 1,600–1,800 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 56: 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 strainer 1 clog/contaminants → clean. • fuel pump filter clog/contaminants → clean. Refer to “fu...

  • Page 57: Insp

    3-10 e insp adj power unit power unit valve clearance adjustment the following procedure applies to all of the valves. Note: • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the piston must be at top dead cen...

  • Page 58: 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 59: 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 • t...

  • Page 60: 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 61: 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 mol...

  • Page 62: 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 63: 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. Place the watercraft in a horizontal posi- tion. 2. Check: • engine oil level checking steps: ...

  • Page 64: Insp

    3-17 e insp adj power unit • remove the oil filler cap 1 and check for oil on the dipstick 2 . • if there is no oil on the dipstick, pour enough oil so that the tip of the dipstick comes into contact with the oil, and then install the filler cap. • in water a. Place the watercraft in water, and then...

  • Page 65: Insp

    3-18 e insp adj power unit • 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. • if the engine oil is above the maximum level mark b , extract sufficient oil using an oil changer to lower it to the correct level. Note...

  • Page 66: 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. Replacing steps: • place a rag under the oil filter...

  • Page 67: Insp

    3-20 e insp adj power unit 6. Pour the specified amount of the recom- mended engine oil into the oil filler hole. 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:...

  • Page 68: 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 69: 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. 4. Clean: • spark plug (with a spark plug cleaner or wire brush) 5. Measure: • spark plug gap a out of specification → regap. Color guide: medium ...

  • Page 70: Insp

    3-23 e insp adj power unit/electrical 7. Install: • air filter element • air filter case cover t r . . Air filter case cover screw: 2.5 n • m (0.25 kgf • m, 1.8 ft • lb) loctite ® 572 electrical battery inspection warning battery electrolyte is poisonous and dan- gerous, causing severe burns, etc. E...

  • Page 71: Insp

    3-24 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

    3-25 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

    3-26 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. Max. Impeller-to-housing clearance: 0.6 mm (0.0236 in) measurement steps: • rem...

  • Page 74: Insp

    3-27 e insp adj jet pump unit/bilge pump water inlet strainer inspection 1. Inspect: • water inlet strainer contaminants → clean. Cracks/damage → replace. Inspection steps: • remove the ride plate. Refer to “intake grate, ride plate, and intake duct” in chapter 6. • remove the rubber plate. Refer to...

  • Page 75: Insp

    3-28 e insp adj bilge pump/general electric bilge pump strainer inspection 1. Inspect: • cap • strainer contaminants → clean. Inspection steps: • remove the band 1 . • remove the cap 2 and strainer 3 . • inspect the cap and strainer. • install the strainer and cap. • install the band. 1 3 2 general ...

  • Page 76: Insp

    3-29 e insp adj general lubrication points 1. Lubricate: • throttle cable (handlebar end) note: before lubricating the throttle cable, squeeze the throttle lever and remove the rubber seal 1 . 2. Lubricate: • throttle cable (throttle body end) recommended lubricant: rust inhibitor recommended lubric...

  • Page 77: Insp

    3-30 e insp adj general 5. Lubricate: • nozzle pivot shaft • steering cable (nozzle end) • qsts cable (nozzle end) recommended grease: yamaha marine grease, yamaha grease a (water resistant grease) 6. Lubricate: • steering cable • steering cable joint • shift cable • shift cable joint note: disconne...

  • Page 78: 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) ...

  • Page 79: Fuel

    E fuel 1 2 3 4 5 6 7 8 9 chapter 4 fuel system fuel tank and fuel pump module...................................................... 4-1 exploded diagram ............................................................................. 4-1 removal and installation chart .....................................

  • Page 80: Fuel

    4-1 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

    4-2 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

    4-3 e fuel fuel tank and fuel pump module exploded diagram step procedure/part name q’ty service points 13 fuel sender assembly 1 14 hose clamp 2 15 fuel filler hose 1 16 nut 1 17 fuel filler neck 1 18 rubber seal 1 19 bolt 2 20 fuel tank assembly 1 21 strainer 1 22 bolt 2 23 fuel tank belt 2 revers...

  • Page 83: Fuel

    4-4 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

    4-5 e fuel fuel tank and fuel pump module check valve inspection 1. Check: • check valve faulty → replace. Checking steps: • connect a hose to the end of check valve “a” and blow into it. Air should come out from end “b”. • connect the hose to the end of check valve “b” and blow into it. Air should ...

  • Page 85: Fuel

    4-6 e fuel fuel tank and fuel pump module fuel pump filter inspection 1. Inspect: • fuel pump filter 1 clog/contaminants → wash the fuel pump filter in kerosene or gasoline. 1 fuel strainer inspection 1. Inspect: • fuel strainer clog/contaminants → clean. Fuel pump module installation 1. Tighten: • ...

  • Page 86: Fuel

    4-7 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 flame arrester 1 note: when re...

  • Page 87: Fuel

    4-8 e fuel fuel injection system exploded diagram step procedure/part name q’ty service points 7 throttle cable 1 8 bolt 2 9 throttle cable holder 1 10 cover 1 11 fuel hose 1 12 bolt 2 13 fuel hose holder 1 14 clamp 1 15 clamp 1 16 bolt 8 a a lt 572 lt lt 572 lt lt 572 lt lt 242 lt e 1 4 5 6 16 22 1...

  • Page 88: Fuel

    4-9 e fuel fuel injection system exploded diagram step procedure/part name q’ty service points 17 throttle bodies 1 18 intake air pressure sensor coupler 1 19 intake air temperature sensor coupler 1 20 fuel injector coupler 4 21 throttle position sensor coupler 1 22 joint connector 2 reverse the rem...

  • Page 89: Fuel

    4-10 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 wire harness. 3 lighting coil coupler 1 from wire...

  • Page 90: Fuel

    4-11 e fuel fuel injection system exploded diagram step procedure/part name q’ty service points 8 wire harness coupler 1 9 bolt 3 10 air filter case 1 11 bolt 2 12 wire harness bracket 1 1 13 sub wire harness 1 14 bolt 2 15 fuel hose bracket 1 16 screw 1 17 wire harness bracket 2 1 3 16 5 15 14 24 2...

  • Page 91: Fuel

    4-12 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

    4-13 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/washer 3/3 2 spacer 3 3 fuel rail 1 4 intake vacuum hose 3 5 joint 1 6 injector 4 7 grommet 4 8 scr...

  • Page 93: Fuel

    4-14 e fuel fuel injection system exploded diagram step procedure/part name q’ty service points 11 intake air temperature sensor 1 12 screw 1 13 bracket 1 1 14 screw 2 15 fuel pipe 1 16 o-ring 1 17 screw 2 18 bracket 2 1 19 screw 2 20 throttle stop guide 1 21 screw 2 22 throttle stop screw bracket 1...

  • Page 94: Fuel

    4-15 e fuel fuel injection system exploded diagram step procedure/part name q’ty service points 23 screw/spring 4/4 24 bypass air screw 4 25 spring 4 26 washer 4 27 o-ring 4 28 screw 2 29 throttle position sensor 1 30 o-ring 1 31 throttle bodies 1 reverse the disassembly steps for assembly. 17 8 9 1...

  • Page 95: Fuel

    4-16 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

    4-17 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 fue...

  • Page 97: Fuel

    4-18 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

    4-19 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

    4-20 e fuel fuel injection system 2. Check: • fuel passages obstruction → clean. Checking steps: • wash the throttle body in a petroleum based solvent. Do not use any caustic carburetor clean- ing solution. • blow out all of passages with com- pressed air. Throttle body installation 1. Install: • th...

  • Page 100: Fuel

    4-21 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 screw 1 should not be adjusted. However, if it is necessary to remove the bypass air screw, be sure to ...

  • Page 101: Fuel

    4-22 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

    4-23 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. È for usa and canada É for worldwide i. Install the throttle bodies. Note: adjust the throttle body synchronization with the air filt...

  • Page 103: Fuel

    4-24 e fuel fuel injection system throttle position sensor output voltage: pink (p) – black/orange (b/o) 0.8 ± 0.1 v note: • to decrease the output voltage, turn the throttle position sensor clockwise. • slightly tighten the throttle position screw. P. Start the engine and let it run at trolling spe...

  • Page 104: Fuel

    4-25 e fuel 3. Remove: • throttle bodies • air filter case 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 –30 ± 10 mmhg (–4.00 ± 1.33 kpa, –1.2 ± 0.4 i...

  • Page 105: Fuel

    4-26 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 1 2 3 4 5 6 7 8 9 oil pump...................................................................................................... 5-26 exploded diagram ........................................................................... 5-26 removal and installation chart .................................

  • Page 108: Powr

    E powr cylinder head.......................................................................................... 5-57 exploded diagram ........................................................................... 5-57 removal and installation chart ............................................. 5-57 serv...

  • Page 109: Powr

    E powr crankshaft .............................................................................................. 5-97 exploded diagram ........................................................................... 5-97 removal and installation chart .............................................. 5-97 s...

  • 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 7. Measure: • compression pressure out of specification → refer to steps (b) and (c). 8. Install: • spark plug minimum compression pressure (reference data): 1,080 kpa (10.8 kgf/cm 2 , 157 psi) measurement steps: a. With the throttle wide open, crank the engine until the readi...

  • Page 115: Powr

    5-6 e powr engine unit 9. Install: • air filter element • air filter case cover t r . . Air filter case cover screw: 2.5 n • m (0.25 kgf • m, 1.8 ft • lb) loctite ® 572 oil filter removal and installation 1. Remove: • oil filter 1 note: install the oil filter with the same special tool that was used...

  • 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 9 bolt 1 10 bolt 2 11 collar 1 12 exhaust pipe 3 1 13 bolt 3 14 exhaust pipe end 1 3 6 18 2 7 17 16...

  • 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 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 242 lt 242 lt...

  • 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 pressure control val...

  • 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. Ignition coil box refer t...

  • Page 125: Powr

    5-16 e powr oil tank exploded diagram step procedure/part name q’ty service points 5 clamp/breather hose 2/1 6 clamp/breather hose 2/1 É to oil pump align the mark a of the breather hose with the parting line of the oil separator. 7 bolt 3 8 collar 2 9 oil separator 1 10 clamp/breather hose 1/1 Ê to...

  • Page 126: Powr

    5-17 e powr oil tank exploded diagram step procedure/part name q’ty service points 12 clamp/cooling water hose 1/1 Ì from cooling water inlet 13 clamp/cooling water hose 1/1 Í from pressure control valve 14 bolt 1 15 collar 1 16 band 1 17 bolt 3 18 cover 1 19 gasket 1 20 bolt 2 21 ground lead 2 22 b...

  • Page 127: Powr

    5-18 e powr oil tank exploded diagram step procedure/part name q’ty service points 23 nut 2 24 oil tank 1 25 pin 2 26 o-ring 4 27 connector 2 28 bolt 2 29 oil tank stay 1 reverse the removal steps for installation. Lt 572 lt 572 lt 572 lt 572 lt 572 lt 572 lt 572 lt 572 lt 572 lt 572 lt 572 lt 572 2...

  • Page 128: Powr

    5-19 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 filter cap 1 6 packing 1 7 bolt 8 8 oil tank cover 1 9 gask...

  • Page 129: Powr

    5-20 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 130: Powr

    5-21 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 131: Powr

    5-22 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 1 2 4 5 6 8 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 plate...

  • Page 132: Powr

    5-23 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 with engine oil. Oil tank installation 1. Install: • oil c...

  • Page 133: Powr

    5-24 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) 7 5 6 10 2 3 9 1 8 4 3. Install: • g...

  • Page 134: Powr

    5-25 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: 28 n • m (2.8 kgf • m, 20 ft • lb) nut 2 , bolt 3 : 1st: 2.0 n • m (0.20 kgf • m, 1.4 ft • lb) 2nd: 15 n • m (1.5 kgf • m, 11 ft ...

  • Page 135: Powr

    5-26 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 clamp/breather hose 1/1 2 drain plug/washer 1/1 drain engine oil. 3 bolt 8 4 bolt 4...

  • Page 136: Powr

    5-27 e powr oil pump service points oil pump removal 1. Remove: • oil pump assembly note: loosen the oil pump bolts in the sequence shown. 5 6 7 8 9 11 1 12 3 10 4 2 oil pump inspection 1. Check: • oil pump operation rough movement → replace the defec- tive part(s). Oil strainer inspection 1. Check:...

  • Page 137: Powr

    5-28 e powr oil pump oil pump installation 1. Install: • oil pump assembly note: • align the projection a on the oil pump assembly with the slit b on the oil pump driven gear shaft. • tighten the oil pump bolts in the sequence shown. T r . . Oil pump assembly bolt: 1st: 1.4 n • m (0.14 kgf • m, 1.0 ...

  • Page 138: Powr

    5-29 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 139: Powr

    5-30 e powr reduction drive gear exploded diagram step procedure/part name q’ty service points 7 reduction drive gear case 1 8 gasket 1 9 pin 2 10 circlip 2 11 reduction drive gear 1 12 washer 2 reverse the removal steps for installation. 9 9 10 12 11 12 10 8 2 4 3 6 5 1 6 5 7 e lt 572 lt lt 572 lt ...

  • Page 140: Powr

    5-31 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 driven gear 1 2 bolt 1 3 holder 1 4 spring 1 5 relief valve 1 6 bo...

  • Page 141: Powr

    5-32 e powr reduction drive gear exploded diagram *1 : epnoc grease ap #0 step procedure/part name q’ty service points 9 circlip 2 10 driven gear 1 11 washer 2 12 circlip 1 13 oil seal 2 14 bearing 1 note: remove parts 12 to 15 as a set. 15 drive shaft 1 16 circlip 1 17 circlip 1 e e e e e 15 13 14 ...

  • Page 142: Powr

    5-33 e powr reduction drive gear exploded diagram *1 : epnoc grease ap #0 step procedure/part name q’ty service points 18 bearing 1 19 circlip 1 20 bearing 1 21 reduction drive gear case 1 reverse the disassembly steps for assembly. E e e e e 15 13 14 16 18 17 12 9 11 10 11 9 8 7 6 1 2 3 4 5 21 20 1...

  • Page 143: Powr

    5-34 e powr reduction drive gear service points drive coupling removal 1. Remove: • drive coupling 1 note: while holding the flywheel magneto 2 with the sheave holder 3 , loosen the drive coupling with coupler wrench 4 . Coupler wrench: yw-06551/90890-06551 sheave holder: ys-01880-a/90890-01701 1 4 ...

  • Page 144: Powr

    5-35 e powr reduction drive gear drive shaft installing 1. Install: • drive shaft note: press in the direction of the arrow. 2. Install: • oil seals 1 distance a : 8.9–9.3 mm (0.35–0.37 in) 1 a drive coupling installation 1. Install: • drive coupling 1 note: while holding the flywheel magneto 2 with...

  • Page 145: Powr

    5-36 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 magnet removal follow the left “step” for removal. Engine unit refer to “engine unit”. 1 nut/washer 1/1 2 star...

  • Page 146: Powr

    5-37 e powr generator and starter motor exploded diagram step procedure/part name q’ty service points 9 bolt 1 10 holder 1 11 bolt 8 12 generator cover 1 13 dowel pin 2 14 packing 1 15 idle gear shaft 1 16 idle gear 1 17 bolt/washer 1/1 18 rotor 1 19 bolt 6 4 3 2 1 5 6 8 7 10 9 11 12 14 13 19 17 18 ...

  • Page 147: Powr

    5-38 e powr generator and starter motor exploded diagram step procedure/part name q’ty service points 20 starter clutch 1 21 starter gear 1 22 woodruff key 1 reverse the removal steps for installation. 4 3 2 1 5 6 8 7 10 9 11 12 14 13 19 17 18 20 21 22 16 15 a a e e e lt 572 lt 572 a a a a 8 × 30 mm...

  • Page 148: Powr

    5-39 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 pulser coil 2 note: there washers holds the pulser coil lead. Make sure to n...

  • Page 149: Powr

    5-40 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 150: Powr

    5-41 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 151: Powr

    5-42 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 152: Powr

    5-43 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 153: Powr

    5-44 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 spark plug 4 2 clamp/breather hose 1/1 È to oi...

  • Page 154: Powr

    5-45 e powr camshafts exploded diagram step procedure/part name q’ty service points 7 bolt 1 8 cooling water pipe 1 9 o-ring 1 10 bolt 6 11 rubber mount 6 12 cylinder head cover 1 13 cylinder head cover gasket 1 14 timing chain guide (top side) 1 reverse the removal steps for installation. E 2 4 3 5...

  • Page 155: Powr

    5-46 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 156: Powr

    5-47 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 157: Powr

    5-48 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 158: Powr

    5-49 e powr camshafts service points camshaft removal 1. Install: • dial gauge needle • dial gauge stand 1 (into spark plug hole #1) • dial gauge 2 dial gauge stand: 90890-06583 dial gauge needle: 90890-06584 dial gauge stand set: yw-06585/90890-06585 dial gauge: yu-03097/90890-01252 2 1 2. Turn the...

  • Page 159: Powr

    5-50 e powr camshafts 4. Remove: • timing chain tensioner 1 • gasket 1 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 cams...

  • Page 160: Powr

    5-51 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: 0.05–0....

  • Page 161: Powr

    5-52 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: 24.44–24.45 mm (0.9622–0.9626 in) camshaft sprockets inspection 1. Check: • cam...

  • Page 162: Powr

    5-53 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. Rotor holder: yu-01235/90890-01235 t r . . Camshaft sprocket bolt: 24 n • m (2.4 kgf...

  • Page 163: Powr

    5-54 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 align...

  • Page 164: Powr

    5-55 e powr camshafts • tighten the timing chain tensioner bolts 3 to the specified torque. Note: the “up” mark on the timing chain ten- sioner should face up. 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 ...

  • Page 165: Powr

    5-56 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 bo...

  • Page 166: Powr

    5-57 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 167: Powr

    5-58 e powr cylinder head exploded diagram step procedure/part name q’ty service points 4 nut/washer 2/2 5 nut/washer 8/8 6 cylinder head 1 7 cylinder head gasket 1 8 dowel pin 2 reverse the removal steps for installation. E e e e e e 2 4 1 7 5 5 6 8 3 5 5 5 lt 271 2nd 49 n • m (4.9 kgf • m, 35 ft •...

  • Page 168: Powr

    5-59 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 169: Powr

    5-60 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 170: Powr

    5-61 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 171: Powr

    5-62 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 172: Powr

    5-63 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 173: Powr

    5-64 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 174: Powr

    5-65 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 175: Powr

    5-66 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: 4.460–4.475 mm (0.1756–0.1762 in) 5. Measure: • valve stem runout out of specification → replace t...

  • Page 176: Powr

    5-67 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 177: Powr

    5-68 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 (4.0 mm): ym-04111/9089...

  • Page 178: Powr

    5-69 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 179: Powr

    5-70 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 180: Powr

    5-71 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 181: Powr

    5-72 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 182: Powr

    5-73 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-04019/90890-04019 valve spring compressor attachment: (for the intake valve) ym-4114/90890-04114 (f...

  • Page 183: Powr

    5-74 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 184: Powr

    5-75 e powr crankcase exploded diagram step procedure/part name q’ty service points 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 bolt 2 5 thermoswitch (engine) ...

  • Page 185: Powr

    5-76 e powr crankcase exploded diagram step procedure/part name q’ty service points 8 bolt 1 9 anode cover 1 10 grommet 1 11 anode 1 12 bolt 4 13 bolt 9 14 oil pan 1 15 gasket 1 16 bolt 2 17 bolt 1 18 bolt 7 6 23 22 22 11 10 9 8 7 2 3 4 5 17 19 16 18 20 14 15 12 13 21 1 lt 271 lt lt 572 lt lt 572 lt...

  • Page 186: Powr

    5-77 e powr crankcase exploded diagram step procedure/part name q’ty service points 19 cap 4 20 bolt/washer 10/10 21 lower crankcase 1 22 dowel pin 2 23 dowel pin/o-ring 1/1 reverse the removal steps for installation. 6 23 22 22 11 10 9 8 7 2 3 4 5 17 19 16 18 20 14 15 12 13 21 1 lt 271 lt lt 572 lt...

  • Page 187: Powr

    5-78 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 screw 2 5 cover 1 6 o-ring 1 7 oil filter b...

  • Page 188: Powr

    5-79 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 189: Powr

    5-80 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 190: Powr

    5-81 e powr crankcase 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. 3. Install: • dowel pins 1 • o-ring 2 gm 1 12 1 4. Install: • crankcase bolts note: • lubricate the bo...

  • Page 191: Powr

    5-82 e powr crankcase tightening steps: • tighten the bolts in the tightening sequence cast on the crankcase. T r . . Crankcase bolt 1 – 0 : 1st: 7.8 n • m (0.78 kgf • m, 5.6 ft • lb) • loosen and retighten the crankcase bolts in the proper tightening sequence as shown. T r . . Crankcase bolt 1 – 0 ...

  • Page 192: Powr

    5-83 e powr crankcase 6. Tighten: • crankcase bolts a – j note: tighten the bolts in the tightening sequence cast on the crankcase. T r . . Crankcase bolt a – j : 12 n • m (1.2 kgf • m, 8.7 ft • lb) 8 6 2 4 0 9 3 1 5 7 i c a e g h f b d j 7. Tighten: • oil pan bolts note: tighten the bolts in the ti...

  • Page 193: Powr

    5-84 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 194: Powr

    5-85 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 195: Powr

    5-86 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 196: Powr

    5-87 e powr connecting rods and pistons 3. Remove: • top ring • 2nd ring • oil ring note: when removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. Cylinder and piston inspection the following procedure applies to all of the cylinders ...

  • Page 197: Powr

    5-88 e powr connecting rods and pistons • if out of specification, replace the piston and piston rings as a set. • measure piston skirt diameter “p” with the micrometer. A 5 mm (0.2 in) from the bottom edge of the piston piston size “p” standard 73.955–73.970 mm (2.9116–2.9121 in) • if out of specif...

  • Page 198: Powr

    5-89 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 199: Powr

    5-90 e powr connecting rods and pistons 2. Measure: • piston pin outside diameter a out of specification → replace the pis- ton pin. Piston pin outside diameter: 16.991–17.000 mm (0.6689–0.6693 in) : 16.971 mm (0.6681 in) 3. Measure: • piston pin bore diameter (in the piston) b out of specification ...

  • Page 200: Powr

    5-91 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 201: Powr

    5-92 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 202: Powr

    5-93 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 203: Powr

    5-94 e powr connecting rods and pistons 3. Offset: • piston ring end gaps a top ring b lower oil ring rail c upper oil ring rail d 2nd ring È intake side 4. Lubricate: • piston • piston rings • cylinder (with the recommended lubricant) recommended lubricant: engine oil 5. Lubricate: • bolt threads •...

  • Page 204: Powr

    5-95 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 connecti...

  • Page 205: Powr

    5-96 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 206: Powr

    5-97 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 207: Powr

    5-98 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 reinstalle...

  • Page 208: Powr

    5-99 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: • clean...

  • Page 209: Powr

    5-100 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 journ...

  • Page 210: Powr

    5-101 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 211: Powr

    5-102 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 2 2 clamp/cooling water hose 1/1 È for cooling water outlet on stern side. 3 clamp/cooling water hose 2/1 note...

  • Page 212: Powr

    5-103 e powr thermostat exploded diagram removal and installation chart step procedure/part name q’ty service points 8 thermostat 1 9 thermostat housing 1 reverse the removal steps for installation. 3 1 3 9 8 7 4 6 5 1 2 lt 572 lt 572 6 × 35 mm 2nd 7.6 n • m (0.76 kgf • m, 5.5 ft • ib) 1st 3.7 n • m...

  • Page 213: Powr

    5-104 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 214: Powr

    5-105 e powr pressure control valve pressure control valve exploded diagram removal and installation chart step procedure/part name q’ty service points pressure control valve removal follow the left “step” for removal. Exhaust manifold refer to “exhaust manifold”. 1 clamp/cooling water hose 1/1 È fr...

  • Page 215: Powr

    5-106 e powr pressure control valve exploded diagram removal and installation chart step procedure/part name q’ty service points 9 bolt 3 10 pressure control valve assembly 1 11 gasket 1 reverse the removal steps for installation. 9 1 8 10 11 8 6 7 4 4 5 3 3 2 2 lt 572 lt 572 6 × 45 mm 2nd 7.6 n • m...

  • Page 216: Powr

    5-107 e powr pressure control valve exploded diagram removal and installation chart step procedure/part name q’ty service points pressure control valve disassembly follow the left “step” for disassembly. 1 bolt 2 2 collar 2 3 pressure control valve housing cover 1 4 spring 1 5 pressure control valve...

  • Page 217: Powr

    5-108 e powr pressure control valve exploded diagram step procedure/part name q’ty service points 8 grommet 1 9 pressure control valve housing 1 reverse the disassembly steps for assembly. Lt 572 lt 572 1 2 3 4 5 6 7 8 6 9 6 × 40 mm 2nd 7.6 n • m (0.76 kgf • m, 5.5 ft • ib) 1st 3.7 n • m (0.37 kgf •...

  • Page 218: Powr

    5-109 e powr pressure control valve service points pressure control valve inspection 1. Check: • pressure control valve 1 • spring 2 damage/wear → replace the defective part(s). 2. Check: • pressure control valve housing cover • pressure control valve housing cracks/damage → replace. 3. Check: • coo...

  • Page 220: 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 221: Jet

    E jet pump 1 2 3 4 5 6 7 8 9 transom plate and hoses.................................................................. 6-19 exploded diagram ........................................................................... 6-19 removal and installation chart .............................................. ...

  • Page 222: 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 223: 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 224: Jet

    6-3 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 225: Jet

    6-4 e jet pump jet pump unit exploded diagram step procedure/part name q’ty service points 7 bolt 4 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 kg...

  • Page 226: Jet

    6-5 e jet pump jet pump unit exploded diagram removal and installation chart step procedure/part name q’ty service points speed sensor disassembly follow the left “step” for disassembly. 1 paddle wheel set 1 2 speed sensor 1 reverse the disassembly steps for assembly. Fwd 1 2 not reusable.

  • Page 227: 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.

  • Page 228: Jet

    6-7 e jet pump reverse gate exploded diagram step procedure/part name q’ty service points 9 roller 1 10 bolt 6 11 reverse gate stay 2 12 nut 1 13 washer 1 14 bolt 1 15 lever 1 1 16 spacer 1 17 nut 1.

  • Page 229: Jet

    6-8 e jet pump reverse gate exploded diagram step procedure/part name q’ty service points 18 washer 1 19 bolt 1 20 washer 1 21 collar 1 22 spring 1 23 lever 2 1 24 washer 1 reverse the removal steps for installation..

  • Page 230: 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 note: • when installing the spring, hook the spring end a ...

  • Page 231: 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 232: 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 233: Jet

    6-12 e jet pump impeller duct and impeller housing 1 exploded diagram step procedure/part name q’ty service points 7 bolt 4 8 water inlet cover 1 9 packing 1 10 water inlet strainer 1 11 packing 1 reverse the removal steps for installation..

  • Page 234: 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 235: 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 236: 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. 2. Remove: • nut 1 drive shaft holder: yb-06151/90890-06519 drive shaft holder: yb-06151/90890-06519 3. Remove: •...

  • Page 237: Jet

    6-16 e jet pump impeller duct and drive shaft 5. Remove: • front bearing note: remove the front bearing with a press. Drive rod: yb-06071 driver rod l3: 90890-06652 needle bearing attachment: yb-06112/90890-06614 6. Remove: • oil seal note: remove the oil seals with press. Impeller inspection refer ...

  • Page 238: Jet

    6-17 e jet pump impeller duct and drive shaft drive shaft installation 1. Install: • oil seals driver rod: yb-06071/90890-06606 ball bearing attachment: yb-06085/90890-06634 distance a : 14.2 ± 0.2 mm (0.56 ± 0.01 in) distance b : 4.7 ± 0.2 mm (0.19 ± 0.01 in) 2. Install: • front bearing • drive sha...

  • Page 239: Jet

    6-18 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 240: Jet

    6-19 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 241: Jet

    6-20 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 242: Jet

    6-21 e jet pump transom plate and hoses exploded diagram step procedure/part name q’ty service points 16 bilge strainer holder 1 17 bilge strainer 1 18 nut/washer 4/4 19 transom plate 1 20 bilge hose 5 1 reverse the removal steps for installation..

  • Page 243: Jet

    6-22 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 244: Jet

    6-23 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 245: Jet

    6-24 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.

  • Page 246: Jet

    6-25 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.

  • Page 247: Jet

    6-26 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 248: Jet

    6-27 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 rod: yb-06071/90890-06606 bearing outer race attachment: yb-06...

  • Page 249: Jet

    6-28 e jet pump bearing housing bearing installation 1. Install: • circlip (rear) 2. Install: • bearing note: support the intermediate housing with steel blocks 1 and press the bearing. Driver rod: yb-06071/90890-06606 bearing outer race attachment: yb-06156/90890-06626 oil seal installation 1. Inst...

  • Page 250: Jet

    6-29 e jet pump bearing housing 3. Install: • oil seal 1 [8 mm (0.31 in)] • oil seal 2 [11 mm (0.43 in)] distance a : 10.3–10.7 mm (0.41–0.42 in) distance b : 0.6–1.0 mm (0.02–0.04 in) b a 2 1 intermediate housing installation 1. Install: • intermediate housing • shim note: install the shim(s) to th...

  • Page 251: Elec

    E – + elec 1 2 3 4 5 6 7 8 9 chapter 7 electrical system electrical components........................................................................ 7-1 electrical box and ignition coil box ............................................. 7-2 exploded diagram ............................................

  • Page 252: Elec

    E – + elec fuel control system ........................................................................... 7-28 wiring diagram ................................................................................. 7-28 fuel pump ...............................................................................

  • Page 253: Elec

    E – + elec indication system .................................................................................. 7-44 wiring diagram ................................................................................. 7-44 fuse ...............................................................................

  • Page 254: Elec

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

  • Page 255: Elec

    7-2 e – + elec electrical box and ignition coil box electrical box and ignition coil 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/...

  • Page 256: Elec

    7-3 e – + elec electrical box and ignition coil 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 1 16 starter motor lead 1 17 bolt 3 18 cover 1 a a a a 22 23 11 14 13 12 1516 21 20 19 23 23 23 ...

  • Page 257: Elec

    7-4 e – + elec electrical box and ignition coil box exploded diagram step procedure/part name q’ty service points 19 gasket 1 20 bolt 2 21 ground lead 2 22 holder 1 23 coupler 15 note: disconnect all couplers. Reverse the removal steps for installation. A a a a 22 23 11 14 13 12 1516 21 20 19 23 23 ...

  • Page 258: Elec

    7-5 e – + elec electrical box and ignition coil 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 screw 4 6 terminal cover 1 7 gasket ...

  • Page 259: Elec

    7-6 e – + elec electrical box and ignition coil box exploded diagram step procedure/part name q’ty service points 9 battery positive lead 1 10 starter motor lead 1 11 wire harness 1 12 tapping screw 1 13 fuse holder stay 1 14 screw 1 15 starter relay 1 16 clamp 2 17 tapping screw/washer 4/4 18 ecm 1...

  • Page 260: Elec

    7-7 e – + elec electrical box and ignition coil box exploded diagram step procedure/part name q’ty service points 19 tapping screw 1 20 bracket 1 21 joint connector 2 22 tapping screw 2 23 slant detection switch 1 24 tapping screw 1 25 main and fuel pump relay 1 26 tapping screw 2 27 rectifier/regul...

  • Page 261: Elec

    7-8 e – + elec electrical box and ignition coil box exploded diagram removal and installation chart step procedure/part name q’ty service points ignition coil box removal follow the left “step” for removal. Air filter refer to “fuel injection system” in chapter 4. 1 spark plug cap 4 2 holder 1 3 ign...

  • Page 262: Elec

    7-9 e – + elec electrical box and ignition coil box exploded diagram removal and installation chart step procedure/part name q’ty service points ignition coil box disassembly follow the left “step” for disassembly. 1 tapping screw 10 2 holder 2 3 ignition coil cover 1 4 tapping screw 4 5 ignition co...

  • Page 263: Elec

    7-10 e – + elec electrical box and ignition coil box up 1 4 3 2 1 4 3 2 2 3 4 5 6 7 8 1 9 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 9 ignition coil È to ignition coil É to battery positive t...

  • Page 264: Elec

    7-11 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 ...

  • Page 265: Elec

    7-12 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

    7-13 e – + elec electrical analysis peak voltage adaptor note: • throughout this chapter the peak voltage adaptor’s part number has been omitted. Refer to the following part number. • the peak voltage adaptor should be used with the digital tester. • when measuring the peak voltage, connect the peak...

  • Page 267: Elec

    7-14 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 k r / y b / w b / w o b / o p / g r l / r r / y r / y b / o b / o b / y b / o b / o b / o b / o b / w r b b / o r / y l / r br l y r / y r / y b g / o g / o r / y r / y b...

  • Page 268: Elec

    7-15 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 k r / y b / w b / w o b / o p / g r l / r r / y r / y b / o b / o b / y b / o b / o b / o b / o b / w r b b / o r / y l / r br l y r / y r / y b g / o g / o r / y r / y b / y b / y b / y...

  • Page 269: Elec

    7-16 e – + elec ignition system ignition spark gap 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 sp...

  • Page 270: Elec

    7-17 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

    7-18 e – + elec ignition system 2. Measure: • pulser coil output peak voltage below specification → replace the pulser coil. Note: to crank the engine, connect the engine shut- off cord (lanyard), and then press the start switch and engine stop switch simultaneously. 3. Measure: • lighting coil outp...

  • Page 272: Elec

    7-19 e – + elec 4. Measure: • rectifier/regulator output voltage below specification → replace the recti- fier/regulator. Note: • before measuring the output peak voltage, make sure that the battery is fully charged. • the output voltage gradually increases after the engine is started, therefore, ma...

  • Page 273: Elec

    7-20 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

    7-21 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

    7-22 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

    7-23 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. • conn...

  • Page 277: Elec

    7-24 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-06793/90890-06793 test connector: yw-06862/90890-...

  • Page 278: Elec

    7-25 e – + elec ignition system cam position sensor 1. Measure: • cam position sensor output voltage out of specification → replace. Note: when operating the yamaha diagnostic sys- tem, electric power is supplied to the cam posi- tion sensor. Test harness (3 pins): yb-06777/90890-06777 cam position ...

  • Page 279: Elec

    7-26 e – + elec ignition system intake air pressure sensor 1. Measure: • intake air pressure sensor output volt- age out of specification → replace. È : output voltage É : vacuum pressure note: when operating the yamaha diagnostic sys- tem, electric power is supplied to the intake air pressure senso...

  • Page 280: Elec

    7-27 e – + elec ignition system slant detection switch 1. Check: • slant detection switch continuity out of specification → replace. Position lead color blue/black (l/b) black/ orange (b/o) normal operation È overturned É up up È É.

  • Page 281: Elec

    7-28 e – + elec fuel control system fuel control system wiring diagram #4 #3 #2 #1 5 7 p / w p / w p / w f o b / o p / g l / r b / o b / o b / o b / y p / g 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 / y b / o b / o b / y b / o b / g b / g l / r b...

  • Page 282: Elec

    7-29 e – + elec fuel control system wiring diagram #4 #3 #2 #1 5 7 p / w p / w p / w f o b / o p / g l / r b / o b / o b / o b / y p / g 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 / y b / o b / o b / y b / o b / g b / g l / r br l y r / y r / y r ...

  • Page 283: Elec

    7-30 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 284: Elec

    7-31 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 “ignition system”. Thermoswitch (engine) refer to “ignition system”. Thermoswitch (exhaust) refer to “ignition system”. S...

  • Page 285: Elec

    7-32 e – + elec starting system starting system wiring diagram free push br br free push w b r br 4 3 2 1 8 7 6 5 r / y 7 18 r / y l / r br l y r / y r / y b r / y r / y y r br br br br r br r b b r 4 3 2 1 8 7 6 r / y r / y r p p o r r r r r r 1 2 3 4 5 6 7 8 b b b 5 br b b b 1 ecm 2 main and fuel ...

  • Page 286: Elec

    7-33 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 287: Elec

    7-34 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 288: Elec

    7-35 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 289: Elec

    7-36 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 290: Elec

    7-37 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 291: Elec

    7-38 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 out of specification → replace. Min. Commutator diameter: 27.0 mm (1.06 in) 4. Che...

  • Page 292: Elec

    7-39 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 out of spe...

  • Page 293: Elec

    7-40 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 294: Elec

    7-41 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 295: Elec

    7-42 e – + elec electric bilge pump electric bilge pump wiring diagram 4 3 2 1 8 7 6 5 7 18 l / r br l y r / y r / y r / y r / y r y br br br b b b b b b r r 3 2 1 4 5 r p p o r b r r r 1 2 3 4 5 6 7 8 b b b r / y r / y b br r / y r / y r / y r / y r / y r / y 1 ecm 2 main and fuel pump relay 3 fuse...

  • Page 296: Elec

    7-43 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 297: Elec

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

  • Page 298: Elec

    7-45 e – + elec indication 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”. Ecm refer to “ignition system”. Engine temperature sensor refer to “ignition system”. Thermoswitch ...

  • Page 299: Elec

    7-46 e – + elec indication system oil pressure switch 1. Measure: • oil pressure switch continuity out of specification → replace. Vacuum/pressure pump gauge set: yb-35956-a/90890-06756 oil pressure switch continuity pressure: 128 kpa (1.28 kgf/cm 2 , 18.2 psi) – 166 kpa (1.66 kgf/cm 2 , 23.6 psi) m...

  • Page 300: Elec

    7-47 e – + elec indication system display function 1. Check: • display function not operate → replace the multifunc- tion meter. L / b l / b b l / r b / y b / y r / w b / g b r / w y y r r w w b b b b / g l / r r b r 1 2 3 4 1 buzzer 2 speed sensor 3 ecm 4 fuel sender b : black r : red w : white y :...

  • Page 301: Elec

    7-48 e – + elec indication system speedometer display 1. Check: • speedometer display does not display → measure the speed sensor output voltage and pulses. Without specification → replace the multifunction meter. 2. Measure: • speed sensor output voltage and pulses out of specification → repair or ...

  • Page 302: 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 303: Elec

    7-50 e – + elec indication system overheat warning indicator 1. Check: • overheat warning indicator not operating → replace the multifunc- tion meter. Checking steps: • disconnect the thermoswitch (engine) connector 1 (blue) or engine tempera- ture sensor connector 2 (black) or ther- moswitch (exhau...

  • Page 304: Elec

    7-51 e – + elec indication system diagnostic display 1. Check: • diagnostic display does not display → replace the multi- function meter. Checking steps: • remove the coupler of the sensor indi- cated in the multifunction meter. • check if “irregular” is indicated in the diagnosis record of the yama...

  • Page 305: Hull

    E hull hood 1 2 3 4 5 6 7 8 9 chapter 8 hull and hood handlebar .................................................................................................. 8-1 exploded diagram ............................................................................. 8-1 removal and installation chart ......

  • Page 306: Hull

    E hull hood front hood ............................................................................................... 8-21 exploded diagram ........................................................................... 8-21 removal and installation chart .............................................. ...

  • Page 307: Hull

    E hull hood deck and hull.......................................................................................... 8-47 exploded diagram ........................................................................... 8-47 removal and installation chart .............................................. 8-4...

  • Page 308: 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 309: 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 310: 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 311: 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 312: 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 313: 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 314: Hull

    8-7 e hull hood handlebar 3. Install: • throttle cable note: fit the seal into the groove in the bracket. 4. 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 the specified length and be sure to tak...

  • Page 315: 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 316: 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 317: Hull

    8-10 e hull hood qsts grip service points qsts cable inspection 1. Inspect: • qsts cables frays/kinks/rough movement → replace. Qsts grip inspection 1. Inspect: • qsts grip damage/wear → replace..

  • Page 318: 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 319: Hull

    8-12 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 320: Hull

    8-13 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 assembly 1 15 steering tube 1 16 bolt/washer/spring washer 2/2/2 17 cap 1 18 shaft 1 1 19 cross piece 1 reverse the disassembly st...

  • Page 321: Hull

    8-14 e hull hood steering master service points steering master components inspection 1. Inspect: • each component part damage/wear → replace the steering master..

  • Page 322: Hull

    8-15 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 323: Hull

    8-16 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 packing 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 324: Hull

    8-17 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 packing 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 installa...

  • Page 325: Hull

    8-18 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 326: Hull

    8-19 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 327: Hull

    8-20 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 328: Hull

    8-21 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 329: Hull

    8-22 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 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...

  • Page 330: Hull

    8-23 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 331: Hull

    8-24 e hull hood front hood exploded diagram step procedure/part name q’ty service points 8 clamp 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 not reusable.

  • Page 332: Hull

    8-25 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 clamp 1 2 multifunction me...

  • Page 333: Hull

    8-26 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 mirror 2 reverse the removal steps for installation. Lt 242 lt 242 5 7 9 5 6 10 11 1 2 3 4 5 × 20 mm 3.9 n • m (0.3...

  • Page 334: Hull

    8-27 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 bolt 8 3 side cover 2 4 nut/washer 4/4 5 bolt 4 6 bracket 2 reverse the removal steps for insta...

  • Page 335: Hull

    8-28 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 336: Hull

    8-29 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 337: Hull

    8-30 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 338: Hull

    8-31 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 339: Hull

    8-32 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 340: Hull

    8-33 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 packing 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 f...

  • Page 341: Hull

    8-34 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 342: Hull

    8-35 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 343: Hull

    8-36 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 344: Hull

    8-37 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 345: Hull

    8-38 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 2 front seat assembly 1 3 bolt 4 4 seat lock assembly 2 5 seat ...

  • Page 346: Hull

    8-39 e hull hood seats and hand grip exploded diagram step procedure/part name q’ty service points 9 nut 1 10 projection 1 11 washer 1 12 packing 1 13 nut 4 14 bolt 4 15 rear seat stay 2 16 nut 1 2 1 4 3 21 20 17 18 19 16 18 6 7 9 13 5 15 14 12 11 10 8 4 3 6 × 25 mm 8 × 30 mm 8 × 30 mm 18 n • m (1.8...

  • Page 347: Hull

    8-40 e hull hood seats and hand grip exploded diagram step procedure/part name q’ty service points 17 projection 1 18 washer 2 19 nut/washer 4/4 20 bolt 4 21 hand grip 1 reverse the removal steps for installation. 2 1 4 3 21 20 17 18 19 16 18 6 7 9 13 5 15 14 12 11 10 8 4 3 6 × 25 mm 8 × 30 mm 8 × 3...

  • Page 348: Hull

    8-41 e hull hood seats and hand grip service points seat lock inspection 1. Inspect: • front seat lock • rear seat lock damage/wear → replace..

  • Page 349: Hull

    8-42 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 350: Hull

    8-43 e hull hood exhaust system exploded diagram step procedure/part name q’ty service points 5 exhaust joint clamp 1 6 exhaust joint 1 7 nut/washer 6/6 8 exhaust valve 1 note: remove parts 8 to 14 as a set. 9 hose clamp 1 10 rubber hose 1 11 hose clamp 1 12 water tank 1 13 rubber hose 1 14 plate 1 ...

  • Page 351: Hull

    8-44 e hull hood exhaust system exploded diagram removal and installation chart step procedure/part name q’ty service points exhaust joint disassembly follow the left “step” for disassembly. 1 bolt 6 2 exhaust joint protector 1 1 3 exhaust joint protector 2 1 4 exhaust joint pipe 1 reverse the disas...

  • Page 352: Hull

    8-45 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 353: Hull

    8-46 e hull hood exhaust system exhaust system installation 1. Install: • exhaust joint note: be sure to fit the slit a on the exhaust joint with the projection b on the exhaust pipe. B a 2. Install: • water lock note: be sure to insert the rubber hose to the line a on the water lock. A.

  • Page 354: Hull

    8-47 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 10 7 sponson 2 8 nut/washer 4/4 9 screw/was...

  • Page 355: Hull

    8-48 e hull hood deck and hull exploded diagram step procedure/part name q’ty service points 11 packing 2 12 nut 4 note: to remove the cleat, remove the exhaust system first. 13 plate 4 14 cleat 2 15 packing 2 16 nut/washer 3/3 17 bolt 4 18 protector 1 reverse the disassembly steps for assembly. 16 ...

  • Page 356: Hull

    8-49 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 357: Hull

    8-50 e hull hood engine mount hull repair shallow scratches 1. Sand the scratches with 400 grit sandpa- per (either wet or dry) until the scratches are smooth. Then, sand the scratches once again with 600 grit sandpaper (either wet or dry). Deep scratches 1. Remove any sharp or rough edges from the ...

  • Page 358: Hull

    8-51 e hull hood engine mount cracks and punctures note: before attempting to repair any cracks or punctures, refer to “watercraft frp repair manual”. 1. Remove any damaged fiberglass. 2. Cut the damaged area and separate it approximately 0.25 inch. 3. On the outside of the hull, grind the sepa- rat...

  • Page 359: Hull

    8-52 e hull hood engine mount insert nut note: use the insert nut when: • a pop nut which was attached to the hull slipped off or, • when a bolt which was fastened to an insert nut or pop nut broke. • nut 1 • thread direction 2 • slot to be threaded 3 note: drilling size part no. Part name remarks e...

  • Page 360: Hull

    8-53 e hull hood engine mount 4. First, apply tape 1 to the inner surface of the hull and then laminate fiberglass mats over the tape with resin. Note: when it is possible to work inside the hull, lam- inate the mats from the inside. 5. Sand the outer surface of the hull until it is smooth. 6. Insta...

  • Page 361: Hull

    8-54 e hull hood engine mount 2. To prevent water from entering the ure- thane foam, apply silicone sealant to the inside of the hole as shown. 3. Install the insert nut as explained in “example 1”. • brass insert nut 1 • hull 2 • urethane foam 3 • silicone sealant 4 graphic removal 1. Hold a hair d...

  • Page 362: Trbl

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

  • Page 363: Trbl

    E trbl anls 1 2 3 4 5 6 7 8 9 stationary test ............................................................................... 9-28 sparking ignition coil procedure: ....................................................... 9-28 operating injector procedure:................................................

  • Page 364: 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 365: Trbl

    9-2 e trbl anls introduction hardware requirements make sure that your computer meets the following requirements before using this software. Note: • the amount of memory and the amount of free space on the hard disk differs depending on the computer. • using this software while there is not enough f...

  • Page 366: Trbl

    9-3 e trbl anls getting started getting started this section provides information on installing the yamaha diagnostic system under windows 95, windows 98, windows me, windows 2000, or windows xp. Installing the yamaha diagnostic system under windows 95, windows 98, windows me, windows 2000, or windo...

  • Page 367: Trbl

    9-4 e trbl anls getting started 4. Click the next button to start the installation process. (fig. 3) fig. 3 note: if the yamaha diagnostic system has already been installed onto your computer, the following dia- log box appears. Click the yes button to update this program, or click the no button to ...

  • Page 368: Trbl

    9-5 e trbl anls getting started 5. Check the target directory and the program name for the yamaha diagnostic system which are displayed in the dialog box. Click the next button to start copying the program files. Note: • to go back to the previous dialog box (step 4), click the back button. • to qui...

  • Page 369: Trbl

    9-6 e trbl anls getting started 6. After the installation is completed, the following dialog box appears. Click the finish button to quit the installation program. Fig. 9 note: install the database file before using the yamaha diagnostic system, otherwise the program will not operate correctly. For ...

  • Page 370: Trbl

    9-7 e trbl anls getting started updating the database note: when installing the yamaha diagnostic system for the first time, be sure to update the database. 1. Turn on your computer and start up windows 95, windows 98, windows me, windows 2000, or windows xp. 2. From the taskbar at the bottom of you...

  • Page 371: Trbl

    9-8 e trbl anls getting started 4. Click the update database [f1] button or press the f1 key on your keyboard. (fig. 12) fig. 12 1 first menu 2 click to update database note: • do not click the starting service tool [enter] button or press the enter key on your keyboard until the database has been u...

  • Page 372: Trbl

    9-9 e trbl anls getting started 5. Insert the compact disc into the computer’s cd-rom drive. Note: • all the database files will be copied from the compact disc to the computer’s hard drive automati- cally. • any earlier version of the database saved on the hard drive will be overwritten. 6. Click t...

  • Page 373: Trbl

    9-10 e trbl anls getting started 7. When the database is updated a confirmation screen is displayed. To quit, click the ok button or press the enter key on your keyboard. (fig. 15) to return to the first menu screen, click the cancel button or press the esc key on your key- board. Fig. 15 note: if t...

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    9-11 e trbl anls operating operating connecting the computer to the watercraft note: be sure to use the enclosed communication cable to connect the computer and adapter to the watercraft. 1. Quit any applications that are running, and then turn off the computer. 2. Connect the communication cable to...

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    9-12 e trbl anls operating connecting the communication cable to the watercraft models: fx140 top view fig. 18 1 3-pin communication coupler 2 wire 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.

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    9-13 e trbl anls operating opening the yamaha diagnostic system 1. Push the start switch to start the engine. 2. Turn on your computer and start up windows 95, windows 98, windows me, windows 2000, or windows xp. 3. From the taskbar at the bottom of your computer screen, click the start button (fig....

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    9-14 e trbl anls operating 5. Click the starting service tool [enter] button or press the enter key on your keyboard. (fig. 21) fig. 21 1 first menu 2 click to start service tool note: • if an error message appears and the program stops operating, follow the error messages. • if the program doesn’t ...

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    9-15 e trbl anls operating 6. Click or press any key to display the main menu. Fig. 22 note: if a diagnosis record is stored in the ecm, “diagnosis record available,” appears as a confirmation message before the main menu is displayed. (fig. 23) fig. 23.

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    9-16 e trbl anls operating selecting commands from the main menu eight commands appear in the main menu. Select a command in any of the following three ways. Two ways to select command: • move the mouse pointer over the selected command ( a or b ) until it appears as a finger mark, and then click th...

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    9-17 e trbl anls operating explanation of each command 1. Diagnosis the diagnosis codes, their corresponding part name, the diagnosing results, and the diagnostic cri- teria are listed. List of items: condition of coils (pulser coils) condition of sensors (throttle position sensor, intake air temper...

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    9-18 e trbl anls operating 6. Data logger two out of six items (engine speed, battery voltage, throttle position, intake air pressure, engine temperature, and oil pressure) are selected and 78 seconds of their recorded data are displayed on a graph. The operating time as compared to the engine speed...

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    9-19 e trbl anls operating diagnosis the diagnosis codes of malfunctions recorded in the watercraft’s ecm, the diagnosis codes’ corre- sponding part name, the results of the diagnosis, and the condition of the part are listed. Eight items can be displayed at one time. Fig. 25 1 other than normal wil...

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    9-20 e trbl anls operating print by selecting the print command in the diagnosis, diagnosis record, engine monitor, or data logger mode, the data from the corresponding window can be printed. 1. Click the print [f1] button or press the f1 key on your keyboard. The print dialog box is dis- played. (f...

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    9-21 e trbl anls operating save by selecting the save command in the diagnosis, diagnosis record, engine monitor, or data logger mode, the corresponding data can be saved on a disk. Operating procedure: 1. Click the save [f2] button or press the f2 key on your keyboard. The save as dialog box is dis...

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    9-22 e trbl anls operating 2. Select the disk and folder where the data will be saved and specify its file name. (fig. 30) fig. 30 1 choose folder to save in 2 choose type of data 3 input file name 3. Click the save button to save the data. To cancel saving, click the cancel button. (fig. 30) the da...

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    9-23 e trbl anls operating diagnosis record the diagnosis codes of malfunctions that have been recorded in the watercraft’s ecm, the diagnos- tic codes’ corresponding part name, and the time when the malfunctions occurred are listed. A maximum of five items can be displayed at one time. The oldest o...

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    9-24 e trbl anls operating deleting diagnosis record in the ecm: 1. Select the item that you wish to delete by either clicking it or pressing the up or down arrow keys on your keyboard. Note: • the selected code is highlighted in light blue. • check that the items deleted are normal in the diagnosis...

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    9-25 e trbl anls operating 3. Click the ok button or press the enter key on your keyboard. (fig. 35) the selected item is deleted. To cancel deleting the item, click the cancel button or press the esc key on your key- board. Note: if an error occurs while an item is being deleted, an error message a...

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    9-26 e trbl anls operating engine monitor warning do not use the engine monitor function to check the engine condition while operating a watercraft, otherwise you could become distracted, which could result in a collision. Caution: be sure to avoid splashing water on the computer, adapter, and commu...

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    9-27 e trbl anls operating operating procedure: 1. To scroll the display and view other items, click or in the scroll bar, or press the up or down arrow keys on your keyboard. 2. To change a displayed item, click the select [f3] button or press the f3 key on your keyboard. 3. Select an item by eithe...

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    9-28 e trbl anls operating stationary test selecting this command displays a window where stationary tests (spark ignition coil #, operate injector #, and operate electric fuel pump) can be selected. Warning avoid clicking the execute and cancel buttons repeatedly, otherwise the ecm or pc will not w...

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    9-29 e trbl anls operating 1. Select the test that you wish to perform by either clicking it or pressing the up or down arrow keys on your keyboard. (fig. 39) note: • make sure that the engine is not running. • the selected item is highlighted in light blue. • the details of the selected test are di...

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    9-30 e trbl anls operating 5. Click the execute button or press the enter key on your keyboard. (fig. 42) fig. 42 fig. 43.

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    9-31 e trbl anls operating note: if the engine is running an error message is displayed. Follow the instructions that appear. (fig. 44) fig. 44 6. While checking the information that appears in the test situation column, follow the test instructions in the messages that are displayed. (see fig. 43.)...

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    9-32 e trbl anls operating 9. To perform the test again to the same cylinder, click the execute button or press the enter key on your keyboard. To perform the test on a different cylinder, click the return [esc] button or press the esc key on your keyboard to return to main menu where a different te...

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    9-33 e trbl anls operating operating injector procedure: a voltage is applied to the injector of the selected cylinder, the injector is activated, and then the fuel system is checked. The fuel is injected 20 times within two seconds. Warning • do not perform the test with the injector removed from t...

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    9-34 e trbl anls operating 3. Click the execute button or press the enter key on your keyboard. (fig. 49) fig. 49 note: if an error occurs while the test is being performed, an error message is displayed. Follow the instructions that appear. 4. Listen to the operating sound of the injector of the cy...

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    9-35 e trbl anls operating 5. To perform the test again on the same cylinder, click the execute button or press the enter key on your keyboard. To perform the test on a different cylinder, click the return [esc] button or press the esc key on your keyboard to return to the window where a different t...

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    9-36 e trbl anls operating 1. Select the test to be performed, and then click the select button or press the enter key on your keyboard. (fig. 52) fig. 52 note: • make sure that the engine is not running. • the selected item is highlighted in light blue. • the details of the selected test are displa...

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    9-37 e trbl anls operating 2. Click the execute button or press the enter key on your keyboard. (fig. 53) fig. 53 note: if an error occurs while the test is being performed, an error message is displayed. Follow the instructions that appear. 3. Listen to the operating sound of the electric fuel pump...

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    9-38 e trbl anls operating active test selecting this command displays a window where active tests can be selected. Warning avoid clicking the execute and cancel buttons repeatedly, otherwise the ecm or pc will not work properly and they could be damaged. Fig. 55 note: the test can be carried out wh...

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    9-39 e trbl anls operating dropping a cylinder: start the engine and observe the changes in engine speed for 20 seconds. For the first ten seconds operate all four cylinders, and then stop one cylinder for five seconds. For the last five seconds operate all four cylinders. A screen that allows you t...

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    9-40 e trbl anls operating note: if the engine is not running, an error message is displayed. Follow the instructions that appear. (fig. 57) fig. 57 5. While checking the information that appears beside test situation and engine speed , follow the test instructions in the messages that are displayed...

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    9-41 e trbl anls operating data logger monitor item selection a window appears that allows you to select the data comparison graph or the engine operating hours according to engine speed . Fig. 59 1 triangle mark operating procedure: 1. Select the desired item by either clicking it or pressing the u...

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    9-42 e trbl anls operating data display item selection a window appears that allows you to select the items to be graphed. No more than two items can be displayed. Fig. 60 1 selected items operating procedure: 1. Select the desired items by either clicking them or pressing the up or down arrow keys ...

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    9-43 e trbl anls operating data comparison graph a line graph appears with the items selected in the data display item selection window on the ver- tical axes and the time before engine stop on the horizontal axis. (fig. 61) fig. 61 note: • the item on the left vertical axis is graphed with a solid ...

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    9-44 e trbl anls operating engine operating hours according to engine speed the operating hours as compared to the engine speed and the total operating hours are displayed. (fig. 62) fig. 62 a window is displayed showing the amount of hours that the engine is operated at each engine speed range. Not...

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    9-45 e trbl anls operating ecm no. The ecm part number of the watercraft is read from the ecm and is displayed. (fig. 63) fig. 63.

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    9-46 e trbl anls operating exit the program is exited. Operating procedure: 1. Click the exit button or press any number key (1–8). Fig. 64 2. Click the ok button or press the enter key on your keyboard to exit the program. To cancel exiting the program, click the cancel button or press the esc key ...

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    9-47 e trbl anls operating uninstalling the yamaha diagnostic system use the following procedure to uninstall the yamaha diagnostic system. 1. Exit all programs before running the uninstaller. 2. From the taskbar at the bottom of your computer screen, click the start button, point to set- tings, and...

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    9-48 e trbl anls operating 5. Click the yes button in the confirmation window to uninstall the utility software. To cancel the uninstall operation of the utility software, click the no button. (see figs. 68–70.) fig. 68 fig. 69 fig. 70

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    9-49 e trbl anls operating 6. If the following message appears, click the details... Button. Fig. 71 1 uninstall completed. Some elements could not be removed. You should manually remove items related to the application. 7. Check the contents of the message. If an element could not be removed, delet...

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    9-50 e trbl anls troubleshooting troubleshooting error content cause action communication cable related error occurs communication cable is discon- nected. Connect communication cable between the computer’s commu- nication port and 3-pin communi- cation coupler of the watercraft. Battery is disconne...

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    9-51 e trbl anls appendix appendix setting the desktop area use the following procedure to set the yamaha diagnostic system desktop area. Compatible with vga (640 × 480 pixels) or svga (800 × 600 pixels) or more recommended 1. From the taskbar at the bottom of your computer screen, click the start b...

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    9-52 e trbl anls appendix 4. Click the ok button in the confirmation window to set the display area. To cancel, click the can- cel button. (see figs. 75–76.) fig. 75 fig. 76.

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    9-53 e trbl anls trouble analysis trouble analysis note: the following items should be checked before the “trouble analysis chart” is consulted. 1. The battery is charged and its specified gravity is within specification. 2. There are no incorrect wiring connections. 3. Wiring connections are proper...

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    9-54 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 press...

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    9-55 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 • pulser coils 7 • ecm 7 • ignition coils 7 • slant detector switch 7 • engine...

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    9-56 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 hull and hood steering master 8 water lock 8 exhaust ho...

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    9-57 e trbl anls trouble analysis self-diagnosis with the engine running, press the hour meter/ voltmeter display select switch 1 and the speedometer display switch 2 for 8 seconds and check if an error code is indicated on the multifunction meter. If the yamaha diagnostic system is not used to chec...

  • Page 422

    Wiring diagram fx140 1 fuse (20a) 2 fuse (3a) 3 starter relay 4 slant detection switch 5 main and fuel pump relay 6 ecm 7 rectifier regulator 8 cam position sensor 9 thermoswitch (exhaust) 0 oil pressure switch a thermoswitch (engine) b engine temperature sensor c intake air pressure sensor d intake...

  • Page 424

    Yamaha motor corporation, usa printed in usa mar. 2002 – ?.? × 1 cr f1b-28197-1e-11 (fx1000-a) (e_1).

  • Page 425

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