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Yamaha WaveRunner FX Cruiser SHO Service Manual

Summary of WaveRunner FX Cruiser SHO

  • Page 1

    Service manual fx sho waverunner f1w-28197-1k-11 fx cruiser sho lit-18616-03-12 *lit186160312*.

  • 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: Contents

    E contents general information gen info specification spec periodic check and adjustment chk adj fuel system fuel power unit powr jet pump unit jet pump electrical system elec hull and hood hull hood trouble analysis trbl anls – + 1 2 3 4 5 6 7 8 9.

  • Page 4: Gen

    E gen info chapter 1 general information how to use this manual ................................................................................. 1-1 manual format............................................................................................ 1-1 symbols....................................

  • Page 5: Gen

    E gen info 1 2 3 4 5 6 7 8 9 water cooled rectifier regulator ............................................................... 1-28 in-tank fuel pump module ........................................................................ 1-29 large intermediate housing and oil seal..............................

  • Page 6: Gen

    1-1 e gen info how to use this manual manual format the format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. • parts are shown and detailed in an exploded diagram and are listed in t...

  • Page 7: Gen

    1-2 e gen info 1 2 3 4 5 6 7 8 9 symbols symbols 1 to 9 are designed to indicate the content of a chapter. 1 general information 2 specification 3 periodic check 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 8: Gen

    1-3 e gen info abbreviation the following abbreviations are used in this service manual. Grease table the following table contains sealants, locking agents, and lubricants used in this service manual that are not listed on the “ symbols ” page. Abbreviation description api american petroleum institu...

  • Page 9: Gen

    1-4 e gen info 1 2 3 4 5 6 7 8 9 safety while working to prevent and accident or injury and to ensure quality service, follow the safety proce- dures provided below. Fire prevention gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. Ventil...

  • Page 10: Gen

    1-5 e gen info 5. Keep a supply of clean, lint-free cloths for wiping up spills, etc. 6. Maintain good standards of personal and industrial hygiene. Good working practices special service tool use the recommended special service tools to protect parts from damage. Use the right tool in the right man...

  • Page 11: Gen

    1-6 e gen info 1 2 3 4 5 6 7 8 9 identification number 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: f1w: 800101 engine serial number the engine serial number is stamped on a label attached to the e...

  • Page 12: Gen

    1-7 e gen info special service tool 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 usa and canada, use part numbers starting with “ yb- ” , “ ym- ” , “ y...

  • Page 13: Gen

    1-8 e gen info 1 2 3 4 5 6 7 8 9 8 fuel pressure gauge yb-06766 90890-06786 9 leakage tester 90890-06840 0 air cooler attachment 90890-06731 a ydis (connecting kit) 60v-85300-04 b ydis (cd-rom, ver. 1.30) 60v-ws853-04 c digital multimeter yu-34899-a d peak voltage adapter yu-39991 e digital circuit ...

  • Page 14: Gen

    1-9 e gen info h test harness (3 pins) yb-06877 test harness hm090-3 (3 pins) 90890-06877 i lower unit pressure/vacuum tester yb-35956-a j vacuum/pressure pump gauge set 90890-06756 k test harness (3 pins) yb-06870 test harness smt250-3 (3 pins) 90890-06870 l test harness (2 pins) 90890-06850 remova...

  • Page 15: Gen

    1-10 e gen info 1 2 3 4 5 6 7 8 9 7 stopper guide stand 90890-06538 8 shaft holder 90890-06721 9 driver handle 90890-06722 0 bearing inner race attachment 90890-06661 a coupler wrench 90890-06729 b camshaft wrench 90890-06724 c valve spring compressor ym-04019 90890-04019 d compressor adapter ym-041...

  • Page 16: Gen

    1-11 e gen info h neway valve seat kit yb-91044 i valve seat cutter holder 90890-06812 j valve seat cutter intake 90890-06720 (30 ° ) 90890-06325 (45 ° ) 90890-06324 (60 ° ) exhaust 90890-06818 (30 ° ) 90890-06555 (45 ° ) 90890-06323 (60 ° ) k crankshaft holder yb-06562 90890-06562 l flywheel puller...

  • Page 17: Gen

    1-12 e gen info 1 2 3 4 5 6 7 8 9 s bearing pressure c 90890-02393 t driver handle (large) yb-06071 u forward gear outer race installer yb-41446 v ball bearing attachment 90890-06657 w piston ring compressor ym-08037 90890-05158 x drive shaft holder yb-06201 drive shaft holder 6 90890-06520 y driver...

  • Page 18: Gen

    1-13 e gen info ] bearing cup installer yb-06167 _ shaft holder 90890-06730 a needle bearing installer yb-06434 b bearing puller legs yb-06523 c bearing attachment 90890-06727 special service tool.

  • Page 19: Gen

    1-14 e gen info 1 2 3 4 5 6 7 8 9 feature and benefit watercraft overview the fx sho series features a newly designed deck, while keeping the popular hull design of the fx. Both the deck and hull are made of nanoxcel, which is 25% lighter compared to conventional materials. The fuel filler cap is no...

  • Page 20: Gen

    1-15 e gen info engine overview the fx sho series features a newly designed 1.8 l in-line 4-cylinder supercharged engine. Because of its light and compact design, this engine is roughly the same size as the mr-1 engine used on the fx series watercraft. Both high output and low fuel consumption are a...

  • Page 21: Gen

    1-16 e gen info 1 2 3 4 5 6 7 8 9 air filter case and air filter element the air filter case and air filter element have been newly designed to handle the increased intake air volume. The air filter element itself is made of water-repellent material, which prevents water from entering the engine. In...

  • Page 22: Gen

    1-17 e gen info air cooler assembly the air cooler assembly uses cooling water to cool the intake air that has been compressed in the supercharger. While the air cooler assembly has an extremely compact design, it functions as a highly efficient heat exchanger to cool the intake air. 1 air cooler as...

  • Page 23: Gen

    1-18 e gen info 1 2 3 4 5 6 7 8 9 electronic control throttle valve (etv) system the flow chart shows a typical etv system. The etv system consists of a throttle lever, a throttle cable, an accelerator position sensor, elec- tronic control throttle bodies, and an electronic control module (ecm). A t...

  • Page 24: Gen

    1-19 e gen info cylinder head assembly the newly designed cylinder head has 4 valves per cylinder: 2 intake valves and 2 exhaust valves. The shapes of the combustion chamber and piston have been designed to obtain the optimum com- pression ratio. The valve lifter is a direct-acting type with a valve...

  • Page 25: Gen

    1-20 e gen info 1 2 3 4 5 6 7 8 9 ignition coil the ignition coils are a direct-ignition type with a coil installed to each cylinder. The coils are installed to the cylinder head cover using 2 bolts each, which ensures a secure installation and waterproofing of the spark plug holes. 1 engine cover 2...

  • Page 26: Gen

    1-21 e gen info cylinder block and crankcase the cylinder block and crankcase have been newly designed. Cast-in iron sleeves, which offer the same high reliability of conventional sleeves, have been adopted. The crankshaft journal portions of the crankcase use a ladder-deck structure in order to ach...

  • Page 27: Gen

    1-22 e gen info 1 2 3 4 5 6 7 8 9 lubrication system the fx sho employs a wet sump lubrication system, which is different from conventional models. There are 2 oil pumps, the scavenge pump and feed pump, located in the oil pan at the bottom of the engine to drawn in and pressure feed the engine oil....

  • Page 28: Gen

    1-23 e gen info oil pump assembly the oil pump assembly is comprised of 2 oil pumps: the scavenge pump and the feed pump. The scavenge pump pressure feeds engine oil from the oil pan to the oil separator tank. The feed pump supplies engine oil from the oil pan to the various engine components. 1 oil...

  • Page 29: Gen

    1-24 e gen info 1 2 3 4 5 6 7 8 9 oil pan the wet-sump type oil pan is divided into 2 internal compartments. Engine oil in the inner oil pan is pressure-fed to the various engine components by the feed pump. Engine oil in the outer oil pan is sent to the oil separator tank by the scavenge pump, and ...

  • Page 30: Gen

    1-25 e gen info oil separator tank the scavenge pump pressure feeds the engine oil to the oil separator tank. The oil saparator tank separates the gas from the engine oil. The gas is routed to the cylinder head cover as blow-by gas and the engine oil flows into the inner oil pan at the center of the...

  • Page 31: Gen

    1-26 e gen info 1 2 3 4 5 6 7 8 9 oil filter the oil filter has been changed from the conventional 5gh type to the 69j type. The 69j type oil fil- ter is also used on large outboard motors. 1 oil filter exhaust system the exhaust system features a compact design that uses double-pipe construction an...

  • Page 32: Gen

    1-27 e gen info cooling system the cooling water is divided into cooling water for the engine and cooling water for the air cooler assembly. The cooling water for the air cooler assembly is at the lowest temperature and it cools the intake air. In addition, a portion of the cooling water for the eng...

  • Page 33: Gen

    1-28 e gen info 1 2 3 4 5 6 7 8 9 water cooled rectifier regulator to improve the reliability of the charging system, a water cooled rectifier regulator has been adopted for the first time in a waverunner. By changing to a water-cooled system, a more stable supply of electrical output has been achie...

  • Page 34: Gen

    1-29 e gen info in-tank fuel pump module a fuel pump module is integrated in the fuel tank. A fuel sender is installed to the side of the pump module. A pressure regulator at the fuel pump outlet controls pressure to the fuel line. Remaining fuel returns to the bottom of the fuel pump, and then re-e...

  • Page 35: Gen

    1-30 e gen info 1 2 3 4 5 6 7 8 9 large intermediate housing and oil seal in order to handle the high output, the intermediate housing has been strengthened. Furthermore, lipped oil seals have been adopted to improve waterproofing. 1 oil seal 2 intermediate housing 3 driven coupling intake grate the...

  • Page 36: Gen

    1-31 e gen info reverse gate assembly a reverse gate assembly shape has been adopted. In addition, a reverse sensor has been adopted to detect when the watercraft is operating in reverse, which improves reverse performance by acti- vating the “ reverse with traction control. ” 1 shift lever 2 revers...

  • Page 37: Gen

    1-32 e gen info 1 2 3 4 5 6 7 8 9 multifunction meter a multifunction meter with an analog speedometer/tachometer located in the center has been adopted. This meter is basically comprised of 3 types of meters. When the multifunction meter starts operating, the analog speedometer/tachometer makes 1 s...

  • Page 38: Gen

    1-33 e gen info the analog speedometer shows the watercraft speed against water. The large inner numbers on the meter show the watercraft speed in miles per hour (mph) and the small outer numbers show the speed in kilometers per hour (km/h) when the speedometer function is selected. To switch the sp...

  • Page 39: Gen

    1-34 e gen info 1 2 3 4 5 6 7 8 9 the “ unlock ” indicator light comes on when the unlock mode of the yamaha security system is selected. The watercraft can be ridden normally when this light is on. The “ l-mode ” indicator light comes on when the l-mode is selected. 1 “ unlock ” indicator light 2 “...

  • Page 40: Gen

    1-35 e gen info right multifunction display (fx cruiser sho) the display mode of the right multifunction display changes in the following order each time the “ mode/reset ” button is pushed briefly. Compass → average speed → tripmeter → trip timer → fuel consumption per hour → fuel con- sumption per...

  • Page 41: Gen

    1-36 e gen info 1 2 3 4 5 6 7 8 9 average speed, tripmeter, and trip time measurements average speed, tripmeter (distance traveled), and trip time are recorded once measurements have started, regardless of the current display. To start the measurements, push the “ start/stop ” button for less than 1...

  • Page 42: Gen

    1-37 e gen info electrical system yamaha diagnostic system (ydis) this model is equipped with the yamaha diagnostic system (ydis). By connecting a computer to the ecm, quick detection of malfunctions and parts that are difficult to check such as the fuel injectors and fuel pump module can be checked...

  • Page 43: Gen

    1-38 e gen info 1 2 3 4 5 6 7 8 9 slant detection switch when the watercraft is overturned, the slant detection switch turns on and the ecm stops the engine to protect the engine. If engine speed is less than 3,000 r/min, the engine is turned off. However, if engine speed exceeds 3,000 r/min, the en...

  • Page 44: Gen

    1-39 e gen info off-throttle steering (ots) system the off-throttle steering (ots) system of the yems activates when the operator releases the throt- tle lever and attempts to steer the watercraft. This assists the operator in turning while the watercraft is decelerating. The system will activate on...

  • Page 45: Gen

    1-40 e gen info 1 2 3 4 5 6 7 8 9 yamaha security system: the user can set the yamaha security system to the lock mode using the remote control transmitter to prevent the engine from starting. To start the engine, the yamaha security system must be set to the unlock mode. L-mode l-mode 1 push the bu...

  • Page 46: Gen

    1-41 e gen info remote control transmitter transmitter registration function (performed by dealers): id codes can be added or re-registered by connecting the entry box to the receiver. Id codes from up to 5 remote control transmitters can be registered. 1 remote control transmitter 2 remote control ...

  • Page 47: Gen

    1-42 e gen info 1 2 3 4 5 6 7 8 9 technical tips engine control the ecm controls ignition timing and fuel injection with information received from the sensors and switches installed on the engine and on the basis of the 3d map saved in the ecm. The following sensors and switches are used for the eng...

  • Page 48: Gen

    1-43 e gen info cruise assist control the cruise assist has been added as a new function. The cruise assist is a function for maintaining a set engine speed while cruising. Activation of the cruise assist will be confirmed by the beeper and the digital speedometer display. The cruise assist can only...

  • Page 49: Gen

    1-44 e gen info 1 2 3 4 5 6 7 8 9 no-wake mode control the no-wake mode has been added as a new function. The no-wake mode is a function for operat- ing the watercraft at a low speed to limit the watercraft's wake. In this mode, the ecm automatically maintains the engine speed at approximately 2,100...

  • Page 50: Gen

    1-45 e gen info reverse with traction control the reverse with traction control is activated when the shift lever is in the reverse position and the reverse sensor operates. The reverse with traction control limits the engine speed to 3,000 r/min so that an efficient water flow is produced when the ...

  • Page 51: Gen

    1-46 e gen info 1 2 3 4 5 6 7 8 9 high intake air pressure control the high intake air pressure control is activated under the following conditions. • if the engine speed exceeds 7,550 r/min. • if the intake air pressure exceeds 145 kpa. • if the above conditions are maintained for 1.5 seconds. Mete...

  • Page 52: Gen

    1-47 e gen info off-throttle steering (ots) control off-throttle steering (ots) system operates as follows: 1. The engine speed is maintained above 4,000 r/min for a few seconds. 2. The aps detects when the throttle lever is completely released. 3. The steering sensor detects on when the handlebar i...

  • Page 53: Gen

    1-48 e gen info 1 2 3 4 5 6 7 8 9 remote control transmitter control to set the yamaha security system, the user aims the remote control transmitter at the watercraft and presses the lock or unlock button to remotely turn the yamaha security system relay on or off. The unlock button can also be used...

  • Page 54: Gen

    1-49 e gen info warning control overheat warning control the overheat warning control is activated under the following conditions. • if the engine temperature rises rapidly within several seconds. • if the thermoswitch is on. • if the exhaust cooling water temperature exceed 75 ° c (167 ° f) if the ...

  • Page 55: Gen

    1-50 e gen info 1 2 3 4 5 6 7 8 9 cam position sensor failure control the cam position sensor failure control is activated under the following conditions. • if the cam position sensor failed. • if the engine speed exceeds about 1,000 r/min. • if the above conditions are maintained for 10 seconds. Me...

  • Page 56: Gen

    1-51 e gen info fail-safe function table symptom ignition control fuel injection control function incorrect pickup coil signal malfunction none none none incorrect cam posi- tion sensor signal sensor malfunction occurs after cylinder identification: normal control. Sensor malfunction occurs before c...

  • Page 57: Gen

    1-52 e gen info 1 2 3 4 5 6 7 8 9 incorrect cooling water temperature sensor signal normal control normal control pseudo cooling water temperature is set to 50 ° c (122 ° f). Etv system malfunction etv failure control etv failure control etv failure control symptom ignition control fuel injection co...

  • Page 58: Gen

    1-53 e gen info — memo — technical tips.

  • Page 59: Spec

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

  • Page 60: Spec

    2-1 e spec general specification item unit model fx sho fx cruiser sho model code hull f1w engine/jet 6s5/6s5 dimensions length mm (in) 3,370 (132.7) width mm (in) 1,230 (48.4) height mm (in) 1,160 (45.7) 1,240 (48.8) weight dry weight kg (lb) 376 (829) 381 (840) maximum capacity person/kg (lb) 3/24...

  • Page 61: Spec

    2-2 e spec 1 2 3 4 5 6 7 8 9 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 m...

  • Page 62: Spec

    2-3 e spec maintenance specifications engine item unit model fx sho fx cruiser sho power unit compression pressure *1 kpa (kgf/cm 2 , psi) 610 (6.1, 86.8) air cooler holding pressure water passage kpa (kgf/cm 2 , psi) 200 (2.0, 28.5) air passage kpa (kgf/cm 2 , psi) 100 (1.0, 14.2) oil cooler holdin...

  • Page 63: Spec

    2-4 e spec 1 2 3 4 5 6 7 8 9 timing chain model/number of links 97rh2015 – 152px/152 tensioning system automatic valve valve clearance (cold) intake mm (in) 0.14 – 0.23 (0.006 – 0.009) exhaust mm (in) 0.28 – 0.37 (0.011 – 0.015) valve dimensions valve head diameter a intake mm (in) 33.9 – 34.1 (1.33...

  • Page 64: Spec

    2-5 e spec valve spring free length intake and exhaust mm (in) 45.58 (1.794) installed length intake and exhaust mm (in) 34.00 (1.339) tilt limit intake and exhaust mm (in) 2.0 (0.08) cylinder bore size mm (in) 86.000 – 86.015 (3.3858 – 3.3864) piston piston outside diameter d mm (in) 85.915 – 85.93...

  • Page 65: Spec

    2-6 e spec 1 2 3 4 5 6 7 8 9 fuel system connecting rod bearing color code 1. Brown 2. Black 3. Blue 4. Green small end inside diameter mm (in) 22.015 – 22.028 (0.8667 – 0.8672) crankshaft crankshaft journal diameter mm (in) 39.976 – 40.000 (1.5739 – 1.5748) crankshaft pin diameter mm (in) 41.976 – ...

  • Page 66: Spec

    2-7 e spec jet pump unit hull and hood electrical item unit model fx sho fx cruiser sho jet pump impeller housing inside diameter mm (in) 155.35 – 155.45 (6.116 – 6.120) impeller material stainless steel number of impeller blades 3 impeller pitch angle degree 16.0 impeller-to-housing clearance mm (i...

  • Page 67: Spec

    2-8 e spec 1 2 3 4 5 6 7 8 9 charging system stator coil (g – g) output peak voltage @cranking (unloaded) v 8.4 @2,000 r/min (unloaded) v 42.7 @3,500 r/min (unloaded) v 74.0 stator coil resistance *1 (g – g) Ω 0.31 – 0.38 @ 20 ° c (68 ° f) rectifier regulator (r – b) output peak voltage @2,000 r/min...

  • Page 68: Spec

    2-9 e spec tps tps output voltage with throttle lever fully closed tps 1 v 0.6 – 0.9 with throttle lever fully open tps 2 v 4.6 – 4.7 throttle valve opening angle with throttle lever fully closed degree 2.0 – 8.0 with throttle lever fully open degree more than 70 aps aps output voltage with throttle...

  • Page 69: Spec

    2-10 e spec 1 2 3 4 5 6 7 8 9 fuel system fuel injector fuel injector resistance *1 Ω 11.5 – 12.5 @ 20 ° c (68 ° f) fuel sender fuel sender resistance *1 (y – b) @ 20 ° c (68 ° f) lower position Ω 133.5 – 136.5 upper position Ω 5.0 – 7.0 starting system fuse rating battery v/a 12/30 main and fuel pu...

  • Page 70: Spec

    2-11 e spec tightening torques specified torques part to tightened thread size tightening torque refer to page n · m kgf · m ft · lb fuel system fuel pump module assembly nut 1st — 3 0.3 2.2 4-1 2nd 6 0.6 4.4 strap bolt m8 16 1.6 11.8 4-1 fuel rail bolt m8 13 1.3 9.6 4-1 fuel tank cap clamp — 1 0.1 ...

  • Page 71: Spec

    2-12 e spec 1 2 3 4 5 6 7 8 9 air cooler assembly nut 1st — 23 2.3 17.0 5-31 2nd 42 4.2 31.0 stud bolt 1st m10 10 1.0 7.4 5-31 2nd 20 2.0 14.8 air cooler assembly bolt 1st m10 23 2.3 17.0 5-31 2nd 42 4.2 31.0 air cooler stay bolt m10 42 4.2 31.0 5-31 supercharger assembly bolt m6 10 1.0 7.4 5-31 m8 ...

  • Page 72: Spec

    2-13 e spec grommet bracket bolt m6 8 0.8 5.9 5-80 generator cover assembly bolt m8 26 2.6 19.2 5-80 transfer shaft — 120 12.0 88.5 5-80 flywheel magneto bolt m8 24 2.4 17.7 5-80 pickup coil bolt m5 5 0.5 3.7 5-82 washer bolt m5 5 0.5 3.7 5-82 stator coil assembly bolt m6 15 1.5 11.1 5-82 clamp bolt...

  • Page 73: Spec

    2-14 e spec 1 2 3 4 5 6 7 8 9 spring nut — 8 0.8 5.9 6-6 spring bolt m8 20 2.0 14.8 6-6 shift cable ball joint nut — 8 0.8 5.9 6-6 reverse gate stay bolt m6 8 0.8 5.9 6-6 bracket 1 and 2 bolt m6 8 0.8 5.9 6-6 jet thrust nozzle bolt m8 16 1.6 11.8 6-8 nozzle ring bolt m8 16 1.6 11.8 6-8 qsts rod ball...

  • Page 74: Spec

    2-15 e spec multifunction meter bolt m5 4 0.4 3.0 8-22 side cover bolt m6 5 0.5 3.7 8-24 side ornament nut — 5 0.5 3.7 8-24 center cover nut — 5 0.5 3.7 8-25 shift lever assembly nut — 5 0.5 3.7 8-25 box cap — 2 0.2 1.5 8-25 lid lock hook/bracket bolt m5 4 0.4 3.0 8-27 steering arm assembly bolt m8 ...

  • Page 75: Spec

    2-16 e spec 1 2 3 4 5 6 7 8 9 drain plug nut — 2 0.2 1.5 8-52 reboarding step assembly bolt m8 16 1.6 11.8 8-52 electrical fuse box bolt m8 13 1.3 9.6 7-4 slant detection switch screw m6 4 0.4 3.0 7-4 ecm bolt m6 5 0.5 3.7 7-4 lead bolt (red, brown, and black) m6 10 1.0 7.4 7-6 starter motor termina...

  • Page 76: Spec

    2-17 e spec 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-fastener assemblie...

  • Page 77: Spec

    E spec 2-18 1 2 3 4 5 6 7 8 9 cable and hose routing starboard bow view g f e e d d c a b b 0 9 8 8 3 2 1 5 6 9 7 4 7 a a bow 1 breather hose (head cover to breather assembly) 2 cooling water hose (exhaust manifold to rectifier regulator) 3 breather hose (breather assembly to intake pipe) 4 right ha...

  • Page 78: Spec

    E spec 2-19 top view a b i j g 9 m e n k l 8 o d 5 q 0 p 6 3 1 f 4 9 2 c h 7 1 breather hose (head cover to breather assembly) 2 multifunction meter lead 3 breather hose (breather assembly to intake pipe) 4 right handlebar switch lead 5 throttle cable 6 left handlebar switch lead 7 qsts cable 8 fuel...

  • Page 79: Spec

    E spec 2-20 1 2 3 4 5 6 7 8 9 a b i j g 9 m e n k l 8 o d 5 q 0 p 6 3 1 f 4 9 2 c h 7 i electric bilge pump coupler j negative battery cable k positive battery cable l battery breather hose m cooling water hose (jet pump to hose joint 1) n flushing hose o cooling water hose (hose joint 1 to hose joi...

  • Page 80: Spec

    E spec 2-21 port view a a 1 3 h p m 5 6 4 8 f i 2 n o l q 0 e 7 k d r j 9 b d g c a È c 1 multifunction meter lead 2 cooling water hose (exhaust manifold to rectifier regulator) 3 left operation button lead 4 right handlebar switch lead 5 throttle cable 6 left handlebar switch lead 7 qsts cable 8 fu...

  • Page 81: Spec

    E spec 2-22 1 2 3 4 5 6 7 8 9 a a 1 3 h p m 5 6 4 8 f i 2 n o l q 0 e 7 k d r j 9 b d g c a È c j negative battery cable k positive battery cable l battery breather hose m steering sensor lead n bilge hose (hose joint to drain joint) o bilge hose (electric bilge pump to hose joint) p buzzer lead q b...

  • Page 82: Spec

    2-23 e spec — memo — cable and hose routing.

  • Page 83: Chk

    E chk adj 1 2 3 4 5 6 7 8 9 chapter 3 periodic check and adjustment maintenance interval chart............................................................................ 3-1 periodic service ............................................................................................. 3-2 control sy...

  • Page 84: Chk

    3-1 e chk adj maintenance interval chart the following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the maintenance intervals should be changed. *1: before long-term storage *2: grease quantity: 33.0 – 35.0 cm 3 (1.12 – 1.18 us o...

  • Page 85: Chk

    3-2 e chk adj 1 2 3 4 5 6 7 8 9 periodic service control system steering system check 1. Check: • steering system excessive play → check the bushings, bolts, and nuts. Refer to “ handlebar assembly removal ” in chapter 8. Checking steps: 1. Turn the handlebar lock to lock and push it back and forth....

  • Page 86: Chk

    3-3 e chk adj 2. Adjust: • steering cable joint (steering master end) adjustment steps: 1. Set the qsts grip to the neutral position. 2. Remove the service lid. Refer to “ front hood removal ” in chapter 8. 3. Loosen the locknut 1 . 4. Disconnect the steering cable joint 2 from the ball joint 3 . 5....

  • Page 87: Chk

    3-4 e chk adj 1 2 3 4 5 6 7 8 9 jet thrust nozzle qsts angle check and adjustment 1. Check: • jet thrust nozzle angle set distances a and b difference → adjust the qsts rod joint. Note: before measuring the jet thrust nozzle qsts angle make sure that the steering position of the jet thrust nozzle is...

  • Page 88: Chk

    3-5 e chk adj 6. If the qsts rod cannot be properly adjusted using the rod joint at the jet pump end, check the rod joint at the qsts con- verter end. Refer to “ qsts grip and converter disas- sembly ” in chapter 8. Throttle lever free play check and adjustment 1. Measure: • throttle lever free play...

  • Page 89: Chk

    3-6 e chk adj 1 2 3 4 5 6 7 8 9 5. If the throttle cable installation length a is out of specification, loosen the locknut 2 , turn the adjusting nut 3 to adjust the length, and then tighten the locknut 2 to the specified torque. Note: apply locking agent to the threads of the adjusting nut 3 . 6. R...

  • Page 90: Chk

    3-7 e chk adj 14. Install the service lid. Note: make sure that the throttle cable is not pulled when the handlebar is turned to the right and left. Trolling speed check 1. Check: • trolling speed out of specification → check the throttle cable or throttle body assembly. Checking steps: 1. Place the...

  • Page 91: Chk

    3-8 e chk adj 1 2 3 4 5 6 7 8 9 2. Adjust: • shift cable joint (jet pump end) adjustment steps: 1. Set the shift lever to the reverse position. 2. Loosen the locknut 1 . 3. Disconnect the shift cable joint 2 from the ball joint 3 . 4. Situate the reverse gate 4 to the stopper 5 . 1 2 3 5 4 4 5. Turn...

  • Page 92: Chk

    3-9 e chk adj fuel system warning • before checking the fuel system, remove the battery and then remove the fuel tank filler cap to reduce any pressure inside the fuel tank. • always reduce the fuel pressure in the fuel line before checking the line or the fuel pipe. If the fuel pressure is not re- ...

  • Page 93: Chk

    3-10 e chk adj 1 2 3 4 5 6 7 8 9 2. Check: • fuel tank water accumulation → extract the water and fuel. Cracks/damage → replace the fuel tank. Note: to extract water and fuel from the fuel tank, remove the cap 1 and use a siphon pump. T r . . Fuel tank cap clamp: 1 n · m (0.1 kgf · m, 0.7 ft · lb) 1...

  • Page 94: Chk

    3-11 e chk adj measurement steps: 1. Remove the spark plugs and cylinder head cover. Refer to “ cylinder head cover removal ” in chapter 5. 2. Install the dial gauge needle and special service tools 1 and 2 into spark plug hole #1. 3. Position piston #1 at tdc by turning the exhaust camshaft sprocke...

  • Page 95: Chk

    3-12 e chk adj 1 2 3 4 5 6 7 8 9 compression pressure measurement 1. Measure: • compression pressure note: make sure that the battery voltage is more than 12 v. Measurement steps: 1. Place the watercraft in the water. 2. Start the engine, allow it to warm up for 5 minutes, and then stop the engine. ...

  • Page 96: Chk

    3-13 e chk adj 8. Install the spark plugs 4 , ignition coils 3 , bolts 2 , and engine cover 1 . T r . . Spark plug: 25 n · m (2.5 kgf · m, 18.4 ft · lb) ignition coil bolt: 8 n · m (0.8 kgf · m, 5.9 ft · lb) loctite 572 engine cover bolt: 5 n · m (0.5 kgf · m, 3.7 ft · lb) 1 3 4 2 lt 572 lt engine o...

  • Page 97: Chk

    3-14 e chk adj 1 2 3 4 5 6 7 8 9 2. Remove the oil level gauge 1 , wipe the gauge clean, and then install the gauge into the oil level pipe completely. 3. Remove the oil level gauge 1 again to check that the oil level is between the min- imum level mark a and maximum level mark b on the gauge. 4. In...

  • Page 98: Chk

    3-15 e chk adj 3. Remove the oil filler cap 1 and oil level gauge 2 . 4. Insert the tube 3 of an oil changer into the oil level pipe 4 . 5. Operate the oil changer to extract the oil. 6. Fill the crankcase with the specified amount of the recommended engine oil through the oil filler hole 5 . 7. Ins...

  • Page 99: Chk

    3-16 e chk adj 1 2 3 4 5 6 7 8 9 5. Tighten a new oil filter to the specified torque with the special service tool. Note: be sure to clean up any oil spills. 6. Install the engine cover. T r . . Oil filter: 18 n · m (1.8 kgf · m, 13.3 ft · lb) air filter element check 1. Remove: • intake pipe 1 • ai...

  • Page 100: Chk

    3-17 e chk adj spark plug check 1. Remove: • engine cover 1 • ignition coil bolts 2 • ignition coils 3 • spark plugs 4 note: • slide the engine cover rearward, and then lift the cover to remove it. • be careful not to get water or any other for- eign substances in the spark plug holes. 1 3 4 2 2. Ch...

  • Page 101: Chk

    3-18 e chk adj 1 2 3 4 5 6 7 8 9 4. Install: • spark plugs 1 note: before installing a spark plug, clean the gasket surface and spark plug surface. 5. Install: • ignition coils 2 • ignition coil bolts 3 • engine cover 4 t r . . Spark plug: 25 n · m (2.5 kgf · m, 18.4 ft · lb) t r . . Ignition coil b...

  • Page 102: Chk

    3-19 e chk adj electrical battery check warning battery electrolyte is poisonous and dan- gerous, causing severe burns, etc. Electro- lyte contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidotes external: flush with water. Internal: drink large quantities of water or milk. Follo...

  • Page 103: Chk

    3-20 e chk adj 1 2 3 4 5 6 7 8 9 1. Remove: • negative battery cable 1 • positive battery cable 2 • battery breather hose 3 • bands 4 • battery 5 caution: when removing the battery, disconnect the negative battery cable first. 2. Check: • electrolyte level low → add distilled water. Adding steps: 1....

  • Page 104: Chk

    3-21 e chk adj 4. Install: • battery 1 • bands 2 • battery breather hose 3 • positive battery cable 4 • negative battery cable 5 caution: connect the positive battery cable 4 to the battery terminal first. Note: • make sure that the battery breather hose 3 is properly connected and is not obstructed...

  • Page 105: Chk

    3-22 e chk adj 1 2 3 4 5 6 7 8 9 3. Check: • water inlet strainer a contaminants → clean the water inlet strainer. Cracks/damage → replace the water inlet strainer. A bilge pump bilge strainer check 1. Remove: • deck beam refer to “ seat and hand grip removal ” in chapter 8. • electrical box • coupl...

  • Page 106: Chk

    3-23 e chk adj electric bilge pump strainer check 1. Remove: • negative battery cable 1 • band 2 • electric bilge pump cap 3 • electric bilge pump strainer 4 2. Check: • electric bilge pump strainer contaminants → clean the cap and strainer. 3. Install: • electric bilge pump strainer • electric bilg...

  • Page 107: Chk

    3-24 e chk adj 1 2 3 4 5 6 7 8 9 caution: be sure to supply sufficient water and wa- ter pressure to the cooling water passages when lubricating the engine internal com- ponents on land, otherwise the engine could overheat. Note: while spraying the rust inhibitor into the breather hose, the engine s...

  • Page 108: Chk

    3-25 e chk adj 3. Lubricate: • qsts cables (handlebar end) note: • before lubricating the qsts cables, remove the qsts grip assembly from the handlebar. Refer to “ handlebar assembly removal ” in chapter 8. • spray the rust inhibitor into the outer cables, and apply grease to the inner cables. Recom...

  • Page 109: Chk

    3-26 e chk adj 1 2 3 4 5 6 7 8 9 6. Lubricate: • steering cable (steering master end) • steering cable joint (steering master end) • shift cable • shift cable joint note: disconnect the joints and apply a small amount of grease. Recommended lubricant: yamaha grease a 7. Lubricate: • intermediate hou...

  • Page 110: Chk

    3-27 e chk adj — memo — general.

  • Page 111: Fuel

    E fuel 1 2 3 4 5 6 7 8 9 chapter 4 fuel system fuel tank, fuel pump module, and fuel hose ............................................... 4-1 fuel tank removal ...................................................................................... 4-1 fuel hose disconnection.............................

  • Page 112: Fuel

    4-1 e fuel fuel tank, fuel pump module, and fuel hose fuel tank removal step procedure/part name q ’ ty service points engine unit refer to “ engine unit ” in chapter 5. Note: when removing the fuel pump module assembly only, it is not necessary to remove the engine unit. Ventilation hose refer to “...

  • Page 113: Fuel

    4-2 e fuel 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 7 check valve 1 8 fuel tank breather hose 1 È to water separator 9 fuel sender coupler 1 10 fuel pump module coupler 1 11 fuel hose assembly 1 caution: do not remove the quick connectors from the fuel hose assembly. 12 nut 9...

  • Page 114: Fuel

    4-3 e fuel step procedure/part name q ’ ty service points 14 fuel pump module assembly 1 15 stopper 1 16 fuel sender 1 17 packing 1 not reusable 18 clamp/fuel filler hose 2/1 19 nut 1 20 fuel filler neck 1 21 rubber seal 1 not reusable 22 clamp/cap 1/1 8 × 18 mm 16 n · m (1.6 kgf · m, 11.8 ft · ib) ...

  • Page 115: Fuel

    4-4 e fuel 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 23 fuel tank 1 24 bolt 4 25 strap 1 a pink thread 26 strap 1 b brown thread 27 bolt 3 28 fuel rail 1 29 fuel injector 4 30 o-ring 4 not reusable 31 seal 4 not reusable reverse the removal steps for installation. 8 × 18 mm 16...

  • Page 116: Fuel

    4-5 e fuel fuel hose disconnection warning • before checking the fuel system, remove the battery and then remove the fuel tank filler cap to reduce any pressure inside the fuel tank. • always reduce the fuel pressure in the fuel line before servicing the line or the fuel pipe. If the fuel pressure i...

  • Page 117: Fuel

    4-6 e fuel 1 2 3 4 5 6 7 8 9 2. Remove: • fuel pump module assembly 1 note: • remove the fuel pump module assembly 1 at an angle so that the float 2 does not catch on the fuel tank. • be careful that the rubber cap 3 does not come off when removing the fuel pump mod- ule assembly 1 . 2 1 3 fuel send...

  • Page 118: Fuel

    4-7 e fuel rollover valve check 1. Check: • rollover valve does not function properly → replace the rollover valve. Checking steps: 1. Blow into the end a of the rollover valve, and make sure that airflow from the end b is unrestricted. 2. Blow into the end b of the rollover valve, and make sure tha...

  • Page 119: Fuel

    4-8 e fuel 1 2 3 4 5 6 7 8 9 fuel line check 1. Check: • fuel hose 1 • quick connectors 2 cracks/damage → replace the fuel hose assembly. Caution: do not remove the quick connectors from the fuel hose assembly. • fuel pipe 3 (fuel pump module end) cracks/damage → replace the fuel pump module assembl...

  • Page 120: Fuel

    4-9 e fuel fuel injector check 1. Check: • fuel injector dirt/residue → clean the fuel injector. Damage → replace the fuel injector. Fuel injector installation 1. Install: • fuel injector installation steps: 1. Apply a thin coat of engine oil to the o-ring 1 . 2. While turning the fuel injector 2 sl...

  • Page 121: Fuel

    4-10 e fuel 1 2 3 4 5 6 7 8 9 fuel pump module installation 1. Install: • fuel pump module assembly note: tighten the nuts to the specified torques in the sequence shown. T r . . Fuel pump module nut: 1st: 3 n · m (0.3 kgf · m, 2.2 ft · lb) 2nd: 6 n · m (0.6 kgf · m, 4.4 ft · lb) 9 6 1 4 8 7 2 3 5 b...

  • Page 122: Fuel

    4-11 e fuel fuel pressure measurement 1. Measure: • fuel pressure out of specification → replace the fuel pump module assembly. Measurement steps: 1. Disconnect the quick connector from the fuel rail. 2. Install the special service tools 1 and 2 as shown. 3. Start the engine and allow it to warm up ...

  • Page 123: Powr

    E powr 1 2 3 4 5 6 7 8 9 chapter 5 power unit engine unit...................................................................................................... 5-1 engine unit removal 1................................................................................ 5-1 engine unit removal 2............

  • Page 124: Powr

    E powr oil cooler, oil pump assembly, and drive gear.......................................... 5-42 oil cooler and oil pump assembly removal .............................................. 5-42 drive gear removal .................................................................................. 5-44 ...

  • Page 125: Powr

    E powr 1 2 3 4 5 6 7 8 9 generator cover and flywheel magneto..................................................... 5-80 generator cover and flywheel magneto removal..................................... 5-80 generator cover disassembly.....................................................................

  • Page 126: Powr

    5-1 e powr engine unit engine unit removal 1 step procedure/part name q ’ ty service points engine oil refer to “ engine oil change ” in chapter 3. Service lid refer to “ front hood removal ” in chapter 8. Deck beam refer to “ seat and hand grip removal ” in chapter 8. Shift cable bracket refer to “...

  • Page 127: Powr

    5-2 e powr 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 6 aps 1 7 aps coupler 1 8 plastic tie 1 note: align the plastic ties with the gray tape a on the wiring harness assembly. 9 plastic tie 1 10 plastic tie 1 11 coupler 8 note: disconnect the multifunction meter, sensor, and sw...

  • Page 128: Powr

    5-3 e powr step procedure/part name q ’ ty service points 12 antenna holder 3 13 remote control receiver coupler 1 14 plastic tie 5 15 fuel pump module coupler 1 16 electric bilge pump coupler 1 reverse the removal steps for installation. 1 3 3 8 4 2 9 11 12 13 14 14 14 14 a a 11 10 15 16 14 a 11 a ...

  • Page 129: Powr

    5-4 e powr 1 2 3 4 5 6 7 8 9 engine unit removal 2 step procedure/part name q ’ ty service points 1 fuel hose assembly 1 È to fuel pump module 2 plastic tie 2 3 clamp/breather hose 2/1 4 connection 1 note: align the mark a on the connection with the mark b on the intake pipe. 5 clamp/intake pipe 2/1...

  • Page 130: Powr

    5-5 e powr step procedure/part name q ’ ty service points 10 air filter case 1 11 collar/grommet 4/4 12 clamp/cooling water hose 1/1 É to cooling water pilot outlet on port side 13 clamp/cooling water hose 1/1 É to cooling water pilot outlet on port side 14 clamp/cooling water hose 1/1 Ê to cooling ...

  • Page 131: Powr

    5-6 e powr 1 2 3 4 5 6 7 8 9 engine unit removal 3 step procedure/part name q ’ ty service points 1 plastic tie 1 2 plastic tie 1 3 thermo sensor coupler 1 4 clamp 1 5 clamp/breather hose 1/1 6 bolt 3 7 breather assembly 1 8 collar/grommet 3/3 9 clamp/breather hose 2/1 10 clamp/cooling water hose 2/...

  • Page 132: Powr

    5-7 e powr step procedure/part name q ’ ty service points 12 clamp/cooling water hose 1/1 13 bolt 2 14 rectifier regulator 1 15 collar/grommet 2/2 16 clamp/cooling water hose 1/1 cooling water inlet 17 clamp/cooling water hose 1/1 18 plastic tie 1 19 clamp/cooling water hose 1/1 È to air cooler 20 b...

  • Page 133: Powr

    5-8 e powr 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 22 stay 1 23 clamp 1 24 bolt 8 25 bolt 3 26 muffler 1 27 gasket 1 not reusable 28 dowel pin 2 a b È lt 572 lt 572 lt 242 lt 242 lt 242 lt 242 a b 6 × 30 mm 8 n · m (0.8 kgf · m, 5.9 ft · ib) 2 n · m (0.2 kgf · m, 1.5 ft · ib...

  • Page 134: Powr

    5-9 e powr engine unit removal 4 *: as required. Step procedure/part name q ’ ty service points 1 bolt 4 2 electrical box 1 3 bolt/collar 1/1 4 coupling cover 1 5 engine mounting bolt 4 6 shim * 7 engine unit 1 reverse the removal steps for installation. Lt 572 lt 271 8 × 28 mm 17 n · m (1.7 kgf · m...

  • Page 135: Powr

    5-10 e powr 1 2 3 4 5 6 7 8 9 engine mount removal step procedure/part name q ’ ty service points 1 bolt 8 2 engine mount 4 note: • make a note of the position of each engine mount so that it can be installed in its origi- nal place. • be sure to adjust the coupling clearance. 3 liner 4 4 bolt 2 5 d...

  • Page 136: Powr

    5-11 e powr step procedure/part name q ’ ty service points 6 bolt 2 7 damper 2 1 reverse the removal steps for installation. 4 6 1 5 7 3 2 a lt 572 lt 572 lt 572 6 × 20 mm 6 n · m (0.6 kgf · m, 4.4 ft · ib) 6 × 12 mm 6 n · m (0.6 kgf · m, 4.4 ft · ib) 8 × 35 mm 17 n · m (1.7 kgf · m, 12.5 ft · ib) b...

  • Page 137: Powr

    5-12 e powr 1 2 3 4 5 6 7 8 9 engine unit removal 1. Remove: • engine unit caution: before removing the engine, be sure to take adequate measures to protect the deck opening from damage. Removal steps: 1. Extract the engine oil. Refer to “ engine oil change ” in chapter 3. 2. Remove the service lid ...

  • Page 138: Powr

    5-13 e powr 8. Disconnect the aps coupler a , and the 8 multifunction meter, sensor, and switch couplers b . A a a b 9. Remove the antenna holders c . 10. Disconnect the remote control receiver coupler d . D a c a 11. Remove the wiring harness from the 5 plastic ties e . E e 12. Disconnect the fuel ...

  • Page 139: Powr

    5-14 e powr 1 2 3 4 5 6 7 8 9 15. Disconnect the breather hose i from the intake pipe j , and then remove the intake pipe j from the supercharger. 16. Unhook the fasteners k , and then remove the air filter case cover l . Remove the air filter case bolts m , and then remove the air filter case n . J...

  • Page 140: Powr

    5-15 e powr 23. Remove the cooling water hoses w . 24. Remove the rectifier regulator bolts x , and then remove the rectifier regulator y . Y w x x w w 25. Remove the plastic tie z from the hose joint 4 [ . 26. Disconnect cooling water hose \ from the hose joint 1 ] . Z \ [ ] 27. Disconnect the cool...

  • Page 141: Powr

    5-16 e powr 1 2 3 4 5 6 7 8 9 31. Remove the electrical box bolts h , and then remove the electrical box i . I h 32. Remove the coupling cover bolt j , and then remove the coupling cover k . K j 33. Loosen the engine mounting bolts l . 34. Lift the engine unit slightly, remove the shims m , and then...

  • Page 142: Powr

    5-17 e powr 37. Lift the engine unit slightly, and then lower the front of the unit. Repeat this step until the engine unit can be removed from the engine compartment. Caution: when removing the engine unit, take care to avoid causing damage to the hull and deck opening. 38. Lift the engine unit out...

  • Page 143: Powr

    5-18 e powr 1 2 3 4 5 6 7 8 9 engine unit installation 1. Install: • engine unit installation steps: 1. Suspend the engine unit using all 3 engine hangers. 2. Lower the front of the engine unit. 3. Lower the engine unit into the engine com- partment vertically. Caution: when installing the engine un...

  • Page 144: Powr

    5-19 e powr 6. Temporarily install the engine mounting bolts 2 . 7. Lift the engine unit slightly, install the shims 3 , and then lower the engine. Note: install the shims in their original positions. 2 3 3 2 8. Measure the coupling clearance a , and if necessary, add or remove shims 3 so that the c...

  • Page 145: Powr

    5-20 e powr 1 2 3 4 5 6 7 8 9 11. Tighten the engine mounting bolts 2 to the specified torque. T r . . Engine mounting bolt: 17 n · m (1.7 kgf · m, 12.5 ft · lb) loctite 271 2 2 lt 271 lt 271 12. Check that the coupling clearances a and b are within specification. If the clear- ances are out of spec...

  • Page 146: Powr

    5-21 e powr 16. Tighten the pipe clamp a to the specified torque. T r . . Pipe clamp: 2 n · m (0.2 kgf · m, 1.5 ft · lb) a 17. Install the stay b , and then tighten the stay bolts c to the specified torque. 18. Connect the cooling water hoses d to the hose joint 3 e . 19. Connect the cooling water h...

  • Page 147: Powr

    5-22 e powr 1 2 3 4 5 6 7 8 9 25. Apply a thin coat of engine oil to the o-ring q of the oil filter r . E q r 26. Install the oil filter r with the special ser- vice tool. Oil filter wrench: 90890-06830 t r . . Oil filter: 18 n · m (1.8 kgf · m, 13.3 ft · lb) r 27. Connect the cooling water hose s t...

  • Page 148: Powr

    5-23 e powr 29. Install the air filter case v , and then tighten the air filter case bolts w to the specified torque. 30. Install the air filter case cover x , and then hook the fasteners y . 31. Install the intake pipe z , and then tighten the clamps [ . 32. Connect the breather hose \ to the intak...

  • Page 149: Powr

    5-24 e powr 1 2 3 4 5 6 7 8 9 38. Connect the aps coupler d , and the 8 multifunction meter, sensor, and switch couplers e . D a a e 39. Install the engine cover f , and then tighten the engine cover bolts g to the specified torque. Note: hold the engine cover down, and slide the cover forward to in...

  • Page 150: Powr

    5-25 e powr muffler muffler disassembly step procedure/part name q ’ ty service points 1 clamp 1 2 pipe 1 3 exhaust pipe 3 1 4 thermo sensor 1 5 bolt 5 6 exhaust pipe 2 1 7 gasket 2 not reusable 8 silencer plate 1 9 dowel pin 2 10 clamp/cooling water hose 1/1 1 2 5 12 11 15 14 16 13 9 8 7 7 9 10 4 3...

  • Page 151: Powr

    5-26 e powr 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 11 bolt 2 12 bolt 4 13 exhaust pipe 1 1 14 gasket 1 not reusable 15 dowel pin 2 16 exhaust manifold 1 reverse the disassembly steps for assembly. 1 2 5 12 11 15 14 16 13 9 8 7 7 9 10 4 3 6 lt 572 lt 242 2 n · m (0.2 kgf · m...

  • Page 152: Powr

    5-27 e powr exhaust pipe 3 removal 1. Remove: • exhaust pipe 3 1 exhaust pipe wrench: 90890-06726 1 muffler check 1. Check: • exhaust manifold 1 • exhaust pipe 1 2 • exhaust pipe 2 3 • exhaust pipe 3 4 cracks/damage → replace. 3 1 4 2 pipe check 1. Check: • pipe cracks/damage → replace the pipe. The...

  • Page 153: Powr

    5-28 e powr 1 2 3 4 5 6 7 8 9 electrical box and starter motor electrical box and starter motor removal step procedure/part name q ’ ty service points 1 ignition coil coupler 4 2 plastic tie 1 3 injector coupler 4 4 knock sensor coupler 1 5 thermoswitch coupler 1 6 plastic tie 1 7 cam position senso...

  • Page 154: Powr

    5-29 e powr step procedure/part name q ’ ty service points 11 plastic tie 1 12 throttle body assembly coupler 1 caution: do not disconnect the throttle body as- sembly coupler a. 13 intake air pressure sensor coupler 1 14 clamp 3 15 earth plate coupler 1 1 16 earth plate coupler 2 1 17 oil pressure ...

  • Page 155: Powr

    5-30 e powr 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 20 bolt 2 21 negative battery cable 1 22 starter motor 1 23 electrical box cover 1 24 plastic tie 1 25 rectifier regulator coupler 1 26 stator coil coupler 1 27 rectifier regulator 1 28 pick up coil coupler 1 reverse the re...

  • Page 156: Powr

    5-31 e powr air cooler, supercharger, and throttle body assembly air cooler and supercharger removal step procedure/part name q ’ ty service points 1 clamp 3 2 clamp 1 3 bolt 1 4 boost pipe 1 5 collar/grommet 1/1 6 hose 1 7 joint 1 8 clamp/cooling water hose 1/1 9 clamp/air cooler intake hose 2/1 10...

  • Page 157: Powr

    5-32 e powr 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 11 bolt 2 12 air cooler assembly 1 13 collar 1 14 grommet 1 15 plate 1 16 stud bolt 1 17 bolt 1 18 bolt 1 19 stay 1 20 3 2 7 1 4 1 6 5 1 8 14 12 9 19 18 17 11 9 15 10 13 16 25 20 21 22 23 24 20 n · m (2.0 kgf · m, 14.8 ft ·...

  • Page 158: Powr

    5-33 e powr step procedure/part name q ’ ty service points 20 bolt/washer 2/2 21 bolt 3 22 bolt 1 23 supercharger assembly 1 24 o-ring 1 not reusable 25 dowel pin 2 reverse the removal steps for installation. 20 3 2 7 1 4 1 6 5 1 8 14 12 9 19 18 17 11 9 15 10 13 16 25 20 21 22 23 24 20 n · m (2.0 kg...

  • Page 159: Powr

    5-34 e powr 1 2 3 4 5 6 7 8 9 intake assembly removal step procedure/part name q ’ ty service points fuel injector refer to “ fuel tank removal ” in chapter 4. 1 plastic tie 1 2 intake air temperature sensor 1 3 washer 1 not reusable 4 clamp/hose 2/1 5 bolt 2 6 intake air pressure sensor 1 7 bolt 2 ...

  • Page 160: Powr

    5-35 e powr step procedure/part name q ’ ty service points 11 bolt 2 12 stay 2 13 bolt 1 14 bolt 6 15 nut 2 16 intake assembly 1 17 packing 1 not reusable 18 dowel pin 2 19 stud bolt 2 reverse the removal steps for installation. 13 10 11 12 10 1 5 6 8 9 2 3 4 7 14 11 19 18 12 9 15 17 16 5 n · m (0.5...

  • Page 161: Powr

    5-36 e powr 1 2 3 4 5 6 7 8 9 intake disassembly step procedure/part name q ’ ty service points 1 nut/washer 4/4 2 throttle body assembly 1 3 gasket 1 not reusable 4 bolt 4 5 joint 1 6 o-ring 1 not reusable 7 ribbon 1 8 holder 1 9 intake manifold 1 reverse the disassembly steps for assembly. 8 7 6 5...

  • Page 162: Powr

    5-37 e powr air cooler check caution: the air cooler assembly should not be dis- assembled. 1. Check: • air cooler assembly cracks/damage → replace the air cooler assembly. • air cooler holding pressure cannot be maintained → replace the air cooler assembly. Checking steps: note: when checking the a...

  • Page 163: Powr

    5-38 e powr 1 2 3 4 5 6 7 8 9 supercharger check caution: the supercharger should not be disassem- bled. 1. Check: • impeller 1 • gear 2 cracks/damage → replace the super- charger assembly. • supercharger operation rough movement → replace the super- charger assembly. 1 2 throttle body assembly chec...

  • Page 164: Powr

    5-39 e powr intake manifold installation 1. Install: • intake manifold note: tighten the bolts to the specified torques in the sequence shown. Supercharger installation 1. Lubricate: • supper charger impeller shaft caution: before installing the supercharger assem- bly, be sure to lubricate the supe...

  • Page 165: Powr

    5-40 e powr 1 2 3 4 5 6 7 8 9 2. Install: • supercharger installation step: 1. Tighten the supercharger bolts 1 , and then bolts 2 to the specified torque. T r . . Supercharger bolt (m8 × 65 mm) 1 : 20 n · m (2.0 kgf · m, 14.8 ft · lb) loctite 242 supercharger bolt (m6 × 65 mm) 2 : 10 n · m (1.0 kgf...

  • Page 166: Powr

    5-41 e powr boost pipe installation 1. Install: • boost pipe 1 • hose 2 • joint 3 installation steps: 1. Install the hose 2 and joint 3 to the boost pipe 1 . Note: • fit the projection a on the boost pipe 1 between the projections b on the hose 2 . • fit the lip c on the boost pipe 1 into the groove...

  • Page 167: Powr

    5-42 e powr 1 2 3 4 5 6 7 8 9 oil cooler, oil pump assembly, and drive gear oil cooler and oil pump assembly removal step procedure/part name q ’ ty service points 1 clamp/cooling water hose 2/2 2 oil filter bolt 1 3 bolt 1 4 bolt 2 5 oil cooler assembly 1 6 connector 2 7 o-ring 4 not reusable 8 bol...

  • Page 168: Powr

    5-43 e powr step procedure/part name q ’ ty service points 11 oil pipe 1 12 bolt 12 13 oil pump assembly 1 14 connector 2 15 o-ring 4 not reusable 16 gasket 1 not reusable 17 dowel pin 2 reverse the removal steps for installation. 3 4 9 8 11 9 10 10 2 13 16 17 17 15 14 12 7 1 6 7 6 × 12 mm 8 n · m (...

  • Page 169: Powr

    5-44 e powr 1 2 3 4 5 6 7 8 9 drive gear removal step procedure/part name q ’ ty service points 1 shaft 1 2 circlip 2 3 washer 1 4 bearing 2 5 collar 1 6 idle gear 1 7 washer 1 8 collar 1 9 bolt 1 left-hand threads 10 circlip 1 11 oil pump drive gear 1 12 bearing 1 14 15 a 17 16 13 12 11 10 9 8 1 3 ...

  • Page 170: Powr

    5-45 e powr step procedure/part name q ’ ty service points 13 washer 1 14 circlip 1 15 washer 1 16 drive gear clutch 1 caution: • make sure that the drive gear clutch is installed so that the side a is facing to- ward the supercharger drive gear as shown. • check the drive gear clutch operation afte...

  • Page 171: Powr

    5-46 e powr 1 2 3 4 5 6 7 8 9 drive gear assembly removal 1. Remove: • drive gear assembly removal steps: 1. Remove the drive coupling and generator cover. Refer to “ generator cover and flywheel magneto removal. ” 2. Hold the flywheel magneto 1 with the spe- cial service tools 2 and 3 . 3. Remove t...

  • Page 172: Powr

    5-47 e powr oil cooler assembly check caution: the oil cooler assembly should not be dis- assembled. 1. Check: • oil cooler assembly cracks/damage → replace the oil cooler assembly. • oil cooler holding pressure cannot be maintained → replace the oil cooler assembly. Checking steps: note: when check...

  • Page 173: Powr

    5-48 e powr 1 2 3 4 5 6 7 8 9 oil pump assembly check caution: the oil pump assembly should not be dis- assembled. 1. Check: • oil pump assembly • oil pump driven gear 1 cracks/damage → replace the oil pump assembly. • oil pump operation rough movement → replace the oil pump assembly. 1 idle gear ch...

  • Page 174: Powr

    5-49 e powr drive gear clutch check 1. Check: • drive gear clutch cracks/damage → replace the drive gear clutch. • drive gear clutch operation does not operate properly → replace the drive gear clutch. Caution: make sure that the drive gear clutch is in- stalled so that the side a is facing toward t...

  • Page 175: Powr

    5-50 e powr 1 2 3 4 5 6 7 8 9 drive gear assembly installation 1. Install: • drive gear assembly installation steps: 1. Hold the flywheel magneto 1 with the spe- cial service tools 2 and 3 . 2. Tighten the drive gear assembly bolt 4 . Note: • apply engine oil to the threads of the drive gear assembl...

  • Page 176: Powr

    5-51 e powr oil pump assembly installation 1. Fill: • oil pump assembly caution: be sure to fill the oil pump assembly with engine oil through the scavenge and feed ports. Filling steps: 1. Fill the oil pump assembly with engine oil through the feed port a and scavenge port b . Note: the oil level s...

  • Page 177: Powr

    5-52 e powr 1 2 3 4 5 6 7 8 9 camshaft cylinder head cover removal step procedure/part name q ’ ty service points 1 clamp/breather hose 2/1 È to cylinder block 2 oil filler cap 1 3 o-ring 1 not reusable 4 bolt 8 5 ignition coil 4 6 spark plug 4 7 bolt 1 8 cam position sensor 1 9 bolt 8 10 cylinder h...

  • Page 178: Powr

    5-53 e powr camshaft and timing chain removal step procedure/part name q ’ ty service points 1 oil level gauge 1 2 bolt 1 3 plug 1 4 oil level pipe 1 5 o-ring 1 not reusable 6 bolt 2 7 gasket 4 not reusable 8 oil pipe 1 a yellow paint 9 bolt 2 note: loosen the timing chain tensioner bolts evenly. D ...

  • Page 179: Powr

    5-54 e powr 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 10 timing chain tensioner 1 11 gasket 1 not reusable 12 timing chain guide (exhaust side) 1 13 bolt 24 14 camshaft cap 2 note: • install the camshaft caps so that the arrow marks b point toward the timing chain. • the exhau...

  • Page 180: Powr

    5-55 e powr step procedure/part name q ’ ty service points 20 bolt 2 21 chain guide plate 1 22 timing chain guide (intake side) 1 23 timing chain tensioner pad 1 24 timing chain 1 reverse the removal steps for installation. D 16 19 18 17 19 18 23 22 21 20 12 24 9 6 7 8 7 a 10 11 1 2 4 13 13 15 14 15...

  • Page 181: Powr

    5-56 e powr 1 2 3 4 5 6 7 8 9 camshaft removal 1. Remove: • camshafts removal steps: 1. Install the special service tools 1 and 2 into spark plug hole #1. 2. Position piston #1 at tdc by turning the drive coupling 3 counterclockwise with the special service tool 4 , using the dial gauge to ensure th...

  • Page 182: Powr

    5-57 e powr 7. Loosen the intake and exhaust camshaft cap bolts in the sequence shown. Note: for reference during installation, put identifica- tion marks d on the camshaft caps. 1 2 2 7 6 4 9 9 5 8 7 3 4 6 0 0 1 5 8 3 a b b a ex in d 8. Remove the intake camshaft 7 and exhaust camshaft 8 . Note: to...

  • Page 183: Powr

    5-58 e powr 1 2 3 4 5 6 7 8 9 camshaft check 1. Check: • camshaft lobes pitting/scratches → replace the cam- shaft. 2. Measure: • camshaft lobe dimensions a and b out of specification → replace the cam- shaft. Camshaft lobe dimensions: intake: a 40.9 mm (1.610 in) b 32.0 mm (1.260 in) exhaust: a 41....

  • Page 184: Powr

    5-59 e powr 5. Measure: • camshaft-journal-to-camshaft-cap clearance out of specification → replace the cyl- inder head assembly. Measurement steps: 1. Remove the valve lifters 1 and valve pads 2 . Note: make a note of the position of each valve lifter and valve pad so that they can be installed in ...

  • Page 185: Powr

    5-60 e powr 1 2 3 4 5 6 7 8 9 camshaft sprocket check 1. Check: • camshaft sprockets damage/wear → replace the camshaft sprockets and timing chain as a set. Timing chain check 1. Check: • timing chain damage/stiffness/wear → replace the timing chain and camshaft sprockets as a set. Timing chain tens...

  • Page 186: Powr

    5-61 e powr camshaft installation 1. Install: • camshafts installation steps: 1. Position piston #1 at tdc. Refer to “ camshaft removal. ” 2. Install the exhaust camshaft sprocket 1 and intake camshaft sprocket 2 . Note: • install each camshaft sprocket with the punch mark a facing outward. • when i...

  • Page 187: Powr

    5-62 e powr 1 2 3 4 5 6 7 8 9 4. Install the exhaust camshaft caps, intake camshaft caps, and bolts. 5. Gradually tighten the camshaft cap bolts to the specified torque in the sequence shown. Note: • apply engine oil to the threads of the cam- shaft cap bolts. • make sure to keep the camshafts level...

  • Page 188: Powr

    5-63 e powr 12. Turn the drive coupling 0 counterclock- wise 2 turns. Note: make sure that the camshafts turn smoothly. If the camshafts do not turn smoothly, reinstall camshafts. Refer to the installation steps. 0 13. Check that the portion g of the timing chain is taut. If the timing chain is not ...

  • Page 189: Powr

    5-64 e powr 1 2 3 4 5 6 7 8 9 valve clearance adjustment note: to measure the valve clearance, refer to “ valve clearance measurement ” in chapter 3. 1. Adjust: • valve clearance adjustment steps: 1. Remove the camshaft. Refer to “ camshaft removal. ” 2. Remove the valve lifter 1 and valve pad 2 . N...

  • Page 190: Powr

    5-65 e powr 8. Rotate the valve lifter and check that it turns smoothly. 9. Install the camshafts, timing chain, and camshaft caps. Refer to “ camshaft installation. ” 10. Install the special service tools 3 and 4 into spark plug hole #1. 11. Position piston #1 at tdc by turning the drive coupling 5...

  • Page 191: Powr

    5-66 e powr 1 2 3 4 5 6 7 8 9 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 0.00 – 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 0.03 – 0.06 120 125 130 135 14...

  • Page 192: Powr

    5-67 e powr cylinder head cylinder head assembly removal step procedure/part name q ’ ty service points 1 bolt 4 2 engine hanger 2 3 bolt 3 4 cylinder head bolt 10 not reusable 5 washer 10 6 cylinder head assembly 1 7 gasket 1 not reusable 8 dowel pin 2 reverse the removal steps for installation. 7 ...

  • Page 193: Powr

    5-68 e powr 1 2 3 4 5 6 7 8 9 cylinder head disassembly step procedure/part name q ’ ty service points 1 valve lifter 16 2 valve pad 16 3 valve cotter 32 4 upper spring seat 16 5 valve spring 16 6 lower spring seat 16 7 intake valve 8 8 exhaust valve 8 9 valve seal 16 not reusable 10 valve guide 16 ...

  • Page 194: Powr

    5-69 e powr cylinder head assembly removal 1. Remove: • cylinder head bolts (m6 × 55 mm) 1 • cylinder head bolts (m12 × 140 mm) 2 note: loosen the cylinder head bolts 2 in the sequence shown. 1 9 5 7 3 4 0 8 2 6 2 2 2 2 2 2 1 valve removal 1. Remove: • valve lifter 1 • valve pad 2 note: make a note ...

  • Page 195: Powr

    5-70 e powr 1 2 3 4 5 6 7 8 9 2. Measure: • cylinder head warpage out of specification → replace the cyl- inder head. Measurement steps: 1. Eliminate carbon deposits from the com- bustion chambers. 2. Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in the directions show...

  • Page 196: Powr

    5-71 e powr 2. Measure: • valve face width a out of specification → replace the valve. Valve face width a: intake and exhaust: 2.26 – 2.83 mm (0.089 – 0.111 in) a • valve margin thickness b out of specification → replace the valve. Valve margin thickness b: intake and exhaust: 0.80 – 1.20 mm (0.031 ...

  • Page 197: Powr

    5-72 e powr 1 2 3 4 5 6 7 8 9 valve guide check 1. Measure: • valve guide inside diameter a valve guide inside diameter: intake and exhaust: 5.504 – 5.522 mm (0.2167 – 0.2174 in) a 2. Calculate: • valve stem-to-valve guide clearance out of specification → replace the valve and valve guide. Valve ste...

  • Page 198: Powr

    5-73 e powr valve guide installation 1. Install: • new valve guide 1 installation steps: 1. Insert the special service tools 2 and 3 into the camshaft end of a new valve guide 1. 2. Strike the special service tool to drive the valve guide into the cylinder head. 3. Insert the special service tool 4 ...

  • Page 199: Powr

    5-74 e powr 1 2 3 4 5 6 7 8 9 valve seat check 1. Measure: • valve seat contact does not seat properly → reface the valve seat. Measurement steps: 1. Eliminate carbon deposits from the valves and valve seats. 2. Apply a thin, even layer of mechanic ’ s blueing dye (dykem) onto the valve seat. 3. Pre...

  • Page 200: Powr

    5-75 e powr valve seat refacing caution: do not over cut the valve seat. Be sure to turn the cutter evenly downward at a pres- sure of 40 – 50 n (4 – 5 kgf, 8.8 – 11 lbf) to pre- vent chatter marks. Note: does not turn the special service tool counter- clockwise when refacing the valve seat. 1. Refa...

  • Page 201: Powr

    5-76 e powr 1 2 3 4 5 6 7 8 9 2. Use a 30 ° cutter to adjust the contact width of the top edge of the valve seat. B previous contact width 30 ˚ b 3. Use a 60 ° cutter to adjust the contact width of the bottom edge of the valve seat. B previous contact width 60 ˚ b 4. Use a 45 ° cutter to adjust the ...

  • Page 202: Powr

    5-77 e powr • if the valve seat contact width is too narrow and situated near the bottom edge of the valve face, use a 60 ° cutter to cut the bottom edge of the valve seat, and then use a 45 ° cutter to center the area and set its width. B previous contact width 60 ˚ b 6. After refacing the valve se...

  • Page 203: Powr

    5-78 e powr 1 2 3 4 5 6 7 8 9 valve installation 1. Install: • valve seal 1 • valve 2 • lower spring seat 3 • valve spring 4 • upper spring seat 5 • valve cotters 6 installation steps: 1. Install a new valve seal 1 onto the valve guide. Caution: do not reuse the valve seal, always replace it with a ...

  • Page 204: Powr

    5-79 e powr 4. Lightly tap the upper spring seat with a plastic hammer to set the valve cotters 6 securely. 6 6 cylinder head installation 1. Install: • cylinder head caution: do not reuse the cylinder head bolts 1 and the cylinder head gasket, always replace them with new ones. Installation steps: ...

  • Page 205: Powr

    5-80 e powr 1 2 3 4 5 6 7 8 9 generator cover and flywheel magneto generator cover and flywheel magneto removal step procedure/part name q ’ ty service points 1 plug 1 2 drive coupling 1 3 washer 1 4 plastic tie 1 5 grommet 2 6 bolt/washer 2/2 7 bracket 2 8 clamp/hose 1/1 9 bolt 9 10 clamp 1 11 gene...

  • Page 206: Powr

    5-81 e powr 1 step procedure/part name q ’ ty service points 14 transfer shaft 1 15 bolt 6 16 flywheel magneto 1 17 woodruff key 1 18 starter clutch assembly 1 caution: make sure that the starter clutch is in- stalled into the outer flange so that the side a is facing toward the flywheel mag- neto a...

  • Page 207: Powr

    5-82 e powr 1 2 3 4 5 6 7 8 9 generator cover disassembly step procedure/part name q ’ ty service points 1 bolt 2 2 bolt 1 3 washer 1 4 bolt 3 5 bolt 2 6 clamp 1 7 stator coil assembly 1 8 oil seal 1 not reusable 9 circlip 1 10 bearing 1 not reusable 11 generator cover 1 reverse the disassembly step...

  • Page 208: Powr

    5-83 e powr drive coupling removal 1. Remove: • drive coupling 1 removal steps: 1. Remove the plug from the drive coupling. 2. Hold the transfer shaft with the special ser- vice tool 2, and then remove the drive coupling 1 with the special service tool 3. Crankshaft holder 2: yb-06562/90890-06562 co...

  • Page 209: Powr

    5-84 e powr 1 2 3 4 5 6 7 8 9 2. Remove: • flywheel magneto 1 removal steps: 1. Remove the flywheel magneto 1 with the special service tools 2 and 3. 2. Remove the flywheel magneto bolts 4, and then remove the starter clutch assem- bly 5. Flywheel puller 2: 90890-06723 rotor puller 3: 90890-01080 1 ...

  • Page 210: Powr

    5-85 e powr transfer shaft check 1. Check: • transfer shaft cracks/damage → replace the transfer shaft. Starter clutch check 1. Check: • starter clutch rollers cracks/damage → replace the starter clutch assembly. 2. Check: • starter gear cracks/damage → replace the starter gear. 3. Check: • starter ...

  • Page 211: Powr

    5-86 e powr 1 2 3 4 5 6 7 8 9 bearing installation caution: do not reuse the bearing, always replace it with a new one. 1. Install: • bearing 1 • circlip 2 È for usa and canada É for worldwide driver handle (large): yb-06071 forward gear outer race installer: yb-41446 driver rod ls: 90890-06606 ball...

  • Page 212: Powr

    5-87 e powr generator cover assembly 1. Install: • stator coil assembly 1 note: pass the pickup coil lead 2 between the cover and the bolt hole a, and then hold the washer 3. T r . . Clamp bolt 4: 15 n · m (1.5 kgf · m, 11.1 ft · lb) stator coil bolt 5: 15 n · m (1.5 kgf · m, 11.1 ft · lb) washer bo...

  • Page 213: Powr

    5-88 e powr 1 2 3 4 5 6 7 8 9 2. Install: • starter gear 1 • woodruff key 2 • flywheel magneto 3 • transfer shaft 4 installation steps: 1. Install the starter gear 1, woodruff key 2, flywheel magneto 3, and transfer shaft 4. Note: be sure to remove any grease from the tapered portion a of the cranks...

  • Page 214: Powr

    5-89 e powr drive coupling installation 1. Install: • drive coupling 1 installation step: 1. Hold the transfer shaft with the special ser- vice tool 2, and then tighten the drive cou- pling 1 with the special service tool 3. Crankshaft holder 2: yb-06562/90890-06562 coupler wrench 3: 90890-06729 t r...

  • Page 215: Powr

    5-90 e powr 1 2 3 4 5 6 7 8 9 oil separator tank and oil pan oil separator tank and oil pan removal step procedure/part name q ’ ty service points 1 bolt 2 2 thermoswitch 1 3 plastic tie 1 4 knock sensor 1 5 bolt 1 6 bolt 1 7 gasket 1 not reusable 8 anode 1 9 grommet 1 10 cover 1 11 clamp/oil return...

  • Page 216: Powr

    5-91 e powr step procedure/part name q ’ ty service points 12 engine temperature sensor 1 13 washer 1 14 bolt 3 15 earth plate 1 16 o-ring 1 17 clamp/oil hose 1/1 18 plastic tie 1 19 clamp/cooling water hose 1/1 note: install the cooling water hose with the white paint a facing away from the crankca...

  • Page 217: Powr

    5-92 e powr 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 20 band 1 not reusable 21 clamp/cooling water hose 1/1 22 bolt 1 23 oil pressure switch 1 24 bolt 9 25 water jacket cover 1 26 gasket 1 not reusable 27 bolt 9 28 bolt 2 29 oil separator tank cover 1 27 17 28 29 30 23 22 25 ...

  • Page 218: Powr

    5-93 e powr step procedure/part name q ’ ty service points 30 gasket 1 not reusable 31 bolt 16 32 bolt 1 33 bolt 1 34 oil pan assembly 1 35 dowel pin 2 reverse the removal steps for installation. 27 17 28 29 30 23 22 25 26 16 15 24 14 13 12 11 10 9 8 21 18 19 19 20 32 31 35 34 a 33 7 6 5 4 1 2 3 8 ×...

  • Page 219: Powr

    5-94 e powr 1 2 3 4 5 6 7 8 9 oil pan disassembly step procedure/part name q ’ ty service points 1 bolt 10 2 baffle plate 1 3 bolt/washer 3/3 4 bolt/washer 1/1 5 bolt 3 6 oil pipe 1 1 7 oil pipe 2 1 8 gasket 1 1 not reusable 9 gasket 2 1 not reusable 10 grommet 1 11 oil pan 1 reverse the disassembly...

  • Page 220: Powr

    5-95 e powr oil pan check 1. Check: • baffle plate 1 clog/contaminants → clean the baffle plate. Cracks/damage → replace the baffle plate. • oil pan 2 cracks/damage → replace the oil pan. 1 2 2. Check: • oil pipe clog/contaminants → clean the oil pipe. Cracks/damage → replace the oil pipe. Oil separ...

  • Page 221: Powr

    5-96 e powr 1 2 3 4 5 6 7 8 9 crankcase, connecting rod, and piston crankcase, connecting rod, and piston disassembly step procedure/part name q ’ ty service points 1 bolt 12 2 bracket 1 2 3 bracket 2 2 4 dowel pin 8 5 bolt 1 6 baffle plate 1 7 bolt 12 8 bolt 10 not reusable 9 crankcase 1 10 dowel 1...

  • Page 222: Powr

    5-97 e powr step procedure/part name q ’ ty service points 11 o-ring 1 not reusable 12 crankshaft journal bearing 10 13 nut 8 14 connecting rod cap 4 15 connecting rod bearing 8 16 crankshaft 1 17 piston pin clip 8 not reusable 18 piston pin 4 19 piston 4 20 1t y 2t 21 22 19 18 17 24 23 15 15 1 14 1...

  • Page 223: Powr

    5-98 e powr 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 20 top ring 4 21 2nd ring 4 22 oil ring 4 23 connecting rod 4 24 bolt 8 not reusable 25 cylinder block 1 reverse the disassembly steps for assembly. 20 1t y 2t 21 22 19 18 17 24 23 15 15 1 14 13 10 11 2 1 4 4 9 8 6 5 3 12 1...

  • Page 224: Powr

    5-99 e powr crankcase disassembly 1. Remove: • crankcase bolts (m6 × 70 mm) 1 – b • crankcase bolts (m8 × 85 mm) c – l note: • place the crankcase upside down on a bench. • the numbers embossed on the crankcase indicate the crankcase tightening sequence. F h l j d c i k g e 3 1 9 a 7 5 6 2 8 b 0 4 2...

  • Page 225: Powr

    5-100 e powr 1 2 3 4 5 6 7 8 9 2. Remove: • piston pin clips 1 • piston pin 2 • piston 3 • connecting rod 4 • connecting rod cap bolts 5 note: for reference during installation, put identifica- tion marks a on the piston crown and con- necting rod. 3. Remove: • top ring • 2nd ring • oil ring a a 4 5...

  • Page 226: Powr

    5-101 e powr piston check 1. Check: • piston wall vertical scratches → replace the piston and piston rings as a set. 2. Measure: • piston outside diameter a out of specification → replace the pis- ton. Piston outside diameter a: 85.915 – 85.930 mm (3.3825 – 3.3831 in) measuring point b: 10.0 mm (0.3...

  • Page 227: Powr

    5-102 e powr 1 2 3 4 5 6 7 8 9 piston ring check 1. Measure: • piston ring dimensions b and t out of specification → replace the pis- ton rings as a set. Piston ring dimensions: top ring a : b: 1.17 – 1.19 mm (0.0461 – 0.0469 in) t: 2.85 – 3.05 mm (0.112 – 0.120 in) 2nd ring b : b: 1.17 – 1.19 mm (0...

  • Page 228: Powr

    5-103 e powr 3. Measure: • piston ring grooves out of specification → replace the pis- ton. Note: before measuring the piston ring grooves, eliminate any carbon deposits from the piston ring grooves. Piston ring groove: top ring a : 1.21 – 1.23 mm (0.0476 – 0.0484 in) 2nd ring b : 1.21 – 1.23 mm (0....

  • Page 229: Powr

    5-104 e powr 1 2 3 4 5 6 7 8 9 connecting rod check 1. Measure: • connecting rod small end inside diameter a out of specification → replace the con- necting rod assembly. Connecting rod small end inside diameter a: 22.015 – 22.028 mm (0.8667 – 0.8672 in) a cylinder check 1. Check: • cylinder wall ve...

  • Page 230: Powr

    5-105 e powr crankshaft check 1. Measure: • crankshaft journal a diameter • crankshaft pin b diameter out of specification → replace the crankshaft. Crankshaft journal a diameter: 39.976 – 40.000 mm (1.5739 – 1.5748 in) crankshaft pin b diameter: 41.976 – 42.000 mm (1.6526 – 1.6535 in) a b 2. Measur...

  • Page 231: Powr

    5-106 e powr 1 2 3 4 5 6 7 8 9 2. Install the upper bearing into the connect- ing rod and lower bearing into the connect- ing rod cap. Note: • install the connecting rod bearings in their original positions. • insert the projection a of each bearing into the slots in the connecting rod cap and con- ...

  • Page 232: Powr

    5-107 e powr 3 2. Select: • connecting rod bearing selecting steps: 1. Check the connecting rod size number a on the connecting rod. 2. Check the crankshaft pin size number b on the crankshaft web. 3. Select the suitable color c for the con- necting rod bearing from the table. Example: “ p1 ” connec...

  • Page 233: Powr

    5-108 e powr 1 2 3 4 5 6 7 8 9 crankshaft journal oil clearance check 1. Measure: • crankshaft journal oil clearance out of specification → replace the crankshaft journal bearings. Measurement steps: 1. Clean the bearings, crankshaft journals, and bearing portions of the crankcase and cylinder block...

  • Page 234: Powr

    5-109 e powr 8. Tighten the crankcase bolts to the speci- fied torques in 2 stages in the sequence shown. Note: • apply engine oil to the crankcase bolts threads. • do not turn the crankshaft until the crank- shaft journal oil clearance measurement has been completed. 9. Remove the crankcase and mea...

  • Page 235: Powr

    5-110 e powr 1 2 3 4 5 6 7 8 9 2. Select: • crankshaft main journal bearing selecting steps: 1. Check the crankcase journal size number a on the crankcase. Note: if the crankcase journal sizes are the same at all positions, the size number a is stamped only at the “ j1 ” position. Example: if “ j1 ”...

  • Page 236: Powr

    5-111 e powr connecting rod and piston installation 1. Install: • piston 1 • connecting rod 2 • piston pin 3 • piston pin clips 4 • connecting rod cap bolts 5 caution: do not reuse the piston pin clips 4 and connecting rod cap bolts 5, always replace them with new ones. Note: • when installing the c...

  • Page 237: Powr

    5-112 e powr 1 2 3 4 5 6 7 8 9 3. Offset: • piston ring end gap a top ring, oil ring expander spacer b 2nd ring c upper oil ring rail d lower oil ring rail È intake side b d c a È 90 ˚ 45 ˚ 45 ˚ 90 ˚ 4. Install: • connecting rod bearings 1 • connecting rod cap 2 • connecting rod assembly 3 installat...

  • Page 238: Powr

    5-113 e powr crankcase assembly 1. Install • dowel pin 1 • o-ring 2 note: • thoroughly clean all the gasket surfaces and crankcase mating surfaces. • apply sealant to the mating surface of the crankcase. • do not get away sealant on the main bear- ing. 2. Install: • crankcase bolts (m10 × 85 mm) 1 •...

  • Page 239: Powr

    5-114 e powr 1 2 3 4 5 6 7 8 9 3. Tighten: • bracket bolts note: tighten the bolts a, and then tighten the bolts b. T r . . Bracket bolt: 50 n · m (5.0 kgf · m, 36.9 ft · lb) loctite 271 a b a b lt 271 crankcase, connecting rod, and piston.

  • Page 240: Powr

    5-115 e powr cooling water cooling water hose routing 1 hose joint 2 2 hose joint 3 È to hose joint 1 É to cooling water pilot outlet on port side Ê to cooling water pilot outlet on starboard side 1 2 È Ê É É cooling water.

  • Page 241: Powr

    5-116 e powr 1 2 3 4 5 6 7 8 9 thermostat removal 1 hose joint 1 2 hose joint 3 3 hose joint 4 É to transom plate Ê to hose joint 2 step procedure/part name q ’ ty service points 1 clamp/cooling water hose 1/1 È to drain joint 2 bolt 2 3 thermostat housing 1 4 thermostat 1 note: install the thermost...

  • Page 242: Powr

    5-117 e powr cooling water line check 1. Check: • thermostat housing 1 • hose joints 2 • cooling water hoses cracks/damage → replace. 1 2 2 thermostat check 1. Check: • thermostat valve opening a out of specification → replace the ther- mostat. Checking steps: 1. Suspend the thermostat 1 in a contai...

  • Page 243: Powr

    5-118 e powr 1 2 3 4 5 6 7 8 9 — memo — cooling water.

  • Page 244: Jet

    E jet pump chapter 6 jet pump unit intake grate and ride plate............................................................................. 6-1 intake grate and ride plate removal ........................................................... 6-1 jet pump unit..............................................

  • Page 245: Jet

    E jet pump 1 2 3 4 5 6 7 8 9 intermediate housing................................................................................... 6-22 intermediate housing removal ................................................................. 6-22 intermediate housing disassembly ................................

  • Page 246: Jet

    6-1 e jet pump intake grate and ride plate intake grate and ride plate removal step procedure/part name q ’ ty service points 1 bolt 2 2 bolt 8 3 intake grate 1 4 screw 4 5 speed sensor 1 fx sho speed and water temperature sensor 1 fx cruiser sho 6 ride plate 1 7 spacer 1 reverse the removal steps f...

  • Page 247: Jet

    6-2 e jet pump 1 2 3 4 5 6 7 8 9 jet pump unit jet pump unit removal step procedure/part name q ’ ty service points ride plate refer to “ intake grate and ride plate. ” 1 shift cable joint 1 2 qsts rod joint 1 3 nut/washer 1/2 4 steering cable joint 1 5 clamp/bilge hose 1/1 6 clamp/spout hose 1/1 7 ...

  • Page 248: Jet

    6-3 e jet pump step procedure/part name q ’ ty service points 11 jet pump unit assembly 1 12 dowel pin 2 13 bolt/washer 2/2 14 gasket 2 not reusable 15 stay 1 reverse the removal steps for installation. 8 × 13 mm 15 n · m (1.5 kgf · m, 11.1 ft · ib) 6 × 22 mm 7 n · m (0.7 kgf · m, 5.2 ft · ib) 8 n ·...

  • Page 249: Jet

    6-4 e jet pump 1 2 3 4 5 6 7 8 9 jet pump unit removal warning be sure to remove the battery before re- moving the jet pump unit. 1. Remove: • intake grate 1 • speed sensor 2 (fx sho) speed and water temperature sensor 2 (fx cruiser sho) • ride plate 3 2 1 3 2. Remove: • steering cable joint 1 • shi...

  • Page 250: Jet

    6-5 e jet pump jet pump unit installation warning be sure to remove the battery before in- stalling the jet pump unit. 1. Install: • jet pump unit 1 note: rotate the drive shaft 2 to align the splines on the drive shaft with the splines on the inside of the intermediate drive shaft. 2. Install: • ru...

  • Page 251: Jet

    6-6 e jet pump 1 2 3 4 5 6 7 8 9 reverse gate reverse gate removal step procedure/part name q ’ ty service points 1 clamp/spout hose 1/1 2 bolt/collar 2/2 3 reverse gate assembly 1 4 nut/washer 2/2 5 shift cable ball joint/washer 1/1 6 bolt 1 7 collar 1 8 spring 1 note: install the spring as shown. ...

  • Page 252: Jet

    6-7 e jet pump step procedure/part name q ’ ty service points 11 bracket 2 1 12 reverse gate stay 2 13 bolt 1 14 bracket 1 1 reverse the removal steps for installation. 2 7 9 11 8 1 5 4 4 10 10 12 3 14 10 2 13 12 6 6 9 8 1 n · m (0.1 kgf · m, 0.7 ft · ib) 8 × 14 mm 20 n · m (2.0 kgf · m, 14.8 ft · i...

  • Page 253: Jet

    6-8 e jet pump 1 2 3 4 5 6 7 8 9 jet thrust nozzle and nozzle ring jet thrust nozzle and nozzle ring removal step procedure/part name q ’ ty service points jet pump unit assembly refer to “ jet pump unit. ” reverse gate refer to “ reverse gate. ” 1 bolt/collar 2/2 2 jet thrust nozzle 1 3 bolt/collar...

  • Page 254: Jet

    6-9 e jet pump impeller duct and impeller housing impeller duct and impeller housing removal step procedure/part name q ’ ty service points nozzle ring refer to “ jet thrust nozzle and nozzle ring. ” 1 bolt 4 2 nozzle 1 3 dowel pin 2 4 impeller duct assembly 1 5 impeller housing 1 6 dowel pin 2 7 bo...

  • Page 255: Jet

    6-10 e jet pump 1 2 3 4 5 6 7 8 9 impeller duct and drive shaft impeller duct and drive shaft disassembly step procedure/part name q ’ ty service points 1 impeller 1 note: the impeller has left-hand threads. 2 spacer 1 3 bolt 3 4 cap 1 5 o-ring 1 not reusable 6 nut 1 7 washer 1 ep a a a a a a 69 n ·...

  • Page 256: Jet

    6-11 e jet pump step procedure/part name q ’ ty service points 8 drive shaft 1 9 rear bearing 1 not reusable inside diameter: 25 mm (0.98 in) 10 spacer 1 11 oil seal 1 not reusable 12 oil seal 1 not reusable 13 front bearing 1 not reusable inside diameter: 30 mm (1.18 in) 14 impeller duct 1 reverse ...

  • Page 257: Jet

    6-12 e jet pump 1 2 3 4 5 6 7 8 9 drive shaft removal 1. Remove: • impeller 1 • spacer 2 • cap 3 • nut 4 note: the impeller has left-hand threads. Turn the impeller clockwise to loosen it. Drive shaft holder 5: yb-06201 drive shaft holder 6 5: 90890-06520 1 2 4 3 5 1 4 5 2. Remove: • drive shaft 1 n...

  • Page 258: Jet

    6-13 e jet pump 3. Remove: • rear bearing È for usa and canada É for worldwide slide hammer and adapters 1: yb-06096 stopper guide plate 2: 90890-06501 bearing puller assembly 3: 90890-06535 stopper guide stand 4: 90890-06538 È 3 4 4 2 É 4. Remove: • oil seals È for usa and canada É for worldwide sl...

  • Page 259: Jet

    6-14 e jet pump 1 2 3 4 5 6 7 8 9 5. Remove: • front bearing È for usa and canada É for worldwide driver handle (large) 1: yb-06071 drive shaft needle bearing installer and remover 2: yb-06194 driver rod l3 3: 90890-06652 needle bearing attachment 4: 90890-06609 1 1 2 2 È 2 3 4 É 3 3 4 4 É impeller ...

  • Page 260: Jet

    6-15 e jet pump 2. Measure: • drive shaft runout out of specification → replace the drive shaft. Drive shaft runout limit: 0.3 mm (0.012 in) measuring point a: 310 mm (12.20 in) a drive shaft installation 1. Install: • oil seal 1 • oil seal 2 note: install the oil seal 1 halfway into the impeller du...

  • Page 261: Jet

    6-16 e jet pump 1 2 3 4 5 6 7 8 9 3. Install: • drive shaft assembly (with front bearing) • spacer bearing attachment 1: 90890-06728 1 a a 4. Apply: • epnoc grease ap #0 (between the drive shaft and spacer) quantity: 20 g (0.04 lb) ep ep 5. Install: • rear bearing 1 bearing attachment 2: 90890-06728...

  • Page 262: Jet

    6-17 e jet pump 8. Install: • spacer 1 • impeller 2 note: the impeller has left-hand threads. Turn the impeller counterclockwise to tighten it. Drive shaft holder 3: yb-06201 drive shaft holder 6 3: 90890-06520 t r . . Impeller: 110 n · m (11.0 kgf · m, 81.1 ft · lb) loctite 572 2 1 lt 572 lt a a 3 ...

  • Page 263: Jet

    6-18 e jet pump 1 2 3 4 5 6 7 8 9 transom plate and hoses transom plate and hose removal step procedure/part name q ’ ty service points exhaust system refer to “ exhaust system ” in chapter 8. Jet pump unit assembly refer to “ jet pump unit. ” 1 clamp/cooling water hose 2/1 2 cap 1 3 nut 1 4 clamp/f...

  • Page 264: Jet

    6-19 e jet pump step procedure/part name q ’ ty service points 11 clamp/bilge hose 1/1 12 clamp/bilge hose 2/1 13 hose joint 1 14 band 1 15 clamp/bilge hose 2/1 16 electric bilge pump assembly 1 17 clamp/bilge hose 2/1 18 nut 1 19 gasket 1 not reusable 20 pilot outlet 1 21 clamp/bilge hose 2/1 22 nu...

  • Page 265: Jet

    6-20 e jet pump 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 23 drain joint 2 note: align the projections a with the holes b on the hull. 24 packing 2 not reusable 25 plastic tie 1 26 hose joint 1 27 clamp/cooling water hose 2/1 28 clamp/bilge hose 1/1 29 nut/washer 4/4 30 transo...

  • Page 266: Jet

    6-21 e jet pump water hose check 1. Check: • bilge hoses • cooling water hoses cracks/damage → replace. Transom plate installation 1. Install: • transom plate note: clean the contacting surfaces before applying silicone sealant. T r . . Transom plate nut: 26 n · m (2.6 kgf · m, 19.2 ft · lb) ss tran...

  • Page 267: Jet

    6-22 e jet pump 1 2 3 4 5 6 7 8 9 intermediate housing intermediate housing removal *: as required step procedure/part name q ’ ty service points engine unit refer to “ engine unit ” in chapter 5. 1 rubber damper 1 2 band 1 not reusable 3 grease hose 1 4 bolt 3 5 intermediate housing assembly 1 6 do...

  • Page 268: Jet

    6-23 e jet pump intermediate housing disassembly step procedure/part name q ’ ty service points 1 band 1 not reusable 2 grease hose 1 3 nipple 1 4 driven coupling 1 5 washer 1 6 intermediate drive shaft 1 7 o-ring 2 not reusable 8 thrust washer 1 not reusable 9 oil seal 1 not reusable 10 oil seal 2 ...

  • Page 269: Jet

    6-24 e jet pump 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 12 bearing 1 not reusable 13 intermediate housing 1 reverse the disassembly steps for assembly. Lt 572 lt 1 2 3 10 11 a a a a 12 13 8 9 11 10 lt 572 lt a a 4 5 6 7 36 n · m (3.6 kgf · m, 26.6 ft · ib) 5 n · m (0.5 kgf ·...

  • Page 270: Jet

    6-25 e jet pump intermediate housing removal 1. Remove: • intermediate housing assembly 1 • shims 2 note: make a note of the position of each removed shim 2 so that it can be installed in its original position. 2 1 driven coupling removal 1. Remove: • driven coupling 1 note: make sure that the speci...

  • Page 271: Jet

    6-26 e jet pump 1 2 3 4 5 6 7 8 9 oil seal removal 1. Remove: • oil seal (front) • oil seals (rear) È for usa and canada É for worldwide slide hammer and adapters 1: yb-06096 bearing puller legs 2: yb-06523 stopper guide plate 3: 90890-06501 bearing puller assembly 4: 90890-06535 stopper guide stand...

  • Page 272: Jet

    6-27 e jet pump driven coupling and intermediate housing check 1. Check: • driven coupling 1 • rubber damper 2 • intermediate housing 3 cracks/damage → replace. 1 2 3 bearing installation caution: do not reuse the bearing, always replace it with a new one. 1. Install: • circlip 1 • bearing 2 install...

  • Page 273: Jet

    6-28 e jet pump 1 2 3 4 5 6 7 8 9 oil seal installation 1. Install: • oil seal 1 È for usa and canada É for worldwide driver handle (large) 2: yb-06071 needle bearing installer 3: yb-06434 driver rod ls 4: 90890-06606 bearing outer race attachment 5: 90890-06623 distance a: 6.5 ± 0.2 mm (0.26 ± 0.01...

  • Page 274: Jet

    6-29 e jet pump 5. Install: • thrust washer 1 bearing attachment 2: 90890-06727 distance a: 4.4 ± 0.3 mm (0.17 ± 0.01 in) 2 1 a driven coupling installation 1. Install: • driven coupling 1 note: make sure that the special service tool 2 is inserted completely into the intermediate drive shaft. Shaft...

  • Page 275: Jet

    6-30 e jet pump 1 2 3 4 5 6 7 8 9 — memo — intermediate housing.

  • Page 276: Elec

    E elec – + chapter 7 electrical system electrical components................................................................................... 7-1 electrical box.................................................................................................. 7-3 electrical components ................

  • Page 277: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 starting system ............................................................................................ 7-47 fuse......................................................................................................... 7-47 left handlebar switch assembly ..............

  • Page 278: Elec

    E elec – + 7-1 electrical components p q o s t u r n m l j i h g f e d c a b 0 9 8 7 4 3 2 1 k 5 6 1 remote control receiver 2 multifunction meter 3 right operation button assembly (fx cruiser sho) 4 steering sensor 5 buzzer 6 reverse sensor 7 right handlebar switch assembly 8 fuel injectors 9 therm...

  • Page 279: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-2 p q o s t u r n m l j i h g f e d c a b 0 9 8 7 4 3 2 1 k 5 6 j speed sensor (fx sho) speed and water temperature sensor (fx cruiser sho) k thermo sensor l starter motor m rectifier regulator n cam position sensor o spark plugs and ignition coils p oil pressure switc...

  • Page 280: Elec

    E elec – + 7-3 electrical box electrical components 0 9 8 7 6 4 3 2 1 5 1 starter relay 2 main and fuel pump relay 3 etv relay 4 slant detection switch 5 ecm 6 fuse (30 a) (battery) 7 fuse (10 a) (main and fuel pump relay) 8 fuse (10 a) (etv relay) 9 fuse (3 a) (remote control receiver) 0 fuse (20 a...

  • Page 281: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-4 electrical box disassembly step procedure/part name q ’ ty service points 1 ecm coupler 3 2 main and fuel pump relay coupler 1 3 etv relay coupler 1 4 slant detection switch coupler 1 5 fuse box coupler 2 6 wiring harness assembly 1 7 bolt 4 8 ecm 1 9 collar/grommet ...

  • Page 282: Elec

    E elec – + 7-5 step procedure/part name q ’ ty service points 11 slant detection switch 1 note: install the slant detection switch with the “ up ” mark a facing upward. 12 bolt 2 13 fuse box assembly 1 14 electrical box case 1 reverse the disassembly steps for assembly. Up 4 n · m (0.4 kgf · m, 3.0 ...

  • Page 283: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-6 fuse box disassembly step procedure/part name q ’ ty service points 1 screw/washer 2/2 2 stay 1 3 main and fuel pump relay 1 4 etv relay 1 5 damper 1 6 cap 1 7 packing 1 not reusable 8 fuse puller 1 9 bolt 6 10 cover 1 11 gasket 1 not reusable 12 screw 3 a a 8 12 14 ...

  • Page 284: Elec

    E elec – + 7-7 step procedure/part name q ’ ty service points 13 clamp 1 14 plate 1 15 bolt 2 16 boot 2 17 starter motor cable 1 a white tape È to starter motor 18 positive battery cable 1 b gray tape É to battery 19 starter relay 1 caution: the starter motor will not function if the cables are reve...

  • Page 285: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-8 step procedure/part name q ’ ty service points 20 bolt 3 21 lead 1 red lead 22 lead 1 brown lead 23 lead 1 black lead 24 housing 1 reverse the disassembly steps for assembly. A a 8 12 14 20 23 12 13 7 6 6 × 25 mm 6 × 20 mm 6 × 10 mm 6 × 10 mm 6 × 7 mm 24 È É 18 22 21...

  • Page 286: Elec

    E elec – + 7-9 electrical analysis check using the ydis when checking the tps, aps, or other sen- sors, use the ydis. When deleting the diagnosis record in the ydis, be sure to check the time that the diag- nostic codes were detected. When checking the input voltage of a part, the coupler or connect...

  • Page 287: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-10 input voltage measurement push the unlock button 1 on the remote con- trol transmitter so that power is supplied to the ecm. Note: to check that the remote control transmitter is working correctly, refer to “ remote control transmitter. ” 1 peak voltage measurement ...

  • Page 288: Elec

    E elec – + 7-11 note: • before measuring the peak voltage, check all wiring for proper connection and corrosion, and check that the battery is fully charged. • use the peak voltage adapter with the rec- ommended digital circuit tester. • connect the positive pin of the peak voltage adapter to the po...

  • Page 289: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-12 4. Using the “ stationary test ” of the ydis, observe the ignition spark through the dis- charge window in the special service tool. Warning • when checking the spark gap, do not touch any of the connections of the spe- cial service tool leads. • when performing the...

  • Page 290: Elec

    E elec – + 7-13 3. Measure: • ecm output peak voltage within specification → replace the igni- tion coil. Below specification → check the pickup coil. Refer to “ pickup coil. ” warning when checking the electrical components, do not touch any of the connections of the digital tester leads. Measureme...

  • Page 291: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-14 pickup coil 1. Measure: • pickup coil output peak voltage below specification → measure the pickup coil resistance. Measurement steps: 1. Disconnect the pickup coil coupler 1. 2. Connect the test harness (3 pins) 2 to the pickup coil coupler 1. 3. Measure the pickup...

  • Page 292: Elec

    E elec – + 7-15 2. Measure: • pickup coil resistance out of specification → replace the sta- tor coil assembly. Measurement steps: 1. Disconnect the pickup coil coupler 1. 2. Measure the pickup coil resistance. Pickup coil resistance at 20 ° c (68 ° f) (reference data): white (w) – black (b) 459 – 5...

  • Page 293: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-16 3. Measure the stator coil output peak volt- age. Note: to crank the engine, connect the engine shut- off cord (lanyard) to the engine shut-off switch, and then push the engine start switch and engine stop switch simultaneously. Stator coil output peak voltage: gree...

  • Page 294: Elec

    E elec – + 7-17 rectifier regulator 1. Measure: • rectifier regulator output peak voltage below specification → check the recti- fier regulator continuity. Measurement steps: 1. Disconnect the rectifier regulator coupler 1. 2. Connect the test harness (2 pins) 2 to the rectifier regulator coupler 1....

  • Page 295: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-18 2. Check: • rectifier regulator continuity out of specification → replace the recti- fier regulator. Checking steps: 1. Remove the rectifier regulator. Refer to “ engine unit removal 3 ” in chap- ter 5. 2. Check the rectifier regulator continuity. Note: be sure to s...

  • Page 296: Elec

    E elec – + 7-19 control system oil pressure switch 1. Measure: • oil pressure switch input voltage out of specification → check the wiring harness. Measurement steps: 1. Disconnect the oil pressure switch coupler 1. 2. Push the unlock button, and then measure the input voltage between the oil pressu...

  • Page 297: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-20 4. Check the oil pressure switch continuity. Note: use a commercially available vacuum/pres- sure pump gauge and meter. Oil pressure switch continuity: pressure terminal thread 1 – body 2 below 128 – 166 kpa (1.28 – 1.66 kgf/cm 2 , 18.2 – 23.6 psi) continuity above ...

  • Page 298: Elec

    E elec – + 7-21 2. Check: • thermoswitch continuity (at the specified temperatures) out of specification → replace the ther- moswitch. Checking steps: 1. Remove the thermoswitch. Refer to “ oil separator tank and oil pan removal ” in chapter 5. 2. Suspend the thermoswitch in a container filled with ...

  • Page 299: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-22 thermo sensor 1. Measure: • thermo sensor input voltage out of specification → check the wiring harness. Measurement steps: 1. Disconnect the thermo sensor coupler 1. 2. Push the unlock button, and then measure the input voltage at the thermo sensor cou- pler termin...

  • Page 300: Elec

    E elec – + 7-23 engine temperature sensor 1. Measure: • engine temperature sensor input voltage out of specification → check the wiring harness. Measurement steps: 1. Disconnect the engine temperature sensor coupler 1. 2. Push the unlock button, and then measure the input voltage at the engine tempe...

  • Page 301: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-24 4. Measure the resistance when the specified temperatures are reached. Engine temperature sensor resistance (reference data): black/yellow (b/y) – black/yellow (b/y) 20 ° c (68 ° f): 54.2 – 69.0 k Ω 100 ° c (212 ° f): 3.12 – 3.48 k Ω intake air temperature sensor 1....

  • Page 302: Elec

    E elec – + 7-25 2. Measure: • intake air temperature sensor input voltage within specification → measure the intake air temperature sensor resis- tance. Out of specification → check the wiring harness. Measurement steps: 1. Disconnect the intake air temperature sen- sor coupler 1. 2. Push the unlock...

  • Page 303: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-26 4. Measure the resistance when the specified temperatures are reached. Intake air temperature sensor resistance (reference data): black (b) – black (b) 0 ° c (32 ° f): 5.4 – 6.6 k Ω 80 ° c (176 ° f): 0.29 – 0.39 k Ω intake air pressure sensor 1. Measure: • intake ai...

  • Page 304: Elec

    E elec – + 7-27 2. Check: • intake air pressure sensor operation does not operate → replace the intake air pressure sensor. Checking steps: 1. Connect the special service tool to the intake air pressure sensor. 2. Connect a computer to the watercraft and use the ydis to display the intake air pres- ...

  • Page 305: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-28 knock sensor 1. Check: • knock sensor ground connection knock sensor not grounded when installed → install the knock sensor cor- rectly. Refer to “ oil separator tank and oil pan removal ” in chapter 5. 2. Measure: • knock sensor resistance out of specification → re...

  • Page 306: Elec

    E elec – + 7-29 1. Check: • throttle valve opening • tps output voltage out of specification → measure the tps input voltage. Checking steps: note: when checking the tps using the ydis, do not start the engine. 1. Connect a computer to the watercraft and use the ydis to display “ throttle position s...

  • Page 307: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-30 5. Operate the throttle lever 1, and then check the tps 2 output voltage and throt- tle valve opening angle at the fully open position É. Note: the actual tps output voltage and throttle valve opening angle may vary according to environmental conditions and engine t...

  • Page 308: Elec

    E elec – + 1 2 3 4 5 7-31 3. Check: • tps circuit no continuity → replace the wiring har- ness assembly. Wiring harness is correct → replace the throttle body assembly. Checking steps: 1. Disconnect the throttle body assembly coupler 1. 2. Disconnect the ecm couplers 2 and 3. 3. Check the wiring har...

  • Page 309: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-32 1. Connect a computer to the watercraft and use the ydis to display the “ accelerator position sensor 1 ” and “ accelerator posi- tion sensor 2. ” note: aps 1 and aps 2 are a single unit, which can- not be disassembled. 2. Check that the aps pulley stopper a con- ta...

  • Page 310: Elec

    E elec – + 7-33 2. Measure: • aps input voltage within specification → measure the aps resistance. Out of specification → check the aps circuit. Measurement steps: 1. Disconnect the aps coupler 1. 2. Push the unlock button, and then measure the input voltage at the aps coupler termi- nals (wiring ha...

  • Page 311: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-34 3. Check that the aps pulley stopper c con- tacts the fully open stopper d when the aps pulley is at the fully open position É. 4. Measure the resistance of the aps at the fully closed position and fully open posi- tion. 4. Check: • aps circuit no continuity → repla...

  • Page 312: Elec

    E elec – + 7-35 electronic throttle valve relay 1. Measure: • etv relay input voltage out of specification → check the wiring harness. Measurement steps: 1. Disconnect the etv relay coupler 1. 2. Push the unlock button, and then measure the input voltage between the etv relay coupler terminals and g...

  • Page 313: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-36 cam position sensor 1. Measure: • cam position sensor input voltage out of specification → check the wiring harness. Measurement steps: 1. Disconnect the cam position sensor cou- pler 1. 2. Push the unlock button, and then measure the input voltage at the cam positi...

  • Page 314: Elec

    E elec – + 7-37 slant detection switch 1. Measure: • slant detection switch input voltage out of specification → check the wiring harness. Measurement steps: 1. Disconnect the slant detection switch cou- pler 1. 2. Push the unlock button, and then measure the input voltage at the slant detection swi...

  • Page 315: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-38 steering sensor 1. Check: • steering sensor operation does not operate → measure the steer- ing sensor input voltage. Checking steps: 1. Connect a computer to the watercraft to use the ydis. 2. Turn the handlebar all the way to the left or right. 3. Install a plasti...

  • Page 316: Elec

    E elec – + 7-39 2. Measure: • steering sensor input voltage within specification → replace the steering sensor. Out of specification → check the wiring harness. Measurement steps: 1. Disconnect the steering sensor coupler 1. 2. Push the unlock button, and then measure the input voltage at the steeri...

  • Page 317: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-40 2. Measure: • reverse sensor input voltage within specification → replace the reverse sensor. Out of specification → check the wiring harness. Measurement steps: 1. Disconnect the reverse sensor coupler 1. 2. Push the unlock button, and then measure the input voltag...

  • Page 318: Elec

    E elec – + 7-41 2. Measure: • right handlebar switch input voltage within specification → replace the right handlebar switch assembly. Out of specification → check the wiring harness. Measurement steps: 1. Disconnect the right handlebar switch cou- pler 1. 2. Push the unlock button, and then measure...

  • Page 319: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-42 ecm circuit 1. Measure: • ecm input voltage out of specification → check the ecm circuit. Measurement steps: 1. Disconnect the ecm coupler 1. 2. Push the unlock button, and then measure the input voltage between the ecm cou- pler terminal (wiring harness end) and gr...

  • Page 320: Elec

    E elec – + 7-43 earth plate 1. Check: • earth plate continuity no continuity → replace the earth plate. Checking steps: 1. Remove the earth plate. Refer to “ oil separator tank and oil pan removal ” in chapter 5. 2. Check the continuity between each termi- nal 1 and the housing 2. 1 2 electric bilge...

  • Page 321: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-44 2. Check: • electric bilge pump operation does not operate → replace the elec- tric bilge pump. Checking steps: 1. Remove the electrical bilge pump. Refer to “ transom plate and hose removal ” in chapter 6. 2. Suspend the electric bilge pump in a con- tainer filled ...

  • Page 322: Elec

    E elec – + 7-45 2. Measure: • fuel injector input voltage out of specification → check the wiring harness. Measurement steps: 1. Disconnect the fuel injector couplers 1. 2. Push the unlock button, and then measure the input voltage between the fuel injector coupler terminals (wiring harness end) and...

  • Page 323: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-46 fuel pump module 1. Check: • fuel pump module operation sound does not sound → measure the fuel pump module input voltage. Checking steps: 1. Connect a computer to the watercraft to use the ydis. 2. Using the “ stationary test ” of the ydis, lis- ten for the fuel pu...

  • Page 324: Elec

    E elec – + 7-47 3. Measure: • fuel sender resistance out of specification → replace the fuel sender. Refer to “ fuel sender removal ” in chap- ter 4. Measurement steps: 1. Remove the fuel pump module. Refer to “ fuel tank removal ” in chapter 4. 2. Measure the fuel sender resistance. Fuel sender res...

  • Page 325: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-48 left handlebar switch assembly 1. Check: • engine start switch continuity out of specification → replace the left handlebar switch assembly. Checking steps: 1. Disconnect the left handlebar switch cou- pler. Refer to “ handlebar assembly removal ” in chapter 8. 2. C...

  • Page 326: Elec

    E elec – + 7-49 2. Check the engine stop switch continuity. Engine stop switch continuity: clip 1 engine stop switch 2 white (w) – black (b) installed È free no continuity pushed continuity removed É free continuity pushed continuity main and fuel pump relay 1. Measure: • main and fuel pump relay in...

  • Page 327: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-50 2. Check: • main relay continuity out of specification → replace the main and fuel pump relay. Checking steps: 1. Remove the main and fuel pump relay. Refer to “ fuse box disassembly. ” 2. Connect the tester leads to the main and fuel pump relay terminals 5 and 6 or...

  • Page 328: Elec

    E elec – + 7-51 checking steps: 1. Connect the tester leads to the main and fuel pump relay terminals 7 and 8. 2. Connect the positive battery lead to the main and fuel pump relay terminal 6. 3. Connect the negative battery lead to the main and fuel pump relay terminal 4. 4. Check the continuity bet...

  • Page 329: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-52 2. Check: • starter relay continuity out of specification → replace the starter relay. Checking steps: 1. Remove the starter relay. Refer to “ electrical box disassembly. ” 2. Connect the tester leads between the starter relay terminals 1 and 2. 3. Connect the posit...

  • Page 330: Elec

    E elec – + 7-53 starter motor starter motor disassembly step procedure/part name q ’ ty service points 1 bolt 2 2 gear cover assembly 1 3 circlip 1 4 drive gear 1 5 o-ring 1 not reusable 6 front cover 1 7 packing 1 not reusable 8 dowel pin 1 9 planetary gear 2 10 ring gear 1 11 bracket 1 3 4 5 1 6 7...

  • Page 331: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-54 *: as required. Step procedure/part name q ’ ty service points 12 shim * 13 rear cover 1 14 shim * 15 packing 1 not reusable 16 brush spring 4 17 armature 1 18 brush holder stay 1 19 nut 1 20 spring washer 1 21 washer 1 22 insulator washer 1 1 3 4 5 1 6 7 8 2 9 10 1...

  • Page 332: Elec

    E elec – + 7-55 step procedure/part name q ’ ty service points 23 insulator washer 2 2 24 o-ring 1 not reusable 25 terminal bolt 1 26 lead plate 1 27 terminal insulator 1 28 plate cover 1 29 starter motor yoke 1 reverse the disassembly steps for assembly. 3 4 5 1 6 7 8 2 9 10 11 12 13 14 15 18 19 20...

  • Page 333: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-56 starter motor operation 1. Check: • starter motor operation does not operate → check the starter motor. Checking steps: 1. Hold the starter motor in a vise using alu- minum plates on both sides. 2. Connect the positive battery cable 1 to the starter motor terminal b...

  • Page 334: Elec

    E elec – + 7-57 2. Measure: • commutator diameter out of specification → replace the armature. Commutator diameter: 27.0 – 28.0 mm (1.06 – 1.10 in) 3. Measure: • commutator undercut a out of specification → replace the armature. Commutator undercut a (reference data): 0.2 – 0.7 mm (0.008 – 0.028 in)...

  • Page 335: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-58 brush holder 1. Measure: • brush length a out of specification → replace the brush holder assembly. Brush length a: 5.0 – 12.5 mm (0.20 – 0.49 in) 2. Check: • brush holder continuity out of specification → replace the brush holder assembly. Brush holder continuity: ...

  • Page 336: Elec

    E elec – + 7-59 rear cover 1. Check: • rear cover 1 • metal 2 cracks/damage → replace the rear cover assembly. 2 1 starter motor assembly 1. Install: • gear cover assembly installation steps: 1. Install the ring gear 1, planetary gears 2, and dowel pin to the front cover 3. 2. Install the front cove...

  • Page 337: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-60 2. Push the lock button 5 or unlock button 6 to transmit the id code from the remote control transmitter to be registered. Note: • at this time, the system enters the registra- tion mode to register the first code. All exist- ing id codes will be deleted from the re...

  • Page 338: Elec

    E elec – + 7-61 checking steps: 1. Push the unlock button 1. The buzzer sounds 2 times. 2. Check that the “ unlock ” indicator light 2 comes on. 3. Push the unlock button 1 for more than 4 seconds. The buzzer sounds 3 times. 4. Check that the “ l-mode ” indicator light 3 comes on. 5. Push the lock b...

  • Page 339: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-62 2. Remove the battery 3. 3. Measure the battery voltage. Caution: • do not touch the internal parts except the battery. • do not touch the battery directly with your hands. Use a pair of non-conductive tweezers to replace the battery. Note: refer to local hazardous ...

  • Page 340: Elec

    E elec – + 7-63 remote control receiver 1. Measure: • remote control receiver input voltage out of specification → check the wiring harness. Measurement steps: 1. Disconnect the remote control receiver coupler 1. 2. Measure the input voltage at the remote control receiver coupler terminals (wiring h...

  • Page 341: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-64 indication system multifunction meter 1. Check: • multifunction meter external appearance cracked meter housing/meter is fogged/ shows signs of water intrusion → replace the multifunction meter. 2. Check: • multifunction meter display intermittent or missing segment...

  • Page 342: Elec

    E elec – + 7-65 3. Measure: • multifunction meter input voltage within specification → replace the mul- tifunction meter. Out of specification → check the wiring harness. Measurement steps: 1. Disconnect the multifunction meter coupler 1. 2. Push the unlock button, and then measure the input voltage...

  • Page 343: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-66 2. Check the left operation button continuity. Note: “ ” indicates a continuity of electricity. Left operation button continuity: button position leads pu/w b g/w “ speed/ rpm ” button 1 free pushed “ volt/hour ” button 2 free pushed g/w pu/w b 1 2 2. Check: • right...

  • Page 344: Elec

    E elec – + 7-67 compass display (fx cruiser sho) 1. Check: • compass display incorrect reading → check the installa- tion condition of the compass and air temperature sensor. Checking steps: 1. Using a compass for reference, point the watercraft north. 2. Select the compass display mode of the multi...

  • Page 345: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-68 air temperature display (fx cruiser sho) 1. Check: • air temperature display incorrect reading → replace the com- pass and air temperature sensor. Checking steps: 1. Measure the ambient air temperature. 2. Select the air temperature display mode of the multifunction...

  • Page 346: Elec

    E elec – + 7-69 2. Measure: • speed and water temperature sensor 1 resistance within specification → replace the com- pass and air temperature sensor. Out of specification → replace the speed and water temperature sensor. Measurement steps: 1. Disconnect the speed and water tempera- ture sensor coup...

  • Page 347: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-70 digital speedometer display (fx sho) 1. Measure: • speed sensor output voltage within specification → replace the mul- tifunction meter. Out of specification → replace the speed sensor. Measurement steps: 1. Disconnect the speed sensor coupler 1. Refer to “ steering...

  • Page 348: Elec

    E elec – + 7-71 digital speedometer display (fx cruiser sho) 1. Measure: • speed and water temperature sensor output voltage within specification → replace the mul- tifunction meter. Out of specification → replace the speed and water temperature sensor or compass and air temperature sensor. Measurem...

  • Page 349: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-72 fuel level meter display and fuel level warning indicator 1. Check: • fuel level meter display 1 and fuel level warning indicator 2 do not come on → replace the multi- function meter. Checking steps: 1. Remove the fuel pump module assembly. Refer to “ fuel tank remo...

  • Page 350: Elec

    E elec – + 7-73 diagnostic display 1. Check: • diagnostic display does not come on → check the “ diag- nosis record ” of the ydis. Checking steps: 1. Create a condition so that a diagnostic code is recorded. 2. Push the unlock button. 3. Simultaneously push the 2 buttons 1 for 8 seconds and check th...

  • Page 351: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-74 engine overheat warning indicator 1. Check: • engine overheat warning indicator does not come on → check the “ diag- nosis record ” of the ydis. Checking steps: 1. Disconnect the thermoswitch coupler 1. 2. Connect the jumper lead 2 to the ther- moswitch coupler term...

  • Page 352: Elec

    E elec – + 7-75 2. Check: • buzzer operation does not sound → replace the buzzer. Checking steps: 1. Remove the buzzer. Refer to “ steering master disassembly ” in chapter 8. 2. Connect the positive battery lead to the terminal 1 and the negative battery lead to the terminal 2. 3. Check that the buz...

  • Page 353: Elec

    E elec – + 1 2 3 4 5 6 7 8 9 7-76 — memo — indication system.

  • Page 354: Hull

    E hull hood chapter 8 hull and hood handlebar ....................................................................................................... 8-1 steering pad removal (fx sho)................................................................ 8-1 steering pad removal (fx cruiser sho) .............

  • Page 355: Hull

    E hull hood 1 2 3 4 5 6 7 8 9 hoses ............................................................................................................ 8-41 hose removal .......................................................................................... 8-41 seats and hand grip.........................

  • Page 356: Hull

    8-1 e hull hood handlebar steering pad removal (fx sho) step procedure/part name q ’ ty service points 1 screw 2 2 screw 6 3 upper handlebar cover 1 4 steering pad 1 5 screw 3 6 lower handlebar cover 1 reverse the removal steps for installation. 4 6 5 2 1 3 4 × 10 mm 1 n · m (0.1 kgf · m, 0.7 ft · i...

  • Page 357: Hull

    8-2 e hull hood 1 2 3 4 5 6 7 8 9 steering pad removal (fx cruiser sho) step procedure/part name q ’ ty service points 1 screw 8 2 screw 2 3 lower handlebar cover 1 4 upper handlebar cover 1 note: be sure to insert the projection a on the upper handlebar cover completely into the grommet. 5 bolt 4 6...

  • Page 358: Hull

    8-3 e hull hood handlebar holder removal step procedure/part name q ’ ty service points 1 throttle cable 1 note: be sure to remove the throttle cable seal as shown. 2 bolt 4 3 upper handlebar holder 2 a punch mark reverse the removal steps for installation. 8 × 48 mm 21 n · m (2.1 kgf · m, 15.5 ft ·...

  • Page 359: Hull

    8-4 e hull hood 1 2 3 4 5 6 7 8 9 handlebar assembly removal step procedure/part name q ’ ty service points 1 bolt 2 2 grip end 2 3 spacer 1 4 screw 1 5 spring washer 1 6 washer 1 7 qsts grip assembly 1 8 right handlebar grip 1 note: apply adhesive to the handlebar and the inner surface of the handl...

  • Page 360: Hull

    8-5 e hull hood step procedure/part name q ’ ty service points 10 left handlebar switch assembly 1 note: align the projection a on the handlebar switch assembly with the handlebar hole b. 11 bolt 2 note: tighten the upper bolt first when installing the right handlebar switch assembly. 12 right handl...

  • Page 361: Hull

    8-6 e hull hood 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 15 handle boss cover 1 note: • route the qsts cables 1 through the starboard side in the cutout of handle boss cover. • route the handlebar switch leads 2 and throttle cable 3 through the port side in the cutout of hand...

  • Page 362: Hull

    8-7 e hull hood left and right handlebar switch disassembly step procedure/part name q ’ ty service points 1 left handlebar switch assembly 1 2 engine shut-off cord 1 3 stop button assembly 1 4 start button assembly 1 5 screw 2 6 right handlebar switch assembly 1 7 e-ring 1 8 washer 2 9 shaft 1 10 l...

  • Page 363: Hull

    8-8 e hull hood 1 2 3 4 5 6 7 8 9 handlebar check 1. Check: • handlebar bends/cracks/damage → replace the handlebar. Handlebar switch assembly check 1. Check: • left handlebar switch assembly • right handlebar switch assembly cracks/damage → replace the handle- bar switch assembly. Note: to check th...

  • Page 364: Hull

    8-9 e hull hood installation steps: 1. Wrap the packings 1, making sure to align the upper edge a of the packing with the upper edge of the marking tape b on the lead and cable. 2. Install the packing into the grommets 2 and 3. 3. Make sure that the edge of the packing is the specified distance c fr...

  • Page 365: Hull

    8-10 e hull hood 1 2 3 4 5 6 7 8 9 2. Route: • throttle cable 1 • qsts cable 2 • right handlebar switch lead 3 • left handlebar switch lead 4 routing steps: 1. Route the throttle cable 1 as shown. 2. Make sure that the throttle cable 1, qsts cables 2, and handlebar switch leads 3 and 4 pass through ...

  • Page 366: Hull

    8-11 e hull hood 4. Install: • throttle cable installation steps: 1. Install the throttle cable end into the throt- tle lever. 2. Fit the seal 1 into the groove in the bracket. 3. Pull the throttle cable 2 in the direction of the arrow shown, and then fit the end of the seal 1 around the inner cable...

  • Page 367: Hull

    8-12 e hull hood 1 2 3 4 5 6 7 8 9 qsts grip and converter qsts grip and converter disassembly step procedure/part name q ’ ty service points jet pump unit refer to “ jet pump unit removal ” in chapter 6. Water tank refer to “ exhaust system and battery removal. ” qsts grip assembly refer to “ handl...

  • Page 368: Hull

    8-13 e hull hood step procedure/part name q ’ ty service points 8 cable guide 1 9 cable end 2 a yellow paint mark 10 bolt/washer 1/1 11 nut 1 12 pulley 1 note: before disassembly, make identification mark near the pulley stbd hole b. 13 qsts converter 1 14 nut 1 15 qsts cable 2 reverse the disassemb...

  • Page 369: Hull

    8-14 e hull hood 1 2 3 4 5 6 7 8 9 qsts cable removal 1. Remove: • qsts converter 2. Remove: • cable guide 1 note: remove the cable guide 1 with needlenose pliers as shown. 3. Remove: • qsts cable ends 1 qsts check 1. Check: • qsts grip cracks/damage/wear → replace the qsts grip. 2. Check: • qsts ca...

  • Page 370: Hull

    8-15 e hull hood 1 2 3 7 qsts cable installation 1. Install: • qsts cable ends note: • be sure to fit the qsts cable end with yellow paint mark a into the stbd hole b of the pulley. • be careful not to twist the qsts cables. Stern a b 2. Install: • qsts rod 1 note: face the hole in the joint a of th...

  • Page 371: Hull

    8-16 e hull hood 1 2 3 4 5 6 7 8 9 3. Fit the grip 4 into the housing 3. 4. Fit the qsts cables 1 into the housing 3. Note: fit the cable with the thin end a into the open- ing with the narrow groove b and the cable with the thick end c into the opening with the wide groove d. 5. Fit the cover 2 int...

  • Page 372: Hull

    8-17 e hull hood 1 2 3 4 5 front hood front hood removal step procedure/part name q ’ ty service points 1 nut 1 2 bolt 1 3 bolt 2 4 nut 1 5 bolt 1 6 damper stay 1 7 band 1 not reusable 8 boot 1 9 damper 1 10 nut 4 5 n · m (0.5 kgf · m, 3.7 ft · ib) 5 n · m (0.5 kgf · m, 3.7 ft · ib) 4 9 3 5 6 8 2 26...

  • Page 373: Hull

    8-18 e hull hood 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 11 bolt 4 12 hinge 1 13 bolt 4 14 screw 8 15 left mirror ornament 1 16 right mirror ornament 1 17 nut/washer 2/2 18 left mirror 1 19 right mirror 1 20 left mirror cover 1 5 n · m (0.5 kgf · m, 3.7 ft · ib) 5 n · m (0.5...

  • Page 374: Hull

    8-19 e hull hood 1 2 3 4 5 step procedure/part name q ’ ty service points 21 right mirror cover 1 22 front hood 1 23 packing 1 not reusable 24 damper 2 not reusable 25 rivet 5 26 service lid 1 reverse the removal steps for installation. 5 n · m (0.5 kgf · m, 3.7 ft · ib) 5 n · m (0.5 kgf · m, 3.7 ft...

  • Page 375: Hull

    8-20 e hull hood 1 2 3 4 5 6 7 8 9 damper check 1. Check: • damper assembly does not hold front hood open → replace the damper assembly. Mirror disassembly 1. Remove: • mirror ornament 1 removal step: 1. Push the projections a on the mirror orna- ment 1 shown and remove the ornament from the mirror ...

  • Page 376: Hull

    8-21 e hull hood rivet removal 1. Remove: • rivets removal step: 1. Push in the rivet pin 1 until it clicks and is below the top of the rivet. 2. Check: • rivets cracks/damage → replace the rivets. 1 1 rivet installation 1. Install: • rivets installation steps: note: before reinstalling a rivet, hol...

  • Page 377: Hull

    8-22 e hull hood 1 2 3 4 5 6 7 8 9 steering console cover multifunction meter and cover removal step procedure/part name q ’ ty service points handlebar assembly refer to “ handlebar assembly removal. ” service lid refer to “ front hood removal. ” 1 rivet 2 2 cover 1 3 plastic tie 1 4 multifunction ...

  • Page 378: Hull

    8-23 e hull hood 4 5 6 step procedure/part name q ’ ty service points 9 left operation button assembly 1 10 cover 1 fx sho 11 right operation button assembly 1 fx cruiser sho 12 bolt 4 13 plastic tie 1 14 multifunction meter 1 reverse the removal steps for installation. 11 10 14 4 1 2 5 8 12 3 7 9 6...

  • Page 379: Hull

    8-24 e hull hood 1 2 3 4 5 6 7 8 9 side cover removal step procedure/part name q ’ ty service points 1 bolt 8 2 left side cover 1 3 right side cover 1 4 nut 6 5 rivet 2 not reusable 6 nut 6 7 bolt 6 8 left side ornament 1 9 right side ornament 1 reverse the removal steps for installation. 1 7 5 1 1 ...

  • Page 380: Hull

    8-25 e hull hood center cover removal step procedure/part name q ’ ty service points 1 reverse sensor coupler 1 2 nut 3 3 bolt 3 4 shift lever assembly 1 5 bolt 2 6 reverse sensor 1 7 nut/washer 2/2 8 nut/washer 6/6 9 bolt 4 11 9 9 13 4 3 6 7 14 10 15 12 14 2 8 1 5 6 × 30 mm 6 × 28 mm 5 n · m (0.5 k...

  • Page 381: Hull

    8-26 e hull hood 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 10 box cap 1 11 center cover 1 12 left induction box 1 13 right induction box 1 14 rivet 3 not reusable 15 box 1 reverse the removal steps for installation. 11 9 9 13 4 3 6 7 14 10 15 12 14 2 8 1 5 6 × 30 mm 6 × 28 mm ...

  • Page 382: Hull

    8-27 e hull hood center cover disassembly step procedure/part name q ’ ty service points 1 bolt 2 2 lid lock hook 1 3 bracket 1 4 nut 2 5 grommet 4 6 hinge pin 2 7 center console box lid 1 8 gear 2 9 lock 1 reverse the disassembly steps for assembly. 1 2 4 3 4 8 5 8 6 7 9 5 × 20 mm 4 n · m (0.4 kgf ...

  • Page 383: Hull

    8-28 e hull hood 1 2 3 4 5 6 7 8 9 side cover removal 1. Remove: • side cover 1 note: while removing the side cover 1, push down on the cover near the tab a to release the raised portion on the tab. A 1 1 shift lever removal 1. Remove: • nut 1 • bolt 2 • shift lever assembly 3 • bolt 4 • reverse sen...

  • Page 384: Hull

    8-29 e hull hood steering master steering master removal step procedure/part name q ’ ty service points center cover assembly refer to “ steering console cover. ” steering cable joint refer to “ remote control cables and speed sensor lead. ” 1 steering sensor coupler 1 2 buzzer coupler 1 3 bolt 1 4 ...

  • Page 385: Hull

    8-30 e hull hood 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 9 bolt 1 10 nut 1 11 cable stopper 1 12 nut/washer 4/4 13 bolt 4 14 steering master assembly 1 15 speed sensor coupler 1 fx cruiser sho 16 nut/washer 2/2 fx cruiser sho 17 screw 2 fx cruiser sho 18 compass and air temp...

  • Page 386: Hull

    8-31 e hull hood steering master disassembly step procedure/part name q ’ ty service points 1 bolt 1 2 bracket 1 1 3 steering shaft 1 È fx sho/É fx cruiser sho caution: do not disassemble the board spring a, otherwise the ots does not function properly. 4 pipe seal 1 not reusable 5 bolt 1 6 bracket ...

  • Page 387: Hull

    8-32 e hull hood 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 8 bushing 1 9 bolt 4 10 steering sensor 1 11 buzzer 1 12 bolt/nut 5/5 13 bracket 3 1 14 left housing 1 15 spring holder 1 16 spring 1 1 17 spring 2 1 18 lever 1 19 lock 1 20 right housing 1 É È 2 10 9 1 7 24 17 24 5 6 ...

  • Page 388: Hull

    8-33 e hull hood step procedure/part name q ’ ty service points 21 bushing 4 22 steering tube 1 23 rubber seal 1 not reusable 24 bushing 2 reverse the disassembly steps for assembly. É È 2 10 9 1 7 24 17 24 5 6 19 18 23 22 8 11 11 14 12 3 3 4 a a a a a a a a a a lt 572 lt a a 20 16 15 12 12 13 12 21...

  • Page 389: Hull

    8-34 e hull hood 1 2 3 4 5 6 7 8 9 steering master component check 1. Check: • bushings 1 • lock 2 cracks/damage/wear → replace. 1 2 2. Check: • steering shaft cracks/damage → replace the steering shaft. Caution: 3. Do not disassemble the board spring a, otherwise the ots does not function prop- erl...

  • Page 390: Hull

    8-35 e hull hood 2. Install: • spring 1 1 installation steps: 1. Install the spring 1 1 into the spring holder 2, and then install the holder to the right housing 3. 2. While compressing the spring 1 1, install it into the lever 4. 3 2 1 4 rubber seal installation 1. Install: • rubber seal 1 • steer...

  • Page 391: Hull

    8-36 e hull hood 1 2 3 4 5 6 7 8 9 remote control cables and speed sensor lead remote control cables and speed sensor lead removal step procedure/part name q ’ ty service points service lid refer to “ front hood removal. ” front seat assembly refer to “ seat and hand grip removal. ” 1 steering cable...

  • Page 392: Hull

    8-37 e hull hood step procedure/part name q ’ ty service points 9 band 1 not reusable 10 grommet 1 11 nut 2 12 shift cable holder 1 1 13 shift cable holder 2 1 14 packing 1 not reusable 15 nut/washer 2/2 16 shift cable bracket 1 17 nut 1 18 shift cable 1 19 seal 1 not reusable reverse the removal st...

  • Page 393: Hull

    8-38 e hull hood 1 2 3 4 5 6 7 8 9 steering cable installation (steering master end) warning if a cable becomes damaged, replace it. Never attempt to repair a damaged cable. 1. Install: • steering cable installation steps: 1. Insert the projection a on the steering cable completely into the indentat...

  • Page 394: Hull

    8-39 e hull hood steering cable installation (jet pump end) 1. Install: • steering cable note: to adjust the steering cable. Refer to “ jet thrust nozzle steering angle check and adjust- ment ” in chapter 3. Steering cable set length a (jet pump end): 14.5 ± 1 mm (0.57 ± 0.04 in) t r . . Steering ca...

  • Page 395: Hull

    8-40 e hull hood 1 2 3 4 5 6 7 8 9 shift cable installation (jet pump end) 1. Install: • shift cable note: to adjust the shift cable. Refer to “ shift cable check and adjustment ” in chapter 3. Shift cable set length a (jet pump end): 13.0 ± 0.8 mm (0.51 ± 0.03 in) t r . . Shift cable locknut (jet p...

  • Page 396: Hull

    8-41 e hull hood hoses hose removal step procedure/part name q ’ ty service points engine unit refer to “ engine unit ” in chapter 5. 1 band 4 not reusable 2 ventilation hose 2 3 fuel tank breather hose 1 1 4 fuel tank breather hose 2 1 5 rivet 2 not reusable 6 water separator 1 7 nut 3 8 seal 3 not...

  • Page 397: Hull

    8-42 e hull hood 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 10 cooling water pilot outlet 3 note: align each projection a with the slits b. 11 cooling water hose 3 È to air cooler/É to oil cooler 12 rivet 2 not reusable 13 ventilation socket 1 14 band 1 not reusable 15 ventilat...

  • Page 398: Hull

    8-43 e hull hood seats and hand grip seat and hand grip removal step procedure/part name q ’ ty service points 1 rear seat assembly 1 È fx sho/É fx cruiser sho 2 front seat assembly 1 È fx sho/É fx cruiser sho 3 bolt 4 4 seat lock assembly 2 5 packing (rear) 1 not reusable 6 packing (front) 1 not re...

  • Page 399: Hull

    8-44 e hull hood 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 13 seal 1 not reusable 14 nut 4 15 bolt 4 16 rear seat stay 2 17 nut/washer 2/2 18 seat holder 1 19 nut/washer 1/1 20 projection/washer 1/1 21 nut/washer 4/4 22 bolt 4 23 hand grip 1 È fx sho/É fx cruiser sho reverse t...

  • Page 400: Hull

    8-45 e hull hood seat lock check 1. Check: • seat lock assembly 1 does not lock → replace the seat lock assembly. • projection 2 damage → replace the projection. 2 2 1 1 seats and hand grip.

  • Page 401: Hull

    8-46 e hull hood 1 2 3 4 5 6 7 8 9 exhaust system exhaust system and battery removal step procedure/part name q ’ ty service points deck beam refer to “ seat and hand grip removal. ” muffler refer to “ engine unit ” in chapter 5. Rubber plate refer to “ jet pump unit removal ” in chapter 6. 1 negati...

  • Page 402: Hull

    8-47 e hull hood step procedure/part name q ’ ty service points 11 clamp 1 12 resonator 1 13 clamp 1 14 camp 1 15 rubber hose 1 note: align the projection a on the rubber hose with the alignment mark b on the water tank. 16 band 1 17 water lock 1 18 clamp 1 19 water tank 1 20 nut/washer 6/6 23 22 21...

  • Page 403: Hull

    8-48 e hull hood 1 2 3 4 5 6 7 8 9 step procedure/part name q ’ ty service points 21 exhaust valve 1 not reusable 22 rubber hose 1 23 plate 1 reverse the removal steps for installation. 23 22 21 3.7 n · m (0.37 kgf · m, 2.7 ft · ib) 5 n · m (0.5 kgf · m, 3.7 ft · ib) 5.4 n · m (0.54 kgf · m, 3.9 ft ...

  • Page 404: Hull

    8-49 e hull hood exhaust system check 1. Check: • rubber hoses burns/cracks/damage → replace the rubber hoses. 2. Check: • water lock 1 • water tank 2 cracks/damage/leaks → replace. 2 1 exhaust system.

  • Page 405: Hull

    8-50 e hull hood 1 2 3 4 5 6 7 8 9 deck and hull deck and hull disassembly 1 step procedure/part name q ’ ty service points 1 bolt 2 2 bow eye 1 3 nut/washer 8/8 4 bolt 2 5 front protector 1 2 note: apply soapy water to the inner surfaces a of the grommets before installing the projec- tions b of th...

  • Page 406: Hull

    8-51 e hull hood step procedure/part name q ’ ty service points 11 gunwale bracket 2 12 inner gunwale 2 13 screw 36 14 side gunwale 2 15 pull-up cleat cover 2 fx cruiser sho 16 bolt 6 fx cruiser sho 17 pull-up cleat assembly 2 fx cruiser sho 18 bolt/collar 10/10 19 sponson 2 reverse the disassembly ...

  • Page 407: Hull

    8-52 e hull hood 1 2 3 4 5 6 7 8 9 deck and hull disassembly 2 step procedure/part name q ’ ty service points 1 nut 2 2 plate 2 3 ski tow 1 4 nut 1 5 spout 1 note: face the mark a toward the bow. 6 nut 4 7 plate 4 8 packing 2 not reusable 9 stern eye 2 10 nut/washer 4/4 11 screw 4 2 2 1 3 a 5 × 25 m...

  • Page 408: Hull

    8-53 e hull hood step procedure/part name q ’ ty service points 12 drain plug 2 13 packing 2 not reusable 14 bolt 6 15 reboarding step assembly 1 16 spacer 2 reverse the disassembly steps for assembly. 2 2 1 3 a 5 × 25 mm 8 × 48 mm 5 n · m (0.5 kgf · m, 3.7 ft · ib) 2 n · m (0.2 kgf · m, 1.5 ft · ib...

  • Page 409: Hull

    8-54 e hull hood 1 2 3 4 5 6 7 8 9 drain plug check 1. Check: • drain plug 1 • o-ring 2 cracks/damage → replace the drain plug. 1 2 front protector 1 installation 1. Install: • front protectors note: apply soapy water to the inner surfaces a of the grommets before installing the projections b of the...

  • Page 410: Hull

    8-55 e hull hood — memo — deck and hull.

  • Page 411: Trbl

    E trbl anls 1 2 3 4 5 6 7 8 9 chapter 9 trouble analysis ydis................................................................................................................. 9-1 introduction................................................................................................ 9-1 features...

  • Page 412: Trbl

    9-1 e trbl anls ydis introduction features the newly developed ydis provides quicker detection and analysis of engine malfunctions. By connecting your computer to the ecm of a watercraft using the communication cable, this soft- ware can be used to display sensor data and data stored in the ecm on a...

  • Page 413: Trbl

    9-2 e trbl anls 1 2 3 4 5 6 7 8 9 3. Engine monitor: each sensor status and the ecm data are displayed. This enables you to find malfunctioning parts quickly. In addition, the data displayed using the engine monitor function can be displayed in a graph. Items: for fx sho, fx cruiser sho (*1) : intak...

  • Page 414: Trbl

    9-3 e trbl anls 4. Stationary test: operation tests can be performed with the engine off. Items: for fx sho, fx cruiser sho (*1) : operate fuel pump module 5. Active test: with the engine running, each cylinder is dropped and the engine speed is checked for changes to determine if the cylinder is ma...

  • Page 415: Trbl

    9-4 e trbl anls 1 2 3 4 5 6 7 8 9 7. Ecm record data graph: when a malfunction occurs in the etv system, 4 seconds (2 seconds before and after the malfunction) of recorded data are saved in the ecm. This data can be dis- played on a graph using the “ ecm record data graph ” of the data logger functi...

  • Page 416: Trbl

    9-5 e trbl anls 8. Some files: other applications can be selected and run while continuing to run the diagnostic program. Contents 1. Cd-rom (software + instruction manual) 2. Adapter 3. Communication cable operating connecting the communication cable to the watercraft 1 wiring harness coupler 2 met...

  • Page 417: Trbl

    9-6 e trbl anls 1 2 3 4 5 6 7 8 9 engine unit trouble analysis note: • before troubleshooting the engine unit, make sure that fresh fuel of the specified type has been used. • check that the battery is charged and that its specific gravity is within specification. • check the diagnostic code using t...

  • Page 418: Trbl

    9-7 e trbl anls self-diagnosis with the engine running, press the 2 buttons 1 simultaneously for 8 seconds and check if a diagnostic code is indicated on the multifunc- tion meter. If the ydis is not used to check the symptoms listed in the “ diagnostic code table, ” the diag- nostic codes can be ch...

  • Page 419: Trbl

    9-8 e trbl anls 1 2 3 4 5 6 7 8 9 diagnostic code table (*1) : pickup coil (*2) : engine temperature sensor (*3) : intake air temperature sensor (*4) : intake air pressure sensor (*5) : thermo sensor (*6) : “ no-wake mode ” switch (*7) : reverse sensor code no. Symptom diagnostic code output multifu...

  • Page 420: Trbl

    9-9 e trbl anls diagnostic code and checking step diagnos- tic code item symptom checking steps refer to page 13 pulser coil (*1) malfunction engine will not start 1. Measure the pickup coil output peak voltage. 7-14 2. Measure the pickup coil resistance. 7-14 3. Check the white/black and black/ ora...

  • Page 421: Trbl

    9-10 e trbl anls 1 2 3 4 5 6 7 8 9 23 intake temp sensor (*1) malfunction trolling speed is unstable (*3) 1. Check the intake air temperature using the ydis. 7-24 2. Measure the intake air temperature sensor input voltage. 7-24 3. Check the black/red and black/orange (b/r and b/o) intake air tempera...

  • Page 422: Trbl

    9-11 e trbl anls 55 steering sensor malfunction normal operation 1. Check the steering sensor operation using the ydis. 7-38 2. Measure the steering sensor input voltage. 7-38 3. Check the orange/red, white/blue, and black/orange (o/r, w/l, and b/o) steering sensor wiring harness leads for continuit...

  • Page 423: Trbl

    9-12 e trbl anls 1 2 3 4 5 6 7 8 9 112 113 114 electronic throttle system (*1) malfunction engine speed is limited 1. Check the tps output voltage and throttle valve opening using the ydis. 7-28 2. Check the ecm circuit for continuity. 7-42 3. Check the etv relay for continuity. 7-35 4. Check the ch...

  • Page 424: Trbl

    9-13 e trbl anls 123 electronic throttle system (*1) malfunction engine speed is limited 1. Check the etv relay and fuse (etv relay) for continuity. 7-35 7-3 2. Check the ecm circuit for continuity. 7-42 124 125 127 128 throttle position sensor malfunction engine speed is limited 1. Check the pink, ...

  • Page 425: Trbl

    9-14 e trbl anls 1 2 3 4 5 6 7 8 9 136 137 138 139 electronic throttle system (*1) malfunction engine speed is limited 1. Check the ecm circuit for continuity. 7-42 2. Check the etv relay for continuity. 7-35 3. Check the charging system. • stator coil output peak voltage • stator coil resistance • ...

  • Page 426: Trbl

    9-15 e trbl anls engine unit trouble analysis (diagnostic code not detected) trouble analysis chart trouble mode check items engin e will not sta rt hard star tin g rou g h idling high idling engin e stalls poor acce ler ation engin e will not stop poor performa nce limited engine speed over heating...

  • Page 427: Trbl

    9-16 e trbl anls 1 2 3 4 5 6 7 8 9 power unit water passage 2 compression pressure 3 engine oil 3 oil filter 3 air filter 3 air cooler 5 supercharger 5 oil cooler 5 oil pump 5 valves and valve seats 5 valve pads 5 camshafts 5 timing chain 5 drive coupling 5 cylinder head gasket 5 cylinder block 5 cr...

  • Page 428: Trbl

    9-17 e trbl anls jet pump unit bilge strainer 3 impeller duct 6 impeller 6 intake grate 6 bearings 6 water inlet hose 6 bilge hose 6 bilge hose joint 6 rubber damper 6 electrical spark plugs 3 ignition coils 7 oil pressure switch 7 electric bilge pump 7 engine start switch 7 engine stop switch 7 eng...

  • Page 429: Trbl

    9-18 e trbl anls 1 2 3 4 5 6 7 8 9 — memo — engine unit trouble analysis.

  • Page 430: Wiring Diagram

    Wiring diagram fx sho/fx cruiser sho 1 battery 2 starter motor 3 fuse (30 a) 4 fuse (20 a) 5 fuse (3 a) 6 fuse (10 a) 7 fuse (10 a) 8 starter relay 9 main and fuel pump relay 0 etv relay a slant detection switch b ignition coil c spark plug d cam position sensor e intake air pressure sensor f intake...

  • Page 432

    Yamaha motor corporation, usa printed in usa jan. 2008 – 0.0 × 1 cr (e).

  • Page 433

    Fx sho, fx cruiser sho 1 2 3 1 1 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 2 1 3 2 1 3 2 1 3 2 1 1 2 3 4 5 6 7 8 4 2 1 3 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 8 4 5 1 3 2 7 6 8 1 7 6 5 4 2 3 1 2 1 2 10a 10a 3a 30a 20a 1 2 1 2 3 1 2 1 2 w br b r set pull b w free p...