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Yamaha WaveRunner GP800R Service Manual

Other manuals for WaveRunner GP800R: Assembly Manual

Summary of WaveRunner GP800R

  • Page 1

    *lit186160226* waverunner gp800r service manual f0w-28197-1a-11 lit-18616-02-26.

  • 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 equip- ment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical ...

  • Page 3: How to Use This Manual

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

  • Page 4

    E important information in this service manual particularly important information is distinguished in the following ways. The safety alert symbol means attention! Become alert! Your safety is involved! Warning failure to follow warning instructions could result in severe injury or death to the machi...

  • Page 5

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

  • Page 6: Gen

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

  • Page 7: Index

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

  • Page 9: Gen

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

  • Page 10: Gen

    1-1 e gen info identification numbers a60700-0* identification numbers primary l.D. Number the primary l.D. Number is stamped on a label attached to the inside of the engine compartment. Starting primary l.D. Number: f0w: 800101– engine serial number the engine serial number is stamped on a label at...

  • Page 11: Gen

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

  • Page 12: Gen

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

  • Page 13: Gen

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

  • Page 14: Gen

    1-5 e gen info special tools special tools using the correct special tools recom- mended by yamaha, will aid the work and enable accurate assembly and tune-up. Improvisations and using improper tools can damage the equipment. Note: ● for u.S.A. And canada, use part numbers starting with “j-”, “yb-”,...

  • Page 15: Gen

    1-6 e gen info special tools removal and installation 1 coupler wrench p/n. Yw-06551 90890-06551 2 flywheel holder p/n. Yw-06550 90890-06550 3 flywheel puller p/n. Yb-06117 90890-06521 4 drive shaft holder (impeller) p/n. Yb-06151 90890-06519 5 slide hammer set (jet pump bearing) p/n. Yb-06096 6 sto...

  • Page 17: Spec

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

  • Page 18: Spec

    2-1 spec e general specifications general specifications item unit model gp800r model code hull f0w engine 68a dimensions length mm (in) 2,930 (115.4) width mm (in) 1,150 (45.3) height mm (in) 1,020 (40.2) dry weight kg (lb) 268 (591) watercraft capacity 2 performance maximum output kw (ps) @ r/min ...

  • Page 19: Spec

    2-2 spec e pon*: pump octane number = (motor octane number + research octane number)/2 ron*: research octane number fuel and oil fuel regular unleaded gasoline fuel rating pon* 86 ron* 90 oil yamalube 2-w or an equivalent tc-w3 certified outboard oil fuel/oil mixing ratio (wide open throttle) 30:1 f...

  • Page 20: Spec

    2-3 spec e maintenance specifications maintenance specifications engine item unit model gp800r cylinder head warpage limit mm (in) 0.1 (0.004) compression pressure *1 kpa (kg/cm 2 ) 560 (5.6) cylinders bore size mm (in) 80.000–80.018 (3.1496–3.1503) taper limit mm (in) 0.08 (0.003) out-of-round limi...

  • Page 21: Spec

    2-4 spec e maintenance specifications jet pump unit hull and hood crankshaft assembly crank width a mm (in) 72.95–73.00 (2.872–2.874) deflection limit b mm (in) 0.05 (0.002) big end side clearance c mm (in) 0.25–0.75 (0.010–0.030) maximum small end axial play d mm (in) 2.0 (0.08) carburetors type fl...

  • Page 22: Spec

    2-5 spec e maintenance specifications electrical item unit model gp800r battery type fluid capacity v/ah (kc) 12/19 (68.4) cdi unit (o – b) output peak voltage lower limit @cranking 1 v 85 @cranking 2 v 110 @2,000 r/min v 205 @3,500 r/min v 200 stator charge coil (br – l) output peak voltage lower l...

  • Page 23: Spec

    2-6 spec e maintenance specifications rectifier/regulator (r – b) output peak voltage lower limit (unloaded) @cranking v 7.5 @2,000 r/min v 12.5 @3,500 r/min v 12.5 thermo switch on temperature ˚c (˚f) 80 (177) off temperature ˚c (˚f) 70 (159) starter motor brush length mm (in) 12.5 (0.49) wear limi...

  • Page 24: Spec

    2-7 spec e tightening torques tightening torques specified torques part to tightened part name thread size q’ty tightening torque remarks n•m kgf•m ft•lb engine unit engine unit – engine mount bolt m8 4 17 1.7 12 572 lt exhaust chamber assembly – muffler stay 1 – muffler stay 3 1st bolt m10 2 2 0.2 ...

  • Page 25: Spec

    2-8 spec e tightening torques drive coupling – crankshaft assembly drive coupling m27 1 36 3.6 25 572 lt generator cover – crankcase 1st bolt m8 8 15 1.5 11 271 lt 2nd 27 2.7 19 pickup coil – generator cover bolt m5 2 5 0.5 3.6 242 lt cable holder – generator cover bolt m6 2 14 1.4 10 242 lt stator ...

  • Page 26: Spec

    2-9 spec e tightening torques handlebar switch assembly – handlebar screw m5 2 3 0.3 2.2 qsts grip assembly – handlebar screw m6 1 3 0.3 2.2 grip end – handlebar bolt m5 2 1 0.1 0.7 choke lever assembly – handlebar screw m5 2 3 0.3 2.2 qsts cable housing – cover screw m4 1 1 0.1 0.7 plate/steering c...

  • Page 27: Spec

    2-10 spec e tightening torques hand grip – deck nut m8 2 5 0.5 3.6 seat bracket – deck nut m8 2 15 1.5 11 battery box/stay – holder nut m6 2 9 0.9 6.5 battery box – bracket/deck nut m8 2 13 1.3 9.4 battery box – electrical box bolt m8 3 15 1.5 11 extension bolt – battery negative terminal bolt m6 1 ...

  • Page 28: Spec

    2-11 spec e cable and hose routing cable and hose routing 20˚ 5 6 7 g-g 4 h-h 8 f-f d-d e-e a c b 1 2 2 2 2 3 2 4 k-k 9 b 0 l i-i 9 0 j-j a 9 9 0 a b l c k k k j j e e k d d f e e f i i h h j j g g c d e f k g h i j a f 1 fuel filter 2 fuel tank breather hose 3 fuel hose 4 cooling water hose 5 choke...

  • Page 29: Spec

    2-12 spec e cable and hose routing a a b c f i j j b c d e j-j g-g 4 8 h-h i f 9 f f g a a e e 0 1 2 3 e e b c d 7 6 5 4 g g h h h k i j 2 5 l m 4 g e f a 7 d d 1 oil delivery hose 2 fuel return hose 3 fuel suction hose 4 speed sensor lead 5 qsts cable 6 cooling water hose 7 steering cable 8 flushin...

  • Page 31: Insp

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

  • Page 32: Insp

    3-1 insp adj e maintenance interval chart maintenance interval chart the following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the intervals of maintenance should be changed. *1: after every ride *2: inspect fluid level before e...

  • Page 33: Insp

    3-2 insp adj e control system periodic service control system steering column inspection 1. Inspect: ● steering column excessive play → replace the steer- ing column. Refer to “steering column” in chapter 8. Steering cable inspection and adjustment 1. Inspect: ● distance a, b (between the nozzle and...

  • Page 34: Insp

    3-3 insp adj e control system note: if the steering cable cannot be properly adjusted at the steering column side, make sure the steering cable at the jet pump side is set to the specified length. Refer to “remote control cables and speed sensor lead” in chapter 8. Throttle cable inspection and adju...

  • Page 35: Insp

    3-4 insp adj e control system warning after adjusting the free play, turn the han- dlebar to the right and left and make sure that the trolling speed does not increase. Choke cable inspection and adjustment 1. Check: ● choke lever operation incorrect operation → adjust. 2. Adjust: ● choke lever oper...

  • Page 36: Insp

    3-5 insp adj e control system qsts cable inspection and adjustment 1. Measure: ● nozzle deflector set length a, b difference → adjust. Measurement steps: ● set the control grip in the neutral posi- tion. ● measure the nozzle deflector set length a and b. ● if a and b length are not even, adjust the ...

  • Page 37: Insp

    3-6 insp adj e control system note: if the qsts cable cannot be properly adjusted at the qsts converter side, make sure the qsts cable at the jet pump side is set to the specified length. Refer to “remote control cables and speed sensor lead” in chapter 8. Ypvs cable adjustment 1. Check: ● ypvs valv...

  • Page 38: Insp

    3-7 insp adj e control system/fuel system 3. Adjust: ● ypvs cables 1 and 2 fuel system warning ● stop the engine, set the fuel cock to “off” before servicing the fuel system. ● when removing fuel system parts, wrap them in a cloth and take care that no fuel spills into the engine compartment. Fuel l...

  • Page 39: Insp

    3-8 insp adj e fuel system 2. Inspect: ● water separator 1 water accumulation → drain. Note: if need the water draining, remove the drain plug 2. Trolling speed check and adjustment 1. Check: ● trolling speed out of specification → adjust. Trolling speed: 1,300 ± 50 r/min checking steps (with the wa...

  • Page 40: Insp

    3-9 insp adj e oil injection system/power unit oil injection system oil line inspection 1. Inspect: ● oil filter contaminants → clean. Frays/tears → replace. ● rubber seal cracks/wear → replace. ● oil hoses ● oil tank ● oil filler cap cracks/damage → replace. ● check valve malfunction → replace. Cau...

  • Page 41: Insp

    3-10 insp adj e power unit/electrical 3. Measure: ● spark plug gap a out of specification → regap. Spark plug gap: 0.7–0.8 mm (0.028–0.031 in) 4. Tighten: ● spark plug note: ● before installing the spark plug, clean the gasket surface and spark plug surface. Also, it is suggested to apply a thin fil...

  • Page 42: Insp

    3-11 insp adj e electrical antidote (internal): ● drink large quantities of water or milk fol- lowed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention. Batteries generate explosive, hydrogen gas. Always follow these preventive mea- sures: ● charge batteries in a wel...

  • Page 43: Insp

    3-12 insp adj e electrical 2. Inspect: ● electrolyte level low → add distilled water. The electrolyte level should be between the upper a and lower b level marks. Caution: use only distilled water. Other types of water contain minerals which are harmful to batteries. Filling steps: ● remove each fil...

  • Page 44: Insp

    3-13 insp adj e electrical/jet pump unit 5. Install: ● battery breather hose 1 ● battery ● battery positive lead 2 ● battery negative lead 3 (with termi- nal extension at battery negative ter- minal) ● band caution: ● connect the positive lead to the battery terminal first. ● make sure the battery l...

  • Page 45: Insp

    3-14 insp adj e jet pump unit/general water inlet strainer inspection 1. Inspect: ● water inlet strainer contaminants → clean. Cracks/damage → replace. Inspection steps: ● remove the water inlet cover 1. ● inspect the water inlet strainer mesh a. ● install the water inlet cover. 1 a bilge strainer i...

  • Page 46: Insp

    3-15 insp adj e general lubrication points 1. Lubricate: ● throttle cable (handlebar side) note: before lubricating the throttle cable, squeeze the throttle lever and remove the rubber seal 1. Recommended lubricant: rust inhibitor 2. Lubricate: ● qsts control cables (handlebar side) note: before lub...

  • Page 47: Insp

    3-16 insp adj e general 4. Lubricate: ● throttle cable (carburetor side) ● oil pump cable ● qsts cables (pulley side) ● ypvs cables recommended grease: yamaha marine grease, yamaha grease a (water resistant grease) 5. Lubricate: ● nozzle pivot shaft ● steering cable (nozzle side) ● qsts cable (nozzl...

  • Page 48: Insp

    3-17 insp adj e general 6. Lubricate: ● steering cable ● steering cable joint note: disconnect the joints and apply a small amount of grease. Recommended grease: yamaha marine grease, yamaha grease a (water resistant grease) 7. Fill: ● intermediate housing note: fill the intermediate housing with th...

  • Page 50: Fuel

    E fuel chapter 4 fuel system fuel cock and fuel filter ..................................................................... 4-1 exploded diagram ............................................................................. 4-1 removal and installation chart ............................................

  • Page 51: Fuel

    E 1 2 3 4 5 6 7 8 9 fuel carburetor .............................................................................................. 4-20 exploded diagram ........................................................................... 4-20 removal and installation chart ......................................

  • Page 52: Fuel

    4-1 fuel e fuel cock and fuel filter fuel cock and fuel filter exploded diagram removal and installation chart step procedure/part name q’ty service points fuel cock and fuel filter removal follow the left “step” for removal. 1 screw 1 2 knob 1 3 nut 1 4 fuel cock assembly 1 5 fuel hose 3 6 holder 1...

  • Page 53: Fuel

    4-2 fuel e fuel cock and fuel filter service points fuel filter inspection refer to “fuel system” in chapter 3. Fuel cock inspection 1. Check: ● fuel cock contaminants → clean. Rough movement → replace..

  • Page 54: Fuel

    4-3 fuel e oil tank oil tank exploded diagram removal and installation chart step procedure/part name q’ty service points oil tank removal follow the left “step” for removal. Engine unit refer to “engine unit” in chapter 5. Steering console cover assembly refer to “steering console cover” in chapter...

  • Page 55: Fuel

    4-4 fuel e oil tank exploded diagram step procedure/part name q’ty service points 6 breather hose 1 7 oil hose 1 8 bolt 2 9 tank belt 2 10 oil tank assembly 1 11 hose clamp 1 12 oil filler hose 1 13 oil level sensor 1 reverse the removal steps for installation..

  • Page 56: Fuel

    4-5 fuel e oil tank service points oil line inspection 1. Inspect: ● oil filter contaminants → clean. Frays/tears → replace. ● rubber seal cracks/wear → replace. ● oil hoses ● oil tank ● oil filler cap cracks/damage → replace. ● check valve malfunction → replace. Oil level sensor inspection refer to...

  • Page 57: Fuel

    4-6 fuel e fuel tank fuel tank exploded diagram removal and installation chart step procedure/part name q’ty service points fuel tank removal follow the left “step” for removal. Oil tank refer to “oil tank”. 1 fuel level sensor coupler 1 2 hose clamp 1 disconnect the fuel filler hose from the fuel f...

  • Page 58: Fuel

    4-7 fuel e fuel tank exploded diagram step procedure/part name q’ty service points 7 fuel hose 1 8 fuel return hose 1 9 fuel tank breather hose 1 10 fuel tank assembly 1 11 hose clamp 1 12 fuel filler hose 1 13 hose clamp 1 14 fuel sensor assembly 1.

  • Page 59: Fuel

    4-8 fuel e fuel tank exploded diagram step procedure/part name q’ty service points 15 one way valve 1 16 screw/washer 1/1 17 filter 1 18 screw/washer 1/1 19 sleeve 1 20 floatation 1 21 bolt 2 22 tank belt 2 reverse the removal steps for installation..

  • Page 60: Fuel

    4-9 fuel e fuel tank service points check valve inspection 1. Check: ● check valve faulty → replace. Fuel level sensor inspection refer to “indication system” in chapter 7. Fuel tank inspection 1. Inspect: ● fuel tank cracks/damage → replace. Pipe joint inspection 1. Inspect: ● pipe contaminants → c...

  • Page 61: Fuel

    4-10 fuel e intake silencer intake silencer exploded diagram removal and installation chart step procedure/part name q’ty service points intake silencer removal follow the left “step” for removal. 1 bolt 3 2 intake silencer cover 1 3 bolt 4 4 spark arrester 1 5 intake silencer 1 6 o-ring 2 reverse t...

  • Page 62: Fuel

    4-11 fuel e carburetor unit carburetor unit exploded diagram removal and installation chart step procedure/part name q’ty service points carburetor removal follow the left “step” for removal. Battery box refer to “battery box” in chapter 8. Intake silencer refer to “intake silencer”. 1 bolt 2 note: ...

  • Page 63: Fuel

    4-12 fuel e carburetor unit exploded diagram step procedure/part name q’ty service points 7 hose clamp 2 slide the outer exhaust joint. 8 hose clamp 2 9 floatation 1 10 water lock band 1 11 bolt 1 12 bolt 1 13 muffler stay 3 1 14 bolt 4 15 nut/washer 2/2.

  • Page 64: Fuel

    4-13 fuel e carburetor unit exploded diagram step procedure/part name q’ty service points 16 muffler stay 1 2 note: make sure to remove spark plugs before removing the muffler stay 1. 17 bolt 2 18 hose clamp 2 19 exhaust chamber assembly 1 20 rubber joint 1 slide the water lock to back 21 outer exha...

  • Page 65: Fuel

    4-14 fuel e carburetor unit exploded diagram step procedure/part name q’ty service points 23 fuel hose 2 Å suction ı return note: use the white marks a on the fuel hoses to distinguish the hose ends. 24 oil feed hose 2 25 choke cable 1 26 throttle cable 1 27 oil pump cable 1.

  • Page 66: Fuel

    4-15 fuel e carburetor unit exploded diagram step procedure/part name q’ty service points 28 pulse hose 2 29 bolt 2 30 bolt 4 31 carburetor unit 1 32 gasket 1 33 dowel pin 2 reverse the removal steps for installation. Not reusable.

  • Page 67: Fuel

    4-16 fuel e carburetor unit exploded diagram removal and installation chart step procedure/part name q’ty service points carburetor unit separation follow the left “step” for removal. 1 pulse hose 2 2 fuel hose 4 Å suction ı return 3 oil feed hose 2 4 accelerator pump fuel hose 3 5 throttle link 1 6...

  • Page 68: Fuel

    4-17 fuel e carburetor unit exploded diagram step procedure/part name q’ty service points 7 bolt 3 8 cable bracket 1 9 bolt 4 10 carburetor 2 11 gasket 2 12 carburetor joint 1 13 bolt/washer 2/2 14 fuel hose guide 1 reverse the removal steps for installation. Not reusable.

  • Page 69: Fuel

    4-18 fuel e carburetor unit service points throttle valve synchronization inspection and adjustment 1. Check: ● throttle valve synchronization different clearances → adjust. Checking steps: ● loosen the throttle stop screw 1 until untouched the screw end from the throttle lever. ● check the each thr...

  • Page 70: Fuel

    4-19 fuel e carburetor unit choke cable and throttle cable installation 1. Install: ● choke cable 1 ● throttle cable 2 2. Adjust: ● throttle lever free play ● choke lever operation refer to “control system” in chapter 3. Choke cable guide installation position a: 13–15 mm (0.51–0.59 in) throttle cab...

  • Page 71: Fuel

    4-20 fuel e carburetor carburetor exploded diagram removal and installation chart step procedure/part name q’ty service points carburetor disassembly follow the left “step” for disassembly. 1 accelerator pump fuel hose 1 carburetor #1 2 screw 4 3 accelerator pump/carburetor cover 1/1 carburetor #1/c...

  • Page 72: Fuel

    4-21 fuel e carburetor exploded diagram step procedure/part name q’ty service points 10 screw 1 11 arm 1 12 arm pin 1 13 spring 1 14 screw 1 15 needle valve seat holder 1 16 needle valve 1 17 needle valve seat 1 18 o-ring 1 reverse the disassembly steps for assembly..

  • Page 73: Fuel

    4-22 fuel e carburetor exploded diagram removal and installation chart step procedure/part name q’ty service points accelerator pump disassembly follow the left “step” for disassembly. 1 screw 1 2 stay 1 3 spring 1 4 spring seat 1 5 screw 4 6 accelerator pump cover 1 7 spring 1 8 diaphragm 1 9 accel...

  • Page 74: Fuel

    4-23 fuel e carburetor service points note: before disassembling the carburetor, make sure to note the number of times the pilot screw is turned in from its set position to the seated position. Caution: do not use steel wire for cleaning the jets. This may enlarge the jet diameters and seriously aff...

  • Page 75: Fuel

    4-24 fuel e regulator body inspection 1. Inspect: ● regulator body contaminants → clean. Damage → replace. ● valve (clear film) 1 damage → replace. Needle valve inspection 1. Inspect: ● needle valve ● needle valve seat contaminants a → clean. Wear b → replace. Note: always replace the needle valve a...

  • Page 76: Fuel

    4-25 fuel e fuel pump fuel pump exploded diagram removal and installation chart step procedure/part name q’ty service points fuel pump disassembly follow the left “step” for disassembly. Carburetors refer to “carburetor unit”. 1 screw 4 2 fuel pump cover 1 3 gasket 1 4 diaphragm 1 5 o-ring 1 6 diaph...

  • Page 77: Fuel

    4-26 fuel e fuel pump exploded diagram step procedure/part name q’ty service points 7 rubber diaphragm 1 8 diaphragm 1 9 packing 1 10 fuel filter 1 reverse the disassembly steps for assembly..

  • Page 78: Fuel

    4-27 fuel e fuel pump service points fuel pump inspection 1. Inspect: ● diaphragm ● rubber diaphragm ● diaphragm body damage → replace. Fuel filter inspection 1. Inspect: ● fuel filter clog/contaminants → clean. Damage → replace..

  • Page 79: Fuel

    4-28 fuel e oil pump oil pump exploded diagram removal and installation chart step procedure/part name q’ty service points oil pump removal follow the left “step” for removal. Exhaust chamber assembly refer to “carburetor unit”. Oil pump cable and oil feed hoses refer to “carburetor unit”. 1 oil ret...

  • Page 80: Fuel

    4-29 fuel e oil pump exploded diagram removal and installation chart step procedure/part name q’ty service points oil pump hoses and cable removal follow the left “step” for removal. 1 air bleed screw 1 2 gasket 1 3 oil feed hose 1 2 4 check valve 2 5 oil feed hose 2 2 6 hose joint 1 7 oil return ho...

  • Page 81: Fuel

    4-30 fuel e oil pump service points oil pump inspection 1. Inspect: ● oil pump contaminants → clean. Damage/wear → replace. ● oil pump joint piece damage/wear → replace. Oil hose inspection 1. Inspect: ● oil hose cracks/damage → replace. Caution: if the oil feed hoses are not full of oil, fill them ...

  • Page 82: Fuel

    4-31 fuel e oil pump 2. Adjust: ● oil pump cable adjustment steps: ● loosen the locknut 1 and the adjust- ing nut 2. ● fully close the carburetor throttle valves. ● adjust the oil pump cable so that the mark a on the oil pump lever is aligned with the mark b on the oil pump body. ● tighten the adjus...

  • Page 83: Fuel

    4-32 fuel e oil pump t r . . Air bleed screw: 5 n • m (0.5 kgf • m, 3.6 ft • lb) caution: do not run the engine if oil does not flow out of the air bleed screw. Inspect the oil pump hoses for proper routing and make sure there are no restrictions in the line..

  • Page 84: Powr

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

  • Page 85: Powr

    E 1 2 3 4 5 6 7 8 9 powr cylinders................................................................................................... 5-20 exploded diagram ........................................................................... 5-20 removal and installation chart ...................................

  • Page 86: Powr

    5-1 powr e engine unit exploded diagram removal and installation chart step procedure/part name q’ty service points engine unit removal follow the left “step” for removal. Battery box refer to “battery box” in chapter 8. Ypvs cables and ypvs servomotor refer to “ypvs servomotor” in chapter 7. Intake...

  • Page 87: Powr

    5-2 powr e engine unit exploded diagram step procedure/part name q’ty service points 4 grease hose 1 5 clamp/cooling water hose 1/1 6 clamp/cooling water hose 1/1 Å for cooling water pilot outlet on starboard side 7 clamp/cooling water hose 1/1 ı for cooling water pilot outlet on port side 8 oil hos...

  • Page 88: Powr

    5-3 powr e engine unit exploded diagram step procedure/part name q’ty service points 10 bolt/collar 1/1 note: ● before removing the engine unit, fix the choke valves to the choke link with a plastic band, etc. To the fully closed position. ● when lifting the engine unit, hook the hoister on the bow ...

  • Page 89: Powr

    5-4 powr e engine unit exploded diagram step procedure/part name q’ty service points 16 shim * 17 engine unit 1 18 rubber joint 1 slide the water lock to back. Reverse the removal steps for installation. *: as required.

  • Page 90: Powr

    5-5 powr e engine unit service points shim removal 1. Remove: ● shims note: to ease reassembly and coupling align- ment, remove the shims and organize them in their respective groups (e.G., front right, rear left) prior to removing the mounting bolts. Engine mount inspection 1. Inspect: ● engine mou...

  • Page 91: Powr

    5-6 powr e exhaust chamber assembly exhaust chamber assembly exploded diagram removal and installation chart step procedure/part name q’ty service points exhaust chamber assembly removal follow the left “step” for removal. Engine unit refer to “engine unit”. 1 bolt 2 2 thermoswitch 1 3 hose clamp 2 ...

  • Page 92: Powr

    5-7 powr e exhaust chamber assembly exploded diagram step procedure/part name q’ty service points 9 nut/washer 2/2 10 muffler stay 1 2 note: make sure to remove spark plugs before removing the muffler stay 1. 11 bolt 2 12 exhaust chamber assembly 1 13 outer exhaust joint 1 14 inner exhaust joint 1 r...

  • Page 93: Powr

    5-8 powr e exhaust chamber assembly exploded diagram removal and installation chart step procedure/part name q’ty service points exhaust chamber disassembly follow the left “step” for disassembly. 1 nut/washer 1/1 2 bolt 3 3 nut/washer 2/2 4 exhaust chamber 1 5 gasket 1 6 pin 2 not reusable.

  • Page 94: Powr

    5-9 powr e exhaust chamber assembly exploded diagram step procedure/part name q’ty service points 7 muffler 1 8 screw 3 9 plate 1 10 gasket 1 reverse the disassembly steps for assembly. Not reusable.

  • Page 95: Powr

    5-10 powr e exhaust chamber joint exhaust chamber joint exploded diagram removal and installation chart step procedure/part name q’ty service points exhaust chamber joint removal follow the left “step” for removal. Exhaust chamber assembly refer to “exhaust chamber assembly”. 1 clamp/cooling water h...

  • Page 96: Powr

    5-11 powr e exhaust chamber joint exploded diagram step procedure/part name q’ty service points 6 bolt 2 7 bolt 2 8 exhaust chamber joint 1 9 gasket 1 10 pin 2 reverse the removal steps for installation. Not reusable.

  • Page 97: Powr

    5-12 powr e exhaust manifold exhaust manifold exploded diagram removal and installation chart step procedure/part name q’ty service points exhaust manifold removal follow the left “step” for removal. Exhaust chamber joint refer to “exhaust chamber joint”. 1 bolt 4 2 bolt 4 3 wire harness bracket 2 4...

  • Page 98: Powr

    5-13 powr e reed valves reed valves exploded diagram removal and installation chart step procedure/part name q’ty service points reed valve removal follow the left “step” for removal. Carburetor unit refer to “carburetor unit” in chapter 4. 1 bolt 12 note: tighten the bolts in the proper sequence as...

  • Page 99: Powr

    5-14 powr e reed valves service points reed valve inspection 1. Inspect: ● reed valves cracks/damage → replace. 2. Measure: ● valve bending a out of specification → replace. 3. Measure: ● valve stopper height b out of specification → adjust or replace. Max. Valve bending: 0.2 mm (0.01 in) valve stop...

  • Page 100: Powr

    5-15 powr e ypvs ypvs exploded diagram removal and installation chart step procedure/part name q’ty service points ypvs removal follow the left “step” for removal. Exhaust manifold refer to “exhaust manifold”. 1 bolt 8 2 ypvs valve cover 2 3 gasket 2 4 spacer 1 5 link joint/cover 1/1 6 circlip 3 7 w...

  • Page 101: Powr

    5-16 powr e ypvs exploded diagram step procedure/part name q’ty service points 8 bolt 2 note: during installation, align the hole a in the ypvs shaft with the bolt. 9 shaft 2 1 10 shaft 1 1 11 ypvs valve lever 2 12 bolt 2 13 ypvs valve assembly 2 14 oil seal 4 note: if the ypvs shaft is removed, the...

  • Page 102: Powr

    5-17 powr e ypvs service points ypvs valve inspection 1. Eliminate: ● carbon deposits (with a rounded scraper 1) caution: do not use a sharp instrument to avoid damaging or scratching the surfaces. 2. Inspect: ● ypvs valve assembly crack/damage/wear → replace. Ypvs valve installation 1. Install: ● o...

  • Page 103: Powr

    5-18 powr e cylinder head cylinder head exploded diagram removal and installation chart step procedure/part name q’ty service points cylinder head removal follow the left “step” for removal. Exhaust manifold refer to “exhaust manifold”. 1 bolt 10 note: tighten the bolts in the proper sequence as sho...

  • Page 104: Powr

    5-19 powr e cylinder head service points cylinder head inspection 1. Eliminate: ● carbon deposits (with a rounded scraper 1) caution: do not use a sharp instrument to avoid damaging or scratching the cylinder head or spark plug bore threads. 2. Inspect: ● cylinder head water jacket corrosion/mineral...

  • Page 105: Powr

    5-20 powr e cylinders cylinders exploded diagram removal and installation chart step procedure/part name q’ty service points cylinder removal follow the left “step” for removal. Ypvs refer to “ypvs”. Cylinder head refer to “cylinder head”. 1 bolt 8 note: tighten the bolts in a crisscross pattern and...

  • Page 106: Powr

    5-21 powr e cylinders service points cylinder inspection 1. Eliminate: ● carbon deposits (with a rounded scraper 1) 2. Inspect: ● cylinder water jacket corrosion/mineral deposits → clean or replace. ● cylinder inner surface score marks → replace. 3. Measure: ● cylinder bore “d” (with a cylinder gaug...

  • Page 107: Powr

    5-22 powr e pistons pistons exploded diagram removal and installation chart step procedure/part name q’ty service points piston removal follow the left “step” for removal. Cylinders refer to “cylinders”. 1 piston pin clip 2 caution: do not align the open end of the clip with the piston pin slot a. 2...

  • Page 108: Powr

    5-23 powr e exploded diagram step procedure/part name q’ty service points 5 bearing 1 6 piston ring 2 caution: align each end gap with its respective locating pin. Reverse the removal steps for installation. Pistons.

  • Page 109: Powr

    5-24 powr e pistons service points piston pin clip removal and installation 1. Remove and install: ● piston pin clip note: before removing or installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. Piston inspection...

  • Page 110: Powr

    5-25 powr e pistons 4. Calculate: ● piston-to-cylinder clearance out of specification → replace the piston, piston rings and cylinder as a set. Cylinder and piston combination select the appropriate piston to match the cylinder size by the table as follows. Note: new cylinder bore size = 80.000 + a/...

  • Page 111: Powr

    5-26 powr e pistons 2. Measure: ● end gap (with a thickness gauge 1) out of specification → replace the piston rings as a set. Note: push the piston ring into the cylinder with the piston crown. End gap: 0.30–0.45 mm (0.012–0.018 in) piston pin and bearing inspection 1. Inspect: ● piston pins ● bear...

  • Page 112: Powr

    5-27 powr e pistons 4. Check: ● piston pin-to-small end bearing-to- connecting rod free play (at the small end of the connecting rod as shown) free play/small end wear → replace the piston pin, connecting rod, or small end bearing..

  • Page 113: Powr

    5-28 powr e starter motor starter motor exploded diagram removal and installation chart step procedure/part name q’ty service points starter motor removal follow the left “step” for removal. Engine unit refer to “engine unit”. 1 nut/washer 1/1 2 starter motor lead 1 3 bolt 2 4 battery negative lead ...

  • Page 114: Powr

    5-29 powr e flywheel magneto flywheel magneto exploded diagram removal and installation chart step procedure/part name q’ty service points flywheel magneto removal follow the left “step” for removal. Engine unit refer to “engine unit”. Oil pump refer to “oil pump” in chapter 4. 1 bolt 2 2 bolt 6 3 g...

  • Page 115: Powr

    5-30 powr e flywheel magneto exploded diagram step procedure/part name q’ty service points 6 drive coupling 1 7 bolt 1 8 flywheel magneto 1 9 woodruff key 1 10 starter clutch assembly 1 reverse the removal steps for installation..

  • Page 116: Powr

    5-31 powr e flywheel magneto exploded diagram removal and installation chart step procedure/part name q’ty service points generator cover disassembly follow the left “step” for disassembly. 1 bolt 3 2 stator coil 1 3 bolt 2 4 cable holder 1 note: this washer holds the pickup coil lead. Make sure to ...

  • Page 117: Powr

    5-32 powr e flywheel magneto exploded diagram removal and installation chart step procedure/part name q’ty service points starter clutch disassembly follow the left “step” for disassembly. 1 clip 1 2 clip stopper 1 3 spring seat 1 4 spring 1 5 washer 1 6 idle gear 1 7 circlip 1 not reusable.

  • Page 118: Powr

    5-33 powr e flywheel magneto exploded diagram step procedure/part name q’ty service points 8 plate 1 9 weight 3 10 spring ring 1 note: install the spring ring after installing the weights, plate and circlip. 11 pinion gear 1 reverse the disassembly steps for assembly..

  • Page 119: Powr

    5-34 powr e flywheel magneto service points drive coupling removal and installation 1. Remove: ● drive coupling note: install the drive coupling with the same special tools that were used for removal. Coupler wrench: yw-06551/90890-06551 flywheel holder: yw-06550/90890-06550 flywheel magneto removal...

  • Page 120: Powr

    5-35 powr e flywheel magneto drive coupling inspection 1. Inspect: ● drive coupling damage/wear → replace. Flywheel magneto inspection 1. Inspect: ● ring gear damage/wear → replace. Starter clutch assembly inspection 1. Inspect: ● pinion gear 1 ● idle gear 2 damage/wear → replace. 2. Check: ● gear m...

  • Page 121: Powr

    5-36 powr e crankcase crankcase exploded diagram removal and installation chart step procedure/part name q’ty service points crankcase disassembly follow the left “step” for disassembly. Pistons refer to “pistons”. Starter motor refer to “starter motor”. Generator cover refer to “flywheel magneto”. ...

  • Page 122: Powr

    5-37 powr e exploded diagram step procedure/part name q’ty service points 8 bolt 3 note: tighten the bolts in sequence as shown. 9 bolt 1 10 bolt 10 11 bolt 2 12 lower crankcase 1 13 pin 2 14 crankshaft assembly 1 15 upper crankcase 1 reverse the disassembly steps for assembly. Crankcase.

  • Page 123: Powr

    5-38 powr e crankcase service points crankcase inspection 1. Inspect: ● mating surfaces scratches → replace the crankcase. ● crankcase cracks/damage → replace. Crankcase installation 1. Apply: ● gasket maker ® (onto the crankcase mating surfaces) note: before applying gasket maker ® , clean the cran...

  • Page 124: Powr

    5-39 powr e crankshaft crankshaft exploded diagram removal and installation chart step procedure/part name q’ty service points crankshaft removal follow the left “step” for removal. Crankcase refer to “crankcase”. 1 oil seal 1 2 bearing 1 3 oil seal 2 4 bearing clip 1 5 bearing 1 6 crankshaft 1 caut...

  • Page 125: Powr

    5-40 powr e crankshaft service points crankshaft inspection 1. Measure: ● crank width a out of specification → replace. Crank width: 72.95–73.00 mm (2.872–2.874 in) 2. Measure: ● deflection b (with a dial gauge) out of specification → replace. Max. Deflection: 0.05 mm (0.002 in) 3. Measure: ● big en...

  • Page 126: Powr

    5-41 powr e crankshaft 5. Inspect: ● bearings damage/pitting → replace. Note: ● before inspection, thoroughly clean the bearings. ● immediately after inspection, lubricate the bearings to prevent rust. 6. Inspect: ● oil seals damage/wear → replace..

  • Page 127: Jet

    E 1 2 3 4 5 6 7 8 9 jet pump chapter 6 jet pump unit jet pump unit ............................................................................................. 6-1 exploded diagram ............................................................................. 6-1 removal and installation chart ........

  • Page 128: Jet

    6-1 e jet pump jet pump unit jet pump unit exploded diagram removal and installation chart step procedure/part name q’ty service points jet pump unit removal follow the left “step” for removal. 1 bolt 2 2 bolt 2 3 intake grate 1 4 bolt 4 5 intake duct 1 6 screw 4 7 speed sensor 1 note: route the spe...

  • Page 129: Jet

    6-2 e jet pump jet pump unit exploded diagram step procedure/part name q’ty service points 8 bolt 4 9 ride plate 1 10 qsts cable joint 1 11 bilge hose 1 12 nut/washer 1/2 13 steering cable joint 1 14 clamp/spout hose 1/1 15 bolt 1 16 bolt 4.

  • Page 130: Jet

    6-3 e jet pump jet pump unit exploded diagram step procedure/part name q’ty service points 17 jet pump unit assembly 1 note: ● pull the jet pump unit straight back. ● when installing the jet pump unit, align the drive shaft spline (male) with the intermediate drive shaft spline (female). 18 dowel pi...

  • Page 131: Jet

    6-4 e jet pump nozzle deflector and nozzle ring nozzle deflector and nozzle ring exploded diagram removal and installation chart step procedure/part name q’ty service points nozzle deflector and nozzle ring removal follow the left “step” for removal. Jet pump unit refer to “jet pump unit”. 1 bolt 2 ...

  • Page 132: Jet

    6-5 e jet pump impeller duct, impeller housing, and intake duct impeller duct, impeller housing, and intake duct exploded diagram removal and installation chart step procedure/part name q’ty service points impeller duct and impeller housing removal follow the left “step” for removal. Nozzle ring ref...

  • Page 133: Jet

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

  • Page 134: Jet

    6-7 e jet pump impeller duct and drive shaft impeller duct and drive shaft exploded diagram removal and installation chart *1 : epnoc grease ap #0 step procedure/part name q’ty service points impeller duct and drive shaft disassembly follow the left “step” for disassembly. 1 impeller 1 left-hand thr...

  • Page 135: Jet

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

  • Page 136: Jet

    6-9 e jet pump impeller duct and drive shaft service points drive shaft removal 1. Remove: ● impeller note: the impeller has left-hand threads. Turn the impeller clockwise to loosen it. 2. Remove: ● nut 1 drive shaft holder: yb-06151/90890-06519 drive shaft holder: yb-06151/90890-06519 3. Remove: ● ...

  • Page 137: Jet

    6-10 e jet pump impeller duct and drive shaft 5. Remove: ● front bearing note: remove the front bearing with a press. 6. Remove: ● oil seals note: remove the oil seals with press. Impeller inspection refer to “jet pump unit” in chapter 3. Drive shaft inspection 1. Inspect: ● drive shaft damage/wear ...

  • Page 138: Jet

    6-11 e jet pump impeller duct and drive shaft 2. Install: ● front bearing ● drive shaft note: install the front bearing and drive shaft with a press. 3. Install: ● drive shaft (with front bearing) ● spacer ● impeller duct note: press the spacer and the front bearing with a 36-mm deep socket. 4. Add:...

  • Page 139: Jet

    6-12 e jet pump impeller duct and drive shaft 6. Add: ● epnoc grease ap #0 (into the cap) quantity: approximately 1/3 of capacity 7. Install: ● nut ● impeller drive shaft holder: yb-06151/90890-06519.

  • Page 140: Jet

    6-13 e jet pump transom plate and hoses transom plate and hoses exploded diagram removal and installation chart step procedure/part name q’ty service points transom plate and hoses removal follow the left “step” for removal. Exhaust system refer to “exhaust system” in chapter 8. Jet pump unit refer ...

  • Page 141: Jet

    6-14 e jet pump transom plate and hoses exploded diagram step procedure/part name q’ty service points 4 cooling water hose 1 cooling water inlet 5 nut/washer 4/4 6 transom plate 1 7 clamp/bilge hose 2 1/1 8 screw 1 9 bilge strainer holder 1 10 bilge strainer 1 reverse the removal steps for installat...

  • Page 142: Jet

    6-15 e jet pump transom plate and hoses service points bilge strainer inspection refer to “jet pump unit” in chapter 3. Bilge hose inspection 1. Inspect: ● bilge hoses cracks/damage/wear → replace..

  • Page 143: Jet

    6-16 e jet pump bearing housing bearing housing exploded diagram removal and installation chart step procedure/part name q’ty service points bearing housing removal follow the left “step” for removal. Engine unit refer to “engine unit” in chapter 5. 1 rubber coupling 1 2 bolt 3 3 intermediate housin...

  • Page 144: Jet

    6-17 e jet pump bearing housing exploded diagram removal and installation chart step procedure/part name q’ty service points bearing housing disassembly follow the left “step” for disassembly. 1 grease hose 1 2 nipple 1 3 driven coupling 1 4 washer 1 5 intermediate drive shaft 1 6 o-ring 2 7 oil sea...

  • Page 145: Jet

    6-18 e jet pump bearing housing exploded diagram step procedure/part name q’ty service points 8 oil seal 1 9 oil seal 1 10 circlip 1 11 bearing 1 12 circlip 1 reverse the disassembly steps for assembly. Not reusable not reusable not reusable.

  • Page 146: Jet

    6-19 e jet pump bearing housing service points driven coupling removal and installation 1. Remove and install: ● driven coupling note: install the driven coupling with the same special tools that were used for removal. Intermediate drive shaft removal 1. Remove: ● intermediate drive shaft note: supp...

  • Page 147: Jet

    6-20 e jet pump bearing housing bearing, driven coupling shaft, and grease hose inspection 1. Inspect: ● bearing rotate the inner race by hand. Damage/rough movement → replace. ● intermediate drive shaft damage/pitting → replace. ● grease hose cracks/wear → replace. Driven coupling inspection 1. Ins...

  • Page 148: Jet

    6-21 e jet pump bearing housing 2. Install: ● intermediate drive shaft note: support the intermediate housing with steel blocks 1 and press the driven cou- pling shaft. 3. Install: ● oil seal 1 [8 mm (0.31 in)] ● oil seal 2 [10 mm (0.39 in)] distance a: 9.5–10.5 mm (0.37–0.41 in) distance a: 10.3–10...

  • Page 150: Elec

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

  • Page 151: Elec

    E 1 2 3 4 5 6 7 8 9 – + elec charging system.................................................................................... 7-22 wiring diagram................................................................................. 7-22 fuse ...............................................................

  • Page 152: Elec

    7-1 e – + elec electrical components electrical components 1 2 3 4 5 6 c b a = 8 9 7 1 buzzer 2 fuel level sensor 3 multifunction meter 4 ypvs servomotor 5 spark plugs 6 electrical box 7 speed sensor 8 battery 9 thermoswitch 0 starter motor a stator coil and pickup coil b engine stop switch, engine ...

  • Page 153: Elec

    7-2 e – + elec electrical box electrical box exploded diagram removal and installation chart step procedure/part name q’ty service points electrical box disassembly follow the left “step” for disassembly. Electrical box refer to “battery box” in chapter 8. 1 plastic locking tie 2 2 bolt/collar 1/1 n...

  • Page 154: Elec

    7-3 e – + elec electrical box exploded diagram step procedure/part name q’ty service points 7 nut 2 8 starter motor lead/ battery positive lead 1/1 9 fuse 1 10 plastic locking tie 1 11 screw 2 12 ignition coil 1 13 screw 2 14 starter relay 1 not reusable.

  • Page 155: Elec

    7-4 e – + elec electrical box exploded diagram step procedure/part name q’ty service points 15 bolt 1 16 rectifier/regulator 1 17 thermoswitch 1 18 wire harness 2 19 cdi unit 1 20 electrical box housing 1 reverse the disassembly steps for assembly..

  • Page 156: Elec

    7-5 e – + elec electrical box 1 cdi unit 2 starter relay 3 fuse (10a) 4 ignition coil 5 rectifier/regulator 6 spark plug caps b : black br : brown g : green p : pink r : red w : white.

  • Page 157: Elec

    7-6 e – + elec electrical analysis electrical analysis inspection caution: ● all measuring instruments should be han- dled with special care. Damaged or mis- handled instruments will not measure properly. ● on an instrument powered by dry batter- ies, check the battery’s voltage periodi- cally and r...

  • Page 158: Elec

    7-7 e – + elec electrical analysis peak voltage measurement note: ● when checking the condition of the igni- tion system it is vital to know the peak voltage. ● cranking speed is dependant on many factors (e.G., fouled or weak spark plugs, a weak battery). If one of these is defected, the peak volta...

  • Page 159: Elec

    7-8 e – + elec electrical analysis test harness note: ● make sure the output lead (red lead) of the rectifier/regulator is disconnected when measuring the peak voltage of the lighting coil and rectifier/regulator. ● if the charge coil and pickup coil are mea- sured unloaded, disconnect the test har-...

  • Page 160: Elec

    7-9 e – + elec ignition system ignition system wiring diagram p w/b w/r w o p o br br l l b b w/b set pull 1 2 6 8 7 4 5 b b o o p p b p w b b w b w b br l w/b w/r 3 b b l br w/r w/b o w p w b r br w b 1 pickup coil 2 charge coil 3 cdi unit 4 engine stop switch 5 engine stop lanyard switch 6 thermos...

  • Page 161: Elec

    7-10 e – + elec ignition system ignition spark gap warning ● when checking the spark gap, do not touch any of the connections of the spark gap tester lead wires. ● when performing the spark gap test, take special care not to let sparks leak out of the removed spark plug cap. ● when performing the sp...

  • Page 162: Elec

    7-11 e – + elec ignition system ignition system peak voltage warning when checking the electrical components, do not touch any of the connections of the digital tester lead wires. Note: ● if there is no spark or the spark is weak, continue with the ignition system test. ● if a good spark is obtained...

  • Page 163: Elec

    7-12 e – + elec ignition system 3. Measure: ● pickup coil output peak voltage below specification → replace the pickup coil. Pickup coil output peak voltage: white/red (w/r) – white/black (w/b) r/min unloaded loaded cranking 2,000 3,500 v 5 3 7 11 test harness (8-pin): yw-06779/90890-06779 spark plu...

  • Page 164: Elec

    7-13 e – + elec ignition system 2. Measure: ● secondary coil resistance out of specification → replace. Secondary coil resistance: spark plug cap – spark plug cap 14.3–30.5 k Ω at 20 ˚c (68 ˚f) engine stop switch 1. Check: ● engine stop switch continuity out of specification → replace. Engine stop s...

  • Page 165: Elec

    7-14 e – + elec starting system starting system wiring diagram set pull 2 3 r br r br br w b r br m 1 r b 4 5 6 b r br br r r b r r br 1 starter motor 2 engine stop lanyard switch 3 starter switch 4 fuse (10a) 5 starter relay 6 battery b : black br : brown r : red w : white.

  • Page 166: Elec

    7-15 e – + elec starting system battery refer to “electrical” in chapter 3. Wiring connections 1. Check: ● wiring connections poor connections → properly connect. Fuse 1. Check: ● fuse holder continuity no continuity → check the fuse holder leads. 2. Check: ● fuse holder lead continuity no continuit...

  • Page 167: Elec

    7-16 e – + elec starting system starter relay 1. Inspect: ● brown lead terminal ● black lead terminal loose → tighten. 2. Check: ● starter relay faulty → replace. Checking steps: ● connect the tester leads between the starter relay terminals as shown. ● connect the brown lead terminal to the positiv...

  • Page 168: Elec

    7-17 e – + elec starter motor exploded diagram removal and installation chart step procedure/part name q’ty service points starter motor disassembly follow the left “step” for disassembly. Starter motor refer to “starter motor” in chapter 5. 1 o-ring 1 2 bolt 2 3 starter motor front cover 1 4 o-ring...

  • Page 169: Elec

    7-18 e – + elec starter motor exploded diagram step procedure/part name q’ty service points 8 starter motor rear cover 1 9 o-ring 1 10 shim * t = 0.2 mm, 0.8 mm 11 armature assembly 1 12 nut/spring washer/washer 1/1/4 13 o-ring 1 14 brush holder 1 15 brush spring 4 16 bolt 1 17 brush assembly 1 *: a...

  • Page 170: Elec

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

  • Page 171: Elec

    7-20 e – + elec starter motor service points armature inspection 1. Inspect: ● armature shaft 1 damage/wear → replace. 1 2. Inspect: ● commutator dirt → clean with 600 grit sandpaper. 3. Measure: ● commutator diameter out of specification → replace. Min. Commutator diameter: 27.0 mm (1.06 in) 4. Che...

  • Page 172: Elec

    7-21 e – + elec starter motor 6. Inspect: ● armature coil continuity out of specification → replace. Armature coil continuity: commutator segments 1 continuity segment - laminations 2 no continuity segment - armature shaft no continuity brush holder inspection 1. Measure: ● brush length a out of spe...

  • Page 173: Elec

    7-22 e – + elec charging system charging system wiring diagram 3 2 r r m b 1 g g 4 b g g b r r r g g 1 lighting coil 2 battery 3 fuse (10a) 4 rectifier/regulator b : black g : green r : red g/w : green/white.

  • Page 174: Elec

    7-23 e – + elec charging system fuse refer to “starting system”. Battery refer to “electrical” in chapter 3. Rectifier/regulator peak voltage 1. Measure: ● rectifier/regulator output peak voltage below specification → measure the lighting coil output peak voltage or replace the rectifier/regulator. ...

  • Page 175: Elec

    7-24 e – + elec ypvs wiring diagram 1 w/b w/r w/r w/b 3 r b b gy b m 5 4 r r r b 2 gy b r gy p w/b w/r w o p o br br l l b b w/b g gy 1 pickup coil 2 cdi unit 3 ypvs servomotor 4 fuse (10a) 5 battery b : black br : brown g : green gy : gray l : blue o : orange p : pink r : red w : white w/b : white/...

  • Page 176: Elec

    7-25 e – + elec ypvs fuse refer to “starting system”. Battery refer to “electrical” in chapter 3. Pickup coil refer to “ignition system”. Cdi unit refer to “ignition system”..

  • Page 177: Elec

    7-26 e – + elec ypvs servomotor ypvs servomotor exploded diagram removal and installation chart step procedure/part name q’ty service points ypvs servomotor removal follow the left “step” for removal. 1 bolt 2 2 cable holder 1 3 ypvs servomotor coupler 1 4 nut/washer 2/2 5 ypvs servomotor 1 6 ypvs c...

  • Page 178: Elec

    7-27 e – + elec ypvs servomotor service points ypvs cable removal and installation 1. Remove: ● ypvs cables 1 and 2 note: ● there is a white paint mark a on ypvs cable 2. ● when installing the ypvs cable, make sure that the ypvs cable locknuts 3 are fully turned in. Removal steps: ● remove the ypvs ...

  • Page 179: Elec

    7-28 e – + elec ypvs servomotor caution: do not disassemble the ypvs servomotor unit. It is a sealed unit and if it is faulty it must be replaced. Ypvs cable adjustment refer to “control system” in chapter 3. ● make sure the servomotor operates properly. Note: make sure the pulley operates three sec...

  • Page 180: Elec

    7-29 e – + elec indication system indication system wiring diagram 1 g g b 9 g g 2 8 b b b p p p b p r r r r g b p r g m b r 0 a b b r br r r set pull 6 7 5 y r br r br r br br r/y b/y b/y r/y b r/y r r b b r y r/w l/r l/b w b r br r p b g l/b l/r r/w b y y r br p w/b w/r w o p o br br l l b b w/b g...

  • Page 181: Elec

    7-30 e – + elec indication system fuse refer to “starting system”. Battery refer to “electrical” in chapter 3. Lighting coil refer to “charging system”. Rectifier/regulator refer to “charging system”. Cdi unit refer to “ignition system”. Thermoswitch refer to “ignition system”. Buzzer 1. Check: ● bu...

  • Page 182: Elec

    7-31 e – + elec indication system fuel level sensor 1. Measure: ● fuel level sensor resistance out of specification → replace. White/blue (w/l) – black (b) float position resistance ( Ω ) a 757–803 b 0–8 multifunction meter multifunction meter 1. Check: ● multifunction meter cracked meter housing → ...

  • Page 183: Elec

    7-32 e – + elec indication system display function 1. Check: ● display function not operate → replace the multifunc- tion meter. 1 oil level sensor 2 fuel level sensor 3 buzzer 4 battery 5 speed sensor b : black g : green l : blue p : pink r : red y : yellow l/b : blue/black l/r : blue/red r/w : red...

  • Page 184: Elec

    7-33 e – + elec indication system fuel level gauge 1. Check: ● fuel level gauge not operating → replace the multi- function meter. Note: when inspecting the multifunction meter unit or emptying the oil tank, connect the blue and black terminals (white two-pin connector) with a jumper lead 1 to preve...

  • Page 185: Elec

    7-34 e – + elec indication system oil level gauge 1. Check: ● oil level gauge not operating → replace the multi- function meter. Note: when inspecting the multifunction meter unit or emptying the fuel tank, connect the white/blue and black terminals (green two- pin connector) with a jumper lead 1 to...

  • Page 186: Elec

    7-35 e – + elec indication system overheat warning indicator 1. Check: ● overheat warning indicator not operating → replace the multi- function meter. Note: ● when inspecting the multifunction meter unit or emptying the fuel tank, connect the white/blue and black terminals (green two-pin connector) ...

  • Page 187: Elec

    7-36 e – + elec indication system speed meter 1. Check: ● speed meter output voltage within specification → check the speed sensor output voltage and pulses. Out of specification → replace. Note: ● when inspecting the multifunction meter unit or emptying the fuel tank, connect the white/blue and bla...

  • Page 188: Elec

    7-37 e – + elec indication system speed sensor 1. Check: ● speed sensor output voltage and pulses out of specification → replace. Speed sensor output voltage (dependant on the paddle wheel position): less than 400 mv/ more than 11.6 v output pulse: 2 pulses/one-full turn checking steps: ● apply dc 1...

  • Page 190: Hull

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

  • Page 191: Hull

    E 1 2 3 4 5 6 7 8 9 hull hood buzzer and hood lock ......................................................................... 8-28 exploded diagram ........................................................................... 8-28 removal and installation chart ............................................

  • Page 192: Hull

    8-1 e hull hood handlebar handlebar exploded diagram removal and installation chart step procedure/part name q’ty service points handlebar cover removal follow the left “step” for removal. 1 screw 4 2 handlebar cover 1 3 screw 4 4 handlebar cover stay 1 5 spiral tube 1 6 band 1.

  • Page 193: Hull

    8-2 e hull hood handlebar exploded diagram step procedure/part name q’ty service points 7 throttle cable 1 8 choke cable 1 9 bolt 4 10 upper handlebar holder 2 11 handlebar assembly 1 12 lower handlebar holder 2 reverse the removal steps for installation..

  • Page 194: Hull

    8-3 e hull hood handlebar exploded diagram removal and installation chart step procedure/part name q’ty service points handlebar removal follow the left “step” for removal. Qsts cable (to jet nozzle) refer to “remote control cables and speed sensor lead”. 1 grommet 1 note: apply soapy water to the g...

  • Page 195: Hull

    8-4 e hull hood handlebar exploded diagram step procedure/part name q’ty service points 4 qsts cable 1 1 note: route the qsts cables behind of the oil filler hose. 5 handlebar assembly 1 6 nut/washer 2/2 7 qsts converter 1 8 throttle cable 1 9 choke cable 1 reverse the removal steps for installation...

  • Page 196: Hull

    8-5 e hull hood handlebar exploded diagram removal and installation chart step procedure/part name q’ty service points handlebar disassembly follow the left “step” for disassembly. 1 band 1 2 bolt 2 3 grip end 2 4 spacer 1 5 screw/washer/spring washer 1/1/1 6 qsts grip assembly 1 7 screw 2 8 handleb...

  • Page 197: Hull

    8-6 e hull hood handlebar exploded diagram step procedure/part name q’ty service points 10 screw 2 11 throttle lever assembly 1 12 screw 2 13 choke lever assembly 1 14 handlebar grip 1 note: apply adhesive to the handlebar and the inner surface of the handlebar grip. 15 handlebar 1 reverse the disas...

  • Page 198: Hull

    8-7 e hull hood handlebar service points handlebar inspection 1. Inspect: ● handlebar bends/cracks/damage → replace. Handlebar switch inspection refer to “ignition system” and “starting system” in chapter 7. Handlebar assembly installation 1. Adjust: ● qsts cable length a note: ● before adjusting th...

  • Page 199: Hull

    8-8 e hull hood handlebar 3. Install: ● throttle cable note: fit the seal into the glove in the bracket. 4. Install: ● band 1 note: after inserting the qsts cables into the grommet, tie the end of grommet with the band. 5. Install: ● spiral tube 1 note: be sure to install the spiral tube, containing...

  • Page 200: Hull

    8-9 e hull hood handlebar 7. Adjust: ● choke lever operation refer to “control system” in chapter 3. 8. Adjust: ● throttle lever free play refer to “control system” in chapter 3. 9. Adjust: ● qsts cable refer to “control system” in chapter 3..

  • Page 201: Hull

    8-10 e hull hood qsts grip qsts grip exploded diagram removal and installation chart step procedure/part name q’ty service points qsts grip disassembly follow the left “step” for disassembly. Qsts grip assembly refer to “handlebar”. 1 screw/washer 1/1 2 cover 1 3 ball 2 4 spring 2 5 qsts cable 1 1 6...

  • Page 202: Hull

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

  • Page 203: Hull

    8-12 e hull hood qsts grip service points qsts cable inspection 1. Inspect: ● qsts cables frays/kinks/rough movement → replace. Qsts grip inspection 1. Inspect: ● qsts grip damage/wear → replace..

  • Page 204: Hull

    8-13 e hull hood steering column steering column exploded diagram removal and installation chart step procedure/part name q’ty service points steering column removal follow the left “step” for removal. Steering console cover assembly refer to “steering console cover”. Steering cable end refer to “re...

  • Page 205: Hull

    8-14 e hull hood steering column exploded diagram removal and installation chart *: be sure to install the same number of shim(s) as installed originally at factory. Step procedure/part name q’ty service points steering column disassembly follow the left “step” for disassembly. 1 grommet 1 2 bolt/wa...

  • Page 206: Hull

    8-15 e hull hood steering column exploded diagram step procedure/part name q’ty service points 5 washer 1 6 steering column 1 7 bushing 2 8 steering column housing 1 reverse the disassembly steps for assembly. 8 × 60 mm 16 n • m (1.6 kgf • m, 11 ft • ib) 5 n • m (0.5 kgf • m, 3.6 ft • ib) 26 n • m (...

  • Page 207: Hull

    8-16 e hull hood steering column service points steering column bushing inspection 1. Inspect: ● bushings damage/wear → replace. 2. Inspect: ● steering column inspection refer to “control system” in chapter 3..

  • Page 208: Hull

    8-17 e hull hood remote control cables and speed sensor lead remote control cables and speed sensor lead exploded diagram removal and installation chart step procedure/part name q’ty service points remote control cables and speed sensor lead removal follow the left “step” for removal. 1 speed sensor...

  • Page 209: Hull

    8-18 e hull hood remote control cables and speed sensor lead exploded diagram step procedure/part name q’ty service points 9 cap 1 10 nut 1 11 steering cable 1 12 nut 1 13 pin 1 14 qsts cable end 1 15 cap 1 16 nut 1 17 qsts cable 1 reverse the removal steps for installation..

  • Page 210: Hull

    8-19 e hull hood remote control cables and speed sensor lead exploded diagram removal and installation chart step procedure/part name q’ty service points speed sensor disassembly follow the left “step” for disassembly. 1 paddle wheel set 1 2 speed sensor housing 1 reverse the disassembly steps for a...

  • Page 211: Hull

    8-20 e hull hood remote control cables and speed sensor lead service points warning when routing the cables, do not grasp the cable by the outer crimped sheath or steel end. This could deform or loosen the cable end due to extreme angles and or pressure. Always hold the cables by the bracket or oute...

  • Page 212: Hull

    8-21 e hull hood remote control cables and speed sensor lead qsts cable (jet pump side) installation 1. Install: ● qsts cable (jet pump side) a warning the qsts cable must be screwed in more than 8 mm (0.31 in). Qsts cable set length (jet pump side): 12.0–14.0 mm (0.47–0.55 in) qsts cable stopper in...

  • Page 213: Hull

    8-22 e hull hood front hood front hood exploded diagram removal and installation chart step procedure/part name q’ty service points front hood removal follow the left “step” for removal. 1 bolt 2 2 screw 8 3 seal washer 8 4 visor 1 5 pop nut 8 6 bolt 2 10 9 1 11 2 3 5 8 4 16 n • m (1.6 kgf • m, 11 f...

  • Page 214: Hull

    8-23 e hull hood exploded diagram step procedure/part name q’ty service points 7 hood lock 1 8 front hood 1 9 nut 2 10 plate 1 11 hinge assembly 1 reverse the removal steps for installation. 10 9 1 11 2 3 5 8 4 16 n • m (1.6 kgf • m, 11 ft • ib) 6 × 14 mm 5 n • m (0.5 kgf • m, 3.6 ft • ib) 6 × 14 mm...

  • Page 215: Hull

    8-24 e hull hood steering console cover steering console cover exploded diagram removal and installation chart step procedure/part name q’ty service points steering console cover removal follow the left “step” for removal. Handlebar assembly refer to “handlebar”. Knob (fuel cock) refer to “fuel cock...

  • Page 216: Hull

    8-25 e hull hood steering console cover exploded diagram step procedure/part name q’ty service points 6 plate 1 7 nut/washer 2/2 8 bolt/square-ring 2/2 9 steering console cover assembly 1 note: remove the oil filler cap to remove the steering console cover assembly easier. Reverse the removal steps ...

  • Page 217: Hull

    8-26 e hull hood steering console cover exploded diagram removal and installation chart step procedure/part name q’ty service points steering console cover disassembly follow the left “step” for disassembly. 1 screw 4 2 side cover 2 3 nut 2 4 holder 1 5 multifunction meter 1 6 8 7 2 n • m (0.2 kgf •...

  • Page 218: Hull

    8-27 e hull hood steering console cover exploded diagram step procedure/part name q’ty service points 6 screw 4 7 glove compartment 1 8 pop nut 4 9 steering console cover 1 reverse the disassembly steps for assembly. 6 8 7 2 n • m (0.2 kgf • m, 1.4 ft • ib) 6 × 18 mm 3 n • m (0.3 kgf • m, 2.2 ft • i...

  • Page 219: Hull

    8-28 e hull hood buzzer and hood lock buzzer and hood lock exploded diagram removal and installation chart step procedure/part name q’ty service points buzzer and hood lock removal follow the left “step” for removal. Steering console cover assembly refer to “steering console cover”. Steering cable r...

  • Page 220: Hull

    8-29 e hull hood buzzer and hood lock exploded diagram step procedure/part name q’ty service points 6 nut 2 7 bolt 2 8 hood lock assembly 1 9 grommet 1 reverse the removal steps for installation..

  • Page 221: Hull

    8-30 e hull hood buzzer and hood lock exploded diagram removal and installation chart step procedure/part name q’ty service points hood lock disassembly follow the left “step” for disassembly. 1 screw 2 2 hood lock button assembly 1 3 circlip 1 4 washer 1 5 pin 1 6 hook lever 1 7 spring 1 8 hood loc...

  • Page 222: Hull

    8-31 e hull hood hoses hoses exploded diagram removal and installation chart step procedure/part name q’ty service points hoses removal follow the left “step” for removal. Engine unit refer to “engine unit” in chapter 5. Steering console cover assembly refer to “steering console cover”. 1 band 2 2 v...

  • Page 223: Hull

    8-32 e hull hood hoses exploded diagram step procedure/part name q’ty service points 4 band 1 5 check valve 1 6 oil tank breather hose 1 7 fuel tank breather hose 2 reverse the removal steps for installation..

  • Page 224: Hull

    8-33 e hull hood hoses service points check valve inspection 1. Check: ● check valve faulty → replace. Checking steps: ● connect a hose to the end of check valve “a” and blow into it. Air should come out from end “b”. ● connect the hose to the end of check valve “b” and blow into it. Air should not ...

  • Page 225: Hull

    8-34 e hull hood seats and hand grip seats and hand grip exploded diagram removal and installation chart step procedure/part name q’ty service points seats and hand grip removal follow the left “step” for removal. 1 seat assembly 1 2 bolt 2 3 seat lock assembly 1 4 nut 1 5 notch 1 6 washer 1.

  • Page 226: Hull

    8-35 e hull hood seats and hand grip exploded diagram step procedure/part name q’ty service points 7 rubber ring 1 8 nut/washer 2/2 9 bolt 2 10 bolt 2 11 hand grip 1 12 bracket 1 reverse the removal steps for installation..

  • Page 227: Hull

    8-36 e hull hood seats and hand grip service points seat lock inspection 1. Inspect: ● seat lock damage/wear → replace..

  • Page 228: Hull

    8-37 e hull hood battery box battery box exploded diagram removal and installation chart step procedure/part name q’ty service points battery box removal follow the left “step” for removal. 1 band 1 2 fire extinguisher container 1 3 band 1 4 bolt 1 5 battery negative lead 1 6 terminal extension 1 7 ...

  • Page 229: Hull

    8-38 e hull hood battery box exploded diagram step procedure/part name q’ty service points 12 electrical box 1 13 cap nut/washer 2/2 14 holder 1 15 holder 1 16 cap nut/washer 2/2 17 battery box 1 note: before installing the battery box, route the battery leads and battery breather hose through the h...

  • Page 230: Hull

    8-39 e hull hood exhaust system exhaust system exploded diagram removal and installation chart step procedure/part name q’ty service points exhaust system removal follow the left “step” for removal. Battery box refer to “battery box”. Jet pump unit assembly refer to “jet pump unit” in chapter 6. 1 f...

  • Page 231: Hull

    8-40 e hull hood exhaust system exploded diagram step procedure/part name q’ty service points 8 water lock 1 9 bolt 3 10 packing 1 11 hose clamp 2 note: remove parts 11 to 14 as a set. 12 water tank 1 13 rubber hose 1 14 exhaust outlet 1 reverse the removal steps for installation..

  • Page 232: Hull

    8-41 e hull hood exhaust system service points exhaust system inspection 1. Inspect: ● water lock band cracks/damage → replace. 2. Inspect: ● rubber hoses burns/cracks/damage → replace. 3. Inspect: ● water lock cracks/leaks → replace. 4. Inspect: ● water tank cracks/damage/leaks → replace. Exhaust c...

  • Page 233: Hull

    8-42 e hull hood deck and hull deck and hull exploded diagram removal and installation chart step procedure/part name q’ty service points deck and hull disassembly follow the left “step” for disassembly. 1 bolt 2 2 bow eye 1 3 nut 2 4 rope hole fitting 2 5 nut 1 6 spout 1 7 bolt 6.

  • Page 234: Hull

    8-43 e hull hood deck and hull exploded diagram step procedure/part name q’ty service points 8 sponson 2 note: make sure install the starboard and port side sponsons to the same position. 9 bolt 8 10 flap 2 11 nut/washer 4/4 12 screw/washer 4/4 13 drain plug 2 14 packing 2 reverse the disassembly st...

  • Page 235: Hull

    8-44 e hull hood engine mount engine mount exploded diagram removal and installation chart step procedure/part name q’ty service points engine mount removal follow the left “step” for removal. Engine unit refer to “engine unit” in chapter 5. 1 bolt 2 2 damper 1 3 bolt 8 4 engine mount 4 reverse the ...

  • Page 236: Hull

    8-45 e hull hood engine mount hull repair shallow scratches 1. Sand the scratches with 400 grit sand- paper (either wet or dry) until the scratches are smooth. Then, sand the scratches once again with 600 grit sand- paper (either wet or dry). Deep scratches 1. Remove any sharp or rough edges from th...

  • Page 237: Hull

    8-46 e hull hood engine mount cracks and punctures note: before attempting to repair any cracks or punctures, refer to “watercraft frp repair manual”. 1. Remove any damaged fiberglass. 2. Cut the damaged area and separate it approximately 0.25 inch. 3. On the outside of the hull, grind the separated...

  • Page 238: Hull

    8-47 e hull hood engine mount insert nut note: use the insert nut when: ● a pop nut which was attached to the hull slipped off or, ● when a bolt which was fastened to an insert nut or pop nut broke. ● nut 1 ● thread direction 2 ● slot to be threaded 3 note: drilling size part no. Part name remarks e...

  • Page 239: Hull

    8-48 e hull hood engine mount 4. First, apply tape 1 to the inner surface of the hull and then laminate fiberglass mats over the tape with resin. Note: when it is possible to work inside the hull, laminate the mats from the inside. 5. Sand the outer surface of the hull until it is smooth. 6. Install...

  • Page 240: Hull

    8-49 e hull hood engine mount 2. To prevent water from entering the ure- thane foam, apply silicone sealant to the inside of the hole as shown. 3. Install the insert nut as explained in “example 1”. ● brass insert nut 1 ● hull 2 ● urethane foam 3 ● silicone sealant 4 graphic removal 1. Hold a hair d...

  • Page 241: Trbl

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

  • Page 242: Trbl

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

  • Page 243: Trbl

    9-2 trbl anls e trouble analysis pilot water hose 5 water hose 5 water passage 5 jet pump unit duct 6 impeller 6 intake grate 6 bearings 6 intake duct 6 water inlet hose 6 bilge hose 6 bilge strainer 6 bilge hose joint 6 valve body 6 electrical cdi unit 7 lighting coil 7 charge coil 7 pickup coil (p...

  • Page 246

    Yamaha motor corporation, usa printed in usa nov. 2000 — ?.? × 1 cr f0w-28197-1a-11 (gp800a).

  • Page 247: Wiring Diagram

    M wiring diagram gp800r y b/y l/b l/r r/w r/y w/b w/l w/r : : : : : : : : : yellow black/yellow blue/black blue/red red/white red/yellow white/black white/blue white/red color code 1 thermoswitch 2 ignition coil 3 lighting coil 4 pickup coil 5 charge coil 6 cdi unit 7 starter motor g engine stop swi...