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Yamaha WaveRunner VXR VX1800A Service Manual

Summary of WaveRunner VXR VX1800A

  • Page 1

    Service manual waverunner vxs vx1800 (f2w) vxr vx1800a (f2w) f2w-28197-zu-11.

  • Page 2

    Preface this manual has been prepared by yamaha primarily for use by yamaha dealers and their trained me- chanics when performing maintenance procedures and repairs to yamaha equipment. It has been writ- ten to suit the needs of persons who have the bronze technical certificate of the yta (yamaha te...

  • Page 3: Contents

    Contents general information 1 specification 2 maintenance 3 fuel system 4 power unit 5 jet pump unit 6 electrical system 7 hull and hood 8 troubleshooting 9 appendix a.

  • Page 4: General Information

    General information safety while working.......................................................... 1-1 rotating parts ............................................................................. 1-1 hot parts..................................................................................... 1-1 e...

  • Page 5

    1 general information ride system............................................................................. 1-23 ride motor............................................................................... 1-24 etv system .................................................................................

  • Page 6

    Safety while working 1-1 safety while working to prevent an accident or injury and to provide quality service, observe the following safety procedures. Rotating parts hands, feet, hair, jewelry, clothing, personal flotation device straps, and so on, can become entangled with internal rotating parts ...

  • Page 7

    1-2 safety while working • protect your hands and feet by wearing pro- tective gloves and safety shoes when neces- sary. Working with crane • when moving the watercraft, or when lifting the engine during removal or installation, make sure to use a crane with a lifting capac- ity that is equal to or ...

  • Page 8

    Safety while working 1-3 handling of sealants • wear protective gloves to protect your skin, when using the sealants. • see the material safety data sheet issued by the manufacturer. Some of the sealants may be harmful to human health. Special service tool use the recommended special service tools t...

  • Page 9

    1-4 identification number identification number primary i.D. Number the primary i.D. Number is stamped on a label attached to the inside of the engine compart- ment. Engine serial number the engine serial number is stamped on a la- bel attached to the engine unit. Jet pump unit serial number the jet...

  • Page 10

    How to use this manual 1-5 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...

  • Page 11

    1-6 how to use this manual conditions when testing and adjusting conditions can affect specifications when checking, measuring and making some adjustments. Service data in this manual was determined under the following conditions: • electrical resistance for components such as pickup coils and senso...

  • Page 12

    How to use this manual 1-7 up upside ydis yamaha diagnostic system abbreviation description.

  • Page 13

    1-8 adhesive, lubricant, sealant, and thread locking agent adhesive, lubricant, sealant, and thread locking agent symbols symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points. Symbols in an exploded diagram or illustration indicate the type of adh...

  • Page 14

    Special service tool 1-9 special service tool special service tools numbered “yb/ym/ys/yu/yw-*****” are distributed by k & l. Special service tools with yamaha part numbers (90890-*****) are distributed by the parts division. Special service tool with part number 90890-06884/lit-ydis2-01-kt is distr...

  • Page 15

    1-10 special service tool fuel pressure gauge adapter 90890-06946 fuel pressure gauge adapter yb-06946 4-3 fuel pressure gauge 90890-06753 fuel pressure gauge yu-03153m 4-3 compression gauge 90890-03160 compression gauge yu-33223 5-1 compression gauge extension 90890-06563 5-1 exhaust pipe wrench 90...

  • Page 16

    Special service tool 1-11 leakage tester 90890-06840 5-29 valve spring compressor 90890-04019 valve spring compressor ym-04019 5-47, 5-53 valve spring compressor attachment 90890-04114 compressor adapter ym-04114 5-47, 5-53 valve guide remover/installer 90890-06801 valve guide remover yb-06801 5-49,...

  • Page 17

    1-12 special service tool valve seat cutter holder 90890-06812 5-51 valve seat cutter 30° 90890-06720 5-51 valve seat cutter 45° 90890-06325 5-51 valve seat cutter 60° 90890-06324 5-51 valve seat cutter 30° 90890-06818 5-51 valve seat cutter 45° 90890-06555 5-51 valve seat cutter 60° 90890-06323 5-5...

  • Page 18

    Special service tool 1-13 shaft holder 90890-06721 shaft holder yw-06721 5-59, 5-59, 5-63, 5-64, 5-64, 5-65, 5-65 drive handle 90890-06722 drive handle yw-06722 5-59, 5-59, 5-63, 5-64, 5-65, 5-65 flywheel puller 90890-06723 flywheel puller yw-06723 5-60 rotor puller 90890-01080 stator rotor puller y...

  • Page 19

    1-14 special service tool ball bearing attachment 90890-06657 5-61 driver handle (large) yb-06071 5-61, 5-61, 6-12 forward gear outer race installer yb-41446 5-61 bearing pressure c 90890-02393 5-61 forward bearing race installer yb-06258 5-61 piston ring compressor 90890-05158 piston ring compresso...

  • Page 20

    Special service tool 1-15 stopper guide stand 90890-06538 6-11, 6-12, 6-20 slide hammer yb-06096 6-11, 6-12, 6-20 driver rod l3 90890-06652 6-12 driver rod sl 90890-06602 6-12 needle bearing attachment 90890-06609 6-12 driveshaft needle bearing installer and re- mover yb-06194 6-12 oil seal installe...

  • Page 21

    1-16 special service tool shaft holder 90890-06730 shaft holder yw-06730 6-20, 6-22 bearing puller legs yb-06523 6-20 needle bearing attachment 90890-06654 6-21, 6-21, 6-21 needle bearing installer yb-06434 6-21, 6-21, 6-21 bearing attachment 90890-06727 bearing attachment yw-06727 6-22, 6-22 ydis2 ...

  • Page 22

    Special service tool 1-17 peak voltage adapter b 90890-03172 peak volt adapter yu-39991 7-10 ignition checker (spark gap tester) 90890-06754 spark checker ym-34487 7-11 test harness (2 pins) 90890-06851 7-12 test harness (3 pins) 90890-06870 test harness (3 pins) yb-06870 7-13 test harness (2 pins) ...

  • Page 23

    1-18 special service tool throttle sensor adjusting lead fwy–3 90890-06857 test harness (3 pins) yb-06857 7-27 tool name/tool no. Illustration reference pages.

  • Page 24

    Model feature 1-19 model feature general feature the f2w features a hull and deck that are based on those of the f2x and is equipped with an 1812 cm³ engine. While retaining the stability and comfort of the f2x, the acceleration performance and maximum speed have been improved by increasing the outp...

  • Page 25

    1-20 model feature model equipment comparison table : equipped —: not equipped model vxs vxr total length 3.34 m (131.5 in) 3.35 m (131.9 in) width 1220 mm (48.0 in) dry weight 347 kg (765 lb) 348 kg (767 lb) reboarding step “1” — front seat “2” normal seat cruiser seat a b 2 2 1 a. Vxs b. Vxr.

  • Page 26

    Technical tips 1-21 technical tips engine control the ecm controls ignition timing and fuel injection with information received from the sensors and switches installed on the engine as well as utilizing the base map saved in the ecm. Part name function 1 tps detects the opening angle of the etv. 2 c...

  • Page 27

    1-22 technical tips 13 aps detects the opening angle of the throttle lever. 14 steering sensor detects when the handlebar is turned all the way to the right or left. Part name function.

  • Page 28

    Technical tips 1-23 ride system unlike previous systems with mechanical shifting and q.S.T.S., the ride motor is driven through elec- tric signals in order to conduct shifting and trim operations. With electrical operation, conventional cables are not used. By using the ride lever and electric trim ...

  • Page 29

    1-24 technical tips ride motor the ride lever employs the same part used for the throttle lever that incorporates the aps. An rps (ride position sensor) is built into the ride lever. The ride motor is an assembly part that includes the shift motor and trim motor, a shift position sensor that detects...

  • Page 30

    Technical tips 1-25 etv system the f2w is equipped with the same throttle lever as that of the f2s. The throttle lever has an aps which senses the degree of throttle opening and converts the status into electronic signals, delivering the information to the ecm. The ecm controls the etv based on the ...

  • Page 31

    1-26 technical tips shift control the reverse gate on ride models is in the f position when the engine is stopped. When the engine is started, the reverse gate returns to the n position automatically. The ecm calculates the throttle lever opening angle and ride lever opening angle to control shiftin...

  • Page 32

    Technical tips 1-27 trolling → neutral neutral → reverse engine stopped condition lever reverse gate.

  • Page 33

    1-28 technical tips engine control system item condition action remarks overheat warning con- trol • engine temperature rises rapidly in a short time. • thermo switch is on. • exhaust cooling wa- ter temperature ex- ceeds 75 °c (167 °f). • opening angle of the etv is regulated. • maximum engine spee...

  • Page 34

    Technical tips 1-29 etv failure control etv failed, or open or short circuit is detect- ed in etv circuit. • opening angle of the etv is fixed to the default opening angle. • maximum engine speed is limited to approximately 3000 r/min. • ignition timing is con- trolled. — battery dis- connection war...

  • Page 35

    1-30 technical tips off-throttle steering (ots) control control is activated when all of the follow- ing conditions are present: • engine speed ex- ceeds 6000 r/min for a few seconds or more. • throttle lever is at the fully closed posi- tion. • steering sensor is on. Engine speed is increased to ap...

  • Page 36

    Technical tips 1-31 deck and hull the f2w uses the same type of hull and deck that the f2x uses. However, the seats are different from the seats of the f2x. The vxr uses a cruiser seat for the front seat in order to increase the comfort of the operator. A. The front and rear seats are separate to ma...

  • Page 37

    1-32 technical tips lubrication system the engine features a wet-sump lubrication system. The oil pan carries out the scavenging function and the engine uses a feed oil pump assy. The blowby gas from the cylinder head cover is sent directly to the oil separator tank. A 1 2 3 4 5 6 b 7 8 9 10 11 12 1...

  • Page 38

    Technical tips 1-33 hose routing h i j g a d e b f c a. From flushing hose connector b. From transom plate c. To cooling water pilot outlet d. To drain joint (transom plate) e. To drain joint f. For water draining when engine is stopped g. Cooling water flow h. Blowby gas flow i. Bilge water flow j....

  • Page 39

    1-34 technical tips cooling water flow a d e b f c g a. From flushing hose connector b. From transom plate c. To cooling water pilot outlet d. To drain joint e. To exhaust valve f. For water draining when engine is stopped g. Cooling water flow.

  • Page 40: — Memo —

    Technical tips 1-35 — memo —.

  • Page 41: Specification

    2 specification model data .......................................................................... 2-1 fuel system technical data ............................................... 2-3 fuel system ................................................................................ 2-3 power unit technic...

  • Page 42

    2-1 model data model data model code hull f2w engine 6ew jet pump 6ew dimensions and weight length vx1800-p 3340 mm (131.5 in) vx1800a-p 3350 mm (131.9 in) width 1220 mm (48.0 in) height 1190 mm (46.9 in) dry weight vx1800-p 347 kg (765 lb) vx1800a-p 348 kg (767 lb) maximum people on board 3 person ...

  • Page 43

    Model data 2-2 shift operation f–n–r reverse system reverse gate fuel and oil recommended fuel regular unleaded gasoline minimum octane rating (pon) 86 minimum octane rating (ron) 90 fuel tank total capacity 70 l (18.5 us gal, 15.4 imp.Gal) recommended engine oil yamalube 4w or 4-stroke motor oil re...

  • Page 44

    2-3 fuel system technical data fuel system technical data fuel system throttle body manufacturer mikuni type/quantity f1-im60–11/1 id mark 6bh 00 fuel pump pump type electrical fuel pressure 345.0–355.0 kpa (3.45–3.55 kgf/cm², 50.0–51.5 psi).

  • Page 45

    Power unit technical data 2-4 power unit technical data power unit compression pressure minimum 780 kpa (7.8 kgf/cm², 113.1 psi) oil cooler water passage holding pressure 200 kpa (2.0 kgf/cm², 29.0 psi) thermostat valve opening temperature 58 °c (136 °f) fully open temperature 70 °c (158 °f) fully o...

  • Page 46

    2-5 power unit technical data valve guide inside diameter-intake 5.504–5.522 mm (0.2167–0.2174 in) inside diameter-exhaust 5.504–5.522 mm (0.2167–0.2174 in) stem to guide clearance-intake 0.012–0.045 mm (0.0005–0.0018 in) limit 0.080 mm (0.0032 in) stem to guide clearance-exhaust 0.025–0.058 mm (0.0...

  • Page 47

    Power unit technical data 2-6 2nd ring type taper height (b) 1.170–1.190 mm (0.0461–0.0469 in) width (t) 2.600–2.800 mm (0.1024–0.1102 in) end gap (installed) 0.450–0.600 mm (0.0177–0.0236 in) limit 0.850 mm (0.0335 in) side clearance 0.020–0.060 mm (0.0008–0.0024 in) limit 0.120 mm (0.0047 in) oil ...

  • Page 48

    2-7 jet pump unit technical data jet pump unit technical data jet pump unit impeller housing inside diameter 155.35–155.45 mm (6.116–6.120 in) limit 156.45 mm (6.1594 in) impeller clearance 0.350–0.450 mm (0.0138–0.0177 in) limit 0.60 mm (0.0236 in) impeller material stainless steel diameter 155 mm ...

  • Page 49

    Electrical technical data 2-8 electrical technical data ignition system ecm unit output peak voltage at cranking (loaded) (reference data) 2.5 v output peak voltage at 2000 r/min (loaded) (reference data) 2.6 v output peak voltage at 3500 r/min (loaded) (reference data) 2.6 v pickup coil output peak...

  • Page 50

    2-9 electrical technical data thermo sensor input voltage 4.75–5.25 v resistance at 0°c (32°f) 24.0–37.1 k Ω resistance at 100°c (212°f) 0.87–1.18 k Ω engine temperature sensor input voltage 4.75–5.25 v resistance at 20°c (68°f) 54.2–69.0 k Ω resistance at 100°c (212°f) 3.12–3.48 k Ω intake air temp...

  • Page 51

    Electrical technical data 2-10 rps output voltage difference 0.1 v or less rps 1 input voltage 4.75–5.25 v rps 2 input voltage 4.75–5.25 v etv relay input voltage 12 v (battery voltage) cam position sensor input voltage 4.75–5.25 v output voltage (position a, c) more than 4.8 v output voltage (posit...

  • Page 52

    2-11 electrical technical data meter system remote control transmitter battery cr2016 rating 3 v remote control receiver input voltage 12 v (battery voltage) output voltage 11–12 v multifunction meter unit input voltage 12 v (battery voltage) buzzer input voltage 11–12 v speed sensor output voltage ...

  • Page 53

    Specified tightening torque 2-12 specified tightening torque specified tightening torques are provided for specific nuts, bolts, and screws. Tightening torque specifications are provided in the ex- ploded diagrams and in the related detailed in- structions. When tightening these fasteners, follow th...

  • Page 54

    2-13 cable and hose routing cable and hose routing starboard bow view a 1 2 2 3 3 5 5 6 a 7 8 9 11 12 13 16 17 14,15 10 4 4 1. Ride motor lead 2. Aps lead 3. Rps lead 4. Trim switch lead 5. Handlebar switch lead (left) 6. Fuel tank breather hose (fuel tank to water separator) 7. Buzzer lead 8. Steer...

  • Page 55

    Cable and hose routing 2-14 top view i-i g-g b-b j-j f h-h a-a e-e c-c d-d 1 2 11 16 17 3 5 6 c f b 10 10 10 5 3 7 3 8 9 7 6 7 6 11 12 16 17 13 10 4 13 14 12 4 a 14 a a b b e e e e e e h h h h i i e e g g j j c c d d 15.

  • Page 56

    2-15 cable and hose routing 1. Remote control receiver antenna 2. Remote control receiver lead 3. Fuel tank breather hose (water separator to ventilation socket) 4. Aps lead 5. Steering cable 6. Wire harness 7. Speed sensor lead 8. Negative battery lead 9. Positive battery lead 10. Ride motor lead 1...

  • Page 57

    Cable and hose routing 2-16 port view b d a-a c-c b d a a c c 1 2 3 4 4 4 5 6 7 8 9 10 10 9 11 12 12 11 13 13 1. Remote control receiver antenna 2. Steering sensor lead 3. Buzzer lead 4. Fuel tank breather hose (fuel tank to water separator) 5. Steering cable 6. Negative battery lead 7. Positive bat...

  • Page 58

    2-17 cable and hose routing coupler layout a 1 2 3 11 10 9 8 7 6 5 4 12 1. Trim switch coupler (black) 2. Aps coupler (black) 3. Rps coupler (gray) 4. Steering sensor coupler (black) 5. Buzzer coupler (black) 6. Buzzer/led coupler (white) 7. Communication coupler (gray) 8. Speed sensor coupler (whit...

  • Page 59: Maintenance

    3 maintenance maintenance interval chart ................................................ 3-1 periodic service.................................................................. 3-3 fuel line check ........................................................................... 3-3 fuel filler cap and wat...

  • Page 60

    3-1 maintenance interval chart maintenance interval chart the following chart should be considered strictly as a guide to general maintenance intervals. Depending on the operating conditions, the maintenance intervals should be changed. Perform the pre-operation checks and post-operation checks befo...

  • Page 61

    Maintenance interval chart 3-2 *1: whichever comes first. *2: check every 200 hours. Exhaust system check for exhaust leakage, and check hoses and clamps 3-10 breather hose check breather hose and clamps 3-10 impeller check for bends, damage, and foreign material 3-10 jet thrust nozzle check movemen...

  • Page 62

    3-3 periodic service periodic service fuel line check 1. Remove the service lid. 2. Check the fuel hoses and hose connec- tions for fuel leakage. 3. Check the fuel hoses. Replace if cracked or damaged. 4. Check the fuel hose routing and the clamps. See “air filter case and fuel hose” (4-1) and “fuel...

  • Page 63

    Periodic service 3-4 2. Check the cooling water hoses. Replace if cracked or damaged. 3. Check the cooling water hose routing and the clamps. See “cable and hose routing” (2-13). Engine oil level check • when starting the engine to check the oil level on land, make sure to connect a gar- den hose to...

  • Page 64

    3-5 periodic service 6. Add the recommended engine oil up to the specified level through the oil filler hole. 7. Install the oil filler cap and oil level gauge. 8. Check the engine oil level. See “engine oil level check” (3-4). Oil filter replacement 1. Extract the engine oil. See“engine oil re- pla...

  • Page 65

    Periodic service 3-6 tip: be careful not to get water or any other foreign substances in the spark plug holes. 2. Clean the electrodes “a”. 3. Check the electrodes “a”. Replace the spark plug if damaged or worn. 4. Measure the spark plug gap “a”. Replace if out of specification. 5. Install the spark...

  • Page 66

    3-7 periodic service 3. Check the specific gravity of the electro- lyte. Charge the battery if below specifica- tion. 4. Check the battery leads and terminals for corrosion. Clean using a file or sandpaper if corroded. 5. Install the battery, and then install the bands. 6. Connect the battery breath...

  • Page 67

    Periodic service 3-8 5. Disconnect the joint and apply a small amount of grease. 6. Check the steering cable for cable end dis- connection and check the locknut for looseness. 7. Install the front and rear seats. Trim rod check 1. Disconnect the shift rod joint “1”, and then lower the reverse gate “...

  • Page 68

    3-9 periodic service 4. Start the engine. Immediately after the en- gine has started, supply water. Do not run the engine over 4000 r/min on land. Also, do not run the engine for more than 15 seconds without supplying water, otherwise the engine could overheat. 5. While squeezing the ride lever full...

  • Page 69

    Periodic service 3-10 2. Spray a rust inhibitor into the throttle valve opening “a”. 3. Connect the air intake pipe, and then tight- en the air intake pipe clamp. Exhaust system check 1. Check the exhaust hoses and hose con- nections for exhaust or cooling water leak- age. See “exhaust system instal...

  • Page 70

    3-11 periodic service tip: place your hand under the bilge strainer to check for clog or dirt. 2. Check the bilge hoses. Replace if cracked or damaged. 3. Disconnect the bilge hose “1”. 4. Run water into the bilge hose “1” and check that the hose is not clogged. 5. Run water into the hose joint “2” ...

  • Page 71

    Periodic service 3-12 3. Position piston #1 at tdc by turning the exhaust camshaft sprocket clockwise. Tip: check that the punch marks “a” on the cam- shafts are aligned with the marks “b” on the camshaft caps. 4. Measure the intake and exhaust valve clearances of the specified cylinders. : specifi...

  • Page 72

    3-13 periodic service 7. Measure the intake and exhaust valve clearances of the specified cylinders. : specified cylinder —: not applicable 8. Adjust the valve clearance if out of specifi- cation. See “valve clearance adjustment” (5-40). 9. Install the cylinder head cover, spark plugs, and ignition...

  • Page 73: Fuel System

    4 fuel system air filter case and fuel hose .............................................. 4-1 fuel hose disconnection............................................................. 4-3 fuel pressure measurement ...................................................... 4-3 fuel hose disassembly.............

  • Page 74

    4-1 air filter case and fuel hose air filter case and fuel hose no. Part name q ’ ty remarks 1 plastic tie 1 2 bolt 2 m6 × 12 mm 3 stay 1 4 grommet 1 5 fuel hose assy 1 6 clamp 4 not reusable 7 quick connector 2 8 corrugated tube 1 9 fuel hose 1 10 clamp 1 11 clamp 2 12 air intake pipe 1 13 connecti...

  • Page 75

    Air filter case and fuel hose 4-2 17 screw 3 m6 × 15 mm 18 air filter element 1 19 drain tube 1 20 collar 4 21 grommet 4 22 plastic tie 1 23 nut 4 24 washer 4 25 bracket 1 no. Part name q ’ ty remarks 1 12 13 10 17 16 20 21 24 23 25 22 18 15 14 19 11 11 7 7 4 6 6 5 8 9 3 2 13 nm (1.3 kgf·m, 9.6 ft·i...

  • Page 76

    4-3 air filter case and fuel hose fuel hose disconnection before checking the fuel system, remove the battery, and then remove the fuel filler cap to reduce any pressure inside the fuel tank. 1. Spread apart the ends of the retainer “a”, and then pull the retainer up. 2. Disconnect the quick connect...

  • Page 77

    Air filter case and fuel hose 4-4 4. Measure the fuel pressure. Replace the fuel pump module if out of specification. Fuel hose disassembly 1. Remove the clamps “1” and quick connec- tor “2”. When cutting each clamp, position the tool. Air filter element check do not start the engine with the air fi...

  • Page 78

    4-5 air filter case and fuel hose distance “b” 17 mm (0.67 in) distance “c” 34.5 mm (1.36 in) distance “d” 1 mm (0.04 in) d 1 1 b c a.

  • Page 79

    Etv and fuel injector 4-6 etv and fuel injector no. Part name q ’ ty remarks 1 plastic tie 5 2 bolt 4 m8 × 58 mm 3 etv 1 4 gasket 1 not reusable 5 bolt 4 m8 × 25 mm 6 joint 1 7 gasket 1 not reusable 8 ribbon 1 9 holder 1 10 wire harness 1 11 bolt 3 m8 × 30 mm 12 fuel rail 1 13 fuel injector 4 14 o-r...

  • Page 80

    4-7 etv and fuel injector etv check • do not disassemble the etv. • do not loosen the throttle stop screw nut or turn the throttle stop screw. • do not loosen or remove the throttle valve shaft screws. 1. Turn the throttle valve manually and check that it moves smoothly. Fuel injector check 1. Check...

  • Page 81

    Etv and fuel injector 4-8 4. Route the wire harness, and then connect the cam position sensor coupler “a”, fuel injector couplers “b”, and ignition coil cou- plers “c”. 5. Fasten the wire harness using the plastic ties “1”. Fuel rail bolt “3” 13 nm (1.3 kgf·m, 9.6 ft·lb) 2 3 3 1 lt 242 1 1 c c b b a.

  • Page 82

    4-9 fuel tank and fuel pump module fuel tank and fuel pump module no. Part name q ’ ty remarks 1 plastic tie 3 2 fuel tank breather hose 2 3 check valve 1 4 clamp 2 5 fuel filler hose 1 6 nut 1 7 fuel filler neck 1 8 packing 1 not reusable 9 fuel filler cap 1 10 packing 1 not reusable 11 screw 1 #6 ...

  • Page 83

    Fuel tank and fuel pump module 4-10 17 pad 2 not reusable 18 pad 2 not reusable 19 rivet 4 20 hook 4 21 fuel sender coupler 1 22 fuel pump module coupler 1 23 nut 9 24 retainer 1 25 fuel pump module 1 26 stopper 1 27 fuel sender 1 28 packing 1 not reusable no. Part name q ’ ty remarks 7 6 4 4 5 8 13...

  • Page 84

    4-11 fuel tank and fuel pump module fuel tank removal before checking the fuel system, remove the battery, and then remove the fuel filler cap to reduce any pressure inside the fuel tank. 1. Extract the fuel using a siphon pump “1”. Tip: use a commercially available siphon pump “1” to extract the fu...

  • Page 85

    Fuel tank and fuel pump module 4-12 fuel pump module removal 1. Remove the fuel pump module “1”. When removing the fuel pump module, make sure that the rubber caps do not come off. Tip: remove the fuel pump module “1” at an angle so that the float “a” does not catch on the fuel tank. Fuel sender rem...

  • Page 86

    4-13 fuel tank and fuel pump module fuel filler cap check 1. Install the fuel filler cap “1” onto the fuel fill- er neck “2”, and then hold the fuel filler neck “2”. 2. Turn the fuel filler cap “1” clockwise “a” and check that it clicks when tightened com- pletely. Replace if it does not click. Fuel...

  • Page 87

    Fuel tank and fuel pump module 4-14 3. Apply a thin coat of engine oil to the con- tact surfaces of the fuel pipe “a”. 4. Connect the quick connector “1” onto the fuel pipe “a”. 5. Push down on the retainer “b” until it clicks. 6. Connect the fuel sender coupler “c” and fuel pump module coupler “d”....

  • Page 88

    4-15 fuel tank and fuel pump module 4. Install the fuel filler hose “1”, and then tight- en the clamps “2” to the specified torque. 5. Check that the distance “a” is within speci- fication. Tip: align the arrow mark “b” on the fuel filler hose “1” with the projection “c” on the fuel filler neck. 6. ...

  • Page 89: Power Unit

    5 power unit engine unit (check and adjustment)................................. 5-1 compression pressure check..................................................... 5-1 engine unit.......................................................................... 5-2 exhaust manifold ...........................

  • Page 90

    Power unit cylinder head cover ......................................................... 5-31 camshaft ........................................................................... 5-32 camshaft removal .................................................................... 5-34 camshaft sprocket removal...

  • Page 91

    5 power unit cylinder block and electrical part................................... 5-67 oil separator tank and oil pan......................................... 5-69 anode check............................................................................. 5-71 oil pan assembly............................

  • Page 92

    5-1 engine unit (check and adjustment) engine unit (check and adjustment) compression pressure check make sure that the battery voltage is more than 12 v. When starting the engine to measure the compression pressure on land, make sure to connect a garden hose to the watercraft for proper water suppl...

  • Page 93

    Engine unit 5-2 engine unit no. Part name q ’ ty remarks 1 screw 2 m6 × 12 mm 2 grommet 2 3 engine cover 1 4 clamp 1 5 antenna holder 3 6 plastic tie 7 7 clamp 1 8 clamp 1 9 plastic tie 1 10 ride motor coupler 2 4 1 2 3 1 2 5 5 6 6 8 9 10 7 6 6 6 5 nm (0.5 kgf·m, 3.7 ft·ib).

  • Page 94

    5-3 exhaust manifold exhaust manifold no. Part name q ’ ty remarks 1 oil filter 1 2 clamp 1 3 clamp 1 4 breather hose 1 5 plastic tie 1 6 plastic tie 2 7 clamp 6 8 cooling water hose 1 9 cooling water hose 1 10 bolt 2 m8 × 35 mm 11 collar 2 12 grommet 2 13 bolt 4 m6 × 35 mm 14 bolt 2 m6 × 25 mm 15 r...

  • Page 95

    Exhaust manifold 5-4 17 cover 1 18 clamp 1 19 bolt 1 m10 × 50 mm 20 bolt 3 m8 × 120 mm 21 bolt 8 m8 × 70 mm 22 gasket 1 not reusable 23 dowel 2 24 bolt 1 m8 × 47 mm 25 stay 1 26 clamp 1 no. Part name q ’ ty remarks 7 6 3 4 6 7 18 21 26 20 23 25 14 13 13 14 24 10 8 7 7 22 23 5 9 7 7 19 15 16 11 11 12...

  • Page 96

    5-5 engine unit and coupling cover engine unit and coupling cover no. Part name q ’ ty remarks 1 bolt 4 m8 × 28 mm 2 bolt 1 m6 × 25 mm 3 collar 1 4 coupling cover 1 5 bolt 4 m8 × 37 mm 6 shim * as required 6 6 6 6 5 5 2 3 4 1 1 1 5 5 17 nm (1.7 kgf·m, 12.5 ft·ib) 17 nm (1.7 kgf·m, 12.5 ft·ib).

  • Page 97

    Engine mount 5-6 engine mount no. Part name q ’ ty remarks 1 bolt 8 m8 × 35 mm 2 engine mount 4 3 liner 4 4 bolt 2 m6 × 21 mm 5 spacer 1 6 bolt 2 m6 × 18 mm 7 spacer 1 lt 572 bow 2 1 2 1 4 1 2 1 2 7 3 3 3 3 5 6 5.5 nm (0.55 kgf·m, 4.06 ft·lb) 17 nm (1.7 kgf·m, 12.5 ft·ib).

  • Page 98

    5-7 engine mount engine unit removal before removing the engine, make sure to take adequate measures to protect the deck opening from damage. 1. Disconnect the negative battery lead, and then disconnect the positive battery lead. 2. Extract the engine oil. See “engine oil re- placement” (3-4). 3. Re...

  • Page 99

    Engine mount 5-8 14. Disconnect the fuel pump module coupler “a”. 15. Remove the wire harness from the plastic ties “1”. 16. Disconnect the cooling water hose “1” from the oil cooler. 17. Disconnect the cooling water hose “1” from the thermostat housing. 18. Remove the plastic tie “2”, and then dis-...

  • Page 100

    5-9 engine mount 23. Disconnect the cooling water hoses “1” and “2”. 24. Remove the stay “3”. 25. Loosen the clamp “1”. 26. Remove the muffler “1”. Tip: when removing the muffler “1”, move it forward and separate it from the water lock. 27. Remove the electrical box “1”. 28. Remove the coupling cove...

  • Page 101

    Engine mount 5-10 32. Suspend the engine unit using all 3 engine hangers, and then separate the unit from the engine mounts and move it forward to disconnect the coupling. 33. Lift the engine unit slightly, and then lower the front of the unit. Repeat this step until the engine unit can be removed f...

  • Page 102

    5-11 engine mount tip: do not install the rubber coupling until the cou- pling clearance adjustment has been made. 6. Temporarily install the engine mounting bolts “1”. 7. Lift the engine unit slightly, install the shims “2”, and then lower the unit. Tip: install the shims “2” in their original posi...

  • Page 103

    Engine mount 5-12 14. Tighten the engine mounting bolts “1” to the specified torque, and then recheck the coupling clearances. 15. Install the coupling cover “1”. 16. Install the electrical box “1”, and then tight- en the electrical box bolts “2” to the speci- fied torque. 17. Install the muffler “1...

  • Page 104

    5-13 engine mount 19. Install the stay “1”, and then tighten the stay bolts “2” and “3” to the specified torques in 2 stages. 20. Connect the cooling water hoses “4” and “5”, and then fasten them using the clamps “6” and “7”. 21. Install the rectifier/regulator “1”, and then tighten the rectifier/re...

  • Page 105

    Engine mount 5-14 29. Fasten the wire harness using the plastic ties “1”. 30. Connect the fuel pump module coupler “a”. 31. Fasten the wire harness using the plastic ties “1”. 32. Connect the sensor and switch couplers “a”. See “coupler layout” (2-17). 33. Connect the remote control receiver cou- pl...

  • Page 106

    5-15 engine mount 40. Install the engine cover “1”, and then tight- en the engine cover screws “2” to the specified torque. 41. Install the deck beam “1”, and then tighten the deck beam nuts “2” to the specified torque. 42. Install the service lid “1”. 43. Fill the engine with engine oil. See “engin...

  • Page 107

    Muffler 5-16 muffler no. Part name q ’ ty remarks 1 clamp 1 2 pipe 1 3 thermo sensor 1 4 clamp 1 5 cooling water hose 1 6 exhaust pipe 1 7 bolt 5 m8 × 35 mm 8 exhaust pipe 1 9 gasket 1 not reusable 10 bolt 2 m8 × 70 mm 11 bolt 4 m8 × 120 mm 12 exhaust pipe 1 13 gasket 1 not reusable 14 dowel pin 2 1...

  • Page 108

    5-17 muffler exhaust pipe disassembly use heat-resistant gloves. Otherwise, burns could result. 1. Remove the exhaust pipe “1”. Tip: heat the area “a” of exhaust pipe “1” to approx- imately 200 °c (392 °f) using a heat gun. Exhaust pipe assembly 1. Install the exhaust pipe “1”, and then tight- en it...

  • Page 109

    Wire harness 5-18 wire harness no. Part name q ’ ty remarks 1 nut 1 2 spring washer 1 3 bolt 2 m8 × 30 mm 4 negative battery lead 1 5 starter motor 1 6 bolt 2 m6 × 35 mm 7 thermostat housing 1 8 thermostat 1 a: hole 9 holder 1 10 grommet 1 11 plastic tie 1 12 plastic tie 5 13 plastic tie 1 14 wire h...

  • Page 110

    5-19 electrical box electrical box no. Part name q ’ ty remarks 1 electrical box cover 1 2 plastic tie 2 3 bolt 8 m6 × 25 mm 4 ecm 1 5 collar 8 6 grommet 8 7 fuse box 1 8 fuse 3 3 a 9 fuse 4 10 a 10 fuse 2 20 a 11 fuse 2 30 a 12 fuse 2 50 a 13 relay 4 main, fuel pump, etv, scu 14 fuse puller 1 15 bo...

  • Page 111

    Electrical box 5-20 17 nut 2 18 holder 1 19 screw 2 m6 × 20 mm 20 slant detection switch 1 21 bolt 2 m6 × 12 mm 22 positive battery lead 1 23 starter motor lead 1 24 starter relay 1 25 bolt 2 m6 × 12 mm 26 holder 1 27 electrical box 1 no. Part name q ’ ty remarks 5 6 4 nm (0.4 kgf·m, 3.0 ft·lb) 20 1...

  • Page 112

    5-21 electrical box starter motor and wire harness removal 1. Disconnect the starter motor lead “1” and negative battery lead “2”, and then remove the starter motor “3”. 2. Remove the plastic ties “1”. 3. Disconnect the fuse box couplers “a”, slant detection switch coupler “b”, starter relay coupler...

  • Page 113

    Electrical box 5-22 3. Measure the thermostat valve opening “a” at the specified water temperatures. Re- place if out of specification. Wire harness and starter motor installation 1. Connect the fuel injector couplers “a” and ignition coil couplers “b”. 2. Connect the etv coupler “a”, cam position s...

  • Page 114

    5-23 electrical box 6. Install the starter motor “1”, and then con- nect the negative battery lead “2” and starter motor lead “3”. 7. Tighten the starter motor lead nut “4” to the specified torque. Starter motor lead nut “4” 7 nm (0.7 kgf·m, 5.2 ft·lb) 3 4 2 1.

  • Page 115

    Intake manifold 5-24 intake manifold no. Part name q ’ ty remarks 1 bolt 8 m8 × 35 mm 2 nut 2 3 intake manifold 1 4 gasket 4 not reusable 5 dowel 2 6 stud bolt 2 7 intake air temperature sensor 1 8 gasket 1 not reusable 9 intake air pressure sensor 1 10 grommet 1 11 hose 1 12 bolt 1 m8 × 16 mm 13 oi...

  • Page 116

    5-25 intake manifold 17 clamp 1 18 oil level pipe plate 1 19 grommet 1 20 o-ring 1 not reusable no. Part name q ’ ty remarks a 1 6 5 5 10 9 2 8 7 11 4 3 14 13 12 15 17 18 19 20 16 6 lt 242 lt 572 lt 572 1322d 1322d 15 nm (1.5 kgf·m, 11.1 ft·ib) 16 nm (1.6 kgf·m, 11.8 ft·ib) 31 nm (3.1 kgf·m, 22.9 ft...

  • Page 117

    Intake manifold 5-26 oil level pipe installation 1. Pass the clamp “1” through the oil level pipe “2”. 2. Install the oil level pipe plate “3”, the grom- met “4”, and a new o-ring “5” onto the oil level pipe “2”. Tip: make sure that the bottom of the grommet “4” is at the specified installation dist...

  • Page 118

    5-27 oil cooler, oil pump, and drive gear oil cooler, oil pump, and drive gear no. Part name q ’ ty remarks 1 bolt 12 m6 × 20 mm 2 oil pump 1 3 gasket 1 not reusable 4 bolt 1 m12 × 58 mm, left-hand threads 5 oil pump drive gear 1 6 dowel 2 7 o-ring 2 not reusable 8 connector 1 9 clamp 2 10 cooling w...

  • Page 119

    Oil cooler, oil pump, and drive gear 5-28 17 o-ring 4 not reusable 18 connector 2 19 bolt 7 m6 × 25 mm 20 washer 3 21 bolt 1 m8 × 25 mm 22 bolt 4 m6 × 20 mm 23 gasket 1 not reusable 24 dowel 2 25 oil filter joint 1 no. Part name q ’ ty remarks e a a a lt 572 lt 572 lt 572 lt 572 lt 572 lt 572 6 5 4 ...

  • Page 120

    5-29 oil cooler, oil pump, and drive gear oil pump and oil pump drive gear removal 1. Remove the oil pump. 2. Hold the drive coupling “1” using the spe- cial service tool “2”. 3. Turn the bolt “1” clockwise to loosen it, and then remove the bolt “1” and oil pump drive gear “2”. Oil cooler check 1. C...

  • Page 121

    Oil cooler, oil pump, and drive gear 5-30 3. Turn the bolt “1” counterclockwise, and then tighten it to the specified torque. 4. Fill the oil pump with engine oil through the feed port “a”. Tip: while turning the oil pump driven gear, make sure to fill the oil pump with engine oil up to the brim of ...

  • Page 122

    5-31 cylinder head cover cylinder head cover no. Part name q ’ ty remarks 1 bolt 8 m6 × 20 mm 2 ignition coil 4 3 spark plug 4 4 bolt 1 m6 × 16 mm 5 cam position sensor 1 6 bolt 8 m6 × 30 mm 7 cylinder head cover 1 8 gasket 1 not reusable 9 oil filler cap 1 10 o-ring 1 not reusable 11 timing chain g...

  • Page 123

    Camshaft 5-32 camshaft no. Part name q ’ ty remarks 1 bolt 2 m10 × 21 mm 2 gasket 4 not reusable 3 oil pipe 1 4 bolt 2 m6 × 25 mm 5 timing chain tensioner 1 6 gasket 1 not reusable 7 timing chain guide 1 exhaust side 8 bolt 24 m7 × 45 mm 9 intake camshaft cap 1 10 intake camshaft cap 2 11 exhaust ca...

  • Page 124

    5-33 camshaft 17 camshaft sprocket 2 18 bolt 2 m6 × 30 mm 19 chain guide plate 1 20 timing chain guide 1 intake side 21 timing chain 1 no. Part name q ’ ty remarks 10 nm (1.0 kgf·m, 7.4 ft·lb) 8 9 13 16 17 14 12 16 1 2 4 5 7 20 21 19 18 6 3 2 17 13 15 b 10 13 8 8 10 13 a 13 8 8 8 12 13 13 13 11 16 2...

  • Page 125

    Camshaft 5-34 camshaft removal when installing the camshafts, piston #1 must be positioned at tdc. Therefore, do not turn the crankshaft after removing the camshafts. 1. Install the special service tools into spark plug hole #1. 2. Position piston #1 at tdc by turning the drive coupling “1” counterc...

  • Page 126

    5-35 camshaft 5. Remove the timing chain guide (exhaust side). 6. Remove the intake camshaft caps and ex- haust camshaft caps. Tip: loosen the camshaft cap bolts in the opposite order used for tightening. 7. Remove the intake camshaft “1” and ex- haust camshaft “2”. Tip: fasten the timing chain usin...

  • Page 127

    Camshaft 5-36 camshaft journal oil clearance check 1. Remove the valve lifters “1” and valve pads “2”. Tip: write down the position of each valve lifter “1” and valve pad “2” so that they can be installed in their original positions. 2. Place the camshafts on the cylinder head. 3. Put a piece of pla...

  • Page 128

    5-37 camshaft 6. Tighten the camshaft cap bolts “1” to the specified torque in the order [1], [2], and so on. Tip: do not turn the camshafts when measuring the camshaft journal oil clearance using the plasti- gauge. 7. Remove the camshaft caps, and then measure the width of the plastigauge “1”. Timi...

  • Page 129

    Camshaft 5-38 • when installing an original camshaft sprock- et, make sure to align the marks “b” made during removal. 2. Hold the camshaft sprocket using the spe- cial service tool “1”, and then tighten the camshaft sprocket bolts “2” to the specified torque. Camshaft installation 1. Position pisto...

  • Page 130

    5-39 camshaft 5. Install the dowel pins “1”, intake camshaft caps “2” and “3”, and exhaust camshaft caps “4” and “5”. Tip: when installing the camshaft caps, make sure that the arrow marks “a” on the camshaft caps point toward the camshaft sprockets. 6. Tighten the camshaft cap bolts “1” until camsh...

  • Page 131

    Camshaft 5-40 10. While squeezing the ends of the snap ring “e” so that it fits into the groove “d” in the timing chain tensioner rod “a”, release the tensioner rod slowly until it is locked in place. 11. Install a new gasket “1” and the timing chain tensioner “2” onto the cylinder head, and then ti...

  • Page 132

    5-41 camshaft 3. Remove the valve lifters “1” and valve pads “2”. Tip: write down the position of each valve lifter “1” and valve pad “2” so that they can be installed in their original positions. 4. Check the valve pad number “a”. Tip: the thickness of each valve pad is marked in hundredths of mill...

  • Page 133

    Camshaft 5-42 12. Position piston #4 at tdc by turning the drive coupling “1” 360° counterclockwise using the special service tool “2”. 13. Measure the intake and exhaust valve clearances of the specified cylinders. : specified cylinder —: not applicable dial gauge set “1” 90890-01252 dial indicato...

  • Page 134

    5-43 camshaft valve pad selection table intake example: measured valve clearance is 0.29 mm (0.0114 in) original valve pad number is 148 (thickness = 1.48 mm) • round off the original valve pad number 148 to 150 (thickness = 1.50 mm). • select the new valve pad number using the valve pad selection t...

  • Page 135

    Camshaft 5-44 exhaust example: measured valve clearance is 0.47 mm (0.0185 in) original valve pad number is 168 (thickness = 1.68 mm) • round off the original valve pad number 168 to 170 (thickness = 1.70 mm). • select the new valve pad number using the valve pad selection table. New valve pad numbe...

  • Page 136

    5-45 cylinder head cylinder head no. Part name q ’ ty remarks 1 bolt 3 m6 × 55 mm 2 bolt 10 not reusable, m12 × 140 mm 3 washer 10 4 cylinder head assy 1 5 gasket 1 not reusable 6 dowel pin 2 7 bolt 1 m10 × 25 mm 8 engine hanger 1 9 bolt 4 m6 × 12 mm 10 engine hanger 2 42 nm (4.2 kgf·m, 31.0 ft·ib) ...

  • Page 137

    Valve and valve spring 5-46 valve and valve spring no. Part name q ’ ty remarks 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 not reusable 11 cylinde...

  • Page 138

    5-47 valve and valve spring cylinder head disassembly 1. Remove the valve lifters “1” and valve pads “2”. Tip: write down the position of each valve lifter “1” and valve pad “2” so that they can be installed in their original positions. 2. Remove the intake valves and exhaust valves. Tip: write down...

  • Page 139

    Valve and valve spring 5-48 2. Measure the valve spring tilt “a”. Replace if out of specification. Valve check 1. Measure the valve face width “a”. 2. Measure the valve margin thickness “a”. 3. Measure the valve stem diameter “a”. Re- place if out of specification. 4. Measure the valve stem runout. ...

  • Page 140

    5-49 valve and valve spring valve guide check 1. Measure the valve guide inside diameter “a”. 2. Calculate the valve-stem-to-valve-guide clearance. Replace the valve and valve guide if out of specification. Valve guide removal 1. Insert the special service tool “1” into the combustion chamber side o...

  • Page 141

    Valve and valve spring 5-50 3. Insert the special service tool “1” into the valve guide “2”, and then ream the valve guide “2”. Tip: • turn the special service tool “1” clockwise to ream the valve guide “2”. • do not turn the special service tool “1” coun- terclockwise when removing the tool. 4. Cle...

  • Page 142

    5-51 valve and valve spring valve seat refacing after every lapping procedure, make sure to clean off any remaining lapping com- pound from the cylinder head and valves. 1. Reface the valve seat. 2. Cut the surface of the valve seat using a 45° cutter by turning the cutter clockwise until the valve ...

  • Page 143

    Valve and valve spring 5-52 3. Adjust the top edge of the valve seat con- tact width using a 30° cutter. 4. Adjust the bottom edge of the valve seat contact width using a 60° cutter. 5. Adjust the valve seat contact width to specification using a 45° cutter. 6. Check the valve seat contact area of t...

  • Page 144

    5-53 valve and valve spring • if the valve seat contact area is too narrow and situated near the bottom edge of the valve face, cut the bottom edge of the valve seat using a 60° cutter to center the area, and then set its width using a 45° cutter. 7. After refacing the valve seat to the speci- fied ...

  • Page 145

    Valve and valve spring 5-54 3. Compress the valve spring, and then in- stall the valve cotters “1”. 4. Tap the valve spring retainer lightly using a plastic hammer to seat the valve cotters “1” securely. 5. Install the valve pads “1” and valve lifters “2” in their original positions. Cylinder head i...

  • Page 146

    5-55 generator cover assy and flywheel magneto generator cover assy and flywheel magneto no. Part name q ’ ty remarks 1 holder 1 left-hand threads 2 drive coupling 1 3 washer 1 not reusable 4 holder 1 5 bolt 2 m6 × 20 mm 6 collar 2 7 grommet 2 8 bolt 9 m8 × 50 mm 9 gasket 1 not reusable 10 dowel pin...

  • Page 147

    Generator cover assy and flywheel magneto 5-56 17 starter clutch 1 18 starter gear 1 19 woodruff key 1 not reusable no. Part name q ’ ty remarks 50 nm (5.0 kgf·m, 36.9 ft·lb) 60 250 nm (25.0 kgf·m, 184.4 ft·lb) 250 nm (25.0 kgf·m, 184.4 ft·lb) 15 15 14 24 nm (2.4 kgf·m, 17.7 ft·lb) 80 nm (8.0 kgf·m,...

  • Page 148

    5-57 generator cover generator cover no. Part name q ’ ty remarks 1 bolt 2 m6 × 15 mm 2 holder 1 3 bolt 2 m5 × 15 mm 4 bolt 1 m5 × 10 mm 5 washer 1 6 bolt 3 m6 × 30 mm 7 stator coil 1 8 oil seal 1 not reusable 9 circlip 1 10 ball bearing 1 not reusable 11 generator cover 1 15 nm (1.5 kgf·m, 11.1 ft·...

  • Page 149

    Generator cover 5-58 drive coupling removal use heat-resistant gloves. Otherwise, burns could result. 1. Heat the holder “1” and drive coupling “2” for 20–30 minutes using a heat gun “3”. Be careful not to damage the wire harness when using the heat gun. 2. Hold the drive coupling “1” using the spe-...

  • Page 150

    5-59 generator cover 3. Hold the flywheel magneto “1” using the special service tools “2” and “3”, and then loosen the special nut “4”. Tip: • loosen the special nut “4” until it can no lon- ger be turned. • use a hexagon bit socket “5” with a length of 150 mm (5.91 in) or more and a width across fl...

  • Page 151

    Generator cover 5-60 6. Hold the flywheel magneto “1” using the special service tool “2”, and then loosen the starter clutch bolts “3”. 7. Remove the starter clutch. Generator cover assy disassembly 1. Remove the washer “1”, pickup coil “2”, holder “3”, and stator coil “4”. 2. Remove the oil seal “1...

  • Page 152

    5-61 generator cover 3. Turn the starter gear “2” counterclockwise “b” and check that it does not turn. Replace if it turns. Generator cover assy assembly 1. Install a new ball bearing “1”. 2. Install the circlip “1”. 3. Install a new oil seal “1”. 4. Install the stator coil “1”, holder “2”, pickup ...

  • Page 153

    Generator cover 5-62 tip: pass the pickup coil lead “a” between the gen- erator cover and the bolt hole “b”, and then se- cure the lead by installing the washer “4”. Flywheel magneto assembly 1. Install the starter clutch “1” to a new fly- wheel magneto “2”. 2. Hold the flywheel magneto “1” using th...

  • Page 154

    5-63 generator cover 2. Clean the tapered portion “a” of the crank- shaft and inner surface “b” of the flywheel magneto “1”. 3. Install a new woodruff key “2” and the fly- wheel magneto “1”. 4. Install the transfer shaft “1”. 5. Hold the flywheel magneto “1” using the special service tools “2” and “...

  • Page 155

    Generator cover 5-64 8. Hold the flywheel magneto “1” using the special service tools “2” and “3”, and then tighten the transfer shaft “4” to the speci- fied angle using the special service tool “5”. 9. Tighten the transfer shaft “1” to the speci- fied torque using the special service tool “2”. 10. ...

  • Page 156

    5-65 generator cover 11. Hold the flywheel magneto “1” using the special service tools “2” and “3”, and then tighten the special nut “4” to the specified torque. After tightening, do not operate the engine at a speed higher than idling speed for 24 hours. Tip: use a hexagon bit socket “5” with a len...

  • Page 157

    Generator cover 5-66 2. Hold the transfer shaft using the special service tool “1”, and then tighten the drive coupling “2” to the specified torque using the special service tool “3”. 3. Remove any grease from the threaded portion of the holder “1”. 4. Install the holder “1”. 5. Hold the drive coupl...

  • Page 158

    5-67 cylinder block and electrical part cylinder block and electrical part no. Part name q ’ ty remarks 1 clamp 1 2 bolt 2 m6 × 25 mm 3 earth plate 1 4 gasket 1 not reusable 5 oil return hose 1 6 bolt 2 m6 × 16 mm 7 bolt 4 m8 × 20 mm 8 plate 1 9 gasket 1 not reusable 10 bolt 2 m6 × 16 mm 11 thermo s...

  • Page 159

    Cylinder block and electrical part 5-68 16 cover 1 17 grommet 1 18 anode 1 19 engine temperature sensor 1 20 gasket 1 not reusable no. Part name q ’ ty remarks lt 572 lt 572 lt 572 a a 1322d 11 nm (1.1 kgf·m, 8.1 ft·ib) 19 nm (1.9 kgf·m, 14.0 ft·ib) 20 nm (2.0 kgf·m, 14.8 ft·ib) 15 nm (1.5 kgf·m, 11...

  • Page 160

    5-69 oil separator tank and oil pan oil separator tank and oil pan no. Part name q ’ ty remarks 1 bolt 1 m4 × 8 mm 2 oil pressure switch 1 3 clamp 1 4 cooling water hose 1 5 bolt 9 m6 × 25 mm 6 water jacket cover 1 7 gasket 1 not reusable 8 bolt 9 m6 × 20 mm 9 bolt 2 m6 × 14 mm 10 oil separator tank...

  • Page 161

    Oil separator tank and oil pan 5-70 16 bolt 6 m6 × 14 mm 17 baffle plate 1 18 bolt 1 m6 × 14 mm 19 bolt 2 m6 × 60 mm 20 washer 2 21 oil pipe 1 22 gasket 1 not reusable 23 grommet 1 24 oil pan plug 1 m8 × 20 mm 25 gasket 1 not reusable no. Part name q ’ ty remarks a a 10 nm (1.0 kgf·m, 7.4 ft·ib) 2 n...

  • Page 162

    5-71 oil separator tank and oil pan anode check 1. Check the anode. Replace if eroded. Clean if there is grease, oil, or scales. Do not apply grease, oil, or paint to the an- ode. Oil pan assembly 1. Install the grommet “1” onto the oil pipe “2”. 2. Install a new gasket “3”, the oil pipe “2”, and th...

  • Page 163

    Oil separator tank and oil pan 5-72 3 4 4 4 4 4 [9] [4] [1] [5] [6] [10] [11] [7] [2] [3] [8].

  • Page 164

    5-73 crankcase, connecting rod, and piston crankcase, connecting rod, and piston no. Part name q ’ ty remarks 1 bolt 12 m6 × 70 mm 2 bolt 10 not reusable, m10 × 85 mm 3 crankcase 1 4 bolt 8 not reusable, m9 × 46 mm 5 connecting rod 4 6 connecting rod bearing 8 7 piston pin clip 8 not reusable 8 pist...

  • Page 165

    Crankcase, connecting rod, and piston 5-74 17 bracket 2 18 dowel pin 8 19 bolt 1 m6 × 12 mm 20 baffle plate 1 21 cylinder block 1 no. Part name q ’ ty remarks e y 1t 2t 6 6 21 15 15 18 13 14 17 16 19 1 17 15 15 18 3 12 18 20 2 15 15 18 11 15 12 16 10 12 12 12 12 8 7 9 4 5 7 50 nm (5.0 kgf·m, 36.9 ft...

  • Page 166

    5-75 crankcase, connecting rod, and piston crankcase disassembly 1. Place the crankcase upside down on a bench. 2. Remove the crankcase “1”. Tip: • loosen the crankcase bolts in the opposite order used for tightening. • the numbers embossed on the crankcase indicate the crankcase tightening order. •...

  • Page 167

    Crankcase, connecting rod, and piston 5-76 cylinder block check 1. Measure the cylinder bore (d1–d6) at measuring points “a”, “b”, and “c”, and in direction “d” (d1, d3, d5), which is parallel to the crankshaft, and direction “e” (d2, d4, d6), which is at a right angle to the crankshaft. Replace the...

  • Page 168

    5-77 crankcase, connecting rod, and piston 2. Measure the piston ring end gap “a” at the specified measuring point “b”. 3. Measure the piston ring grooves. 4. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification. A. Top ring b. 2nd ring c. Oil ...

  • Page 169

    Crankcase, connecting rod, and piston 5-78 piston pin check 1. Measure the piston pin outside diameter “a” at measuring points “b”, “c”, and “d”, and in directions “e” and “f”. Replace if out of specification. Connecting rod check 1. Measure the connecting rod small end in- side diameter “a”. Replac...

  • Page 170

    5-79 crankcase, connecting rod, and piston 2. Measure the crankshaft runout. Replace if out of specification. Crankshaft pin oil clearance check 1. Clean the connecting rod bearings “1” and connecting rod big end. 2. Install the upper bearing into the connect- ing rod “2” and lower bearing into the ...

  • Page 171

    Crankcase, connecting rod, and piston 5-80 6. Before installing the connecting rod onto the crankshaft, assemble the connecting rod, which the connecting rod bearings were installed in step 2, to the crankshaft kept in the current condition. Tip: tighten the connecting rod bolts while check- ing tha...

  • Page 172

    5-81 crankcase, connecting rod, and piston connecting rod bearing selection 1. Check the connecting rod size number “a” on the connecting rod. 2. Check the crankshaft pin size number “a” on the crankshaft web. 3. Select the suitable color “a” for the con- necting rod bearing from the table. Example:...

  • Page 173

    Crankcase, connecting rod, and piston 5-82 2. Place the cylinder block upside down on a bench. 3. Install the crankshaft bearings “1” into the cylinder block and crankcase. Tip: • install the crankshaft bearings “1” in their original positions. • fit the protrusion “a” on each bearing into the slots...

  • Page 174: 55545

    5-83 crankcase, connecting rod, and piston 8. Remove the crankcase and measure the width “a” of the compressed plastigauge on each crankshaft journal. Replace the crankshaft bearings if out of specification. Crankshaft bearing selection 1. Check the crankcase journal size number “a” on the crankcase...

  • Page 175

    Crankcase, connecting rod, and piston 5-84 example: “j1” crankcase journal size number “5” “j1” crankshaft journal size number “2” 5 - 2 = 3 select the size “3”, “blue” crankshaft bear- ing. Connecting rod and piston installation 1. Assemble the connecting rod “1”, piston “2”, piston pin “3”, and ne...

  • Page 176

    5-85 crankcase, connecting rod, and piston 5. Install the upper bearing into the connect- ing rod “2” and lower bearing into the con- necting rod cap “3”. Tip: • install the connecting rod bearings “1” in their original positions. • fit the protrusion “a” on each bearing into the slots “b” in the co...

  • Page 177

    Crankcase, connecting rod, and piston 5-86 12. Install half of the crankshaft bearings “1” into the cylinder block. Tip: • install the crankshaft bearings “1” in their original positions. • fit the protrusion “a” on each bearing into the slots “b” in the cylinder block. 13. Install the crankshaft. 1...

  • Page 178

    5-87 crankcase, connecting rod, and piston 3. Install the dowel pin “1” and a new o-ring “2”. 4. Apply sealant to the mating surface of the crankcase. 5. Install the crankcase “1” and new crank- case bolts “2”, and then tighten the crank- case bolts “2” to the specified torques in 2 stages and in th...

  • Page 179

    Crankcase, connecting rod, and piston 5-88 crankcase bolt “1” 10 nm (1.0 kgf·m, 7.4 ft·lb) [12] [11] [10] [4] [2] [6] [8] [9] [3] [1] [5] [7] 1.

  • Page 180: — Memo —

    Crankcase, connecting rod, and piston 5-89 — memo —.

  • Page 181: Jet Pump Unit

    6 jet pump unit intake grate and ride plate................................................. 6-1 jet pump unit...................................................................... 6-2 jet pump unit removal ................................................................ 6-3 impeller check ............

  • Page 182

    6-1 intake grate and ride plate intake grate and ride plate no. Part name q ’ ty remarks 1 screw 4 m5 × 12 mm 2 speed sensor 1 3 bolt 10 m8 × 35 mm 4 ride plate 1 5 bracket 2 6 spacer 1 7 intake grate 1 8 bracket 1 9 bracket 2 2 1 1 1 3 3 7 9 3 3 3 3 8 4 6 5 5 9 ss lt 242 lt 242 lt 242 ss ss ss ss 4...

  • Page 183

    Jet pump unit 6-2 jet pump unit no. Part name q ’ ty remarks 1 shift rod joint 1 2 trim rod joint 1 3 nut 1 4 washer 2 5 steering cable joint 1 6 clamp 1 7 bilge hose 1 8 clamp 1 9 bolt 2 m8 × 18 mm 10 bolt 1 m6 × 30 mm 11 bolt 4 m10 × 45 mm 12 dowel pin 2 13 bolt 2 m8 × 13 mm 14 washer 2 15 gasket ...

  • Page 184

    6-3 jet pump unit jet pump unit removal make sure to remove the battery before re- moving the jet pump unit. 1. Remove the speed sensor “1” and ride plate “2”. 2. Remove the spacer “3” and intake grate “4”. 3. Disconnect the shift rod joint “1”, trim rod joint “2” steering cable joint “3”, bilge hos...

  • Page 185

    Jet pump unit 6-4 3. Install the jet pump unit, and then tighten the bolts “1” and “2” to the specified torques. 4. Tighten the jet pump unit bolt “3”. 5. Connect the spout hose “1”, and then tight- en the clamp “2” to the specified torque. 6. Connect the bilge hose “3”, and then fas- ten it using t...

  • Page 186

    6-5 jet pump unit 5. Adjust the trim rod joint “1” until the dis- tances “a” and “b” are equal. Do not rotate the trim rod joint more than 2 turns on either end. Otherwise, the trim rod joint may not be screwed in more than 8 mm (0.31 in). Tip: when adjusting, make sure to rotate the trim rod joint ...

  • Page 187

    Jet pump unit 6-6 5. Connect the steering cable joint to the ball joint, and then tighten the locknut to the specified torque. 6. Check the difference of distances “a” and “b” again. 7. Install the service lid. Turn in distance “a” is increased. Turn out distance “b” is increased. Distance “c” 8.0 m...

  • Page 188

    6-7 reverse gate reverse gate no. Part name q ’ ty remarks 1 spring 1 2 bolt 2 m8 × 25 mm 3 collar 2 4 reverse gate 1 5 nut 2 6 washer 3 7 ball joint 1 8 bolt 1 m6 × 35 mm 9 collar 1 10 bolt 6 m6 × 25 mm 11 reverse gate stay 2 a a a a 20 nm (2.0 kgf·m, 14.8 ft·ib) 10 11 3 6 5 2 7 6 11 10 1 8 9 5 6 2...

  • Page 189

    Nozzle and nozzle ring 6-8 nozzle and nozzle ring no. Part name q ’ ty remarks 1 bolt 4 m8 × 25 mm 2 collar 4 3 jet thrust nozzle 1 4 nozzle ring 1 5 nut 1 6 washer 2 7 ball joint 1 16 nm (1.6 kgf·m, 11.8 ft·lb) 16 nm (1.6 kgf·m, 11.8 ft·lb) 7 4 2 5 1 2 3 2 1 2 1 1 6.

  • Page 190

    6-9 impeller housing and impeller duct assy impeller housing and impeller duct assy no. Part name q ’ ty remarks 1 clamp 1 2 spout hose 1 a: yellow paint mark 3 bolt 4 m10 × 125 mm 4 bracket 1 5 nozzle 1 6 impeller housing 1 7 dowel pin 4 8 bolt 4 m6 × 20 mm 9 water inlet strainer 1 10 gasket 1 not ...

  • Page 191

    Impeller, drive shaft, and impeller duct 6-10 impeller, drive shaft, and impeller duct no. Part name q ’ ty remarks 1 impeller 1 2 bolt 3 m6 × 20 mm 3 cap 1 4 o-ring 1 not reusable 5 nut 1 6 washer 1 7 spacer 1 8 o-ring 1 not reusable 9 oil seal 1 not reusable 10 oil seal 1 not reusable 11 ball bear...

  • Page 192

    6-11 impeller, drive shaft, and impeller duct impeller duct assy disassembly 1. Remove the impeller “1”. 2. Remove the cap “1”, o-ring “2”, and nut “3”. 3. Remove the drive shaft “1”. Do not press the drive shaft threads direct- ly. 4. Remove the ball bearing “1”. 5. Remove the oil seals “1” and “2”...

  • Page 193

    Impeller, drive shaft, and impeller duct 6-12 6. Remove the spacer “1”, and then remove the ball bearing “2” using a press. Impeller housing check 1. Measure the impeller housing inside diam- eter “a”. Replace if out of specification. Drive shaft check 1. Measure the drive shaft runout. Replace if o...

  • Page 194

    6-13 impeller, drive shaft, and impeller duct 2. Install a new ball bearing “1” onto the drive shaft “2”. 3. Install the drive shaft “1” (along with the ball bearing “2”) and spacer “3”. 4. Apply epnoc grease ap #0 to the space between the drive shaft “1” and the spacer “2”. 5. Install a new ball be...

  • Page 195

    Impeller, drive shaft, and impeller duct 6-14 6. Install the washer “1”, and then tighten the drive shaft nut “2” to the specified torque. 7. Apply epnoc grease ap #0 to the inside of the cap “3”, and then install a new o-ring “4” and the cap “3”. 8. Install the o-ring “1” to the spacer “2”. 9. Inst...

  • Page 196

    6-15 impeller, drive shaft, and impeller duct impeller duct bolt “5” 40 nm (4.0 kgf·m, 29.5 ft·lb) 1 3 2 5 5 5 5 4 3.

  • Page 197

    Transom plate and hoses 6-16 transom plate and hoses no. Part name q ’ ty remarks 1 clamp 4 2 cooling water hose 1 3 plastic tie 2 4 cap 1 5 nut 1 6 clamp 1 7 flushing hose 1 8 hose joint 1 1 9 cooling water hose 1 a: white paint mark 10 rivet 1 11 plastic tie 1 12 bilge strainer assy 1 13 clamp 2 1...

  • Page 198

    6-17 transom plate and hoses 17 bilge hose 1 18 plastic tie 1 19 clamp 2 20 cooling water hose 1 21 nut 4 22 washer 2 23 washer 2 24 plastic tie 1 25 bilge hose 1 26 transom plate 1 no. Part name q ’ ty remarks 3 17 13 14 15 1 11 12 19 20 18 14 20 19 2 10 21 16 17 22 21 26 23 25 24 1 2 8 1 9 1 6 4 5...

  • Page 199

    Transom plate and hoses 6-18 bilge strainer check 1. Check the bilge strainer. See “jet vacuum bilge draining system check” (3-10). Transom plate installation 1. Clean the mating surfaces of the transom plate “1”. 2. Apply silicone sealant to the mating sur- face of the transom plate “1”. 3. Install...

  • Page 200

    6-19 intermediate housing intermediate housing no. Part name q ’ ty remarks 1 rubber coupling 1 2 bolt 3 m8 × 48 mm 3 shim * as required 4 dowel pin 2 5 driven coupling 1 6 washer 1 7 intermediate drive shaft 1 8 o-ring 2 not reusable 9 oil seal 2 not reusable 10 circlip 2 not reusable 11 ball beari...

  • Page 201

    Intermediate housing 6-20 intermediate housing removal 1. Remove the engine unit. See “engine unit removal” (5-7). 2. Remove the intermediate housing “1”. Tip: if shims “2” are installed, remove the shims and write down the position of each removed shim so that it can be installed in its original po...

  • Page 202

    6-21 intermediate housing 4. Remove the circlips “1”, and then remove the ball bearing “2” using a press. Intermediate housing assembly do not reuse a thrust washer, always re- place it with a new one. 1. Install a new circlip (rear) “1”. 2. Install a new ball bearing “2” until it con- tacts the cir...

  • Page 203

    Intermediate housing 6-22 6. Install a new oil seal “1”. 7. Install a new thrust washer “1”. 8. Install the washer “1”, and then tighten the driven coupling “2” to the specified torque. Intermediate housing installation 1. Install the intermediate housing “1”, and then tighten the intermediate housi...

  • Page 204

    6-23 intermediate housing intermediate housing bolt “2” 17 nm (1.7 kgf·m, 12.5 ft·lb) 1 2 3.

  • Page 205: — Memo —

    Intermediate housing 6-24 — memo —.

  • Page 206: Electrical System

    Electrical system electrical components ....................................................... 7-1 engine ........................................................................................ 7-1 deck and hull.............................................................................. 7-2 elec...

  • Page 207

    7 electrical system fuel system ...................................................................... 7-29 fuel injector check ................................................................... 7-29 fuel pump relay check ............................................................. 7-29 fuel pump ...

  • Page 208

    7-1 electrical components electrical components engine 14 11 12 1 2 4 3 5 10 9 15 13 6 7 8 1. Spark plug and ignition coil 2. Cam position sensor 3. Electrical box 4. Thermo sensor 5. Rectifier/regulator 6. Starter motor 7. Oil pressure switch 8. Etv (tps) 9. Intake air pressure sensor 10. Fuel inje...

  • Page 209

    Electrical components 7-2 deck and hull 2 3 4 8 9 10 6 1 7 5 1. Remote control receiver 2. Steering sensor 3. Aps (electric throttle without wire cable) 4. Rps (electric shift without wire cable) 5. Speed sensor 6. Buzzer 7. Fuel pump module and fuel sender 8. Multifunction meter 9. Battery 10. Ride...

  • Page 210

    7-3 electrical components electrical box 12 13 14 5 6 7 8 9 15 10 11 15 16 17 1 2 3 4 1. Fuse box 2. Slant detection switch 3. Ecm 4. Starter relay 5. Fuse (10 a) (etv relay) 6. Fuse (10 a) (fuel pump relay) 7. Main relay 8. Fuse (10 a) (main relay) 9. Fuse (20 a) (main relay) 10. Fuse (3 a) (not us...

  • Page 211

    Electrical components 7-4 ecm circuit diagram , : indicate a connection between the symbols. Stator coil fuse (20 a) main relay 8.Fuse (30 a) 7.Engine start switch 10.Starter relay 12.Starter motor pickup coil cam position sensor 15.Intake air pressure sensor 16.Intake air temperature sensor 17.Engi...

  • Page 212

    7-5 electrical components oil pressure switch engine shut-off switch 5 v ground 5 v ground 5 v ground 39.Aps 43.Rps aps full close switch 5 v ground 44.Rps 1 45.Rps 2 5 v ground aps 1 aps 2 ground 5 v tps 1 tps 2 etv 46.Etv motor 35.Ecm 36. 37.Thermo switch 38. 40. 41. 42. A. A. A. A. A. A. 49. 48. ...

  • Page 213

    Electrical components 7-6 1. Rectifier/regulator 2. Stator coil 3. Fuse (20 a) 4. Fuse (10 a) 5. Main relay 6. Fuse (3 a) 7. Engine start switch 8. Fuse (30 a) 9. Remote control receiver 10. Starter relay 11. Battery 12. Starter motor 13. Pickup coil 14. Cam position sensor 15. Intake air pressure s...

  • Page 214

    7-7 electrical components ecm coupler layout 20 14 15 16 17 18 19 8 9 10 11 12 13 21 22 23 24 25 26 1 2 3 4 5 6 7 46 40 41 42 43 44 45 34 35 36 37 38 39 47 48 49 50 51 52 27 28 29 30 31 32 33 78 79 80 81 82 83 84 85 86 54 55 56 57 58 59 60 61 70 71 72 73 74 75 62 63 64 65 66 67 76 77 68 69 53 20 14 ...

  • Page 215

    Electrical components 7-8 38 immobilizer serial communication white 39 etv relay power source (contact) red/yellow 40 sensor ground black/orange 41 tps ground black/orange 42 tps 1 pink 43 tps 2 pink/black 44 tps power source orange 45 etv relay power source (contact) red/yellow 46 ecm ground black ...

  • Page 216

    7-9 electrical analysis electrical analysis electrical component check using the ydis when checking the tps, aps, rps or other sensors, use the ydis. When deleting the diagnosis record in the ydis, make sure to check the time when the diagnostic codes were detected. When checking the input voltage o...

  • Page 217

    Electrical analysis 7-10 • use the peak voltage adapter with the rec- ommended digital circuit tester. • connect the positive pin of the peak voltage adapter to the positive terminal of the digital circuit tester, and the negative pin to the neg- ative terminal. • when measuring the peak voltage, se...

  • Page 218

    7-11 ignition system ignition system ignition spark check when performing the spark gap check, keep flammable gas or liquids away, since this test can produce sparks. 1. Connect the ydis. 2. Remove the ignition coil for the cylinder that will be tested. 3. Connect the ignition coil to the special se...

  • Page 219

    Ignition system 7-12 5. Disconnect the test harness, and then con- nect the ignition coil couplers. Pickup coil check 1. Disconnect the pickup coil coupler “a”, and then connect the special service tool “1”. 2. Measure the pickup coil output peak volt- age. Tip: • to crank the engine, connect the en...

  • Page 220

    7-13 charging system charging system stator coil check 1. Disconnect the stator coil coupler “a”, and then connect the special service tool “1”. 2. Measure the stator coil output peak volt- age. 3. Disconnect the special service tool. 4. Measure the stator coil resistance. Re- place the stator coil ...

  • Page 221

    Charging system 7-14 3. Disconnect the special service tool. 4. Remove the rectifier/regulator. See “ex- haust manifold” (5-3). 5. Check the rectifier/regulator for continuity. Replace if out of specification. Tip: make sure to set the measurement range to “a” when checking the rectifier/regulator c...

  • Page 222

    7-15 control system control system oil pressure switch check 1. Disconnect the oil pressure switch coupler “a”. 2. Supply power to the ecm, and then mea- sure the input voltage between the oil pressure switch coupler terminal (wire har- ness end) and ground. Check the wire har- ness if out of specif...

  • Page 223

    Control system 7-16 5. Check the thermo switch for continuity when the specified temperatures are reached. Replace if out of specification. 6. Install the thermo switch. See “cylinder block and electrical part” (5-67). 7. Connect the thermo switch coupler. Thermo sensor check 1. Disconnect the therm...

  • Page 224

    7-17 control system 2. Supply power to the ecm, and then mea- sure the input voltage at the engine tem- perature sensor coupler terminals (wire harness end). Check the wire harness if out of specification. 3. Remove the engine temperature sensor. See “cylinder block and electrical part” (5-67). 4. S...

  • Page 225

    Control system 7-18 8. Measure the intake air temperature sensor resistance when the specified tempera- tures are reached. Replace if out of speci- fication. 9. Install the intake air temperature sensor. See “intake manifold” (5-24). 10. Connect the intake air temperature sensor coupler. Intake air ...

  • Page 226

    7-19 control system 1. Connect the ydis to display “tps 1”, “throttle valve opening angle”, and “tps 2”. Tip: when checking the tps using the ydis, do not start the engine. 2. Squeeze the throttle lever “1” slowly and check that the displayed throttle valve opening increases. 3. Check the tps 1 outp...

  • Page 227

    Control system 7-20 8. Connect the etv coupler. Etv circuit continuity 1. Disconnect the etv coupler “a” and ecm couplers “b” and “c”. 2. Check the wire harness for continuity. Re- place if there is no continuity. Replace the etv if there is continuity. 3. Connect the etv coupler and ecm cou- plers....

  • Page 228

    7-21 control system tip: the actual aps output voltage may vary ac- cording to environmental conditions. 3. Squeeze the throttle lever “1” to the fully open position, and then check the voltage difference between aps 1 and aps 2. Measure the aps input voltage if out of specification. 4. Squeeze the ...

  • Page 229

    Control system 7-22 2. Check the wire harness for continuity. Replace if there is no continuity. 3. Connect the aps coupler and ecm cou- plers. Etv relay check 1. Remove the fuse box cover and etv relay “1”. 2. Check the etv relay. See “main relay check” (7-31). 3. Measure the input voltage between ...

  • Page 230

    7-23 control system rps check rps 1 and rps 2 are components of the ride lever, which cannot be disassembled. 1. Connect the ydis to display “rps main” and “rps sub”. Tip: • when checking the rps using the ydis, do not start the engine. • the values displayed for “rps main” are the rps 1 values and ...

  • Page 231

    Control system 7-24 2. Check the wire harness for continuity. Re- place if there is no continuity. 3. Connect the rps coupler and ecm cou- plers. Scu relay check 1. Remove the fuse box cover and scu relay “1”. 2. Check the scu relay. See “main relay check” (7-31). 3. Measure the input voltage betwee...

  • Page 232

    7-25 control system electric trim switch check 1. Connect the ydis to display “trim up switch” and “trim down switch”. 2. Push the electric trim switches “1” and “2”. 3. Check that the following is displayed in the “engine monitor” window of the ydis. 4. Disconnect the electric trim switch coupler “...

  • Page 233

    Control system 7-26 5. Supply power to the ecm, and then mea- sure the output voltage when a screw- driver is passed under the cam position sensor in direction “a”. Replace the cam position sensor if out of specification. 6. Disconnect the special service tool. 7. Install the cam position sensor. Se...

  • Page 234

    7-27 control system steering sensor check 1. Connect the ydis to display “steering sensor.” 2. Check that the following is displayed in the “engine monitor” window of the ydis when the handlebar is in each position. Measure the steering sensor input voltage if out of specification. 3. Disconnect the...

  • Page 235

    Control system 7-28 3. Disconnect the ecm coupler “b”, and then check the continuity between the ecm coupler terminals (wire harness end) and ground. Replace the wire harness if there is no continuity. 4. Connect the ecm couplers. Earth plate check 1. Remove the earth plate. 2. Check the continuity ...

  • Page 236

    7-29 fuel system fuel system fuel injector check 1. Connect the ydis. 2. Using the “stationary test” of the ydis, lis- ten for the fuel injector operation sound. 3. Disconnect the fuel injector couplers “a”. 4. Supply power to the ecm, and then mea- sure the input voltage between the fuel in- jector...

  • Page 237

    Fuel system 7-30 5. Install the fuel pump relay and fuse box cover. Fuel pump module check 1. Connect the ydis. 2. Using the “stationary test” of the ydis, lis- ten for the fuel pump module operation sound. 3. Disconnect the fuel pump module coupler “a”. 4. Supply power to the ecm, and then mea- sur...

  • Page 238

    7-31 starting system starting system fuse check 1. Check the fuse for continuity. Replace if there is no continuity. Handlebar switch (left) check 1. Disconnect the handlebar switch (left) cou- pler (white coupler). 2. Check the engine start switch for continui- ty. Replace the handlebar switch (lef...

  • Page 239

    Starting system 7-32 3. Measure the input voltage between the ter- minal “a” and ground. 4. Supply power to the ecm, and then mea- sure the input voltage between the termi- nals “a” and “b”. 5. Install the main relay and fuse box cover. Starter relay check 1. Slide the boot away from the starter rel...

  • Page 240

    7-33 starting system 6. Install the starter relay. Connected continuity starter relay continuity battery lead “c”–“d” terminal “a”–“b”.

  • Page 241

    Starter motor 7-34 starter motor no. Part name q ’ ty remarks 1 bolt 2 m6 × 120 mm 2 starter motor rear cover 1 3 packing seal 1 not reusable 4 front cover 1 5 packing seal 1 not reusable 6 plate 1 7 starter motor yoke 1 8 armature 1 9 brush holder 1 10 o-ring 1 not reusable 11 circlip 1 12 drive ge...

  • Page 242

    7-35 starter motor starter motor operation 1. Remove the starter motor. See “wire har- ness” (5-18). 2. Hold the starter motor in a vise using alu- minum plates on both sides. 3. Connect the positive battery lead “1” to the starter motor terminal bolt “a”. 4. Connect the negative battery lead “2” to...

  • Page 243

    Starter motor 7-36 brush holder check 1. Measure the brush length “a”. Replace the brush holder if below specification. 2. Check the brush holder for continuity. Re- place if out of specification. Armature continuity commutator seg- ment “a” continuity segment “a”–arma- ture core “b” no continuity s...

  • Page 244

    7-37 remote control system remote control system remote control transmitter check 1. Push the unlock button “a”. The buzzer sounds 2 times, and then check that the “unlock” indicator light “b” comes on. 2. Push the unlock button “a” for more than 4 seconds. The buzzer sounds 3 times, and then check ...

  • Page 245

    Remote control system 7-38 tip: install the battery (cr2016) “1” with the posi- tive side “a” facing down. 8. Tighten the screws “1” to the specified torque in the order [1], [2], and so on. Remote control receiver check 1. Disconnect the remote control receiver coupler “a”, and then measure the inp...

  • Page 246

    7-39 remote control system 2. Push the lock button “a” or unlock button “b” to transmit the id code from the remote control transmitter to be registered. Tip: • 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 remote...

  • Page 247

    Indication system 7-40 indication system multifunction meter check 1. Check the multifunction meter external ap- pearance. Replace the multifunction meter if there is cracked meter housing, fogged meter, or water intrusion. 2. Supply power to the ecm, and then check that all indicator lights “a” and...

  • Page 248

    7-41 indication system 4. Connect the positive battery lead to the terminal “a”, and the negative battery lead to the terminal “b”. 5. Connect the tester leads between the ter- minal “c” and terminal “b”. 6. Rotate the paddle wheel “d” by hand and measure the output voltage between the terminal “c” ...

  • Page 249

    Indication system 7-42 3. If the light and indicator do not blink, check the “diagnosis record” of the ydis. If a di- agnosis record is available and the light and indicator do not blink, replace the mul- tifunction meter. 4. Connect the engine temperature sensor coupler. Diagnostic display check 1....

  • Page 250

    7-43 indication system and remain on, and the buzzer sounds continuously. After 30 seconds, check that the buzzer stops. 4. If the light and indicator do not blink, check the “diagnosis record” of the ydis. If a di- agnosis record is available and the light and indicator do not blink, replace the mu...

  • Page 251: — Memo —

    Indication system 7-44 — memo —.

  • Page 252: Hull and Hood

    Hull and hood steering pad and handlebar cover ................................... 8-1 handlebar and handlebar switch ...................................... 8-2 lead routing ............................................................................... 8-3 handlebar installation ......................

  • Page 253

    8 hull and hood rear section...................................................................... 8-31 spout installation ...................................................................... 8-33 reboarding step installation (vxr) .......................................... 8-33 deck and hull .......

  • Page 254

    8-1 steering pad and handlebar cover steering pad and handlebar cover no. Part name q ’ ty remarks 1 screw 6 m5 × 16 mm 2 upper handlebar cover 1 3 steering pad 1 4 screw 4 m6 × 14 mm 5 lower handlebar cover 1 0.5 nm (0.05 kgf·m, 0.37 ft·lb) 5.5 nm (0.55 kgf·m, 4.06 ft·lb) 4 1 5 3 2 lt 242.

  • Page 255

    Handlebar and handlebar switch 8-2 handlebar and handlebar switch no. Part name q ’ ty remarks 1 bolt 6 m5 × 30 mm 2 handlebar switch (left) 1 3 handlebar switch (right) 1 4 bolt 2 m4 × 30 mm 5 bolt 2 m6 × 12 mm 6 washer 2 7 handlebar grip 2 8 bolt 2 m5 × 23 mm 9 bolt 4 m8 × 45 mm 10 upper handlebar...

  • Page 256

    8-3 handlebar and handlebar switch lead routing 1. Wrap the packing “1”, making sure to align the upper edge of the packing with the up- per edges of the tape markings “a” and “b”, on the handlebar switch (right) lead “2” and handlebar switch (left) leads “3”. 2. Align the upper edge of the packing ...

  • Page 257

    Handlebar and handlebar switch 8-4 2. Install the stopper bolts “1”, and then tight- en them to the specified torque. 3. Install the handlebar switch (left) “1”, and then tighten the bolts “2” to the specified torque in the order [1], [2], and so on. Tip: align the hole “a” in the handlebar switch (...

  • Page 258

    8-5 handlebar and handlebar switch 7. Install the washers “3” and bolts “4”, and then tighten the bolts “4” to the specified torque. Tip: align the slit “a” in the handlebar grip “2” with the stopper bolt “5”. Handlebar grip end bolt “4” 7 nm (0.7 kgf·m, 5.2 ft·lb) 1 1 2 2 3 4 3 4 lt 242 lt 242 2 2 ...

  • Page 259

    Front hood 8-6 front hood no. Part name q ’ ty remarks 1 screw 8 1/4 – 10 × 3/4 ” 2 mirror (left) 1 3 mirror (right) 1 4 ornament 1 5 ornament 1 6 nut 2 7 washer 2 8 bolt 2 m6 × 95 mm 9 screw 17 m5 × 16 mm 10 latch 1 11 upper front hood 1 12 ornament 1 13 lower front hood 1 14 ornament 1 15 front ho...

  • Page 260

    8-7 front hood 17 pad 1 not reusable 18 packing 1 not reusable 19 screw 4 m6 × 18 mm 20 hinge 1 21 band 1 22 rivet 4 23 hook 2 24 fire extinguisher box 1 25 mat 2 not reusable 26 rivet 5 27 service lid 1 no. Part name q ’ ty remarks 26 27 19 20 7 8 5 4 2 3 13 14 12 11 1 10 18 17 15 16 9 6 25 22 25 2...

  • Page 261

    Side cover 8-8 side cover no. Part name q ’ ty remarks 1 nut 2 2 screw 4 m6 × 25 mm 3 outer ornament (left) 1 4 outer ornament (right) 1 5 cap (left) 1 6 cap (right) 1 7 inner ornament (left) 1 8 inner ornament (right) 1 9 bolt 4 m6 × 29 mm 10 nut 2 11 screw 2 m6 × 18 mm 12 side cover (left) 1 13 si...

  • Page 262

    8-9 center cover center cover no. Part name q ’ ty remarks 1 plastic tie 1 2 bolt 2 m6 × 29 mm 3 latch 1 4 nut 2 5 cover 1 6 bolt 4 m6 × 29 mm 7 center cover 1 8 screw 2 m5 × 16 mm 9 meter cover 1 10 bolt 4 m5 × 12 mm 11 multifunction meter 1 12 grommet 4 13 grommet 2 14 glove box 1 15 glove box lid...

  • Page 263

    Center cover 8-10 17 grommet 1 no. Part name q ’ ty remarks 11 7 3 5 4 4 13 6 6 16 15 14 12 13 10 2 1 17 8 9 lt 572 4 nm (0.4 kgf·m, 3.0 ft·ib) 5.5 nm (0.55 kgf·m, 4.06 ft·lb) 5.5 nm (0.55 kgf·m, 4.06 ft·lb) 2.5 nm (0.25 kgf·m, 1.84 ft·lb).

  • Page 264

    8-11 steering master assy steering master assy no. Part name q ’ ty remarks 1 bolt 1 m6 × 18 mm 2 cable stopper 1 3 steering cable 1 4 plastic tie 2 5 bolt 4 m8 × 30 mm 6 steering master 1 7 rivet 2 8 bracket 1 9 grommet 2 7 nm (0.7 kgf·m, 5.2 ft·ib) 17 nm (1.7 kgf·m, 12.5 ft·ib) lt 242 a lt 242 1 7...

  • Page 265

    Steering master 8-12 steering master no. Part name q ’ ty remarks 1 plastic tie 1 2 buzzer 1 3 cable guide 1 4 bolt 2 m5 × 16 mm 5 bracket 1 6 screw 3 m5 × 12 mm 7 steering sensor 1 8 nut 1 9 bolt 1 m8 × 50 mm 10 lock washer 1 not reusable 11 steering arm assy 1 12 nut 1 13 ball joint 1 14 steering ...

  • Page 266

    8-13 steering master 17 magnet holder 1 18 cap 1 19 steering shaft housing 1 20 rubber seal 1 not reusable no. Part name q ’ ty remarks 4 nm (0.4 kgf·m, 3.0 ft·ib) 4 nm (0.4 kgf·m, 3.0 ft·ib) 4 nm (0.4 kgf·m, 3.0 ft·ib) 16 nm (1.6 kgf·m, 11.8 ft·ib) 7 nm (0.7 kgf·m, 5.2 ft·ib) a 1 12 4 3 13 10 9 8 1...

  • Page 267

    Steering master 8-14 steering arm assy installation 1. Install the steering arm assy “1” to the steering shaft. 2. Install the nut “2” to the steering arm “1”. 3. Align the tab “a” on the plate “3” with the projection “b” on the arm. 4. Tighten the steering arm bolt “4” to the specified torque. 5. B...

  • Page 268

    8-15 steering cable and speed sensor lead steering cable and speed sensor lead no. Part name q ’ ty remarks 1 steering cable joint 1 2 bolt 1 m6 × 18 mm 3 cable stopper 1 4 plastic tie 1 5 nut 1 6 steering cable 1 7 packing 1 not reusable 8 plastic tie 6 9 nut 1 10 screw 4 m5 × 12 mm 11 speed sensor...

  • Page 269

    Steering cable and speed sensor lead 8-16 steering cable installation (steering master end) if a cable becomes damaged, replace it. Never attempt to repair a damaged cable. 1. Install the steering cable “1” and cable stopper “2”, and then tighten the bolt “3” to the specified torque. Tip: install th...

  • Page 270

    8-17 seat and handgrip seat and handgrip no. Part name q ’ ty remarks 1 rear seat 1 2 bolt 4 m6 × 40 mm 3 seat lock 1 4 packing 1 not reusable 5 front seat 1 a: vxs, b: vxr 6 seat lock 1 7 packing 1 not reusable 8 cap 1 9 packing 1 not reusable 10 watertight storage compartment 1 11 packing 1 not re...

  • Page 271

    Seat and handgrip 8-18 17 washer 2 18 projection 1 19 handgrip 1 20 bolt 1 m10 × 20 mm 21 washer 2 22 projection 1 23 seat holder 1 no. Part name q ’ ty remarks a bow 7 nm (0.7 kgf·m, 5.2 ft·ib) 7 nm (0.7 kgf·m, 5.2 ft·ib) 16 nm (1.6 kgf·m, 11.8 ft·ib) 16 nm (1.6 kgf·m, 11.8 ft·ib) 26 nm (2.6 kgf·m,...

  • Page 272

    8-19 ventilation hose and water separator ventilation hose and water separator no. Part name q ’ ty remarks 1 rivet 8 2 ventilator 2 3 plastic tie 2 4 ventilation hose 2 5 plastic tie 3 6 plastic tie 3 7 fuel tank breather hose 1 8 fuel tank breather hose 1 9 rivet 2 10 plate 1 11 water separator 1 ...

  • Page 273

    Ventilation hose and water separator 8-20 17 plastic tie 1 18 nut 1 19 seal 1 not reusable 20 clamp 1 21 cooling water hose 1 22 cooling water pilot outlet 1 23 holder 5 no. Part name q ’ ty remarks 18 23 14 19 22 20 21 17 6 14 23 6 14 23 7 3 4 3 4 6 14 23 23 5 14 15 16 2 1 1 2 14 9 5 5 11 10 13 12 ...

  • Page 274

    8-21 ventilation hose and water separator cooling water pilot outlet installation 1. Install a new seal “1” and the cooling water pilot outlet “2”, and then tighten the cooling water pilot outlet nut “3” to the specified torque. Tip: align the protrusion “a” with the slit “b”. Cooling water pilot ou...

  • Page 275

    Exhaust system 8-22 exhaust system no. Part name q ’ ty remarks 1 negative battery lead 1 2 positive battery lead 1 3 clamp 1 4 battery breather hose 1 5 band 2 6 battery 1 7 bolt 2 m6 × 30 mm 8 nut 2 9 battery case 1 10 pad 1 not reusable 11 pad 1 not reusable 12 pad 3 not reusable 13 clamp 1 14 re...

  • Page 276

    8-23 exhaust system 17 rubber hose 1 a: projection 18 band 1 19 water lock 1 20 water tank 1 b: alignment mark, c: alignment mark 21 nut 6 22 exhaust valve 1 not reusable 23 rubber hose 1 d: alignment mark 24 plate 1 25 pad 3 not reusable 26 rivet 8 27 hook 2 28 bracket 1 29 bracket 1 no. Part name ...

  • Page 277

    Exhaust system 8-24 exhaust system installation 1. Install the plate “1” onto the rubber hose “2”. Tip: make sure to fit the projections “a” on the rub- ber hose “2” with the grooves in the plate “1”. 2. Install the rubber hose “1” and a new ex- haust valve “2”, and then tighten the nuts “3” to the ...

  • Page 278

    8-25 exhaust system 6. Install the band. Rubber hose clamp “2” 3.5 nm (0.35 kgf·m, 2.58 ft·lb).

  • Page 279

    Ride motor 8-26 ride motor no. Part name q ’ ty remarks 1 plastic tie 1 2 plastic tie 1 3 trim rod 1 4 shift rod 1 5 bolt 2 m6 × 20 mm 6 trim arm 1 7 shift arm 1 8 bolt 2 m8 × 20 mm 9 nut 3 10 plate 1 11 ride motor 1 12 packing 1 not reusable 13 rivet 2 14 hook 2 15 rivet 1 16 holder 1 a a 2 1 15 11...

  • Page 280

    8-27 ride motor ride motor removal 1. Remove the deck beam “1”. 2. Remove the plastic tie “1”, and then dis- connect the ride motor couplers “a” and “b”. 3. Remove the resonator “1”, rubber hose “2”, and water tank “3”. 4. Remove the ride motor harness “1” from the holders “2” and the plastic tie “3...

  • Page 281

    Ride motor 8-28 10. Remove the ride motor “1”. Ride motor installation 1. Hold the ride motor “1” at the installation position of the hull. 2. Install the plate “1”, and then tighten the ride motor nuts “2” and ride motor bolts “3” to the specified torque in the order [1], [2], and so on. 3. Install...

  • Page 282

    8-29 ride motor 7. Turn the shift rod joint so that the 2 holes “d” face in the same directions, and then tighten the locknut “4” to the specified torque. 8. Connect the shift rod joint “1” and trim rod joints “2”. 9. Raise the reverse gate, and then connect the shift rod joint “1”. 10. Install the ...

  • Page 283

    Ride motor 8-30 tip: align the mark “a” on the rubber hose “3” with the mark “b” on the water tank “1”. 14. Install the rubber hose “1”, and then tight- en the rubber hose clamps “2” and “3” to the specified torque. Tip: align the protrusion “a” on the rubber hose “1” with the mark “b” on the water ...

  • Page 284

    8-31 rear section rear section no. Part name q ’ ty remarks 1 nut 6 2 plate 6 3 cleat 1 4 clamp 1 5 nut 1 6 spout 1 7 stern eye 2 8 packing 2 not reusable 9 nut 4 10 washer 4 11 screw 4 m5 × 25 mm 12 drain plug 2 13 packing 2 not reusable 14 bolt 4 vxr, m8 × 47 mm 15 reboarding step 1 vxr 16 bracket...

  • Page 285

    Rear section 8-32 17 packing 2 vxr, not reusable no. Part name q ’ ty remarks 15 14 14 14 14 6 5 4 17 16 1 2 12 13 11 1 2 2 3 2 7 8 10 9 bow lt 271 lt 271 2 nm (0.2 kgf·m, 1.5 ft·ib) 16 nm (1.6 kgf·m, 11.8 ft·ib) 16 nm (1.6 kgf·m, 11.8 ft·ib) 16 nm (1.6 kgf·m, 11.8 ft·ib) 5.5 nm (0.55 kgf·m, 4.06 ft...

  • Page 286

    8-33 rear section spout installation 1. Install the spout “1”, and then tighten the spout nut “2” to the specified torque. 2. Connect the hose “3”, and then tighten the spout hose clamp “4” to the specified torque. Tip: face the mark “a” toward the bow. Reboarding step installation (vxr) 1. Secure t...

  • Page 287

    Deck and hull 8-34 deck and hull no. Part name q ’ ty remarks 1 bolt 2 m6 × 20 mm 2 bow eye 1 3 nut 2 4 washer 2 5 nut 2 6 washer 2 7 nut 4 8 nut 2 9 screw 2 m6 × 25 mm 10 front protector 1 11 bolt 4 m6 × 25 mm 12 rivet 7 13 rear protector 1 14 rear protector 1 15 bolt 10 m8 × 40 mm 16 collar 10 7 n...

  • Page 288

    8-35 deck and hull 17 sponson 1 18 sponson 1 19 bracket 2 20 inner gunwale 2 21 rivet 30 22 washer 30 23 side gunwale 2 24 mat 1 not reusable 25 mat 1 not reusable 26 mat 1 not reusable 27 mat 1 not reusable 28 mat 1 not reusable 29 mat 1 not reusable 30 mat 1 not reusable 31 ornament 1 32 ornament ...

  • Page 289

    Deck and hull 8-36 34 ornament 1 35 screw 6 #10 – 14 × 2/5 ” 36 ornament 1 37 ornament 1 no. Part name q ’ ty remarks 7 nm (0.7 kgf·m, 5.2 ft·ib) 7 nm (0.7 kgf·m, 5.2 ft·ib) 7 nm (0.7 kgf·m, 5.2 ft·ib) 13 nm (1.3 kgf·m, 9.6 ft·ib) 16 nm (1.6 kgf·m, 11.8 ft·ib) 16 nm (1.6 kgf·m, 11.8 ft·ib) 18 nm (1....

  • Page 290: — Memo —

    Deck and hull 8-37 — memo —.

  • Page 291: Troubleshooting

    9 troubleshooting ydis ..................................................................................... 9-1 basic components ...................................................................... 9-1 function...................................................................................... ...

  • Page 292

    9-1 ydis ydis the yamaha diagnostic system uses precision fault diagnosis to offer better serviceability at a time when there is increasing demand for service tools for electronically controlled products. It provides quick, reliable, safe, and reasonable service, and is intended to obtain customer s...

  • Page 293

    Ydis 9-2 function 1. Diagnosis: each sensor’s status and each ecm diagnostic code or item is displayed. This enables you to find malfunctioning parts and controls quickly. The diagnostic codes displayed are the same as those described in “diagnostic code and checking step” in this chapter. 2. Diagno...

  • Page 294

    9-3 ydis when the communication cable is used to connect a computer to the ecm, the ecm record data can be saved and viewed on the computer. The saved ecm record data can also be viewed offline. Tip: to display the data and graphs, see the ydis (ver. 2.20) instruction manual. 8. Logging: while the c...

  • Page 295

    Ydis 9-4 tip: to perform the scu initial learning, see the ydis (ver. 2.20) instruction manual. Connecting the communication cable to the watercraft tip: be careful not to pinch the communication cable between the front hood and the deck or to damage it. W/b r/y b a b 1 2 3 4 a. Wire harness coupler...

  • Page 296

    9-5 engine unit troubleshooting engine unit troubleshooting tip: • before troubleshooting the engine unit, make sure that fresh fuel of the specified type has been used. • check that all wiring connections are secured properly and that they are not corroded or rusty. • check that the engine shut-off...

  • Page 297

    Engine unit troubleshooting 9-6 if the multifunction meter is turned on before the problem is solved, the information display will indicate the diagnostic code “c” and the “warning” indicator light “a” will blink. If the engine is started, the “warning” indicator light “a” and the check engine warni...

  • Page 298

    9-7 engine unit troubleshooting diagnostic code table : indicated —: not indicated code no. Item diagnostic code output multifunc- tion meter ydis diagnosis diagnosis record 13 pulser coil (pickup coil) 15 engine temperature sensor 19 battery voltage 23 air temperature sensor (intake air temperatur...

  • Page 299

    Engine unit troubleshooting 9-8 diagnostic code and checking step *1: this symptom may only be exhibited in certain environmental conditions. —: not applicable diag- nostic code item symptom checking steps see page 13 pulser coil (pickup coil) engine will not start measure the pickup coil output pea...

  • Page 300

    9-9 engine unit troubleshooting 24 cam position sensor engine speed is limited measure the cam position sensor input voltage. 7-25 check the orange (o), green/orange (g/o), and black/orange (b/o) cam posi- tion sensor leads for continui- ty. A-2 measure the cam position sensor output voltage. 7-25 2...

  • Page 301

    Engine unit troubleshooting 9-10 55 steering sensor normal operation check the steering sensor op- eration using the ydis. 7-27 measure the steering sensor input voltage. 7-27 check the orange/red (o/r), white/blue (w/l), and black/or- ange (b/o) steering sensor leads for continuity. A-2 112 113 114...

  • Page 302

    9-11 engine unit troubleshooting 117 118 119 etv system engine speed is limited check the etv coupler termi- nals for corrosion and rust. 4-7 check the green (g) and blue (l) etv leads for continuity. A-2 check the ecm circuit for con- tinuity. 7-27 121 etv system engine speed is limited cross-check...

  • Page 303

    Engine unit troubleshooting 9-12 136 137 138 139 etv system engine speed is limited check the ecm circuit for con- tinuity. 7-27 check the etv relay for conti- nuity. 7-22 check the charging system. • stator coil output peak volt- age • stator coil resistance • rectifier/regulator output peak voltag...

  • Page 304

    9-13 engine unit troubleshooting 143 144 etv system engine speed is limited check the ecm circuit for con- tinuity. 7-27 check the etv relay for conti- nuity. 7-22 check the charging system. • stator coil output peak volt- age • stator coil resistance • rectifier/regulator output peak voltage • rect...

  • Page 305

    Engine unit troubleshooting 9-14 159 scu engine speed is limited shifting is impossible check that there is no foreign matter on the rotating part of the reverse gate. 6-7 replace the ride motor. 8-26 161 scu engine speed is limited shifting is impossible replace the ride motor. 8-26 162 scu changin...

  • Page 306

    9-15 engine unit troubleshooting engine unit troubleshooting (diagnostic code not detected) troubleshooting when diagnostic codes are not available consists of the following 3 items. Symptom 1: specific trouble conditions symptom 2: trouble conditions of an area or individual part cause: the content...

  • Page 307

    Engine unit troubleshooting 9-16 discharged battery battery performance de- crease check the battery voltage and spe- cific gravity. 3-6 stator coil malfunction check the stator coil 7-13 short, open, or loose con- nection in charging circuit check the battery lead and terminal for proper connection...

  • Page 308

    9-17 engine unit troubleshooting symptom 1: unstable engine idle speed, poor acceleration, poor performance, or limited engine speed fuel not supplied (all cylinders) fuel leakage check the fuel hose. 4-1 blown fuse check the fuse for continuity. 7-3 7-31 clogged fuel pump filter clean the fuel pump...

  • Page 309

    Engine unit troubleshooting 9-18 spark plug does not spark (some cylin- ders) spark plug malfunction check the spark plug. 3-5 ignition coil malfunction check the ignition spark. 7-11 short, open, or loose con- nection in ignition coil cir- cuit measure the ignition coil input volt- age (from the ba...

  • Page 310

    9-19 engine unit troubleshooting symptom 1: limited engine speed symptom 2 cause checking step see page • buzzer sounds in- termittently • overheat warning indicator blinks • check engine warning indicator blinks clogged cooling water pas- sage check the cooling water pilot outlet for water discharg...

  • Page 311

    Engine unit troubleshooting 9-20 symptom 1: discharged battery symptom 1: poor performance symptom 2 cause checking step see page — battery performance de- crease check the battery voltage and spe- cific gravity. 3-6 loose connection of bat- tery terminal check the battery lead and terminal for prop...

  • Page 312: — Memo —

    Engine unit troubleshooting 9-21 — memo —.

  • Page 313: Appendix

    A appendix wiring diagram ...................................................................A-1 how to use the wiring diagram ................................................... A-1 vxs, vxr................................................................................... A-2.

  • Page 314

    A-1 wiring diagram wiring diagram how to use the wiring diagram legend symbols in the wiring diagrams color code example: r/y: red with yellow tracer stripe wire 1 2 1. Double colors wire 2. No wire connector b : black br : brown b/g : black/green b/l : black/blue b/o : black/orange b/r : black/red ...

  • Page 315

    1 2 3 4 5 7 8 1 2 4 8 3 2 5 7 8 9 13 11 14 15 16 17 20 21 23 22 26 25 27 28 29 30 31 32 33 34 35 36 37 39 40 41 42 43 44 45 46 47 49 50 51 52 3 4 6 7 9 10 12 13 14 15 16 18 7 13 19 26 27 34 40 46 33 39 45 52 53 62 70 78 61 69 77 86 58 59 60 61 62 64 67 70 72 78 79 80 81 83 84 86 85 1 2 3 4 5 8 9 10 ...

  • Page 316

    A-3 wiring diagram a. To entry box b. Antenna a. Fuse (10 a) (fuel pump relay) b. Fuse (3 a) (not used) c. Fuse (20 a) (main relay) d. Fuse (10 a) (main relay) e. Fuse (10 a) (etv relay) f. Fuse (3 a) (remote control receiver) g. Fuse (30 a) (battery) h. Fuse (50 a) (scu relay) i. Fuel pump relay j....

  • Page 318

    Mar. 2015 cr (e).