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Yamaha WaveRunner XL1200Ltd Service Manual

Manual is about: Yamaha WaveRunner XL1200Ltd Service manual

Summary of WaveRunner XL1200Ltd

  • Page 1

    Lit186160198 lit-18616-01-98 f0d-28197-z9-11 service manual waverunner xl1200ltd.

  • Page 2: Notice

    E notice this manual has been prepared by the yamaha motor company ltd. Primarily for use by yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mecha...

  • Page 3: How to Use This Manual

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

  • Page 4

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

  • Page 5

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

  • Page 6: Gen

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

  • Page 7: Index

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

  • Page 8: Gen

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

  • Page 9: Gen

    1-1 e gen info identification numbers a60700-0* identification numbers primary l.D. Number the primary l.D. Number is stamped on a label attached to the inside of the engine compartment. Starting primary l.D. Number: f0d: 800101 ~ engine serial number the engine serial number is stamped on a label a...

  • Page 10: Gen

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

  • Page 11: Gen

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

  • Page 12: Gen

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

  • Page 13: Gen

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

  • Page 14: Gen

    1-6 e gen info special tools removal and installation 1. Coupler wrench p/n. Yw-06551 90890-06551 2. Flywheel holder p/n. Yw-06550 90890-06550 3. Flywheel puller p/n. Yb-06117 90890-06521 4. Shaft holder (intermediate shaft) p/n. Yb-06552 90890-06552 5. Driver rod (intermediate shaft and jet pump) p...

  • Page 15: Spec

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

  • Page 16: Spec

    2-1 spec e general specifications general specifications item unit model xl1200ltd model code hull f0d engine 66v dimensions length mm (in) 3,160 (124.4) width mm (in) 1,220 (48.0) height mm (in) 1,130 (44.5) dry weight kg (lb) 354 (780) vehicle capacity 3 performance maximum output kw (ps) @ r/min ...

  • Page 17: Spec

    2-2 spec e pon*: pump octane number ron*: research octane number yamalube 2-w*: yamalube 2-w is developed for this water vehicle and available from a yamaha water vehicle dealer. Caution: use only yamalube 2-w oil. Using another oil can seriously damage the catalytic converter and other engine compo...

  • Page 18: Spec

    2-3 spec e maintenance specifications maintenance specifications engine item unit model xl1200ltd cylinder head warpage limit mm (in) 0.1 (0.004) compression pressure *1 kpa (kg/cm 2 ) 500 (5.0) cylinders bore size mm (in) 80.000 ~ 80.018 (3.1496 ~ 3.1503) taper limit mm (in) 0.08 (0.003) out-of-rou...

  • Page 19: Spec

    2-4 spec e maintenance specifications jet pump unit hull and hood crankshaft assembly crank width a mm (in) 72.95 ~ 73.00 (2.872 ~ 2.874) deflection limit b mm (in) 0.05 (0.002) deflection limit c mm (in) 0.15 (0.006) big end side clearance d mm (in) 0.25 ~ 0.75 (0.010 ~ 0.030) maximum small end axi...

  • Page 20: Spec

    2-5 spec e maintenance specifications electrical item unit model xl1200ltd battery type fluid capacity v-ah (kc) 12 - 19 (68.4) cdi unit (b/w – b) output peak voltage lower limit @cranking 1 v 200 @cranking 2 v 180 @2,000 r/min v 190 @3,500 r/min v 180 stator pickup coil (w/r – b/o) output peak volt...

  • Page 21: Spec

    2-6 spec e maintenance specifications rectifier/regulator (r – b) output peak voltage lower limit @cranking 1 v — @cranking 2 v 7 @2,000 r/min v 12.6 @3,500 r/min v 12.6 starter motor brush length mm (in) 12.5 (0.49) wear limit mm (in) 6.5 (0.26) commutator undercut mm (in) 0.7 (0.03) limit mm (in) ...

  • Page 22: Spec

    2-7 spec e tightening torques tightening torques specified torques part to tightened part name thread size q’ty tightening torque remarks nm m•kg ft•lb engine exhaust chamber/stay – bracket bolt m10 2 40 4.0 29 271 lt exhaust chamber stay/ cylinder head – cylinder 1st bolt m8 2 15 1.5 11 2nd 36 3.6 ...

  • Page 23: Spec

    2-8 spec e tightening torques stator coil – generator cover bolt m6 3 15 1.5 11 242 lt flywheel magneto – crankshaft bolt m10 1 75 7.5 54 e upper crankcase – lower crankcase 1st bolt m8 17 15 1.5 11 2nd 28 2.8 20 m6 10 11 1.1 8.0 engine bracket – lower crankcase 1st bolt m8 6 15 1.5 11 271 lt 2nd 28...

  • Page 24: Spec

    2-9 spec e tightening torques general torque this chart specifies tightening torques for standard fasteners with a standard iso thread pitch. Tightening torque specifica- tions for special components or assemblies are provided in applicable sections of this manual. To avoid warpage, tighten multi- f...

  • Page 25: Spec

    2-10 spec e cable and hose routing cable and hose routing 1 fuel breather hose 2 pilot water hose 3 qsts cable 4 fuel hose 5 shift cable 6 steering cable 7 fuel filter 8 ventilation hose 9 ground lead 0 starter motor lead a electrical box lead b generator lead c pickup coil lead d ypvs cable e speed...

  • Page 26: Spec

    2-11 spec e cable and hose routing 1 throttle cable 2 switch box lead 3 qsts cable 4 buzzer lead 5 to pickup coil 6 to battery positive terminal 7 to starter motor 8 to multi-function meter 9 to water/exhaust temperature sensor 0 to generator a battery breather hose b battery negative lead c water h...

  • Page 27: Insp

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

  • Page 28: Insp

    3-1 insp adj e maintenance interval chart maintenance interval chart the following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the intervals of maintenance should be changed. *1: grease capacity 33.0 ~ 35.0 cm 3 (1.11 ~ 1.18 oz....

  • Page 29: Insp

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

  • Page 30: Insp

    3-3 insp adj e control system note: if the steering cable cannot be properly adjusted at the steering column side, make adjustments at the jet pump side. ● connect the cable joint and tighten the locknut. T r . . Locknut: 7 nm (0.7 m • kg, 5.1 ft • lb) warning the cable joint must be screwed in more...

  • Page 31: Insp

    3-4 insp adj e control system choke cable inspection and adjustment 1. Inspect: ● choke knob (pull the choke knob all the way out) choke knob automatically returns → adjust. Adjustment steps: ● turn in the adjusting nut 1 until the choke knob does not automatically return. Qsts cable inspection and ...

  • Page 32: Insp

    3-5 insp adj e control system 2. Adjust: ● qsts cable note: if correct adjustment by using the cable joint at the wheel end is not obtained, adjust the cable joint on the trim nozzle end. Adjustment steps: ● set the control grip in the neutral posi- tion. ● set the jet nozzle in the center posi- tio...

  • Page 33: Insp

    3-6 insp adj e control system shift cable inspection and adjustment 1. Check: ● reverse gate stopper lever position incorrect → adjust. Checking steps: ● set the shift lever to the reverse posi- tion. ● check to make sure the reverse gate 1 contacts the stopper 2 on the bracket and the lever 3 conta...

  • Page 34: Insp

    3-7 insp adj e control system ypvs cable adjustment 1. Check: ● ypvs valve position incorrect position → adjust the ypvs cable. Checking steps: ● initiate the multi-function meter “start” mode so the display comes on. ● start the engine and then stop it. ● check that the hole a in the pulley is alig...

  • Page 35: Insp

    3-8 insp adj e control system/fuel system 3. Adjust: ● ypvs cables 1 and 2 adjustment steps: ● loosen locknuts 1 and 2. ● turn in the adjuster 3 and 4 until there is slack in the cable. ● align the hole a in the pulley with the hole in the cylinder. ● insert a 4-mm-diameter pin through the holes in ...

  • Page 36: Insp

    3-9 insp adj e fuel system fuel line inspection 1. Inspect: ● fuel filter 1 contaminants → replace. Cracks/damage → replace. Water contamination → replace and check the fuel tank. ● fuel hose ● fuel tank ● fuel hoses through part ● fuel filler cap cracks/damage → replace. 2. Inspect: ● water separat...

  • Page 37: Insp

    3-10 insp adj e fuel system/oil injection system 2. Adjust: ● trolling speed adjustment steps: ● start the engine and allow it to warm up for several minutes. ● attach the engine tachometer to the spark plug lead. Engine tachometer: yu-8036-a/90890-06760 ● turn the remote throttle stop screw 1 in or...

  • Page 38: Insp

    3-11 insp adj e oil injection system/power unit 1. Bleed: ● air air bleeding steps: ● place rags around the air bleed screw 1 to catch any oil that might spill. ● fill the oil tank with oil. Recommended engine oil: yamalube 2-w oil only ● loosen the air bleed screw 1 two full turns and make sure tha...

  • Page 39: Insp

    3-12 insp adj e power unit/electrical 3. Measure: ● spark plug gap a out of specification → regap. Spark plug gap: 1.0 ~ 1.1 mm (0.039 ~ 0.043 in) 4. Tighten: ● spark plug note: ● before installing the spark plug, clean the gasket surface and spark plug surface. Also, it is suggested to apply a thin...

  • Page 40: Insp

    3-13 insp adj e electrical antidote (external): ● skin - wash with water. ● eyes - flush with water for 15 minutes and get immediate medical attention. Antidote (internal): ● drink large quantities of water or milk fol- lowed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical ...

  • Page 41: Insp

    3-14 insp adj e electrical 2. Inspect: ● electrolyte level low → add distilled water. The electrolyte level should be between the upper 1 and lower 2 level marks. Caution: use only distilled water. Other types of water contain minerals which are harmful to batteries. Filling steps: ● remove each fil...

  • Page 42: Insp

    3-15 insp adj e electrical/jet pump unit 5. Install: ● battery breather hose 1 ● battery ● positive lead 2 ● negative lead 3 ● battery band caution: ● connect the positive lead to the battery terminal first. ● make sure the battery leads are con- nected properly. Reversing the leads can seriously da...

  • Page 43: Insp

    3-16 insp adj e jet pump unit/general water inlet filter inspection 1. Inspect: ● water inlet filter contaminants → clean. Cracks/damage → replace. Inspection steps: ● remove the water inlet cover 1. ● inspect the water inlet filter mesh a. ● reinstall the removed parts. Bilge strainer inspection 1....

  • Page 44: Insp

    3-17 insp adj e general lubrication points 1. Lubricate: ● throttle cable (handlebar side) ● qsts control cables (handlebar side) note: ● before lubricating the throttle cable, squeeze the throttle lever and remove the rubber seal 1. ● before lubricating the qsts control cables, remove the trim grip...

  • Page 45: Insp

    3-18 insp adj e general 3. Lubricate: ● nozzle pivot shaft ● steering cable (nozzle side) ● qsts cable (nozzle side) recommended grease: yamaha marine grease, yamaha grease a (water resistant grease) 4. Lubricate: ● steering cable ● steering cable joint ● shift cable ● shift cable joint note: discon...

  • Page 46: Fuel

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

  • Page 47: Fuel

    E 1 2 3 4 5 6 7 8 9 fuel carburetor .............................................................................................. 4-18 exploded diagram ........................................................................... 4-18 removal and installation chart ......................................

  • Page 48: Fuel

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

  • Page 49: Fuel

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

  • Page 50: Fuel

    4-3 fuel e choke cable choke cable exploded diagram removal and installation chart step procedure/part name q’ty service points choke cable removal follow the left “step” for removal. 1 screw 1 2 knob 1 3 friction adjusting nut 1 4 nut 1 5 choke cable 1 reverse the removal steps for installation..

  • Page 51: Fuel

    4-4 fuel e oil tank oil tank exploded diagram removal and installation chart step procedure/part name q’ty service points oil tank removal follow the left “step” for removal. Exhaust chamber assembly refer to “exhaust chamber assembly” in chapter 5. Intake duct refer to “intake duct and silencer”. 1...

  • Page 52: Fuel

    4-5 fuel e oil tank exploded diagram step procedure/part name q’ty service points 7 breather hose 1 8 oil hose 1 9 bolt 2 10 tank belt 2 11 oil tank assembly 1 12 hose clamp 1 13 oil filler hose 1 14 oil level sensor 1 reverse the removal steps for installation..

  • Page 53: Fuel

    4-6 fuel e oil tank service points oil filter inspection refer to “oil injection system” in chapter 3. Oil level switch inspection refer to “indication system” in chapter 7. Oil tank inspection 1. Inspect: ● oil tank cracks/damage → replace..

  • Page 54: Fuel

    4-7 fuel e fuel tank fuel tank exploded diagram removal and installation chart step procedure/part name q’ty service points fuel tank removal follow the left “step” for removal. Engine unit refer to “engine unit” in chapter 5. Oil tank refer to “oil tank”. 1 hose clamp 1 2 fuel filler cap 1 3 nut 1 ...

  • Page 55: Fuel

    4-8 fuel e fuel tank exploded diagram step procedure/part name q’ty service points 8 fuel hose 1 9 fuel breather hose 1 10 fuel tank assembly 1 11 hose clamp 1 12 fuel filler hose 1 13 hose clamp 1 14 fuel sensor assembly 1 15 one way valve 1 16 screw 1 17 filter 1 reverse the removal steps for inst...

  • Page 56: Fuel

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

  • Page 57: Fuel

    4-10 fuel e intake duct and silencer intake duct and silencer exploded diagram removal and installation chart step procedure/part name q’ty service points intake duct and silencer removal follow the left “step” for removal. Exhaust chamber assembly refer to “exhaust chamber assembly” in chapter 5. M...

  • Page 58: Fuel

    4-11 fuel e intake duct and silencer exploded diagram step procedure/part name q’ty service points 5 hook 5 6 silencer case 1 7 bolt 6 8 filter 1 9 silencer plate 1 10 o-ring 3 reverse the removal steps for installation..

  • Page 59: Fuel

    4-12 fuel e carburetor unit carburetor unit exploded diagram removal and installation chart step procedure/part name q’ty service points carburetor unit removal follow the left “step” for removal. Silencer refer to “intake duct and silencer”. 1 oil pump cable 1 2 throttle cable 1 3 choke cable 1 4 f...

  • Page 60: Fuel

    4-13 fuel e carburetor unit exploded diagram step procedure/part name q’ty service points 7 fuel pump vacuum hose 3 8 bolt 6 9 bolt 4 10 carburetor assembly 1 11 gasket 1 reverse the removal steps for installation. Not reusable.

  • Page 61: Fuel

    4-14 fuel e carburetor unit exploded diagram removal and installation chart step procedure/part name q’ty service points carburetor unit separation follow the left “step” for removal. 1 hose 2 2 hose 2 3 accelerator pump hose 3 4 remote throttle stop screw assembly 1 5 throttle link 1 6 choke link 1.

  • Page 62: Fuel

    4-15 fuel e carburetor unit exploded diagram step procedure/part name q’ty service points 7 bolt 3 8 cable holder 1 9 bolt 6 10 carburetor 3 11 gasket 3 12 plate 1 reverse the removal steps for installation. Not reusable.

  • Page 63: Fuel

    4-16 fuel e carburetor unit service points throttle valve synchronization inspection and adjustment 1. Check: ● throttle valve synchronization different clearances → adjust. Checking steps: ● loosen the remote throttle stop screw 1 until untouched the screw end from the throttle lever. ● check the e...

  • Page 64: Fuel

    4-17 fuel e carburetor unit choke cable and throttle cable installation 1. Install: ● choke cable 1 ● throttle cable 2 choke cable guide installation position a: 13 ~ 15 mm (0.51 ~ 0.59 in) throttle cable guide installation position b: 18 ~ 20 mm (0.71 ~ 0.79 in) 2. Adjust: ● throttle lever free pla...

  • Page 65: Fuel

    4-18 fuel e carburetor carburetor exploded diagram removal and installation chart step procedure/part name q’ty service points carburetor disassembly follow the left “step” for disassembly. 1 accelerator pump delivery hose 3 carburetor #3 2 accelerator pump fuel hose 1 carburetor #3 3 screw 4 4 acce...

  • Page 66: Fuel

    4-19 fuel e carburetor exploded diagram step procedure/part name q’ty service points 10 pilot jet 1 11 screw 1 12 arm 1 13 arm pin 1 14 spring 1 15 screw 1 16 needle valve seat holder 1 17 needle valve 1 18 needle valve seat 1 19 o-ring 1 reverse the disassembly steps for assembly..

  • Page 67: Fuel

    4-20 fuel e carburetor exploded diagram removal and installation chart step procedure/part name q’ty service points accelerator pump disassembly follow the left “step” for disassembly. 1 screw 1 2 stay 1 3 spring 1 4 spring seat 1 5 screw 4 6 accelerator pump cover assembly 1 7 spring 1 8 diaphragm ...

  • Page 68: Fuel

    4-21 fuel e carburetor service points caution: do not use steel wire for cleaning the jets. This may enlarge the jet diameters and seriously affect performance. Diaphragm inspection 1. Inspect: ● diaphragm damage → replace. Accelerator pump body inspection 1. Inspect: ● one way valve crack/damage → ...

  • Page 69: Fuel

    4-22 fuel e regulator body inspection 1. Inspect: ● regulator body contaminants → clean. Damage → replace. ● valve (clear film) 1 damage → replace. Needle valve inspection 1. Inspect: ● needle valve ● needle valve seat contaminants a → clean. Wear b → replace. Note: always replace the needle valve a...

  • Page 70: Fuel

    4-23 fuel e fuel pump fuel pump exploded diagram removal and installation chart step procedure/part name q’ty service points fuel pump disassembly follow the left “step” for disassembly. Carburetors refer to “carburetor”. 1 screw 4 2 fuel pump cover 1 3 gasket 1 4 diaphragm 1 5 o-ring 1 6 diaphragm ...

  • Page 71: Fuel

    4-24 fuel e fuel pump exploded diagram step procedure/part name q’ty service points 7 rubber diaphragm 1 8 diaphragm 1 9 packing 1 10 fuel filter 1 reverse the disassembly steps for assembly..

  • Page 72: Fuel

    4-25 fuel e fuel pump service points fuel pump inspection 1. Inspect: ● diaphragm ● rubber diaphragm ● diaphragm body damage → replace. Fuel filter inspection 1. Inspect: ● fuel filter clog/contaminants → clean. Damage → replace..

  • Page 73: Fuel

    4-26 fuel e oil pump oil pump exploded diagram removal and installation chart step procedure/part name q’ty service points oil pump removal follow the left “step” for removal. Exhaust chamber assembly refer to “exhaust chamber assembly” in chapter 5. Intake duct refer to “intake duct and silencer”. ...

  • Page 74: Fuel

    4-27 fuel e oil pump exploded diagram step procedure/part name q’ty service points 6 oil pump assembly 1 7 gasket 1 8 oil hose 1 1 9 oil hose 2 1 reverse the removal steps for installation. Not reusable.

  • Page 75: Fuel

    4-28 fuel e oil pump exploded diagram removal and installation chart step procedure/part name q’ty service points oil pump hoses and cable removal follow the left “step” for removal. 1 bleed hose 1 2 air bleed screw 1 3 gasket 1 4 bleed hose stay 1 5 oil delivery hose 1 3 6 oil delivery hose 2 3 7 c...

  • Page 76: Fuel

    4-29 fuel e oil pump service points oil pump inspection 1. Inspect: ● oil pump contaminants → clean. Damage/wear → replace. ● oil pump joint piece damage/wear → replace. Oil hose inspection 1. Inspect: ● oil hose cracks/damage → clean. Caution: ● if the oil delivery hoses are not full of oil, fill t...

  • Page 77: Fuel

    4-30 fuel e oil pump oil pump cable adjustment 1. Check: ● oil pump lever position incorrect → adjust. Checking steps: ● fully close the carburetor throttle valves. ● check that the mark a on the oil pump lever is aligned with the mark b on the oil pump body. 2. Adjust: ● oil pump cable adjustment s...

  • Page 78: Powr

    E powr chapter 5 power unit exhaust chamber assembly ................................................................ 5-1 exploded diagram ............................................................................. 5-1 removal and installation chart ............................................... ...

  • Page 79: Powr

    E 1 2 3 4 5 6 7 8 9 powr cylinders ................................................................................................... 5-25 exploded diagram ........................................................................... 5-25 removal and installation chart ..................................

  • Page 80: Powr

    5-1 powr e exhaust chamber assembly exhaust chamber assembly exploded diagram removal and installation chart step procedure/part name q’ty service points exhaust chamber assembly removal follow the left “step” for removal. 1 exhaust temperature sensor coupler 1 2 cap/bolt 3/3 3 cover 1 4 clamp/hose ...

  • Page 81: Powr

    5-2 powr e exhaust chamber assembly exploded diagram step procedure/part name q’ty service points 9 exhaust chamber stay 1 10 bolt 3 11 bolt 1 12 exhaust chamber assembly 1 13 clamp/hose 1/1 14 gasket 1 15 pin 2 16 outer exhaust joint 1 17 inner exhaust joint 1 reverse the removal steps for installa...

  • Page 82: Powr

    5-3 powr e exhaust chamber assembly exploded diagram removal and installation chart step procedure/part name q’ty service points exhaust chamber disassembly follow the left “step” for disassembly. 1 bolt 5 2 bolt 1 3 exhaust chamber joint 1 4 gasket 1 5 pin 2 6 exhaust chamber 1 reverse the disassem...

  • Page 83: Powr

    5-4 powr e muffler assembly muffler assembly exploded diagram removal and installation chart step procedure/part name q’ty service points muffler assembly removal follow the left “step” for removal. Exhaust chamber assembly refer to “exhaust chamber assembly”. Cylinder head refer to “cylinder head”....

  • Page 84: Powr

    5-5 powr e muffler assembly exploded diagram step procedure/part name q’ty service points 7 hose clamp 1 8 water lock band 1 slide the water lock toward back to disconnect the muffler assembly. 9 bolt 4 10 gear case grease hose 1 11 bolt 2 12 bolt 2 13 bolt 1 14 muffler stay 2 1 15 muffler assembly ...

  • Page 85: Powr

    5-6 powr e muffler assembly exploded diagram removal and installation chart step procedure/part name q’ty service points muffler disassembly follow the left “step” for disassembly. 1 exhaust temperature sensor 1 2 water temperature sensor 1 3 nut 2 4 hanger 2 5 bolt 2 6 muffler stay 1 7 bolt 6 8 cov...

  • Page 86: Powr

    5-7 powr e muffler assembly exploded diagram step procedure/part name q’ty service points 10 catalyst housing 1 11 gasket 1 12 catalyst 1 13 gasket 1 14 pin 2 15 bolt 6 16 mixing joint 1 17 gasket 1 18 muffler 1 reverse the disassembly steps for assembly. Not reusable not reusable not reusable.

  • Page 87: Powr

    5-8 powr e muffler assembly service point catalyst inspection 1. Inspect: ● catalyst cracks/damage → replace..

  • Page 88: Powr

    5-9 powr e exhaust manifold and leads exhaust manifold and leads exploded diagram removal and installation chart step procedure/part name q’ty service points exhaust manifold and leads removal follow the left “step” for removal. Battery lead (negative and positive) refer to “electrical box” in chapt...

  • Page 89: Powr

    5-10 powr e exhaust manifold and leads exploded diagram step procedure/part name q’ty service points 6 bolt 4 7 bolt 6 8 nut 2 9 exhaust manifold 1 10 gasket 1 11 pin 2 12 bolt 1 13 battery negative lead 1 14 nut/washer 1/1 15 starter motor lead 1 reverse the removal steps for installation. Not reus...

  • Page 90: Powr

    5-11 powr e exhaust manifold and leads exploded diagram removal and installation chart step procedure/part name q’ty service points exhaust manifold disassembly follow the left “step” for disassembly. 1 clamp/hose 1/1 2 bolt 6 3 joint pipe 1 4 o-ring 3 5 exhaust manifold 1 reverse the disassembly st...

  • Page 91: Powr

    5-12 powr e engine unit engine unit exploded diagram removal and installation chart step procedure/part name q’ty service points engine unit removal follow the left “step” for removal. Exhaust chamber assembly refer to “exhaust chamber assembly”. Muffler assembly refer to “muffler assembly”. Carbure...

  • Page 92: Powr

    5-13 powr e engine unit exploded diagram step procedure/part name q’ty service points 4 coupling cover 1 5 bolt/washer 4/4 6 engine assembly 1 7 shim * install the shims original position. Reverse the removal steps for installation. *: as required.

  • Page 93: Powr

    5-14 powr e engine unit service points shim removal 1. Remove: ● shims note: to ease reassembly and coupling align- ment, remove the shims and organize them in their respective groups (e.G., front right, rear left) prior to removing the mounting bolts. Engine mount inspection 1. Inspect: ● engine mo...

  • Page 94: Powr

    5-15 powr e reed valves reed valves exploded diagram removal and installation chart step procedure/part name q’ty service points reed valve removal follow the left “step” for removal. Exhaust chamber assembly refer to “exhaust chamber assembly”. Muffler assembly refer to “muffler assembly”. Carburet...

  • Page 95: Powr

    5-16 powr e reed valves exploded diagram step procedure/part name q’ty service points 3 reed valve assembly 3 4 screw 24 5 valve stopper 6 6 reed valve 6 reverse the removal steps for installation..

  • Page 96: Powr

    5-17 powr e reed valves service points reed valve inspection 1. Inspect: ● reed valves cracks/damage → replace. 2. Measure: ● valve bending a out of specification → replace. 3. Measure: ● valve stopper height b out of specification → adjust or replace. Max. Valve bending: 0.2 mm (0.01 in) valve stop...

  • Page 97: Powr

    5-18 powr e ypvs ypvs exploded diagram removal and installation chart step procedure/part name q’ty service points ypvs removal follow the left “step” for removal. Ypvs cable 1 and 2 refer to “exhaust manifold and leads”. Exhaust chamber assembly refer to “exhaust chamber assembly”. 1 bolt 12 2 ypvs...

  • Page 98: Powr

    5-19 powr e ypvs exploded diagram step procedure/part name q’ty service points 7 bolt (m4) 3 8 circlip 5 9 shaft 3 1 10 shaft 2 1 11 shaft 1 1 12 washer 5 13 ypvs valve lever 3 note: during installation, align the hole a in the ypvs shaft with the screw. Not reusable.

  • Page 99: Powr

    5-20 powr e ypvs exploded diagram step procedure/part name q’ty service points 14 bolt (m5) 3 15 ypvs valve assembly 3 16 oil seal 6 reverse the removal steps for installation. Note: if the ypvs shaft is removed, the oil seal must be replaced..

  • Page 100: Powr

    5-21 powr e service points ypvs valve inspection 1. Eliminate: ● carbon deposits (with a rounded scraper 1) caution: do not use a sharp instrument to avoid damaging or scratching the surfaces. 2. Inspect: ● ypvs valve assembly crack/damage/wear → replace. Ypvs.

  • Page 101: Powr

    5-22 powr e cylinder head cylinder head exploded diagram removal and installation chart step procedure/part name q’ty service points cylinder head removal follow the left “step” for removal. Exhaust chamber assembly refer to “exhaust chamber assembly”. 1 spark plug 3 2 bolt 2 3 bolt 2 4 bolt 6 5 bol...

  • Page 102: Powr

    5-23 powr e cylinder head exploded diagram step procedure/part name q’ty service points 6 cylinder head cover 1 7 gasket 1 8 cylinder head 1 9 gasket 1 reverse the removal steps for installation. Not reusable not reusable.

  • Page 103: Powr

    5-24 powr e cylinder head service points cylinder head inspection 1. Eliminate: ● carbon deposits (with a rounded scraper 1 ) caution: do not use a sharp instrument to avoid damaging or scratching the cylinder head or spark plug bore threads. 2. Inspect: ● cylinder head water jacket corrosion/minera...

  • Page 104: Powr

    5-25 powr e cylinders cylinders exploded diagram removal and installation chart step procedure/part name q’ty service points cylinder removal follow the left “step” for removal. Ypvs refer to “ypvs”. Cylinder head refer to “cylinder head”. 1 bolt 12 2 cylinder 3 3 cylinder gasket 3 4 pin 6 reverse t...

  • Page 105: Powr

    5-26 powr e cylinders service points cylinder inspection 1. Eliminate: ● carbon deposits (with a rounded scraper 1 ) 2. Inspect: ● cylinder water jacket corrosion/mineral deposits → clean or replace. ● cylinder inner surface score marks → replace. 3. Measure: ● cylinder bore “d” (with a cylinder gau...

  • Page 106: Powr

    5-27 powr e pistons pistons exploded diagram removal and installation chart step procedure/part name q’ty service points piston removal follow the left “step” for removal. Cylinders refer to “cylinders”. 1 piston pin clip 6 2 piston pin 3 3 piston 3 4 washer 6 caution: do not align the open end of t...

  • Page 107: Powr

    5-28 powr e pistons exploded diagram step procedure/part name q’ty service points 5 bearing 3 6 piston ring 6 reverse the removal steps for installation. Caution: align each end gap with its respective locating pin..

  • Page 108: Powr

    5-29 powr e pistons service points piston pin clip removal and installation 1. Remove and install: ● piston pin clip note: before removing or installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. Piston inspection...

  • Page 109: Powr

    5-30 powr e pistons 4. Calculate: ● piston-to-cylinder clearance out of specification → replace the piston, piston rings and cylinder as a set. Cylinder and piston combination select the appropriate piston to match the cylinder size by the table as follows. Note: new cylinder bore size = 80.000 + a ...

  • Page 110: Powr

    5-31 powr e pistons 2. Measure: ● end gap (with a thickness gauge 1) out of specification → replace the piston rings as a set. Note: push the piston ring into the cylinder with the piston crown. End gap: 0.45 ~ 0.60 mm (0.018 ~ 0.024 in) piston pin and bearing inspection 1. Inspect: ● piston pins ● ...

  • Page 111: Powr

    5-32 powr e pistons 4. Check: ● piston-pin-to-connecting-rod free play (with the piston pin in the small end of the connecting rod as shown) free play/small end wear → replace the piston pin, connecting rod or both..

  • Page 112: Powr

    5-33 powr e generator and starter motor generator and starter motor exploded diagram removal and installation chart step procedure/part name q’ty service points generator cover removal follow the left “step” for removal. Engine unit refer to “engine unit”. Oil pump refer to “oil pump” in chapter 4. ...

  • Page 113: Powr

    5-34 powr e generator and starter motor exploded diagram step procedure/part name q’ty service points 7 spring 1 8 packing 1 9 pin 2 10 bolt 2 11 bolt 2 12 bracket 1 reverse the removal steps for installation..

  • Page 114: Powr

    5-35 powr e exploded diagram removal and installation chart step procedure/part name q’ty service points stator coil and pickup coil removal follow the left “step” for removal. 1 bolt 3 2 washer 1 3 cable holder 1 4 bolt 2 5 pickup coil 1 6 bolt 3 7 stator coil 1 reverse the removal steps for instal...

  • Page 115: Powr

    5-36 powr e generator and starter motor exploded diagram removal and installation chart step procedure/part name q’ty service points generator rotor and starter motor removal follow the left “step” for removal. 1 drive coupling 1 2 flywheel magneto bolt 1 3 flywheel magneto 1 4 woodruff key 1 5 star...

  • Page 116: Powr

    5-37 powr e generator and starter motor exploded diagram removal and installation chart step procedure/part name q’ty service points starter clutch disassembly follow the left “step” for disassembly. 1 clip 1 2 clip stopper 1 3 spring seat 1 4 spring 1 5 idle gear 1 6 circlip 1 7 plate 1 not reusabl...

  • Page 117: Powr

    5-38 powr e generator and starter motor exploded diagram step procedure/part name q’ty service points 8 weight 3 9 spring 1 10 pinion gear 1 reverse the disassembly steps for assembly..

  • Page 118: Powr

    5-39 powr e service points drive coupling removal and installation 1. Remove: ● drive coupling note: install the drive coupling with the same special tools that were used for removal. Coupler wrench: yw-06551/90890-06551 flywheel holder: yw-06550/90890-06550 flywheel magneto removal and installation...

  • Page 119: Powr

    5-40 powr e generator and starter motor drive coupling inspection 1. Inspect: ● drive coupling damage/wear → replace. Flywheel magneto inspection 1. Inspect: ● ring gear damage/wear → replace. Starter clutch assembly inspection 1. Inspect: ● pinion gear 1 ● idle gear 2 damage/wear → replace. 2. Chec...

  • Page 120: Powr

    5-41 powr e crankcase crankcase exploded diagram removal and installation chart step procedure/part name q’ty service points crankcase disassembly follow the left “step” for disassembly. Pistons refer to “pistons”. Generator cover and starter motor refer to “generator and starter motor”. 1 bolt 6 2 ...

  • Page 121: Powr

    5-42 powr e crankcase exploded diagram step procedure/part name q’ty service points 7 bolt 1 8 bolt 12 9 bolt 4 10 lower crankcase 1 11 pin 2 12 crankshaft assembly 1 13 upper crankcase 1 reverse the disassembly steps for assembly. Note: tighten the bolts in sequence as shown..

  • Page 122: Powr

    5-43 powr e crankcase service points crankcase inspection 1. Inspect: ● mating surfaces scratches → replace the crankcase. ● crankcase cracks/damage → replace. Crankcase installation 1. Apply: ● gasket maker (onto the crankcase mating surfaces) note: before applying gasket maker , clean the crankcas...

  • Page 123: Powr

    5-44 powr e crankshaft crankshaft exploded diagram removal and installation chart step procedure/part name q’ty service points crankshaft removal follow the left “step” for removal. Crankcase refer to “crankcase”. 1 oil seal 1 2 bearing 1 3 oil seal 2 4 crankshaft assembly 1 reverse the removal step...

  • Page 124: Powr

    5-45 powr e crankshaft service points crankshaft inspection 1. Measure: ● crank width a out of specification → replace. Crank width: 72.95 ~ 73.00 mm (2.872 ~ 2.835 in) 2. Measure: ● deflection b (with a dial gauge) out of specification → replace. Max. Deflection: b 0.05 mm (0.002 in) c 0.15 mm (0.0...

  • Page 125: Powr

    5-46 powr e crankshaft 5. Inspect: ● bearings damage/pitting → replace. Note: ● before inspection, thoroughly clean the bearings. ● immediately after inspection, lubricate the bearings to prevent rust. 6. Inspect: ● oil seals damage/wear → replace..

  • Page 126: Jet

    E jet pump chapter 6 jet pump unit jet pump unit ............................................................................................. 6-1 exploded diagram ............................................................................. 6-1 removal and installation chart ..........................

  • Page 127: Jet

    E 1 2 3 4 5 6 7 8 9 jet pump bearing housing ..................................................................................... 6-15 exploded diagram ........................................................................... 6-15 removal and installation chart ......................................

  • Page 128: Jet

    6-1 e jet pump jet pump unit jet pump unit exploded diagram removal and installation chart step procedure/part name q’ty service points jet pump unit removal follow the left “step” for removal. 1 bolt 2 2 bolt 2 3 intake screen 1 4 bolt 4 5 intake duct 1 6 screw 4 7 speed sensor 1 8 bolt 4 9 jet pum...

  • Page 129: Jet

    6-2 e jet pump jet pump unit exploded diagram step procedure/part name q’ty service points 12 clamp/bilge hose 1/1 13 nut/washer 1/2 14 steering cable joint 1 15 clamp/spout hose 1/1 16 bolt 1 17 bolt 4 18 jet pump unit assembly 1 19 dowel pin 2 reverse the removal steps for installation. Note: ● pu...

  • Page 130: Jet

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

  • Page 131: Jet

    6-4 e jet pump reverse gate exploded diagram step procedure/part name q’ty service points 9 roller 1 10 bolt 6 11 reverse gate stay 2 12 nut 1 13 washer 1 14 bolt 1 15 lever 1 16 spacer 1 17 nut 1.

  • Page 132: Jet

    6-5 e jet pump reverse gate exploded diagram step procedure/part name q’ty service points 18 washer 1 19 collar 1 20 spring 1 21 lever 1 22 bolt 1 23 washer 2 reverse the removal steps for installation..

  • Page 133: Jet

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

  • Page 134: Jet

    6-7 e jet pump impeller duct, impeller housing, and intake duct impeller duct, impeller housing, and intake duct exploded diagram removal and installation chart step procedure/part name q’ty service points impeller duct and impeller housing removal follow the left “step” for removal. Nozzle ring ref...

  • Page 135: Jet

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

  • Page 136: Jet

    6-9 e jet pump impeller duct and drive shaft impeller duct and drive shaft exploded diagram removal and installation chart *1 : epnoc grease ap #0 step procedure/part name q’ty service points impeller duct and drive shaft disassembly follow the left “step” for disassembly. 1 impeller 1 left-hand thr...

  • Page 137: Jet

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

  • Page 138: Jet

    6-11 e jet pump impeller duct and drive shaft service points drive shaft removal 1. Remove: ● impeller note: the impeller has left-hand threads. Turn the impeller clockwise to loosen it. 2. Remove: ● nut 1 drive shaft holder: yb-06151/90890-06519 drive shaft holder: yb-06151/90890-06519 3. Remove: ●...

  • Page 139: Jet

    6-12 e jet pump impeller duct and drive shaft drive shaft installation 1. Install: ● oil seal driver rod: yb-06071/90890-06606 ball bearing attachment: yb-06156/90890-06634 2. Install: ● front bearing ● drive shaft note: install the front bearing and drive shaft with a press. 3. Add: ● epnoc grease ...

  • Page 140: Jet

    6-13 e jet pump transom plate and hoses transom plate and hoses exploded diagram removal and installation chart step procedure/part name q’ty service points transom plate and hoses removal follow the left “step” for removal. 1 hose clamp 3 2 hose 1 cooling water outlet 3 bilge hose 1 1 4 hose 1 cool...

  • Page 141: Jet

    6-14 e jet pump transom plate and hoses service points bilge strainer inspection refer to “jet pump unit” in chapter 3. Bilge hose inspection 1. Inspect: ● bilge hose cracks/damage/wear → replace..

  • Page 142: Jet

    6-15 e jet pump bearing housing bearing housing exploded diagram removal and installation chart step procedure/part name q’ty service points bearing housing removal follow the left “step” for removal. Engine unit refer to “engine unit” in chapter 5. 1 rubber coupling 1 2 bolt/washer 3/3 3 bearing ho...

  • Page 143: Jet

    6-16 e jet pump bearing housing exploded diagram removal and installation chart step procedure/part name q’ty service points bearing housing disassembly follow the left “step” for disassembly. 1 grease hose 1 2 grease nipple 1 3 grease nipple stay 1 4 nipple 2 5 driven coupling 1 6 washer 1 7 driven...

  • Page 144: Jet

    6-17 e jet pump bearing housing exploded diagram step procedure/part name q’ty service points 8 o-ring 2 9 oil seal 2 10 oil seal 1 11 circlip 1 12 bearing 1 13 circlip 1 reverse the disassembly steps for assembly..

  • Page 145: Jet

    6-18 e jet pump bearing housing service points driven coupling removal and installation 1. Remove and install: ● driven coupling note: install the driven coupling with the same special tools that were used for removal. Driven coupling shaft removal 1. Remove: ● driven coupling shaft coupler wrench: ...

  • Page 146: Jet

    6-19 e jet pump bearing housing bearing, driven coupling shaft, and grease hose inspection 1. Inspect: ● bearing rotate the inner race by hand. Damage/rough movement → replace. ● driven coupling shaft damage/pitting → replace. ● grease hose cracks/wear → replace. Driven coupling inspection 1. Inspec...

  • Page 147: Jet

    6-20 e jet pump bearing housing 2. Install: ● driven coupling shaft distance a: 9.5 ~ 10.5 mm (0.37 ~ 0.41 in) 3. Install: ● oil seal 1 [8 mm (0.31 in)] ● oil seal 2 [10 mm (0.39 in)] distance a: 10.3 ~ 10.7 mm (0.41 ~ 0.42 in) distance b: 1.6 ~ 2.0 mm (0.06 ~ 0.07 in) bearing housing installation 1...

  • Page 148: Elec

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

  • Page 149: Elec

    E 1 2 3 4 5 6 7 8 9 – + elec charging system .................................................................................... 7-26 wiring diagram................................................................................. 7-26 fuse ..............................................................

  • Page 150: Elec

    7-1 e – + elec electrical components electrical components 1 ypvs servomotor 2 multi-function meter 3 fuel level sensor 4 buzzer 5 oil level sensor 6 stator coil and pickup coil 7 spark plugs 8 exhaust temperature sensor 9 battery 0 speed sensor a electrical box b water temperature sensor c starter ...

  • Page 151: Elec

    7-2 e – + elec electrical box electrical box exploded diagram removal and installation chart step procedure/part name q’ty service points electrical box removal follow the left “step” for removal. Exhaust chamber assembly refer to “exhaust chamber assembly” in chapter 5. Exhaust manifold refer to “e...

  • Page 152: Elec

    7-3 e – + elec electrical box exploded diagram step procedure/part name q’ty service points 6 damper 1 7 bolt 4 8 battery box 1 9 coupler 4 for multi-function meter 10 bolt 4 11 electrical box 1 reverse the removal steps for installation..

  • Page 153: Elec

    7-4 e – + elec electrical box exploded diagram removal and installation chart step procedure/part name q’ty service points electrical box disassembly follow the left “step” for disassembly. 1 clamp 5 2 coupler 3 for overheat, exhaust temperature sensor and lighting coil 3 screw 2 4 rectifier/regulat...

  • Page 154: Elec

    7-5 e – + elec electrical box exploded diagram step procedure/part name q’ty service points 11 ground lead 3 12 ignition coil 3 13 ignition coil lead 3 14 bolt 3 15 ground lead 6 16 lead 3 black/orange 17 nut 2 18 starter motor lead 1 19 battery positive lead 1 20 fuse lead 1 21 starter relay lead 1...

  • Page 155: Elec

    7-6 e – + elec electrical box exploded diagram step procedure/part name q’ty service points 23 lead holder 1 24 fuse lead 5 25 screw 2 26 fuse holder 1 27 lead/coupler 1/6 28 screw 2 29 coupler bracket 1 30 cdi unit 1 31 screw 8 32 lead holder plate 2 reverse the disassembly steps for assembly..

  • Page 156: Elec

    7-7 e – + elec electrical box 1 ignition coil 2 cdi unit 3 rectifier/regulator 4 fuse holder 5 starter relay 6 tape 7 clear tube 8 red tube 9 white tape Å to battery positive terminal ı to starter motor Ç affix the ignition coil connector to the electrical box holder. Î pass the 8 pin coupler leads ...

  • Page 157: Elec

    7-8 e – + elec electrical analysis electrical analysis inspection caution: ● all measuring instruments should be han- dled with special care. Damaged or mis- handled instruments will not measure properly. ● on an instrument powered by dry batter- ies, check the battery’s voltage periodi- cally and r...

  • Page 158: Elec

    7-9 e – + elec electrical analysis low resistance measurement note: ● when measuring a resistance of 10 Ω or less with the digital tester, the correct measurement cannot be obtained because of the tester’s internal resistance. ● to obtain the correct value, subtract the internal resistance from the ...

  • Page 159: Elec

    7-10 e – + elec electrical analysis ● when measuring the peak voltage, con- nect the peak voltage adaptor to the digi- tal tester and switch the selector to the dc voltage mode. Note: ● make sure that the adaptor leads are properly installed in the digital circuit tester. ● make sure that the positi...

  • Page 160: Elec

    7-11 e – + elec ignition system ignition system wiring diagram 1 engine stop switch 2 engine stop lanyard switch 3 lighting coil 4 pickup coil 5 cdi unit 6 ignition coil 7 spark plug 8 battery 9 rectifier/regulator 0 exhaust temperature sensor a water temperature sensor b : black o : orange r : red ...

  • Page 161: Elec

    7-12 e – + elec ignition system ignition spark gap warning ● when checking the spark gap, do not touch any of the connections of the spark gap tester lead wires. ● when performing the spark gap test, take special care not to let sparks leak out of the removed spark plug cap. ● when performing the sp...

  • Page 162: Elec

    7-13 e – + elec ignition system ignition system peak voltage warning when checking the cdi unit do not touch any of the connections of the digital tester lead wires. Note: ● if there is no spark, or the spark is weak, continue with the ignition system test. ● if a good spark is obtained, the problem...

  • Page 163: Elec

    7-14 e – + elec ignition system 2. Measure: ● pick-up coil output peak voltage below specification → replace the pick-up coil. Note: the starter motor will not operate when the test harness on the output side coupler is disconnected to measure the unloaded peak voltage for the pickup coil(s) and lig...

  • Page 164: Elec

    7-15 e – + elec ignition system battery refer to “electrical” in chapter 3. Fuse refer to “starting system”. Spark plugs refer to “electrical” in chapter 3. Spark plug lead assembly 1. Inspect: ● spark plug lead assembly cracks/damage → replace. 2. Measure: ● spark plug lead resistance out of specif...

  • Page 165: Elec

    7-16 e – + elec 2. Measure: ● secondary coil resistance out of specification → replace. Secondary coil resistance: black/white (b/w) – spark plug lead terminal 3.5 ~ 4.7 k Ω at 20 ˚c (68 ˚f) engine stop switch 1. Check: ● engine stop switch continuity out of specification → replace. Engine stop swit...

  • Page 166: Elec

    7-17 e – + elec exhaust temperature sensor 1. Measure: ● exhaust temperature sensor resis- tance (at the specified temperature) out of specification → replace. Exhaust temperature sensor resistance: 300 ˚c (572 ˚f): 73 ~ 241 k Ω 600 ˚c (1,112 ˚f): 0.86 ~ 1.58 k Ω 900 ˚c (1,652 ˚f): 64 ~ 90 Ω measure...

  • Page 167: Elec

    7-18 e – + elec starting system starting system wiring diagram 1 cdi unit 2 engine stop lanyard switch 3 starter switch 4 multi-function meter 5 fuse 6 starter relay 7 starter motor 8 battery b : black br : brown r : red r/y : red/yellow.

  • Page 168: Elec

    7-19 e – + elec starting system battery refer to “electrical” in chapter 3. Wiring connections 1. Check: ● wiring connections poor connections → properly connect. Fuse 1. Check: ● fuse holder continuity no continuity → check the fuse or replace the fuse holder. Fuse holder continuity: between 1 and ...

  • Page 169: Elec

    7-20 e – + elec starting system starter switch 1. Check: ● continuity out of specification → replace. Starter continuity (red coupler) lock plate position leads red brown installed free push removed free push starter relay 1. Inspect: ● brown lead terminal ● black lead terminal loose → tighten. 2. C...

  • Page 170: Elec

    7-21 e – + elec starter motor starter motor exploded diagram removal and installation chart step procedure/part name q’ty service points starter motor disassembly follow the left “step” for disassembly. Starter motor refer to “generator and starter motor” in chapter 5. 1 o-ring 1 2 bolt 2 3 starter ...

  • Page 171: Elec

    7-22 e – + elec starter motor exploded diagram step procedure/part name q’ty service points 8 starter motor rear cover 1 9 o-ring 1 10 shim * t = 0.2 mm, 0.8 mm 11 armature assembly 1 12 nut/spring washer/washer 1/1/4 13 o-ring 1 14 brush holder 1 15 brush spring 4 16 bolt 1 17 brush assembly 1 *: a...

  • Page 172: Elec

    7-23 e – + elec starter motor exploded diagram step procedure/part name q’ty service points 18 spacer 1 19 holder 1 20 starter motor yoke 1 reverse the disassembly steps for assembly..

  • Page 173: Elec

    7-24 e – + elec starter motor service points armature inspection 1. Inspect: ● armature shaft 1 damage/wear → replace. 2. Inspect: ● commutator dirt → clean with 600 grit sandpaper. 3. Measure: ● commutator diameter out of specification → replace. Min. Commutator diameter: 27.0 mm (1.06 in) 4. Check...

  • Page 174: Elec

    7-25 e – + elec starter motor 6. Inspect: ● armature coil continuity out of specification → replace. Armature coil continuity: commutator segments 1 continuity segment - laminations 2 no continuity segment - armature shaft no continuity brush holder inspection 1. Measure: ● brush length a out of spe...

  • Page 175: Elec

    7-26 e – + elec charging system charging system wiring diagram 1 lighting coil 2 battery 3 fuse (20a) 4 rectifier/regulator b : black g : green r : red g/w : green/white.

  • Page 176: Elec

    7-27 e – + elec charging system fuse refer to “starting system”. Battery refer to “electrical” in chapter 3. Lighting coil refer to “ignition system”. Rectifier/regulator refer to “ignition system”..

  • Page 177: Elec

    7-28 e – + elec ypvs ypvs wiring diagram 1 lighting coil 2 pickup coil 3 cdi unit 4 ypvs servomotor 5 fuse 6 battery 7 rectifier/regulator b : black gy : gray r : red b/o : black/orange r/l : red/blue r/w : red/white w/r : white/red.

  • Page 178: Elec

    7-29 e – + elec ypvs fuse refer to “starting system”. Battery refer to “electrical” in chapter 3. Pickup coil refer to “ignition system”. Cdi unit refer to “ignition system”. Lighting coil refer to “ignition system”. Rectifier/regulator refer to “ignition system”..

  • Page 179: Elec

    7-30 e – + elec ypvs servomotor ypvs servomotor exploded diagram removal and installation chart step procedure/part name q’ty service points ypvs servomotor removal follow the left “step” for removal. 1 bolt 2 2 cable holder 1 3 ypvs servomotor coupler 1 4 bolt 2 5 ypvs servomotor 1 6 spacer 2 7 ypv...

  • Page 180: Elec

    7-31 e – + elec ypvs servomotor service points ypvs cable removal and installation 1. Remove: ● ypvs cables 1 and 2 note: there is a white paint mark a on ypvs cable 2. Removal steps: ● remove the ypvs cable holder 1. ● remove the ypvs cables 2 from the both drams. Ypvs cable inspection 1. Inspect: ...

  • Page 181: Elec

    7-32 e – + elec ypvs servomotor caution: do not disassemble the ypvs servomotor unit. It is a sealed unit and if it is faulty it must be replaced. Ypvs cable adjustment refer to “control system” in chapter 3. ● make sure the servomotor operates properly. Note: make sure the pulley operates three sec...

  • Page 182: Elec

    7-33 e – + elec indication system indication system wiring diagram 1 cdi unit 2 fuel level sensor 3 oil level sensor 4 buzzer 5 multi-function meter 6 speed sensor 7 engine stop lanyard switch 8 starter switch 9 battery 0 fuse a exhaust temperature sensor b water temperature sensor b : black br : br...

  • Page 183: Elec

    7-34 e – + elec indication system fuse refer to “starting system”. Battery refer to “electrical” in chapter 3. Lighting coil refer to “charging system”. Rectifier/regulator refer to “charging system”. Cdi unit refer to “ignition system”. Water temperature sensor refer to “ignition system”. Exhaust t...

  • Page 184: Elec

    7-35 e – + elec indication system fuel level sensor 1. Measure: ● fuel level sensor resistance out of specification → replace. White/blue (w/l) – black (b) float position resistance ( Ω ) a 757 ~ 803 b 0 ~ 8 multi-function meter multi-function meter 1. Check: ● multi-function meter cracked meter hou...

  • Page 185: Elec

    7-36 e – + elec indication system exploded diagram removal and installation chart step procedure/part name q’ty service points multi-function meter removal follow the left “step” for removal. 1 multi-function meter coupler 8 2 nut/washer 2/2 3 holder 1 4 multi-function meter 1 reverse the removal st...

  • Page 186: Elec

    7-37 e – + elec indication system display function 1. Check: ● display function not operate → replace the multi- function meter. 1 oil level sensor 2 fuel level sensor 3 buzzer 4 electrical box 5 start switch 6 battery 7 speed sensor *: disconnected b : black br : brown ch : chocolate g : green gy :...

  • Page 187: Elec

    7-38 e – + elec indication system checking steps: ● connect the battery terminals to the white six-pin connector as shown. ● disconnect the blue one-pin connector 1 and make sure the “warning” lamp 2 lights. ● press the “a/set” 3 and “c” 5 but- tons at the same time. While still pressing the two but...

  • Page 188: Elec

    7-39 e – + elec indication system fuel level gauge 1. Check: ● fuel level gauge not operating → replace the multi- function meter. Checking steps: ● supply dc 12 voltage to the white six- pin connector (+: red, –: black) with a battery. ● disconnect the green two-pin connec- tor (white/blue and blac...

  • Page 189: Elec

    7-40 e – + elec indication system oil level gauge 1. Check: ● oil level gauge not operating → replace the multi- function meter. Checking steps: ● supply dc 12 voltage to the white six- pin connector (+: red, –: black) with a battery. ● disconnect the white two-pin connec- tor (blue and black leads)...

  • Page 190: Elec

    7-41 e – + elec indication system overheat warning indicator 1. Check: ● overheat 1 warning indicator not operating → replace the multi- function meter. Checking steps: ● supply dc 12 voltage to the white six- pin connector (+: red, –: black) with a battery. ● connect the gray/black and black ter- m...

  • Page 191: Elec

    7-42 e – + elec indication system ● make sure the water temperature warning indicator display 3 and the “ ” message 4 display, the “warning” lamp 5 operates prop- erly, and the buzzer sounds continuity. 3. Check: ● exhaust temperature warning indicator not operating → replace the multi- function met...

  • Page 192: Elec

    7-43 e – + elec indication system speed meter 1. Check: ● speed meter output voltage within specification → check the speed sensor output voltage and pulses. Out of specification → replace. Speed meter output voltage: 10.5 v checking steps: ● supply dc 12 voltage to the white six- pin connector (+: ...

  • Page 193: Elec

    7-44 e – + elec indication system speed sensor 1. Check: ● speed sensor output voltage and pulses out of specification → replace. Speed sensor output voltage (dependant on the paddle wheel position): less than 400 mv/11.6 - 12 v output pulse: 2 pulses/one-full turn checking steps: ● apply dc 12 volt...

  • Page 194: Hull

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

  • Page 195: Hull

    E 1 2 3 4 5 6 7 8 9 hull hood hoses ........................................................................................................... 8-24 exploded diagram ........................................................................... 8-24 removal and installation chart .........................

  • Page 196: Hull

    8-1 e hull hood handlebar handlebar exploded diagram removal and installation chart step procedure/part name q’ty service points handlebar cover removal follow the left “step” for removal. 1 screw 4 2 handlebar cover 1 3 band 2 4 pad 1 5 bolt 2 6 handlebar cover stay 1 7 throttle cable 1 8 bolt 4 9 ...

  • Page 197: Hull

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

  • Page 198: Hull

    8-3 e hull hood handlebar exploded diagram step procedure/part name q’ty service points 6 buzzer coupler 1 7 screw 4 8 handle boss cover 1 9 band 2 10 handlebar assembly 1 11 buzzer 1 reverse the removal steps for installation..

  • Page 199: Hull

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

  • Page 200: Hull

    8-5 e hull hood handlebar exploded diagram step procedure/part name q’ty service points 7 handlebar switch assembly 1 8 screw 2 9 throttle lever assembly 1 10 handlebar grip 1 11 handlebar 1 reverse the disassembly steps for assembly. Note: apply adhesive to the handlebar and the inner surface of th...

  • Page 201: Hull

    8-6 e hull hood handlebar service points handlebar inspection 1. Inspect: ● handlebar bends/cracks/damage → replace. Handlebar switch inspection refer to “starting system” in chapter 7. Handlebar assembly installation 1. Install: ● qsts cables ● buzzer lead ● handlebar switch lead ● throttle cable n...

  • Page 202: Hull

    8-7 e hull hood handlebar 3. Adjust: ● qsts cable length a note: ● before adjusting the qsts cables, set the trim grip to the neutral position. ● adjust the qsts cable lengths a to the specified length and be sure to take up any slack. Qsts cable length: 77 ± 0.5 mm (3.03 ± 0.02 in) 4. Adjust: ● thr...

  • Page 203: Hull

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

  • Page 204: Hull

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

  • Page 205: Hull

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

  • Page 206: Hull

    8-11 e hull hood steering master steering master exploded diagram removal and installation chart step procedure/part name q’ty service points steering master removal follow the left “step” for removal. Handlebar assembly refer to “handlebar”. Steering master cover refer to “steering master cover”. 1...

  • Page 207: Hull

    8-12 e hull hood steering master exploded diagram removal and installation chart step procedure/part name q’ty service points steering master disassembly follow the left “step” for disassembly. 1 bolt/washer 2/2 2 stay 1 3 spring 1 4 bolt/washer 6/6 5 lower housing 1 6 spring 1 7 bushing 1 8 bushing...

  • Page 208: Hull

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

  • Page 209: Hull

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

  • Page 210: Hull

    8-15 e hull hood remote control cables and speed sensor lead remote control cables and speed sensor lead exploded diagram removal and installation chart step procedure/part name q’ty service points remote control cables and speed sensor lead removal follow the left “step” for removal. 1 speed sensor...

  • Page 211: Hull

    8-16 e hull hood remote control cables and speed sensor lead exploded diagram step procedure/part name q’ty service points 8 nut 2 9 steering cable holder 1 10 cap 1 11 nut 1 12 steering cable 1 13 shift cable end 1 14 bolt 2 15 shift cable holder 1 16 cap 1.

  • Page 212: Hull

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

  • Page 213: Hull

    8-18 e hull hood remote control cables and speed sensor lead service points remote control cables inspection 1. Inspect: ● steering cable ● qsts cable ● shift cable frays/kinks/rough movement → replace. Steering cable (jet pump side) installation 1. Install: ● steering cable a warning the steering c...

  • Page 214: Hull

    8-19 e hull hood remote control cables and speed sensor lead qsts cable (jet pump side) installation 1. Install: ● qsts cable (jet pump side) a warning the qsts cable must be screwed in more than 8 mm (0.31 in). Qsts cable set length (jet pump side): 12.0 ~ 14.0 mm (0.47 ~ 0.55 in) qsts cable stoppe...

  • Page 215: Hull

    8-20 e hull hood remote control cables and speed sensor lead shift cable stopper installation 1. Install: ● shift cable stopper warning be sure to fit the projection 1 on the shift cable stopper into the groove in the outer cable. Remote control cables adjustment refer to “control system” in chapter...

  • Page 216: Hull

    8-21 e hull hood front hood front hood exploded diagram removal and installation chart step procedure/part name q’ty service points front hood removal follow the left “step” for removal. 1 nut/washer 4/4 2 front hood assembly 1 3 circlip 4 4 pin 2 5 damper 2 6 bolt 2 7 hood lock assembly 1.

  • Page 217: Hull

    8-22 e hull hood exploded diagram step procedure/part name q’ty service points 8 nut 1 9 notch 1 10 washer 2 11 damper 1 12 bolt 4 13 plate 2 14 mirror 2 15 packing 2 reverse the removal steps for installation. Front hood.

  • Page 218: Hull

    8-23 e hull hood steering master cover steering master cover exploded diagram removal and installation chart step procedure/part name q’ty service points steering master cover removal follow the left “step” for removal. Handlebar assembly refer to “handlebar”. Fuel cock refer to “fuel cock and fuel ...

  • Page 219: Hull

    8-24 e hull hood hoses hoses exploded diagram removal and installation chart step procedure/part name q’ty service points hoses removal follow the left “step” for removal. Steering master cover refer to “steering master cover”. 1 band 2 2 ventilation hose 2 3 screw 4 4 ventilation duct 1 5 band 1 6 ...

  • Page 220: Hull

    8-25 e hull hood hoses exploded diagram step procedure/part name q’ty service points 7 oil tank breather hose 1 8 fuel tank breather hose 2 9 clamp/pilot water hose 2/2 10 nut/washer 2/2 11 pilot water outlet 2 12 packing 2 reverse the removal steps for installation..

  • Page 221: Hull

    8-26 e hull hood hoses service points check valve inspection 1. Check: ● check valve faulty → replace. Checking steps: ● connect a hose to the end of check valve “a” and blow into it. Air should come out from end “b”. ● connect the hose to the end of check valve “b” and blow into it. Air should not ...

  • Page 222: Hull

    8-27 e hull hood shift lever shift lever exploded diagram removal and installation chart step procedure/part name q’ty service points shift lever removal follow the left “step” for removal. Steering master cover refer to “steering master cover”. Shift cable refer to “remote control cables and speed ...

  • Page 223: Hull

    8-28 e hull hood shift lever shift lever exploded diagram removal and installation chart step procedure/part name q’ty service points 4 screw 3 5 base assembly 1 6 nut/washer 3/3 7 screw 3 8 plate 1 reverse the removal steps for installation..

  • Page 224: Hull

    8-29 e hull hood shift lever exploded diagram removal and installation chart step procedure/part name q’ty service points base disassembly follow the left “step” for disassembly. 1 bolt/washer 2/2 2 plate 1 3 spring 1 4 actuator 1 5 roller 1 6 shaft 1 7 shift arm 1 reverse the disassembly steps for ...

  • Page 225: Hull

    8-30 e hull hood shift lever service points base assembly 1. Install: ● shift arm ● shaft installation steps: ● install the shift arm 1 so that it comes in contact with the stopper 2 as shown. ● install the shaft 3 to the base so that it come in contact with the stopper 4 as shown..

  • Page 226: Hull

    8-31 e hull hood seats and hand grip seats and hand grip exploded diagram removal and installation chart step procedure/part name q’ty service points seats and hand grip removal follow the left “step” for removal. 1 rear seat assembly 1 2 front seat assembly 1 3 bolt 4 4 seat lock assembly 2 5 nut/w...

  • Page 227: Hull

    8-32 e hull hood seats and hand grip exploded diagram step procedure/part name q’ty service points 8 rear seat stay 1 9 nut/washer 4/4 10 front seat stay 2 11 nut/washer 4/4 12 bolt 4 13 hand grip 1 reverse the removal steps for installation..

  • Page 228: Hull

    8-33 e hull hood seats and hand grip service points seat lock inspection 1. Inspect: ● front seat lock ● rear seat lock damage/wear → replace..

  • Page 229: Hull

    8-34 e hull hood exhaust system exhaust system exploded diagram removal and installation chart step procedure/part name q’ty service points exhaust system removal follow the left “step” for removal. 1 hose clamp 2 2 band 1 3 rubber joint 1 slide the water lock to back 4 hose clamp 2 5 rubber hose 1 ...

  • Page 230: Hull

    8-35 e hull hood exhaust system exploded diagram step procedure/part name q’ty service points 9 hose clamp 1 10 rubber hose 1 align hose parting line with tank mark 11 hose clamp 1 12 water tank 1 13 hose clamp 1 14 rubber hose 1 align hose parting line with tank parting line 15 bolt 3 16 exhaust ou...

  • Page 231: Hull

    8-36 e hull hood exhaust system service points exhaust system inspection 1. Inspect: ● water lock band cracks → replace. 2. Inspect: ● rubber hoses burns/cracks/damage → replace. 3. Inspect: ● water lock cracks/leaks → replace. Water → drain. 4. Inspect: ● resonator ● water tank cracks/damage → repl...

  • Page 232: Hull

    8-37 e hull hood deck and hull deck and hull exploded diagram removal and installation chart step procedure/part name q’ty service points deck and hull disassembly follow the left “step” for disassembly. 1 nut 1 2 rope hole bolt 1 3 nut/washer 2/2 4 bow eye 1 5 nut 1 6 rope hole bolt 1 7 nut 1 8 spo...

  • Page 233: Hull

    8-38 e hull hood deck and hull exploded diagram step procedure/part name q’ty service points 10 plate 1 11 cleat 1 12 nut 8 13 sponson 2 14 spacer 8 15 nut/washer 4/4 16 screw/washer 4/4 17 drain plug 2 18 packing 2 reverse the disassembly steps for assembly..

  • Page 234: Hull

    8-39 e hull hood engine mount engine mount exploded diagram removal and installation chart step procedure/part name q’ty service points engine mount removal follow the left “step” for removal. Engine assembly refer to “engine unit” in chapter 5. 1 bolt 6 2 damper 1 1 3 damper 2 1 4 bolt 8 5 engine m...

  • Page 235: Hull

    8-40 e hull hood engine mount hull repair shallow scratches 1. Sand the scratches with 400 grit sand- paper (either wet or dry) until the scratches are smooth. Then, sand the scratches once again with 600 grit sand- paper (either wet or dry). Deep scratches 1. Remove any sharp or rough edges from th...

  • Page 236: Hull

    8-41 e hull hood engine mount cracks and punctures note: before attempting to repair any cracks or punctures, refer to “water vehicle frp repair manual”. 1. Remove any damaged fiberglass. 2. Cut the damaged area and separate it approximately 0.25 inch. 3. On the outside of the hull, grind the separa...

  • Page 237: Hull

    8-42 e hull hood engine mount insert nut note: use the insert nut when: ● a pop nut which was attached to the hull slipped off or, ● when a bolt which was fastened to an insert nut or pop nut broke. ● nut 1 ● thread direction 2 ● slot to be threaded 3 note: drilling size part no. Part name remarks e...

  • Page 238: Hull

    8-43 e hull hood engine mount 4. First, apply tape 1 to the inner surface of the hull and then laminate fiberglass mats over the tape with resin. Note: when it is possible to work inside the hull, laminate the mats from the inside. 5. Sand the outer surface of the hull until it is smooth. 6. Install...

  • Page 239: Hull

    8-44 e hull hood engine mount 2. To prevent water from entering the ure- thane foam, apply silicone sealant to the inside of the hole as shown. 3. Install the insert nut as explained in “example 1”. ● brass insert nut 1 ● hull 2 ● urethane foam 3 ● silicone sealant 4 graphic removal 1. Hold a hair d...

  • Page 240: Trbl

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

  • Page 241: Trbl

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

  • Page 242: Trbl

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

  • Page 243

    Wiring diagram 1 lighting coil 2 pickup coil 3 cdi unit 4 oil level sensor 5 fuel level sensor 6 buzzer 7 multi-function meter 8 speed sensor 9 engine stop switch 0 engine stop lanyard switch a start switch b ypvs servomotor c battery d starter motor e starter relay f fuse g ignition coil h spark pl...

  • Page 244

    Yamaha motor co., ltd. Printed in usa mar. 1999 – ?.? × 1 cr (xa1200x) printed on recycled paper.