Service manual

ManualsBrandsYamaha ManualsBoatFX140 WaveRunner 2003

WaveRunner

FX140

F1B-28197-1E-11

*LIT186160238*

LIT-18616-02-38

SERVICE MANUAL

Summary of content (426 pages)

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WaveRunner FX140 SERVICE MANUAL *LIT186160238* LIT-18616-02-38 F1B-28197-1E-11
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E NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
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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 reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.
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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 machine operator, passenger(s), a bystander, or a person inspecting or repairing the watercraft. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the watercraft.
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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”). 4 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.
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E 1 A50001-1-4 2 GEN INFO SYMBOLS Symbols 1 to 9 are designed as thumb-tabs to indicate the content of a chapter.
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E A30000-0 INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT FUEL SYSTEM POWER UNIT JET PUMP UNIT GEN INFO SPEC INSP ADJ FUEL POWR JET PUMP – ELECTRICAL SYSTEM HULL AND HOOD TROUBLE ANALYSIS + ELEC HULL HOOD TRBL ANLS 1 2 3 4 5 6 7 8 9
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GEN INFO E CHAPTER 1 GENERAL INFORMATION IDENTIFICATION NUMBERS ......................................................................... 1-1 PRIMARY l.D. NUMBER ...........................................................................1-1 ENGINE SERIAL NUMBER ...................................................................... 1-1 JET PUMP UNIT SERIAL NUMBER .........................................................1-1 HULL IDENTIFICATION NUMBER (H.l.N.)...............................................
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GEN INFO IDENTIFICATION NUMBERS E 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: F1B: 800101 ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the engine unit. Starting serial number: 60E: 000101 JET PUMP UNIT SERIAL NUMBER The jet pump unit serial number is stamped on a label attached to the intermediate housing.
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GEN INFO SAFETY WHILE WORKING E SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be followed by Yamaha dealers and their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Gasoline vapor is explosive if ignited. Do not smoke while handling gasoline (petrol) and keep it away from heat, sparks, and open flames. VENTILATION Gasoline vapor is heavier than air and is deadly if inhaled in large quantities. Engine exhaust gases are harmful to breathe.
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GEN INFO SAFETY WHILE WORKING E Under normal conditions of use there should be no hazards from the use of the lubricants mentioned in this manual, but safety is allimportant, and by adopting good safety practises any risk is minimized. A summary of the most important precautions is as follows: 1. While working, maintain good standards of personal and industrial hygiene. 2. Clothing which has become contaminated with lubricants should be changed as soon as practicable and laundered before further use. 3.
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GEN INFO SAFETY WHILE WORKING E 3. Non-reusable items Always use new gaskets, packings, Orings, 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. After assembly, check that moving parts operate normally. 4. Install bearings with the manufacturer’s markings on the side exposed to view and liberally oil the bearings.
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GEN INFO SPECIAL TOOLS E SPECIAL TOOLS Using the correct special tools recommended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvisations and using improper tools can damage the equipment. 1 YU-03097 NOTE: • For U.S.A. and Canada, use part numbers starting with “J-”, “YB-”, “YM-”, “YS-”, “YU-” or “YW-”. • For other countries, use part numbers starting with “90890-”. 90890-01252 MEASURING 2 90890-06583 3 1 Dial gauge P/N. YU-03097 90890-01252 2 Dial gauge stand P/N.
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GEN INFO A YB-06766 B 90890-06582 SPECIAL TOOLS C YU-03017 90890-06759 90890-03160 E YU-39991 90890-03172 F YM-34487 90890-06754 G YB-06792 H YB-06791 I YB-06770 J YB-06790 K YB-06793 L YB-06777 90890-06770 90890-06793 A Fuel pressure gauge P/N. YB-06766 90890-06786 B Compression gauge extension P/N. 90890-06582 C Cylinder gauge set P/N. YU-03017 90890-06759 D Compression gauge P/N. YU-33223-1 90890-03160 E Peak voltage adapter P/N. YU-39991 90890-03172 F Spark gap tester P/N.
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GEN INFO M YB-06769 90890-06769 SPECIAL TOOLS E M Test harness (3 pins) P/N. YB-06769 90890-06769 N Vacuum/pressure pump gauge set P/N. YB-35956-A 90890-06756 O Yamaha diagnostic system for Watercraft P/N. 60E-85300-01 P Yamaha diagnostic system for Watercraft (CD-ROM only) P/N.
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GEN INFO SPECIAL TOOLS E REMOVAL AND INSTALLATION 1 YU-38411 90890-01426 2 YW-06551 1 Oil filter wrench P/N. YU-38411 90890-01426 2 Coupler wrench P/N. YW-06551 90890-06551 3 Sheave holder P/N. YS-01880-A 90890-01701 4 Rotor puller P/N. YM-01082 90890-01080 5 Rotor holder P/N. YU-01235 90890-01235 6 Valve spring compressor P/N. YM-04019 90890-04019 7 Valve spring compressor attachment P/N. YM-4114 (ø19 mm) 90890-04114 (ø19 mm) YM-4108 (ø22 mm) 90890-04108 (ø22 mm) 8 Valve guide remover P/N.
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GEN INFO A B SPECIAL TOOLS 90890-06813 (60°) 90890-06814 (45°) 90890-06815 (30°) 90890-06811 (ø4.0 mm) 90890-06812 (ø4.5 mm) C YM-91043-C 90890-05158 F YB-06096 G 90890-06501 H 90890-06535 I 90890-06536 J 90890-06538 K 90890-06652 L YB-06151 90890-06519 A Valve seat cutter Intake P/N. 90890-06813 (60°) 90890-06814 (45°) 90890-06815 (30°) Exhaust P/N. 90890-06315 (60°) 90890-06312 (45°) 90890-06328 (30°) B Valve seat cutter holder P/N. 90890-06811 (ø4.0 mm) 90890-06812 (ø4.
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GEN INFO M YB-06085 N YB-06071 P YB-06552 90890-06552 SPECIAL TOOLS E M Ball bearing attachment (jet pump oil seal) P/N. YB-06085 90890-06634 N Driver rod (intermediate shaft and jet pump) P/N. YB-06071 90890-06606 O Bearing inner/outer race attachment (jet pump bearing) P/N. YB-34474 P Shaft holder (intermediate shaft) P/N. YB-06552 90890-06552 Q Bearing outer race attachment (intermediate shaft) P/N.
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SPEC E CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ....................................................................... 2-1 MAINTENANCE SPECIFICATIONS ............................................................... 2-3 ENGINE .................................................................................................... 2-3 JET PUMP UNIT ......................................................................................2-6 HULL AND HOOD ......................................................
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SPEC GENERAL SPECIFICATIONS E GENERAL SPECIFICATIONS Item Model code Hull Engine/jet Dimensions Length Width Height Dry weight Maximum capacity Performance Maximum output Maximum fuel consumption Cruising range Engine Engine type Displacement Bore × stroke Compression ratio Exhaust system Lubrication system Cooling system Starting system Ignition system Ignition timing Spark plug model (manufacturer) Spark plug gap Battery capacity Generator output Drive unit Propulsion system Jet pump type Impeller rota
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SPEC GENERAL SPECIFICATIONS Item Fuel and oil Fuel type Minimum fuel rating Fuel tank capacity Engine oil type Engine oil grade Engine oil quantity (without oil filter replacement) (with oil filter replacement) E Model FX140 Unit PON* RON* L (US gal, Imp gal) Regular unleaded gasoline 86 90 70 (18.5, 15.4) 4-stroke motor oil SE, SF, SG, SH, or SJ 10W-30 4.3 (4.5, 3.8) API SAE L (US qt, Imp qt) L (US qt, Imp qt) L (US qt, Imp qt) 2.0 (2.1, 1.8) 2.2 (2.3, 1.
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SPEC MAINTENANCE SPECIFICATIONS E MAINTENANCE SPECIFICATIONS ENGINE Item Cylinder head Warpage limit Compression pressure*1 Cylinder Bore size Taper limit Out-of-round limit Wear limit Camshaft Drive system Intake A Exhaust A Intake and exhaust B Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaftcap clearance Max.
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SPEC MAINTENANCE SPECIFICATIONS Item Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve-stem-to-valve-guide clearance Intake Exhaust Valve stem runout E Unit Model FX140 mm (in) mm (in) 0.9–1.1 (0.0354–0.0433) 0.9–1.1 (0.0354–0.0433) mm (in) mm (in) 0.5–0.9 (0.0197–0.0354) 0.5–0.9 (0.0197–0.0354) mm (in) mm (in) 3.975–3.990 (0.1565–0.1571) 4.460–4.475 (0.1756–0.1762) mm (in) mm (in) 4.
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SPEC MAINTENANCE SPECIFICATIONS Item B B Model FX140 Unit Piston ring Top ring T Type Dimension (B × T) End gap (installed) Ring groove clearance 2nd ring Type T Dimensions (B × T) End gap (installed) Ring groove clearance Oil ring Dimensions T (B × T) End gap (installed) Ring groove clearance Connecting rod Big end oil clearance Bearing color code Small end inside diameter Crankshaft E B mm (in) mm (in) mm (in) Barrel 0.90 × 2.75 (0.04 × 0.11) 0.38–0.55 (0.0150–0.0217) 0.030–0.065 (0.0012–0.
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SPEC MAINTENANCE SPECIFICATIONS Item Oil filter Oil filter type Oil pump Oil pump type Rotor tip clearance Oil pump housing clearance Rotor (feed pump) Rotor (scavenge pump) E Model FX140 Unit Cartridge type mm (in) Trochoid 0.09–0.15 (0.004–0.006) mm (in) mm (in) 0.09–0.17 (0.0035–0.0067) 0.09–0.19 (0.0035–0.
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SPEC MAINTENANCE SPECIFICATIONS Item Stator Pulser coil (W – B, R – B) Output peak voltage @cranking 1 @cranking 2 @2,000 r/min @3,500 r/min Lighting coil (G – G) Output peak voltage @cranking 1 @cranking 2 @2,000 r/min @3,500 r/min Pulser coil resistance Pulser coil resistance 2 Lighting coil resistance Minimum charging current Ignition coil Minimum spark gap Primary coil resistance Secondary coil resistance Spark plug lead resistance #1 #2 #3 #4 Rectifier/regulator (R – B) Output peak voltage (loaded) @
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SPEC MAINTENANCE SPECIFICATIONS Item Thermoswitch ON temperature (Engine) OFF temperature (Engine) ON temperature (Exhaust) OFF temperature (Exhaust) Engine temperature sensor Engine temperature sensor resistance (B/Y – B/Y) @ 20 °C (68 °F) @ 100 °C (212 °F) Intake air temperature sensor Intake air temperature sensor resistance @ 0 °C (32 °F) @ 80 °C (176 °F) Intake air pressure sensor output voltage (P/G – B/O) Speed sensor Output voltage (on pulse) Output pulse/one full turn Throttle position sensor Ou
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SPEC TIGHTENING TORQUES E TIGHTENING TORQUES SPECIFIED TORQUES 5.5 3.8 0.38 2.7 7.6 0.76 5.5 2.5 0.25 1.8 3 15 39 15 39 5.0 1.5 3.9 1.5 3.9 0.5 11 28 11 28 3.6 M5 2 3.5 0.35 2.5 Nut — 1 15 1.5 11 Screw Screw Screw Screw M6 M5 M5 M6 1 2 2 2 5.0 3.5 3.5 5.0 0.5 0.35 0.35 0.5 3.6 2.5 2.5 3.6 Screw M6 2 5.0 0.5 3.6 Screw M4 2 2.0 0.2 1.
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TIGHTENING TORQUES Exhaust pipe 1 – exhaust pipe stay Exhaust pipe 2 – exhaust pipe 1 Exhaust pipe 1 – exhaust manifold 1/ exhaust manifold 2 0.44 3.2 — 2 2nd 4.4 0.44 3.2 1st 5th 9th 2nd 6th 10th 3rd 7th 11th 4th 8th 12th 1st 2nd 1st 2nd 1st 2nd 1st 6th 2nd 7th 3rd 8th 4th 9th 5th 10th 1st 2nd 3rd 2.0 15 39 2.0 15 39 2.0 15 39 2.0 15 39 3.7 7.6 15 42 15 42 39 39 39 39 39 39 39 39 39 39 22 22 35 0.2 1.5 3.9 0.2 1.5 3.9 0.2 1.5 3.9 0.2 1.5 3.9 0.37 0.76 1.5 4.2 1.5 4.2 3.9 3.9 3.9 3.9 3.9 3.
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TIGHTENING TORQUES Bolt M6 4 Bolt M6 8 Bolt M5 10 Bolt M5 3 Bolt M6 2 Bolt M6 24 Screw M4 1 Bolt M6 12 Bolt M8 Bolt — 2-11 0.19 1.4 4.4 0.44 3.2 1 1.9 4.4 3.7 7.6 3.7 7.6 3.7 1.4 10 18 0.19 0.44 0.37 0.76 0.37 0.76 0.37 0.14 1.0 1.8 1.4 3.2 2.7 5.5 2.7 5.5 2.7 1.0 7.2 13 M6 2 7.9 0.79 5.7 — 1 28 2.8 20 LT 1.9 LT 2 242 M6 LT Bolt 242 2 LT M10 572 Bolt 572 2 5.5 5.5 11 20 1.4 11 28 1.4 11 28 2.7 5.5 2.7 5.5 2.7 5.5 LT — 0.76 0.76 1.5 2.8 0.
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TIGHTENING TORQUES Cylinder head – crankcase 1st 2nd 1st 2nd 2 Bolt M8 7 Bolt M6 1 10 1.0 7.2 Bolt M8 4 15 28 1.5 2.8 11 20 Nut — 1 18 1.8 13 A Bolt Bolt M8 M8 1 1 M10 8 Bolt Bolt M10 M8 1 6 0.49 1.8 1.5 5.0 7.5 2.4 3.5 13 11 36 54 17 A Bolt 4.9 18 15 50 75 24 Bolt M5 3 4.9 0.49 3.5 Bolt M5 4 4.9 0.49 3.5 Bolt M6 2 14 1.4 10 Bolt — Bolt M6 — M6 3 4 1 Bolt M6 1 14 13 10 3.7 7.6 1.4 1.3 1.0 0.37 0.76 10 9.4 7.2 2.7 5.5 Bolt M6 6 12 1.2 8.
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TIGHTENING TORQUES 7.6 0.76 5.5 Nut — 1 6.8 0.68 4.9 Bolt Bolt Bolt Screw Bolt Bolt Bolt Bolt Nut Bolt Bolt Bolt Nut Bolt Bolt M8 M8 M6 M5 M10 M6 M6 M8 — M6 M8 M6 — M8 M8 4 4 4 4 4 1 4 1 1 6 2 1 1 2 2 17 20 7.8 3.7 40 7.8 6.8 8.3 26 7.8 20 7.8 7.8 15 15 1.7 2.0 0.78 0.37 4.0 0.78 0.68 0.83 2.6 0.78 2.0 0.78 0.78 1.5 1.5 12 14 5.6 2.7 29 5.6 4.9 6.0 19 5.6 14 5.6 5.6 11 11 Bolt M10 4 40 4.0 29 2-13 LT 2.7 2 572 0.37 M6 LT 3.
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TIGHTENING TORQUES 4 6.6 0.66 4.8 Nut — 1 69 6.9 50 Impeller M22 1 27 2.7 19 Nut Screw Bolt Driven coupling — M5 M8 4 1 3 26 3.7 17 2.6 0.37 1.7 19 2.8 12 M24 1 36 3.6 25 Nipple — 1 5.4 0.54 3.9 Bolt M8 4 20 2.0 14 Bolt M6 2 1.1 0.11 0.8 Screw M6 4 1.1 0.11 0.8 Screw M6 4 0.9 0.09 0.7 Nut — 2 5.4 0.54 3.9 Screw M5 2 3 0.3 2.2 Screw M5 2 3.4 0.34 2.5 Screw Bolt M6 M5 1 2 3.4 1.2 0.34 0.12 2.5 0.9 Screw M4 1 1 0.1 0.
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TIGHTENING TORQUES — — — M6 M4 M5 2 1 4 4 4 4 5.4 5.9 5.4 5.4 1.5 3.9 0.54 0.59 0.54 0.54 0.15 0.39 3.9 4.3 3.9 3.9 1.1 2.8 Bolt M5 4 3.9 0.39 2.8 Nut Bolt Bolt — M6 M6 4 8 4 6.9 5.4 5.4 0.69 0.54 0.54 5.0 3.9 3.9 Bolt M6 2 5.4 0.54 3.9 Bolt Nut Nut Bolt Screw Nut Screw M6 — — M6 M6 — M6 2 2 2 2 2 2 3 5.4 5.4 20 5.4 5.4 4.2 5.4 0.54 0.54 2.0 0.54 0.54 0.42 0.54 3.9 3.9 14 3.9 3.9 3.0 3.9 Screw M6 3 5.4 0.54 3.
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TIGHTENING TORQUES Cover – electrical box Starter motor lead– electrical box Battery positive lead – electrical box Fuse holder stay – electrical box ECM – electrical box Bracket (coupler) – electrical box Slant detection switch – electrical box Main and fuel pump relay Rectifier/regulator Ignition coil – oil tank Ignition coil cover – ignition coil case Ignition coil – ignition coil case LT LT M6 M6 M8 M5 2 2 4 4 5.4 5.4 17 4.9 0.54 0.54 1.7 0.49 3.9 3.9 12 3.5 ø5 18 4.9 0.49 3.5 M6 1 7.
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SPEC TIGHTENING TORQUES Nut A Bolt B 8 mm 10 mm 12 mm 14 mm 17 mm M5 M6 M8 M10 M12 E GENERAL TORQUE General torque specifications N•m kgf•m ft•lb 5.0 0.5 3.6 8.0 0.8 5.8 18 1.8 13 36 3.6 25 43 4.3 31 This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this manual.
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SPEC CABLE AND HOSE ROUTING E CABLE AND HOSE ROUTING 1 1 BOW DOWN DOWN 7 F A-A 20˚ UP 8 E G 9 G A D 1 BA 6 B-B F F B C C 5 F-F D C 1 E 6 G 5 E C-C 5 0 + E-E 2 D 6 A B 3 3 4 2 1 2 3 4 5 6 7 8 9 0 A B C D E F G Fuel tank breather hose QSTS cable Steering cable Shift cable Electrical box lead Speed sensor lead Cooling water pilot outlet Cooling water pilot outlet hose Cooling water pilot outlet Battery negative lead 2-18 Battery positive lead Battery Throttle cabl
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SPEC CABLE AND HOSE ROUTING E 1 3 2 5 5 4 C B A B A B A E 01 C D F C D F B 3 A G MAIN 3A 3A 20A 3A 3A 3A 3A 3A 3A 0 SPARE 5 E 6 7 8 E A 5 B D 9 0 5 E-E F 1 2 3 4 5 6 7 8 9 0 A B C D E F G Throttle cable Handlebar switch lead QSTS cable Buzzer lead Fuel tank breather hose Ignition coil lead Battery positive lead Starter motor lead Wire harness Fuel hose 2-19 Shift cable Steering cable Electrical box lead Cooling water pilot outlet hose Battery negative lead Battery bre
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SPEC CABLE AND HOSE ROUTING 2 1 E 3 4 5 6 7 8 4 6 7 2 5 2 0 È 9 A 5 2 H 1 8 0 2 G F B C 8 E D 1 2 3 4 5 6 7 8 9 0 A B C D E F G H Cooling water hose (cooling water inlet) Bilge hose 1 Electric bilge pump Bilge hose 4 Cooling water hose (from thermostat) Bilge hose 3 Bilge hose 2 Cooling water hose (from exhaust pipe) Electrical box QSTS cable Battery positive lead Speed sensor lead Electric bilge pump lead Bilge strainer Battery negative lead Steering cable Shift cable Flushing hose
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SPEC CABLE AND HOSE ROUTING E Ê È Î Ë Ë Ë 1 B Ì C Í Õ 1 É A Ë Ö × Ï A C B D E D Ð F Ì Ø Ê Ó 5 Ð 4 3 Ò Ì Ô F 1 2 3 4 5 Ë Ð Ò E Ñ 2 D-D Ë From exhaust manifold Ì To install the hose, align the white paint mark on the cooling water hose with the projection of hose joint. Í Insert the cooling water hose until it contacts the joint.
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SPEC CABLE AND HOSE ROUTING E Ê È Î Ë Ë Ë 1 B Ì C Í Õ 1 É A Ë Ö × Ï A C B D E D Ð F Ì Ø Ê Ó 5 Ð 4 Ë Ð 3 Ò Ì Ô F Ò E Ñ 2 D-D Ö Bundle the cooling water pilot outlet hose and the cooling water hoses, pass a plastic locking tie through the stay hole, and then fasten the tie. × Insert the cooling water hose to the paint mark. Ø Fasten the cooling water hose tube contacting the hose joint.
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SPEC CABLE AND HOSE ROUTING E 0 9 Ë É 1 B A È Ê 2 A 8 7 6 5 4 3 A 1 1 B A-A 1 2 3 4 5 6 7 8 9 0 A Oil pressure switch lead Wire harness Ground lead Wire harness coupler Cam position sensor coupler Thermoswitch (exhaust) Thermoswitch (exhaust) coupler Oil pressure switch coupler Pulser coil coupler Thermoswitch (engine) coupler Lighting coil coupler È É Ê Ë 2-23 To electrical box To cam position sensor To oil pressure switch To engine temperature sensor
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SPEC CABLE AND HOSE ROUTING E 1 2 A ÊÉ A È 5 7Í 4 3 Ë Ì Î Ï 6 B 9 8 0 D Ï A-A Î Ñ 1 2 3 4 5 6 7 8 9 0 Ð Engine temperature sensor coupler Lighting coil coupler Pulser coil coupler Thermoswitch (engine) coupler Thermoswitch (engine) Starter motor Engine temperature sensor Engine temperature sensor lead Thermoswitch (engine) lead Lighting coil lead 2-24
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SPEC CABLE AND HOSE ROUTING E 1 2 A ÊÉ A È 5 7Í 4 3 Ë Ì Î Ï 6 B 9 8 0 D Ï A-A Î Ñ Ð Ð Route the starter motor and battery negative leads behind the cooling water hose. Ñ Route the starter motor lead over the cooling water hose. È É Ê Ë Ì Í To generator To engine temperature sensor To thermoswitch (engine) To thermoswitch (engine) coupler To engine temperature sensor coupler Route the starter motor lead to the outside of the engine temperature sensor.
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INSP ADJ E CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART .............................................................. 3-1 PERIODIC SERVICE .......................................................................................3-2 CONTROL SYSTEM ................................................................................. 3-2 Steering master inspection..................................................................3-2 Steering cable inspection and adjustment ..............
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INSP ADJ MAINTENANCE INTERVAL CHART E MAINTENANCE INTERVAL CHART The following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the intervals of maintenance should be changed. (●) This mark indicates maintenance that you may do yourself. (❍) This mark indicates work to be done by a Yamaha dealer.
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INSP ADJ CONTROL SYSTEM E PERIODIC SERVICE CONTROL SYSTEM Steering master inspection 1. Inspect: • Steering master Excessive play → Replace the steering master. Refer to “STEERING MASTER” in Chapter 8. Inspection steps: • Move the handlebar up and down and back and forth. • Check the excessive play of the handlebar. Steering cable inspection and adjustment 1. Inspect: • Jet thrust nozzle clearance a, b Difference → Adjust. Inspection steps: • Set the control grip in the neutral position.
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INSP ADJ CONTROL SYSTEM E WARNING The cable joint must be screwed in more than 8 mm (0.31 in). • Connect the cable joint and tighten the locknut. T. Locknut: 6.4 N • m (0.64 kgf • m, 4.6 ft • lb) R. NOTE: If the steering cable cannot be properly adjusted by the cable joint at the steering master end, adjust the cable joint at the jet pump end so that the same clearances are obtained. Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD” in Chapter 8.
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INSP ADJ CONTROL SYSTEM E 2. Adjust: • Throttle lever free play Adjustment steps: NOTE: • When not replacing the throttle cable or removing the cable from the throttle body, adjust the throttle cable free play by following steps (f) through (j). • When replacing the throttle cable or removing the cable from the throttle body, adjust the throttle cable free play by following steps (a) through (k). a. Remove the air filter case cover 1 and flame arrester. b. Pull back the cover 2. c. Loosen the locknut 3.
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INSP ADJ CONTROL SYSTEM E j. Install the handlebar cover. T. R. Handlebar cover screw: 1.1 N • m (0.11 kgf • m, 0.8 ft • lb) LOCTITE® 242 k. Install the flame arrester and air filter case cover. T. R. Flame arrester bolt: 1st: 3.3 N • m (0.33 kgf • m, 2.4 ft • lb) 2nd: 6.5 N • m (0.65 kgf • m, 4.7 ft • lb) LOCTITE® 242 Air filter case cover screw: 2.5 N • m (0.25 kgf • m, 1.
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INSP ADJ CONTROL SYSTEM E 2. Adjust: • QSTS cable Adjustment steps: • Set the control grip in the neutral position. • Loosen the locknut 1. • Remove the nut 2 and pivot pin 3. • Set the jet thrust nozzle in the center position. • Turn the cable joint 4 for adjusting. Turn in Length a is increased. Turn out Length b is increased. WARNING The cable joint must be screwed in more than 8 mm (0.31 in). • Connect the cable joint 4 and pivot pin 3 and tighten the nut 2. T. Nut: 3.8 N • m (0.38 kgf • m, 2.
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INSP ADJ CONTROL SYSTEM E Shift cable inspection and adjustment 1. Check: • Reverse gate stopper lever position Incorrect → Adjust. Checking steps: • Set the shift lever to the reverse position. • Check that the reverse gate 1 contacts the stopper 2 on the bracket and the lever 3 contacts the reverse gate. • Set the shift lever to the forward position. • Check that the lever 4 has been shifted over the bracket 5. 5 4 2. Adjust: • Shift cable joint Adjustment steps: • Loosen the locknut 1.
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INSP ADJ CONTROL SYSTEM E Trolling speed check and adjustment 1. Measure: • Trolling speed Out of specification → Adjust. Trolling speed: 1,600–1,800 r/min Checking steps: (Watercraft on water) • Start the engine and allow it to warm up for a 15 minutes. • Check the engine trolling speed using the tachometer of the multifunction meter or using the Yamaha Diagnostic System. 2. Adjust: • Trolling speed Adjustment steps: • Remove the air filter case cover 1. • Start the engine.
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INSP ADJ FUEL SYSTEM E FUEL SYSTEM WARNING When removing fuel system parts, wrap them in a cloth and take care that no fuel spills into the engine compartment. Fuel line inspection 1. Inspect: • Fuel strainer 1 Clog/contaminants → Clean. • Fuel pump filter Clog/contaminants → Clean. Refer to “FUEL TANK AND FUEL PUMP MODULE” in Chapter 4. • Fuel hose Damage/cracks → Replace. • O-rings (quick connector) Damage/cracks → Replace the quick connector. • Fuel pipe Damage/cracks → Replace the fuel pump.
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INSP ADJ POWER UNIT E POWER UNIT Valve clearance adjustment The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: • Air filter case Refer to “FUEL INJECTION SYSTEM” in Chapter 4. 2.
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INSP ADJ POWER UNIT E 4. Measure: • Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake valve: 0.11–0.20 mm (0.0043–0.0079 in) Exhaust valve: 0.25–0.34 mm (0.0098–0.0134 in) EX IN Measurement steps: • Turn the drive coupling counterclockwise, and then check if cylinder #1 is at TDC of the compression stroke with a dial gauge. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.
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INSP ADJ POWER UNIT E 5. Remove: • Timing chain tensioner cap bolt 1 • Gasket 1 6. Turn the timing chain tensioner rod fully clockwise with a thin screwdriver 1. NOTE: Make sure that the tensioner rod has been fully set clockwise. 1 7. Remove: • Intake camshaft caps • Exhaust camshaft caps • Timing chain (from the camshaft sprockets) • Intake camshaft • Exhaust camshaft NOTE: • Refer to “CAMSHAFTS” in Chapter 5.
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INSP ADJ POWER UNIT E 8. Adjust: • Valve clearance Adjustment steps: • Remove the valve lifter 1 and the valve pad 2. 1 2 NOTE: • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. • Make a note of the position of each valve lifter 3 and valve pad 4 so that they can be installed in the correct place. • Select the proper valve pad from the following table. Valve pad thickness range Nos. 120–240 Available valve pads 1.20– 25 thicknesses in 2.40 mm 0.
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INSP ADJ POWER UNIT E NOTE: The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect. 6 5 • Install the new valve pad 5 and the valve lifter 6. NOTE: • Lubricate the valve pad with molybdenum disulfide grease. • Lubricate the valve lifter with molybdenum disulfide oil. • The valve lifter must turn smoothly when rotated by hand.
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INSP ADJ POWER UNIT E Intake MEASURED CLEARANCE 0.00–0.02 0.03–0.07 0.08–0.10 0.11–0.20 0.21–0.22 0.23–0.27 0.28–0.32 0.33–0.37 0.38–0.42 0.43–0.47 0.48–0.52 0.53–0.57 0.58–0.62 0.63–0.67 0.68–0.72 0.73–0.77 0.78–0.82 0.83–0.87 0.88–0.92 0.93–0.97 0.98–1.02 1.03–1.07 1.08–1.12 1.13–1.17 1.18–1.22 1.23–1.27 1.28–1.32 1.33–1.
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INSP ADJ POWER UNIT E 9. Remove: • Dial gauge • Dial gauge stand • Dial gauge needle 10. Install: • All removed parts NOTE: For installation, reverse the removal procedure. Engine oil level check 1. Place the watercraft in a horizontal position. 2. Check: • Engine oil level Checking steps: CAUTION: • When checking the oil level in water, stay clear of other boats. The watercraft could be drifted away by the current or wind.
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INSP ADJ POWER UNIT E • Remove the oil filler cap 1 and check for oil on the dipstick 2. • If there is no oil on the dipstick, pour enough oil so that the tip of the dipstick comes into contact with the oil, and then install the filler cap. • In water a. Place the watercraft in water, and then start the engine. b. Run the engine at 7,000 r/min or more for more than 5 minutes. c. Run the engine at trolling speed for 2– 3 minutes. d. Stop the engine. • On land a.
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INSP ADJ POWER UNIT E • If the engine oil is below the minimum level mark a, add sufficient oil of the recommended type to raise it to the correct level. • If the engine oil is above the maximum level mark b, extract sufficient oil using an oil changer to lower it to the correct level. NOTE: If the oil temperature is low, the reading on the dipstick will be low, and if the temperature is high, the reading on the dipstick will be high.
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INSP ADJ POWER UNIT E 2. Remove: • Oil filler cap 1 1 3. Insert the tube of an oil changer into the oil filler hole. 4. Operate the oil changer to extract the oil. 5. If the oil filter is also to be replaced, perform the following procedure. Replacing steps: • Place a rag under the oil filter. • Remove the oil filter 1 with an oil filter wrench 2. 1 2 Oil filter wrench: YU-38411/90890-01426 • Lubricate the O-ring 3 of the new oil filter with a thin coat of engine oil.
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INSP ADJ POWER UNIT E 6. Pour the specified amount of the recommended engine oil into the oil filler hole. 7. Fill: • Oil tank (with the specified amount of the recommended engine oil) Recommended oil: SAE 10W-30 API SE, SF, SG, SH, SJ Oil quantity: Total amount: 4.3 L (4.5 US qt, 3.8 Imp qt) With oil filter replacement: 2.2 L (2.3 US qt, 1.9 Imp qt) Without oil filter replacement: 2.0 L (2.1 US qt, 1.8 Imp qt) CAUTION: When starting the engine make sure the dipstick is securely fitted into the oil tank.
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INSP ADJ POWER UNIT E 2. Remove the air filter element and check it for dirt and oil. Replace the air filter element if there is any oil buildup. CAUTION: • Make sure that the air filter element is installed in the filter case properly. • Do not start the engine with the air filter element removed, otherwise the engine could be damaged. • If cleaning the air filter element, use cold or lukewarm water and let it air dry completely.
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INSP ADJ POWER UNIT E 3. Inspect: • Electrodes 1 Damage/wear → Replace. • Insulator color 2 Distinctly different color → Check the engine condition. Color guide: Medium to light tan color: Normal Whitish color: Lean fuel mixture Air leak Incorrect settings Blackish color: Overly rich mixture Electrical malfunction Defective spark plug 4. Clean: • Spark plug (with a spark plug cleaner or wire brush) 5. Measure: • Spark plug gap a Out of specification → Regap. Spark plug gap: 0.7–0.8 mm (0.028–0.031 in) 6.
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INSP ADJ POWER UNIT/ELECTRICAL E 7. Install: • Air filter element • Air filter case cover T. R. Air filter case cover screw: 2.5 N • m (0.25 kgf • m, 1.8 ft • lb) LOCTITE® 572 ELECTRICAL Battery inspection WARNING Battery electrolyte is poisonous and dangerous, causing severe burns, etc. Electrolyte contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidotes External: Flush with water. Internal: Drink large quantities of water or milk.
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INSP ADJ ELECTRICAL 1 E 1. Remove: • Bands • Battery negative lead 1 • Battery positive lead 2 • Battery • Battery breather hose 3 2 3 WARNING • When removing the battery, disconnect the negative lead first. • Remove the battery to prevent acid loss during turning the machine on its side for the impeller service. 2. Inspect: • Electrolyte level Low → Add distilled water. The electrolyte level should be between the upper a and lower b level marks. Filling steps: • Remove each filler cap.
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INSP ADJ ELECTRICAL E 3. Inspect: • Specific gravity Out of specification → Charge. Specific gravity at 20 °C (68 °F): 1.28 Charging current: 1.9 amps × 10 hrs 4. Install: • Filler caps CAUTION: Before installation, rinse off any fluid from the battery box and battery and make sure that the battery is dry before installing it. 3 5.
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INSP ADJ JET PUMP UNIT E JET PUMP UNIT Impeller inspection 1. Check: • Impeller 1 Damage/wear → Replace. Nicks/scratches → File or grind. 2. Measure: • Impeller-to-housing clearance a Out of specification → Replace. Max. impeller-to-housing clearance: 0.6 mm (0.0236 in) Measurement steps: • Remove the battery leads. • Remove the intake grate and intake duct. Refer to “INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT” in Chapter 6.
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INSP ADJ JET PUMP UNIT/BILGE PUMP E Water inlet strainer inspection 1. Inspect: • Water inlet strainer Contaminants → Clean. Cracks/damage → Replace. Inspection steps: • Remove the ride plate. Refer to “INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT” in Chapter 6. • Remove the rubber plate. Refer to “JET PUMP UNIT” in Chapter 6. • Remove the water inlet cover 1. • Inspect the water inlet strainer mesh a. • Install the water inlet cover. • Install the rubber plate. Refer to “JET PUMP UNIT” in Chapter 6.
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INSP ADJ BILGE PUMP/GENERAL Electric bilge pump strainer inspection 1. Inspect: • Cap • Strainer Contaminants → Clean. Inspection steps: • Remove the band 1. • Remove the cap 2 and strainer 3. • Inspect the cap and strainer. • Install the strainer and cap. • Install the band. 1 3 2 GENERAL Drain plug inspection 1. Inspect: • Drain plugs Cracks/damage → Replace. • O-rings Cracks/wear → Replace. • Screw threads Contaminants → Clean.
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INSP ADJ GENERAL E Lubrication points 1. Lubricate: • Throttle cable (handlebar end) Recommended lubricant: Rust inhibitor NOTE: Before lubricating the throttle cable, squeeze the throttle lever and remove the rubber seal 1. 2. Lubricate: • Throttle cable (throttle body end) Recommended lubricant: Yamaha marine grease, Yamaha grease A (Water resistant grease) 3.
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INSP ADJ GENERAL E 5. Lubricate: • Nozzle pivot shaft • Steering cable (nozzle end) • QSTS cable (nozzle end) Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) 6. Lubricate: • Steering cable • Steering cable joint • Shift cable • Shift cable joint NOTE: Disconnect the joints and apply a small amount of grease.
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INSP ADJ GENERAL E 7. Fill: • Intermediate housing 1 Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) Grease quantity: Initial 10 hours: 33.0–35.0 cm3 (1.11–1.18 oz) Every 100 hours or 12 months: 6.0–8.0 cm3 (0.20–0.27 oz) NOTE: Fill the intermediate housing with the recommended grease through the grease nipple 1.
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FUEL E CHAPTER 4 FUEL SYSTEM FUEL TANK AND FUEL PUMP MODULE......................................................4-1 EXPLODED DIAGRAM .............................................................................4-1 REMOVAL AND INSTALLATION CHART ................................................ 4-1 SERVICE POINTS .................................................................................... 4-4 Fuel hose disconnection .....................................................................
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FUEL FUEL TANK AND FUEL PUMP MODULE E FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM 1st 4 9 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 5 3 6 1.3 N • m (0.13 kgf • m, 0.9 ft • Ib) 2 17 18 16 7 10 1 2 8 11 13 5.9 N • m (0.59 kgf • m, 4.3 ft • Ib) 14 12 19 14 15 21 22 LT 572 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) 20 23 LT 572 16 N • m (1.
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FUEL FUEL TANK AND FUEL PUMP MODULE E EXPLODED DIAGRAM 1st 4 9 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 5 3 6 1.3 N • m (0.13 kgf • m, 0.9 ft • Ib) 2 17 18 16 7 10 1 2 8 11 13 5.9 N • m (0.59 kgf • m, 4.3 ft • Ib) 14 12 19 14 15 21 22 LT 572 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) 20 23 LT 572 16 N • m (1.
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FUEL FUEL TANK AND FUEL PUMP MODULE E EXPLODED DIAGRAM 1st 4 9 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 5 3 6 1.3 N • m (0.13 kgf • m, 0.9 ft • Ib) 2 17 18 16 7 10 1 2 8 11 13 5.9 N • m (0.59 kgf • m, 4.3 ft • Ib) 14 12 19 14 15 21 22 LT 572 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) 20 23 LT 572 16 N • m (1.
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FUEL FUEL TANK AND FUEL PUMP MODULE E SERVICE POINTS Fuel hose disconnection 1. Disconnect: • Fuel hose Refer to “FUEL INJECTION SYSTEM”. 8 7 3 2 Fuel pump module removal 1. Remove: • Nuts • Retainer 5 NOTE: Loosen the nuts in the sequence shown. 1 6 9 4 2. Remove: • Fuel pump module 1 1 NOTE: Remove the float 2 at an angle because it could catch on the fuel tank. 2 Fuel sender disassembly 1. Disconnect: • Fuel sender coupler a 2.
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FUEL FUEL TANK AND FUEL PUMP MODULE A B A B A B A B E 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 come out from end “A”. Rollover valve inspection 1. Check: • Rollover valve Faulty → Replace. Checking steps: • Connect a hose to the end of rollover valve “A” and blow into it.
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FUEL FUEL TANK AND FUEL PUMP MODULE E Fuel pump filter inspection 1. Inspect: • Fuel pump filter 1 Clog/contaminants → Wash the fuel pump filter in kerosene or gasoline. 1 Fuel strainer inspection 1. Inspect: • Fuel strainer Clog/contaminants → Clean. 2 3 7 5 T. 8 Fuel pump module installation 1. Tighten: • Nuts 4 1 R. 9 6 Fuel pump module nut: 1st: 3.2 N • m (0.32 kgf • m, 2.3 ft • lb) 2nd: 6.4 N • m (0.64 kgf • m, 4.6 ft • lb) NOTE: Tighten the nuts in the sequence shown.
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FUEL FUEL INJECTION SYSTEM E FUEL INJECTION SYSTEM EXPLODED DIAGRAM 3.3 N • m (0.33 kgf • m, 2.4 ft • Ib) 2nd 6.5 N • m (0.65 kgf • m, 4.7 ft • Ib) 6 × 7 mm 4 1st 2.5 N • m (0.25 kgf • m, 1.8 ft • Ib) 5 × 70 mm 1 2 LT LT 572 5 242 6 16 22 3 E 18 17 21 20 20 19 11 N • m (1.1 kgf • m, 8.0 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 8 × 50 mm 1st 12 7 13 LT 8 572 10 14 LT A 15 572 9 11 4 × 8 mm 1st 1.7 N • m (0.17 kgf • m, 1.2 ft • Ib) 2nd 3.3 N • m (0.33 kgf • m, 2.
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FUEL FUEL INJECTION SYSTEM E EXPLODED DIAGRAM 3.3 N • m (0.33 kgf • m, 2.4 ft • Ib) 2nd 6.5 N • m (0.65 kgf • m, 4.7 ft • Ib) 6 × 7 mm 4 1st 2.5 N • m (0.25 kgf • m, 1.8 ft • Ib) 5 × 70 mm 1 2 LT LT 572 5 242 6 16 22 3 E 18 17 21 20 20 19 11 N • m (1.1 kgf • m, 8.0 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 8 × 50 mm 1st 12 7 13 LT 8 572 10 14 LT A 15 572 9 11 4 × 8 mm 1st 1.7 N • m (0.17 kgf • m, 1.2 ft • Ib) 2nd 3.3 N • m (0.33 kgf • m, 2.
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FUEL FUEL INJECTION SYSTEM E EXPLODED DIAGRAM 3.3 N • m (0.33 kgf • m, 2.4 ft • Ib) 2nd 6.5 N • m (0.65 kgf • m, 4.7 ft • Ib) 6 × 7 mm 4 1st 2.5 N • m (0.25 kgf • m, 1.8 ft • Ib) 5 × 70 mm 1 2 LT LT 572 5 242 6 16 22 3 E 18 17 21 20 20 19 11 N • m (1.1 kgf • m, 8.0 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 8 × 50 mm 1st 12 7 13 LT 8 572 10 14 LT A 15 572 9 11 4 × 8 mm 1st 1.7 N • m (0.17 kgf • m, 1.2 ft • Ib) 2nd 3.3 N • m (0.33 kgf • m, 2.
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FUEL FUEL INJECTION SYSTEM E EXPLODED DIAGRAM 1st 7 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 2nd 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 35 mm 9 6 13 8 LT 1st 12 242 15 N • m (1.5 kgf • m, 11 ft • Ib) 9 2nd 39 N • m (3.9 kgf • m, 28 ft • Ib) 8 × 16 mm LT 11 572 25 23 10 17 24 1st 18 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 4 LT 2 5 271 14 15 LT 242 3 6 × 16 mm kgf m, 2.7 ft • Ib) 3.8 N • m (0.38 • 1 16 20 21 5 × 14 mm 1.8 N • m (0.18 kgf • m, 1.
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FUEL FUEL INJECTION SYSTEM E EXPLODED DIAGRAM 1st 7 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 2nd 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 35 mm 9 6 13 8 LT 1st 12 242 15 N • m (1.5 kgf • m, 11 ft • Ib) 9 2nd 39 N • m (3.9 kgf • m, 28 ft • Ib) 8 × 16 mm LT 11 572 25 23 10 17 24 1st 18 2nd 7.6 N • m (0.76 kgf • m, 5.
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FUEL FUEL INJECTION SYSTEM E EXPLODED DIAGRAM 1st 7 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 2nd 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 35 mm 9 6 13 8 LT 1st 12 242 15 N • m (1.5 kgf • m, 11 ft • Ib) 9 2nd 39 N • m (3.9 kgf • m, 28 ft • Ib) 8 × 16 mm LT 11 572 25 23 10 17 24 1st 18 2nd 7.6 N • m (0.76 kgf • m, 5.
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FUEL FUEL INJECTION SYSTEM E EXPLODED DIAGRAM 5 × 7 mm 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 5 × 15 mm 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 17 18 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib) 6 × 50 mm 1 8 2 9 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 2 5 × 15 mm 10 1 15 N • m (1.5 kgf • m, 11 ft • Ib) 3 14 11 15 16 6 × 10 mm 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib) 23 21 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib) 6 × 9 mm 24 25 26 27 12 13 22 7 6 23 4 28 20 29 30 31 19 2.0 N • m (0.2 kgf • m, 1.
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FUEL FUEL INJECTION SYSTEM E EXPLODED DIAGRAM 5 × 7 mm 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 5 × 15 mm 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 17 18 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib) 6 × 50 mm 1 8 2 9 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 2 5 × 15 mm 10 1 15 N • m (1.5 kgf • m, 11 ft • Ib) 3 14 11 15 16 6 × 10 mm 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib) 23 21 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib) 6 × 9 mm 24 25 26 27 12 13 22 7 6 23 4 28 20 29 30 31 19 2.0 N • m (0.2 kgf • m, 1.
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FUEL FUEL INJECTION SYSTEM E EXPLODED DIAGRAM 5 × 7 mm 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 5 × 15 mm 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 17 18 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib) 6 × 50 mm 1 8 2 9 3.5 N • m (0.35 kgf • m, 2.5 ft • Ib) 2 5 × 15 mm 10 1 15 N • m (1.5 kgf • m, 11 ft • Ib) 3 14 11 15 16 6 × 10 mm 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib) 23 21 5.0 N • m (0.5 kgf • m, 3.6 ft • Ib) 6 × 9 mm 24 25 26 27 12 13 22 7 6 23 4 28 20 29 30 31 19 2.0 N • m (0.2 kgf • m, 1.
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FUEL FUEL INJECTION SYSTEM E SERVICE POINTS Hose clamps removal 1. Remove: • Hose clamps CAUTION: If the hose clamps are removed without cutting the joint first, the fuel hose will be damaged. Hose clamps installation 1. Install: • Hose clamps WARNING Do not reuse the hose clamps, always replace them with new ones. NOTE: Crimp the hose clamps properly to securely fasten them.
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FUEL FUEL INJECTION SYSTEM E CAUTION: • Do not rotate the quick connector tab 1 past the stopper position a, otherwise it could be damaged. • When the fuel hoses are disconnected, quickly remove the retainer 2 from the quick connector, otherwise the retainer could be lost. 2. Disconnect the fuel hose 1 from the fuel pipe 2 directly. 1 WARNING Always reduce the fuel pressure in the fuel line before servicing the line or the fuel pipe.
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FUEL FUEL INJECTION SYSTEM Fuel hose installation (replacing with new fuel hose) 1. Install: • Fuel hose 1 a 2 E NOTE: • To install the fuel hose, be sure to align the white mark a of the fuel hose with the checker tab 2 of the quick connector. • When replacing the fuel hose with a new one, a checker tab 2 that has half engagement prevention is attached to the quick connector of the hose. If the quick connector is completely installed to the fuel pipe, it is removable. 1 2 Fuel hose connection 1.
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FUEL FUEL INJECTION SYSTEM E Fuel injector inspection CAUTION: The throttle bodies should not be disassembled unnecessarily. 1. Check: • Injector Dirt/residue → Clean. Damage → Replace. 2. Measure: • Fuel injectors resistance Out of specification → Replace. Digital circuit tester: YU-34899-A/90890-03174 Fuel injector resistance: 14.0–15.0 Ω at 20 °C (68 °F) 3. Check the operation of the fuel injector using the “Stationary Test” of the Yamaha Diagnostic System. Throttle body inspection 1.
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FUEL FUEL INJECTION SYSTEM E 2. Check: • Fuel passages Obstruction → Clean. Checking steps: • Wash the throttle body in a petroleum based solvent. Do not use any caustic carburetor cleaning solution. • Blow out all of passages with compressed air. Throttle body installation 1. Install: • Throttle body 1 CAUTION: Do not bend the fuel pipe 1. 2. Install: • Fuel hose 1 (throttle body side) • Clamp a NOTE: Install the fuel hose with the white mark a facing up. 1 3.
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FUEL FUEL INJECTION SYSTEM E Throttle bodies synchronization 1. Remove: • Throttle bodies • Air filter case 2. Adjust: • Throttle bodies synchronization Adjustment steps: NOTE: The bypass air screw 1 should not be adjusted. However, if it is necessary to remove the bypass air screw, be sure to note the number of times the screw is turned from its set position. When installing the screw, be sure to tighten the screw the same number of turns as noted at removal.
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FUEL FUEL INJECTION SYSTEM E c. Turn synchronizing screw #1 3 clockwise approximately 7 times until it starts to contact the lever. NOTE: • Butterfly valve #1 should be fully closed. Butterfly valves #2 and #3 open if the screw is turned more than 7 times. • If butterfly valves #1, #2, and #3 are not fully closed, close the valves by adjusting synchronizing screw #1 3. d. Turn synchronizing screw #3 5 clockwise approximately 7 times until it starts to contact the lever.
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FUEL FUEL INJECTION SYSTEM E NOTE: For best results, use a vacuum gauge (commercially obtainable), like 9 or 0 shown in the illustration, that has four adapters. 0 9 È For USA and Canada É For worldwide i. Install the throttle bodies. NOTE: Adjust the throttle body synchronization with the air filter case uninstalled. j. Connect the fuel hose and clamp. k. Connect the Yamaha Diagnostic System. l.
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FUEL FUEL INJECTION SYSTEM E Throttle position sensor output voltage: Pink (P) – Black/Orange (B/O) 0.8 ± 0.1 V NOTE: • To decrease the output voltage, turn the throttle position sensor clockwise. • Slightly tighten the throttle position screw. p. Start the engine and let it run at trolling speed for 20 minutes. NOTE: • Warm the engine up in the water. • While checking the engine temperature with the Yamaha Diagnostic System, warm the engine up until the engine temperature is 50 °C (122 °F). q.
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FUEL FUEL INJECTION SYSTEM E Vacuum pressure at trolling speed: Cylinder difference Cylinder #1 Example –30 ± 10 mmHg –210 ± 10 mmHg (–4.00 ± (–27.99 ± 1.33 kPa, 1.33 kPa, –1.2 ± 0.4 inHg) –8.3 ± 0.4 inHg) #2 Standard*0 –180 mmHg (–23.99 kPa, –7.1 inHg) #3 0 ± 10 mmHg (0 ± 1.33 kPa, 0 ± 0.4 inHg) –180 ± 10 mmHg (–23.99 ± 1.33 kPa, –7.1 ± 0.4 inHg) #4 –20 ± 10 mmHg –200 ± 10 mmHg (–2.67 ± (–26.66 ± 1.33 kPa, 1.33 kPa, –0.8 ± 0.4 inHg) –7.8 ± 0.
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FUEL FUEL INJECTION SYSTEM E Fuel pressure measurement 1. Disconnect: • Fuel hose Refer to “Fuel hose disconnection”. 2 2. Install: • Fuel pressure gauge adapter 1 • Fuel pressure gauge 2 1 Fuel pressure gauge adapter: YW-06842/90890-06842 Fuel pressure gauge: YB-06766/90890-06786 NOTE: To connect the fuel pressure gauge adapter, follow the procedures for connecting a fuel hose. (Refer to “Fuel hose connection”.) 3. Start the engine and arrow it to warm up for several minutes. 4.
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POWR E CHAPTER 5 POWER UNIT ENGINE UNIT .................................................................................................. 5-1 EXPLODED DIAGRAM ............................................................................. 5-1 REMOVAL AND INSTALLATION CHART ................................................ 5-1 SERVICE POINTS .................................................................................... 5-4 Compression pressure measurement ...............................................
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POWR OIL PUMP...................................................................................................... 5-26 EXPLODED DIAGRAM ........................................................................... 5-26 REMOVAL AND INSTALLATION CHART .............................................. 5-26 SERVICE POINTS .................................................................................. 5-27 Oil pump removal ..............................................................................
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POWR CYLINDER HEAD.......................................................................................... 5-57 EXPLODED DIAGRAM ........................................................................... 5-57 REMOVAL AND INSTALLATION CHART ............................................. 5-57 SERVICE POINTS .................................................................................. 5-59 Cylinder head removal ......................................................................
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POWR CRANKSHAFT .............................................................................................. 5-97 EXPLODED DIAGRAM ........................................................................... 5-97 REMOVAL AND INSTALLATION CHART .............................................. 5-97 SERVICE POINTS .................................................................................. 5-98 Crankshaft removal ...........................................................................
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POWR ENGINE UNIT E ENGINE UNIT EXPLODED DIAGRAM 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 6 × 25 mm 11 4 LT 12 6 572 10 3 7 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 40 mm LT 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 28 mm 15 2 13 LT 572 271 9 9 8 1 5 14 9 17 N • m (1.
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POWR ENGINE UNIT E EXPLODED DIAGRAM 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 6 × 25 mm 11 4 LT 12 6 572 10 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 40 mm LT 17 N • m (1.
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POWR ENGINE UNIT E EXPLODED DIAGRAM 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 6 × 25 mm 11 4 LT 12 6 572 10 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 40 mm LT 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 28 mm 3 7 15 2 13 LT 572 271 9 9 8 1 5 14 9 Step 13 14 15 Procedure/Part name Bolt/washer Shim Engine unit Q’ty 4/4 * 1 17 N • m (1.7 kgf • m, 12 ft • Ib) Service points Reverse the removal steps for installation. *: As required.
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POWR ENGINE UNIT E SERVICE POINTS Compression pressure measurement The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: • Valve clearance Out of specification → Adjust. Refer to “POWER UNIT” in Chapter 3. 2. Warm the engine up, and then put the watercraft in a horizontal position. 3. Remove: • Air filter case cover 1 • Air filter element 4. Disconnect: • Spark plug cap 5.
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POWR ENGINE UNIT E 7. Measure: • Compression pressure Out of specification → Refer to steps (b) and (c). Minimum compression pressure (reference data): 1,080 kPa (10.8 kgf/cm2, 157 psi) Measurement steps: a. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. WARNING To prevent sparking, ground all spark plug leads before cranking the engine. NOTE: The difference in compression pressure between cylinders should not exceed 100 kPa (1 kgf/cm2, 14 psi). b.
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POWR ENGINE UNIT E 9. Install: • Air filter element • Air filter case cover T. R. Air filter case cover screw: 2.5 N • m (0.25 kgf • m, 1.8 ft • lb) LOCTITE® 572 Oil filter removal and installation 1. Remove: • Oil filter 1 Oil filter wrench 2: YU-38411/90890-01426 1 2 T. Oil filter: 17 N • m (1.7 kgf • m, 12 ft • lb) R. NOTE: Install the oil filter with the same special tool that was used for removal. Engine unit removal 1.
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POWR ENGINE UNIT E Shim removal 1. Remove: • Shims NOTE: To ease reassembly and coupling alignment, remove the shims and organize them in their respective groups (e.g., front right, rear left) prior to removing the mounting bolts. Engine mount inspection 1. Inspect: • Engine mounts Cracks/damage → Replace. Refer to “ENGINE MOUNT” in Chapter 8. Coupling clearance inspection 1. Measure: • Clearance a • Clearance b (with the rubber damper) Out of specification → Adjust.
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POWR EXHAUST PIPE 3 E EXHAUST PIPE 3 EXPLODED DIAGRAM 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 5th 15 N • m (1.5 kgf • m, 11 ft • Ib) 9th 39 N • m (3.9 kgf • m, 28 ft • Ib) 10 × 35 mm Ê 1st 2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 6th 15 N • m (1.5 kgf • m, 11 ft • Ib) 10th 39 N • m (3.9 kgf • m, 28 ft • Ib) 10 × 35 mm 3 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 6 10 4 5 17 18 LT 16 1 572 È 13 15 14 LT 242 2 É LT 7 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib) 2nd 4.4 N • m (0.
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POWR EXHAUST PIPE 3 E EXPLODED DIAGRAM 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 5th 15 N • m (1.5 kgf • m, 11 ft • Ib) 9th 39 N • m (3.9 kgf • m, 28 ft • Ib) 10 × 35 mm Ê 1st 2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 6th 15 N • m (1.5 kgf • m, 11 ft • Ib) 10th 39 N • m (3.9 kgf • m, 28 ft • Ib) 10 × 35 mm 3 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 6 10 4 5 17 18 LT 16 1 572 È 13 15 14 LT 242 2 É LT 7 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib) 2nd 4.4 N • m (0.44 kgf • m, 3.
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POWR EXHAUST PIPE 3 E EXPLODED DIAGRAM 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 5th 15 N • m (1.5 kgf • m, 11 ft • Ib) 9th 39 N • m (3.9 kgf • m, 28 ft • Ib) 10 × 35 mm Ê 1st 2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 6th 15 N • m (1.5 kgf • m, 11 ft • Ib) 10th 39 N • m (3.9 kgf • m, 28 ft • Ib) 10 × 35 mm 3 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 6 10 4 5 17 18 LT 16 1 572 È 13 15 14 LT 242 2 É LT 7 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib) 2nd 4.4 N • m (0.44 kgf • m, 3.
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POWR EXHAUST PIPES 1 AND 2 E EXHAUST PIPES 1 AND 2 EXPLODED DIAGRAM 4th 39 N • m (3.9 kgf • m, 28 ft • Ib) 9th 39 N • m (3.9 kgf • m, 28 ft • Ib) 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 3rd 35 N • m (3.5 kgf • m, 25 ft • Ib) 8 × 75 mm 1st 3rd 39 N • m (3.9 kgf • m, 28 ft • Ib) 8th 39 N • m (3.9 kgf • m, 28 ft • Ib) 4 39 N • m (3.9 kgf • m, 28 ft • Ib) 6th 39 N • m (3.9 kgf • m, 28 ft • Ib) 1st 4 E 5 13 È 7 È 12 6 4 8 E 5th 39 N • m (3.
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POWR EXHAUST PIPES 1 AND 2 E EXPLODED DIAGRAM 4th 39 N • m (3.9 kgf • m, 28 ft • Ib) 9th 39 N • m (3.9 kgf • m, 28 ft • Ib) 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 3rd 35 N • m (3.5 kgf • m, 25 ft • Ib) 8 × 75 mm 1st 3rd 39 N • m (3.9 kgf • m, 28 ft • Ib) 8th 39 N • m (3.9 kgf • m, 28 ft • Ib) 4 39 N • m (3.9 kgf • m, 28 ft • Ib) 6th 39 N • m (3.9 kgf • m, 28 ft • Ib) 1st 4 E 5 13 È 7 È 12 6 4 8 E 5th 39 N • m (3.9 kgf • m, 28 ft • Ib) 10th 39 N • m (3.
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POWR EXHAUST MANIFOLD E EXHAUST MANIFOLD EXPLODED DIAGRAM a 1 È 5 LT 8 242 10 4 LT 242 6 3 5 LT 10 7 242 LT 2 242 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 3rd 35 N • m (3.5 kgf • m, 25 ft • Ib) 8 × 70 mm 1st 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 3rd 35 N • m (3.5 kgf • m, 25 ft • Ib) 8 × 55 mm 1st 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 3rd 35 N • m (3.
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POWR EXHAUST MANIFOLD E EXPLODED DIAGRAM a 1 È 5 LT 8 242 10 4 LT 242 6 3 5 LT 7 242 LT 2 242 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 3rd 35 N • m (3.5 kgf • m, 25 ft • Ib) 8 × 70 mm 1st 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 3rd 35 N • m (3.5 kgf • m, 25 ft • Ib) 8 × 55 mm 1st 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 3rd 35 N • m (3.
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POWR OIL TANK E OIL TANK EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 1st 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 35 mm 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 15 N • m (1.5 kgf • m, 11 ft • Ib) 3rd 39 N • m (3.9 kgf • m, 28 ft • Ib) 1st 24 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 20 mm LT 2 572 3 4 23 5 LT 1 È 11 4 16 15 572 14 5 E Í 9 8 b Ë 19 Ê LT 572 7 6 25 12 13 10 Ì 26 a 29 27 18 17 20 LT 26 572 LT 572 28 6 21 LT 572 A 22 É 3.
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POWR OIL TANK E EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 1st 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 35 mm 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 15 N • m (1.5 kgf • m, 11 ft • Ib) 3rd 39 N • m (3.9 kgf • m, 28 ft • Ib) 1st 24 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 20 mm LT 2 572 3 4 23 5 LT 1 È 11 4 16 15 572 14 5 E Í 9 8 b Ë 19 Ê LT 572 7 6 25 12 13 10 Ì 26 a 29 LT 572 17 20 LT 26 572 LT A 22 É 3.7 N • m (0.37 kgf • m, 2.
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POWR OIL TANK E EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 1st 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 35 mm 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 15 N • m (1.5 kgf • m, 11 ft • Ib) 3rd 39 N • m (3.9 kgf • m, 28 ft • Ib) 1st 24 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 20 mm LT 2 572 3 4 23 5 LT 1 È 11 4 16 15 572 14 5 E Í 9 8 b Ë 19 Ê LT 572 7 6 25 12 13 10 Ì 26 a 29 LT 572 17 20 LT 26 572 LT A 22 É 3.7 N • m (0.37 kgf • m, 2.
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POWR OIL TANK E EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 1st 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 35 mm 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 2nd 15 N • m (1.5 kgf • m, 11 ft • Ib) 3rd 39 N • m (3.9 kgf • m, 28 ft • Ib) 1st 24 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 20 mm LT 2 572 3 4 23 5 LT 1 È 11 4 16 15 572 14 5 E Í 9 8 b Ë 19 Ê LT 572 7 6 25 12 13 10 Ì 26 a 29 LT 572 17 20 LT 26 572 LT A 22 É 3.7 N • m (0.37 kgf • m, 2.
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POWR OIL TANK E EXPLODED DIAGRAM 5 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 20 mm 3 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 25 mm 1st 1st 6 8 1.9 N • m (0.19 kgf • m, 1.4 ft • Ib) 2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib) 5 × 14 mm 1st 7 4 LT LT 572 9 13 12 11 572 18 14 E 15 LT 572 5 × 35 mm E 16 10 1.9 N • m (0.19 kgf • m, 1.4 ft • Ib) 2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib) 17 1st 3.
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POWR OIL TANK E EXPLODED DIAGRAM 5 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 20 mm 3 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 25 mm 1st 1st 6 8 1.9 N • m (0.19 kgf • m, 1.4 ft • Ib) 2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib) 5 × 14 mm 1st 7 4 LT LT 572 9 13 12 11 572 18 14 E 15 LT 572 5 × 35 mm E 16 10 1.9 N • m (0.19 kgf • m, 1.4 ft • Ib) 2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib) 17 1st 3.
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POWR OIL TANK E EXPLODED DIAGRAM 5 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 20 mm 3 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 25 mm 1st 1st 6 8 1.9 N • m (0.19 kgf • m, 1.4 ft • Ib) 2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib) 5 × 14 mm 1st 7 4 LT LT 572 9 13 12 11 572 18 14 E 15 LT 572 E 5 × 35 mm 16 10 1.9 N • m (0.19 kgf • m, 1.4 ft • Ib) 2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib) 17 1st 3.
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POWR OIL TANK E SERVICE POINTS Oil tank removal 1. Remove: • Oil tank NOTE: Loosen the oil tank bolts and nuts in the sequence shown. 3 1 2 4 8 6 7 5 5 2. Remove: • Oil tank cover • Gasket 8 1 4 2 3 6 4 6 7 7 3. Remove: • Oil breather plate 1 • Oil breather plate 2 • Gasket 3 10 5 NOTE: Loosen the oil tank cover bolts in the sequence shown. 9 2 8 1 NOTE: Loosen the oil breather plate bolts in the sequence shown.
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POWR OIL TANK E 4. Remove: • Oil cooler covers • Gaskets 9 1 NOTE: Loosen the oil cooler cover bolts in the sequence shown. 8 12 2 7 3 6 4 5 10 11 Oil strainer inspection 1. Check: • Oil strainer 1 Damage → Replace. Contaminants → Clean with engine oil. Oil tank installation 1. Install: • Oil cooler covers • Gaskets 4 12 NOTE: Tighten the oil cooler bolts in the sequence shown. 5 1 11 6 T. R. 10 9 7 8 3 2 5-23 Oil cooler cover bolt: 1st: 3.7 N • m (0.37 kgf • m, 2.
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POWR OIL TANK 7 2. Install: • Gasket • Oil breather plate 2 • Oil breather plate 1 8 1 2 6 5 E 4 3 9 NOTE: Tighten the oil breather plate bolts in the sequence shown. 10 T. R. 4 3. Install: • Gasket • Oil tank cover 1 8 5 7 6 3 Oil breather plate bolt: 1st: 1.9 N • m (0.19 kgf • m, 1.4 ft • lb) 2nd: 4.4 N • m (0.44 kgf • m, 3.2 ft • lb) NOTE: Tighten the oil tank cover bolts in the sequence shown. 2 T. R. 5-24 Oil tank cover bolt: 1st: 3.7 N • m (0.37 kgf • m, 2.7 ft • lb) 2nd: 7.
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POWR OIL TANK E 4. Install: • Oil tank NOTE: Tighten the oil tank nuts and bolts in the sequence shown. 2 6 3 8 T. R. 2 7 5 1 2 3 4 1 5-25 Bolt 1: 1st: 15 N • m (1.5 kgf • m, 11 ft • lb) 2nd: 28 N • m (2.8 kgf • m, 20 ft • lb) Nut 2, bolt 3: 1st: 2.0 N • m (0.20 kgf • m, 1.4 ft • lb) 2nd: 15 N • m (1.5 kgf • m, 11 ft • lb) 3rd: 39 N • m (3.
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POWR OIL PUMP E OIL PUMP EXPLODED DIAGRAM 1.4 N • m (0.14 kgf • m, 1.0 ft • Ib) 2nd 10 N • m (0.1 kgf • m, 7.2 ft • Ib) 6 × 25 mm 1st 1.4 N • m (0.14 kgf • m, 1.0 ft • Ib) 2nd 10 N • m (0.1 kgf • m, 7.2 ft • Ib) 6 × 95 mm 1st LT 572 3 4 7 LT 572 7 1 5 2 6 18 N • m (1.
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POWR OIL PUMP E SERVICE POINTS Oil pump removal 1. Remove: • Oil pump assembly NOTE: Loosen the oil pump bolts in the sequence shown. 5 7 6 9 8 12 3 11 1 2 4 10 Oil pump inspection 1. Check: • Oil pump operation Rough movement → Replace the defective part(s). Oil strainer inspection 1. Check: • Oil strainer 1 Damage → Replace. Contaminants → Clean with engine oil.
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POWR OIL PUMP E Oil pump installation 1. Install: • Oil pump assembly NOTE: • Align the projection a on the oil pump assembly with the slit b on the oil pump driven gear shaft. • Tighten the oil pump bolts in the sequence shown. a b T. R. 8 6 7 4 1 5 10 2 12 11 9 3 5-28 Oil pump assembly bolt: 1st: 1.4 N • m (0.14 kgf • m, 1.0 ft • lb) 2nd: 10 N • m (1.0 kgf • m, 7.
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POWR REDUCTION DRIVE GEAR E REDUCTION DRIVE GEAR EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 55 mm 1st 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N • m (2.8 kgf • m, 20 ft • Ib) 8 × 40 mm 1st 9 8 LT 572 12 2 11 LT 4 572 10 9 12 10 E LT 3 572 7 6 5 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 35 mm 1st LT 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N • m (2.
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POWR REDUCTION DRIVE GEAR E EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 55 mm 1st 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N • m (2.8 kgf • m, 20 ft • Ib) 8 × 40 mm 1st 9 8 LT 572 12 2 11 LT 4 572 10 9 12 10 E LT 3 572 7 6 5 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 35 mm 1st LT 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N • m (2.
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POWR REDUCTION DRIVE GEAR E EXPLODED DIAGRAM A *1 15 13 E 14 16 E 5 × 10 mm 9 10 11 9 18 17 12 *1 11 21 8 20 19 E E E E 7 6 1 4 2 E 3 5 E E 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N • m (2.8 kgf • m, 20 ft • Ib) 8 × 40 mm 1st 10 N • m (1.0 kgf • m, 7.
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POWR REDUCTION DRIVE GEAR E EXPLODED DIAGRAM A *1 15 13 E 14 16 E 5 × 10 mm 9 10 11 9 18 17 12 *1 11 21 8 20 19 E E E E 7 6 1 2 E E 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 × 16 mm Step 9 10 11 12 13 14 Circlip Driven gear Washer Circlip Oil seal Bearing Q’ty 2 1 2 1 2 1 15 16 17 Drive shaft Circlip Circlip 1 1 1 *1: 3 5 E 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N • m (2.
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POWR REDUCTION DRIVE GEAR E EXPLODED DIAGRAM A *1 15 13 E 14 16 E 5 × 10 mm 9 10 11 9 18 17 12 *1 11 21 8 20 19 E E E E 7 6 1 2 E Procedure/Part name Bearing Circlip Bearing Reduction drive gear case 3 5 E E 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 28 N • m (2.8 kgf • m, 20 ft • Ib) 8 × 40 mm 1st Step 18 19 20 21 4 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 × 16 mm Q’ty 1 1 1 1 Service points Not reusable Not reusable Not reusable Reverse the disassembly steps for assembly.
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POWR REDUCTION DRIVE GEAR E SERVICE POINTS Drive coupling removal 1. Remove: • Drive coupling 1 1 4 NOTE: While holding the flywheel magneto 2 with the sheave holder 3, loosen the drive coupling with coupler wrench 4. Coupler wrench: YW-06551/90890-06551 Sheave holder: YS-01880-A/90890-01701 3 2 Drive shaft removal 1. Remove: • Circlip • Drive shaft NOTE: Press in the direction of the arrow. Oil pump driven gear inspection 1. Check: • Oil pump driven gear 1 Cracks/damage/wear → Replace.
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POWR REDUCTION DRIVE GEAR E Drive shaft installing 1. Install: • Drive shaft NOTE: Press in the direction of the arrow. 2. Install: • Oil seals 1 Distance a: 8.9–9.3 mm (0.35–0.37 in) a 1 Drive coupling installation 1. Install: • Drive coupling 1 1 4 NOTE: While holding the flywheel magneto 2 with the sheave holder 3, tighten the drive coupling with coupler wrench 4.
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POWR GENERATOR AND STARTER MOTOR E GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 30 mm A 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 3 4 1 5 2 A 15 6 22 16 75 N • m (7.5 kgf • m, 54 ft • Ib) 10 × 47 mm E 21 20 18 13 17 8 A E 19 7 10 E 9 LT 11 5 × 10 mm 572 12 24 N • m (2.4 kgf • m, 17 ft • Ib) 8 × 20 mm 14 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 50 N • m (5.
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POWR GENERATOR AND STARTER MOTOR E EXPLODED DIAGRAM 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 30 mm A 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 3 4 1 5 2 A 15 6 22 16 75 N • m (7.5 kgf • m, 54 ft • Ib) 10 × 47 mm E 21 20 18 13 17 8 A E 19 7 10 E 9 LT 11 5 × 10 mm Step 9 10 11 12 13 14 15 16 17 18 19 572 12 24 N • m (2.4 kgf • m, 17 ft • Ib) 8 × 20 mm 14 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 50 N • m (5.
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POWR GENERATOR AND STARTER MOTOR E EXPLODED DIAGRAM 18 N • m (1.8 kgf • m, 13 ft • Ib) 8 × 30 mm A 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 3 4 1 5 2 A 15 6 22 16 75 N • m (7.5 kgf • m, 54 ft • Ib) 10 × 47 mm E 21 20 18 13 17 8 A E 19 7 10 E 9 LT 11 5 × 10 mm Step 20 21 22 572 12 24 N • m (2.4 kgf • m, 17 ft • Ib) 8 × 20 mm 14 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 50 N • m (5.
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POWR GENERATOR AND STARTER MOTOR E EXPLODED DIAGRAM 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 10 mm 1 LT 242 7 1 LT 1 242 6 3 3 2 5 LT LT 242 2 242 4 6 × 14 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) 5 × 14 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 33 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) REMOVAL AND INSTALLATION CHART Step 1 2 3 Procedure/Part name GENERATOR DISASSEMBLY Bolt/washer Bolt Pulser coil 4 Bolt Q’ty 3/3 4 2 2 5-39 Service points Follow the left “Step” for disassembly.
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POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 10 mm 1 LT 242 7 1 LT 1 242 6 3 3 2 5 LT LT 242 242 2 4 6 × 14 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) 5 × 14 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 33 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) Step 5 6 7 Procedure/Part name Holder Bolt Lighting coil Q’ty 1 3 1 Service points Reverse the disassembly steps for assembly.
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POWR GENERATOR AND STARTER MOTOR E SERVICE POINTS Flywheel magneto removal 1. Remove: • Flywheel magneto bolt 1 • Washer NOTE: While holding the flywheel magneto 2 with the sheave holder 3, loosen the flywheel magneto bolt. Sheave holder: YS-01880-A/90890-01701 2. Remove: • Flywheel magneto 1 • Woodruff key NOTE: While holding the flywheel magneto with sheave holder 2, remove the flywheel magneto with the rotor puller 3. Rotor puller: YM-01082/90890-01080 Starter clutch inspection 1.
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POWR 1 GENERATOR AND STARTER MOTOR E 2. Check: • Starter clutch 1 • Starter gear 2 Burrs/chips/roughness/wear → Replace the defective part(s). 2 a 3. Check: • Starter clutch gear’s contacting surfaces a Damage/pitting/wear → Replace the starter clutch gear. 4. Check: • Starter clutch operation Checking steps: • Install the starter gear 1 onto the starter clutch 2 and hold the starter clutch.
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POWR GENERATOR AND STARTER MOTOR E Flywheel magneto installation 1. Install: • Woodruff key • Flywheel magneto • Washer • Flywheel magneto bolt NOTE: • Clean the tapered portion of the crankshaft and the flywheel magneto hub. • When installing the flywheel magneto, make sure the woodruff key is properly seated in the keyway of the crankshaft. • Lubricate the flywheel magneto bolt and washer with engine oil. 2.
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POWR CAMSHAFTS E CAMSHAFTS EXPLODED DIAGRAM 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 × 16 mm 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 1st 7 È a 6 5 3 2 É LT 4 572 8 12 LT 572 9 10 14 11 E 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 6 × 22 mm 13 1 13 N • m (1.3 kgf • m, 9.
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POWR CAMSHAFTS E EXPLODED DIAGRAM 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 × 16 mm 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 1st 7 È a 6 5 3 2 É LT 4 572 8 12 LT 572 9 10 14 11 E 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 6 × 22 mm 13 1 13 N • m (1.3 kgf • m, 9.
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POWR CAMSHAFTS E EXPLODED DIAGRAM 6 × 35 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 10 11 10 11 10 11 24 N • m (2.4 kgf • m, 17 ft • Ib) 7 × 11 mm E 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 × 35 mm 17 E 7 16 E 8 12 18 E 8 24 N • m (2.4 kgf • m, 17 ft • Ib) 7 × 11 mm E 9 14 8 M 13 20 15 E 6 M 19 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 × 8 mm 2 5 1 4 6 × 25 mm 10 N • m (1.0 kgf • m, 7.
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POWR CAMSHAFTS E EXPLODED DIAGRAM 6 × 35 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 10 11 10 11 10 11 24 N • m (2.4 kgf • m, 17 ft • Ib) 7 × 11 mm E 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 × 35 mm 17 E 7 16 E 8 12 18 E 8 24 N • m (2.4 kgf • m, 17 ft • Ib) 7 × 11 mm E 9 14 8 M 13 20 15 E 6 M 19 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 × 8 mm 2 5 1 4 6 × 25 mm 10 N • m (1.0 kgf • m, 7.
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POWR CAMSHAFTS E EXPLODED DIAGRAM 6 × 35 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 10 11 10 11 10 11 24 N • m (2.4 kgf • m, 17 ft • Ib) 7 × 11 mm E 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 × 35 mm 17 E 7 16 E 8 12 18 E 8 24 N • m (2.4 kgf • m, 17 ft • Ib) 7 × 11 mm E 9 14 8 13 M 20 15 E 6 M 19 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 × 8 mm 2 5 1 4 6 × 25 mm 10 N • m (1.0 kgf • m, 7.
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POWR CAMSHAFTS E SERVICE POINTS Camshaft removal 1. Install: • Dial gauge needle • Dial gauge stand 1 (into spark plug hole #1) • Dial gauge 2 2 1 Dial gauge stand: 90890-06583 Dial gauge needle: 90890-06584 Dial gauge stand set: YW-06585/90890-06585 Dial gauge: YU-03097/90890-01252 2. Turn the drive coupling counterclockwise, and then check if cylinder #1 is at TDC of the compression stroke with a dial gauge.
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POWR CAMSHAFTS E 4. Remove: • Timing chain tensioner 1 • Gasket 1 3 6 7 10 5 3 9 4 8 6 9 13 17 8 2 16 12 1 5 7 10 4 1115 1814 2 5. Remove: • Camshaft caps • Dowel pins 1 NOTE: Loosen the intake and exhaust camshaft cap bolts in the sequence shown. 6. Remove: • Intake camshaft 1 • Exhaust camshaft 2 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire 3. Camshaft inspection 1.
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POWR CAMSHAFTS E 3. Measure: • Camshaft runout Out of specification → Replace. Maximum camshaft runout: 0.03 mm (0.0012 in) 4. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft journal diameter. Camshaft-journal-to-camshaftcap clearance: 0.05–0.08 mm (0.0020–0.0031 in) 8 5 4 1 6 16 10 7 11 13 2 6 2 3 9 3 7 18 14 12 9 15 8 4 1 5 17 Measurement steps: • Install the camshaft into the cylinder head (without the dowel pins and camshaft caps).
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POWR CAMSHAFTS E 5. Measure: • Camshaft journal diameter a Out of specification → Replace the camshaft. Within specification → Replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter: 24.44–24.45 mm (0.9622–0.9626 in) Camshaft sprockets inspection 1. Check: • Camshaft sprocket Wear/damage → Replace the camshaft sprockets and timing chain as a set. a b 1 2 1/4 of a tooth Correct Timing chain Camshaft sprocket Timing chain tensioner inspection 1.
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POWR CAMSHAFTS E Camshaft installation 1. Install: • Exhaust camshaft sprocket 1 • Intake camshaft sprocket 2 (with the special tool 3) Rotor holder: YU-01235/90890-01235 NOTE: Install the camshaft sprocket with the punch mark a facing outside. T. Camshaft sprocket bolt: 24 N • m (2.4 kgf • m, 17 ft • lb) R. 2.
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POWR CAMSHAFTS 8 5 4 1 6 16 10 7 11 13 2 6 2 3 9 3 7 18 14 12 9 15 8 4 1 5 17 E • Install the exhaust and intake camshaft caps. 10 NOTE: Gradually tighten the intake and exhaust camshaft cap bolts in 2–3 steps in the sequence shown. T. Camshaft cap bolt: 10 N • m (1.0 kgf • m, 7.2 ft • lb) R. NOTE: Make sure that the punch marks c on the camshafts are aligned with the arrow marks d on the camshaft caps. Out of alignment → Reinstall. • Remove the wire from the timing chain. 3.
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POWR CAMSHAFTS E • Tighten the timing chain tensioner bolts 3 to the specified torque. NOTE: The “UP” mark on the timing chain tensioner should face up. T. Timing chain tensioner bolt: 10 N • m (1.0 kgf • m, 7.2 ft • lb) R. • Remove the screwdriver, make sure the timing chain tensioner rod releases, and then tighten the cap bolt to the specified torque. T. Cap bolt: 10 N • m (1.0 kgf • m, 7.2 ft • lb) R. 4. Turn: • Drive coupling (several turns counterclockwise) 5.
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POWR CAMSHAFTS E 7. Install: • Cylinder head cover gasket • Cylinder head cover NOTE: • Apply Gasket Maker® onto the mating surfaces of the cylinder head cover gasket and cylinder head. • Tighten the cylinder head cover bolts stages and in a crisscross pattern. T. R. 5-56 Cylinder head cover bolt: 12 N • m (1.2 kgf • m, 8.
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POWR CYLINDER HEAD E CYLINDER HEAD EXPLODED DIAGRAM 20 N • m (2.0 kgf • m, 14 ft • Ib) 2nd 49 N • m (4.9 kgf • m, 35 ft • Ib) 1st 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 × 12 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 × 55 mm 20 N • m (2.0 kgf • m, 14 ft • Ib) 2nd 64 N • m (6.4 kgf • m, 46 ft • Ib) 1st 3 E 5 E 5 5 E 5 5 E 4 E 2 E 6 1 LT 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 × 12 mm 7 271 8 40 N • m (4.
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POWR CYLINDER HEAD E EXPLODED DIAGRAM 20 N • m (2.0 kgf • m, 14 ft • Ib) 2nd 49 N • m (4.9 kgf • m, 35 ft • Ib) 1st 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 × 12 mm 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 × 55 mm 20 N • m (2.0 kgf • m, 14 ft • Ib) 2nd 64 N • m (6.4 kgf • m, 46 ft • Ib) 1st 3 E 5 E 5 5 E 5 5 E 4 E 2 E 6 1 LT 10 N • m (1.0 kgf • m, 7.2 ft • Ib) 6 × 12 mm 7 271 8 40 N • m (4.
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POWR CYLINDER HEAD E SERVICE POINTS Cylinder head removal 1. Remove: • Cylinder head bolts 1 2. Remove: • Cylinder head nuts NOTE: Loosen the cylinder head nuts in the sequence shown. Cylinder head inspection 1. Eliminate: • Combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: • spark plug bore threads • valve seats 2. Check: • Cylinder head Damage/scratches → Replace.
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POWR CYLINDER HEAD E 3. Measure: • Cylinder head warpage Out of specification → Replace the cylinder head. Cylinder head warpage limit: 0.1 mm (0.004 in) Measurement steps: • Place a straightedge 1 and a thickness gauge 2 across the cylinder head. • Measure the warpage. • If the limit is exceeded, replace the cylinder head. Cylinder head installation 1. Install: • Cylinder head NOTE: • Pass the timing chain through the timing chain cavity. • Lubricate the cylinder head nuts with engine oil.
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POWR CYLINDER HEAD E 2. Tighten: • Cylinder head bolts 1 NOTE: Lubricate the cylinder head bolts with engine oil. T. R. 5-61 Cylinder head bolt: 10 N • m (1.0 kgf • m, 7.
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POWR VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EXPLODED DIAGRAM 10 11 12 13 14 1 2 3 4 5 3 E 12 15 16 6 7 E 18 9 8 17 E REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 Procedure/Part name VALVES AND VALVE SPRINGS REMOVAL Cylinder head Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve oil seal Intake valve lower spring seat Intake valve Intake valve guide Q’ty Service points Follow the left “Step” for remova
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POWR VALVES AND VALVE SPRINGS E EXPLODED DIAGRAM 10 11 12 13 14 1 2 3 4 5 3 E 12 15 16 6 7 E 18 9 8 17 E Step 10 11 12 13 14 15 16 17 18 Procedure/Part name Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide Q’ty 8 8 16 8 8 8 8 8 8 Service points Reverse the removal steps for installation.
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POWR VALVES AND VALVE SPRINGS E SERVICE POINTS Valve removal 1. Remove: • Valve lifter 1 • Valve pad 2 NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place. 2. Remove: • Valve cotters 1 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3.
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POWR VALVES AND VALVE SPRINGS E Valve spring inspection 1. Measure: • Valve spring free length a Out of specification → Replace the valve spring. Valve spring free length: Intake valve spring: 38.90 mm (1.53 in) Exhaust valve spring: 40.67 mm (1.60 in) 2. Measure: • Valve spring tilt a Out of specification → Replace the valve spring. Valve spring tilt: Intake valve spring: 1.7 mm (0.067 in) Exhaust valve spring: 1.8 mm (0.071 in) Valve inspection 1.
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POWR VALVES AND VALVE SPRINGS E 4. Measure: • Valve stem diameter a Out of specification → Replace the valve. Valve stem diameter a: Intake valve: 3.975–3.990 mm (0.1565–0.1571 in) Exhaust valve: 4.460–4.475 mm (0.1756–0.1762 in) 5. Measure: • Valve stem runout Out of specification → Replace the valve. NOTE: • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always replace the oil seal. Valve stem runout: 0.01 mm (0.
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POWR VALVES AND VALVE SPRINGS E 1. Measure: • Valve guide inside diameter a Valve guide inside diameter: Intake: 4.000–4.012 mm (0.1575–0.1580 in) Exhaust: 4.500–4.512 mm (0.1772–0.1776 in) a 2. Calculate the valve stem-to-valve guide clearance as follows. Replace the valve guide if out of specification. Valve stem-to-valve guide clearance = valve guide inside diameter – valve stem diameter: Intake: 0.010–0.037 mm (0.0004–0.0015 in) Exhaust: 0.025–0.052 mm (0.0010–0.0020 in) Valve guide replacement 1.
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POWR VALVES AND VALVE SPRINGS E 2. Install the new valve guide 2 by striking the special service tool from the camshaft side until the valve guide clip 3 contacts the cylinder head. 2 NOTE: Apply engine oil to the surface of the new valve guide. E 3 Valve guide remover: Intake (4.0 mm): YM-04111/90890-04111 Exhaust (4.5 mm): YM-04116/90890-04116 Valve guide installer: Intake (4.0 mm): YM-04112/90890-04112 Exhaust (4.5 mm): YM-04117/90890-04117 3.
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POWR VALVES AND VALVE SPRINGS E Valve seat inspection 1. Eliminate carbon deposits from the valve with a scraper. 2. Apply a thin, even layer of Mechanic’s blueing dye (Dykem) onto the valve seat. 3. Lap the valve slowly on the valve seat with a valve lapper (commercially obtainable) as shown. 4. Measure the valve seat contact width a where the blueing dye is adhered to the valve face. Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification.
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POWR VALVES AND VALVE SPRINGS E Valve seat reface 1. Reface the valve seat with the valve seat cutter. Valve seat cutter holder: Intake (4.0 mm): 90890-06811 Exhaust (4.5 mm): 90890-06812 Valve seat cutter: 30° (intake): 90890-06815 45° (intake): 90890-06814 60° (intake): 90890-06813 30° (exhaust): 90890-06328 45° (exhaust): 90890-06312 60° (exhaust): 90890-06315 Valve seat cutter set: YM-91043-C 2.
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POWR VALVES AND VALVE SPRINGS E 4. Use a 60° cutter to adjust the contact width of the bottom edge of the valve seat. b b Previous contact width 60˚ 5. Use a 45° cutter to adjust the contact width of the valve seat to specification. b b Previous contact width c Specified contact width c 45˚ 6.
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POWR VALVES AND VALVE SPRINGS E 9. Apply a thin, even layer of lapping compound onto the valve seat, and then lap the valve using a valve lapper (commercially obtainable). CAUTION: Do not get the lapping compound on the valve stem and valve guide. 10. After every lapping procedure, be sure to clean off any remaining lapping compound from the cylinder head and the valve. 11. Check the valve seat contact area of the valve again. Valve installation 1.
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POWR VALVES AND VALVE SPRINGS E 2. Compress the valve spring, and then install the valve cotter 1 using a thin screwdriver with a small amount of grease applied to it. Valve spring compressor: YM-04019/90890-04019 Valve spring compressor attachment: (for the intake valve) YM-4114/90890-04114 (for the exhaust valve) YM-4108/90890-04108 3. Lightly tap the valve spring retainer with a plastic hammer to set the valve cotter securely.
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POWR CRANKCASE E CRANKCASE EXPLODED DIAGRAM 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 6 × 20 mm 8.4 N • m (0.84 kgf • m, 6.1 ft • Ib) 20 N • m (2.0 kgf • m, 14 ft • Ib) 8 × 40 mm LT 7 271 LT 9 10 11 572 1 8 15 N • m (1.5 kgf • m, 11 ft • Ib) 2 6 3 A 22 23 4 21 5 LT 22 572 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 20 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 2nd 15 N • m (1.5 kgf • m, 11 ft • Ib) 3rd 49 ± 5˚ 9 × 105 mm 1st LT 6 × 70 mm 12 N • m (1.2 kgf • m, 8.
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POWR CRANKCASE E EXPLODED DIAGRAM 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 6 × 20 mm 8.4 N • m (0.84 kgf • m, 6.1 ft • Ib) 20 N • m (2.0 kgf • m, 14 ft • Ib) 8 × 40 mm LT 7 271 LT 9 10 11 572 1 8 15 N • m (1.5 kgf • m, 11 ft • Ib) 2 6 3 A 22 23 4 21 5 LT 22 572 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 20 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 2nd 15 N • m (1.5 kgf • m, 11 ft • Ib) 3rd 49 ± 5˚ 9 × 105 mm 1st LT 6 × 70 mm 12 N • m (1.2 kgf • m, 8.
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POWR CRANKCASE E EXPLODED DIAGRAM 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 6 × 20 mm 8.4 N • m (0.84 kgf • m, 6.1 ft • Ib) 20 N • m (2.0 kgf • m, 14 ft • Ib) 8 × 40 mm LT 7 271 LT 9 10 11 572 1 8 15 N • m (1.5 kgf • m, 11 ft • Ib) 2 6 3 A 22 23 4 21 5 LT 22 572 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 20 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 2nd 15 N • m (1.5 kgf • m, 11 ft • Ib) 3rd 49 ± 5˚ 9 × 105 mm 1st LT 6 × 70 mm 12 N • m (1.2 kgf • m, 8.
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POWR CRANKCASE E EXPLODED DIAGRAM 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 6 × 20 mm 8.4 N • m (0.84 kgf • m, 6.1 ft • Ib) 20 N • m (2.0 kgf • m, 14 ft • Ib) 8 × 40 mm LT 7 271 LT 9 10 11 572 1 8 15 N • m (1.5 kgf • m, 11 ft • Ib) 2 6 3 A 22 23 4 21 5 LT 22 572 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 20 7.8 N • m (0.78 kgf • m, 5.6 ft • Ib) 2nd 15 N • m (1.5 kgf • m, 11 ft • Ib) 3rd 49 ± 5˚ 9 × 105 mm 1st LT 6 × 70 mm 12 N • m (1.2 kgf • m, 8.
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POWR CRANKCASE E EXPLODED DIAGRAM 6 × 10 mm 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 1 2 E A 3 8 E 7 6 35 N • m (3.5 kgf • m, 25 ft • Ib) 5 4 LT 572 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 6 × 12 mm REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name OIL PIPE AND OIL FILTER BOLT REMOVAL Crankshaft Bolt Oil pipe O-ring Screw Cover O-ring Oil filter bolt Lower crankcase Q’ty Service points Follow the left “Step” for removal. Refer to “CRANKSHAFT”.
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POWR CRANKCASE E SERVICE POINTS 6 10 13 H 9 4 2 5 1 3 Crankcase disassembly 1. Remove: • Oil pan bolts 8 NOTE: • Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration). • The numbers embossed on the oil pan indicate the oil pan tightening sequence. 12 7 11 F B D J 8 6 2 4 0 9 3 1 5 7 C A E I 2.
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POWR CRANKCASE E 4. Remove: • Dowel pins Crankcase inspection 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • Crankcase Cracks/damage → Replace. • Oil delivery passages Obstruction → Blow out with compressed air. Timing chain inspection 1. Check: • Timing chain 1 Damage/stiffness → Replace the timing chain and camshaft sprockets as a set. Crankcase assembly 1.
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POWR CRANKCASE E 2. Apply: • Gasket Maker® (onto the crankcase mating surfaces) GM 1 NOTE: Do not allow any Gasket Maker® to come into contact with the oil gallery or crankshaft journal bearings. 12 1 3. Install: • Dowel pins 1 • O-ring 2 H F B D J 8 6 2 4 0 9 3 1 5 7 C A E F B D J 8 6 2 4 0 9 3 1 5 7 C A E I H I 4. Install: • Crankcase bolts NOTE: • Lubricate the bolt 1–0 threads and washers with engine oil. • Finger tighten the crankcase bolts.
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POWR CRANKCASE E Tightening steps: • Tighten the bolts in the tightening sequence cast on the crankcase. T. R. Crankcase bolt 1–0: 1st: 7.8 N • m (0.78 kgf • m, 5.6 ft • lb) • Loosen and retighten the crankcase bolts in the proper tightening sequence as shown. T. R. Crankcase bolt 1–0: 2nd: 15 N • m (1.5 kgf • m, 11 ft • lb) • Tighten the crankcase bolts further to reach the specified angle 49° in the proper tightening sequence as shown. T. R.
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POWR H CRANKCASE J F B D 8 6 2 4 0 9 3 1 5 7 C A E 6. Tighten: • Crankcase bolts A–J NOTE: Tighten the bolts in the tightening sequence cast on the crankcase. G T. Crankcase bolt A–J: 12 N • m (1.2 kgf • m, 8.7 ft • lb) R. I E 7. Tighten: • Oil pan bolts 6 10 13 9 4 2 5 1 3 NOTE: Tighten the bolts in the tightening sequence cast on the oil pan. 8 12 7 11 T. R. 5-83 Oil pan bolt: 12 N • m (1.2 kgf • m, 8.
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POWR CONNECTING RODS AND PISTONS E CONNECTING RODS AND PISTONS EXPLODED DIAGRAM 10 11 12 E E 4 5 6 8 7 9 E E 3 2 1 1st 20 N • m (2.0 kgf • m, 14 ft • Ib) 2nd 120 ± 5˚ REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name CONNECTING RODS AND PISTONS REMOVAL Crankcase Nut Connecting rod cap Big end lower bearing Piston pin clip Piston pin Piston Connecting rod Q’ty 8 4 4 8 4 4 4 5-84 Service points Follow the left “Step” for removal. Separate Refer to “CRANKCASE”.
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POWR CONNECTING RODS AND PISTONS E EXPLODED DIAGRAM 10 11 12 E E 4 5 6 8 7 9 E E 3 2 1 1st 20 N • m (2.0 kgf • m, 14 ft • Ib) 2nd 120 ± 5˚ Step 8 9 10 11 12 Procedure/Part name Bolt Big end upper bearing Top ring 2nd ring Oil ring Q’ty 8 4 4 4 4 Service points Not reusable Reverse the removal steps for installation.
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POWR CONNECTING RODS AND PISTONS E SERVICE POINTS 1 Connecting rod and piston removal The following procedure applies to all of the connecting rods and pistons. 1. Remove: • Connecting rod cap 1 • Big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place. 2. Remove: • Piston pin clips 1 • Piston pin 2 • Piston 3 • Connecting rod 4 CAUTION: Do not use a hammer to drive the piston pin out.
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POWR CONNECTING RODS AND PISTONS E 3. Remove: • Top ring • 2nd ring • Oil ring NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. Cylinder and piston inspection The following procedure applies to all of the cylinders and pistons. 1. Check: • Piston wall • Cylinder wall Vertical scratches → Replace the cylinder, and the piston and piston rings as a set. 2.
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POWR CONNECTING RODS AND PISTONS E • If out of specification, replace the piston and piston rings as a set. • Measure piston skirt diameter “P” with the micrometer. a 5 mm (0.2 in) from the bottom edge of the piston Piston size “P” Standard 73.955–73.970 mm (2.9116–2.9121 in) • If out of specification, replace the piston and piston rings as a set. • Calculate the piston-to-cylinder clearance with the following formula.
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POWR CONNECTING RODS AND PISTONS E 2. Install: • Piston ring (into the cylinder) NOTE: Level the piston ring in the cylinder with the piston crown. a 5 mm (0.2 in) 3. Measure: • Piston ring end gap Out of specification → Replace the piston ring. NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is excessive, replace all three piston rings. Piston ring end gap: Top ring: 0.38–0.55 mm (0.0150–0.0217 in) 2nd ring: 0.49–0.69 mm (0.0193–0.0272 in) Oil ring: 0.29–0.
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POWR CONNECTING RODS AND PISTONS E 2. Measure: • Piston pin outside diameter a Out of specification → Replace the piston pin. Piston pin outside diameter: 16.991–17.000 mm (0.6689–0.6693 in) : 16.971 mm (0.6681 in) 3. Measure: • Piston pin bore diameter (in the piston) b Out of specification → Replace the piston. Piston pin bore diameter (in the piston): 17.002–17.013 mm (0.6693–0.6698 in) 4. Calculate: • Piston-pin-to-piston clearance Out of specification → Replace the piston pin.
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POWR CONNECTING RODS AND PISTONS E Connecting rod inspection 1. Measure: • Crankshaft-pin-to-big-end-bearing clearance Out of specification → Replace the big end bearings. Crankshaft-pin-to-big-endbearing clearance: 0.016–0.040 mm (0.0006–0.0016 in) Measurement steps: The following procedure applies to all of the connecting rods. CAUTION: Do not interchange the big end bearings and connecting rods.
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POWR CONNECTING RODS AND PISTONS E d NOTE: • Do not move the connecting rod or crankshaft until the clearance measurement has been completed. • Lubricate the bolts threads and nut seats with molybdenum disulfide grease. • Make sure the “Y” mark c on the connecting rod faces towards the front side of the crankshaft. • Make sure the characters d on both the connecting rod and connecting rod cap are aligned. c • Tighten the connecting rod nuts. Refer to “Connecting rod and piston installation”.
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POWR CONNECTING RODS AND PISTONS E For example, if the connecting rod “P1” and the crankshaft web “P1” numbers are “5” and “1” respectively, then the bearing size for “P1” is: Bearing size of P1: “P1” (connecting rod) – “P1” (crankshaft web) 5 – 1 = 4 (green) 5G BEARING COLOR CODE P1 P2 P3 P4 1 brown 2 black 3 blue 4 green Connecting rod and piston installation The following procedure applies to all of the pistons and connecting rods. 1.
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POWR CONNECTING RODS AND PISTONS E 3. Offset: • Piston ring end gaps a b c d È Top ring Lower oil ring rail Upper oil ring rail 2nd ring Intake side 4. Lubricate: • Piston • Piston rings • Cylinder (with the recommended lubricant) Recommended lubricant: Engine oil 5. Lubricate: • Bolt threads • Nut seats (with the recommended lubricant) Recommended lubricant: Molybdenum disulfide grease 6.
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POWR CONNECTING RODS AND PISTONS E 7. Install: • Big end bearings • Connecting rod assembly 1 (into the cylinder and onto the crankshaft pin) • Connecting rod cap (onto the crankshaft pin) NOTE: • Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps. • Be sure to reinstall each big end bearing in its original place.
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POWR CONNECTING RODS AND PISTONS E 9. Tighten: • Connecting rod nuts WARNING • Replace the connecting rod bolts and nuts with new ones. • Clean the connecting rod bolts and nuts. NOTE: The tightening procedure of the connecting rod nuts is angle controlled, therefore tighten the nuts using the following procedure. Tightening steps: • Tighten the connecting rod nuts to the specified torque. T. R. Connecting rod nut: 1st: 20 N • m (2.
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POWR CRANKSHAFT E CRANKSHAFT EXPLODED DIAGRAM 3 3 1 2 2 REMOVAL AND INSTALLATION CHART Step Procedure/Part name CRANKSHAFT REMOVAL Crankcase Q’ty Connecting rod caps 1 2 3 Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Service points Follow the left “Step” for removal. Separate Refer to “CRANKCASE”. Refer to “CONNECTING RODS AND PISTONS”. 1 5 5 Reverse the removal steps for installation.
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POWR CRANKSHAFT E SERVICE POINTS Crankshaft removal 1. Remove: • Crankshaft 1 • Crankshaft journal lower bearings (from the lower crankcase) • Crankshaft journal upper bearings (from the upper crankcase) 1 NOTE: Identify the position of each crankshaft journal bearing so that it can be reinstalled in its original place. Crankshaft inspection 1. Measure: • Crankshaft runout Out of specification → Replace the crankshaft. Maximum crankshaft runout: 0.03 mm (0.0012 in) 2.
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POWR CRANKSHAFT E CAUTION: Do not interchange the crankshaft journal bearings. To obtain the correct crankshaftjournal-to-crankshaft-journal-bearing clearance and prevent engine damage, the crankshaft journal bearings must be installed in their original positions. a Measurement steps: • Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase. • Place the upper crankcase upside down on a bench.
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POWR CRANKSHAFT E • Tighten the bolts to specification in the tightening sequence cast on the crankcase. Refer to “Crankcase assembly”— “CRANKCASE”. • Remove the lower crankcase and the crankshaft journal lower bearings. • Measure the compressed Plastigauge® width c on each crankshaft journal. If the crankshaft-journal-to-crankshaftjournal-bearing clearance is out of specification, select replacement crankshaft journal bearings. c 4.
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POWR CRANKSHAFT E Crankshaft installation 1. Install: • Crankshaft journal upper bearings (into the upper crankcase) • Crankshaft journal lower bearings (into the lower crankcase) a b NOTE: • Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase. • Be sure to install each crankshaft journal bearing in its original place. 2.
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POWR THERMOSTAT E THERMOSTAT EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 35 mm 1st a 3 É 3 4 1 7 9 8 LT 572 6 5 2 1 È REMOVAL AND INSTALLATION CHART Step Q’ty 1 2 3 Procedure/Part name THERMOSTAT REMOVAL Band Clamp/cooling water hose Clamp/cooling water hose 4 Clamp/cooling water hose 1/1 5 6 7 Band/grease hose Bolt Thermostat housing cover 1/1 2 1 2 1/1 2/1 5-102 Service points Follow the left “Step” for removal.
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POWR THERMOSTAT E EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 35 mm 1st a 3 É 3 4 1 7 9 8 LT 572 6 5 2 1 È REMOVAL AND INSTALLATION CHART Step 8 9 Procedure/Part name Thermostat Thermostat housing Q’ty 1 1 Service points Reverse the removal steps for installation.
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POWR THERMOSTAT E SERVICE POINTS Thermostat inspection 1. Check: • Thermostat 1 Does not open at 50–60 °C (123– 141 °F) → Replace. Checking steps: • Suspend the thermostat in a container filled with water. • Slowly heat the water. • Place a thermometer in the water. • While stirring the water, observe the thermostat and thermometer’s indicated temperature.
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POWR PRESSURE CONTROL VALVE E PRESSURE CONTROL VALVE EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 1st 2nd 7.6 N • m (0.76 kgf • m, 5.
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POWR PRESSURE CONTROL VALVE E EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 1st 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 45 mm È È È È LT 572 11 9 10 Ì 1 8 3 8 2 É Ê É 3 6 2 4 5 4 Ë 7 REMOVAL AND INSTALLATION CHART Step 9 10 11 Procedure/Part name Bolt Pressure control valve assembly Gasket Q’ty 3 1 1 5-106 Service points Not reusable Reverse the removal steps for installation.
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POWR PRESSURE CONTROL VALVE E EXPLODED DIAGRAM 9 5 6 4 7 8 6 3 2 LT 572 1 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 40 mm 1st REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name PRESSURE CONTROL VALVE DISASSEMBLY Bolt Collar Pressure control valve housing cover Spring Pressure control valve Gasket Plate Q’ty Service points Follow the left “Step” for disassembly.
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POWR PRESSURE CONTROL VALVE E EXPLODED DIAGRAM 9 5 6 4 7 8 6 3 2 LT 572 1 Step 8 9 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 40 mm 1st Procedure/Part name Grommet Pressure control valve housing Q’ty 1 1 Service points Reverse the disassembly steps for assembly.
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POWR PRESSURE CONTROL VALVE E SERVICE POINTS Pressure control valve inspection 1. Check: • Pressure control valve 1 • Spring 2 Damage/wear → Replace the defective part(s). 2. Check: • Pressure control valve housing cover • Pressure control valve housing Cracks/damage → Replace. 3. Check: • Cooling system Leaks → Repair or replace any faulty part.
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JET PUMP E CHAPTER 6 JET PUMP UNIT INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT....................................6-1 EXPLODED DIAGRAM .............................................................................6-1 REMOVAL AND INSTALLATION CHART ................................................ 6-1 JET PUMP UNIT.............................................................................................. 6-3 EXPLODED DIAGRAM .............................................................................
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JET PUMP TRANSOM PLATE AND HOSES.................................................................. 6-19 EXPLODED DIAGRAM ...........................................................................6-19 REMOVAL AND INSTALLATION CHART .............................................. 6-19 SERVICE POINTS .................................................................................. 6-22 Bilge strainer inspection ....................................................................
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JET PUMP INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT E INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT REMOVAL Bolt Bolt Intake grate Screw Speed sensor 6 Bolt Q’ty 2 2 1 4 1 4 6-1 Service points Follow the left “Step” for removal. NOTE: Route the speed sensor lead between the jet pump unit and the bilge hose.
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JET PUMP INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT E EXPLODED DIAGRAM Step 7 8 9 10 Procedure/Part name Ride plate Bolt Intake duct Felt packing Q’ty 1 4 1 1 6-2 Service points Not reusable Reverse the removal steps for installation.
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JET PUMP JET PUMP UNIT E JET PUMP UNIT EXPLODED DIAGRAM 6.8 N • m (0.68 kgf • m, 4.9 ft • Ib) 6 × 22 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) 8 × 24 mm 9 7 LT 8 271 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib) 5 6 LT A 242 2 4 12 11 40 N • m (4.0 kgf • m, 29 ft • Ib) 10 × 95 mm 1 LT 572 10 14 13 4 4 LT 3 572 6.8 N • m (0.68 kgf • m, 4.9 ft • Ib) 15 M 4 6 × 80 mm 7.8 N • m (0.78 kgf • m, 5.
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JET PUMP JET PUMP UNIT E EXPLODED DIAGRAM 6.8 N • m (0.68 kgf • m, 4.9 ft • Ib) 6 × 22 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) 8 × 24 mm 9 7 LT 8 271 2.2 N • m (0.22 kgf • m, 1.6 ft • Ib) 5 6 LT A 242 2 4 12 11 40 N • m (4.0 kgf • m, 29 ft • Ib) 10 × 95 mm 1 LT 572 10 14 13 4 4 LT 3 572 6.8 N • m (0.68 kgf • m, 4.
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JET PUMP JET PUMP UNIT E EXPLODED DIAGRAM 1 2 FWD REMOVAL AND INSTALLATION CHART Step 1 2 Procedure/Part name SPEED SENSOR DISASSEMBLY Paddle wheel set Speed sensor Q’ty 1 1 Service points Follow the left “Step” for disassembly. Not reusable Reverse the disassembly steps for assembly.
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JET PUMP REVERSE GATE E REVERSE GATE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name REVERSE GATE REMOVAL Clamp/spout hose Bolt Washer Collar Reverse gate assembly Nut Bolt Washer Q’ty 1/1 2 2 2 1 1 1 2 6-6 Service points Follow the left “Step” for removal.
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JET PUMP REVERSE GATE E EXPLODED DIAGRAM Step 9 10 11 12 13 14 15 16 17 Procedure/Part name Roller Bolt Reverse gate stay Nut Washer Bolt Lever 1 Spacer Nut Q’ty 1 6 2 1 1 1 1 1 1 6-7 Service points
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JET PUMP REVERSE GATE E EXPLODED DIAGRAM Step 18 19 20 21 22 23 24 Procedure/Part name Washer Bolt Washer Collar Spring Lever 2 Washer Q’ty 1 1 1 1 1 1 1 Service points Reverse the removal steps for installation.
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JET PUMP REVERSE GATE E SERVICE POINTS Lever 1 installation 1. Install: • Bolt 1 • Lever 1 2 • Spacer 3 • Reverse gate 4 • Washer 5 • Nut 6 Lever 2 installation 1. Install: • Bolt 1 • Washer 2 • Collar 3 • Spring 4 • Lever 2 5 • Washer 6 4 NOTE: • When installing the spring, hook the spring end a to lever 2 and spring end b to the reverse gate, as shown in the illustration. • When installing the lever 2, hook the lever 2 end c to lever 1 end d, as shown in the illustration. b a d c 2.
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JET PUMP JET THRUST NOZZLE AND NOZZLE RING E JET THRUST NOZZLE AND NOZZLE RING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name JET THRUST NOZZLE AND NOZZLE RING REMOVAL Jet pump unit Reverse gate Bolt Collar Jet thrust nozzle Bolt Washer Collar Nozzle ring Q’ty Service points Follow the left “Step” for removal. Refer to “JET PUMP UNIT”. Refer to “REVERSE GATE”. 2 2 1 2 2 2 1 Reverse the removal steps for installation.
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JET PUMP IMPELLER DUCT AND IMPELLER HOUSING 1 E IMPELLER DUCT AND IMPELLER HOUSING 1 EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name IMPELLER DUCT AND IMPELLER HOUSING 1 REMOVAL Nozzle ring Bolt Nozzle Pin Impeller duct assembly Impeller housing 1 Pin Q’ty Service points Follow the left “Step” for removal. Refer to “JET THRUST NOZZLE AND NOZZLE RING”. 4 1 2 1 1 2 6-11 NOTE: Clean the contacting surfaces before applying the Yamabond #4 (Yamaha bond number 4).
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JET PUMP IMPELLER DUCT AND IMPELLER HOUSING 1 E EXPLODED DIAGRAM Step 7 8 9 10 11 Procedure/Part name Bolt Water inlet cover Packing Water inlet strainer Packing Q’ty 4 1 1 1 1 Service points Reverse the removal steps for installation.
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JET PUMP IMPELLER DUCT AND DRIVE SHAFT IMPELLER DUCT AND DRIVE SHAFT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 *1 Procedure/Part name IMPELLER DUCT AND DRIVE SHAFT DISASSEMBLY Impeller Spacer Bolt Cap O-ring Nut Washer Q’ty 1 1 3 1 1 1 1 : EPNOC grease AP #0 6-13 Service points Follow the left “Step” for disassembly.
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JET PUMP IMPELLER DUCT AND DRIVE SHAFT EXPLODED DIAGRAM Step 8 9 10 11 12 13 14 Procedure/Part name Drive shaft Rear bearing Spacer Front bearing Oil seal Oil seal Impeller duct Q’ty 1 1 1 1 1 1 1 Service points Not reusable Not reusable Not reusable Not reusable Reverse the disassembly steps for assembly.
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JET PUMP IMPELLER DUCT AND DRIVE SHAFT E SERVICE POINTS Drive shaft removal 1. Remove: • Impeller Drive shaft holder: YB-06151/90890-06519 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 3. Remove: • Drive shaft 1 NOTE: Remove the drive shaft with a press. 4.
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JET PUMP IMPELLER DUCT AND DRIVE SHAFT 5. Remove: • Front bearing Drive rod: YB-06071 Driver rod L3: 90890-06652 Needle bearing attachment: YB-06112/90890-06614 NOTE: Remove the front bearing with a press. 6. Remove: • Oil seal Drive rod: YB-06071 Driver rod L3: 90890-06652 Needle bearing attachment: YB-06196/90890-06653 NOTE: Remove the oil seals with press. Impeller inspection Refer to “JET PUMP UNIT” in Chapter 3. Drive shaft inspection 1. Inspect: • Drive shaft Damage/wear → Replace.
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JET PUMP IMPELLER DUCT AND DRIVE SHAFT E Drive shaft installation 1. Install: • Oil seals Driver rod: YB-06071/90890-06606 Ball bearing attachment: YB-06085/90890-06634 Distance a: 14.2 ± 0.2 mm (0.56 ± 0.01 in) Distance b: 4.7 ± 0.2 mm (0.19 ± 0.01 in) 2. Install: • Front bearing • Drive shaft NOTE: Install the front bearing and drive shaft with a press. a Distance a: 23 ± 0.1 mm (0.91 ± 0.004 in) 3.
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JET PUMP IMPELLER DUCT AND DRIVE SHAFT E 5. Install: • Rear bearing Bearing inner/outer race attachment: YB-34474 NOTE: • Press the bearing inner/outer race at the same time holding the drive shaft and impeller duct. • If a bearing inner/outer race attachment is not available, use a washer or pipe with an outer diameter of 46 mm (1.81 in) and an inner diameter of 20 mm (0.79 in). 6. Add: • EPNOC grease AP #0 (into the cap) Quantity: Approximately 1/3 of capacity 7.
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JET PUMP TRANSOM PLATE AND HOSES E TRANSOM PLATE AND HOSES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 Procedure/Part name TRANSOM PLATE AND HOSES REMOVAL Exhaust system Jet pump unit assembly Hose clamp Cooling water hose Bilge hose 1 4 5 Hose clamp Cooling water hose Q’ty Service points Follow the left “Step” for removal. Refer to “EXHAUST SYSTEM” in Chapter 8. Refer to “JET PUMP UNIT”.
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JET PUMP TRANSOM PLATE AND HOSES E EXPLODED DIAGRAM Step 6 7 8 9 10 11 12 13 14 15 Procedure/Part name Hose clamp Cooling water hose Bilge hose 2 Hose clamp Bilge hose 3 Band Electric bilge pump assembly Hose clamp Bilge hose 4 Screw Q’ty 2 1 1 1 1 1 1 1 1 1 6-20 Service points Cooling water outlet (thermostat)
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JET PUMP TRANSOM PLATE AND HOSES E EXPLODED DIAGRAM Step 16 17 18 19 20 Procedure/Part name Bilge strainer holder Bilge strainer Nut/washer Transom plate Bilge hose 5 Q’ty 1 1 4/4 1 1 Service points Reverse the removal steps for installation.
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JET PUMP TRANSOM PLATE AND HOSES E SERVICE POINTS Bilge strainer inspection Refer to “JET PUMP UNIT” in Chapter 3. Electric bilge pump inspection Refer to “BILGE PUMP” in Chapter 3. Refer to “ELECTRIC BILGE PUMP” in Chapter 7. Bilge hose inspection 1. Inspect: • Bilge hoses Cracks/damage/wear → Replace. Cooling water hose inspection 1. Inspect: • Cooling water hoses Cracks/damage/wear → Replace.
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JET PUMP BEARING HOUSING E BEARING HOUSING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name BEARING HOUSING REMOVAL Engine unit Rubber coupling Bolt Intermediate housing assembly Pin Shim Q’ty 1 3 1 2 * Service points Follow the left “Step” for removal. Refer to “ENGINE UNIT” in Chapter 5. NOTE: Install the shims in their original locations. Reverse the removal steps for installation.
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JET PUMP BEARING HOUSING E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name BEARING HOUSING DISASSEMBLY Grease hose Nipple Driven coupling Washer Intermediate drive shaft O-ring Q’ty 1 1 1 1 1 2 6-24 Service points Follow the left “Step” for disassembly.
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JET PUMP BEARING HOUSING E EXPLODED DIAGRAM Step 7 8 9 10 11 12 Procedure/Part name Oil seal Oil seal Oil seal Circlip Bearing Circlip Q’ty 1 1 1 1 1 1 Service points Not reusable Not reusable Not reusable Not reusable Reverse the disassembly steps for assembly.
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JET PUMP BEARING HOUSING E SERVICE POINTS Driven coupling removal and installation 1. Remove and install: • Driven coupling Coupler wrench: YW-06551/90890-06551 Shaft holder: YB-06552/90890-06552 NOTE: • Install the driven coupling with the same special tools that were used for removal. • Check that the shaft holder and intermediate drive shaft are properly engaged. Intermediate drive shaft removal 1.
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JET PUMP BEARING HOUSING E Bearing removal 1. Remove: • Bearing Driver rod: YB-06071/90890-06606 Bearing outer race attachment: YB-06156/90890-06626 NOTE: • Install the bearing with the same special tools that were used for removal. • Support the intermediate housing with steel blocks 1 and press the bearing. Bearing, intermediate drive shaft, and grease hose inspection 1. Inspect: • Bearing Rotate the inner race by hand. Damage/rough movement → Replace.
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JET PUMP BEARING HOUSING E Bearing installation 1. Install: • Circlip (rear) 2. Install: • Bearing Driver rod: YB-06071/90890-06606 Bearing outer race attachment: YB-06156/90890-06626 NOTE: Support the intermediate housing with steel blocks 1 and press the bearing. Oil seal installation 1. Install: • Oil seal a Driver rod: YB-06071/90890-06606 Bearing outer race attachment: YB-06156/90890-06626 NOTE: Before installing the oil seal, lubricate the clip glove with water resistant grease. Distance a: 6.
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JET PUMP a BEARING HOUSING E 3. Install: • Oil seal 1 [8 mm (0.31 in)] • Oil seal 2 [11 mm (0.43 in)] b Distance a: 10.3–10.7 mm (0.41–0.42 in) Distance b: 0.6–1.0 mm (0.02–0.04 in) 2 1 Intermediate housing installation 1. Install: • Intermediate housing • Shim Installation steps: • Install the intermediate housing. • Measure the clearance a at each bolt hole. • Install the suitable shim from the table below. Clearance a Shim thickness 0–0.2 mm (0–0.008 in) No need 0.3–0.7 mm (0.012–0.028 in) 0.
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ELEC – + E CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS........................................................................ 7-1 ELECTRICAL BOX AND IGNITION COIL BOX .............................................7-2 EXPLODED DIAGRAM .............................................................................7-2 REMOVAL AND INSTALLATION CHART ................................................ 7-2 ELECTRICAL ANALYSIS .............................................................................
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ELEC – + FUEL CONTROL SYSTEM ...........................................................................7-28 WIRING DIAGRAM ................................................................................. 7-28 FUEL PUMP ............................................................................................ 7-30 FUEL SENDER ....................................................................................... 7-30 FUEL INJECTOR .......................................................................
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ELEC – + INDICATION SYSTEM .................................................................................. 7-44 WIRING DIAGRAM ................................................................................. 7-44 FUSE ....................................................................................................... 7-45 BATTERY ................................................................................................7-45 LIGHTING COIL .......................................................
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ELEC – + ELECTRICAL COMPONENTS E ELECTRICAL COMPONENTS L K J I 1 H G F 2 3 4 E D C 5 6 B A 7 0 9 8 1 2 3 4 5 6 7 8 9 Thermoswitch (engine) Starter motor Engine temperature sensor Spark plugs Ignition coils Electrical box Battery Speed sensor Electric bilge pump 0 A B C D E F G H Cam position sensor Fuel injectors Thermoswitch (exhaust) Oil pressure switch Intake air pressure sensor Intake air temperature sensor Throttle position sensor Lighting coil and pulser coil Engine stop switch, engin
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ELEC – + ELECTRICAL BOX AND IGNITION COIL BOX E ELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 16 mm 4 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 28 mm A A 5 × 20 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 11 3 LT (VENT) 572 7 22 5 6 9 LT 23 572 8 1516 A 2 1 LT 271 12 23 23 23 21 20 23 23 17 19 18 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 30 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 10 mm E LT 7.6 N • m (0.76 kgf • m, 5.
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ELEC – + ELECTRICAL BOX AND IGNITION COIL BOX E EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 16 mm 4 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 28 mm A A 5 × 20 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 11 3 LT (VENT) 572 7 22 5 6 9 LT 23 572 8 1516 A 2 1 LT 271 12 23 23 23 21 20 23 23 17 19 18 LT Step 9 10 11 12 13 14 15 16 17 18 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 30 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 10 mm E 7.6 N • m (0.76 kgf • m, 5.
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ELEC – + ELECTRICAL BOX AND IGNITION COIL BOX E EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 16 mm 4 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 28 mm A A 5 × 20 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 11 3 LT (VENT) 572 7 22 5 6 9 LT 23 572 8 1516 A 2 1 LT 23 23 23 21 20 23 14 13 23 17 19 18 LT Step 19 20 21 22 23 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 30 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 10 mm E 7.6 N • m (0.76 kgf • m, 5.
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ELEC – + ELECTRICAL BOX AND IGNITION COIL BOX E EXPLODED DIAGRAM 1 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 30 mm 2 3 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 20 mm 24 25 26 21 22 20 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 19 16 6 × 16 mm 6 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 18 23 12 17 13 14 27 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 30 mm 10 8 15 9 4 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 16 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 12 mm 7 5 × 20 mm 5 4.
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ELEC – + ELECTRICAL BOX AND IGNITION COIL BOX E EXPLODED DIAGRAM 1 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 30 mm 2 3 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 20 mm 24 25 26 21 22 20 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 19 16 6 × 16 mm 6 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 18 23 12 17 13 14 27 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 30 mm 10 8 15 9 4 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 16 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 12 mm 7 5 × 20 mm 5 4.
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ELEC – + ELECTRICAL BOX AND IGNITION COIL BOX E EXPLODED DIAGRAM 1 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 30 mm 2 3 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 20 mm 24 25 26 21 22 20 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 19 16 6 × 16 mm 6 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 18 23 12 17 13 14 27 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 30 mm 10 8 15 9 4 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 16 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 12 mm 7 5 × 20 mm 5 4.
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ELEC – + ELECTRICAL BOX AND IGNITION COIL BOX E EXPLODED DIAGRAM 1 6 4 2 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 28 mm 3 5 REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name IGNITION COIL BOX REMOVAL Air filter Q’ty Spark plug cap Holder Ignition coil coupler Bolt/washer Ignition coil box Collar 4 1 2 3/3 1 3 Service points Follow the left “Step” for removal. Refer to “FUEL INJECTION SYSTEM” in Chapter 4. Reverse the removal steps for installation.
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ELEC – + ELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 19 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 24 mm 2 1 1 4 2 3 5 6 4 6 5 7 REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name IGNITION COIL BOX DISASSEMBLY Tapping screw Holder Ignition coil cover Tapping screw Ignition coil Hightention code Ignition coil case Q’ty Service points Follow the left “Step” for disassembly.
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ELEC – + ELECTRICAL BOX AND IGNITION COIL BOX 3 2 4 5 E 6 7 1 UP È 8 Ê 1 1 9 4 4 3 3 2 2 1 2 3 4 5 6 7 8 9 È To ignition coil É To battery positive terminal Ê To starter motor Starter relay Fuse holder ECM Joint connector Joint connector Main and fuel pump relay Rectifier/regulator Slant detection switch Ignition coil 7-10 É
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ELEC – + ELECTRICAL ANALYSIS E ELECTRICAL ANALYSIS INSPECTION CAUTION: • All measuring instruments should be handled with special care. Damaged or mishandled instruments will not measure properly. • On an instrument powered by dry batteries, check the battery’s voltage periodically and replace the batteries if necessary. Digital tester NOTE: Throughout this chapter the digital tester’s part number has been omitted. Refer to the following part number.
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ELEC – + ELECTRICAL ANALYSIS E 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 displayed measurement. • The internal resistance of the tester can be obtained by connecting both of its terminals.
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ELEC – + ELECTRICAL ANALYSIS E Peak voltage adaptor NOTE: • Throughout this chapter the peak voltage adaptor’s part number has been omitted. Refer to the following part number. • The peak voltage adaptor should be used with the digital tester. Peak voltage adaptor: YU-39991/90890-03172 È • When measuring the peak voltage, connect the peak voltage adaptor to the digital circuit tester and switch the selector to the DC voltage mode.
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– ELEC + IGNITION SYSTEM E IGNITION SYSTEM WIRING DIAGRAM Y Br 13 : B/R 15 : G/O 17 : L/B 18 : R/Y 19 : P/G 20 : P 21 : B/Y 27 : B 28 : B/W 2 :W 3 : P/W 4 :P 5 : B/Y 6 : B/O 7 :Y 8 :O 9 : W/R 10 : W/B 11 : L/R B L/R L 1 R/Y R/Y 3 R/Y R/Y 2 R/Y R R 4 3 2 1 8 7 6 5 R P R R P Br B R/Y R/Y R/Y R O 12 3 456 R/Y 7 8 O O P P R R R 4 Y L/R P/W 5 6 W B B Pu/B R/Y R Br W B FREE PUSH FREE PUSH B/O Pu/G P/W Pu/R B Bu/Y Br W R B/Y W G/O O P/W P P/G B/Y B R/Y
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– ELEC + IGNITION SYSTEM E WIRING DIAGRAM Y Br 13 : B/R 15 : G/O 17 : L/B 18 : R/Y 19 : P/G 20 : P 21 : B/Y 27 : B 28 : B/W 2 :W 3 : P/W 4 :P 5 : B/Y 6 : B/O 7 :Y 8 :O 9 : W/R 10 : W/B 11 : L/R B L/R L 1 R/Y R/Y 3 R/Y R/Y 2 R/Y R R 4 3 2 1 8 7 6 5 R P R R P Br B R/Y R/Y R/Y R O 12 3 456 R/Y 7 8 O O P P R R R 4 Y L/R P/W 5 6 W B B Pu/B R/Y R Br W B FREE PUSH FREE PUSH B/O Pu/G P/W Pu/R B Bu/Y Br W R B/Y W G/O O P/W P P/G B/Y B R/Y B/O Pu/B B W
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ELEC – + IGNITION SYSTEM E 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 spark gap check, keep flammable gas or liquids away, since this test can produce sparks. È 1. Check: • Ignition spark gap Below specification → Check the ECM output peak voltage.
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ELEC – + IGNITION SYSTEM E IGNITION SYSTEM PEAK VOLTAGE WARNING When checking the electrical components, do not touch any of the connections of the digital tester lead wires. NOTE: • If there is no spark, or the spark is weak, continue with the ignition system test. • If a good spark is obtained, the problem is not with the ignition system, but possibly with the spark plug(-s) or another component. 1. Measure: • ECM output peak voltage Below specification → Measure the pulser coil output peak voltage.
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ELEC – + IGNITION SYSTEM E 2. Measure: • Pulser coil output peak voltage Below specification → Replace the pulser coil. Test harness (3 pins): YB-06791/90890-06791 Pulser coil output peak voltage: White (W) – Black (B) Red (R) – Black (B) r/min V Unloaded Loaded Cranking 4 4 2,000 3,500 23 38 NOTE: To crank the engine, connect the engine shutoff cord (lanyard), and then press the start switch and engine stop switch simultaneously. 3.
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ELEC – + IGNITION SYSTEM E 4. Measure: • Rectifier/regulator output voltage Below specification → Replace the rectifier/regulator. Test harness (6 pins): YB-06790/90890-06790 Rectifier/regulator output voltage: Red (R) – Black (B) Loaded r/min 3,500 V 14.5 NOTE: • Before measuring the output peak voltage, make sure that the battery is fully charged.
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ELEC – + IGNITION SYSTEM E IGNITION COIL 1. Measure: • Primary coil resistance Out of specification → Replace. Primary coil resistance: Black/white (B/W) – Red (R) 1.53–2.07 Ω at 20 °C (68 °F) NOTE: When measuring a resistance of 10 Ω or less with the digital tester, the correct measurement cannot be obtained because of the tester’s internal resistance. Refer to “Low resistance measurement”. 2. Measure: • Secondary coil resistance Out of specification → Replace. Secondary coil resistance: 12.5–16.
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ELEC – + IGNITION SYSTEM E ENGINE TEMPERATURE SENSOR 1. Measure: • Engine temperature sensor resistance (at the specified temperature) Out of specification → Replace. Engine temperature sensor resistance: 20 °C (68 °F): 54.2–69.0 kΩ 100 °C (212 °F): 3.12–3.48 kΩ Measurement steps: • Suspend the engine temperature sensor in a container filled with water. • Slowly heat the water. • Measure the resistance when the specified temperature is reached. INTAKE AIR TEMPERATURE SENSOR 1.
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ELEC – + IGNITION SYSTEM E THERMOSWITCH (ENGINE) 1. Check: • Thermoswitch (engine) continuity (at the specified temperature) Out of specification → Replace. Thermoswitch (engine) continuity temperature: a 84–90 °C (183–194 °F) b 70–84 °C (158–183 °F) 1 No continuity 2 Continuity È Temperature É Time Checking steps: • Suspend the thermoswitch (engine) in a container filled with water. • Place a thermometer in the water. • Slowly heat the water.
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ELEC – + IGNITION SYSTEM E MAIN AND FUEL PUMP RELAY 1. Check: • Main and fuel pump relay continuity Faulty → Replace. Checking steps: • Connect the tester leads between the main and fuel pump relay terminals 5, 6 and 7. • Connect the terminals 2 or 3 to the positive battery terminal. • Connect the terminal 1 to the negative battery terminal. • Check that there is continuity between the main and fuel pump relay terminals.
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ELEC – + IGNITION SYSTEM E THROTTLE POSITION SENSOR 1. Measure: • Throttle position sensor output voltage Out of specification → Adjust the throttle bodies synchronization. Refer to “FUEL INJECTION SYSTEM” in Chapter 4. 1 B/O Test harness (3 pins): YB-06793/90890-06793 Test connector: YW-06862/90890-06862 P 2 Throttle position sensor output voltage: Pink (P) – Black/Orange (B/O) 0.760 ± 0.016 V Measurement steps: • Connect the test harness (3 pins) to the throttle position sensor 1.
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ELEC – + IGNITION SYSTEM E CAM POSITION SENSOR 1. Measure: • Cam position sensor output voltage Out of specification → Replace. Test harness (3 pins): YB-06777/90890-06777 Cam position sensor output voltage: Green/orange (G/O) – Black/orange (B/O) Position Voltage (V) A More than 0.8 B Less than 4.8 Measurement steps: • Remove the cam position sensor. • Connect the test harness (3 pins) to the cam position sensor. • Operate the Yamaha Diagnostic System.
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ELEC – + IGNITION SYSTEM E INTAKE AIR PRESSURE SENSOR 1. Measure: • Intake air pressure sensor output voltage Out of specification → Replace. Test harness (3 pins): YB-06769/90890-06769 Vacuum/pressure pump gauge set: YB-35956-A/90890-06756 B/O P/G Intake air pressure sensor output voltage: Pink/green (P/G) – Black/orange (B/O) 1 101.3 kPa (1.01 kgf/cm2, 14.4 psi): a 4.00 V 2 50 kPa (0.5 kgf/cm2, 7.1 psi): b 1.97 V 3 20 kPa (0.2 kgf/cm2, 2.8 psi): c 0.
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ELEC – + IGNITION SYSTEM E SLANT DETECTION SWITCH È 1. Check: • Slant detection switch continuity Out of specification → Replace.
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ELEC – + FUEL CONTROL SYSTEM E FUEL CONTROL SYSTEM WIRING DIAGRAM Br 3 : P/W 5 : B/Y 7 :Y 8 :O 17 :L/B 18 : R/Y 19 : P/G Y B L/R 20 : P 21 : B/Y 12 : W/B 23 : Pu/Y 24 : Pu/B 25 : Pu/R 26 : Pu/G L 1 R/Y R/Y R R 4 3 2 1 8 7 6 5 R/Y R/Y 3 R R R/Y P R R P R/Y R/Y O 2 R/Y R/Y 12 3 456 7 8 P R R O O R/Y 4 Y L/B P/W L/R P/W Pu/B R/Y B/O L Pu/G Pu/R L Bu/Y P/W B/Y O F L B B P P/G B/G B/Y B Pu/B Pu/Y 6 Pu/R Pu/G 5 B B/O L/B R/Y B B/G 7 P B B/O P B B
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ELEC – + FUEL CONTROL SYSTEM E WIRING DIAGRAM Br 3 : P/W 5 : B/Y 7 :Y 8 :O 17 :L/B 18 : R/Y 19 : P/G Y B L/R 20 : P 21 : B/Y 12 : W/B 23 : Pu/Y 24 : Pu/B 25 : Pu/R 26 : Pu/G L 1 R/Y R/Y R R 4 3 2 1 8 7 6 5 R/Y R/Y 3 R R R/Y P R R P R/Y R/Y O 2 R/Y R/Y 12 3 456 7 8 P R R O O R/Y 4 Y L/B P/W L/R P/W Pu/B R/Y B/O L Pu/G Pu/R L Bu/Y P/W B/Y O F L B B P P/G B/G B/Y B Pu/B Pu/Y 6 Pu/R Pu/G 5 B B/O L/B R/Y B B/G 7 P B B/O P B B B R/Y B A R/Y R
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ELEC – + FUEL CONTROL SYSTEM E FUEL PUMP 1. Check: • Fuel pump operating sound Fuel pump does not sound → Measure the fuel pressure. Refer to “FUEL INJECTION SYSTEM” in Chapter 4. NOTE: After the engine is stopped, the fuel pump will operate for 10 seconds. FUEL SENDER 1. Measure: • Fuel sender resistance Out of specification → Replace.
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ELEC – + FUEL CONTROL SYSTEM E FUEL INJECTOR Refer to “FUEL INJECTION SYSTEM” in Chapter 4. MAIN AND FUEL PUMP RELAY Refer to “IGNITION SYSTEM”. OIL PRESSURE SWITCH Refer to “IGNITION SYSTEM”. THERMOSWITCH (ENGINE) Refer to “IGNITION SYSTEM”. THERMOSWITCH (EXHAUST) Refer to “IGNITION SYSTEM”. SLANT DETECTION SWITCH Refer to “IGNITION SYSTEM”.
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– ELEC + STARTING SYSTEM E STARTING SYSTEM WIRING DIAGRAM Br Y B L/R L R 4 3 2 1 8 7 6 5 1 R/Y R/Y R/Y R/Y R R 2 R/Y P P O R/Y 12 3 456 7 8 7 R/Y 18 R/Y R R R Y 3 R B B Br B B B B Br 4 B R 8 W B FREE PUSH 7 R Br Br Br 5 FREE PUSH B Br 6 Br R R Br Br R 1 2 3 4 5 6 7 8 ECM Main and fuel pump relay Fuse (20A) Starter relay Starter motor Battery Start switch Engine shut-off switch B Br R Y R/Y 7-32 : Black : Brown : Red : Yellow : Red/yellow
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ELEC – + STARTING SYSTEM E BATTERY Refer to “ELECTRICAL” in Chapter 3. WIRING CONNECTIONS 1. Check: • Wiring connections Poor connections → Properly connect. FUSE 1. Check: • Fuse broken Broken → Replace. Fuse rating: 3A, 20A NOTE: 20A fuse is for main relay, engine shut-off switch and rectifier/regulator. 3A fuse is for multifunction meter and electric bilge pump. START SWITCH 1. Check: • Continuity Out of specification → Replace.
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ELEC – + STARTING SYSTEM E STARTER RELAY 1. Inspect: • Brown lead terminal • Black lead terminal Loose → Tighten. 2. Check: • Starter relay Faulty → Replace. Checking steps: • Connect the tester leads between the starter relay terminals as shown. • Connect the brown lead terminal to the positive battery terminal. • Connect the black lead terminal to the negative battery terminal. • Check that there is continuity between the starter relay terminals.
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ELEC – + STARTER MOTOR E STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name STARTER MOTOR DISASSEMBLY Starter motor O-ring Bolt Starter motor front cover O-ring Oil seal retainer Washer Shim Q’ty 1 2 1 1 1 1 * *: As required 7-35 Service points Follow the left “Step” for disassembly. Refer to “GENERATOR AND STARTER MOTOR” in Chapter 5. Not reusable Not reusable t = 0.2 mm, 0.
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ELEC – + STARTER MOTOR E EXPLODED DIAGRAM Step 8 9 10 11 12 13 14 15 16 17 Procedure/Part name Starter motor rear cover O-ring Shim Armature assembly Nut/spring washer/washer O-ring Brush holder Brush spring Bolt Brush assembly Q’ty 1 1 * 1 1/1/4 1 1 4 1 1 *: As required 7-36 Service points Not reusable t = 0.2 mm, 0.
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ELEC – + STARTER MOTOR E EXPLODED DIAGRAM Step 18 19 20 Procedure/Part name Spacer Holder Starter motor yoke Q’ty 1 1 1 Service points Reverse the disassembly steps for assembly.
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ELEC – + STARTER MOTOR E SERVICE POINTS Armature inspection 1. Inspect: • Armature shaft 1 Damage/wear → Replace. 1 2. Inspect: • Commutator Dirt → Clean with 600 grit sandpaper. 3. Measure: • Commutator diameter Out of specification → Replace. Min. commutator diameter: 27.0 mm (1.06 in) 4. Check: • Commutator undercut Contaminants → Clean. NOTE: Remove all mica and metal particles with compressed air. 5. Measure: • Commutator undercut Out of specification → Replace. Min. commutator undercut: 0.
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ELEC – + STARTER MOTOR E 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 specification → Replace. Min. brush length: 6.5 mm (0.26 in) 2. Check: • Brush holder continuity Out of specification → Replace.
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ELEC – + CHARGING SYSTEM E CHARGING SYSTEM WIRING DIAGRAM 1 B R G G 2 B G G G R R G G R R G 4 G G G G B 3 1 2 3 4 Rectifier/regulator Fuse (20A) Battery Lighting coil B G R 7-40 : Black : Green : Red
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ELEC – + CHARGING SYSTEM E FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in Chapter 3. LIGHTING COIL Refer to “IGNITION SYSTEM”. RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM”.
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ELEC – + ELECTRIC BILGE PUMP E ELECTRIC BILGE PUMP WIRING DIAGRAM Br Y B L/R L 1 R/Y R/Y R/Y 4 3 2 1 8 7 6 5 R R/Y R R 2 P P R/Y O R/Y 12 3 456 7 8 R R/Y 7 R R/Y 18 R/Y Y 3 R/Y B R B Br B B B Br B R 5 R R/Y Br B B B Br R/Y B 4 1 2 3 4 5 ECM Main and fuel pump relay Fuse (3A) Battery Electric bilge pump B Br R Y R/Y 7-42 : Black : Brown : Red : Yellow : Red/yellow
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ELEC – + ELECTRIC BILGE PUMP E ELECTRIC BILGE PUMP Br 1. Check: • Electric bilge pump operation Incorrect → Replace. B – Checking steps: • Suspend the electric bilge pump in a container filled with water. • Connect the brown lead terminal to the positive battery terminal. • Connect the black lead terminal to the negative battery terminal. • Check the water flows from the electric bilge pump hose.
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ELEC – + INDICATION SYSTEM E INDICATION SYSTEM WIRING DIAGRAM Y Br B L/R 1 L R R 4 3 2 1 8 7 6 5 R/Y R/Y R R P 2 R/Y R/Y R/Y 3 P O 12 3 3 12 21 4 R/Y Br R/Y R/Y 56 4 Br R/Y R P P P R R 7 1 Y B P/W 5 B P/W G B R/Y W B R W/B 6 G W/B R/Y P/W B/O B P B/O B B P D P B B/O W B R B/O 7 B P P 0 P B B/O B/O B/Y L/B Y B R/W L/R B/Y B/O B/O B/Y B/Y B/Y R/W B/Y B B/G L/R L/B B/G 8 B 9 B/Y Y B/O B R P B B/Y B/O R/Y B/O B R B/Y
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ELEC – + INDICATION SYSTEM E FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in Chapter 3. LIGHTING COIL Refer to “IGNITION SYSTEM”. RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM”. ECM Refer to “IGNITION SYSTEM”. ENGINE TEMPERATURE SENSOR Refer to “IGNITION SYSTEM”. THERMOSWITCH (ENGINE) Refer to “IGNITION SYSTEM”. THERMOSWITCH (EXHAUST) Refer to “IGNITION SYSTEM”. BUZZER 1. Check: • Buzzer Buzzer does not sound → Replace.
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ELEC – + INDICATION SYSTEM E OIL PRESSURE SWITCH 1. Measure: • Oil pressure switch continuity Out of specification → Replace. Vacuum/pressure pump gauge set: YB-35956-A/90890-06756 Oil pressure switch continuity pressure: 128 kPa (1.28 kgf/cm2, 18.2 psi) – 166 kPa (1.66 kgf/cm2, 23.6 psi) MULTIFUNCTION METER Multifunction meter 1. Check: • Multifunction meter Cracked meter housing → Replace the multifunction meter. Meter is fogged/shows signs of water intrusion → Replace the multifunction meter.
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ELEC – + INDICATION SYSTEM E Display function 1. Check: • Display function Not operate → Replace the multifunction meter.
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ELEC – + INDICATION SYSTEM E Speedometer display 1. Check: • Speedometer display Does not display → Measure the speed sensor output voltage and pulses. Without specification → Replace the multifunction meter. 2. Measure: • Speed sensor output voltage and pulses Out of specification → Repair or replace. Speed sensor output voltage (dependant on the paddle wheel position): Less than 400 mV/ More than 11.
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ELEC – + INDICATION SYSTEM E Tachometer display 1. Check: • Tachometer display Does not display → Check the engine speed using the “Engine monitor” of the Yamaha Diagnostic System. Replace the multifunction meter. Hour meter display 1. Check: • Hour meter display Does not display → Replace the multifunction meter. Voltage meter display 1. Check: • Voltage meter display Does not display → Check the battery voltage using the “Engine monitor” of the Yamaha Diagnostic System.
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ELEC – + INDICATION SYSTEM E Overheat warning indicator 1. Check: • Overheat warning indicator Not operating → Replace the multifunction meter. Checking steps: • Disconnect the thermoswitch (engine) connector 1 (blue) or engine temperature sensor connector 2 (black) or thermoswitch (exhaust) 3 connector. • Connect the jumper lead to the female terminal of the disconnected connector. • Check that the multifunction meter overheat warning indicator comes on and the buzzer sounds.
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ELEC – + INDICATION SYSTEM E Diagnostic display 1. Check: • Diagnostic display Does not display → Replace the multifunction meter. 1 Checking steps: • Remove the coupler of the sensor indicated in the multifunction meter. • Check if “Irregular” is indicated in the Diagnosis Record of the Yamaha Diagnostic System. • Start the engine and check that the engine check warning indicator comes on and the buzzer sounds.
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HULL HOOD E CHAPTER 8 HULL AND HOOD HANDLEBAR ..................................................................................................8-1 EXPLODED DIAGRAM .............................................................................8-1 REMOVAL AND INSTALLATION CHART ................................................ 8-1 SERVICE POINTS .................................................................................... 8-6 Handlebar inspection .......................................................
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HULL HOOD FRONT HOOD ...............................................................................................8-21 EXPLODED DIAGRAM ...........................................................................8-21 REMOVAL AND INSTALLATION CHART .............................................. 8-21 STEERING CONSOLE COVER .................................................................... 8-25 EXPLODED DIAGRAM ...........................................................................
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HULL HOOD DECK AND HULL.......................................................................................... 8-47 EXPLODED DIAGRAM ...........................................................................8-47 REMOVAL AND INSTALLATION CHART .............................................. 8-47 ENGINE MOUNT ........................................................................................... 8-49 EXPLODED DIAGRAM ...........................................................................
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HULL HOOD HANDLEBAR E HANDLEBAR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 Procedure/Part name HANDLEBAR COVER REMOVAL Screw Handlebar cover Pad Bolt Handlebar cover stay Throttle cable Bolt Upper handlebar holder Q’ty 4 1 1 2 1 1 4 2 Service points Follow the left “Step” for removal. NOTE: Position the corrugated tube for the throttle cable as shown in the illustration so that the tube attaches to the end of the outer throttle cable.
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HULL HOOD HANDLEBAR E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 Procedure/Part name HANDLEBAR REMOVAL QSTS cable (to jet thrust nozzle) Q’ty Nut/washer QSTS converter QSTS cable 2 QSTS cable 1 Handlebar switch coupler Buzzer coupler Screw Handle boss cover Band 2/2 1 1 1 2 1 4 1 2 8-2 Service points Follow the left “Step” for removal. Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”.
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HULL HOOD HANDLEBAR E EXPLODED DIAGRAM Step 10 11 12 13 Procedure/Part name Hose packing Buzzer Handlebar assembly Grommet Q’ty 1 1 1 Service points Not reusable NOTE: • Pass the QSTS cable and handlebar switch lead through the handle boss cover, and then install the handlebar assembly. • Install the sponges of the QSTS cables as shown and make sure that the grommet is installed to the deck securely. 2 Reverse the removal steps for installation.
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HULL HOOD HANDLEBAR E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name HANDLEBAR DISASSEMBLY Bolt Grip end Spacer Screw/spring washer/washer QSTS grip assembly Special nut Screw Q’ty 2 2 1 1/1/1 1 1 2 8-4 Service points Follow the left “Step” for disassembly. NOTE: Tighten the screw from the engine stop switch side.
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HULL HOOD HANDLEBAR E EXPLODED DIAGRAM Step 8 9 10 11 12 Procedure/Part name Handlebar switch assembly Screw Throttle lever assembly Handlebar grip Handlebar Q’ty 1 2 1 1 Service points NOTE: Apply adhesive to the handlebar and the inner surface of the handlebar grip. 1 Reverse the disassembly steps for assembly.
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HULL HOOD HANDLEBAR E SERVICE POINTS Handlebar inspection 1. Inspect: • Handlebar Bends/cracks/damage → Replace. Handlebar switch inspection Refer to “STARTING SYSTEM” in Chapter 7. Handlebar assembly installation 1. Install: • Bands 1 NOTE: After inserting the QSTS cables, buzzer lead, handlebar switch lead and throttle cable into the grommets, tie the end of grommets with the bands. 2.
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HULL HOOD HANDLEBAR E 3. Install: • Throttle cable NOTE: Fit the seal into the groove in the bracket. 4. Adjust: • QSTS cable length a QSTS cable length: 72 ± 0.5 mm (2.83 ± 0.02 in) 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. 5.
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HULL HOOD QSTS GRIP E QSTS GRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name QSTS GRIP DISASSEMBLY QSTS grip assembly Screw/washer Cover Ball Spring QSTS cable 1 QSTS cable 2 Q’ty 1/1 1 2 2 1 1 8-8 Service points Follow the left “Step” for disassembly. Refer to “HANDLEBAR”.
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HULL HOOD QSTS GRIP E EXPLODED DIAGRAM Step 7 8 9 10 11 12 13 Procedure/Part name Screw/washer Spacer QSTS shift lock lever Spring Spacer Cable housing QSTS grip Q’ty 2/2 1 1 1 1 1 1 Service points Reverse the disassembly steps for assembly.
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HULL HOOD QSTS GRIP E SERVICE POINTS QSTS cable inspection 1. Inspect: • QSTS cables Frays/kinks/rough movement → Replace. QSTS grip inspection 1. Inspect: • QSTS grip Damage/wear → Replace.
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HULL HOOD STEERING MASTER E STEERING MASTER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name STEERING MASTER REMOVAL Steering console cover Steering cable end Q’ty Bolt/washer Steering arm Nut/washer Steering master assembly Bolt 1/1 1 4/4 1 4 Service points Follow the left “Step” for removal. Refer to “STEERING CONSOLE COVER”. Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”. Reverse the removal steps for installation.
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HULL HOOD STEERING MASTER E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 10 Procedure/Part name STEERING MASTER DISASSEMBLY Bolt/washer Stay Spring Bolt/washer Lower housing Spring Bushing Bushing Upper housing Tilt lever Q’ty 2/2 1 1 6/6 1 1 1 1 1 1 8-12 Service points Follow the left “Step” for disassembly.
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HULL HOOD STEERING MASTER E EXPLODED DIAGRAM Step 11 12 13 14 15 16 17 18 19 Procedure/Part name Tilt stopper Bolt/nut/holder Retainer Steering shaft assembly Steering tube Bolt/washer/spring washer Cap Shaft 1 Cross piece Q’ty 1 4/4/4 2 1 1 2/2/2 1 1 1 Service points Reverse the disassembly steps for assembly.
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HULL HOOD STEERING MASTER E SERVICE POINTS Steering master components inspection 1. Inspect: • Each component part Damage/wear → Replace the steering master.
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HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD E REMOTE CONTROL CABLES AND SPEED SENSOR LEAD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL Service lid 1 Front seat assembly Glove compartment Steering cable end Nut/washer Bracket Nut Steering cable holder Q’ty Service points Follow the left “Step” for removal. Refer to “FRONT HOOD”. Refer to “SEATS AND HAND GRIP”. Refer to “STEERING CONSOLE COVER”.
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HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD EXPLODED DIAGRAM Step 6 7 8 9 10 11 12 13 14 15 Procedure/Part name Nut Steering cable Packing Speed sensor coupler Nut Cap Screw Speed sensor Shift cable end Nut Q’ty 1 1 1 1 1 1 4 1 1 2 8-16 Service points E
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HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD E EXPLODED DIAGRAM Step 16 17 18 19 20 21 22 23 24 25 Procedure/Part name Shift cable holder Nut Shift cable Packing Nut Pin QSTS cable end Nut QSTS cable Packing Q’ty 2 1 1 1 1 1 1 1 1 1 Service points Reverse the removal steps for installation.
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HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD E SERVICE POINTS WARNING When routing the cables, do not grasp the cable by the outer crimped sheath or steel end. This could deform or loosen the cable end due to extreme angles and or pressure. Always hold the cables by the outer cover below the crimp. If a cable becomes damaged replace it. Never attempt to repair a damaged cable. Remote control cables inspection 1.
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HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD E QSTS cable (jet pump end) installation 1. Install: • QSTS cable (jet pump end) QSTS cable set length a (jet pump end): 13.6 mm (0.54 in) WARNING The QSTS cable must be screwed in more than 8 mm (0.31 in). QSTS cable stopper installation 1. Install: • QSTS cable stopper WARNING Be sure to fit the projection 1 on the QSTS cable stopper into the groove in the outer cable. Shift cable (jet pump end) installation 1.
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HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD E Shift cable holder installation 1. Install: • Shift cable holders NOTE: Install the shift cable holders so that mark a and mark b are in the positions shown in the illustration. Shift cable stopper installation 1. Install: • Shift cable 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 3.
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HULL HOOD FRONT HOOD E FRONT HOOD EXPLODED DIAGRAM 6 × 10 mm 7 6 2 6 × 18 mm LT 242 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 18 mm 8 4 LT 242 LT 242 9 LT 271 3 5 6 × 30 mm 11 10 1 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 1.5 N • m (0.15 kgf • m, 1.
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HULL HOOD FRONT HOOD E EXPLODED DIAGRAM 6 × 10 mm 7 6 2 6 × 18 mm LT 242 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 18 mm 8 4 LT 242 LT 242 9 LT 271 3 5 6 × 30 mm 11 10 1 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) Step 8 9 10 11 Procedure/Part name Bolt Service lid 1 Screw Service lid 2 Q’ty 4 1 4 1 1.5 N • m (0.15 kgf • m, 1.1 ft • Ib) 4 × 8 mm Service points Reverse the removal steps for installation.
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HULL HOOD FRONT HOOD E EXPLODED DIAGRAM 4 1 5 7 6 10 2 7 3 6 1 8 9 REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name HINGE DISASSEMBLY Circlip Pin (long) Hinge Pin (short) Damper stay Collar Grommet Q’ty 2 1 1 1 1 2 2 8-23 Service points Follow the left “Step” for disassembly.
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HULL HOOD FRONT HOOD E EXPLODED DIAGRAM 4 1 5 7 6 10 2 7 3 6 1 8 9 Step 8 9 10 Procedure/Part name Clamp Damper boots Damper Q’ty 1 1 1 Service points Not reusable Reverse the disassembly steps for assembly.
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HULL HOOD STEERING CONSOLE COVER E STEERING CONSOLE COVER EXPLODED DIAGRAM 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 5 × 20 mm 7 6.9 N • m (0.69 kgf • m, 5.0 ft • Ib) 8 5 6 10 LT 9 4 242 5 3 11 LT 1 242 2 3.9 N • m (0.39 kgf • m, 2.
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HULL HOOD STEERING CONSOLE COVER E EXPLODED DIAGRAM 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 5 × 20 mm 7 6.9 N • m (0.69 kgf • m, 5.0 ft • Ib) 8 5 6 10 LT 9 242 5 4 3 11 LT 1 242 2 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 5 × 20 mm Step 6 7 8 9 10 11 Procedure/Part name Bolt Multifunction meter Hose packing Grommet Nut/washer Mirror Q’ty 4 1 1 1 4/4 2 Service points Not reusable Reverse the removal steps for installation.
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HULL HOOD STEERING CONSOLE COVER E EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 22 mm 5 1 5 3 6 2 2 2 6 4 4 2 2 3 LT 271 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 22 mm REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name SIDE COVER REMOVAL Cup holder Bolt Side cover Nut/washer Bolt Bracket Q’ty Service points Follow the left “Step” for removal. 1 8 2 4/4 4 2 Reverse the removal steps for installation.
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HULL HOOD STEERING CONSOLE COVER E EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 30 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 18 mm 8 × 22 mm 4 2 11 7 8 × 30 mm LT 242 9 LT 242 8 12 6 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 14 mm 5 LT 271 3 1 10 20 N • m (0.2 kgf • m, 14 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.
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HULL HOOD STEERING CONSOLE COVER E EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 30 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 18 mm 8 × 22 mm 4 2 11 7 8 × 30 mm LT 242 9 LT 242 8 12 6 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 14 mm 5 LT 271 3 1 10 20 N • m (0.2 kgf • m, 14 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.
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HULL HOOD STEERING CONSOLE COVER E EXPLODED DIAGRAM 3 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 14 mm 5 2 2 6 LT 4 271 4 1 REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name GLOVE COMPARTMENT DISASSEMBLY Glove compartment Hinge assembly Lid Gear assembly Screw Latch Q’ty Service points Follow the left “Step” for disassembly. 1 2 1 2 2 1 Reverse the disassembly steps for assembly.
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HULL HOOD STEERING CONSOLE COVER E SERVICE POINTS Glove compartment assembly installation 1. Install: • Hinge assembly NOTE: When installing the hinge assembly, make sure that the springs are in the position shown.
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HULL HOOD HOSES E HOSES EXPLODED DIAGRAM (VENT) D FW 1 2 7 8 3 (VENT) 1 2 1 1 6 4 5 5 (VENT) 4 6 8 3 7 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) REMOVAL AND INSTALLATION CHART Step Procedure/Part name HOSES REMOVAL Fuel tank Q’ty Service points Follow the left “Step” for removal. Refer to “FUEL TANK AND FUEL PUMP MODULE” in Chapter 4. NOTE: When removing the ventilation hose and fuel tank breather hose, it is not necessary to remove the fuel tank.
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HULL HOOD HOSES E EXPLODED DIAGRAM (VENT) D FW 1 2 7 8 3 (VENT) 1 2 1 1 6 4 5 5 (VENT) 8 3 Procedure/Part name Clamp Cooling water hose Nut Cooling water pilot outlet Packing 7 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) 4.2 N • m (0.42 kgf • m, 3.0 ft • Ib) Step 4 5 6 7 8 4 6 Q’ty 2 2 2 2 2 Service points Reverse the removal steps for installation.
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HULL HOOD SHIFT LEVER E SHIFT LEVER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 Procedure/Part name SHIFT LEVER REMOVAL Side cover Shift cable Bolt Shift lever handle Bolt Washer Shift lever Q’ty 2 1 1 1 1 8-34 Service points Follow the left “Step” for removal. Refer to “STEERING CONSOLE COVER”. Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”.
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HULL HOOD SHIFT LEVER E EXPLODED DIAGRAM Step 6 7 8 9 10 Procedure/Part name Screw Base assembly Nut/washer Screw Plate Q’ty 3 1 3/3 3 1 Service points Reverse the removal steps for installation.
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HULL HOOD SHIFT LEVER E EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name BASE DISASSEMBLY Bolt/washer Plate Spring Actuator Roller Shaft Shift arm Q’ty Service points Follow the left “Step” for disassembly. 2/2 1 1 1 1 1 1 Reverse the disassembly steps for assembly.
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HULL HOOD SHIFT LEVER E SERVICE POINTS Base assembly 1. Install: • Shift arm • Shaft Installation steps: • Install the shift arm 1 so that it comes in contact with the stopper 2 as shown. • Install the shaft 3 to the base so that it come in contact with the stopper 4 as shown. Shift lever 1. Install: • Shift lever a b NOTE: To install the shift lever, align the arrow mark a on the shift lever with the punch mark b on base assembly.
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HULL HOOD SEATS AND HAND GRIP E SEATS AND HAND GRIP EXPLODED DIAGRAM 2 1 4 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 4 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 10 3 20 LT 3 11 12 8 × 30 mm LT 271 8 × 30 mm 271 6 × 25 mm 14 7 21 15 17 8 9 18 13 18 5 6 26 N • m (2.6 kgf • m, 19 ft • Ib) 16 19 5.2 N • m (0.52 kgf • m, 3.8 ft • Ib) 18 N • m (1.8 kgf • m, 13 ft • Ib) 15 N • m (1.5 kgf • m, 11 ft • Ib) 5.2 N • m (0.52 kgf • m, 3.8 ft • Ib) 26 N • m (2.
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HULL HOOD SEATS AND HAND GRIP E EXPLODED DIAGRAM 2 1 4 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 4 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 10 3 20 LT 3 11 12 8 × 30 mm LT 271 8 × 30 mm 271 6 × 25 mm 14 7 21 15 17 8 9 18 13 18 5 6 26 N • m (2.6 kgf • m, 19 ft • Ib) 16 19 5.2 N • m (0.52 kgf • m, 3.8 ft • Ib) 18 N • m (1.8 kgf • m, 13 ft • Ib) 15 N • m (1.5 kgf • m, 11 ft • Ib) 5.2 N • m (0.52 kgf • m, 3.8 ft • Ib) 26 N • m (2.
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HULL HOOD SEATS AND HAND GRIP E EXPLODED DIAGRAM 2 1 4 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 4 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 × 40 mm 10 3 20 LT 3 11 12 8 × 30 mm LT 271 8 × 30 mm 271 6 × 25 mm 14 7 21 15 17 8 9 18 13 18 5 6 26 N • m (2.6 kgf • m, 19 ft • Ib) 16 19 5.2 N • m (0.52 kgf • m, 3.8 ft • Ib) 18 N • m (1.8 kgf • m, 13 ft • Ib) 15 N • m (1.5 kgf • m, 11 ft • Ib) 5.2 N • m (0.52 kgf • m, 3.8 ft • Ib) 26 N • m (2.
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HULL HOOD SEATS AND HAND GRIP SERVICE POINTS Seat lock inspection 1. Inspect: • Front seat lock • Rear seat lock Damage/wear → Replace.
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HULL HOOD EXHAUST SYSTEM E EXHAUST SYSTEM EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 10 9 12 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 11 3 14 13 8 7 4 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 1 5 2 6 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) REMOVAL AND INSTALLATION CHART Step Procedure/Part name EXHAUST SYSTEM REMOVAL Deck beam Jet pump unit assembly Q’ty Service points Follow the left “Step” for removal. Refer to “SEATS AND HAND GRIP”. Refer to “JET PUMP UNIT” in Chapter 6.
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HULL HOOD EXHAUST SYSTEM E EXPLODED DIAGRAM 10 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 9 12 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 11 3 14 13 8 7 4 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 1 5 2 6 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) Step 5 6 7 8 9 10 11 12 13 14 Procedure/Part name Exhaust joint clamp Exhaust joint Nut/washer Exhaust valve Hose clamp Rubber hose Hose clamp Water tank Rubber hose Plate Q’ty 1 1 6/6 1 Service points NOTE: Remove parts 8 to 14 as a set.
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HULL HOOD EXHAUST SYSTEM E EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 2nd 12 N • m (1.2 kgf • m, 8.8 ft • Ib) 6 × 25 mm 1st 1 2 LT 572 4 3 REMOVAL AND INSTALLATION CHART Step 1 2 3 4 Procedure/Part name EXHAUST JOINT DISASSEMBLY Bolt Exhaust joint protector 1 Exhaust joint protector 2 Exhaust joint pipe Q’ty Service points Follow the left “Step” for disassembly. 6 1 1 1 Reverse the disassembly steps for assembly.
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HULL HOOD EXHAUST SYSTEM E SERVICE POINTS Exhaust system inspection 1. Inspect: • Water lock band Cracks/damage → Replace. 2. Inspect: • Rubber hoses Burns/cracks/damage → Replace. 3. Inspect: • Water lock Cracks/leaks → Replace. 4. Inspect: • Water tank Cracks/damage/leaks → Replace. Exhaust component parts sub-assembly 1. Install: • Rubber hose • Plate NOTE: Be sure to fit the projections on the rubber hose with the grooves in the plate. 2.
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HULL HOOD EXHAUST SYSTEM E Exhaust system installation 1. Install: • Exhaust joint NOTE: Be sure to fit the slit a on the exhaust joint with the projection b on the exhaust pipe. b a 2. Install: • Water lock NOTE: Be sure to insert the rubber hose to the line a on the water lock.
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HULL HOOD DECK AND HULL E DECK AND HULL EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 22 mm 13 N • m (1.3 kgf • m, 9.4 ft • Ib) 17 16 N • m (1.6 kgf • m, 12 ft • Ib) 8 × 35 mm LT 16 271 15 N • m (1.5 kgf • m, 11 ft • Ib) 5 3 5 4 18 12 2 7 13 8 6 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 1 11 10 9 5 × 25 mm • kgf • m, 1.4 ft • Ib) 2.0 N m (0.2 15 13 14 15 N • m (1.
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HULL HOOD DECK AND HULL E EXPLODED DIAGRAM 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 22 mm 13 N • m (1.3 kgf • m, 9.4 ft • Ib) 17 16 N • m (1.6 kgf • m, 12 ft • Ib) 8 × 35 mm LT 16 271 15 N • m (1.5 kgf • m, 11 ft • Ib) 5 3 5 4 18 12 2 7 13 8 6 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 1 11 10 9 5 × 25 mm • kgf • m, 1.4 ft • Ib) 2.0 N m (0.
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HULL HOOD ENGINE MOUNT E ENGINE MOUNT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 Procedure/Part name ENGINE MOUNT REMOVAL Engine unit Bolt Damper 1 Damper 2 Bolt Engine mount Liner Q’ty 4 1 1 8 4 2 8-49 Service points Follow the left “Step” for removal. Refer to “ENGINE UNIT” in Chapter 5. Stern side Reverse the removal steps for installation.
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HULL HOOD ENGINE MOUNT E HULL REPAIR Shallow scratches 1. Sand the scratches with 400 grit sandpaper (either wet or dry) until the scratches are smooth. Then, sand the scratches once again with 600 grit sandpaper (either wet or dry). Deep scratches 1. Remove any sharp or rough edges from the hull surface. 2. Sand the scratches and a 1-inch circumference around them with 80 grit sandpaper (either wet or dry). 3. Clean the entire area with acetone and let it completely dry. 4.
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HULL HOOD ENGINE MOUNT E Cracks and punctures NOTE: Before attempting to repair any cracks or punctures, refer to “WATERCRAFT FRP REPAIR MANUAL”. 1. Remove any damaged fiberglass. 2. Cut the damaged area and separate it approximately 0.25 inch. 3. On the outside of the hull, grind the separated edge of the area to less than 5° as shown. 4. Working from inside the hull, grind the damaged area approximately 4 inches beyond the damage. 5.
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HULL HOOD ENGINE MOUNT E 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. Part No. Part name Remarks EW2-62733-09 Nut Stainless steel, M6 • Nut 1 • Thread direction 2 • Slot to be threaded 3 NOTE: Drilling size Material Pilot hole diameter FRP or SMC 9.1–9.2 mm (0.36 in) Brass 9.4 mm (0.
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HULL HOOD ENGINE MOUNT E 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 the ride plate. 7. Drill a 20 mm (0.79 in) deep hole in the center of the laminated fiberglass layers with a 9.2 mm (0.36 in) diameter drill bit. 8.
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HULL HOOD ENGINE MOUNT E 2. To prevent water from entering the urethane 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 dryer approximately 1.5 inches above the graphic 1. 2. Apply heat to one corner of the graphic. 3.
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TRBL ANLS E CHAPTER 9 TROUBLE ANALYSIS INTRODUCTION.............................................................................................. 9-1 FEATURES ............................................................................................... 9-1 Functions............................................................................................. 9-1 CONTENTS............................................................................................... 9-1 HARDWARE REQUIREMENTS...............
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TRBL ANLS E STATIONARY TEST ............................................................................... 9-28 Sparking ignition coil procedure: .......................................................9-28 Operating injector procedure:............................................................ 9-33 Operating the electric fuel pump: ......................................................9-35 ACTIVE TEST .........................................................................................
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TRBL ANLS INTRODUCTION E INTRODUCTION FEATURES The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ECM (Electronic Control Module) of a watercraft using the communication cable, this software can be used to display sensor data and data stored in the ECM on a computer’s monitor.
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TRBL ANLS INTRODUCTION E HARDWARE REQUIREMENTS Make sure that your computer meets the following requirements before using this software.
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TRBL ANLS GETTING STARTED E GETTING STARTED This section provides information on installing the Yamaha Diagnostic System under Windows 95, Windows 98, Windows Me, Windows 2000, or Windows XP. INSTALLING THE YAMAHA DIAGNOSTIC SYSTEM UNDER Windows 95, Windows 98, Windows Me, Windows 2000, or Windows XP NOTE: • Before installing the Yamaha Diagnostic System, check that your computer meets the specified requirements. For detailed information on the system requirements, see page 2.
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TRBL ANLS GETTING STARTED E 4. Click the Next button to start the installation process. (Fig. 3) Fig. 3 NOTE: If the Yamaha Diagnostic System has already been installed onto your computer, the following dialog box appears. Click the Yes button to update this program, or click the No button to quit the installation. (Fig. 4) Fig. 4 NOTE: • To quit the installation, click the Cancel button. The following dialog box appears. Fig. 5 • To quit the installation program, click the Exit Setup button.
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TRBL ANLS GETTING STARTED E 5. Check the target directory and the program name for the Yamaha Diagnostic System which are displayed in the dialog box. Click the Next button to start copying the program files. NOTE: • To go back to the previous dialog box (step 4), click the Back button. • To quit the installation, click the Cancel button. Fig. 6 Fig. 7 Fig.
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TRBL ANLS GETTING STARTED E 6. After the installation is completed, the following dialog box appears. Click the Finish button to quit the installation program. Fig. 9 NOTE: Install the Database file before using the Yamaha Diagnostic System, otherwise the program will not operate correctly. For installation procedures, refer to “UPDATING THE DATABASE” on the next page.
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TRBL ANLS GETTING STARTED E UPDATING THE DATABASE NOTE: When installing the Yamaha Diagnostic System for the first time, be sure to update the database. 1. Turn on your computer and start up Windows 95, Windows 98, Windows Me, Windows 2000, or Windows XP. 2. From the taskbar at the bottom of your computer screen, click the Start button (fig. 10), point to Programs, and then click YAMAHA DIAGNOSTIC SYSTEM for WaterCraft to open the Yamaha Diagnostic System window. (Fig. 11) Fig. 10 3.
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TRBL ANLS GETTING STARTED E 4. Click the Update database [F1] button or press the F1 key on your keyboard. (Fig. 12) Fig. 12 1 First menu 2 Click to update database NOTE: • Do not click the Starting service tool [Enter] button or press the Enter key on your keyboard until the database has been updated, otherwise the program will not operate correctly. • To quit the update of the database, press the ESC key on your keyboard.
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TRBL ANLS GETTING STARTED E 5. Insert the compact disc into the computer’s CD-ROM drive. NOTE: • All the database files will be copied from the compact disc to the computer’s hard drive automatically. • Any earlier version of the database saved on the hard drive will be overwritten. 6. Click the OK button or press the Enter key on your keyboard to start copying the database files. (Fig. 13) Fig. 13 NOTE: If an error message appears and the program stops operating, follow the error message. (Fig.
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TRBL ANLS GETTING STARTED E 7. When the database is updated a confirmation screen is displayed. To quit, click the OK button or press the Enter key on your keyboard. (Fig. 15) To return to the first menu screen, click the Cancel button or press the Esc key on your keyboard. Fig. 15 NOTE: If the OK button is clicked, the program is exited. Start the program again and check that the database version indicated in the first menu is J1.00. (Fig. 16) Fig.
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TRBL ANLS OPERATING E OPERATING CONNECTING THE COMPUTER TO THE WATERCRAFT NOTE: Be sure to use the enclosed communication cable to connect the computer and adapter to the watercraft. 1. Quit any applications that are running, and then turn off the computer. 2. Connect the communication cable to the 3-pin communication coupler of the watercraft, the adapter, and the communication port of your computer. 1 Fig.
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TRBL ANLS OPERATING E CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT Models: FX140 Top view 1 2 3 Fig. 18 1 3-pin communication coupler 2 Wire harness coupler 3 Meter coupler NOTE: Be careful not to pinch the communication cable between the hood and the deck or to damage it.
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TRBL ANLS OPERATING E OPENING THE YAMAHA DIAGNOSTIC SYSTEM 1. Push the start switch to start the engine. 2. Turn on your computer and start up Windows 95, Windows 98, Windows Me, Windows 2000, or Windows XP. 3. From the taskbar at the bottom of your computer screen, click the Start button (Fig. 19), point to Programs, and then click YAMAHA DIAGNOSTIC SYSTEM for WaterCraft. Fig. 19 4. Open the Yamaha Diagnostic System window. (Fig.
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TRBL ANLS OPERATING E 5. Click the Starting service tool [Enter] button or press the Enter key on your keyboard. (Fig. 21) Fig. 21 1 First menu 2 Click to start service tool NOTE: • If an error message appears and the program stops operating, follow the error messages. • If the program doesn’t start, an error message will explain the problem. If the program doesn’t start and an error message is not displayed, the cause of the problem is most likely insufficient computer memory.
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TRBL ANLS OPERATING E 6. Click or press any key to display the main menu. Fig. 22 NOTE: If a diagnosis record is stored in the ECM, “Diagnosis record available,” appears as a confirmation message before the Main Menu is displayed. (Fig. 23) Fig.
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TRBL ANLS OPERATING E SELECTING COMMANDS FROM THE MAIN MENU Eight commands appear in the Main Menu. Select a command in any of the following three ways. Two ways to select command: • Move the mouse pointer over the selected command (a or b) until it appears as a finger mark, and then click the selected command. • Press the number key (1–8) corresponding to the selected command. Fig.
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TRBL ANLS OPERATING E EXPLANATION OF EACH COMMAND 1. Diagnosis The diagnosis codes, their corresponding part name, the diagnosing results, and the diagnostic criteria are listed. List of items: Condition of coils (pulser coils) Condition of sensors (throttle position sensor, intake air temperature sensor, intake air pressure sensor, engine temperature sensor, and cam position sensor) Condition of battery (battery voltage) Operation of switches (slant detection switch) 2.
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TRBL ANLS OPERATING E 6. Data logger Two out of six items (engine speed, battery voltage, throttle position, intake air pressure, engine temperature, and oil pressure) are selected and 78 seconds of their recorded data are displayed on a graph. The operating time as compared to the engine speed and the total operating time are also displayed. 7. ECM No. The ECM part number and model information are displayed. 8. Exit The program is exited.
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TRBL ANLS OPERATING E DIAGNOSIS The diagnosis codes of malfunctions recorded in the watercraft’s ECM, the diagnosis codes’ corresponding part name, the results of the diagnosis, and the condition of the part are listed. Eight items can be displayed at one time. Fig. 25 1 Other than Normal will be highlighted in red and will be listed from the top 2 Displays troubleshooting procedures for selected code.
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TRBL ANLS OPERATING E Print By selecting the Print command in the Diagnosis, Diagnosis record, Engine monitor, or Data logger mode, the data from the corresponding window can be printed. 1. Click the Print [F1] button or press the F1 key on your keyboard. The Print dialog box is displayed. (Fig. 26) Fig. 26 2. Specify the printer, the printing range, and the number of copies to be printed. Fig. 27 1 Select printer 2 Select the number of copies 3 Select which page to print 3.
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TRBL ANLS OPERATING E Save By selecting the Save command in the Diagnosis, Diagnosis record, Engine monitor, or Data logger mode, the corresponding data can be saved on a disk. Operating procedure: 1. Click the Save [F2] button or press the F2 key on your keyboard. The Save As dialog box is displayed. (Fig. 28) Fig. 28 Fig.
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TRBL ANLS OPERATING E 2. Select the disk and folder where the data will be saved and specify its file name. (Fig. 30) Fig. 30 1 Choose folder to save in 2 Choose type of data 3 Input file name 3. Click the Save button to save the data. To cancel saving, click the Cancel button. (Fig. 30) The data you saved can be viewed in Microsoft® Excel. (Fig. 31) Fig.
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TRBL ANLS OPERATING E DIAGNOSIS RECORD The diagnosis codes of malfunctions that have been recorded in the watercraft’s ECM, the diagnostic codes’ corresponding part name, and the time when the malfunctions occurred are listed. A maximum of five items can be displayed at one time. The oldest occurrence appears on top. In addition, diagnosis codes stored in the ECM can be deleted. Fig. 32 1 Displays time of occurrence 2 Displays troubleshooting procedures for selected code.
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TRBL ANLS OPERATING E Deleting diagnosis record in the ECM: 1. Select the item that you wish to delete by either clicking it or pressing the up or down arrow keys on your keyboard. NOTE: • The selected code is highlighted in light blue. • Check that the items deleted are normal in the Diagnosis Record. If the items remain irregular, they will appear as irregular in the Diagnosis Record even if you try to delete them they are undeletable. Fig. 34 2.
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TRBL ANLS OPERATING E 3. Click the OK button or press the Enter key on your keyboard. (Fig. 35) The selected item is deleted. To cancel deleting the item, click the Cancel button or press the Esc key on your keyboard. NOTE: If an error occurs while an item is being deleted, an error message appears. Follow the instructions that appear in the error message. (Fig. 36) Fig.
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TRBL ANLS OPERATING E ENGINE MONITOR WARNING Do not use the Engine Monitor function to check the engine condition while operating a watercraft, otherwise you could become distracted, which could result in a collision. CAUTION: Be sure to avoid splashing water on the computer, adapter, and communication cable, and to avoid damaging them with strong sudden jolts or vibration. The data from the ECM of the watercraft is displayed. Ten items can be displayed at one time.
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TRBL ANLS OPERATING E Operating procedure: 1. To scroll the display and view other items, click or in the scroll bar, or press the up or down arrow keys on your keyboard. 2. To change a displayed item, click the Select [F3] button or press the F3 key on your keyboard. 3. Select an item by either clicking it or pressing the up or down arrow keys on your keyboard, and then press the space bar. (Fig. 38) Fig. 38 1 Selected items NOTE: • Selected items have a light blue background.
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TRBL ANLS OPERATING E STATIONARY TEST Selecting this command displays a window where stationary tests (spark ignition coil #, operate injector #, and operate electric fuel pump) can be selected. WARNING Avoid clicking the Execute and Cancel buttons repeatedly, otherwise the ECM or PC will not work properly and they could be damaged. Fig.
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TRBL ANLS OPERATING E 1. Select the test that you wish to perform by either clicking it or pressing the up or down arrow keys on your keyboard. (Fig. 39) NOTE: • Make sure that the engine is not running. • The selected item is highlighted in light blue. • The details of the selected test are displayed in the column on the right, and the items that must be either checked or performed before the test can start are displayed below the table. • Only one item can be selected at one time.
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TRBL ANLS OPERATING E 5. Click the Execute button or press the Enter key on your keyboard. (Fig. 42) Fig. 42 Fig.
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TRBL ANLS OPERATING E NOTE: If the engine is running an error message is displayed. Follow the instructions that appear. (Fig. 44) Fig. 44 6. While checking the information that appears in the Test situation column, follow the test instructions in the messages that are displayed. (See fig. 43.) NOTE: If an error occurs while the test is being performed, an error message is displayed. Follow the instructions that appear in the error message. (Fig. 45) Fig. 45 7.
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TRBL ANLS OPERATING E 9. To perform the test again to the same cylinder, click the Execute button or press the Enter key on your keyboard. To perform the test on a different cylinder, click the Return [ESC] button or press the Esc key on your keyboard to return to main menu where a different test can be selected. (Fig. 46) Fig. 46 NOTE: If an error occurs while the test is being performed, the following message is displayed. (Fig. 47) Fig.
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TRBL ANLS OPERATING E Operating injector procedure: A voltage is applied to the injector of the selected cylinder, the injector is activated, and then the fuel system is checked. The fuel is injected 20 times within two seconds. WARNING • Do not perform the test with the injector removed from the throttle body or with any fuel system parts removed. High-pressure fuel could spurt out. • When performing this operation, keep all sparks, flames, or other sources of ignition away from the testing area.
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TRBL ANLS OPERATING E 3. Click the Execute button or press the Enter key on your keyboard. (Fig. 49) Fig. 49 NOTE: If an error occurs while the test is being performed, an error message is displayed. Follow the instructions that appear. 4. Listen to the operating sound of the injector of the cylinder being tested. Fig. 50 WARNING Do not touch the injector connector.
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TRBL ANLS OPERATING E 5. To perform the test again on the same cylinder, click the Execute button or press the Enter key on your keyboard. To perform the test on a different cylinder, click the Return [ESC] button or press the Esc key on your keyboard to return to the window where a different test can be selected. (Fig. 51) Fig. 51 CAUTION: Do not test the same cylinder three or more times, otherwise the spark plug insulator could be damaged.
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TRBL ANLS OPERATING E 1. Select the test to be performed, and then click the Select button or press the Enter key on your keyboard. (Fig. 52) Fig. 52 NOTE: • Make sure that the engine is not running. • The selected item is highlighted in light blue. • The details of the selected test are displayed in the column on the right, and the items that must be either checked or performed before the test can start are displayed below the table. • Only one item can be selected at one time.
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TRBL ANLS OPERATING E 2. Click the Execute button or press the Enter key on your keyboard. (Fig. 53) Fig. 53 NOTE: If an error occurs while the test is being performed, an error message is displayed. Follow the instructions that appear. 3. Listen to the operating sound of the electric fuel pump. 4. To perform the test again, click the Execute button or press the Enter key on your keyboard.
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TRBL ANLS OPERATING E ACTIVE TEST Selecting this command displays a window where active tests can be selected. WARNING Avoid clicking the Execute and Cancel buttons repeatedly, otherwise the ECM or PC will not work properly and they could be damaged. Fig. 55 NOTE: The test can be carried out while the engine is running. It is not possible to carry out the test while the watercraft is running.
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TRBL ANLS OPERATING E Dropping a cylinder: Start the engine and observe the changes in engine speed for 20 seconds. For the first ten seconds operate all four cylinders, and then stop one cylinder for five seconds. For the last five seconds operate all four cylinders. A screen that allows you to select which ignition and fuel to cut is displayed. 1. Select which ignition and fuel you wish to cut by either clicking it or pressing the up or down arrow keys on your keyboard. (Fig.
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TRBL ANLS OPERATING E NOTE: If the engine is not running, an error message is displayed. Follow the instructions that appear. (Fig. 57) Fig. 57 5. While checking the information that appears beside Test situation and Engine Speed, follow the test instructions in the messages that are displayed. (Fig. 56) NOTE: If an error occurs while the test is being performed, an error message is displayed. Follow the instructions that appear. (Fig. 58) Fig. 58 6.
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TRBL ANLS OPERATING E DATA LOGGER Monitor item selection A window appears that allows you to select the Data comparison graph or the Engine operating hours according to engine speed. Fig. 59 1 Triangle mark Operating procedure: 1. Select the desired item by either clicking it or pressing the up or down arrow keys on your keyboard. (Fig. 59) NOTE: A triangle appears to the right of the selected item. 2. Press the Enter key on your keyboard. The window of the selected item is displayed. (Fig.
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TRBL ANLS OPERATING E Data display item selection A window appears that allows you to select the items to be graphed. No more than two items can be displayed. Fig. 60 1 Selected items Operating procedure: 1. Select the desired items by either clicking them or pressing the up or down arrow keys on your keyboard, then pressing the space bar. (Fig. 60) NOTE: • Selected items have a light blue background. Items that are not selected have a blue background.
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TRBL ANLS OPERATING E Data comparison graph A line graph appears with the items selected in the Data display item selection window on the vertical axes and the Time before engine stop on the horizontal axis. (Fig. 61) Fig. 61 NOTE: • The item on the left vertical axis is graphed with a solid line and the item on the right vertical axis is graphed with a dotted line. • Although the engine is running, graphs do not show the present engine condition.
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TRBL ANLS OPERATING E Engine operating hours according to engine speed The operating hours as compared to the engine speed and the total operating hours are displayed. (Fig. 62) Fig. 62 A window is displayed showing the amount of hours that the engine is operated at each engine speed range. NOTE: • Although the engine is running the displayed time refers to the added hours until the Data logger starts.
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TRBL ANLS OPERATING E ECM No. The ECM part number of the watercraft is read from the ECM and is displayed. (Fig. 63) Fig.
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TRBL ANLS OPERATING E EXIT The program is exited. Operating procedure: 1. Click the Exit button or press any number key (1–8). Fig. 64 2. Click the OK button or press the Enter key on your keyboard to exit the program. To cancel exiting the program, click the Cancel button or press the Esc key on your keyboard. (Fig. 65) Fig.
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TRBL ANLS OPERATING E UNINSTALLING THE YAMAHA DIAGNOSTIC SYSTEM Use the following procedure to uninstall the Yamaha Diagnostic System. 1. Exit all programs before running the uninstaller. 2. From the taskbar at the bottom of your computer screen, click the Start button, point to Settings, and then open the Control Panel. 3. In the Control Panel dialog box, double-click Add/Remove Programs. (Fig. 66) Fig. 66 4. Select YAMAHA DIAGNOSTIC SYSTEM for WaterCraft and click the Add/Remove button. (Fig.
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TRBL ANLS OPERATING E 5. Click the Yes button in the confirmation window to uninstall the utility software. To cancel the uninstall operation of the utility software, click the No button. (See figs. 68–70.) Fig. 68 Fig. 69 Fig.
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TRBL ANLS OPERATING E 6. If the following message appears, click the Details... button. Fig. 71 1 Uninstall completed. Some elements could not be removed. You should manually remove items related to the application. 7. Check the contents of the message. If an element could not be removed, delete it manually. Fig. 72 1 Elements that could not be removed.
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TRBL ANLS TROUBLESHOOTING E TROUBLESHOOTING Error content Communication cable related error occurs Cause Action Communication cable is disconnected. Connect communication cable between the computer’s communication port and 3-pin communication coupler of the watercraft. Battery is disconnected from the watercraft. Connect battery to watercraft. The battery voltage is below 12 V. Connect battery of 12 V or higher. The hardware does not meet the requirements to operate this application.
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TRBL ANLS APPENDIX E APPENDIX SETTING THE DESKTOP AREA Use the following procedure to set the Yamaha Diagnostic System desktop area. Compatible with VGA (640 × 480 pixels) or SVGA (800 × 600 pixels) or more recommended 1. From the taskbar at the bottom of your computer screen, click the Start button, point to Settings, and then open the Control Panel. 2. In the Control Panel, double-click Display. (Fig. 73) Fig. 73 3. Select Settings and slide the Desktop area slider. (Fig. 74) Fig.
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TRBL ANLS APPENDIX E 4. Click the OK button in the confirmation window to set the display area. To cancel, click the Cancel button. (See figs. 75–76.) Fig. 75 Fig.
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TRBL ANLS TROUBLE ANALYSIS E 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 properly secured and are not rusty. 4. The engine shut-off cord (lanyard) is installed onto the engine shut-off switch. 5. Fuel is reaching the throttle body.
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TRBL ANLS TROUBLE ANALYSIS POOR BATTERY CHARGING IRREGULAR WARNING INDICATION BILGE INCREASE LOOSE STEERING Check elements LOW OIL PRESSURE OVERHEATING LIMITED ENGINE SPEED POOR PERFORMANCE ENGINE WILL NOT STOP POOR ACCELERATION ENGINE STALLS HIGH IDLING ROUGH IDLING HARD STARTING ENGINE WILL NOT START Trouble mode E Relative part POWER UNIT Compression Cylinder head gaskets Cylinder block Crankcase Piston rings Pistons Bearings Thermostat Valve(s) and valve seat(s) Valve clearance adju
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TRBL ANLS TROUBLE ANALYSIS POOR BATTERY CHARGING IRREGULAR WARNING INDICATION BILGE INCREASE LOOSE STEERING Check elements LOW OIL PRESSURE OVERHEATING LIMITED ENGINE SPEED POOR PERFORMANCE ENGINE WILL NOT STOP POOR ACCELERATION ENGINE STALLS HIGH IDLING ROUGH IDLING HARD STARTING ENGINE WILL NOT START Trouble mode E Relative part Reference chapter JET PUMP UNIT Duct Impeller Intake grate Bearings Intake duct Water inlet hose Bilge hose Bilge strainer Bilge hose joint ELECTRICAL Igniti
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TRBL ANLS TROUBLE ANALYSIS POOR BATTERY CHARGING IRREGULAR WARNING INDICATION BILGE INCREASE LOOSE STEERING Check elements LOW OIL PRESSURE OVERHEATING LIMITED ENGINE SPEED POOR PERFORMANCE ENGINE WILL NOT STOP POOR ACCELERATION ENGINE STALLS HIGH IDLING ROUGH IDLING HARD STARTING ENGINE WILL NOT START Trouble mode E Relative part Starting system • Start switch • Starter relay • Starter motor Charging system • Lighting coil • Rectifier/regulator • Fuses • Battery leads • Battery Electri
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TRBL ANLS TROUBLE ANALYSIS E Self-diagnosis With the engine running, press the hour meter/ voltmeter display select switch 1 and the speedometer display switch 2 for 8 seconds and check if an error code is indicated on the multifunction meter.
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WIRING DIAGRAM FX140 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R S T U Fuse (20A) Fuse (3A) Starter relay Slant detection switch Main and fuel pump relay ECM Rectifier Regulator Cam position sensor Thermoswitch (exhaust) Oil pressure switch Thermoswitch (engine) Engine temperature sensor Intake air pressure sensor Intake air temperature sensor Throttle position sensor Fuel injector Ignition coil Spark plug Pulser coil Lighting coil Battery Starter motor Electrical bilge pump Fuel pump Fuel send
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YAMAHA MOTOR CORPORATION, USA Printed in USA Mar. 2002 – ?.
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FX140 G G B G B/O B/O B B P/W B/O G/O P B/O G W/R B/O W/B B/O B/O 3 R P/G R R Br 2 R R/Y Pu/Y P B/O B B P B/O W R B P B/Y B/Y B/Y B/Y B/Y 0 Pu/G R/Y P/W B/O B/O R/Y G/O B/Y Pu/R B R/Y B G/O O P P B/O B 1 B/O P/W R/Y B P B/O 2 8 R/Y Pu/B R/Y Br Br B/O P R R R/Y O A D P/G B B/Y B/Y O P/G B/O B/O C Pu/Y Pu/R 4 9 Pu/G B/O R/Y B/O B/O B/O B/O B/O R/Y P E L/B L/B 5 C L/B L Pu/G L/R Pu/Y Pu/B Pu/R O Br R/Y Y R/Y A
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A C 123 C B Br R/Y R/Y R/Y Br R R R/Y B B L B/O Y L/R L/B R/Y R 4 5 D P O Pu/R Pu/Y R/Y P/G B/Y Pu/B B/O Pu/G B/O B/O B/O B/O R/Y R/Y R/Y R/Y O E O O P R P P O R/Y R/Y R/Y R/Y R/Y B/W Pu/G B Pu/B Pu/R Pu/Y W/B B/Y P P/G G/O B/R W/B W/R B/O B/Y W G P/W 6 F F F F D A GH B D B/Y W/B B/O P G/O R/Y Pu/B B/Y P/G P W/R P/W R/Y Pu/G Pu/Y Pu/R O P B B/Y G G G P W/B W/R B/O P/W P R/Y G/O B/O B/O B B 8 9 0 A B I J B/W R/Y B/R R/Y 7 P D O Pu/R Pu/Y Pu/G P/G B/Y Pu/B R/Y B/O C R B G