WaveRunner

XLT1200

SERVICE MANUAL

*LIT186160227*
LIT-18616-02-27 F0V-28197-1A-11
 E

NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their
trained mechanics when performing maintenance procedures and repairs to Yamaha equip-
ment. It has been written to suit the needs of persons who have a basic understanding of the
mechanical and electrical 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.
Because Yamaha has a policy of continuously improving its products, models may differ in
detail from the descriptions and illustrations given in this publication. Use only the latest edi-
tion of this manual. Authorized Yamaha dealers are notified periodically of modifications and
significant changes in specifications and procedures, and these are incorporated in succes-
sive editions of this manual.

A10001-0*

WaveRunner XLT1200
SERVICE MANUAL
©2001 by Yamaha Motor Corporation, USA
1st Edition, January 2001
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-02-27
 E

HOW TO USE THIS MANUAL

MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The
information has been compiled to provide the mechanic with an easy to read, handy refer-
ence that contains comprehensive explanations of all disassembly, repair, 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.,
● Bearings
Pitting/scratches → Replace.
To assist you in finding your way through this manual, the section title and major heading is
given at the top of every page.

ILLUSTRATIONS
The illustrations within this service manual represent all of the designated models.

CROSS REFERENCES
The cross references have been kept to a minimum. Cross references will direct you to the
appropriate section or chapter.
 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 water-
craft.

NOTE:
A NOTE provides key information to make procedures easier or clearer.

IMPORTANT:
This part has been subjected to change of specification during production.
 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.
5 Dimension figures and the number of parts, are provided for fasteners that require a tight-
ening torque.
Example:
Bolt or screw size 10 × 25 mm : M10 (D) × 25 mm (L)
D

6 Jobs requiring more information (such as special tools and technical data) are described
sequentially.
 E
A50001-1-4
1 2
SYMBOLS
GEN Symbols 1 to 9 are designed as thumb-
INFO SPEC tabs to indicate the content of a chapter.
3 4 1 General Information
2 Specifications
INSP FUEL 3 Periodic Inspection and Adjustment
ADJ 4
5
Fuel System
Power Unit
5 6 6 Jet Pump Unit
7 Electrical System
POWR JET 8 Hull and Hood
PUMP 9 Trouble analysis

7 8

– + HULL
ELEC HOOD
9 0
Symbols 0 to E indicate specific data:
0 Special tool
TRBL A Specified liquid
ANLS B Specified engine speed
C Specified torque
A B D Specified measurement
E Specified electrical value
[Resistance (Ω), Voltage (V), Electric current
(A)]
C D

Symbol F to H in an exploded diagram

indicate the grade of lubricant and the loca-
T.
R.

tion of lubrication point:

E F
F Apply YAMALUBE 2-W oil
G Apply water resistant grease
E (Yamaha grease A, Yamaha marine grease)
H Apply molybdenum disulfide grease
G H

A M Symbols I to N in an exploded diagram

indicate the grade of the sealing or locking
agent, and the location of the application
I J point:
GM 4 I Apply Gasket Maker®
J Apply Yamabond #4
(Yamaha bond number 4)
K L K Apply LOCTITE® No. 271 (Red LOCTITE)
L Apply LOCTITE® No. 242 (Blue LOCTITE)
LT LT M Apply LOCTITE® No. 572
271 242
N Apply silicone sealant

M N NOTE:
In this manual, the above symbols may not
LT SS
LT be used in every case.
572
 E

INDEX
A30000-0

GENERAL INFORMATION GEN

INFO
1
SPECIFICATIONS
SPEC 2
PERIODIC INSPECTION AND
ADJUSTMENT INSP
ADJ
3
FUEL SYSTEM
FUEL 4
POWER UNIT
POWR 5
JET PUMP UNIT JET
PUMP
6
– +

ELECTRICAL SYSTEM
ELEC 7
HULL AND HOOD HULL
HOOD
8
TROUBLE ANALYSIS TRBL
ANLS
9
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
1
HULL IDENTIFICATION NUMBER (H.l.N.).............................................. 1-1

SAFETY WHILE WORKING....................................................................... 1-2

FIRE PREVENTION ................................................................................... 1-2
VENTILATION........................................................................................... 1-2
2
SELF-PROTECTION.................................................................................. 1-2
OILS, GREASES AND SEALING FLUIDS................................................ 1-2
GOOD WORKING PRACTICES ................................................................ 1-3
DISASSEMBLY AND ASSEMBLY ........................................................... 1-4

SPECIAL TOOLS ............................................................................................. 1-5

3
MEASURING ............................................................................................ 1-5
REMOVAL AND INSTALLATION ............................................................ 1-6

4
5
6
7
8
9
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:
F0V: 800101

ENGINE SERIAL NUMBER

The engine serial number is stamped on a
label attached to the cylinder head.

Starting serial number:

68N: 000101

JET PUMP UNIT SERIAL NUMBER

The jet pump unit serial number is stamped
on a label attached to the intermediate
housing.

Starting serial number:

68N: 800101

HULL IDENTIFICATION NUMBER

(H.l.N.)
The H.l.N. is stamped on a plate attached to
the aft deck.

1-1
GEN
INFO SAFETY WHILE WORKING E

SAFETY WHILE WORKING

The procedures given in this manual are
those recommended by Yamaha to be fol-
lowed by Yamaha dealers and their
mechanics.

FIRE PREVENTION
Gasoline (petrol) is highly flammable.
Gasoline vapor is explosive if ignited.
Do not smoke while 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.
When test-running an engine indoors,
maintain good ventilation.

SELF-PROTECTION
Protect your eyes with suitable safety spec-
tacles or safety goggles when grinding or
doing any operation which may cause parti-
cles to fly off.
Protect hands and feet by wearing safety
gloves or protective shoes if appropriate to
the work you are doing.

OILS, GREASES AND SEALING

FLUIDS
Use only genuine Yamaha oils, greases,
and sealing fluids or those recommended
by Yamaha.

1-2
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 all-important, and by adopting
good safety practises any risk is minimized.
A summary of the most important precau-
tions is as follows:
1. While working, maintain good stan-
dards of personal and industrial
hygiene.
2. Clothing which has become contami-
nated with lubricants should be
changed as soon as practicable and
laundered before further use.
3. Avoid skin contact with lubricants (e.g.,
do not place a soiled rag in your
pocket).
4. Hands and any other part of the body
which have been in contact with lubri-
cants or lubricant-contaminated cloth-
ing should be thoroughly washed with
hot water and soap as soon as practica-
ble.
5. To protect the skin, the application of a
suitable barrier cream to the hands
before working is recommended.
6. A supply of clean lint-free cloths should
be available for wiping purposes.

GOOD WORKING PRACTICES

1. The right tools
Use the recommended special tools to
protect parts from damage. Use the
right tool in the right manner – do not
improvise.
2. Tightening torque
Follow the tightening torque instruc-
tions. When tightening bolts, nuts and
screws, tighten the larger sizes first and
tighten inner-positioned fixings before
outer-positioned ones.

1-3
GEN
INFO SAFETY WHILE WORKING E

3. Non-reusable items
Always use new gaskets, packings, O-
rings, oil seals, split-pins, circlips, etc.,
on reassembly.

DISASSEMBLY AND ASSEMBLY

1. Clean parts with compressed air when
disassembling.
2. Oil the contact surfaces of moving parts
during assembly.

3. 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.

CAUTION:
Do not spin bearings with compressed air
because this will damage their surfaces.

5. When installing oil seals, apply a light

coat of water-resistant grease to the
outside diameter.

1-4
GEN
INFO SPECIAL TOOLS E

SPECIAL TOOLS
Using the correct special tools recom-
mended by Yamaha, will aid the work and
enable accurate assembly and tune-up.
Improvisations and using improper tools
can damage the equipment.

NOTE:
● For U.S.A. and Canada, use part numbers
starting with “J-”, “YB-”, “YM-”, “YU-” or
“YW-”.
● For other countries, use part numbers
1 YU-08036-B 90890-06760
starting with “90890-”.

MEASURING
1 Engine tachometer
P/N. YU-8036-B
2 YU-03097 90890-01252
YU-01256 90890-06760
2 Dial gauge and stand
P/N. YU-03097, YU-01256
90890-01252
3 Pocket tester
P/N. YU-03112
3 YU-03112 4 YU-03017
90890-03112
90890-03112 90890-06759
4 Cylinder gauge set
P/N. YU-03017
90890-06759
5 Compression gauge
P/N. YU-33223
90890-03160
5 YU-33223 90890-03160
6 Digital multimeter
P/N. J-39299
90890-06752
7 Peak voltage adapter
6 J-39299 90890-06752 P/N. YU-39991
90890-03169
8 Peak voltage test harness
P/N. YW-06780
90890-06780
7 YU-39991 8 YW-06780
9 Spark gap tester
90890-03169 90890-06780
P/N. YM-34487
90890-06754

9 YM-34487 90890-06754

1-5
GEN
INFO SPECIAL TOOLS E

REMOVAL AND INSTALLATION

1 YW-06551 2 YW-06550 90890-06550
1 Coupler wrench
90890-06551 P/N. YW-06551
90890-06551
2 Flywheel holder
P/N. YW-06550
90890-06550
3 YB-06117 90890-06521
3 Flywheel puller
P/N. YB-06117
90890-06521
4 Drive shaft holder (impeller)
P/N. YB-06151
90890-06519
4 YB-06151 90890-06519 5 YB-06096 5 Slide hammer set (jet pump bearing)
P/N. YB-06096
6 Stopper guide plate (jet pump bearing)
P/N. 90890-06501
7 Bearing puller (jet pump bearing)
P/N. 90890-06535
6 90890-06501 7 90890-06535
8 Bearing puller claw 1 (jet pump bearing)
P/N. 90890-06536
9 Stopper guide stand (jet pump bearing)
P/N. 90890-06538
0 Drive rod L3 (jet pump bearing)
8 90890-06536 9 90890-06538
P/N. 90890-06652
A Needle bearing attachment
(jet pump bearing and oil seal)
P/N. YB-06112, YB-06196
90890-06614, 90890-06653
0 90890-06652 A YB-06112 90890-06614
YB-06196 90890-06653 B Ball bearing attachment
(jet pump oil seal)
P/N. YB-06085
90890-06634
C Driver rod
B YB-06085 90890-06634 (intermediate shaft and jet pump)
P/N. YB-06071
90890-06606
D Bearing inner/outer race attachment
(jet pump bearing)
C YB-06071 90890-06606 D YB-34474 P/N. YB-34474
E Shaft holder (intermediate shaft)
P/N. YB-06552
90890-06552
F Bearing outer race attachment
E YB-06552 F YB-06156 90890-06626 (intermediate shaft)
90890-06552 P/N. YB-06156
90890-06626

1-6
SPEC E

CHAPTER 2
SPECIFICATIONS

GENERAL SPECIFICATIONS ......................................................................... 2-1

MAINTENANCE SPECIFICATIONS................................................................ 2-3

1
ENGINE .................................................................................................... 2-3
JET PUMP UNIT ...................................................................................... 2-4
HULL AND HOOD ................................................................................... 2-4
ELECTRICAL ............................................................................................ 2-5

TIGHTENING TORQUES ................................................................................ 2-7

2
SPECIFIED TORQUES .............................................................................. 2-7
GENERAL TORQUE ............................................................................... 2-10

CABLE AND HOSE ROUTING...................................................................... 2-11

3
4
5
6
7
8
9
SPEC GENERAL SPECIFICATIONS E

GENERAL SPECIFICATIONS
Model
Item Unit
XLT1200
MODEL CODE
Hull F0V
Engine/jet 68N (with catalytic converter)
DIMENSIONS
Length mm (in) 3,160 (124.4)
Width mm (in) 1,220 (48.0)
Height mm (in) 1,130 (44.5)
Dry weight kg (lb) 364 (803)
Maximum capacity Person/kg (lb) 3/240 (529)
PERFORMANCE
Maximum output kW (PS) @ r/min 114 (155) @ 7,000
Maximum fuel consumption R/h (US gal/h, 64 (16.9, 14.1)
lmp gal/h)
Cruising range h 1.1
ENGINE
Engine type 2-stroke, L3
3
Displacement cm (cu. in) 1,176 (71.8)
Bore × stroke mm (in) 80.0 × 78.0 (3.15 × 3.07)
Compression ratio 5.9:1
Intake system Reed valve
Carburetor model BN44 (MIKUNI) × 3
(manufacturer) × quantity
Enrichment control Choke valve
Scavenging system Loop charged
Lubrication system Variable oil injection
Cooling system Water cooled
Starting system Electric starter
Ignition system Digital CDI
Ignition timing Degree 18 BTDC–24 BTDC
Spark plug model BR8ES-11 (NGK)
(manufacturer)
Battery capacity V/Ah (kC) 12/19 (68.4)
Generator output A @ r/min 9–11 @ 6,000
DRIVE UNIT
Propulsion system Jet pump
Jet pump type Axial flow, single stage
Impeller rotation (from rear) Counterclockwise
Transmission Direct drive from engine
Jet thrust nozzle horizontal Degree 24 + 24
angle
Jet thrust nozzle trim angle Degree –7, –2, 3, 8, 13
Trim system Manual 5 positions
Reverse system Reverse gate

2-1
SPEC GENERAL SPECIFICATIONS E

Model
Item Unit
XLT1200
FUEL AND OIL
Fuel Regular unleaded gasoline
Minimum fuel rating PON* 86
RON* 90
Oil YAMALUBE 2-W*
Fuel/oil mixing ratio 200:1–30:1
Fuel tank capacity R(US gal, 70 (18.5, 15.5)
Imp gal)
Fuel tank reserve capacity R(US gal, 12 (3.2, 2.7)
Imp gal)
Oil tank capacity R(US gal, 5.5 (1.5, 1.3)
Imp gal)

PON*: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2
RON*: Research Octane Number
YAMALUBE 2-W*: YAMALUBE 2-W is developed for this watercraft and available from a
Yamaha dealer.

CAUTION:
Use only YAMALUBE 2-W oil. Using another oil can seriously damage the catalytic converter
and other engine components.

2-2
SPEC MAINTENANCE SPECIFICATIONS E

MAINTENANCE SPECIFICATIONS
ENGINE
Model
Item Unit
XLT1200
CYLINDER HEAD
Warpage limit mm (in) 0.05 (0.002)
Compression pressure*1 kPa (kg/cm2) 500 (5.0)
CYLINDERS
Bore size mm (in) 80.000–80.018 (3.1496–3.1503)
Taper limit mm (in) 0.08 (0.003)
Out-of-round limit mm (in) 0.05 (0.002)
Wear limit mm (in) Original cylinder bore + 0.04 (0.0016)
PISTONS
Diameter mm (in) Red: 79.899–79.902 (3.1456–3.1457)
Orange: 79.903–79.906 (3.1458–3.1459)
Green: 79.907–79.910 (3.1459–3.1461)
Purple: 79.911–79.914 (3.1461–3.1462)
Measuring point* mm (in) 22 (0.87)
Piston-to-cylinder clearance mm (in) 0.100–0.105 (0.0039–0.0041)
Wear limit mm (in) Cylinder bore – 0.105 (0.0041)
Piston pin bore inside mm (in) 22.004–22.025 (0.8663–0.8671)
diameter
PISTON RINGS
Top
Type Keystone
Dimensions (B) mm (in) 1.47–1.49 (0.058–0.059)
Dimensions (T) mm (in) 2.8–2.9 (0.110–0.114)
End gap mm (in) 0.45–0.60 (0.018–0.024)
Ring groove clearance mm (in) 0.03–0.05 (0.001–0.002)
2nd*2
Type Keystone
Dimensions (B) mm (in) 1.47–1.49 (0.058–0.059)
Dimensions (T) mm (in) 2.8–2.9 (0.110–0.114)
End gap mm (in) 0.45–0.60 (0.018–0.024)
Ring groove clearance mm (in) 0.03–0.05 (0.001–0.002)
PISTON PINS
Diameter mm (in) 21.995–22.000 (0.8659–0.8661)
Wear limit mm (in) 21.990 (0.8657)
*1: At 760 mmHg and 20 ˚C (68 ˚F)
*2: The top ring and 2nd ring are of the same type.

2-3
SPEC MAINTENANCE SPECIFICATIONS E

Model
Item Unit
XLT1200
CRANKSHAFT ASSEMBLY
Crank width A mm (in) 72.95–73.00 (2.872–2.874)
Deflection limit B mm (in) 0.05 (0.002)
Deflection limit C mm (in) 0.15 (0.006)
Big end side clearance D mm (in) 0.25–0.75 (0.010–0.030)
Maximum small end axial mm (in) 2.0 (0.08)
play E

CARBURETORS
Type Floatless
Identification mark #1: 68N011, #2: 68N012, #3: 68N013
Main nozzle mm (in) 3.2 (0.13)
Main jet 117.5
Pilot jet 87.5
Throttle valve 180
Valve seat size mm (in) 1.2 (0.05)
Trolling speed r/min 1,350 ± 50
REED VALVES
Thickness mm (in) 0.6 (0.02)
Reed valve stopper height mm (in) 10.4–11.0 (0.41–0.43)
Reed valve warpage limit mm (in) 0.2 (0.01)

JET PUMP UNIT

Model
Item Unit
XLT1200
JET PUMP
Impeller material Stainless steel
Number of impeller blades 3
Impeller pitch angle Degree 15.6
Impeller clearance mm (in) 0.35–0.45 (0.014–0.018)
Impeller clearance limit mm (in) 0.6 (0.02)
Drive shaft runout limit mm (in) 0.3 (0.012)
Nozzle diameter mm (in) 86.8 (3.42)

HULL AND HOOD

Model
Item Unit
XLT1200
FREE PLAY
YPVS cable slack mm (in) 0.5–1.5 (0.02–0.06)
Throttle lever free play mm (in) 4–7 (0.16–0.28)

2-4
SPEC MAINTENANCE SPECIFICATIONS E

ELECTRICAL
Model
Item Unit
XLT1200
BATTERY
Type Fluid
Capacity V/Ah (kC) 12/19 (68.4)
CDI UNIT
(B/O – B for cylinder #1)
(B/W – B for cylinder #2)
(B/Y – B for cylinder #3)
Output peak voltage lower
limit
@cranking 1 V 200
@cranking 2 V 180
@2,000 r/min V 190
@3,500 r/min V 180
STATOR
Pickup coil (W/R – B/O)
Output peak voltage
lower limit
@cranking 1 V 5
@cranking 2 V 2.8
@2,000 r/min V 7.9
@3,500 r/min V 11
Lighting coil (G – G)
Output peak voltage
lower limit
@cranking 1 V 9
@cranking 2 V 9
@2,000 r/min V 14
@3,500 r/min V 14
Pickup coil resistance Ω (color) 445–545 (W/R – B/O)
Lighting coil resistance Ω (color) 0.49–0.59 (G – G)
Minimum charging current A @ r/min 9 @ 6,000
IGNITION COIL
Minimum spark gap mm (in) 10 (0.39)
Primary coil resistance Ω (color) 0.26–0.36 (B/W – Body)
Secondary coil resistance kΩ (color) 3.5–4.7 (B/W – Spark plug lead terminal)
Spark plug lead resistance
#1 kΩ 6.1–14.3
#2 kΩ 4.6–11.1
#3 kΩ 3.3–8.2
Cranking 1: unloaded
Cranking 2: loaded

2-5
SPEC MAINTENANCE SPECIFICATIONS E

Model
Item Unit
XLT1200
RECTIFIER/REGULATOR
(R – B)
Output peak voltage lower
limit (unloaded)
@cranking V 7
@2,000 r/min V 12.6
@3,500 r/min V 12.6
STARTER MOTOR
Brush length mm (in) 12.5 (0.49)
Wear limit mm (in) 6.5 (0.26)
Commutator undercut mm (in) 0.7 (0.03)
Limit mm (in) 0.2 (0.01)
Commutator diameter mm (in) 28.0 (1.10)
Limit mm (in) 27.0 (1.06)
FUSE
Rating V/A 12/10
12/20

2-6
SPEC TIGHTENING TORQUES E

TIGHTENING TORQUES
SPECIFIED TORQUES
Thread Tightening torque
Part to tightened Part name Q’ty Remarks
size N•m kgf•m ft•lb
ENGINE
Muffler cover – muffler Bolt M6 3 12 1.2 8.7

242
LT
Exhaust chamber stay/ 1st 15 1.5 11
Bolt M8 2
cylinder head – cylinder 2nd 35 3.5 25
Exhaust chamber/stay – bracket Bolt M10 2 39 3.9 28

271
LT
Exhaust chamber joint –
Bolt M10 4 39 3.9 28

271
LT
exhaust manifold
Exhaust chamber –
Bolt M10 6 39 3.9 28

271
LT
exhaust chamber joint
Muffler – eye Nut M10 2 39 3.9 28

271
LT
Eye – cylinder head Bolt M10 4 39 3.9 28

271
LT
Muffler stay – cylinder body Bolt M10 2 39 3.9 28

271
LT
Muffler stay 2 – crankcase Bolt M10 2 39 3.9 28

271
LT
Muffler – muffler stay 2 Bolt M10 1 39 3.9 28

271
LT
Exhaust temperatur sensor –
— — 1 39 3.9 28

572
LT
muffler
Muffler stay – catalyst 1st 15 1.5 11
Bolt M10 2

271
LT
housing/muffler 2nd 39 3.9 28
Water temperature sensor –
— — 1 20 2.0 14

572
LT
mixing joint
Muffler – catalyst 1st 15 1.5 11
Bolt M8 6

271
LT
housing 2nd 33 3.3 24
1st 11 1.1 8.0
Muffler – mixing joint Bolt M8 6

271
LT
2nd 22 2.2 16
1st 22 2.2 16
Bolt M10 10
271
LT

Exhaust manifold – 2nd 39 3.9 28

cylinder 1st 15 1.5 11
Nut M10 2
271
LT

2nd 39 3.9 28
Water pipe – exhaust manifold Bolt M6 6 12 1.2 8.7
242
LT

Engine – engine mount Bolt M8 4 17 1.7 12

572
LT

Reed valve plate/reed valve –

Bolt M6 18 12 1.2 8.7
242
LT

crankcase
Reed valve – reed valve base Screw M3 24 0.8 0.08 0.6
242
LT

YPVS cable holder/valve cover –

Bolt M6 2 10 1.0 7.2
572
LT

cylinder
YPVS valve cover – cylinder Bolt M6 10 10 1.0 7.2
572
LT

YPVS valve arm – shaft Bolt M4 3 3 0.3 2.2

242
LT

YPVS valve assembly – cylinder Bolt M5 3 4 0.4 2.9

242
LT

Spark plug – cylinder head Spark plug M14 3 25 2.5 18

1st 22 2.2 16
Cylinder head cover/
2nd Bolt M8 22 22 2.2 16
cylinder head – cylinder
3rd 35 3.5 25

2-7
SPEC TIGHTENING TORQUES E

Thread Tightening torque

Part to tightened Part name Q’ty Remarks
size N•m kgf•m ft•lb
1st 22 2.2 16
Cylinder – crankcase Bolt M10 12

572
LT
2nd 39 3.9 28
Generator cover – 1st 15 1.5 11
Bolt M10 7

271
LT
crankcase 2nd 50 5.0 36
Generator cover/ground 1st 15 1.5 11
Bolt M10 1
lead – crankcase 2nd 50 5.0 36
Bracket – crankcase Bolt M10 4 39 3.9 28

271
LT
Pickup coil – generator cover Bolt M6 2 5 0.5 3.6

242
LT
Stator coil – generator cover Bolt M6 3 14 1.4 10

242
LT
Drive
Drive coupling – crankshaft M27 1 36 3.6 25

572
LT
coupling
Flywheel magneto – crankshaft Bolt M10 1 74 7.4 53

E
1st 15 1.5 11
Upper crankcase – lower M8 17
2nd Bolt 27 2.7 19
crankcase
M6 10 11 1.1 8.0
Engine bracket – lower 1st 15 1.5 11
Bolt M8 6

271
LT
crankcase 2nd 27 2.7 19
JET PUMP UNIT
Steering cable joint – jet thrust
Nut M6 1 7 0.7 5.1

242
LT
nozzle
Ride plate – hull Bolt M8 4 17 1.7 12

572
LT
Intake duct – hull Bolt M8 4 17 1.7 12

572
LT
Intake grate – hull Bolt M6 4 7 0.7 5.1

572
LT
Speed sensor – ride plate Screw M5 4 4 0.4 2.9

242
LT
Bolt M8 1 8 0.8 5.8

271
LT
Roller – reverse gate stay
Nut — 1 26 2.6 19
Nozzle ring – nozzle Bolt M8 2 15 1.5 11
271
LT

Jet thrust nozzle – nozzle ring Bolt M8 2 15 1.5 11 271

LT

Water inlet cover/water inlet

Bolt M6 4 7 0.7 5.1
572
LT

strainer – impeller duct

Drive shaft nut – drive shaft Nut M16 1 74 7.4 53
Impeller (left-hand threads) –
Impeller M22 1 18 1.8 13
572
LT

drive shaft
Transom plate – hull Nut M10 4 26 2.6 19
Bilge strainer holder – bulkhead Screw M5 1 3.7 0.37 2.8
Intermediate housing – bulkhead Bolt M8 3 17 1.7 12
572
LT

Driven
Driven coupling – shaft M24 1 36 3.6 25
572
LT

coupling
Grease nipple – intermediate
Nipple — 1 5 0.5 3.6
572
LT

housing
HULL AND HOOD
Handlebar holder – steering
Bolt M8 4 16 1.6 12
master
Handlebar cover stay – steering
Bolt M6 2 1.1 0.11 0.8
master

2-8
SPEC TIGHTENING TORQUES E

Thread Tightening torque

Part to tightened Part name Q’ty Remarks
size N•m kgf•m ft•lb
Handle cover – handlebar cover
Screw M6 4 1.1 0.11 0.8
stay
Handle boss cover – steering
Screw M6 4 0.9 0.09 0.7
master
QSTS converter – hull Bolt M6 2 5 0.5 3.6
Throttle lever assembly –
Screw M5 2 3 0.3 2.2
handlebar
Handlebar switch assembly –
Screw M5 2 3 0.3 2.2
handlebar
QSTS grip assembly – handlebar Screw M6 1 3 0.3 2.2

242
LT
Grip end – handlebar Bolt M5 2 1 0.1 0.7

242
LT
Cable housing – QSTS grip
Screw M4 1 1 0.1 0.7
assembly
Steering master – deck Nut M8 4 20 2.0 14
Steering cable ball joint –
Nut — 1 7 0.7 5.1
steering arm
QSTS cable locknut
Nut — 1 3 0.3 2.2
(nozzle ring side)
QSTS cable grommet – hull Nut — 1 6 0.6 4.3
QSTS cable end pin – QSTS con-
Nut — 1 4 0.4 2.9
verter
Shift cable locknut
Nut — 1 3 0.3 2.2
(reverse gate side)
Shift cable grommet – hull Nut — 1 6 0.6 4.3
Shift cable holder – shift lever
Bolt M6 2 5 0.5 3.6
base
Steering cable locknut
Nut — 1 6 0.6 4.3
(jet thrust nozzle side)
Steering cable grommet – hull Nut — 1 6 0.6 4.3
Steering cable bracket – deck Nut — 3 5 0.5 3.6
Speed sensor lead grommet –
Nut — 1 6 0.6 4.3
hull
Mirror – front hood Bolt M8 4 7 0.7 5.1
Notch – deck Nut — 1 17 1.7 12
Hood lock assembly – front hood
Screw M6 2 6 0.6 4.3
assembly
Hinge assembly – front hood
Bolt M6 4 6 0.6 4.3
assembly
Hinge assembly – deck Nut — 4 6 0.6 4.3
Bolt M6 8 5 0.5 3.6
572
LT

Steering console cover – deck

Nut M6 3 5 0.5 3.6
Shift lever handle – shift lever Bolt M6 2 5 0.5 3.6
Pilot water outlet – hull Nut — 2 4 0.4 2.9
Shift lever plate – deck Screw M6 3 5 0.5 3.6
Shift lever plate – deck/shift lever
Screw M6 3 5 0.5 3.6
242
LT

base assembly

2-9
SPEC TIGHTENING TORQUES E

Thread Tightening torque

Part to tightened Part name Q’ty Remarks
size N•m kgf•m ft•lb
Shift lever – base assembly Bolt M6 1 5 0.5 3.6
Hand grip – deck Nut M6 4 5 0.5 3.6
Front seat stay – deck Nut M6 4 5 0.5 3.6
Seat lock notch – deck Nut — 2 26 2.6 19
Rear seat stay – deck Nut M10 2 26 2.6 19
Seat lock assembly – seat Bolt M6 4 6 0.6 4.3

572
LT
Plate/exhaust outlet – hull Bolt M6 6 6 0.6 4.3
M8 2 16 1.6 12
Sponson – hull Nut
M6 6 6 0.6 4.3
Cleat – deck Nut — 2 15 1.5 11
Spout – hull Nut — 1 5 0.5 3.6
Rope hole – hull Nut — 2 5 0.5 3.6
Bow eye – hull Nut — 2 15 1.5 11
Drain plug/packing – hull Nut — 4 2 0.2 1.4
Engine mount – hull Bolt M8 8 17 1.7 12

572
LT
Engine damper – hull Bolt M6 4 5 0.5 3.6

General torque GENERAL TORQUE

Nut A Bolt B specifications This chart specifies tightening torques for
N•m kgf•m ft•lb standard fasteners with a standard ISO
8 mm M5 5.0 0.5 3.6 thread pitch. Tightening torque specifica-
tions for special components or assemblies
10 mm M6 8.0 0.8 5.8
are provided in applicable sections of this
12 mm M8 18 1.8 13
manual. To avoid warpage, tighten multi-
14 mm M10 36 3.6 25
fastener assemblies in a crisscross fashion
17 mm M12 43 4.3 31 and progressive stages until the specified
tightening torque is reached. Unless other-
wise specified, tightening torque specifica-
tions require clean, dry threads.
Components should be at room tempera-
ture.

2-10
SPEC CABLE AND HOSE ROUTING E

CABLE AND HOSE ROUTING

90°
1
1
A
F A-A

O A
B C
1
O
1
A A 3 B
E G
N N

N D D
E E
A M C
F F
M-M L
M M
I G H HG 9 2 3
A C L L
D D-D
C
L-L
4
L L
B J H H
E-E
K K
0 J
K H
A
K-K 3 4

F-F
I

9 J 5
J-J
G-G
D 6
3
7
I 8 H-H

1 Fuel tank breather hose 0 Starter motor lead I Battery

2 Cooling water hose A Electrical box lead J Battery breather hose
3 QSTS cable B Generator lead K Battery negative lead
4 Choke cable C YPVS cables L Oil pump cable
5 Fuel hose D Speed sensor lead M Choke knob
6 Shift cable E YPVS servomotor N Fuel cock
7 Steering cable F Cooling water pilot outlet
8 Fuel filter G Throttle cable
9 Ventilation hose H Battery positive lead

2-11
SPEC CABLE AND HOSE ROUTING E

1 3 A
2 4
E-E
5 9
6 78
C
B
A

B
B
0
I
A J
A
3
C
E E

G D

G F F

3 J I

H C
F D 0

G F-F

4
E

E G-G
D

1 Throttle cable 9 To water/exhaust F To fuel filter

2 Handlebar switch lead temperature sensor G Choke cable
3 QSTS cable 0 Battery negative lead H Fuel return hose
4 Buzzer lead A Battery breather hose I Shift cable
5 To generator B Bilge hose J Steering cable
6 To battery positive terminal C Flushing hose
7 To starter motor D Speed sensor lead
8 To multifunction meter E Fuel tank breather hose

2-12
INSP
E
ADJ
CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENT

MAINTENANCE INTERVAL CHART .............................................................. 3-1

PERIODIC SERVICE ........................................................................................ 3-2

1
CONTROL SYSTEM ................................................................................. 3-2
Steering master inspection .............................................................. 3-2
Steering cable inspection and adjustment ..................................... 3-2
Throttle cable inspection and adjustment ...................................... 3-3
Choke cable inspection and adjustment ......................................... 3-4
QSTS cable inspection and adjustment .......................................... 3-4
2
Shift cable inspection and adjustment............................................ 3-6
YPVS cable adjustment .................................................................... 3-7
FUEL SYSTEM.......................................................................................... 3-8
Fuel line inspection ........................................................................... 3-8
Trolling speed check and adjustment ............................................. 3-9
OIL INJECTION SYSTEM....................................................................... 3-10
3
Oil line inspection ........................................................................... 3-10

4
POWER UNIT.......................................................................................... 3-10
Spark plug inspection ..................................................................... 3-10
ELECTRICAL ........................................................................................... 3-11
Battery inspection ........................................................................... 3-11
JET PUMP UNIT..................................................................................... 3-14
Impeller inspection ......................................................................... 3-14

5
Water inlet strainer inspection....................................................... 3-15
Bilge strainer inspection................................................................. 3-15
GENERAL................................................................................................ 3-15
Drain plug inspection...................................................................... 3-15
Lubrication points ........................................................................... 3-16

6
7
8
9
 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.
Initial Every
Refer to
Item Remarks 10 hours 50 hours 100 hours 200 hours page
(Break-in) (3 months) (6 months) (1 year)
CONTROL SYSTEM
Steering cable Inspect/adjust 3-2
Steering master Inspect 3-2
Throttle cable Inspect/adjust 3-3
Carburetor throttle shaft Inspect/adjust —
Choke cable Inspect/adjust 3-4
Shift cable Inspect/adjust 3-6
QSTS cable Inspect/adjust 3-4
YPVS cable Inspect/adjust 3-7
FUEL SYSTEM
Fuel tank Clean 4-10
Fuel filter Clean/replace 3-8
Fuel line Inspect 3-8
Trolling speed Check/adjust 3-9
Carburetor setting Inspect/adjust 4-17
OIL INJECTION SYSTEM
Oil injection system Check/clean 3-10
Oil pump cable Inspect/adjust 4-32
POWER UNIT
Spark plugs Inspect/clean/adjust 3-10
Cooling water passage Inspect/clean *1 —
Rubber coupling Inspect —
ELECTRICAL
Battery Inspect *2 3-11
JET PUMP UNIT
Impeller Inspect 3-14
Water inlet strainer Clean 3-15
Bilge strainer Clean 3-15
GENERAL
Bolts and nuts Retighten —
Drain plugs Inspect/replace 3-15
Lubrication points Grease 3-16
Intermediate housing Grease *3 *4 3-18
*1: After every ride
*2: Inspect fluid level before every ride
*3: Grease capacity 33.0–35.0 cm3 (1.11–1.18 oz)
*4: Grease capacity 6.0–8.0 cm3 (0.20–0.27 oz)

3-1
INSP
ADJ CONTROL SYSTEM E

PERIODIC SERVICE
CONTROL SYSTEM
Steering master inspection
1. Inspect:
● Steering master
Excessive play → Replace the steer-
ing master.
Refer to “STEERING MASTER” in
Chapter 8.

Inspection steps:
● Move the handlebar up and down and
back and forth.
● Check the excessive play of the han-
dlebar.

Steering cable inspection and adjustment

1. Inspect:
● Jet thrust nozzle clearance a, b
Difference → Adjust.

Inspection steps:
● Set the control grip in the neutral posi-
tion.
● Turn the handlebar from lock to lock.
● Measure clearances a and b.
● If clearances a and b are not the
same, adjust them.

2. Adjust:
● Steering cable joint
(steering master end)

Adjustment steps:
● Set the control grip in the neutral posi-
tion.
● Loosen the locknut 1.
● Disconnect the steering cable joint 2
from the ball joint 3.
● Turn the cable joint in or out for adjust-
ing the clearance.
Turn in Clearance a is increased.
Turn out Clearance b is increased.

3-2
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.

Locknut:
6 N • m (0.6 kgf • m, 4.3 ft • lb)

T.
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.

Throttle cable inspection and adjustment

NOTE:
Before adjusting the throttle lever free play,
adjust the trolling speed.

1. Measure:
● Throttle lever free play a
Out of specification → Adjust.

Throttle lever free play:

4–7 mm (0.16–0.28 in)

2. Adjust:
● Throttle lever free play

Adjustment steps:
● Remove the handlebar cover.
● Loosen the locknut 1.
● Turn the adjuster 2 in or out until the
specified free play is obtained.

3-3
INSP
ADJ CONTROL SYSTEM E

Turn in Free play is increased.

Turn out Free play is decreased.
● Tighten the locknut.
● Install the handlebar cover.

WARNING
After adjusting the free play, turn the han-
dlebar to the right and left and make sure
that the trolling speed does not increase.

Choke cable inspection and adjustment

1. Inspect:
● Choke knob
(pull the choke knob all the way out)
Choke knob automatically returns →
Adjust.

Adjustment steps:
● Turn in the adjusting nut 1 until the
choke knob does not automatically
return.

QSTS cable inspection and adjustment

1. Measure:
● Jet thrust nozzle set length a, b
Difference → Adjust.

Measurement steps:
● Set the control grip in the neutral posi-
tion.
● Set the jet thrust nozzle in the center
position.
● Measure the jet thrust nozzle set
length a and b.
● If a and b length are not even, adjust
the cable joint.

3-4
INSP
ADJ CONTROL SYSTEM E

2. Adjust:
● QSTS cable

Adjustment steps:
● Set the control grip in the neutral posi-
tion.
● 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 b is increased.

Turn out Length a 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.

Nut:
4 N • m (0.4 kgf • m, 2.9 ft • lb)
T.
R.

● Tighten the locknut 1.

Locknut:
3 N • m (0.3 kgf • m, 2.2 ft • lb)
T.
R.

NOTE:
If the QSTS cable cannot be properly
adjusted by the cable joint at the QSTS con-
verter end, adjust the cable joint at the jet
pump end so that the same lengths are
obtained. Refer to “REMOTE CONTROL
CABLES AND SPEED SENSOR LEAD” in
Chapter 8.

3-5
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 posi-
tion.
● 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 posi-
tion.
● 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.
● Disconnect the cable joint 2 from the
ball joint 3.
● Situate the reverse gate to the stopper
on the bracket and the lever to the
reverse gate.
● Turn the cable joint to align it with the
ball joint.
Turn in Shortens.
Turn out Lengthens.
● Turn out the cable joint nine times a
to extend cable 7 mm (0.28 in) from
the aligned position.

WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).

● Connect the cable joint and tighten the

locknut.

Locknut:
3 N • m (0.3 kgf • m, 2.2 ft • lb)
T.
R.

3-6
INSP
ADJ CONTROL SYSTEM E

YPVS cable adjustment

1. Check:
● YPVS valve position
Incorrect position → Adjust the YPVS
cable.

Checking steps:
● Start the engine and then stop it.
NOTE:
When the engine has been stopped for 3
seconds, the YPVS valve assembly will
retract and extend one time.

● Check that the hole a in the pulley is

aligned with the hole in the cylinder
when the YPVS valve is fully closed.

2. Measure:
● YPVS cable slack a
Out of specification → Adjust.

YPVS cable slack:

0.5–1.5 mm (0.02–0.06 in)

3-7
INSP
ADJ CONTROL SYSTEM/FUEL SYSTEM E

3. Adjust:
● YPVS cables 1 and 2

Adjustment steps:
● Loosen locknuts 1 and 2.
● Turn in adjusters 3 and 4 until there
is slack in the cables.
● Align the hole a in the pulley with the
hole in the cylinder.
● Insert a 4-mm-diameter pin through
the holes in the pulley and cylinder.
● Turn adjusters 3 and 4 in or out until
the specified slack is obtained.
Turn in Slack is increased.
Turn out Slack is decreased.
● Finger tighten locknuts 1 and 2.
● Remove the pin.
● Start and stop the engine.
● Recheck the hole alignment.
● If the hole alignment is correctly,
tighten the locknuts.
● If the hole alignment is incorrect,
repeat the above steps.

FUEL SYSTEM

WARNING
● Stop the engine, set the fuel cock to
“OFF” before servicing the fuel system.
● When removing fuel system parts, wrap
them in a cloth and take care that no fuel
spills into the engine compartment.

Fuel line inspection

1. Inspect:
● Fuel filter 1
Contaminants → Replace.
Cracks/damage → Replace.
Water contamination → Replace and
check the fuel tank.
● Fuel hoses
● Fuel tank
● Fuel hoses through part
● Fuel filler cap
Cracks/damage → Replace.

3-8
INSP
ADJ FUEL SYSTEM E

2. Inspect:
● Water separator 1
Water accumulation → Drain.

NOTE:
If need the water draining, remove the drain
plug 2.

Trolling speed check and adjustment

1. Check:
● Trolling speed
Out of specification → Adjust.

Trolling speed:
1,350 ± 50 r/min

Checking steps (with the watercraft in

the water):
● Start the engine and allow it to warm
up for several minutes.
● Attach the engine tachometer to the
spark plug lead.

Engine tachometer:
YU-8036-B/90890-06760

● Measure the engine trolling speed.

2. Adjust:
● Trolling speed

Adjustment steps:
● Start the engine and allow it to warm
up for several minutes.
● Attach the engine tachometer to the
spark plug lead.

Engine tachometer:
YU-8036-B/90890-06760

● Turn the remote throttle stop screw 1

in or out until the specified trolling
speed is obtain.

3-9
INSP
ADJ OIL INJECTION SYSTEM/POWER UNIT E

OIL INJECTION SYSTEM

Oil line inspection
1. Inspect:
● Oil filter
Contaminants → Clean.
Frays/tears → Replace.
● Rubber seal
Cracks/wear → Replace.
● Oil hoses
● Oil tank
● Oil filler cap
Cracks/damage → Replace.
● Check valve
Malfunction → Replace.

CAUTION:
Do not allow the oil tank to become com-
pletely empty. If the oil tank becomes
empty the oil injection pump must be bled
to ensure proper oil flow, otherwise engine
damage may occur. Refer to “OIL PUMP” in
Chapter 4.

POWER UNIT
Spark plug inspection
1. 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
Excessive oil use
Defective spark plug

2. Clean:
● Spark plug
(with a spark plug cleaner or wire
brush)

3-10
INSP
ADJ POWER UNIT/ELECTRICAL E

3. Measure:
● Spark plug gap a
Out of specification → Regap.

Spark plug gap:

1.0–1.1 mm (0.039–0.043 in)

4. Tighten:
● Spark plug

Spark plug:
25 N • m (2.5 kgf • m, 18 ft • lb)

T.
R.
NOTE:
● Before installing the spark plug, clean the
gasket surface and spark plug surface.
Also, it is suggested to apply a thin film of
anti-seize compound to the spark plug
threads to prevent thread seizure.
● If a torque wrench is not available, a good
estimate of the correct tightening torque
for a new spark plug is to finger tighten a
the spark plug and then tighten it another
1/4 to 1/2 of a turn b.

ELECTRICAL
Battery inspection

WARNING
Battery electrolyte is poisonous and dan-
gerous, causing severe burns, etc. Electro-
lyte contains sulfuric acid. Avoid contact
with skin, eyes or clothing.
Antidotes
External: Flush with water.
Internal: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten
egg or vegetable oil. Call physician immedi-
ately.
Eyes: Flush with water for 15 minutes and
get prompt medical attention.

3-11
INSP
ADJ ELECTRICAL E

Batteries produce explosive gases. Keep

sparks, flame, cigarettes, etc., well away. If
using or charging the battery in an
enclosed space, make sure that it is well
ventilated. Always shield your eyes when
working near batteries.
KEEP OUT OF THE REACH OF CHILDREN.

CAUTION:
Be careful not to place the battery on its
side.
Make sure to remove the battery from the
battery compartment when adding battery
electrolyte or charging the battery.
When checking the battery, make sure the
breather hose is connected to the battery
and not obstructed.

1. Remove:
1 2 ● Bands
● Battery negative lead 1
● Battery positive lead 2
3
● Battery
● Battery breather hose 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.

3-12
INSP
ADJ ELECTRICAL E

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.
● Add distilled water.
● When the electrolyte level reaches the
upper level mark, allow the cell to
stand for 20 minutes. If the electrolyte
level drops, add more distilled water
so the level reaches the upper level
mark.

CAUTION:
Use only distilled water. Other types of
water contain minerals which are harmful
to batteries.

3. Inspect:
● Specific gravity
Out of specification → Charge.

Specific gravity at 20 ˚C (68 ˚F):

1.28
Charging current:
1.9 amps × 10 hrs (68.4 kC)

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.

3-13
INSP
ADJ ELECTRICAL/JET PUMP UNIT E

5. Install:
3 2 ● Battery breather hose 1
● Battery
● Battery positive lead 2
1
● Battery negative lead 3
● Bands

CAUTION:
● Connect the positive lead to the battery
terminal first.
● Make sure the battery leads are con-
nected properly. Reversing the leads can
seriously damage the electrical system.
● Make sure that the battery breather hose is
properly connected and is not obstructed.
● Coat the terminals with a water resistant
grease to minimize terminal corrosion.

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 (0.02 in)

Measurement steps:
● Remove the battery leads.
● Remove the intake grate and intake
duct.
Refer to “JET PUMP UNIT” in Chapter
6.
● Measure the clearance at each impel-
ler blade as shown (a total of three
measurements).
● Install the intake duct and intake grate.
Refer to “JET PUMP UNIT” in Chapter
6.
● Install the battery leads.

3-14
INSP
ADJ JET PUMP UNIT/GENERAL E

Water inlet strainer inspection

1. Inspect:
● Water inlet strainer
Contaminants → Clean.
Cracks/damage → Replace.

Inspection steps:
● Remove the ride 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 ride plate.
Refer to “JET PUMP UNIT” in Chapter
6.

Bilge strainer inspection

1. Inspect:
● Bilge strainer
Contaminants → Clean.
Cracks/damage → Replace.

Inspection steps:
● Remove the ventilation hose and elec-
trical box.
Refer to “ELECTRICAL BOX” in Chap-
ter 7.
● Remove the coupling cover.
● Disconnect the bilge strainer 1 from
the bilge strainer holder.
● Inspect the bilge strainer.
● Install the coupling cover.
● Install the electrical box and ventila-
tion hose.
Refer to “ELECTRICAL BOX” in Chap-
ter 7.

GENERAL
Drain plug inspection
1. Inspect:
● Drain plugs
Cracks/damage → Replace.
● O-rings
Cracks/wear → Replace.
● Screw threads
Contaminants → Clean.

3-15
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:
● QSTS control cables (handlebar end)

Recommended lubricant:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)

NOTE:
Before lubricating the QSTS control cables,
remove the QSTS cable housing cover.
Spray the rust inhibitor into the outer
cables, and apply grease to the inner
cables.

3-16
INSP
ADJ GENERAL E

3. Lubricate:
● Throttle cable (carburetor end)
● Oil pump cable
● QSTS cables (pulley end)
● YPVS cables

Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)

4. Lubricate:
● Nozzle pivot shaft
● Steering cable (nozzle end)
● QSTS cable (nozzle end)

Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)

3-17
INSP
ADJ GENERAL E

5. Lubricate:
● Steering cable
● Steering cable joint
● Shift cable
● Shift cable joint

NOTE:
Disconnect the joints and apply a small
amount of grease.

Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)

6. Fill:
● Intermediate housing

Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)

NOTE:
Fill the intermediate housing with the rec-
ommended grease through the grease nip-
ples.

3-18
FUEL E

CHAPTER 4
FUEL SYSTEM

FUEL COCK AND FUEL FILTER ..................................................................... 4-1

EXPLODED DIAGRAM ............................................................................. 4-1
REMOVAL AND INSTALLATION CHART ............................................... 4-1
SERVICE POINTS ..................................................................................... 4-2
Fuel filter inspection ......................................................................... 4-2
Fuel cock inspection.......................................................................... 4-2

CHOKE CABLE ................................................................................................ 4-3

EXPLODED DIAGRAM ............................................................................. 4-3
REMOVAL AND INSTALLATION CHART ............................................... 4-3

OIL TANK ........................................................................................................ 4-4

EXPLODED DIAGRAM ............................................................................. 4-4
REMOVAL AND INSTALLATION CHART ............................................... 4-4
SERVICE POINTS ..................................................................................... 4-6
Oil line inspection ............................................................................. 4-6
Oil level sensor inspection ............................................................... 4-6
Oil tank inspection ............................................................................ 4-6

FUEL TANK ..................................................................................................... 4-7

EXPLODED DIAGRAM ............................................................................. 4-7
REMOVAL AND INSTALLATION CHART ............................................... 4-7
SERVICE POINTS ................................................................................... 4-10
Check valve inspection ................................................................... 4-10
Fuel level sensor inspection........................................................... 4-10
Fuel tank inspection ........................................................................ 4-10

INTAKE DUCT AND SILENCER ................................................................... 4-11

EXPLODED DIAGRAM ........................................................................... 4-11
REMOVAL AND INSTALLATION CHART ............................................. 4-11

CARBURETOR UNIT..................................................................................... 4-13

EXPLODED DIAGRAM ........................................................................... 4-13
REMOVAL AND INSTALLATION CHART ............................................. 4-13
SERVICE POINTS ................................................................................... 4-17
Throttle valve synchronization inspection and adjustment ........ 4-17
Choke valve synchronization inspection and adjustment ........... 4-18
Choke cable and throttle cable installation................................... 4-19
Oil pump cable installation ............................................................ 4-19
Carburetor assembly ...................................................................... 4-19
FUEL E

CARBURETOR .............................................................................................. 4-20

EXPLODED DIAGRAM ........................................................................... 4-20
REMOVAL AND INSTALLATION CHART ............................................. 4-20
EXPLODED DIAGRAM ........................................................................... 4-22

1
REMOVAL AND INSTALLATION CHART ............................................. 4-22
SERVICE POINTS ................................................................................... 4-23
Diaphragm inspection .................................................................... 4-23
Accelerator pump body inspection ............................................... 4-23
Arm inspection ................................................................................ 4-23
Regulator body inspection ............................................................. 4-24
Needle valve inspection ................................................................. 4-24
Jet and carburetor body inspection .............................................. 4-24
Carburetor assembly ...................................................................... 4-24 2
FUEL PUMP .................................................................................................. 4-25
EXPLODED DIAGRAM ........................................................................... 4-25
REMOVAL AND INSTALLATION CHART ............................................. 4-25
SERVICE POINTS ................................................................................... 4-27
Fuel pump inspection ..................................................................... 4-27
Fuel filter inspection ....................................................................... 4-27
3
OIL PUMP...................................................................................................... 4-28
EXPLODED DIAGRAM ........................................................................... 4-28
REMOVAL AND INSTALLATION CHART ............................................. 4-28
SERVICE POINTS ................................................................................... 4-31
Oil pump inspection........................................................................ 4-31
4
Oil hose inspection ......................................................................... 4-31
Check valve inspection ................................................................... 4-31
Oil pump cable adjustment ............................................................ 4-32
Oil injection pump air bleeding ..................................................... 4-33 5
6
7
8
9
FUEL FUEL COCK AND FUEL FILTER E

FUEL COCK AND FUEL FILTER

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
FUEL COCK AND FUEL FILTER Follow the left “Step” for removal.
REMOVAL
1 Screw 1
2 Knob 1
3 Nut 1
4 Washer 1
5 Fuel cock assembly 1
6 Fuel hose 3
7 Holder 1
8 Fuel filter 1
9 Fuel hose 1
Reverse the removal steps for installation.

4-1
FUEL FUEL COCK AND FUEL FILTER E

SERVICE POINTS
Fuel filter inspection
Refer to “FUEL SYSTEM” in Chapter 3.

Fuel cock inspection

1. Check:
● Fuel cock
Contaminants → Clean.
Rough movement → Replace.

4-2
FUEL CHOKE CABLE E

CHOKE CABLE
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
CHOKE CABLE REMOVAL Follow the left “Step” for removal.
1 Screw 1
2 Knob 1
3 Friction adjusting nut 1
4 Nut 1
5 Choke cable 1
Reverse the removal steps for installation.

4-3
FUEL OIL TANK E

OIL TANK
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
OIL TANK REMOVAL Follow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT” in Chapter 5.
1 Hose clamp 1
2 Nut 1 Disconnect the oil filler hose from the oil
filler neck.
3 Oil filler neck 1
4 Rubber seal 1
5 Oil level sensor coupler 1
6 Breather hose 1

4-4
FUEL OIL TANK E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

7 Oil hose 1 Face the white mark a to the stern.
8 Bolt 2
9 Tank belt 2
10 Oil tank assembly 1
11 Hose clamp 1
12 Oil filler hose 1
13 Oil level sensor 1
Reverse the removal steps for installation.

4-5
FUEL OIL TANK E

SERVICE POINTS
Oil line inspection
1. Inspect:
● Oil filter
Contaminants → Clean.
Frays/tears → Replace.
● Rubber seal
Cracks/wear → Replace.
● Oil hoses
● Oil tank
● Oil filler cap
Cracks/damage → Replace.
● Check valve
Malfunction → Replace.

Oil level sensor inspection

Refer to “INDICATION SYSTEM” in
Chapter 7.

Oil tank inspection

1. Inspect:
● Oil tank
Cracks/damage → Replace.

4-6
FUEL FUEL TANK E

FUEL TANK
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
FUEL TANK REMOVAL Follow the left “Step” for removal.
Oil tank Refer to “OIL TANK”.
1 Hose clamp 1
2 Nut 1 Disconnect the fuel filler hose from the
fuel filler neck.
3 Fuel filler neck 1
4 Rubber seal 1
5 Fuel level sensor coupler 1
6 Fuel reserve hose 1

4-7
FUEL FUEL TANK E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

7 Fuel hose 1
8 Fuel return hose 1 Fasten the fuel return hose to the band
that is used to fasten the front ventilation
hose.
9 Fuel breather hose 1
10 Fuel tank assembly 1
11 Hose clamp 1
12 Fuel filler hose 1
13 Hose clamp 1
14 Fuel sensor assembly 1

4-8
FUEL FUEL TANK E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

15 Check valve 1
16 Fuel breather hose 1
17 Screw/washer 1/1
18 Filter 1
19 Screw/washer 1/1
20 Sleeve 1
21 Bolt 2
22 Tank belt 2
Reverse the removal steps for installation.

4-9
FUEL FUEL TANK E

SERVICE POINTS
A B Check valve inspection
1. Check:
● Check valve
Faulty → Replace.
A B
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”.

Fuel level sensor inspection

Refer to “INDICATION SYSTEM” in
Chapter 7.

Fuel tank inspection

1. Inspect:
● Fuel tank
Cracks/damage → Replace.

4-10
FUEL INTAKE DUCT AND SILENCER E

INTAKE DUCT AND SILENCER

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
INTAKE DUCT AND SILENCER Follow the left “Step” for removal.
REMOVAL
Muffler assembly Refer to “MUFFLER ASSEMBLY” in
Chapter 5.
1 Hose clamp 2
2 Joint hose 1
3 Bolt/collar/grommet 1/1/1

4-11
FUEL INTAKE DUCT AND SILENCER E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

4 Intake duct 1
5 Silencer case 1
6 Bolt 6
7 Spark arrester 1
8 Silencer plate 1
9 O-ring 3
Reverse the removal steps for installation.

4-12
FUEL CARBURETOR UNIT E

CARBURETOR UNIT
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
CARBURETOR UNIT REMOVAL Follow the left “Step” for removal.
Silencer plate Refer to “INTAKE DUCT AND SILENCER”.
1 Oil pump cable 1 NOTE:
Before removing the oil pump cable,
mark the cable’s installation position for
reference when installing the oil pump
cable.

2 Throttle cable 1
3 Choke cable 1
4 Fuel suction hose 1

4-13
FUEL CARBURETOR UNIT E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

5 Fuel return hose 1 Fasten the fuel return hose to the band
that is used to fasten the front ventilation
hose.
6 Oil delivery hose 3
7 Clamp/fuel pump vacuum hose 3/3
8 Remote throttle stop screw 1
9 Bolt 4
10 Bolt 6
11 Carburetor assembly 1
12 Gasket 1 Not reusable
Reverse the removal steps for installation.

4-14
FUEL CARBURETOR UNIT E

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
CARBURETOR UNIT Follow the left “Step” for removal.
SEPARATION
1 Hose 2 Fuel suction
2 Hose 2 Fuel return
3 Accelerator pump hose 1
4 Remote throttle stop screw 1
assembly
5 Bolt 3
6 Cable holder 1

4-15
FUEL CARBURETOR UNIT E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

7 Throttle link 1
8 Choke link 1
9 Bolt 6
10 Carburetor 3
11 Gasket 3 Not reusable
12 Plate 1
Reverse the removal steps for installation.

4-16
FUEL CARBURETOR UNIT E

SERVICE POINTS
Throttle valve synchronization inspection
and adjustment
1. Check:
● Throttle valve synchronization
Not synchronized → Adjust.

Checking steps:
● Loosen the remote throttle stop screw
1 until untouched the screw end from
the throttle lever.
● Check the each throttle valve is fully
closed.

2. Adjust:
● Throttle valve synchronization

Adjustment steps:
● Loosen the remote throttle stop screw
1 until untouched the screw end from
the throttle lever.
● Loosen the screws 2.

NOTE:
Make sure that the throttle valves are in
the fully closed position.

● Tighten the screws 2.

Screw:
2 N • m (0.2 kgf • m, 1.4 ft • lb)
T.
R.

● Turn in the remote throttle stop screw

to the original position.

4-17
FUEL CARBURETOR UNIT E

Choke valve synchronization inspection

and adjustment
1. Check:
● Choke valve synchronization
Not synchronized → Adjust.

Checking steps:
● Turn the choke lever 1 and check the
each choke valve is fully closed.

2. Adjust:
● Choke valve synchronization

Adjustment steps:
● Loosen the screws 1, 2.
● Fully close all choke valves, and then
tighten screws 1 and 2.

Screw:
2 N • m (0.2 kgf • m, 1.4 ft • lb)
T.
R.

4-18
FUEL CARBURETOR UNIT E

Choke cable and throttle cable installation

1. Install:
● Choke cable 1
● Throttle cable 2

Choke cable guide installation

position a:
16–18 mm (0.63–0.71 in)
Throttle cable guide installation
position b:
18–20 mm (0.71–0.79 in)

2. Adjust:
● Throttle lever free play
Refer to “CONTROL SYSTEM” in
Chapter 3.

Oil pump cable installation

1. Adjust:
● Oil pump cable
Refer to “OIL PUMP”.

Carburetor assembly
1. Adjust:
● Trolling speed
Refer to “FUEL SYSTEM” in Chapter 3.

4-19
FUEL CARBURETOR E

CARBURETOR
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
CARBURETOR DISASSEMBLY Follow the left “Step” for disassembly.
1 Accelerator pump delivery hose 2 For carburetor #3
2 Accelerator pump fuel hose 1
3 Screw 4
4 Accelerator pump/carburetor 1/1 Carburetor #3/carburetor #1 and #2
cover
5 Diaphragm 1
6 Screw 2
7 Regulator body 1
8 Gasket 1
9 Main jet 1

4-20
FUEL CARBURETOR E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

10 Pilot jet 1
11 Screw 1
12 Arm 1
13 Arm pin 1
14 Spring 1
15 Screw 1
16 Needle valve 1
17 Needle valve seat 1
18 O-ring 1
Reverse the disassembly steps for
assembly.

4-21
FUEL CARBURETOR E

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
ACCELERATOR PUMP Follow the left “Step” for disassembly.
DISASSEMBLY
1 Screw 1
2 Stay 1
3 Spring 1
4 Spring seat 1
5 Screw 4
6 Accelerator pump cover assembly 1
7 Spring 1
8 Diaphragm 1
9 Accelerator pump body 1
Reverse the disassembly steps for
assembly.

4-22
FUEL CARBURETOR E

SERVICE POINTS
NOTE:
Before disassembling the carburetor, make
sure to note the number of times the pilot
screw is turned in from its set position to
the seated position.

CAUTION:
Do not use steel wire for cleaning the jets.
This may enlarge the jet diameters and
seriously affect performance.

Diaphragm inspection
1. Inspect:
● Diaphragm
Damage → Replace.

Accelerator pump body inspection

1. Inspect:
● One way valve
Crack/damage → Replace the acceler-
ator pump body.
● Fuel passage
Clog → Clean or replace.

Arm inspection
1. Inspect:
● Arm 1
Bends/damage → Repair or replace.
2. Measure:
● Arm height a

Arm height:
0–0.2 mm (0–0.008 in)

NOTE:
● Measure the distance between the surface
of the carburetor body b and the top sur-
face of the arm.
● The arm should be resting on the needle
valve, but not compressing it.

4-23
FUEL CARBURETOR E

Regulator body inspection

1. Inspect:
● Regulator body
Contaminants → Clean.
Damage → Replace.
● Valve (clear film) 1
Damage → Replace.

Needle valve inspection

1. Inspect:
● Needle valve
● Needle valve seat
Contaminants a → Clean.
Wear b → Replace.

NOTE:
Always replace the needle valve and needle
valve seat as a set.

Jet and carburetor body inspection

1. Inspect:
● Main jet
● Pilot jet
● Carburetor body
Clog/contaminants → Clean.
Damage/wear → Replace.

CAUTION:
Do not use a steel wire to clean the jets.
This may enlarge the jet diameters and
seriously affect performance.

Carburetor assembly

NOTE:
Before assembling the carburetor, make
sure to turn out the pilot screw the same
number of times, as noted before disassem-
bly, from the seated position to the set posi-
tion.

1. Adjust:
● Trolling speed
Refer to “FUEL SYSTEM” in Chapter 3.

4-24
FUEL FUEL PUMP E

FUEL PUMP
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
FUEL PUMP DISASSEMBLY Follow the left “Step” for disassembly.
Carburetors Refer to “CARBURETOR”.
1 Screw 4
2 Fuel pump cover 1
3 Gasket 1 Not reusable
4 Diaphragm 1
5 O-ring 1
6 Diaphragm body 1

4-25
FUEL FUEL PUMP E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

7 Rubber diaphragm 1
8 Diaphragm 1
9 Packing 1
10 Fuel filter 1
Reverse the disassembly steps for
assembly.

4-26
FUEL FUEL PUMP E

SERVICE POINTS
Fuel pump inspection
1. Inspect:
● Diaphragm
● Rubber diaphragm
● Diaphragm body
Damage → Replace.

Fuel filter inspection

1. Inspect:
● Fuel filter
Clog/contaminants → Clean.
Damage → Replace.

4-27
FUEL OIL PUMP E

OIL PUMP
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
OIL PUMP REMOVAL Follow the left “Step” for removal.
Exhaust chamber assembly Refer to “EXHAUST CHAMBER
ASSEMBLY” in Chapter 5.
Intake duct Refer to “INTAKE DUCT AND
SILENCER”.
1 Oil pump cable 1 Route the oil pump cable outside of the
bleed hose and inside of the oil delivery
hose.
2 Oil delivery hose 3
3 Bolt 1

4-28
FUEL OIL PUMP E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

4 Bleed hose stay 1
5 Bolt 2
6 Oil pump assembly 1
7 Gasket 1 Not reusable
8 Oil suction hose 1
9 Oil return hose 1
Reverse the removal steps for installation.

4-29
FUEL OIL PUMP E

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
OIL PUMP HOSES AND CABLE Follow the left “Step” for removal.
REMOVAL
1 Bleed hose 1
2 Air bleed screw 1
3 Gasket 1
4 Bleed hose stay 1
5 Oil delivery hose 1 3
6 Oil delivery hose 2 3
7 Check valve 3
8 Oil pump cable 1
Reverse the removal steps for installation.

4-30
FUEL OIL PUMP E

SERVICE POINTS
Oil pump inspection
1. Inspect:
● Oil pump
Contaminants → Clean.
Damage/wear → Replace.
● Oil pump joint piece
Damage/wear → Replace.

Oil hose inspection

1. Inspect:
● Oil hose
Cracks/damage → Replace.

CAUTION:
● If the oil delivery hoses are not full of oil,
fill them up.
● After installing the oil injection system,
bleed the system of any air.

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”.

4-31
FUEL OIL PUMP E

Oil pump cable adjustment

1. Check:
● Oil pump lever position
Incorrect → Adjust.

Checking steps:
● Fully close the carburetor throttle
valves.
● Check that the mark a on the oil pump
lever is aligned with the mark b on the
oil pump body.

2. Adjust:
● Oil pump cable

Adjustment steps:
● Loosen the locknut 1 and the adjust-
ing nut 2.
● Fully close the carburetor throttle
valves.
● Adjust the oil pump cable so that the
mark a on the oil pump lever is
aligned with the mark b on the oil
pump body.
● Tighten the adjusting nut and locknut.

NOTE:
If the installation position has been marked
for reference on the inner cable at the car-
buretor end while marks a and b are
aligned, adjusting the cable at the carbure-
tor end is easier.

4-32
FUEL OIL PUMP E

Oil injection pump air bleeding

1. Bleed:
● Air

Air bleeding steps:

● Place rags around the air bleed screw
1 to catch any oil that might spill.
● Fill the oil tank with the recommended
oil.

NOTE:
If the oil pump is replaced or the oil suc-
tion hose is reinstalled, bleed air from
the oil suction hose by removing it from
the oil pump.
After bleeding the air, reconnect the
hose with a locking tie.

Recommended engine oil:

YAMALUBE 2-W oil only

● Loosen the air bleed screw 1 two full

turns and make sure that both the oil
and air bubbles flow out.
● When there are no air bubbles left,
tighten the air bleed screw.
● Wipe up any spilt oil.

Air bleed screw:

3.4 N • m (0.34 kgf • m, 2.5 ft • lb)
T.
R.

CAUTION:
● Do not run the engine if oil does not
flow out of the air bleed screw. Inspect
the oil pump hoses for proper routing
and make sure there are no restrictions
in the line.
● Use only YAMALUBE 2-W oil. Using
another oil can seriously damage the
catalytic converter and other engine
components.

4-33
POWR E

CHAPTER 5
POWER UNIT

EXHAUST CHAMBER ASSEMBLY................................................................ 5-1

EXPLODED DIAGRAM ............................................................................. 5-1
REMOVAL AND INSTALLATION CHART ............................................... 5-1

MUFFLER ASSEMBLY ................................................................................... 5-5

EXPLODED DIAGRAM ............................................................................. 5-5
REMOVAL AND INSTALLATION CHART ............................................... 5-5
SERVICE POINT...................................................................................... 5-10
Catalyst inspection.......................................................................... 5-10

EXHAUST MANIFOLD AND LEADS............................................................ 5-11

EXPLODED DIAGRAM ........................................................................... 5-11
REMOVAL AND INSTALLATION CHART ............................................. 5-11

ENGINE UNIT ............................................................................................... 5-15

EXPLODED DIAGRAM ........................................................................... 5-15
REMOVAL AND INSTALLATION CHART ............................................. 5-15
SERVICE POINTS ................................................................................... 5-17
Shim removal .................................................................................. 5-17
Engine mount inspection ............................................................... 5-17
Coupling clearance inspection....................................................... 5-17

REED VALVES .............................................................................................. 5-18

EXPLODED DIAGRAM ........................................................................... 5-18
REMOVAL AND INSTALLATION CHART ............................................. 5-18
SERVICE POINTS ................................................................................... 5-19
Reed valve inspection..................................................................... 5-19

YPVS ............................................................................................................. 5-20

EXPLODED DIAGRAM ........................................................................... 5-20
REMOVAL AND INSTALLATION CHART ............................................. 5-20
SERVICE POINTS ................................................................................... 5-23
YPVS valve inspection .................................................................... 5-23
YPVS valve installation................................................................... 5-23

CYLINDER HEAD .......................................................................................... 5-24

EXPLODED DIAGRAM ........................................................................... 5-24
REMOVAL AND INSTALLATION CHART ............................................ 5-24
SERVICE POINTS ................................................................................... 5-26
Cylinder head inspection................................................................ 5-26
POWR E

CYLINDERS................................................................................................... 5-27
EXPLODED DIAGRAM ........................................................................... 5-27
REMOVAL AND INSTALLATION CHART ............................................. 5-27
SERVICE POINTS ................................................................................... 5-28

1
Cylinder inspection ......................................................................... 5-28

PISTONS ....................................................................................................... 5-29

EXPLODED DIAGRAM ........................................................................... 5-29
REMOVAL AND INSTALLATION CHART ............................................. 5-29
SERVICE POINTS ................................................................................... 5-31
Piston pin clip removal and installation........................................ 5-31
Piston inspection............................................................................. 5-31
Cylinder and piston combination .................................................. 5-32
Piston ring inspection ..................................................................... 5-32
2
Piston pin and bearing inspection ................................................. 5-33

GENERATOR AND STARTER MOTOR........................................................ 5-35

EXPLODED DIAGRAM ........................................................................... 5-35
REMOVAL AND INSTALLATION CHART ............................................ 5-35
SERVICE POINTS ................................................................................... 5-41
3
Drive coupling removal and installation ....................................... 5-41
Flywheel magneto removal and installation ................................ 5-41
Drive coupling inspection............................................................... 5-42
Flywheel magneto inspection ........................................................ 5-42
Starter clutch assembly inspection ............................................... 5-42
4
5
CRANKCASE................................................................................................. 5-43
EXPLODED DIAGRAM ........................................................................... 5-43
REMOVAL AND INSTALLATION CHART ............................................. 5-43
SERVICE POINTS ................................................................................... 5-45
Crankcase inspection ...................................................................... 5-45
Crankcase installation..................................................................... 5-45

CRANKSHAFT............................................................................................... 5-46
EXPLODED DIAGRAM ........................................................................... 5-46
REMOVAL AND INSTALLATION CHART ............................................. 5-46
6
SERVICE POINTS ................................................................................... 5-47
Crankshaft inspection ..................................................................... 5-47

7
8
9
POWR EXHAUST CHAMBER ASSEMBLY E

EXHAUST CHAMBER ASSEMBLY

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
EXHAUST CHAMBER Follow the left “Step” for removal.
ASSEMBLY REMOVAL
1 Exhaust temperature sensor 1
coupler
2 Cap/bolt 3/3
3 Cover 1
4 Clamp/cooling water hose 4/4 Å For cooling water pilot outlet on
starboard side
ı For cooling water pilot outlet on port
side
5 Hose clamp 2 Slide the outer exhaust joint.
6 Hose clamp 2

5-1
POWR EXHAUST CHAMBER ASSEMBLY E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

7 Bolt 2
8 Bolt 2
9 Exhaust chamber stay 1
10 Bolt 3
11 Bolt 1
12 Exhaust chamber assembly 1 NOTE:
Before installing the exhaust chamber
assembly, place the bolts (step No.10) in
the bolts holes of the exhaust chamber
assembly.

5-2
POWR EXHAUST CHAMBER ASSEMBLY E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

13 Clamp/cooling water hose 1/1
14 Gasket 1 Not reusable
15 Pin 2
16 Outer exhaust joint 1
17 Inner exhaust joint 1
Reverse the removal steps for installation.

5-3
POWR EXHAUST CHAMBER ASSEMBLY E

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
EXHAUST CHAMBER Follow the left “Step” for disassembly.
DISASSEMBLY
1 Bolt 5
2 Bolt 1
3 Exhaust chamber joint 1
4 Gasket 1 Not reusable
5 Pin 2
6 Exhaust chamber 1
Reverse the disassembly steps for
assembly.

5-4
POWR MUFFLER ASSEMBLY E

MUFFLER ASSEMBLY
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
MUFFLER ASSEMBLY REMOVAL Follow the left “Step” for removal.
Exhaust chamber assembly Refer to “EXHAUST CHAMBER
ASSEMBLY”.
1 Band 1
2 Screw 4
3 Ventilation duct 1
4 Ventilation hose 1
5 Water temperature sensor 1
coupler
6 Clamp/cooling water hose 1/1

5-5
POWR MUFFLER ASSEMBLY E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

7 Hose clamp 1
8 Water lock band 1 Slide the water lock.
9 Nut 2
10 Bolt 4
11 Intermediate housing grease 1
hose
12 Eye 2 NOTE:
Remove the spark plug before removing
the eye, and reinstall it to make removing
the muffler assembly easier.

5-6
POWR MUFFLER ASSEMBLY E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

13 Bolt 2
14 Bolt 1
15 Bolt 1
16 Bolt 1
17 Muffler stay 2 1
18 Muffler assembly 1 NOTE:
Remove the cylinder head if it is difficult
to remove the muffler assembly.

Reverse the removal steps for installation.

5-7
POWR MUFFLER ASSEMBLY E

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
MUFFLER DISASSEMBLY Follow the left “Step” for disassembly.
1 Exhaust temperature sensor 1
2 Water temperature sensor 1
3 Bolt 2
4 Muffler stay 1
5 Bolt 6
6 Cover 1
7 Gasket 1 Not reusable
8 Catalyst housing 1

5-8
POWR MUFFLER ASSEMBLY E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

9 Gasket 1 Not reusable
10 Catalyst 1
11 Gasket 1 Not reusable
12 Pin 2
13 Bolt 6
14 Mixing joint 1
15 Gasket 1 Not reusable
16 Muffler 1
Reverse the disassembly steps for
assembly.

5-9
POWR MUFFLER ASSEMBLY E

SERVICE POINT
Catalyst inspection
1. Inspect:
● Catalyst
Cracks/damage → Replace.

5-10
POWR EXHAUST MANIFOLD AND LEADS E

EXHAUST MANIFOLD AND LEADS

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
EXHAUST MANIFOLD AND Follow the left “Step” for removal.
LEADS REMOVAL
Battery lead Refer to “ELECTRICAL BOX” in Chapter
(negative and positive) 7.
Exhaust chamber assembly Refer to “EXHAUST CHAMBER
ASSEMBLY”.
1 AC magneto coupler 1
2 Bolt 2
3 YPVS cable holder 1
4 YPVS cable 2
5 Clamp/cooling water hose 1/1 Should be white mark a up side

5-11
POWR EXHAUST MANIFOLD AND LEADS E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

6 Bolt 4
7 Bolt 6
8 Nut 2
9 Exhaust manifold 1 NOTE:
Before installing the exhaust manifold
place the bolts (step No.6) in the bolts
holes of the exhaust manifold.

10 Gasket 1 Not reusable

11 Pin 2
12 Bolt 1

5-12
POWR EXHAUST MANIFOLD AND LEADS E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

13 Battery negative lead 1
14 Nut/washer 1/1
15 Starter motor lead 1
Reverse the removal steps for installation.

5-13
POWR EXHAUST MANIFOLD AND LEADS E

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
EXHAUST MANIFOLD Follow the left “Step” for disassembly.
DISASSEMBLY
1 Clamp/cooling water hose 1/1
2 Bolt 6
3 Water pipe 1
4 O-ring 3
5 Exhaust manifold 1
Reverse the disassembly steps for
assembly.

5-14
POWR ENGINE UNIT E

ENGINE UNIT
EXPLODED DIAGRAM

6 × 25 mm
2
LT
572

17 N • m (1.7 kgf • m, 12 ft • Ib)

8 × 40 mm 3
1
4
5

LT
572

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
ENGINE UNIT REMOVAL Follow the left “Step” for removal.
Carburetor Refer to “CARBURETOR” in Chapter 4.
Oil pump Refer to “OIL PUMP” in Chapter 4.
Muffler assembly Refer to “MUFFLER ASSEMBLY”.
Exhaust manifold Refer to “EXHAUST MANIFOLD AND
LEADS”.
1 Spark plug lead 3
2 Bolt/collar 1/1
3 Coupling cover 1

5-15
POWR ENGINE UNIT E

EXPLODED DIAGRAM

6 × 25 mm
2
LT
572

17 N • m (1.7 kgf • m, 12 ft • Ib)

8 × 40 mm 3
1
4
5

LT
572

Step Procedure/Part name Q’ty Service points

4 Bolt/washer 4/4
5 Engine assembly 1
6 Shim * Install the shims original position.
Reverse the removal steps for installation.
*: As required

5-16
POWR ENGINE UNIT E

SERVICE POINTS
Shim removal
1. Remove:
● Shims

NOTE:
To ease reassembly and coupling align-
ment, remove the shims and organize them
in their respective groups (e.g., front right,
rear left) prior to removing the mounting
bolts.

Engine mount inspection

1. Inspect:
● Engine mounts
Cracks/damage → Replace.

Coupling clearance inspection

1. Measure:
● Clearance a
● Clearance b
(with the rubber damper)
Out of specification → Adjust.

NOTE:
Measure the clearances with a straightedge
and thickness gauge.

Clearance a:
0–0.5 mm (0–0.020 in)
Clearance b:
2–4 mm (0.079–0.157 in)

2. Adjust:
● Clearance a and b

Adjustment steps:
● Adjust the clearance a by adding or
removing shims.
● Adjust the clearance b by moving the
engine unit position.

5-17
POWR REED VALVES E

REED VALVES
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
REED VALVE REMOVAL Follow the left “Step” for removal.
Carburetor unit Refer to “CARBURETOR UNIT” in
Chapter 4.
1 Bolt 18 NOTE:
2 Reed valve plate 1 Tighten the bolts in the proper sequence
as shown.

3 Reed valve assembly 3

4 Screw 24
5 Valve stopper 6
6 Reed valve 6
Reverse the removal steps for installation.

5-18
POWR REED VALVES E

SERVICE POINTS
Reed valve inspection
1. Inspect:
● Reed valves
Cracks/damage → Replace.
2. Measure:
● Valve bending a
Out of specification → Replace.

Max. valve bending:

0.2 mm (0.01 in)

3. Measure:
● Valve stopper height b
Out of specification → Adjust or
replace.

Valve stopper height:

10.4–11.0 mm (0.41–0.43 in)

5-19
POWR YPVS E

YPVS
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
YPVS REMOVAL Follow the left “Step” for removal.
Exhaust chamber assembly Refer to “EXHAUST CHAMBER
ASSEMBLY”.
1 Bolt 12
2 YPVS valve cover 3
3 Gasket 3 Not reusable
4 Spacer 2
5 Link joint/cover 2/2
6 Circlip 5 Not reusable

5-20
POWR YPVS E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

7 Washer 5
8 Bolt 3 NOTE:
During installation, align the hole a in
the YPVS shaft with the bolt.

9 Shaft 3 1
10 Shaft 2 1
11 Shaft 1 1
12 YPVS valve arm 3

5-21
POWR YPVS E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

13 Bolt 3
14 YPVS valve assembly 3
15 Oil seal 6 NOTE:
If the YPVS shaft is removed, the oil seal
must be replaced.

Reverse the removal steps for installation.

5-22
POWR YPVS E

SERVICE POINTS
YPVS valve inspection
1. Eliminate:
● Carbon deposits
(with a rounded scraper 1)

CAUTION:
Do not use a sharp instrument to avoid
damaging or scratching the surfaces.

2. Inspect:
● YPVS valve assembly
Crack/damage/wear → Replace.

YPVS valve installation

1. Install:
● Oil seal

Distance a:
1.0–1.5 mm (0.04–0.06 in)

NOTE:
The oil seal should be installed with the
marks b facing inward.

5-23
POWR CYLINDER HEAD E

CYLINDER HEAD
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
CYLINDER HEAD REMOVAL Follow the left “Step” for removal.
Muffler assembly Refer to “MUFFLER ASSEMBLY”.
1 Spark plug 3
2 Bolt 1 NOTE:
3 Ground lead 1 Tighten the bolts in the proper sequence
4 Bolt 2 as shown and in three stages. (No. 23, 24
5 Bolt 6 in two stages)
6 Bolt 16

5-24
POWR CYLINDER HEAD E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

7 Cylinder head cover 1
8 Gasket 1 Not reusable
9 Cylinder head 1
10 Gasket 1 Not reusable
11 Clamp/cooling water hose 2/2 a white mark
Reverse the removal steps for installation.

5-25
POWR CYLINDER HEAD E

SERVICE POINTS
Cylinder head inspection
1. Eliminate:
● Carbon deposits
(with a rounded scraper 1)

CAUTION:
Do not use a sharp instrument to avoid
damaging or scratching the cylinder head
or spark plug bore threads.

2. Inspect:
● Cylinder head water jacket
Corrosion/mineral deposits → Clean
or replace.

3. Measure:
● Cylinder head warpage
(with a straightedge and thickness
gauge)
Out of specification/score marks →
Resurface.

Warpage limit:
0.05 mm (0.002 in)

NOTE:
Place a 400–600 grit wet sandpaper on a
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.

5-26
POWR CYLINDERS E

CYLINDERS
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
CYLINDER REMOVAL Follow the left “Step” for removal.
YPVS Refer to “YPVS”.
Cylinder head Refer to “CYLINDER HEAD”.
1 Bolt 12 NOTE:
Tighten the bolts in a crisscross pattern
and in two stages.

2 Cylinder 3 NOTE:
Install the original position.

3 Cylinder gasket 3 Not reusable

4 Pin 6
Reverse the removal steps for installation.

5-27
POWR CYLINDERS E

SERVICE POINTS
Cylinder inspection
1. Eliminate:
● Carbon deposits
(with a rounded scraper 1)

2. Inspect:
● Cylinder water jacket
Corrosion/mineral deposits → Clean
or replace.
● Cylinder inner surface
Score marks → Replace.

3. Measure:
● Cylinder bore “D”
(with a cylinder gauge)
Out of specification → Replace cylin-
der and piston as a set.

NOTE:
Measure the cylinder bore in parallel and at
a right angle to the crankshaft. Then, aver-
age the measurements.

Standard Limit

80.000–
Original cylinder
Cylinder 80.018 mm
bore + 0.04 mm
bore “D” (3.1496–
(0.0016 in)
3.1503 in)
0.08 mm
Taper “T” —
(0.003 in)
Out of 0.05 mm
—
round “R” (0.002 in)
D = Maximum (D1–D6)
T = (Maximum D1 or D2) – (Maximum D5
or D6)
R = (Maximum D1, D3 or D5) – (Minimum
D2, D4 or D6)

5-28
POWR PISTONS E

PISTONS
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
PISTON REMOVAL Follow the left “Step” for removal.
Cylinders Refer to “CYLINDERS”.
1 Piston pin clip 2 CAUTION:
Do not align the open end of the clip
with the piston pin slot a.

2 Piston pin 1
3 Piston 1 NOTE:
4 Washer 2 Make sure that the arrow b faces
towards the exhaust side.

5-29
POWR PISTONS E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

5 Bearing 1
6 Piston ring 2 CAUTION:
Align each end gap with its respective
locating pin.

Reverse the removal steps for installation.

5-30
POWR PISTONS E

SERVICE POINTS
Piston pin clip removal and installation
1. Remove and install:
● Piston pin clip

NOTE:
Before removing or installing the piston pin
clip, cover the crankcase opening with a
clean rag to prevent the piston pin clip from
falling into the crankcase.

Piston inspection
1. Eliminate:
● Carbon deposits
(from the piston crown and piston
ring gloves)

2. Inspect:
● Piston wall
Score marks → Repair with 600–800
grit wet sandpaper or replace.

NOTE:
Lightly sand the piston wall in a crisscross
pattern.

3. Measure:
● Piston skirt diameter
(with a micrometer)
Out of specification → Replace.

Piston diameter Distance a

79.899–79.914 mm 22 mm
(3.1456–3.1462 in) (0.87 in)

5-31
POWR PISTONS E

4. Calculate:
● Piston-to-cylinder clearance
Out of specification → Replace the
piston, piston rings and cylinder as a
set.
PISTON CYLINDER PISTON
= –
CLEARANCE BORE DIAMETER

Piston-to-cylinder clearance:
0.100–0.105 mm
(0.0039–0.0041 in)

Cylinder and piston combination

Select the appropriate piston to match the
cylinder size by the table as follows.
Cylinder size
Piston color mark
indication a
0–5 Red
6–10 Orange
11–15 Green
16–18 Purple

NOTE:
New cylinder bore size = 80.000 + a/1,000
Example: a = 12 → 80.012 mm.

Piston ring inspection

1. Measure:
● Side clearance
(with a thickness gauge 1)
Out of specification → Replace the
piston and piston rings as a set.

Side clearance:
0.03–0.05 mm (0.001–0.002 in)

5-32
POWR PISTONS E

2. Measure:
● End gap
(with a thickness gauge 1)
Out of specification → Replace the
piston rings as a set.

End gap:
0.45–0.60 mm (0.018–0.024 in)

NOTE:
Push the piston ring into the cylinder with
the piston crown.

Piston pin and bearing inspection

1. Inspect:
● Piston pins
● Bearings
Signs of heat discoloration → Replace.
2. Measure:
● Piston pin outside diameter
(with a micrometer 1)
Out of specification → Replace.

Piston pin outside diameter:

Standard
21.995–22.000 mm
(0.8659–0.8661 in)
Limit
21.990 mm (0.8657 in)

3. Check:
● Piston pin-to-piston free play
(with the piston pin in the piston as
shown)
Free play → Replace the piston pin,
piston or both.

5-33
POWR PISTONS E

4. Check:
● Piston pin-to-small end bearing-to-
connecting rod free play
(at the small end of the connecting
rod as shown)
Free play/small end wear → Replace
the piston pin, connecting rod, small
end bearing or both.

5-34
POWR GENERATOR AND STARTER MOTOR E

GENERATOR AND STARTER MOTOR

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
GENERATOR COVER REMOVAL Follow the left “Step” for removal.
Oil pump Refer to “OIL PUMP” in Chapter 4.
1 Bolt 1
2 Bolt 7 NOTE:
Do not apply LOCTITE® to the bolt that is
used to install the ground lead.

3 Ground lead 1
4 Generator cover 1
5 Washer 2

5-35
POWR GENERATOR AND STARTER MOTOR E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

6 Spring 1
7 Packing 1
8 Pin 2
9 Bolt 2
10 Bolt 2
11 Bracket 1
Reverse the removal steps for installation.

5-36
POWR GENERATOR AND STARTER MOTOR E

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
STATOR COIL AND PICKUP COIL Follow the left “Step” for removal.
REMOVAL
1 Bolt 3 NOTE:
2 Washer 1 This washer holds the pickup coil lead.
3 Cable holder 1 Make sure to not pinch the lead between
4 Bolt 2 the projection and the washer when
5 Pickup coil 1 installing the bolt.
6 Bolt 3
7 Stator coil 1
Reverse the removal steps for installation.

5-37
POWR GENERATOR AND STARTER MOTOR E

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
GENERATOR ROTOR AND Follow the left “Step” for removal.
STARTER MOTOR REMOVAL
1 Drive coupling 1
2 Flywheel magneto bolt 1
3 Flywheel magneto 1
4 Woodruff key 1
5 Starter clutch assembly 1
6 Bolt 2
7 Starter motor 1
Reverse the removal steps for installation.

5-38
POWR GENERATOR AND STARTER MOTOR E

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
STARTER CLUTCH Follow the left “Step” for disassembly.
DISASSEMBLY
1 Clip 1 Not reusable
2 Clip stopper 1
3 Spring seat 1
4 Spring 1
5 Washer 1
6 Idle gear 1
7 Circlip 1

5-39
POWR GENERATOR AND STARTER MOTOR E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

8 Plate 1
9 Weight 3
10 Spring ring 1 NOTE:
Install the spring ring after installing the
weights, plate and circlip.

11 Pinion gear 1
Reverse the disassembly steps for
assembly.

5-40
POWR GENERATOR AND STARTER MOTOR E

SERVICE POINTS
Drive coupling removal and installation
1. Remove:
● Drive coupling

Coupler wrench:
YW-06551/90890-06551
Flywheel holder:
YW-06550/90890-06550

NOTE:
Install the drive coupling with the same
special tools that were used for removal.

Flywheel magneto removal and installation

1. Remove:
● Flywheel magneto bolt

Flywheel holder:
YW-06550/90890-06550

NOTE:
Install the bolt with the same special tool
that was used for removal.
Å
2. Remove:
● Generator rotor

Flywheel puller:
YB-06117/90890-06521
Set bolt:
M8 × 60 mm

Å For USA and Canada

ı For worldwide

ı
CAUTION:
To prevent damage to the engine or tools,
screw in the flywheel puller set bolts
evenly and completely so that the puller
plate is parallel to the generator rotor.

5-41
POWR GENERATOR AND STARTER MOTOR E

Drive coupling inspection

1. Inspect:
● Drive coupling
Damage/wear → Replace.

Flywheel magneto inspection

1. Inspect:
● Ring gear
Damage/wear → Replace.

Starter clutch assembly inspection

1. Inspect:
● Pinion gear 1
● Idle gear 2
Damage/wear → Replace.
2. Check:
● Gear movement
Rough movement → Replace the
defective part(s).

5-42
POWR CRANKCASE E

CRANKCASE
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
CRANKCASE DISASSEMBLY Follow the left “Step” for disassembly.
Pistons Refer to “PISTONS”.
Generator cover and starter Refer to “GENERATOR AND STARTER
motor MOTOR”.
1 Bolt 6
2 Mount bracket 2
3 Pin 4
4 Bolt 3
5 Bolt 1
6 Bolt 6

5-43
POWR CRANKCASE E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

7 Bolt 1 NOTE:
8 Bolt 16 Tighten the bolts in sequence as shown.
9 Lower crankcase 1
10 Pin 2
11 Crankshaft assembly 1
12 Upper crankcase 1
Reverse the disassembly steps for
assembly.

5-44
POWR CRANKCASE E

SERVICE POINTS
Crankcase inspection
1. Inspect:
● Mating surfaces
Scratches → Replace the crankcase.
● Crankcase
Cracks/damage → Replace.

Crankcase installation
1. Apply:
● Gasket Maker®
(onto the crankcase mating surfaces)

NOTE:
Before applying Gasket Maker®, clean the
crankcase mating surfaces.

2. Check:
● Crankshaft
Rough movement → Recheck.

NOTE:
Make sure that the crankshaft rotates
smoothly after installing it.

5-45
POWR CRANKSHAFT E

CRANKSHAFT
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
CRANKSHAFT REMOVAL Follow the left “Step” for removal.
Crankcase Refer to “CRANKCASE”.
1 Oil seal 1
2 Bearing 1
3 Oil seal 2
4 Crankshaft assembly 1 CAUTION:
Install the bearing locating pins into the
gloves in the crankcase body.

Reverse the removal steps for installation.

5-46
POWR CRANKSHAFT E

SERVICE POINTS
Crankshaft inspection
1. Measure:
● Crank width A
Out of specification → Replace.

Crank width:
72.95–73.00 mm (2.872–2.874 in)

2. Measure:
● Deflection B
(with a dial gauge)
Out of specification → Replace.

Max. deflection:
B 0.05 mm (0.002 in)
C 0.15 mm (0.006 in)

3. Measure:
● Big end side clearance D
(with a thickness gauge)
Out of specification → Replace.

Big end side clearance:

0.25–0.75 mm (0.010–0.030 in)

4. Measure:
● Small end free play E
(with a dial gauge)
Out of specification → Replace.

Small end free play:

2.0 mm (0.08 in)

5-47
POWR CRANKSHAFT E

5. Inspect:
● Bearings
Damage/pitting → Replace.

NOTE:
● Before inspection, thoroughly clean the
bearings.
● Immediately after inspection, lubricate the
bearings to prevent rust.

6. Inspect:
● Oil seals
Damage/wear → Replace.

5-48
 JET
PUMP E

CHAPTER 6
JET PUMP UNIT

JET PUMP UNIT ............................................................................................. 6-1

EXPLODED DIAGRAM ............................................................................. 6-1
REMOVAL AND INSTALLATION CHART ............................................... 6-1

REVERSE GATE.............................................................................................. 6-4

EXPLODED DIAGRAM ............................................................................. 6-4
REMOVAL AND INSTALLATION CHART ............................................... 6-4
SERVICE POINTS ..................................................................................... 6-7
Lever 1 installation............................................................................ 6-7
Lever 2 installation............................................................................ 6-7

JET THRUST NOZZLE AND NOZZLE RING.................................................. 6-8

EXPLODED DIAGRAM ............................................................................. 6-8
REMOVAL AND INSTALLATION CHART ............................................... 6-8

IMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCT.................... 6-9

EXPLODED DIAGRAM ............................................................................. 6-9
REMOVAL AND INSTALLATION CHART ............................................... 6-9

IMPELLER DUCT AND DRIVE SHAFT......................................................... 6-11

EXPLODED DIAGRAM ........................................................................... 6-11
REMOVAL AND INSTALLATION CHART ............................................. 6-11
SERVICE POINTS ................................................................................... 6-13
Drive shaft removal......................................................................... 6-13
Impeller inspection ......................................................................... 6-14
Drive shaft inspection ..................................................................... 6-14
Drive shaft installation.................................................................... 6-14

TRANSOM PLATE AND HOSES.................................................................. 6-17

EXPLODED DIAGRAM ........................................................................... 6-17
REMOVAL AND INSTALLATION CHART ............................................. 6-17
SERVICE POINTS ................................................................................... 6-19
Bilge strainer inspection................................................................. 6-19
Bilge hose inspection...................................................................... 6-19
 JET
PUMP E

BEARING HOUSING..................................................................................... 6-20

EXPLODED DIAGRAM ........................................................................... 6-20
REMOVAL AND INSTALLATION CHART ............................................. 6-20
SERVICE POINTS ................................................................................... 6-23

1
Driven coupling removal and installation..................................... 6-23
Intermediate drive shaft removal .................................................. 6-23
Bearing removal.............................................................................. 6-23
Bearing, intermediate drive shaft, and
grease hose inspection .................................................................. 6-24
Driven coupling inspection ............................................................ 6-24
Bearing installation ......................................................................... 6-24
Oil seal installation.......................................................................... 6-25
Intermediate housing installation.................................................. 6-26 2
3
4
5
6
7
8
9
 JET
PUMP JET PUMP UNIT E

JET PUMP UNIT

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
JET PUMP UNIT REMOVAL Follow the left “Step” for removal.
1 Bolt 2
2 Bolt 2
3 Intake grate 1
4 Bolt 4
5 Intake duct 1
6 Screw 4
7 Speed sensor 1 NOTE:
Route the speed sensor lead between the
jet pump unit and the bilge hose.

8 Bolt 4

6-1
 JET
PUMP JET PUMP UNIT E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

9 Ride plate 1
10 Shift cable joint 1
11 QSTS cable joint 1
12 Bilge hose 1
13 Nut/washer 1/2
14 Steering cable joint 1
15 Clamp/spout hose 1/1
16 Bolt 1
17 Bolt 4
18 Jet pump unit assembly 1
19 Dowel pin 2
Reverse the removal steps for installation.

6-2
 JET
PUMP JET PUMP UNIT E

EXPLODED DIAGRAM

1 2

FWD

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
SPEED SENSOR DISASSEMBLY Follow the left “Step” for disassembly.
1 Paddle wheel set 1 Not reusable
2 Speed sensor housing 1
Reverse the disassembly steps for
assembly.

6-3
 JET
PUMP REVERSE GATE E

REVERSE GATE
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
REVERSE GATE REMOVAL Follow the left “Step” for removal.
1 Clamp/spout hose 1/1
2 Bolt 2
3 Washer 2
4 Collar 2
5 Reverse gate assembly 1
6 Nut 1
7 Bolt 1
8 Washer 2

6-4
 JET
PUMP REVERSE GATE E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

9 Roller 1
10 Bolt 6
11 Reverse gate stay 2
12 Nut 1
13 Washer 1
14 Bolt 1
15 Lever 1 1
16 Spacer 1
17 Nut 1

6-5
 JET
PUMP REVERSE GATE E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

18 Washer 1
19 Bolt 1
20 Washer 1
21 Collar 1
22 Spring 1
23 Lever 2 1
24 Washer 1
Reverse the removal steps for installation.

6-6
 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

NOTE:
● When installing the spring, hook the
4 b spring end a to lever 2 and spring end b
to the reverse gate, as shown in the illus-
tration.
● When installing the lever 2, hook the lever
2 end c to lever 1 end d, as shown in the
illustration.
d
a c

2. Install:
● Washer 1
● Nut 2

3. Check:
● Lever 1 and lever 2 movements
Stick → Reassembly lever 1 and
lever 2.

6-7
 JET
PUMP JET THRUST NOZZLE AND NOZZLE RING E

JET THRUST NOZZLE AND NOZZLE RING

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
JET THRUST NOZZLE AND Follow the left “Step” for removal.
NOZZLE RING REMOVAL
Jet pump unit Refer to “JET PUMP UNIT”.
Reverse gate Refer to “REVERSE GATE”.
1 Bolt 2
2 Collar 2
3 Jet thrust nozzle 1
4 Bolt 2
5 Collar 2
6 Nozzle ring 1
Reverse the removal steps for installation.

6-8
 JET IMPELLER DUCT, IMPELLER HOUSING,
PUMP AND INTAKE DUCT E

IMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCT

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
IMPELLER DUCT AND IMPELLER Follow the left “Step” for removal.
HOUSING REMOVAL
Nozzle ring Refer to “JET THRUST NOZZLE AND
NOZZLE RING”.
1 Bolt 4
2 Nozzle 1 NOTE:
3 Pin 2 Clean the contacting surfaces before
4 Impeller duct assembly 1 applying the Gasket Maker®.
5 Impeller housing 1
6 Pin 2

6-9
 JET IMPELLER DUCT, IMPELLER HOUSING,
PUMP AND INTAKE DUCT E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

7 Bolt 4
8 Water inlet cover 1
9 Packing 1
10 Water inlet strainer 1
11 Packing 1
Reverse the removal steps for installation.

6-10
 JET
PUMP IMPELLER DUCT AND DRIVE SHAFT E

IMPELLER DUCT AND DRIVE SHAFT

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
IMPELLER DUCT AND DRIVE Follow the left “Step” for disassembly.
SHAFT DISASSEMBLY
1 Impeller 1 Left-hand threads
2 Spacer 1
3 Bolt 3
4 Cap 1
5 O-ring 1
6 Nut 1
7 Washer 1
*1: EPNOC grease AP #0

6-11
 JET
PUMP IMPELLER DUCT AND DRIVE SHAFT E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

8 Drive shaft 1
9 Rear bearing 1 Not reusable
10 Spacer 1
11 Front bearing 1 Not reusable
12 Oil seal 1 Not reusable
13 Oil seal 1 Not reusable
Reverse the disassembly steps for
assembly.
*1: EPNOC grease AP #0

6-12
 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.

Å 4. Remove:
● Rear bearing

Slide hammer set:

YB-06096
Stopper guide plate:
90890-06501
Bearing puller:
90890-06535
Bearing puller claw 1:
90890-06536
Stopper guide stand:
ı 90890-06538

Å For USA and Canada

ı For worldwide

6-13
 JET
PUMP IMPELLER DUCT AND DRIVE SHAFT E

5. Remove:
● Front bearing

Driver rod L3:

YB-06071/90890-06652
Needle bearing attachment:
YB-06112/90890-06614

NOTE:
Remove the front bearing with a press.

6. Remove:
● Oil seal

Driver rod L3:

YB-06071/90890-06652
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.

Drive shaft installation

1. Install:
● Oil seal

Driver rod:
YB-06071/90890-06606
Ball bearing attachment:
YB-06085/90890-06634

6-14
 JET
PUMP IMPELLER DUCT AND DRIVE SHAFT E

2. Install:
● Front bearing
● Drive shaft

NOTE:
Install the front bearing and drive shaft with
a
a press.

Distance a:
23 ± 0.1 mm (0.91 ± 0.004 in)

3. Install:
● Drive shaft (with front bearing)
● Spacer
● Impeller duct

NOTE:
Press the spacer and the front bearing with
a 36-mm deep socket.

4. Add:
● EPNOC grease AP #0
(between the drive shaft and spacer)

Quantity:
Approximately 1/3 of capacity

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).

6-15
 JET
PUMP IMPELLER DUCT AND DRIVE SHAFT E

6. Add:
● EPNOC grease AP #0 (into the cap)

Quantity:
Approximately 1/3 of capacity

7. Install:
● Nut
● Impeller

Drive shaft holder:

YB-06151/90890-06519

6-16
 JET
PUMP TRANSOM PLATE AND HOSES E

TRANSOM PLATE AND HOSES

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
TRANSOM PLATE AND HOSES Follow the left “Step” for removal.
REMOVAL
Exhaust system Refer to “EXHAUST SYSTEM” in
Chapter 8.
Jet pump unit Refer to “JET PUMP UNIT”.
1 Hose clamp 3
2 Cooling water hose 1 Cooling water outlet
3 Bilge hose 1 1 NOTE:
Route the bilge hose 1 under the drive
shaft tube.

6-17
 JET
PUMP TRANSOM PLATE AND HOSES E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

4 Cooling water hose 1 Cooling water inlet
5 Nut/washer 4/4
6 Transom plate 1
7 Bilge hose 2 1
8 Screw 1
9 Bilge strainer holder 1
10 Bilge strainer 1
Reverse the removal steps for installation.

6-18
 JET
PUMP TRANSOM PLATE AND HOSES E

SERVICE POINTS
Bilge strainer inspection
Refer to “JET PUMP UNIT” in
Chapter 3.

Bilge hose inspection

1. Inspect:
● Bilge hose
Cracks/damage/wear → Replace.

6-19
 JET
PUMP BEARING HOUSING E

BEARING HOUSING
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
BEARING HOUSING REMOVAL Follow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT” in Chapter 5.
1 Rubber coupling 1
2 Bolt 3
3 Intermediate housing assembly 1
4 Pin 2
5 Shim * NOTE:
Install the shims in their original locations.

Reverse the removal steps for installation.

*: As required

6-20
 JET
PUMP BEARING HOUSING E

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
BEARING HOUSING Follow the left “Step” for disassembly.
DISASSEMBLY
1 Grease hose 1
2 Grease nipple 1
3 Grease nipple stay 1
4 Nipple 2
5 Driven coupling 1
6 Washer 1
7 Intermediate drive shaft 1

6-21
 JET
PUMP BEARING HOUSING E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

8 O-ring 2
9 Oil seal 1 Not reusable
10 Oil seal 1 Not reusable
11 Oil seal 1 Not reusable
12 Circlip 1
13 Bearing 1 Not reusable
14 Circlip 1
Reverse the disassembly steps for
assembly.

6-22
 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.

Intermediate drive shaft removal

1. Remove:
● Intermediate drive shaft

Removal steps:
1
● Temporarily install the driven coupling
to the intermediate drive shaft.
● Insert the long rod to the driven cou-
pling shaft.
● Press out the intermediate drive shaft
by pushing the rod.

NOTE:
Support the intermediate housing with
steel blocks 1 and press the driven cou-
pling shaft.

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.

6-23
 JET
PUMP BEARING HOUSING E

Bearing, intermediate drive shaft, and

grease hose inspection
1. Inspect:
● Bearing
Rotate the inner race by hand.
Damage/rough movement → Replace.
● Intermediate drive shaft
Damage/pitting → Replace.
● Grease hose
Cracks/wear → Replace.

Driven coupling inspection

1. Inspect:
● Driven coupling
● Driven coupling damper
Damage/wear → Replace.

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.

6-24
 JET
PUMP BEARING HOUSING E

Oil seal installation

1. Install:
● Oil seal

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:
6.8–7.2 mm (0.27–0.28 in)

2. Install:
● Intermediate drive shaft

Distance a:
9.5–10.5 mm (0.37–0.41 in)

NOTE:
Support the intermediate housing with
steel blocks 1 and press the driven cou-
pling shaft.

3. Install:
b ● Oil seal 1 [8 mm (0.31 in)]
a
● Oil seal 2 [10 mm (0.39 in)]
2
1 Distance a:
10.3–10.7 mm (0.41–0.42 in)
Distance b:
1.6–2.0 mm (0.06–0.08 in)

6-25
 JET
PUMP BEARING HOUSING E

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
No need
(0–0.008 in)
0.3–0.7 mm
0.5 mm
(0.012–0.028 in)
0.8–1.2 mm
1.0 mm
(0.031–0.047 in)
1.3–2.0 mm
1.5 mm
(0.051–0.079 in)

NOTE:
Install the shim(s) to the original position if
the intermediate housing is not replaced.

6-26
 – +
ELEC E

CHAPTER 7
ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS......................................................................... 7-1

ELECTRICAL BOX........................................................................................... 7-2

EXPLODED DIAGRAM ............................................................................. 7-2
REMOVAL AND INSTALLATION CHART ............................................... 7-2

ELECTRICAL ANALYSIS ................................................................................ 7-9

INSPECTION............................................................................................. 7-9
Digital tester ...................................................................................... 7-9
Low resistance measurement ........................................................ 7-10
Peak voltage measurement............................................................ 7-10
Peak voltage adaptor ...................................................................... 7-10
Test harness ................................................................................... 7-11

IGNITION SYSTEM....................................................................................... 7-12

WIRING DIAGRAM................................................................................. 7-12
IGNITION SPARK GAP........................................................................... 7-13
IGNITION SYSTEM PEAK VOLTAGE.................................................... 7-14
BATTERY ................................................................................................ 7-16
FUSE ....................................................................................................... 7-16
SPARK PLUGS ....................................................................................... 7-16
SPARK PLUG LEAD ASSEMBLY........................................................... 7-16
IGNITION COIL ....................................................................................... 7-17
ENGINE STOP SWITCH ......................................................................... 7-17
WATER TEMPERATURE SENSOR........................................................ 7-18
EXHAUST TEMPERATURE SENSOR ................................................... 7-18

STARTING SYSTEM..................................................................................... 7-19

WIRING DIAGRAM................................................................................. 7-19
BATTERY ................................................................................................ 7-20
WIRING CONNECTIONS ....................................................................... 7-20
FUSE ....................................................................................................... 7-20
START SWITCH...................................................................................... 7-21
STARTER RELAY.................................................................................... 7-21

STARTER MOTOR ........................................................................................ 7-22

EXPLODED DIAGRAM ........................................................................... 7-22
REMOVAL AND INSTALLATION CHART ............................................ 7-22
SERVICE POINTS ................................................................................... 7-25
Armature inspection ....................................................................... 7-25
Brush holder inspection ................................................................. 7-26
Starter motor front cover inspection............................................. 7-26
 – +
ELEC E

CHARGING SYSTEM.................................................................................... 7-27

WIRING DIAGRAM................................................................................. 7-27
FUSE ....................................................................................................... 7-28
BATTERY ................................................................................................ 7-28

1
LIGHTING COIL ...................................................................................... 7-28
RECTIFIER/REGULATOR........................................................................ 7-28

YPVS ............................................................................................................. 7-29

WIRING DIAGRAM................................................................................. 7-29
FUSE ....................................................................................................... 7-30
BATTERY ................................................................................................ 7-30
PICKUP COIL .......................................................................................... 7-30
CDI UNIT................................................................................................. 7-30
LIGHTING COIL ...................................................................................... 7-30
2
RECTIFIER/REGULATOR........................................................................ 7-30

YPVS SERVOMOTOR .................................................................................. 7-31

EXPLODED DIAGRAM ........................................................................... 7-31
REMOVAL AND INSTALLATION CHART ............................................. 7-31
SERVICE POINTS ................................................................................... 7-32
3
YPVS cable removal and installation ............................................ 7-32
YPVS cable inspection .................................................................... 7-32
YPVS servomotor inspection ......................................................... 7-32
YPVS cable adjustment .................................................................. 7-33 4
INDICATION SYSTEM.................................................................................. 7-34

5
WIRING DIAGRAM................................................................................. 7-34
FUSE ....................................................................................................... 7-35
BATTERY ................................................................................................ 7-35
LIGHTING COIL ...................................................................................... 7-35
RECTIFIER/REGULATOR........................................................................ 7-35
CDI UNIT................................................................................................. 7-35
WATER TEMPERATURE SENSOR........................................................ 7-35
EXHAUST TEMPERATURE SENSOR ................................................... 7-35
BUZZER .................................................................................................. 7-35
OIL LEVEL SENSOR ............................................................................... 7-35
FUEL LEVEL SENSOR............................................................................ 7-36
6
MULTIFUNCTION METER ..................................................................... 7-36
Multifunction meter ........................................................................ 7-36
EXPLODED DIAGRAM ........................................................................... 7-37
REMOVAL AND INSTALLATION CHART ............................................. 7-37
Display function .............................................................................. 7-38
Fuel level gauge .............................................................................. 7-40
7
Oil level gauge................................................................................. 7-41
Overheat warning indicator ........................................................... 7-42
Speed meter .................................................................................... 7-45
Speed sensor................................................................................... 7-46 8
9
 – +
ELEC ELECTRICAL COMPONENTS E

ELECTRICAL COMPONENTS

B 1

2
3

A 5

7
0
8

1 Fuel level sensor 9 Speed sensor

2 Oil level sensor 0 Water temperature sensor
3 Buzzer A Starter motor
4 Lighting coil and pickup coil B Engine stop switch, engine shut-off switch
5 Spark plugs and start switch
6 Exhaust temperature sensor C YPVS servomotor
7 Electrical box D Multifunction meter
8 Battery

7-1
 – +
ELEC ELECTRICAL BOX E

ELECTRICAL BOX
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
ELECTRICAL BOX REMOVAL Follow the left “Step” for removal.
Ventilation hose, water Refer to “MUFFLER ASSEMBLY” in
temperature sensor coupler Chapter 5.
Exhaust temperature sensor Refer to “EXHAUST CHAMBER
coupler ASSEMBLY” in Chapter 5.
Generator lead, starter motor Refer to “EXHAUST MANIFOLD AND
lead LEADS” in Chapter 5.
Spark plug lead
1 Battery negative lead 1
2 Battery positive lead 1
3 Clip/breather hose 1/1

7-2
 – +
ELEC ELECTRICAL BOX E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

4 Band 2
5 Battery 1
6 Damper 1
7 Bolt 4
8 Battery box 1
9 Coupler 4 For multifunction meter, handlebar
switch and YPVS servomotor
10 Bolt 4
11 Electrical box 1
Reverse the removal steps for installation.

7-3
 – +
ELEC ELECTRICAL BOX E

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
ELECTRICAL BOX DISASSEMBLY Follow the left “Step” for disassembly.
1 Clamp 5
2 Coupler 3 For water temperature sensor, exhaust
temperature sensor, lighting coil and pick
up coil
3 Screw 2
4 Rectifier/regulator 1
5 Screw 10
6 Cover 1
7 Packing 1
8 Spark plug lead holder 3

7-4
 – +
ELEC ELECTRICAL BOX E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

9 Screw 6
10 Ground lead 3
11 Ignition coil 3
12 Ignition coil lead 3
13 Spark plug lead/cap 3/3
14 Bolt 3
15 Ground lead 6
16 Lead 3 Black/orange
17 Nut 2
18 Starter motor lead 1

7-5
 – +
ELEC ELECTRICAL BOX E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

19 Battery positive lead 1
20 Fuse lead 1
21 Starter relay lead 1
22 Starter relay 1
23 Lead holder 1
24 Fuse lead 5
25 Screw 2
26 Fuse holder 1
27 Lead/coupler 1/6
28 Screw 2

7-6
 – +
ELEC ELECTRICAL BOX E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

29 Coupler bracket 1
30 CDI unit 1
31 Screw 8
32 Lead holder plate 2
Reverse the disassembly steps for
assembly.

7-7
 – +
ELEC ELECTRICAL BOX E

1 Ignition coil Å To battery positive terminal O : Orange

2 CDI unit ı To starter motor R : Red
3 Rectifier/regulator Ç Affix the ignition coil connector to W : White
4 Fuse holder the electrical box holder. B/O : Black/orange
5 Starter relay Î Pass the 8 pin coupler leads B/W : Black/white
6 Tape behind the CDI unit and insert B/Y : Black/yellow
7 Clear tube them into the bracket. Gy/B : Gray/black
8 Red tube Gy/R : Gray/red
9 White tape Br : Brown Gy/Y : Gray/yellow
G : Green R/L : Red/blue
Gy : Gray R/W : Red/white
R/Y : Red/yellow

7-8
 – +
ELEC ELECTRICAL ANALYSIS E

ELECTRICAL ANALYSIS
INSPECTION

CAUTION:
● All measuring instruments should be han-
dled with special care. Damaged or mis-
handled instruments will not measure
properly.
● On an instrument powered by dry batter-
ies, check the battery’s voltage periodi-
cally and 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.

Digital tester:
J-39299/90890-06752

NOTE:
“ ” indicates a continuity of electric-
ity; i.e., a closed circuit at the respective
switch position.

7-9
 – +
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 termi-
nals.

Correct value =
Displayed measurement –
Internal resistance

Peak voltage measurement

NOTE:
● When checking the condition of the igni-
tion system it is vital to know the peak
voltage.
● Cranking speed is dependant on many
factors (e.g., fouled or weak spark plugs, a
weak battery). If one of these is defected,
the peak voltage will be lower than speci-
fication.
● If the peak voltage measurement is not
within specification the engine will not
operate properly.
● A low peak voltage will also cause compo-
nents to prematurely wear.

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-39991/90890-03169

7-10
 – +
ELEC ELECTRICAL ANALYSIS E

Å ● When measuring the peak voltage, con-

nect the peak voltage adaptor to the digi-
tal tester and switch the selector to the
DC voltage mode.

NOTE:
● Make sure that the adaptor leads are
properly installed in the digital tester.
● Make sure that the positive pin (the “+”
mark facing up as shown) on the adaptor
is installed into the positive terminal of
ı the tester.
● The test harness is needed for the follow-
ing tests.
Å Voltage measurement
ı Peak voltage measurement

Test harness
YW- 90890- Pin Usage
06780 06780 6 Pickup coil and
lighting coil

Checking steps:
● Disconnect the coupler connections.
● Connect the test harness between the
couplers.
● Connect the tester terminals to the ter-
minals which are being checked.
● Run the engine and observe the mea-
surement.

NOTE:
● Make sure the output lead (red lead) of the
rectifier/regulator is disconnected when
measuring the peak voltage of the lighting
coil and rectifier/regulator.
● If the lighting coil and pickup coil(s) are
measured unloaded, disconnect the test
harness on the output side coupler.

7-11
 – +
ELEC IGNITION SYSTEM E

IGNITION SYSTEM
WIRING DIAGRAM

1 Engine stop switch 0 Rectifier/regulator B : Black

2 Engine shut-off switch A Exhaust temperature sensor G : Green
3 Lighting coil B Water temperature sensor O : Orange
4 Pickup coil R : Red
5 CDI unit W : White
6 Ignition coil B/O : Black/orange
7 Spark plug B/W : Black/white
8 Fuse (20A) B/Y : Black/yellow
9 Battery W/R : White/red

7-12
 – +
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,
Å since this test can produce sparks.

1. Check:
● Ignition spark gap
Below specification → Check the CDI
unit output peak voltage.
Check the ignition coil for resistance.

Spark gap:
10 mm (0.39 in)
ı
Checking steps:
● Connect the spark plug cap to the
spark gap tester.
● Set the spark gap length on the adjust-
ing knob.

Spark gap tester:

YM-34487/90890-06754

● Crank the engine and observe the igni-

Å tion system spark through the dis-
OK
charge window.

0 5
Å For USA and Canada
ı For worldwide
0 5 10

OK

7-13
 – +
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 compo-
nent.

1. Measure:
● CDI unit output peak voltage
Below specification → Measure the
rectifier/regulator output peak volt-
age.
Replace the CDI unit.

CDI unit output peak voltage:

Black/orange (B/O) – Black (B)
Black/white (B/W) – Black (B)
Black/yellow (B/Y) – Black (B)
Unloaded Loaded
r/min
Cranking 2,000 3,500
V 200 180 190 180

NOTE:
B/O – B for cylinder #1.
B/W – B for cylinder #2.
B/Y – B for cylinder #3.

7-14
 – +
ELEC IGNITION SYSTEM E

2. Measure:
● Pickup coil output peak voltage
Below specification → Replace the
pickup coil.

Pickup coil output peak voltage:

White/red (W/R) –
Black/orange (B/O)
Unloaded Loaded
r/min
Cranking 2,000 3,500
V 5 2.8 7.9 11

NOTE:
The starter motor will not operate when the
test harness on the output side coupler is
disconnected to measure the unloaded
peak voltage for the pickup coil(s). There-
fore, connect the black lead of the test har-
ness to the ground with a lead.

3. Measure:
● Lighting coil output peak voltage
Below specification → Replace the
lighting coil.

Lighting coil output peak voltage:

Green (G) – Green (G)
Unloaded Loaded
r/min
Cranking 2,000 3,500
V 9 9 14 14

NOTE:
● Make sure the output lead (red lead) of the
rectifier/regulator is disconnected when
measuring the output peak voltage.
● The starter motor will not operate when
the test harness on the output side cou-
pler is disconnected to measure the
unloaded peak voltage for the lighting
coil. Therefore, connect the black lead of
the test harness to the ground with a lead.

7-15
 – +
ELEC IGNITION SYSTEM E

4. Measure:
● Rectifier/regulator output peak
voltage
Below specification → Replace the
rectifier/regulator.

Rectifier/regulator output peak

voltage:
Red (R) – Black (B)
Unloaded
r/min
Cranking 2,000 3,500
V 7 12.6 12.6

NOTE:
Make sure the output lead (red lead) of the
rectifier/regulator is disconnected when
measuring the output peak voltage.

BATTERY
Refer to “ELECTRICAL” in Chapter 3.

FUSE
Refer to “STARTING SYSTEM”.

SPARK PLUGS
Refer to “POWER UNIT” in Chapter 3.

SPARK PLUG LEAD ASSEMBLY

1. Inspect:
● Spark plug lead assembly
Cracks/damage → Replace.

2. Measure:
● Spark plug lead resistance
Out of specification → Replace.

Spark plug lead resistance:

#1: 6.1–14.3 kΩ
#2: 4.5–10.9 kΩ
#3: 3.0–7.4 kΩ

7-16
 – +
ELEC IGNITION SYSTEM E

IGNITION COIL
1. Measure:
● Primary coil resistance
Out of specification → Replace.

Primary coil resistance:

Black/white (B/W) – Body
0.26–0.36 Ω at 20 ˚C (68 ˚F)

NOTE:
When measuring a resistance of 10 Ω or
less with the digital tester, the correct mea-
surement 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:

Black/white (B/W) – Spark plug
lead terminal
3.5–4.7 kΩ at 20 ˚C (68 ˚F)

ENGINE STOP SWITCH

1. Check:
● Engine stop switch continuity
Out of specification → Replace.

Engine stop switch continuity

(black coupler)

Lead color
Clip Position
White Black
Free
Installed
Push
Free
Removed
Push

7-17
 – +
ELEC IGNITION SYSTEM E

WATER TEMPERATURE SENSOR

1. Measure:
● Water temperature sensor resistance
(at the specified temperature)
Out of specification → Replace.

Water temperature sensor

resistance:
0 ˚C (32 ˚F): 24.0–37.1 kΩ
100 ˚C (212 ˚F): 0.87–1.18 kΩ
200 ˚C (392 ˚F): 104–153 Ω

Measurement steps:
● Ice the water temperature sensor and
measure the resistance.
● Suspend the water temperature sen-
sor in a container filled with oil.
● Slowly heat the oil.
● Measure the resistance when the spec-
ified temperature is reached.

EXHAUST TEMPERATURE SENSOR

1. Measure:
● Exhaust temperature sensor resis-
tance (at the specified temperature)
Out of specification → Replace.

Exhaust temperature sensor

resistance:
300 ˚C (572 ˚F): 73–241 kΩ
600 ˚C (1,112 ˚F): 0.86–1.58 kΩ
900 ˚C (1,652 ˚F): 64–90 Ω

Measurement steps:
● Heat the exhaust temperature sensor
using an electric furnace or equivalent.
● Measure the resistance when the spec-
ified temperature.

7-18
 – +
ELEC STARTING SYSTEM E

STARTING SYSTEM
WIRING DIAGRAM

1 CDI unit B : Black

2 Engine shut-off switch Br : Brown
3 Start switch R : Red
4 Multifunction meter R/W : Red/white
5 Fuse (10A) R/Y : Red/yellow
6 Fuse (20A)
7 Starter relay
8 Starter motor
9 Battery

7-19
 – +
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 holder continuity
No continuity → Check the fuse or
replace the fuse holder.

Fuse holder continuity:

Between 1 and 2
Between 2 and 3

2. Check:
● Fuse broken
Broken → Replace.

Fuse rating:
10A, 20A

NOTE:
20A fuse is for CDI unit and rectifier/regula-
tor.
10A fuse is for multifunction meter, YPVS
motor and start switch.

7-20
 – +
ELEC STARTING SYSTEM E

START SWITCH
1. Check:
● Continuity
Out of specification → Replace.

Start continuity
(natural color coupler)

Leads
Clip Position
Red Brown
Free
Installed
Push
Free
Removed
Push

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.
● Check that there is no continuity after
the brown or black lead is removed.

7-21
 – +
ELEC STARTER MOTOR E

STARTER MOTOR
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
STARTER MOTOR Follow the left “Step” for disassembly.
DISASSEMBLY
Starter motor Refer to “GENERATOR AND STARTER
MOTOR” in Chapter 5.
1 O-ring 1 Not reusable
2 Bolt 2
3 Starter motor front cover 1
4 O-ring 1 Not reusable
5 Oil seal retainer 1
6 Washer 1
7 Shim * t = 0.2 mm, 0.5 mm
*: As required

7-22
 – +
ELEC STARTER MOTOR E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

8 Starter motor rear cover 1
9 O-ring 1 Not reusable
10 Shim * t = 0.2 mm, 0.8 mm
11 Armature assembly 1
12 Nut/spring washer/washer 1/1/4
13 O-ring 1 Not reusable
14 Brush holder 1
15 Brush spring 4
16 Bolt 1
17 Brush assembly 1
*: As required

7-23
 – +
ELEC STARTER MOTOR E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

18 Spacer 1
19 Holder 1
20 Starter motor yoke 1
Reverse the disassembly steps for
assembly.

7-24
 – +
ELEC STARTER MOTOR E

SERVICE POINTS
Armature inspection
1. Inspect:
1 ● Armature shaft 1
Damage/wear → Replace.

2. Inspect:
● Commutator
Dirt → Clean with 600 grit sandpaper.

3. Measure:
● Commutator diameter
Out of specification → Replace.

Min. commutator diameter:

27.0 mm (1.06 in)

4. Check:
● 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:

0.2 mm (0.01 in)

7-25
 – +
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.

Brush holder continuity:

Brush holder - Base No continuity

Starter motor front cover inspection

1. Inspect:
● Starter motor front cover bushing
Damage/wear → Replace the starter
motor front cover.

7-26
 – +
ELEC CHARGING SYSTEM E

CHARGING SYSTEM
WIRING DIAGRAM

1 Lighting coil B : Black

2 Battery G : Green
3 Fuse (20A) R : Red
4 Rectifier/regulator

7-27
 – +
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”.

7-28
 – +
ELEC YPVS E

YPVS
WIRING DIAGRAM

1 Lighting coil B : Black

2 Pickup coil G : Green
3 CDI unit Gy : Gray
4 YPVS servomotor R : Red
5 Fuse (10A) B/O : Black/orange
6 Fuse (20A) R/L : Red/blue
7 Battery R/W : Red/white
8 Rectifier/regulator W/R : White/red

7-29
 – +
ELEC YPVS E

FUSE
Refer to “STARTING SYSTEM”.

BATTERY
Refer to “ELECTRICAL” in Chapter 3.

PICKUP COIL
Refer to “IGNITION SYSTEM”.

CDI UNIT
Refer to “IGNITION SYSTEM”.

LIGHTING COIL
Refer to “IGNITION SYSTEM”.

RECTIFIER/REGULATOR
Refer to “IGNITION SYSTEM”.

7-30
 – +
ELEC YPVS SERVOMOTOR E

YPVS SERVOMOTOR
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
YPVS SERVOMOTOR REMOVAL Follow the left “Step” for removal.
1 Bolt 2
2 YPVS cable bracket 1
3 YPVS servomotor coupler 1
4 Bolt 2
5 YPVS servomotor 1
6 Spacer 2
7 YPVS cable 2 Slide the cover.
8 Cover 1
Reverse the removal steps for installation.

7-31
 – +
ELEC YPVS SERVOMOTOR E

SERVICE POINTS
YPVS cable removal and installation
1. Remove:
● YPVS cables 1 and 2

Removal steps:
● Remove the YPVS cable holder 1.
● Remove the YPVS cables 2 from the
both drams.

NOTE:
There is a “22222.....” mark a on YPVS
cable 2.

YPVS cable inspection

1. Inspect:
● YPVS cables 1 and 2
Frays/kinks/rough movement →
Replace.

YPVS servomotor inspection

1. Check:
● YPVS servomotor
YPVS servomotor does not move →
Replace.

Checking steps:
● Connect the battery (12 V) to the YPVS
servomotor coupler as shown.

Battery positive terminal →

Red (R) terminal 1
Battery negative terminal →
Black (B) terminal 2

● Install a jumper lead 4 between the

black 2 and gray 3 terminals as
shown. Only install the jumper lead for
1 or 2 seconds.

Black (B) terminal 2 ↔

Gray (Gy) terminal 3

7-32
 – +
ELEC YPVS SERVOMOTOR E

● Make sure the servomotor operates

properly.
NOTE:
Make sure the pulley operates three sec-
onds after the jumper lead is removed.

CAUTION:
Do not disassemble the YPVS servomotor
unit. It is a sealed unit and if it is faulty it
must be replaced.

YPVS cable adjustment

Refer to “CONTROL SYSTEM” in
Chapter 3.

7-33
 – +
ELEC INDICATION SYSTEM E

INDICATION SYSTEM
WIRING DIAGRAM

1 CDI unit A Fuse (20A) B : Black Gy/B : Gray/black

2 Fuel level sensor B Exhaust temperature Br : Brown Gy/R : Gray/red
3 Oil level sensor sensor Ch : Chocolate Gy/Y : Gray/yellow
4 Buzzer C Water temperature G : Green L/B : Blue/black
5 Multifunction meter sensor Gy : Gray L/R : Blue/red
6 Speed sensor L : Blue R/B : Red/black
7 Engine shut-off O : Orange R/W : Red/white
switch R : Red R/Y : Red/yellow
8 Start switch Y : Yellow W/L : White/blue
9 Battery B/O : Black/orange
0 Fuse (10A) B/Y : Black/yellow

7-34
 – +
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”.

CDI UNIT
Refer to “IGNITION SYSTEM”.

WATER TEMPERATURE SENSOR

Refer to “IGNITION SYSTEM”.

EXHAUST TEMPERATURE SENSOR

Refer to “IGNITION SYSTEM”.

BUZZER
1. Check:
● Buzzer
Buzzer does not sound → Replace.

Checking steps:
● Connect the battery (12 V) to the
buzzer coupler as shown.

Battery positive terminal →

Red (R) terminal 1
Battery negative terminal →
Black (B) terminal 2

OIL LEVEL SENSOR

1. Measure:
● Oil level sensor resistance
Out of specification → Replace.
Blue (L) – Black (B)

Float position Resistance (Ω)

A 292–308
B 97–103
C 0–3

7-35
 – +
ELEC INDICATION SYSTEM E

FUEL LEVEL SENSOR

1. Measure:
● Fuel level sensor resistance
Out of specification → Replace.
White/blue (W/L) – Black (B)

Float position Resistance (Ω)

A 757–803
B 0–8

MULTIFUNCTION METER
Multifunction meter
1. Check:
● Multifunction meter
Cracked meter housing → Replace
the multifunction meter.
Meter is fogged/shows signs of water
intrusion → Replace the multifunction
meter.

7-36
 – +
ELEC INDICATION SYSTEM E

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
MULTIFUNCTION METER Follow the left “Step” for removal.
REMOVAL
1 Multifunction meter coupler 8
2 Nut 2
3 Holder 1
4 Multifunction meter 1
Reverse the removal steps for installation.

7-37
 – +
ELEC INDICATION SYSTEM E

Display function
1. Check:
● Display function
Not operate → Replace the multifunc-
tion meter.

1 Oil level sensor B : Black Gy/R : Gray/red

2 Fuel level sensor Br : Brown Gy/Y : Gray/yellow
3 Buzzer Ch : Chocolate L/B : Blue/black
4 Electrical box G : Green L/R : Blue/red
5 Start switch Gy : Gray R/B : Red/black
6 Battery L : Blue R/W : Red/white
7 Speed sensor R : Red R/Y : Red/yellow
*: Disconnected Y : Yellow W/L : White/blue
Gy/B : Gray/black

7-38
 – +
ELEC INDICATION SYSTEM E

Checking steps:
● Connect the battery terminals to the
natural six-pin connector as shown.
NOTE:
If the multifunction meter has been
removed from the watercraft, supply DC
12 voltage to the connector (+: red, –:
black) with a battery.

● Disconnect the blue one-pin connector

1 and make sure the “WARNING”
lamp 2 lights.
NOTE:
If the “WARNING” lamp does not light,
disconnect the battery and then recon-
nect it.

● Press the “A/SET” 3 and “C” 5 but-

tons at the same time. While still
pressing the two buttons, press the
“MODE” button 6 and hold all three
for more than 3 seconds. The self-indi-
cating function will then activate.
NOTE:
If the “ ” message displays, recon-
nect and then disconnect the blue one-
pin connector.

Sequential output (73 seconds/cycle)

1 Display begins operation
2 “ ”
3 All LCD readouts turn on
4 “ ” is displayed
5 “ ” is displayed
6 “ ” is displayed
7 “ ” is displayed
8 “ ” is displayed
9 “ ” is displayed
10 “ ” is displayed
11 “ ” is displayed
12 “ ” is displayed
13 “ ” is displayed
14 “ ” is displayed
15 “ ” is displayed
● Press either button 3, 4, 5, or 6. The
self-indicating function will then stop
and the “WARNING” lamp 2 will light.
● Reconnect the blue one-pin connector.
The “WARNING” lamp 2 will turn off.

7-39
 – +
ELEC INDICATION SYSTEM E

Fuel level gauge

1. Check:
● Fuel level gauge
Not operating → Replace the multi-
function meter.

Checking steps:
● Supply DC 12 voltage to the natural
six-pin connector (+: red, –: black) with
a battery.
● Disconnect the green two-pin connec-
tor (white/blue and black leads).
● Connect the white/blue and black ter-
minals with a jumper lead 1.
● Connect the green and red terminals
with a jumper lead 2.

NOTE:
If the jumper lead is installed for more
than 30 seconds, the display will auto-
matically turn off.

● Check the fuel level segments is full

indicated.
● Remove the jumper lead 1 from the
green two-pin connector.
● Disconnect the jumper lead 2 and
then connect it to green and red ter-
minal again.
● Make sure the fuel low level segment
3, fuel level warning indicator 4,
“ ” message 5 and “WARNING”
lamp 6 blink, and the buzzer sounds
intermittently.

7-40
 – +
ELEC INDICATION SYSTEM E

Oil level gauge

1. Check:
● Oil level gauge
Not operating → Replace the multi-
function meter.

Checking steps:
● Supply DC 12 voltage to the natural
six-pin connector (+: red, –: black) with
a battery.
● Disconnect the white two-pin connec-
tor (blue and black leads).
● Connect the blue and black terminals
with a jumper lead 1.
● Connect the green and red terminals
with a jumper lead 2.

NOTE:
If the jumper lead is installed for more
than 30 seconds, the display will auto-
matically turn off.

● Check the oil level segments is full

indicated.
● Remove the jumper lead 1 from the
white two-pin connector.
● Disconnect the jumper lead 2 and
then connect it to green and red ter-
minal again.
● Make sure the oil low level segment
3, oil level warning indicator 4,
“ ” message 5 and “WARNING”
lamp 6 blink, and the buzzer sounds
intermittently.

7-41
 – +
ELEC INDICATION SYSTEM E

Overheat warning indicator

1. Check:
● Overheat 1 warning indicator
Not operating → Replace the multi-
function meter.

Checking steps:
● Supply DC 12 voltage to the natural
six-pin connector (+: red, –: black) with
a battery.
● Connect the gray/black and black ter-
minals with a jumper lead 1.
● Connect the green and red terminals
with a jumper lead 2.
● Make sure the water temperature
warning indicator 3, “ ” mes-
sage 4 and “WARNING” lamp 5
blink, and the buzzer sounds intermit-
tently.

7-42
 – +
ELEC INDICATION SYSTEM E

2. Check:
● Overheat 2 warning indicator
Not operating → Replace the multi-
function meter.

Checking steps:
● Supply DC 12 voltage to the natural
six-pin connector (+: red, –: black) with
a battery.
● Connect the gray/red and black termi-
nals with a jumper lead 1.
● Connect the green and red terminals
with a jumper lead 2.
● Make sure the water temperature
warning indicator 3 and the
“ ” message 4, the “WARN-
ING” lamp 5 light constantly, and
the buzzer sounds continuity.

7-43
 – +
ELEC INDICATION SYSTEM E

3. Check:
● Exhaust temperature warning
indicator
Not operating → Replace the multi-
function meter.

Checking steps:
● Supply DC 12 voltage to the natural
six-pin connector (+: red, –: black) with
a battery.
● Connect the gray/yellow and black ter-
minals with a jumper lead 1.
● Connect the green and red terminals
with a jumper lead 2.
● Make sure the exhaust temperature
warning indicator 3, “ ” mes-
sage 4 and “WARNING” lamp 5
blink, and the buzzer sounds intermit-
tently.

7-44
 – +
ELEC INDICATION SYSTEM E

Speed meter
1. Check:
● Speed meter output voltage
Within specification → Check the speed
sensor output voltage and pulses.
Out of specification → Replace.

Speed meter output voltage:

10.5 V

Checking steps:
● Supply DC 12 voltage to the natural
six-pin connector (+: red, –: black) with
a battery.
● Disconnect the blue one-pin connector
1 and make sure the “WARNING” lamp
lights 2.

NOTE:
If the “WARNING” lamp does not light,
disconnect the battery and then recon-
nect it.

● Measure the voltage on the speed

meter connector (white three-pin con-
nector) (between the red/white and
black leads).

7-45
 – +
ELEC INDICATION SYSTEM E

Speed sensor
1. Check:
● 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 11.6 V
Output pulse:
2 pulses/one-full turn

Checking steps:
● Apply DC 12 voltage to the white color
three-pin connector (between the red/
yellow and black/yellow leads).
● Rotate the paddle wheel by hand and
measure the voltage between the
black and yellow leads.
NOTE:
As the paddle wheel is rotated, a square-
wave voltage signal a is produced.

● Two pulses occur every time the pad-

dle wheel makes one-full turn.

7-46
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........................................................................ 8-6
Handlebar switch inspection............................................................ 8-6
Handlebar assembly installation ..................................................... 8-6

QSTS GRIP...................................................................................................... 8-8

EXPLODED DIAGRAM ............................................................................. 8-8
REMOVAL AND INSTALLATION CHART ............................................... 8-8
SERVICE POINTS ................................................................................... 8-10
QSTS cable inspection.................................................................... 8-10
QSTS grip inspection...................................................................... 8-10

STEERING MASTER..................................................................................... 8-11

EXPLODED DIAGRAM ........................................................................... 8-11
REMOVAL AND INSTALLATION CHART ............................................. 8-11
SERVICE POINTS ................................................................................... 8-14
Steering master components inspection ...................................... 8-14

REMOTE CONTROL CABLES AND SPEED SENSOR LEAD ...................... 8-15

EXPLODED DIAGRAM ........................................................................... 8-15
REMOVAL AND INSTALLATION CHART ............................................. 8-15
SERVICE POINTS ................................................................................... 8-18
Remote control cables inspection ................................................. 8-18
Steering cable (jet pump end) installation.................................... 8-18
Steering cable stopper installation................................................ 8-18
QSTS cable (jet pump end) installation ........................................ 8-19
QSTS cable stopper installation .................................................... 8-19
Shift cable (jet pump end) installation .......................................... 8-19
Shift cable stopper installation ...................................................... 8-20
Remote control cables adjustment................................................ 8-20

FRONT HOOD ............................................................................................... 8-21

EXPLODED DIAGRAM ........................................................................... 8-21
REMOVAL AND INSTALLATION CHART ............................................. 8-21

STEERING CONSOLE COVER ..................................................................... 8-24

EXPLODED DIAGRAM ........................................................................... 8-24
REMOVAL AND INSTALLATION CHART ............................................. 8-24
HULL
HOOD E

HOSES........................................................................................................... 8-26
EXPLODED DIAGRAM ........................................................................... 8-26
REMOVAL AND INSTALLATION CHART ............................................. 8-26
SERVICE POINTS ................................................................................... 8-28

1
Check valve inspection ................................................................... 8-28

SHIFT LEVER ................................................................................................ 8-29

EXPLODED DIAGRAM ........................................................................... 8-29
REMOVAL AND INSTALLATION CHART ............................................. 8-29
SERVICE POINTS ................................................................................... 8-32
Base assembly................................................................................. 8-32

SEATS AND HAND GRIP ............................................................................. 8-33

EXPLODED DIAGRAM ........................................................................... 8-33
2
REMOVAL AND INSTALLATION CHART ............................................. 8-33
SERVICE POINTS ................................................................................... 8-35
Seat lock inspection ........................................................................ 8-35

EXHAUST SYSTEM...................................................................................... 8-36

3
EXPLODED DIAGRAM ........................................................................... 8-36

4
REMOVAL AND INSTALLATION CHART ............................................. 8-36
SERVICE POINTS ................................................................................... 8-38
Exhaust system inspection............................................................. 8-38
Exhaust component parts sub-assembly...................................... 8-38

DECK AND HULL .......................................................................................... 8-39

EXPLODED DIAGRAM ........................................................................... 8-39
REMOVAL AND INSTALLATION CHART ............................................. 8-39

ENGINE MOUNT .......................................................................................... 8-41

5
EXPLODED DIAGRAM ........................................................................... 8-41
REMOVAL AND INSTALLATION CHART ............................................. 8-41
HULL REPAIR ......................................................................................... 8-42
Shallow scratches ........................................................................... 8-42
Deep scratches ................................................................................ 8-42
Cracks and punctures ..................................................................... 8-43
6
Insert nut.......................................................................................... 8-44
Graphic removal.............................................................................. 8-46
Graphic installation......................................................................... 8-46
7
8
9
HULL
HOOD HANDLEBAR E

HANDLEBAR
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
HANDLEBAR COVER REMOVAL Follow the left “Step” for removal.
1 Screw 4
2 Handlebar cover 1
3 Band 2
4 Pad 1
5 Bolt 2
NOTE:
6 Handlebar cover stay 1
Position the corrugated tube for the throt-
7 Throttle cable 1
tle cable as shown in the illustration so
8 Bolt 4 that the tube attaches to the end of the
9 Upper handlebar holder 2 outer throttle cable.
10 Handlebar assembly 1
Reverse the removal steps for installation.

8-1
HULL
HOOD HANDLEBAR E

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
HANDLEBAR REMOVAL Follow the left “Step” for removal.
QSTS cable (to jet thrust nozzle) Refer to “REMOTE CONTROL CABLES
AND SPEED SENSOR LEAD”.
1 Bolt 2
2 QSTS converter 1
3 QSTS cable 2 1 with white tape a
4 QSTS cable 1 1 NOTE:
Route the QSTS cables in front of the fuel
level sensor.

5 Handlebar switch coupler 3

8-2
HULL
HOOD HANDLEBAR E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

6 Buzzer coupler 1
7 Band 2
8 Screw 4
9 Handle boss cover 1
10 Buzzer 1
Reverse the removal steps for installation.

8-3
HULL
HOOD HANDLEBAR E

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
HANDLEBAR DISASSEMBLY Follow the left “Step” for disassembly.
1 Bolt 2
2 Grip end 2
3 Spacer 1
4 Screw/spring washer/washer 1/1/1
5 QSTS grip assembly 1
6 Screw 2 NOTE:
Tighten the screw from the engine stop
switch side.

8-4
HULL
HOOD HANDLEBAR E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

7 Handlebar switch assembly 1
8 Screw 2
9 Throttle lever assembly 1
10 Handlebar grip 1 NOTE:
Apply adhesive to the handlebar and the
inner surface of the handlebar grip.

11 Handlebar 1
Reverse the disassembly steps for
assembly.

8-5
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. Install:
● Upper handlebar holder 1

NOTE:
● Align the punch mark a on the handlebar
with the top surface of the handlebar
holder.
● The upper handlebar holder should be
installed with the punch mark b facing
forward.

CAUTION:
Clearance c should be narrower than
clearance d.

Reference clearance:
c: 1.5 mm (0.06 in)
d: 3.5 mm (0.14 in)

8-6
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:

77 ± 0.5 mm (3.03 ± 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. Install:
● Handlebar cover 1

NOTE:
a 1 When the handlebar cover is in contact with
the steering boss cover, adjust the handle-
bar mount angle so that the clearance a
and b are equal.
b

6. Adjust:
● Throttle cable free play
Refer to “CONTROL SYSTEM” in
Chapter 3.
7. Adjust:
● QSTS cable
Refer to “CONTROL SYSTEM” in
Chapter 3.

8-7
HULL
HOOD QSTS GRIP E

QSTS GRIP
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
QSTS GRIP DISASSEMBLY Follow the left “Step” for disassembly.
QSTS grip assembly Refer to “HANDLEBAR”.
1 Screw/washer 1/1
2 Cover 1
3 Ball 2
4 Spring 2
5 QSTS cable 1 1
6 QSTS cable 2 1 with white tape a

8-8
HULL
HOOD QSTS GRIP E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

7 Screw/washer 2/2
8 Spacer 1
9 QSTS shift lock lever 1
10 Spring 1
11 Spacer 1
12 Cable housing 1
13 QSTS grip 1
Reverse the disassembly steps for
assembly.

8-9
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.

8-10
HULL
HOOD STEERING MASTER E

STEERING MASTER
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
STEERING MASTER REMOVAL Follow the left “Step” for removal.
Steering console cover Refer to “STEERING CONSOLE COVER”.
Steering cable end Refer to “REMOTE CONTROL CABLES
AND SPEED SENSOR LEAD”.
1 Bolt/washer 1/1
2 Steering arm 1
3 Nut/washer 4/4
4 Steering master assembly 1
5 Bolt 4
6 Grommet 2
Reverse the removal steps for installation.

8-11
HULL
HOOD STEERING MASTER E

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
STEERING MASTER Follow the left “Step” for disassembly.
DISASSEMBLY
1 Bolt/washer 2/2
2 Stay 1
3 Spring 1
4 Bolt/washer 6/6
5 Lower housing 1
6 Spring 1
7 Bushing 1
8 Bushing 1
9 Upper housing 1
10 Tilt lever 1

8-12
HULL
HOOD STEERING MASTER E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

11 Tilt stopper 1
12 Bolt/nut 4/4
13 Retainer 2
14 Steering shaft assembly 1
15 Steering tube 1
16 Bolt/washer/spring washer 2/2/2
17 Cap 1
18 Shaft 1 1
19 Cross piece 1
Reverse the disassembly steps for
assembly.

8-13
HULL
HOOD STEERING MASTER E

SERVICE POINTS
Steering master components inspection
1. Inspect:
● Each component part
Damage/wear → Replace the steer-
ing master.

8-14
HULL REMOTE CONTROL CABLES AND
HOOD SPEED SENSOR LEAD E

REMOTE CONTROL CABLES AND SPEED SENSOR LEAD

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
REMOTE CONTROL CABLES Follow the left “Step” for removal.
AND SPEED SENSOR LEAD
REMOVAL
1 Speed sensor coupler 1
2 Cap 1
3 Nut 1
4 Screw 4
5 Speed sensor 1
6 Steering cable end 1
7 Nut/washer 3/3
8 Bracket 1

8-15
HULL REMOTE CONTROL CABLES AND
HOOD SPEED SENSOR LEAD E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

9 Nut 2
10 Steering cable holder 1
11 Cap 1
12 Nut 1
13 Steering cable 1
14 Shift cable end 1
15 Bolt 2
16 Shift cable holder 1
17 Cap 1

8-16
HULL REMOTE CONTROL CABLES AND
HOOD SPEED SENSOR LEAD E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

18 Nut 1
19 Shift cable 1
20 Nut 1
21 Pin 1
22 QSTS cable end 1
23 Cap 1
24 Nut 1
25 QSTS cable 1
Reverse the removal steps for installation.

8-17
HULL REMOTE CONTROL CABLES AND
HOOD 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. Inspect:
● Steering cable
● QSTS cable
● Shift cable
Frays/kinks/rough movement →
Replace.

Steering cable (jet pump end) installation

1. Install:
● Steering cable a

Steering cable set length

(jet pump end):
13.5–15.5 mm (0.53–0.61 in)

WARNING
The steering cable must be screwed in at
least 8 mm (0.31 in).

Steering cable stopper installation

1. Install:
● Steering cable stopper

WARNING
Be sure to fit the projection 1 on the steer-
ing cable stopper into the groove in the
outer cable.

8-18
HULL REMOTE CONTROL CABLES AND
HOOD SPEED SENSOR LEAD E

QSTS cable (jet pump end) installation

1. Install:
● QSTS cable (jet pump end) a

QSTS cable set length

(jet pump end):
12.0–14.0 mm (0.47–0.55 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. Install:
● Shift cable (jet pump end) a

Shift cable set length

(jet pump end):
12.2–13.8 mm (0.48–0.54 in)

WARNING
The shift cable must be screwed in more
than 8 mm (0.31 in).

8-19
HULL REMOTE CONTROL CABLES AND
HOOD SPEED SENSOR LEAD E

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.

8-20
HULL
HOOD FRONT HOOD E

FRONT HOOD
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
FRONT HOOD REMOVAL Follow the left “Step” for removal.
1 Nut/washer 4/4
2 Front hood assembly 1
3 Bolt 4
4 Hinge assembly 1
5 Screw 2
6 Hood lock assembly 1
7 Bolt 4
8 Mirror (with seal) 2

8-21
HULL
HOOD FRONT HOOD E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

9 Nut 1
10 Washer 1
11 Notch 1
12 Collar 1
13 Damper 1
Reverse the removal steps for installation.

8-22
HULL
HOOD FRONT HOOD E

EXPLODED DIAGRAM

1
6
4

5 3

8
7

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
HINGE DISASSEMBLY Follow the left “Step” for disassembly.
1 Circlip 3
2 Pin (long) 1
3 Pin (short) 2
4 Wire 1
5 Spacer 1
6 Spacer 1
7 Damper 1
8 Hinge 1
Reverse the disassembly steps for
assembly.

8-23
HULL
HOOD STEERING CONSOLE COVER E

STEERING CONSOLE COVER

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
STEERING CONSOLE COVER Follow the left “Step” for removal.
REMOVAL
Handlebar assembly Refer to “HANDLEBAR”.
Fuel cock assembly Refer to “FUEL COCK AND FUEL FILTER”
in Chapter 4.
Choke cable Refer to “CHOKE CABLE” in Chapter 4.
Front hood assembly and notch Refer to “FRONT HOOD”.
1 Bolt 2
2 Shift lever handle 1
3 Nut/washer 1/1

8-24
HULL
HOOD STEERING CONSOLE COVER E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

4 Bolt 8
5 Nut/washer 2/2
6 Bolt 2
7 Steering console cover 1
Reverse the removal steps for installation.

8-25
HULL
HOOD HOSES E

HOSES
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
HOSES REMOVAL Follow the left “Step” for removal.
Steering console cover Refer to “STEERING CONSOLE COVER”.
1 Band 2
2 Ventilation hose 1
3 Band 1
4 Check valve 1
5 Oil tank breather hose 1
6 Fuel tank breather hose 2

8-26
HULL
HOOD HOSES E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

7 Clamp/cooling water hose 2/2
8 Nut/washer 2/2
9 Cooling water pilot outlet 2
10 Packing 2
Reverse the removal steps for installation.

8-27
HULL
HOOD HOSES E

SERVICE POINTS
Check valve inspection
1. Check:
● Check valve
Faulty → Replace.

Checking steps:
● Connect a hose to the end of check
valve “A” and blow into it.
Air should come out from end “B”.
● Connect the hose to the end of check
valve “B” and blow into it.
Air should not come out from end “A”.

8-28
HULL
HOOD SHIFT LEVER E

SHIFT LEVER
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
SHIFT LEVER REMOVAL Follow the left “Step” for removal.
Steering console cover Refer to “STEERING CONSOLE COVER”.
Shift cable Refer to “REMOTE CONTROL CABLES
AND SPEED SENSOR LEAD”.
1 Bolt 1
2 Washer 1
3 Shift lever 1 Mark its original position

8-29
HULL
HOOD SHIFT LEVER E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

4 Screw 3
5 Base assembly 1
6 Nut/washer 3/3
7 Screw 3
8 Plate 1
Reverse the removal steps for installation.

8-30
HULL
HOOD SHIFT LEVER E

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
BASE DISASSEMBLY Follow the left “Step” for disassembly.
1 Bolt/washer 2/2
2 Plate 1
3 Spring 1
4 Actuator 1
5 Roller 1
6 Shaft 1
7 Shift arm 1
Reverse the disassembly steps for
assembly.

8-31
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.

8-32
HULL
HOOD SEATS AND HAND GRIP E

SEATS AND HAND GRIP

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
SEATS AND HAND GRIP Follow the left “Step” for removal.
REMOVAL
1 Rear seat assembly 1
2 Front seat assembly 1
3 Bolt 4
4 Seat lock assembly 2
5 Nut/washer 4/5
6 Notch 2
7 Bolt 2

8-33
HULL
HOOD SEATS AND HAND GRIP E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

8 Rear seat stay 1
9 Nut/washer 4/4
10 Bolt 4
11 Front seat stay 2
12 Nut/washer 4/4
13 Bolt 4
14 Hand grip 1
Reverse the removal steps for installation.

8-34
HULL
HOOD SEATS AND HAND GRIP E

SERVICE POINTS
Seat lock inspection
1. Inspect:
● Front seat lock
● Rear seat lock
Damage/wear → Replace.

8-35
HULL
HOOD EXHAUST SYSTEM E

EXHAUST SYSTEM
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
EXHAUST SYSTEM REMOVAL Follow the left “Step” for removal.
Jet pump unit assembly Refer to “JET PUMP UNIT” in Chapter 6.
1 Band 1
2 Hose clamp 2
3 Exhaust joint 1
4 Hose clamp 2
5 Rubber hose 1 Mark a should be upside
6 Water lock 1 Mark b should be upside
7 Bolt 6

8-36
HULL
HOOD EXHAUST SYSTEM E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

8 Hose clamp 2 NOTE:
9 Resonator assembly 1 Remove parts 8 to 14 as a set.
10 Rubber hose 1
11 Hose clamp 1
12 Water tank 1
13 Rubber hose 1
14 Plate 1
Reverse the removal steps for installation.

8-37
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. Install:
● Rubber hose
● Water tank

NOTE:
● Insert the water tank 45 mm (1.8 in) a into
the rubber hose.
● Align the white mark b of the rubber hose
with the parting line c of the water tank.
● Align the mark d of the water tank with
the parting line e of the rubber hose.
● Insert the resonator assembly 45 mm (1.8
in) f into the rubber hose.
● Make sure that there is a surface distance
of 25 mm (1.0 in) g between the parting
lines of the resonator assembly and rub-
ber hose.

8-38
HULL
HOOD DECK AND HULL E

DECK AND HULL

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
DECK AND HULL DISASSEMBLY Follow the left “Step” for disassembly.
1 Nut/washer 2/2
2 Bow eye 1
3 Nut 2
4 Rope hole fitting 2
5 Nut 1
6 Spout 1
7 Nut 2
8 Plate 1

8-39
HULL
HOOD DECK AND HULL E

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

9 Cleat 1
10 Nut 6 For M6 stud bolts
11 Nut 2 For M8 stud bolts
12 Sponson 2
13 Nut/washer 4/4
14 Screw/washer 4/4
15 Drain plug 2
16 Packing 2
Reverse the disassembly steps for
assembly.

8-40
HULL
HOOD ENGINE MOUNT E

ENGINE MOUNT
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points
ENGINE MOUNT REMOVAL Follow the left “Step” for removal.
Engine assembly Refer to “ENGINE UNIT” in Chapter 5.
1 Bolt 4
2 Damper 2
3 Bolt 8
4 Engine mount 4
Reverse the removal steps for installation.

8-41
HULL
HOOD ENGINE MOUNT E

HULL REPAIR
Shallow scratches
1. Sand the scratches with 400 grit sand-
paper (either wet or dry) until the
scratches are smooth. Then, sand the
scratches once again with 600 grit sand-
paper (either wet or dry).

Deep scratches
1. Remove any sharp or rough edges from
the hull surface.
2. Sand the scratches and a 1-inch circum-
ference around them with 80 grit sand-
paper (either wet or dry).
3. Clean the entire area with acetone and
let it completely dry.
4. Mix gel-coat and gel-coat thickener to
form a putty, and then add the catalyst
to the putty.
5. Apply the putty, spread it with a squee-
gee, and then cover the putty with wax
paper.
6. When the putty has set, sand it. Smooth
the area with 80–400 grit sandpaper
(either wet or dry) and a sanding block.
7. Clean the area with a dry cloth and then
polish it.

WARNING
Resins, catalysts, and solvents are flamma-
ble and toxic; only use them in a well-venti-
lated area and keep them away from open
flames and sparks. Always follow the man-
ufacturer’s instructions and warnings.

8-42
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. Clean the area with acetone, apply BP-1
or an equivalent primer onto both sides
of the damaged area, and then allow it
to cure for approximately 30 minutes.
6. Cover a piece of cardboard with wax
paper 1 and then cover the damaged
area with it.
7. Combine the polyester resin and the
catalyst, and then apply the mixture
onto the hull.
8. Install a glass mat 2 (2 inches smaller
than the ground area).
9. Apply the resin.
10. Install a 20 oz. fiberglass cloth 3 (1 inch
smaller than the glass mat).
11. Apply the resin.
12. Install another glass mat 4 (1 inch
smaller than the ground area).
13. When the resin has hardened remove
the piece of cardboard.
14. Finish the outer surface.
Refer to steps (3)–(7) in the “Deep
scratches” section.

8-43
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
Part No. Remarks
name
Stainless
EW2-62733-09 Nut
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 (0.37 in)

Example 1:

NOTE:
Before attempting to install the insert nut,
refer to “WATERCRAFT FRP REPAIR MAN-
UAL”.

The insert nut is used to repair the pop nut

designed for the ride plate.
(By repairing the FRP portion, the insert nut
can be used for all models.)
1. Remove:
● Pop nut
2. Clean the surface to be scarfed and the
inside of the hull with acetone.
3. Scarf the shaded portion of the hull.

8-44
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. Pass the bolt 2 through the insert nut
and lock the bolt with the nut 3 as
shown.
9. Screw in the insert nut so that the top is
flush with the FRP surface.
10. Loosen the locknut and remove the
bolt.

CAUTION:
● Only use a steel bolt with a tensile
strength of 8T or more.
● If the bolt is inferior in strength or is
made of stainless steel it may break.

● Bolt 2
● Locknut 3
Example 2:
The brass insert nut, which is designed for
the Super Jet ride plate or the intake screen,
is used as follows.

NOTE:
If the bolt is broken, drill it out.

1. Drill a hole in the hull.

NOTE:
● First, use a small-diameter drill bit fol-
lowed by drill bits of gradually increasing
diameter.
● Use a 9.4 mm (0.37 in) drill bit for the final
drilling.

8-45
HULL
HOOD ENGINE MOUNT E

2. To prevent water from entering the ure-

thane foam, apply silicone sealant to
the inside of the hole as shown.
3. Install the insert nut as explained in
“Example 1”.
● Brass insert nut 1
● Hull 2
● Urethane foam 3
● Silicone sealant 4

Graphic removal
1. Hold a hair dryer approximately 1.5
inches above the graphic 1.
2. Apply heat to one corner of the graphic.
3. Slowly peel off the heated portion of the
graphic and continue working until you
reach the opposite corner and the entire
graphic is removed.
4. After the graphic is removed, clean the
entire bow area with isopropyl alcohol
to remove any residual adhesive.

Graphic installation
1. Mix 1 tablespoon of liquid detergent
and water in a 1-quart spray bottle.
2. Remove the backing from the new
graphic.
3. Spray the soap and water mixture onto
both sides of the graphic, and also onto
the hull area where the graphic will be
installed.

NOTE:
Spraying the front of the graphic with the
soap and water mixture will protect it from
being scratched during installation.

4. Align the graphic onto the fitting area of

the hull and position it with a squeegee.

NOTE:
Be sure to remove any air bubbles from the
graphic with the squeegee. Work from the
top of the graphic down and slide the
squeegee outwards from the graphic’s cen-
ter line.

5. Allow the graphic to dry before waxing

or using the watercraft.

8-46
TRBL
ANLS E

CHAPTER 9
TROUBLE ANALYSIS

TROUBLE ANALYSIS ..................................................................................... 9-1

TROUBLE ANALYSIS CHART ................................................................. 9-1 1
2
3
4
5
6
7
8
9
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 not rusty.
4. The clip is attached to the engine shut-off switch.
5. Fuel is reaching the carburetors.

TROUBLE ANALYSIS CHART

Problems Items to be checked
YPVS SERVOMOTOR DOES NOT MOVE
IRREGULAR WARNING INDICATION

POOR BATTERY CHARGING

ENGINE WILL NOT START

ENGINE WILL NOT STOP

Reference
POOR PERFORMANCE

Items
chapter
LOOSE STEERING

BILGE INCREASE
ENGINE STALLS
ROUGH IDLING

OVERHEATING

FUEL SYSTEM
Fuel tank 4
Fuel tank breather hose 4
Fuel hose 4
Fuel filter 4
Fuel pump 4
Carburetors 4
Carburetor synchronization 4
Trolling speed 3
POWER UNIT
Spark plug(s) 3
Compression 5
Reed valves 5
Cylinder head gasket 5
Piston rings 5
Cylinder block 5
Seals 5
Crankcase 5
Pistons 5
Bearings 5
Bearing housing 5
Drive couplings 5

9-1
TRBL
ANLS TROUBLE ANALYSIS E

Problems Items to be checked

YPVS SERVOMOTOR DOES NOT MOVE

IRREGULAR WARNING INDICATION

POOR BATTERY CHARGING

ENGINE WILL NOT START

ENGINE WILL NOT STOP

Reference
POOR PERFORMANCE

Items
chapter
LOOSE STEERING

BILGE INCREASE
ENGINE STALLS
ROUGH IDLING

OVERHEATING

Rubber coupling 5
Pilot water hose 5
Water hose 5
Water passage 5
JET PUMP UNIT
Duct 6
Impeller 6
Intake grate 6
Bearings 6
Intake duct 6
Water inlet hose 6
Bilge hose 6
Bilge strainer 6
Bilge hose joint 6
Valve body 6
ELECTRICAL
CDI unit 7
Lighting coil 7
Pickup coil (Pulser coil) 7
Ignition coil 7
Rectifier/regulator 7
Electrical sender(s) 7
Starter relay, starter motor 7
YPVS unit 7
Battery 3
Fuse(s) 7
Wire harness, electrical coupler(s) 7
HULL AND HOOD
Steering master 8
Water lock 8
Exhaust hose 8
Muffler 8
Drain plugs 8

9-2
 YAMAHA MOTOR CORPORATION, USA

Printed in USA
Jan. 2001 — ?.? × 1 CR
F0V-28197-1A-11
(XA1200A-Z)
Printed on recycled paper
WIRING DIAGRAM XLT1200
COLOR CODE
B
Br
Ch
:
:
:
Black
Brown
Chocolate
B/Y : Black/yellow
Gy/B : Gray/black
Gy/R : Gray/red
G : Green Gy/Y : Gray/yellow
Gy : Gray L/B : Blue/black
L : Blue L/R : Blue/red
1 Lighting coil O : Orange R/B : Red/black
R : Red R/L : Red/blue
W : White R/W : Red/white
2 Pickup Y : Yellow R/Y : Red/yellow
coil B/O : Black/orange W/L : White/blue
3 CDI unit
B/W : Black/white W/R : White/red
G G W/R B/O B

Gy/B
B/O Gy/Y
W/R Gy Br
G B/Y
B B/W
O
B/O

B/O
B
G W L
W/R B/Y
Gy/R Br R L
L

G
W/R
B/O B/Y Br Gy/B Gy W B/W B Br R 4 Oil level sensor B B
W/R O Gy/R G Gy/Y B/O B/Y B B B
B/O
B
B/O
W/L
B B/O

G G W/R B
Gy/Y W/L W/L
W/L
W 5 Fuel level sensor
B/O O
W W

B/Y B/O Gy/Y Gy/Y

B/O R/B
G G
B/Y O G

B/O Gy Gy Gy
Gy/B
G G G B
K Rectifier/regulator R/W
B
Gy R/B
B/Y O R Gy/R
G Gy/R Gy Gy/Y Gy/B
B/O B/O
R/W
L/R R 6 Buzzer
B G Gy/Y
Gy/B Gy/B Gy/B G L/R R
R B/Y B/O O B/O Gy/R Gy/R R L/B B
Gy/R
Gy/B B Gy/Y
G G B L/B B
J Water temperature sensor Gy/R
R
R/Y R/Y
B B/Y
B/Y R/W B 7 Multi-function meter
B B/O
R/Y R/W
I Exhaust B B B/Y B/O
Br Br
Y Y
temperature sensor B/O
Br Br
B/Y B
W
W O R R
Y 0 Engine shut-off A Start
8 Speed sensor
R
R/W
R
R/L
9 Engine stop switch switch
B B/O R/W R/Y switch SET
W B R Br
Ch
B R/W R/W
G Ignition coil O PULL Ch

W W Br
B
B
R R
W W
#1 Br
B/W B/O B B
F Fuse (20A,10A) B
B
H Spark plug
G Ignition coil

R R/W R/Y Br
D Starter motor Br R/Y Br
#2 R
N Br R R/Y R
B/W B/W

B R M R/Y Br Br Br
H Spark plug Br Br R
G Ignition coil S

R
#3 B
B/W B/Y R
B R
R R
B R/L
H Spark plug Br + – R/L R
B B B
Gy Gy B YPVS servomotor
E Starter relay B B
B C Battery Gy
B
B B
B
B