Yamaha FX HO Service Manual PDF

WaveRunner
FX High Output
FX Cruiser High Output
SERVICE MANUAL
*LIT186160283*
LIT-18616-02-83
F1S-28197-1G-11
NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
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 edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
A10001-0*
WaveRunner
FX High Output, FX Cruiser High Output
SERVICE MANUAL
2004 by Yamaha Motor Corporation, USA
1st Edition, February 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-02-83
HOW TO USE THIS MANUAL

MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the
course of action required will follow the symbol, e.g.,
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.
IMPORTANT INFORMATION
In this Service Manual particularly important information is distinguished in the following ways.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, passenger(s), a bystander, or a person inspecting or repairing the watercraft.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the watercraft.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
IMPORTANT:
This part has been subjected to change of specification during production.

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 tightening
torque.
Example:
Bolt or screw size
10 25 mm
: M10 (D) 25 mm (L)

D
L
6 Jobs requiring more information (such as special tools and technical data) are described
sequentially.
E
1
A50001-1-4
GEN
INFO
SYMBOLS
Symbols 1 to 9 are designed to indicate the
content of a chapter.
SPEC
1
2
3
4
5
6
7
8
9
INSP
ADJ
FUEL
JET
PUMP
POWR
7
General Information
Specifications
Periodic Inspection and Adjustment
Fuel System
Power Unit
Jet Pump Unit
Electrical System
Hull and Hood
Trouble Analysis
ELEC
9
HULL
HOOD
Symbols 0 to E indicate specific data.
0
A
B
C
D
E
TRBL
ANLS
A
Special tool
Specified oil or fluid
Specified engine speed
Specified tightening torque
Specified measurement
Specified electrical value
(resistance, voltage, electric current)
T.
R.
Symbols F to H in an exploded diagram indicate the grade of lubricant and the lubrication
point.
E
G
H
A
GM
L
LT
LT
271
242
N
LT
572
SS
F Apply Yamaha 4-stroke motor oil

G Apply water resistant grease
(Yamaha grease A, Yamaha marine grease)
H Apply molybdenum disulfide grease
Symbols I to N in an exploded diagram indicate the type of sealant or locking agent and
the application point.
I
J
K
L
M
N
Apply Gasket Maker

Apply Yamabond No. 4
Apply LOCTITE 271 (red)
Apply LOCTITE 242 (blue)
Apply LOCTITE 572
Apply silicone sealant
NOTE:
Additional symbols may be used in this manual.
E
A30000-0
INDEX
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENT
FUEL SYSTEM
POWER UNIT
JET PUMP UNIT
GEN
INFO
SPEC
INSP
ADJ
FUEL
POWR
JET
PUMP
ELECTRICAL SYSTEM
HULL AND HOOD
TROUBLE ANALYSIS
ELEC
HULL
HOOD
TRBL
ANLS
1
2
3
4
5
6
7
8
9
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION NUMBERS ......................................................................... 1-1
PRIMARY l.D. NUMBER ...........................................................................1-1
ENGINE SERIAL NUMBER ...................................................................... 1-1
JET PUMP UNIT SERIAL NUMBER .........................................................1-1
HULL IDENTIFICATION NUMBER (H.l.N.)............................................... 1-1
SAFETY WHILE WORKING...................................................................... 1-2
FIRE PREVENTION .................................................................................. 1-2
VENTILATION ........................................................................................... 1-2
SELF-PROTECTION................................................................................. 1-2
PARTS, LUBRICANTS, AND SEALANTS ................................................ 1-2
GOOD WORKING PRACTICES ............................................................... 1-3
DISASSEMBLY AND ASSEMBLY ............................................................ 1-4
SPECIAL TOOLS ............................................................................................ 1-5
MEASURING............................................................................................. 1-5
REMOVAL AND INSTALLATION.............................................................. 1-7
GEN
INFO
IDENTIFICATION NUMBERS
A60700-0*
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:
F1S: 800101
ENGINE SERIAL NUMBER

The engine serial number is stamped on a
label attached to the engine unit.
Starting serial number:
6B6: 1000001
JET PUMP UNIT SERIAL NUMBER

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

To prevent and accident or injury and to
ensure quality service, follow the safety procedures provided below.
FIRE PREVENTION
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
VENTILATION
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled in
large quantities they may cause loss of consciousness and death within a short time.
When test running an engine indoors (e.g., in a
water tank), be sure to do so where adequate
ventilation can be maintained.
SELF-PROTECTION
Protect your eyes by wearing safety glasses or
safety goggles during all operation involving
drilling and grinding, or when using an air compressor.
Protect your hands and feet by wearing protective gloves or safety shoes when necessary.
PARTS, LUBRICANTS, AND

SEALANTS
Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the
watercraft.
1-2
GEN
INFO
Under normal conditions, the lubricants mentioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Maintain good standards of personal and
industrial hygiene.
2. Change and wash clothing as soon as
possible if soiled with lubricants.
3. Avoid contact with skin. Do not, for example, place a soiled rag in your pocket.
4. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.
5. To protect your skin, apply a protective
cream to your hands before working on the
watercraft.
6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.
GOOD WORKING PRACTICES

1. The right tools
Use the recommended special service
tools to protect parts from damage. Use
the right tool in the right mannerdo not
improvise.
2. Tightening torques
Follow the tightening torque specifications
provided throughout the manual. When
tightening nuts, bolts, and screws, tighten
the large sizes first, and tighten fasteners
starting in the center and moving outward.
1-3
GEN
INFO
3. Non-reusable parts
Always use new gaskets, seals, O-rings,
oil seals, cotter pins, circlips, etc., when
installing or assembling parts.
DISASSEMBLY AND ASSEMBLY

1. Use compressed air to remove dust and
dirt during disassembly.
2. Apply engine oil to the contact surfaces of
moving parts during assembly.
3. Install bearings with the manufacture identification mark in the direction indication in
the installation procedure. In addition, be
sure to lubricate the bearings liberally.
4. Apply a thin coat of water-resistant grease
to the lip and periphery of an oil seal
before installation.
5. Check that moving parts operate normally
after assembly.
1-4
GEN
INFO
SPECIAL TOOLS
SPECIAL TOOLS
Using the correct special tools recommended
by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvisations
and using improper tools can damage the
equipment.
1 YU-03097
NOTE:
For U.S.A. and Canada, use part numbers
starting with J-, YB-, YM-, YS-, YU- or
YW-.
For other countries, use part numbers starting with 90890-.
90890-01252
MEASURING
2 90890-06583
90890-06584
5 YU-03112
YU-34899-A
7 90890-03174
YU-08030
9 90890-03094
0 YW-06862
1 Dial gauge
P/N. YU-03097
90890-01252
2 Dial gauge stand
P/N. 90890-06583
3 Dial gauge needle
P/N. 90890-06584
4 Dial gauge stand set
P/N. YW-06585
90890-06585
5 Pocket tester
P/N. YU-03112
90890-03112
6 Digital multimeter
P/N. YU-34899-A
7 Digital circuit tester
P/N. 90890-03174
8 Carburetor synchronizer
P/N. YU-08030
9 Vacuum gauge
P/N. 90890-03094
0 Test connector
P/N. YW-06862
Test connector FMY-8
P/N. 90890-06862
A Fuel pressure gauge adapter
P/N. YW-06842
90890-06842
4 YW-06585
90890-06585
90890-03112
90890-06862
A YW-06842
90890-06842
1-5
GEN
INFO
B YB-06766
C 90890-06582
E YU-33223-1
SPECIAL TOOLS
D YU-03017
90890-06759
90890-03160
G 90890-03172
H YM-34487
I 90890-06754
J YB-06867 (-06767)
K YB-06870 (-06770)
L YB-06848
M YB-06793
90890-06848
B Fuel pressure gauge

P/N. YB-06766
90890-06786
C Compression gauge extension
P/N. 90890-06582
D Cylinder gauge set
P/N. YU-03017
90890-06759
E Compression gauge
P/N. YU-33223-1
90890-03160
F Peak volt meter adapter
P/N. YU-39991
G Peak voltage adapter B
P/N. 90890-03172
H Spark gap tester
P/N. YM-34487
I Ignition tester
P/N. 90890-06754
J Test harness (2 pins)
P/N. New: YB-06867
Current: YB-06767
Test harness FWY-2 (2 pins)
P/N. New: 90890-06867
Current: 90890-06767
K Test harness (3 pins)
P/N. New: YB-06870
Current: YB-06770
Test harness SMT250-3 (3 pins)
P/N. New: 90890-06870
Current: 90890-06770
L Test harness (6 pins)
P/N. YB-06848
Test harness FSW-6A (6 pins)
P/N. 90890-06848
M Test harness (3 pins)
P/N. YB-06793
Test harness SMHW099-3 (3 pins)
P/N. 90890-06793
90890-06786
F YU-39991
90890-06867 (-06767)
90890-06870 (-06770)
90890-06793
1-6
GEN
INFO
N YB-06877 (-06777)
90890-06877 (-06777)
SPECIAL TOOLS
E
N Test harness (3 pins)
P/N. New: YB-06877
Current: YB-06777
Test harness HM090-3 (3 pins)
P/N. New: 90890-06877
Current: 90890-06777
O Lower unit pressure/vacuum tester
P/N. YB-35956-A
Vacuum/pressure pump gauge set
P/N. 90890-06756
P Yamaha diagnostic system
P/N. 60V-85300-02
Q Yamaha diagnostic system
P/N. 60V-WS853-02
O YB-35956-A
90890-06756
P 60V-85300-02
Q 60V-WS853-02
YAMAHA
DIAGNOSTIC
SYSTEM
INSTALLATION MANUAL
REMOVAL AND INSTALLATION

1 YU-38411
90890-01426
1 Oil filter wrench

P/N. YU-38411
90890-01426
2 Coupler wrench
P/N. YW-06551
90890-06551
3 Sheave holder
P/N. YS-01880-A
90890-01701
4 Rotor puller
P/N. YM-01082
90890-01080
2 YW-06551
90890-06551
3 YS-01880-A
90890-01701
4 YM-01082
90890-01080
1-7
GEN
INFO
SPECIAL TOOLS
5 YU-01235
6 YB-06111
7 90890-06631
8 YB-06726-B
9 90890-06657
0 YM-01253
A YM-4114 (19 mm)
B YM-04111 (4.0 mm)
C YM-04112 (4.0 mm)
D YM-04113 (4.0 mm)
90890-01235
90890-04114 (19 mm)

YM-4108 (22 mm)
90890-04108 (22 mm)
90890-04112 (4.0 mm)

YM-04117 (4.5 mm)
90890-04117 (4.5 mm)
E
5 Universal magneto and rotor holder
P/N. YU-01235
Rotor holder
P/N. 90890-01235
6 Bearing housing needle bearing installer
(reduction drive gear)
P/N. YB-06111
7 Ball bearing attachment
P/N. 90890-06631
8 Forward gear bearing cup installer
P/N. YB-06726-B
9 Ball bearing attachment
P/N. 90890-06657
0 Valve spring compressor
P/N. YM-01253
90890-04019
A Valve spring compressor attachment
P/N. YM-4114 (19 mm)
90890-04114 (19 mm)
YM-4108 (22 mm)
90890-04108 (22 mm)
B Valve guide remover
P/N. YM-04111 (4.0 mm)
90890-04111 (4.0 mm)
YM-04116 (4.5 mm)
90890-04116 (4.5 mm)
C Valve guide installer
P/N. YM-04112 (4.0 mm)
90890-04112 (4.0 mm)
YM-04117 (4.5 mm)
90890-04117 (4.5 mm)
D Valve guide reamer
P/N. YM-04113 (4.0 mm)
90890-04113 (4.0 mm)
YM-04118 (4.5 mm)
90890-04118 (4.5 mm)
90890-04019
90890-04111 (4.0 mm)

YM-04116 (4.5 mm)
90890-04116 (4.5 mm)
90890-04113 (4.0 mm)

YM-04118 (4.5 mm)
90890-04118 (4.5 mm)
1-8
GEN
INFO
E
SPECIAL TOOLS
90890-06813 (60)
90890-06814 (45)
90890-06815 (30)
90890-06811 (4.0 mm)

90890-06812 (4.5 mm)
YM-91043-C
90890-05158
YB-06096
K 90890-06501
90890-06535
M 90890-06538
90890-06652
YB-06151
90890-06519
E Valve seat cutter

Intake
P/N. 90890-06813 (60)
90890-06814 (45)
90890-06815 (30)
Exhaust
P/N. 90890-06315 (60)
90890-06312 (45)
90890-06328 (30)
F Valve seat cutter holder
P/N. 90890-06811 (4.0 mm)
90890-06812 (4.5 mm)
G Valve seat cutter set
P/N. YM-91043-C
H Piston ring compressor
P/N. YM-08037
90890-05158
I Drive shaft holder (impeller)
P/N. YB-06151
Drive shaft holder 5 (impeller)
P/N. 90890-06519
J Slide hammer and adapters
(jet pump bearing and reduction drive
gear)
P/N. YB-06096
K Stopper guide plate (jet pump bearing)
P/N. 90890-06501
L Bearing puller assembly
gear)
P/N. 90890-06535
M Stopper guide stand
gear)
P/N. 90890-06538
N Drive rod L3
gear)
P/N. 90890-06652
90890-06315 (60)
90890-06312 (45)
90890-06328 (30)
H YM-08037
1-9
GEN
INFO
SPECIAL TOOLS
O YB-06112
Q YB-06085
90890-06631
S YB-06071
90890-06606
U YB-34474
V YB-06552
YB-06196
W YB-06156
E
O Bearing housing needle bearing remover
(jet pump bearing)
P/N. YB-06112
Drive shaft needle bearing installer and
remover (jet pump oil seal)
P/N. YB-06196
P Needle bearing attachment
(jet pump bearing, oil seal, and reduction
drive gear)
P/N. 90890-06614, 90890-06653
Q Outer race installerforward gear
(jet pump oil seal and reduction drive gear)
P/N. YB-06085
R Ball bearing attachment
(jet pump oil seal and reduction drive gear)
P/N. 90890-06631
S Driver handlelarge
(intermediate shaft, jet pump, and
reduction drive gear)
P/N. YB-06071
T Driver rod LS
(intermediate shaft, jet pump, and
reduction drive gear)
P/N. 90890-06606
U Bearing inner/outer race attachment
(jet pump bearing)
P/N. YB-34474
V Shaft holder (intermediate shaft)
P/N. YB-06552
Crankshaft holder 20 (intermediate shaft)
P/N. 90890-06552
W Drive shaft taper roller bearing cup
installer (intermediate shaft and reduction
drive gear)
P/N. YB-06156
Bearing outer race attachment
(intermediate shaft and reduction drive
gear)
P/N. 90890-06624, 90890-06626
90890-06614
90890-06653
90890-06552
90890-06624
90890-06626
1-10
SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................................... 2-1
MAINTENANCE SPECIFICATIONS ............................................................... 2-3
ENGINE .................................................................................................... 2-3
JET PUMP UNIT ......................................................................................2-6
HULL AND HOOD .................................................................................... 2-6
ELECTRICAL ............................................................................................ 2-7
TIGHTENING TORQUES ................................................................................ 2-9
SPECIFIED TORQUES.............................................................................2-9
GENERAL TORQUE ............................................................................... 2-17
CABLE AND HOSE ROUTING ..................................................................... 2-18
SPEC
GENERAL SPECIFICATIONS
Item
Model code
Hull
Engine/jet
Dimensions
Length
Width
Height
Dry weight
Maximum capacity
Performance
Maximum output
Maximum fuel consumption
Cruising range
Engine
Engine type
Displacement
Bore stroke
Compression ratio
Exhaust system
Lubrication system
Cooling system
Starting system
Ignition system
Ignition timing
Spark plug model
(manufacturer)
Spark plug gap
Battery capacity
Generator output
Drive unit
Propulsion system
Jet pump type
Impeller rotation
Transmission
Jet thrust nozzle horizontal
angle
Jet thrust nozzle trim angle
Trim system
Reverse system
Model
FX High Output
Unit
F1S
6B6
mm (in)
mm (in)
mm (in)
kg (lb)
Person/kg (lb)
3,340 (131.5)
1,230 (48.4)
1,160 (45.7)
350 (772)
3/240 (530)
kW (PS) @ r/min
l/h (US gal/h,
lmp gal/h)
h
117.7 (160) @ 10,000

45 (11.9, 9.9)
cm (cu. in)
mm (in)
Degree
1.56
4-stroke, L4, DOHC
1,052 (64.2)
76.0 58.0 (2.99 2.28)
11.9:1
Wet exhaust
Dry sump
Water cooled
Electric starter
TCI
BTDC 5BTDC 32
CR9EB (NGK)
mm (in)
V/Ah
A @ r/min
0.70.8 (0.0280.031)
12/19
1416 @ 6,000
Degree
Jet pump
Axial flow, single stage
Counterclockwise (viewed from rear)
Constant mesh 1-speed
24 + 24
Degree
10, 5, 0, 5, 10
Manual 5 positions
Reverse gate
2-1
SPEC
Item
Fuel and oil

Fuel type
Minimum fuel rating
Fuel tank capacity
Engine oil type
Engine oil grade
Engine oil quantity
(without oil filter replacement)
(with oil filter replacement)
Model
FX High Output
Unit
PON*
RON*
L
(US gal, Imp gal)
API
SAE
L
(US qt, Imp qt)
L
(US qt, Imp qt)
L
(US qt, Imp qt)
Regular unleaded gasoline

86
90
70 (18.5, 15.4)
4-stroke motor oil
SE, SF, SG, SH, SJ, SL
10W-30
4.5 (4.8, 4.0)
2.1 (2.2, 1.8)
2.3 (2.4, 2.0)
PON*: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2
RON*: Research Octane Number
2-2
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item
Cylinder head
Warpage limit
Compression pressure*1
Cylinder
Bore size
Taper limit
Out-of-round limit
Wear limit
Camshaft
Drive system
Intake A
Exhaust A
Intake and exhaust B
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaftcap clearance
Maximum camshaft runout
Timing chain
Model/number of links
Tensioning system
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
Valve head diameter A
Intake
Exhaust
Valve face width B
Intake
Exhaust
Unit
FX High Output
Model
mm (in)
0.1 (0.004)
kPa
(kgf/cm2, psi)
1,150 (11.5, 164)
mm (in)
mm (in)
mm (in)
mm (in)
76.00076.015 (2.99212.9927)
0.08 (0.003)
0.05 (0.002)
76.100 (2.9961)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
Chain drive
32.55 (1.281)
33.00 (1.299)
25.00 (0.984)
24.5 (0.9646)
24.4624.47 (0.96300.9634)
0.030.06 (0.00120.0024)
mm (in)
0.03 (0.0012)
DID SCR-0412SV/130
Automatic
mm (in)
mm (in)
0.110.20 (0.00430.0079)
0.250.34 (0.00980.0134)
mm (in)
mm (in)
22.923.1 (0.90160.9094)
24.424.6 (0.96060.9685)
mm (in)
mm (in)
1.762.90 (0.06930.1142)
1.762.90 (0.06930.1142)
*1 Measuring conditions:
Ambient temperature 20 C (68 F), wide open throttle, with spark plugs removed from all
cylinders.
The figures are for reference only.
2-3
SPEC
Item
Valve seat width C

Intake
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-guide
clearance
Intake
Exhaust
Valve stem runout
Model
FX High Output
Unit
mm (in)
mm (in)
0.91.1 (0.03540.0433)
0.91.1 (0.03540.0433)
mm (in)
mm (in)
0.50.9 (0.01970.0354)
0.50.9 (0.01970.0354)
mm (in)
mm (in)
3.9753.990 (0.15650.1571)
4.4654.480 (0.17580.1764)
mm (in)
mm (in)
4.0004.012 (0.15750.1580)
4.5004.512 (0.17720.1776)
mm (in)
mm (in)
mm (in)
0.0100.037 (0.00040.0015)
0.0200.047 (0.00080.0019)
0.01 (0.0004)
Valve spring
Free length
Intake
mm (in)
Exhaust
mm (in)
Installed length
Intake
mm (in)
Exhaust
mm (in)
Spring limit
Intake
Degree/mm (in)
Exhaust
Degree/mm (in)
Piston
Piston-to-cylinder clearance
mm (in)
Piston diameter
mm (in)
Measuring point H*
mm (in)
Wear limit
mm (in)
Piston pin boss inside diameter
mm (in)
Piston pins
Outside diameter
mm (in)
Wear limit
mm (in)
2-4
38.90 (1.53)
40.67 (1.60)
34.50 (1.36)
35.00 (1.38)
2.5/1.7 (0.067)
2.5/1.8 (0.071)
0.100.11 (0.00390.0043)
75.89575.910 (2.98802.9886)
5 (0.2)
0.17 (0.0067)
17.00217.013 (0.66930.6698)
16.99117.000 (0.66890.6693)
16.98 (0.67)
SPEC
Item
Model
FX High Output
Unit
Piston ring
Top ring
T
Type
Dimension (B T)
End gap (installed)
Ring groove clearance
2nd ring
Type
T
Dimensions (B T)
End gap (installed)
Oil ring
Dimensions
T
(B T)
End gap (installed)
Connecting rod
Big end oil clearance
Bearing color code
Small end inside diameter
Crankshaft
mm (in)
mm (in)
mm (in)
Barrel
0.90 2.75 (0.04 0.11)
0.320.44 (0.01260.0173)
0.0300.065 (0.00120.0026)
mm (in)
mm (in)
mm (in)
Taper
0.80 2.80 (0.03 0.11)
0.430.58 (0.01690.0228)
0.0200.055 (0.00080.0022)
mm (in)
1.50 2.60 (0.06 0.10)
mm (in)
mm (in)
0.100.35 (0.00390.0138)
0.0400.160 (0.00160.0063)
mm (in)
0.0160.040 (0.00060.0016)
1. Brown 2. Black 3. Blue 4. Green
17.00517.018 (0.66940.6699)
mm (in)
Crank width A
Deflection limit B
Crankshaft journal oil clearance
Bearing color code
Throttle body
Type/quantity
Manufacturer
ID mark
Trolling speed
Fuel pump
Pump type
Fuel pressure
mm (in)
mm (in)
mm (in)
304.8306.0 (12.0012.05)
0.03 (0.0012)
0.0040.028 (0.00020.0011)
1. Brown 2. Black 3. Blue 4. Green 5. Yellow
42EIS/4
Mikuni
6B600
1,5501,750
r/min
kPa
(kgf/cm2, psi)
2-5
Electrical
310330 (3.13.3, 4547)
SPEC
Item
Oil filter
Oil filter type
Oil pump
Oil pump type
Rotor tip clearance
(scavenge pump)
Oil pump housing clearance
Rotor (feed pump)
Rotor (scavenge pump)
Model
FX High Output
Unit
Cartridge type
mm (in)
Trochoid
0.090.15 (0.00350.0059)
mm (in)
mm (in)
0.090.17 (0.00350.0067)
0.090.15 (0.00350.0059)
JET PUMP UNIT

Item
Jet pump
Impeller material
Number of impeller blades
Impeller pitch angle
Impeller clearance
Impeller clearance limit
Drive shaft runout limit
Nozzle diameter
Model
FX High Output
Unit
Stainless steel
3
16.8
0.350.45 (0.01380.0177)
0.6 (0.0236)
0.3 (0.0118)
86.587.1 (3.413.43)
Degree
mm (in)
mm (in)
mm (in)
mm (in)
HULL AND HOOD

Item
Free play
Throttle lever free play
Unit
FX High Output
mm (in)
Model
47 (0.160.28)
2-6
SPEC
ELECTRICAL
Item
Battery
Type
Capacity
Specific gravity
ECM unit
(B/R R/Y, B/W R/Y,
B/Y R/Y, B/L R/Y)
Output peak voltage lower limit
@cranking (loaded)
@2,000 r/min (loaded)
Stator
Pickup coil
(W B, R B)
Output peak voltage
@cranking (unloaded)
@cranking (loaded)
Lighting coil
(G G)
Output peak voltage
@2,000 r/min (unloaded)
Pickup coil resistance (W B)
Pickup coil resistance (R B)
Lighting coil resistance (G G)
Minimum charging current
Ignition coil
Primary coil resistance
Secondary coil resistance
Rectifier/regulator
(R B)
Output peak voltage
Starter motor
Type
Output
Rating
Brush length
Wear limit
Commutator undercut
Limit
Commutator diameter
Limit
Unit
FX High Output
Model
V/Ah
Fluid
12/19
1.28
V
V
V
87
86
85
V
V
V
V
5.2
4.7
26.1
41.3
V
V
V
(color)
(color)
(color)
A @ r/min
9.2
38.5
63.2
459561
459561
0.540.66
14 @ 6,000
1.191.61
8.511.5
15.0
kW
Seconds
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
Constant mesh
0.8
30
12.5 (0.49)
6.5 (0.26)
0.7 (0.03)
0.2 (0.01)
28.0 (1.10)
27.0 (1.06)
2-7
SPEC
Item
Starter relay
Rating
Thermoswitch
ON temperature (engine)
OFF temperature (engine)
ON temperature (exhaust)
OFF temperature (exhaust)
Engine temperature sensor
resistance
(B/Y B/Y)
@ 20 C (68 F)
@ 100 C (212 F)
Speed sensor
Output voltage (on pulse)
Output pulse/one full turn
Throttle position sensor
Output voltage
(P B/O)
@ trolling speed
Cam position sensor
Output voltage
(G/O B/O)
Position A
Position B
Position C
Fuel sender
Fuel sender resistance
Position A
Position B
Oil pressure switch
Oil pressure switch continuity
pressure
Fuel injector
Fuel injector resistance*1
Fuse
Rating
Main
Remote control unit
Electrical bilge pump
Model
FX High Output
Unit
Seconds
30
C (F)
C (F)
C (F)
C (F)
8490 (183194)
7084 (158183)
94100 (201212)
8094 (176201)
k
k
54.269.0
3.123.48
11.6
2
0.756 0.016
V
V
V
More than 4.8

Less than 0.8
More than 4.8
133.5136.5
57
kPa
(kgf/cm2, psi)
128 (1.28, 18.2)166 (1.66, 23.6)
11.512.5
V/A
V/A
V/A
12/20
12/3
12/3
*1 The figures are for reference only.
2-8
SPEC
TIGHTENING TORQUES
TIGHTENING TORQUES
SPECIFIED TORQUES
3.0
Screw
M5
2.5
0.25
1.8
Bolt
M6
6.5
0.65
4.7
Bolt
M6
7.6
0.76
5.5
Bolt
M4
3.3
0.33
2.4
Bolt
M8
22
2.2
16
8.8
0.88
6.4
Bolt
M8
18
1.8
13
Bolt
M6
7.6
0.76
5.5
Bolt
M6
7.6
0.76
5.5
Screw
M5
1.3
0.13
0.9
Bolt
M8
Bolt
M8
Screw
Screw
Bolt
Screw
Screw
Nut
Screw
M5
M5
M6
M5
M6
M6
1
3
4
2
3
2
2
15
39
15
39
1.3
1.8
5.0
3.5
5.0
13
5.0
1.5
3.9
1.5
3.9
0.13
0.18
0.5
0.35
0.5
1.3
0.5
11
28
11
28
0.9
1.3
3.6
2.5
3.6
9.4
3.6
Screw
M6
5.0
0.5
3.6
Screw
M4
2.0
0.2
1.4
2-9
LT
0.42
572
4.2
LT
572
LT
242
0.9
LT
0.13
572
1.3
LT
LT
242
LT
572
LT
LT
M8
572
Nut
Bolt
2.3
4.6
4.3
11
LT
0.32
0.64
0.59
1.6
242
1
4
3.2
6.4
5.9
16
Nut
Remarks
572
Tightening torque
Nm kgfm
ftlb
271
Thread
Qty
size
LT
Fuel system
1st
Retainer/fuel pump module
fuel tank
2nd
Fuel filler neck/rubber seal deck
Fuel tank belt/fuel tank hull
Fuel tank cap screw clamp
fuel tank cap/fuel tank
Fuel filter hose clamp fuel filter
hose/fuel tank/fuel filter neck
Air filter case cover air filter case
Ribbon sub assembly
throttle bodies
Throttle cable holder
air filter case
Fuel hose holder
fuel hose bracket
Throttle bodies throttle body joint
Air filter case
1st
air filter case stay 1/
2nd
air filter case stay 2
Wire harness bracket 1/sub wire
harness air filter case
Fuel hose bracket/wire harness
bracket 2 air filter case
Wire harness bracket 2
air filter case
1st
Air filter case stay 1
exhaust pipe 3
2nd
1st
cylinder head
2nd
Band air filter case
Breather cover air filter case
Fuel rail throttle bodies
Sensor assembly fuel rail
Bracket throttle bodies
Bracket bypass valve motor
Throttle stop guide throttle bodies
Throttle stop screw bracket
throttle bodies
throttle bodies
Part name
271
Part to tightened
TIGHTENING TORQUES
0.44
3.2
4.4
0.44
3.2
2.0
15
39
3.7
7.6
15
42
15
42
39
39
22
22
35
22
22
35
22
22
35
3.7
7.6
0.2
1.5
3.9
0.37
0.76
1.5
4.2
1.5
4.2
3.9
3.9
2.2
2.2
3.5
2.2
2.2
3.5
2.2
2.2
3.5
0.37
0.76
1.4
11
28
2.7
5.5
11
30
11
30
28
28
16
16
25
16
16
25
16
16
25
2.7
5.5
3.7
0.37
2.7
7.6
0.76
5.5
7.6
7.6
15
39
0.76
0.76
1.5
3.9
5.5
5.5
11
28
M10
Bolt
M6
Bolt
M8
Bolt
M10
Nut
Bolt
M8
10
Bolt
M8
Bolt
M8
Bolt
M6
Bolt
M6
Bolt
Bolt
M6
M6
3
2
Bolt
M8
*1 For details, refer to the tightening procedures in this manual.
2-10
LT
Bolt
LT
4.4
271
3.2
0.44
LT
4.4
572
3.2
LT
0.44
572
4.4
LT
5.5
242
0.76
LT
7.6
572
LT
M6
242
Bolt
LT
5.6
242
0.78
7.8
LT
242
M6
LT
Bolt
242
12
12
LT
1.7
1.7
242
17
17
LT
4
1
572
M8
LT
Bolt
Remarks
572
Tightening torque
Nm kgfm
ftlb
572
Thread
Qty
size
Engine
Engine unit engine mount
Oil filter
Coupling cover intermediate
housing
Thermoswitch (exhaust)
exhaust pipe 3
Outer exhaust joint clamp
1st
exhaust pipe 3/exhaust
2nd
pipe 2
Inner exhaust joint clamp
1st
exhaust pipe 3/exhaust
2nd
pipe 2
1st
Exhaust pipe 3
2nd
crankcase*1
3rd
1st
Exhaust pipe end
exhaust pipe 3
2nd
1st
Exhaust pipe stay
crankcase
2nd
1st
Exhaust pipe 1
exhaust pipe stay
2nd
1st
Exhaust pipe 2
*1
exhaust pipe 1
2nd
1st
Exhaust pipe 1
2nd
exhaust manifold 1/
exhaust manifold 2
3rd
1st
Exhaust manifold 1
2nd
cylinder head
3rd
1st
Exhaust manifold 2
2nd
cylinder head
3rd
1st
Water jacket oil tank
2nd
Oil tank stay/reduction
1st
drive gear case
2nd
oil separator
Cover (ground lead) oil tank
Ground lead oil tank
1st
Oil tank reduction drive
gear case
2nd
Part name
LT
Part to tightened
572
SPEC
TIGHTENING TORQUES
2nd
1st
2nd
1st
2nd
1st
2nd
M5
Bolt
M6
Bolt
M6
24
Screw
M4
M6
1
5
1st
2nd
M8
Drain plug (engine oil)

1st
Strainer reduction drive
gear case
2nd
Oil pump housing cover 1 oil seal
housing 1
Oil pump housing cover 1/oil seal
housing 1/oil pump housing cover 2
oil pump housing 2
Oil pump housing cover 2 oil seal
housing 1
Drive coupling drive shaft
1st
2nd
Reduction drive gear case
crankcase
1st
2nd
Starter motor lead starter motor
Starter motor crankcase
Bolt
M8
Bolt
M6
Bolt
M8
Bolt
1.4
4.4
0.44
3.2
1.9
4.4
3.7
7.6
3.7
7.6
3.7
10
15
28
20
3.7
7.6
0.19
0.44
0.37
0.76
0.37
0.76
0.37
1.0
1.5
2.8
2.0
0.37
0.76
1.4
3.2
2.7
5.5
2.7
5.5
2.7
7.2
11
20
14
2.7
5.5
20
2.0
14
M8
20
2.0
14
Screw
M4
2.0
0.2
1.4
Bolt
M6
Bolt
M8
Nut
Bolt
M8
1
2
28
3.7
7.6
15
28
4.9
18
2.8
0.37
0.76
1.5
2.8
0.49
1.8
20
2.7
5.5
11
20
3.5
13
Bolt
2-11
0.19
LT
Bolt
1.9
572
10
LT
M5
572
Bolt
LT
572
M6
LT
Bolt
572
LT
M6
572
Bolt
LT
572
M6
Bolt
1st
Anode oil tank

Oil pump assembly
reduction drive gear case
M6
LT
Oil cooler cover oil tank
Bolt
572
Oil strainer oil tank
Baffle plate oil tank
M10
LT
Oil breather plate 1/

oil breather plate 2
oil tank cover
Bolt
572
Oil tank cover oil tank
LT
Hanger oil tank cover
1st
2nd
1st
2nd
1st
2nd
Remarks
572
Band/collar oil tank

Bracket (coupling cover)
oil tank
Nut
Tightening torque
Nm kgfm
ftlb
2.0
0.2
1.4
15
1.5
11
39
3.9
28
2.0
0.2
1.4
15
1.5
11
39
3.9
28
7.6
0.76
5.5
3.7
0.37
2.7
7.6
0.76
5.5
3.7
0.37
2.7
7.6
0.76
5.5
3.7
0.37
2.7
7.6
0.76
5.5
LT
Oil tank stay cylinder

head
1st
2nd
3rd
1st
2nd
3rd
Thread
Qty
size
572
Oil tank oil tank stay
Part name
LT
Part to tightened
572
SPEC
TIGHTENING TORQUES
Plug (vacuum pressure)

crankcase
10
Bolt
Bolt
M6
M6
3
4
4
14
13
7.6
1.4
1.3
0.76
10
9.4
5.5
Bolt
M6
10
1.0
7.2
Bolt
M6
3.7
7.6
0.37
0.76
2.7
5.5
Bolt
M6
12
1.2
8.7
Bolt
M6
10
1.0
7.2
Bolt
M6
10
1.0
7.2
Bolt
M6
10
10
1.0
7.2
Bolt
M6
18
10
1.0
7.2
Bolt
M7
24
2.4
17
Bolt
M7
24
2.4
17
Bolt
Bolt
M8
M6
2
3
Nut
40
10
20
29
7.2
14
Nut
Nut
Bolt
M6
10
4.0
1.0
2.0
140 5
2.0
121 5
2.0
105 5
1.0
1st
2nd
1st
2nd
1st
2nd
15
1.5
11
*1 For details, refer to the tightening procedures in this manual.
2-12
20
20
LT
1.4
572
14
LT
572
M6
Bolt
LT
3.5
242
0.49
LT
4.9
242
LT
M5
242
Bolt
LT
3.5
242
0.49
LT
4.9
572
LT
M5
572
Bolt
LT
1
6
572
M10
M8
Bolt
Bolt
M10
Bolt
LT
271
Rotor crankshaft
Rotor starter clutch
Washer/pickup coil lead and
lighting coil lead generator cover
Pickup coil generator cover
Holder (wire harness)
generator cover
Lighting coil generator cover
Spark plug
Ignition coil cylinder head cover
Cam position sensor
cylinder head cover
1st
Cooling water pipe
cylinder head
2nd
Cylinder head cover
cylinder head
Timing chain tensioner cap bolt
Timing chain tensioner
cylinder head
Exhaust camshaft cap
cylinder head
Intake camshaft cap
cylinder head
Exhaust camshaft sprocket
exhaust camshaft
Intake camshaft sprocket
intake camshaft
Hanger cylinder head
Cylinder head
upper crankcase*1
Nut
Remarks
1st
2nd
1st
2nd
Thread
Qty
size
Generator cover
crankcase
Tightening torque
Nm kgfm
ftlb
15
1.5
11
50
5.0
36
15
1.5
11
50
5.0
36
75
7.5
54
24
2.4
17
Part name
14
E
Part to tightened
14
E
SPEC
7.2
TIGHTENING TORQUES
1.2
0.12
0.9
Bolt
Bolt
M8
M8
2
2
15
15
1.5
1.5
11
11
LT
572
LT
572
12
12
5.5
2.7
29
5.6
4.9
10
6.0
19
5.6
14
5.6
5.6
5.6
LT
1.7
1.7
0.76
0.37
4.0
0.78
0.68
1.4
0.83
2.6
0.78
2.0
0.78
0.78
0.78
271
17
17
7.6
3.7
40
7.8
6.8
14
8.3
26
7.8
20
7.8
7.8
7.8
LT
4
4
4
4
4
1
6
2
1
1
6
2
1
1
1
572
M8
M8
M6
M5
M10
M6
M6
M8
M8
M6
M8
M6
LT
Bolt
Bolt
Bolt
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Bolt
Bolt
Bolt
Nut
Nut
572
4.9
0.68
6.8
LT
572
Nut
LT
4.3
572
0.59
LT
5.9
572
LT
242
LT
572
M6
LT
Bolt
242
LT
M6
242
Bolt
LT
242
LT
Nut
572
1
1
LT
M6
271
Bolt
LT
10
271
M9
LT
Bolt
8.4
0.84
6.1
12
1.2
8.7
20
2.0
14
12
1.2
8.7
12
1.2
8.7
7.8
0.78
5.6
Loosen completely
15
1.5
11
49 5
12
1.2
8.7
35
3.5
25
20
2.0
14
120 5
3.7
0.37
2.7
7.6
0.76
5.5
3.7
0.37
2.7
7.6
0.76
5.5
242
1
1
1
13
10
LT
M6
M8
M6
M6
242
5.5
LT
Bolt
Bolt
Bolt
Bolt
2-13
0.76
242
Reverse gate stay jet pump

Reverse gate reverse gate stay
Lever 1 Reverse gate stay
Lever 2 Reverse gate stay
Shift cable ball joint lever 1
Spout hose clamp
spout hose/nozzle
Nozzle ring nozzle
Jet thrust nozzle nozzle ring
7.6
LT
Roller reverse gate stay
242
Oil pipe lower crankcase

Oil filter bolt lower crankcase
1st
Connecting rod cap
2nd
1st
Thermostat housing cover
Thermostat housing
2nd
1st
Thermostat housing holder
oil tank
2nd
Grease nipple
thermostat housing cover
Jet pump unit
Steering cable joint
jet thrust nozzle
Ride plate hull
Intake duct hull
Intake grate hull
Speed sensor ride plate
Jet pump unit assembly/impeller
housing 2 transom plate
Rubber plate bracket
Bracket hull
M6
LT
1st
2nd
3rd
4th
Bolt
Remarks
242
Lower crankcase
upper crankcase
Tightening torque
Nm kgfm
ftlb
LT
Thermoswitch (engine)
crankcase
Oil pressure switch
Anode cover anode
Anode cover upper crankcase
Oil pan lower crankcase
Thread
Qty
size
271
Part name
LT
Part to tightened
271
SPEC
TIGHTENING TORQUES
54
Nut
Bolt
Driven
coupling
M8
4
3
26
17
2.6
1.7
19
12
M24
36
3.6
25
Nipple
5.4
0.54
3.9
Bolt
M8
20
2.0
14
Bolt
M6
1.1
0.11
0.8
Screw
M6
1.1
0.11
0.8
Screw
M6
0.9
0.09
0.7
Nut
5.4
0.54
3.9
Screw
M5
3.5
0.35
2.5
Screw
M5
3.4
0.34
2.5
Screw
Bolt
M6
M5
1
2
3.4
1.2
0.34
0.12
2.5
0.9
Screw
M4
0.1
0.7
Nut
20
2.0
14
Nut
6.8
0.68
4.9
Bolt
Bolt
Bolt
M8
M5
M5
1
2
1
18
2.8
2.8
1.8
0.28
0.28
13
2.1
2.1
Nut
0.3
2.2
Nut
Bolt
Bolt
Bolt
Nut
M5
M6
M6
1
2
4
4
1
2.9
6.8
6.8
6.8
5.9
0.29
0.68
0.68
0.68
0.59
2.1
4.9
4.9
4.9
4.3
2-14
LT
7.5
572
75
LT
572
M22
LT
Impeller
572
50
LT
6.9
572
69
LT
572
LT
Nut
572
4.8
LT
0.66
242
6.6
LT
271
M6
LT
Bolt
242
29
LT
4.0
242
40
LT
242
Grease nipple intermediate

housing
Hull and hood
Handlebar holder steering master
Handlebar cover stay
steering master
Handlebar cover
handlebar cover stay
Handle boss cover
steering master
QSTS converter hull
Throttle lever assembly
handlebar
Handlebar switch assembly
handlebar
QSTS grip assembly handlebar
Grip end handlebar
Cable housing
QSTS grip assembly
Steering master deck
Steering cable ball joint
steering arm
Steering arm steering master
Steering switch steering master
Magneto steering arm
QSTS cable locknut
(QSTS converter side)
QSTS cable locknut (jet pump side)
Steering shaft 1 cap
Upper housing lower housing
Retainer steering tube
QSTS cable grommet hull
M10
LT
Driven coupling shaft
Bolt
Remarks
271
Nut
Tightening torque
Nm kgfm
ftlb
7.8
0.78
5.6
LT
QSTS cable ball joint nozzle ring

Nozzle/impeller duct assembly
impeller housing 1
Water inlet cover/water inlet
strainer impeller duct
Drive shaft nut drive shaft
Impeller (left-hand threads)
drive shaft
Transom plate hull
Intermediate housing bulkhead
Thread
Qty
size
572
Part name
LT
Part to tightened
271
SPEC
TIGHTENING TORQUES
6.4
0.64
4.6
Nut
6.5
0.65
4.7
Nut
Nut
Nut
1
1
1
5.9
16
16
0.59
1.6
1.6
4.3
11
11
Nut
6.4
0.64
4.6
Nut
Nut
2
1
5.4
5.9
0.54
0.59
3.9
4.3
Bolt
M6
5.4
0.54
3.9
Bolt
M6
5.4
0.54
3.9
Nut
Bolt
Screw
Bolt
M6
M4
M5
4
4
4
4
5.4
5.4
1.5
3.9
0.54
0.54
0.15
0.39
3.9
3.9
1.1
2.8
Bolt
M5
3.9
0.39
2.8
Nut
Bolt
M6
4
8
6.9
5.4
0.69
0.54
5.0
3.9
Bolt
M6
5.4
0.54
3.9
Bolt
Nut
Nut
Bolt
Screw
Nut
Nut
M6
M6
M6
2
2
2
2
2
2
3
5.4
5.4
20
5.4
5.4
4.2
5.4
0.54
0.54
2.0
0.54
0.54
0.42
0.54
3.9
3.9
14
3.9
3.9
3.0
3.9
Screw
M6
5.4
0.54
3.9
Bolt
M6
5.4
0.54
3.9
Nut
6.8
0.68
4.9
2-15
LT
572
LT
Nut
572
4.3
3.9
LT
0.59
0.54
242
5.9
5.4
LT
1
2
242
LT
Nut
Nut
271
2.1
LT
0.29
242
2.9
LT
242
LT
Nut
271
2.7
LT
0.38
242
3.8
LT
271
LT
Nut
Remarks
271
Tightening torque
Nm kgfm
ftlb
LT
Thread
Qty
size
242
QSTS cable end pin

QSTS converter
Shift cable locknut
(reverse gate side)
Shift cable grommet hull
Shift cable holder shift lever base
Steering cable locknut
(steering master side)
Steering cable locknut
(jet pump side)
Steering cable grommet hull
QSTS cable 1 locknut
Steering cable bracket
steering cable holder
Steering cable bracket deck
Speed sensor lead grommet hull
Hinge assembly
front hood assembly
Hood lock assembly
front hood assembly
Hinge assembly deck
Service lid 1 deck
Service lid 2 deck
Panel steering console cover
Multifunction meter
steering console cover
Mirror steering console cover
Side cover deck
Steering console cover
glove box
Hood lock assembly
Steering console cover deck
Glove compartment deck
Shift lever handle shift lever
Latch glove compartment
Pilot water outlet hull
Shift lever plate deck
Shift lever plate
deck/shift lever base assembly
Shift lever base assembly
Shift cable ball joint
base assembly
Part name
LT
Part to tightened
271
SPEC
TIGHTENING TORQUES
Cover electrical box

Starter motor lead electrical box
Battery positive lead
electrical box
Fuse holder stay electrical box
ECM electrical box
3.9
3.7
0.37
2.7
3.7
0.37
2.7
Bolt
Nut
Nut
Nut
Bolt
Nut
Nut
Screw
Bolt
Bolt
M8
M6
M5
M8
M6
1
1
2
10
2
4
1
4
3
2
4
8
4
3.7
3.7
2.5
16
15
15
5.4
5.4
5.4
13
2.0
17
6.4
0.37
0.37
0.25
1.6
1.5
1.5
0.54
0.54
0.54
1.3
0.2
1.7
0.64
2.7
2.7
1.8
12
11
11
3.9
3.9
3.9
9.4
1.4
12
4.6
Bolt
Bolt
Bolt
Screw
Tapping
screw
Screw
M6
M6
M8
M5
2
2
4
4
5.4
5.4
17
4.9
0.54
0.54
1.7
0.49
3.9
3.9
12
3.5
18
4.9
0.49
3.5
M6
7.6
0.76
5.5
Screw
M6
7.6
0.76
5.5
3.9
0.39
2.8
3.9
0.39
2.8
Tapping
screw
Tapping
screw
2-16
LT
LT
LT
LT
LT
271
LT
0.54
271
LT
5.4
LT
242
271
Bow eye hull

Drain plug/packing hull
Engine mount hull
Engine damper hull
Electrical
Battery box hull
Battery box/spacer hull
Electrical box bulk head
Terminal cover electrical box
Nut
LT
Protector (bow) hull
Remarks
271
Nut
Nut
Nut
Nut
Nut
Nut
Bolt
Bolt
Tightening torque
Nm kgfm
ftlb
5.2
0.52
3.8
15
1.5
11
26
2.6
19
26
2.6
19
6.4
0.64
4.6
18
1.8
13
6.4
0.64
4.6
6.4
0.64
4.6
572
Hand grip deck

Front seat stay deck
Seat lock projection deck beam
Seat lock projection deck
Rear seat stay deck beam
Deck beam deck
Seat lock assembly front seat
Seat lock assembly rear seat
Plate/rubber hose/exhaust valve
hull
Hose clamp
rubber hose/water lock
Hose clamp
rubber hose/water tank
Joint clamp joint/water lock
Joint clamp joint/exhaust pipe 3
Joint clamp joint/exhaust joint
Sponson hull
Cleat deck
Cleat hull
Spout hull
Thread
Qty
size
4
M6
2
M6
2
271
Part name
572
Part to tightened
572
SPEC
TIGHTENING TORQUES
Bracket (coupler) electrical box

Slant detection switch electrical
box
Main and fuel pump relay
electrical box
Rectifier/regulator electrical box
Ignition coil cylinder head cover
Brush assembly/spacer
starter motor yoke
Starter motor rear cover
starter motor front cover
Cover remote control transmitter
Nut A
Bolt B
8 mm
10 mm
12 mm
14 mm
17 mm
M5
M6
M8
M10
M12
Part name
Tapping
screw
Tapping
screw
Tapping
screw
Tapping
screw
Bolt
Thread
Qty
size
Tightening torque
Nm kgfm
ftlb
3.9
0.39
2.8
3.9
0.39
2.8
3.9
0.39
2.8
3.9
0.39
2.8
M6
7.6
0.76
5.5
Nut
8.8
0.88
6.4
Bolt
M5
6.4
0.64
4.6
Tapping
screw
0.1
0.01
0.07
Remarks
LT
Part to tightened
572
SPEC
GENERAL TORQUE
General torque
specifications
Nm kgfm ftlb
5.0
0.5
3.6
8.0
0.8
5.8
18
1.8
13
36
3.6
25
43
4.3
31
This chart specifies tightening torques for standard fasteners with a standard ISO thread
pitch. Tightening torque specifications for special components or assemblies are provided in
applicable sections of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross fashion and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads.
Components should be at room temperature.
2-17
SPEC
CABLE AND HOSE ROUTING
H
F
BOW
9 4
20
DOWN
DOWN
A-A
9
UP
0
B-B
8
I
H
B
H
C D
6
E
E
C-C
7
A
H-H
D
G
F
D-D
F
7
+
G-G
4
E-E
6
5
G
F-F
3
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
Steering switch lead

Fuel tank breather hose
QSTS cable
Steering cable
Shift cable
Speed sensor lead
Electrical box lead
Cooling water pilot outlet
Cooling water pilot outlet hose
2-18
Negative battery lead

Positive battery lead
Battery
Throttle cable
Fuel hose
Handlebar switch lead
Electrical bilge pump lead
Remote control unit lead
Remote control unit antenna
SPEC
2
1
K
A
B
C
A
D E
C
D
I C
MAIN
3A
A
6
6
A
7
8
9 E
Steering switch lead

Throttle cable
QSTS cable
Buzzer lead
Ignition coil lead
Starter motor lead
Wire harness
3A
D
9
F
1
2
3
4
5
6
7
8
9
0
20A
3A
B
6
3A
SPARE
A
B
C
D
E
F
G
H
I
Fuel hose
Shift cable
Steering cable
Electrical box lead
hose
Battery breather hose
Speed sensor lead
2-19
E-E
J Remote control unit lead

K Remote control unit antenna
SPEC
4 5
6
8
6
0
H
5
2
A C
1
A
2
D
8
A-A
F
E
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
Cooling water hose (cooling water inlet)

Bilge hose 1
Electric bilge pump
Bilge hose 4
Cooling water hose (from thermostat)
Bilge hose 3
Bilge hose 2
Shift cable
Cooling water hose (from exhaust pipe)
Electrical box
QSTS cable
Speed sensor lead
Electric bilge pump lead
Bilge strainer
Steering cable
Flushing hose
Pass the QSTS cable between the bilge hoses.

2-20
SPEC
C-C
1
A
C
D
B
C
A
E
4
5
G
1
2
3
4
Thermostat
Cooling water hose
Cooling water hose (cooling
water inlet)
5 Negative battery lead
To cooling water pilot outlet on

starboard side
To cooling water outlet on starboard side of stern
To cylinder block
From exhaust manifold
To install the hose, align the
white paint mark on the cooling
water hose with the projection
of the hose joint.
2-21
E-E
When installing the cooling

water hoses, be sure to push
them down until they contact
the hose joint.
SPEC
C-C
1
A
C
D
B
C
A
E
4
5
G
Bundle the cooling water pilot outlet hose and

cooling water hoses, pass a plastic tie through the
stay hole, and then fasten the tie.
Set the tie in the direction shown.
To cooling water pilot outlet on port side
To cooling water outlet at stern
Cooling water inlet
To exhaust pipe
E-E
To install the cooling water hose, align the white

paint mark on the hose with the parting line on the
hose joint.
Fasten the cooling water hose and negative battery lead with a plastic tie. Set the tie in the direction shown.
2-22
SPEC
C-C
1
A
C
D
B
C
A
E
4
5
G
Bundle the cooling water hose (cylinder head

cover to thermostat) and cooling water hose (starboard cooling water pilot outlet), and then fasten
them with a plastic tie to the oil tank boss. When
bundling the hoses, make sure that the cooling
water hose (cylinder head cover to thermostat) is
routed on the deck side and that the cooling water
hose (starboard cooling water pilot outlet) is
routed on the engine side.
Insert the cooling water hose to the paint mark.
E-E
Fasten the end of the cooling water hose tube

that is contacting the hose joint with a plastic tie.
Cooling water passage
2-23
SPEC
8
7
2
A
0
B
1
4
A-A
1
2
3
4
5
6
7
8
9
0
Wiring harness
Ground lead
Wiring harness coupler
Noise filter
Oil pressure switch coupler
Pickup coil coupler
Thermoswitch (engine) coupler
Lighting coil coupler
Thermoswitch (exhaust) coupler
A Cam position sensor coupler

B Oil pressure switch lead
To electrical box
To cam position sensor
Fasten the plastic tie with its end facing downward.
To oil pressure switch
To engine temperature sensor
2-24
SPEC
1
2
A
4
3
B
6
A-A
1
2
3
4
5
6
7
8
9
0
Engine temperature sensor coupler

Pickup coil coupler
Starter motor
Engine temperature sensor lead
Thermoswitch (engine) lead
Lighting coil lead
2-25
SPEC
1
2
A
4
3
B
6
A-A
Fasten the engine temperature sensor lead, thermoswitch lead, and lighting coil lead with a plastic
tie. Fasten the engine temperature sensor lead
1020 mm (0.40.8 in) from the end of the protective cover of the lead.
To generator
To thermoswitch (engine)
To thermoswitch (engine) coupler
To engine temperature sensor coupler
Route the starter motor lead to the outside of the

engine temperature sensor lead.
To starter relay
To negative battery terminal
Route the starter motor and negative battery
leads behind the cooling water hose.
Route the starter motor lead over the cooling
water hose.
2-26
INSP
ADJ
CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENT
MAINTENANCE INTERVAL CHART .............................................................. 3-1
PERIODIC SERVICE .......................................................................................3-2
CONTROL SYSTEM ................................................................................. 3-2
Steering master inspection..................................................................3-2
Steering cable inspection and adjustment .......................................... 3-2
Throttle cable inspection and adjustment............................................3-3
QSTS cable inspection and adjustment ..............................................3-5
Shift cable inspection and adjustment................................................. 3-7
Trolling speed check and adjustment.................................................. 3-8
FUEL SYSTEM.......................................................................................... 3-9
Fuel line inspection .............................................................................3-9
Water separator inspection ...............................................................3-10
POWER UNIT.......................................................................................... 3-10
Valve clearance adjustment ..............................................................3-10
Engine oil level check........................................................................3-16
Engine oil change using oil changer............................................. 3-18
Air filter element clean....................................................................... 3-20
Spark plug inspection........................................................................3-21
ELECTRICAL .......................................................................................... 3-24
Battery inspection.............................................................................. 3-24
JET PUMP UNIT .....................................................................................3-27
Impeller inspection ............................................................................3-27
Water inlet strainer inspection........................................................... 3-27
BILGE PUMP........................................................................................... 3-28
Bilge strainer inspection .................................................................... 3-28
Electric bilge pump strainer inspection.............................................. 3-28
GENERAL ...............................................................................................3-29
Drain plug inspection.........................................................................3-29
Lubrication points .............................................................................. 3-29
INSP
ADJ
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.
THEREAFTER
PAGE
EVERY
10 hours 50 hours 100 hours 100 hours 200 hours
6
12
12
24
months months months months
Inspect, clean, adjust
3-21
Lubricate
3-29
Lubricate
*1
*2
*2
3-31
Inspect
3-9
Inspect, clean
3-9
Inspect, adjust
3-8
Inspect
Flush
*3
Inspect, clean
3-27
Clean
3-28
MAINTENANCE INTERVAL
ITEM
Spark plug
Lubrication points
Intermediate housing
Fuel system
Fuel tank
Trolling speed
Throttle shaft
Cooling water passages
Water inlet strainer
Bilge strainer
Electric bilge pump
strainer
Impeller
Jet thrust nozzle angle
Steering master
QSTS mechanism
Shift cable and
mechanism
Throttle cable
Stern drain plugs
Battery
Rubber coupling
Engine mount
Nuts and bolts
Air filter
Engine oil
Engine oil filter
Valve clearance
INITIAL
Inspect, clean
3-28
Inspect
Inspect, adjust
Inspect
Inspect, adjust
3-27
3-2
3-2
3-5
Inspect, adjust
3-7
Inspect, adjust
Inspect, replace
Inspect
Inspect
Inspect
Inspect
Inspect
Replace
Replace
Inspect, adjust
3-3
3-29
3-24
5-7
3-20
3-16
3-18
3-10
*1: Grease quantity: 33.035.0 cm3 (1.111.18 oz)

*3: After every use
3-1
INSP
ADJ
CONTROL SYSTEM
PERIODIC SERVICE
CONTROL SYSTEM
Steering master inspection
1. Inspect:
Steering master
Excessive play Replace the steering
master.
Refer to STEERING MASTER in
Chapter 8.
Inspection steps:
Move the handlebar up and down and
back and forth.
Check the excessive play of the handlebar.
Steering cable inspection and adjustment

1. Inspect:
Jet thrust nozzle clearance a, b
Difference Adjust.
Inspection steps:
Set the control grip in the neutral position.
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 master end)
Adjustment steps:
Loosen the locknut 1.
Disconnect the cable joint 2 from the ball
joint 3.
Turn the cable joint 2 in or out for adjusting the clearances a and b.
3-2
Turn in
Clearance a is increased.
Turn out
Clearance b is increased.
INSP
ADJ
CONTROL SYSTEM
WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).
Connect the cable joint and tighten the
locknut.
T.
Locknut:
6.4 N m (0.64 kgf m, 4.6 ft lb)
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:
47 mm (0.160.28 in)
3-3
INSP
ADJ
CONTROL SYSTEM
E
2. Adjust:
Adjustment steps:
NOTE:
When not replacing the throttle cable or
removing the cable from the throttle body,
adjust the throttle cable free play by following steps (f) through (j).
When replacing the throttle cable or
adjust the throttle cable free play by following steps (a) through (k).
a. Remove the air filter case cover 1 and
ribbon sub assemblies.
b. Loosen the locknut 2.
c. Turn the adjusting nut 3 to adjust the
length a.
Throttle cable installation length:
24.4 1.0 mm (0.96 0.04 in)
NOTE:
Apply locking agent (LOCTITE) to the
threads of the adjusting nut 3.
d. Remove the handlebar cover.
e. Loosen the locknut 4.
f. Turn the adjuster 5 in or out until the
specified free play is obtained.
Turn in
Free play is increased.
Turn out
Free play is decreased.
g. Tighten the locknut.

NOTE:
When adjusting the throttle cable at the
throttle body, fully open the throttle lever
and check that the butterfly valve is fully
open.
If the throttle cable free play cannot be
adjusted properly, replace the throttle
cable.
3-4
INSP
ADJ
CONTROL SYSTEM
h. Install the handlebar cover.
T.
Handlebar cover screw:

1.1 N m (0.11 kgf m, 0.8 ft lb)
LOCTITE 242
i. Install the ribbon sub assemblies and air

filter case cover.
T.
Ribbon sub assembly bolt:

6.5 N m (0.65 kgf m, 4.7 ft lb)
LOCTITE 242
Air filter case cover screw:
2.5 N m (0.25 kgf m, 1.8 ft lb)
LOCTITE 572
WARNING
After adjusting the free play, turn the handlebar to the right and left and make sure
that the trolling speed does not increase.
QSTS cable inspection and adjustment

1. Measure:
Jet thrust nozzle set length a, b
Difference Adjust.
Measurement steps:
Set the jet thrust nozzle in the center
position.
Measure the jet thrust nozzle set length
a and b.
If a and b lengths are not even, adjust
the cable joint.
3-5
INSP
ADJ
CONTROL SYSTEM
E
2. Adjust:
QSTS cable
Adjustment steps:
Remove the nut 2 and pivot pin 3.
Set the jet thrust nozzle in the center
position.
Turn the cable joint 4 for adjusting.
Turn in
Length a is increased.
Turn out
Length b is increased.
WARNING
Connect the cable joint 4 and pivot pin
3 and tighten the nut 2.
T.
Nut:
3.8 N m (0.38 kgf m, 2.7 ft lb)
Tighten the locknut 1.
T.
Locknut:
3 N m (0.3 kgf m, 2.2 ft lb)
NOTE:
If the QSTS cable cannot be properly adjusted
by the cable joint at the QSTS converter 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.
3-6
INSP
ADJ
CONTROL SYSTEM
E
Shift cable inspection and adjustment
1. Check:
Reverse gate stopper lever position
Incorrect Adjust.
Checking steps:
Set the shift lever to the reverse position.
Check that the reverse gate 1 contacts
the stopper 2 on the bracket and the
lever 3 contacts the reverse gate.
Set the shift lever to the forward position.
Check that the lever 4 has been shifted
over the bracket 5.
5
4
2. Adjust:
Shift cable joint
Adjustment steps:
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
locknut.
T.
3-7
Locknut:
2.9 N m (0.29 kgf m, 2.1 ft lb)
LOCTITE 572
INSP
ADJ
CONTROL SYSTEM
E
Trolling speed check and adjustment
1. Measure:
Trolling speed
Trolling speed:
1,5501,750 r/min
Checking steps: (Watercraft on water)
Start the engine and allow it to warm up
for a 15 minutes.
Check the engine trolling speed using the
tachometer of the multifunction meter or
using the Yamaha Diagnostic System.
2. Adjust:
Trolling speed
Adjustment steps:
Remove the air filter case cover 1.
Start the engine.
Turn the throttle stop screw 2 in or out
until the specified speed is obtained.
Turn in a
Increase trolling speed.
Turn out b
Decrease trolling speed.
Install the air filter case cover.
T.
3-8

2.5 N m (0.25 kgf m, 1.8 ft lb)
LOCTITE 572
INSP
ADJ
FUEL SYSTEM
FUEL SYSTEM
WARNING
When removing fuel system parts, wrap
them in a cloth and take care that no fuel
spills into the engine compartment.
Fuel line inspection
1. Inspect:
Fuel pump filter
Clog/contaminants Clean.
Refer to FUEL TANK AND FUEL
PUMP MODULE in Chapter 4.
Fuel hose
Damage/cracks Replace.
O-rings (quick connector)
Damage/cracks Replace the quick
connector.
Fuel pipe
Damage/cracks Replace the fuel
pump.
Refer to FUEL INJECTION SYSTEM
in Chapter 4.
Fuel filler hose
Fuel tank
Fuel filler cap
Cracks/damage Replace.
2. Inspect:
Fuel tank
Water accumulation Remove.
NOTE:
To remove water from the fuel tank, remove
the cap 1 and use a siphon pump.
T.
3-9
Fuel tank cap screw clamp:

1.3 N m (0.13 kgf m, 0.9 ft lb)
INSP
ADJ
FUEL SYSTEM/POWER UNIT
Water separator inspection

1. Inspect:
Water separator 1
Water accumulation Drain.
NOTE:
If need the water draining, remove the drain
plug 2.
POWER UNIT
Valve clearance adjustment
The following procedure applies to all of the
valves.
NOTE:
Valve clearance adjustment should be made
on a cold engine, at room temperature.
When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.
1. Remove:
Air filter case
in Chapter 4.
2. Remove:
Ignition coils
Spark plugs
Cylinder head cover
Cylinder head cover gasket
Refer to CAMSHAFTS in Chapter 5.
3. Install:
Dial gauge needle
Dial gauge stand 1
(into spark plug hole #1)
Dial gauge 2
Dial gauge stand:
90890-06583
Dial gauge needle:
90890-06584
Dial gauge stand set:
YW-06585/90890-06585
Dial gauge:
YU-03097/90890-01252
2
1
3-10
INSP
ADJ
POWER UNIT
E
4. Measure:
Valve clearance
Valve clearance (cold):
Intake valve:
0.110.20 mm
(0.00430.0079 in)
Exhaust valve:
0.250.34 mm
(0.00980.0134 in)
EX
IN
Measurement steps:
Turn the drive coupling counterclockwise,
and then check if cylinder #1 is at TDC of
the compression stroke with a dial gauge.
NOTE:
TDC on the compression stroke can be
found when the camshaft lobes are turned
away from each other.
Measure the valve clearance with a thickness gauge 1.
NOTE:
If the valve clearance is incorrect, record
the measured reading.
Measure the valve clearance in the following sequence.
Valve clearance measuring sequence

Cylinder #1 #2 #4 #3
Bow side
To measure the valve clearances of the

other cylinders, starting with cylinder #1
at TDC, turn the drive coupling counterclockwise as specified in the following
table.
Degrees that the crankshaft is turned clockwise
Cylinder
Combustion cycle
#1
#2
180
360
540
#3
#4
720
3-11
Cylinder #2
180
Cylinder #4
360
Cylinder #3
540
INSP
ADJ
POWER UNIT
E
5. Remove:
Timing chain tensioner cap bolt 1
Gasket
6. Turn the timing chain tensioner rod fully

clockwise with a thin screwdriver 1.
NOTE:
Make sure that the tensioner rod has been fully
set clockwise.
7. Remove:
Intake camshaft caps
Exhaust camshaft caps
Timing chain
(from the camshaft sprockets)
Intake camshaft
Exhaust camshaft
NOTE:
Refer to CAMSHAFTS in Chapter 5.
When removing the timing chain and camshafts, fasten the timing chain with a wire to
prevent it from falling into the crankcase.
3-12
INSP
ADJ
POWER UNIT
E
8. Adjust:
Valve clearance
Adjustment steps:
Remove the valve lifter 1 and the valve
pad 2.
1
2
NOTE:
Cover the timing chain opening with a rag
to prevent the valve pad from falling into
the crankcase.
Make a note of the position of each valve
lifter 3 and valve pad 4 so that they can
be installed in the correct place.
Select the proper valve pad from the following table.
Valve pad thickness
range
Nos.
120240
Available valve
pads
1.20
25 thicknesses in
2.40 mm 0.05 mm increments
NOTE:
The thickness a of each valve pad is
marked in hundredths of millimeters on
the side that touches the valve lifter.
Since valve pads of various sizes are originally installed, the valve pad number
must be rounded in order to reach the
closest equivalent to the original.
a
148
Round off the original valve pad number

according to the following table.
Last digit
Rounded value
0 or 2
10
EXAMPLE:
Original valve pad number = 148 (thickness
= 1.48 mm)
Rounded value = 150
Locate the rounded number of the original valve pad and the measured valve
clearance in the valve pad selection
table. The point where the column and
row intersect is the new valve pad number.
3-13
INSP
ADJ
POWER UNIT
NOTE:
The new valve pad number is only an
approximation. The valve clearance must
be measured again and the above steps
should be repeated if the measurement is
still incorrect.
6
5
Install the new valve pad 5 and the valve

lifter 6.
NOTE:
Lubricate the valve pad with molybdenum
disulfide grease.
Lubricate the valve lifter with molybdenum
disulfide oil.
The valve lifter must turn smoothly when
rotated by hand.
Install the valve lifter and the valve pad in
the correct place.
Install the exhaust and intake camshafts,
timing chain and camshaft caps.
T.
Camshaft cap bolt:

10 N m (1.0 kgf m, 7.2 ft lb)
NOTE:
Refer to Camshaft installation CAMSHAFTS in Chapter 5.
Lubricate the camshafts, camshaft lobes
and camshaft journals.
First, install the exhaust camshaft.
Align the camshaft marks with the camshaft cap marks.
Turn the crankshaft clockwise several full
turns to seat the parts.
Measure the valve clearance again.
If the valve clearance is still out of specification, repeat all of the valve clearance
adjustment steps until the specified clearance is obtained.
3-14
INSP
ADJ
POWER UNIT
Intake
MEASURED
CLEARANCE
0.000.02
0.030.07
0.080.10
0.110.20
0.210.22
0.230.27
0.280.32
0.330.37
0.380.42
0.430.47
0.480.52
0.530.57
0.580.62
0.630.67
0.680.72
0.730.77
0.780.82
0.830.87
0.880.92
0.930.97
0.981.02
1.031.07
1.081.12
1.131.17
1.181.22
1.231.27
1.281.32
1.331.37
120 125 130 135

120
120 125
120 125 130
140
125
130
135
145
130
135
140
150
135
140
145
155
140
145
150
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
120 125 130 135 140 145 150

120
120 125
120 125 130
120 125 130 135
120 125 130 135 140
120 125 130 135 140 145
155
125
130
135
140
145
150
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
ORIGINAL VALVE PAD NUMBER

165 170 175 180 185 190 195 200 205 210
150 155 160 165 170 175 180 185 190 195
155 160 165 170 175 180 185 190 195 200
160 165 170 175 180 185 190 195 200 205
STANDARD CLEARANCE
165 170 175 180 185 190 195 200 205 210 215
170 175 180 185 190 195 200 205 210 215 220
175 180 185 190 195 200 205 210 215 220 225
180 185 190 195 200 205 210 215 220 225 230
185 190 195 200 205 210 215 220 225 230 235
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
230 235 240
235 240
Example:
240
Intake valve clearance (cold)
160
145
150
155
215
200
205
210
220
205
210
215
225
210
215
220
230
215
220
225
235
220
225
230
220
225
230
235
240
225 230 235 240

230 235 240
235 240
240
240
225
230
235
0.110.20 mm (0.00430.0079 in)

Rounded value 150
Measured valve clearance is 0.24 mm (0.0094 in)
Replace pad 150 with pad 160
Pad No. 150 = 1.50 mm (0.0591 in)
Pad No. 160 = 1.60 mm (0.0630 in)
Exhaust
MEASURED
CLEARANCE
0.000.01
0.020.06
0.070.11
0.120.16
0.170.21
0.220.24
0.250.34
0.350.37
0.380.42
0.430.47
0.480.52
0.530.57
0.580.62
0.630.67
0.680.72
0.730.77
0.780.82
0.830.87
0.880.92
0.930.97
0.981.02
1.031.07
1.081.12
1.131.17
1.181.22
1.231.27
1.281.32
1.331.37
1.381.42
1.431.47
1.481.52
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
ORIGINAL VALVE PAD NUMBER

165 170 175 180 185 190 195 200 205 210 215
135 140 145 150 155 160 165 170 175 180 185
140 145 150 155 160 165 170 175 180 185 190
145 150 155 160 165 170 175 180 185 190 195
150 155 160 165 170 175 180 185 190 195 200
155 160 165 170 175 180 185 190 195 200 205
160 165 170 175 180 185 190 195 200 205 210
STANDARD CLEARANCE
165 170 175 180 185 190 195 200 205 210 215 220
170 175 180 185 190 195 200 205 210 215 220 225
175 180 185 190 195 200 205 210 215 220 225 230
180 185 190 195 200 205 210 215 220 225 230 235
185 190 195 200 205 210 215 220 225 230 235 240
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
230 235 240
235 240
Example:
240
Exhaust valve clearance (cold)
160
130
135
140
145
150
155
220
190
195
200
205
210
215
225
195
200
205
210
215
220
230
200
205
210
215
220
225
235
205
210
215
220
225
230
240
210
215
220
225
230
235
225 230 235 240

230 235 240
235 240
240
0.250.34 mm (0.00980.0134 in)

Rounded value 170
Measured valve clearance is 0.44 mm (0.0173 in)
Replace pad 170 with pad 185
Pad No. 170 = 1.70 mm (0.0669 in)
Pad No. 185 = 1.85 mm (0.0728 in)
3-15
INSP
ADJ
POWER UNIT
E
9. Remove:
Dial gauge
Dial gauge stand
Dial gauge needle
10. Install:
All removed parts
NOTE:
For installation, reverse the removal procedure.
Engine oil level check

1. Check:
Engine oil level
Checking steps:
CAUTION:
When checking the engine oil level on
water, be careful of other watercraft,
boats, swimmers, or obstacles. The
water current or wind can cause the
watercraft to move and lead to a collision.
When checking the engine oil level on
land, supply water to the cooling water
passages.
Make sure that engine has enough oil
but do not overfill. If there is too little
oil, the engine can be damaged. if there
is too much oil, the air filter can
become saturated with oil, permanently damaging the filter and reducing engine performance. Follow the
checking procedure carefully.
Make sure that debris or water does
not enter the oil tank filler hole. Debris
or water in the engine oil can cause
serious engine damage.
3-16
INSP
ADJ
POWER UNIT
Place the watercraft in a horizontal position or launch the watercraft.

Remove the rear and front seats.
Remove the oil tank filler cap 1 and
check for oil on the dipstick 2.
If there is no oil on the dipstick, pour
enough oil so that the tip of the dipstick
comes into contact with the oil, and then
install the filler cap.
Start the engine.
CAUTION:
When starting the engine make sure the
dipstick is securely fitted into the oil
tank.
NOTE:
The engine cannot be started if the
Yamaha Security System is in the lock
mode.
For information on the Yamaha Security
System, see the owners manual.
Run the engine at trolling speed for 6
minutes or more, and then stop the
engine.
CAUTION:
When checking the oil level on land, be
sure to connect a garden hose to the
watercraft for proper water supply.
NOTE:
If the ambient temperature is 20 C (68 F)
or less, warm up the engine for an additional 5 minutes.
Remove the oil tank filler cap 1, wipe the
dipstick 2 clean, and then screw the filler
cap into the filler hole completely.
3-17
INSP
ADJ
POWER UNIT
Remove the filler cap again and check

that the oil level is between the minimum
level mark a and maximum level mark
b on the dipstick.
If the engine oil is below the minimum
level mark a, add sufficient oil of the recommended type to raise it to the correct
level.
If the engine oil is above the maximum
level mark b, extract sufficient oil using
an oil changer to lower it to the correct
level.
NOTE:
If the oil temperature is low, the reading on
the dipstick will be low, and if the temperature is high, the reading on the dipstick will
be high.
Engine oil change using oil changer
WARNING
Avoid changing the engine oil immediately
after turning the engine off. The oil is hot
and should be handled with care to avoid
burns.
CAUTION:
Do not run the engine with too much or
not enough oil in the oil tank. Oil could
spray out or the engine could be damaged.
Do not run the engine for more than 15
seconds without supplying water, when
checking the oil level on land.
The engine could overheat.
Be sure to change the engine oil after the
first 10 hours of operation, and every 100
hours thereafter or at the start of a new
season, otherwise the engine will wear
quickly.
1. Warm the engine up, and then put the
watercraft in a horizontal position.
3-18
INSP
ADJ
POWER UNIT
E
2. Remove:
Oil filler cap 1
3. Insert the tube of an oil changer into the oil

filler hole.
4. Operate the oil changer to extract the oil.
5. If the oil filter is also to be replaced, perform the following procedure.

Replacing steps:
Place a rag under the oil filter.
Remove the oil filter 1 with an oil filter
wrench.
Oil filter wrench:
YU-38411/90890-01426
Lubricate the O-ring 2 of the new oil filter

with a thin coat of engine oil.
CAUTION:
Make sure the O-ring 2 is positioned
correctly in the groove of the oil filter.
Tighten the new oil filter to specification
with an oil filter wrench.
T.
Oil filter:
17 N m (1.7 kgf m, 12 ft lb)
6. Pour the specified amount of the recommended engine oil into the oil filler hole.
3-19
INSP
ADJ
POWER UNIT
E
7. Fill:
Oil tank
(with the specified amount of the recommended engine oil)
Recommended oil:
SAE 10W-30
API SE, SF, SG, SH, SJ, SL
Oil quantity:
Total amount:
4.5 L (4.8 US qt, 4.0 Imp qt)
Without oil filter replacement:
2.1 L (2.2 US qt, 1.8 Imp qt)
With oil filter replacement:
2.3 L (2.4 US qt, 2.0 Imp qt)
CAUTION:
When starting the engine make sure the
dipstick is securely fitted into the oil tank.
8. Install:
Oil filler cap
Air filter element clean

1. Remove:
Air filter case cover 1
3-20
INSP
ADJ
POWER UNIT
E
2. Remove the air filter element and check it
for dirt and oil. Replace the air filter element if there is any oil buildup.
CAUTION:
Make sure that the air filter element is
installed in the filter case properly.
Do not start the engine with the air filter
element removed, otherwise the engine
could be damaged.
If cleaning the air filter element, use cold
or lukewarm water and let it air dry completely. Do not use detergent or an solvent to clean the air filter element, or dry
it with heat or compressed air, otherwise
it could be damaged.
3. Install:
Air filter case cover
T.

2.5 N m (0.25 kgf m, 1.8 ft lb)
LOCTITE 572
Spark plug inspection

1. Remove:
2. Remove:
Air filter element
Ignition coils
CAUTION:
Be careful not to get any foreign substances or water in the air intake port and
spark plug hole.
3-21
INSP
ADJ
POWER UNIT
E
3. Inspect:
Electrodes 1
Damage/wear Replace.
Insulator color 2
Distinctly different color Check the
engine condition.
Color guide:
Medium to light tan color:
Normal
Whitish color:
Lean fuel mixture
Air leak
Incorrect settings
Blackish color:
Overly rich mixture
Electrical malfunction
Defective spark plug
4. Clean:
Spark plug
(with a spark plug cleaner or wire brush)
5. Measure:
Spark plug gap a
Out of specification Regap.
Spark plug gap:
0.70.8 mm (0.0280.031 in)
3-22
INSP
ADJ
POWER UNIT
E
6. Tighten:
Spark plug
T.
Spark plug:
13 N m (1.3 kgf m, 9.4 ft lb)
NOTE:
Before installing the spark plug, clean the
gasket surface and spark plug surface. Also,
it is suggested to apply a thin film of antiseize 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.
7. Install:
Ignition coils
Air filter element
T.
3-23
Ignition coil bolt:

7.6 N m (0.76 kgf m, 5.5 ft lb)
LOCTITE 572
2.5 N m (0.25 kgf m, 1.8 ft lb)
LOCTITE 572
INSP
ADJ
ELECTRICAL
ELECTRICAL
Battery inspection
WARNING
Battery electrolyte is poisonous and dangerous, causing severe burns, etc. Electrolyte contains sulfuric acid. Avoid contact
with skin, eyes or clothing.
Antidotes
External: Flush with water.
Internal: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten
egg or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and
get prompt medical attention.
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.
3-24
INSP
ADJ
ELECTRICAL
E
1. Remove:
Bands
Battery negative lead 1
Battery positive lead 2
Battery
Battery breather hose 3
2
3
WARNING
When removing the battery, disconnect
the negative lead first.
Remove the battery to prevent acid loss
during turning the machine on its side for
the impeller service.
2. Inspect:
Electrolyte level
Low Add distilled water.
The electrolyte level should be between
the upper a and lower b level marks.
Filling steps:
Remove each filler cap.
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.
3-25
INSP
ADJ
ELECTRICAL
E
3. Inspect:
Specific gravity
Out of specification Charge.
Specific gravity at 20 C (68 F):
1.28
Charging current:
1.9 amps 10 hrs
4. Install:
Filler caps
CAUTION:
Before installation, rinse off any fluid from
the battery box and battery and make sure
that the battery is dry before installing it.
5. Install:
Battery breather hose 1
Battery
Battery positive lead 2
Battery negative lead 3
Bands
2
1
CAUTION:
Connect the positive lead to the battery
terminal first.
Make sure the battery leads are connected 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.
3-26
INSP
ADJ
JET PUMP UNIT
JET PUMP UNIT

Impeller inspection
1. Check:
Impeller 1
Nicks/scratches File or grind.
2. Measure:
Impeller-to-housing clearance a
Out of specification Replace.
Maximum impeller-to-housing
clearance:
0.350.45 mm (0.01380.0177 in)
Measurement steps:
Remove the battery leads.
Remove the intake grate and intake duct.
Refer to INTAKE GRATE, RIDE PLATE,
AND INTAKE DUCT in Chapter 6.
Measure the clearance at each impeller
blade as shown (a total of three measurements).
Install the intake duct and intake grate.
Install the battery leads.
Water inlet strainer inspection

1. Inspect:
Contaminants Clean.
Inspection steps:
Remove the ride plate.
Remove the rubber plate.
Refer to JET PUMP UNIT in Chapter 6.
Remove the water inlet cover 1.
Inspect the water inlet strainer mesh a.
Install the water inlet cover.
Install the rubber plate.
Install the ride plate.
3-27
INSP
ADJ
BILGE PUMP
BILGE PUMP
Bilge strainer inspection
1. Inspect:
Bilge strainer
Contaminants Clean.
Inspection steps:
Remove the deck beam.
Refer to SEATS AND HAND GRIP in
Chapter 8.
Remove the coupling cover.
Disconnect the bilge strainer case 1
from the bilge strainer.
Inspect the bilge strainer.
Install the coupling cover.
Install the deck beam.
Refer to SEATS AND HAND GRIP in
Chapter 8.
Electric bilge pump strainer inspection

1. Inspect:
Cap
Strainer
Contaminants Clean.
Inspection steps:
Remove the band 1.
Remove the cap 2 and strainer 3.
Inspect the cap and strainer.
Install the strainer and cap.
Install the band.
3
2
3-28
INSP
ADJ
GENERAL
GENERAL
Drain plug inspection
1. Inspect:
Drain plugs
O-rings
Cracks/wear Replace.
Screw threads
Contaminants Clean.
Lubrication points
1. Lubricate:
Throttle cable (handlebar end)
Recommended lubricant:
Rust inhibitor
NOTE:
Before lubricating the throttle cable, squeeze
the throttle lever and remove the rubber seal
1.
2. Lubricate:
Throttle cable (throttle body end)
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
3. Lubricate:
QSTS control cables (handlebar end)
Yamaha grease A
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.
3-29
INSP
ADJ
GENERAL
E
4. Lubricate:
QSTS cables (pulley end)
Recommended grease:
Yamaha grease A
5. Lubricate:
Nozzle pivot shaft
Steering cable (nozzle end)
QSTS cable (nozzle end)
Recommended grease:
Yamaha grease A
6. Lubricate:
Steering cable
Shift cable
Shift cable joint
NOTE:
Disconnect the joints and apply a small
amount of grease.
Recommended grease:
Yamaha grease A
3-30
INSP
ADJ
GENERAL
E
7. Fill:
Recommended grease:
Yamaha grease A
Grease quantity:
Initial 10 hours:
33.035.0 cm3 (1.111.18 oz)
Every 100 hours or 12 months:
6.08.0 cm3 (0.200.27 oz)
NOTE:
Fill the intermediate housing with the recommended grease through the grease nipple 1.
3-31
FUEL
CHAPTER 4
FUEL SYSTEM
ARRANGEMENT OF THE THROTTLE BODY COMPONENTS
COUPLERS .................................................................................................... 4-1
FUEL TANK AND FUEL PUMP MODULE......................................................4-2
EXPLODED DIAGRAM .............................................................................4-2
REMOVAL AND INSTALLATION CHART ................................................ 4-2
SERVICE POINTS .................................................................................... 4-5
Fuel hose disconnection ..................................................................... 4-5
Fuel pump module removal.................................................................4-5
Check valve inspection ....................................................................... 4-5
Rollover valve inspection .................................................................... 4-6
Fuel sender inspection ........................................................................ 4-6
Fuel tank inspection ............................................................................4-6
Fuel hose inspection ...........................................................................4-6
Fuel pump filter inspection ..................................................................4-6
Fuel pump module installation ............................................................ 4-7
Fuel hose connect............................................................................... 4-7
FUEL INJECTION SYSTEM............................................................................4-8
SERVICE POINTS .................................................................................. 4-17
Hose clamps removal........................................................................4-17
Hose clamps installation ................................................................... 4-17
Fuel hose disconnection ................................................................... 4-17
Fuel line inspection ...........................................................................4-18
Fuel hose installation (replacing with new fuel hose)........................ 4-19
Fuel hose connection ........................................................................4-19
Throttle body removal ....................................................................... 4-19
Fuel injector inspection ..................................................................... 4-20
Throttle body inspection .................................................................... 4-20
Bypass valve motor inspection.......................................................... 4-21
Throttle body installation ................................................................... 4-21
Throttle bodies synchronization ........................................................ 4-22
Fuel pressure measurement ............................................................. 4-27
ARRANGEMENT OF THE THROTTLE BODY

COMPONENTS COUPLERS
FUEL
ARRANGEMENT OF THE THROTTLE BODY COMPONENTS COUPLERS
A
B
1
2
3
4
5
6
7
8
Bypass valve motor coupler

Joint coupler
Sensor assembly coupler
Fuel injector #4 coupler
coupler
To wiring harness
Route the throttle cable
between the sub-wiring harness.
Route the sub-wiring harness
under the intake vacuum hose.
To fuel injector #3
Fasten the sub-wiring harness
to the joint coupler bracket with
a plastic tie as shown in the
illustration.
4-1
Fasten the ring, which is

attached to the sub-wiring harness, to the sensor assembly
bracket with a plastic tie. Face
the end of the plastic tie
towards the sensor assembly.
FUEL
FUEL TANK AND FUEL PUMP MODULE

EXPLODED DIAGRAM
1st
15
10
1
17
6
1.3 N m (0.13 kgf m, 0.9 ft Ib)
2
16
3.2 N m (0.32 kgf m, 2.3 ft Ib)
2nd 6.4 N m (0.64 kgf m, 4.6 ft Ib)
8
11
5.9 N m (0.59 kgf m, 4.3 ft Ib)
13
12
18
13
14
20
LT
572
4.2 N m (0.42 kgf m, 3.0 ft Ib)
19
21
LT
572
16 N m (1.6 kgf m, 11 ft Ib)

8 18 mm
REMOVAL AND INSTALLATION CHART

Step
1
2
3
Procedure/Part name
FUEL TANK REMOVAL
Service lid 1
Service lid 2
Ventilation hose
Engine unit
Rollover valve
Check valve
Qty
Service points
Follow the left Step for removal.
Refer to FRONT HOOD in Chapter 8.
From ventilation fitting
Refer to ENGINE UNIT in Chapter 5.
NOTE:
When removing the pump module only, it is
not necessary to remove the engine unit.
1
2
1
4-2
FUEL
EXPLODED DIAGRAM
1st
15
10
1
17
6
1.3 N m (0.13 kgf m, 0.9 ft Ib)
2
16
3.2 N m (0.32 kgf m, 2.3 ft Ib)
2nd 6.4 N m (0.64 kgf m, 4.6 ft Ib)
8
11
5.9 N m (0.59 kgf m, 4.3 ft Ib)
13
12
18
13
14
20
LT
572
4.2 N m (0.42 kgf m, 3.0 ft Ib)
19
21
LT
572
16 N m (1.6 kgf m, 11 ft Ib)

8 18 mm
Step
4
5
6
7
8
9
10
11
12
Procedure/Part name
Fuel sender coupler
Fuel pump module coupler

Cover
Fuel hose
Nut
Retainer
Fuel pump module
Packing
Qty
1
1
1
1
1
9
1
1
1
4-3
Service points
NOTE:
Make sure that the inner seal of the coupler
is installed properly before connecting the
coupler.
FUEL
EXPLODED DIAGRAM
1st
15
10
1
17
6
1.3 N m (0.13 kgf m, 0.9 ft Ib)
2
16
3.2 N m (0.32 kgf m, 2.3 ft Ib)
2nd 6.4 N m (0.64 kgf m, 4.6 ft Ib)
8
11
5.9 N m (0.59 kgf m, 4.3 ft Ib)
13
12
14
18
13
20
LT
572
4.2 N m (0.42 kgf m, 3.0 ft Ib)
19
21
LT
572
16 N m (1.6 kgf m, 11 ft Ib)

8 18 mm
Step
13
14
15
16
17
18
19
20
21
Procedure/Part name
Hose clamp
Fuel filler hose
Nut
Fuel filler neck
Rubber seal
Bolt
Fuel tank assembly
Bolt
Fuel tank belt
Qty
2
1
1
1
1
2
1
2
2
Service points
Reverse the removal steps for installation.
4-4
FUEL
SERVICE POINTS
Fuel hose disconnection
1. Disconnect:
Fuel hose
Refer to FUEL INJECTION SYSTEM.
3
2
Fuel pump module removal

1. Remove:
Nuts
Retainer
NOTE:
Loosen the nuts in the sequence shown.
1
6
2. Remove:
Fuel pump module 1
NOTE:
Remove the float 2 at an angle because it
could catch on the fuel tank.
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 come out from end A.
4-5
FUEL
Rollover valve inspection

1. Check:
Rollover valve
Faulty Replace.
Checking steps:
Connect a hose to the end of rollover
valve A and blow into it.
Air should come out from end B.
Connect the hose to the end of rollover
valve B and blow into it.
Air should not come out from end A.
Fuel sender inspection

Refer to FUEL CONTROL SYSTEM in
Chapter 7.
Fuel tank inspection
1. Inspect:
Fuel tank
Fuel hose inspection
Fuel pump filter inspection

1. Inspect:
Fuel pump filter 1
Clog/contaminants Wash the fuel
pump filter in kerosene or gasoline.
4-6
FUEL
Fuel pump module installation

1. Tighten:
Nuts
5
T.
8
1
9
4
Fuel pump module nut:

1st:
3.2 N m
(0.32 kgf m, 2.3 ft lb)
2nd:
6.4 N m
(0.64 kgf m, 4.6 ft lb)
NOTE:
Tighten the nuts in the sequence shown.
Fuel hose connect
4-7
FUEL
FUEL INJECTION SYSTEM

EXPLODED DIAGRAM
2.5 N m (0.25 kgf m, 1.8 ft Ib)

5 70 mm
6.5 N m (0.65 kgf m, 4.7 ft Ib)

6 7 mm
5
6
LT
LT
572
242
16
3
18
21
17
22
19
20
19
23
22 N m (2.2 kgf m, 16 ft Ib)

8 50 mm
12
7
13
LT
572
10
4 8 mm
3.3 N m (0.33 kgf m, 2.4 ft Ib)
14
LT
15
572
11
6 14 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)

Step
1
2
3
4
5
6
7
8
9
10
Procedure/Part name
THROTTLE BODIES REMOVAL
Screw
Air filter
Bolt
Ribbon sub assembly
Holder
Throttle cable
Bolt
Throttle cable holder
Cover
Qty
2
1
1
4
2
2
1
2
1
1
4-8
Service points
FUEL
EXPLODED DIAGRAM
2.5 N m (0.25 kgf m, 1.8 ft Ib)

5 70 mm
6.5 N m (0.65 kgf m, 4.7 ft Ib)

6 7 mm
5
6
LT
LT
572
242
16
3
18
21
17
22
19
20
19
23
22 N m (2.2 kgf m, 16 ft Ib)

8 50 mm
12
7
13
LT
572
10
4 8 mm
3.3 N m (0.33 kgf m, 2.4 ft Ib)
Step
11
12
13
14
15
16
17
18
19
20
14
15
572
11
Procedure/Part name
Fuel hose
Bolt
Fuel hose holder
Clamp
Clamp
Bolt
Throttle bodies
Fuel injector coupler
Throttle position sensor coupler
LT
6 14 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)
Qty
1
2
1
1
1
8
1
1
4
1
4-9
Service points
Not reusable
FUEL
EXPLODED DIAGRAM
2.5 N m (0.25 kgf m, 1.8 ft Ib)

5 70 mm
6.5 N m (0.65 kgf m, 4.7 ft Ib)

6 7 mm
5
6
LT
LT
572
242
16
3
18
21
17
22
19
20
19
23
22 N m (2.2 kgf m, 16 ft Ib)

8 50 mm
12
7
13
LT
572
10
4 8 mm
3.3 N m (0.33 kgf m, 2.4 ft Ib)
Step
21
22
23
14
15
572
11
Procedure/Part name
Joint connector
Ring
LT
6 14 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)
Qty
1
1
1
Service points
4-10
FUEL
EXPLODED DIAGRAM
1st
8.8 N m (0.88 kgf m, 6.4 ft Ib)
2nd 18 N m (1.8 kgf m, 13 ft Ib)

8 30 mm
9
13
8
LT
1st
12
242
15 N m (1.5 kgf m, 11 ft Ib)
2nd 39 N m (3.9 kgf m, 28 ft Ib)

8 16 mm
LT
11
572
25
23
10
17
24
6 16 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)
18
4
LT
271
14
15
LT
242
16
20
21
5 14 mm
1.8 N m (0.18 kgf m, 1.3 ft Ib)
LT
572
LT
271
19
6 16 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)
22
8 16 mm
1st 15 N m (1.5 kgf m, 11 ft Ib)
2nd 39 N m (3.9 kgf m, 28 ft Ib)
1.3 N m (0.13 kgf m, 0.9 ft Ib)

5 14 mm
5 14 mm
1.3 N m (0.13 kgf m, 0.9 ft Ib)

Step
1
2
3
4
5
6
7
Procedure/Part name
AIR FILTER CASE REMOVAL
Throttle bodies
Clamp/breather hose
Band
Thermoswitch coupler (engine)
Pickup coil coupler
Thermoswitch coupler (exhaust)
Cam position sensor coupler
Qty
1/1
1
1
1
1
1
1
4-11
Service points
Unfasten the wiring harness.

From wiring harness bracket 2
FUEL
EXPLODED DIAGRAM
1st
8.8 N m (0.88 kgf m, 6.4 ft Ib)
2nd 18 N m (1.8 kgf m, 13 ft Ib)

8 30 mm
9
13
8
LT
1st
12
242
15 N m (1.5 kgf m, 11 ft Ib)
2nd 39 N m (3.9 kgf m, 28 ft Ib)

8 16 mm
LT
11
572
25
23
10
17
24
6 16 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)
18
4
LT
271
14
15
LT
242
16
5 14 mm
1.8 N m (0.18 kgf m, 1.3 ft Ib)
LT
271
19
Step
8
9
10
11
12
13
14
15
16
17
Procedure/Part name
Bolt
Air filter case
Bolt
Wiring harness bracket 1
Sub wiring harness
Bolt
Fuel hose bracket
Screw
Wiring harness bracket 2
20
21
LT
572
6 16 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)
22
8 16 mm
1st 15 N m (1.5 kgf m, 11 ft Ib)
2nd 39 N m (3.9 kgf m, 28 ft Ib)
1.3 N m (0.13 kgf m, 0.9 ft Ib)

5 14 mm
5 14 mm
1.3 N m (0.13 kgf m, 0.9 ft Ib)
Qty
1
3
1
2
1
1
2
1
1
1
4-12
Service points
FUEL
EXPLODED DIAGRAM
1st
8.8 N m (0.88 kgf m, 6.4 ft Ib)
2nd 18 N m (1.8 kgf m, 13 ft Ib)

8 30 mm
9
13
8
LT
1st
12
242
15 N m (1.5 kgf m, 11 ft Ib)
2nd 39 N m (3.9 kgf m, 28 ft Ib)

8 16 mm
LT
11
572
25
23
10
17
24
6 16 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)
18
4
LT
271
14
15
LT
242
16
5 14 mm
1.8 N m (0.18 kgf m, 1.3 ft Ib)
LT
271
19
Step
18
19
20
21
22
23
24
25
Procedure/Part name
Grommet
Throttle body joint
Band
Bolt
Band
Bolt
20
21
LT
572
6 16 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)
22
8 16 mm
1st 15 N m (1.5 kgf m, 11 ft Ib)
2nd 39 N m (3.9 kgf m, 28 ft Ib)
1.3 N m (0.13 kgf m, 0.9 ft Ib)

5 14 mm
5 14 mm
1.3 N m (0.13 kgf m, 0.9 ft Ib)
Qty
1
4
2
2
2
1
1
1
Service points
4-13
FUEL
EXPLODED DIAGRAM
3.5 N m (0.35 kgf m, 2.5 ft Ib)

5 15 mm
13
9
7
14
11
12
10
3
8 18 mm
22
24
1
5.0 N m (0.5 kgf m, 3.6 ft Ib)
6 10 mm
23
13 N m (1.3 kgf m, 9.4 ft Ib)
5.0 N m (0.5 kgf m, 3.6 ft Ib)

6 10 mm
5.0 N m (0.5 kgf m, 3.6 ft Ib)
6 9 mm
19 17
24
18
25
26
27
28
15
29
21
32
30 31
20
2.0 N m (0.2 kgf m, 1.4 ft Ib)

6 9 mm
4 12 mm
5.0 N m (0.5 kgf m, 3.6 ft Ib)
15
16

Step
1
2
3
4
5
6
7
8
9
10
Procedure/Part name
THROTTLE BODY
DISASSEMBLY
Screw
Bracket
Bolt/nut
Bypass valve motor
Holder
Holder
Hose #4
Hose #3
Hose #2
Hose #1
Qty
3
1
2/2
1
1
1
1
1
1
1
4-14
Service points
Follow the left Step for disassembly.
FUEL
EXPLODED DIAGRAM
3.5 N m (0.35 kgf m, 2.5 ft Ib)

5 15 mm
13
9
7
14
11
12
10
3
8 18 mm
22
24
1
5.0 N m (0.5 kgf m, 3.6 ft Ib)
6 10 mm
23
5.0 N m (0.5 kgf m, 3.6 ft Ib)

6 10 mm
5.0 N m (0.5 kgf m, 3.6 ft Ib)
6 9 mm
13 N m (1.3 kgf m, 9.4 ft Ib)
19 17
24
18
25
26
27
28
15
29
21
30 31
32
20
2.0 N m (0.2 kgf m, 1.4 ft Ib)

6 9 mm
4 12 mm
5.0 N m (0.5 kgf m, 3.6 ft Ib)
Step
11
12
13
14
15
16
17
18
19
20
21
22
Procedure/Part name
Bolt
Fuel rail
Screw
Sensor assembly
Intake vacuum hose
Joint
Fuel injector
O-ring
Grommet
Screw
Throttle stop guide
Screw
Qty
4
1
2
1
3
1
4
4
4
2
1
2
4-15
15
16
Service points
Not reusable
Not reusable
FUEL
EXPLODED DIAGRAM
3.5 N m (0.35 kgf m, 2.5 ft Ib)

5 15 mm
13
9
7
14
11
12
10
3
8 18 mm
22
24
1
5.0 N m (0.5 kgf m, 3.6 ft Ib)
6 10 mm
23
5.0 N m (0.5 kgf m, 3.6 ft Ib)

6 10 mm
5.0 N m (0.5 kgf m, 3.6 ft Ib)
6 9 mm
13 N m (1.3 kgf m, 9.4 ft Ib)
19 17
24
18
25
26
27
28
15
29
21
30 31
32
20
2.0 N m (0.2 kgf m, 1.4 ft Ib)

6 9 mm
4 12 mm
5.0 N m (0.5 kgf m, 3.6 ft Ib)
Step
23
24
25
26
27
28
29
30
31
32
Procedure/Part name
Throttle stop screw bracket
Screw/spring
Bypass air screw
Spring
Washer
O-ring
Screw
O-ring
Throttle bodies
Qty
1
4/4
4
4
4
4
2
1
1
1
15
16
Service points
Not reusable
Not reusable
Reverse the disassembly steps for
assembly.
4-16
FUEL
SERVICE POINTS
Hose clamps removal
1. Remove:
Hose clamps
CAUTION:
If the hose clamps are removed without
cutting the joint first, the fuel hose will be
damaged.
Hose clamps installation
1. Install:
Hose clamps
WARNING
Do not reuse the hose clamps, always
replace them with new ones.
NOTE:
Crimp the hose clamps properly to securely
fasten them.
Fuel hose disconnection
WARNING
Before disconnecting the hose, remove the
fuel tank filler cap to reduce any pressure
inside the fuel tank, and then disconnect
the battery negative lead to cut off the electric current to the electrical systems.
1. Wrap the quick connector with a cloth, and
then rotate the quick connector tab 1 to
the stopper position a.
WARNING
If the quick connector is removed suddenly, pressurized fuel could spray out. To
gradually release the fuel pressure, be sure
to remove the quick connector slowly.
4-17
FUEL
CAUTION:
Do not rotate the quick connector tab 1

past the stopper position a, otherwise it
could be damaged.
When the fuel hoses are disconnected,
quickly remove the retainer 2 from the
quick connector, otherwise the retainer
could be lost.
2. Disconnect the fuel hose 1 from the fuel

pipe 2 directly.
WARNING
Always reduce the fuel pressure in the fuel
line before servicing the line or the fuel
pipe. If the fuel pressure is not released,
pressurized fuel could spray out.
3. Cover the quick connector and fuel pipe

with a plastic bag to prevent damage and
to protect them from dirt.
Fuel line inspection

1. Inspect:
Fuel hose
O-rings (quick connector)
Damage/cracks Replace the quick
connector.
Fuel pipe
Damage/cracks Replace the fuel
pump.
4-18
FUEL
Fuel hose installation (replacing with new

fuel hose)
1. Install:
Fuel hose 1
NOTE:
To install the fuel hose, be sure to align the
white mark a of the fuel hose with the
checker tab 2 of the quick connector.
When replacing the fuel hose with a new
one, a checker tab 2 that has half engagement prevention is attached to the quick connector of the hose. If the quick connector is
completely installed to the fuel pipe, it is
removable.
Fuel hose connection

1. Apply a thin coat of engine oil to the contact surfaces of the fuel pipe.
2. Insert the quick connector into the fuel
pipe until you hear a click.
3. To check the connection of the quick connector, push and pull on the quick connector several times until there is free play of
23 mm (0.080.12 in).
NOTE:
If free is not obtained, disconnect the fuel hose
and check the O-ring for damage and that it is
properly installed.
Throttle body removal

1. Remove:
Throttle body
CAUTION:
Do not bend the fuel pipe 1.
4-19
FUEL
Fuel injector inspection
CAUTION:
The throttle bodies should not be disassembled unnecessarily.
1. Check:
Injector
Dirt/residue Clean.
Damage Replace.
2. Measure:
Fuel injectors resistance
Digital multimeter:
YU-34899-A
Digital circuit tester:
90890-03174
Fuel injector resistance:
(reference data)
11.512.5 at 20 C (68 F)
3. Check the operation of the fuel injector
using the Stationary Test of the Yamaha
Diagnostic System.
Throttle body inspection

1. Check:
Throttle body
Cracks/damage Replace the throttle
bodies.
2. Check:
Fuel passages
Obstruction Clean.
Checking steps:
Wash the throttle body in a petroleum
based solvent.
Do not use any caustic carburetor cleaning solution.
Blow out all of passages with compressed air.
4-20
FUEL
Bypass valve motor inspection

1. Inspect:
Hoses
2. Check:
Check the bypass valve motor operation
using the Yamaha Diagnostic System.
Throttle body installation

1. Install:
Throttle body
CAUTION:
Do not bend the fuel pipe 1.
2. Install:
Fuel hose 1 (throttle body side)
Clamp
NOTE:
Install the fuel hose with the white mark a facing up.
1
3. Adjust:
Refer to CONTROL SYSTEM in Chapter 3.
4-21
FUEL
Throttle bodies synchronization

1. Remove:
Throttle bodies
Air filter case
2. Adjust:
Throttle bodies synchronization
Adjustment steps:
#4
#3
#1
#2
1
#2 2 #3
#1
NOTE:
The bypass air screws 1 should not be
adjusted. However, if it is necessary to
remove the bypass air screw, be sure to
note the number of times the screw is
turned from its set position. When installing
the screw, be sure to tighten the screw the
same number of turns as noted at removal.
If the number of turns is not known, turn the
screw approximately 2.5 times counterclockwise from the fully closed position.
#4
CAUTION:
Do not start the engine when removing
the fuel hose. Fuel can spurt out when
the fuel pump is operated.
a. Loosen the throttle stop screw 2 and

synchronizing screws #1 3, #2 4, and
#3 5 until released from the levers.
NOTE:
Only butterfly valve #2 should be fully
closed and the other valves should be
halfway closed.
Check the valve for light leaks with a
flashlight. If there are no light leaks, the
valve is fully closed.
b. Turn synchronizing screw #2 4 clockwise approximately 7 times until it starts
to contact the lever.
NOTE:
Butterfly valves #2 and #3 should be fully
closed. Butterfly valve #2 opens if the
screw is turned more than 7 times.
If butterfly valves #2 and #3 are not fully
closed, close the valves by adjusting synchronizing screw #2 4.
4-22
FUEL
c. Turn synchronizing screw #1 3 clockwise approximately 7 times until it starts

NOTE:
Butterfly valve #1 should be fully closed.
Butterfly valves #2 and #3 open if the
If butterfly valves #1, #2, and #3 are not
fully closed, close the valves by adjusting
synchronizing screw #1 3.
d. Turn synchronizing screw #3 5 clockwise approximately 7 times until it starts
NOTE:
Butterfly valve #4 should be fully closed.
Butterfly valves #1, #2, and #3 open if the
If all butterfly valves are not fully closed,
close the valves by adjusting synchronizing screw #3 5.
e. Check that all butterfly valves are fully
closed and that they open simultaneously.
#1
#3
#2
#4
NOTE:
If all butterfly valves are not fully closed,
close the valves by repeating steps ad.
f. Turn the throttle stop screw 2 clockwise

approximately 1.5 times until it starts to
contact the throttle lever.
g. Remove the plugs 6.
h. Install the carburetor synchronizer 7 or
vacuum gauge 8.
For USA and Canada

For worldwide
Carburetor synchronizer:
YU-08030
Vacuum gauge:
90890-03094
4-23
FUEL
NOTE:
For best results, use a vacuum gauge
(commercially obtainable), like 9 or 0
shown in the illustration, that has four
adapters.
0
9
i. Install the throttle bodies.

NOTE:
Adjust the throttle body synchronization
with the air filter case uninstalled.
j. Connect the fuel hose and clamp.
k. Connect the Yamaha Diagnostic System.
l. Remove the sub wiring harness from the
air filter case, and then connect it to the
throttle bodies and main wiring harness.
m. Connect the test harness (3 pin) to the
throttle position sensor A.
Test harness (3 pins):
YB-06793
Test harness SMHW099-3
(3 pins):
90890-06793
n. To start the ECM normally, start the

Yamaha Diagnostic System.
B/O
CAUTION:
If the Yamaha Diagnostic System and

ECM are started, fuel can spurt out. Be
sure to connect the fuel hoses and throttle bodies when adjusting the throttle
position sensor.
NOTE:
Use the test connector B to start the ECM
normally only if the Yamaha Diagnostic
System is not available.
Test connector:
YW-06862
Test connector FMY-8:
90890-06862
4-24
FUEL
o. Measure the throttle position sensor output voltage (DC). Adjust the throttle position sensor A position if out of
specification.
Throttle position sensor output
voltage:
Pink (P) Black/orange (B/O)
0.756 0.016 V
NOTE:
To decrease the output voltage, turn the
throttle position sensor clockwise.
Slightly tighten the throttle position screw.
p. Start the engine and let it run at trolling
speed for 20 minutes.
NOTE:
Warm the engine up in the water.
While checking the engine temperature
with the Yamaha Diagnostic System,
warm the engine up until the engine temperature is 50 C (122 F).
q. Adjust the throttle stop screw until trolling
speed is within specification.
1,740
1,720
r/min
1,700
1,680
Trolling speed:
1,660
1,640
1,620
1,600
10
15
20
25 30
35 40 45
50
Season
Temperature
Specified
engine speed
Summer
30 C (86 F)
or more
1,650 r/min
Winter
10 C (50 F)
or less
1,720 r/min
Spring/
Fall
20 C (68 F)
1,680 r/min
r. Adjust each cylinder to the cylinder differences shown in the table using synchronizing screws 35 and using
cylinder #2 as the standard.
4-25
FUEL
Vacuum pressure at trolling

speed:
Cylinder
difference
Cylinder
#1
Example
18 10 mmHg 230 10 mmHg

(2.45
(30.68
1.33 kPa,
1.33 kPa,
0.8 0.4 inHg) 9.1 0.4 inHg)
#2
Standard*0
212 mmHg
(28.23 kPa,
8.3 inHg)
#3
11 10 mmHg 223 10 mmHg

(1.53
(29.76
1.33 kPa,
1.33 kPa,
0.5 0.4 inHg) 8.8 0.4 inHg)
#4
+1.0 10 mmHg 211 10 mmHg

(+0.04
(28.19
1.33 kPa,
1.33 kPa,
0 0.4 inHg) 8.3 0.4 inHg)
Standard*: When setting the specified

engine speed, the value is zero.
NOTE:
Always maintain the specified trolling speed
when making this adjustment.
s. Measure the throttle position sensor output voltage. Adjust the throttle position
sensor position if out of specification.
voltage:
0.756 0.016 V
3. Remove:
Throttle bodies
4. Remove:
Carburetor synchronizer or vacuum
gauge
5. Install:
Plugs
T.
Plug (vacuum pressure):

10 N m (1.0 kgf m, 7.2 ft lb)
6. Install:
Air filter case
Throttle bodies
4-26
FUEL
Fuel pressure measurement

1. Disconnect:
Fuel hose
Refer to Fuel hose disconnection.
2. Install:
Fuel pressure gauge adapter 1
Fuel pressure gauge 2
Fuel pressure gauge adapter:

YW-06842/90890-06842
Fuel pressure gauge:
YB-06766/90890-06786
NOTE:
To connect the fuel pressure gauge adapter,
follow the procedures for connecting a fuel
hose. (Refer to Fuel hose connection.)
3. Start the engine and arrow it to warm up
for several minutes.
4. Measure:
Fuel pressure
Out of specification Replace the fuel
pump module.
Fuel pressure:
310330 kPa
(3.13.3 kgf/cm2, 4547 psi)
5. Remove:
Fuel pressure gauge
Fuel pressure gauge adapter
NOTE:
To disconnect the fuel pressure gauge
adapter, follow the procedures for disconnecting a fuel hose. (Refer to Fuel hose disconnection.)
6. Connect:
Fuel hose
Refer to Fuel hose connection.
4-27
POWR
CHAPTER 5
POWER UNIT
ENGINE UNIT ..................................................................................................5-1
SERVICE POINTS .................................................................................... 5-4
Compression pressure measurement ................................................. 5-4
Oil filter removal and installation .........................................................5-6
Engine unit removal ............................................................................5-6
Shim removal ......................................................................................5-7
Engine mount inspection..................................................................... 5-7
Coupling clearance inspection ............................................................ 5-7
EXHAUST PIPE 3............................................................................................ 5-8
EXHAUST PIPES 1 AND 2............................................................................5-11
EXPLODED DIAGRAM ...........................................................................5-11
REMOVAL AND INSTALLATION CHART .............................................. 5-11
EXHAUST MANIFOLD .................................................................................. 5-13
OIL TANK ...................................................................................................... 5-15
SERVICE POINTS .................................................................................. 5-21
Oil tank removal ................................................................................ 5-21
Oil strainer inspection........................................................................5-22
Oil tank installation ............................................................................5-22
POWR
OIL PUMP...................................................................................................... 5-25

SERVICE POINTS .................................................................................. 5-30
Oil pump inspection...........................................................................5-30
Check valve inspection ..................................................................... 5-30
Oil strainer inspection........................................................................5-31
Oil pump installation..........................................................................5-31
REDUCTION DRIVE GEAR ..........................................................................5-32
SERVICE POINTS .................................................................................. 5-36
Drive coupling removal...................................................................... 5-36
Drive shaft removal ...........................................................................5-36
Bearing removal ................................................................................ 5-36
Oil pump drive shaft inspection ......................................................... 5-37
Drive shaft inspection........................................................................5-37
Bearing installing............................................................................... 5-38
Drive shaft installation ....................................................................... 5-40
Drive coupling installation .................................................................5-40
GENERATOR AND STARTER MOTOR .......................................................5-41
REMOVAL AND INSTALLATION CHART ............................................. 5-41
SERVICE POINTS .................................................................................. 5-46
Flywheel magneto removal ...............................................................5-46
Starter clutch inspection.................................................................... 5-46
Flywheel magneto installation ........................................................... 5-48
CAMSHAFTS.................................................................................................5-49
SERVICE POINTS .................................................................................. 5-55
Camshaft removal ............................................................................. 5-55
Camshaft inspection..........................................................................5-56
Camshaft sprockets inspection ......................................................... 5-58
Timing chain tensioner inspection.....................................................5-58
Camshaft installation.........................................................................5-59
POWR
CYLINDER HEAD.......................................................................................... 5-63
SERVICE POINTS .................................................................................. 5-65
Cylinder head removal ...................................................................... 5-65
Cylinder head inspection................................................................... 5-65
Cylinder head installation .................................................................. 5-66
VALVES AND VALVE SPRINGS.................................................................. 5-68
SERVICE POINTS .................................................................................. 5-70
Valve removal ...................................................................................5-70
Valve spring inspection ..................................................................... 5-71
Valve inspection ................................................................................ 5-71
Valve guide inspection ...................................................................... 5-72
Valve guide replacement................................................................... 5-73
Valve seat inspection ........................................................................5-75
Valve seat reface .............................................................................. 5-76
Valve installation ............................................................................... 5-78
CRANKCASE ................................................................................................5-80
SERVICE POINTS .................................................................................. 5-85
Crankcase disassembly .................................................................... 5-85
Crankcase inspection........................................................................5-86
Timing chain inspection..................................................................... 5-86
Crankcase assembly.........................................................................5-87
CONNECTING RODS AND PISTONS .......................................................... 5-90
SERVICE POINTS .................................................................................. 5-92
Connecting rod and piston removal .................................................. 5-92
Cylinder and piston inspection .......................................................... 5-93
Piston ring inspection ........................................................................5-94
Piston pin inspection .........................................................................5-96
Connecting rod inspection.................................................................5-97
Connecting rod and piston installation .............................................. 5-99
POWR
CRANKSHAFT ............................................................................................5-103
EXPLODED DIAGRAM .........................................................................5-103
REMOVAL AND INSTALLATION CHART ............................................ 5-103
SERVICE POINTS ................................................................................ 5-104
Crankshaft removal .........................................................................5-104
Crankshaft inspection......................................................................5-104
Crankshaft installation..................................................................... 5-107
THERMOSTAT ............................................................................................5-108
SERVICE POINTS ................................................................................ 5-110
Thermostat inspection..................................................................... 5-110
Thermostat installation .................................................................... 5-110
COOLING WATER HOSE ........................................................................... 5-111
POWR
ENGINE UNIT
ENGINE UNIT
EXPLODED DIAGRAM
7.8 N m (0.78 kgf m, 5.6 ft Ib)

6 25 mm
11
4
LT
12
572
10
17 N m (1.7 kgf m, 12 ft Ib)
8 40 mm
LT
17 N m (1.7 kgf m, 12 ft Ib)

8 28 mm
7
15
13
LT
572
271
1
5
14
9
17 N m (1.7 kgf m, 12 ft Ib)

Step
Procedure/Part name
ENGINE UNIT REMOVAL
Engine oil
Qty
Service lid 1
Battery negative and positive lead
Throttle cable and fuel hose
1
2
Water lock and exhaust joint

Oil filter
Bolt
1
4
5-1
Service points
Drain.
Refer to POWER UNIT in Chapter 3.
Refer to FRONT HOOD in Chapter 8.
Refer to ELECTRICAL BOX in Chapter 7.
Refer to FUEL INJECTION SYSTEM in
Chapter 4.
Refer to EXHAUST SYSTEM in Chapter 8.
POWR
ENGINE UNIT
EXPLODED DIAGRAM
7.8 N m (0.78 kgf m, 5.6 ft Ib)

6 25 mm
11
4
LT
12
572
10
17 N m (1.7 kgf m, 12 ft Ib)
8 40 mm
LT
17 N m (1.7 kgf m, 12 ft Ib)

8 28 mm
7
15
13
LT
572
271
1
5
14
9
Step
3
4
5
6
7
8
9
10
11
12
Procedure/Part name
Electrical box
Clamp/cooling water hose
Coupler
Grease hose
Bolt/collar
Coupling cover
Qty
1
1/1
1/1
1/1
1/1
1/1
10
1
1/1
1
5-2
17 N m (1.7 kgf m, 12 ft Ib)
Service points
Cooling water outlet
Cooling water outlet
Cooling water inlet
POWR
ENGINE UNIT
EXPLODED DIAGRAM
7.8 N m (0.78 kgf m, 5.6 ft Ib)

6 25 mm
11
4
LT
12
572
10
17 N m (1.7 kgf m, 12 ft Ib)
8 40 mm
LT
17 N m (1.7 kgf m, 12 ft Ib)

8 28 mm
7
15
13
LT
572
271
1
5
14
9
Step
13
14
15
Procedure/Part name
Bolt/washer
Shim
Engine unit
Qty
4/4
*
1
17 N m (1.7 kgf m, 12 ft Ib)
Service points

*: As required.
5-3
POWR
ENGINE UNIT
SERVICE POINTS
Compression pressure measurement
cylinders.
NOTE:
Insufficient compression pressure will result in
a loss of performance.
1. Measure:
Valve clearance
2. Warm the engine up, and then put the
watercraft in a horizontal position.
3. Remove:
Air filter element
Ignition coils
Spark plugs
CAUTION:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it
from falling into the cylinders.
4. Install:
Compression gauge extension 1
Compression gauge 2
Compression gauge extension:

90890-06582
Compression gauge:
YU-33223-1/90890-03160
5-4
POWR
ENGINE UNIT
E
5. Measure:
Compression pressure
Out of specification Refer to steps (b)
and (c).
Minimum compression pressure
(reference data):
1,150 kPa
(11.5 kgf/cm2, 164 psi)
Measurement steps:
a. With the throttle wide open, crank the
engine until the reading on the compression gauge stabilizes.
NOTE:
The difference in compression pressure
between cylinders should not exceed 100
kPa (1 kgf/cm2, 14 psi).
b. If the compression pressure is extremely
high, check the cylinder head, valve surfaces and piston crown for carbon deposits.
Carbon deposits Eliminate.
c. If the compression pressure is below the
minimum specification, squirt a few drops
of oil into the cylinder and measure
again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading
Diagnosis
Higher than
without oil
Piston ring wear,

piston wear or
damage Repair.
Same as without
oil
Valves, cylinder
head gasket or piston possibly defective Repair.
6. Install:
Spark plug
T.
5-5
Spark plug:
13 N m (1.3 kgf m, 9.4 ft lb)
POWR
ENGINE UNIT
E
7. Install:
Ignition coils
Air filter element
T.
Ignition coils bolt:

7.6 N m (0.76 kgf m, 5.5 ft lb)
LOCTITE 572
2.5 N m (0.25 kgf m, 1.8 ft lb)
LOCTITE 572
Oil filter removal and installation

1. Remove:
Oil filter 1
Oil filter wrench:
YU-38411/90890-01426
1
T.
Oil filter:
17 N m (1.7 kgf m, 12 ft lb)
NOTE:
Install the oil filter with the same special tool
that was used for removal.
Engine unit removal
1. Remove:
Engine unit
Removal steps:
CAUTION:
Lift the engine unit carefully trying not to
hit it on the deck or letting it fall hard on
the hull.
Suspend the engine unit using all three
engine hangers, and then separate the
unit from the engine mount.
Remove the hoist cable from the front
engine hanger and use the two rear
engine hangers to suspend the engine
unit.
Lift the engine unit out vertically while
turning it clockwise.
5-6
POWR
ENGINE UNIT
E
Shim removal
1. Remove:
Shims
NOTE:
To ease reassembly and coupling alignment,
remove the shims and organize them in their
respective groups (e.g., front right, rear left)
prior to removing the mounting bolts.
Engine mount inspection
1. Inspect:
Engine mounts
Refer to ENGINE MOUNT in Chapter
8.
Coupling clearance inspection

1. Measure:
Clearance a
Clearance b
NOTE:
Measure the clearances with a straightedge
and thickness gauge.
Clearance a:
00.5 mm (00.020 in)
Clearance b:
24 mm (0.0790.157 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.
5-7
POWR
EXHAUST PIPE 3
EXHAUST PIPE 3
EXPLODED DIAGRAM
2.0 N m (0.2 kgf m, 1.4 ft Ib)

5th 15 N m (1.5 kgf m, 11 ft Ib)
9th 39 N m (3.9 kgf m, 28 ft Ib)
10 35 mm
1st
2nd 2.0 N m (0.2 kgf m, 1.4 ft Ib)

6th 15 N m (1.5 kgf m, 11 ft Ib)
10th 39 N m (3.9 kgf m, 28 ft Ib)
10 35 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 16 mm
10
4
5
17
18
LT
16
572
13
15 14
LT
242
LT
7
4.4 N m (0.44 kgf m, 3.2 ft Ib)
2nd 4.4 N m (0.44 kgf m, 3.2 ft Ib)
1st
572
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 16 mm
1st
12
11
9
LT
LT
242
242
4th 2.0 N m (0.2 kgf m, 1.4 ft Ib)

8th 15 N m (1.5 kgf m, 11 ft Ib)
12th 39 N m (3.9 kgf m, 28 ft Ib)
10 45 mm
3rd 2.0 N m (0.2 kgf m, 1.4 ft Ib)

7th 15 N m (1.5 kgf m, 11 ft Ib)
11th 39 N m (3.9 kgf m, 28 ft Ib)
10 40 mm

Step
1
2
3
4
5
Procedure/Part name
EXHAUST PIPE 3 REMOVAL
Engine unit
Air filter case
Qty

Bolt
1/1
2/1
2/1
2
1
5-8
Service points
Refer to ENGINE UNIT.
Chapter 4.
For cooling water outlet on stern side
For cooling water pilot outlet on port side
From water jacket
POWR
EXHAUST PIPE 3
EXPLODED DIAGRAM
2.0 N m (0.2 kgf m, 1.4 ft Ib)

5th 15 N m (1.5 kgf m, 11 ft Ib)
9th 39 N m (3.9 kgf m, 28 ft Ib)
10 35 mm
1st
2nd 2.0 N m (0.2 kgf m, 1.4 ft Ib)

6th 15 N m (1.5 kgf m, 11 ft Ib)
10th 39 N m (3.9 kgf m, 28 ft Ib)
10 35 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 16 mm
10
4
5
17
18
LT
16
572
13
15 14
LT
242
LT
7
4.4 N m (0.44 kgf m, 3.2 ft Ib)
2nd 4.4 N m (0.44 kgf m, 3.2 ft Ib)
1st
572
11
LT
242
242
4th 2.0 N m (0.2 kgf m, 1.4 ft Ib)

8th 15 N m (1.5 kgf m, 11 ft Ib)
12th 39 N m (3.9 kgf m, 28 ft Ib)
10 45 mm
7
8
9
10
11
12
13
14
Procedure/Part name
Exhaust joint clamp
Exhaust joint clamp
Bolt
Bolt
Bolt
Collar
Exhaust pipe 3
Bolt
Exhaust pipe end
LT
Step
6
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 16 mm
1st
12
Qty
2
2
1
1
2
1
1
3
1
5-9
3rd 2.0 N m (0.2 kgf m, 1.4 ft Ib)

7th 15 N m (1.5 kgf m, 11 ft Ib)
11th 39 N m (3.9 kgf m, 28 ft Ib)
10 40 mm
Service points
Slide the outer exhaust joint for exhaust
manifold side
NOTE:
Tighten the bolts in the sequence indicated.
POWR
EXHAUST PIPE 3
EXPLODED DIAGRAM
2.0 N m (0.2 kgf m, 1.4 ft Ib)

5th 15 N m (1.5 kgf m, 11 ft Ib)
9th 39 N m (3.9 kgf m, 28 ft Ib)
10 35 mm
1st
2nd 2.0 N m (0.2 kgf m, 1.4 ft Ib)

6th 15 N m (1.5 kgf m, 11 ft Ib)
10th 39 N m (3.9 kgf m, 28 ft Ib)
10 35 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 16 mm
10
4
5
17
18
LT
16
572
13
15 14
LT
242
LT
7
4.4 N m (0.44 kgf m, 3.2 ft Ib)
2nd 4.4 N m (0.44 kgf m, 3.2 ft Ib)
1st
572
11
242
4th 2.0 N m (0.2 kgf m, 1.4 ft Ib)

8th 15 N m (1.5 kgf m, 11 ft Ib)
12th 39 N m (3.9 kgf m, 28 ft Ib)
10 45 mm
Procedure/Part name
Gasket
Inner exhaust joint
Exhaust joint seal
Outer exhaust joint
LT
Step
15
16
17
18
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 16 mm
1st
12
Qty
1
1
1
1
LT
242
3rd 2.0 N m (0.2 kgf m, 1.4 ft Ib)

7th 15 N m (1.5 kgf m, 11 ft Ib)
11th 39 N m (3.9 kgf m, 28 ft Ib)
10 40 mm
Service points
Not reusable
5-10
POWR
EXHAUST PIPES 1 AND 2

EXPLODED DIAGRAM
4th 39 N m (3.9 kgf m, 28 ft Ib)
9th 39 N m (3.9 kgf m, 28 ft Ib)
22 N m (2.2 kgf m, 16 ft Ib)

2nd 22 N m (2.2 kgf m, 16 ft Ib)
3rd 35 N m (3.5 kgf m, 25 ft Ib)
8 75 mm
1st
3rd 39 N m (3.9 kgf m, 28 ft Ib)

8th 39 N m (3.9 kgf m, 28 ft Ib)
39 N m (3.9 kgf m, 28 ft Ib)

6th 39 N m (3.9 kgf m, 28 ft Ib)
1st
13
12
6
4
8
E
5th 39 N m (3.9 kgf m, 28 ft Ib)

10th 39 N m (3.9 kgf m, 28 ft Ib)
2nd 39 N m (3.9 kgf m, 28 ft Ib)
7th 39 N m (3.9 kgf m, 28 ft Ib)
4
11
LT
242
15 N m (1.5 kgf m, 11 ft Ib)

2nd 42 N m (4.2 kgf m, 30 ft Ib)
10 35 mm
1st
LT
242
15 N m (1.5 kgf m, 11 ft Ib)

2nd 42 N m (4.2 kgf m, 30 ft Ib)
8 45 mm
1st
242
LT
10
22 N m (2.2 kgf m, 16 ft Ib)

2nd 22 N m (2.2 kgf m, 16 ft Ib)
3rd 35 N m (3.5 kgf m, 25 ft Ib)
8 125 mm
1st

Step
Procedure/Part name
REMOVAL
Exhaust pipe 3
Generator cover
Qty
Service points
Refer to EXHAUST PIPE 3.
Refer to GENERATOR AND STARTER
MOTOR.
1
2
3
4
Bolt
Bolt
Exhaust pipe stay
Nut
2
1
1
5
Exhaust pipe 2
5-11
NOTE:
Tighten the nuts in the sequence indicated.
POWR
EXPLODED DIAGRAM
4th 39 N m (3.9 kgf m, 28 ft Ib)
9th 39 N m (3.9 kgf m, 28 ft Ib)
22 N m (2.2 kgf m, 16 ft Ib)

2nd 22 N m (2.2 kgf m, 16 ft Ib)
3rd 35 N m (3.5 kgf m, 25 ft Ib)
8 75 mm
1st
3rd 39 N m (3.9 kgf m, 28 ft Ib)

8th 39 N m (3.9 kgf m, 28 ft Ib)
39 N m (3.9 kgf m, 28 ft Ib)

6th 39 N m (3.9 kgf m, 28 ft Ib)
1st
13
12
6
4
8
E
5th 39 N m (3.9 kgf m, 28 ft Ib)

10th 39 N m (3.9 kgf m, 28 ft Ib)
2nd 39 N m (3.9 kgf m, 28 ft Ib)
7th 39 N m (3.9 kgf m, 28 ft Ib)
4
11
242
15 N m (1.5 kgf m, 11 ft Ib)

2nd 42 N m (4.2 kgf m, 30 ft Ib)
10 35 mm
1st
LT
15 N m (1.5 kgf m, 11 ft Ib)

2nd 42 N m (4.2 kgf m, 30 ft Ib)
8 45 mm
Procedure/Part name
Gasket
Dowel pin
Bolt
Bolt
Exhaust pipe 1
Gasket
Dowel pin
Qty
1
2
2/2
4
6
1
1
2
3
E
242
1st
Step
6
7
8
9
10
11
12
13
LT
242
LT
10
22 N m (2.2 kgf m, 16 ft Ib)

2nd 22 N m (2.2 kgf m, 16 ft Ib)
3rd 35 N m (3.5 kgf m, 25 ft Ib)
8 125 mm
1st
Service points
Not reusable
From cooling water inlet
Not reusable
5-12
POWR
EXHAUST MANIFOLD
EXHAUST MANIFOLD
EXPLODED DIAGRAM
a
1
5
LT
242
10
LT
242
6
3
LT
10
7
242
LT
242
22 N m (2.2 kgf m, 16 ft Ib)

2nd 22 N m (2.2 kgf m, 16 ft Ib)
3rd 35 N m (3.5 kgf m, 25 ft Ib)
8 70 mm
1st
22 N m (2.2 kgf m, 16 ft Ib)

2nd 22 N m (2.2 kgf m, 16 ft Ib)
3rd 35 N m (3.5 kgf m, 25 ft Ib)
8 55 mm
1st
22 N m (2.2 kgf m, 16 ft Ib)

2nd 22 N m (2.2 kgf m, 16 ft Ib)
3rd 35 N m (3.5 kgf m, 25 ft Ib)
8 95 mm
1st
22 N m (2.2 kgf m, 16 ft Ib)

2nd 22 N m (2.2 kgf m, 16 ft Ib)
3rd 35 N m (3.5 kgf m, 25 ft Ib)
8 95 mm
1st

Step
Procedure/Part name
EXHAUST MANIFOLD REMOVAL
Exhaust pipes 1 and 2
Joint assembly
Qty
Service points
Refer to EXHAUST PIPES 1 AND 2.
To cylinder block
NOTE:
Install the cooling water hose with the white
mark a facing up.
2
3
4
5
Bolt
Bolt
Exhaust manifold 1
Dowel pin
2
4
1
2
5-13
POWR
EXHAUST MANIFOLD
EXPLODED DIAGRAM
a
1
5
LT
242
10
LT
242
6
3
LT
242
LT
242
22 N m (2.2 kgf m, 16 ft Ib)

2nd 22 N m (2.2 kgf m, 16 ft Ib)
3rd 35 N m (3.5 kgf m, 25 ft Ib)
8 70 mm
1st
22 N m (2.2 kgf m, 16 ft Ib)

2nd 22 N m (2.2 kgf m, 16 ft Ib)
3rd 35 N m (3.5 kgf m, 25 ft Ib)
8 55 mm
1st
22 N m (2.2 kgf m, 16 ft Ib)

2nd 22 N m (2.2 kgf m, 16 ft Ib)
3rd 35 N m (3.5 kgf m, 25 ft Ib)
8 95 mm
1st
Step
6
7
8
9
10
10
Procedure/Part name
Bolt
Bolt
Exhaust manifold 2
Gasket
Dowel pin
22 N m (2.2 kgf m, 16 ft Ib)

2nd 22 N m (2.2 kgf m, 16 ft Ib)
3rd 35 N m (3.5 kgf m, 25 ft Ib)
8 95 mm
1st
Qty
1
4
1
1
2
Service points
Not reusable
5-14
POWR
OIL TANK
OIL TANK
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib)
1st
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 35 mm
2.0 N m (0.2 kgf m, 1.4 ft Ib)

2nd 15 N m (1.5 kgf m, 11 ft Ib)
3rd 39 N m (3.9 kgf m, 28 ft Ib)
1st
24
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 20 mm
LT
572
22
LT
11
15 14
572
13
5
8
LT
572
18
LT
572
26
12
10
27
25
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 30 mm
10 70 mm
1st 2.0 N m (0.2 kgf m, 1.4 ft Ib)
LT
572
16
19
LT
27
572
LT
23
6 12 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)
1st
2nd 15 N m (1.5 kgf m, 11 ft Ib)

3rd 39 N m (3.9 kgf m, 28 ft Ib)
28
17
572
21
20
15 N m (1.5 kgf m, 11 ft Ib)

2nd 39 N m (3.9 kgf m, 28 ft Ib)
6 16 mm
8 85 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)
1st

Step
1
2
3
4
5
6
Procedure/Part name
OIL TANK REMOVAL
Engine unit
Air filter case
Thermostat housing
Bolt
Water jacket
Gasket
Clamp/breather hose
Clamp/breather hose
Qty
1/1
4
1
1
2/1
2/1
5-15
Service points
Chapter 4.
Refer to THERMOSTAT.
To exhaust joint
Not reusable
To oil pump
POWR
OIL TANK
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib)
1st
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 35 mm
2.0 N m (0.2 kgf m, 1.4 ft Ib)

2nd 15 N m (1.5 kgf m, 11 ft Ib)
3rd 39 N m (3.9 kgf m, 28 ft Ib)
1st
24
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 20 mm
LT
572
22
LT
11
15 14
572
13
5
8
LT
572
18
LT
572
26
12
10
27
25
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 30 mm
10 70 mm
1st 2.0 N m (0.2 kgf m, 1.4 ft Ib)
LT
572
Step
7
8
9
10
11
12
13
14
15
16
17
Procedure/Part name
16
19
LT
27
572
LT
23
6 12 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)
1st
2nd 15 N m (1.5 kgf m, 11 ft Ib)

3rd 39 N m (3.9 kgf m, 28 ft Ib)
28
17
572
21
20
15 N m (1.5 kgf m, 11 ft Ib)

2nd 39 N m (3.9 kgf m, 28 ft Ib)
6 16 mm
8 85 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)
1st
Bolt
Collar
Oil separator
Clamp/breather hose
Qty
2
2
1
1/1
Clamp/breather hose
Bolt
Collar
Band
Bolt
Cover
1/1
1/1
1
1
1
3
1
5-16
Service points
To air filter case

Mark a
From cylinder head cover
POWR
OIL TANK
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib)
1st
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 35 mm
2.0 N m (0.2 kgf m, 1.4 ft Ib)

2nd 15 N m (1.5 kgf m, 11 ft Ib)
3rd 39 N m (3.9 kgf m, 28 ft Ib)
1st
24
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 20 mm
LT
572
22
LT
11
15 14
572
13
5
8
LT
572
18
LT
572
26
12
10
27
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 30 mm
10 70 mm
1st 2.0 N m (0.2 kgf m, 1.4 ft Ib)
LT
572
Step
18
19
20
21
22
23
24
25
26
27
28
Procedure/Part name
Gasket
Bolt
Ground lead
Bolt
Nut
Bolt
Oil tank
Oil tank stay
Pin
O-ring
Connector
16
19
LT
27
572
LT
23
6 12 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)
1st
2nd 15 N m (1.5 kgf m, 11 ft Ib)

3rd 39 N m (3.9 kgf m, 28 ft Ib)
28
17
572
21
25
20
15 N m (1.5 kgf m, 11 ft Ib)

2nd 39 N m (3.9 kgf m, 28 ft Ib)
6 16 mm
8 85 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)
1st
Qty
1
2
2
2
2
5
1
1
2
4
2
Service points
Not reusable
Not reusable
5-17
POWR
OIL TANK
EXPLODED DIAGRAM
5
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 16 mm
3
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 25 mm
1st
1st
6
8
1.9 N m (0.19 kgf m, 1.4 ft Ib)

2nd 4.4 N m (0.44 kgf m, 3.2 ft Ib)
5 14 mm
1st
LT
LT
572
9
13
12
11
572
18
14
E
15
LT
572
5 35 mm
16
10
1.9 N m (0.19 kgf m, 1.4 ft Ib)

2nd 4.4 N m (0.44 kgf m, 3.2 ft Ib)
17
1st
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 14 mm
1st
19
20
22
23
21
1
LT
572
6 20 mm
18
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
1st
20
LT
572
3.7 N m (0.37 kgf m, 2.7 ft Ib)

19 2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
4 12 mm
6 20 mm
3.7 N m (0.37 kgf m, 2.7 ft Ib)
1st

Step
1
2
3
4
5
6
7
8
9
10
Procedure/Part name
OIL TANK DISASSEMBLY
Bolt/washer
Bracket/grommet
Bolt
Hunger
Oil tank filler cap
Packing
Bolt
Oil tank cover
Gasket
Bolt
Qty
2/2
2/2
4
2
1
1
8
1
1
10
5-18
Service points
Not reusable
POWR
OIL TANK
EXPLODED DIAGRAM
5
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 16 mm
3
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 25 mm
1st
1st
6
8
1.9 N m (0.19 kgf m, 1.4 ft Ib)

2nd 4.4 N m (0.44 kgf m, 3.2 ft Ib)
5 14 mm
1st
LT
LT
572
9
13
12
11
572
18
14
E
15
LT
572
5 35 mm
16
10
1.9 N m (0.19 kgf m, 1.4 ft Ib)

2nd 4.4 N m (0.44 kgf m, 3.2 ft Ib)
17
1st
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 14 mm
1st
19
20
22
23
21
1
LT
572
6 20 mm
18
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
1st
Step
11
12
13
14
15
16
17
18
19
20
Procedure/Part name
Oil breather plate 1
Gasket
Bolt
Baffle plate
Bolt
Oil strainer
Bolt
Oil cooler cover
Gasket
20
LT
572
3.7 N m (0.37 kgf m, 2.7 ft Ib)

19 2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
4 12 mm
6 20 mm
3.7 N m (0.37 kgf m, 2.7 ft Ib)
1st
Qty
1
1
1
3
1
2
1
24
2
2
5-19
Service points
Not reusable
Not reusable
POWR
OIL TANK
EXPLODED DIAGRAM
5
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 16 mm
3
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 25 mm
1st
1st
6
8
1.9 N m (0.19 kgf m, 1.4 ft Ib)

2nd 4.4 N m (0.44 kgf m, 3.2 ft Ib)
5 14 mm
1st
LT
LT
572
9
13
12
11
572
18
14
E
15
LT
572
E
5 35 mm
16
10
1.9 N m (0.19 kgf m, 1.4 ft Ib)

2nd 4.4 N m (0.44 kgf m, 3.2 ft Ib)
17
1st
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 14 mm
1st
19
20
22
23
21
1
LT
572
6 20 mm
18
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
1st
Step
21
22
23
Procedure/Part name
Screw
Anode
Oil tank
20
LT
572
3.7 N m (0.37 kgf m, 2.7 ft Ib)

19 2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
4 12 mm
6 20 mm
3.7 N m (0.37 kgf m, 2.7 ft Ib)
1st
Qty
1
1
1
Service points

assembly.
5-20
POWR
OIL TANK
SERVICE POINTS
Oil tank removal
1. Remove:
Oil tank
NOTE:
Loosen the oil tank bolts and nuts in the
sequence shown.
3
1
2
4
5
6
2. Remove:
Oil tank cover
Gasket
3
6
NOTE:
Loosen the oil tank cover bolts in the sequence
shown.
3. Remove:
Gasket
2
8
NOTE:
Loosen the oil breather plate bolts in the
sequence shown.
5-21
POWR
OIL TANK
E
4. Remove:
Oil cooler covers
Gaskets
NOTE:
Loosen the oil cooler cover bolts in the
sequence shown.
12
5
10
11
Oil strainer inspection

1. Check:
Oil strainer 1
Damage Replace.
Contaminants Clean.
Oil tank installation

1. Install:
Gaskets
Oil cooler covers
12
NOTE:
Tighten the oil cooler bolts in the sequence
shown.
11
6
T.
10
8
3
5-22
Oil cooler cover bolt:

1st:
3.7 N m
(0.37 kgf m, 2.7 ft lb)
2nd:
7.6 N m
(0.76 kgf m, 5.5 ft lb)
LOCTITE 572
POWR
OIL TANK
E
2. Install:
Gasket
7
1
NOTE:
Tighten the oil breather plate bolts in the
sequence shown.
T.
3. Install:
Gasket
Oil tank cover
6
3
Oil breather plate bolt:

1st:
1.9 N m
(0.19 kgf m, 1.4 ft lb)
2nd:
4.4 N m
(0.44 kgf m, 3.2 ft lb)
NOTE:
Tighten the oil tank cover bolts in the
sequence shown.
2
T.
5-23
Oil tank cover bolt:

1st:
3.7 N m
(0.37 kgf m, 2.7 ft lb)
2nd:
7.6 N m
(0.76 kgf m, 5.5 ft lb)
LOCTITE 572
POWR
OIL TANK
E
4. Install:
Oil tank
NOTE:
Tighten the oil tank nuts and bolts in the
sequence shown.
2
7
3
T.
8
6
5
1
2
3
4
5-24
Bolt 1:
1st:
15 N m (1.5 kgf m, 11 ft lb)
2nd:
39 N m (3.9 kgf m, 28 ft lb)
LOCTITE 572
Nut 2, bolt 3:
1st:
2.0 N m (0.2 kgf m, 1.4 ft lb)
2nd:
15 N m (1.5 kgf m, 11 ft lb)
3rd:
39 N m (3.9 kgf m, 28 ft lb)
LOCTITE 572
POWR
OIL PUMP
OIL PUMP
EXPLODED DIAGRAM
1st
1st
15 N m (1.5 kgf m, 11 ft Ib)
2nd 28 N m (2.8 kgf m, 20 ft Ib)

8 100 mm
15 N m (1.5 kgf m, 11 ft Ib)
2nd 28 N m (2.8 kgf m, 20 ft Ib)

8 80 mm
10 N m (1.0 kgf m, 7.2 ft Ib)
6 25 mm
LT
572
LT
572
1st
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 16 mm
LT
572
7
9
1
6
8
18 N m (1.8 kgf m, 13 ft Ib)
8 12 mm
9
1st
10
15 N m (1.5 kgf m, 11 ft Ib)
2nd 28 N m (2.8 kgf m, 20 ft Ib)

8 130 mm

Step
1
2
3
4
5
6
7
8
Procedure/Part name
OIL PUMP ASSEMBLY
REMOVAL
Oil tank
Drain plug/washer
Bolt
Bolt
Bolt
Bolt
Oil pump assembly
Gasket
Pin
Qty
1/1
6
1
1
2
1
1
2
5-25
Service points
Refer to OIL TANK.
Drain engine oil.
Not reusable
POWR
OIL PUMP
EXPLODED DIAGRAM
1st
1st
15 N m (1.5 kgf m, 11 ft Ib)
2nd 28 N m (2.8 kgf m, 20 ft Ib)

8 100 mm
15 N m (1.5 kgf m, 11 ft Ib)
2nd 28 N m (2.8 kgf m, 20 ft Ib)

8 80 mm
10 N m (1.0 kgf m, 7.2 ft Ib)
6 25 mm
LT
572
LT
572
1st
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 16 mm
LT
572
7
9
1
6
8
18 N m (1.8 kgf m, 13 ft Ib)
8 12 mm
9
1st
10
Step
9
10
Procedure/Part name
Bolt
Strainer
15 N m (1.5 kgf m, 11 ft Ib)
2nd 28 N m (2.8 kgf m, 20 ft Ib)

8 130 mm
Qty
2
1
Service points
5-26
POWR
OIL PUMP
EXPLODED DIAGRAM
2.0 N m (0.2 kgf m, 1.4 ft Ib)
4 12 mm
13
14
12
15
6
16
19
9
10
10
20 N m (2.0 kgf m, 14 ft Ib)
8 70 mm
9
17
22
11
23
5
3
2
21
18
20
20 N m (2.0 kgf m, 14 ft Ib)

8 20 mm

Step
1
2
3
4
5
6
7
8
9
10
Procedure/Part name
OIL PUMP DISASSEMBLY
Bolt
Bolt
Oil pump housing cover 1
Gasket
Oil pump housing 1
Check valve assembly
Oil pump housing 2
Gasket
Outer rotor (scavenge)
Inner rotor (scavenge)
Qty
1
3
1
1
1
1
1
1
2
2
5-27
Service points
Not reusable
Not reusable
POWR
OIL PUMP
EXPLODED DIAGRAM
2.0 N m (0.2 kgf m, 1.4 ft Ib)
4 12 mm
13
14
12
15
6
16
19
9
10
10
20 N m (2.0 kgf m, 14 ft Ib)
8 70 mm
9
17
22
11
23
5
3
2
21
18
20
Step
11
12
13
14
15
16
17
18
19
20
21
20 N m (2.0 kgf m, 14 ft Ib)

8 20 mm
Procedure/Part name
Pin
Screw
Oil pump housing cover 2
Gasket
Spring
Plunger
Pin
Pin
Oil pump shaft
Inner rotor (feed)
Outer rotor (feed)
Qty
1
1
1
1
1
1
1
1
1
1
1
5-28
Service points
Not reusable
POWR
OIL PUMP
EXPLODED DIAGRAM
2.0 N m (0.2 kgf m, 1.4 ft Ib)
4 12 mm
13
14
12
15
6
16
19
9
10
10
20 N m (2.0 kgf m, 14 ft Ib)
8 70 mm
9
17
22
11
23
5
3
2
21
18
20
Step
22
23
20 N m (2.0 kgf m, 14 ft Ib)

8 20 mm
Procedure/Part name
Check valve seat
Oil seal
Qty
1
1
5-29
Service points
Not reusable
assembly.
POWR
OIL PUMP
SERVICE POINTS
Oil pump inspection
1. Check:
Oil pump housing cover 1 1
Oil pump housing cover 2 2
Oil pump housing 1 3
Oil pump housing 2 4
Cracks/damage/wear Replace the
defective part(s).
2. Measure:
Inner-rotor-to-outer-rotor-tip clearance
a
Outer-rotor-to-oil-pump-housing
clearance b
Out of specification Replace the oil
pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance a:
0.090.15 mm (0.00350.0059 in)
clearance b (scavenge pump):
0.090.15 mm (0.00350.0059 in)
clearance b (feed pump):
0.090.17 mm (0.00350.0067 in)
3. Check:
Oil pump operation
Rough movement Replace the defective part(s).
Check valve inspection

1. Check:
Check valve seat 1
Check valve body 2
Check valve 3
Spring 4
Damage/wear Replace the defective
part(s).
5-30
POWR
OIL PUMP
E
Oil strainer inspection
1. Check:
Oil strainer 1
Damage Replace.
Contaminants Clean.
Oil pump installation

1. Install:
Oil pump assembly
NOTE:
Align the projection a on the oil pump shaft
with the slit b on the oil pump driven gear
shaft.
b
a
T.
5-31
Oil pump assembly bolt:

M6:
10 N m (1.0 kgf m, 7.2 ft lb)
LOCTITE 572
M8:
1st:
15 N m
(1.5 kgf m, 11 ft lb)
2nd:
28 N m
(2.8 kgf m, 20 ft lb)
LOCTITE 572
POWR
REDUCTION DRIVE GEAR

EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 55 mm
1st
15 N m (1.5 kgf m, 11 ft Ib)

2nd 28 N m (2.8 kgf m, 20 ft Ib)
8 40 mm
1st
8
7
LT
572
11
3
1
9
LT
10
11
572
9
8
2
6
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 35 mm
LT
1st
572
4
LT
15 N m (1.5 kgf m, 11 ft Ib)

2nd 28 N m (2.8 kgf m, 20 ft Ib)
8 70 mm
1st
572
LT
12
572
15 N m (1.5 kgf m, 11 ft Ib)

2nd 28 N m (2.8 kgf m, 20 ft Ib)
8 100 mm
1st
28 N m (2.8 kgf m, 20 ft Ib)

Step
1
2
3
4
5
Procedure/Part name
REMOVAL
Generator cover
Oil pump
Bolt
Bolt
Bolt
Bolt
Bolt
Qty
Service points
MOTOR.
Refer to OIL PUMP.
1
1
1
3
1
5-32
POWR
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 55 mm
1st
15 N m (1.5 kgf m, 11 ft Ib)

2nd 28 N m (2.8 kgf m, 20 ft Ib)
8 40 mm
1st
8
7
LT
572
11
3
1
9
LT
10
11
572
9
8
2
6
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 35 mm
LT
1st
572
4
LT
15 N m (1.5 kgf m, 11 ft Ib)

2nd 28 N m (2.8 kgf m, 20 ft Ib)
8 70 mm
1st
572
LT
12
572
15 N m (1.5 kgf m, 11 ft Ib)

2nd 28 N m (2.8 kgf m, 20 ft Ib)
8 100 mm
1st
28 N m (2.8 kgf m, 20 ft Ib)
Step
6
7
8
9
10
11
12
Procedure/Part name
assembly
Gasket
Pin
Circlip
Reduction drive gear
Washer
Drive coupling
Qty
1
1
2
2
1
2
1
Service points
Not reusable
Not reusable
5-33
POWR
EXPLODED DIAGRAM
*1
3
4
8
7
5 10 mm
11
5
2
*1
10
9
1
E

Step
1
2
3
4
5
6
7
8
*1
Procedure/Part name
DISASSEMBLY
Oil pump drive shaft
Drive shaft
Collar
Oil seal
Circlip
Bearing
Collar
Bearing
Qty
1
1
1
2
1
1
1
1
: EPNOC grease AP #0
5-34
Service points
Not reusable
Not reusable
Not reusable
Not reusable
POWR
EXPLODED DIAGRAM
*1
3
4
8
7
5 10 mm
11
5
2
*1
10
9
1
E
Step
9
10
11
Procedure/Part name
Circlip
Bearing
Qty
1
1
1
Service points
Not reusable
Not reusable
assembly.
*1
5-35
POWR
SERVICE POINTS
Drive coupling removal
1. Remove:
Reduction drive gear housing
1
4
2. Remove:
Drive coupling 1
NOTE:
While holding the drive shaft 2 with the rotor
holder 3, loosen the drive coupling with the
coupler wrench 4.
3
2
Coupler wrench:
YW-06551/90890-06551
Universal magneto and rotor
holder:
YU-01235
Rotor holder:
90890-01235
Drive shaft removal
1. Remove:
Drive shaft
NOTE:
Press in the direction of the arrow.
Bearing removal
1. Remove:
Circlip
Rear bearing
Collar
Front bearing
NOTE:
Remove the front bearing, spacer, and rear
bearing using a press.
Driver handlelarge:
YB-06071
Driver rod L3:
90890-06652
Bearing housing needle bearing
installer:
YB-06111
Needle bearing attachment:
90890-06653
For USA and Canada

For worldwide
5-36
POWR
2. Remove:
Circlip
Reduction drive gear bearing
Slide hammer and adapters:

YB-06096
Stopper guide plate:
90890-06501
Bearing puller assembly:
90890-06535
Stopper guide stand:
90890-06538
For USA and Canada

For worldwide
Oil pump drive shaft inspection

1. Check:
Oil pump drive shaft 1
Cracks/damage/wear Replace.
Drive shaft inspection

1. Check:
Drive shaft 1
5-37
POWR
Bearing installing
1. Install:
Reduction drive gear bearing
NOTE:
Install the reduction driver gear bearing using
a press.
Driver handlelarge:
YB-06071
Driver rod LS:
90890-06606
Outer race installerforward
gear:
YB-06085
Ball bearing attachment:
90890-06631
2. Install:
Front bearing
NOTE:
Install the front bearing using a press.
Driver rod LS:
90890-06606
Forward gear bearing cup
installer:
YB-06726-B
90890-06657
For USA and Canada

For worldwide
5-38
POWR
3. Install:
Collar
Rear bearing
NOTE:
Install the front bearing using a press.
Before installing the rear bearing, hold both
the inner and outer races of the front bearing
in place as shown with a pipe that is at least
40 mm (1.57 in) long and has an outer diameter of 70 mm (2.76 in) and an inner diameter of 30 mm (1.18 in).
Driver rod LS:

90890-06606
gear:
YB-06085
Bearing outer race attachment:
90890-06624
For USA and Canada
For worldwide
4. Install:
Oil seals
Driver handlelarge:
YB-06071
Driver rod LS:
90890-06606
gear:
YB-06085
90890-06624
For USA and Canada

For worldwide
Distance a:
17.9 0.2 mm (0.70 0.01 in)
Distance b:
9.3 0.2 mm (0.37 0.01 in)
5-39
POWR
Drive shaft installation

1. Install:
Drive shaft
Collar
NOTE:
Press the into the reduction drive gear case
with a pipe that is more than 30 mm (1.18 in)
long, and which has an outer diameter of
approximately 35 mm (1.97 in) and an inner
diameter of approximately 28 0.5 mm (1.10
0.02 in).
Drive coupling installation

1. Install:
Drive coupling 1
1
4
NOTE:
While holding the drive shaft 2 with the rotor
holder 3, tighten the drive coupling with the
coupler wrench 4.
Coupler wrench:
YW-06551/90890-06551
holder:
YU-01235
Rotor holder:
90890-01235
3
2
2. Install:
Reduction drive gear housing
5-40
POWR
GENERATOR AND STARTER MOTOR

EXPLODED DIAGRAM
18 N m (1.8 kgf m, 13 ft Ib)

8 30 mm
A
4.9 N m (0.49 kgf m, 3.5 ft Ib)
1
2
15 N m (1.5 kgf m, 11 ft Ib)

2nd 50 N m (5.0 kgf m, 36 ft Ib)
1st
14
5
21
6
15
75 N m (7.5 kgf m, 54 ft Ib)
10 47 mm
12
20
19
17
16
8
A
LT
572
E
18
7
E
9
LT
10
572
11
24 N m (2.4 kgf m, 17 ft Ib)

8 20 mm
13
15 N m (1.5 kgf m, 11 ft Ib)

2nd 50 N m (5.0 kgf m, 36 ft Ib)
10 60 mm
1st

Step
1
2
3
4
5
6
7
Procedure/Part name
GENERATOR COVER AND
FLYWHEEL MAGNETO
REMOVAL
Engine unit
Nut/washer
Starter motor lead
Bolt
Battery negative lead
Starter motor
Band
Qty
Service points

1/1
1
2
1
1
1
1
5-41
POWR
EXPLODED DIAGRAM
18 N m (1.8 kgf m, 13 ft Ib)

8 30 mm
A
4.9 N m (0.49 kgf m, 3.5 ft Ib)
1
2
15 N m (1.5 kgf m, 11 ft Ib)

2nd 50 N m (5.0 kgf m, 36 ft Ib)
1st
14
5
21
6
15
75 N m (7.5 kgf m, 54 ft Ib)
10 47 mm
12
20
19
17
16
8
A
LT
572
E
18
7
E
9
LT
10
572
11
24 N m (2.4 kgf m, 17 ft Ib)

8 20 mm
13
15 N m (1.5 kgf m, 11 ft Ib)

2nd 50 N m (5.0 kgf m, 36 ft Ib)
10 60 mm
1st
Step
8
9
10
11
12
13
14
15
16
17
18
Procedure/Part name
Pulser coil coupler
Nut
Bolt
Generator cover
Dowel pin
Gasket
Idle gear shaft
Idle gear
Bolt/washer
Flywheel magneto
Bolt
Qty
1
2
8
1
2
1
1
1
1/1
1
6
5-42
Service points
Not reusable
Not reusable
POWR
EXPLODED DIAGRAM
18 N m (1.8 kgf m, 13 ft Ib)

8 30 mm
A
4.9 N m (0.49 kgf m, 3.5 ft Ib)
1
2
15 N m (1.5 kgf m, 11 ft Ib)

2nd 50 N m (5.0 kgf m, 36 ft Ib)
1st
14
5
21
6
15
75 N m (7.5 kgf m, 54 ft Ib)
10 47 mm
12
20
19
17
16
8
A
LT
572
E
18
7
E
9
LT
10
572
11
24 N m (2.4 kgf m, 17 ft Ib)

8 20 mm
13
15 N m (1.5 kgf m, 11 ft Ib)

2nd 50 N m (5.0 kgf m, 36 ft Ib)
10 60 mm
1st
Step
19
20
21
Procedure/Part name
Starter clutch
Starter gear
Woodruff key
Qty
1
1
1
Service points
5-43
POWR
EXPLODED DIAGRAM
4.9 N m (0.49 kgf m, 3.5 ft Ib)

5 10 mm
LT
242
7
1
LT
242
6
3
3
2
5
LT
LT
242
242
6 14 mm
14 N m (1.4 kgf m, 10 ft Ib)
5 14 mm
4.9 N m (0.49 kgf m, 3.5 ft Ib)
6 33 mm
14 N m (1.4 kgf m, 10 ft Ib)

Step
1
2
3
Procedure/Part name
GENERATOR DISASSEMBLY
Bolt/washer
Bolt
Pickup coil
Bolt
Qty
3/3
4
2
5-44
Service points
NOTE:
There washers holds the pickup coil lead.
Make sure to not pitch the lead between the
projection and the washer when installing
the bolt.
POWR
EXPLODED DIAGRAM
4.9 N m (0.49 kgf m, 3.5 ft Ib)

5 10 mm
LT
242
7
1
LT
242
6
3
3
2
5
LT
LT
242
242
6 14 mm
14 N m (1.4 kgf m, 10 ft Ib)
5 14 mm
4.9 N m (0.49 kgf m, 3.5 ft Ib)
6 33 mm
14 N m (1.4 kgf m, 10 ft Ib)
Step
5
6
7
Procedure/Part name
Holder
Bolt
Lighting coil
Qty
1
3
1
Service points

assembly.
5-45
POWR
SERVICE POINTS
Flywheel magneto removal
1. Remove:
Flywheel magneto bolt 1
Washer
NOTE:
While holding the flywheel magneto 2 with the
sheave holder 3, loosen the flywheel magneto
bolt.
Sheave holder:
YS-01880-A/90890-01701
2. Remove:
Flywheel magneto 1
Woodruff key
NOTE:
While holding the flywheel magneto with
sheave holder 2, remove the flywheel magneto with the rotor puller 3.
Rotor puller:
YM-01082/90890-01080
Starter clutch inspection

1. Check:
Starter clutch rollers 1
5-46
POWR
2. Check:
Starter clutch 1
Starter gear 2
Burrs/chips/roughness/wear Replace
the defective part(s).
2
a
3. Check:
Starter clutch gears contacting surfaces
a
Damage/pitting/wear Replace the
starter clutch gear.
4. Check:
Starter clutch operation
Checking steps:
Install the starter gear 1 onto the starter
clutch 2 and hold the starter clutch.
When turning the starter gear clockwise
, it should turn freely, otherwise the
starter clutch is faulty and must be
replaced.
When turning the starter gear counterclockwise , the starter clutch and the
starter gear should engage, otherwise
the starter clutch is faulty and must be
replaced.
5-47
POWR
Flywheel magneto installation

1. Install:
Woodruff key
Flywheel magneto
Washer
Flywheel magneto bolt
NOTE:
Clean the tapered portion of the crankshaft
and the flywheel magneto hub.
When installing the flywheel magneto, make
sure the woodruff key is properly seated in
the keyway of the crankshaft.
Lubricate the flywheel magneto bolt and
washer with engine oil.
2. Tighten:
Flywheel magneto bolt 1
NOTE:
While holding the flywheel magneto 2 with the
sheave holder 3, tighten the flywheel magneto bolt.
T.
Flywheel magneto bolt:

75 N m (7.5 kgf m, 54 ft lb)
Sheave holder:
YS-01880-A/90890-01701
CAUTION:
Do not reuse the flywheel magneto bolt and
washer, always replace them with new
ones.
5-48
POWR
CAMSHAFTS
CAMSHAFTS
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 16 mm
1st
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 16 mm
10 N m (1.0 kgf m, 7.2 ft Ib)

6 16 mm
6 16 mm
12
a
4
14
13
LT
LT
10
17
572
11
572
19
15
16
E
GM
18
12 N m (1.2 kgf m, 8.7 ft Ib)
6 22 mm
GM
13 N m (1.3 kgf m, 9.4 ft Ib)

Step
Procedure/Part name
CYLINDER HEAD COVER
REMOVAL
Air filter case
Qty
1
2
3
4
Bolt
Ignition coil
Spark plug
Clamp/breather hose
4
4
4
1/1
5
6
Bolt
Cam position sensor
1
1
Service points
Chapter 4.
5-49
To oil tank
Paint mark a
POWR
CAMSHAFTS
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 16 mm
1st
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 16 mm
10 N m (1.0 kgf m, 7.2 ft Ib)

6 16 mm
6 16 mm
12
a
4
14
13
LT
LT
10
17
572
11
572
19
15
16
E
GM
18
12 N m (1.2 kgf m, 8.7 ft Ib)
6 22 mm
GM
13 N m (1.3 kgf m, 9.4 ft Ib)
Step
7
8
9
10
11
12
13
14
15
16
17
Procedure/Part name
Rubber seal
Bolt
Cooling water pipe
O-ring
Bolt
Band
Collar
Bolt
Rubber mount
Cylinder head cover
Qty
1/1
1
1
1
1
1
1
1
6
6
1
5-50
Service points
To thermostat
Not reusable
POWR
CAMSHAFTS
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 16 mm
1st
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 16 mm
10 N m (1.0 kgf m, 7.2 ft Ib)

6 16 mm
6 16 mm
12
a
4
14
13
LT
LT
10
17
572
11
572
19
15
16
E
GM
18
12 N m (1.2 kgf m, 8.7 ft Ib)
6 22 mm
GM
13 N m (1.3 kgf m, 9.4 ft Ib)
Step
18
19
Procedure/Part name
Timing chain guide (top side)
Qty
1
1
Service points
Not reusable
5-51
POWR
CAMSHAFTS
EXPLODED DIAGRAM
6 35 mm
10 N m (1.0 kgf m, 7.2 ft Ib)
10
11
10
11
10
11
24 N m (2.4 kgf m, 17 ft Ib)

7 11 mm
E
10 N m (1.0 kgf m, 7.2 ft Ib)

6 35 mm
17
16
12
18
24 N m (2.4 kgf m, 17 ft Ib)

7 11 mm
14
8
M
13
20
15
19
10 N m (1.0 kgf m, 7.2 ft Ib)
6 8 mm
2
5
1
4
6 25 mm
10 N m (1.0 kgf m, 7.2 ft Ib)

Step
1
2
3
4
Procedure/Part name
CAMSHAFT REMOVAL
Cylinder head cover
Cap bolt
Gasket
Bolt
Qty
Service points
Refer to REDUCTION DRIVE GEAR.
NOTE:
When removing camshafts it is not necessary to remove the reduction drive gear
case.
1
1
2
1
5-52
Not reusable
POWR
CAMSHAFTS
EXPLODED DIAGRAM
6 35 mm
10 N m (1.0 kgf m, 7.2 ft Ib)
10
11
10
11
10
11
24 N m (2.4 kgf m, 17 ft Ib)

7 11 mm
E
10 N m (1.0 kgf m, 7.2 ft Ib)

6 35 mm
17
16
12
18
24 N m (2.4 kgf m, 17 ft Ib)

7 11 mm
14
8
M
13
20
15
19
10 N m (1.0 kgf m, 7.2 ft Ib)
6 8 mm
2
5
1
4
6 25 mm
10 N m (1.0 kgf m, 7.2 ft Ib)
Step
5
6
7
8
9
10
11
12
13
14
15
Procedure/Part name
Timing chain tensioner gasket
Timing chain guide (exhaust side)
Bolt
Intake camshaft cap
Dowel pin
Bolt
Exhaust camshaft cap
Dowel pin
Intake camshaft
Bolt
Intake camshaft sprocket
Qty
1
1
18
3
6
10
3
6
1
2
1
5-53
Service points
Not reusable
NOTE:
During removal, the dowel pins may still be
connected to the camshaft caps.
POWR
CAMSHAFTS
EXPLODED DIAGRAM
6 35 mm
10 N m (1.0 kgf m, 7.2 ft Ib)
10
11
10
11
10
11
24 N m (2.4 kgf m, 17 ft Ib)

7 11 mm
E
10 N m (1.0 kgf m, 7.2 ft Ib)

6 35 mm
17
16
12
18
24 N m (2.4 kgf m, 17 ft Ib)

7 11 mm
14
8
13
20
15
19
10 N m (1.0 kgf m, 7.2 ft Ib)
6 8 mm
2
5
1
4
6 25 mm
10 N m (1.0 kgf m, 7.2 ft Ib)
Step
16
17
18
19
20
Procedure/Part name
Exhaust camshaft
Bolt
Exhaust camshaft sprocket
Pin
Timing chain guide (intake side)
Qty
1
2
1
1
1
Service points
5-54
POWR
CAMSHAFTS
SERVICE POINTS
Camshaft removal
1. Install:
Dial gauge needle
Dial gauge stand 1
(into spark plug hole #1)
Dial gauge 2
2
1
Dial gauge stand:

90890-06583
Dial gauge needle:
90890-06584
Dial gauge stand set:
YW-06585/90890-06585
Dial gauge:
YU-03097/90890-01252
2. Turn the drive coupling counterclockwise,
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
EX
IN
3. Make the alignment marks a on the timing

chain and camshaft sprockets.
4. Remove:
Timing chain tensioner 1
Gasket
5-55
POWR
CAMSHAFTS
10
5
3 9
4
8 6
9
13 17
8
2
16 12 1
5 7
10 4
1115
1814 2
E
5. Remove:
Camshaft caps
Dowel pins
NOTE:
Loosen the intake and exhaust camshaft cap
bolts in the sequence shown.
6. Remove:
Intake camshaft 1
Exhaust camshaft 2
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire 3.
7. Remove:
Exhaust camshaft sprocket 1
Intake camshaft sprocket 2
(with the special tool 3)
holder:
YU-01235
Rotor holder:
90890-01235
Camshaft inspection
1. Check:
Camshaft lobes
Blue discoloration/pitting/scratches
Replace the camshaft.
2. Measure:
Camshaft lobe dimensions a and b
Out of specification Replace the camshaft.
Cam lobe dimensions:
Intake camshaft:
a 32.55 mm (1.281 in)
b 25.00 mm (0.984 in)
Exhaust camshaft:
a 33.00 mm (1.299 in)
b 25.00 mm (0.984 in)
5-56
POWR
CAMSHAFTS
E
3. Measure:
Camshaft runout
Maximum camshaft runout:
0.03 mm (0.0012 in)
6
16 10
7
11 13
2
6 2
14 12
9 15
8 4
4. Measure:
Camshaft-journal-to-camshaft-cap
clearance
Out of specification Measure the
camshaft journal diameter.
10
3
9
3 7 18
Camshaft-journal-to-camshaftcap clearance:
0.030.06 mm (0.00120.0024 in)
1 5 17
Measurement steps:
Install the camshaft into the cylinder head
(without the dowel pins and camshaft
caps).
Position a strip of Plastigauge 1 onto the
camshaft journal as shown.
Install the dowel pins and camshaft caps.
NOTE:
Tighten the intake and exhaust camshaft
cap bolts in the sequence shown.
Do not turn the camshaft when measuring
the camshaft journal-to-camshaft cap
clearance with the Plastigauge.
T.
Camshaft cap bolt:

10 N m (1.0 kgf m, 7.2 ft lb)
Remove the camshaft caps and then

measure the width of the Plastigauge 1.
5-57
POWR
CAMSHAFTS
E
5. Measure:
Camshaft journal diameter a
Out of specification Replace the camshaft.
Within specification Replace the cylinder head and the camshaft caps as a
set.
Camshaft journal diameter:
24.4624.47 mm
(0.96300.9634 in)
Camshaft sprockets inspection

1. Check:
Camshaft sprocket
Wear/damage Replace the camshaft
sprockets and timing chain as a set.
a
b
1
2
1/4 of a tooth
Correct
Timing chain
Camshaft sprocket
Timing chain tensioner inspection

1. Check:
Cracks/damage/rough movement
Replace.
Checking steps:
While lightly pressing the timing chain
tensioner rod by hand, turn the tensioner
rod fully clockwise with a thin screwdriver
1.
Remove the screwdriver and slowly
release the timing chain tensioner rod.
Make sure that the timing chain tensioner
rod comes out of the timing chain tensioner housing smoothly. If there is rough
movement, replace the timing chain tensioner.
5-58
POWR
CAMSHAFTS
E
Camshaft installation
1. Install:
Exhaust camshaft sprocket 1
Intake camshaft sprocket 2
(with the special tool 3)
holder:
YU-01235
Rotor holder:
90890-01235
NOTE:
Install the camshaft sprocket with the punch
mark a facing outside.
T.
Camshaft sprocket bolt:

24 N m (2.4 kgf m, 17 ft lb)
2. Install:
Exhaust camshaft
Intake camshaft
Exhaust camshaft caps
Intake camshaft caps
Installation steps:
Turn the drive coupling counterclockwise,
Install the timing chain onto both camshaft sprockets, and then install the camshaft.
CAUTION:
Do not turn the crankshaft when installing the camshaft to avoid damage or
improper valve timing.
NOTE:
Make sure that the punch marks a on the
camshafts face up.
Be sure to align the alignment marks b
made during removal to install the timing
chain and camshaft sprockets.
5-59
POWR
CAMSHAFTS
6
16 10
7
11 13
2
6 2
3
9
3 7 18
14 12
9 15
8 4
1 5 17
Install the exhaust and intake camshaft

caps.
10
NOTE:
Gradually tighten the intake and exhaust
camshaft cap bolts in 23 steps in the
sequence shown.
T.
Camshaft cap bolt:

10 N m (1.0 kgf m, 7.2 ft lb)
NOTE:
Make sure that the punch marks c on the
camshafts are aligned with the arrow marks
d on the camshaft caps.
Out of alignment Reinstall.
Remove the wire from the timing chain.
3. Install:
Installation steps:
While lightly pressing the timing chain
tensioner rod by hand, turn the tensioner
rod fully clockwise with a thin screwdriver
1.
NOTE:
Make sure that the tensioner rod has been
fully set clockwise.
With the timing chain tensioner rod
turned all the way into the timing chain
tensioner housing (with the thin screwdriver still installed), install the gasket and
the timing chain tensioner 2 onto the cylinder block.
3
2
WARNING
Always use a new gasket.
Tighten the timing chain tensioner bolts
3 to the specified torque.
NOTE:
The UP mark on the timing chain tensioner should face up.
5-60
POWR
CAMSHAFTS
T.
Timing chain tensioner bolt:

10 N m (1.0 kgf m, 7.2 ft lb)
Remove the screwdriver, make sure the

timing chain tensioner rod releases, and
then tighten the cap bolt to the specified
torque.
T.
Cap bolt:
10 N m (1.0 kgf m, 7.2 ft lb)
4. Turn:
Drive coupling
(several turns counterclockwise)
5. Check:
Turn the drive coupling counterclockwise, and then check if cylinder #1 is at
TDC of the compression stroke with a
dial gauge.
Camshaft punch marks a
Make sure that the camshaft punch
marks are aligned with the arrow marks
b on the camshaft caps.
Out of alignment Adjust.
Refer to the installation steps above.
6. Measure:
Valve clearance
5-61
POWR
CAMSHAFTS
E
7. Install:
Cylinder head cover
NOTE:
Apply Gasket Maker onto the mating surfaces of the cylinder head cover gasket and
cylinder head.
Tighten the cylinder head cover bolts stages
and in a crisscross pattern.
T.
5-62
Cylinder head cover bolt:

12 N m (1.2 kgf m, 8.7 ft lb)
POWR
CYLINDER HEAD
CYLINDER HEAD
EXPLODED DIAGRAM
1st
20 N m (2.0 kgf m, 14 ft Ib)

10 N m (1.0 kgf m, 7.2 ft Ib)
6 12 mm
2nd 121 5
20 N m (2.0 kgf m, 14 ft Ib)
1st
10 N m (1.0 kgf m, 7.2 ft Ib)

6 55 mm
2nd 140 5
E
1st
3
5 5
20 N m (2.0 kgf m, 14 ft Ib)
2nd 105 5
1
LT
10 N m (1.0 kgf m, 7.2 ft Ib)

6 12 mm
271
40 N m (4.0 kgf m, 29 ft Ib)

8 20 mm

Step
1
2
3
Procedure/Part name
CYLINDER HEAD REMOVAL
Engine unit
Air filter case
Exhaust pipe 3
Oil tank
Intake and exhaust camshaft
Bolt
Hunger
Bolt
Qty
2
1
3
5-63
Service points
Chapter 4.
Refer to OIL TANK.
Refer to CAMSHAFTS.
POWR
CYLINDER HEAD
EXPLODED DIAGRAM
1st
20 N m (2.0 kgf m, 14 ft Ib)

10 N m (1.0 kgf m, 7.2 ft Ib)
6 12 mm
2nd 121 5
20 N m (2.0 kgf m, 14 ft Ib)
1st
10 N m (1.0 kgf m, 7.2 ft Ib)

6 55 mm
2nd 140 5
E
1st
3
5 5
20 N m (2.0 kgf m, 14 ft Ib)
2nd 105 5
1
LT
10 N m (1.0 kgf m, 7.2 ft Ib)

6 12 mm
271
40 N m (4.0 kgf m, 29 ft Ib)

8 20 mm
Step
4
5
6
7
8
9
Procedure/Part name
Nut/washer
Nut/washer
Nut/washer
Cylinder head
Cylinder head gasket
Dowel pin
Qty
2/2
6/6
2/2
1
1
2
Service points
Not reusable
5-64
POWR
CYLINDER HEAD
SERVICE POINTS
Cylinder head removal
1. Remove:
Cylinder head bolts 1
2. Remove:
Cylinder head nuts
NOTE:
Loosen the cylinder head nuts in the sequence
shown.
Cylinder head inspection

1. Eliminate:
Combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
spark plug bore threads
valve seats
2. Check:
Cylinder head
Damage/scratches Replace.
Cylinder head water jacket
Mineral deposits/rust Eliminate.
5-65
POWR
CYLINDER HEAD
E
3. Measure:
Cylinder head warpage
Out of specification Replace the cylinder head.
Cylinder head warpage limit:
0.1 mm (0.004 in)
Measurement steps:
Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
Measure the warpage.
If the limit is exceeded, replace the cylinder head.
Cylinder head installation

1. Install:
Cylinder head
NOTE:
Pass the timing chain through the timing
chain cavity.
Lubricate the cylinder head nuts with engine
oil.
Tighten the cylinder head nuts in the
sequence shown.
T.
5-66
Cylinder head nut 1:

1st:
20 N m (2.0 kgf m, 14 ft lb)
2nd:
121 5
1st:
20 N m (2.0 kgf m, 14 ft lb)
2nd:
105 5
1st:
20 N m (2.0 kgf m, 14 ft lb)
2nd:
140 5
POWR
CYLINDER HEAD
E
2. Tighten:
Cylinder head bolts 1
NOTE:
Lubricate the cylinder head bolts with engine
oil.
T.
5-67
Cylinder head bolt:

10 N m (1.0 kgf m, 7.2 ft lb)
POWR
VALVES AND VALVE SPRINGS

EXPLODED DIAGRAM
10
11
12
13
14
1
2
3
4
5
3
E
12
15
16
6
7
18
9
8
17
E

Step
1
2
3
4
5
6
7
8
9
Procedure/Part name
REMOVAL
Cylinder head
Intake valve lifter
Intake valve pad
Intake valve cotter
Intake valve upper spring seat
Intake valve spring
Intake valve oil seal
Intake valve lower spring seat
Intake valve
Intake valve guide
Qty
Service points
Refer to CYLINDER HEAD.
12
12
24
12
12
12
12
12
12
5-68
Not reusable
Not reusable
POWR
EXPLODED DIAGRAM
10
11
12
13
14
1
2
3
4
5
3
E
12
15
16
6
7
18
9
8
17
E
Step
10
11
12
13
14
15
16
17
18
Procedure/Part name
Exhaust valve lifter
Exhaust valve pad
Exhaust valve cotter
Exhaust valve upper spring seat
Exhaust valve spring
Exhaust valve oil seal
Exhaust valve lower spring seat
Exhaust valve
Exhaust valve guide
Qty
8
8
16
8
8
8
8
8
8
5-69
Service points
Not reusable
Not reusable
POWR
SERVICE POINTS
Valve removal
1. Remove:
Valve lifter 1
Valve pad 2
NOTE:
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Remove:
Valve cotters 1
NOTE:
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
2 and attachment 3.
Valve spring compressor:
YM-01253/90890-04019
Valve spring compressor
attachment:
(for the intake valve)
YM-4114/90890-04114
(for the exhaust valve)
YM-4108/90890-04108
3. Remove:
Upper spring seat 1
Valve spring 2
Valve 3
Oil seal 4
Lower spring seat 5
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
5-70
POWR
Valve spring inspection

1. Measure:
Valve spring free length a
Out of specification Replace the
valve spring.
Valve spring free length:
Intake valve spring:
38.90 mm (1.53 in)
Exhaust valve spring:
40.67 mm (1.60 in)
2. Measure:
Valve spring tilt a
valve spring.
Valve spring tilt:
Intake valve spring:
1.7 mm (0.067 in)
Exhaust valve spring:
1.8 mm (0.071 in)
Valve inspection
1. Eliminate:
Carbon deposits
(from the valve face and valve seat)
2. Check:
Valve face
Pitting/wear Replace the valve.
3. Measure:
Valve margin thickness a
valve.
Valve margin thickness:
0.50.9 mm (0.01970.0354 in)
5-71
POWR
4. Measure:
Valve stem diameter a
valve.
Valve stem diameter a:
Intake valve:
3.9753.990 mm
(0.15650.1571 in)
Exhaust valve:
4.4654.480 mm
(0.17580.1764 in)
5. Measure:
Valve stem runout
valve.
NOTE:
When installing a new valve, always replace
the valve guide.
If the valve is removed or replaced, always
replace the oil seal.
Valve stem runout:
0.01 mm (0.0004 in)
Valve guide inspection

NOTE:
Before checking the valve guide make sure
that the valve stem diameter is within specification.
5-72
POWR
1. Measure:
Valve guide inside diameter a
Valve guide inside diameter:
Intake:
4.0004.012 mm
(0.15750.1580 in)
Exhaust:
4.5004.512 mm
(0.17720.1776 in)
2. Calculate the valve stem-to-valve guide

clearance as follows. Replace the valve
guide if out of specification.
Valve stem-to-valve guide
clearance = valve guide inside
diameter valve stem diameter:
Intake:
0.0100.037 mm
(0.00040.0015 in)
Exhaust:
0.0200.047 mm
(0.00080.0019 in)
Valve guide replacement

1. Remove the valve guide 1 by striking the
special service tool from the combustion
chamber side.
Valve guide remover:

Intake (4.0 mm):
YM-04111/90890-04111
Exhaust (4.5 mm):
YM-04116/90890-04116
5-73
POWR
2. Install the new valve guide 2 by striking

the special service tool from the camshaft
side until the valve guide clip 3 contacts
the cylinder head.
NOTE:
Apply engine oil to the surface of the new
valve guide.
Valve guide remover:

Intake (4.0 mm):
YM-04111/90890-04111
Exhaust (4.5 mm):
YM-04116/90890-04116
Valve guide installer:
Intake (4.0 mm):
YM-04112/90890-04112
Exhaust (4.5 mm):
YM-04117/90890-04117
3. Insert the special service tool into the

valve guide 2, and then ream the valve
guide.
NOTE:
Turn the valve guide reamer clockwise to
ream the valve guide.
Do not turn the reamer counterclockwise
when removing the reamer.
Valve guide reamer:

Intake (4.0 mm):
YM-04113/90890-04113
Exhaust (4.5 mm):
YM-04118/90890-04118
4. Measure:
Valve guide inside diameter:
Intake:
4.0004.012 mm
(0.15750.1580 in)
Exhaust:
4.5004.512 mm
(0.17720.1776 in)
5-74
POWR
Valve seat inspection

1. Eliminate carbon deposits from the valve
with a scraper.
2. Apply a thin, even layer of Mechanics
blueing dye (Dykem) onto the valve seat.
3. Lap the valve slowly on the valve seat with

a valve lapper (commercially obtainable)
as shown.
4. Measure the valve seat contact width a

where the blueing dye is adhered to the
valve face. Reface the valve seat if the
valve is not seated properly or if the valve
seat contact width is out of specification.
Replace the valve guide if the valve seat
contact is uneven.
Valve seat contact width a:
0.91.1 mm (0.03540.0433 in)
5-75
POWR
Valve seat reface

1. Reface the valve seat with the valve seat
cutter.
Valve seat cutter holder:
Intake (4.0 mm):
90890-06811
Exhaust (4.5 mm):
90890-06812
Valve seat cutter:
30 (intake):
90890-06815
45 (intake):
90890-06814
60 (intake):
90890-06813
30 (exhaust):
90890-06328
45 (exhaust):
90890-06312
60 (exhaust):
90890-06315
Valve seat cutter set:
YM-91043-C
2. Cut the surface of the valve seat with a 45
cutter by turning the cutter clockwise until
the valve seat face has become smooth.
a Slag or rough surface
CAUTION:
Do not over cut the valve seat. Be sure to
turn the cutter evenly downward at a pressure of 4050 N (45 kgf, 8.811 lbf) to prevent chatter marks.
3. Use a 30 cutter to adjust the contact width

of the top edge of the valve seat.
b Previous contact width
30
5-76
POWR

of the bottom edge of the valve seat.
60

of the valve seat to specification.

c Specified contact width
45
6. If the valve seat contact area is too wide

and situated in the center of the valve
face, use a 30 cutter to cut the top edge
of the valve seat, a 60 cutter to cut the
bottom edge to center the area and set its
width.
7. If the valve seat contact area is too narrow

and situated near the top edge of the valve
face, use a 30 cutter to cut the top edge
of the valve seat. If necessary, use a 45
cutter to center the area and set its width.
8. If the valve seat contact area is too narrow

and situated near the bottom edge of the
valve face, use a 60 cutter to cut the bottom edge of the valve seat. If necessary,
use a 45 cutter to center the area and set
its width.
5-77
POWR
9. Apply a thin, even layer of lapping compound onto the valve seat, and then lap
the valve using a valve lapper (commercially obtainable).
CAUTION:
Do not get the lapping compound on the
valve stem and valve guide.
10. After every lapping procedure, be sure to
clean off any remaining lapping compound
from the cylinder head and the valve.
11. Check the valve seat contact area of the
valve again.
Valve installation
1. Install:
Lower spring seat 1
Oil seal 2
Valve 3
Valve spring 4
Upper spring seat 5
(into the cylinder head)
NOTE:
Make sure that each valve is installed in its
original place. Refer to the following
embossed marks.
Right and left intake valve(s): 4XV:
Middle intake valve(s): 4XV.
Exhaust valve(s): 5LV
Install the valve spring with the larger pitch
a facing up.
b Smaller pitch
5-78
POWR
2. Compress the valve spring, and then

install the valve cotter 1 using a thin
screwdriver with a small amount of grease
applied to it.
Valve spring compressor:
YM-01253/90890-04019
Valve spring compressor
attachment:
(for the intake valve)
YM-4114/90890-04114
(for the exhaust valve)
YM-4108/90890-04108
3. Lightly tap the valve spring retainer with a

plastic hammer to set the valve cotter
securely.
NOTE:
Apply engine oil to the valve pads and valve
lifters before installation.
5-79
POWR
CRANKCASE
CRANKCASE
EXPLODED DIAGRAM
12 N m (1.2 kgf m, 8.7 ft Ib)

6 20 mm
8.4 N m (0.84 kgf m, 6.1 ft Ib)
20 N m (2.0 kgf m, 14 ft Ib)

8 40 mm
LT
271
A
LT
9 10 11
572
8
15 N m (1.5 kgf m, 11 ft Ib)
20
21
19
5
LT
572
20
GM
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 16 mm
18
1st
LT
6 70 mm
12 N m (1.2 kgf m, 8.7 ft Ib)
572
2nd *
3rd 15 N m (1.5 kgf m, 11 ft Ib)
4th 49 5
16
18
LT
572
15
7.8 N m (0.78 kgf m, 5.6 ft Ib)
17
9 105 mm
14
13
12 N m (1.2 kgf m, 8.7 ft Ib)
6 55 mm
12 N m (1.2 kgf m, 8.7 ft Ib)
6 55 mm
LT
572
12
12 N m (1.2 kgf m, 8.7 ft Ib)

6 20 mm

Step
Procedure/Part name
OIL PAN AND CRANKCASE
REMOVAL
Engine unit
Air filter case
Qty
Service points
Chapter 4.
Refer to EXHAUST MANIFOLD.
MOTOR.
Exhaust pipe 3
Exhaust manifold
Generator cover
*: Loosen completely
5-80
POWR
CRANKCASE
EXPLODED DIAGRAM
12 N m (1.2 kgf m, 8.7 ft Ib)

6 20 mm
8.4 N m (0.84 kgf m, 6.1 ft Ib)
20 N m (2.0 kgf m, 14 ft Ib)

8 40 mm
LT
271
A
LT
9 10 11
572
8
15 N m (1.5 kgf m, 11 ft Ib)
20
21
19
5
LT
572
20
GM
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 16 mm
18
1st
LT
6 70 mm
12 N m (1.2 kgf m, 8.7 ft Ib)
572
2nd *
3rd 15 N m (1.5 kgf m, 11 ft Ib)
4th 49 5
16
18
LT
572
E
15
7.8 N m (0.78 kgf m, 5.6 ft Ib)
17
9 105 mm
14
13
12 N m (1.2 kgf m, 8.7 ft Ib)
6 55 mm
12 N m (1.2 kgf m, 8.7 ft Ib)
6 55 mm
Step
1
2
3
4
5
6
Procedure/Part name
Oil tank
Oil pump
Cylinder head
Timing chain
Washer
Bolt
Oil pressure switch
LT
572
Qty
1
1
1
2
1
1
5-81
12
12 N m (1.2 kgf m, 8.7 ft Ib)

6 20 mm
Service points
Refer to OIL TANK.
Refer to OIL PUMP.
Refer to REDUCTION DRIVE GEAR.
Refer to CAMSHAFTS.
POWR
CRANKCASE
EXPLODED DIAGRAM
12 N m (1.2 kgf m, 8.7 ft Ib)

6 20 mm
8.4 N m (0.84 kgf m, 6.1 ft Ib)
20 N m (2.0 kgf m, 14 ft Ib)

8 40 mm
LT
271
A
LT
9 10 11
572
8
15 N m (1.5 kgf m, 11 ft Ib)
20
21
19
5
LT
572
20
GM
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 16 mm
18
1st
LT
6 70 mm
12 N m (1.2 kgf m, 8.7 ft Ib)
572
2nd *
3rd 15 N m (1.5 kgf m, 11 ft Ib)
4th 49 5
16
18
LT
572
E
15
7.8 N m (0.78 kgf m, 5.6 ft Ib)
17
9 105 mm
14
13
12 N m (1.2 kgf m, 8.7 ft Ib)
6 55 mm
12 N m (1.2 kgf m, 8.7 ft Ib)
6 55 mm
Step
7
8
9
10
11
12
13
14
15
16
17
Procedure/Part name
Bolt
Bolt
Anode cover
Grommet
Anode
Bolt
Oil pan
Gasket
Bolt
Bolt
Bolt
LT
572
Qty
1
1
1
1
1
15
1
1
2
1
7
5-82
12
12 N m (1.2 kgf m, 8.7 ft Ib)

6 20 mm
Service points
Not reusable
POWR
CRANKCASE
EXPLODED DIAGRAM
12 N m (1.2 kgf m, 8.7 ft Ib)

6 20 mm
8.4 N m (0.84 kgf m, 6.1 ft Ib)
20 N m (2.0 kgf m, 14 ft Ib)

8 40 mm
LT
271
A
LT
9 10 11
572
8
15 N m (1.5 kgf m, 11 ft Ib)
20
21
19
5
LT
572
20
GM
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 16 mm
18
1st
LT
6 70 mm
12 N m (1.2 kgf m, 8.7 ft Ib)
572
2nd *
3rd 15 N m (1.5 kgf m, 11 ft Ib)
4th 49 5
16
18
LT
572
E
15
7.8 N m (0.78 kgf m, 5.6 ft Ib)
17
9 105 mm
14
13
12 N m (1.2 kgf m, 8.7 ft Ib)
6 55 mm
12 N m (1.2 kgf m, 8.7 ft Ib)
6 55 mm
Step
18
19
20
21
Procedure/Part name
Bolt/washer
Lower crankcase
Dowel pin
Dowel pin/O-ring
LT
572
Qty
10/10
1
2
1/1
5-83
12
12 N m (1.2 kgf m, 8.7 ft Ib)

6 20 mm
Service points
Not reusable
Not reusable
POWR
CRANKCASE
EXPLODED DIAGRAM
6 10 mm
12 N m (1.2 kgf m, 8.7 ft Ib)
1
2
E
3
5
E
4
35 N m (3.5 kgf m, 25 ft Ib)

Step
1
2
3
4
5
Procedure/Part name
OIL PIPE AND OIL FILTER BOLT
REMOVAL
Crankshaft
Bolt
Oil pipe
O-ring
Oil filter bolt
Lower crankcase
Qty
Service points
Refer to CRANKSHAFT.
1
1
2
1
1
Not reusable
5-84
POWR
CRANKCASE
SERVICE POINTS
10
14
13 9
2
1
12
15
11
Crankcase disassembly
1. Remove:
Oil pan bolts
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
Loosen the bolts in decreasing numerical
order (refer to the numbers in the illustration).
The numbers embossed on the oil pan indicate the oil pan tightening sequence.
2. Remove:
Crankcase bolts
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
Loosen the bolts in decreasing numerical
order (refer to the numbers in the illustration).
The numbers embossed on the crankcase
indicate the crankcase tightening sequence.
3. Remove:
Lower crankcase
CAUTION:
Tap on one side of the crankcase with a
soft-face hammer. Tap only on reinforced
portions of the crankcase, not on he crankcase mating surfaces. Work slowly and
carefully and make sure the crankcase
halves separate evenly.
M9 105 mm bolts: 10
M6 55 mm bolts: AF
M6 55 mm bolts: G, H
M6 70 mm bolts: I
M6 55 mm bolts: J
5-85
POWR
CRANKCASE
E
4. Remove:
Dowel pins
Crankcase inspection
1. Thoroughly wash the crankcase halves in
a mild solvent.
2. Thoroughly clean all the gasket surfaces
and crankcase mating surfaces.
3. Check:
Crankcase
Oil delivery passages
Obstruction Blow out with compressed air.
Timing chain inspection

1. Check:
Timing chain 1
Damage/stiffness Replace the timing
chain and camshaft sprockets as a set.
5-86
POWR
CRANKCASE
E
Crankcase assembly
1. Lubricate:
Crankshaft journal bearings
(with the recommended lubricant)
Engine oil
2. Apply:
Gasket Maker
(onto the crankcase mating surfaces)
NOTE:
Do not allow any Gasket Maker to come into
contact with the oil gallery or crankshaft journal
bearings.
3. Install:
Dowel pins 1
O-ring 2
GM
12
4. Install:
Crankcase bolts
NOTE:
Lubricate the bolt 10 threads and washers with engine oil.
Finger tighten the crankcase bolts.
M9 105 mm bolts: 10
M6 55 mm bolts: AF
M6 55 mm bolts: G, H
M6 70 mm bolts: I
M6 55 mm bolts: J
5-87
POWR
H
CRANKCASE
F
E
5. Tighten:
Crankcase bolts 10
NOTE:
Do not reuse crankcase bolts 10.
The tightening procedure of crankcase bolts
10 is angle controlled, therefore tighten
the bolts using the following procedure.
Tightening steps:
Tighten the bolts in the tightening
sequence cast on the crankcase.
T.
Crankcase bolt 10:

1st:
7.8 N m
(0.78 kgf m, 5.6 ft lb)
Loosen and retighten the crankcase bolts

in the proper tightening sequence as
shown.
T.
Crankcase bolt 10:

2nd:
Loosen completely
3rd:
15 N m (1.5 kgf m, 11 ft lb)
Tighten the crankcase bolts further to

reach the specified angle 49 in the
proper tightening sequence as shown.
T.
Crankcase bolt 10:

Final:
Specified angle 49 5
WARNING
When the bolts are tightened more than
the specified angle, do not loosen the
bolt and then retighten it.
Replace the bolt with a new one and perform the procedure again.
5-88
POWR
CRANKCASE
CAUTION:
Do not use a torque wrench to tighten
the bolt to the specified angle.
Tighten the bolt until it is at the specified angle.
NOTE:
When using a hexagonal bolt, note that the
angle from one corner to another is 60.
6. Tighten:
Crankcase bolts AJ
NOTE:
Tighten the bolts in the tightening sequence
cast on the crankcase.
Crankcase bolt AJ:
12 N m (1.2 kgf m, 8.7 ft lb)
T.
7. Tighten:
Oil pan bolts
10
14
13 9
6
5
2
1
NOTE:
Tighten the bolts in the tightening sequence
cast on the oil pan.
12
15
11
T.
5-89
Oil pan bolt:

12 N m (1.2 kgf m, 8.7 ft lb)
LOCTITE 572
POWR
CONNECTING RODS AND PISTONS

EXPLODED DIAGRAM
10
11
12
4
5
6
8
7
1st
20 N m (2.0 kgf m, 14 ft Ib)
2nd 120 5

Step
1
2
3
4
5
6
7
Procedure/Part name
CONNECTING RODS AND
PISTONS REMOVAL
Crankcase
Nut
Connecting rod cap
Big end lower bearing
Piston pin clip
Piston pin
Piston
Connecting rod
Qty
8
4
4
8
4
4
4
5-90
Service points
Separate
Refer to CRANKCASE.
Not reusable
Not reusable
POWR
EXPLODED DIAGRAM
10
11
12
4
5
6
8
7
1st
20 N m (2.0 kgf m, 14 ft Ib)
2nd 120 5
Step
8
9
10
11
12
Procedure/Part name
Bolt
Big end upper bearing
Top ring
2nd ring
Oil ring
Qty
8
4
4
4
4
Service points
Not reusable
5-91
POWR
SERVICE POINTS
Connecting rod and piston removal

connecting rods and pistons.
1. Remove:
Connecting rod cap 1
Big end bearings
NOTE:
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
2. Remove:
Piston pin clips 1
Piston pin 2
Piston 3
Connecting rod 4
CAUTION:
Do not use a hammer to drive the piston
pin out.
NOTE:
For reference during installation, put an identification number a on the piston crown.
Before removing the piston pin, deburr the
piston pin clips groove and the pistons pin
bore area.
3. Remove:
Top ring
2nd ring
Oil ring
NOTE:
When removing a piston ring, open the end
gap with your fingers and lift the other side of
the ring over the piston crown.
5-92
POWR
Cylinder and piston inspection

cylinders and pistons.
1. Check:
Piston wall
Cylinder wall
Vertical scratches Replace the cylinder, and the piston and piston rings as a
set.
2. Measure:
D2
D1
D4
D3
D6
D5
Measurement steps:
Measure cylinder bore C with the cylinder bore gauge.
Cylinder bore C
76.00076.015 mm
(2.99212.9927 in)
Taper limit T
0.08 mm (0.003 in)
Out of round R
0.05 mm (0.002 in)
C = maximum of D1D6
T = maximum of D1D5 (direction d)
and D2D6 (direction e)
R = maximum of D2D1 (measuring
point a) and D6D5 (measuring point c)
If out of specification, replace the cylinder, and the piston and piston rings as a
set.
Measure piston skirt diameter P with the
micrometer.
a 5 mm (0.2 in) from the bottom edge of the
piston
Piston size P
Standard
5-93
75.89575.910 mm
(2.98802.9986 in)
POWR
If out of specification, replace the piston

and piston rings as a set.
Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance = Cylinder
bore C Piston skirt diameter P
Piston-to-cylinder clearance:
0.100.11 mm (0.00390.0043 in)
<Limit>: 0.17 mm (0.0067 in)
If out of specification, replace the piston
and piston rings as a set.
Piston ring inspection

1. Measure:
Piston ring side clearance
Out of specification Replace the piston and piston rings as a set.
NOTE:
Before measuring the piston ring side clearance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
Side clearance:
Top ring:
0.0300.065 mm
(0.00120.0026 in)
2nd ring:
0.0200.055 mm
(0.00080.0022 in)
Oil ring:
0.0400.160 mm
(0.00160.0063 in)
5-94
POWR
2. Install:
Piston ring
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with the
piston crown.
a 5 mm (0.2 in)
3. Measure:
Piston ring end gap
Out of specification Replace the piston ring.
NOTE:
The oil ring expander spacers end gap cannot
be measured. If the oil ring rails gap is excessive, replace all three piston rings.
Piston ring end gap:
Top ring:
0.320.44 mm
(0.01260.0173 in)
2nd ring:
0.430.58 mm
(0.01690.0228 in)
Oil ring:
0.100.35 mm
(0.00390.0138 in)
5-95
POWR
Piston pin inspection

piston pins.
1. Check:
Piston pin
Blue discoloration/grooves Replace
the piston pin and then check the lubrication system.
2. Measure:
Piston pin outside diameter a
Out of specification Replace the piston pin.
Piston pin outside diameter:
16.99117.000 mm
(0.66890.6693 in)
<Limit>: 16.98 mm (0.67 in)
3. Measure:
Piston pin bore diameter (in the piston)
b
Out of specification Replace the piston.
Piston pin bore diameter
(in the piston):
17.00217.013 mm
(0.66930.6698 in)
4. Calculate:
Piston-pin-to-piston clearance
Out of specification Replace the piston pin.
Piston-pin-to-piston clearance =
Piston pin bore diameter (in the piston)
b Piston pin outside diameter a
Piston-pin-to-piston clearance:
0.0020.022 mm
(0.00010.0009 in)
5-96
POWR
Connecting rod inspection

1. Measure:
Crankshaft-pin-to-big-end-bearing
clearance
Out of specification Replace the big
end bearings.
Crankshaft-pin-to-big-endbearing clearance:
0.0160.040 mm
(0.00060.0016 in)
Measurement steps:
connecting rods.
CAUTION:
Do not interchange the big end bearings
and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing
clearance and prevent engine damage,
the big end bearings must be installed in
their original positions.
Clean the big end bearings, crankshaft
pins, and the inside of the connecting rod
halves.
Install the big end upper bearing into the
connecting rod and the big end lower
bearing into the connecting rod cap.
NOTE:
Align the projections a on the big end bearings with the notches b in the connecting
rod and connecting rod cap.
Put a piece of Plastigauge 1 on the

crankshaft pin.
Assemble the connecting rod halves.
5-97
POWR
d
NOTE:
Do not move the connecting rod or crankshaft until the clearance measurement
has been completed.
Lubricate the bolts threads and nut seats
with molybdenum disulfide grease.
Make sure the Y mark c on the connecting rod faces towards the front side of
the crankshaft.
Make sure the characters d on both the
connecting rod and connecting rod cap
are aligned.
Tighten the connecting rod nuts.

Refer to Connecting rod and piston
installation.
Remove the connecting rod and big end
bearings.
Refer to Connecting rod and piston
removal.
Measure the compressed Plastigauge
width e on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select
replacement big end bearings.
2. Select:
Big end bearings (P1P4)
NOTE:
The numbers stamped into the crankshaft
web and the numbers on the connecting rods
are used to determine the replacement big
end bearing sizes.
P1P4 refer to the bearings shown in the
crankshaft illustration.
P4
P1
P2
P3
5-98
POWR
For example, if the connecting rod P1 and the

crankshaft web P1 numbers are 5 and 1
respectively, then the bearing size for P1 is:
Bearing size of P1:
P1 (connecting rod)
P1 (crankshaft web)
5 1 = 4 (green)
5G
BEARING COLOR CODE
P1 P2 P3 P4
brown
black
blue
green
Connecting rod and piston installation

pistons and connecting rods.
1. Install:
Oil ring
2nd ring
Top ring
NOTE:
Be sure to install the piston rings so that the
manufacturers marks or numbers face up.
2. Install:
Piston 1
Connecting rod 2
Piston pin 3
Piston pin clips 4
NOTE:
Apply engine oil onto the piston pin.
When installing the connecting rod to the piston, make sure that the Y mark a on the
connecting rod faces towards the left when
the exhaust valve recesses b on the piston
face upward. Refer to the illustration.
Reinstall each piston into its original cylinder
(numbering order starting from the front: #1
to #4).
5-99
POWR

3. Offset:
Piston ring end gaps
a
b
c
90
90
45
Top ring, oil ring expander spacer

2nd ring, lower oil ring rail
Upper oil ring rail
Exhaust side
a
4. Lubricate:
Piston
Piston rings
Cylinder
Engine oil
5. Lubricate:
Bolt threads
Nut seats
Molybdenum disulfide grease
6. Lubricate:
Crankshaft pins
Big end bearings
Connecting rod inner surface
Engine oil
5-100
POWR
7. Install:
Big end bearings
Connecting rod assembly 1
(into the cylinder and onto the
crankshaft pin)
Connecting rod cap
(onto the crankshaft pin)
NOTE:
Align the projections on the big end bearings
with the notches in the connecting rods and
connecting rod caps.
Be sure to reinstall each big end bearing in
its original place.
While compressing the piston rings with piston ring compressor 2, install the connecting
rod assembly into the cylinder with the other
hand.
Make sure the Y marks a on the connecting rods face towards the front side of the
crankshaft.
Make sure the characters b on both the connecting rod and connecting rod cap are
aligned.
Piston ring compressor:
YM-08037/90890-05158
8. Align:
Bolt heads
(with the connecting rod)
5-101
POWR
9. Tighten:
Connecting rod nuts
WARNING
Replace the connecting rod bolts and
nuts with new ones.
Clean the connecting rod bolts and nuts.
NOTE:
The tightening procedure of the connecting rod
nuts is angle controlled, therefore tighten the
nuts using the following procedure.
Tightening steps:
Tighten the connecting rod nuts to the
specified torque.
T.
Connecting rod nut:

1st:
20 N m (2.0 kgf m, 14 ft lb)
Tighten the connecting rod nuts further to

reach the specified angle 120.
T.
Connecting rod nut:

Final:
Specified angle 120 5
WARNING
When the nuts are tightened more than
the specified angle, do not loosen the
nut and then retighten it.
Replace the bolt and nut with a new one
and perform the procedure again.
CAUTION:
Do not use a torque wrench to tighten
the nut to the specified angle.
Tighten the nut until it is at the specified angle.
NOTE:
When using a hexagonal nut, note that the
angle from one corner to another is 60.
5-102
POWR
CRANKSHAFT
CRANKSHAFT
EXPLODED DIAGRAM
3
3
2
E

Step
Procedure/Part name
CRANKSHAFT REMOVAL
Crankcase
Qty
Connecting rod caps

1
2
3
Crankshaft
Crankshaft journal lower bearing
Crankshaft journal upper bearing
Service points
Separate
Refer to CRANKCASE.
Refer to CONNECTING RODS AND
PISTONS.
1
5
5
5-103
POWR
CRANKSHAFT
SERVICE POINTS
Crankshaft removal
1. Remove:
Crankshaft 1
Crankshaft journal lower bearings
(from the lower crankcase)
Crankshaft journal upper bearings
(from the upper crankcase)
NOTE:
Identify the position of each crankshaft journal
bearing so that it can be reinstalled in its original place.
Crankshaft inspection
1. Measure:
Crankshaft runout
crankshaft.
Maximum crankshaft runout:
0.03 mm (0.0012 in)
2. Check:
Crankshaft journal surfaces
Crankshaft pin surfaces
Scratches/wear Replace the crankshaft.
Bearing surfaces
Scratches/wear Replace the crankshaft journal bearing.
3. Measure:
crankshaft-journal-to-crankshaft-journalbearing clearance
crankshaft journal bearings.
Crankshaft-journal-to-crankshaftjournal-bearing clearance:
0.0040.028 mm
(0.00020.0011 in)
5-104
POWR
CRANKSHAFT
CAUTION:
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaftjournal-to-crankshaft-journal-bearing clearance and prevent engine damage, the
crankshaft journal bearings must be
installed in their original positions.
Measurement steps:
Clean the crankshaft journal bearings,
crankshaft journals, and bearing portions
of the crankcase.
Place the upper crankcase upside down
on a bench.
Install the crankshaft journal upper bearings 1 and the crankshaft into the upper
crankcase.
NOTE:
Align the projections a of the crankshaft
journal upper bearings with the notches b
in the upper crankcase.
Put a piece of Plastigauge 2 on each

crankshaft journal.
NOTE:
Do not put the Plastigauge over the oil hole
in the crankshaft journal.
Install the crankshaft journal lower bearings into the lower crankcase and assemble the crankcase halves.
NOTE:
Align the projections a of the crankshaft
journal lower bearings with the notches b
in the lower crankcase.
Do not move the crankshaft until the
clearance measurement has been completed.
5-105
POWR
CRANKSHAFT
Tighten the bolts to specification in the

tightening sequence cast on the crankcase.
Refer to Crankcase assembly
CRANKCASE.
Remove the lower crankcase and the
crankshaft journal lower bearings.
Measure the compressed Plastigauge
width c on each crankshaft journal.
If the crankshaft-journal-to-crankshaftjournal-bearing clearance is out of specification, select replacement crankshaft
journal bearings.
4. Select:
Crankshaft journal bearings (J1J5)
J1
J2
J3
J4
NOTE:
The numbers stamped into the crankshaft
web and the numbers stamped into the lower
crankcase are used to determine the
replacement crankshaft journal bearing
sizes.
J1J5 refer to the bearings shown in the
crankshaft illustration.
If J1J5 are the same, use the same size
for all of the bearings.
J5
For example, if the crankcase J1 and crankshaft web J1 numbers are 5 and 2 respectively, then the bearing size for J1 is:
Bearing size of J1:
J1 (crankcase) J1 (crankshaft web)
5 2 = 3 (blue)
J5 J4 J3 J2 J1
BEARING COLOR CODE
J1 J2 J3 J4 J5
5-106
brown
black
blue
green
yellow
POWR
CRANKSHAFT
E
Crankshaft installation
1. Install:
Crankshaft journal upper bearings
(into the upper crankcase)
Crankshaft journal lower bearings
(into the lower crankcase)
a
b
NOTE:
Align the projections a on the crankshaft
journal upper bearings with the notches b in
the upper crankcase.
Be sure to install each crankshaft journal
bearing in its original place.
2. Lubricate:
Crankshaft pins
Connecting rod inner surface
Engine oil
5-107
POWR
THERMOSTAT
THERMOSTAT
EXPLODED DIAGRAM
1st
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 35 mm
5.9 N m (0.59 kgf m, 4.3 ft Ib)
12
8
13
10
9
11
12
LT
572
LT
572
6
5
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 70 mm
1st

Step
Qty
1
2
3
4
Procedure/Part name
THERMOSTAT REMOVAL
Band
5
6
7
8
Band/grease hose
Bolt
Thermostat
1/1
2
1
1
1
1/1
2/1
1/1
5-108
Service points
For cooling water outlet on stern side.
For cooling water pilot outlet on starboard
side.
POWR
THERMOSTAT
EXPLODED DIAGRAM
1st
3.7 N m (0.37 kgf m, 2.7 ft Ib)
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 35 mm
5.9 N m (0.59 kgf m, 4.3 ft Ib)
12
8
13
10
9
11
12
LT
572
LT
572
6
5
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 70 mm
1st
Step
9
10
11
12
13
Procedure/Part name
Gasket
Thermostat housing
Bolt
Collar
Thermostat housing holder
Qty
1
1
2
2
1
Service points
Not reusable
5-109
POWR
THERMOSTAT
SERVICE POINTS
Thermostat inspection
1. Check:
Thermostat 1
Does not open at 5060 C (123
141 F) Replace.
Checking steps:
Suspend the thermostat in a container
filled with water.
Slowly heat the water.
Place a thermometer in the water.
While stirring the water, observe the thermostat and thermometers indicated temperature.
3
1
4
1
2
3
4
Thermostat
Thermometer
Water
Container
Fully closed
Fully open
NOTE:
If the accuracy of the thermostat is in doubt,
replace it. A faulty thermostat could cause serious overheating or over cooling.
2. Check:
Thermostat housing
3. Check:
Cooling system
Leaks Repair or replace any faulty
part.
Thermostat installation
1. Install:
Thermostat housing 1
Thermostat 2
Gasket
5-110
POWR
COOLING WATER HOSE
COOLING WATER HOSE

EXPLODED DIAGRAM
2
4
5

Step
Qty
Procedure/Part name
COOLING WATER HOSE
REMOVAL
Exhaust manifold
2
3
4
5
6
7

Joint
Joint
2/2
2/1
2/1
1
1/1
1
1/1
5-111
Service points
Refer to EXHAUST MANIFOLD.
To cylinder block
To exhaust pipe
To cylinder block
To oil tank
JET
PUMP
CHAPTER 6
JET PUMP UNIT
INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT....................................6-1
JET PUMP UNIT.............................................................................................. 6-4
REVERSE GATE ............................................................................................. 6-6
SERVICE POINTS .................................................................................... 6-9
Lever 1 installation ..............................................................................6-9
Lever 2 installation ..............................................................................6-9
JET THRUST NOZZLE AND NOZZLE RING ............................................... 6-10
IMPELLER DUCT AND IMPELLER HOUSING 1 .........................................6-11
IMPELLER DUCT AND DRIVE SHAFT ........................................................ 6-13
SERVICE POINTS .................................................................................. 6-15
Drive shaft removal ...........................................................................6-15
Impeller inspection ............................................................................6-17
Drive shaft inspection........................................................................6-17
Drive shaft installation ....................................................................... 6-17
JET
PUMP
TRANSOM PLATE AND HOSES.................................................................. 6-20

SERVICE POINTS .................................................................................. 6-23
Bilge strainer inspection .................................................................... 6-23
Electric bilge pump inspection........................................................... 6-23
Bilge hose inspection ........................................................................6-23
Cooling water hose inspection .......................................................... 6-23
BEARING HOUSING.....................................................................................6-24
SERVICE POINTS .................................................................................. 6-27
Driven coupling removal and installation...........................................6-27
Intermediate drive shaft removal.......................................................6-27
Bearing removal ................................................................................ 6-28
Bearing, intermediate drive shaft, and grease hose inspection ........ 6-28
Driven coupling inspection ................................................................6-28
Bearing installation............................................................................6-29
Oil seal installation ............................................................................6-29
Intermediate housing installation.......................................................6-30
JET
PUMP
INTAKE GRATE, RIDE PLATE, AND INTAKE DUCT

EXPLODED DIAGRAM

Step
1
2
3
4
5
Procedure/Part name
INTAKE GRATE, RIDE PLATE,
AND INTAKE DUCT REMOVAL
Bolt
Bolt
Intake grate
Screw
Speed sensor
Bolt
Qty
2
2
1
4
1
6-1
Service points
NOTE:
Route the speed sensor lead between the
jet pump unit and the bilge hose.
JET
PUMP
EXPLODED DIAGRAM
Step
7
8
9
10
Procedure/Part name
Ride plate
Bolt
Intake duct
Felt packing
Qty
1
4
1
1
6-2
Service points
Not reusable
JET
PUMP
EXPLODED DIAGRAM
2
3
FWD

Step
1
2
3
Procedure/Part name
SPEED SENSOR DISASSEMBLY
Holder
Paddle wheel set
Speed sensor
Qty
1
1
1
Service points
Not reusable
assembly.
6-3
JET
PUMP
JET PUMP UNIT
JET PUMP UNIT

EXPLODED DIAGRAM
6.8 N m (0.68 kgf m, 4.9 ft Ib)

6 22 mm
14 N m (1.4 kgf m, 10 ft Ib)

8 24 mm
LT
271
2.2 N m (0.22 kgf m, 1.6 ft Ib)
LT
242
12
11
40 N m (4.0 kgf m, 29 ft Ib)
10 95 mm
LT
572
10
14
13
4
LT
572
6.8 N m (0.68 kgf m, 4.9 ft Ib)
15
M
4
6 80 mm
7.8 N m (0.78 kgf m, 5.6 ft Ib)

Step
Qty
1
2
3
Procedure/Part name
JET PUMP UNIT REMOVAL
Shift cable joint
QSTS cable joint
Bilge hose
4
5
6
7
Nut/washer
Clamp/spout hose
Bolt
1/2
1
1/1
6
1
1
1
6-4
Service points
NOTE:
Route the speed sensor lead between the
jet pump unit and the bilge hose.
JET
PUMP
JET PUMP UNIT
EXPLODED DIAGRAM
6.8 N m (0.68 kgf m, 4.9 ft Ib)

6 22 mm
14 N m (1.4 kgf m, 10 ft Ib)

8 24 mm
LT
271
2.2 N m (0.22 kgf m, 1.6 ft Ib)
LT
242
12
11
40 N m (4.0 kgf m, 29 ft Ib)
10 95 mm
LT
572
10
14
13
4
LT
572
6.8 N m (0.68 kgf m, 4.9 ft Ib)
15
M
4
Step
8
9
10
11
12
13
14
15
Procedure/Part name
Collar
Rubber plate
Bolt
Bolt
Jet pump unit assembly
Dowel pin
Impeller housing 2
Dowel pin
Qty
4
2
1
4
1
2
1
2
6 80 mm
7.8 N m (0.78 kgf m, 5.6 ft Ib)
Service points
6-5
JET
PUMP
REVERSE GATE
REVERSE GATE
EXPLODED DIAGRAM

Step
1
2
3
4
5
6
7
8
9
Procedure/Part name
REVERSE GATE REMOVAL
Clamp/spout hose
Bolt
Washer
Collar
Reverse gate assembly
Nut
Bolt
Washer
Roller
Qty
1/1
2
2
2
1
1
1
2
1
6-6
Service points
JET
PUMP
REVERSE GATE
EXPLODED DIAGRAM
Step
10
11
12
13
14
15
16
17
18
19
Procedure/Part name
Bolt
Bracket
Reverse gate stay
Nut
Washer
Bolt
Lever 1
Spacer
Nut
Washer
Qty
6
1
2
1
1
1
1
1
1
1
6-7
Service points
JET
PUMP
REVERSE GATE
EXPLODED DIAGRAM
Step
20
21
22
23
24
25
26
Procedure/Part name
Collar
Bolt
Washer
Collar
Spring
Lever 2
Washer
Qty
1
1
1
1
1
1
1
Service points
6-8
JET
PUMP
REVERSE GATE
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
Collar 7
NOTE:
When installing the spring, hook the spring
end a to lever 2 and spring end b to the
reverse gate, as shown in the illustration.
When installing the lever 2, hook the lever 2
end c to lever 1 end d, as shown in the
illustration.
d
c
2. Install:
Washer 1
Nut 2
3. Check:
Lever 1 and lever 2 movements
Stick Reassemble lever 1 and
lever 2.
6-9
JET
PUMP
JET THRUST NOZZLE AND NOZZLE RING
JET THRUST NOZZLE AND NOZZLE RING

EXPLODED DIAGRAM

Step
1
2
3
4
5
6
Procedure/Part name
JET THRUST NOZZLE AND
NOZZLE RING REMOVAL
Jet pump unit
Reverse gate
Bolt
Collar
Jet thrust nozzle
Bolt
Collar
Nozzle ring
Qty
Service points
Refer to JET PUMP UNIT.
Refer to REVERSE GATE.
2
2
1
2
2
1
6-10
JET
PUMP
IMPELLER DUCT AND IMPELLER HOUSING 1

EXPLODED DIAGRAM

Step
1
2
3
4
5
6
7
Procedure/Part name
IMPELLER DUCT AND IMPELLER
HOUSING 1 REMOVAL
Nozzle ring
Bolt
Nozzle
Pin
Impeller duct assembly
Impeller housing 1
Pin
Bolt
Qty
Service points
Refer to JET THRUST NOZZLE AND
NOZZLE RING.
4
1
2
1
1
2
4
6-11
NOTE:
Clean the contacting surfaces before applying the Yamabond #4 (Yamaha bond number 4).
JET
PUMP
EXPLODED DIAGRAM
Step
8
9
10
11
Procedure/Part name
Water inlet cover
Packing
Packing
Qty
1
1
1
1
Service points
6-12
JET
PUMP
IMPELLER DUCT AND DRIVE SHAFT

EXPLODED DIAGRAM

Step
1
2
3
4
5
6
7
*1
Procedure/Part name
IMPELLER DUCT AND DRIVE
SHAFT DISASSEMBLY
Impeller
Spacer
Bolt/washer
Cap
O-ring
Nut
Washer
Qty
Service points
1
1
3/3
1
1
1
1
Left-hand threads
6-13
Not reusable
JET
PUMP
EXPLODED DIAGRAM
Step
8
9
10
11
12
13
14
Procedure/Part name
Drive shaft
Rear bearing
Spacer
Front bearing
Oil seal
Oil seal
Impeller duct
Qty
1
1
1
1
1
1
1
Service points
Not reusable
Not reusable
Not reusable
Not reusable
assembly.
*1
6-14
JET
PUMP
SERVICE POINTS
Drive shaft removal
1. Remove:
Impeller
Drive shaft holder:
YB-06151
Drive shaft holder 5:
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.
6-15
JET
PUMP
4. Remove:
Rear bearing
Slide hammer and adapters:

YB-06096
Stopper guide plate:
90890-06501
Bearing puller assembly:
90890-06535
Stopper guide stand:
90890-06538
For USA and Canada

For worldwide
5. Remove:
Front bearing
Driver handlelarge:
YB-06071
Driver rod L3:
90890-06652
Bearing housing needle bearing
remover:
YB-06112
90890-06614
NOTE:
Remove the front bearing with a press.
6-16
JET
PUMP

6. Remove:
Oil seal
Driver handlelarge:
YB-06071
Driver rod L3:
90890-06652
Drive shaft needle bearing
installer and remover:
YB-06196
90890-06614
NOTE:
Remove the oil seals with press.
Impeller inspection
Refer to JET PUMP UNIT in
Chapter 3.
Drive shaft inspection
1. Inspect:
Drive shaft
Drive shaft installation

1. Install:
Oil seals
Driver handlelarge:
YB-06071
Driver rod LS:
90890-06606
gear:
YB-06085
90890-06631
Distance a:
14.2 0.2 mm (0.56 0.01 in)
Distance b:
4.7 0.2 mm (0.19 0.01 in)
6-17
JET
PUMP
2. Install:
Front bearing
Drive shaft
NOTE:
Install the front bearing and drive shaft with a
press.
Press the front bearing with a pipe that is
more than 85 mm (3.35 in) long, and which
has an inner diameter of 25 mm (0.98 in).
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
pipe that is more than 33 mm (1.30 in) long,
and which has an outer diameter less than
50 mm (1.97 in) and an inner diameter more
than 26 mm (1.02 in).
4. Add:
EPNOC grease AP #0
(between the drive shaft and spacer)
Quantity:
20 g (0.7 oz)
6-18
JET
PUMP
5. Install:
Rear bearing
Bearing inner/outer race
attachment:
YB-34474
NOTE:
Press the bearing inner/outer race at the
same time holding the drive shaft and impeller duct.
If a bearing inner/outer race attachment is
not available, use a washer or pipe with an
outer diameter of 46 mm (1.81 in) and an
inner diameter of 20 mm (0.79 in).
6. Add:
EPNOC grease AP #0 (into the cap)
Quantity:
20 g (0.7 oz)
7. Install:
Nut
Impeller
T.
Drive shaft nut:

69 N m (6.9 kgf m, 50 ft lb)
Impeller:
75 N m (7.5 kgf m, 54 ft lb)
LOCTITE 572
Drive shaft holder:
YB-06151
90890-06519
6-19
JET
PUMP
TRANSOM PLATE AND HOSES

EXPLODED DIAGRAM

Step
1
2
3
Procedure/Part name
REMOVAL
Exhaust system
Hose clamp
Cooling water hose
Bilge hose 1
4
5
Hose clamp
Cooling water hose
Qty
Service points
Refer to EXHAUST SYSTEM in Chapter 8.
Refer to JET PUMP UNIT.
2
1
1
1
1
6-20
Cooling water outlet (exhaust pipe)

NOTE:
Route the bilge hose 1 under the drive shaft
tube.
Cooling water inlet
JET
PUMP
EXPLODED DIAGRAM
Step
6
7
8
9
10
11
12
13
14
15
Procedure/Part name
Hose clamp
Cooling water hose
Bilge hose 2
Hose clamp
Bilge hose 3
Band
Electric bilge pump assembly
Hose clamp
Bilge hose 4
Bilge strainer
Qty
2
1
1
1
1
1
1
1
1
1
6-21
Service points
Cooling water outlet (thermostat)
JET
PUMP
EXPLODED DIAGRAM
Step
16
17
18
Procedure/Part name
Nut/washer
Transom plate
Bilge hose 5
Qty
4/4
1
1
Service points
6-22
JET
PUMP
SERVICE POINTS
Bilge strainer inspection
Refer to JET PUMP UNIT in
Chapter 3.
Electric bilge pump inspection
Refer to BILGE PUMP in Chapter 3.
Refer to ELECTRIC BILGE PUMP in
Chapter 7.
Bilge hose inspection
1. Inspect:
Bilge hoses
Cooling water hose inspection
1. Inspect:
Cooling water hoses
6-23
JET
PUMP
BEARING HOUSING
BEARING HOUSING
EXPLODED DIAGRAM

Step
1
2
3
4
5
Procedure/Part name
BEARING HOUSING REMOVAL
Engine unit
Rubber coupling
Bolt
Intermediate housing assembly
Pin
Shim
Qty
1
3
1
2
*
Service points
NOTE:
Install the shims in their original locations.
*: As required
6-24
JET
PUMP
BEARING HOUSING
EXPLODED DIAGRAM

Step
1
2
3
4
5
6
Procedure/Part name
BEARING HOUSING
DISASSEMBLY
Grease hose
Nipple
Driven coupling
Washer
Intermediate drive shaft
O-ring
Qty
1
1
1
1
1
2
6-25
Service points
Not reusable
JET
PUMP
BEARING HOUSING
EXPLODED DIAGRAM
Step
7
8
9
10
11
12
Procedure/Part name
Oil seal
Oil seal
Oil seal
Circlip
Bearing
Circlip
Qty
1
1
1
1
1
1
6-26
Service points
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
assembly.
JET
PUMP
BEARING HOUSING
SERVICE POINTS
Driven coupling removal and installation
1. Remove and install:
Driven coupling
Coupler wrench:
YW-06551/90890-06551
Shaft holder:
YB-06552
Crankshaft holder 20:
90890-06552
NOTE:
Install the driven coupling with the same special tools that were used for removal.
Check that the shaft holder and intermediate
drive shaft are properly engaged.
Intermediate drive shaft removal

1. Remove:
Removal steps:
Temporarily install the driven coupling to
the intermediate drive shaft.
Insert a long rod to the driven coupling
shaft.
Press out the intermediate drive shaft by
pushing the rod.
NOTE:
Support the intermediate housing with steel
blocks 1 and press the driven coupling shaft
with a rod that is more than 210 mm (8.27 in)
long, and which has an outer diameter less
than 16 mm (0.63 in).
6-27
JET
PUMP
BEARING HOUSING
E
Bearing removal
1. Remove:
Bearing
Driver handlelarge:
YB-06071
Driver rod LS:
90890-06606
Drive shaft taper roller bearing
cup installer:
YB-06156
90890-06626
NOTE:
Install the bearing with the same special
tools that were used for removal.
blocks 1 and press the bearing.
Bearing, intermediate drive shaft, and

grease hose inspection
1. Inspect:
Bearing
Rotate the inner race by hand.
Damage/rough movement Replace.
Damage/pitting Replace.
Grease hose
Driven coupling inspection
1. Inspect:
Driven coupling
Driven coupling damper
6-28
JET
PUMP
BEARING HOUSING
E
Bearing installation
1. Install:
Circlip (front)
2. Install:
Bearing
Driver handlelarge:
YB-06071
Driver rod LS:
90890-06606
Driveshaft taper roller bearing
cup installer:
YB-06156
90890-06626
NOTE:
blocks 1 and press the bearing.
Oil seal installation
1. Install:
Oil seal
Driver handlelarge:
YB-06071
Driver rod LS:
90890-06606
Driveshaft taper roller bearing
cup installer:
YB-06156
90890-06626
NOTE:
Before installing the oil seal, lubricate the clip
glove with water resistant grease.
Distance a:
7.0 0.2 mm (0.28 0.01 in)
6-29
JET
PUMP
BEARING HOUSING
E
2. Install:
Circlip (rear)
NOTE:
Hold the bearing in place as shown with a pipe
that is more than 80 mm (3.15 in) long, and
which has an outer diameter of 51 mm (2.00
in) and an inner diameter of 26 mm (1.02 in).
Distance a:
46.0 0.5 mm (1.81 0.02 in)
3. Install:
Oil seal 1 [8 mm (0.31 in)]
Oil seal 2 [11 mm (0.43 in)]
2
1
Distance a:
10.5 0.2 mm (0.41 0.01 in)
Distance b:
0.8 0.2 mm (0.03 0.01 in)
Intermediate housing installation
1. Install:
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
00.2 mm
(00.008 in)
No need
0.30.7 mm
(0.0120.028 in)
0.5 mm
0.81.2 mm
(0.0310.047 in)
1.0 mm
1.32.0 mm
(0.0510.079 in)
1.5 mm
NOTE:
Install the shim(s) to the original position if the
intermediate housing is not replaced.
6-30
ELEC
CHAPTER 7
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS........................................................................ 7-1
ELECTRICAL BOX.......................................................................................... 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 adapter ........................................................................7-11
Test harness ....................................................................................7-11
IGNITION SYSTEM ....................................................................................... 7-12
WIRING DIAGRAM ................................................................................. 7-12
IGNITION SPARK ...................................................................................7-14
IGNITION SYSTEM PEAK VOLTAGE ....................................................7-15
BATTERY ................................................................................................7-17
FUSE ....................................................................................................... 7-17
SPARK PLUGS ....................................................................................... 7-17
IGNITION COIL ....................................................................................... 7-18
ENGINE STOP SWITCH.........................................................................7-18
ENGINE TEMPERATURE SENSOR ......................................................7-19
SENSOR ASSEMBLY ............................................................................. 7-19
THERMOSWITCH (ENGINE).................................................................. 7-20
THERMOSWITCH (EXHAUST) ..............................................................7-20
MAIN AND FUEL PUMP RELAY............................................................. 7-21
THROTTLE POSITION SENSOR ........................................................... 7-22
CAM POSITION SENSOR ...................................................................... 7-23
NOISE FILTER ........................................................................................ 7-24
SLANT DETECTION SWITCH ................................................................7-24
FUEL CONTROL SYSTEM ...........................................................................7-25
WIRING DIAGRAM ................................................................................. 7-25
FUEL PUMP ............................................................................................ 7-27
FUEL SENDER ....................................................................................... 7-27
FUEL INJECTOR ....................................................................................7-28
OIL PRESSURE SWITCH....................................................................... 7-28
SLANT DETECTION SWITCH ................................................................7-28
REMOTE CONTROL UNIT ..................................................................... 7-28
ELEC
STARTING SYSTEM .....................................................................................7-29

WIRING DIAGRAM ................................................................................. 7-29
BATTERY ................................................................................................7-30
WIRING CONNECTIONS........................................................................7-30
FUSE ....................................................................................................... 7-30
START SWITCH......................................................................................7-30
STARTER RELAY ...................................................................................7-31
STARTER MOTOR........................................................................................ 7-32
SERVICE POINTS .................................................................................. 7-35
Armature inspection ..........................................................................7-35
Brush holder inspection..................................................................... 7-36
Starter motor front cover inspection .................................................. 7-36
CHARGING SYSTEM....................................................................................7-37
WIRING DIAGRAM ................................................................................. 7-37
FUSE ....................................................................................................... 7-38
BATTERY ................................................................................................7-38
LIGHTING COIL ......................................................................................7-38
RECTIFIER/REGULATOR ...................................................................... 7-38
ELECTRIC BILGE PUMP.............................................................................. 7-39
WIRING DIAGRAM ................................................................................. 7-39
ELECTRIC BILGE PUMP........................................................................7-40
FUSE ....................................................................................................... 7-40
BATTERY ................................................................................................7-40
OFF THROTTLE STEERING SYSTEM......................................................... 7-41
WIRING DIAGRAM ................................................................................. 7-41
STEERING SWITCH ............................................................................... 7-42
ECM.........................................................................................................7-42
PICKUP COIL.......................................................................................... 7-42
THROTTLE POSITION SENSOR ........................................................... 7-42
BYPASS VALVE MOTOR ....................................................................... 7-42
ELEC
INDICATION SYSTEM .................................................................................. 7-43

WIRING DIAGRAM ................................................................................. 7-43
FUSE ....................................................................................................... 7-45
BATTERY ................................................................................................7-45
ECM.........................................................................................................7-45
ENGINE TEMPERATURE SENSOR ......................................................7-45
BUZZER .................................................................................................. 7-45
OIL PRESSURE SWITCH....................................................................... 7-46
MULTIFUNCTION METER...................................................................... 7-46
Multifunction meter............................................................................7-46
MULTIFUNCTION METER REMOVAL ...................................................7-46
Display function................................................................................. 7-47
Speedometer display ........................................................................7-48
Tachometer display...........................................................................7-49
Hour meter display ............................................................................7-49
Voltage meter display........................................................................7-49
Low oil pressure warning indicator....................................................7-49
Fuel level meter display and fuel warning indicator .......................... 7-49
Overheat warning indicator ...............................................................7-50
Check the engine warning indicator .................................................. 7-50
REMOTE CONTROL SYSTEM ..................................................................... 7-51
WIRING DIAGRAM ................................................................................. 7-51
REMOTE CONTROL SYSTEM...............................................................7-52
Yamaha Security System indicator ...................................................7-52
Low-rpm mode indicator.................................................................... 7-52
Diagnostic display ............................................................................. 7-53
Checking the remote control transmitter ...........................................7-53
Transmitter registration ..................................................................... 7-55
Replacing of the transmitter battery .................................................. 7-56
ELEC
ELECTRICAL COMPONENTS
M
L
K
J
I
H
1
G
F
E
3
4
C
B
A
0
9
8
7
1
2
3
4
5
6
7
8
9
0
A
Starter motor
Spark plugs and ignition coils
Electrical box
Battery
Speed sensor
Electric bilge pump
Cam position sensor
Fuel injectors
B
C
D
E
F
G
Oil pressure switch

Sensor assembly
Bypass valve motor
Lighting coil and pickup coil
Engine stop switch, engine
shut-off switch, and start
switch
H Steering switch
I Buzzer
J Fuel pump
7-1
K Fuel sender
L Multifunction meter
M Remote control unit
ELEC
ELECTRICAL BOX
ELECTRICAL BOX
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 16 mm
4
17 N m (1.7 kgf m, 12 ft Ib)

8 28 mm
A
A
5 20 mm
4.9 N m (0.49 kgf m, 3.5 ft Ib)
11
3
LT
(VENT)
572
5
6
9
LT
572
22
1516
LT
271
4
12
21
20
22
22
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 30 mm
17
19 18
22
7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 10 mm
LT
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 16 mm
572
22
10
14
22 13
22
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 12 mm

Step
1
2
3
4
5
6
7
8
Procedure/Part name
ELECTRICAL BOX REMOVAL
Battery negative lead
Battery positive lead
Clip/breather hose
Band
Battery
Damper
Bolt
Bolt
Qty
1
1
1/1
2
1
1
2
2
7-2
Service points
ELEC
ELECTRICAL BOX
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 16 mm
4
17 N m (1.7 kgf m, 12 ft Ib)

8 28 mm
A
A
5 20 mm
4.9 N m (0.49 kgf m, 3.5 ft Ib)
11
3
LT
(VENT)
572
5
6
9
LT
572
22
1516
LT
271
4
12
21
20
22
22
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 30 mm
17
19 18
22
7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 10 mm
LT
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 16 mm
572
22
Step
9
10
11
12
13
14
15
16
17
18
10
14
22 13
22
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 12 mm
Procedure/Part name
Battery box
Spacer
Bolt
Screw
Terminal cover
Gasket
Screw
Starter motor lead
Bolt
Cover
Qty
1
2
4
4
1
1
2
1
3
1
7-3
Service points
Not reusable
ELEC
ELECTRICAL BOX
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 16 mm
4
17 N m (1.7 kgf m, 12 ft Ib)

8 28 mm
A
A
5 20 mm
4.9 N m (0.49 kgf m, 3.5 ft Ib)
11
3
LT
(VENT)
572
5
6
9
LT
572
22
1516
LT
271
4
12
21
20
22
22
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 30 mm
17
19 18
22
7.6 N m (0.76 kgf m, 5.5 ft Ib)
6 10 mm
LT
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 16 mm
572
22
Step
19
20
21
22
10
14
22 13
22
7.6 N m (0.76 kgf m, 5.5 ft Ib)

6 12 mm
Procedure/Part name
Gasket
Bolt
Ground lead
Coupler
Qty
1
2
2
22
Service points
Not reusable
NOTE:
Disconnect all couplers.
7-4
ELEC
ELECTRICAL BOX
EXPLODED DIAGRAM
4.9 N m (0.49 kgf m, 3.5 ft Ib)

5 30 mm
3.9 N m (0.39 kgf m, 2.8 ft Ib)

6 20 mm
20
19
16
17 15
3.9 N m (0.39 kgf m, 2.8 ft Ib)

6 16 mm
6 30 mm
14 11
21
18
3.9 N m (0.39 kgf m, 2.8 ft Ib)

3.9 N m (0.39 kgf m, 2.8 ft Ib)
6 16 mm
6
13
12
7
10
22
3.9 N m (0.39 kgf m, 2.8 ft Ib)
6 30 mm
9
8
5
4

Step
1
2
3
4
5
6
7
8
9
Procedure/Part name
ELECTRICAL BOX
DISASSEMBLY
Tapping screw
Cover
Gasket
Clamp
Wiring harness
Tapping screw
Fuse holder stay
Wiring harness
Fuse
Qty
18
1
1
3
1
1
1
1
6
7-5
Service points
ELEC
ELECTRICAL BOX
EXPLODED DIAGRAM
4.9 N m (0.49 kgf m, 3.5 ft Ib)

5 30 mm
3.9 N m (0.39 kgf m, 2.8 ft Ib)

6 20 mm
20
19
16
17 15
3.9 N m (0.39 kgf m, 2.8 ft Ib)

6 16 mm
6 30 mm
14 11
21
18
3.9 N m (0.39 kgf m, 2.8 ft Ib)

3.9 N m (0.39 kgf m, 2.8 ft Ib)
6 16 mm
6
13
12
7
10
22
3.9 N m (0.39 kgf m, 2.8 ft Ib)
6 30 mm
9
8
5
4
Step
10
11
12
13
14
15
16
17
18
19
20
Procedure/Part name
Starter relay
Clamp
Tapping screw/washer
ECM
Tapping screw
Bracket
Joint connector
Tapping screw
Slant detection switch
Tapping screw
Qty
1
2
4/4
1
1
1
2
2
1
1
1
7-6
Service points
ELEC
ELECTRICAL BOX
EXPLODED DIAGRAM
4.9 N m (0.49 kgf m, 3.5 ft Ib)

5 30 mm
3.9 N m (0.39 kgf m, 2.8 ft Ib)

6 20 mm
20
19
16
17 15
3.9 N m (0.39 kgf m, 2.8 ft Ib)

6 16 mm
6 30 mm
14 11
21
18
3.9 N m (0.39 kgf m, 2.8 ft Ib)

3.9 N m (0.39 kgf m, 2.8 ft Ib)
6 16 mm
6
13
12
7
10
22
3.9 N m (0.39 kgf m, 2.8 ft Ib)
6 30 mm
9
8
5
4
Step
21
22
Procedure/Part name
Tapping screw
Rectifier/regulator
Qty
2
1
Service points

assembly.
7-7
ELEC
ELECTRICAL BOX
7
1
UP
1
2
3
4
5
6
7
8
To ignition coil
To battery positive terminal
To starter motor
Starter relay
Fuse holder
ECM
Joint connector
Joint connector
Rectifier/regulator
7-8
ELEC
ELECTRICAL ANALYSIS
ELECTRICAL ANALYSIS
INSPECTION
CAUTION:
All measuring instruments should be handled with special care. Damaged or mishandled instruments will not measure
properly.
On an instrument powered by dry batteries, check the batterys voltage periodically and replace the batteries if
necessary.
Digital tester
NOTE:
Throughout this chapter the part numbers of
the specified digital testers have been omitted.
Refer to the following part numbers.
Digital multimeter:
YU-34899-A
90890-03174
NOTE:
indicates a continuity of electricity;

i.e., a closed circuit at the respective switch
position.
7-9
ELEC
ELECTRICAL ANALYSIS
Low resistance measurement

NOTE:
When measuring a resistance of 10 or less
with the digital tester, the correct measurement cannot be obtained because of the
testers internal resistance.
To obtain the correct value, subtract the
internal resistance from the displayed measurement.
The internal resistance of the tester can be
obtained by connecting both of its terminals.
Correct value =
Displayed measurement
Internal resistance
Peak voltage measurement

NOTE:
When checking the condition of the ignition
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 defective,
the peak voltage will be lower than specification.
If the peak voltage measurement is not
within specification the engine will not operate properly.
A low peak voltage will also cause components to prematurely wear.
7-10
ELEC
ELECTRICAL ANALYSIS
Peak voltage adapter

NOTE:
Throughout this chapter the peak voltage
adapters part number has been omitted.
Refer to the following part number.
The peak voltage adapter should be used
with the digital tester.
Peak volt meter adapter:
YU-39991
Peak voltage adapter B:
90890-03172
When measuring the peak voltage, connect

the peak voltage adapter to the digital circuit
tester and switch the selector to the DC voltage mode.
NOTE:
Make sure that the adapter leads are properly installed in the digital circuit tester.
Make sure that the positive pin (the + mark
facing up as shown) on the adaptor is
installed into the positive terminal of the
tester.
The test harness is needed for the following
tests.
Voltage measurement
Peak voltage measurement
Test harness
Checking steps:
Disconnect the coupler connections.
Connect the test harness between the
couplers.
Connect the tester terminals to the terminals which are being checked.
Run the engine and observe the measurement.
NOTE:
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
IGNITION SYSTEM
WIRING DIAGRAM
Y
3 : G/O
4 :W
5 :P
6 : P/W
9 :O
12 : W/R
13 : W/B
21 : L/R
22 : B/R
L/R
28 : L/B
30 : R/Y
33 : P/G
34 : P
35 : B/Y
42 : B/L
43 : B/Y
44 : B/W
R/Y
R/Y
R/Y
R
P
P
Br B
R/Y
R/Y
R/Y
R/Y
12 3 456
7 8
O O P
R/Y
P R R R
P/W
L/R
P/G
P/W
R/Y
G
B/Y
B/O
G/B
G/Y
G/B
G
Pu/R
Br
B
B
W
W
B
B
R/Y
P/G
B
B
B/O
G/O
B/O
FREE
7 PUSH
B
B
R/Y
G
R
Br
Br
Br
#1
L/B
R/Y
B/O
B/O
P
B
B/O
G/O
B/O
R/Y
P
B
B/O
#2
B/O
B/Y
B/O
B/Y
B/Y
B/Y
G
B/Y
R/Y
B/Y
B/O
W/B
#3
W B
I
B/L
R/Y
B/O
B/O
G
G
B/O
#4
B/O
B/Y
F
P/G
B/O
B/O
B/O
B/O
B/O
B/O
B/O
1
2
3
4
5
6
7
8
9
ECM
Fuse (20A)
Battery
Engine shut-off switch
Engine stop switch
Start switch
0
A
B
C
D
E
F

Cam position sensor
Rectifier/regulator
Lighting coil
Pickup coil
Sensor assembly
(intake air temperature,
intake air pressure)
7-12
B/O
W/R
P
B/W
Br Br
B/R
W B
FREE
PUSH
R/Y
B/O
Pu/B
Pu/Y
Br
G/R
Pu/G
FREE
PUSH
G/R
G/Y
W B
Pu/R
Pu/G
P/W
Pu/B
Pu/Y
G
H
I
J
K

Spark plug
Ignition coil
Oil pressure switch
Noise filter
ELEC
IGNITION SYSTEM
WIRING DIAGRAM
Y
3 : G/O
4 :W
5 :P
6 : P/W
9 :O
12 : W/R
13 : W/B
21 : L/R
22 : B/R
L/R
28 : L/B
30 : R/Y
33 : P/G
34 : P
35 : B/Y
42 : B/L
43 : B/Y
44 : B/W
R/Y
R/Y
R/Y
R
P
P
Br B
R/Y
R/Y
R/Y
R/Y
12 3 456
7 8
O O P
R/Y
P R R R
P/W
L/R
P/G
P/W
R/Y
G
B/Y
B/O
G/B
G/Y
G/B
G
Pu/R
Br
B
B
W
W
B
B
R/Y
P/G
W
B
B/O
B/O
G/O
FREE
7 PUSH
B
B
R/Y
G
R
Br
Br
Br
#1
L/B
R/Y
B/O
B/O
P
B
B/O
G/O
B/O
R/Y
P
B
B/O
#2
B/O
B/Y
B/O
B/Y
B/Y
B/Y
G
B/Y
R/Y
B/Y
B/O
W/B
#3
W B
I
B/L
R/Y
B/O
B/O
G
G
B/O
#4
B/O
B/O
B/O
B/O
B/O
B/O
B/O
B
Br
G
L
O
P
R
W
Y
: Black
: Brown
: Green
: Blue
: Orange
: Pink
: Red
: White
: Yellow
B/L
B/O
B/R
B/W
B/Y
G/O
L/B
L/R
P/G
B/O
B/Y
F
P/G
: Black/blue
: Black/orange
: Black/red
: Black/white
: Black/yellow
: Green/orange
: Blue/black
: Blue/red
: Pink/green
7-13
B/O
W/R
P
B/W
Br Br
B/R
W B
FREE
PUSH
R/Y
B/O
Pu/B
Pu/Y
Br
G/R
Pu/G
FREE
PUSH
G/R
G/Y
W B
Pu/R
Pu/G
P/W
Pu/B
Pu/Y
P/W
R/Y
W/B
W/R
: Pink/white
: Red/yellow
: White/black
: White/red
ELEC
IGNITION SYSTEM
IGNITION SPARK
WARNING
When checking the spark gap, do not
touch any of the connections of the spark
gap tester lead wires.
When performing the spark gap test, take
special care not to let sparks leak out of
the removed spark plug cap.
When performing the spark gap check,
keep flammable gas or liquids away,
since this test can produce sparks.
1. Check:
Ignition spark
Weak Check the ECM output peak
voltage.
Check the ignition coil for resistance.
Checking steps:
Connect the spark plug cap to the spark
gap tester.
Spark gap tester:
YM-34487
Ignition tester:
90890-06754
Crank the engine and observe the ignition system spark through the discharge
window.
For USA and Canada
For worldwide
7-14
ELEC
IGNITION SYSTEM
IGNITION SYSTEM PEAK VOLTAGE

WARNING
When checking the electrical components,
do not touch any of the connections of the
digital tester lead wires.
NOTE:
If there is no spark, or the spark is weak,
continue with the ignition system test.
If a good spark is obtained, the problem is
not with the ignition system, but possibly with
the spark plug(s) or another component.
1. Measure:
ECM output peak voltage
Below specification Measure the
pickup coil output peak voltage.
New: YB-06867
Current: YB-06767
Test harness FWY-2 (2 pins):
New: 90890-06867
Current: 90890-06767
ECM output peak voltage:
Black/red (B/R)
Red/yellow (R/Y)
Black/white (B/W)
Red/yellow (R/Y)
Black/yellow (B/Y)
Red/yellow (R/Y)
Black/blue (B/L)
Red/yellow (R/Y)
r/min
V
Loaded
Cranking
2,000
3,500
87
86
85
NOTE:
When measuring the ECM output peak voltage while cranking the engine, disconnect
the ignition coil couplers for all cylinders
except for the cylinder being measured.
To crank the engine, connect the engine
shut-off cord (lanyard) to the engine shut-off
switch, and then press the start switch.
7-15
ELEC
IGNITION SYSTEM
E
2. Measure:
Pickup coil output peak voltage
Below specification Replace the
pickup coil.
Above specification Replace the
ECM.
New: YB-06877
Current: YB-06777
Test harness HM090-3 (3 pins):
New: 90890-06877
Current: 90890-06777
Pickup coil output peak voltage:
White (W) Black (B)
Red (R) Black (B)
r/min
V
Unloaded
Loaded
Cranking
5.2
2,000
3,500
26.1
41.3
4.7
NOTE:
To crank the engine, connect the engine shutoff cord (lanyard) to the engine shut-off switch,
and then press the start switch and engine
stop switch simultaneously.
3. Measure:
Lighting coil output peak voltage
Below specification Replace the lighting coil.
New: YB-06870
Current: YB-06770
Test harness SMT250-3 (3 pins):
New: 90890-06870
Current: 90890-06770
Lighting coil output peak voltage:
Green (G) Green (G)
r/min
V
7-16
Unloaded
Cranking
2,000
3,500
9.2
38.5
63.2
ELEC
IGNITION SYSTEM
E
NOTE:
To crank the engine, connect the engine shutoff cord (lanyard) to the engine shut-off switch,
and then press the start switch and engine
stop switch simultaneously.
4. Measure:
Rectifier/regulator output voltage
Below specification Replace the rectifier/regulator.
YB-06848
Test harness FSW-6A (6 pins):
90890-06848
Rectifier/regulator output
voltage:
Red (R) Black (B)
r/min
V
Unloaded
3,500
15.0
NOTE:
Do not use the peak voltage adapter to measure the output voltage.
Disconnect the output lead of the tester harness.
BATTERY
Refer to ELECTRICAL in Chapter 3.
FUSE
Refer to STARTING SYSTEM.
SPARK PLUGS
7-17
ELEC
IGNITION SYSTEM
IGNITION COIL
1. Measure:
Primary coil resistance:
1.191.61 at 20 C (68 F)
NOTE:
When measuring a resistance of 10 or less
with the digital tester, the correct measurement
cannot be obtained because of the testers
internal resistance.
Refer to Low resistance measurement.
2. Measure:
Secondary coil resistance:
8.511.5 k at 20 C (68 F)
ENGINE STOP SWITCH

1. Check:
Engine stop switch continuity
Engine stop switch continuity
(black coupler)
Clip
Installed
Removed
7-18
Position
Free
Push
Free
Push
Lead color
White
Black
ELEC
IGNITION SYSTEM
ENGINE TEMPERATURE SENSOR

1. Measure:
Engine temperature sensor resistance
(at the specified temperature)
resistance:
20 C (68 F): 54.269.0 k
100 C (212 F): 3.123.48 k
Measurement steps:
Suspend the engine temperature sensor
in a container filled with water.
Measure the resistance when the specified temperature is reached.
SENSOR ASSEMBLY
1. Check:
Intake air temperature sensor
Out of specification Replace the sensor assembly.
Checking steps:
Measure the ambient temperature.
Connect a computer to the watercraft and
use the Yamaha Diagnostic System to
display the intake air temperature.
If the ambient temperature and the displayed intake air temperature differ by
more than 5 C ( 9 F), replace the
sensor assembly.
7-19
ELEC
IGNITION SYSTEM
THERMOSWITCH (ENGINE)
1. Check:
Thermoswitch (engine) continuity
Thermoswitch (engine) continuity
temperature:
a 8490 C (183194 F)
b 7084 C (158183 F)
1 No continuity
2 Continuity
Temperature
Time
Checking steps:
Suspend the thermoswitch (engine) in a
container filled with water.
Measure the continuity when the specified temperature is reached.
THERMOSWITCH (EXHAUST)
1. Check:
Thermoswitch (exhaust) continuity
continuity temperature:
a 94100 C (201212 F)
b 8094 C (176201 F)
1 No continuity
2 Continuity
Temperature
Time
Checking steps:
Suspend the thermoswitch (exhaust) in a
container filled with water.
Measure the continuity when the specified temperature is reached.
7-20
ELEC
IGNITION SYSTEM
MAIN AND FUEL PUMP RELAY

1. Check:
Main and fuel pump relay continuity
Faulty Replace.
Checking steps:
Connect the tester leads between the
main and fuel pump relay terminals 5, 6
and 7.
Connect the terminals 2 or 3 to the positive battery terminal.
Connect the terminal 1 to the negative
battery terminal.
Check that there is continuity between
the main and fuel pump relay terminals.
Check that there is no continuity between
the main and fuel pump relay terminals
after disconnecting terminals 2, 3 or 1.
main and fuel pump relay terminals 7
and 8.
Connect the terminals 4 to the negative
battery terminal.
Connect the terminal 6 to the positive
battery terminal.
the main and fuel pump relay terminals.
Check that there is no continuity between
the main and fuel pump relay terminals
after disconnecting terminals 4 or 6.
UP
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
7-21
ELEC
IGNITION SYSTEM
THROTTLE POSITION SENSOR

1. Measure:
Throttle position sensor output voltage
Out of specification Adjust the throttle
bodies synchronization.
in Chapter 4.
YB-06793
Test harness SMHW099-3
(3 pins):
90890-06793
Test connector:
YW-06862
Test connector FMY-8:
90890-06862
voltage:
0.756 0.016 V
Measurement steps:
Connect the test harness (3 pins) to the
throttle position sensor 1.
To start the ECM normally, use the
Yamaha Diagnostic System. Use the test
connector 2 to start the ECM normally
only if the Yamaha Diagnostic System is
not available.
Measure the throttle position sensor output voltage.
B/O
7-22
ELEC
IGNITION SYSTEM
CAM POSITION SENSOR

1. Measure:
Cam position sensor output voltage
New: YB-06877
Current: YB-06777
Test harness HM090-3 (3 pins):
New: 90890-06877
Current: 90890-06777
Cam position sensor output
voltage:
Green/orange (G/O)
Black/orange (B/O)
Voltage (V)
More than 4.8
Less than 0.8
More than 4.8
Measurement steps:
Remove the cam position sensor.
Connect the test harness (3 pins) to the
cam position sensor.
Operate the Yamaha Diagnostic System.
Measure the output voltage when a
screwdriver is passed under the cam
position sensor in the direction shown.
Position
B
C
NOTE:
The cam position sensor contains two individual sensors as shown in the illustration:
sensor 1 1 and sensor 2 2.
To measure the output voltage, pass the
screwdriver under the measuring positions
A, B (center), and C of the cam position sensor in order.
When operating the Yamaha Diagnostic System, electric power is supplied to the cam
position sensor.
7-23
ELEC
IGNITION SYSTEM
NOISE FILTER
B
1. Check:
Noise filter continuity
R
G
Noise filter continuity:

B
Black (B) Red (R)
No continuity
SLANT DETECTION SWITCH
1. Check:
Slant detection switch continuity
UP
Lead color
Position Blue/black
(L/B)
UP
Normal
operation
Overturned
7-24
Black/
orange
(B/O)
ELEC
FUEL CONTROL SYSTEM
FUEL CONTROL SYSTEM

WIRING DIAGRAM
Br
5 :P
6 : P/W
8 : B/Y
9 :O
14 : L
28 : L/B
30 : R/Y
33 : P/G
35 : B/Y
37 : Pu/G
38 : Pu/Y
39 : Pu/B
40 : Pu/R
1
R/Y
L/R
R/Y
R/Y
P
R
R/Y
R/Y
R/Y
O
2
R/Y
12 3 456 7 8
P R R
O O
R/Y
L/B
P/W
L/R
18 15
P/W
P/G
O
R/Y
Pu/R
Pu/G
P/W
G/R
G/Y
Pu/B
Pu/Y
G
B/Y
B/O
G/B
G/Y
G/B
G/R
G
Pu/R
Pu/G
6
L/B
B/O
Pu/B
Pu/Y
R/Y
P/G
B
B
B
P
R/Y
R/Y
R/Y
B/Y
R/Y
R/Y
B/Y
P
P
O
P/G
Pu/R
R/Y
Pu/B
B/O
B/Y
B/O
B/Y
B/Y
B/Y
B/O
#2
B/Y
O
O
P
Pu/B
B/O
R/Y
R/Y
B/O
Pu/Y
Pu/Y
B/O
#3
B/O
B/O
R/Y
B/O
R/Y
B/O
Pu/G
Pu/G
1
2
3
4
5
6
7
8
9
B/O
#4
B/O
R/Y
R/Y
ECM
Fuse (20A)
Battery
Fuel pump
Multifunction meter
Fuel sender
B/O
R/Y
B/O
B/O
B/O
#1
P/G
Pu/R
B
B/O
B/O
B/O
B/O
0
A
B
C
D
E
F
7-25

Sensor assembly
Fuel injector
Oil pressure switch
Remote control unit
ELEC
FUEL CONTROL SYSTEM
WIRING DIAGRAM
Br
5 :P
6 : P/W
8 : B/Y
9 :O
14 : L
28 : L/B
30 : R/Y
33 : P/G
35 : B/Y
37 : Pu/G
38 : Pu/Y
39 : Pu/B
40 : Pu/R
1
R/Y
L/R
R/Y
R/Y
P
R
R/Y
R/Y
R/Y
O
2
R/Y
12 3 456 7 8
P R R
O O
R/Y
L/B
P/W
L/R
18 15
P/W
P/G
O
R/Y
Pu/R
Pu/G
P/W
G/R
G/Y
Pu/B
Pu/Y
G
B/Y
B/O
G/B
G/Y
G/B
G/R
G
Pu/R
Pu/G
6
L/B
B/O
Pu/B
Pu/Y
R/Y
P/G
B
B
B
P
R/Y
R/Y
R/Y
B/Y
R/Y
R/Y
B/Y
B
B/O
P
O
P/G
Pu/R
R/Y
Pu/B
B/Y
O
O
Pu/B
B/O
B/Y
B/O
B/Y
B/O
#2
B/Y
B/Y
B/O
R/Y
R/Y
B/O
Pu/Y
Pu/Y
B/O
#3
B/O
B/O
R/Y
B/O
R/Y
B/O
Pu/G
Pu/G
B
Br
G
L
O
P
R
W
Y
B/O
#4
B/O
R/Y
: Black
: Brown
: Green
: Blue
: Orange
: Pink
: Red
: White
: Yellow
B/O
R/Y
B/O
B/O
B/O
#1
P/G
Pu/R
B/O
B/O
R/Y
B/O
B/O
B/Y
G/O
L/B
L/R
P/G
P/W
Pu/B
Pu/G
: Black/orange
: Black/yellow
: Green/orange
: Blue/black
: Blue/red
: Pink/green
: Pink/white
: Purple/black
: Purple/green
7-26
Pu/R
Pu/Y
R/Y
W/R
: Purple/red
: Purple/yellow
: Red/yellow
: White/red
ELEC
FUEL CONTROL SYSTEM
FUEL PUMP
1. Check:
Fuel pump operating sound
Fuel pump does not sound Measure
the fuel pressure.
in Chapter 4.
NOTE:
After the engine is stopped, the fuel pump will
operate for 10 seconds.
FUEL SENDER
1. Measure:
Float
position
7-27
Resistance ()
133.5136.5
57
ELEC
FUEL CONTROL SYSTEM
FUEL INJECTOR
in Chapter 4.

Refer to IGNITION SYSTEM.
OIL PRESSURE SWITCH

Refer to INDICATION SYSTEM.
SLANT DETECTION SWITCH

REMOTE CONTROL UNIT

Refer to REMOTE CONTROL SYSTEM.
7-28
ELEC
STARTING SYSTEM
STARTING SYSTEM
WIRING DIAGRAM
Y
L/R
1
R
R/Y
R/Y
R
R/Y
P
R/Y
P
O
R/Y
12 3 456 7 8
31 14
21
R/Y
30
R R
L/R
L
Y
B
L
B
B
L
B
Br
B
B
B
Br
B
8
W B
FREE
PUSH
7
R
Br
Br Br
FREE
PUSH
5
B
Br
Br
R
Br
Br
R
11 15 14 18 12 3 4 13
123456789
0ABCDEFGH
1
2
3
4
5
6
7
8
9
ECM
Fuse (20A)
Starter relay
Starter motor
Battery
Start switch
Fuse (3A)
0 Remote control unit

A Fuel pump
7-29
B
Br
L
R
Y
L/R
R/Y
: Black
: Brown
: Blue
: Red
: Yellow
: Blue/red
: Red/yellow
ELEC
STARTING SYSTEM
BATTERY
WIRING CONNECTIONS
1. Check:
Wiring connections
Poor connections Properly connect.
FUSE
1. Check:
Fuse broken
Broken Replace.
Fuse rating:
3A, 20A
NOTE:
20A fuse is for main relay, engine shut-off
switch and rectifier/regulator.
3A fuse is for multifunction meter, electric bilge
pump, and remote control unit.
START SWITCH
1. Check:
Continuity
Start continuity
(natural color coupler)
Clip
Installed
Removed
7-30
Position
Free
Push
Free
Push
Leads
Red
Brown
ELEC
STARTING SYSTEM
STARTER RELAY
1. Inspect:
Brown lead terminal
Black lead terminal
Loose Tighten.
2. Check:
Starter relay
Faulty Replace.
Checking steps:
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.
the starter relay terminals.
Check that there is no continuity after the
brown or black lead is removed.
Br
B
REMOTE CONTROL UNIT

7-31
ELEC
STARTER MOTOR
STARTER MOTOR
EXPLODED DIAGRAM

Step
1
2
3
4
5
6
7
Procedure/Part name
STARTER MOTOR
DISASSEMBLY
Starter motor
O-ring
Bolt
Starter motor front cover
O-ring
Oil seal retainer
Washer
Shim
Qty
1
2
1
1
1
1
*
*: As required
7-32
Service points
MOTOR in Chapter 5.
Not reusable
Not reusable
t = 0.2 mm, 0.5 mm
ELEC
STARTER MOTOR
EXPLODED DIAGRAM
Step
8
9
10
11
12
13
14
15
16
17
Procedure/Part name
Starter motor rear cover
O-ring
Shim
Armature assembly
Nut/spring washer/washer
O-ring
Brush holder
Brush spring
Bolt
Brush assembly
Qty
1
1
*
1
1/1/4
1
1
4
1
1
*: As required
7-33
Service points
Not reusable
t = 0.2 mm, 0.8 mm
Not reusable
ELEC
STARTER MOTOR
EXPLODED DIAGRAM
Step
18
19
20
Procedure/Part name
Spacer
Holder
Starter motor yoke
Qty
1
1
1
Service points

assembly.
7-34
ELEC
STARTER MOTOR
SERVICE POINTS
Armature inspection
1. Inspect:
Armature shaft 1
2. Inspect:
Commutator
Dirt Clean with 600 grit sandpaper.
3. Measure:
Commutator diameter
Below specification Replace.
Minimum 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
Minimum commutator undercut:
0.2 mm (0.01 in)
7-35
ELEC
STARTER MOTOR
E
6. Inspect:
Armature coil continuity
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
Minimum brush length:
6.5 mm (0.26 in)
2. Check:
Brush holder continuity
Brush holder continuity:
Brush holder - Base
No continuity
Starter motor front cover inspection

1. Inspect:
Starter motor front cover oil seal
Damage/wear Replace the starter
motor front cover.
7-36
ELEC
CHARGING SYSTEM
CHARGING SYSTEM
WIRING DIAGRAM
1
B
B G G G R
G
G
G
G
1
2
3
4
Rectifier/regulator
Fuse (20A)
Battery
Lighting coil
B
G
R
7-37
: Black
: Green
: Red
ELEC
CHARGING SYSTEM
FUSE
BATTERY
LIGHTING COIL
RECTIFIER/REGULATOR
7-38
ELEC
ELECTRIC BILGE PUMP
ELECTRIC BILGE PUMP

WIRING DIAGRAM
R/Y
L/R
R/Y
R/Y
R/Y
P
R/Y
R/Y
12 3 456 7 8
21
30
R/Y
R/Y
L/R
3
R/Y
B
B
R/Y
Br
B
Br
R/Y
R
15
1
2
3
4
5
6
7
ECM
Fuse (3A)
Battery
Electric bilge pump
Remote control unit
Fuse (20A)
B
Br
R
Y
L/R
R/Y
7-39
: Black
: Brown
: Red
: Yellow
: Blue/red
: Red/yellow
ELEC
ELECTRIC BILGE PUMP
ELECTRIC BILGE PUMP
Br
1. Check:
Electric bilge pump operation
Incorrect Replace.
Checking steps:
Suspend the electric bilge pump in a container filled with water.
Connect the brown lead terminal to the
positive battery terminal.
Connect the black lead terminal to the
negative battery terminal.
Check the water flows from the electric
bilge pump hose.
FUSE
BATTERY

REMOTE CONTROL UNIT

7-40
ELEC
OFF THROTTLE STEERING SYSTEM

WIRING DIAGRAM
9 :O
12 : W/R
13 : W/B
16 : G/B
17 : G/Y
18 : G/R
20 : G
29 : W/L
30 : R/Y
34 : P
1
R
P
B/O
B/O
P
B/O
B/O
O
R
R/Y
R/Y
W/L
B/O
R/Y
R/Y
R/Y
R/Y
Y/B
B
R/W
W/L
R/Y
R/Y
R/W
R/Y
B/O
R/Y
P/G
O
Pu/B
Pu/R
Pu/G
B/O
W/B
G
B/Y
B/O
G/B
G/Y
G/B
G/R
G
Pu/R
Pu/G
B/O
B/O
Pu/B
Pu/Y
R/Y
B/O
B/O
W/R
G/R
G/Y
R/Y
B/O
W/R W/B
B/O
B/O B/O
R/Y
Pu/Y
R/Y
P/G
B
R W
R/Y
R/Y
3
G R/Y G/R
G/Y R/Y G/B
R/Y
B/O
G/R
G/Y
B/O
P
O
G
G/B
R/Y
1
2
3
4
5
Y/B
ECM
Steering switch
Pickup coil
Bypass valve motor
B
G
O
P
W
B/O
G/B
G/R
G/Y
: Black
: Green
: Orange
: Pink
: White
: Black/orange
: Green/black
: Green/red
: Green/yellow
7-41
R/Y
R/W
W/B
W/L
W/R
Y/B
: Red/yellow
: Red/white
: White/black
: White/blue
: White/red
: Yellow/black
ELEC
STEERING SWITCH
1. Check:
Steering switch
For checking instructions, refer to
SELF-DIAGNOSIS in Chapter 9.
Malfunction Use the Engine monitor
of the Yamaha Diagnostic System to
check that the steering switch switches
on and off when the handlebar is turned
to the right and to the left.
Does not operate Replace.
ECM
PICKUP COIL
THROTTLE POSITION SENSOR

BYPASS VALVE MOTOR

in Chapter 4.
7-42
ELEC
INDICATION SYSTEM
INDICATION SYSTEM
WIRING DIAGRAM
Y
L/R
R/Y
R/Y
R/Y
R/Y
P
O
R/Y
1 2 3456 7 8
14 6 15 35 5
R/Y
R/Y
P P P R R
1 21 30
R/Y
L/R
P/W
R/Y
B
P/W
W/B
B/O
W/B
G
R/Y
B
P/W
B/O
B
B/O
G
P
W B R
P
B
B/O
B/O
0
P
P
L/R
L/B Gy
B/Y
L/R
Gy
R/W
B
B/O
B/Y
B/O
L/Y
B/O
B/Y
B/Y
B/Y
Y
L/R
15 18 16 7 6
Y
L
P
B/Y
R/Y
B/O
L/R
B/L
L/R
B/Y
R/Y
B/O
B/O
B/O
B/O
B
B
B/O
B/O
B/O
B/O
B/O
B/O
B/O
C
1
2
3
4
5
6
7
8
9
B/Y
L/Y
L/B
B/L
R/W
B/Y
L/B
B/O
B/O
0
A
B
C
D
ECM
Fuse (20A)
Remote control unit
Battery
Tacho pulse
7-43
Multifunction meter
Fuel sender
Speed sensor
Buzzer
Oil pressure switch
ELEC
INDICATION SYSTEM
WIRING DIAGRAM
Y
L/R
R/Y
R/Y
R/Y
R/Y
P
O
R/Y
1 2 3456 7 8
14 6 15 35 5
R/Y
R/Y
P P P R R
1 21 30
R/Y
L/R
P/W
R/Y
B
P/W
W/B
B/O
W/B
G
R/Y
B
P/W
B/O
B
B/O
G
P
W B R
P
B
B/O
B/O
0
P
P
L/R
L/B Gy
B/Y
L/R
Gy
R/W
B
B/O
B/Y
B/O
L/Y
B/O
B/Y
B/Y
B/Y
Y
L/R
15 18 16 7 6
Y
L
P
B/Y
R/Y
B/O
L/R
B/L
L/R
B/Y
B/O
R/Y
B/O
B/O
B/O
B
B
B/O
B/O
B/O
B/O
B/O
B/O
B/O
C
B
Br
G
Gy
L
O
P
: Black
: Brown
: Green
: Gray
: Blue
: Orange
: Pink
B/Y
L/Y
L/B
B/L
R
W
Y
B/L
B/O
B/Y
L/B
R/W
B/Y
L/B
B/O
B/O
: Red
: White
: Yellow
: Black/blue
: Black/orange
: Black/yellow
: Blue/black
7-44
L/R
L/Y
P/W
R/W
R/Y
W/B
: Blue/red
: Blue/yellow
: Pink/white
: Red/white
: Red/yellow
: White/black
ELEC
INDICATION SYSTEM
FUSE
BATTERY

ECM
ENGINE TEMPERATURE SENSOR

REMOTE CONTROL UNIT

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
7-45
ELEC
INDICATION SYSTEM
OIL PRESSURE SWITCH

1. Measure:
Lower unit pressure/vacuum
tester:
YB-35956-A
Vacuum/pressure pump gauge
set:
90890-06756
pressure:
128 kPa (1.28 kgf/cm2, 18.2 psi)
166 kPa (1.66 kgf/cm2, 23.6 psi)
MULTIFUNCTION METER
Multifunction meter
1. Check:
Multifunction meter
Cracked meter housing Replace the
multifunction meter.
Meter is fogged/shows signs of water
intrusion Replace the multifunction
meter.
MULTIFUNCTION METER REMOVAL

Refer to STEERING
COVER in Chapter 8.
7-46
CONSOLE
ELEC
INDICATION SYSTEM
E
Display function
1. Check:
Display function
Does not operate Replace the multifunction meter.
L/Y
L/B
B/L
Gy
B/L
L/B
L/R
B
R
L/R
L/R
R
B/Y
R/W
B/Y
R/W
Y
Y
W
W
B
5
B
1
2
3
4
5
Remote control unit

Buzzer
Speed sensor
ECM
Fuel sender
B
Gy
P
R
W
Y
B/G
B/L
B/Y
L/B
L/R
R/W
: Black
: Gray
: Pink
: Red
: White
: Yellow
7-47
: Black/green
: Black/blue
: Black/yellow
: Blue/black
: Blue/red
: Red/white
ELEC
INDICATION SYSTEM
E
Speedometer display
1. Check:
Speedometer display
Does not display Measure the speed
sensor output voltage and pulses.
2. Measure:
Speed sensor output voltage and pulses
Out of specification Repair or
replace.
Within specification Replace the multifunction meter.
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
Measurement steps:
Apply DC 12 voltage to the natural 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/
yellow and yellow leads.
NOTE:
As the paddle wheel is rotated, a squarewave voltage signal a is produced.
Two pulses occur every time the paddle
wheel makes one-full turn.
7-48
ELEC
INDICATION SYSTEM
E
Tachometer display
1. Check:
Tachometer display
Does not display Check the engine
speed using the Engine monitor of the
Replace the multifunction meter.
Hour meter display
1. Check:
Hour meter display
Does not display Replace the multifunction meter.
Voltage meter display
1. Check:
Voltage meter display
Does not display Check the battery
voltage using the Engine monitor of
the Yamaha Diagnostic System.
Low oil pressure warning indicator
1. Check:
Low oil pressure warning indicator
No operating Check the oil pressure
switch using the Engine monitor of the
Fuel level meter display and fuel warning
indicator
1. Check:
Fuel level meter display and fuel warning indicator
Does not display Measure the fuel
sender resistance.
If the fuel sender resistance is within
specification, replace the multifunction
meter.
2. Measure:
Refer to FUEL CONTROL SYSTEM.
7-49
ELEC
INDICATION SYSTEM
E
Overheat warning indicator
1. Check:
Checking steps:
Start the engine.
Disconnect the thermoswitch (engine)
connector 1 (blue), engine temperature
sensor connector 2 (black) or thermoswitch (exhaust) 3 connector.
Connect the jumper lead to the female
terminal of the disconnected connector.
Check that the multifunction meter overheat warning indicator comes on and the
buzzer sounds.
Check the engine warning indicator

1. Check:
Checking steps:
Start the engine.
Disconnect the coupler of a sensor (e.g.,
engine temperature sensor) that normally
activates the check engine warning indicator when a malfunction occurs.
Check that the warning light and check
engine warning indicator blink and that
the buzzer sounds intermittently.
7-50
ELEC
REMOTE CONTROL SYSTEM

WIRING DIAGRAM
Y
L/R
1
R
R/Y
R
R/Y
R/Y
R
P
P
R/Y
O
R/Y
14 : L
15 : W/B
21 : L/R
30 : R/Y
31 : Y
37 : Pu/G
38 : Pu/Y
39 : Pu/B
40 : Pu/R
12 3 456 7 8
31 14
21
R/Y
R
R/Y
30 15
L/R
Y
P/G
R/Y
Pu/B
Pu/Y
Pu/R
Pu/G
G/R
G/Y
Br
B
B/O
G/B
G/Y
G/B
G/R
G
Pu/R
Pu/G
G
B/Y
Br
R/Y
Pu/B
Pu/Y
R/Y
W/B
P/G
W/B
B
R/Y
B/O
R/Y
R/Y
R/Y
R/Y
Pu/R
Pu/R
#1
R/Y
R/Y
Pu/B
L/R
Pu/B
L/B Gy
L/R
Gy
W
#2
R/Y
16 7 6 11 15 14 18 12 3 4 13 10
R/Y
123456789
0ABCDEFGH
Pu/Y
#3
R/Y
R/Y
Pu/G
#4
R/Y
L/R
L/R
Pu/G
L/Y
L/B
Pu/Y
L/R
B/L
L/Y
L/B
R/Y
1 ECM
2 Main and fuel pump
relay
3 Fuse (20A)
4 Starter relay
5 Starter motor
6 Battery
7 Fuse (3A)
9
0
A
B
B/L
Multifunction meter
Fuel injector
Antenna
Buzzer
B
Br
Gy
L
R
W
Y
B/L
L/B
7-51
: Black
: Brown
: Gray
: Blue
: Red
: White
: Yellow
: Black/blue
: Blue/black
L/R
L/Y
Pu/B
Pu/G
Pu/R
Pu/Y
R/Y
W/B
: Blue/red
: Blue/yellow
: Purple/black
: Purple/green
: Purple/red
: Purple/yellow
: Red/yellow
: White/black
ELEC

Yamaha Security System indicator
1. Check:
Check that the SECURITY indicator
light 1 comes on when the Yamaha
Security System is deactivated (i.e., the
engine can be started).
Does not come on Measure the
remote control unit output voltage.
2. Measure:
Remote control unit output voltage
remote control unit.
Remote control unit output

voltage:
Blue/yellow (L/Y) ground
1113 V
Measurement steps:
Disconnect the remote control unit 1
coupler from the multifunction meter.
Measure the remote control unit output
voltage while pushing the unlock button
of the remote control transmitter.
L/Y
Low-rpm mode indicator

1. Check:
Does not come on Replace the multifunction meter.
Checking steps:
Press the unlock button 1 of remote control transmitter for more than four seconds to select the low-rpm mode.
Check that the beeper sounds three
times and the L-MODE indicator light 2
comes on.
7-52
ELEC
Diagnostic display
1. Check:
Diagnostic display
Checking steps:
Start the engine.
Disconnect the coupler of a sensor (e.g,.
engine temperature sensor) that is normally displayed when a malfunction
occurs. Refer to SELF-DIAGNOSIS in
Chapter 9.
Check that the check engine warning
indicator is displayed and that the buzzer
sounds.
Press the select switch 1 for 8 seconds
and check the error code indicated on the
Checking the remote control transmitter

1. Check:
Remote control transmitter
Does not operate Replace the remote
control transmitter.
Checking steps:
CAUTION:
If the buttons on the remote control
transmitter are pushed but the transmitter does not operate, the battery may be
low.
Press the lock button 1 of the remote
control transmitter. The beeper sounds
once.
light goes off and the engine cannot be
started.
Press the unlock button 2 of the remote
control transmitter for a short time. The
beeper sounds two or three times.
light comes on and the engine can be
started.
7-53
ELEC
Number of
beeps
Yamaha
Security
System mode
Engine
startability
1 beep
Lock
Unable
2 beeps
Unlock
(normal mode)
Able
3 beeps
Unlock
(low-rpm
mode)
Able
Press the unlock button for more than 4

seconds to select the low-rpm mode.
times and the L-MODE indicator light
comes on.
NOTE:
If the start switch or the remote control
transmitter is not operated for more than
25 seconds, the multifunction meter display and the L-MODE indicator light will
go off. To change the modes again, press
the lock button for a short time, and then
start the procedures from the lock mode.
While the engine is running, input from the
remote control transmitter is not received.
7-54
ELEC
Transmitter registration
1. Register:
Remote control transmitter 1
ID codes can be added or re-registered
by connecting the entry box 2.
Gy
Registration steps:
Connect the entry box.
Transmit the ID code from the remote
control transmitter to be registered.
NOTE:
The remote control transmitters can be registered in any sequence, regardless of
whether they are original equipment or
additional transmitters.
At this time, the system enters the registration mode to register the first code. All
existing ID codes will be deleted from the
EEPROM.
The SECURITY indicator light flashes
when the registration of the ID code has
been completed. (If the registration could
not be completed, the SECURITY indicator light comes on. Re-transmit the ID
code.)
After confirming that the registration of
the ID code has been completed using
the SECURITY indicator light, transmit
the next ID code.
Register the ID codes for up to five
remote control transmitters.
After ID code registration has been completed, disconnect the entry box to exit
the registration mode.
7-55
ELEC
Replacing of the transmitter battery
CAUTION:
Do not allow any water, dust, or dirt to
enter the remote control transmitter case
when replacing the battery.
Make sure that no foreign material is
trapped between the upper case and
lower case of the remote control transmitter during assembly.
1. Remove:
Cover
NOTE:
Loosen the transmitter cover screws in the
sequence shown.
2. Install:
Battery 1
NOTE:
Install the battery (CR2016) with the positive
side facing down.
3. Install:
Cover
NOTE:
Tighten the transmitter cover screws in the
sequence shown.
T.
7-56
Transmitter cover screw:

0.1 N m
(0.01 kgf m, 0.07 ft lb)
HULL
HOOD
CHAPTER 8
HULL AND HOOD
HANDLEBAR ..................................................................................................8-1
SERVICE POINTS .................................................................................... 8-6
Handlebar inspection ..........................................................................8-6
Handlebar switch inspection ............................................................... 8-6
Handlebar assembly installation .........................................................8-6
QSTS GRIP ..................................................................................................... 8-8
SERVICE POINTS .................................................................................. 8-10
QSTS cable inspection and adjustment ............................................8-10
QSTS grip inspection ........................................................................8-10
STEERING MASTER.....................................................................................8-11
SERVICE POINTS .................................................................................. 8-15
Steering master components inspection ...........................................8-15
REMOTE CONTROL CABLES AND SPEED SENSOR LEAD ....................8-16
SERVICE POINTS .................................................................................. 8-19
Remote control cables inspection .....................................................8-19
Steering cable (jet pump end) installation .........................................8-19
Steering cable stopper installation ....................................................8-19
QSTS cable (jet pump end) installation............................................. 8-20
QSTS cable stopper installation........................................................ 8-20
Shift cable (jet pump end) installation ............................................... 8-20
Shift cable holder installation ............................................................ 8-21
Shift cable stopper installation .......................................................... 8-21
Remote control cables adjustment....................................................8-21
FRONT HOOD ...............................................................................................8-22
HULL
HOOD
STEERING CONSOLE COVER .................................................................... 8-26

SERVICE POINTS .................................................................................. 8-32
Glove compartment assembly installation.........................................8-32
HOSES ..........................................................................................................8-33
SHIFT LEVER................................................................................................8-35
SERVICE POINTS .................................................................................. 8-38
Base assembly.................................................................................. 8-38
Shift lever .......................................................................................... 8-38
SEATS AND HAND GRIP ............................................................................. 8-39
SERVICE POINTS .................................................................................. 8-42
Seat lock inspection ..........................................................................8-42
EXHAUST SYSTEM ......................................................................................8-43
SERVICE POINTS .................................................................................. 8-46
Exhaust system inspection................................................................8-46
Exhaust component parts sub-assembly ..........................................8-46
Exhaust system installation...............................................................8-47
DECK AND HULL.......................................................................................... 8-48
ENGINE MOUNT ........................................................................................... 8-50
HULL
HOOD
HANDLEBAR
HANDLEBAR
EXPLODED DIAGRAM

Step
1
2
3
4
5
6
7
8
Procedure/Part name
HANDLEBAR COVER REMOVAL
Screw
Handlebar cover
Pad
Bolt
Throttle cable
Bolt
Upper handlebar holder
Qty
4
1
1
2
1
1
4
2
Service points
NOTE:
Position the corrugated tube for the throttle
cable as shown in the illustration so that the
tube attaches to the end of the outer throttle
cable.
8-1
HULL
HOOD
HANDLEBAR
EXPLODED DIAGRAM

Step
1
2
3
4
5
6
7
8
9
Procedure/Part name
HANDLEBAR REMOVAL
QSTS cable (to jet thrust nozzle)
Qty
Nut/washer
QSTS converter
QSTS cable 2
QSTS cable 1
Handlebar switch coupler
Buzzer coupler
Screw
Handle boss cover
Band
2/2
1
1
1
2
1
4
1
2
8-2
Service points
Refer to REMOTE CONTROL CABLES
AND SPEED SENSOR LEAD.
with white tape a
HULL
HOOD
HANDLEBAR
EXPLODED DIAGRAM
Step
10
11
12
13
Procedure/Part name
Hose packing
Buzzer
Handlebar assembly
Grommet
Qty
1
1
1
Service points
Not reusable
NOTE:
Pass the QSTS cable and handlebar
switch lead through the handle boss
cover, and then install the handlebar
assembly.
Install the sponges of the QSTS cables as
shown and make sure that the grommet is
installed to the deck securely.
2
8-3
HULL
HOOD
HANDLEBAR
EXPLODED DIAGRAM

Step
1
2
3
4
5
6
7
Procedure/Part name
HANDLEBAR DISASSEMBLY
Bolt
Grip end
Spacer
Screw/spring washer/washer
QSTS grip assembly
Special nut
Screw
Qty
2
2
1
1/1/1
1
1
2
8-4
Service points
NOTE:
Tighten the screw from the engine stop
switch side.
HULL
HOOD
HANDLEBAR
EXPLODED DIAGRAM
Step
8
9
10
11
12
Procedure/Part name
Handlebar switch assembly
Screw
Throttle lever assembly
Handlebar grip
Handlebar
Qty
1
2
1
1
Service points
NOTE:
Apply adhesive to the handlebar and the
inner surface of the handlebar grip.
1
assembly.
8-5
HULL
HOOD
HANDLEBAR
SERVICE POINTS
Handlebar inspection
1. Inspect:
Handlebar
Bends/cracks/damage Replace.
Handlebar switch inspection
Refer to STARTING SYSTEM in
Chapter 7.
Handlebar assembly installation
1. Install:
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 marks 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.
T.
Handlebar holder bolt:

20 N m (2.0 kgf m, 14 ft lb)
LOCTITE 242
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. Install:
Handlebar cover 1
NOTE:
When the handlebar cover is in contact with
the steering boss cover, adjust the handlebar
mount angle so that the clearance a and b
are equal.
5. Adjust:
Throttle cable free play
6. Adjust:
QSTS cable
8-7
HULL
HOOD
QSTS GRIP
QSTS GRIP
EXPLODED DIAGRAM

Step
1
2
3
4
5
6
Procedure/Part name
QSTS GRIP DISASSEMBLY
QSTS grip assembly
Screw/washer
Cover
Ball
Spring
QSTS cable 1
QSTS cable 2
Qty
1/1
1
2
2
1
1
8-8
Service points
Refer to HANDLEBAR.
with white tape a
HULL
HOOD
QSTS GRIP
EXPLODED DIAGRAM
Step
7
8
9
10
11
12
13
Procedure/Part name
Screw/washer
Spacer
QSTS shift lock lever
Spring
Spacer
Cable housing
QSTS grip
Qty
2/2
1
1
1
1
1
1
Service points

assembly.
8-9
HULL
HOOD
QSTS GRIP
SERVICE POINTS
QSTS cable inspection and adjustment
1. Inspect:
QSTS cables
Frays/kinks/rough movement
Replace.
2. Adjust:
QSTS cable length a
QSTS cable length:
72 0.5 mm (2.83 0.02 in)
NOTE:
Before adjusting the QSTS cables, set the
trim grip to the neutral position.
Adjust the QSTS cable lengths a to the
specified length and be sure to take up any
slack.
QSTS grip inspection

1. Inspect:
QSTS grip
8-10
HULL
HOOD
STEERING MASTER
STEERING MASTER
EXPLODED DIAGRAM

Step
1
2
3
4
5
Procedure/Part name
STEERING MASTER REMOVAL
Steering cable end
Qty
Bolt/washer
Steering arm
Nut/washer
Steering master assembly
Bolt
1/1
1
4/4
1
4
8-11
Service points
Refer to STEERING CONSOLE COVER.
HULL
HOOD
STEERING MASTER
EXPLODED DIAGRAM
Step
6
7
8
Procedure/Part name
Bolt
Magnet
Steering switch
Qty
3
1
1
Service points
8-12
HULL
HOOD
STEERING MASTER
EXPLODED DIAGRAM

Step
1
2
3
4
5
6
7
8
9
10
Procedure/Part name
STEERING MASTER
DISASSEMBLY
Bolt/washer
Stay
Spring
Bolt/washer
Lower housing
Spring
Bushing
Bushing
Upper housing
Tilt lever
Qty
2/2
1
1
6/6
1
1
1
1
1
1
8-13
Service points
HULL
HOOD
STEERING MASTER
EXPLODED DIAGRAM
Step
11
12
13
14
15
16
17
18
19
Procedure/Part name
Tilt stopper
Bolt/nut/holder
Retainer
Steering shaft
Steering tube
Bolt
Cap
Shaft 1
Cross piece
Qty
1
4/4/4
2
1
1
2
1
1
1
Service points

assembly.
8-14
HULL
HOOD
STEERING MASTER
SERVICE POINTS
Steering master components inspection
1. Inspect:
Each component part
Damage/wear Replace the steering
master.
8-15
HULL
HOOD
REMOTE CONTROL CABLES AND

SPEED SENSOR LEAD
REMOTE CONTROL CABLES AND SPEED SENSOR LEAD

EXPLODED DIAGRAM

Step
1
2
3
4
5
Procedure/Part name
REMOTE CONTROL CABLES
AND SPEED SENSOR LEAD
REMOVAL
Service lid 1
Front seat assembly
Glove compartment
Steering cable end
Nut/washer
Bracket
Nut
Steering cable holder
Qty
Service points
Refer to FRONT HOOD.

Refer to SEATS AND HAND GRIP.
1
2/2
1
2
1
8-16
HULL
HOOD

SPEED SENSOR LEAD
EXPLODED DIAGRAM
Step
6
7
8
9
10
11
12
13
14
15
Procedure/Part name
Nut
Steering cable
Seal
Speed sensor coupler
Nut
Cap
Screw
Speed sensor
Shift cable end
Nut
Qty
1
1
1
1
1
1
4
1
1
2
8-17
Service points
HULL
HOOD

SPEED SENSOR LEAD
EXPLODED DIAGRAM
Step
16
17
18
19
20
21
22
23
24
25
Procedure/Part name
Shift cable holder
Nut
Shift cable
Seal
Nut
Pin
QSTS cable end
Nut
QSTS cable
Packing
Qty
2
1
1
1
1
1
1
1
1
1
Service points
8-18
HULL
HOOD

SPEED SENSOR LEAD
SERVICE POINTS
WARNING
When routing the cables, do not grasp the
cable by the outer crimped sheath or steel
end. This could deform or loosen the cable
end due to extreme angles and or pressure.
Always hold the cables by the 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
Steering cable set length a
(jet pump end):
14.5 mm (0.57 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 the steering cable stopper into
the groove in the outer cable as shown in
the illustration.
8-19
HULL
HOOD

SPEED SENSOR LEAD
QSTS cable (jet pump end) installation

1. Install:
QSTS cable (jet pump end)
QSTS cable set length a
(jet pump end):
13.6 mm (0.54 in)
WARNING
The QSTS cable must be screwed in more
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)
Shift cable set length a
(jet pump end):
13.6 mm (0.54 in)
WARNING
The shift cable must be screwed in more
8-20
HULL
HOOD

SPEED SENSOR LEAD
Shift cable holder installation

1. Install:
Shift cable holders
NOTE:
Install the shift cable holders so that mark a
and mark b are in the positions shown in the
illustration.
Shift cable stopper installation

1. Install:
Shift cable stopper
WARNING
Be sure to fit the projection 1 on the shift
cable stopper into the groove in the outer
cable.
Remote control cables adjustment
8-21
HULL
HOOD
FRONT HOOD
FRONT HOOD
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 10 mm
7
6
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 18 mm
LT
242
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 18 mm
8
4
LT
242
LT
242
LT
271
5
6 30 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)
11 10
1
5.4 N m (0.54 kgf m, 3.9 ft Ib)
1.5 N m (0.15 kgf m, 1.1 ft Ib)

4 8 mm

Step
1
2
3
4
5
6
7
Procedure/Part name
FRONT HOOD REMOVAL
Nut/washer
Front hood assembly
Bolt
Bolt
Hinge assembly
Bolt
Hood lock assembly
Qty
4/4
1
4
2
1
2
1
8-22
Service points
HULL
HOOD
FRONT HOOD
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 10 mm
7
6
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 18 mm
LT
242
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 18 mm
8
4
LT
242
LT
242
LT
271
5
6 30 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)
11 10
1
5.4 N m (0.54 kgf m, 3.9 ft Ib)
Step
8
9
10
11
Procedure/Part name
Bolt
Service lid 1
Screw
Service lid 2
Qty
4
1
4
1
1.5 N m (0.15 kgf m, 1.1 ft Ib)

4 8 mm
Service points
8-23
HULL
HOOD
FRONT HOOD
EXPLODED DIAGRAM
4
1
6
10
2
7
8
9

Step
1
2
3
4
5
6
7
Procedure/Part name
HINGE DISASSEMBLY
Circlip
Pin (long)
Hinge
Pin (short)
Damper stay
Collar
Grommet
Qty
2
1
1
1
1
2
2
8-24
Service points
HULL
HOOD
FRONT HOOD
EXPLODED DIAGRAM
4
1
6
10
2
7
8
9
Step
8
9
10
Procedure/Part name
Band
Damper boots
Damper
Qty
1
1
1
Service points

assembly.
8-25
HULL
HOOD
STEERING CONSOLE COVER

EXPLODED DIAGRAM
3.9 N m (0.39 kgf m, 2.8 ft Ib)

5 20 mm
6.9 N m (0.69 kgf m, 5.0 ft Ib)
11
10
5
6
LT
9
4
242
3
12
LT
242
2
3.9 N m (0.39 kgf m, 2.8 ft Ib)
5 20 mm

Step
1
2
3
4
5
Procedure/Part name
METER AND MIRROR REMOVAL
Handlebar assembly
Service lid 1
Band
Multifunction meter coupler
Bolt
Panel
Band
Qty
1
4
4
1
1
8-26
Service points
Refer to HANDLEBAR.
HULL
HOOD
EXPLODED DIAGRAM
3.9 N m (0.39 kgf m, 2.8 ft Ib)

5 20 mm
6.9 N m (0.69 kgf m, 5.0 ft Ib)
11
10
5
6
LT
242
4
3
12
LT
242
2
3.9 N m (0.39 kgf m, 2.8 ft Ib)
5 20 mm
Step
6
7
8
9
10
11
12
Procedure/Part name
Bolt
Multifunction meter
Hose packing
Grommet
Nut/washer
Plate
Mirror
Qty
4
1
1
1
4/4
2
2
Service points
Not reusable
8-27
HULL
HOOD
EXPLODED DIAGRAM
2
1
3
4 3
3
3
5
LT
271
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 22 mm

Step
1
2
3
4
5
Procedure/Part name
SIDE COVER REMOVAL
Cup holder
Holder
Bolt
Washer
Side cover
Qty
Service points
1
1
8
2
2
8-28
HULL
HOOD
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 30 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 18 mm
6 22 mm
11
8 30 mm
LT
242
LT
242
8
12
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 14 mm
LT
271
10
20 N m (2.0 kgf m, 14 ft Ib)

5.4 N m (0.54 kgf m, 3.9 ft Ib)

Step
1
2
3
4
5
6
Procedure/Part name
AND GLOVE BOX ASSEMBLY
REMOVAL
Nut/washer
Bolt
Nut/washer
Bolt
Bolt
Shift handle lever
Qty
2/2
2
2/2
2
2
1
8-29
Service points
HULL
HOOD
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 30 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 18 mm
6 22 mm
11
8 30 mm
LT
242
LT
242
8
12
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 14 mm
LT
271
10
20 N m (2.0 kgf m, 14 ft Ib)

5.4 N m (0.54 kgf m, 3.9 ft Ib)
Step
7
8
9
10
11
12
Procedure/Part name
Bolt
Qty
2
1
Hood lock assembly

Nut/washer
Bolt
Glove compartment assembly
1
2/2
2
1
Service points
NOTE:
To remove the console cover easily, pull the
tilt lever up.
8-30
HULL
HOOD
EXPLODED DIAGRAM
3
5.4 N m (0.54 kgf m, 3.9 ft Ib)
6 14 mm
5
2
2
6
LT
271

Step
1
2
3
4
5
6
Procedure/Part name
GLOVE COMPARTMENT
DISASSEMBLY
Glove compartment
Hinge assembly
Lid
Gear assembly
Screw
Latch
Qty
Service points
1
2
1
2
2
1
assembly.
8-31
HULL
HOOD
SERVICE POINTS
Glove compartment assembly installation
1. Install:
Hinge assembly
NOTE:
When installing the hinge assembly, make
sure that the springs are in the position shown.
8-32
HULL
HOOD
HOSES
HOSES
EXPLODED DIAGRAM
(VENT)
FW
1
2
7
3
(VENT)
1
2
1
1
6
5
5
(VENT)
4 6
8
4.2 N m (0.42 kgf m, 3.0 ft Ib)
4.2 N m (0.42 kgf m, 3.0 ft Ib)

Step
Procedure/Part name
HOSES REMOVAL
Fuel tank
Qty
Service points
Refer to FUEL TANK AND FUEL PUMP
MODULE in Chapter 4.
NOTE:
When removing the ventilation hose and
fuel tank breather hose, it is not necessary
to remove the fuel tank.
1
2
3
Band
Ventilation hose
4
2
2
8-33
HULL
HOOD
HOSES
EXPLODED DIAGRAM
(VENT)
FW
1
2
7
3
(VENT)
1
2
1
1
6
5
5
(VENT)
Procedure/Part name
Clamp
Cooling water hose
Nut
Seal
4.2 N m (0.42 kgf m, 3.0 ft Ib)
4.2 N m (0.42 kgf m, 3.0 ft Ib)
Step
4
5
6
7
8
4 6
Qty
2
2
2
2
2
Service points
8-34
HULL
HOOD
SHIFT LEVER
SHIFT LEVER
EXPLODED DIAGRAM

Step
1
2
3
4
5
Procedure/Part name
SHIFT LEVER REMOVAL
Side cover
Shift cable
Bolt
Shift lever handle
Bolt
Washer
Shift lever
Qty
2
1
1
1
1
8-35
Service points
HULL
HOOD
SHIFT LEVER
EXPLODED DIAGRAM
Step
6
7
8
9
10
Procedure/Part name
Screw
Base assembly
Nut/washer
Screw
Plate
Qty
3
1
3/3
3
1
Service points
8-36
HULL
HOOD
SHIFT LEVER
EXPLODED DIAGRAM

Step
1
2
3
4
5
6
7
Procedure/Part name
BASE DISASSEMBLY
Bolt/washer
Plate
Spring
Actuator
Roller
Shaft
Shift arm
Qty
Service points
2/2
1
1
1
1
1
1
assembly.
8-37
HULL
HOOD
SHIFT LEVER
SERVICE POINTS
Base assembly
1. Install:
Shift arm
Shaft
Installation steps:
Install the shift arm 1 so that it comes in
contact with the stopper 2 as shown.
Install the shaft 3 to the base so that it
come in contact with the stopper 4 as
shown.
Shift lever
1. Install:
Shift lever
a
b
NOTE:
To install the shift lever, align the arrow mark
a on the shift lever with the punch mark b on
base assembly.
8-38
HULL
HOOD
SEATS AND HAND GRIP
SEATS AND HAND GRIP

EXPLODED DIAGRAM
6.4 N m (0.64 kgf m, 4.6 ft Ib)

6 40 mm
2
5
LT
4
5
11
12
13
8 30 mm
4
LT
6.4 N m (0.64 kgf m, 4.6 ft Ib)

6 40 mm
21
6 25 mm
271
271
8 30 mm
15
16
9
14
10
22
18
19
19 6
26 N m (2.6 kgf m, 19 ft Ib)
20
17
5.2 N m (0.52 kgf m, 3.8 ft Ib)

18 N m (1.8 kgf m, 13 ft Ib)
15 N m (1.5 kgf m, 11 ft Ib)
6.4 N m (0.64 kgf m, 4.6 ft Ib)
26 N m (2.6 kgf m, 19 ft Ib)

Step
1
2
3
4
5
6
7
8
Procedure/Part name
SEATS AND HAND GRIP
REMOVAL
Rear seat assembly
Rear seat assembly
Front seat assembly
Bolt
Seat lock assembly
Seat storage compartment
Nut/washer
Bolt/washer
Qty
Service points
1
1
1
4
2
1
4/4
4/4
FX High Output
8-39
HULL
HOOD
SEATS AND HAND GRIP
EXPLODED DIAGRAM
6.4 N m (0.64 kgf m, 4.6 ft Ib)

6 40 mm
2
5
LT
4
5
11
12
13
8 30 mm
4
LT
6.4 N m (0.64 kgf m, 4.6 ft Ib)

6 40 mm
21
6 25 mm
271
271
8 30 mm
15
16
9
14
10
22
18
19
19 6
26 N m (2.6 kgf m, 19 ft Ib)
20
7
17
5.2 N m (0.52 kgf m, 3.8 ft Ib)
18 N m (1.8 kgf m, 13 ft Ib)

15 N m (1.5 kgf m, 11 ft Ib)
6.4 N m (0.64 kgf m, 4.6 ft Ib)
26 N m (2.6 kgf m, 19 ft Ib)
Step
9
10
11
12
13
14
15
16
17
Procedure/Part name
Deck beam
Nut
Projection
Washer
Seal
Nut
Bolt
Rear seat stay
Nut
Qty
1
1
1
1
1
4
4
2
1
8-40
Service points
HULL
HOOD
SEATS AND HAND GRIP
EXPLODED DIAGRAM
6.4 N m (0.64 kgf m, 4.6 ft Ib)

6 40 mm
2
5
LT
4
5
11
12
13
8 30 mm
4
LT
6.4 N m (0.64 kgf m, 4.6 ft Ib)

6 40 mm
21
6 25 mm
271
271
8 30 mm
15
16
9
14
10
22
18
19
19 6
26 N m (2.6 kgf m, 19 ft Ib)
20
7
17
5.2 N m (0.52 kgf m, 3.8 ft Ib)
18 N m (1.8 kgf m, 13 ft Ib)

15 N m (1.5 kgf m, 11 ft Ib)
6.4 N m (0.64 kgf m, 4.6 ft Ib)
26 N m (2.6 kgf m, 19 ft Ib)
Step
18
19
20
21
22
Procedure/Part name
Projection
Washer
Nut/washer
Bolt
Hand grip
Qty
1
2
4/4
4
1
Service points
8-41
HULL
HOOD
SEATS AND HAND GRIP

SERVICE POINTS
Seat lock inspection
1. Inspect:
Front seat lock
Rear seat lock
8-42
HULL
HOOD
EXHAUST SYSTEM
EXHAUST SYSTEM
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib)
14
13
16
3.7 N m (0.37 kgf m, 2.7 ft Ib)
3
15
18
17
12
4
11
5.4 N m (0.54 kgf m, 3.9 ft Ib)
3.7 N m (0.37 kgf m, 2.7 ft Ib)
7
6
5
10
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2.5 N m (0.25 kgf m, 1.8 ft Ib)

Step
Procedure/Part name
EXHAUST SYSTEM REMOVAL
Deck beam
Qty
Service points
NOTE:
When removing the water lock and exhaust
joint, it is not necessary to remove the jet
pump unit.
1
2
3
4
Band
Joint clamp
Hose clamp
Water lock
1
1
1
1
8-43
HULL
HOOD
EXHAUST SYSTEM
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib)
14
13
16
3.7 N m (0.37 kgf m, 2.7 ft Ib)
3
15
18
17
12
4
11
5.4 N m (0.54 kgf m, 3.9 ft Ib)
3.7 N m (0.37 kgf m, 2.7 ft Ib)
7
6
5
10
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2.5 N m (0.25 kgf m, 1.8 ft Ib)
Step
5
6
7
8
9
10
11
12
13
14
Procedure/Part name
Joint clamp
Joint
Joint clamp
Joint
Joint clamp
Exhaust joint
Nut/washer
Exhaust valve
Hose clamp
Rubber hose
Qty
1
1
1
1
1
1
6/6
1
1
1
8-44
Service points
NOTE:
Remove parts 12 to 18 as a set.
HULL
HOOD
EXHAUST SYSTEM
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib)
14
13
16
3.7 N m (0.37 kgf m, 2.7 ft Ib)
3
15
18
17
12
4
11
5.4 N m (0.54 kgf m, 3.9 ft Ib)
3.7 N m (0.37 kgf m, 2.7 ft Ib)
7
6
5
10
3.7 N m (0.37 kgf m, 2.7 ft Ib)

2.5 N m (0.25 kgf m, 1.8 ft Ib)
Step
15
16
17
18
Procedure/Part name
Hose clamp
Water tank
Rubber hose
Plate
Qty
1
1
1
1
Service points
8-45
HULL
HOOD
EXHAUST SYSTEM
SERVICE POINTS
Exhaust system inspection
1. Inspect:
Water lock band
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 hoses
Water tank
NOTE:
Be sure to insert the rubber hose to the line
a on the water tank.
Make sure that there is a surface distance of
47 mm (1.9 in) b between the parting lines
of the water tank and rubber hose.
Align the parting line c of the rubber hose
with the parting line d of the water tank.
b
a
8-46
HULL
HOOD
EXHAUST SYSTEM
E
Exhaust system installation
1. Install:
Exhaust joint
a
NOTE:
Be sure to install the projections a on the
exhaust pipe and exhaust joint into the slots b
in the joint.
b
a
2. Install:
Water lock
NOTE:
Be sure to insert the rubber hose to the line a
on the water lock.
8-47
HULL
HOOD
DECK AND HULL
DECK AND HULL

EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib)

5.4 N m (0.54 kgf m, 3.9 ft Ib)
6 22 mm
13 N m (1.3 kgf m, 9.4 ft Ib)
17
16 N m (1.6 kgf m, 12 ft Ib)
8 45 mm
LT
16
271
15 N m (1.5 kgf m, 11 ft Ib)
5 3
5
18
12
13
6
8
5.4 N m (0.54 kgf m, 3.9 ft Ib)
1
11
10
15
13
14
LT
271
9
5 25 mm
2.0 N m (0.2 kgf m, 1.4 ft Ib)
15 N m (1.5 kgf m, 11 ft Ib)

Step
1
2
3
4
5
6
7
8
9
10
Procedure/Part name
Qty
Service points
DECK AND HULL DISASSEMBLY
Nut
1
Spout
1
Nut
2
Cleat
1
Plate
2
Bolt/collar
10/10
Sponson
2
Nut/washer
4/4
Screw/washer
4/4
Drain plug
2
8-48
HULL
HOOD
DECK AND HULL
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib)

5.4 N m (0.54 kgf m, 3.9 ft Ib)
6 22 mm
13 N m (1.3 kgf m, 9.4 ft Ib)
17
16 N m (1.6 kgf m, 12 ft Ib)
8 45 mm
LT
16
271
15 N m (1.5 kgf m, 11 ft Ib)
5 3
5
18
12
13
6
8
5.4 N m (0.54 kgf m, 3.9 ft Ib)
1
11
10
13
14
15
16
17
18
Procedure/Part name
14
LT
271
9
5 25 mm
2.0 N m (0.2 kgf m, 1.4 ft Ib)
Step
11
12
15
13
Seal
Nut
Qty
2
4
Plate
Cleat
Seal
Nut/washer
Bolt
Protector
4
2
2
3/3
4
1
15 N m (1.5 kgf m, 11 ft Ib)
Service points
NOTE:
To remove the cleat, remove the exhaust
system first.

assembly.
8-49
HULL
HOOD
ENGINE MOUNT
ENGINE MOUNT
EXPLODED DIAGRAM

Step
1
2
3
4
5
6
Procedure/Part name
ENGINE MOUNT REMOVAL
Engine unit
Bolt
Damper 1
Damper 2
Bolt
Engine mount
Liner
Qty
4
1
1
8
4
2
8-50
Service points
Stern side
TRBL
ANLS
CHAPTER 9
TROUBLE ANALYSIS
INTRODUCTION.............................................................................................. 9-1
FEATURES ............................................................................................... 9-1
Functions............................................................................................. 9-1
CONTENTS............................................................................................... 9-1
HARDWARE REQUIREMENTS................................................................9-2
OPERATING.................................................................................................... 9-3
CONNECTING THE COMMUNICATION CABLE TO THE
WATERCRAFT......................................................................................... 9-3
Top view.............................................................................................. 9-3
TROUBLE ANALYSIS.....................................................................................9-4
TROUBLE ANALYSIS CHART..................................................................9-4
SELF-DIAGNOSIS .................................................................................... 9-8
TRBL
ANLS
INTRODUCTION
INTRODUCTION
FEATURES
The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine
malfunctions for quicker troubleshooting procedures than traditional methods.
By connecting your computer to the ECM (Electronic Control Module) of a watercraft using the communication cable, this software can be used to display sensor data and data stored in the ECM on a
computers monitor.
If this software is run on Microsoft Windows 95, Windows 98, Windows Me, Windows 2000, or
Windows XP the information can be displayed in colorful graphics. Also, the software can be operated using either a mouse or a keyboard.
In addition, the data for the main functions (Diagnosis, Diagnosis record, Engine monitor, and Data
logger) can be saved on a disk or printed out.
Functions
1. Diagnosis: Each sensors status and each ECM diagnosis code or item are displayed. This
enables you to find malfunctioning parts and controls quickly.
2. Diagnosis record: Sensors that had been activated and ECM diagnostic codes that have been
recorded are displayed. This allows you to check the watercrafts record of malfunctions.
3. Engine monitor: Each sensors status and the ECM data are displayed. This enables you to
find malfunctioning parts quickly.
4. Stationary test: With the engine off, ignition, fuel injection, and the electric fuel pump are
checked. These tests can be performed quickly.
5. Active test: With the engine running, each firing cylinder drops and the engine speed is
checked for changes to determine if the cylinder is malfunctioning. These tests can be performed quickly.
6. Data logger: From the data stored in the ECM, at least two items of 78 seconds of recorded
data are displayed on a graph. In addition, the operating time as compared to the engine speed
and the total operating time are displayed. This allows you to check the operating status of the
engine.
7. Some files: Lets you select and run other applications while continuing to run the diagnostic
program.
CONTENTS
1. Software (1)
2. Adapter (1)
3. Communication cable (1)
4. Instruction Manual (1)
5. Installation Manual (1)
YAMAHA
DIAGNOSTIC
SYSTEM
YAMAHA
DIAGNOSTIC
SYSTEM
INSTALLATION MANUAL
INSTRUCTION MANUAL
9-1
TRBL
ANLS
INTRODUCTION
HARDWARE REQUIREMENTS
Make sure that your computer meets the following requirements before using this software.
Computer:
IBM-compatible computer
Operating system:
Microsoft (Windows 95), Windows 98, Windows Me, Windows 2000, or

Windows XP (English version)
CPU:
Windows 95/98:
Windows Me/2000:
Windows XP:
i486X, 100 MHz or higher (Pentium 100 MHz or higher recommended)

Pentium, 166 MHz or higher (Pentium 233 MHz or higher recommended)
Pentium, 300 MHz or higher (Pentium 500 MHz or higher recommended)
Memory:
Windows 95/98:
Windows Me:
Windows 2000:
Windows XP:
16 MB or more (32 MB or more recommended)

Hard disk free space:
Drive:
CD-ROM drive
Display:
VGA (640 480 pixels), (SVGA [800 600 pixels] or more recommended)
256 or more colors
Mouse:
Compatible with the operating systems mentioned above
Communication port:
RS232C (Dsub-9 pin) port, USB port
Printer:
Compatible with the operating systems mentioned above
NOTE:
The amount of memory and the amount of free space on the hard disk differs depending on the
computer.
Using this software while there is not enough free space on the hard disk could cause errors and
result in insufficient memory.
This software will not run properly on some computers.
When starting up this program, do not start other software applications.
Do not use the screen saver function or the energy saving feature when using this program.
If the ECM is changed, restart the program.
Windows XP is a multiuser operating system, therefore, be sure to end this program if the login
user is changed.
The USB adapter cannot be used with Windows 95.
For operating instructions of the Yamaha Diagnostic System, refer to the Yamaha Diagnostic System Instruction Manual.
9-2
TRBL
ANLS
OPERATING
OPERATING
CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT
Top view
1
2
1 3-pin communication coupler

2 Wiring harness coupler
3 Meter coupler
NOTE:
Be careful not to pinch the communication cable between the hood and the deck or to damage it.
9-3
TRBL
ANLS
TROUBLE ANALYSIS
TROUBLE ANALYSIS
NOTE:
Before consulting the TROUBLE ANALYSIS CHART, check the following items.
1. Check that the battery is charged and that its specified gravity is within specification.
2. Check that there are no incorrect wiring connections.
3. Check that all wiring connections are properly secured and that they are not rusty.
4. Check that the engine shut-off cord (lanyard) is connect to the engine shut-off switch.
5. Check that fuel is reaching the throttle bodies.
TROUBLE ANALYSIS CHART
POOR BATTERY CHARGING
IRREGULAR WARNING INDICATION
BILGE INCREASE
LOOSE STEERING
Check elements
LOW OIL PRESSURE
OVERHEATING
LIMITED ENGINE SPEED
POOR PERFORMANCE
ENGINE WILL NOT STOP
POOR ACCELERATION
ENGINE STALLS
HIGH IDLING
ROUGH IDLING
HARD STARTING
ENGINE WILL NOT START
Trouble mode
Relative part
FUEL SYSTEM
Fuel tank
Fuel hose
Fuel filter
Fuel pump
Fuel injectors
Trolling speed
Air filter
9-4
Reference
chapter
4
4
4
4
4
4
3
3
TRBL
ANLS
TROUBLE ANALYSIS
BILGE INCREASE
LOOSE STEERING
Check elements
LOW OIL PRESSURE
OVERHEATING
POOR PERFORMANCE
POOR ACCELERATION
ENGINE STALLS
HIGH IDLING
ROUGH IDLING
HARD STARTING
Trouble mode
Relative part
POWER UNIT
Compression
Cylinder head gaskets
Cylinder block
Crankcase
Piston rings
Pistons
Bearings
Thermostat
Valve(s) and valve seat(s)
Valve clearance adjusting
pad(s)
Camshaft(s)
Timing chain
Oil pump
Engine oil
Oil filter
Oil pressure switch
Bearing housing
Drive couplings
Rubber coupling
Pilot water hose
Water hose
Water passage
9-5
Reference
chapter
5
5
5
5
5
5
5
5
5
3
5
5
5
3
3
7
5
5
5
5
5
5
TRBL
ANLS
TROUBLE ANALYSIS
BILGE INCREASE
LOOSE STEERING
Check elements
LOW OIL PRESSURE
OVERHEATING
POOR PERFORMANCE
POOR ACCELERATION
ENGINE STALLS
HIGH IDLING
ROUGH IDLING
HARD STARTING
Trouble mode
Relative part
Reference
chapter
JET PUMP UNIT

Duct
Impeller
Intake grate
Bearings
Intake duct
Water inlet hose
Bilge hose
Bilge strainer
Bilge hose joint
ELECTRICAL
Ignition system, fuel control system
Pickup coils
ECM
Ignition coils
Slant detector switch
Engine stop switch
Spark plugs
Thermoswitch
Sensor assembly
Engine temperature
sensor
Cam position sensor
9-6
6
6
6
6
6
6
6
3
6
7
7
7
7
7
7
3
7
7
7
7
7
7
TRBL
ANLS
TROUBLE ANALYSIS
BILGE INCREASE
LOOSE STEERING
Check elements
LOW OIL PRESSURE
OVERHEATING
POOR PERFORMANCE
POOR ACCELERATION
ENGINE STALLS
HIGH IDLING
ROUGH IDLING
HARD STARTING
Trouble mode
Relative part
Starting system
Start switch
Starter relay
Starter motor
Charging system
Lighting coil
Rectifier/regulator
Fuses
Battery leads
Battery
Electric bilge pump
Electric bilge pump
Remote control system
Remote control unit
HULL AND HOOD
Steering master
Water lock
Exhaust hose
Muffler
Drain plugs
9-7
Reference
chapter
7
7
7
7
7
7
3
7
7
8
8
8
8
8
TRBL
ANLS
TROUBLE ANALYSIS
SELF-DIAGNOSIS
1
With the engine running, press the select button 1 for 8 seconds and check if an error code
is indicated on the multifunction meter.
Code
Symptom
01
Normal
13
Pickup coil malfunction
15

malfunction
18

malfunction
19
Incorrect battery voltage
23

malfunction
24
Cam position sensor malfunction
29
Intake air pressure sensor

malfunction
47
Slant detection switch malfunction
48
Incorrect data transmission
54
Bypass valve motor malfunction
55
Steering switch malfunction
63
Intake air system malfunction
If the Yamaha Diagnostic System is not used

to check the symptoms listed in the table, the
error codes can be checked easily with the
self-diagnosis in the multifunction meter. However, if there are numerous error codes displayed, be sure to check them with the
9-8
WIRING DIAGRAM
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Fuse (20 A)
Fuse (3 A)
Starter relay
ECM
Rectifier/regulator
Noise filter
Cam position sensor
Oil pressure switch
Sensor assembly
(intake air pressure, intake air temperature)
Fuel injector
Bypass valve motor
Ignition coil
Spark plug
Pickup coil
Lighting coil
Battery
Starter motor
Electric bilge pump
Fuel pump
Fuel sender
Engine stop switch
Start switch
Steering switch
Multifunction meter
Speed sensor
Buzzer
Remote control unit
Antenna
To tachometer
To entry box
Color code
B
Br
G
L
O
P
R
W
Y
B/G
B/O
B/R
B/W
B/Y
G/B
G/O
G/R
G/Y
L/B
L/R
P/G
P/W
Pu/B
Pu/G
Pu/R
Pu/Y
R/Y
R/W
W/B
W/L
W/R
: Black
: Brown
: Green
: Blue
: Orange
: Pink
: Red
: White
: Yellow
: Black/green
: Black/orange
: Black/red
: Black/white
: Black/yellow
: Green/black
: Green/orange
: Green/red
: Green/yellow
: Blue/black
: Blue/red
: Pink/green
: Pink/white
: Purple/black
: Purple/green
: Purple/red
: Purple/yellow
: Red/yellow
: Red/white
: White/black
: White/blue
: White/red

B
B/O
B/O
P/W
B/O
R/Y
W/B
P/G
P/W
Br Br B
Pu/R
G/R
G/Y
B/O
G/Y
G/B
G/R
G
Pu/R
R/Y
B/O R/Y
G/O
L/R
Y
O
Br
B
B/O
R/Y
Pu/B
G/R
Pu/Y
B/L
R W
B
B
GGG
R/Y
P/G
B/O
#1
F
I
B/R
R/Y
R/Y
G/B
#2
D
R/Y
R/Y
R/Y
Pu/G
R/Y
Br
B
Pu/R
G/Y
R
R/Y
Br
P
R
L/Y L/B Gy
B/Y
R/Y
R
B
R/Y
12 13 14 15 16 18
R/Y
R/Y
3 4 6 7 9 10 11
L/B
R/Y
G/O
R/Y
P/G
Pu/B
Br
B/O
Pu/Y
R/Y
R
B/Y
B/O
Br
B/O
B/Y
G
G/B
Pu/G
B/Y
B/Y B/Y
Pu/B
B/Y
R/Y
Pu/G
L/B
B/O
Pu/Y
R/Y
L/B
B/O
G
B
B/O
B/O
R/Y
B/O
P/W
B/O
R
Br
B/O
B/O
W/R
G/O
B/O
B/O
B/O
B
B
#3
#4
B/O
R
B
FREE
PUSH
Br
Br Br
FREE
PUSH
B
S
W B
FREE
PUSH
W
Br
W
B
Br
#1
Br
R
Br
R/Y
R/Y
R/Y
B/W
R/Y
R/Y
B/O
#2
B/Y
R/Y
L B
#3
W/B
W
R/Y
R
B
W
R
B
B/Y
R/Y
B/L
R/Y
#4
B/O
R/W
Y
B/Y
R/Y
Y
B/Y
R/W
Y
Gy
L/Y
P
L/Y
L/R
L/B
Gy
L/R
L/B
1 3 4 5 6 8 9 10 12 13
G
G/O W
P/W B/Y
Br
W/B G/B G/Y G/R
L/R B/R L/B
29 30 31 33 34 35 37 38 39 40
W/L R/Y
P/G
W/L
B/O
L/R
B/L B/Y B/W

B
B
R/Y
B
Gy
B/L
7
G
B/O
R
R
B/L
Y/B
L/R
B/Y Pu/G Pu/Y Pu/B Pu/R
B
Y/B
B
R/W
41 42 43 44
B
R/W
W/L
B/O
R/Y
B/O W/R W/B
L/R
B
P
R/Y
B/O
14 15 16 17 18 19 20 21 22 28
L/B
L/R
Br B
Gy
123
B
R/Y
R/Y
B
L
B/O
Y
L/R
L/B
R
R
4
5
R R
R
B Br
R/Y Br
P Pu/B G/R G G/B Pu/G B/Y

Pu/R O G/Y B/O Pu/Y P/G R/Y
R
R
O
P
R
P
P
O
R
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
L/B
L/R
P
O
R/Y
B/W
Pu/G
B
Pu/B
Pu/R
Pu/Y
W/B
B/Y
P
P/G
G/O
B/R
W/B
W/R
B/O
B/Y
W
G
P/W
G
G/R
G/B
G/Y
W/L
L
Y
B
B/L
B/Y
R/Y R/Y R/Y

R/Y R/Y R/Y
O
B/O
R/Y
R/Y
G
G/R
G/B B G B/Y W/B B/O P G/O R/Y Pu/B B/Y P/G B/O
G/Y G G P W/R P/W R/Y Pu/G Pu/Y Pu/R O P B
B/R B/W R/Y B/Y

R/Y R/Y R/Y B/L
B
B/Y
G
G
G
P
W/B
W/R
B/O
P/W
P
R/Y
G/O
B/O
B/O
B
B
8
9
0
A
B
C
J
K
B/O
B
7
P
O Pu/R Pu/Y Pu/G

P/G B/Y Pu/B R/Y B/O
G/Y G/R
G/B G
P
B
G
G
G
W/L
R/Y
R
R/Y
L
R/Y
W/B
Y
G
L
W
B
Br
R
B
B
B
B/O
Br
Y
N
O
P
Q
R
S
T
U
V
W
X
YAMAHA MOTOR CORPORATION, USA
Printed in USA
Feb. 2004
1 CR
(E)
WaveRunner
FX
FX Cruiser
FX High Output
SUPPLEMENTARY
SERVICE MANUAL
*LIT186160293*
LIT-18616-02-93
F1X-28197-1H-1X
NOTICE
This Supplementary Service Manual has been prepared to introduce new service and new data
information for the FX, FX Cruiser, FX High Output, and FX Cruiser High Output which are based on
the 2002 FX140, 2003 FX140/FX Cruiser, and 2004 FX High Output/FX Cruiser High Output. For
complete information on service procedures, it is necessary to use this Supplementary Service
Manual together with the following manuals.
FX140 SERVICE MANUAL: F1B-28197-1E-11 (LIT-18616-02-38)
FX140/FX Cruiser SUPPLEMENTARY SERVICE MANUAL:
F1B-28197-1F-1X (LIT-18616-02-45)
FX High Output/FX Cruiser High Output SERVICE MANUAL:
F1S-28197-1G-11 (LIT-18616-02-83)
A10001-0*
WaveRunner
FX/FX Cruiser
FX High Output/FX Cruiser High Output
SUPPLEMENTARY SERVICE MANUAL
2005 by Yamaha Motor Corporation, USA
1st Edition, December 2005
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-02-93

MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the
course of action required will follow the symbol, e.g.,
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.
IMPORTANT INFORMATION
In this Supplementary Service Manual particularly important information is distinguished in the following ways.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, passenger(s), a bystander, or a person inspecting or repairing the watercraft.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the watercraft.
NOTE:
A NOTE provides key information to make procedures easier or clearer.

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 tightening
torque.
Example:
Bolt or screw size
10 25 mm
: M10 (D) 25 mm (L)

D
L
6 Jobs requiring more information (such as special service tools and technical data) are described
sequentially.
E
1
A50001-1-4
GEN
INFO
SYMBOLS
Symbols 1 to 9 are designed to indicate the
content of a chapter.
SPEC
1
2
3
4
5
6
7
8
9
INSP
ADJ
FUEL
JET
PUMP
POWR
7
General Information
Specifications
Periodic Inspection and Adjustment
Fuel System
Power Unit
Jet Pump Unit
Electrical System
Hull and Hood
Trouble Analysis
ELEC
9
HULL
HOOD
Symbols 0 to E indicate specific data.
0
A
B
C
D
E
TRBL
ANLS
A
Special service tool

Specified oil or fluid
Specified engine speed
Specified tightening torque
Specified measurement
Specified electrical value
(resistance, voltage, electric current)
T.
R.
Symbols F to I in an exploded diagram indicate the grade of lubricant and the lubrication
point.
E
G
H
A
1104J
1280B
J
M
GM
L
LT
LT
271
242
N
LT
572
SS
F Apply Yamaha 4-stroke motor oil

G Apply water resistant grease
(Yamaha grease A, Yamaha marine grease)
H Apply ThreeBond 1104J or ThreeBond 1280B
I Apply molybdenum disulfide grease
Symbols J to N in an exploded diagram indicate the type of sealant or locking agent and
the application point.
J
K
L
M
N
Apply Gasket Maker

Apply LOCTITE 271 (red)
Apply LOCTITE 242 (blue)
Apply LOCTITE 572
Apply silicone sealant
NOTE:
Additional symbols may be used in this manual.
E
A30000-0
INDEX
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENT
FUEL SYSTEM
POWER UNIT
JET PUMP UNIT
GEN
INFO
SPEC
INSP
ADJ
FUEL
POWR
JET
PUMP
ELECTRICAL SYSTEM
HULL AND HOOD
TROUBLE ANALYSIS
ELEC
HULL
HOOD
TRBL
ANLS
1
2
3
4
5
6
7
8
9
GENERAL INFORMATION
IDENTIFICATION NUMBERS ............................................................................ 1
PRIMARY l.D. NUMBER .............................................................................. 1
ENGINE SERIAL NUMBER ......................................................................... 1
JET PUMP UNIT SERIAL NUMBER ............................................................ 1
HULL IDENTIFICATION NUMBER (H.l.N.).................................................. 1
SPECIAL TOOLS ............................................................................................... 2
MEASURING................................................................................................ 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................... 3
MAINTENANCE SPECIFICATIONS .................................................................. 7
ENGINE ....................................................................................................... 7
JET PUMP UNIT ....................................................................................... 10
HULL AND HOOD ..................................................................................... 10
ELECTRICAL ............................................................................................. 11
ENGINE ..................................................................................................... 13
JET PUMP UNIT ....................................................................................... 16
HULL AND HOOD ..................................................................................... 16
ELECTRICAL ............................................................................................. 16
TIGHTENING TORQUES ................................................................................. 19
SPECIFIED TORQUES.............................................................................. 19
GENERAL TORQUE .................................................................................. 20
CABLE AND HOSE ROUTING ........................................................................ 21
CABLE AND HOSE ROUTING (For FX/FX Cruiser) ...................................... 32
(For FX High Output/FX Cruiser High Output)............................................. 37
PERIODIC INSPECTION AND ADJUSTMENT

MAINTENANCE INTERVAL CHART ............................................................... 41
PERIODIC SERVICE ........................................................................................ 42
CONTROL SYSTEM .................................................................................. 42
Steering master inspection................................................................... 42
Steering cable inspection and adjustment ........................................... 42
Throttle cable inspection and adjustment............................................. 43
GENERAL .................................................................................................. 45
Drain plug inspection............................................................................ 45
Lubrication points ................................................................................. 46
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS (For FX/FX Cruiser)....................................... 49
OFF THROTTLE STEERING SYSTEM............................................................ 52
WIRING DIAGRAM .................................................................................... 52
STEERING SENSOR ................................................................................. 53
E
INDICATION SYSTEM ..................................................................................... 54
WIRING DIAGRAM (For FX Cruiser High Output) ..................................... 54
WIRING DIAGRAM (For FX High Output).................................................. 56
WIRING DIAGRAM (For FX/FX Cruiser).................................................... 58
MULTIFUNCTION METER......................................................................... 59
Multifunction meter............................................................................... 59
Operation button .................................................................................. 59
MULTIFUNCTION METER REMOVAL ...................................................... 60
OPERATION BUTTON REMOVAL ............................................................ 60
Display function (for FX Cruiser High Output)...................................... 61
Display function (for FX High Output) .................................................. 62
Display function (for FX/FX Cruiser) .................................................... 63
Compass display (for FX Cruiser High Output).................................... 64
Air temperature display (for FX Cruiser High Output) .......................... 64
Speedometer/average speed/tripmeter display
(for FX Cruiser High Output) ............................................................... 65
Water temperature display (for FX Cruiser High Output) ..................... 66
Trip timer display (for FX Cruiser High Output).................................... 67
Fuel consumption per hour, fuel consumption per kilometer/
mile display (for FX Cruiser High Output) ........................................... 67
Overheat warning indicator .................................................................. 67
Check engine warning indicator ........................................................... 68
Diagnostic display ................................................................................ 68
WIRING DIAGRAM .................................................................................... 69
REMOTE CONTROL SYSTEM.................................................................. 71
Yamaha Security System indicator ...................................................... 71
Low-rpm mode indicator....................................................................... 72
HULL AND HOOD

HANDLEBAR ................................................................................................... 73
EXPLODED DIAGRAM (For FX/FX High Output) ...................................... 73
REMOVAL AND INSTALLATION CHART ................................................. 73
EXPLODED DIAGRAM (For FX Cruiser/FX Cruiser High Output)............. 74
EXPLODED DIAGRAM .............................................................................. 75
SERVICE POINTS ..................................................................................... 79
Handlebar assembly installation .......................................................... 79
STEERING MASTER........................................................................................ 82
SERVICE POINTS ..................................................................................... 87
Steering master components inspection .............................................. 87
Rubber seal installation........................................................................ 87
REMOTE CONTROL CABLES AND SPEED SENSOR LEAD ....................... 88
SERVICE POINTS ..................................................................................... 91
Steering cable removal ........................................................................ 91
SERVICE POINTS ..................................................................................... 92
Steering cable installation .................................................................... 92
FRONT HOOD .................................................................................................. 93
SERVICE POINTS ..................................................................................... 95
Rivet Installation................................................................................... 95
SERVICE POINTS ..................................................................................... 98
Ornament disassembly ........................................................................ 98
Front hood assembly............................................................................ 98
Visor installation ................................................................................... 99
Double-sided tape installation .............................................................. 99
Ornament installation ......................................................................... 100
MIRROR.......................................................................................................... 101
EXPLODED DIAGRAM ............................................................................ 101
REMOVAL AND INSTALLATION CHART ............................................... 101
STEERING CONSOLE COVER ..................................................................... 103
E
SHIFT LEVER................................................................................................. 111
SEATS AND HAND GRIP .............................................................................. 112
REBOARDING STEP (For FX Cruiser/FX Cruiser High Output)................ 115
SERVICE POINTS ................................................................................... 116
Reboarding step installation............................................................... 116
DECK AND HULL........................................................................................... 117
CLEAT ASSEMBLY (For FX Cruiser High Output) ..................................... 120
SERVICE POINTS ................................................................................... 121
Cleat cover installation ....................................................................... 121
TROUBLE ANALYSIS
TROUBLE ANALYSIS.................................................................................... 122
SELF-DIAGNOSIS ................................................................................... 122
WIRING DIAGRAM
GEN
INFO
A60700-0*
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. numbers:
F1X: 800101
F1Y: 800101
ENGINE SERIAL NUMBER

The engine serial number is stamped on a
label attached to the engine unit.
Starting serial numbers:
6B6: 1018901
60E: 1017501
JET PUMP UNIT SERIAL NUMBER

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

(H.l.N.)
The H.l.N. is stamped on a plate attached to
the aft deck.
GEN
INFO
SPECIAL TOOLS
SPECIAL TOOLS
Using the correct special tools recommended
by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvisations
and using improper tools can damage the
equipment.
NOTE:
For U.S.A. and Canada, use part numbers
starting with J-, YB-, YM-, YS-, YU- or
YW-.
For other countries, use part numbers starting with 90890-.
MEASURING
1
YU-34899-A
1 Digital multimeter
P/N. YU-34899-A
2 Digital circuit tester
P/N. 90890-03174
2 90890-03174
SPEC
Item
Model code
Hull
Engine/jet
Dimensions
Length
Width
Height
Dry weight
Maximum capacity
Performance
Maximum output
Cruising range
Engine
Engine type
Displacement
Bore stroke
Compression ratio
Exhaust system
Lubrication system
Cooling system
Starting system
Ignition system
Ignition timing
Spark plug model
(manufacturer)
Spark plug gap
Battery capacity
Generator output
Drive unit
Propulsion system
Jet pump type
Impeller rotation
Transmission
angle
Trim system
Reverse system
Model
FX High Output
Unit
F1X
6B6
mm (in)
mm (in)
mm (in)
kg (lb)
Person/kg (lb)
3,340 (131.5)
1,230 (48.4)
1,160 (45.7)
1,240 (48.8)
372 (820)
380 (838)
3/240 (530)
kW (PS) @ r/min
l/h (US gal/h,
lmp gal/h)
h
117.7 (160) @ 10,000

45 (11.9, 9.9)
cm (cu. in)
mm (in)
Degree
1.56
4-stroke, L4, DOHC
1,052 (64.2)
76.0 58.0 (2.99 2.28)
11.9:1
Wet exhaust
Dry sump
Water cooled
Electric starter
TCI
BTDC 5BTDC 32
CR9EB (NGK)
mm (in)
V/Ah
A @ r/min
0.70.8 (0.0280.031)
12/19
1416 @ 6,000
Degree
Jet pump
24 + 24
Degree
10, 5, 0, 5, 10
Manual 5 positions
Reverse gate
SPEC
Item
Fuel and oil

Fuel type
Minimum fuel rating
Fuel tank capacity
Engine oil type
Engine oil grade
Engine oil quantity
Model
FX High Output
Unit
PON*
RON*
L
(US gal, Imp gal)
API
SAE
L
(US qt, Imp qt)
L
(US qt, Imp qt)
L
(US qt, Imp qt)

86
90
70 (18.5, 15.4)
4-stroke motor oil
10W-30
4.5 (4.8, 4.0)
2.1 (2.2, 1.8)
2.3 (2.4, 2.0)
SPEC
Item
Model code
Hull
Engine/jet
Dimensions
Length
Width
Height
Dry weight
Maximum capacity
Performance
Maximum output
Cruising range
Engine
Engine type
Displacement
Bore stroke
Compression ratio
Exhaust system
Lubrication system
Cooling system
Starting system
Ignition system
Ignition timing
Spark plug model
(manufacturer)
Spark plug gap
Battery capacity
Generator output
Drive unit
Propulsion system
Jet pump type
Impeller rotation
Transmission
angle
Trim system
Reverse system
E
Model
Unit
FX
FX Cruiser
F1Y
60E
mm (in)
mm (in)
mm (in)
kg (lb)
Person/kg (lb)
3,340 (131.5)
1,230 (48.4)
1,160 (45.7)
1,240 (48.8)
384 (847)
392 (864)
3/240 (530)
kW (PS) @ r/min
l/h (US gal/h,
lmp gal/h)
h
103 (140) @ 10,000

44 (11.6, 9.7)
cm (cu. in)
mm (in)
Degree
1.59
4-stroke, L4, DOHC
998 (60.9)
74.0 58.0 (2.91 2.28)
11.4:1
Wet exhaust
Dry sump
Water cooled
Electric starter
TCI
BTDC 34ATDC 5
CR9EB (NGK)
mm (in)
V/Ah
A @ r/min
0.70.8 (0.0280.031)
12/19
1416 @ 6,000
Degree
Jet pump
24 + 24
Degree
10, 5, 0, 5, 10
Manual 5 positions
Reverse gate
SPEC
Item
Fuel and oil

Fuel type
Minimum fuel rating
Fuel tank capacity
Engine oil type
Engine oil grade
Engine oil quantity
E
Model
Unit
FX
PON*
RON*
L
(US gal, Imp gal)
API
SAE
L
(US qt, Imp qt)
L
(US qt, Imp qt)
L
(US qt, Imp qt)
FX Cruiser

86
90
70 (18.5, 15.4)
4-stroke motor oil
10W-30
4.3 (4.5, 3.8)
2.0 (2.1, 1.8)
2.2 (2.3, 1.9)
SPEC
ENGINE
Item
Cylinder head
Warpage limit
Cylinder
Bore size
Taper limit
Out-of-round limit
Wear limit
Camshaft
Drive system
Intake A
Exhaust A
Timing chain
Tensioning system
Intake
Exhaust
Valve dimensions
Intake
Exhaust
Valve face width B
Intake
Exhaust
Unit
FX High Output
Model
mm (in)
0.1 (0.004)
kPa
(kgf/cm2, psi)
1,150 (11.5, 164)
mm (in)
mm (in)
mm (in)
mm (in)
76.00076.015 (2.99212.9927)
0.08 (0.003)
0.05 (0.002)
76.100 (2.9961)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
Chain drive
33.00 (1.299)
33.00 (1.299)
25.00 (0.984)
24.5 (0.9646)
24.4624.47 (0.96300.9634)
0.030.06 (0.00120.0024)
mm (in)
0.03 (0.0012)
92RH2015-130/130
Automatic
mm (in)
mm (in)
0.110.20 (0.00430.0079)
0.250.34 (0.00980.0134)
mm (in)
mm (in)
22.923.1 (0.90160.9094)
24.424.6 (0.96060.9685)
mm (in)
mm (in)
1.912.64 (0.07520.1039)
1.912.64 (0.07520.1039)
cylinders.
7
SPEC
Item
Valve seat width C

Intake
Exhaust
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Intake
Exhaust
clearance
Intake
Exhaust
Valve stem runout
Model
FX High Output
Unit
mm (in)
mm (in)
0.91.1 (0.03540.0433)
0.91.1 (0.03540.0433)
mm (in)
mm (in)
0.851.15 (0.03350.0453)
0.851.15 (0.03350.0453)
mm (in)
mm (in)
3.9753.990 (0.15650.1571)
4.4654.480 (0.17580.1764)
mm (in)
mm (in)
4.0004.012 (0.15750.1580)
4.5004.512 (0.17720.1776)
mm (in)
mm (in)
mm (in)
0.0100.037 (0.00040.0015)
0.0200.047 (0.00080.0019)
0.01 (0.0004)
Valve spring
Free length
Intake
mm (in)
Exhaust
mm (in)
Installed length
Intake
mm (in)
Exhaust
mm (in)
Spring limit
Intake
Degree/mm (in)
Exhaust
Degree/mm (in)
Piston
mm (in)
Piston diameter
mm (in)
Measuring point H*
mm (in)
Wear limit
mm (in)
mm (in)
Piston pins
Outside diameter
mm (in)
Wear limit
mm (in)
38.90 (1.53)
40.67 (1.60)
34.50 (1.36)
35.00 (1.38)
2.5/1.7 (0.067)
2.5/1.8 (0.071)
0.100.11 (0.00390.0043)
75.89575.910 (2.98802.9886)
5 (0.2)
0.17 (0.0067)
17.00217.013 (0.66930.6698)
16.99117.000 (0.66890.6693)
16.98 (0.67)
SPEC
Item
Model
FX High Output
Unit
Piston ring
Top ring
T
Type
Dimension (B T)
End gap (installed)
2nd ring
Type
T
Dimensions (B T)
End gap (installed)
Oil ring
Dimensions
T
(B T)
End gap (installed)
Connecting rod
Bearing color code
Crankshaft
mm (in)
mm (in)
mm (in)
Barrel
0.90 2.75 (0.04 0.11)
0.320.44 (0.01260.0173)
0.0300.065 (0.00120.0026)
mm (in)
mm (in)
mm (in)
Taper
0.80 2.80 (0.03 0.11)
0.430.58 (0.01690.0228)
0.0200.055 (0.00080.0022)
mm (in)
1.50 2.60 (0.06 0.10)
mm (in)
mm (in)
0.100.35 (0.00390.0138)
0.0400.160 (0.00160.0063)
mm (in)
0.0160.040 (0.00060.0016)
17.00517.018 (0.66940.6699)
mm (in)
Crank width A
Deflection limit B
Bearing color code
Throttle body
Type/quantity
Manufacturer
ID mark
Trolling speed
Fuel pump
Pump type
Fuel pressure
mm (in)
mm (in)
mm (in)
304.8306.0 (12.0012.05)
0.03 (0.0012)
0.0040.028 (0.00020.0011)
42EIS/4
Mikuni
6B601
1,6001,700
r/min
kPa
(kgf/cm2, psi)
Electrical
320.8327.2 (3.23.3, 4547)
SPEC
Item
Oil filter
Oil filter type
Oil pump
Oil pump type
Rotor tip clearance
(scavenge pump)
Rotor (feed pump)
Model
FX High Output
Unit
Cartridge type
mm (in)
Trochoid
0.090.15 (0.00350.0059)
mm (in)
mm (in)
0.090.17 (0.00350.0067)
0.090.15 (0.00350.0059)
JET PUMP UNIT

Item
Jet pump
Impeller material
Impeller clearance
Nozzle diameter
Model
FX High Output
Unit
Stainless steel
3
16.8
0.350.45 (0.01380.0177)
0.6 (0.0236)
0.3 (0.0118)
86.587.1 (3.413.43)
Degree
mm (in)
mm (in)
mm (in)
mm (in)
HULL AND HOOD

Item
Free play
Unit
FX High Output
mm (in)
Model
47 (0.160.28)
10
SPEC
ELECTRICAL
Item
Battery
Type
Capacity
Specific gravity
ECM unit
(B/R R/Y, B/W R/Y,
B/Y R/Y, B/L R/Y)
@cranking (loaded)
Stator
Pickup coil
(W B, R B)
Output peak voltage
@cranking (loaded)
Lighting coil
(G G)
Output peak voltage
Ignition coil
Rectifier/regulator
(R B)
Output peak voltage
Starter motor
Type
Output
Rating
Brush length
Wear limit
Commutator undercut
Limit
Commutator diameter
Limit
Unit
FX High Output
Model
V/Ah
Fluid
12/19
1.28
V
V
V
87
86
85
V
V
V
V
5.2
4.7
26.1
41.3
V
V
V
(color)
(color)
(color)
A @ r/min
9.2
38.5
63.2
459561
459561
0.540.66
14 @ 6,000
1.191.61
8.511.5
15.0
kW
Seconds
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
Constant mesh
0.8
30
12.5 (0.49)
6.5 (0.26)
0.7 (0.03)
0.2 (0.01)
28.0 (1.10)
27.0 (1.06)
11
SPEC
Item
Starter relay
Rating
Thermoswitch
resistance
(B/Y B/Y)
@ 20 C (68 F)
@ 100 C (212 F)
Speed sensor
Water temperature sensor
resistance
(Y B/Y)
@ 25 C (77 F)
Output voltage
(P B/O)
@ trolling speed
Cam position sensor
Output voltage
(G/O B/O)
Position A
Position B
Position C
Fuel level sensor
Fuel level sensor resistance
Position A
Position B
Oil pressure switch
pressure
Fuel injector
Fuse
Rating
Main
Remote control unit
Model
FX High Output
Unit
Seconds
30
C (F)
C (F)
C (F)
C (F)
8490 (183194)
7084 (158183)
94100 (201212)
8094 (176201)
k
k
54.269.0
3.123.48
11.6
5.0
2
10
0.756 0.016
V
V
V
More than 4.8

Less than 0.8
More than 4.8
133.5136.5
57
kPa
(kgf/cm2, psi)
128166 (1.281.66, 18.223.6)
11.512.5
V/A
V/A
V/A
12/20
12/3
12/3
12
SPEC
ENGINE
Item
Cylinder head
Warpage limit
Cylinder
Bore size
Taper limit
Out-of-round limit
Wear limit
Camshaft
Drive system
Intake A
Exhaust A
Timing chain
Tensioning system
Intake
Exhaust
Valve dimensions
Intake
Exhaust
Valve face width B
Intake
Exhaust
Model
Unit
FX
FX Cruiser
mm (in)
0.1 (0.004)
kPa
(kgf/cm2, psi)
1,350 (13.5, 192)
mm (in)
mm (in)
mm (in)
mm (in)
74.06074.075 (2.91572.9163)
0.08 (0.003)
0.05 (0.002)
74.200 (2.9213)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
Chain drive
32.25 (1.270)
32.65 (1.285)
25.00 (0.984)
24.5 (0.9646)
24.4424.45 (0.96220.9626)
0.050.08 (0.0020.0031)
mm (in)
0.03 (0.0012)
92RH2015-130/130
Automatic
mm (in)
mm (in)
0.110.20 (0.00430.0079)
0.250.34 (0.00980.0134)
mm (in)
mm (in)
22.923.1 (0.90160.9094)
24.424.6 (0.96060.9685)
mm (in)
mm (in)
1.912.64 (0.07520.1039)
1.912.64 (0.07520.1039)
cylinders.
13
SPEC
Item
Valve seat width C

Intake
Exhaust
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Intake
Exhaust
clearance
Intake
Exhaust
Valve stem runout
E
Model
Unit
FX
FX Cruiser
mm (in)
mm (in)
0.91.1 (0.03540.0433)
0.91.1 (0.03540.0433)
mm (in)
mm (in)
0.851.15 (0.03350.0453)
0.851.15 (0.03350.0453)
mm (in)
mm (in)
3.9753.990 (0.15650.1571)
4.4654.480 (0.17580.1764)
mm (in)
mm (in)
4.0004.012 (0.15750.1580)
4.5004.512 (0.17720.1776)
mm (in)
mm (in)
mm (in)
0.0100.037 (0.00040.0015)
0.0200.047 (0.00080.0019)
0.01 (0.0004)
Valve spring
Free length
Intake
mm (in)
Exhaust
mm (in)
Installed length
Intake
mm (in)
Exhaust
mm (in)
Spring limit
Intake
Degree/mm (in)
Exhaust
Degree/mm (in)
Piston
mm (in)
Piston diameter
mm (in)
Measuring point H*
mm (in)
Wear limit
mm (in)
mm (in)
Piston pins
Outside diameter
mm (in)
Wear limit
mm (in)
14
38.90 (1.53)
40.67 (1.60)
34.50 (1.36)
35.00 (1.38)
2.5/1.7 (0.067)
2.5/1.8 (0.071)
0.100.11 (0.00390.0043)
73.95573.970 (2.91162.9121)
5 (0.2)
0.17 (0.0067)
17.00217.013 (0.66930.6698)
16.99117.000 (0.66890.6693)
16.98 (0.67)
SPEC
Item
Model
Unit
Piston ring
Top ring
T
Type
Dimension (B T)
End gap (installed)
2nd ring
Type
T
Dimensions (B T)
End gap (installed)
Oil ring
Dimensions
T
(B T)
End gap (installed)
Connecting rod
Bearing color code
Crankshaft
FX
FX Cruiser
mm (in)
mm (in)
mm (in)
Barrel
0.90 2.75 (0.04 0.11)
0.190.31 (0.00750.0122)
0.0300.065 (0.00120.0026)
mm (in)
mm (in)
mm (in)
Taper
0.80 2.80 (0.03 0.11)
0.300.45 (0.01180.0177)
0.0200.055 (0.00080.0022)
mm (in)
1.50 2.60 (0.06 0.10)
mm (in)
mm (in)
0.100.35 (0.00390.0138)
0.0400.160 (0.00160.0063)
mm (in)
0.0160.040 (0.00060.0016)
17.00517.018 (0.66940.6699)
mm (in)
Crank width A
Deflection limit B
Bearing color code
Throttle body
Type/quantity
Manufacturer
ID mark
Trolling speed
Fuel pump
Pump type
Fuel pressure
mm (in)
mm (in)
mm (in)
304.8306.0 (12.0012.05)
0.03 (0.0012)
0.0040.028 (0.00020.0011)
40EIS/4
Mikuni
60E21
1,6001,700
r/min
kPa
(kgf/cm2, psi)
15
Electrical
320.8327.2 (3.23.3, 4547)
SPEC
Item
Oil filter
Oil filter type
Oil pump
Oil pump type
Rotor tip clearance
(scavenge pump)
Rotor (feed pump)
E
Model
Unit
FX
FX Cruiser
Cartridge type
mm (in)
Trochoid
0.090.15 (0.00350.0059)
mm (in)
mm (in)
0.090.17 (0.00350.0067)
0.090.15 (0.00350.0059)
JET PUMP UNIT

Item
Jet pump
Impeller material
Impeller clearance
Nozzle diameter
Model
Unit
FX
FX Cruiser
Stainless steel
3
16.3
0.350.45 (0.01380.0177)
0.6 (0.0236)
0.3 (0.0118)
86.587.1 (3.413.43)
Degree
mm (in)
mm (in)
mm (in)
mm (in)
HULL AND HOOD

Item
Free play
Model
Unit
FX
mm (in)
FX Cruiser
47 (0.160.28)
ELECTRICAL
Item
Battery
Type
Capacity
Specific gravity
ECM unit
(B/R R/Y, B/W R/Y,
B/Y R/Y, B/L R/Y)
@cranking (loaded)
Model
Unit
FX
FX Cruiser
V/Ah
Fluid
12/19
1.28
V
V
V
87
86
85
16
SPEC
Item
Stator
Pickup coil
(W B, R B)
Output peak voltage
@cranking (loaded)
Lighting coil
(G G)
Output peak voltage
Ignition coil
Rectifier/regulator
(R B)
Output peak voltage
Starter motor
Type
Output
Rating
Brush length
Wear limit
Commutator undercut
Limit
Commutator diameter
Limit
Starter relay
Rating
Thermoswitch
resistance
(B/Y B/Y)
@ 20 C (68 F)
@ 100 C (212 F)
E
Model
Unit
FX
FX Cruiser
V
V
V
V
4
4
23
38
V
V
V
(color)
(color)
(color)
A @ r/min
9
11
12
459561
459561
0.540.66
14 @ 6,000
1.191.61
8.511.5
15.0
kW
Seconds
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
Constant mesh
0.8
30
12.5 (0.49)
6.5 (0.26)
0.7 (0.03)
0.2 (0.01)
28.0 (1.10)
27.0 (1.06)
Seconds
30
C (F)
C (F)
C (F)
C (F)
8490 (183194)
7084 (158183)
94100 (201212)
8094 (176201)
k
k
54.269.0
3.123.48
17
SPEC
Item

resistance
(B/Y B/O)
@ 0 C (32 F)
@ 80 C (176 F)
Output voltage
(P/G B/O)
Speed sensor
Output voltage
(P B/O)
@ trolling speed
Cam position sensor
Output voltage
(G/O B/O)
Position A
Position B
Position C
Fuel level sensor
Fuel level sensor resistance
Position A
Position B
Oil pressure switch
pressure
Fuel injector
Fuse
Rating
Main
Multifunction meter
E
Model
Unit
FX
FX Cruiser
k
k
5.46.6
0.290.39
V @ kPa
(kgf/cm2, psi)
V @ kPa
(kgf/cm2, psi)
V @ kPa
(kgf/cm2, psi)
4.00 @ 101.3 (1.01, 14.4)
11.6
2
0.756 0.016
V
V
V
More than 4.8

Less than 0.8
More than 4.8
133.5136.5
57
kPa
(kgf/cm2, psi)
128166 (1.281.66, 18.223.6)
11.512.5
V/A
V/A
V/A
12/20
12/3
12/3
18
1.84 @ 47 (0.47, 6.68)

0.79 @ 20 (0.2, 2.8)
SPEC
TIGHTENING TORQUES
TIGHTENING TORQUES
SPECIFIED TORQUES
Side cover
0.54
3.9
Bolt
M6
1.1
0.11
0.8
Bolt
Screw
Nut
Nut
Nut
Nut
Screw
Nut
Nut
Nut
Nut
Nut
Nut
Nut
Nut
Nut
M8
M6
M5
4
4
2
1
1
4
4
1
2
2
1
1
1
1
1
1
20
0.9
5.4
16
16
20
5.2
6.4
6.4
15
5.9
5.9
3.8
5.9
2.9
5.9
2.0
0.09
0.54
1.6
1.6
2.0
0.52
0.64
0.64
1.5
0.59
0.59
0.38
0.59
0.29
0.59
14
0.7
3.9
12
12
14
3.8
4.6
4.6
11
4.3
4.3
2.7
4.3
2.1
4.3
Nut
2.9
0.29
2.1
Nut
Bolt
Bolt
Screw
Bolt
Bolt
Nut
Screw
Screw
Screw
Bolt
Bolt
Nut
M6
M6
M5
M5
M6
M5
M5
M5
M5
M6
4
6
2
8
6
4
2
12
8
4
4
8
2
6.4
5.4
5.4
2.2
1.1
5.4
5.4
3.7
3.7
2.2
3.7
5.4
5.4
0.64
0.54
0.54
0.22
0.11
0.54
0.54
0.37
0.37
0.22
0.37
0.54
0.54
4.6
3.9
3.9
1.6
0.8
3.9
3.9
2.7
2.7
1.6
2.7
3.9
3.9
19
LT
5.4
242
LT
M6
271
Screw
LT
0.8
242
0.11
LT
1.1
271
LT
M5
242
Screw
LT
0.8
242
0.11
LT
1.1
242
LT
M6
572
Bolt
LT
0.8
572
0.11
LT
1.1
242
LT
M6
242
Screw
Remarks
LT
Mirror cover
Mirror
Multifunction meter cover
Multifunction meter
Tightening torque
Nm kgfm
ftlb
242
Mirror assembly
Thread
Qty
size
LT
Hull and hood

Handlebar cover (for FX/FX High
Output)
Handlebar cover stay (for FX/FX
High Output)
Upper handlebar cover (for FX
Cruiser/FX Cruiser High Output)
Lower handlebar cover (for FX
Cruiser/FX Cruiser High Output)
Steering pad (for FX Cruiser/FX
Cruiser High Output)
Handlebar holder
Handle boss cover
QSTS converter
Steering master
Speed sensor
Steering cable joint (jet pump side)
Shift cable holder
Shift cable bracket
Steering cable grommet
Speed sensor lead grommet
QSTS cable end pin
QSTS cable grommet
QSTS cable locknut (jet pump side)
Shift cable grommet
Shift cable locknut (reverse gate
side)
Hinge assembly
Front hood assembly
Hood lock assembly
Front hood
Visor
Part name
242
Part to tightened
TIGHTENING TORQUES
Nut A
Bolt B
8 mm
10 mm
12 mm
14 mm
17 mm
M5
M6
M8
M10
M12
3.8
0.38
2.7
Nut
Bolt
Nut
Nut
Nut
Nut
Nut
Nut
Nut
Bolt
Screw
Bolt
Bolt
Nut
Nut
Bolt
M6
M8
M5
M6
M8
M6
3
4
4
2
4
2
4
1
6
10
4
2
6
3
4
6
5.4
6.4
18
26
6.4
15
5.4
5.4
15
16
2.0
13
15
5.4
5.4
2.4
0.54
0.64
1.8
2.6
0.64
1.5
0.54
0.54
1.5
1.6
0.2
1.3
1.5
0.54
0.54
0.24
3.9
4.6
13
19
4.6
11
3.9
3.9
11
12
1.4
9.4
11
3.9
3.9
1.7
LT
LT
271
Nut
Remarks
LT
Tightening torque
Nm kgfm
ftlb
2.2
0.22
1.6
5.4
0.54
3.9
6.4
0.64
4.6
572
Screw
Nut
Nut
Thread
Qty
size
M5
4
LT
Side ornament
Center cover
Hood lock
Compass sensor and air temperature sensor
Shift lever assembly
Seat lock assembly
Deck beam
Projection
Rear seat stay
Front seat stay
Hand grip
Spout
Cleat
Sponson
Drain plug/screw
Bow eye
Reboarding step
Front protector 1
Front protector 2/3
Cleat
Part name
271
Part to tightened
271
SPEC
GENERAL TORQUE
General torque
specifications
Nm kgfm ftlb
5.0
0.5
3.6
8.0
0.8
5.8
18
1.8
13
36
3.6
26
43
4.3
31
This chart specifies tightening torques for standard fasteners with a standard ISO thread
pitch. Tightening torque specifications for special components or assemblies are provided in
applicable sections of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross fashion and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads.
Components should be at room temperature.
20
SPEC

H
G
F
A-A
2
2
J
BOW
20
UP
DOWN
3
J
D
B
1
B-B
CE
UP
C-C
4
H-H
H
G
D-D
UP
0
A
6
E-E
A
G-G
0
7
9
7
9
F-F
8
1
2
3
4
5
6
7
8
9
0

Battery
Steering cable
QSTS cable
Shift cable
Speed sensor lead
A
B
C
D
E
F

Electrical box lead
Throttle cable
Fuel hose
(FX High Output/FX Cruiser
High Output)
G Compass sensor
(FX Cruiser High Output)
21
H Remote control unit

High Output)
I Remote control unit antenna
High Output)
Fasten the speed sensor lead
and
electrical
box
lead
securely with a plastic band.
SPEC
1 2
8
3
45 6 7
1
2
3
H
J
5
4
6
A 0
H
B
1
2
3
H
5
4
H
A
6
B
1 Buzzer lead
2 Steering sensor lead
3 Handlebar switch assembly
lead
4 Fuel level sensor lead
5 Speed sensor lead
6 Electrical box lead
7 Throttle cable
8 Negative battery lead
9 Positive battery lead
0
A
B
C
D
Shift cable
QSTS cable
Steering cable
High Output)
E Remote control unit
High Output)
22
F Remote control unit antenna

High Output)
G Right operation button lead
H Multifunction meter lead
I Left operation button lead
J Compass sensor lead
SPEC
1 2
8
3
45 6 7
1
2
3
H
J
5
4
6
A 0
H
B
1
2
3
H
5
4
H
A
6
B
Connect the left operation button lead coupler

(natural) to the multifunction meter lead coupler
(natural).
FX/FX Cruiser/FX High Output
Fasten the handlebar switch assembly lead, fuel

level sensor lead, speed sensor lead, and electrical box lead securely with a plastic tie.
When installing the remote control unit antenna
holders, insert the projection on each holder into
a hole in the front storage compartment from the
engine compartment side.
Connect the right operation button lead coupler
(blue) to the multifunction meter lead coupler
(blue). (FX Cruiser High Output)
23
SPEC
B
1
2 3
6 7
A
4
A
F
B
H
G
E
A
3
9
2
1 2
A
A
3
MAIN
3A
A
3A
A
20A
3A
SPARE
C
7
D C
1
2
3
4
5
6
7
8
9
0
A
C-C
D-D
D
B
C
D
E
F
G
Shift cable
Steering cable
Fuel hose
Throttle cable
Battery breather hose
QSTS cable
Water separator
Ignition coil lead
Starter motor positive lead
Wiring harness
Electric fuel pump
(FX High Output/FX Cruiser High Output)
H Remote control unit
I Remote control unit antenna
24
SPEC
B
1
2 3
6 7
A
4
A
F
B
H
G
E
A
3
9
2
1 2
A
A
3
MAIN
3A
A
3A
A
20A
3A
SPARE
C
7
D C
C-C
To ventilation socket
To fuel tank
Route the fuel tank breather hose as shown in
the illustration.
Bow
57 mm (0.200.28 in)
Point the arrow on the cover toward the fuel
tank.
25
D-D
SPEC
2 3
A
5
1
3
4
B-B
C-C
6
D
D
8
7
1
2
3
4
5
6
7
9 Remote control unit antenna

Throttle cable
QSTS cable
Grommet
Hose packing
Less than 10 mm (0.39 in)

Position the throttle cable and handlebar switch
lead packing in the opening in the grommet so
that the plastic tie fastened around both the
grommet and the packing.
26
SPEC
2 3
A
5
1
3
4
B-B
C-C
6
D
D
8
7
Position the QSTS cable packing in the opening

in the grommet so that the plastic tie is fastened
around both the grommet and the packing.
FX Cruiser/FX Cruiser High Output
FX/FX High Output
37 mm (0.120.28 in)
27
SPEC
4 5
6
8
6
0
H
5
2
A C
1
A
2
D
8
A-A
9
E
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H

Bilge hose 1
Electric bilge pump
Bilge hose 4
Cooling water hose (from thermostat)
Bilge hose 3
Bilge hose 2
Shift cable
Cooling water hose (from exhaust pipe)
Electrical box
QSTS cable
Speed sensor lead
Electric bilge pump lead
Bilge strainer
Steering cable
Flushing hose
Pass the QSTS cable between the bilge hoses.

28
SPEC
9 0 A
8
7
2
A
0
B
1
4
A-A
1
2
3
4
5
6
7
8
9
0
Wiring harness
Ground lead
Noise filter
Oil pressure switch coupler
Pickup coil coupler
Thermoswitch (exhaust) coupler
A Cam position sensor coupler

B Oil pressure switch lead
After connecting the coupler to
the wiring harness, insert the
projection on the coupler into
the hole in the bracket.
To oil pressure switch
To cam position sensor
To electrical box
29
Fasten the plastic tie with its

end facing downward.
812 mm (0.310.47 in)
1525 mm (0.590.98 in)
1520 mm (0.590.79 in)
SPEC
1
2
A-A
4
3
1
2
3
4
5
6
7
8
9
0
Fasten the engine temperature sensor lead,

thermoswitch lead, and lighting coil lead with a
plastic tie. Fasten the engine temperature sensor lead 1020 mm (0.40.8 in) from the end of
the protective cover of the lead.
To generator
To thermoswitch (engine)
To thermoswitch (engine) coupler
To engine temperature sensor coupler
Engine temperature sensor coupler

Pickup coil coupler
Starter motor
Engine temperature sensor lead
Thermoswitch (engine) lead
Lighting coil lead
30
SPEC
1
2
A-A
4
3

FX/FX Cruiser
Route the starter motor lead to the outside of the

engine temperature sensor lead.
To starter relay
To negative battery terminal
Route the starter motor and negative battery
leads behind the cooling water hose.
Route the starter motor lead over the cooling
water hose.
Insert the projection on the plastic tie completely
into the hole in the bracket.
31
SPEC
CABLE AND HOSE ROUTING (For FX/FX Cruiser)
1
1
C-C
C
D
A
E
5
6
G
1
2
3
4
5
6
7
E-E
To cooling water pilot outlet on starboard side

To cooling water outlet on starboard side of
stern
To pressure control valve
To install the hose, align the white paint mark on
the cooling water hose with the projection of the
hose joint.
Thermostat
Cooling water hose
Pressure control valve
Breather hose
32
SPEC
1
1
C-C
C
D
A
E
5
6
G
E-E
To oil tank
To exhaust pipe
paint mark on the hose with the parting line on
the hose joint.
Fasten the cooling water hose, negative battery
lead, and breather hose with a plastic tie. Set
the tie in the direction shown.
When installing the cooling water hoses, be sure

to push them down until they contact the hose
joint.
cooling water hoses, pass a plastic tie through
the stay hole, and then fasten the tie.
33
SPEC
1
1
C-C
C
D
A
E
5
6
G
E-E

Face the ends of the clamps downward.
From cooling water passage

cover to thermostat) and cooling water hose
(starboard cooling water pilot outlet), and then
fasten them with a plastic tie to the oil tank boss.
When bundling the hoses, make sure that the
cooling water hose (cylinder head cover to thermostat) is routed on the deck side and that the
cooling water hose (starboard cooling water
pilot outlet) is routed on the engine side.
34
SPEC
A
B
1
2
3
4
5
6
7
8
Route the throttle cable between the sub-wiring

harness.
Route the sub-wiring harness under the intake
vacuum hose.
To wiring harness
To intake air temperature sensor coupler.
To fuel injector #3 coupler
Fasten the sub-wiring harness to the joint coupler bracket with a plastic tie as shown in the
illustration.
Intake air temperature sensor coupler

Intake air pressure sensor coupler
Joint coupler
35
SPEC
A
B
Fasten the ring, which is attached to the subwiring harness, to the sensor bracket with a
plastic tie. Face the end of the plastic tie
towards the sensor.
To bypass valve motor coupler.
36
CABLE AND HOSE ROUTING (For FX High Output/

FX Cruiser High Output)
SPEC
CABLE AND HOSE ROUTING (For FX High Output/FX Cruiser High Output)
C-C
B
C
A
E
4
5
G
1
2
3
4
5
E-E
To cooling water pilot outlet on starboard side

To cooling water outlet on starboard side of
stern
To cylinder block
To install the hose, align the white paint mark on
the cooling water hose with the projection of the
hose joint.
Thermostat
Cooling water hose
37

SPEC
1
1
C-C
B
C
A
E
4
5
G
E-E
To exhaust pipe
paint mark on the hose with the parting line on
the hose joint.
Fasten the cooling water hose and negative battery lead with a plastic tie. Set the tie in the
direction shown.
When installing the cooling water hoses, be sure

to push them down until they contact the hose
joint.
cooling water hoses, pass a plastic tie through
the stay hole, and then fasten the tie.
38

SPEC
1
1
C-C
B
C
A
E
4
5
G
E-E

From cooling water passage
Face the ends of the clamps downward.

cover to thermostat) and cooling water hose
(starboard cooling water pilot outlet), and then
fasten them with a plastic tie to the oil tank boss.
When bundling the hoses, make sure that the
cooling water hose (cylinder head cover to thermostat) is routed on the deck side and that the
cooling water hose (starboard cooling water
pilot outlet) is routed on the engine side.
39

SPEC
A
B
1
2
3
4
5
6
7
8

Joint coupler
To wiring harness
Route the throttle cable
between the sub-wiring harness.
Route the sub-wiring harness
under the intake vacuum hose.
To fuel injector #3 coupler
40
Fasten the sub-wiring harness

to the joint coupler bracket with
a plastic tie as shown in the
illustration.
Fasten the ring, which is
attached to the sub-wiring harness, to the sensor assembly
bracket with a plastic tie. Face
the end of the plastic tie
towards the sensor assembly.
INSP
ADJ

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.
MAINTENANCE INTERVAL
10 hours
ITEM
Spark plug
Lubrication points
Fuel system
Fuel tank
Trolling speed
Throttle shaft
Cooling water passages
Bilge strainer
Electric bilge pump strainer
Impeller
Jet thrust nozzle angle
Steering master
QSTS mechanism
Shift cable and mechanism
Throttle cable
Stern drain plugs
Battery
Rubber coupling
Engine mount
Nuts and bolts
Air filter
Engine oil
Engine oil filter
Valve clearance
Inspect, clean, adjust

Lubricate
Lubricate
Inspect
Inspect, clean
Inspect, adjust
Inspect
Flush
Inspect, clean
Clean
Inspect, clean
Inspect
Inspect, adjust
Inspect
Inspect, adjust
Inspect, adjust
Inspect, adjust
Inspect, replace
Inspect
Inspect
Inspect
Inspect
Inspect, replace
Replace
Replace
Inspect, adjust
*1
*3

*3: After every use
41
INITIAL
THEREAFTER EVERY
50 hours 100 hours 100 hours 200 hours
6 months 12 months 12 months 24 months
*2
*2
INSP
ADJ
CONTROL SYSTEM
PERIODIC SERVICE
CONTROL SYSTEM
Steering master inspection
1. Inspect:
Steering master
Excessive play Replace the steering
master.
Refer to STEERING MASTER.
Inspection steps:
Move the handlebar up and down and
back and forth.
Check the excessive play of the handlebar.
3
Steering cable inspection and adjustment
1. Inspect:
Jet thrust nozzle difference of distances
a and b
Difference of distances a and b:
Maximum 5 mm (0.2 in)
Inspection steps:
Turn the handlebar lock to lock.
Measure distances a and b.
If difference of distances a and b is not
within specification, adjust the cable joint.
42
INSP
ADJ
CONTROL SYSTEM
E
2. Adjust:
(steering master end)
Adjustment steps:
joint 3.
Turn the cable joint 2 in or out for adjusting the distances a and b.
Turn in
Distance a is increased.
Turn out
Distance b is increased.
WARNING
locknut.
T.
Locknut:
6.4 N m (0.64 kgf m, 4.6 ft lb)
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.
Throttle cable inspection and adjustment

NOTE:
Before adjusting the throttle lever free play,
adjust the trolling speed.
1. Measure:
Throttle lever free play a
Throttle lever free play:
47 mm (0.160.28 in)
43
INSP
ADJ
CONTROL SYSTEM
E
2. Adjust:
Adjustment steps:
NOTE:
When not replacing the throttle cable or
adjust the throttle cable free play by following steps (d) through (h).
When replacing the throttle cable or
adjust the throttle cable free play by following steps (a) through (i).
a. Remove the air filter case cover 1 and
ribbon sub assemblies.
b. Loosen the locknut 2.
c. Turn the adjusting nut 3 to adjust the
length a, and then tighten the locknut.
Throttle cable installation length:
23.9 1.0 mm (0.94 0.04 in)
NOTE:
Apply locking agent (LOCTITE) to the
threads of the adjusting nut 3.
d. Remove the handlebar cover.
e. Loosen the locknut 4.
f. Turn the adjuster 5 in or out until the
specified free play is obtained.
Turn in
Turn out
g. Tighten the locknut.

NOTE:
When adjusting the throttle cable at the
throttle body, fully open the throttle lever
and check that the butterfly valve is fully
open.
If the throttle cable free play cannot be
adjusted properly, replace the throttle
cable.
44
INSP
ADJ
CONTROL SYSTEM/GENERAL
h. Install the handlebar cover.
T.
Handlebar cover screw:

1.1 N m (0.11 kgf m, 0.8 ft lb)
LOCTITE 242
i. Install the ribbon sub assemblies and air

filter case cover.
T.
Ribbon sub assembly bolt:

6.5 N m (0.65 kgf m, 4.7 ft lb)
LOCTITE 242
2.5 N m (0.25 kgf m, 1.8 ft lb)
LOCTITE 572
WARNING
After adjusting the free play, turn the handlebar to the right and left and make sure
that the trolling speed does not increase.
GENERAL
Drain plug inspection
1. Inspect:
Drain plugs
O-rings
Screw threads
Contaminants Clean.
45
INSP
ADJ
GENERAL
E
Lubrication points
1. Lubricate:
Throttle cable (handlebar end)
Rust inhibitor
NOTE:
Before lubricating the throttle cable, remove
the throttle cable 1 from the throttle lever
assembly.
2. Lubricate:
Throttle cable (throttle body end)
Throttle bodies (throttle cable pulley,
throttle cam, and return spring)
Yamaha grease A
3. Lubricate:
QSTS control cables (handlebar end)
Yamaha grease A
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.
46
INSP
ADJ
GENERAL
E
4. Lubricate:
QSTS cables (pulley end)
Recommended grease:
Yamaha grease A
5. Lubricate:
Nozzle pivot shaft
Steering cable (nozzle end)
QSTS cable (nozzle end)
Recommended grease:
Yamaha grease A
6. Lubricate:
Steering cable
Shift cable
Shift cable joint
NOTE:
Disconnect the joints and apply a small
amount of grease.
Recommended grease:
Yamaha grease A
47
INSP
ADJ
GENERAL
E
7. Fill:
Recommended grease:
Yamaha grease A
Grease quantity:
Initial 10 hours:
33.035.0 cm3 (1.111.18 oz)
Every 100 hours or 12 months:
6.08.0 cm3 (0.200.27 oz)
NOTE:
Fill the intermediate housing with the recommended grease through the grease nipple 1.
48
ELEC
ELECTRICAL COMPONENTS (For FX/FX Cruiser)
ELECTRICAL COMPONENTS (For FX/FX Cruiser)
N
M
L
K
J
I
H
G
F
E
D
C
2
3
4
B
5
A
6
0
9
8
1
2
3
4
5
6
7
8
9
0
A
Starter motor
Electrical box
Battery
Speed sensor
Electric bilge pump
Cam position sensor
Fuel injectors
B
C
D
E
F
G
H
Oil pressure switch

Bypass valve motor
Lighting coil and pickup coil
Engine stop switch, engine
switch
I Steering sensor
J Buzzer
49
K
L
M
N
Electric fuel pump

Fuel level sensor
Left operation button
Multifunction meter
ELEC
ELECTRICAL COMPONENTS (For FX High Output/

(For FX High Output/FX Cruiser High Output)
O
N
M
L
K
J
I
H
G
F
E
3
4
C
B
5
A
0
9
8
1
2
3
4
5
6
7
Starter motor
Electrical box
Battery
Speed sensor and water temperature sensor
Speed sensor
(FX High Output)
8
9
0
A
B
C
Electric bilge pump

Cam position sensor
Fuel injectors
Oil pressure switch
Sensor assembly (intake air
pressure and intake air temperature sensor)
D Bypass valve motor
E Throttle position sensor
F Lighting coil and pickup coil
50
G Engine stop switch, engine

switch
H Steering sensor
I Buzzer
ELEC
ELECTRICAL COMPONENTS (For FX High Output/

O
N
M
L
K
J
I
H
G
F
E
3
4
C
B
5
A
0
9
8
J
K
L
M
N
Electric fuel pump

Fuel level sensor
Multifunction meter
Right operation button
O Remote control unit
P Compass sensor and air temperature sensor
51
ELEC

WIRING DIAGRAM
8 :O
12 : W/R
13 : W/B
16 : G/B
17 : G/Y
18 : G/R
20 : G
27 : W/L
30 : R/Y
34 : P
1
R
P
B/O
B/O
P
B/O
B/O
O
R
R/Y
R/Y
W/L
B/O
O
R/Y
R/Y
O
B
W/L
W/L
R/Y
R/Y
B/O
R/Y
P/G
O
Pu/B
Pu/R
Pu/G
B/O
W/B
G
B/Y
B/O
G/B
G/Y
G/B
G/R
G
Pu/R
Pu/G
B/O
B/O
Pu/B
Pu/Y
R/Y
B/O
B/O
W/R
G/R
G/Y
R/Y
B/O
W/R W/B
B/O
B/O B/O
R/Y
Pu/Y
R/Y
P/G
B
R W
R/Y
R/Y
3
G R/Y G/R
G/Y R/Y G/B
R/Y
B/O
G/R
G/Y
B/O
P
O
G
G/B
R/Y
1
2
3
4
5
W/L
ECM
Steering sensor
Pickup coil
Bypass valve motor
B
G
O
P
R
W
B/O
G/B
G/R
: Black
: Green
: Orange
: Pink
: Red
: White
: Black/orange
: Green/black
: Green/red
52
G/Y
R/Y
W/B
W/L
W/R
: Green/yellow
: Red/yellow
: White/black
: White/blue
: White/red
ELEC
STEERING SENSOR
1. Check:
Steering sensor
Malfunction Replace the steering
sensor.
Checking steps:
Turn the handlebar all the way to the left
or right, and then release it.
Install a plastic tie 1 loosely around the
center of the handlebar grip as shown.
Hook a spring gauge 2 onto the plastic
tie.
Hold the spring gauge at a 90 angle
from the handlebar, and then pull the
spring gauge with a force of 10 kgf
(22 lb).
When handlebar
pulled
When handlebar
not pulled
ON
OFF
Check that the following is displayed in

the Engine Monitor window of the
Use the same procedure to check that
the steering sensor operates correctly
when the handlebar is turned to both the
left and right. Replace the steering sensor if it is a malfunction.
53
ELEC
INDICATION SYSTEM
INDICATION SYSTEM
WIRING DIAGRAM (For FX Cruiser High Output)
L/R
R/Y
R/Y
R/Y
R/Y
P
O
R/Y
1 2 3456 7 8
14 6 15 35 5
R/Y
R/Y
P P P R R
1 21 30
R/Y
L/R
P/W
R/Y
B
P/W
W/B
R/Y
W/B
R/Y
B/O
B/O
B/O
P/W
B/O
W/B
G
P
W/B B R/Y
P
B
B/O
B/O
0
P
P
4
L/R
L/R
L/B L/Y
L G R W B
B/G
B
B/O
L/B
B/G
B/Y
B/O
L
L/R
15 18 16 7 6
L/Y
L/B
L/R
Y
L
B/O
B/Y
B/Y
B/Y
B/Y
B/O
L G R W B
B/L
B/O
B/O
B/O
E
R
B/O
B
B/Y
R/Y
B/O
B/O
B/Y
R
B/Y
R/Y
Y
1
2
3
4
5
6
7
8
9
B/L
L/R
G
L/Y
B/O
B/Y
R/Y
Y
B/O
B/O
B/O
B/O
B/O
B/O
0
A
B
C
D
E
ECM
Fuse (20 A)
Remote control unit
Battery
Tacho pulse
54
Multifunction meter
Fuel level sensor
Buzzer
Oil pressure switch
ELEC
INDICATION SYSTEM
WIRING DIAGRAM (For FX Cruiser High Output)
L/R
R/Y
R/Y
R/Y
R/Y
P
O
R/Y
1 2 3456 7 8
14 6 15 35 5
R/Y
R/Y
P P P R R
1 21 30
R/Y
L/R
P/W
R/Y
B
P/W
W/B
R/Y
W/B
R/Y
B/O
B/O
B/O
P/W
B/O
W/B
G
P
W/B B R/Y
P
B
B/O
B/O
0
P
P
4
L/R
L/R
L/B L/Y
L G R W B
B/G
B
B/O
L/B
B/G
B/Y
B/O
L
L/R
15 18 16 7 6
L/Y
L/B
L/R
Y
L
B/O
B/Y
B/Y
B/Y
B/Y
B/O
L G R W B
B/L
B/O
B
B/Y
R/Y
B/O
B/O
B/Y
R
B/Y
R/Y
Y
B
G
L
O
P
R
W
Y
B/G
B/O
B/O
B/O
E
R
B
B/L
L/R
G
L/Y
B/O
B/Y
R/Y
Y
B/O
B/O
B/O
B/O
B/O
B/O
B/L
B/O
B/Y
L/B
L/R
L/Y
P/W
R/Y
W/B
: Black
: Green
: Blue
: Orange
: Pink
: Red
: White
: Yellow
: Black/green
55
: Black/blue
: Black/orange
: Black/yellow
: Blue/black
: Blue/red
: Blue/yellow
: Pink/white
: Red/yellow
: White/black
ELEC
INDICATION SYSTEM
WIRING DIAGRAM (For FX High Output)
Y
L/R
R/Y
R/Y
R/Y
R/Y
P
O
R/Y
1 2 3456 7 8
14 6 15 35 5
R/Y
R/Y
P P P R R
1 21 30
R/Y
L/R
P/W
R/Y
B
P/W
W/B
R/Y
B/O
B/O
B/O
P/W
B/O
W/B
G
P
W B R
P
B
B/O
B/O
0
P
P
L/R
L/B Gy
L/R
B/Y
B/G
R/W
Gy
P
B
B/O
B/O
B/Y
R/W
L/B
B/G
B/Y
B/O
L/Y
L/R
B/O
B/Y
B/Y
B/Y
15 18 16 7 6
Y
L
P
R/Y
B/Y
B/O
L/R
B/L
L/R
B/Y
R/Y
B/O
B/O
B/O
B/O
B
B
B/O
B/O
B/O
B/O
B/O
B/O
B/O
C
1
2
3
4
5
6
7
8
9
B/Y
L/Y
L/B
B/L
B/O
0
A
B
C
D
ECM
Fuse (20 A)
Remote control unit
Battery
Tacho pulse
56
Multifunction meter
Fuel level sensor
Speed sensor
Buzzer
Oil pressure switch
ELEC
INDICATION SYSTEM
WIRING DIAGRAM (For FX High Output)
Y
L/R
R/Y
R/Y
R/Y
R/Y
P
O
R/Y
1 2 3456 7 8
14 6 15 35 5
R/Y
R/Y
P P P R R
1 21 30
R/Y
L/R
P/W
R/Y
B
P/W
W/B
R/Y
B/O
B/O
B/O
P/W
B/O
W/B
G
P
W B R
P
B
B/O
B/O
0
P
P
L/R
L/B Gy
L/R
B/Y
B/G
R/W
Gy
P
B
B/O
B/O
B/Y
R/W
L/B
B/G
B/Y
B/O
L/Y
L/R
B/O
B/Y
B/Y
B/Y
15 18 16 7 6
Y
L
P
R/Y
B/Y
B/O
L/R
B/L
L/R
B/Y
R/Y
B/O
B/O
B/O
B/O
B
B
B/O
B/O
B/O
B/O
B/O
B/O
B/O
C
B
G
Gy
L
O
P
R
W
Y
: Black
: Green
: Gray
: Blue
: Orange
: Pink
: Red
: White
: Yellow
B/Y
L/Y
L/B
B/L
B/G
B/L
B/O
B/Y
L/B
L/R
L/Y
P/W
R/W
B/O
: Black/green
: Black/blue
: Black/orange
: Black/yellow
: Blue/black
: Blue/red
: Blue/yellow
: Pink/white
: Red/white
57
R/Y : Red/yellow
W/B : White/black
ELEC
INDICATION SYSTEM
WIRING DIAGRAM (For FX/FX Cruiser)
Br
L/R
4 3 2 1
8 7 6 5
R/Y
R/Y
R
P
R/Y
R/Y
R/Y
P
O
12
R/Y
R/Y
56
R/Y
R/Y
P P P R R
6 15 35 5 31 1
Y
P/W
B/O
B
P/W
R/Y
W
W/B
G
B/O
W/B
6
G
R/Y
P/W
B/O
B
B
B/O
P
B
B/O
W B R
B/O
P
P
P
B
B/O
B/O
B/Y
L/B
R/W
L/R
B/G
B/G
B/Y
B/Y
B/Y
L/B
L/R
B/Y
B/O
B/O
B/Y
R/W
B/Y
Y
B/O
P
R/Y
B/O
B/O
B/O
B/Y
B/Y
B/O
R/Y
B/O
B/O
B/O
B/O
B/O
B/O
1 ECM
2 Main and fuel pump
relay
3 Fuse (20 A)
4 Fuse (3 A)
5 Battery
6 Tacho pulse
7 Thermoswitch
(exhaust)
8 Thermoswitch
(engine)
9 Engine temperature
sensor
0 Multifunction meter
A Fuel level sensor
B Speed sensor
C Buzzer
D Oil pressure switch
B
Br
G
O
P
R
W
Y
B/G
58
: Black
: Brown
: Green
: Orange
: Pink
: Red
: White
: Yellow
: Black/green
B/O
B/Y
L/B
L/R
P/W
R/W
R/Y
W/B
: Black/orange
: Black/yellow
: Blue/black
: Blue/red
: Pink/white
: Red/white
: Red/yellow
: White/black
ELEC
INDICATION SYSTEM
MULTIFUNCTION METER
Multifunction meter
1. Check:
Multifunction meter
Cracked meter housing Replace the
Meter is fogged/shows signs of water
intrusion Replace the multifunction
meter.
Operation button
1. Check:
Left operation button continuity
Digital multimeter:
YU-34899-A
90890-03174
Left operation button continuity
Button
Position
Speed/
RPM
Free
Volt/
Hour
Leads
Pu/W
G/W
Push
Free
Push
Right operation button continuity

Digital multimeter:
YU-34899-A
90890-03174
Right operation button continuity
Button
Start/
Stop
Mode/
Reset
59
Position
Free
Push
Free
Push
Leads
R/W
Y/W
ELEC
INDICATION SYSTEM
MULTIFUNCTION METER REMOVAL

Refer to
COVER.
STEERING
CONSOLE
OPERATION BUTTON REMOVAL

Refer to
COVER.
60
STEERING
CONSOLE
ELEC
INDICATION SYSTEM
E
Display function
(for FX Cruiser High Output)
1. Check:
Display function
G/W
Pu/W
Pu/W
B
G/W
B
G/W
R/W
Y/W
R/W
B
Y/W
Pu/W
Pu/W
B
G/W
R/W
Y/W
R/W
B
Y/W
L/Y
L/B
B/L
L/Y
B/L
L/B
L/R
B
R
L/R
L/R
R
G
R
G
W
L
R/Y
W/B
R/Y
W/B
B
B
B/G
5
B/G
1
2
3
4
5
6
7
Remote control unit

Buzzer
Compass sensor
ECM
Fuel level sensor
B
G
L
P
R
W
B/G
B/L
G/W
: Black
: Green
: Blue
: Pink
: Red
: White
: Black/green
: Black/blue
: Green/white
61
L/B
L/R
L/Y
Pu/W
R/W
R/Y
W/B
Y/W
: Blue/black
: Blue/red
: Blue/yellow
: Purple/white
: Red/white
: Red/yellow
: White/black
: Yellow/white
ELEC
INDICATION SYSTEM
E
Display function (for FX High Output)
1. Check:
Display function
G/W
Pu/W
Pu/W
B
G/W
B
L/Y
G/W
L/B
Pu/W
Pu/W
B
G/W
B/L
B
Gy
B/L
L/B
L/R
B
R
L/R
L/R
R
R/W
B/Y
B/Y
R/W
Y
Y
W
W
B
B/G
5
B/G
1
2
3
4
5
6
Remote control unit

Buzzer
Speed sensor
ECM
Fuel level sensor
B
Gy
P
R
W
Y
B/G
B/L
: Black
: Gray
: Pink
: Red
: White
: Yellow
: Black/green
: Black/blue
62
B/Y
G/W
L/B
L/R
L/Y
Pu/W
R/W
: Black/yellow
: Green/white
: Blue/black
: Blue/red
: Blue/yellow
: Purple/white
: Red/white
ELEC
INDICATION SYSTEM
E
Display function (for FX/FX Cruiser)
1. Check:
Display function
Not operate Replace the multifunction meter.
G/W
Pu/W
Pu/W
B
G/W
B
G/W
Pu/W
Pu/W
B
G/W
L/B
L/B
B
R
L/R
L/R
R/W
B/Y
B/Y
R/W
Y
W
R
W
B
B/G
B/G
4
B
1
2
3
4
5
Buzzer
Speed sensor
ECM
Fuel level sensor
B
R
W
Y
B/G
B/Y
: Black
: Red
: White
: Yellow
: Black/green
: Black/yellow
63
G/W
L/B
L/R
Pu/W
R/W
: Green/white
: Blue/black
: Blue/red
: Purple/white
: Red/white
ELEC
INDICATION SYSTEM
E
Compass display
1. Check:
Compass display
Incorrect reading Replace the compass sensor.
Checking steps:
Using a compass for reference, point the
watercraft north.
Turn on the multifunction meter and
check that NORTH appears on the
meter.
If NORTH does not appear on the multifunction meter, replace the compass sensor.
NOTE:
Be sure to check the compass display again
after replacing the compass sensor. If the
compass display is still incorrect, replace
the multifunction meter.
Air temperature display

1. Check:
Air temperature display
Incorrect reading Replace the compass sensor.
Checking steps:
Measure the ambient air temperature.
check the air temperature displayed on
the meter.
If the air temperature displayed on the
multifunction meter is more than 5 C
(9 F) different from the ambient air temperature, replace the compass sensor.
NOTE:
Be sure to check the air temperature display again after replacing the compass sensor. If the air temperature display is still
incorrect, replace the multifunction meter.
64
ELEC
INDICATION SYSTEM
Speedometer/average speed/tripmeter display (for FX Cruiser High Output)

1. Check:
Speedometer/average speed/tripmeter
display
Does not display Measure the speed
sensor output voltage.
G
N
B
S
DC V
2. Measure:
speed sensor.
Digital multimeter:
YU-34899-A
90890-03174
(dependant on the paddle wheel
position):
Less than 400 mV/
More than 5 V
Output pulse:
2 pulses/one-full turn
Measuring steps:
Disconnect the coupler between the multifunction meter and the compass sensor
1, and then connect it to a 12 V battery
as shown in the illustration.
Rotate the paddle wheel and check the
output voltage and output pulses.
NOTE:
As the paddle wheel is rotated, a squarewave voltage signal a is produced.
If within specification, replace the multifunction meter. If out of specification,
replace the speed sensor 2.
NOTE:
Be sure to check the output voltage and
output pulses again after replacing the
speed sensor. If still out of specification,
replace the compass sensor.
65
ELEC
INDICATION SYSTEM
E
Water temperature display
1. Check:
Water temperature display
Incorrect reading Measure the speed
sensor (water temperature sensor)
resistance.
Checking steps:
Measure the ambient water temperature.
check the water temperature displayed
on the meter.
If the water temperature displayed on the
multifunction meter is more than 5 C
(9 F) different from the ambient water
temperature, measure the speed sensor
(water temperature sensor) resistance.
2. Measure:
Speed sensor (water temperature sensor) resistance.
speed sensor.
Within specification Replace the compass sensor.
R/Y
Y
N
B/Y
S
Digital multimeter:
YU-34899-A
90890-03174
Speed sensor (water temperature
sensor) resistance:
10 k at 25 C (77 F)
Measuring steps:
Disconnect the coupler, and then measure the resistance between the yellow
and black/yellow leads as shown in the
illustration.
If the speed sensor (water temperature
sensor) resistance is within specification,
replace the compass sensor. If out of
specification, replace the speed sensor.
NOTE:
Be sure to check the water temperature display again after replacing the compass sensor. If the water temperature display is still
incorrect, replace the multifunction meter.
66
ELEC
INDICATION SYSTEM
E
Trip timer display
1. Check:
Trip timer display
Fuel consumption per hour, fuel consumption per kilometer/mile display
1. Check:
Fuel consumption per hour, fuel consumption per kilometer/mile display
Does not display Check the fuel injection duration using the Engine monitor
of the Yamaha Diagnostic System.

1. Check:
Checking steps:
Start the engine.
Disconnect the thermoswitch (engine)
coupler 1 (blue), engine temperature
sensor coupler 2 (black) or thermoswitch (exhaust) 3 coupler.
Connect the jumper lead to the female
terminal of the disconnected coupler.
Check that the multifunction meter overheat warning indicator comes on and the
buzzer sounds.
67
ELEC
INDICATION SYSTEM
E
Check engine warning indicator
1. Check:
Checking steps:
Start the engine.
Disconnect the coupler of a sensor (e.g.,
engine temperature sensor) that normally
activates the check engine warning indicator when a malfunction occurs.
Check that the warning light and check
engine warning indicator blink and that
the buzzer sounds intermittently.
Diagnostic display
1. Check:
Diagnostic display
Checking steps:
Start the engine.
Disconnect the coupler of a sensor (e.g,.
engine temperature sensor) that is normally displayed when a malfunction
occurs. Refer to SELF-DIAGNOSIS.
Check that the check engine warning
indicator is displayed and that the buzzer
sounds.
Simultaneously press the two buttons 1
for 8 seconds and check the error code
indicated on the multifunction meter.
68
ELEC
REMOTE CONTROL SYSTEM (For FX High Output/

REMOTE CONTROL SYSTEM (For FX High Output/FX Cruiser High Output)

WIRING DIAGRAM
Y
L/R
1
R
R/Y
R/Y
R/Y
R/Y
R
P
P
R/Y
O
R/Y
14 : L
15 : W/B
21 : L/R
30 : R/Y
31 : Y
37 : Pu/G
38 : Pu/Y
39 : Pu/B
40 : Pu/R
12 3 456 7 8
31 14
21
R/Y
R/Y
R/Y
30 15
L/R
Y
P
P/G
O
R/Y
Pu/B
Pu/Y
Pu/R
Pu/G
G/R
G/Y
Br
B
B/O
G/B
G/Y
G/B
G/R
G
Pu/R
Pu/G
B
B
Br
Pu/B
Pu/Y
O
R/Y
P/G
W/B( )
W
W/B
W/B
R/Y
R/Y
W/B( )
W
R/Y
R/Y
R/Y
Pu/R
Pu/R
#1
R/Y
R/Y
L/Y( )
L/B Gy L/R
L/R
L/Y( )
Gy
Pu/B
Pu/B
#2
R/Y
L/B
R/Y
Pu/Y
L/Y
R/Y
L/R
Pu/G
Pu/G
#4
R/Y
L/R
123456789
0ABCDEFGH
R/Y
1
2
3
4
5
6
7
8
9
16 7 6 11 15 14 18 12 3 4 13 10
Pu/Y
#3
G
B/Y
L/R
B/L
L/Y
L/B
R/Y
B/L
0 Fuel injector
A Antenna
B Buzzer
ECM
Fuse (20 A)
Starter relay
Starter motor
Battery
Fuse (3 A)
Remote control unit
Multifunction meter
69
ELEC

WIRING DIAGRAM
Y
L/R
1
R
R/Y
R/Y
R/Y
R/Y
R
P
P
R/Y
O
R/Y
14 : L
15 : W/B
21 : L/R
30 : R/Y
31 : Y
37 : Pu/G
38 : Pu/Y
39 : Pu/B
40 : Pu/R
12 3 456 7 8
31 14
21
R/Y
R/Y
R/Y
30 15
L/R
Y
P/G
R/Y
Pu/B
Pu/Y
Pu/R
Pu/G
G/R
G/Y
Br
B
B/O
G/B
G/Y
G/B
G/R
G
Pu/R
Pu/G
B
B
Br
Pu/B
Pu/Y
O
R/Y
P/G
W/B( )
W
W/B
W/B
R/Y
R/Y
W/B( )
W
R/Y
R/Y
R/Y
Pu/R
Pu/R
#1
R/Y
R/Y
L/Y( )
L/B Gy L/R
L/R
L/Y( )
Gy
Pu/B
Pu/B
#2
R/Y
L/B
R/Y
Pu/Y
L/Y
R/Y
Pu/G
Pu/G
: Black
: Brown
: Gray
: Blue
: Red
: White
: Yellow
A
W
L/R
#4
R/Y
L/R
123456789
0ABCDEFGH
R/Y
B
Br
Gy
L
R
W
Y
16 7 6 11 15 14 18 12 3 4 13 10
W
Pu/Y
#3
G
B/Y
L/R
B/L
L/Y
L/B
R/Y
B/L
L/B
L/R
L/Y
Pu/B
Pu/G
Pu/R
B/L
: Black/blue
: Blue/black
: Blue/red
: Blue/yellow
: Purple/black
: Purple/green
: Purple/red
70
Pu/Y : Purple/yellow
R/Y : Red/yellow
W/B : White/black
* : FX Cruiser High Output
ELEC


1. Check:
light 1 comes on when the Yamaha
Security System is deactivated (i.e., the
engine can be started).
Does not come on Measure the
remote control unit output voltage.
2. Measure:
Remote control unit output voltage
remote control unit.
Digital multimeter:
YU-34899-A
90890-03174
Remote control unit output

voltage:
Blue/yellow (L/Y) ground
1113 V
Measurement steps:
Disconnect the remote control unit 1
coupler from the multifunction meter.
Measure the remote control unit output
voltage while pushing the unlock button
of the remote control transmitter.
L/Y
71
ELEC


1. Check:
Does not come on Replace the multifunction meter.
Checking steps:
Press the unlock button 1 of remote control transmitter for more than four seconds to select the low-rpm mode.
times and the L-MODE indicator light 2
comes on.
72
HULL
HOOD
HANDLEBAR
HANDLEBAR
EXPLODED DIAGRAM (For FX/FX High Output)

Step
1
2
3
4
5
Procedure/Part name
STEERING PAD REMOVAL
Screw
Handlebar cover
Pad
Bolt
Qty
Service points
4
1
1
2
1
73
HULL
HOOD
HANDLEBAR
EXPLODED DIAGRAM (For FX Cruiser/FX Cruiser High Output)

Step
1
2
3
4
Procedure/Part name
STEERING PAD REMOVAL
Screw
Screw (black)
Lower handlebar cover
Upper handlebar cover
5
6
7
Bolt
Steering pad
Grommet
Qty
8
2
1
1
Service points
NOTE:
Be sure to insert the projection on the upper
handlebar cover completely into the grommet.
4
1
1
74
HULL
HOOD
HANDLEBAR
EXPLODED DIAGRAM

Step
Procedure/Part name
HANDLEBAR HOLDER
REMOVAL
Throttle cable
2
3
Bolt
Upper handlebar holder
Qty
Service points
NOTE:
Be sure to remove the throttle cable seal as
shown in the illustration.
4
2
75
HULL
HOOD
HANDLEBAR
EXPLODED DIAGRAM

Step
1
2
3
4
5
Procedure/Part name
HANDLEBAR REMOVAL
QSTS cable (to jet thrust nozzle)
Qty
Nut/washer
QSTS converter
QSTS cable 2
QSTS cable 1
Handlebar switch coupler
2/2
1
1
1
2
76
Service points
With white tape a

NOTE:
Route the QSTS cables through the starboard side in the steering console.
Route the handlebar switch lead, and throttle cable through the port side in the steering console.
HULL
HOOD
HANDLEBAR
EXPLODED DIAGRAM
Step
6
7
8
9
10
Procedure/Part name
Screw
Handle boss cover
Plastic tie
Hose packing
Throttle cable
Qty
Service points
4
1
2
1
Not reusable
NOTE:
1
Position the corrugated tube for the throttle
cable as shown in the illustration so that the
tube attaches to the end of the outer throttle
cable.
77
HULL
HOOD
HANDLEBAR
EXPLODED DIAGRAM
Step
Procedure/Part name
11 Handlebar assembly
12 Handlebar switch lead
13 Grommet
Qty
Service points
NOTE:
1
Pass the QSTS cable and handlebar switch
1
lead through the handle boss cover, and
2
then install the handlebar assembly.
Install the sponges of the QSTS cables as
shown and make sure that the grommet is
installed to the deck securely.
78
HULL
HOOD
HANDLEBAR
SERVICE POINTS
Handlebar assembly installation

1. Install:
Plastic ties 1
QSTS cables 2
Handlebar switch lead 3
Throttle cable 4
3
2
1
NOTE:
After inserting the QSTS cables, handlebar
switch lead and throttle cable into the grommets, tie the end of grommets with the plastic
ties.
FX/FX High Output

2
1
2. Install:
Upper handlebar holder 1
NOTE:
Align the punch marks 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.
T.
Handlebar holder bolt:

20 N m (2.0 kgf m, 14 ft lb)
LOCTITE 242
Reference clearance:
c: 1.5 mm (0.06 in)
d: 3.5 mm (0.14 in)
79
HULL
HOOD
HANDLEBAR
E
3. Connect:
Throttle cable
3
4
Installing steps (for FX/FX High Output):

Route the throttle cable 1 over the handlebar 2, and then install the throttle
cable end into the throttle lever.
Make sure that the throttle cable, QSTS
cable 3, and handlebar switch lead 4
pass through the opening a in the center
of the steering boss cover. Reroute the
cables and lead if they are not routed correctly.
Make sure that there is slack in the throttle cable, QSTS cable, and handlebar
switch lead when the handlebar is turned
to the left and right. Reroute the cables
and lead if there is no slack.
2
1
a
3
4
Installing steps
(for FX Cruiser/FX Cruiser High Output):
Route the throttle cable 1 under the handlebar 2, and then install the throttle
cable end into the throttle lever.
Make sure that the throttle cable, QSTS
cable 3, and handlebar switch lead 4
pass through the opening a in the center
of the steering boss cover. Reroute the
cables and lead if they are not routed correctly.
Make sure that there is slack in the throttle cable, QSTS cable, and handlebar
switch lead when the handlebar is turned
to the left and right. Reroute the cables
and lead if there is no slack.
2
1
a
80
HULL
HOOD
HANDLEBAR
E
4. Install:
Throttle cable seal
Installing steps:
Install the throttle cable end into the throttle lever.
Fit the seal 1 into the groove in the
bracket as shown.
Pull the throttle cable 2 in the direction of
the arrow shown in the illustration, and
then fit the end of the seal 3 around
inner cable.
Turn the adjuster 4 in/out until the specified free play is obtained.
Throttle lever free play a:

47mm (0.160.28 in)
2
3
Turn in
Turn out
Tighten the lock nut 5.
81
HULL
HOOD
STEERING MASTER
STEERING MASTER
EXPLODED DIAGRAM
8
9
8
8 35 mm
2
5
7
20 N m (2.0 kgf m, 14 ft Ib)
6 60 mm
4
LT
271
8 30 mm

Step
1
2
3
4
5
6
Procedure/Part name
STEERING MASTER REMOVAL
Mirror assembly
Center cover assembly
Steering cable end
Bolt
Steering arm assembly
Ball joint
Nut
Bolt/washer/nut
Cable stopper assembly
Qty
1
1
1
1
1/1/1
1
82
Service points
Refer to MIRROR.
HULL
HOOD
STEERING MASTER
EXPLODED DIAGRAM
8
9
8
8 35 mm
2
5
7
20 N m (2.0 kgf m, 14 ft Ib)
6 60 mm
4
LT
271
8 30 mm
Step
Procedure/Part name
7
Nut/washer
8
9
Bolt
Qty
4/4
1
4
Service points
83
HULL
HOOD
STEERING MASTER
EXPLODED DIAGRAM
8 30 mm
LT
572
11
11
11
13
9
3
5 16 mm
10
LT
572
16
18
11
14
A
15
21
21
19
20
4
11
17
A
11
LT
8 30 mm
22
271
12
11
6 25 mm
11
FW

Step
1
2
3
4
5
6
7
8
Procedure/Part name
STEERING MASTER
DISASSEMBLY
Steering shaft
Steering shaft
Bushing
Bushing
Buzzer
Bolt
Bracket 1
Steering sensor
Qty
1
1
1
1
1
4
1
1
84
Service points
FX/FX High Output
HULL
HOOD
STEERING MASTER
EXPLODED DIAGRAM
8 30 mm
LT
572
11
11
11
13
9
3
5 16 mm
10
LT
572
16
18
11
14
A
15
21
21
19
20
4
11
17
A
LT
8 30 mm
271
22
11
12
11
11
FW
Step
9
10
11
12
13
14
15
16
17
18
Procedure/Part name
Bolt
Bracket 2
Bolt/nut
Left housing
Spring holder
Spring 1
Lever
Lock
Spring 2
Right housing
Qty
1
1
5/5
1
1
1
1
1
1
1
85
Service points
6 25 mm
HULL
HOOD
STEERING MASTER
EXPLODED DIAGRAM
8 30 mm
LT
572
11
11
11
13
9
3
5 16 mm
10
LT
572
16
18
11
14
A
15
21
21
19
20
4
11
17
A
LT
8 30 mm
271
22
11
12
11
6 25 mm
11
FW
Step
19
20
21
22
Procedure/Part name
Steering tube
Rubber seal
Bushing
Qty
1
1
2
1
Service points

assembly.
86
HULL
HOOD
STEERING MASTER
SERVICE POINTS
FWD
Steering master components inspection

1. Inspect:
Each component part
Rubber seal installation

1. Apply:
Instant adhesive
(onto the mating surfaces of the rubber
seal 1 and steering master assembly
2)
NOTE:
After assembling the steering master assembly 2, apply instant adhesive onto the mating
surfaces of the rubber seal 1 and steering
master assembly 2 in the area a shown in
the illustration.
87
HULL
HOOD

SPEED SENSOR LEAD
REMOTE CONTROL CABLES AND SPEED SENSOR LEAD

EXPLODED DIAGRAM

Step
1
2
3
4
5
6
Procedure/Part name
REMOTE CONTROL CABLES
AND SPEED SENSOR LEAD
REMOVAL
Service lid 1
Front seat assembly
Steering cable end
Nut
Steering cable
Seal
Speed sensor coupler
Nut
Qty
Service points

1
1
1
1
1
1
88
HULL
HOOD

SPEED SENSOR LEAD
EXPLODED DIAGRAM
Step
Procedure/Part name
7
Cap
8
Screw
9
Speed sensor
Speed sensor and water
temperature sensor
10 Shift cable end
11 Plastic tie
12 Grommet
13 Nut
14 Shift cable holder
15 Nut
16 Bolt
Qty
Service points
1
4
1
1
1
1
1
2
2
2
1
89
HULL
HOOD

SPEED SENSOR LEAD
EXPLODED DIAGRAM
Step
17
18
19
20
21
22
23
24
25
26
Procedure/Part name
Shift cable bracket
Nut
Shift cable
Seal
Nut
Pin
QSTS cable end
Nut
QSTS cable
Packing
Qty
1
1
1
1
1
1
1
1
1
1
Service points
90

SPEED SENSOR LEAD
HULL
HOOD
SERVICE POINTS
Steering cable removal
1. Remove:
Steering cable
Removal steps:
Rotate the steering stopper plate 1 on
the steering stopper clockwise and
remove it from the steering stopper plate
2.
Rotate the steering stopper plate 2
counterclockwise.
Remove the steering cable 3 from the
steering stopper 4.
Disconnect the cable joint 5 to the ball
joint 6.
2
1
2
1
4
3
91

SPEED SENSOR LEAD
HULL
HOOD
SERVICE POINTS
Steering cable installation
1. Install:
Steering cable
Installing steps:
Connect the cable joint 1 to the ball joint
2.
Insert the projection 3 on the steering
cable completely into the indentation 4
in the steering stopper.
Slightly lift up the steering stopper plate
5 on the steering stopper, and then
rotate it clockwise.
Rotate the steering stopper plate 6 on
the steering stopper counterclockwise,
making sure to fit the hole in the stopper
plate 6 onto the projection 7 on the
other steering stopper plate 5.
4
3
5
6
7
5
6
92
HULL
HOOD
FRONT HOOD
FRONT HOOD
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 18 mm
LT
242
6
7
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 18 mm
8
4
LT
242
LT
242
9
3
5
6 30 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)
10
11
1
6.4 N m (0.64 kgf m, 4.6 ft Ib)

Step
1
2
3
4
5
6
7
8
9
Procedure/Part name
FRONT HOOD REMOVAL
Nut/washer
Front hood assembly
Bolt
Bolt
Hinge assembly
Bolt
Hood lock assembly
Rivet
Service lid 1
Qty
4/4
1
4
2
1
2
1
4
1
93
Service points
HULL
HOOD
FRONT HOOD
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 18 mm
LT
242
6
7
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 18 mm
8
4
LT
242
LT
242
9
3
5
6 30 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)
10
11
1
6.4 N m (0.64 kgf m, 4.6 ft Ib)
Step
Procedure/Part name
10 Rivet
11 Service lid 2
Qty
4
1
Service points
94
HULL
HOOD
FRONT HOOD
SERVICE POINTS
2
Rivet Installation
1. Install:
Rivets
Installing steps:
Insert a rivet completely in the holes in
both the service lid 1 and inner hull.
Push in the rivet pin 2 until it clicks and
is flush with the top of the rivet.
NOTE:
To remove a rivet, push the rivet pin in
until it clicks and is below the top of the
rivet.
Before reinstalling a rivet, hold the rivet
flange a with both hands and push the
rivet pin perpendicularly against a hard
flat surface until the pin protrudes from the
top of the rivet.
95
HULL
HOOD
FRONT HOOD
EXPLODED DIAGRAM
9
1.1 N m (0.11 kgf m, 0.8 ft Ib)
5 17 mm
10
9
11
9
1.1 N m (0.11 kgf m, 0.8 ft Ib)

5 17 mm
10
10
2.2 N m (0.22 kgf m, 1.6 ft Ib)

5 16 mm
12
12
9 10
3
8
12
7
6
1
12
5
4
1
1
1
2.2 N m (0.22 kgf m, 1.6 ft Ib)

5 16 mm

Step
1
2
3
4
5
6
7
Procedure/Part name
FRONT HOOD DISASSEMBLY
Screw
Front hood 1
Front hood 2
Nut
Center ornament
Left ornament
Right ornament
8
9
Double-sided tape
Bolt
Qty
8
1
1
4
1
1
1
2
6
96
Service points
NOTE:
Be careful not to scratch the ornaments.
Install the center ornament after installing
the left and right ornaments.
Not reusable
HULL
HOOD
FRONT HOOD
EXPLODED DIAGRAM
9
1.1 N m (0.11 kgf m, 0.8 ft Ib)
5 17 mm
10
9
11
9
1.1 N m (0.11 kgf m, 0.8 ft Ib)

5 17 mm
10
10
2.2 N m (0.22 kgf m, 1.6 ft Ib)

5 16 mm
12
12
9 10
3
8
12
7
6
1
12
5
4
1
1
1
Step
Procedure/Part name
10 Bushing
11 Visor
12 Nut
2.2 N m (0.22 kgf m, 1.6 ft Ib)

5 16 mm
Qty
Service points
6
1
NOTE:
6
Apply soapy water to the nuts to make their
installation easier.
assembly.
97
HULL
HOOD
FRONT HOOD
SERVICE POINTS
Ornament disassembly
1. Disassembly:
Center ornament
Left ornament
Right ornament
Removal steps:
From the bottom side of the front hood
1, push the projections 2 on the center
ornament shown in the illustration and
remove the ornament from the doublesided tape.
From the bottom side of the front hood
1, push the projections 3 on the left
ornament shown in the illustration and
remove the ornament from the doublesided tape.
Remove the right ornament in the same
way as the left ornament.
3
1
NOTE:
When removing the ornaments, be sure to
remove the center ornament first.
Be careful not to break the front hood projections and ornament projections when
removing the ornaments.
Front hood assembly

1. Install:
Front hood 1
Front hood 2
1
2
NOTE:
Fit the end of the front hood 1 under the projection 3 on the front hood 2.
98
HULL
HOOD
FRONT HOOD
2
E
Visor installation
1. Install:
Visor
Installing steps:
Install the bushings 1 onto the screws 2
as shown in the illustration.
Install the visor and tighten the screws,
making sure to hold the nuts so that they
do not turn.
T.
Screw:
1.1 N m (0.11 kgf m, 0.8 ft lb)
Double-sided tape installation

1. Install:
Double-sided tape 1
NOTE:
Before affixing the double-sided tape 1, be
sure to clean the areas on the front hood
where the tape will be affixed to remove any
dirt.
99
HULL
HOOD
FRONT HOOD
E
Ornament installation
1. Install:
Left ornament
Right ornament
Center ornament
Installing steps:
Peel off the backing of the double-sided
tape 1 on the watercraft.
Install the left and right ornaments from
the sides as shown in the illustration.
Install the center ornament from above as
shown in the illustration.
NOTE:
Be sure to install the left and right ornaments before installing the center ornament. The left and right ornaments cannot
be installed if the center ornament is
installed first.
100
HULL
HOOD
MIRROR
MIRROR
EXPLODED DIAGRAM
5.4 N m (0.54 kgf m, 3.9 ft Ib)

6 23 mm
6 22 mm
LT
242
5
2
1
4
LT
242
6 23 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)

Step
1
2
3
4
5
6
Procedure/Part name
MIRROR REMOVAL
Nut
Washer
Bolt
Bolt
Left mirror assembly
Right mirror assembly
Qty
Service points
2
2
2
4
1
1
101
HULL
HOOD
MIRROR
EXPLODED DIAGRAM
3.7 N m (0.37 kgf m, 2.7 ft Ib)

5 15 mm
8
3
9
2
5
1
1
6
1
3.7 N m (0.37 kgf m, 2.7 ft Ib)

5 15 mm
3.7 N m (0.37 kgf m, 2.7 ft Ib)

5 15 mm

Step
1
2
3
4
5
6
7
8
9
Procedure/Part name
MIRROR DISASSEMBLY
Screw
Left mirror upper cover
Screw
Left mirror
Nut
Left mirror lower cover
Right mirror upper cover
Right mirror
Right mirror lower cover
Qty
Service points
12
1
8
1
2
1
1
1
1
assembly.
102
HULL
HOOD

EXPLODED DIAGRAM
2.2 N m (0.22 kgf m, 1.6 ft Ib)

5 15 mm
14
3
3
15
13
5
4
6
5
12
12
11
11
10
9
1
2
3.7 N m (0.37 kgf m, 2.7 ft Ib)
5 12 mm

Step
1
2
3
4
Procedure/Part name
METER AND METER COVER
REMOVAL
Handlebar assembly
Service lid 1
Band
Multifunction meter coupler
Screw
Multifunction meter cover
Qty
Service points
Refer to HANDLEBAR.
1
4
4
1
103
HULL
HOOD
EXPLODED DIAGRAM
2.2 N m (0.22 kgf m, 1.6 ft Ib)

5 15 mm
14
3
3
15
13
5
4
6
5
12
12
11
11
10
9
1
2
3.7 N m (0.37 kgf m, 2.7 ft Ib)
5 12 mm
Step
5
6
7
8
9
10
11
12
13
14
15
Procedure/Part name
Left operation button coupler
Right operation button coupler
Bolt
Washer
Band
Grommet
Multifunction meter
Cover
Multifunction meter
Qty
Service points
1
1
1
1
4
4
1
1
1
1
1
104
HULL
HOOD
EXPLODED DIAGRAM
2.2 N m (0.22 kgf m, 1.6 ft Ib)
5 15 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)
6 23 mm
11
LT
2.2 N m (0.22 kgf m, 1.6 ft Ib)

5 15 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)
6 23 mm
242
LT
242
7 3
LT
242
9 6
10
10
8
LT
242
6 22 mm
6 22 mm
2
2
LT
242
1
6 23 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)

Step
1
2
3
4
5
6
7
8
9
Procedure/Part name
SIDE COVER REMOVAL
Bolt
Nut/washer
Bolt
Left side cover
Left inner side pad
Nut
Screw
Left side ornament
Right side cover
Qty
2
2/2
8
1
2
6
4
1
1
105
Service points
HULL
HOOD
EXPLODED DIAGRAM
2.2 N m (0.22 kgf m, 1.6 ft Ib)
5 15 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)
6 23 mm
11
LT
2.2 N m (0.22 kgf m, 1.6 ft Ib)

5 15 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)
6 23 mm
242
LT
242
7 3
LT
242
9 6
10
10
8
LT
242
6 22 mm
6 22 mm
2
2
LT
242
1
6 23 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)

Step
Procedure/Part name
10 Right inner side pad
11 Right side ornament
Qty
2
1
Service points
106
HULL
HOOD
EXPLODED DIAGRAM
6 22 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)
3
3
11
9
5 24 mm
10
12
FW
6 30 mm
3.8 N m (0.38 kgf m, 2.7 ft Ib)

6.4 N m (0.64 kgf m, 4.6 ft Ib)
5.4 N m (0.54 kgf m, 3.9 ft Ib)

Step
Qty
1
2
3
4
Procedure/Part name
CENTER COVER REMOVAL
Nut/washer
Bolt
Nut/washer
Center cover assembly
5
6
7
8
Nut/washer
Bolt
Hood lock
Nut/washer
2/2
2
1
2/2
2/2
2
2/2
1
107
Service points
NOTE:
To remove the center cover assembly easily,
pull the tilt lever up.
HULL
HOOD
EXPLODED DIAGRAM
6 22 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)
3
3
11
9
5 24 mm
10
12
FW
6 30 mm
3.8 N m (0.38 kgf m, 2.7 ft Ib)

6.4 N m (0.64 kgf m, 4.6 ft Ib)
5.4 N m (0.54 kgf m, 3.9 ft Ib)
Step
Procedure/Part name
9
Screw
10 Compass sensor and air
temperature sensor
11 Case cap
12 Inner pad
Qty
Service points
2
1
1
1
108
HULL
HOOD
EXPLODED DIAGRAM
7
6
6
10
11
2
1
3
2
1

Step
1
2
3
4
5
6
7
8
9
Procedure/Part name
CENTER COVER DISASSEMBLY
Damper
Nut
Grommet
Damper
Damper
Hinge assembly
Gear assembly
Lid
Lid lock
Qty
2
4
4
6
1
2
2
1
1
109
Service points
HULL
HOOD
EXPLODED DIAGRAM
7
6
6
10
11
2
1
3
2
1
Step
Procedure/Part name
10 Plug
11 Center cover
Qty
1
1
Service points

assembly.
110
HULL
HOOD
SHIFT LEVER
SHIFT LEVER
EXPLODED DIAGRAM
6 30 mm
2
5.4 N m (0.54 kgf m, 3.9 ft Ib)
6 30 mm
1
2
1
5.4 N m (0.54 kgf m, 3.9 ft Ib)

Step
1
2
3
Procedure/Part name
SHIFT LEVER REMOVAL
Front hood assembly
Mirror assembly
Right side cover
Shift cable
Nut/washer
Bolt
Shift lever assembly
Qty
Service points
Refer to MIRROR.
Disconnect.
3/3
3
1
111
HULL
HOOD
SEATS AND HAND GRIP
SEATS AND HAND GRIP

EXPLODED DIAGRAM
4
1
3
2
6
LT
6.4 N m (0.64 kgf m, 4.6 ft Ib)

6 40 mm
6
12
13
14
8 30 mm
26
5
271
11
15
22
16
17
24
8 30 mm
6 25 mm
LT
271
19
10
23
20
20
26 N m (2.6 kgf m, 19 ft Ib)
21
18
5.4 N m (0.54 kgf m, 3.9 ft Ib)

18 N m (1.8 kgf m, 13 ft Ib)
25
15 N m (1.5 kgf m, 11 ft Ib)
6.4 N m (0.64 kgf m, 4.6 ft Ib)

26 N m (2.6 kgf m, 19 ft Ib)

Step
1
2
3
4
5
6
7
8
9
10
Procedure/Part name
SEATS AND HAND GRIP
REMOVAL
Rear seat assembly
Rear seat assembly
Front seat assembly
Front seat assembly
Bolt
Seat lock assembly
Seat storage compartment
Nut/washer
Bolt/washer
Deck beam
Qty
Service points
1
1
1
1
4
2
1
4/4
4/4
1
FX/FX High Output

FX/FX High Output
112
HULL
HOOD
SEATS AND HAND GRIP
EXPLODED DIAGRAM
4
1
3
2
6
LT
6.4 N m (0.64 kgf m, 4.6 ft Ib)

6 40 mm
6
12
13
14
8 30 mm
26
5
271
11
15
22
16
17
24
8 30 mm
6 25 mm
LT
271
19
10
23
20
20
26 N m (2.6 kgf m, 19 ft Ib)
21
18
5.4 N m (0.54 kgf m, 3.9 ft Ib)

18 N m (1.8 kgf m, 13 ft Ib)
25
15 N m (1.5 kgf m, 11 ft Ib)
Step
11
12
13
14
15
16
17
18
19
20
Procedure/Part name
Nut
Projection
Washer
Seal
Nut
Bolt
Rear seat stay
Nut
Projection
Washer
6.4 N m (0.64 kgf m, 4.6 ft Ib)

26 N m (2.6 kgf m, 19 ft Ib)
Qty
1
1
1
1
4
4
2
1
1
2
113
Service points
HULL
HOOD
SEATS AND HAND GRIP
EXPLODED DIAGRAM
4
1
3
2
6
LT
6.4 N m (0.64 kgf m, 4.6 ft Ib)

6 40 mm
6
12
13
14
8 30 mm
26
5
271
11
15
22
16
17
24
8 30 mm
6 25 mm
LT
271
19
10
23
20
20
26 N m (2.6 kgf m, 19 ft Ib)
21
18
5.4 N m (0.54 kgf m, 3.9 ft Ib)

18 N m (1.8 kgf m, 13 ft Ib)
25
15 N m (1.5 kgf m, 11 ft Ib)
Step
21
22
23
24
25
26
Procedure/Part name
Nut/washer
Bolt
Hand grip
Hand grip
Nut/washer
Seat holder
6.4 N m (0.64 kgf m, 4.6 ft Ib)

26 N m (2.6 kgf m, 19 ft Ib)
Qty
Service points
4/4
4
1
FX/FX High Output
1
2/1
1
114
REBOARDING STEP (For FX Cruiser/FX

HULL
HOOD
REBOARDING STEP (For FX Cruiser/FX Cruiser High Output)

EXPLODED DIAGRAM
2
1
LT
271
15 N m (1.5 kgf m, 11 ft Ib)

8 42 mm
15 N m (1.5 kgf m, 11 ft Ib)

8 42 mm

Step
1
2
Procedure/Part name
REBOARDING STEP REMOVAL
Bolt
Reboarding step
Qty
Service points
6
1
115
HULL
HOOD
1
REBOARDING STEP (For FX Cruiser/FX

SERVICE POINTS
Reboarding step installation

1. Install:
Reboarding step
Installing steps:
Fasten the brackets on both sides of the
reboarding step in the down position with
a plastic tie 1 as shown in the illustrations so that they will not return to the up
position.
Finger tighten all of the bolts, and then
tighten them to specification.
T.
116
Bolt:
15 N m (1.5 kgf m, 11 ft lb)
HULL
HOOD
DECK AND HULL
DECK AND HULL

EXPLODED DIAGRAM
2.4 N m (0.24 kgf m, 1.7 ft Ib)

6 25 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)

13 N m (1.3 kgf m, 9.4 ft Ib)
6 20 mm
22
23
23
23
16
24
16
18
16
15 N m (1.5
21
20
16 N m (1.6 kgf m, 12 ft Ib)

8 40 mm
kgf m, 11 ft Ib)
LT
572
19
17
2
12
13
5.4 N m (0.54 kgf m, 3.9 ft Ib)
11
10
2.0 N m (0.2 kgf m, 1.4 ft Ib)

5 25 mm
15
13
14
LT
271
15 N m (1.5 kgf m, 11 ft Ib)

Step
1
2
3
4
5
6
7
8
9
10
Procedure/Part name
DECK AND HULL DISASSEMBLY
Nut
Spout
Nut
Cleat
Plate
Bolt/collar
Sponson
Nut/washer
Screw
Drain plug
Qty
1
1
2
1
2
10/10
2
4/4
4
2
117
Service points
HULL
HOOD
DECK AND HULL
EXPLODED DIAGRAM
2.4 N m (0.24 kgf m, 1.7 ft Ib)

6 25 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)

13 N m (1.3 kgf m, 9.4 ft Ib)
6 20 mm
22
23
23
23
16
24
16
18
16
15 N m (1.5
21
20
16 N m (1.6 kgf m, 12 ft Ib)

8 40 mm
kgf m, 11 ft Ib)
LT
572
19
17
2
12
13
5.4 N m (0.54 kgf m, 3.9 ft Ib)

2.0 N m (0.2 kgf m, 1.4 ft Ib)
5 25 mm
Step
11 Seal
12 Nut
13
14
15
16
17
18
19
Procedure/Part name
Plate
Cleat
Seal
Nut/washer
Front protector 1
Front protector 2
Front protector 3
11
10
9
15
13
14
LT
271
15 N m (1.5 kgf m, 11 ft Ib)
Qty
Service points
2
NOTE:
4
To remove the cleat, remove the exhaust
system first.
4
2
2
7/7
1
1
1
118
NOTE:
Install the front protector 1 and 2 after installing the front protector 3.
HULL
HOOD
DECK AND HULL
EXPLODED DIAGRAM
2.4 N m (0.24 kgf m, 1.7 ft Ib)

6 25 mm
5.4 N m (0.54 kgf m, 3.9 ft Ib)

13 N m (1.3 kgf m, 9.4 ft Ib)
6 20 mm
22
23
23
23
16
24
16
18
16
15 N m (1.5
21
20
16 N m (1.6 kgf m, 12 ft Ib)

8 40 mm
kgf m, 11 ft Ib)
LT
572
19
17
2
12
13
5.4 N m (0.54 kgf m, 3.9 ft Ib)

2.0 N m (0.2 kgf m, 1.4 ft Ib)
5 25 mm
Step
20
21
22
23
24
Procedure/Part name
Bolt
Bow eye
Cleat cover
Screw
Cleat assembly
11
10
9
15
13
14
LT
271
15 N m (1.5 kgf m, 11 ft Ib)
Qty
Service points
2
1
2
6
2
assembly.
119
HULL
HOOD
CLEAT ASSEMBLY (For FX Cruiser High Output)

EXPLODED DIAGRAM
4
4
2
6
1

Step
1
2
3
4
5
6
Procedure/Part name
CLEAT DISASSEMBLY
Circlip
Spring
Cleat
O-ring
Plate
Packing
Qty
2
2
1
2
1
1
120
Service points
The following procedure applies to both of
the cleat assembly.
Not reusable
Not reusable
assembly.
HULL
HOOD
SERVICE POINTS
Cleat cover installation
1. Install:
Cleat cover
NOTE:
Make sure that the word YAMAHA a on the
cleat covers faces outward as shown in the
illustration.
121
TRBL
ANLS
TROUBLE ANALYSIS
TROUBLE ANALYSIS
SELF-DIAGNOSIS
With the engine running, simultaneously press

the two buttons 1 for 8 seconds and check if
an error code is indicated on the multifunction
meter.
Code
Symptom
01
Normal
13
Pickup coil malfunction
15

malfunction
18

malfunction
19
Incorrect battery voltage
23

malfunction
24
Cam position sensor malfunction
29

malfunction
47
Slant detection switch malfunction
48
Incorrect data transmission
54
Bypass valve motor malfunction
55
Steering sensor malfunction
63
Intake air system malfunction
If the Yamaha Diagnostic System is not used

to check the symptoms listed in the table, the
error codes can be checked easily with the
self-diagnosis in the multifunction meter. However, if there are numerous error codes displayed, be sure to check them with the
122
FX/FX Cruiser
R
R
R
Br
R/Y
P
B
R/Y
12
P
B/O
R/Y
P/W
R/Y
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
R
R
B/O
G/O
O
B/O
B/O
L/B
G
G
G
2
1
3
2
1
B
G
R
G
G
123
12
123456
123456
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
G
G
G
B/O
B/O
B/O
B/O
10
9
8
7
6
5
4
3
2
1
321
B
W
R
P
B
B/Y
B/O
L
R/Y
R/Y
R
L/R
Br
Y
B
1
2
P
B/O
2 3 4 16 5 6 7 15 1 8 121110 9 1314
2
3
1
B/Y
B/Y
O
B/O
P/G
8
7
6
5
4
3
2
1
R
R
R
1
2
B/Y
B/O
P
P/G
O
B/Y
Pu/R
Pu/B
Pu/Y
B/O
R/Y
Pu/G
G/R
G/Y
G/B
G
O
O
O
P
P
P
B/O
W/B
W/R
P
P/G
O
B/Y
Pu/R
Pu/B
Pu/Y
B/O
R/Y
Pu/G
G/R
G/Y
G/B
G
10
9
8
7
6
5
4
3
2
1
Br
Br
P/W
B
R
B/O
P
O
R
R
R/Y
R/Y
R/Y
R
B
1
2
3
B
B
Br
Br
FREE
FREE
FREE
PUSH
PUSH
PUSH
Pu/B
R/Y
Pu/R
R/Y
21
21
R
G/O
B/O
Br
R
Br
Pu/Y
R/Y
21
W
B
Pu/G
R/Y
21
21
21
R
Br
W/R
W/B
2
1
Pu/G
Pu/Y
Pu/B
Pu/R
B
B/L
B/Y
B/W
B/L
R/Y
2
1
Y
B/Y
R/Y
3
2
1
Y
B
R/W
2
1
B
R
12
12
B
L
B/G
P
B
L
R
G
G
G
B
B
W
R
B/Y
R/Y
R/Y
Y
B/O
P/G
P
B/Y
3
2
1
L/B
L/R
2
1
B/W
R/Y
L/B
W/L
B/O
W/B
R/Y
2
1
B/Y
B/R
R/Y
B/Y
W/B
G/B
G/Y
G/R
B
G
L/R
B/R
P
B/G
G/W
Pu/W
B
G
B/O
2
1
3
G/W
Pu/W
B
1
2
3
B
O
W/L
1
2
R
R
654321
12345678
B
R/Y
B
B
B
B
B
B
B
109 8 7 6 5 4 3 2 1
21
B
Br
Br
B
B/O
B/O
B/O
B/O
B/O
B/O
B/O
O
W/L
B/O
B/O
B/O
R/Y
B/Y
Y
1
2
3
134625
W
B
W
B/O
R
G
B
B/O
B/O
B/O
6
5
4
3
2
1
G/O
W
P
P/W
B/Y
O
O
B/O
B/O
B/O
L/B
G/R
G/Y
G/B
G
R/Y
R/Y
B/O
Br
WIRING DIAGRAM
FX/FX Cruiser
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Fuse (20 A)
Fuse (3 A)
Starter relay
Noise filter
Cam position sensor
Oil pressure switch
Intake air pressure
Intake air temperature
Bypass valve motor
Fuel injector
Pickup coil
Lighting coil
Engine stop switch
Start switch
Multifunction meter
Buzzer
Steering sensor
Fuel level sensor
Fuel pump
Starter motor
Ignition coil
Spark plug
Rectifier/regulator
Battery
Electric bilge pump
Speed sensor
ECM
To tachometer
Color code
B
Br
G
L
O
P
R
W
Y
B/G
B/L
B/O
B/R
B/W
B/Y
G/B
G/O
G/R
G/W
G/Y
L/B
L/R
P/G
P/W
Pu/B
Pu/G
Pu/R
Pu/W
Pu/Y
R/Y
R/W
W/B
W/L
W/R
: Black
: Brown
: Green
: Blue
: Orange
: Pink
: Red
: White
: Yellow
: Black/green
: Black/blue
: Black/orange
: Black/red
: Black/white
: Black/yellow
: Green/black
: Green/orange
: Green/red
: Green/white
: Green/yellow
: Blue/black
: Blue/red
: Pink/green
: Pink/white
: Purple/black
: Purple/green
: Purple/red
: Purple/white
: Purple/yellow
: Red/yellow
: Red/white
: White/black
: White/blue
: White/red

R
R
W
B
R
Br
G
P
B
R/Y
12
P
B/O
R
B
W
B
B/O
W/B
W/R
2
3
1
B
W
R
G
G
G
3
2
1
G
G
G
21
21
P
B
1
2
3
G/W
Pu/W
B
G/W
Pu/W
B
B
G
R
B/Y
B/Y
3214
123456
B
B
B/O
W/B
R/Y
B/O
P
O
R/Y
R/Y
R/Y
1
2
3
3
2
1
B
W/B
R/Y
Y
B/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
321
1
2
1
2
O
B/O
P/G
B/Y
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
Br
321
G/O
W
P
P/W
B/Y
O
O
B/O
B/R
R/Y
W/R
W/B
L
W/B
G/B
G/Y
G/R
B
G
L/R
B/R
Pu/B
R/Y
Pu/R
R/Y
R
G
B
Pu/Y
R/Y
1
2
3
Pu/G
R/Y
R
G
B
G/R
G/Y
G/B
G
R/Y
R/Y
B/O
134625
21
21
21
21
L/B
L/R
L/Y
2
1
B/W
R/Y
2
1
B/Y
R/Y
2
1
B/L
R/Y
2
1
1
2
3
4
5
6
G
R
B
L
W
R/Y
B/Y
Y
3
2
1
2
1
3
Y/W
R/W
B
G/W
Pu/W
B
1
2
3
G/W
Pu/W
B
B/Y
B/Y
15 11 3 4 7 616 9 10
Y
Y
B
B
L/B
L/Y
B/L
Gy
W
13 14 12 18
R
Br
B
L
12
B/G
P
B
L
12
B
L
R
Pu/G
Pu/Y
Pu/B
Pu/R
B
B/L
B/Y
B/W
L/B
L/R
L/Y
Y/W
R/W
B
L/B
W/L
R/Y
Y
B/O
P/G
P
B/Y
G
R
B
L
W
P
B/G
B/O
W/B
R/Y
3
2
1
B
W
R
Y
B/Y
R/Y
3
2
1
Y
B/Y
R/W
L/B
L/R
L/Y
3
2
1
L/B
L/R
Gy
P
B/G
G
G
G
B
R
G
B/O
109 8 7 6 5 4 3 2 1
1
2
3
B
O
W/L
L/R
B/L
1
2
R
B
Gy
B
1
2
3
4
5
6
B
R/Y
B
B
B
654321
1
2
B/O
O
W/L
21
B
Br
B/O
B/O
B/O
B/O
B/O
B/O
109 8 7 6 5 4 3 2 1
B
B
B
B
B
B
B/O
B/O
B/O
B/O
B/O
B/O
B/O
B/O
6
5
4
3
2
1
Br
B
L/B
Br
FREE
PUSH
P
P/G
O
B/Y
Pu/R
Pu/B
Pu/Y
B/O
R/Y
Pu/G
G/R
G/Y
G/B
G
B/O
L/B
B/O
G/O
O
2
1
R/Y
R/Y
R/Y
R/Y
R/Y
P
B/O
2 3 4 16 5 6 7 15 1 8 121110 9 1314
10
9
8
7
6
5
4
3
2
1
3
4
1
2
B/O
B
B
B/O
L
R/Y
R/Y
R
L/R
Y
B/Y
B/O
P
P/G
O
B/Y
Pu/R
Pu/B
Pu/Y
B/O
R/Y
Pu/G
G/R
G/Y
G/B
G
R
Br
Br
R/Y
R/Y
B
R
R
R
R
R
8
7
6
5
4
3
2
1
Br
W
B/O
O
O
O
P
P
P
FREE
PUSH
84269 531
10
9
8
7
6
5
4
3
2
1
FREE
PUSH
R
Br
R/Y
R
Br
Br
R/Y
R/Y
B
R
R
P/W
G
G
R
Br
W
B
P/W
Gy
B
1
2
Br
WIRING DIAGRAM
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
[
\
Fuse (20 A)
Fuse (3 A)
Starter relay
Noise filter
Cam position sensor
Oil pressure switch
Sensor assembly
(intake air pressure, intake air temperature)
Bypass valve motor
Fuel injector
Pickup coil
Lighting coil
Remote control unit
Antenna
Engine stop switch
Start switch
Multifunction meter
Steering sensor
Speed sensor (FX High Output)
Buzzer
Fuel level sensor
Fuel pump
Starter motor
Ignition coil
Spark plug
Rectifier/regulator
Battery
Electric bilge pump
ECM
To tachometer
To entry box
FX Cruiser High Output model
Color code
B
Br
G
Gy
L
O
P
R
W
Y
B/G
B/L
B/O
B/R
B/W
B/Y
G/B
G/O
G/R
G/W
G/Y
L/B
L/R
L/Y
P/G
P/W
Pu/B
Pu/G
Pu/R
Pu/W
Pu/Y
R/Y
R/W
W/B
W/L
W/R
Y/W
: Black
: Brown
: Green
: Gray
: Blue
: Orange
: Pink
: Red
: White
: Yellow
: Black/green
: Black/blue
: Black/orange
: Black/red
: Black/white
: Black/yellow
: Green/black
: Green/orange
: Green/red
: Green/white
: Green/yellow
: Blue/black
: Blue/red
: Blue/yellow
: Pink/green
: Pink/white
: Purple/black
: Purple/green
: Purple/red
: Purple/white
: Purple/yellow
: Red/yellow
: Red/white
: White/black
: White/blue
: White/red
: Yellow/white
YAMAHA MOTOR CORPORATION, USA
Printed in USA
Dec. 2005 0.0 1 CR
(E)

Yamaha FX HO Service Manual PDF

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WaveRunner

HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

: M10 (D) 25 mm (L)

F Apply Yamaha 4-stroke motor oil

Apply Gasket Maker

ENGINE SERIAL NUMBER

JET PUMP UNIT SERIAL NUMBER

HULL IDENTIFICATION NUMBER

SAFETY WHILE WORKING

SAFETY WHILE WORKING

PARTS, LUBRICANTS, AND

SAFETY WHILE WORKING

GOOD WORKING PRACTICES

SAFETY WHILE WORKING

DISASSEMBLY AND ASSEMBLY

B Fuel pressure gauge

REMOVAL AND INSTALLATION

1 Oil filter wrench

A YM-4114 (19 mm)

B YM-04111 (4.0 mm)

C YM-04112 (4.0 mm)

D YM-04113 (4.0 mm)

90890-04114 (19 mm)

90890-04112 (4.0 mm)

90890-04111 (4.0 mm)

90890-04113 (4.0 mm)

90890-06811 (4.0 mm)

E Valve seat cutter

117.7 (160) @ 10,000

Fuel and oil

Regular unleaded gasoline

1,150 (11.5, 164)

Valve seat width C

1.50 2.60 (0.06 0.10)

JET PUMP UNIT

HULL AND HOOD

More than 4.8

128 (1.28, 18.2)166 (1.66, 23.6)

*1 The figures are for reference only.

*1 For details, refer to the tightening procedures in this manual.

Drain plug (engine oil)

Anode oil tank

Oil cooler cover oil tank

Oil strainer oil tank

Baffle plate oil tank

Oil breather plate 1/

Oil tank cover oil tank

Hanger oil tank cover

Band/collar oil tank

Oil tank stay cylinder

Oil tank oil tank stay

Plug (vacuum pressure)

*1 For details, refer to the tightening procedures in this manual.

Reverse gate stay jet pump

Roller reverse gate stay

Oil pipe lower crankcase

Grease nipple intermediate

Driven coupling shaft

QSTS cable ball joint nozzle ring

QSTS cable end pin

Cover electrical box

Bow eye hull