2012 Yamaha Waverunner FX Cruiser Ho Sho Service Manual Wave Runner

WaveRunner
FX HO
FB1800 (F2T)
FX Cruiser HO
FB1800A (F2T)
FX SHO
FA1800 (F2S)
FX Cruiser SHO
FA1800A (F2S)
SERVICE MANUAL
LIT-18616-03-41
F2S-28197-1R-11
Preface
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 the Bronze Technical Certificate of the YTA
(Yamaha Technical Academy) marine or the equivalent 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. Also, up-to-date parts information is available on YDS (Yamaha Dealer System). Additional
information and up-to-date information on Yamaha products and services are available on YDS
(Yamaha Dealer System).
Important information
Particularly important information is distinguished in this manual by the following notations:
 The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
A WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
A NOTICE indicates special precautions that must be taken to avoid damages to the water-
craft or other property.
TIP:
A TIP provides key information to make procedures easier or clearer.
WaveRunner
FX HO, FX Cruiser HO,
FX SHO, FX Cruiser SHO
SERVICE MANUAL
©2012 by Yamaha Motor Corporation, U.S.A.
1st Edition, February 2012
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-18616-03-41
Contents
General information GEN

INFO
1
Specification
SPEC 2
Maintenance
MNT 3
Fuel system
FUEL 4
Power unit
POWR 5
Jet pump unit JET
PUMP
6
Electrical system
ELEC 7
Hull and hood HULL
HOOD
8
Troubleshooting TRBL
SHTG
9
Appendix A
GEN
INFO
General information 1
Safety while working .................................................... 1-1

Rotating part .............................................................................. 1-1
Hot part ...................................................................................... 1-1
Electric shock ............................................................................ 1-1
Impeller ...................................................................................... 1-1
Handling of gasoline .................................................................. 1-1
Ventilation .................................................................................. 1-2
Self-protection ........................................................................... 1-2
Working with crane .................................................................... 1-2
Handling of heat gun ................................................................. 1-3
Part, lubricant, and sealant ........................................................ 1-3
Handling of sealant .................................................................... 1-3
Special service tool ................................................................... 1-3
Tightening torque ...................................................................... 1-3
Non-reusable part ...................................................................... 1-4
Disassembly and assembly ....................................................... 1-4
Identification number ........................................................ 1-5

Primary I.D. number .................................................................. 1-5
Engine serial number ................................................................ 1-5
Jet pump unit serial number ...................................................... 1-5
Hull identification number (H.I.N.) ............................................. 1-5
How to use this manual .................................................... 1-7

Manual format ........................................................................... 1-7
Abbreviation .............................................................................. 1-8
Adhesive, lubricant, sealant, and

thread locking agent ......................................................... 1-9
Symbol ...................................................................................... 1-9
Special service tool ......................................................... 1-11
Model feature ................................................................... 1-19

General feature (FX SHO, FX Cruiser SHO) ........................... 1-19
General feature (FX HO, FX Cruiser HO) ............................... 1-20
Model equipment comparison table ........................................ 1-21
Hull and deck ........................................................................... 1-22
Technical tips .................................................................. 1-24

Engine control ......................................................................... 1-24
ETV system ............................................................................. 1-26
Mechanical Neutral .................................................................. 1-27
Engine control system ............................................................. 1-28
YDIS .................................................................................. 1-31

New functions .......................................................................... 1-32
Menu item ................................................................................ 1-32
Logging .................................................................................... 1-33 1
Engine .............................................................................. 1-34
Lubrication system .................................................................. 1-35
Hose routing (FX SHO, FX Cruiser SHO) ............................... 1-36
Hose routing (FX HO, FX Cruiser HO) .................................... 1-37
Cooling water flow ................................................................... 1-38
2
3
4
5
6
7
8
9
A
GEN
INFO General information
Safety while working

To prevent an accident or injury and to pro-
vide quality service, observe the following
safety procedures.
Rotating part
• Hands, feet, hair, jewelry, clothing, personal
flotation device straps, and so on, can
become entangled with internal rotating
parts of the engine or jet pump unit, result-
ing in serious injury or death.
• Keep hands, feet, hair, jewelry, clothing,
personal flotation device straps, and so on,
away from any exposed moving parts when
operating the engine with the seat
removed.
• Keep away from intake grate while engine
is on. Items such as hair, clothing, or per-
sonal flotation device straps can become Handling of gasoline
entangled in moving parts resulting in • Gasoline is highly flammable. Keep gaso-
severe injury. line and all flammable products away from
heat, sparks, and open flames.
Hot part • Gasoline is poisonous and can cause injury
During and after operation, engine parts are or death. Handle gasoline with care. Never
hot enough to cause burns. Do not touch any siphon gasoline by mouth. If you swallow
parts in the engine compartment until the some gasoline, inhale a lot of gasoline
engine has cooled. vapor, or get some gasoline in your eyes,
see your doctor immediately. If gasoline
Electric shock spills on your skin, wash with soap and
Do not touch any electrical parts while start- water. If gasoline spills on your clothing,
ing or operating the engine. Otherwise, shock change your clothes.
or electrocution could result.
Impeller
Do not hold the impeller with your hands
when loosening or tightening the impeller.
1-1
Ventilation Working with crane
• Gasoline vapor and exhaust gas are • When moving the watercraft, or when lifting
heavier than air and extremely poisonous. If the engine during removal or installation,
1
gasoline vapor or exhaust gas is inhaled in make sure to use a crane with a lifting
large quantities, it may cause loss of con- capacity that is equal to or more than the
sciousness and death within a short time. weight of the watercraft or engine respec-
• When test running an engine indoors (for tively.
example, in a water tank) make sure to do • When lifting the watercraft, use the water-
2
so where adequate ventilation can be main- craft lift harness and make sure that the
tained. watercraft is in a stable position when mov-
ing it.
• Use the wire ropes of adequate strength,
and lift up the engine unit using the three
3
point suspension.
• If the engine unit does not have three or
more points to be suspended, support it
using additional ropes or the like so that the
engine unit can be lifted and carried in a
4
stable manner.
Self-protection
• Protect your eyes by wearing safety
glasses or safety goggles during all opera-
tions involving drilling and grinding, or when
using an air compressor.
• Protect your hands and feet by wearing pro-
tective gloves and safety shoes when nec-
5
essary.
6
7
8
9
1-2
A
GEN
Handling of heat gun Handling of sealant
• Improper handling of a heat gun may result • Wear protective gloves to protect your skin,
in burns. For information on the proper han- when using the sealants.
dling of the heat gun, see the operation • See the material safety data sheet issued
manual issued by the manufacturer. by the manufacturer. Some of the sealants
• When using a heat gun, keep it away from may be harmful to human health.
the gasoline and oil, to prevent a fire.
• Components become hot enough to cause
burns. Do not touch any hot components
directly.
Special service tool

Use the recommended special service tools
to work safely, and to protect parts from dam-
age.
Part, lubricant, and sealant
Use only genuine Yamaha parts, lubricants,
and sealants, or those recommended by
Yamaha, when servicing or repairing the
watercraft.
Tightening torque
Follow the tightening torque specifications
provided throughout the manual. When tight-
ening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting
in the center and moving outward.
1-3
Non-reusable part
Always use new gaskets, seals, O-rings, cot-
ter pins, and so on, when installing or assem-
1
bling parts.
2
Disassembly and assembly
• Use compressed air to remove dust and dirt
during disassembly.
3
• Apply engine oil to the contact surfaces of
moving parts before assembly.
4
5
• Install bearings so that the bearing identifi-
cation mark is facing in the direction indi-
cated in the installation procedure. In
6
addition, make sure to lubricate the bear-
ings liberally.
• Apply a thin coat of water resistant grease
to the lip and periphery of an oil seal before
installation.
7
• Check that moving parts operate normally
after assembly.
8
9
1-4
A
GEN
Identification number B
Primary I.D. number
The primary I.D. number is stamped on a
label attached to the inside of the engine
compartment.
b c
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON
a b c
PRI-I.D. a Engine name
MODEL F2S b Engine type
YAMAHA MOTOR CO., LTD.
ASSEMBLED IN U.S.A. FROM AMERICAN AND JAPANESE c Engine serial number
COMPONENTS.
ASSEMBLÉ AUX ÉTATS-UNIS DE PIÈCES AMÉRICAINES ET
JAPONAISES. Starting engine serial number:
A 6CS: 1000001 (F2S)
a Model name B 6CR: 1000001 (F2T)
b Hull type
c Primary I.D. number Jet pump unit serial number
The jet pump unit serial number is stamped
Starting primary I.D. number:
on a label attached to the intermediate hous-
F2S: 800101
ing.
F2T: 800101
Engine serial number

The engine serial number is stamped on a
label attached to the engine unit.
A
a c
a Jet pump unit name

b Jet pump unit type
c Jet pump unit serial number
Hull identification number (H.I.N.)

The H.I.N. is stamped on a plate attached to
the boarding platform.
1-5
Identification number
1
2
U S - Y AM
3
4
5
6
7
8
9
1-6
A
GEN
How to use this manual

Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the information below as a guide for effective and quality service.
• Parts are shown and detailed in an exploded diagram and are listed in the component list (see a
in the following figure for an example page).
• The component list consists of part names and quantities, as well as bolt and screw dimensions
(see b in the following figure).
• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
the lubrication point (see c in the following figure).
• Tightening torque specifications are provided in the exploded diagrams (see d in the following fig-
ure), and in the related detailed instructions. Some torque specifications are listed in stages as
torque figures or angles in degrees.
• Separate procedures and illustrations are used to explain the details of removal, checking, and
installation where necessary (see e in the following figure for an example page).
TIP:
• The illustrations used in this manual show the FX Cruiser SHO unless otherwise specified.
• For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
1-7
How to use this manual
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
API
APS
BOW
American Petroleum Institute
Accelerator Position Sensor
Bow side
1
BTDC Before Top Dead Center
DOHC
ECM
ETV
Double Overhead Camshaft
Electronic Control Module
Electronic Throttle Valve
2
EX Exhaust
ID
IN
ISO
Identification
Intake
International Organization for Standardization
3
OTS Off-throttle steering system
PON
PORT
RON
Pump Octane Number
Port side
Research Octane Number
4
RPM Revolutions Per Minute
SAE
STBD
STERN
Society of Automotive Engineers
Starboard side
Stern side
5
TCI Transistor Controlled Ignition
TDC
TPS
UP
Top Dead Center
Throttle Position Sensor
Upside
6
YDIS Yamaha Diagnostic System
7
8
9
1-8
A
GEN
Adhesive, lubricant, sealant, and thread locking agent

Symbol
Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication
points.
Symbol Name Application
YAMALUBE 4W or Yamaha 4-stroke motor oil Lubricant
Water resistant grease Lubricant

(YAMALUBE MARINE GREASE)
Molybdenum disulfide grease Lubricant
Epnoc grease AP#0 Lubricant
Silicone grease Lubricant
Symbols in an exploded diagram or illustration indicate the type of adhesive, sealant, or thread lock-
ing agent and the application points.
ThreeBond 1207B Sealant
ThreeBond 1280B Sealant
ThreeBond 1322 Thread locking agent
ThreeBond 1360 Thread locking agent
ThreeBond 1530D Adhesive
LOCTITE 242 (blue) Thread locking agent
LOCTITE 271 (red) Thread locking agent
1-9
Adhesive, lubricant, sealant, and thread locking agent

LOCTITE 572 (white) Sealant
LOCTITE 648 (green) Thread locking agent 1

Silicone sealant Sealant
2
3
4
5
6
7
8
9
1-10
A
GEN

Special service tools numbered “YB/YM/YS/YU/YW-*****” are distributed by K & L.
Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division.
Special service tools with part number 90890-06883 is distributed by the Marine Service Division.
Oil filter wrench Dial gauge needle

YB-06830 90890-06584
90890-06830
Dial gauge set

Gauge stand 90890-01252
90890-06725
Camshaft wrench
Dial gauge stand set 90890-06724
YB-06585
Fuel pressure gauge adapter

Dial indicator gauge YB-06946
YU-03097 90890-06946
1-11
Fuel pressure gauge Exhaust pipe wrench
YU-03153M 90890-06726
1
Fuel pressure gauge
90890-06753
Leakage tester
90890-06840 2
3
Compression gauge Coupler wrench
YU-33223 90890-06729
4
5
Compression gauge Bearing puller assembly
90890-03160 90890-06535
6
Compression gauge extension
90890-06563
Stopper guide plate
90890-06501
7
8
9
1-12
A
GEN
Stopper guide stand Valve guide installer
90890-06538 90890-06810
Valve spring compressor Valve guide reamer

YM-04019 YM-01196
90890-04019 90890-06804
Compressor adapter Valve lapping tool

YM-04114 YM-A8998
Valve spring compressor attachment Valve lapper
90890-04114 90890-04101
Valve guide remover Neway valve seat kit

YB-06801 YB-91044
Valve guide remover/installer
90890-06801
Valve seat cutter holder

90890-06812
Valve guide installer
YB-06810
1-13
Valve seat cutter Flywheel puller
Intake 90890-06723
90890-06720 (30°)
90890-06325 (45°)
90890-06324 (60°)
Exhaust
90890-06818 (30°)
90890-06555 (45°)
1
90890-06323 (60°)
Rotor puller
90890-01080 2
Crankshaft holder
90890-06732
3
Primary sheave holder
YS-01880-A
Sheave holder
90890-01701
4
Shaft holder
90890-06721 5
Driver handle (small)
YB-06229
6
Driver handle
90890-06722
7
Bearing and seal installer
YW-06356
8
9
1-14
A
GEN
Driver rod LS Forward bearing race installer
90890-06606 YB-06258
Bearing outer race attachment Bearing pressure C

90890-06627 90890-02393
Driver handle (large) Piston ring compressor

YB-06071 YM-08037
Forward gear outer race installer Piston ring compressor

YB-41446 90890-05158
Ball bearing attachment Driveshaft holder

90890-06657 YB-06201
Drive shaft holder 6
90890-06520
1-15
Slide hammer Bearing attachment
YB-06096 90890-06728
1
Driveshaft needle bearing installer and
remover
YB-06194
Shaft holder
90890-06730 2
3
Bearing puller legs
Driver rod L3
90890-06652
YB-06523
4
5
Needle bearing installer
Needle bearing attachment YB-06434
90890-06609
6
Bearing attachment
Needle bearing attachment
90890-06654
7
90890-06727
8
9
1-16
A
GEN
YDIS 2 starter kit Spark checker
90890-06883 YM-34487
Ignition tester (Spark gap tester)
90890-06754
***
******
******
Digital multimeter
YU-34899-A
Test harness (3 pins)
YB-06877
90890-06877
Peak volt adapter

YU-39991

YB-06870
90890-06870
Digital circuit tester

90890-03189

YW-06850
90890-06850
Peak voltage adapter B

90890-03172
Lower unit pressure/vacuum tester

YB-35956-A
1-17
Vacuum/pressure pump gauge set
90890-06756
1
YB-06872
90890-06849
2
3
YB-06879
90890-06879
4
5
6
7
8
9
1-18
A
GEN
Model feature
General feature (FX SHO, FX Cruiser SHO)
The F2S is equipped with a newly designed NanoXcel hull and deck. The body length has increased
compared to the previous model (F1W).
The 6CS engine installed into the F2S is based on a high output, 1.8L supercharged 6AN engine
with changes to the lubrication system. The engine has also undergone either an anodic coating or
has had a black paint layer added, increasing anti-corrosion properties.
a Power unit c Electrical

• 4-stroke, L4, DOHC, 16 valve, 1812 cm3 • Electronic control throttle valve system
engine with electronic fuel injection • Electric throttle without wire cable
• Supercharged • In-tank fuel pump module
• Single throttle body • Multifunction meter
• 4-in-1 exhaust system • L-MODE
• Wet-sump lubrication • No-wake mode
b Jet pump • Cruise assist
• Stainless steel, 3-blade, ø155 mm, 17.6° • OTS
pitched impeller • YDIS Ver. 2.00
• Impeller turning direction: counterclock- d Deck and hull
wise (when viewed from the rear) • V-shaped hull
• Aluminum jet thrust nozzle • NanoXcel hull, NanoXcel deck
• Mechanical Neutral • 2 seat types (different shapes according to
• Q.S.T.S. the model)
• Adjustable tilt steering system
• Flushing hose connector placed in the stern
storage compartment
1-19
Model feature
General feature (FX HO, FX Cruiser HO)
The F2T is equipped with the same hull and deck as the F2S.
The 6CR engine installed into the F2T is based on a high output, 1.8L 6CN engine with changes to
1
the lubrication system. The engine has also undergone either an anodic coating or has had a black
paint layer added, increasing anti-corrosion properties.
d
2
b
3
a
4
a Power unit
• 4-stroke, L4, DOHC, 16 valve, 1812 cm3
engine with electronic fuel injection
• Single throttle body
c Electrical
• Electronic control throttle valve system
• Electric throttle without wire cable
• In-tank fuel pump module
5
• 4-in-1 exhaust system • Multifunction meter
• Wet-sump lubrication
b Jet pump
• Stainless steel, 3-blade, ø155 mm, 15.3°
pitched impeller
• L-MODE
• No-wake mode
• Cruise assist
• OTS
6
• Impeller turning direction: counterclock- • YDIS Ver. 2.00
wise (when viewed from the rear)
• Aluminum jet thrust nozzle
• Mechanical Neutral
• Q.S.T.S.
d Deck and hull
• V-shaped hull
• NanoXcel hull, NanoXcel deck
• 2 seat types (different shapes according to
7
the model)
• Adjustable tilt steering system
• Flushing hose connector placed in the stern
storage compartment
8
9
1-20
A
GEN
Model equipment comparison table
Model FX HO FX Cruiser HO FX SHO FX Cruiser SHO
Total length 3.56 m (140.2 in)
Width 1.23 m (48.4 in)
Dry weight 373 kg (822 lb) 374 kg (825 lb) 386 kg (851 lb) 387 kg (853 lb)
Seats Normal seat a Cruiser seat b Normal seat a Cruiser seat b
Pull-up cleat c —  — 
“START/STOP” and
“MODE/RESET” — — — 
button d
Speed and water Speed sensor Speed sensor Speed sensor

temperature sensor e f only f only f only
Compass and air
— — — 
temperature sensor g
Multifunction display
— — — 
h (*1)
: Equipped
—: Not equipped
(*1) Compass, average speed, tripmeter, trip timer, fuel consumption, water temperature, and air
temperature display.
a f
h
b
e
c d
A FX SHO B FX Cruiser SHO

1-21
Model feature
Hull and deck
The F2S and F2T share the same newly designed NanoXcel hull and deck. The length has
increased by 190 mm (7.5 in) compared to the previous model, the F1W. The enlarged body has
1
allowed for a bigger seat and boarding platform, more gear capacity, and enhanced riding comfort.
The form of the hull improves the handling of the vehicle, and it also is designed to improve agility in
spite of the increases in weight.
Model Previous FX series New FX series

Total length a
Seat length b
Reboarding step
height c
3.37 m (132.7 in)
610 mm (24 in)
172 mm (6.8 in)

3.56 m (140.2 in)
686 mm (27 in)
380 mm (15 in)

2
Storage
compartment d
4 locations 5 locations
The gear space at the rear of the vehicle will comfortably fit snorkeling gear and tow ropes a. The
3
gear space is designed so that the rope can be housed while fitted to the tow hook. Also in the gear
space there is a flushing hose connector b, allowing for the vehicle to be flushed just by opening
the gear space and attaching a garden hose c.
The reboarding step d is designed so that only a minimal step is required to place your foot. The
grip e located in the front part of the platform makes reboarding from the water easier.
4
5
6
7
8
9
1-22
A
GEN
a
d b
A
d
d
d
a
d b
B
d d
d
d
A Previous FX series
B New FX series
1-23
Model feature / Technical tips
Technical tips
Engine control
The ECM controls ignition timing and fuel injection with information received from the sensors and
switches installed on the engine as well as utilizing the base map saved in the ECM.
A
a
b
c
1
f
2
d
3
e
4
g
h
m
l
o
n
k
j
i
5
6
7
8
9
1-24
A
GEN
B a b
c
n g
o
j
l
k
A FX SHO, FX Cruiser SHO

B FX HO, FX Cruiser HO
Part name Functions
a Cam position sensor Detects the rotational position of the camshaft.
b Slant detection switch Detects whether the watercraft is capsized.
Properly controls ignition timing, fuel injection timing and
c ECM volume, opening angle of the ETV, and fail-safe function with
information received from the sensors and switches.
d Thermo sensor Detects the temperature of the exhaust cooling water.
e Oil pressure switch Detects the pressure of the engine oil.
f Thermoswitch Detects overheat.
g Intake air temperature sensor Detects the temperature of the intake air.
h Knock sensor Detects engine knocking.
i TPS Detects the opening angle of the ETV.
j Intake air pressure sensor Detects the pressure of the intake air.
k Engine temperature sensor Detects the temperature of the cylinder block.
l Pickup coil Detects the crankshaft angle.
m APS Detects the opening angle of the throttle lever.
Detects when the handlebar is turned all the way to the right
n Steering sensor
or left and a load is applied.
o Reverse sensor Detects the N and R positions of the shift lever.
1-25
Technical tips
ETV system
The F2S and F2T are equipped with a newly developed throttle lever.
The throttle lever has an APS which senses the degree of throttle opening and converts the status
1
into electronic signals, delivering the information to the ECM. The ECM controls the ETV based on
the input signals of the APS.
Employing the APS in the throttle lever has eliminated the need for throttle cables, reducing the
number of parts used, thereby improving throttle response and serviceability.
The newly developed throttle lever has 2 sensors as per the previous APS – the APS 1 and APS 2,
2
which mutually diagnose any failures each system may encounter.
In addition, an APS full close switch has been newly added. This switch detects the fully closed
throttle lever position.
A b
3
5V
APS 1
Ground c
5V a
APS 2
4
Ground
B
d
e
f
5
5V
6
APS 1
7
Ground
5V
APS 2
Ground
5V
8
APS full
Ground close switch
a Throttle lever B New ETV system

b Throttle cable
c APS
d ECM
e ETV
9
f Electric throttle without wire cable
A Previous ETV system
1-26
A
GEN
Mechanical Neutral
In addition to the F and R positions, an N position has been added to the F2S and the F2T.
The shift lever is used to change the shift position. The shift lever will not slide unless the shift lock
lever a is held. An N mark b will be displayed when the shift lever is in the N position.
By operating the shift lever, the reverse gate position changes. In the N position, the flow of water is
dispersed forwards and backwards, preventing the water craft from moving in either direction.
With previous reverse sensor, the mechanism switched on when the shift lever was placed in the R
position, and the reverse traction control was engaged. In this model, the reverse sensor turns on in
both the N and R positions, activating reverse traction control in both modes. For this reason, the
engine speed is also limited in the N position.
b
a
A F position
B N position
C R position
1-27
Technical tips
Engine control system
Item Condition Action Remarks
Overheat • Engine temperature • Opening angle of the ETV Cancel:
warning
control
rises rapidly in a
short time.
• Thermoswitch is on.
• Exhaust cooling
is regulated.
• Maximum engine speed is
limited to approximately
3000–3300 r/min.
• Stop the engine and wait
for 30 seconds or more.
• Engine temperature is
below 140 °C (248 °F)
1
water temperature with the thermoswitch off.
exceeds 75 °C
(167 °F).
• Exhaust cooling water
temperature is below
70 °C (158 °F) with the
ETV fully closed.
2
If the engine is stopped
Oil pressure
warning
Control is activated
when all of the
• Opening angle of the ETV
is regulated.
during overheat warning
control, it can be restarted.
Cancel:
• Stop the engine and wait
3
control following conditions • Maximum engine speed is for 30 seconds or more.
are present:
• Oil pressure switch is
on.
• ETV is open.
3000–3300 r/min.
• Engine is restarted and
the oil pressure switch is
off.
If the engine is stopped
4
• Engine speed during oil pressure warning
exceeds 4500 r/min.
Cam position Control is activated
sensor failure when the following
control conditions are
• Opening angle of the ETV
is regulated.
control, it can be restarted.
Cancel:
Engine is stopped.
5
maintained for 10 limited to approximately
seconds:
• Cam position sensor
failed.
3000–3300 r/min.
6
• Engine speed
exceeds approxi-
mately 1000 r/min.
Control is activated
when all of the
Ignition and fuel injection are Cancel:
cut to all cylinders and the Engine is stopped.
7
following conditions engine is stopped.
are present:
• Cam position sensor
failed.
• Engine speed
8
exceeds 5000 r/min.
ETV failure ETV failed, or open or • Opening angle of the ETV
control short circuit is detected
in ETV circuit.
is fixed to the default open-
ing angle.
9
A
3000 r/min.
• Ignition timing is controlled.
1-28
GEN

Battery Battery lead is Control is performed using
disconnection disconnected during the same actions as the ETV
warning normal operation. failure control.
Idle speed Throttle lever is in theEngine speed is limited to Engine speed is limited to
control fully closed (idle) 1150–1350 r/min. 1200–1400 r/min.
position. (FX SHO, FX Cruiser SHO) (FX HO, FX Cruiser HO)
Over Engine speed exceeds Ignition is controlled.
revolution 7800 r/min. Condi-
Action
control tion
Normal None
Level 1 Ignition is cut off to
1 cylinder.
2 cylinders.
3 cylinders.
all cylinders.
High intake air In a state where The throttle valve is limited Completely shutting off the
pressure engine speed has from opening more than the throttle valve will disengage
control exceeded 7550 r/min point where the control was the control. (FX SHO, FX
and intake pressure is engaged. Cruiser SHO)
higher than 145 kPa
(21.0 psi) has lasted
longer than 1.5
seconds.
Knock control When engine speed Ignition timing is delayed (FX SHO, FX Cruiser SHO)
exceeds 2000 r/min according to the volume of
after warming up knocking
Off-throttle Engine speed is Slightly opens the throttle Throttle valve opening is
steering (OTS) sustained at or above valve so that the vehicle can controlled based on the
control 4000 r/min for several maneuver. APS signal and the amount
seconds and then of force applied to the
throttle lever is fully steering sensor.
closed –
simultaneously, the
steering handle is
maneuvered to the
point the steering
sensor is engaged.
Reverse with When the shift lever is Engine speed will be limited The control will be
traction control in the N or R position. to 3000 r/min. disengaged when the shift
lever is moved forward.
While the control is
engaged, the no-wake
mode cannot be activated.
1-29
Technical tips

Slant detection Control is activated Ignition and fuel injection are Cancel:
control when all of the cut to all cylinders and the Engine is stopped.
following conditions
are present:
• Slant detection
switch is on.
engine is stopped. (The check engine warning
indicator does not come on
and the buzzer does not
sound.)
1
• Engine speed is
control
3000 r/min or less.
Cruise assist When engine speed is
between 3000–7000
r/min
The vehicle can cruise at a Cruise control cannot be set
sustained, set engine speed. when the L-MODE is active.
2
No-wake 5 seconds or more Engine speed is limited to The digital speedometer
mode control have elapsed since the
L-MODE
control
engine was started.
L-MODE is activated.
2100 r/min. flashes at 8 km/h (5 mph).
• Opening angle of the ETV Cancel:

is regulated. L-MODE is deactivated.
3
• Ignition timing is controlled.
75 % of the maximum
engine speed in the normal
4
mode.
5
6
7
8
9
1-30
A
GEN
YDIS
F2S and F2T are only compatible with YDIS version 2.00.
YDIS version 2.00 retains the functionality of YDIS version 1 series, while adding new functionality.
The screen has been redesigned, improving ease-of-use.
TIP:
• There is no compatibility between the YDIS version 2.00 and version 1 series.
• Use of the Windows function a to change the screen size and to end programs is now possible.
• Displays the current level b.
• Displays the communications status.
Communicating: c
Communications error: d
• For details of operation methods, see the YDIS (Ver. 2.00) instruction manual.
• These tools are restricted for use by Yamaha service technicians of distributors or dealers only.
a
b
c
1-31
YDIS
New functions
• The settings function now enables switching of the language (English, French, Spanish, Japa-
nese). The units for measurement cannot be changed.
1
• By connecting commercially available external instruments, the external input function enables
display of this information on the engine monitor.
• The new adapter has 1.6 MB of memory, meaning that logging of engine monitor information is
possible while the computer is not connected. The adapter has an internal battery, which is
recharged by being connected to the computer or to the water craft (while the engine start switch
2
is ON), and one hour of recharging is sufficient for 48 hours backup.
While your water craft is connected to the YDIS, the ECM power cannot be turned off. This
can drain battery power. Remove the YDIS connection when you are not using the YDIS.
Menu item
Top Menu Main Menu 2nd-level Menu 3rd-level Menu 4th-level Menu
3
4
Start Engine Diagnosis Diagnosis
Diagnosis Record
Engine operating
5
hours by RPM
Engine Monitor Digital Display
Graph Display
Component Test
Input Setting
Stationary Test
6
Active Test
Data Logger Logger Graph 7

Update ECM Rec Graph
Setting
Off Line
Logging Record Set
Show Data
8
9
Clear Data
1-32
A
GEN
Logging
In version 2.00, it is possible to configure items to be logged, and logging intervals. Configure log-
ging, and disconnect the USB cable between the computer and the adapter to start logging.
Because the computer is not connected during logging, the adapter can be placed within the bow
storage compartment. This enables logging under conditions that are the same as those during nor-
mal use. This makes it easier to reproduce trouble conditions, and to investigate the causes of any
faults.
Take care when riding while the YDIS is connected as the multifunction meter display will not
operate.
a e
b c b c b d
c
f
A B
a Adapter f Adapter recording status

a Logging start
b Engine start A Recording (engine speed: 500 r/min or
c Engine stop more)
d Fault occurs B Stop recording (engine speed: less than
e Logging stop 500 r/min)
TIP:
• Starts and stops logging by connecting and disconnecting the USB cable between the computer
and adapter.
• The adapter has a built-in battery. Therefore during operation, this is recharged using electricity
from the engine. When the engine stops, backup uses the internal battery.
• Guaranteed for 48 hours continuous operation with the battery charged for one hour. If the internal
battery becomes depleted, recorded data will be deleted.
• Recording normal (default condition) engine data (engine speed ranges) enables comparison with
fault data.
1-33
YDIS / Engine
Engine
The new 6CS engine is derived from the modified 6AN engine, and the new 6CR engine is based on
the modified 6CN engine. Main points of change include discarding the scavenging pump, external
breather, simplifying the lubrication system. The parts surrounding the timing chain have been
changed to those used in the 6BH engine in order to increase usage of common parts.
The engine has also undergone either an anodic coating or has had a black paint layer added,
increasing anti-corrosion properties.
1
A
2
C
B 3
A
A
A
4
B
5
A
B
B 6
7
A Anodic oxide coating
B Black paint layer
C FX SHO, FX Cruiser SHO
8
9
1-34
A
GEN
Lubrication system
The 6CS and 6CR engines feature a wet-sump lubrication system. The oil pump assy. is different
from the oil pump assy. that was used for the base engine and does not contain a scavenge oil
pump. In addition, the breather assy. was eliminated. As a result, the blowby gas from the cylinder
head cover is sent directly to the oil separator tank.
b
n
l
c
m
k
A
j f
i g C
h
a Intake camshaft k Oil cooler assy.

b Exhaust camshaft l Oil filter
c Cylinder block m Oil pump drive gear
d Crankshaft n Super charged (FX SHO, FX Cruiser SHO
e Oil separator tank only)
f Oil pan
g Oil strainer A To air intake pipe
h Oil pipe B Oil flow
i Oil pump assy. (feed pump) C Oil flow (FX SHO, FX Cruiser SHO only)
j Relief valve
1-35
Engine
Hose routing (FX SHO, FX Cruiser SHO)
A
1
F 2
D
E
D
B
3
G
4
H
5
I
C J
K
L
6
A
B
C
D
From flushing hose connector
From transom plate
To cooling water pilot outlet on port side
To drain joint (transom plate)
7
E To drain joint
F
G
H
I
To drain joint
To cooling water pilot outlet on starboard side
For water draining when engine is stopped
Cooling water flow
8
J Blowby gas flow
K
L
Bilge water flow
Fuel flow
9
1-36
A
GEN
Hose routing (FX HO, FX Cruiser HO)
D
E
D
B
H
C I
J
K
A From flushing hose connector

B From transom plate
C To cooling water pilot outlet on port side
D To drain joint (transom plate)
E To drain joint
F To drain joint
G For water draining when engine is stopped
H Cooling water flow
I Blowby gas flow
J Bilge water flow
K Fuel flow
1-37
Engine
Cooling water flow
H I
F
D
1
E
2
3
H H
A
B
4
A
I B
5
C
6
G 7
A From flushing hose connector
B
8
From transom plate
C To cooling water pilot outlet on port side
D To drain joint
E To exhaust valve
F To cooling water pilot outlet on starboard side
G
9
For water draining when engine is stopped
H FX SHO, FX Cruiser SHO
I FX HO, FX Cruiser HO
1-38
A
GEN
— MEMO —
1-39
SPEC
Specification 2
Model data ......................................................................... 2-1

Model code ................................................................................ 2-1
Dimensions and weight ............................................................. 2-1
Performance .............................................................................. 2-1
1
Power unit ................................................................................. 2-1
Jet pump unit ............................................................................. 2-2
Fuel and oil requirement ............................................................ 2-2
Battery requirement ................................................................... 2-3 2
Fuel system technical data .............................................. 2-3
3
Fuel system ............................................................................... 2-3
Power unit technical data ................................................. 2-4

Power unit ................................................................................. 2-4
Cylinder head assy. ................................................................... 2-4
Crankcase assy. ........................................................................ 2-6
Jet pump unit technical data ............................................ 2-8

4
Jet pump unit ............................................................................. 2-8
Electrical technical data ................................................... 2-8

Ignition system .......................................................................... 2-8
Charging system ....................................................................... 2-9
5
Control system .......................................................................... 2-9
Fuel system ............................................................................. 2-11
Starting system ........................................................................ 2-11
Meter system ........................................................................... 2-12 6
Specified tightening torque ............................................ 2-13
Fuel system ............................................................................. 2-13
Power unit ............................................................................... 2-13
Jet pump unit ........................................................................... 2-16
Electrical system ..................................................................... 2-16
7
Hull and hood .......................................................................... 2-16
Torque wrench reading (setting value) ......................... 2-18

8
General tightening torque .............................................. 2-18
Cable and hose routing .................................................. 2-19

Starboard bow view ................................................................. 2-19
Top view .................................................................................. 2-20
9
Port view .................................................................................. 2-22
A
SPEC
Specification
Model data
Model code
Model
FX FX
Item Unit
FX HO Cruiser FX SHO Cruiser
HO SHO
Hull F2T F2S
Engine/jet 6CR/6CR 6CS/6CS
Dimensions and weight

Model
FX FX
Item Unit
HO SHO
Length mm (in) 3560 (140.2)
Width mm (in) 1230 (48.4)
Height mm (in) 1230 (48.4)
Dry weight kg (lb) 373 (822) 374 (825) 386 (851) 387 (853)
Maximum capacity person/kg (lb) 3/240 (530)
Performance
Model
FX FX
Item Unit
HO SHO
Full throttle operating range r/min 7600 7500
Trolling speed r/min 1200–1400 1150–1350
L/h (US gal/
Maximum fuel consumption 48.7 (12.9, 10.7) 70.6 (18.7, 15.5)
h, lmp.gal/h)
Cruising range h 1.44 0.99
Power unit
Model
FX FX
Item Unit
HO SHO
Type 4-stroke, L4, DOHC
Cylinder quantity 4
Total displacement cm3 (cu. in) 1812 (110.6)
Bore  stroke mm (in) 86.0 × 78.0 (3.39 × 3.07)
Compression ratio 11:1 8.6:1
Exhaust system Wet exhaust
Lubrication system Wet sump
Cooling system Water cooled
Starting system Electric starter
Camshaft drive system Chain drive
2-1
Model data
Model
FX FX
Item Unit
Timing chain tensioning system

Ignition system
Maximum ignition timing
HO
Automatic
TCI
SHO
1
degree BTDC 25 BTDC 20
advance
Spark plug
Spark plug gap
Firing order
mm (in)
LFR6A (NGK)
0.8–0.9 (0.031–0.035)
1–2–4–3
2
Oil filter type Cartridge type
3
Oil pump type Trochoid
Jet pump unit

Model
FX FX
Item Unit
4
HO SHO
Jet pump type Axial flow, single stage
Impeller rotation Counterclockwise (viewed from rear)
Transmission Direct drive from engine
Jet thrust nozzle horizontal angle
Trim system
Jet thrust nozzle trim angle
Shift operation
Degree 24 + 24
Manual 5 positions
–10, –5, 0, 5, 10
F-N-R
5
Reverse system Reverse gate
Fuel and oil requirement

Model
6
FX FX
Item Unit
7
HO SHO
Fuel type Regular unleaded gasoline
PON 86
Fuel minimum rating
RON 90
Fuel tank capacity
Engine oil type

Engine oil grade
L (US gal,
Imp.gal)
API
70 (18.5, 15.4)
YAMALUBE 4W or 4-stroke motor oil

SE, SF, SG, SH, SJ, SL
8
SAE 10W-30, 10W-40, 20W-40, 20W-50
9
2-2
A
SPEC
Specification
Model
FX FX
Item Unit
HO SHO
Engine oil quantity
L (US gal,
Total amount 4.3 (4.5, 3.8)
Imp.gal)
L (US gal,
Without oil filter replacement 3.0 (3.2, 2.6)
Imp.gal)
L (US gal,
With oil filter replacement 3.1 (3.3, 2.7)
Imp.gal)
Battery requirement
Model
FX FX
Item Unit
HO SHO
Type Fluid
Capacity V/Ah 12/19
Specific gravity
At 20 °C (68 °F) 1.265
Fuel system technical data

Fuel system
Model
FX FX
Item Unit
HO SHO
Throttle body
Manufacturer Mikuni
ID mark 6BH** 6S5**
Fuel pump
Fuel pump type Electrical
kPa (kgf/
Fuel pressure 345–370 (3.45–3.70, 49.1–52.6)
cm2, psi)
2-3
Model data / Fuel system technical data / Power unit technical data
Power unit technical data

Power unit
Model
Item Unit
FX HO
FX
Cruiser
HO
FX SHO
FX
Cruiser
SHO
1
Compression pressure
2
kPa (kgf/
Minimum (*1) 780 (7.8, 113.1) 610 (6.1, 86.8)
cm2, psi)
Air cooler
Water passage holding pres- kPa (kgf/
— 200 (2.0, 28.5)
sure cm2, psi)
Air passage holding pres-
sure
Oil cooler
Water passage holding pres-
kPa (kgf/
cm2, psi)
kPa (kgf/
— 100 (1.0, 14.2)
3
200 (2.0, 28.5)
sure cm2, psi)
Thermostat
Valve opening temperature
Fully open temperature
Fully open stroke
°C (°F)
°C (°F)
mm (in)
58–62 (136–144)
70 (158)
48–52 (118–126)
4.3 (0.17)
60 (140)
4
5
(*1) Measuring conditions:
Ambient temperature 20 °C (68 °F), with spark plugs removed from all cylinders.
The figures are for reference only.
Cylinder head assy.
Item Unit
FX HO
FX
Cruiser
HO
Model
FX SHO
FX
Cruiser
SHO
6
Cylinder head
Warpage limit
Camshaft cap inside diame-
ter
mm (in)
mm (in)
0.10 (0.0039)
25.000–25.021 (0.9843–0.9851) 7
8
9
2-4
A
SPEC
Specification
Model
FX FX
Item Unit
HO SHO
Camshaft
Cam lobe height
Intake mm (in) 41.330–41.430 (1.627–1.631)
Limit mm (in) 41.320 (1.626)
Exhaust mm (in) 41.220–41.320 (1.623–1.627)
Limit mm (in) 41.210 (1.622)
Cam lobe width
Intake and exhaust mm (in) 31.956–32.056 (1.258–1.262)
Runout mm (in) 0.015 (0.0006)
Limit mm (in) 0.05 (0.0020)
Journal diameter
Journal oil clearance mm (in) 0.020–0.061 (0.0008–0.0024)
Limit mm (in) 0.08 (0.0031)
Valve
Clearance
Intake mm (in) 0.14–0.23 (0.0055–0.0091)
Exhaust mm (in) 0.28–0.37 (0.0110–0.0146)
Head diameter
Intake mm (in) 33.900–34.100 (1.3346–1.3425)
Exhaust mm (in) 28.900–29.100 (1.1378–1.1457)
Face width
Seat contact width
Intake mm (in) 1.400–1.600 (0.0551–0.0630)
Limit mm (in) 2.100 (0.0827)
Exhaust mm (in) 1.500–1.700 (0.0591–0.0669)
Limit mm (in) 2.200 (0.0866)
Margin thickness
Valve stem
Diameter
Intake mm (in) 5.477–5.492 (0.2156–0.2162)
Limit mm (in) 5.447 (0.2144)
Exhaust mm (in) 5.464–5.479 (0.2151–0.2157)
Limit mm (in) 5.434 (0.2139)
Runout limit mm (in) 0.01 (0.0004)
2-5
Power unit technical data
Model
FX FX
Item Unit
Valve guide
Inside diameter
Intake and exhaust mm (in)
HO
5.504–5.522 (0.2167–0.2174)
SHO
1
Stem to guide clearance
Intake
Limit
Exhaust
mm (in)
mm (in)
mm (in)
0.012–0.045 (0.0005–0.0018)
0.080 (0.0031)
0.025–0.058 (0.0010–0.0023)
2
Limit mm (in) 0.100 (0.0039)
3
Valve spring
Free length
Intake and exhaust mm (in) 45.58 (1.79)
Limit mm (in) 43.30 (1.70)
Installed length
Intake and exhaust
Tilt limit
Intake and exhaust
mm (in)
mm (in)
34.0 (1.34)
2.0 (0.08)
4
Crankcase assy.
Item Unit
FX HO
FX
Model
Cruiser
HO
FX SHO
FX
Cruiser
SHO
5
Cylinder
Bore
Piston
Limit
mm (in)
mm (in)
86.000–86.015 (3.3858–3.3864)
86.100 (3.3898) 6
Diameter mm (in) 85.915–85.930 (3.3825–3.3831)
Measuring point
Piston clearance
Limit
Ring groove (top)
mm (in)
mm (in)
mm (in)
mm (in)
9.5 (0.37) 10 (0.39)
0.070–0.100 (0.0028–0.0039)
0.200 (0.0059)
1.210–1.230 (0.0476–0.0484)
7
Ring groove (2nd) mm (in) 1.210–1.230 (0.0476–0.0484)
Ring groove (oil)
Pin boss bore diameter
Limit
mm (in)
mm (in)
mm (in)
2.510–2.530 (0.0988–0.0996)
22.004–22.015 (0.8663–0.8667)
22.045 (0.8679)
8
Pin outside diameter mm (in) 21.991–22.000 (0.8658–0.8661)
Limit mm (in) 21.981 (0.8654)
9
2-6
A
SPEC
Specification
Model
FX FX
Item Unit
HO SHO
Piston ring
End gap measuring point mm (in) 6.0 (0.24)
Top ring
Type Barrel
Dimension height (B) mm (in) 1.170–1.190 (0.0461–0.0469)
Dimension width (T) mm (in) 2.850–3.050 (0.1122–0.1201)
End gap (*1) mm (in) 0.300–0.450 (0.0118–0.0177)
Limit mm (in) 0.700 (0.0276)
Side clearance mm (in) 0.020–0.060 (0.0008–0.0024)
Limit mm (in) 0.110 (0.0043)
2nd ring
Type Taper
Dimension width (T) mm (in) 2.600–2.800 (0.1024–0.1102)
End gap (*1) mm (in) 0.450–0.600 (0.0177–0.0236)
Limit mm (in) 0.850 (0.0335)
Limit mm (in) 0.120 (0.0047)
Oil ring
Dimension width (T) (*1) mm (in) 2.500 (0.0984)
End gap (*1) mm (in) 0.100–0.350 (0.0039–0.0138)
Connecting rod
Small end inside diameter mm (in) 22.015–22.028 (0.8667–0.8672)
Bearing color code 1.Brown 2.Black 3.Blue 4.Green
Big end side clearance mm (in) 0.160–0.262 (0.0063–0.0103)
Limit mm (in) 0.5 (0.0197)
Big end width mm (in) 26.788–26.840 (1.0547–1.0566)
Crankshaft pin width mm (in) 27.000–27.050 (1.0630–1.0649)
Crankshaft
Journal diameter mm (in) 39.976–40.000 (1.5739–1.5748)
Pin diameter mm (in) 41.976–42.000 (1.6526–1.6535)
Runout limit mm (in) 0.03 (0.0012)
Journal oil clearance mm (in) 0.024–0.053 (0.0009–0.0021)
Limit mm (in) 0.10 (0.0039)
Pin oil clearance mm (in) 0.020–0.056 (0.0008–0.0022)
Limit mm (in) 0.09 (0.0035)
Bearing color code 1.Brown 2.Black 3.Blue 4.Green 5.Yellow
(*1) The figures are for reference only.
2-7
Jet /pump
Power unit technical data / Jet pump unit technical data unit technical data
Electrical
Jet pump unit technical data

Jet pump unit
Model
Item Unit
FX HO
FX
Cruiser
HO
FX SHO
FX
Cruiser
SHO
1
Impeller housing
2
Inside diameter mm (in) 155.35–155.45 (6.116–6.120)
Limit 156.45 (6.159)
Impeller-to-housing clear-
mm (in) 0.35–0.45 (0.014–0.018)
ance
Clearance limit mm (in) 0.60 (0.024)
Impeller
Material
Blades number
Pitch angle degree 15.3
Stainless steel
3
17.6
3
Drive shaft
Runout limit
Nozzle
Diameter
mm (in)
mm (in)
0.3 (0.012)
86.60–87.20 (3.409–3.433)
4
Electrical technical data
Ignition system
FX
Model
FX
5
Item Unit
ECM unit
Output peak voltage
At cranking (loaded) V
HO
2.5
SHO
6
At 2000 r/min (loaded) V 2.6
At 3500 r/min (loaded)
Pickup coil
Output peak voltage
V 2.6
7
At cranking (unloaded) V 5.5
8
At cranking (loaded) V 4.7
Resistance (*1)
At 20 °C (68 °F)  459–561
9
2-8
A
SPEC
Specification
Charging system
Model
FX FX
Item Unit
HO SHO
Stator coil
Output peak voltage
At cranking (unloaded) V 8.3
At 2000 r/min (unloaded) V 36.4
At 3500 r/min (unloaded) V 64.7
Resistance (*1)
At 20 °C (68 °F)  0.31–0.38
Rectifier regulator
Output peak voltage
Control system
Model
FX FX
Item Unit
HO SHO
Oil pressure switch
Input voltage (*1) V 11.0–12.0
kPa (kgf/
Continuity pressure 128–166 (1.28–1.66, 18.6–24.1)
cm2, psi)
Thermoswitch
Input voltage (*1) V 11.0–12.0
Continuity temperature °C (°F) 94–100 (201–212)
No continuity temperature °C (°F) 80–94 (176–201)
Thermo sensor
Input voltage V 4.75–5.25
Resistance (*1)
At 0 °C (32 °F) k 24.0–37.1
At 100 °C (212 °F) k 0.87–1.18
Engine temperature sensor
Resistance (*1)
At 20 °C (68 °F) k 54.2–69.0
At 100 °C (212 °F) k 3.12–3.48
Intake air temperature sensor
Resistance (*1)
At 0 °C (32 °F) k 5.4–6.6
At 80 °C (176 °F) k 0.29–0.39
2-9
Model
FX FX
Item Unit
Intake air pressure sensor

Input voltage
Knock sensor
V
HO
4.75–5.25
SHO
1
Resistance (*1)
TPS
At 20 °C (68 °F)
Output voltage
k — 504.0–616.0
2
With throttle lever fully
3
closed
TPS 1 V 0.6–0.9
open
TPS 2 V 4.5–4.8
Throttle valve opening angle
closed
degree 2–8 4
degree More than 70
open
APS
Input voltage
Output voltage
V 4.75–5.25
5
closed
APS 1
APS 2
V
V
0.68–0.74
0.68–0.74 6
open
7
APS 1 V 3.95–4.15
APS 2 V 3.95–4.15
Input voltage
APS 1 V 4.75–5.25
APS 2 V 4.75–5.25
APS full close switch
ETV relay
Input voltage
Cam position sensor
V
V
4.75–5.25
12 (battery voltage)
8
Output voltage
Position b, d
Position c
V
V
More than 4.8
Less than 0.8
9
Slant detection switch
A
2-10
SPEC
Specification
Model
FX FX
Item Unit
HO SHO
Steering sensor
Electric bilge pump
Input voltage V 12 (battery voltage)
ECM unit
Fuel system
Model
FX FX
Item Unit
HO SHO
Fuel injector
Resistance (*1)
At 20 °C (68 °F)  11.5–12.5
Fuel pump module
Fuel sender resistance (*1)
At 20 °C (68 °F)
Lower position  133.5–136.5
Upper position  5.0–7.0
Starting system
Model
FX FX
Item Unit
HO SHO
Fuse
Rating
Battery V/A 12/30
Main and fuel pump relay
V/A 12/20
(main side)
V/A 12/10
(fuel pump side)
ETV relay V/A 12/10
Remote control receiver V/A 12/3
2-11
Model
FX FX
Item Unit
Starter motor
Type
Output kW
HO
Constant mesh
0.6
SHO
1
Cranking time limit seconds 30
Commutator diameter
Commutator undercut (*1)
Brush length
mm (in)
mm (in)
mm (in)
27–28 (1.06–1.10)
0.2–0.7 (0.008–0.028)
5.0–12.5 (0.20–0.49)
2
Meter system
FX
Model
FX
3
Item Unit
Remote control transmitter

Battery
HO SHO
4
Type CR2016
5
Rating V 3
Remote control receiver
Output voltage (*1) V 11.0–12.0
Multifunction meter unit
Input voltage
Buzzer
Input voltage (*1)
Speed and water temperature
V
V
12 (battery voltage)
11.0–12.0
6
sensor
Output voltage (on pulse)
Water temperature sensor

mV
V
—
—
Less than 400
More than 4.5 7
resistance
At 20 °C (68 °F) k — 54.2–69.0
Speed sensor
Output voltage (on pulse)

mV
V
Less than 400
More than 11.6
—
—
8
9
2-12
A
SPEC
Specification
Specified tightening torque

Specified tightening torques are provided for specific nuts, bolts, and screws. When tightening these
fasteners, follow the tightening torque specifications indicated throughout the manual to meet the
design aims of the watercraft.
(*1) FX HO FX, Cruiser HO only

(*2) FX SHO FX, Cruiser SHO only
Fuel system
Tightening torques
Part to be tightened Screw size
N·m kgf·m ft·lb
Air intake pipe clamp — 3.5 0.35 2.58
Air filter case bracket nut — 17 1.7 12.5
Air filter case bolt M8 13 1.3 9.6
Fuel rail bolt M8 13 1.3 9.6
ETV nut (*1) — 13 1.3 9.6
ETV joint bolt (*1) M8 24 2.4 17.7
1st 3.5 0.35 2.58
Fuel pump module nut —
2nd 7 0.7 5.2
Fuel filler neck nut — 6 0.6 4.4
Fuel filler hose clamp — 4 0.4 3.0
Power unit
Tightening torques
N·m kgf·m ft·lb
Engine cover screw M6 5 0.5 3.7
Rectifier regulator bolt M8 26 2.6 19.2
Rectifier regulator cover bolt M6 13 1.3 9.6
1st 23 2.3 17.0
M8
2nd 42 4.2 31.0
Stay bolt
1st 23 2.3 17.0
M10
2nd 42 4.2 31.0
Engine cover stay bolt (*2) M6 10 1.0 7.4
Pipe clamp — 2.5 0.25 1.84
1st 20 2.0 14.8
Exhaust manifold bolt 2nd M8 20 2.0 14.8
3rd 35 3.5 25.8
Oil filter — 18 1.8 13.3
Electrical box bolt M8 17 1.7 12.5
Engine mounting bolt M8 17 1.7 12.5
Engine mount bolt M8 17 1.7 12.5
Damper 1 bolt M6 5.5 0.55 4.06
Damper 2 bolt M6 5.5 0.55 4.06
Exhaust pipe 3 — 200 20.0 147.5
Thermo sensor — 20 2.0 14.8
2-13
Tightening torques
N·m kgf·m ft·lb
1st 20 2.0 14.8
Exhaust pipe 1 bolt
Exhaust pipe 2 bolt

2nd
3rd
1st
2nd
M8
M8
20
35
15
29
2.0
3.5
1.5
2.9
14.8
25.8
11.1
21.4
1
Starter motor lead nut — 7 0.7 5.2
Slant detection switch screw
Starter relay bolt
ECM bolt
M6
M6
M6
4
4
5
0.4
0.4
0.5
3.0
3.0
3.7
2
Fuse box assy. bolt M6 8 0.8 5.9
Boost pipe joint 1 clamp (*2)
Boost pipe joint 2 clamp (*2)
Boost pipe bolt (*2)
Air cooler intake pipe clamp (*2)
—
—
M8
—
3.5
3.5
20
4
0.35
0.35
2.0
0.4
2.58
2.58
14.8
3.0
3
1st 23 2.3 17.0
4
Air cooler nut (*2) —
2nd 42 4.2 31.0
1st 23 2.3 17.0
Air cooler bolt (*2) M10
2nd 42 4.2 31.0
1st 23 2.3 17.0
Stud bolt (*2) —
2nd 42 4.2 31.0
Air cooler stay bolt (*2)
Supercharger bolt (*2)
Supercharger bolt (*2)
M10
M6
M8
42
10
20
4.2
1.0
2.0
31.0
7.4
14.8
5
Supercharger oil filler hole bolt M5 4 0.4 3.0
Intake manifold bolt
Intake manifold nut

1st
2nd
1st
2nd
M8
—
10
20
10
20
1.0
2.0
1.0
2.0
7.4
14.8
7.4
14.8
6
1st 10 1.0 7.4
7
Stud bolt —
2nd 20 2.0 14.8
Intake air temperature sensor — 15 1.5 11.1
1st 15 1.5 11.1
Intake manifold stay bolt M8
2nd 30 3.0 22.1
ETV nut (*2) — 13 1.3 9.6
ETV joint bolt (*2)
Oil pipe bolt (*2)
Oil pump assy. bolt
M8
M10
M6
24
21
11
2.4
2.1
1.1
17.7
15.5
8.1
8
Oil pump drive gear bolt (left-hand threads) (*1) M12 80 8.0 59.0
Oil cooler assy. bolt
Oil cooler cover bolt
Oil cooler cover bolt
Drive gear assy. bolt (left-hand threads) (*2)
M8
M6
M8
M12
19
12
20
80
1.9
1.2
2.0
8.0
14.0
8.9
14.8
59.0
9
Oil filter joint bolt — 18 1.8 13.3
Spark plug — 25 2.5 18.4
2-14
A
SPEC
Specification
Tightening torques
N·m kgf·m ft·lb
Cam position sensor bolt M6 10 1.0 7.4
Engine cover grommet bolt (*1) M6 6 0.6 4.4
Camshaft sprocket bolt M7 18 1.8 13.3
Camshaft cap bolt M7 16 1.6 11.8
Oil pipe bolt M10 20 2.0 14.8
Timing chain tensioner bolt M6 10 1.0 7.4
Chain guide plate bolt M6 10 1.0 7.4
Engine hanger bolt (*1) M10 42 4.2 31.0
Engine hanger bolt M6 12 1.2 8.9
1st 55 5.5 40.6
Cylinder head bolt M12
2nd 90°
Cylinder head bolt M6 10 1.0 7.4
Holder (left-hand threads) — 80 8.0 59.0
Drive coupling — 250 25.0 184.4
Generator cover assy. bolt M8 26 2.6 19.2
Flywheel magneto bolt M8 24 2.4 17.7
Special nut — 250 25.0 184.4
1st 50 5.0 36.9
Transfer shaft 2nd — 60°
3rd 250 25.0 184.4
Holder bolt M6 15 1.5 11.1
Stator coil assy. bolt M6 15 1.5 11.1
Plate bolt (*1) M6 11 1.1 8.1
Oil level pipe plate bolt (*1) M8 19 1.9 14.0
Anode cover bolt M8 20 2.0 14.8
Engine temperature sensor — 15 1.5 11.1
Knock sensor (*2) — 15 1.5 11.1
1st 0.3 0.03 0.2
Oil pipe stay bolt M6
2nd 12 1.2 8.9
Oil pipe bolt M6 9 0.9 6.6
Baffle plate bolt M6 12 1.2 8.9
Oil pressure switch lead bolt M4 2 0.2 1.5
Oil pressure switch — 9 0.9 6.6
Oil pan assy. bolt M6 10 1.0 7.4
Oil pan plug M8 20 2.0 14.8
1st 51 5.1 37.6
Connecting rod nut —
2nd 90°
Engine mount bracket bolt M10 50 5.0 36.9
1st 30 3.0 22.1
Crankcase bolt M10
2nd 90°
Crankcase bolt M6 10 1.0 7.4
Baffle plate bolt M6 10 1.0 7.4
2-15
Jet pump unit
Tightening torques
N·m kgf·m ft·lb
Intake grate bolt
Ride plate bolt
Speed sensor screw
M8
M8
M5
17
17
4
1.7
1.7
0.4
12.5
12.5
3.0
1
Steering cable joint nut — 7 0.7 5.2
2
Spout hose clamp (hull end) — 2 0.2 1.5
Rubber plate bolt M6 7 0.7 5.2
Rubber plate nut — 7 0.7 5.2
M8 17 1.7 12.5
Jet pump unit assy. bolt
M10 40 4.0 29.5
Bracket bolt
Reverse gate assy. bolt
Spring nut
Ball joint nut
M8
M8
—
—
15
20
8
8
1.5
2.0
0.8
0.8
11.1
14.8
5.9
5.9
3
Jet thrust nozzle bolt M8 16 1.6 11.8
Impeller duct bolt
Water inlet cover/water inlet strainer bolt
Impeller
M10
M6
—
40
7
330
4.0
0.7
33.0
29.5
5.2
243.4
4
Drive shaft nut — 74 7.4 54.6
5
Flushing hose nut — 6 0.6 4.4
Transom plate nut — 26 2.6 19.2
Hose joint bolt M6 3.5 0.35 2.58
Intermediate housing assy. bolt M8 17 1.7 12.5
Driven coupling — 205 20.5 151.2
Grease nipple
Electrical system
— 3 0.3
Tightening torques
2.2
6
N·m kgf·m ft·lb
Starter motor cover bolt
Starter motor terminal nut
Transmitter cover tapping screw
M6
—
M2
7
9
0.1
0.7
0.9
0.01
5.2
6.6
0.07
7
Hull and hood
Part to be tightened
Upper handlebar cover tapping screw

Screw size
M4
N·m
1
Tightening torques
kgf·m
0.1
ft·lb
0.7
8
Handlebar grip bolt M5 3.5 0.35 2.58
Handlebar grip end bolt
Left handlebar switch screw
Throttle lever assy. bolt
Handlebar holder bolt
M5
M5
M5
M8
7
3.5
3.5
20
0.7
0.35
0.35
2.0
5.2
2.58
2.58
14.8
9
Q.S.T.S. cable locknut (grip end) — 16 1.6 11.8
Steering boss cover screw M6 1 0.1 0.7
2-16
A
SPEC
Specification
Tightening torques
N·m kgf·m ft·lb
Mirror bolt M6 5 0.5 3.7
Mirror bolt M8 13 1.3 9.6
Hood lock bolt M5 4 0.4 3.0
Hood lock screw M5 1.5 0.15 1.11
Front hood screw M5 2 0.2 1.5
Hinge nut M6 5 0.5 3.7
Hinge bolt M6 5 0.5 3.7
Damper nut M6 5 0.5 3.7
Damper bracket bolt M6 5 0.5 3.7
Multifunction meter cover screw M5 2 0.2 1.5
Multifunction meter bolt M6 4 0.4 3.0
Hood lock hook bolt M6 4 0.4 3.0
Shift lever screw M6 5 0.5 3.7
Side cover bolt M6 5 0.5 3.7
Side cover screw M6 5 0.5 3.7
Ornament bolt M6 5 0.5 3.7
Shift lever bolt M6 5 0.5 3.7
Center cover bolt M6 5 0.5 3.7
Center console screw M6 5 0.5 3.7
Center console bolt M6 5 0.5 3.7
Steering master assy. nut M8 21 2.1 15.5
Cable stopper bolt M6 7 0.7 5.2
Steering arm bolt M8 16 1.6 11.8
Ball joint nut M6 7 0.7 5.2
Compass nut M5 4 0.4 3.0
Steering boss cover bracket bolt M5 4 0.4 3.0
Buzzer bracket bolt M5 4 0.4 3.0
Steering sensor bolt M6 7 0.7 5.2
Shift lever assy. nut M6 5 0.5 3.7
Steering cable joint locknut — 7 0.7 5.2
Speed sensor lead grommet nut — 6 0.6 4.4
Shift cable bracket nut M6 5 0.5 3.7
Shift cable holder nut M6 5 0.5 3.7
Steering cable locknut (hull) — 7 0.7 5.2
Shift cable locknut (hull) — 7 0.7 5.2
Shift cable locknut — 4 0.4 3.0
Q.S.T.S. cable locknut (hull) — 7 0.7 5.2
Q.S.T.S. converter bolt M6 5 0.5 3.7
Seat lock assy. bolt M6 6 0.6 4.4
Projection nut M10 26 2.6 19.2
Handgrip nut M8 5 0.5 3.7
Deck beam nut M8 16 1.6 11.8
Seat holder nut M6 5 0.5 3.7
Cooling water pilot outlet nut — 4 0.4 3.0
2-17
Torque
Specified tightening wrench
torque reading
/ General (setting torque
tightening value)
Tightening torques
N·m kgf·m ft·lb
Rubber hose nut M6 5 0.5 3.7
Rubber hose clamp
Ski tow nut
Spout nut
Stern eye nut
—
M8
—
M8
3.7
16
5
16
0.37
1.6
0.5
1.6
2.73
11.8
3.7
11.8
1
Drain plug nut M5 2 0.2 1.5
Reboarding step assy. bolt
Bow eye bolt
Bow eye nut
M8
M6
—
16
13
18
1.6
1.3
1.8
11.8
9.6
13.3
2
Stern storage bolt M8 5 0.5 3.7
Stern grip bolt
Stern grip nut
Front protector nut
Cleat bolt
M6
M8
M6
M6
5
5
5
2
0.5
0.5
0.5
0.2
3.7
3.7
3.7
1.5
3
Sponson bolt M8 16 1.6 11.8
Torque wrench reading (setting

value)
T
Am
Specified tightening torque (N·m)
SST length (m)
4
The correct setting value of the torque Bm Torque wrench length (m)
wrench varies depending on its length.
When tightening bolts, nuts, or parts using
the SST as an extension to the torque
wrench, use the following calculation formula
General tightening torque
This chart indicates the tightening torques for
standard fasteners with a standard ISO
5
to obtain the correct setting value. thread pitch.
When tightening bolts, nuts, or parts

using an extension to the torque wrench,
Width
across
flats (A)
8 mm
Screw
size (B)
M5
General torque
specifications
N·m kgf·m ft·lb
5 0.5 3.7
6
do not set the torque wrench to the speci-
10 mm M6 8 0.8 5.9
7
fied tightening torque. If an extension is
attached to the torque wrench, the actual 12 mm M8 18 1.8 13.3
tightening torque will be greater than the 14 mm M10 36 3.6 26.6
setting value on the torque wrench. 17 mm M12 43 4.3 31.7
8
Am Bm 9
Torque wrench setting value
= T ÷ (A m + B m)  B m
2-18
A
SPEC
Specification
Cable and hose routing

Starboard bow view
a b c
e
f
g
h
i
o
n
m j
l k
a Right handlebar switch lead j Fuel tank breather hose (water separator
b Throttle lever assy. lead to ventilation socket)
c Left handlebar switch lead k Fuel tank breather hose (fuel tank to water
d Q.S.T.S. cable separator)
e Reverse sensor lead l Remote control receiver antenna
f Left operation button lead m Wiring harness
g Steering sensor lead n Speed sensor lead
h Buzzer lead o Shift cable
i Right operation button lead (FX Cruiser p Steering cable
SHO) q Electric bilge pump lead
2-19
Top view
l
i
1
f g
t
h
k
u
j
2
c
e
b 3
m
a
q
4
w
s
p
5
v
n
r
o
6
d
7
a Right handlebar switch lead
b Throttle lever assy. lead
c Left handlebar switch lead
j Fuel tank breather hose (water separator
to ventilation socket)
k Fuel tank breather hose (fuel tank to water
8
d Q.S.T.S. cable separator)
9
e Reverse sensor lead l Remote control receiver antenna
f Left operation button lead m Wiring harness
g Steering sensor lead n Speed sensor lead
h Buzzer lead o Steering cable
i Right operation button lead (FX Cruiser p Electric bilge pump lead
A
SHO) q Electric bilge pump coupler
r Battery breather hose
2-20
SPEC
Specification
l
i
f g
t
h u
k
j
e
c
b
m
a
q
s v
r
n
o
d
s Shift cable
t Fuel sender lead
u Fuel pump module lead
v Positive battery lead
w Negative battery lead
2-21
Port view
1
t g h f e b c a j n q u w v p x 2
3
4
5
6
k i s d l r o m
7
a Right handlebar switch lead
b Throttle lever assy. lead
c Left handlebar switch lead
j Fuel tank breather hose (fuel tank to water
separator)
k Remote control receiver antenna
8
d Q.S.T.S. cable l Wiring harness
9
e Reverse sensor lead m Speed sensor lead
f Steering sensor lead n Steering cable
g Left operation button lead o Electric bilge pump lead
h Buzzer lead p Battery breather hose
i Fuel tank breather hose (water separator q Positive battery lead
A
to ventilation socket) r Negative battery lead
s Shift cable
2-22
SPEC
Specification
t g h f e b c a j n q u w v p x
k i s d l r o m
t Multifunction meter lead

u Bilge hose (hose joint to drain joint)
v Bilge hose (electric bilge pump to hose
joint)
w Bilge hose joint to drain joint
x Flushing hose
2-23
MNT
Maintenance 3
Maintenance interval chart ............................................... 3-1
Periodic service ................................................................. 3-2

Jet thrust nozzle angle check .................................................... 3-2
1
Jet thrust nozzle angle adjustment ............................................ 3-2
Steering master check ............................................................... 3-2
Shift cable and reverse gate check ........................................... 3-3
Shift cable adjustment ............................................................... 3-3
Q.S.T.S. mechanism check ....................................................... 3-3
2
Q.S.T.S. rod adjustment ............................................................ 3-4
3
Fuel tank check ......................................................................... 3-4
Water separator check .............................................................. 3-4
Spark plug check ....................................................................... 3-5
Engine oil level check ................................................................ 3-5
Engine oil replacement .............................................................. 3-6
Oil filter replacement ................................................................. 3-7
Trolling speed check ................................................................. 3-7
Nut and bolt check ..................................................................... 3-7
Valve clearance measurement .................................................. 3-7
Impeller check ........................................................................... 3-9
4
Water inlet strainer check .......................................................... 3-9
Battery check ............................................................................. 3-9
Bilge strainer check ................................................................. 3-10
Electric bilge pump strainer check ........................................... 3-10
Drain plug check ...................................................................... 3-11
5
Throttle valve lubrication (FX SHO, FX Cruiser SHO) ............. 3-11
Throttle valve lubrication (FX HO, FX Cruiser HO) ................. 3-11
Q.S.T.S. cable (handlebar end) lubrication ............................. 3-12
Q.S.T.S. cable (converter end) and
Q.S.T.S. rod joint lubrication ................................................... 3-12
Nozzle pivot bolt and steering cable lubrication ...................... 3-12
6
Steering cable and steering cable joint lubrication .................. 3-12
Shift lever assy., shift cable, and
shift cable joint lubrication ....................................................... 3-12
Intermediate housing lubrication ............................................. 3-13 7
8
9
A
MNT
Maintenance
Maintenance interval chart

The following chart should be considered strictly as a guide to general maintenance intervals.
Depending on the operating conditions, the maintenance intervals should be changed.
Maintenance interval Initial Thereafter every
10 100 200
50 hours See
hours hours hours
page
6 12 12 24
Item
months months months months
Spark plugs Check, clean,
  3-5
replace
Lubrication points Lubricate 3-12
3-12
 3-12
3-12
3-12
Internal engine Spray lubricant 3-11

components 3-11
Intermediate housing Lubricate   3-13
Fuel system Check  4-14
Fuel tank Check, clean  3-4
Engine idling speed Check, adjust  3-7
Throttle shaft Check 4-10

5-49
Water inlet strainer Check, clean  3-9
Bilge strainer Clean  3-10
Electric bilge pump Clean
 3-10
strainer
Impeller Check  3-9
Jet thrust nozzle Check, adjust 3-2

angle 3-2
Steering master Check, adjust   3-2
Q.S.T.S. mechanism Check, adjust 3-3
 
3-4
Shift cable and Check, adjust 3-3

reverse gate 3-3
Stern drain plugs Check, replace  3-11
Battery Check, charge  3-9
Rubber coupling Check  6-20
Engine mount Check  5-19
Nuts and bolts Check   3-7
Air filter element Check  4-6
Engine oil Replace 3-5
 
3-6
Oil filter Replace  3-7
Valve clearance Check, adjust  3-7
3-1
Maintenance interval chart / Periodic service
Periodic service
Jet thrust nozzle angle check
1. Set the Q.S.T.S. grip to the neutral posi-
tion.
2. Turn the handlebar lock to lock.

a b
1
3. Measure distances a and b. Adjust if
2
out of specification.
a b 3
c
Difference of distances a and b:

Maximum 5 mm (0.2 in) Turn in
Turn out
Distance a is increased.
Distance b is increased.
4
Jet thrust nozzle angle adjustment
6. Connect the steering cable joint b to the
5
tion. ball joint c, and then tighten the locknut
a to the specified torque.
2. Remove the service lid. Locknut a: 7 N·m (0.7 kgf·m, 5.2 ft·lb)
3. Loosen the locknut a. 7. Check the difference of distances a and
4. Disconnect the steering cable joint b

from the ball joint c.
b again.
8. Install the service lid.

6
5. Turn the steering cable joint b in or out Steering master check
to adjust distances a and b.
WARNING! The steering cable joint
must be screwed in more than 8 mm
(0.31 in) c.
1. Turn the handlebars to the right and left
several times to make sure that operation
is smooth and unrestricted throughout
7
the whole range, and that the free play is
not excessive.
b
c
8
a
9
3-2
A
MNT
Maintenance
Shift cable and reverse gate check 5. Turn the shift cable joint b in or out until
1. Set the shift lever to the reverse position. the specified distance b between the
center of the shift cable joint and the
2. Check that the reverse gate a contacts center of the ball joint c is obtained.
the stopper a. WARNING! The shift cable joint must
be screwed in more than 8 mm
(0.31 in) c.
a
a c
b
a b
a
3. Adjust the shift cable joint if the reverse

gate a does not contact the stopper a.
Shift cable adjustment

1. Set the shift lever to the reverse position.
2. Loosen the locknut a.
3. Disconnect the shift cable joint b from

the ball joint c. c
Turn in Distance b is decreased.

a
Turn out Distance b is increased.
Distance b: 7.0 mm (0.28 in)

c
6. Connect the shift cable joint b to the ball
b
joint c, and then tighten the locknut a to
the specified torque.
4. Position the reverse gate d so that it is Locknut a: 4 N·m (0.4 kgf·m, 3.0 ft·lb)
contacting the stopper a.
Q.S.T.S. mechanism check
d
tion.
2. Set the shift lever to the forward position.

a
3. Measure distances a and b. If the
distances a and b are not equal, adjust
the Q.S.T.S. rod.
d
3-3
Periodic service
1
c
Q.S.T.S. rod adjustment

b

Turn out
Turn in
Distance a is increased.
Distance b is increased.
2
tion.
3
6. Connect the Q.S.T.S. rod joint b to the
2. Set the shift lever to the reverse position. ball joint c, and then tighten the locknut
a to the specified torque.
3. Loosen the locknut a.
Locknut a: 4 N·m (0.4 kgf·m, 3.0 ft·lb)
4. Disconnect the Q.S.T.S. rod joint b from
the ball joint c.
b
Fuel tank check
1. Check for water in the fuel tank. Extract
the water and fuel if there is water in the
fuel tank.
4
a
c
a
5
5. Adjust the Q.S.T.S. rod joint b until the
distances a and b are equal.
6
WARNING! The Q.S.T.S. rod joint
7
must be screwed in more than 8 mm TIP:
(0.31 in) c. Use a commercially available siphon pump
a.
b
a Water separator check
1. Check the water separator a. Drain the
water if water has accumulated.
2. Check the O-ring b of the drain plug c.

8
Replace the O-ring if cracked or
9
damaged.
b
3-4
A
MNT
Maintenance
Specified spark plug (manufacturer):

a
LFR6A (NGK)
Spark plug gap b:
0.8–0.9 mm (0.031–0.035 in)
5. Install the spark plugs, and then tighten

them to the specified torque.
b
c Spark plug:
25 N·m (2.5 kgf·m, 18.4 ft·lb)
TIP: TIP:
To drain water from the water separator a, Before installing a spark plug, clean the gas-
loosen the drain plug b. ket surface and spark plug surface.
Spark plug check

Engine oil level check
1. Remove the spark plugs.
TIP:
• When starting the engine to check the
Be careful not to get water or any other for-
oil level on land, make sure to connect a
eign substances in the spark plug holes.
garden hose to the watercraft for proper
water supply.
2. Clean the electrodes a. • Make sure that debris or water does not
enter the oil filler hole.
3. Check the electrodes a. Replace the
spark plug if damaged or worn.
1. Place the watercraft in a horizontal posi-
tion.
a
TIP:
If the engine was running, allow the engine oil
to settle by waiting 5 minutes or more before
checking the oil level.
2. Remove the oil level gauge a, wipe the

gauge clean, and then insert the oil level
4. Measure the spark plug gap b. Replace gauge a into the oil level pipe
if out of specification. completely.
3. Remove the oil level gauge a again to

b check that the oil level is between the
minimum level mark a and the maximum
level mark b on the gauge.
3-5
Periodic service
A A FX SHO, FX Cruiser SHO

1
a Recommended engine oil:
YAMALUBE 4W or 4-stroke motor oil
b
API: SE, SF, SG, SH, SJ, SL
a SAE: 10W-30, 10W-40, 20W-40, 20W-50
6. If the engine oil is above the maximum
B
level mark b, extract oil using an oil
changer to lower it to the correct level. 2
a Engine oil replacement
b
a
Be careful when handling the engine oil to
avoid burns. The engine oil is hot immedi-
3
ately after the engine is turned off.

• When starting the engine to check the
oil level on land, make sure to connect a
4
4. If the engine oil is below the minimum garden hose to the watercraft for proper
level mark a, remove the oil filler cap b,
and then add sufficient oil of the
recommended type to raise it to the
water supply.
• Make sure that debris or water does not
enter the oil filler hole.
5
correct level.
1. Place the watercraft in a horizontal posi-
5. Install the oil filler cap b.
A
tion.
2. Start the engine and warm it up for 5

minutes or more at engine idle speed.
6
b
3. Stop the engine.
4. Remove the oil filler cap and oil level

gauge.
7
B
b
5. Extract the oil using the oil changer a.
8
a 9
3-6
A
MNT
Maintenance
6. Add the recommended engine oil up to
Oil filter a:
the specified level through the oil filter
18 N·m (1.8 kgf·m, 13.3 ft·lb)
hole.
Recommended engine oil: TIP:
YAMALUBE 4W or 4-stroke motor oil Make sure to clean up any oil spills.
API: SE, SF, SG, SH, SJ, SL
SAE: 10W-30, 10W-40, 20W-40, 20W-50
4. Check the engine oil level. See “Engine
Engine oil quantity:
oil level check” (3-5).
Without oil filter replacement:
3.0 L (3.2 US qt, 2.6 Imp.qt) Trolling speed check
With oil filter replacement:
1. Place the watercraft in the water.
3.1 L (3.3 US qt, 2.7 Imp.qt)
7. Install the oil filler cap and oil level gauge.
minutes or more.
8. Check the engine oil level. See “Engine
3. Check the trolling speed using the
oil level check” (3-5).
tachometer of the multifunction meter or
using the YDIS. Check the ETV and APS
Oil filter replacement
if out of specification.
1. Place a rag under the oil filter a.
Trolling speed:
2. Remove the oil filter a. FX SHO, FX Cruiser SHO:
1150–1350 r/min
FX HO, FX Cruiser HO:
1200–1400 r/min
a
Nut and bolt check
b
1. Check the engine, deck, and hull for
loose nuts and bolts. Tighten if loose.
See “Specified tightening torque” (2-13).
Valve clearance measurement

Oil filter wrench b: YB-06830 Measure the valve clearance when the
Oil filter wrench b: 90890-06830 engine is cold.
3. Install the oil filter, and then tighten it to 1. Remove the ignition coils, spark plugs,
the specified torque. and cylinder head cover.
2. Install the special service tools a, b,

and c into spark plug hole #1.
b a c
a
b
Oil filter wrench b: YB-06830

Oil filter wrench b: 90890-06830
3-7
Periodic service
Gauge stand a: 90890-06725 IN EX

Dial gauge stand set b: YB-06585
Dial indicator gauge c: YU-03097 c d
Dial gauge needle b: 90890-06584
Dial gauge set c: 90890-01252
3. Position piston #1 at TDC by turning the

1
exhaust camshaft sprocket clockwise.
d Valve clearance (cold)

Intake c:
2
0.14–0.23 mm (0.0055–0.0091 in)
Exhaust d:
0.28–0.37 mm (0.0110–0.0146 in)
#1 #2 #3 #4
3
IN ✔ — ✔ —
b
a
EX ✔
✔: Specified cylinder
—: Not applicable
✔ — —
4
5. Install the special service tools a, b,
and c into spark plug hole #4.

exhaust camshaft sprocket 180°
5
clockwise.
#1 #2 #3 #4
7. Measure the intake and exhaust valve
4
clearances of the specified cylinders.
#1 #2 #3 #4
6
Camshaft wrench d: 90890-06724 IN — ✔ — ✔
TIP:
Check that the punch marks a on the cam-
EX —
—: Not applicable
— ✔ ✔
7
shafts are aligned with the marks b on the
8
camshaft caps. 8. Adjust the valve clearance if out of
specification. See “Valve clearance
4. Measure the intake and exhaust valve adjustment” (5-75).
9. Install the cylinder head cover, spark
9
plugs, and ignition coils. See “Cylinder
head cover” (5-64).
3-8
A
MNT
Maintenance
Impeller check
a
Make sure to remove the battery before

checking the jet pump unit. b
1. Remove the jet pump unit. See “Jet

pump unit removal” (6-4).
2. Check the impeller a. Replace if

damaged. 3. Install the water inlet strainer b and
water inlet cover a. See “Impeller
3. Measure the impeller-to-housing housing and impeller duct assy.” (6-9).
clearance a. Measure the impeller
housing inside diameter if the impeller-to- Battery check
housing clearance a is out of
specification. See “Impeller housing
check” (6-12). Battery electrolyte is poisonous and dan-
gerous, causing severe burns, etc. Elec-
a trolyte contains sulfuric acid. Avoid
contact with skin, eyes or clothing.
Antidotes
External: Flush with water.
Internal: Drink large quantities of water or
a milk. Follow with milk of magnesia, beaten
egg or vegetable oil. Call physician imme-
diately.
Eyes: Flush with water for 15 minutes and
Impeller-to-housing clearance a: get prompt medical attention.
0.35–0.45 mm (0.014–0.018 in) Batteries produce explosive gases. Keep
Limit: 0.6 mm (0.024 in) sparks, flame, cigarettes, etc., well away.
If using or charging the battery in an
4. Install the jet pump unit. See “Jet pump enclosed space, make sure that it is well
unit installation” (6-5). ventilated. Always shield your eyes when
working near batteries.
Water inlet strainer check KEEP OUT OF THE REACH OF CHIL-
1. Remove the water inlet cover a and DREN.
water inlet strainer b. See “Impeller
housing and impeller duct assy.” (6-9).
2. Check the water inlet strainer b. Clean if Be careful not to place the battery on its
contaminated. 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.
3-9
Periodic service
1. Remove the battery. NOTICE: When
removing the battery, disconnect the TIP:
negative battery lead first. Apply water resistant grease to the terminals
to minimize corrosion.
2. Check the battery electrolyte level. If the
level is at or below the minimum level
mark a, add distilled water until the level
Bilge strainer check
1. Remove the bilge strainer case a.
1
is between the maximum level mark b
and the minimum level mark a. 2. Check the bilge strainer. Clean if
contaminated.
2
b
a
a
a
a
3
3. Check the specific gravity of the
electrolyte. Charge the battery if below
specification.
TIP:
Remove the bilge strainer case a by pushing
4
Specific gravity at 20 °C (68 °F): 1.265 the hooks a on the bilge strainer inward.
4. Install the battery, and then install the

bands.
3. Install the bilge strainer case a.
Electric bilge pump strainer check

5
5. Connect the battery breather hose a,
1. Disconnect the negative battery lead a.
6
and then fasten it using the clamp b.
NOTICE: Make sure that the battery
2. Remove the band b and electric bilge
breather hose is connected properly
pump c.
and is not obstructed.
3. Check the bilge strainer d. Clean if
6. Connect the positive battery lead c, and
then connect the negative battery lead
d. NOTICE: Connect the positive
battery lead to the battery terminal
contaminated.
a 7
first.
b
c b
d
8
9
a
c 4. Install the electric bilge pump c and
d
band b.
a
5. Connect the negative battery lead a.
3-10
A
MNT
Maintenance
Drain plug check
1. Check the O-ring a of each drain plug
b.
b a
a
Recommended lubricant: Rust inhibitor
b
3. Connect the blowby hose b, and then
fasten it using the clamp a.
Throttle valve lubrication (FX SHO,
FX Cruiser SHO) Throttle valve lubrication (FX HO, FX
Cruiser HO)
1. Loosen the air intake pipe clamp a, and
When lubricating the engine internal com- then disconnect the air intake pipe b.
ponents on land, make sure to supply suf-
ficient water and water pressure to the
a
cooling water passage. Otherwise, the b
engine could overheat.
1. Remove the clamp a, and then discon-

nect the blowby hose b.
2. Spray a rust inhibitor into the throttle

valve opening a.
b
a
2. Start the engine, and then spray a rust

inhibitor into the air intake pipe hole a for
about 5 seconds while the engine is
running.
TIP: Recommended lubricant: Rust inhibitor

While spraying the rust inhibitor into the air
intake pipe, the engine speed will drop. 3. Connect the air intake pipe b, and then
tighten the air intake pipe clamp a.
Air intake pipe clamp a:
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
3-11
Periodic service
Q.S.T.S. cable (handlebar end) Recommended lubricant:
lubrication Yamaha grease A
1. Remove the left handlebar grip and
Q.S.T.S. grip.
2. Lubricate the Q.S.T.S. cable (handlebar

end).
TIP:
Disconnect the joint and apply a small
amount of grease.
1
Nozzle pivot bolt and steering cable
lubrication
1. Lubricate the nozzle pivot bolt and steer-
ing cable.
2
3
Recommended lubricant: Rust inhibitor
4
Recommended lubricant:
Yamaha grease A
Steering cable and steering cable

joint lubrication
5
1. Lubricate the steering cable and steering
Yamaha grease A
cable joint.
6
Q.S.T.S. cable (converter end) and
Q.S.T.S. rod joint lubrication
1. Lubricate the Q.S.T.S. cable (converter
end) and Q.S.T.S. rod joint. 7
Yamaha grease A
8
Shift lever assy., shift cable, and shift
cable joint lubrication
1. Remove the side cover. See “Side cover
removal” (8-13).
9
2. Lubricate the shift lever assy., shift cable,
and shift cable joint.
3-12
A
MNT
Maintenance
Yamaha grease A
TIP:
Disconnect the joint and apply a small
amount of grease.
3. Install the side cover. See “Side cover

installation” (8-13).
Intermediate housing lubrication

1. Lubricate the intermediate housing
through the grease nipple a.
Yamaha grease A
3-13
FUEL
Fuel system 4
Air filter case and fuel hose

(FX SHO, FX Cruiser SHO) ............................................... 4-1
Air filter case and fuel hose

1
(FX HO, FX Cruiser HO) .................................................... 4-3
Fuel hose disconnection ............................................................ 4-5
Fuel pressure measurement ..................................................... 4-5
Fuel hose disassembly .............................................................. 4-6
Air filter element check .............................................................. 4-6
2
Fuel hose assembly .................................................................. 4-6
Fuel injector (FX SHO, FX Cruiser SHO) ......................... 4-8 3

ETV and fuel injector (FX HO, FX Cruiser HO) ................ 4-9
ETV check (FX HO, FX Cruiser HO) ....................................... 4-10
Fuel injector check .................................................................. 4-10
Fuel rail and injector installation .............................................. 4-10
4
Fuel tank and fuel pump module assy. ......................... 4-12
Fuel pump module removal ..................................................... 4-14
Fuel sender removal ................................................................ 4-14
Fuel pump module check ........................................................ 4-14
Check valve check .................................................................. 4-14
5
Fuel filler cap check ................................................................. 4-15
Fuel sender installation ........................................................... 4-15
Fuel pump module installation ................................................. 4-15
Fuel tank installation ................................................................ 4-16
6
7
8
9
A
FUEL
Fuel system
Air filter case and fuel hose (FX SHO, FX Cruiser SHO)
13 N·m (1.3 kgf·m, 9.6 ft·lb)

20
16
17
21
16 12 10
12
19 17 12
18 11
16 17 12
13
19 14
18 16
19 19 18 17
12
18 12
7
13 6
10 9
12
17 N·m (1.7 kgf·m, 12.5 ft·lb) 12
15
10
8
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
6
3
2
5 1
2 22
3
4
No. Part name Q’ty Remarks

1 Fuel hose assy. 1
2 Clamp 4 
3 Quick connector 2
4 Corrugated tube 1
5 Fuel hose 1
6 Clamp 2
7 Clamp 1
8 Air intake pipe 1
9 Connection 1
10 Bolt 4 M8  35 mm
11 Air filter case assy. 1
12 Hook 8
13 Screw 3 M6  15 mm
14 Air filter element 1
15 Drain tube 1
16 Collar 4
4-1
Air filter case and fuel hose (FX SHO, FX Cruiser SHO)
13 N·m (1.3 kgf·m, 9.6 ft·lb)

20
21
16
19 17
16
17
12 12
12
10
1
18 11
16 17 12
19
19
18 16
19 18 17
12
13
14
2
18 12
7
10
17 N·m (1.7 kgf·m, 12.5 ft·lb)
12
15
13
12
6 9
3
10
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

6
8
4
5
2
3
1 5
2 22
3
4
6
17
18
19
Grommet
Nut
Washer
4
4
4
7
20 Bracket 1
21 Plastic tie 1
22 Holder 1
8
9
4-2
A
FUEL
Fuel system
Air filter case and fuel hose (FX HO, FX Cruiser HO)
21 20
16 13 N·m (1.3 kgf·m, 9.6 ft·lb)
17
16 12 12
19 17 10
12
18 11
1617 12
13
19 14
18
16
19 19 17 12
18 18
12
13 9
10
17 N·m (1.7 kgf·m, 12.5 ft·lb) 12 1
12
15
10
7
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
8
4 7
3
6
2
3
4

1 Plastic tie 1
2 Fuel hose assy. 1
3 Clamp 4 
4 Quick connector 2
5 Corrugated tube 1
6 Fuel hose 1
7 Clamp 2
8 Air intake pipe 1
9 Connection 1
10 Bolt 4 M8  35 mm
11 Air filter case assy. 1
12 Hook 8
13 Screw 3 M6  15 mm
14 Air filter element 1
15 Drain tube 1
16 Collar 4
4-3
21 20
16 13 N·m (1.3 kgf·m, 9.6 ft·lb)
16
19 17
18
17
12 12
12
10
11
1
1617 12
13
19 19
19
18
18
16
17 12
14
2
18 12
10
17 N·m (1.7 kgf·m, 12.5 ft·lb) 12
15
13
12
9
1 3
10
4
7
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
6
3
4 7
2
5
3
4
5
6
17
18
19
Grommet
Nut
Washer
4
4
4
7
20 Bracket 1
21 Plastic tie 1
8
9
4-4
A
FUEL
Fuel system
Fuel hose disconnection
b
Before checking the fuel system, remove

the battery, and then remove the fuel filler
cap to reduce any pressure inside the fuel
tank.
1. Spread apart the ends of the retainer a,

and then pull the retainer up.
Fuel pressure measurement
1. Disconnect the quick connector from the
a
fuel rail.
2. Install the special service tools a and b.

A
2. Disconnect the quick connector a. b

WARNING! Make sure to disconnect
the quick connector slowly.
Otherwise, pressurized fuel could a
spray out.
B
a b
A U.S.A. and Canada

TIP: B Worldwide
Make sure to clean up any fuel spills. Fuel pressure gauge adapter a:
YB-06946/90890-06946
3. Cover the quick connector, fuel rail, and Fuel pressure gauge b:
fuel pipe using plastic bags b to protect YU-03153M/90890-06753
them from dirt.
minutes or more at engine idle speed.
4. Measure the fuel pressure. Replace the

fuel pump module assy. if out of
specification.
4-5
1. Install new clamps a and the quick con-
Fuel pressure:
nector b onto the fuel hose c.
345–370 kPa
(3.45–3.70 kgf/cm2, 49.1–52.6 psi)
Fuel hose disassembly

1. Remove the clamps a and quick con-
nector b. NOTICE: When cutting each
b
c
1
clamp, position the tool.
a
2
a
a a
3
b
Air filter element check

4
Do not start the engine with the air filter
element removed. Otherwise, the engine
TIP:
could be damaged.
1. Remove the air filter case cover and air

Make sure to face the locking slider a on
each quick connector in the same direction.
2. Crimp the clamps a.

5
filter element.
2. Check the air filter element. Replace if

damaged or dirty. 6
d
7
e a a
Fuel hose assembly

8
b
Do not reuse a clamp, always replace it

with a new one. Otherwise, fuel could
leak.
c
Distance b: 17 mm (0.67 in)

9
Distance c: 34.5 mm (1.36 in)
Distance d: 1 mm (0.04 in)
4-6
A
FUEL
Fuel system
TIP:
• Make sure to align the projection e on the
quick connector with the crimped section of
the clamp.
• Position the crimped sections of the clamps
180° away from each other.
4-7
Air filter case and fuel hose (FX HO, FX Cruiser HO) /
Fuel injector (FX SHO, FX Cruiser SHO)
Fuel injector (FX SHO, FX Cruiser SHO)
5
3
4 1
5
3
4
2
2
5
3
4
3
1
1
1 4
13 N·m (1.3 kgf·m, 9.6 ft·lb)
5
3
4
5
6
1
2
3
Bolt
Fuel rail
Fuel injector
3
1
4
M8  17 mm
7
4 Seal 4 
5 O-ring 4 
8
9
4-8
A
FUEL
Fuel system
ETV and fuel injector (FX HO, FX Cruiser HO)

13
11
12
13
11
10 12
9 13
11
12
9
9
13 N·m (1.3 kgf·m, 9.6 ft·lb)
13
11
12
13 N·m (1.3 kgf·m, 9.6 ft·lb)
7 5 1
A
7
8 4
3
2
5 3
5
6
A 5 2
24 N·m (2.4 kgf·m, 17.7 ft·lb) 3
3 2

1 Plastic tie 2
2 Nut 4
3 Washer 4
4 ETV 1
5 Bolt 4 M8  20 mm
6 Joint 1
7 Holder 1
8 Ribbon 1
9 Bolt 3 M8  17 mm
10 Fuel rail 1
11 Fuel injector 4
12 Seal 4 
13 O-ring 4 
4-9
ETV and fuel injector (FX HO, FX Cruiser HO)
ETV check (FX HO, FX Cruiser HO) a
• Do not disassemble the ETV.

• Do not loosen the throttle stop screw
nut a or turn the throttle stop screw b.
• Do not loosen or remove the throttle
1
valve shaft screws c.
a b
c
2. While turning the fuel injectors b slowly
to the left and right, install them to the
2
fuel rail c. NOTICE: Make sure to
apply a thin coat of engine oil to the O-
rings before installing the fuel
injectors to the fuel rail. Otherwise,
the O-rings could twist and break,
3
causing fuel leakage.
1. Turn the throttle valve manually and
check that it moves smoothly.
Fuel injector check

4
1. Check the fuel injector filter a. Clean b
using kerosene or gasoline if clogged or
contaminated.
a
c
5
3. Install new seals d and the fuel rail c,
and then tighten the fuel rail bolts e to
the specified torque. NOTICE: Do not
reuse a seal, always replace it with a
6
new one.
2. Measure the fuel injector resistance. See

“Fuel injector check” (7-29).
A d
7
Fuel rail and injector installation
1. Install new O-rings a onto the fuel injec-
tors, and then apply a thin coat of engine
oil to the O-rings.
c
8
e 9
4-10
A
FUEL
Fuel system
B d

Fuel rail bolt e:
13 N·m (1.3 kgf·m, 9.6 ft·lb)
4. Install the holders f, and then connect

the fuel injector couplers a and ignition
coil couplers b.
A a b
B a b

4-11
ETV and fuel injector (FX HO, FX Cruiser HO) / Fuel tank and fuel pump module assy.
Fuel tank and fuel pump module assy.
a 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
1
b 7 N·m (0.7 kgf·m, 5.2 ft·lb)
18
19 20
2
5
6 1
14
12
10
15 4
1 23
2
16
13 11 9
16
16
15
17
16 3
1 21
22
3
7 26
17
4
8 7
6 N·m (0.6 kgf·m, 4.4 ft·lb)
24
27
5
4 N·m (0.4 kgf·m, 3.0 ft·lb)
25
28
25 6
1
2
3
Plastic tie
Breather hose
Breather hose
3
1
1
7
4 Check valve 1
5 Fuel filler cap 1
6
7
8
Packing
Clamp
Fuel filler hose
1
2
1

8
9 Nut 1
9
10 Fuel filler neck 1
11 Packing 1 
12 Tapping screw 1 M4  9 mm
13 Rivet 1
14 Chain ball 1
15
16
Strap
Rivet
2
4
4-12
A
FUEL
Fuel system
a 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

b 7 N·m (0.7 kgf·m, 5.2 ft·lb)
18
19 20
2
5
6 1
12 15 4
10
14 1 23
16
3 22
9 15 16
13 11
16 17
16 1 21
7 26
17
8 7
6 N·m (0.6 kgf·m, 4.4 ft·lb)
24
27
4 N·m (0.4 kgf·m, 3.0 ft·lb)
25 25
28

17 Hook 4
18 Nut 9
19 Retainer 1
20 Fuel pump module assy. 1
21 Packing 1 
22 Stopper 1
23 Fuel sender 1
24 Fuel tank 1
25 Pad 2 
26 Pad 4 
27 Pad 2 
28 Pad 1 
4-13
Fuel pump module removal
b
e
d
Before checking the fuel system, remove
the battery, and then remove the fuel filler
cap to reduce any pressure inside the fuel
tank.
1
1. Remove the fuel pump module assy. a.
NOTICE: When removing the fuel
pump module assy. a, make sure that
the rubber caps a do not come off.
Fuel pump module check 2
a Do not disassemble the fuel pump mod-
ule.
1. Check the fuel pump filter a. Clean

3
b a
using kerosene or gasoline if clogged or
contaminated.
a
4
5
TIP:
Remove the fuel pump module assy. a at an
angle so that the float b does not catch on
the fuel tank.
Fuel sender removal

1. Disconnect the fuel sender coupler a.
2. Squeeze the hooks b on the stopper a,

Check valve check
1. Blow into the end a of the check valve,
6
and then slide the stopper in direction c and check that airflow from the end b is
7
to remove it. unrestricted. Replace if the air flow is
restricted.
a
a 2. Blow into the end b of the check valve,
c and check that airflow from the end a is
restricted. Replace if the air flow is
a
b
unrestricted.
A a B b
8
3. Push the tabs d on the fuel sender b,
and then slide the fuel sender in direction
e to remove it.
9
A
b a
4-14
FUEL
Fuel system
A Upright
B Inverted b
b
Fuel filler cap check
1. Install the fuel filler cap a onto the fuel
filler neck b, and then hold the fuel filler c
neck b.
d
2. Turn the fuel filler cap a clockwise a
and check that it clicks when tightened
completely. Replace if it does not click.
TIP:
Make sure that the hooks d on the stopper
b are hooked securely onto the fuel pump
a
a module.
Fuel pump module installation

1. Install a new packing and the fuel pump
module assy. a. NOTICE: When
b installing the fuel pump module assy.
a, make sure that the rubber caps a
Fuel sender installation do not come off.
1. Install the fuel sender a.
a
a
a b a
b b
TIP:
TIP: Make sure to insert the float b into the fuel
Make sure that the tabs a on the fuel sender tank.
a are seated securely into the slots b in the
fuel pump module. 2. Install the retainer b, and then tighten
the fuel pump module nuts c to the
2. Install the stopper b, and then connect specified torques in 2 stages and in the
the fuel sender coupler c. order a, b, and so on.
b
b c
e
g
i
h
d a f
4-15
Fuel pump module nut c: Fuel filler neck nut f:

1st: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 7 N·m (0.7 kgf·m, 5.2 ft·lb)
Fuel tank installation

1. Install the fuel tank a, and then fasten
the fuel tank using the straps b.
TIP:
Align the protrusion c on the fuel filler neck
d with the holes d in the packing c and
deck.
1
a b
b
a
b
4. Install the fuel filler hose g, and then
tighten the fuel filler hose clamps h to
2
5. Check that the distance e is within
3
b
specification.
b h
a e c
f
g
h
4
h
TIP:
g 5
• Install the straps b so that the rubber band
portions a of the straps are positioned on
top.
• Make sure that the metal loops b on the
end of the straps b are hooked securely
Fuel filler hose clamp h:
4 N·m (0.4 kgf·m, 3.0 ft·lb) 6
onto the holders on the hull. Distance e: 25–35 mm (1.0–1.4 in)
2. Install a new packing c, fuel filler neck

d, and the fuel filler cap e.
TIP:
Align the arrow mark f on the fuel filler hose
g with the protrusion c on the fuel filler
7
3. Tighten the fuel filler neck nut f to the neck.
8
specified torque.
6. Connect the fuel sender coupler g and
e
fuel pump module coupler h.
c
d 7. Install the fuel tank breather hoses i
c
d
f
and check valve j.
8. Fasten the fuel tank breather hoses i

using the plastic ties k.
9
4-16
A
FUEL
Fuel system
j
g
k k
h
i
TIP:
Point the arrow mark k toward the fuel tank.
4-17
— MEMO —
1
2
3
4
5
6
7
8
9
4-18
A
POWR
Power unit 5
Engine unit (check and adjustment) ................................ 5-1

Compression pressure check .................................................... 5-1
Engine unit (FX SHO, FX Cruiser SHO) ........................... 5-2
Engine unit (FX HO, FX Cruiser HO) ................................ 5-3
Exhaust manifold (FX SHO, FX Cruiser SHO) ................. 5-4
Exhaust manifold (FX HO, FX Cruiser HO) ..................... 5-6
Engine unit and coupling cover

(FX SHO, FX Cruiser SHO) ............................................... 5-8
Engine unit and coupling cover

(FX HO, FX Cruiser HO) .................................................... 5-9
Engine mount .................................................................. 5-10

Engine unit removal (FX SHO, FX Cruiser SHO) .................... 5-11
Engine unit removal (FX HO, FX Cruiser HO) ......................... 5-15
Engine mount and damper check ............................................ 5-19
Engine unit installation (FX SHO, FX Cruiser SHO) ................ 5-19
Engine unit installation (FX HO, FX Cruiser HO) .................... 5-25
Muffler .............................................................................. 5-31

Exhaust pipe disassembly ....................................................... 5-32
Exhaust pipe assembly ........................................................... 5-32
Wiring harness assy. (FX SHO, FX Cruiser SHO) ......... 5-33
Wiring harness assy. (FX HO, FX Cruiser HO) ............. 5-34
Electrical box ................................................................... 5-35

Starter motor and wiring harness assy. removal
(FX SHO, FX Cruiser SHO) ..................................................... 5-37
Starter motor and wiring harness assy. removal
(FX HO, FX Cruiser HO) ......................................................... 5-38
Thermostat check .................................................................... 5-39
Starter motor and wiring harness assy. installation
Starter motor and wiring harness assy. installation
Air cooler and supercharger assy. ................................ 5-42
Intake assy. (FX SHO, FX Cruiser SHO) ........................ 5-45
Intake assy. (FX HO, FX Cruiser HO) ............................. 5-47 1

ETV and intake manifold
(FX SHO, FX Cruiser SHO) ............................................. 5-48
Air cooler check (FX SHO, FX Cruiser SHO) .......................... 5-49
Supercharger check (FX SHO, FX Cruiser SHO) ................... 5-49
2
ETV check (FX SHO, FX Cruiser SHO) .................................. 5-49
Intake assy. installation (FX SHO, FX Cruiser SHO) .............. 5-49
Intake manifold installation (FX HO, FX Cruiser HO) .............. 5-50
Oil level pipe installation (FX SHO, FX Cruiser SHO) ............. 5-51
Supercharger installation (FX SHO, FX Cruiser SHO) ............ 5-52
Air cooler, air cooler intake hose, and boost pipe installation
3
Oil cooler and oil pump assy.

(FX SHO, FX Cruiser SHO) ............................................. 5-55
4
Idle gear assy. and drive gear assy.
(FX SHO, FX Cruiser SHO) ............................................. 5-57 5
Oil cooler, oil pump assy. and drive gear
(FX HO, FX Cruiser HO) .................................................. 5-58
Oil pump assy., idle gear assy., and drive gear assy. removal
Oil pump assy. and oil pump drive gear removal
6
Oil cooler assy. check ............................................................. 5-60
Oil pump assy. check .............................................................. 5-61
Idle gear check (FX SHO, FX Cruiser SHO) ........................... 5-61
Drive gear assy. check (FX SHO, FX Cruiser SHO) ............... 5-61
7
Drive gear assy., idle gear assy., and oil pump assy. installation
Oil pump drive gear and oil pump assy. installation
(FX HO, FX Cruiser HO) ......................................................... 5-62 8
Cylinder head cover ........................................................ 5-64
Camshaft (FX SHO, FX Cruiser SHO) ............................ 5-65 9

Camshaft (FX HO, FX Cruiser HO) ................................. 5-67
Camshaft removal ................................................................... 5-69
Camshaft sprocket removal ..................................................... 5-70
A
POWR
Camshaft check ....................................................................... 5-70
Camshaft journal oil clearance check ...................................... 5-71
Timing chain tensioner check .................................................. 5-72
Camshaft sprocket installation ................................................ 5-72
Camshaft installation ............................................................... 5-73
Valve clearance adjustment .................................................... 5-75
Valve pad selection table ........................................................ 5-78
Cylinder head .................................................................. 5-79
Valve and valve spring ................................................... 5-80

Cylinder head disassembly ..................................................... 5-81
Cylinder head check ................................................................ 5-81
Valve spring check .................................................................. 5-81
Valve check ............................................................................. 5-82
Valve guide check ................................................................... 5-82
Valve guide removal ................................................................ 5-83
Valve guide installation ............................................................ 5-83
Valve seat check ..................................................................... 5-84
Valve seat refacing .................................................................. 5-84
Cylinder head assembly .......................................................... 5-86
Cylinder head installation ........................................................ 5-88
Generator cover assy. and flywheel magneto .............. 5-89
Generator cover .............................................................. 5-91

Drive coupling removal ............................................................ 5-92
Flywheel magneto removal ..................................................... 5-92
Generator cover assy. disassembly ........................................ 5-94
Starter clutch operation check ................................................. 5-94
Generator cover assy. assembly ............................................. 5-95
Flywheel magneto installation ................................................. 5-96
Drive coupling installation ........................................................ 5-99
Cylinder block and electrical part

(FX SHO, FX Cruiser SHO) ........................................... 5-100
Cylinder block and electrical part

(FX HO, FX Cruiser HO) ................................................ 5-102
Oil separator tank and oil pan ...................................... 5-104

Anode check .......................................................................... 5-106
Oil pan assembly ................................................................... 5-106
Oil level pipe installation (FX HO, FX Cruiser HO) ................ 5-106
Oil separator tank cover installation ...................................... 5-107
Crankcase, connecting rod, and piston ...................... 5-108

Crankcase disassembly ........................................................ 5-110
Connecting rod and piston removal ....................................... 5-110
Crankcase check ................................................................... 5-111
Cylinder block check ............................................................. 5-111
Piston check .......................................................................... 5-111
Piston clearance check ......................................................... 5-111
Piston ring check ................................................................... 5-111
Piston pin check .................................................................... 5-112
1
Connecting rod check ............................................................ 5-113
Crankshaft check ................................................................... 5-113
Crankshaft pin oil clearance check ........................................ 5-113
Connecting rod big end side clearance check ....................... 5-114
Connecting rod bearing selection .......................................... 5-115
2
Crankshaft journal oil clearance check .................................. 5-116
3
Crankshaft bearing selection ................................................. 5-117
Connecting rod and piston installation .................................. 5-118
Crankcase assembly ............................................................. 5-120
4
5
6
7
8
9
A
POWR
Power unit
Engine unit (check and 8. Measure the compression pressure for

adjustment) all cylinders according to steps 5 and 6.
Compression pressure check Compression pressure (reference data):
Make sure that the battery voltage is more FX SHO, FX Cruiser SHO:
than 12 V. 610 kPa (6.1 kgf/cm2, 86.8 psi)
FX HO, FX Cruiser HO:
780 kPa (7.8 kgf/cm2, 113.1 psi)
When starting the engine to measure the
9. If the compression pressure is below
compression pressure on land, make sure
specification, squirt a few drops of engine
to connect a garden hose to the watercraft
oil into the cylinder and measure again.
for proper water supply.
Compression pressure
1. Place the watercraft in a horizontal posi- (with engine oil added into the cylinder)
tion. Reading Check
Higher than without Piston ring and
2. Start the engine and warm it up for 5 engine oil piston
minutes or more at engine idle speed. Same as without Valve clearance,
engine oil valve, valve seat,
3. Stop the engine. cylinder head, and
cylinder head
4. Remove the ignition coils and spark
gasket
plugs.
10. Install the spark plugs, and then tighten
5. Disconnect the fuel injector couplers. them to the specified torque.
Spark plug:
TIP:
25 N·m (2.5 kgf·m, 18.4 ft·lb)
Be careful not to get water or any other for-
eign substances in the spark plug holes. 11. Install the ignition coils.
6. Install the special service tools a and b. 12. Connect the fuel injector couplers.
a
b
Compression gauge a:
YU-33223/90890-03160
Compression gauge extension b:
90890-06563
7. Crank the engine until the reading on the

compression gauge stabilizes.
5-1
Engine unit (check and adjustment) / Engine unit (FX SHO, FX Cruiser SHO)
Engine unit (FX SHO, FX Cruiser SHO)
5 N·m (0.5 kgf·m, 3.7 ft·lb) 1

1
2
2
1
3
8 2
3
10
6
4
6
9 7
5
5
4
6
1
2
3
Screw
Grommet
Engine cover
2
2
1
M6  12 mm
7
4 Clamp 1
5 Breather hose 1
6
7
8
Antenna holder
Clamp
Clamp
3
1
1
8
9 Clamp 1
9
10 Clamp 1
5-2
A
POWR
Power unit
Engine unit (FX HO, FX Cruiser HO)
1
5 N·m (0.5 kgf·m, 3.7 ft·lb) 2
1
2
3
8
7
5

1 Screw 2 M6  12 mm
2 Grommet 2
3 Engine cover 1
4 Clamp 1
5 Breather hose 1
6 Antenna holder 3
7 Clamp 1
8 Clamp 1
5-3
Engine unit (FX HO, FX Cruiser HO) / Exhaust manifold (FX SHO, FX Cruiser SHO)
Exhaust manifold (FX SHO, FX Cruiser SHO)

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) 26 N·m (2.6 kgf·m, 19.2 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb)
b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
10 N·m (1.0 kgf·m, 7.4 ft·lb)
23
5
3
4
12
9 1
16 7
4 6
22
2
13
10
11
11
12
6 2
8 14 15 10
20
21
13 13 N·m (1.3 kgf·m, 9.6 ft·lb)
2.5 N·m (0.25 kgf·m, 1.84 ft·lb)
a 23 N·m (2.3 kgf·m, 17.0 ft·lb)
3
28 b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
28
19
4
24
18 N·m (1.8 kgf·m, 13.3 ft·lb)

27
18
25
5
26 17
a 20 N·m (2.0 kgf·m, 14.8 ft·lb)

b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
c 35 N·m (3.5 kgf·m, 25.8 ft·lb)
a 20 N·m (2.0 kgf·m, 14.8 ft·lb)
b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
c 35 N·m (3.5 kgf·m, 25.8 ft·lb)
6
1
2
3
Oil filter
Plastic tie
Plastic tie
1
1
1
7
4 Clamp 2
5 Cooling water hose 1
6
7
8
Clamp
Cooling water hose
Clamp
2
1
1
8
9 Bolt 2 M8  35 mm
9
10 Collar 2
11 Grommet 2
12 Bolt 4 M6  35 mm
13 Bolt 2 M6  25 mm
14 Rectifier regulator 1
15
16
Gasket
Cover
1
1

5-4
A
POWR
Power unit
a 23 N·m (2.3 kgf·m, 17.0 ft·lb) 26 N·m (2.6 kgf·m, 19.2 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb)
b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
5
10 N·m (1.0 kgf·m, 7.4 ft·lb) 4 9
3
23 12
16 7
4 6
11
10 12
22 13 6
11
2
8 14 15 10
13 13 N·m (1.3 kgf·m, 9.6 ft·lb)

20 2.5 N·m (0.25 kgf·m, 1.84 ft·lb)
21
a 23 N·m (2.3 kgf·m, 17.0 ft·lb)
28 b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
19
28
24
27
1
18
18 N·m (1.8 kgf·m, 13.3 ft·lb) 25
26 17
a 20 N·m (2.0 kgf·m, 14.8 ft·lb) a 20 N·m (2.0 kgf·m, 14.8 ft·lb)
b 20 N·m (2.0 kgf·m, 14.8 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
c 35 N·m (3.5 kgf·m, 25.8 ft·lb) c 35 N·m (3.5 kgf·m, 25.8 ft·lb)

17 Clamp 1
18 Clamp 1
19 Bolt 1 M10  50 mm
20 Bolt 1 M8  47 mm
21 Stay 1
22 Bolt 4 M6  12 mm
23 Stay 4
24 Clamp 1
25 Bolt 3 M8  120 mm
26 Bolt 8 M8  70 mm
27 Gasket 1 
28 Dowel pin 2
5-5
Exhaust manifold (FX SHO, FX Cruiser SHO) / Exhaust manifold (FX HO, FX Cruiser HO)
Exhaust manifold (FX HO, FX Cruiser HO)

26 N·m (2.6 kgf·m, 19.2 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb)
a 23 N·m (2.3 kgf·m, 17.0 ft·lb)

b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
3
4
3
11
8 1
15 6
5
2
12
9
10
10
11
5 2
7 13 14 9
19
20
12 13 N·m (1.3 kgf·m, 9.6 ft·lb)
2.5 N·m (0.25 kgf·m, 1.84 ft·lb)
a 23 N·m (2.3 kgf·m, 17.0 ft·lb)
3
25 b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
25
18
4
21
18 N·m (1.8 kgf·m, 13.3 ft·lb)

24
17
22
5
23 16
a 20 N·m (2.0 kgf·m, 14.8 ft·lb)

b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
c 35 N·m (3.5 kgf·m, 25.8 ft·lb)
a 20 N·m (2.0 kgf·m, 14.8 ft·lb)
b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
c 35 N·m (3.5 kgf·m, 25.8 ft·lb)
6
1
2
3
Oil filter
Plastic tie
Clamp
1
1
2
7
5 Clamp 2
6
7
8
Cooling water hose
Clamp
Bolt
1
1
2 M8  35 mm
8
9 Collar 2
9
10 Grommet 2
11 Bolt 4 M6  35 mm
12 Bolt 2 M6  25 mm
13 Rectifier regulator 1
14 Gasket 1 
15
16
Cover
Clamp
1
1
5-6
A
POWR
Power unit
4
3 3 8
a 23 N·m (2.3 kgf·m, 17.0 ft·lb)
b 42 N·m (4.2 kgf·m, 31.0 ft·lb) 11
15 6
5
10
9 11
12 5
10
2
7 13 14 9
12 13 N·m (1.3 kgf·m, 9.6 ft·lb)

19 2.5 N·m (0.25 kgf·m, 1.84 ft·lb)
20
a 23 N·m (2.3 kgf·m, 17.0 ft·lb)
25 b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
18
25
21
24
1
17
18 N·m (1.8 kgf·m, 13.3 ft·lb) 22
23 16
a 20 N·m (2.0 kgf·m, 14.8 ft·lb) a 20 N·m (2.0 kgf·m, 14.8 ft·lb)

17 Clamp 1
18 Bolt 1 M10  50 mm
19 Bolt 1 M8  47 mm
20 Stay 1
21 Clamp 1
22 Bolt 3 M8  120 mm
23 Bolt 8 M8  70 mm
24 Gasket 1 
25 Dowel pin 2
5-7
Exhaust manifold (FX HO, FX Cruiser HO) /
Engine unit and coupling cover (FX SHO, FX Cruiser SHO)
Engine unit and coupling cover (FX SHO, FX Cruiser SHO)
17 N·m (1.7 kgf·m, 12.5 ft·lb)

1
1
5
6
2
3
2
1
3
1
4
17 N·m (1.7 kgf·m, 12.5 ft·lb)
5
4
6
6
5
6
5
6
1
2
3
Bolt
Bolt
Collar
4
1
1
M8  28 mm
M6  25 mm 7
4 Coupling cover 1
5 Bolt 4 M8  37 mm
6 Shim * As required
8
9
5-8
A
POWR
Power unit
Engine unit and coupling cover (FX HO, FX Cruiser HO)
17 N·m (1.7 kgf·m, 12.5 ft·lb)
1
5
2
6
3
1 1
5 17 N·m (1.7 kgf·m, 12.5 ft·lb)
6
5

1 Bolt 4 M8  28 mm
2 Bolt 1 M6  25 mm
3 Collar 1
4 Coupling cover 1
5 Bolt 4 M8  37 mm
6 Shim * As required
5-9
Engine unit and coupling cover (FX HO, FX Cruiser HO) / Engine mount
Engine mount
17 N·m (1.7 kgf·m, 12.5 ft·lb) 5.5 N·m (0.55 kgf·m, 4.06 ft·lb)
1
1
1
2
2 3
3
5.5 N·m (0.55 kgf·m, 4.06 ft·lb)

2
4
6
5 3
4
7 1
1
1 3
5
2 3
6
1
2
3
Bolt
Engine mount
Liner
8
4
4
M8  35 mm
7
4 Bolt 2 M6  19 mm
5 Damper 1 1
6
7
Bolt
Damper 2
2
1
M6  12 mm
8
9
5-10
A
POWR
Power unit
Engine unit removal (FX SHO, FX 6. Disconnect the quick connector d from
Cruiser SHO) the fuel rail. See “Fuel hose
disconnection” (4-5).
Before removing the engine, make sure to

take adequate measures to protect the d
deck opening from damage.
1. Disconnect the negative battery lead,

and then disconnect the positive battery
lead.
2. Extract the engine oil. See “Engine oil

replacement” (3-6). 7. Remove the breather hose e, air intake
pipe f, air filter case cover g, air filter,
3. Remove the service lid a. and air filter case h.
h g
a
4. Remove the deck beam b. 8. Remove the plastic tie i from the
cooling water hose j.
b i
j
5. Remove the engine cover c.

9. Remove the electrical box cover k.
c
k
5-11
Engine mount
10. Remove the antenna holders l.
m
11. Disconnect the remote control receiver
coupler a.
l 1
m 2
a
12. Disconnect the

couplers b.
sensor and switch
3
b
15. Disconnect
coupler d.
the fuel pump module 4
13. Disconnect the electric bilge pump
5
coupler c.
c
d
6
16. Disconnect the cooling water hose j
from the oil cooler assy.
7
j
14. Remove the wiring harness from the
plastic ties m.
m
8
17. Disconnect the cooling water hose n
from the thermostat housing.
9
5-12
A
POWR
Power unit
n t e
18. Disconnect the cooling water hoses o 21. Disconnect the cooling water hoses u,
and p from the air cooler. v, and w.
22. Remove the plastic tie x and rectifier

regulator y.
x
o u
y
v
w
p
23. Disconnect the cooling water hoses z
19. Place a rag under the oil filter q, and and A.
then remove it.
24. Remove the stay B.
q r
z
A
B
Oil filter wrench r: YB-06830

Oil filter wrench r: 90890-06830 25. Remove the stays C.
TIP:
Make sure to clean up any oil spills.
C
20. Remove the holder s and plastic tie t, C
and then disconnect the thermo sensor
coupler e.
5-13
Engine mount
26. Remove the pipe clamp D from the pipe 30. Loosen the engine mounting bolts I.
E.
31. Lift the engine unit slightly, remove the
D
shims J, and then lower the unit.
32. Remove the engine mounting bolts I. 1

E
I 2
27. Remove the muffler assy. F. J
F
I
J
3
TIP:
Write down the position of each removed
4
shim J so that it can be installed in its origi-
TIP:
When removing the muffler assy. F, move it
forward and separate it from the water lock.
nal position.
33. Suspend the engine unit using all 3

engine hangers, and then separate the
5
unit from the engine mounts and move it
28. Remove the electrical box G.
G
forward to disconnect the coupling.
6
7
29. Remove the coupling cover H.
34. Lift the engine unit slightly, and then
lower the front of the unit. Repeat this
8
H step until the engine unit can be removed
from the engine compartment.
NOTICE: When removing the engine
unit, take care to avoid causing
damage to the hull liner and deck
9
opening.
5-14
A
POWR
Power unit
35. Lift the engine unit out vertically. 5. Remove the plastic tie c, and then
disconnect the quick connector d from
the fuel rail. See “Fuel hose
disconnection” (4-5).
Engine unit removal (FX HO, FX

Cruiser HO) d
6. Remove the engine cover e.

Before removing the engine, make sure to
take adequate measures to protect the
deck opening from damage.

and then disconnect the positive battery
lead.
2. Extract the engine oil. See “Engine oil e

replacement” (3-6).
7. Remove the breather hose f, air intake
3. Remove the service lid a. pipe g, air filter case cover h, air filter,
and air filter case i.
h
a
i
g
4. Remove the deck beam b.
5-15
Engine mount
8. Remove the plastic tie j from the 13. Disconnect the electric bilge pump
cooling water hose k. coupler c.
j c
1
k
2
9. Remove the electrical box cover l. 14. Remove the wiring harness from the
plastic ties n.
n 3
l 4
10. Remove the antenna holders m.

coupler a.
n 5
m
6
a
n
7
12. Disconnect the sensor and switch
couplers b.
b 8
15. Disconnect
coupler d.
the fuel pump module
9
5-16
A
POWR
Power unit
TIP:
Make sure to clean up any oil spills.
19. Remove the holder r and plastic tie s,

and then disconnect the thermo sensor
coupler e.
d s e
16. Disconnect the cooling water hose k

from the oil cooler assy.
r
k
20. Disconnect the cooling water hoses t,

u, and v, and then remove the rectifier
regulator w.
t
17. Disconnect the cooling water hose o w
from the thermostat housing. u
21. Disconnect the cooling water hoses x

and y.
22. Remove the stay z.

18. Place a rag under the oil filter p, and
then remove it.
x
p q y
z
23. Remove the pipe clamp A from the pipe

B.
Oil filter wrench q: YB-06830
Oil filter wrench q: 90890-06830
5-17
Engine mount
A 27. Remove the ETV. See “ETV and fuel

injector (FX HO, FX Cruiser HO)” (4-9).
28. Loosen the engine mounting bolts F.

shims G, and then lower the unit.
1
30. Remove the engine mounting bolts F.
B
24. Remove the muffler assy. C. 2

C F
G 3
F
G
4
TIP:
When removing the muffler assy. C, move it
forward and separate it from the water lock.
25. Remove the electrical box D.

TIP:
Write down the position of each removed
shim G so that it can be installed in its origi-
nal position.
5
D
engine hangers, and then separate the
unit from the engine mounts and move it
forward to disconnect the coupling.
6
7
26. Remove the coupling cover E.
E 8
9
5-18
A
POWR
Power unit
32. Lift the engine unit slightly, and then 1. Suspend the engine unit using all 3
lower the front of the unit. Repeat this engine hangers.
step until the engine unit can be removed
from the engine compartment. 2. Lower the front of the engine unit.
NOTICE: When removing the engine
unit, take care to avoid causing 3. Lower the engine unit into the engine
damage to the hull liner and deck compartment vertically.
opening.
4. Lift the front of the engine unit slightly,

33. Lift the engine unit out vertically. and then lower the unit. Repeat this step
until the drive and driven couplings are
aligned.
Engine mount and damper check

1. Check the engine mounts and dampers.
5. Move the engine unit rearward to connect
Replace if cracked or damaged.
the driven coupling a, and then lower
the unit onto the engine mounts.
TIP:
• Write down the position of each engine
mount so that it can be installed in its origi-
nal position.
• When replacing the engine mounts, make
sure to check the coupling clearance.
Engine unit installation (FX SHO, FX

Cruiser SHO)
When installing the engine unit, take care

to avoid causing damage to the hull liner
and deck opening.
5-19
Engine mount
8. Measure the coupling clearances a and
b. If the clearances are out of
specification, add or remove shims c so
1
that the clearances are within
specification.
a
2
Clearance a:
Less than 1 mm (0.039 in)
b
3
(without rubber coupling)
TIP:
Do not install the rubber coupling until the
coupling clearance adjustment has been
made.
Clearance b:
2–4 mm (0.079–0.157 in)
Available shim thicknesses:

4
0.10, 0.30, 0.50, 1.00, 2.00 mm
6. Temporarily install the engine mounting

bolts b.
7. Lift the engine unit slightly, install the

shims, and then lower the engine unit. 5
10. Remove the engine mounting bolts.
shims c, and then lower the unit.
11. Separate the engine unit from the engine
mounts and move it forward to
disconnect the coupling.
6
12. Install the rubber coupling d.
b
c
7
b
c
d
8
TIP:
Install the shims in their original positions.
13. Install the shims, and then adjust the
position of the engine unit so that the
coupling clearances a and b are within
specification.
9
5-20
A
POWR
Power unit
f
a
g
g
g
b
Clearance a: Electrical box bolt g:

Less than 0.5 mm (0.020 in) 17 N·m (1.7 kgf·m, 12.5 ft·lb)
(with rubber coupling)
Clearance b: 17. Install the muffler assy. h into the water
2–4 mm (0.079–0.157 in) lock, and then tighten the exhaust
manifold bolts i and j to the specified
14. Tighten the engine mounting bolts b to torques in 3 stages and in the order a,
the specified torque, and then recheck b, and so on.
the coupling clearances.
j h
b
i f b c g j
j j
h ie a d k
i
b j i
Exhaust manifold bolt i and j:

Engine mounting bolt b: 1st: 20 N·m (2.0 kgf·m, 14.8 ft·lb)
17 N·m (1.7 kgf·m, 12.5 ft·lb) 2nd: 20 N·m (2.0 kgf·m, 14.8 ft·lb)
3rd: 35 N·m (3.5 kgf·m, 25.8 ft·lb)
15. Install the coupling cover e.
18. Install the pipe clamp k, and then
tighten it to the specified torque.
16. Install the electrical box f, and then

tighten the electrical box bolts g to the
specified torque. Pipe clamp k:
2.5 N·m (0.25 kgf·m, 1.84 ft·lb)
5-21
Engine mount
24. Fasten the cooling water hose w using
TIP: the plastic tie C.
Make sure that the pipe on the end of the
muffler assy. is installed securely into the C
w
water lock.
19. Install the stays l, and then tighten the v

y
B
u
v
z
1
stay bolts m to the specified torque.
m
l l
v
x
A
2
Rectifier regulator bolt v:
m
m
26 N·m (2.6 kgf·m, 19.2 ft·lb)
25. Connect the thermo sensor coupler c. 3

26. Fasten the leads using the holder D and
plastic tie E.
Stay bolt m:
10 N·m (1.0 kgf·m, 7.4 ft·lb)
20. Install the stay n, and then tighten the

E c
4
stay bolts o and p to the specified
5
torques in 2 stages.
21. Connect the cooling water hoses q and

r, and then fasten them using the
clamps s and t. D
o q
st
r 27. Install the oil filter F, and then tighten it
to the specified torque. 6
p
o
n
p
F G
7
Stay bolts o and p:
1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb)
2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb)
Oil filter wrench G: YB-06830
8
22. Install the rectifier regulator u, and then
Oil filter wrench G: 90890-06830
tighten the rectifier regulator bolts v to
23. Connect the cooling water hoses w, x,

and y, and then fasten them using the
Oil filter F:
18 N·m (1.8 kgf·m, 13.3 ft·lb) 9
28. Connect the cooling water hoses H and
clamps z, A, and B. I, and then fasten them using the
clamps J and K.
5-22
A
POWR
Power unit
32. Connect the electric bilge pump coupler
e.
H
J e
K
I 33. Connect the sensor and switch couplers
f.
29. Connect the cooling water hose L, and
then fasten it using the clamp M. f
34. Connect the remote control receiver

coupler g, and then install the antenna
30. Connect the cooling water hose N, and holders P.
then fasten it using the clamp O.
P
O
g
35. Fasten the wiring harness using the

31. Connect the fuel pump module coupler plastic ties Q.
d.
Q
5-23
Engine mount
T
Q
U
U
1
Q Air filter case bolt U:
12 N·m (1.2 kgf·m, 8.9 ft·lb)
2
39. Install the air filter, air filter case cover V,
and air intake pipe W, and then tighten
the air intake pipe clamps X to the
specified torque.
3
40. Install the breather hose Y, and then
36. Install the electrical box cover R.

Y
fasten it using the clamp Z.
V
4
Z
X
W
5
6
R
Air intake pipe clamp X:

37. Fasten the cooling water hose N using 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
the plastic tie S.
41. Connect the quick connector 1 to the
N
S fuel rail.
7
1
8
38. Install the air filter case T, and then
tighten the air filter case bolts U to the
specified torque.
42. Install the engine cover 2, and then
tighten the engine cover screws 3 to the
9
specified torque.
5-24
A
POWR
Power unit
3
2
3
Engine cover screw 3: 4. Lift the front of the engine unit slightly,
5 N·m (0.5 kgf·m, 3.7 ft·lb) and then lower the unit. Repeat this step
until the drive and driven couplings are
43. Install the service lid 4. aligned.
44. Fill the engine with engine oil. See 5. Move the engine unit rearward to connect
“Engine oil replacement” (3-6). the driven coupling a, and then lower
the unit onto the engine mounts.
45. Connect the positive battery lead, and
then connect the negative battery lead.
Engine unit installation (FX HO, FX

Cruiser HO)
When installing the engine unit, take care

to avoid causing damage to the hull liner
and deck opening.
a
engine hangers.
2. Lower the front of the engine unit.
3. Lower the engine unit into the engine

compartment vertically.
5-25
Engine mount
Available shim thicknesses:

TIP:
Do not install the rubber coupling until the 0.10, 0.30, 0.50, 1.00, 2.00 mm
coupling clearance adjustment has been
made.
6. Temporarily install the engine mounting

shims, and then lower the engine unit.
10. Remove the engine mounting bolts.

1
bolts b.
11. Separate the engine unit from the engine
7. Lift the engine unit slightly, install the
shims c, and then lower the unit.
mounts and move it forward to
disconnect the coupling. 2
12. Install the rubber coupling d.
b
3
c
c
d
4
b
5
13. Install the shims, and then adjust the
position of the engine unit so that the
coupling clearances a and b are within
TIP:
specification.
Install the shims in their original positions.
8. Measure the coupling clearances a and

b. If the clearances are out of
specification, add or remove shims c so
that the clearances are within
a
6
specification.
a
b 7
Clearance a:
Less than 0.5 mm (0.020 in)
(with rubber coupling)
Clearance b:
2–4 mm (0.079–0.157 in)
8
b
14. Tighten the engine mounting bolts b to
Clearance a:
Less than 1 mm (0.039 in)
(without rubber coupling)
the specified torque, and then recheck
the coupling clearances. 9
Clearance b:
2–4 mm (0.079–0.157 in)
5-26
A
POWR
Power unit
18. Install the muffler assy. h into the water
lock, and then tighten the exhaust
manifold bolts i and j to the specified
torques in 3 stages and in the order a,
b, and so on.
b
j h
i f b c g j
j j
b h ie a d k
i
j i
Engine mounting bolt b:

17 N·m (1.7 kgf·m, 12.5 ft·lb) Exhaust manifold bolt i and j:
1st: 20 N·m (2.0 kgf·m, 14.8 ft·lb)
15. Install the ETV. See “ETV and fuel 2nd: 20 N·m (2.0 kgf·m, 14.8 ft·lb)
injector (FX HO, FX Cruiser HO)” (4-9). 3rd: 35 N·m (3.5 kgf·m, 25.8 ft·lb)
16. Install the coupling cover e. 19. Install the pipe clamp k, and then
tighten it to the specified torque.
17. Install the electrical box f, and then

tighten the electrical box bolts g to the Pipe clamp k:
specified torque. 2.5 N·m (0.25 kgf·m, 1.84 ft·lb)
f TIP:
g Make sure that the pipe on the end of the
g muffler assy. is installed securely into the
water lock.
20. Install the stay l, and then tighten the

g
stay bolts m and n to the specified
torques in 2 stages.
Electrical box bolt g: 21. Connect the cooling water hoses o and
17 N·m (1.7 kgf·m, 12.5 ft·lb) p, and then fasten them using the
clamps q and r.
5-27
Engine mount
r
m oq p D
n
n
C 1
m
l
Stay bolts m and n:

1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb)
Oil filter wrench D: YB-06830
Oil filter wrench D: 90890-06830
2
2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb)
3
Oil filter C:
22. Install the rectifier regulator s, and then 18 N·m (1.8 kgf·m, 13.3 ft·lb)
tighten the rectifier regulator bolts t to
the specified torque. 27. Connect the cooling water hose E to the
thermostat housing, and then fasten it
23. Connect the cooling water hoses u, v, using the clamp F.
and w, and then fasten them using the
clamps x, y, and z.
x u
E 4
s
z F
t
w
t 5
t
6
v y
28. Connect the cooling water hose G, and
then fasten it using the clamp H.
Rectifier regulator bolt t:
26 N·m (2.6 kgf·m, 19.2 ft·lb)
24. Connect the thermo sensor coupler c.
25. Fasten the leads using the holder A and

plastic tie B.
G
H
7
8
B c
29. Connect the fuel pump module coupler

d.
A
9
26. Install the oil filter C, and then tighten it
to the specified torque.
5-28
A
POWR
Power unit
30. Connect the electric bilge pump coupler

e. J
31. Connect the sensor and switch couplers

f.
34. Install the electrical box cover K.

coupler g, and then install the antenna
holders I.
K
I
35. Fasten the cooling water hose G using

the plastic tie L.
33. Fasten the wiring harness using the

plastic ties J.
5-29
Engine mount
L
G
T T
1
S
36. Install the air filter case M, and then

tighten the air filter case bolts N to the
Engine cover screw T:
5 N·m (0.5 kgf·m, 3.7 ft·lb)
2
specified torque.
40. Connect the quick connector U to the
M fuel rail.
41. Pass the fuel hose through the clamp h

3
N on the air intake pipe, and then clamp the
plastic tie V.
N
V
h
4
Air filter case bolt N:
12 N·m (1.2 kgf·m, 8.9 ft·lb)
37. Install the air filter, air filter case cover O,

5
and air intake pipe P, and then tighten U
the air intake pipe clamps Q to the
specified torque.
38. Install the breather hose R.

42. Install the service lid W.
6
W
O
R
P
7
Q 43. Fill the engine with engine oil. See
“Engine oil replacement” (3-6).
8
Air intake pipe clamp Q:
9
3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 44. Connect the positive battery lead, and
then connect the negative battery lead.
39. Install the engine cover S, and then
tighten the engine cover screws T to the
specified torque.
5-30
A
POWR
Power unit
Muffler
B
A 20 N·m (2.0 kgf·m, 14.8 ft·lb)
a 15 N·m (1.5 kgf·m, 11.1 ft·lb)

16
b 29 N·m (2.9 kgf·m, 21.4 ft·lb)
3 7
8
12
15
7
13 14
14
9
5
2
6 1
10 2.5 N·m (0.25 kgf·m, 2.58 ft·lb)

200 N·m (20.0 kgf·m, 147.5 ft·lb)
a 20 N·m (2.0 kgf·m, 14.8 ft·lb) 11 a 20 N·m (2.0 kgf·m, 14.8 ft·lb)

1 Clamp 1
2 Pipe 1
3 Thermo sensor 1
4 Clamp 1
6 Exhaust pipe 3 1
7 Bolt 5 M8  35 mm
8 Exhaust pipe 2 1
9 Gasket 1 
10 Bolt 2 M8  70 mm
11 Bolt 4 M8  120 mm
12 Exhaust pipe 1 1
13 Gasket 1 
14 Dowel pin 2
15 Exhaust manifold 1 A FX SHO, FX Cruiser SHO
16 Exhaust manifold 1 B FX HO, FX Cruiser HO
5-31
Muffler
Exhaust pipe disassembly Exhaust pipe assembly
1. Install exhaust pipe 3 a, and then tighten
it to the specified torque. NOTICE: To
1
Use heat-resistant gloves. Otherwise, allow the LOCTITE 648 to set, wait
burns could result. approximately 1 hour after completing
this procedure.
1. Remove exhaust pipe 3 a.
b
15°
15°
2
a
a
a
3
Exhaust pipe wrench b: 90890-06726
TIP:
Heat the area a of exhaust pipe 3 a to
b
15° 15° 4
approximately 200 °C (392 °F) using a heat
gun.
Exhaust pipe wrench b: 90890-06726
Exhaust pipe 3 a:
5
200 N·m (20.0 kgf·m, 147.5 ft·lb)
6
7
8
9
5-32
A
POWR
Power unit
Wiring harness assy. (FX SHO, FX Cruiser SHO)

3 1 7 N·m (0.7 kgf·m, 5.2 ft·lb)
3 2
5
4
8 UP
a
A A 8
7
9
10
13
11 12

1 Nut 1
2 Spring washer 1
3 Bolt 2 M8  30 mm
4 Negative battery lead 1
5 Starter motor 1
6 Bolt 2 M6  35 mm
7 Thermostat housing 1
8 Thermostat 1 a Hole
9 Holder 1
10 Plastic tie 1
11 Plastic tie 1
12 Plastic tie 1
13 Wiring harness 1
5-33
Wiring harness assy. (FX SHO, FX Cruiser SHO) /
Wiring harness assy. (FX HO, FX Cruiser HO)
Wiring harness assy. (FX HO, FX Cruiser HO)
3 1
7 N·m (0.7 kgf·m, 5.2 ft·lb)
3 2
5 1
4
8 UP
a
2
A A
7
8
10
3
6
9
4
10
5
11
12
13 6
1
2
3
Nut
Spring washer
Bolt
1
1
2 M8  30 mm
7
4 Negative battery lead 1
5 Starter motor 1
6
7
8
Bolt
Thermostat housing
Thermostat
2
1
1
M6  35 mm
a Hole
8
9 Holder 1
9
10 Plastic tie 2
11 Plastic tie 1
12 Plastic tie 1
13 Wiring harness 1
5-34
A
POWR
Power unit
Electrical box
4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb)
11
24
12
22
10
20
23
21
15
14 8 N·m (0.8 kgf·m, 5.9 ft·lb)
13
16 25
17 7
18 9
19
8
2
1
4
5
6
3 5 N·m (0.5 kgf·m, 3.7 ft·lb)

1 Electrical box cover 1
2 Plastic tie 1
3 Bolt 4 M6  25 mm
4 ECM 1
5 Collar 4
6 Grommet 4
7 Bolt 6 M6  16 mm
8 Fuse box assy. 1
9 Gasket 1 
10 Rubber mount 1
11 Main and fuel pump relay 1
12 ETV relay 1
13 Fuse box cap 1
14 Gasket 1 
15 Fuse puller 1
16 Fuse (30 A) 2
5-35
Electrical box
4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb)
11
1
24
12
22
10
20
13
14
15
21
23
8 N·m (0.8 kgf·m, 5.9 ft·lb)

2
16
17
18
19
9
25
7
3
8
2
1
4
4
5
5
3
6
5 N·m (0.5 kgf·m, 3.7 ft·lb)

6
17
18
19
Fuse (10 A)
Fuse (3 A)
Fuse (20 A)
4
2
2
7
20 Starter relay 1
21 Starter motor lead 1
22
23
24
Positive battery lead
Screw
Slant detection switch
1
2
1
M6  20 mm 8
25 Electrical box 1
9
5-36
A
POWR
Power unit
Starter motor and wiring harness 5. Disconnect the earth plate couplers k
assy. removal (FX SHO, FX Cruiser and oil pressure switch coupler m.
SHO)
1. Disconnect the starter motor lead a and
negative battery lead b, and then k
remove the starter motor c. m
6. Remove the plastic tie e and holder f,

and then disconnect the thermoswitch
coupler n, engine temperature sensor
coupler p, intake air pressure sensor
coupler r, intake air temperature sensor
b
coupler s, cam position sensor coupler
c t knock sensor coupler u, and ETV
coupler v.
2. Remove the plastic tie d. p e u
r
3. Disconnect the fuse box couplers a,
main and fuel pump relay coupler b,
ETV relay coupler c, slant detection
switch coupler d, and ECM couplers e.
n
t
4. Disconnect the rectifier regulator coupler s
f, stator coil coupler g, and pick up coil v
coupler h.
c
f
b
7. Disconnect the ignition coil couplers w

and fuel injector couplers x.
d
w
a d e
5-37
Electrical box
Starter motor and wiring harness 5. Disconnect the earth plate couplers k
assy. removal (FX HO, FX Cruiser and oil pressure switch coupler m.
HO)
1. Disconnect the starter motor lead a and
negative battery lead b, and then
remove the starter motor c. m
k
1
a
2
6. Disconnect the thermoswitch coupler n,
b
and then remove the plastic ties e.
e n
3
c
2. Remove the plastic tie d.

4
3. Disconnect the fuse box couplers a,
main and fuel pump relay coupler b,
ETV relay coupler c, slant detection
switch coupler d, and ECM couplers e.
7. Remove the holder f, and then
disconnect the engine temperature
sensor coupler p, intake air pressure
5
4. Disconnect the rectifier regulator coupler sensor coupler r, intake air temperature
f, stator coil coupler g, and pick up coil
coupler h.
c
sensor coupler s, and cam position
sensor coupler t.
p
6
r
b
s
7
d f
g
d e t
8. Disconnect the ignition coil couplers u

and fuel injector couplers v.
8
f
h
9
5-38
A
POWR
Power unit
u B FX HO, FX Cruiser HO
Starter motor and wiring harness

assy. installation (FX SHO, FX
Cruiser SHO)
1. Connect the fuel injector couplers a and
ignition coil couplers b.
v
b
Thermostat check
1. Suspend the thermostat in a container of
water.
2. Place a thermometer in the water and

heat the water slowly.
a
2. Connect the ETV coupler c, knock

sensor coupler d, cam position sensor
coupler e, intake air temperature sensor
coupler f, intake air pressure sensor
coupler g, engine temperature sensor
coupler h, and thermoswitch coupler k,
and then fasten the wiring harness using
the holder a and plastic tie b.
3. Measure the thermostat valve opening a
g h b d
at the specified water temperatures.
Replace if out of specification.
a
k
e
f
c
a
m
Water temperature Valve opening a
A : 48–52 °C TIP:
(118–126 °F) Fasten the wiring harness at the gray tape m
Starts opening
B : 58–62 °C using the holder a.
(136–144 °F)
A : above 60 °C
3. Connect the oil pressure switch coupler
(140 °F) 4.3 mm (0.17 in) or
n and earth plate couplers p.
B : above 70 °C above
(158 °F)
5-39
Electrical box
f
p g
n
1
4. Connect the pick up coil coupler r,
stator coil coupler s, and rectifier d
e 2
regulator coupler t.
5. Connect the ECM couplers u, slant

detection switch coupler v, ETV relay
coupler w, main and fuel pump relay
Starter motor lead nut g:
7 N·m (0.7 kgf·m, 5.2 ft·lb) 3
coupler x, and fuse box couplers y, and Starter motor and wiring harness
4
then fasten the wiring harness using the assy. installation (FX HO, FX Cruiser
plastic tie c. HO)
w 1. Connect the fuel injector couplers a and
ignition coil couplers b.
x
c
b
5
y
s
v u
a
6
t
2. Connect the cam position sensor coupler
r
c, intake air temperature sensor coupler
d, intake air pressure sensor coupler e,
and engine temperature sensor coupler
f, and then fasten the wiring harness
7
using the holder a.
6. Install the starter motor d, and then
connect the negative battery lead e and
starter motor lead f. e
f
8
7. Tighten the starter motor lead nut g to
g
a
d 9
c
5-40
A
POWR
Power unit
TIP: u
Fasten the wiring harness at the gray tape g
using the holder a. v
3. Connect the thermoswitch coupler h,

and then fasten the thermoswitch lead
c
using the plastic ties b.
w t s
b p
h
r
4. Connect the oil pressure switch coupler 7. Install the starter motor d, and then
k and earth plate couplers m. connect the negative battery lead e and
starter motor lead f.
m 8. Tighten the starter motor lead nut g to

k
f
g
5. Connect the pick up coil coupler n,

stator coil coupler p, and rectifier
regulator coupler r.
6. Connect the ECM couplers s, slant e

detection switch coupler t, ETV relay d
coupler u, main relay coupler v, and
fuse box couplers w, and then fasten the
wiring harness using the plastic tie c. Starter motor lead nut g:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
5-41
Electrical box / Air cooler and supercharger assy.
Air cooler and supercharger assy.

20 N·m (2.0 kgf·m, 14.8 ft·lb)
25 27
1
10 N·m (1.0 kgf·m, 7.4 ft·lb) 28
a 23 N·m (2.3 kgf·m, 17.0 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 26
b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
4 N·m (0.4 kgf·m, 3.0 ft·lb)

30
31
a 23 N·m (2.3 kgf·m, 17.0 ft·lb) 29
2
33
b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
19 13 12
2
4 N·m (0.4 kgf·m, 3.0 ft·lb)
16 11
32 14
3
8 11 24
4
3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 20
22
23
21
4
1
7
1
10
9
17
15
42 N·m (4.2 kgf·m, 31.0 ft·lb)
42 N·m (4.2 kgf·m, 31.0 ft·lb)

5
5 9
a 23 N·m (2.3 kgf·m, 17.0 ft·lb)
6
6 18
b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
3
20 N·m (2.0 kgf·m, 14.8 ft·lb)

1
2
3
Clamp
Clamp
Bolt
3
1
1 M8  35 mm
7
4 Boost pipe 1
5 Collar 1
6
7
8
Grommet
Joint 1
Joint 2
1
1
1
8
9 Clamp 2
9
11 Clamp 2
12 Air cooler intake pipe 1
13 Nut 1
14 Bolt 2 M10  45 mm
15
16
Air cooler
Collar
1
1
5-42
A
POWR
Power unit
20 N·m (2.0 kgf·m, 14.8 ft·lb)

25 27
10 N·m (1.0 kgf·m, 7.4 ft·lb) 28
b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
4 N·m (0.4 kgf·m, 3.0 ft·lb)

30
31
33 a 23 N·m (2.3 kgf·m, 17.0 ft·lb) 29
b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
19 13 12
16 11
32 14
2
4 N·m (0.4 kgf·m, 3.0 ft·lb)
8 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 11 24 20
22
23
21
7 42 N·m (4.2 kgf·m, 31.0 ft·lb)
1
1 9
4 10 15 42 N·m (4.2 kgf·m, 31.0 ft·lb)
17
5 9
6 18 a 23 N·m (2.3 kgf·m, 17.0 ft·lb)
b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
3
20 N·m (2.0 kgf·m, 14.8 ft·lb)

17 Grommet 1
18 Plate 1
19 Stud bolt 1
20 Bolt 1 M10  50 mm
21 Bolt 1 M10  80 mm
22 Stay 1
23 Collar 2
24 Grommet 2
25 Bolt 2 M6  65 mm
26 Washer 2
27 Bolt 3 M8  65 mm
28 Bolt 1 M8  65 mm
29 Supercharger assy. 1
30 Bolt 1 M5  9 mm
31 Gasket 1 
32 O-ring 1 
5-43
Air cooler and supercharger assy.
20 N·m (2.0 kgf·m, 14.8 ft·lb)

25 27
1
10 N·m (1.0 kgf·m, 7.4 ft·lb) 28
b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
4 N·m (0.4 kgf·m, 3.0 ft·lb)

30
31
a 23 N·m (2.3 kgf·m, 17.0 ft·lb) 29
2
33
b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
19 13 12
2
4 N·m (0.4 kgf·m, 3.0 ft·lb)
16 11
32 14
3
8 11 24
4
3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 20
22
23
21
4
1
7
1
10
9
17
15
42 N·m (4.2 kgf·m, 31.0 ft·lb)
42 N·m (4.2 kgf·m, 31.0 ft·lb)

5
5 9
a 23 N·m (2.3 kgf·m, 17.0 ft·lb)
6
6 18
b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
3
20 N·m (2.0 kgf·m, 14.8 ft·lb)

33 Dowel pin 2
7
8
9
5-44
A
POWR
Power unit
Intake assy. (FX SHO, FX Cruiser SHO)
15 N·m (1.5 kgf·m, 11.1 ft·lb)

a 10 N·m (1.0 kgf·m, 7.4 ft·lb)
17 b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
15 a 10 N·m (1.0 kgf·m, 7.4 ft·lb)
18 b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
16 13
7 5 10
14 8
15
9 10
19
11 9
12
4
2
1
3
a 10 N·m (1.0 kgf·m, 7.4 ft·lb) 6 11 25
b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
12 20
a 15 N·m (1.5 kgf·m, 11.1 ft·lb)
b 30 N·m (3.0 kgf·m, 22.1 ft·lb) 22
4 21
23
a 15 N·m (1.5 kgf·m, 11.1 ft·lb)
24
b 30 N·m (3.0 kgf·m, 22.1 ft·lb)

1 Holder 1
2 Plastic tie 1
3 Bolt 1 M6  12 mm
4 Bolt 2 M8  25 mm
5 Nut 2
6 Bolt 6 M8  35 mm
7 Intake assy. 1
8 Gasket 1 
9 Dowel pin 2
10 Stud bolt 2
11 Bolt 2 M8  40 mm
12 Stay 2
13 Intake air temperature sensor 1
14 Gasket 1 
15 Clamp 2
16 Hose 1
5-45
Intake assy. (FX SHO, FX Cruiser SHO)
15 N·m (1.5 kgf·m, 11.1 ft·lb)
15
17
18
a 10 N·m (1.0 kgf·m, 7.4 ft·lb)
b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
a 10 N·m (1.0 kgf·m, 7.4 ft·lb)
b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
1
16 13
2
7 5 10
14 8
15
9 10
11 9
19
3
2
1
12
4
3
4
a 10 N·m (1.0 kgf·m, 7.4 ft·lb) 6 11 25
b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
a 15 N·m (1.5 kgf·m, 11.1 ft·lb)

b 30 N·m (3.0 kgf·m, 22.1 ft·lb)
12 20
22
5
4 21
23
a 15 N·m (1.5 kgf·m, 11.1 ft·lb)
b 30 N·m (3.0 kgf·m, 22.1 ft·lb)
24
6
17
18
19
Intake air pressure sensor
Grommet
Oil level gauge
1
1
1
7
20 Bolt 2 M6  12 mm
21 Oil level pipe assy. 1
22
23
24
Clamp
Oil level pipe plate
Grommet
1
1
1
8
25 O-ring 1 
9
5-46
A
POWR
Power unit
Intake assy. (FX HO, FX Cruiser HO)

15 N·m (1.5 kgf·m, 11.1 ft·lb)
12
10 a 10 N·m (1.0 kgf·m, 7.4 ft·lb)
11 b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
14 13
3 a 10 N·m (1.0 kgf·m, 7.4 ft·lb)
5
b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
7
6
6
2
4
9
a 10 N·m (1.0 kgf·m, 7.4 ft·lb)
b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
a 15 N·m (1.5 kgf·m, 11.1 ft·lb)

b 30 N·m (3.0 kgf·m, 22.1 ft·lb)
8
a 15 N·m (1.5 kgf·m, 11.1 ft·lb)
b 30 N·m (3.0 kgf·m, 22.1 ft·lb) 1
8
9
1

1 Bolt 2 M8  25 mm
2 Bolt 6 M8  35 mm
3 Nut 2
4 Intake manifold 1
5 Gasket 1 
6 Dowel pin 2
7 Stud bolt 2
8 Bolt 2 M8  40 mm
9 Stay 2
10 Intake air temperature sensor 1
11 Gasket 1 
12 Intake air pressure sensor 1
13 Grommet 1
14 Hose 1
5-47
Intake assy. (FX HO, FX Cruiser HO) / ETV and intake manifold (FX SHO, FX Cruiser SHO)
ETV and intake manifold (FX SHO, FX Cruiser SHO)
6
1
2
A
6
3
A 8
3
7
24 N·m (2.4 kgf·m, 17.7 ft·lb)

4
2
1
5
5
13 N·m (1.3 kgf·m, 9.6 ft·lb)
4
6
1
2
3
Nut
Washer
ETV
4
4
1
7
4 Bolt 4 M8  20 mm
5 Joint 1
6
7
8
Holder
Ribbon
Intake manifold
1
1
1
8
9
5-48
A
POWR
Power unit
Air cooler check (FX SHO, FX Cruiser Leakage tester b: 90890-06840
SHO) Air cooler attachment e: 90890-06731
Specified positive pressure (air passage):

Do not disassemble the air cooler. 100 kPa (1.0 kgf/cm2, 14.2 psi)
Supercharger check (FX SHO, FX

1. Connect the hose a and special service
tool b to the inlet or outlet of the cooling Cruiser SHO)
water passage. Block the inlet or outlet
using a rubber plug c.
Do not disassemble the supercharger.
2. Apply the specified pressure and check
that the pressure is maintained. If the 1. Check the impeller and gear. Replace the
specified pressure cannot be maintained, supercharger if cracked or worn.
replace the air cooler.
2. Check that the supercharger impeller
c shaft turns smoothly. Replace the
supercharger if it does not turn smoothly.
a
ETV check (FX SHO, FX Cruiser SHO)
b
• Do not disassemble the ETV.
nut a or turn the throttle stop screw b.
Leakage tester b: 90890-06840 • Do not loosen or remove the throttle
valve shaft screws c.
Specified positive pressure
(water passage):
a b
200 kPa (2.0 kgf/cm2, 28.5 psi)
c
3. Connect the hoses d and special
service tools b and e to the inlet or
outlet of the air cooler passage.
4. Apply the specified pressure and check

that the pressure is maintained. If the
specified pressure cannot be maintained,
replace the air cooler. 1. Turn the throttle valve manually and
check that it moves smoothly.
d
d
e Intake assy. installation (FX SHO, FX
Cruiser SHO)
1. Install the dowel pins a, a new gasket
e b, and the intake assy. c, and then
tighten the intake manifold bolts d and
b nuts e temporarily.
5-49
4. Tighten the intake manifold stay bolts g
e
and h to the specified torques in 2
b
stages.
Intake manifold stay bolt g and h:
1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb)
2nd: 30 N·m (3.0 kgf·m, 22.1 ft·lb)
1
5. Fasten the ETV lead using the plastic tie
d c
a
i.
2
2. Install the stays f, and then tighten the
intake manifold stay bolts g and h
temporarily.
3
i
f
4
g
h
h
f
Intake manifold installation (FX HO,
FX Cruiser HO)
b, and the intake manifold c, and then
5
3. Tighten the intake manifold bolts d and tighten the intake manifold bolts d and
nuts e to the specified torques in 2
stages and in the order a, b, and so on.
d e
nuts e temporarily.
e
b
6
e a b f
h d c g
d
7
c
Intake manifold bolt d:

1st: 10 N·m (1.0 kgf·m, 7.4 ft·lb)
a
a
8
2nd: 20 N·m (2.0 kgf·m, 14.8 ft·lb)
Intake manifold nut e:
1st: 10 N·m (1.0 kgf·m, 7.4 ft·lb)
2nd: 20 N·m (2.0 kgf·m, 14.8 ft·lb)
2. Install the stays f, and then tighten the
intake manifold stay bolts g and h
temporarily.
9
5-50
A
POWR
Power unit
d
f c b
a
e
gh a c
b d
g
h f e
3. Tighten the intake manifold bolts d and Installation distance a: 49.8 mm (2.0 in)
intake manifold nuts e to the specified
torques in 2 stages and in the order a, TIP:
b, and so on. Make sure that the bottom of the grommet d
is at the specified installation distance a
d e from the end of the oil level pipe b.
e a b f
3. Install the oil level pipe assy. onto the

cylinder block, and then tighten the oil
h d c g level pipe plate bolts f and oil level pipe
bolt g temporarily.
4. Tighten the oil level pipe plate bolts f.
Intake manifold bolt d: 5. Tighten the oil level pipe bolt g.

1st: 10 N·m (1.0 kgf·m, 7.4 ft·lb)
2nd: 20 N·m (2.0 kgf·m, 14.8 ft·lb)
Intake manifold nut e:
1st: 10 N·m (1.0 kgf·m, 7.4 ft·lb)
2nd: 20 N·m (2.0 kgf·m, 14.8 ft·lb)
4. Tighten the intake manifold stay bolts g

and h to the specified torques in 2 g
stages. f
Intake manifold stay bolt g and h:
1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb)
2nd: 30 N·m (3.0 kgf·m, 22.1 ft·lb)
f
Oil level pipe installation (FX SHO,
FX Cruiser SHO) 6. Fasten the grommet d using the clamp
1. Pass the clamp a through the oil level a.
pipe b.
2. Install the oil level pipe plate c, the

grommet d, and a new O-ring e onto
the oil level pipe b.
5-51
g f
a
d
e
1
d
2
c
Supercharger installation (FX SHO, f f

FX Cruiser SHO)
1. Remove the supercharger oil filler hole
bolt a and gasket b, and then apply
engine oil to the supercharger impeller
shaft through the oil filler hole a.
g
3
a
b
Supercharger bolt (M8  65mm) f:
20 N·m (2.0 kgf·m, 14.8 ft·lb)
4
Supercharger bolt (M6  65mm) g:
5
10 N·m (1.0 kgf·m, 7.4 ft·lb)
a
Air cooler, air cooler intake hose,
and boost pipe installation (FX SHO,
TIP: FX Cruiser SHO)
6
Apply engine oil to the supercharger impeller 1. Install the plate a and air cooler b.
shaft through the oil filler hole a while turn-
ing the supercharger impeller shaft. 2. Tighten the air cooler bolts c and air
cooler nut d alternately in 2 stages to
2. Install a new gasket, and then tighten the the specified torque.
supercharger oil filler hole bolt a to the
specified torque.
Supercharger oil filler hole bolt a:
4 N·m (0.4 kgf·m, 3.0 ft·lb) d
c
7
3. Install the dowel pins c, a new O-ring d,
and the supercharger e, and then
tighten the supercharger bolts f to the
specified torque.
8
4. Tighten the supercharger bolts g to the
specified torque.
b
a 9
5-52
A
POWR
Power unit
Air cooler bolt c:

e
1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb) d
2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb)
Air cooler nut d:
1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb)
2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb)
3. Install the air cooler intake pipe e, and h g

then tighten the air cooler intake pipe
clamps f to the specified torque.
j
e f
k
g f
c b
Boost pipe joint 1 clamp j:

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
e Boost pipe joint 2 clamp k:
a 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
TIP:
c • Position the protrusion d on the boost pipe
i between the protrusions e on the boost
f pipe joint 1 g.
• Fit the lip f of the boost pipe i into the
Air cooler intake pipe clamp f: groove g in boost pipe joint 2 h.
4 N·m (0.4 kgf·m, 3.0 ft·lb)
5. Install the boost pipe assy., and then
TIP: tighten the boost pipe bolt l to the
• Face the arrow a of the air cooler intake specified torque.
pipe e upward.
• Check that the air cooler intake pipe e con- 6. Tighten the boost pipe joint 1 clamp m
tacts the protrusion b on the air cooler. and boost pipe joint 2 clamp n to the
• Align the air cooler intake pipe clamps f specified torque.
with the paint marks c on the air cooler
intake pipe e.
4. Install boost pipe joint 1 g and boost

pipe joint 2 h to the boost pipe i, and
then tighten the boost pipe joint 1 clamp
j and boost pipe joint 2 clamp k to the
specified torque.
5-53
g
b
h
1
m
2
m n
n
h
o l l 3
Boost pipe bolt l:
20 N·m (2.0 kgf·m, 14.8 ft·lb)
Boost pipe joint 1 clamp m:
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
4
Boost pipe joint 2 clamp n:
TIP:
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
• Fit the lip h of the air cooler b into the

5
groove k in boost pipe joint 1 g.
• Fit the lip m of the ETV o into the groove
n in boost pipe joint 2 h.
6
7
8
9
5-54
A
POWR
Power unit
Oil cooler and oil pump assy. (FX SHO, FX Cruiser SHO)
11 N·m (1.1 kgf·m, 8.1 ft·lb)
24
23
20
25
18
19
25 1 20
19
26 21
27 2 21 N·m (2.1 kgf·m, 15.5 ft·lb)
22 26 1 19 N·m (1.9 kgf·m, 14.0 ft·lb)
15
9
7
10 3 4 12 N·m (1.2 kgf·m, 8.9 ft·lb)
11
10
17 5
10 12
11
10 6
12
15 13
17 16 12 8
12 N·m (1.2 kgf·m, 8.9 ft·lb)
14
20 N·m (2.0 kgf·m, 14.8 ft·lb) 8

1 Clamp 2
3 Clamp 1
4 Plastic tie 1
6 Oil filter joint 1
7 Bolt 1 M8  55 mm
8 Bolt 2 M8  70 mm
9 Oil cooler assy. 1
10 O-ring 4 
11 Connector 2
12 Bolt 7 M6  25 mm
13 Washer 3
14 Bolt 1 M8  25 mm
15 Bolt 4 M6  20 mm
16 Gasket 1 
5-55
Oil cooler and oil pump assy. (FX SHO, FX Cruiser SHO)
11 N·m (1.1 kgf·m, 8.1 ft·lb)
23
24
25
20
1
25 1 20
18
19 2
19
3
26 21
27 2 21 N·m (2.1 kgf·m, 15.5 ft·lb)
22 26 1 19 N·m (1.9 kgf·m, 14.0 ft·lb)
15
9
10
11
10
17
3
5
4
7
12 N·m (1.2 kgf·m, 8.9 ft·lb) 4
10
11
10
12
12
6 5
15 13
17 16 12 8
12 N·m (1.2 kgf·m, 8.9 ft·lb)
20 N·m (2.0 kgf·m, 14.8 ft·lb)
14
8
6
17
18
19
Dowel pin
Bolt
Bolt
2
1
2
M6  12 mm
M10  21 mm
7
20 Gasket 4 
21 Oil pipe 1
22
23
24
Bolt
Oil pump assy.
Gasket
12
1
1
M6  20 mm

8
25 Dowel pin 2
9
26 O-ring 2 
27 Connector 1
5-56
A
POWR
Power unit
Idle gear assy. and drive gear assy. (FX SHO, FX Cruiser SHO)
3
5
E
4
3
6
1
E
7
8
80 N·m (8.0 kgf·m, 59.0 ft·lb)

1 Shaft 1
2 Idle gear assy. 1
3 Circlip 2
4 Washer 1
5 Washer 1
6 Collar 1
7 Bolt 1 M12  58 mm, Left-hand threads
8 Drive gear assy. 1
5-57
Idle gear assy. and drive gear assy. (FX SHO, FX Cruiser SHO) /
Oil cooler, oil pump assy. and drive gear (FX HO, FX Cruiser HO)
11 N·m (1.1 kgf·m, 8.1 ft·lb)
1
80 N·m (8.0 kgf·m, 59.0 ft·lb)
4 5
6 9
2
3
3
7
8
2 7 9
10 19 N·m (1.9 kgf·m, 14.0 ft·lb)
1
23
17
18
19
18
25
11
13
12
15
12 N·m (1.2 kgf·m, 8.9 ft·lb) 4
18
19
18
20
20
14 5
23 21
25 24 20 16
12 N·m (1.2 kgf·m, 8.9 ft·lb)
20 N·m (2.0 kgf·m, 14.8 ft·lb)
22
16
6
1
2
3
Bolt
Oil pump assy.
Gasket
12
1
1
M6  20 mm

7
4 Bolt 1 M12  58 mm, left-hand threads
5 Oil pump drive gear 1
6
7
8
Dowel pin
O-ring
Connector
2
2
1
 8
9 Clamp 2
9
11 Clamp 1
12 Plastic tie 1
14 Oil filter joint 1
15
16
Bolt
Bolt
1
2
M8  55 mm
M8  70 mm
5-58
A
POWR
Power unit
11 N·m (1.1 kgf·m, 8.1 ft·lb)

80 N·m (8.0 kgf·m, 59.0 ft·lb)
4 5
6 9
3 7
8
2 7 9
10 19 N·m (1.9 kgf·m, 14.0 ft·lb)
1
23
17
15
18 11 12 12 N·m (1.2 kgf·m, 8.9 ft·lb)
19
18
25 13
18 20
19 14
18
20
23 21
25 24 20 16
12 N·m (1.2 kgf·m, 8.9 ft·lb) 22
20 N·m (2.0 kgf·m, 14.8 ft·lb) 16

17 Oil cooler assy. 1
18 O-ring 4 
19 Connector 2
20 Bolt 7 M6  25 mm
21 Washer 3
22 Bolt 1 M8  25 mm
23 Bolt 4 M6  20 mm
24 Gasket 1 
25 Dowel pin 2
5-59
Oil pump assy., idle gear assy., and Oil pump assy. and oil pump drive
drive gear assy. removal (FX SHO, FX gear removal (FX HO, FX Cruiser HO)
Cruiser SHO) 1. Remove the oil pump assy.
1. Remove the oil pump assy.
2. Remove the idle gear assy.

2. Hold the drive coupling a using the
special service tool b. 1
3. Hold the drive coupling a using the
special service tool b.
2
b a
Coupler wrench b: 90890-06729

3
b a
3. Turn the oil pump drive gear bolt c
Coupler wrench b: 90890-06729
4. Turn the drive gear assy. bolt c

clockwise to loosen it, and then remove
the oil pump drive gear bolt c and oil
pump drive gear d.
4
clockwise to loosen it, and then remove
the drive gear assy. bolt c.
d
5
c
c
6
Oil cooler assy. check
5. Remove the drive gear assy. d using the

special service tools e, f, and g. Do not disassemble the oil cooler assy.
7
d 1. Connect the hose a and special service
e e
tool b to the inlet of the oil cooler water
passage. Block the oil cooler assy. outlet
using the rubber plugs c.
8
2. Apply the specified positive pressure and
Bearing puller assy. e: 90890-06535

g check that the pressure is maintained. If
the specified pressure cannot be
maintained, replace the oil cooler assy.
9
Stopper guide plate f: 90890-06501
Stopper guide stand g: 90890-06538
5-60
A
POWR
Power unit
4. Turn the supercharger drive gear b
c b counterclockwise b and check that it
does not turn. Replace the drive gear
assy. if it turns.
c
a
b
a a
Leakage tester b: 90890-06840
Specified positive pressure b

(water passage):
200 kPa (2.0 kgf/cm2, 28.5 psi) Drive gear assy., idle gear assy., and
oil pump assy. installation (FX SHO,
Oil pump assy. check
FX Cruiser SHO)
1. Install the drive gear assy. a, and then
tighten the drive gear assy. bolt b tem-
Do not disassemble the oil pump assy.
porarily.
1. Check that the oil pump driven gear turns

smoothly. Replace the oil pump assy. if
the movement is rough.
a
Idle gear check (FX SHO, FX Cruiser
SHO)
1. Check the idle gear. Replace the idle b
gear assy. if cracked or worn.
2. Check the shaft. Replace if bent or worn.

2. Hold the holder c.
Drive gear assy. check (FX SHO, FX
Cruiser SHO)
c
Do not disassemble the drive gear assy.
1. Check the oil pump drive gear a and

supercharger drive gear b. Replace the
drive gear assy. if cracked or worn.
3. Turn the drive gear assy. bolt b
2. Hold the oil pump drive gear a. counterclockwise, and then tighten it to
3. Turn the supercharger drive gear b
clockwise a and check that it turns
smoothly. Replace the drive gear assy. if
it does not turn smoothly.
5-61
f
b g
f
1
Drive gear assy. bolt b:
80 N·m (8.0 kgf·m, 59.0 ft·lb) i
2
4. Install the idle gear assy. c, collar d,
and shaft e.
c
Oil pump assy. bolt i:
11 N·m (1.1 kgf·m, 8.1 ft·lb) 3
E Oil pump drive gear and oil pump
4
d assy. installation (FX HO, FX Cruiser
HO)
e 1. Install the oil pump drive gear a, and
then tighten the oil pump drive gear bolt
E
b temporarily.
E
5. Fill the oil pump assy. with engine oil

through the feed port a.
5
a
b
6
a 2. Hold the holder c.
7
TIP:
8
c
While turning the oil pump driven gear, make
sure to fill the oil pump assy. with engine oil
up to the brim of the port.
6. Install the dowel pins f, a new gasket

g, and the oil pump assy. h, and then
tighten the oil pump assy. bolts i to the
specified torque.
3. Turn the oil pump drive gear bolt b
counterclockwise, and then tighten it to
9
5-62
A
POWR
Power unit
Oil pump assy. bolt g:

11 N·m (1.1 kgf·m, 8.1 ft·lb)
b
Oil pump drive gear bolt b:

80 N·m (8.0 kgf·m, 59.0 ft·lb)
4. Fill the oil pump assy. with engine oil

through the feed port a.
TIP:
While turning the oil pump driven gear, make
sure to fill the oil pump assy. with engine oil
up to the brim of the port.
5. Install the dowel pins d, a new gasket

e, and the oil pump assy. f, and then
tighten the oil pump assy. bolts g to the
specified torque.
d
e
5-63
Oil cooler, oil pump assy. and drive gear (FX HO, FX Cruiser HO) / Cylinder head cover
Cylinder head cover

1 10 N·m (1.0 kgf·m, 7.4 ft·lb)
6
1
7
10
11
4
5
1
2
2
2
2
3
7
7
2
3
A
3
3
3
14
15 13
8
6 N·m (0.6 kgf·m, 4.4 ft·lb)
25 N·m (2.5 kgf·m, 18.4 ft·lb)

12
9
4
5
6
1
2
3
Bolt
Ignition coil
Spark plug
8
4
4
M6  20 mm
7
4 Bolt 1 M6  16 mm
5 Cam position sensor 1
6
7
8
Clamp
Bolt
Cylinder head cover
1
8
1
M6  30 mm 8
9 Gasket 1 
9
10 Oil filler cap 1
11 O-ring 1 
12 Timing chain guide 1
13 Bolt 2 A FX HO, FX Cruiser HO, M6  25 mm
14 Collar 2 A FX HO, FX Cruiser HO
15 Grommet 2 A FX HO, FX Cruiser HO
5-64
A
POWR
Power unit
Camshaft (FX SHO, FX Cruiser SHO)
8 8
16 N·m (1.6 kgf·m, 11.8 ft·lb)
8
10
10 13 8
13 8
9 13 8
13 12
18 N·m (1.8 kgf·m, 13.3 ft·lb) 12
13 13
14
16 11 13
17 13 13
20 N·m (2.0 kgf·m, 14.8 ft·lb)
17
10 N·m (1.0 kgf·m, 7.4 ft·lb) 16
15
1
2
3 16
2
4 2 1
20 5 6
18 19 21

1 Bolt 2 M10  21 mm
2 Gasket 4 
3 Oil pipe 1
4 Bolt 2 M6  25 mm
5 Timing chain tensioner 1
6 Gasket 1 
7 Timing chain guide 1 Exhaust side
8 Bolt 24 M7  45 mm
9 Intake camshaft cap 1
11 Exhaust camshaft cap 1
13 Dowel pin 12
14 Intake camshaft 1
15 Exhaust camshaft 1
16 Bolt 4 M7  11 mm
5-65
Camshaft (FX SHO, FX Cruiser SHO)
1
8 8
16 N·m (1.6 kgf·m, 11.8 ft·lb)
8
10
10 13 8
18 N·m (1.8 kgf·m, 13.3 ft·lb)

9
13
13
13
8
12
8
12 2
13 13
14
16
20 N·m (2.0 kgf·m, 14.8 ft·lb)
10 N·m (1.0 kgf·m, 7.4 ft·lb)

17
11
17
13 13
13
3
16
4
15
1
2
3 16
2
4 2 1
20 5 6 5
18 19 21
7
6
17
18
19
Camshaft sprocket
Bolt
Chain guide plate
2
2
1
M6  30 mm 7
20 Timing chain guide 1 Intake side
21 Timing chain 1
8
9
5-66
A
POWR
Power unit
Camshaft (FX HO, FX Cruiser HO)
8 8
16 N·m (1.6 kgf·m, 11.8 ft·lb)
8
10
10 13 8
13 8
9 13 8
13 12
18 N·m (1.8 kgf·m, 13.3 ft·lb) 12
13 13
14
16 11 13
17 13 13
20 N·m (2.0 kgf·m, 14.8 ft·lb)
17
10 N·m (1.0 kgf·m, 7.4 ft·lb) 16
15
1
2
3 16
2
4 2 1
20 5 6
18 19 21

1 Bolt 2 M10  21 mm
2 Gasket 4 
3 Oil pipe 1
4 Bolt 2 M6  25 mm
5 Timing chain tensioner 1
6 Gasket 1 
7 Timing chain guide 1 Exhaust side
8 Bolt 24 M7  45 mm
13 Dowel pin 12
14 Intake camshaft 1
15 Exhaust camshaft 1
16 Bolt 4 M7  11 mm
5-67
1
8 8
16 N·m (1.6 kgf·m, 11.8 ft·lb)
8
10
10 13 8
18 N·m (1.8 kgf·m, 13.3 ft·lb)

9
13
13
13
8
12
8
12 2
13 13
14
16
20 N·m (2.0 kgf·m, 14.8 ft·lb)
10 N·m (1.0 kgf·m, 7.4 ft·lb)

17
11
17
13 13
13
3
16
4
15
1
2
3 16
2
4 2 1
20 5 6 5
18 19 21
7
6
17
18
19
Camshaft sprocket
Bolt
Chain guide plate
2
2
1
M6  30 mm 7
20 Timing chain guide 1 Intake side
21 Timing chain 1
8
9
5-68
A
POWR
Power unit
Camshaft removal
b
When installing the camshafts, piston #1 a
must be positioned at TDC. Therefore, do
not turn the crankshaft after removing the
camshafts.
1. Install the special service tools into spark

plug hole #1.
#1 #2 #3 #4
a
c
b
Coupler wrench e: 90890-06729
TIP:
Make sure that the punch marks a on the
camshafts are aligned with the marks b on
the camshaft caps.
Dial indicator gauge a: YU-03097
Dial gauge stand set b: YB-06585 3. Make marks c on the camshaft
Dial gauge set a: 90890-01252 sprockets and camshafts.
Dial gauge needle b: 90890-06584
Gauge stand c: 90890-06725 c

drive coupling d counterclockwise using
the special service tool e, referring to
the dial gauge to ensure that the piston
has reached TDC.
4. Remove the oil pipe f, gaskets g,

timing chain tensioner h, and gasket i.
g
e d
f
i
g h
5. Remove the timing chain guide (exhaust

side).
5-69
6. Remove the intake camshaft caps and
exhaust camshaft caps.
TIP:
Loosen the camshaft cap bolts in the oppo-
site order used for tightening.
a
1
7. Remove the intake camshaft j and
b
exhaust camshaft k.
j
k Cam lobe height a:
Intake:
2
IN 41.330–41.430 mm (1.627–1.631 in)
l
EX
Limit:
41.320 mm (1.626 in)
Exhaust:
41.220–41.320 mm (1.623–1.627 in)
3
Limit:
TIP:
Fasten the timing chain using a wire l.
41.210 mm (1.622 in)
Cam lobe width b:
Intake and exhaust:
31.956–32.056 mm (1.258–1.262 in)
4
5
Camshaft sprocket removal 3. Measure the camshaft journal diameter.
1. Hold the camshaft sprocket using the c
special service tool a, and then loosen
the camshaft sprocket bolts b.
a
6
b Camshaft journal diameter c:
Intake and exhaust:
24.960–24.980 mm
7
Camshaft wrench a: 90890-06724 (0.9827–0.9835 in)
2. Remove the intake camshaft sprocket

and exhaust camshaft sprocket.
4. Measure the camshaft runout. Replace if
out of specification. 8
Camshaft check
1. Check the camshaft lobes. Replace if pit-
ted or scratched.
2. Measure the cam lobe height a and

9
width b. Replace if out of specification.
5-70
A
POWR
Power unit
TIP:
Do not put the Plastigauge over the oil hole in
the camshaft journal.
4. Install the dowel pins d, intake camshaft

caps e and f, and exhaust camshaft
caps g and h.
f
f
h
Camshaft runout:
d
0.015 mm (0.0006 in)
Limit: h
e d
0.05 mm (0.0020 in) d
Camshaft journal oil clearance check d d

g
1. Remove the valve lifters a and valve
d
pads b.
a
IN R IN L IN
a a a
TIP:
Write down the position of each valve lifter a
EX EX R EX L
and valve pad b so that they can be installed
in their original positions.
TIP:
When installing the camshaft caps, make
2. Place the camshafts on the cylinder
sure that the arrow marks a on the camshaft
head.
caps point toward the camshaft sprockets.
3. Put a piece of Plastigauge c on each
camshaft journal, parallel to the 5. Tighten the camshaft cap bolts i until
camshaft. camshaft caps contact the cylinder head
in the order a, b, and so on.
IN
c
f
k g a i d
h
l e b j c
g
k f i b c
e
l h j a d
EX i
5-71
2. While squeezing the ends of the snap
TIP: ring e so that it fits into the groove d in
Make sure to keep the camshafts level. the timing chain tensioner rod a, release
1
the tensioner rod slowly until it is locked
6. Tighten the camshaft cap bolts i to the in place.
specified torque in the order a, b, and
so on.
b
IN
a
b
c
d
e
f
g
h
i
j
k
l
c
a
2
c
a e g i k
3
d
b f h j l
EX i
Camshaft cap bolt i:
TIP:
16 N·m (1.6 kgf·m, 11.8 ft·lb)
Do not turn the camshafts when measuring

e 4
the camshaft journal oil clearance using the e
d
Plastigauge.
7. Remove the camshaft caps, and then

measure the width of the Plastigauge c.
TIP:
Make sure that the timing chain tensioner rod
5
a is locked in place before releasing the
c
snap ring e.
3. Push the timing chain tensioner rod a

slightly. Check that the snap ring e
6
releases the timing chain tensioner rod
a, allowing the tensioner rod to pop out.
Camshaft sprocket installation

1. Install the exhaust camshaft sprocket and
7
Camshaft journal oil clearance: intake camshaft sprocket.
0.020–0.061 mm (0.0008–0.0024 in)
Limit:
0.08 mm (0.0031 in) a
8
Timing chain tensioner check
1. While pushing the timing chain tensioner
rod a, turn the timing chain tensioner
housing b in direction c until the groove
b
9
d in the tensioner rod is aligned with the
snap ring e.
5-72
A
POWR
Power unit
TIP: a
• Install each camshaft sprocket with the IN c
punch mark a facing outward. d
• When installing an original camshaft e
sprocket, make sure to align the marks b
made during removal.
2. Hold the camshaft sprocket using the EX

special service tool a, and then tighten
the camshaft sprocket bolts b to the
specified torque. IN EX
b
a
b
TIP:
• Make sure that the punch marks a on the
Camshaft wrench a: 90890-06724 camshafts face up.
• Make sure that the exhaust side b of the
Camshaft sprocket bolt b: timing chain is taut.
18 N·m (1.8 kgf·m, 13.3 ft·lb)
Camshaft installation 5. Install the dowel pins f, intake camshaft

caps g and h, and exhaust camshaft
1. Position piston #1 at TDC. See “Cam-
caps i and j.
shaft removal” (5-69).
h
2. Install the valve pads a and valve lifters h
j
b in their original positions.
f
b j
g f
a f
f f
i
f
3. Install the timing chain guide (exhaust

side).
4. Install the exhaust camshaft c, intake

camshaft d, and timing chain e.
5-73
8. Align the punch marks d on the
IN R IN L IN camshafts with the marks e on the
camshaft caps.
c c c e
d
1
TIP:
EX EX R EX L
When installing the camshaft caps, make

2
sure that the arrow marks c on the camshaft
caps point toward the camshaft sprockets.
6. Tighten the camshaft cap bolts k until

#1 #2 #3 #4
3
camshaft caps contact the cylinder head
9. While pushing the timing chain tensioner
in the order a, b, and so on.
k
f
g
IN
a i d
rod f, turn the timing chain tensioner
housing g in direction h until the groove
k in the tensioner rod is aligned with the
snap ring m.
4
h
l e b j c
5
10. While squeezing the ends of the snap
g
k f i b c ring m so that it fits into the groove k in
e the timing chain tensioner rod f, release
l h j a d
the tensioner rod slowly until it is locked
EX k in place.
TIP:
Make sure to keep the camshafts level.
g 6
f
7. Tighten the camshaft cap bolts k to the
specified torque in the order a, b, and
so on.
IN
h
7
c
a
b
a
d
c
d
e
f
e
g
h
g
i
j
i
k
l
k
8
b f h j l
Camshaft cap bolt k:

EX k
m
k
m
9
16 N·m (1.6 kgf·m, 11.8 ft·lb)
5-74
A
POWR
Power unit
11. Install a new gasket l and the timing
chain tensioner m onto the cylinder
head, and then tighten the timing chain n
tensioner bolts n temporarily.
12. Install new gaskets o and the oil pipe p

to the cylinder head and timing chain
tensioner m, and then tighten the oil pipe
bolts q temporarily.
13. Tighten the timing chain tensioner bolts

Coupler wrench s: 90890-06729
n to the specified torque.
14. Tighten the oil pipe bolts q to the TIP:

specified torque. Check that the portion n of the timing chain
is taut. If the timing chain is not taut, turn the
drive coupling slightly clockwise, and then
check that the timing chain is taut again.
o
q 16. Position piston #1 at TDC. See

n “Camshaft removal” (5-69).
p m Valve clearance adjustment

l 1. Measure the valve clearances. See
o n
“Valve clearance measurement” (3-7).
Timing chain tensioner bolt n:
10 N·m (1.0 kgf·m, 7.4 ft·lb) 2. Remove the camshaft caps and
Oil pipe bolt q: camshafts. See “Camshaft removal” (5-
20 N·m (2.0 kgf·m, 14.8 ft·lb) 69).
15. Turn the drive coupling r 3. Remove the valve lifters a and valve
counterclockwise 2 full turns, and then pads b.
check that the camshaft turns smoothly. a
s r
TIP:
and valve pad b so that they can be installed
4. Check the valve pad number a.
5-75
a
148 1
TIP:
The thickness of each valve pad is marked in
2
hundredths of millimeters on the side that #1 #2 #3 #4
contacts the valve lifter.
5. Round off the original valve pad number

IN
EX
✔
✔
—
✔
✔
—
—
—
3
according to the following table. —: Not applicable
Last digit
0, 1, 2
4, 5, 6
8, 9
Rounded value
0
5
10
11. Install the special service tools into spark
plug hole #4.
c
4
e
6. Select the new valve pad number from
the “Valve pad selection table” (5-78).
TIP:
d
5
The valve pads are available in 23 thick-
nesses, ranging from 1.20 mm to 2.30 mm in
0.05 mm increments.
7. Install the selected valve pad b and

Dial indicator gauge c: YU-03097
6
Dial gauge stand set d: YB-06585
valve lifter a. Dial gauge set c: 90890-01252
b
a Dial gauge needle d: 90890-06584
Gauge stand e: 90890-06725

7
drive coupling f 360° counterclockwise
using the special service tool g.
8
8. Turn the valve lifter and check that it
turns smoothly. 9
9. Position piston #1 at TDC, and then
install the camshafts and camshaft caps. g
A
f
See “Camshaft installation” (5-73).
5-76
POWR
Power unit
Coupler wrench g: 90890-06729

4
#1 #2 #3 #4
IN — ✔ — ✔
EX — — ✔ ✔
—: Not applicable
5-77
Valve pad selection table
Intake
Measured Original valve pad number
1
clearance 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.00–0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210
0.03–0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.07–0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.11–0.13 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.14–0.23 Standard clearance
0.24–0.26 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
2
0.27–0.31 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.32–0.36 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.37–0.41 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.42–0.46 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.47–0.51 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.52–0.56 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.57–0.61 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
3
0.62–0.66 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.67–0.71 170 175 180 185 190 195 200 205 210 215 220 225 230
0.72–0.76 175 180 185 190 195 200 205 210 215 220 225 230
0.77–0.81 180 185 190 195 200 205 210 215 220 225 230
0.82–0.86 185 190 195 200 205 210 215 220 225 230 Example:
0.87–0.91 190 195 200 205 210 215 220 225 230 Measured valve clearance is 0.29 mm (0.0114 in)
0.92–0.96 195 200 205 210 215 220 225 230 Original valve pad number is 148 (thickness =
4
0.97–1.01 200 205 210 215 220 225 230 1.48 mm)
1.02–1.06 205 210 215 220 225 230 • Round off the original valve pad number 148 to 150
1.07–1.11 210 215 220 225 230
(thickness = 1.50 mm).
1.12–1.16 215 220 225 230
1.17–1.21 220 225 230
• Select the new valve pad number using the valve pad
1.22–1.26 225 230 selection table.
1.27–1.31 230 New valve pad number is 160 (thickness = 1.60 mm)
Exhaust
Measured
clearance
0.00–0.01
120 125 130 135 140 145 150 155
120
160
125
Original valve pad number
165 170 175 180 185 190 195 200 205 210 215 220 225
130 135 140 145 150 155 160 165 170 175 180 185 190
230
195
5
0.02–0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
6
0.05–0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205
0.10–0.14 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210
0.15–0.19 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.20–0.24 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.25–0.27 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.28–0.37 Standard clearance
0.38–0.40 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
7
0.41–0.45 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.46–0.50 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.51–0.55 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.56–0.60 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.61–0.65 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.66–0.70 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.71–0.75 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
8
0.76–0.80 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.81–0.85 170 175 180 185 190 195 200 205 210 215 220 225 230
0.86–0.90 175 180 185 190 195 200 205 210 215 220 225 230
0.91–0.95 180 185 190 195 200 205 210 215 220 225 230
0.96–1.00 185 190 195 200 205 210 215 220 225 230 Example:
1.01–1.05 190 195 200 205 210 215 220 225 230 Measured valve clearance is 0.47 mm (0.0185 in)
1.06–1.10 195 200 205 210 215 220 225 230 Original valve pad number is 168 (thickness =
9
1.11–1.15 200 205 210 215 220 225 230 1.68 mm)
1.16–1.20 205 210 215 220 225 230 • Round off the original valve pad number 168 to 170
1.21–1.25 210 215 220 225 230
(thickness = 1.70 mm).
1.26–1.30 215 220 225 230
1.31–1.35 220 225 230
• Select the new valve pad number using the valve pad
1.36–1.40 225 230 selection table.
1.41–1.45 230 New valve pad number is 185 (thickness = 1.85 mm)
5-78
A
POWR
Power unit
Cylinder head
2
9 10
55 N·m (5.5 kgf·m, 40.6 ft·lb)
42 N·m (4.2 kgf·m, 31.0 ft·lb) 90°
3
10 N·m (1.0 kgf·m, 7.4 ft·lb) 2
3
10
1
9
4
12 N·m (1.2 kgf·m, 8.9 ft·lb)
A
8
5

1 Bolt 3 M6  55 mm
2 Bolt 10  M12  140 mm
3 Washer 10
4 Cylinder head assy. 1
5 Gasket 1 
6 Dowel pin 2
7 Bolt 1 A FX HO, FX Cruiser HO, M10  25 mm
8 Engine hanger 1 A FX HO, FX Cruiser HO
9 Bolt 4 M6  12 mm
10 Engine hanger 2
5-79
Cylinder head / Valve and valve spring
Valve and valve spring
1
1 1
2 2
3 3 3
3
4 4
5 5
6
9 9
6 2
10 10
3
11 4
5
8
6
7

1
2
3
Valve lifter
Valve pad
Valve cotter
16
16
32
7
4 Upper spring seat 16
5 Valve spring 16
6
7
8
Lower spring seat
Intake valve
Exhaust valve
16
8
8
8
9 Valve seal 16 
9
10 Valve guide 16 
11 Cylinder head 1
5-80
A
POWR
Power unit
Cylinder head disassembly 3. Remove the valve seals.
1. Remove the valve lifters a and valve
pads b. Cylinder head check
1. Remove carbon deposits from the com-
a bustion chambers.
b
2. Check the cylinder head water jacket.
Clean if there are mineral deposits or
rust.
3. Check the cylinder head warpage using a

straightedge a and thickness gauge b
in the directions shown. Replace if out of
specification.
TIP:
and valve pad b so that they can be installed a b
2. Remove the intake valves and exhaust

valves.
Cylinder head warpage limit:

0.10 mm (0.0039 in)
c Valve spring check

1. Measure the valve spring free length a.
Valve spring compressor c:
YM-04019/90890-04019
Compressor adapter d: YM-04114
Valve spring compressor attachment d:
90890-04114
TIP:
Write down the position of each valve, spring,
and other parts so that they can be installed
a
5-81
Valve spring free length a: Valve margin thickness b:

Intake and exhaust: Intake and exhaust:
45.58 mm (1.79 in) 0.800–1.200 mm (0.0315–0.0472 in)
Limit:
43.30 mm (1.70 in)
2. Measure the valve spring tilt b. Replace

3. Measure the valve stem diameter c.
Replace if out of specification. 1
c
b
2
Valve stem diameter c:
3
Intake:
Valve spring tilt limit b:
Intake and exhaust:
2.0 mm (0.08 in)
5.477–5.492 mm (0.2156–0.2162 in)
Limit:
5.447 mm (0.2144 in)
Exhaust:
4
Valve check 5.464–5.479 mm (0.2151–0.2157 in)
1. Measure the valve face width a.
a
Limit:
5.434 mm (0.2139 in)
4. Measure the valve stem runout. Replace

5
6
Valve face width a:
Intake and exhaust:
2.260–2.830 mm (0.0890–0.1114 in)
7
2. Measure the valve margin thickness b.
b
Valve stem runout limit:
Intake and exhaust:
0.01 mm (0.0004 in)
8
Valve guide check
1. Measure the valve guide inside diameter
a.
9
5-82
A
POWR
Power unit
Valve guide remover a: YB-06801

Valve guide remover/installer a:
90890-06801
a Valve guide installation

1. Insert the special service tools a and b
into the camshaft side of the valve guide
c. NOTICE: Do not reuse a valve
guide, always replace it with a new
one.
Valve guide inside diameter a:
Intake and exhaust: 2. Strike the special service tool a to drive
5.504–5.522 mm (0.2167–0.2174 in) the valve guide into the cylinder head.
2. Calculate the valve-stem-to-valve-guide a

clearance. Replace the valve and valve
guide if out of specification.
Valve-stem-to-valve-guide clearance = b
valve guide inside diameter – valve stem
diameter: a
Intake:
0.012–0.045 mm (0.0005–0.0018 in) c
Limit:
0.080 mm (0.0031 in) Valve guide remover a: YB-06801
Exhaust: Valve guide remover/installer a:
0.025–0.058 mm (0.0010–0.0023 in) 90890-06801
Limit: Valve guide installer b:
0.100 mm (0.0039 in) YB-06810/90890-06810
Valve guide removal Valve guide installation height a:

1. Insert the special service tool a into the Intake and exhaust:
combustion chamber side of the valve 12.3–12.7 mm (0.4843–0.5000 in)
guide b.
3. Insert the special service tool d into the
2. Strike the special service tool a to drive valve guide c, and then ream the valve
the valve guide b out of the cylinder guide c.
head.
d
a
c
b
Valve guide reamer d:

YM-01196/90890-06804
5-83
4. Measure the valve seat contact width a
TIP: where the blueing dye is adhered to the
• Turn the special service tool d clockwise to valve face. Reface the valve seat if the
ream the valve guide.
1
valve is not seated properly or if the valve
• Do not turn the special service tool d seat contact width a is out of
counterclockwise when removing the tool. specification. Replace the valve guide if
the valve seat contact width a is uneven.
4. Clean the valve guide inner surface.
2
Measure the valve guide inside diameter
b.
b
3
Valve guide inside diameter b:
Intake and exhaust:
4
5.504–5.522 mm (0.2167–0.2174 in)
Valve seat check

1. Remove carbon deposits from the valves
and valve seats.
5
2. Apply a thin, even layer of Mechanic’s
blueing dye (Dykem) onto the valve seat.
3. Press the valve lightly against the valve Valve seat contact width a:
6
seat using the special service tool a. Intake:
7
1.400–1.600 mm (0.0551–0.0630 in)
a Limit:
2.100 mm (0.0827 in)
Exhaust:
1.500–1.700 mm (0.0591–0.0669 in)
8
Limit:
2.200 mm (0.0866 in)
Valve seat refacing
Valve lapping tool a: YM-A8998

Valve lapper a: 90890-04101 After every lapping procedure, make sure
to clean off any remaining lapping com-
pound from the cylinder head and valves.
9
1. Reface the valve seat.
5-84
A
POWR
Power unit
A
45
a
30 45 60
30
45
B
a Slag or rough surface
30 45 60 3. Adjust the top edge of the valve seat
contact width using a 30° cutter.
A U.S.A. and Canada

30
B Worldwide
b
Neway valve seat kit: YB-91044
Valve seat cutter holder: 90890-06812
Intake:
Valve seat cutter 30°: 90890-06720
Exhaust:
Valve seat cutter 30°: 90890-06818 b Previous contact width
4. Adjust the bottom edge of the valve seat
contact width using a 60° cutter.
2. Cut the surface of the valve seat using a
45° cutter by turning the cutter clockwise
until the valve seat face has become b
smooth. NOTICE: Do not over cut the
valve seat. To prevent chatter marks,
make sure to turn the cutter evenly
using a downward force of 40–50 N
(4.0–5.0 kgf, 8.8–11.0 lbf). 60
b Previous contact width
5. Adjust the valve seat contact width to

specification using a 45° cutter.
5-85
• If the valve seat contact area is too narrow
and situated near the bottom edge of the
b valve face, cut the bottom edge of the valve
c
1
seat using a 60° cutter to center the area,
and then set its width using a 45° cutter.
45 b

c Specified contact width
2
60
6. Check the valve seat contact area of the
valve. See “Valve seat check” (5-84).
Example:
• If the valve seat contact area is too wide
7. After refacing the valve seat to the

3
and situated in the center of the valve face, specified contact width, apply a thin,
cut the top edge of the valve seat using a
30° cutter, and then cut the bottom edge
using a 60° cutter to center the area and set
its width.
even layer of lapping compound onto the
valve seat, and then lap the valve using
the special service tool a. NOTICE: Do
not get the lapping compound on the
4
valve stem and valve guide.
30
b
a 5
60 6
• If the valve seat contact area is too narrow

and situated near the top edge of the valve
face, cut the top edge of the valve seat
Valve lapping tool a: YM-A8998
Valve lapper a: 90890-04101
8. Recheck the valve seat contact area of

7
using a 30° cutter to center the area, and
the valve. See “Valve seat check” (5-84).
then set its width using a 45° cutter.
30
b
Cylinder head assembly
1. Install a new valve seal.
8
2. Install the valve a, valve spring seat b,
valve spring c, and valve spring retainer
d in this order, and then install the
special service tools e and f.
9
5-86
A
POWR
Power unit
d
c g
b f
4. Tap the valve spring retainer lightly using

a plastic hammer to seat the valve
e cotters g securely.
a
c
g g
b
Valve spring compressor e:

YM-04019/90890-04019
Compressor adapter f: YM-04114
Valve spring compressor attachment f:
90890-04114
5. Install the valve pads h and valve lifters
TIP: i in their original positions.
• When installing a new valve, always replace i
the valve guide with a new one.
• Install the valve spring with the larger pitch h
a toward the camshaft and the smaller
pitch b toward the combustion chamber.
• The upper end c of the valve spring with
the larger pitch is painted red.
3. Compress the valve spring, and then

install the valve cotters g.
5-87
Cylinder head installation
b, the cylinder head assy. c, the wash-
1
ers d, and the cylinder head bolts e,
and then tighten the cylinder head bolts
e to the specified torques in 2 stages
and in the order a, b, and so on.
2. Install the cylinder head bolts f, and

then tighten them to the specified torque.
e
2
d
f
c
3
b
a
a
4
j
e
f b
e
c
e
g
5
f
i e a d h
6
e e e
Cylinder head bolt e (M12):

1st: 55 N·m (5.5 kgf·m, 40.6 ft·lb)
2nd: 90°
7
Cylinder head bolt f (M6):
8
10 N·m (1.0 kgf·m, 7.4 ft·lb)
9
5-88
A
POWR
Power unit
Generator cover assy. and flywheel magneto
12
7
11
6
4 10
8 19
7
3 6
1 5
2
26 N·m (2.6 kgf·m, 19.2 ft·lb)

250 N·m (25.0 kgf·m, 184.4 ft·lb) 10
80 N·m (8.0 kgf·m, 59.0 ft·lb)
17
24 N·m (2.4 kgf·m, 17.7 ft·lb)
18 9
15
14 16
15
13 60°
250 N·m (25.0 kgf·m, 184.4 ft·lb)

1 Holder 1 Left-hand threads
2 Drive coupling 1
3 Washer 1 
4 Holder 1
5 Bolt 2 M6  20 mm
6 Collar 2
7 Grommet 2
8 Bolt 9 M8  50 mm
9 Gasket 1 
10 Dowel pin 2
11 Shaft 1
12 Idle gear 1
13 Transfer shaft 1 
14 Special nut 1 
15 Bolt 6  M8  20 mm
16 Flywheel magneto 1 
5-89
Generator cover assy. and flywheel magneto
1
12
7
11
6
4
8
10
19
2
7
3
3
1 6
5
2
26 N·m (2.6 kgf·m, 19.2 ft·lb)

250 N·m (25.0 kgf·m, 184.4 ft·lb) 10
80 N·m (8.0 kgf·m, 59.0 ft·lb)
24 N·m (2.4 kgf·m, 17.7 ft·lb)
17
18 9 4
14
15
16
5
15
13
50 N·m (5.0 kgf·m, 36.9 ft·lb)
60°
250 N·m (25.0 kgf·m, 184.4 ft·lb)
250 N·m (25.0 kgf·m, 184.4 ft·lb)
6
17
18
19
Starter clutch assy.
Starter gear
Woodruff key
1
1
1 
7
8
9
5-90
A
POWR
Power unit
Generator cover
8
15 N·m (1.5 kgf·m, 11.1 ft·lb)
15 N·m (1.5 kgf·m, 11.1 ft·lb)
2 9
10
5
4
11
3
3
1 Bolt 2 M6  15 mm
2 Holder 1
3 Bolt 2 M5  15 mm
4 Bolt 1 M5  10 mm
5 Washer 1
6 Bolt 3 M6  30 mm
7 Stator coil assy. 1
8 Oil seal 1 
9 Circlip 1
10 Ball bearing 1 
11 Generator cover 1
5-91
Generator cover
Drive coupling removal
Use heat-resistant
burns could result.
gloves. Otherwise,
1. Heat the holder a and drive coupling b

1
for 20–30 minutes using a heat gun c. f
d b
NOTICE: Be careful not to damage
the wiring harness when using the
heat gun.
f
d e
2
c
b
3
a
b
2. Hold the drive coupling b using the

Coupler wrench d: 90890-06729
Crankshaft holder f: 90890-06732
Flywheel magneto removal

4
special service tool d, and then loosen
the holder a by turning it clockwise.
Use heat-resistant
burns could result.
gloves. Otherwise,
5
1. Remove the generator cover assy.
2. Heat the transfer shaft assy. a for 20–30

minutes using a heat gun b.
6
d b
7
b
d a
b
a
3. Hold the flywheel magneto c using the

8
special service tools d and e, and then
9
loosen the special nut f.
3. Hold the transfer shaft e using the
special service tool f, and then remove
the drive coupling b using the special
service tool d.
5-92
A
POWR
Power unit
e e
g h
d c ad c
d d
g f h a
c c
Shaft holder d: 90890-06721 Shaft holder d: 90890-06721

Driver handle e: 90890-06722 Driver handle e: 90890-06722
Crankshaft holder h: 90890-06732
TIP:
5. Remove the flywheel magneto c and
• Loosen the special nut f until it can no
Woodruff key using the special service
longer be turned.
tools i and j.
• Use a width across flats 12 mm hexagon bit
socket g with a length of 150 mm (5.91 in)
or more. c
i
j
special service tools d and e, and then
remove the transfer shaft assy. a using
the special service tool h.
Flywheel puller i: 90890-06723

Rotor puller j: 90890-01080

special service tool k, and then loosen
the starter clutch bolts l.
5-93
Generator cover
c l A
l g h
l
k
i
1
Primary sheave holder k: YS-01880-A
Sheave holder k: 90890-01701
B
j
2
g
k
3
7. Remove the starter clutch.
Generator cover assy. disassembly

1. Remove the washer a, pickup coil b,
holder c, and stator coil assy. d.
c A U.S.A. and Canada

B Worldwide
4
Driver handle (small) h: YB-06229
d
a
Bearing and seal installer i: YW-06356
Driver rod LS j: 90890-06606
Bearing outer race attachment k:
90890-06627
5
b
Starter clutch operation check
1. Install the starter clutch a onto the
starter gear b and hold the starter clutch
a.
6
2. Remove the oil seal e and circlip f.
f
2. Turn the starter gear b clockwise a and
check that it turns smoothly. Replace if it
does not turn smoothly. 7
3. Turn the starter gear b counterclockwise
b and check that it does not turn.
Replace if it turns.
8
3. Remove the ball bearing g.
b
a
9
a
b
5-94
A
POWR
Power unit
Generator cover assy. assembly A
1. Install a new ball bearing a. b
A h
b
EP
c g
a
A
B i
d
e EP
g
a
A
A U.S.A. and Canada

B Worldwide
A U.S.A. and Canada Driver handle (large) b: YB-06071
B Worldwide Forward bearing race installer h:
Driver handle (large) b: YB-06071 YB-06258
Forward gear outer race installer c: Bearing pressure C i: 90890-02393
YB-41446
Driver rod LS d: 90890-06606 4. Install the stator coil assy. j, holder k,
Ball bearing attachment e: 90890-06657 pickup coil l, and washer m, and then
tighten the holder bolts n and stator coil
2. Install the circlip f. assy. bolts o to the specified torques.
o
o
f n
j
l
a l
b k
3. Install a new oil seal g.
Holder bolt n:
15 N·m (1.5 kgf·m, 11.1 ft·lb)
Stator coil assy. bolt o:
15 N·m (1.5 kgf·m, 11.1 ft·lb)
5-95
Generator cover
3. Install the flywheel magneto b to the
TIP: starter gear e.
Pass the pickup coil lead a between the gen-
erator cover and the bolt hole b, and then
secure the lead by installing the washer m.
Flywheel magneto installation

e
1
Do not reuse a flywheel magneto, special
nut, flywheel magneto bolt, transfer shaft,
or woodruff key, always replace it with a
b
2
new one. TIP:
1. Install the starter clutch a to a new fly-

wheel magneto b. NOTICE: Make sure
that the starter clutch is installed into
Turn the starter gear e clockwise while
installing it onto the flywheel magneto b.
3
4. Remove any grease from a new special
the outer flange so that the side a is nut f and the inner surface of a new
facing toward the flywheel magneto. transfer shaft g, and then install the
special nut f into the transfer shaft g
until it can no longer be turned.
4
a
g f
a 5
b f
2. Hold the flywheel magneto b using the

special service tool c, and then tighten
new flywheel magneto bolts d to the
g 6
5. Clean the tapered portion b of the
specified torque. crankshaft and inner surface c of the
d
d
b
flywheel magneto b.
6. Install a new Woodruff key h and the

7
flywheel magneto b.
c
d 8
Primary sheave holder c: YS-01880-A
Sheave holder c: 90890-01701 9
Flywheel magneto bolt d:
24 N·m (2.4 kgf·m, 17.7 ft·lb)
5-96
A
POWR
Power unit
h Shaft holder i: 90890-06721

Driver handle j: 90890-06722
h Crankshaft holder k: 90890-06732
b Transfer shaft g:
50 N·m (5.0 kgf·m, 36.9 ft·lb)
9. Using the hexagonal portion of the

c special service tool k as reference, mark
the special service tool i at 0°, 60°, and
120°.
b 10. Make a mark d on the transfer shaft g

where the shaft is aligned with the 0°
7. Install the transfer shaft g. mark on the special service tool i.
A g d
0°
i 60°
120°
60°
g
k
8. Hold the flywheel magneto b using the Shaft holder i: 90890-06721

special service tools i and j, and then Crankshaft holder k: 90890-06732
tighten the transfer shaft g to the
specified torque using the special service TIP:
tool k. The angle from one corner of the hexagonal
head of the special service tool k to another
b corner is 60°.
i
g 11. Hold the flywheel magneto b using the
special service tools i and j, and then
k
tighten the transfer shaft g to the
specified angle using the special service
j
tool k.
b
b i
i
k g g
k
5-97
Generator cover
g b
60° i
l
1
j
k
Shaft holder i: 90890-06721

l
i
2
Crankshaft holder k: 90890-06732
Transfer shaft g: 60°
12. Tighten the transfer shaft g to the

f
b
3
specified torque using the special service
tool k. NOTICE: If the mark d on the
transfer shaft g moves past the 120°
mark on the special service tool i
before the specified torque is reached,
Special nut f:
4
repeat the procedure from step 5. 250 N·m (25.0 kgf·m, 184.4 ft·lb)
i
g d
60° j
TIP:
Use a width across flats 12 mm hexagon bit
socket l with a length of 150 mm (5.91 in) or
5
OK more.
k
120°
14. Install the idle gear.
15. Install the dowel pins m, a new gasket

6
n, and the generator cover o, and then
7
tighten the generator cover assy. bolts p
Crankshaft holder k: 90890-06732
m
Transfer shaft g:
8
250 N·m (25.0 kgf·m, 184.4 ft·lb)
o
13. Hold the flywheel magneto b using the
special service tools i and j, and then
tighten the special nut f to the specified
torque. NOTICE: To allow the LOCTITE
648 to set, wait approximately 1 hour
after completing this procedure.
n
m
9
p
5-98
A
POWR
Power unit
4. Remove any grease from the threaded
Generator cover assy. bolt p:
portion of the holder e.
26 N·m (2.6 kgf·m, 19.2 ft·lb)
Drive coupling installation 5. Install the holder e.

1. Remove any grease from the threaded
portion of the transfer shaft, making sure
that the threads are clean and dry.
2. Install a new washer a and the drive

coupling b. NOTICE: Do not reuse a
washer, always replace it with a new
one.
e
b a 6. Hold the drive coupling b using the

special service tool d, and then turn the
holder e counterclockwise to tighten it to
the specified torque. NOTICE: To allow
the LOCTITE 648 to set, wait
approximately 1 hour after completing
this procedure.
3. Hold the transfer shaft using the special

service tool c, and then tighten the drive d
coupling b to the specified torque using
the special service tool d.
b
d
b
c
d b
d e
b
c
Holder e:
80 N·m (8.0 kgf·m, 59.0 ft·lb)
Crankshaft holder c: 90890-06732

Drive coupling b:
250 N·m (25.0 kgf·m, 184.4 ft·lb)
5-99
Generator cover / Cylinder block and electrical part (FX SHO, FX Cruiser SHO)
Cylinder block and electrical part (FX SHO, FX Cruiser SHO)
5
1
1 3
4
7 6
2
1
2
17
6 3
18
4
14 15 N·m (1.5 kgf·m, 11.1 ft·lb)
13
5
12
11
10 9
16
6
15
15 N·m (1.5 kgf·m, 11.1 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 8

1
2
3
Bolt
Earth plate
Gasket
2
1
1
M6  25 mm

7
4 Clamp 2
5 Oil return hose 1
6
7
8
Bolt
Thermoswitch
Bolt
2
1
1
M6  16 mm
M8  40 mm
8
9 Anode assy. 1
9
10 Bolt 1 M6  20 mm
11 Gasket 1 
12 Cover 1
13 Grommet 1
14 Anode 1
15
16
Gasket
1
1 
5-100
A
POWR
Power unit
1 3
4
7 6
2
1
6
17
18
14 15 N·m (1.5 kgf·m, 11.1 ft·lb)
13
12
11
10 9
16
15
15 N·m (1.5 kgf·m, 11.1 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 8

17 Holder 1
18 Knock sensor 1
5-101
Cylinder block and electrical part (FX SHO, FX Cruiser SHO) /
Cylinder block and electrical part (FX HO, FX Cruiser HO)
Cylinder block and electrical part (FX HO, FX Cruiser HO)

11 N·m (1.1 kgf·m, 8.1 ft·lb) 14 6
14
5
7
15
7
7
19 N·m (1.9 kgf·m, 14.0 ft·lb)
1
7
16
1 3
4
9
2
1
2
18 17
8 3
17
10
11
12
4
25
24 13
23
22
21 20 5
27
15 N·m (1.5 kgf·m, 11.1 ft·lb)

26
20 N·m (2.0 kgf·m, 14.8 ft·lb)

19 6
1
2
3
Bolt
Earth plate
Gasket
2
1
1
M6  25 mm

7
4 Clamp 2
5 Oil return hose 1
6
7
8
Oil level gauge
Bolt
Bolt
1
4
2
M8  20 mm
M6  12 mm
8
9 Oil level pipe assy. 1
9
10 Clamp 1
11 Oil level pipe plate 1
12 Grommet 1
13 O-ring 1 
14 Bolt 2 M6  16 mm
15
16
Plate
Gasket
1
1 
5-102
A
POWR
Power unit
11 N·m (1.1 kgf·m, 8.1 ft·lb) 14 6

14
7 7
4 7
19 N·m (1.9 kgf·m, 14.0 ft·lb)
5 15
7
16
9
1 3
4
2
1 18 17
8
10
17
11
12
25
24 13
23
22
21 20
27
26
19

17 Bolt 2 M6  16 mm
18 Thermoswitch 1
19 Bolt 1 M8  40 mm
20 Anode assy. 1
21 Bolt 1 M6  20 mm
22 Gasket 1 
23 Cover 1
24 Grommet 1
25 Anode 1
26 Engine temperature sensor 1
27 Gasket 1 
5-103
Cylinder block and electrical part (FX HO, FX Cruiser HO) / Oil separator tank and oil pan
Oil separator tank and oil pan
10
9
8
7
1
4 3
2
14
6
13
2
9 N·m (0.9 kgf·m, 6.6 ft·lb) 1
12 N·m (1.2 kgf·m, 8.9 ft·lb)

2 N·m (0.2 kgf·m, 1.5 ft·lb)
11
11
3
12
20
18
19
17
18 28
27
12
11
11
4
20 N·m (2.0 kgf·m, 14.8 ft·lb)
21
5
a 0.3 N·m (0.03 kgf·m, 0.2 ft·lb)
b 12 N·m (1.2 kgf·m, 8.9 ft·lb)
16
9 N·m (0.9 kgf·m, 6.6 ft·lb) 24
26
22
23 15
25
10 N·m (1.0 kgf·m, 7.4 ft·lb)
A A
6
1
2
3
Bolt
Oil pressure switch
Plastic tie
1
1
1
M4  8 mm
7
4 Clamp 1
6
7
8
Clamp
Breather hose
Bolt
1
1
9 M6  25 mm
8
9 Water jacket cover 1
9
10 Gasket 1 
11 Bolt 9 M6  20 mm
12 Bolt 2 M6  14 mm
13 Oil separator tank cover 1
14 Gasket 1 
15
16
Bolt
Bolt
17
1
M6  35 mm
M6  20 mm
5-104
A
POWR
Power unit
8
9
10 7
4 3
6
2 13
14
9 N·m (0.9 kgf·m, 6.6 ft·lb) 1

2 N·m (0.2 kgf·m, 1.5 ft·lb)
12 N·m (1.2 kgf·m, 8.9 ft·lb) 11

11
12
20
19 12
11
27 11
18 28
17
18 20 N·m (2.0 kgf·m, 14.8 ft·lb)
21
a 0.3 N·m (0.03 kgf·m, 0.2 ft·lb)
b 12 N·m (1.2 kgf·m, 8.9 ft·lb)
16
9 N·m (0.9 kgf·m, 6.6 ft·lb) 24
26
25
22 15 A
23 10 N·m (1.0 kgf·m, 7.4 ft·lb) A

17 Oil pan 1
18 Dowel pin 2
19 Bolt 6 M6  14 mm
20 Baffle plate 1
21 Bolt 1 M6  14 mm
22 Bolt 2 M6  60 mm
23 Washer 2
24 Oil pipe 1
25 Gasket 1 
26 Grommet 1
27 Oil pan plug 1 M8  20 mm
28 Gasket 1 
5-105
Oil separator tank and oil pan
Anode check 5. Install the baffle plate g, and then
1. Check the anode. Replace if eroded. tighten the baffle plate bolts h to the
Clean if there is grease, oil, or scales. specified torque.
1
NOTICE: Do not apply grease, oil, or
paint to the anode. 6. Install a new gasket i and the oil pan
plug j, and then tighten the oil pan plug
Oil pan assembly j to the specified torque.
1. Install the grommet a onto the oil pipe
2
b. h
2. Install a new gasket c, the oil pipe b,

and the washers d, and then tighten the
oil pipe stay bolts e temporarily.
c
b
a
g i
j 3
Baffle plate bolt h:
4
12 N·m (1.2 kgf·m, 8.9 ft·lb)
Oil pan plug j:
20 N·m (2.0 kgf·m, 14.8 ft·lb)
Oil level pipe installation (FX HO, FX

Cruiser HO)
e d
1. Pass the clamp a through the oil level
pipe b. 5
3. Tighten the oil pipe bolt f to the 2. Install the oil level pipe plate c, the
grommet d, and a new O-ring e onto
specified torque for the 1st stage.
4. Tighten the oil pipe stay bolts e to the

specified torque, and then tighten the oil
b
the oil level pipe b.
d
6
pipe bolt f to the specified torque for the c
7
2nd stage.
a
c e
a
d
b
e
f
e
Installation distance a:
42.5 mm (1.67 in)
8
Oil pipe stay bolt e:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
Oil pipe bolt f:
TIP:
Make sure that the bottom of the grommet d
is at the specified installation distance a
from the end of the oil level pipe b.
9
1st: 0.3 N·m (0.03 kgf·m, 0.2 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
5-106
A
POWR
Power unit
3. Install the oil level pipe assy. onto the
cylinder block, and then tighten the oil
level pipe plate bolts f and oil level pipe
bolt g temporarily.
a b
4. Tighten the oil level pipe plate bolts f to
5. Tighten the oil level pipe bolt g.
g
f c
d
c a d e f d
j
d
i
h c b g k
d d d
Oil level pipe bolt g:
19 N·m (1.9 kgf·m, 14.0 ft·lb)
6. Fasten the grommet d using the clamp

a.
Oil separator tank cover installation

1. Install a new gasket a and the oil sepa-
rator tank cover b, and then tighten the
oil separator tank cover bolts c and d in
the order a, b, and so on.
5-107
Oil separator tank and oil pan / Crankcase, connecting rod, and piston
Crankcase, connecting rod, and piston

A
10 1T
B 8
2T
12
14
50 N·m (5.0 kgf·m, 36.9 ft·lb)
1
13 18
11 E
8 9
7
5
17 19 2
14
3
Y
51 N·m (5.1 kgf·m, 37.6 ft·lb) 14 14
6
90°
14
14 3
4 15
6 16
19
4
23
20
17
17 19
22
21
2
17 5
17 19 17 1
6
18
10 N·m (1.0 kgf·m, 7.4 ft·lb)
20 17
30 N·m (3.0 kgf·m, 22.1 ft·lb)
10 N·m (1.0 kgf·m, 7.4 ft·lb) 90°

1
2
3
Bolt
Bolt
Crankcase
12
10
1
M6  70 mm
 M10  85 mm 7
4 Nut 8
5 Connecting rod assy. 4
6
7
8
Connecting rod bearing
Bolt
Piston pin clip
8
8
8
 M9  50 mm

8
9 Piston pin 4
9
10 Piston 4
11 Piston 4 B FX HO, FX Cruiser HO
12 Piston ring set 4
13 Crankshaft 1
14 Crankshaft bearing 10
15
16
O-ring
Dowel pin
1
1

5-108
A
POWR
Power unit
A
10 1T
12
50 N·m (5.0 kgf·m, 36.9 ft·lb)
2T
14
B 8
13 18
11 E
17 19
7
8 9
5
Y 14
51 N·m (5.1 kgf·m, 37.6 ft·lb) 14 14
6
90°
14
14 3
4 15
6 16
23 19
20
17
2
17 19
17
22
21
17 19 17 1
18
10 N·m (1.0 kgf·m, 7.4 ft·lb)
20 17
30 N·m (3.0 kgf·m, 22.1 ft·lb)
10 N·m (1.0 kgf·m, 7.4 ft·lb) 90°

17 Bolt 12 M10  30 mm
18 Bracket 2
19 Dowel pin 8
20 Bracket 2
21 Bolt 1 M6  12 mm
22 Baffle plate 1
23 Cylinder block 1
5-109
Crankcase disassembly Connecting rod and piston removal
1. Place the crankcase upside down on a 1. Remove the connecting rod cap a, and
bench. then remove the connecting rod bearings
1
b and piston and connecting rod c.
2. Loosen the crankcase bolts in the
opposite order used for tightening. a
a
TIP: b
2
The numbers embossed on the crankcase a
indicate the crankcase tightening order.
3. Remove the crankcase a.
a
a
a
a
a
3
b c
b a 4
TIP:
• Insert a flat-head screwdriver between the
reinforced portions a of the cylinder block
b and the crankcase a to separate them.
TIP:
For reference during installation, make identi-
fication marks a on the connecting rod cap,
5
• Work carefully and make sure that the cylin-
connecting rod, connecting rod bearings, and
der block and crankcase separate evenly.
4. Remove the crankshaft bearings c from

the crankcase.
piston crown.
2. Remove the piston pin clips d, piston pin

e, connecting rod c, and connecting
6
rod bolts f.
c
f
7
c
d
8
f
TIP: e
Write down the position of each crankshaft
bearing so that it can be installed in its origi-
nal position.
d
9
3. Remove the piston rings.
5-110
A
POWR
Power unit
Crankcase check A FX SHO, FX Cruiser SHO
1. Check the oil passages. Blow out using B FX HO, FX Cruiser HO
compressed air if there are obstructions.
2. Measure the piston pin boss bore
Cylinder block check diameter c. Replace if out of
1. Measure the cylinder bore (D1–D6) at specification.
measuring points a, b, and c, and in c
direction d (D1, D3, D5), which is parallel e
to the crankshaft, and direction e (D2, d d
D4, D6), which is at a right angle to the
crankshaft. Replace the crankcase assy.
a
b D2 D1 d
c
D4 D3 e Piston pin boss bore diameter c:
22.004–22.015 mm
D6 D5 (0.8663–0.8667 in)
Limit:
22.045 mm (0.8679 in)
a 20 mm (0.79 in)
TIP:
b 50 mm (1.97 in)
When measuring the piston pin boss bore
c 80 mm (3.15 in)
diameter c, do not measure it at the oil
Cylinder bore (D1–D6): grooves d or piston pin slot e.
86.000–86.015 mm
(3.3858–3.3864 in) Piston clearance check
Limit: 1. Measure the piston diameter. See “Pis-
86.100 mm (3.3898 in) ton check” (5-111).
Piston check 2. Measure the cylinder bore. See “Cylinder
1. Measure the piston diameter a. block check” (5-111).
a
3. Calculate the piston clearance. Replace
b the piston or cylinder block if out of
specification.
Piston clearance = maximum cylinder bore
– piston outside diameter:
0.070–0.100 mm (0.0028–0.0039 in)
Limit:
0.200 mm (0.0079 in)
Piston diameter a: Piston ring check

85.915–85.930 mm 1. Measure piston ring dimensions B and T.
(3.3825–3.3831 in) Replace the piston rings as a set if out of
Measuring point b: specification.
A : 10 mm (0.39 in)
B : 9.5 mm (0.37 in)
5-111
a b
B B f
1
T T
g
c B
h
2
T
Piston ring dimensions: Piston ring groove:

Top ring a: Top ring f:
B: 1.170–1.190 mm (0.0461–0.0469 in) 1.210–1.230 mm (0.0476–0.0484 in)
T: 2.850–3.050 mm (0.1122–0.1201 in)
2nd ring b:
B: 1.170–1.190 mm (0.0461–0.0469 in)
T: 2.600–2.800 mm (0.1024–0.1102 in)
2nd ring g:
1.210–1.230 mm (0.0476–0.0484 in)
Oil ring h:
2.510–2.530 mm (0.0988–0.0996 in)
3
Oil ring c:
4
B: 2.370–2.470 mm (0.0933–0.0972 in) 4. Measure the piston ring side clearance.
T (reference data): Replace the piston and piston rings as a
2.500 mm (0.0984 in) set if out of specification.
2. Measure the piston ring end gap d.

k
m 5
n
e
d
Piston ring side clearance:

6
Top ring k:
Piston ring end gap d:
Top ring:
0.300–0.450 mm (0.0118–0.0177 in)
Limit:
0.020–0.060 mm (0.0008–0.0024 in)
Limit:
0.110 mm (0.0043 in)
2nd ring m:
7
0.700 mm (0.0276 in) 0.020–0.060 mm (0.0008–0.0024 in)
2nd ring:
0.450–0.600 mm (0.0177–0.0236 in)
Limit:
0.850 mm (0.0335 in)
Limit:
0.120 mm (0.0047 in)
Oil ring n:
0.040–0.160 mm (0.0016–0.0063 in)
8
Oil ring:
9
0.100–0.350 mm (0.0039–0.0138 in) Piston pin check
Measuring point e: 1. Measure the piston pin outside diameter
6 mm (0.24 in) a at measuring points b, c, and d,
and in directions e and f. Replace if
3. Measure the piston ring grooves. out of specification.
5-112
A
POWR
Power unit
b
e
c
f
b
Piston pin outside diameter a:
21.991–22.000 mm
(0.8658–0.8661 in) Crankshaft journal diameter a:
Limit: 39.976–40.000 mm
21.981 mm (0.8654 in) (1.5739–1.5748 in)
Crankshaft pin diameter b:
Connecting rod check 41.976–42.000 mm
1. Measure the connecting rod small end (1.6526–1.6535 in)
inside diameter a. Replace the connect-
2. Measure the crankshaft runout. Replace
ing rod assy. if out of specification.
Connecting rod small end inside diameter

Crankshaft runout limit:
a: 22.015–22.028 mm (0.8667–0.8672 in)
0.03 mm (0.0012 in)
Crankshaft check
Crankshaft pin oil clearance check
1. Measure the crankshaft journal diameter
1. Clean the connecting rod bearings a
a and crankshaft pin diameter b.
and connecting rod big end.
2. Install the upper bearing into the

connecting rod b and lower bearing into
the connecting rod cap c.
5-113
Connecting rod nut:

a 1st: 51 N·m (5.1 kgf·m, 37.6 ft·lb)
b 2nd: 90°
B
b b
TIP:
• When checking the oil clearance, reuse the
removed connecting rod bolts.
1
a
5B
c • Make sure that the “Y” mark c on the con-
TIP:
• Install the connecting rod bearings a in
necting rod faces toward the timing chain
drive gear d of the crankshaft.
• Make sure that the characters e on the
connecting rod cap and connecting rod are
2
their original positions. aligned.
• Fit the protrusion a on each bearing into
the slots b in the connecting rod cap c
and connecting rod b.
• Do not turn the connecting rod until the
crankshaft pin oil clearance measurement
has been completed.
3
3. Put a piece of Plastigauge d on the 6. Remove the connecting rod cap and
crankshaft pin, parallel to the crankshaft.
d
measure the width f of the compressed
Plastigauge on each crankshaft pin.
Replace the connecting rod bearings if
4
out of specification.
5
6
f
TIP:
Do not put the Plastigauge d over the oil
hole in the crankshaft pin.
7
Crankshaft pin oil clearance:
0.020–0.056 mm (0.0008–0.0022 in)
4. Install the connecting rod onto the
Limit:
crankshaft pin.
0.09 mm (0.0035 in)
5. Tighten the connecting rod nuts to the
Connecting rod big end side
specified torques in 2 stages.
e
clearance check
1. Measure the connecting rod big end side
clearance a. Measure the connecting
8
d rod big end width b and crankshaft pin
9
width c if out of specification.
5-114
A
POWR
Power unit
5B
a a
2. Check the crankshaft pin size number b

on the crankshaft web.
P1 P2 P3 P4
b
P
P2 P3
P1 P4
3. Select the suitable color c for the

connecting rod bearing from the table.
c
b c
Connecting rod big end side clearance: a

0.160–0.262 mm (0.0063–0.0103 in)
Limit:
0.5 mm (0.0197 in)
Connecting rod big end width: b
26.788–26.840 mm
(1.0547–1.0566 in)
Calculation formula:
Crankshaft pin width: c
Connecting rod bearing size number =
27.000–27.050 mm
connecting rod size number a –
(1.0630–1.0649 in)
crankshaft pin size number b
Connecting rod bearing selection Bearing size num-
Bearing color c
1. Check the connecting rod size number a ber
on the connecting rod. 1 Brown
2 Black
3 Blue
4 Green
Example:
“P1” connecting rod size number “5”
“P1” crankshaft pin size number “1”
5–1=4
5-115
Select the size “4”, “Green” connecting rod
bearing. TIP:
Do not put the Plastigauge b over the oil
Crankshaft journal oil clearance hole in the main journals of the crankshaft.
check
1. Clean the crankshaft bearings, crank-
shaft journals, and bearing portions of
6. Install the crankcase c and crankcase
bolts d, and then tighten the crankcase
1
the crankcase and cylinder block. bolts d to the specified torques in 2
stages and in the order a, b, and so on.
2. Place the cylinder block upside down on
a bench.
c d
d 2
3. Install the crankshaft bearings a into the
cylinder block and crankcase.
a
a
3
b
4
TIP:
• Install the crankshaft bearings a in their
original positions.
5
the slots b in the cylinder block and crank-
case.
4. Install the crankshaft.

g e a c i d 6
7
5. Put a piece of Plastigauge b on each j d b f h
crankshaft journal, parallel to the
crankshaft.
Crankcase bolt d:
8
b 1st: 30 N·m (3.0 kgf·m, 22.1 ft·lb)
2nd: 90°
TIP:
• When checking the journal oil clearance,
reuse the removed crankcase bolts.
• Do not turn the crankshaft until the journal
oil clearance measurement has been com-
pleted.
9
5-116
A
POWR
Power unit
7. Install the crankcase bolts e, and then
tighten them to the specified torque in the
order a, b, and so on.
J1 J2 J3 J4 J5
k g e a c i
TIP:
If the crankcase journal sizes are the same at
all positions, the size number a is stamped
e only at the “J1” position.
Example:
If “J1”–“J5” are different:
lj d b f h
J1 J2 J3 J4 J5
Crankcase bolt e: 5 5 5 4 5
10 N·m (1.0 kgf·m, 7.4 ft·lb)
8. Remove the crankcase and measure the

width c of the compressed Plastigauge
on each crankshaft journal. Replace the
crankshaft bearings if out of 55545
specification.
If “J1”–“J5” are the same:
J1 J2 J3 J4 J5
5 5 5 5 5
c
5
Crankshaft journal oil clearance:
0.024–0.053 mm (0.0009–0.0021 in)
2. Check the crankshaft journal size
Limit:
number b on the crankshaft web.
0.10 mm (0.0039 in)
Crankshaft bearing selection

1. Check the crankcase journal size number
a on the crankcase.
5-117
2. Assemble the connecting rod b, piston
J1 J2 J3 J4 J5
c, piston pin d, and new piston pin clips
b J e. NOTICE: Do not reuse a
1
connecting rod cap bolt or piston pin
clip, always replace it with a new one.
e
J1 J2 J3 J4 J5 b a
3. Select the suitable color c for the

crankshaft bearing from the table. a
2
c
c e
3
a
c
e
d
b
c
4
Calculation formula:
Main bearing size number =
crankcase journal size number a –
crankshaft journal size number b
Bearing size num-
TIP:
• When installing the connecting rod to the
piston, make sure that the “Y” mark a on
the connecting rod faces toward the front
5
Bearing color c
ber mark b on the piston crown.
1
2
3
Brown
Black
Blue
• Do not allow the piston pin clip ends to align
with the piston pin slot c. 6
4 Green 3. Install the oil ring f, 2nd ring g, and top
ring h. NOTICE: Do not scratch the
7
5 Yellow
pistons or break the piston rings.
Example:
“J1” crankcase journal size number “5” 4. Offset the piston ring end gaps.
“J1” crankshaft journal size number “2”
5–2=3
f
Select the size “3”, “Blue” main bearing.
Connecting rod and piston

installation
#5
#4
#3 g
8
1. Install new connecting rod cap bolts a to #2
the connecting rod b.
#5
45 45
#1
#4
#1
9
#2 #3
h
5-118
A
POWR
Power unit
TIP: TIP:
• Make sure to install the piston rings so that Make sure that the “Y” mark on the connect-
the “1T” mark on the top ring h and the ing rod faces toward the timing chain drive
“2T” mark on the 2nd ring g face up. gear of the crankshaft.
• After installing the piston rings, make sure
that they move smoothly. 8. Install half of the crankshaft bearings m
into the cylinder block.
5. Clean the connecting rod bearings i
and connecting rod big end. f
m
6. Install the upper bearing into the
connecting rod b and lower bearing into
the connecting rod cap j. g
e b
i TIP:
j • Install the crankshaft bearings in their origi-
e nal positions.
d • Fit the protrusion f on each bearing into
the slots g in the cylinder block.
TIP: 9. Install the crankshaft.

• Install the connecting rod bearings i in
their original positions. 10. Install the connecting rod cap j onto the
• Fit the protrusion d on each bearing into piston and connecting rod assy., and
the slots e in the connecting rod cap j then tighten the connecting rod nuts n to
and connecting rod b. the specified torques in 2 stages.
7. While compressing the piston rings using n n

the special service tool k, install the
piston and connecting rod assy. l into
the cylinder. h j
h
k
l
Y Connecting rod nut n:
1st: 51 N·m (5.1 kgf·m, 37.6 ft·lb)
2nd: 90°
TIP:
Piston ring compressor k: Make sure that the characters h on the con-
YM-08037/90890-05158 necting rod cap j and connecting rod assy.
are aligned.
5-119
Crankcase assembly 5. Install the crankcase d and new
1. Thoroughly clean all the gasket surfaces crankcase bolts e, and then tighten the
and crankcase mating surfaces. crankcase bolts e to the specified
torques in 2 stages and in the order a,
2. Install half of the crankshaft bearings a
into the crankcase.
a
b, and so on. NOTICE: Do not reuse a
crankcase bolt, always replace it with
a new one.
1
e
2
d e
a
b
TIP:
3
• Install the crankshaft bearings a in their
original positions.
the slots b in the crankcase.
4
3. Install the dowel pin b and a new O-ring
c.
c
5
b g e a c i e
j d b f h
6
4. Apply sealant to the mating surface of the
crankcase.
Crankcase bolt e:
1st: 30 N·m (3.0 kgf·m, 22.1 ft·lb)
7
2nd: 90°
6. Install the crankcase bolts f, and then

tighten them to the specified torque in the
order a, b, and so on.
8
9
5-120
A
POWR
Power unit
k g e a c i
lj d b f h
Crankcase bolt f:
10 N·m (1.0 kgf·m, 7.4 ft·lb)
5-121
JET
PUMP
Jet pump unit 6
Intake grate and ride plate ................................................ 6-1
Jet pump unit ..................................................................... 6-2

Jet pump unit removal ............................................................... 6-4
1
Jet pump unit installation ........................................................... 6-5
Reverse gate ...................................................................... 6-7 2

Nozzle and nozzle ring ...................................................... 6-8
Impeller housing and impeller duct assy. ....................... 6-9 3

Impeller, drive shaft, and impeller duct ........................ 6-10
Impeller duct assy. disassembly .............................................. 6-11
Impeller housing check ............................................................ 6-12
Drive shaft check ..................................................................... 6-12
Impeller duct assy. assembly .................................................. 6-12
4
Impeller duct, impeller housing, and nozzle installation .......... 6-14
Transom plate and hoses ............................................... 6-15

5
Bilge and hoses ............................................................... 6-17
6
Bilge strainer check ................................................................. 6-19
Electric bilge pump strainer check ........................................... 6-19
Transom plate installation ....................................................... 6-19
Intermediate housing ...................................................... 6-20

Intermediate housing assy. removal ........................................ 6-22
Intermediate housing assy. disassembly ................................. 6-22
Intermediate housing assy. assembly ..................................... 6-23
Intermediate housing assy. installation ................................... 6-24
7
8
9
A
JET
PUMP Jet pump unit
Intake grate and ride plate
10
10 6
4
5
9
7
4
A B
8
1
2 3
4
1
4 1
4 17 N·m (1.7 kgf·m, 12.5 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb)

2 Speed and water temperature sensor 1 A FX Cruiser SHO
3 Speed sensor 1 B FX SHO, FX HO, FX Cruiser HO
4 Bolt 10 M8  35 mm
5 Ride plate 1
6 Bracket 2
7 Spacer 1
8 Intake grate 1
9 Bracket 1
10 Bracket 2
6-1
Intake grate and ride plate / Jet pump unit
Jet pump unit

7 N·m (0.7 kgf·m, 5.2 ft·lb)
6
1
7
2 N·m (0.2 kgf·m, 1.5 ft·lb)
6
16 7
17
5 6
7
9
18
2
10
10
7
6 2
3
8
12
13
4
14
12
3
4
7
6
5
11
14
7 N·m (0.7 kgf·m, 5.2 ft·lb)
2
1
12
40 N·m (4.0 kgf·m, 29.5 ft·lb)
6
1
2
3
Nut
Washer
Clamp
1
2
1
7
4 Bilge hose 1
5 Clamp 1
6
7
8
Bolt
Collar
Rubber plate 1
6
6
1
M6  22 mm
8
9 Rubber plate 2 1
9
10 Bolt 2 M8  18 mm
11 Bolt 1 M6  30 mm
12 Bolt 4 M10  45 mm
13 Jet pump unit assy. 1
14 Dowel pin 2
15
16
Bolt
Washer
2
2
M8  13 mm
6-2
A
JET
PUMP Jet pump unit
7 N·m (0.7 kgf·m, 5.2 ft·lb)
7 6
2 N·m (0.2 kgf·m, 1.5 ft·lb)
6
16 7
17
5 6
7
9
2 10 6
18 7
10
8
12
13
14 6
3
7
12 4
11
2 12
14
7 N·m (0.7 kgf·m, 5.2 ft·lb) 1 40 N·m (4.0 kgf·m, 29.5 ft·lb)

17 Gasket 2 
18 Bracket 1
6-3
Jet pump unit
Jet pump unit removal
j
k
i
removing the jet pump unit.
1. Remove the rubber plate bolts a.

h
l
1
g
7. Disconnect the bilge hose m. 2

8. Remove the jet pump unit assy. bolts n,
3
o, and p.
n
a a
2. Remove the speed sensor b and ride

plate c.
3. Remove the spacer d and intake grate

e.
m
4
o
b p
5
e
d
c
6
o
4. Disconnect the steering cable joint f.
9. Gradually increase the distance between
the jet pump unit q and the transom
plate r, and then remove the jet pump
7
f unit q.
8
5. Disconnect the shift cable joint g,
Q.S.T.S. rod joint h, and spout hose i. q
s
r 9
6. Remove the rubber plate bolts j, and
then remove the rubber plates k and l.
6-4
A
JET
PUMP Jet pump unit
d
TIP:
The illustration shows the case where the
disk brake piston tool s is used to remove d
the jet pump unit.
Jet pump unit installation c
c
installing the jet pump unit. Jet pump unit assy. bolt (M10  45 mm) c:
40 N·m (4.0 kgf·m, 29.5 ft·lb)
1. Clean the mating surfaces of the jet Jet pump unit assy. bolt (M8  18 mm) d:
pump unit a and transom plate b. 17 N·m (1.7 kgf·m, 12.5 ft·lb)
2. Apply sealant to the mating surfaces of 6. Install the rubber plates h and i, and
the transom plate b. then tighten the rubber plate bolts j to
a
b 7. Connect the spout hose k, and then
tighten the spout hose clamp m to the
specified torque.
8. Connect the shift cable joint l and

Q.S.T.S. rod joint n.
m
j
i
k
3. Install the jet pump unit, and then tighten
the jet pump unit assy. bolts c and d to h
the specified torques.
b a
n j
4. Tighten the jet pump unit assy. bolts e.
l
5. Connect the bilge hose f, and then
fasten it using the clamp g.
Rubber plate bolt j:
g 7 N·m (0.7 kgf·m, 5.2 ft·lb)
e
Spout hose clamp m:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
e TIP:
• When installing the rubber plate h, pass
f the spout hose k through the hole a in the
plate.
c c • When installing the rubber plate i, pass
the shift cable joint l through the hole b in
the plate.
6-5
Jet pump unit
9. Connect the steering cable joint o, and 13. Tighten the rubber plate bolts x to the
then tighten the steering cable joint nut specified torque.
p to the specified torque.
x
o
1
p x x
2
Rubber plate bolt x:
Steering cable joint nut p:
TIP:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
7 N·m (0.7 kgf·m, 5.2 ft·lb)
3
Make sure that steering and shifting operate
properly.
10. Install the intake grate q, and then

tighten the intake grate bolt r to the
4
specified torque.
11. Install the spacer s and ride plate t,

and then tighten the ride plate bolt u to
5
12. Install the speed sensor v, and then
tighten the speed sensor screw w to the
specified torque.
6
vt
q
7
Intake grate bolt r:
s
r u 8
17 N·m (1.7 kgf·m, 12.5 ft·lb)
Ride plate bolt u:
17 N·m (1.7 kgf·m, 12.5 ft·lb)
Speed sensor screw w:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
9
6-6
A
JET
PUMP Jet pump unit
Reverse gate
10
11
11
10
5
6
65 3 2
A
1 6
7
9 3
8
2
20 N·m (2.0 kgf·m, 14.8 ft·lb)
1
4
11 A 9

1 Spring 1
2 Bolt 2 M8  25 mm
3 Collar 2
4 Reverse gate 1
5 Nut 2
6 Washer 3
7 Ball joint 1
8 Bolt 1 M6  35 mm
9 Collar 1
10 Bolt 6 M6  25 mm
11 Reverse gate stay 2
6-7
Reverse gate / Nozzle and nozzle ring
Nozzle and nozzle ring
16 N·m (1.6 kgf·m, 11.8 ft·lb)
1
1
2
16 N·m (1.6 kgf·m, 11.8 ft·lb)

7 6 2
2
1
5 3
3
2
1
2 4
4 1
5
6
1
2
3
Bolt
Collar
Jet thrust nozzle
4
4
1
M8  20 mm
7
4 Nozzle ring 1
5 Nut 1
6
7
Washer
Ball joint
2
1 8
9
6-8
A
JET
PUMP Jet pump unit
Impeller housing and impeller duct assy.
4
6 3
3
2
3
7
12
5
7 3
7
10
11
10
9
7
7 N·m (0.7 kgf·m, 5.2 ft·lb) 8

1 Clamp 1
2 Spout hose 1
3 Bolt 4 M10  125 mm
4 Bracket 1
5 Nozzle 1
6 Impeller housing 1
7 Dowel pin 4
8 Bolt 4 M6  35 mm
9 Water inlet cover 1
10 Gasket 2 
11 Water inlet strainer 1
12 Impeller duct assy. 1
6-9
Impeller housing and impeller duct assy. / Impeller, drive shaft, and impeller duct
Impeller, drive shaft, and impeller duct
14
1
74 N·m (7.4 kgf·m, 54.6 ft·lb)
2
2
9 3
4 2
7
8
11
3
1
4
330 N·m (33.0 kgf·m, 243.4 ft·lb) 5
6
10
12
13 5
6
1
2
3
Impeller
Bolt
Cap
1
3
1
M6  20 mm 7
4 O-ring 1 
5 Nut 1
6
7
8
Washer
Spacer
Oil seal
1
1
1 
8
9 Oil seal 1 
9
11 Spacer 1
13 Drive shaft 1
14 Impeller duct 1
6-10
A
JET
PUMP Jet pump unit
Impeller duct assy. disassembly
1. Remove the impeller a.
f
a
4. Remove the ball bearing g.
A g
Driveshaft holder b: YB-06201
Drive shaft holder 6 b: 90890-06520
h
2. Remove the cap c, O-ring d, and nut
e. h
d
c
e
B g
b i j
A U.S.A. and Canada

B Worldwide
e
Slide hammer h: YB-06096
Stopper guide plate i: 90890-06501
Driveshaft holder b: YB-06201 Bearing puller assembly j: 90890-06535
Drive shaft holder 6 b: 90890-06520 Stopper guide stand k: 90890-06538
3. Remove the drive shaft f. NOTICE: Do 5. Remove the oil seals l and m.
not press the drive shaft threads
A
directly.
l
m
h
6-11
B Impeller housing inside diameter a:

l 155.35–155.45 mm (6.116–6.120 in)
m Limit:
j
1
i 156.45 mm (6.160 in)
k
Drive shaft check
j 1. Measure the drive shaft runout. Replace
A U.S.A. and Canada

B Worldwide
2
Slide hammer h: YB-06096
Stopper guide plate i: 90890-06501
Bearing puller assembly j: 90890-06535
Stopper guide stand k: 90890-06538 a
3
6. Remove the spacer n, and then remove
the ball bearing o using a press.
p
p
q
Drive shaft runout limit:
0.3 mm (0.012 in)
Distance a:
310 mm (12.20 in)
4
q
o
n
Impeller duct assy. assembly
1. Install a new oil seal a halfway into the
impeller duct, and then install a new oil
seal b.
5
Driver handle (large) p: YB-06071
Driveshaft needle bearing installer and
remover q: YB-06194
c 6
Driver rod L3 p: 90890-06652
Needle bearing attachment q:
90890-06609
Impeller housing check

b a
7
a
1. Measure the impeller housing inside
diameter a. Replace if out of specifica-
tion.
Bearing attachment c:
8
90890-06628
Distance a:
7.0 ± 0.2 mm (0.28 ± 0.008 in)
9
a 2. Install a new ball bearing d onto the
A
drive shaft e.
6-12
JET
PUMP Jet pump unit
e h f h
d
f
Bearing attachment f: Bearing attachment f: 90890-06728

90890-06728
6. Install the washer i, and then tighten
Distance b: the drive shaft nut j to the specified
23.0 ± 0.1 mm (0.91 ± 0.004 in) torque.
3. Install the drive shaft e (along with the 7. Apply EPNOC grease AP #0 to the inside
ball bearing d) and spacer g. of the cap k, and then install a new
O-ring k and the cap l.
g k
e i l
j
d m
Bearing attachment f:
90890-06728
4. Apply EPNOC grease AP #0 to the

space between the drive shaft e and the
spacer g.
j
g
Driveshaft holder m: YB-06201
Drive shaft holder 6 m: 90890-06520
e
Drive shaft nut j:
74 N·m (7.4 kgf·m, 54.6 ft·lb)
Grease quantity: 20 g (0.7 oz)

Grease quantity: 20 g (0.7 oz)
8. Install the spacer n and impeller o.
5. Install a new ball bearing h.
6-13
4. Apply sealant to the mating surfaces of
the nozzle e and impeller duct assy. a.
5. Install the dowel pins d and nozzle e.

o
6. Install the bracket f, and then tighten
the impeller duct bolts g to the specified
torque.
1
2
n f g
g
9. Tighten the impeller o to the specified
torque.
3
o a d
g
m
g
d
e
4
Impeller duct bolt g:
Drive shaft holder m: YB-06201
5
40 N·m (4.0 kgf·m, 29.5 ft·lb)
Drive shaft holder 6 m: 90890-06520
Impeller o:
330 N·m (33.0 kgf·m, 243.4 ft·lb)
6
Impeller duct, impeller housing, and
nozzle installation
1. Clean the mating surfaces of the impeller
duct assy., impeller housing, and nozzle.
2. Apply sealant to the mating surfaces of

the impeller duct assy. a and impeller
housing b. 7
3. Install the dowel pins c, and then install
the impeller housing b.
b
c
8
a
9
c
6-14
A
JET
PUMP Jet pump unit
Transom plate and hoses
12 6 N·m (0.6 kgf·m, 4.4 ft·lb)

15
26 N·m (2.6 kgf·m, 19.2 ft·lb)

15
13 19
14
17
17
2 16
16 16 18
1 3
2 3
A
6 3
9 18
6 16
8 11
26 N·m (2.6 kgf·m, 19.2 ft·lb)
7
4 3 22
B
10
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
20 23
20 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
4
3 21
5

1 Clamp 1
3 Clamp 5
5 Hose joint 1
6 Clamp 2 A FX SHO, FX Cruiser SHO
7 Hose joint 1 A FX SHO, FX Cruiser SHO
8 Cooling water hose 1 A FX SHO, FX Cruiser SHO
9 Hose joint 1 A FX SHO, FX Cruiser SHO
10 Hose joint 1 B FX HO, FX Cruiser HO
12 Nut 1
13 Cap 1
14 Clamp 1
15 Flushing hose 1
16 Nut 4
6-15
Transom plate and hoses
1
12 6 N·m (0.6 kgf·m, 4.4 ft·lb)
15
26 N·m (2.6 kgf·m, 19.2 ft·lb)

15
13 19
14
2 16
17
16 16 18
17
2
1 3
2
3
3
A
6 3
9 18
6 16
8 11
4
26 N·m (2.6 kgf·m, 19.2 ft·lb)
7
4 3 22
B
10
3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 5

6
20 23
20 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
4
3 21
5

17
18
19
Washer
Washer
Transom plate
2
2
1
7
20 Clamp 2
21 Hose 1
22
23
Tapping bolt
Hose joint
3
1
M6  32 mm
8
9
6-16
A
JET
PUMP Jet pump unit
Bilge and hoses

6 8
5
7
10 5.5 N·m (0.55 kgf·m, 4.06 ft·lb)
3 2 4 22
6 2 20
7
11
8
9
2
12
15
13 10
14 26
20 23
21
14 25
24
3
19 18
1 17
2
4
16
14 7 N·m (0.7 kgf·m, 5.2 ft·lb)

1 Plastic tie 1
2 Clamp 5
3 Bilge hose 1
4 Bilge hose 1
5 Hose joint 1
6 Plastic tie 2
7 Rivet 2
8 Holder 2
9 Bilge hose 1
10 Clamp 2
11 Bilge hose 1
12 Band 1
13 Electric bilge pump assy. 1
14 Rivet 3
15 Holder 1
16 Bilge strainer assy. 1
6-17
Bilge and hoses
6 8
5
3 2
6
4 22
2
7
20
10 5.5 N·m (0.55 kgf·m, 4.06 ft·lb)
1
7
11
8
9
2
2
12
15
13 10 3
26
4
14 20 23
21
14 25
24
3
19 18
1
5
17
2
4
16
14 7 N·m (0.7 kgf·m, 5.2 ft·lb)

6
17
18
19
Nut
Packing
Hose joint
1
1
1
 7
20 Clamp 2
21 Bilge hose 1
22
23
24
Hose joint
Nut
Drain joint
1
1
1
8
25 Packing 1 
9
26 Pad 1
6-18
A
JET
PUMP Jet pump unit
Bilge strainer check
1. Check the bilge strainer. See “Bilge
strainer check” (3-10).
Electric bilge pump strainer check

1. Check the electric bilge pump strainer.
See “Electric bilge pump strainer check”
(3-10).
Transom plate installation

1. Clean the mating surface of the transom
plate a.
2. Apply sealant to the mating surface of the

transom plate a.
3. Install the transom plate a and washers

b and c, and then tighten the transom
plate nuts d to the specified torque.
a
b
d
c
Transom plate nut d:

26 N·m (2.6 kgf·m, 19.2 ft·lb)
6-19
Bilge and hoses / Intermediate housing
Intermediate housing
1
17 N·m (1.7 kgf·m, 12.5 ft·lb)
4
12
13
2
14 4
2
10
15
3
9
10
11
2 16
17 3
8
8
4
7
1
6
3 N·m (0.3 kgf·m, 2.2 ft·lb)
5
5
205 N·m (20.5 kgf·m, 151.2 ft·lb)

6
1
2
3
Rubber coupling
Bolt
Shim
1
3
*
M8  48 mm
As required
7
4 Dowel pin 2
5 Driven coupling 1
6
7
8
Washer
Intermediate drive shaft
O-ring
1
1
2 
8
9 Oil seal 1 
9
10 Circlip 2 
12 Thrust washer 1 
13 Oil seal 1 
14 Oil seal 1 
15
16
Nipple
1
1
6-20
A
JET
PUMP Jet pump unit
17 N·m (1.7 kgf·m, 12.5 ft·lb)
4
12
13
14 4
2
10
15
3
11
10 17
9
2 16
8
7 3 N·m (0.3 kgf·m, 2.2 ft·lb)
1
6
205 N·m (20.5 kgf·m, 151.2 ft·lb)

17 Cap 1
6-21
Intermediate housing assy. removal
1. Remove the engine unit. See “Engine
d
unit removal (FX SHO, FX Cruiser SHO)”
e
1
(5-11) or “Engine unit removal (FX HO,
FX Cruiser HO)” (5-15).
2. Remove the intermediate housing assy.

a.
a 3. Remove the oil seals f, g, and h.

A
2
f
b
j
i
g j
3
h
TIP:
If shims b are installed, remove the shims
and write down the position of each removed
shim so that it can be installed in its original B
j
4
position. k
Intermediate housing assy.

disassembly
l 5
1. Remove the driven coupling a.
m
b
a
h f
6
c l g
7
l
A U.S.A. and Canada

B Worldwide
Slide hammer i: YB-06096
Shaft holder b: 90890-06730
Coupler wrench c: 90890-06729
2. Remove the intermediate drive shaft d

Bearing puller legs j: YB-06523
Stopper guide plate k: 90890-06501
Bearing puller assembly l: 90890-06535
Stopper guide stand m: 90890-06538
8
and thrust washer e using a press.
9
NOTICE: Do not press the
4. Remove the circlips n, and then remove
intermediate drive shaft directly.
the ball bearing o using a press.
6-22
A
JET
PUMP Jet pump unit
n a
c
p d
n
o
Needle bearing installer p: YB-06434 Needle bearing installer c: YB-06434

Bearing outer race attachment p: Bearing outer race attachment c:
90890-06654 90890-06654
Intermediate housing assy. assembly Distance a:

6.5 ± 0.2 mm (0.26 ± 0.01 in)
Do not reuse a thrust washer, always 4. Install the intermediate drive shaft e
replace it with a new one. using a press. NOTICE: Do not press
the intermediate drive shaft directly.
1. Install a new circlip (rear) a.

e
2. Install a new ball bearing b until it
contacts the circlip (rear) a using a
press. f
b
c a
Bearing attachment f:
b 90890-06728
Distance b:
46.0 ± 0.5 mm (1.81 ± 0.02 in)
Needle bearing installer c: YB-06434 5. Install a new circlip (front) g, and then
Bearing outer race attachment c: install a new oil seal h.
90890-06654
3. Install a new oil seal d.

f
Bearing attachment f: 90890-06728
6-23
6. Install a new oil seal i.
n
m
j
i c 1
o
Bearing attachment j: 90890-06727

Shaft holder n: 90890-06730
Coupler wrench o: 90890-06729
2
3
Distance c: Driven coupling m:
1.6 ± 0.2 mm (0.06 ± 0.01 in) 205 N·m (20.5 kgf·m, 151.2 ft·lb)
7. Install a new thrust washer k. Intermediate housing assy.
installation
j
k
k
d
1. Install the intermediate housing assy. a,
and then tighten the intermediate hous-
ing assy. bolts b to the specified torque. 4
b c
I
a
5
Bearing attachment j: 90890-06727
Distance d:
3.7 ± 0.3 mm (0.17 ± 0.01 in)
8. Install the washer l, and then tighten Intermediate housing assy. bolt b:
6
the driven coupling m to the specified 17 N·m (1.7 kgf·m, 12.5 ft·lb)
torque.
TIP:
If shims c were removed, install the shims in
their original positions.
7
8
m
l
9
6-24
A
ELEC
Electrical system 7
Electrical components ...................................................... 7-1

Engine (FX SHO, FX Cruiser SHO) .......................................... 7-1
Engine (FX HO, FX Cruiser HO) ............................................... 7-2
Deck and hull ............................................................................. 7-3
Electrical box ............................................................................. 7-4
ECM circuit diagram .................................................................. 7-5
ECM coupler layout ................................................................... 7-7
Electrical analysis ............................................................. 7-9

Electrical component check using the YDIS .............................. 7-9
Power supply to the ECM .......................................................... 7-9
Peak voltage measurement ....................................................... 7-9
Ignition system ................................................................ 7-10

Ignition spark check ................................................................. 7-10
Ignition coil check .................................................................... 7-11
Pickup coil check ..................................................................... 7-11
Charging system ............................................................. 7-12

Stator coil check ...................................................................... 7-12
Rectifier regulator check .......................................................... 7-13
Control system ................................................................ 7-14

Oil pressure switch check ........................................................ 7-14
Thermoswitch check ................................................................ 7-15
Thermo sensor check .............................................................. 7-16
Engine temperature sensor check ........................................... 7-17
Intake air temperature sensor check ....................................... 7-17
Intake air pressure sensor check ............................................ 7-18
Knock sensor check ................................................................ 7-19
TPS check ............................................................................... 7-19
ETV circuit continuity ............................................................... 7-21
APS check ............................................................................... 7-21
APS circuit continuity ............................................................... 7-22
ETV relay check ...................................................................... 7-23
Cam position sensor check ..................................................... 7-24
Slant detection switch check ................................................... 7-25
Steering sensor check ............................................................. 7-25
Reverse sensor check ............................................................. 7-26
Right handlebar switch check .................................................. 7-26
ECM check .............................................................................. 7-27
Earth plate check ..................................................................... 7-28
Electric bilge pump check ........................................................ 7-28
Fuel system ..................................................................... 7-29

Fuel injector check .................................................................. 7-29
Fuel pump module check ........................................................ 7-29
Starting system ............................................................... 7-30

Left handlebar switch assy. check ........................................... 7-30
Main and fuel pump relay check .............................................. 7-31
Starter relay check .................................................................. 7-32 1
Starter motor ................................................................... 7-33
Starter motor operation ........................................................... 7-34
Armature check ....................................................................... 7-34
Brush holder check .................................................................. 7-35
2
Remote control system .................................................. 7-35
Remote control transmitter check ............................................ 7-35
Remote control receiver check ................................................ 7-37
Transmitter registration ........................................................... 7-37
3
Indication system ............................................................ 7-38
Multifunction meter check ........................................................ 7-38
Multifunction meter operation button check ............................. 7-39
Compass display check (FX Cruiser SHO) ............................. 7-39
4
Air temperature display check (FX Cruiser SHO) .................... 7-40
5
Water temperature display check (FX Cruiser SHO) .............. 7-40
Speed sensor check (FX Cruiser SHO) .................................. 7-40
Speed sensor check
(FX HO, FX Cruiser HO, and FX SHO) ................................... 7-41
Fuel level meter display and
fuel level warning indicator check ............................................ 7-41
Check engine warning indicator check .................................... 7-42
Diagnostic display check ......................................................... 7-42
Oil pressure warning indicator check ...................................... 7-43
Engine overheat warning indicator check ................................ 7-43
6
Buzzer check ........................................................................... 7-44
7
8
9
A
ELEC
Electrical system
Electrical components
Engine (FX SHO, FX Cruiser SHO)
b
a c
i
e
f
j
g
k
l
p n
o
a Spark plug and ignition coil i Fuel injector

b Cam position sensor j Thermoswitch
c Electrical box k Intake air temperature sensor
d Thermo sensor l Knock sensor
e Rectifier regulator m ETV (TPS)
f Starter motor n Engine temperature sensor
g Oil pressure switch o Earth plate
h Intake air pressure sensor p Stator coil and pickup coil
7-1
Engine (FX HO, FX Cruiser HO)
b
1
a c
2
h
d
3
f
e
j
4
i
5
g
k
l
6
7
o m
n
8
a Spark plug and ignition coil i Intake air pressure sensor
9
b Cam position sensor j Fuel injector
c Electrical box k Thermoswitch
d Thermo sensor l Intake air temperature sensor
e Rectifier regulator m Engine temperature sensor
f Starter motor n Earth plate
A
g Oil pressure switch o Stator coil and pickup coil
h ETV (TPS)
7-2
ELEC
Electrical system
Deck and hull
c
b
a
e
f
i j
h
g
l
m
a Remote control receiver f Buzzer

b Compass and air temperature sensor (FX g Fuel pump module and fuel sender
Cruiser SHO only) h Left handlebar switch assy.
c Steering sensor i Right handlebar switch
d APS (electric throttle without wire cable) j Multifunction meter
e Speed and water temperature sensor (FX k Reverse sensor
Cruiser SHO)/speed sensor (FX SHO, FX l Electric bilge pump
HO, FX Cruiser HO) m Battery
7-3
Electrical box
a b c d e
1
A
2
3
4
o
5
k
f
g
n
6
h
i
j
m l 7
A
8
a Starter relay i Fuse (3 A) (remote control receiver)
9
b Main and fuel pump relay j Fuse (20 A) (main and fuel pump relay)
c ETV relay k Positive battery lead (gray tape)
d Slant detection switch l Starter motor lead (white tape)
e ECM m Lead (black)
f Fuse (30 A) (battery) n Lead (brown)
A
g Fuse (10 A) (main and fuel pump relay) o Lead (red)
h Fuse (10 A) (ETV relay)
7-4
ELEC
Electrical system
ECM circuit diagram
Rectifier Stator
Fuel injector #1
regulator coil 58
Fuse 7 Fuel injector #2
(20 A) 59
27
Fuel injector #3
20 84
Main relay
Fuel injector #4
Fuse 21
83
(3 A)
14
Engine start Ignition coil #1
Remote control
switch receiver
28 85
Fuse
(30 A)
Starter Ignition coil #2
relay
86
Battery
Starter
motor
Ignition coil #3
Pickup coil 61
8
26
Ignition coil #4
Cam position sensor 3
ECM
60
Intake air pressure sensor 16
Fuel pump module

Reverse sensor 18
81 Fuse
Intake air temperature sensor (10 A)
15 Fuel pump relay
23 Multifunction
47 (YDIS)
Thermo sensor meter
13
25 ETV relay
80
Steering sensor 17 Fuse (10 A)
39
Slant detection switch 45
5
No-Wake mode switch

24
40
: Indicates a connection between the symbols.
7-5
A Knock sensor
1
1
Oil pressure switch
Thermoswitch
79
78
TPS
2
64
Engine shut-off switch

72
52
62
70
ETV motor
3
5V
44
Cruise assist set switch
Cruise assist up switch

19
ECM
42
43 TPS 2
TPS 1
4
54 Ground
41
Cruise assist down switch

63
46
67
5
5V
APS 30
APS full
close
switch Ground
5V
22
29
49
6
APS 1 36
Ground
7
34
5V
50
APS 2 37
Ground
35
A FX SHO, FX Cruiser SHO only

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

No. No. No.
color tion lead color tion lead color tion lead
Knock sensor Intake air temper- APS full close
1 G 15 B/R 29 B/G
(*1) ature sensor switch ground
APS full close
Intake air
2 — — 16 P/G 30 O/G switch power
pressure sensor
sourse
Cam position
3 G/O 17 W/L Steering sensor 31 — —
sensor
4 — — 18 G/W Reverse sensor 32 — —
Slant detection Cruise assist set
5 L/B 19 Y/B 33 — —
switch switch
Main and fuel pump
6 — — 20 Y/G 34 B/R APS 1 ground
relay (main relay)
Battery power Engine start
7 R/Y 21 Y 35 B/W APS 2 ground
source switch
APS full close
8 W/B Pickup coil 22 W/G 36 P/R APS 1
switch
Engine tempera-
9 — — 23 B/Y 37 P/W APS 2
ture sensor
No-wake mode
10 — — 24 L/R 38 — —
switch
Steering sensor ETV relay power
11 — — 25 O/R 39 R/Y
power source source (contact)
Sensor power
12 — — 26 O 40 B/O Sensor ground
source
Battery power
13 B/L Thermo sensor 27 R/Y 41 B/O TPS ground
source
Main relay drive Immobilizer serial
14 Y/W 28 W 42 P TPS 1
signal communication
7-7
Lead External connec- Lead External connec- Lead External connec-

No. No. No.
color tion lead color tion lead color tion lead
43 P/B TPS 2 58 Pu/R Fuel injector #1 73 — —
44
45
O
R/Y
TPS power
source
ETV relay power
source (contact)
59
60
Pu/B
B/G
Fuel injector #2
Ignition coil #4
74
75
—
—
—
—
1
46 B ECM ground 61 B/Y Ignition coil #3 76 — —
47 W/B
Self-diagnosis lead
(communication),
meter unit
62 B ETV ground 77 — — 2
communication
3
Cruise assist ETV motor
48 — — 63 Y/G 78 G
down switch (positive)
APS 1 power Oil pressure
49 O/R 64 P Thermoswitch 79 P/W
source switch
APS 2 power ETV relay power
50 O/W 65 — — 80 Y/W
51 —
source
— 66 — — 81 L/R
source (coil)
Main and fuel
pump relay (fuel
pump relay)
4
ETV motor
52 L 67 B Ground 82 G/L —
53
54
—
Y/R
(negative)
—
Cruise assist up
switch
68
69
—
—
—
—
83
84
Pu/G Fuel injector #4
Pu/Y Fuel injector #3

5
55 — — 70 B ETV ground 85 B/R Ignition coil #1
56
57
—
—
—
—
71
72
—
W
—
Engine shut-off
switch
86 B/W Ignition coil #2
6
(*1) FX SHO and FX Cruiser SHO only.
Color code
B
B/G
: Black
: Black/Green
L/R
O
: Blue/Red
: Orange
Pu/R
Pu/Y
: Purple/Red
: Purple/Yellow
7
B/O : Black/Orange O/G : Orange/Green R/Y : Red/Yellow
B/R
B/W
B/Y
: Black/Red
: Black/White
: Black/Yellow
O/R
O/W
P
: Orange/Red
: Orange/White
: Pink
W
W/B
W/G
: White
: White/Black
: White/Green
8
G : Green P/B : Pink/Black W/L : White/Blue
9
G/L : Green/Blue P/G : Pink/Green Y : Yellow
G/O : Green/Orange P/R : Pink/Red Y/B : Yellow/Black
G/W : Green/White P/W : Pink/White Y/G : Yellow/Green
L : Blue Pu/B : Purple/Black Y/R : Yellow/Red
L/B : Blue/Black Pu/G : Purple/Green Y/W : Yellow/White
7-8
A
ELEC
Electrical system
Electrical analysis
TIP:
Electrical component check using
• Before checking the electrical components,
the YDIS make sure that the battery is fully charged.
When checking the TPS, APS, or other sen- • If the test leads are connected while using
sors, use the YDIS. the YDIS, diagnostic codes will be
When deleting the diagnosis record in the detected.
YDIS, make sure to check the time when the • If a diagnosis record is displayed and it is
diagnostic codes were detected. caused by the checking steps, delete the
record by using the “Diagnosis record”
function of the YDIS.
• The YDIS requires that you use an exclu-
sive communication cable and CD-ROM to
connect to a computer. For a description of
the communication cable and CD-ROM to
R/Y
W/B
be used, see “YDIS” (9-1). Also, make sure

B
to check the CD-ROM version before using

it.
• To connect the YDIS, see “YDIS” (9-1) or
When checking the input voltage of a part,
the YDIS (Ver. 2.00) Instruction Manual.
the coupler or connector must be discon-
nected. As a result, the ECM determines that
the part is disconnected and a diagnostic Power supply to the ECM
code is detected. Therefore, make sure to Push the unlock button a on the remote con-
delete the diagnosis record after checking the trol transmitter so that power is supplied to
input voltage. the ECM.
Power is supplied to the ECM for about 30
seconds after stopping the engine. Therefore, a
wait for more than 30 seconds before restart-
ing the engine, otherwise the diagnostic
codes will not be cleared from the ECM.
YDIS 2 starter kit:
90890-06883
TIP:
To check that the remote control transmitter
is working properly, see “Remote control
transmitter check” (7-35).
Peak voltage measurement
When measuring the peak voltage, do not

touch any of the connections of the digital
tester probes.
7-9
Electrical analysis / Ignition system
TIP:
• When testing the voltage between the • Before measuring the peak voltage, check
terminals of an electrical component all wiring for proper connection and corro-
using the digital tester, do not allow any
of the leads to touch any metal parts.
• When starting the engine on land, make
sure to connect a garden hose to the
sion, and check that the battery is fully
charged.
• Use the peak voltage adapter with the rec-
ommended digital circuit tester.
1
watercraft for proper water supply. • Connect the positive pin of the peak voltage
To check the electrical components or mea-

sure the peak voltage, use the special ser-
adapter to the positive terminal of the digital
circuit tester, and the negative pin to the
negative terminal.
2
vice tools. A faulty electrical component can • When measuring the peak voltage, set the
selector on the digital circuit tester to the
3
be easily checked by measuring the peak
voltage. The specified engine speed when DC voltage mode.
measuring the peak voltage is affected by
many factors, such as fouled spark plugs or a Ignition system
weak battery. If one of these factors is Ignition spark check
4
present, the peak voltage cannot be mea-
sured properly.
A When performing the spark gap check,
keep flammable gas or liquids away, since
this test can produce sparks.
5
V
1. Connect the YDIS.
2. Remove the ignition coils for the cylinder

that will be tested.
B
a b
3. Connect the ignition coil to the special
service tool a.
6
c
4. Using the “Stationary test” of the YDIS,
DC V check the ignition spark. WARNING! Do
not touch any of the connections of
the special service tool leads.
a
7
d
A U.S.A. and Canada

B Worldwide
8
Digital multimeter a: YU-34899-A
Peak volt adapter b: YU-39991
Digital circuit tester c: 90890-03189
Peak voltage adapter B d: 90890-03172
Spark checker a: YM-34487
9
Ignition tester (Spark gap tester) a:
90890-06754
7-10
A
ELEC
Electrical system
5. Disconnect the special service tool, and
then install the ignition coils.
R/Y
B
Ignition coil check #1 B/R
1. Disconnect the ignition coil couplers a. #2 B/W
#3 B/Y
#4 B/G
2. Supply power to the ECM, and then
measure the input voltage at the ignition
coil coupler terminals (wiring harness
end). Check the wiring harness if out of
specification. Check the ECM output
peak voltage if within specification.
R/Y B a
ECM output peak voltage:

#1 Black/Red (B/R) –Black (B)
#2 Black/White (B/W) –Black (B)
#3 Black/Yellow (B/Y) –Black (B)
Ignition coil input voltage (from the #4 Black/Green (B/G) –Black (B)
battery): Loaded
Red/Yellow (R/Y)–Black (B) r/min
Cranking 2000 3500
12 V (battery voltage)
V 2.5 2.6 2.6
3. Connect the test harness.
TIP:
4. Measure the ECM output peak voltage. • When measuring the ECM output peak volt-
WARNING! When checking the age under the “Cranking” condition, discon-
electrical components, do not touch nect the fuel injector couplers for all
any of the connections of the digital cylinders.
tester leads. • To crank the engine, connect the engine
shut-off cord (lanyard) to the engine shut-
off switch, and then push the engine start
switch.
• When measuring the ECM output peak volt-
age, use only a properly functioning ignition
coil. If the ignition coil is not functioning
properly, ECM output peak voltage will not
be generated.
5. Disconnect the test harness, and then

connect the ignition coil couplers.
Pickup coil check

1. Disconnect the pickup coil coupler a,
and then connect the special service tool
a.
7-11
Ignition system / Charging system
2. Measure the pickup coil output peak
voltage.
1
B B/O
W W/B
WB
b
W B
2
a b a
a
BW
Pickup coil resistance at 20 °C (68 °F)
(reference data):
White (W)–Black (B)
3
459–561 
W B
Test harness (3 pins) a:

YB-06877/90890-06877
5. Connect the pickup coil coupler.
Charging system
4
Stator coil check
Pickup coil output peak voltage:
White (W)–Black (B)
Un-
r/min loaded
Loaded
1. Disconnect the stator coil coupler a, and
then connect the special service tool a.
2. Measure the stator coil output peak

5
Cranking 2000 3500 voltage.
V
TIP:
5.5 4.7 16.4 21.5 G
G
G
W R B
G
G
G 6
• To crank the engine, connect the engine
shut-off cord to the engine shut-off switch,
and then push the engine start switch and
engine stop switch simultaneously.
• If measuring the pickup coil output peak a
7
voltage under the “Cranking” and a
“Unloaded” conditions, disconnect the
pickup coil coupler (wiring harness end) b.
3. Disconnect the special service tool a.

B
R
W 8
4. Measure the pickup coil resistance.
Replace the stator coil assy. if out of
specification.
9
YB-06870/90890-06870
7-12
A
ELEC
Electrical system
Stator coil output peak voltage: G

Green (G)–Green (G) G
Unloaded G
r/min R R
Cranking 2000 3500 B B
V 8.3 36.4 64.7 B R
3. Disconnect the special service tool.
4. Measure the stator coil resistance.

Replace the stator coil assy. if out of
a
specification. Measure the rectifier a
regulator output peak voltage if within
specification.
a R
G B
G Test harness (2 pins) a: YW-06850

G Test harness (2 pins) a: 90890-06850
Rectifier regulator output peak voltage:

Red (R)–Black (B)
Stator coil resistance at 20 °C (68 °F) Loaded
r/min
(reference data): 2000 3500
Green (G)–Green (G) V 13.0
0.31–0.38 
TIP:
5. Connect the stator coil coupler.
Do not use the peak voltage adapter to mea-
sure the output voltage.
Rectifier regulator check
1. Disconnect the rectifier regulator coupler
a, and then connect the special service 3. Disconnect the special service tool.
tool a.
4. Remove the rectifier regulator. See
2. Measure the rectifier regulator output “Exhaust manifold (FX SHO, FX Cruiser
peak voltage. SHO)” (5-4) or “Exhaust manifold (FX
HO, FX Cruiser HO)” (5-6).
5. Check the rectifier regulator for

continuity. Replace if out of specification.
cG
Ge
dG
Bf bR
7-13
Charging system / Control system
Rectifier regulator continuity (testing diode

bR
mode):
cG Tester lead Display value (V)
dG
eG

b

c
d
(reference data)
OL
1
e
2
fB f
b 0.43–0.51
A d
c
e OL
f
d
b
c
e
0.43–0.51
OL
3
g f
4
b 0.43–0.51
c
B e
d OL
f
b 0.66–0.74
g
g
f
c
d
e
0.43–0.51
0.43–0.51
0.43–0.51
5
OL: Indicates an overload
A U.S.A. and Canada

B Worldwide
TIP:
Make sure to set the measurement range g
when checking the rectifier regulator continu-
6
ity.
6. Install the rectifier regulator. See

“Exhaust manifold (FX SHO, FX Cruiser
SHO)” (5-4) or “Exhaust manifold (FX
7
7. Connect the rectifier regulator coupler.
Control system
8
Oil pressure switch check
1. Disconnect the oil pressure switch cou-
pler a. 9
7-14
A
ELEC
Electrical system
Oil pressure switch continuity:
measure the input voltage between the
Terminal thread
oil pressure switch coupler terminal Pressure
b–Body c
(wiring harness end) and ground. Check
the wiring harness if out of specification. Below 128–166 kPa
(1.28–1.66 kgf/cm2, Continuity
18.6–24.1 psi)
Above 128–166 kPa
(1.28–1.66 kgf/cm2, No continuity
18.6–24.1 psi)
P/W
7. Install the oil pressure switch. See “Oil
separator tank and oil pan” (5-104).
a 8. Connect the oil pressure switch coupler.
Oil pressure switch input voltage Thermoswitch check

(reference data): 1. Disconnect the thermoswitch coupler a.
Pink/White (P/W)–Ground
11.0–12.0 V 2. Supply power to the ECM, and then
measure the input voltage at the
3. Remove the oil pressure switch. See “Oil thermoswitch coupler terminals (wiring
separator tank and oil pan” (5-104). harness end). Check the wiring harness
4. Connect the tester leads to the terminal
thread b and body c of the oil pressure A
switch.
B/O P
5. Connect the special service tool a to the
oil pressure switch, and then apply
positive pressure. a
b a
B
c
B/O P
a
Lower unit pressure/vacuum tester a:

YB-35956-A
Vacuum/pressure pump gauge set a:
90890-06756 A FX SHO, FX Cruiser SHO
6. Check the oil pressure switch for
continuity. Replace if out of specification. Thermoswitch input voltage
(reference data):
Pink (P)–Black/Orange (B/O)
11.0–12.0 V
7-15
Control system
3. Remove the thermoswitch. See “Cylinder Thermo sensor check
block and electrical part (FX SHO, FX 1. Disconnect the thermo sensor coupler
Cruiser SHO)” (5-100) or “Cylinder block a.
1
and electrical part (FX HO, FX Cruiser
HO)” (5-102). 2. Supply power to the ECM, and then
measure the input voltage at the thermo
4. Suspend the thermoswitch in a container sensor coupler terminals (wiring harness
filled with water, and then heat the water end). Check the wiring harness if out of
slowly.
2
specification.
a B/L B/O
P B
3
5. Check the thermoswitch for continuity
when the specified temperatures are
reached. Replace if out of specification.
Thermo sensor input voltage:
Black/Blue (B/L)–Black/Orange (B/O)
4.75–5.25 V
4
e
5
3. Remove the thermo sensor. See
“Muffler” (5-31).
e
e
b
C 4. Suspend the thermo sensor in a
c
d container filled with water, and then
d
slowly heat the water.
D
6
d No continuity B B
e Continuity
C Temperature
D Time 7
Thermoswitch continuity temperature:
Pink (P)–Black (B)
b: 94–100 °C (201–212 °F)
c: 80–94 °C (176–201 °F)
6. Install the thermoswitch. See “Cylinder

5. Measure the thermo sensor resistance
when the specified temperatures are
reached. Replace if out of specification.
8
block and electrical part (FX SHO, FX Thermo sensor resistance:
Cruiser SHO)” (5-100) or “Cylinder block
HO)” (5-102).
Black (B)–Black (B)
0 °C (32 °F): 24.0–37.1 k
100 °C (212 °F): 0.87–1.18 k
9
7. Connect the thermoswitch coupler. 6. Install the thermo sensor. See “Muffler”
(5-31).
7-16
A
ELEC
Electrical system
7. Connect the thermo sensor coupler.
Engine temperature sensor check

1. Disconnect the engine temperature sen- B/Y B/Y
sor coupler a.

measure the input voltage at the engine
temperature sensor coupler terminals
(wiring harness end). Check the wiring
harness if out of specification. 5. Measure the engine temperature sensor
A resistance when the specified
temperatures are reached. Replace if out
a B/O B/Y
specification.
Engine temperature sensor resistance:
Black/Yellow (B/Y)–Black/Yellow (B/Y)
20 °C (68 °F): 54.2–69.0 k
100 °C (212 °F): 3.12–3.48 k
6. Install the engine temperature sensor.

See “Cylinder block and electrical part
B
(FX SHO, FX Cruiser SHO)” (5-100) or
a
B/O B/Y “Cylinder block and electrical part (FX
7. Connect the engine temperature sensor

coupler.
Intake air temperature sensor check

1. Measure the ambient temperature.
A FX SHO, FX Cruiser SHO 2. Connect the YDIS to display “Intake

B FX HO, FX Cruiser HO temperature.”
Engine temperature sensor input voltage:
Black/Yellow (B/Y)–Black/Orange (B/O) 3. If the ambient temperature and the
4.75–5.25 V displayed intake air temperature differ by
more than ± 5 °C (± 9 °F), measure the
3. Remove the engine temperature sensor. intake air temperature sensor resistance.
See “Cylinder block and electrical part
(FX SHO, FX Cruiser SHO)” (5-100) or TIP:
“Cylinder block and electrical part (FX Check the intake air temperature sensor
HO, FX Cruiser HO)” (5-102). when the engine is cold.
4. Suspend the engine temperature sensor

4. Disconnect the intake air temperature
in a container filled with water, and then
sensor coupler a.
heat the water slowly.
7-17
Control system
B
measure the input voltage at the intake
air temperature sensor coupler (wiring
1
harness end). Check the wiring harness
A
B/O B/R
a
2
3
8. Measure the intake air temperature
sensor resistance when the specified
B temperatures are reached. Replace if out
of specification.
B/O B/R
Intake air temperature sensor resistance:
0 °C (32 °F): 5.4–6.6 k
80 °C (176 °F): 0.29–0.39 k
9. Install the intake air temperature sensor.

4
See “Intake assy. (FX SHO, FX Cruiser
a
SHO)” (5-45) or “Intake assy. (FX HO, FX
Cruiser HO)” (5-47).
10. Connect the air temperature sensor

5
Intake air temperature sensor input volt- coupler.
age:
Black/Red (B/R)–Black/Orange (B/O)
4.75–5.25 V
Intake air pressure sensor check
1. Disconnect the intake air pressure sen-
sor coupler a.
6
6. Remove the intake air temperature
7
sensor. See “Intake assy. (FX SHO, FX 2. Supply power to the ECM, and then
Cruiser SHO)” (5-45) or “Intake assy. (FX measure the input voltage at the intake
HO, FX Cruiser HO)” (5-47). air pressure sensor coupler (wiring
harness end). Check the wiring harness
7. Suspend the intake air temperature if out of specification.
8
sensor in a container filled with water,
and then slowly heat the water.
a B/O O
A
B B
9
7-18
A
ELEC
Electrical system
Intake air pressure sensor input voltage:

Orange (O)–Black/Orange (B/O)
4.75–5.25 V
G
3. Connect the intake air pressure sensor
coupler a.
4. Disconnect the vacuum hose from the

intake air pressure sensor. a
5. Connect the special service tool to the Knock sensor resistance at 20 °C (68 °F)
intake air pressure sensor. (reference data):
504–616 k
6. Connect the YDIS to display “Intake air
pressure.” 3. Connect the knock sensor coupler a.
7. Apply negative pressure to the intake air TPS check

pressure sensor slowly and check that
the displayed intake air pressure
increases. Replace if it does not
increase.
nut a and do not turn the throttle stop
screw b.
• Do not disconnect the ETV coupler
a
(throttle body end) c.
• TPS 1 and TPS 2 are components of the
ETV, which cannot be disassembled.
c
Lower unit pressure/vacuum tester a:
YB-35956-A
Vacuum/pressure pump gauge set a:
90890-06945
8. Disconnect the special service tool, and a b

then connect the vacuum hose.
Knock sensor check

1. Disconnect the knock sensor coupler a.
2. Measure the knock sensor resistance.

Replace the knock sensor if out of
specification.
1. Connect the YDIS to display “TPS 1,”
“Throttle valve opening angle,” and “TPS
2.”
7-19
Control system
TIP: TIP:
When checking the TPS using the YDIS, do The actual TPS output voltage and throttle
not start the engine. valve opening angle may vary according to
2. Squeeze the throttle lever a slowly and

check that the displayed throttle valve
environmental conditions and engine temper-
ature. 1
opening increases. 5. Operate the throttle lever a so that the
2
TPS 2 output voltage is 4.5 V or less, and
3. Check the TPS 1 output voltage and then check the voltage difference
throttle valve opening angle at the fully between TPS 1 and TPS 2. Measure the
closed position A . TPS input voltage if out of specification.
TPS output voltage difference: 1.9–2.1 V
a
A
Example:
If the TPS 1 output voltage is 2.5 V and the
TPS 2 output voltage is 4.5 V, then 4.5 – 2.5
3
= 2.0 V.
6. Disconnect the ETV coupler d.

measure the input voltage at the ETV
4
TPS 1 output voltage with throttle lever
coupler terminals (wiring harness end).
5
fully closed: 0.6–0.9 V
Check the TPS circuit continuity if out of
Throttle valve opening angle with throttle
specification.
lever fully closed: 2–8°
C
4. Operate the throttle lever a, and then d
check the TPS 2 output voltage and
throttle valve opening angle at the fully
open position B .
O
6
a
B
D
B/O
7
TPS 2 output voltage with throttle lever
O
8
fully open: 4.5–4.8 V
9
Throttle valve opening angle with throttle
d B/O
lever fully open: More than 70°
C FX SHO, FX Cruiser SHO

D FX HO, FX Cruiser HO
7-20
A
ELEC
Electrical system
TPS input voltage:

Orange (O)–Black/Orange (B/O) a
4.75–5.25 V 3 2 1
6 5 4
8. Connect the ETV coupler.
ETV circuit continuity b c

1. Disconnect the ETV coupler a and ECM
couplers b and c.
A
44 43 42 41
a 52 78
ETV circuit continuity:

Terminal No. Color
Coupler a Coupler b, c code
a P P
b R O
B
c { G
d Q P/B
e O B/O
f Z L
3. Connect the ETV coupler and ECM

couplers.
a
APS check
APS 1, APS 2, and APS full close switch
are components of the throttle lever,
b c which cannot be disassembled.
1. Connect the YDIS to display “APS 1,”

“APS 2,” and “APS full close switch.”
TIP:
When checking the APS using the YDIS, do
not start the engine.
2. Check the wiring harness for continuity.
Replace if there is no continuity. Replace 2. Operate the throttle lever a, and then
the ETV if there is continuity. check the output voltages of APS 1 and
APS 2 at the fully closed position A and
fully open position B .
7-21
Control system
measure the input voltage at the APS
a a coupler terminals (wiring harness end).
1
A Check the APS circuit continuity if out of
B specification.
APS output voltage:

Throttle lever position
a O/R
B/R
2
Item
Fully closed A Fully open B
O/W B/W
APS 1
APS 2
0.68–0.74 V
0.68–0.74 V
3.95–4.15 V
3.95–4.15 V
APS 1 input voltage:
O/G
Orange/Red (O/R)–Black/Red (B/R)

B/G
3
TIP: 4.75–5.25 V
The actual APS output voltage may vary
according to environmental conditions.
3. Squeeze the throttle lever a to the fully

APS 2 input voltage:
Orange/White (O/W)–Black/White (B/W)
4.75–5.25 V
APS full close switch input voltage:
4
open position B , and then check the Orange/Green (O/G)–Black/Green (B/G)
5
voltage difference between APS 1 and 4.75–5.25 V
APS 2. Measure the APS input voltage if
out of specification. 7. Connect the APS coupler.
APS output voltage difference: APS circuit continuity
0.1 V or less
1. Disconnect the APS coupler a and ECM
4. Squeeze the throttle lever a slowly and
check that the “APS full close switch”
display changes from the “ON” to “OFF.”
couplers b and c.
6
a
C
D
a
7
8
APS full close switch: b c
Throttle lever position
C
D
YDIS display
ON
OFF
9
5. Disconnect the APS coupler a.
7-22
A
ELEC
Electrical system
2. Check the wiring harness for continuity.
Replace if there is no continuity. a
R/Y
a
3 2 1
6 5 4
9 8 7
R
b c
30 29
ETV relay input voltage:
37 36 35 34 Red/Yellow (R/Y)–Ground
Red (R)–Ground
22 50 49
3. Remove the ETV relay. See “Electrical

APS circuit continuity: box” (5-35).
Terminal No. Color
4. Connect the special service tool a.
Coupler a Coupler b, c code
a J P/R 5. Connect the tester leads to the
b H B/R connectors b and c or to the
c W O/R connectors b and d.
d K P/W
6. Connect the positive battery lead to the
e I B/W
connectors e or f.
f X O/W
g v W/G 7. Connect the negative battery lead to the
h C B/G connector g.
i D O/G
8. Check the continuity between connectors
3. Connect the APS coupler and ECM b and c or connectors b and d.
coupler. Replace the ETV relay if out of
specification.
ETV relay check
1. Disconnect the ETV relay coupler a.

ETV relay coupler terminals and ground. 1 2 3
Check the wiring harness if out of 4 5 6
specification.
7-23
Control system
a
g f e B/O O
1
W/R
W/Y
W/B
1
2
a
2
3
4
5
6 Cam position sensor input voltage:
W/G
W/L
W/Br
Orange (O)–Black/Orange (B/O)

4.75–5.25 V
b c d
3. Remove the cam position sensor. See
“Cylinder head cover” (5-64), and then
connect the special service tool a to the
3
cam position sensor and the wiring
4
Test harness (6 pins) a: harness.
YB-06872/90890-06849
ETV relay continuity: measure the output voltage when a
screwdriver is passed under the cam
Battery lead Terminal
position sensor in direction b. Replace
e or f–g
Disconnected
Connected
b–c or d
No continuity
Continuity
the cam position sensor if out of
specification. 5
9. Install the ETV relay. See “Electrical box”
(5-35).
10. Connect the ETV relay coupler.

G/O BW
6
Cam position sensor check
7
1. Disconnect the cam position sensor cou-
pler a. B/O a
measure the input voltage at the cam
8
position sensor coupler terminals (wiring
harness end). Check the wiring harness b
if out of specification. Measure the cam
position sensor output voltage if within
specification. b
9
c d e

YB-06877/90890-06877
7-24
A
ELEC
Electrical system
Cam position sensor output voltage: A

Green/Orange (G/O)–
Black/Orange (B/O) UP
Position Voltage (V)
c, e More than 4.8
d Less than 0.8 B
L/B B/O B
5. Disconnect the special service tool a,
and then install the cam position sensor.
UP
UP
See “Cylinder head cover” (5-64).
6. Connect the cam position sensor

coupler.
B
Slant detection switch check UP
1. Disconnect the slant detection switch
coupler a.
2. Supply power to the ECM, and then Slant detection switch continuity:
measure the input voltage at the slant Blue/Black (L/B)–Black/
detection switch coupler (wiring harness Position
Orange (B/O)
end). Check the wiring harness if out of Normal
specification. No continuity
position A
Overturned B Continuity
a
B/O L/B
TIP:
Make sure to turn the switch over to both the
left and right.
5. Install the slant detection switch. See

“Electrical box” (5-35).
6. Connect the slant detection switch

Slant detection switch input voltage:
coupler.
Blue/Black (L/B)–Black/Orange (B/O)
4.75–5.25 V
Steering sensor check
3. Remove the slant detection switch. 1. Connect the YDIS to display “Steering
sensor.”
4. Check the slant detection switch for
continuity. Replace if out of specification. 2. Turn the handlebar all the way to the left
or right.
3. Install a plastic tie a loosely around the

center a of the handlebar grip, and then
hook a spring gauge b onto the plastic
tie a.
7-25
Control system
4. Hold the spring gauge b at a 90° angle 8. Supply power to the ECM, and then
from the handlebar grip, and then pull the measure the input voltage at the steering
spring gauge in direction b using a force sensor coupler terminals (wiring harness
1
of approximately 100 N (10 kgf, 22 lbf). end). Replace the steering sensor if
within specification. Check the wiring
TIP: harness if out of specification.
At this time, the button c in the steering sen-
sor c will be pushed in direction d.
B/O O/R
5. Check that the following is displayed in
the “Engine monitor” window of the YDIS.
2
c e
Steering sensor input voltage:

3
d
c Orange/Red (O/R)–Black/Orange (B/O)
b
b 4.75–5.25 V
9. Connect the steering sensor coupler. 4

Reverse sensor check
a
5
1. Connect the YDIS to display “Reverse
switch.”
a
2. Operate the shift lever a at the F, N, and
R positions.
Steering sensor operation:

Handlebar YDIS display
the “Engine monitor” window of the YDIS. 6
Not pulled OFF RNF
a
7
Pulled ON
6. Use the same procedure to check that

the steering sensor operates properly
when the handlebar is turned to both the
left and right. Measure the steering
sensor input voltage if the steering
sensor does not operate.
7. Disconnect the steering sensor coupler

Reverse sensor operation:
8
Shift lever position YDIS display
e.
9
F position OFF
N position ON
R position ON
Right handlebar switch check

1. Connect the YDIS to display “Reverse
switch.”
7-26
A
ELEC
Electrical system
2. Push the right handlebar switches a, b, ECM check
c, and d. 1. Disconnect the ECM coupler a.

the “Engine monitor” window of the YDIS.
a

d c measure the input voltage between the
ECM coupler terminal (wiring harness
Right handlebar switch operation: end) and ground. Check the ECM circuit
Switch YDIS display continuity if out of specification.
Up a Free OFF
Down a
“SET” c
Pushed ON c b
“NO-WAKE
MODE” d
4. Disconnect the right handlebar switch

coupler a.

right handlebar switch coupler terminals a
harness if out of specification. 27
L/R Y/B Y/R

a
ECM input voltage:
Terminal A–Ground
B Y/G 12 V (battery voltage)
TIP:
Right handlebar switch input voltage: Do not disconnect the coupler b or c when
Blue/Red (L/R)–Black (B) measuring the ECM input voltage.
Yellow/Black (Y/B)–Black (B)
4.75–5.25 V 3. Disconnect the ECM couplers b, and
Yellow/Red (Y/R)–Black (B) then check the continuity between the
Yellow/Green (Y/G)–Black (B) ECM coupler terminals (wiring harness
11.0–12.0 V end) and ground. Replace the wiring
harness if there is no continuity.
7-27
Control system
Electric bilge pump check
1. Disconnect the electric bilge pump cou-
pler a.
a b
electric bilge pump coupler terminals
1
2
harness or electric bilge pump fuse if out
of specification.
a b
B Br
a
46
67 62
70
3
ECM circuit continuity:
Terminal T–Ground
Terminal 0–Ground
Terminal ^–Ground
Continuity
Electric bilge pump input voltage:
Brown (Br)–Black (B)
4
Terminal (–Ground
4. Connect the ECM couplers.
Earth plate check

3. Remove the electric bilge pump. See
“Bilge and hoses” (6-17). 5
4. Set the electric bilge pump in a container
1. Remove the earth plate. filled with water.
2. Check the continuity between each
terminal a and the housing b. Replace
the earth plate if there is no continuity.
terminal b and the negative battery lead
to the terminal c.
6
b
6. Check that water flows from the electric
bilge pump hose a.
a
7
Br B
a
b c
8
3. Install the earth plate. See “Cylinder
block and electrical part (FX SHO, FX
Cruiser SHO)” (5-100) or “Cylinder block
HO)” (5-102).
7. Install the electric bilge pump. See “Bilge
9
and hoses” (6-17).
8. Connect the electric bilge pump coupler.
7-28
A
ELEC
Electrical system
Fuel system 7. Install the fuel injectors. See “Fuel rail

Fuel injector check and injector installation” (4-10).
1. Connect the YDIS.
8. Connect the fuel injector couplers.
2. Using the “Stationary test” of the YDIS,
listen for the fuel injector operation Fuel pump module check
sound. 1. Connect the YDIS.
3. Disconnect the fuel injector couplers a. 2. Using the “Stationary test” of the YDIS,
listen for the fuel pump module operation
4. Supply power to the ECM, and then sound.
fuel injector coupler terminals (wiring 3. Disconnect the fuel pump module
harness end) and ground. Check the coupler a.
wiring harness if out of specification.
a R/Y measure the input voltage at the fuel
pump module coupler terminals (wiring
harness end). Replace the fuel pump
module if within specification. Check the
wiring harness if out of specification.
a
L B
Fuel injector input voltage:

Red/Yellow (R/Y)–Ground
5. Remove the fuel injectors. See “Fuel

injector (FX SHO, FX Cruiser SHO)” (4-
8) or “ETV and fuel injector (FX HO, FX Fuel pump module input voltage:
Cruiser HO)” (4-9). Blue (L)–Black (B)
6. Measure the fuel injector resistance.
Replace the fuel injector if out of TIP:
specification. After the unlock button is pushed, voltage will
only be applied to the fuel pump module for 3
seconds.
5. Remove the fuel pump module assy. See

“Fuel pump module removal” (4-14).
6. Measure the fuel sender resistance.

Replace the fuel sender if out of
specifications.
Fuel injector resistance at 20 °C (68 °F)

(reference data): 11.5–12.5 
7-29
Fuel system / Starting system
Engine start switch continuity:

B B Engine
R Red (R)–
Clip a start switch
1
Brown (Br)
b
Free No continuity
Installed A
Pushed Continuity
Removed Free No continuity
A
B
2
Pushed No continuity
3. Connect the left handlebar switch coupler

Fuel sender resistance at 20 °C (68 °F)
(white coupler).
(reference data):
Float position Red (R)–Black (B) 4. Disconnect the left handlebar switch
Lower position A
Upper position B
133.5–136.5 
5.0–7.0 
7. Install the fuel pump module assy. See

coupler (black coupler).
5. Check the engine stop switch for

continuity. Replace the left handlebar
3
“Fuel pump module installation” (4-15). switch assy. if out of specification.
8. Connect the fuel pump module coupler.
Starting system
A a
W B
4
Left handlebar switch assy. check
1. Disconnect the left handlebar switch cou-
pler (white coupler).
2. Check the engine start switch for

b
5
B
continuity. Replace the left handlebar
A
switch assy. if out of specification.
a
b
R Br b
a
6
Engine stop switch continuity:
b
Clip a
Engine
stop switch
b
White (W)–
Black (B)
7
Free No continuity
B Installed A
8
Pushed Continuity
a Removed Free Continuity
B Pushed Continuity
6. Connect the left handlebar switch coupler
9
(black coupler).
7-30
A
ELEC
Electrical system
Main and fuel pump relay check
Do not reverse the battery leads. Other-

wise, the main and fuel pump relay may 1 2 3 4
be seriously damaged.
5 6 7 8
1. Disconnect the main and fuel pump relay

coupler a, and then measure the input
voltage between the main and fuel pump
relay coupler terminals c or e (wring
harness end) and ground.
12345678 a
cR
e R B d
Y L
P Br
Re f c
W O
g b
Main and fuel pump relay input voltage:
Red (R)–Ground Test harness (8 pins) a:
12 V (battery voltage) YB-06879/90890-06879
2. Remove the main and fuel pump relay.
Main relay continuity:
See “Electrical box” (5-35).
Battery lead Terminal
3. Connect the special service tool a. e or f–g b–c or d
Disconnected No continuity
4. Connect the tester leads to the Connected Continuity
connectors b and c or to the
connectors b and d. 8. Connect the tester leads to connectors
d and h.
connector e or f. 9. Connect the positive battery lead to the
connector c.
6. Connect the negative battery lead to the
connector g. 10. Connect the negative battery lead to the
connector k.
7. Check the continuity between the
connectors b and c or the connectors 11. Check the continuity between the
b and d. Replace the main and fuel connectors d and h. Replace the main
pump relay if out of specification. and fuel pump relay if out of specification.
7-31
Starting system
TIP:
The positive battery lead is marked with gray
tape a.
k 12345678
a
h
3. Install the starter relay. See “Electrical
box” (5-35).
1
R B
d 4. Connect the tester leads between the
Y
P
W
L
Br
O c
starter relay terminals b and c.

terminal d, and the negative battery lead
2
to the terminal e.
Fuel pump relay continuity:
Battery lead c–k
Disconnected
Terminal d–h
No continuity
6. Check the continuity between the starter
relay terminals b and c. Replace the
starter relay if out of specification.
3
Connected Continuity
12. Install the main and fuel pump relay. See

b c
4
13. Connect the main and fuel pump relay
coupler.
Starter relay check

1. Remove the starter relay cover. See
d
Br B
e 5
Starter relay continuity:
2. Slide the boot away from the starter relay
terminal a, and then measure the input
voltage between the starter relay
Battery lead d–e
Disconnected
Connected
Terminal b–c
No continuity
Continuity
6
terminal a and ground.
7. Install the starter relay. See “Electrical
a aR
box” (5-35).
7
8
Starter relay input voltage:
Red (R)–Ground
12 V (battery voltage) 9
7-32
A
ELEC
Electrical system
Starter motor
9 9 N·m (0.9 kgf·m, 6.6 ft·lb)

7
10
7 N·m (0.7 kgf·m, 5.2 ft·lb) 3
13
1
6 M
12 11
8
M
4

1 Bolt 2 M6  120 mm
2 Rear cover 1
3 Packing 1 
4 Front cover assy. 1
5 Packing 1 
6 Plate 1
7 Starter motor yoke 1
8 Armature 1
9 Brush holder assy. 1
10 O-ring 1 
11 Circlip 1
12 Drive gear 1
13 O-ring 1 
7-33
Starter motor
Starter motor operation
1. Remove the starter motor. See “Starter
motor and wiring harness assy. removal
1
(FX SHO, FX Cruiser SHO)” (5-37) or
“Starter motor and wiring harness assy.
removal (FX HO, FX Cruiser HO)” (5-38).
2. Hold the starter motor in a vise using
2
aluminum plates on both sides.
3. Connect the positive battery lead a to 2. Measure the commutator diameter a.

the starter motor terminal bolt a. Replace the armature if below
specification.
4. Connect the negative battery lead b to
the starter motor body b, and then check
the starter motor operation. WARNING!
Do not touch the drive gear c.
3
a c
a
b
a
4
b
Commutator diameter a:
27.0–28.0 mm (1.06–1.10 in)
3. Measure the commutator undercut b.

5
TIP: Replace the armature if below
• Check the starter motor operation for a few
seconds.
• If the starter motor is disassembled, make
sure to check the operation again after
specification.
b
6
assembling it.

and then the positive battery lead from
the battery terminals.
7
6. Install the starter motor. See “Starter
motor and wiring harness assy.
installation (FX SHO, FX Cruiser SHO)”
(5-39) or “Starter motor and wiring
Commutator undercut b (reference data):
0.2–0.7 mm (0.008–0.028 in)
8
harness assy. installation (FX HO, FX 4. Check the armature for continuity.
Cruiser HO)” (5-40).
Armature check
1. Check the commutator. Clean using 600-
9
grit sandpaper and compressed air if
dirty.
7-34
A
ELEC
Electrical system
b d
e c
c d e
b
Armature continuity:
d
Commutator
Continuity
segments c
Segment c–
No continuity e
Armature core d
c
Segment c– f
No continuity
Armature core e
Brush holder check Brush holder assy. continuity:

1. Measure the brush length a. Replace Brush b–Brush c
the brush holder assy. if below specifica- Brush d–Brush e
Continuity
tion. Brush d–Terminal f
Brush e–Terminal f
For all brush and terminal
combinations not listed No continuity
above.
a Remote control system

Remote control transmitter check
1. Push the unlock button a. The buzzer
sounds twice, and then check that the
“UNLOCK” indicator light b comes on.
Brush length a:
5.0–12.5 mm (0.20–0.49 in) 2. Push the unlock button a for more than
4 seconds. The buzzer sounds 3 times,
2. Check the brush holder assy. for and then check that the “L-MODE”
continuity. Replace if out of specification. indicator light c comes on.
3. Push the lock button d. The buzzer

sounds once, and then check that the
“UNLOCK” indicator light b goes off.
7-35
Starter motor / Remote control system
5. Remove the battery (CR2016) c.
NOTICE: Do not touch the battery
d a
directly using your hands. Use a pair
1
of non-conductive tweezers to replace
the battery.
6. Measure the battery voltage. Replace the

remote control transmitter battery if
below specification.
b c
c 2
3
Number of beeps
Yamaha Security
System mode
Remote control transmitter battery voltage:
3V 4
1 beep Lock TIP:
2 beeps
3 beeps
Unlock
(normal mode)
L-MODE
(low-rpm mode)
Refer to local hazardous waste regulations
when disposing of transmitter batteries.
7. Install the battery (CR2016) c and

5
transmitter cover b.
TIP:
While the engine is running, input from the
remote control transmitter is not received.
c
b
6
4. Loosen the transmitter screws a in the
order a, b, and so on, and then remove
the transmitter cover b. NOTICE: Do
not touch the internal parts except the
e
7
battery.
b
d f
a
TIP:
Install the battery (CR2016) c so that the
positive side e is facing down.
8
a b
e c
8. Tighten the transmitter cover screws a
to the specified torque in the order a, b,
and so on. 9
7-36
A
ELEC
Electrical system
c a
a L/Y
b
f e b
b d
Transmitter cover screw a: Remote control receiver output voltage

0.1 N·m (0.01 kgf·m, 0.07 ft·lb) (reference data):
Blue/Yellow (L/Y)–Ground
Remote control receiver check 11.0–12.0 V
coupler a, and then measure the input 5. Connect the remote control receiver
voltage at the remote control receiver coupler.
Transmitter registration
B • Each remote control transmitter a has a
unique ID code.
• To add or re-register the ID code of a
remote control transmitter to the remote
control receiver b, connect the entry box
R c.
a
1. Connect the entry box c to the 2-pin
communication coupler a.
Remote control receiver input voltage:
Red (R)–Black (B)
a
coupler a.

coupler b from the multifunction meter.
Gy Gy
4. Supply power to the ECM, and then B B
a
measure the remote control receiver
output voltage at the remote control b a c
receiver coupler terminal (wiring harness
end) and ground. Replace the remote 2. Push the lock button b or unlock button
control receiver if out of specification. c to transmit the ID code from the
remote control transmitter to be
registered.
7-37
Remote control system / Indication system
Indication system
b c Multifunction meter check
1. Check the multifunction meter external
appearance. Replace the multifunction
meter if there is cracked meter housing,
fogged meter, or water intrusion. 1
TIP:
• At this time, the system enters the registra-
check that all indicator lights a and
display elements b and c on the
multifunction meter come on. Replace
the multifunction meter if it does not
2
tion mode to register the first code. All exist- operate properly.
ing ID codes will be deleted from the
remote control receiver.
• The “UNLOCK” indicator light d blinks
when the registration of the ID code has
a a
3
been completed. (If the registration could
not be completed, the “UNLOCK” indicator
light comes on. Re-transmit the ID code.)
b
a c
4
3. After checking that the registration of the
ID code has been completed using the
“UNLOCK” indicator light d, transmit the
next ID code.
TIP:
• When the multifunction meter is activated,
all displays come on for 2 seconds, and
then the multifunction meter starts to oper-
5
d
ate normally.
• Display elements c is FX Cruiser SHO
only. 6
3. Check the multifunction meter display.
7
Replace the multifunction meter if there
is intermittent or missing segment d.
TIP:
• Up to 5 remote control transmitters can be
registered in any sequence, regardless of
whether they are original equipment or
additional transmitters.
• The same ID code cannot be registered
8
twice in the remote control receiver.
d
4. After ID code registration has been

completed, disconnect the entry box to
exit the registration mode.
4. Disconnect
coupler e.
the multifunction meter 9
7-38
A
ELEC
Electrical system
Left operation button continuity:
measure the input voltage at the
Leads
multifunction meter coupler terminals Button Position
(wiring harness end). Replace the wiring Pu/W B G/W
harness if out of specification. Replace “Speed/RPM” Free
the multifunction meter if within button a Pushed  
specification and there is no display on “Volt/Hour” Free
the multifunction meter. button b Pushed  
3. Connect the left operation button coupler.
4. Disconnect the right operation button

coupler. See “Multifunction meter” (8-10).
R/Y
5. Check the right operation button for
continuity.
e B
Multifunction meter input voltage: R/W Y/W

Red/Yellow (R/Y)–Black (B)
B
6. Connect the multifunction meter coupler.
Multifunction meter operation button

check a
Right operation button is installed in FX
b
Cruiser only.
1. Disconnect the left operation button cou-

pler. See “Multifunction meter” (8-10). Right operation button continuity:
Leads
2. Check the left operation button for Button Position
R/W B Y/W
continuity. Free
“Start/Stop”
button a Pushed  
“Mode/Reset” Free
Pu/W G/W button b Pushed  
6. Connect the right operation button

B
coupler.
Compass display check (FX Cruiser

SHO)
a 1. Using a compass for reference, point the
watercraft north.
b
2. Select the compass display mode of the
multifunction meter and check that
“NORTH” appears on the meter.
7-39
Indication system
3. Check that the arrow a on the compass 3. Select the water temperature display
and air temperature sensor is facing mode of the multifunction meter and
toward the bow. check the water temperature displayed
1
on the meter.
N
4. Check that the ambient water

a temperature and the displayed water
temperature differ by less than ± 5 °C (±
9 °F).
2
3
Air temperature display check (FX
Cruiser SHO)
1. Measure the ambient air temperature.
2. Select the air temperature display mode

5. Disconnect the speed and
temperature sensor coupler.
water
4
6. Measure the water temperature sensor
of the multifunction meter and check the
a resistance.
air temperature displayed on the meter.
3. Check that the ambient temperature and

the displayed air temperature differ by
5
less than ± 5 °C (± 9 °F). B/Y
Y 6
a
Water temperature sensor resistance

(reference data):
Yellow (Y)–Black/Yellow (B/Y)
7
20 °C (3268 °F): 10 k
TIP:
Check the air temperature display when the
engine is cold.
7. Connect the speed
temperature sensor coupler.
and water
8
Speed sensor check (FX Cruiser
SHO)
9
Water temperature display check (FX
Cruiser SHO) 1. Disconnect the compass and air temper-
1. Place the watercraft in a water. ature sensor coupler a.
2. Measure the ambient water temperature.
7-40
A
ELEC
Electrical system
a
a
2. Connect the positive battery lead to the 2. Connect the positive battery lead to the
terminal b, and the negative battery lead terminal b, and the negative battery lead
to the terminal c. to the terminal c.
3. Connect the tester leads between the 3. Connect the tester leads between the
terminal c and the terminal d. terminal d and the terminal c.
4. Rotate the paddle wheel a manually and 4. Rotate the paddle wheel a manually and
measure the output voltage between the measure the output voltage between the
terminal c and the terminal d. Replace terminal d and the terminal c. Replace
if out of specification. if out of specification.
B/Y c b R/Y
bR a
Bc dG
a dY
Speed sensor output voltage (dependant

on the paddle wheel position):
Yellow (Y)–Black/Yellow (B/Y)
Less than 400 mV/More than 11.6 V
Speed sensor output voltage (dependant
on the paddle wheel position): 5. Connect the speed sensor coupler.
Green (G)–Black (B)
Less than 400 mV/More than 4.5 V Fuel level meter display and fuel
level warning indicator check
5. Connect the compass and air 1. Remove the fuel pump module assy. See
temperature sensor coupler. “Fuel pump module removal” (4-14).
Speed sensor check (FX HO, FX 2. Connect the fuel sender coupler a.
Cruiser HO, and FX SHO)
1. Disconnect the speed sensor coupler a. 3. Lift the float to the upper position A .
7-41
Indication system
check that the “WARNING” indicator light
A
b and the check engine warning
indicator c begin to blink.
1
B
a

check that all fuel level segments come
2
on. Replace the multifunction meter if c b
any one of the segments does not come
on.
5. Lower the float to the lowest position B ,

3. If the light and indicator do not blink,
check the “Diagnosis record” of the YDIS.
If a diagnosis record is available and the
3
and then check that the fuel level warning light and indicator do not blink, replace
4
indicator b, the lowest 2 fuel level the multifunction meter.
segments c, and the “WARNING”
indicator light d blink. If the indicator, 4. Connect the engine temperature sensor
segments, and the light do not blink, coupler.
replace the multifunction meter.
5
Diagnostic display check
b 1. Create a condition so that a diagnostic
code is recorded.
2. With the engine running, push the 2

buttons a for approximately 8 seconds
c d
and check that the diagnostic code b is
indicated.
b
6
6. Install the fuel pump module assy. See
“Fuel pump module installation” (4-15).
Check engine warning indicator

7
check
1. Disconnect the engine temperature sen-
sor coupler a.
8
a
a
3. If the diagnostic code is not indicated,

9
diagnostic code is not indicated, replace
the multifunction meter.
7-42
A
ELEC
Electrical system
Oil pressure warning indicator check A
1. Disconnect the oil pressure switch cou-
pler a, and then ground the terminal.
a
P/W
B/O P a
B
a a
2. Start the engine, and then increase the B/O P a

engine speed to 4500 r/min or more.
3. Check that the “WARNING” indicator light

b and the oil pressure warning indicator
c blink, and the buzzer sounds
intermittently.
2. Start the engine and operate it at trolling

speed for about 2 minutes.
3. Check that the “WARNING” indicator light

b and the engine overheat warning
indicator c blink, and then come on, and
c b the buzzer begins to sound intermittently,
and then it sounds continuously.
light and indicator do not blink, replace
5. Connect the oil pressure switch coupler.
Engine overheat warning indicator

check c b
1. Disconnect the thermoswitch coupler a,
and then connect the test lead a to the
thermoswitch coupler terminals (wiring
harness end).
light and indicator do not blink, replace
5. Connect the thermoswitch coupler.
7-43
Indication system
Buzzer check
1. Disconnect the buzzer coupler a.
1
measure the input voltage at the buzzer
Check the wiring harness if out of
specification.
L/R B/L
a
2
3
Buzzer input voltage (reference data):
Blue/Red (L/R)–Black/Blue (B/L)
11.0–12.0 V 4
3. Remove the buzzer. See “Steering
5
master” (8-18).

terminal b and the negative battery lead
to the terminal c.
5. Check that the buzzer sounds. Replace

the buzzer if it does not sound. 6
Bc bR
7
6. Install the buzzer. See “Steering master”
8
(8-18).
7. Connect the buzzer coupler.

9
7-44
A
HULL
HOOD
Hull and hood 8
Steering pad and handlebar cover .................................. 8-1
Handlebar and handlebar switch assy. ........................... 8-2
Left handlebar switch assy. and

throttle lever assy. ............................................................ 8-4
Cable and lead routing .............................................................. 8-5
Handlebar assy. installation ...................................................... 8-5
Front hood ......................................................................... 8-8
Multifunction meter ......................................................... 8-10
Side cover ........................................................................ 8-12

Side cover removal .................................................................. 8-13
Side cover installation ............................................................. 8-13
Center cover .................................................................... 8-14
Steering master assy. ..................................................... 8-16
Steering master ............................................................... 8-18

Steering shaft check ................................................................ 8-20
Steering arm assy. installation ................................................ 8-20
Steering cable and speed sensor lead .......................... 8-21

Steering cable installation (steering master end) .................... 8-24
Steering cable installation (jet pump end) ............................... 8-24
Shift cable installation (shift lever end) .................................... 8-25
Q.S.T.S. cable installation (Q.S.T.S. converter end) ............... 8-25
Seat and handgrip ........................................................... 8-27
Ventilation hose and water separator ........................... 8-29

Cooling water pilot outlet installation ....................................... 8-31
Ventilation hose installation ..................................................... 8-31
Exhaust system ............................................................... 8-32

Exhaust system installation ..................................................... 8-34
Rear section ..................................................................... 8-35
Spout installation ..................................................................... 8-38
Reboarding step assy. installation ........................................... 8-38
Deck and hull ................................................................... 8-39 1

2
3
4
5
6
7
8
9
A
HULL
HOOD Hull and hood
Steering pad and handlebar cover
1 N·m (0.1 kgf·m, 0.7 ft·lb)

2 Upper handlebar cover 1
3 Steering pad cover 1
4 Steering pad 1
6 Lower handlebar cover 1
8-1
Steering pad and handlebar cover / Handlebar and handlebar switch assy.
Handlebar and handlebar switch assy.

3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
7 N·m (0.7 kgf·m, 5.2 ft·lb)
1
7 6
10
1 2 6
5
2
8
3 2
9 1
5
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
15
20 N·m (2.0 kgf·m, 14.8 ft·lb)

1 N·m (0.1 kgf·m, 0.7 ft·lb)
16
12 3
13
13
11
4
14
5
17
16 N·m (1.6 kgf·m, 11.8 ft·lb)
14 14 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
20
a
19
18 6
1
2
3
Bolt
Washer
Handlebar grip
2
2
1
M6  12 mm
7
4 Handlebar grip 1
5 Bolt 2 M5  23 mm
6
7
8
Bolt
Right handlebar switch
Throttle lever assy.
2
1
1
M5  30 mm
8
9
10 Q.S.T.S. grip 1
11 Screw 2 M5  30 mm
12 Left handlebar switch assy. 1
13 Bolt 4 M8  48 mm
14 Upper handlebar holder 2 a Punch mark
15
16
Handlebar
Bolt
1
4 M6  9 mm
8-2
A
HULL
HOOD Hull and hood
7 N·m (0.7 kgf·m, 5.2 ft·lb)
7 6
10
1 2 6
5
8 4
3 2
9 1
5
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
15
12
1 N·m (0.1 kgf·m, 0.7 ft·lb)
20 N·m (2.0 kgf·m, 14.8 ft·lb) 16
13
11
13
14
17
16 N·m (1.6 kgf·m, 11.8 ft·lb)
14 14 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
20
19
a 18

17 Steering boss cover 1
18 Plastic tie 1
19 Packing 1 
20 Grommet 1
8-3
Handlebar and handlebar switch assy. / Left handlebar switch assy. and throttle lever assy.
Left handlebar switch assy. and throttle lever assy.
5
2
1
2
3
6
6
4
4
5
3
3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 6
1
2
3
Left handlebar switch assy.
Engine shut-off cord
Screw
1
1
2 M5  30 mm
7
4 Stop button 1
5 Start button 1
8
9
8-4
A
HULL
HOOD Hull and hood
Cable and lead routing
1. Wrap the packing a at the paint marks f e
a on the left handle bar switch assy. lead
b, right handle bar switch lead c, and g
h g
throttle lever assy. lead d.
i
d
c
h
a
Distance g:
a 10.0 mm (0.4 in)
b
Handlebar assy. installation
2. Make sure that the upper edge b of the

packing a is the specified distance c After installing the handlebar assy., make
from the upper edge d of the grommet sure that the Q.S.T.S. cable, right handle-
e. bar switch, and left handlebar switch lead
are not pulled when the handlebar is
3. Fasten the grommet e using the plastic turned to the right and left.
tie f.
1. Pass the Q.S.T.S. cables a, left handle-
bar switch assy. b, right handlebar
b switch c, and throttle lever assy. d
d a c through the opening of the steering boss
cover e.
f
2. Install the steering boss cover e, and
e then tighten the steering boss cover
screws f to the specified torque.
Distance c: f
10.0 mm (0.4 in) e
4. Wrap the packing g, making sure to

align the upper edge of the packing with c
the upper edge of the marking tape e on a
the Q.S.T.S. cable. f
5. Make sure that the upper edge f of the d c

packing g is specified distance g from
df
the upper edge h of the grommet h.
b
b a
6. Fasten the grommet h using the plastic
tie i.
Steering boss cover screw f:
1 N·m (0.1 kgf·m, 0.7 ft·lb)
8-5
Left handlebar switch assy. and throttle lever assy.
3. Install the right handlebar switch c and
throttle lever assy. d, and then tighten
the right handlebar switch screws g to
1
e
i
c
a g
b
Cable locknut i:
16 N·m (1.6 kgf·m, 11.8 ft·lb)
2
d
3
Cable length e:
Right handlebar switch screw g: 73.0 mm (2.9 in)
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
7. Route the Q.S.T.S. cables a through the
cover j and housing k.
TIP:
Align the protrusion a on the handlebar
switch with the handlebar hole b.
4. Install the left handlebar switch assy. b,

TIP:
Make sure to route the Q.S.T.S. cables
through the housing e recesses that have
4
the same shapes as the cables f.
and then tighten the left handlebar switch
d
screws h to the specified torque.
b
8. Fit the cable ends g into the holes h in
the Q.S.T.S. grip l.
g
5
f
c
b
l
h
j
6
h h k
Left handlebar switch screw h:

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
e
7
a
TIP:
Align the protrusion c on the handlebar
switch assy. with the handlebar hole d.
9. Install the Q.S.T.S. grip l onto the
handle bar, and then tighten the Q.S.T.S.
8
5. Loosen the cable locknuts i, and then grip screw m to the specified torque.
adjust the length e of the Q.S.T.S.
cables.
6. Tighten the cable locknuts i to the

9
specified torque.
8-6
A
HULL
HOOD Hull and hood
Clearance (reference data):

n: 0.4 mm (0.02 in)
l p: 2.4 mm (0.1 in)
TIP:
• Align the punched marks k on the handle-
bar n with the top surface of the steering
master q.
m
• The upper handlebar holder o should be
installed with the punch mark m facing
Q.S.T.S. grip screw m:
down.
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
• Tighten the bolts p so that there is clear-
10. Install the handlebar n and upper ance between the steering master q and
handlebar holders o, and then tighten the upper handlebar holders o at both
the handlebar holder bolts p to the ends of the upper handlebar holders.
specified torque. • Make sure that clearance n is narrower
than clearance p.
p
11. Tighten the handlebar grip bolts r to the
n specified torque.
12. Install the handlebar grips s, and then

o tighten the grip end bolts t to the
q specified torque.
t
s
s
k t
n k
r
q r
Handlebar grip bolts r:

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
o Handlebar grip end bolts t:
p 7 N·m (0.7 kgf·m, 5.2 ft·lb)
o p
n
n n
Handlebar holder bolt p:

20 N·m (2.0kgf·m, 14.8 ft·lb)
8-7
Left handlebar switch assy. and throttle lever assy. / Front hood
Front hood
3 1.5 N·m (0.15 kgf·m, 1.11 ft·lb)
25
30
1
23 27 28 5 N·m (0.5 kgf·m, 3.7 ft·lb)
2
22 6
7
18 8
9
2 1
14
21
30 2 7
5
5
2
1 10
16
24 26
2
4 11
3
13 N·m (1.3 kgf·m, 9.6 ft·lb)
17 14
17
19
17
20
13
12
4
14
5
15
2 N·m (0.2 kgf·m, 1.5 ft·lb)

29
5 N·m (0.5 kgf·m, 3.7 ft·lb)

5
5 N·m (0.5 kgf·m, 3.7 ft·lb)

6
1
2
3
Bolt
Bolt
Right mirror
2
4
1
M6  23 mm
M8  25 mm 7
4 Left mirror 1
5 Nut 6
6
7
8
Bolt
Bolt
Damper stay
2
2
1
M6  18 mm 8
9 Damper 1
9
10 Plastic tie 1
11 Boot 1
12 Bolt 4 M6  30 mm
13 Hinge 1
14 Rivet 6
15
16
Plate
Plate
1
1
8-8
A
HULL
HOOD Hull and hood
3 1.5 N·m (0.15 kgf·m, 1.11 ft·lb)

25
23 27 28 5 N·m (0.5 kgf·m, 3.7 ft·lb)
2
22 6
7
18 8
9
21 5
30 2 7
2 1
5
14
1 10
4 11
16
2
24 26
13 N·m (1.3 kgf·m, 9.6 ft·lb)
17 14
19
17 13
20
17
12
14
15
5
29
2 N·m (0.2 kgf·m, 1.5 ft·lb)

18 Front hood cover 1
19 Center ornament 1
20 Front hood 1
22 Bolt 2 M5  20 mm
23 Hood lock assy. 1
24 Front hood inner 1
25 Packing 1 
26 Damper 2
27 Damper 4
28 Packing 1 
29 Nut 4
30 Packing 2 
8-9
Front hood / Multifunction meter
Multifunction meter
2 N·m (0.2 kgf·m, 1.5 ft·lb) B A
1
8 28
7 2 1
3
11 10
27
17
19
2
12
18
19
21 5 N·m (0.5 kgf·m, 3.7 ft·lb)
6 4
3
23
20
5 4
22
13
24
25
15 5
16
25 24 14
26
26
4
4 N·m (0.4 kgf·m, 3.0 ft·lb) 9

6
1
2
3
Right operation button assy.
Cover
Left operation button assy.
1
1
1
A FX Cruiser SHO
B FX SHO, FX HO, FX Cruiser HO 7
4 Bolt 4 M6  29 mm
5 Lid lock hook 1
6
7
8
Nut
Tapping screw
Cover
4
4
1
M5  15 mm 8
9 Bolt 4 M5  12 mm
9
10 Multifunction meter 1 A FX Cruiser SHO
11 Multifunction meter 1 B FX SHO, FX HO, FX Cruiser HO
12 Grommet 4
13 Transmitter 2 FX HO, FX Cruiser HO: 1
14 Remote control receiver 1
15
16
Rivet
Bracket
2
1
8-10
A
HULL
HOOD Hull and hood
2 N·m (0.2 kgf·m, 1.5 ft·lb) B A

8 28
7 2 1
3
11 10
27
17
19
12
5 N·m (0.5 kgf·m, 3.7 ft·lb)
18 21
19 6 4
23 5
20
22
13
15
24
25
16
25 24 14
26
4
26
4 N·m (0.4 kgf·m, 3.0 ft·lb) 9

17 Rivet 5
18 Service lid 1
19 Rivet 4
20 Bow locker 1
21 Plug 1
22 Band 1
23 Fire extinguisher box 1
24 Mat 2 
25 Rivet 2
26 Hook 2
27 Plastic tie 1
28 Plastic tie 1 A FX Cruiser SHO
8-11
Multifunction meter / Side cover
Side cover
1
5 6
5 5 N·m (0.5 kgf·m, 3.7 ft·lb)
1 8
4
1
9
1
1
1
2
2
3
7
11
3
2 1
4
7
5
10
5 N·m (0.5 kgf·m, 3.7 ft·lb) 2 6

1
2
3
Bolt
Nut
Left side ornament
6
8
1
M6  30 mm
7
4 Right side ornament 1
6
7
8
Shift lever
Screw
Bolt
1
2
1
M6  18 mm
M6  23 mm
8
9 Right side cover 1
9
10 Left side cover 1
11 Nut 4
8-12
A
HULL
HOOD Hull and hood
Side cover removal Side cover installation
1. Set the shift lever to the reverse position. 1. Set the shift lever to the forward position.
2. Remove the shift lever a. 2. Install the side cover a, and then tighten
the side cover bolts b and c and side
3. Set the shift lever to the forward position. cover screws d to the specified torque.
c c
b d
a b
F
TIP: Side cover bolts b and c:

Set the shift lever assy. b to the forward 5 N·m (0.5 kgf·m, 3.7 ft·lb)
position while pushing down the lock lever c. Side cover screw d:
5 N·m (0.5 kgf·m, 3.7 ft·lb)
4. Remove the side cover bolts d and e 3. Set the shift lever to the neutral position.
and side cover screw f.
e 4. Install the shift lever e, and then tighten
the shift lever screws f to the specified
torque.
f
d
R
f e
f
5. Slide the side cover g, and then push

down on the side cover near the tab to
release the protrusion a on the tab from
the center cover h. Shift lever screw f:
h 5 N·m (0.5 kgf·m, 3.7 ft·lb)
8-13
Side cover / Center cover
Center cover
13 11
12
5 N·m (0.5 kgf·m, 3.7 ft·lb)
5 N·m (0.5 kgf·m, 3.7 ft·lb)

6 3
6
17 13
10
1
7 3 16
7
1
5
15
2
14
4
8
5 N·m (0.5 kgf·m, 3.7 ft·lb)
21
18
3
1 20
9
2
2 N·m (0.2 kgf·m, 1.5 ft·lb)
19
22
4
23
2
24
5
25
6
1
2
3
Bolt
Nut
Bolt
4
4
2
M6  29 mm
M6  23 mm
7
4 Center cover 1
5 Pad 1
6
7
8
Pad
Grommet
Nut
6
2
6

8
9 Pad 1 
9
10 Beverage holder 1
11 Lock 1
12 Center console box lid 1
13 Hinge pin 2
14 Screw 4 M6  18 mm
15
16
Center console box
Plug
1
1
8-14
A
HULL
HOOD Hull and hood
13 11
12
5 N·m (0.5 kgf·m, 3.7 ft·lb)
6 3 17 13
5 N·m (0.5 kgf·m, 3.7 ft·lb) 10
6
7 3 16
7
15
5
1
14
18
5 N·m (0.5 kgf·m, 3.7 ft·lb)
21
4
8
1 20
2 N·m (0.2 kgf·m, 1.5 ft·lb)
2
9 19
22
23
24
2
25

17 Packing 1 
18 Box cap 1
19 Packing 1
21 Chain ball 1
22 Transmitter holder 1
23 Rivet 3
24 Box 1
25 Pad 1 
8-15
Center cover / Steering master assy.
Steering master assy.
1
13
13
a
2
19 A
3
14 12
15
18
4
7
9 11
4 10
21 N·m (2.1 kgf·m, 15.5 ft·lb)
4
5
a 5
A 17 8
16 3
6 7 N·m (0.7 kgf·m, 5.2 ft·lb)
4 N·m (0.4 kgf·m, 3.0 ft·lb) 2
7 N·m (0.7 kgf·m, 5.2 ft·lb)
6
1
16 N·m (1.6 kgf·m, 11.8 ft·lb)

1
2
3
Bolt
Plate
Steering arm assy.
1
1
1
M8  24 mm
7
4 Steering arm 1 a Alignment hole
5 Nut 1
6
7
8
Ball joint
Nut
Bolt
1
1
1 M6  60 mm
8
9 Cable stopper 1
9
10 Nut 4
11 Washer 4
12 Bolt 4 M8  35 mm
13 Steering master assy. 1 a Alignment hole
14 Screw 2 A FX Cruiser SHO, M5  25 mm
15
16
Compass and air temperature sensor
Nut
1
2
A FX Cruiser SHO
A FX Cruiser SHO
8-16
A
HULL
HOOD Hull and hood
13
13
19 A 12
14
15
18
7
9 11
4 10
21 N·m (2.1 kgf·m, 15.5 ft·lb)
4
a 5
A 17 8
16 3
6 7 N·m (0.7 kgf·m, 5.2 ft·lb)
4 N·m (0.4 kgf·m, 3.0 ft·lb) 2
1 7 N·m (0.7 kgf·m, 5.2 ft·lb)
16 N·m (1.6 kgf·m, 11.8 ft·lb)

17 Washer 2 A FX Cruiser SHO
18 Plastic tie 1
19 Grommet 1
8-17
Steering master assy. / Steering master
Steering master
4 N·m (0.4 kgf·m, 3.0 ft·lb)
1
7 N·m (0.7 kgf·m, 5.2 ft·lb)
2 3
6
12
2
11
13 2
4
10
3
14
8
13
13
9
4
17
13
5
15
1
5
17
7 N·m (0.7 kgf·m, 5.2 ft·lb) 16

6
1
2
3
Steering master assy.
Bolt
Bracket
1
2
1
M5  15 mm 7
4 Bracket 1
5 Buzzer 1
6
7
8
Bolt
Steering sensor
Rubber seal
4
1
1
M6  25 mm

8
9 Lever 1
9
10 Lock 1
11 Steering shaft 1
12 Pipe seal 1
13 Bushing 4
14 Bushing 1
15
16
Rivet
Plate
2
1
8-18
A
HULL
HOOD Hull and hood
4 N·m (0.4 kgf·m, 3.0 ft·lb)

7 N·m (0.7 kgf·m, 5.2 ft·lb)
2 3
6
12
7
11
13 2
4
10
13
8
9
14 13
17
13 1
15
5
17
7 N·m (0.7 kgf·m, 5.2 ft·lb) 16

17 Pad 2 
8-19
Steering master
Steering shaft check
1. Check the steering shaft. Replace if i
cracked or damaged. NOTICE: Do not
1
disassemble the board spring a. Oth- g
erwise, the OTS will not function prop-
erly. h
f
a
4. Assemble the steering master. 2

5. Apply instant adhesive onto the mating
3
surfaces of the rubber seal j and
a
steering master assy. k in the area a as
shown, and then install the seal.
Steering arm assy. installation NOTICE: Do not reuse the rubber
1. Install the bushings a and b. seal, always replace it with a new one.
a a
k j a
4
a
b
a
k
j
5
2. Install the spring c, steering tube d,
lock e, and lever f to the right housing
g.
6
d
f
e
f
7
g
c e 8
3. Install the spring h and spring holder i
to the right housing g and lever f.
9
8-20
A
HULL
HOOD Hull and hood
Steering cable and speed sensor lead

1 19
26
25 20 21
15 5 7 N·m (0.7 kgf·m, 5.2 ft·lb)
16
2
2 17
3 4
8 7 N·m (0.7 kgf·m, 5.2 ft·lb)

5 N·m (0.5 kgf·m, 3.7 ft·lb) 29
14 4 N·m (0.4 kgf·m, 3.0 ft·lb)
13 5 N·m (0.5 kgf·m, 3.7 ft·lb)
14 5 30 22
13 10
6 31
11
7 33
9 12 32
18
7 N·m (0.7 kgf·m, 5.2 ft·lb)

19
35 28
27
37 34
37 37 37 37
36 36 36
36 36 23
7 N·m (0.7 kgf·m, 5.2 ft·lb)
6 N·m (0.6 kgf·m, 4.4 ft·lb)

1 Shift cable joint 1
2 Shift cable 1
3 Nut 1
4 Packing 1 
5 Plastic tie 2
6 Packing 1 
7 Grommet 1
8 Nut 2
9 Shift cable bracket 1
10 Nut 2
11 Shift cable holder 1
12 Shift cable holder 1
13 Nut 2
14 Washer 2
15 Shift lever assy. 1
16 Screw 2 M5  12 mm
8-21
15 5
25
26
19
20 21
7 N·m (0.7 kgf·m, 5.2 ft·lb)
1
16
2
2 17
3 4
2
8 7 N·m (0.7 kgf·m, 5.2 ft·lb)
5 N·m (0.5 kgf·m, 3.7 ft·lb) 29
13
14
14
5 N·m (0.5 kgf·m, 3.7 ft·lb)
5
10
30
4 N·m (0.4 kgf·m, 3.0 ft·lb)
22
3
13 6 31
11
7
9 12
33
32
4
18
37
7 N·m (0.7 kgf·m, 5.2 ft·lb)
37 37
19
37
35
37
27
28
34
5
36 36 36
36
6
36 7 N·m (0.7 kgf·m, 5.2 ft·lb) 23
6 N·m (0.6 kgf·m, 4.4 ft·lb)

17
18
19
Reverse sensor
Steering cable joint
Steering cable
1
1
1
7
20 Nut 1
21 Packing 1 
22
23
Speed and water temperature sensor
Speed sensor
Nut
1
1
1
FX Cruiser SHO
FX SHO, FXHO, FX Cruiser HO 8
24 Q.S.T.S. cable 1
9
25 Packing 1 
26 Grommet 1
27 Nut 1
28 Packing 1 
29 Bolt 4 M6  33 mm
30
31
Washer
Packing
4
4 
8-22
A
HULL
HOOD Hull and hood
1 19
26
25 20 21
15 5 7 N·m (0.7 kgf·m, 5.2 ft·lb)
16
2
2 17
3 4
8 7 N·m (0.7 kgf·m, 5.2 ft·lb)

5 N·m (0.5 kgf·m, 3.7 ft·lb) 29
14 4 N·m (0.4 kgf·m, 3.0 ft·lb)
13 5 N·m (0.5 kgf·m, 3.7 ft·lb)
14 5 30 22
13 10
6 31
11
7 33
9 12 32
18
7 N·m (0.7 kgf·m, 5.2 ft·lb)

19
35 28
27
37 34
37 37 37 37
36 36 36
36 36 23
7 N·m (0.7 kgf·m, 5.2 ft·lb)
6 N·m (0.6 kgf·m, 4.4 ft·lb)

32 Q.S.T.S. rod 1
33 Q.S.T.S. converter 1
34 Cable guide 1
35 Plastic tie 5
36 Rivet 5
37 Holder 5
8-23
Steering cable installation (steering
master end)
b
If a cable becomes damaged, replace it.

Never attempt to repair a damaged cable.
c
c
1
1. Insert the projection a on the steering
cable completely into the indentation b
in the cable stopper assy. NOTICE: Do
not attempt to twist the steering cable
to align it. Be sure to turn the drum
4. Connect the steering cable joint d to the
ball joint e.
2
nut a to install the steering cable.
b
d
e
3
4
a a 5. Adjust the steering cable. See “Jet thrust
TIP:
If the projection a on the steering cable is
not aligned properly to fit back the indenta-
nozzle angle adjustment” (3-2).
Steering cable installation (jet pump

end)
5
tion, rotate the drum nut a counterclockwise 1. Adjust the steering cable set length a,
a maximum of 90° for proper alignment.
2. Slightly pull out the clamp plate b on the

cable stopper assy., and then rotate it
and then tighten the steering cable lock-
nut a to the specified torque.
a
6
clockwise to lock it in place securely.
7
b a
Steering cable locknut a:

7 N·m (0.7 kgf·m, 5.2 ft·lb)
8
3. Rotate the clamp plate c on the cable
stopper assy. counterclockwise, making
sure to fit the projection c on the other
clamp plate b into the hole in the plate.
Steering cable set length a (jet pump
end): 14.5 ± 1 mm (0.57 ± 0.04 in)
2. Install the washer b and steering cable

9
joint c, and then tighten the steering
cable joint c to the specified torque.
8-24
A
HULL
HOOD Hull and hood
3. Install the washer d and steering cable
joint nut e, and then tighten the steering TIP:
cable joint nut e to the specified torque. Make sure that the edge of the packing c is
at the specified distance e from the edge of
the grommet d.
c
4. Install the shift cable holder a and
b grommet d to the shift cable bracket f,
and then tighten the shift cable holder
nuts g to the specified torque.
d
e 5. Install the plastic tie h.
6. Install the shift cable bracket f, and then

Steering cable joint c:
tighten the shift cable bracket nuts i to
7 N·m (0.7 kgf·m, 5.2 ft·lb)
Steering cable joint nut e:
7 N·m (0.7 kgf·m, 5.2 ft·lb) e e
Shift cable installation (shift lever c
h
end) d
1. Install the shift cable holder a so that the i
projection a on the holder fits into the g
groove b in the outer cable.
f a
a
Distance e:
a 5–15 mm (0.20–0.59 in)
Shift cable holder nut g:

5 N·m (0.5 kgf·m, 3.7 ft·lb)
b Shift cable bracket nut i:
5 N·m (0.5 kgf·m, 3.7 ft·lb)
2. Slide the shift cable holder b onto the Q.S.T.S. cable installation (Q.S.T.S.
shift cable holder a so that the marks c converter end)
and d are positioned as shown. 1. Make sure to fit the Q.S.T.S. cable end
d a with yellow paint mark a into the STBD
c hole b of the pulley. NOTICE: Be care-
ful not to twist the Q.S.T.S. cables.
b a
3. Install the packing c and grommet d

onto the shift cable e. b STERN
8-25
2. Adjust the Q.S.T.S. rod set length c.
WARNING! The Q.S.T.S. rod joint
must be screwed in more than 8 mm
(0.31 in) d.
3. Face the hole e in the joint of the

Q.S.T.S. rod a in the direction shown.
1
c
a
e
2
d 3
Distance c:
4
167.0 ± 0.5 mm (6.93 ± 0.02 in)
5
6
7
8
9
8-26
A
HULL
HOOD Hull and hood
Seat and handgrip

1 5 15 13
14 9
A A 16
17
3
3
6 18
2
4
2 6 N·m (0.6 kgf·m, 4.4 ft·lb) 10
12 11
26 N·m (2.6 kgf·m, 19.2 ft·lb)
13 20
14
B B 21
12 29
3
11 23 8
6
3
22
2 27 8
4 26
2 7
31 19
28
6 N·m (0.6 kgf·m, 4.4 ft·lb)
30 25 5 N·m (0.5 kgf·m, 3.7 ft·lb)


1 Front seat assy. 1 A FX Cruiser SHO, FX Cruiser HO
2 Bolt 4 M6  40 mm
3 Seat lock assy. 2
4 Packing 1 
5 Rear seat assy. 1 A FX Cruiser SHO, FX Cruiser HO
6 Packing 1 
7 Nut 4
8 Washer 9
9 Bolt 4 M8  30 mm
10 Handgrip 1
11 Nut 2
12 Washer 2
13 Projection 2
14 Washer 2
15 Cap 1
16 Packing 1
8-27
Seat and handgrip
1 5 15 13
9
1
A A 16 14
17
3
2
3
6 18
2
4
2 6 N·m (0.6 kgf·m, 4.4 ft·lb) 10
12 11
3
26 N·m (2.6 kgf·m, 19.2 ft·lb)
13 20
14
B B 21
6
3 12
11 23 8
29
4
3
22
4
2
2
31
26
28
27
19
8
7 5
6
6 N·m (0.6 kgf·m, 4.4 ft·lb)
30 25 5 N·m (0.5 kgf·m, 3.7 ft·lb)


17
18
19
Watertight storage compartment
Nut
Packing
1
5
1 
7
20 Bolt 5 M8  30 mm
21 Deck beam 1
22
23
24
Packing
Packing
Nut
1
2
2

 8
25 Washer 2
9
26 Seat holder 1
27 Plastic tie 1
28 Battery breather hose 1
29 Nipple 1
30 Front seat assy. 1 B FX SHO, FX HO
31 Rear seat assy. 1 B FX SHO, FX HO
8-28
A
HULL
HOOD Hull and hood
Ventilation hose and water separator

A 2
1
14 29
27 28
26 30 29
25 29 30
23 15 31 28
24
30 16 29 9
30 30 28 6
28 28 6
28 29
8
29 10 13
5 12 7
11
1
2
6
29 4
28 5 1
3 20
19
4 21
22
17 28 29
18
3
4 N·m (0.4 kgf·m, 3.0 ft·lb)

1 Rivet 6
2 Induction box 2
3 Plastic tie 2
4 Ventilation hose 2
5 Grommet 2
6 Plastic tie 3
7 Fuel tank breather hose 1 1
8 Fuel tank breather hose 2 1
9 Rivet 2
10 Water separator 1
11 Drain bolt 1
12 O-ring 1 
13 Plate 1
14 Rivet 2
15 Ventilation socket 1
16 Ventilation pipe 1
8-29
Ventilation hose and water separator
A 2
1
14 29
27 28
23
24
26
25 29
15 31
30
30
28
29
1
30 16 29 9
30 28
2
30 6
28 28 6
28 29
8
29 10 13
5 12 7
3
11
1
29
28
4
6
5 1
2
4
3
4
20
19
21
5
22
6
17 28 29
18
3
4 N·m (0.4 kgf·m, 3.0 ft·lb)

17
18
19
Holder
Nut
Clamp
1
1
1
7
21 Cooling water pilot outlet 1
22
23
24
Seal
Nut
Clamp
1
1
1

8
25 Cooling water hose 1 A FX SHO, FX Cruiser SHO
9
26 Cooling water pilot outlet 1 A FX SHO, FX Cruiser SHO
27 Seal 1 A FX SHO, FX Cruiser SHO
28 Rivet 8
29 Holder 8
30 Plastic tie 5
31 Plastic tie 1
8-30
A
HULL
HOOD Hull and hood
Cooling water pilot outlet installation c
1. Install a new seal a and the cooling
water pilot outlet b, and then tighten the
cooling water pilot outlet nut c to the
specified torque.
a
c
2
b
a
a a
b
c
Installation distance a:
Cooling water pilot outlet nut c: 30–40 mm (1.18–1.57 in)
4 N·m (0.4 kgf·m, 3.0 ft·lb)
TIP:
TIP: • Make sure to route the ventilation hose
Align each protrusion a with the slit b. (PORT) in front of the ventilation hose
(STBD).
Ventilation hose installation • Make sure that the end of the ventilation
hose c is at the specified distance a from
1. Install the grommets a.
the groove around the outside of the grom-
a met a.
a b
TIP:
Make sure that the grommet a is seated
properly in the hole in the inner hull b.
2. Install the ventilation hoses c.
8-31
Ventilation hose and water separator / Exhaust system
Exhaust system
3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 15
21
27
22
12
1
21 22 23 23 13
11
2
14
13
5 N·m (0.5 kgf·m, 3.7 ft·lb)

20
19 18
3
27 5
4
3
17
1 27 26
16
2
28 24
5
9
28
29 6 24
25
7 25
24
8
24
30
4
10
26
26
26
6
1
2
3
Negative battery lead
Positive battery lead
Clamp
1
1
1
7
4 Band 2
5 Battery 1
6
7
8
Bolt
Nut
Battery case
2
2
1
M6  22 mm
8
9 Pad 1
9
10 Flotation 1
11 Clamp 1
12 Resonator 1
13 Clamp 2
14 Clamp 1
15
16
Rubber hose
Band
1
1
8-32
A
HULL
HOOD Hull and hood
3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 15
27
12
21 22
11
21 22 23 23 13
14
13
20
5 N·m (0.5 kgf·m, 3.7 ft·lb)
19 18
27 5
3
17
1 27 26
16
2
28 24
9
28
29 6 24
25
7 25
24 24
8 26
4
30 26
26
10

17 Water lock 1
18 Water tank 1
19 Nut 6
20 Washer 6
21 Plate 1
22 Rubber hose 1
23 Exhaust valve 1 
24 Rivet 8
25 Hook 2
26 Pad 4 
27 Pad 3 
28 Pad 3 
29 Bracket 1
30 Bracket 1
8-33
Exhaust system
Exhaust system installation
1. Install the plate a onto the rubber hose TIP:
b. Align the mark b on the rubber hose b with
the mark c on the water tank e.
a
b
a
4. Install the water lock g and band h. 1
5. Install the rubber hose i, and then
tighten the rubber hose clamps j and k
a
i
2
k
TIP:
Make sure to fit the protrusions a on the rub-
ber hose b with the grooves in the plate a.
d
e h 3
2. Install the rubber hose b and a new j
exhaust valve c, and then tighten the
rubber hose nuts d to the specified
torque. g
4
b
c
Rubber hose clamp j and k:
3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 5
TIP:
d
Align the protrusions d on the rubber hose
i with the mark e on the water tank.
6. Install the resonator l, and then tighten

6
Rubber hose nut d:
the rubber hose clamp m to the specified
7
5 N·m (0.5 kgf·m, 3.7 ft·lb)
torque.
3. Install the water tank e, and then tighten
l
the rubber hose clamp f to the specified
torque.
b f
e
m
8
b
c Rubber hose clamp m:
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
9
A
Rubber hose clamp f:
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
8-34
HULL
HOOD Hull and hood
Rear section
5 N·m (0.5 kgf·m, 3.7 ft·lb)
3
15
16 N·m (1.6 kgf·m, 11.8 ft·lb)
16 5 N·m (0.5 kgf·m, 3.7 ft·lb)

18 17
9
10 16
14
18
8 19 13
11
10
8 21 12
7 6
17 2
7 5
4 5 1
4
22 28 5 N·m (0.5 kgf·m, 3.7 ft·lb)
21 25 16 N·m (1.6 kgf·m, 11.8 ft·lb)
20 26
27 BOW
5 N·m (0.5 kgf·m, 3.7 ft·lb)
24
23
16 N·m (1.6 kgf·m, 11.8 ft·lb)
31 30 2 N·m (0.2 kgf·m, 1.5 ft·lb)
23
33
29 32

2 Side cover 1
3 Side cover 1
4 Nut 2
5 Washer 2
6 Grip 1
7 Packing 2 
8 Bolt 2 M6  10 mm
9 Stern storage compartment lid 1
10 Rivet 8
11 Latch 2
12 Nut 2
13 Washer 2
14 Bolt 2 M8  30 mm
15 Stern storage compartment 1
16 Damper 2
8-35
Rear section
5 N·m (0.5 kgf·m, 3.7 ft·lb)
1
3
15
16 N·m (1.6 kgf·m, 11.8 ft·lb)
16 5 N·m (0.5 kgf·m, 3.7 ft·lb)

18 17
9
2
10 16
14
18
8
7 6
8
11
10
21
17
19
12
13
2
3
7 5
4
4 5 1
4
22 28 5 N·m (0.5 kgf·m, 3.7 ft·lb)
21 25 16 N·m (1.6 kgf·m, 11.8 ft·lb)
20 26
27 BOW
24
5 N·m (0.5 kgf·m, 3.7 ft·lb)
5
23
31 30 2 N·m (0.2 kgf·m, 1.5 ft·lb)
16 N·m (1.6 kgf·m, 11.8 ft·lb) 23
29 32
33
6
17
18
19
Nut
Plate
Cleat
6
2
1
7
20 Stern eye 2
21 Plate 4
22
23
24
Packing
Bolt
Reboarding step assy.
2
4
1

M8  45 mm 8
25 Bracket 2
9
26 Packing 2 
27 Nut 1
28 Spout 1
29 Screw 4
30 Nut 4
31
32
Washer
Drain plug
4
2
8-36
A
HULL
HOOD Hull and hood
5 N·m (0.5 kgf·m, 3.7 ft·lb)
3
15
16 N·m (1.6 kgf·m, 11.8 ft·lb)
16 5 N·m (0.5 kgf·m, 3.7 ft·lb)

18 17
9
10 16
14
18
8 19 13
11
10
8 21 12
7 6
17 2
7 5
4 5 1
4
22 28 5 N·m (0.5 kgf·m, 3.7 ft·lb)
21 25 16 N·m (1.6 kgf·m, 11.8 ft·lb)
20 26
27 BOW
5 N·m (0.5 kgf·m, 3.7 ft·lb)
24
23
16 N·m (1.6 kgf·m, 11.8 ft·lb)
31 30 2 N·m (0.2 kgf·m, 1.5 ft·lb)
23
33
29 32

33 Packing 2 
8-37
Rear section
Spout installation
1. Install the spout a, and then tighten the
spout nut b to the specified torque.
2. Connect the hose c, and then tighten

the spout hose clamp d to the specified
torque. b
1
c
a a
2
c
BOW b
Reboarding step assy. bolt c:
d
16 N·m (1.6 kgf·m, 11.8 ft·lb)
c
3
Spout nut b: 5 N·m (0.5 kgf·m, 3.7 ft·lb)
4
Spout hose clamp d:
TIP:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
Face the mark a toward the BOW.

5
Reboarding step assy. installation
1. Secure the brackets on both sides of the
reboarding step in the down position
6
using the plastic ties a so that they will
not return to the up position.
7
8
a a
2. Install the reboarding step assy. b, and

then tighten the reboarding step assy.
bolts c to the specified torque.
9
8-38
A
HULL
HOOD Hull and hood
Deck and hull

STBD
2 N·m (0.2 kgf·m, 1.5 ft·lb) 26 22
32
33 24
23
PORT
34
27 24
10 11 10
18 N·m (1.8 kgf·m, 13.3 ft·lb)
25 7 10
8 17
10
9 18 3 12
20 3
7 8 35 10
21
21 7
8
6
5 37
7 36 19
7 18
28 17
29 15
30
31 16
3 3
7
7 16 N·m (1.6 kgf·m, 11.8 ft·lb)

3 3 7 14
7 7
2
4
1 13

1 Bolt 2 M6  20 mm
2 Bow eye 1
3 Nut 12
4 Front protector 1
5 Front protector 1
6 Front protector 1
7 Bolt 12 M6  25 mm
8 Rivet 11
9 Front cover 1
10 Rivet 7
11 Rear protector 1
12 Rear protector 1
13 Inner gunwale 2
14 Rivet 30
15 Washer 30
16 Side gunwale 2
8-39
Deck and hull
STBD
2 N·m (0.2 kgf·m, 1.5 ft·lb) 26 22
PORT
33
34
32
27
24
23 1
24
10 11 10
2
18 N·m (1.8 kgf·m, 13.3 ft·lb)
25 7 10
8 17
10
9 18 3 12
3
7
6
8 35
8
20
21
21
7
10
3
4
5 37
7 36 19
7 18
28 17
29 15
30
31 16
3
5
7 3
7 16 N·m (1.6 kgf·m, 11.8 ft·lb)

3 3 7 14
7 7
2
1
13 N·m (1.3 kgf·m, 9.6 ft·lb)
4
13
5 N·m (0.5 kgf·m, 3.7 ft·lb)
6
17
18
19
Bolt
Collar
Sponson
8
8
1
M8  40 mm
7
20 Sponson 1
21 Bracket 2
22
23
24
Mat
Mat
Mat
1
1
2



8
25 Mat 1 
9
26 Mat 1 
27 Mat 1 
28 Nut 2
29 Washer 2
30 Washer 2
31
32
Nut
Cover
2
2
M6  24 mm
8-40
A
HULL
HOOD Hull and hood
STBD
2 N·m (0.2 kgf·m, 1.5 ft·lb) 26 22
32
33 24
23
PORT
34
27 24
10 11 10
18 N·m (1.8 kgf·m, 13.3 ft·lb)
25 7 10
8 17
10
9 18 3 12
20 3
7 8 35 10
21
21 7
8
6
5 37
7 36 19
7 18
28 17
29 15
30
31 16
3 3
7
7 16 N·m (1.6 kgf·m, 11.8 ft·lb)

3 3 7 14
7 7
2
4
1 13

33 Bolt 6 M6  20 mm
34 Cleat 2
35 Packing 2 
36 Bracket 2
37 Packing 2 
8-41
TRBL
SHTG
Troubleshooting 9
YDIS .................................................................................... 9-1

Function ..................................................................................... 9-1
Basic components ..................................................................... 9-3
Connecting the communication cable to the watercraft ............. 9-4
1
2
Engine unit troubleshooting ............................................ 9-5
Using the YDIS for engine unit troubleshooting ........................ 9-5
Diagnostic code table ................................................................ 9-7
Diagnostic code and checking step ........................................... 9-8
Engine unit troubleshooting
3
(diagnostic code not detected) ................................................ 9-14
4
5
6
7
8
9
A
TRBL
SHTG Troubleshooting
YDIS
The Yamaha Diagnostic System uses precision fault diagnosis to offer better serviceability at a time
when there is increasing demand for service tools for electronically controlled products. It provides
quick, reliable, safe, and reasonable service, and is intended to obtain customer satisfaction. The
Yamaha Diagnostic System features updated software and expanded tool functions that allow it to
respond to new models and technologies, maintaining compatibility with regulations. This manual
contains the model-specific information. See YDIS (Ver. 2.00) instruction manual for detailed infor-
mation.
Function
1. Diagnosis: Each sensor’s status and each ECM diagnostic code or item is displayed. This
enables you to find malfunctioning parts and controls quickly. The diagnostic codes displayed
are the same as those described in “Diagnostic code and checking step” in this chapter.
2. Diagnosis record: Sensors that had been activated and ECM diagnostic codes that have been
recorded are displayed. This allows you to check the watercraft’s record of malfunctions. The
diagnostic codes displayed are the same as those described in “Diagnostic code and checking
step” in this chapter.
3. Engine monitor: Each sensor status and the ECM data are displayed. This enables you to find
malfunctioning parts quickly. In addition, the data displayed using the Engine monitor function
can be displayed in a graph.
Items: FX SHO, FX Cruiser SHO, FX HO, FX Cruiser HO

Engine speed Fuel injection duration No-wake mode switch
Intake air pressure Engine temperature Cruise assist set switch
TPS 1 Intake air temperature Cruise assist up switch
Throttle valve opening angle Ex. manifold water Cruise assist down switch
temperature (*1)
TPS 2 Thermoswitch Reverse switch
APS 1 Slant detection switch Main relay (*2)
APS 2 Oil pressure switch ETV relay
Atmospheric pressure Engine start switch Fuel pump relay (*2)
Ignition timing APS full close switch
Battery voltage Steering sensor
(*1): Thermo sensor (*2): Main and fuel pump relay
4. Stationary test: Operation tests can be performed with the engine off.

Activate ignition coil (#1–#4) Activate injector (#1–#4) Activate electric fuel pump
(*1)
(*1): Operate fuel pump module
5. Active test: With the engine running, each cylinder is dropped and the engine speed is
checked for changes to determine if the cylinder is malfunctioning. These tests can be per-
formed quickly.
9-1
YDIS
6. Logger graph: Data stored in the ECM for the last 78 seconds (in 6 seconds intervals) is dis-
played on a graph.

Engine speed
Battery voltage
TPS
Engine temperature
Intake air pressure
Oil pressure switch
1
7. ECM record graph: When a malfunction occurs in the ETV system or APS system, 4 seconds
2
(2 seconds before and after the malfunction) of recorded data is saved in the ECM. This data
can be displayed on a graph using the “ECM record data graph” of the Data logger function.
When the communication cable is used to connect a computer to the ECM, the ECM record
data can be saved and viewed on the computer.
The saved ECM record data can also be viewed offline.

Engine speed
APS 1
Ref. TPS voltage (*2)
Ref. APS voltage (*3)
No-wake mode
Low-RPM mode
3
APS 2 Target TPS voltage for ISC Engine shut-off switch
Steering sensor
TPS 1
(*4)
Engine stop mode
Engine start mode
Main relay
ETV relay
4
TPS 2 SW-activated engine stop Thermoswitch
mode (*5)
Intake air pressure
Battery voltage
Target TPS voltage (*1)
OTS mode
Cruise assist mode
Reverse mode
Oil pressure switch
Warning
ETV limit
5
(*1): Target TPS voltage (3): Reference APS voltage
This item shows the target output
voltage of the TPS.
This value is the control voltage
that the ECM requires to set the
This item shows the criterion out-
put voltage of the APS.
This value is used to detect the
APS output voltage when the throt-
6
target opening angle of the throttle tle lever is opened.
valve.
(*2): Reference TPS voltage
This item shows the criterion out-
put voltage of the TPS.
(*4): Target TPS voltage for Idle Speed
Control
ECM controls the engine idle
speed by using the throttle valve
7
This value is used to detect the attached to the TPS.
TPS output voltage during engine
operation.
This target voltage is used by the
ECM to achieve the target opening
angle of the throttle valve at the
engine idle speed.
8
(*5): Engine stop mode with switch
TIP:
To display the data and graphs, see the YDIS (Ver. 2.00) Instruction Manual.
9
8. Logging: While the computer and engine are not connected, record “Engine Monitor” data
using the adapter.
9-2
A
TRBL
Basic components
1
4
*** 2 3
******
******
5
6 8
7
11
10

1 YDIS 2 starter kit 1 90890-06883
2 CD-ROM 1 Software and instruction manual
3 Adapter 1
4 USB cable 1 5 m (16.4 ft)
5 Adapter cap 1
6 AD harness 1 For external input
7 CAN-Line harness 1
8 K-Line harness 1
9 Power supply harness 1
10 Trigger switch harness 1
11 Trigger switch extension harness 1
9-3
YDIS
Connecting the communication cable to the watercraft
f
1
d e
2
b c
a
3
R/Y
B
W/B
4
a Wiring harness coupler
b Meter coupler
c K-Line harness coupler
d Adapter
e USB cable
5
f Adapter cap
TIP:
Be careful not to pinch the communication cable between the front hood and the deck or to damage
it.
6
7
8
9
9-4
A
TRBL
TIP:
• Before troubleshooting the engine unit, make sure that fresh fuel of the specified type has been
used.
• Check that all wiring connections are secured properly and that they are not corroded or rusty.
• Check that the engine shut-off cord is connected to the engine shut-off switch.
• Check that the battery is charged and that its specific gravity is within specification.
• Check the diagnostic code using the YDIS (or self-diagnosis) first, and then check the electronic
control system by following the diagnostic code chart.
• The multifunction meter cannot display more than 1 diagnostic code. Even if multiple diagnostic
codes are present, only 1 will be displayed.
• When an ETV system (ETV, TPS, and APS) diagnostic code is detected, check the data logger of
the “ECM record data graph” as well.
• Using the YDIS is recommended because self-diagnosis may be insufficient for proper trouble-
shooting of the ETV system (ETV, TPS, and APS).
• If a diagnostic code is not detected, check the engine unit according to “Engine unit troubleshoot-
ing (diagnostic code not detected).”
• When deleting the diagnosis record on the YDIS, make sure to check the time that the diagnostic
codes were detected.
• When checking the input voltage of a part, the coupler or connector must be disconnected. As a
result, the ECM determines that the part is disconnected and a diagnostic code is detected.
Therefore, make sure to delete the diagnosis record after checking the input voltage.
Using the YDIS for engine unit troubleshooting
TIP:
• Use the diagnostic codes displayed by the YDIS to check each part according to the “Diagnostic
code and checking step” table.
• Delete the diagnostic codes after checking, repairing, or replacing a part, and check that the diag-
nostic codes are not detected again. If the same diagnostic codes are detected, the ECM may be
faulty.
• Check the items listed in the table. If all the items are in good condition, delete the diagnostic
code, and then check the diagnostic codes again. If the same diagnostic codes are detected
again, the ECM is faulty.
• A breakdown of the engine symptoms are described in the “Diagnostic code table,” however, mul-
tiple malfunctions that have been duplicated cannot be limited to these items. The symptoms may
change depending on the operating conditions and other conditions.
9-5
Self-diagnosis
While the engine is running, the diagnostic
codes a can be checked by pushing the 2
buttons b simultaneously for approximately
8 seconds.
TIP:
1
Because the multifunction meter cannot dis-
play more than 1 diagnostic code even if
there are multiple diagnostic codes, using the
YDIS is recommended. 2
a
3
4
b
5
6
7
8
9
9-6
A
TRBL
Diagnostic code table
Diagnostic code output
YDIS
Code No. Symptom Multifunc-
Diagnosis
tion meter Diagnosis
record
01 Normal  — —
13 Pulser coil (*1) malfunction   
15   
malfunction
17 Knock sensor malfunction (*2)   
19 Battery voltage malfunction   
Air temperature sensor (*3)
23   
malfunction
24 Cam position sensor malfunction   
Air pressure sensor (*4)
29   
malfunction
47 Slant detection switch malfunction   
51 APS full close switch malfunction   
55 Steering sensor malfunction   
EX. manifold water temp sensor
65   
(*5) malfunction
68 No-wake mode switch malfunction   
78 Reverse switch (*6) malfunction   
112, 113, 114,
115, 116, 117,
118, 119, 121,
122, 123, 129, ETV system malfunction   
136, 137, 138,
139, 141, 142,
143, 144, 145
124, 125, 126,
TPS malfunction   
127, 128
131, 132, 133,
APS malfunction   
134, 135
252 Overheat warning — — 
253 Low oil pressure warning — — 
(*1): Pickup coil
(*2): FX SHO, FX Cruiser SHO only
(*3): Intake air temperature sensor
(*4): Intake air pressure sensor
(*5): Thermo sensor
(*6): Reverse sensor
9-7
Diagnostic code and checking step
Diagnos- See
Item Symptom Checking steps
tic code page
13
Pulser coil (*1)
malfunction
Engine will not
start
1. Measure the pickup coil output peak
voltage.
2. Measure the pickup coil resistance.
3. Check the white/black (W/B) and
7-11
7-11
A-1
1
black/orange (B/O) pickup coil leads A-3
for continuity.
1. Check the engine temperature using
the YDIS.
7-17 2
2. Measure the engine temperature 7-17
sensor input voltage.
3
Engine
temperature Trolling speed 3. Check the black/yellow (B/Y) and A-1
15
sensor is unstable (*3) black/orange (B/O) engine A-3
malfunction temperature sensor leads for
continuity.
4
sensor resistance.
1. Measure the knock sensor resis- 7-19
Knock sensor
Trolling speed tance.
17 malfunction
is unstable (*3) 2. Check the green (G) knock sensor A-1
(*2)
lead for continuity.
1. Check the battery voltage using the
YDIS.
2. Check the fuse for continuity.
9-1
7-4
5
3. Measure the stator coil output peak 7-12
6
Battery voltage Trolling speed
19 voltage.
malfunction is unstable (*3)
4. Measure the rectifier regulator output 7-13
peak voltage.
5. Check the battery leads and 8-32
terminals for proper connection.
Air
1. Check the intake air temperature
using the YDIS.
7-17
7-17
7
temperature Trolling speed
23 3. Check the black/red (B/R) and black/ A-1
sensor (*4)
malfunction
is unstable (*3)
orange (B/O) intake air temperature
sensor leads for continuity.
A-3
7-17
8
sensor resistance.
9
(*1): Pickup coil
(*2): FX SHO, FX Cruiser SHO only
(*3): This symptom may only be exhibited in certain environmental conditions.
(*4): Intake air temperature sensor
9-8
A
TRBL
Diagnos- See
tic code page
1. Measure the cam position sensor 7-24
input voltage.
Cam position 2. Check the orange (O), green/orange A-1
Engine speed
24 sensor (G/O), and black/orange (B/O) cam A-3
is limited
malfunction position sensor leads for continuity.
3. Measure the cam position sensor 7-24
output voltage.
1. Check the intake air pressure using 7-18
the YDIS.
2. Measure the intake air pressure 7-18
Intake press Engine stalls
29 sensor (*1) Trolling speed
3. Check the orange (O), pink/green A-1
(P/G), and black/orange (B/O) intake A-3
air pressure sensor leads for
continuity.
1. Check the slant detection switch 7-25
operation using the YDIS.
2. Measure the slant detection switch 7-25
Slant detection input voltage.
Normal
47 switch 3. Check the blue/black (L/B) and black/ A-1
operation
malfunction orange (B/O) slant detection switch A-3
leads for continuity.
4. Check the slant detection switch for 7-25
continuity.
1. Check the APS full close switch oper- 7-21
ation using the YDIS.
2. Measure the APS full close switch 7-21
APS full close Engine stalls
input voltage.
51 switch Trolling speed
3. Check the orange/green (O/G), A-1
black/green (B/G), and white/green A-3
(W/G) APS full close switch leads for
continuity.
1. Check the steering sensor operation 7-25
using the YDIS.
Steering 2. Measure the steering sensor input 7-25
Normal
55 sensor voltage.
operation
malfunction 3. Check the orange/red (O/R), white/ A-1
blue (W/L), and black/orange (B/O) A-3
steering sensor leads for continuity.
(*1): Intake air pressure sensor
(*2): This symptom may only be exhibited in certain environmental conditions.
9-9
Diagnos- See
tic code page
1. Measure the thermo sensor input 7-16
65
Ex. manifold
water temp.
sensor (*1)
Normal
operation
voltage.
2. Check the black/blue (B/L) and black/
orange (B/O) thermo sensor leads for
continuity.
A-1
A-3
1
malfunction
3. Measure the thermo sensor 7-16
resistance.
1. Check the right handlebar switch
operation using the YDIS.
2. Measure the right handlebar switch
7-26
7-26
2
No-wake
Normal input voltage.
68 mode switch
malfunction
operation 3. Check the blue/red (L/R), yellow/
black (Y/B), yellow/red (Y/R), yellow/
green (Y/G), and black (B) right
handlebar switch leads for continuity.
A-1
A-3 3
1. Check the reverse sensor operation 7-26
78
Reverse
switch (*2)
Normal
operation
using the YDIS.
2. Measure the reverse sensor input
voltage.
7-26 4
malfunction 3. Check the orange (O), green/white A-1
(G/W), and black/orange (B/O) A-3
reverse sensor leads for continuity.
1. Check the TPS output voltage and
throttle valve opening using the
7-19 5
YDIS.
6
2. Check the ECM circuit for continuity. 7-27
3. Check the ETV relay for continuity. 7-23
4. Check the charging system. 7-12
• Stator coil output peak voltage 7-12
112
ETV system Engine speed • Stator coil resistance 7-13
113
114
malfunction is limited • Rectifier regulator output peak voltage
• Rectifier regulator continuity
6. Check the battery voltage and
7-13
7-4
3-9
7
specific gravity.
7. Check the red (R) and black (B)
power supply circuit cables and leads
for continuity.
A-1
A-3
8
(*1): Thermo sensor
(*2): Reverse sensor
9
9-10
A
TRBL
Diagnos- See
tic code page
1. Check the pink (P), orange (O), pink/ A-1
black (P/B), and black/orange (B/O) A-3
ETV leads for continuity.
115 ETV system Engine speed 2. Check the TPS output voltage and 7-19
116 malfunction is limited throttle valve opening using the
YDIS.
3. Check the throttle shaft and throttle 4-10
inner surface for damage and wear. 5-49
1. Check the ETV coupler terminals for 4-10
117 corrosion and rust. 5-49
ETV system Engine speed
118 2. Check the green (G) and blue (L) A-1
malfunction is limited
119 ETV leads for continuity. A-3
ETV system Engine speed 1. Cross-check the ECM or replace.
121 —
ETV system Engine speed 1. Cross-check the ETV.
122 —
1. Check the ETV relay and fuse (ETV 7-23
123 relay) for continuity. 7-4
124 1. Check the pink (P), orange (O), pink/ A-1
125 TPS Engine speed black (P/B), and black/orange (B/O) A-3
127 malfunction is limited ETV leads for continuity.
128 2. Check the ECM circuit for continuity. 7-27
1. Check the TPS output voltage using 7-19
TPS Engine speed
126 the YDIS.
1. Check the TPS output voltage using 7-19
ETV system Engine speed the YDIS.
129
malfunction is limited 2. Check the ETV relay and fuse (ETV 7-23
relay) for continuity. 7-4
131 1. Check the APS output voltage using 7-21
132 APS Engine speed the YDIS.
133 malfunction is limited 2. Check the APS circuit for continuity. 7-22
134
APS Engine speed 3. Check the APS circuit for continuity. 7-22
135
9-11
Diagnos- See
tic code page
2. Check the ETV relay for continuity.
3. Check the charging system.
• Stator coil output peak voltage
• Stator coil resistance
7-23
7-12
7-12
7-13
1
136 • Rectifier regulator output peak voltage 7-13
2
137 ETV system Engine speed
138 malfunction is limited
4. Check the fuse for continuity. 7-4
139
5. Check the battery voltage and 3-9
specific gravity.
6. Check the red (R) and black (B) A-1

for continuity.
1. Check the ECM circuit for continuity.
A-3
7-27
3
141 2. Check the ETV relay and fuse (ETV 7-23
relay) for continuity. 7-4
142
ETV system
malfunction
Engine speed
is limited
1. Check the TPS output voltage and
throttle valve opening using the
YDIS.
7-19
4
2. Check the throttle shaft and throttle 4-10
5
inner surface for damage and wear. 5-49
2. Check the ETV relay for continuity. 7-23
3. Check the charging system. 7-12
• Stator coil output peak voltage 7-12
143
144
ETV system
malfunction
Engine speed
is limited
• Stator coil resistance
• Rectifier regulator output peak voltage
7-13
7-13
7-4
6
5. Check the battery voltage and 3-9
specific gravity.
6. Check the red (R) and black (B)
for continuity.
A-1
A-3
7
1. Check the ETV relay and fuse (ETV 7-23
145
ETV system
malfunction
Engine speed
is limited
relay) for continuity.
2. Check the throttle shaft and throttle
inner surface for wear or damage.
7-4
4-10
5-49
8
9
9-12
A
TRBL
Diagnos- See
tic code page
1. Check the cooling water passages 2-19
for obstructions.
sensor resistance.
3. Check that there is no short circuit A-1
between the black/yellow (B/Y) and A-3
black/orange (B/O) engine
temperature sensor leads (*1).
4. Check the thermoswitch for 7-15
Overheat Engine speed
252 continuity.
warning is limited
between the pink (P) and black (B) A-3
thermoswitch leads (*1).
6. Check the thermo sensor for 7-16
continuity.
between the black/blue (B/L) and A-3
black/orange (B/O) thermo sensor
leads (*1).
1. Check the oil level. 3-5
2. Check the oil pressure switch for 7-14
continuity.
Low oil
Engine speed 3. Check that there is no short circuit in A-1
253 pressure
is limited the pink/white (P/W) oil pressure A-3
warning
switch lead (*1).
4. Check the oil passages for 2-19
obstructions.
(*1): Disconnect the sensor coupler or switch coupler, and then check that there is no short circuit
at the coupler (wiring harness end).
9-13
Engine unit troubleshooting (diagnostic code not detected)
Troubleshooting when diagnostic codes are not available consists of the following 3 items.
Symptom 1: Specific trouble conditions
1
Symptom 2: Trouble conditions of an area or individual part
Cause: The contents considered to be the trouble factors for symptom 2
—: Not applicable
Symptom 1: Engine does not crank.
Symptom 2
Starter motor does

not operate
Cause
Yamaha Security System

set to lock mode
Checking step
Check that the Yamaha Security

System is set to the unlock mode.
See
page
7-35
2
Discharged battery Check the battery voltage and 3-9
Loose connection of
battery terminal
Blown fuse
specific gravity.
Check the battery lead and
terminal for proper connection.
Check the fuse for continuity.
8-32
7-4
3
Starter relay malfunction Check the starter relay. 7-32
Engine start switch
malfunction
Short, open, or loose
Check the engine start switch
(left handlebar switch).
Measure the starter relay input
7-30
7-32
4
connection in starter motor voltage.
5
circuit Check the wiring harness. A-1
A-3
Starter motor malfunction Disassemble and check the starter 7-33
motor.
Stuck piston or crankshaft Disassemble and check the engine 5-108
Starter motor
Stuck impeller
Idle gear or starter clutch

unit.
Disassemble and check the jet
pump unit.
Check the idle gear, starter clutch,
6-10
5-89
6
operates, but the malfunction or crankshaft Woodruff key. 5-94
engine does not
crank
Symptom 1: Engine will not start (engine cranks).

7
See
8
Symptom 2 Cause Checking step
page
Throttle valve does Throttle lever squeezed Check that the throttle lever is in
—
not move properly the fully closed position.
APS malfunction Measure the APS 1 and 2 output 7-21
voltage.
TPS malfunction
Throttle valve malfunction
Check the throttle valve opening.
Check the ETV.
7-19
4-10
5-49
9
9-14
A
TRBL
See
page
Discharged battery Battery performance Check the battery voltage and 3-9
decrease specific gravity.
Stator coil malfunction Check the stator coil assy. 7-12
Short, open, or loose Check the battery lead and 8-32
connection in charging terminal for proper connection.
circuit Check the wiring harness. A-1
A-3
ECM does not Blown fuse Check the fuse for continuity. 7-4
operate Main and fuel pump relay Check the main and fuel pump 7-31
malfunction relay.
Short, open, or loose Measure the ECM input voltage. 7-27
connection in ECM circuit Check the ECM circuit for 7-27
continuity.
ECM malfunction Replace the ECM. —
Spark plug does not Engine shut-off cord clip Check that the engine shut-off cord 7-30
spark (all cylinders) not installed clip is installed properly.
Engine stop switch Check the engine stop switch 7-30
malfunction continuity. (left handlebar switch)
Pickup coil malfunction Measure the pickup coil output 7-11
peak voltage.
Measure the pickup coil resistance. 7-11
Short, open, or loose Check the white/black (W/B) and A-1
connection in pickup coil black/orange (B/O) pickup coil A-3
circuit leads for continuity.
Short, open, or loose Measure the ignition coil input 7-11
connection in ignition coil voltage (from the battery).
circuit Check the red/yellow (R/Y), black/ A-1
red (B/R), black/white (B/W), black/ A-3
yellow (B/Y), and black/green (B/G)
ignition coil leads for continuity.
Ignition coil malfunction Exchange the ignition coil with a
different one, and then check the —
ignition spark.
ECM malfunction Measure the ECM output peak 7-27
voltage.
9-15
See
page
Fuel not supplied (all Fuel leakage Check the fuel hose. 4-1
cylinders) Blown fuse
Clogged fuel pump filter
Fuel pump module
malfunction
Check the fuse for continuity.
Clean the fuel pump filter.
Check the fuel pump module
operation sound using the YDIS.
7-4
4-14
7-29
1
Measure the fuel pump module 7-29
input voltage.
Check the blue (L) and black (B)
fuel pump module leads for
continuity.
A-1
A-3
2
Measure the fuel pressure. 4-5
Compression
malfunction
Compression leakage
Check the main and fuel pump
relay.
Measure the compression
7-31
5-1
3
pressure is low pressure.
4
Measure the valve clearance. 3-7
Check the camshaft for damage. 5-70
Check the cylinder head gasket 5-81
and cylinder head warpage.
Check the valve and valve seat for 5-82
wear.
Check the piston and piston ring for
damage.
Check the cylinder for damage.
5-111
5-111
5-111
5
Improper valve timing Check the timing chain. 5-72
6
7
8
9
9-16
A
TRBL
Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited
engine speed
See
page
Throttle valve does Throttle valve malfunction Check the ETV. 4-10
not move properly 5-49
Spark plug does not Spark plug malfunction Check the spark plug. 3-5
spark (some Ignition coil malfunction Check the ignition spark. 7-10
cylinders) Short, open, or loose Measure the ignition coil input 7-11
connection in ignition coil voltage (from the battery).
circuit Check the red/yellow (R/Y), black/ A-1
red (B/R), black/white (B/W), black/ A-3
yellow (B/Y), and black/green (B/G)
ignition coil leads for continuity.
ECM malfunction Measure the ECM output peak
7-27
voltage.
Fuel not supplied Fuel injector malfunction Check the fuel injector operation 7-29
(some cylinders) sound using the YDIS.
Measure the fuel injector 7-29
resistance.
Short, open, or loose Measure the fuel injector input 7-29
connection in fuel injector voltage.
circuit Check the red/yellow (R/Y), purple/ A-1
red (Pu/R), purple/black (Pu/B), A-3
purple/yellow (Pu/Y), and purple/
green (Pu/G) fuel injector leads for
continuity.
Clogged fuel injector filter Clean the fuel injector. 4-10
ECM malfunction Replace the ECM. —
Compression Compression leakage Measure the compression 5-1
pressure is low pressure.
Measure the valve clearance. 3-7
Check the camshaft for damage. 5-70
Check the cylinder head gasket 5-81
and cylinder head warpage.
Check the valve and valve seat for 5-82
wear.
Check the piston and piston ring for 5-111
damage. 5-111
Check the cylinder for damage. 5-111
Improper valve timing Check the timing chain. 5-69
9-17
Symptom 1: Limited engine speed
See
page
• Buzzer sounds
intermittently
• Overheat warning
indicator blinks
Clogged cooling water
passage
Check the cooling water pilot outlet
for water discharge.
Check the water inlet strainer.
Check the cooling water passage.
—
3-9
1-38
1
• Check engine Thermostat malfunction Check the thermostat. 5-39
warning indicator
blinks
• Buzzer sounds
intermittently
Insufficient engine oil Check the engine oil level.
Check for engine oil leakage.
3-5
—
2
• Oil pressure warn- Check the oil pump. 5-61
ing indicator blinks
Oil pressure switch

Check the oil strainer.
Check the oil passage.
Check the oil pressure switch
5-104
1-35
7-14
3
malfunction continuity.
4
Check that there is no short circuit A-1
in the pink/white (P/W) oil pressure A-3
switch lead.
Symptom 1: Discharged battery
Symptom 2
—
Cause
Battery performance
decrease
Checking step
Check the battery voltage and

specific gravity.
See
page
3-9 5
Loose connection of Check the battery lead and 8-32
battery terminal
Short, open, or loose
connection in charging
circuit
terminal for proper connection.
Check the charging circuit for wiring
connection and damage.
A-1
A-3
6
Stator coil malfunction Check the stator coil assy. 7-12
Rectifier regulator
malfunction
Measure the rectifier regulator
output peak voltage.
7-13
7
8
9
9-18
A
TRBL
Symptom 1: Poor performance
See
page
Watercraft cannot Jet pump unit malfunction Check the impeller, impeller duct, 3-9
reach high speeds and intake grate. 6-1
6-10
Water entered hull Check the drain plugs and O-rings 8-35
for damage.
Check the cooling water hoses for 2-20
damage.
Check the water lock, water tank, 8-32
and rubber hoses for damage.
Check the exterior of the hull for 8-39
damage.
9-19
Appendix A
Wiring diagram ...................................................................A-1

How to use the wiring diagram ................................................... A-1
FX SHO, FX Cruiser SHO .......................................................... A-1
FX HO, FX Cruiser HO............................................................... A-3
1
2
3
4
5
6
7
8
9
A
Wiring diagram
How to use the wiring diagram
Legend symbols in the wiring diagrams
a b
a Double colors wire

b No wire connector
Color Code
B : Black P : Pink
Br : Brown P/B : Pink/Black
B/G : Black/Green P/G : Pink/Green
B/L : Black/Blue P/R : Pink/Red
B/O : Black/Orange P/W : Pink/White
B/R : Black/Red Pu/B : Purple/Black
B/W : Black/White Pu/G : Purple/Green
B/Y : Black/Yellow Pu/R : Purple/Red
G : Green Pu/Y : Purple/Yellow
Gy : Gray R : Red
G/L : Green/Blue R/Y : Red/Yellow
G/O : Green/Orange W : White
G/W : Green/White W/B : White/Black
L : Blue W/G : White/Green
L/B : Blue/Black W/L : White/Blue
L/R : Blue/Red Y : Yellow
L/Y : Blue/Yellow Y/B : Yellow/Brack
O : Orange Y/G : Yellow/Green
O/G : Orange/Green Y/R : Yellow/Red
O/R : Orange/Red Y/W : Yellow/White
O/W : Orange/White
FX SHO, FX Cruiser SHO

A To entry box
B Antenna
C Nonuse
a Fuse (30 A) (battery)

b Fuse (20 A) (main and fuel pump relay)
c Fuse (10 A) (ETV relay)
d Fuse (10 A) (main and fuel pump relay)
e Fuse (3 A) (remote control receiver)
f Fuse (3 A) (electric bilge pump)
A-1
Printed in U.S.A.
Feb. 2012 – **  1 ABE
(E)
FX SHO, FX Cruiser SHO Fuel sender Multifunction meter Right Remote control Main and
R
B/G G
R
D B/Y
Y
E handlebar
Reverse
receiver fuel pump
ETV
P switch relay B
B R/W switch relay Br
Buzzer R
L B
B W W B R Br Left operation button W a
FREE SET G/W Compass and B
Y/W Br
W
1 9
R
Pu/W
B
PUSH PULL R/W air temperature
L/R
L/B
B 10 18
Gy
B sensor
W
b d
B
1
3
4
5
6
B B/O Fuse box Starter motor
Br Br
B
W W W Speed A C 4 c e
8 5 3 1
R
Y/W
R/Y
R/Y
R/Y
FREE sensor 6 4
10
12
13
14
15
16
18
3
4
6
7
9
1
3
4
5
6
7
8
Left handlebar PUSH Speed and water 4 1
Br
B
Y/G
L/R
Y/B
Y/R
switch Br 8 5 Battery
O
G/W
B/O
Br R R Right operation temperature
R
R
L
Y/G
L/R
R/Y
R/Y
W
W
R
Y
L/Y
L
Gy
Y/W
Gy
B
B
B
L/Y
L/B
L/B
L/R
B/L
B/L
L/R
G/L
Br 2 1
1
2
2
3
4
5
6
7
8
button sensor 1
R/Y
1 G R/Y 2 1 4 8 12
3
R
R
Y
R
R
R
R
Br
L
R/Y
W/B
B
R/Y
3 G/O R/Y 4
R/Y 5
5 L/B
1 8 14 20 7 R/Y R/Y 8
8 W/B R/Y 9
R/Y 10
R/Y 11 3 7 11 14
Joint coupler 2
13 B/L R/Y 13
14 Y/W R/Y 14
15 B/R 1 4
16 P/G
17 W/L R/Y 1
18 G/W R/Y 2
19 Y/B R/Y 3
20 Y/G R/Y 4
7 13 19 26 21 Y R/Y 5 36
22 W/G R/Y 6 Joint coupler 6
23 B/Y
24 L/R 15
25 O/R 1
26 O 2
3
4
27 R/Y O 5
28 W O 6
29 B/G O 7
30 O/G O 8 48
Joint coupler 1
27 34 40 46
34 B/R B/O 1 15 8
ECM 35 B/W B/O 2
36 P/R B/O 3
37 P/W B/O 4
B/O 5
39 R/Y B/O 6
40 B/O B/O 7
41 B/O B/O 8 4 7 10
42 P B/O 9
43 P/B B/O 10 Joint coupler 3
44 O
33 39 45 52 45 R/Y 1 4
46 B Y 1
47 W/B Y 2
Y 3
49 O/R
50 O/W
3 6
52 L Joint coupler 7
15 8
54 Y/R B 2
B 3
B 4
B 5
58 Pu/R B 6
59 Pu/B B 7
60 B/G 4 7 10
61 B/Y B 9
62 B B 10 Joint coupler 4
53 62 70 78 63 Y/G
64 P
B 1
B 2 1 4 8 12
67 B B 3
B 4
B 5
70 B B 6
W/B
B 7
B/O
R/Y
G
G
G
8
W/L
O/R
72 B/O
B/O
B/O
B/O
B/O
B/O
W
B/Y
f
B/L
L/B
G/O
B/O
P/W
B/W
G
B/O 9
B/G
B/O
B/O
P/G
R/Y
R/Y
R/Y
R/Y
B/R
B/R
B/Y
R
B
P
O
W/G
O/W
B/W
P/W
O/G
O/R
B/G
B/O
B/R
P/R
O
P/B
B
B
L
B/O 11 3 7 11 14
Pu/G
Pu/B
Pu/R
G
O
Pu/Y
P
L
78 G Joint coupler 5
R/Y
R/Y
R/Y
R/Y
1
2
3
61 69 77 86 79 P/W
80 Y/W B/O 14
81 L/R Earth plate
Br
82 G/L
B
83 #1 #2 #3 #4 B 1 4 8
Pu/G
84 Pu/Y B 2
G
G
G
P/W
85 B/R B 3
G
G
G
86 #1 #2 #3 #4 B 4
B/W
B 5
Intake air
pressure Knock B 7
Steering sensor Thermo Pickup B 8 1 5
sensor
Cam sensor Fuel injector switch coil B 1
APS (electric throttle position Oil Slant Electric Ignition coil Air Engine
ETV Fuel pump Rectifier
without wire cable) sensor pressure detection bilge temperature temperature Stator
module Thermo sensor regulator
switch switch pump sensor sensor coil
A-2
FX HO, FX Cruiser HO
A To entry box
B Antenna
C Nonuse
a Fuse (30 A) (battery)

b Fuse (20 A) (main and fuel pump relay)
c Fuse (10 A) (ETV relay)
d Fuse (10 A) (main and fuel pump relay)
e Fuse (3 A) (remote control receiver)
f Fuse (3 A) (electric bilge pump)
A-3
FX HO, FX Cruiser HO Multifunction meter Right handlebar Remote control Main and
ETV R
Fuel switch receiver relay fuel
B/G Reverse relay
sender pump B
B W W B R Br P B/Y switch R Br
FREE SET Y Buzzer B
Left operation button R/W a
Left handlebar switch PUSH PULL B
G/W Br
W
1 9
R
R
B
B
Pu/W
L/R
L/B
W 10 18
Gy
B
B
B 3 1 d
1
3
4
5
6
4 1 b Starter motor
Br Br B B/O A C 8 5
6 4 c
e
W W W
R
Y/W
R/Y
R/Y
R/Y
FREE
10
12
13
14
15
16
18
3
4
6
7
9
1
3
4
5
6
7
8
PUSH
B
Y/G
L/R
Y/B
Y/R
O
G/W
B/O
Br Fuse box Battery
R
R
L
Speed
Y/G
L/R
R/Y
R/Y
W
W
R
Y
L/Y
L
Gy
Y/W
Gy
B
B
B
L/Y
L/B
L/B
L/R
B/L
B/L
L/R
G/L
Br Br Br 2 1 4 1
1
2
2
3
4
5
6
7
8
R R sensor 8 5 R/Y 1
R/Y 2 1 4 8 12
3
R
R
Y
R
R
R
R
Br
L
R/Y
W/B
B
R/Y
3 G/O R/Y 4
1 8 14 20 R/Y 5
5 L/B
7 R/Y R/Y 8
8 W/B R/Y 9
R/Y 10
R/Y 11 3 7 11 14
13 Joint coupler 2
13 B/L R/Y
14 Y/W R/Y 14
15 B/R 1 4
16 P/G
17 W/L R/Y 1
7 13 19 26 18 G/W R/Y 2
19 Y/B R/Y 3
20 Y/G R/Y 4
21 Y R/Y 5 36
22 W/G R/Y 6 Joint coupler 6
23 B/Y
24 L/R 15
25 O/R 1
26 O 2
3
4
27 R/Y O 5
28 W O 6
29 B/G O 7
30 O/G O 8 48
Joint coupler 1
27 34 40 46
34 B/R B/O 1 15 8
ECM 35 B/W B/O 2
36 P/R B/O 3
37 P/W B/O 4
B/O 5
39 R/Y B/O 6
40 B/O B/O 7
41 B/O B/O 8 4 7 10
42 P B/O 9
43 P/B B/O 10 Joint coupler 3
44 O
33 39 45 52 45 R/Y 1 4
46 B Y 1
47 W/B Y 2
Y 3
49 O/R
50 O/W
3 6
52 L Joint coupler 7
B 1 15 8
54 Y/R B 2
B 3
B 5
58 Pu/R B 6
59 Pu/B B 7
60 B/G B 8 4 7 10
61 B/Y B 9
53 62 70 78 62 B Joint coupler 4
63 Y/G
64 P
B 1
B 2 1 4 8 12
67 B B 3
B 4
B 5
70 B B 6
W/B
B 7
B/O
G
G
G
R/Y
8
W/L
O/R
72 B/O
B/O
B/O
B/O
B/O
B/O
W
B/Y
B/L
L/B
G/O
B/O
P/W
B/W
9
B/G
B/O
B/O
B/O
P/G
R/Y
R/Y
R/Y
R/Y
B/R
B/R
R
B/Y
B
P
O
W/G
O/W
B/W
P/W
O/G
O/R
B/O
B/G
B/R
P/R
O
P/B
B
B
L
B/O 11 3 7 11 14
Pu/G
Pu/B
Pu/R
G
O
Pu/Y
P
L
78 G
R/Y
R/Y
R/Y
R/Y
P/W Joint coupler 5
61 69 77 86 79
80 Y/W B/O 14
81 L/R Earth plate
Br
82 G/L
B
83 #1 #2 #3 #4 B 1 4 8
Pu/G
B 2
P/W
84 Pu/Y
G
G
G
85 B 3
G
G
G
B/R #1 #2 #3 #4
86 B/W B 4
B 5
Intake air
Intake air B 7
pressure B 8
Steering temperature Thermo Pickup 1 5
sensor
Cam sensor Fuel injector sensor switch coil B 1
APS (electric throttle Oil Slant Electric Ignition coil Engine
ETV position Fuel pump Rectifier
without wire cable) sensor pressure detection bilge temperature Stator
module Thermo sensor regulator
switch switch pump sensor coil
A-4

2012 Yamaha Waverunner FX Cruiser Ho Sho Service Manual Wave Runner

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2012 Yamaha Waverunner FX Cruiser Ho Sho Service Manual Wave Runner

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WaveRunner

General information GEN

Safety while working .................................................... 1-1

Identification number ........................................................ 1-5

How to use this manual .................................................... 1-7

Adhesive, lubricant, sealant, and

Special service tool ......................................................... 1-11

Model feature ................................................................... 1-19

Technical tips .................................................................. 1-24

YDIS .................................................................................. 1-31

Safety while working

Special service tool

Engine serial number

a Jet pump unit name

Hull identification number (H.I.N.)

How to use this manual

Adhesive, lubricant, sealant, and thread locking agent

Water resistant grease Lubricant

Molybdenum disulfide grease Lubricant

Epnoc grease AP#0 Lubricant

Silicone grease Lubricant

ThreeBond 1280B Sealant

ThreeBond 1322 Thread locking agent

ThreeBond 1360 Thread locking agent

ThreeBond 1530D Adhesive

LOCTITE 242 (blue) Thread locking agent

LOCTITE 271 (red) Thread locking agent

Symbol Name Application

LOCTITE 648 (green) Thread locking agent 1

Special service tool

Oil filter wrench Dial gauge needle

Dial gauge set

Fuel pressure gauge adapter

Valve spring compressor Valve guide reamer

Compressor adapter Valve lapping tool

Valve guide remover Neway valve seat kit

Valve seat cutter holder

Bearing outer race attachment Bearing pressure C

Driver handle (large) Piston ring compressor

Forward gear outer race installer Piston ring compressor

Ball bearing attachment Driveshaft holder

Peak volt adapter

Test harness (3 pins)

Digital circuit tester

Test harness (2 pins)

Peak voltage adapter B

Lower unit pressure/vacuum tester

a Power unit c Electrical

A FX SHO B FX Cruiser SHO

Model Previous FX series New FX series

172 mm (6.8 in)

380 mm (15 in)

A FX SHO, FX Cruiser SHO

a Throttle lever B New ETV system

A Previous ETV system

Item Condition Action Remarks

Item Condition Action Remarks

• Opening angle of the ETV Cancel:

Engine Monitor Digital Display

Data Logger Logger Graph 7

a Adapter f Adapter recording status

a Intake camshaft k Oil cooler assy.

A From flushing hose connector