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WaveRunner GP1200R
SERVICE MANUAL
*LIT186160215*
LIT-18616-02-15 |
F0X-28197-ZA-11 |
E
NOTICE
This manual has been prepared by the Yamaha Motor Company Ltd. primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the 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 the Yamaha Motor Company, Ltd. has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual.
A10001-0*
WaveRunner GP1200R
SERVICE MANUAL
©2000 Yamaha Motor Co., Ltd. 1st Edition, February 2000 All rights reserved.
No part of this publication may be reproduced or transmitted in any form or by any means including photocopying and recording without the written permission of the copyright holder.
Such written permission must also be obtained before any part of this publication is stored in a retrieval system of any nature. Printed in USA
LIT-18616-02-15
E
HOW TO USE THIS MANUAL
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.,
●Bearings
Pitting/scratches → Replace.
To assist you in finding your way through this manual, the section title and major heading is given at the top of every page.
ILLUSTRATIONS
The illustrations within this service manual represent all of the designated models.
CROSS REFERENCES
The cross references have been kept to a minimum. Cross references will direct you to the appropriate section or chapter.
E
IMPORTANT INFORMATION
In this Service Manual particularly important information is distinguished in the following ways.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the water vehicle.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the water vehicle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
IMPORTANT:
This part has been subjected to change of specification during production.
E
HOW TO USE THIS MANUAL
1To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.
2 Numbers are given in the order of the jobs in the exploded diagram.
3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
4A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.
5Dimension figures and the number of parts, are provided for fasteners that require a tightening torque.
Example: |
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Bolt or screw size |
10 × 25 mm : M10 (D) × 25 mm (L) |
D
L
6Jobs requiring more information (such as special tools and technical data) are described sequentially.
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SPEC |
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INFO |
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INSP |
FUEL |
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ADJ |
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56
POWR 
JET 
PUMP
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ELEC |
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HULL |
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– + |
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HOOD |
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90
TRBL
ANLS
AB
CD
T .
R .
EF
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GH
A |
M |
IJ
GM |
4 |
KL
LT |
LT |
271 |
242 |
MN
LT |
SSLT |
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572
E
A50001-1-4
SYMBOLS
Symbols 1 to 9 are designed as thumbtabs to indicate the content of a chapter.
1 General Information
2 Specifications
3 Periodic Inspection and Adjustment
4 Fuel System
5 Power Unit
6 Jet Pump Unit
7 Electrical System
8 Hull and Hood
9 Trouble analysis
Symbols 0 to E indicate specific data:
0 Special tool
A Specified liquid
B Specified engine speed C Specified torque
D Specified measurement
ESpecified electrical value
[Resistance (Ω), Voltage (V), Electric current (A)]
Symbol F to H in an exploded diagram indicate the grade of lubricant and the location of lubrication point:
F Apply YAMALUBE 2-W oil
GApply water resistant grease
(Yamaha grease A, Yamaha marine grease)
H Apply molybdenum disulfide grease
Symbols I to N in an exploded diagram indicate the grade of the sealing or locking agent, and the location of the application point:
I Apply Gasket Maker®
JApply Yamabond #4 (Yamaha bond number 4)
K Apply LOCTITE® No. 271 (Red LOCTITE) L Apply LOCTITE® No. 242 (Blue LOCTITE) M Apply LOCTITE® No. 572
N Apply silicone sealant
NOTE:
In this manual, the above symbols may not be used in every case.
E
A30000-0 |
INDEX |
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GENERAL INFORMATION |
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INFOGEN |
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SPECIFICATIONS |
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PERIODIC INSPECTION AND |
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ADJUSTMENT |
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INSPADJ |
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FUEL SYSTEM |
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FUEL |
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POWER UNIT |
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POWR |
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JET PUMP UNIT |
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PUMPJET |
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7 |
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– + |
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ELECTRICAL SYSTEM |
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ELEC |
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HULL AND HOOD |
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HOODHULL |
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TROUBLE ANALYSIS |
9 |
ANLSTRBL |
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GEN |
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INFO |
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E |
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CHAPTER 1 |
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GENERAL INFORMATION |
IDENTIFICATION NUMBERS......................................................................... |
1-1 |
PRIMARY l.D. NUMBER........................................................................... |
1-1 |
ENGINE SERIAL NUMBER ...................................................................... |
1-1 |
JET PUMP UNIT SERIAL NUMBER ........................................................ |
1-1 |
HULL IDENTIFICATION NUMBER (H.l.N.).............................................. |
1-1 |
SAFETY WHILE WORKING........................................................................... |
1-2 |
FIRE PREVENTION................................................................................... |
1-2 |
VENTILATION........................................................................................... |
1-2 |
SELF-PROTECTION.................................................................................. |
1-2 |
OILS, GREASES AND SEALING FLUIDS................................................ |
1-2 |
GOOD WORKING PRACTICES................................................................ |
1-3 |
DISASSEMBLY AND ASSEMBLY........................................................... |
1-4 |
SPECIAL TOOLS............................................................................................. |
1-5 |
MEASURING ............................................................................................ |
1-5 |
REMOVAL AND INSTALLATION ............................................................ |
1-6 |
1
2
3
4
5
6
7
8
9
GEN INFO
IDENTIFICATION NUMBERS |
E |
A60700-0*
IDENTIFICATION NUMBERS
PRIMARY l.D. NUMBER
The primary l.D. number is stamped on a label attached to the inside of the engine compartment.
Starting primary l.D. number:
F0X: 800101 ~
ENGINE SERIAL NUMBER
The engine serial number is stamped on a label attached to the cylinder head.
Starting serial number: 67X: 000101 ~
JET PUMP UNIT SERIAL NUMBER
The jet pump unit serial number is stamped on a label attached to the intermediate housing.
Starting serial number: 67X: 800101 ~
HULL IDENTIFICATION NUMBER (H.l.N.)
The H.l.N. is stamped on a plate attached to the aft deck.
1-1
GEN INFO
SAFETY WHILE WORKING |
E |
SAFETY WHILE WORKING
The procedures given in this manual are those recommended by Yamaha to be followed by Yamaha dealers and their mechanics.
FIRE PREVENTION
Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited.
Do not smoke while handling gasoline (petrol) and keep it away from heat, sparks, and open flames.
VENTILATION
Petroleum vapor is heavier than air and is deadly if inhaled in large quantities. Engine exhaust gases are harmful to breathe. When test-running an engine indoors, maintain good ventilation.
SELF-PROTECTION
Protect your eyes with suitable safety spectacles or safety goggles when grinding or doing any operation which may cause particles to fly off.
Protect hands and feet by wearing safety gloves or protective shoes if appropriate to the work you are doing.
OILS, GREASES AND SEALING FLUIDS
Use only genuine Yamaha oils, greases, and sealing fluids or those recommended by Yamaha.
1-2
GEN INFO
SAFETY WHILE WORKING |
E |
Under normal conditions of use there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all-important, and by adopting good safety practises any risk is minimized. A summary of the most important precautions is as follows:
1.While working, maintain good standards of personal and industrial hygiene.
2.Clothing which has become contaminated with lubricants should be changed as soon as practicable and laundered before further use.
3.Avoid skin contact with lubricants (e.g., do not place a soiled rag in your pocket).
4.Hands and any other part of the body which have been in contact with lubricants or lubricant-contaminated clothing should be thoroughly washed with hot water and soap as soon as practicable.
5.To protect the skin, the application of a suitable barrier cream to the hands before working is recommended.
6.A supply of clean lint-free cloths should be available for wiping purposes.
GOOD WORKING PRACTICES
1.The right tools
Use the recommended special tools to protect parts from damage. Use the right tool in the right manner – do not improvise.
2.Tightening torque
Follow the tightening torque instructions. When tightening bolts, nuts and screws, tighten the larger sizes first and tighten inner-positioned fixings before outer-positioned ones.
1-3
GEN INFO
SAFETY WHILE WORKING |
E |
3.Non-reusable items
Always use new gaskets, packings, O- rings, oil seals, split-pins, circlips, etc., on reassembly.
DISASSEMBLY AND ASSEMBLY
1.Clean parts with compressed air when disassembling.
2.Oil the contact surfaces of moving parts during assembly.
3.After assembly, check that moving parts operate normally.
4.Install bearings with the manufacturer’s markings on the side exposed to view and liberally oil the bearings.
CAUTION:
Do not spin bearings with compressed air because this will damage their surfaces.
5.When installing oil seals, apply a light coat of water-resistant grease to the outside diameter.
1-4
GEN INFO
SPECIAL TOOLS
SPECIAL TOOLS
E
1 YU-08036-A |
90890-06760 |
2 YU-03097 |
90890-01252 |
YU-01256 |
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3 YU-03112 |
4 YU-03017 |
90890-03112 |
90890-06759 |
5 YU-33223 |
90890-03160 |
6 J-39299 |
90890-06752 |
7 YU-39991 |
8 YW-06780 |
90890-03169 |
90890-06780 |
Using the correct special tools recommended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvisations and using improper tools can damage the equipment.
NOTE:
●For U.S.A. and Canada, use part numbers starting with “J-”, “YB-”, “YM-”, “YU-” or “YW-”.
●For other countries, use part numbers starting with “90890-”.
MEASURING
1.Engine tachometer P/N. YU-08036-A
90890-06760
2.Dial gauge and stand P/N. YU-03097, YU-01256
90890-01252
3.Pocket tester P/N. YU-03112
90890-03112
4.Cylinder gauge set P/N. YU-03017
90890-06759
5.Compression gauge P/N. YU-33223
90890-03160
6.Digital multimeter P/N. J-39299
90890-06752
7.Peak voltage adapter P/N. YU-39991
90890-03169
8.Peak voltage test harness P/N. YW-06780
90890-06780
9.Spark gap tester P/N. YM-34487
90890-06754
9 YM-34487 |
90890-06754 |
1-5
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GEN |
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SPECIAL TOOLS |
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INFO |
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REMOVAL AND INSTALLATION |
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1 YW-06551 |
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2 YW-06550 |
90890-06550 |
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1. Coupler wrench |
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90890-06551 |
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P/N. YW-06551 |
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90890-06551 |
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2. Flywheel holder |
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P/N. YW-06550 |
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90890-06550 |
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3 YB-06117 |
90890-06521 |
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3. Flywheel puller |
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P/N. YB-06117 |
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90890-06521 |
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4. Drive shaft holder (impeller) |
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P/N. YB-06151 |
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90890-06519 |
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4 YB-06151 |
90890-06519 5 YB-06096 |
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5. Slide hammer set (jet pump bearing) |
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P/N. YB-06096 |
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6. Stopper guide plate (jet pump bearing) |
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P/N. 90890-06501 |
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7. Bearing puller (jet pump bearing) |
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6 90890-06501 |
7 90890-06535 |
P/N. 90890-06535 |
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8. Bearing puller claw 1 (jet pump bearing) |
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P/N. 90890-06536 |
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9. Stopper guide stand (jet pump bearing) |
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P/N. 90890-06538 |
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8 90890-06536 |
9 90890-06538 |
10. Drive rod L3 (jet pump bearing) |
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P/N. 90890-06652 |
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11. Needle bearing attachment |
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(jet pump bearing and oil seal) |
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P/N. YB-06112, YB-06196 |
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0 90890-06652 |
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A YB-06112 |
90890-06614 |
90890-06614, 90890-06653 |
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12. Ball bearing attachment |
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YB-06196 |
90890-06653 |
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(jet pump oil seal) |
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P/N. YB-06156 |
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90890-06634 |
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13. Driver rod |
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B YB-06156 90890-06634 |
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(intermediate shaft and jet pump) |
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P/N. YB-06071 |
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90890-06606 |
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14. Bearing inner/outer race attachment |
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(jet pump bearing) |
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C YB-06071 |
90890-06606 D YB-34474 |
P/N. YB-34474 |
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15. Shaft holder (intermediate shaft) |
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P/N. YB-06552 |
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90890-06552 |
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16. Bearing outer race attachment |
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E YB-06552 |
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F YB-06016 90890-06626 |
(intermediate shaft) |
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90890-06552 |
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P/N. YB-06016 |
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90890-06626 |
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1-6
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SPEC |
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CHAPTER 2 |
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SPECIFICATIONS |
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GENERAL SPECIFICATIONS ......................................................................... |
2-1 |
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MAINTENANCE SPECIFICATIONS................................................................ |
2-3 |
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ENGINE .................................................................................................... |
2-3 |
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JET PUMP UNIT ...................................................................................... |
2-4 |
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HULL AND HOOD ................................................................................... |
2-4 |
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ELECTRICAL ............................................................................................ |
2-5 |
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TIGHTENING TORQUES................................................................................ |
2-7 |
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SPECIFIED TORQUES.............................................................................. |
2-7 |
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GENERAL TORQUE ............................................................................... |
2-10 |
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CABLE AND HOSE ROUTING...................................................................... |
2-11 |
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1
2
3
4
5
6
7
8
9
SPEC 
GENERAL SPECIFICATIONS |
E |
GENERAL SPECIFICATIONS
Item |
Unit |
Model |
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GP1200R |
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MODEL CODE |
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Hull |
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F0X |
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Engine |
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67X |
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DIMENSIONS |
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Length |
mm (in) |
2,930 (115.4) |
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Width |
mm (in) |
1,150 (45.3) |
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Height |
mm (in) |
1,020 (40.2) |
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Dry weight |
kg (lb) |
306 (675) |
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Vehicle capacity |
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2 |
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PERFORMANCE |
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Maximum output |
kW (PS) @ r/min |
114.0 (155) @ 7,000 |
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Maximum fuel consumption |
R/h (US gal/h, |
64.0 (16.9, 14.1) |
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lmp gal/h) |
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Cruising range |
hr |
1.1 |
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ENGINE |
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Engine type |
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2-stroke |
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Number of cylinders |
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3 |
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Displacement |
cm3 (cu. in) |
1,176 (71.74) |
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Bore × stroke |
mm (in) |
80.0 × 78.0 (3.15 × 3.07) |
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Compression ratio |
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5.9:1 |
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Intake system |
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Reed valve |
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Carburetor model |
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BN44 (MIKUNI) × 3 |
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(manufacturer) × quantity |
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Enrichment control |
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Choke valve |
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Scavenging system |
|
Loop charge |
|
Lubrication system |
|
Variable oil injection |
|
Cooling system |
|
Water cooled |
|
Starting system |
|
Electric starter |
|
Ignition system |
|
Digital CDI |
|
Ignition timing |
Degree |
18 BTDC ~ 24 BTDC |
|
Spark plug model |
|
BR8ES-11 (NGK) |
|
(manufacturer) |
|
|
|
Battery capacity |
V-Ah (kC) |
12 - 19 (68.4) |
|
Lighting coil |
A @ r/min |
9 ~ 11 @ 6,000 |
|
|
|
|
|
DRIVE UNIT |
|
|
|
Propulsion system |
|
Jet pump |
|
Jet pump type |
|
Axial flow, single stage |
|
Impeller rotation (from rear) |
|
Counterclockwise |
|
Transmission |
|
Direct drive from engine |
|
Steering nozzle angle |
Degree |
23 + 23 |
|
Trim nozzle angle |
Degree |
–5, 0, 5, 10, 15 |
|
Trim system |
|
Manual 5 positions |
|
Reverse system |
|
N.A. |
|
|
2-1 |
|
SPEC 
GENERAL SPECIFICATIONS |
E |
Item |
Unit |
Model |
|
GP1200R |
|||
|
|
||
|
|
|
|
FUEL AND OIL |
|
|
|
Fuel |
|
Regular unleaded gasoline |
|
Minimum fuel rating |
PON* |
86 |
|
|
RON* |
90 |
|
Oil |
|
YAMALUBE 2-W* |
|
Fuel/oil mixing ratio |
|
30:1 |
|
(wide open throttle) |
|
|
|
Fuel tank capacity |
R(US gal, |
60 (15.9, 13.2) |
|
|
Imp gal) |
|
|
Fuel tank reserve capacity |
R(US gal, |
10 (2.6, 2.2) |
|
|
Imp gal) |
|
|
Oil tank capacity |
R(US gal, |
5.5 (1.45, 1.21) |
|
|
Imp gal) |
|
PON*: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2 RON*: Research Octane Number
YAMALUBE 2-W*: YAMALUBE 2-W is developed for this water vehicles and available from a Yamaha water vehicle dealer.
CAUTION:
Use only YAMALUBE 2-W oil. Using another oil can seriously damage the catalytic converter and other engine components.
2-2
|
|
|
|
|
|
SPEC |
|
|
MAINTENANCE SPECIFICATIONS |
|
|
|
|
|
MAINTENANCE SPECIFICATIONS
ENGINE
E
Item |
Unit |
|
Model |
|
GP1200R |
||
|
|
|
|
CYLINDER HEAD |
|
|
|
Warpage limit |
mm (in) |
|
0.1 (0.004) |
Compression pressure*1 |
KPa (kg/cm2) |
|
500 (5.0) |
CYLINDERS |
|
|
|
Bore size |
mm (in) |
80.000 ~ 80.018 (3.1496 ~ 3.1503) |
|
Taper limit |
mm (in) |
|
0.08 (0.003) |
Out-of-round limit |
mm (in) |
|
0.05 (0.002) |
Wear limit |
mm (in) |
Original cylinder bore + 0.04 (0.0016) |
|
PISTONS |
|
|
|
Diameter |
mm (in) |
Red: 79.899 ~ 79.902 (3.1456 ~ 3.1457) |
|
|
|
Orange: 79.903 ~ 79.906 (3.1458 ~ 3.1459) |
|
|
|
Green: 79.907 ~ 79.910 (3.1459 ~ 3.1461) |
|
|
|
Purple: 79.911 ~ 79.914 (3.1461 ~ 3.1462) |
|
Measuring point* |
mm (in) |
|
22 (0.87) |
Piston-to-cylinder clearance |
mm (in) |
0.100 ~ 0.105 (0.0039 ~ 0.0041) |
|
Wear limit |
mm (in) |
Cylinder bore – 0.105 (0.0041) |
|
Piston pin bore inside |
mm (in) |
22.004 ~ 22.025 (0.8663 ~ 0.8671) |
|
diameter |
|
|
|
|
|
|
|
PISTON RINGS |
|
|
|
Top |
|
|
|
Type |
|
|
Keystone |
Dimensions (B) |
mm (in) |
1.47 |
~ 1.49 (0.058 ~ 0.059) |
Dimensions (T) |
mm (in) |
2.8 |
~ 2.9 (0.110 ~ 0.114) |
End gap |
mm (in) |
0.45 |
~ 0.60 (0.018 ~ 0.024) |
Ring groove clearance |
mm (in) |
0.03 |
~ 0.05 (0.001 ~ 0.002) |
2nd |
|
|
|
Type |
|
|
Keystone |
Dimensions (B) |
mm (in) |
1.47 |
~ 1.49 (0.058 ~ 0.059) |
Dimensions (T) |
mm (in) |
2.8 |
~ 2.9 (0.110 ~ 0.114) |
End gap |
mm (in) |
0.45 |
~ 0.60 (0.018 ~ 0.024) |
Ring groove clearance |
mm (in) |
0.03 |
~ 0.05 (0.001 ~ 0.002) |
PISTON PINS |
|
|
|
Diameter |
mm (in) |
21.995 ~ 22.000 (0.8659 ~ 0.8661) |
|
Wear limit |
mm (in) |
|
21.990 (0.8657) |
*1: At 760 mmHg and 20 ˚C (68 ˚F).
2-3
SPEC 
MAINTENANCE SPECIFICATIONS |
E |
Item |
Unit |
Model |
|
GP1200R |
|||
|
|
||
CRANKSHAFT ASSEMBLY |
|
|
|
Crank width A |
mm (in) |
72.95 ~ 73.00 (2.872 ~ 2.874) |
|
Deflection limit B |
mm (in) |
0.05 (0.002) |
|
Deflection limit C |
mm (in) |
0.15 (0.006) |
|
Big end side clearance D |
mm (in) |
0.25 ~ 0.75 (0.010 ~ 0.030) |
|
Maximum small end axial |
mm (in) |
2.0 (0.08) |
|
play E |
|
|
|
|
|
|
|
CARBURETORS |
|
|
|
Type |
|
Floatless |
|
Identification mark |
|
#1: 67X-01, #2: 67X-02, #3: 67X-03 |
|
Main nozzle |
mm (in) |
3.2 (0.13) |
|
Main jet |
|
117.5 |
|
Pilot jet |
|
95 |
|
Throttle valve |
|
150 |
|
Valve seat size |
mm (in) |
1.2 (0.05) |
|
Trolling speed |
r/min |
1,350 ± 50 |
|
|
|
|
|
REED VALVES |
|
|
|
Thickness |
mm (in) |
0.6 (0.024) |
|
Reed valve stopper height |
mm (in) |
10.4 ~ 11.0 (0.41 ~ 0.43) |
|
Reed valve warpage limit |
mm (in) |
0.2 (0.01) |
|
JET PUMP UNIT |
|
|
|
|
|
|
|
Item |
Unit |
Model |
|
GP1200R |
|||
|
|
||
JET PUMP |
|
|
|
Impeller material |
|
Stainless steel |
|
Number of impeller blades |
|
3 |
|
Impeller pitch angle |
Degree |
13.5 |
|
Impeller clearance |
mm (in) |
0.35 ~ 0.45 (0.014 ~ 0.018) |
|
Impeller clearance limit |
mm (in) |
0.6 (0.02) |
|
Drive shaft runout limit |
mm (in) |
0.3 (0.012) |
|
Nozzle diameter |
mm (in) |
86.8 (3.42) |
|
HULL AND HOOD |
|
|
|
|
|
|
|
Item |
Unit |
Model |
|
GP1200R |
|||
|
|
||
FREE PLAY |
|
|
|
YPVS cable slack |
mm (in) |
0.5 ~ 1.5 (0.02 ~ 0.06) |
|
Throttle lever free play |
mm (in) |
4 ~ 7 (0.16 ~ 0.28) |
2-4
|
|
|
|
|
|
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|
|
SPEC |
|
|
|
MAINTENANCE SPECIFICATIONS |
E |
||
|
|
|
|
|
|
|
|
|
|
ELECTRICAL |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Item |
Unit |
Model |
|
|||
|
|
GP1200R |
|
|||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
BATTERY |
|
|
|
|
|
|
|
|
Type |
|
|
|
|
Fluid |
|
|
|
Capacity |
|
|
|
V-Ah (kC) |
12 - 19 (68.4) |
|
|
|
|
|
|
|
|
|
|
|
|
CDI UNIT |
|
|
|
|
|
|
|
|
(B/O – B for cylinder #1) |
|
|
|
||||
|
(B/W – B for cylinder #2) |
|
|
|
||||
|
(B/Y – B for cylinder #3) |
|
|
|
||||
|
Output peak voltage lower |
|
|
|
||||
|
limit |
|
|
|
|
|
|
|
|
|
|
@cranking 1 |
V |
200 |
|
||
|
|
|
@cranking 2 |
V |
180 |
|
||
|
|
|
@2,000 r/min |
V |
190 |
|
||
|
|
|
@3,500 r/min |
V |
180 |
|
||
|
|
|
|
|
|
|
|
|
|
STATOR |
|
|
|
|
|
|
|
|
Pickup coil |
(W/R – B/O) |
|
|
|
|||
|
Output peak voltage |
|
|
|
||||
|
lower limit |
|
|
|
|
|
|
|
|
|
|
@cranking 1 |
V |
5 |
|
||
|
|
|
@cranking 2 |
V |
2.8 |
|
||
|
|
|
@2,000 r/min |
V |
7.9 |
|
||
|
|
|
@3,500 r/min |
V |
11 |
|
||
|
Lighting coil |
|
|
(G – G) |
|
|
|
|
|
Output peak voltage |
|
|
|
||||
|
lower limit |
|
|
|
|
|
|
|
|
|
|
@cranking 1 |
V |
9 |
|
||
|
|
|
@cranking 2 |
V |
9 |
|
||
|
|
|
@2,000 r/min |
V |
14 |
|
||
|
|
|
@3,500 r/min |
V |
14 |
|
||
|
Pickup coil resistance |
Ω (color) |
445 ~ 545 (W/R – B/O) |
|
||||
|
Lighting coil resistance |
Ω (color) |
0.49 ~ 0.59 (G – G) |
|
||||
|
Minimum charging current |
A @ r/min |
9 @ 6,000 |
|
||||
|
|
|
|
|
||||
|
IGNITION COIL |
|
|
|
||||
|
Minimum spark gap |
mm (in) |
10 (0.39) |
|
||||
|
Primary coil resistance |
Ω (color) |
0.26 ~ 0.36 (B/W – Body) |
|
||||
|
Secondary coil resistance |
kΩ (color) |
3.5 ~ 4.7 (B/W – Spark plug lead terminal) |
|||||
|
Spark plug lead resistance |
|
|
|
||||
|
|
|
#1 |
kΩ |
6.1 ~ 14.3 |
|
||
|
|
|
#2 |
kΩ |
4.6 ~ 11.1 |
|
||
|
|
|
#3 |
kΩ |
3.3 ~ 8.2 |
|
||
Cranking 1: unloaded
Cranking 2: loaded
2-5
SPEC 
MAINTENANCE SPECIFICATIONS |
E |
Item |
Unit |
Model |
|
GP1200R |
|||
|
|
||
|
|
|
|
RECTIFIER/REGULATOR |
|
|
|
(R – B) |
|
|
|
Output peak voltage lower |
|
|
|
limit (unloaded) |
|
|
|
@cranking |
V |
7 |
|
@2,000 r/min |
V |
12.6 |
|
@3,500 r/min |
V |
12.6 |
|
|
|
|
|
STARTER MOTOR |
|
|
|
Brush length |
mm (in) |
12.5 (0.49) |
|
Wear limit |
mm (in) |
6.5 (0.26) |
|
Commutator undercut |
mm (in) |
0.7 (0.03) |
|
Limit |
mm (in) |
0.2 (0.01) |
|
Commutator diameter |
mm (in) |
28.0 (1.10) |
|
Limit |
mm (in) |
27.0 (1.06) |
|
|
|
|
|
FUSE |
|
|
|
Rating |
V-A |
12-10 |
|
|
|
12-20 |
|
|
|
|
2-6
SPEC 
TIGHTENING TORQUES |
E |
TIGHTENING TORQUES
SPECIFIED TORQUES
Part to tightened |
|
Part name |
|
Thread |
|
|
|
|
|
|
size |
ENGINE |
|
|
|
|
|
Muffler cover – muffler |
|
Bolt |
|
M6 |
|
|
|
||||
Muffler stay – cylinder body |
|
Bolt |
|
M10 |
|
Muffler – muffler stay 2 |
|
Bolt |
|
M10 |
|
Eye – cylinder head |
|
Bolt |
|
M10 |
|
Muffler – eye |
|
Nut |
|
M10 |
|
Muffler stay 2 – crankcase |
|
Bolt |
|
M10 |
|
Exhaust temperature sensor – |
— |
|
— |
||
muffler |
|
|
|||
|
|
|
|
||
Water temperature sensor – |
|
— |
|
— |
|
mixing joint |
|
|
|||
|
|
|
|
||
|
1st |
|
|
|
|
Muffler stay – catalyst |
|
Bolt |
|
M10 |
|
housing |
|
2nd |
|
||
|
|
|
|
||
Muffler – catalyst |
|
1st |
Bolt |
|
M8 |
housing |
|
2nd |
|
||
|
|
|
|
||
Muffler – mixing joint |
|
1st |
Bolt |
|
M8 |
|
|
|
|||
|
2nd |
|
|||
|
|
|
|
|
|
Exhaust chamber joint – |
|
|
Bolt |
|
M10 |
exhaust manifold |
|
|
|||
|
|
|
|
||
Exhaust chamber/stay – bracket |
Bolt |
|
M10 |
||
|
1st |
|
|
|
|
Exhaust chamber stay/ |
|
Bolt |
|
M8 |
|
cylinder head – cylinder |
|
2nd |
|
||
|
|
|
|
||
Exhaust chamber – |
|
|
Bolt |
|
M10 |
exhaust chamber joint |
|
|
|||
|
|
|
|
||
Engine – engine mount |
|
Bolt |
|
M8 |
|
|
|
1st |
Bolt |
|
M10 |
|
|
|
|||
|
|
|
|
||
Exhaust manifold – |
|
2nd |
|
||
|
|
|
|
||
cylinder |
|
1st |
Nut |
|
M10 |
|
|
|
|
||
|
|
2nd |
|
||
|
|
|
|
|
|
Water pipe – exhaust manifold |
Bolt |
|
M6 |
||
Reed valve plat/reed valve – |
|
Bolt |
|
M6 |
|
crankcase |
|
|
|||
|
|
|
|
||
Reed valve – reed valve base |
Screw |
|
M4 |
||
YPVS cable holder/valve cover – |
Bolt |
|
M6 |
||
cylinder |
|
|
|||
|
|
|
|
||
YPVS valve cover – cylinder |
|
Bolt |
|
M6 |
|
YPVS valve arm – shaft |
|
Bolt |
|
M4 |
|
YPVS valve assembly – cylinder |
Bolt |
|
M5 |
||
Spark plug – cylinder head |
|
Bolt |
|
M14 |
|
Cylinder head cover/ |
|
1st |
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
2nd |
Bolt |
|
M8 |
|
cylinder head – cylinder |
|
|
|||
|
|
|
|
|
|
|
3rd |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Tightening torque
Q’ty Remarks Nm m•kgf ft•lb
3 |
12 |
1.2 |
8.7 |
LT |
242 |
|
2 |
39 |
3.9 |
28 |
LT |
271 |
|
1 |
39 |
3.9 |
28 |
LT |
271 |
|
4 |
39 |
3.9 |
28 |
LT |
271 |
|
2 |
39 |
3.9 |
28 |
LT |
271 |
|
2 |
39 |
3.9 |
28 |
LT |
271 |
|
1 |
39 |
3.9 |
28 |
LT |
572 |
|
1 |
20 |
2.0 |
14 |
LT |
572 |
|
2 |
15 |
1.5 |
11 |
LT |
271 |
|
|
|
|
||||
39 |
3.9 |
28 |
||||
|
|
|
||||
6 |
15 |
1.5 |
11 |
LT |
271 |
|
|
|
|
||||
33 |
3.3 |
24 |
||||
|
|
|
||||
6 |
11 |
1.1 |
8.0 |
LT |
271 |
|
|
|
|
||||
22 |
2.2 |
16 |
||||
|
|
|
||||
4 |
39 |
3.9 |
28 |
LT |
271 |
|
2 |
39 |
3.9 |
28 |
LT |
271 |
|
2 |
15 |
1.5 |
11 |
|
|
|
|
|
|
|
|
||
35 |
3.5 |
25 |
|
|
||
|
|
|
||||
6 |
39 |
3.9 |
28 |
LT |
271 |
|
4 |
17 |
1.7 |
12 |
LT |
572 |
|
10 |
22 |
2.2 |
16 |
LT |
271 |
|
|
|
|
||||
39 |
3.9 |
28 |
||||
|
|
|
||||
2 |
15 |
1.5 |
11 |
LT |
271 |
|
|
|
|
||||
39 |
3.9 |
28 |
||||
|
|
|
||||
6 |
12 |
1.2 |
8.7 |
LT |
242 |
|
18 |
12 |
1.2 |
8.7 |
LT |
242 |
|
24 |
1 |
0.1 |
0.7 |
LT |
242 |
|
2 |
10 |
1.0 |
7.2 |
LT |
572 |
|
10 |
10 |
1.0 |
7.2 |
LT |
572 |
|
3 |
3 |
0.3 |
2.2 |
LT |
242 |
|
3 |
4 |
0.4 |
2.9 |
LT |
242 |
|
3 |
25 |
2.5 |
18 |
|
|
|
|
22 |
2.2 |
16 |
|
|
|
22 |
|
|
|
|
|
|
22 |
2.2 |
16 |
|
|
||
|
|
|
|
|
|
|
|
35 |
3.5 |
25 |
|
|
|
|
|
|
|
|
|
2-7
TIGHTENING TORQUES |
E |
Part name |
Thread |
|
size |
Bolt |
M10 |
Bolt |
M10 |
Bolt |
M10 |
Bolt |
M10 |
Bolt |
M5 |
Bolt |
M6 |
Coupling |
M27 |
Bolt |
M10 |
Bolt |
M8 |
|
|
|
M6 |
Bolt |
M8 |
|
|
Q’ty
12
7
1
4
2
3
1
1
17
10
6
Tightening torque
Nm |
m•kgf |
ft•lb |
22 |
2.2 |
16 |
|
|
|
39 |
3.9 |
28 |
15 |
1.5 |
11 |
|
|
|
50 |
5.0 |
36 |
15 |
1.5 |
11 |
|
|
|
50 |
5.0 |
36 |
39 |
3.9 |
28 |
5 |
0.5 |
3.6 |
15 |
1.5 |
11 |
36 |
3.6 |
25 |
75 |
7.5 |
54 |
15 |
1.5 |
11 |
|
|
|
27 |
2.7 |
19 |
11 |
1.1 |
8.0 |
15 |
1.5 |
11 |
|
|
|
27 |
2.7 |
19 |
|
|
|
Remarks
|
LT |
572 |
|
LT |
271 |
|
LT |
271 |
|
LT |
242 |
|
LT |
242 |
|
LT |
572 |
|
|
|
|
|
E |
|
|
|
|
|
|
|
LT |
271 |
Nut |
|
— |
|
1 |
|
7 |
|
0.7 |
|
5.1 |
Bolt |
|
M8 |
|
4 |
|
17 |
|
1.7 |
|
12 |
Bolt |
|
M8 |
|
4 |
|
17 |
|
1.7 |
|
12 |
Bolt |
|
M6 |
|
4 |
|
7 |
|
0.7 |
|
5.1 |
Bolt |
|
M8 |
|
2 |
|
15 |
|
1.5 |
|
11 |
Bolt |
|
M8 |
|
2 |
|
15 |
|
1.5 |
|
11 |
Bolt |
|
M6 |
|
4 |
|
7 |
|
0.7 |
|
5.1 |
Nut |
|
— |
|
1 |
|
74 |
|
7.4 |
|
53 |
Impeller |
|
— |
|
1 |
|
18 |
|
1.8 |
|
13 |
Nut |
|
— |
|
4 |
|
26 |
|
2.6 |
|
19 |
Bolt |
|
M8 |
|
3 |
|
17 |
|
1.7 |
|
12 |
Coupling |
|
— |
|
1 |
|
36 |
|
3.6 |
|
25 |
Screw |
|
— |
|
4 |
|
4 |
|
0.4 |
|
2.9 |
Screw |
|
M6 |
|
4 |
|
1.1 |
|
0.11 |
|
0.8 |
|
|
|
|
|
||||||
Screw |
|
M6 |
|
4 |
|
2.9 |
|
0.29 |
|
2.1 |
Bolt |
|
M8 |
|
4 |
|
16 |
|
1.6 |
|
11 |
Nut |
|
— |
|
2 |
|
5 |
|
0.5 |
|
3.6 |
Screw |
|
M5 |
|
2 |
|
3 |
|
0.3 |
|
2.2 |
Screw |
|
M5 |
|
2 |
|
3 |
|
0.3 |
|
2.2 |
Screw |
|
M6 |
|
1 |
|
3 |
|
0.3 |
|
2.2 |
|
2-8 |
|
|
|
|
|
|
|
|
|
LT |
572 |
|
|
LT |
572 |
|
|
LT |
572 |
|
|
LT |
271 |
LT |
271 |
LT |
572 |
LT |
572 |
LT |
572 |
|
|
LT |
572 |
|
|
LT |
242 |
SPEC 
TIGHTENING TORQUES |
E |
Part to tightened |
Part name |
Thread |
Q’ty |
Tightening torque |
Remarks |
|||
size |
Nm |
m•kgf |
ft•lb |
|||||
|
|
|
|
|||||
|
|
|
|
|
|
|
|
|
Grip end – handlebar |
Bolt |
M5 |
2 |
1 |
0.1 |
0.7 |
|
|
|
|
|
|
|
|
|
|
|
Choke lever assembly – |
Screw |
M5 |
2 |
3 |
0.3 |
2.2 |
|
|
handlebar |
|
|||||||
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
QSTS cable housing – cover |
Screw |
M4 |
1 |
1 |
0.1 |
0.7 |
|
|
|
|
|
|
|
|
|
|
|
Plate/steering column assembly |
Nut |
— |
2 |
16 |
1.6 |
11 |
|
|
– deck |
|
|||||||
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
Steering column – deck |
Nut |
— |
2 |
16 |
1.6 |
11 |
|
|
|
|
|
|
|
|
|
|
|
Steering arm – steering column |
Nut |
M8 |
1 |
16 |
1.6 |
11 |
|
|
|
|
|
|
|
|
|
|
|
QSTS cable locknut |
Nut |
— |
1 |
3 |
0.3 |
2.2 |
|
|
(nozzle ring side) – hull |
|
|||||||
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
QSTS cable – hull |
Nut |
— |
1 |
6 |
0.6 |
4.3 |
|
|
|
|
|
|
|
|
|
|
|
QSTS cable – QSTS converter |
Nut |
— |
1 |
4 |
0.4 |
2.9 |
|
|
|
|
|
|
|
|
|
|
|
Steering cable locknut |
Nut |
— |
1 |
6 |
0.6 |
4.3 |
|
|
(nozzle deflector side) – hull |
|
|||||||
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
Steering cable – hull |
Nut |
— |
1 |
6 |
0.6 |
4.3 |
|
|
|
|
|
|
|
|
|
|
|
Steering cable holder – bracket |
Bolt |
M6 |
1 |
5 |
0.5 |
3.6 |
|
|
|
|
|
|
|
|
|
|
|
Speed sensor lead – hull |
Nut |
— |
1 |
6 |
0.6 |
4.3 |
|
|
|
|
|
|
|
|
|
|
|
Hinge assembly – front hood |
Bolt |
M6 |
2 |
6 |
0.6 |
4.3 |
|
|
|
|
|
|
|
|
|
|
|
Wind shield – front hood |
Screw |
M5 |
8 |
1 |
0.1 |
0.7 |
|
|
|
|
|
|
|
|
|
|
|
Hood lock – front hood |
Bolt |
M6 |
2 |
5 |
0.5 |
3.6 |
|
|
|
|
|
|
|
|
|
|
|
|
Nut |
— |
2 |
5 |
0.5 |
3.6 |
|
|
|
|
|
|
|
|
|
|
|
Steering console cover assembly |
Bolt |
M6 |
4 |
3 |
0.3 |
2.2 |
|
|
– deck |
Screw |
M5 |
2 |
2 |
0.2 |
1.4 |
|
|
|
|
|
|
|
|
|
|
|
|
Nut |
M8 |
2 |
16 |
1.6 |
11 |
|
|
|
|
|
|
|
|
|
|
|
Multifunction meter – holder |
Nut |
— |
2 |
2 |
0.2 |
1.4 |
|
|
|
|
|
|
|
|
|
|
|
Steering console cover – side |
Screw |
M6 |
4 |
3 |
0.3 |
2.2 |
|
|
cover |
|
|||||||
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
Steering console cover – glove |
Screw |
M5 |
4 |
1 |
0.1 |
0.7 |
|
|
compartment |
|
|||||||
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
Steering cable bracket – deck |
Bolt |
M6 |
3 |
5 |
0.5 |
3.6 |
|
|
|
|
|
|
|
|
|
|
|
Hood lock assembly – deck |
Nut |
M6 |
2 |
5 |
0.5 |
3.6 |
|
|
|
|
|
|
|
|
|
|
|
Seat lock assembly – seat |
Bolt |
M6 |
2 |
6 |
0.6 |
4.3 |
|
|
|
|
|
|
|
|
|
|
|
Bracket/deck – notch |
Nut |
— |
1 |
26 |
2.6 |
19 |
|
|
|
|
|
|
|
|
|
|
|
Bracket/deck – hand grip |
Bolt |
M8 |
2 |
5 |
0.5 |
3.6 |
|
|
|
|
|
|
|
|
|
|
|
Hand grip – deck |
Bolt |
M8 |
2 |
5 |
0.5 |
3.6 |
|
|
|
|
|
|
|
|
|
|
|
Battery box/stay – holder |
Bolt |
M6 |
2 |
5 |
0.5 |
3.6 |
|
|
|
|
|
|
|
|
|
|
|
Battery box – deck |
Nut |
— |
2 |
13 |
1.3 |
9.4 |
|
|
|
|
|
|
|
|
|
|
|
Battery box – electrical box |
Nut |
— |
4 |
15 |
1.5 |
11 |
|
|
|
|
|
|
|
|
|
|
|
Exhaust outlet – hull |
Bolt |
M6 |
3 |
5 |
0.5 |
3.6 |
|
|
|
|
|
|
|
|
|
|
|
Sponson – hull |
Bolt |
M8 |
6 |
18 |
1.8 |
13 |
|
|
|
|
|
|
|
|
|
|
|
Spout – hull |
Nut |
— |
1 |
5 |
0.5 |
3.6 |
|
|
|
|
|
|
|
|
|
|
|
Rope hole bolt |
Nut |
— |
2 |
5 |
0.5 |
3.6 |
|
|
|
|
|
|
|
|
|
|
|
Bow eye – hull |
Bolt |
M6 |
2 |
13 |
1.3 |
9.4 |
|
|
|
|
|
|
|
|
|
|
|
Flap – hull |
Bolt |
M6 |
8 |
6 |
0.6 |
4.3 |
|
|
|
|
|
|
|
|
|
|
|
Drain plug/packing – hull |
Nut |
— |
4 |
2 |
0.2 |
1.4 |
|
|
2-9
SPEC 
TIGHTENING TORQUES
E
Part to tightened |
Part name |
Thread |
Q’ty |
Tightening torque |
|||
size |
Nm |
m•kgf |
ft•lb |
||||
|
|
|
|||||
Engine mount – hull |
Bolt |
M8 |
6 |
17 |
1.7 |
12 |
|
Engine mount/plate – hull |
Bolt |
M8 |
2 |
17 |
1.7 |
12 |
|
Engine damper – hull |
Bolt |
M6 |
4 |
5 |
0.5 |
3.6 |
|
|
|
|
|
|
|
|
|
Remarks
LT |
572 |
|
|
LT |
572 |
|
|
|
|
General torque |
||
Nut A |
Bolt B |
specifications |
||
|
|
Nm |
m•kgf |
ft•lb |
|
|
|
|
|
8 mm |
M5 |
5.0 |
0.5 |
3.6 |
10 mm |
M6 |
8.0 |
0.8 |
5.8 |
12 mm |
M8 |
18 |
1.8 |
13 |
14 mm |
M10 |
36 |
3.6 |
25 |
17 mm |
M12 |
43 |
4.3 |
31 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
GENERAL TORQUE
This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this manual. To avoid warpage, tighten multifastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads.
Components should be at room temperature.
2-10
|
|
|
|
|
|
SPEC |
|
|
CABLE AND HOSE ROUTING |
|
|
|
|
|
CABLE AND HOSE ROUTING
E
|
|
2 |
|
|
|
|
|
C |
|
|
|
|
|
|
A |
|
|
|
|
|
|
|
|
|
|
|
|
A |
|
|
|
|
|
|
|
B |
|
2 |
|
|
|
|
|
C |
|
1 |
B |
|
|
G E |
|
|
E |
||
|
|
G |
D |
D |
|
||
|
|
E |
|
|
|
D |
|
|
|
|
|
E |
|
|
|
|
|
J |
|
|
2 |
2 |
|
|
|
|
|
|
|
||
20˚ |
I |
|
|
|
|
|
C |
|
|
|
|
|
|
|
|
|
A |
G |
G |
|
|
|
2 |
|
|
|
|
|
|
||
B |
|
|
|
|
|
|
3 |
|
|
|
|
|
|
D-D |
|
J |
|
I |
I |
|
|
|
|
|
|
|
|
|
|||
|
|
|
|
|
|
|
4 |
6 |
H |
H |
H |
F |
F |
|
|
|
G |
G |
|
E-E |
|||
7 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
A |
|
|
|
|
|
|
5 |
|
|
|
|
|
|
|
|
I-I |
I |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
0 |
|
|
|
|
|
E |
F-F |
|
|
|
|
|
|
6 |
|
9 |
|
|
|
|
|
|
|
6 |
|
|
|
|
F |
|
|
|
|
|
|
|
7 |
||
|
|
|
|
|
|
|
|
8 |
|
|
|
|
|
C |
|
H-H |
|
|
|
|
|
G-G |
|
|
|
|
|
|
|
1 Fuel filter |
9 Generator lead |
G Battery breather hose |
2 Fuel breather hose |
0 Battery negative lead |
H Battery positive lead |
3 Fuel hose |
A YPVS cable |
I YPVS servomotor |
4 Pilot water hose |
B Pilot water outlet |
|
5 Bilge hose |
C QSTS cable |
|
6 Speed sensor lead |
D Choke cable |
|
7 Electrical box lead |
E Battery |
|
8 Starter motor lead |
F Steering cable |
|
|
2-11 |
|
SPEC 
CABLE AND HOSE ROUTING
E
6
E |
E |
F |
F |
|
|
|
|
|
|
|
|
1 2 |
2 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
A |
|
B |
|
C |
D |
3 4 5 E-E |
|||||||
|
|
|
|
|||||||||||
|
|
|
|
|
||||||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
I
A |
1 |
|
|
|
|
|
|
H |
B |
|
J |
|
|
G |
|
|
4 |
|
D |
H |
|
G |
|
|
C |
|
|
|
F 9 |
2 5 |
|
H |
|
|
|
|
|
8 |
|
|
|
|
|
|
|
|
|
|
|
G |
|
|
|
8 |
|
|
|
|
|
|
|
|
|
|
|
|
|
D |
I |
|
|
|
A |
|
|
G |
F |
I |
I |
D |
B |
9 |
|
|
|
I |
|
|
|
||||
D |
|
|
|
CK0 |
|
|||
|
I |
I |
|
|
||||
F |
|
|
|
|
7 |
5 |
||
I-I |
|
|
FE G |
|
||||
|
|
|
H |
|
|
F-F |
||
1 Choke cable |
9 To stator assembly |
F To starter motor positive |
2 Steering cable |
0 To water temperature sensor |
terminal |
3 Cooling water hose |
A To cylinder #1 |
G Battery positive lead |
4 QSTS cable |
B To cylinder #2 |
H Battery negative lead |
5 Speed sensor lead |
C To cylinder #3 |
I Buzzer lead |
6 Bilge hose |
D To meter |
J Battery breather hose |
7 Flushing hose |
E To battery positive terminal |
K Exhaust temperature sensor |
8 Electrical box |
|
|
|
2-12 |
|
INSP |
|
ADJ |
E |
|
CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENT
MAINTENANCE INTERVAL CHART.............................................................. |
3-1 |
PERIODIC SERVICE ........................................................................................ |
3-2 |
CONTROL SYSTEM ................................................................................. |
3-2 |
Steering column inspection ............................................................. |
3-2 |
Steering cable inspection and adjustment ..................................... |
3-2 |
Throttle cable inspection and adjustment ...................................... |
3-3 |
Choke cable inspection and adjustment ......................................... |
3-4 |
QSTS cable inspection and adjustment .......................................... |
3-5 |
YPVS cable adjustment .................................................................... |
3-6 |
FUEL SYSTEM.......................................................................................... |
3-7 |
Fuel line inspection ........................................................................... |
3-7 |
Trolling speed check and adjustment ............................................. |
3-8 |
OIL INJECTION SYSTEM......................................................................... |
3-9 |
Oil line inspection ............................................................................. |
3-9 |
POWER UNIT............................................................................................ |
3-9 |
Spark plug inspection ....................................................................... |
3-9 |
ELECTRICAL ........................................................................................... |
3-10 |
Battery inspection ........................................................................... |
3-10 |
JET PUMP UNIT..................................................................................... |
3-13 |
Impeller inspection ......................................................................... |
3-13 |
Water inlet strainer inspection....................................................... |
3-14 |
Bilge strainer inspection................................................................. |
3-14 |
GENERAL................................................................................................ |
3-14 |
Drain plug inspection...................................................................... |
3-14 |
Lubrication points ........................................................................... |
3-15 |
1
2
3
4
5
6
7
8
9
INSP ADJ
MAINTENANCE INTERVAL CHART |
E |
MAINTENANCE INTERVAL CHART
The following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the intervals of maintenance should be changed.
Item |
Remarks |
Initial |
Every |
Refer to |
|||
|
|
|
|
||||
10 hours |
50 hours |
100 hours |
200 hours |
page |
|||
|
|
||||||
|
|
(Break-in) |
(3 months) |
(6 months) |
(1 year) |
|
|
CONTROL SYSTEM |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Steering cable |
Inspect/adjust |
|
|
|
|
3-2 |
|
Steering column |
Inspect |
|
|
|
|
3-2 |
|
Throttle cable |
Inspect/adjust |
|
|
|
|
3-3 |
|
Carburetor throttle shaft |
Inspect/adjust |
|
|
|
|
— |
|
Choke cable |
Inspect/adjust |
|
|
|
|
3-4 |
|
QSTS cable |
Inspect/adjust |
|
|
|
|
3-5 |
|
YPVS cable |
Inspect/adjust |
|
|
|
|
3-6 |
|
|
|
|
|
|
|
|
|
FUEL SYSTEM |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Fuel tank |
Clean |
|
|
|
|
4-9 |
|
Fuel filter |
Clean/replace |
|
|
|
|
3-7 |
|
Fuel line |
Inspect |
|
|
|
|
3-7 |
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Trolling speed |
Check/adjust |
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3-8 |
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Carburetor setting |
Inspect/adjust |
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4-16 |
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OIL INJECTION SYSTEM |
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Oil injection system |
Check/clean |
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4-30 |
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Oil pump cable |
Inspect/adjust |
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4-29 |
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POWER UNIT |
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Spark plugs |
Inspect/clean/adjust |
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3-9 |
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Cooling-water passage |
Inspect/clean |
*1 |
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— |
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Rubber coupling |
Inspect |
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— |
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ELECTRICAL |
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Battery |
Inspect |
*2 |
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3-10 |
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JET PUMP UNIT |
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Impeller |
Inspect |
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3-13 |
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Water inlet strainer |
Clean |
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3-14 |
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Bilge strainer |
Clean |
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3-14 |
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GENERAL |
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Bolts and nuts |
Retighten |
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— |
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Drain plugs |
Inspect/replace |
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3-14 |
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Lubrication points |
Grease |
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3-15 |
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Intermediate housing |
Grease |
*3 |
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*4 |
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3-17 |
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*1: After every ride
*2: Inspect fluid level before every ride
*3: Grease capacity 33.0 ~ 35.0 cm3 (1.11 ~ 1.18 oz.) *4: Grease capacity 6.0 ~ 8.0 cm3 (0.20 ~ 0.27 oz.)
3-1
INSP ADJ
CONTROL SYSTEM |
E |
PERIODIC SERVICE
CONTROL SYSTEM
Steering column inspection
1.Inspect:
●Steering column
Excessive play → Replace the steering column.
Refer to “STEERING COLUMN” in chapter 8.
Inspection steps:
● Move the handlebar up and down and back and forth.
● Check the excessive play of the handlebar.
Steering cable inspection and adjustment
1. Inspect:
● Distance a, b
Out of specification → Adjust.
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Inspection steps: |
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● Turn the handlebar from lock to lock. |
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● Measure distances a and b. |
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● If the difference is not within specifica- |
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tion, adjust the cable joint. |
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Difference of distances a and b: |
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Maximum 5 mm (0.2 in) |
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2. Adjust: |
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● Steering cable joint |
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(steering column side) |
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Adjustment steps: |
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● Loosen the locknut 1. |
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● Disconnect the steering cable joint 2 |
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from the ball joint 3. |
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● Turn the cable joint in or out for adjust- |
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ing the distances a and b. |
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Turn in |
Distance a is increased. |
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2 |
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Turn out |
Distance b is increased. |
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1 |
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3
3-2
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