Yamaha GP1300R Service Manual

WaveRunner

GP1300R

SERVICE MANUAL

*LIT186160244*

F1G-28197-1F-11LIT-18616-02-44

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NOTICE

This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.

Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.

A10001-0*

WaveRunner GP1300R

SERVICE MANUAL

©2003 by Yamaha Motor Corporation, USA

1st Edition, February 2003

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, USA

is expressly prohibited.

Printed in USA

LIT-18616-02-44

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.

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IMPORTANT INFORMATION

In this Service Manual particularly important information is distinguished in the following ways.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, passenger(s), a bystander, or a person inspecting or repairing the watercraft.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the water­craft.

NOTE:

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

IMPORTANT:

This part has been subjected to change of specification during production.

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D

L

HOW TO USE THIS MANUAL

1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

2 Numbers are given in the order of the jobs in the exploded diagram.

3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).

4 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

5 Dimension figures and the number of parts, are provided for fasteners that require a tightening

torque.

Example:
Bolt or screw size : M10 (D) × 25 mm (L)

6 Jobs requiring more information (such as special service tools and technical data) are described

sequentially.

10 × 25 mm

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12

GEN

INFO

34

SPEC

INSP

FUEL

ADJ

56

JET

POWR

PUMP

78

–+

HULL

ELEC

HOOD

90

TRBL
ANLS

AB

A50001-1-4

SYMBOLS

Symbols 1 to 9 are designed to indicate the
content of a chapter.

General Information

1

Specifications

2

Periodic Inspection and Adjustment

3

Fuel System

4

Power Unit

5

Jet Pump Unit

6

Electrical System

7

Hull and Hood

8

Trouble Analysis

9

Symbols 0 to E indicate specific data.

Special service tool

0

Specified oil or fluid

A

Specified engine speed

B

Specified tightening torque

C

Specified measurement

D

Specified electrical value

E

(resistance, voltage, electric current)

CD

T

.

R

.

EF

E

GH

A M

IJ

GM

KL

LT

271

4

LT

242

Symbols F to H in an exploded diagram indi­cate the grade of lubricant and the lubrication
point.

Apply Yamaha 2-stroke motor oil

F

Apply water resistant grease

G

(Yamaha grease A, Yamaha marine grease)
Apply molybdenum disulfide grease

H

Symbols I to N in an exploded diagram indi­cate the type of sealant or locking agent and
the application point.

Apply Gasket Maker

I

Apply Yamabond No. 4

J

Apply LOCTITE 271 (red)

K

Apply LOCTITE 242 (blue)

L

Apply LOCTITE 572

M

Apply silicone sealant

N

MN

LT

572

SS

NOTE:

Additional symbols may be used in this man­ual.

A30000-0

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INDEX

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND
ADJUSTMENT

FUEL SYSTEM

GEN

INFO

SPEC

INSP

ADJ

FUEL

1
2
3
4

POWER UNIT

JET PUMP UNIT

ELECTRICAL SYSTEM

HULL AND HOOD

POWR

JET

PUMP

– +

ELEC

HULL

HOOD

5
6
7
8

TROUBLE ANALYSIS

TRBL
ANLS

9

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

IDENTIFICATION NUMBERS .........................................................................1-1

PRIMARY l.D. NUMBER ...........................................................................1-1

ENGINE SERIAL NUMBER ......................................................................1-1

JET PUMP UNIT SERIAL NUMBER .........................................................1-1

HULL IDENTIFICATION NUMBER (H.l.N.)...............................................1-1

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1

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

FIRE PREVENTION ..................................................................................1-2

VENTILATION ...........................................................................................1-2

SELF-PROTECTION.................................................................................1-2

PARTS, LUBRICANTS, AND SEALANTS ................................................1-2

GOOD WORKING PRACTICES ...............................................................1-3

DISASSEMBLY AND ASSEMBLY ............................................................ 1-4

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

MEASURING AND DIAGNOSIS ............................................................... 1-5

REMOVAL AND INSTALLATION..............................................................1-7

2
3
4
5
6
7
8
9

GEN

INFO

IDENTIFICATION NUMBERS

1

E

A60700-0*

IDENTIFICATION NUMBERS

PRIMARY l.D. NUMBER

The primary l.D. number is stamped on a label

1

attached inside the engine compartment.

Starting primary l.D. number:

F1G: 800301

ENGINE SERIAL NUMBER

The engine serial number is stamped on a
label 1 attached to the engine unit.

Starting serial number:

60T: 1000001

JET PUMP UNIT SERIAL NUMBER

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

HULL IDENTIFICATION NUMBER
(H.l.N.)

The H.l.N. is stamped on a plate 1 attached to
the hull on the aft, starboard (right) side.

1-1

GEN

INFO

SAFETY WHILE WORKING

SAFETY WHILE WORKING

To prevent and accident or injury and to
ensure quality service, follow the safety proce­dures provided below.

FIRE PREVENTION

Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.

E

VENTILATION

Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled in
large quantities they may cause loss of con­sciousness and death within a short time.
When test running an engine indoors (e.g., in a
water tank), be sure to do so where adequate
ventilation can be maintained.

SELF-PROTECTION

Protect your eyes by wearing safety glasses or
safety goggles during all operation involving
drilling and grinding, or when using an air com­pressor.
Protect your hands and feet by wearing protec­tive gloves or safety shoes when necessary.

PARTS, LUBRICANTS, AND
SEALANTS

Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the
watercraft.

1-2

GEN

INFO

SAFETY WHILE WORKING

Under normal conditions, the lubricants men­tioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.

1. Maintain good standards of personal and
industrial hygiene.

2. Change and wash clothing as soon as
possible if soiled with lubricants.

3. Avoid contact with skin. Do not, for exam­ple, place a soiled rag in your pocket.

4. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.

5. To protect your skin, apply a protective
cream to your hands before working on the
watercraft.

6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.

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GOOD WORKING PRACTICES

The right tools

1.
Use the recommended special service
tools to protect parts from damage. Use
the right tool in the right manner—do not
improvise.

Tightening torques

2.
Follow the tightening torque specifications
provided throughout the manual. When
tightening nuts, bolts, and screws, tighten
the large sizes first, and tighten fasteners
starting in the center and moving outward.

1-3

GEN

INFO

SAFETY WHILE WORKING

Non-reusable parts

3.
Always use new gaskets, seals, O-rings,
oil seals, cotter pins, circlips, etc., when
installing or assembling parts.

DISASSEMBLY AND ASSEMBLY

1. Use compressed air to remove dust and
dirt during disassembly.

2. Apply engine oil to the contact surfaces of
moving parts during assembly.

E

3. Install bearings with the manufacture iden­tification mark in the direction indication in
the installation procedure. In addition, be
sure to lubricate the bearings liberally.

4. Apply a thin coat of water-resistant grease
to the lip and periphery of an oil seal
before installation.

5. Check that moving parts operate normally
after assembly.

1-4

GEN

INFO

YU-34899-A 90890-03174

1

YU-03097 90890-01252

3

YU-03112

45

90890-03112

YB-06766 90890-06786

6

YU-03017

7

90890-06759

SPECIAL SERVICE TOOLS

2

YW-06842
90890-06842

E

SPECIAL SERVICE TOOLS

Using the special service tools recommended
by Yamaha will aid service and enable accu­rate assembly and tune-up. Improvisations
and using improper tools can damage the
equipment.

NOTE:

• For USA and Canada, use the special ser­vice tools starting with part numbers “J-,”

“YB-,” “YM-,” “YS-,” “YU-,” or “YW-.”

• For all other countries, use the special ser-
vice tools starting with part number “90890-.”

MEASURING AND DIAGNOSIS

1

Digital multimeter
YU-34899-A

2

Digital circuit tester
90890-03174

3

Dial gauge
YU-03097
90890-01252

4

Pocket tester
YU-03112
90890-03112

5

Fuel pressure gauge adapter
YW-06842
90890-06842

6

Fuel pressure gauge
YB-06766
90890-06786

7

Cylinder gauge set
YU-03017
90890-06759

8

Compression gauge
YU-33223-1
90890-03160

YU-33223-1 90890-03160

8

1-5

GEN

INFO

YU-39991 90890-03172

90

YM-34487 90890-06754

AB

YB-06870

CD

90890-06870

YB-06848

EF

90890-06848

SPECIAL SERVICE TOOLS

YB-06869
90890-06869

YB-06849
90890-06849

9

Peak volt meter adapter
YU-39991

0

Peak voltage adapter B
90890-03172

A

Spark gap tester
YM-34487

B

Ignition tester
90890-06754

C

Lighting coil tester (3 pins)
YB-06870
Test harness SMT250-3 (3 pins)
90890-06870

D

Air pressure sensor tester (3 pins)
YB-06869
Test harness EJ-II-3 (3 pins)
90890-06869

E

Test harness (6 pins)
YB-06848
Test harness FSW-6A (6 pins)
90890-06848

F

Test harness (6 pins)
YB-06849
Test harness SM6195021-6 (6 pins)
90890-06849

G

Lower unit pressure/vacuum tester
YB-35956-A
Vacuum/pressure pump gauge set
90890-06756

H

Yamaha diagnostic system
(CD-ROM only)
60V-WS853-01

E

YB-35956-A

G

90890-06756

60V-WS853-01

H

YAMAHA

DIAGNOSTIC

SYSTEM

INSTALLATION MANUAL

60V-2819K-10

1-6

GEN

INFO

YW-06551 YW-06550

1

90890-06551

YB-06117 90890-06521

3

YB-06151 YB-06096

5

90890-06519

90890-06501 90890-06535

7

90890-06538 90890-06652

9

SPECIAL SERVICE TOOLS

2

4

6

8

0

90890-06550

REMOVAL AND INSTALLATION

1

Coupler wrench
YW-06551
90890-06551

2

Flywheel holder
YW-06550
90890-06550

3

Universal puller
YB-06117

4

Flywheel puller
90890-06521

5

Drive shaft holder (impeller)
YB-06151
Drive shaft holder 5 (impeller)
90890-06519

6

Slide hammer and adapters
(jet pump bearing)
YB-06096

7

Stopper guide plate (jet pump bearing)
90890-06501

8

Bearing puller assembly
(jet pump bearing)
90890-06535

9

Stopper guide stand (jet pump bearing)
90890-06538

0

Driver rod L3 (jet pump bearing)
90890-06652

A

Bearing housing needle bearing remover
(jet pump bearing)
YB-06112
Drive shaft needle bearing installer and
remover (jet pump oil seal)
YB-06196

B

Needle bearing attachment
(jet pump bearing and oil seal)
90890-06614, 90890-06653

E

YB-06112 90890-06614

A

YB-06196 90890-06653

B

1-7

GEN

INFO

YB-06085 90890-06634

C

YB-06071 90890-06606

E

YB-34474 YB-06552

G

YB-06156

I

90890-06626

SPECIAL SERVICE TOOLS

D

F

H

90890-06552

C

Outer race installer—forward gear
(jet pump oil seal)
YB-06085

D

Ball bearing attachment (jet pump oil seal)
90890-06634

E

Driver handle—large
(intermediate shaft and jet pump)
YB-06071

F

Driver rod LS
(intermediate shaft and jet pump)
90890-06606

G

Drive shaft needle bearing depth stop
(jet pump bearing)
YB-34474

H

Shaft holder (intermediate shaft)
YB-06552
Crankshaft holder 20 (intermediate shaft)
90890-06552

I

Drive shaft taper roller bearing cup
installer (intermediate shaft)
YB-06156
Bearing outer race attachment
(intermediate shaft)
90890-06626

E

1-8

SPEC

CHAPTER 2

SPECIFICATIONS

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

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

ENGINE ....................................................................................................2-3

JET PUMP UNIT ......................................................................................2-4

HULL AND HOOD ....................................................................................2-5

ELECTRICAL ............................................................................................2-5

TIGHTENING TORQUES ................................................................................2-8

SPECIFIED TORQUES.............................................................................2-8

GENERAL TORQUE ...............................................................................2-14

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1
2

CABLE AND HOSE ROUTING .....................................................................2-15

3
4
5
6
7
8
9

SPEC

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

E

Item Unit

Model code

Hull F1G
Engine/jet 60T

Dimensions

Length mm (in) 2,930 (115.4)
Width mm (in) 1,150 (45.3)
Height mm (in) 1,020 (40.2)
Dry weight kg (lb) 297 (653)
Maximum capacity Person/kg (lb) 2/160 (353)

Performance

Maximum output kW (PS) at r/min 121.4 (165) at 7,000
Maximum fuel consumption l/h (US gal/h,

lmp gal/h)

Cruising range h 0.95

Engine

Engine type 2-stroke
Number of cylinders 3
Displacement cm
Bore × stroke mm (in) 84 × 78 (3.31 × 3.07)
Compression ratio

#1, #2 5.9:1

#3 5.7:1
Intake system Reed valve
Scavenging system Loop charge
Exhaust system Wet exhaust/YPVS
Lubrication system Variable oil injection
Cooling system Water cooled
Starting system Electric starter
Ignition system Digital CDI
Spark plug model

(manufacturer)
Spark plug gap mm (in) 1.0–1.1 (0.039–0.043)
Battery

Voltage, capacity V, Ah 12, 19
Generator output A at r/min 15 at 6,000

3

(cu. in) 1,297 (79.1)

Model

GP1300R

63.0 (16.6, 13.9)

BR8ES-11 (NGK)

2-1

SPEC

GENERAL SPECIFICATIONS

E

Item Unit

Model

GP1300R

Drive unit

Propulsion system Jet pump
Jet pump type Axial flow, single stage
Impeller rotation Counterclockwise (viewed from rear)
Transmission Direct drive from engine
Jet thrust nozzle horizontal

Degree 23 + 23

angle
Jet thrust nozzle trim angle Degree –5, 0, 5, 10, 15
Trim system Manual 5 positions
Reverse system NA

Fuel and oil

Fuel Regular unleaded gasoline

RON

*1

86

*2

90

30:1

*3

Minimum fuel rating PON

Oil YAMALUBE 2-W
Fuel-oil ratio

(wide open throttle)
Fuel tank capacity L (US gal,

60 (15.9, 13.2)

Imp gal)

Oil tank quantity L (US qt,

5.5 (1.5, 1.2)

Imp qt)

*1

Pump Octane Number = (Motor Octane Number + Research Octane Number)/2

*2

Research Octane Number

*3

YAMALUBE 2-W has been developed for this watercraft and it is available at a Yamaha dealer.

CAUTION:

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

2-2

SPEC

MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

ENGINE

E

Item Unit

Cylinder head

Warpage limit mm (in) 0.05 (0.002)
Minimum compression

pressure

Cylinders

Bore size mm (in) 84.000–84.018 (3.3071–3.3078)
Taper limit mm (in) 0.080 (0.0031)
Out-of-round limit mm (in) 0.050 (0.0020)
Wear limit mm (in) 84.100 (3.3110)

Pistons

Piston diameter mm (in) Red: 83.899–83.902 (3.3031–3.3032)

Measuring point
Piston-to-cylinder clearance mm (in) 0.100–0.105 (0.0039–0.0041)
Wear limit mm (in) 0.155 (0.0061)
Piston pin boss inside diameter mm (in) 22.008–22.020 (0.8665–0.8669)

Piston rings

Top

Type Keystone

Dimension (B) mm (in) 1.47–1.49 (0.058–0.059)

Dimension (T) mm (in) 3.0–3.2 (0.118–0.126)

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

Ring groove clearance mm (in) 0.020–0.070 (0.0008–0.0028)
2nd

Type Keystone

Dimension (B) mm (in) 1.47–1.49 (0.058–0.059)

Dimension (T) mm (in) 3.0–3.2 (0.118–0.126)

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

Ring groove clearance mm (in) 0.020–0.070 (0.0008–0.0028)

Piston pins

Outside diameter mm (in) 21.995–22.000 (0.8659–0.8661)
Wear limit mm (in) 21.990 (0.8657)

Connecting rod

Small end inside diameter mm (in) 26.995–27.008 (1.0628–1.0633)

*1

Measuring conditions:
Engine temperature 48 °C (118 °F), wide open throttle, with spark plugs removed from all cylin­ders.
The figures are for reference only.

*1

*

mm (in) 11 (0.43)

kPa

(kgf/cm

2

, psi)

Orange: 83.903–83.906 (3.3033–3.3034)

Green: 83.907–83.910 (3.3034–3.3035)

Purple: 83.911–83.914 (3.3036–3.3037)

Model

GP1300R

640 (6.4, 91)

2-3

SPEC

MAINTENANCE SPECIFICATIONS

E

Item Unit

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) 0.250–0.750 (0.0098–0.0295)
Maximum small end axial

playE

Throttle body

Model/quantity 60TA/3
Manufacturer SANSHIN
ID mark 60T00
Trolling speed r/min 1,250–1,450

Reed valves

Thickness mm (in) 0.6 (0.024)
Reed valve stopper height mm (in) 10.5–10.9 (0.413–0.429)
Reed valve warpage limit mm (in) 1.5 (0.059)

Fuel pump

Pump type Electrical
Output pressure kPa

Coupling clearance

Vertical mm (in) 0–0.5 (0–0.020)
Horizontal mm (in) 2–4 (0.079–0.157)

mm (in) 2.000 (0.0787)

320.8–327.2 (3.21–3.27, 45.62–46.53)

(kgf/cm

2

, psi)

Model

GP1300R

JET PUMP UNIT

Item Unit

Jet pump

Impeller material Stainless steel
Number of impeller blades 4
Impeller pitch angle Degree 16.3
Impeller clearance mm (in) 0.7–0.9 (0.028–0.035)
Impeller clearance limit mm (in) 0.9 (0.035)
Drive shaft runout limit mm (in) 0.30 (0.0118)
Nozzle diameter mm (in) 85.0–85.6 (3.35–3.37)

2-4

Model

GP1300R

SPEC

HULL AND HOOD

MAINTENANCE SPECIFICATIONS

E

Item Unit

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)

Model

GP1300R

ELECTRICAL

Item Unit

Battery

Type Fluid
Voltage, capacity V, Ah 12, 19
Specific gravity 1.28

ECM unit
(B/R – Ground for cylinder #1)
(B/W – Ground for cylinder #2)
(B/Y – Ground for cylinder #3)

Output peak voltage lower
limit

at cranking V 0.8
at 2,000 r/min V 174
at 3,500 r/min V 156

Stator

Pickup coil

(W/R, W/B, W/Y – B)

Output peak voltage

at cranking 1 V 6.0

at cranking 2 V 6.0
at 2,000 r/min V 24
at 3,500 r/min V 40

Pickup coil resistance 1

(W/R – B)

Pickup coil resistance 2

(W/B – B)

Pickup coil resistance 3

(W/Y – B)

Lighting coil (G – G)

Output peak voltage

at cranking 1 V 9.0

at cranking 2 V 7.5
at 2,000 r/min V 12.5
at 3,500 r/min V 12.5

Lighting coil resistance

(G – G)

Cranking 1: unloaded
Cranking 2: loaded

Ω

459–561

Ω

459–561

Ω

459–561

Ω

0.54–0.66

Model

GP1300R

2-5

SPEC

MAINTENANCE SPECIFICATIONS

E

Item Unit

Model

GP1300R

Ignition coil

Minimum spark gap mm (in) 10–11 (0.39–0.43)
Primary coil resistance

Ω

0.26–0.36

(B/W – body)

Secondary coil resistance

Ω

k

3.5–4.7

(B/W – spark plug lead

terminal)

Spark plug lead resistance

#1 kΩ 6.1–14.3
#2 kΩ 4.5–10.9
#3 kΩ 3.3–8.2

Rectifier/regulator (R – B)

Output peak voltage
(unloaded)

at 3,500 r/min V 14.5

Starter motor

Type Bendix
Output kW 0.8
Rating Seconds 30
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)

Starter relay

Rating Seconds 30

Engine temperature sensor

Engine temperature sensor
resistance (B/Y – B/Y)

at 20 °C (68 °F) kΩ 54.2–69.0
at 100 °C (212 °F) kΩ 3.12–3.48

Intake air temperature sensor

Intake air temperature sensor
resistance

at 0 °C (32 °F) kΩ 5.4–6.6
at 80 °C (176 °F) k

Atmospheric pressure sensor
output voltage (P/G – B/O)

(kgf/cm

(kgf/cm

(kgf/cm

Ω

V at kPa

2

, psi)

V at kPa

2

, psi)

V at kPa

2

, psi)

0.29–0.39

4.00 at 101.3 (1.01, 14.4)

1.97 at 50 (0.5, 7.1)

0.79 at 20 (0.2, 2.8)

2-6

SPEC

MAINTENANCE SPECIFICATIONS

E

Item Unit

Exhaust temperature sensor
resistance

at 300 °C (572 °F) k
at 600 °C (1,112 °F) k
at 900 °C (1,652 °F)

Cooling water temperature
sensor resistance

at 0 °C (32 °F) k
at 100 °C (212 °F) k
at 200 °C (392 °F)

Speed sensor

Output voltage (on pulse) V 11.6
Output pulse/one full turn 2

Throttle position sensor

Output voltage (P – B/O)

at trolling speed V 0.793–0.807

Fuel sender

Fuel sender resistance

Position A
Position B

Fuel injector

Fuel injector resistance

Oil level sensor

Oil level sensor resistance

Position A
Position B
Position C

Fuse

Rating

Main V/A 12/20
Multifunction meter V/A 12/3
Electrical bilge pump V/A 12/3

*1

The figures are for reference only.

*1

Ω
Ω

Ω

Ω
Ω

Ω

Ω
Ω

Ω

13.8

Ω
Ω
Ω

GP1300R

73–241

0.86–1.58

24.0–37.1

0.87–1.18
104–153

133.5–136.5

292–308

97–103

Model

64–90

5–7

0–3

2-7

SPEC

TIGHTENING TORQUES

TIGHTENING TORQUES

SPECIFIED TORQUES

E

Part to be tightened Part name

Thread

size

Q’ty

Tightening torques

N•mkgf•mft•lb

Remarks

Fuel system

Strap/fuel tank/oil tank – hull Bolt M8 4 16 1.6 11
Oil filler hose screw clamp ——1 0.6 0.06 0.4
Retainer/fuel pump module

– fuel tank

1st

2nd 6.4 0.64 4.6

Nut — 9

3.2 0.32 2.3

Fuel filler hose screw clamp ——2 3.7 0.37 2.7
Cap screw clamp (fuel tank) ——1 1.3 0.13 0.9
Intake silencer screw clamp ——1 2.5 0.25 1.8
Intake silencer pipe screw clamp ——2 2.5 0.25 1.8
Intake duct –

exhaust chamber bracket

Intake duct –
generator cover

Throttle bodies assembly –
throttle bodies bracket 1, 2

1st

2nd 18 1.8 13

1st

2nd 18 1.8 13

1st

2nd 18 1.8 13

Throttle cable locknut and adjuster
(throttle bodies end)

Intake air temperature sensor –
intake silencer case cover

Intake silencer case cover – intake
silencer case

Flame arrester – intake silencer
case

Bolt M8 1

Bolt M8 2

Bolt M8 2

——1111.18.0

——1 7.5 0.75 5.4

Tapping

screw

ø6 13 1.8 0.18 1.3

Screw M5 6 0.8 0.08 0.6

9.0 0.9 6.5

9.0 0.9 6.5

9.0 0.9 6.5

Fuel rail – throttle bodies Bolt M6 3 8.8 0.88 6.4
Oil pump cable –

oil pump lever
Oil pump cable locknut and

adjuster
Bleed hose stay –

exhaust chamber bracket

Oil pump – generator cover

1st

2nd 4.4 0.44 3.2

Bolt M5 1

——1111.18.0

Bolt M6 1 7.6 0.76 5.5

1st

2nd 7.6 0.76 5.5

Bolt M6 2

2.2 0.22 1.6

3.8 0.38 2.7

Air bleed screw ——1 3.4 0.34 2.5

Engine

Spark plug ——3252.5 18
Muffler cover – muffler Bolt M6 3 12 1.2 8.7
Outer exhaust joint screw clamp ——2 2.5 0.25 1.8
Inner exhaust joint screw clamp ——2 1.5 0.15 1.1
Exhaust joint screw clamp ——2 2.5 0.25 1.8
Eye – muffler Nut M10 2 39 3.9 28
Eye – cylinder head Bolt M10 4 39 3.9 28
Muffler stay – cylinder Bolt M10 2 39 3.9 28

LT

572

LT

242

LT

242

LT

242

LT

572

LT

572

LT

242

LT

271

LT

271

LT

271

2-8

SPEC

TIGHTENING TORQUES

E

Part to be tightened Part name

Thread

size

Q’ty

Tightening torques

N•mkgf•mft•lb

Remarks

Muffler stay 2 – crankcase Bolt M10 2 39 3.9 28
Muffler – muffler stay 2 Bolt M10 1 39 3.9 28
Exhaust temperature sensor ——1393.928
Cooling water temperature sensor ——1202.0 14
Muffler stay – catalytic

converter housing

Cover/catalytic converter
housing/catalytic converter
– muffler

Mixing joint – muffler

Exhaust chamber assembly –
exhaust manifold

1st

2nd 39 3.9 28

Bolt M10 2

1st

Bolt M8 6

2nd 33 3.3 24

1st

2nd 22 2.2 16

Bolt M8 6

Bolt M10 4 39 3.9 28

15 1.5 11

15 1.5 11

11 1.1 8.0

Exhaust chamber stay/
exhaust chamber assembly –

Bolt M10 2 39 3.9 28

exhaust chamber bracket
Exhaust chamber joint –

exhaust chamber
Coupling cover –

intermediate housing assembly

Bolt M10 6 39 3.9 28

Bolt M6 1 7.9 0.79 5.7

Engine unit – engine mount Bolt M8 4 17 1.7 12

1st

Exhaust manifold –
cylinder

2nd 39 3.9 28

1st

2nd 39 3.9 28

Cooling water joint –
exhaust manifold

Throttle bodies bracket 1, 2/
throttle bodies joint/balance
plate/plate/reed valve
assembly – crankcase

Throttle bodies joint/
balance plate/plate/reed
valve assembly –
crankcase

Balance plate/plate/reed

1st

2nd 7.6 0.76 5.5

1st

2nd 7.6 0.76 5.5

1st

valve assembly –
crankcase

2nd 7.6 0.76 5.5

Valve stopper/reed valve –
reed valve base

YPVS cable holder/YPVS valve
cover – cylinder

Bolt M10 10

Nut M10 2

Bolt M6 6 12 1.2 8.7

Bolt M6 4

Bolt M6 14

Bolt M6 4

Screw M3 24 1.0 0.1 0.7

Bolt M6 2 9.8 0.98 7.1

22 2.2 16

22 2.2 16

3.8 0.38 2.7

3.8 0.38 2.7

3.8 0.38 2.7

YPVS valve cover – cylinder Bolt M6 10 9.8 0.98 7.1
YPVS valve arm – shaft 1, 2, 3 Bolt M4 3 2.8 0.28 2.0
YPVS valve stopper bolt — M5 3 3.8 0.38 2.7

LT

271

LT

271

LT

572

LT

572

LT

271

LT

271

LT

271

LT

271

LT

271

LT

271

LT

572

LT

572

LT

271

LT

242

LT

572

LT

572

LT

572

LT

242

LT

572

LT

572

LT

242

LT

242

2-9

SPEC

TIGHTENING TORQUES

E

Part to be tightened Part name

Ground lead –
cylinder head

Exhaust chamber stay/
cylinder head – cylinder

Cylinder head – cylinder

Thread

size

1st

2nd 7.6 0.76 5.5

1st

2nd 35 3.5 25

Bolt M6 1

Bolt M8 2

Q’ty

1st

2nd 22 2.2 16

Bolt M8 16

Tightening torques

N•mkgf•mft•lb

3.8 0.38 2.7

15 1.5 11

22 2.2 16

3rd 35 3.5 25
Anode – cylinder head Screw M5 2 4.4 0.44 3.2
Engine temperature sensor –

cylinder

Cylinder – crankcase

Generator cover –
crankcase

Generator cover/ground
lead – crankcase

Exhaust chamber bracket –
crankcase

1st

2nd 39 3.9 28

1st

2nd 50 5.0 36

1st

2nd 50 5.0 36

——1151.5 11

Bolt M10 12

Bolt M10 7

Bolt M10 1

22 2.2 16

15 1.5 11

15 1.5 11

Bolt M10 4 39 3.9 28

Cable holder – generator cover Bolt M6 2 14 1.4 10
Pickup coil – generator cover Bolt M5 6 4.9 0.49 3.5
Lighting coil – generator cover Bolt M6 3 14 1.4 10
Drive coupling –

crankshaft assembly
Flywheel magneto –

crankshaft assembly
Starter motor/negative

battery lead – crankcase

Starter motor – crankcase

Mount bracket – lower
crankcase

Upper crankcase –
lower crankcase

1st

2nd 18 1.8 13

1st

2nd 18 1.8 13

1st

2nd 27 2.7 19

1st

2nd 27 2.7 19

Drive

coupling

— 136 3.625

Bolt M10 1 74 7.4 53

Bolt M8 1

Bolt M8 1

Bolt M8 6

Bolt

M8 17

9.0 0.9 6.5

9.0 0.9 6.5

15 1.5 11

15 1.5 11

M6 10 11 1.1 8.0

Jet pump unit

Steering cable joint –
jet thrust nozzle

Nut — 1 6.8 0.68 4.9

Ride plate – hull Bolt M8 4 17 1.7 12
Intake duct – hull Bolt M8 4 17 1.7 12
Intake grate – hull Bolt M6 4 7.4 0.74 5.4
Speed sensor – ride plate Screw M5 4 3.7 0.37 2.7

Jet pump unit assembly/impeller
housing 2 – transom

Bolt

M10 4 40 4.0 29

M6 1 7.8 0.78 5.6

Nozzle ring – nozzle Bolt M8 2 15 1.5 11

Remarks

LT

572

LT

572

LT

572

LT

271

LT

271

LT

242

LT

242

LT

242

LT

572

E

A

LT

271

LT

271

LT

242

LT

572

LT

572

LT

572

LT

242

LT

572

LT

271

2-10

SPEC

TIGHTENING TORQUES

E

Part to be tightened Part name

Thread

size

Q’ty

Tightening torques

N•mkgf•mft•lb

Remarks

Jet thrust nozzle – nozzle ring Bolt M8 2 15 1.5 11
Spout hose screw clamp ——1 1.2 0.12 0.9
Nozzle/impeller duct assembly –

impeller housing 1
Water inlet cover/water inlet

strainer – impeller duct

Bolt M10 4 40 4.0 29

Bolt M6 4 6.6 0.66 4.8

Drive shaft nut – drive shaft Nut — 174 7.4 53
Impeller (left-hand threads) –

drive shaft

Impeller M22 1 75 7.5 54

Transom plate – hull Nut — 426 2.6 19
Intermediate housing – bulkhead Bolt M8 3 17 1.7 12

Driven coupling – shaft

Grease nipple –
intermediate housing

Driven

coupling

Nipple — 1 5.4 0.54 3.9

M24 1 36 3.6 25

Hull and hood

Handlebar cover –
handlebar cover stay

Handlebar cover stay –
steering column

Upper handlebar holder/lower
handlebar holder – steering column

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

QSTS converter – hull Nut M6 2 5.4 0.54 3.9
QSTS cable 1, 2 locknut ——2161.6 11
Throttle lever assembly –

handlebar
Handlebar switch assembly –

handlebar

Screw M5 2 3.4 0.34 2.5

Screw M5 2 3.4 0.34 2.5

QSTS grip assembly – handlebar Screw M6 1 3.4 0.34 2.5
Grip end – handlebar Bolt M5 2 1.2 0.12 0.9
QSTS cable housing – cover Screw M4 1 1.0 0.1 0.7
Plate/steering column assembly –

deck

Nut M8 2 16 1.6 11

Steering column assembly – deck Nut M8 2 16 1.6 11
Steering arm – steering column Nut M8 1 16 1.6 11
Magnet – steering arm Screw M5 1 2.0 0.2 1.4
Steering cable ball joint –

steering arm
Handlebar stopper –

steering column housing
QSTS cable locknut

(nozzle ring side)

Nut M6 1 5.0 0.5 3.6

Nut M10 1 26 2.6 19

——1 3.8 0.38 2.7

QSTS cable – hull Nut — 1 5.9 0.59 4.3
QSTS cable end – pin –

QSTS converter

Nut M6 1 3.8 0.38 2.7

LT

271

LT

572

LT

572

LT

572

LT

572

LT

572

LT

572

LT

242

2-11

SPEC

TIGHTENING TORQUES

E

Part to be tightened Part name

Steering cable locknut
(jet thrust nozzle end)

Thread

size

Q’ty

——1 6.5 0.65 4.7

Tightening torques

N•mkgf•mft•lb

Steering cable – hull Nut — 1 5.9 0.59 4.3
Steering cable holder – bracket Bolt M6 1 6.4 0.64 4.6
Speed sensor lead – hull Nut — 1 5.9 0.59 4.3
Hinge assembly – hood Bolt M6 2 12 1.2 8.7
Visor – hood Screw M5 8 1.0 0.1 0.7
Hood lock – hood Bolt M6 2 5.4 0.54 3.9
Hinge assembly – deck Nut M8 2 16 1.6 11

Nut M6 2 5.4 0.54 3.9

Steering console cover assembly –
deck

Bolt M6 4 2.9 0.29 2.1

Screw M5 2 2.0 0.2 1.4

Nut M8 2 16 1.6 11
Multifunction meter – holder Nut M5 2 1.8 0.18 1.3
Steering console cover – side cover Screw M6 4 2.9 0.29 2.1
Steering console cover – glove

compartment

Screw M5 4 1.3 0.13 0.9

Steering cable bracket – deck Bolt M6 1 6.4 0.64 4.6
Buzzer bracket/deck – steering

cable bracket

Bolt M6 2 6.4 0.64 4.6

Hood lock assembly – deck Nut M6 2 6.4 0.64 4.6
Seat lock assembly – seat Bolt M6 2 6.4 0.64 4.6
Bracket/deck – projection Nut M10 1 26 2.6 19
Bracket/deck – handgrip Bolt M8 2 5.2 0.52 3.8
Handgrip – deck Nut M8 2 5.2 0.52 3.8
Seat bracket – deck Nut M8 2 15 1.5 11
Battery box/stay – holder Nut M6 2 8.9 0.89 6.4
Battery box – deck/bracket Nut M8 2 13 1.3 9.4
Battery box – electrical box Bolt M8 1 13 1.3 9.4
Battery box/stay – electrical box Nut M8 2 13 1.3 9.4
Extension bolt –

negative battery terminal

— M6 1 6.4 0.64 4.6

Exhaust outlet – hull Bolt M6 3 6.4 0.64 4.6
Hose screw clamp ——3 3.7 0.37 2.7
Sponson – hull Bolt M8 6 18 1.8 13
Spout – hull Nut M24 1 5.4 0.54 3.9
Rope hole – hull Nut M24 2 5.4 0.54 3.9
Bow eye – hull Bolt M6 2 13 1.3 9.4
Flap – hull Bolt M6 8 7.4 0.74 5.4
Drain plug/packing – hull Nut — 4 2.0 0.2 1.4
Engine mount – hull Bolt M8 8 17 1.7 12
Engine damper – hull Bolt M6 4 6.4 0.64 4.6

Remarks

LT

572

LT

271

2-12

SPEC

TIGHTENING TORQUES

E

Part to be tightened Part name

Electrical

Cover – electrical box

Lead retainer – electrical box

Positive battery lead – starter relay Bolt M6 1 3.4 0.34 2.5
Starter motor lead – starter relay Bolt M6 1 3.4 0.34 2.5

Rectifier/regulator – electrical box

Coupler bracket – electrical box

Wire harness retainer –
electrical box

Ignition coil #1, # 2, #3 – electrical
box

Fuse holder stay – electrical box

Main and fuel pump relay –
electrical box

Ground leads – electrical box Bolt M6 2 7.6 0.76 5.5
ECM – hull Nut — 2 5.4 0.54 3.9
Slant detection switch – hull Nut — 2 5.4 0.54 3.9
Nut/spring washer/washer (starter

motor lead terminal) – starter motor
Starter motor rear cover/starter

motor yoke – starter motor front
cover

YPVS servomotor bracket – deck Nut — 315 1.511
YPVS servomotor/

throttle cable plastic tie bracket –
YPVS servomotor bracket

Tapping

screw

Tapping

screw

Tapping

screw

Tapping

screw

Tapping

screw

Tapping

screw

Tapping

screw

Tapping

screw

Nut — 1 8.8 0.88 6.4

Bolt M5 2 6.4 0.64 4.6

Nut — 2 5.4 0.54 3.9

Thread

size

ø6 11 4.9 0.49 3.5

ø624.90.493.5

ø623.90.392.8

ø623.40.342.5

ø624.90.493.5

ø663.90.392.8

ø613.40.342.5

ø613.90.392.8

Q’ty

Tightening torques

N•mkgf•mft•lb

Remarks

2-13