WaveRunner
GP800R
SERVICE MANUAL
*LIT186160226*
F0W-28197-1A-11LIT-18616-02-26
E
NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their
trained mechanics when performing maintenance procedures and repairs to Yamaha 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 GP800R
SERVICE MANUAL
©2000 by Yamaha Motor Corporation, USA
1st Edition, November 2000
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-02-26
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
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.
→
Replace.
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
operator, a bystander, or a person inspecting or repairing the watercraft.
to the machine
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the watercraft.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
IMPORTANT:
This part has been subjected to change of specification during production.
1
2
3
4
5
6
HOW TO USE THIS MANUAL
To help identify parts and clarify procedure steps, there are exploded diagrams at the start
of each removal and disassembly section.
Numbers are given in the order of the jobs in the exploded diagram.
Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
A job instruction chart accompanies the exploded diagram, providing the order of jobs,
names of parts, notes in jobs, etc.
Dimension figures and the number of parts, are provided for fasteners that require a tightening torque.
Example:
Bolt or screw size : M10 (D)
10 × 25 mm
Jobs requiring more information (such as special tools and technical data) are described
sequentially.
×
25 mm (L)
D
L
E
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
E
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 as thumbtabs to indicate the content of a chapter.
General Information
Specifications
Periodic Inspection and Adjustment
Fuel System
Power Unit
Jet Pump Unit
Electrical System
Hull and Hood
Trouble analysis
Symbols 0 to E indicate specific data:
Special tool
Specified liquid
Specified engine speed
Specified torque
Specified measurement
Specified electrical value
[Resistance (
(A)]
Ω
), Voltage (V), Electric current
CD
T
.
R
.
EF
E
GH
A
IJ
GM
KL
LT
271
M
4
LT
242
Symbol F to H in an exploded diagram
indicate the grade of lubricant and the location of lubrication point:
Apply YAMALUBE 2-W oil or TC-W3 cirtified
outboard oil
Apply water resistant grease
(Yamaha grease A, Yamaha marine grease)
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:
Apply Gasket Maker
J Apply 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
®
MN
LT
572
SS
LT
NOTE:
In this manual, the above symbols may not
be used in every case.
A30000-0
E
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
E
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
2
3
4
5
6
7
8
9
GEN
INFO
IDENTIFICATION NUMBERS
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:
F0W: 800101–
ENGINE SERIAL NUMBER
The engine serial number is stamped on a
label attached to the cylinder head.
Starting serial number:
68A: 000101–
E
JET PUMP UNIT SERIAL NUMBER
The jet pump unit serial number is stamped
on a label attached to the intermediate
housing.
Starting serial number:
68A: 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
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.
Gasoline vapor is explosive if ignited.
Do not smoke while handling gasoline
(petrol) and keep it away from heat, sparks,
and open flames.
E
VENTILATION
Gasoline vapor is heavier than air and is
deadly if inhaled in large quantities. Engine
exhaust gases are harmful to breathe.
When test-running an engine indoors,
maintain good ventilation.
SELF-PROTECTION
Protect your eyes with suitable safety 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
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.
E
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
3. Non-reusable items
Always use new gaskets, packings, Orings, 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.
E
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
YU-8036-A 90890-06760
1
YU-03097
2
YU-01256
YU-03112
90890-03112
YU-33223 90890-03160
5
J-39299 90890-06752
6
YU-39991
90890-03169
SPECIAL TOOLS
43
87
90890-01252
YU-03017
90890-06759
YW-06779
90890-06779
E
SPECIAL TOOLS
Using the correct special tools recommended by Yamaha, will aid the work and
enable accurate assembly and tune-up.
Improvisations and using improper tools
can damage the equipment.
NOTE:
● For U.S.A. and Canada, use part numbers
starting with “J-”, “YB-”, “YM-”, “YU-” or
“YW-”.
● For other countries, use part numbers
starting with “90890-”.
MEASURING
1 Engine tachometer
P/N. YU-8036-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 tester
P/N. J-39299
90890-06752
7 Peak voltage adapter
P/N. YU-39991
90890-03169
8 Peak voltage test harness
P/N. YW-06779
90890-06779
9 Spark gap tester
P/N. YM-34487
90890-06754
YM-34487 90890-06754
9
1-5
GEN
INFO
SPECIAL TOOLS
E
YW-06551
90890-06551
3
YB-06117 90890-06521
YB-06151 90890-06519
90890-06501 90890-06535
90890-06536 90890-06538
90890-06652 YB-06112
YB-06156 90890-06634
B
YB-06071 90890-06606 YB-34474
YB-06552 YB-06016 90890-06626
E
90890-06552
YW-06550 90890-06550
21
YB-06096
54
76
98
A0
YB-06196
DC
F
90890-06614
90890-06653
REMOVAL AND INSTALLATION
1 Coupler wrench
P/N. YW-06551
90890-06551
2 Flywheel holder
P/N. YW-06550
90890-06550
3 Flywheel puller
P/N. YB-06117
90890-06521
4 Drive shaft holder (impeller)
P/N. YB-06151
90890-06519
5 Slide hammer set (jet pump bearing)
P/N. YB-06096
6 Stopper guide plate (jet pump bearing)
P/N. 90890-06501
7 Bearing puller (jet pump bearing)
P/N. 90890-06535
8 Bearing puller claw 1 (jet pump bearing)
P/N. 90890-06536
9 Stopper guide stand (jet pump bearing)
P/N. 90890-06538
0 Drive rod L3 (jet pump bearing)
P/N. 90890-06652
A Needle bearing attachment
(jet pump bearing and oil seal)
P/N. YB-06112, YB-06196
90890-06614, 90890-06653
B Ball bearing attachment
(jet pump oil seal)
P/N. YB-06156
90890-06634
C Driver rod
(intermediate shaft and jet pump)
P/N. YB-06071
90890-06606
D Bearing inner/outer race attachment
(jet pump bearing)
P/N. YB-34474
E Shaft holder (intermediate shaft)
P/N. YB-06552
90890-06552
F Bearing outer race attachment
(intermediate shaft)
P/N. YB-06016
90890-06626
1-6
SPEC
E
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS.......................................................................... 2-1
1
MAINTENANCE SPECIFICATIONS................................................................ 2-3
ENGINE..................................................................................................... 2-3
JET PUMP UNIT....................................................................................... 2-4
HULL AND HOOD .................................................................................... 2-4
ELECTRICAL ............................................................................................. 2-5
2
TIGHTENING TORQUES................................................................................ 2-7
SPECIFIED TORQUES.............................................................................. 2-7
GENERAL TORQUE ............................................................................... 2-10
CABLE AND HOSE ROUTING...................................................................... 2-11
3
4
5
6
7
8
9
SPEC
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
E
Item Unit
MODEL CODE
Hull F0W
Engine 68A
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) 268 (591)
Watercraft capacity 2
PERFORMANCE
Maximum output kW (PS) @ r/min 88.2 (120) @ 7,000
Maximum fuel consumption R/h (US gal/h,
lmp gal/h)
Cruising range h 1.2
ENGINE
Engine type 2-stroke
Number of cylinders 2
3
Displacement cm
Bore × stroke mm (in) 80.0 × 78.0 (3.15 × 3.07)
Compression ratio 6.6:1
Intake system Reed valve
Carburetor model
(manufacturer) × quantity
Enrichment control Choke valve
Scavenging system Loop charge
Lubrication system Oil injection
Cooling system Water
Starting system Electric
Ignition system Digital CDI
Ignition timing Degree 15 BTDC–20 BTDC
Spark plug model
(manufacturer)
Battery capacity V/Ah (kC) 12/19 (68.4)
Lighting coil max. A @ r/min 8 @ 6,000
Propulsion system Jet pump
DRIVE UNIT
Jet pump type Axial flow, single stage
Impeller rotation (from rear) Counterclockwise
Transmission Direct drive from engine
Nozzle angle (horizontal) Degree 23 + 23
Nozzle angle (vertical) Degree –5, 0, 5, 10, 15
Trim system Manual 5 positions
(cu. in) 784 (47.8)
Model
GP800R
49 (12.9, 10.8)
BN44 (Mikuni) × 2
BR8ES (NGK)
2-1
SPEC
GENERAL SPECIFICATIONS
E
Item Unit
FUEL AND OIL
Fuel Regular unleaded gasoline
Fuel rating PON* 86
RON* 90
Oil YAMALUBE 2-W or an equivalent TC-W3
certified outboard oil
Fuel/oil mixing ratio
(wide open throttle)
Fuel tank capacity R(US gal,
Imp gal)
Fuel tank reserve capacity R(US gal,
Imp gal)
Oil tank capacity R(US gal,
Imp gal)
PON*: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2
RON*: Research Octane Number
Model
GP800R
30:1
60 (15.9, 13.2)
10 (2.6, 2.2)
5.5 (1.45, 1.21)
2-2
SPEC
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
E
Item Unit
CYLINDER HEAD
Warpage limit mm (in) 0.1 (0.004)
Compression pressure
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)
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
diameter
PISTON RINGS
Top
Type Keystone
Dimensions (B) mm (in) 1.2 (0.05)
Dimensions (T) mm (in) 2.85 (0.112)
End gap mm (in) 0.30–0.45 (0.012–0.018)
Ring groove clearance mm (in) 0.03–0.05 (0.001–0.002)
*2
2nd
Type Keystone
Dimensions (B) mm (in) 1.2 (0.05)
Dimensions (T) mm (in) 2.85 (0.112)
End gap mm (in) 0.30–0.45 (0.012–0.018)
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
kPa (kg/cm2) 560 (5.6)
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)
mm (in) 22.004–22.025 (0.8663–0.8671)
Model
GP800R
*1: At 760 mmHg and 20 ˚C (68 ˚F)
*2: The top ring and 2nd ring are of the same type.
2-3
SPEC
MAINTENANCE SPECIFICATIONS
E
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)
Big end side clearance C mm (in) 0.25–0.75 (0.010–0.030)
Maximum small end axial
play D
CARBURETORS
Type Floatless
Identification mark #1: 68A-01, #2: 68A-02
Main nozzle mm (in) 3.0 (0.12)
Main jet 150
Pilot jet 90
Throttle valve 120
Valve seat size mm (in) 1.2 (0.05)
Trolling speed r/min 1,300 ± 50
REED VALVES
Thickness mm (in) 0.52 (0.020)
Reed valve stopper height mm (in) 10.8–11.4 (0.43–0.45)
Reed valve warpage limit mm (in) 0.2 (0.01)
mm (in) 2.0 (0.08)
Model
GP800R
JET PUMP UNIT
Item Unit
JET PUMP
Impeller material Stainless steel
Number of impeller blades 3
Impeller pitch angle Degree 13.2
Impeller clearance mm (in) 0.35–0.45 (0.014–0.018)
Impeller clearance limit mm (in) 0.6 (0.024)
Drive shaft runout limit mm (in) 0.3 (0.012)
Nozzle diameter mm (in) 86.8 (3.42)
Model
GP800R
HULL AND HOOD
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
GP800R
2-4
SPEC
ELECTRICAL
MAINTENANCE SPECIFICATIONS
E
Item Unit
BATTERY
Type Fluid
Capacity V/Ah (kC) 12/19 (68.4)
CDI UNIT (O – B)
Output peak voltage lower
limit
@cranking 1 V 85
@cranking 2 V 110
@2,000 r/min V 205
@3,500 r/min V 200
STATOR
Charge coil (Br – L)
Output peak voltage
lower limit
@cranking 1 V 90
@cranking 2 V 120
@2,000 r/min V 220
@3,500 r/min V 210
Pickup coil (W/R – W/B)
Output peak voltage
lower limit
@cranking 1 V 5
@cranking 2 V 3
@2,000 r/min V 7
@3,500 r/min V 11
Lighting coil (G – G)
Output peak voltage
lower limit
@cranking 1 V 8.5
@cranking 2 V 8.5
@2,000 r/min V 13
@3,500 r/min V 13
Charge coil resistance Ω (color) 299–365 (Br – L)
Pickup coil resistance Ω (color) 446–545 (W/R – W/B)
Lighting coil resistance Ω (color) 0.86–1.06 (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) 0.078–0.106 (O – B)
Secondary coil resistance kΩ 14.3–30.5
(#1 Spark plug cap – #2 Spark plug cap)
Model
GP800R
Cranking 1: unloaded
Cranking 2: loaded
2-5
SPEC
MAINTENANCE SPECIFICATIONS
E
Item Unit
RECTIFIER/REGULATOR
(R – B)
Output peak voltage lower
limit (unloaded)
@cranking V 7.5
@2,000 r/min V 12.5
@3,500 r/min V 12.5
THERMO SWITCH
On temperature ˚C (˚F) 80 (177)
Off temperature ˚C (˚F) 70 (159)
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
Model
GP800R
2-6
SPEC
TIGHTENING TORQUES
TIGHTENING TORQUES
SPECIFIED TORQUES
E
Part to tightened Part name
Thread
size
Q’ty
Tightening torque
N•m kgf•m ft•lb
ENGINE UNIT
Engine unit – engine mount Bolt M8 4 17 1.7 12
Exhaust chamber
assembly – muffler stay 1
– muffler stay 3
Exhaust chamber –
muffler
Exhaust chamber joint –
exhaust manifold
Exhaust chamber joint –
muffler stay
Exhaust manifold –
cylinder
1st
4th 51 5.1 37
2nd
6th 39 3.9 28
3rd
5th 51 5.1 37
7th
9th 49 4.9 35
8th
10th 49 4.9 35
1st
2nd 39 3.9 28
1st
2nd 33 3.3 24
1st
2nd 51 5.1 37
1st
2nd 34 3.4 24
1st
3rd 49 4.9 35
2nd
4th 37 3.7 27
1st
2nd 51 5.1 37
Bolt M10 2
Bolt M10 4
Nut M10 2
Bolt M10 1
Bolt M10 1
Nut M8 2
Bolt M8 3
Nut M10 1
Bolt M8 5
Bolt M10 1
Bolt M8 2
Bolt M10 8
2 0.2 1.4
2 0.2 1.4
2 0.2 1.4
2 0.2 1.4
2 0.2 1.4
15 1.5 11
15 1.5 11
15 1.5 11
17 1.7 12
2 0.2 1.4
2 0.2 1.4
23 2.3 17
Reed valve – reed valve seat Screw M3 16 0.8 0.08 0.58
YPVS cable bracket – YPVS cover
– cylinder
Bolt M6 2 10 1.0 7.2
YPVS cover – cylinder Bolt M6 6 10 1.0 7.2
YPVS valve assembly – cylinder Bolt M5 2 4 0.4 2.9
YPVS valve lever – shaft Bolt M4 2 3 0.3 2.2
Spark plug – cylinder head Spark plug M14 2 25 2.5 18
Cylinder head – cylinder
Cylinder – crankcase
1st
2nd 37 3.7 27
1st
2nd 39 3.9 28
Starter motor lead – starter
motor
Flywheel magneto – crankshaft
assembly
Bolt M8 10
Bolt M10 8
Nut M6 1 5 0.5 3.6
Bolt M10 1 74 7.4 53
15 1.5 11
22 2.2 16
Remarks
LT
572
LT
271
LT
271
LT
271
LT
271
LT
271
LT
271
LT
242
LT
572
LT
572
LT
271
LT
242
LT
572
LT
572
E
2-7
SPEC
TIGHTENING TORQUES
E
Part to tightened Part name
Drive coupling – crankshaft
assembly
Generator cover –
crankcase
Thread
size
Drive
coupling
1st
2nd 27 2.7 19
Bolt M8 8
M27 1 36 3.6 25
Q’ty
Tightening torque
N•m kgf•m ft•lb
15 1.5 11
Pickup coil – generator cover Bolt M5 2 5 0.5 3.6
Cable holder – generator cover Bolt M6 2 14 1.4 10
Stator coil – generator cover Bolt M6 3 14 1.4 10
Lower crankcase – upper
crankcase
1st
2nd 27 2.7 19
Bolt
M8 13
15 1.5 11
M6 7 11 1.1 8.0
Mount bracket –
crankcase
1st
2nd 27 2.7 19
Bolt M8 6
15 1.5 11
JET PUMP UNIT
Steering cable joint – nozzle
deflector
Nut M6 1 7 0.7 5.1
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 0.7 5.1
Speed sensor – ride plate Screw M5 4 4 0.4 2.9
Nozzle ring – nozzle Bolt M8 2 15 1.5 11
Nozzle deflector – nozzle ring Bolt M8 2 15 1.5 11
Water inlet cover – water inlet
strainer – impeller duct
Bolt M6 4 7 0.7 5.1
Drive shaft nut – drive shaft Nut M16 1 74 7.4 53
Impeller (left-hand threads) –
drive shaft
Impeller M22 1 18 1.8 13
Transom plate – hull Nut M10 4 26 2.6 19
Bilge strainer holder – bulkhead Screw M5 1 4 0.4 2.9
Intermediate housing – bulkhead Bolt M8 3 17 1.7 12
Driven coupling – shaft
Grease nipple – intermediate
housing
Driven
coupling
M27 1 36 3.6 25
Nipple — 1 5 0.5 3.6
HULL AND HOOD
Handlebar cover – handlebar
cover stay
Handlebar cover stay – steering
column
Upper handlebar holder/lower
handle 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 0.5 3.6
QSTS cable 1, 2 locknut Nut M8 2 16 1.6 11
Throttle lever assembly –
handlebar
Screw M5 2 3 0.3 2.2
Remarks
LT
572
LT
271
LT
242
LT
242
LT
242
LT
572
LT
271
LT
242
LT
572
LT
572
LT
572
LT
242
LT
271
LT
271
LT
572
LT
572
LT
572
LT
572
LT
572
2-8
SPEC
TIGHTENING TORQUES
E
Part to tightened Part name
Handlebar switch assembly –
handlebar
Thread
size
Q’ty
Screw M5 2 3 0.3 2.2
Tightening torque
N•m kgf•m ft•lb
QSTS grip assembly – handlebar Screw M6 1 3 0.3 2.2
Grip end – handlebar Bolt M5 2 1 0.1 0.7
Choke lever assembly –
handlebar
Screw M5 2 3 0.3 2.2
QSTS cable housing – cover Screw M4 1 1 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
Steering cable ball joint –
steering arm
Handlebar stopper – steering
column housing
QSTS cable locknut
(nozzle ring side)
Nut M6 1 5 0.5 3.6
Nut M10 1 26 2.6 19
Nut M5 1 3 0.3 2.2
QSTS cable – hull Nut — 1 6 0.6 4.3
QSTS cable end – pin – QSTS
converter
Steering cable locknut
(nozzle deflector side)
Nut M6 1 4 0.4 2.9
Nut M6 1 6 0.6 4.3
Steering cable – hull Nut — 1 6 0.6 4.3
Steering cable holder – bracket Bolt M6 1 6 0.6 4.3
Speed sensor lead – hull Nut — 1 6 0.6 4.3
Hinge assembly – front hood Bolt M6 2 12 1.2 8.7
Wind shield – front hood Screw M5 8 1 0.1 0.7
Hood lock – front hood Bolt M6 2 5 0.5 3.6
Hinge assembly – deck Nut M8 2 16 1.6 11
Nut M6 2 5 0.5 3.6
Steering console cover assembly
– deck
Bolt M6 4 3 0.3 2.2
Screw M5 2 2 0.2 1.4
Nut M8 2 16 1.6 11
Multifunction meter – holder Nut M5 2 2 0.2 1.4
Steering console cover – side
cover
Steering console cover – glove
compartment
Screw M6 4 3 0.3 2.2
Screw M5 4 1 0.1 0.7
Steering cable bracket – deck Bolt M6 1 6 0.6 4.3
Buzzer bracket – deck – steering
cable bracket
Bolt M6 2 6 0.6 4.3
Hood lock assembly – deck Nut M6 2 6 0.6 4.3
Seat lock assembly – seat Bolt M6 2 6 0.6 4.3
Bracket/deck – notch Nut M10 1 26 2.6 19
Bracket/deck – hand grip Bolt M8 2 5 0.5 3.6
Remarks
LT
572
2-9
SPEC
TIGHTENING TORQUES
E
Part to tightened Part name
Thread
size
Q’ty
Tightening torque
N•m kgf•m ft•lb
Hand grip – deck Nut M8 2 5 0.5 3.6
Seat bracket – deck Nut M8 2 15 1.5 11
Battery box/stay – holder Nut M6 2 9 0.9 6.5
Battery box – bracket/deck Nut M8 2 13 1.3 9.4
Battery box – electrical box Bolt M8 3 15 1.5 11
Extension bolt – battery negative
terminal
Bolt M6 1 6 0.6 4.3
Exhaust outlet – hull Bolt M6 3 6 0.6 4.3
Sponson – hull Bolt M8 6 18 1.8 13
Spout – hull Nut M24 1 5 0.5 3.6
Rope hole – hull Nut M24 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 M5 4 2 0.2 1.4
Engine mount – hull Bolt M8 8 17 1.7 12
Engine damper – hull Bolt M6 2 6 0.6 4.3
General torque
Nut A Bolt B
specifications
N•m kgf•m 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.
Remarks
LT
572
2-10
SPEC
CABLE AND HOSE ROUTING
CABLE AND HOSE ROUTING
E
B
F
L
K-K
J-J
I-I
9
9
9
8
0
A
0
0
20˚
K
A
J
I
H
G
9
2
A
B
C
L
K
E
E
K
E
D
E
F
F
2
D
1
2
A
B
2
C
2
K
K
3
D-D
J
J
J J
I I
GG
H H
4
E-E
C
D
E
F
5
6
7
F-F
4
H-H
1 Fuel filter
2 Fuel tank breather hose
3 Fuel hose
4 Cooling water hose
5 Choke cable
6 Throttle cable
7 Oil return hose
8 Bilge hose
9 Speed sensor lead
0 Electrical box lead
A YPVS cables
B Cooling water pilot outlet
C Battery negative lead
D Battery
E Steering cable
F QSTS cable
2-11
G-G
G Battery breather hose
H Battery positive lead
I Starter motor lead
J Generator lead
K YPVS servomotor
SPEC
CABLE AND HOSE ROUTING
D
D
1
2
E
3
E
A
B
E
D E
C
H
A
B
I
2
J
K
L
M
5
J
F
C
I
E
A
F
J
7
4
G
0
E
A
F
G
J-J
1 Oil delivery hose
2 Fuel return hose
3 Fuel suction hose
4 Speed sensor lead
5 QSTS cable
6 Cooling water hose
7 Steering cable
8 Flushing hose
A
F
8
G-G
D
E
I
9 Bilge hoses
0 To multifunction meter
A To stator assembly
B To cylinder #1
C To cylinder #2
D To battery positive terminal
E To starter motor positive
B
C
terminal
H-H
2-12
9
4
6
G
5
H
H
7
F
F To thermoswitch
G Battery negative lead
H Buzzer lead
I Choke cable
J YPVS servomotor
K YPVS cables
L Battery positive lead
M Battery breather hose
G
4
INSP
ADJ
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
E
1
2
3
4
5
6
7
8
9
INSP
ADJ
MAINTENANCE INTERVAL CHART
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.
E
Item Remarks
Initial Every
10 hours
(Break-in)
50 hours
(3 months)
100 hours
(6 months)
200 hours
(1 year)
Refer to
page
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
Trolling speed Check/adjust 3-8
Carburetor setting Inspect/adjust 4-18
OIL INJECTION SYSTEM
Oil injection system Check/clean 3-9
Oil pump cable Inspect/adjust 4-30
POWER UNIT
Spark plugs Inspect/clean/adjust 3-9
Cooling water passage Inspect/clean
*1
—
Rubber coupling Inspect —
ELECTRICAL
Battery Inspect
*2
3-10
JET PUMP UNIT
Impeller Inspect 3-13
Water inlet strainer Clean 3-14
Bilge strainer Clean 3-14
GENERAL
Bolts and nuts Retighten —
Drain plugs Inspect/replace 3-14
Lubrication points Grease 3-15
Intermediate housing Grease
*3
*4
3-17
*1: After every ride
*2: Inspect fluid level before every ride
*3: Grease capacity 33.0–35.0 cm
*4: Grease capacity 6.0–8.0 cm
3
(1.11–1.18 oz)
3
(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 steer-
ing 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 han-
dlebar.
Steering cable inspection and adjustment
1. Inspect:
● Distance a, b (between the nozzle
and nozzle deflector)
Out of specification → Adjust.
2
Inspection steps:
● Set the control grip in the neutral posi-
tion.
● Turn the handlebar from lock to lock.
● Measure distances a and b.
● If the difference is not within specifica-
tion, adjust the cable joint.
Difference of distances a and b:
Maximum 5 mm (0.2 in)
2. Adjust:
● Steering cable joint
(steering column side)
Adjustment steps:
● Loosen the locknut 1.
● Disconnect the steering cable joint 2
from the ball joint 3.
● Turn the cable joint in or out for adjust-
ing the distances a and b.
Turn in Distance a is increased.
1
Turn out Distance b is increased.
3
3-2
INSP
ADJ
CONTROL SYSTEM
E
WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).
● Connect the cable joint and tighten the
locknut.
Locknut:
T
6 N • m (0.6 kgf • m, 4.3 ft • lb)
.
R
.
NOTE:
If the steering cable cannot be properly
adjusted at the steering column side, make
sure the steering cable at the jet pump side
is set to the specified length. Refer to
“REMOTE CONTROL CABLES AND SPEED
SENSOR LEAD” in chapter 8.
Throttle cable inspection and adjustment
NOTE:
Before adjusting the throttle lever free play,
adjust the trolling speed.
1. Measure:
● Throttle lever free play a
Out of specification → Adjust.
Throttle lever free play:
4–7 mm (0.16–0.28 in)
2. Adjust:
● Throttle lever free play
Adjustment steps:
● Loosen the locknut 1.
● Turn the adjuster 2 in or out until the
specified free play is obtained.
Turn in Free play is increased.
Turn out Free play is decreased.
● Tighten the locknut.
3-3
INSP
ADJ
CONTROL SYSTEM
E
WARNING
After adjusting the free play, turn the handlebar to the right and left and make sure
that the trolling speed does not increase.
Choke cable inspection and adjustment
1. Check:
● Choke lever operation
Incorrect operation → Adjust.
Checking steps:
● Check that the choke lever moves back
slightly when it is fully opened.
● Check that the inner cable has some
slack when the choke lever is completely closed.
2. Adjust:
● Choke lever operation
Adjustment steps:
● Loosen the locknut 1.
● Screw the adjuster 2 fully into the
bracket.
● Align the choke lever end a within the
line marks b.
● Turn out the adjuster 2 until the inner
cable is taut.
NOTE:
If the inner cable is difficult to make taut
using the adjuster 2, adjust the choke
lever so that the cable is taut. The cable
must be taut when the choke lever end
a is positioned within the line marks b.
Reset the adjuster if necessary.
● Tighten the locknut 1.
3-4
INSP
ADJ
CONTROL SYSTEM
E
QSTS cable inspection and adjustment
1. Measure:
● Nozzle deflector set length a, b
Difference → Adjust.
Measurement steps:
● Set the control grip in the neutral posi-
tion.
● Measure the nozzle deflector set
length a and b.
● If a and b length are not even, adjust
the cable joint.
2. Adjust:
● QSTS cable
Adjustment steps:
● Set the control grip in the neutral posi-
tion.
● Loosen the locknut 1.
● Remove the nut 2 and pivot pin 3.
● Set the nozzle deflector in the center
position.
● Turn the cable joint 4 for adjusting.
Turn in Length b is increased.
Turn out Length a is increased.
WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).
● Connect the cable joint 4 and pivot
pin 3 and tighten the nut 2.
Nut:
T
4 N • m (0.4 kgf • m, 2.9 ft • lb)
.
R
.
● Tighten the locknut 1.
Locknut:
T
4 N • m (0.4 kgf • m, 2.9 ft • lb)
.
R
.
3-5
INSP
ADJ
CONTROL SYSTEM
E
NOTE:
If the QSTS cable cannot be properly
adjusted at the QSTS converter side, make
sure the QSTS cable at the jet pump side is
set to the specified length.
Refer to “REMOTE CONTROL CABLES AND
SPEED SENSOR LEAD” in chapter 8.
YPVS cable adjustment
1. Check:
● YPVS valve position
Incorrect position → Adjust the YPVS
cable.
Checking steps:
● Start the engine and then stop it.
NOTE:
When the engine has been stopped for 3
seconds, the YPVS valve assembly will
retract and extend one time.
● Check that the hole a in the pulley is
aligned with the hole in the cylinder
when the YPVS valve is fully closed.
2. Measure:
● YPVS cable slack a
Out of specification → Adjust.
YPVS cable slack:
0.5–1.5 mm (0.02–0.06 in)
3-6
INSP
ADJ
41
3
2
CONTROL SYSTEM/FUEL SYSTEM
3. Adjust:
● YPVS cables 1 and 2
Adjustment steps:
● Loosen locknuts 1 and 2.
● Turn in adjusters 3 and 4 until there
is slack in the cables.
● Align the hole a in the pulley with the
hole in the cylinder.
● Insert a 4-mm-diameter pin through
the holes in the pulley and cylinder.
● Turn adjusters 3 and 4 in or out until
the specified slack is obtained.
Turn in Slack is increased.
Turn out Slack is decreased.
● Finger tighten locknuts 1 and 2.
● Remove the pin.
● Start and stop the engine.
● Recheck the hole alignment.
● If the hole alignment is correctly,
tighten the locknuts.
● If the hole alignment is incorrect,
repeat the above steps.
E
FUEL SYSTEM
WARNING
● Stop the engine, set the fuel cock to
“OFF” before servicing the fuel system.
● When removing fuel system parts, wrap
them in a cloth and take care that no fuel
spills into the engine compartment.
Fuel line inspection
1. Inspect:
● Fuel filter 1
Contaminants → Replace.
Cracks/damage → Replace.
Water contamination → Replace and
check the fuel tank.
● Fuel hoses
● Fuel tank
● Fuel hoses through part
● Fuel filler cap
Cracks/damage → Replace.
3-7
INSP
ADJ
FUEL SYSTEM
E
2. Inspect:
● Water separator 1
Water accumulation → Drain.
NOTE:
If need the water draining, remove the drain
plug 2.
Trolling speed check and adjustment
1. Check:
● Trolling speed
Out of specification → Adjust.
Trolling speed:
1,300 ± 50 r/min
Checking steps (with the watercraft in
the water):
● Start the engine and allow it to warm
up for several minutes.
● Attach the engine tachometer to the
spark plug lead.
1
Engine tachometer:
YU-8036-A/90890-06760
● Measure the engine trolling speed.
2. Adjust:
● Trolling speed
Adjustment steps:
● Start the engine and allow it to warm
up for several minutes.
● Attach the engine tachometer to the
spark plug lead.
Engine tachometer:
YU-8036-A/90890-06760
● Turn the throttle stop screw 1 in or
out until the specified trolling speed is
obtain.
3-8
INSP
ADJ
OIL INJECTION SYSTEM/POWER UNIT
OIL INJECTION SYSTEM
Oil line inspection
1. Inspect:
● Oil filter
Contaminants → Clean.
Frays/tears → Replace.
● Rubber seal
Cracks/wear → Replace.
● Oil hoses
● Oil tank
● Oil filler cap
Cracks/damage → Replace.
● Check valve
Malfunction → Replace.
CAUTION:
Do not allow the oil tank to become completely empty. If the oil tank becomes
empty the oil injection pump must be bled
to ensure proper oil flow, otherwise engine
damage may occur. Refer to “OIL PUMP” in
chapter 4.
E
POWER UNIT
Spark plug inspection
1. Inspect:
● Electrodes 1
Damage/wear → Replace.
● Insulator color 2
Distinctly different color → Check the
engine condition.
Color guide:
Medium to light tan color:
Normal
Whitish color:
Lean fuel mixture
Air leak
Incorrect settings
Blackish color:
Overly rich mixture
Electrical malfunction
Excessive oil use
Defective spark plug
2. Clean:
● Spark plug
(with a spark plug cleaner or wire
brush)
3-9
INSP
ADJ
POWER UNIT/ELECTRICAL
3. Measure:
● Spark plug gap a
4. Tighten:
● Spark plug
NOTE:
● Before installing the spark plug, clean the
gasket surface and spark plug surface.
Also, it is suggested to apply a thin film of
anti-seize compound to the spark plug
threads to prevent thread seizure.
● If a torque wrench is not available, a good
estimate of the correct tightening torque
for a new spark plug is to finger tighten a
the spark plug and then tighten it another
1/4 to 1/2 of a turn b.
Out of specification → Regap.
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Spark plug:
T
25 N • m (2.5 kgf • m, 18 ft • lb)
.
R
.
E
ELECTRICAL
Battery inspection
WARNING
Battery electrolyte is dangerous; it contains
sulfuric acid which is poisonous and highly
caustic.
Always follow these preventive measures:
● Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
● Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
● SKIN - Wash with water.
● EYES - Flush with water for 15 minutes
and get immediate medical attention.
3-10
INSP
ADJ
ELECTRICAL
E
Antidote (INTERNAL):
● Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
Batteries generate explosive, hydrogen
gas. Always follow these preventive measures:
● Charge batteries in a well-ventilated area.
● Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
● DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
CAUTION:
● Do not place the battery on its side.
● Before adding electrolyte or recharging,
be sure to remove the battery from the
battery box.
● Make sure that the battery breather hose
is properly connected and is not pinched
or damaged.
1. Remove:
● Band
● Battery negative lead 1
● Battery positive lead 2
● Battery
● Battery breather hose 3
WARNING
● When removing the battery, disconnect
the negative lead first.
● Remove the battery to prevent acid loss
during turning the machine on its side for
the impeller service.
3-11
INSP
ADJ
ELECTRICAL
E
2. Inspect:
● Electrolyte level
Low → Add distilled water.
The electrolyte level should be
between the upper a and lower b
level marks.
Filling steps:
● Remove each filler cap.
● Add distilled water.
● When the electrolyte level reaches the
upper level mark, allow the cell to
stand for 20 minutes. If the electrolyte
level drops, add more distilled water
so the level reaches the upper level
mark.
CAUTION:
Use only distilled water. Other types of
water contain minerals which are harmful
to batteries.
3. Inspect:
● Specific gravity
Out of specification → Charge.
Specific gravity at 20 ˚C (68 ˚F):
1.28
Charging current:
1.9 amps × 10 hrs (68.4 kC)
4. Install:
● Filler caps
CAUTION:
Before installation, rinse off any fluid from
the battery box and battery and make sure
that the battery is dry before installing it.
3-12
INSP
ADJ
ELECTRICAL/JET PUMP UNIT
5. Install:
● Battery breather hose 1
● Battery
● Battery positive lead 2
● Battery negative lead 3 (with termi-
nal extension at battery negative terminal)
● Band
CAUTION:
● Connect the positive lead to the battery
terminal first.
● Make sure the battery leads are con-
nected properly. Reversing the leads can
seriously damage the electrical system.
● Make sure that the battery breather hose is
properly connected and is not obstructed.
● Coat the terminals with a water resistant
grease to minimize terminal corrosion.
E
JET PUMP UNIT
Impeller inspection
1. Check:
● Impeller 1
Damage/wear → Replace.
Nicks/scratches → File or grind.
2. Measure:
● Impeller-to-housing clearance a
Out of specification → Replace.
Max. impeller-to-housing
clearance:
0.6 mm (0.02 in)
Measurement steps:
● Remove the battery leads.
● Remove the intake grate 1 and intake
duct 2.
● Measure the clearance at each impel-
ler blade as shown (a total of three
measurements).
● Install the intake grate and intake duct.
3-13
Bolt:
T
M6: 7 N • m
.
R
.
(0.7 kgf • m, 5.1 ft • lb)
M8: 17 N • m
(1.7 kgf • m, 12 ft • lb)
● Install the battery leads.
INSP
ADJ
1
JET PUMP UNIT/GENERAL
a
E
Water inlet strainer inspection
1. Inspect:
● Water inlet strainer
Contaminants → Clean.
Cracks/damage → Replace.
Inspection steps:
● Remove the water inlet cover 1.
● Inspect the water inlet strainer mesh
a.
● Install the water inlet cover.
1
Bilge strainer inspection
1. Inspect:
● Bilge strainer
Contaminants → Clean.
Cracks/damage → Replace.
Inspection steps:
● Disconnect the bilge strainer 1 from
the bilge strainer holder.
● Inspect the bilge strainer.
GENERAL
Drain plug inspection
1. Inspect:
● Drain plugs
Cracks/damage → Replace.
● O-rings
Cracks/wear → Replace.
● Screw threads
Contaminants → Clean.
3-14
INSP
ADJ
GENERAL
E
Lubrication points
1. Lubricate:
● Throttle cable (handlebar side)
Recommended lubricant:
Rust inhibitor
NOTE:
Before lubricating the throttle cable,
squeeze the throttle lever and remove the
rubber seal 1.
2. Lubricate:
● QSTS control cables (handlebar side)
Recommended lubricant:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
NOTE:
Before lubricating the QSTS control cables,
remove the QSTS cable housing cover.
Spray the rust inhibitor into the outer
cables, and apply grease to the inner
cables.
3. Lubricate:
● Choke cable (handlebar side)
3-15
Recommended lubricant:
Rust inhibitor
INSP
ADJ
GENERAL
E
4. Lubricate:
● Throttle cable (carburetor side)
● Oil pump cable
● QSTS cables (pulley side)
● YPVS cables
Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
3-16
5. Lubricate:
● Nozzle pivot shaft
● Steering cable (nozzle side)
● QSTS cable (nozzle side)
Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
INSP
ADJ
GENERAL
E
6. Lubricate:
● Steering cable
● Steering cable joint
NOTE:
Disconnect the joints and apply a small
amount of grease.
Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
7. Fill:
● Intermediate housing
Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
NOTE:
Fill the intermediate housing with the recommended grease through the grease nipples.
3-17
FUEL
E
CHAPTER 4
FUEL SYSTEM
FUEL COCK AND FUEL FILTER ..................................................................... 4-1
EXPLODED DIAGRAM............................................................................. 4-1
REMOVAL AND INSTALLATION CHART ............................................... 4-1
SERVICE POINTS ..................................................................................... 4-2
Fuel filter inspection ......................................................................... 4-2
Fuel cock inspection.......................................................................... 4-2
OIL TANK ........................................................................................................ 4-3
EXPLODED DIAGRAM............................................................................. 4-3
REMOVAL AND INSTALLATION CHART ............................................... 4-3
SERVICE POINTS ..................................................................................... 4-5
Oil line inspection ............................................................................. 4-5
Oil level sensor inspection ............................................................... 4-5
Oil tank inspection ............................................................................ 4-5
FUEL TANK ..................................................................................................... 4-6
EXPLODED DIAGRAM............................................................................. 4-6
REMOVAL AND INSTALLATION CHART ............................................... 4-6
SERVICE POINTS ..................................................................................... 4-9
Check valve inspection ..................................................................... 4-9
Fuel level sensor inspection............................................................. 4-9
Fuel tank inspection .......................................................................... 4-9
Pipe joint inspection ......................................................................... 4-9
INTAKE SILENCER ....................................................................................... 4-10
EXPLODED DIAGRAM........................................................................... 4-10
REMOVAL AND INSTALLATION CHART ............................................. 4-10
CARBURETOR UNIT..................................................................................... 4-11
EXPLODED DIAGRAM........................................................................... 4-11
REMOVAL AND INSTALLATION CHART ............................................. 4-11
SERVICE POINTS ................................................................................... 4-18
Throttle valve synchronization inspection and adjustment ........ 4-18
Choke cable and throttle cable installation................................... 4-19
Oil pump cable installation ............................................................ 4-19
Carburetor assembly ...................................................................... 4-19
FUEL
CARBURETOR .............................................................................................. 4-20
EXPLODED DIAGRAM........................................................................... 4-20
REMOVAL AND INSTALLATION CHART ............................................. 4-20
SERVICE POINTS ................................................................................... 4-23
Diaphragm inspection .................................................................... 4-23
Accelerator pump body inspection ............................................... 4-23
Arm inspection ................................................................................ 4-23
Regulator body inspection ............................................................. 4-24
Needle valve inspection ................................................................. 4-24
Jet and carburetor body inspection .............................................. 4-24
Carburetor assembly ...................................................................... 4-24
E
1
FUEL PUMP .................................................................................................. 4-25
EXPLODED DIAGRAM........................................................................... 4-25
REMOVAL AND INSTALLATION CHART ............................................. 4-25
SERVICE POINTS ................................................................................... 4-27
Fuel pump inspection ..................................................................... 4-27
Fuel filter inspection ....................................................................... 4-27
OIL PUMP...................................................................................................... 4-28
EXPLODED DIAGRAM........................................................................... 4-28
REMOVAL AND INSTALLATION CHART ............................................. 4-28
SERVICE POINTS ................................................................................... 4-30
Oil pump inspection........................................................................ 4-30
Oil hose inspection ......................................................................... 4-30
Check valve inspection ................................................................... 4-30
Oil pump cable adjustment ............................................................ 4-30
Oil injection pump air bleeding ..................................................... 4-31
2
3
4
5
6
7
8
9
FUEL
FUEL COCK AND FUEL FILTER
FUEL COCK AND FUEL FILTER
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
FUEL COCK AND FUEL FILTER
REMOVAL
1 Screw 1
2 Knob 1
3 Nut 1
4 Fuel cock assembly 1
5 Fuel hose 3
6 Holder 1
7 Fuel filter 1
8 Fuel hose 1
Follow the left “Step” for removal.
Reverse the removal steps for installation.
4-1
FUEL
FUEL COCK AND FUEL FILTER
SERVICE POINTS
Fuel filter inspection
Refer to “FUEL SYSTEM” in chapter 3.
Fuel cock inspection
1. Check:
● Fuel cock
Contaminants → Clean.
Rough movement → Replace.
E
4-2
FUEL
OIL TANK
OIL TANK
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
OIL TANK REMOVAL Follow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT” in chapter 5.
Steering console cover assembly Refer to “STEERING CONSOLE COVER”
in chapter 8.
1 Oil level sensor coupler 1
2 Band 1
3 Nut 1
4 Oil filler neck 1
5 Rubber seal 1
Not reusable
Disconnect the oil filler hose from the oil
filler neck.
4-3
FUEL
OIL TANK
EXPLODED DIAGRAM
E
Step Procedure/Part name Q’ty Service points
6 Breather hose 1
7 Oil hose 1
8 Bolt 2
9 Tank belt 2
10 Oil tank assembly 1
11 Hose clamp 1
12 Oil filler hose 1
13 Oil level sensor 1
Reverse the removal steps for installation.
4-4
FUEL
OIL TANK
E
SERVICE POINTS
Oil line inspection
1. Inspect:
● Oil filter
Contaminants → Clean.
Frays/tears → Replace.
● Rubber seal
Cracks/wear → Replace.
● Oil hoses
● Oil tank
● Oil filler cap
Cracks/damage → Replace.
● Check valve
Malfunction → Replace.
Oil level sensor inspection
Refer to “INDICATION SYSTEM” in
chapter 7.
Oil tank inspection
1. Inspect:
● Oil tank
Cracks/damage → Replace.
4-5
FUEL
FUEL TANK
FUEL TANK
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
FUEL TANK REMOVAL Follow the left “Step” for removal.
Oil tank Refer to “OIL TANK”.
1 Fuel level sensor coupler 1
2 Hose clamp 1 Disconnect the fuel filler hose from the
fuel filler neck.
3 Nut 1
4 Fuel filler neck 1
5 Rubber seal 1
6 Fuel reserve hose 1
4-6
FUEL
FUEL TANK
EXPLODED DIAGRAM
E
Step Procedure/Part name Q’ty Service points
7 Fuel hose 1
8 Fuel return hose 1
9 Fuel tank breather hose 1
10 Fuel tank assembly 1
11 Hose clamp 1
12 Fuel filler hose 1
13 Hose clamp 1
14 Fuel sensor assembly 1
4-7
FUEL
FUEL TANK
EXPLODED DIAGRAM
E
Step Procedure/Part name Q’ty Service points
15 One way valve 1
16 Screw/washer 1/1
17 Filter 1
18 Screw/washer 1/1
19 Sleeve 1
20 Floatation 1
21 Bolt 2
22 Tank belt 2
Reverse the removal steps for installation.
4-8
FUEL
FUEL TANK
E
SERVICE POINTS
A
A
B
Check valve inspection
1. Check:
● Check valve
Faulty → Replace.
B
Checking steps:
● Connect a hose to the end of check
valve “A” and blow into it.
Air should come out from end “B”.
● Connect the hose to the end of check
valve “B” and blow into it.
Air should not come out from end “A”.
Fuel level sensor inspection
Refer to “INDICATION SYSTEM” in
chapter 7.
Fuel tank inspection
1. Inspect:
● Fuel tank
Cracks/damage → Replace.
Pipe joint inspection
1. Inspect:
● Pipe
Contaminants → Clean.
Bends/damage → Replace.
4-9
FUEL
INTAKE SILENCER
INTAKE SILENCER
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
INTAKE SILENCER REMOVAL Follow the left “Step” for removal.
1 Bolt 3
2 Intake silencer cover 1
3 Bolt 4
4 Spark arrester 1
5 Intake silencer 1
6 O-ring 2
Reverse the removal steps for installation.
4-10
FUEL
CARBURETOR UNIT
CARBURETOR UNIT
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
CARBURETOR REMOVAL Follow the left “Step” for removal.
Battery box Refer to “BATTERY BOX” in chapter 8.
Intake silencer Refer to “INTAKE SILENCER”.
1 Bolt 2
2 Thermoswitch 1
3 Clamp/cooling water hose 1/1
4 Grease hose 1
5 Clamp/cooling water hose 1/1 Å For cooling water pilot outlet on
6 Clamp/cooling water hose 1/1 ı For cooling water pilot outlet on port
NOTE:
When removing the carburetor, the
exhaust chamber assembly does not
need to be removed if the engine unit has
already been removed.
starboard side
side
4-11
FUEL
CARBURETOR UNIT
EXPLODED DIAGRAM
E
Step Procedure/Part name Q’ty Service points
7 Hose clamp 2 Slide the outer exhaust joint.
8 Hose clamp 2
9 Floatation 1
10 Water lock band 1
11 Bolt 1
12 Bolt 1
13 Muffler stay 3 1
14 Bolt 4
15 Nut/washer 2/2
4-12
FUEL
CARBURETOR UNIT
EXPLODED DIAGRAM
E
Step Procedure/Part name Q’ty Service points
16 Muffler stay 1 2
17 Bolt 2
18 Hose clamp 2
19 Exhaust chamber assembly 1
20 Rubber joint 1 Slide the water lock to back
21 Outer exhaust joint 1
22 Inner exhaust joint 1
NOTE:
Make sure to remove spark plugs before
removing the muffler stay 1.
4-13
FUEL
CARBURETOR UNIT
EXPLODED DIAGRAM
E
Step Procedure/Part name Q’ty Service points
23 Fuel hose 2 Å suction
ı return
NOTE:
Use the white marks a on the fuel hoses
to distinguish the hose ends.
24 Oil feed hose 2
25 Choke cable 1
26 Throttle cable 1
27 Oil pump cable 1
4-14
FUEL
CARBURETOR UNIT
EXPLODED DIAGRAM
E
Step Procedure/Part name Q’ty Service points
28 Pulse hose 2
29 Bolt 2
30 Bolt 4
31 Carburetor unit 1
32 Gasket 1
33 Dowel pin 2
4-15
Not reusable
Reverse the removal steps for installation.
FUEL
CARBURETOR UNIT
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
CARBURETOR UNIT
SEPARATION
1 Pulse hose 2
2 Fuel hose 4 Å suction
3 Oil feed hose 2
4 Accelerator pump fuel hose 3
5 Throttle link 1
6 Choke link 1
Follow the left “Step” for removal.
ı return
4-16
FUEL
CARBURETOR UNIT
EXPLODED DIAGRAM
E
Step Procedure/Part name Q’ty Service points
7 Bolt 3
8 Cable bracket 1
9 Bolt 4
10 Carburetor 2
11 Gasket 2
12 Carburetor joint 1
13 Bolt/washer 2/2
14 Fuel hose guide 1
4-17
Not reusable
Reverse the removal steps for installation.
FUEL
CARBURETOR UNIT
aa
E
SERVICE POINTS
Throttle valve synchronization inspection
and adjustment
1. Check:
● Throttle valve synchronization
Different clearances → Adjust.
Checking steps:
● Loosen the throttle stop screw 1 until
untouched the screw end from the
throttle lever.
● Check the each throttle valve is fully
closed a.
2. Adjust:
● Throttle valve synchronization
Adjustment steps:
● Loosen the throttle stop screw 1 until
untouched the screw end from the
throttle lever.
● Loosen the screws 2.
NOTE:
Make sure that the throttle valves are in
the fully closed position.
● Tighten the screws 2.
Screw:
2 N • m (0.2 kgf • m, 1.4 ft • lb)
T
.
R
.
● Turn in the throttle stop screw to the
original position.
4-18
FUEL
CARBURETOR UNIT
E
Choke cable and throttle cable installation
1. Install:
● Choke cable 1
● Throttle cable 2
Choke cable guide installation
position a:
13–15 mm (0.51–0.59 in)
Throttle cable guide installation
position a:
18–20 mm (0.71–0.79 in)
2. Adjust:
● Throttle lever free play
● Choke lever operation
Refer to “CONTROL SYSTEM” in
chapter 3.
Oil pump cable installation
1. Adjust:
● Oil pump cable
Refer to “OIL PUMP”.
Carburetor assembly
1. Adjust:
● Trolling speed
Refer to “FUEL SYSTEM” in chapter 3.
4-19
FUEL
CARBURETOR
CARBURETOR
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
CARBURETOR DISASSEMBLY Follow the left “Step” for disassembly.
1 Accelerator pump fuel hose 1 Carburetor #1
2 Screw 4
3 Accelerator pump/carburetor
cover
4 Diaphragm 1
5 Screw 2
6 Regulator body 1
7 Gasket 1
8 Main jet 1
9 Pilot jet 1
1/1 Carburetor #1/carburetor #2
4-20
FUEL
CARBURETOR
EXPLODED DIAGRAM
E
Step Procedure/Part name Q’ty Service points
10 Screw 1
11 Arm 1
12 Arm pin 1
13 Spring 1
14 Screw 1
15 Needle valve seat holder 1
16 Needle valve 1
17 Needle valve seat 1
18 O-ring 1
Reverse the disassembly steps for
assembly.
4-21
FUEL
CARBURETOR
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
ACCELERATOR PUMP
DISASSEMBLY
1 Screw 1
2 Stay 1
3 Spring 1
4 Spring seat 1
5 Screw 4
6 Accelerator pump cover 1
7 Spring 1
8 Diaphragm 1
9 Accelerator pump body 1
Follow the left “Step” for disassembly.
Reverse the disassembly steps for
assembly.
4-22
FUEL
CARBURETOR
E
SERVICE POINTS
NOTE:
Before disassembling the carburetor, make
sure to note the number of times the pilot
screw is turned in from its set position to
the seated position.
CAUTION:
Do not use steel wire for cleaning the jets.
This may enlarge the jet diameters and
seriously affect performance.
Diaphragm inspection
1. Inspect:
● Diaphragm
Damage → Replace.
Accelerator pump body inspection
1. Inspect:
● One way valve
Crack/damage → Replace the acceler-
ator pump body.
● Fuel passage
Clog → Clean or replace.
Arm inspection
1. Inspect:
● Arm 1
Bends/damage → Repair or replace.
2. Measure:
● Arm height a
Arm height:
0–0.2 mm (0–0.008 in)
NOTE:
● Measure the distance between the surface
of the carburetor body b and the top surface of the arm.
● The arm should be resting on the needle
valve, but not compressing it.
4-23
FUEL
CARBURETOR
E
Regulator body inspection
1. Inspect:
● Regulator body
Contaminants → Clean.
Damage → Replace.
● Valve (clear film) 1
Damage → Replace.
Needle valve inspection
1. Inspect:
● Needle valve
● Needle valve seat
Contaminants a → Clean.
Wear b → Replace.
NOTE:
Always replace the needle valve and needle
valve seat as a set.
Jet and carburetor body inspection
1. Inspect:
● Main jet
● Pilot jet
● Carburetor body
Clog/contaminants → Clean.
Damage/wear → Replace.
CAUTION:
Do not use a steel wire to clean the jets.
This may enlarge the jet diameters and
seriously affect performance.
Carburetor assembly
NOTE:
Before assembling the carburetor, make
sure to turn out the pilot screw the same
number of times, as noted before disassembly, from the seated position to the set position.
4-24
1. Adjust:
● Trolling speed
Refer to “FUEL SYSTEM” in chapter 3.
FUEL
FUEL PUMP
FUEL PUMP
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
FUEL PUMP DISASSEMBLY Follow the left “Step” for disassembly.
Carburetors Refer to “CARBURETOR UNIT”.
1 Screw 4
2 Fuel pump cover 1
3 Gasket 1
4 Diaphragm 1
5 O-ring 1
6 Diaphragm body 1
4-25
Not reusable
FUEL
FUEL PUMP
EXPLODED DIAGRAM
E
Step Procedure/Part name Q’ty Service points
7 Rubber diaphragm 1
8 Diaphragm 1
9 Packing 1
10 Fuel filter 1
Reverse the disassembly steps for
assembly.
4-26
FUEL
FUEL PUMP
E
SERVICE POINTS
Fuel pump inspection
1. Inspect:
● Diaphragm
● Rubber diaphragm
● Diaphragm body
Damage → Replace.
Fuel filter inspection
1. Inspect:
● Fuel filter
Clog/contaminants → Clean.
Damage → Replace.
4-27
FUEL
OIL PUMP
OIL PUMP
EXPLODED DIAGRAM
1
E
4
5
2
LT
3
6 × 20 mm
LTLT
572572
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
OIL PUMP REMOVAL Follow the left “Step” for removal.
Exhaust chamber assembly Refer to “CARBURETOR UNIT”.
Oil pump cable and oil feed
hoses
1 Oil return hose 1
2 Oil hose 1
3 Bolt 2
4 Oil pump assembly 1
Refer to “CARBURETOR UNIT”.
NOTE:
When removing the oil pump, the exhaust
chamber assembly does not need to be
removed if the engine unit has already
been removed.
5 Gasket 1
4-28
Not reusable
Reverse the removal steps for installation.
FUEL
OIL PUMP
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
OIL PUMP HOSES AND CABLE
REMOVAL
1 Air bleed screw 1
2 Gasket 1
3 Oil feed hose 1 2
4 Check valve 2
5 Oil feed hose 2 2
6 Hose joint 1
7 Oil return hose 2
8 Oil pump cable 1
9 Oil pump 1
Follow the left “Step” for removal.
Reverse the removal steps for installation.
4-29
FUEL
OIL PUMP
E
SERVICE POINTS
Oil pump inspection
1. Inspect:
● Oil pump
Contaminants → Clean.
Damage/wear → Replace.
● Oil pump joint piece
Damage/wear → Replace.
Oil hose inspection
1. Inspect:
● Oil hose
Cracks/damage → Replace.
CAUTION:
If the oil feed hoses are not full of oil, fill
them up.
Check valve inspection
1. Check:
● Check valve
Faulty → Replace.
Checking steps:
● Connect a hose to the end of check
valve “A” and blow into it.
Air should come out from end “B”.
● Connect the hose to the end of check
valve “B” and blow into it.
Air should not come out from end “A”.
Oil pump cable adjustment
1. Check:
● Oil pump lever position
Incorrect → Adjust.
4-30
Checking steps:
● Fully close the carburetor throttle
valves.
● Check that the mark a on the oil pump
lever is aligned with the mark b on the
oil pump body.
FUEL
1
2
OIL PUMP
E
2. Adjust:
● Oil pump cable
Adjustment steps:
● Loosen the locknut 1 and the adjust-
ing nut 2.
● Fully close the carburetor throttle
valves.
● Adjust the oil pump cable so that the
mark a on the oil pump lever is
aligned with the mark b on the oil
pump body.
● Tighten the adjusting nut and locknut.
1
Oil injection pump air bleeding
1. Bleed:
● Air
Air bleeding steps:
● Place rags around the air bleed screw
1 to catch any oil that might spill.
● Fill the oil tank with the recommended
oil.
NOTE:
If the oil pump is replaced or the oil suction hose is removed, bleed air from the
oil suction hose by removing it from the
oil pump.
After bleeding the air, reconnect the
hose with a locking tie.
Recommended engine oil:
YAMALUBE 2-W or an
equivalent TC-W3 certified
outboard oil
4-31
● Loosen the air bleed screw 1 two full
turns and make sure that both the oil
and air bubbles flow out.
● When there are no air bubbles left,
tighten the air bleed screw.
● Wipe up any spilt oil.
FUEL
OIL PUMP
E
Air bleed screw:
5 N • m (0.5 kgf • m, 3.6 ft • lb)
T
.
R
.
CAUTION:
Do not run the engine if oil does not
flow out of the air bleed screw. Inspect
the oil pump hoses for proper routing
and make sure there are no restrictions
in the line.
4-32
POWR
ENGINE UNIT ................................................................................................. 5-1
EXHAUST CHAMBER ASSEMBLY................................................................ 5-6
EXHAUST CHAMBER JOINT....................................................................... 5-10
E
CHAPTER 5
POWER UNIT
EXPLODED DIAGRAM............................................................................. 5-1
REMOVAL AND INSTALLATION CHART ............................................... 5-1
SERVICE POINTS ..................................................................................... 5-5
Shim removal .................................................................................... 5-5
Engine mount inspection ................................................................. 5-5
Coupling clearance inspection......................................................... 5-5
EXPLODED DIAGRAM............................................................................. 5-6
REMOVAL AND INSTALLATION CHART ............................................... 5-6
EXPLODED DIAGRAM........................................................................... 5-10
REMOVAL AND INSTALLATION CHART ............................................. 5-10
EXHAUST MANIFOLD ................................................................................. 5-12
EXPLODED DIAGRAM........................................................................... 5-12
REMOVAL AND INSTALLATION CHART ............................................. 5-12
REED VALVES .............................................................................................. 5-13
EXPLODED DIAGRAM........................................................................... 5-13
REMOVAL AND INSTALLATION CHART ............................................. 5-13
SERVICE POINTS ................................................................................... 5-14
Reed valve inspection..................................................................... 5-14
YPVS ............................................................................................................. 5-15
EXPLODED DIAGRAM........................................................................... 5-15
REMOVAL AND INSTALLATION CHART ............................................. 5-15
SERVICE POINTS ................................................................................... 5-17
YPVS valve inspection .................................................................... 5-17
YPVS valve installation................................................................... 5-17
CYLINDER HEAD .......................................................................................... 5-18
EXPLODED DIAGRAM........................................................................... 5-18
REMOVAL AND INSTALLATION CHART ............................................ 5-18
SERVICE POINTS ................................................................................... 5-19
Cylinder head inspection................................................................ 5-19
POWR
CYLINDERS................................................................................................... 5-20
E
EXPLODED DIAGRAM........................................................................... 5-20
REMOVAL AND INSTALLATION CHART ............................................. 5-20
SERVICE POINTS ................................................................................... 5-21
Cylinder inspection ......................................................................... 5-21
PISTONS ....................................................................................................... 5-22
EXPLODED DIAGRAM........................................................................... 5-22
REMOVAL AND INSTALLATION CHART ............................................. 5-22
SERVICE POINTS ................................................................................... 5-24
Piston pin clip removal and installation........................................ 5-24
Piston inspection............................................................................. 5-24
Cylinder and piston combination .................................................. 5-25
Piston ring inspection ..................................................................... 5-25
Piston pin and bearing inspection ................................................. 5-26
STARTER MOTOR........................................................................................ 5-28
EXPLODED DIAGRAM........................................................................... 5-28
REMOVAL AND INSTALLATION CHART ............................................ 5-28
FLYWHEEL MAGNETO ................................................................................ 5-29
EXPLODED DIAGRAM........................................................................... 5-29
REMOVAL AND INSTALLATION CHART ............................................. 5-29
SERVICE POINTS ................................................................................... 5-34
Drive coupling removal and installation ....................................... 5-34
Flywheel magneto removal and installation ................................ 5-34
Drive coupling inspection............................................................... 5-35
Flywheel magneto inspection ........................................................ 5-35
Starter clutch assembly inspection ............................................... 5-35
1
2
3
4
5
CRANKCASE................................................................................................. 5-36
EXPLODED DIAGRAM........................................................................... 5-36
REMOVAL AND INSTALLATION CHART ............................................. 5-36
SERVICE POINTS ................................................................................... 5-38
Crankcase inspection ...................................................................... 5-38
Crankcase installation..................................................................... 5-38
CRANKSHAFT............................................................................................... 5-39
EXPLODED DIAGRAM........................................................................... 5-39
REMOVAL AND INSTALLATION CHART ............................................. 5-39
SERVICE POINTS ................................................................................... 5-40
Crankshaft inspection ..................................................................... 5-40
6
7
8
9
POWR
ENGINE UNIT
ENGINE UNIT
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
ENGINE UNIT REMOVAL Follow the left “Step” for removal.
Battery box Refer to “BATTERY BOX” in chapter 8.
YPVS cables and YPVS
servomotor
Intake silencer Refer to “INTAKE SILENCER” in
Choke cable, throttle cable and
fuel hoses
1 Coupler 3
2 Band 6
3 Clamp/Cooling water hose 1
Refer to “YPVS SERVOMOTOR” in
chapter 7.
chapter 4.
Refer to “CARBURETOR UNIT” in
chapter 4.
5-1
POWR
ENGINE UNIT
EXPLODED DIAGRAM
E
Step Procedure/Part name Q’ty Service points
4 Grease hose 1
5 Clamp/cooling water hose 1/1
6 Clamp/cooling water hose 1/1 Å For cooling water pilot outlet on
starboard side
7 Clamp/cooling water hose 1/1 ı For cooling water pilot outlet on port
side
8 Oil hose 1
9 Oil return hose 1
5-2
POWR
ENGINE UNIT
EXPLODED DIAGRAM
E
Step Procedure/Part name Q’ty Service points
10 Bolt/collar 1/1
11 Coupling cover 1
12 Floatation 1
13 Water lock band 1
14 Hose clamp 2
15 Bolt/washer 4/4
NOTE:
● Before removing the engine unit, fix the
choke valves to the choke link with a
plastic band, etc. to the fully closed
position.
● When lifting the engine unit, hook the
hoister on the bow side of muffler stay
1.
● Lift the engine unit carefully trying not
hit it on the deck.
5-3
POWR
ENGINE UNIT
EXPLODED DIAGRAM
E
Step Procedure/Part name Q’ty Service points
16 Shim *
17 Engine unit 1
18 Rubber joint 1 Slide the water lock to back.
Reverse the removal steps for installation.
*: As required
5-4
POWR
ENGINE UNIT
E
SERVICE POINTS
Shim removal
1. Remove:
● Shims
NOTE:
To ease reassembly and coupling alignment, remove the shims and organize them
in their respective groups (e.g., front right,
rear left) prior to removing the mounting
bolts.
Engine mount inspection
1. Inspect:
● Engine mounts
Cracks/damage → Replace.
Coupling clearance inspection
1. Measure:
● Clearance a
● Clearance b
(with the rubber damper)
Out of specification → Adjust.
NOTE:
Measure the clearances with a straightedge
and thickness gauge.
Clearance a:
0–0.5 mm (0–0.020 in)
Clearance b:
2–4 mm (0.079–0.157 in)
2. Adjust:
● Clearance a and b
Adjustment steps:
● Adjust the clearance a by adding or
removing shims.
● Adjust the clearance b by moving the
engine unit position.
5-5
POWR
EXHAUST CHAMBER ASSEMBLY
EXHAUST CHAMBER ASSEMBLY
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
EXHAUST CHAMBER
ASSEMBLY REMOVAL
Engine unit Refer to “ENGINE UNIT”.
1 Bolt 2
2 Thermoswitch 1
3 Hose clamp 2 Slide the outer exhaust joint.
4 Hose clamp 2
5 Bolt 1
6 Bolt 1
7 Muffler stay 3 1
8 Bolt 4
Follow the left “Step” for removal.
5-6
POWR
EXHAUST CHAMBER ASSEMBLY
EXPLODED DIAGRAM
E
Step Procedure/Part name Q’ty Service points
9 Nut/washer 2/2
10 Muffler stay 1 2
11 Bolt 2
12 Exhaust chamber assembly 1
13 Outer exhaust joint 1
14 Inner exhaust joint 1
NOTE:
Make sure to remove spark plugs before
removing the muffler stay 1.
Reverse the removal steps for installation.
5-7
POWR
EXHAUST CHAMBER ASSEMBLY
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
EXHAUST CHAMBER
DISASSEMBLY
1 Nut/washer 1/1
2 Bolt 3
3 Nut/washer 2/2
4 Exhaust chamber 1
5 Gasket 1
6 Pin 2
Follow the left “Step” for disassembly.
Not reusable
5-8
POWR
EXHAUST CHAMBER ASSEMBLY
EXPLODED DIAGRAM
E
Step Procedure/Part name Q’ty Service points
7 Muffler 1
8 Screw 3
9 Plate 1
10 Gasket 1
Not reusable
Reverse the disassembly steps for
assembly.
5-9
POWR
EXHAUST CHAMBER JOINT
EXHAUST CHAMBER JOINT
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
EXHAUST CHAMBER JOINT
REMOVAL
Exhaust chamber assembly Refer to “EXHAUST CHAMBER
1 Clamp/cooling water hose 2/1 a white mark
2 Bolt 2
3 Bolt 1
4 Muffler stay 1
5 Bolt 1
Follow the left “Step” for removal.
ASSEMBLY”.
5-10
POWR
EXHAUST CHAMBER JOINT
EXPLODED DIAGRAM
E
Step Procedure/Part name Q’ty Service points
6 Bolt 2
7 Bolt 2
8 Exhaust chamber joint 1
9 Gasket 1
10 Pin 2
5-11
Not reusable
Reverse the removal steps for installation.
POWR
EXHAUST MANIFOLD
EXHAUST MANIFOLD
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
EXHAUST MANIFOLD REMOVAL Follow the left “Step” for removal.
Exhaust chamber joint Refer to “EXHAUST CHAMBER JOINT”.
1 Bolt 4
2 Bolt 4
3 Wire harness bracket 2
4 Exhaust manifold 1
5 Gasket 1
6 Pin 2
7 Clamp/cooling water hose 2/2
5-12
Not reusable
Reverse the removal steps for installation.
POWR
REED VALVES
REED VALVES
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
REED VALVE REMOVAL Follow the left “Step” for removal.
Carburetor unit Refer to “CARBURETOR UNIT” in
chapter 4.
1 Bolt 12
2 Reed valve plate 1
3 Reed valve assembly 2
4 Screw 16
5 Valve stopper 4
6 Reed valve 4
NOTE:
Tighten the bolts in the proper sequence
as shown.
Reverse the removal steps for installation.
5-13
POWR
REED VALVES
E
SERVICE POINTS
Reed valve inspection
1. Inspect:
● Reed valves
Cracks/damage → Replace.
2. Measure:
● Valve bending a
Out of specification → Replace.
Max. valve bending:
0.2 mm (0.01 in)
3. Measure:
● Valve stopper height b
Out of specification → Adjust or
replace.
Valve stopper height:
10.8–11.4 mm (0.43–0.45 in)
5-14
POWR
YPVS
YPVS
EXPLODED DIAGRAM
E
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
YPVS REMOVAL Follow the left “Step” for removal.
Exhaust manifold Refer to “EXHAUST MANIFOLD”.
1 Bolt 8
2 YPVS valve cover 2
3 Gasket 2
4 Spacer 1
5 Link joint/cover 1/1
6 Circlip 3
7 Washer 3
5-15
Not reusable
Not reusable
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