Yamaha GP800R Service Manual

WaveRunner

GP800R

SERVICE MANUAL

*LIT186160226*

F0W-28197-1A-11LIT-18616-02-26

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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 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

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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

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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