Yamaha GP800R Service Manual

WaveRunner

GP800R

SERVICEMANUAL

*LIT186160226*

LIT-18616-02-26

F0W-28197-1A-11

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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 → Replace.

To assist you in finding your way through this manual, the section title and major heading is given at the top of every page.

ILLUSTRATIONS

The illustrations within this service manual represent all of the designated models.

CROSS REFERENCES

The cross references have been kept to a minimum. Cross references will direct you to the appropriate section or chapter.

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IMPORTANT INFORMATION

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

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

WARNING

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

CAUTION:

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

NOTE:

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

IMPORTANT:

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

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HOW TO USE THIS MANUAL

1To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

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

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

4A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

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

Example:
Bolt or screw size	10 × 25 mm : M10 (D) × 25 mm (L)

D

L

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

12

	GEN				SPEC
	INFO

34

	INSP	FUEL
	ADJ

56

POWR JET PUMP

78

ELEC

HULL

– +

HOOD

90

TRBL

ANLS

AB

CD

T .

R .

EF

E

GH

A

M

IJ

GM

4

KL

LT	LT
271	242

MN

LT	SSLT

572

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A50001-1-4

SYMBOLS

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

1 General Information

2 Specifications

3 Periodic Inspection and Adjustment

4 Fuel System

5 Power Unit

6 Jet Pump Unit

7 Electrical System

8 Hull and Hood

9 Trouble analysis

Symbols 0 to E indicate specific data:

0 Special tool

A Specified liquid

B Specified engine speed C Specified torque

D Specified measurement

ESpecified electrical value

[Resistance (Ω), Voltage (V), Electric current (A)]

Symbol F to H in an exploded diagram indicate the grade of lubricant and the location of lubrication point:

FApply YAMALUBE 2-W oil or TC-W3 cirtified outboard oil

GApply water resistant grease

(Yamaha grease A, Yamaha marine grease)

H Apply molybdenum disulfide grease

Symbols I to N in an exploded diagram indicate the grade of the sealing or locking agent, and the location of the application point:

I Apply Gasket Maker®

JApply Yamabond #4 (Yamaha bond number 4)

K Apply LOCTITE® No. 271 (Red LOCTITE) L Apply LOCTITE® No. 242 (Blue LOCTITE) M Apply LOCTITE® No. 572

N Apply silicone sealant

NOTE:

In this manual, the above symbols may not be used in every case.

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A30000-0

INDEX

GENERAL INFORMATION

1

INFOGEN

SPECIFICATIONS

2

SPEC

PERIODIC INSPECTION AND

3

ADJUSTMENT

INSPADJ

FUEL SYSTEM

4

FUEL

POWER UNIT

5

POWR

JET PUMP UNIT

6

PUMPJET

7

– +

ELECTRICAL SYSTEM

ELEC

HULL AND HOOD

8

HOODHULL

TROUBLE ANALYSIS	9
ANLSTRBL

	GEN
	INFO			E
				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
SAFETY WHILE WORKING ......................................................................	1-2
FIRE PREVENTION...................................................................................	1-2
VENTILATION...........................................................................................	1-2
SELF-PROTECTION..................................................................................	1-2
OILS, GREASES AND SEALING FLUIDS................................................	1-2
GOOD WORKING PRACTICES................................................................	1-3
DISASSEMBLY AND ASSEMBLY...........................................................	1-4
SPECIAL TOOLS.............................................................................................	1-5
MEASURING ............................................................................................	1-5
REMOVAL AND INSTALLATION ............................................................	1-6

1

2

3

4

5

6

7

8

9

GEN INFO

IDENTIFICATION NUMBERS

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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–

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

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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.

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

E

Under normal conditions of use there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all-important, and by adopting good safety practises any risk is minimized. A summary of the most important precautions is as follows:

1.While working, maintain good standards of personal and industrial hygiene.

2.Clothing which has become contaminated with lubricants should be changed as soon as practicable and laundered before further use.

3.Avoid skin contact with lubricants (e.g., do not place a soiled rag in your pocket).

4.Hands and any other part of the body which have been in contact with lubricants or lubricant-contaminated clothing should be thoroughly washed with hot water and soap as soon as practicable.

5.To protect the skin, the application of a suitable barrier cream to the hands before working is recommended.

6.A supply of clean lint-free cloths should be available for wiping purposes.

GOOD WORKING PRACTICES

1.The right tools

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

2.Tightening torque

Follow the tightening torque instructions. When tightening bolts, nuts and screws, tighten the larger sizes first and tighten inner-positioned fixings before outer-positioned ones.

1-3

GEN INFO

SAFETY WHILE WORKING

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3.Non-reusable items

Always use new gaskets, packings, O- rings, oil seals, split-pins, circlips, etc., on reassembly.

DISASSEMBLY AND ASSEMBLY

1.Clean parts with compressed air when disassembling.

2.Oil the contact surfaces of moving parts during assembly.

3.After assembly, check that moving parts operate normally.

4.Install bearings with the manufacturer’s markings on the side exposed to view and liberally oil the bearings.

CAUTION:

Do not spin bearings with compressed air because this will damage their surfaces.

5.When installing oil seals, apply a light coat of water-resistant grease to the outside diameter.

1-4

GEN INFO

SPECIAL TOOLS

SPECIAL TOOLS

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1 YU-8036-A

90890-06760

2 YU-03097	90890-01252
YU-01256

3 YU-03112	4 YU-03017
90890-03112	90890-06759

5 YU-33223

90890-03160

6 J-39299

90890-06752

7 YU-39991	8 YW-06779
90890-03169	90890-06779

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

1Engine tachometer P/N. YU-8036-A

90890-06760

2 Dial gauge and stand P/N. YU-03097, YU-01256

90890-01252

3Pocket tester P/N. YU-03112

90890-03112

4 Cylinder gauge set P/N. YU-03017

90890-06759

5Compression gauge P/N. YU-33223

90890-03160

6Digital tester P/N. J-39299

90890-06752

7Peak voltage adapter P/N. YU-39991

90890-03169

8Peak voltage test harness P/N. YW-06779

90890-06779

9Spark gap tester P/N. YM-34487

90890-06754

9 YM-34487

90890-06754

1-5

	GEN				SPECIAL TOOLS
	INFO							E
							REMOVAL AND INSTALLATION
	1 YW-06551				2 YW-06550	90890-06550
							1	Coupler wrench
			90890-06551					P/N. YW-06551
								90890-06551
							2	Flywheel holder
								P/N. YW-06550
								90890-06550
	3 YB-06117		90890-06521				3	Flywheel puller
								P/N. YB-06117
								90890-06521
							4	Drive shaft holder (impeller)
								P/N. YB-06151
								90890-06519
	4 YB-06151		90890-06519 5 YB-06096				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)
	6 90890-06501		7 90890-06535					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
	8 90890-06536		9 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
	0 90890-06652				A YB-06112	90890-06614		90890-06614, 90890-06653
							B	Ball bearing attachment
					YB-06196	90890-06653
								(jet pump oil seal)
								P/N. YB-06156
								90890-06634
							C Driver rod
	B YB-06156 90890-06634							(intermediate shaft and jet pump)
								P/N. YB-06071
								90890-06606
							D Bearing inner/outer race attachment
								(jet pump bearing)
	C YB-06071		90890-06606 D YB-34474					P/N. YB-34474
							E Shaft holder (intermediate shaft)
								P/N. YB-06552
								90890-06552
							F Bearing outer race attachment
	E YB-06552				F YB-06016 90890-06626			(intermediate shaft)
	90890-06552							P/N. YB-06016
								90890-06626

1-6

	SPEC				E
				CHAPTER 2
				SPECIFICATIONS
	GENERAL SPECIFICATIONS..........................................................................				2-1
	MAINTENANCE SPECIFICATIONS................................................................				2-3
		ENGINE.....................................................................................................			2-3
		JET PUMP UNIT.......................................................................................			2-4
		HULL AND HOOD ....................................................................................			2-4
		ELECTRICAL .............................................................................................			2-5
	TIGHTENING TORQUES................................................................................				2-7
		SPECIFIED TORQUES..............................................................................			2-7
		GENERAL TORQUE ...............................................................................			2-10
	CABLE AND HOSE ROUTING......................................................................				2-11

1

2

3

4

5

6

7

8

9

SPEC

GENERAL SPECIFICATIONS

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GENERAL SPECIFICATIONS

	Item	Unit	Model
			GP800R
	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,	49 (12.9, 10.8)
		lmp gal/h)
	Cruising range	h	1.2
	ENGINE
	Engine type		2-stroke
	Number of cylinders		2
	Displacement	cm3 (cu. in)	784 (47.8)
	Bore × stroke	mm (in)	80.0 × 78.0 (3.15 × 3.07)
	Compression ratio		6.6:1
	Intake system		Reed valve
	Carburetor model		BN44 (Mikuni) × 2
	(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		BR8ES (NGK)
	(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

2-1

SPEC

GENERAL SPECIFICATIONS

E

	Item	Unit	Model
			GP800R
	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		30:1
	(wide open throttle)
	Fuel tank capacity	R(US gal,	60 (15.9, 13.2)
		Imp gal)
	Fuel tank reserve capacity	R(US gal,	10 (2.6, 2.2)
		Imp gal)
	Oil tank capacity	R(US gal,	5.5 (1.45, 1.21)
		Imp gal)

PON*: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2 RON*: Research Octane Number

2-2

	SPEC			MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

ENGINE

E

	Item	Unit	Model
			GP800R
	CYLINDER HEAD
	Warpage limit	mm (in)	0.1 (0.004)
	Compression pressure*1	kPa (kg/cm2)	560 (5.6)
	CYLINDERS
	Bore size	mm (in)	80.000–80.018 (3.1496–3.1503)
	Taper limit	mm (in)	0.08 (0.003)
	Out-of-round limit	mm (in)	0.05 (0.002)
	Wear limit	mm (in)	Original cylinder bore + 0.04 (0.0016)
	PISTONS
	Diameter	mm (in)	Red: 79.899–79.902 (3.1456–3.1457)
			Orange: 79.903–79.906 (3.1458–3.1459)
			Green: 79.907–79.910 (3.1459–3.1461)
			Purple: 79.911–79.914 (3.1461–3.1462)
	Measuring point*	mm (in)	22 (0.87)
	Piston-to-cylinder clearance	mm (in)	0.100–0.105 (0.0039–0.0041)
	Wear limit	mm (in)	Cylinder bore – 0.105 (0.0041)
	Piston pin bore inside	mm (in)	22.004–22.025 (0.8663–0.8671)
	diameter
	PISTON RINGS
	Top
	Type		Keystone
	Dimensions (B)	mm (in)	1.2 (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)
	2nd*2
	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: 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	Model
			GP800R
	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	mm (in)	2.0 (0.08)
	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)
	JET PUMP UNIT
	Item	Unit	Model
			GP800R
	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)
	HULL AND HOOD
	Item	Unit	Model
			GP800R
	FREE PLAY
	YPVS cable slack	mm (in)	0.5–1.5 (0.02–0.06)
	Throttle lever free play	mm (in)	4–7 (0.16–0.28)

2-4

	SPEC				MAINTENANCE SPECIFICATIONS			E
	ELECTRICAL
		Item				Unit	Model
							GP800R
	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)

Cranking 1: unloaded

Cranking 2: loaded

2-5

SPEC

MAINTENANCE SPECIFICATIONS

E

	Item	Unit	Model
			GP800R
	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

2-6

SPEC

TIGHTENING TORQUES

E

TIGHTENING TORQUES

SPECIFIED TORQUES

	Part to tightened	Part name	Thread	Q’ty	Tightening torque			Remarks
			size		N•m	kgf•m	ft•lb

ENGINE UNIT

	Engine unit – engine mount		Bolt	M8	4	17	1.7	12	LT	572
		1st	Bolt	M10	2	2	0.2	1.4
		4th				51	5.1	37
		2nd	Bolt	M10	4	2	0.2	1.4
		6th				39	3.9	28
	Exhaust chamber
		3rd	Nut	M10	2	2	0.2	1.4
	assembly – muffler stay 1								LT	271
		5th				51	5.1	37
	– muffler stay 3
		7th				2	0.2	1.4
			Bolt	M10	1
		9th				49	4.9	35
		8th	Bolt	M10	1	2	0.2	1.4
		10th				49	4.9	35
		1st	Nut	M8	2	15	1.5	11
		2nd				39	3.9	28
	Exhaust chamber –	1st	Bolt	M8	3	15	1.5	11	LT	271
	muffler	2nd				33	3.3	24
		1st	Nut	M10	1	15	1.5	11
		2nd				51	5.1	37
	Exhaust chamber joint –	1st	Bolt	M8	5	17	1.7	12	LT	271
	exhaust manifold	2nd				34	3.4	24
		1st	Bolt	M10	1	2	0.2	1.4	LT	271
	Exhaust chamber joint –	3rd				49	4.9	35
	muffler stay	2nd	Bolt	M8	2	2	0.2	1.4	LT	271
		4th				37	3.7	27
	Exhaust manifold –	1st	Bolt	M10	8	23	2.3	17	LT	271
	cylinder	2nd				51	5.1	37
	Reed valve – reed valve seat		Screw	M3	16	0.8	0.08	0.58	LT	242

	YPVS cable bracket – YPVS cover		Bolt	M6	2	10	1.0	7.2	LT		572
	– cylinder
	YPVS cover – cylinder		Bolt	M6	6	10	1.0	7.2	LT		572
	YPVS valve assembly – cylinder		Bolt	M5	2	4	0.4	2.9	LT		271
	YPVS valve lever – shaft		Bolt	M4	2	3	0.3	2.2	LT		242
	Spark plug – cylinder head		Spark plug	M14	2	25	2.5	18
	Cylinder head – cylinder	1st	Bolt	M8	10	15	1.5	11	LT		572
		2nd				37	3.7	27
	Cylinder – crankcase	1st	Bolt	M10	8	22	2.2	16	LT		572
		2nd				39	3.9	28
	Starter motor lead – starter		Nut	M6	1	5	0.5	3.6
	motor
	Flywheel magneto – crankshaft		Bolt	M10	1	74	7.4	53			E
	assembly

2-7

SPEC

TIGHTENING TORQUES

E

Part to tightened				Part name		Thread
						size
Drive coupling – crankshaft				Drive		M27
assembly				coupling
		1st
Generator cover –				Bolt		M8
crankcase		2nd
Pickup coil – generator cover				Bolt		M5
Cable holder – generator cover				Bolt		M6
Stator coil – generator cover				Bolt		M6
Lower crankcase – upper		1st				M8
				Bolt
		2nd
crankcase
						M6
		1st
Mount bracket –				Bolt		M8
crankcase		2nd
JET PUMP UNIT
Steering cable joint – nozzle				Nut		M6
deflector
Ride plate – hull				Bolt		M8
Intake duct – hull				Bolt		M8
Intake grate – hull				Bolt		M6
Speed sensor – ride plate				Screw		M5
Nozzle ring – nozzle				Bolt		M8
Nozzle deflector – nozzle ring				Bolt		M8
Water inlet cover – water inlet				Bolt		M6
strainer – impeller duct
Drive shaft nut – drive shaft				Nut		M16
Impeller (left-hand threads) –				Impeller		M22
drive shaft
Transom plate – hull				Nut		M10
Bilge strainer holder – bulkhead				Screw		M5
Intermediate housing – bulkhead				Bolt		M8
Driven coupling – shaft				Driven		M27
				coupling
Grease nipple – intermediate				Nipple		—
housing
HULL AND HOOD
Handlebar cover – handlebar				Screw		M6
cover stay
Handlebar cover stay – steering				Screw		M6
column
Upper handlebar holder/lower				Bolt		M8
handle holder – steering column
QSTS converter – hull				Nut		M6
QSTS cable 1, 2 locknut				Nut		M8
Throttle lever assembly –				Screw		M5
handlebar

2-8

Q’ty	Tightening torque					Remarks
	N•m	kgf•m		ft•lb
1	36	3.6		25		LT	572
8	15	1.5		11		LT	271
	27	2.7		19
2	5	0.5		3.6		LT	242
2	14	1.4		10		LT	242
3	14	1.4		10		LT	242
13	15	1.5		11
	27	2.7		19		LT	572
7	11	1.1		8.0
6	15	1.5		11		LT	271
	27	2.7		19
1		0.7		5.1		LT	242
	7
4	17	1.7		12		LT	572
4	17	1.7		12
						LT	572
4	7	0.7		5.1
						LT	572
4	4	0.4		2.9
						LT	242
2	15	1.5		11		LT	271
2	15	1.5		11		LT	271
4	7	0.7		5.1		LT	572
1	74	7.4		53
1	18	1.8		13		LT	572
4	26	2.6		19
1	4	0.4		2.9
3	17	1.7		12		LT	572
1	36	3.6		25		LT	572
1	5	0.5		3.6		LT	572
4		0.11		0.8
	1.1
4	2.9	0.29		2.1
4	16	1.6		11
2	5	0.5		3.6
2	16	1.6		11
2	3	0.3		2.2

SPEC

TIGHTENING TORQUES

E

Part to tightened

Handlebar switch assembly – handlebar

QSTS grip assembly – handlebar

Grip end – handlebar

Choke lever assembly – handlebar

QSTS cable housing – cover

Plate/steering column assembly

– deck

Steering column assembly – deck

Steering arm – steering column

Steering cable ball joint – steering arm

Handlebar stopper – steering column housing

QSTS cable locknut (nozzle ring side)

QSTS cable – hull

QSTS cable end – pin – QSTS converter

Steering cable locknut (nozzle deflector side)

Steering cable – hull

Steering cable holder – bracket

Speed sensor lead – hull

Hinge assembly – front hood

Wind shield – front hood

Hood lock – front hood

Hinge assembly – deck

Steering console cover assembly

– deck

Multifunction meter – holder

Steering console cover – side cover

Steering console cover – glove compartment

Steering cable bracket – deck

Buzzer bracket – deck – steering cable bracket

Hood lock assembly – deck

Seat lock assembly – seat

Bracket/deck – notch

Bracket/deck – hand grip

	Part name	Thread	Q’ty	Tightening torque			Remarks
		size		N•m	kgf•m	ft•lb
	Screw	M5	2	3	0.3	2.2
	Screw	M6	1	3	0.3	2.2
	Bolt	M5	2	1	0.1	0.7
	Screw	M5	2	3	0.3	2.2
	Screw	M4	1	1	0.1	0.7
	Nut	M8	2	16	1.6	11
	Nut	M8	2	16	1.6	11
	Nut	M8	1	16	1.6	11
	Nut	M6	1	5	0.5	3.6
	Nut	M10	1	26	2.6	19
	Nut	M5	1	3	0.3	2.2
	Nut	—	1	6	0.6	4.3
	Nut	M6	1	4	0.4	2.9
	Nut	M6	1	6	0.6	4.3
	Nut	—	1	6	0.6	4.3
	Bolt	M6	1	6	0.6	4.3
	Nut	—	1	6	0.6	4.3
	Bolt	M6	2	12	1.2	8.7
	Screw	M5	8	1	0.1	0.7
	Bolt	M6	2	5	0.5	3.6
	Nut	M8	2	16	1.6	11
	Nut	M6	2	5	0.5	3.6
	Bolt	M6	4	3	0.3	2.2
	Screw	M5	2	2	0.2	1.4
	Nut	M8	2	16	1.6	11
	Nut	M5	2	2	0.2	1.4
	Screw	M6	4	3	0.3	2.2
	Screw	M5	4	1	0.1	0.7
	Bolt	M6	1	6	0.6	4.3
	Bolt	M6	2	6	0.6	4.3
	Nut	M6	2	6	0.6	4.3
	Bolt	M6	2	6	0.6	4.3	LT 572
	Nut	M10	1	26	2.6	19
	Bolt	M8	2	5	0.5	3.6

2-9

SPEC

TIGHTENING TORQUES

E

	Part to tightened	Part name	Thread	Q’ty	Tightening torque
			size		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	Bolt	M6	1	6	0.6	4.3
	terminal
	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

Remarks

LT

572

		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.

2-10

	SPEC			CABLE AND HOSE ROUTING

CABLE AND HOSE ROUTING

E

		2						A
F
					A	2	1	B
			C B
	L	K	K		E
	20˚	E		D		D
							2	2
		E			E			C
					F
	K
B					F			2
L			K
	A	K						3
9
								D-D
0		J	J	G	G
	J	J	J					4
K-K	I
9		I	I	H	H			E-E
0
A
J-J	H					C
	G
9						D	5
0						E	6
						F	7
I-I								F-F
	9
8								4
H-H								G-G

1 Fuel filter	9 Speed sensor lead	G Battery breather hose
2 Fuel tank breather hose	0 Electrical box lead	H Battery positive lead
3 Fuel hose	A YPVS cables	I Starter motor lead
4 Cooling water hose	B Cooling water pilot outlet	J Generator lead
5 Choke cable	C Battery negative lead	K YPVS servomotor
6 Throttle cable	D Battery
7 Oil return hose	E Steering cable
8 Bilge hose	F QSTS cable
	2-11

SPEC

CABLE AND HOSE ROUTING

E

D

			1	2	3
		D
	E	E	D		E
A	B	C
	H
A	I
	2 J K
	B			L
				M
				5

J

I

F

C

J

E A F

G 7 4

0 A	8	4
E		G-G
A
F		9
G

H	G	G
	H

J-J
F E D C B		7	6	5	4
I	H-H		F
1 Oil delivery hose	9 Bilge hoses	F To thermoswitch
2 Fuel return hose	0 To multifunction meter	G Battery negative lead
3 Fuel suction hose	A To stator assembly	H Buzzer lead
4 Speed sensor lead	B To cylinder #1	I Choke cable
5 QSTS cable	C To cylinder #2	J YPVS servomotor
6 Cooling water hose	D To battery positive terminal	K YPVS cables
7 Steering cable	E To starter motor positive	L Battery positive lead
8 Flushing hose	terminal	M Battery breather hose
	2-12