Yamaha VX700 Service Manual
WaveRunner
VX 700
VX 700 (F2V)
SERVICE MANUAL
F2V-28197-ZN-11
Preface
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. Also, up-to-date parts information is available on YPEC-web. Additional information and
up-to-date information on Yamaha products and services are available on Yamaha Service Portal.
Important information
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
A WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
A NOTICE indicates special precautions that must be taken to avoid damages to the watercraft or other property.
TIP:
A TIP provides key information to make procedures easier or clearer.
WaveRunner
VX 700
SERVICE MANUAL
©2010 by Yamaha Motor Co., Ltd.
1st Edition, September 2010
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Contents
General information
Specification
Maintenance
Fuel system
Power unit
GEN
INFO
SPEC
MNT
FUEL
POWR
1
2
3
4
5
Jet pump unit
Electrical system
Hull and hood
Troubleshooting
Appendix
JET
PUMP
–+
ELEC
HULL
HOOD
TRBL
SHTG
6
7
8
9
A
GEN
INFO
General information
Safety while working ..................................................... 1-1
Rotating part............................................................................... 1-1
Hot part....................................................................................... 1-1
Electric shock ............................................................................. 1-1
Impeller....................................................................................... 1-1
Handling of gasoline................................................................... 1-1
Ventilation................................................................................... 1-2
Self-protection ............................................................................ 1-2
Working with crane..................................................................... 1-2
Handling of heat gun .................................................................. 1-3
Part, lubricant, and sealant......................................................... 1-3
Handling of sealant..................................................................... 1-3
Special service tool .................................................................... 1-3
Tightening torque ....................................................................... 1-3
Non-reusable part....................................................................... 1-3
Disassembly and assembly........................................................ 1-4
1
How to use this manual ..................................................... 1-5
Manual format ............................................................................ 1-5
Abbreviation ............................................................................... 1-6
Adhesive, lubricant, sealant,
and thread locking agent................................................... 1-7
Symbol ....................................................................................... 1-7
Special service tool............................................................ 1-8
Model feature.................................................................... 1-10
Identification number ................................................................ 1-10
GEN
INFO
General information
Safety while working
To prevent an accident or injury and to provide quality service, observe the following
safety procedures.
Rotating part
• Hands, feet, hair, jewelry, clothing, personal flotation device straps, and so on,
can become entangled with internal rotating
parts of the engine or jet pump unit, resulting in serious injury or death.
• Keep hands, feet, hair, jewelry, clothing,
personal flotation device straps, and so on,
away from any exposed moving parts when
operating the engine with the seat
removed.
• Keep away from intake grate while engine
is on. Items such as hair, clothing, or personal flotation device straps can become
entangled in moving parts resulting in
severe injury.
Hot part
During and after operation, engine parts are
hot enough to cause burns. Do not touch any
parts in the engine compartment until the
engine has cooled.
Electric shock
Do not touch any electrical parts while starting or operating the engine. Otherwise, shock
or electrocution could result.
Handling of gasoline
• Gasoline is highly flammable. Keep gasoline and all flammable products away from
heat, sparks, and open flames.
• Gasoline is poisonous and can cause injury
or death. Handle gasoline with care. Never
siphon gasoline by mouth. If you swallow
some gasoline, inhale a lot of gasoline
vapor, or get some gasoline in your eyes,
see your doctor immediately. If gasoline
spills on your skin, wash with soap and
water. If gasoline spills on your clothing,
change your clothes.
Impeller
Do not hold the impeller with your hands
when loosening or tightening the impeller.
1-1
Safety while working
Ventilation
• Gasoline vapor and exhaust gas are
heavier than air and extremely poisonous.
If gasoline vapor or exhaust gas is inhaled
in large quantities, it may cause loss of consciousness and death within a short time.
• When test running an engine indoors (for
example, in a water tank) make sure to do
so where adequate ventilation can be maintained.
Self-protection
• Protect your eyes by wearing safety
glasses or safety goggles during all operations involving drilling and grinding, or when
using an air compressor.
• Protect your hands and feet by wearing
protective gloves and safety shoes when
necessary.
Working with crane
• When moving the watercraft, or when lifting
the engine during removal or installation,
make sure to use a crane with a lifting
capacity that is equal to or more than the
weight of the watercraft or engine respectively.
• When lifting the watercraft, use the watercraft lift harness and make sure that the
watercraft is in a stable position when moving it.
• Use the wire ropes of adequate strength,
and lift up the engine unit using the three
point suspension. If the engine unit does
not have three or more points to be suspended, support it using additional ropes or
the like so that the engine unit can be lifted
and carried in a stable manner.
1
1-2
GEN
INFO
General information
Handling of heat gun
• Improper handling of a heat gun may result
in burns. For information on the proper handling of the heat gun, see the operation
manual issued by the manufacturer.
• When using a heat gun, keep it away from
the gasoline and oil, to prevent a fire.
• Components become hot enough to cause
burns. Do not touch any hot components
directly.
Part, lubricant, and sealant
Use only genuine Yamaha parts, lubricants,
and sealants, or those recommended by
Yamaha, when servicing or repairing the
watercraft.
Special service tool
Use the recommended special service tools
to work safely, and to protect parts from damage.
Tightening torque
Follow the tightening torque specifications
provided throughout the manual. When tightening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting
in the center and moving outward.
Non-reusable part
Always use new gaskets, seals, O-rings, cotter pins, and so on, when installing or assembling parts.
Handling of sealant
• Wear protective gloves to protect your skin,
when using the sealants.
• See the material safety data sheet issued
by the manufacturer. Some of the sealants
may be harmful to human health.
1-3
Disassembly and assembly
• Use compressed air to remove dust and dirt
during disassembly.
• Apply engine oil to the contact surfaces of
moving parts before assembly.
• Install bearings so that the bearing identification mark is facing in the direction indicated in the installation procedure. In
addition, make sure to lubricate the bearings liberally.
• Apply a thin coat of water resistant grease
to the lip and periphery of an oil seal before
installation.
• Check that moving parts operate normally
after assembly.
Safety while working
1
1-4
GEN
INFO
General information
How to use this manual
Manual format
The format of this manual has been designed to make service procedures clear and easy to understand. Use the information below as a guide for effective and quality service.
• Parts are shown and detailed in an exploded diagram and are listed in the component list (see 1
in the following figure for an example page).
• The component list consists of part names and quantities, as well as bolt and screw dimensions
(see 2 in the following figure). To assemble or install the components, reverse the steps indicated
in the component list.
• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
the lubrication point (see 3 in the following figure).
• Tightening torque specifications are provided in the exploded diagrams (see 4 in the following fig-
ure), and in the related detailed instructions. Some torque specifications are listed in stages as
torque figures or angles in degrees.
• Separate procedures and illustrations are used to explain the details of removal, checking, and
installation where necessary (see 5 in the following figure for an example page).
TIP:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
Jet thrust nozzle, impeller duct, and impeller housing / Impeller duct and drive shaft
Impeller duct and drive shaft
No. Part name Q’ty Remarks
1 Bolt 3 M6 20 mm
2Cap 1
3O-ring 1
4Cap 1
5 Impeller 1
6 Drive shaft 1
7 Oil seal 1
8 Oil seal 1
9 Rear bearing 1
10 Spacer 1
11 Front bearing 1
12 Impeller duct 1
*: EPNOC grease AP #0
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
2
4
1
3
JET
PUMP
Drive shaft removal
1. Remove the impeller.
Crankshaft holder 20: 90890-06552
TIP:
Hold the impeller duct assy. in a vise
between two aluminum plates a.
2. Remove the drive shaft 1.
TIP:
6-6
Remove the drive shaft using a press.
3. Remove the rear bearing.
6-7
a
1
Jet pump unit
Stopper guide plate: 90890-06501
Bearing puller assembly: 90890-06535
Stopper guide stand: 90890-06538
a
4. Remove the oil seals.
TIP:
Remove the oil seals using a flat head screwdriver.
5. Remove the front bearing.
Driver rod L3: 90890-06652
Needle bearing attachment: 90890-06614
TIP:
Remove the front bearing using a press.
Impeller check
1. Check the impeller. Replace if damaged.
5
1-5
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
BOW Bow end
CDI Capacitor discharge ignition
EX Exhaust
IN Intake
NMMA National Marine Manufacturers Association
PON Pump Octane Number
PORT Port side
RON Research Octane Number
STBD Starboard side
STERN Stern end
TDC Top Dead Center
How to use this manual
1
1-6
GEN
INFO
General information
Adhesive, lubricant, sealant, and thread locking agent
Symbol
Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication
points.
Symbol Name Application
Yamaha 2-stroke motor oil Lubricant
Water resistant grease
Lubricant
(Yamaha grease A)
Molybdenum disulfide grease Lubricant
Epnoc grease AP#0 Lubricant
EP
Symbols in an exploded diagram or illustration indicate the type of adhesive, sealant, or thread locking agent and the application points.
Symbol Name Application
Gasket Maker Sealant
LOCTITE 271 (red) Thread locking agent
LOCTITE 242 (blue) Thread locking agent
LT
242
1-7
LOCTITE 572 (white) Sealant
Silicone sealant Sealant
ThreeBond 1207B Sealant
ThreeBond 1207D Sealant
ThreeBond 1322 Thread locking agent
Adhesive, lubricant, sealant, and thread locking agent / Special service tool
Special service tool
Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division.
Digital tachometer
90890-06760
Compression gauge
90890-03160
Flywheel holder
90890-06522
Driver rod L3
90890-06652
1
Needle bearing attachment
90890-06614
Ball bearing attachment
90890-06634
Stopper guide plate
90890-06501
Flywheel puller
90890-06521
Coupler wrench
90890-06425
Bearing puller assembly
90890-06535
1-8
GEN
INFO
General information
Stopper guide stand
90890-06538
Driver rod LS
90890-06606
Ball bearing attachment
90890-06631
Drive shaft holder 5
90890-06519
Digital circuit tester
90890-03174
Peak voltage adapter B
90890-03172
Crankshaft holder 20
90890-06552
Bearing outer race attachment
90890-06628
Ignition tester (Spark gap tester)
90890-06754
1-9
Model feature
Identification number
Primary I.D. number
The primary I.D. number is stamped on a
label attached to the inside of the engine
compartment.
321
PRI-I.D.
MODEL
YAMAHA MOTOR CO., LTD.
ASSEMBLED IN U.S.A. FROM AMERICAN AND JAPANESE
COMPONENTS.
ASSEMBLÉ AUX ÉTATS-UNIS DE PIÈCES AMÉRICAINES ET
JAPONAISES.
F2V
Special service tool / Model feature
Starting engine serial number:
6CP: 1000001
Jet pump unit serial number
The jet pump unit serial number is stamped
on a label attached to the intermediate housing.
2 1 3
1
1 Model name
2 Hull type
3 Primary I.D. number
Starting primary I.D. number:
F2V: 800101
Engine serial number
The engine serial number is stamped on a
label attached to the engine unit.
1
2
3
1 Jet pump unit name
2 Jet pump unit type
3 Jet pump unit serial number
Hull identification number (H.I.N.)
The H.I.N. is stamped on a plate attached to
the boarding platform.
1 Engine name
2 Engine type
3 Engine serial number
1-10
GEN
INFO
General information
— MEMO —
1-11
SPEC
Specification
Model data .......................................................................... 2-1
Model code................................................................................. 2-1
Dimension and weight ................................................................ 2-1
Performance............................................................................... 2-1
Power unit .................................................................................. 2-1
Drive unit .................................................................................... 2-2
Fuel and oil requirement............................................................. 2-2
Battery requirement.................................................................... 2-2
Fuel system technical data ............................................... 2-3
Fuel system ................................................................................ 2-3
1
2
Power unit technical data.................................................. 2-3
Power unit .................................................................................. 2-3
Cylinder head assy..................................................................... 2-3
Crank case assy......................................................................... 2-4
Jet pump unit technical data............................................. 2-5
Jet pump unit.............................................................................. 2-5
Electrical technical data .................................................... 2-5
Ignition system ........................................................................... 2-5
Charging system ........................................................................ 2-6
Control system ........................................................................... 2-6
Starting system........................................................................... 2-7
Meter system.............................................................................. 2-7
Specified tightening torque............................................... 2-8
Fuel system ................................................................................ 2-8
Power unit .................................................................................. 2-8
Jet pump unit............................................................................ 2-10
Electrical system ...................................................................... 2-10
Hull and hood ........................................................................... 2-11
3
4
5
6
7
General tightening torque ............................................... 2-12
Cooling system ................................................................ 2-13
Cable and hose routing ................................................... 2-14
Starboard bow view.................................................................. 2-14
Top view ................................................................................... 2-15
Port view................................................................................... 2-17
8
9
A
SPEC
Model data
Model code
Specification
Item Unit
Hull F2V
Engine/jet 6CP/6CP
Model
VX 700
Dimension and weight
Item Unit
Length mm (in) 3220 (126.8)
Width mm (in) 1170 (46.1)
Height mm (in) 1160 (45.7)
Dry weight kg (lb) 283 (624)
Maximum capacity
Person/
kg (lb)
Model
VX 700
3/240 (530)
Performance
Item Unit
Full throttle operating range r/min 7200
Trolling speed r/min 1250–1350
Maximum fuel consumption
Cruising range h 1.47
L/h (US gal/
h, lmp.gal/h)
Model
VX 700
34.0 (9.0, 7.5)
Power unit
Item Unit
Type 2-stroke L2
Cylinder quantity 2
Total displacement cm
Bore × stroke mm (in) 81.0 × 68.0 (3.19 × 2.68)
Compression ratio 7.2 : 1
Intake system Reed valve
Starting enrichment Choke valve
Scavenging system Loop charge
Exhaust system Wet exhaust
Lubrication system Oil injection
Cooling system Water cooled
Starting system Electric starter
Ignition system CDI
Maximum ignition timing
advance
Spark plug BR8HS (NGK)
Spark plug gap mm (in) 0.6–0.7 (0.024–0.038)
Firing order 1–2
3
(cu. in) 701 (42.8)
Degree BTDC 21°
Model
VX 700
2-1
Drive unit
Model data
Item Unit
Jet pump type Axial flow, single stage
Impeller rotation Counterclockwise (viewed from rear)
Transmission Constant mesh 1-speed
Jet thrust nozzle horizontal
angle
Trim system —
Jet thrust nozzle trim angle Degree 3
Fuel and oil requirement
Item Unit
Fuel type Regular unleaded gasoline
Fuel minimum rating PON 86
Fuel tank capacity
Total
Reserve
Engine oil type YAMALUBE 2-W
Fuel and oil mixing ratio
(Wide open throttle) 50:1
Engine oil grade NMMA-
Oil tank capacity
Degree 24 + 24
RON 90
L (US gal,
Imp.gal)
L (US gal,
Imp.gal)
certified
L (US gal,
Imp.gal)
Model
VX 700
Model
VX 700
50 (13.2, 11.0)
12 (3.2, 2.6)
TC-W3
3.8 (1.0, 0.8)
1
2
3
4
5
Battery requirement
Item Unit
Type Fluid
Capacity V/Ah 12/19
Specific gravity at 20 °C (68 °F) 1.265
Model
VX 700
6
7
8
9
A
2-2
SPEC
Specification
Fuel system technical data
Fuel system
Item Unit
Carburetor
Manufacturer Mikuni
Model × quantity BN38 × 2
Type Floatless
ID mark 62T03F/03R
Main jet (MJ) 120 (front), 130 (rear)
Main nozzle (MN) mm (in) 2.5 (0.10)
Pilot jet (PJ) 67.5
Low speed screw turns out 5/8 ± 1/4
Throttle valve 190
Valve seat size mm (in) 1.5 (0.06)
Arm height mm (in) 0–0.2 (0–0.008)
High speed screw turns out 5/8 ± 1/4 (front), 1 1/8 ± 1/4 (rear)
Throttle lever free play mm (in) 4.0–7.0 (0.16–0.28)
Model
VX 700
Power unit technical data
Power unit
Item Unit
Cylinder
Minimum compression
pressure (*1)
kPa (kgf/
2
cm
, psi)
Model
VX 700
590 (5.9, 84)
(*1) Measuring conditions:
Ambient temperature 20 °C (68 °F), with spark plugs removed from all cylinders.
The figures are for reference only.
Cylinder head assy.
Item Unit
Cylinder head
Warpage limit mm (in) 0.1 (0.004)
Model
VX 700
2-3
Crank case assy.
Fuel system technical data / Power unit technical data
Item Unit
Cylinder
Bore mm (in) 81.000–81.020 (3.1890–3.1898)
Bore wear limit mm (in) 81.100 (3.1929)
Taper limit mm (in) 0.080 (0.0031)
Out-of-round limit mm (in) 0.050 (0.0020)
Piston
Diameter mm (in) 80.922–80.941 (3.1859–3.1866)
Measuring point mm (in) 10.0 (0.39)
Ring groove (Top) mm (in) 1.210–1.240 (0.0476–0.0488)
Ring groove (2nd) mm (in) 1.210–1.240 (0.0476–0.0488)
Pin boss bore diameter mm (in) 20.008–20.020 (0.7877–0.7882)
Pin outside diameter mm (in) 19.995–20.000 (0.7872–0.7874)
Piston-to-cylinder clearance mm (in) 0.080–0.085 (0.0031–0.0033)
Piston ring
End gap measuring point mm (in) 10.0 (0.39)
Top ring
Type Keystone
Dimension height (B) mm (in) 1.170–1.190 (0.0461–0.0469)
Dimension width (T) mm (in) 2.750–2.950 (0.1083–0.1161)
End gap (*1) mm (in) 0.20–0.40 (0.008–0.015)
Side clearance mm (in) 0.03–0.05 (0.001–0.002)
2nd ring
Type Keystone
Dimension height (B) mm (in) 1.170–1.190 (0.0461–0.0469)
Dimension width (T) mm (in) 2.750–2.950 (0.1083–0.1161)
End gap (*1) mm (in) 0.20–0.40 (0.008–0.015)
Side clearance mm (in) 0.03–0.05 (0.001–0.002)
Connecting rod
Small end inside diameter mm (in) 24.995–25.008 (0.9841–0.9846)
Maximum small end axial
play
Crankshaft
Width mm (in) 61.950–62.000 (2.4390–2.4409)
Deflection limit mm (in) 0.050 (0.0020)
Big end side clearance mm (in) 0.250–0.750 (0.0098–0.0295)
Reed valve
Thickness mm (in) 0.2 (0.01)
Stopper height mm (in) 8.8–9.2 (0.35–0.36)
Warpage limit mm (in) 0.2 (0.01)
(*1) The figures are for reference only.
mm (in) 2.000 (0.0787)
Model
VX 700
1
2
3
4
5
6
7
8
2-4
9
A
SPEC
Specification
Jet pump unit technical data
Jet pump unit
Item Unit
Impeller housing
Inside diameter mm (in) 155.35–155.45 (6.116–6.120)
Impeller-to-housing
clearance
Clearance limit mm (in) 0.60 (0.024)
Impeller
Material Stainless steel
Blades number 3
Pitch angle Degree 13.2
Drive shaft
Runout limit mm (in) 0.01 (0.0004)
Intermediate drive shaft
Runout limit mm (in) 0.30 (0.012)
Nozzle
Diameter mm (in) 86.80–87.40 (3.417–3.441)
maximum difference of jet
thrust nozzle distances
mm (in) 0.35–0.45 (0.014–0.018)
mm (in) 5 (0.2)
Model
VX 700
Electrical technical data
Ignition system
Item Unit
CDI unit
Output peak voltage
at cranking (loaded) V 10
at 1500 r/min (loaded) V 200
at 3500 r/min (loaded) V 130
Pickup coil
Output peak voltage
at cranking (unloaded) V 5.2
at cranking (loaded) V 5.1
at 1500 r/min (loaded) V 14.1
at 3500 r/min (loaded) V 29.3
Resistance (*1)
at 20 °C (68 °F) Ω 12.6–15.4
(*1) The figures are for reference only.
Model
VX 700
2-5
Charging system
Jet pump unit technical data / Electrical technical data
Item Unit
Charge coil
Output peak voltage
at cranking (unloaded) V 180
at cranking (loaded) V 20
at 1500 r/min (loaded) V 210
at 3500 r/min (loaded) V 150
Resistance (*1)
at 20 °C (68 °F) Ω 497.7–608.3
Lighting coil
Output peak voltage
at cranking (unloaded) V 8.7
at 1500 r/min (unloaded) V 25.6
at 3500 r/min (unloaded) V 47.3
Resistance (*1)
at 20 °C (68 °F) Ω 1.143–1.397
Minimum charging
current
Rectifier regulator
Output peak voltage
at 3500 r/min (loaded) V 13.0
(*1) The figures are for reference only.
Model
VX 700
1
2
3
A at r/min 14 at 6000
4
Control system
Item Unit
Ignition coil
Primary coil resistance
at 20 °C (68 °F) Ω 0.078–0.106
Secondary coil resistance
at 20 °C (68 °F) kΩ 14.336–30.464
Thermoswitch (engine)
Input voltage (*1) V 11.0–12.0
Continuity temperature °C (°F) 77–83 (171–181)
No continuity temperature °C (°F) 63–77 (145–171)
(*1) The figures are for reference only.
Model
VX 700
5
6
7
8
9
2-6
A
SPEC
Starting system
Specification
Item Unit
Fuse
Rating
Main V/A 12/10
Starter motor
Type Constant mesh
Output kW 0.8
Cranking time limit Seconds 30
Commutator diameter mm (in) 27.0–28.0 (1.06–1.10)
Commutator undercut (*1) mm (in) 0.2–0.7 (0.008–0.028)
Brush length mm (in) 6.5–12.5 (0.26–0.49)
(*1) The figures are for reference only.
Model
VX 700
Meter system
Item Unit
Fuel level sensor
Resistance
at 20 °C (68 °F)
Empty position Ω 757.0–803.0
Full position Ω 0–8.0
Oil level sensor
Float distance (for continuity) mm 37.0–41.0 (1.46–1.61)
Model
VX 700
2-7
Specified tightening torque
Fuel system
Electrical technical data / Specified tightening torque
Part to tightened
Fuel cock knob screw ø4 2 0.2 1.5 4-1
Fuel cock assy./washer nut — 50.53.74-1
Choke knob screw ø3 2 0.2 1.5 4-3
Choke knob nut — 20.21.54-3
Oil filler neck/rubber seal nut — 60.64.44-4
Oil filler hose clamp — 3.70.372.7 4-4
Fuel filler neck/rubber seal nut — 60.64.44-6
Fuel filler hose clamp — 3.70.372.7 4-6
Fuel level sensor assy. clamp 1 0.1 0.7 4-6
Carburetor cover 1 bolt M5 1 0.1 0.7 4-8
Flame arrester holder bolt M6 8 0.8 5.9 4-8
Throttle cable locknut — 80.85.94-8
Choke cable locknut — 80.85.94-8
Carburetor assy. nut — 18 1.8 13.3 4-8
Needle valve assy. plate screw ø3 1 0.1 0.7 4-11
Float arm screw ø3 1 0.1 0.7 4-11
Cover (carburetor 1) screw ø5 4.4 0.44 3.2 4-11
Cover (carburetor 2) screw ø5 3.4 0.34 2.5 4-11
Diaphragm cover screw ø5 3.4 0.34 2.5 4-11
Body assy. screw ø4 2 0.2 1.5 4-11
Main jet — 1.8 0.18 1.3 4-11
Pilot jet — 0.7 0.07 0.5 4-11
Air bleed screw ø6 5 0.5 3.7 4-17
Oil pump bolt M6 8 0.8 5.9 4-17
Screw
size
Tightening torque See
pageN·mkgf·mft·lb
1
2
3
4
5
Power unit
Part to tightened
Coupling cover bolt M6 8 0.8 5.9 5-1
Engine mounting bolt M8 17 1.7 12.5 5-1
Engine mount bolt M8 17 1.7 12.5 5-3
Exhaust joint clamp — 50.53.75-10
Exhaust ring joint clamp — 20.21.55-10
Exhaust ring bolt M8 29 2.9 21.4 5-10
1st
2nd 2 0.2 1.5 5-11
Muffler stay bolt
Exhaust outer cover 1 M6 8 0.8 5.9 5-12
Exhaust outer cover 2 M6 8 0.8 5.9 5-12
Muffler bolt
Reed valve/valve stopper screw ø3 1 0.1 0.7 5-14
3rd 2 0.2 1.5 5-11
4th 39 3.9 28.8 5-11
5th 46 4.6 33.9 5-11
6th 39 3.9 28.8 5-11
1st
2nd 39 3.9 28.8 5-13
Screw
size
M10
M10
Tightening torque See
pageN·mkgf·mft·lb
20.21.55-11
21 2.1 15.5 5-13
2-8
6
7
8
9
A
SPEC
Specification
Part to tightened
Reed valve assy. bolt M5 4 0.4 3.0 5-14
Intake manifold bolt M6 8 0.8 5.9 5-14
Thermoswitch bolt M6 8 0.8 5.9 5-16
Spark plug — 25 2.5 18.4 5-16
Cylinder head bolt
Cylinder bolt
Anode screw ø4 3 0.3 2.2 5-18
Starter motor bolt M8 18 1.8 13.3 5-25
Starter motor positive lead nut — 50.53.75-25
Flywheel cover bolt M6 8 0.8 5.9 5-25
Flywheel magneto bolt M10 74 7.4 54.6 5-25
Drive coupling — 36 3.6 26.6 5-25
Base assy. screw ø6 8 0.8 5.9 5-25
Engine bracket/lower
crankcase bolt
Upper crankcase/lower
crankcase bolt
1st
2nd 29 2.9 21.4 5-16
1st
2nd 39 3.9 28.8 5-18
1st
2nd 52 5.2 38.4 5-30
1st
2nd 27 2.7 19.9 5-30
Screw
size
M8
M10
M10
M8
Tightening torque See
pageN·mkgf·mft·lb
15 1.5 11.1 5-16
22 2.2 16.2 5-18
23 2.3 17.0 5-30
15 1.5 11.1 5-30
2-9
Jet pump unit
Specified tightening torque
Part to tightened
Intake grate bolt
Ride plate bolt M8 17 1.7 12.5 6-1
Cover screw ø5 4 0.4 3.0 6-1
Steering cable joint nut — 6.80.684.9 6-2
Jet pump unit assy. bolt
Rubber plate bolt M6 7 0.7 5.2 6-2
Rubber plate nut — 70.75.26-2
Bracket bolt M8
Spout hose clamp —
Jet thrust nozzle bolt M8 15 1.5 11.1 6-5
Nozzle/bracket bolt M10 40 4.0 29.5 6-5
Water inlet cover/water inlet strainer
bolt
Cap bolt M6 8 0.8 5.9 6-6
Impeller M22 75 7.5 55.3 6-6
Transom plate nut — 26 2.6 19.2 6-10
Flushing hose nut — 5.5 0.55 4.1 6-10
Intermediate housing cover bolt M8 17 1.7 12.5 6-12
Rubber hose clamp — 40.43.06-12
Joint bolt M6 7 0.7 5.2 6-12
Driven coupling M24 36 3.6 26.6 6-13
Intermediate drive shaft extension M24 36 3.6 26.6 6-13
Screw
size
M6 8 0.8 5.9 6-1
M10 40 4.0 29.5 6-1
M6 8 0.8 5.9 6-2
M10 40 4.0 29.5 6-2
M6 7 0.7 5.2 6-5
Tightening torque See
pageN·mkgf·mft·lb
17 1.7 12.5 6-2
14 1.4 10.3 6-2
10.10.76-2
20.21.56-2
1
2
3
4
5
Electrical system
Part to tightened
Electrical box bracket nut — 15 1.5 11.1 7-2
Ground lead screw ø6 4 0.4 3.0 7-2
Starter relay bolt M6 3 0.3 2.2 7-2
CDI unit screw ø6 4 0.4 3.0 7-2
Rectifier regulator screw ø6 4 0.4 3.0 7-2
Ignition coil screw ø6 4 0.4 3.0 7-2
Electrical box case screw ø6 4 0.4 3.0 7-2
Bracket nut — 17 1.7 12.5 7-2
Starter motor terminal nut — 50.53.77-12
Starter motor rear cover bolt M5 6 0.6 4.4 7-12
Screw
size
Tightening torque See
pageN·mkgf·mft·lb
2-10
6
7
8
9
A
SPEC
Hull and hood
Specification
Part to tightened
Upper handlebar cover screw
Lower handlebar cover screw ø6 4 0.4 3.0 8-1
Grip end bolt M5 1 0.1 0.7 8-2
Left handlebar switch assy. screw ø5 3 0.3 2.2 8-2
Throttle lever assy. bolt M5 3 0.3 2.2 8-2
Handlebar holder bolt M8 20 2 14.8 8-2
Mirror nut — 70.75.28-8
Hood lock bolt M5 4 0.4 3.0 8-8
Front hood screw ø5 2 0.2 1.5 8-8
Hinge nut — 70.75.28-8
Hinge bolt M6 7 0.7 5.2 8-8
Engine hatch cover nut — 50.53.78-11
Engine hatch cover bolt M6 5 0.5 3.7 8-11
Multifunction meter screw ø5 4 0.4 3.0 8-11
Steering cable stopper bolt M6 7 0.7 5.2 8-13
Steering master assy. bolt M8 17 1.7 12.5 8-13
Steering arm assy. bolt M8 16 1.6 11.8 8-13
Ball joint nut — 70.75.28-14
Ball joint — 70.75.28-14
Buzzer bracket bolt M5 4 0.4 3.0 8-14
Case assy. bolt M6 7 0.7 5.2 8-14
Steering cable locknut — 70.75.28-16
Packing nut — 5.9 0.59 4.4 8-16
Seat lock assy. bolt M6 6 0.6 4.4 8-18
Projection nut — 26 2.6 19.2 8-18
Handgrip nut — 50.53.78-18
Seat holder nut — 15 1.5 11.1 8-19
Cooling water pilot outlet nut — 40.43.08-19
Water lock/rubber hose clamp — 50.53.78-23
Exhaust outlet/rubber hose clamp — 50.53.78-23
Exhaust outlet/Exhaust outlet bolt 5 0.5 3.7 8-23
Bow eye bolt M6 13 1.3 9.6 8-25
Front protector nut — 70.75.28-25
Sponson bolt M8 15 1.5 11.1 8-25
Ski tow nut — 15 1.5 11.1 8-27
Spout hose clamp — 20.21.58-27
Spout nut — 50.53.78-27
Stern eye nut — 15 1.5 11.1 8-27
Drain plug nut — 20.21.58-27
Screw
size
ø4 1 0.1 0.7 8-1
ø5 1 0.1 0.7 8-1
Tightening torque See
pageN·mkgf·mft·lb
2-11
Specified tightening torque / General tightening torque
General tightening torque
This chart indicates the tightening torques for
standard fasteners with a standard ISO
thread pitch. Tightening torque specifications
for special components and assemblies are
provided in the applicable sections of this
manual. To prevent warpage, tighten multifastener assemblies in a crisscross fashion
and progressive stages until the specified
torque is reached. Unless otherwise indicated, torque specifications require clean, dry
threads.
Components should be at room temperature.
1
2
Width
across
flats (A)
8 mm M5 5 0.5 3.7
10 mm M6 8 0.8 5.9
12 mm M8 18 1.8 13.3
14 mm M10 36 3.6 26.6
17 mm M12 43 4.3 31.7
Screw
size (B)
General torque
specifications
N·mkgf·mft·lb
3
4
5
6
2-12
7
8
9
A
SPEC
Cooling system
Specification
To pilot
outlet
4
5
To stern outlet
6
To exhaust
outlet
7
3
2
From flushing hose
7 Water lock
Exhaust outlet
Pilot outlet
1
6 Exhaust outer cover 1
5 Exhaust chamber
4 Exhaust ring
3 Cylinder head
2 Cylinder block
1 Exhaust manifold
Jet pump
From jet pump
cooling water flow
Stern outlet
Flushing hose
2-13
Water
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