Yamaha FZR Service Manual
Yamaha FZR Service Manual
Yamaha FZR Service Manual
WaveRunner
F2C-28197-1M-11
LIT-18616-03-18
FZR
GX1800 (F2R)
FZS
GX1800A (F2C)
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.
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!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, passengers, a bystander, or a person inspecting or repairing the watercraft.
NOTICE
A NOTICE indicates special precautions that must be taken to avoid damage to the water-
craft.
TIP
A TIP provides key information to make procedures easier or clearer.
WaveRunner
FZR, FZS
SERVICE MANUAL
2009 by Yamaha Motor Corporation, USA
1st Edition, January 2009
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-03-18
E
Contents
General information
GEN
INFO
Specification
SPEC
Periodic check and adjustment
CHK
ADJ
Fuel system
FUEL
Power unit
POWR
Jet pump unit
JET
PUMP
Electrical system
ELEC
Hull and hood
HULL
HOOD
Troubleshooting
TRBL
SHTG
+
1
2
3
4
5
6
7
8
9
E
GEN
INFO
2
3
4
5
6
7
8
9
Chapter 1
General information
How to use this manual ................................................................................. 1-1
Manual format............................................................................................ 1-1
Symbols..................................................................................................... 1-2
Abbreviation............................................................................................... 1-3
Safety while working...................................................................................... 1-4
Fire prevention........................................................................................... 1-4
Ventilation.................................................................................................. 1-4
Self-protection ........................................................................................... 1-4
Parts, lubricants, and sealants .................................................................. 1-4
Good working practices............................................................................. 1-5
Disassembly and assembly....................................................................... 1-5
Identification number..................................................................................... 1-6
Primary I.D. number .................................................................................. 1-6
Engine serial number................................................................................. 1-6
Jet pump unit serial number ...................................................................... 1-6
Hull identification number (H.I.N.).............................................................. 1-6
Special service tool ....................................................................................... 1-7
Measuring.................................................................................................. 1-7
Removal and installation ........................................................................... 1-9
Feature and benefit ...................................................................................... 1-14
Watercraft overview................................................................................. 1-14
Rear seat ................................................................................................. 1-15
Telescopic steering system..................................................................... 1-16
Shift lever assembly ................................................................................ 1-17
Watertight compartment .......................................................................... 1-18
Fire extinguisher location......................................................................... 1-18
Hull design............................................................................................... 1-19
Engine overview...................................................................................... 1-20
Supercharger assembly........................................................................... 1-21
Air cooler assembly ................................................................................. 1-21
ECM......................................................................................................... 1-22
Drive shaft ............................................................................................... 1-22
Dual analog meter unit ............................................................................ 1-23
Information display warnings................................................................... 1-24
Self-diagnosis.......................................................................................... 1-24
Yamaha Security System........................................................................ 1-25
E
GEN
INFO
1
2
3
4
5
6
7
8
9
Technical tips............................................................................................... 1-26
Engine control.......................................................................................... 1-26
ECM circuit diagram.......................................................................... 1-27
ECM coupler layout........................................................................... 1-28
Control system......................................................................................... 1-30
1-1
E
GEN
INFO
2
3
4
5
6
7
8
9
How to use this manual
Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. 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 (refer to
1 in the figure below for an example page).
The component list consists of part names and quantities (refer to 2 in the figure below). 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
lubrication point (refer to 3 in the figure below).
Tightening torque specifications are provided in the exploded diagrams (refer to 4 in the figure
below for an example), 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 (refer to 5 in the figure below for an example page).
TIP
For troubleshooting procedures, refer to Troubleshooting in Chapter 9.
How to use this manual
1-2
E
GEN
INFO
1
2
3
4
5
6
7
8
9
Symbols
Symbols 1 to 6 indicate specific data.
1 Special service tool
2 Specified oil or fluid
3 Specified engine speed
4 Specified tightening torque
5 Specified measurement
6 Specified electrical value
(resistance, voltage, electric current)
Symbols 7 to A in an exploded diagram indi-
cate the grade of lubricant and the lubrication
point.
7 Apply 4-stroke motor oil
8 Apply water resistant grease
(Yamaha grease A)
9 Apply molybdenum disulfide grease
0 Apply Epnoc grease AP #0
A Apply Silicone grease
Symbols B to H in an exploded diagram indi-
cate the type of sealant or locking agent and
the application point.
B Apply ThreeBond 1194E or ThreeBond 1280B
C Apply Gasket Maker
D Apply LOCTITE 271 (red)
E Apply LOCTITE 242 (blue)
F Apply LOCTITE 572
G Apply LOCTITE 648
H Apply silicone sealant
TIP
Additional symbols may be used in this man-
ual.
1 2
3 4
5 6
7 8
9 0
A B
C D
E F
G H
T
R
.
.
E
A
M EP
SG
1280B 1194E
GM
271
LT
242
LT
572
LT
648
LT
SS
How to use this manual
1-3
E
GEN
INFO
2
3
4
5
6
7
8
9
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
API American Petroleum Institute
APS Accelerator position sensor
BOW Bow end
ECM Electronic Control Module
ETV Electronic throttle valve
EX Exhaust
IN Intake
OL Overload
OTS Off-throttle steering system
PORT Port side
QSTS Quick Shift Trim System
RPM Revolutions Per Minute
SAE Society of Automotive Engineers
STBD Starboard side
STERN Stern end
TCI Transistor Controlled Ignition
TDC Top Dead Center
TPS Throttle Position Sensor
UP Upside
YDIS Yamaha Diagnostic System
How to use this manual
1-4
E
GEN
INFO
1
2
3
4
5
6
7
8
9
Safety while working
To prevent and accident or injury and to
ensure quality service, follow the safety proce-
dures provided below.
Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
Ventilation
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled in
large quantities, they may cause loss of con-
sciousness and death within a short time.
When test running an engine indoors (e.g., in a
water tank), make sure to do so where ade-
quate ventilation can be maintained.
Self-protection
Protect your eyes by wearing safety glasses or
safety goggles during all operation involving
drilling and grinding, or when using an air com-
pressor.
Protect your hands and feet by wearing protec-
tive gloves and safety shoes when necessary.
Parts, lubricants, and sealants
Use only genuine Yamaha parts, lubricants,
and sealants, or those recommended by
Yamaha, when servicing or repairing the
watercraft.
Under normal conditions, the lubricants men-
tioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Avoid contact with skin. Do not, for exam-
ple, place a soiled rag in your pocket.
2. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.
3. Change and wash clothing as soon as
possible if soiled with lubricants.
4. To protect your skin, apply a protective
cream to your hands before working on the
watercraft.
Safety while working
1-5
E
GEN
INFO
2
3
4
5
6
7
8
9
5. Keep a supply of clean, lint-free cloths for
wiping up spills, others.
6. Maintain good standards of personal and
industrial hygiene.
Good working practices
Special service tool
Use the recommended special service tools to
protect parts from damage. Use the right tool
in the right manner; do not improvise.
Tightening torques
Follow the tightening torque specifications pro-
vided throughout the manual. When tightening
nuts, bolts, and screws, tighten the large sizes
first, and tighten fasteners starting in the cen-
ter and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cotter
pins, others, when installing or assembling
parts.
Disassembly and assembly
1. Use compressed air to remove dust and
dirt during disassembly.
2. Apply oil or fluid to the contact surfaces of
moving parts before assembly.
3. Install bearings with the manufacture iden-
tification mark in the direction indicated in
the installation procedure. In addition,
make sure to lubricate the bearings liber-
ally.
4. Apply a thin coat of water resistant grease
to the lip and periphery of an oil seal
before installation.
5. Check that moving parts operate normally
after assembly.
Safety while working
1-6
E
GEN
INFO
1
2
3
4
5
6
7
8
9
Identification number
Primary I.D. number
The primary I.D. number is stamped on a label
attached to the inside of the engine compart-
ment.
Starting primary I.D. number:
F2R: 800101
F2C: 800101
Engine serial number
The engine serial number is stamped on a
label attached to the engine unit.
TIP
The label stamped with the engine serial
number is located on the cylinder head
cover. Remove the engine cover to check
the engine serial number.
Slide the engine cover rearward, and then lift
the cover to remove it.
Starting serial number:
6AN: 1000001
Jet pump unit serial number
The jet pump unit serial number is stamped on
a label attached to the intermediate housing.
Hull identification number (H.I.N.)
The H.I.N. is stamped on a plate attached to
the boarding platform.
Identification number
1-7
E
GEN
INFO
2
3
4
5
6
7
8
9
Special service tool
Using the correct special tools recommended
by Yamaha will aid the work and enable accu-
rate assembly and tune-up. Improvisations
and using improper tools can damage the
equipment.
TIP
For USA and Canada, use part numbers
starting with YB-, YM-, YU-, or YW-.
For other countries, use part numbers start-
ing with 90890-.
Measuring
1Gauge stand
90890-06725
2Dial gauge stand set (use needle only)
YB-06585
3Dial gauge needle
90890-06584
4Dial gauge
YU-03097
90890-01252
5Compression gauge extension
90890-06582
6Compression gauge
YU-33223
90890-03160
7Fuel pressure gauge adapter
YW-06842
90890-06842
Special service tool
1-8
E
GEN
INFO
1
2
3
4
5
6
7
8
9
8Fuel pressure gauge
YB-06766
90890-06786
9Leakage tester
90890-06840
0Air cooler attachment
90890-06731
AYDIS (connecting kit)
60V-85300-04
BYDIS (CD-ROM, Ver. 1.30)
60V-WS853-04
YDIS (CD-ROM, Ver. 1.32)
60V-WS853-05
CDigital multimeter
YU-34899-A
DPeak voltage adapter
YU-39991
EDigital circuit tester
90890-03174
FPeak voltage adapter B
90890-03172
GSpark checker
YM-34487
Ignition tester
90890-06754
Special service tool
1-9
E
GEN
INFO
2
3
4
5
6
7
8
9
HTest harness (3 pins)
YB-06877
Test harness HM090-3 (3 pins)
90890-06877
ILower unit pressure/vacuum tester
YB-35956-A
JVacuum/pressure pump gauge set
90890-06756
KTest harness (3 pins)
YB-06870
Test harness SMT250-3 (3 pins)
90890-06870
LTest harness (2 pins)
90890-06850
Removal and installation
1Oil filter wrench
90890-06830
2Exhaust pipe wrench
90890-06726
3Bearing separator
90890-06534
4Slide hammer and adapters
YB-06096
5Bearing puller assembly
90890-06535
6Stopper guide plate
90890-06501
Special service tool
1-10
E
GEN
INFO
1
2
3
4
5
6
7
8
9
7Stopper guide stand
90890-06538
8Shaft holder
90890-06721
9Driver handle
90890-06722
0Bearing inner race attachment
90890-06661
ACoupler wrench
90890-06729
BCamshaft wrench
90890-06724
CValve spring compressor
YM-04019
90890-04019
DCompressor adapter
YM-04114
Valve spring compressor attachment
90890-04114
EValve guide remover
YB-06801
90890-06801
FValve guide installer
YB-06810
90890-06810
GValve guide reamer
YM-01196
90890-06804
Special service tool
1-11
E
GEN
INFO
2
3
4
5
6
7
8
9
HNeway valve seat kit
YB-91044
IValve seat cutter holder
90890-06812
JValve seat cutter
Intake
90890-06720 (30)
90890-06325 (45)
90890-06324 (60)
Exhaust
90890-06818 (30)
90890-06555 (45)
90890-06323 (60)
KCrankshaft holder
90890-06732
LFlywheel puller
90890-06723
MRotor puller
90890-01080
NDriver handle (small)
YB-06229
ODriver rod LS
90890-06606
PBearing and seal installer
YW-06356
QBearing outer race attachment
90890-06623, 90890-06627, 90890-06628
RForward bearing race installer
YB-06258
Special service tool
1-12
E
GEN
INFO
1
2
3
4
5
6
7
8
9
SBearing pressure C
90890-02393
TDriver handle (large)
YB-06071
UForward gear outer race installer
YB-41446
VBall bearing attachment
90890-06657
WPiston ring compressor
YM-08037
90890-05158
XDrive shaft holder
YB-06201
Drive shaft holder 6
90890-06520
YDriver rod L3
90890-06652
ZDrive shaft needle bearing installer and
remover
YB-06194
[Needle bearing attachment
90890-06609
\Bearing attachment
90890-06728
C
Special service tool
1-13
E
GEN
INFO
2
3
4
5
6
7
8
9
]Bearing cup installer
YB-06167
_Shaft holder
90890-06730
aNeedle bearing installer
YB-06434
bBearing puller legs
YB-06523
cBearing attachment
90890-06727
Special service tool
1-14
E
GEN
INFO
1
2
3
4
5
6
7
8
9
Feature and benefit
Watercraft overview
The FZR and FZS feature a newly designed hull, which is made of NanoXcel. Because the FZR is
designed for 2 riders and the FZS is designed for 3 riders, the shape of the rear seat is different for
each model. Only the FZS is equipped with a reboarding step.
New features
1 Rear seat
2 Telescopic steering system
3 Shift lever assembly
4 Watertight compartment
5 Fire extinguisher holder and cover
6 Dual analog meter unit
5
4
6
2
1
3
Feature and benefit
1-15
E
GEN
INFO
2
3
4
5
6
7
8
9
Rear seat
The rear seats and handgrips for the FZR and FZS have different shape. Therefore, the rear seats
and handgrips are not interchangeable.
1 Front seat
2 Deck beam
3 Rear seat
4 Handgrip
FZR
FZS
2
3
4
3
4
1
2
3
4
3
4
u
t
]
e
l
v
~
d
b
c
a
f
{
W
Q
J
K
D
R
8
P
3
F
H
E
M
C
O
G
5
`
1
i
Z
X
j
[
Y
: Indicates a connection between the symbols.
Rectifier
regulator
Stator
coil
Fuse
(30A)
Fuse (3A)
Engine
start switch
Battery
Starter
relay
Starter motor
Fuse (20A)
Main relay
Remote control receiver
Pickup coil
Cam position sensor
Intake air pressure sensor
Reverse sensor
Intake air temperature sensor
Engine temperature sensor
Thermo sensor
Steering sensor
Slant detection switch
Knock sensor
Oil pressure switch
Thermoswitch
Thermo sensor
Engine shut-off switch
APS
APS 1
APS 2
5V
5V
Ground
Ground
Ground
5V
TPS 2
TPS 1
TPS
ETV motor
Fuse (10A)
ETV relay
YDIS
Dual analog
meter
Fuel pump relay
Fuse (10A)
Fuel pump module
Ignition coil #4
Ignition coil #3
Ignition coil #2
Ignition coil #1
Fuel injector #4
Fuel injector #3
Fuel injector #2
Fuel injector #1
Technical tips
1-28
E
GEN
INFO
1
2
3
4
5
6
7
8
9
ECM coupler layout
No.
Lead
color
External connec-
tion lead
No.
Lead
color
External connec-
tion lead
No.
Lead
color
External connec-
tion lead
1 G
Knock sensor
15 B/R
Intake air tem-
perature sensor
29
2 16 P/G
Intake air pres-
sure sensor
30
3 G/O
Cam position
sensor
17 W/L
Steering sensor
31
4 18 G/W Reverse sensor 32
5 L/B
Slant detection
switch
19 33
6 20 Y/G
Main and fuel
pump relay (main
relay)
34 B/R
APS 1 ground
7 R/Y
Battery power
source
21 Y
Engine start
switch
35 B/W
APS 2 ground
8 W/B Pickup coil 22 36 P/R APS 1
9 23 B/Y
Engine tempera-
ture sensor
37 P/W
APS 2
10 24 38
11 25 O/R
Steering sensor
power source
39 R/Y
ETV relay power
source (contact)
12 26 O
Sensor power
source
40 B/O
Sensor ground
13 B/L
Thermo sensor
27 R/Y
Battery power
source
41 B/O
TPS ground
14 Y/W
Main relay drive
signal 28 W
Immobilizer
serial communi-
cation
42 P
TPS 1
20
14 15 16 17 18 19
8 9 10 11 12 13
21 22 23 24 25 26
1 2 3 4 5 6 7
46
40 41 42 43 44 45
34 35 36 37 38 39
47 48 49 50 51 52
27 28 29 30 31 32 33
78 79 80 81 82 83 84 85 86
54 55 56 57 58 59 60 61
70 71 72 73 74 75
62 63 64 65 66 67
76 77
68 69
53
20
14 15 16 17 18 19
8 9 10 11 12 13
21 22 23 24 25 26
1 2 3 4 5 6 7
46
40 41 42 43 44 45
34 35 36 37 38 39
47 48 49 50 51 52
27 28 29 30 31 32 33
78 79 80 81 82 83 84 85 86
54 55 56 57 58 59 60 61
70 71 72 73 74 75
62 63 64 65 66 67
76 77
68 69
53
Technical tips
1-29
E
GEN
INFO
2
3
4
5
6
7
8
9
43 P/B TPS 2 58 Pu/R Fuel injector #1 73
44 O
TPS power
source
59 Pu/B
Fuel injector #2
74
45 R/Y
ETV relay power
source (contact)
60 B/G
Ignition coil #4
75
46 B ECM ground 61 B/Y Ignition coil #3 76
47 W/B
Self-diagnosis
lead (communi-
cation), dual ana-
log meter unit
communication
62 B
ETV ground
77
48 63 78 G
ETV motor
(positive)
49 O/R
APS 1 power
source
64 P
Thermoswitch
79 P/W
Oil pressure
switch
50 O/W
APS 2 power
source
65 80 Y/W
ETV relay power
source (coil)
51 66 81 L/R
Main and fuel
pump relay (fuel
pump relay)
52 L
ETV motor
(negative)
67 B
Ground
82
53 68 83 Pu/G Fuel injector #4
54 69 84 Pu/Y Fuel injector #3
55 70 B ETV ground 85 B/R Ignition coil #1
56 71 86 B/W Ignition coil #2
57 72 W
Engine shut-off
switch
No.
Lead
color
External connec-
tion lead
No.
Lead
color
External connec-
tion lead
No.
Lead
color
External connec-
tion lead
Color code
B : Black B/R : Black/red P/G : Pink/green
Br : Brown B/W : Black/white P/R : Pink/red
G : Green B/Y : Black/yellow P/W : Pink/white
Gy : Gray G/L : Green/blue Pu/B : Purple/black
L : Blue G/O : Green/orange Pu/G : Purple/green
O : Orange G/W : Green/white Pu/R : Purple/red
P : Pink L/B : Blue/black Pu/Y : Purple/yellow
R : Red L/R : Blue/red R/Y : Red/yellow
W : White L/Y : Blue/yellow W/B : White/black
Y : Yellow O/R : Orange/red W/L : White/blue
B/G : Black/green O/W : Orange/white Y/G : Yellow/green
B/L : Black/blue P/B : Pink/black Y/W : Yellow/white
B/O : Black/orange
Technical tips
1-30
E
GEN
INFO
1
2
3
4
5
6
7
8
9
Control system
Item Condition Action Remarks
Reverse with
traction con-
trol
Shift lever is in the
reverse position and
the reverse sensor
operates.
Maximum engine speed is
limited to 3,000 r/min.
Cancel:
Shift lever is returned to the
forward position.
Overheat
warning con-
trol
Engine temperature
rises rapidly in a
short time.
Thermoswitch is on.
Exhaust cooling
water temperature
exceeds 75 C
(167 F).
Opening angle of the ETV
is regulated.
Maximum engine speed is
limited to approximately
3,5003,800 r/min.
Cancel:
Stop the engine and wait
for 30 seconds or more.
Engine temperature is
below 140 C (248 F)
with the thermoswitch off.
Exhaust cooling water tem-
perature is below 70 C
(158 F) with the ETV fully
closed.
If the engine is stopped
during overheat warning
control, it can be restarted.
Oil pressure
warning con-
trol
Control is activated
when the following
conditions are
present:
Oil pressure switch
is on.
ETV is open.
Engine speed
exceeds 4,500 r/min.
Opening angle of the ETV
is regulated.
Maximum engine speed is
limited to approximately
3,5003,800 r/min.
Cancel:
Engine is stopped and
electric power supply to
the ECM is stopped.
Engine is restarted and
the oil pressure switch is
off.
If the engine is stopped
during oil pressure warning
control, it can be restarted.
ETV failure
control
ETV failed, or open or
short circuit is
detected in ETV cir-
cuit.
Opening angle of the ETV
is fixed to the default open-
ing angle.
Maximum engine speed is
limited to 3,000 r/min.
Ignition timing is con-
trolled.
Technical tips
1-31
E
GEN
INFO
2
3
4
5
6
7
8
9
Cam position
sensor failure
control
Control is activated
when the following
conditions are main-
tained for 10 seconds:
Cam position sensor
failed.
Engine speed
exceeds approxi-
mately 1,000 r/min.
Opening angle of the ETV
is regulated.
Maximum engine speed is
limited to approximately
3,5003,800 r/min.
Cancel:
Engine is stopped.
Control is activated
when the following
conditions are
present:
Cam position sensor
failed.
Engine speed
exceeds 5,000 r/min.
Ignition and fuel injection are
cut to all cylinders and the
engine is stopped.
Battery dis-
connection
warning
Battery cable is dis-
connected during nor-
mal operation.
Control is performed using
the same actions as the ETV
failure control.
Idle speed
control
Throttle lever is in the
fully closed (idle) posi-
tion.
Engine speed is limited to
1,1501,350 r/min.
Over revolu-
tion control
Engine speed
exceeds 7,800 r/min.
Ignition is controlled.
Condi-
tion
Action r/min
Normal None Below
7,800
Level 1 Ignition
is cut off
to 1 cyl-
inder.
7,800
8,200
Level 2 Ignition
is cut off
to 2 cyl-
inders.
Level 3 Ignition
is cut off
to 3 cyl-
inders.
Level 4 Ignition
is cut off
to all cyl-
inders.
Item Condition Action Remarks
Technical tips
1-32
E
GEN
INFO
1
2
3
4
5
6
7
8
9
L-MODE con-
trol
L-MODE is activated. Opening angle of the ETV
is regulated.
Ignition timing is con-
trolled.
Maximum engine speed is
limited to 5,400 r/min.
Cancel:
L-MODE is deactivated.
Slant detec-
tion control
Control is activated
when the following
conditions are
present:
Slant detection
switch is on.
Engine speed is
3,000 r/min or less.
Ignition and fuel injection are
cut to all cylinders and the
engine is stopped.
Cancel:
Engine is stopped.
* The check engine warn-
ing indicator does not
come on and the buzzer
does not sound.
High intake
air pressure
control
Control is activated
when the following
conditions are main-
tained for 1.5 sec-
onds:
Intake air pressure
exceeds 145 kPa.
Engine speed
exceeds 7,550 r/min.
Opening angle of the ETV is
regulated so that it does not
exceed the opening angle
when the pressure control
was activated.
Cancel:
APS pulley is returned to
the fully closed position.
Knock control Control is activated
when the following
conditions are
present:
Knock sensor
detects the engine
knock.
Engine speed
exceeds 2,000 r/min
after the engine has
been warmed up.
Ignition timing is controlled
(retarded).
Item Condition Action Remarks
Technical tips
1-33
E
GEN
INFO
2
3
4
5
6
7
8
9
MEMO
Technical tips
E
SPEC
1
2
3
4
5
6
7
8
9
Chapter 2
Specification
General specification..................................................................................... 2-1
Maintenance specifications .......................................................................... 2-3
Engine ...................................................................................................... 2-3
Fuel system............................................................................................... 2-6
Jet pump unit ............................................................................................ 2-7
Hull and hood ........................................................................................... 2-7
Electrical .................................................................................................... 2-7
Tightening torques....................................................................................... 2-11
Specified torques..................................................................................... 2-11
General torque......................................................................................... 2-16
Lubrication system...................................................................................... 2-17
Cooling system............................................................................................ 2-18
Cable and hose routing............................................................................... 2-20
Starboard bow view................................................................................. 2-20
Top view.................................................................................................. 2-21
Port view.................................................................................................. 2-23
2-1
E
SPEC
1
3
4
5
6
7
8
9
General specification
Item Unit
Model
FZR FZS
Model code
Hull F2R F2C
Engine/jet 6AN/6AN
Dimensions
Length mm (in) 3,350 (131.9) 3,370 (132.7)
Width mm (in) 1,230 (48.4)
Height mm (in) 1,160 (45.7)
Weight
Dry weight kg (lb) 366 (807) 369 (813)
Maximum capacity Person/kg (lb) 2/160 (353) 3/240 (529)
Performance
Maximum fuel consumption L/h (US gal/h,
lmp.gal/h)
71.3 (18.8, 15.7)
Cruising range h 0.98
Engine
Engine type 4-stroke, L4, DOHC
Displacement cm
3
(cu. in) 1,812 (110.6)
Bore stroke mm (in) 86.0 78.0 (3.39 3.07)
Compression ratio 8.6:1
Exhaust system Wet exhaust
Lubrication system Wet sump
Cooling system Water cooled
Starting system Electric starter
Ignition system TCI
Maximum ignition timing
advance
Degree BTDC 20
Spark plug (manufacturer) LFR6A (NGK)
Spark plug gap mm (in) 0.80.9 (0.0310.035)
Generator output A @ r/min 23.325.3 @ 6,000
Drive unit
Propulsion system Jet pump
Jet pump type Axial flow, single stage
Impeller rotation Counterclockwise (viewed from rear)
Transmission Direct drive from engine
Jet thrust nozzle horizontal
angle
Degree 24 + 24
Trim system Manual 5 positions
Jet thrust nozzle trim angle Degree 10, 5, 0, 5, 10
Reverse system Reverse gate
General specification
2-2
E
SPEC
1
2
3
4
5
6
7
8
9
PON*: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2
RON*: Research Octane Number
Fuel and oil
Fuel type Regular unleaded gasoline
Minimum fuel rating PON* 86
RON* 90
Fuel tank capacity L
(US gal, Imp.gal)
70 (18.5, 15.4)
Engine oil type 4-stroke motor oil
Engine oil grade API SE, SF, SG, SH, SJ, or SL
SAE 10W-30, 10W-40, 20W-40, or 20W-50
Engine oil quantity
Total amount L
(US qt, Imp.qt)
4.3 (4.5, 3.8)
Without oil filter replacement L
(US qt, Imp.qt)
3.0 (3.2, 2.6)
With oil filter replacement L
(US qt, Imp.qt)
3.1 (3.3, 2.7)
Battery
Type Fluid
Capacity V/Ah 12/19
Specific gravity @ 20 C (68 F) 1.265
Item Unit
Model
FZR FZS
General specification
2-3
E
SPEC
1
3
4
5
6
7
8
9
Maintenance specifications
Engine
Item Unit
Model
FZR FZS
Power unit
Compression pressure
*1
kPa
(kgf/cm
2
, psi)
610 (6.1, 86.8)
Air cooler
Holding pressure
Water passage kPa
(kgf/cm
2
, psi)
200 (2.0, 28.5)
Air passage kPa
(kgf/cm
2
, psi)
100 (1.0, 14.2)
Oil cooler
Holding pressure
Water passage kPa
(kgf/cm
2
, psi)
200 (2.0, 28.5)
Cylinder head
Warpage limit
(lines indicate straightedge
position)
mm (in) 0.1 (0.004)
Camshaft cap inside diameter mm (in) 25.00025.021 (0.98430.9851)
Camshaft
Drive system Chain drive
Intake A mm (in) 40.9 (1.610)
Intake B mm (in) 32.0 (1.260)
Exhaust A mm (in) 41.0 (1.614)
Exhaust B mm (in) 32.2 (1.268)
Camshaft journal diameter mm (in) 24.96024.980 (0.98270.9835)
Camshaft-journal-to-camshaft-
cap clearance
mm (in) 0.0200.061 (0.00080.0024)
Camshaft runout limit mm (in) 0.015 (0.0006)
*1 Measuring conditions:
Ambient temperature 20 C (68 F), with spark plugs removed from all cylinders.
The figures are for reference only.
Maintenance specifications
2-4
E
SPEC
1
2
3
4
5
6
7
8
9
Timing chain
Model/number of links 97RH2015152PX/152
Tensioning system Automatic
Valve
Valve clearance (cold)
Intake mm (in) 0.140.23 (0.0060.009)
Exhaust mm (in) 0.280.37 (0.0110.015)
Valve dimensions
Valve head diameter A
Intake mm (in) 33.934.1 (1.3351.343)
Exhaust mm (in) 28.929.1 (1.1381.146)
Valve face width B
Intake and exhaust mm (in) 2.262.83 (0.0890.111)
Valve seat contact width C
Intake mm (in) 1.401.60 (0.0550.063)
Exhaust mm (in) 1.501.70 (0.0590.067)
Valve margin thickness D
Intake and exhaust mm (in) 0.801.20 (0.0310.047)
Valve stem diameter
Intake mm (in) 5.4775.492 (0.21560.2162)
Exhaust mm (in) 5.4645.479 (0.21510.2157)
Valve guide inside diameter
Intake and exhaust mm (in) 5.5045.522 (0.21670.2174)
Valve-stem-to-valve-guide
clearance
Intake mm (in) 0.0120.045 (0.00050.0018)
Exhaust mm (in) 0.0250.058 (0.00100.0023)
Valve guide installation height
Intake and exhaust mm (in) 12.312.7 (0.4840.500)
Valve stem runout limit
Intake and exhaust mm (in) 0.01 (0.0004)
Item Unit
Model
FZR FZS
Maintenance specifications
2-5
E
SPEC
1
3
4
5
6
7
8
9
Valve spring
Free length
Intake and exhaust mm (in) 45.58 (1.794)
Installed length
Intake and exhaust mm (in) 34.00 (1.339)
Tilt limit
Intake and exhaust mm (in) 2.0 (0.08)
Cylinder
Bore size mm (in) 86.00086.015 (3.38583.3864)
Piston
Piston outside
diameter D
mm (in) 85.91585.930 (3.38253.3831)
Measuring point H mm (in) 10.0 (0.39)
Piston ring groove
Top ring mm (in) 1.211.23 (0.04760.0484)
2nd ring mm (in) 1.211.23 (0.04760.0484)
Oil ring mm (in) 2.512.53 (0.09880.0996)
Piston pin boss bore diameter mm (in) 22.00422.015 (0.86630.8667)
Piston pin
Outside diameter mm (in) 21.99122.000 (0.86580.8661)
Piston ring
Top ring
Type Barrel
Dimension B mm (in) 1.171.19 (0.04610.0469)
Dimension T mm (in) 2.853.05 (0.1120.120)
End gap (installed)
*1
mm (in) 0.300.45 (0.0120.018)
Side clearance mm (in) 0.020.06 (0.00080.0024)
2nd ring
Type Taper
Dimension B mm (in) 1.171.19 (0.04610.0469)
Dimension T mm (in) 2.602.80 (0.1020.110)
End gap (installed)
*1
mm (in) 0.450.60 (0.0180.024)
Side clearance mm (in) 0.020.06 (0.00080.0024)
Oil ring
Dimension B mm (in) 2.372.47 (0.0930.097)
Dimension T
*1
mm (in) 2.50 (0.098)
End gap (installed)
*1
mm (in) 0.100.35 (0.0040.014)
Side clearance mm (in) 0.040.16 (0.00160.0063)
*1 The figures are for reference only.
Item Unit
Model
FZR FZS
T
B
T
B
B
T
Maintenance specifications
2-6
E
SPEC
1
2
3
4
5
6
7
8
9
Fuel system
Connecting rod
Bearing color code 1. Brown 2. Black 3. Blue 4. Green
Small end inside diameter mm (in) 22.01522.028 (0.86670.8672)
Crankshaft
Crankshaft journal diameter mm (in) 39.97640.000 (1.57391.5748)
Crankshaft pin diameter mm (in) 41.97642.000 (1.65261.6535)
Crankshaft runout limit mm (in) 0.03 (0.0012)
Crankshaft pin oil clearance mm (in) 0.0200.056 (0.00080.0022)
Crankshaft journal oil clearance mm (in) 0.0240.053 (0.00090.0021)
Bearing color code 1. Brown 2. Black 3. Blue 4. Green 5. Yellow
Oil filter
Oil filter type Cartridge type
Oil pump
Oil pump type Trochoid
Thermostat
Opening temperature
@ 0.05 mm (0.002 in) C (F) 4852 (118126)
Fully open temperature C (F) 60 (140)
Valve open lower limit mm (in) More than 4.3 (0.17)
Item Unit
Model
FZR FZS
Throttle body
Manufacturer Mikuni
ID mark 6S5 00
Trolling speed r/min 1,1501,350
Throttle cable installation length mm (in) 18.4 1.0 (0.72 0.04)
Fuel pump
Pump type Electrical
Fuel pressure kPa
(kgf/cm
2
, psi)
345370 (3.453.70, 49.152.6)
Item Unit
Model
FZR FZS
Maintenance specifications
2-7
E
SPEC
1
3
4
5
6
7
8
9
Jet pump unit
Hull and hood
Electrical
Item Unit
Model
FZR FZS
Jet pump
Impeller housing inside
diameter
mm (in) 155.35155.45 (6.1166.120)
Impeller material Stainless steel
Number of impeller blades 3
Impeller pitch angle Degree 16.0
Impeller-to-housing clearance mm (in) 0.350.45 (0.0140.018)
Impeller clearance limit mm (in) 0.6 (0.024)
Drive shaft runout limit mm (in) 0.3 (0.012)
Nozzle diameter mm (in) 82.282.8 (3.243.26)
Item Unit
Model
FZR FZS
Throttle lever
Free play mm (in) 2.05.0 (0.080.20)
Item Unit
Model
FZR FZS
Ignition system
ECM unit
(B/R B, B/W B,
B/Y B, B/G B)
Output peak voltage
@cranking (loaded) V 2.5
@2,000 r/min (loaded) V 2.6
@3,500 r/min (loaded) V 2.6
Pickup coil (W B)
Output peak voltage
@cranking (unloaded) V 5.4
@cranking (loaded) V 4.6
@2,000 r/min (loaded) V 18.1
@3,500 r/min (loaded) V 23.9
Pickup coil resistance
*1
(W B)
@ 20 C (68 F) 459561
*1 The figures are for reference only.
Maintenance specifications
2-8
E
SPEC
1
2
3
4
5
6
7
8
9
Charging system
Stator coil (G G)
Output peak voltage
@cranking (unloaded) V 8.4
@2,000 r/min (unloaded) V 42.7
@3,500 r/min (unloaded) V 74.0
Stator coil resistance
*1
(G G)
@ 20 C (68 F) 0.310.38
Rectifier regulator (R B)
Output peak voltage
@2,000 r/min (loaded) V 13
@3,500 r/min (loaded) V 13
Control system
Oil pressure switch
Oil pressure switch continuity
pressure
kPa
(kgf/cm
2
, psi)
128166 (1.281.66, 18.223.6)
Thermoswitch
Thermoswitch continuity
temperature
C (F) 94100 (201212)
Thermoswitch no continuity
temperature
C (F) 8094 (176201)
Thermo sensor
Thermo sensor resistance
*1
(B B)
@ 0 C (32 F) k 24.037.1
@ 100 C (212 F) k 0.871.18
Engine temperature sensor
Engine temperature sensor
resistance
*1
(B/Y B/Y)
@ 20 C (68 F) k 54.269.0
@ 100 C (212 F) k 3.123.48
Intake air temperature sensor
Intake air temperature sensor
resistance
*1
(B B)
@ 0 C (32 F) k 5.46.6
@ 80 C (176 F) k 0.290.39
Knock sensor
Knock sensor resistance
*1
@ 20 C (68 F) k 504616
*1 The figures are for reference only.
Item Unit
Model
FZR FZS
Maintenance specifications
2-9
E
SPEC
1
3
4
5
6
7
8
9
TPS
TPS output voltage
with throttle lever fully
closed
TPS 1 V 0.60.9
with throttle lever fully open
TPS 2 V 4.64.7
Throttle valve opening angle
with throttle lever fully
closed
degree 2.08.0
with throttle lever fully open degree more than 70
APS
APS output voltage
with throttle lever fully
closed
APS 1 V 0.500.90
APS 2 V 0.351.05
with throttle lever fully open
APS 1 V 3.754.35
APS 2 V 3.604.50
APS resistance
*1
@ 20 C (68 F)
with APS pulley fully closed
APS 1 k 0.500.90
APS 2 k 0.351.05
with APS pulley fully open
APS 1 k 3.754.35
APS 2 k 3.604.50
Cam position sensor
Output voltage (G/O B/O)
Position a, c V More than 4.8
Position b V Less than 0.8
*1 The figures are for reference only.
Item Unit
Model
FZR FZS
a b c
Maintenance specifications
2-10
E
SPEC
1
2
3
4
5
6
7
8
9
Fuel system
Fuel injector
Fuel injector resistance
*1
11.512.5
@ 20 C (68 F)
Fuel sender
Fuel sender resistance
*1
(Y B)
@ 20 C (68 F)
Lower position 133.5136.5
Upper position 5.07.0
Starting system
Fuse
Rating
Battery V/A 12/30
Main and fuel pump relay V/A 12/20
Main and fuel pump relay V/A 12/10
ETV relay V/A 12/10
Remote control receiver V/A 12/3
Starter motor
Type Constant mesh
Output kW 0.6
Cranking time limit Seconds 30
Brush length mm (in) 5.012.5 (0.200.49)
Commutator undercut
*1
mm (in) 0.20.7 (0.0080.028)
Commutator diameter mm (in) 27.028.0 (1.061.10)
Remote control system
Remote control receiver
Output voltage
*1
(L/Y Ground)
V 11.012.0
Indication system
Speed sensor
Output voltage (on pulse)
(Y B/Y) mV Less than 400
V More than 11.6
*1 The figures are for reference only.
Item Unit
Model
FZR FZS
Maintenance specifications
2-11
E
SPEC
1
3
4
5
6
7
8
9
Tightening torques
Specified torques
Part to tightened
Thread
size
Tightening torque
Refer to
page
Nm kgfm ftlb
Fuel system
Fuel pump module assembly nut
1st
3 0.3 2.2
4-1
2nd 6 0.6 4.4
Strap bolt M8 16 1.6 11.8 4-1
Fuel rail bolt M8 13 1.3 9.6 4-1
Fuel tank cap clamp 1 0.1 0.7 4-1
Fuel filler neck nut 6 0.6 4.4 4-1
Fuel filler hose clamp 4 0.4 3.0 4-1
Engine
Deck beam nut 18 1.8 13.3 5-1
Deck beam bolt M8 18 1.8 13.3 5-1
APS nut 17 1.7 12.5 5-1
Engine cover screw M6 5 0.5 3.7 5-1
Engine cover grommet bolt M6 6 0.6 4.4 5-3
Engine cover stay bolt M6 8 0.8 5.9 5-3
Oil filter 18 1.8 13.3 5-3
Air filter case bolt M8 12 1.2 8.9 5-3
Intake pipe clamp 3 0.3 2.2 5-3
Air filter case bracket nut 17 1.7 12.5 5-3
Breather assembly bolt M6 8 0.8 5.9 5-5
Rectifier regulator bolt M8 26 2.6 19.2 5-5
Pipe clamp 2 0.2 1.5 5-5
Exhaust pipe 1 stay bolt
1st
M8, M10
22 2.2 16.2
5-5
2nd 42 4.2 31.0
Exhaust manifold bolt
1st
M8
20 2.0 14.8
5-5
2nd 35 3.5 25.8
Electrical box bolt M8 17 1.7 12.5 5-8
Coupling cover bolt M6 8 0.8 5.9 5-8
Engine mounting bolt M8 17 1.7 12.5 5-8
Damper 1 bolt M6 6 0.6 4.4 5-9
Damper 2 bolt M6 6 0.6 4.4 5-9
Spacer 1 bolt M6 5 0.5 3.7 5-9
Spacer 2 bolt M6 5 0.5 3.7 5-9
Engine mount bolt M8 17 1.7 12.5 5-9
Exhaust pipe 3 63 6.3 46.5 5-24
Thermo sensor 20 2.0 14.8 5-24
Exhaust pipe 1 bolt
1st
M8
20 2.0 14.8
5-24
2nd 35 3.5 25.8
Exhaust pipe 2 bolt
1st
M8
15 1.5 11.1
5-24
2nd 29 2.9 21.4
Starter motor cable nut 5 0.5 3.7 5-27
Tightening torques
2-12
E
SPEC
1
2
3
4
5
6
7
8
9
Starter motor bolt M8 18 1.8 13.3 5-27
Thermostat housing bolt M6 8 0.8 5.9 5-27
Joint 1 hose clamp 3 0.3 2.2 5-31
Boost pipe bolt M8 20 2.0 14.8 5-31
Joint 2 hose clamp 3 0.3 2.2 5-31
Air cooler intake pipe clamp 4 0.4 3.0 5-31
Air cooler assembly nut
1st
22 2.2 16.2
5-31
2nd 42 4.2 31.0
Stud bolt
1st
M10
10 1.0 7.4
5-31
2nd 20 2.0 14.8
Air cooler assembly bolt
1st
M10
22 2.2 16.2
5-31
2nd 42 4.2 31.0
Air cooler stay bolt M10 42 4.2 31.0 5-31
Supercharger assembly bolt
M6 10 1.0 7.4
5-31
M8 20 2.0 14.8
Intake air temperature sensor 15 1.5 11.1 5-33
Intake air pressure sensor bolt M5 3.5 0.35 2.6 5-33
Intake air pressure sensor bracket bolt M6 5 0.5 3.7 5-33
Intake manifold stay bolt
1st
M8
22 2.2 16.2
5-33
2nd 42 4.2 31.0
Oil level pipe bolt M6 8 0.8 5.9 5-33
Intake manifold bolt
1st
M8
10 1.0 7.4
5-33
2nd 20 2.0 14.8
Intake manifold nut
1st
10 1.0 7.4
2nd 20 2.0 14.8
Stud bolt
1st
M8
10 1.0 7.4
5-33
2nd 20 2.0 14.8
Throttle body joint bolt M8 13 1.3 9.6 5-35
Throttle body assembly nut 13 1.3 9.6 5-35
Supercharger oil filler hole bolt 4 0.4 3.0 5-38
Oil filter bolt 18 1.8 13.3 5-41
Oil cooler assembly bolt M8 18 1.8 13.3 5-41
Oil pipe holder bolt M6 8 0.8 5.9 5-41
Oil pipe bolt M10 21 2.1 15.5 5-41
Oil pump assembly bolt M6 10 1.0 7.4 5-41
Drive gear assembly bolt (left-hand
threads)
M12 80 8.0 59.0 5-43
Ignition coil bolt M6 8 0.8 5.9 5-51
Spark plug 25 2.5 18.4 5-51
Cam position sensor bolt M6 10 1.0 7.4 5-51
Cylinder head cover bolt M6 8 0.8 5.9 5-51
Oil pipe bolt M10 20 2.0 14.8 5-52
Timing chain tensioner bolt M6 10 1.0 7.4 5-52
Camshaft cap bolt M7 16 1.6 11.8 5-52
Part to tightened
Thread
size
Tightening torque
Refer to
page
Nm kgfm ftlb
Tightening torques
2-13
E
SPEC
1
3
4
5
6
7
8
9
Camshaft sprocket bolt M7 24 2.4 17.7 5-52
Chain guide plate bolt M6 10 1.0 7.4 5-52
Engine hanger bolt M6 12 1.2 8.9 5-66
Cylinder head assembly bolt
M6 10 1.0 7.4
5-66 1st
M12
48 4.8 35.4
2nd 90
Drive coupling M30 250 25.0 184.4 5-79
Grommet bracket bolt M6 8 0.8 5.9 5-79
Generator cover assembly bolt M8 26 2.6 19.2 5-79
Transfer shaft
1st
50 5.0 36.9
5-79 2nd 60
3rd 250 25.0 184.4
Holder (left-hand threads) 80 8.0 59.0 5-79
Special nut 250 25.0 184.4 5-79
Flywheel magneto bolt M8 24 2.4 17.7 5-79
Pickup coil bolt M5 5 0.5 3.7 5-81
Washer bolt M5 5 0.5 3.7 5-81
Stator coil assembly bolt M6 14 1.4 10.3 5-81
Clamp bolt M6 14 1.4 10.3 5-81
Thermoswitch bolt M6 8 0.8 5.9 5-95
Knock sensor 15 1.5 11.1 5-95
Anode cover bolt M8 20 2.0 14.8 5-95
Anode bolt M6 8 0.8 5.9 5-95
Engine temperature sensor 15 1.5 11.1 5-95
Earth plate bolt M6 8 0.8 5.9 5-95
Water jacket cover bolt M6 8 0.8 5.9 5-95
Oil pressure switch lead bolt M4 2 0.2 1.5 5-95
Oil pressure switch 8 0.8 5.9 5-95
Oil separator tank cover bolt M6 8 0.8 5.9 5-95
Oil pan assembly bolt M6 10 1.0 7.4 5-95
Baffle plate bolt M6 12 1.2 8.9 5-98
Oil pipe 1 and 2 bolt M6 9 0.9 6.6 5-98
Bracket 1 and 2 bolt M10 50 5.0 36.9 5-100
Baffle plate bolt M6 10 1.0 7.4 5-100
Crankcase bolt
M6 10 1.0 7.4
5-100 1st
M10
30 3.0 22.1
2nd 90
Connecting rod cap nut
1st
51 5.1 37.6
5-100
2nd 90
Jet pump unit
Intake grate bolt M10 40 4.0 29 6-1
Speed sensor screw M5 4 0.4 3.0 6-1
Rubber plate bolt M6 7 0.7 5.2 6-1
Ride plate bolt M8 17 1.7 12.5 6-1
Part to tightened
Thread
size
Tightening torque
Refer to
page
Nm kgfm ftlb
Tightening torques
2-14
E
SPEC
1
2
3
4
5
6
7
8
9
Steering cable joint nut 7 0.7 5.2 6-2
Steering cable joint 7 0.7 5.2 6-2
Spout hose clamp (hull end) 2 0.2 1.5 6-2
Bracket bolt M8 17 1.7 12.5 6-2
Jet pump unit assembly bolt
M6 8 0.8 5.9
6-2
M10 40 4.0 29.5
Stay bolt M8 14 1.4 10.3 6-2
Spout hose clamp (jet pump end) 1 0.1 0.7 6-6
Reverse gate assembly bolt M8 20 2.0 14.8 6-6
Shift cable ball joint nut 8 0.8 5.9 6-6
Spring nut 8 0.8 5.9 6-6
Spring bolt M8 20 2.0 14.8 6-6
Reverse gate bracket bolt M6 8 0.8 5.9 6-6
Jet thrust nozzle bolt M8 15 1.5 11.1 6-7
Nozzle ring bolt M8 15 1.5 11.1 6-7
QSTS rod ball joint nut 8 0.8 5.9 6-7
Impeller duct bolt M10 40 4.0 29.5 6-8
Water inlet cover/water inlet strainer
bolt
M6 7 0.7 5.2 6-8
Impeller (left-hand threads) 205 20.5 151.2 6-9
Cap bolt M6 8 0.8 5.9 6-9
Drive shaft nut 69 6.9 50.9 6-9
Flushing hose nut 6 0.6 4.4 6-17
Pilot water outlet joint nut 5 0.5 3.7 6-17
Drain joint nut 7 0.7 5.2 6-17
Transom plate nut 26 2.6 19.2 6-17
Intermediate housing assembly bolt M8 17 1.7 12.5 6-21
Grease nipple 5 0.5 3.7 6-22
Driven coupling 205 20.5 151.2 6-22
Hull and hood
Upper handlebar cover screw M5 1 0.1 0.7 8-1
Lower handlebar cover screw M6 5 0.5 3.7 8-1
Upper handlebar holder bolt M8 20 2.0 14.8 8-2
QSTS grip assembly screw M6 3 0.3 2.2 8-3
Left handlebar switch assembly screw M5 3 0.3 2.2 8-3
Throttle lever assembly bolt M5 3 0.3 2.2 8-3
Throttle cable locknut 7 0.7 5.2 8-3
Grip end bolt M5 1 0.1 0.7 8-3
QSTS converter bolt M6 5 0.5 3.7 8-10
Pulley nut 7 0.7 5.2 8-10
QSTS cable grommet nut 5.9 0.59 4.4 8-10
QSTS rod locknut 4 0.4 3.0 8-13
Damper nut 5 0.5 3.7 8-15
Hinge assembly nut 6 0.6 4.4 8-15
Part to tightened
Thread
size
Tightening torque
Refer to
page
Nm kgfm ftlb
Tightening torques
2-15
E
SPEC
1
3
4
5
6
7
8
9
Front hood assembly bolt M6 5 0.5 3.7 8-15
Mirror assembly nut 6 0.6 4.4 8-15
Damper stay bolt M6 5 0.5 3.7 8-15
Ventilation cover screw M5 2 0.2 1.5 8-17
Hood lock bolt M5 4 0.4 3.0 8-17
Dual analog meter unit cover screw M5 2 0.2 1.5 8-20
Dual analog meter unit bolt M5 4 0.4 3.0 8-20
Grip screw M6 5 0.5 3.7 8-21
Side cover bolt M6 5 0.5 3.7 8-21
Side cover nut 5 0.5 3.7 8-21
Side ornament bolt M6 5 0.5 3.7 8-21
Knee pad bolt M6 5 0.5 3.7 8-21
Side cover bracket bolt M6 5 0.5 3.7 8-21
Center cover bolt M6 5 0.5 3.7 8-23
Center cover nut 5 0.5 3.7 8-23
Shift lever assembly nut 5 0.5 3.7 8-23
Reverse sensor screw M5 4 0.4 3.0 8-23
Lid lock hook/bracket bolt M5 4 0.4 3.0 8-25
Steering master assembly bolt M8 20 2.0 14.8 8-27
Steering arm assembly bolt M8 17 1.7 12.5 8-28
Steering cable ball joint nut 7 0.7 5.2 8-28
Steering cable ball joint 7 0.7 5.2 8-28
Cable stopper assembly bolt M6 7 0.7 5.2 8-28
Sensor base bolt M8 17 1.7 12.5 8-28
Grease nipple 2 0.2 1.5 8-28
Lock assembly bolt M6 7 0.7 5.2 8-28
Steering sensor bolt M6 7 0.7 5.2 8-28
Steering cable grommet nut 5.9 0.59 4.4 8-32
Steering cable joint locknut 7 0.7 5.2 8-32
Speed sensor lead grommet nut 5.9 0.59 4.4 8-32
Shift cable bracket nut 5 0.5 3.7 8-32
Shift cable grommet nut 5.9 0.59 4.4 8-32
Shift cable joint locknut 7 0.7 5.2 8-32
Cooling water pilot outlet nut 4 0.4 3.0 8-36
Seat lock assembly bolt M6 7 0.7 5.2 8-39
Deck beam nut 18 1.8 13.3 8-39
Projection nut 26 2.6 19.2 8-39
Deck beam 1 bolt M8 18 1.8 13.3 8-39
Seat holder nut 15 1.5 11.1 8-39
Handgrip bolt M8 5 0.5 3.7 8-39
Rubber hose/resonator clamp 3.7 0.37 2.7 8-43
Rubber hose/water tank clamp 3.7 0.37 2.7 8-43
Water tank/rubber hose clamp 3.7 0.37 2.7 8-43
Plate/rubber hose/exhaust valve nut 5 0.5 3.7 8-43
Part to tightened
Thread
size
Tightening torque
Refer to
page
Nm kgfm ftlb
Tightening torques
2-16
SPEC
1
2
3
4
5
6
7
8
9
E
Bow eye bolt M6 13 1.3 9.6 8-46
Front protector 1 nut 5 0.5 3.7 8-46
Front protector 1 bolt M6 2.5 0.25 1.9 8-46
Front protector 2 nut 5 0.5 3.7 8-46
Sponson bolt M8 16 1.6 11.8 8-46
Ski tow nut (FZS) 26 2.6 19.2 8-48
Spout nut 5 0.5 3.7 8-48
Stern eye nut 15 1.5 11.1 8-48
Drain plug nut 2 0.2 1.5 8-48
Reboarding step assembly bolt (FZS) M8 15 1.5 11.1 8-48
Electrical
ECM bolt M6 5 0.5 3.7 7-4
Slant detection switch screw M6 4 0.4 3.0 7-4
Fuse box bolt M6 8 0.8 5.9 7-4
Starter relay terminal bolt M6 4 0.4 3.0 7-6
Starter motor terminal nut 9 0.9 6.6 7-49
Starter motor cover bolt M6 7 0.7 5.2 7-49
Transmitter cover screw 0.1 0.01 0.1 7-58
Part to tightened
Thread
size
Tightening torque
Refer to
page
Nm kgfm ftlb
General torque
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread
pitch. Tightening torque specifications for spe-
cial components or assemblies are provided in
applicable sections of this manual. To prevent
warpage, tighten multi-fastener assemblies in
a crisscross fashion and progressive stages
until the specified torque is reached. Unless
otherwise specified, torque specifications
require clean, dry threads.
Components should be at room temperature.
Width
across flat
(A)
Screw
size (B)
General torque
specifications
Nm kgfm ftlb
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
Tightening torques
SPEC
2-17
1
3
4
5
6
7
8
9
E
Lubrication system
C
B
0
E
D
8 9 7
5
6
4
3
1
2
A
1 Intake camshaft
2 Exhaust camshaft
3 Cylinder block
4 Crankshaft
5 Oil separator tank
6 Oil pan
7 Oil strainer
8 Oil pipe
9 Oil pump assembly (feed pump)
0 Relief valve
A Oil pump assembly (scavenge pump)
B Oil cooler assembly
C Oil filter
D Drive gear assembly
E Supercharger assembly
Lubrication system
SPEC
2-18
1
2
3
4
5
6
7
8
9
E
Cooling system
1
2
4
2
3
1 Hose joint 2
2 Hose joint 3
3 Hose joint 4
4 Hose joint 1
To hose joint 1
To cooling water pilot outlet on port side
To cooling water pilot outlet on starboard side
To drain joint
To hose joint 2
To transom plate
Cooling system
SPEC
2-19
1
3
4
5
6
7
8
9
E
3
1
2
1 Thermostat housing
2 Air cooler assembly
3 Oil cooler assembly
From jet pump unit
To cooling water pilot outlet on port side
To cooling water pilot outlet on starboard side
Cooling system
SPEC
2-20
1
2
3
4
5
6
7
8
9
E
Cable and hose routing
Starboard bow view
F
E
D
C
B
0
A
9
8
7
3
2
1
5
8
6
4
1 Breather hose (head cover to breather
assembly)
2 Cooling water hose (exhaust manifold to rectifier
regulator)
3 Breather hose (breather assembly to intake pipe)
4 Throttle cable
5 Left handlebar switch lead
6 QSTS cable
7 Fuel tank breather hose (water separator to fuel
tank)
8 Cooling water pilot outlet hose
9 Speed sensor lead
0 Remote control receiver antenna
A Fuel tank breather hose (ventilation socket to
water separator)
B Wiring harness
C Steering cable
D Shift cable
E Fuel hose (fuel tank to fuel rail)
F Cooling water hose (hose joint 1 to hose joint 4)
Cable and hose routing
SPEC
2-21
1
3
4
5
6
7
8
9
E
Top view
0
A
H
I
F
8
L
D
M
J
K
7
5
N
C
9
O
3
1
E
8
2
B
4
G
6
1 Breather hose (head cover to breather
assembly)
2 Dual analog meter lead
3 Breather hose (breather assembly to intake
pipe)
4 Throttle cable
5 Left handlebar switch lead
6 QSTS cable
7 Fuel tank breather hose (water separator to fuel
tank)
8 Cooling water pilot outlet hose
9 Speed sensor lead
0 Remote control receiver antenna
A Fuel tank breather hose (ventilation socket to
water separator)
B Wiring harness
C Steering cable
D Shift cable
E Fuel hose (fuel tank to fuel rail)
F Cooling water hose (hose joint 1 to hose joint 4)
G Reverse sensor lead
H Electric bilge pump coupler
Cable and hose routing
SPEC
2-22
1
2
3
4
5
6
7
8
9
E
0
A
H
I
F
8
L
D
M
J
K
7
5
N
C
9
O
3
1
E
8
2
B
4
G
6
I Negative battery cable
J Positive battery cable
K Battery breather hose
L Cooling water hose (jet pump to hose joint 1)
M Flushing hose
N Cooling water hose (hose joint 1 to hose joint 3)
O Buzzer lead
Cable and hose routing
SPEC
2-23
1
3
4
5
6
7
8
9
E
Port view
A
A
1 L 7 G E H 2 3 M N K O
9 D 6 J C P I 8 A 4 5 C F
B 0
B
b
b
c
c
4 N m (0.4 kgf m, 3.0 ft Ib)
1 N m (0.1 kgf m, 0.7 ft Ib)
6 N m (0.6 kgf m, 4.4 ft Ib)
13 N m (1.3 kgf m, 9.6 ft Ib)
16 N m (1.6 kgf m, 11.8 ft Ib)
16 N m (1.6 kgf m, 11.8 ft Ib)
2nd 6 N m (0.6 kgf m, 4.4 ft Ib)
1st 3 N m (0.3 kgf m, 2.2 ft Ib)
Fuel tank, fuel pump module, and fuel hose
4-2
FUEL
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
13 Corrugated tube 1
14 Fuel hose 1 a Paint mark
15 Nut 9
16 Retainer 1
17 Fuel pump module assembly 1
18 Stopper 1
19 Fuel sender 1
20 Packing 1 Not reusable
21 Clamp/fuel filler hose 2/1
22 Nut 1
23 Fuel filler neck 1
24 Packing 1 Not reusable
25 Clamp/cap 1/1
34
34
26
28
27
23
24
21
21
17
2
5
7
6
1
3
4
1
25
20
22
LT
242
LT
LT
242
LT
LT
242
LT
9
8
16 15
10
13
14
a
a
11
11
12
12
30
30
31
32
33
32
26
29
19
18
E
1
b
b
c
c
4 N m (0.4 kgf m, 3.0 ft Ib)
1 N m (0.1 kgf m, 0.7 ft Ib)
6 N m (0.6 kgf m, 4.4 ft Ib)
13 N m (1.3 kgf m, 9.6 ft Ib)
16 N m (1.6 kgf m, 11.8 ft Ib)
16 N m (1.6 kgf m, 11.8 ft Ib)
2nd 6 N m (0.6 kgf m, 4.4 ft Ib)
1st 3 N m (0.3 kgf m, 2.2 ft Ib)
Fuel tank, fuel pump module, and fuel hose
4-3
FUEL
1
2
3
5
6
7
8
9
E
Step Part name Qty Remarks
26 Bolt 2 M8 18 mm
27 Strap 1 b Blue thread
28 Strap 1 c Black thread
29 Fuel tank 1
30 Bolt 3 M8 17 mm
31 Fuel rail 1
32 Fuel injector 4
33 O-ring 4 Not reusable
34 Seal 4 Not reusable
34
34
26
28
27
23
24
21
21
17
2
5
7
6
1
3
4
1
25
20
22
LT
242
LT
LT
242
LT
LT
242
LT
9
8
16 15
10
13
14
a
a
11
11
12
12
30
30
31
32
33
32
26
29
19
18
E
1
b
b
c
c
4 N m (0.4 kgf m, 3.0 ft Ib)
1 N m (0.1 kgf m, 0.7 ft Ib)
6 N m (0.6 kgf m, 4.4 ft Ib)
13 N m (1.3 kgf m, 9.6 ft Ib)
16 N m (1.6 kgf m, 11.8 ft Ib)
16 N m (1.6 kgf m, 11.8 ft Ib)
2nd 6 N m (0.6 kgf m, 4.4 ft Ib)
1st 3 N m (0.3 kgf m, 2.2 ft Ib)
Fuel tank, fuel pump module, and fuel hose
4-4
FUEL
1
2
3
4
5
6
7
8
9
E
Fuel hose disconnection
WARNING
Before checking the fuel system, remove
the battery and then remove the fuel tank
filler cap to reduce any pressure inside
the fuel tank.
Always reduce the fuel pressure in the
fuel line before servicing the line or the
fuel pipe. If the fuel pressure is not re-
leased, pressurized fuel could spray out.
1. Disconnect:
Quick connector
Disconnecting steps:
1. Wrap the quick connector with a cloth.
2. Spread apart the ends of the locking slider
1 with your fingers as shown, and then
pull up on the slider.
WARNING
Make sure to disconnect the quick connec-
tor slowly, otherwise pressured fuel could
spray out.
3. Disconnect the quick connector 2 from
the fuel pipe 3 directly.
4. Cover the quick connector and fuel pipe
with a plastic bag 4 to protect them from
dirt.
1
2
3
4
Quick connector removal
1. Remove:
Clamps 1
Quick connector
NOTICE
Before removing the quick connector, cut
each clamp in the direction shown.
1
Fuel tank, fuel pump module, and fuel hose
4-5
FUEL
1
2
3
5
6
7
8
9
E
Fuel pump module removal
1. Remove:
Nuts
Retainer
TIP
Loosen the nuts in the sequence shown.
1
4
9
6
2
3
8 7
5
BOW
2. Remove:
Fuel pump module assembly 1
TIP
Remove the fuel pump module assembly 1
at an angle so that the float 2 does not catch
on the fuel tank.
Make sure that the rubber cap 3 does not
come off when removing the fuel pump mod-
ule assembly 1.
2
1
3
Fuel sender removal
1. Remove:
Fuel sender 1
Removal steps:
1. Disconnect the fuel sender coupler 2.
2. Squeeze the hooks a on the stopper 3,
and then slide the clip in direction to
remove it.
3. Push the tabs b on the fuel sender 1,
and then slide the sender in direction to
remove it.
a
3
3
1
2
1
Fuel tank, fuel pump module, and fuel hose
4-6
FUEL
1
2
3
4
5
6
7
8
9
E
Rollover valve check
1. Check:
Rollover valve
Does not function properly Replace
the rollover valve.
Checking steps:
1. Blow into the end a of the rollover valve,
and make sure that airflow from the end b
is unrestricted.
2. Blow into the end b of the rollover valve,
and make sure that air does not come out
from the end a.
Upright
Inverted
b
a
a
b
Check valve check
1. Check:
Check valve
Does not function properly Replace
the check valve.
Checking steps:
1. Blow into the end a of the check valve,
and make sure that airflow from the end b
is restricted.
2. Blow into the end b of the check valve,
and make sure that airflow from the end a
is unrestricted.
a
b
Fuel tank, fuel pump module, and fuel hose
4-7
FUEL
1
2
3
5
6
7
8
9
E
Fuel line check
1. Check:
Fuel hose 1
Cracks/damage Replace the fuel
hose.
Quick connectors 2
Cracks/damage Replace the quick
connector.
Fuel pipe 3 (fuel pump module end)
Cracks/damage Replace the fuel
pump module assembly.
Fuel rail 4
Cracks/damage Replace the fuel rail.
2
3
1
2
4
Fuel pump module check
1. Check:
Fuel pump filter 1
Clog/contaminants Clean the fuel
pump filter with kerosene or gasoline.
NOTICE
Do not disassemble the fuel pump module.
1
Fuel filler neck and hose check
1. Check:
Fuel filler neck 1
Cracks/damage Replace the fuel filler
neck.
Fuel filler hose 2
Cracks/damage Replace the fuel filler
hose.
2
1
Fuel tank, fuel pump module, and fuel hose
4-8
FUEL
1
2
3
4
5
6
7
8
9
E
Fuel tank check
1. Check:
Fuel tank
Cracks/damage Replace the fuel
tank.
TIP
Before removing the fuel tank, it is necessary
to remove the engine unit.
Refer to Engine unit removal in Chapter 5.
Fuel injector check
1. Check:
Fuel injector
Clog/contaminants Clean the fuel
injector.
Damage Replace the fuel injector.
Fuel injector installation
1. Install:
Fuel injector
Installation steps:
1. Apply a thin coat of engine oil to the O-ring
1.
2. While turning the fuel injector 2 slowly to
the left and right, install it to the fuel rail 3.
NOTICE
Make sure to apply a thin coat of engine oil
to the O-ring before installing the fuel injec-
tor to the fuel rail, otherwise the O-ring
could twist and break, causing fuel leak-
age.
E
1
3
2
Fuel tank, fuel pump module, and fuel hose
4-9
FUEL
1
2
3
5
6
7
8
9
E
Fuel sender installation
1. Install:
Fuel sender 1
Installation steps:
1. Install the fuel sender 1.
TIP
Make sure that the tabs a on the fuel sender
1 are securely seated into the slots b in the
fuel pump module.
2. Install the stopper 2.
TIP
Make sure that the hooks c on the stopper 2
are securely hooked onto the fuel pump mod-
ule.
3. Connect the fuel sender coupler 3.
a
b b
1
c
2
3
2
Fuel pump module installation
1. Install:
Fuel pump module assembly
TIP
Tighten the nuts to the specified torques in the
sequence shown.
T
R
.
.
Fuel pump module nut:
1st:
3 Nm (0.3 kgfm, 2.2 ftlb)
2nd:
6 Nm (0.6 kgfm, 4.4 ftlb)
9
6
1
4
8
7
2 3
5
BOW
Fuel tank, fuel pump module, and fuel hose
4-10
FUEL
1
2
3
4
5
6
7
8
9
E
Quick connector installation
1. Install:
Quick connectors
Installation steps:
1. Install the corrugated tube 1, clamps 2,
and quick connectors 3 onto the fuel hose
4.
WARNING
Do not reuse the clamps, always replace
them with new ones, otherwise fuel could
leak.
TIP
Align the paint marks a on the fuel hose with
the notch b and projection c on the quick
connectors.
Make sure to face the locking slider d on
each quick connector in the same direction.
2. Crimp the clamps 2.
TIP
Position the crimped sections of the clamps
180 away from each other.
Crimp each clamp as shown.
Crimp each clamp so that the gap a is 1 mm
(0.04 in) or less.
Fuel hose connection
1. Connect:
Quick connector
Connecting steps:
1. Apply a thin coat of engine oil to the con-
tact surfaces of the fuel pipe 1.
2. Connect the quick connector 2 onto the
fuel pipe 1.
3. Push down on the locking slider 3 until it
clicks.
1
4
3
2
c b d d a a
a
3
2
1
E
Fuel tank, fuel pump module, and fuel hose
4-11
FUEL
1
2
3
5
6
7
8
9
E
TIP
If the fuel hose quick connector 2 is not
installed completely onto the fuel pipe 1, the
locking slider 3 cannot be pushed down.
Confirm that the fuel hose quick connector is
correctly installed by making sure there is a
small amount of free play when the quick
connector is pulled and pushed.
If there is no free play in the fuel hose quick
connector, disconnect the fuel hose and
check the O-ring for damage and proper
installation.
Fuel pressure measurement
1. Measure:
Fuel pressure
Out of specification Replace the fuel
pump module assembly.
Measurement steps:
1. Disconnect the quick connector from the
fuel rail.
2. Install the special service tools 1 and 2
as shown.
3. Start the engine and allow it to warm up for
5 minutes.
4. Measure the fuel pressure.
Fuel pressure gauge adapter 1:
YW-06842/90890-06842
Fuel pressure gauge 2:
YB-06766/90890-06786
Fuel pressure:
345370 kPa
(3.453.70 kgf/cm
2
, 49.152.6 psi)
2
1
Fuel tank, fuel pump module, and fuel hose
E
POWR
1
2
3
4
5
6
7
8
9
Chapter 5
Power unit
Engine unit...................................................................................................... 5-1
Engine unit removal 1................................................................................ 5-1
Engine unit removal 2................................................................................ 5-3
Engine unit removal 3................................................................................ 5-5
Engine unit removal 4................................................................................ 5-8
Engine mount removal............................................................................... 5-9
Engine unit removal ................................................................................. 5-10
Breather assembly check ........................................................................ 5-15
Hose joint check ...................................................................................... 5-16
Engine mount check................................................................................ 5-16
Engine unit installation............................................................................. 5-16
Muffler ........................................................................................................... 5-24
Muffler disassembly................................................................................. 5-24
Exhaust pipe 3 removal ........................................................................... 5-26
Muffler check ........................................................................................... 5-26
Thermo sensor check.............................................................................. 5-26
Exhaust pipe 3 installation....................................................................... 5-26
Thermostat and electrical component ....................................................... 5-27
Thermostat and electrical component removal........................................ 5-27
Thermostat housing check ...................................................................... 5-30
Thermostat check.................................................................................... 5-30
Air cooler, supercharger, and throttle body assembly............................. 5-31
Air cooler and supercharger removal ...................................................... 5-31
Intake assembly removal ......................................................................... 5-33
Intake disassembly.................................................................................. 5-35
Air cooler check....................................................................................... 5-36
Supercharger check ................................................................................ 5-37
Throttle body assembly check................................................................. 5-37
Intake manifold check.............................................................................. 5-37
Intake manifold installation ...................................................................... 5-38
Supercharger installation......................................................................... 5-38
Air cooler intake pipe installation............................................................. 5-39
Boost pipe installation.............................................................................. 5-40
E
POWR
1
2
3
4
6
7
8
9
Oil cooler, oil pump assembly, and drive gear.......................................... 5-41
Oil cooler and oil pump assembly removal .............................................. 5-41
Drive gear removal .................................................................................. 5-43
Drive gear assembly removal .................................................................. 5-45
Drive gear disassembly ........................................................................... 5-45
Oil cooler assembly check....................................................................... 5-46
Oil pump assembly check........................................................................ 5-47
Idle gear check ........................................................................................ 5-47
Drive gear check...................................................................................... 5-47
Drive gear clutch check ........................................................................... 5-48
Oil pump drive gear assembly................................................................. 5-49
Drive gear assembly installation.............................................................. 5-49
Oil pump assembly installation................................................................ 5-50
Camshaft....................................................................................................... 5-51
Cylinder head cover removal ................................................................... 5-51
Camshaft and timing chain removal ........................................................ 5-52
Camshaft removal ................................................................................... 5-54
Camshaft check....................................................................................... 5-56
Camshaft sprocket check ........................................................................ 5-58
Timing chain check.................................................................................. 5-58
Timing chain tensioner check.................................................................. 5-58
Camshaft installation ............................................................................... 5-59
Cylinder head cover installation............................................................... 5-62
Valve clearance adjustment .................................................................... 5-62
Cylinder head ............................................................................................... 5-66
Cylinder head assembly removal ............................................................ 5-66
Cylinder head disassembly...................................................................... 5-67
Cylinder head assembly removal ............................................................ 5-68
Valve removal .......................................................................................... 5-68
Cylinder head check................................................................................ 5-68
Valve spring check .................................................................................. 5-69
Valve check ............................................................................................. 5-69
Valve guide check ................................................................................... 5-71
Valve guide removal ................................................................................ 5-71
Valve guide installation............................................................................ 5-72
Valve seat check ..................................................................................... 5-73
Valve seat refacing.................................................................................. 5-74
Valve installation...................................................................................... 5-77
Cylinder head installation ........................................................................ 5-78
E
POWR
1
2
3
4
5
6
7
8
9
Generator cover and flywheel magneto..................................................... 5-79
Generator cover and flywheel magneto removal ..................................... 5-79
Generator cover disassembly.................................................................. 5-81
Drive coupling removal ............................................................................ 5-82
Flywheel magneto removal...................................................................... 5-83
Bearing removal ...................................................................................... 5-85
Idle gear and shaft check ........................................................................ 5-85
Starter clutch check................................................................................. 5-85
Bearing installation .................................................................................. 5-86
Oil seal installation................................................................................... 5-87
Generator cover assembly ...................................................................... 5-87
Flywheel magneto installation ................................................................. 5-88
Drive coupling installation........................................................................ 5-93
Oil separator tank and oil pan..................................................................... 5-95
Oil separator tank and oil pan removal .................................................... 5-95
Oil pan disassembly ................................................................................ 5-98
Oil separator tank cover removal............................................................. 5-99
Oil separator tank cover check................................................................ 5-99
Oil pan check........................................................................................... 5-99
Oil separator tank cover installation ........................................................ 5-99
Crankcase, connecting rod, and piston................................................... 5-100
Crankcase, connecting rod, and piston disassembly ............................ 5-100
Crankcase disassembly......................................................................... 5-102
Connecting rod and piston removal ....................................................... 5-102
Crankcase check................................................................................... 5-103
Anode check.......................................................................................... 5-103
Piston check .......................................................................................... 5-104
Piston ring check ................................................................................... 5-105
Piston pin check .................................................................................... 5-106
Connecting rod check............................................................................ 5-107
Cylinder check....................................................................................... 5-107
Crankshaft check................................................................................... 5-108
Crankshaft pin oil clearance check........................................................ 5-108
Crankshaft journal oil clearance check.................................................. 5-111
Connecting rod and piston installation................................................... 5-114
Crankcase assembly ............................................................................. 5-116
5-1
POWR
1
2
3
4
6
7
8
9
E
Engine unit
Engine unit removal 1
Step Part name Qty Remarks
Engine oil Refer to Engine oil change in Chapter 3.
Service lid Refer to Front hood removal in Chapter 8.
1 Negative battery cable 1
2 Positive battery cable 1
3 Electrical box cover 1
4 Nut/washer 4/4
5 Bolt/washer 2/2
6 Bolt 2
7 Bolt 3
8 Deck beam assembly 1
9 Screw/grommet 2/2 M6 12 mm
10 Engine cover 1
1
9
9
14
10
2
3
5
17
18
19
20
20
20
20
16
21
22
20
17
13
11
12
15
4
4
8
6
7
AA
5 N m (0.5 kgf m, 3.7 ft Ib)
18 N m (1.8 kgf m, 13.3 ft Ib)
18 N m (1.8 kgf m, 13.3 ft Ib)
LT
242
17 N m (1.7 kgf m, 12.5 ft Ib)
Engine unit
5-2
POWR
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
11 Nut 2
12 APS 1
13 APS coupler 1
14 Plastic tie 1
15 Plastic tie 1
16 Plastic tie 1
17 Coupler 7
18 Antenna holder 3
19 Remote control receiver coupler 1
20 Plastic tie 5
21 Fuel pump module coupler 1
22 Electric bilge pump coupler 1
1
9
9
14
10
2
3
5
17
18
19
20
20
20
20
16
21
22
20
17
13
11
12
15
4
4
8
6
7
AA
5 N m (0.5 kgf m, 3.7 ft Ib)
18 N m (1.8 kgf m, 13.3 ft Ib)
18 N m (1.8 kgf m, 13.3 ft Ib)
LT
242
17 N m (1.7 kgf m, 12.5 ft Ib)
Engine unit
5-3
POWR
1
2
3
4
6
7
8
9
E
Engine unit removal 2
Step Part name Qty Remarks
1 Fuel hose assembly 1 To fuel pump module
2 Plastic tie 2
3 Clamp/breather hose 2/1
4 Clamp/intake pipe 2/1
5 Connection 1
6 Air filter case cover 1
7 Screw 3 6 15 mm
8 Air filter element 1
9 Bolt 4 M8 35 mm
10 Air filter case 1
11 Collar/grommet 4/4
12 Plastic tie 1
A
16
17
18
19
1
15
5
7
9
9
11
11
8
6
4
4
14
13
3
3
10
12
20
19
17
18
2
LT
242
2nd 35 N m (3.5 kgf m, 25.8 ft Ib)
1st 20 N m (2.0 kgf m, 14.8 ft Ib)
C
B
8 N m (0.8 kgf m, 5.9 ft Ib)
LT
572
LT
572
LT
242
A
Engine unit
5-6
POWR
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
10 Clamp/cooling water hose 2/1
11 Clamp/cooling water hose 1/1
12 Bolt 2 M8 35 mm
13 Rectifier regulator 1
14 Collar/grommet 2/2
15 Plastic tie 1
16 Clamp/cooling water hose 1/1 To air cooler
17 Clamp/cooling water hose 1/1 Cooling water inlet
18 Clamp/cooling water hose 1/1
A
B C
10
15
2 1
18
17
23
3
24
16
25
27
21
27
20
11
6
14
10
22
10
19
12
9
9
4
4
8
5
26
7
14
12
13
2 N m (0.2 kgf m, 1.5 ft Ib)
26 N m (2.6 kgf m, 19.2 ft Ib)
2nd 42 N m (4.2 kgf m, 31.0 ft Ib)
1st 22 N m (2.2 kgf m, 16.2 ft Ib)
2nd 42 N m (4.2 kgf m, 31.0 ft Ib)
1st 22 N m (2.2 kgf m, 16.2 ft Ib)
LT
242
LT
242
LT
242
2nd 35 N m (3.5 kgf m, 25.8 ft Ib)
1st 20 N m (2.0 kgf m, 14.8 ft Ib)
C
B
8 N m (0.8 kgf m, 5.9 ft Ib)
LT
572
LT
572
LT
242
A
Engine unit
5-7
POWR
1
2
3
4
6
7
8
9
E
Step Part name Qty Remarks
19 Bolt 1 M10 50 mm
20 Bolt 1 M8 47 mm
21 Stay 1
22 Clamp 1
23 Bolt 8 M8 70 mm
24 Bolt 3 M8 120 mm
25 Muffler assembly 1
26 Gasket 1 Not reusable
27 Dowel pin 2
A
B C
10
15
2 1
18
17
23
3
24
16
25
27
21
27
20
11
6
14
10
22
10
19
12
9
9
4
4
8
5
26
7
14
12
13
2 N m (0.2 kgf m, 1.5 ft Ib)
26 N m (2.6 kgf m, 19.2 ft Ib)
2nd 42 N m (4.2 kgf m, 31.0 ft Ib)
1st 22 N m (2.2 kgf m, 16.2 ft Ib)
2nd 42 N m (4.2 kgf m, 31.0 ft Ib)
1st 22 N m (2.2 kgf m, 16.2 ft Ib)
LT
242
LT
242
LT
242
2nd 35 N m (3.5 kgf m, 25.8 ft Ib)
1st 20 N m (2.0 kgf m, 14.8 ft Ib)
C
B
8 N m (0.8 kgf m, 5.9 ft Ib)
LT
572
LT
572
LT
242
A
Engine unit
5-8
POWR
1
2
3
4
5
6
7
8
9
E
Engine unit removal 4
*: As required.
Step Part name Qty Remarks
1 Bolt 4 M8 28 mm
2 Electrical box 1
3 Bolt/collar 1/1 M6 25 mm
4 Coupling cover 1
5 Engine mounting bolt 4 M8 37 mm
6 Shim *
7 Engine unit 1
LT
572
LT
242
LT
271
17 N m (1.7 kgf m, 12.5 ft Ib)
17 N m (1.7 kgf m, 12.5 ft Ib)
8 N m (0.8 kgf m, 5.9 ft Ib)
6
5
3
4
1 7
2
Engine unit
5-9
POWR
1
2
3
4
6
7
8
9
E
Engine mount removal
Step Part name Qty Remarks
1 Bolt 8 M8 35 mm
2 Engine mount 4
3 Liner 4
4 Bolt 2 M6 19 mm
5 Damper 1 1
6 Bolt 2 M6 12 mm
7 Damper 2 1
8 Bolt 4 M6 25 mm
9 Spacer 1 1
10 Spacer 2 1
4
1 1
6
8
8
1 1
5
9
7
2 3
10
A
A
5
LT
572
LT
LT
572
LT
LT
572
LT
6 N m (0.6 kgf m, 4.4 ft Ib)
6 N m (0.6 kgf m, 4.4 ft Ib)
BOW BOW
5 N m (0.5 kgf m, 3.7 ft Ib)
17 N m (1.7 kgf m, 12.5 ft Ib)
Engine unit
5-10
POWR
1
2
3
4
5
6
7
8
9
E
Engine unit removal
1. Remove:
Engine unit
NOTICE
Before removing the engine, make sure to
take adequate measures to protect the
deck opening from damage.
Removal steps:
1. Disconnect the negative battery cable 1
and positive battery cable 2 from the bat-
tery.
2. Remove the electrical box cover 3.
3. Extract the engine oil.
Refer to Engine oil change in Chapter 3.
1
2
3
4. Remove the service lid 4.
4
5. Remove the deck beam bolts 5, 6, and
7 and nuts 8, and then remove the deck
beam assembly 9.
6
7
8
9
5
6. Remove the engine cover screws 0, and
then remove the engine cover A.
TIP
Slide the engine cover rearward, and then lift
the cover to remove it.
A
0
Engine unit
5-11
POWR
1
2
3
4
6
7
8
9
E
7. Disconnect the APS coupler B, and the 7
dual analog meter unit, sensor, and switch
couplers C.
B
A
A
C
8. Remove the antenna holders D.
9. Disconnect the remote control receiver
coupler E.
E
A
D
A
10. Remove the wiring harness from the 5
plastic ties F.
F F
11. Disconnect the fuel pump module coupler
G and electric bilge pump coupler H.
12. Wrap the quick connector I with a cloth,
and then disconnect it from the fuel rail.
Refer to Fuel tank removal in Chapter 4.
WARNING
Make sure to disconnect the quick connec-
tor slowly, otherwise pressured fuel could
spray out.
G
I H
Engine unit
5-12
POWR
1
2
3
4
5
6
7
8
9
E
13. Disconnect the breather hose J from the
intake pipe K, and then remove the intake
pipe K from the supercharger.
14. Unhook the fasteners L, and then remove
the air filter case cover M. Remove the air
filter case bolts N, and then remove the
air filter case O.
15. Remove the plastic tie P from the cooling
water hose Q.
J
K
L
M
N
O
P
Q
16. Disconnect the cooling water hoses R
from the oil cooler assembly.
R
R
17. Disconnect the cooling water hose S from
the air cooler and cooling water hose T
from the thermostat housing.
T
S
18. Place a cloth under the oil filter U, and
then remove it with the special service
tool.
TIP
Make sure to clean up any oil spills.
Oil filter wrench:
90890-06830
U
Engine unit
5-13
POWR
1
2
3
4
6
7
8
9
E
19. Remove the leads from the plastic ties V.
20. Disconnect the thermo sensor coupler W.
21. Remove the breather hose X.
22. Remove the breather assembly bolts Y
and hose Z, and then remove the
breather assembly [.
W
A
A
[
X
Y
V Z
23. Remove the cooling water hoses \.
24. Remove the rectifier regulator bolts ],
and then remove the rectifier regulator _.
_
\
]
]
\
\
25. Remove the plastic tie a from the cooling
water hose b.
26. Disconnect the cooling water hose c from
the hose joint 1 d.
a
c
b
d
27. Disconnect the cooling water hoses e
from the hose joint 3 f.
28. Remove the stay bolts g, and then
remove the stay h.
e
g
h
f
29. Remove the clamp i from the pipe j.
i
j
Engine unit
5-14
POWR
1
2
3
4
5
6
7
8
9
E
30. Remove the muffler assembly bolts k,
and then remove the muffler assembly l.
TIP
When removing the muffler assembly, move it
forward and separate it from the water lock.
k
l
31. Remove the electrical box bolts m, and
then remove the electrical box n.
n
m
m
32. Remove the coupling cover bolt o and
collar, and then remove the coupling cover
p.
p
o
33. Loosen the engine mounting bolts q.
34. Lift the engine unit slightly, remove the
shims r, and then lower the engine.
TIP
Make a note of the position of each removed
shim so that it can be installed in its original
position.
35. Remove the engine mounting bolts q.
q
r
r
q
Engine unit
5-15
POWR
1
2
3
4
6
7
8
9
E
36. Suspend the engine unit using all 3 engine
hangers, and then separate the unit from
the engine mounts and move it forward to
disconnect the coupling.
37. Lift the engine unit slightly, and then lower
the front of the unit. Repeat this step until
the engine unit can be removed from the
engine compartment.
NOTICE
When removing the engine unit, take care
to avoid causing damage to the hull liner
and deck opening.
38. Lift the engine unit out vertically.
Breather assembly check
NOTICE
The breather assembly should not be dis-
assembled.
1. Check:
Breather assembly
Cracks/damage Replace the breather
assembly.
Breather hoses
Cracks/damage Replace the breather
hoses.
Engine unit
5-16
POWR
1
2
3
4
5
6
7
8
9
E
Hose joint check
1. Check:
Hose joints 1
Cracks/damage Replace the hose
joints.
Cooling water hoses
Cracks/damage Replace the cooling
water hoses.
1
1
Engine mount check
1. Check:
Engine mounts
Cracks/damage Replace the engine
mounts.
TIP
Make a note of the position of each engine
mount so that it can be installed in its original
place.
When replacing the engine mounts, make
sure to check the coupling clearance.
Engine unit installation
1. Install:
Engine unit
Installation steps:
1. Suspend the engine unit using all 3 engine
hangers.
2. Lower the front of the engine unit.
3. Lower the engine unit into the engine com-
partment vertically.
NOTICE
When installing the engine unit, take care
to avoid causing damage to the hull liner
and deck opening.
4. Lift the front of the engine unit slightly, and
lower the unit. Repeat this step until the
drive and driven couplings are aligned.
Engine unit
5-17
POWR
1
2
3
4
6
7
8
9
E
5. Move the engine unit rearward to connect
the coupling 1, and lower the unit onto the
engine mounts.
TIP
Do not install the rubber damper until the cou-
pling clearance adjustment has been made.
1
6. Temporarily install the engine mounting
bolts 2.
7. Lift the engine unit slightly, install the
shims 3, and then lower the engine.
TIP
Install the shims in their original positions.
2
3
3
2
Engine unit
5-18
POWR
1
2
3
4
5
6
7
8
9
E
8. Measure the coupling clearance a, and if
necessary, add or remove shims 3 so that
the clearance is within specification.
9. Install the rubber damper 4.
10. Adjust the position of the engine unit so
that the coupling clearances a and b are
within specification.
Available shim thicknesses:
0.10, 0.30, 0.50, 1.00, and 2.00 mm
Clearance a:
Less than 1.0 mm (0.039 in) (without
rubber damper)
Clearance b:
2.04.0 mm (0.0790.157 in)
4
11. Tighten the engine mounting bolts 2 to
the specified torque.
T
R
.
.
Engine mounting bolt:
17 Nm (1.7 kgfm, 12.5 ftlb)
LOCTITE 271
2
2
LT
271
LT
271
12. Check that the coupling clearances a and
b are within specification. If the clear-
ances are out of specification, adjust them
again.
Clearance a:
Less than 0.5 mm (0.020 in) (with
rubber damper)
Clearance b:
2.04.0 mm (0.0790.157 in)
Engine unit
5-19
POWR
1
2
3
4
6
7
8
9
E
13. Install the coupling cover 5 and collar,
and then tighten the coupling cover bolt 6
to the specified torque.
T
R
.
.
Coupling cover bolt:
8 Nm (0.8 kgfm, 5.9 ftlb)
LOCTITE 572
5
6
LT
572
LT
14. Install the electrical box 7, and then
tighten the electrical box bolts 8 to the
specified torque.
T
R
.
.
Electrical box bolt:
17 Nm (1.7 kgfm, 12.5 ftlb)
LOCTITE 242
LT
242
8
LT
242
8
7
15. Install the muffler assembly 9 into the
water lock, and then tighten the muffler
assembly bolts 0 to the specified torque.
NOTICE
Do not reuse the gasket, always replace it
with a new one.
TIP
Tighten the muffler assembly bolts in the
sequence shown.
16. Tighten the pipe clamp A to the specified
torque.
TIP
Make sure that the pipe on the end of the muf-
fler assembly is installed securely into the
water lock.
T
R
.
.
Muffler assembly bolt:
1st: 20 Nm (2.0 kgfm, 14 ftlb)
2nd: 35 Nm (3.5 kgfm, 25 ftlb)
LOCTITE 242
T
R
.
.
Pipe clamp:
2 Nm (0.2 kgfm, 1.5 ftlb)
8
5 4
A
0
7
3 2
6
9
1
9 0
LT
242
A
Engine unit
5-20
POWR
1
2
3
4
5
6
7
8
9
E
17. Install the stay B, and then tighten the
stay bolts C to the specified torque.
18. Connect the cooling water hoses D to the
hose joint 3 E.
19. Connect the cooling water hose F to the
hose joint 1 G.
20. Clamp the cooling water hose H with the
plastic tie I.
T
R
.
.
Stay bolt:
1st:
22 Nm (2.2 kgfm, 16.2 ftlb)
2nd:
42 Nm (4.2 kgfm, 31.0 ftlb)
LOCTITE 242
D
C
B
E
LT
242
I
F
H
G
21. Install the rectifier regulator J, and then
tighten the rectifier regulator bolts K to the
specified torque.
22. Connect the cooling water hoses L.
23. Install the hose M and breather assembly
N, and then tighten the breather assembly
bolts O to the specified torque.
24. Connect the breather hose P and the
thermo sensor coupler Q.
25. Clamp the leads with the plastic ties R.
T
R
.
.
Rectifier regulator bolt:
26 Nm (2.6 kgfm, 19.2 ftlb)
LOCTITE 572
T
R
.
.
Breather assembly bolt:
8 Nm (0.8 kgfm, 5.9 ftlb)
LOCTITE 572
J
L
K
K
LT
572
LT
L
L
Q
A
A
N
P
O
R M
LT
572
LT
26. Apply a thin coat of engine oil to the O-ring
S of the oil filter T.
E
S
T
Engine unit
5-21
POWR
1
2
3
4
6
7
8
9
E
27. Install the oil filter T with the special ser-
vice tool.
Oil filter wrench:
90890-06830
T
R
.
.
Oil filter:
18 Nm (1.8 kgfm, 13.3 ftlb)
T
28. Connect the cooling water hose U to the
air cooler and cooling water hose V to the
thermostat housing.
V
U
29. Connect the cooling water hoses W to the
oil cooler assembly.
W
W
30. Clamp the cooling water hose X with the
plastic tie Y.
31. Install the air filter case Z, and then
tighten the air filter case bolts [ to the
specified torque.
32. Install the air filter case cover \, and then
hook the fasteners ].
T
R
.
.
Air filter case bolt:
12 Nm (1.2 kgfm, 8.9 ftlb)
Z
[
]
\
X
Y
Engine unit
5-22
POWR
1
2
3
4
5
6
7
8
9
E
33. Apply adhesive onto the mating surface of
the connection _, and then install it.
TIP
Align the mark c on the connection with the
mark d on the intake pipe.
34. Install the intake pipe a, and then tighten
the clamps b.
35. Connect the breather hose c to the con-
nection _.
T
R
.
.
Intake pipe clamp:
3 Nm (0.3 kgfm, 2.2 ftlb)
a
_
b
c
c
d
36. Connect the quick connector d to the fuel
rail.
Refer to Fuel tank removal in Chapter 4.
37. Connect the electric bilge pump coupler e
and fuel pump module coupler f.
f
d e
38. Align the plastic tie with the gray tape e
on the wiring harness assembly.
39. Clamp the wiring harness assembly with 5
plastic ties. e
40. Connect the remote control receiver cou-
pler g.
41. Install the antenna holders h.
g
A
h
A
Engine unit
5-23
POWR
1
2
3
4
6
7
8
9
E
42. Connect the APS coupler i, and the 7
dual analog meter unit, sensor, and switch
couplers j.
i
A
A
j
43. Install the engine cover k, and then
tighten the engine cover screws l to the
specified torque.
TIP
Hold the engine cover down, and slide the
cover forward to install it.
44. Install the deck beam assembly m and
tighten the deck beam bolts n, o, and p
and nuts q to the specified torque.
45. Install the service lid.
46. Install the electrical box cover r.
47. Connect the positive battery cable s and
negative battery cable t to the battery.
48. Coat the battery cable terminals and bat-
tery terminals with a water resistance
grease.
T
R
.
.
Engine cover screw:
5 Nm (0.5 kgfm, 3.7 ftlb)
T
R
.
.
Deck beam bolt p:
18 Nm (1.8 kgfm, 13.3 ftlb)
LOCTITE 242
Deck beam nut q:
18 Nm (1.8 kgfm, 13.3 ftlb)
k l
o
p
q
m
n
LT
242
r
t
s
AA
Engine unit
5-24
POWR
1
2
3
4
5
6
7
8
9
E
Muffler
Muffler disassembly
Step Part name Qty Remarks
1 Clamp 1
2 Pipe 1
3 Thermo sensor 1
4 Exhaust pipe 3 1
5 Bolt 5 M8 35 mm
6 Exhaust pipe 2 1
7 Gasket 2 Not reusable
8 Silencer plate 1
9 Dowel pin 2
10 Clamp/cooling water hose 1/1
1
2
5
12
11
15
14
16
13
9
8
7
7
9
10
3
4
6
LT
572
LT
242
2 N m (0.2 kgf m, 1.5 ft Ib)
2nd 29 N m (2.9 kgf m, 21.4 ft Ib)
1st 15 N m (1.5 kgf m, 11.1 ft Ib)
2nd 35 N m (3.5 kgf m, 25.8 ft Ib)
1st 20 N m (2.0 kgf m, 14.8 ft Ib)
20 N m (2.0 kgf m, 14.8 ft Ib)
LT
648
LT
242
LT
242
63 N m (6.3 kgf m, 46.5 ft Ib)
Muffler
5-25
POWR
1
2
3
4
6
7
8
9
E
Step Part name Qty Remarks
11 Bolt 2 M8 70 mm
12 Bolt 4 M8 120 mm
13 Exhaust pipe 1 1
14 Gasket 1 Not reusable
15 Dowel pin 2
16 Exhaust manifold 1
1
2
5
12
11
15
14
16
13
9
8
7
7
9
10
3
4
6
LT
572
LT
242
2 N m (0.2 kgf m, 1.5 ft Ib)
2nd 29 N m (2.9 kgf m, 21.4 ft Ib)
1st 15 N m (1.5 kgf m, 11.1 ft Ib)
2nd 35 N m (3.5 kgf m, 25.8 ft Ib)
1st 20 N m (2.0 kgf m, 14.8 ft Ib)
20 N m (2.0 kgf m, 14.8 ft Ib)
LT
648
LT
242
LT
242
63 N m (6.3 kgf m, 46.5 ft Ib)
Muffler
5-26
POWR
1
2
3
4
5
6
7
8
9
E
Exhaust pipe 3 removal
WARNING
When using a heat gun, protect your hands
by wearing heat-resistant gloves. Compo-
nents become hot enough to cause burns.
1. Remove:
Exhaust pipe 3 1
TIP
Heat the area a of exhaust pipe 3 1 to
approximately 200 C (392 F) with a heat gun.
Exhaust pipe wrench:
90890-06726
1
a
Muffler check
1. Check:
Exhaust manifold 1
Exhaust pipe 1 2
Exhaust pipe 2 3
Exhaust pipe 3 4
Pipe 5
Cracks/damage Replace.
3
1
4
5
2
Thermo sensor check
1. Check:
Thermo sensor tube 1
Bends/damage Replace the thermo
sensor.
Exhaust pipe 3 installation
1. Install:
Exhaust pipe 3 1
Exhaust pipe wrench:
90890-06726
T
R
.
.
Exhaust pipe 3:
63 Nm (6.3 kgfm, 46.5 ftlb)
LOCTITE 648
1
1
Muffler
5-27
POWR
1
2
3
4
6
7
8
9
E
Thermostat and electrical component
Thermostat and electrical component removal
Step Part name Qty Remarks
1 Bolt 2 M6 35 mm
2 Thermostat housing 1
3 Thermostat 1 aHole
4 Ignition coil coupler 4
5 Plastic tie 1
6 Injector coupler 4
7 Knock sensor coupler 1
8 Thermoswitch coupler 1
9 Plastic tie 1
10 Cam position sensor coupler 1
11 Intake air temperature sensor
coupler
1
12 Engine temperature sensor coupler 1
13 Plastic tie 1
UP
3
a
SG
SG
23
22
21
24
25
27
30
31
28
29
26
14
13
5
19
16
18
20
11
15
9
12
10
7
8
4
6 17
29
15
27 31 28
A
A B
B
2
3
1
18 N m (1.8 m kg, 13.3 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
AA
8 N m (0.8 kgf m, 5.9 ft Ib)
LT
572
Thermostat and electrical component
5-28
POWR
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
14 Plastic tie 1
15 Throttle body assembly coupler 1
16 Intake air pressure sensor coupler 1
17 Clamp 3
18 Earth plate coupler 1 1
19 Earth plate coupler 2 1
20 Oil pressure switch coupler 1
21 Nut 1
22 Washer 1
23 Starter motor cable 1
UP
3
a
SG
SG
23
22
21
24
25
27
30
31
28
29
26
14
13
5
19
16
18
20
11
15
9
12
10
7
8
4
6 17
29
15
27 31 28
A
A B
B
2
3
1
18 N m (1.8 m kg, 13.3 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
AA
8 N m (0.8 kgf m, 5.9 ft Ib)
LT
572
Thermostat and electrical component
5-29
POWR
1
2
3
4
6
7
8
9
E
Step Part name Qty Remarks
24 Bolt 2 M8 30 mm
25 Negative battery cable 1
26 Starter motor 1
27 Plastic tie 1
28 Rectifier regulator coupler 1
29 Stator coil coupler 1
30 Rectifier regulator 1
31 Pick up coil coupler 1
UP
3
a
SG
SG
23
22
21
24
25
27
30
31
28
29
26
14
13
5
19
16
18
20
11
15
9
12
10
7
8
4
6 17
29
15
27 31 28
A
A B
B
2
3
1
18 N m (1.8 m kg, 13.3 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
AA
8 N m (0.8 kgf m, 5.9 ft Ib)
LT
572
Thermostat and electrical component
5-30
POWR
1
2
3
4
5
6
7
8
9
E
Thermostat housing check
1. Check:
Thermostat housing 1
Cracks/damage Replace the thermo-
stat housing.
1
Thermostat check
1. Check:
Thermostat valve opening a
Out of specification Replace the ther-
mostat.
Checking steps:
1. Suspend the thermostat 1 in a container
of water.
2. Place a thermometer in the water and
slowly heat the water.
3. Measure the thermostat valve opening a
at the specified water temperatures.
Water
temperature
Valve opening
4852 C
(118126 F)
0.05 mm (0.002 in)
(valve begins to open)
above 60 C (140 F)
more than 4.3 mm
(0.17 in)
1
Thermostat and electrical component
5-31
POWR
1
2
3
4
6
7
8
9
E
Air cooler, supercharger, and throttle body assembly
Air cooler and supercharger removal
Step Part name Qty Remarks
1 Clamp 3
2 Clamp 1
3 Bolt 1 M8 35 mm
4 Boost pipe 1
5 Collar/grommet 1/1
6 Joint 1 1
7 Joint 2 1
8 Clamp/cooling water hose 1/1
9 Clamp/air cooler intake pipe 2/1
10 Nut 1
11 Bolt 2 M10 45 mm
12 Air cooler assembly 1
13 Collar 1
20
3
2
7
1
4
1
6
5
1
8
14
12
9
19
18
17
11
9
15
10
13
16
25
20
21
22
23
24
20 N m (2.0 kgf m, 14.8 ft Ib)
20 N m (2.0 kgf m, 14.8 ft Ib)
4 N m (0.4 kgf m, 3.0 ft Ib)
2nd 42 N m (4.2 kgf m, 31.0 ft Ib)
1st 22 N m (2.2 kgf m, 16.2 ft Ib)
LT
242
LT
242
LT
242
LT
242
42 N m (4.2 kgf m, 31.0 ft Ib)
3 N m (0.3 kgf m, 2.2 ft Ib)
10 N m (1.0 kgf m, 7.4 ft Ib)
LT
242
2nd 20 N m (2.0 kgf m, 14.8 ft Ib)
1st 10 N m (1.0 kgf m, 7.4 ft Ib)
2nd 42 N m (4.2 kgf m, 31.0 ft Ib)
1st 22 N m (2.2 kgf m, 16.2 ft Ib)
Air cooler, supercharger, and throttle body assembly
5-32
POWR
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
14 Grommet 1
15 Plate 1
16 Stud bolt 1
17 Bolt 1 M10 50 mm
18 Bolt 1 M10 80 mm
19 Stay 1
20 Bolt/washer 2/2 M6 65 mm
21 Bolt 3 M8 65 mm
22 Bolt 1 M8 65 mm
23 Supercharger assembly 1
24 O-ring 1 Not reusable
25 Dowel pin 2
20
3
2
7
1
4
1
6
5
1
8
14
12
9
19
18
17
11
9
15
10
13
16
25
20
21
22
23
24
20 N m (2.0 kgf m, 14.8 ft Ib)
20 N m (2.0 kgf m, 14.8 ft Ib)
4 N m (0.4 kgf m, 3.0 ft Ib)
2nd 42 N m (4.2 kgf m, 31.0 ft Ib)
1st 22 N m (2.2 kgf m, 16.2 ft Ib)
LT
242
LT
242
LT
242
LT
242
42 N m (4.2 kgf m, 31.0 ft Ib)
3 N m (0.3 kgf m, 2.2 ft Ib)
10 N m (1.0 kgf m, 7.4 ft Ib)
LT
242
2nd 20 N m (2.0 kgf m, 14.8 ft Ib)
1st 10 N m (1.0 kgf m, 7.4 ft Ib)
2nd 42 N m (4.2 kgf m, 31.0 ft Ib)
1st 22 N m (2.2 kgf m, 16.2 ft Ib)
Air cooler, supercharger, and throttle body assembly
5-33
POWR
1
2
3
4
6
7
8
9
E
Intake assembly removal
Step Part name Qty Remarks
Fuel injector Refer to Fuel tank removal in Chapter 4.
1 Plastic tie 1
2 Intake air temperature sensor 1
3 Washer 1 Not reusable
4 Clamp 2
5 Hose 1
6 Bolt 2 M5 15 mm
7 Intake air pressure sensor 1
8 Bolt 2 M6 25 mm
9 Bracket 1
10 Collar 2
11 Grommet 2
12 Bolt 2 M8 25 mm
15
12
13
14
12
1
6
7
9
11
2
3
4
5
8
16
13
21
20
14
10
17
19
18
21
20
5 N m (0.5 kgf m, 3.7 ft Ib)
3.5 N m (0.35 kgf m, 2.6 ft Ib)
LT
572
15 N m (1.5 kgf m, 11.1 ft Ib)
8 N m (0.8 kgf m, 5.9 ft Ib)
1st 22 N m (2.2 kgf m, 16.2 ft Ib)
2nd 42 N m (4.2 kgf m, 31.0 ft Ib)
2nd 20 N m (2.0 kgf m, 14.8 ft Ib)
1st 10 N m (1.0 kgf m, 7.4 ft Ib)
2nd 20 N m (2.0 kgf m, 14.8 ft Ib)
1st 10 N m (1.0 kgf m, 7.4 ft Ib)
2nd 20 N m (2.0 kgf m, 14.8 ft Ib)
1st 10 N m (1.0 kgf m, 7.4 ft Ib)
LT
242
LT
242
LT
242
LT
242
LT
242
Air cooler, supercharger, and throttle body assembly
5-34
POWR
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
13 Bolt 2 M8 40 mm
14 Stay 2
15 Bolt 1 M6 12 mm
16 Bolt 6 M8 35 mm
17 Nut 2
18 Intake assembly 1
19 Packing 1 Not reusable
20 Dowel pin 2
21 Stud bolt 2
15
12
13
14
12
1
6
7
9
11
2
3
4
5
8
16
13
21
20
14
10
17
19
18
21
20
5 N m (0.5 kgf m, 3.7 ft Ib)
3.5 N m (0.35 kgf m, 2.6 ft Ib)
LT
572
15 N m (1.5 kgf m, 11.1 ft Ib)
8 N m (0.8 kgf m, 5.9 ft Ib)
1st 22 N m (2.2 kgf m, 16.2 ft Ib)
2nd 42 N m (4.2 kgf m, 31.0 ft Ib)
2nd 20 N m (2.0 kgf m, 14.8 ft Ib)
1st 10 N m (1.0 kgf m, 7.4 ft Ib)
2nd 20 N m (2.0 kgf m, 14.8 ft Ib)
1st 10 N m (1.0 kgf m, 7.4 ft Ib)
2nd 20 N m (2.0 kgf m, 14.8 ft Ib)
1st 10 N m (1.0 kgf m, 7.4 ft Ib)
LT
242
LT
242
LT
242
LT
242
LT
242
Air cooler, supercharger, and throttle body assembly
5-35
POWR
1
2
3
4
6
7
8
9
E
Intake disassembly
Step Part name Qty Remarks
1 Nut 4
2 Washer 4
3 Throttle body assembly 1
4 Gasket 1 Not reusable
5 Bolt 4 M8 20 mm
6 Joint 1
7 O-ring 1 Not reusable
8 Ribbon 1
9 Holder 1
10 Intake manifold 1
9
8
7
6
4
3
1
2
10
5
13 N m (1.3 kgf m, 9.6 ft Ib)
13 N m (1.3 kgf m, 9.6 ft Ib)
LT
242
Air cooler, supercharger, and throttle body assembly
5-36
POWR
1
2
3
4
5
6
7
8
9
E
Air cooler check
NOTICE
The air cooler assembly should not be dis-
assembled.
1. Check:
Air cooler assembly
Cracks/damage Replace the air
cooler assembly.
Air cooler holding pressure
Cannot be maintained Replace the
air cooler assembly.
Checking steps:
TIP
When checking the air cooler, connect the
hoses 1 to the air cooler.
1. Connect the special service tool 2 to the
inlet or outlet of the air cooler water pas-
sage.
2. Cover the other end a of the water pas-
sage with a finger.
3. Apply the specified positive pressure and
check that the pressure is maintained.
4. Connect the special service tools 2 and
3 to the inlet and outlet of the air cooler
air passage.
5. Apply the specified positive pressure and
check that the pressure is maintained.
Leakage tester 2:
90890-06840
Specified positive pressure (water
passage):
200 kPa (2.0 kgf/cm
2
, 28.5 psi)
Air cooler attachment 3:
90890-06731
Specified positive pressure (air
passage):
100 kPa (1.0 kgf/cm
2
, 14.2 psi)
2
1
a
3
2
3
1
1
Air cooler, supercharger, and throttle body assembly
5-37
POWR
1
2
3
4
6
7
8
9
E
Supercharger check
NOTICE
The supercharger should not be disassem-
bled.
1. Check:
Impeller 1
Gear 2
Cracks/damage Replace the super-
charger assembly.
Supercharger operation
Rough movement Replace the super-
charger assembly.
1
2
Throttle body assembly check
NOTICE
The throttle body assembly should not be
disassembled.
1. Check:
Throttle shaft 1
Cracks/damage Replace the throttle
body assembly.
Throttle valve opening
Refer to Throttle position sensor in
Chapter 7.
1
Intake manifold check
1. Check:
Intake manifold
Cracks/damage Replace the intake
manifold.
Air cooler, supercharger, and throttle body assembly
5-38
POWR
1
2
3
4
5
6
7
8
9
E
Intake manifold installation
1. Install:
Intake manifold
TIP
Tighten the bolts to the specified torques in the
sequence shown.
Supercharger installation
1. Lubricate:
Supercharger impeller shaft
NOTICE
Before installing the supercharger assem-
bly, make sure to lubricate the supercharg-
er impeller shaft with engine oil.
Lubricating steps:
1. Remove the bolt 1 and gasket 2.
NOTICE
Do not reuse the gasket, always replace it
with a new one.
2. Lubricate the supercharger impeller shaft
with engine oil through the oil filler hole a.
TIP
Turn the supercharger impeller while lubricat-
ing the supercharger impeller shaft through the
hole a.
3. Tighten the bolt 1 to the specified torque.
T
R
.
.
Intake manifold bolt:
1st: 10 Nm (1.0 kgfm, 7.4 ftlb)
2nd: 20 Nm (2.0 kgfm, 14.8 ftlb)
LOCTITE 242
Recommended engine oil:
API: SE, SF, SG, SH, SJ, or SL
SAE: 10W-30, 10W-40, 20W-40, or
20W-50
T
R
.
.
Supercharger oil filler hole bolt:
4 Nm (0.4 kgfm, 3.0 ftlb)
!
# $
% &
(
LT
242
a
2
1
Air cooler, supercharger, and throttle body assembly
5-39
POWR
1
2
3
4
6
7
8
9
E
2. Install:
Supercharger
TIP
Tighten the supercharger bolts 1, and then
bolts 2 to the specified torque.
T
R
.
.
Supercharger bolt (M8 65 mm) 1:
20 Nm (2.0 kgfm, 14.8 ftlb)
LOCTITE 242
Supercharger bolt (M6 65 mm) 2:
10 Nm (1.0 kgfm, 7.4 ftlb)
LOCTITE 242
2
1 1
LT
242
Air cooler intake pipe installation
1. Install:
Air cooler intake pipe 1
Installation steps:
1. Install the air cooler intake pipe 1
between the supercharger and air cooler.
TIP
Make sure that the arrow mark a on the air
cooler intake pipe 1 is pointing up.
Make sure that the pipe 1 contacts the pro-
jection b on the air cooler.
2. Tighten each clamp 2 to the specified
torque.
TIP
Fit each hose clamp 2 over the white paint
mark c on each end of the air cooler intake
pipe 1, making sure that the fastener of the
clamp is aligned with the wide portion of the
paint mark as shown.
T
R
.
.
Air cooler intake pipe clamp:
4 Nm (0.4 kgfm, 3.0 ftlb)
b
1
2
a
c
1
2
c
Air cooler, supercharger, and throttle body assembly
5-40
POWR
1
2
3
4
5
6
7
8
9
E
Boost pipe installation
1. Install:
Boost pipe 1
Joint 1 2
Joint 2 3
Installation steps:
1. Install the joint 1 2 and joint 2 3 to the
boost pipe 1.
TIP
Fit the projection a on the boost pipe 1
between the projections b on the joint 1 2.
Fit the lip c on the boost pipe 1 into the
groove d in the joint 2 3.
2. Tighten the joint clamps 4 to the specified
torque.
3. Install the boost pipe assembly between
the air cooler assembly 5 and the throttle
body assembly 6.
TIP
Fit the lip e on the air cooler assembly 5
into the groove f in the joint 1 2.
Fit the lip g on the throttle body assembly 6
into the groove h in the joint 2 3.
4. Tighten the joint clamps 4 to the specified
torque.
5. Tighten the boost pipe bolt 7 to the speci-
fied torque.
T
R
.
.
Joint clamp:
3 Nm (0.3 kgfm, 2.2 ftlb)
T
R
.
.
Joint clamp:
3 Nm (0.3 kgfm, 2.2 ftlb)
T
R
.
.
Boost pipe bolt:
20 Nm (2.0 kgfm, 14.8 ftlb)
LOCTITE 242
3
b
c
4
2
1
a
d
6
6
3
h
g
e
5
2
2 5
7
LT
242
f
4
Air cooler, supercharger, and throttle body assembly
5-41
POWR
1
2
3
4
6
7
8
9
E
Oil cooler, oil pump assembly, and drive gear
Oil cooler and oil pump assembly removal
Step Part name Qty Remarks
1 Clamp 2
2 Cooling water hose 2
3 Oil filter bolt 1
4 Bolt 1 M8 55 mm
5 Bolt 2 M8 70 mm
6 Oil cooler assembly 1
7 Connector 2
8 O-ring 4 Not reusable
9 Bolt 1 M6 12 mm
10 Bolt 2 M10 21 mm
11 Gasket 4 Not reusable
4
5
10
9
12
10
11
11
3
14
17
18
18
16
15
13
8
1
2
7
8
6
8 N m (0.8 kgf m, 5.9 ft Ib)
18 N m (1.8 kgf m, 13.3 ft Ib)
LT
572
LT
572
LT
572
LT
572
AA
AA
21 N m (2.1 kgf m, 15.5 ft Ib)
10 N m (1.0 kgf m, 7.4 ft Ib)
Oil cooler, oil pump assembly, and drive gear
5-42
POWR
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
12 Oil pipe 1
13 Bolt 12 M6 20 mm
14 Oil pump assembly 1
15 Connector 2
16 O-ring 4 Not reusable
17 Gasket 1 Not reusable
18 Dowel pin 2
4
5
10
9
12
10
11
11
3
14
17
18
18
16
15
13
8
1
2
7
8
6
8 N m (0.8 kgf m, 5.9 ft Ib)
18 N m (1.8 kgf m, 13.3 ft Ib)
LT
572
LT
572
LT
572
LT
572
AA
AA
21 N m (2.1 kgf m, 15.5 ft Ib)
10 N m (1.0 kgf m, 7.4 ft Ib)
Oil cooler, oil pump assembly, and drive gear
5-43
POWR
1
2
3
4
6
7
8
9
E
Drive gear removal
Step Part name Qty Remarks
1 Shaft 1
2 Idle gear assembly 1
3 Circlip 2
4 Washer 1
5 Washer 1
6 Collar 1
7 Bolt 1 Left-hand threads
M12 58 mm
8 Circlip 1
9 Oil pump drive gear 1
10 Bearing 1
12
13
15
14
11
10
9
8
7
6
1
4
2
3
5
3
80 N m (8.0 kgf m, 59.0 ft Ib)
E
E
E
E
E
E
Oil cooler, oil pump assembly, and drive gear
5-44
POWR
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
11 Washer 1
12 Circlip 1
13 Washer 1
14 Drive gear clutch 1
15 Supercharger drive gear 1
12
13
15
14
11
10
9
8
7
6
1
4
2
3
5
3
80 N m (8.0 kgf m, 59.0 ft Ib)
E
E
E
E
E
E
Oil cooler, oil pump assembly, and drive gear
5-45
POWR
1
2
3
4
6
7
8
9
E
Drive gear assembly removal
1. Remove:
Drive gear assembly
Removal steps:
1. Hold the drive coupling 1 with the special
service tool 2.
2. Remove the drive gear assembly bolt 3.
TIP
The drive gear assembly bolt has left-hand
threads. Turn the bolt clockwise to loosen it.
3. Remove the drive gear assembly 4 with
the special service tools.
Coupler wrench 2:
90890-06729
Bearing puller assembly 5:
90890-06535
Stopper guide plate 6:
90890-06501
Stopper guide stand 7:
90890-06538
1 2
3
7
5
6
5
4
Drive gear disassembly
1. Remove:
Circlip 1
Oil pump drive gear 2
Bearing 3
Washer 4
Circlip 5
Washer 6
Drive gear clutch 7
Supercharger drive gear 8
Bearing separator:
90890-06534
5
6
7
8
4
1
2
3
2
3
Oil cooler, oil pump assembly, and drive gear
5-46
POWR
1
2
3
4
5
6
7
8
9
E
Oil cooler assembly check
NOTICE
The oil cooler assembly should not be dis-
assembled.
1. Check:
Oil cooler assembly
Cracks/damage Replace the oil
cooler assembly.
Oil cooler holding pressure
Cannot be maintained Replace the oil
cooler assembly.
Checking steps:
TIP
When checking the oil cooler, connect the
hoses 1 to the oil cooler.
1. Connect the special service tool 2 to the
inlet of the oil cooler water passage a.
2. Cover the outlet of the oil cooler water
passage b with a finger.
3. Apply the specified positive pressure and
check that the pressure is maintained.
4. Repeat steps 13 to check the oil cooler
water passage between c and d.
Leakage tester 2:
90890-06840
Specified positive pressure (water
passage):
200 kPa (2.0 kgf/cm
2
, 28.5 psi)
d
c
a
2
b
1
Oil cooler, oil pump assembly, and drive gear
5-47
POWR
1
2
3
4
6
7
8
9
E
Oil pump assembly check
NOTICE
The oil pump assembly should not be dis-
assembled.
1. Check:
Oil pump assembly
Oil pump driven gear 1
Cracks/damage Replace the oil pump
assembly.
Oil pump operation
Rough movement Replace the oil
pump assembly.
1
Idle gear check
1. Check:
Idle gear 1
Cracks/damage Replace the idle
gear assembly.
Shaft 2
Bends/wear Replace the shaft.
1
2
Drive gear check
1. Check:
Oil pump drive gear 1
Supercharger drive gear 2
Cracks/damage Replace.
1
2
Oil cooler, oil pump assembly, and drive gear
5-48
POWR
1
2
3
4
5
6
7
8
9
E
Drive gear clutch check
1. Check:
Drive gear clutch
Cracks/damage Replace the drive
gear clutch.
Drive gear clutch operation
Does not operate properly Replace
the drive gear clutch.
NOTICE
Make sure that the drive gear clutch is in-
stalled so that the side a is facing toward
the supercharger drive gear as shown.
Check the drive gear clutch operation af-
ter installation.
Checking steps:
1. Install the drive gear clutch onto the super-
charger drive gear 1.
2. Install the oil pump drive gear 2 onto the
supercharger drive gear 1.
3. Hold the oil pump drive gear 2.
4. Turn the supercharger drive gear 1 coun-
terclockwise and check that it does not
turn.
5. Turn the supercharger drive gear 1 clock-
wise and check that it turns smoothly.
a
1
2
LT
572
LT
572
LT
572
1280B
8 N m (0.8 kgf m, 5.9 ft Ib)
8 N m (0.8 kgf m, 5.9 ft Ib)
AA
AA
25 N m (2.5 kgf m, 18.4 ft lb)
10 N m (1.0 kgf m, 7.4 ft lb)
Camshaft
5-52
POWR
1
2
3
4
5
6
7
8
9
E
Camshaft and timing chain removal
Step Part name Qty Remarks
1 Oil level gauge 1
2 Bolt 1 M6 14 mm
3 Plug 1
4 Oil level pipe 1
5 O-ring 1 Not reusable
6 Bolt 2 M10 21 mm
7 Gasket 4 Not reusable
8 Oil pipe 1
9 Bolt 2 M6 25 mm
10 Timing chain tensioner 1
11 Gasket 1 Not reusable
12 Timing chain guide (exhaust side) 1
13 Bolt 24 M7 45 mm
c
16
19
18 17
19
18
23
22
21
20
12
24
9
6
7
8 7
10
11
1
2
4
13
13
15
14
15
15
14
15
5
3
E
E
E
E
b
8 N m (0.8 kgf m, 5.9 ft Ib)
10 N m (1.0 kgf m, 7.4 ft Ib)
LT
572
LT
572
E
E
24 N m (2.4 kgf m, 17.7 ft Ib)
16 N m (1.6 kgf m, 11.8 ft Ib)
20 N m (2.0 kgf m, 14.8 ft Ib)
M
M
A
A
a
Camshaft
5-53
POWR
1
2
3
4
6
7
8
9
E
Step Part name Qty Remarks
14 Camshaft cap 2 aArrow mark
15 Camshaft cap 4 aArrow mark
16 Intake camshaft 1
17 Exhaust camshaft 1 bYellow paint
18 Bolt 4 M7 11 mm
19 Camshaft sprocket 2 cPunch mark
20 Bolt 2 M6 30 mm
21 Chain guide plate 1
22 Timing chain guide (intake side) 1
23 Timing chain tensioner pad 1
24 Timing chain 1
c
16
19
18 17
19
18
23
22
21
20
12
24
9
6
7
8 7
10
11
1
2
4
13
13
15
14
15
15
14
15
5
3
E
E
E
E
b
8 N m (0.8 kgf m, 5.9 ft Ib)
10 N m (1.0 kgf m, 7.4 ft Ib)
LT
572
LT
572
E
E
24 N m (2.4 kgf m, 17.7 ft Ib)
16 N m (1.6 kgf m, 11.8 ft Ib)
20 N m (2.0 kgf m, 14.8 ft Ib)
M
M
A
A
a
Camshaft
5-54
POWR
1
2
3
4
5
6
7
8
9
E
Camshaft removal
1. Remove:
Camshafts
Removal steps:
1. Install the special service tools 1 and 2
into spark plug hole #1.
2. Position piston #1 at TDC by turning the
drive coupling 3 counterclockwise with
the special service tool 4, using the dial
gauge to ensure that the piston has
reached TDC.
TIP
Make sure that the punch marks a on the
camshafts are aligned with the alignment
marks b on the camshaft caps.
Gauge stand 1:
90890-06725
Dial gauge stand set:
YB-06585
Dial gauge 2:
YU-03097/90890-01252
Dial gauge needle:
90890-06584
Coupler wrench 4:
90890-06729
1
2
3 4
#1 #2 #3 #4
b
a
3. Make alignment marks c on the camshaft
sprockets and camshafts.
c
4. Remove the oil pipe 5, gaskets, timing
chain tensioner 6 and gasket.
TIP
Loosen the timing chain tensioner bolts 7
evenly.
5. Remove the timing chain guide (exhaust
side).
6
5
7
Camshaft
5-55
POWR
1
2
3
4
6
7
8
9
E
6. Loosen the intake and exhaust camshaft
cap bolts in the sequence shown.
TIP
For reference during installation, put identifi-
cation marks d on the camshaft caps.
Gradually loosen the camshaft cap bolts.
1
2
2
7
6 4 9
9
5
8
7
3
4
6
0
0
1 5
8
3
A
B
B
A
EX
IN d
7. Remove the intake camshaft 8 and
exhaust camshaft 9.
TIP
To prevent the timing chain from falling into the
crankcase, secure it with a wire 0.
8
9
0
IN
EX
8. Hold each camshaft sprocket with the spe-
cial service tool A, and then loosen the
bolts B.
9. Remove the exhaust camshaft sprocket C
and intake camshaft sprocket D.
Camshaft wrench A:
90890-06724
CD
A
B
Camshaft
5-56
POWR
1
2
3
4
5
6
7
8
9
E
Camshaft check
1. Check:
Camshaft lobes
Pitting/scratches Replace the cam-
shaft.
2. Measure:
Camshaft lobe dimensions a and b
Out of specification Replace the cam-
shaft.
Camshaft lobe dimensions:
Intake:
a 40.9 mm (1.610 in)
b 32.0 mm (1.260 in)
Exhaust:
a 41.0 mm (1.614 in)
b 32.2 mm (1.268 in)
3. Measure:
Camshaft runout
Out of specification Replace the cam-
shaft.
Camshaft runout limit:
0.015 mm (0.0006 in)
4. Measure:
Camshaft journal diameter a
Out of specification Replace the cam-
shaft.
Camshaft journal diameter a:
24.96024.980 mm
(0.98270.9835 in)
Camshaft
5-57
POWR
1
2
3
4
6
7
8
9
E
5. Measure:
Camshaft-journal-to-camshaft-cap
clearance
Out of specification Replace the cyl-
inder head assembly.
Measurement steps:
1. Remove the valve lifters 1 and valve pads
2.
TIP
Make a note of the position of each valve lifter
and valve pad so that they can be installed in
their original positions.
2. Place the camshafts on the cylinder head.
3. Put a piece of Plastigauge 3 on each
camshaft journal.
TIP
Do not put the Plastigauge over the oil hole in
the camshaft journal.
4. Install the camshaft caps.
5. Apply engine oil to the threads of the cam-
shaft cap bolts.
6. Tighten the camshaft cap bolts until the
camshaft caps contact the cylinder head.
TIP
Gradually tighten the camshaft cap bolts in
the sequence shown .
Make sure to keep the camshafts level.
Do not turn the camshafts when measuring
the camshaft-journal-to-camshaft-cap clear-
ance with the Plastigauge.
7. Tighten the camshaft cap bolts to the
specified torque in the sequence shown
.
8. Remove the camshaft caps, and then
measure the width of the Plastigauge 3.
Camshaft-journal-to-camshaft-cap
clearance:
0.0200.061 mm (0.00080.0024 in)
T
R
.
.
Camshaft cap bolt:
16 Nm (1.6 kgfm, 11.8 ftlb)
1
2
3
E
7
6
4
4
9
9
5
5
8
7
3
3 6
0
0 8
B
B
A
A
1
1
2
2
IN
EX
3
A
B
9
7
6
5
4
4
3
B
A 5
0
8 6
2
2
1
1
7
0
9
8
IN
EX
3
Camshaft
5-58
POWR
1
2
3
4
5
6
7
8
9
E
Camshaft sprocket check
1. Check:
Camshaft sprockets
Damage/wear Replace the camshaft
sprockets and timing chain as a set.
Timing chain check
1. Check:
Timing chain
Damage/stiffness/wear Replace the
timing chain and camshaft sprockets as
a set.
Timing chain tensioner check
1. Check:
Timing chain tensioner
Cracks/damage/rough movement
Replace the timing chain tensioner.
Checking steps:
1. While pushing the timing chain tensioner
rod 1, turn the timing chain tensioner
housing 2 in direction until the groove
a in the tensioner rod is aligned with the
snap ring 3.
2. While squeezing the end of the snap ring
3 so that it fits into the groove a in the
timing chain tensioner rod 1, slowly
release the tensioner rod until it is locked
in place.
TIP
Make sure that the timing chain tensioner rod
1 is locked in place before releasing the snap
ring 3.
3. Slightly push the timing chain tensioner
rod 1. Check that the snap ring 3
releases the timing chain tensioner rod 1,
allowing the tensioner rod to pop out.
2
1
3
a
Camshaft
5-59
POWR
1
2
3
4
6
7
8
9
E
Camshaft installation
1. Install:
Camshafts
Installation steps:
1. Position piston #1 at TDC.
Refer to Camshaft removal.
2. Install the exhaust camshaft sprocket 1
and intake camshaft sprocket 2.
TIP
Install each camshaft sprocket with the
punch mark a facing outward.
When installing an original camshaft
sprocket, make sure to align the alignment
marks b made during removal.
3. Apply engine oil to the threads of the cam-
shaft sprocket bolts.
4. Tighten the camshaft sprocket bolt to the
specified torque.
5. Apply molybdenum disulfide grease to the
camshaft journals, camshaft journal bear-
ings, and camshaft lobes.
6. Install the exhaust camshaft 3, and then
intake camshaft 4.
TIP
Make sure that the punch marks c on the
camshafts face up.
When installing the exhaust camshaft 3,
make sure that the exhaust side d of the
timing chain is taut.
Camshaft wrench:
90890-06724
T
R
.
.
Camshaft sprocket bolt:
24 Nm (2.4 kgfm, 17.7 ftlb)
12
b
a
E
EX IN
d
MM
4
3
EX
IN
M
c
Camshaft
5-60
POWR
1
2
3
4
5
6
7
8
9
E
7. Install the exhaust camshaft caps and
intake camshaft caps.
8. Apply engine oil to the threads of the cam-
shaft cap bolts.
9. Tighten the camshaft cap bolts until the
camshaft caps contact the cylinder head.
TIP
Gradually tighten the camshaft cap bolts in
the sequence shown .
Make sure to keep the camshafts level.
10. Tighten the camshaft cap bolts to the
specified torque in the sequence shown
.
11. Install the timing chain guide (exhaust
side).
12. Remove the wire from the timing chain.
TIP
Make sure that the punch marks c on the
camshafts are aligned with the alignment
marks e on the camshaft caps.
13. While pushing the timing chain tensioner
rod 5, turn the timing chain tensioner
housing 6 in direction until the groove
f in the tensioner rod is aligned with the
snap ring 7.
14. While squeezing the end of the snap ring
7 so that it fits into the groove f in the
timing chain tensioner rod 5, slowly
release the tensioner rod until it is locked
in place.
T
R
.
.
Camshaft cap bolt:
16 Nm (1.6 kgfm, 11.8 ftlb)
E
7
6
4
4
9
9
5
5
8
7
3
3 6
0
0 8
B
B
A
A
1
1
2
2
IN
EX
3
A
B
9
7
6
5
4
4
3
B
A 5
0
8 6
2
2
1
1
7
0
9
8
IN
EX
e
c
EX
IN
6
5
7
f
Camshaft
5-61
POWR
1
2
3
4
6
7
8
9
E
15. Install the gasket and the timing chain ten-
sioner 8 onto the cylinder block, and then
temporarily tighten the timing chain ten-
sioner bolts 9.
16. Install the oil pipe 0 to the cylinder block
and timing chain tensioner, and then tem-
porarily tighten the oil pipe bolts A.
17. Tighten the oil pipe bolts A to the speci-
fied torque, and then tighten the timing
chain tensioner bolts 9 to the specified
torque.
T
R
.
.
Oil pipe bolt:
20 Nm (2.0 kgfm, 14.8 ftlb)
Timing chain tensioner bolt:
10 Nm (1.0 kgfm, 7.4 ftlb)
LOCTITE 572
9
A
A
0
8
LT
572
LT
18. Turn the drive coupling B counterclock-
wise 2 turns.
TIP
Make sure that the camshafts turn smoothly. If
the camshafts do not turn smoothly, reinstall
camshafts. Refer to the installation steps.
B
19. Check that the portion g of the timing
chain is taut. If the timing chain is not taut,
turn the drive coupling slightly clockwise,
and then check that the timing chain is taut
again.
g
20. Position piston #1 at TDC.
Refer to Camshaft removal.
TIP
Make sure that the punch marks c on the
camshaft are aligned with the alignment marks
e on the camshaft caps. If the marks are not
aligned, reinstall the camshafts.
e
c
Camshaft
5-62
POWR
1
2
3
4
5
6
7
8
9
E
Cylinder head cover installation
1. Install:
Cylinder head cover
Installation steps:
1. Apply sealant onto the locations a of the
new cylinder head cover gasket 1.
2. Tighten the cylinder head cover bolts in a
crisscross pattern.
T
R
.
.
Cylinder head cover bolt:
8 Nm (0.8 kgfm, 5.9 ftlb)
LOCTITE 572
1280B
1
a
Valve clearance adjustment
TIP
To measure the valve clearance, refer to
Valve clearance measurement in Chapter 3.
1. Adjust:
Valve clearance
Adjustment steps:
1. Remove the camshaft.
Refer to Camshaft removal.
2. Remove the valve lifter 1 and valve pad
2.
TIP
Make a note of the position of each valve lifter
1 and valve pad 2 so that they can be
installed in their original positions.
3. Select the proper valve pad from the fol-
lowing table.
Valve pad thickness
range
Available valve pads
Nos.
120230
1.20
2.30 mm
23 thicknesses in
0.05 mm increments
1
2
1 2
Camshaft
5-63
POWR
1
2
3
4
6
7
8
9
E
TIP
The thickness a of each valve pad is marked
in hundredths of millimeters on the side that
touches the valve lifter.
4. Round off the original valve pad number
according to the following table.
5. Select the new valve pad number from the
valve pad selection table.
6. Apply the valve pad and valve lifter with
engine oil.
7. Install the selected valve pad 2 and the
valve lifter 1.
8. Rotate the valve lifter.
TIP
Make sure that the valve lifter turns smoothly.
9. Install the camshafts, timing chain, and
camshaft caps.
Refer to Camshaft installation.
10. Install the special service tools 3 and 4
into spark plug hole #1.
11. Position piston #1 at TDC by turning the
drive coupling 5 with the special service
tool.
Last digit Rounded value
0, 1, 2 0
4, 5, 6 5
8, 9 10
T
R
.
.
Camshaft cap bolt:
16 Nm (1.6 kgfm, 11.8 ftlb)
Gauge stand 3:
90890-06725
Dial gauge stand set:
YB-06585
Dial gauge 4:
YU-03097/90890-01252
Dial gauge needle:
90890-06584
Coupler wrench:
90890-06729
148
a
M
1
2
E
3
4
5
Camshaft
5-64
POWR
1
2
3
4
5
6
7
8
9
E
TIP
Make sure that the punch marks b on the
camshafts are aligned with the alignment
marks c on the camshaft caps.
12. Measure the intake and exhaust valve
clearances of the specified cylinders.
13. Install the dial gauge needle and special
service tools 3 and 4 into spark plug hole
#4.
14. Position piston #4 at TDC by turning the
drive coupling 360 counterclockwise with
the special service tool.
15. Measure the intake and exhaust valve
clearances of the specified cylinders.
#1 #2 #3 #4
IN
EX
:Specified cylinder
#1 #2 #3 #4
IN
EX
:Specified cylinder
c
b
EX
IN
#1 #2 #3 #4
Camshaft
5-65
POWR
1
2
3
4
6
7
8
9
E
Intake
Exhaust
MEASURED
CLEARANCE
ORIGINAL VALVE PAD NUMBER
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.000.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210
0.030.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.070.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.110.13 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.140.23 STANDARD CLEARANCE
0.240.26 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.270.31 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.320.36 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.370.41 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.420.46 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.470.51 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.520.56 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.570.61 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.620.66 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.670.71 170 175 180 185 190 195 200 205 210 215 220 225 230
0.720.76 175 180 185 190 195 200 205 210 215 220 225 230
0.770.81 180 185 190 195 200 205 210 215 220 225 230
0.820.86 185 190 195 200 205 210 215 220 225 230 Example:
Measured valve clearance is 0.29 mm (0.0114 in)
Original valve pad number is 148 (thickness = 1.48
mm)
Round off the original valve pad number 148 to 150
(thickness = 1.50 mm).
Select the new valve pad number using the valve
pad selection table.
New valve pad number is 160 (thickness = 1.60 mm)
0.870.91 190 195 200 205 210 215 220 225 230
0.920.96 195 200 205 210 215 220 225 230
0.971.01 200 205 210 215 220 225 230
1.021.06 205 210 215 220 225 230
1.071.11 210 215 220 225 230
1.121.16 215 220 225 230
1.171.21 220 225 230
1.221.26 225 230
1.271.31 230
MEASURED
CLEARANCE
ORIGINAL VALVE PAD NUMBER
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.000.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195
0.020.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
0.050.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205
0.100.14 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210
0.150.19 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.200.24 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.250.27 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.280.37 STANDARD CLEARANCE
0.380.40 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.410.45 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.460.50 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.510.55 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.560.60 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.610.65 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.660.70 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.710.75 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.760.80 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.810.85 170 175 180 185 190 195 200 205 210 215 220 225 230
0.860.90 175 180 185 190 195 200 205 210 215 220 225 230
0.910.95 180 185 190 195 200 205 210 215 220 225 230
0.961.00 185 190 195 200 205 210 215 220 225 230 Example:
Measured valve clearance is 0.47 mm (0.0185 in)
Original valve pad number is 168 (thickness = 1.68
mm)
Round off the original valve pad number 168 to 170
(thickness = 1.70 mm).
Select the new valve pad number using the valve
pad selection table.
New valve pad number is 185 (thickness = 1.85 mm)
1.011.05 190 195 200 205 210 215 220 225 230
1.061.10 195 200 205 210 215 220 225 230
1.111.15 200 205 210 215 220 225 230
1.161.20 205 210 215 220 225 230
1.211.25 210 215 220 225 230
1.261.30 215 220 225 230
1.311.35 220 225 230
1.361.40 225 230
1.411.45 230
Camshaft
5-66
POWR
1
2
3
4
5
6
7
8
9
E
Cylinder head
Cylinder head assembly removal
Step Part name Qty Remarks
1 Bolt 4 M6 12 mm
2 Engine hanger 2
3 Bolt 3 M6 55 mm
4 Cylinder head bolt 10 Not reusable
M12 140 mm
5 Washer 10
6 Cylinder head assembly 1
7 Gasket 1 Not reusable
8 Dowel pin 2
7
6
8
8
4
5
10 N m (1.0 kgf m, 7.4 ft Ib)
LT
242
LT
242
E
E
12 N m (1.2 kgf m, 8.9 ft Ib)
2nd 90
1st 48 N m (4.8 kgf m, 35.4 ft Ib) 12 N m (1.2 kgf m, 8.9 ft Ib)
1
2
2
1
3
Cylinder head
5-67
POWR
1
2
3
4
6
7
8
9
E
Cylinder head disassembly
Step Part name Qty Remarks
1 Valve lifter 16
2 Valve pad 16
3 Valve cotter 32
4 Upper spring seat 16
5 Valve spring 16
6 Lower spring seat 16
7 Intake valve 8
8 Exhaust valve 8
9 Valve seal 16 Not reusable
10 Valve guide 16 Not reusable
11 Cylinder head 1
E
E
E
E
8
9
9
1
1
2
2
3
3
3
4
4
5
5
6
6
7
3
10
10
11
MM M
Cylinder head
5-68
POWR
1
2
3
4
5
6
7
8
9
E
Cylinder head assembly removal
1. Remove:
Cylinder head bolts (M6 55 mm) 1
Cylinder head bolts (M12 140 mm) 2
TIP
Loosen the cylinder head bolts 2 in the
sequence shown.
1 9 5
7 3
4
0
8
2 6
2 2 2
2 2 2
1
Valve removal
1. Remove:
Valve lifter 1
Valve pad 2
TIP
Make a note of the position of each valve lifter
1 and valve pad 2 so that they can be
installed in their original positions.
2. Remove:
Valve cotters 1
Upper spring seat 2
Valve spring 3
Lower spring seat 4
Valve 5
Valve seal 6
TIP
Make a note of the position of each valve,
spring, and other part so that they can be
installed in their original positions.
Valve spring compressor 7:
YM-04019/90890-04019
Compressor adapter 8:
YM-04114
Valve spring compressor attachment
8:
90890-04114
1
2
8
7
5
6
4
3
2
1
Cylinder head check
1. Check:
Cylinder head
Damage/eroded Replace the cylinder
head.
Cylinder head water jacket
Mineral deposits/rust Eliminate
deposits or rust.
Cylinder head
5-69
POWR
1
2
3
4
6
7
8
9
E
2. Measure:
Cylinder head warpage
Out of specification Replace the cyl-
inder head.
Measurement steps:
1. Eliminate carbon deposits from the com-
bustion chambers.
2. Check the cylinder head warpage using a
straightedge 1 and thickness gauge 2 in
the directions shown.
Cylinder head warpage limit:
0.1 mm (0.004 in)
1 2
Valve spring check
1. Measure:
Valve spring free length a
Out of specification Replace the
valve spring.
Valve spring free length a:
Intake and exhaust:
45.58 mm (1.794 in)
a
2. Measure:
Valve spring tilt a
Out of specification Replace the
valve spring.
Valve spring tilt limit a:
Intake and exhaust:
2.0 mm (0.08 in)
Valve check
TIP
To ensure accurate measurements, make sure
to clean the valves before measuring them.
1. Check:
Valve face
Pitting Replace the valve.
Cylinder head
5-70
POWR
1
2
3
4
5
6
7
8
9
E
2. Measure:
Valve face width a
Out of specification Replace the
valve.
Valve face width a:
Intake and exhaust:
2.262.83 mm (0.0890.111 in)
a
Valve margin thickness b
Out of specification Replace the
valve.
Valve margin thickness b:
Intake and exhaust:
0.801.20 mm (0.0310.047 in)
b
3. Measure:
Valve stem diameter a
Out of specification Replace the
valve.
Valve stem diameter a:
Intake:
5.4775.492 mm
(0.21560.2162 in)
Exhaust:
5.4645.479 mm
(0.21510.2157 in)
a
4. Measure:
Valve stem runout
Out of specification Replace the
valve.
Valve stem runout limit:
Intake and exhaust:
0.01 mm (0.0004 in)
Cylinder head
5-71
POWR
1
2
3
4
6
7
8
9
E
Valve guide check
1. Measure:
Valve guide inside diameter a
Valve guide inside diameter:
Intake and exhaust:
5.5045.522 mm
(0.21670.2174 in)
a
2. Calculate:
Valve-stem-to-valve-guide clearance
Out of specification Replace the
valve and valve guide.
Valve-stem-to-valve-guide clearance
= valve guide inside diameter valve
stem diameter:
Intake:
0.0120.045 mm
(0.00050.0018 in)
Exhaust:
0.0250.058 mm
(0.00100.0023 in)
Valve guide removal
1. Remove:
Valve guide 1
Removal steps:
1. Insert the special service tool 2 into the
combustion chamber end of the valve
guide 1.
2. Strike the special service tool to drive the
valve guide out of the cylinder head.
Valve guide remover 2:
YB-06801/90890-06801
2
1
Cylinder head
5-72
POWR
1
2
3
4
5
6
7
8
9
E
Valve guide installation
1. Install:
Valve guide 1
Installation steps:
1. Insert the special service tools 2 and 3
into the camshaft end of the valve guide
1.
NOTICE
Do not reuse the valve guide 1, always re-
place it with a new one.
2. Strike the special service tool to drive the
valve guide into the cylinder head.
3. Apply engine oil to the inner surface of the
valve guide and surface of the special ser-
vice tool 4.
4. Insert the special service tool 4 into the
valve guide 1, and then ream the valve
guide.
TIP
Turn the valve guide reamer clockwise to
ream the valve guide.
Do not turn the special service tool 4 coun-
terclockwise when removing the tool.
5. Clean the valve guide inner surface.
6. Measure the valve guide inside diameter.
Valve guide remover 2:
YB-06801/90890-06801
Valve guide installer 3:
YB-06810/90890-06810
Valve guide installation height a:
Intake and exhaust:
12.312.7 mm (0.4840.500 in)
Valve guide reamer 4:
YM-01196/90890-06804
Valve guide inside diameter b:
Intake and exhaust:
5.5045.522 mm
(0.21670.2174 in)
a
E
1
3
2
E
1
4
b
Cylinder head
5-73
POWR
1
2
3
4
6
7
8
9
E
Valve seat check
1. Measure:
Valve seat contact width
Does not seat properly Reface the
valve seat.
Measurement steps:
1. Eliminate carbon deposits from the valves
and valve seats.
2. Apply a thin, even layer of Mechanics
blueing dye (Dykem) onto the valve seat.
3. Press the valve lightly against the valve
seat with a valve lapper (commercially
available).
4. Measure the valve seat contact width a
where the blueing dye is adhered to the
valve face. Reface the valve seat if the
valve is not seated properly or if the valve
seat contact width is out of specification.
Replace the valve guide if the valve seat
contact is uneven.
Valve seat contact width a:
Intake:
1.401.60 mm (0.0550.063 in)
Exhaust:
1.501.70 mm (0.0590.067 in)
Cylinder head
5-74
POWR
1
2
3
4
5
6
7
8
9
E
Valve seat refacing
NOTICE
Do not over cut the valve seat. Make sure to
turn the cutter evenly downward at a pres-
sure of 4050 N (45 kgf, 8.811 lbf) to pre-
vent chatter marks.
TIP
Do not turn the special service tool counter-
clockwise when refacing the valve seat.
1. Reface:
Valve seats
Neway valve seat kit:
YB-91044
Valve seat cutter holder:
90890-06812
Valve seat cutter:
30 (intake):
90890-06720
45 (intake):
90890-06325
60 (intake):
90890-06324
30 (exhaust):
90890-06818
45 (exhaust):
90890-06555
60 (exhaust):
90890-06323
Refacing steps:
1. Cut the surface of the valve seat with a 45
cutter by turning the cutter clockwise until
the valve seat face has become smooth.
a Slag or rough surface
a
45
Cylinder head
5-75
POWR
1
2
3
4
6
7
8
9
E
2. Use a 30 cutter to adjust the contact width
of the top edge of the valve seat.
b Previous contact width
30
b
3. Use a 60 cutter to adjust the contact width
of the bottom edge of the valve seat.
b Previous contact width
60
b
4. Use a 45 cutter to adjust the contact width
of the valve seat to specification.
b Previous contact width
c Specified contact width
5. Check the valve seat contact area of the
valve.
Refer to Valve seat check.
45
b
c
Example:
If the valve seat contact width is too wide and
situated in the center of the valve face, use a
30 cutter to cut the top edge of the valve
seat, and then use a 60 cutter to cut the bot-
tom edge to center the area and set its width.
b Previous contact width
30
60
b
If the valve seat contact width is too narrow
and situated near the top edge of the valve
face, use a 30 cutter to cut the top edge of
the valve seat, and then use a 45 cutter to
center the area and set its width.
b Previous contact width
30
b
Cylinder head
5-76
POWR
1
2
3
4
5
6
7
8
9
E
If the valve seat contact width is too narrow
and situated near the bottom edge of the
valve face, use a 60 cutter to cut the bottom
edge of the valve seat, and then use a 45
cutter to center the area and set its width.
b Previous contact width
60
b
6. After refacing the valve seat to the speci-
fied contact width, apply a thin, even layer
of lapping compound onto the valve seat,
and then lap the valve using a valve lapper
(commercially available).
NOTICE
Do not get the lapping compound on the
valve stem and valve guide.
7. After every lapping procedure, clean off
any remaining lapping compound from the
cylinder head and the valves.
8. Check the valve seat contact area of the
valve again.
Refer to Valve seat check.
TIP
After refacing the valve seat, check that the
valve clearance is within specification. Refer to
Valve clearance measurement in Chapter 3.
Cylinder head
5-77
POWR
1
2
3
4
6
7
8
9
E
Valve installation
1. Install:
Valve seal 1
Valve 2
Lower spring seat 3
Valve spring 4
Upper spring seat 5
Valve cotters 6
Installation steps:
1. Install the valve seal 1 onto the valve
guide.
NOTICE
Do not reuse the valve seal, always replace
it with a new one.
2. Install the valve 2, lower spring seat 3,
valve spring 4, and upper spring seat 5
in the sequence shown, and then attach
the special service tools 7 and 8.
TIP
When installing a new valve, always replace
the valve guide and valve seal with new
ones.
Install the valve spring with the larger pitch
a toward the camshaft and the smaller pitch
b toward the combustion chamber.
The end c of the valve spring with the larger
pitch is painted red.
Valve spring compressor 7:
YM-04019/90890-04019
Compressor adapter 8:
YM-04114
Valve spring compressor attachment
8:
90890-04114
1
E
8
7
2
3
4
5
6
E
a
c
b
3. Compress the valve spring, and then
install the valve cotters 6.
6
Cylinder head
5-78
POWR
1
2
3
4
5
6
7
8
9
E
4. Lightly tap the upper spring seat with a
plastic hammer to set the valve cotters 6
securely.
6 6
Cylinder head installation
1. Install:
Cylinder head
Installation steps:
1. Pass the timing chain 1 through the tim-
ing chain cavity.
2. Apply engine oil to the cylinder head bolts.
3. Tighten the cylinder head bolts 2 and 3
to the specified torques.
NOTICE
Do not reuse the cylinder head bolts, al-
ways replace them with new ones.
TIP
Tighten the cylinder head bolts in the
sequence shown.
Use a commercially available angle gauge to
tighten the bolts to the specified angle.
T
R
.
.
Cylinder head bolt (M12 140 mm) 2:
1st: 48 Nm (4.8 kgfm, 35.4 ftlb)
2nd: 90
Cylinder head bolt (M6 55 mm) 3:
10 Nm (1.0 kgfm, 7.4 ftlb)
2
9 5
7 3
4
0
8 1
6
2 2 2
2
1
2 2
3
E
Cylinder head
5-79
POWR
1
2
3
4
6
7
8
9
E
Generator cover and flywheel magneto
Generator cover and flywheel magneto removal
Step Part name Qty Remarks
1 Holder 1 Left-hand threads
2 Drive coupling 1
3 Washer 1 Not reusable
4 Plastic tie 1
5 Grommet 2
6 Bolt 2 M6 20 mm
7 Washer 2
8 Bracket 2
9 Clamp 1
10 Hose 1
11 Bolt 9 M8 50 mm
12 Clamp 1
13 Generator cover assembly 1
15
2
9
8
7
6
3
1
4
5
11
10
7
6
12
11
8
14
21
22
17
18
20
19
16
25
15
13
5
24
23
E
LT
648
LT
648
LT
648
E
250 N m (25.0 kgf m, 184.4 ft Ib)
8 N m (0.8 kgf m, 5.9 ft Ib)
80 N m (8.0 kgf m, 59.0 ft Ib)
26 N m (2.6 kgf m, 19.2 ft Ib)
LT
572
LT
572
24 N m (2.4 kgf m, 17.7 ft Ib)
23
AA
AA
AA
E
250 N m (25.0 kgf m, 184.4 ft Ib)
2nd 60
1st 50 N m (5.0 kgf m, 36.9 ft Ib)
3rd 250 N m (25.0 kgf m, 184.4 ft Ib)
Generator cover and flywheel magneto
5-80
POWR
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
14 O-ring 1 Not reusable
15 Dowel pin 2
16 Transfer shaft assembly 1 Not reusable
17 Transfer shaft 1 Not reusable
18 Special nut 1 Not reusable
19 Bolt 6 Not reusable
M8 20 mm
20 Flywheel magneto 1 Not reusable
21 Starter gear 1
22 Starter clutch assembly 1
23 Woodruff key 1 Not reusable
24 Idle gear 1
25 Shaft 1
15
2
9
8
7
6
3
1
4
5
11
10
7
6
12
11
8
14
21
22
17
18
20
19
16
25
15
13
5
24
23
E
LT
648
LT
648
LT
648
E
250 N m (25.0 kgf m, 184.4 ft Ib)
8 N m (0.8 kgf m, 5.9 ft Ib)
80 N m (8.0 kgf m, 59.0 ft Ib)
26 N m (2.6 kgf m, 19.2 ft Ib)
LT
572
LT
572
24 N m (2.4 kgf m, 17.7 ft Ib)
23
AA
AA
AA
E
250 N m (25.0 kgf m, 184.4 ft Ib)
2nd 60
1st 50 N m (5.0 kgf m, 36.9 ft Ib)
3rd 250 N m (25.0 kgf m, 184.4 ft Ib)
Generator cover and flywheel magneto
5-81
POWR
1
2
3
4
6
7
8
9
E
Generator cover disassembly
Step Part name Qty Remarks
1 Bolt 2 M5 15 mm
2 Bolt 1 M5 10 mm
3 Washer 1
4 Bolt 3 M6 30 mm
5 Bolt 2 M6 15 mm
6 Clamp 1
7 Stator coil assembly 1
8 Oil seal 1 Not reusable
9 Circlip 1
10 Bearing 1 Not reusable
11 Generator cover 1
8
9
10
11
3
2
1
7
4
6
5
LT
242
AA
AA
E
LT
242
5 N m (0.5 kgf m, 3.7 ft Ib)
LT
242
5 N m (0.5 kgf m, 3.7 ft Ib)
LT
242
EP
14 N m (1.4 kgf m, 10.3 ft Ib)
14 N m (1.4 kgf m, 10.3 ft Ib)
Generator cover and flywheel magneto
5-82
POWR
1
2
3
4
5
6
7
8
9
E
Drive coupling removal
WARNING
When using a heat gun, protect your hands
by wearing heat-resistant gloves. Compo-
nents become hot enough to cause burns.
1. Remove:
Holder 1
Drive coupling 2
Removal steps:
1. Heat the holder 1 and drive coupling 2
for 20-30 minutes with a heat gun 3.
NOTICE
Do not use a gas torch.
Be careful not to damage the wiring har-
ness when using the heat gun.
TIP
Heat the holder 1 and drive coupling 2 with a
heat gun 3 at approximately 200 C (392 F).
2. Hold the drive coupling 2 with the special
service tool 4, and then loosen the holder
1 with a hexagon bit socket 5.
TIP
The holder 1 has left-hand threads. Turn the
holder clockwise to loosen it.
Use a 12 mm hexagon bit socket 5 with a
length of 150 mm or more.
3. Hold the transfer shaft 6 with the special
service tool 7, and then remove the drive
coupling 2 with the special service tool 4.
Coupler wrench 4:
90890-06729
Crankshaft holder 7:
90890-06732
2 1
3
2 4
5
4
1
2
5
2 7
4
4 6
2
7
Generator cover and flywheel magneto
5-83
POWR
1
2
3
4
6
7
8
9
E
Flywheel magneto removal
WARNING
When using a heat gun, protect your hands
by wearing heat-resistant gloves. Compo-
nents become hot enough to cause burns.
1. Remove:
Generator cover assembly
Transfer shaft assembly 1
Removal steps:
1. Remove the generator cover assembly.
2. Heat the transfer shaft assembly 1 for 20-
30 minutes with a heat gun 2.
NOTICE
Do not use a gas torch.
Be careful not to damage the wiring har-
ness when using the heat gun.
TIP
Heat the transfer shaft assembly 1 with a heat
gun 2 at approximately 200 C (392 F).
3. Hold the flywheel magneto 3 with the spe-
cial service tools 4 and 5, and then
loosen the special nut 6 with a hexagon
bit socket 7.
TIP
Loosen the special nut 6 until it can no
longer be turned.
Use a 12 mm hexagon bit socket 7 with a
length of 150 mm or more.
1
2
5
7
4 3
6 7
3
4
Generator cover and flywheel magneto
5-84
POWR
1
2
3
4
5
6
7
8
9
E
4. Hold the flywheel magneto 3 with the spe-
cial service tools 4 and 5, and then
remove the transfer shaft assembly 1 with
the special service tool 8.
NOTICE
Do not reuse the transfer shaft assembly
1, always replace it with a new one.
Shaft holder 4:
90890-06721
Driver handle 5:
90890-06722
Crankshaft holder 8:
90890-06732
5
8
1 4 3
1
8
3
4
2. Remove:
Flywheel magneto 1
Removal steps:
1. Remove the flywheel magneto 1 with the
special service tools 2 and 3.
2. Remove the Woodruff key.
3. Remove the flywheel magneto bolts 4,
and then remove the starter clutch assem-
bly 5.
NOTICE
Do not reuse the flywheel magneto 1,
Woodruff key, and flywheel magneto bolts
4, always replace them with new ones.
Flywheel puller 2:
90890-06723
Rotor puller 3:
90890-01080
1
2
3
4
1
5
Generator cover and flywheel magneto
5-85
POWR
1
2
3
4
6
7
8
9
E
Bearing removal
1. Remove:
Oil seal1
Circlip 2
Bearing 3
TIP
Make sure to remove the circlip before remov-
ing the bearing.
For USA and Canada
For worldwide
Idle gear and shaft check
1. Check:
Shaft 1
Bends/wear Replace the idle gear
shaft.
Idle gear 2
Cracks/damage Replace the idle
gear.
Driver handle (small):
YB-06229
Bearing and seal installer:
YW-06356
Driver rod LS:
90890-06606
Bearing outer race attachment:
90890-06627
1
2
3
1
2
3
1
2
Starter clutch check
1. Check:
Starter clutch rollers
Cracks/damage Replace the starter
clutch assembly.
2. Check:
Starter gear
Cracks/damage Replace the starter
gear.
Generator cover and flywheel magneto
5-86
POWR
1
2
3
4
5
6
7
8
9
E
3. Check:
Starter clutch operation
Does not operate properly Replace
the starter clutch assembly.
Checking steps:
1. Install the starter clutch assembly 1 onto
the starter gear 2 and hold the starter
clutch assembly.
2. Turn the starter gear clockwise and
check that it turns smoothly.
3. Turn the starter gear counterclockwise
and check that it does not turn.
1
2
Bearing installation
1. Install:
Bearing 1
Circlip 2
NOTICE
Do not reuse the bearing, always replace it
with a new one.
For USA and Canada
For worldwide
Driver handle (large):
YB-06071
Forward gear outer race installer:
YB-41446
Driver rod LS:
90890-06606
Ball bearing attachment:
90890-06657
AA
E
2
1
2
1
AA
E
EP
1
AA
4
5
4. Install:
Connecting rod bearings 1
Connecting rod cap 2
Connecting rod assembly 3
Installation steps:
1. Clean the bearings and connecting rod big
end.
2. Install the upper bearing into the connect-
ing rod assembly 3 and lower bearing into
the connecting rod cap 2.
TIP
Install the connecting rod bearings in their
original positions.
Insert the projections a of the bearings into
the slots in the connecting rod cap and con-
necting rod.
3. Install the connecting rod cap 2 into the
connecting rod assembly 3.
TIP
Make sure that the characters b on the con-
necting rod cap and connecting rod are
aligned.
4. While compressing the piston rings with
the special service tool, install the con-
necting rod assembly into the cylinder.
Piston ring compressor:
YM-08037/90890-05158
E
3
2
a b
1
1
Crankcase, connecting rod, and piston
5-116
POWR
1
2
3
4
5
6
7
8
9
E
5. Tighten:
Connecting rod nuts 1
TIP
Use a commercially available angle gauge to
tighten the nuts to the specified angle.
T
R
.
.
Connecting rod nut:
1st: 51 Nm (5.1 kgfm, 37.6 ftlb)
2nd: 90
1
M
Crankcase assembly
1. Install:
Dowel pin 1
O-ring 2
Installation steps:
1. Thoroughly clean all the gasket surfaces
and crankcase mating surfaces.
2. Install the dowel pin 1 and O-ring 2.
3. Apply sealant to the mating surface of the
crankcase.
TIP
Do not get away sealant on the main bearing.
EX
IN
2
1
1280B
1280B
AA
Crankcase, connecting rod, and piston
5-117
POWR
1
2
3
4
6
7
8
9
E
2. Tighten:
Crankcase bolts (M10 85 mm) 1
Crankcase bolts (M6 70 mm) 2
Tightening steps:
1. Apply engine oil to the threads of the
crankcase bolts and flange surface of the
crankcase bolts.
2. Tighten the crankcase bolts 10 to the
specified torque in 2 stages.
NOTICE
Do not reuse the crankcase bolts 1, al-
ways replace them with new ones.
TIP
Tighten the crankcase bolts in the sequence
shown.
Use a commercially available angle gauge to
tighten the bolts to the specified angle.
3. Tighten the crankcase bolts AL to the
specified torques.
TIP
Tighten the crankcase bolts in the sequence
shown.
T
R
.
.
Crankcase bolt 10:
1st: 30 Nm (3.0 kgfm, 22.1 ftlb)
2nd: 90
Crankcase bolt AL:
10 Nm (1.0 kgfm, 7.4 ftlb)
EX
IN
7 5 1 3 9
0 4 2 6 8
J L D B F H
G K E A C I
E
2
1
3. Tighten:
Bracket bolts
TIP
Tighten the bolts a, and then tighten the bolts
b.
T
R
.
.
Bracket bolt:
50 Nm (5.0 kgfm, 36.9 ftlb)
LOCTITE 271
a
b
a
b
LT
271
Crankcase, connecting rod, and piston
E
JET
PUMP
1
2
3
4
5
6
7
8
9
Chapter 6
Jet pump unit
Intake grate and ride plate............................................................................. 6-1
Intake grate and ride plate removal ........................................................... 6-1
Jet pump unit.................................................................................................. 6-2
Jet pump unit removal ............................................................................... 6-2
Jet pump unit removal ............................................................................... 6-4
Jet pump unit installation........................................................................... 6-4
Reverse gate................................................................................................... 6-6
Reverse gate removal ............................................................................... 6-6
Jet thrust nozzle and nozzle ring.................................................................. 6-7
Jet thrust nozzle and nozzle ring removal ................................................. 6-7
Impeller duct and impeller housing.............................................................. 6-8
Impeller duct, impeller housing and nozzle removal.................................. 6-8
Impeller duct and drive shaft ........................................................................ 6-9
Impeller duct and drive shaft disassembly................................................. 6-9
Drive shaft removal.................................................................................. 6-11
Impeller check ......................................................................................... 6-13
Impeller housing check............................................................................ 6-13
Drive shaft check..................................................................................... 6-13
Drive shaft installation ............................................................................. 6-14
Impeller duct, impeller housing and nozzle installation ........................... 6-16
Transom plate and hoses............................................................................ 6-17
Transom plate and hose removal ............................................................ 6-17
Water hose check.................................................................................... 6-20
Transom plate installation........................................................................ 6-20
Intermediate housing................................................................................... 6-21
Intermediate housing removal ................................................................. 6-21
Intermediate housing disassembly .......................................................... 6-22
Intermediate housing removal ................................................................. 6-23
Driven coupling removal .......................................................................... 6-23
Intermediate housing disassembly .......................................................... 6-23
Intermediate drive shaft and grease hose check..................................... 6-24
Driven coupling and intermediate housing check.................................... 6-25
Intermediate housing assembly............................................................... 6-25
Driven coupling installation...................................................................... 6-27
Intermediate housing installation............................................................. 6-27
6-1
JET
PUMP
1
2
3
4
5
7
8
9
E
Intake grate and ride plate
Intake grate and ride plate removal
Step Part name Qty Remarks
1 Bolt 4 M10 25 mm
2 Intake grate 1
3 Screw 4 5 12 mm
4 Speed sensor 1
5 Bolt 2 M6 22 mm
6 Collar 2
7 Bolt 4 M8 35 mm
8 Ride plate 1
9 Spacer 2
7
4
1
2
8
5
5
9
9
3
17 N m (1.7 kgf m, 12.5 ft Ib)
4 N m (0.4 kgf m, 3.0 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
LT
572
LT
LT
572
LT
LT
572
LT
40 N m (4.0 kgf m, 29 ft Ib)
6
6
LT
572
LT
LT
271
Intake grate and ride plate
6-2
JET
PUMP
1
2
3
4
5
6
7
8
9
E
Jet pump unit
Jet pump unit removal
Step Part name Qty Remarks
Ride plate Refer to Intake grate and ride plate.
1 Shift cable joint 1
2 QSTS rod joint 1
3 Nut 1
4 Washer 2
5 Steering cable joint 1
6 Clamp 1
7 Bilge hose 1
8 Clamp 1
9 Spout hose 1
10 Bolt 4 M6 22 mm
11 Collar 4
14 N m (1.4 kgf m, 10.3 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
8 N m (0.8 kgf m, 5.9 ft Ib)
2 N m (0.2 kgf m, 1.5 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
40 N m (4.0 kgf m, 29.5 ft Ib)
17 N m (1.7 kgf m, 12.5 ft Ib)
21
2 4
5
15
17
3
4
7
6
14
1
16
LT
572
LT
5
LT
572
LT
LT
572
LT
LT
242
M
LT
572
LT
LT
572
LT
10
11
20
19
18
1194E
AA
AA
8
9
12
13
12
AA
Jet pump unit
6-3
JET
PUMP
1
2
3
4
5
7
8
9
E
Step Part name Qty Remarks
12 Rubber plate 2
13 Bolt 2 M8 18 mm
14 Bolt 1 M6 30 mm
15 Bolt 4 M10 45 mm
16 Jet pump unit assembly 1
17 Dowel pin 2
18 Bolt 2 M8 13 mm
19 Washer 2
20 Gasket 2 Not reusable
21 Stay 1
14 N m (1.4 kgf m, 10.3 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
8 N m (0.8 kgf m, 5.9 ft Ib)
2 N m (0.2 kgf m, 1.5 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
40 N m (4.0 kgf m, 29.5 ft Ib)
17 N m (1.7 kgf m, 12.5 ft Ib)
21
2 4
5
15
17
3
4
7
6
14
1
16
LT
572
LT
5
LT
572
LT
LT
572
LT
LT
242
M
LT
572
LT
LT
572
LT
10
11
20
19
18
1194E
AA
AA
8
9
12
13
12
AA
Jet pump unit
6-4
JET
PUMP
1
2
3
4
5
6
7
8
9
E
Jet pump unit removal
WARNING
Make sure to remove the battery before re-
moving the jet pump unit.
1. Remove:
Jet pump unit
Removal steps:
1. Remove the intake grate 1, speed sensor
2, and ride plate 3.
2. Remove the steering cable joint 4, shift
cable joint 5, QSTS rod joint 6, spout
hose 7, and rubber plates 8.
3. Remove the bolts 9 and 0, and then
remove the jet pump unit A.
TIP
Insert a flat-head screwdriver into the gap a
between the jet pump unit A and the transom
plate B to separate them.
1 2
3
5 4
6
7 8
9
0
0
B
a
A
Jet pump unit installation
WARNING
Make sure to remove the battery before in-
stalling the jet pump unit.
1. Install:
Jet pump unit
Jet pump unit
6-5
JET
PUMP
1
2
3
4
5
7
8
9
E
Installation steps:
1. Clean the contacting surfaces of the jet
pump unit 1 and transom plate 2.
2. Apply sealant to the contacting surfaces of
the transom plate 2.
3. Install the jet pump unit 1.
TIP
Rotate the drive shaft 3 to align the splines on
the drive shaft with the splines on the inside of
the intermediate drive shaft.
4. Install the rubber plates 4 and 5, spout
hose 6, QSTS rod joint 7, shift cable joint
8, and steering cable joint 9.
TIP
When installing the rubber plate 4, pass the
shift cable through the hole a in the plate.
When installing the rubber plate 5, pass the
spout hose 6 through the hole b in the
plate.
Make sure that the steering, shifting, and
QSTS operate correctly.
T
R
.
.
Jet pump unit assembly bolt:
M10 45 mm:
40 Nm (4.0 kgfm, 29.5 ftlb)
LOCTITE 572
M6 30 mm:
8 Nm (0.8 kgfm, 5.9 ftlb)
LOCTITE 572
T
R
.
.
Rubber plate bolt:
7 Nm (0.7 kgfm, 5.2 ftlb)
LOCTITE 572
Spout hose clamp:
2 Nm (0.2 kgfm, 1.5 ftlb)
Steering cable joint:
7 Nm (0.7 kgfm, 5.2 ftlb)
LOCTITE 242
1
2
2
M
3
1194E
8 9
7
4 6
a
b
5
AA
AA
LT
242
Jet pump unit
6-6
JET
PUMP
1
2
3
4
5
6
7
8
9
E
Reverse gate
Reverse gate removal
Step Part name Qty Remarks
1 Clamp/spout hose 1/1
2 Bolt/collar 2/2 M8 25 mm
3 Reverse gate assembly 1
4 Nut/washer 2/2
5 Shift cable ball joint/washer 1/1
6 Bolt/collar 1/1 M6 35 mm
7 Spring 1
8 Bolt 1 M8 14 mm
9 Bolt 6 M6 25 mm
10 Reverse gate bracket 2
LT
242
2
8
7
1
5
4
4
9
10
3
9
2
10
6
6
6 8
7
1 N m (0.1 kgf m, 0.7 ft Ib)
20 N m (2.0 kgf m, 14.8 ft Ib)
8 N m (0.8 kgf m, 5.9 ft Ib)
20 N m (2.0 kgf m, 14.8 ft Ib)
8 N m (0.8 kgf m, 5.9 ft Ib)
AA
LT
242
AA
LT
242
LT
242
LT
572
LT
572
A
A
Reverse gate
6-7
JET
PUMP
1
2
3
4
5
7
8
9
E
Jet thrust nozzle and nozzle ring
Jet thrust nozzle and nozzle ring removal
Step Part name Qty Remarks
Jet pump unit assembly Refer to Jet pump unit.
Reverse gate Refer to Reverse gate.
1 Bolt 2 M8 20 mm
2 Collar 2
3 Jet thrust nozzle 1
4 Bolt 2 M8 20 mm
5 Collar 2
6 Nozzle ring 1
7 Nut 1
8 Washer 1
9 Ball joint 1
10 Washer 1
3
9
10
4
5
7
8
4
5
2
1
2
6
1
LT
271
LT
271
LT
271
LT
271
AA
15 N m (1.5 kgf m, 11.1 ft Ib)
15 N m (1.5 kgf m, 11.1 ft Ib)
15 N m (1.5 kgf m, 11.1 ft Ib)
8 N m (0.8 kgf m, 5.9 ft Ib)
LT
242
Jet thrust nozzle and nozzle ring
6-8
JET
PUMP
1
2
3
4
5
6
7
8
9
E
Impeller duct and impeller housing
Impeller duct, impeller housing and nozzle removal
Step Part name Qty Remarks
Nozzle ring Refer to Jet thrust nozzle and nozzle ring.
1 Bolt 4 M10 125 mm
2 Bracket 1
3 Nozzle 1
4 Dowel pin 2
5 Impeller housing 1
6 Dowel pin 2
7 Bolt 4 M6 35 mm
8 Water inlet cover 1
9 Packing 2 Not reusable
10 Water inlet strainer 1
11 Impeller duct assembly 1
LT
572
LT
LT
572
LT
1194E
3
2
4
11
6
6
9
9
4
10
8
5
1
40 N m (4.0 kgf m, 29.5 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
7
1194E
Impeller duct and impeller housing
6-9
JET
PUMP
1
2
3
4
5
7
8
9
E
Impeller duct and drive shaft
Impeller duct and drive shaft disassembly
Step Part name Qty Remarks
1 Impeller 1 Left-hand threads
2 Spacer 1
3 Bolt 3 M6 20 mm
4 Cap 1
5 O-ring 1 Not reusable
6 Nut 1
7 Washer 1
8 Drive shaft 1
EP
AA
AA
AA
69 N m (6.9 kgf m, 50.9 ft Ib)
205 N m (20.5 kgf m, 151.2 ft Ib)
EP
13
12
11
LT
572
LT
LT
572
LT
3
8 N m (0.8 kgf m, 5.9 ft Ib)
1
14
Impeller duct and drive shaft
6-10
JET
PUMP
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
9 Rear bearing 1 Not reusable
Inside diameter: 25 mm (0.98 in)
10 Spacer 1
11 Oil seal 1 Not reusable
12 Oil seal 1 Not reusable
13 Front bearing 1 Not reusable
Inside diameter: 30 mm (1.18 in)
14 Impeller duct 1
EP
AA
AA
AA
69 N m (6.9 kgf m, 50.9 ft Ib)
205 N m (20.5 kgf m, 151.2 ft Ib)
EP
13
12
11
LT
572
LT
LT
572
LT
3
8 N m (0.8 kgf m, 5.9 ft Ib)
1
14
Impeller duct and drive shaft
6-11
JET
PUMP
1
2
3
4
5
7
8
9
E
Drive shaft removal
1. Remove:
Impeller 1
Spacer 2
Cap 3
Nut 4
TIP
The impeller has left-hand threads. Turn the
impeller clockwise to loosen it.
Drive shaft holder 5:
YB-06201
Drive shaft holder 6 5:
90890-06520
1
2
4
3
5
1
4
5
2. Remove:
Drive shaft 1
NOTICE
Do not press the drive shaft threads direct-
ly.
1
Impeller duct and drive shaft
6-12
JET
PUMP
1
2
3
4
5
6
7
8
9
E
3. Remove:
Rear bearing
For USA and Canada
For worldwide
Slide hammer and adapters 1:
YB-06096
Stopper guide plate 2:
90890-06501
Bearing puller assembly 3:
90890-06535
Stopper guide stand 4:
90890-06538
1
3
4 4
2
4. Remove:
Oil seals
For USA and Canada
For worldwide
Slide hammer and adapters 1:
YB-06096
Stopper guide plate 2:
90890-06501
Bearing puller assembly 3:
90890-06535
Stopper guide stand 4:
90890-06538
1
2
3
4
2
3
4
3
3
4
4
Impeller check
1. Check:
Impeller
Refer to Jet pump unit check in Chap-
ter 3.
Impeller housing check
1. Measure:
Impeller housing inside diameter a
Out of specification Replace the
impeller housing.
Impeller housing inside diameter a:
155.35155.45 mm
(6.1166.120 in)
Drive shaft check
1. Check:
Drive shaft spline
Cracks/damage Replace the drive
shaft.
Impeller duct and drive shaft
6-14
JET
PUMP
1
2
3
4
5
6
7
8
9
E
2. Measure:
Drive shaft runout
Out of specification Replace the drive
shaft.
Drive shaft runout limit:
0.3 mm (0.012 in)
Measuring point a:
310 mm (12.20 in)
a
Drive shaft installation
1. Install:
Oil seal 1
Oil seal 2
TIP
Install the oil seal 1 halfway into the impeller
duct, and then install the oil seal 2.
For USA and Canada
For worldwide
2. Install:
Front bearing (to the drive shaft)
NOTICE
Do not reuse the front bearing, always re-
place it with a new one.
Driver handle (large) 3:
YB-06071
Bearing cup installer 4:
YB-06167
Driver rod LS 5:
90890-06606
Bearing outer race attachment 6:
90890-06628
Distance a:
7.0 0.2 mm (0.28 0.008 in)
Bearing attachment 1:
90890-06728
Distance a:
23.0 0.1 mm (0.91 0.004 in)
A A
4
3 2
1
a
A A
6
5
a
2
1
1
a
AA
Impeller duct and drive shaft
6-15
JET
PUMP
1
2
3
4
5
7
8
9
E
3. Install:
Drive shaft assembly (with front bearing)
Spacer
Bearing attachment 1:
90890-06728
1
4. Apply:
EPNOC grease AP #0
(between the drive shaft and spacer)
5. Install:
Rear bearing 1
NOTICE
Do not reuse the rear bearing, always re-
place it with a new one.
6. Apply:
EPNOC grease AP #0 (into the cap)
7. Install:
Nut 1
O-ring 2
Cap 3
Cap bolt 4
Quantity:
20 g (0.04 lb)
Bearing attachment 2:
90890-06728
Quantity:
20 g (0.04 lb)
Drive shaft holder 5:
YB-06201
Drive shaft holder 6 5:
90890-06520
T
R
.
.
Drive shaft nut:
69 Nm (6.9 kgfm, 50.9 ftlb)
Cap bolt:
8 Nm (0.8 kgfm, 5.9 ftlb)
LOCTITE 572
EP
EP
1 2
AA
EP
1
2
3
4
5
AA
LT
572
LT
5
Impeller duct and drive shaft
6-16
JET
PUMP
1
2
3
4
5
6
7
8
9
E
8. Install:
Spacer 1
Impeller 2
TIP
The impeller has left-hand threads. Turn the
impeller counterclockwise to tighten it.
Drive shaft holder 3:
YB-06201
Drive shaft holder 6 3:
90890-06520
T
R
.
.
Impeller:
205 Nm (20.5 kgfm, 151.2 ftlb)
LOCTITE 572
2
1
LT
572
LT
AA
3
Impeller duct, impeller housing and
nozzle installation
1. Install:
Impeller duct assembly 1
Impeller housing 2
Nozzle 3
Bracket 4
Installation steps:
1. Clean the contacting surfaces of the impel-
ler duct assembly 1, impeller housing 2,
and nozzle 3.
2. Apply sealant to the contacting surfaces of
the impeller duct assembly 1, impeller
housing 2, and nozzle 3.
3. Install the dowel pins 5 and 6 to the
impeller duct assembly 1, and then install
the impeller housing 2, nozzle 3, and
bracket 4.
4. Tighten the bolts 7 to the specified
torque.
T
R
.
.
Impeller duct bolt:
40 Nm (4.0 kgfm, 29.5 ftlb)
LOCTITE 572
5
5
2
1
6
3
7
4
6
1194E
1194E
LT
572
LT
Impeller duct and drive shaft
6-17
JET
PUMP
1
2
3
4
5
7
8
9
E
Transom plate and hoses
Transom plate and hose removal
Step Part name Qty Remarks
Exhaust system Refer to Exhaust system in Chapter 8.
Jet pump unit assembly Refer to Jet pump unit.
1 Clamp/cooling water hose 2/1
2 Cap 1
3 Nut 1
4 Clamp/flushing hose 1/1
5 Clamp/cooling water hose 2/1
6 Clamp/cooling water hose 2/1
7 Hose joint 1 1
8 Band 1 Not reusable
9 Bilge strainer assembly 1
10 Plastic tie 1
13
10
31
28
24
45
23
21
22
23
22
12
30
1
29
15
6
9
27
26
25
15
19
20
17
18
7
3
2
SS
8
11
5 N m (0.5 kgf m, 3.7 ft Ib)
6 N m (0.6 kgf m, 4.4 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
11
12
17
21
5
4
1
5
16
14
27
A
A
6
4
26 N m (2.6 kgf m, 19.2 ft Ib)
Transom plate and hoses
6-18
JET
PUMP
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
11 Clamp/bilge hose 1/1
12 Clamp/bilge hose 2/1
13 Hose joint 1
14 Band 1
15 Clamp/bilge hose 2/1
16 Electric bilge pump assembly 1
17 Clamp/bilge hose 2/1
18 Nut 1
19 Gasket 1 Not reusable
20 Pilot outlet 1
21 Clamp/bilge hose 2/1
22 Nut 1
13
10
31
28
24
45
23
21
22
23
22
12
30
1
29
15
6
9
27
26
25
15
19
20
17
18
7
3
2
SS
8
11
5 N m (0.5 kgf m, 3.7 ft Ib)
6 N m (0.6 kgf m, 4.4 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
11
12
17
21
5
4
1
5
16
14
27
A
A
6
4
26 N m (2.6 kgf m, 19.2 ft Ib)
Transom plate and hoses
6-19
JET
PUMP
1
2
3
4
5
7
8
9
E
Step Part name Qty Remarks
23 Drain joint 1
24 Packing 1 Not reusable
25 Plastic tie 1
26 Hose joint 1
27 Clamp/cooling water hose 2/1
28 Clamp/bilge hose 1/1
29 Nut/washer 2/2
30 Nut/washer 2/2
31 Transom plate 1
13
10
31
28
24
45
23
21
22
23
22
12
30
1
29
15
6
9
27
26
25
15
19
20
17
18
7
3
2
SS
8
11
5 N m (0.5 kgf m, 3.7 ft Ib)
6 N m (0.6 kgf m, 4.4 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
11
12
17
21
5
4
1
5
16
14
27
A
A
6
4
26 N m (2.6 kgf m, 19.2 ft Ib)
Transom plate and hoses
6-20
JET
PUMP
1
2
3
4
5
6
7
8
9
E
Water hose check
1. Check:
Bilge hoses
Cooling water hoses
Cracks/damage Replace.
Transom plate installation
1. install:
Transom plate
Installation steps:
1. Clean the contacting surfaces of the tran-
som plate.
2. Apply silicone sealant to the contacting
surfaces of the transom plate.
3. Install the transom plate.
T
R
.
.
Transom plate nut:
26 Nm (2.6 kgfm, 19.2 ftlb)
SS
Transom plate and hoses
6-21
JET
PUMP
1
2
3
4
5
7
8
9
E
Intermediate housing
Intermediate housing removal
*: As required
Step Part name Qty Remarks
Engine unit Refer to Engine unit in Chapter 5.
1 Rubber damper 1
2 Band 1 Not reusable
3 Grease hose 1
4 Bolt 3 M8 48 mm
5 Intermediate housing assembly 1
6 Dowel pin 2
7 Shim *
17 N m (1.7 kgf m, 12.5 ft Ib)
LT
572
LT
4
7
5
2
3
1
6
Intermediate housing
6-22
JET
PUMP
1
2
3
4
5
6
7
8
9
E
Intermediate housing disassembly
Step Part name Qty Remarks
1 Band 1 Not reusable
2 Grease hose 1
3 Nipple 1
4 Driven coupling 1
5 Washer 1
6 Intermediate drive shaft 1
7 O-ring 2 Not reusable
8 Thrust washer 1 Not reusable
9 Oil seal 1 Not reusable
10 Oil seal 2 Not reusable
11 Circlip 2 Not reusable
12 Bearing 1 Not reusable
13 Intermediate housing 1
LT
572
LT
1
2
3
10
11
AA
AA
12
13
8
9
11
10
LT
572
LT
AA
4
5
6
7
205 N m (20.5 kgf m, 151.2 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
M
Intermediate housing
6-23
JET
PUMP
1
2
3
4
5
7
8
9
E
Intermediate housing removal
1. Remove:
Intermediate housing assembly 1
Shims 2
TIP
Make a note of the position of each removed
shim 2 so that it can be installed in its original
position.
2
1
Driven coupling removal
1. Remove:
Driven coupling 1
TIP
Make sure to insert the special service tool 2
completely into the intermediate drive shaft.
Shaft holder 2:
90890-06730
Coupler wrench 3:
90890-06729
3
1
2
Intermediate housing disassembly
1. Remove:
Intermediate drive shaft 1
Thrust washer 2
NOTICE
Do not press the intermediate drive shaft
directly.
1
2
Intermediate housing
6-24
JET
PUMP
1
2
3
4
5
6
7
8
9
E
2. Remove:
Oil seal (front)
Oil seals (rear)
For USA and Canada
For worldwide
Slide hammer and adapters 1:
YB-06096
Bearing puller legs 2:
YB-06523
Stopper guide plate 3:
90890-06501
Bearing puller assembly 4:
90890-06535
Stopper guide stand 5:
90890-06538
1
2
3
4
5
3. Remove:
Circlips 1
Bearing 2
TIP
Make sure to remove the circlips 1 before
removing the bearing 2.
For USA and Canada
For worldwide
Driver handle (large) 3:
YB-06071
Needle bearing installer 4:
YB-06434
Driver rod LS 5:
90890-06606
Bearing outer race attachment 6:
90890-06623
1
1 4
2
3
1
1 6
2
5
5
6
1
2
AA
Intermediate housing
6-26
JET
PUMP
1
2
3
4
5
6
7
8
9
E
2. Install:
Oil seal 1
For USA and Canada
For worldwide
Driver handle (large) 2:
YB-06071
Needle bearing installer 3:
YB-06434
Driver rod LS 4:
90890-06606
Bearing outer race attachment 5:
90890-06623
Distance a:
6.5 0.2 mm (0.26 0.01 in)
2
3
AA
AA
1
a
4
5
AA
AA
1
a
3. Install:
Intermediate drive shaft 1
Bearing attachment 2:
90890-06728
Distance a:
46.0 0.5 mm (1.81 0.02 in)
1
a
2
4. Install:
Circlip 1
Oil seal 2
Bearing attachment 3:
90890-06728
1
3
2
1
AA
5. Install:
Oil seal 1
Bearing attachment 2:
90890-06727
Distance a:
1.6 0.2 mm (0.06 0.01 in)
2
1
a
AA
Intermediate housing
6-27
JET
PUMP
1
2
3
4
5
7
8
9
E
6. Install:
Thrust washer 1
NOTICE
Do not reuse the thrust washer, always re-
place it with a new one.
Bearing attachment 2:
90890-06727
Distance a:
4.4 0.3 mm (0.17 0.01 in)
2
1
a
Driven coupling installation
1. Install:
Driven coupling 1
TIP
Make sure to insert the special service tool 2
completely into the intermediate drive shaft.
Shaft holder 2:
90890-06730
Coupler wrench 3:
90890-06729
T
R
.
.
Driven coupling:
205 Nm (20.5 kgfm, 151.2 ftlb)
LOCTITE 572
3
2
1
Intermediate housing installation
1. Install:
Intermediate housing assembly 1
Shims 2
TIP
Make sure to install the shims in their original
positions.
1
2
Intermediate housing
6-28
E
JET
PUMP
1
2
3
4
5
6
7
8
9
MEMO
Intermediate housing
E
ELEC
+
1
2
3
4
5
8
9
Chapter 7
Electrical system
Engine electrical components ...................................................................... 7-1
Electrical box.................................................................................................. 7-3
Electrical components ............................................................................... 7-3
Electrical box disassembly ........................................................................ 7-4
Fuse box disassembly............................................................................... 7-6
Electrical analysis.......................................................................................... 7-8
Check using the YDIS ............................................................................... 7-8
Input voltage measurement ....................................................................... 7-9
Peak voltage measurement ....................................................................... 7-9
Ignition system............................................................................................. 7-10
Ignition coil............................................................................................... 7-10
Pickup coil ............................................................................................... 7-13
Charging system.......................................................................................... 7-14
Stator coil................................................................................................. 7-14
Rectifier regulator .................................................................................... 7-16
Control system............................................................................................. 7-18
Oil pressure switch .................................................................................. 7-18
Thermoswitch .......................................................................................... 7-19
Thermo sensor ........................................................................................ 7-21
Engine temperature sensor ..................................................................... 7-22
Intake air temperature sensor.................................................................. 7-23
Intake air pressure sensor ....................................................................... 7-25
Knock sensor........................................................................................... 7-26
Throttle position sensor ........................................................................... 7-26
Accelerator position sensor ..................................................................... 7-29
Electronic throttle valve relay................................................................... 7-33
Cam position sensor................................................................................ 7-34
Slant detection switch.............................................................................. 7-35
Steering sensor ....................................................................................... 7-36
Reverse sensor ....................................................................................... 7-37
ECM circuit .............................................................................................. 7-38
Earth plate ............................................................................................... 7-39
Electric bilge pump .................................................................................. 7-40
Fuel system.................................................................................................. 7-41
Fuel injector ............................................................................................. 7-41
Fuel pump module................................................................................... 7-42
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Starting system............................................................................................ 7-44
Fuse......................................................................................................... 7-44
Left handlebar switch assembly .............................................................. 7-44
Main and fuel pump relay ........................................................................ 7-45
Starter relay............................................................................................. 7-47
Starter motor ................................................................................................ 7-49
Starter motor disassembly....................................................................... 7-49
Starter motor operation............................................................................ 7-52
Armature.................................................................................................. 7-52
Brush holder ............................................................................................ 7-54
Gear cover............................................................................................... 7-54
Rear cover ............................................................................................... 7-55
Starter motor assembly ........................................................................... 7-55
Remote control system............................................................................... 7-55
Transmitter registration............................................................................ 7-55
Remote control transmitter ...................................................................... 7-56
Remote control receiver .......................................................................... 7-59
Indication system......................................................................................... 7-60
Dual analog meter unit ............................................................................ 7-60
Switch assembly...................................................................................... 7-61
Speed sensor .......................................................................................... 7-61
Fuel level meter display and fuel indicator .............................................. 7-63
Check engine warning indicator .............................................................. 7-63
Diagnostic display.................................................................................... 7-64
Oil pressure warning indicator ................................................................. 7-64
Engine overheat warning indicator .......................................................... 7-65
Buzzer ..................................................................................................... 7-65
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Engine electrical components
1
2
3
4
5
9
8
A
0
B
C
D
E
F
6
7
16
20
19
15
21
b
a
20
18
1
2
4
5
6
3
17
15
14 13
14
13
16
19
4 N m (0.4 kgf m, 3.0 ft Ib)
Electrical box
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Step Part name Qty Remarks
13 Bolt 2 M6 10 mm
14 Boot 2
15 Starter motor cable 1 aWhite tape
To starter motor
16 Positive battery cable 1 bGray tape
To battery
17 Starter relay 1
18 Bolt 3 M6 7 mm
19 Lead 1 Red lead
20 Lead 1 Brown lead
21 Lead 1 Black lead
22 Housing 1
A
A
9
10
12
18
21
10
11
8
7
22
16
20
19
15
21
b
a
20
18
1
2
4
5
6
3
17
15
14 13
14
13
16
19
4 N m (0.4 kgf m, 3.0 ft Ib)
Electrical box
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Electrical analysis
Check using the YDIS
When checking the TPS, APS, or other sen-
sors, use the YDIS.
When deleting the diagnosis record in the
YDIS, make sure to check the time that the
diagnostic codes were detected.
When checking the input voltage of a part, the
coupler or connector must be disconnected.
As a result, the ECM determines that the part
is disconnected and a diagnostic code is
detected. Therefore, make sure to delete the
diagnosis record after checking the input volt-
age.
Power is supplied to the ECM for about 30
seconds after stopping the engine. Therefore,
wait longer than 30 seconds before restarting
the engine, otherwise the diagnostic codes will
not be cleared from the ECM.
TIP
Before checking the electrical components,
make sure that the battery is fully charged.
If the tester leads are connected while using
the YDIS, diagnostic codes will be detected.
If a diagnosis record is displayed and it is
caused by the checking steps, delete the
record by using the Diagnosis record func-
tion of the YDIS.
The YDIS requires that you use an exclusive
communication cable and CD-ROM to con-
nect to a computer. For a description of the
communication cable and CD-ROM to be
used, refer to YDIS in Chapter 9. Also,
make sure to check the CD-ROM version
before using it.
To connect the YDIS, refer to YDIS in
Chapter 9 or the YDIS (Ver. 1.32) Instruction
Manual.
YDIS (connecting kit):
60V-85300-04
YDIS (CD-ROM, Ver. 1.32):
60V-WS853-05
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Input voltage measurement
Push the unlock button 1 on the remote con-
trol transmitter so that power is supplied to the
ECM.
TIP
To check that the remote control transmitter is
working correctly, refer to Remote control
transmitter.
1
Peak voltage measurement
To check the electrical components or mea-
sure the peak voltage, use the special service
tools. A faulty electrical component can be
easily checked by measuring the peak voltage.
The specified engine speed when measuring
the peak voltage is affected by many factors,
such as fouled spark plugs or a weak battery.
If one of these factors is present, the peak volt-
age cannot be measured properly.
WARNING
When checking the peak voltage, do not
touch any of the connections of the digital
tester leads.
NOTICE
When testing the voltage between the ter-
minals of an electrical component with
the digital tester, do not allow any of the
leads to touch any metal parts.
Place the watercraft in the water when
starting the engine, otherwise the engine
could be damaged.
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TIP
Before measuring the peak voltage, check all
wiring for proper connection and corrosion,
and check that the battery is fully charged.
Use the peak voltage adapter with the rec-
ommended digital circuit tester.
Connect the positive pin of the peak voltage
adapter to the positive terminal of the digital
tester, and the negative pin to the negative
terminal.
When measuring the peak voltage, set the
selector on the digital circuit tester to the DC
voltage mode.
For USA and Canada
For worldwide
Digital multimeter 1:
YU-34899-A
Peak voltage adapter 2:
YU-39991
Digital circuit tester 3:
90890-03174
Peak voltage adapter B 4:
90890-03172
V
1
2
DC V
3
4
Ignition system
Ignition coil
1. Check:
Ignition spark
No spark Measure the ignition coil
input voltage.
Checking steps:
1. Connect a computer to the watercraft and
use the YDIS.
2. Remove the ignition coil for the cylinder
that will be tested.
3. Connect the ignition coil to the special ser-
vice tool 1.
Spark checker:
YM-34487
Ignition tester:
90890-06754
1
Electrical analysis / Ignition system
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4. Using the Stationary test of the YDIS,
observe the ignition spark through the dis-
charge window in the special service tool.
WARNING
When checking the ignition spark, do not
touch any of the connections of the spe-
cial service tool leads.
When performing the ignition spark
check, keep flammable gas or liquids
away, since this test can produce sparks.
2. Measure:
Ignition coil input voltage (from the
battery)
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the ignition coil couplers 1.
2. Push the unlock button, and then measure
the input voltage at the ignition coil coupler
terminals (wiring harness end).
Ignition coil input voltage (from the
battery):
Red/yellow (R/Y) Black (B)
12 V (battery voltage)
B R/Y
1
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3. Measure:
ECM output peak voltage
Within specification Replace the igni-
tion coil.
Below specification Check the pickup
coil.
Refer to Pickup coil.
WARNING
When checking the electrical components,
do not touch any of the connections of the
digital tester leads.
Measurement steps:
1. Disconnect the ignition coil couplers 1.
2. Measure the ECM output peak voltage as
shown.
TIP
If measuring the ECM output peak voltage
under the Cranking condition, disconnect
the fuel injector couplers for all cylinders.
To crank the engine, connect the engine
shut-off cord (lanyard) to the engine shut-off
switch, and then push the engine start
switch.
ECM output peak voltage:
#1 Black/red (B/R)
Black (B)
#2 Black/white (B/W)
Black (B)
#3 Black/yellow (B/Y)
Black (B)
#4 Black/green (B/G)
Black (B)
r/min
Loaded
Cranking 2,000 3,500
V 2.5 2.6 2.6
B
#1 B/R
#2 B/W
#3 B/Y
#4 B/G
#1 B/R
#2 B/W
#3 B/Y
#4 B/G
R/Y
B
1
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Pickup coil
1. Measure:
Pickup coil output peak voltage
Below specification Measure the
pickup coil resistance.
Measurement steps:
1. Disconnect the pickup coil coupler 1.
2. Connect the test harness (3 pins) 2 to the
pickup coil coupler 1.
3. Measure the pickup coil output peak volt-
age.
TIP
To crank the engine, connect the engine
shut-off cord (lanyard) to the engine shut-off
switch, and then push the engine start switch
and engine stop switch simultaneously.
If measuring the pickup coil output peak volt-
age under the Cranking and Unloaded
conditions, disconnect the coupler 3.
Test harness (3 pins):
YB-06877
Test harness HM090-3 (3 pins):
90890-06877
Pickup coil output peak voltage:
White (W) Black (B)
r/min
Unloaded Loaded
Cranking 2,000 3,500
V 5.4 4.6 18.1 23.9
B W
B W
B
W W/B
B/O
W B
3
3
1
2
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2. Measure:
Pickup coil resistance
Out of specification Replace the sta-
tor coil assembly.
Measurement steps:
1. Disconnect the pickup coil coupler 1.
2. Measure the pickup coil resistance.
Pickup coil resistance at 20 C (68 F)
(reference data):
White (W) Black (B)
459561
B W
1
Charging system
Stator coil
1. Measure:
Stator coil output peak voltage
Below specification Measure the sta-
tor coil resistance.
Measurement steps:
1. Disconnect the stator coil coupler 1.
2. Connect the test harness (3 pins) 2 to the
stator coil coupler 1.
Test harness (3 pins):
YB-06870
Test harness SMT250-3 (3 pins):
90890-06870
G
G
G
W R B
G
G
G
B
R
W
G G
G
1
2
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3. Measure the stator coil output peak volt-
age.
TIP
To crank the engine, connect the engine shut-
off cord (lanyard) to the engine shut-off switch,
and then push the engine start switch and
engine stop switch simultaneously.
Stator coil output peak voltage:
Green (G) Green (G)
r/min
Unloaded
Cranking 2,000 3,500
V 8.4 42.7 74.0
2. Measure:
Stator coil resistance
Out of specification Replace the sta-
tor coil assembly.
Measurement steps:
1. Disconnect the stator coil coupler 1.
2. Measure the stator coil resistance.
Stator coil resistance at 20 C (68 F)
(reference data):
Green (G) Green (G)
0.310.38
G
G G
1
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Rectifier regulator
1. Measure:
Rectifier regulator output peak voltage
Below specification Check the recti-
fier regulator continuity.
Measurement steps:
1. Disconnect the rectifier regulator coupler
1.
2. Connect the test harness (2 pins) 2 to the
rectifier regulator coupler 1.
3. Measure the rectifier regulator output peak
voltage.
TIP
Do not use the peak voltage adapter to mea-
sure the output voltage.
Test harness (2 pins):
90890-06850
Rectifier regulator output peak
voltage:
Red (R) Black (B)
r/min
Loaded
2,000 3,500
V 13 13
R
B
R
G
G
G
B
R
B
1 2
B R
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2. Check:
Rectifier regulator continuity
Out of specification Replace the recti-
fier regulator.
Checking steps:
1. Remove the rectifier regulator.
Refer to Engine unit removal 3 in Chap-
ter 5.
2. Check the rectifier regulator continuity.
TIP
Make sure to set the measurement range a
when checking the rectifier regulator continu-
ity.
For USA and Canada
For worldwide
OL: overload
Rectifier regulator continuity
(testing diode):
Tester lead
Display value (V)
(reference data)
+ -
1 R 2 G
OL
1 R 3 G
1 R 4 G
1 R 5 B
5 B 2 G 0.430.51
5 B 3 G 0.430.51
5 B 4 G 0.430.51
5 B 1 R 0.660.74
2 G 1 R 0.430.51
3 G 1 R 0.430.51
4 G 1 R 0.430.51
2 G 5 B
OL 3 G 5 B
4 G 5 B
a
a
a
G 2
G 3
B5 R 1
4 G
1R
2G
3G
4G
5B
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Control system
Oil pressure switch
1. Measure:
Oil pressure switch input voltage
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the oil pressure switch coupler
1.
2. Push the unlock button, and then measure
the input voltage between the oil pressure
switch coupler terminal (wiring harness
end) and ground.
Oil pressure switch input voltage
(reference data):
Pink/white (P/W) Ground
11.012.0 V
P/W
1
2. Check:
Oil pressure switch continuity
Out of specification Replace the oil
pressure switch.
Checking steps:
1. Remove the oil pressure switch.
Refer to Oil separator tank and oil pan
removal in Chapter 5.
2. Connect the tester leads to the terminal
thread 1 and body 2 of the oil pressure
switch as shown.
3. Connect a vacuum/pressure pump gauge
to the oil pressure switch, and then apply
positive pressure.
2
1
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4. Check the oil pressure switch continuity.
TIP
Use a commercially available vacuum/pres-
sure pump gauge and meter.
Oil pressure switch continuity:
Pressure
Terminal thread 1
Body 2
Below 128166 kPa
(1.281.66 kgf/cm
2
,
18.223.6 psi)
Continuity
Above 128166 kPa
(1.281.66 kgf/cm
2
,
18.223.6 psi)
No continuity
Thermoswitch
1. Measure:
Thermoswitch input voltage
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the thermoswitch coupler 1.
2. Push the unlock button, and then measure
the input voltage at the thermoswitch cou-
pler terminals (wiring harness end).
Thermoswitch input voltage (reference
data):
Pink (P) Black/orange (B/O)
11.012.0 V
1
P B/O
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2. Check:
Thermoswitch continuity (at the speci-
fied temperatures)
Out of specification Replace the ther-
moswitch.
Checking steps:
1. Remove the thermoswitch.
Refer to Oil separator tank and oil pan
removal in Chapter 5.
2. Suspend the thermoswitch in a container
filled with water.
3. Slowly heat the water.
4. Check the continuity when the specified
temperatures are reached.
a 94100 C (201212 F)
b 8094 C (176201 F)
c No continuity
d Continuity
Temperature
Time
Thermoswitch continuity:
Pink (P) Black (B)
Temperature
(reference data)
Pink (P)
Black (B)
Increasing
Below
94100 C
(201212 F)
No continuity
Above
94100 C
(201212 F)
Continuity
Decreasing
Above
8094 C
(176201 F)
Continuity
Below
8094 C
(176201 F)
No continuity
P B
c
c
d
d
d
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Thermo sensor
1. Measure:
Thermo sensor input voltage
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the thermo sensor coupler 1.
2. Push the unlock button, and then measure
the input voltage at the thermo sensor cou-
pler terminals (wiring harness end).
Thermo sensor input voltage
(reference data):
Black/blue (B/L)
Black/orange (B/O)
4.755.25 V
1
B/O B/L
2. Measure:
Thermo sensor resistance (at the speci-
fied temperatures)
Out of specification Replace the
thermo sensor.
Measurement steps:
1. Remove the thermo sensor.
Refer to Muffler disassembly in Chapter
5.
2. Suspend the thermo sensor in a container
filled with water.
3. Slowly heat the water.
4. Measure the resistance when the specified
temperatures are reached.
Thermo sensor resistance (reference
data):
Black (B) Black (B)
0 C (32 F): 24.037.1 k
100 C (212 F): 0.871.18 k
B B
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Engine temperature sensor
1. Measure:
Engine temperature sensor input
voltage
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the engine temperature sensor
coupler 1.
2. Push the unlock button, and then measure
the input voltage at the engine tempera-
ture sensor coupler terminals (wiring har-
ness end).
Engine temperature sensor input
voltage (reference data):
Black/yellow (B/Y)
Black/orange (B/O)
4.755.25 V
1
B/Y B/O
2. Measure:
Engine temperature sensor resistance
(at the specified temperatures)
Out of specification Replace the
engine temperature sensor.
Measurement steps:
1. Remove the engine temperature sensor.
Refer to Oil separator tank and oil pan
removal in Chapter 5.
2. Suspend the engine temperature sensor in
a container filled with water.
3. Slowly heat the water.
B/Y B/Y
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4. Measure the resistance when the specified
temperatures are reached.
Engine temperature sensor resistance
(reference data):
Black/yellow (B/Y)
Black/yellow (B/Y)
20 C (68 F): 54.269.0 k
100 C (212 F): 3.123.48 k
Intake air temperature sensor
1. Check:
Intake air temperature
Incorrect reading Measure the intake
air temperature sensor input voltage.
Checking steps:
1. Measure the ambient temperature.
2. Connect a computer to the watercraft and
use the YDIS to display the intake air tem-
perature.
TIP
Check the intake air temperature sensor when
the engine is cold.
3. If the ambient temperature and the dis-
played intake air temperature differ by
more than 5 C ( 9 F), measure the
intake air temperature sensor resistance.
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2. Measure:
Intake air temperature sensor input
voltage
Within specification Measure the
intake air temperature sensor resis-
tance.
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the intake air temperature sen-
sor coupler 1.
2. Push the unlock button, and then measure
the input voltage at the intake air tempera-
ture sensor coupler (wiring harness end).
3. Measure:
Intake air temperature sensor resistance
(at the specified temperatures)
Out of specification Replace the
intake air temperature sensor.
Measurement steps:
1. Remove the intake air temperature sensor.
Refer to Intake assembly removal in
Chapter 5.
2. Suspend the intake air temperature sensor
in a container filled with water.
3. Slowly heat the water.
4. Measure the resistance when the specified
temperatures are reached.
Intake air temperature sensor input
voltage (reference data):
Black/red (B/R)
Black/orange (B/O)
4.505.50 V
Intake air temperature sensor
resistance (reference data):
Black (B) Black (B)
0 C (32 F): 5.46.6 k
80 C (176 F): 0.290.39 k
B/R B/O
1
B B
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Intake air pressure sensor
1. Measure:
Intake air pressure sensor input voltage
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the intake air pressure sensor
coupler 1.
2. Push the unlock button, and then measure
the input voltage at the intake air pressure
sensor coupler terminals (wiring harness
end).
2. Check:
Intake air pressure sensor operation
Does not operate Replace the intake
air pressure sensor.
Checking steps:
1. Connect the special service tool to the
intake air pressure sensor.
2. Connect a computer to the watercraft and
use the YDIS to display the intake air pres-
sure.
3. Push the unlock button.
4. Apply negative pressure to the intake air
pressure sensor slowly and check that the
displayed intake air pressure decreases.
Intake air pressure sensor input
voltage (reference data):
Orange (O) Black/orange (B/O)
4.755.25 V
Lower unit pressure/vacuum tester:
YB-35956-A
Vacuum/pressure pump gauge set:
90890-06756
1
O B/O
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Knock sensor
1. Check:
Knock sensor ground connection
Knock sensor not grounded when
installed Install the knock sensor cor-
rectly.
Refer to Oil separator tank and oil pan
removal in Chapter 5.
2. Measure:
Knock sensor resistance
Out of specification Replace the
knock sensor.
Measurement steps:
1. Remove the knock sensor.
Refer to Oil separator tank and oil pan
removal in Chapter 5.
2. Measure the knock sensor resistance.
Knock sensor resistance at 20 C
(68 F) (reference data):
504616 k
Throttle position sensor
NOTICE
Do not loosen the throttle stop screw nut
1 and do not turn the throttle stop screw
2.
Do not disconnect the throttle body as-
sembly coupler (throttle body end) 3.
1
3
2
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1. Check:
Throttle valve opening
TPS output voltage
Out of specification Measure the TPS
input voltage.
Checking steps:
TIP
When checking the TPS using the YDIS, do
not start the engine.
1. Connect a computer to the watercraft and
use the YDIS to display Throttle position
sensor 1, Throttle valve opening, and
Throttle position sensor 2.
TIP
TPS 1 and TPS 2 are components of the elec-
tronic throttle valve, which cannot be disas-
sembled.
2. Squeeze the throttle lever slowly and
check that the displayed throttle valve
opening increases.
3. Check that the APS pulley stopper a con-
tacts the fully closed stopper b when the
throttle lever 1 is at the fully closed posi-
tion .
TIP
To adjust the throttle cable, refer to Throttle
lever free play check and adjustment in Chap-
ter 3.
4. Push the unlock button, and then check
the TPS 1 output voltage and throttle valve
opening angle at the fully closed position
.
TPS 1 output voltage with throttle
lever fully closed:
0.60.9 V
Throttle valve opening angle with
throttle lever fully closed:
2.08.0
b
a
1
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5. Operate the throttle lever 1, and then
check the TPS 2 output voltage and throt-
tle valve opening angle at the fully open
position .
TIP
The actual TPS output voltage and throttle
valve opening angle may vary according to
environmental conditions and engine tempera-
ture.
6. Operate the throttle lever 1 so that the
TPS 2 output voltage is at 4.5 V or less,
and then check the voltage difference
between TPS 1 and TPS 2.
Example:
If the TPS 1 output voltage is 2.5 V and the
TPS 2 output voltage is 4.5 V, then 4.5
2.5 = 2.0 V.
2. Measure:
TPS input voltage
Out of specification Check the TPS
circuit.
Measurement steps:
1. Disconnect the throttle body assembly
coupler 1.
2. Push the unlock button, and then measure
the input voltage at the throttle body
assembly coupler terminals (wiring har-
ness end).
TPS 2 output voltage with throttle
lever fully open:
4.64.7 V
Throttle valve opening angle with
throttle lever fully open:
more than 70
TPS output voltage difference:
1.92.1 V
TPS input voltage (reference data):
Orange (O) Black/orange (B/O)
4.755.25 V
1
O
B/O
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3. Check:
TPS circuit continuity
No continuity Replace the wiring har-
ness assembly.
Wiring harness is correct Replace the
throttle body assembly.
Checking steps:
1. Disconnect the throttle body assembly
coupler 1.
2. Disconnect the ECM couplers 2 and 3.
3. Check the wiring harness for continuity.
Wiring harness continuity:
Terminal No.
Color
Coupler 1 Coupler 2, 3
1 42 P
2 44 O
3 78 G
4 43 P/B
5 41 B/O
6 52 L
1
2 3
1
44
52
43 42 41
78
2 3
3 2 1
6 5 4
Accelerator position sensor
1. Check:
APS output voltage
Out of specification Measure the APS
input voltage.
Checking steps:
TIP
When checking the APS using the YDIS, do
not start the engine.
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1. Connect a computer to the watercraft and
use the YDIS to display the Accelerator
position sensor 1 and Accelerator posi-
tion sensor 2.
TIP
APS 1 and APS 2 are a single unit, which can-
not be disassembled.
2. Check that the APS pulley stopper a con-
tacts the fully closed stopper b when the
throttle lever 1 is at the fully closed posi-
tion .
TIP
To adjust the throttle cable, refer to Throttle
lever free play check and adjustment in Chap-
ter 3.
3. Push the unlock button, operate the throt-
tle lever 1, and then check the output volt-
ages of APS 1 and APS 2 at the fully
closed position and fully open position
.
TIP
The actual APS output voltage may vary
according to environmental conditions.
4. Squeeze the throttle lever 1 to the fully
open position, and then check the voltage
difference between APS 1 and APS 2.
APS output voltage:
Item
Throttle lever position
Fully closed Fully open
APS 1 0.500.90 V 3.754.35 V
APS 2 0.351.05 V 3.604.50 V
APS output voltage difference (with
throttle lever fully open):
0.75 V or less
b
a
1
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2. Measure:
APS input voltage
Within specification Measure the APS
resistance.
Out of specification Check the APS
circuit.
Measurement steps:
1. Disconnect the APS coupler 1.
2. Push the unlock button, and then measure
the input voltage at the APS coupler termi-
nals (wiring harness end).
APS 1 input voltage (reference data):
Orange/red (O/R) Black/red (B/R)
4.755.25 V
APS 2 input voltage (reference data):
Orange/white (O/W)
Black/white (B/W)
4.755.25 V
1
O/R B/R O/W B/W
3. Measure:
APS resistance
Out of specification Replace the APS.
Measurement steps:
1. Disconnect the APS coupler.
2. Check that the APS pulley stopper a con-
tacts the fully closed stopper b when the
APS pulley is at the fully closed position
.
b
a
1 2 3 4 5 6 7 8
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3. Check that the APS pulley stopper c con-
tacts the fully open stopper d when the
APS pulley is at the fully open position .
4. Measure the resistance of the APS at the
fully closed position and fully open posi-
tion.
4. Check:
APS circuit continuity
No continuity Replace the wiring har-
ness assembly.
Checking steps:
1. Disconnect the APS coupler 1.
2. Disconnect the ECM coupler 2.
3. Check the wiring harness for continuity.
APS resistance at 20 C (68 F)
(reference data):
Item
Termi-
nal
APS pulley position
Fully
closed
Fully
open
APS 1 13
0.50
0.90 k
3.75
4.35 k
APS 2 67
0.35
1.05 k
3.60
4.50 k
Wiring harness continuity:
Terminal No.
Color
Coupler 1 Coupler 2
1 34 B/R
2 49 O/R
3 36 P/R
6 37 P/W
7 35 B/W
8 50 O/W
c
d
1 2 3 4 5 6 7 8
1
2
2 1
8 7 6 3 2 1 37
50 49
36 35 34
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Electronic throttle valve relay
1. Measure:
ETV relay input voltage
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the ETV relay coupler 1.
2. Push the unlock button, and then measure
the input voltage between the ETV relay
coupler terminals and ground.
ETV relay input voltage:
Red/yellow (R/Y) Ground
Red (R) Ground
12 V (battery voltage)
1
R
R/Y
2. Check:
ETV relay continuity
Out of specification Replace the ETV
relay.
Checking steps:
1. Remove the ETV relay.
Refer to Fuse box disassembly.
2. Connect the tester leads to the ETV relay
terminals 4 and 5 or to the terminals 4
and 6.
3. Connect the positive battery lead to the
ETV relay terminal 1 or 2.
4. Connect the negative battery lead to the
ETV relay terminal 3.
5. Check the continuity between terminals 4
and 5 or terminals 4 and 6.
ETV relay continuity:
Battery lead
1 or 2 3
Terminal
4 5 or 6
Disconnected No continuity
Connected Continuity
1 2 3
4 5 6
6
5
4
3
2
1
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Cam position sensor
1. Measure:
Cam position sensor input voltage
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the cam position sensor cou-
pler 1.
2. Push the unlock button, and then measure
the input voltage at the cam position sen-
sor coupler terminals (wiring harness end).
2. Measure:
Cam position sensor output voltage
Out of specification Replace the cam
position sensor.
Measurement steps:
1. Remove the cam position sensor.
Refer to Cylinder head cover removal in
Chapter 5.
2. Connect the test harness (3 pins) to the
cam position sensor.
3. Push the unlock button, and then measure
the output voltage when a screwdriver is
passed under the cam position sensor in
direction as shown.
Cam position sensor input voltage
(reference data):
Orange (O) Black/orange (B/O)
4.755.25 V
Test harness (3 pins):
YB-06877
Test harness HM090-3 (3 pins):
90890-06877
Cam position sensor output voltage:
Green/orange (G/O)
Black/orange (B/O)
Position Voltage (V)
a, c More than 4.8
b Less than 0.8
O B/O
1
G/O
B/O
W B
b
a c
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Slant detection switch
1. Measure:
Slant detection switch input voltage
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the slant detection switch cou-
pler 1.
2. Push the unlock button, and then measure
the input voltage at the slant detection
switch coupler (wiring harness end).
2. Check:
Slant detection switch continuity
Out of specification Replace the slant
detection switch.
Checking steps:
1. Remove the slant detection switch.
Refer to Electrical box disassembly.
2. Check the slant detection switch continu-
ity.
TIP
Make sure to turn the switch over to both the
left and right as shown.
Slant detection switch input voltage
(reference data):
Blue/black (L/B)
Black/orange (B/O)
4.755.25 V
Slant detection switch continuity:
Position
Blue/black (L/B)
Black/orange (B/O)
Normal
position
No continuity
Overturned Continuity
L/B B/O
1
UP
U
P
U P
U
P
B/O L/B
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Steering sensor
1. Check:
Steering sensor operation
Does not operate Measure the steer-
ing sensor input voltage.
Checking steps:
1. Connect a computer to the watercraft to
use the YDIS.
2. Turn the handlebar all the way to the left or
right.
3. Install a plastic tie 1 loosely around the
center a of the handlebar grip as shown.
4. Hook a spring gauge 2 onto the plastic tie
1.
5. Push the unlock button.
6. Hold the spring gauge 2 at a 90 angle
from the handlebar grip, and then pull the
spring gauge in direction as shown with
a force of 10 kgf (22 lb).
TIP
At this time, the button 3 in the steering sen-
sor will be pushed in direction .
7. Check that the following is displayed in the
Engine monitor window of the YDIS.
8. Use the same procedure to check that the
steering sensor operates correctly when
the handlebar is turned to both the left and
right.
Steering sensor operation:
Handlebar YDIS display
Not pulled OFF
Pulled ON
a
2
3
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2. Measure:
Steering sensor input voltage
Within specification Replace the
steering sensor.
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the steering sensor coupler 1.
2. Push the unlock button, and then measure
the input voltage at the steering sensor
coupler terminals (wiring harness end).
Reverse sensor
1. Check:
Reverse sensor operation
Does not operate Measure the
reverse sensor input voltage.
Checking steps:
1. Connect a computer to the watercraft to
use the YDIS.
2. Push the unlock button.
3. Operate the shift lever 1 and check that
the following is displayed in the Engine
monitor window of the YDIS.
Steering sensor input voltage
(reference data):
Orange/red (O/R)
Black/orange (B/O)
4.755.25 V
Reverse sensor operation:
Shift lever position YDIS display
Forward OFF
Reverse ON
1
O/R B/O
1
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2. Measure:
Reverse sensor input voltage
Within specification Replace the
reverse sensor.
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the reverse sensor coupler 1.
2. Push the unlock button, and then measure
the input voltage at the reverse sensor
coupler terminals (wiring harness end).
Reverse sensor input voltage
(reference data):
Orange (O) Black/orange (B/O)
4.755.25 V
O B/O
1
ECM circuit
1. Measure:
ECM input voltage
Out of specification Check the ECM
circuit.
Measurement steps:
1. Disconnect the ECM coupler 1.
2. Push the unlock button, and then measure
the input voltage between the ECM cou-
pler terminal (wiring harness end) and
ground.
TIP
Do not disconnect the coupler 2 or coupler 3
when measuring the ECM input voltage.
ECM input voltage:
Red/yellow (R/Y) Ground
12 V (battery voltage)
R/Y
2 1 3
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2. Check:
ECM circuit continuity
No continuity Replace the wiring har-
ness assembly.
Checking steps:
1. Disconnect the ECM couplers 1 and 2.
2. Check the continuity between the ECM
coupler terminals 3 (wiring harness end)
and ground.
B B
B
2 1
1 2
B
3
Earth plate
1. Check:
Earth plate continuity
No continuity Replace the earth plate.
Checking steps:
1. Remove the earth plate.
Refer to Oil separator tank and oil pan
removal in Chapter 5.
2. Check the continuity between each termi-
nal 1 and the housing 2.
1
2
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Electric bilge pump
1. Measure:
Electric bilge pump input voltage
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the electric bilge pump coupler
1.
2. Push the unlock button, and then measure
the input voltage at the electric bilge pump
coupler (wiring harness end).
Electric bilge pump input voltage:
Red/yellow (R/Y) Black (B)
12 V (battery voltage)
R/Y B
1
2. Check:
Electric bilge pump operation
Does not operate Replace the elec-
tric bilge pump.
Checking steps:
1. Remove the electrical bilge pump.
Refer to Transom plate and hose
removal in Chapter 6.
2. Suspend the electric bilge pump in a con-
tainer filled with water.
3. Connect the positive battery lead to the
terminal 1, and the negative battery lead
to the terminal 2.
4. Check that water flows from the electric
bilge pump hose 3.
3
Br 1 2B
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Fuel system
Fuel injector
1. Check:
Fuel injector operation sound
Does not sound Measure the fuel
injector input voltage.
Checking steps:
1. Connect a computer to the watercraft to
use the YDIS.
2. Using the Stationary test of the YDIS, lis-
ten for the fuel injector operation sound.
2. Measure:
Fuel injector input voltage
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the fuel injector couplers 1.
2. Push the unlock button, and then measure
the input voltage between the fuel injector
coupler terminals (wiring harness end) and
ground.
Fuel injector input voltage:
Red/yellow (R/Y) Ground
12 V (battery voltage)
R/Y
1
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3. Measure:
Fuel injector resistance
Out of specification Replace the fuel
injector.
Measurement steps:
1. Remove the fuel injector.
Refer to Fuel tank removal in Chapter 4.
2. Measure the fuel injector resistance.
Fuel injector resistance at 20 C
(68 F) (reference data):
11.512.5
Fuel pump module
1. Check:
Fuel pump module operation sound
Does not sound Measure the fuel
pump module input voltage.
Checking steps:
1. Connect a computer to the watercraft to
use the YDIS.
2. Using the Stationary test of the YDIS, lis-
ten for the fuel pump module operation
sound.
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2. Measure:
Fuel pump module input voltage
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the fuel pump module coupler
1.
2. Push the unlock button, and then measure
the input voltage at the fuel pump module
coupler terminals (wiring harness end).
TIP
After the unlock button is pushed, voltage will
only be applied to the fuel pump module for 3
seconds.
3. Measure:
Fuel sender resistance
Out of specification Replace the fuel
sender.
Refer to Fuel sender removal in Chap-
ter 4.
Measurement steps:
1. Remove the fuel pump module.
Refer to Fuel tank removal in Chapter 4.
2. Measure the fuel sender resistance.
Fuel pump module input voltage:
Blue (L) Black (B)
12 V (battery voltage)
Fuel sender resistance at 20 C
(68 F) (reference data):
Float position
Yellow (Y)
Black (B)
Lower position 133.5136.5
Upper position 5.07.0
B L
1
Y B
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Starting system
Fuse
1. Check:
Fuse continuity
No continuity Replace the fuse.
Left handlebar switch assembly
1. Check:
Engine start switch continuity
Out of specification Replace the left
handlebar switch assembly.
Checking steps:
1. Disconnect the left handlebar switch cou-
pler.
Refer to Handlebar assembly removal in
Chapter 8.
2. Check the engine start switch continuity.
Engine start switch continuity:
Clip 1
Engine start
switch 2
Red (R)
Brown (Br)
Installed
Free No continuity
Pushed Continuity
Removed
Free No continuity
Pushed No continuity
R Br
1
2
2
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2. Check:
Engine stop switch continuity
Out of specification Replace the left
handlebar switch assembly.
Checking steps:
1. Disconnect the left handlebar switch cou-
pler.
Refer to Handlebar assembly removal in
Chapter 8.
2. Check the engine stop switch continuity.
Main and fuel pump relay
1. Measure:
Main and fuel pump relay input voltage
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the main and fuel pump relay
coupler 1.
2. Measure the input voltage between the
main and fuel pump relay coupler termi-
nals 2 or 3 (wring harness end) and
ground.
Engine stop switch continuity:
Clip 1
Engine stop
switch 2
White (W)
Black (B)
Installed
Free No continuity
Pushed Continuity
Removed
Free Continuity
Pushed Continuity
Main and fuel pump relay input
voltage:
Red (R) Ground
12 V (battery voltage)
W B
2
2
1
1
R
R
2
3
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2. Check:
Main relay continuity
Out of specification Replace the main
and fuel pump relay.
Checking steps:
1. Remove the main and fuel pump relay.
Refer to Fuse box disassembly.
2. Connect the tester leads to the main and
fuel pump relay terminals 5 and 6 or to
the terminals 5 and 7.
3. Connect the positive battery lead to the
main and fuel pump relay terminal 2 or
3.
4. Connect the negative battery lead to the
main and fuel pump relay terminal 1.
5. Check the continuity between the termi-
nals 5 and 6 or the terminals 5 and 7.
Main relay continuity:
Battery lead
2 or 3 1
Terminal
5 6 or 7
Disconnected No continuity
Connected Continuity
1 2 3 4
5 6 7 8
7
8
6
5
3
4
2
1
3. Check:
Fuel pump relay continuity
Out of specification Replace the main
and fuel pump relay.
NOTICE
Do not reverse the battery leads, otherwise
the main and fuel pump relay may be seri-
ously damaged.
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Checking steps:
1. Connect the tester leads to the main and
fuel pump relay terminals 7 and 8.
2. Connect the positive battery lead to the
main and fuel pump relay terminal 6.
3. Connect the negative battery lead to the
main and fuel pump relay terminal 4.
4. Check the continuity between the termi-
nals 7 and 8.
Starter relay
1. Measure:
Starter relay input voltage
Out of specification Check the wiring
harness.
Measurement steps:
1. Slide the boot away from the starter relay
terminal 1.
TIP
The positive battery cable is marked with gray
tape a.
2. Measure the input voltage between the
starter relay terminal 1 and ground.
Fuel pump relay continuity:
Battery lead
6 4
Terminal
7 8
Disconnected No continuity
Connected Continuity
Starter relay input voltage:
Red (R) Ground
12 V (battery voltage)
8
7
6
4
3
2
1
5
1R
a
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2. Check:
Starter relay continuity
Out of specification Replace the
starter relay.
Checking steps:
1. Remove the starter relay.
Refer to Electrical box disassembly.
2. Connect the tester leads between the
starter relay terminals 1 and 2.
3. Connect the positive battery lead to the
terminal 3, and the negative battery lead
to the terminal 4.
4. Check the continuity between the starter
relay terminals 1 and 2.
Starter relay continuity:
Battery lead
3 4
Terminal
1 2
Disconnected No continuity
Connected Continuity
Br B
1 2
3 4
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Starter motor
Starter motor disassembly
Step Part name Qty Remarks
1 Bolt 2 M6 120 mm
2 Gear cover assembly 1
3 Circlip 1
4 Drive gear 1
5 O-ring 1 Not reusable
6 Front cover 1
7 Packing 1 Not reusable
8 Dowel pin 1
9 Planetary gear 2
10 Ring gear 1
11 Bracket 1
3
4
5
1
6
7
8
2
9
10
11
12
13
14
15
19
20
21
22
23
24
25
26
28
27
29
17
30
M
MM
M
16
18
18
9 N m (0.9 kgf m, 6.6 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
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*: As required.
Step Part name Qty Remarks
12 Shim *
13 Rear cover 1
14 Shim *
15 Packing 1 Not reusable
16 Armature 1
17 Brush holder assembly 1
18 Brush spring 4
19 Brush holder stay 1
20 Nut 1
21 Spring washer 1
22 Washer 1
3
4
5
1
6
7
8
2
9
10
11
12
13
14
15
19
20
21
22
23
24
25
26
28
27
29
17
30
M
MM
M
16
18
18
9 N m (0.9 kgf m, 6.6 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
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Step Part name Qty Remarks
23 Insulator washer 1 1
24 Insulator washer 2 2
25 O-ring 1 Not reusable
26 Terminal bolt 1
27 Lead plate 1
28 Terminal insulator 1
29 Plate cover 1
30 Starter motor yoke 1
3
4
5
1
6
7
8
2
9
10
11
12
13
14
15
19
20
21
22
23
24
25
26
28
27
29
17
30
M
MM
M
16
18
18
9 N m (0.9 kgf m, 6.6 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
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Starter motor operation
1. Check:
Starter motor operation
Does not operate Check the starter
motor.
Checking steps:
1. Hold the starter motor in a vise using alu-
minum plates on both sides.
2. Connect the positive battery cable 1 to
the starter motor terminal bolt 2.
3. Connect the negative battery cable 3 to
the starter motor body 4.
4. Check the starter motor operation.
TIP
Check the starter motor operation for a few
seconds.
If the starter motor is disassembled, make
sure to check the operation again after
assembling it.
1
3
2
4
Armature
1. Check:
Armature shaft 1
Damage/wear Replace the armature.
Commutator 2
Dirt Clean with 600-grit sandpaper.
TIP
Remove all metal particles with compressed
air.
1
2
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2. Measure:
Commutator diameter
Out of specification Replace the
armature.
Commutator diameter:
27.028.0 mm (1.061.10 in)
3. Measure:
Commutator undercut a
Out of specification Replace the
armature.
Commutator undercut a
(reference data):
0.20.7 mm (0.0080.028 in)
4. Check:
Armature coil continuity
Out of specification Replace the
armature.
Armature coil continuity:
Commutator
segments a
Continuity
Segment a
Armature core b
No continuity
Segment a
Armature shaft c
No continuity
b c a
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Brush holder
1. Measure:
Brush length a
Out of specification Replace the
brush holder assembly.
Brush length a:
5.012.5 mm (0.200.49 in)
a
2. Check:
Brush holder continuity
Out of specification Replace the
brush holder assembly.
Brush holder continuity:
Brush 1 Brush 2
Brush 3 Brush 4
Brush 3 Terminal 5
Brush 4 Terminal 5
Continuity
For all brush and terminal
combinations not listed
above.
No continuity
5
1
3
4
5
3 1
4
2
2
Gear cover
1. Check:
Drive shaft 1
Bearing 2
Rough movement/wear Replace the
gear cover assembly.
1
2
2. Check:
Planetary gears 1
Ring gear 2
Broken gear teeth Replace the gear
cover assembly.
1
2
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Rear cover
1. Check:
Rear cover 1
Metal 2
Cracks/damage Replace the rear
cover assembly.
2
1
Starter motor assembly
1. Install:
Gear cover assembly
Installation steps:
1. Install the ring gear 1, planetary gears 2,
and dowel pin to the front cover 3.
2. Install the front cover to the starter motor
yoke 4.
TIP
Make sure that the notch a in the ring gear is
aligned with the projection b on the starter
motor yoke 4.
a b
2 4 1
3
M
Remote control system
Transmitter registration
1. Register:
ID code
TIP
The remote control transmitter 1 can be
added or re-registered with the remote con-
trol receiver 2 by connecting the entry box
3.
The entry box is necessary to register the ID
code of a remote control transmitter.
Registration steps:
1. Connect the entry box to the 2-pin commu-
nication coupler 4.
1
3
2
Gy
B
Gy
B
4
B Gy
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2. Push the lock button 5 or unlock button 6
to transmit the ID code from the remote
control transmitter to be registered.
TIP
At this time, the system enters the registra-
tion mode to register the first code. All exist-
ing ID codes will be deleted from the remote
control receiver.
The UNLOCK indicator light 7 blinks when
the registration of the ID code has been com-
pleted. (If the registration could not be com-
pleted, the UNLOCK indicator light comes
on. Re-transmit the ID code.)
3. After confirming that the registration of the
ID code has been completed using the
UNLOCK indicator light 7, transmit the
next ID code.
TIP
Up to 5 remote control transmitters can be
registered in any sequence, regardless of
whether they are original equipment or addi-
tional transmitters.
The same ID code cannot be registered
twice in the remote control receiver.
4. After ID code registration has been com-
pleted, disconnect the entry box to exit the
registration mode.
Remote control transmitter
1. Check:
Remote control transmitter operation
Does not operate Measure the
remote control transmitter battery volt-
age or check the remote control
receiver.
5 6
7
Remote control system
ELEC
+
1
2
3
4
5
6
8
9
7-57
E
Checking steps:
1. Push the unlock button 1. The buzzer
sounds 2 times.
2. Check that the UNLOCK indicator light
2 comes on.
3. Push the unlock button 1 for more than 4
seconds. The buzzer sounds 3 times.
4. Check that the L-MODE indicator light 3
comes on.
5. Push the lock button 4. The buzzer
sounds once.
6. Check that the UNLOCK indicator light
2 goes off.
TIP
While the engine is running, input from the
remote control transmitter is not received.
Number of beeps
Yamaha Security
System mode
1 beep Lock
2 beeps
Unlock
(normal mode)
3 beeps
L-MODE
(low-rpm mode)
4 1
2
3
2. Measure:
Remote control transmitter battery
voltage
Below specification Replace the
remote control transmitter battery.
Measurement steps:
1. Remove the transmitter cover 1.
TIP
Loosen the transmitter cover screws 2 in the
sequence shown.
$
!
% #
&
2
1
Remote control system
ELEC
+
1
2
3
4
5
6
7
8
9
7-58
E
2. Remove the battery 3.
3. Measure the battery voltage.
NOTICE
Do not touch the internal parts except the
battery.
Do not touch the battery directly with
your hands. Use a pair of non-conductive
tweezers to replace the battery.
TIP
Refer to local hazardous waste regulations
when disposing of transmitter batteries.
4. Install the battery 3 and transmitter cover
1.
TIP
Install the battery (CR2016) 3 with the posi-
tive side a facing down.
5. Tighten the transmitter cover screws 2 in
the sequence shown.
Remote control transmitter battery
voltage:
3.0 V
T
R
.
.
Transmitter cover screw:
0.1 Nm (0.01 kgfm, 0.1 ftlb)
3
3
1
a
#
&
$
%
!
2
1
Remote control system
ELEC
+
1
2
3
4
5
6
8
9
7-59
E
Remote control receiver
1. Measure:
Remote control receiver input voltage
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the remote control receiver
coupler 1.
2. Measure the input voltage at the remote
control receiver coupler terminals (wiring
harness end).
Remote control receiver input voltage:
Red (R) Black (B)
12 V (battery voltage)
1
R
B
2. Measure:
Remote control receiver output voltage
Out of specification Replace the
remote control receiver.
Measurement steps:
1. Disconnect the dual analog meter unit
coupler 1 from the remote control
receiver.
2. Push the unlock button, and then measure
the remote control receiver output voltage
at the dual analog meter unit coupler ter-
minal (wiring harness end) and ground.
Remote control receiver output
voltage (reference data):
Blue/yellow (L/Y) Ground
11.012.0 V
L/Y
1
Remote control system
ELEC
+
1
2
3
4
5
6
7
8
9
7-60
E
Indication system
Dual analog meter unit
1. Check:
Dual analog meter unit external appear-
ance
Cracked meter housing/meter is fogged/
shows signs of water intrusion
Replace the dual analog meter unit.
2. Check:
Information display
Intermittent or missing segment a
Replace the dual analog meter unit.
No display Measure the dual analog
meter unit input voltage.
TIP
Push the unlock button, and then check that
all indicator lights and display elements on
the dual analog meter unit light up.
1 Speedometer
2 Information display
3 Tachometer
4 Indicator lights
When pushing the unlock button, the speed-
ometer and tachometer make 1 sweep, all
displays light up for 2 seconds, and then it
starts to operate normally.
3. Measure:
Dual analog meter unit input voltage
Within specification Replace the dual
analog meter unit.
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the dual analog meter unit
coupler 1.
2. Push the unlock button, and then measure
the input voltage at the dual analog meter
unit coupler terminals (wiring harness
end).
Dual analog meter unit input voltage:
Red/yellow (R/Y) Black (B)
12 V (battery voltage)
1 2 3
4 4
a
B
R/Y
1
Indication system
ELEC
+
1
2
3
4
5
6
8
9
7-61
E
Switch assembly
1. Check:
Switch assembly continuity
Out of specification Replace the
switch assembly.
Checking steps:
1. Disconnect the switch assembly coupler
1.
Refer to Dual analog meter unit and cover
removal in Chapter 8.
2. Check the switch assembly continuity.
Switch assembly continuity:
Button Position
Green/white
(G/W)Black
(B)
Hour Volt
button
Free No continuity
Pushed Continuity
G/W B
1
Speed sensor
1. Check:
Speed sensor paddle wheel 1
Cracks/damage/rough movement
Replace the speed sensor.
1
1
Indication system
ELEC
+
1
2
3
4
5
6
7
8
9
7-62
E
2. Measure:
Speed sensor output voltage
Out of specification Replace the
speed sensor.
Measurement steps:
1. Disconnect the speed sensor coupler 1.
Refer to Dual analog meter unit and cover
removal in Chapter 8.
2. Connect the positive battery lead to the
terminal 2, and the negative battery lead
to the terminal 3.
3. Connect the tester leads between the ter-
minal 4 and terminal 3.
4. Rotate the paddle wheel 5 by hand and
measure the output voltage between the
terminal 4 and terminal 3.
Speed sensor output voltage
(dependant on the paddle wheel
position):
Yellow (Y) Black/yellow (B/Y)
Less than 400 mV/
More than 11.6 V
R/Y 2
B/Y3
Y 4
1
5
Indication system
ELEC
+
1
2
3
4
5
6
8
9
7-63
E
Fuel level meter display and fuel
indicator
1. Check:
Fuel level meter display 1 and fuel indi-
cator 2
Do not come on Replace the dual
analog meter unit.
Checking steps:
1. Remove the fuel pump module assembly.
Refer to Fuel tank removal in Chapter 4.
2. Connect the fuel sender coupler 3.
3. Lift the float to the upper position .
4. Push the unlock button.
5. Check that all fuel level segments come
on.
6. Lower the float to the lowest position .
7. Check that the fuel indicator 2, the lowest
fuel level segment a, and the WARN-
ING indicator light 4 blink.
Check engine warning indicator
1. Check:
Check engine warning indicator
Does not come on Check the Diag-
nosis record of the YDIS.
Checking steps:
1. Disconnect the engine temperature sensor
coupler 1.
2. Push the unlock button.
3. Check that the WARNING indicator light
2 and the check engine warning indicator
3 begin to blink.
4. If the light and indicator do not blink, check
the Diagnosis record of the YDIS. If a
diagnosis record is available and it is
caused by the checking steps, replace the
dual analog meter unit.
4
1 2
a
3
1
B/O B/Y
2
3
Indication system
ELEC
+
1
2
3
4
5
6
7
8
9
7-64
E
Diagnostic display
1. Check:
Diagnostic display
Does not come on Check the Diag-
nosis record of the YDIS.
Checking steps:
1. Create a condition so that a diagnostic
code is recorded.
2. Push the unlock button.
3. Push the Hour Volt button 1 for approxi-
mately 8 seconds and check that the diag-
nostic code 2 is indicated.
4. If the diagnostic code is not indicated,
check the Diagnosis record of the YDIS.
If a diagnosis record is available and it is
caused by the checking steps, replace the
dual analog meter unit.
Oil pressure warning indicator
1. Check:
Oil pressure warning indicator
Does not come on Check the Diag-
nosis record of the YDIS.
Checking steps:
1. Disconnect the oil pressure switch coupler
1, and then ground the terminal 2.
2. Start the engine.
3. Increase the engine speed to 4,500 r/min
or more.
4. Check that the WARNING indicator light
3 and the oil pressure warning indicator
4 blink, and the buzzer sounds intermit-
tently.
5. If the light and indicator do not blink, check
the Diagnosis record of the YDIS. If a
diagnosis record is available and it is
caused by the checking steps, replace the
dual analog meter unit.
1 2
1
P/W2
3
4
Indication system
ELEC
+
1
2
3
4
5
6
8
9
7-65
E
Engine overheat warning indicator
1. Check:
Engine overheat warning indicator
Does not come on Check the Diag-
nosis record of the YDIS.
Checking steps:
1. Disconnect the thermoswitch coupler 1.
2. Connect the jumper lead 2 to the ther-
moswitch coupler terminals (wiring har-
ness end).
3. Start the engine and operate it at trolling
speed for about 2 minutes.
4. Check that the WARNING indicator light
3 and the engine overheat warning indi-
cator 4 blink, and then come on, and the
buzzer begins to sound intermittently, and
then it sounds continuously.
5. If the light and indicator do not blink, check
the Diagnosis record of the YDIS. If a
diagnosis record is available and it is
caused by the checking steps, replace the
dual analog meter unit.
1
B/O P
2
3
4
Buzzer
1. Measure:
Buzzer input voltage
Out of specification Check the wiring
harness.
Measurement steps:
1. Disconnect the buzzer coupler 1.
2. Push the unlock button, and then measure
the input voltage at the buzzer coupler ter-
minals (wiring harness end).
Buzzer input voltage (reference data):
Blue/red (L/R) Black/blue (B/L)
11.012.0 V
B/L L/R
1
Indication system
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+
1
2
3
4
5
6
7
8
9
7-66
E
2. Check:
Buzzer operation
Does not sound Replace the buzzer.
Checking steps:
1. Remove the buzzer.
Refer to Steering master disassembly in
Chapter 8.
2. Connect the positive battery lead to the
terminal 1 and the negative battery lead
to the terminal 2.
3. Check that the buzzer sounds.
1R 2 B
Indication system
E
HULL
HOOD
1
2
3
4
5
6
7
9
Chapter 8
Hull and hood
Handlebar ....................................................................................................... 8-1
Handlebar cover removal .......................................................................... 8-1
Handlebar holder removal ......................................................................... 8-2
Handlebar assembly removal .................................................................... 8-3
Left handlebar switch disassembly............................................................ 8-5
Handlebar cover removal .......................................................................... 8-6
Throttle cable removal ............................................................................... 8-6
Handlebar check........................................................................................ 8-6
Left handlebar switch assembly check...................................................... 8-6
Handlebar assembly installation................................................................ 8-7
Handlebar cover installation ...................................................................... 8-9
QSTS grip and converter............................................................................. 8-10
QSTS grip and converter disassembly.................................................... 8-10
QSTS cable removal ............................................................................... 8-12
QSTS check ............................................................................................ 8-12
QSTS cable installation ........................................................................... 8-13
Front hood.................................................................................................... 8-15
Front hood removal ................................................................................. 8-15
Front hood disassembly .......................................................................... 8-17
Damper check ......................................................................................... 8-18
Hood lock check ...................................................................................... 8-18
Rivet removal........................................................................................... 8-18
Front hood assembly............................................................................... 8-18
Rivet installation ...................................................................................... 8-19
Steering console cover................................................................................ 8-20
Dual analog meter unit and cover removal .............................................. 8-20
Side cover removal .................................................................................. 8-21
Center cover removal .............................................................................. 8-23
Center cover disassembly ....................................................................... 8-25
Shift lever check ...................................................................................... 8-26
Shift lever installation............................................................................... 8-26
Side cover installation.............................................................................. 8-26
Steering master............................................................................................ 8-27
Steering master removal ......................................................................... 8-27
Steering master disassembly .................................................................. 8-28
Steering master component check.......................................................... 8-31
Steering arm installation.......................................................................... 8-31
E
HULL
HOOD
1
2
3
4
5
6
7
8
9
Remote control cables and speed sensor lead......................................... 8-32
Remote control cables and speed sensor lead removal.......................... 8-32
Steering cable installation (steering master end) .................................... 8-34
Steering cable installation (jet pump end) ............................................... 8-35
Shift cable installation (shift lever end) .................................................... 8-35
Shift cable installation (jet pump end)...................................................... 8-35
Hoses ............................................................................................................ 8-36
Hose removal .......................................................................................... 8-36
Water separator check ............................................................................ 8-38
Cooling water pilot outlet installation ....................................................... 8-38
Seats and handgrip...................................................................................... 8-39
Seat and handgrip removal ..................................................................... 8-39
Seat lock check ....................................................................................... 8-42
Handgrip installation................................................................................ 8-42
Exhaust system............................................................................................ 8-43
Exhaust system and battery removal ...................................................... 8-43
Exhaust system check............................................................................. 8-45
Rubber hose installation.......................................................................... 8-45
Deck and hull................................................................................................ 8-46
Deck and hull disassembly 1................................................................... 8-46
Deck and hull disassembly 2................................................................... 8-48
Drain plug check...................................................................................... 8-50
Front protector 1 installation.................................................................... 8-50
Spout installation ..................................................................................... 8-50
Reboarding step installation (FZS) .......................................................... 8-50
8-1
HULL
HOOD
1
2
3
4
5
6
7
9
E
Handlebar
Handlebar cover removal
Step Part name Qty Remarks
1 Screw 5 5 15 mm
2 Upper handlebar cover 1
3 Steering pad 1
4 Screw 4 6 14 mm
5 Lower handlebar cover 1
2
3
3
5
4
1
5 N m (0.5 kgf m, 3.7 ft Ib)
1 N m (0.1 kgf m, 0.7 ft Ib)
LT
242
Handlebar
8-2
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Handlebar holder removal
Step Part name Qty Remarks
1 Throttle cable 1
2 Corrugated tube 1
3 Bolt 4 M8 48 mm
4 Upper handlebar holder 2 aPunch mark
b0.4 mm (0.02 in)
c2.4 mm (0.09 in)
1
2
2
4
3
20 N m (2.0 kgf m, 14.8 ft Ib)
c
4
b
a
LT
242
AA
Handlebar
8-3
HULL
HOOD
1
2
3
4
5
6
7
9
E
Handlebar assembly removal
Step Part name Qty Remarks
1 Bolt 2 M5 35 mm
2 Grip end 2
3 Spacer 1
4 Screw 1 6 70 mm
5 Spring washer 1
6 Washer 1
7 QSTS grip assembly 1
8 Right handlebar grip 1
9 Screw 2 5 25 mm
15
1
2
3
7
10
13
12
12
8
2
1
11
10
9
19
6
5
4
3 N m (0.3 kgf m, 2.2 ft Ib)
1 N m (0.1 kgf m, 0.7 ft Ib)
14
14
16
7 N m (0.7 kgf m, 5.2 ft Ib)
17
LT
242
18
A
A
LT
242
LT
242
LT
242
3 N m (0.3 kgf m, 2.2 ft Ib)
1 N m (0.1 kgf m, 0.7 ft Ib)
Handlebar
8-4
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
10 Left handlebar switch assembly 1
11 Bolt 2 M5 25 mm
12 Throttle lever assembly 1
13 Handlebar 1
14 Plastic tie 2
15 Packing 1 Not reusable
16 Boot 1
17 Left handlebar switch coupler 2
18 Plastic tie 1
19 Throttle cable 1
15
1
2
3
7
10
13
12
12
8
2
1
11
10
9
19
6
5
4
3 N m (0.3 kgf m, 2.2 ft Ib)
1 N m (0.1 kgf m, 0.7 ft Ib)
14
14
16
7 N m (0.7 kgf m, 5.2 ft Ib)
17
LT
242
18
A
A
LT
242
LT
242
LT
242
3 N m (0.3 kgf m, 2.2 ft Ib)
1 N m (0.1 kgf m, 0.7 ft Ib)
Handlebar
8-5
HULL
HOOD
1
2
3
4
5
6
7
9
E
Left handlebar switch disassembly
Step Part name Qty Remarks
1 Left handlebar switch assembly 1
2 Engine shut-off cord 1
3 Stop button assembly 1
4 Start button assembly 1
5 Screw 2 3 8 mm
6 Throttle lever assembly 1
7 E-ring 1
8 Washer 2
9 Shaft 1
10 Lever 1
11 Spring 1
2
3
1
4
5
6
8
10
8
11
7
9
Handlebar
8-6
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Handlebar cover removal
1. Remove:
Handlebar cover screws 1
Handlebar covers 2
Steering pad 3
TIP
Move the handlebar 4 to the highest position.
2
2
1
3
4
Throttle cable removal
1. Remove:
Throttle cable 1
NOTICE
Make sure to remove the throttle cable seal
2 as shown.
1
2
Handlebar check
1. Check:
Handlebar
Bends/cracks/damage Replace the
handlebar.
Left handlebar switch assembly check
1. Check:
Left handlebar switch assembly
Cracks/damage Replace the left han-
dlebar switch assembly.
TIP
To check the operation and continuity of the
left handlebar switch assembly, refer to Left
handlebar switch assembly in Chapter 7.
Handlebar
8-7
HULL
HOOD
1
2
3
4
5
6
7
9
E
Handlebar assembly installation
1. Install:
Packing 1
Grommet 2
QSTS cables 3
Throttle cable 4
Left handlebar switch lead 5
Plastic ties 6
Handlebar 7
Corrugated tube (throttle cable) 8
Left handlebar switch assembly 9
Installation steps:
1. Wrap the packing 1 around the QSTS
cables 3, throttle cable 4 and left handle-
bar switch lead 5.
TIP
Make sure to align the upper edge of the pack-
ing with the upper edge of the white tape a on
the cables.
2. Install the packing 1 into the grommet 2.
TIP
Make sure to align the upper edge of the pack-
ing with the upper edge of the grommet.
3. Fasten the end of the grommet with the
plastic tie 6.
TIP
Position the corrugated tube 8 for the throttle
cable so that the end of the tube makes con-
tact with the grommet 2 as shown.
8
9
7
5
6
2
6
3
4
a
3 4
5
1
2
2
8
Handlebar
8-8
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
4. Install the left handlebar switch assembly
9.
TIP
Align the projection b on the handlebar switch
assembly with the handlebar hole c.
5. Install the throttle lever assembly.
TIP
Tighten the upper bolt first when installing the
throttle lever assembly.
T
R
.
.
Left handlebar switch screw:
3 Nm (0.3 kgfm, 2.2 ftlb)
T
R
.
.
Throttle lever assembly bolt:
3 Nm (0.3 kgfm, 2.2 ftlb)
9
9
b
c
2. Install:
Handlebar 1
Upper handlebar holders 2
TIP
Install the upper handlebar holders 2 with the
punch marks a facing down, making sure that
clearance b is narrower than clearance c.
Clearance (reference data):
b: 0.4 mm (0.02 in)
c: 2.4 mm (0.09 in)
T
R
.
.
Handlebar holder bolt:
20 Nm (2.0 kgfm, 14.8 ftlb)
LOCTITE 242
c 2
b
2
c
a
b
1
Handlebar
8-9
HULL
HOOD
1
2
3
4
5
6
7
9
E
3. Install:
Throttle cable
Right handlebar grip
Installation steps:
1. Install the throttle cable end into the throt-
tle lever.
2. Fit the seal 1 into the groove in the
bracket.
3. Pull the throttle cable 2 in the direction of
the arrow shown, and then fit the end of
the seal 1 around the inner cable.
4. Adjust the throttle lever free play.
Refer to Throttle lever free play check and
adjustment in Chapter 3.
NOTICE
Make sure to adjust the free play with the
handlebar bracket in the lowest position.
Otherwise, the specified free play with the
handlebar bracket in the highest position
cannot be obtained.
5. Apply adhesive to the handlebar and the
inner surface of the handlebar grip.
6. Install the right handlebar grip.
Throttle lever free play a:
2.05.0 mm (0.080.20 in)
1
1
2
a
Handlebar cover installation
1. Install:
Lower handlebar cover
Steering pad 1
Upper handlebar cover
TIP
Fit the throttle cable into the groove in the
steering pad.
1
Handlebar
8-10
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
QSTS grip and converter
QSTS grip and converter disassembly
Step Part name Qty Remarks
Jet pump unit Refer to Jet pump unit removal in Chapter
6.
Water tank Refer to Exhaust system and battery
removal.
QSTS grip assembly Refer to Handlebar assembly removal.
1 Cover 1
2 Cable end 2
3 Grip 1
4 Housing 1
5 Bolt 4 M6 33 mm
6 Washer 4
7 Washer 4
8 QSTS rod 1
STERN
8
15
11
8
14
15
13
5
3
4
1
2
10
17
2
1
4
3
9
17
16
3 mm (0.12 in)
6 mm (0.24 in)
a
7 N m (0.7 kgf m, 5.2 ft Ib)
5.9 N m (0.59 kgf m, 4.4 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
a
A
AA
AA
7
AA
A
AA
AA
LT
242
12
6
QSTS grip and converter
8-11
HULL
HOOD
1
2
3
4
5
6
7
9
E
Step Part name Qty Remarks
9 Cable guide 1
10 Cable end 2 aYellow paint mark
11 Nut 1
12 Washer 1
13 Bolt 1 M6 14 mm
14 Pulley 1
15 QSTS converter 1
16 Nut 1
17 QSTS cable 2
STERN
8
15
11
8
14
15
13
5
3
4
1
2
10
17
2
1
4
3
9
17
16
3 mm (0.12 in)
6 mm (0.24 in)
a
7 N m (0.7 kgf m, 5.2 ft Ib)
5.9 N m (0.59 kgf m, 4.4 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
a
A
AA
AA
7
AA
A
AA
AA
LT
242
12
6
QSTS grip and converter
8-12
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
QSTS cable removal
1. Remove:
QSTS converter
2. Remove:
Cable guide 1
TIP
Remove the cable guide 1 with needlenose
pliers as shown.
3. Remove:
QSTS cable ends
1
QSTS check
1. Check:
QSTS grip
Cracks/damage/wear Replace the
QSTS grip.
2. Check:
QSTS cables
Damage/kinks Replace the QSTS
cables.
QSTS rod
Bends/damage Replace the QSTS
rod.
3. Check:
Pulley 1
Rough movement/stiffness Clean the
pulley.
Damage Replace the pulley.
QSTS converter
Cracks/damage/wear Replace the
QSTS converter.
1
QSTS grip and converter
8-13
HULL
HOOD
1
2
3
4
5
6
7
9
E
QSTS cable installation
1. Install:
QSTS cable ends
NOTICE
Make sure to fit the QSTS cable end with
yellow paint mark a into the STBD hole
b of the pulley.
Be careful not to twist the QSTS cables.
2. Install:
QSTS rod 1
TIP
Face the hole in the joint a of the QSTS rod
1 in the direction shown.
WARNING
The QSTS rod joint must be screwed in
more than 8 mm (0.31 in) c.
QSTS rod set length b:
176 0.5 mm (6.93 0.02 in)
T
R
.
.
QSTS rod locknut:
4 Nm (0.4 kgfm, 3.0 ftlb)
LOCTITE 572
STERN
a
b
b
1
a
c
LT
572
LT
3. Install:
QSTS cables (handlebar end)
Installation steps:
1. Pass the QSTS cables 1 through the
cover 2 and housing 3 as shown.
TIP
Pass the cable with the thin end a into the
hole of the narrow groove b side and the
cable with the thick end c into the hole of the
wide groove d side.
2. Fit the cable ends e into the holes f of
the grip 4.
1
2
3
b
d
a
c
f
3
e
4
QSTS grip and converter
8-14
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
3. Fit the grip 4 into the housing 3.
4. Fit the QSTS cables 1 into the housing
3.
TIP
Fit the cable with the thin end a into the open-
ing with the narrow groove b and the cable
with the thick end c into the opening with the
wide groove d.
5. Fit the cover 2 into the housing 3 and
grip 4.
4. Check:
QSTS nozzle angle
Refer to Jet thrust nozzle steering
angle check and adjustment in Chapter
3.
d
b
3
2
4
QSTS grip and converter
8-15
HULL
HOOD
1
2
3
4
5
6
7
9
E
Front hood
Front hood removal
Step Part name Qty Remarks
1 Nut 4
2 Washer 4
3 Left mirror 1
4 Left mirror spacer 1
5 Right mirror 1
6 Right mirror spacer 1
7 Nut 1
8 Bolt 1 M6 10 mm
9 Bolt 2 M6 18 mm
10 Nut 1
11 Bolt 1 M6 10 mm
R
L
LT
572
LT
LT
572
LT
5 N m (0.5 kgf m, 3.7 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
10
15
9
11
12
14
8
21
16
7
13
20
19
6 N m (0.6 kgf m, 4.4 ft Ib)
17
18
5 N m (0.5 kgf m, 3.7 ft Ib)
6 N m (0.6 kgf m, 4.4 ft Ib)
1
2
1
2
3
4
5
6
Front hood
8-16
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
12 Damper stay 1
13 Band 1 Not reusable
14 Boot 1
15 Damper 1
16 Nut 4
17 Bolt 4 M6 30 mm
18 Hinge 1
19 Front hood assembly 1
20 Rivet 5
21 Service lid 1
R
L
LT
572
LT
LT
572
LT
5 N m (0.5 kgf m, 3.7 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
10
15
9
11
12
14
8
21
16
7
13
20
19
6 N m (0.6 kgf m, 4.4 ft Ib)
17
18
5 N m (0.5 kgf m, 3.7 ft Ib)
6 N m (0.6 kgf m, 4.4 ft Ib)
1
2
1
2
3
4
5
6
Front hood
8-17
HULL
HOOD
1
2
3
4
5
6
7
9
E
Front hood disassembly
Step Part name Qty Remarks
1 Screw 14 5 15 mm
2 Bolt 2 M5 20 mm
3 Ventilation cover 1
4 Packing 1 Not reusable
5 Damper 2 Not reusable
6 Visor 1
7 Hood lock 1
8 Packing 1
9 Front hood 1
LT
572
LT
7
5
4
1
3
2
1
1
1
9
6
1
8
2 N m (0.2 kgf m, 1.5 ft Ib)
4 N m (0.4 kgf m, 3.0 ft Ib)
Front hood
8-18
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Damper check
1. Check:
Damper assembly
Does not hold front hood open
Replace the damper assembly.
Hood lock check
1. Check:
Hood lock 1
Does not lock Check the hood lock
installation.
Cracks/damage Replace the hood
lock.
1
Rivet removal
1. Remove:
Rivets
TIP
Push in the rivet pin 1 until it clicks and is
below the top of the rivet.
2. Check:
Rivets
Cracks/damage Replace the rivets.
Front hood assembly
1. Install:
Hood lock 1
Visor 2
TIP
Fit the locking portion a of the hood lock into
the hole b in the front hood 3 and fit the but-
ton c on the hood lock into the hole d in the
visor.
1
1
1
3
d
2
c a b
Front hood
8-19
HULL
HOOD
1
2
3
4
5
6
7
9
E
Rivet installation
1. Install:
Rivets
Installation steps:
TIP
Before reinstalling a rivet, hold the rivet flange
a with both hands and push the rivet pin per-
pendicularly against a hard flat surface until
the pin protrudes from the top of the rivet.
1. Insert a rivet completely in the holes in
both the service lid 1 and inner hull 2.
2. Push in the rivet pin 3 until it clicks and is
flush with the top of the rivet.
a
3 1
2
Front hood
8-20
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Steering console cover
Dual analog meter unit and cover removal
Step Part name Qty Remarks
Handlebar assembly Refer to Handlebar assembly removal.
Service lid Refer to Front hood removal.
1 Rivet 2
2 Cover 1
3 Plastic tie 1
4 Dual analog meter unit coupler 4
5 Switch assembly coupler 1
6 Screw 2 5 15 mm
7 Dual analog meter unit cover 1
8 Switch assembly 1
9 Bolt 4 M5 12 mm
10 Dual analog meter unit 1
2
4
5
3
1
8
10
7
6
9
2 N m (0.2 kgf m, 1.5 ft Ib)
4 N m (0.4 kgf m, 3.0 ft Ib)
Steering console cover
8-21
HULL
HOOD
1
2
3
4
5
6
7
9
E
Side cover removal
Step Part name Qty Remarks
1 Screw 2 6 14 mm
2 Grip 1
3 Drink holder 1
4 Bolt 8 M6 29 mm
5 Bolt 1 M6 29 mm
6 Left side cover 1
7 Right side cover 1
8 Bolt 4 M6 29 mm
9 Left side ornament 1
10 Right side ornament 1
7
8
8
1
4
5
4
17
19
18
4
11
11
11
14
13
9
6
15
8
8
3
4
11
11
11
2
16
10
12
14
4
4
4
4
LT
572
LT
LT
572
LT
LT
572
LT
LT
242
5 N m (0.5 kgf m, 3.7 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
Steering console cover
8-22
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
11 Nut 8
12 Rivet 2 Not reusable
13 Nut 6
14 Bolt 6 M6 20 mm
15 Left knee pad 1
16 Right knee pad 1
17 Bolt 4 M6 29 mm
18 Left side cover bracket 1
19 Right side cover bracket 1
7
8
8
1
4
5
4
17
19
18
4
11
11
11
14
13
9
6
15
8
8
3
4
11
11
11
2
16
10
12
14
4
4
4
4
LT
572
LT
LT
572
LT
LT
572
LT
LT
242
5 N m (0.5 kgf m, 3.7 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
Steering console cover
8-23
HULL
HOOD
1
2
3
4
5
6
7
9
E
Center cover removal
Step Part name Qty Remarks
1 Left induction box 1
2 Right induction box 1
3 Nut 6
4 Bolt 4
5 Bolt 1 M6 29 mm
6 Center cover 1
7 Shift cable end 1
8 Reverse sensor coupler 1
9 Plastic tie 1
10 Nut 2
11 Washer 2
LT
572
LT
LT
242
5
4
4
3
3
3
2
1
8
6
13
12
15
14
7
9
4
11
10
5 N m (0.5 kgf m, 3.7 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
4 N m (0.4 kgf m, 3.0 ft Ib)
Steering console cover
8-24
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
12 Shift lever assembly 1
13 Screw 2 5 12 mm
14 Band 1 Not reusable
15 Reverse sensor 1
LT
572
LT
LT
242
5
4
4
3
3
3
2
1
8
6
13
12
15
14
7
9
4
11
10
5 N m (0.5 kgf m, 3.7 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
4 N m (0.4 kgf m, 3.0 ft Ib)
Steering console cover
8-25
HULL
HOOD
1
2
3
4
5
6
7
9
E
Center cover disassembly
Step Part name Qty Remarks
1 Bolt 2 M5 20 mm
2 Lid lock hook 1
3 Bracket 1
4 Grommet 4
5 Hinge pin 2
6 Center console box lid 1
7 Lock 1
LT
572
LT
7
1
2
3
5
6
4 4
4 N m (0.4 kgf m, 3.0 ft Ib)
Steering console cover
8-26
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Shift lever check
1. Check:
Shift lever assembly
Crack/damage Replace the shift lever
assembly.
NOTICE
Do not disassemble the shift lever assem-
bly except the reverse sensor.
Shift lever installation
1. Remove:
Band 1
Reverse sensor 2
Screws 3
Shift lever assembly 4
Washers 5
Nuts 6
T
R
.
.
Reverse sensor screw:
4 Nm (0.4 kgfm, 3.0 ftlb)
LOCTITE 242
Shift lever assembly nut:
5 Nm (0.5 kgfm, 3.7 ftlb)
6
5
4
3
2
1 LT
242
Side cover installation
1. Install:
Side covers 1
TIP
When installing a side cover 1, position the
lower portion a of the cover between the
knee pad 2 and the hull.
Fit the protrusions b on the cover into the
holes c in the center cover 3.
1
a
2
c
b
3
Steering console cover
8-27
HULL
HOOD
1
2
3
4
5
6
7
9
E
Steering master
Steering master removal
Step Part name Qty Remarks
Center cover assembly Refer to Steering console cover.
Steering cable joint Refer to Remote control cables and speed
sensor lead.
1 Steering sensor coupler 1
2 Buzzer coupler 1
3 Bolt 4 M8 30 mm
4 Steering master assembly 1
5 Grommet 1
5
1
3
4
LT
242
2
20 N m (2.0 kgf m, 14.8 ft Ib)
Steering master
8-28
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Steering master disassembly
Step Part name Qty Remarks
1 Bolt 1 M8 50 mm
2 Plate 1
3 Nut 1
4 Steering arm assembly 1
5 Nut 1
6 Steering cable ball joint 1
7 Arm 1
8 Steering shaft assembly 1 Do not disassemble the handlebar bracket a and
board spring b.
9 Bolt 3 M6 12 mm
10 Lock assembly 1
AA
AA
AA
AA
LT
242
LT
242
1
3
2
4
5
6
7
8
12
10
11
9
13
14
15
16
17
18
19
20
21
21
22
23
24
25
26
27
b
a
LT
242
2 N m (0.2 kgf m, 1.5 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
17 N m (1.7 kgf m, 12.5 ft Ib)
17 N m (1.7 kgf m, 12.5 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
Steering master
8-29
HULL
HOOD
1
2
3
4
5
6
7
9
E
Step Part name Qty Remarks
11 Grease nipple 1
12 Cap 1
13 Shaft assembly 1
14 Bolt 1 M6 60 mm
15 Nut 1
16 Cable stopper 1
17 Bushing 1
18 Bushing 1
19 Bolt 4 M6 25 mm
20 Steering sensor 1
AA
AA
AA
AA
LT
242
LT
242
1
3
2
4
5
6
7
8
12
10
11
9
13
14
15
16
17
18
19
20
21
21
22
23
24
25
26
27
b
a
LT
242
2 N m (0.2 kgf m, 1.5 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
17 N m (1.7 kgf m, 12.5 ft Ib)
17 N m (1.7 kgf m, 12.5 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
Steering master
8-30
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
21 Buzzer 1
22 Rubber seal 1 Not reusable
23 Housing assembly 1
24 Bolt 4 M8 30 mm
25 Sensor base 1
26 Seal 1 Not reusable
27 Housing 1
AA
AA
AA
AA
LT
242
LT
242
1
3
2
4
5
6
7
8
12
10
11
9
13
14
15
16
17
18
19
20
21
21
22
23
24
25
26
27
b
a
LT
242
2 N m (0.2 kgf m, 1.5 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
17 N m (1.7 kgf m, 12.5 ft Ib)
17 N m (1.7 kgf m, 12.5 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
Steering master
8-31
HULL
HOOD
1
2
3
4
5
6
7
9
E
Steering master component check
1. Check:
Bushings
Cracks/damage/wear Replace the
bushings.
2. Check:
Steering shaft assembly
Cracks/damage Replace the steering
shaft assembly.
NOTICE
Do not disassemble the handlebar brack-
et a.
Do not disassemble the board spring b,
otherwise the OTS will not function prop-
erly.
3. Check:
Lock assembly 1
Cracks/damage Replace the lock
assembly.
Handlebar bracket 2
Cracks/damage Replace the steering
shaft assembly.
Handlebar bracket operation
Does not operate smoothly Clean or
replace the steering shaft assembly.
TIP
After checking the handlebar bracket, lubricate
the bracket.
Refer to Lubrication points in Chapter 3.
Steering arm installation
1. Install:
Arm 1
Nut 2
Plate 3
Bolt 4
TIP
Align the tab a on the plate 3 with the pro-
jection b on the arm 1.
Bend a tab c along a flat side of the bolt.
T
R
.
.
Arm bolt:
17 Nm (1.7 kgfm, 12.5 ftlb)
b
a
2
1
1
2
3
4
a
b
c c
b
Steering master
8-32
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Remote control cables and speed sensor lead
Remote control cables and speed sensor lead removal
Step Part name Qty Remarks
Service lid Refer to Front hood removal.
Front seat assembly Refer to Seat and handgrip removal.
Right side cover Refer to Side cover removal.
1 Steering cable joint 1
2 Drum nut 1
3 Nut 1
4 Steering cable 1
5 Packing 1 Not reusable
6 Speed sensor coupler 1
7 Nut 1
8 Screw 4 5 12 mm
9 Speed sensor 1 To dual analog meter unit
17 18 16
3 5 4
8
10
14
15
1
2 4
6
13
11
12
7
9
AA
AA
AA
AA
LT
572
LT
LT
572
LT
LT
572
LT
7 N m (0.7 kgf m, 5.2 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
5.9 N m (0.59 kgf m, 4.4 ft Ib)
5.9 N m (0.59 kgf m, 4.4 ft Ib)
5.9 N m (0.59 kgf m, 4.4 ft Ib)
4 N m (0.4 kgf m, 3.0 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
7
6
Hoses
8-37
HULL
HOOD
1
2
3
4
5
6
7
9
E
Step Part name Qty Remarks
11 Cooling water pilot outlet 3
12 Cooling water hose 3 To air cooler/ To oil cooler
13 Rivet 2 Not reusable
14 Ventilation socket 1
15 Band 1 Not reusable
16 Ventilation pipe 1
3
1
3
8
2
9
12
12
12
11
10
8
4 N m (0.4 kgf m, 3.0 ft Ib)
4 N m (0.4 kgf m, 3.0 ft Ib)
2
5
4
13
16
15
14
10
11
11
9
8
1
7
6
Hoses
8-38
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Water separator check
1. Check:
Water separator 1
Cracks/damage Replace the water
separator.
O-ring 2
Cracks/damage Replace the O-ring.
Drain plug 3
Cracks/damage Replace the drain
plug.
1
2
3
Cooling water pilot outlet installation
1. Install:
Cooling water pilot outlets 1
TIP
Align each projection a with the slits b.
T
R
.
.
Cooling water pilot outlet nut:
4 Nm (0.4 kgfm, 3.0 ftlb)
1
b
a
Hoses
8-39
HULL
HOOD
1
2
3
4
5
6
7
9
E
Seats and handgrip
Seat and handgrip removal
Step Part name Qty Remarks
1 Rear seat assembly 1 FZR/ FZS
2 Front seat assembly 1
3 Bolt 4 M6 40 mm
4 Seat lock assembly (rear) 1
5 Seat lock assembly (front) 1
6 Packing (rear) 1 Not reusable
7 Packing (front) 1 Not reusable
8 Seat storage compartment 1
9 Packing 1 Not reusable
LT
271
LT
271
18 N m (1.8 kgf m, 13.3 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
LT
271
15 N m (1.5 kgf m, 11.1 ft Ib)
18 N m (1.8 kgf m, 13.3 ft Ib) 5 N m (0.5 kgf m, 3.7 ft Ib)
26 N m (2.6 kgf m, 19.2 ft Ib)
14
1
1
15
15
10
11
8
9
17
21
22
18
13
24
25
27
20
19
26
23
28
29
16
12
3
5
7
3
4
6
3
4
6
2
LT
242
LT
271
Seats and handgrip
8-40
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
10 Seat storage compartment cap 1
11 Packing 1
12 Nut/washer 2/2
13 Bolt 2 M8 19 mm (T27)
14 Bolt 2 M8 30 mm (T40)
15 Handgrip 1 FZR/ FZS
16 Nut/washer 2/2
17 Bolt 2 M8 30 mm
18 Bolt 3 M8 10 mm
LT
271
LT
271
18 N m (1.8 kgf m, 13.3 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
LT
271
15 N m (1.5 kgf m, 11.1 ft Ib)
18 N m (1.8 kgf m, 13.3 ft Ib) 5 N m (0.5 kgf m, 3.7 ft Ib)
26 N m (2.6 kgf m, 19.2 ft Ib)
14
1
1
15
15
10
11
8
9
17
21
22
18
13
24
25
27
20
19
26
23
28
29
16
12
3
5
7
3
4
6
3
4
6
2
LT
242
LT
271
Seats and handgrip
8-41
HULL
HOOD
1
2
3
4
5
6
7
9
E
Step Part name Qty Remarks
19 Deck beam 1 1
20 Packing 1 Not reusable
21 Nut/washer 1/1
22 Projection/washer 1/1
23 Nut/washer 2/2
24 Bolt/washer 2/2 M8 19 mm
25 Deck beam 2 1
26 Nut/washer 1/1
27 Projection/washer 1/1
28 Nut/washer 2/2
29 Seat holder 1
LT
271
LT
271
18 N m (1.8 kgf m, 13.3 ft Ib)
7 N m (0.7 kgf m, 5.2 ft Ib)
LT
271
15 N m (1.5 kgf m, 11.1 ft Ib)
18 N m (1.8 kgf m, 13.3 ft Ib) 5 N m (0.5 kgf m, 3.7 ft Ib)
26 N m (2.6 kgf m, 19.2 ft Ib)
14
1
1
15
15
10
11
8
9
17
21
22
18
13
24
25
27
20
19
26
23
28
29
16
12
3
5
7
3
4
6
3
4
6
2
LT
242
LT
271
Seats and handgrip
8-42
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Seat lock check
1. Check:
Seat lock assembly 1
Does not lock Replace the seat lock
assembly.
Projection 2
Damage Replace the projection.
1
2
2
1
Handgrip installation
1. Install:
Handgrip 1
TIP
The handgrips for the FZR and FZS are not
interchangeable.
The bolts 2 are T27 TORX bolts and the
bolts 3 are T40 TORX bolts.
FZR
FZS
T
R
.
.
Handgrip bolt 2:
5 Nm (0.5 kgfm, 3.7 ftlb)
LOCTITE 271
Handgrip nut 4:
18 Nm (1.8 kgfm, 13.3 ftlb)
2
1 1
3
4
LT
271
Seats and handgrip
8-43
HULL
HOOD
1
2
3
4
5
6
7
9
E
Exhaust system
Exhaust system and battery removal
Step Part name Qty Remarks
Deck beam assembly Refer to Engine unit in Chapter 5.
Muffler assembly Refer to Engine unit in Chapter 5.
Rubber plate Refer to Jet pump unit removal in Chapter
6.
1 Negative battery cable 1
2 Positive battery cable 1
3 Clip 1
4 Battery breather hose 1
5 Band 2
6 Battery 1
7 Battery case 1
8 Clamp 1
9 Resonator 1
10 Clamp 1
21 20 19
8
12
10
11
13
14
9
15
18
17
1
16
19
21
20
2
4
3 6
7
5
AA
3.7 N m (0.37 kgf m, 2.7 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
a
a
b
3.7 N m (0.37 kgf m, 2.7 ft Ib)
3.7 N m (0.37 kgf m, 2.7 ft Ib)
b
AA
Exhaust system
8-44
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Step Part name Qty Remarks
11 Clamp 1
12 Rubber hose 1 aProjection
13 Band 1
14 Water lock 1
15 Clamp 1
16 Water tank 1 bAlignment mark
17 Nut 6
18 Washer 6
19 Exhaust valve 1 Not reusable
20 Rubber hose 1
21 Plate 1
21 20 19
8
12
10
11
13
14
9
15
18
17
1
16
19
21
20
2
4
3 6
7
5
AA
3.7 N m (0.37 kgf m, 2.7 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
a
a
b
3.7 N m (0.37 kgf m, 2.7 ft Ib)
3.7 N m (0.37 kgf m, 2.7 ft Ib)
b
AA
Exhaust system
8-45
HULL
HOOD
1
2
3
4
5
6
7
9
E
Exhaust system check
1. Check:
Rubber hoses
Burns/cracks/damage Replace the
rubber hoses.
2. Check:
Water lock 1
Water tank 2
Cracks/damage/leaks Replace.
2
1
Rubber hose installation
1. Install:
Rubber hose 1
TIP
Align the projection a on the rubber hose with
the alignment mark b on the water tank.
a
a
b
1
2. Tighten:
Clamps 1
T
R
.
.
Clamp:
3.7 Nm (0.37 kgfm, 2.7 ftlb)
1
1
1
Exhaust system
8-46
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Deck and hull
Deck and hull disassembly 1
Step Part name Qty Remarks
1 Bolt 2 M6 20 mm
2 Bow eye 1
3 Nut 8
4 Washer 8
5 Bolt 2 M6 15 mm
6 Front protector 1 2
7 Grommet 2
8 Rivet 4 Not reusable
9 Bracket 2
10 Front protector 2 1
11 Bolt 8 M6 25 mm
12 Rivet 9 Not reusable
13 N m (1.3 kgf m, 9.6 ft Ib)
2.5 N m (0.25 kgf m, 1.8 ft Ib)
16 N m (1.6 kgf m, 11.8 ft Ib)
1
2
3
4
5
6
10
572
LT
7
4
3
LT
242
16
18
17
b
11
11
12
12
13
19
21
20
14
15
9
8
LT
271
5 N m (0.5 kgf m, 3.7 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
Deck and hull
8-47
HULL
HOOD
1
2
3
4
5
6
7
9
E
Step Part name Qty Remarks
13 Rear protector 2
14 Rivet 10 Not reusable
15 Gunwale bracket 2
16 Inner gunwale 2
17 Screw 36 5 12 mm
18 Side gunwale 2
19 Bolt 10 M8 40 mm
20 Collar 10
21 Sponson 2
13 N m (1.3 kgf m, 9.6 ft Ib)
2.5 N m (0.25 kgf m, 1.8 ft Ib)
16 N m (1.6 kgf m, 11.8 ft Ib)
1
2
3
4
5
6
10
572
LT
7
4
3
LT
242
16
18
17
b
11
11
12
12
13
19
21
20
14
15
9
8
LT
271
5 N m (0.5 kgf m, 3.7 ft Ib)
5 N m (0.5 kgf m, 3.7 ft Ib)
Deck and hull
8-48
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Deck and hull disassembly 2
Step Part name Qty Remarks
1 Nut 2 FZS
2 Plate 2 FZS
3 Ski tow 1 FZS
4 Nut 1
5 Spout 1
6 Nut 4
7 Plate 4
8 Stern eye 2
9 Packing 2 Not reusable
10 Nut 4
2
3
5 N m (0.5 kgf m, 3.7 ft Ib)
2 N m (0.2 kgf m, 1.5 ft Ib)
2
1
15
17
15
16
17
8
7
9
10
11
14
13
12
6
7
5
4
LT
271
BOW
15 N m (1.5 kgf m, 11.1 ft Ib)
R
L
15 N m (1.5 kgf m, 11.1 ft Ib)
26 N m (2.6 kgf m, 19.2 ft Ib)
Deck and hull
8-49
HULL
HOOD
1
2
3
4
5
6
7
9
E
Step Part name Qty Remarks
11 Washer 4
12 Screw 4 5 25 mm
13 Drain plug 2
14 Packing 2 Not reusable
15 Bolt 6 M8 48 mm
FZS
16 Reboarding step assembly 1 FZS
17 Spacer 2 FZS
2
3
5 N m (0.5 kgf m, 3.7 ft Ib)
2 N m (0.2 kgf m, 1.5 ft Ib)
2
1
15
17
15
16
17
8
7
9
10
11
14
13
12
6
7
5
4
LT
271
BOW
15 N m (1.5 kgf m, 11.1 ft Ib)
R
L
15 N m (1.5 kgf m, 11.1 ft Ib)
26 N m (2.6 kgf m, 19.2 ft Ib)
Deck and hull
8-50
HULL
HOOD
1
2
3
4
5
6
7
8
9
E
Drain plug check
1. Check:
Drain plug 1
O-ring 2
Cracks/damage Replace the drain
plug.
1
2
Front protector 1 installation
1. Install:
Front protectors
TIP
Apply soapy water to the inner surfaces a of
the grommets before installing the projections
b of the front protectors.
a
b
Spout installation
1. Install:
Spout 1
TIP
Face the mark a toward the bow.
T
R
.
.
Spout nut:
5 Nm (0.5 kgfm, 3.7 ftlb)
BOW
1
a
Reboarding step installation (FZS)
1. Install:
Reboarding step
Installation steps:
1. Fasten the brackets on both sides of the
reboarding step in the down position with
plastic ties 1 as shown so that they will
not return to the up position.
2. Finger tighten all of the bolts, and then
tighten them to the specified torque.
T
R
.
.
Reboarding step assembly bolt:
15 Nm (1.5 kgfm, 11.1 ftlb)
LOCTITE 271
1
1
Deck and hull
8-51
E
HULL
HOOD
1
2
3
4
5
6
7
9
MEMO
Deck and hull
E
TRBL
SHTG
1
2
3
4
5
6
7
8
9
Chapter 9
Troubleshooting
YDIS................................................................................................................. 9-1
Introduction................................................................................................ 9-1
Features.............................................................................................. 9-1
Functions............................................................................................. 9-1
Contents.............................................................................................. 9-5
Operating................................................................................................... 9-5
Connecting the communication cable to the watercraft ...................... 9-5
Engine unit troubleshooting......................................................................... 9-6
Using the YDIS for engine unit troubleshooting......................................... 9-6
Self-diagnosis...................................................................................... 9-7
Diagnostic code table.......................................................................... 9-8
Diagnostic code and checking step........................................................... 9-9
Engine unit troubleshooting (diagnostic code not detected).................... 9-16
9-1
E
TRBL
SHTG
1
2
3
4
5
6
7
YDIS
Introduction
Features
The newly developed YDIS provides quicker detection and analysis of engine malfunctions.
By connecting your computer to the ECM of a watercraft using the communication cable, this soft-
ware can be used to display sensor data and data stored in the ECM on a computers monitor.
If this software is run on Microsoft Windows
(*1)
: Throttle body assembly
WD: Refer to the wiring diagram.
Diagnos-
tic code
Item Symptom Checking steps
Refer
to
page
Engine unit troubleshooting
9-13
E
TRBL
SHTG
1
2
3
4
5
6
7
8
123
Electronic
throttle
system
(*1)
malfunction
Engine speed
is limited
1. Check the ETV relay and fuse (ETV
relay) for continuity.
7-33
7-44
2. Check the ECM circuit for continuity. 7-38
124
125
127
128
Throttle
position
sensor
malfunction
Engine speed
is limited
1. Check the pink (P), orange (O), pink/
black (P/B), and black/orange (B/O)
throttle body assembly wiring harness
leads for continuity.
WD
2. Check the ECM circuit for continuity. 7-38
126
Throttle
position
sensor
malfunction
Engine speed
is limited
1. Check the TPS output voltage using
the YDIS.
7-26
2. Check the ECM circuit for continuity. 7-38
129
Electronic
throttle
system
(*1)
malfunction
Engine speed
is limited
1. Check the TPS output voltage using
the YDIS.
7-26
2. Check the ETV relay and fuse (ETV
relay) for continuity.
7-33
7-44
131
132
133
134
Accelerator
position
sensor
malfunction
Engine speed
is limited
1. Check the APS output voltage using
the YDIS.
7-29
2. Check the APS circuit for continuity. 7-29
3. Measure the APS 1 and 2 resistance. 7-29
135
Accelerator
position
sensor
malfunction
Engine speed
is limited
1. Measure the APS 1 and 2 resistance. 7-29
2. Check the APS circuit for continuity. 7-29
(*1)
: Throttle body assembly
WD: Refer to the wiring diagram.
Diagnos-
tic code
Item Symptom Checking steps
Refer
to
page
Engine unit troubleshooting
9-14
E
TRBL
SHTG
1
2
3
4
5
6
7
8
9
136
137
138
139
Electronic
throttle
system
(*1)
malfunction
Engine speed
is limited
1. Check the ECM circuit for continuity. 7-38
2. Check the ETV relay for continuity. 7-33
3. Check the charging system.
Stator coil output peak voltage
Stator coil resistance
Rectifier regulator output peak voltage
Rectifier regulator continuity
7-14
7-14
7-16
7-16
4. Check the fuse for continuity. 7-44
5. Check the battery voltage and specific
gravity.
3-19
6. Check the red (R) and black (B) power
supply circuit cables and leads for con-
tinuity.
WD
141
Electronic
throttle
system
(*1)
malfunction
Engine speed
is limited
1. Check the ECM circuit for continuity. 7-38
2. Check the ETV relay and fuse (ETV
relay) for continuity.
7-33
7-44
142
Electronic
throttle
system
(*1)
malfunction
Engine speed
is limited
1. Check the TPS output voltage and
throttle valve opening using the YDIS.
7-26
2. Check the throttle shaft and throttle
inner surface for wear or damage.
5-37
143
144
Electronic
throttle
system
(*1)
malfunction
Engine speed
is limited
1. Check the ECM circuit for continuity. 7-38
2. Check the ETV relay for continuity. 7-33
3. Check the charging system.
Stator coil output peak voltage
Stator coil resistance
Rectifier regulator output peak voltage
Rectifier regulator continuity
7-14
7-14
7-16
7-16
4. Check the fuse for continuity. 7-44
5. Check the battery voltage and specific
gravity.
3-19
6. Check the red (R) and black (B) power
supply circuit cables and leads for con-
tinuity.
WD
145
Electronic
throttle
system
(*1)
malfunction
Engine speed
is limited
1. Check the ETV relay and fuse (ETV
relay) for continuity.
7-33
7-44
2. Check the throttle shaft and throttle
inner surface for wear or damage.
5-37
(*1)
: Throttle body assembly
WD: Refer to the wiring diagram.
Diagnos-
tic code
Item Symptom Checking steps
Refer
to
page
Engine unit troubleshooting
9-15
E
TRBL
SHTG
1
2
3
4
5
6
7
8
252
Overheat
warning
Engine speed
is limited
1. Check the cooling water passages for
obstructions.
2-18
2. Measure the engine temperature sen-
sor resistance.
7-22
3. Check that there is no short circuit
between the black/yellow (B/Y) and
black/orange (B/O) engine tempera-
ture sensor wiring harness leads*.
WD
4. Check the thermoswitch for continuity. 7-19
5. Check that there is no short circuit
between the pink (P) and black/orange
(B/O) thermoswitch wiring harness
leads*.
WD
6. Measure the thermo sensor resis-
tance.
7-21
7. Check that there is no short circuit
between the black/blue (B/L) and
black/orange (B/O) thermo sensor wir-
ing harness leads*.
WD
253
Low oil
pressure
warning
Engine speed
is limited
1. Check the oil pressure switch for conti-
nuity.
7-18
2. Check that there is no short circuit in
the pink/white (P/W) oil pressure
switch wiring harness lead*.
WD
3. Check the oil passages for obstruc-
tions.
2-17
WD: Refer to the wiring diagram.
*: Disconnect the sensor coupler or switch coupler, and then check that there is no short circuit at the
coupler (wiring harness end).
Diagnos-
tic code
Item Symptom Checking steps
Refer
to
page
Engine unit troubleshooting
9-16
E
TRBL
SHTG
1
2
3
4
5
6
7
8
9
Engine unit troubleshooting (diagnostic code not detected)
Troubleshooting when diagnostic codes are not available consists of the following 3 items.
Symptom 1: Specific trouble conditions
Symptom 2: Trouble conditions of an area or individual part
Cause: The content considered as the trouble factors for symptom 2
: Not applicable
Symptom 1: Engine does not crank.
Symptom 2 Cause Checking step
Refer
to page
Starter motor does
not operate
Yamaha Security System
set to lock mode
Check that the Yamaha Security
System is set to the unlock mode.
7-56
Discharged battery Check the battery voltage and
specific gravity.
3-19
Loose connection of bat-
tery terminal
Check the battery cable and
terminal for proper connection.
8-43
Blown fuse Check the fuse for continuity. 7-44
Starter relay malfunction Check the starter relay. 7-47
Engine start switch mal-
function
Check the engine start switch.
(left handlebar switch)
7-44
Short, open, or loose con-
nection in starter motor cir-
cuit
Measure the starter relay input
voltage.
7-47
Check the wiring harness. WD
Starter motor malfunction Disassemble and check the starter
motor.
7-49
Stuck piston or crankshaft Disassemble and check the engine
unit.
5-100
Stuck impeller Disassemble and check the jet
pump unit.
6-9
Starter motor
operates, but the
engine does not
crank
Idle gear or starter clutch
malfunction
Check the idle gear, starter clutch,
or crankshaft Woodruff key.
5-79
WD: Refer to the wiring diagram.
Engine unit troubleshooting
9-17
E
TRBL
SHTG
1
2
3
4
5
6
7
8
Symptom 1: Engine will not start (engine cranks).
Symptom 2 Cause Checking step
Refer
to page
Throttle valve does
not move properly.
Throttle lever squeezed Check that the throttle lever is in
the fully closed position.
J
J
W
R P N
Q
R
S
T U
V
X
W
Y
Z
\
[
_
]
c
9
0
A
C
B
C
B
C
B
C
D G F
E
H I
J
K K K K
B
1
2
3
4 5 6 7
8
b
a
A7
J
A
T
V
C
F
H
B
D
H
H
W
X G U
1 2 3 4
B T J M H H K
E
B Y
A10
A1 A2 A3
A4 A5 A6 A7 A8 A9 A10
N P R S T U V W X Y A B C D E F G H J K L M
1 2 3 4
A5
A3 A9 A9 A9 A9 A8 A8 A8 A8 A3
A5
A3 A4
A1
A3
A2
A6