Marine

WaveRunner XL700
SUPPLEMENTARY SERVICE MANUAL

LIT-18616-02-00

F0M-28197-Z8-1X

PREFACE
This Supplemmentary Service Manual has been prepared to introduce new service and data for the XL700. For complete service information procedures, it is necessary to use this Supplementary Service Manual together with the following manual.

XL760, XL1200 SERVICE MANUAL: GU2-28197-Z7-11

For what is not mentioned in this manual, please refer to the descriptions for XL760 in the above SERVICE MANUAL.

A10001-0*

XL700 SUPPLEMENTARY SERVICE MANUAL 1998 Yamaha Motor Co., Ltd. 1st Edition, September 1998 All rights reserved. No part of this publication may be reproduced or transmitted in any from or by any means including photocopying and recording without the written permission of the copyright holder. Such written permission must also be obtalned before any part of this publication is stored in a retrieval system of any nature. Printed in USA P/N F0M-28197-Z8-1X

GENERAL INFORMATION
IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRIMARY I.D. NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HULL IDENTIFICATION NUMBER (H.I.N.) . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JET UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 5 5

TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SPECIFIED TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FUEL LINE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CABLE LINE ROTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

PERIODIC INSPECTION AND ADJUSTMENT

MAINTANANCE INTERVAL CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 PERIODIC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trolling speed adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 12 12 12

FUEL SYSTEM
FUEL LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 13 CARBURETOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 14 CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High and low speed screws adjustment . . . . . . . . . . . . . . . . . . Throttle valve synchronization inspection and adjustment . Choke valve synchronization inspection and adjustment . . . Carburetor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 16 16 17 17 17 18 18

POWER UNIT
ENGINE UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 19 REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 21 EXHAUST RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 22 EXHAUST CHAMBER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 23 EXHAUST CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 24 CYLILNDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 25 CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLYWHEEL MAGNETO AND BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coupling flange removal and installation . . . . . . . . . . . . . . . . . Flywheel magneto removal and installation . . . . . . . . . . . . . . . 26 26 26 27 27 28 28 28 29 29 30 30 30 32 32 32

ELECTRICAL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 33 INTERMEDIATE SHAFT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coupling removal and installation . . . . . . . . . . . . . . . . . . . . . . . 35 35 35 36 36

ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ELECTRICAL ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 PEAK VOLTAGE MEASURMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION SISTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peak voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGE COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PULSER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMO SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDI UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 41 42 42 44 44 44 45

STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECTIFIER/REGULATOR OUT PUT PEAK VOLTAGE . . . . . . . . . . . LIGHTING COIL OUT PUT PEAK VOLTAGE . . . . . . . . . . . . . . . . . . . INDICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL LEVEL WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 47 48 48 49 49 50 50

HULL AND HOOD

THORTTLE CABLE AND CHOKE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . 51 EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 51 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 52 HULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 53

GEN INFO

IDENTIFICATION NUMBERS
A80700-0*

IDENTIFICATION NUMBERS
PRIMARY I.D. NUMBER The primary I.D. number is stamped on a plate attached to the hull on the front of the engine hood.

Starting primary I.D. number: F0M: 800101

ENGINE SERIAL NUMBER The engine serial number is stamped on a plate attached to the crankcase. Starting serial number: 67E : 300101

PUMP SERIAL NUMBER The jet pump unit serial number is stamped on a plate attached to the intermediate housing.

HULL IDENTIFICATION NUMBER (H.I.N) The H.I.N. is stamped on a plate attached to the rear end of the footrest floor.

GEN INFO

SPECIAL TOOLS

SPECIAL TOOLS
Use of the correct special tools recommended by Yamaha will aid the work and enable accurate assembly and tune-up. Improvisations and use of improper tools can cause damage to the equlpment.

MEASURING 1. Peak voltage adaptor P/N. 90890-03169

REMOVAL AND INSTALLATION 1. Coupler wrench P/N. YW-38741 90890-06425

SPEC

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS
Item MODEL CODE: Hull Engine DIMENSIONS: Length Width Height Dry weight PERFORMANCE: Maximum speed Maximum output Maximum fuel consumption Cruising range (at full throttle) ENGINE: Engine type Number of cylinders Displacement Bore and stroke Compression ratio Intake system Carburetor type Number of carburetor Carburetor starting system Scavenging system Lubrication system Cooling system Starting system Ignition system Ignition timing Spark plug (NGK) Battery capacity Lighting coil DRIVE UNIT: Propulsion system Jet pump type Impeller rotation (rear view) Transmission Nozzle angle FUEL AND OIL: Fuel Oil Fuel and oil mixing ratio (Wide open throttle) Fuel tank capacity Reserve Oil tank capacity mm (in) mm (in) mm (in) kg (lb) km/ h (mph) kW (hp) / rpm Vh (US gal / h, lmp gal / h) hr. Unit XL700 F0M 67E 3,150 (124.0) 1,250 (49.2) 1,100 (43.3) 245 (54.0) 74 (46) 58.8 (80) / 6250 34 (8.98, 7.48) 1.5 2-stroke 2 701 (42.78) 81 68 (3.19 2.68) 7.2 : 1 Reed valve Floatless 2 Choke valve Loop charged Oil lnjection Water-cooled Electric starter C.D.I 15 BTDC 21 BTDC BR8HS 12 / 68.4 (19) 2 4 / 5,500 Jet pump Axial flow, single stage Counterclockwise Direct drive from engine 24 1 Unleaded regular gasoline 2 stroke outboard motor oil 50 : 1 l (US gal, lmp gal) l (US gal, lmp gal) l (US gal, lmp gal) 50 (13.2, 11.0) 12 (3.17, 2.64) 3.8 (1.0, 0.8)

cm3 (cu.in) mm(in)

Degree V/ kC (ASh) A/ rpm

Degree

SPEC
ENGINE
Item Cylinder head: Warpage limit Cylinder: Bore size Wear limit Taper limit Out of round limit Piston: Piston size Measuring point* Piston clearance Weat limit Offset Piston ring: Type Sectional sketch Side clearance End gap Piston pin: Outside diameter Limit

MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS
Unit mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) XL700 0.1 (0.004) 81.00 81.02 (3.189 3.190) 81.1 (3.193) 0.08 (0.003) 0.05 (0.002) 80.925 80.950 (3.186 3.187) 10 (0.39) 0.080 0.085 (0.0031 0.0033) 0.135 (0.0053) 0.5 (0.02) Keystone 1.2 2.9 (0.05 0.11) 0.02 0.07 (0.001 0.003) 0.2 0.4 (0.008 0.016) 19.995 20.000 (0.7872 0.7874) 19.98 (0.786) 61.95 62.00 (2.439 2.441) 0.05 (0.002) 0.25 0.75 (0.010 0.030) 2.0 (0.08) 62T02F / R 2.5 (0.10) 120 (F), 130 (R) 67.5 5 / 8, 1 / 4 190 1.5 (0.06) 5 / 8 (F), 1-1 / 8 (R) 1 / 4 1,250 50 0.2 (0.01) 9.0 0.2 (0.35 0.01) 0.2 (0.008)

(exhaust side)

(installed)

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

Crankshaft: Crank width A Run out limit B Connecting rod big end side clearance C Small end free play limit D Carburetor: Stamped mark Main nozzle Main jet Pilot jet Low speed screw Throttle valve Valve seat High speed screw Trolling speed Reed valve: Thickness Valve lift Bending limit

mm (in) (M.J.) (P.J.) Turns out (Th.V.) (V.S.) mm (in) Turns out r/ min mm (in) mm (in) mm (in)

SPEC
JET UNIT
Item

MAINTENANCE SPECIFICATIONS

Unit mm (in) mm (in) mm (in)

XL700 0.25 0.35 (0.010 0.014) 0.6 (0.024) 0.3 (0.012)

Jet pump: Impeller clearance Service limit Impeller shaft run out

ELECTRICAL
Item Ignition system: Type Ignition timing Stator: Model / Manufacturer Pulser coil resistance Charging coil resistance CDI unit: Stamped mark Model / Manufacturer Over revolution limit Overheat revolution control Ignition coil: Stamped mark Model / Manufacturer Primary winding resistance Secondary winding resistance Charging system: Type Lighting coil resistance Rectifier regulator: Model / Manufacturer Regulator voltage Thermo switch: ON OFF Starter motor: Model / Manufacturer Brush length Wear limit Commutator under cut Limit Commutator diameter Limit Fuse: Rating _C (_F) _C (_F) 76 84 (169 183) 63 77 (145 171) SM13237/ MITSUBA 12.5 (0.44) 6.5 (0.26) 0.7 (0.028) 0.2 (0.008) 28.0 (1.10) 27.0 (1.06) 12-10 Unit XL700 CDI magneto 15 BTDC 21 BTDC F4T31671/ MITSUBISHI 12.6 15.4 (W / R B) 497.7 608.3 (Br / W B) 62T-01 F8T13175/ MITSUBISHI 7,000 7,400 3,000 3,800 62E-11 F6T532 / MITSUBISHI 0.078 0.106 (Or B) 14.3 30.5 (High tension cords) Flywheel magneto 1.14 1.40 (G G) SH589-12/ SHINDENGEN 14.3 15.3

at 1,200 rpm at 5,500 rpm

Degree Degree

(color) (color)

r/ min r/ min

(color)

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) VA

SPEC
SPECIFIED TORCUE

TIGHTENING TORQUE

TIGHTENING TORQUE
Part name Tightening torque S e Size Q Qty Nm mSkg ftSlb Re Remark

Part to be e tightened he e ENGINE: Electric box Mounting bolt Reed valve Exhaust ring Exhaust chamber Muffler stay E h Exhaust chamberh eMuffler stay M le 1 Muffler 1st 2nd 1st 2nd 1st Cylinder l e body 2nd 1st Cylinder l e head he Spark plug Flywheel bolt Coupling 1st Crankcase e 2nd 1st M Mount bracket e Flame arrester cover Starter motor terminal nut JET UNIT: 2nd 2nd

Bolt Bolt Screw Bolt Bolt Bolt Bolt l

M8 M8 M4 M8 M10 M10 M10

2 4 16 4 2 4 2

17 17 1 30 40 40 2 47 22

1.7 1.7 0.1 3.0 4.0 4.0 0.2 4.7 2.2 4.0 2.3 4.0 1.5 3.6 2.5 7.0 3.7 1.5 2.8 2.3 5.3 0.2 0.5

12 12 0.7 22 29 29 1.4 34

Bolt l

M10

40 23

29
572 271 572 572 242 242 271 572 271 572 572 572

17 29 11 25 18 50 27 11 20 17 38 1.4 3.6

Bolt l

M10

40 15

Bolt l Bolt Bolt Nut Bolt l

M8 M14 M10 M27 M8

10 2 1 1 8

36 25 70 37 15 28 23

Bolt l Bolt Nut

M10 M6 M6

7 6 1

53 2 5

Bolt M Mounting bolt l Ride plate Impeller Coupling Intermediate housing Housing Bolt Bolt Bolt Nut Bolt Bolt

M10 M6 M8 M20 M27 M8 M10

4 2 6 1 1 3 4

34 7 17 18 37 17 34

3.4 0.7 1.7 1.8 3.7 1.7 3.4

24 5.1 12 13 27 12 25

271

16

271

271

271

271

242

271

271

SPEC

FUEL LINE ROUTING

FUEL LINE ROUTING

Pilot water hose Fuel cock Fuel return hose

Fuel filter Battery breather hose

Pass the oil hose out of belt

SPEC

FUEL LINE ROUTING

Align mark Align mark

Fuel hose (Fuel cockfuel filter) AA Fuel hose (Fuel cockfuel filter) BB Fuel hose (Fuel cockfuel filter) CC

Fuel return hose (Carburetor-fuel tank) I

J Align mark 10 mm Fuel hose (Fuel filter-engine) K Fuel tank Pilot water hose Ventilation socket L To nipple

EE

Pilot water hose Fuel tank breater hose

Battery breather hose 5 mm

MM

OUT N IN G Electric equipment box $ Handlebar switch lead Oil level warning lamp lead Fuel tank brether hose Fuel hose (RES) H Fuel hose (ON) Fuel hose (Fuel cock-fuel filter) QQ Oil sensor lead Oil level warning lamp lead Fuel tank breather hose Oil sensor lead Handlebar switch lead

Bow Align mark

Handlebar switch lead

SPEC

CABLE LINE ROUTING

CABLE LINE ROUTING

Throttle cable

Choke cable

Battery positive lead

Battery negative lead

To themo switch lead Steering cable To starting motor negative To starting motor terminal positibve terminal

SPEC

CABLE LINE ROUTING

Electric equipment box lead $ Handlebar switch Throttle cable AA Handlebar switch lead BB Electric equipment box $ Handlebar switch Oil level warning CC lamp lead Oil level warning lamp lead Oil sensor lead MM To CDI magneto To starting motor positive terminal Handlebar switch lead To thermo switch Choke cable DD

Pilot water hose Oil level warning lamp lead

J Electric equipment box lead EE $ Handlebar switch

Electric equipment box lead $ Handlber switch Oil sensor lead Handlebar switch lead

To #1 cylinder (Black) To #2 cylinder (Black) To CDI magneto (Black) To handlebar switch (Gray) To thermo switch (Black) To battery positive terminal (Red) To starting motor positive terminal (Red) Electric equipment box Battery negative lead Grease nipple hose Battery positive lead Steering cable

Oil sensor $ Meter (White)

Electric equipment box $ Handlebar switch (Black)

Handlebar switch $ Electric equipment box (Natural) Electric equipment box $ Oil lever warning lamp (White) G

10

INSP ADJ

MAINTANCE INTERVAL CHART

MAINTANCE INTERVAL CHART

The following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the intervals of maintenance should be changed.
Initial e Item CONTROL SYSTEM: Steering cable Throttle cable Carburetor throttle shaft Choke cable FUEL SYSTEM: Fuel tank Fuel filter Fuel line Trolling speed Carburetor setting Oil injection system POWER UNIT: Spark plug Inspection / Cleaning / Adjustment Cooling-water passage Cleaning / Flashing Coupling rubber Inspection ELECTRICAL: Battery JET PUMP UNIT: Impeller Bilge strainer GENERAL: Bolt and nut Drain plug Greasing point Bearing housing Retightening Inspection/Replacement Greasing Greasing f f*1 f f f*2 f 3-14 3-14 3-15 Inspection Cleaning f f f f 3-13 3-13 Inspection f 3-11 f f f f f 3-10 Cleaning Cleaning / Replacement Inspection Inspection / Adjustment Inspection / Adfustment Inspection / Cleaning f f f f f 4-7 3-6 13 12 12 3-8 Inspection / Adjustment Inspection / Adjustment Inspection Inspection / Adjustment f f f f 3-2 3-3 3-4 Re Remarks Every Refer to page e

10 h hours 50 h hours 100 hours h 200 hours h (Break-in) (3 months) (6 months) (1 year)

f f f

OIL INJECTION SYSTEM: f

*1: Grease capacity 33.0 35.0 cm3 (1.11 1.18 oz.) *2: Grease capacity 6.0 8.0 cm3 (0.20 0.27 oz.)

11

INSP ADJ

PERIODIC SERVICE

PERIODIC SERVICE
FUEL SYSTEM Trolling speed inspection and adjustment 1. Check: S Trolling speed Out of specification ! Adjust. Trolling speed: 1,250 50 r/min Checking steps: (vehicle on water) S Start the engine and allow it to warm up for a few minutes. S Attach the engine tachometer to the spark plug lead. Engine tachometer: YU-8036-A/90890-06760 S Measure the engine trolling speed. 2. Adjust: S Trolling speed Adjustment steps: S Screw in the low speed screws 1 until they are lightly seated. S Back the screws out by the specified number of turns. Low speed screw: 5/8 1/4 (turns out) S Start the engine and allow it to warm up for a few minutes. S Turn the throttle stop screw(s) 2 in or out until the specified speed is obtained. Turning in Turning out Increase trolling speed. Decrease trolling speed.

Carburetor adjustment 1. Adjust: S High speed screw Adjustment steps: S Screw in the high speed screws 1 until they are lightly seated. S Back the screws out by the specified number of turns. High speed screw: 5/8 (F), 1-1/8 (R) 1/4 (turns out)
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FUEL
FUEL LINE

FUEL LINE

Gasoline (Petrol) is highly flammable and explosive. Handle with special care. EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART Step Procedure/Part name AIR VENTILATION HOSE, FUEL COCK AND FUEL FILTER REMOVAL Hose tie Clamp Air ventilation hose Fuel hose (RETURN) Fuel filter Fuel hose Fuel hose Check valve Fuel cock body Qty Service points Follow the left Step for removal.

1 2 3 4 5 6 7 8 9

1 6 1 1 1 1 3 1 1 Reverse the removal steps for installation.

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FUEL
EXPLODED DIAGRAM

CARBURETOR UNIT REMOVAL

CARBURETOR UNIT REMOVAL

2 Nm (0.2 mSkg, 1.4 ftSlb)

9 Nm (0.9 mSkg, 6.5 ftSlb)

REMOVAL AND INSTALLATION CHART Step Procedure/Part name CARBURETOR REMOVAL Fuel cock High tension cord Bolt Cover 1 Flame arrester Hose tie Oil delivery hose Bolt (with washer) Cord clamp Plate washer Bolt (with washer) Cover 2 Cover gasket Plate
14

Qty

Service points Follow the left Step for removal. NOTE: Turn the fuel cock to OFF.

1 2 3 4 5 6 7 8 9 10 11 12

6 1 2 2 2 2 1 1 6 1 1 1

FUEL

CARBURETOR UNIT REMOVAL

2 Nm (0.2 mSkg, 1.4 ftSlb)

9 Nm (0.9 mSkg, 6.5 ftSlb)

Step 13 14 15

Procedure/Part name Cover gasket Choke cable Throttle calbe

Qty 1 1 1

Service points

16 17 18 19 20 21 22 23

Hose tie Fuel hose (fuel filter-fuel pump) Pulse hose (fuel pump-crank case) Fuel hose (carburetor-fuel tank) Nut Plate washer Carburetor assembly Gasket

3 1 1 1 4 4 1 1

Cable guide set position a : 17 mm (0.67 in) Between cable guide top and plate top.

Reverse the removal steps for installation.

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FUEL
CARBURETOR
EXPLODED DIAGRAM

CARBURETOR

1 Nm (0.1 mSkg, 0.7 ftSlb) 4 Nm (0.4 mSkg, 2.9 ftSlb)

2 Nm (0.2 mSkg, 1.4 ftSlb)

2 Nm (0.2 mSkg, 1.4 ftSlb) 1 Nm (0.1 mSkg, 0.7 ftSlb)

5 Nm (0.5 mSkg, 3.6 ftSlb)

REMOVAL AND INSTALLATION CHART Step Procedure/Part name CARBURETOR DISASSEMBLY Carburetor assembly Bolt Collar Diaphragm assembly Float arm Needle valve assembly Body assembly Main jet Pilot jet High speed screw Low speed screw Qty Service points Follow the left Step for removal. Refer to CARBURETOR REMOVAL. 4 2 2 2 2 2 2 2 2 2 Reverse the removal steps for installation.

1 2 3 4 5 6 7 8 9 10

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FUEL

CARBURETOR
SERVICE POINTS High and low speed screws adjustment 1. Adjust: S High speed screw S Low speed screw Adjustment steps: S Screw in the high speed screw 1 or lower speed screw 2 until it is lightly seated. S Back out by the specified number of turns. High speed screw: 5/8 (#1), 1-1/8 (#2) 1/4 turns out Low speed screw: 5/8 (#1) 1/4 turns out

Throttle valve synchronization inspection and adjustment 1. Check: S Throttle valve synchronization Out of specification ! Adjust. Checking steps: S While turning the throttle lever, check the opening of all throttle valves. 2. Adjust: S Throttle valve synchronization Adjustment steps: S Turn out the idle adjust screws 1 until their tips are apart from the throttle lever 2 . NOTE: Record the set position of the idle adjust screw. S Check that the throttle valve R 3 is fully closed. S Turn the synchronization screw 4 in or out until the throttle valve F 5 is fully closed. S Turn in the idle adjust screws to the set position.

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FUEL

CARBURETOR
Choke valve synchronization inspection and adjustment 1. Check: S Choke valve synchronization Out of specification ! Adjust. Checking steps: S While turning the choke lever, check the opening of all choke valves. 2. Adjust: S Choke valve synchronization Adjustment steps: a. Turn in or out the synchronization screw 1 to bring all the choke valves into a fully closed position when the choke lever is turned on the closed side.

Carburetor assembly 1. Adjust: S Trolling speed Refer to the FUEL SYSTEM section in chapter 3.

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EXPLODED DIAGRAM

ENGINE UNIT REMOVAL

ENGINE UNIT REMOVAL

7 Nm (0.7 mSkg, 5.1 ftSlb)

1 Nm (0.1 mSkg, 0.7 ftSlb)

17 Nm (1.7 mSkg, 12 ftSlb)

4 Nm (0.4 mSkg, 2.9 ftSlb)

REMOVAL AND INSTALLATION CHART Step Procedure/Part name ENGINE UNIT REMOVAL Engine hood assembly Oil tank assembly Fuel tank assembly Ventilation hose Battery lead Wire clamp Lead coupler Electrical box Choke cable Throttle cable Housing grease nipple plate Coupling cover Water hose
19

Qty

Service points Follow the left Step for removal. Refer to the ENGINE HOOD REMOVAL section in chapter 8. Refer to the OIL TANK AND FUEL TANK REMOVAL section in chapter 4. Refer to the DECK section in chapter 8.

1 2 3 4 5 6 7 8 9

2 4 2 1 1 1 1 1 3

POWR

ENGINE UNIT REMOVAL

7 Nm (0.7 mSkg, 5.1 ftSlb)

1 Nm (0.1 mSkg, 0.7 ftSlb)

17 Nm (1.7 mSkg, 12 ftSlb)

4 Nm (0.4 mSkg, 2.9 ftSlb)

Step 10 11 12 13 14

Procedure/Part name Clamp Fuel hose Engine mounting bolt Shim Engine unit

Qty 1 2 4 * 1

Service points

Reverse the removal steps for installation.

20

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REED VALVE
EXPLODED DIAGRAM

REED VALVE

1 Nm (0.1 mSkg, 0.7 ftSlb)

REMOVAL AND INSTALLATION CHART Step Procedure/Part name REED VALVE REMOVAL Carburetor assembly 1 2 3 4 5 6 7 8 Bolt (with washer) Plate Bolt (with washer) Intake manifold assembly Reed valve assembly Plate Valve stopper Reed valve 3 1 8 1 2 1 4 4 Qty Service points Follow the left Step for removal. Refer to the CARBURETOR REMOVAL section in chapter 4. 6 35 mm 6 25 mm

Reverse the removal steps for installation.

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EXHAUST RING
EXPLODED DIAGRAM

EXHAUST RING

2 Nm (0.2 mSkg, 1.4 ftSlb)

2 Nm (0.2 mSkg, 1.4 ftSlb)

30 Nm (3.0 mSkg, 22 ftSlb)

REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 Procedure/Part name EXHAUST RING REMOVAL Pilot water hose Clamp Exhaust joint Clamp Bolt (with washer) Ring assembly Clamp Qty 1 2 1 1 4 1 1 Service points Follow the left Step for removal. NOTE: S Pull and side the exhaust joint. S Loosen the clamp on the chamber side.

CAUTION:
Tighten the clamp before installing the ring on the muffler.

8 9

Joint Exhaust ring

1 1 Reverse the removal steps for installation.

22

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EXPLODED DIAGRAM

EXHAUST CHAMBER REMOVAL

EXHAUST CHAMBER REMOVAL

40 Nm (4.0 mSkg, 29 ftSlb) 1st 2nd 2 Nm (0.2 mSkg, 1.4 ftSlb) 47 Nm (4.7 mSkg, 34 ftSlb)

40 Nm (4.0 mSkg, 29 ftSlb)

4 Nm (0.4 mSkg, 2.9 ftSlb)

REMOVAL AND INSTALLATION CHART Step Procedure/Part name EXHAUST CHAMBER REMOVAL Ring Exhaust hose Water outlet hose Bolt (exhaust chamber) Qty Service points Follow the left Step for removal. Refer to EXHAUST RING. 1 1 2

1 2 3

NOTE: Tighten the bolts in sequence.

4 5 6 7

Bolt (muffler stay) Muffler stay Bolt Exhaust chamber assembly

4 1 2 1 Reverse the removal steps for installation.

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POWR
EXPLODED DIAGRAM

EXHAUST CHAMBER

EXHAUST CHAMBER

REMOVAL AND INSTALLATION CHART Step Procedure/Part name CHAMBER DISASSEMBLY Exhaust chamber assembly 1 2 3 4 5 6 7 8 9 10 Bolt (with washer) Exhaust outer cover 1 Gasket Exhaust inner cover Seal Gasket Bolt (with washer) Exhaust outer cover 2 Gasket Exhaust chamber 6 1 1 1 1 1 6 1 1 1 Reverse the removal steps for installation. Qty Service points Follow the left Step for removal. Refer to EXHAUST CHAMBER REMOVAL.

24

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CYLINDER HEAD
EXPLODED DIAGRAM

CYLINDER HEAD

25 Nm (2.5 mSkg, 18 ftSlb)

1st 2nd

15 Nm (1.5 mSkg, 11 ftSlb) 36 Nm (3.6 mSkg, 25 ftSlb)

REMOVAL AND INSTALLATION CHART Step Procedure/Part name CYLINDER HEAD REMOVAL Muffler Spark plug Water hose Bolt (with washer) Qty Service points Follow the left Step for removal. Refer to MUFFLER. 2 1 10

1 2 3

NOTE: Tighten the bolts in sequence and two steps of torque. Reverse the removal steps for installation.

Cylinder head

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CYLINDER
EXPLODED DIAGRAM

CYLINDER

1st 2nd

23 Nm (2.3 mSkg, 17 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb)

REMOVAL AND INSTALLATION CHART Step Procedure/Part name CYLINDER REMOVAL Cylinder head Bolt (with washer) Qty Service points Follow the left Step for removal. Refer to CYLINDER HEAD NOTE: Tighten the bolts in sequence and in two steps of torque. NOTE: After installing, check the smooth movement of the piston.

Cylinder

Pin

2 Reverse the removal steps for installation.

26

POWR

CYLINDER
SERVICE POINTS Cylinder inspection 1. Eliminate: D Carbon deposits Use a rounded scraper 1 .

2. Inspect: D Cylinder water jacket Mineral deposits/Corrosion ! Clean. D Cylinder inner surface Score marks ! Repair or replace. Use #600 X 800 grit wet sandpaper.

3. Measure: D Cylinder bore D Use cylinder gauge. Out of limit ! Replace. NOTE: Measure the cylinder bore D in parallel. Then, find the average of the measurement.

Standard Cylinder bore D Taper T Out of round R

Limit

81.00 X 81.02 mm 81.10 mm (3.189 X 3.190 in) (3.193 in) 0.08 mm (0.003 in) 0.05 mm (0.002 in)

D = Maximum (D1 X D6) T = (Maximum D1 or D2) (Maximum D5 or D6) R = (Maximum D1, D3 or D5) (Minimum D2, D4 or D6)

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POWR
PISTON
EXPLODED DIAGRAM

PISTON

REMOVAL AND INSTALLATION CHART Step Procedure/Part name PISTON REMOVAL Cylinder 1 2 3 4 Piston pin clip Piston pin Piston Washer 4 2 2 4 Qty Service points Follow the left Step for removal. Refer to CYLINDER.

CAUTION:
Do not allow the clip open ends to meet the piston pin slot a . NOTE: Be sure the arrow b side is positioned exhaust pipe.

Piston ring

CAUTION:
Align each end gap with the locating pin. Reverse the removal steps for installation.

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POWR

PISTON
SERVICE POINT Piston inspection 1. Eliminate: S Carbon deposits From the piston crown and ring groove.

2. Inspect: S Piston wall Score marks ! Repair or replace. Use #600 800 grit wet sandpaper. NOTE: Sand in a criss-cross pattern. Do not sand excessively. 3. Measure: S Piston skirt diameter Use micrometer. Out of specification ! Replace. Piston diameter 80.925 80.950 mm (3.186 3.187 in) Distance a 10 mm (0.39 in)

4. Calculate: S Piston clearance Out of limit ! Replace piston, piston rings as a set.
PISTON CYLINDER PISTON = CLEARANCE BORE DIAMETER

Piston clearance: 0.080 0.085 mm (0.0031 0.0033 in)

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EXPLODED DIAGRAM

FLYWEEL MAGNETO AND BASE

FLYWEEL MAGNETO AND BASE

37 Nm (3.7 mSkg, 27 ftSlb)

70 Nm (7.0 mSkg, 50 ftSlb)

REMOVAL AND INSTALLATION CHART Step Procedure/Part name FLYWHEEL MAGNETO AND BASE REMOVAL Engine unit 1 2 3 4 5 Oil pump Flywheel cover Coupling flange Flange bolt Flywheel magneto 1 1 1 1 1 Qty Service points Follow the left Step for removal. Refoer to the ENGINE UNIT REMOVAL section.

NOTE: When installing the flywheel magneto make sure that the woodruff key is properly seated in the keyway of the crankshaft.

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FLYWHEEL MAGNETO AND BASE

37 Nm (3.7 mSkg, 27 ftSlb)

70 Nm (7.0 mSkg, 50 ftSlb)

Step 6

Procedure/Part name Idle gear assembly

Qty 1

Service points NOTE: Fill the flywheel cover groove with water resistant grease. NOTE: Align the punch mark on the crankcase with the punch mark on the base assembly. Reverse the removal steps for installation.

Base assembly

31

POWR

FLYWHEEL COVER AND FLYWHEEL MAGNETO

SERVICE POINTS Coupling flange removal and installation 1. Remove and install: S Coupling flange Coupler wrench: YW-38741/90890-06425 Flywheel holder: YB-06139/90890-06522 Flywheel magneto removal and installation 1. Remove and install: S Bolt Flywheel holder: YB-06139/90890-06522 2. Remove: S Flywheel magneto Flywheel puller: YB-06117/90890-06521 Bolt: M8 80 mm
A For USA and CANADA B Except for USA and CANADA

CAUTION:
To prevent damage to the engine or tools, screw in the flywheel puller set- bolts evenly and completely so that the puller plate is parallel to the flywheel.

32

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EXPLODED DIAGRAM

ELECTRICAL UNIT

ELECTRICAL UNIT

5 Nm (0.5 mSkg, 3.6 ftSlb)

4 Nm (0.4 mSkg, 2.9 ftSlb)

4 Nm (0.4 mSkg, 2.9 ftSlb)

4 Nm (0.4 mSkg, 2.9 ftSlb)

REMOVAL AND INSTALLATION CHART Step Procedure/Part name ELECTRICAL UNIT REMOVAL Electrical box Base assembly 1 2 3 4 5 6 Spark plug cap Bolt (with washer) Thermo switch Nut Spring washer Starter motor negative lead 2 2 1 1 1 1 Qty Service points Follow the left Step for removal. Refer to the ENGINE UNIT REMOVAL section. Refer to the FLYWHEEL MAGNETO AND BASE section.

33

POWR

ELECTRICAL UNIT

5 Nm (0.5 mSkg, 3.6 ftSlb)

4 Nm (0.4 mSkg, 2.9 ftSlb)

4 Nm (0.4 mSkg, 2.9 ftSlb)

4 Nm (0.4 mSkg, 2.9 ftSlb)

Step
1 2 3 4 5 6 7 8 9 10 11 12 13 14

Procedure/Part name ELECTRICAL UNIT DISASSEMBLY Screw Case cover Screw Ignition coil Screw Clamp Rectier-regulator Screw Clamp bracket CDI unit Nut Spring washer Starter relay Housing

Qty 14 1 2 1 3 1 1 3 1 1 2 2 1 1

Service points

Reverse the removal steps for installation.

34

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EXPLODED DIAGRAM

INTERMEDIATE HOUSING

INTERMEDIATE HOUSING

6 Nm (0.6 mSkg, 4.3 ftSlb)

37 Nm (3.7 mSkg, 27 ftSlb)

REMOVAL AND INSTALLATION CHART Step Procedure/Part name INTERMEDIATE HOUSING DISASSEMBLY Bearing housing assembly 1 2 3 4 5 6 Coupling Shaft Oil seal Oil seal Clip Bearing 1 1 1 1 1 1 Qty Service points Follow the left Step for removal. Refer to INTERMEDIATE HOUSING REMOVAL.
Distance: a : 1.6 X 2.0 mm (0.06 X 0.08 in) b : 14.5 X 15.5 mm : (0.57 X 0,61 in) c : 6.8 X 7.2 mm (0.27 X 0.28 in) d : 17.6 X 17.7 mm (0.69 X 0.70 in)

Reverse the removal steps for installation.

35

POWR

INTERMEDIATE SHAFT AND HOUSING

SERVICE POINT Coupling removal and installation 1. Remove and install: S Coupling Coupler wrench: YW-38741/90890-06425 Shaft holder: YW-38742/90890-06069

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ELEC

ELECTRICAL COMPONENTS

ELECTRICAL COMPONENTS

1 2 3 4 5 6 7 8

Throttle cable Oil level sensor lead Battery lead (positive) Battery lead (negative) Oil level warning lamp lead Handlebar switch lead Starter motor lead (positive) Thermo sensor lead

9 10 11 12 13 14 15 16

CDI magneto lead Choke cable Steering cable Sterter motor lead (nagative) Grease nipple hose Electrical box High tension cord Pilot water hose

37

ELECTRICAL DIAGRAM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Thermo switch Ignition coil Lighting coil Pulser coil Charge coil CDI unit Starter motor Stop switch Engine stop switch Starter switch Battery Fuse Starter relay Rectifier regulator Oil level sensor Oil level warning lamp

ELEC
ELECTRICAL DIAGRAM

B Br Br/W G L O P R W W/R

: Black : Brown : Brown/White : Green : Blue : Orange : Pink : Red : White : White/Red

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ELECTRICAL ANALYSIS

ELECTRICAL ANALYSIS
PEAK VOLTAGE MEASUREMENT NOTE: S If the spark produces no sparks, check the wiring for any disconnection, looseness, insufficient contact, etc. Then measure the peak voltage. S The peak voltages are listed for the loaded and the circuit state. The loaded value is used for measuring a normally operating system and the circuit valve for measuring a coil disconnected from the system. S The peakvoltage value measured at cranking is the one at which no load is applied to the jet pump. S To measure the peak voltage of lighting coil and rectifier regulator, take off the output wire of the rectifier regulator.

Measuring step: S Remove the electrical box and disassembly it. Refer to ENGINE UNIT REMOVAL. S Attach the tachometer to the high tension lead of the cylinder #1, (No need during cranking measurement). S Set the peak voltage adaptor to the tester. NOTE: The peak voltage adaptor plugs a have polarity. Connect the red plug of the peak voltage adaptor to the volt test plug of the tester.

39

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ELECTRICAL ANALYSIS
S Set the digital tester dial at the DCV position. S Connect the peak voltage adaptor leads b to the correct terminals to be measured. NOTE: S The peak voltage leads have no polarity connection of either lead to either terminal c for measurement will result in the same measurement. S Wire colors for connection purposes will be indicated. S Connect the water vehicles to a fully charged battery. (In cranking measurement) S Start or crank the engine and read the indication.

CAUTION:
When the peak voltage is measured during engine operation, measure it with cooling water passing through the engine cooling water passage. NOTE: S Before measuring cranking, remove the spark plug caps from the spark plug. S Cranking speed changes the output measurement. S The specified values shown in the manuals will be indicated as the lower limit of the specification. If the meters reading is higher, then there is no problem with the tested component. S If the output reading is lower, then the component is probably faulty, as long as the components input voltages are correct at the time when testing.

40

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WIRING DIAGRAM

IGNITION SYSTEM

IGNITION SYSTEM

1 2 3 4 5 6 7

Pulser coil Charge coil CDI unit Stop switch Engine stop switch Thermo switch Ignition coil

B Br/ W O P W W/ R

: Black : Brown / White : Orange : Pink : White : White / Red

41

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IGNITION SYSTEM
IGNITION SYSTEM Peak voltage

When checking the peak voltage do not touch any of the connections of the digital tester lead wires. NOTE: S If there is no spark or the spark is weak, continue with the ignition system test. S If a good spark is obtained, the problem is not with the ignition system, but possibly with the spark plug(s) or another component. 1. Measure: S CDI unit output peak voltage Above specification ! Replace the ignition coil. Below specification ! Measure the charge coil output peak voltage. CDI unit output peak voltage Orange (O) Brack (B) r/min V Circuit Cranking 105 Loaded 1,500 175 3,500 135

2. Measure: S Charge coil output peak voltage Above specification ! Measure the pulser coil output peak voltage. Below specification ! Replace the charge coil. Charge coil output peak voltage Brown / White (Br/W) Black (B) r/min V Circuit Cranking 120 115 Loaded 1,500 205 3,500 150

42

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IGNITION SYSTEM
3. Measure: S Pulser coil output peak voltage Above specification ! Replace the CDI unit. Below specification ! Replace the pulser coil. Pulser coil output peak voltage White/red (W/R) Black (B) r/min V Circuit Cranking 3.0 3.0 Loaded 1,500 17.0 3,500 29.5

43

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IGNITION SYSTEM
CHARGE COIL 1. Measure: S Charge coil resistance Out of specification ! Replace. Charge coil resistance: Brown/White (Br/W) Black (B) 497.7 608.3 at 20 _C (68 _F) PULSER COIL 1. Measure: S Pulser coil resistance Out of specification ! Replace. Pulser coil resistance: White/Red (W/R) Black (B) 12.6 15,4 at 20 _C (68 _F) THERMO SWITCH 1. Measure S Thermo switch continuity Out of specification ! Replace. Thermo switch continuity temperature: Pink (P) Black (B) a 66 74 _C (100.4 125.6 _F) b 57 43 _C (93.2 78.8 _F)
1 Discontinuity 2 Continuity 3 Discontinuity A Temperature B Time

Measurement steps: S Suspend thermostat in a vessel. S Place known reliable thermometer in water. S Heat water slowly. S Observe thermometer, while stirring water continually.

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IGNITION SYSTEM
CDI UNIT 1. Measure: S CDI unit resistance Out of specification ! Replace. Pocket tester: YU-03112/90890-03112 NOTE: S The resistance values will vary from meter to meter, especially with electronic digital meters. For some testers, the polarity of the leads is reversed. S The needle swings once to the S mark and then returns to the home position. S The mark stands for discontinuity.
Unit: k

B Br/ W O P W W/ R

B 20 80 S 9 36

Br/ W 26 S 17 70

O S S S

P 3 11 50 200 S 10 40

W W/ R 10 40 150 600 15 60 250 1000 S S 50 200

B Br/ w O P W W/ R

: Black : Brown / white : Orange : Pink : White : White / Red

45

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WIRING DIAGRAM

STARTING SYSTEM

STARTING SYSTEM

1 2 3 4 5 6

Fuse Engine stop switch Starter switch Battery Starter motor Starter relay

B Br R

: Black : Brown : Red

46

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WIRING DIAGRAM

CHARGING SYSTEM

CHARGING SYSTEM

1 2 3 4

Fuse Battery Lighting coil Rectifier regulator

B G R

: Black : Green : Red

47

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CHARGING SYSTEM
RECTIFIER/REFULATOR OUTPUT PEAK VOLTAGE 1. Measure: S Rectifier/regulator output peak voltage Below specification ! Check the lighting coil. Rectifier/regulator output peak voltage Red (R) Black (B) r/min V Circuit Cranking Loaded 1,500 12.6 3,500 12.5

NOTE: Before measuring the rectifier/regulator output peak voltage, disconnect the lighting coil coupler and remove the fuses.

LIGHTING COIL OUTPUT PEAK VOLTAGE 1. Measure: S Lighting coil output peak voltage Above specification ! Replace the rectifier/regulator. Below specification ! Replace the lighting coil. Lighting coil output peak voltage Green (G) Green (G) r/min V Circuit Cranking 7.3 7.3 Loaded 1,500 13.6 3,500 12.6

48

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WIRING DIAGRAM

INDICATION SYSTEM

INDICATION SYSTEM

1 2 3 4

Oil level sensor Lighting coil Oil levle warning lamp Rectifier regulator

B G L R

: Black : Grren : Blue : Red

49

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INDICATION SYSTEM
OIL LEVEL SENSOR 1. Meadure: S Oil level sensor continuity Out of specification ! Replace.
ON Max. 2.5 mm (0.010 in.) OFF

Float position OFF ON

Checing leads L B

Float length a : 37,0 41,0 mm (1,46 1,61 in) OIL LEVEL WARNING LAMP 1. Check: S Display function Not working ! Replace. Checking steps: S Connect the battery. Voltage range: 10 16 V
1 Red lead ! Positive terminal. 2 Green lead ! Positive terminal. 3 Black lead ! Negative terminal.

S After connecting the battery, oil, warning LED starts to lighy up for 3 seconds and then blinks. S Connect the jumper lead a to the blue and black terminals to check the oil warning LED goes off, after blinking for 10 30 seconds.

50

HULL HOOD
EXPLODED DIAGRAM

THORTTLE CABLE AND CHOKE CABLE

THROTTLE CABLE AND CHOKE CABLE

8 Nm (0.8 mSkg, 6.0 ftSlb)

REMOVAL AND INSTALLATION CHART Step 1 2 3 4 5 6 7 8 9 Procedure/Part name THROTTLE CABLE REMOVAL Spiral tube Throttle cable lock nut Throttle cable adjusting Seal packing Throttle cable Choke knob Choke cable lock nut Choke cable adjusting nut Choke cable Qty 1 1 1 1 1 1 1 1 1 Reverse the removal steps for installation. Service points Follow the left Step fot removal.

51

HULL HOOD
EXPLODED DIAGRAM

EXHAUST SYSTEM

EXHAUST SYSTEM

4 Nm (0.4 mSkgf, 2.9 ftSlb)

3 Nm (0.3 mSkgf, 2.2 ftSlb) 4 Nm (0.4 mSkgf, 2.9 ftSlb)

7 Nm (0.7 mSkgf, 5.1 ftSlb)

4 Nm (0.4 mSkgf, 2.9 ftSlb)

REMOVAL AND INSTALLATION CHART Step Procedure/Part name EXHAUST SYSTEM REMOVAL Storage box Band Exhaust hose Exhaust hose Water lock Water outlet hose Exhaust guide Qty Service points Follow the left Step for removal. 2 1 1 1 1 Reverse the removal steps for installation.

1 2 3 4 5 6

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HULL HOOD
HULL
EXPLODED DIAGRAM

HULL

7 Nm (0.7 mSkgf, 5.1 ftSlb)

REMOVAL AND INSTALLATION CHART Step 1 2 3 4 Procedure/Part name HULL DISASSEMBLY Nut Plate washer Packing Sponson Qty 8 8 8 2 Reverse the removal steps for installation. Service points Follow the left Step for removal.

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Printed on ohlorine-free paper