Waverunner Vxs vx1800 PDF

WaveRunner
VXS
VX1800 (F2W)
VXR
VX1800A (F2W)
SERVICE MANUAL
F2W-28197-ZU-11
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Preface
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained me-
chanics when performing maintenance procedures and repairs to Yamaha equipment. It has been writ-
ten to suit the needs of persons who have the Bronze Technical Certificate of the YTA (Yamaha
Technical Academy) marine or the equivalent 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. Au-
thorized Yamaha dealers are notified periodically of modifications and significant changes in specifica-
tions and procedures, and these are incorporated in successive editions of this manual. Also, up-to-
date parts information is available on YPEC-web. Additional information and up-to-date information on
Yamaha products and services are available on Yamaha Service Portal.
Important information
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
A WARNING indicates a hazardous situation which, if not avoided, could result in death or se-
rious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to the watercraft
or other property.
TIP:
A TIP provides key information to make procedures easier or clearer.
WaveRunner
VXS, VXR
SERVICE MANUAL
©2015 by Yamaha Motor Co., Ltd.
1st Edition, March 2015
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

Contents
General information 1
Specification 2
Maintenance 3
Fuel system 4
Power unit 5
Jet pump unit 6
Electrical system 7
Hull and hood 8
Troubleshooting 9
Appendix A
General information
Safety while working.......................................................... 1-1

Rotating parts ............................................................................. 1-1
Hot parts..................................................................................... 1-1
Electric shock ............................................................................. 1-1
Impeller....................................................................................... 1-1
Handling of gasoline................................................................... 1-1
Ventilation................................................................................... 1-1
Self-protection ............................................................................ 1-1
Working with crane..................................................................... 1-2
Handling of heat gun .................................................................. 1-2
Parts, lubricants, and sealants ................................................... 1-2
Handling of sealants................................................................... 1-3
Special service tool .................................................................... 1-3
Tightening torque ....................................................................... 1-3
Non-reusable parts..................................................................... 1-3
Disassembly and assembly........................................................ 1-3
Identification number......................................................... 1-4

Primary I.D. number ................................................................... 1-4
Engine serial number ................................................................. 1-4
Jet pump unit serial number ....................................................... 1-4
Craft identification number (C.I.N.) (Europe).............................. 1-4
Hull identification number (H.I.N.) (Oceania).............................. 1-4
How to use this manual ..................................................... 1-5

Manual format ............................................................................ 1-5
Conditions when testing and adjusting....................................... 1-6
Abbreviation ............................................................................... 1-6
Adhesive, lubricant, sealant,

and thread locking agent................................................... 1-8
Symbols...................................................................................... 1-8
Special service tool............................................................ 1-9
Model feature .................................................................... 1-19

General feature ........................................................................ 1-19
Model equipment comparison table ......................................... 1-20
Technical tips ................................................................... 1-21

Engine control .......................................................................... 1-21

General information
RiDE system............................................................................. 1-23

RiDE motor............................................................................... 1-24
ETV system .............................................................................. 1-25
Shift control .............................................................................. 1-26
Engine control system .............................................................. 1-28
1
Deck and hull............................................................................ 1-31
Lubrication system ................................................................... 1-32
Hose routing ............................................................................. 1-33
Cooling water flow .................................................................... 1-34

Safety while working
Safety while working Handling of gasoline

To prevent an accident or injury and to provide • Gasoline is highly flammable. Keep gasoline
quality service, observe the following safety and all flammable products away from heat,
procedures. sparks, and open flames.
• Gasoline is poisonous and can cause injury
Rotating parts or death. Handle gasoline with care. Never
Hands, feet, hair, jewelry, clothing, personal siphon gasoline by mouth. If you swallow
flotation device straps, and so on, can become some gasoline, inhale a lot of gasoline vapor,
entangled with internal rotating parts of the en- or get some gasoline in your eyes, see your
gine or jet pump unit, resulting in serious injury doctor immediately. If gasoline spills on your
or death. skin, wash with soap and water. If gasoline
• Keep hands, feet, hair, jewelry, clothing, per- spills on your clothing, change your clothes.
sonal flotation device straps, and so on,
away from any exposed moving parts when
operating the engine with the seat removed.
• Keep away from intake grate while engine is
on.
Hot parts
During and after operation, engine parts are
hot enough to cause burns. Do not touch any
parts in the engine compartment until the en-
gine has cooled. Ventilation
• Gasoline vapor and exhaust gas are heavier
Electric shock than air and extremely poisonous. If gasoline
Do not touch any electrical parts while starting vapor or exhaust gas is inhaled in large
or operating the engine. Otherwise, shock or quantities, it may cause loss of conscious-
electrocution could result. ness and death within a short time.
• When test running an engine indoors (for ex-
Impeller ample, in a water tank) make sure to do so
Do not hold the impeller with your hands when where adequate ventilation can be main-
loosening or tightening the impeller. tained.
Self-protection
• Protect your eyes by wearing safety glasses
or safety goggles during all operations involv-
ing drilling and grinding, or when using an air
compressor.
1-1

• Protect your hands and feet by wearing pro-
tective gloves and safety shoes when neces-
sary.
Working with crane

• When moving the watercraft, or when lifting Handling of heat gun
the engine during removal or installation, • Improper handling of a heat gun may result in
make sure to use a crane with a lifting capac- burns. For information on the proper handling
ity that is equal to or more than the weight of of the heat gun, see the operation manual is-
the watercraft or engine respectively. sued by the manufacturer.
• When lifting the watercraft, use the watercraft • When using a heat gun, keep it away from
lift harness and make sure that the watercraft the gasoline and oil, to prevent a fire.
is in a stable position when moving it. • Components become hot enough to cause
• Use the wire ropes of adequate strength, and burns. Do not touch any hot components di-
lift up the engine unit using the three point rectly.
suspension.
• If the engine unit does not have three or more
points to be suspended, support it using ad-
ditional ropes or the like so that the engine
unit can be lifted and carried in a stable man-
ner.
Parts, lubricants, and sealants

Use only genuine Yamaha parts, lubricants,
and sealants, or those recommended by Ya-
maha, when servicing or repairing the water-
craft.
1-2

Handling of sealants
• Wear protective gloves to protect your skin,
when using the sealants.
• See the material safety data sheet issued by
the manufacturer. Some of the sealants may
be harmful to human health.
Disassembly and assembly

• Use compressed air to remove dust and dirt
during disassembly.
• Apply engine oil to the contact surfaces of
moving parts before assembly.
Special service tool

Use the recommended special service tools to
work safely, and to protect parts from damage.
• Install bearings so that the bearing identifica-

tion mark is facing in the direction indicated in
the installation procedure. In addition, make
sure to lubricate the bearings liberally.
• Apply a thin coat of water resistant grease to
Tightening torque the lip and periphery of an oil seal before in-
Follow the tightening torque specifications pro- stallation.
vided throughout the manual. When tightening • Check that moving parts operate normally af-
nuts, bolts, and screws, tighten the large sizes ter assembly.
first, and tighten fasteners starting in the center
and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cotter
pins, and so on, when installing or assembling
parts.
1-3

Identification number
Identification number Jet pump unit serial number

Primary I.D. number The jet pump unit serial number is stamped on
The primary I.D. number is stamped on a label a label attached to the intermediate housing.
attached to the inside of the engine compart-
ment.
1 3
1 2 3
2
PRI-I.D.
MODEL F2W
YAMAHA MOTOR CO., LTD.
ASSEMBLED IN U.S.A. FROM AMERICAN AND JAPANESE
COMPONENTS.
ASSEMBLÉ AUX ÉTATS-UNIS DE PIÈCES AMÉRICAINES ET 1. Jet pump unit name
JAPONAISES.
2. Jet pump unit type
1. Model name 3. Jet pump unit serial number
2. Hull type
3. Primary I.D. number
Craft identification number (C.I.N.)
(Europe)
Starting primary I.D. number The C.I.N. is stamped on a plate attached to
F2W: 800101 the boarding platform.
Engine serial number Hull identification number (H.I.N.)

The engine serial number is stamped on a la- (Oceania)
bel attached to the engine unit. The H.I.N. is stamped on a plate attached to
the boarding platform.
2 3
1. Engine name
2. Engine type
3. Engine serial number
Starting engine serial number

6EW: 1000001
1-4

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 (see “1” in
the following figure for an example page).
• The component list consists of part names and quantities, as well as bolt and screw dimensions (see
“2” in the following figure).
• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
the lubrication point (see “3” in the following figure).
• Tightening torque specifications are provided in the exploded diagrams (see “4” in the following fig-
ure), and in the related detailed instructions. Some torque specifications are listed in stages as torque
figures or angles in degrees.
• Separate procedures and illustrations are used to explain the details of removal, checking, and instal-
lation where necessary (see “5” in the following figure for an example page).
TIP:
For troubleshooting procedures, see Chapter 9, “Troubleshooting”.
4 3 1
5
Impeller housing and impeller duct ASSY
1 Nm (0.1 kgf·m, 0.7 ft·lb) 40 Nm (4.0 kgf·m, 29.5 ft·lb)
4
6 3
3
2 Impeller, drive shaft, and impeller duct

3
Impeller duct ASSY disassembly
1. Remove the impeller “1”.
7 2
12
5
1
1
7 3 4. Remove the ball bearing “1”.
A 1
Drive shaft holder 6 “2”
90890-06520
2 3
7 Driveshaft holder “2”
YB-06201 4
10
11 2. Remove the cap “1”, O-ring “2”, and nut 3
10 “3”.
9
7
7 Nm (0.7 kgf·m, 5.2 ft·lb) 8
2
1 B 1
No. Part name Q’ty Remarks
3
1 Clamp 1
5
2 Spout hose 1
3 Bolt 4 M10 × 125 mm
4 5
4 Bracket 1
5 Nozzle 1
6 Impeller housing 1
7 Dowel pin 4
8 Bolt 4 M6 × 35 mm
A. Worldwide
9 Water inlet cover 1
B. U.S.A. and Canada
10 Gasket 2 Not reusable
11 Water inlet strainer 1 Stopper guide plate “2”
12 Impeller duct ASSY 1 90890-06501
3
Bearing puller assembly “3”
90890-06535
Drive shaft holder 6 “4” Stopper guide stand “4”
90890-06520 90890-06538
Driveshaft holder “4” Slide hammer “5”
6-12 YB-06201 YB-06096
3. Remove the drive shaft “1”. 5. Remove the oil seals “1” and “2”.
Do not press the drive shaft threads

2 directly.
6-14
1-5

Conditions when testing and adjusting

Conditions can affect specifications when checking, measuring and making some adjustments. Service
data in this manual was determined under the following conditions:
• Electrical resistance for components such as pickup coils and sensors was measured at 20 °C (68
°F).
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
API American Petroleum Institute
APS Accelerator Position Sensor
BOW Bow end
BTDC Before Top Dead Center
DOHC Double Overhead Camshaft
ECM Electronic Control Module
ETV Electronic Throttle Valve
EX Exhaust
F Forward
ID Identification
IN Intake
ISC Idle Speed Control
ISO International Organization for Standardization
N Neutral
OBD-M On-Board Diagnostics-Marine system
OTS Off-Throttle Steering
PON Pump Octane Number
PORT Port side
R Reverse
RiDE Reverse with Intuitive Deceleration Electronics
RON Research Octane Number
RPM Revolutions Per Minute
RPS RiDE Position Sensor
SAE Society of Automotive Engineers
SCU Shift Control Unit
SPS Shift Position Sensor
STBD Starboard side
STERN Stern end
TCI Transistor-Controlled Ignition
TDC Top Dead Center
TPS Throttle Position Sensor
1-6

Abbreviation Description
UP Upside
YDIS Yamaha Diagnostic System
1-7

Adhesive, lubricant, sealant, and thread locking agent
Adhesive, lubricant, sealant, and thread locking agent

Symbols
Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points.
Symbol Name Application
YAMALUBE 4W or Yamaha 4-stroke motor oil Lubricant
Water resistant grease

Lubricant
(YAMALUBE MARINE GREASE)
Molybdenum disulfide grease Lubricant
Epnoc grease AP#0 Lubricant
Silicone grease Lubricant
Symbols in an exploded diagram or illustration indicate the type of adhesive, sealant, or thread locking
agent and the application points.
Symbol Name Application
ThreeBond 1207B Sealant
ThreeBond 1280B Sealant
ThreeBond 1322D Thread locking agent
ThreeBond 1360 Thread locking agent
ThreeBond 1530D Adhesive
LOCTITE 242 (blue) Thread locking agent
LOCTITE 271 (red) Thread locking agent
LOCTITE 572 (white) Sealant
LOCTITE 648 (green) Thread locking agent
Silicone sealant Sealant
1-8


Special service tools numbered “YB/YM/YS/YU/YW-*****” are distributed by K & L.
Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division.
Special service tool with part number 90890-06884/LIT-YDIS2-01-KT is distributed by the Marine Ser-
vice Division.
Reference
Tool name/Tool No. Illustration
pages
Oil filter wrench 3-5, 3-5, 5-8,
90890-06830 5-13
Oil filter wrench
YB-06830
Gauge stand 3-12, 5-34,

90890-06725 5-42
Dial gauge needle 3-12, 5-34,

90890-06584 5-42
Dial gauge stand set 3-12, 5-34,

YB-06585 5-42
Dial gauge set 3-12, 5-34,

90890-01252 5-42
Dial indicator gauge 3-12, 5-34,

YU-03097 5-42
Camshaft wrench 3-12, 5-35,

90890-06724 5-38
Camshaft wrench
YW-06724
1-9

Reference
pages
Fuel pressure gauge adapter 4-3
90890-06946
Fuel pressure gauge adapter
YB-06946
Fuel pressure gauge 4-3

90890-06753
Fuel pressure gauge
YU-03153M
Compression gauge 5-1

90890-03160
Compression gauge
YU-33223
YU-33223
Compression gauge extension 5-1

90890-06563
Exhaust pipe wrench 5-17, 5-17

90890-06726
Exhaust pipe wrench
YW-06726
Coupler wrench 5-29, 5-34,

90890-06729 5-40, 5-42,
Coupler wrench 5-58, 5-58,
YW-06729 5-66, 5-66,
6-20, 6-22
1-10

Reference
pages
Leakage tester 5-29
90890-06840
Valve spring compressor 5-47, 5-53

90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attachment 5-47, 5-53

90890-04114
Compressor adapter
YM-04114
Valve guide remover/installer 5-49, 5-50

90890-06801
Valve guide remover
YB-06801
Valve guide installer 5-50

90890-06810
Valve guide installer
YB-06810
Valve guide reamer 5-50

90890-06804
Valve guide reamer
YM-01196
Valve lapper 5-50, 5-53

90890-04101
Valve lapping tool
YM-A8998
1-11

Reference
pages
Valve seat cutter holder 5-51
90890-06812
Valve seat cutter 30° 5-51

90890-06720

90890-06325

90890-06324

90890-06818

90890-06555

90890-06323
Neway valve seat kit 5-51

YB-91044
Crankshaft holder 5-58, 5-59,

90890-06732 5-63, 5-64,
Crankshaft holder 5-64, 5-65,
YW-06562 5-66
1-12

Reference
pages
Shaft holder 5-59, 5-59,
90890-06721 5-63, 5-64,
Shaft holder 5-64, 5-65,
YW-06721 5-65
Drive handle 5-59, 5-59,

90890-06722 5-63, 5-64,
Drive handle 5-65, 5-65
YW-06722
Flywheel puller 5-60

90890-06723
Flywheel puller
YW-06723
Rotor puller 5-60

90890-01080
Stator rotor puller
YM-01080-A
Sheave holder 5-60, 5-62

90890-01701
Primary sheave holder
YS-01880-A
Driver rod LS 5-60, 5-61

90890-06606
Bearing outer race attachment 5-60

90890-06627
Driver handle (small) 5-60

YB-06229
Bearing and seal installer 5-60

YW-06356
1-13

Reference
pages
Ball bearing attachment 5-61
90890-06657
Driver handle (large) 5-61, 5-61,

YB-06071 6-12
Forward gear outer race installer 5-61

YB-41446
Bearing pressure C 5-61

90890-02393
C
Forward bearing race installer 5-61

YB-06258
Piston ring compressor 5-86

90890-05158
Piston ring compressor
YM-08037
Drive shaft holder 6 6-11, 6-11,

90890-06520 6-14, 6-14
Driveshaft holder
YB-06201
Stopper guide plate 6-11, 6-12,

90890-06501 6-20
Bearing puller assembly 6-11, 6-12,

90890-06535 6-20
1-14

Reference
pages
Stopper guide stand 6-11, 6-12,
90890-06538 6-20
Slide hammer 6-11, 6-12,

YB-06096 6-20
Driver rod L3 6-12

90890-06652
Driver rod SL 6-12

90890-06602
Needle bearing attachment 6-12

90890-06609
Driveshaft needle bearing installer and re- 6-12

mover
YB-06194
Oil seal installer attachment 6-13

90890-06733
Oil seal installer attachment 6-13

YW-06628
Bearing attachment 6-13, 6-13,

90890-06728 6-13, 6-21,
Bearing attachment 6-22
YW-06728
1-15

Reference
pages
Shaft holder 6-20, 6-22
90890-06730
Shaft holder
YW-06730
Bearing puller legs 6-20

YB-06523
Needle bearing attachment 6-21, 6-21,

90890-06654 6-21
Needle bearing installer 6-21, 6-21,

YB-06434 6-21
Bearing attachment 6-22, 6-22

90890-06727
Bearing attachment
YW-06727
YDIS2 Hardware Kit 7-9, 9-1

90890-06884
YDIS2 Hardware Kit
LIT-YDIS2-01-KT
Digital circuit tester 7-10

90890-03243
Digital multimeter
YU-34899-A
1-16

Reference
pages
Peak voltage adapter B 7-10
90890-03172
Peak volt adapter
YU-39991
Ignition checker (Spark gap tester) 7-11

90890-06754
Spark checker
YM-34487
Test harness (2 pins) 7-12

90890-06851

90890-06870
Test harness (3 pins)
YB-06870

90890-06850
YW-06850
Vacuum/pressure pump gauge set 7-15, 7-18

90890-06945
Pressure/vacuum tester
YB-35956-B

90890-06877
YB-06877
1-17

Reference
pages
Throttle sensor adjusting lead FWY–3 7-27
90890-06857
YB-06857
1-18

Model feature
Model feature
General feature
The F2W features a hull and deck that are based on those of the F2X and is equipped with an 1812
cm³ engine.
While retaining the stability and comfort of the F2X, the acceleration performance and maximum speed
have been improved by increasing the output of the engine.
The 6EW engine is based on the 6CN engine and the size and weight of the fuse box have been re-
duced.
c
a. Power unit • Self-diagnosis system with YDIS (version

• 4-stroke, L4, DOHC, 16-valve, 1812 cm³ en- 2.20)
gine with electronic fuel injection
• Single throttle body d. Deck and hull
• 4-in-1 exhaust system • V-shaped hull
• Wet sump lubrication • 2 seat types (different shapes according to
the model)
b. Jet pump • Separate front and rear seats
• Stainless steel, 3-blade, ø155 mm, 15.6° • Reboarding step for easier reboarding (VXR)
pitched impeller • Easy handgrip position
• Impeller turning direction: counterclockwise • Large-chine hull
(when viewed from the stern) • NanoXcel hull, NanoXcel deck
• Aluminum jet thrust nozzle
• RiDE system
c. Electrical
• Electronic control throttle valve system
• In-tank fuel pump module
• Multifunction meter
• L-MODE
• OTS
1-19

Model feature
Model equipment comparison table

Model VXS VXR
Total length 3.34 m (131.5 in) 3.35 m (131.9 in)
Width 1220 mm (48.0 in)
Dry weight 347 kg (765 lb) 348 kg (767 lb)
Reboarding step “1”  —
Front seat “2” Normal seat Cruiser seat
: Equipped
—: Not equipped
A. VXS
B. VXR
1-20

Technical tips
Technical tips
Engine control
The ECM controls ignition timing and fuel injection with information received from the sensors and
switches installed on the engine as well as utilizing the base map saved in the ECM.
2 3
5
1
6
13 7
12 8
14
9
11
10
Part name Function

1 TPS Detects the opening angle of the ETV.
2 Cam position sensor Detects the rotational position of the camshaft.
3 Slant detection switch Detects whether the watercraft is capsized.
Properly controls ignition timing, fuel injection timing and vol-
4 ECM ume, opening angle of the ETV, and fail-safe function with in-
formation received from the sensors and switches.
5 Thermo sensor Detects the temperature of the exhaust cooling water.
6 Oil pressure switch Detects the pressure of the engine oil.
7 Thermo switch Detects engine overheating.
Intake air temperature sen-
8 Detects the temperature of the intake air.
sor
9 Intake air pressure sensor Detects the pressure of the intake air.
10 Engine temperature sensor Detects the temperature of the cylinder block.
11 Pickup coil Detects the crankshaft angle.
12 RPS Detects the opening angle of the RiDE lever.
1-21

Technical tips
Part name Function

13 APS Detects the opening angle of the throttle lever.
Detects when the handlebar is turned all the way to the right or
14 Steering sensor
left.
1-22

Technical tips
RiDE system
Unlike previous systems with mechanical shifting and Q.S.T.S., the RiDE motor is driven through elec-
tric signals in order to conduct shifting and trim operations.
With electrical operation, conventional cables are not used. By using the RiDE lever and electric trim
switch unit incorporated into the left handlebar switch, shifting and trim operations are easy to control.
The number of parts has been reduced, and serviceability has improved.
The trim function drives the RiDE motor through the electric trim switch in order to move the nozzle.
The trim position is sent to the ECM in order to display the trim angle on the multifunction meter.
The shift function transfers the RiDE lever opening angle into electric signals and then delivers the sig-
nals to the ECM. The ECM controls the engine based on the RiDE lever signals, shift position, and en-
gine status, and sends a shift request to the RiDE motor.
When changing the shift, the reverse gate operates after the engine speed has dropped and the water
jet stream intensity has been reduced. This reduces the strain on the reverse gate and allows for
smooth shifting.
A 3 1
2
7 6 5 4
B 3 10 9 8
11
7
13
C
12 D
A. Q.S.T.S. models 6. Q.S.T.S. converter
B. RiDE models 7. Jet thrust nozzle
C. Mechanical link 8. RiDE lever
D. Electrical signal 9. ECM
10. SCU
1. Shift lever 11. Shift rod
2. Shift cable 12. Electric trim switch
3. Reverse gate 13. Trim rod
4. Q.S.T.S. selector
5. Q.S.T.S. cable
1-23

Technical tips
RiDE motor
The RiDE lever employs the same part used for the throttle lever that incorporates the APS. An RPS
(RiDE position sensor) is built into the RiDE lever.
The RiDE motor is an assembly part that includes the shift motor and trim motor, a shift position sensor
that detects the position of each motor, the trim position sensor, and a built-in SCU to control each mo-
tor.
This system has sensors, and also has a fail-safe function.
The ECM and SCU use CAN to deliver shift request, shift position, and trim position information.
3. Multifunction meter
5. RiDE motor
7. Shift motor
1. RPS 4. ECM
8. Shift position
sensor
6. SCU
9. Trim motor
2. Electric trim switch

10. Trim position
sensor
Part name Function

1 RPS Detects the RiDE lever angle.
2 Electric trim switch Drives the trim motor.
3 Multifunction meter Displays information on shift position and trim position.
• Controls the engine operation based on signals transmitted
by each sensor and switch, and sends signals to SCU.
4 ECM
• Sends information on shift position and trim position to the
multifunction meter.
An assembly that incorporates SCU, shift motor, SPS, trim mo-
5 RiDE motor
tor, and trim position sensor.
Shift control: Transmits a shift position signal to the ECM and
drives the shift motor based on the shift request from the ECM.
6 SCU
Trim control: Controls the trim motor based on the signal from
the trim switch and sends trim position information to the ECM.
7 Shift motor Switches the reverse gate angle.
Detects the shift position based on the rotation angle of the
8 Shift position sensor
shift motor.
9 Trim motor Switches the angle of jet thrust nozzle.
Detects the trim position based on the rotation angle of the trim
10 Trim position sensor
motor.
1-24

Technical tips
ETV system
The F2W is equipped with the same throttle lever as that of the F2S.
The throttle lever has an APS which senses the degree of throttle opening and converts the status into
electronic signals, delivering the information to the ECM. The ECM controls the ETV based on the input
signals of the APS.
Employing the APS in the throttle lever has eliminated the need for throttle cables, reducing the number
of parts used, thereby improving throttle response and serviceability.
The throttle lever has 2 sensors as per the previous APS, the APS 1 and APS 2, which mutually diag-
nose any failures each system may encounter.
The APS full-close switch detects the fully closed throttle lever position.
A 2
5V
APS 1
b. Ground 3
5V 1
APS 2
b. Ground
4
5
B 6
4
5V
APS 1
b. Ground
5V
APS 2
b. Ground
5V
a. APS full close
b. Ground switch
C
5 D
A. Previous ETV system 6. Electric throttle without wire cable
B. New ETV system
a. APS full-close switch
C. Mechanical link
b. Ground
D. Electrical signal
1. Throttle lever
2. Throttle cable
3. APS
4. ECM
5. ETV
1-25

Technical tips
Shift control
The reverse gate on RiDE models is in the F position when the engine is stopped. When the engine is
started, the reverse gate returns to the N position automatically.
The ECM calculates the throttle lever opening angle and RiDE lever opening angle to control shifting.
Engine speed and reverse gate positions are also controlled. This control function automatically adjusts
the engine speed, even while the throttle lever is being held in position, preventing sudden acceleration
or sudden shift changes. The shift control is also equipped with a learning function that automatically
corrects the shift position. The learning function corrects the shift position through being connected to
the YDIS from an early stage, moving the reverse gate from the F position to the R position in order to
find an optimum shift position.
Condition Lever Reverse gate
Engine stopped
Engine starting
Engine starting → Trolling
Engine running
Deceleration while engine

running
1-26

Technical tips
Condition Lever Reverse gate
Trolling → Neutral
Neutral → Reverse
Engine stopped
1-27

Technical tips
Engine control system

Item Condition Action Remarks
Cancel:
• Stop the engine and wait
for 30 seconds or more.
• Engine temperature • Engine temperature is
rises rapidly in a below 140 °C (248 °F)
• Opening angle of the ETV
short time. with the thermo switch
Overheat is regulated.
• Thermo switch is on. off.
warning con- • Maximum engine speed is
• Exhaust cooling wa- • Exhaust cooling water
trol limited to approximately
ter temperature ex- temperature is below 70
3000–3300 r/min.
ceeds 75 °C (167 °C (158 °F) with the ETV
°F). fully closed.
If the engine is stopped
during overheat warning
control, it can be restarted.
Cancel:
Control is activated
• Stop the engine and wait
when all of the follow-
for 30 seconds or more.
ing conditions are • Opening angle of the ETV
• Engine is restarted and
Oil pressure present: is regulated.
the oil pressure switch is
warning con- • Oil pressure switch is • Maximum engine speed is
off.
trol on. limited to approximately
If the engine is stopped
• ETV is open. 3000–3300 r/min.
during oil pressure warn-
• Engine speed ex-
ing control, it can be re-
ceeds 4500 r/min.
started.
when the following
conditions are main- • Opening angle of the ETV
tained for 10 seconds: is regulated.
Cancel:
• Cam position sensor • Maximum engine speed is
Engine is stopped.
failed. limited to approximately
• Engine speed ex- 3000–3300 r/min.
Cam position ceeds approximate-
sensor failure ly 1000 r/min.
control Control is activated
when all of the follow-
ing conditions are If the engine is stopped
Ignition and fuel injection
present: during cam position sensor
are cut to all cylinders and
• Cam position sensor failure control, it can be re-
the engine is stopped.
failed. started.
ceeds 5000 r/min.
1-28

Technical tips

is fixed to the default
opening angle.
ETV failed, or open or
ETV failure • Maximum engine speed is
short circuit is detect- —
control limited to approximately
ed in ETV circuit.
3000 r/min.
• Ignition timing is con-
trolled.
Battery dis- Battery lead is discon- Control is performed using
connection nected during normal the same actions as the —
warning operation. ETV failure control.
Throttle lever is in the
Idle speed Engine speed is limited to
fully closed (idle) posi- —
control 1200–1400 r/min.
tion.
Ignition is controlled.
Condi-
Action
tion
Normal None
Ignition is cut off
Level 1
Over revolu- Engine speed exceeds to 1 cylinder.
—
tion control 7800 r/min. Ignition is cut off
Level 2
to 2 cylinders.
Ignition is cut off
Level 3
to 3 cylinders.
Ignition is cut off
Level 4
to all cylinders.
when all of the follow- Cancel:
ing conditions are Engine is stopped.
Ignition and fuel injection
Slant detec- present: (The check engine warning
are cut to all cylinders and
tion control • Slant detection indicator does not come on
the engine is stopped.
switch is on. and the buzzer does not
• Engine speed is sound.)
3000 r/min or less.
is regulated.
• Ignition timing is con-
trolled.
L-MODE con- Cancel:
L-MODE is activated. • Maximum engine speed is
trol L-MODE is deactivated.
limited to approximately
75% of the maximum en-
gine speed in the normal
mode.
1-29

Technical tips

Off-throttle Control is activated Engine speed is increased
steering when all of the follow- to approximately 3500 r/min
(OTS) control ing conditions are for a few seconds.
present:
ceeds 6000 r/min for
a few seconds or —
more.
• Throttle lever is at
the fully closed posi-
tion.
• Steering sensor is
ON.
1-30

Technical tips
Deck and hull

The F2W uses the same type of hull and deck that the F2X uses. However, the seats are different from
the seats of the F2X. The VXR uses a cruiser seat for the front seat in order to increase the comfort of
the operator.
a. The front and rear seats are separate to make them easy to remove and install.
b. The passenger seating surfaces are wide for passenger comfort.
c. The height of the footwell floor makes it easy for the riders to grip the watercraft using their knees.
d. The hull width provides a feeling of stability.
e. The short strakes provide good turning performance.
f. The shape and position of the handgrip make it easy for the passenger to grasp the handgrip.
g. The reboarding step makes reboarding easy.
h. The handlebar width makes it easy to operate the watercraft. In addition, the same handlebar grips
as those for the F2S were adopted.
c a f
b
e
1-31

Technical tips
Lubrication system
The engine features a wet-sump lubrication system. The oil pan carries out the scavenging function and
the engine uses a feed oil pump ASSY.
The blowby gas from the cylinder head cover is sent directly to the oil separator tank.
12
3
13
11
A
10 6
9 8 7
B
1. Intake camshaft 11. Oil cooler ASSY
2. Exhaust camshaft 12. Oil filter
3. Cylinder block 13. Oil pump drive gear
4. Crankshaft
A. To air intake pipe
5. Oil separator tank
B. Oil flow
6. Oil pan
7. Oil strainer
8. Oil pipe
9. Oil pump
10. Relief valve
1-32

Technical tips
Hose routing
E
B
C
F
G
H
I
J
A. From flushing hose connector
B. From transom plate
C. To cooling water pilot outlet
D. To drain joint (transom plate)
E. To drain joint
F. For water draining when engine is
stopped
G. Cooling water flow
H. Blowby gas flow
I. Bilge water flow
J. Fuel flow
1-33

Technical tips
Cooling water flow

D
E
A
B
F G
A. From flushing hose connector
B. From transom plate
C. To cooling water pilot outlet
D. To drain joint
E. To exhaust valve
F. For water draining when engine is
stopped
G. Cooling water flow
1-34

Technical tips
— MEMO —
1-35

Specification
Model data .......................................................................... 2-1
Fuel system technical data ............................................... 2-3

Fuel system ................................................................................ 2-3
Power unit technical data .................................................. 2-4

Power unit .................................................................................. 2-4
2
Cylinder head ASSY................................................................... 2-4
Crankcase ASSY........................................................................ 2-5
Jet pump unit technical data............................................. 2-7

Jet pump unit.............................................................................. 2-7
Electrical technical data .................................................... 2-8

Ignition system ........................................................................... 2-8
Charging system ........................................................................ 2-8
Control system ........................................................................... 2-8
Fuel system .............................................................................. 2-10
Starting system......................................................................... 2-10
Meter system............................................................................ 2-11
Specified tightening torque............................................. 2-12
Torque wrench reading (setting value) .......................... 2-12
General tightening torque ............................................... 2-12
Cable and hose routing ................................................... 2-13

Starboard bow view.................................................................. 2-13
Top view ................................................................................... 2-14
Port view................................................................................... 2-16
Coupler layout .......................................................................... 2-17

Model data
Model data
Model code
Hull F2W
Engine 6EW
Jet pump 6EW
Dimensions and weight
Length VX1800-P 3340 mm (131.5 in)
VX1800A-P 3350 mm (131.9 in)
Width 1220 mm (48.0 in)
Height 1190 mm (46.9 in)
Dry weight VX1800-P 347 kg (765 lb)
VX1800A-P 348 kg (767 lb)
Maximum people on board 3 person
Maximum load capacity 240 kg (530 lb)
Performance
Maximum output 132.4 kW at 7600 r/min
Full throttle operating range 7600 r/min
Trolling speed 1300 ± 100 r/min
Maximum fuel consumption 48.7 L/h (12.9 US gal/h, 10.7 Imp.gal/h)
Cruising range at full throttle 1.44 hour
Engine
Engine type Liquid cooled 4-stroke, DOHC
Number of cylinders 4
Engine displacement 1812 cm³
Bore × stroke 86.0 × 78.0 mm (3.39 × 3.07 in)
Compression ratio 11.0 : 1
Exhaust system Wet exhaust
Lubrication system Wet sump
Cooling system Water
Starting system Electric
Camshaft drive system Chain drive
Timing chain tensioning system Automatic
Ignition system T.C.I.
Ignition timing BTDC25.0
Spark plug (NGK) LFR6A
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
Firing order 1–3–4–2
Oil filter type Cartridge type
Oil pump type Trochoid
Drive unit
Propulsion system Jet pump
Jet pump type Axial flow, single stage
Impeller rotation Counterclockwise
Transmission Direct drive from engine
Jet thrust nozzle angle 24.0+24.0°
Trim adjusting system Electrical 5 position
Jet thrust nozzle trim angle -6, -3, 0, 3, 6°
2-1

Model data
Shift operation F–N–R
Reverse system Reverse gate
Fuel and oil
Recommended fuel Regular unleaded gasoline
Minimum octane rating (PON) 86
Minimum octane rating (RON) 90
Fuel tank total capacity 70 L (18.5 US gal, 15.4 Imp.gal)
Recommended engine oil YAMALUBE 4W or 4-stroke motor oil
Recommended engine oil grade API API SE, SF, SG, SH, SJ, SL
Recommended engine oil type SAE SAE 10W-30, 10W-40, 20W-40, 20W-50
Engine oil total quantity 5.3 L (5.60 US qt, 4.66 Imp.qt)
Engine oil quantity without oil filter
replacement 3.5 L (3.70 US qt, 3.08 Imp.qt)
Engine oil quantity with oil filter replacement 3.6 L (3.81 US qt, 3.17 Imp.qt)
Battery requirement
Type Fluid
Battery capacity 12 V, 19 Ah
Specific gravity 1.265
2-2

Fuel system technical data
Fuel system technical data

Fuel system
Throttle body
Manufacturer Mikuni
Type/quantity F1-IM60–11/1
ID mark 6BH 00
Fuel pump
Pump type Electrical
Fuel pressure 345.0–355.0 kPa (3.45–3.55 kgf/cm², 50.0–51.5
psi)
2-3

Power unit technical data

Power unit
Compression pressure
Minimum 780 kPa (7.8 kgf/cm², 113.1 psi)
Oil cooler
Water passage holding pressure 200 kPa (2.0 kgf/cm², 29.0 psi)
Thermostat
Valve opening temperature 58 °C (136 °F)
Fully open temperature 70 °C (158 °F)
Fully open stroke 4.3 mm (0.17 in)
Cylinder head ASSY

Cylinder head
Warpage limit 0.100 mm (0.0039 in)
Camshaft cap inside diameter 25.000–25.021 mm (0.9843–0.9851 in)
Camshaft
Cam lobe height-intake 41.330–41.430 mm (1.6272–1.6311 in)
Limit 41.230 mm (1.6232 in)
Cam lobe height-exhaust 41.220–41.320 mm (1.6228–1.6268 in)
Limit 41.120 mm (1.6189 in)
Runout 0.015 mm (0.0006 in)
Limit 0.05 mm (0.0020 in)
Journal diameter 24.960–24.980 mm (0.9827–0.9835 in)
Journal oil clearance 0.020–0.061 mm (0.0008–0.0024 in)
Limit 0.08 mm (0.0032 in)
Valve clearance
Valve clearance-intake (cold) 0.14–0.23 mm (0.0055–0.0091 in)
Valve clearance-exhaust (cold) 0.28–0.37 mm (0.0110–0.0146 in)
Valve
Head diameter-intake 33.900–34.100 mm (1.3346–1.3425 in)
Head diameter-exhaust 28.900–29.100 mm (1.1378–1.1457 in)
Face width-intake 2.260–2.830 mm (0.0890–0.1114 in)
Face width-exhaust 2.260–2.830 mm (0.0890–0.1114 in)
Seat contact width-intake 1.400–1.600 mm (0.0551–0.0630 in)
Limit 2.100 mm (0.0827 in)
Seat contact width-exhaust 1.500–1.700 mm (0.0591–0.0669 in)
Limit 2.200 mm (0.0866 in)
Margin thickness-intake 0.800–1.200 mm (0.0315–0.0472 in)
Margin thickness-exhaust 0.800–1.200 mm (0.0315–0.0472 in)
Valve stem
Diameter-intake 5.477–5.492 mm (0.2156–0.2162 in)
Limit 5.447 mm (0.2144 in)
Diameter-exhaust 5.464–5.479 mm (0.2151–0.2157 in)
Limit 5.434 mm (0.2139 in)
Runout limit 0.010 mm (0.0004 in)
2-4

Valve guide
Inside diameter-intake 5.504–5.522 mm (0.2167–0.2174 in)
Inside diameter-exhaust 5.504–5.522 mm (0.2167–0.2174 in)
Stem to guide clearance-intake 0.012–0.045 mm (0.0005–0.0018 in)
Limit 0.080 mm (0.0032 in)
Stem to guide clearance-exhaust 0.025–0.058 mm (0.0010–0.0023 in)
Limit 0.100 mm (0.0039 in)
Valve guide installation height 12.3–12.7 mm (0.48–0.50 in)
Valve spring
Free length-intake 45.58 mm (1.79 in)
Free length-exhaust 45.58 mm (1.79 in)
Limit 43.30 mm (1.70 in)
Installed length-intake (valve closed) 34.0 mm (1.34 in)
Installed length-exhaust (valve closed) 34.0 mm (1.34 in)
Tilt limit-intake 2.5°/2.0 mm
Tilt limit-exhaust 2.5°/2.0 mm
Crankcase ASSY
Cylinder
Bore size 86.000–86.015 mm (3.3858–3.3864 in)
Limit 86.100 mm (3.3898 in)
Taper limit 0.080 mm (0.0032 in)
Out of round limit 0.050 mm (0.0020 in)
Piston
Diameter 85.915–85.930 mm (3.3825–3.3831 in)
Measuring point 9.5 mm (0.37 in)
Piston clearance 0.080–0.090 mm (0.0032–0.0035 in)
Limit 0.200 mm (0.0079 in)
Ring groove (Top ring) 1.210–1.230 mm (0.0476–0.0484 in)
Ring groove (2nd ring) 1.210–1.230 mm (0.0476–0.0484 in)
Ring groove (Oil ring) 2.510–2.530 mm (0.0988–0.0996 in)
Pin boss bore diameter 22.004–22.015 mm (0.8663–0.8667 in)
Limit 22.045 mm (0.8679 in)
Piston pin
Outside diameter 21.991–22.000 mm (0.8658–0.8661 in)
Limit 21.981 mm (0.8654 in)
Piston ring
End gap measuring point 6.0 mm (0.24 in)
Top ring
Type Barrel
Height (B) 1.170–1.190 mm (0.0461–0.0469 in)
Width (T) 2.850–3.050 mm (0.1122–0.1201 in)
End gap (installed) 0.300–0.450 mm (0.0118–0.0177 in)
Limit 0.700 mm (0.0276 in)
Side clearance 0.020–0.060 mm (0.0008–0.0024 in)
Limit 0.110 mm (0.0043 in)
2-5

2nd ring
Type Taper
Height (B) 1.170–1.190 mm (0.0461–0.0469 in)
Width (T) 2.600–2.800 mm (0.1024–0.1102 in)
Limit 0.850 mm (0.0335 in)
Limit 0.120 mm (0.0047 in)
Oil ring
Height (B) 2.370–2.470 mm (0.0933–0.0972 in)
Width (T) 2.500 mm (0.0984 in)
Connecting rod
Small end inside diameter 22.015–22.028 mm (0.8667–0.8672 in)
Bearing color code 1.Blue 2.Black 3.Brown 4.Green
Big end side clearance 0.160–0.262 mm (0.0063–0.0103 in)
Limit 0.50 mm (0.0197 in)
Big end width 26.788–26.840 mm (1.0546–1.0567 in)
Crankshaft pin width 27.000–27.050 mm (1.0630–1.0650 in)
Crankshaft
Journal diameter 39.976–40.000 mm (1.5739–1.5748 in)
Pin diameter 41.976–42.000 mm (1.6526–1.6535 in)
Journal oil clearance 0.024–0.053 mm (0.0009–0.0021 in)
Limit 0.10 mm (0.0039 in)
Pin oil clearance 0.020–0.056 mm (0.0008–0.0022 in)
Limit 0.09 mm (0.0035 in)
Bearing color code 1.Brown 2.Black 3.Blue 4.Green 5.Yellow
2-6

Jet pump unit technical data
Jet pump unit technical data

Jet pump unit
Impeller housing
Inside diameter 155.35–155.45 mm (6.116–6.120 in)
Limit 156.45 mm (6.1594 in)
Impeller clearance 0.350–0.450 mm (0.0138–0.0177 in)
Limit 0.60 mm (0.0236 in)
Impeller
Material Stainless steel
Diameter 155 mm (6.10 in)
Number of impeller blade 3
Pitch angle 15.6°
Drive shaft
Nozzle
Diameter 86.6–87.2 mm (3.41–3.43 in)
2-7

Electrical technical data

Ignition system
ECM unit
Output peak voltage at cranking (loaded)
(reference data) 2.5 V
Output peak voltage at 2000 r/min (loaded)
Pickup coil
Output peak voltage at cranking (unloaded)
Output peak voltage at cranking (loaded)
Resistance 459.0–561.0 Ω
Ignition coil
Input voltage 12 V (battery voltage)
Charging system
Stator coil
Output peak voltage at cranking (unloaded)
Output peak voltage at 2000 r/min (unloaded)
Output peak voltage at 3500 r/min (unloaded)
Rectifier/regulator
(reference data) 13 V
(reference data) 13 V
Control system
Oil pressure switch
Input voltage 11–12 V
Continuity pressure 128–166 kPa (1.3–1.7 kgf/cm², 18.6–24.1 psi)
Thermo switch
Continuity temperature 94–100 °C (201–212 °F)
No continuity temperature 80–94 °C (176–201 °F)
2-8

Thermo sensor
Input voltage 4.75–5.25 V
Resistance at 0°C (32°F) 24.0–37.1 kΩ
Engine temperature sensor
Intake air temperature sensor
Intake air pressure sensor
TPS
TPS 1 output voltage with the throttle lever fully
closed 0.45–0.55 V
TPS 2 output voltage with the throttle lever fully
open 4.60–4.70 V
TPS output voltage difference 1.9–2.1 V
Throttle valve opening angle with the throttle
lever fully closed 2–8°
Throttle valve opening angle with the throttle
lever fully open More than 70°
APS
APS 1 output voltage with the throttle lever
fully closed 0.68–0.74 V
fully closed 0.68–0.74 V
fully open 3.95–4.15 V
fully open 3.95–4.15 V
APS output voltage difference 0.1 V or less
APS 1 input voltage 4.75–5.25 V
APS 2 input voltage 4.75–5.25 V
APS full close switch input voltage 4.75–5.25 V
RPS
RPS 1 output voltage with the RiDE lever fully
closed 0.68–0.74 V
closed 0.68–0.74 V
open 3.95–4.15 V
open 3.95–4.15 V
2-9

RPS output voltage difference 0.1 V or less
RPS 1 Input voltage 4.75–5.25 V
RPS 2 Input voltage 4.75–5.25 V
ETV relay
Cam position sensor
Output voltage (position a, c) More than 4.8 V
Output voltage (position b) Less than 0.8 V
Slant detection switch
Steering sensor
ECM unit
Fuel system
Fuel injector
Fuel pump module
Fuel sender
Lower position resistance 133.5–136.5 Ω
Upper position resistance 5.0–7.0 Ω
Starting system
Fuse
SCU 50 A
Battery 12 V, 30 A
Main relay 12 V, 20 A
Fuel pump relay 12 V, 10 A
ETV relay 12 V, 10 A
Remote control receiver 3A
Starter motor
Type Constant mesh
Output 0.60 kW
Cranking time limit 30.00 sec
Commutator diameter 28.0 mm (1.10 in)
Limit 27.0 mm (1.06 in)
Commutator undercut 0.7 mm (0.03 in)
Brush length 12.5 mm (0.49 in)
Wear limit 5.0 mm (0.20 in)
2-10

Meter system
Remote control transmitter
Battery CR2016
Rating 3V
Remote control receiver
Output voltage 11–12 V
Multifunction meter unit
Buzzer
Speed sensor
Output voltage (dependant on the paddle
wheel position) Less than 400 mV/More than 11.6 V
2-11

Specified tightening torque
Specified tightening torque General tightening torque

Specified tightening torques are provided for This chart indicates the tightening torques for
specific nuts, bolts, and screws. Tightening standard fasteners with a standard ISO thread
torque specifications are provided in the ex- pitch.
ploded diagrams and in the related detailed in-
Width General torque speci-
structions. When tightening these fasteners, Thread
across fications
follow the tightening torque specifications indi- size (B)
cated throughout the manual to meet the de- flats (A) Nm kgf·m ft·lb
sign aims of the watercraft. 8 mm M5 5 0.5 3.7
10 mm M6 8 0.8 5.9
Torque wrench reading (setting
12 mm M8 18 1.8 13.3
value)
14 mm M10 36 3.6 26.6
The correct setting value of the torque wrench
varies depending on its length. 17 mm M12 43 4.3 31.7
When tightening bolts, nuts, or parts using the
SST as an extension to the torque wrench, use
the following calculation formula to obtain the
correct setting value.
When tightening bolts, nuts, or parts using

an extension to the torque wrench, do not
set the torque wrench to the specified tight-
ening torque. If an extension is attached to
the torque wrench, the actual tightening
torque will be greater than the setting value
on the torque wrench.
Am Bm
Torque wrench setting value

= T ÷ (A m + B m) × B m
T Specified tightening torque (Nm)
Am SST length (m)
Bm Torque wrench length (m)
2-12

Cable and hose routing

Starboard bow view
3 4
2
1 5
2 3 A
17
4
A 5
6 7 8
16 9
14,15
13
12
11
10
1. RiDE motor lead 10. Remote control receiver antenna

2. APS lead 11. Remote control receiver lead
3. RPS lead 12. Fuel tank breather hose (water separator
4. Trim switch lead to ventilation socket)
5. Handlebar switch lead (left) 13. Steering cable
6. Fuel tank breather hose (fuel tank to 14. Wire harness
water separator) 15. Speed sensor lead
7. Buzzer lead 16. Negative battery lead
8. Steering sensor lead 17. Positive battery lead
9. Cooling water pilot outlet hose
2-13

Top view
A
17
1
A A 11
3 16
2 16 17
15 B B C C
F 14 3 A-A
13 D
D
E E
F
12 4
13
5
E E 4 14 12
11
G-G B-B
5
10 E E
6
7
6
G G
H-H C-C
J E
C E
7
J
I I 3
10
10
I-I D-D
H H 8
B
10
H H
7
9 6
J-J E-E
2-14

1. Remote control receiver antenna

2. Remote control receiver lead
3. Fuel tank breather hose (water separator
to ventilation socket)
4. APS lead
5. Steering cable
6. Wire harness
7. Speed sensor lead
8. Negative battery lead
9. Positive battery lead
10. RiDE motor lead
11. Fuel tank breather hose (fuel tank to
water separator)
12. RPS lead
13. Handlebar switch lead (left)
14. Trim switch lead
15. Cooling water pilot outlet hose
16. Buzzer lead
17. Steering sensor lead
A. Route the remote control receiver

antenna under the ventilation hose.
B. Fasten the RiDE motor lead at the yellow
tape using the hook.
C. Fasten the RiDE motor lead at the yellow
tape using the plastic tie.
2-15

Port view
4 10
9
12 4 11
13
A-A
C-C D
2
1 3
4 5 6 7 8
B D
A A C
C
13 12 11 10 9
1. Remote control receiver antenna 11. Fuel tank breather hose (water separator
2. Steering sensor lead to ventilation socket)
3. Buzzer lead 12. Cooling water pilot outlet hose
4. Fuel tank breather hose (fuel tank to 13. Remote control receiver lead
water separator)
5. Steering cable
6. Negative battery lead
7. Positive battery lead
8. RiDE motor lead
9. Speed sensor lead
10. Wire harness
2-16

Coupler layout
11 12 A 1 2 3
10 6 5 4
9 7
8
1. Trim switch coupler (black)

2. APS coupler (black)
3. RPS coupler (gray)
4. Steering sensor coupler (black)
5. Buzzer coupler (black)
6. Buzzer/LED coupler (white)
7. Communication coupler (gray)
8. Speed sensor coupler (white)
9. Fuel sender coupler (black)
10. Entry box coupler (black)
11. Engine stop switch coupler (black)
12. Engine start switch coupler (white)
A. Fasten the wire harness using the plastic

tie, making sure to align the tie with the
tape on the harness.
2-17

Maintenance
Maintenance interval chart ................................................ 3-1
Periodic service.................................................................. 3-3

Fuel line check ........................................................................... 3-3
Fuel filler cap and water separator check................................... 3-3
Fuel tank check .......................................................................... 3-3
Water inlet strainer check........................................................... 3-3
Cooling water hose check .......................................................... 3-3
Engine oil level check................................................................. 3-4
Engine oil replacement............................................................... 3-4
Oil filter replacement .................................................................. 3-5
Intermediate housing lubrication ................................................ 3-5
Spark plug check........................................................................ 3-5
3
Battery and battery lead check................................................... 3-6
Steering master check................................................................ 3-7
Steering cable check .................................................................. 3-7
Trim rod check............................................................................ 3-8
Shift rod and reverse gate check................................................ 3-8
Air intake hose check ................................................................. 3-9
Throttle valve lubrication ............................................................ 3-9
Exhaust system check.............................................................. 3-10
Breather hose check ................................................................ 3-10
Impeller check .......................................................................... 3-10
Jet thrust nozzle check............................................................. 3-10
Jet vacuum bilge draining system check.................................. 3-10
Drain plug check....................................................................... 3-11
Anode check............................................................................. 3-11
Valve clearance measurement................................................. 3-11
Rubber coupling check............................................................. 3-13
Engine mount check................................................................. 3-13

Maintenance interval chart

The following chart should be considered strictly as a guide to general maintenance intervals.
Depending on the operating conditions, the maintenance intervals should be changed.
Perform the pre-operation checks and post-operation checks before performing periodic maintenance.
Initial Thereafter every
See
Item Operation 50 hours or 100 hours or 200 hours or
10 hours page
12 months *1 12 months *1 24 months *1
Check fuel hoses and
Fuel line  3-3
clamps
Check O-rings for
Fuel filler cap/Wa-
cracks and deforma-  3-3
ter separator
tion
Check installation
Fuel tank  3-3
and straps
Water inlet strain- Check for clogs and
 3-3
er damage
Check for damage
Cooling water hos-
and leakage, and  3-3
es
check clamps
Engine oil Replace   3-4
Oil filter Replace  3-5
Intermediate
Lubricate  3-5
housing
Spark plugs Check   3-5
Check specific gravi-
ty of electrolyte, ter-
Battery  3-6
minals, bands, and
breather hose
Battery leads Check terminals  3-6
Check operation and
Steering master   3-7
for looseness
Check exterior and
Steering cable connections, and lu-  3-7
bricate
Check exterior and
Electric trim rod connections, and lu-  3-8
bricate
Check exterior and
Shift rod and re-
connections, and lu-  3-8
verse gate
bricate
Check for damage
Air filter element  4-4
and dirt
Check for damage,
Air intake hoses  3-9
and check clamps
Lubricate throttle
Throttle body  3-9
valves
3-1

Initial Thereafter every

See
Item Operation 50 hours or 100 hours or 200 hours or
10 hours page
12 months *1 12 months *1 24 months *1
Check for exhaust
Exhaust system leakage, and check  3-10
hoses and clamps
Check breather hose
Breather hose  3-10
and clamps
Check for bends,
Impeller damage, and foreign  3-10
material
Check movement,
Jet thrust nozzle  3-10
and lubricate
Check hoses for
clogs and damage,
Jet vacuum bilge  3-10
check clamps, and
clean bilge strainer
Stern drain plugs Check O-rings  3-11
Check for corrosion,
Anode  *2 3-11
and clean
Valve clearance Check and adjust  *2 3-11
Check for cracks, in-
Rubber coupling dentations, loose-  3-13
ness, and noise
Check for damage
Engine mount  3-13
and peeling
*1: Whichever comes first.

*2: Check every 200 hours.
3-2

Periodic service
Periodic service
TIP:
Fuel line check To drain water from the water separator “1”,
1. Remove the service lid. loosen the drain plug “3”.
2. Check the fuel hoses and hose connec-
tions for fuel leakage. 1
3. Check the fuel hoses. Replace if cracked
or damaged. 2
3
4. Check the fuel hose routing and the
clamps. See “Air filter case and fuel hose”
(4-1) and “Fuel tank and fuel pump mod-
ule” (4-9).
5. Supply power to the ECM and check that Fuel tank check
the fuel pump module functions. 1. Check that the fuel tank is secured using
the straps. Replace the straps if they are
6. Check the fuel hoses and hose connec-
loose.
tions for fuel leakage.
2. Check the straps. Replace if cracked or
7. Install the service lid.
damaged.
Fuel filler cap and water separator
Water inlet strainer check
check
1. Remove the water inlet strainer “1”. See
1. Remove the fuel filler cap and check the
“Impeller housing and impeller duct ASSY”
packing. Replace if cracked or damaged. (6-9).
2. Turn the fuel filler cap “1” clockwise “a”,
2. Check the water inlet strainer “1”. Clean if
and then check that a click sound is heard contaminated. Replace if cracked or dam-
when the fuel filler cap is fully tightened.
aged.
Replace the fuel filler cap if there is no click
sound. 1 1
a
1
3. Install a new O-ring and the water inlet
strainer. See “Impeller housing and impel-
3. Check the water separator “1”. Drain the
ler duct ASSY” (6-9).
water if water has accumulated.
Cooling water hose check
4. Check the O-ring “2” of the drain plug “3”.
Replace the O-ring if cracked or damaged. 1. Check the cooling water hoses and hose
connections for cooling water leakage.
See “Cable and hose routing” (2-13).
3-3

Periodic service
2. Check the cooling water hoses. Replace if 5. If the engine oil is above the maximum lev-
cracked or damaged. el mark, extract oil using an oil changer to
lower it to the correct level.
3. Check the cooling water hose routing and
the clamps. See “Cable and hose routing” 6. Install the oil filler cap “1”.
(2-13).
1
Engine oil level check
• When starting the engine to check the oil

level on land, make sure to connect a gar-
den hose to the watercraft for proper wa-
ter supply.
• Make sure that debris or water does not
enter the oil filler hole. Recommended engine oil
YAMALUBE 4W or 4-stroke motor oil
1. Place the watercraft in a horizontal posi-
tion. Recommended engine oil grade API
API SE, SF, SG, SH, SJ, SL
TIP: Recommended engine oil type SAE
If the engine was running, allow the engine oil SAE 10W-30, 10W-40, 20W-40, 20W-
to settle by waiting 5 minutes or more before 50
checking the oil level.
Engine oil replacement
2. Remove the oil level gauge “1”, wipe the
gauge clean, and then insert the oil level Be careful when handling the engine oil to
gauge “1” into the oil level pipe completely. avoid burns. The engine oil is hot immedi-
ately after the engine is turned off.
3. Remove the oil level gauge “1” again to
check that the oil level is between the min-
imum level mark “a” and the maximum lev-
el mark “b” on the gauge. • When starting the engine to check the oil
level on land, make sure to connect a gar-
den hose to the watercraft for proper wa-
ter supply.
b • Make sure that debris or water does not
enter the oil filler hole.
a
1. Place the watercraft in a horizontal posi-
tion.
1 2. Start the engine and warm it up for 5 min-

utes or more at engine idle speed.
4. If the engine oil is below the minimum level
mark, remove the oil filler cap “1”, and then 3. Stop the engine.
add sufficient oil of the recommended type
to raise it to the correct level. 4. Remove the oil filler cap and oil level
gauge.
5. Extract the oil using the oil changer “1”.
3-4

Periodic service
Oil filter wrench “2”

90890-06830
YB-06830
4. Install the oil filter “1”, and then tighten it to

the specified torque.
1
TIP:
Make sure to clean up any oil spills.
6. Add the recommended engine oil up to the
specified level through the oil filler hole.
Recommended engine oil
YAMALUBE 4W or 4-stroke motor oil
Recommended engine oil grade API 2 1
API SE, SF, SG, SH, SJ, SL
Recommended engine oil type SAE
SAE 10W-30, 10W-40, 20W-40, 20W-
50
Engine oil quantity without oil filter re-
placement Oil filter wrench “2”
3.5 L (3.70 US qt, 3.08 Imp.qt) 90890-06830
Engine oil quantity with oil filter replace- Oil filter wrench “2”
ment YB-06830
3.6 L (3.81 US qt, 3.17 Imp.qt)
Oil filter “1”
7. Install the oil filler cap and oil level gauge. 18 Nm (1.8 kgf·m, 13.3 ft·lb)
8. Check the engine oil level. See “Engine oil 5. Check the engine oil level. See “Engine oil
level check” (3-4). level check” (3-4).
Oil filter replacement Intermediate housing lubrication

1. Extract the engine oil. See“Engine oil re- 1. Lubricate the intermediate housing
placement” (3-4). through the grease nipple “1”.
2. Place a rag under the oil filter “1”.
3. Remove the oil filter “1”.

1
2
Recommended lubricant
YAMALUBE MARINE GREASE
Spark plug check

1. Remove the spark plugs.
3-5

Periodic service
Battery and battery lead check

TIP:
Be careful not to get water or any other foreign
substances in the spark plug holes. Battery electrolyte is poisonous and dan-
gerous, causing severe burns, etc. Electro-
2. Clean the electrodes “a”. lyte contains sulfuric acid. Avoid contact
with skin, eyes or clothing.
3. Check the electrodes “a”. Replace the Antidotes
spark plug if damaged or worn. External: Flush with water.
Internal: Drink large quantities of water or
a milk. Follow with milk of magnesia, beaten
egg or vegetable oil. Call physician immedi-
ately.
Eyes: Flush with water for 15 minutes and
get prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes, etc., well away. If
using or charging the battery in an en-
closed space, make sure that it is well ven-
4. Measure the spark plug gap “a”. Replace if tilated. Always shield your eyes when
out of specification. working near batteries.
KEEP OUT OF THE REACH OF CHILDREN.
a
• Be careful not to place the battery on its
side.
• Make sure to remove the battery from the
battery compartment when adding bat-
tery electrolyte or charging the battery.
• When checking the battery, make sure the
breather hose is connected to the battery
Spark plug (NGK) and not obstructed.
LFR6A
Spark plug gap 1. Remove the battery.
0.8–0.9 mm (0.031–0.035 in)
5. Install the spark plugs, and then tighten When removing the battery, disconnect the
them to the specified torque. negative battery lead first.
TIP:
2. Check the battery electrolyte level. If the
Before installing a spark plug, clean the gasket
level is at or below the minimum level mark
surface and spark plug surface.
“a”, add distilled water until the level is be-
tween the maximum level mark “b” and the
Spark plug minimum level mark “a”.
25 Nm (2.5 kgf·m, 18.4 ft·lb)
3-6

Periodic service
b 2
a
1
4
3
1
3. Check the specific gravity of the electro- Steering master check

lyte. Charge the battery if below specifica- 1. Turn the handlebar lock to lock and push it
tion. back and forth.
Specific gravity
1.265
4. Check the battery leads and terminals for

corrosion. Clean using a file or sandpaper
if corroded.
5. Install the battery, and then install the

bands.
6. Connect the battery breather hose “1”, and

then fasten it using the clamp “2”.
Make sure that the battery breather hose is

connected properly and is not obstructed.
7. Connect the positive battery lead “3”, and

then connect the negative battery lead “4”.
2. Check for excessive play of the handlebar.

Connect the positive battery lead to the bat-
Check the bushings, bolts, and nuts if
tery terminal first.
there is excessive play. See “Steering pad
and handlebar cover” (8-1).
TIP:
Apply water resistant grease to the terminals to Steering cable check
minimize corrosion. 1. Remove the rear and front seats.
2. Check the steering cable. Replace if

cracked or damaged.
3. Check the steering cable routing.
4. Lubricate the steering cable.
3-7

Periodic service
5. Disconnect the joint and apply a small Recommended lubricant

amount of grease. YAMALUBE MARINE GREASE
3. Connect the trim rod joints to the ball joints.
4. Check the trim rod for rod end disconnec-

tion and check the locknut for looseness.
5. Rise the reverse gate “1”, and then con-

nect the shift rod joint “2”.
1
2
6. Check the steering cable for cable end dis-

connection and check the locknut for
looseness.
7. Install the front and rear seats.

Shift rod and reverse gate check
Trim rod check 1. Check the reverse gate. Replace if
1. Disconnect the shift rod joint “1”, and then cracked or damaged.
lower the reverse gate “2”.
2. Check that the reverse gate “1” is in con-
2 tact with the reverse gate stopper “a” at the
1
F position.
2. Disconnect the trim rod joints and apply a a

small amount of grease.
3. Connect the garden hose adapter to the

flushing hose connector.
3-8

Periodic service
4. Start the engine. Immediately after the en-
gine has started, supply water.
Do not run the engine over 4000 r/min on

land. Also, do not run the engine for more
than 15 seconds without supplying water,
otherwise the engine could overheat.
5. While squeezing the RiDE lever fully, posi-

tion the reverse gate “1” so that it contacts Recommended lubricant
the R position stopper “a”. YAMALUBE MARINE GREASE
10. Check the shift rod for rod end disconnec-

tion and check the locknut for looseness.
11. Connect the shift rod joint to the shift arm.
12. Rise the reverse gate “1”, and then con-

nect the shift rod joint “2”.
a 1
1 2
6. Stop supplying water, and then stop the

engine.
7. If the reverse gate does not contact the re-

verse gate stopper at either of the F posi-
tion or R position, connect the YDIS to
conduct “Initial learning”. See the YDIS In-
struction Manual.
Air intake hose check
8. Disconnect the shift rod joint “1”, and then 1. Check the air intake hoses and hose con-
lower the reverse gate “2”. nections for intake air leakage.
2 2. Check the air intake hoses. Replace if
1
cracked or damaged.
3. Check the air intake hose routing and the

clamps.
Throttle valve lubrication

1. Loosen the air intake pipe clamp “1”, and
then disconnect the air intake pipe “2”.
9. Disconnect the shift rod joint and apply a

small amount of grease.
3-9

Periodic service
3. Check the breather hose routing and the
clamps. See “Cable and hose routing”
2 1 (2-13).
Impeller check
Make sure to remove the battery before

checking the jet pump unit.
1. Check the impeller from the jet intake side.

2. Spray a rust inhibitor into the throttle valve
Clean if there is foreign material.
opening “a”.
a 2. Check the impeller. Replace if bent or

damaged. See “Jet pump unit removal”
(6-3).
Jet thrust nozzle check

1. Disconnect the trim rod and steering cable.
2. Remove the jet thrust nozzle and nozzle

ring.
Recommended lubricant 3. Apply grease to the nozzle pivot.

Rust inhibitor
3. Connect the air intake pipe, and then tight-

en the air intake pipe clamp.
Air intake pipe clamp
3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
Exhaust system check

1. Check the exhaust hoses and hose con-
nections for exhaust or cooling water leak-
age. See “Exhaust system installation”
(8-24).
4. Check that the jet thrust nozzle moves
2. Check the exhaust hoses. Replace if
smoothly.
cracked or damaged.
5. Install the nozzle ring and jet thrust nozzle.
3. Check the exhaust hose routing and the
clamps. 6. Connect the trim rod and steering cable.
Breather hose check Jet vacuum bilge draining system

1. Check the breather hoses and hose con- check
nections for blowby gas or oil leakage. See
1. Check the bilge strainer “1”. Clean if
“Cable and hose routing” (2-13).
clogged or dirty.
2. Check the breather hoses. Replace if
cracked or damaged.
3-10

Periodic service
10. Check the bilge hose routing and the
TIP: clamps.
Place your hand under the bilge strainer to
check for clog or dirt. Drain plug check
1. Check the O-ring “1” of drain plug “2”. Re-
place if cracked or damaged.
1
2
2
1
2. Check the bilge hoses. Replace if cracked
or damaged.
Anode check
3. Disconnect the bilge hose “1”. 1. Remove the cover and anode.
4. Run water into the bilge hose “1” and 2. Check the anode “1”. Clean if there is oil or
check that the hose is not clogged. water stain.
5. Run water into the hose joint “2” and check

1
that the joint and hose are not clogged.
6. Disconnect the bilge hose “3”.
7. Check the hole “a” in the hose joint. Clean

if clogged.
8. Check the check valve “b” of the hose joint.

Replace the hose joint if it is open or dam-
aged.
b a
b
A
3. Check the anode for erosion. Replace if it
A is half the original size.
2 3 2 Valve clearance measurement

Measure the valve clearance when the engine
is cold.
1. Remove the ignition coils, spark plugs, and
1 cylinder head cover.
1
2. Install the special service tools “1”, “2”, and
“3” into spark plug hole #1.
9. Connect the bilge hoses and hose joint.
3-11

Periodic service
3
b
1
2 a
Gauge stand “1”

#1 #2 #3 #4
90890-06725
Dial gauge needle “2”
90890-06584
Dial gauge stand set “2” Camshaft wrench “1”
YB-06585 90890-06724
Dial gauge set “3” Camshaft wrench “1”
90890-01252 YW-06724
Dial indicator gauge “3”
YU-03097 4. Measure the intake and exhaust valve
clearances of the specified cylinders.
3. Position piston #1 at TDC by turning the
exhaust camshaft sprocket clockwise. IN EX
TIP:
Check that the punch marks “a” on the cam-
shafts are aligned with the marks “b” on the
camshaft caps.
1 Valve clearance-intake (cold)

0.14–0.23 mm (0.0055–0.0091 in)
Valve clearance-exhaust (cold)
0.28–0.37 mm (0.0110–0.0146 in)
#1 #2 #3 #4
IN  —  —
EX   — —
: Specified cylinder
—: Not applicable
5. Install the special service tools into spark

plug hole #4.

exhaust camshaft sprocket 180° clock-
wise.
3-12

Periodic service
7. Measure the intake and exhaust valve
#1 #2 #3 #4
IN —  — 
EX — —  
—: Not applicable
8. Adjust the valve clearance if out of specifi-

cation. See “Valve clearance adjustment”
(5-40).
9. Install the cylinder head cover, spark

plugs, and ignition coils. See “Cylinder
head cover” (5-31).
Rubber coupling check

1. Remove the coupling cover “1”.
2. Apply force in the directions of the arrow to

check that there is no rattling. If there is rat-
tling, remove the engine unit and check the
rubber coupling. See “Engine unit remov-
al” (5-7).
Engine mount check

1. Check the engine mount. Replace if there
is damage or peeling.
3-13

Fuel system
Air filter case and fuel hose .............................................. 4-1

Fuel hose disconnection............................................................. 4-3
Fuel pressure measurement ...................................................... 4-3
Fuel hose disassembly............................................................... 4-4
Air filter element check ............................................................... 4-4
Fuel hose assembly ................................................................... 4-4
ETV and fuel injector ......................................................... 4-6

ETV check .................................................................................. 4-7
Fuel injector check ..................................................................... 4-7
Fuel rail and injector installation ................................................. 4-7
Fuel tank and fuel pump module ...................................... 4-9

Fuel tank removal..................................................................... 4-11
Fuel pump module removal...................................................... 4-12
Fuel sender removal................................................................. 4-12
Fuel pump module check ......................................................... 4-12
4
Check valve check ................................................................... 4-12
Fuel filler cap check.................................................................. 4-13
Fuel sender installation ............................................................ 4-13
Fuel pump module installation.................................................. 4-13
Fuel tank installation................................................................. 4-14

Air filter case and fuel hose

22 25 13 Nm (1.3 kgf·m, 9.6 ft·Ib)
20
21
14
15
16
17
18
24
23
10
13
17 Nm (1.7 kgf·m, 12.5 ft·Ib) 1
19
11
3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
12
11
7
4 6
9
5
3 6
2 7
8

1 Plastic tie 1
2 Bolt 2 M6 × 12 mm
3 Stay 1
4 Grommet 1
5 Fuel hose ASSY 1
6 Clamp 4 Not reusable
7 Quick connector 2
8 Corrugated tube 1
9 Fuel hose 1
10 Clamp 1
11 Clamp 2
12 Air intake pipe 1
13 Connection 1
14 Bolt 4 M8 × 35 mm
15 Air filter case 1
16 Hook 8
4-1

22 25 13 Nm (1.3 kgf·m, 9.6 ft·Ib)

20
21
14
15
16
17
18
24
23
10
13
17 Nm (1.7 kgf·m, 12.5 ft·Ib) 1
19
11
3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
12
11
7
4 6
9
5
3 6
2 7
8

17 Screw 3 M6 × 15 mm
18 Air filter element 1
19 Drain tube 1
20 Collar 4
21 Grommet 4
22 Plastic tie 1
23 Nut 4
24 Washer 4
25 Bracket 1
4-2

Fuel hose disconnection

1
Before checking the fuel system, remove
the battery, and then remove the fuel filler
cap to reduce any pressure inside the fuel
tank.
1. Spread apart the ends of the retainer “a”,

and then pull the retainer up.
Fuel pressure measurement

a
1. Disconnect the quick connector from the
fuel rail.
2. Install the special service tools “1” and “2”.

A
2. Disconnect the quick connector “1”.
Make sure to disconnect the quick connec-

tor slowly. Otherwise, pressurized fuel 1
could spray out.
B
TIP:
Make sure to clean up any fuel spills.
2
1 1
A. Worldwide
Fuel pressure gauge adapter “1”

90890-06946
3. Cover the quick connector, fuel rail, and Fuel pressure gauge adapter “1”
fuel pipe using plastic bags “1” to protect YB-06946
them from dirt. Fuel pressure gauge “2”
90890-06753
Fuel pressure gauge “2”
YU-03153M
3. Start the engine and warm it up for 5 min-

utes or more at engine idle speed.
4-3

4. Measure the fuel pressure. Replace the Fuel hose assembly
fuel pump module if out of specification.
Fuel pressure
Do not reuse a clamp, always replace it with
345.0–355.0 kPa (3.45–3.55 kgf/cm²,
a new one. Otherwise, fuel could leak.
50.0–51.5 psi)
1. Install new clamps “1” and the quick con-
Fuel hose disassembly nector “2” onto the fuel hose “3”.
1. Remove the clamps “1” and quick connec-
tor “2”. TIP:
Make sure to face the locking slider “a” on each
quick connector in the same direction.
When cutting each clamp, position the tool.
1
2
Air filter element check

a a
Do not start the engine with the air filter el-
ement removed. Otherwise, the engine
could be damaged.
1. Remove the air filter case cover and air fil-

ter element.
2. Crimp the clamps “1”.
2. Check the air filter element. Replace if
damaged or dirty.
TIP:
• Make sure to align the projection “a” on the
quick connector with the crimped section of
the clamp.
• Position the crimped sections of the clamps
180° away from each other.
4-4

a
1 1
b
c
Distance “b”
17 mm (0.67 in)
Distance “c”
34.5 mm (1.36 in)
Distance “d”
1 mm (0.04 in)
4-5

ETV and fuel injector

11 13 Nm (1.3 kgf·m, 9.6 ft·Ib)
10
LT
12
242
14
E
13
1
15
9
A
8 1
3
7
LT
242 9
6 2
4
5
LT
242
A
24 Nm (2.4 kgf·m, 17.7 ft·Ib)

1 Plastic tie 5
2 Bolt 4 M8 × 58 mm
3 ETV 1
5 Bolt 4 M8 × 25 mm
6 Joint 1
8 Ribbon 1
9 Holder 1
10 Wire harness 1
11 Bolt 3 M8 × 30 mm
12 Fuel rail 1
13 Fuel injector 4
14 O-ring 4 Not reusable
15 Seal 4 Not reusable
4-6

ETV check 1
• Do not disassemble the ETV.

• Do not loosen the throttle stop screw nut
or turn the throttle stop screw.
• Do not loosen or remove the throttle valve
shaft screws.
b
a 2. While turning the fuel injectors “1” slowly to
c the left and right, install them to the fuel rail
“2”.
Make sure to apply a thin coat of engine oil

to the O-rings before installing the fuel in-
jectors to the fuel rail. Otherwise, the O-
rings could twist and break, causing fuel
a. Throttle stop screw nut leakage.
b. Throttle stop screw
c. Throttle valve shaft screw
1. Turn the throttle valve manually and check
that it moves smoothly.
Fuel injector check 1

1. Check the fuel injector filter “a”. Clean us- 2
ing kerosene or gasoline if clogged or con-
taminated.
a
3. Install new seals “1” and the fuel rail “2”,
and then tighten the fuel rail bolts “3” to the
specified torque.
Do not reuse a seal, always replace it with a

new one.
2. Measure the fuel injector resistance. See

“Fuel injector check” (7-29).
Fuel rail and injector installation

1. Install new O-rings “1” onto the fuel injec-
tors, and then apply a thin coat of engine
oil to the O-rings “1”.
4-7

3
LT
242
3
Fuel rail bolt “3”

13 Nm (1.3 kgf·m, 9.6 ft·lb)
4. Route the wire harness, and then connect

the cam position sensor coupler “a”, fuel
injector couplers “b”, and ignition coil cou-
plers “c”.
5. Fasten the wire harness using the plastic

ties “1”.
1 1
c
c
b
a
4-8

Fuel tank and fuel pump module

12 3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
6 Nm (0.6 kgf·m, 4.4 ft·Ib) 7 Nm (0.7 kgf·m, 5.2 ft·Ib)
23
19 19 19 24
10 19
11
20
7
20 22
2
8 28 20
3
1 2
6 21
1 25
4 27
26
5
17
18
4 15
16
3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
17
13 16
14

1 Plastic tie 3
2 Fuel tank breather hose 2
3 Check valve 1
4 Clamp 2
5 Fuel filler hose 1
6 Nut 1
7 Fuel filler neck 1
8 Packing 1 Not reusable
9 Fuel filler cap 1
11 Screw 1 #6 × 1/2”
12 Strap 2
13 Fuel tank 1
14 Pad 1 Not reusable
4-9

12 3.5 Nm (0.35 kgf·m, 2.58 ft·lb)

23
19 19 19 24
10 19
11
20
7
20 22
2
8 28 20
3
1 2
6 21
1 25
4 27
26
5
17
18
4 15
16
3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
17
13 16
14

19 Rivet 4
20 Hook 4
21 Fuel sender coupler 1
22 Fuel pump module coupler 1
23 Nut 9
24 Retainer 1
25 Fuel pump module 1
26 Stopper 1
27 Fuel sender 1
4-10

Fuel tank removal
Before checking the fuel system, remove 1

the battery, and then remove the fuel filler
cap to reduce any pressure inside the fuel
tank. 2
1. Extract the fuel using a siphon pump “1”.

1
TIP:
Use a commercially available siphon pump “1” 7. Remove the nut “1”, and then remove the
to extract the fuel. fuel filler neck “2”, packing “3”, and fuel fill-
er cap “4”.
1
4
2. Remove the air filter case and air filter 8. Remove the straps “1”, and then remove
case bracket. See “Air filter case and fuel the fuel tank “2”.
hose” (4-1).
TIP:
3. Remove the engine unit. See “Engine unit Pull the straps “1” in the directions of the ar-
removal” (5-7). rows to unhook the metal loops “a” on the end
of the straps.
4. Remove the plastic ties “1”, fuel tank
breather hoses “2”, and check valve “3”.
1
5. Disconnect the fuel sender coupler “a” and
fuel pump module coupler “b”. 1
a
2
a
3
a b
1 2 2
6. Remove the clamps “1” and fuel filler hose

“2”.
4-11

Fuel pump module removal

1
1. Remove the fuel pump module “1”. b
a
When removing the fuel pump module,
make sure that the rubber caps do not
come off.
TIP:
Remove the fuel pump module “1” at an angle
so that the float “a” does not catch on the fuel Fuel pump module check
tank.
Do not disassemble the fuel pump module.

1
1. Check the fuel pump module “1”. Replace
if cracked or damaged.
b
a
b. Rubber cap 1
Fuel sender removal

1. Disconnect the fuel sender coupler “a”.
2. Check the fuel pump filter “a”. Clean with
2. Squeeze the hooks “b” on the stopper “1”, kerosene or gasoline if clogged or contam-
and then slide the stopper in direction “c” to inated.
remove it.
1 a
1
c
a
b
Check valve check

3. Push the tabs “a” on the fuel sender “1”, 1. Blow into the end “a” of the check valve,
and then slide the sender in direction “b” to and make sure that airflow from the end “b”
remove it. is unrestricted. Replace if the air flow is re-
stricted.
2. Blow into the end “b” of the check valve,

and make sure that airflow from the end “a”
is restricted. Replace if the air flow is unre-
stricted.
4-12

2. Install the stopper “1”, and then connect
A a B b
the fuel sender coupler “a”.
TIP:
Make sure that the hooks “b” on the stopper “1”
are securely hooked onto the fuel pump mod-
ule.
b a 1
1
A. Upright
B. Inverted
Fuel filler cap check a

1. Install the fuel filler cap “1” onto the fuel fill- b
er neck “2”, and then hold the fuel filler
neck “2”.
2. Turn the fuel filler cap “1” clockwise “a” and Fuel pump module installation
check that it clicks when tightened com- 1. Install a new packing and the fuel pump
pletely. Replace if it does not click. module “1”.
a When installing the fuel pump module,

1 make sure that the rubber caps do not
come off.
TIP:
Make sure to insert the float “a” into the fuel
2
tank.
Fuel sender installation

1. Install the fuel sender “1”. 1
TIP:
Make sure that the tabs “a” on the fuel sender a b
“1” are securely seated into the slots “b” in the
fuel pump module.
b. Rubber cap
a
2. Install the retainer “1”, and then tighten the
nuts to the specified torques in 2 stages
b b and in the order [1], [2], and so on.
4-13

Fuel tank installation

1
1. Install the fuel tank “1”, and then fasten the
[3]
[2] fuel tank using the straps “2”.
[5]
[7] TIP:
[9] • Install the straps “2” so that the rubber band
[8] portions “a” of the straps are positioned on
top.
[4] [1] [6]
• Make sure that the metal loops “b” on the end
of the straps “2” are hooked securely onto the
Fuel pump module nut holders on the hull.
1st: 3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
2nd: 7 Nm (0.7 kgf·m, 5.2 ft·lb) a
2
3. Apply a thin coat of engine oil to the con- a
tact surfaces of the fuel pipe “a”. 2
b
4. Connect the quick connector “1” onto the
fuel pipe “a”. b
b
5. Push down on the retainer “b” until it clicks.
b
6. Connect the fuel sender coupler “c” and 1
fuel pump module coupler “d”.
TIP:
• If the quick connector “1” is not installed com-
pletely onto the fuel pipe “a”, the retainer “b”
cannot be pushed down.
• Check that the quick connector “1” is correct-
ly installed by making sure there is a small
amount of free play when the quick connec- 2. Install a new packing “1”, fuel filler neck
tor is pulled and pushed. If there is no free “2”, and the fuel filler cap “3”.
play in the quick connector “1”, disconnect
the fuel hose and check the O-rings for dam- 3. Tighten the nut “4” to the specified torque.
age and proper installation.
TIP:
Align the projection “a” on the fuel filler neck “2”
with the holes “b” in the packing “3” and deck.
d
b
a
a
c 3
2
1
1
7. Install the service lid. See “Front hood”
(8-6). b
4
4-14

Fuel filler neck nut “4” 1

6 Nm (0.6 kgf·m, 4.4 ft·lb)
2
a b
4. Install the fuel filler hose “1”, and then tight-
en the clamps “2” to the specified torque. c
5. Check that the distance “a” is within speci- 3 1

fication.
TIP:
Align the arrow mark “b” on the fuel filler hose 9. Install the engine unit. See “Engine unit in-
“1” with the projection “c” on the fuel filler neck. stallation” (5-10).
10. Install the air filter case bracket and air fil-
ter case. See “Air filter case and fuel hose”
(4-1).
a c
b 2
2 1
1 2
Distance “a”
30–40 mm (1.2–1.6 in)
Fuel filler hose clamp “2”

3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
6. Connect the fuel sender coupler “a” and

fuel pump module coupler “b”.
7. Install the fuel tank breather hoses “1” and

check valve “2”.
8. Fasten the fuel tank breather hoses “1” us-

ing new plastic ties “3”.
TIP:
Point the arrow mark “c” toward the fuel tank.
4-15

Power unit
Engine unit (check and adjustment)................................. 5-1

Compression pressure check..................................................... 5-1
Engine unit.......................................................................... 5-2
Exhaust manifold ............................................................... 5-3
Engine unit and coupling cover........................................ 5-5
Engine mount ..................................................................... 5-6

Engine unit removal.................................................................... 5-7
Engine mount and spacer check .............................................. 5-10
Engine unit installation ............................................................. 5-10
Muffler ............................................................................... 5-16

Exhaust pipe disassembly........................................................ 5-17
Exhaust pipe assembly ............................................................ 5-17
5
Wire harness..................................................................... 5-18
Electrical box .................................................................... 5-19

Starter motor and wire harness removal .................................. 5-21
Thermostat check..................................................................... 5-21
Wire harness and starter motor installation.............................. 5-22
Intake manifold ................................................................. 5-24

Oil level pipe installation........................................................... 5-26
Intake manifold installation ....................................................... 5-26
Oil cooler, oil pump, and drive gear ............................... 5-27

Oil pump and oil pump drive gear removal............................... 5-29
Oil cooler check........................................................................ 5-29
Oil pump check......................................................................... 5-29
Oil pump drive gear and oil pump installation .......................... 5-29

Power unit
Cylinder head cover ......................................................... 5-31
Camshaft ........................................................................... 5-32

Camshaft removal .................................................................... 5-34
Camshaft sprocket removal...................................................... 5-35
Camshaft check........................................................................ 5-35
Camshaft journal oil clearance check....................................... 5-36
Timing chain tensioner check................................................... 5-37
Camshaft sprocket installation ................................................. 5-37
Camshaft installation ................................................................ 5-38
Valve clearance adjustment ..................................................... 5-40
Valve pad selection table ......................................................... 5-43
Cylinder head ................................................................... 5-45
Valve and valve spring .................................................... 5-46

Cylinder head disassembly ...................................................... 5-47
Cylinder head check................................................................. 5-47
Valve spring check ................................................................... 5-47
Valve check .............................................................................. 5-48
Valve guide check .................................................................... 5-49
Valve guide removal................................................................. 5-49
Valve guide installation............................................................. 5-49
Valve seat check ...................................................................... 5-50
Valve seat refacing................................................................... 5-51
Cylinder head assembly ........................................................... 5-53
Cylinder head installation ......................................................... 5-54
Generator cover ASSY and flywheel magneto .............. 5-55
Generator cover ............................................................... 5-57

Drive coupling removal............................................................. 5-58
Flywheel magneto removal ...................................................... 5-58
Generator cover ASSY disassembly ........................................ 5-60
Starter clutch operation check.................................................. 5-60
Generator cover ASSY assembly............................................. 5-61
Flywheel magneto assembly .................................................... 5-62
Flywheel magneto installation .................................................. 5-62
Drive coupling installation......................................................... 5-65

Power unit
Cylinder block and electrical part................................... 5-67
Oil separator tank and oil pan......................................... 5-69

Anode check............................................................................. 5-71
Oil pan assembly...................................................................... 5-71
Oil separator tank cover installation ......................................... 5-71
Crankcase, connecting rod, and piston ......................... 5-73

Crankcase disassembly ........................................................... 5-75
Connecting rod and piston removal.......................................... 5-75
Crankcase check...................................................................... 5-75
Cylinder block check ................................................................ 5-76
Piston check ............................................................................. 5-76
Piston clearance check ............................................................ 5-76
Piston ring check ...................................................................... 5-76
Piston pin check ....................................................................... 5-78
Connecting rod check............................................................... 5-78
Crankshaft check...................................................................... 5-78
Crankshaft pin oil clearance check........................................... 5-79
Connecting rod big end side clearance check.......................... 5-80
Connecting rod bearing selection............................................. 5-81
Crankshaft journal oil clearance check..................................... 5-81
Crankshaft bearing selection.................................................... 5-83
5
Connecting rod and piston installation ..................................... 5-84
Crankcase assembly ................................................................ 5-86

Engine unit (check and adjustment)
Engine unit (check and 8. Measure the compression pressure for all
adjustment) cylinders according to steps 6 and 7.
Compression pressure check TIP:

Make sure that the battery voltage is more than Measuring conditions: Ambient temperature
12 V. 20 °C (68 °F), with spark plugs removed from
all cylinders. The figures are for reference only.
When starting the engine to measure the

Compression pressure
compression pressure on land, make sure
Minimum
to connect a garden hose to the watercraft
780 kPa (7.8 kgf/cm², 113.1 psi)
for proper water supply.
1. Place the watercraft in a horizontal posi- 9. If the compression pressure is below spec-
tion. ification, squirt a few drops of engine oil
into the cylinder and measure again.
2. Start the engine and warm it up for 5 min- Compression pressure (with engine oil add-
utes or more at engine idle speed. ed into the cylinder)
3. Stop the engine. Reading Check
Higher than without Piston ring and pis-
4. Remove the ignition coils and spark plugs. engine oil ton
5. Disconnect the fuel injector couplers. Valve clearance,
Same as without en- valve, valve seat,
TIP: gine oil cylinder head, and
Be careful not to get water or any other foreign cylinder head gasket
substances in the spark plug holes.
10. Install the spark plugs, and then tighten
them to the specified torque.
6. Install the special service tools “1” and “2”.
Spark plug
25 Nm (2.5 kgf·m, 18.4 ft·lb)
1
2 11. Install the ignition coils.
12. Connect the fuel injector couplers.
Compression gauge “1”

90890-03160
Compression gauge “1”
YU-33223
Compression gauge extension “2”
90890-06563
7. Crank the engine until the reading on the

compression gauge stabilizes.
5-1

Engine unit
Engine unit
1
5 Nm (0.5 kgf·m, 3.7 ft·Ib)
2
1
3
8
6 6
6
5
10
6
5
7
6
4

1 Screw 2 M6 × 12 mm
2 Grommet 2
3 Engine cover 1
4 Clamp 1
5 Antenna holder 3
6 Plastic tie 7
7 Clamp 1
8 Clamp 1
9 Plastic tie 1
10 RiDE motor coupler 2
5-2

Exhaust manifold
Exhaust manifold
26 Nm (2.6 kgf·m, 19.2 ft·Ib)

13 Nm (1.3 kgf·m, 9.6 ft·Ib)
10
1 23 Nm (2.3 kgf·m, 17.0 ft·lb) 8
7 7
2 42 Nm (4.2 kgf·m, 31.0 ft·lb) LT
17 13 572
12 9
2 11 7
4
13
6
14 7
LT
3 12 572
16 11
15
6
7
24 14
LT
13 Nm (1.3 kgf·m, 9.6 ft·Ib)
LT
572
2.5 Nm (0.25 kgf·m, 1.84 ft·lb)
242 25
1 23 Nm (2.3 kgf·m, 17.0 ft·lb)
5 23 2 42 Nm (4.2 kgf·m, 31.0 ft·lb)
19 LT
242
23
22 26
LT
1 242
18 20
18 Nm (1.8 kgf·m, 13.3 ft·Ib) LT
242
1 20 Nm (2.0 kgf·m, 14.8 ft·lb) 7 1 20 Nm (2.0 kgf·m, 14.8 ft·lb)
3 35 Nm (3.5 kgf·m, 25.8 ft·lb) 3 35 Nm (3.5 kgf·m, 25.8 ft·lb)

1 Oil filter 1
2 Clamp 1
3 Clamp 1
4 Breather hose 1
5 Plastic tie 1
6 Plastic tie 2
7 Clamp 6
8 Cooling water hose 1
10 Bolt 2 M8 × 35 mm
11 Collar 2
12 Grommet 2
13 Bolt 4 M6 × 35 mm
14 Bolt 2 M6 × 25 mm
15 Rectifier/regulator 1
5-3

Exhaust manifold
26 Nm (2.6 kgf·m, 19.2 ft·Ib)

13 Nm (1.3 kgf·m, 9.6 ft·Ib)
10
1 23 Nm (2.3 kgf·m, 17.0 ft·lb) 8
7 7
2 42 Nm (4.2 kgf·m, 31.0 ft·lb) LT
17 13 572
12 9
2 11 7
4
13
6
14 7
LT
3 12 572
16 11
15
6
7
24 14
LT
13 Nm (1.3 kgf·m, 9.6 ft·Ib)
LT
572
2.5 Nm (0.25 kgf·m, 1.84 ft·lb)
242 25
1 23 Nm (2.3 kgf·m, 17.0 ft·lb)
5 23 2 42 Nm (4.2 kgf·m, 31.0 ft·lb)
19 LT
242
23
22 26
LT
1 242
18 20
18 Nm (1.8 kgf·m, 13.3 ft·Ib) LT
242
3 35 Nm (3.5 kgf·m, 25.8 ft·lb) 3 35 Nm (3.5 kgf·m, 25.8 ft·lb)

17 Cover 1
18 Clamp 1
19 Bolt 1 M10 × 50 mm
20 Bolt 3 M8 × 120 mm
21 Bolt 8 M8 × 70 mm
23 Dowel 2
24 Bolt 1 M8 × 47 mm
25 Stay 1
26 Clamp 1
5-4

Engine unit and coupling cover
Engine unit and coupling cover
17 Nm (1.7 kgf·m, 12.5 ft·Ib)
1
5
2
6
3
1 1
5 17 Nm (1.7 kgf·m, 12.5 ft·Ib)
6
5

1 Bolt 4 M8 × 28 mm
2 Bolt 1 M6 × 25 mm
3 Collar 1
4 Coupling cover 1
5 Bolt 4 M8 × 37 mm
6 Shim * As required
5-5

Engine mount
Engine mount
BOW
2 2
3 3
1 1
5.5 Nm (0.55 kgf·m, 4.06 ft·lb)
2 2
1 1
LT
3 572 17 Nm (1.7 kgf·m, 12.5 ft·Ib)

3

1 Bolt 8 M8 × 35 mm
2 Engine mount 4
3 Liner 4
4 Bolt 2 M6 × 21 mm
5 Spacer 1
6 Bolt 2 M6 × 18 mm
7 Spacer 1
5-6

Engine mount
Engine unit removal 7. Remove the plastic tie “2”, and then dis-
connect the quick connector “3” from the
fuel rail. See “Fuel hose disconnection”
Before removing the engine, make sure to (4-3).
take adequate measures to protect the
deck opening from damage.
1 3
1. Disconnect the negative battery lead, and 2
then disconnect the positive battery lead.
2. Extract the engine oil. See “Engine oil re-

placement” (3-4).
3. Remove the service lid “1”.
8. Remove the breather hose “1”, air intake

pipe “2”, air filter case cover “3”, air filter,
1 and air filter case “4”.
4
3
2
1
4. Remove the deck beam “1”.
1
9. Remove the antenna holders “1”.
10. Disconnect the remote control receiver

coupler “a”.
11. Remove the wire harness from the plastic

tie “2”.
5. Remove the engine cover “1”. 1
1
1
a
2
12. Disconnect the sensor and switch cou-

plers “a”.
6. Remove the oil level gauge “1”.
ties “1”.
5-7

Engine mount
1 18. Remove the plastic tie “2”, and then dis-

connect the RiDE motor couplers “a” and
“b”.
b 2
1
1
a
a
14. Disconnect the fuel pump module coupler
“a”.
19. Place a rag under the oil filter “1”, and then
remove the oil filter “1”.
TIP:
Make sure to clean up any oil spills.
a

ties “1”. 2
1
1
1
1
1
90890-06830
YB-06830
20. Remove the plastic tie “1”, and then dis-

16. Disconnect the cooling water hose “1” from connect the thermo sensor coupler “a”.
the oil cooler.
1 a
21. Disconnect the cooling water hoses “1”,

17. Disconnect the cooling water hose “1” from “2”, and “3”.
the thermostat housing.
22. Remove the rectifier/regulator “4”.
5-8

Engine mount
27. Remove the electrical box “1”.
1
4
2
3
1
23. Disconnect the cooling water hoses “1”

and “2”. 28. Remove the coupling cover “1”.
24. Remove the stay “3”. 1
1
2
3
29. Loosen the engine mounting bolts “1”.
25. Loosen the clamp “1”. 30. Lift the engine unit slightly, remove the
shims “2”, and then lower the unit.
1 31. Remove the engine mounting bolts “1”.
TIP:
Write down the position of each removed shim
“2” so that it can be installed in its original posi-
tion.
1
26. Remove the muffler “1”.
TIP: 2
When removing the muffler “1”, move it forward
and separate it from the water lock.
1 1
5-9

Engine mount
32. Suspend the engine unit using all 3 engine
hangers, and then separate the unit from TIP:
the engine mounts and move it forward to • Write down the position of each engine
disconnect the coupling. mount so that it can be installed in its original
position.
• When replacing the engine mounts, make
sure to check the coupling clearance.
Engine unit installation
When installing the engine unit, take care to

avoid causing damage to the hull liner and
deck opening.
33. Lift the engine unit slightly, and then lower
the front of the unit. Repeat this step until 1. Suspend the engine unit using all 3 engine
the engine unit can be removed from the hangers.
engine compartment.
2. Lower the front of the engine unit.
When removing the engine unit, take care 3. Lower the engine unit into the engine com-
to avoid causing damage to the hull liner partment vertically.
and deck opening.
4. Lift the front of the engine unit slightly, and

then lower the unit. Repeat this step until
34. Lift the engine unit out vertically. the drive and driven couplings are aligned.
Engine mount and spacer check 5. Move the engine unit rearward to connect
1. Check the engine mounts and spacers. the driven coupling “1”, and then lower the
Replace if cracked or damaged. unit onto the engine mounts.
5-10

Engine mount
TIP:
Do not install the rubber coupling until the cou- a
pling clearance adjustment has been made.
Clearance “a”
Less than 1 mm (0.039 in)
(without rubber coupling)
Clearance “b”
2–4 mm (0.079–0.157 in)
1
Available shim thicknesses
0.10, 0.30, 0.50, 1.00, 2.00 mm
9. Lift the engine unit slightly, remove the

shims, and then lower the engine unit.
10. Remove the engine mounting bolts.

6. Temporarily install the engine mounting
bolts “1”. 11. Separate the engine unit from the engine
mounts and move it forward to disconnect
7. Lift the engine unit slightly, install the the coupling.
shims “2”, and then lower the unit.
12. Install the rubber coupling “1”.
TIP:
Install the shims “2” in their original positions.
2
1
13. Install the shims, and then adjust the posi-

1 tion of the engine unit so that the coupling
clearances “a” and “b” are within specifica-
2
tion.
8. Measure the coupling clearances “a” and

“b”. If the clearances are out of specifica-
tion, add or remove shims so that the
clearances are within specification.
5-11

Engine mount
1
a 2
2
2
2
b
Clearance “a” Electrical box bolt “2”

Less than 0.5 mm (0.020 in) 17 Nm (1.7 kgf·m, 12.5 ft·lb)
(with rubber coupling)
Clearance “b” 17. Install the muffler “1” into the water lock,
2–4 mm (0.079–0.157 in) and then tighten the exhaust manifold
bolts “2” and “3” to the specified torques in
14. Tighten the engine mounting bolts “1” to 3 stages and in the order [1], [2], and so
the specified torque, and then recheck the on.
coupling clearances.
3 1
1
[9] [6] [2] [3] [7] [10]
[5]
3
[8]
2 [4] 3
[1] [11]
2
3 2
1
Exhaust manifold bolt “2” and “3”

Engine mounting bolt “1” 1st: 20 Nm (2.0 kgf·m, 14.8 ft·lb)
17 Nm (1.7 kgf·m, 12.5 ft·lb) 2nd: 20 Nm (2.0 kgf·m, 14.8 ft·lb)
3rd: 35 Nm (3.5 kgf·m, 25.8 ft·lb)
15. Install the coupling cover “1”.
18. Tighten the clamp “1”, to the specified
torque.
TIP:
Make sure that the pipe on the end of the muf-
fler is installed securely into the water lock.
1
1
16. Install the electrical box “1”, and then tight-

en the electrical box bolts “2” to the speci-
fied torque.
5-12

Engine mount
Clamp “1” 1 a
2.5 Nm (0.25 kgf·m, 1.84 ft·lb)
19. Install the stay “1”, and then tighten the

stay bolts “2” and “3” to the specified
torques in 2 stages.
20. Connect the cooling water hoses “4” and

“5”, and then fasten them using the clamps
“6” and “7”.
25. Install the oil filter “1”, and then tighten it to
6 7
2 4 the specified torque.
5
2 3
1 2
1
Stay bolt “2” and “3”

1st: 23 Nm (2.3 kgf·m, 17.0 ft·lb)
2nd: 42 Nm (4.2 kgf·m, 31.0 ft·lb) Oil filter wrench “2”
90890-06830
21. Install the rectifier/regulator “1”, and then Oil filter wrench “2”
tighten the rectifier/regulator bolts “2” to YB-06830
Oil filter “1”
22. Connect the cooling water hoses “3”, “4”,
18 Nm (1.8 kgf·m, 13.3 ft·lb)
and “5”, and then fasten them using the
clamps “6”, “7”, and “8”. 26. Connect the RiDE motor couplers “a” and
3 “b”, and then fasten the RiDE motor lead
1 6 using the plastic tie “1”.
8
5
2 2 27. Connect the cooling water hose “2”, and
2 7
4
a 1
2 3
Rectifier/regulator bolt “2”

26 Nm (2.6 kgf·m, 19.2 ft·lb)
b
23. Connect the thermo sensor coupler “a”.
24. Fasten the lead using the plastic tie “1”.

28. Connect the cooling water hose “1”, and
5-13

Engine mount
33. Connect the remote control receiver cou-
pler “a”, and then fasten the wire harness
using the plastic tie “1”.
1
34. Install the antenna holders “2”.
2
2

ties “1”. a
1 1
1
1
35. Install the air filter case “1”, and then tight-
1 en the air filter case bolts “2” to the speci-
fied torque.
36. Install the air filter, air filter case cover “3”,
and air intake pipe “4”, and then tighten the
air intake pipe clamps “5” to the specified
torque.
30. Connect the fuel pump module coupler “a”.
37. Install the breather hose “6”, and then fas-
ten it using the clamp “7”.
1 3
2
7
a 4
6
5
2
5
ties “1”.
Air filter case bolt “2”
32. Connect the sensor and switch couplers
13 Nm (1.3 kgf·m, 9.6 ft·lb)
“a”. See “Coupler layout” (2-17).
Air intake pipe clamp “5”
1 3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
38. Connect the quick connector “1” to the fuel

rail, and then install the plastic tie “3”.
39. Install the oil level gauge “2”.
1
a
5-14

Engine mount
2 1
3
1
40. Install the engine cover “1”, and then tight- 43. Fill the engine with engine oil. See “Engine
en the engine cover screws “2” to the oil replacement” (3-4).
specified torque.
44. Connect the positive battery lead, and then
connect the negative battery lead.
1
Engine cover screw “2”

5 Nm (0.5 kgf·m, 3.7 ft·lb)
41. Install the deck beam “1”, and then tighten

the deck beam nuts “2” to the specified
torque.
LT
271
Deck beam nut “2”

16 Nm (1.6 kgf·m, 11.8 ft·lb)
42. Install the service lid “1”.
5-15

Muffler
Muffler
20 Nm (2.0 kgf·m, 14.8 ft·lb)
15 Nm (1.5 kgf·m, 11.1 ft·lb)

29 Nm (2.9 kgf·m, 21.4 ft·lb)
3 7
8
12
15
7
13 14
14
9
5
2
6 1
10 2.5 Nm (0.25 kgf·m, 2.58 ft·lb)

200 Nm (20.0 kgf·m, 147.5 ft·lb)
11


1 Clamp 1
2 Pipe 1
3 Thermo sensor 1
4 Clamp 1
6 Exhaust pipe 1
7 Bolt 5 M8 × 35 mm
8 Exhaust pipe 1
10 Bolt 2 M8 × 70 mm
11 Bolt 4 M8 × 120 mm
12 Exhaust pipe 1
14 Dowel pin 2
15 Exhaust manifold 1
5-16

Muffler
Exhaust pipe disassembly
Use heat-resistant gloves. Otherwise,

burns could result. 15°
15°
1. Remove the exhaust pipe “1”.
TIP:
Heat the area “a” of exhaust pipe “1” to approx-
imately 200 °C (392 °F) using a heat gun. 1
2
2
15° 15°
Exhaust pipe wrench “2”

a
1 90890-06726
Exhaust pipe wrench “2”
Exhaust pipe wrench “2” YW-06726
90890-06726
Exhaust pipe wrench “2” Exhaust pipe “1”
YW-06726 200 Nm (20.0 kgf·m, 147.5 ft·lb)
Exhaust pipe assembly

1. Install the exhaust pipe “1”, and then tight-
en it to the specified torque.
To allow the LOCTITE 648 to set, wait ap-

proximately 1 hour after completing this
procedure.
5-17

Wire harness
Wire harness
3 1
3 2 7 Nm (0.7 kgf·m, 5.2 ft·lb)
5
4
8 UP
a
10
9
A
A 8
7
6
12
11
14
13
1 Nut 1
2 Spring washer 1
3 Bolt 2 M8 × 30 mm
4 Negative battery lead 1
5 Starter motor 1
6 Bolt 2 M6 × 35 mm
7 Thermostat housing 1
8 Thermostat 1 a: Hole
9 Holder 1
10 Grommet 1
11 Plastic tie 1
12 Plastic tie 5
13 Plastic tie 1
14 Wire harness 1
5-18

Electrical box
Electrical box
5 Nm (0.5 kgf·m, 3.7 ft·lb) 5 Nm (0.5 kgf·m, 3.7 ft·lb) 5 Nm (0.5 kgf·m, 3.7 ft·lb)
21 25 20
3 18
22 24
SG
21 19
13 5
12 23
17 4 Nm (0.4 kgf·m, 3.0 ft·lb)
14 9 13 26
16 6
10 15
9 12 15 5 Nm (0.5 kgf·m, 3.7 ft·lb)
10 8 11 27
9
11 7
13
2
1
4 5
6 2
3 5 Nm (0.5 kgf·m, 3.7 ft·lb)

1 Electrical box cover 1
2 Plastic tie 2
3 Bolt 8 M6 × 25 mm
4 ECM 1
5 Collar 8
6 Grommet 8
7 Fuse box 1
8 Fuse 3 3A
9 Fuse 4 10 A
10 Fuse 2 20 A
11 Fuse 2 30 A
12 Fuse 2 50 A
13 Relay 4 Main, fuel pump, ETV, SCU
14 Fuse puller 1
15 Bolt 2 M6 × 14 mm
16 Stay 1
5-19

Electrical box
5 Nm (0.5 kgf·m, 3.7 ft·lb) 5 Nm (0.5 kgf·m, 3.7 ft·lb) 5 Nm (0.5 kgf·m, 3.7 ft·lb)
21 25 20
3 18
22 24
SG
21 19
13 5
12 23
17 4 Nm (0.4 kgf·m, 3.0 ft·lb)
14 9 13 26
16 6
10 15
9 12 15 5 Nm (0.5 kgf·m, 3.7 ft·lb)
10 8 11 27
9
11 7
13
2
1
4 5
6 2
3 5 Nm (0.5 kgf·m, 3.7 ft·lb)

17 Nut 2
18 Holder 1
19 Screw 2 M6 × 20 mm
20 Slant detection switch 1
21 Bolt 2 M6 × 12 mm
22 Positive battery lead 1
23 Starter motor lead 1
24 Starter relay 1
25 Bolt 2 M6 × 12 mm
26 Holder 1
27 Electrical box 1
5-20

Electrical box
Starter motor and wire harness 1 b a

removal
1. Disconnect the starter motor lead “1” and
negative battery lead “2”, and then remove
the starter motor “3”.
2 c
1
3
6. Remove the plastic ties “1”, and then dis-
connect the thermo switch coupler “a”, en-
gine temperature sensor coupler “b”,
intake air pressure sensor coupler “c”, in-
take air temperature sensor coupler “d”,
2 cam position sensor coupler “e”, and ETV
coupler “f”.
3 1
1
2. Remove the plastic ties “1”.

a
3. Disconnect the fuse box couplers “a”, slant f
c d
detection switch coupler “b”, starter relay
coupler “c”, ECM couplers “d”, and RiDE e
motor couplers “e”. b
1
a b c d
7. Disconnect the ignition coil couplers “a”
and fuel injector couplers “b”.
a
1 1 e
4. Remove the holder “1” and grommet “2”,

and then disconnect the earth plate cou-
b
plers “a”, oil pressure switch coupler “b”,
and pickup coil coupler “c”.
Thermostat check
5. Remove the holder “3”.
1. Suspend the thermostat in a container of
water.
2. Place a thermometer in the water and heat

the water slowly.
5-21

Electrical box
sor coupler “e”, and thermo switch coupler
“f”, and then fasten the wire harness using
the plastic ties “1”.
TIP:
Fasten the wire harness at the gray tape “g” us-
ing the plastic tie.
1 1
3. Measure the thermostat valve opening “a”

f
at the specified water temperatures. Re- a
place if out of specification. d c
g b
a e
1
3. Install the holder “1”, and then connect the

pickup coil coupler “a”, oil pressure switch
coupler “b”, and earth plate couplers “c”.
4. Install the grommet “2” to the stator coil

lead and wire harness, and then fasten the
Water temperature Valve opening “a” grommet “2” using the holder “3”.
58–62 °C 3
Starts opening b c
(136–144 °F)
above 70 °C 4.3 mm (0.17 in) or
(158 °F) above
Wire harness and starter motor 2 a

installation
1. Connect the fuel injector couplers “a” and
ignition coil couplers “b”. 1
b 5. Connect the RiDE motor couplers “a”,
ECM couplers “b”, starter relay coupler “c”,
slant detection switch coupler “d”, and fuse
box couplers “e”, and then fasten the wire
harness using the plastic ties “1”.
e d c b
a
2. Connect the ETV coupler “a”, cam position

sensor coupler “b”, intake air temperature
sensor coupler “c”, intake air pressure sen-
sor coupler “d”, engine temperature sen-
1 1 a
5-22

Electrical box
6. Install the starter motor “1”, and then con-
nect the negative battery lead “2” and
starter motor lead “3”.
7. Tighten the starter motor lead nut “4” to the

specified torque.
3
4
2
1
Starter motor lead nut “4”

7 Nm (0.7 kgf·m, 5.2 ft·lb)
5-23

Intake manifold
Intake manifold
15 Nm (1.5 kgf·m, 11.1 ft·Ib)
9 7
1 16 Nm (1.6 kgf·m, 11.8 ft·Ib)
8 2 31 Nm (3.1 kgf·m, 22.9 ft·Ib)
10
11
2 4 1 10 Nm (1.0 kgf·m, 7.4 ft·lb)
5 2 20 Nm (2.0 kgf·m, 14.8 ft·lb)
6
1322D
6
5
4
LT
242
1 1322D
3
1 16 Nm (1.6 kgf·m, 11.8 ft·Ib)

2 31 Nm (3.1 kgf·m, 22.9 ft·Ib) 14
19 Nm (1.9 kgf·m, 14.0 ft·Ib) 13
12
15 17
LT
572
LT
16
572
18
19
A
20
1 Bolt 8 M8 × 35 mm
2 Nut 2
3 Intake manifold 1
5 Dowel 2
6 Stud bolt 2
7 Intake air temperature sensor 1
9 Intake air pressure sensor 1
10 Grommet 1
11 Hose 1
12 Bolt 1 M8 × 16 mm
13 Oil level gauge 1
15 Bolt 2 M6 × 12 mm
16 Oil level pipe 1
5-24

Intake manifold
15 Nm (1.5 kgf·m, 11.1 ft·Ib)

9 7
1 16 Nm (1.6 kgf·m, 11.8 ft·Ib)
8 2 31 Nm (3.1 kgf·m, 22.9 ft·Ib)
10
11
2 4 1 10 Nm (1.0 kgf·m, 7.4 ft·lb)
5 2 20 Nm (2.0 kgf·m, 14.8 ft·lb)
6
1322D
6
5
4
LT
242
1 1322D
3
1 16 Nm (1.6 kgf·m, 11.8 ft·Ib)

2 31 Nm (3.1 kgf·m, 22.9 ft·Ib) 14
19 Nm (1.9 kgf·m, 14.0 ft·Ib) 13
12
15 17
LT
572
LT
16
572
18
19
A
20
17 Clamp 1
18 Oil level pipe plate 1
19 Grommet 1
5-25

Intake manifold
Oil level pipe installation 6. Fasten the grommet “1” using the clamp
1. Pass the clamp “1” through the oil level “2”.
pipe “2”.
2. Install the oil level pipe plate “3”, the grom-

2
met “4”, and a new O-ring “5” onto the oil
level pipe “2”.
1
TIP:
Make sure that the bottom of the grommet “4”
is at the specified installation distance “a” from
the end of the oil level pipe “2”.
Intake manifold installation

4 1. Install the dowels “1”, new gaskets “2”, and
3 2 the intake manifold “a”, and then tighten
1 the bolts “3” and nuts “4” to the specified
torques in 2 stages and in the order [1], [2],
and so on.
5
a 3
4 2
2 4
5
Installation distance “a” (reference data)

51.0 mm (2.0 in) 2
3
3. Install the oil level pipe onto the cylinder 1322D
a 1322D
block, and then tighten the oil level pipe
plate bolts “1” and oil level pipe bolt “2”
temporarily.
1
4. Tighten the oil level pipe plate bolts “1”.
5. Tighten the oil level pipe bolt “2” to the

4 [5] 3 [1] [2] 3 [6] 4
specified torque.
3 3
[8] [4] [3] [7]
2
[10] 3 3 [9]
Intake manifold bolt “3”

1 1st: 16 Nm (1.6 kgf·m, 11.8 ft·lb)
2nd: 31 Nm (3.1 kgf·m, 22.9 ft·lb)
Intake manifold nut “4”
LT
1st: 16 Nm (1.6 kgf·m, 11.8 ft·lb)
572
2nd: 31 Nm (3.1 kgf·m, 22.9 ft·lb)
Oil level pipe bolt “2”
19 Nm (1.9 kgf·m, 14.0 ft·lb)
5-26

Oil cooler, oil pump, and drive gear

11 Nm (1.1 kgf·m, 8.1 ft·Ib)
80 Nm (8.0 kgf·m, 59.0 ft·Ib)
3
2 5
4
6
E
18 Nm (1.8 kgf·m, 13.3 ft·Ib)
6 9
25
7
19 Nm (1.9 kgf·m, 14.0 ft·Ib)
8 A 10
1 LT
22 7 A 9 LT
572 572 16
LT
14
572 11 12
17 12 Nm (1.2 kgf·m, 8.9 ft·Ib)
18
17
24 13 LT
572
17 19
18
17
19
A 22 20
24
LT
19 15
23 572
12 Nm (1.2 kgf·m, 8.9 ft·Ib) 21 LT
20 Nm (2.0 kgf·m, 14.8 ft·Ib) 15 572

19 Nm (1.9 kgf·m, 14.0 ft·Ib)

1 Bolt 12 M6 × 20 mm
2 Oil pump 1
4 Bolt 1 M12 × 58 mm, left-hand threads
5 Oil pump drive gear 1
6 Dowel 2
8 Connector 1
9 Clamp 2
11 Clamp 1
12 Plastic tie 1
14 Bolt 1 M8 × 55 mm
15 Bolt 2 M8 × 70 mm
16 Oil cooler ASSY 1
5-27

11 Nm (1.1 kgf·m, 8.1 ft·Ib)

80 Nm (8.0 kgf·m, 59.0 ft·Ib)
3
2 5
4
6
E
18 Nm (1.8 kgf·m, 13.3 ft·Ib)
6 9
25
7
19 Nm (1.9 kgf·m, 14.0 ft·Ib)
8 A 10
1 LT
22 7 A 9 LT
572 572 16
LT
14
572 11 12
17 12 Nm (1.2 kgf·m, 8.9 ft·Ib)
18
17
24 13 LT
572
17 19
18
17
19
A 22 20
24
LT
19 15
23 572
12 Nm (1.2 kgf·m, 8.9 ft·Ib) 21 LT
20 Nm (2.0 kgf·m, 14.8 ft·Ib) 15 572

19 Nm (1.9 kgf·m, 14.0 ft·Ib)

18 Connector 2
19 Bolt 7 M6 × 25 mm
20 Washer 3
21 Bolt 1 M8 × 25 mm
22 Bolt 4 M6 × 20 mm
24 Dowel 2
25 Oil filter joint 1
5-28

Oil pump and oil pump drive gear

removal 3 2
1. Remove the oil pump.
3
2. Hold the drive coupling “1” using the spe-
cial service tool “2”.
1
Leakage tester “2”

90890-06840
Water passage holding pressure

200 kPa (2.0 kgf/cm², 29.0 psi)
2 1
Coupler wrench “2” Oil pump check

90890-06729
Coupler wrench “2”
Do not disassemble the oil pump.
YW-06729
1. Check that the oil pump driven gear turns
3. Turn the bolt “1” clockwise to loosen it, and
smoothly. Replace if the movement is
then remove the bolt “1” and oil pump drive
rough.
gear “2”.
Oil pump drive gear and oil pump
installation
2
1. Install the oil pump drive gear “1”, and then
tighten the bolt “2” temporarily.
1
1
Oil cooler check 2

1. Connect the hose “1” and special service
tool “2” to the inlet of the oil cooler water
passage. Block the oil cooler ASSY outlet
using rubber plugs “3”. 2. Hold the holder “1”.
2. Apply the specified positive pressure and
check that the pressure is maintained. If
the specified pressure cannot be main-
tained, replace the oil cooler. 1
5-29

3. Turn the bolt “1” counterclockwise, and
Oil pump bolt “4”
then tighten it to the specified torque.
11 Nm (1.1 kgf·m, 8.1 ft·lb)
Oil pump drive gear bolt “1”

80 Nm (8.0 kgf·m, 59.0 ft·lb)
4. Fill the oil pump with engine oil through the

feed port “a”.
TIP:
While turning the oil pump driven gear, make
sure to fill the oil pump with engine oil up to the
brim of feed port.
5. Install the dowels “1”, a new gasket “2”,

and the oil pump “3”, and then tighten the
bolts “4” to the specified torque.
1
2
4
LT
572
5-30

Cylinder head cover
Cylinder head cover

1 A 9 10 Nm (1.0 kgf·m, 7.4 ft·Ib)
LT
1 572
6 4 LT
572
10
5
A
2 6
2
2
2 6
3 LT
3 572
3 LT
7 13 242
3 14
12 12
13 14 6 Nm (0.6 kgf·m, 4.4 ft·Ib)
11 1530D
8
25 Nm (2.5 kgf·m, 18.4 ft·Ib)
1280B

1 Bolt 8 M6 × 20 mm
2 Ignition coil 4
3 Spark plug 4
4 Bolt 1 M6 × 16 mm
5 Cam position sensor 1
6 Bolt 8 M6 × 30 mm
7 Cylinder head cover 1
9 Oil filler cap 1
11 Timing chain guide 1
12 Bolt 2 M6 × 25 mm
13 Collar 2
14 Grommet 2
5-31

Camshaft
Camshaft
8 8
16 Nm (1.6 kgf·m, 11.8 ft·Ib)
8
10
10 13 8
13 8
a
9 13 8
13 12
21 Nm (2.1 kgf·m, 15.5 ft·Ib) 12
13 13
14
16 11 13
17 b
20 Nm (2.0 kgf·m, 14.8 ft·Ib) 13
17
10 Nm (1.0 kgf·m, 7.4 ft·lb)
16
15
1
2
3 16
2
4 2 1
20 5 6
18 19 21

1 Bolt 2 M10 × 21 mm
3 Oil pipe 1
4 Bolt 2 M6 × 25 mm
5 Timing chain tensioner 1
7 Timing chain guide 1 Exhaust side
8 Bolt 24 M7 × 45 mm
9 Intake camshaft cap 1
10 Intake camshaft cap 2
11 Exhaust camshaft cap 1
12 Exhaust camshaft cap 2
13 Dowel pin 12
14 Intake camshaft 1 a: Light blue paint
15 Exhaust camshaft 1 b: Pink paint
16 Bolt 4 M7 × 11 mm
5-32

Camshaft
8 8
16 Nm (1.6 kgf·m, 11.8 ft·Ib)
8
10
10 13 8
13 8
a
9 13 8
13 12
21 Nm (2.1 kgf·m, 15.5 ft·Ib) 12
13 13
14
16 11 13
17 b
20 Nm (2.0 kgf·m, 14.8 ft·Ib) 13
17
10 Nm (1.0 kgf·m, 7.4 ft·lb)
16
15
1
2
3 16
2
4 2 1
20 5 6
18 19 21

17 Camshaft sprocket 2
18 Bolt 2 M6 × 30 mm
19 Chain guide plate 1
20 Timing chain guide 1 Intake side
21 Timing chain 1
5-33

Camshaft
Camshaft removal
When installing the camshafts, piston #1

must be positioned at TDC. Therefore, do
not turn the crankshaft after removing the
camshafts.
1. Install the special service tools into spark

plug hole #1. 2 1
1
3 b
2 a
Dial gauge set “1”

#1 #2 #3 #4
90890-01252
YU-03097
Dial gauge needle “2” Coupler wrench “2”
90890-06584 90890-06729
Dial gauge stand set “2” Coupler wrench “2”
YB-06585 YW-06729
Gauge stand “3”
90890-06725 3. Make marks “a” on the camshaft sprockets
and camshafts.
a
drive coupling “1” counterclockwise using
the special service tool “2”, referring to 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 marks “b” on
the camshaft caps.
4. Remove the oil pipe “1”, gaskets “2”, timing
chain tensioner “3”, and gasket “4”.
5-34

Camshaft
Camshaft wrench “1”

90890-06724
2 Camshaft wrench “1”
YW-06724
2. Remove the intake camshaft sprocket and

1 exhaust camshaft sprocket.
4 Camshaft check
2 3
1. Check the camshaft lobes. Replace if pit-
5. Remove the timing chain guide (exhaust ted or scratched.
side).
2. Measure the cam lobe height “a”. Replace
6. Remove the intake camshaft caps and ex- if out of specification.
haust camshaft caps.
TIP:
Loosen the camshaft cap bolts in the opposite
order used for tightening.
a
7. Remove the intake camshaft “1” and ex-

haust camshaft “2”.
TIP:
Fasten the timing chain using a wire “3”. Cam lobe height-intake
41.330–41.430 mm (1.6272–1.6311 in)
2 Limit
1
41.230 mm (1.6232 in)
IN Cam lobe height-exhaust
3 41.220–41.320 mm (1.6228–1.6268 in)
Limit
41.120 mm (1.6189 in)
EX
3. Measure the camshaft journal diameter
“a”.
Camshaft sprocket removal a

1. Hold the camshaft sprocket using the spe-
cial service tool “1”, and then loosen the
camshaft sprocket bolts “2”.
1
Journal diameter
24.960–24.980 mm (0.9827–0.9835 in)
2
4. Measure the camshaft runout. Replace if
out of specification.
5-35

Camshaft
Runout 4. Install the dowel pins “1”, intake camshaft

0.015 mm (0.0006 in) caps “2” and “3”, and exhaust camshaft
Limit caps “4” and “5”.
0.05 mm (0.0020 in)
TIP:
Camshaft journal oil clearance check When installing the camshaft caps, make sure
that the arrow marks “a” on the camshaft caps
1. Remove the valve lifters “1” and valve
pads “2”. point toward the camshaft sprockets.
TIP: 3
Write down the position of each valve lifter “1” 3
5
and valve pad “2” so that they can be installed
1
in their original positions.
5
2 1
1 1
1 4 1
2
1
IN R IN L IN
2. Place the camshafts on the cylinder head.
3. Put a piece of Plastigauge “1” on each

camshaft journal, parallel to the camshaft.
a a a
TIP:
Do not put the Plastigauge over the oil hole in
the camshaft journal. EX EX R EX L
5. Tighten the camshaft cap bolts “1” until

camshaft caps contact the cylinder head in
the order [1], [2], and so on.
TIP:
Make sure to keep the camshafts level.
5-36

Camshaft
Timing chain tensioner check

IN
1. While pushing the timing chain tensioner
[6] rod “a”, turn the timing chain tensioner
[11] [7] [1] [9] [4]
[8] housing “b” in direction “c” until the groove
[12] [5] [2] [10] [3]
“d” in the tensioner rod is aligned with the
[11] [6] [9] [2] [3] snap ring “e”.
[7]
[12] [8] [10] [1] [4]
[5] 2. While squeezing the ends of the snap ring
EX 1 “e” so that it fits into the groove “d” in the
timing chain tensioner rod “a”, release the
6. Tighten the camshaft cap bolts “1” to the tensioner rod slowly until it is locked in
specified torque in the order [1], [2], and so place.
on.
TIP:
TIP: Make sure that the timing chain tensioner rod
Do not turn the camshafts when measuring the “a” is locked in place before releasing the snap
camshaft journal oil clearance using the Plasti- ring “e”.
gauge.
IN b
[3]
[1] [5] [7] [9] [11] a
[4]
[2] [6] [8] [10] [12]
[1] [5] [7] [9] [11] c

[3]
[2] [6] [8] [10] [12]
[4]
EX 1
Camshaft cap bolt “1”

16 Nm (1.6 kgf·m, 11.8 ft·lb)
7. Remove the camshaft caps, and then

measure the width of the Plastigauge “1”. e
e
d
1
3. Push the timing chain tensioner rod slight-

ly. Check that the snap ring releases the
timing chain tensioner rod, allowing the
tensioner rod to pop out.
Camshaft sprocket installation

Journal oil clearance 1. Install the exhaust camshaft sprocket and
0.020–0.061 mm (0.0008–0.0024 in) intake camshaft sprocket.
Limit
0.08 mm (0.0032 in) TIP:
• Install each camshaft sprocket with the
punch mark “a” facing outward.
5-37

Camshaft
• When installing an original camshaft sprock-
2
et, make sure to align the marks “b” made
during removal. 1
3. Install the timing chain guide (exhaust

side).
b
4. Install the exhaust camshaft “1”, intake
2. Hold the camshaft sprocket using the spe- camshaft “2”, and timing chain “3”.
cial service tool “1”, and then tighten the
camshaft sprocket bolts “2” to the specified TIP:
torque. • Make sure that the punch marks “a” on the
camshafts are facing up.
• Make sure that the exhaust side “b” of the
1
timing chain is taut.
IN 1
2
2 3
EX

90890-06724
YW-06724
IN a
Camshaft sprocket bolt “2”
21 Nm (2.1 kgf·m, 15.5 ft·lb)
Camshaft installation
1. Position piston #1 at TDC. See “Camshaft
removal” (5-34).
2. Install the valve pads “1” and valve lifters

EX a
“2” in their original positions.
5-38

Camshaft
IN
IN EX
[6]
[11] [7] [1] [9] [4]
b [8]
[12] [5] [2] [10] [3]
[11] [6] [9] [2] [3]

[7]
[12] [8] [10] [1] [4]
[5]
EX 1
5. Install the dowel pins “1”, intake camshaft 7. Tighten the camshaft cap bolts “1” to the
caps “2” and “3”, and exhaust camshaft specified torque in the order [1], [2], and so
caps “4” and “5”. on.
TIP: IN
When installing the camshaft caps, make sure [3]
that the arrow marks “a” on the camshaft caps [1] [5] [7] [9] [11]
[4]
point toward the camshaft sprockets. [2] [6] [8] [10] [12]
[1] [5] [7] [9] [11]

3 [3]
[2] [6] [8] [10] [12]
3 [4]
5
1 EX 1
5
1 Camshaft cap bolt “1”
2 1 16 Nm (1.6 kgf·m, 11.8 ft·lb)
1 4 1 8. Align the punch marks “a” on the cam-
shafts with the marks “b” on the camshaft
1
caps.
b
a
IN R IN L IN
a a a
#1 #2 #3 #4
EX EX R EX L
6. Tighten the camshaft cap bolts “1” until 9. While pushing the timing chain tensioner
camshaft caps contact the cylinder head in rod “a”, turn the timing chain tensioner
the order [1], [2], and so on. housing “b” in direction “c” until the groove
“d” in the tensioner rod is aligned with the
TIP:
snap ring “e”.
Make sure to keep the camshafts level.
5-39

Camshaft
10. While squeezing the ends of the snap ring
Timing chain tensioner bolt “3”
“e” so that it fits into the groove “d” in the
10 Nm (1.0 kgf·m, 7.4 ft·lb)
timing chain tensioner rod “a”, release the
Oil pipe bolt “6”
tensioner rod slowly until it is locked in
20 Nm (2.0 kgf·m, 14.8 ft·lb)
place.
15. Turn the drive coupling “1” counterclock-
b wise 2 full turns, and then check that the
camshaft turns smoothly.
a TIP:
Check that the portion “a” of the timing chain is
c taut. If the timing chain is not taut, turn the drive
coupling “1” slightly clockwise, and then check
that the timing chain is taut again.
e
d
2 1
11. Install a new gasket “1” and the timing

chain tensioner “2” onto the cylinder head,
and then tighten the timing chain tensioner a
bolts “3” temporarily.
12. Install new gaskets “4” and the oil pipe “5”
to the cylinder head and timing chain ten-
sioner “2”, and then tighten the oil pipe
bolts “6” temporarily.
13. Tighten the timing chain tensioner bolts “3” Coupler wrench “2”
to the specified torque. 90890-06729
14. Tighten the oil pipe bolts “6” to the speci-
YW-06729
fied torque.
16. Position piston #1 at TDC. See “Camshaft
removal” (5-34).
4
Valve clearance adjustment
6 1. Measure the valve clearances. See “Valve
3 clearance measurement” (3-11).
5 2 2. Remove the camshaft caps and cam-
1 shafts. See “Camshaft removal” (5-34).
4 3
5-40

Camshaft
3. Remove the valve lifters “1” and valve 7. Install the selected valve pad “1” and valve
pads “2”. lifter “2”.
TIP: 2
Write down the position of each valve lifter “1”
1
and valve pad “2” so that they can be installed
in their original positions.
8. Turn the valve lifter and check that it turns

smoothly.
9. Position piston #1 at TDC, and then install

the camshafts and camshaft caps. See
“Camshaft installation” (5-38).
4. Check the valve pad number “a”.
TIP: clearances of the specified cylinders.
The thickness of each valve pad is marked in
hundredths of millimeters on the side that con-
tacts the valve lifter.
148
#1 #2 #3 #4
IN  —  —
EX   — —
5. Round off the original valve pad number
according to the following table. : Specified cylinder
—: Not applicable
Last digit Rounded value
0, 1, 2 0 11. Install the special service tools into spark
plug hole #4.
4, 5, 6 5
8, 9 10 1
3
6. Select the new valve pad number from the
“Valve pad selection table” (5-43). 2
TIP:
The valve pads are available in 23 thickness-
es, ranging from 1.20 mm to 2.30 mm in 0.05
mm increments.
5-41

Camshaft
Dial gauge set “1”

90890-01252
YU-03097
Dial gauge needle “2”
90890-06584
Dial gauge stand set “2”
YB-06585
Gauge stand “3”
90890-06725

drive coupling “1” 360° counterclockwise
using the special service tool “2”.
2 1
90890-06729
YW-06729

#1 #2 #3 #4
IN —  — 
EX — —  
—: Not applicable
5-42

Camshaft
Valve pad selection table

Intake
Measured Original valve pad number
clearance 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.00–0.02 1 20 12 5 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210
0.03–0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.07–0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.11–0.13 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.14–0.23 St a n d a r d c l e a r a n c e
0.24–0.26 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.27–0.31 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.32–0.36 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.37–0.41 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.42–0.46 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.47–0.51 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.52–0.56 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.57–0.61 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.62–0.66 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.67–0.71 170 175 180 185 190 195 200 205 210 215 220 225 230
0.72–0.76 175 180 185 190 195 200 205 210 215 220 225 230
0.77–0.81 180 185 190 195 200 205 210 215 220 225 230
0.82–0.86 185 190 195 200 205 210 215 220 225 230
0.87–0.91 190 195 200 205 210 215 220 225 230
0.92–0.96 195 200 205 210 215 220 225 230
0.97–1.01 200 205 210 215 220 225 230
1.02–1.06 205 210 215 220 225 230
1.07–1.11 210 215 220 225 230
1.12–1.16 215 220 225 230
1.17–1.21 220 225 230
1.22–1.26 225 230
1.27–1.31 230
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)
5-43

Camshaft
Exhaust
Measured Original valve pad number
clearance 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.00–0.01 12 0 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195
0.02–0.04 1 2 0 12 5 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
0.05–0.09 1 2 0 1 2 5 13 0 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205
0.10–0.14 1 20 1 2 5 1 3 0 13 5 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210
0.15–0.19 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.20–0.24 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.25–0.27 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.28–0.37 S ta n d a rd c l e a r a n ce
0.38–0.40 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.41–0.45 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.46–0.50 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.51–0.55 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.56–0.60 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.61–0.65 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.66–0.70 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.71–0.75 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.76–0.80 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.81–0.85 170 175 180 185 190 195 200 205 210 215 220 225 230
0.86–0.90 175 180 185 190 195 200 205 210 215 220 225 230
0.91–0.95 180 185 190 195 200 205 210 215 220 225 230
0.96–1.00 185 190 195 200 205 210 215 220 225 230
1.01–1.05 190 195 200 205 210 215 220 225 230
1.06–1.10 195 200 205 210 215 220 225 230
1.11–1.15 200 205 210 215 220 225 230
1.16–1.20 205 210 215 220 225 230
1.21–1.25 210 215 220 225 230
1.26–1.30 215 220 225 230
1.31–1.35 220 225 230
1.36–1.40 225 230
1.41–1.45 230
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)
5-44

Cylinder head
Cylinder head
2
9 10 1 55 Nm (5.5 kgf·m, 40.6 ft·lb)
2 90˚
42 Nm (4.2 kgf·m, 31.0 ft·Ib)
3 E
10 Nm (1.0 kgf·m, 7.4 ft·Ib) 2
3
10
1
9
LT
242
4
12 Nm (1.2 kgf·m, 8.9 ft·Ib)
7 LT
242

1 Bolt 3 M6 × 55 mm
2 Bolt 10 Not reusable, M12 × 140 mm
3 Washer 10
4 Cylinder head ASSY 1
6 Dowel pin 2
7 Bolt 1 M10 × 25 mm
8 Engine hanger 1
9 Bolt 4 M6 × 12 mm
10 Engine hanger 2
5-45

Valve and valve spring
1 1
2 2
3 3 3
3
4 4
5 5
6 6
9 9
10 10
11
8
7

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
5-46

Cylinder head disassembly Valve spring compressor “1”

1. Remove the valve lifters “1” and valve 90890-04019
pads “2”. Valve spring compressor “1”
YM-04019
TIP:
Write down the position of each valve lifter “1” Valve spring compressor attachment “2”
and valve pad “2” so that they can be installed 90890-04114
in their original positions. Compressor adapter “2”
YM-04114
1 3. Remove the valve seals.

2
Cylinder head check
1. Remove carbon deposits from the com-
bustion chambers.
2. Check the cylinder head water jacket.

Clean if there are mineral deposits or rust.
3. Check the cylinder head warpage using a

2. Remove the intake valves and exhaust straightedge “1” and thickness gauge “2” in
valves. the directions shown. Replace if out of
specification.
TIP:
Write down the position of each valve, spring,
and other parts so that they can be installed in 1
their original positions. 2
1 Warpage limit
0.100 mm (0.0039 in)
Valve spring check

1. Measure the valve spring free length “a”.
Replace if out of specification.
5-47

Face width-intake
2.260–2.830 mm (0.0890–0.1114 in)
Face width-exhaust
2.260–2.830 mm (0.0890–0.1114 in)
2. Measure the valve margin thickness “a”.

a
a
Free length-intake
45.58 mm (1.79 in)
Free length-exhaust
45.58 mm (1.79 in)
Limit
43.30 mm (1.70 in)
Margin thickness-intake
2. Measure the valve spring tilt “a”. Replace if 0.800–1.200 mm (0.0315–0.0472 in)
Margin thickness-exhaust
a 0.800–1.200 mm (0.0315–0.0472 in)
3. Measure the valve stem diameter “a”. Re-

place if out of specification.
Tilt limit-intake
2.5°/2.0 mm
Tilt limit-exhaust
2.5°/2.0 mm
Diameter-intake
Valve check 5.477–5.492 mm (0.2156–0.2162 in)
1. Measure the valve face width “a”. Limit
a 5.447 mm (0.2144 in)
Diameter-exhaust
5.464–5.479 mm (0.2151–0.2157 in)
Limit
5.434 mm (0.2139 in)
4. Measure the valve stem runout. Replace if

5-48

Valve guide removal

1. Insert the special service tool “1” into the
combustion chamber side of the valve
guide “2”.
2. Strike the special service tool “1” to drive

the valve guide “2” out of the cylinder
head.
Runout limit 1
0.010 mm (0.0004 in)
2
Valve guide check
1. Measure the valve guide inside diameter
“a”.
Valve guide remover/installer “1”

90890-06801
Valve guide remover “1”
a
YB-06801
Valve guide installation

1. Insert the special service tools “1” and “2”
into the camshaft side of the valve guide
Inside diameter-intake “3”.
5.504–5.522 mm (0.2167–0.2174 in)
Inside diameter-exhaust
Do not reuse a valve guide, always replace
5.504–5.522 mm (0.2167–0.2174 in)
it with a new one.
2. Calculate the valve-stem-to-valve-guide
clearance. Replace the valve and valve 2. Strike the special service tool “1” to drive
guide if out of specification. the valve guide “3” into the cylinder head.
Valve-stem-to-valve-guide clearance =
valve guide inside diameter – valve stem 1
diameter
Stem to guide clearance-intake
0.012–0.045 mm (0.0005–0.0018 in) 2
Limit
0.080 mm (0.0032 in) a
Stem to guide clearance-exhaust
0.025–0.058 mm (0.0010–0.0023 in) 3
Limit
a. Valve guide installation height
0.100 mm (0.0039 in)
5-49

Valve guide remover/installer “1” Inside diameter-intake

90890-06801 5.504–5.522 mm (0.2167–0.2174 in)
Valve guide remover “1” Inside diameter-exhaust
YB-06801 5.504–5.522 mm (0.2167–0.2174 in)
Valve guide installer “2”
90890-06810 Valve seat check
Valve guide installer “2” 1. Remove carbon deposits from the valves
YB-06810 and valve seats.
Valve guide installation height 2. Apply a thin, even layer of blue layout fluid
12.3–12.7 mm (0.48–0.50 in) (Dykem) onto the valve seat.
3. Insert the special service tool “1” into the 3. Press the valve lightly against the valve
valve guide “2”, and then ream the valve seat using the special service tool “1”.
guide “2”.
1
TIP:
• Turn the special service tool “1” clockwise to
ream the valve guide “2”.
• Do not turn the special service tool “1” coun-
terclockwise when removing the tool.
1
Valve lapper “1”
90890-04101
2 Valve lapping tool “1”
YM-A8998
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 guide reamer “1” valve is not seated properly or if the valve
90890-06804 seat contact width “a” is out of specifica-
Valve guide reamer “1” tion. Replace the valve guide if the valve
YM-01196 seat contact width “a” is uneven.
4. Clean the valve guide inner surface. Mea-

sure the valve guide inside diameter “a”.
5-50

Valve seat cutter holder

90890-06812
Intake:
Valve seat cutter 30°
90890-06720
90890-06325
90890-06324
Exhaust:
90890-06818
90890-06555
Seat contact width-intake
1.400–1.600 mm (0.0551–0.0630 in) Valve seat cutter 60°
90890-06323
Limit
2.100 mm (0.0827 in) Neway valve seat kit
YB-91044
Seat contact width-exhaust
1.500–1.700 mm (0.0591–0.0669 in) 2. Cut the surface of the valve seat using a
Limit 45° cutter by turning the cutter clockwise
2.200 mm (0.0866 in) until the valve seat face has become
smooth.
Valve seat refacing
Do not over cut the valve seat. To prevent

After every lapping procedure, make sure chatter marks, make sure to turn the cutter
to clean off any remaining lapping com- evenly using a downward force of 40–50 N
pound from the cylinder head and valves. (4.0–5.0 kgf, 8.8–11.0 lbf).
1. Reface the valve seat.
A
30 45 60
30 45 60
30
45
A. Worldwide
5-51

45
a a
b
45
a. Slag or rough surface a. Previous contact width

b. Specified contact width
3. Adjust the top edge of the valve seat con-
tact width using a 30° cutter. 6. Check the valve seat contact area of the
valve “Valve seat check” (5-50).
30 Example:
a • If the valve seat contact area is too wide and
situated in the center of the valve face, cut
the top edge of the valve seat using a 30° cut-
ter, and then cut the bottom edge using a 60°
cutter to center the area and set its width.
30
a
a. Previous contact width
4. Adjust the bottom edge of the valve seat

contact width using a 60° cutter.
60
a
• If the valve seat contact area is too narrow
and situated near the top edge of the valve
face, cut the top edge of the valve seat using
60 a 30° cutter to center the area, and then set
its width using a 45° cutter.
30
5. Adjust the valve seat contact width to a
specification using a 45° cutter.
5-52

• If the valve seat contact area is too narrow 2. Install the valve “1”, valve spring seat “2”,
and situated near the bottom edge of the valve spring “3”, and valve spring retainer
valve face, cut the bottom edge of the valve “4” in this order, and then install the special
seat using a 60° cutter to center the area, service tools “5” and “6”.
and then set its width using a 45° cutter.
TIP:
• When installing a new valve, always replace
a the valve guide with a new one.
• Install the valve spring “3” with the larger
pitch “a” toward the camshaft and the smaller
pitch “b” toward the combustion chamber.
• The upper end “c” of the valve spring “3” with
60 the larger pitch “a” is painted red.
4
a. Previous contact width 3
7. After refacing the valve seat to the speci- 2 6
fied contact width, apply a thin, even layer
of lapping compound onto the valve seat,
and then lap the valve using the special
service tool “1”.
Do not get the lapping compound on the

valve stem and valve guide.
5
1
1
a
3
Valve lapper “1”
90890-04101
Valve lapping tool “1” b
YM-A8998
8. Recheck the valve seat contact area of the

Valve spring compressor “5”
valve. See “Valve seat check” (5-50).
90890-04019
Cylinder head assembly Valve spring compressor “5”
YM-04019
1. Install a new valve seal.
Valve spring compressor attachment “6”
90890-04114
Compressor adapter “6”
YM-04114
5-53

3. Compress the valve spring, and then in- Cylinder head installation
stall the valve cotters “1”. 1. Install the dowel pins “1”, a new gasket “2”,
the cylinder head ASSY “3”, the washers
1 “4”, and the cylinder head bolts “5”, and
then tighten the cylinder head bolts “5” to
the specified torques in 2 stages and in the
order [1], [2], and so on.
2. Install the cylinder head bolts “6”, and then

tighten them to the specified torque.
5
4
4. Tap the valve spring retainer lightly using a 6
plastic hammer to seat the valve cotters
“1” securely.
3
2
1
5 5 5
1 1 [10] [6] [2] [3] [7]
[9] [5] [1] [4] [8]

5 5 5
Cylinder head bolt “5” (M12)

5. Install the valve pads “1” and valve lifters 1st: 55 Nm (5.5 kgf·m, 40.6 ft·lb)
“2” in their original positions. 2nd: 90°
Cylinder head bolt “6” (M6)
2
10 Nm (1.0 kgf·m, 7.4 ft·lb)
1
5-54

Generator cover ASSY and flywheel magneto
12
7
11
6
4 10
8 19
7
3 6
1 5
2
26 Nm (2.6 kgf·m, 19.2 ft·lb)

250 Nm (25.0 kgf·m, 184.4 ft·lb) 10
80 Nm (8.0 kgf·m, 59.0 ft·lb)
17
24 Nm (2.4 kgf·m, 17.7 ft·lb)
18 9
15
14 16
15

13 60
250 Nm (25.0 kgf·m, 184.4 ft·lb)

1 Holder 1 Left-hand threads
2 Drive coupling 1
3 Washer 1 Not reusable
4 Holder 1
5 Bolt 2 M6 × 20 mm
6 Collar 2
7 Grommet 2
8 Bolt 9 M8 × 50 mm
10 Dowel pin 2
11 Shaft 1
12 Idle gear 1
13 Transfer shaft 1 Not reusable
14 Special nut 1 Not reusable
16 Flywheel magneto 1 Not reusable
5-55

12
7
11
6
4 10
8 19
7
3 6
1 5
2
26 Nm (2.6 kgf·m, 19.2 ft·lb)

250 Nm (25.0 kgf·m, 184.4 ft·lb) 10
80 Nm (8.0 kgf·m, 59.0 ft·lb)
17
24 Nm (2.4 kgf·m, 17.7 ft·lb)
18 9
15
14 16
15

13 60
250 Nm (25.0 kgf·m, 184.4 ft·lb)

17 Starter clutch 1
18 Starter gear 1
19 Woodruff key 1 Not reusable
5-56

Generator cover
Generator cover
8
15 Nm (1.5 kgf·m, 11.1 ft·lb)
15 Nm (1.5 kgf·m, 11.1 ft·lb)
2 9
10
5
4
11
3
3
1 Bolt 2 M6 × 15 mm
2 Holder 1
3 Bolt 2 M5 × 15 mm
4 Bolt 1 M5 × 10 mm
5 Washer 1
6 Bolt 3 M6 × 30 mm
7 Stator coil 1
8 Oil seal 1 Not reusable
9 Circlip 1
10 Ball bearing 1 Not reusable
11 Generator cover 1
5-57

Generator cover
Drive coupling removal 3. Hold the transfer shaft “1” using the special
service tool “2”, and then remove the drive
coupling “3” using the special service tool
Use heat-resistant gloves. Otherwise, “4”.
burns could result.
1. Heat the holder “1” and drive coupling “2”

for 20–30 minutes using a heat gun “3”.
Be careful not to damage the wire harness

when using the heat gun.
2 3
4
3
4 1
1
2 3
2. Hold the drive coupling “1” using the spe- Crankshaft holder “2”
cial service tool “2”, and then remove the 90890-06732
holder “3” by turning it clockwise. Crankshaft holder “2”
YW-06562
90890-06729
YW-06729
Flywheel magneto removal
2 1
3 Use heat-resistant gloves. Otherwise,
2 burns could result.
1. Remove the generator cover.
2. Heat the transfer shaft “1” for 20–30 min-

utes using a heat gun “2”.
1 2

90890-06729
YW-06729
5-58

Generator cover
3. Hold the flywheel magneto “1” using the
special service tools “2” and “3”, and then
loosen the special nut “4”.
3
TIP:
• Loosen the special nut “4” until it can no lon- 5
ger be turned.
• Use a hexagon bit socket “5” with a length of 4 2 1
150 mm (5.91 in) or more and a width across
flats of 12 mm.
2
5 4
5
1
2 1
Shaft holder “2”
90890-06721
2 Shaft holder “2”
5 4 YW-06721
Drive handle “3”
90890-06722
YW-06722
1 Crankshaft holder “5”
90890-06732
Shaft holder “2” Crankshaft holder “5”
90890-06721 YW-06562
5. Remove the flywheel magneto “1” and
YW-06721
Woodruff key using the special service
tools “2” and “3”.
90890-06722
Drive handle “3” 1
YW-06722
2
3
remove the transfer shaft “4” using the
special service tool “5”.
5-59

Generator cover
Flywheel puller “2”

1
90890-06723
Flywheel puller “2” 2
YW-06723
Rotor puller “3”
90890-01080
Stator rotor puller “3”
YM-01080-A

special service tool “2”, and then loosen 3. Remove the ball bearing “1”.
the starter clutch bolts “3”. A
1 3 1 2
3 3
2
3
B
Sheave holder “2” 4
1
90890-01701
Primary sheave holder “2” 5
YS-01880-A
7. Remove the starter clutch.
Generator cover ASSY disassembly

1. Remove the washer “1”, pickup coil “2”,
A. Worldwide
holder “3”, and stator coil “4”.
Driver rod LS “2”

3 90890-06606
Bearing outer race attachment “3”
90890-06627
4 Driver handle (small) “4”
YB-06229
Bearing and seal installer “5”
1 YW-06356
Starter clutch operation check

1. Install the starter clutch “1” onto the starter
2 gear “2” and hold the starter clutch “1”.
2. Remove the oil seal “1” and circlip “2”. 2. Turn the starter gear “2” clockwise “a” and
check that it turns smoothly. Replace if it
does not turn smoothly.
5-60

Generator cover
3. Turn the starter gear “2” counterclockwise
“b” and check that it does not turn. Replace
if it turns.
1
a
1 3. Install a new oil seal “1”.
2
A
Generator cover ASSY assembly 2

1. Install a new ball bearing “1”. EP
A 1
2
3 A
E
B
3
4
EP
1
B
4
A
5
1
E
A. Worldwide
Bearing pressure C “2”

90890-02393
A. Worldwide
B. U.S.A. and Canada Driver handle (large) “3”
YB-06071
Driver rod LS “2” Forward bearing race installer “4”
90890-06606 YB-06258
Ball bearing attachment “3”
90890-06657 4. Install the stator coil “1”, holder “2”, pickup
coil “3”, and washer “4”, and then tighten
Driver handle (large) “4”
the holder bolts “5” and stator coil bolts “6”
YB-06071
to the specified torques.
Forward gear outer race installer “5”
YB-41446
2. Install the circlip “1”.
5-61

Generator cover
TIP: 3
Pass the pickup coil lead “a” between the gen- 3 1
erator cover and the bolt hole “b”, and then se-
cure the lead by installing the washer “4”.
2
6
3
6
1 5
Sheave holder “2”

90890-01701
3
Primary sheave holder “2”
a 3 YS-01880-A
b
2
Flywheel magneto bolt “3”
24 Nm (2.4 kgf·m, 17.7 ft·lb)
4 3. Install the flywheel magneto “1” to the

starter gear “2”.
Holder bolt “5”
15 Nm (1.5 kgf·m, 11.1 ft·lb) TIP:
Stator coil bolt “6” Turn the starter gear “2” clockwise while install-
15 Nm (1.5 kgf·m, 11.1 ft·lb) ing it onto the flywheel magneto “1”.
Flywheel magneto assembly

1. Install the starter clutch “1” to a new fly- 2
wheel magneto “2”.
Flywheel magneto installation

2
Do not reuse a flywheel magneto, special
nut, flywheel magneto bolt, transfer shaft,
special service tool “2”, and then tighten
or Woodruff key, always replace it with a
new flywheel magneto bolts “3” to the
new one.
specified torque.
1. Remove any grease from a new special
nut “1” and the inner surface of a new
transfer shaft “2”, and then install the spe-
cial nut “1” into the transfer shaft “2” until it
can no longer be turned.
5-62

Generator cover
2 1 1
2
4
5
1
3
2
2. Clean the tapered portion “a” of the crank- 1

shaft and inner surface “b” of the flywheel 2
5 4
magneto “1”.
3. Install a new Woodruff key “2” and the fly-

wheel magneto “1”.
2 Shaft holder “2”

a 90890-06721
YW-06721
b 90890-06722
YW-06722
Crankshaft holder “5”
1 90890-06732
YW-06562
4. Install the transfer shaft “1”.
A Transfer shaft “4”

50 Nm (5.0 kgf·m, 36.9 ft·lb)
6. Using the hexagonal portion of the special

service tool “1” as reference, make marks
on the special service tool “2” at 0°, 60°,
1 and 120°.
7. Make a mark “a” on the transfer shaft “3”

where the shaft is aligned with the 0° mark
5. Hold the flywheel magneto “1” using the on the special service tool “2”.
tighten the transfer shaft “4” to the speci- TIP:
The angle from one corner of the hexagonal
fied torque using the special service tool
head of the special service tool “1” to another
“5”.
corner is 60°.
5-63

Generator cover

3 a
90890-06721
0° Shaft holder “2”
2 60° YW-06721
120° 90890-06722
60° Drive handle “3”
1 YW-06722
90890-06732
90890-06732 Crankshaft holder “5”
YW-06562
YW-06562
Transfer shaft “4”
60°
90890-06721
Shaft holder “2” 9. Tighten the transfer shaft “1” to the speci-
YW-06721 fied torque using the special service tool
“2”.
special service tools “2” and “3”, and then 10. Check that the mark “a” on the transfer
tighten the transfer shaft “4” to the speci- shaft is positioned between the 60° mark
fied angle using the special service tool and the 120° mark on the special service
“5”. tool.
1
2 If the mark on the transfer shaft passes
over the 120° mark on the special service
4
tool, repeat the procedure from step 1. The
5 flywheel magneto may not have been in-
stalled properly.
3
1 a
60°
4
4
3
60° OK
120°
2
5-64

Generator cover
Crankshaft holder “2” Shaft holder “2”

90890-06732 90890-06721
Crankshaft holder “2” Shaft holder “2”
YW-06562 YW-06721
Shaft holder “3” Drive handle “3”
90890-06721 90890-06722
Shaft holder “3” Drive handle “3”
YW-06721 YW-06722
90890-06722 Special nut “4”
Drive handle “4” 250 Nm (25.0 kgf·m, 184.4 ft·lb)
YW-06722
12. Install the idle gear.
Transfer shaft “1”
13. Install the dowel pins “1”, a new gasket “2”,
250 Nm (25.0 kgf·m, 184.4 ft·lb)
and the generator cover “3”, and then tight-
11. Hold the flywheel magneto “1” using the en the generator cover ASSY bolts “4” to
special service tools “2” and “3”, and then the specified torque.
tighten the special nut “4” to the specified
1
torque.
3
After tightening, do not operate the engine
at a speed higher than idling speed for 24
hours.
TIP: 1
Use a hexagon bit socket “5” with a length of
150 mm (5.91 in) or more and a width across 2
flats of 12 mm.
4
1 Generator cover ASSY bolt “4”

2 26 Nm (2.6 kgf·m, 19.2 ft·lb)
5 Drive coupling installation

Remove any grease from the threaded por-
tions of the transfer shaft and drive coupling,
3 making sure that the threads are clean and dry.
1. Install a new washer “1” and the drive cou-
pling “2”.
2
5 Do not reuse a washer, always replace it
with a new one.
4
1
5-65

Generator cover
2 1
2. Hold the transfer shaft using the special 5. Hold the drive coupling “1” using the spe-
service tool “1”, and then tighten the drive cial service tool “2”, and then turn the hold-
coupling “2” to the specified torque using er “3” counterclockwise to tighten it to the
the special service tool “3”. specified torque.
2
3 After tightening, do not operate the engine
1 at a speed higher than idling speed for 24
hours.
3 2
1
2 1

90890-06732
Crankshaft holder “1” 3
YW-06562
90890-06729 Coupler wrench “2”
Coupler wrench “3” 90890-06729
YW-06729 Coupler wrench “2”
YW-06729
Drive coupling “2”
250 Nm (25.0 kgf·m, 184.4 ft·lb) Holder “3”
80 Nm (8.0 kgf·m, 59.0 ft·lb)
3. Remove any grease from the threaded
portion of the holder “1”.
4. Install the holder “1”.
5-66

Cylinder block and electrical part

11 Nm (1.1 kgf·m, 8.1 ft·Ib) 6 19 Nm (1.9 kgf·m, 14.0 ft·Ib)
6
1 7 7
7 7 LT
572
8
5 9
A
2 4
11 10
3
2 LT
572
10
LT
572
18
17
16 13
15
A
14
1322D
20
19
15 Nm (1.5 kgf·m, 11.1 ft·Ib)

20 Nm (2.0 kgf·m, 14.8 ft·Ib) 12

1 Clamp 1
2 Bolt 2 M6 × 25 mm
3 Earth plate 1
5 Oil return hose 1
6 Bolt 2 M6 × 16 mm
7 Bolt 4 M8 × 20 mm
8 Plate 1
10 Bolt 2 M6 × 16 mm
11 Thermo switch 1
12 Bolt 1 M8 × 40 mm
13 Anode ASSY 1
14 Bolt 1 M6 × 20 mm
5-67

11 Nm (1.1 kgf·m, 8.1 ft·Ib) 6 19 Nm (1.9 kgf·m, 14.0 ft·Ib)

6
1 7 7
7 7 LT
572
8
5 9
A
2 4
11 10
3
2 LT
572
10
LT
572
18
17
16 13
15
A
14
1322D
20
19
15 Nm (1.5 kgf·m, 11.1 ft·Ib)

20 Nm (2.0 kgf·m, 14.8 ft·Ib) 12

16 Cover 1
17 Grommet 1
18 Anode 1
19 Engine temperature sensor 1
5-68

Oil separator tank and oil pan

10 Nm (1.0 kgf·m, 7.4 ft·Ib)
6 5
7
4
2 10
11
9 Nm (0.9 kgf·m, 6.6 ft·Ib) 1

2 Nm (0.2 kgf·m, 1.5 ft·Ib)
12 Nm (1.2 kgf·m, 8.9 ft·Ib) 8

8
9
17
16 9
8
24 8
15 25
14
15 20 Nm (2.0 kgf·m, 14.8 ft·Ib)
18
1 0.3 Nm (0.03 kgf·m, 0.22 ft·lb)
2 12 Nm (1.2 kgf·m, 8.9 ft·lb)
13
21
9 Nm (0.9 kgf·m, 6.6 ft·Ib)
23
22
19 20 A
12 10 Nm (1.0 kgf·m, 7.4 ft·Ib) A

1 Bolt 1 M4 × 8 mm
2 Oil pressure switch 1
3 Clamp 1
5 Bolt 9 M6 × 25 mm
6 Water jacket cover 1
8 Bolt 9 M6 × 20 mm
9 Bolt 2 M6 × 14 mm
10 Oil separator tank cover 1
12 Bolt 17 M6 × 35 mm
13 Bolt 1 M6 × 20 mm
14 Oil pan 1
15 Dowel pin 2
5-69

10 Nm (1.0 kgf·m, 7.4 ft·Ib)
6 5
7
4
2 10
11
9 Nm (0.9 kgf·m, 6.6 ft·Ib) 1

2 Nm (0.2 kgf·m, 1.5 ft·Ib)
12 Nm (1.2 kgf·m, 8.9 ft·Ib) 8

8
9
17
16 9
8
24 8
15 25
14
15 20 Nm (2.0 kgf·m, 14.8 ft·Ib)
18
1 0.3 Nm (0.03 kgf·m, 0.22 ft·lb)
2 12 Nm (1.2 kgf·m, 8.9 ft·lb)
13
21
9 Nm (0.9 kgf·m, 6.6 ft·Ib)
23
22
19 20 A
12 10 Nm (1.0 kgf·m, 7.4 ft·Ib) A

16 Bolt 6 M6 × 14 mm
17 Baffle plate 1
18 Bolt 1 M6 × 14 mm
19 Bolt 2 M6 × 60 mm
20 Washer 2
21 Oil pipe 1
23 Grommet 1
24 Oil pan plug 1 M8 × 20 mm
5-70

Anode check Oil pipe bolt “1”

1. Check the anode. Replace if eroded. 1st: 0.3 Nm (0.03 kgf·m, 0.2 ft·lb)
Clean if there is grease, oil, or scales. 2nd: 12 Nm (1.2 kgf·m, 8.9 ft·lb)
Oil pipe stay bolt “2”
9 Nm (0.9 kgf·m, 6.6 ft·lb)
Do not apply grease, oil, or paint to the an-
ode. 5. Install the baffle plate “1”, and then tighten
the baffle plate bolts “2” to the specified
Oil pan assembly torque.
1. Install the grommet “1” onto the oil pipe “2”. 6. Install a new gasket “3” and the oil pan
plug “4”, and then tighten the oil pan plug
2. Install a new gasket “3”, the oil pipe “2”,
“4” to the specified torque.
and the washers “4”, and then tighten the
oil pipe stay bolts “5” temporarily.
2
2
3
1
1 3
4
Baffle plate bolt “2”

12 Nm (1.2 kgf·m, 8.9 ft·lb)
Oil pan plug “4”
5 4 20 Nm (2.0 kgf·m, 14.8 ft·lb)
Oil separator tank cover installation

3. Tighten the oil pipe bolt “1” to the specified
torque for the 1st stage. 1. Install a new gasket “1” and the oil separa-
tor tank cover “2”, and then tighten the oil
4. Tighten the oil pipe stay bolts “2” to the separator tank cover bolts “3” and “4” in the
specified torque, and then tighten the oil order [1], [2], and so on.
pipe bolt “1” to the specified torque for the
2nd stage.
1 2
2
3
4
5-71

3 [4] [1] 4 [5] [6] 4 [10]

[9]
[8] 4 [3] 4 [2] [7] 4 [11]
5-72

Crankcase, connecting rod, and piston
1T
7 10
2T 50 Nm (5.0 kgf·m, 36.9 ft·Ib)
12
9 11
E 16
8 15 18
7 5
Y
12
1 51 Nm (5.1 kgf·m, 37.6 ft·lb) 12 12
6
2 90˚ 12
12 3
4 13
6 14
21 18
17
15
2
15 18
15
20
19
15 18 15 1
16
17 10 Nm (1.0 kgf·m, 7.4 ft·Ib)
15
1 30 Nm (3.0 kgf·m, 22.1 ft·lb)
10 Nm (1.0 kgf·m, 7.4 ft·Ib) 2 90˚

1 Bolt 12 M6 × 70 mm
3 Crankcase 1
5 Connecting rod 4
6 Connecting rod bearing 8
7 Piston pin clip 8 Not reusable
8 Piston pin 4
9 Piston 4
10 Piston ring set 4
11 Crankshaft 1
12 Crankshaft bearing 10
14 Dowel pin 1
15 Bolt 12 M10 × 30 mm
16 Bracket 2
5-73

1T
7 10
2T 50 Nm (5.0 kgf·m, 36.9 ft·Ib)
12
9 11
E 16
8 15 18
7 5
Y
12
1 51 Nm (5.1 kgf·m, 37.6 ft·lb) 12 12
6
2 90˚ 12
12 3
4 13
6 14
21 18
17
15
2
15 18
15
20
19
15 18 15 1
16
17 10 Nm (1.0 kgf·m, 7.4 ft·Ib)
15
1 30 Nm (3.0 kgf·m, 22.1 ft·lb)
10 Nm (1.0 kgf·m, 7.4 ft·Ib) 2 90˚

17 Bracket 2
18 Dowel pin 8
19 Bolt 1 M6 × 12 mm
20 Baffle plate 1
21 Cylinder block 1
5-74

Crankcase disassembly
1. Place the crankcase upside down on a TIP:
For reference during installation, make identifi-
bench.
cation marks “a” on the connecting rod cap,
2. Remove the crankcase “1”. connecting rod, connecting rod bearings, and
piston crown.
TIP:
• Loosen the crankcase bolts in the opposite
order used for tightening.
• The numbers embossed on the crankcase 1
indicate the crankcase tightening order. a
• Insert a flat-head screwdriver between the 2
reinforced portions “a” of the cylinder block a
“2” and the crankcase “1” to separate them.
• Work carefully and make sure that the cylin-
der block and crankcase separate evenly.
a
1
a
a a 3
2
2 a
3. Remove the crankshaft bearings “1” from 2. Remove the piston pin clips “1”, piston pin
the crankcase. “2”, and connecting rod “3”.
TIP:
Write down the position of each crankshaft
bearing “1” so that it can be installed in its orig- 3
1
inal position.
1
2
1
3. Remove the piston rings.
Connecting rod and piston removal Crankcase check

1. Remove the connecting rod cap “1”, and 1. Check the oil passages. Blow out using
then remove the connecting rod bearings compressed air if there are obstructions.
“2” and piston and connecting rod “3”.
5-75

Cylinder block check

1. Measure the cylinder bore (D1–D6) at TIP:
When measuring the piston pin boss inside di-
measuring points “a”, “b”, and “c”, and in
ameter “a”, do not measure it at the oil grooves
direction “d” (D1, D3, D5), which is parallel
“b” or piston pin slot “c”.
to the crankshaft, and direction “e” (D2,
D4, D6), which is at a right angle to the
crankshaft. Replace the crankcase if out of a
c
specification.
b b
a D2 D1
b d
c
D4 D3 e
D6 D5
Pin boss bore diameter
22.004–22.015 mm (0.8663–0.8667 in)
Limit
a. 20 mm (0.79 in)
22.045 mm (0.8679 in)
b. 50 mm (1.97 in)
c. 80 mm (3.15 in)
Piston clearance check
Bore size 1. Measure the piston diameter. See “Piston
86.000–86.015 mm (3.3858–3.3864 in) check” (5-76).
Limit
2. Measure the cylinder bore. See “Cylinder
86.100 mm (3.3898 in)
block check” (5-76).
Piston check 3. Calculate the piston clearance. Replace
1. Measure the piston diameter “a” at the the piston or crankcase if out of specifica-
specified measuring point “b”. tion.
a Piston clearance = maximum cylinder bore
b - piston outside diameter
Piston clearance
0.080–0.090 mm (0.0032–0.0035 in)
Limit
0.200 mm (0.0079 in)
Piston ring check

1. Measure piston ring dimensions B and T.
Diameter Replace the piston rings as a set if out of
85.915–85.930 mm (3.3825–3.3831 in) specification.
Measuring point
9.5 mm (0.37 in)
2. Measure the piston pin boss bore diameter

“a”. Replace if out of specification.
5-76

a b Top ring
End gap (installed)
B B
0.300–0.450 mm (0.0118–0.0177 in)
T T
Limit
0.700 mm (0.0276 in)
2nd ring
c B
End gap (installed)
0.450–0.600 mm (0.0177–0.0236 in)
T
Limit
a. Top ring 0.850 mm (0.0335 in)
b. 2nd ring Oil ring
c. Oil ring End gap (installed)
0.100–0.350 mm (0.0039–0.0138 in)
Top ring End gap measuring point
Height (B) 6.0 mm (0.24 in)
1.170–1.190 mm (0.0461–0.0469 in)
Width (T) 3. Measure the piston ring grooves.
2.850–3.050 mm (0.1122–0.1201 in)
2nd ring
a
Height (B)
1.170–1.190 mm (0.0461–0.0469 in)
Width (T) b
2.600–2.800 mm (0.1024–0.1102 in)
Oil ring c
Height (B)
2.370–2.470 mm (0.0933–0.0972 in)
Width (T)
a. Ring groove (Top)
2.500 mm (0.0984 in)
b. Ring groove (2nd)
2. Measure the piston ring end gap “a” at the c. Ring groove (Oil)
specified measuring point “b”.
Ring groove (Top ring)
1.210–1.230 mm (0.0476–0.0484 in)
Ring groove (2nd ring)
1.210–1.230 mm (0.0476–0.0484 in)
Ring groove (Oil ring)
2.510–2.530 mm (0.0988–0.0996 in)
a
4. Measure the piston ring side clearance.
Replace the piston and piston rings as a
b set if out of specification.
5-77

a
a
a. Top ring side clearance

b
b. 2nd ring side clearance e
c. Oil ring side clearance
c
f
Top ring
Side clearance d
0.020–0.060 mm (0.0008–0.0024 in)
Limit
0.110 mm (0.0043 in) Outside diameter
2nd ring 21.991–22.000 mm (0.8658–0.8661 in)
Side clearance Limit
0.020–0.060 mm (0.0008–0.0024 in) 21.981 mm (0.8654 in)
Limit
0.120 mm (0.0047 in) Connecting rod check
Oil ring 1. Measure the connecting rod small end in-
Side clearance side diameter “a”. Replace if out of specifi-
0.040–0.160 mm (0.0016–0.0063 in) cation.
Piston pin check

1. Measure the piston pin outside diameter
“a” at measuring points “b”, “c”, and “d”, a
and in directions “e” and “f”. Replace if out
of specification.
Small end inside diameter

22.015–22.028 mm (0.8667–0.8672 in)
Crankshaft check
1. Measure the crankshaft journal diameter
“a” and crankshaft pin diameter “b”. Re-
5-78

TIP:
• Install the connecting rod bearings “1” in their
original positions.
• Fit the protrusion “a” on each bearing into the
slots “b” in the connecting rod cap “3” and
connecting rod “2”.
1
b
2
b
a
3
b
3. Put a piece of Plastigauge “1” on the
crankshaft pin, parallel to the crankshaft.
Journal diameter
TIP:
39.976–40.000 mm (1.5739–1.5748 in) Do not put the Plastigauge “1” over the oil hole
Pin diameter in the crankshaft pin.
41.976–42.000 mm (1.6526–1.6535 in)
2. Measure the crankshaft runout. Replace if 1

4. Clean the connecting rod bolts.
5. Lubricate the threads of the connecting rod

Runout limit bolts with molybdenum disulfide grease.
0.030 mm (0.0012 in)
Crankshaft pin oil clearance check

1. Clean the connecting rod bearings “1” and
connecting rod big end.
2. Install the upper bearing into the connect-

ing rod “2” and lower bearing into the con-
necting rod cap “3”.
5-79

6. Before installing the connecting rod onto • Do not turn the connecting rod or crankshaft
the crankshaft, assemble the connecting until the crankshaft pin oil clearance mea-
rod, which the connecting rod bearings surement has been completed.
were installed in step 2, to the crankshaft
kept in the current condition.
c
TIP:
Tighten the connecting rod bolts while check- b
ing that the sections shown “a” and “b” are
flush with each other by touching the surface.
YH
a
9. Tighten the connecting rod bolts to the

specified torques in 2 stages.
Connecting rod bolt
1st: 51 Nm (5.1 kgf·m, 37.6 ft·lb)
2nd: 90°
10. Remove the connecting rod cap and mea-

sure the width “a” of the compressed Plas-
a tigauge on each crankshaft pin. Replace
the connecting rod bearings if out of spec-
b ification.
7. Tighten the connecting rod bolts to the a

specified torque.
Connecting rod bolt
30 Nm (3.0 kgf·m, 22.1 ft·lb)
Pin oil clearance
8. Loosen the connecting rod bolts, remove
0.020–0.056 mm (0.0008–0.0022 in)
the connecting rod and connecting rod cap
Limit
and install these parts to the crankshaft
0.09 mm (0.0035 in)
with the connecting rod bearings kept in
the current condition.
Connecting rod big end side
TIP: clearance check
• Make sure that the “Y” mark “a” on the con- 1. Measure the connecting rod big end side
necting rod faces toward the timing chain clearance “a”. Measure the connecting rod
drive gear “b” of the crankshaft. big end width “b” and crankshaft pin width
• After installation, check that the section “c” is “c” if out of specification.
flush by running your finger across the sur-
face.
5-80

2. Check the crankshaft pin size number “a”
on the crankshaft web.
P1 P2 P3 P4
a
P
a
P2 P3
P1 P4
3. Select the suitable color “a” for the con-

necting rod bearing from the table.
a
Calculation formula:
Connecting rod bearing size number = con-
b c necting rod size number - crankshaft pin
size number
Big end side clearance
Bearing size number Bearing color
0.160–0.262 mm (0.0063–0.0103 in)
Limit 1 Blue
0.50 mm (0.0197 in) 2 Black
Big end width 3 Brown
26.788–26.840 mm (1.0546–1.0567 in)
4 Green
Crankshaft pin width
27.000–27.050 mm (1.0630–1.0650 in) Example:
“P1” connecting rod size number “5”
Connecting rod bearing selection “P1” crankshaft pin size number “1”
1. Check the connecting rod size number “a” 5-1=4
on the connecting rod. Select the size “4”, “Green” connecting rod
bearing.
a Crankshaft journal oil clearance
check
C5 1. Clean the crankshaft bearings, crankshaft
journals, and bearing portions of the crank-
case and cylinder block.
5-81

2. Place the cylinder block upside down on a • Do not turn the crankshaft until the journal oil
bench. clearance measurement has been complet-
ed.
3. Install the crankshaft bearings “1” into the
cylinder block and crankcase.
1 2 2
TIP:
• Install the crankshaft bearings “1” in their
original positions.
slots “b” in the cylinder block and crankcase.
a
1
4. Install the crankshaft.
5. Put a piece of Plastigauge “1” on each

crankshaft journal, parallel to the crank- [7] [5] [1] [3] [9] 2
shaft.
TIP:
Do not put the Plastigauge “1” over the oil hole [10] [4] [2] [6] [8]
in the main journals of the crankshaft.
1 Crankcase bolt “2”

1st: 30 Nm (3.0 kgf·m, 22.1 ft·lb)
2nd: 90°
7. Install the crankcase bolts “1”, and then

tighten them to the specified torque in the
1
6. Install the crankcase “1” and crankcase
bolts “2”, and then tighten the crankcase
bolts “2” to the specified torques in 2 stag-
es and in the order [1], [2], and so on.
TIP:
• When checking the journal oil clearance, re-
use the removed crankcase bolts “2”.
5-82

[11] [7] [5] [1] [3] [9] J1 J2 J3 J4 J5

5 5 5 4 5
1
[12] [10] [4] [2] [6] [8] 55545

If “J1”–“J5” are the same:
Crankcase bolt “1”
10 Nm (1.0 kgf·m, 7.4 ft·lb) J1 J2 J3 J4 J5
8. Remove the crankcase and measure the 5 5 5 5 5
width “a” of the compressed Plastigauge
on each crankshaft journal. Replace the
crankshaft bearings if out of specification.
Journal oil clearance

0.024–0.053 mm (0.0009–0.0021 in)
Limit J5 J4 J3 J2 J1
0.10 mm (0.0039 in)
Crankshaft bearing selection a

1. Check the crankcase journal size number
“a” on the crankcase.
2. Check the crankshaft journal size number
TIP: “a” on the crankshaft web.
If the crankcase journal sizes are the same at
all positions, the size number “a” is stamped J1 J2 J3 J4 J5
only at the “J1” position. a J
Example:
If “J1”–“J5” are different:
J1 J2 J3 J4 J5
3. Select the suitable color “a” for the crank-

shaft bearing from the table.
5-83

a
4
a
c
a 4
Calculation formula:
Crankshaft bearing size number = crank-
case journal size number - crankshaft jour- 3
nal size number
4
Bearing size number Bearing color 2
1 Brown
b
2 Black
3 Blue 2. Install the oil ring “1”, 2nd ring “2”, and top
ring “3”.
4 Green
5 Yellow
Do not scratch the pistons or break the pis-
Example: ton rings.
“J1” crankcase journal size number “5”
“J1” crankshaft journal size number “2”
5-2=3 3. Offset the piston ring end gaps.
Select the size “3”, “Blue” crankshaft bear-
ing.
TIP:
• Make sure to install the piston rings so that
the “1T” mark on the top ring “3” and the “2T”
Connecting rod and piston
mark on the 2nd ring “2” face up.
installation
• After installing the piston rings, make sure
1. Assemble the connecting rod “1”, piston that they move smoothly.
“2”, piston pin “3”, and new piston pin clips
“4”.
1
Do not reuse a piston pin clip, always re-
#5
place it with a new one. #4
#3 2
TIP: #2
• When installing the connecting rod to the pis- #1
ton, make sure that the “Y” mark “a” on the 45 45
#5 #1
connecting rod faces toward the front mark #4
“b” on the piston crown.
• Do not allow the piston pin clip ends to align
3
with the piston pin slot “c”. #2 #3
4. Clean the connecting rod bearings “1” and

connecting rod big end.
5-84

5. Install the upper bearing into the connect-
ing rod “2” and lower bearing into the con-
necting rod cap “3”.
TIP:
• Install the connecting rod bearings “1” in their
original positions.
slots “b” in the connecting rod cap “3” and
connecting rod “2”.
a
1
b
b
2
b
a
3
9. Tighten the connecting rod bolts to the
6. Clean the connecting rod bolts. specified torque.
7. Lubricate the threads of the connecting rod Connecting rod bolt
bolts with molybdenum disulfide grease. 30 Nm (3.0 kgf·m, 22.1 ft·lb)
10. Loosen the connecting rod bolts, and then

remove the connecting rod and connecting
rod cap, keeping the connecting rod bear-
ings in the present state.
11. While compressing the piston rings using

the special service tool “1”, install the pis-
ton and connecting rod “2” into the cylin-
der, keeping the connecting rod bearings
in their present state.
8. Before installing the connecting rod onto
the crankshaft, assemble the connecting TIP:
rod to which the connecting rod bearings Make sure that the “Y” mark on the connecting
have been installed in step 5 to the crank- rod faces toward the timing chain drive gear of
shaft, keeping the present state. the crankshaft.
TIP:
Tighten the connecting rod bolts while check-
ing that the sections shown “a” and “b” are
1
flush with each other by touching the surface.
2
Y
5-85

Piston ring compressor “1” TIP:

90890-05158 After installation, check that section “a” is flush
Piston ring compressor “1” by running your finger across the surface.
YM-08037
12. Install half of the crankshaft bearings “1” 17. Tighten the connecting rod bolts “2” to the
into the cylinder block. specified torques in 2 stages.
TIP:
• Install the crankshaft bearings “1” in their • When a connecting rod bolt is tightened
original positions. more than the specified angle, do not
• Fit the protrusion “a” on each bearing into the loosen the connecting rod bolt and then
slots “b” in the cylinder block. retighten it. Replace the connecting rod
bolt with a new one and perform the pro-
cedure again.
a
• If the mating surfaces between the con-
1 necting rod and connecting rod cap are
uneven, remove the connecting rod bolts
and connecting rod bearings, and then
b
perform the bearing installation proce-
dure again. In this case, make sure to re-
place the connecting rod bolts.
2
13. Install the crankshaft. 2
14. Replace the connecting rod bolt with a new

one.
1
a
Do not reuse a connecting rod bolt, always

replace it with a new one.
15. Lubricate the threads of the connecting rod Connecting rod bolt “2”
bolts with molybdenum disulfide grease. 1st: 51 Nm (5.1 kgf·m, 37.6 ft·lb)
2nd: 90°
Crankcase assembly
1. Thoroughly clean all the gasket surfaces
and crankcase mating surfaces.
2. Install half of the crankshaft bearings “1”

into the crankcase.
TIP:
• Install the crankshaft bearings “1” in their
16. Install the connecting rod cap “1” onto the original positions.
piston and connecting rod, keeping the • Fit the protrusion “a” on each bearing into the
connecting rod bearings in their present slots “b” in the crankcase.
state.
5-86

a 2
1 2
1
b
3. Install the dowel pin “1” and a new O-ring

“2”.
2
1
[7] [5] [1] [3] [9] 2

4. Apply sealant to the mating surface of the
crankcase.
[10] [4] [2] [6] [8]

1st: 30 Nm (3.0 kgf·m, 22.1 ft·lb)
2nd: 90°
6. Install the crankcase bolts “1”, and then

tighten them to the specified torque in the
5. Install the crankcase “1” and new crank-
case bolts “2”, and then tighten the crank- 1
case bolts “2” to the specified torques in 2
stages and in the order [1], [2], and so on.
Do not reuse a crankcase bolt, always re-

place it with a new one.
5-87

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

10 Nm (1.0 kgf·m, 7.4 ft·lb)
5-88

— MEMO —
5-89

Jet pump unit
Intake grate and ride plate................................................. 6-1
Jet pump unit...................................................................... 6-2

Jet pump unit removal ................................................................ 6-3
Impeller check ............................................................................ 6-3
Jet pump unit installation............................................................ 6-3
Trim rod adjustment ................................................................... 6-4
Jet thrust nozzle angle adjustment............................................. 6-5
Reverse gate ....................................................................... 6-7
Nozzle and nozzle ring....................................................... 6-8
Impeller housing and impeller duct ASSY ....................... 6-9
Impeller, drive shaft, and impeller duct ......................... 6-10

Impeller duct ASSY disassembly ............................................. 6-11
Impeller housing check............................................................. 6-12
Drive shaft check...................................................................... 6-12
Impeller duct ASSY assembly .................................................. 6-12
Impeller duct, impeller housing, and nozzle installation ........... 6-14
Transom plate and hoses ................................................ 6-16

6
Bilge strainer check .................................................................. 6-18
Transom plate installation ........................................................ 6-18
Intermediate housing ....................................................... 6-19

Intermediate housing removal .................................................. 6-20
Intermediate housing disassembly ........................................... 6-20
Intermediate housing assembly................................................ 6-21
Intermediate housing installation.............................................. 6-22

Intake grate and ride plate
Intake grate and ride plate
SS
9 3
5
SS
SS
SS
4
3
LT
8 242
3
SS
6
7 1
2
17 Nm (1.7 kgf·m, 12.5 ft·Ib)
3 LT
1 242
LT 1
242
3
3

2 Speed sensor 1
3 Bolt 10 M8 × 35 mm
4 Ride plate 1
5 Bracket 2
6 Spacer 1
7 Intake grate 1
8 Bracket 1
9 Bracket 2
6-1

Jet pump unit
Jet pump unit
13 15 Nm (1.5 kgf·m, 11.1 ft·Ib)

2.5 Nm (0.25 kgf·m, 1.84 ft·lb)
14
8 A
15
5
17 Nm (1.7 kgf·m, 12.5 ft·Ib)
LT
4 242
LT
9
16 572
9
LT
11 572
1
12
2
10 11
11 6
12 4
LT
3 572
1207B 7

1 Shift rod joint 1
2 Trim 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 Bolt 2 M8 × 18 mm
10 Bolt 1 M6 × 30 mm
11 Bolt 4 M10 × 45 mm
12 Dowel pin 2
13 Bolt 2 M8 × 13 mm
14 Washer 2
16 Bracket 1
6-2

Jet pump unit
Jet pump unit removal

TIP:
The illustration shows the case where the disk
Make sure to remove the battery before re- brake piston tool “3” is used to remove the jet
moving the jet pump unit. pump unit “1”.
1. Remove the speed sensor “1” and ride

plate “2”.
2. Remove the spacer “3” and intake grate

“4”.
2
1
2 3 1
4
Impeller check
1. Check the impeller “1”. Replace if dam-
aged.
3
2. Measure the impeller-to-housing clear-
3. Disconnect the shift rod joint “1”, trim rod ance “a”. Measure the impeller housing in-
joint “2” steering cable joint “3”, bilge hose side diameter if the impeller-to-housing
“4”, and spout hose “5”. clearance “a” is out of specification.
2
1
5
5
3
1 4 a
4. Remove the bolts “1”, “2”, and “3”. Impeller clearance

2 0.350–0.450 mm (0.0138–0.0177 in)
1 Limit
0.60 mm (0.0236 in)
Jet pump unit installation
Make sure to remove the battery before in-

3 stalling the jet pump unit.
3
1. Clean the mating surfaces of the jet pump
5. Gradually increase the distance between
unit “1” and transom plate “2”.
the jet pump unit “1” and the transom plate
“2”, and then remove the jet pump unit “1”. 2. Apply sealant to the mating surfaces of the
jet pump unit “1” and transom plate “2”.
6-3

Jet pump unit
1207B 1 4 1
2
2
1
5
3. Install the jet pump unit, and then tighten
3 6
the bolts “1” and “2” to the specified
torques. 7
4. Tighten the jet pump unit bolt “3”. Spout hose clamp “2”
2 2.5 Nm (0.25 kgf·m, 1.84 ft·lb)
3
1 Steering cable joint nut “7”
7 Nm (0.7 kgf·m, 5.2 ft·lb)
9. Initialize the RiDE system using the YDIS.

See “YDIS Instruction Manual”.
1
LT LT
Trim rod adjustment
572 2 572 3 1. Push the unlock button on the remote con-
1
trol transmitter so that power is supplied to
Jet pump unit bolt (M10 × 45 mm) “1” the ECM and the trim position is set to the
40 Nm (4.0 kgf·m, 29.5 ft·lb) N position.
Jet pump unit bolt (M8 × 18 mm) “2”
17 Nm (1.7 kgf·m, 12.5 ft·lb) 2. Disconnect the shift rod joint “1”.
5. Connect the spout hose “1”, and then tight-

en the clamp “2” to the specified torque.
1
6. Connect the bilge hose “3”, and then fas-
ten it using the clamp.
7. Connect the trim rod joint “4” and shift rod

joint “5”.
8. Connect the steering cable joint “6”, and

then tighten the nut “7” to the specified 3. Disconnect the trim rod joints “1”.
torque.
4. Loosen the locknut “2”.
TIP:
Make sure that the steering and shifting oper-
ate correctly.
6-4

Jet pump unit
1 Turn out Distance “a” is increased.

1
Turn in Distance “b” is increased.
Distance “c”
2 8.0 mm (0.31 in) or more
6. Connect the trim rod joints, and then tight-

1 en the locknut to the specified torque.
Locknut
5. Adjust the trim rod joint “1” until the dis- 4 Nm (0.4 kgf·m, 3.0 ft·lb)
tances “a” and “b” are equal.
7. Connect the shift rod joint “1”.
Do not rotate the trim rod joint more than 2

turns on either end. Otherwise, the trim rod
joint may not be screwed in more than 8 1
mm (0.31 in).
TIP:
When adjusting, make sure to rotate the trim
rod joint 1 full turn each time. The trim rod is re-
tracted by 0.8 mm (0.03 in) per 1 trim rod joint
8. Initialize the RiDE system using the YDIS.
rotation.
See “YDIS Instruction Manual”.
Jet thrust nozzle angle adjustment

1 1. Remove the service lid.
2. Loosen the locknut “1”.
3. Disconnect the steering cable joint “2” from

a the ball joint “3”.
4. Turn the steering cable joint “2” in or out to

adjust distances “a” and “b”.
The steering cable joint must be screwed in

b
more than 8 mm (0.31 in).
c 1
3
6-5

Jet pump unit
a b
Turn in Distance “a” is increased.

Turn out Distance “b” is increased.
Distance “c”
8.0 mm (0.31 in) or more
5. Connect the steering cable joint to the ball

joint, and then tighten the locknut to the
specified torque.
Locknut
7 Nm (0.7 kgf·m, 5.2 ft·lb)
6. Check the difference of distances “a” and

“b” again.
a b
7. Install the service lid.
6-6

Reverse gate
Reverse gate
A
10
A 9 8
1
6
11 5
10
A
2
11 3
5
6
A
3
20 Nm (2.0 kgf·m, 14.8 ft·Ib)
6
4
7

1 Spring 1
2 Bolt 2 M8 × 25 mm
3 Collar 2
4 Reverse gate 1
5 Nut 2
6 Washer 3
7 Ball joint 1
8 Bolt 1 M6 × 35 mm
9 Collar 1
10 Bolt 6 M6 × 25 mm
11 Reverse gate stay 2
6-7

Nozzle and nozzle ring
Nozzle and nozzle ring
16 Nm (1.6 kgf·m, 11.8 ft·lb)
16 Nm (1.6 kgf·m, 11.8 ft·lb)

5 6
1
7 3
2
1
2
4 1

1 Bolt 4 M8 × 25 mm
2 Collar 4
3 Jet thrust nozzle 1
4 Nozzle ring 1
5 Nut 1
6 Washer 2
7 Ball joint 1
6-8


40 Nm (4.0 kgf·m, 29.5 ft·lb)
4 3
1 Nm (0.1 kgf·m, 0.7 ft·lb)
2 3
a 5
1
7
3
11
LT
572
8
10
7
7 Nm (0.7 kgf·m, 5.2 ft·Ib)
9

1 Clamp 1
2 Spout hose 1 a: Yellow paint mark
3 Bolt 4 M10 × 125 mm
4 Bracket 1
5 Nozzle 1
6 Impeller housing 1
7 Dowel pin 4
8 Bolt 4 M6 × 20 mm
9 Water inlet strainer 1
11 Impeller duct ASSY 1
6-9

Impeller, drive shaft, and impeller duct

15
10 74 Nm (7.4 kgf·m, 54.6 ft·Ib)

9
8
2
3
4
7
12 2
1
330 Nm (33.0 kgf·m, 243.4 ft·lb)
5
6
11
13
14

1 Impeller 1
2 Bolt 3 M6 × 20 mm
3 Cap 1
5 Nut 1
6 Washer 1
7 Spacer 1
12 Spacer 1
14 Drive shaft 1
15 Impeller duct 1
6-10

Impeller duct ASSY disassembly

1. Remove the impeller “1”.
1
1
4. Remove the ball bearing “1”.
A 1
90890-06520
2 3
Driveshaft holder “2”
YB-06201 4
2. Remove the cap “1”, O-ring “2”, and nut 3

“3”.
2
1 B 1
3
5
4 5
A. Worldwide
Stopper guide plate “2”

90890-06501
3
Bearing puller assembly “3”
90890-06535
Stopper guide stand “4”
90890-06520
90890-06538
Driveshaft holder “4”
Slide hammer “5”
YB-06201
YB-06096
3. Remove the drive shaft “1”.
5. Remove the oil seals “1” and “2”.
Do not press the drive shaft threads direct-

ly.
6-11

A Driver rod L3 “3”

1 90890-06652
2
4 Driver handle (large) “3”
3
YB-06071
5 Needle bearing attachment “4”
5
90890-06609
4 Driveshaft needle bearing installer and
remover “4”
YB-06194
B Impeller housing check

1
2 1. Measure the impeller housing inside diam-
6 eter “a”. Replace if out of specification.
A. Worldwide
a
Stopper guide plate “3”

90890-06501 Inside diameter
Bearing puller assembly “4” 155.35–155.45 mm (6.116–6.120 in)
90890-06535
Stopper guide stand “5” Drive shaft check
90890-06538 1. Measure the drive shaft runout. Replace if
Slide hammer “6” out of specification.
YB-06096
6. Remove the spacer “1”, and then remove

the ball bearing “2” using a press.
3
3 4
4 a
2
Runout limit
1 0.30 mm (0.0118 in)
Distance “a”
310 mm (12.20 in)
Impeller duct ASSY assembly

1. Install a new oil seal “1” halfway into the
impeller duct, and then install a new oil
seal “2”.
6-12

A 3. Install the drive shaft “1” (along with the

ball bearing “2”) and spacer “3”.
3 2
a
4
1 3
1
A
2
B
4 2 Bearing attachment “4”
a
90890-06728
Bearing attachment “4”
YW-06728
1
A
4. Apply EPNOC grease AP #0 to the space
between the drive shaft “1” and the spacer
“2”.
A. Worldwide
Oil seal installer attachment “3” 2

90890-06733
Oil seal installer attachment “4”
YW-06628 1
Distance “a”
7.0 ± 0.2 mm (0.28 ± 0.008 in)
Grease quantity
2. Install a new ball bearing “1” onto the drive
20 g (0.7 oz)
shaft “2”.
5. Install a new ball bearing “1”.
2
1
3 1 2 1

90890-06728 Bearing attachment “2”
Bearing attachment “3” 90890-06728
YW-06728 Bearing attachment “2”
YW-06728
Distance “a”
23.0 ± 0.1 mm (0.91 ± 0.004 in)
6-13

6. Install the washer “1”, and then tighten the
drive shaft nut “2” to the specified torque. 1
7. Apply EPNOC grease AP #0 to the inside 2
of the cap “3”, and then install a new O-ring
“4” and the cap “3”.
4
1 3
2
90890-06520
EP Driveshaft holder “2”
5 LT YB-06201
572
Impeller “1”
330 Nm (33.0 kgf·m, 243.4 ft·lb)
Impeller duct, impeller housing, and

nozzle installation
1. Clean the mating surfaces of the impeller
duct, impeller housing, and nozzle.
2
2. Apply sealant to the mating surfaces of the
Drive shaft holder 6 “5” impeller duct “1” and impeller housing “2”.
90890-06520
Driveshaft holder “5” 3. Install the dowel pins “3”, and then install
YB-06201 the impeller housing “2”.
Drive shaft nut “2” 2

74 Nm (7.4 kgf·m, 54.6 ft·lb) 3
Grease quantity
20 g (0.7 oz)
8. Install the O-ring “1” to the spacer “2”. 1

3
9. Install the spacer “2” and impeller “3”.
4. Apply sealant to the mating surfaces of the
nozzle “1” and impeller duct “2”.
5. Install the dowel pins “3” and nozzle “1”.

3 1
6. Install the bracket “4”, and then tighten the
impeller duct bolts “5” to the specified
torque.
2
10. Tighten the impeller “1” to the specified

torque.
6-14

4 5
5
3
2 5
1
3
Impeller duct bolt “5”

40 Nm (4.0 kgf·m, 29.5 ft·lb)
6-15

Transom plate and hoses

15 17 26 Nm (2.6 kgf·m, 19.2 ft·Ib)
3
22 26
21
20
19 13 20 19
14
25
18 16 24
17
23
21
1
9 4
5
7
6
a 9
14 1
11 8 7
3
1
2
12
2 6 Nm (0.6 kgf·m, 4.4 ft·Ib)

1
10 26 Nm (2.6 kgf·m, 19.2 ft·Ib)

1 Clamp 4
3 Plastic tie 2
4 Cap 1
5 Nut 1
6 Clamp 1
7 Flushing hose 1
8 Hose joint 1 1
9 Cooling water hose 1 a: White paint mark
10 Rivet 1
11 Plastic tie 1
12 Bilge strainer ASSY 1
13 Clamp 2
14 Bilge hose 1
15 Hose joint 1
16 Clamp 1
6-16

15 17 26 Nm (2.6 kgf·m, 19.2 ft·Ib)

3
22 26
21
20
19 13 20 19
14
25
18 16 24
17
23
21
1
9 4
5
7
6
a 9
14 1
11 8 7
3
1
2
12
2 6 Nm (0.6 kgf·m, 4.4 ft·Ib)

1
10 26 Nm (2.6 kgf·m, 19.2 ft·Ib)

17 Bilge hose 1
18 Plastic tie 1
19 Clamp 2
21 Nut 4
22 Washer 2
23 Washer 2
24 Plastic tie 1
25 Bilge hose 1
26 Transom plate 1
6-17

Bilge strainer check

1. Check the bilge strainer. See “Jet vacuum
bilge draining system check” (3-10).
Transom plate installation

1. Clean the mating surfaces of the transom
plate “1”.
2. Apply silicone sealant to the mating sur-

face of the transom plate “1”.
3. Install the transom plate “1”, washers “2”,

and “3”, and then tighten the nuts “4” to the
specified torque.
1
2
4
3
Transom plate nut “4”

26 Nm (2.6 kgf·m, 19.2 ft·lb)
6-18

Intermediate housing
17 Nm (1.7 kgf·m, 12.5 ft·lb)
4
12
13
9 4
2
10
14
3
11
10 16
9
2 15
8
7 3 Nm (0.3 kgf·m, 2.2 ft·lb)
1
6
205 Nm (20.5 kgf·m, 151.2 ft·lb)

1 Rubber coupling 1
2 Bolt 3 M8 × 48 mm
3 Shim * As required
4 Dowel pin 2
5 Driven coupling 1
6 Washer 1
7 Intermediate drive shaft 1
10 Circlip 2 Not reusable
12 Thrust washer 1 Not reusable
14 Intermediate housing 1
15 Grease nipple 1
16 Cap 1
6-19

Intermediate housing removal

1. Remove the engine unit. See “Engine unit
1
removal” (5-7).
2
2. Remove the intermediate housing “1”.
TIP:
If shims “2” are installed, remove the shims and
write down the position of each removed shim
so that it can be installed in its original position.
3. Remove the oil seals “1”, “2”, and “3”.
A
1 4
2 6
Intermediate housing disassembly 3 1

1. Remove the driven coupling “1”.
5 2
2 5
1
B 1
3 2 8
8
7
3
8
90890-06730
Shaft holder “2” A. Worldwide
YW-06730 B. U.S.A. and Canada
90890-06729 Stopper guide plate “4”
Coupler wrench “3” 90890-06501
YW-06729 Bearing puller assembly “5”
90890-06535
2. Remove the intermediate drive shaft “1” Stopper guide stand “6”
and thrust washer “2” using a press. 90890-06538
Slide hammer “7”
YB-06096
Do not press the intermediate drive shaft Bearing puller legs “8”
directly. YB-06523
6-20

4. Remove the circlips “1”, and then remove
the ball bearing “2” using a press.
2 a
1
1
3
1
2
Needle bearing attachment “2”

90890-06654
Needle bearing attachment “3” Needle bearing installer “2”
90890-06654 YB-06434
Needle bearing installer “3”
YB-06434 Distance “a”
6.5 ± 0.2 mm (0.26 ± 0.01 in)
Intermediate housing assembly
4. Install the intermediate drive shaft “1” us-
ing a press.
Do not reuse a thrust washer, always re-
place it with a new one.
Do not press the intermediate drive shaft
1. Install a new circlip (rear) “1”. directly.
2. Install a new ball bearing “2” until it con-

tacts the circlip (rear) “1” using a press.
1
3 1
2
2
a

90890-06728
Needle bearing attachment “3” Bearing attachment “2”
90890-06654 YW-06728
Needle bearing installer “3”
YB-06434 Distance “a”
46.0 ± 0.5 mm (1.81 ± 0.02 in)
3. Install a new oil seal “1”.
5. Install a new circlip (front) “1”, and then in-
stall a new oil seal “2”.
6-21

Distance “a”
3.7 ± 0.3 mm (0.17 ± 0.01 in)
3
8. Install the washer “1”, and then tighten the
2 driven coupling “2” to the specified torque.

90890-06728
Bearing attachment “3” 2
YW-06728
1
6. Install a new oil seal “1”.
3
2
2
1 a

Bearing attachment “2” 90890-06730
90890-06727 Shaft holder “3”
Bearing attachment “2” YW-06730
YW-06727 Coupler wrench “4”
90890-06729
Distance “a” Coupler wrench “4”
1.6 ± 0.2 mm (0.06 ± 0.01 in) YW-06729
7. Install a new thrust washer “1”.
Driven coupling “2”
205 Nm (20.5 kgf·m, 151.2 ft·lb)
1
2 Intermediate housing installation
a 1. Install the intermediate housing “1”, and
1
then tighten the intermediate housing bolts
TIP:
If shims “3” were removed, install the shims in
their original positions.
90890-06727
YW-06727
6-22

2 3
1
Intermediate housing bolt “2”

17 Nm (1.7 kgf·m, 12.5 ft·lb)
6-23

— MEMO —
6-24

Electrical system
Electrical components ....................................................... 7-1

Engine ........................................................................................ 7-1
Deck and hull.............................................................................. 7-2
Electrical box .............................................................................. 7-3
ECM circuit diagram ................................................................... 7-4
ECM coupler layout .................................................................... 7-7
Electrical analysis .............................................................. 7-9

Electrical component check using the YDIS............................... 7-9
Power supply to the ECM........................................................... 7-9
Peak voltage measurement........................................................ 7-9
Test lead preparation ............................................................... 7-10
Ignition system ................................................................. 7-11

Ignition spark check.................................................................. 7-11
Ignition coil check ..................................................................... 7-11
Pickup coil check...................................................................... 7-12
Charging system .............................................................. 7-13

Stator coil check ....................................................................... 7-13
Rectifier/regulator check........................................................... 7-13
Control system ................................................................. 7-15

Oil pressure switch check......................................................... 7-15
Thermo switch check................................................................ 7-15
Thermo sensor check............................................................... 7-16
Engine temperature sensor check............................................ 7-16
Intake air temperature sensor check ........................................ 7-17
Intake air pressure sensor check ............................................. 7-18
TPS check ................................................................................ 7-18
ETV circuit continuity................................................................ 7-20
APS check................................................................................ 7-20
APS circuit continuity................................................................ 7-21
ETV relay check ....................................................................... 7-22
RPS check................................................................................ 7-23
RPS circuit continuity ............................................................... 7-23
SCU relay check....................................................................... 7-24
Electric trim switch check ......................................................... 7-25
Cam position sensor check ...................................................... 7-25
Slant detection switch check .................................................... 7-26
Steering sensor check.............................................................. 7-27
ECM check ............................................................................... 7-27
Earth plate check...................................................................... 7-28

Electrical system
Fuel system ...................................................................... 7-29

Fuel injector check ................................................................... 7-29
Fuel pump relay check ............................................................. 7-29
Fuel pump module check ......................................................... 7-30
Starting system ................................................................ 7-31

Fuse check ............................................................................... 7-31
Handlebar switch (left) check ................................................... 7-31
Main relay check ...................................................................... 7-31
Starter relay check ................................................................... 7-32
Starter motor .................................................................... 7-34

Starter motor operation ............................................................ 7-35
Armature check ........................................................................ 7-35
Brush holder check................................................................... 7-36
Remote control system ................................................... 7-37

Remote control transmitter check............................................. 7-37
Remote control receiver check................................................. 7-38
Transmitter registration ............................................................ 7-38
Indication system ............................................................. 7-40

Multifunction meter check......................................................... 7-40
Speed sensor check................................................................. 7-40
Fuel level meter display
and fuel level warning indicator check...................................... 7-41
Check engine warning indicator check..................................... 7-41
Diagnostic display check .......................................................... 7-42
Oil pressure warning indicator check ....................................... 7-42
Engine overheat warning indicator check................................. 7-42
7
Buzzer check............................................................................ 7-43

Electrical components
Engine
1 3
10
5 9
8
6
11
12
15 13
14
1. Spark plug and ignition coil

2. Cam position sensor
3. Electrical box
4. Thermo sensor
5. Rectifier/regulator
6. Starter motor
7. Oil pressure switch
8. ETV (TPS)
9. Intake air pressure sensor
10. Fuel injector
11. Thermo switch
12. Intake air temperature sensor
13. Engine temperature sensor
14. Stator coil and pickup coil
15. Earth plate
7-1

Deck and hull
3
2 4
6 8
10
1. Remote control receiver

2. Steering sensor
3. APS (electric throttle without wire cable)
4. RPS (electric shift without wire cable)
5. Speed sensor
6. Buzzer
7. Fuel pump module and fuel sender
9. Battery
10. RiDE motor
7-2

Electrical box
2
3
1
8 9 15 10 11
7 12
6 13
5 14
17 16 15
1. Fuse box 15. Spare fuse

2. Slant detection switch 16. Fuel pump relay
3. ECM 17. ETV relay
4. Starter relay
5. Fuse (10 A) (ETV relay)
6. Fuse (10 A) (fuel pump relay)
7. Main relay
8. Fuse (10 A) (main relay)
9. Fuse (20 A) (main relay)
10. Fuse (3 A) (Not used)
11. Fuse (3 A) (remote control receiver)
12. SCU relay
13. Fuse (30 A) (battery)
14. Fuse (50 A) (SCU)
7-3

ECM circuit diagram
1.Rectifier/ 2.Stator
21.Fuel injector #1
regulator coil r
3.Fuse 7 22.Fuel injector #2
(20 A) s
Q
4.Fuse (10 A) 23.Fuel injector #3
J µ
5.Main relay
24.Fuel injector #4
6. Fuse K ¥
(3 A)
D 25.Ignition coil #1
7.Engine 9.Remote
start switch control receiver
\ º
8.Fuse
(30 A)
10.Starter 26. Ignition coil #2
relay
11.Battery
12.Starter motor
27. Ignition coil #3
13. Pickup coil u

8
5V
P
14.Cam position sensor 3 35.ECM
t
15.Intake air pressure sensor F
29. Fuel pump module
16.Intake air temperature sensor
E
©
17.Engine temperature sensor
M 30.Fuel pump relay
18.Thermo sensor
C g 31.(YDIS) 32.Multifunction
meter
O
33. ETV relay
19.Steering sensor G ®
34. Fuse (10 A)
]
20. Slant detection switch e
5
a.Ground
^
, : Indicate a connection between the symbols.
7-4

36.Oil pressure switch

ß
37.Thermo switch
x
38.Engine shut-off switch

ç
46.ETV
¶
39.APS
5V l
i 47.ETV motor
v
40.APS 1 Z
a.Ground ~
X
5V 5V
j d
41.APS 2 [
a.Ground b 48.TPS 1
Y 35.ECM
5V
T c 49.TPS 2
42. APS full
close L a.Ground
a
switch a.Ground
S
43.RPS 2
5V
R 50.SCU
44.RPS 1 W 9
a.Ground
U
5V
f
k
45.RPS 2 A {
a.Ground
V
7-5

1. Rectifier/regulator 50. SCU

2. Stator coil
a. Ground
3. Fuse (20 A)
4. Fuse (10 A)
5. Main relay
6. Fuse (3 A)
7. Engine start switch
8. Fuse (30 A)
9. Remote control receiver
10. Starter relay
11. Battery
12. Starter motor
13. Pickup coil
14. Cam position sensor
15. Intake air pressure sensor
16. Intake air temperature sensor
17. Engine temperature sensor
18. Thermo sensor
19. Steering sensor
20. Slant detection switch
21. Fuel injector #1
29. Fuel pump module
30. Fuel pump relay
31. (YDIS)
33. ETV relay
34. Fuse (10 A)
35. ECM
36. Oil pressure switch
37. Thermo switch
38. Engine shut-off switch
39. APS
40. APS 1
41. APS 2
42. APS full close switch
43. RPS
44. RPS 1
45. RPS 2
46. ETV
47. ETV motor
48. TPS 1
49. TPS 2
7-6

ECM coupler layout
1 2 3 4 5 6 7 27 28 29 30 31 32 33 53 54 55 56 57 58 59 60 61
8 9 10 11 12 13 34 35 36 37 38 39 62 63 64 65 66 67 68 69
14 15 16 17 18 19 40 41 42 43 44 45 70 71 72 73 74 75 76 77
20 21 22 23 24 25 26 46 47 48 49 50 51 52 78 79 80 81 82 83 84 85 86
1 2 3 4 5 6 7 27 28 29 30 31 32 33 53 54 55 56 57 58 59 60 61
8 9 10 11 12 13 34 35 36 37 38 39 62 63 64 65 66 67 68 69
14 15 16 17 18 19 40 41 42 43 44 45 70 71 72 73 74 75 76 77
20 21 22 23 24 25 26 46 47 48 49 50 51 52 78 79 80 81 82 83 84 85 86
No. Connecting part Color No. Connecting part Color

1 — — 20 Main relay Yellow/Green
2 SCU White 21 Engine start switch Yellow
Green/ 22 APS full close switch White/Green
3 Cam position sensor
Orange Engine temperature
23 Black/Yellow
4 — — sensor
5 Slant detection switch Blue/Black 24 — —
6 — — Steering sensor pow-
25 Orange/Red
er source
7 Battery power source Red/Yellow
26 Sensor power source Orange
8 Pickup coil White/Black
27 Battery power source Red/Yellow
9 SCU Blue
28 RPS 1 power source Orange/Red
10 — —
APS full close switch
11 RPS 2 Pink/White 29 Black/Green
ground
12 — —
APS full close switch Orange/
13 Thermo sensor Black/Blue 30
power source Green
Main relay drive sig- 31 RPS 1 ground Black/Red
14 Yellow/White
nal
32 RPS 2 ground Black/White
Intake air tempera-
15 Black/Red 33 RPS 1 Pink/Red
ture sensor
34 APS 1 ground Black/Red
Intake air pressure
16 Pink/Green 35 APS 2 ground Black/White
sensor
17 Steering sensor White/Blue 36 APS 1 Pink/Red
18 — — 37 APS 2 Pink/White
19 — —
7-7

No. Connecting part Color No. Connecting part Color

Immobilizer serial 71 — —
38 White
communication Engine shut-off
72 White
ETV relay power switch
39 Red/Yellow
source (contact) 73 — —
40 Sensor ground Black/Orange 74 — —
41 TPS ground Black/Orange 75 — —
42 TPS 1 Pink 76 — —
43 TPS 2 Pink/Black 77 — —
44 TPS power source Orange 78 ETV motor (positive) Green
ETV relay power 79 Oil pressure switch Pink/White
45 Red/Yellow
source (contact)
ETV relay power
46 ECM ground Black 80 Yellow/White
source (coil)
Self-diagnosis lead 81 Fuel pump relay Blue/Red
(communication),
47 White/Black 82 — —
meter unit communi-
cation 83 Fuel injector #4 Purple/Green
48 — — 84 Fuel injector #3 Purple/Yellow
49 APS 1 power source Orange/Red 85 Ignition coil #1 Black/Red
50 APS 2 power source Orange/White 86 Ignition coil #2 Black/White
51 RPS 2 power source Orange/White
52 ETV motor (negative) Blue
53 — —
54 — —
55 — —
56 — —
57 — —
58 Fuel injector #1 Purple/Red
59 Fuel injector #2 Purple/Black
60 Ignition coil #4 Black/Green
61 Ignition coil #3 Black/Yellow
62 ETV ground Black
63 — —
64 Thermo switch Pink
65 — —
66 — —
67 Ground Black
68 — —
69 — —
70 ETV ground Black
7-8

Electrical analysis
Electrical analysis Power supply to the ECM

Electrical component check using the Push the unlock button “a” on the remote con-
YDIS trol transmitter so that power is supplied to the
When checking the TPS, APS, RPS or other ECM.
sensors, use the YDIS.
TIP:
When deleting the diagnosis record in the To check that the remote control transmitter is
YDIS, make sure to check the time when the working properly, see “Remote control trans-
diagnostic codes were detected. mitter check” (7-37).
R/Y
W/B
B
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 Peak voltage measurement
disconnected and a diagnostic code is detect-
ed. Therefore, make sure to delete the diagno-
When measuring the peak voltage, do not
sis record after checking the input voltage.
touch any of the connections of the digital
Power is supplied to the ECM for about 30 sec-
tester probes.
onds after stopping the engine. Therefore, wait
for more than 30 seconds before restarting the
engine, otherwise the diagnostic codes will not
be cleared from the ECM. • When testing the voltage between the ter-
minals of an electrical component using
TIP: the digital tester, do not allow any of the
• Before checking the electrical components, leads to touch any metal parts.
make sure that the battery is fully charged. • When starting the engine on land, make
• If the tester leads are connected while using sure to connect a garden hose to the wa-
the YDIS, diagnostic codes will be detected. tercraft for proper water supply.
• If a diagnosis record is displayed and it is
caused by the checking steps, delete the re- To check the electrical components or mea-
cord by using the “Diagnosis record” function sure the peak voltage, use the special service
of the YDIS. tools. A faulty electrical component can be
• To connect and operate the YDIS, see easily checked by measuring the peak voltage.
“YDIS” (9-1) or the YDIS (Ver. 2.20) Instruc- The specified engine speed when measuring
tion Manual. the peak voltage is affected by many factors,
• The software is available through YMAN (Ya- such as fouled spark plugs or a weak battery.
maha Marine Associate Network). If one of these factors is present, the peak volt-
age cannot be measured properly.
YDIS2 Hardware Kit
90890-06884 TIP:
• Before measuring the peak voltage, check all
YDIS2 Hardware Kit
wiring for proper connection and corrosion,
LIT-YDIS2-01-KT
and check that the battery is fully charged.
7-9

Electrical analysis
• 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 1 2
circuit tester, and the negative pin to the neg-
ative terminal.
• When measuring the peak voltage, set the 3
selector on the digital circuit tester to the DC
voltage mode.
A Test lead
Terminal, male “1”
DC V 9E212-10303
1 Terminal, female “2”
9E212-11303
Terminal, female “3”
2 (commercially available)
A. Worldwide
Digital circuit tester “1”

90890-03243
Peak voltage adapter B “2”
90890-03172
Digital multimeter “3”
YU-34899-A
Peak volt adapter “4”
YU-39991
Test lead preparation

If the special service tool test harness is not
available, make test leads suitable for the mea-
surement.
7-10

Ignition system
Ignition system
Ignition spark check R/Y B
When performing the spark gap check, a

keep flammable gas or liquids away, since
this test can produce sparks.
1. Connect the YDIS.
2. Remove the ignition coil for the cylinder

Input voltage
that will be tested.
12 V (battery voltage)
3. Connect the ignition coil to the special ser- Red/Yellow (R/Y)–Black (B)
vice tool “1”.
3. Connect the test harness. See “Test lead
4. Using the “Stationary test” of the YDIS, preparation” (7-10).
check the ignition spark.
4. Measure the ECM output peak voltage.
Do not touch any of the connections of the

special service tool leads. When checking the electrical components,
do not touch any of the connections of the
1 digital tester leads.
TIP:
• When measuring the ECM output peak volt-
age under the “Cranking” condition, discon-
nect 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
Ignition checker (Spark gap tester) “1” switch.
90890-06754 • When measuring the ECM output peak volt-
Spark checker “1” age, use only a properly functioning ignition
YM-34487 coil. If the ignition coil is not functioning prop-
erly, ECM output peak voltage will not be
5. Disconnect the special service tool, and generated.
then install the ignition coil.
Ignition coil check

1. Disconnect the ignition coil couplers “a”.
2. Supply power to the ECM, and then mea-

sure the input voltage at the ignition coil
coupler terminals (wire harness end).
Check the wire harness if out of specifica-
tion. Check the ECM output peak voltage if
within specification.
7-11

Ignition system
R/Y B B/O
B W W/B
#1 B/R WB
#2 B/W
#3 B/Y a 1 b
#4 B/G
a 1 W b
B
Output peak voltage Test harness (2 pins) “1”

#1 Black/Red (B/R)—Black (B) 90890-06851
#2 Black/White (B/W)—Black (B)
#3 Black/Yellow (B/Y)—Black (B) Output peak voltage
#4 Black/Green (B/G)—Black (B) White (W)–Black (B)
Loaded Unloaded Loaded
r/min r/min
Cranking 2000 3500 Cranking 2000 3500
V 2.5 2.6 2.6 V 5.5 4.7 16.4 21.5
5. Disconnect the test harness, and then con- 3. Disconnect the special service tool.
nect the ignition coil couplers.
4. Measure the pickup coil resistance. Re-
Pickup coil check place the pickup coil if out of specification.
1. Disconnect the pickup coil coupler “a”, and
then connect the special service tool “1”.
W B
2. Measure the pickup coil output peak volt-
age.
TIP:
• To crank the engine, connect the engine
shut-off cord to the engine shut-off switch,
and then push the engine start switch and
engine stop switch simultaneously. Resistance
• If measuring the pickup coil output peak volt- 459.0–561.0 Ω
age under the “Cranking” and “Unloaded” White (W)–Black (B)
conditions, disconnect the pickup coil coupler
(wire harness end) “b”. 5. Connect the pickup coil coupler.
7-12

Charging system
Charging system
Stator coil check
1. Disconnect the stator coil coupler “a”, and
G
then connect the special service tool “1”.
2. Measure the stator coil output peak volt-

age. G G
G G
G G
G G
W R B Resistance
a 1 0.27–0.40 Ω
Green (G)–Green (G)
5. Connect the stator coil coupler.

1
Rectifier/regulator check
1. Disconnect the rectifier/regulator coupler
“a”, and then connect the special service
tool “1”.
a 2. Measure the rectifier/regulator output peak

B voltage.
R
W TIP:
Do not use the peak voltage adapter to mea-
Test harness (3 pins) “1” sure the output voltage.
90890-06870
Test harness (3 pins) “1”
G
YB-06870 G
G
Output peak voltage R R
Green (G)–Green (G) B B
R B
Unloaded
r/min a 1
Cranking 2000 3500
V 8.3 36.4 64.7
3. Disconnect the special service tool.
4. Measure the stator coil resistance. Re-

place the stator coil if out of specification.
Measure the rectifier/regulator output peak
voltage if within specification.
a 1

90890-06850
YW-06850
7-13

Charging system
Output voltage B
Red (R)–Black (B)
Loaded
r/min
2000 3500
V 13
3. Disconnect the special service tool. a

4. Remove the rectifier/regulator. See “Ex-
haust manifold” (5-3). A. Worldwide
5. Check the rectifier/regulator for continuity.
Replace if out of specification. Rectifier/regulator continuity
(testing diode mode)
TIP:
Make sure to set the measurement range to “a” Tester lead Display value (V)
when checking the rectifier/regulator continui- (+) (–) (reference data)
ty.
c
d
cG b OL
e
Ge dG f
b 0.43–0.51
d
c
e OL
Bf bR f
b 0.43–0.51
c
b R d
e OL
c G
f
d G b 0.43–0.51
e G c
e
d OL
f B f
b 0.66–0.74
A c 0.43–0.51
f
d 0.43–0.51
e 0.43–0.51
a OL: Indicates an overload

a 6. Install the rectifier/regulator. See “Exhaust
manifold” (5-3).
7. Connect the rectifier/regulator coupler.
7-14

Control system
Control system 6. Check the oil pressure switch for continui-

Oil pressure switch check ty. Replace if out of specification.
1. Disconnect the oil pressure switch coupler Oil pressure switch continuity
“a”. Terminal thread “a”–
Pressure
Body “b”
sure the input voltage between the oil Below 128–166 kPa
pressure switch coupler terminal (wire har- (1.3–1.7 kgf/cm², Continuity
ness end) and ground. Check the wire har- 18.6–24.1 psi)
ness if out of specification. Above 128–166 kPa
(1.3–1.7 kgf/cm², No continuity
18.6–24.1 psi)
7. Install the oil pressure switch. See “Oil

separator tank and oil pan” (5-69).
P/W
a 8. Connect the oil pressure switch coupler.
Thermo switch check

1. Disconnect the thermo switch coupler “a”.
Input voltage 2. Supply power to the ECM, and then mea-
11–12 V sure the input voltage at the thermo switch
Pink/White (P/W)–Ground coupler terminals (wire harness end).
3. Remove the oil pressure switch. See “Oil
tion.
separator tank and oil pan” (5-69).
a
4. Connect the tester leads to the terminal
threads “a” and body “b” of the oil pressure
switch. B P
5. Connect the special service tool “1” to the
oil pressure switch, and then apply positive
pressure.
a 1 Input voltage
11–12 V
Pink (P)–Black (B)
b
3. Remove the thermo switch. See “Cylinder
block and electrical part” (5-67).
4. Suspend the thermo switch in a container

filled with water, and then heat the water
Vacuum/pressure pump gauge set “1”
slowly.
90890-06945
Pressure/vacuum tester “1”
YB-35956-B
7-15

Control system
a
B/L B/O
P B
5. Check the thermo switch for continuity Input voltage

when the specified temperatures are 4.75–5.25 V
reached. Replace if out of specification. Black/Blue (B/L)–Black/Orange (B/O)
b 3. Remove the thermo sensor. See “Muffler”

(5-16).
b
b
c 4. Suspend the thermo sensor in a container
A
d filled with water, and then slowly heat the
a
a water.
B
a. No continuity B B
b. Continuity
c. Continuity temperature
d. No continuity temperature
A. Temperature
B. Time
5. Measure the thermo sensor resistance
Continuity temperature when the specified temperatures are
94–100 °C (201–212 °F) reached. Replace if out of specification.
No continuity temperature
Resistance at 0°C (32°F)
80–94 °C (176–201 °F)
24.0–37.1 kΩ
6. Install the thermo switch. See “Cylinder Resistance at 100°C (212°F)
block and electrical part” (5-67). 0.87–1.18 kΩ
7. Connect the thermo switch coupler. 6. Install the thermo sensor. See “Muffler”
(5-16).
Thermo sensor check
1. Disconnect the thermo sensor coupler “a”. 7. Connect the thermo sensor coupler.
2. Supply power to the ECM, and then mea- Engine temperature sensor check
sure the input voltage at the thermo sensor 1. Disconnect the engine temperature sensor
coupler terminals (wire harness end). coupler “a”.
tion.
7-16

Control system
2. Supply power to the ECM, and then mea- Intake air temperature sensor check
sure the input voltage at the engine tem- 1. Measure the ambient temperature.
perature sensor coupler terminals (wire
harness end). Check the wire harness if 2. Connect the YDIS to display “Intake tem-
out of specification. perature”.
3. If the ambient temperature and the dis-

a
B/O B/Y played intake air temperature differ by
more than ± 5 °C (± 9 °F), measure the in-
take air temperature sensor resistance.
TIP:
Check the intake air temperature sensor when
the engine is cold.
Input voltage 4. Disconnect the intake air temperature sen-

4.75–5.25 V sor coupler “a”.
Black/Yellow (B/Y)–Black/Orange (B/O)
3. Remove the engine temperature sensor. sure the input voltage at the intake air tem-
See “Cylinder block and electrical part” perature sensor coupler (wire harness
(5-67). end). Check the wire harness if out of
specification.
4. Suspend the engine temperature sensor in
a container filled with water, and then heat
the water slowly. B/O B/R
B/Y B/Y
Input voltage
4.75–5.25 V
Black/Red (B/R)–Black/Orange (B/O)
5. Measure the engine temperature sensor
6. Remove the intake air temperature sen-
resistance when the specified tempera-
sor. See “Intake manifold” (5-24).
tures are reached. Replace if out specifica-
tion. 7. Suspend the intake air temperature sensor
Resistance at 20°C (68°F) in a container filled with water, and then
54.2–69.0 kΩ slowly heat the water.
3.12–3.48 kΩ
6. Install the engine temperature sensor. See

“Cylinder block and electrical part” (5-67).
7. Connect the engine temperature sensor

coupler.
7-17

Control system
4. Disconnect the vacuum hose from the in-
take air pressure sensor.
5. Connect the special service tool “1” to the

intake air pressure sensor.
6. Connect the YDIS to display “Intake air

pressure”.
7. Apply negative pressure to the intake air

8. Measure the intake air temperature sensor pressure sensor slowly and check that the
resistance when the specified tempera- displayed intake air pressure increases.
tures are reached. Replace if out of speci- Replace if it does not increase.
fication.
Resistance at 0°C (32°F) 1
5.4–6.6 kΩ
0.29–0.39 kΩ
9. Install the intake air temperature sensor.

See “Intake manifold” (5-24).
10. Connect the intake air temperature sensor

coupler. Vacuum/pressure pump gauge set “1”
90890-06945
Intake air pressure sensor check Pressure/vacuum tester “1”
1. Disconnect the intake air pressure sensor YB-35956-B
coupler “a”.
8. Disconnect the special service tool, and
2. Supply power to the ECM, and then mea- then connect the vacuum hose.
sure the input voltage at the intake air
pressure sensor coupler (wire harness TPS check
end). Check the wire harness if out of
specification.
• Do not loosen the throttle stop screw nut
a and do not turn the throttle stop screw.
• Do not disconnect the ETV coupler (throt-
B/O O tle body end).
• TPS 1 and TPS 2 are components of the
ETV, which cannot be disassembled.
Input voltage
4.75–5.25 V
Orange (O)–Black/Orange (B/O)
3. Connect the intake air pressure sensor

coupler.
7-18

Control system
TIP:
Operate the throttle lever “1”, and then check
the TPS 2 output voltage and throttle valve
c opening angle at the fully open position “B”.
A B
1 1
a b
TPS 2 output voltage with the throttle le-

ver fully open
4.60–4.70 V
a. Throttle stop screw nut
b. Throttle stop screw Throttle valve opening angle with the
c. ETV coupler (throttle body end) throttle lever fully open
More than 70°
1. Connect the YDIS to display “TPS 1”,
“Throttle valve opening angle”, and “TPS 5. Operate the throttle lever so that the TPS
2”. 2 output voltage is 4.5 V or less, and then
check the voltage difference between TPS
TIP: 1 and TPS 2. Measure the TPS input volt-
When checking the TPS using the YDIS, do age if out of specification.
not start the engine.
TPS output voltage difference
1.9–2.1 V
2. Squeeze the throttle lever “1” slowly and
check that the displayed throttle valve Example:
opening increases. If the TPS 1 output voltage is 2.5 V and the
TPS 2 output voltage is 4.5 V, then 4.5 -
3. Check the TPS 1 output voltage and throt- 2.5 = 2.0 V.
tle valve opening angle at the fully closed
position “A”. 6. Disconnect the ETV coupler “a”.
TPS 1 output voltage with the throttle le- 7. Supply power to the ECM, and then mea-
ver fully closed sure the input voltage at the ETV coupler
0.45–0.55 V terminals (wire harness end). Check the
Throttle valve opening angle with the TPS circuit continuity if out of specification.
throttle lever fully closed
2–8°
4. Check the TPS 2 output voltage and throt-

tle valve opening angle at the fully open
position “B”.
7-19

Control system
a a
3 2 1
6 5 4
O
b c
B/O
44 43 42 41
Input voltage 52 78
4.75–5.25 V
Orange (O)–Black/Orange (B/O)
8. Connect the ETV coupler. ETV circuit continuity

Terminal No. Color
ETV circuit continuity code
Coupler “a” Coupler “b”, “c”
1. Disconnect the ETV coupler “a” and ECM
couplers “b” and “c”. 1 42 P
2 44 O
3 78 G
4 43 P/B
5 41 B/O
a 6 52 L
3. Connect the ETV coupler and ECM cou-

plers.
APS check
b c
APS 1, APS 2, and APS full close switch are
components of the throttle lever, which
cannot be disassembled.
1. Connect the YDIS to display “APS 1”,

“APS 2”, and “APS full close switch”.
TIP:
2. Check the wire harness for continuity. Re- When checking the APS using the YDIS, do
place if there is no continuity. Replace the not start the engine.
ETV if there is continuity.
2. Operate the throttle lever “1”, and then

check the output voltages of APS 1 and
APS 2 at the fully closed position “A” and
fully open position “B”.
7-20

Control system
TIP: APS full close switch

The actual APS output voltage may vary ac- Throttle lever position YDIS display
cording to environmental conditions. C ON
D OFF
A B
1 1
5. Disconnect the APS coupler “a”.

sure the input voltage at the APS coupler
terminals (wire harness end). Check the
APS circuit for continuity if out of specifica-
tion.
APS 1 output voltage with the throttle le-

ver fully closed
0.68–0.74 V O/R
B/R
APS 2 output voltage with the throttle le- a
ver fully closed
0.68–0.74 V
APS 1 output voltage with the throttle le- O/W B/W
ver fully open O/G B/G
3.95–4.15 V
APS 2 output voltage with the throttle le- APS 1 input voltage
ver fully open 4.75–5.25 V
3.95–4.15 V Orange/Red (O/R)–Black/Red (B/R)
APS 2 input voltage
3. Squeeze the throttle lever “1” to the fully
4.75–5.25 V
open position, and then check the voltage
Orange/White (O/W)–Black/White (B/W)
difference between APS 1 and APS 2.
APS full close switch input voltage
Measure the APS input voltage if out of
4.75–5.25 V
specification.
Orange/Green (O/G)–Black/Green (B/G)
APS output voltage difference
0.1 V or less 7. Connect the APS coupler.
4. Squeeze the throttle lever “1” slowly and APS circuit continuity
check that the “APS full close switch” dis- 1. Disconnect the APS coupler “a” and ECM
play changes from the “ON” to “OFF.” couplers “b” and “c”.
C
1 D
7-21

Control system
b c
2. Check the wire harness for continuity. 2. Check the ETV relay. See “Main relay
Replace if there is no continuity. check” (7-31).
3. Measure the input voltage between the ter-

a
minal “a” and ground.
3 2 1
6 5 4
9 8 7
b c
30 29
37 36 35 34
a
22 50 49
Input voltage
APS circuit continuity
Terminal “a”–Ground
Terminal No. Color
Coupler “a” Coupler “b”, “c” code 4. Supply power to the ECM, and then mea-
sure the input voltage between the termi-
1 36 P/R
nals “a” and “b”.
2 34 B/R
3 49 O/R
4 37 P/W
5 35 B/W
6 50 O/W
7 22 W/G
8 29 B/G b a
9 30 O/G
Input voltage
3. Connect the APS coupler and ECM cou-
plers.
Terminal “a”–Terminal “b”
ETV relay check 5. Install the ETV relay and fuse box cover.
1. Remove the fuse box cover and ETV relay
“1”.
7-22

Control system
RPS check 3. Squeeze the RiDE lever to the fully open

position, and then check the voltage differ-
ence between RPS 1 and RPS 2. Measure
RPS 1 and RPS 2 are components of the the RPS input voltage if out of specifica-
RiDE lever, which cannot be disassembled. tion.
1. Connect the YDIS to display “RPS main” RPS output voltage difference
and “RPS sub”. 0.1 V or less
TIP: 4. Disconnect the RPS coupler “a”.

• When checking the RPS using the YDIS, do
not start the engine. 5. Supply power to the ECM, and then mea-
• The values displayed for “RPS main” are the sure the input voltage at the RPS coupler
RPS 1 values and the values displayed for terminals (wire harness end). Check the
“RPS sub” are the RPS 2 values. RPS circuit for continuity if out of specifica-
tion.
2. Operate the RiDE lever “1”, and then

check the output voltages of RPS 1 and
a
RPS 2 at the fully closed position “A” and
fully open position “B”. O/R B/R
TIP:
The actual RPS output voltage may vary ac-
cording to environmental conditions.
O/W B/W
A B
1 1 RPS 1 Input voltage
4.75–5.25 V
Orange/Red (O/R)–Black/Red (B/R)
RPS 2 Input voltage
4.75–5.25 V
Orange/White (O/W)–Black/White (B/W)
6. Connect the RPS coupler.
RPS 1 output voltage with the RiDE lever RPS circuit continuity
fully closed 1. Disconnect the RPS coupler “a” and ECM
0.68–0.74 V couplers “b” and “c”.
RPS 2 output voltage with the RiDE lever
fully closed
0.68–0.74 V
a
fully open
3.95–4.15 V
fully open
3.95–4.15 V
7-23

Control system
b c
1
2. Check the wire harness for continuity. Re- 2. Check the SCU relay. See “Main relay
place if there is no continuity. check” (7-31).

a
3 2 1
6 5 4
a
b c
33 32 31 28
11
51
Input voltage
RPS circuit continuity
Terminal No. Color
Coupler “a” Coupler “b”, “c” code 4. Turn the engine start switch to ON, and
then measure the input voltage between
1 33 P/R
the terminals “a” and “b”.
2 31 B/R
3 28 O/R
a
4 11 P/W
5 32 B/W
6 51 O/W b
3. Connect the RPS coupler and ECM cou-

plers.
SCU relay check Input voltage

1. Remove the fuse box cover and SCU relay 12 V (battery voltage)
“1”. Terminal “a”–Terminal “b”
5. Install the SCU relay and fuse box cover.
7-24

Control system
Electric trim switch check Electric trim switch resistance (reference

1. Connect the YDIS to display “Trim up data)
switch” and “Trim down switch”. Free
5.6 kΩ
2. Push the electric trim switches “1” and “2”.
Sky blue (Sb)–Black (B)
3. Check that the following is displayed in the Switch “1” pushed
“Engine monitor” window of the YDIS. 0.98 kΩ
Sky blue (Sb)–Black (B)
Free
5.6 kΩ
Light green (Lg)–Black (B)
Switch “2” pushed
0.98 kΩ
Light green (Lg)–Black (B)
1
2 Cam position sensor check
1. Disconnect the cam position sensor cou-
Electric trim switch operation pler “a”.
Switch YDIS display
Up “1” Free OFF sure the input voltage at the cam position
Down “2” Pushed ON sensor coupler terminals (wire harness
end). Check the wire harness if out of
4. Disconnect the electric trim switch coupler specification. Measure the cam position
“a”. sensor output voltage if within specifica-
tion.
B/O O
a a
5. Measure the electric trim switch resis-

tance. Input voltage
4.75–5.25 V
1 Orange (O)–Black/Orange (B/O)
Sb B Lg 3. Remove the cam position sensor. See

“Cylinder head cover” (5-31).
2 4. Connect the special service tool “1” to the

cam position sensor and wire harness.
7-25

Control system
sure the output voltage when a screw-
driver is passed under the cam position
sensor in direction “A”. Replace the cam B/O L/B
position sensor if out of specification.
a
G/O BW Input voltage

4.75–5.25 V
Blue/Black (L/B)–Black/Orange (B/O)
B/O 1
3. Remove the slant detection switch. See
“Electrical box” (5-19).
4. Check the slant detection switch for conti-

nuity. Replace if out of specification.
A
TIP:
Make sure to turn the switch over to both the
A left and right.
a b c
A
UP
90890-06877
YB-06877
B B
L/B B/O
Output voltage (position a, c)
More than 4.8 V
UP
Output voltage (position b) UP

Less than 0.8 V
Green/Orange (G/O)–Black/Orange
(B/O)
6. Disconnect the special service tool. B

UP
7. Install the cam position sensor. See “Cylin-
der head cover” (5-31).
Slant detection switch check Slant detection switch continuity

1. Disconnect the slant detection switch cou- Blue/Black (L/B)–
pler “a”. Position
Black/Orange (B/O)
2. Supply power to the ECM, and then mea- Normal position “A” No continuity
sure the input voltage at the slant detection Overturned “B” Continuity
switch coupler (wire harness end). Check
the wire harness if out of specification. 5. Install the slant detection switch. See
“Electrical box” (5-19).
7-26

Control system
Steering sensor check 5. Connect the special service tool “1” to the
1. Connect the YDIS to display “Steering steering sensor coupler.
sensor.”
2. Check that the following is displayed in the sure the output voltage when the handle-
“Engine monitor” window of the YDIS bar is in each position.
when the handlebar is in each position.
Measure the steering sensor input voltage
if out of specification.
1
R
P
O
Throttle sensor adjusting lead FWY–3 “1”

90890-06857
Steering sensor operation YB-06857
Handlebar position YDIS display
Steering sensor output voltage
Straight ahead OFF
Handlebar position V
Turn to the left and
ON Straight ahead 4.5
right
Turn to the left and
1.8
3. Disconnect the steering sensor coupler right
“a”.
7. Disconnect the special service tool, and
4. Supply power to the ECM, and then mea- then connect the steering sensor coupler.
sure the input voltage at the steering sen-
sor coupler terminals (wire harness end). ECM check
Check the steering sensor output voltage if 1. Disconnect the ECM coupler “a”.
within specification. Check the wire har-
ness if out of specification. 2. Supply power to the ECM, and then mea-
sure the input voltage between the ECM
coupler terminal (wire harness end) and
B/O O/R
a ground. Check the ECM circuit for continu-
ity if out of specification.
TIP:
Do not disconnect the coupler “b” or coupler “c”
when measuring the ECM input voltage.
Input voltage
4.75–5.25 V
Orange/Red (O/R)–Black/Orange (B/O)
7-27

Control system
ECM circuit continuity
c a b Terminal “46”–Ground
Terminal “62”–Ground
Continuity
4. Connect the ECM couplers.
Earth plate check

1. Remove the earth plate.
a
2. Check the continuity between each termi-
nal “a” and the housing “b”. Replace the
27 earth plate if there is no continuity.
b
Input voltage
3. Disconnect the ECM coupler “b”, and then a

check the continuity between the ECM
3. Install the earth plate. See “Cylinder block
coupler terminals (wire harness end) and
and electrical part” (5-67).
ground. Replace the wire harness if there
is no continuity.
a b
a b
67 62
70
46
7-28

Fuel system
Fuel system Fuel pump relay check

Fuel injector check 1. Remove the fuse box cover and fuel pump
1. Connect the YDIS. relay “1”.
2. Using the “Stationary test” of the YDIS, lis-

ten for the fuel injector operation sound.
3. Disconnect the fuel injector couplers “a”.

sure the input voltage between the fuel in- 1
jector coupler terminals (wire harness end)
and ground. Check the wire harness if out
of specification.
2. Check the fuel pump relay. See “Main re-
lay check” (7-31).
R/Y
a a
Input voltage
Red/Yellow (R/Y)–Ground
5. Remove the fuel injectors. See “ETV and Input voltage

fuel injector” (4-6).
6. Measure the fuel injector resistance. Terminal “a”–Ground
7. Replace the fuel injector if out of specifica- 4. Supply power to the ECM, and then mea-
tion. sure the input voltage between the termi-
Resistance Input voltage

11.5–12.5 Ω 12 V (battery voltage)
8. Install the fuel injectors. See “ETV and fuel
injector” (4-6).
7-29

Fuel system
5. Install the fuel pump relay and fuse box
cover.
Y B B
Fuel pump module check
1. Connect the YDIS.
2. Using the “Stationary test” of the YDIS, lis-

ten for the fuel pump module operation
A
sound.
3. Disconnect the fuel pump module coupler A. Lower position

“a”. B. Upper position
4. Supply power to the ECM, and then mea- Lower position resistance
sure the input voltage at the fuel pump 133.5–136.5 Ω
module coupler terminals (wire harness
Upper position resistance
end). Replace the fuel pump module if
5.0–7.0 Ω
within specification. Check the wire har-
ness if out of specification. 7. Install the fuel pump module. See “Fuel
tank and fuel pump module” (4-9).
TIP:
After the power is supplied to the ECM, voltage
will only be applied to the fuel pump module for
3 seconds.
a L B
Input voltage
Blue (L)–Black (B)
5. Remove the fuel pump module. See “Fuel

tank and fuel pump module” (4-9).
6. Measure the fuel sender resistance. Re-

place the fuel sender if out of specifica-
tions.
7-30

Starting system
Starting system 1
Fuse check W B
1. Check the fuse for continuity. Replace if A
there is no continuity.
2
Engine stop switch continuity

Engine stop White (W)–
Clip “1”
switch “2” Black (B)
Free No continuity
Handlebar switch (left) check Installed “A”
Pushed Continuity
1. Disconnect the handlebar switch (left) cou-
Removed Free Continuity
pler (white coupler).
“B” Pushed Continuity
2. Check the engine start switch for continui-
ty. Replace the handlebar switch (left) if 6. Connect the handlebar switch (left) cou-
out of specification. pler (black coupler).
2 Main relay check

R Br 1. Remove the fuse box cover and main relay
A “1”.
1 2
1
B
Engine start switch continuity

Engine start Red (R)–
Clip “1”
switch “2” Brown (Br)
Free No continuity 2. Connect the positive battery lead to the
Installed “A”
Pushed Continuity terminal “a”, and the negative battery lead
Free No continuity to the terminal “b”, and then check for con-
Removed
tinuity between the terminals “c” and “d”.
“B” Pushed No continuity Replace the relay if there is no continuity.
3. Connect the handlebar switch (left) cou-
pler (white coupler). Do not reverse the battery leads. Other-
wise, the relay may be seriously damaged.
4. Disconnect the handlebar switch (left) cou-
pler (black coupler).
5. Check the engine stop switch for continui-

ty. Replace the handlebar switch (left) if
7-31

Starting system
Starter relay check

1. Slide the boot away from the starter relay
c
terminal “1”, and then measure the input
d a
voltage between the starter relay terminal
“1” and ground.
TIP:
The positive battery lead is marked with yel-
b lowish green tape “a”.
Relay terminals continuity 1

Terminal “c”–Terminal “d”

R
a
a
Starter relay input voltage
Red (R)–Ground
2. Remove the starter relay.

Input voltage
3. Connect the tester leads between the
starter relay terminals “a” and “b”.
4. Connect the positive battery lead to the
4. Supply power to the ECM, and then mea- terminal “c”, and the negative battery lead
sure the input voltage between the termi- to the terminal “d”.
5. Check the continuity between the starter
a b relay terminals “a” and “b”. Replace the
starter relay if out of specification.
a b
c d
Input voltage
Starter relay continuity
5. Install the main relay and fuse box cover.
Battery lead “c”–“d” Terminal “a”–“b”
Disconnected No continuity
7-32

Starting system
Starter relay continuity

Battery lead “c”–“d” Terminal “a”–“b”
Connected Continuity
6. Install the starter relay.
7-33

Starter motor
Starter motor
9 9 Nm (0.9 kgf·m, 6.6 ft·lb)

7
10
7 Nm (0.7 kgf·m, 5.2 ft·lb) 3
13
1
6 M
12 11
8
M
4

1 Bolt 2 M6 × 120 mm
2 Starter motor rear cover 1
3 Packing seal 1 Not reusable
4 Front cover 1
5 Packing seal 1 Not reusable
6 Plate 1
7 Starter motor yoke 1
8 Armature 1
9 Brush holder 1
11 Circlip 1
12 Drive gear 1
7-34

Starter motor
Starter motor operation

1. Remove the starter motor. See “Wire har-
ness” (5-18).
2. Hold the starter motor in a vise using alu-

minum plates on both sides.
3. Connect the positive battery lead “1” to the

starter motor terminal bolt “a”.
4. Connect the negative battery lead “2” to

2. Measure the commutator diameter “a”.
the starter motor body “b”, and then check
Replace the armature if below specifica-
the starter motor operation.
tion.
Do not touch the drive gear.
TIP:
• Check the starter motor operation for a few
seconds.
• If the starter motor is disassembled, make
sure to check the operation again after as-
sembling it. a
Commutator diameter
1 a 28.0 mm (1.10 in)
Limit
27.0 mm (1.06 in)
2
3. Measure the commutator undercut “a”.
Replace the armature if below specifica-
tion.
b
a
5. Disconnect the negative battery lead, and
then the positive battery lead from the bat-
tery terminals.
6. Install the starter motor. See “Wire har-

ness” (5-18).
Armature check
1. Check the commutator. Clean using 600- Commutator undercut
grit sandpaper and compressed air if dirty. 0.7 mm (0.03 in)
4. Check the armature for continuity. Re-

7-35

Starter motor
a c
d b
a b c
a
Armature continuity
c
Commutator seg-
Continuity
ment “a”
Segment “a”–Arma- d
No continuity
ture core “b” b
Segment “a”–Arma- e
No continuity
ture shaft “c”
Brush holder continuity
Brush holder check
Brush “a”–Brush “b”
1. Measure the brush length “a”. Replace the
Brush “c”–Brush “d”
brush holder if below specification. Continuity
Brush “c”–Terminal “e”
Brush “d”–Terminal “e”
For all brush and terminal
combinations not listed No continuity
above.
a
Brush length
12.5 mm (0.49 in)
Wear limit
5.0 mm (0.20 in)
2. Check the brush holder for continuity. Re-

7-36

Remote control system
Remote control system 4. Loosen the screws “1” in the order [1], [2],
Remote control transmitter check and so on, and then remove the transmit-
ter cover “2”.
1. Push the unlock button “a”. The buzzer
sounds 2 times, and then check that the
“UNLOCK” indicator light “b” comes on. Do not touch the internal parts except the
battery.
2. Push the unlock button “a” for more than 4
seconds. The buzzer sounds 3 times, and
then check that the “L-MODE” indicator [4] [6]
light “c” comes on. 1
2
3. Push the lock button “d”. The buzzer
[1] [2]
sounds once, and then check that the “UN-
LOCK” indicator light “b” goes off.
TIP: [5] [3]

While the engine is running, input from the re-
mote control transmitter is not received.
5. Remove the battery (CR2016) “1”.
d a Do not touch the battery directly using your

hands. Use a pair of non-conductive twee-
zers to replace the battery.
6. Measure the battery voltage. Replace the

remote control transmitter battery if below
specification.
TIP:
b c Refer to local hazardous waste regulations
when disposing of transmitter batteries.
Yamaha Security
Number of beeps
System mode
1 beep Lock
Unlock Rating
2 beeps
(normal mode) 3V
L-MODE
3 beeps 7. Install the battery (CR2016) “1” and trans-
(low-rpm mode)
mitter cover “2”.
7-37

2. Connect the remote control receiver cou-
TIP: pler.
Install the battery (CR2016) “1” with the posi-
tive side “a” facing down. 3. Disconnect the multifunction meter cou-
pler “a” from the remote control receiver.
1 4. Supply power to the ECM, and then mea-

2
sure the remote control receiver output
a voltage at the multifunction meter coupler
terminal (wire harness end) and ground.
Replace the remote control receiver if out
of specification.
a
L/Y
8. Tighten the screws “1” to the specified
torque in the order [1], [2], and so on.
[3] [1]
[6] [5]
Output voltage
11–12 V
Blue/Yellow (L/Y)–Ground
[2] [4]
5. Connect the multifunction meter coupler.
Transmitter cover screw “1”
0.1 Nm (0.01 kgf·m, 0.07 ft·lb) Transmitter registration
Remote control receiver check TIP:

• Each remote control transmitter “1” has a
1. Disconnect the remote control receiver
unique ID code.
coupler “a”, and then measure the input
• To add or re-register the ID code of a remote
voltage at the remote control receiver cou-
control transmitter to the remote control re-
pler terminals (wire harness end).
ceiver “2”, connect the entry box “3”.
1. Connect the entry box to the 2-pin commu-

4 nication coupler “a”.
13
Input voltage
Red (R)–Black (B)
7-38

a b
Gy Gy
1 B B
c
2 a 3
2. Push the lock button “a” or unlock button

“b” 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- 4. After ID code registration has been com-
ing ID codes will be deleted from the remote pleted, disconnect the entry box to exit the
control receiver. registration mode.
• The “UNLOCK” indicator light “c” 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 checking that the registration of the

ID code has been completed using the
“UNLOCK” indicator light “c”, 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.
7-39

Indication system
Indication system
Multifunction meter check
1. Check the multifunction meter external ap-
pearance. Replace the multifunction meter
if there is cracked meter housing, fogged R/Y
meter, or water intrusion.
2. Supply power to the ECM, and then check

a B
that all indicator lights “a” and display ele-
ments “b” on the multifunction meter come
on. Replace if it does not operate properly. Input voltage
TIP: Red/Yellow (R/Y)–Black (B)
When the multifunction meter is activated, all
displays come on for 2 seconds, and then the 6. Connect the multifunction meter coupler.
multifunction meter starts to operate normally.
Speed sensor check
a b a 1. Remove the speed sensor. See “Intake
grate and ride plate” (6-1), and then check
the speed sensor paddle wheel “a”. Re-
place the speed sensor if there are cracks,
damage, or rough movement.
3. Check the multifunction meter display. Re-

place the multifunction meter if there is in-
termittent or missing segment “a”.
a
2. Install the speed sensor. See “Intake grate

a and ride plate” (6-1).
3. Disconnect the speed sensor coupler “a”.

4. Disconnect the multifunction meter cou-
pler “a”.

sure the input voltage at the multifunction
meter coupler terminals (wire harness a
end). Replace the wire harness if out of
specification. Replace the multifunction
meter if within specification and there is no
display on the multifunction meter.
7-40

Indication system
terminal “a”, and the negative battery lead
A
to the terminal “b”.
5. Connect the tester leads between the ter-

minal “c” and terminal “b”.
6. Rotate the paddle wheel “d” by hand and

measure the output voltage between the B
a
terminal “c” and terminal “b”. Replace if out
of specification.
B/Yb a R/Y
d
b c
cY
d
6. Install the fuel pump module. See “Fuel
Output voltage (dependant on the paddle tank and fuel pump module” (4-9).
wheel position)
Less than 400 mV/More than 11.6 V Check engine warning indicator
Yellow (Y)–Black/Yellow (B/Y) check
7. Connect the speed sensor coupler. 1. Start the engine, and then disconnect the
engine temperature sensor coupler “a”.
Fuel level meter display and fuel level
warning indicator check
1. Remove the fuel pump module. See “Fuel
tank and fuel pump module” (4-9). a
2. Connect the fuel sender coupler “a”.
3. Lift the float to the upper position “A”.

that all fuel level segments come on. Re- 2. Check that the “WARNING” indicator light
place if it does not come on. “a” and the check engine warning indicator
“b” begin to blink.
5. Lower the float to the lowest position “B”,
and then check that the fuel level warning
indicator “b”, the lowest 2 fuel level seg-
ments “c”, and the “WARNING” indicator
light “d” blink. If the indicator, segments,
and the light do not blink, replace the mul-
tifunction meter.
b a
7-41

Indication system
3. If the light and indicator do not blink, check 3. Check that the oil pressure warning indica-
the “Diagnosis record” of the YDIS. If a di- tor “a”, the check engine warning indicator
agnosis record is available and the light “b”, and the “WARNING” indicator light “c”
and indicator do not blink, replace the mul- blink, and the buzzer sounds intermittently
tifunction meter. for 30 seconds.
4. Connect the engine temperature sensor

coupler.
Diagnostic display check

1. Create a condition so that a diagnostic
code is recorded.

that the “WARNING” indicator light “a” a b c
blinks and the diagnostic code “b” is indi-
4. If the light and indicator do not blink, check
cated.
the “Diagnosis record” of the YDIS. If a di-
b agnosis record is available and the light
and indicator do not blink, replace the mul-
tifunction meter.
5. Connect the oil pressure switch coupler.
Engine overheat warning indicator

check
a 1. Disconnect the thermo switch coupler “a”,
and then connect the jumper lead “1” to the
3. If the diagnostic code is not indicated, thermo switch coupler terminals (wire har-
check the “Diagnosis record” of the YDIS. ness end).
If a diagnosis record is available and the
diagnostic code is not indicated, replace 1
the multifunction meter.
B P
Oil pressure warning indicator check
a
1. Disconnect the oil pressure switch coupler
“a”, and then ground the terminal.
P/W
2. Start the engine and operate it at trolling

a speed for about 2 minutes.
3. Check that the engine overheat warning

indicator “a”, the check engine warning in-
dicator “b”, and the “WARNING” indicator
light “c” blink, and the buzzer sounds inter-
2. Start the engine, and then increase the en- mittently. After 5 seconds, check that the
gine speed to 6000 r/min or more. engine overheat warning indicator and the
“WARNING” indicator light stop blinking
7-42

Indication system
and remain on, and the buzzer sounds 5. Check that the buzzer sounds. Replace
continuously. After 30 seconds, check that the buzzer if does not sound.
the buzzer stops.
b a
B R
a b c
6. Install the buzzer. See “Steering master”
4. If the light and indicator do not blink, check (8-12).
the “Diagnosis record” of the YDIS. If a di-
agnosis record is available and the light 7. Connect the buzzer coupler.
and indicator do not blink, replace the mul-
tifunction meter.
5. Connect the thermo switch coupler.
Buzzer check
1. Disconnect the buzzer coupler “a”.

sure the input voltage at the buzzer cou-
pler terminals (wire harness end). Check
the wire harness if out of specification.
L/R B/L
a
Input voltage
11–12 V
Blue/Red (L/R)–Black/Blue (B/L)
3. Remove the buzzer. See “Steering mas-

ter” (8-12).

terminal “a” and the negative battery lead
to the terminal “b”.
7-43

Indication system
— MEMO —
7-44

Hull and hood
Steering pad and handlebar cover ................................... 8-1
Handlebar and handlebar switch ...................................... 8-2

Lead routing ............................................................................... 8-3
Handlebar installation................................................................. 8-3
Front hood .......................................................................... 8-6
Side cover ........................................................................... 8-8
Center cover ....................................................................... 8-9
Steering master ASSY ..................................................... 8-11
Steering master ................................................................ 8-12

Steering arm ASSY installation ................................................ 8-14
Steering cable and speed sensor lead ........................... 8-15

Steering cable installation (steering master end) ..................... 8-16
Steering cable installation (jet pump end) ................................ 8-16
Seat and handgrip ............................................................ 8-17
Ventilation hose and water separator ............................ 8-19

Cooling water pilot outlet installation ........................................ 8-21
Exhaust system ................................................................ 8-22

Exhaust system installation ...................................................... 8-24
RiDE motor ....................................................................... 8-26

RiDE motor removal ................................................................. 8-27
RiDE motor installation............................................................. 8-28
RiDE system initialization ......................................................... 8-30

Hull and hood
Rear section...................................................................... 8-31

Spout installation ...................................................................... 8-33
Reboarding step installation (VXR) .......................................... 8-33
Deck and hull .................................................................... 8-34

Steering pad and handlebar cover
Steering pad and handlebar cover
3
5.5 Nm (0.55 kgf·m, 4.06 ft·lb)
4
LT
1 242
0.5 Nm (0.05 kgf·m, 0.37 ft·lb)

2 Upper handlebar cover 1
3 Steering pad 1
5 Lower handlebar cover 1
8-1

Handlebar and handlebar switch

5 7 Nm (0.7 kgf·m, 5.2 ft·Ib) 1 3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
6
7 3
8 2 Nm (0.2 kgf·m, 1.5 ft·Ib)
3.5 Nm (0.35 kgf·m, 2.58 ft·lb)

LT
1
242
9 4 11 2
8
10 LT
242
21 Nm (2.1 kgf·m, 15.5 ft·Ib) 10
LT 9 6 5
242 4
21 Nm (2.1 kgf·m, 15.5 ft·Ib)

7
LT
242
7 Nm (0.7 kgf·m, 5.2 ft·Ib)
2 Nm (0.2 kgf·m, 1.5 ft·Ib)

1 Bolt 6 M5 × 30 mm
2 Handlebar switch (left) 1
3 Handlebar switch (right) 1
4 Bolt 2 M4 × 30 mm
5 Bolt 2 M6 × 12 mm
6 Washer 2
7 Handlebar grip 2
8 Bolt 2 M5 × 23 mm
9 Bolt 4 M8 × 45 mm
10 Upper handlebar holder 2 a: Punch mark
11 Handlebar 1
8-2

Lead routing
1. Wrap the packing “1”, making sure to align
the upper edge of the packing with the up-
per edges of the tape markings “a” and “b”,
on the handlebar switch (right) lead “2” and
handlebar switch (left) leads “3”.
2. Align the upper edge of the packing “1”

with the upper edge of the grommet “4”.
1
3. Fasten the grommet “4” using the plastic
tie “5”. 1
a
4 3
2
a. Blue tape
b
Handlebar installation
1
a 1
After installing the handlebar, make sure
3 4
that the handlebar switch leads are not
2 pulled when the handlebar is turned to the
right and left.
5
1. Install the handlebar “1” and upper handle-
bar holders “2”, and then tighten the bolts
a. Green tape “3” to the specified torque.
b. Blue tape
TIP:
4. Wrap the packing “1”, making sure to align • The upper handlebar holder “2” should be in-
the upper edge of the packing with the up- stalled with the punch mark “a” facing down.
per edges of the tape markings “a”, on the • Tighten the bolts “3” so that there is clear-
buzzer lead “2” and steering sensor lead ance between the steering master and the
“3”. upper handlebar holders “2” at both ends of
the upper handlebar holders.
5. Align the upper edge of the packing “1” • Make sure that clearance “b” is narrower
with the upper edge of the grommet “4”. than clearance “c”.
6. Fasten the grommet “4” using the plastic

tie “5”.
8-3

3 a a
LT
242 2 1 2
3
3
2
3
2 2
c [3]
2 c
[1]
a
[2]
b
b [4]
1
Clearance (reference data) Handlebar switch bolt (left) “2”

“b”: 0.4 mm (0.02 in) 3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
“c”: 1.1 mm (0.09 in)
4. Install the handlebar switch (right) “1”, and
Handlebar holder bolt “3” then tighten the bolts “2” to the specified
21 Nm (2.1 kgf·m, 15.5 ft·lb) torque.
2. Install the stopper bolts “1”, and then tight- TIP:

en them to the specified torque. Align the hole “a” in the handlebar switch (right)
“1” with the stopper bolt “3”.
1
3a 2
1
3
a
1
Handlebar switch stopper bolt “1”
2 Nm (0.2 kgf·m, 1.5 ft·lb)
Handlebar switch bolt (right) “2”
3. Install the handlebar switch (left) “1”, and 3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
then tighten the bolts “2” to the specified
torque in the order [1], [2], and so on. 5. Install the stopper bolts “1”, and then tight-
en them to the specified torque.
TIP: Handlebar grip stopper bolt “1”
Align the hole “a” in the handlebar switch (left) 3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
“1” with the stopper bolt “3”.
6. Install the handlebar grips “2”.
8-4

7. Install the washers “3” and bolts “4”, and
then tighten the bolts “4” to the specified
torque.
TIP:
Align the slit “a” in the handlebar grip “2” with
the stopper bolt “5”.
4 3
2 1
1 2
LT
4
LT 242
242
a 2
a
2
5 5
Handlebar grip end bolt “4”

7 Nm (0.7 kgf·m, 5.2 ft·lb)
8-5

Front hood
Front hood
10 3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
5
17
15
1
3
2
11 16
14 12 9
18
4
13 7 Nm (0.7 kgf·m, 5.2 ft·Ib)
8
22
6
20 7
24
21
26 27 19
25
25
22
22
23
7 Nm (0.7 kgf·m, 5.2 ft·Ib) 2.5 Nm (0.25 kgf·m, 1.84 ft·lb)

1 Screw 8 1/4–10 × 3/4”
2 Mirror (left) 1
3 Mirror (right) 1
4 Ornament 1
5 Ornament 1
6 Nut 2
7 Washer 2
8 Bolt 2 M6 × 95 mm
9 Screw 17 M5 × 16 mm
10 Latch 1
11 Upper front hood 1
12 Ornament 1
13 Lower front hood 1
14 Ornament 1
15 Front hood inner 1
16 Damper 2
8-6

Front hood
10 3.5 Nm (0.35 kgf·m, 2.58 ft·lb)

5
17
15
1
3
2
11 16
14 12 9
18
4
13 7 Nm (0.7 kgf·m, 5.2 ft·Ib)
8
22
6
20 7
24
21
26 27 19
25
25
22
22
23
7 Nm (0.7 kgf·m, 5.2 ft·Ib) 2.5 Nm (0.25 kgf·m, 1.84 ft·lb)

19 Screw 4 M6 × 18 mm
20 Hinge 1
21 Band 1
22 Rivet 4
23 Hook 2
24 Fire extinguisher box 1
25 Mat 2 Not reusable
26 Rivet 5
27 Service lid 1
8-7

Side cover
Side cover
5.5 Nm (0.55 kgf·m, 4.06 ft·lb)
2 4
8
1
9
9
14
6 12
11 7
LT 3
14
572 13
9
5.5 Nm (0.55 kgf·m, 4.06 ft·lb) 10
9
11
10 2
5.5 Nm (0.55 kgf·m, 4.06 ft·lb)

5
LT
5.5 Nm (0.55 kgf·m, 4.06 ft·lb)
572
5.5 Nm (0.55 kgf·m, 4.06 ft·lb)

1 Nut 2
3 Outer ornament (left) 1
4 Outer ornament (right) 1
5 Cap (left) 1
6 Cap (right) 1
7 Inner ornament (left) 1
8 Inner ornament (right) 1
9 Bolt 4 M6 × 29 mm
10 Nut 2
11 Screw 2 M6 × 18 mm
12 Side cover (left) 1
13 Side cover (right) 1
14 Nut 2
8-8

Center cover
Center cover
8 2.5 Nm (0.25 kgf·m, 1.84 ft·lb)
16
9 15
11
7 6
13
5
3 14
12
4 6
10
5.5 Nm (0.55 kgf·m, 4.06 ft·lb)
13
4
LT
572 2
1
5.5 Nm (0.55 kgf·m, 4.06 ft·lb) 17 4 Nm (0.4 kgf·m, 3.0 ft·Ib)

1 Plastic tie 1
2 Bolt 2 M6 × 29 mm
3 Latch 1
4 Nut 2
5 Cover 1
6 Bolt 4 M6 × 29 mm
7 Center cover 1
9 Meter cover 1
10 Bolt 4 M5 × 12 mm
11 Multifunction meter 1
12 Grommet 4
13 Grommet 2
14 Glove box 1
15 Glove box lid 1
16 Lock 1
8-9

Center cover
8 2.5 Nm (0.25 kgf·m, 1.84 ft·lb)

16
9 15
11
7 6
13
5
3 14
12
4 6
10
5.5 Nm (0.55 kgf·m, 4.06 ft·lb)
13
4
LT
572 2
1
5.5 Nm (0.55 kgf·m, 4.06 ft·lb) 17 4 Nm (0.4 kgf·m, 3.0 ft·Ib)

17 Grommet 1
8-10

Steering master ASSY
Steering master ASSY
5
17 Nm (1.7 kgf·m, 12.5 ft·Ib)
6
LT
242
7
4
3
9 8
2
LT
242
7 Nm (0.7 kgf·m, 5.2 ft·Ib) 1

1 Bolt 1 M6 × 18 mm
2 Cable stopper 1
3 Steering cable 1
4 Plastic tie 2
5 Bolt 4 M8 × 30 mm
6 Steering master 1
7 Rivet 2
8 Bracket 1
9 Grommet 2
8-11

Steering master
Steering master
18
17
15
6
16 A
6
4 Nm (0.4 kgf·m, 3.0 ft·Ib)
4 Nm (0.4 kgf·m, 3.0 ft·Ib)

19 3
4 Nm (0.4 kgf·m, 3.0 ft·Ib)
7
4
5
1
20
8
2
11
10
9
14
12 13 16 Nm (1.6 kgf·m, 11.8 ft·Ib)
7 Nm (0.7 kgf·m, 5.2 ft·Ib)

1 Plastic tie 1
2 Buzzer 1
3 Cable guide 1
4 Bolt 2 M5 × 16 mm
5 Bracket 1
7 Steering sensor 1
8 Nut 1
9 Bolt 1 M8 × 50 mm
10 Lock washer 1 Not reusable
11 Steering arm ASSY 1
12 Nut 1
13 Ball joint 1
14 Steering arm 1
15 Steering shaft 1
16 Bushing 1
8-12

Steering master
18
17
15
6
16 A
6
4 Nm (0.4 kgf·m, 3.0 ft·Ib)
4 Nm (0.4 kgf·m, 3.0 ft·Ib)

19 3
4 Nm (0.4 kgf·m, 3.0 ft·Ib)
7
4
5
1
20
8
2
11
10
9
14
12 13 16 Nm (1.6 kgf·m, 11.8 ft·Ib)
7 Nm (0.7 kgf·m, 5.2 ft·Ib)

17 Magnet holder 1
18 Cap 1
19 Steering shaft housing 1
20 Rubber seal 1 Not reusable
8-13

Steering master
Steering arm ASSY installation

1. Install the steering arm ASSY “1” to the
steering shaft.
2. Install the nut “2” to the steering arm “1”.
3. Align the tab “a” on the plate “3” with the

projection “b” on the arm.
4. Tighten the steering arm bolt “4” to the

specified torque.
5. Bend the tabs “c” along the flat sides of the

bolt.
b
4
3
b
c
1
a
2
c
Steering arm bolt “4”

16 Nm (1.6 kgf·m, 11.8 ft·lb)
8-14

Steering cable and speed sensor lead
LT
572
4 6
13
12
7
5 4 Nm (0.4 kgf·m, 3.0 ft·Ib)
10 LT
242
3
LT
242
2 9
7 Nm (0.7 kgf·m, 5.2 ft·Ib)
7 Nm (0.7 kgf·m, 5.2 ft·Ib)
11
8
12
13

1 Steering cable joint 1
2 Bolt 1 M6 × 18 mm
3 Cable stopper 1
4 Plastic tie 1
5 Nut 1
6 Steering cable 1
8 Plastic tie 6
9 Nut 1
10 Screw 4 M5 × 12 mm
11 Speed sensor 1
12 Rivet 6
13 Holder 6
8-15

Steering cable installation (steering

master end) 1
If a cable becomes damaged, replace it.

Never attempt to repair a damaged cable.
1. Install the steering cable “1” and cable LT a

572
stopper “2”, and then tighten the bolt “3” to
Steering cable set length “a” (jet pump
TIP:
Install the cable stopper “2” into the groove “a” end)
in the outer cable. 14.5 ± 1 mm (0.57 ± 0.04 in)
Steering cable locknut (jet pump end) “1”

7 Nm (0.7 kgf·m, 5.2 ft·lb)
2. Install the washer “1” and steering cable

joint “2”, and then tighten the steering ca-
1 ble joint “2” to the specified torque.
a
3. Install the washer “3” and locknut “4”, and
2 then tighten the locknut “4” to the specified
LT
3 torque.
242
Cable stopper bolt “3”

7 Nm (0.7 kgf·m, 5.2 ft·lb)
2
2. Connect the steering cable joint “1” to the
ball joint “2”. LT 1
242
A 3
2 4
Steering cable joint “2”

1
A
7 Nm (0.7 kgf·m, 5.2 ft·lb)
Locknut “4”
7 Nm (0.7 kgf·m, 5.2 ft·lb)
3. Adjust the steering cable. See “Jet thrust

nozzle angle adjustment” (6-5).
Steering cable installation (jet pump

end)
1. Adjust the steering cable set length “a”,
and then tighten the locknut “1” to the
specified torque. (jet pump end)
8-16

Seat and handgrip
Seat and handgrip

16 Nm (1.6 kgf·m, 11.8 ft·Ib) 8
9
14
19 10 1
3 7 Nm (0.7 kgf·m, 5.2 ft·Ib)
4
2
18
BOW 11
17
14 A
A 5
22
15
17 21
23
A 16 B
6
13
12 7 2
21
20
13
12
5 6
13
16 Nm (1.6 kgf·m, 11.8 ft·Ib)
7
26 Nm (2.6 kgf·m, 19.2 ft·Ib) 2
12 16 Nm (1.6 kgf·m, 11.8 ft·Ib) 7 Nm (0.7 kgf·m, 5.2 ft·Ib)

1 Rear seat 1
2 Bolt 4 M6 × 40 mm
3 Seat lock 1
5 Front seat 1 A: VXS, B: VXR
6 Seat lock 1
8 Cap 1
10 Watertight storage compartment 1
12 Nut 11
13 Washer 11
14 Bolt 9 M8 × 30 mm
15 Deck beam 1
16 Nut 1
8-17

Seat and handgrip
16 Nm (1.6 kgf·m, 11.8 ft·Ib) 8

9
14
19 10 1
3 7 Nm (0.7 kgf·m, 5.2 ft·Ib)
4
2
18
BOW 11
17
14 A
A 5
22
15
17 21
23
A 16 B
6
13
12 7 2
21
20
13
12
5 6
13
16 Nm (1.6 kgf·m, 11.8 ft·Ib)
7
26 Nm (2.6 kgf·m, 19.2 ft·Ib) 2
12 16 Nm (1.6 kgf·m, 11.8 ft·Ib) 7 Nm (0.7 kgf·m, 5.2 ft·Ib)

17 Washer 2
18 Projection 1
19 Handgrip 1
20 Bolt 1 M10 × 20 mm
21 Washer 2
22 Projection 1
23 Seat holder 1
8-18

Ventilation hose and water separator
14 15
2
1
9 2
16 14
23
14
SS
6
5
5
23 11
14 5
6
8 10
17 13
12 7
21
23
4 20
23 22
14 6 19
3 18
4
14
23
3 4 Nm (0.4 kgf·m, 3.0 ft·Ib)

1 Rivet 8
2 Ventilator 2
3 Plastic tie 2
4 Ventilation hose 2
5 Plastic tie 3
6 Plastic tie 3
9 Rivet 2
10 Plate 1
11 Water separator 1
12 Drain bolt 1
14 Rivet 7
15 Ventilation socket 1
16 Ventilation pipe 1
8-19

14 15
2
1
9 2
16 14
23
14
SS
6
5
5
23 11
14 5
6
8 10
17 13
12 7
21
23
4 20
23 22
14 6 19
3 18
4
14
23
3 4 Nm (0.4 kgf·m, 3.0 ft·Ib)

17 Plastic tie 1
18 Nut 1
19 Seal 1 Not reusable
20 Clamp 1
22 Cooling water pilot outlet 1
23 Holder 5
8-20

Cooling water pilot outlet installation

1. Install a new seal “1” and the cooling water
pilot outlet “2”, and then tighten the cooling
water pilot outlet nut “3” to the specified
torque.
TIP:
Align the protrusion “a” with the slit “b”.
2
a
1
b
3
Cooling water pilot outlet nut “3”

4 Nm (0.4 kgf·m, 3.0 ft·lb)
8-21

Exhaust system
Exhaust system
3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
d b
24 23 a 17
d
c
a
16
24 23 22 15 13
14
c b
22
15
5.5 Nm (0.55 kgf·m, 4.06 ft·lb)
21
6 3
11 20 19
4 2
26
3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
1 18
12 10 26
12
7
LT
8 27 27
240
28 26 26 5 25 25
9 25
5.5 Nm (0.55 kgf·m, 4.06 ft·lb)
29 3.5 Nm (0.35 kgf·m, 2.58 ft·lb)

1 Negative battery lead 1
2 Positive battery lead 1
3 Clamp 1
4 Battery breather hose 1
5 Band 2
6 Battery 1
7 Bolt 2 M6 × 30 mm
8 Nut 2
9 Battery case 1
13 Clamp 1
14 Resonator 1
15 Clamp 2
16 Clamp 1
8-22

Exhaust system
3.5 Nm (0.35 kgf·m, 2.58 ft·lb)

d b
24 23 a 17
d
c
a
16
24 23 22 15 13
14
c b
22
15
5.5 Nm (0.55 kgf·m, 4.06 ft·lb)
21
6 3
11 20 19
4 2
26
3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
1 18
12 10 26
12
7
LT
8 27 27
240
28 26 26 5 25 25
9 25
5.5 Nm (0.55 kgf·m, 4.06 ft·lb)
29 3.5 Nm (0.35 kgf·m, 2.58 ft·lb)

17 Rubber hose 1 a: Projection
18 Band 1
19 Water lock 1
20 Water tank 1 b: Alignment mark, c: Alignment mark
21 Nut 6
22 Exhaust valve 1 Not reusable
23 Rubber hose 1 d: Alignment mark
24 Plate 1
26 Rivet 8
27 Hook 2
28 Bracket 1
29 Bracket 1
8-23

Exhaust system
Exhaust system installation 3

1. Install the plate “1” onto the rubber hose 2
“2”. 1
TIP:
Make sure to fit the projections “a” on the rub-
ber hose “2” with the grooves in the plate “1”.
b
a
2
a
Rubber hose clamp “2”
a 3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
4. Install the water lock and rubber hose “1”,

and then tighten the clamp “2” to the spec-
ified torque.
1
TIP:
2. Install the rubber hose “1” and a new ex- Align the projection “a” on the rubber hose “1”
haust valve “2”, and then tighten the nuts with the alignment mark “b” on the water tank.
1
Do not reuse a exhaust valve, always re-
place it with a new one. a
b
1
2
2
3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
3 5. Install the resonator “1”, and then tighten
the clamp “2” to the specified torque.
Rubber hose nut “3”
5.5 Nm (0.55 kgf·m, 4.06 ft·lb) TIP:
Fit the protrusion “a” on the resonator “1” be-
3. Install the water tank “1”, and then tighten tween the protrusions “b” on the rubber hose.
the clamp “2” to the specified torque.
TIP:
Align the alignment mark “a” on the rubber
hose “3” with the alignment mark “b” on the wa- b
ter tank “1”.
2
1
8-24

Exhaust system

3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
6. Install the band.
8-25

RiDE motor
RiDE motor
11 2
4 Nm (0.4 kgf·m, 3.0 ft·Ib) A 16
LT
7 Nm (0.7 kgf·m, 5.2 ft·Ib)
12 242
4
17 Nm (1.7 kgf·m, 12.5 ft·Ib)
15
10
3 13
9
5 14
A 13
14
6
5 LT
A 8
LT
7 242
242
11 Nm (1.1 kgf·m, 8.1 ft·Ib)

1 Plastic tie 1
2 Plastic tie 1
3 Trim rod 1
4 Shift rod 1
5 Bolt 2 M6 × 20 mm
6 Trim arm 1
7 Shift arm 1
8 Bolt 2 M8 × 20 mm
9 Nut 3
10 Plate 1
11 RiDE motor 1
13 Rivet 2
14 Hook 2
15 Rivet 1
16 Holder 1
8-26

RiDE motor
RiDE motor removal 5. Remove the speed sensor “1” and ride
1. Remove the deck beam “1”. plate “2”.
1
1
2. Remove the plastic tie “1”, and then dis- 6. Disconnect the shift rod joint “1”.
connect the RiDE motor couplers “a” and
“b”.
1
1
a b
7. Lower the reverse gate, and then remove

the trim rod “1” and shift rod “2”.
3. Remove the resonator “1”, rubber hose
2
“2”, and water tank “3”.
1
2
3
1
8. Remove the trim arm “1” and shift arm “2”.
4. Remove the RiDE motor harness “1” from 2

the holders “2” and the plastic tie “3”.
1 3
2
1
9. While holding the RiDE motor “1” against

the inner wall of the hull, remove the RiDE
motor bolts “2”, nuts “3”, and plate “4”.
8-27

RiDE motor
10. Remove the RiDE motor “1”.
[5]
3
[4]
1 2
[3] [2] [1]
RiDE motor nuts “2”

2 17 Nm (1.7 kgf·m, 12.5 ft·lb)
RiDE motor bolts “3”
17 Nm (1.7 kgf·m, 12.5 ft·lb)
3. Install the shift arm “1” and trim arm “2”,

and then tighten the shift arm bolt “3” and
trim arm bolt “4” to the specified torque.
4 3
3 1
RiDE motor installation

1. Hold the RiDE motor “1” at the installation
position of the hull. 2
Shift arm bolt “3”

1 11 Nm (1.1 kgf·m, 8.1 ft·lb)
Trim arm bolt “4”
11 Nm (1.1 kgf·m, 8.1 ft·lb)
4. Adjust the length “a” of the trim rod “1”.

2. Install the plate “1”, and then tighten the
RiDE motor nuts “2” and RiDE motor bolts
• The trim rod joint must be screwed in
“3” to the specified torque in the order [1],
[2], and so on.
• The shift rod joint must be screwed in
3
5. Turn the trim rod joint 180° so that the 2
holes “b” face in the opposite directions,
and then tighten the locknut “2” to the
specified torque.
1 2 6. Adjust the length “c” of the shift rod “3”.
8-28

RiDE motor
7. Turn the shift rod joint so that the 2 holes
“d” face in the same directions, and then
tighten the locknut “4” to the specified
torque. 1
a b
b 2 1 c
d 4 d
3 10. Install the ride plate “1”, and then tighten
the ride plate bolts “2” to the specified
torque.
e
11. Install the speed sensor “3”, and then tight-
Trim rod length “a”
en the speed sensor screws “4” to the
141.0 ± 0.5 mm (5.55 ± 0.02 in)
specified torque.
Shift rod length “c”
233 ± 0.7 mm (9.17 ± 0.03 in) 3
Distance “e” LT
242
4
Trim rod: More than 8.0 mm (0.31 in)
Shift rod: More than 9.0 mm (0.35 in)
Locknut “2”
4 Nm (0.4 kgf·m, 3.0 ft·lb) 2
Locknut “4” LT
7 Nm (0.7 kgf·m, 5.2 ft·lb) 1 572
8. Connect the shift rod joint “1” and trim rod Ride plate bolt “2”
joints “2”. 17 Nm (1.7 kgf·m, 12.5 ft·lb)
Speed sensor screw “4”
1 4 Nm (0.4 kgf·m, 3.0 ft·lb)
2
12. Fasten the RiDE motor harness “1” using
the holders “2” and plastic tie “3”.
1 3
2
9. Raise the reverse gate, and then connect

the shift rod joint “1”.
13. Install the water tank “1”, and then tighten

the rubber hose clamp “2” to the specified
torque.
8-29

RiDE motor
TIP: 1
Align the mark “a” on the rubber hose “3” with a b
the mark “b” on the water tank “1”.
3
2
1
17. Install the deck beam “1”, and then tighten

the deck beam nut “2” to the specified
b
torque.
a
Rubber hose clamp “2” 1

3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
14. Install the rubber hose “1”, and then tight-

en the rubber hose clamps “2” and “3” to
the specified torque. LT
271
TIP: 2
Align the protrusion “a” on the rubber hose “1”
with the mark “b” on the water tank “4”. Deck beam nut “2”
16 Nm (1.6 kgf·m, 11.8 ft·lb)
15. Install the resonator “5”, and then tighten 18. Initialize the RiDE system using the YDIS.
the clamp “6” to the specified torque. See “YDIS Instruction Manual”.
TIP: RiDE system initialization
Fit the protrusion “c” on the resonator “5” be-
Connect the YDIS and initialize the RiDE sys-
tween the protrusions “d” on the rubber hose
tem. See “YDIS Instruction Manual”.
“1”.
1 4 d
2
5
c
6
a 3
b
Rubber hose clamp “2”, “3”, and “6”

3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
16. Connect the RiDE motor couplers “a” and

“b”, and then fasten the RiDE motor lead
using a plastic tie “1”.
8-30

Rear section
Rear section
16 Nm (1.6 kgf·m, 11.8 ft·Ib)
1
BOW 2
2
3
6
5.5 Nm (0.55 kgf·m, 4.06 ft·lb)
5
14
4
17 16
2.5 Nm (0.25 kgf·m, 1.84 ft·lb)
2
LT
1
14 271
14
15
8
14 9
72 10
LT
13 2 Nm (0.2 kgf·m, 1.5 ft·Ib)
271
16 Nm (1.6 kgf·m, 11.8 ft·Ib) 11 12 16 Nm (1.6 kgf·m, 11.8 ft·Ib)

1 Nut 6
2 Plate 6
3 Cleat 1
4 Clamp 1
5 Nut 1
6 Spout 1
7 Stern eye 2
9 Nut 4
10 Washer 4
11 Screw 4 M5 × 25 mm
12 Drain plug 2
14 Bolt 4 VXR, M8 × 47 mm
15 Reboarding step 1 VXR
16 Bracket 2 VXR
8-31

Rear section
16 Nm (1.6 kgf·m, 11.8 ft·Ib)

1
BOW 2
2
3
6
5.5 Nm (0.55 kgf·m, 4.06 ft·lb)
5
14
4
17 16
2.5 Nm (0.25 kgf·m, 1.84 ft·lb)
2
LT
1
14 271
14
15
8
14 9
72 10
LT
13 2 Nm (0.2 kgf·m, 1.5 ft·Ib)
271
16 Nm (1.6 kgf·m, 11.8 ft·Ib) 11 12 16 Nm (1.6 kgf·m, 11.8 ft·Ib)

17 Packing 2 VXR, Not reusable
8-32

Rear section
Spout installation
1. Install the spout “1”, and then tighten the
spout nut “2” to the specified torque. 2
2. Connect the hose “3”, and then tighten the

spout hose clamp “4” to the specified
torque.
LT
TIP: 2 271
Face the mark “a” toward the BOW. 2
1
1 2 LT
a 271
BOW
2 4 Reboarding step bolt “2”
3 16 Nm (1.6 kgf·m, 11.8 ft·lb)
3. Remove the plastic ties. Check that the re-

boarding step returns properly.
Spout nut “2”

5.5 Nm (0.55 kgf·m, 4.06 ft·lb)
Spout hose clamp “4”
2.5 Nm (0.25 kgf·m, 1.84 ft·lb)
Reboarding step installation (VXR)

1. Secure the brackets on both sides of the
reboarding step in the down position using
the plastic ties “1” so that they will not re-
turn to the up position.
1 1
2. Install the reboarding step “1”, and then

tighten the reboarding step bolts “2” to the
specified torque.
8-33

Deck and hull
Deck and hull

30 24
29
28
27
26
25
16 Nm (1.6 kgf·m, 11.8 ft·Ib)
1.5 Nm (0.15 kgf·m, 1.11 ft·lb)
34 7 Nm (0.7 kgf·m, 5.2 ft·Ib)
15 37
33 13 12
16
7
18 11 14
19 36
19
35
7 Nm (0.7 kgf·m, 5.2 ft·Ib) 17
16
13 Nm (1.3 kgf·m, 9.6 ft·Ib) 15
7 3
4
23
11 56
2
1 8 32
22
31
10
9 21 20 16 Nm (1.6 kgf·m, 11.8 ft·Ib)

1 Bolt 2 M6 × 20 mm
2 Bow eye 1
3 Nut 2
4 Washer 2
5 Nut 2
6 Washer 2
7 Nut 4
8 Nut 2
10 Front protector 1
11 Bolt 4 M6 × 25 mm
12 Rivet 7
13 Rear protector 1
14 Rear protector 1
15 Bolt 10 M8 × 40 mm
16 Collar 10
8-34

Deck and hull
30 24
29
28
27
26
25
16 Nm (1.6 kgf·m, 11.8 ft·Ib)
1.5 Nm (0.15 kgf·m, 1.11 ft·lb)
34 7 Nm (0.7 kgf·m, 5.2 ft·Ib)
15 37
33 13 12
16
7
18 11 14
19 36
19
35
7 Nm (0.7 kgf·m, 5.2 ft·Ib) 17
16
13 Nm (1.3 kgf·m, 9.6 ft·Ib) 15
7 3
4
23
11 56
2
1 8 32
22
31
10
9 21 20 16 Nm (1.6 kgf·m, 11.8 ft·Ib)

17 Sponson 1
18 Sponson 1
19 Bracket 2
20 Inner gunwale 2
21 Rivet 30
22 Washer 30
23 Side gunwale 2
31 Ornament 1
32 Ornament 1
33 Ornament 1
8-35

Deck and hull
30 24
29
28
27
26
25
16 Nm (1.6 kgf·m, 11.8 ft·Ib)
1.5 Nm (0.15 kgf·m, 1.11 ft·lb)
34 7 Nm (0.7 kgf·m, 5.2 ft·Ib)
15 37
33 13 12
16
7
18 11 14
19 36
19
35
7 Nm (0.7 kgf·m, 5.2 ft·Ib) 17
16
13 Nm (1.3 kgf·m, 9.6 ft·Ib) 15
7 3
4
23
11 56
2
1 8 32
22
31
10
9 21 20 16 Nm (1.6 kgf·m, 11.8 ft·Ib)

34 Ornament 1
35 Screw 6 #10–14 × 2/5”
36 Ornament 1
37 Ornament 1
8-36

Deck and hull
— MEMO —
8-37

Troubleshooting
YDIS ..................................................................................... 9-1

Basic components ...................................................................... 9-1
Function...................................................................................... 9-2
Connecting the communication cable to the watercraft.............. 9-4
Engine unit troubleshooting ............................................. 9-5

Using the YDIS for engine unit troubleshooting ......................... 9-5
Diagnostic code table ................................................................. 9-7
Diagnostic code and checking step............................................ 9-8
Engine unit troubleshooting (diagnostic code not detected)..... 9-15

YDIS
YDIS
The Yamaha Diagnostic System uses precision fault diagnosis to offer better serviceability at a time
when there is increasing demand for service tools for electronically controlled products. It provides
quick, reliable, safe, and reasonable service, and is intended to obtain customer satisfaction. The Ya-
maha Diagnostic System features updated software and expanded tool functions that allow it to re-
spond to new models and technologies, maintaining compatibility with regulations. This manual con-
tains the model-specific information. See YDIS (Ver. 2.20) instruction manual for detailed information.
Basic components
YDIS2 Hardware Kit
90890-06884
YDIS2 Hardware Kit
LIT-YDIS2-01-KT
TIP:
The software is available through YMAN (Yamaha Marine Associate Network).
1 2 3 4
5 6 7
8 9 10

1 Adapter interface 1
2 Adapter cap 1
3 Power supply harness 1
4 Trigger switch harness 1
5 AD harness 1 For external input
6 CAN-Line harness 1
7 K-Line harness 1
8 Trigger switch extension harness 1
9 USB cable 1 5 m (16.4 ft)
10 VPP harness 1
9-1

YDIS
Function
1. Diagnosis: Each sensor’s status and each ECM diagnostic code or item is displayed. This enables
you to find malfunctioning parts and controls quickly. The diagnostic codes displayed are the same
as those described in “Diagnostic code and checking step” in this chapter.
2. Diagnosis record: Sensors that had been activated and ECM diagnostic codes that have been
recorded are displayed. This allows you to check the watercraft’s record of malfunctions. The diag-
nostic codes displayed are the same as those described in “Diagnostic code and checking step” in
this chapter.
3. Engine monitor: Each sensor status and the ECM data are displayed. This enables you to find
malfunctioning parts quickly. In addition, the data displayed using the Engine monitor function can
be displayed in a graph.
Engine speed Battery voltage No-wake mode switch
Intake air pressure Fuel injection duration Cruise assist set switch
TPS 1 Engine temperature Cruise assist up switch
Throttle valve opening angle Intake air temperature Cruise assist down switch
Ex. manifold water tempera-
TPS 2 Trim up switch
ture*3
APS 1 Thermoswitch Trim down switch
APS 2 Slant detection switch Main relay
RPS main*1 Oil pressure switch ETV relay
RPS sub*2 Engine start switch Fuel pump relay
Atmospheric pressure APS full close switch Shift position angle
Ignition timing Steering sensor
*1. RPS 1
*2. RPS 2
*3. Thermo sensor
4. Stationary test: Operation tests can be performed with the engine off.
Activate ignition coil (#1–#4) Activate injector (#1–#4) Activate electric fuel pump*1
*1. Operate fuel pump module
5. Active test: With the engine running, the ignition for each cylinder is dropped and the engine speed
is checked for changes to determine if the cylinder is malfunctioning. These tests can be performed
quickly.
6. Logger graph: Data stored in the ECM for the last 78 seconds (in 6-second intervals) is displayed
on a graph.
Engine speed TPS Intake air pressure
Battery voltage Engine temperature Oil pressure switch
7. ECM record graph: When a malfunction occurs in the ETV system or APS system, 4 seconds (2
seconds before and after the malfunction) of recorded data is saved in the ECM. This data can be
displayed on a graph using the “ECM record data graph” of the Data logger function.
9-2

YDIS
When the communication cable is used to connect a computer to the ECM, the ECM record data
can be saved and viewed on the computer.
The saved ECM record data can also be viewed offline.
Engine speed Ref. TPS voltage*2 No-wake mode
APS 1 Ref. APS voltage*3 Low-RPM mode
APS 2 Target TPS voltage for ISC*4 Engine shut-off switch
Steering sensor Engine stop mode Main relay
TPS 1 Engine start mode ETV relay
SW-activated engine stop
TPS 2 Thermoswitch
mode*5
Intake air pressure OTS mode Oil pressure switch
Battery voltage Cruise assist mode WARNING
Target TPS voltage*1 Reverse mode ETV limit
*1. Target TPS voltage

This item shows the target output voltage of the TPS.
This value is the control voltage that the ECM requires to set the target opening angle of the
throttle valve.
*2. Reference TPS voltage
This item shows the criterion output voltage of the TPS.
This value is used to detect the TPS output voltage during engine operation.
*3. Reference APS voltage
This item shows the criterion output voltage of the APS.
This value is used to detect the APS output voltage when the throttle lever is opened.
*4. Target TPS voltage for Idle Speed Control
ECM controls the engine idle speed by using the throttle valve attached to the TPS.
This target voltage is used by the ECM to achieve the target opening angle of the throttle
valve at the engine idle speed.
*5. Engine stop mode with switch
TIP:
To display the data and graphs, see the YDIS (Ver. 2.20) Instruction Manual.
8. Logging: While the computer and engine are not connected, record “Engine Monitor” data using
the adapter interface.
9. Engine record: Displays the number of times the engine was started during the period when en-
gine control was deactivated.
10. SCU initial learning: The RiDE system needs to be initialized again if any of the jet pump unit com-
ponent or RiDE motor has been replaced (or removed).
9-3

YDIS
TIP:
To perform the SCU initial learning, see the YDIS (Ver. 2.20) Instruction Manual.
Connecting the communication cable to the watercraft
TIP:
Be careful not to pinch the communication cable between the front hood and the deck or to damage it.
2 3
1
a
R/Y
W/B
B
a. Wire harness coupler

b. Meter coupler
1. K-Line harness
2. Adapter interface
3. USB cable
4. Adapter cap
9-4

Engine unit troubleshooting

TIP:
• Before troubleshooting the engine unit, make sure that fresh fuel of the specified type has been used.
• Check that all wiring connections are secured properly and that they are not corroded or rusty.
• Check that the engine shut-off cord is connected to the engine shut-off switch.
• Check that the battery is charged and that its specific gravity is within specification.
• Check the diagnostic code using the YDIS (or self-diagnosis) first, and then check the electronic con-
trol system by following the diagnostic code chart.
• The multifunction meter cannot display more than 1 diagnostic code. Even if multiple diagnostic codes
are present, only 1 will be displayed.
• When an ETV system (ETV, TPS, and APS) diagnostic code is detected, check the data logger of the
“ECM record data graph” as well.
• Using the YDIS is recommended because self-diagnosis may be insufficient for proper troubleshoot-
ing of the ETV system (ETV, TPS, and APS).
• If a diagnostic code is not detected, check the engine unit according to “Engine unit troubleshooting
(diagnostic code not detected)”.
• When deleting the diagnosis record on 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 re-
sult, 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 voltage.
Using the YDIS for engine unit troubleshooting
TIP:
• Use the diagnostic codes displayed by the YDIS to check each part according to the “Diagnostic code
and checking step” table.
• Delete the diagnostic codes after checking, repairing, or replacing a part, and check that the diagnos-
tic codes are not detected again. If the same diagnostic codes are detected, the ECM may be faulty.
• Check the items listed in the table. If all the items are in good condition, delete the diagnostic code,
and then check the diagnostic codes again. If the same diagnostic codes are detected again, the ECM
is faulty.
• A breakdown of the engine symptoms are described in the “Diagnostic code table”, however, multiple
malfunctions that have been duplicated cannot be limited to these items. The symptoms may change
depending on the operating conditions and other conditions.
• Even though this model is not fitted with OBD-M function, SPN (Suspect Parameter Number) codes
will be displayed on the computer screen when YDIS version 2.20 is connected to the computer.
Self-diagnosis
If a sensor malfunction or a short circuit is detected while the engine is running, the “WARNING” indi-
cator light “a” and the check engine warning indicator “b” blink and the buzzer sounds intermittently for
30 seconds.
When the engine is stopped after the check engine warning is activated, the information display will in-
dicate a diagnostic code “c”.
9-5

If the multifunction meter is turned on before the problem is solved, the information display will indicate
the diagnostic code “c” and the “WARNING” indicator light “a” will blink. If the engine is started, the
“WARNING” indicator light “a” and the check engine warning indicator “b” blink and the buzzer sounds
intermittently for 30 seconds.
When the engine is started for the first time after the problem is solved, the “WARNING” indicator light
and the check engine warning indicator blink and the buzzer sounds intermittently for 30 seconds to
indicate that malfunction history exists.
TIP:
Because the multifunction meter cannot display more than 1 diagnostic code even if there are multiple
diagnostic codes, using the YDIS is recommended.
b a
9-6

Diagnostic code table

: Indicated
—: Not indicated
Diagnostic code output
YDIS
Code No. Item Multifunc-
tion meter Diagnosis
Diagnosis
record
Pulser coil
13   
(Pickup coil)
15 Engine temperature sensor   
19 Battery voltage   
Air temperature sensor
23   
(Intake air temperature sensor)
24 Cam position sensor   
Air pressure sensor
29   
(Intake air pressure sensor)
47 Slant detection switch   
51 APS full close switch   
55 Steering sensor   
112, 113, 114,
115, 116, 117,
119, 123, 138, ETV system   
141, 142, 143,
144, 145
118, 121, 122,
129, 136, 137, ETV system   —
139
124, 125, 126,
TPS   
127, 128
131, 132, 133,
APS   
134, 135
150, 151, 152,
RPS   
153, 154
157, 158, 159,
161, 162, 163, SCU   
164
9-7

Diagnostic code and checking step

*1: This symptom may only be exhibited in certain environmental conditions.
—: Not applicable
Diag-
See
nostic Item Symptom Checking steps
page
code
Measure the pickup coil output
7-12
peak voltage.
Measure the pickup coil resis-
Pulser coil 7-12
13 Engine will not start tance.
(Pickup coil)
Check the white/black (W/B)
and black/orange (B/O) pickup A-2
coil leads for continuity.
Check the engine temperature
7-16
using the YDIS.
Measure the engine tempera-
7-16
ture sensor input voltage.
Engine tem- Check the black/yellow (B/Y)
15 Trolling speed is unstable*1
perature sensor and black/orange (B/O) en-
A-2
gine temperature sensor leads
for continuity.
Measure the engine tempera-
7-16
ture sensor resistance.
Check the battery voltage us-
9-2
ing the YDIS.
7-3
Check the fuse for continuity.
7-31
Measure the stator coil output
7-13
19 Battery voltage Trolling speed is unstable*1 peak voltage.
Measure the rectifier/regula-
7-13
tor output peak voltage.
Check the battery leads and
terminals for proper connec- 3-6
tion.
Check the intake air tempera-
7-17
ture using the YDIS.
Measure the intake air tem-
Air tempera- 7-17
perature sensor input voltage.
ture sensor
23 (Intake air tem- Trolling speed is unstable*1 Check the black/red (B/R) and
perature sen- black/orange (B/O) intake air
A-2
sor) temperature sensor leads for
continuity.
Measure the intake air tem-
7-17
perature sensor resistance.
9-8

Diag-
See
page
code
Measure the cam position
7-25
sensor input voltage.
Check the orange (O),
green/orange (G/O), and
Cam position
24 Engine speed is limited black/orange (B/O) cam posi- A-2
sensor
tion sensor leads for continui-
ty.
Measure the cam position
7-25
sensor output voltage.
Check the intake air pressure
7-18
using the YDIS.
Measure the intake air pres-
Air pressure 7-18
sure sensor input voltage.
sensor Engine stalls
29 Check the orange (O),
(Intake air pres- Trolling speed is unstable
sure sensor) pink/green (P/G), and
black/orange (B/O) intake air A-2
pressure sensor leads for con-
tinuity.
Check the slant detection
switch operation using the 7-26
YDIS.
Measure the slant detection
7-26
switch input voltage.
Slant detection
47 Normal operation Check the blue/black (L/B)
switch
and black/orange (B/O) slant
A-2
detection switch leads for con-
tinuity.
Check the slant detection
7-26
switch for continuity.
Check the APS full close
switch operation using the 7-20
YDIS.
Measure the APS full close
7-20
APS full close Engine stalls switch input voltage.
51
switch Trolling speed is unstable *1 Check the orange/green
(O/G), black/green (B/G), and
white/green (W/G) APS full A-2
close switch leads for continui-
ty.
9-9

Diag-
See
page
code
Check the steering sensor op-
7-27
eration using the YDIS.
Measure the steering sensor
7-27
input voltage.
55 Steering sensor Normal operation
Check the orange/red (O/R),
white/blue (W/L), and black/or-
A-2
ange (B/O) steering sensor
leads for continuity.
Check the TPS output voltage
and throttle valve opening us- 7-18
ing the YDIS.
Check the ECM circuit for con-
7-27
tinuity.
Check the ETV relay for conti-
7-22
nuity.
Check the charging system.
• Stator coil output peak volt-
112 7-13
age
113 ETV system Engine speed is limited 7-13
• Stator coil resistance
114 7-13
• Rectifier/regulator output
7-13
peak voltage
• Rectifier/regulator continuity
Check the fuse for continuity. 7-31
Check the battery voltage and
3-6
specific gravity.
Check the red (R) and black
(B) power supply circuit cables A-2
and leads for continuity.
Check the pink (P), orange
(O), pink/black (P/B), and
A-2
black/orange (B/O) ETV leads
for continuity.
115 Check the TPS output voltage
ETV system Engine speed is limited
116 and throttle valve opening us- 7-18
ing the YDIS.
Check the throttle shaft and
throttle inner surface for dam- A-2
age and wear.
9-10

Diag-
See
page
code
Check the ETV coupler termi-
4-7
nals for corrosion and rust.
117
Check the green (G) and blue
118 ETV system Engine speed is limited A-2
(L) ETV leads for continuity.
119
7-27
tinuity.
Cross-check the ECM or re-
121 ETV system Engine speed is limited —
place.
122 ETV system Engine speed is limited Cross-check the ETV. —
7-3
Check the ETV relay and fuse
7-22
(ETV relay) for continuity.
7-27
tinuity.
Check the pink (P), orange
124 (O), pink/black (P/B), and
A-2
125 black/orange (B/O) ETV leads
TPS Engine speed is limited for continuity.
127
128 Check the ECM circuit for con-
7-27
tinuity.
7-18
using the YDIS.
126 TPS Engine speed is limited
7-27
tinuity.
7-18
using the YDIS.
129 ETV Engine speed is limited
Check the ETV relay and fuse 7-3
(ETV relay) for continuity. 7-22
131 Check the APS output voltage
7-20
132 using the YDIS.
APS Engine speed is limited
133 Check the APS circuit for con-
134 7-21
tinuity.
Check the APS circuit for con-
135 APS Engine speed is limited 7-21
tinuity.
9-11

Diag-
See
page
code
7-27
tinuity.
7-22
nuity.
7-13
age
7-13
136 • Stator coil resistance
7-13
137 • Rectifier/regulator output
ETV system Engine speed is limited 7-13
138 peak voltage
139 • Rectifier/regulator continuity
7-3
7-31
3-6
specific gravity.
7-27
tinuity.
7-22
7-31
and throttle valve opening us- 7-18
ing the YDIS.
142 ETV system Engine speed is limited
throttle inner surface for dam- 4-7
age and wear.
9-12

Diag-
See
page
code
7-27
tinuity.
7-22
nuity.
7-13
age
7-13
7-13
143 • Rectifier/regulator output
ETV system Engine speed is limited 7-13
144 peak voltage
7-3
7-31
3-6
specific gravity.
7-3
7-22
7-31
145 ETV system Engine speed is limited
throttle inner surface for wear 4-7
or damage.
Check the orange/red (O/R),
orange/white (O/W), pink/red
150 (P/R), pink/white (P/W),
A-2
151 Engine speed is limited black/red (B/R), and
RPS black/white (B/W) RPS leads
152 Shifting is impossible
153 for continuity.
7-27
tinuity.
Check the RPS output volt-
7-23
Engine speed is limited age using the YDIS.
154 RPS
Shifting is impossible Check the ECM circuit for con-
7-27
tinuity.
Engine speed is limited
157 SCU Replace the RiDE motor. 8-26
Shifting is impossible
Check the electric trim switch
7-25
Changing the trim angle is im- operation using the YDIS.
158 SCU
possible Measure the electric trim
7-25
switch resistance.
9-13

Diag-
See
page
code
Check that there is no foreign
Engine speed is limited matter on the rotating part of 6-7
159 SCU the reverse gate.
Replace the RiDE motor. 8-26
Changing the trim angle is im-
possible
7-3
Check the SCU relay and fuse
7-24
(SCU) for continuity.
7-31
3-6
specific gravity.
Engine speed is limited Check the charging system.
163 SCU
Shifting is impossible • Stator coil output peak volt-
7-13
age
7-13
7-13
• Rectifier/regulator output
7-13
peak voltage
9-14

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 contents considered to be the trouble factors for symptom 2
—: Not applicable
Symptom 1: Engine does not crank.

See
Symptom 2 Cause Checking step
page
Yamaha Security System Check that the Yamaha Security
7-37
set to lock mode System is set to the unlock mode.
Check the battery voltage and spe-
Discharged battery 3-6
cific gravity.
Loose connection of bat- Check the battery lead and terminal
3-6
tery terminal for proper connection.
7-3
Blown fuse Check the fuse for continuity.
7-31
Starter relay malfunction Check the starter relay. 7-32
Starter motor does Engine start switch mal- Check the engine start switch. [han-
7-31
not operate function dlebar switch (left)].
Short, open, or loose con- Measure the starter relay input volt- 7-32
nection in starter motor cir- age.
cuit Check the wire harness. A-2
Disassemble and check the starter
Starter motor malfunction 7-34
motor.
Disassemble and check the engine
Stuck piston or crankshaft 5-73
unit.
Disassemble and check the jet
Stuck impeller 6-10
pump unit.
Starter motor oper-
Idle gear or starter clutch Check the idle gear, starter clutch, 5-55
ates, but the engine
malfunction or crankshaft Woodruff key. 5-60
does not crank
Symptom 1: Engine will not start (engine cranks).

See
page
Check that the throttle lever is in the
Throttle lever squeezed —
fully closed position.
Throttle valve does Measure the APS 1 and 2 output
APS malfunction 7-20
not move properly voltage.
TPS malfunction Check the throttle valve opening. 7-18
Throttle valve malfunction Check the ETV. 4-7
9-15

See
page
Battery performance de- Check the battery voltage and spe-
3-6
crease cific gravity.
Stator coil malfunction Check the stator coil 7-13
Discharged battery
Check the battery lead and terminal
Short, open, or loose con- 3-6
for proper connection.
nection in charging circuit
Check the wire harness. A-2
7-3
7-31
ECM does not oper- Main relay malfunction Check the main relay. 7-31
ate Short, open, or loose con- Measure the ECM input voltage. 7-27
nection in ECM circuit Check the ECM circuit for continuity. 7-27
ECM malfunction Replace the ECM. —
Engine shut-off cord clip Check that the engine shut-off cord
7-31
not installed clip is installed properly.
Engine stop switch mal- Check the engine stop switch conti-
7-31
function nuity. [handlebar switch (left)]
Measure the pickup coil output peak
7-12
Pickup coil malfunction voltage.
Measure the pickup coil resistance. 7-12
Check the white/black (W/B) and
Short, open, or loose con-
black/orange (B/O) pickup coil leads A-2
nection in pickup coil circuit
for continuity.
Spark plug does not Measure the ignition coil input volt-
spark (all cylinders) 7-11
age (from the battery).
Short, open, or loose con- Check the red/yellow (R/Y),
nection in ignition coil cir- black/red (B/R), black/white (B/W),
cuit black/yellow (B/Y), and black/green A-2
(B/G) ignition coil leads for continui-
ty.
Exchange the ignition coil with a dif-
Ignition coil malfunction ferent one, and then check the igni- —
tion spark.
Measure the ECM output peak volt-
ECM malfunction 7-11
age.
9-16

See
page
Fuel leakage Check the fuel hose. 4-1
7-3
7-31
Clogged fuel pump filter Clean the fuel pump filter. 4-12
Check the fuel pump module opera-
4-12
tion sound using the YDIS.
Fuel not supplied (all
cylinders) Measure the fuel pump module in-
Fuel pump module mal- 4-12
put voltage.
function
Check the blue (L) and black (B) fuel
A-2
pump module leads for continuity.
Measure the fuel pressure. 4-3
Fuel pump relay malfunc-
Check the fuel pump relay. 7-29
tion
Measure the compression pressure. 5-1
Measure the valve clearance. 3-11
Check the camshaft for damage. 5-35
Check the cylinder head gasket and
5-47
cylinder head warpage.
Compression pres- Compression leakage
sure is low Check the valve and valve seat for
5-48
wear.
Check the piston and piston ring for 5-76
damage. 5-76
Check the cylinder for damage. 5-76
Improper valve timing Check the timing chain. 5-37
Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited engine
speed
See
page
Throttle valve does
Throttle valve malfunction Check the ETV. 4-7
not move properly
9-17

See
page
Spark plug malfunction Check the spark plug. 3-5
Ignition coil malfunction Check the ignition spark. 7-11
Measure the ignition coil input volt-
7-11
age (from the battery).
Spark plug does not Short, open, or loose con- Check the red/yellow (R/Y),
spark (some cylin- nection in ignition coil cir- black/red (B/R), black/white (B/W),
ders) cuit black/yellow (B/Y), and black/green A-2
(B/G) ignition coil leads for continui-
ty.
Measure the ECM output peak volt-
ECM malfunction 7-11
age.
Check the fuel injector operation
7-29
Fuel injector malfunction sound using the YDIS.
Measure the fuel injector resistance. 7-29
Measure the fuel injector input volt-
7-29
age.
Fuel not supplied Short, open, or loose con- Check the red/yellow (R/Y), pur-
(some cylinders) nection in fuel injector cir- ple/red (Pu/R), purple/black (Pu/B),
cuit purple/yellow (Pu/Y), and pur- A-2
ple/green (Pu/G) fuel injector leads
for continuity.
Clogged fuel injector filter Clean the fuel injector. 4-7
ECM malfunction Replace the ECM. —
Measure the compression pressure. 5-1
Measure the valve clearance. 3-11
Check the camshaft for damage. 5-35
Check the cylinder head gasket and
5-47
cylinder head warpage.
Compression pres- Compression leakage
sure is low Check the valve and valve seat for
5-48
wear.
Check the piston and piston ring for 5-76
damage. 5-76
Check the cylinder for damage. 5-76
Improper valve timing Check the timing chain. 5-37
9-18

Symptom 1: Limited engine speed
See
page
Check the cooling water pilot outlet
—
Clogged cooling water pas- for water discharge.
sage Check the water inlet strainer. 3-3
Check the cooling water passage. 1-33
Thermostat malfunction Check the thermostat. 5-21
Measure the engine temperature
7-16
sensor resistance.
• Buzzer sounds in- Engine temperature sen- Check that there is no short circuit
termittently sor malfunction between the black/yellow (B/Y) and
• Overheat warning A-2
black/orange (B/O) engine tempera-
indicator blinks ture sensor leads.
• Check engine
Check the thermo switch for continu-
warning indicator 7-15
ity.
blinks
Thermo switch malfunction Check that there is no short circuit
between the pink (P) and black (B) A-2
thermo switch leads.
Check the thermo sensor. 7-16
Check that there is no short circuit
Thermo sensor malfunction between the black/blue (B/L) and
A-2
black/orange (B/O) thermo sensor
leads.
Check the engine oil level. 3-4
Insufficient engine oil Check for engine oil leakage. —
• Buzzer sounds in- Check the oil passage. 1-32
termittently Check the oil pressure switch conti-
• Oil pressure warn- 7-15
nuity.
ing indicator blinks Oil pressure switch mal-
function Check that there is no short circuit in
the pink/white (P/W) oil pressure A-2
switch lead.
9-19

Symptom 1: Discharged battery
See
page
Battery performance de- Check the battery voltage and spe-
3-6
crease cific gravity.
Loose connection of bat- Check the battery lead and terminal
3-6
tery terminal for proper connection.
— Short, open, or loose con- Check the charging circuit for wiring
A-2
nection in charging circuit connection and damage.
Stator coil malfunction Check the stator coil 7-13
Rectifier/regulator malfunc- Measure the rectifier/regulator out-
7-13
tion put peak voltage.
Symptom 1: Poor performance

See
page
3-10
Check the impeller, impeller duct,
Jet pump unit malfunction 6-1
and intake grate.
6-10
Check the drain plugs and O-rings
8-31
for damage.
Watercraft cannot
Check the cooling water hoses for
reach high speeds 1-33
damage.
Water entered hull
Check the water lock, water tank,
8-22
and rubber hoses for damage.
Check the exterior of the hull for
—
damage.
9-20

— MEMO —
9-21

Appendix
Wiring diagram ...................................................................A-1

How to use the wiring diagram ................................................... A-1
VXS, VXR................................................................................... A-2
A
Wiring diagram
Wiring diagram
How to use the wiring diagram
Legend symbols in the wiring diagrams

1 2
1. Double colors wire

2. No wire connector
Color code
B : Black P/B : Pink/Black
Br : Brown P/G : Pink/Green
B/G : Black/Green P/R : Pink/Red
B/L : Black/Blue P/W : Pink/White
B/O : Black/Orange Pu/B : Purple/Black
B/R : Black/Red Pu/G : Purple/Green
B/W : Black/White Pu/R : Purple/Red
B/Y : Black/Yellow Pu/Y : Purple/Yellow
G : Green R : Red
Gy : Gray R/W : Red/White
G/O : Green/Orange R/Y : Red/Yellow
L : Blue Sb : Sky blue
L/B : Blue/Black W : White
L/R : Blue/Red W/B : White/Black
L/W : Blue/White W/G : White/Green
L/Y : Blue/Yellow W/L : White/Blue
Lg : Light green Y : Yellow
O : Orange Y/B : Yellow/Black
O/G : Orange/Green Y/G : Yellow/Green
O/R : Orange/Red Y/R : Yellow/Red
O/W : Orange/White Y/W : Yellow/White
P : Pink
Example:
R/Y: Red with Yellow tracer stripe wire
A-1

VXS, VXR Multifunction meter APS (electric throttle
Remote control receiver
Fuel sender
B/Y without wire cable) a b c d e f g Fuse box
B/G Y
B W W B R Br P R/W Buzzer
FREE SET Starter motor
h
W
PUSH PULL 1 9
R
B
R
k
L/R
L/B
10 18
Gy
Br Br W B
B i
W
FREE A B
B
R
PUSH
Br j 3 L
10
12
13
14
15
16
18
3
4
6
7
9
Br 4 Y
B
Speed sensor
Handlebar switch (left)
Br
W
R
Y
L/Y
Gy
L
B
B
Y/W
Gy
B
W
L/B
L/R
B/L
B/L
R
B
L/Y
L/B
L/R
W/G
O/W
B/W
P/W
O/G
O/R
B/G
B/R
3 1 P/R
W/B
B
R/Y
6 4
Sb
Lg
B
Starter
10
11
12
1
2
3
4
5
6
7
1
2
3
3 1
1
2
3
4
5
6
7
8
9
4 1 4 1 relay
O/W
B/W
P/W
O/R
B/R
P/R
8 5 Battery
5
R/W
8
Y/W
12 9
Y/W
R
R
R
Y/G
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
L/R
Br
Br
W
B
R
Y
Y
Y
R
R
L
2 W R/Y 1
3 G/O R/Y 2 1 4 8 12
R/Y 3
5 L/B R/Y 4
R/Y 5
1 8 14 20 7 R/Y
8 W/B
9 L R/Y 8
11 P/W R/Y 9
B/L R/Y 10
13 R/Y 11 3 7 11 14
14 Y/W L/W 12
15 B/R Joint coupler 2
16 P/G R/Y 14
17 W/L
20 Y/G 1 4
7 13 19 26 21 Y
22 W/G
23 B/Y
25 O/R O 4
26 O O 5 36
O 6
27 R/Y Joint coupler 1
27 34 40 46 28 O/R
29 B/G B/O 1
30 O/G B/O 2 15 8
31 B/R B/O 3
32 B/W B/O 4
B/O 5
33 P/R B/O 6
34 B/R B/O 7
35 B/W B/O 8
36 P/R B/O 9 4 7 10
37 P/W
38 W
39 R/Y Joint coupler 3
33 39 45 52 40 B/O
41 B/O
42 P
43 P/B
44 O
45 R/Y
46 B 1 4
47 W/B B 1
B 2
49 O/R B 3
50 O/W B 4
51 O/W
52 L B 6 36
Joint coupler 4
1 5
B 2
58 Pu/R B 3
59 Pu/B B 4
60 B/G B 5
W/B
B 6
B/O
61 B/Y
G
G
G
ECM
B/O
B/O
B/O
62 B B 7
B/Y
B/L
L/B
P/W
B/W
B/G
8
B/O
B
B/O
P/G
R/Y
R/Y
R/Y
R/Y
B/R
B/R
B/Y
R
B
B
P
4 8
W/L
O/R
B/O
64 P
B/O
R/W
Y/W
O
P/B
B
B
G/O
L/W
L
B/O
Sb
Pu/G
Lg
Pu/B
Pu/R
G
O
Pu/Y
W
P
L
R
Joint coupler 5
B
B
L
R/Y
R/Y
R/Y
R/Y
53 62 70 78 67 B
1
2
3
1 5 Earth plate
70 B
#1 #2 #3 #4 B 1
72 W B 2
G
G
G
P/W
B 3
R
B
G
G
G
#1 #2 #3 #4 B 4
B 5
78 G
79 P/W Intake air B 7
80 Y/W pressure 8 4 8
B
81 L/R sensor Thermo Pickup 1
Slant switch coil B 1
83 Pu/G ETV Oil detection Steering Fuel injector Engine
61 69 77 86 Cam Fuel pump Ignition coil Intake air Rectifier/ B 2
84 Pu/Y pressure switch sensor temperature temperature
85 B/R position module Stator regulator
86 B/W RiDE motor sensor switch sensor sensor Thermo sensor coil 2

Wiring diagram
A. To entry box
B. Antenna
a. Fuse (10 A) (fuel pump relay)

b. Fuse (3 A) (not used)
c. Fuse (20 A) (main relay)
d. Fuse (10 A) (main relay)
e. Fuse (10 A) (ETV relay)
f. Fuse (3 A) (remote control receiver)
g. Fuse (30 A) (battery)
h. Fuse (50 A) (SCU relay)
i. Fuel pump relay
j. Main relay
k. ETV relay
l. SCU relay
A-3

Mar. 2015 CR
(E)

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WaveRunner

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Particularly important information is distinguished in this manual by the following notations:

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Safety while working.......................................................... 1-1

Identification number......................................................... 1-4

How to use this manual ..................................................... 1-5

Adhesive, lubricant, sealant,

Special service tool............................................................ 1-9

Model feature .................................................................... 1-19

Technical tips ................................................................... 1-21

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RiDE system............................................................................. 1-23

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Safety while working Handling of gasoline

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Working with crane

Parts, lubricants, and sealants

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Disassembly and assembly

Special service tool

• Install bearings so that the bearing identifica-

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Identification number Jet pump unit serial number

Engine serial number Hull identification number (H.I.N.)

Starting engine serial number

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How to use this manual

Impeller housing and impeller duct ASSY

1 Nm (0.1 kgf·m, 0.7 ft·lb) 40 Nm (4.0 kgf·m, 29.5 ft·lb)

2 Impeller, drive shaft, and impeller duct

Do not press the drive shaft threads

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Conditions when testing and adjusting

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Adhesive, lubricant, sealant, and thread locking agent

YAMALUBE 4W or Yamaha 4-stroke motor oil Lubricant

Water resistant grease

Epnoc grease AP#0 Lubricant

Silicone grease Lubricant

ThreeBond 1207B Sealant

ThreeBond 1280B Sealant

ThreeBond 1322D Thread locking agent

ThreeBond 1360 Thread locking agent

ThreeBond 1530D Adhesive

LOCTITE 242 (blue) Thread locking agent

LOCTITE 271 (red) Thread locking agent

LOCTITE 572 (white) Sealant

LOCTITE 648 (green) Thread locking agent

Silicone sealant Sealant

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Special service tool

Gauge stand 3-12, 5-34,

Dial gauge needle 3-12, 5-34,

Dial gauge stand set 3-12, 5-34,

Dial gauge set 3-12, 5-34,

Dial indicator gauge 3-12, 5-34,