General: Personal Water Craft

General
PERSONAL WATER CRAFT
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180466
INTRODUCTION
More than 20 years have elapsed since our personal watercraft (hereinafter the “PWC”)
first appeared on the market, and now the PWC has become a product that occupies a
major place in the world of marine pleasure just like outboards and motorboats.
The increasing opportunities for the use of the PWC by people are accompanied by the
increasing needs for more of the product knowledge of the PWC and its servicing
techniques and skills. And we, who handle our own PWC, should commit ourselves to
enhancing the product reliability through improved servicing skills and user
enlightenment of safety.
This book has been produced as a textbook for those PWC servicemen who receive
Marine YTA training. The text contains important basics that are required to better
understand the engines, propellers, hulls, and so on that are involved in the PWC.
Therefore, you are requested to carefully read and understand the contents of this
textbook so you will be knowledgeable enough to win customer reliance. Also if,
together with this book, you use the CAI (Computer Aided Instructions) containing
animation, we assure you that you will be able to get further and more effective learning
and knowledge.
Marine Business Operations

Yamaha Motor Co., Ltd.
YTA PWC Text
Issued in December 2008

All rights reserved
memo Compiled and issued by:
Marine Business Operations
Yamaha Motor Co., Ltd.
WHAT WE LEARN IN VOLUME
INTRODUCTION
In this volume you will learn about how to prepare
yourself as a member on Yamaha marine service
staff, a necessary skill in operating instruments for
maintenance, and various kinds of basic
information. With the contents introduced in this
volume as the base, work hard to improve yourself
to become an excellent serviceman.
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CHAPTER 1 CHAPTER 3
UNITS/ TERMINOLOGY AND RULES AND FLOW OF
STANDARD MACHINE WORK
PARTS
INTRODUCTION ………………………...…3-1
INTRODUCTION…….…………..….........…1-1 WHAT WE LEARN IN CHAPTER 3.…...3-1
WHAT WE LEARN IN CHAPTER…...…1-1 RULES FOR WORK……………..………....3-2
UNITS AND TECHNICAL TERM................1-2 COMPLIANCE WITH LAW…………......3-2
UNIFYING INTO SI UNITS….………..1-2 MARITIME MANNERS….…………..…..3-2
MARINE TERMS……….………….…..1-3 SAFE OPERATIONS………………..…..3-3
ENGINE-RELATED TERMS……….…..1-5 FLOW OF PWC SERVICING…...………....3-4
CRAFT-RELATED TERMINOLOGY…..1-7 FLOW OF WORK FOR
STANDARD MACHINE PARTS…….....1-11 A WHOLE YEAR…………………………3-4
BOLTS/NUTS……..…….…...………....1-11 WHAT TO DO BEFORE DELIVERY..…....3-5
WASHER………..…………………......1-12
WHAT TO DO BEFORE DELIVERY…..3-5
OTHER FIXTURES………………….....1-13
WHAT TO DO FOR DELIVERY………..3-5
BEARING………….………………….....1-14
OIL SEAL………….………………….....1-15
CHAPTER 2
KINDS OF TOOLS
INTRODUCTION ………………………...…2-1
WHAT WE LEARN IN CHAPTER ...…...2-1
GENERAL TOOLS……….……….………...2-2
FASTENING THE HEX HEAD
SCREWS………………………………….2-2
FASTENING OTHER SCREWS...…..2-11
GRIPPING THE PARTS………….…..2-14
FIXING THE PARTS……...………..…..2-18
TOOLS FOR REWORK…..………..…..2-22
TOOLS FOR MACHINING..……..…..2-27
MEASUREMENT HARDWARE….……...2-34
MEASURING THE LENGTHS…..…..2-34
MEASUREMENT OF VOLUME…..…..2-38
MEASURING THE CLEARANCES…..2-39
MEASURING THE FORCES.……..…..2-43
MEASURING THE ELECTRICITY.…..2-46
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CORRECT MEASUREMENT……..…..2-53
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INTRODUCTION
CHAPTER 1. UNITS/
TERMINOLOGY AND
STANDARD MACHINE PARTS
INTRODUCTION
WHAT WE LEARN IN CHAPTER 1
In this chapter we will learn about various units and
technical terms including how to work with various
machine parts and tools essential for maintenance.
These will appear actually over and over again as
you go along, so you should be well grounded in
them.
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1-1
UNITS AND TECHNICAL TERMS
UNIFYING INTO SI UNITS
The SI units are an internationally unified system of
measures and were developed on the basis of the
metric system in 1960. The SI units are legally used
in almost every country in the world and it is official
policy to use these units in some countries. Base SI
units include the meter for length, the kilogram for
mass, and the second for time, and a wide variety
of measurements are derived from combinations of
these three base units.
1. International system of units
Basic units consist of time (s), length (m), mass
(kg), electric current (A), thermodynamic
temperature (K), amount of substance (mol), and
luminosity (cd). These are generally used with the
size-indicating SI prefixes placed before them.
Others include derived units, supplementary units,
and so on.
2. Units as used in marine applications

The marine industry uses the industry-specific
standard units. Here are some representative ones.
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1-2
MARINE TERMS
We will learn about marine terms.
1. Wave length
Wave length is the distance as measured between
one wave crest and the neighboring one.
2. Wave height
Wave height is the difference in height between the
wave crest and trough.
3. Water depth
Water depth is the distance between the sea
surface and bottom and is changed by the tide level.
On a marine chart the water depth is referred to as
the distance measured from the lowest water level
when the tide recedes at its lowest.
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1-3
4. Sea tide
Tide is the periodic (about every 6 hours) slow rise
and fall of the waters of the ocean produced by the
attraction of the moon and sun (mainly the moon).
The ebb and flow occur twice a day. (Several times
a year they may occur only once a day.)
1) Spray tide
At spring tides, the greatest difference arises
between the ebb and flow of water. Spring tides
occur when the moon and sun are aligned in a
straight line, namely, either at a new or full moon.
The water level becomes 20% above average on
the moon and its opposite sides.
2) Neap tide
At neap tides, the least difference arises between
the ebb and flow. Neap tides occur when the moon
and such are positioned about right angles with
each other, causing conflict in their attraction. The
rise of water shows a 20% difference below
average.
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1-4
ENGINE-RELATED TERMS
Though this chapter gives only basic terms, there
are still many others you have to learn and
remember. Try to learn little by little as you go
along in your daily service activities.
1. TDC/BDC
While an engine is running, the piston goes up and
down in the cylinder. The top limiting position the
piston reaches is called the top dead center or TDC.
The TDC provides the benchmark in disassembling,
reassembling, and adjusting the engine. The
bottom dead center or BDC is likewise the limiting
position of the reciprocating piston, only it is the
bottom.
2. Bore/Stroke/Displacement
Bore is the inside diameter of a cylinder. In the
reciprocating motion of a piston, the length between
the top and bottom dead centers is called stroke.
Displacement is the volume of the space created in
a cylinder by the piston traveling between the top
and bottom centers in a single stroke.
3. Engine speed
Engine speed is expressed in rpm, which
represents revolutions per minute.
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1-5
4. Compression ratio
Compression ratio of an engine means the ratio at
which the air-fuel mixture is compressed in the
cylinder during a full stroke. For example, the air-
fuel mixture is compressed by a tenth of its volume
in an engine with a 10 compression ratio engine
and by an eighth of its volume in an engine with an
8 compression ratio.
5. Consumption of fuel
Fuel consumption is calculated by so much fuel
consumed per hour when an engine is continuously
run at a certain engine speed.
6. Power (horsepower)
One well-known unit that represents the work done
by a human, animal, or machine is the rate of doing
work = power. In the metric system, the power of
moving an object weighing 75kg per sec. is one (1)
horsepower.
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1-6
7. Power (kw)
In the current SI (International System of Units), W
is used for the power unit. The relationship between
PS and KW in the conventional metric units system
is shown to the illustration.
CRAFT-RELATED TERMINOLOGY
There are many terms specifically assigned to
marine boats. Let's work hard to remember them.
1. Bow eye
A piece of metal, as fastened to the edge of a
compact motorboat or marine jet, through which a
rope is passed.
2. Stem
Foremost part of a boat, which is reinforced with a
stem material or keel.
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1-7
3. Gunwale
In the current FRP boats, the gunwale is the part of
a boat where the hull and deck meet.
4. Cleats
Metal fitting around which a rope is made fast,
generally used for holding a rope that moors a boat.
5. Hull
Bottom.
6. Bow
Forward end of a boat.
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1-8
7. Hatch
Watertight opening as made in a deck.
8. Port
Left-hand side of a boat.
9. Starboard
Right-hand side of a boat.
10. Deck
Top floorlike part of a boat.
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1-9
11. Stern
Rear part of a boat.
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1-10
BOLTS/NUTS
Bolts and nuts are used in a great many
applications because they contribute to the ease
and secureness of dis- and re-assembly.
1. Dimensions of hex head bolt

In the hex bolts and nuts, the dimensions are
definitely related between the bolt diameter, pitch,
and head.
2. Ways of fastening
The illustration shows 4 typical ways of fastening
bolts and nuts. Bolt-and-nut fastening is controlled
by the tightening torque, so follow the instructions in
the service manual and so on for tightening.
Torque the first nut to

specification.
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1-11
Hold the first nut with an

open end wrench
While doing so; apply force to

the first one in the opposite
(loosening) direction.
Torque the second nut to

specification a.
Nut A
Nut B
Bolt
This causes the nuts A (second) and B (first) to
push each other for secure fastening.
WASHER
Washer is inserted between the bolt head or the
bearing seat of a nut and the part to be fastened.
Most bolts and nuts use plane washers to achieve a
steady axial force. Spring washer is used. For bolt
and nut that are intended for low-toque application,
a spring washer is used to prevent them from
becoming loose.
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1-12
OTHER FIXTURES
These are other standard parts that are commonly
used.
1. Circlip
2. O-ring
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1-13
BEARING
Bearing is a supporting machine part for a shaft that
rotates while bearing against the force on it.
Bearing comes in a variety of types that are used
according to the magnitude and direction of the
force on it. Thrust bearing is designed to absorb
thrusts parallel to the axis of revolution and the
bearing that absorbs the force exerted
perpendicular to the axial direction is called a radial
bearing. As illustrated, there are a variety of
bearings.
1. Point when attaching

To fit a bearing, push the inner race when fitting it
over a shaft and push the outer race when fitting it
into the case. If it is to be fitted into a cylindrical
member, press it in so that the race gets even
pressure.
2. Plain bearing and bushing

Plain bearing is designed to contain a shaft, etc.
with a thin film of oil formed between the two
contacting surfaces to mechanically separate them.
It is used as a crankshaft bearing for the 4-stroke
engine. Bushing is a cylindrical bearing integrated
with a plain bearing and is made mainly of a copper
alloy.
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1-14
OIL SEAL
Oil seal is designed to seal oils or the like inside
and to prevent water or dust from coming in from
outside. The illustration indicates the names of the
respective parts comprising an oil seal.
1. Point when attaching

Let us explain some of the points of note for oil seal
installation.
2. Type
Oil seal comes in the kinds as shown.
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1-15
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1-16
INTRODUCTION
CHAPTER 2. KINDS OF
TOOLS
INTRODUCTION
In this chapter you will learn about the names of
general tools and measurement hardware and how
to use them. This chapter provides information that
is essential to proper service. Learn it thoroughly so
you can put it into practice.
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2-1
GENERAL TOOLS
GENERAL TOOLS
FASTENING THE HEX HEAD SCREWS
Illustrated are some of the tools used to tighten or
untighten a hex head screw while holding its head
tight. Learn to use each of them correctly.
1. Offset wrench
This wrench can apply a large torque without
damage to the corners of a bolt or nut because it
can contain all sides of the hex head.
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2-2
GENERAL TOOLS
2. Socket wrench
Socket wrench is used with a combination of a
variety of handles. The handle (except for the
universal joint) is turned with the socket inclined at
right angles to it. For quick work, the handle is held
upright position and is turned. The important thing
in the procedure is to hold the socket and handle in
your hand so they will not come apart.
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2-3
GENERAL TOOLS
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2-4
GENERAL TOOLS
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2-5
GENERAL TOOLS
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2-6
GENERAL TOOLS
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2-7
GENERAL TOOLS
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2-8
GENERAL TOOLS
3. Spanner
Open end wrench cannot hold in the whole of a bolt
head or nut. It is used in applications that reject the
use of a socket wrench. For quarter-close work,
you can use an open end wrench with the reverse
side on for ease of operation.
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2-9
GENERAL TOOLS
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2-10
GENERAL TOOLS
FASTENING OTHER SCREWS
Tools as illustrated are available the tightening or
loosening screws. Learn to use each of them
properly.
1. Screwdriver
Screwdriver is a tool used to fasten or unfasten
screws or the like for small fastening. The driver
comes in various types according to the shape of
the tip or the way in which the shank is fixed. A
through driver with a square shank convenient for
outboard motor maintenance.
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2-11
GENERAL TOOLS
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2-12
GENERAL TOOLS
2. Allen wrench
Allen wrench is used to tighten or loosen a bolt with
a hex socket. It is bent to a right angle to be L-
shaped, and both ends can be used. The type with
a ball on the tip can be use without being set to a
right angle, resulting in increased work efficiency.
But this type cannot withstand strong torque, so it is
used for temporary tightening and so forth.
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2-13
GENERAL TOOLS
GRIPPING THE PARTS

Illustrated are the kinds of tools that hold parts.
Learn to use each of them properly.
1. Plier
These types of pliers are the most frequently used
of all tools for gripping hoses, pipes, and so on.
They have the jaws adjustable to two positions
depending on the objects to grip and can also cut
wire at the joint.。
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2-14
GENERAL TOOLS
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2-15
GENERAL TOOLS
2. Waterpump plier
Water pump pliers are used for gripping items that
are too large for ordinary pliers to grip.
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2-16
GENERAL TOOLS
3. Snap ring plier

These pliers are used for putting on or taking off
snap rings. Snap rings come in two types, for
application in bores and for application on axles
and shafts. For application in a bore, the ring is
pressed together and for application on an axle or
shaft, the ring is expanded. The former is called the
snap ring pliers and the latter the snap ring
expander. They are used according to the type of
ring to work with.
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2-17
GENERAL TOOLS
FIXING THE PARTS

Illustrated are some of the types of tools for fixing
parts.
1. Vise
Vise can hold an object with a great force. Take
care not to damage the object while work is being
done or not to allow yourself to be pinched by
accident.
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2-18
GENERAL TOOLS
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2-19
GENERAL TOOLS
2. Locking plier
Small item is firmly locked between the jaws of the
vise pliers with the lever locked when the plier
handles are gripped. There is no need to hold the
handles tightly in the hand as with other pliers.
When releasing the lock, it will spring back with
force, so be careful not to allow it to hit your finger
or allow the gripped item to drop.
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2-20
GENERAL TOOLS
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2-21
GENERAL TOOLS
TOOLS FOR REWORK

Illustrated are some of the typical tools for repairs.
Learn to make proper use of each of them.
1. Hammer
Appropriate hammer should be selected according
to the object on which a hammer is used and to the
force with which the object is pounded.
・Select a hammer according to the size of its head.
・Select the hammer head depending on the force
to apply to the object.
・Select a hammer according to its material.
If the object is broken or deformed by the hammer,
change to the one with a head whose material is
softer than that of the object.
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2-22
GENERAL TOOLS
2. Nipper
Nippers are used to cut electric wire and suchlike. If
great load is applied to the tip, the cutting edge will
be chipped.
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2-23
GENERAL TOOLS
3. File
Files are used to smoothen rough surfaces of parts.
In using a file, apply force in the pushing direction.
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2-24
GENERAL TOOLS
4. Oil stone
Oil stone is used to produce a better final finish
than a file. Before use, dip an oil stone in specific oil
for full internal permeation. Always see that oil
stays on the surface of the oil stone.
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2-25
GENERAL TOOLS
5. Scraper
Scrapers are used to scrape adhering gaskets or
paint off the surfaces of parts. The tip is provided
with a sharp edge, so take care not to be injured by
it. Also, do not use too much force for scraping
because it may damage the machine itself.
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2-26
GENERAL TOOLS
TOOLS FOR MACHINING

Here are some of the tools illustrated for the
processing of parts. Learn to make proper use of
each of them.
1. Center punch
Punch is used to impress a marking for the dis- and
re-assembly of parts, drilling of a hole, and so on.
Oil stone is used to maintain the edge.
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2-27
GENERAL TOOLS
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2-28
GENERAL TOOLS
2. Reamer
Reamer is used to finish precision bores of valve
stems, bushings, and so on.
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2-29
GENERAL TOOLS
3. Tap
Tapping drill is a tool that cuts a female thread in an
opening. This drill has 3 kinds of teeth for rough,
medium, and final finish. To repair damaged thread,
the medium teeth are used. Take care not to use a
drill with a wrong diameter and pitch for the thread
to be repaired.
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2-30
GENERAL TOOLS
4. Dies
Threading tool cuts male screw threads. Take care
not to use a wrong pitch for the screw to be
repaired.
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2-31
GENERAL TOOLS
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2-32
GENERAL TOOLS
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2-33
MEASUREMENT HARDWARE
MEASURING THE LENGTHS
Here are illustrated some of the instruments for
measuring lengths. Accurate work cannot be done
without accurate measurement. As with tools, learn
to make correct and safe use of them.
1. Slide caliper
Vernier caliper is used for measurement of outside
and inside diameters and depths. An object is
measured between the data scale (fixed) and the
indicating scale (sliding) and the measurement is
read off from them. With its approximate precision
of 0.05, the vernier caliper is used for rough
measurement.
memo
2-34
2. Micrometer
Micrometer is used to measure outside diameters
and thicknesses. It has a measuring precision of
0.01mm and the 0 point setting is done before
measurement. When it is put away after use,
provide the jaw surfaces (anvil and spindle) with
some clearance between them to avoid force on
them.
memo
2-35
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2-36
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2-37
MEASUREMENT OF VOLUME
Measuring cylinder is mainly used in measurement
of volumes. Inaccurate measurement results in
inaccurate work.
1. Measuring cylinder
Correct measurement cannot be taken if bubbles or
the like are mixed in the liquid. Put liquid in the
cylinder slowly and carefully. Read the scale while
taking the liquid level irregularity in consideration.
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2-38
MEASURING THE CLEARANCES

Tools as illustrated here are used for measuring
clearances. Inaccurate measurement results in
inaccurate work.
1. Thickness gauge
Thickness gauge measures valve clearances,
piston ring groove gaps, and so on. If one leaf is not
enough for measurement, use a combination of
leaves.
memo
2-39
memo
2-40
2. Cylinder gauge
Cylinder gauge and adjusting rods are used in
combination with a micrometer to measure the
cylinder bore.
memo
2-41
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2-42
MEASURING THE FORCES

Instruments as illustrated are used for
measurement of forces. Inaccurate measurement
results in inaccurate work.
1. Torque wrench
Torque wrench is used for tightening a bolt or nut to
the specified torque. Torque wrench has a different
graduation range according to its length and comes
in a variety of types. The effective accuracy of a
torque wrench is generally 20 to 80% tightening
torque of the graduated range, outside which the
wrench is not used because of a great error. For
the increased operation efficiency, temporarily
tighten the bolt or nut using another wrench.
memo
2-43
memo
2-44
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2-45
MEASURING THE ELECTRICITY
Circuit tester (AC and DC Volt-Ohm-Milliammeter)
is used to measure electricity. This tester can
measure voltage, current, and resistance. Before
measurement, select the corresponding electric
range on the tester. If the range is unknown, select
a larger range and then narrow it down to the
corresponding one. Do not touch the measuring
terminals with the bare hand as there is a danger of
an electric shock.
1. Voltage
DC voltage is measured. Connect the test leads in
parallel to the object to be measured.
memo
2-46
2. Electric current
AC is measured. Connect the test leads in series to
the object to be measured.
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2-47
3. Resistor
Electric resistance is measured. Connect the test
leads in parallel to the object to be measured.
Adjust to the 0 point before measuring the
resistance. Make the 0 point setting every time the
resistance range is changed on the tester.
memo
2-48
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2-49
memo
2-50
memo
2-51
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2-52
CORRECT MEASUREMENT
However precise the measuring instrument may be,
it is impossible to achieve accurate measurements
if it is not used correctly. We will introduce some
useful tips for measurement.
BEFORE MEASUREMENT
Before measurement, clean both the items to be
measured and the instrument to measure those
items. Select the instrument suited for the purpose.
DURING MEASUREMENT
For measurement, apply the instrument
perpendicular to the item to be measured. Also
make the level of your eyes perpendicular to the
dial face and pointer.
memo
2-53
memo
2-54
INTRODUCTION
CHAPTER 3. RULES AND
FLOW OF WORK
INTRODUCTION
This chapter is focused on the main points to follow
in servicing PWC as well as on considerations to
take in daily work.
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3-1
RULES FOR WORK
RULES FOR WORK
COMPLIANCE WITH LAW
The sea is connected to the countries of the world
and many ships of many nationalities are going and
coming on it.Maritime traffic rules are universal.
Observance of these rules leads to maritime safety.
MARITIME MANNERS
The sea is just like a common park a lot of people
use together. You have to be constantly careful
about the people and objects around you and must
never do anything that may cause inconvenience to
others. You must also never dump anything like
wastes into the sea that is hazardous to the marine
environment.
●Be careful not to spill gasoline or oil.
●Don' go too fast.
●When taking a PWC touring, don' go alone but
with others.
●You give way first to a sail boat or dingy
approaching you.
●When going out on the sea, head straight out to
sea.
●Make sure that you stay away from the bathing
area.
●There may be someone swimming around your
moored PWC, so be careful about such a person.
●Don't race your PWC without load on a sand
beach. It will be a nuisance to others.
●Run slowly around a small boat so as not to
make waves.
●Be careful when riding in shallow waters because
divers may be there.
●Keep good distance from a fishing boat without
making waves around it.
●Be sure to slow down when going into or out of
the bay.
●Watch out for the fixed net close to the entrance
to the bay.
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3-2
RULES FOR WORK
SAFE OPERATIONS
You may have opportunities to work in various
places and environments like a workshop or marina.
Wherever you work, you must avoid doing anything
that may injure or damage others or objects. You
should consider how you can prevent injuries or
accidents in your daily operation.
Those who sell products that could cause fatal

injury if used improperly, such as marine products,
bear a significant responsibility. This responsibility
includes viewing things from the customer's
position and ranges from supplying products to
explaining proper equipment use. In short, fulfilling
this sales responsibility is a precondition of earning
trust from the community.
memo
3-3
FLOW OF PWC SERVICING
FLOW OF PWC SERVICING
FLOW OF WORK FOR A WHOLE YEAR
The PWC season is very short, with an off season
of more than a half year. If your PWC is not
provided with proper maintenance during this off
season, you may have trouble with it during the
season or have its service life shortened. With this
fact well in mind you should carry out service
activities or give advice to the users.
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3-4
WHAT TO DO BEFORE DELIVERY
PWC are delivered with the steering removed. You
must reinstall the steering before delivery to the
customers and ensure that all functions work
properly.
WHAT TO DO FOR DELIVERY

For delivery you have quite a lot of things to do,
such as an explanation of the product, how to
operate and maintain the machine, and so on.
Proceed smoothly according to the owner's manual.
After delivery, provide the customer with the
warranty card and have him or her sign it.
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3-5
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3-6
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General: Personal Water Craft

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General

PERSONAL WATER CRAFT

Marine Business Operations

YTA PWC Text

Issued in December 2008

2. Units as used in marine applications

1. Dimensions of hex head bolt

Torque the first nut to

Hold the first nut with an

While doing so; apply force to

Torque the second nut to

1. Point when attaching

2. Plain bearing and bushing

1. Point when attaching

GRIPPING THE PARTS

3. Snap ring plier

FIXING THE PARTS

TOOLS FOR REWORK

TOOLS FOR MACHINING

MEASURING THE CLEARANCES

MEASURING THE FORCES

Those who sell products that could cause fatal

WHAT TO DO FOR DELIVERY

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