F3P 28197 ZV 11

GP1800
WaveRunner
GP1800
GP1800 (F3P)
SERVICE MANUAL
LIT-18616-03-72
Nov. 2017 ! F3P-28197-ZV-11
(E_2)
F3P-28197-ZV-11_cover.indd 1-3 2017/11/03 17:46:48

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 YDS (Yamaha Dealer System, U.S.A. only) or YPEC-web (except
U.S.A.). Additional information and up-to-date information on Yamaha products and services are avail-
able on YDS, YMPE (Yamaha Multimedia Product Encyclopedia, Canada only), or Yamaha Service
Portal (except U.S.A. and Canada).
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.
A TIP provides key information to make procedures easier or clearer.
WaveRunner
GP1800
SERVICE MANUAL
©2017 by Yamaha Motor Co., Ltd.
3rd Edition, November 2017
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
LIT-18616-03-72
F3P-28197-ZV-11_cover.indd 4-6 2017/11/03 17:46:49

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................................................................................... 1-2
Self-protection ............................................................................ 1-2
Working with crane..................................................................... 1-2
Handling of heat gun .................................................................. 1-3
Parts, lubricants, and sealants ................................................... 1-3
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......................................................... 1-5

Primary I.D. number ................................................................... 1-5
Engine serial number ................................................................. 1-5
Jet pump unit serial number ....................................................... 1-5
Craft identification number (C.I.N.) (Europe).............................. 1-5
Hull identification number (H.I.N.) (except Europe).................... 1-5
How to use this manual ..................................................... 1-6

Manual format ............................................................................ 1-6
Conditions when testing and adjusting....................................... 1-7
Abbreviation ............................................................................... 1-7
Adhesive, lubricant, sealant, and thread locking

agent.................................................................................... 1-8
Symbols...................................................................................... 1-8
Special service tool............................................................ 1-9
Model feature .................................................................... 1-22

General feature ........................................................................ 1-22
Technical tips.................................................................... 1-23

Engine control .......................................................................... 1-23
Engine control system .............................................................. 1-25
General information
1
Deck and hull............................................................................ 1-28
Lubrication system ................................................................... 1-29
Hose routing ............................................................................. 1-30
Cooling water flow .................................................................... 1-31
2
3
4
5
6
7
8
9
A
Safety while working

To prevent an accident or injury and to provide
quality service, observe the following safety
procedures.
Rotating parts
Hands, feet, hair, jewelry, clothing, personal
flotation device straps, and so on, can become
entangled with internal rotating parts of the en-
gine or jet pump unit, resulting in serious injury
or death.
• Keep hands, feet, hair, jewelry, clothing, per-
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. Items such as hair, clothing, or personal
flotation device straps can become entan-
gled in moving parts resulting in severe inju- Handling of gasoline
ry. • Gasoline is highly flammable. Keep gasoline
and all flammable products away from heat,
Hot parts sparks, and open flames.
During and after operation, engine parts are • Gasoline is poisonous and can cause injury
hot enough to cause burns. Do not touch any or death. Handle gasoline with care. Never
parts in the engine compartment until the en- siphon gasoline by mouth. If you swallow
gine has cooled. some gasoline, inhale a lot of gasoline vapor,
or get some gasoline in your eyes, see your
Electric shock doctor immediately. If gasoline spills on your
Do not touch any electrical parts while starting skin, wash with soap and water. If gasoline
or operating the engine. Otherwise, shock or spills on your clothing, change your clothes.
electrocution could result.
Impeller
Do not hold the impeller with your hands when
loosening or tightening the impeller.
1-1
Ventilation Working with crane

• Gasoline vapor and exhaust gas are heavier • When moving the watercraft, or when lifting
than air and extremely poisonous. If gasoline the engine during removal or installation,
vapor or exhaust gas is inhaled in large make sure to use a crane with a lifting capac-
quantities, it may cause loss of conscious- ity that is equal to or more than the weight of
ness and death within a short time. the watercraft or engine respectively.
• When test running an engine indoors (for ex- • When lifting the watercraft, use the watercraft
ample, in a water tank) make sure to do so lift harness and make sure that the watercraft
where adequate ventilation can be main- is in a stable position when moving it.
tained. • Use the wire ropes of adequate strength, and
lift up the engine unit using the three point
suspension.
• If the engine unit does not have three or more
points to be suspended, support it using ad-
ditional ropes or the like so that the engine
unit can be lifted and carried in a stable man-
ner.
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.
• Protect your hands and feet by wearing pro-
tective gloves and safety shoes when neces-
sary.
1-2
Handling of heat gun

• Improper handling of a heat gun may result in
burns. For information on the proper handling
of the heat gun, see the operation manual is-
sued by the manufacturer.
• When using a heat gun, keep it away from
the gasoline and oil, to prevent a fire.
• Components become hot enough to cause
burns. Do not touch any hot components di-
rectly.
Special service tool
Use the recommended special service tools to
work safely, and to protect parts from damage.
Parts, lubricants, and sealants

Use only genuine Yamaha parts, lubricants,
and sealants, or those recommended by
Yamaha, when servicing or repairing the wa- Tightening torque
tercraft. Follow the tightening torque specifications pro-
vided throughout the manual. When tightening
nuts, bolts, and screws, tighten the large sizes
first, and tighten fasteners starting in the center
and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cotter
pins, and so on, when installing or assembling
parts.
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.
1-3
• 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
the lip and periphery of an oil seal before in-
stallation.
• Check that moving parts operate normally af-
ter assembly.
1-4
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 F3P
YAMAHA MOTOR CO., LTD.
ASSEMBLED IN U.S.A. FROM AMERICAN AND JAPANESE
1. Jet pump unit name

COMPONENTS.
ASSEMBLÉ AUX ÉTATS-UNIS DE PIÈCES AMÉRICAINES ET
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
F3P: 800101 the boarding platform.
Engine serial number Hull identification number (H.I.N.) (ex-

The engine serial number is stamped on a la- cept Europe)
bel attached to the engine unit. The H.I.N. is stamped on a plate attached to
the boarding platform.
2 3
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON
1. Engine name
2. Engine type
3. Engine serial number
Starting engine serial number

6DH:1000001
1-5
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).
For troubleshooting procedures, see Chapter 9, “Troubleshooting”.
4 3 1
5
Impeller housing and impeller duct ASSY
1 N·m (0.1 kgf·m, 0.7 lb·ft) 40 N·m (4.0 kgf·m, 29.5 lb·ft)
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 N·m (0.7 kgf·m, 5.2 lb·ft) 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
1-6
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
APS Accelerator Position Sensor
BOW Bow end
ECM Electronic Control Module
ETV Electronic Throttle Valve
ISC Idle Speed Control
OBD-M On-Board Diagnostics-Marine system
OTS Off-Throttle Steering system
PON Pump Octane Number
PORT Port side
RiDE Reverse with Intuitive Deceleration Electronics
RON Research Octane Number
RPM Revolutions Per Minute
RPS RiDE Position Sensor
SCU Shift Control Unit
STBD Starboard side
STERN Stern end
TCI Transistor-Controlled Ignition
TDC Top Dead Center
TPS Throttle Position Sensor
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.
Worldwide
Reference
Tool name/Tool No. Illustration
pages
Oil filter wrench 3-5, 5-8, 5-14
90890-06874
Gauge stand 3-12, 5-44,

90890-06725 5-52
Dial gauge needle 3-12, 5-44,

90890-06584 5-52
Dial gauge set 3-12, 5-44,

90890-01252 5-52
Camshaft wrench 3-12, 5-45,

90890-06724 5-48
Fuel pressure gauge adapter 4-3

90890-06946
Fuel pressure gauge 4-3

90890-06753
1-9
Reference
pages
Compression gauge 5-1
90890-03160
Compression gauge extension 5-1

90890-06563
Exhaust pipe wrench 5-18

90890-06726
Leakage tester 5-30, 5-38

90890-06840
Air cooler attachment 5-30

90890-06731
Coupler wrench 5-38, 5-44,

90890-06729 5-51, 5-52,
5-69, 5-77,
5-78, 6-21,
6-23
Bearing puller assembly 5-38, 6-11,
90890-06535 6-12, 6-21
Stopper guide plate 5-38, 6-11,

90890-06501 6-12, 6-21
Stopper guide stand 5-38, 6-11,

90890-06538 6-12, 6-21
1-10
Reference
pages
Valve spring compressor 5-57, 5-64
90890-04019
Valve spring compressor attachment 5-57, 5-64

90890-04114
Valve guide remover/installer 5-59, 5-60

90890-06801
Valve guide installer 5-60

90890-06810
Valve guide reamer 5-60

90890-06804
Valve lapper 5-60, 5-63

90890-04101
Valve seat cutter holder 5-61

90890-06812
Valve seat cutter 30 5-61

90890-06720

90890-06325
1-11
Reference
pages
90890-06324

90890-06818

90890-06555

90890-06323
Crankshaft holder 5-69, 5-70,

90890-06732 5-74, 5-75,
5-76, 5-77
Shaft holder 5-70, 5-74,

90890-06721 5-75, 5-76
Drive handle 5-70, 5-74,

90890-06722 5-75, 5-76
Flywheel puller 5-71

90890-06723
Rotor puller 5-71

90890-01080
1-12
Reference
pages
Sheave holder 5-71, 5-73
90890-01701
Driver rod LS 5-71, 5-72

90890-06606
Bearing outer race attachment 5-71

90890-06627
Ball bearing attachment 5-72

90890-06657
Bearing pressure C 5-72

90890-02393
C
Piston ring compressor 5-98

90890-05158
Drive shaft holder 6 6-11, 6-14,

90890-06520 6-15
Driver rod L3 6-12

90890-06652
Needle bearing attachment 6-12

90890-06609
1-13
Reference
pages
Bearing attachment 6-13, 6-14,
90890-06728 6-22, 6-23
Oil seal installer attachment 6-13

90890-06733
Shaft holder 6-21, 6-23

90890-06730
Needle bearing attachment 6-22

90890-06654
Bearing attachment 6-23

90890-06727
YDIS2 Hardware Kit 7-9, 9-1

90890-06884
Digital circuit tester 7-10

90890-03243
Peak voltage adapter B 7-10

90890-03172
Ignition checker (Spark gap tester) 7-11

90890-06754
1-14
Reference
pages
Test harness (2 pins) 7-12
90890-06851

90890-06870

90890-06850
Vacuum/pressure pump gauge set 7-16, 7-19

90890-06945

90890-06877
Throttle sensor adjusting lead FWY-3 7-29

90890-06857
1-15
U.S.A. and Canada
Reference
pages
Oil filter wrench 3-5, 5-8, 5-14
YB-06874
Dial gauge stand set 3-12, 5-44,

YB-06585 5-52
Dial indicator gauge 3-12, 5-44,

YU-03097 5-52
Camshaft wrench 3-12

YW-06724
Fuel pressure gauge adapter 4-3

YB-06946
Fuel pressure gauge 4-3

YU-03153M
Compression gauge YU-33223 5-1

YU-33223
Exhaust pipe wrench 5-18

YW-06726
1-16
Reference
pages
Air cooler attachment 5-30
YW-06731
Coupler wrench 5-38, 5-44,

YW-06729 5-51, 5-52,
5-69, 5-77,
5-78, 6-21,
6-23
Valve spring compressor 5-57, 5-64
YM-04019
Compressor adapter 5-57, 5-64

YM-04114
Valve guide remover 5-59, 5-60

YB-06801
Valve guide installer 5-60

YB-06810
Valve guide reamer 5-60

YM-01196
Valve lapping tool 5-60, 5-63

YM-A8998
Neway valve seat kit 5-61

YB-91044
1-17
Reference
pages
Crankshaft holder 5-69, 5-70,
YW-06562 5-74, 5-75,
5-76, 5-77
Shaft holder 5-70, 5-74,

YW-06721 5-75, 5-76
Drive handle 5-70, 5-74,

YW-06722 5-75, 5-76
Flywheel puller 5-71

YW-06723
Stator rotor puller 5-71

YM-01080-A
Primary sheave holder 5-71, 5-73

YS-01880-A
Driver handle (small) 5-71

YB-06229
Bearing and seal installer 5-71

YW-06356
Driver handle (large) 5-72, 6-12

YB-06071
1-18
Reference
pages
Forward gear outer race installer 5-72
YB-41446
Forward bearing race installer 5-72

YB-06258
Piston ring compressor 5-98

YM-08037
Driveshaft holder 6-11, 6-14,

YB-06201 6-15
Slide hammer 6-11, 6-12,

YB-06096 6-21
Driveshaft needle bearing installer and 6-12

remover
YB-06194
Bearing attachment 6-13, 6-14,

YW-06728 6-22, 6-23
Oil seal installer attachment 6-13

YW-06628
Shaft holder 6-21, 6-23

YW-06730
1-19
Reference
pages
Bearing puller legs 6-21
YB-06523
Needle bearing installer 6-22

YB-06434
Bearing attachment 6-23

YW-06727
YDIS2 Hardware Kit 7-9, 9-1

LIT-YDIS2-01-KT
Digital multimeter 7-10

YU-34899-A
Peak volt adapter 7-10

YU-39991
Spark checker 7-11

YM-34487

YB-06870

YW-06850
1-20
Reference
pages
Pressure/ vacuum tester 7-16, 7-19
YB-35956-B

YB-06877

YB-06857
1-21
Model feature
Model feature
General feature
Based on the F2W hull, the F3P has adopted a powerful 1.8 L engine with super charger, and it features
a large diameter jet pump.
The hull is lightweight thanks to use of NanoXcel 2, while maneuverability has been further enhanced
without compromising the stability and comfort of the F2W.
a. Power unit c. Electrical

• 4-stroke, L4, DOHC, 16-valve, 1812 cm³ en- • Electronic control throttle valve system
gine with electronic fuel injection • In-tank fuel pump module
• Supercharged • Multifunction meter
• Single throttle body • L-MODE
• 4-in-1 exhaust system • OTS
• Wet sump lubrication • Self-diagnosis system with YDIS (version
2.20)
b. Jet pump
• Stainless steel, 3-blade, ø160 mm, 17.0 d. Deck and hull
pitched impeller • V-shaped hull
• Impeller turning direction: counterclockwise • Separate front and rear seats
(when viewed from the stern) • Reboarding step for easier reboarding
• Aluminum jet thrust nozzle • Easy handgrip position
• RiDE system • NanoXcel 2 hull, NanoXcel 2 deck
1-22
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
1 3
5
7
8
14 13
15 12
9
10
11
Part name Function

1 Cam position sensor Detects the rotational position of the camshaft.
2 Slant detection switch Detects whether the watercraft is capsized.
Properly controls ignition timing, fuel injection timing and vol-
3 ECM ume, opening angle of the ETV, and fail-safe function with
information received from the sensors and switches.
4 Thermo sensor Detects the temperature of the exhaust cooling water.
5 Oil pressure switch Detects the pressure of the engine oil.
6 Thermo switch Detects engine overheating.
Intake air temperature sen-
7 Detects the temperature of the intake air.
sor
8 Knock sensor Detects engine knocking.
9 TPS Detects the opening angle of the ETV.
10 Intake air pressure sensor Detects the pressure of the intake air.
11 Engine temperature sensor Detects the temperature of the cylinder block.
12 Pickup coil Detects the crankshaft angle.
1-23
Technical tips
Part name Function

13 RPS Detects the opening angle of the RiDE lever.
14 APS Detects the opening angle of the throttle lever.
Detects when the handlebar is turned all the way to the right or
15 Steering sensor
left.
1-24
Technical tips
Engine control system

Item Condition Action Remarks
• Engine temperature • Opening angle of the ETV Cancel:
rises rapidly in a is regulated. • Stop the engine and wait
short time. • Maximum engine speed is for 30 seconds or more.
• Thermo switch is on. limited to approximately • Engine temperature is
• Exhaust cooling 2100–2300 r/min. below 140 C (248 F)
water temperature with the thermo switch
Overheat
exceeds 65 C (149 off.
warning con-
F). • Exhaust cooling water
trol
temperature is below 70
C (158 F) with the ETV
fully closed.
If the engine is stopped
during overheat warning
control, it can be restarted.
• Opening angle of the ETV Cancel:
Control is activated
is regulated. • Stop the engine and wait
when all of the follow-
• Maximum engine speed is for 30 seconds or more.
ing conditions are
limited to approximately • Engine is restarted and
Oil pressure present:
2100–2300 r/min. the oil pressure switch is
warning con- • Oil pressure switch is
off.
trol on.
If the engine is stopped
• ETV is open.
during oil pressure warn-
• Engine speed
ing control, it can be
exceeds 4500 r/min.
restarted.
Control is activated • Opening angle of the ETV
when the following is regulated.
conditions are main- • Maximum engine speed is
tained for 10 seconds: limited to approximately
Cancel:
• Cam position sensor 2100–2300 r/min.
Engine is stopped.
failed.
• Engine speed
Cam position exceeds approxi-
sensor failure mately 1000 r/min.
control Control is activated
when all of the follow-
ing conditions are
Ignition and fuel injection
present: Cancel:
are cut to all cylinders and
• Cam position sensor Engine is stopped.
the engine is stopped.
failed.
• Engine speed
exceeds 5000 r/min.
1-25
Technical tips

• Opening angle of the ETV
is fixed to the default
ETV failed, or open or opening angle.
ETV failure short circuit is • Maximum engine speed is
—
control detected in ETV cir- limited to approximately
cuit. 2500 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 1150–1350 r/min.
tion.
Ignition is controlled and
fuel is cut.
Condi-
Action
tion
Normal None
Ignition is cut off
Level 1 to 1 cylinder and
fuel is cut.
Over revolu- Engine speed exceeds
Ignition is cut off —
tion control 7800 r/min.
Level 2 to 2 cylinders and
fuel is cut.
Ignition is cut off
Level 3 to 3 cylinders and
fuel is cut.
Ignition is cut off
Level 4 to all cylinders
and fuel is cut.
In a state where
engine speed has
exceeded 7550 r/min The throttle valve is limited
High intake Completely shutting off the
and intake pressure is from opening more than the
air pressure throttle valve will disengage
higher than 177 kPa point where the control was
control the control.
(25.7 psi) has lasted engaged.
longer than 1.5 sec-
onds.
When engine speed Ignition timing is delayed
Knock control exceeds 2000 r/min according to the volume of —
after warming up knocking
1-26
Technical tips

Control is activated
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
engine speed in the nor-
mal mode.
Engine speed is sus-
tained at or above
3000 r/min for several
Throttle valve opening is
seconds and then
Off-throttle Slightly opens the throttle controlled based on the
throttle lever is fully
steering valve so that the watercraft APS signal and the amount
closed - simultane-
(OTS) control can maneuver. of force applied to the
ously, the steering
steering sensor.
handle is maneuvered
to the point the steer-
ing sensor is engaged.
Control activates when • Opening angle of the ETV
knocking has been is regulated.
Low octane detected more than a • Maximum engine speed is Cancel:
fuel detection specified number of limited. Engine is stopped.
times in a specified
period of time.
Maximum Maximum engine
is regulated.
engine speed speed is controlled by —
• Maximum engine speed is
control the ECM.
limited.
1-27
Technical tips
Deck and hull

The hull is the same type as that of the F2W. It uses the new material NanoXcel 2 with specific gravity
of the SMC material at 1.20, making it extremely lightweight compared with conventional NanoXcel
(specific gravity of SMC material: 1.45). The hull also has enhanced maneuverability.
Additionally, CNC-cut mats have been adopted as a design improvement.
a. NanoXcel 2 hull and deck
b. Newly designed CNC-cut mats
c. Sporty-designed grips and seat
c
c
1-28
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.
2
14
12
3
13
11
A
10 6
B
9 8 7
1. Intake camshaft 13. Oil pump drive gear

2. Exhaust camshaft 14. Supercharger
3. Cylinder block
A. To air intake pipe
4. Crankshaft
B. Oil flow
5. Oil separator tank
6. Oil pan
7. Oil strainer
8. Oil pipe
9. Oil pump
10. Relief valve
11. Oil cooler ASSY
12. Oil filter
1-29
Technical tips
Hose routing
A
D
F B
G
C
H
I
J
K
A. From flushing hose connector

B. From transom plate
C. To cooling water pilot outlet on port side
D. To drain joint (transom plate)
E. To drain joint
F. To cooling water pilot outlet on starboard
side
G. For water draining when engine is
stopped
H. Cooling water flow
I. Blowby gas flow
J. Bilge water flow
K. Fuel flow
1-30
Technical tips
Cooling water flow
A
B
G H
A. From flushing hose connector

B. From transom plate
C. To cooling water pilot outlet on port side
D. To drain joint
E. To exhaust valve
F. To cooling water pilot outlet on starboard
side
G. For water draining when engine is
stopped
H. Cooling water flow
1-31
Specification
1
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
3
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
4
Charging system ........................................................................ 2-8
5
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

6
General tightening torque ............................................... 2-12
7
Cable and hose routing ................................................... 2-13
Starboard bow view.................................................................. 2-13
Top view ................................................................................... 2-14
Port view................................................................................... 2-16
Coupler layout .......................................................................... 2-17
8
9
A
Model data
Model data
Model code
Hull F3P
Engine 6DH
Jet pump 6DH
Dimensions and weight
Length 3350 mm (131.9 in)
Width 1220 mm (48.0 in)
Height 1190 mm (46.9 in)
Dry weight 349 kg (769 lb)
Maximum people on board 3 person
Maximum load capacity 240 kg (530 lb)
Performance
Full throttle operating range 7500 r/min
Trolling speed 1250 ±100 r/min
Maximum fuel consumption 83.7 L/h (22.1 US gal/h, 18.4 Imp.gal/h)
Cruising range at full throttle 0.84 hour
Engine
Engine type Liquid cooled 4-stroke, DOHC
Number of cylinders 4
Engine displacement 1812 cm³ (110.6 c.i.)
Bore  stroke 86.0  78.0 mm (3.39  3.07 in)
Compression ratio 8.5 : 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.
Spark plug (NGK) LFR7A
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
Firing order 1–2–4–3
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+24 
Trim adjusting system Electrical 5 position
Jet thrust nozzle trim angle -5, -2.5, 0, 3, 6 
Shift operation F–N–R
Reverse system Reverse gate
2-1
Model data
Fuel and oil

Recommended fuel Premium unleaded gasoline
Minimum octane rating (PON) 91
Minimum octane rating (RON) 95
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 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 re- 3.5 L (3.70 US qt, 3.08 Imp.qt)
placement
Engine oil quantity with oil filter replace- 3.6 L (3.81 US qt, 3.17 Imp.qt)
ment
Battery requirement
Type YB16CL-B
Battery capacity 12 V, 19 Ah
Specific gravity 1.265
2-2
Fuel system technical data
Fuel system technical data

Fuel system
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 490 kPa (4.9 kgf/cm², 71.1 psi)
Air cooler
Water passage holding pressure 200 kPa (2.0 kgf/cm², 29.0 psi)
Air passage holding pressure 100 kPa (1.0 kgf/cm², 14.5 psi)
Oil cooler
Water passage holding pressure 200 kPa (2.0 kgf/cm², 29.0 psi)
Thermostat
Valve opening temperature 58–62 C (136–144 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 40.850–40.950 mm (1.6083–1.6122 in)
Limit 40.750 mm (1.6043 in)
Cam lobe height-exhaust 41.048–41.148 mm (1.6161–1.6200 in)
Limit 40.948 mm (1.6121 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) 0.36–0.45 mm (0.0142–0.0177 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)
2-4
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)
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 spring
Free length-intake 45.58 mm (1.79 in)
Limit 43.30 mm (1.70 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)
Tilt limit-intake 2.5 /2.0 mm
Installed length-exhaust (valve closed) 34.0 mm (1.34 in)
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 10.0 mm (0.39 in)
Piston clearance 0.080–0.090 mm (0.0032–0.0035 in)
Limit 0.200 mm (0.0079 in)
Ring groove (Top ring) 1.210–1.240 mm (0.0476–0.0488 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)
2-5
End gap (installed) 0.300–0.450 mm (0.0118–0.0177 in)
Limit 0.700 mm (0.0276 in)
Side clearance 0.020–0.070 mm (0.0008–0.0028 in)
Limit 0.120 mm (0.0047 in)
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 160.75–160.85 mm (6.329–6.333 in)
Limit 161.85 mm (6.3720 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 160 mm (6.30 in)
Number of impeller blade 3
Pitch angle 17.0 
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 (unload- 3.0 V
ed) (reference data)
Output peak voltage at 2000 r/min (load- 2.6 V
Pickup coil
Output peak voltage at cranking (loaded) 4.9 V
(reference data)
Resistance 459.0–561.0 
Ignition coil
Input voltage 12 V
Charging system
Stator coil
Output peak voltage at 2000 r/min (un- 41.7 V
loaded) (reference data)
Output peak voltage at 3500 r/min (un- 58.5 V
loaded) (reference data)
Rectifier/regulator
Output peak voltage at 2000 r/min (load- 13 V
Output peak voltage at 3500 r/min (load- 13 V
Control system
Oil pressure switch
Input voltage 11–12 V
Continuity pressure 128–167 kPa (1.3–1.7 kgf/cm², 18.6–24.2 psi)
Thermo switch
Input voltage 11–12 V
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 k
Engine temperature sensor

Intake air temperature sensor

Intake air pressure sensor
Knock sensor
Resistance 504.0–616.0 k
TPS
TPS 1 output voltage with throttle lever ful- 0.60–0.90 V
ly closed
TPS 2 output voltage with throttle lever ful- 4.50–4.80 V
ly open
TPS output voltage difference 1.9–2.1 V
APS
APS 1 output voltage with the throttle le- 0.68–0.74 V
ver fully closed
ver fully closed
ver fully open
ver fully open
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
APS output voltage difference 0.1 V or less
RPS
RPS 1 output voltage with the RiDE lever 0.68–0.74 V
fully closed
fully closed
fully open
fully open
2-9
RPS 1 Input voltage 4.75–5.25 V
RPS 2 Input voltage 4.75–5.25 V
RPS output voltage difference 0.1 V or less
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
Input voltage 12 V
Fuel system
Fuel injector
Input voltage 12 V
Fuel pump module

Input voltage 12 V
Fuel sender
Lower position resistance 133.5–136.5 
Upper position resistance 5.0–7.0 
Starting system
Fuse
Battery fuse 30 A
Electronic throttle valve fuse 10 A
Main relay drive fuse 10 A
Fuel pump fuse 10 A
SCU fuse 50 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

Input voltage 12 V
Output voltage 11–12 V
Multifunction meter unit
Input voltage 12 V
Buzzer
Input voltage 12 V
Speed sensor
Output voltage (dependent on the paddle Less than 400 mV/More than 11.6 V
wheel position)
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) N·m kgf·m lb·ft
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)
The correct setting value of the torque wrench 14 mm M10 36 3.6 26.6
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 (N·m)
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
18
4
A 5
6 7 8
17 9
16
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. Fuel sender lead
8. Steering sensor lead 17. Negative battery lead
9. Cooling water pilot outlet hose 18. Positive battery lead
2-13
Top view
A
18
1
A A 12
3 17
2 17 18
16 B B C C
F 15 3 A-A
14 D
D
E E
F
13 4
14
5
E E 4 15 13
12
G-G B-B
5
6
11 E E
7
8
7
G G
H-H C-C
J E
C E
8
J
I I 3
11
11
I-I D-D
H H 9
B
11
H H 8
67
10
J-J E-E
1. Remote control receiver antenna 11. RiDE motor lead

2. Remote control receiver lead 12. Fuel tank breather hose (fuel tank to
3. Fuel tank breather hose (water separator water separator)
to ventilation socket) 13. RPS lead
4. APS lead 14. Handlebar switch lead (left)
5. Steering cable 15. Trim switch lead
6. Fuel sender lead 16. Cooling water pilot outlet hose
7. Wire harness 17. Buzzer lead
8. Speed sensor lead 18. Steering sensor lead
9. Negative battery lead
10. Positive battery lead
2-14
A
18
1
A A 12
3 17
2 17 18
16 B B C C
F 15 3 A-A
14 D
D
E E
F
13 4
14
5
E E 4 15 13
12
G-G B-B
5
6
11 E E
7
8
7
G G
H-H C-C
J E
C E
8
J
I I 3
11
11
I-I D-D
H H 9
B
11
H H 8
67
10
J-J E-E
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
1
Maintenance interval chart ................................................ 3-1
Periodic service.................................................................. 3-3

Fuel line check ........................................................................... 3-3
2
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
3
Engine oil replacement............................................................... 3-4
Oil filter replacement .................................................................. 3-5
Intermediate housing lubrication ................................................ 3-6
Spark plug check........................................................................ 3-6
Battery and battery lead check................................................... 3-6
4
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
5
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.................................. 3-11
Drain plug check....................................................................... 3-11
Anode check............................................................................. 3-11
Valve clearance measurement................................................. 3-12
Rubber coupling check............................................................. 3-13
6
Engine mount check................................................................. 3-13
7
8
9
A
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/
cracks and deforma-  3-3
Water separator
tion
Check installation
Fuel tank  3-3
and straps
Water inlet Check for clogs and
 3-3
strainer damage
Check for damage
Cooling water
and leakage, and  3-3
hoses
check clamps
Engine oil Replace   3-4
Oil filter Replace  3-5
Intermediate
Lubricate  3-6
housing
Spark plugs Check   3-6
Check specific grav-
ity 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  3-7
lubricate
Check exterior and
Electric trim rod connections, and  3-8
lubricate
Check exterior and
Shift rod and
connections, and  3-8
reverse gate
lubricate
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  3-11
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 3-12
Check for cracks,
Rubber coupling indentations, 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
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” (4-8).
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”. 1. Check the cooling water hoses and hose
Replace the O-ring if cracked or damaged. 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).
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- 1
ter supply.
• Make sure that debris or water does not
enter the oil filler hole.
Recommended engine oil
YAMALUBE 4W or 4-stroke mo-
1. Place the watercraft in a horizontal posi-
tor oil
tion.
Recommended engine oil grade
API
If the engine was running, allow the engine oil API SG, SH, SJ, SL
to settle by waiting 5 minutes or more before Recommended engine oil type SAE
checking the oil level. SAE 10W-30, 10W-40, 20W-40,
20W-50
2. Remove the oil level gauge “1”, wipe the Engine oil replacement
gauge clean, and then insert the oil level
gauge “1” into the oil level pipe completely.
Be careful when handling the engine oil to
3. Remove the oil level gauge “1” again to
avoid burns. The engine oil is hot immedi-
check that the oil level is between the min-
ately after the engine is turned off.
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-
1 den hose to the watercraft for proper wa-
b ter supply.
• Make sure that debris or water does not
a
enter the oil filler hole.

tion.
4. If the engine oil is below the minimum level
mark, remove the oil filler cap “1”, and then 2. Start the engine and warm it up for 5 min-
add sufficient oil of the recommended type utes or more at engine idle speed.
to raise it to the correct level.
3. Stop the engine.
3-4
Periodic service
4. Remove the oil filler cap and oil level
gauge.
5. Extract the oil using the oil changer “1”.

1
1 Oil filter wrench “2”

90890-06874
Oil filter wrench “2”
6. Add the recommended engine oil up to the YB-06874
specified level through the oil filler hole.
4. Install the oil filter “1”, and then tighten it to
the specified torque.
Recommended engine oil
YAMALUBE 4W or 4-stroke mo-
tor oil Make sure to clean up any oil spills.
Recommended engine oil grade
API
API SG, SH, SJ, SL
Recommended engine oil type SAE
SAE 10W-30, 10W-40, 20W-40,
2 1
20W-50
Engine oil quantity without oil filter
replacement
3.5 L (3.70 US qt, 3.08 Imp.qt)
Engine oil quantity with oil filter re-
placement
3.6 L (3.81 US qt, 3.17 Imp.qt)
7. Install the oil filler cap and oil level gauge. 90890-06874
8. Check the engine oil level. See “Engine oil YB-06874
level check” (3-4).
Oil filter replacement Oil filter “1”

1. Extract the engine oil. See“Engine oil re- 18 N·m (1.8 kgf·m, 13.3 lb·ft)
T.
R.
placement” (3-4).
5. Check the engine oil level. See “Engine oil
2. Place a rag under the oil filter “1”. level check” (3-4).
3. Remove the oil filter “1”.
3-5
Periodic service
Intermediate housing lubrication

1. Lubricate the intermediate housing Spark plug (NGK)
through the grease nipple “1”. LFR7A
Spark plug gap
0.8–0.9 mm (0.031–0.035 in)
1 5. Install the spark plugs, and then tighten

them to the specified torque.
Before installing a spark plug, clean the gasket

surface and spark plug surface.
Spark plug
Recommended lubricant 25 N·m (2.5 kgf·m, 18.4 lb·ft)
T.
YAMALUBE MARINE GREASE
R.
Battery and battery lead check
Spark plug check
1. Remove the spark plugs.
Battery electrolyte is poisonous and dan-
gerous, causing severe burns, etc. Electro-
Be careful not to get water or any other foreign
lyte contains sulfuric acid. Avoid contact
substances in the spark plug holes.
with skin, eyes or clothing.
Antidotes
2. Clean the electrodes “a”. External: Flush with water.
Internal: Drink large quantities of water or
3. Check the electrodes “a”. Replace the milk. Follow with milk of magnesia, beaten
spark plug if damaged or worn. egg or vegetable oil. Call physician immedi-
ately.
a 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-
tilated. Always shield your eyes when
working near batteries.
KEEP OUT OF THE REACH OF CHILDREN.
4. Measure the spark plug gap “a”. Replace if
out of specification.
• Be careful not to place the battery on its
side.
a • 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
and not obstructed.
3-6
Periodic service
1. Remove the battery.
Apply water resistant grease to the terminals to

When removing the battery, disconnect the minimize corrosion.
negative battery lead first.
2. Check the battery electrolyte level. If the

level is at or below the minimum level mark
2
“a”, add distilled water until the level is be-
tween the maximum level mark “b” and the 1
minimum level mark “a”. 4
3
1
b Steering master check

a 1. Turn the handlebar lock to lock and push it
back and forth.
3. Check the specific gravity of the electro-

lyte. Charge the battery if below specifica-
tion.
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”.
2. Check for excessive play of the handlebar.
Check the bushings, bolts, and nuts if
Make sure that the battery breather hose is there is excessive play. See “Steering pad
connected properly and is not obstructed. and handlebar cover” (8-1).
7. Connect the positive battery lead “3”, and Steering cable check
then connect the negative battery lead “4”. 1. Remove the rear and front seats.
2. Check the steering cable. Replace if

Connect the positive battery lead to the bat- cracked or damaged.
tery terminal first.
3. Check the steering cable routing.
3-7
Periodic service
4. Lubricate the steering cable.
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
Recommended lubricant
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
1. Check the reverse gate. Replace if
Trim rod check cracked or damaged.
1. Disconnect the shift rod joint “1”, and then
lower the reverse gate “2”. 2. Check that the reverse gate “1” is in con-
tact with the reverse gate stopper “a” at the
2
1 F position.
a
2. Disconnect the trim rod joints and apply 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”.
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-

a nect the shift rod joint “2”.
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 “YDIS In-
struction Manual”.
8. Disconnect the shift rod joint “1”, and then

Air intake hose check
lower the reverse gate “2”. 1. Check the air intake hoses and hose con-
nections for intake air leakage.
2
1
2. Check the air intake hoses. Replace if
cracked or damaged.
3. Check the air intake hose routing and the

clamps.
Throttle valve lubrication
9. Disconnect the shift rod joint and apply a When lubricating the engine internal com-
small amount of grease. ponents on land, make sure to supply suffi-
cient water and water pressure to the
cooling water passage. Otherwise, the en-
gine could overheat.
3-9
Periodic service
1. Remove the clamp “1”, and then discon- Breather hose check
nect the breather hose “2”. 1. Check the breather hoses and hose con-
nections for blowby gas or oil leakage. See
1 “Cable and hose routing” (2-13).
2. Check the breather hoses. Replace if

cracked or damaged.
2 3. Check the breather hose routing and the

clamps. See “Cable and hose routing”
(2-13).
2. Start the engine, and then spray a rust in-

Impeller check
hibitor into the air intake pipe hole “a” for
approximately 5 seconds.
Make sure to remove the battery before
checking the jet pump unit.
Engine speed drops while a rust inhibitor is be-
ing sprayed into the air intake pipe hole. 1. Check the impeller from the jet intake side.
Clean if there is foreign material.
2. Check the impeller. Replace if bent or

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

a 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 breather hose, and then fas-

ten it using the clamp.
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).
2. Check the exhaust hoses. Replace if Recommended lubricant

cracked or damaged. YAMALUBE MARINE GREASE
3. Check the exhaust hose routing and the
4. Check that the jet thrust nozzle moves
clamps.
smoothly.
5. Install the nozzle ring and jet thrust nozzle.
3-10
Periodic service
6. Connect the trim rod and steering cable.
b a
b
Jet vacuum bilge draining system A
check
1. Check the bilge strainer “1”. Clean if A
clogged or dirty.
2 3 2
Place your hand under the bilge strainer to

check for clog or dirt.
1
1
9. Connect the bilge hoses and hose joint.

1
10. Check the bilge hose routing and the
clamps.
Drain plug check

1. Check the O-ring “1” of drain plug “2”. Re-
2. Check the bilge hoses. Replace if cracked
place if cracked or damaged.
or damaged.
3. Disconnect the bilge hose “1”.
4. Run water into the bilge hose “1” and

check that the hose is not clogged. 2
5. Run water into the hose joint “2” and check

that the joint and hose are not clogged. 2
1
6. Disconnect the bilge hose “3”.
Anode check
7. Check the hole “a” in the hose joint. Clean
1. Remove the cover and anode.
if clogged.
2. Check the anode “1”. Clean if there is oil or
8. Check the check valve “b” of the hose joint.
water stain.
Replace the hose joint if it is open or dam-
aged.
3-11
Periodic service
Check that the punch marks “a” on the cam-

shafts are aligned with the marks “b” on the
camshaft caps.
1
1
3. Check the anode for erosion. Replace if it

is half the original size.
b
Valve clearance measurement
Measure the valve clearance when the engine a
is cold.
1. Remove the ignition coils, spark plugs, and

cylinder head cover.
2. Install the special service tools “1”, “2”, and

“3” into spark plug hole #1.
#1 #2 #3 #4
3
1
2 Camshaft wrench “1”
90890-06724
Camshaft wrench “1”
YW-06724
4. Measure the intake and exhaust valve

clearances of the specified cylinders.
Gauge stand “1”
IN EX
90890-06725
Dial gauge needle “2”
90890-06584
Dial gauge stand set “2”
YB-06585
Dial gauge set “3”
90890-01252
Dial indicator gauge “3”
YU-03097
3. Position piston #1 at TDC by turning the

exhaust camshaft sprocket clockwise.
3-12
Periodic service
Valve clearance
Valve clearance-intake (cold)
1
0.14–0.23 mm (0.0055–0.0091
in)
Valve clearance-exhaust (cold)
0.36–0.45 mm (0.0142–0.0177
in)
#1 #2 #3 #4
IN  —  — 2. Apply force in the directions of the arrow to
check that there is no rattling. If there is rat-
EX   — —
tling, remove the engine unit and check the
: Specified cylinder rubber coupling. See “Engine unit remov-
—: Not applicable al” (5-7).
5. Install the special service tools into spark

plug hole #4.
6. Position piston #4 at TDC by turning the

exhaust camshaft sprocket 180 clock-
wise.

#1 #2 #3 #4 Engine mount check
IN —  —  1. Check the engine mount. Replace if there
is damage or peeling.
EX — —  
: Specified cylinder
—: Not applicable
8. Adjust the valve clearance if out of specifi-

cation. See “Valve clearance adjustment”
(5-51).
9. Install the cylinder head cover, spark

plugs, and ignition coils. See “Cylinder
head cover” (5-41).
Rubber coupling check

1. Remove the coupling cover “1”.
3-13
Fuel system
1
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
2
Fuel hose assembly ................................................................... 4-4
Fuel injector ........................................................................ 4-6

Fuel injector check ..................................................................... 4-7
3
Fuel rail and injector installation ................................................. 4-7
Fuel tank and fuel pump module ...................................... 4-8

Fuel tank removal..................................................................... 4-10
4
Fuel pump module removal...................................................... 4-11
Fuel sender removal................................................................. 4-11
Fuel pump module check ......................................................... 4-11
Check valve check ................................................................... 4-11
Fuel filler cap check.................................................................. 4-12
5
Fuel sender installation ............................................................ 4-12
Fuel pump module installation.................................................. 4-12
Fuel tank installation................................................................. 4-13
6
7
8
9
A
Air filter case and fuel hose

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

1 Bolt 2 M6  12 mm
2 Stay 1
3 Grommet 1
4 Fuel hose ASSY 1
5 Clamp 4 Not reusable
6 Quick connector 2
7 Corrugated tube 1
8 Fuel hose 1
9 Clamp 2
10 Clamp 1
11 Air intake pipe 1
12 Connection 1
13 Bolt 4 M8  35 mm
14 Air filter case 1
15 Hook 8
16 Screw 3 M6  15 mm
4-1
23 13 N·m (1.3 kgf·m, 9.6 lb·ft)

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

17 Air filter element 1
18 Drain tube 1
19 Collar 4
20 Grommet 4
21 Nut 4
22 Washer 4
23 Bracket 1
24 Plastic tie 1
25 Holder 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- 1

tor slowly. Otherwise, pressurized fuel
could spray out. B
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 a new one. Otherwise, fuel could leak.
kgf/cm², 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”.
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. Check the air filter element. Replace if

damaged or dirty.
4-4
2. Crimp the clamps “1”.
• 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.
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
Fuel injector
Fuel injector
5
3
4
5
3
4
5
3
4
2
1
1
1
6
6
13 N·m (1.3 kgf·m, 9.6 lb·ft)
6
5
3
4

1 Bolt 3 M8  17 mm
2 Fuel rail 1
3 Fuel injector 4
4 Seal 4 Not reusable
5 O-ring 4 Not reusable
6 Plastic tie 3 Not reusable
4-6
Fuel injector
Fuel injector check

1. Check the fuel injector filter “a”. Clean us-
ing kerosene or gasoline if clogged or con-
taminated.
a 1
2
3. Install new seals “1” and the fuel rail “2”,

and then tighten the fuel rail bolts “3” to the
specified torque.
2. Measure the fuel injector resistance. See

“Fuel injector check” (7-30). Do not reuse a seal, always replace it with a
new one.
Fuel rail and injector installation
1. Install new O-rings “1” onto the fuel injec- 1
tors, and then apply a thin coat of engine
oil to the O-rings “1”.
1
2
2. While turning the fuel injectors “1” slowly to

the left and right, install them to the fuel rail Fuel rail bolt “3”
“2”. 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
4. Install the holders “1”, and then connect

Make sure to apply a thin coat of engine oil the fuel injector couplers “a” and ignition
to the O-rings before installing the fuel in- coil couplers “b”.
jectors to the fuel rail. Otherwise, the O-
rings could twist and break, causing fuel a
b
leakage.
4-7
Fuel tank and fuel pump module

12 3.5 N·m (0.35 kgf·m, 2.58 lb·ft)
6 N·m (0.6 kgf·m, 4.4 lb·ft) 6.5 N·m (0.65 kgf·m, 4.79 lb·ft)
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
4 N·m (0.4 kgf·m, 2.95 lb·ft)
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
4-8
12 3.5 N·m (0.35 kgf·m, 2.58 lb·ft)

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
4 N·m (0.4 kgf·m, 2.95 lb·ft)
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
4-9
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
7. Remove the nut “1”, and then remove the

Use a commercially available siphon pump “1” fuel filler neck “2”, packing “3”, and fuel fill-
to extract the fuel. er cap “4”.
1
4
8. Remove the straps “1”, and then remove

2. Remove the air filter case and air filter
the fuel tank “2”.
case bracket. See “Air filter case and fuel
hose” (4-1).
Pull the straps “1” in the directions of the ar-
3. Remove the engine unit. See “Engine unit rows to unhook the metal loops “a” on the end
removal” (5-7). 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 1

a
fuel pump module coupler “b”.
2 a
3
a b
2
1 2
6. Remove the clamps “1” and fuel filler hose

“2”.
4-10
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.
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

b if cracked or damaged.
a
b. Rubber cap
1
Fuel sender removal
1. Disconnect the fuel sender coupler “a”.
2. Squeeze the hooks “b” on the stopper “1”, 2. Check the fuel pump filter “a”. Clean with
and then slide the stopper in direction “c” to kerosene or gasoline if clogged or contam-
remove it. inated.
1
1 a
c
a
b
3. Push the tabs “a” on the fuel sender “1”, Check valve check
and then slide the sender in direction “b” to 1. Blow into the end “a” of the check valve,
remove it. and make sure that airflow from the end “b”
is unrestricted. Replace if the air flow is re-
stricted.
4-11
2. Blow into the end “b” of the check valve,
1
and make sure that airflow from the end “a”
is restricted. Replace if the air flow is unre-
stricted. a
A a B b
b b
2. Install the stopper “1”, and then connect

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

check that it clicks when tightened com- a
pletely. Replace if it does not click. b
a
1 Fuel pump module installation
1. Install a new packing and the fuel pump
module “1”.
2 When installing the fuel pump module,

make sure that the rubber caps do not
Fuel sender installation come off.
1. Install the fuel sender “1”.
Make sure that the tabs “a” on the fuel sender

“1” are securely seated into the slots “b” in the
fuel pump module.
4-12
Make sure to insert the float “a” into the fuel • If the quick connector “1” is not installed com-
tank. pletely onto the fuel pipe “a”, the retainer “b”
cannot be pushed down.
1 • 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-
tor is pulled and pushed. If there is no free
a b play in the quick connector “1”, disconnect
the fuel hose and check the O-rings for dam-
age and proper installation.
d
b. Rubber cap b
a
2. Install the retainer “1”, and then tighten the
nuts to the specified torques in 2 stages c
and in the order [1], [2], and so on.
1 1
[3]
[2]
[5]
7. Install the service lid. See “Front hood”
[7] (8-6).
[9]
[8] Fuel tank installation
[4] [1] [6] 1. Install the fuel tank “1”, and then fasten the
fuel tank using the straps “2”.
Fuel pump module nut • Install the straps “2” so that the rubber band
1st: 3.5 N·m (0.35 kgf·m, 2.58 portions “a” of the straps are positioned on
T.
R.
lb·ft) top.
2nd: 6.5 N·m (0.65 kgf·m, 4.79 • Make sure that the metal loops “b” on the end
lb·ft) of the straps “2” are hooked securely onto the
holders on the hull.
3. Apply a thin coat of engine oil to the con-
tact surfaces of the fuel pipe “a”.
4. Connect the quick connector “1” onto the

fuel pipe “a”.
5. Push down on the retainer “b” until it clicks.
6. Connect the fuel sender coupler “c” and

fuel pump module coupler “d”.
4-13
a
2
a
2
b a c
b 2
b 2 1
b
b
1 2
1
Distance “a”
30–40 mm (1.2–1.6 in)
2. Install a new packing “1”, fuel filler neck Fuel filler hose clamp “2”
“2”, and the fuel filler cap “3”. 4 N·m (0.4 kgf·m, 2.95 lb·ft)
T.
R.
3. Tighten the nut “4” to the specified torque. 6. Connect the fuel sender coupler “a” and
fuel pump module coupler “b”.
Align the projection “a” on the fuel filler neck “2”
7. Install the fuel tank breather hoses “1” and
with the holes “b” in the packing “1” and deck.
check valve “2”.
8. Fasten the fuel tank breather hoses “1” us-

a
3 ing new plastic ties “3”.
2
Point the arrow mark “c” toward the fuel tank.
1
1
b 2
4
a b
c
Fuel filler neck nut “4”
6 N·m (0.6 kgf·m, 4.4 lb·ft) 3 1
T.
R.
4. Install the fuel filler hose “1”, and then tight-

en the clamps “2” to the specified torque.
9. Install the engine unit. See “Engine unit in-
5. Check that the distance “a” is within speci-
stallation” (5-11).
fication.
10. Install the air filter case bracket and air fil-
Align the arrow mark “b” on the fuel filler hose ter case. See “Air filter case and fuel hose”
“1” with the projection “c” on the fuel filler neck. (4-1).
4-14
— MEMO —
4-15
Power unit
1
Engine unit (check and adjustment)................................. 5-1
Compression pressure check..................................................... 5-1
Engine unit.......................................................................... 5-2
Exhaust manifold ............................................................... 5-3 2

3
Engine unit and coupling cover........................................ 5-5
Engine mount ..................................................................... 5-6

Engine unit removal.................................................................... 5-7
4
Engine mount and damper check............................................. 5-10
Rubber coupling check............................................................. 5-10
Engine unit installation ............................................................. 5-11
Muffler ............................................................................... 5-17

Exhaust pipe disassembly........................................................ 5-18
Exhaust pipe assembly ............................................................ 5-18 5
Wire harness..................................................................... 5-19
Electrical box .................................................................... 5-20

Starter motor and wire harness removal .................................. 5-22
6
7
Thermostat check..................................................................... 5-22
Starter motor and wire harness installation .............................. 5-23
Air cooler and supercharger ........................................... 5-25
Intake ................................................................................. 5-27

8
ETV and intake manifold.................................................. 5-29
Air cooler check........................................................................ 5-30
Supercharger check ................................................................. 5-30
ETV check ................................................................................ 5-31
Intake installation...................................................................... 5-31
9
Oil level pipe installation........................................................... 5-32
Supercharger installation.......................................................... 5-32
A
Power unit
Air cooler, air cooler intake hose, and boost pipe

installation ................................................................................ 5-33
Oil cooler and oil pump ................................................... 5-35
Idle gear and drive gear................................................... 5-37

Oil pump, idle gear, and drive gear removal ............................ 5-38
Oil cooler check........................................................................ 5-38
Oil pump check......................................................................... 5-39
Idle gear check ......................................................................... 5-39
Drive gear check ...................................................................... 5-39
Drive gear, idle gear, and oil pump installation ........................ 5-39
Cylinder head cover ......................................................... 5-41
Camshaft ........................................................................... 5-42

Camshaft removal .................................................................... 5-44
Camshaft sprocket removal...................................................... 5-45
Camshaft check........................................................................ 5-45
Camshaft journal oil clearance check....................................... 5-46
Timing chain tensioner check................................................... 5-47
Camshaft sprocket installation ................................................. 5-48
Camshaft installation ................................................................ 5-48
Valve clearance adjustment ..................................................... 5-51
Valve pad selection table ......................................................... 5-53
Cylinder head ................................................................... 5-55
Valve and valve spring..................................................... 5-56

Cylinder head disassembly ...................................................... 5-57
Cylinder head check................................................................. 5-57
Valve spring check ................................................................... 5-58
Valve check .............................................................................. 5-58
Valve guide check .................................................................... 5-59
Valve guide removal................................................................. 5-59
Valve guide installation............................................................. 5-59
Valve seat check ...................................................................... 5-60
Valve seat refacing................................................................... 5-61
Cylinder head assembly ........................................................... 5-63
Cylinder head installation ......................................................... 5-64
Power unit
1
Generator cover ASSY and flywheel magneto .............. 5-66
Generator cover................................................................ 5-68

Drive coupling removal............................................................. 5-69
2
Flywheel magneto removal ...................................................... 5-69
Generator cover ASSY disassembly ........................................ 5-71
Starter clutch operation check.................................................. 5-71
Generator cover ASSY assembly............................................. 5-72
Flywheel magneto assembly .................................................... 5-73
3
Flywheel magneto installation .................................................. 5-73
Drive coupling installation......................................................... 5-77
Cylinder block and electrical part................................... 5-79
Oil separator tank and oil pan......................................... 5-81

Anode check............................................................................. 5-83
Oil pan assembly...................................................................... 5-83
4
5
Oil separator tank cover installation ......................................... 5-83
Crankcase, connecting rod, and piston ......................... 5-85

Crankcase disassembly ........................................................... 5-87
6
Connecting rod and piston removal.......................................... 5-87
Crankcase check...................................................................... 5-87
Cylinder block check ................................................................ 5-88
Piston check ............................................................................. 5-88
Piston clearance check ............................................................ 5-88
7
Piston ring check ...................................................................... 5-89
Piston pin check ....................................................................... 5-90
Connecting rod check............................................................... 5-90
Crankshaft check...................................................................... 5-91
Crankshaft pin oil clearance check........................................... 5-91
8
Connecting rod big end side clearance check.......................... 5-93
Connecting rod bearing selection............................................. 5-93
Crankshaft journal oil clearance check..................................... 5-94
Crankshaft bearing selection.................................................... 5-95
Connecting rod and piston installation ..................................... 5-96
Crankcase assembly ................................................................ 5-99
9
A
Engine unit (check and adjustment)
Engine unit (check and adjust- 8. Measure the compression pressure for all
ment) cylinders according to steps 6 and 7.
Compression pressure check
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 on land, make sure Compression pressure
to connect a garden hose to the watercraft Minimum
for proper water supply. 490 kPa (4.9 kgf/cm², 71.1 psi)
9. If the compression pressure is below spec-

ification, squirt a few drops of engine oil
tion.
into the cylinder and measure again.
2. Start the engine and warm it up for 5 min- Compression pressure (with engine oil
utes or more at engine idle speed. added into the cylinder)
Reading Check
3. Stop the engine.
Higher than without Piston ring and pis-
4. Remove the ignition coils and spark plugs. engine oil ton
Valve clearance,
5. Disconnect the fuel injector couplers.
Same as without valve, valve seat,
engine 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
1 25 N·m (2.5 kgf·m, 18.4 lb·ft)
T.
R.
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
5 N·m (0.5 kgf·m, 3.7 lb·ft) 1
1 2
2
3 9
7
11 7
7
12
6 13
7
6
8
10
7
10

1 Screw 2 M6  12 mm
2 Grommet 2
3 Engine cover 1
4 Clamp 1
5 Breather hose 1
6 Antenna holder 3
7 Plastic tie 7
8 Clamp 1
9 Clamp 1
10 Clamp 2
11 Clamp 1
12 Plastic tie 1
13 RiDE motor coupler 2
5-2
Exhaust manifold
Exhaust manifold
23 N·m (2.3 kgf·m, 17.0 lb·ft) 26 N·m (2.6 kgf·m, 19.2 lb·ft) 13 N·m (1.3 kgf·m, 9.6 lb·ft)
42 N·m (4.2 kgf·m, 31.0 lb·ft)
10 N·m (1.0 kgf·m, 7.4 lb·ft) 8
7 10
23 7
4 20
17 13
21 7 9
22 12
2 11 13
6 14 7
3 12
7
6 15 16 11
28 14 13 N·m (1.3 kgf·m, 9.6 lb·ft)

2.5 N·m (0.25 kgf·m, 1.84 lb·ft)
27 23 N·m (2.3 kgf·m, 17.0 lb·ft)

5 42 N·m (4.2 kgf·m, 31.0 lb·ft)
19
28 24
18
1 25
26 7
18 N·m (1.8 kgf·m, 13.3 lb·ft)
20 N·m (2.0 kgf·m, 14.8 lb·ft)
35 N·m (3.5 kgf·m, 25.8 lb·ft)

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
42 N·m (4.2 kgf·m, 31.0 lb·ft)
10 N·m (1.0 kgf·m, 7.4 lb·ft) 8
7 10
23 7
4 20
17 13
21 7 9
22 12
2 11 13
6 14 7
3 12
7
6 15 16 11
28 14 13 N·m (1.3 kgf·m, 9.6 lb·ft)

2.5 N·m (0.25 kgf·m, 1.84 lb·ft)
27 23 N·m (2.3 kgf·m, 17.0 lb·ft)

5 42 N·m (4.2 kgf·m, 31.0 lb·ft)
19
28 24
18
1 25
26 7
18 N·m (1.8 kgf·m, 13.3 lb·ft)
20 N·m (2.0 kgf·m, 14.8 lb·ft)
35 N·m (3.5 kgf·m, 25.8 lb·ft)

17 Cover 1
18 Clamp 1
19 Bolt 1 M10  50 mm
20 Bolt 1 M8  47 mm
21 Stay 1
22 Bolt 4 M6  12 mm
23 Stay 4
24 Clamp 1
25 Bolt 3 M8  120 mm
26 Bolt 8 M8  70 mm
28 Dowel pin 2
5-4
Engine unit and coupling cover
Engine unit and coupling cover
17 N·m (1.7 kgf·m, 12.5 lb·ft)

1
5
2
6
3
1 1
4
17 N·m (1.7 kgf·m, 12.5 lb·ft)
6
6
5 6

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 N·m (0.55 kgf·m, 4.06 lb·ft)
2 2
1 1
LT
3 572 17 N·m (1.7 kgf·m, 12.5 lb·ft)

3

1 Bolt 8 M8  35 mm
2 Engine mount 4
3 Liner 4
4 Bolt 2 M6  19 mm
5 Damper 1
6 Bolt 2 M6  12 mm
7 Damper 1
5-6
Engine mount
Engine unit removal 7. Disconnect the quick connector “3” from

the fuel rail. See “Fuel hose disconnection”
(4-3).
Before removing the engine, make sure to
take adequate measures to protect the 2
1
deck opening from damage. 3
1. Disconnect the negative battery lead, and

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,
and air filter case “4”.
1
4 3
1
4. Remove the deck beam “1”.
9. Remove the antenna holders “1”.

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
a
2
12. Disconnect the sensor and switch cou-

1 plers “a”.

6. Remove the oil level gauge “1” and holder
ties “1”.
“2”.
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
a
1
a
ties “1”.
1
1 19. Disconnect the cooling water hoses “1”
1 and “2” from the air cooler.
15. Disconnect the fuel pump module coupler

“a”.
a 20. Place a rag under the oil filter “1”, and then
remove the oil filter “1”.
Make sure to clean up any oil spills.

16. Disconnect the cooling water hose “1” from
the oil cooler.
1 2
1

17. Disconnect the cooling water hose “1” from 90890-06874
the thermostat housing. Oil filter wrench “2”
YB-06874
5-8
Engine mount
21. Remove the plastic tie “1”, and then dis-
connect the thermo sensor coupler “a”.
1 a
27. Remove the pipe clamp “1” from the pipe

“2”.
22. Disconnect the cooling water hoses “1”, 1
“2”, and “3” and rectifier/regulator coupler
“a”.
23. Remove the rectifier/regulator “4”.

1 2
4
2
3
28. Remove the muffler “1”.

a
When removing the muffler “1”, move it forward
and separate it from the water lock.
24. Disconnect the cooling water hoses “1”
and “2”. 1
25. Remove the stay “3”.
1
2 29. Remove the electrical box “1”.
3
26. Remove the stays “1”.
30. Remove the coupling cover “1”.
5-9
Engine mount
35. Lift the engine unit slightly, and then lower
1 the front of the unit. Repeat this step until
the engine unit can be removed from the
engine compartment.
When removing the engine unit, take care

to avoid causing damage to the hull liner
and deck opening.
31. Loosen the engine mounting bolts “1”.
32. Lift the engine unit slightly, remove the

shims “2”, and then lower the unit.
33. Remove the engine mounting bolts “1”.
Write down the position of each removed shim

“2” so that it can be installed in its original posi-
tion. 36. Lift the engine unit out vertically.
Engine mount and damper check

1 2 1. Check the engine mounts and dampers.
Replace if cracked or damaged.
34. Suspend the engine unit using all 3 engine • Write down the position of each engine
hangers, and then separate the unit from mount so that it can be installed in its original
the engine mounts and move it forward to position.
disconnect the coupling. • When replacing the engine mounts, make
sure to check the coupling clearance.
Rubber coupling check

1. Check the rubber coupling. Replace if
cracked or indented.
5-10
Engine mount
Engine unit installation
When installing the engine unit, take care to

avoid causing damage to the hull liner and
deck opening.
1. Suspend the engine unit using all 3 engine

hangers.
2. Lower the front of the engine unit. 1

3. Lower the engine unit into the engine com-
partment vertically.
6. Temporarily install the engine mounting

bolts “1”.
7. Lift the engine unit slightly, install the

shims “2”, and then lower the unit.
4. Lift the front of the engine unit slightly, and

Install the shims “2” in their original positions.
then lower the unit. Repeat this step until
the drive and driven couplings are aligned.
1 2
5. Move the engine unit rearward to connect
the driven coupling “1”, and then lower the
unit onto the engine mounts.
8. Measure the coupling clearances “a” and
“b”. If the clearances are out of specifica-
Do not install the rubber coupling until the cou-
tion, add or remove shims so that the
pling clearance adjustment has been made.
clearances are within specification.
5-11
Engine mount
a a
b b
Height difference “a” Height difference “a”

Less than 1 mm (0.039 in) Less than 0.5 mm (0.020 in)
(without rubber coupling) (with rubber coupling)
Clearance “b” Clearance “b”
2–4 mm (0.079–0.157 in) 2–4 mm (0.079–0.157 in)
14. Tighten the engine mounting bolts “1” to

Available shim thicknesses the specified torque, and then recheck the
0.10, 0.30, 0.50, 1.00, 2.00 mm coupling clearances.
9. Lift the engine unit slightly, remove the

shims, and then lower the engine unit.
1
10. Remove the engine mounting bolts.
11. Separate the engine unit from the engine

mounts and move it forward to disconnect
the coupling.
12. Install the rubber coupling “1”.

1
Engine mounting bolt “1”

17 N·m (1.7 kgf·m, 12.5 lb·ft)
T.
R.
1 15. Install the coupling cover “1”.
13. Install the shims, and then adjust the posi-

tion of the engine unit so that the coupling
clearances “a” and “b” are within specifica-
tion.
5-12
Engine mount
16. Install the electrical box “1”, and then tight-
en the electrical box bolts “2” to the speci-
1
fied torque.
1
2
2
2
2
Pipe clamp “1”
2.5 N·m (0.25 kgf·m, 1.84 lb·ft)
T.
R.
Electrical box bolt “2” 19. Install the stays “1”, and then tighten the
17 N·m (1.7 kgf·m, 12.5 lb·ft) stay bolts “2” to the specified torque.
T.
R.
17. Install the muffler “1” into the water lock, 1

and then tighten the exhaust manifold
2
bolts “2” and “3” to the specified torques in
3 stages and in the order [1], [2], and so
2 1
on.
3 1
[9] [6] [2] [3] [7] [10] 2
[5]
3 Stay bolt “2”
[8]
2 [4] 3
[1] [11] 10 N·m (1.0 kgf·m, 7.4 lb·ft)
2
T.
R.
3 2
20. Install the stay “1”, and then tighten the
stay bolts “2” and “3” to the specified
torques in 2 stages.
Exhaust manifold bolt “2” and “3”
1st: 20 N·m (2.0 kgf·m, 14.8 lb·ft) 21. Connect the cooling water hoses “4” and
T.
R.
2nd: 20 N·m (2.0 kgf·m, 14.8 lb·ft) “5”, and then fasten them using the clamps
3rd: 35 N·m (3.5 kgf·m, 25.8 lb·ft) “6” and “7”.
6 7
18. Install the pipe clamp “1”, and then tighten 4
2 5
it to the specified torque.
3
Make sure that the pipe on the end of the muf-
fler is installed securely into the water lock.
2 3
1
5-13
Engine mount
Stay bolt “2” and “3”

1st: 23 N·m (2.3 kgf·m, 17.0 lb·ft)
T.
R.
2nd: 42 N·m (4.2 kgf·m, 31.0 lb·ft)
22. Install the rectifier/regulator “1”, and then 1 2

tighten the rectifier/regulator bolts “2” to
23. Connect the rectifier/regulator coupler “a”.
24. Connect the cooling water hoses “3”, “4”, Oil filter wrench “2”
and “5”, and then fasten them using the 90890-06874
clamps “6”, “7”, and “8”. Oil filter wrench “2”
3 YB-06874
1 6
8
5
Oil filter “1”
2 2 18 N·m (1.8 kgf·m, 13.3 lb·ft)
T.
R.
2 4 28. Connect the cooling water hoses “1” and

7
a “2”, and then fasten them using the clamps
“3” and “4”.
3
Rectifier/regulator bolt “2”

26 N·m (2.6 kgf·m, 19.2 lb·ft)
T.
R.
3 1
25. Connect the thermo sensor coupler “a”.
26. Fasten the lead using the plastic tie “1”.

1 a
4
2
29. Connect the RiDE motor couplers “a” and

“b”, and then fasten the RiDE motor lead
using the plastic tie “1”.
27. Install the oil filter “1”, and then tighten it to

5-14
Engine mount
30. Connect the cooling water hose “2”, and 35. Connect the sensor and switch couplers
then fasten it using the clamp “3”. “a”. See “Coupler layout” (2-17).
1
a 1
2 3
b
a
1
31. Connect the cooling water hose “1”, and 36. Connect the remote control receiver cou-
then fasten it using the clamp “2”. pler “a”, and then fasten the wire harness
using the plastic tie “1”.
37. Install the antenna holders “2”.

1
2
2
2
a
32. Connect the fuel pump module coupler “a”. 1
38. Install the air filter case “1”, and then tight-
en the air filter case bolts “2” to the speci-
fied torque.
a 1
33. Fasten the wire harness using the plastic 2

ties “1”.
1
1
1
1 Air filter case bolt “2”
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
39. Install the air filter, air filter case cover “1”,
and air intake pipe “2”, and then tighten the
air intake pipe clamps “3” to the specified
torque.
34. Fasten the wire harness using the plastic
ties “1”.
5-15
Engine mount
40. Install the breather hose “4”, and then fas- 44. Install the deck beam “1”, and then tighten
ten it using the clamp “5”. the deck beam bolts “2” to the specified
torque.
4 1
5 1
2
2
3
LT
271
Air intake pipe clamp “3”

3.5 N·m (0.35 kgf·m, 2.58 lb·ft) Deck beam bolt “2”
T.
R.
16 N·m (1.6 kgf·m, 11.8 lb·ft)
T.
R.
41. Connect the quick connector “1” to the fuel
rail. 45. Install the service lid “1”.
42. Install the oil level gauge “2” and holder

“3”. 1
3
2
1
46. Fill the engine with engine oil. See “Engine

oil replacement” (3-4).
43. Install the engine cover “1”, and then tight- 47. Connect the positive battery lead, and then
en the engine cover screws “2” to the connect the negative battery lead.
specified torque.
1
2
Engine cover screw “2”

5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.
5-16
Muffler
Muffler
20 N·m (2.0 kgf·m, 14.8 lb·ft)
15 N·m (1.5 kgf·m, 11.1 lb·ft)

29 N·m (2.9 kgf·m, 21.4 lb·ft)
3 7
8
12
15
7
13 14
14
9
5
2
6 1
10 2.5 N·m (0.25 kgf·m, 1.84 lb·ft)

200 N·m (20.0 kgf·m, 147.5 lb·ft)
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
5-17
Muffler
Exhaust pipe disassembly
Use heat-resistant gloves. Otherwise,

burns could result. 15°
15°
1. Remove the exhaust pipe “1”.
Heat the area “a” of exhaust pipe “1” to approx- 1

imately 200 C (392 F) using a heat gun.
2
2 15° 15°
a Exhaust pipe wrench “2”

1 90890-06726
Exhaust pipe wrench “2”
YW-06726
Exhaust pipe wrench “2”
90890-06726
Exhaust pipe wrench “2” Exhaust pipe “1”
YW-06726 200 N·m (20.0 kgf·m, 147.5 lb·ft)
T.
R.
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.
5-18
Wire harness
Wire harness
1
3 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)

3
8 UP 5
a
10
9
A
A 8
7
14
13
12
11 15
4 N·m (0.4 kgf·m, 3.0 lb·ft) 16

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 Bolt 1 M6  12 mm
13 Bracket 1
14 Plastic tie 2
15 Plastic tie 1
16 Wire harness 1
5-19
Electrical box
Electrical box
21 25 20
3 18
22 24
SG
21 19
13 5
12 23
17 4 N·m (0.4 kgf·m, 3.0 lb·ft)
14 9 13 26
16 6
10 15
9 12 15 5 N·m (0.5 kgf·m, 3.7 lb·ft)
10 8 11 27
9
11 7
13
2
1
4 5
6 2
3 5 N·m (0.5 kgf·m, 3.7 lb·ft)

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

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
5-21
Electrical box
Starter motor and wire harness re- 1 b a

moval
1. Disconnect the starter motor lead “1” and
negative battery lead “2”, and then remove
the starter motor “3”.
2 c
1
6. Remove the plastic ties “1” and “2”, and

then disconnect the thermo switch coupler
“a”, engine temperature sensor coupler
“b”, intake air pressure sensor coupler “c”,
intake air temperature sensor coupler “d”,
2 cam position sensor coupler “e”, knock
sensor coupler “f”, and ETV coupler “g”.
3 c b 1
f
2. Remove the plastic ties “1”.
3. Disconnect the fuse box couplers “a”, slant

detection switch coupler “b”, starter relay
coupler “c”, ECM couplers “d”, and RiDE a
e
motor couplers “e”.
d
g
a b c d
7. Disconnect the ignition coil couplers “a”

and fuel injector couplers “b”, and then re-
e move the plastic tie “1”.
1 1
4. Remove the holder “1” and grommet “2”, b

a
and then disconnect the earth plate cou-
plers “a”, oil pressure switch coupler “b”,
and stator coil coupler “c”.
5. Remove the holder “3”.
Thermostat check
1. Suspend the thermostat in a container of
water.
5-22
Electrical box
2. Place a thermometer in the water and heat 2. Connect the ETV coupler “a”, knock sen-
the water slowly. sor coupler “b”, cam position sensor cou-
pler “c”, intake air temperature sensor
coupler “d”, intake air pressure sensor
coupler “e”, engine temperature sensor
coupler “f”, and thermo switch coupler “g”,
and then fasten the wire harness using the
plastic ties “1” and “2”.
Fasten the wire harness at the gray tape “h” us-

ing the plastic tie “1”.
3. Measure the thermostat valve opening “a”
at the specified water temperatures. Re- e f 2 b
place if out of specification.
a
g
c
a d
1
h
Water temperature Valve opening “a”
58–62 C 3. Install the plastic tie “1”, and then connect
Starts opening the stator coil coupler “a”, oil pressure
(136–144 F)
switch coupler “b”, and earth plate cou-
above 70 C 4.3 mm (0.17 in) or
plers “c”.
(158 F) above
4. Install the grommet “2” to the stator coil
Starter motor and wire harness instal-
lead and wire harness, and then fasten the
lation grommet “2” using the holder “3”.
1. Fasten the wire harness using the plastic
tie “1”, and then connect the fuel injector 3 b c
couplers “a” and ignition coil couplers “b”.
a
b
2 a
1 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”.
5-23
Electrical box
e d c b
1 1 a
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 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
5-24
Air cooler and supercharger

20 N·m (2.0 kgf·m, 14.8 lb·ft)
20 22
10 N·m (1.0 kgf·m, 7.4 lb·ft) 23
10 N·m (1.0 kgf·m, 7.4 lb·ft) 21
20 N·m (2.0 kgf·m, 14.8 lb·ft)
20 N·m (2.0 kgf·m, 14.8 lb·ft)
4 N·m (0.4 kgf·m, 3.0 lb·ft)

25
26
28 23 N·m (2.3 kgf·m, 17.0 lb·ft) 24
42 N·m (4.2 kgf·m, 31.0 lb·ft)
14
8 7
11 6
27 9
2
6 N·m (0.6 kgf·m, 4.4 lb·ft)
6 15
6 N·m (0.6 kgf·m, 4.4 lb·ft) 19
17 16
1 18
3 42 N·m (4.2 kgf·m, 31.0 lb·ft)
4
6 N·m (0.6 kgf·m, 4.4 lb·ft) 5 10 42 N·m (4.2 kgf·m, 31.0 lb·ft)
12
4
13 23 N·m (2.3 kgf·m, 17.0 lb·ft)
42 N·m (4.2 kgf·m, 31.0 lb·ft)

1 Clamp 1
2 Clamp 1
3 Boost pipe 1
4 Clamp 2
6 Clamp 2
7 Air cooler intake pipe 1
8 Nut 1
9 Bolt 2 M10  45 mm
10 Air cooler 1
11 Collar 1
12 Grommet 1
13 Plate 1
14 Stud bolt 1
15 Bolt 1 M10  50 mm
16 Bolt 1 M10  80 mm
5-25
20 N·m (2.0 kgf·m, 14.8 lb·ft)

20 22
10 N·m (1.0 kgf·m, 7.4 lb·ft) 23
10 N·m (1.0 kgf·m, 7.4 lb·ft) 21
20 N·m (2.0 kgf·m, 14.8 lb·ft)
20 N·m (2.0 kgf·m, 14.8 lb·ft)
4 N·m (0.4 kgf·m, 3.0 lb·ft)

25
26
28 23 N·m (2.3 kgf·m, 17.0 lb·ft) 24
42 N·m (4.2 kgf·m, 31.0 lb·ft)
14
8 7
11 6
27 9
2
6 N·m (0.6 kgf·m, 4.4 lb·ft)
6 15
6 N·m (0.6 kgf·m, 4.4 lb·ft) 19
17 16
1 18
3 42 N·m (4.2 kgf·m, 31.0 lb·ft)
4
12
4
13 23 N·m (2.3 kgf·m, 17.0 lb·ft)
42 N·m (4.2 kgf·m, 31.0 lb·ft)

17 Stay 1
18 Collar 2
19 Grommet 2
20 Bolt 2 M6  65 mm
21 Washer 2
22 Bolt 3 M8  65 mm
23 Bolt 1 M8  65 mm
24 Supercharger 1
25 Bolt 1 M5  9 mm
28 Dowel pin 2
5-26
Intake
Intake
17 20 N·m (2.0 kgf·m, 14.8 lb·ft)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
15
18 20 N·m (2.0 kgf·m, 14.8 lb·ft)
16
13
7 5 10
8
15 14
9 10
19
9
11 20
12
2 4 3
1
10 N·m (1.0 kgf·m, 7.4 lb·ft) 6 26
20 N·m (2.0 kgf·m, 14.8 lb·ft) 11
19 N·m (1.9 kgf·m, 14.0 lb·ft) 22
12
15 N·m (1.5 kgf·m, 11.1 lb·ft)
30 N·m (3.0 kgf·m, 22.1 lb·ft) 21
4 23
15 N·m (1.5 kgf·m, 11.1 lb·ft)
24
30 N·m (3.0 kgf·m, 22.1 lb·ft)
25

1 Holder 1
2 Plastic tie 1
3 Bolt 1 M8  16 mm
4 Bolt 2 M8  20 mm
5 Nut 2
6 Bolt 6 M4  35 mm
7 Intake 1
9 Dowel pin 2
10 Stud bolt 2
11 Bolt 2 M8  25 mm
12 Stay 2
13 Intake air temperature sensor 1
15 Clamp 2
16 Hose 1
5-27
Intake
17 20 N·m (2.0 kgf·m, 14.8 lb·ft)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
15
18 20 N·m (2.0 kgf·m, 14.8 lb·ft)
16
13
7 5 10
8
15 14
9 10
19
9
11 20
12
2 4 3
1
10 N·m (1.0 kgf·m, 7.4 lb·ft) 6 26
20 N·m (2.0 kgf·m, 14.8 lb·ft) 11
19 N·m (1.9 kgf·m, 14.0 lb·ft) 22
12
15 N·m (1.5 kgf·m, 11.1 lb·ft)
30 N·m (3.0 kgf·m, 22.1 lb·ft) 21
4 23
15 N·m (1.5 kgf·m, 11.1 lb·ft)
24
30 N·m (3.0 kgf·m, 22.1 lb·ft)
25

17 Intake air pressure sensor 1
18 Grommet 1
19 Oil level gauge 1
21 Bolt 2 M6  12 mm
22 Oil level pipe 1
23 Clamp 1
24 Oil level pipe plate 1
25 Grommet 1
5-28
ETV and intake manifold
6
A 8
7
3
24 N·m (2.4 kgf·m, 17.7 lb·ft)
2 5
1
13 N·m (1.3 kgf·m, 9.6 lb·ft)

1 Nut 4
2 Washer 4
3 ETV 1
4 Bolt 4 M8  20 mm
5 Joint 1
6 Holder 1
7 Ribbon 1
8 Intake manifold 1
5-29
Air cooler check 2 6

5 6
Do not disassemble the air cooler.

3
1. Connect the hose “1” and special service
tool “2” to the inlet or outlet of the cooling 1 4
water passage. Block the inlet or outlet us- 5
ing the rubber plugs “3”. 3
2. Apply the specified pressure and check

Clamp “5”
that the pressure is maintained. If the
6 N·m (0.6 kgf·m, 4.4 lb·ft)
specified pressure cannot be maintained,
T.
R.
Clamp “6”
replace the air cooler.
6 N·m (0.6 kgf·m, 4.4 lb·ft)
3
Joint 1 “2”
1 6S5-13652-00*1
Air cooler attachment “3”
90890-06731
3 2 Air cooler attachment “3”
YW-06731
Leakage tester “4”
90890-06840
Clamp “6”
Leakage tester “2” 90450-70005*1
90890-06840
*1. Order from Yamaha Parts warehouse.
Water passage holding pressure Air passage holding pressure

200 kPa (2.0 kgf/cm², 29.0 psi) 100 kPa (1.0 kgf/cm², 14.5 psi)
3. Remove any grease from the connections Supercharger check

of the hose “1” and joint 1 “2”.
4. Connect the hose “1”, joint 1 “2”, and spe- Do not disassemble the supercharger.
cial service tools “3” and “4” to the inlet or
outlet of the air cooler passage, and then
tighten the clamps “5” and “6” to the spec- 1. Check the impeller and gear. Replace the
ified torque. supercharger if cracked or worn.
5. Apply the specified pressure and check 2. Check that the supercharger impeller shaft
that the pressure is maintained. If the turns smoothly. Replace the supercharger
specified pressure cannot be maintained, if it does not turn smoothly.
replace the air cooler.
5-30
ETV check 3. Tighten the intake manifold bolts “4” and

nuts “5” to the specified torques in 2 stages
and in the order [1], [2], and so on.
• Do not disassemble the ETV.
• Do not loosen the throttle stop screw nut 4. Tighten the intake manifold stay bolts “2”
or turn the throttle stop screw. and “3” to the specified torques in 2 stag-
• Do not loosen or remove the throttle valve es.
shaft screws.
b
a 1
c
3
2 1
3
4 5
[5] [1] [2] [6]
a. Throttle stop screw nut
b. Throttle stop screw
c. Throttle valve shaft screw
[8] [4] [3] [7]
1. Turn the throttle valve manually and check
that it moves smoothly.
Intake installation
1. Install the dowel pins “1”, a new gasket “2”,
and the intake “3”, and then tighten the in- Intake manifold stay bolt “2” and “3”
take manifold bolts “4” and nuts “5” tempo- 1st: 15 N·m (1.5 kgf·m, 11.1 lb·ft)
T.
rarily.
R.
2nd: 30 N·m (3.0 kgf·m, 22.1 lb·ft)

5 Intake manifold bolt “4”
2 1st: 10 N·m (1.0 kgf·m, 7.4 lb·ft)
2nd: 20 N·m (2.0 kgf·m, 14.8 lb·ft)
Intake manifold nut “5”
1st: 10 N·m (1.0 kgf·m, 7.4 lb·ft)
2nd: 20 N·m (2.0 kgf·m, 14.8 lb·ft)
5. Fasten the ETV lead using the plastic tie

4 3
“1”.
2. Install the stays “1”, and then tighten the in-

take manifold stay bolts “2” and “3” tempo-
rarily.
5-31
2
1
1
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-

met “4”, and a new O-ring “5” onto the oil
level pipe “2”.
2
Make sure that the bottom of the grommet “4”
is at the specified installation distance “a” from 1
the end of the oil level pipe “2”.
Supercharger installation
4 1. Remove the supercharger oil filler hole bolt
3 2 “1” and gasket “2”, and then apply engine
1 oil to the supercharger impeller shaft
through the oil filler hole “a”.
5
a 3
4 Apply engine oil to the supercharger impeller
2
shaft through the oil filler hole “a” while turning
5 the supercharger impeller shaft.
Installation distance “a” (reference 2. Install a new gasket “2”, and then tighten
data) the supercharger oil filler hole bolt “1” to
51.0 mm (2.0 in) the specified torque.
3. Install the oil level pipe onto the cylinder

block, and then tighten the oil level pipe 1
plate bolts “1” and oil level pipe bolt “2” 2
temporarily.
4. Tighten the oil level pipe plate bolts “1”.
5. Tighten the oil level pipe bolt “2”. a
5-32
3
Supercharger oil filler hole bolt “1”
4 N·m (0.4 kgf·m, 3.0 lb·ft)
T.
R.
4
3. Install the dowel pins “1”, a new O-ring “2”,
and the supercharger “3”, and then tighten
the supercharger bolts “4” to the specified
torque.
After installing the supercharger, check that

the supercharger impeller turns smoothly. 2
1
4. Tighten the supercharger bolts “5” to the
specified torque.
Air cooler bolt “3”
5 4 1st: 23 N·m (2.3 kgf·m, 17.0 lb·ft)
T.
R.
2nd: 42 N·m (4.2 kgf·m, 31.0 lb·ft)
Air cooler nut “4”
1st: 23 N·m (2.3 kgf·m, 17.0 lb·ft)
2nd: 42 N·m (4.2 kgf·m, 31.0 lb·ft)
2
3 3. Remove any grease from the connections
of the air cooler intake pipe “1”.
1
4. Install the air cooler intake pipe “1”, and
4 4 then tighten the air cooler intake pipe
clamps “2” to the specified torque.
• Face the arrow “a” of the air cooler intake

pipe “1” upward.
• Check that the air cooler intake pipe “1” con-
5
tacts the protrusion “b” on the air cooler.
• Align the air cooler intake pipe clamps “2”
with the paint marks “c” on the air cooler in-
take pipe “1”.
Supercharger bolt (M8  65 mm) “4”
20 N·m (2.0 kgf·m, 14.8 lb·ft)
T.
R.
Supercharger bolt (M6  65 mm) “5”

10 N·m (1.0 kgf·m, 7.4 lb·ft)
Air cooler, air cooler intake hose, and

boost pipe installation
1. Install the plate “1” and air cooler “2”.
2. Tighten the air cooler bolts “3” and air cool-

er nut “4” alternately in 2 stages to the
specified torque.
5-33
1 2 Boost pipe clamp “1”

6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
b
1
a
Air cooler intake pipe clamp “2”

6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
5. Install the boost pipe, and then tighten the

boost pipe clamps “1” to the specified
torque.
• Fit the lip “a” of the air cooler “2” into the
groove “b” in the boost pipe “3”.
• Fit the lip “c” of the ETV “4” into the groove “d”
in the boost pipe “3”.
3 a
2
1
d
4
3
5-34
Oil cooler and oil pump
11 N·m (1.1 kgf·m, 8.1 lb·ft)
24
23 20
25
18
19
20
19
25 21
26 21 N·m (2.1 kgf·m, 15.5 lb·ft)
1 18 N·m (1.8 kgf·m, 13.3 lb·ft)
26 27
22
17 19 N·m (1.9 kgf·m, 14.0 lb·ft)
2
14 1 LT
572 8
LT
6
572 3
9 4 12 N·m (1.2 kgf·m, 8.9 lb·ft)
10
9
5 LT
16 572
9 11
10
9
11
A 12
14 16
LT
11 7
15 572 LT
12 N·m (1.2 kgf·m, 8.9 lb·ft) 13
572
20 N·m (2.0 kgf·m, 14.8 lb·ft) 7
19 N·m (1.9 kgf·m, 14.0 lb·ft)

1 Clamp 2
3 Clamp 1
4 Plastic tie 1
6 Bolt 1 M8  55 mm
7 Bolt 2 M8  70 mm
8 Oil cooler ASSY 1
10 Connector 2
11 Bolt 7 M6  25 mm
12 Washer 3
13 Bolt 1 M8  25 mm
14 Bolt 4 M6  20 mm
16 Dowel pin 2
5-35
11 N·m (1.1 kgf·m, 8.1 lb·ft)
24
23 20
25
18
19
20
19
25 21
26 21 N·m (2.1 kgf·m, 15.5 lb·ft)
1 18 N·m (1.8 kgf·m, 13.3 lb·ft)
26 27
22
17 19 N·m (1.9 kgf·m, 14.0 lb·ft)
2
14 1 LT
572 8
LT
6
572 3
9 4 12 N·m (1.2 kgf·m, 8.9 lb·ft)
10
9
5 LT
16 572
9 11
10
9
11
A 12
14 16
LT
11 7
15 572 LT
12 N·m (1.2 kgf·m, 8.9 lb·ft) 13
572
20 N·m (2.0 kgf·m, 14.8 lb·ft) 7
19 N·m (1.9 kgf·m, 14.0 lb·ft)

17 Oil filter joint 1
18 Bolt 1 M6  12 mm
19 Bolt 2 M10  22.5 mm
21 Oil pipe 1
22 Bolt 12 M6  20 mm
23 Oil pump 1
25 Dowel pin 2
27 Connector 1
5-36
Idle gear and drive gear
3
5
E
4
3
6
1
E
7
8
80 N·m (8.0 kgf·m, 59.0 lb·ft)

1 Shaft 1
2 Idle gear 1
3 Circlip 2
4 Washer 1
5 Washer 1
6 Collar 1
7 Bolt 1 M12  58 mm, Left-hand threads
8 Drive gear 1
5-37
Oil pump, idle gear, and drive gear re-

moval 1
1. Remove the oil pump.
2. Remove the idle gear. 2 2

3. Hold the drive coupling “1” using the spe-
cial service tool “2”.
4
3

90890-06535
Stopper guide plate “3”
90890-06501
Stopper guide stand “4”
90890-06538
2 1
Oil cooler check
Coupler wrench “2” 1. Connect the hose “1” and special service
90890-06729 tool “2” to the inlet of the oil cooler water
Coupler wrench “2” passage. Block the oil cooler outlet using
YW-06729 the rubber plug “3”.
4. Turn the drive gear bolt “1” clockwise to 2. Apply the specified positive pressure and
loosen it, and then remove the drive gear check that the pressure is maintained. If
bolt “1”. the specified pressure cannot be main-
tained, replace the oil cooler.
3 2
1
1
5. Remove the drive gear “1” using the spe-

cial service tools “2”, “3”, and “4”.
Leakage tester “2”
90890-06840
The special service tools may not always be
necessary to remove the drive gear “1”.
Water passage holding pressure
200 kPa (2.0 kgf/cm², 29.0 psi)
5-38
Oil pump check
Do not disassemble the oil pump. 1
1. Check that the oil pump driven gear turns

smoothly. Replace the oil pump if the
movement is rough. 2
Idle gear check

1. Check the idle gear. Replace the idle gear 2. Hold the holder “1”.
if cracked or worn.
2. Check the shaft. Replace if bent or worn.

1
Drive gear check
Do not disassemble the drive gear.
1. Check the oil pump drive gear “1” and su-

percharger drive gear “2”. Replace the 3. Turn the drive gear bolt “1” counterclock-
drive gear if cracked or worn. wise, and then tighten it to the specified
torque.
2. Hold the oil pump drive gear “1”.
3. Turn the supercharger drive gear “2” clock- 1

wise “a” and check that it turns smoothly.
Replace the drive gear if it does not turn
smoothly.
4. Turn the supercharger drive gear “2” coun-

terclockwise “b” and check that it does not
turn. Replace the drive gear if it turns.
Drive gear bolt “1”

80 N·m (8.0 kgf·m, 59.0 lb·ft)
T.
R.
b 4. Install the idle gear “1”, collar “2”, and shaft

“3”.
1 a
1
2
2
Drive gear, idle gear, and oil pump in-
stallation 3
1. Install the drive gear “1”, and then tighten
the drive gear bolt “2” temporarily.
5-39
5. Fill the oil pump with engine oil through the
feed port “a”.
While turning the oil pump driven gear, make

sure to fill the oil pump with engine oil up to the
brim of the port.

and the oil pump “3”, and then tighten the
oil pump bolts “4” to the specified torque.
1
2
Oil pump bolt “4”

11 N·m (1.1 kgf·m, 8.1 lb·ft)
T.
R.
5-40
Cylinder head cover
Cylinder head cover
1 10 N·m (1.0 kgf·m, 7.4 lb·ft)

6
1 10
4
7 11 5
2
2
7
2
2 3
3 7
3
3
12
25 N·m (2.5 kgf·m, 18.4 lb·ft) 9

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 Clamp 1
7 Bolt 8 M6  30 mm
8 Cylinder head cover 1
10 Oil filler cap 1
12 Timing chain guide 1
5-41
Camshaft
Camshaft
8 8
16 N·m (1.6 kgf·m, 11.8 lb·ft)
8
10
10 13 8
13 8
9 13 8
13 12
21 N·m (2.1 kgf·m, 15.5 lb·ft) 12
13 13
14
16 11 13
17 a
20 N·m (2.0 kgf·m, 14.8 lb·ft) 13
17
10 N·m (1.0 kgf·m, 7.4 lb·ft)
16
15
1
2
3 16
2
4 2 1
20 5 6
18 19 21

1 Bolt 2 M10  22.5 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
15 Exhaust camshaft 1 a: Purple paint
16 Bolt 4 M7  12.5 mm
5-42
Camshaft
8 8
16 N·m (1.6 kgf·m, 11.8 lb·ft)
8
10
10 13 8
13 8
9 13 8
13 12
21 N·m (2.1 kgf·m, 15.5 lb·ft) 12
13 13
14
16 11 13
17 a
20 N·m (2.0 kgf·m, 14.8 lb·ft) 13
17
10 N·m (1.0 kgf·m, 7.4 lb·ft)
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
5-43
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 2 1

plug hole #1.
1 b
3
a
2
#1 #2 #3 #4
Dial gauge set “1”
90890-01252
YU-03097
Coupler wrench “2”
90890-06729
90890-06584
YW-06729
YB-06585
Gauge stand “3” 3. Make marks “a” on the camshaft sprockets
90890-06725 and camshafts.
2. Position piston #1 at TDC by turning the a

drive coupling “1” counterclockwise using
the special service tool “2”, referring to the
dial gauge to ensure that the piston has
reached TDC.
Make sure that the punch marks “a” on the

camshafts are aligned with the marks “b” on
the camshaft caps.
5-44
Camshaft
4. Remove the oil pipe “1”, gaskets “2”, timing
chain tensioner “3”, and gasket “4”.
2 1
2
1
4
2 3
Camshaft wrench “1”
5. Remove the timing chain guide (exhaust 90890-06724
side).
2. Remove the intake camshaft sprocket and
6. Remove the intake camshaft caps and ex- exhaust camshaft sprocket.
haust camshaft caps.
Camshaft check
1. Check the camshaft lobes. Replace if pit-
Loosen the camshaft cap bolts in the opposite ted or scratched.
order used for tightening.
2. Measure the cam lobe height “a”. Replace
if out of specification.
7. Remove the intake camshaft “1” and ex-
haust camshaft “2”.
Fasten the timing chain using a wire “3”.

a
2
1
IN
3
EX Cam lobe height-intake

40.850–40.950 mm (1.6083–
1.6122 in)
Limit
Camshaft sprocket removal 40.750 mm (1.6043 in)
1. Hold the camshaft sprocket using the spe- Cam lobe height-exhaust
cial service tool “1”, and then loosen the 41.048–41.148 mm (1.6161–
camshaft sprocket bolts “2”. 1.6200 in)
Limit
40.948 mm (1.6121 in)
3. Measure the camshaft journal diameter

“a”.
5-45
Camshaft
a 1
2. Place the camshafts on the cylinder head.

Journal diameter
24.960–24.980 mm (0.9827– 3. Put a piece of Plastigauge “1” on each
0.9835 in) camshaft journal, parallel to the camshaft.
4. Measure the camshaft runout. Replace if

out of specification. Do not put the Plastigauge over the oil hole in
the camshaft journal.
Runout
0.015 mm (0.0006 in)
Limit
0.05 mm (0.0020 in)
Camshaft journal oil clearance check

1. Remove the valve lifters “1” and valve
pads “2”.
Write down the position of each valve lifter “1”

and valve pad “2” so that they can be installed
in their original positions.
5-46
Camshaft
4. Install the dowel pins “1”, intake camshaft 6. 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.
When installing the camshaft caps, make sure Do not turn the camshafts when measuring the
that the arrow marks “a” on the camshaft caps camshaft journal oil clearance using the Plasti-
point toward the camshaft sprockets. gauge.
3 IN
3
5 [3]
1 [1] [5] [7] [9] [11]
[4]
5 [2] [6] [8] [10] [12]
2 1
1 [1] [5] [7] [9] [11]
[3]
1 [2] [6] [8] [10] [12]
4 1 [4]
EX 1
1
Camshaft cap bolt “1”

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

IN R IN L IN measure the width of the Plastigauge “1”.
1
a a a
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. Journal oil clearance
0.020–0.061 mm (0.0008–0.0024
in)
Make sure to keep the camshafts level.
Limit
0.08 mm (0.0032 in)
IN
[6] Timing chain tensioner check
[11] [7] [1] [9] [4] 1. While pushing the timing chain tensioner
[8]
[12] [5] [2] [10] [3] rod “a”, turn the timing chain tensioner
[3] housing “b” in direction “c” until the groove
[11] [6] [9] [2]
[7] “d” in the tensioner rod is aligned with the
[12] [8] [10] [1] [4]
[5] snap ring “e”.
EX 1
5-47
Camshaft
2. While squeezing the ends of the snap ring
“e” so that it fits into the groove “d” in the
timing chain tensioner rod “a”, release the a
tensioner rod slowly until it is locked in
place.
Make sure that the timing chain tensioner rod

“a” is locked in place before releasing the snap b
ring “e”.
2. Hold the camshaft sprocket using the spe-
cial service tool “1”, and then tighten the
b camshaft sprocket bolts “2” to the specified
torque.
a
When installing the cam sprocket, first tighten

c the bolt “a” with the punch mark “b”, and then
tighten the bolt “c”.
e
2
e
d
b
3. Push the timing chain tensioner rod slight-
a
ly. Check that the snap ring releases the
timing chain tensioner rod, allowing the
tensioner rod to pop out.
Camshaft sprocket installation

1. Install the exhaust camshaft sprocket and
intake camshaft sprocket.
c
• Install each camshaft sprocket with the Camshaft wrench “1”

punch mark “a” facing outward. 90890-06724
• When installing an original camshaft sprock-
et, make sure to align the marks “b” made
during removal. Camshaft sprocket bolt “2”
21 N·m (2.1 kgf·m, 15.5 lb·ft)
T.
R.
Camshaft installation
1. Position piston #1 at TDC. See “Camshaft
removal” (5-44).
5-48
Camshaft
2. Install the valve pads “1” and valve lifters
“2” in their original positions. IN EX
2
b
1
5. Install the dowel pins “1”, intake camshaft

caps “2” and “3”, and exhaust camshaft
3. Install the timing chain guide (exhaust caps “4” and “5”.
side).
4. Install the exhaust camshaft “1”, intake When installing the camshaft caps, make sure
camshaft “2”, and timing chain “3”. that the arrow marks “a” on the camshaft caps
point toward the camshaft sprockets.
• Make sure that the punch marks “a” on the 3

camshafts are facing up. 3
5
• Make sure that the exhaust side “b” of the
1
timing chain is taut.
5
2 1
1
IN 1 1 4 1
2
3 1
EX
IN R IN L IN
IN a
a a a
EX EX R EX L
EX a 6. Tighten the camshaft cap bolts “1” until

camshaft caps contact the cylinder head in
the order [1], [2], and so on.
Make sure to keep the camshafts level.
5-49
Camshaft
10. While squeezing the ends of the snap ring
IN “e” so that it fits into the groove “d” in the
[6] timing chain tensioner rod “a”, release the
[7] [1] [9] [4]
[11]
[8] tensioner rod slowly until it is locked in
[12] [5] [2] [10] [3] place.
[11] [6] [9] [2] [3]
[7]
[12] [8] [10] [1] [4] b
[5]
EX 1
a
7. Tighten the camshaft cap bolts “1” to the
specified torque in the order [1], [2], and so c
on.
IN
[3]
[1] [5] [7] [9] [11]
[4]
[2] [6] [8] [10] [12]
[1] [5] [7] [9] [11]

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

16 N·m (1.6 kgf·m, 11.8 lb·ft) 11. Install a new gasket “1” and the timing
T.
R.
chain tensioner “2” onto the cylinder head,

8. Align the punch marks “a” on the cam- and then tighten the timing chain tensioner
shafts with the marks “b” on the camshaft bolts “3” temporarily.
caps.
12. Install new gaskets “4” and the oil pipe “5”
to the cylinder head and timing chain ten-
b sioner “2”, and then tighten the oil pipe
a bolts “6” temporarily.
13. Tighten the timing chain tensioner bolts “3”

to the specified torque.
14. Tighten the oil pipe bolts “6” to the speci-

fied torque.
#1 #2 #3 #4
6
9. While pushing the timing chain tensioner 3
rod “a”, turn the timing chain tensioner
housing “b” in direction “c” until the groove 5 2
“d” in the tensioner rod is aligned with the 1
snap ring “e”. 4 3
5-50
Camshaft
3. Remove the valve lifters “1” and valve
Timing chain tensioner bolt “3” pads “2”.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
Oil pipe bolt “6”

20 N·m (2.0 kgf·m, 14.8 lb·ft) Write down the position of each valve lifter “1”
and valve pad “2” so that they can be installed
15. Turn the drive coupling “1” counterclock- in their original positions.
wise 2 full turns, and then check that the
camshaft turns smoothly. 1
2
Check that the portion “a” of the timing chain is
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.
4. Check the valve pad number “a”.
The thickness of each valve pad is marked in

hundredths of millimeters on the side that con-
tacts the valve lifter.
2 1
a
148
5. Round off the original valve pad number

according to the following table.
90890-06729 Last digit Rounded value
Coupler wrench “2” 0, 1, 2 0
YW-06729 4, 5, 6 5
16. Position piston #1 at TDC. See “Camshaft 8, 9 10

removal” (5-44).
6. Select the new valve pad number from the
“Valve pad selection table” (5-53).
Valve clearance adjustment
1. Measure the valve clearances. See “Valve
clearance measurement” (3-12). The valve pads are available in 23 thickness-
es, ranging from 1.20 mm to 2.30 mm in 0.05
2. Remove the camshaft caps and cam-
mm increments.
shafts. See “Camshaft removal” (5-44).
5-51
Camshaft
7. Install the selected valve pad “1” and valve
lifter “2”. Dial gauge set “1”
90890-01252
2
1 YU-03097
90890-06584
YB-06585
Gauge stand “3”
90890-06725
8. Turn the valve lifter and check that it turns 12. Position piston #4 at TDC by turning the
smoothly. drive coupling “1” 360 counterclockwise
using the special service tool “2”.
9. Position piston #1 at TDC, and then install
the camshafts and camshaft caps. See
“Camshaft installation” (5-48).

2 1

90890-06729
YW-06729

#1 #2 #3 #4
IN  —  —
#1 #2 #3 #4
EX   — —
IN —  — 
EX — —  
—: Not applicable
11. Install the special service tools into spark —: Not applicable
plug hole #4.
1
3
2
5-52
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
0.00–0.03 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.04–0.08 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.09–0.13 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.14–0.23 Standard clearance
0.24–0.28 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.29–0.33 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.34–0.38 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.39–0.43 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.44–0.48 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.49–0.53 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.54–0.58 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.59–0.63 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.64–0.68 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.69–0.73 170 175 180 185 190 195 200 205 210 215 220 225 230
0.74–0.78 175 180 185 190 195 200 205 210 215 220 225 230
0.79–0.83 180 185 190 195 200 205 210 215 220 225 230
0.84–0.88 185 190 195 200 205 210 215 220 225 230
0.89–0.93 190 195 200 205 210 215 220 225 230
0.94–0.98 195 200 205 210 215 220 225 230
0.99–1.03 200 205 210 215 220 225 230
1.04–1.08 205 210 215 220 225 230
1.09–1.13 210 215 220 225 230
1.14–1.18 215 220 225 230
1.19–1.23 220 225 230
1.24–1.28 225 230
1.29–1.33 230
Example:
Measured valve clearance is 0.31 mm (0.0122 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)
5-53
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
0.00–0.00 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190
0.01–0.05 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195
0.06–0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
0.11–0.15 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205
0.16–0.20 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210
0.21–0.25 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.26–0.30 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.31–0.35 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.36–0.45 Standard clearance
0.46–0.50 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.51–0.55 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.56–0.60 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.61–0.65 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.66–0.70 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.71–0.75 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.76–0.80 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.81–0.85 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.86–0.90 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.91–0.95 170 175 180 185 190 195 200 205 210 215 220 225 230
0.96–1.00 175 180 185 190 195 200 205 210 215 220 225 230
1.01–1.05 180 185 190 195 200 205 210 215 220 225 230
1.06–1.10 185 190 195 200 205 210 215 220 225 230
1.11–1.15 190 195 200 205 210 215 220 225 230
1.16–1.20 195 200 205 210 215 220 225 230
1.21–1.25 200 205 210 215 220 225 230
1.26–1.30 205 210 215 220 225 230
1.31–1.35 210 215 220 225 230
1.36–1.40 215 220 225 230
1.41–1.45 220 225 230
1.46–1.50 225 230
1.51–1.55 230
Example:
Measured valve clearance is 0.58 mm (0.0228 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)
5-54
Cylinder head
Cylinder head
2
7 8
55 N·m (5.5 kgf·m, 40.6 lb·ft)
90
3
10 N·m (1.0 kgf·m, 7.4 lb·ft) 2
3
8
1
7
4
12 N·m (1.2 kgf·m, 8.9 lb·ft)

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 4 M6  12 mm
8 Engine hanger 2
5-55
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
5-56
Cylinder head disassembly

1. Remove the valve lifters “1” and valve Valve spring compressor “1”
pads “2”. 90890-04019
Valve spring compressor “1”
YM-04019
Write down the position of each valve lifter “1” Valve spring compressor attach-
and valve pad “2” so that they can be installed ment “2”
in their original positions. 90890-04114
Compressor adapter “2”
1 YM-04114
2
3. Remove the valve seals.
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.
2. Remove the intake valves and exhaust
valves. 3. Check the cylinder head warpage using a
straightedge “1” and thickness gauge “2” in
the directions shown. Replace if out of
Write down the position of each valve, spring, specification.
and other parts so that they can be installed in
their original positions.
1
2
Warpage limit
0.100 mm (0.0039 in)
5-57
Valve spring check

1. Measure the valve spring free length “a”. Face width-intake
Replace if out of specification. 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
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
out of specification. in)
Margin thickness-exhaust
a 0.800–1.200 mm (0.0315–0.0472
in)
3. Measure the valve stem diameter “a”. Re-

Tilt limit-intake
2.5 /2.0 mm
Tilt limit-exhaust
2.5 /2.0 mm
Valve check
1. Measure the valve face width “a”. Diameter-intake
5.477–5.492 mm (0.2156–0.2162
a
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)
5-58
4. Measure the valve stem runout. Replace if
out of specification. Valve-stem-to-valve-guide clear-
ance = valve guide inside diameter –
valve stem diameter
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
0.010 mm (0.0004 in)
Valve guide removal
Valve guide check 1. Insert the special service tool “1” into the
1. Measure the valve guide inside diameter combustion chamber side of the valve
“a”. guide “2”.
2. Strike the special service tool “1” to drive

the valve guide “2” out of the cylinder
head.
a
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 Valve guide remover/installer “1”
in) 90890-06801
Valve guide remover “1”
2. Calculate the valve-stem-to-valve-guide YB-06801
clearance. Replace the valve and valve
guide if out of specification. Valve guide installation
1. Insert the special service tools “1” and “2”
into the camshaft side of the valve guide
“3”.
Do not reuse a valve guide, always replace

it with a new one.
2. Strike the special service tool “1” to drive

the valve guide “3” into the cylinder head.
5-59
4. Clean the valve guide inner surface. Mea-
1 sure the valve guide inside diameter “a”.
a
a
3
a. Valve guide installation height
Valve guide remover/installer “1”

Inside diameter-intake
90890-06801
5.504–5.522 mm (0.2167–0.2174
Valve guide remover “1”
in)
YB-06801
Inside diameter-exhaust
Valve guide installer “2”
5.504–5.522 mm (0.2167–0.2174
90890-06810
in)
Valve guide installer “2”
YB-06810
Valve seat check
1. Remove carbon deposits from the valves
Valve guide installation height and valve seats.
12.3–12.7 mm (0.48–0.50 in)
2. Apply a thin, even layer of blue layout fluid
3. Insert the special service tool “1” into the (Dykem) onto the valve seat.
valve guide “2”, and then ream the valve
3. Press the valve lightly against the valve
guide “2”.
seat using the special service tool “1”.
• Turn the special service tool “1” clockwise to 1

ream the valve guide “2”.
• Do not turn the special service tool “1” coun-
terclockwise when removing the tool.
2 Valve lapper “1”

90890-04101
Valve lapping tool “1”
YM-A8998
Valve guide reamer “1”

90890-06804
Valve guide reamer “1”
YM-01196
5-60
4. Measure the valve seat contact width “a” 1. Reface the valve seat.
where the blueing dye is adhered to the A
valve face. Reface the valve seat if the
valve is not seated properly or if the valve 30 45 60
seat contact width “a” is out of specifica-
tion. Replace the valve guide if the valve
seat contact width “a” is uneven. B
30 45 60
30
a 45
A. Worldwide
Valve seat cutter holder

90890-06812
Intake:
Valve seat cutter 30
90890-06720
90890-06325
90890-06324
Exhaust:
90890-06818
Seat contact width-intake 90890-06555
1.400–1.600 mm (0.0551–0.0630 Valve seat cutter 60
in) 90890-06323
Limit Neway valve seat kit
2.100 mm (0.0827 in) YB-91044
Seat contact width-exhaust
1.500–1.700 mm (0.0591–0.0669 2. Cut the surface of the valve seat using a
in) 45 cutter by turning the cutter clockwise
Limit until the valve seat face has become
2.200 mm (0.0866 in) smooth.
Valve seat refacing

Do not overcut the valve seat. To prevent
chatter marks, make sure to turn the cutter
After every lapping procedure, make sure evenly using a downward force of 40–50 N
to clean off any remaining lapping com- (4.0–5.0 kgf, 8.8–11.0 lbf).
pound from the cylinder head and valves.
5-61
5. Adjust the valve seat contact width to
specification using a 45 cutter.
a
b
45
45
a a. Previous contact width
b. Specified contact width
6. Check the valve seat contact area of the

valve “Valve seat check” (5-60).
Example:
• If the valve seat contact area is too wide
and situated in the center of the valve face,
a. Slag or rough surface cut the top edge of the valve seat using a
30 cutter, and then cut the bottom edge
3. Adjust the top edge of the valve seat con- using a 60 cutter to center the area and
tact width using a 30 cutter. set its width.
30 30
a a
60
a. Previous contact width a. Previous contact width

4. Adjust the bottom edge of the valve seat
contact width using a 60 cutter.
60
a. Previous contact width
5-62
• If the valve seat contact area is too narrow
and situated near the top edge of the valve
1
face, cut the top edge of the valve seat us-
ing a 30 cutter to center the area, and
then set its width using a 45 cutter.
30
a
Valve lapper “1”

90890-04101
Valve lapping tool “1”
YM-A8998
a. Previous contact width
8. Recheck the valve seat contact area of the
• If the valve seat contact area is too narrow
valve. See “Valve seat check” (5-60).
and situated near the bottom edge of the
valve face, cut the bottom edge of the Cylinder head assembly
valve seat using a 60 cutter to center the 1. Install a new valve seal.
area, and then set its width using a 45 cut-
ter. 2. Install the valve “1”, valve spring seat “2”,
valve spring “3”, and valve spring retainer
“4” in this order, and then install the special
a service tools “5” and “6”.
• When installing a new valve, always replace

the valve guide with a new one.
60 • Install the valve spring “3” with the larger
pitch “a” toward the camshaft and the smaller
pitch “b” toward the combustion chamber.
a. Previous contact width • The upper end “c” of the valve spring “3” with
the larger pitch “a” is painted red.
7. After refacing the valve seat to the speci-
fied contact width, apply a thin, even layer
of lapping compound onto the valve seat,
and then lap the valve using the special
service tool “1”.
Do not get the lapping compound on the

valve stem and valve guide.
5-63
4. Tap the valve spring retainer lightly using a
4 plastic hammer to seat the valve cotters
3 “1” securely.
2 6
5
1 1
1
a
3
5. Install the valve pads “1” and valve lifters
“2” in their original positions.
b 2
1
90890-04019
YM-04019
Valve spring compressor attach-
ment “6”
90890-04114
Cylinder head installation
Compressor adapter “6”
YM-04114
the cylinder head ASSY “3”, the washers
3. Compress the valve spring, and then in- “4”, and the cylinder head bolts “5”, and
stall the valve cotters “1”. then tighten the cylinder head bolts “5” to
the specified torques in 2 stages and in the
order [1], [2], and so on.
1
5-64
2. Install the cylinder head bolts “6”, and then
tighten them to the specified torque.
5
4
6
2
1
5 5 5
[10] [6] [2] [3] [7]
[9] [5] [1] [4] [8]

5 5 5
Cylinder head bolt “5” (M12)

1st: 55 N·m (5.5 kgf·m, 40.6 lb·ft)
T.
R.
2nd: 90
Cylinder head bolt “6” (M6)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
5-65
Generator cover ASSY and flywheel magneto
12
7
11
6
4 10
8 19
7
3 6
1 5
2
26 N·m (2.6 kgf·m, 19.2 lb·ft)

250 N·m (25.0 kgf·m, 184.4 lb·ft) 10
80 N·m (8.0 kgf·m, 59.0 lb·ft)
17
24 N·m (2.4 kgf·m, 17.7 lb·ft)
18 9
15
14 16
15
13 60
250 N·m (25.0 kgf·m, 184.4 lb·ft)

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
5-66
12
7
11
6
4 10
8 19
7
3 6
1 5
2
26 N·m (2.6 kgf·m, 19.2 lb·ft)

250 N·m (25.0 kgf·m, 184.4 lb·ft) 10
80 N·m (8.0 kgf·m, 59.0 lb·ft)
17
24 N·m (2.4 kgf·m, 17.7 lb·ft)
18 9
15
14 16
15
13 60
250 N·m (25.0 kgf·m, 184.4 lb·ft)

17 Starter clutch 1
18 Starter gear 1
19 Woodruff key 1 Not reusable
5-67
Generator cover
Generator cover
8
15 N·m (1.5 kgf·m, 11.1 lb·ft)
15 N·m (1.5 kgf·m, 11.1 lb·ft)
2 9
10
5
4
11
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
5-68
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 wiring har-

ness when using the heat gun. 2
4 3
3 4 1
1 3
2
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
Use heat-resistant gloves. Otherwise,
3
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

90890-06729
YW-06729
5-69
Generator cover
4. Hold the flywheel magneto “1” using the
2 special service tools “2” and “3”, and then
remove the transfer shaft “4” using the
special service tool “5”.
3
1
5

special service tools “2” and “3”, and then 4 2 1
loosen the special nut “4”.
2
5 4
• Loosen the special nut “4” until it can no lon-
ger be turned.
• Use a width across flats 12 mm hexagon bit
socket “5” with a length of 150 mm (5.91 in)
or more.
1
Shaft holder “2”

3
90890-06721
5 Shaft holder “2”
YW-06721
Drive handle “3”
2 1 90890-06722
2 YW-06722
5 4 Crankshaft holder “5”
90890-06732
Crankshaft holder “5”
YW-06562
5. Remove the flywheel magneto “1” and

1
Woodruff key using the special service
tools “2” and “3”.
Shaft holder “2” 1

90890-06721
YW-06721 3
90890-06722
YW-06722
5-70
Generator cover
Flywheel puller “2” 1

90890-06723
2
Flywheel puller “2”
YW-06723
Rotor puller “3”
90890-01080
Stator rotor puller “3”
YM-01080-A
6. Hold the flywheel magneto “1” using the 3. Remove the ball bearing “1”.
special service tool “2”, and then loosen
A
the starter clutch bolts “3”.
1 2
1 3
3
3
2
3
1 4
Sheave holder “2”
5
90890-01701
Primary sheave holder “2”
YS-01880-A
7. Remove the starter clutch.
Generator cover ASSY disassembly A. Worldwide

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

3 90890-06606
Bearing outer race attachment “3”
90890-06627
Driver handle (small) “4”
4 YB-06229
Bearing and seal installer “5”
YW-06356
1
Starter clutch operation check
1. Install the starter clutch “1” onto the starter
gear “2” and hold the starter clutch “1”.
2
2. Turn the starter gear “2” clockwise “a” and
2. Remove the oil seal “1” and circlip “2”. check that it turns smoothly. Replace if it
does not turn smoothly.
5-71
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
B 1
4
5 A
E
A. Worldwide
Bearing pressure C “2”

A. Worldwide 90890-02393
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
Driver handle (large) “4”
YB-06071
Forward gear outer race installer
“5”
YB-41446
2. Install the circlip “1”.
5-72
Generator cover
4. Install the stator coil “1”, holder “2”, pickup
3
coil “3”, and washer “4”, and then tighten
the holder bolts “5” and stator coil bolts “6” 3 1
to the specified torques.
2
Pass the pickup coil lead “a” between the gen-
erator cover and the bolt hole “b”, and then se- 3
cure the lead by installing the washer “4”.
6
Sheave holder “2”
6
5 90890-01701
1 Primary sheave holder “2”
YS-01880-A
3
a 3 Flywheel magneto bolt “3”
b 24 N·m (2.4 kgf·m, 17.7 lb·ft)
2 T.
R.
3. Install the flywheel magneto “1” to the

starter gear “2”.
4
Turn the starter gear “2” clockwise while install-
Holder bolt “5” ing it onto the flywheel magneto “1”.
15 N·m (1.5 kgf·m, 11.1 lb·ft)
T.
R.
Stator coil bolt “6”

15 N·m (1.5 kgf·m, 11.1 lb·ft)
2
Flywheel magneto assembly
1. Install the starter clutch “1” to a new fly-
wheel magneto “2”.
1
1
Flywheel magneto installation
Do not reuse a flywheel magneto, special

2 nut, flywheel magneto bolt, transfer shaft,
or Woodruff key, always replace it with a
2. Hold the flywheel magneto “1” using the new one.
special service tool “2”, and then tighten
new flywheel magneto bolts “3” to the 1. Remove any grease from a new special
specified torque. 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.
5-73
Generator cover
2 1 1
2
4
5
1
3
2
2. Clean the tapered portion “a” of the crank- 1

2
shaft and inner surface “b” of the flywheel 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 Drive handle “3”
90890-06722
YW-06722
1 90890-06732
4. Install the transfer shaft “1”. YW-06562
A
Transfer shaft “4”
50 N·m (5.0 kgf·m, 36.9 lb·ft)
T.
R.
6. Using the hexagonal portion of the special

service tool “1” as reference, make marks
1 on the special service tool “2” at 0, 60,
and 120.

special service tools “2” and “3”, and then
tighten the transfer shaft “4” to the speci-
fied torque using the special service tool
“5”.
5-74
Generator cover
7. Make a mark “a” on the transfer shaft “3”
where the shaft is aligned with the 0 mark 4
on the special service tool “2”. 60°
The angle from one corner of the hexagonal

head of the special service tool “1” to another
corner is 60.
5
3 a
0° Shaft holder “2”
2 60° 90890-06721
120° YW-06721
60° Drive handle “3”
1 90890-06722
YW-06722
Crankshaft holder “1” Crankshaft holder “5”
90890-06732 90890-06732
Crankshaft holder “1” Crankshaft holder “5”
YW-06562 YW-06562
90890-06721 Transfer shaft “4”
Shaft holder “2” 60
T.
YW-06721
R.
9. Tighten the transfer shaft “1” to the speci-

fied torque using the special service tool
special service tools “2” and “3”, and then
“2”.
tighten the transfer shaft “4” to the speci-
fied angle using the special service tool 10. Check that the mark “a” on the transfer
“5”. shaft is positioned between the 60 mark
1 and the 120 mark on the special service
tool.
2
4
5 If the mark on the transfer shaft passes
over the 120 mark on the special service
tool, repeat the procedure from step 1. The
3
flywheel magneto may not have been in-
stalled properly.
5-75
Generator cover
1 a 1
60° 2
4
3 5
OK
3
120°
2
Crankshaft holder “2” 2

90890-06732 5
YW-06562
90890-06721 1
YW-06721
Drive handle “4” Shaft holder “2”
90890-06722 90890-06721
Drive handle “4” Shaft holder “2”
YW-06722 YW-06721
90890-06722
Transfer shaft “1”
250 N·m (25.0 kgf·m, 184.4 lb·ft)
YW-06722
T.
R.

special service tools “2” and “3”, and then Special nut “4”
tighten the special nut “4” to the specified 250 N·m (25.0 kgf·m, 184.4 lb·ft)
T.
R.
torque.
12. Install the idle gear.
After tightening, do not operate the engine

at a speed higher than idling speed for 24
hours.
Use a width across flats 12 mm hexagon bit

socket “5” with a length of 150 mm (5.91 in) or
more.
5-76
Generator cover
and the generator cover “3”, and then tight- 2
en the generator cover ASSY bolts “4” to 3
the specified torque. 1
3 2
1
1
Generator cover ASSY bolt “4” Crankshaft holder “1”

26 N·m (2.6 kgf·m, 19.2 lb·ft) 90890-06732
T.
R.

Drive coupling installation YW-06562
1. Remove any grease from the threaded Coupler wrench “3”
portion of the transfer shaft, making sure 90890-06729
that the threads are clean and dry. Coupler wrench “3”
YW-06729
2. Install a new washer “1” and the drive cou-
pling “2”.
Drive coupling “2”
250 N·m (25.0 kgf·m, 184.4 lb·ft)
T.
R.
Do not reuse a washer, always replace it

with a new one. 4. Remove any grease from the threaded
portion of the holder “1”.
5. Install the holder “1”.

2 1
1
3. Hold the transfer shaft using the special
service tool “1”, and then tighten the drive
coupling “2” to the specified torque using 6. Hold the drive coupling “1” using the spe-
the special service tool “3”. cial service tool “2”, and then turn the hold-
er “3” counterclockwise to tighten it to the
specified torque.
5-77
Generator cover
After tightening, do not operate the engine

at a speed higher than idling speed for 24
hours.
2 1

90890-06729
YW-06729
Holder “3”
80 N·m (8.0 kgf·m, 59.0 lb·ft)
T.
R.
5-78
Cylinder block and electrical part
1 5
2 4
3 7 6
2
17 6
18
14 24 N·m (2.4 kgf·m, 17.7 lb·ft)
13
12
11 9
10
16
15
15 N·m (1.5 kgf·m, 11.1 lb·ft)
20 N·m (2.0 kgf·m, 14.8 lb·ft) 8

1 Clamp 1
2 Bolt 2 M4  9 mm
3 Earth plate 1
5 Oil return hose 1
6 Bolt 2 M6  16 mm
7 Thermo switch 1
8 Bolt 1 M8  40 mm
9 Anode ASSY 1
10 Bolt 1 M6  20 mm
12 Cover 1
13 Grommet 1
14 Anode 1
15 Engine temperature sensor 1
5-79
1 5
2 4
3 7 6
2
17 6
18
14 24 N·m (2.4 kgf·m, 17.7 lb·ft)
13
12
11 9
10
16
15
15 N·m (1.5 kgf·m, 11.1 lb·ft)
20 N·m (2.0 kgf·m, 14.8 lb·ft) 8

17 Holder 1
18 Knock sensor 1
5-80
Oil separator tank and oil pan

10 N·m (1.0 kgf·m, 7.4 lb·ft)
9 8
5
10 7
4 3
6
2 13
14
9 N·m (0.9 kgf·m, 6.6 lb·ft) 1

2 N·m (0.2 kgf·m, 1.5 lb·ft)
12 N·m (1.2 kgf·m, 8.9 lb·ft) 11

11
12
20
19 12
11
27 11
18 28
17
18 20 N·m (2.0 kgf·m, 14.8 lb·ft)
21
0.3 N·m (0.03 kgf·m, 0.22 lb·ft)
12 N·m (1.2 kgf·m, 8.9 lb·ft)
16
24
9 N·m (0.9 kgf·m, 6.6 lb·ft)
26
25
22 23 A
15 10 N·m (1.0 kgf·m, 7.4 lb·ft) A

1 Bolt 1 M4  8 mm
2 Oil pressure switch 1
3 Plastic tie 1
4 Clamp 1
6 Clamp 1
7 Breather hose 1
8 Bolt 9 M6  35 mm
9 Water jacket cover 1
11 Bolt 9 M6  20 mm
12 Bolt 2 M6  14 mm
13 Oil separator tank cover 1
15 Bolt 17 M6  35 mm
16 Bolt 1 M6  20 mm
5-81
10 N·m (1.0 kgf·m, 7.4 lb·ft)
9 8
5
10 7
4 3
6
2 13
14
9 N·m (0.9 kgf·m, 6.6 lb·ft) 1

2 N·m (0.2 kgf·m, 1.5 lb·ft)
12 N·m (1.2 kgf·m, 8.9 lb·ft) 11

11
12
20
19 12
11
27 11
18 28
17
18 20 N·m (2.0 kgf·m, 14.8 lb·ft)
21
0.3 N·m (0.03 kgf·m, 0.22 lb·ft)
12 N·m (1.2 kgf·m, 8.9 lb·ft)
16
24
9 N·m (0.9 kgf·m, 6.6 lb·ft)
26
25
22 23 A
15 10 N·m (1.0 kgf·m, 7.4 lb·ft) A

17 Oil pan 1
18 Dowel pin 2
19 Bolt 6 M6  14 mm
20 Baffle plate 1
21 Bolt 1 M6  14 mm
22 Bolt 2 M6  60 mm
23 Washer 2
24 Oil pipe 1
26 Grommet 1
27 Oil pan plug 1 M8  20 mm
5-82
Anode check
1. Check the anode. Replace if eroded. Oil pipe bolt “1”
Clean if there is grease, oil, or scales. 1st: 0.3 N·m (0.03 kgf·m, 0.22
T.
R.
lb·ft)
2nd: 12 N·m (1.2 kgf·m, 8.9 lb·ft)
Do not apply grease, oil, or paint to the an- Oil pipe stay bolt “2”
ode. 9 N·m (0.9 kgf·m, 6.6 lb·ft)
5. Install the baffle plate “1”, and then tighten

Oil pan assembly the baffle plate bolts “2” to the specified
1. Install the grommet “1” onto the oil pipe “2”.
torque.
2. Install a new gasket “3”, the oil pipe “2”,
6. Install a new gasket “3” and the oil pan
and the washers “4”, and then tighten the
plug “4”, and then tighten the oil pan plug
oil pipe stay bolts “5” temporarily.
“4” to the specified torque.
2
2
3
1
1 3
4
Baffle plate bolt “2”

5 4 12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
Oil pan plug “4”

3. Tighten the oil pipe bolt “1” to the specified 20 N·m (2.0 kgf·m, 14.8 lb·ft)
torque for the 1st stage.
Oil separator tank cover installation
4. Tighten the oil pipe stay bolts “2” to the 1. Install a new gasket “1” and the oil separa-
specified torque, and then tighten the oil tor tank cover “2”, and then tighten the oil
pipe bolt “1” to the specified torque for the separator tank cover bolts “3” and “4” in the
2nd stage. order [1], [2], and so on.
1 2
3
4
5-83
3 [4] [1] 4 [5] [6] 4 [10]

[9]
[8] 4 [3] 4 [2] [7] 4 [11]
5-84
Crankcase, connecting rod, and piston
1T
7 10
2T 50 N·m (5.0 kgf·m, 36.9 lb·ft)
12
9 11 16
8 15 17
7 5
Y
12
51 N·m (5.1 kgf·m, 37.6 lb·ft) 12 12
6
90° 12
12 3
4 13
6 14
21 17
18
15
2
15 17
15
20
19
15 17 15 1
16
10 N·m (1.0 kgf·m, 7.4 lb·ft)
18 15
30 N·m (3.0 kgf·m, 22.1 lb·ft)
10 N·m (1.0 kgf·m, 7.4 lb·ft) 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
5-85
1T
7 10
2T 50 N·m (5.0 kgf·m, 36.9 lb·ft)
12
9 11 16
8 15 17
7 5
Y
12
51 N·m (5.1 kgf·m, 37.6 lb·ft) 12 12
6
90° 12
12 3
4 13
6 14
21 17
18
15
2
15 17
15
20
19
15 17 15 1
16
10 N·m (1.0 kgf·m, 7.4 lb·ft)
18 15
30 N·m (3.0 kgf·m, 22.1 lb·ft)
10 N·m (1.0 kgf·m, 7.4 lb·ft) 90°

17 Dowel pin 8
18 Bracket 2
19 Bolt 1 M6  12 mm
20 Baffle plate 1
21 Cylinder block 1
5-86
Crankcase disassembly
1. Place the crankcase upside down on a
bench. For reference during installation, make identifi-
cation marks “a” on the connecting rod cap,
2. Remove the crankcase “1”. connecting rod, connecting rod bearings, and
piston crown.
• Loosen the crankcase bolts in the opposite

order used for tightening.
1
• The numbers embossed on the crankcase a
indicate the crankcase tightening order.
• 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”.
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”.
5-87
Cylinder block check

1. Measure the cylinder bore (D1–D6) at
measuring points “a”, “b”, and “c”, and in When measuring the piston pin boss inside di-
direction “d” (D1, D3, D5), which is parallel ameter “a”, do not measure it at the oil grooves
to the crankshaft, and direction “e” (D2, “b” or piston pin slot “c”.
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–
a. 20 mm (0.79 in) 0.8667 in)
b. 50 mm (1.97 in) Limit
c. 80 mm (3.15 in) 22.045 mm (0.8679 in)
Bore size
Piston clearance check
86.000–86.015 mm (3.3858– 1. Measure the piston diameter. See “Piston
check” (5-88).
3.3864 in)
Limit
2. Measure the cylinder bore. See “Cylinder
86.100 mm (3.3898 in)
block check” (5-88).
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
b
bore – piston outside diameter
Piston clearance
0.080–0.090 mm (0.0032–0.0035
in)
Limit
0.200 mm (0.0079 in)
Diameter
85.915–85.930 mm (3.3825–
3.3831 in)
Measuring point
10.0 mm (0.39 in)
2. Measure the piston pin boss bore diameter

“a”. Replace if out of specification.
5-88
Piston ring check

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

specified measuring point “b”. a. Ring groove (Top)
b. Ring groove (2nd)
c. Ring groove (Oil)
5-89
Piston pin check

Ring groove (Top ring) 1. Measure the piston pin outside diameter
1.210–1.240 mm (0.0476–0.0488 “a” at measuring points “b”, “c”, and “d”,
in) and in directions “e” and “f”. Replace if out
Ring groove (2nd ring) of specification.
1.210–1.230 mm (0.0476–0.0484
in) a
Ring groove (Oil ring)
2.510–2.530 mm (0.0988–0.0996
in)
4. Measure the piston ring side clearance.

Replace the piston and piston rings as a
set if out of specification.
a b
e
b c
f
d
c
a. Top ring side clearance Outside diameter

b. 2nd ring side clearance 21.991–22.000 mm (0.8658–
c. Oil ring side clearance 0.8661 in)
Limit
Top ring 21.981 mm (0.8654 in)
Side clearance
0.020–0.070 mm (0.0008–0.0028 Connecting rod check
in) 1. Measure the connecting rod small end in-
Limit side diameter “a”. Replace if out of specifi-
0.120 mm (0.0047 in) cation.
2nd ring
Side clearance
0.020–0.060 mm (0.0008–0.0024
in)
a
Limit
0.120 mm (0.0047 in)
Oil ring
Side clearance
0.040–0.160 mm (0.0016–0.0063
in)
Small end inside diameter
22.015–22.028 mm (0.8667–
0.8672 in)
5-90
Crankshaft check Crankshaft pin oil clearance check

1. Measure the crankshaft journal diameter 1. Clean the connecting rod bearings “1” and
“a” and crankshaft pin diameter “b”. Re- 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”.
• Install the connecting rod bearings “1” in their

original positions.
• Fit the protrusion “a” on each bearing into the
a slots “b” in the connecting rod cap “3” and
connecting rod “2”.
1
b
2
b
b a
3
Journal diameter 3. Put a piece of Plastigauge “1” on the

39.976–40.000 mm (1.5739– crankshaft pin, parallel to the crankshaft.
1.5748 in)
Pin diameter
Do not put the Plastigauge “1” over the oil hole
41.976–42.000 mm (1.6526–
in the crankshaft pin.
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

bolts with molybdenum disulfide grease.
Runout limit
0.030 mm (0.0012 in)
5-91
8. Loosen the connecting rod bolts, remove
the connecting rod and connecting rod cap
and install these parts to the crankshaft
with the connecting rod bearings kept in
the current condition.
• Make sure that the “Y” mark “a” on the con-

necting rod faces toward the timing chain
drive gear “b” of the crankshaft.
• After installation, check that the section “c” is
6. Before installing the connecting rod onto
flush by running your finger across the sur-
the crankshaft, assemble the connecting
face.
rod, which the connecting rod bearings
• Do not turn the connecting rod or crankshaft
were installed in step 2, to the crankshaft
until the crankshaft pin oil clearance mea-
kept in the current condition.
surement has been completed.
Tighten the connecting rod bolts while check- c

ing that the sections shown “a” and “b” are
flush with each other by touching the surface. b
9. Tighten the connecting rod bolts to the

specified torques in 2 stages.
Connecting rod bolt

1st: 51 N·m (5.1 kgf·m, 37.6 lb·ft)
T.
R.
a 2nd: 90
b 10. Remove the connecting rod cap and mea-

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

specified torque.
Connecting rod bolt a

30 N·m (3.0 kgf·m, 22.1 lb·ft)
T.
R.
5-92
Pin oil clearance Big end side clearance

0.020–0.056 mm (0.0008–0.0022 0.160–0.262 mm (0.0063–0.0103
in) in)
Limit Limit
0.09 mm (0.0035 in) 0.50 mm (0.0197 in)
Big end width
Connecting rod big end side clear- 26.788–26.840 mm (1.0546–
ance check 1.0567 in)
1. Measure the connecting rod big end side Crankshaft pin width
clearance “a”. Measure the connecting rod 27.000–27.050 mm (1.0630–
big end width “b” and crankshaft pin width 1.0650 in)
“c” if out of specification.
Connecting rod bearing selection
1. Check the connecting rod size number “a”
on the connecting rod.
a
C5
2. Check the crankshaft pin size number “a”

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

b c necting rod bearing from the table.
a
5-93
5. Put a piece of Plastigauge “1” on each
Calculation formula:
crankshaft journal, parallel to the crank-
Connecting rod bearing size number = con-
shaft.
necting rod size number – crankshaft pin
size number
Bearing size number Bearing color Do not put the Plastigauge “1” over the oil hole
1 Blue in the main journals of the crankshaft.
2 Black
3 Brown 1
4 Green
Example:
“P1” connecting rod size number “5”
“P1” crankshaft pin size number “1”
5–1=4
Select the size “4”, “Green” connecting rod
bearing.
6. Install the crankcase “1” and crankcase
bolts “2”, and then tighten the crankcase
Crankshaft journal oil clearance
bolts “2” to the specified torques in 2 stag-
check
es and in the order [1], [2], and so on.
1. Clean the crankshaft bearings, crankshaft
journals, and bearing portions of the crank-
case and cylinder block. • When checking the journal oil clearance, re-
use the removed crankcase bolts “2”.
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
• Install the crankshaft bearings “1” in their

original positions.
slots “b” in the cylinder block and crankcase.
a
1
4. Install the crankshaft.
5-94
[7] [5] [1] [3] [9] 2
a
[10] [4] [2] [6] [8]
Crankcase bolt “2” Journal oil clearance

1st: 30 N·m (3.0 kgf·m, 22.1 lb·ft) 0.024–0.053 mm (0.0009–0.0021
T.
R.
2nd: 90 in)

Limit
7. Install the crankcase bolts “1”, and then 0.10 mm (0.0039 in)
tighten them to the specified torque in the
order [1], [2], and so on. Crankshaft bearing selection
1. Check the crankcase journal size number
1 “a” on the crankcase.
If the crankcase journal sizes are the same at

all positions, the size number “a” is stamped
only at the “J1” position.
Example:
If “J1”–“J5” are different:
J1 J2 J3 J4 J5
[11] [7] [5] [1] [3] [9]
5 5 5 4 5
55545
[12] [10] [4] [2] [6] [8]
If “J1”–“J5” are the same:
Crankcase bolt “1” J1 J2 J3 J4 J5

10 N·m (1.0 kgf·m, 7.4 lb·ft)
5 5 5 5 5
T.
R.
8. Remove the crankcase and measure the

width “a” of the compressed Plastigauge
on each crankshaft journal. Replace the
crankshaft bearings if out of specification.
5
5-95
Calculation formula:
Crankshaft bearing size number = crank-
case journal size number – crankshaft jour-
nal size number
Bearing size number Bearing color
1 Brown
2 Black
a 3 Blue
4 Green
5 Yellow
J1 J2 J3 J4 J5
Example:
2. Check the crankshaft journal size number “J1” crankcase journal size number “5”
“a” on the crankshaft web. “J1” crankshaft journal size number “2”
5–2=3
J1 J2 J3 J4 J5
Select the size “3”, “Blue” crankshaft bear-
a J ing.
Connecting rod and piston installa-

tion
1. Assemble the connecting rod “1”, piston
J1 J2 J3 J4 J5 “2”, piston pin “3”, and new piston pin clips
“4”.
3. Select the suitable color “a” for the crank-

shaft bearing from the table. Do not reuse a piston pin clip, always re-
place it with a new one.
a
5-96
1
• When installing the connecting rod to the pis-
ton, make sure that the “Y” mark “a” on the #5
connecting rod faces toward the front mark #4
“b” on the piston crown. #3 2
• Do not allow the piston pin clip ends to align #2
with the piston pin slot “c”. #1
45 45
#5 #1
#4
4
1 3
#2 #3
a 4. Clean the connecting rod bearings “1” and

c connecting rod big end.
4 5. Install the upper bearing into the connect-

ing rod “2” and lower bearing into the con-
necting rod cap “3”.
3
4 • Install the connecting rod bearings “1” in their
2 original positions.
b slots “b” in the connecting rod cap “3” and
connecting rod “2”.
2. Install the oil ring “1”, 2nd ring “2”, and top
ring “3”.
1
b
Do not scratch the pistons or break the pis-
ton rings.
2
b
3. Offset the piston ring end gaps. a
3
• Make sure to install the piston rings so that
the “1T” mark on the top ring “3” and the “2T” 6. Clean the connecting rod bolts.
mark on the 2nd ring “2” face up.
• After installing the piston rings, make sure 7. Lubricate the threads of the connecting rod
that they move smoothly. bolts with molybdenum disulfide grease.
5-97
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
Make sure that the “Y” mark on the connecting
rod to which the connecting rod bearings
rod faces toward the timing chain drive gear of
have been installed in step 5 to the crank-
the crankshaft.
shaft, keeping the present state.
Tighten the connecting rod bolts while check- 1

ing that the sections shown “a” and “b” are
flush with each other by touching the surface.
2
Y
Piston ring compressor “1”

90890-05158
Piston ring compressor “1”
YM-08037
12. Install half of the crankshaft bearings “1”

a into the cylinder block.
b
• Install the crankshaft bearings “1” in their
original positions.
slots “b” in the cylinder block.
a
specified torque. 1
Connecting rod bolt

b
30 N·m (3.0 kgf·m, 22.1 lb·ft)
T.
R.
5-98
13. Install the crankshaft. 2
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

bolts with molybdenum disulfide grease.
Connecting rod bolt “2”
1st: 51 N·m (5.1 kgf·m, 37.6 lb·ft)
T.
R.
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.
16. Install the connecting rod cap “1” onto the
piston and connecting rod, keeping the • Install the crankshaft bearings “1” in their
connecting rod bearings in their present original positions.
state. • Fit the protrusion “a” on each bearing into the
slots “b” in the crankcase.
After installation, check that section “a” is flush
by running your finger across the surface. a
17. Tighten the connecting rod bolts “2” to the 1

specified torques in 2 stages.
b
• When a connecting rod bolt is tightened

more than the specified angle, do not
loosen the connecting rod bolt and then
retighten it. Replace the connecting rod 3. Install the dowel pin “1” and a new O-ring
bolt with a new one and perform the pro- “2”.
cedure again.
• If the mating surfaces between the con-
2
necting rod and connecting rod cap are
uneven, remove the connecting rod bolts 1
and connecting rod bearings, and then
perform the bearing installation proce-
dure again. In this case, make sure to re-
place the connecting rod bolts.
5-99
4. Apply sealant to the mating surface of the
crankcase. Crankcase bolt “2”
1st: 30 N·m (3.0 kgf·m, 22.1 lb·ft)
T.
R.
2nd: 90
6. Install the crankcase bolts “1”, and then

tighten them to the specified torque in the
order [1], [2], and so on.
5. Install the crankcase “1” and new crank-

case bolts “2”, and then tighten the crank-
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. [11] [7] [5] [1] [3] [9]
1 2 2
1
[12] [10] [4] [2] [6] [8]
Crankcase bolt “1”

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
[7] [5] [1] [3] [9] 2
[10] [4] [2] [6] [8]
5-100
— MEMO —
5-101
Jet pump unit
1
Intake grate and ride plate................................................. 6-1
Jet pump unit...................................................................... 6-2

Jet pump unit removal ................................................................ 6-3
2
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

3
Impeller housing and impeller duct ASSY ....................... 6-9
4
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 .................................................. 6-13
5
6
Impeller duct, impeller housing, and nozzle installation ........... 6-15
Transom plate and hoses ................................................ 6-16

Bilge strainer check .................................................................. 6-19
7
Transom plate installation ........................................................ 6-19
Intermediate housing ....................................................... 6-20

Intermediate housing removal .................................................. 6-21
8
Intermediate housing disassembly ........................................... 6-21
Intermediate housing assembly................................................ 6-22
Intermediate housing installation.............................................. 6-23
9
A
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 N·m (1.7 kgf·m, 12.5 lb·ft)
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 N·m (1.5 kgf·m, 11.1 lb·ft)

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

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-

ance “a”. Measure the impeller housing in-
3. Disconnect the shift rod joint “1”, trim rod side diameter if the impeller-to-housing
joint “2” steering cable joint “3”, bilge hose clearance “a” is out of specification.
“4”, and spout hose “5”.
1
2
5
5
3
a
1 4
Impeller clearance
4. Remove the bolts “1”, “2”, and “3”.
0.350–0.450 mm (0.0138–0.0177
2 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
5. Gradually increase the distance between

1. Clean the mating surfaces of the jet pump
the jet pump unit “1” and the transom plate
unit “1” and transom plate “2”.
“2”, and then remove the jet pump unit “1”.
6-3
Jet pump unit
2. Apply sealant to the mating surfaces of the
4 1
jet pump unit “1” and transom plate “2”.
1207B 1
2
2
1
5
3 6
3. Install the jet pump unit, and then tighten 7
the bolts “1” and “2” to the specified
torques.
Spout hose clamp “2”
4. Tighten the jet pump unit bolt “3”. 2.5 N·m (0.25 kgf·m, 1.84 lb·ft)
T.
R.
Steering cable joint nut “7”
2
3 7 N·m (0.7 kgf·m, 5.2 lb·ft)
1
9. Initialize the RiDE system using the YDIS.
See “YDIS Instruction Manual”.
Trim rod adjustment

1 1. Push the unlock button on the remote con-
LT LT
trol transmitter so that power is supplied to
572 2 572 3
1 the ECM and the trim position is set to the
N position.
Jet pump unit bolt (M10  45 mm)
“1” 2. Disconnect the shift rod joint “1”.
T.
R.
40 N·m (4.0 kgf·m, 29.5 lb·ft)

Jet pump unit bolt (M8  18 mm) “2”
17 N·m (1.7 kgf·m, 12.5 lb·ft)
1
5. Connect the spout hose “1”, and then tight-
en the clamp “2” to the specified torque.
6. Connect the bilge hose “3”, and then fas-

ten it using the clamp.
7. Connect the trim rod joint “4” and shift rod 3. Disconnect the trim rod joints “1”.
joint “5”.
8. Connect the steering cable joint “6”, and

then tighten the nut “7” to the specified
torque.
Make sure that the steering and shifting oper-

ate correctly.
6-4
Jet pump unit
4. Loosen the locknut “2”.
Turn out Distance “a” is increased.
1 1 Turn in Distance “b” is increased.
Distance “c”
8.0 mm (0.31 in) or more
2
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 N·m (0.4 kgf·m, 3.0 lb·ft)
T.
tances “a” and “b” are equal.
R.
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
mm (0.31 in). 1
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
rotation. 8. Initialize the RiDE system using the YDIS.
See “YDIS Instruction Manual”.
1 Jet thrust nozzle angle adjustment

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

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

adjust distances “a” and “b”.
b
The steering cable joint must be screwed in
more than 8 mm (0.31 in).
6-5
Jet pump unit
1 a b
3
7. Install the service lid.
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 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
6. Check the difference of distances “a” and

“b” again.
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 N·m (2.0 kgf·m, 14.8 lb·ft)
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 N·m (1.6 kgf·m, 11.8 lb·ft)
16 N·m (1.6 kgf·m, 11.8 lb·ft)

5 6
1
7 3
2
1
2
4 1

1 Bolt 4 M8  20 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 N·m (4.0 kgf·m, 29.5 lb·ft)

1 N·m (0.1 kgf·m, 0.7 lb·ft) 4 3
3
2
a 5
1
7 3
11
6
7
7
LT
572
8
10
7
9 7 N·m (0.7 kgf·m, 5.2 lb·ft)

1 Clamp 1
2 Spout hose 1 a: Yellow paint mark
3 Bolt 4 M10  126 mm
4 Bracket 1
5 Nozzle 1
6 Impeller housing 1
7 Dowel pin 4
8 Bolt 4 M6  35 mm
9 Water inlet strainer 1
11 Impeller duct ASSY 1
6-9
Impeller, drive shaft, and impeller duct

15
74 N·m (7.4 kgf·m, 54.6 lb·ft)

10
9 10
8 2
3
4 2
12
1
330 N·m (33.0 kgf·m, 243.4 lb·ft) 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
3
2. Remove the cap “1”, O-ring “2”, and nut
“3”.
2 B 1
1
3
5
5
4
A. Worldwide

90890-06501
3
90890-06535
90890-06538
90890-06520
Slide hammer “5”
YB-06096
YB-06201
5. Remove the oil seals “1” and “2”.
3. Remove the drive shaft “1”.
Do not press the drive shaft threads direct-

ly.
6-11
A 1 Driver rod L3 “3”

2 90890-06652
4
3 Driver handle (large) “3”
YB-06071
5
5 Needle bearing attachment “4”
4 90890-06609
Driveshaft needle bearing installer
and remover “4”
YB-06194
B 1 Impeller housing check
2 1. Measure the impeller housing inside diam-
6
eter “a”. Replace if out of specification.
A. Worldwide
B. U.S.A. and Canada a

90890-06501
Bearing puller assembly “4” Inside diameter
90890-06535 160.75–160.85 mm (6.329–6.333
Stopper guide stand “5” in)
90890-06538
Slide hammer “6” Drive shaft check
YB-06096 1. Measure the drive shaft runout. Replace if
6. Remove the spacer “1”, and then remove
the ball bearing “2” using a press.
3
3 4
4
a
2
1
Runout limit
0.30 mm (0.0118 in)
Distance “a”
310 mm (12.20 in)
6-12
Impeller duct ASSY assembly

1. Install a new oil seal “1” halfway into the Distance “a”
impeller duct, and then install a new oil 7.0 ± 0.2 mm (0.28 ± 0.008 in)
seal “2”.
3. Install a new ball bearing “1” onto the drive
shaft “2”.
3
2
1
3
2
1 a
Bearing attachment “3”

90890-06728
Bearing attachment “3” Bearing attachment “3”
YW-06728 90890-06728
2. Install a new oil seal “1”. YW-06728
A
2 Distance “a”
29.0 ± 0.1 mm (1.14 ± 0.004 in)
1
a
4. Install the drive shaft “1” (along with the
ball bearing “2”) and spacer “3”.
B 3
1
2
1
a
2

90890-06728
A. Worldwide Bearing attachment “4”
B. U.S.A. and Canada YW-06728
5. Apply EPNOC grease AP #0 to the space

Oil seal installer attachment “2” between the drive shaft “1” and the spacer
90890-06733 “2”.
Oil seal installer attachment “2”
YW-06628
6-13
4
1 3
2 2
1
EP
5 LT
572
Grease quantity
20 g (0.7 oz)
6. Install a new ball bearing “1”.
1 2 2
1

90890-06520
YB-06201
Drive shaft nut “2”

Bearing attachment “2” 74 N·m (7.4 kgf·m, 54.6 lb·ft)
T.
R.
90890-06728
YW-06728 Grease quantity
20 g (0.7 oz)
7. Install the washer “1”, and then tighten the
drive shaft nut “2” to the specified torque. 9. Install the O-ring “1” to the spacer “2”.
8. Apply EPNOC grease AP #0 to the inside 10. Install the spacer “2” and impeller “3”.
of the cap “3”, and then install a new O-ring
“4” and the cap “3”.
3 1
6-14
11. Tighten the impeller “1” to the specified
4 5
torque.
5
1
3
2
2 5
1
3
90890-06520
Driveshaft holder “2” Impeller duct bolt “5”
YB-06201 40 N·m (4.0 kgf·m, 29.5 lb·ft)
T.
R.
Impeller “1”
330 N·m (33.0 kgf·m, 243.4 lb·ft)
T.
R.
Impeller duct, impeller housing, and

nozzle installation
1. Clean the mating surfaces of the impeller
duct, impeller housing, and nozzle.

impeller duct “1” and impeller housing “2”.
3. Install the dowel pins “3”, and then install

the impeller housing “2”.
2
3
1
3

nozzle “1” and impeller duct “2”.
5. Install the dowel pins “3” and nozzle “1”.
6. Install the bracket “4”, and then tighten the

impeller duct bolts “5” to the specified
torque.
6-15
Transom plate and hoses

21 26 N·m (2.6 kgf·m, 19.2 lb·ft)
3 27 31
26
25 23 30
24
19 25 24
20
29
22
23
28
26
1 4
15
9 5
13
7 8
11 6
12 11 15
13
34
1 10
14 7
20 35
1 3
17 2
32
18 33
6 N·m (0.6 kgf·m, 4.4 lb·ft)
2
1
26 N·m (2.6 kgf·m, 19.2 lb·ft)
16 3.5 N·m (0.35 kgf·m, 2.58 lb·ft)

1 Clamp 4
3 Plastic tie 2
4 Cap 1
5 Nut 1
6 Clamp 1
7 Flushing hose 1
8 Rivet 3
9 Bracket 1
10 Holder 1
11 Clamp 2
12 Hose joint 1
14 Hose joint 1 1
16 Rivet 1
6-16
21 26 N·m (2.6 kgf·m, 19.2 lb·ft)

3 27 31
26
25 23 30
24
19 25 24
20
29
22
23
28
26
1 4
15
9 5
13
7 8
11 6
12 11 15
13
34
1 10
14 7
20 35
1 3
17 2
32
18 33
6 N·m (0.6 kgf·m, 4.4 lb·ft)
2
1
26 N·m (2.6 kgf·m, 19.2 lb·ft)
16 3.5 N·m (0.35 kgf·m, 2.58 lb·ft)

17 Plastic tie 1
18 Bilge strainer ASSY 1
19 Clamp 2
20 Bilge hose 1
21 Hose joint 1
22 Clamp 1
23 Bilge hose 1
24 Clamp 2
26 Nut 4
27 Washer 2
28 Washer 2
29 Clamp 1
30 Bilge hose 1
31 Transom plate 1
32 Clamp 2
6-17
21 26 N·m (2.6 kgf·m, 19.2 lb·ft)

3 27 31
26
25 23 30
24
19 25 24
20
29
22
23
28
26
1 4
15
9 5
13
7 8
11 6
12 11 15
13
34
1 10
14 7
20 35
1 3
17 2
32
18 33
6 N·m (0.6 kgf·m, 4.4 lb·ft)
2
1
26 N·m (2.6 kgf·m, 19.2 lb·ft)
16 3.5 N·m (0.35 kgf·m, 2.58 lb·ft)

33 Hose 1
34 Tapping bolt 3 M6  32 mm
35 Hose joint 1
6-18
Bilge strainer check

1. Check the bilge strainer. See “Jet vacuum
bilge draining system check” (3-11).
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 N·m (2.6 kgf·m, 19.2 lb·ft)
T.
R.
6-19
Intermediate housing
17 N·m (1.7 kgf·m, 12.5 lb·ft)
3
11
12
8 3
2
9
13
10
9 15
8
2 14
7
6 3 N·m (0.3 kgf·m, 2.2 lb·ft)
1
5
205 N·m (20.5 kgf·m, 151.2 lb·ft)

1 Rubber coupling 1
2 Bolt 3 M8  48 mm
3 Dowel pin 2
4 Driven coupling 1
5 Washer 1
6 Intermediate drive shaft 1
9 Circlip 2 Not reusable
11 Thrust washer 1 Not reusable
13 Intermediate housing 1
14 Grease nipple 1
15 Cap 1
6-20
Intermediate housing removal

1. Remove the engine unit. See “Engine unit
1
removal” (5-7).
2
2. Remove the intermediate housing “1” and
dowel pins “2”.
3. Remove the oil seals “1”, “2”, and “3”.

A
2
4
5
Intermediate housing disassembly
1. Remove the driven coupling “1”.
6
2
1
3 1
3 5 2
5
B 1
2 8
8
90890-06730
YW-06730 8
90890-06729
Coupler wrench “3” A. Worldwide
YW-06729 B. U.S.A. and Canada
2. Remove the intermediate drive shaft “1”

and thrust washer “2” using a press.
90890-06501
90890-06535
Do not press the intermediate drive shaft
directly.
90890-06538
Slide hammer “7”
YB-06096
Bearing puller legs “8”
YB-06523
6-21
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”
Intermediate housing assembly 6.5 ± 0.2 mm (0.26 ± 0.01 in)
4. Install the intermediate drive shaft “1” us-

Do not reuse a thrust washer, always re- ing a press.
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”
3. Install a new oil seal “1”. 46.0 ± 0.5 mm (1.81 ± 0.02 in)
6-22
5. Install a new circlip (front) “1”, and then in-
stall a new oil seal “2”. Bearing attachment “2”
90890-06727
YW-06727
3
2 Distance “a”
3.7 ± 0.3 mm (0.17 ± 0.01 in)
1 8. Install the washer “1”, and then tighten the

driven coupling “2” to the specified torque.

90890-06728
YW-06728
6. Install a new oil seal “1”.

2
1
2
1 a 3
4
90890-06727
YW-06727 Shaft holder “3”
90890-06730
Distance “a” YW-06730
1.6 ± 0.2 mm (0.06 ± 0.01 in) Coupler wrench “4”
90890-06729
7. Install a new thrust washer “1”. Coupler wrench “4”
YW-06729
1
2 Driven coupling “2”
a
1 205 N·m (20.5 kgf·m, 151.2 lb·ft)
T.
R.
Intermediate housing installation

1. Install the dowel pins “1” and intermediate
housing “2”, and then tighten the interme-
diate housing bolts “3” to the specified
torque.
6-23
Intermediate housing bolt “3”

17 N·m (1.7 kgf·m, 12.5 lb·ft)
T.
R.
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................................................................ 7-16
Thermo sensor check............................................................... 7-16
Engine temperature sensor check............................................ 7-17
Intake air temperature sensor check ........................................ 7-18
Intake air pressure sensor check ............................................. 7-18
Knock sensor check ................................................................. 7-19
TPS check ................................................................................ 7-19
ETV circuit continuity................................................................ 7-21
APS check................................................................................ 7-21
APS circuit continuity................................................................ 7-22
ETV relay check ....................................................................... 7-23
RPS check................................................................................ 7-23
RPS circuit continuity ............................................................... 7-25
SCU relay check....................................................................... 7-25
Electric trim switch check ......................................................... 7-26
Cam position sensor check ...................................................... 7-26
Slant detection switch check .................................................... 7-27
Steering sensor check.............................................................. 7-28
ECM check ............................................................................... 7-29
Electrical system
1
Earth plate check...................................................................... 7-30
Fuel system ...................................................................... 7-30

Fuel injector check ................................................................... 7-30
2
Fuel pump relay check ............................................................. 7-31
Fuel pump module check ......................................................... 7-31
Starting system ................................................................ 7-32
3
Fuse check ............................................................................... 7-32
Handlebar switch (left) check ................................................... 7-32
Main relay check ...................................................................... 7-33
Starter relay check ................................................................... 7-34
Starter motor .................................................................... 7-35

Starter motor operation ............................................................ 7-36
Armature check ........................................................................ 7-36
Brush holder check................................................................... 7-37
4
Remote control system.................................................... 7-37
Remote control transmitter check............................................. 7-37
Remote control receiver check................................................. 7-39
5
6
Transmitter registration ............................................................ 7-39
Indication system ............................................................. 7-40

Multifunction meter check......................................................... 7-40
7
Speed sensor check................................................................. 7-41
Fuel level meter display and fuel level warning indicator
check ........................................................................................ 7-41
Check engine warning indicator check..................................... 7-42
Diagnostic display check .......................................................... 7-42
8
Oil pressure warning indicator check ....................................... 7-43
Engine overheat warning indicator check................................. 7-43
Buzzer check............................................................................ 7-43
9
A
Electrical components
Engine
2
1 3
5
9
6
7 10
11
12
13
14
16 15
1. Spark plug and ignition coil 13. ETV (TPS)

2. Cam position sensor 14. Engine temperature sensor
3. Electrical box 15. Earth plate
4. Thermo sensor 16. Stator coil and pickup coil
5. Rectifier/regulator
6. Starter motor
7. Oil pressure switch
8. Intake air pressure sensor
9. Fuel injector
10. Thermo switch
11. Intake air temperature sensor
12. Knock sensor
7-1
Deck and hull
3
2 4
6 8
10
1. Remote control receiver 10. RiDE motor

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
8. Multifunction meter
9. Battery
7-2
Electrical box
2
3
1
8 9 15 10 11
7 12
6 13
5 14
17 16 15
1. Fuse box 14. Fuse (50 A) (SCU)

2. Slant detection switch 15. Spare fuse
3. ECM 16. Fuel pump relay
4. Starter relay 17. ETV 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)
7-3
ECM circuit diagram
1.Rectifier/ 2.Stator
22.Fuel injector #1
regulator coil
3.Fuse 23.Fuel injector #2
(20 A)
4.Fuse (10 A) 24.Fuel injector #3
5.Main relay
25.Fuel injector #4
6. Fuse
(3 A)
7.Engine 9.Remote 26.Ignition coil #1
start switch control receiver
8.Fuse
(30 A)
10.Starter 27. Ignition coil #2
relay
11.Battery
12.Starter motor
28. Ignition coil #3
13. Pickup coil
5V
14.Cam position sensor 36.ECM
15.Intake air pressure sensor
30. Fuel pump module

16.Intake air temperature sensor
17.Engine temperature sensor

31.Fuel pump relay
18.Thermo sensor 33.Multifunction

32.(YDIS)
meter
34. ETV relay

19.Steering sensor 35. Fuse (10 A)
20. Slant detection switch
a.Ground
21. Knock sensor
, : Indicate a connection between the symbols.
7-4
37.Oil pressure switch
38.Thermo switch
39.Engine shut-off switch
47.ETV
40.APS
5V
48.ETV motor
41.APS 1
a.Ground
5V 5V
42.APS 2
a.Ground 49.TPS 1
36.ECM
5V 50.TPS 2
43. APS full
close a.Ground
switch a.Ground
44.RPS
5V
51.SCU
45.RPS 1
a.Ground
5V
46.RPS 2
a.Ground
7-5
1. Rectifier/regulator 50. TPS 2

2. Stator coil 51. SCU
3. Fuse (20 A)
a. Ground
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. Knock sensor
22. Fuel injector #1
30. Fuel pump module
31. Fuel pump relay
32. (YDIS)
33. Multifunction meter
34. ETV relay
35. Fuse (10 A)
36. ECM
37. Oil pressure switch
38. Thermo switch
39. Engine shut-off switch
40. APS
41. APS 1
42. APS 2
43. APS full close switch
44. RPS
45. RPS 1
46. RPS 2
47. ETV
48. ETV motor
49. TPS 1
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 Knock sensor Green 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
25 Orange/Red
power 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.
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 a
W/B
B
When checking the input voltage of a part, the

coupler or connector must be disconnected. As
Peak voltage measurement
a result, the ECM determines that the part is
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
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 such as fouled spark plugs or a weak battery.
(Yamaha Marine Associate Network). If one of these factors is present, the peak volt-
age cannot be measured properly.
YDIS2 Hardware Kit

90890-06884
YDIS2 Hardware Kit
LIT-YDIS2-01-KT
7-9
Electrical analysis
Test lead preparation

If the special service tool test harness is not
• Before measuring the peak voltage, check all available, make test leads suitable for the mea-
wiring for proper connection and corrosion, surement.
and check that the battery is fully charged.
• Use the peak voltage adapter with the rec-
ommended digital circuit tester.
• Connect the positive pin of the peak voltage
1 2
adapter to the positive terminal of the digital
circuit tester, and the negative pin to the neg-
ative terminal. 3
• When measuring the peak voltage, set the
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
7-10
Ignition system
Ignition system 2. Supply power to the ECM, and then mea-

Ignition spark check sure the input voltage at the ignition coil
coupler terminals (wire harness end).
Check the wire harness if out of specifica-
When performing the spark gap check, tion. Check the ECM output peak voltage if
keep flammable gas or liquids away, since within specification.
this test can produce sparks.
R/Y B
1. Connect the YDIS.
2. Remove the ignition coil for the cylinder a

that will be tested.
3. Connect the ignition coil to the special ser-

vice tool “1”.
4. Using the “Stationary test” of the YDIS,

check the ignition spark. Input voltage
12 V
Red/Yellow (R/Y)–Black (B)
Do not touch any of the connections of the
special service tool leads. 3. Connect the test harness. See “Test lead
preparation” (7-10).
1
4. Measure the ECM output peak voltage.
When checking the electrical components,

do not touch any of the connections of the
digital tester leads.
• When measuring the ECM output peak volt-

age under the “Cranking” condition, discon-
Ignition checker (Spark gap tester)
nect the fuel injector couplers for all
“1”
cylinders.
90890-06754
• To crank the engine, connect the engine
Spark checker “1”
shut-off cord (lanyard) to the engine shut-off
YM-34487
switch, and then push the engine start
5. Disconnect the special service tool, and switch.
then install the ignition coil. • When measuring the ECM output peak volt-
age, use only a properly functioning ignition
Ignition coil check coil. If the ignition coil is not functioning prop-
1. Disconnect the ignition coil couplers “a”. erly, ECM output peak voltage will not be
generated.
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)
#4 Black/Green (B/G)–Black (B) Output peak voltage
White (W)–Black (B)
Loaded
r/min Unloaded Loaded
Cranking 2000 3500 r/min
Cranking 2000 3500
V 3.0 2.6 2.6
V 5.4 4.9 18.1 25.0
5. Disconnect the test harness, and then con-
nect the ignition coil couplers. 3. Disconnect the special service tool.
Pickup coil check 4. Measure the pickup coil resistance. Re-

1. Disconnect the pickup coil coupler “a”, and place the pickup coil if out of specification.
then connect the special service tool “1”.
2. Measure the pickup coil output peak volt- W B

age.
• 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.
• If measuring the pickup coil output peak volt-
age under the “Cranking” and “Unloaded” Resistance
conditions, disconnect the pickup coil coupler 459.0–561.0 
(wire harness end) “b”. White (W)–Black (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- G

G
age.
G G
G G
G G
W R B
a 1 Resistance
0.27–0.40 
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
B 2. Measure the rectifier/regulator output peak
R voltage.
W
Do not use the peak voltage adapter to mea-

Test harness (3 pins) “1” sure the output voltage.
90890-06870
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 6.6 41.7 58.5
1 a
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.
7-13
Charging system
A
90890-06850
YW-06850
a
Output voltage a
Red (R)–Black (B)
Loaded
r/min
2000 3500
B
V 13
3. Disconnect the special service tool.
4. Remove the rectifier/regulator. See “Ex-

haust manifold” (5-3).
a
5. Check the rectifier/regulator for continuity.
Replace if out of specification.
A. Worldwide
Make sure to set the measurement range to “a”
when checking the rectifier/regulator continu-
ity.
cG
Ge dG
Bf bR
b R
c G
d G
e G
f B
7-14
Control system
Rectifier/regulator continuity Control system

(testing diode mode) Oil pressure switch check
1. Disconnect the oil pressure switch coupler
Tester lead Display value (V)
“a”.
(+) (–) (reference data)
c 2. Supply power to the ECM, and then mea-
sure the input voltage between the oil
d
b OL pressure switch coupler terminal (wire har-
e ness end) and ground. Check the wire har-
f ness if out of specification.
b 0.43–0.51
d
c
e OL
f P/W
b 0.43–0.51 a
c
d
e OL
f
b 0.43–0.51 Input voltage
c 11–12 V
e Pink/White (P/W)–Ground
d OL
f
3. Remove the oil pressure switch. See “Oil
b 0.66–0.74 separator tank and oil pan” (5-81).
c 0.43–0.51
f 4. Connect the tester leads to the terminal
d 0.43–0.51
thread “a” and body “b” of the oil pressure
e 0.43–0.51 switch.
OL: Indicates an overload
5. Connect the special service tool “1” to the
oil pressure switch, and then apply positive
6. Install the rectifier/regulator. See “Exhaust
pressure.
manifold” (5-3).
7. Connect the rectifier/regulator coupler.

a 1
7-15
Control system
4. Suspend the thermo switch in a container
Vacuum/pressure pump gauge set filled with water, and then heat the water
“1” slowly.
90890-06945
Pressure/ vacuum tester “1”
YB-35956-B
P B
6. Check the oil pressure switch for continu-
ity. Replace if out of specification.
Oil pressure switch continuity
Terminal thread “a”–
Pressure
Body “b”
Below 128–167 kPa 5. Check the thermo switch for continuity
(1.28–1.67 kgf/cm², Continuity when the specified temperatures are
18.6–24.2 psi) reached. Replace if out of specification.
Above 128–167 kPa
(1.28–1.67 kgf/cm², No continuity b
18.6–24.2 psi) b
b
c
7. Install the oil pressure switch. See “Oil A
d
separator tank and oil pan” (5-81). a
a
8. Connect the oil pressure switch coupler.
Thermo switch check B

1. Disconnect the thermo switch coupler “a”. a. No continuity
b. Continuity
2. Supply power to the ECM, and then mea- c. Continuity temperature
sure the input voltage at the thermo switch d. No continuity temperature
coupler terminals (wire harness end).
Check the wire harness if out of specifica- A. Temperature
tion. B. Time
a Continuity temperature
94–100 C (201–212 F)
B P No continuity temperature
80–94 C (176–201 F)
6. Install the thermo switch. See “Cylinder

block and electrical part” (5-79).
7. Connect the thermo switch coupler.
Input voltage Thermo sensor check

11–12 V 1. Disconnect the thermo sensor coupler “a”.
Pink (P)–Black (B)
3. Remove the thermo switch. See “Cylinder

block and electrical part” (5-79).
7-16
Control system
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”.
Check the wire harness if out of specifica-
tion. 2. Supply power to the ECM, and then mea-
sure the input voltage at the engine tem-
a perature sensor coupler terminals (wire
B/L B/O harness end). Check the wire harness if
a B/O B/Y
Input voltage
4.75–5.25 V
Black/Blue (B/L)–Black/Orange
(B/O)
Input voltage
3. Remove the thermo sensor. See “Muffler” 4.75–5.25 V
(5-17). Black/Yellow (B/Y)–Black/Orange
(B/O)
4. Suspend the thermo sensor in a container
filled with water, and then slowly heat the 3. Remove the engine temperature sensor.
water. See “Cylinder block and electrical part”
(5-79).
4. Suspend the engine temperature sensor in

B B a container filled with water, and then heat
the water slowly.
B/Y B/Y
5. Measure the thermo sensor resistance

when the specified temperatures are
reached. Replace if out of specification.
Resistance at 0 C (32 F)

24.0–37.1 k 5. Measure the engine temperature sensor
Resistance at 100 C (212 F) resistance when the specified tempera-
0.87–1.18 k tures are reached. Replace if out of speci-
fication.
6. Install the thermo sensor. See “Muffler”
(5-17).
7. Connect the thermo sensor coupler.
7-17
Control system
6. Remove the intake air temperature sen-
Resistance at 20 C (68 F) sor. See “Intake” (5-27).
54.2–69.0 k
Resistance at 100 C (212 F) 7. Suspend the intake air temperature sensor
3.12–3.48 k in a container filled with water, and then
slowly heat the water.
6. Install the engine temperature sensor. See
“Cylinder block and electrical part” (5-79).
B B
7. Connect the engine temperature sensor
coupler.
Intake air temperature sensor check

1. Measure the ambient temperature.
2. Connect the YDIS to display “Intake air

temperature”.
8. Measure the intake air temperature sensor
resistance when the specified tempera-
3. If the ambient temperature and the dis-
tures are reached. Replace if out of speci-
played intake air temperature differ by
fication.
more than ± 5 C (± 9 F), measure the in-
take air temperature sensor resistance.
Resistance at 0 C (32 F)
5.4–6.6 k
Check the intake air temperature sensor when Resistance at 80 C (176 F)
the engine is cold. 0.29–0.39 k
9. Install the intake air temperature sensor.

4. Disconnect the intake air temperature sen- See “Intake” (5-27).
sor coupler “a”.
10. Connect the air temperature sensor cou-
5. Supply power to the ECM, and then mea- pler.
sure the input voltage at the intake air tem-
perature sensor coupler (wire harness Intake air pressure sensor check
end). Check the wire harness if out of 1. Disconnect the intake air pressure sensor
specification. coupler “a”.
2. Supply power to the ECM, and then mea-

sure the input voltage at the intake air
B/O B/R pressure sensor coupler (wire harness
end). Check the wire harness if out of
specification.
a a B/O O
Input voltage
4.75–5.25 V
Black/Red (B/R)–Black/Orange
(B/O)
7-18
Control system
Input voltage
4.75–5.25 V
Orange (O)–Black/Orange (B/O) G
3. Connect the intake air pressure sensor

coupler.
4. Disconnect the vacuum hose from the in- a

take air pressure sensor.
5. Connect the special service tool “1” to the Resistance

intake air pressure sensor. 504.0–616.0 k
6. Connect the YDIS to display “Intake air 3. Connect the knock sensor coupler.
pressure”.
TPS check
7. Apply negative pressure to the intake air
pressure sensor slowly and check that the
displayed intake air pressure decreases. • Do not loosen the throttle stop screw nut
Replace if it does not decrease. and do not turn the throttle stop screw.
• Do not disconnect the ETV coupler (throt-
tle body end).
1 • TPS 1 and TPS 2 are components of the
ETV, which cannot be disassembled.
Vacuum/pressure pump gauge set

“1”
90890-06945
Pressure/ vacuum tester “1” a b
YB-35956-B
8. Disconnect the special service tool, and

then connect the vacuum hose.
Knock sensor check

1. Disconnect the knock sensor coupler “a”.
2. Measure the knock sensor resistance. Re- a. Throttle stop screw nut
place the knock sensor if out of specifica- b. Throttle stop screw
tion. c. ETV coupler (throttle body end)
1. Connect the YDIS to display “TPS 1”,

“Throttle valve opening angle”, and “TPS
2”.
7-19
Control system
5. Operate the throttle lever so that the TPS
2 output voltage is 4.5 V or less, and then
When checking the TPS using the YDIS, do check the voltage difference between TPS
not start the engine. 1 and TPS 2. Measure the TPS input volt-
age if out of specification.
2. Squeeze the throttle lever “1” slowly and
check that the displayed throttle valve TPS output voltage difference
opening increases. 1.9–2.1 V
3. Check the TPS 1 output voltage and throt- Example:

tle valve opening angle at the fully closed If the TPS 1 output voltage is 2.5 V and the
position “A”. TPS 2 output voltage is 4.5 V, then 4.5 -
2.5 = 2.0 V.
TPS 1 output voltage with throttle
lever fully closed 6. Disconnect the ETV coupler “a”.
0.60–0.90 V
Throttle valve opening angle with 7. Supply power to the ECM, and then mea-
throttle lever fully closed sure the input voltage at the ETV coupler
2–8  terminals (wire harness end). Check the
TPS circuit continuity if out of specification.
4. Check the TPS 2 output voltage and throt-
tle valve opening angle at the fully open
position “B”.
O
Operate the throttle lever “1”, and then check
the TPS 2 output voltage and throttle valve
opening angle at the fully open position “B”.
a B/O
A B
1 1
Input voltage
4.75–5.25 V
Orange (O)–Black/Orange (B/O)
8. Connect the ETV coupler.
TPS 2 output voltage with throttle

lever fully open
4.50–4.80 V
Throttle valve opening angle with
throttle lever fully open
More than 70 degree
7-20
Control system
ETV circuit continuity ETV circuit continuity

1. Disconnect the ETV coupler “a” and ECM
couplers “b” and “c”. Terminal No. Color
Coupler “a” Coupler “b”, “c” code
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.
b c
APS check
APS 1, APS 2, and APS full close switch are

components of the throttle lever, which
cannot be disassembled.
2. Check the wire harness for continuity. Re- 1. Connect the YDIS to display “APS 1”,
place if there is no continuity. Replace the “APS 2”, and “APS full close switch”.
ETV if there is continuity.
When checking the APS using the YDIS, do

a not start the engine.
3 2 1
6 5 4
2. Operate the throttle lever “1”, and then
check the output voltages of APS 1 and
b c APS 2 at the fully closed position “A” and
fully open position “B”.
44 43 42 41
The actual APS output voltage may vary ac-
52 78 cording to environmental conditions.
A B
1 1
7-21
Control system
APS 1 output voltage with the throt-

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

Throttle lever position YDIS display
C ON
D OFF
b c
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.
7-22
Control system
2. Check the wire harness for continuity. check” (7-33).
Replace if there is no continuity.
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
12 V
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
3. Connect the APS coupler and ECM cou- Input voltage

plers. 12 V
Terminal “a”–Terminal “b”
ETV relay check
1. Remove the fuse box cover and ETV relay 5. Install the ETV relay and fuse box cover.
“1”.
RPS check
RPS 1 and RPS 2 are components of the

RiDE lever, which cannot be disassembled.
1
1. Connect the YDIS to display “RPS main”
and “RPS sub”.
2. Check the ETV relay. See “Main relay
7-23
Control system
4. Disconnect the RPS coupler “a”.
• When checking the RPS using the YDIS, do 5. Supply power to the ECM, and then mea-
not start the engine. sure the input voltage at the RPS coupler
• The values displayed for “RPS main” are the terminals (wire harness end). Check the
RPS 1 values and the values displayed for RPS circuit for continuity if out of specifica-
“RPS sub” are the RPS 2 values. 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
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)
RPS 1 output voltage with the RiDE 6. Connect the RPS coupler.
lever fully closed
0.68–0.74 V
RPS 2 output voltage with the RiDE
lever fully closed
0.68–0.74 V
lever fully open
3.89–4.21 V
lever fully open
3.89–4.21 V
3. Squeeze the RiDE lever to the fully open

position, and then check the voltage differ-
ence between RPS 1 and RPS 2. Measure
the RPS input voltage if out of specifica-
tion.
RPS output voltage difference

0.1 V or less
7-24
Control system
RPS circuit continuity RPS circuit continuity

1. Disconnect the RPS coupler “a” and ECM
couplers “b” and “c”. Terminal No. Color
Coupler “a” Coupler “b”, “c” code
1 33 P/R
2 31 B/R
a 3 28 O/R
4 11 P/W
5 32 B/W
6 51 O/W
3. Connect the RPS coupler and ECM cou-

plers.
b c
SCU relay check
1. Remove the fuse box cover and SCU relay
“1”.
2. Check the wire harness for continuity. Re-

place if there is no continuity.
a
3 2 1
6 5 4
2. Check the SCU relay. See “Main relay
check” (7-33).
b c
3. Measure the input voltage between the ter-
minal “a” and ground.
33 32 31 28
11
a
51
Input voltage
12 V
Terminal “a”–Ground
7-25
Control system
4. Turn the engine start switch to ON, and
then measure the input voltage between
the terminals “a” and “b”.
a a
5. Measure the electric trim switch resis-

tance.
Input voltage 1
12 V Sb B Lg
5. Install the SCU relay and fuse box cover. 2
Electric trim switch check

1. Connect the YDIS to display “Trim up
switch” and “Trim down switch”.
Electric trim switch resistance (refer-
2. Push the electric trim switches “1” and “2”. ence data)
Free
3. Check that the following is displayed in the
5.6 k
“Engine monitor” window of the YDIS.
Sky blue (Sb)–Black (B)
Switch “1” pushed
0.98 k
Sky blue (Sb)–Black (B)
Free
5.6 k
Light green (Lg)–Black (B)
Switch “2” pushed
1 0.98 k
2 Light green (Lg)–Black (B)
Electric trim switch operation Cam position sensor check

Switch YDIS display 1. Disconnect the cam position sensor cou-
pler “a”.
Up “1” Free OFF
Down “2” Pushed ON
4. Disconnect the electric trim switch coupler

“a”.
7-26
Control system
sure the input voltage at the cam position
sensor coupler terminals (wire harness
end). Check the wire harness if out of
specification. Measure the cam position
sensor output voltage if within specifica-
tion.
a b c
B/O O
90890-06877
a YB-06877
Output voltage (position a, c)

Input voltage More than 4.8 V
4.75–5.25 V Output voltage (position b)
Orange (O)–Black/Orange (B/O) Less than 0.8 V
Green/Orange (G/O)–Black/Or-
ange (B/O)
3. Remove the cam position sensor. See
“Cylinder head cover” (5-41), and then
connect the special service tool “1” to the
then install the cam position sensor. See
cam position sensor and the wire harness.
“Cylinder head cover” (5-41).
6. Connect the cam position sensor coupler.
sure the output voltage when a screw-
driver is passed under the cam position Slant detection switch check
sensor in direction of the arrow. Replace
1. Disconnect the slant detection switch cou-
the cam position sensor if out of specifica-
pler “a”.
tion.
sure the input voltage at the slant detection
switch coupler (wire harness end). Check
the wire harness if out of specification.
G/O BW
B/O L/B
B/O
1
a
7-27
Control system
2. Check that the following is displayed in the
Input voltage “Engine monitor” window of the YDIS
4.75–5.25 V when the handlebar is in each position.
Blue/Black (L/B)–Black/Orange Measure the steering sensor input voltage
(B/O) if out of specification.
3. Remove the slant detection switch.
4. Check the slant detection switch for conti-

nuity. Replace if out of specification.
Make sure to turn the switch over to both the

left and right.
A
Steering sensor operation
UP Handlebar position YDIS display
Straight ahead OFF
Turn to the left and
B ON
right
L/B B/O B
3. Disconnect the steering sensor coupler
“a”.
UP
UP

sure the input voltage at the steering sen-
sor coupler terminals (wire harness end).
B Check the steering sensor output voltage if
UP within specification. Check the wire har-
ness if out of specification.
Slant detection switch continuity B/O O/R

a
Blue/Black (L/B)–
Position
Black/Orange (B/O)
Normal position
No continuity
“A”
Overturned “B” Continuity
5. Install the slant detection switch. See

“Electrical box” (5-20).
Input voltage
6. Connect the slant detection switch cou- 4.75–5.25 V
pler. Orange/Red (O/R)–Black/Orange
(B/O)
Steering sensor check
5. Connect the special service tool “1” to the
1. Connect the YDIS to display “Steering
steering sensor coupler.
sensor”.
7-28
Control system
sure the output voltage when the handle-
bar is in each position. c a b
R
P
O
Throttle sensor adjusting lead 27

FWY-3 “1”
90890-06857
YB-06857
Input voltage
Steering sensor output voltage 12 V
Terminal “27”–Ground
Handlebar position V
3. Disconnect the ECM coupler “b”, and then
Straight ahead 4.5
check the continuity between the ECM
Turn to the left and coupler terminals (wire harness end) and
1.8
right ground. Replace the wire harness if there
is no continuity.
then connect the steering sensor coupler.
a b
ECM check
1. Disconnect the ECM coupler “a”.

sure the input voltage between the ECM
coupler terminal (wire harness end) and
ground. Check the ECM circuit for continu-
ity if out of specification. a b
Do not disconnect the coupler “b” or coupler “c”

when measuring the ECM input voltage. 67 62
70
46
7-29
Fuel system
ECM circuit continuity a R/Y

Continuity
4. Connect the ECM couplers.
Earth plate check

1. Remove the earth plate. Input voltage
12 V
2. Check the continuity between each termi-
Red/Yellow (R/Y)–Ground
nal “a” and the housing “b”. Replace the
earth plate if there is no continuity.
5. Remove the fuel injectors. See “Fuel injec-
b tor” (4-6).
6. Measure the fuel injector resistance. Re-

place the fuel injector if out of specification.
3. Install the earth plate. See “Cylinder block

and electrical part” (5-79).
Fuel system
Fuel injector check
1. Connect the YDIS. Fuel injector
Resistance
2. Using the “Stationary test” of the YDIS, lis- 11.5–12.5 
ten for the fuel injector operation sound.
7. Install the fuel injectors. See “Fuel rail and
3. Disconnect the fuel injector couplers “a”. injector installation” (4-7).
4. Supply power to the ECM, and then mea- 8. Connect the fuel injector couplers.
sure the input voltage between the fuel in-
jector coupler terminals (wire harness end)
and ground. Check the wire harness if out
of specification.
7-30
Fuel system
Fuel pump relay check 5. Install the fuel pump relay and fuse box
1. Remove the fuse box cover and fuel pump cover.
relay “1”.
Fuel pump module check
1. Connect the YDIS.
2. Using the “Stationary test” of the YDIS, lis-

ten for the fuel pump module operation
sound.
1 3. Disconnect the fuel pump module coupler

“a”.

2. Check the fuel pump relay. See “Main re- sure the input voltage at the fuel pump
lay check” (7-33). module coupler terminals (wire harness
end). Replace the fuel pump module if
3. Measure the input voltage between the ter- within specification. Check the wire har-
minal “a” and ground. ness if out of specification.
After the power is supplied to the ECM, voltage

a will only be applied to the fuel pump module for
3 seconds.
a L B
Input voltage
12 V
Terminal “a”–Ground

sure the input voltage between the termi-
nals “a” and “b”. Input voltage
12 V
Blue (L)–Black (B)
5. Remove the fuel pump module. See “Fuel

a tank and fuel pump module” (4-8).
6. Measure the fuel sender resistance. Re-

place the fuel sender if out of specifica-
b
tions.
Input voltage
12 V
7-31
Starting system
Starting system
B Fuse check
P B/G
1. Check the fuse for continuity. Replace if
there is no continuity.
A. Lower position
B. Upper position
Lower position resistance

133.5–136.5  Handlebar switch (left) check
Upper position resistance 1. Disconnect the handlebar switch (left) cou-
5.0–7.0  pler (white coupler).
7. Install the fuel pump module. See “Fuel 2. Check the engine start switch for continu-
tank and fuel pump module” (4-8). ity. Replace the handlebar switch (left) if
2
R Br
A
1 2
Engine start switch continuity

Engine start Red (R)–
Clip “1”
switch “2” Brown (Br)
Free No continuity
Installed “A”
Pushed Continuity
Removed Free No continuity
“B” Pushed No continuity
3. Connect the handlebar switch (left) cou-

pler (white coupler).
4. Disconnect the handlebar switch (left) cou-

pler (black coupler).
7-32
Starting system
5. Check the engine stop switch for continu-
ity. Replace the handlebar switch (left) if
c
d a
1
W B
A
2
b
B
Relay terminals continuity
2 Terminal “c”–Terminal “d”
Engine stop switch continuity 3. Measure the input voltage between the ter-
minal “a” and ground.
Engine stop White (W)–
Clip “1”
switch “2” Black (B)
a
Free No continuity
Installed “A”
Pushed Continuity
Removed Free Continuity
“B” Pushed Continuity
6. Connect the handlebar switch (left) cou-

pler (black coupler).
Main relay check Input voltage

1. Remove the fuse box cover and main relay 12 V
“1”. Terminal “a”–Ground

1 sure the input voltage between the termi-
nals “a” and “b”.
a b
2. Connect the positive battery lead to the

terminal “a”, and the negative battery lead
to the terminal “b”, and then check for con-
tinuity between the terminals “c” and “d”.
Replace the relay if there is no continuity.
Input voltage
12 V
Do not reverse the battery leads. Other- Terminal “a”–Terminal “b”
wise, the relay may be seriously damaged.
5. Install the main relay and fuse box cover.
7-33
Starting system
Starter relay check Starter relay continuity

1. Slide the boot away from the starter relay
terminal “1”, and then measure the input Battery lead “c”–“d” Terminal “a”–“b”
voltage between the starter relay terminal Disconnected No continuity
“1” and ground. Connected Continuity
6. Install the starter relay.

The positive battery lead is marked with yel-
lowish green tape “a”.
Starter relay input voltage

12 V
Red (R)–Ground
2. Remove the starter relay.
3. Connect the tester leads between the

starter relay terminals “a” and “b”.

terminal “c”, and the negative battery lead
to the terminal “d”.
5. Check the continuity between the starter

relay terminals “a” and “b”. Replace the
starter relay if out of specification.
a b
c d
7-34
Starter motor
Starter motor
9 N·m (0.9 kgf·m, 6.6 lb·ft)

9 7
10
7 N·m (0.7 kgf·m, 5.2 lb·ft) 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
7-35
Starter motor
Starter motor operation

1. Remove the starter motor. See “Wire har-
ness” (5-19).
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.
• 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
1 Commutator diameter
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
5. Disconnect the negative battery lead, and a

then the positive battery lead from the bat-
tery terminals.
6. Install the starter motor. See “Wire har-

ness” (5-19).
Armature check
1. Check the commutator. Clean using 600-
grit sandpaper and compressed air if dirty. Commutator undercut
0.7 mm (0.03 in)
7-36
Remote control system
4. Check the armature for continuity. Re-
place if out of specification. a c
d b
a b c
e
a
c
Armature continuity
Commutator seg- d
Continuity
ment “a”
b
Segment “a”–Arma- e
No continuity
ture core “b”
Segment “a”–Arma- Brush holder continuity
No continuity
ture shaft “c”
Brush “a”–Brush “b”
Brush “c”–Brush “d”
Brush holder check Continuity
Brush “c”–Terminal “e”
1. Measure the brush length “a”. Replace the
Brush “d”–Terminal “e”
brush holder if below specification.
For all brush and terminal
combinations not listed No continuity
above.

a Remote control transmitter check
1. Push the unlock button “a”. The buzzer
sounds 2 times, and then check that the
“UNLOCK” indicator light “b” comes on.
2. Push the unlock button “a” for more than 4

Brush length seconds. The buzzer sounds 3 times, and
12.5 mm (0.49 in) then check that the “L-MODE” indicator
Wear limit light “c” comes on.
5.0 mm (0.20 in)
3. Push the lock button “d”. The buzzer
2. Check the brush holder for continuity. Re- sounds once, and then check that the “UN-
place if out of specification. LOCK” indicator light “b” goes off.
While the engine is running, input from the re-

mote control transmitter is not received.
7-37
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.
b c Refer to local hazardous waste regulations

when disposing of transmitter batteries.
Yamaha Security
Number of beeps
System mode
1 beep Lock
Unlock
2 beeps Rating
(normal mode)
3V
L-MODE
3 beeps
(low-rpm mode)
7. Install the battery (CR2016) “1” and trans-
4. Loosen the screws “1” in the order [1], [2], mitter cover “2”.
and so on, and then remove the transmit-
ter cover “2”.
Install the battery (CR2016) “1” with the posi-
tive side “a” facing down.
Do not touch the internal parts except the
battery. 1
2
[4] [6]
a
1
2
[1] [2]
[5] [3]
5. Remove the battery (CR2016) “1”.
7-38
8. Tighten the screws “1” to the specified
torque in the order [1], [2], and so on. a
L/Y
[3] [1]
[6] [5]
[2] [4]
Output voltage
11–12 V
Transmitter cover screw “1” Blue/Yellow (L/Y)–Ground
0.1 N·m (0.01 kgf·m, 0.07 lb·ft)
T.
R.
5. Connect the multifunction meter coupler.

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

R nication coupler “a”.
Input voltage a
12 V
Red (R)–Black (B)
2. Connect the remote control receiver cou-

pler.
Gy Gy
1 B B
3. Disconnect the multifunction meter cou-
pler “a” from the remote control receiver. a
2 3
sure the remote control receiver output 2. Push the lock button “a” or unlock button
voltage at the multifunction meter coupler “b” to transmit the ID code from the remote
terminal (wire harness end) and ground. control transmitter to be registered.
Replace the remote control receiver if out
of specification.
7-39
Indication system
Indication system
• At this time, the system enters the registra-
Multifunction meter check
1. Check the multifunction meter external ap-
tion mode to register the first code. All exist-
pearance. Replace the multifunction meter
ing ID codes will be deleted from the remote
if there is cracked meter housing, fogged
control receiver.
meter, or water intrusion.
• The “UNLOCK” indicator light “c” blinks when
the registration of the ID code has been com-
2. Supply power to the ECM, and then check
pleted. (If the registration could not be com-
that all indicator lights “a” and display ele-
pleted, the “UNLOCK” indicator light comes
ments “b” on the multifunction meter come
on. Re-transmit the ID code.)
on. Replace if it does not operate properly.
3. After checking that the registration of the

ID code has been completed using the When the multifunction meter is activated, all
“UNLOCK” indicator light “c”, transmit the displays come on for 2 seconds, and then the
next ID code. multifunction meter starts to operate normally.
a b a
• 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.
a
a b
3. Check the multifunction meter display. Re-
place the multifunction meter if there is in-
termittent or missing segment “a”.
4. Disconnect the multifunction meter cou-

pler “a”.
4. After ID code registration has been com-

pleted, disconnect the entry box to exit the
registration mode.
7-40
Indication system
sure the input voltage at the multifunction
meter coupler terminals (wire harness
end). Replace the wire harness if out of
specification. Replace the multifunction
meter if within specification and there is no a
display on the multifunction meter.

R/Y terminal “a”, and the negative battery lead
to the terminal “b”.
5. Connect the tester leads between the ter-

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

Input voltage measure the output voltage between the
12 V terminal “c” and terminal “b”. Replace if out
Red/Yellow (R/Y)–Black (B) of specification.
6. Connect the multifunction meter coupler. B/Yb a R/Y

d
Speed sensor check
1. Remove the speed sensor. See “Intake cY
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.
Output voltage (dependent on the

paddle wheel position)
Less than 400 mV/More than 11.6
V
Yellow (Y)–Black/Yellow (B/Y)
7. Connect the speed 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” (4-8).
2. Install the speed sensor. See “Intake grate
2. Connect the fuel sender coupler “a”.
and ride plate” (6-1).
3. Lift the float to the upper position “A”.
3. Disconnect the speed sensor coupler “a”.
7-41
Indication system
4. Supply power to the ECM, and then check 2. Check that the “WARNING” indicator light
that all fuel level segments come on. Re- “a” and the check engine warning indicator
place if it does not come on. “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
A
3. If the light and indicator do not blink, check
the “Diagnosis record” of the YDIS. If a di-
agnosis record is available and the light
and indicator do not blink, replace the mul-
tifunction meter.
B
a
4. Connect the engine temperature sensor
coupler.
Diagnostic display check

1. Create a condition so that a diagnostic
c code is recorded.
b
2. Supply power to the ECM, and then check
that the “WARNING” indicator light “a”
blinks and the diagnostic code “b” is indi-
d cated.
6. Install the fuel pump module. See “Fuel b

tank and fuel pump module” (4-8).
Check engine warning indicator

check
1. Start the engine, and then disconnect the
engine temperature sensor coupler “a”.
a
3. If the diagnostic code is not indicated,

a check the “Diagnosis record” of the YDIS.
If a diagnosis record is available and the
diagnostic code is not indicated, replace
the multifunction meter.
7-42
Indication system
Oil pressure warning indicator check

1. Disconnect the oil pressure switch coupler a
“a”, and then ground the terminal.
1
P/W
a B P
2. Start the engine and operate it at trolling

speed for about 2 minutes.
2. Start the engine, and then increase the en- 3. Check that the engine overheat warning
gine speed to 6000 r/min or more. indicator “a”, the check engine warning in-
dicator “b”, and the “WARNING” indicator
3. Check that the oil pressure warning indica- light “c” blink, and the buzzer sounds inter-
tor “a”, the check engine warning indicator mittently. After 5 seconds, check that the
“b”, and the “WARNING” indicator light “c” engine overheat warning indicator and the
blink, and the buzzer sounds intermittently “WARNING” indicator light stop blinking
for 30 seconds. and remain on, and the buzzer sounds
continuously. After 30 seconds, check that
the buzzer stops.
a b c
4. If the light and indicator do not blink, check a b c

the “Diagnosis record” of the YDIS. If a di-
agnosis record is available and the light 4. If the light and indicator do not blink, check
and indicator do not blink, replace the mul- the “Diagnosis record” of the YDIS. If a di-
tifunction meter. agnosis record is available and the light
and indicator do not blink, replace the mul-
5. Connect the oil pressure switch coupler. tifunction meter.
Engine overheat warning indicator 5. Connect the thermo switch coupler.

check
1. Disconnect the thermo switch coupler “a”, Buzzer check
and then connect the jumper lead “1” to the 1. Disconnect the buzzer coupler “a”.
thermo switch coupler terminals (wire har-
ness end). 2. Supply power to the ECM, and then mea-
sure the input voltage at the buzzer cou-
pler terminals (wire harness end). Check
the wire harness if out of specification.
7-43
Indication system
L/R B/L
a
Input voltage
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”.
5. Check that the buzzer sounds. Replace

the buzzer if does not sound.
b a
B R
6. Install the buzzer. See “Steering master”

(8-12).
7. Connect the buzzer coupler.
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
1
Rear section...................................................................... 8-31
Spout installation ...................................................................... 8-33
Reboarding step installation ..................................................... 8-33
2
Deck and hull .................................................................... 8-34
3
4
5
6
7
8
9
A
Steering pad and handlebar cover
Steering pad and handlebar cover
3 5.5 N·m (0.55 kgf·m, 4.06 lb·ft)
4
LT
1 242
0.4 N·m (0.04 kgf·m, 0.30 lb·ft)

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

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

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

7
LT
242
7 N·m (0.7 kgf·m, 5.2 lb·ft)
2 N·m (0.2 kgf·m, 1.5 lb·ft)

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
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 LT
1 Align the hole “a” in the handlebar switch (left)

242 2
“1” with the stopper bolt “3”.
2
3
a a
2
3
3
2
c
2 c
1
a
[3] 2
b [1]
b
1
[2]
Clearance (reference data)
“b”: 0.4 mm (0.02 in) [4]
“c”: 1.1 mm (0.09 in)
Handlebar switch bolt (left) “2”

Handlebar holder bolt “3”
3.5 N·m (0.35 kgf·m, 2.58 lb·ft)
21 N·m (2.1 kgf·m, 15.5 lb·ft)
T.
R.
T.
R.
4. Install the handlebar switch (right) “1”, and

2. Install the stopper bolts “1”, and then tight-
then tighten the bolts “2” to the specified
en them to the specified torque.
torque.
1
Align the hole “a” in the handlebar switch (right)
“1” with the stopper bolt “3”.
3a 2
1
1
Handlebar switch stopper bolt “1”

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

3.5 N·m (0.35 kgf·m, 2.58 lb·ft)
T.
R.
6. Install the handlebar grips “2”.
7. Install the washers “3” and bolts “4”, and

torque.
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 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
8-5
Front hood
Front hood
10 3.5 N·m (0.35 kgf·m, 2.58 lb·ft)
5
17
15
1
3
2
11 16
14 12 9
18
4
13 7 N·m (0.7 kgf·m, 5.2 lb·ft)
8
22
6
20 7
24
21
26 27 19
25
25
22
22
23

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 N·m (0.35 kgf·m, 2.58 lb·ft)

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

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

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

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

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 N·m (0.25 kgf·m, 1.84 lb·ft)

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

17 Grommet 1
8-10
Steering master ASSY
Steering master ASSY
5
17 N·m (1.7 kgf·m, 12.5 lb·ft)
6
LT
242
7
4
3
9 8
2
LT
242
7 N·m (0.7 kgf·m, 5.2 lb·ft) 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 N·m (0.4 kgf·m, 3.0 lb·ft)
4 N·m (0.4 kgf·m, 3.0 lb·ft)

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

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 N·m (0.4 kgf·m, 3.0 lb·ft)
4 N·m (0.4 kgf·m, 3.0 lb·ft)

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

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 ASSY

“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 N·m (1.6 kgf·m, 11.8 lb·ft)
T.
R.
8-14
Steering cable and speed sensor lead
LT
7 N·m (0.7 kgf·m, 5.2 lb·ft) 572
4 6
13
12
7
5 4 N·m (0.4 kgf·m, 3.0 lb·ft)
10 LT
242
1 11
LT
3
242
2
9
7 N·m (0.7 kgf·m, 5.2 lb·ft)
12
8
12 13
12 13
12 13
12 13 7 N·m (0.7 kgf·m, 5.2 lb·ft)

13
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 7
13 Holder 7
8-15
Steering cable installation (steering

master end) 1
If a cable becomes damaged, replace it.

Never attempt to repair a damaged cable.
LT a
1. Install the steering cable “1” and cable 572
stopper “2”, and then tighten the bolt “3” to

Steering cable set length “a” (jet
pump end)
Install the cable stopper “2” into the groove “a”
14.5 ± 1 mm (0.57 ± 0.04 in)
in the outer cable.
Steering cable locknut (jet pump

end) “1”
T.
R.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
1 2. Install the washer “1” and steering cable

a
joint “2”, and then tighten the steering ca-
ble joint “2” to the specified torque.
2
LT
242
3 3. Install the washer “3” and locknut “4”, and
then tighten the locknut “4” to the specified
Cable stopper bolt “3” torque.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
2. Connect the steering cable joint “1” to the

2
ball joint “2”.
LT 1
A
242
2 3
4
1
A
Steering cable joint “2”
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
Locknut “4”
7 N·m (0.7 kgf·m, 5.2 lb·ft)
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 N·m (1.6 kgf·m, 11.8 lb·ft) 8
9
14
19 10
1
3
4
18 2
BOW 11
17
14
A
22 7 N·m (0.7 kgf·m, 5.2 lb·ft)
15
17 21
23
A 16
13
12
21
20
13
12
5 6
13
7
26 N·m (2.6 kgf·m, 19.2 lb·ft) 2
12 16 N·m (1.6 kgf·m, 11.8 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft)

1 Rear seat 1
2 Bolt 4 M6  40 mm
3 Seat lock 1
5 Front seat 1
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 N·m (1.6 kgf·m, 11.8 lb·ft) 8

9
14
19 10
1
3
4
18 2
BOW 11
17
14
A
22 7 N·m (0.7 kgf·m, 5.2 lb·ft)
15
17 21
23
A 16
13
12
21
20
13
12
5 6
13
7
26 N·m (2.6 kgf·m, 19.2 lb·ft) 2
12 16 N·m (1.6 kgf·m, 11.8 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft)

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 4 N·m (0.4 kgf·m, 3.0 lb·ft)
3

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 4 N·m (0.4 kgf·m, 3.0 lb·ft)
3

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.
Align the protrusion “a” with the slit “b”.
2
a
1
b
3
Cooling water pilot outlet nut “3”

4 N·m (0.4 kgf·m, 3.0 lb·ft)
T.
R.
8-21
Exhaust system
Exhaust system
4.5 N·m (0.45 kgf·m, 3.32 lb·ft)
d b
24 23 a 17
d
c
a
16
24 23 22 15 13
14
c b
22
15
5.5 N·m (0.55 kgf·m, 4.06 lb·ft)
21
6 3
11 20 19
4 2
26
4.5 N·m (0.45 kgf·m, 3.32 lb·ft)
1 18
12 10 26
12
7
LT
8 27 27
242
28 26 26 5 25 25
9 25
5.5 N·m (0.55 kgf·m, 4.06 lb·ft)
29 4.5 N·m (0.45 kgf·m, 3.32 lb·ft)

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
4.5 N·m (0.45 kgf·m, 3.32 lb·ft)

d b
24 23 a 17
d
c
a
16
24 23 22 15 13
14
c b
22
15
5.5 N·m (0.55 kgf·m, 4.06 lb·ft)
21
6 3
11 20 19
4 2
26
4.5 N·m (0.45 kgf·m, 3.32 lb·ft)
1 18
12 10 26
12
7
LT
8 27 27
242
28 26 26 5 25 25
9 25
5.5 N·m (0.55 kgf·m, 4.06 lb·ft)
29 4.5 N·m (0.45 kgf·m, 3.32 lb·ft)

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
Make sure to fit the projections “a” on the rub-

ber hose “2” with the grooves in the plate “1”.
b
2 a
a
a Rubber hose clamp “2”

4.5 N·m (0.45 kgf·m, 3.32 lb·ft)
T.
R.
4. Install the water lock and rubber hose “1”,
and then tighten the clamp “2” to the spec-
1 ified torque.
2. Install the rubber hose “1” and a new ex-

haust valve “2”, and then tighten the nuts Align the projection “a” on the rubber hose “1”
“3” to the specified torque. with the alignment mark “b” on the water tank.
Do not reuse an exhaust valve, always re- 1

a
b
1
2
2
Rubber hose clamp “2”

3 4.5 N·m (0.45 kgf·m, 3.32 lb·ft)
T.
R.
Rubber hose nut “3”

5.5 N·m (0.55 kgf·m, 4.06 lb·ft)
T.
R.
3. Install the water tank “1”, and then tighten

the clamp “2” to the specified torque.
Align the alignment mark “a” on the rubber

hose “3” with the alignment mark “b” on the wa-
ter tank “1”.
8-24
Exhaust system
5. Install the resonator “1”, and then tighten
the clamp “2” to the specified torque.
Fit the protrusion “a” on the resonator “1” be-

tween the protrusions “b” on the rubber hose.
2
1
Rubber hose clamp “2”

4.5 N·m (0.45 kgf·m, 3.32 lb·ft)
T.
R.
6. Install the band.
8-25
RiDE motor
RiDE motor
11 2
4 N·m (0.4 kgf·m, 3.0 lb·ft) A 16
LT
7 N·m (0.7 kgf·m, 5.2 lb·ft)
12 242
4
17 N·m (1.7 kgf·m, 12.5 lb·ft)
15
10
3 13
9
5 14
A 13
14
6
5 LT
A 8
LT
7 242
242
11 N·m (1.1 kgf·m, 8.1 lb·ft)

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”, and water tank “3”. 2
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]
2
1
[3] [2] [1]
RiDE motor nuts “2”

2 17 N·m (1.7 kgf·m, 12.5 lb·ft)
T.
R.
RiDE motor bolts “3”
17 N·m (1.7 kgf·m, 12.5 lb·ft)
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
1
Shift arm bolt “3”
11 N·m (1.1 kgf·m, 8.1 lb·ft)
T.
R.
Trim arm bolt “4”

11 N·m (1.1 kgf·m, 8.1 lb·ft)
2. Install the plate “1”, and then tighten the 4. Adjust the length “a” of the trim rod “1”.
RiDE motor nuts “2” and RiDE motor bolts
“3” to the specified torque in the order [1],
[2], and so on. • The trim rod joint must be screwed in
more than 8 mm (0.31 in).
• The shift rod joint must be screwed in
3 more than 9 mm (0.35 in).
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
1 2 specified torque.
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
LT
Distance “e” 242
4
Trim rod: More than 8.0 mm (0.31
in)
Shift rod: More than 9.0 mm (0.35
in)
2
LT
1 572
Locknut “2”
4 N·m (0.4 kgf·m, 3.0 lb·ft)
T.
R.
Locknut “4” Ride plate bolt “2”

T.
R.
Speed sensor screw “4”

8. Connect the shift rod joint “1” and trim rod 4 N·m (0.4 kgf·m, 3.0 lb·ft)
joints “2”.
12. Fasten the RiDE motor harness “1” using
1
the holders “2” and plastic tie “3”.
2
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
16. Connect the RiDE motor couplers “a” and
“b”, and then fasten the RiDE motor lead
Align the mark “a” on the rubber hose “3” with using a plastic tie “1”.
the mark “b” on the water tank “1”.
1
3 a
2 b
1
b
a
17. Install the deck beam “1”, and then tighten
the deck beam bolts “2” to the specified
Rubber hose clamp “2” torque.
4.5 N·m (0.45 kgf·m, 3.32 lb·ft)
T.
R.
14. Install the rubber hose “1”, and then tight- 1

en the rubber hose clamps “2” and “3” to
the specified torque. 2
Align the protrusion “a” on the rubber hose “1” LT
271
with the mark “b” on the water tank “4”.
15. Install the resonator “5”, and then tighten

the clamp “6” to the specified torque. Deck beam bolt “2”
16 N·m (1.6 kgf·m, 11.8 lb·ft)
T.
R.
Fit the protrusion “c” on the resonator “5” be- 18. Initialize the RiDE system using the YDIS.
tween the protrusions “d” on the rubber hose See “YDIS Instruction Manual”.
“1”.
RiDE system initialization
1 4 d Connect the YDIS and initialize the RiDE sys-
2 tem. See “YDIS Instruction Manual”.
5
c
6
a 3
b
Rubber hose clamp “2”, “3”, and “6”

4.5 N·m (0.45 kgf·m, 3.32 lb·ft)
T.
R.
8-30
Rear section
Rear section
16 N·m (1.6 kgf·m, 11.8 lb·ft)
1
BOW 2
2
3
6
5.5 N·m (0.55 kgf·m, 4.06 lb·ft)
5
14
4
17 16
2.5 N·m (0.25 kgf·m, 1.84 lb·ft)
2
LT
1
14 271
14
15
8
14 9
72 10
LT
2 N·m (0.2 kgf·m, 1.5 lb·ft)
271 13

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 M8  47 mm
15 Reboarding step 1
16 Bracket 2
8-31
Rear section
16 N·m (1.6 kgf·m, 11.8 lb·ft)

1
BOW 2
2
3
6
5.5 N·m (0.55 kgf·m, 4.06 lb·ft)
5
14
4
17 16
2.5 N·m (0.25 kgf·m, 1.84 lb·ft)
2
LT
1
14 271
14
15
8
14 9
72 10
LT
2 N·m (0.2 kgf·m, 1.5 lb·ft)
271 13

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
2 271
Face the mark “a” toward the BOW. 2
1
1 2
a LT
271
BOW
2 4
3 Reboarding step bolt “2”
16 N·m (1.6 kgf·m, 11.8 lb·ft)
T.
R.
3. Remove the plastic ties. Check that the re-
boarding step returns properly.
Spout nut “2”

5.5 N·m (0.55 kgf·m, 4.06 lb·ft)
T.
R.
Spout hose clamp “4”

2.5 N·m (0.25 kgf·m, 1.84 lb·ft)
Reboarding step installation

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
25 26
16 N·m (1.6 kgf·m, 11.8 lb·ft)
34 7 N·m (0.7 kgf·m, 5.2 lb·ft)

15
33 13 12
16
7
18 11 14
19 19
7 N·m (0.7 kgf·m, 5.2 lb·ft) 17

16
13 N·m (1.3 kgf·m, 9.6 lb·ft) 15
7 3
4
23
11 56
2
1 8 32
22
31
10
9 21 20 16 N·m (1.6 kgf·m, 11.8 lb·ft)

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
25 26
16 N·m (1.6 kgf·m, 11.8 lb·ft)
34 7 N·m (0.7 kgf·m, 5.2 lb·ft)

15
33 13 12
16
7
18 11 14
19 19
7 N·m (0.7 kgf·m, 5.2 lb·ft) 17

16
13 N·m (1.3 kgf·m, 9.6 lb·ft) 15
7 3
4
23
11 56
2
1 8 32
22
31
10
9 21 20 16 N·m (1.6 kgf·m, 11.8 lb·ft)

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
8-35
Deck and hull
30 24
29
28
27
25 26
16 N·m (1.6 kgf·m, 11.8 lb·ft)
34 7 N·m (0.7 kgf·m, 5.2 lb·ft)

15
33 13 12
16
7
18 11 14
19 19
7 N·m (0.7 kgf·m, 5.2 lb·ft) 17

16
13 N·m (1.3 kgf·m, 9.6 lb·ft) 15
7 3
4
23
11 56
2
1 8 32
22
31
10
9 21 20 16 N·m (1.6 kgf·m, 11.8 lb·ft)

33 Ornament 1
34 Ornament 1
8-36
Deck and hull
— MEMO —
8-37
Troubleshooting
1
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
2
Diagnostic code and checking step............................................ 9-8
3
Engine unit troubleshooting (diagnostic code not detected)..... 9-19
4
5
6
7
8
9
A
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
Yamaha 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
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 Steering sensor
Intake air pressure Fuel injection duration No-wake mode switch
TPS 1 Engine temperature Cruise assist set switch
Throttle valve opening angle Intake air temperature Cruise assist up switch
Ex. manifold water tempera-
TPS 2 Cruise assist down switch
ture*3
APS 1 Engine shut-off switch Trim up switch
APS 2 Thermo switch Trim down switch
RPS main*1 Slant detection switch Main relay
RPS sub*2 Oil pressure switch ETV relay
Atmospheric pressure Engine start switch Fuel pump relay
Ignition timing APS full close switch Shift position angle
*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
9-2
YDIS
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.
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 Thermo switch
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
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.
9-3
YDIS
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).
To perform the SCU initial learning, see the YDIS (Ver. 2.20) Instruction Manual.
Connecting the communication cable to the watercraft
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
• 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
• 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”.
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.
9-5
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.
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   
63 Intake system   
EX. manifold water temp sensor
65   
(Thermo sensor)
68 No-wake mode switch   
112, 113, 114,
115, 116, 117,
119, 123, 138, ETV system   
141, 142, 143,
144, 145
124, 125, 126,
TPS   
127, 128
131, 132, 133,
APS   
134, 135
150, 151, 152,
RPS   
153, 154
157, 158, 159,
160, 161, 162, SCU   
163, 164
251 Low octane fuel — — 
252 Overheat — — 
253 Low oil pressure — — 
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
7-17
using the YDIS.
Measure the engine tempera-
7-17
ture sensor input voltage.
Engine temper- Check the black/yellow (B/Y)
15 Trolling speed is unstable.*1
ature sensor and black/orange (B/O)
A-2
engine temperature sensor
leads for continuity.
7-17
ture sensor resistance.
Check the battery voltage
9-2
using the YDIS.
7-3
Check the fuse for continuity.
7-32
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-
7-18
ture using the YDIS.
Measure the intake air tem-
Air tempera- 7-18
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-
7-18
perature sensor resistance.
9-8
Diag-
See
page
code
Measure the cam position
7-26
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 continu-
ity.
Measure the cam position
7-26
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 7-27
YDIS.
Measure the slant detection
7-27
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
7-27
switch for continuity.
Check the APS full close
switch operation using the 7-21
YDIS.
Measure the APS full close
7-21
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 continu-
ity.
9-9
Diag-
See
page
code
Check the steering sensor
7-28
operation using the YDIS.
Measure the steering sensor
7-28
input voltage.
55 Steering sensor Normal operation.
Check the orange/red (O/R),
white/blue (W/L), and
A-2
black/orange (B/O) steering
sensor leads for continuity.
Check the TPS output voltage
and throttle valve opening 7-19
using the YDIS.
Check the ECM circuit for con-
7-29
tinuity.
Check the ETV relay for conti-
7-23
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. 7-32
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 7-19
using 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-
5-31
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
7-29
tinuity.
Cross-check the ECM or
121 ETV system Engine speed is limited. —
replace.
122 ETV system Engine speed is limited. Cross-check the ETV. —
7-3
Check the ETV relay and fuse
7-23
(ETV relay) for continuity.
7-29
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-
7-29
tinuity.
7-19
using the YDIS.
126 TPS Engine speed is limited.
7-29
tinuity.
7-19
using the YDIS.
129 ETV Engine speed is limited.
Check the ETV relay and fuse 7-3
(ETV relay) for continuity. 7-23
131 Check the APS output voltage
7-21
132 using the YDIS.
APS Engine speed is limited.
133 Check the APS circuit for con-
134 7-22
tinuity.
Check the APS circuit for con-
135 APS Engine speed is limited. 7-22
tinuity.
9-11
Diag-
See
page
code
7-29
tinuity.
7-23
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
7-32
3-6
specific gravity.
7-29
tinuity.
7-23
7-32
and throttle valve opening 7-19
using the YDIS.
142 ETV system Engine speed is limited.
throttle inner surface for dam- 5-31
age and wear.
9-12
Diag-
See
page
code
7-29
tinuity.
7-23
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
7-32
3-6
specific gravity.
7-3
7-23
7-32
145 ETV system Engine speed is limited.
throttle inner surface for wear 5-31
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.
7-29
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-
7-29
tinuity.
9-13
Diag-
See
page
code
3-6
specific gravity.
Stop the engine, leave it off for
more than 1 minute, and then
—
restart it to check the opera-
tion.
Check the coupler connection
—
(for poor connection).
Engine speed is limited. Check the fuse for continuity. 7-3
157 SCU
Shifting is impossible. Check the SCU relay for conti-
7-25
nuity.
(B) RiDE motor leads of the
A-2
RiDE power supply circuit for
continuity.
Check the white (W) and blue
(L) RiDE communication leads A-2
for continuity.
Check the electric trim switch
7-26
Changing the trim angle is operation using the YDIS.
158 SCU
impossible. Measure the electric trim
7-26
switch resistance.
9-14
Diag-
See
page
code
Check that there is no foreign
matter on the rotating part of 6-7
the reverse gate.
3-6
specific gravity.
—
tion.
Check the shift arm for wob-
8-26
bles or deflection.
Check the shift rod for discon-
Engine speed is limited. nection, looseness, and defor- 8-26
159 SCU
Shifting is impossible. mation. Check the shift rod 8-28
length.
Check the reverse gate opera-
tion and for deformation. 6-7
Check the ball joint.
—
Check the SCU relay for conti-
7-25
nuity.
Connect the YDIS to conduct
—
“Initial leaming”.
9-15
Diag-
See
page
code
Check that there is no foreign
matter on the rotating part of 6-7
the jet nozzle.
3-6
specific gravity.
—
tion.
Check the trim arm for wob-
8-26
bles or deflection.
Check the trim rod for discon-
Changing the trim angle is nection, looseness, and defor- 8-26
160 SCU
impossible. mation. Check the trim rod 8-28
length.
Check the jet nozzle for defor-
mation and proper operation. 6-8
Check the ball joint.
—
7-25
nuity.
Connect the YDIS to conduct
—
“Initial leaming”.
3-6
specific gravity.
Engine speed is limited. —
161 SCU restart it to check the opera-
Shifting is impossible. tion.
7-25
nuity.
9-16
Diag-
See
page
code
3-6
specific gravity.
Changing the trim angle is —
162 SCU restart it to check the opera-
impossible. tion.
7-25
nuity.
—
(B) RiDE motor leads of the
A-2
RiDE power supply circuit for
continuity.
—
specific gravity.
Engine speed is limited. 7-25
163 SCU nuity.
Shifting is impossible.
—
tion.
7-13
age
7-13
7-13
• Rectifier/regulator output
7-13
peak voltage
3-6
specific gravity.
Engine speed is limited. Stop the engine, leave it off for
164 SCU
Shifting is impossible. more than 1 minute, and then
—
tion.
251 Low octane fuel — Check the fuel octane. 2-1
9-17
Diag-
See
page
code
Check the cooling water pas-
1-31
sages for obstructions.
7-17
ture sensor resistance.
Check that there is no short
circuit between the black/yel-
low (B/Y) and black/orange A-2
(B/O) engine temperature
sensor leads.
Check the thermo switch for
7-16
252 Overheat Engine speed is limited continuity.
circuit between the pink (P)
A-2
and black (B) thermo switch
leads.
Measure the thermo sensor
7-16
resistance.
circuit between the black/blue
A-2
(B/L) and black/orange (B/O)
thermo sensor leads.
Check the engine oil level. 3-4
Check the oil pressure switch
7-15
for continuity.
Low oil pres- Check that there is no short
253 Engine speed is limited
sure circuit in the pink/white (P/W) A-2
oil pressure switch lead.
Check the oil passages for
1-29
obstructions.
9-18
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.
7-32
Starter relay malfunction Check the starter relay. 7-34
Starter motor does Engine start switch mal- Check the engine start switch. [han-
7-32
not operate function dlebar switch (left)].
Short, open, or loose con- Measure the starter relay input volt- 7-34
nection in starter motor cir- age.
cuit Check the wire harness. A-2
Disassemble and check the starter
Starter motor malfunction 7-35
motor.
Disassemble and check the engine
Stuck piston or crankshaft 5-85
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, 5-66
ates, but the engine
malfunction or crankshaft Woodruff key. 5-71
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.
Check the APS output voltage using
Throttle valve does APS malfunction 7-21
the YDIS.
not move properly
Check the TPS output voltage using
TPS malfunction 7-19
the YDIS.
Throttle valve malfunction Check the ETV. 5-31
9-19
See
page
Battery performance Check the battery voltage and spe-
3-6
decrease 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
7-32
ECM does not oper- Main relay malfunction Check the main relay. 7-33
ate Short, open, or loose con- Measure the ECM input voltage. 7-29
nection in ECM circuit Check the ECM circuit for continuity. 7-29
ECM malfunction Replace the ECM. —
Engine shut-off cord clip Check that the engine shut-off cord
7-32
not installed clip is installed properly.
Engine stop switch mal- Check the engine stop switch conti-
7-32
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 continu-
ity.
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.
9-20
See
page
Fuel leakage Check the fuel hose. 4-1
7-3
7-32
Clogged fuel pump filter Clean the fuel pump filter. 4-11
Check the fuel pump module opera-
7-31
tion sound using the YDIS.
Fuel not supplied (all
cylinders) Measure the fuel pump module
Fuel pump module mal- 7-31
input 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. 7-31
tion
Measure the compression pressure. 5-1
Measure the valve clearance. 3-12
Check the camshaft for damage. 5-45
Check the cylinder head gasket and
5-57
cylinder head warpage.
Compression pres- Compression leakage
sure is low Check the valve and valve seat for
5-58
wear.
Check the piston and piston ring for 5-88
damage. 5-89
Check the cylinder for damage. 5-88
Improper valve timing Check the timing chain. 5-47
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. 5-31
not move properly
9-21
See
page
Spark plug malfunction Check the spark plug. 3-6
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 continu-
ity.
Measure the ECM output peak volt-
ECM malfunction 7-11
age.
Check the fuel injector operation
7-30
Fuel injector malfunction sound using the YDIS.
Measure the fuel injector resistance. 7-30
Measure the fuel injector input volt-
7-30
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. 3-12
Check the camshaft for damage. 5-45
Check the cylinder head gasket and
5-57
cylinder head warpage.
Compression pres- Compression leakage
sure is low Check the valve and valve seat for
5-58
wear.
Check the piston and piston ring for 5-88
damage. 5-89
Check the cylinder for damage. 5-88
Improper valve timing Check the timing chain. 5-47
9-22
Symptom 1: Limited engine speed
See
page
• Buzzer sounds Check the cooling water pilot outlet
—
intermittently Clogged cooling water pas- for water discharge.
• Overheat warning sage Check the water inlet strainer. 3-3
indicator blinks
Check the cooling water passage. 1-30
• Check engine
warning indicator Thermostat malfunction Check the thermostat. 5-22
blinks Measure the engine temperature
7-17
sensor resistance.
Engine temperature sen- Check that there is no short circuit
sor malfunction between the black/yellow (B/Y) and
A-2
black/orange (B/O) engine tempera-
ture sensor leads.
Check the thermo switch for continu-
7-16
ity.
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.
• Buzzer sounds Check the engine oil level. 3-4
intermittently Check for engine oil leakage. —
• Oil pressure warn-
Insufficient engine oil Check the oil pump. 5-39
ing indicator blinks
Check the oil strainer. 5-81
Check the oil passage. 1-29
Check the oil pressure switch conti-
7-15
nuity.
Oil pressure switch mal-
function Check that there is no short circuit in
the pink/white (P/W) oil pressure A-2
switch lead.
9-23
Symptom 1: Discharged battery
See
page
Battery performance Check the battery voltage and spe-
3-6
decrease 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 1-30
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.
9-24
— MEMO —
9-25
Appendix
1
Wiring diagram ...................................................................A-1
How to use the wiring diagram ................................................... A-1
GP1800 ...................................................................................... A-2
2
3
4
5
6
7
8
9
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 : Pink
Br : Brown P/B : Pink/Black
B/G : Black/Green P/G : Pink/Green
B/L : Black/Blue P/R : Pink/Red
B/O : Black/Orange P/W : Pink/White
B/R : Black/Red Pu/B : Purple/Black
B/W : Black/White Pu/G : Purple/Green
B/Y : Black/Yellow Pu/R : Purple/Red
G : Green Pu/Y : Purple/Yellow
Gy : Gray R : Red
G/O : Green/Orange R/W : Red/White
L : Blue R/Y : Red/Yellow
L/B : Blue/Black Sb : Sky blue
L/R : Blue/Red W : White
L/W : Blue/White W/B : White/Black
L/Y : Blue/Yellow W/G : White/Green
Lg : Light green W/L : White/Blue
O : Orange Y : Yellow
O/G : Orange/Green Y/G : Yellow/Green
O/R : Orange/Red Y/W : Yellow/White
O/W : Orange/White
Example:
R/Y: Red with Yellow tracer stripe wire
A-1
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 YDS (Yamaha Dealer System, U.S.A. only) or YPEC-web (except
U.S.A.). Additional information and up-to-date information on Yamaha products and services are avail-
able on YDS, YMPE (Yamaha Multimedia Product Encyclopedia, Canada only), or Yamaha Service
Portal (except U.S.A. and Canada).
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.
A TIP provides key information to make procedures easier or clearer.
WaveRunner
GP1800
SERVICE MANUAL
©2017 by Yamaha Motor Co., Ltd.
3rd Edition, November 2017
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
LIT-18616-03-72
F3P-28197-ZV-11_cover.indd 4-6 2017/11/03 17:46:49

GP1800
WaveRunner
GP1800
GP1800 (F3P)
SERVICE MANUAL
LIT-18616-03-72
Nov. 2017 ! F3P-28197-ZV-11
(E_2)
F3P-28197-ZV-11_cover.indd 1-3 2017/11/03 17:46:48

GP1800 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
1 9 h
W
PUSH PULL
R
B
R
10 18 k
L/R
L/B
Gy
Br Br W B
B
A i
B
W
FREE
B
l
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)
W
Br
R
Y
L/Y
L
Gy
Y/W
Gy
B
B
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
P/R
3 1
W/B
B
R/Y
6 4
Sb
Lg
B
Starter
10
11
12
4 1 4 1 3 1
1
2
3
4
5
6
7
1
2
3
1
2
3
4
5
6
7
8
9
relay
O/W
B/W
P/W
O/R
8 5 Battery
B/R
P/R
8 5
R/W
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
1 G
2 W R/Y 1
3 G/O 2
R/Y 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
R/Y 10
13 B/L 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
7 13 19 26 21 Y
22 W/G
23 B/Y
25 O/R O 4
26 O O 5
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
47 W/B B
B 2
49 O/R B 3
50 O/W B 4
51 O/W
52 L B 6
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
ECM 61 B/Y
G
G
G
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
4 8
P
B
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
Joint coupler 5
W
P
L
R
O
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
#1 #2 #3 #4
G
G
G
B 4
B 5
78 G
79 P/W Intake air B 7
80 Y/W pressure Knock 8 4 8
B
81 L/R sensor sensor Thermo Pickup 1
Slant Fuel injector switch coil B 1
83 Pu/G ETV Cam Oil detection Steering Intake air Engine
61 69 77 86 84 Fuel pump Ignition coil Rectifier/ B 2
Pu/Y position pressure switch sensor temperature temperature Stator
85 B/R module sensor Thermo sensor regulator
86 B/W RiDE motor sensor switch sensor coil 2
A-2
SF3PZV11_W.D.indd 2 2016/10/05 15:08:47

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
GP1800
WaveRunner
GP1800
GP1800 (F3P)
SERVICE MANUAL
LIT-18616-03-72
Nov. 2017 ! F3P-28197-ZV-11
(E_2)
F3P-28197-ZV-11_cover.indd 1-3 2017/11/03 17:46:48

F3P 28197 ZV 11

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F3P 28197 ZV 11

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GP1800

F3P-28197-ZV-11_cover.indd 1-3 2017/11/03 17:46:48

A TIP provides key information to make procedures easier or clearer.

F3P-28197-ZV-11_cover.indd 4-6 2017/11/03 17:46:49

Safety while working.......................................................... 1-1

Identification number......................................................... 1-5

How to use this manual ..................................................... 1-6

Adhesive, lubricant, sealant, and thread locking

Special service tool............................................................ 1-9

Model feature .................................................................... 1-22

Technical tips.................................................................... 1-23

Safety while working

Ventilation Working with crane

Handling of heat gun

Parts, lubricants, and sealants

Disassembly and assembly

• Install bearings so that the bearing identifica-

Identification number Jet pump unit serial number

1. Jet pump unit name

Engine serial number Hull identification number (H.I.N.) (ex-

Starting engine serial number

How to use this manual

For troubleshooting procedures, see Chapter 9, “Troubleshooting”.

Impeller housing and impeller duct ASSY

2 Impeller, drive shaft, and impeller duct

Do not press the drive shaft threads

Conditions when testing and adjusting

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

Special service tool

Gauge stand 3-12, 5-44,

Dial gauge needle 3-12, 5-44,

Dial gauge set 3-12, 5-44,

Camshaft wrench 3-12, 5-45,

Fuel pressure gauge adapter 4-3

Fuel pressure gauge 4-3

Compression gauge extension 5-1

Exhaust pipe wrench 5-18

Leakage tester 5-30, 5-38

Air cooler attachment 5-30

Coupler wrench 5-38, 5-44,

Stopper guide plate 5-38, 6-11,

Stopper guide stand 5-38, 6-11,

Valve spring compressor attachment 5-57, 5-64

Valve guide remover/installer 5-59, 5-60

Valve guide installer 5-60

Valve guide reamer 5-60

Valve lapper 5-60, 5-63

Valve seat cutter holder 5-61

Valve seat cutter 30 5-61