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WaveRunner FZR-GX1800
Yamaha WaveRunner FZR-GX1800 User Manual
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SER
VICE MANU
AL
W
a
veRunner
F2C-28197-1M-11
LIT
-18616-03-18
FZR
GX1800 (F2R)
FZS
GX1800A (F2C)
2
Table of Contents
Chapter 1 General Information
4
General Information
3
Table of Contents
4
How to Use this Manual
6
Manual Format
6
Symbols
7
Abbreviation
8
Safety While Working
9
Fire Prevention
9
Ventilation
9
Self-Protection
9
Parts, Lubricants, and Sealants
9
Good Working Practices
10
Disassembly and Assembly
10
Identification Number
11
Primary I.D. Number
11
Engine Serial Number
11
Jet Pump Unit Serial Number
11
Hull Identification Number (H.I.N.)
11
Special Service Tool
12
Measuring
12
Removal and Installation
14
Feature and Benefit
19
Watercraft Overview
19
Rear Seat
20
Telescopic Steering System
21
Shift Lever Assembly
22
Watertight Compartment
23
Fire Extinguisher Location
23
Hull Design
24
Engine Overview
25
Supercharger Assembly
26
Air Cooler Assembly
26
Ecm
27
Drive Shaft
27
Dual Analog Meter Unit
28
Information Display Warnings
29
Self-Diagnosis
29
Yamaha Security System
30
Gen Info
30
Technical Tips
31
Engine Control
31
ECM Circuit Diagram
32
ECM Coupler Layout
33
Control System
35
Chapter 2 Specification
39
General Specification
40
Engine
42
Maintenance Specifications
42
Fuel System
45
Electrical
46
Hull and Hood
46
Jet Pump Unit
46
Specified Torques
50
Tightening Torques
50
General Torque
55
Lubrication System
56
Cooling System
57
Cable and Hose Routing
59
Starboard Bow View
59
Top View
60
Port View
62
Chapter 3 Periodic Check and Adjustment
65
Maintenance Interval Chart
66
Control System
67
Jet Thrust Nozzle Steering Angle Check and Adjustment
67
Periodic Service
67
Steering System Check
67
Jet Thrust Nozzle QSTS Angle Check and Adjustment
69
Throttle Lever Free Play Check and Adjustment
70
Shift Cable Check and Adjustment
73
Fuel System
74
Trolling Speed Check
74
Fuel Line Check
75
Power Unit
76
Valve Clearance Measurement
76
Water Separator Check
76
Compression Pressure Measurement
78
Engine Oil Level Check
79
Engine Oil Change
80
Oil Filter Replacement
81
Air Filter Element Check
82
Spark Plug Check
83
Battery Check
84
Electrical
84
Jet Pump Unit
86
Jet Pump Unit Check
86
Bilge Strainer
87
Bilge Strainer Check
87
Drain Plug Check
88
Electric Bilge Pump Strainer Check
88
General
88
Throttle Valve and Engine Internal Components
88
Lubrication Points
89
Chapter 4 Fuel System
93
Fuel Tank Removal
94
Fuel Tank, Fuel Pump Module, and Fuel Hose
94
Fuel Hose Disconnection
97
Quick Connector Removal
97
Fuel Pump Module Removal
98
Fuel Sender Removal
98
Check Valve Check
99
Rollover Valve Check
99
Fuel Filler Neck and Hose Check
100
Fuel Line Check
100
Fuel Pump Module Check
100
Fuel Injector Check
101
Fuel Injector Installation
101
Fuel Tank Check
101
Fuel Pump Module Installation
102
Fuel Sender Installation
102
Fuel Hose Connection
103
Quick Connector Installation
103
Fuel Pressure Measurement
104
Chapter 5 Power Unit
105
Engine Unit
112
Engine Unit Removal 1
112
Engine Unit Removal 2
115
Engine Mount Removal
116
Engine Unit Removal
117
Breather Assembly Check
122
Engine Mount Check
123
Engine Unit Installation
123
Hose Joint Check
123
Muffler
131
Muffler Disassembly
131
Exhaust Pipe 3 Installation
133
Exhaust Pipe 3 Removal
133
Thermo Sensor Check
133
Thermostat and Electrical Component
134
Thermostat and Electrical Component Removal
134
Thermostat Check
137
Thermostat Housing Check
137
Air Cooler and Supercharger Removal
138
Air Cooler, Supercharger, and Throttle Body Assembly
138
Intake Assembly Removal
140
Intake Disassembly
142
Air Cooler Check
143
Intake Manifold Check
144
Supercharger Check
144
Throttle Body Assembly Check
144
Intake Manifold Installation
145
Supercharger Installation
145
Air Cooler Intake Pipe Installation
146
Boost Pipe Installation
147
Oil Cooler and Oil Pump Assembly Removal
148
Oil Cooler, Oil Pump Assembly, and Drive Gear
148
Drive Gear Assembly Removal
152
Drive Gear Disassembly
152
Oil Cooler Assembly Check
153
Drive Gear Check
154
Idle Gear Check
154
Oil Pump Assembly Check
154
Drive Gear Clutch Check
155
Drive Gear Assembly Installation
156
Oil Pump Drive Gear Assembly
156
Oil Pump Assembly Installation
157
Camshaft
158
Cylinder Head Cover Removal
158
Camshaft and Timing Chain Removal
159
Camshaft Removal
161
Camshaft Check
163
Camshaft Sprocket Check
165
Timing Chain Check
165
Timing Chain Tensioner Check
165
Camshaft Installation
166
Cylinder Head Cover Installation
169
Valve Clearance Adjustment
169
Cylinder Head
173
Cylinder Head Assembly Removal
173
Cylinder Head Disassembly
174
Cylinder Head Assembly Removal
175
Cylinder Head Check
175
Valve Removal
175
Valve Check
176
Valve Spring Check
176
Valve Guide Check
178
Valve Guide Removal
178
Valve Guide Installation
179
Valve Seat Check
180
Valve Seat Refacing
181
Valve Installation
184
Cylinder Head Installation
185
Generator Cover and Flywheel Magneto
186
Generator Cover and Flywheel Magneto Removal
186
Generator Cover Disassembly
188
Drive Coupling Removal
189
Flywheel Magneto Removal
190
Bearing Removal
192
Idle Gear and Shaft Check
192
Starter Clutch Check
192
Bearing Installation
193
Generator Cover Assembly
194
Oil Seal Installation
194
Flywheel Magneto Installation
195
Drive Coupling Installation
200
Oil Separator Tank and Oil Pan
202
Oil Separator Tank and Oil Pan Removal
202
Oil Pan Disassembly
205
Oil Pan Check
206
Oil Separator Tank Cover Check
206
Oil Separator Tank Cover Installation
206
Oil Separator Tank Cover Removal
206
Crankcase, Connecting Rod, and Piston
207
Crankcase, Connecting Rod, and Piston Disassembly
207
Connecting Rod and Piston Removal
209
Crankcase Disassembly
209
Anode Check
210
Crankcase Check
210
Piston Check
211
Piston Ring Check
212
Piston Pin Check
213
Connecting Rod Check
214
Cylinder Check
214
Crankshaft Check
215
Crankshaft Pin Oil Clearance Check
215
Crankshaft Journal Oil Clearance Check
218
Connecting Rod and Piston Installation
221
Crankcase Assembly
223
Chapter 6 Jet Pump Unit
225
Intake Grate and Ride Plate
226
Intake Grate and Ride Plate Removal
226
Jet Pump Unit
227
Jet Pump Unit Removal
227
Jet Pump Unit Installation
229
Reverse Gate
231
Reverse Gate Removal
231
Jet Thrust Nozzle and Nozzle Ring
232
Jet Thrust Nozzle and Nozzle Ring Removal
232
Impeller Duct and Impeller Housing
233
Impeller Duct, Impeller Housing and Nozzle Removal
233
Impeller Duct and Drive Shaft
234
Impeller Duct and Drive Shaft Disassembly
234
Drive Shaft Removal
236
Drive Shaft Check
238
Impeller Check
238
Impeller Housing Check
238
Drive Shaft Installation
239
Impeller Duct, Impeller Housing and Nozzle Installation
241
Transom Plate and Hoses
244
Transom Plate Installation
245
Water Hose Check
245
Driven Coupling Removal
248
Intermediate Housing Disassembly
248
Intermediate Housing Removal
248
Intermediate Drive Shaft and Grease Hose Check
249
Driven Coupling and Intermediate Housing Check
250
Intermediate Housing Assembly
250
Driven Coupling Installation
252
Intermediate Housing Installation
252
Chapter 7 Electrical System
254
Engine Electrical Components
256
Electrical Box
258
Electrical Components
258
Electrical Box Disassembly
259
Fuse Box Disassembly
261
Check Using the YDIS
263
Electrical Analysis
263
Input Voltage Measurement
264
Peak Voltage Measurement
264
Ignition Coil
265
Ignition System
265
Pickup Coil
268
Charging System
269
Stator Coil
269
Rectifier Regulator
271
Control System
273
Oil Pressure Switch
273
Thermoswitch
274
Thermo Sensor
276
Engine Temperature Sensor
277
Intake Air Temperature Sensor
278
Intake Air Pressure Sensor
280
Knock Sensor
281
Throttle Position Sensor
281
Accelerator Position Sensor
284
Electronic Throttle Valve Relay
288
Cam Position Sensor
289
Slant Detection Switch
290
Steering Sensor
291
Reverse Sensor
292
ECM Circuit
293
Earth Plate
294
Electric Bilge Pump
295
Fuel Injector
296
Fuel System
296
Fuel Pump Module
297
Fuse
299
Left Handlebar Switch Assembly
299
Starting System
299
Main and Fuel Pump Relay
300
Starter Relay
302
Armature
307
Starter Motor Operation
307
Rear Cover
310
Remote Control System
310
Starter Motor Assembly
310
Transmitter Registration
310
Remote Control Transmitter
311
Remote Control Receiver
314
Dual Analog Meter Unit
315
Indication System
315
Speed Sensor
316
Switch Assembly
316
Check Engine Warning Indicator
318
Fuel Level Meter Display and Fuel Indicator
318
Diagnostic Display
319
Oil Pressure Warning Indicator
319
Buzzer
320
Engine Overheat Warning Indicator
320
Chapter 8 Hull and Hood
322
Handlebar
324
Handlebar Cover Removal
324
Handlebar Holder Removal
325
Handlebar Assembly Removal
326
Handlebar Check
329
Handlebar Cover Removal
329
Left Handlebar Switch Assembly Check
329
Throttle Cable Removal
329
Handlebar Assembly Installation
330
Handlebar Cover Installation
332
QSTS Grip and Converter
333
QSTS Grip and Converter Disassembly
333
QSTS Cable Removal
335
QSTS Check
335
QSTS Cable Installation
336
Front Hood
338
Front Hood Removal
338
Damper Check
341
Front Hood Assembly
341
Hood Lock Check
341
Rivet Removal
341
Rivet Installation
342
Side Cover Removal
344
Center Cover Disassembly
348
Steering Master Disassembly
351
Hull Hood
354
Steering Arm Installation
354
Steering Master Component Check
354
Remote Control Cables and Speed Sensor Lead
355
Remote Control Cables and Speed Sensor Lead Removal
355
Steering Cable Installation (Steering Master End)
357
Shift Cable Installation (Jet Pump End)
358
Shift Cable Installation (Shift Lever End)
358
Steering Cable Installation (Jet Pump End)
358
Hoses
359
Cooling Water Pilot Outlet Installation
361
Water Separator Check
361
Seat and Handgrip Removal
362
Seats and Handgrip
362
Handgrip Installation
365
Seat Lock Check
365
Exhaust System Check
368
Rubber Hose Installation
368
Deck and Hull
369
Drain Plug Check
373
Front Protector 1 Installation
373
Reboarding Step Installation (FZS)
373
Spout Installation
373
Features
376
Functions
376
Introduction
376
Ydis
376
Engine Unit Troubleshooting
381
Using the YDIS for Engine Unit Troubleshooting
381
Self-Diagnosis
382
Diagnostic Code Table
383
Diagnostic Code and Checking Step
384
Engine Unit Troubleshooting (Diagnostic Code Not Detected)
391
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Yamaha WaveRunner FZR-GX1800 Specifications
General
Brand
Yamaha
Model
WaveRunner FZR-GX1800
Category
Offroad Vehicle
Language
English
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