Yamaha WaveRunner

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YAMAHA MOTOR CORPORATION, USA

Printed in USA

Dec. 2005 – 0.0 × 1 CR

(E)

Main Page

Lit-186162
Important Information4
How to Use this Manual5
Symbols6
Current:6
Index7
General Information8
Primary I.D. Number9
Engine Serial Number9
Jet Pump Unit Serial Number9
Hull Identification Number (H.I.N.)9
Safety While Working10
Fire Prevention10
Ventilation10
Self-Protection10
Good Working Practices11
Disassembly and Assembly12
Measuring13
Special Tools13
Removal and Installation15
Special Tools16
Specifications19
General Specifications20
Maintenance Specifications22
Electrical26
Current:26
Tightening Torques28
General Torque36
Cable and Hose Routing37
Periodic Inspection and Adjustment46
Maintenance Interval Chart47
Control System48
Periodic Service48
Steering Master Inspection48
Steering Cable Inspection and Adjustment48
Throttle Cable Inspection and Adjustment49
QSTS Cable Inspection and Adjustment51
Shift Cable Inspection and Adjustment53
Trolling Speed Check and Adjustment54
Fuel Line Inspection55
Fuel System/Power Unit56
Water Separator Inspection56
Valve Clearance Adjustment56
Intake61
Exhaust61
Engine Oil Level Check62
Engine Oil Change-Using Oil Changer64
Air Filter Element Clean66
Spark Plug Inspection67
Battery Inspection70
Impeller Inspection73
Water Inlet Strainer Inspection73
Bilge Strainer Inspection74
Electric Bilge Pump Strainer Inspection74
Drain Plug Inspection75
Lubrication Points75
Fuel System78
Arrangement of the Throttle Body Components Couplers79
Fuel Tank and Fuel Pump Module80
Exploded Diagram80
Removal and Installation Chart80
Service Points83
Fuel Hose Disconnection83
Fuel Pump Module Removal83
Check Valve Inspection83
Rollover Valve Inspection84
Fuel Tank Inspection84
Fuel Pump Module Installation85
Fuel Injection System86
Hose Clamps Removal95
Hose Clamps Installation95
Fuel Hose Installation (Replacing with New Fuel Hose)97
Fuel Hose Connection97
Throttle Body Removal97
Fuel Injector Inspection98
Throttle Body Inspection98
Bypass Valve Motor Inspection99
Throttle Body Installation99
Throttle Bodies Synchronization100
Fuel Pressure Measurement105
Power Unit106
Engine Unit110
Compression Pressure Measurement113
Oil Filter Removal and Installation115
Engine Unit Removal115
Shim Removal116
Engine Mount Inspection116
Coupling Clearance Inspection116
Exhaust Pipe 3117
Exhaust Pipes 1 and 2120
Exhaust Manifold122
Oil Tank124
Oil Tank Removal130
Oil Strainer Inspection131
Oil Tank Installation131
Oil Pump134
Oil Pump Inspection139
Oil Pump Installation140
Reduction Drive Gear141
Drive Coupling Removal145
Drive Shaft Removal145
Bearing Removal145
Oil Pump Drive Shaft Inspection146
Drive Shaft Inspection146
Bearing Installing147
Drive Shaft Installation149
Drive Coupling Installation149
Generator and Starter Motor150
Flywheel Magneto Removal155
Starter Clutch Inspection155
Flywheel Magneto Installation157
Camshafts158
Camshaft Removal164
Camshaft Inspection165
Camshaft Sprockets Inspection167
Timing Chain Tensioner Inspection167
Camshaft Installation168
Cylinder Head172
Cylinder Head Removal174
Cylinder Head Inspection174
Cylinder Head Installation175
Valves and Valve Springs177
Valve Removal179
Valve Spring Inspection180
Valve Inspection180
Valve Guide Replacement182
Valve Seat Inspection184
Valve Seat Reface185
Valve Installation187
Crankcase189
Crankcase Disassembly194
Timing Chain Inspection195
Crankcase Assembly196
Connecting Rods and Pistons199
Connecting Rod and Piston Removal201
Cylinder and Piston Inspection202
Piston Ring Inspection203
Piston Pin Inspection205
Connecting Rod Inspection206
Connecting Rod and Piston Installation208
Crankshaft212
Crankshaft Removal213
Crankshaft Inspection213
Crankshaft Installation216
Thermostat217
Thermostat Inspection219
Thermostat Installation219
Cooling Water Hose220
Jet Pump Unit221
Intake Grate, Ride Plate, and Intake Duct223
Reverse Gate228
Lever 1, 2 Installation231
Jet Thrust Nozzle and Nozzle Ring232
Impeller Duct and Impeller Housing 1233
Impeller Duct and Drive Shaft235
Transom Plate and Hoses242
Electric Bilge Pump Inspection245
Bilge Hose Inspection245
Cooling Water Hose Inspection245
Bearing Housing246
Driven Coupling Removal and Installation249
Intermediate Drive Shaft Removal249
Bearing, Intermediate Drive Shaft, and Grease Hose Inspection250
Driven Coupling Inspection250
Bearing Installation251
Oil Seal Installation251
Intermediate Housing Installation252
Electrical System253
Electrical Components256
Electrical Box257
Electrical Analysis264
Inspection264
Digital Tester264
Low Resistance Measurement265
Peak Voltage Measurement265
Peak Voltage Adapter266
Test Harness266
Ignition System267
Wiring Diagram267
Ignition Coil267
Ignition Spark269
Ignition System Peak Voltage270
Ignition Coil273
Engine Stop Switch273
Engine Temperature Sensor274
Sensor Assembly274
Thermoswitch (Engine)275
Thermoswitch (Exhaust)275
Main and Fuel Pump Relay276
Throttle Position Sensor277
Cam Position Sensor278
Noise Filter279
Slant Detection Switch279
Fuel Control System280
Fuel Pump282
Fuel Sender282
Starting System284
Wiring Connections285
Fuse285
Start Switch285
Starter Relay286
Starter Motor287
Armature Inspection290
Brush Holder Inspection291
Starter Motor Front Cover Inspection291
Charging System292
Electric Bilge Pump294
Off Throttle Steering System296
Steering Switch297
Indication System298
Buzzer300
Oil Pressure Switch301
Multifunction Meter301
Display Function302
Speedometer Display303
Tachometer Display304
Voltage Meter Display304
Low Oil Pressure Warning Indicator304
Fuel Level Meter Display and Fuel Warning Indicator304
Overheat Warning Indicator305
Check the Engine Warning Indicator305
Remote Control System306
Yamaha Security System Indicator307
Low-Rpm Mode Indicator307
Diagnostic Display308
Checking the Remote Control Transmitter308
Transmitter Registration310
Replacing of the Transmitter Battery311
Hull and Hood312
Handlebar314
Handlebar Inspection319
Handlebar Assembly Installation319
QSTS Grip321
QSTS Grip Inspection323
Steering Master324
Steering Master Components Inspection328
Remote Control Cables and Speed Sensor Lead329
Remote Control Cables Inspection332
Steering Cable (Jet Pump End) Installation332
Steering Cable Stopper Installation332
QSTS Cable (Jet Pump End) Installation333
QSTS Cable Stopper Installation333
Shift Cable (Jet Pump End) Installation333
Shift Cable Holder Installation334
Shift Cable Stopper Installation334
Front Hood335
Steering Console Cover339
Glove Compartment Assembly Installation345
Hoses346
Shift Lever348
Base Assembly351
Seats and Hand Grip352
Seat Lock Inspection355
Exhaust System356
Exhaust System Inspection359
Exhaust Component Parts Sub-Assembly359
Exhaust System Installation360
Deck and Hull361
Engine Mount363
Trouble Analysis364
Introduction365
Features365
Functions365
Hardware Requirements366
Operating367
Connecting the Communication Cable to the Watercraft367
Trouble Analysis Chart368
Self-Diagnosis372
FX High Output, FX Cruiser High Output373
F1S-28197-1G378
Specifications382
Periodic Inspection and383
Identification Numbers389
Specified Torques407
Cable and Hose Routing (for FX/FX Cruiser)420
Cable and Hose Routing (for FX High Output/Fx Cruiser High Output)425
Fuel System429
Electrical Components (for FX/FX Cruiser)437
Electrical Components (for FX High Output/Fx Cruiser High Output)438
Steering Sensor441
Indication System (for FX Cruiser High Output)442
Wiring Diagram (for FX Cruiser High Output)443
Wiring Diagram (for FX High Output)444
Wiring Diagram (for FX/FX Cruiser)446
Operation Button447
Display Function (for FX Cruiser High Output)449
Display Function (for FX High Output)450
Display Function (for FX/FX Cruiser)451
Compass Display (for FX Cruiser High Output)452
Air Temperature Display (for FX Cruiser High Output)452
Speedometer/Average Speed/Tripmeter Display (for FX Cruiser High Output)453
Water Temperature Display (for FX Cruiser High Output)454
Trip Timer Display (for FX Cruiser High Output)455
Fuel Consumption Per Hour, Fuel Consumption Per Kilometer/Mile Display (for FX Cruiser High Output)455
Check Engine Warning Indicator456
Remote Control System (for FX High Output/Fx Cruiser High Output)457
Exploded Diagram (for FX/FX High Output)461
Exploded Diagram (for FX Cruiser/Fx Cruiser High Output)462
Installing Steps (for FX/FX High Output)468
Installing Steps (for FX Cruiser/Fx Cruiser High Output)468
Rubber Seal Installation475
Steering Cable Removal479
Steering Cable Installation480
Rivet Installation483
Ornament Disassembly486
Front Hood Assembly486
Visor Installation487
Double-Sided Tape Installation487
Ornament Installation488
Mirror489
Reboarding Step (for FX Cruiser/Fx Cruiser High Output)503
Reboarding Step Installation504
Cleat Assembly (for FX Cruiser High Output)508
Cleat Cover Installation509
FX/FX Cruiser511
FX High Output/Fx Cruiser High Output513

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