WaveRunner

VXS
VX1800 (F2M)
VXR
VX1800A (F2M)

SERVICE MANUAL

LIT-18616-03-31
F2M-28197-1N-11
 Preface
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written 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. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications 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). Additional
information and up-to-date information on Yamaha products and services are available on YDS
(Yamaha Dealer System).

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
serious injury.

A NOTICE indicates special precautions that must be taken to avoid damages to the water-
craft or other property.

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

WaveRunner
VXS, VXR
SERVICE MANUAL
©2010 by Yamaha Motor Corporation, U.S.A.
1st Edition, October 2010
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-18616-03-31
 Contents

General information GEN

INFO
1
Specification
SPEC 2
Maintenance
MNT 3
Fuel system
FUEL 4
Power unit
POWR 5
Jet pump unit JET
PUMP
6
Electrical system
ELEC 7
Hull and hood HULL
HOOD
8
Troubleshooting TRBL
SHTG
9
Appendix A
GEN
INFO
General information 1

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

Rotating part .............................................................................. 1-1
Hot part ...................................................................................... 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
Part, lubricant, and sealant ........................................................ 1-3
Handling of sealant .................................................................... 1-3
Special service tool ................................................................... 1-3
Tightening torque ...................................................................... 1-3
Non-reusable part ...................................................................... 1-4
Disassembly and assembly ....................................................... 1-4

How to use this manual .................................................... 1-5

Manual format ........................................................................... 1-5
Abbreviation .............................................................................. 1-6

Adhesive, lubricant, sealant, and thread locking agent 1-7

Symbol ...................................................................................... 1-7

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

Model feature ................................................................... 1-17

General feature ....................................................................... 1-17
Identification number ............................................................... 1-18
Model equipment comparison table ........................................ 1-19
Jet pump .................................................................................. 1-20
Multifunction meter unit ........................................................... 1-21
Multifunction display warning .................................................. 1-22

Technical tips .................................................................. 1-24

Engine control ......................................................................... 1-24
 GEN
INFO General information

Safety while working

To prevent an accident or injury and to pro-
vide quality service, observe the following
safety procedures.

Rotating part
• Hands, feet, hair, jewelry, clothing, personal
flotation device straps, and so on, can
become entangled with internal rotating
parts of the engine or jet pump unit, result-
ing in serious injury or death.
• Keep hands, feet, hair, jewelry, clothing,
personal 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 per-
sonal flotation device straps can become Handling of gasoline
entangled in moving parts resulting in • Gasoline is highly flammable. Keep gaso-
severe injury. line and all flammable products away from
heat, sparks, and open flames.
Hot part • Gasoline is poisonous and can cause injury
During and after operation, engine parts are or death. Handle gasoline with care. Never
hot enough to cause burns. Do not touch any siphon gasoline by mouth. If you swallow
parts in the engine compartment until the some gasoline, inhale a lot of gasoline
engine has cooled. vapor, or get some gasoline in your eyes,
see your doctor immediately. If gasoline
Electric shock spills on your skin, wash with soap and
Do not touch any electrical parts while start- water. If gasoline spills on your clothing,
ing or operating the engine. Otherwise, shock change your clothes.
or electrocution could result.

Impeller
Do not hold the impeller with your hands
when loosening or tightening the impeller.

1-1
 Safety while working
Ventilation Working with crane
• Gasoline vapor and exhaust gas are • When moving the watercraft, or when lifting
heavier than air and extremely poisonous. If the engine during removal or installation,

1
gasoline vapor or exhaust gas is inhaled in make sure to use a crane with a lifting
large quantities, it may cause loss of con- capacity that is equal to or more than the
sciousness and death within a short time. weight of the watercraft or engine respec-
• When test running an engine indoors (for tively.
example, in a water tank) make sure to do • When lifting the watercraft, use the water-

2
so where adequate ventilation can be main- craft lift harness and make sure that the
tained. watercraft is in a stable position when mov-
ing it.
• Use the wire ropes of adequate strength,
and lift up the engine unit using the three

3
point suspension.
• If the engine unit does not have three or
more points to be suspended, support it
using additional ropes or the like so that the
engine unit can be lifted and carried in a

4
stable manner.

Self-protection
• Protect your eyes by wearing safety
glasses or safety goggles during all opera-
tions involving drilling and grinding, or when
using an air compressor.
• Protect your hands and feet by wearing pro-
tective gloves and safety shoes when nec-
5
essary.

6
7
8
9
1-2
A
 GEN
INFO General information
Handling of heat gun Handling of sealant
• Improper handling of a heat gun may result • Wear protective gloves to protect your skin,
in burns. For information on the proper han- when using the sealants.
dling of the heat gun, see the operation • See the material safety data sheet issued
manual issued by the manufacturer. by the manufacturer. Some of the sealants
• When using a heat gun, keep it away from may be harmful to human health.
the gasoline and oil, to prevent a fire.
• Components become hot enough to cause
burns. Do not touch any hot components
directly.

Special service tool

Use the recommended special service tools
to work safely, and to protect parts from dam-
age.
Part, lubricant, and sealant
Use only genuine Yamaha parts, lubricants,
and sealants, or those recommended by
Yamaha, when servicing or repairing the
watercraft.

Tightening torque
Follow the tightening torque specifications
provided throughout the manual. When tight-
ening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting
in the center and moving outward.

1-3
 Safety while working
Non-reusable part
Always use new gaskets, seals, O-rings, cot-
ter pins, and so on, when installing or assem-

1
bling parts.

2
Disassembly and assembly
• Use compressed air to remove dust and dirt
during disassembly.
3
• Apply engine oil to the contact surfaces of
moving parts before assembly.
4
5
• Install bearings so that the bearing identifi-
cation mark is facing in the direction indi-
cated in the installation procedure. In
6
addition, make sure to lubricate the bear-
ings liberally.
• Apply a thin coat of water resistant grease
to the lip and periphery of an oil seal before
installation.
7
• Check that moving parts operate normally
after assembly.

8
9
1-4
A
 GEN
INFO General information

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 a
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 b 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 c in the following figure).
• Tightening torque specifications are provided in the exploded diagrams (see d 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
installation where necessary (see e in the following figure for an example page).

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

1-5
 How to use this manual
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
API
APS
BOW
American Petroleum Institute
Accelerator Position Sensor
Bow side
1
BTDC Before Top Dead Center
DOHC
ECM
ETV
Double Over Head Camshaft
Electronic Control Module
Electronic Throttle Valve
2
EX Exhaust
ID
IN
ISO
Identification
Intake
International Organization for Standardization
3
OTS Off-throttle steering system
PON
PORT
RON
Pump Octane Number
Port side
Research Octane Number
4
RPM Revolutions Per Minute
SAE
STBD
TCI
Society of Automotive Engineers
Starboard side
Transistor Controlled Ignition
5
TDC Top Dead Center
TPS
UP
YDIS
Throttle Position Sensor
Upside
Yamaha Diagnostic System
6
7
8
9
1-6
A
 GEN
INFO General information

Adhesive, lubricant, sealant, and thread locking agent

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

Water resistant grease Lubricant

(Yamaha grease A)

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 lock-
ing agent and the application points.
Symbol Name Application
ThreeBond 1280B Sealant

LOCTITE 271 (red) Thread locking agent

LOCTITE 242 (blue) Thread locking agent

LOCTITE 572 (white) Sealant

ThreeBond 1360 Thread locking agent

LOCTITE 648 (green) Thread locking agent

Silicone sealant Sealant

1-7
 Adhesive, lubricant, sealant, and thread locking agent

Symbol Name Application

ThreeBond 1530D Adhesive

ThreeBond 1207B Sealant 1

LOCTITE 410 (black) Instant adhesive

2
3
4
5
6
7
8
9
1-8
A
 GEN
INFO General information

Special service tool

Special service tools with part numbers “YB-*****” are distributed by K & L.
Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division.

Compression gauge Dial indicator gauge

YU-33223 YU-03097

Compression gauge Dial gauge needle

90890-03160 90890-06584

Compression gauge extension Dial gauge set

90890-06563 90890-01252

Gauge stand Camshaft wrench

90890-06725 90890-06724

Dial gauge stand set Oil filter wrench

YB-06585 90890-06830

1-9
 Special service tool
Fuel pressure gauge adapter Leakage tester
YW-06842 90890-06840
90890-06842

1
Fuel pressure gauge
YB-06766
Valve spring compressor
YM-04019
90890-04019
2
3
Fuel pressure gauge
90890-06786
Compressor adapter
YM-04114
Valve spring compressor attachment
90890-04114
4
5
Exhaust pipe wrench
90890-06726
Valve guide remover
YB-06801
Valve guide remover/installer
6
90890-06801

Coupler wrench
7
90890-06729

Valve guide installer

YB-06810
8
9
1-10
A
 GEN
INFO General information
Valve guide installer Valve seat cutter
90890-06810 Intake
90890-06720 (30°)
90890-06325 (45°)
90890-06324 (60°)
Exhaust
90890-06818 (30°)
90890-06555 (45°)
90890-06323 (60°)

Valve guide reamer

YM-01196
90890-06804

Crankshaft holder
90890-06732

Valve lapping tool

YM-A8998
Valve lapper
90890-04101

Shaft holder
90890-06721

Neway valve seat kit

YB-91044

Driver handle
90890-06722

Valve seat cutter holder

90890-06812

1-11
 Special service tool
Flywheel puller Driver rod LS
90890-06723 90890-06606

1
Rotor puller
90890-01080
Bearing outer race attachment
90890-06627 2
3
Primary sheave holder Driver handle (large)
YS-01880-A
Sheave holder
90890-01701
YB-06071
4
5
Forward gear outer race installer
YB-41446
Driver handle (small)
YB-06229
6
Ball bearing attachment
90890-06657
7
Bearing and seal installer
YW-06356
8
9
1-12
A
 GEN
INFO General information
Forward bearing race installer Slide hammer
YB-06258 YB-06096

Bearing pressure C Stopper guide plate

90890-02393 90890-06501

Piston ring compressor Bearing puller assembly

YM-08037 90890-06535

Piston ring compressor Stopper guide stand

90890-05158 90890-06538

Drive shaft holder Driveshaft needle bearing installer and

YB-06201 remover
Drive shaft holder 6 YB-06194
90890-06520

1-13
 Special service tool
Driver rod L3 Shaft holder
90890-06652 90890-06730

1
Needle bearing attachment
90890-06609
Bearing puller legs
YB-06523 2
3
Bearing cup installer Needle bearing installer
YB-06167 YB-06434
4
5
Bearing outer race attachment Bearing outer race attachment
90890-06628 90890-06623

6
Bearing attachment
90890-06728
Bearing attachment
90890-06727
7
8
9
1-14
A
 GEN
INFO General information
YDIS (CD-ROM, Ver. 1.33) Peak voltage adapter B
60V-WS853-06 90890-03172

YDIS USB adapter and cable Spark checker

60V-WS850-00 YM-34487
Ignition tester (Spark gap tester)
90890-06754

Digital multimeter
YU-34899-A
Test harness (3 pins)
YB-06877
90890-06877

Peak volt adapter

YU-39991

Test harness (3 pins)

YB-06870
90890-06870

Digital circuit tester

90890-03174

Test harness (2 pins)

90890-06850

1-15
 Special service tool
Lower unit pressure/vacuum tester
YB-35956-A

1
Vacuum/pressure pump gauge set
90890-06756 2
3
Test harness (6 pins)
YB-06872
90890-06849 4
5
Test harness (8 pins)
YB-06879
90890-06879
6
7
8
9
1-16
A
 GEN
INFO General information

Model feature
General feature
This model utilizes the same shape hull as the F2N. Changing the hull material to NanoXcel allowed
a reduction in weight of approximately 20 kg.
It is equipped with a 6CN engine. This engine is based on a high-output, 1.8 L 6BH engine, with
alterations to the ECM, wire harness, hoses and other areas.
The combination of a lightweight hull with a high-powered engine offers acceleration comparable to
that of a supercharged model. Additionally, the excellent fuel consumption and environment charac-
teristics of this engine make this watercraft a clean and economical yet sporty runabout.
c b

a Power unit d Deck and hull

• 4-stroke, L4, DOHC, 16 valve, 1812 cm3 • V-shaped hull
engine with electronic fuel injection • NanoXcel hull, NanoXcel deck
• Single throttle body • 2 seat types (different shapes according to
• 4-in-1 exhaust system the model)
• Wet-sump lubrication

b Jet pump
• Stainless steel, 3-blade, ø155 mm, 15.6°
pitched impeller
• Impeller turning direction: counterclock-
wise (when viewed from the rear)
• Aluminum jet thrust nozzle

c Electrical
• Electronic control throttle valve system
• In-tank fuel pump module
• Multifunction meter
• L-MODE

1-17
 Model feature
Identification number Jet pump unit serial number
Primary I.D. number The jet pump unit serial number is stamped
The primary I.D. number is stamped on a on a label attached to the intermediate hous-

1
label attached to the inside of the engine ing.
compartment.

2
a c

3
a b c
PRI-I.D.

MODEL F2M b
YAMAHA MOTOR CO., LTD.
ASSEMBLED IN U.S.A. FROM AMERICAN AND JAPANESE
COMPONENTS.
ASSEMBLÉ AUX ÉTATS-UNIS DE PIÈCES AMÉRICAINES ET
JAPONAISES.

a Model name
b Hull type
c Primary I.D. number
a Jet pump unit name
b Jet pump unit type
c Jet pump unit serial number 4
Hull identification number (H.I.N.)
Starting primary I.D. number:

5
The H.I.N. is stamped on a plate attached to
F2M: 800101 the boarding platform.
Engine serial number
The engine serial number is stamped on a
label attached to the engine unit.

6
a
7
b
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON
c

8
a Engine name
b Engine type
c Engine serial number
Starting engine serial number:
9
6CN: 1000001

1-18
A
 GEN
INFO General information
Model equipment comparison table
Model VXS VXR
Total length 3.22 m 3.27 m
Weight 327 kg 330 kg
Graphic Dedicated VXS Dedicated VXR
Seats a Normal seat Two-tone step-up seat
Two beverage holders in the glove
Beverage holders b —
box
Reboarding steps c — U
U: Equipped
—: Not equipped

A VXS
B VXR

1-19
 Model feature
Jet pump
This model is equipped with the F2H intermediate housing a and impeller duct assembly b, and
F2N nozzle, jet thrust nozzle c, and reverse gate d. The jet intake e is a new design that improves

1
the efficiency of water uptake.

b
2
c
3
a 4
5
e

6
7
8
9
1-20
A
 GEN
INFO General information
Multifunction meter unit
a b c d c

e
b
h g f e

Item Functions
Comes on when the unlock mode of the Yamaha Security
a “SECURITY” indicator light
System is selected.
• Switches the display units to “mph” or “km/h.” (*1)
b Select button • Switches the display to the hour meter or to the voltmeter.
(*2)
Shows watercraft operating conditions.
a Tachometer f Oil pressure warning indi-
b Speedometer cator
c Information display c Hour meter/voltmeter g Engine overheat warning
d Fuel level meter indicator
e Fuel level warning indica- h Check engine warning
tor indicator
d “L-MODE” indicator light Comes on when the L-MODE (low-RPM mode) is selected.
Flashes or comes on, along with each warning indicator in the
e “WARNING” indicator light
information display, when a malfunction has occurred.
(*1) Within 10 seconds after the multifunction meter unit is activated
(*2) After the multifunction meter unit is activated for more than 10 seconds

Initial operation
When the multifunction meter unit is activated, the buzzer sounds 2 or 3 times, all displays come on
for 2 seconds, and then the unit starts to operate normally.

Hour meter/voltmeter
Hour meter display:
The hour meter shows the hours of engine operation that have
elapsed since the watercraft was new.
Voltmeter display:
The voltmeter shows the battery voltage. When the battery voltage
is normal, the voltmeter displays approximately 12 volts. If the
battery voltage has dropped significantly, “Lo” is displayed on the
voltmeter. If the battery voltage has risen significantly, “HI” is
displayed.

1-21
 Model feature
Push the select button for 1 second or more to switch the display to the hour meter or to the voltme-
ter.

Multifunction display warning

Warning Condition

The engine
Action

The engine
“WARNING”
indicator light
Flashes 5
Buzzer (*1)

Sounds
1
temperature overheat times, and then intermittently,
a rises above
specification.
warning
indicator a
flashes 5 times,
and then comes
comes on and then
sounds
continuously.
2
on.

b
The fuel
remaining in the
fuel tank drops
to about 13 L
The lowest 2
fuel level
segments and
the fuel level
Flashes Sounds
intermittently. 3
(*2). warning

The oil pressure

indicator b
flash.
The oil pressure Flashes Sounds
4
does not rise to warning intermittently.
c specification. indicator c

A sensor
flashes.

The check Flashes Sounds

5
malfunction or a engine warning intermittently.
d short circuit is
detected.
indicator d
flashes. 6
(*1) Push the select button to stop the buzzer.
(*2) Fuel tank capacity: 60 L (15.9 US gal, 13.2 Imp gal)

When multiple warnings overlap, the indicators will be displayed in the multifunction meter unit as
7
indicated in the following table:
Overlapping warnings
a, b, c, d
b, c, d
Only the indicator a flashes.
Action

The indicators flash repeatedly in the order b G c G d.

8
9
1-22
A
 GEN
INFO General information
Self-diagnosis
While the engine is running, the diagnostic codes a can be checked by pushing the select button b
for approximately 8 seconds. Because more than 1 diagnostic code cannot be shown even if multi-
ple malfunctions have occurred, it is recommended to use the YDIS.

a
b

a Diagnostic code
b Select button

1-23
 Model feature / Technical tips

Technical tips
Engine control
The ECM controls ignition timing and fuel injection using the information received from the sensors
and switches installed on the engine and on the basis of the map saved in the ECM.

b
c 1
d

a
e
2
g

3
f
4
m

l
k i
h
5
j

a TPS
Part name Functions
Detects the opening angle of the ETV.
6
b Cam position sensor Detects the rotational position of the camshaft.

7
c Slant detection switch Detects whether the watercraft is capsized.
Properly controls ignition timing, fuel injection timing and
d ECM volume, opening angle of the ETV, and fail-safe function with
information received from the sensors and switches.
e Thermo sensor Detects the temperature of the exhaust cooling water.
f Oil pressure switch
g Thermoswitch
h Intake air temperature sensor
Detects the pressure of the engine oil.
Detects overheat.
Detects the temperature of the intake air.
8
i Intake air pressure sensor Detects the pressure of the intake air.
j Engine temperature sensor Detects the temperature of the cylinder block.
k Pickup coil
l APS

m Steering sensor
Detects the crankshaft angle.
Detects the opening angle of the throttle lever.
Detects when the handlebar is turned all the way to the right
9
or left and a load is applied.

1-24
A
 GEN
INFO General information
ECM circuit diagram

Fuel injector #1
Stator 58
Rectifier
regulator coil Fuel injector #2
59
Fuel injector #3
84
Main relay 7 Fuel injector #4
Fuse (20 A) 83
27
Fuse (10 A)
20 Ignition coil #1
21 85
Fuse (3 A)
Ignition coil #2
Fuse Remote 14
Engine start switch control 86
(30 A)
receiver 28
Starter relay
Ignition coil #3
Battery Starter motor 61
Pickup coil Ignition coil #4
8
60
26
Cam position sensor 3 Fuel pump module

Intake air pressure

16 ECM 81
sensor
Fuel pump relay
Intake air temperature sensor
15 47 Multifunction
Engine temperature sensor (YDIS)
meter
23
Thermo sensor 39
Fuse (10 A)
13 45
25 80
ETV relay Throttle body
Steering sensor 17
assy.
40
Slant detection switch 78
5
Oil pressure switch 52
ETV motor
79 62
Thermoswitch 70
64 5V
Engine shut-off switch 44
72 42 TPS 1

5V 43 TPS 2
APS 49
Ground
APS 1 36 41
Ground
34 46
5V
50 67
APS 2 37
Ground
35

: Indicates a connection between the symbols.

1-25
 Technical tips
ECM coupler layout

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

3
—

G/O
Cam position
sensor
— 16

17
P/G

W/L
Intake air
pressure sensor

Steering sensor
30

31
—

—
—

—
5
4 — — 18 — — 32 — —

5 L/B
Slant detection
switch
19 —

Main and fuel

— 33 — —
6
6 — — 20 Y/G pump relay (main 34 B/R APS 1 ground

7
relay)
Battery power Engine start
7 R/Y 21 Y 35 B/W APS 2 ground
source switch
8 W/B Pickup coil 22 — — 36 P/R APS 1
Engine tempera-
9 — — 23 B/Y 37 P/W APS 2

10

11
—

—
—

—
24

25
—

O/R
ture sensor
—
Steering sensor
power source
38

39
—

R/Y
—
ETV relay power
source (contact)
8
Sensor power
12

13
—

B/L
—

Thermo sensor
26

27
O

R/Y
source
Battery power
source
40

41
B/O

B/O
Sensor ground

TPS ground 9
Main relay drive Immobilizer serial
14 Y/W 28 W 42 P TPS 1
signal communication

1-26
A
 GEN
INFO General information

Lead External connec- Lead External connec- Lead External connec-

No. No. No.
color tion lead color tion lead color tion lead
43 P/B TPS 2 58 Pu/R Fuel injector #1 73 — —
TPS power
44 O 59 Pu/B Fuel injector #2 74 — —
source
ETV relay power
45 R/Y 60 B/G Ignition coil #4 75 — —
source (contact)
46 B ECM ground 61 B/Y Ignition coil #3 76 — —
Self-diagnosis
lead
47 W/B (communication), 62 B ETV ground 77 — —
meter unit
communication
ETV motor
48 — — 63 — — 78 G
(positive)
APS 1 power Oil pressure
49 O/R 64 P Thermoswitch 79 P/W
source switch
APS 2 power ETV relay power
50 O/W 65 — — 80 Y/W
source source (coil)
Main and fuel
51 — — 66 — — 81 L/R pump relay (fuel
pump relay)
ETV motor
52 L 67 B Ground 82 G/L —
(negative)
53 — — 68 — — 83 Pu/G Fuel injector #4
54 — — 69 — — 84 Pu/Y Fuel injector #3
55 — — 70 B ETV ground 85 B/R Ignition coil #1
56 — — 71 — — 86 B/W Ignition coil #2
Engine shut-off
57 — — 72 W
switch

Color code
B : Black L/R : Blue/Red Pu/R : Purple/Red
B/G : Black/Green O : Orange Pu/Y : Purple/Yellow
B/O : Black/Orange O/R : Orange/Red R/Y : Red/Yellow
B/R : Black/Red O/W : Orange/White W : White
B/W : Black/White P : Pink W/B : White/Black
B/Y : Black/Yellow P/B : Pink/Black W/L : White/Blue
G : Green P/G : Pink/Green Y : Yellow
G/L : Green/Blue P/R : Pink/Red Y/G : Yellow/Green
G/O : Green/Orange P/W : Pink/White Y/W : Yellow/White
L : Blue Pu/B : Purple/Black
L/B : Blue/Black Pu/G : Purple/Green

1-27
 Technical tips
Engine control system
Item Condition Action Remarks
Overheat • Engine temperature • Opening angle of the ETV Cancel:
warning
control
rises rapidly in a
short time.
• Thermoswitch is on.
• Exhaust cooling
is regulated.
• Maximum engine speed is
limited to approximately
3000–3300 r/min.
• Stop the engine and wait
for 30 seconds or more.
• Engine temperature is
below 140 °C (248 °F) with
1
water temperature is the thermoswitch off.
more than 75 °C
(167 °F).
• Exhaust cooling water
temperature is below
70 °C (158 °F) with the
ETV fully closed.
2
If the engine is stopped

Oil pressure
warning
Control is activated
when all of the
• Opening angle of the ETV
is regulated.
during overheat warning
control, it can be restarted.
Cancel:
• Stop the engine and wait
3
control following conditions • Maximum engine speed is for 30 seconds or more.
are present:
• Oil pressure switch is
on.
• ETV is open.
limited to approximately
3000–3300 r/min.
• Engine is restarted and
the oil pressure switch is
off.
If the engine is stopped
4
• Engine speed is during oil pressure warning
more than
4500 r/min.
Cam position Control is activated
sensor failure when the following
• Opening angle of the ETV
is regulated.
control, it can be restarted.

Cancel:
Engine is stopped.
5
control conditions are • Maximum engine speed is
maintained for 10
seconds:
• Cam position sensor
failed.
limited to approximately
3000–3300 r/min. 6
• Engine speed is
more than approxi-
mately 1000 r/min.
Control is activated
when all of the
Ignition and fuel injection are Cancel:
cut to all cylinders and the Engine is stopped.
7
following conditions engine is stopped.
are present:
• Cam position sensor
failed.
8
• Engine speed is
more than
5000 r/min.
9
1-28
A
 GEN
INFO General information

Item Condition Action Remarks

ETV failure ETV failed, or open or • Opening angle of the ETV
control short circuit is detected is fixed to the default open-
in the ETV circuit. ing angle.
• Maximum engine speed is
limited to approximately
3000 r/min.
• Ignition timing is controlled.
Battery Battery cable is Control is performed using
disconnection disconnected during the same actions as the ETV
warning normal operation. failure control.
Idle speed Throttle lever is in the Engine speed is limited to
control fully closed (idle) 1200–1400 r/min.
position.
Over Engine speed is more Ignition is controlled.
revolution than 7800 r/min. Condi-
Action r/min
control tion
Normal None Below
7898
Level 1 Ignition is 7898–
cut off to 1 7948
cylinder.
Level 2 Ignition is 7949–
cut off to 2 8101
cylinders.
Level 3 Ignition is 8102–
cut off to 3 8147
cylinders.
Level 4 Ignition is Above
cut off to 8147
all
cylinders.
L-MODE L-MODE is activated. • Opening angle of the ETV Cancel:
control is regulated. L-MODE is deactivated.
• Ignition timing is controlled.
• Maximum engine speed is
limited to approximately
75% of the maximum
engine speed in the normal
mode.
Slant detection Control is activated Ignition and fuel injection are Cancel:
control when all of the cut to all cylinders and the Engine is stopped.
following conditions engine is stopped. (The check engine warning
are present: indicator does not come on
• Slant detection and the buzzer does not
switch is on. sound.)
• Engine speed is
3000 r/min or less.

1-29
 Technical tips

— MEMO —

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1-30
A
SPEC

Specification 2

Model data ......................................................................... 2-1

Model code ................................................................................ 2-1
Dimensions and weight ............................................................. 2-1
Performance .............................................................................. 2-1
Power unit ................................................................................. 2-1
Drive unit ................................................................................... 2-2
Fuel and oil requirement ............................................................ 2-2
Battery requirement ................................................................... 2-2

Fuel system technical data .............................................. 2-3

Fuel system ............................................................................... 2-3

Power unit technical data ................................................. 2-3

Power unit ................................................................................. 2-3
Cylinder head assy. ................................................................... 2-3
Crank case assy. ....................................................................... 2-5

Jet pump unit technical data ............................................ 2-6

Jet pump unit ............................................................................. 2-6

Electrical technical data ................................................... 2-6

Ignition system .......................................................................... 2-6
Charging system ....................................................................... 2-7
Control system .......................................................................... 2-7
Fuel system ............................................................................... 2-9
Starting system .......................................................................... 2-9
Meter system ........................................................................... 2-10

Specified tightening torque ............................................ 2-11

Fuel system ............................................................................. 2-11
Power unit ............................................................................... 2-11
Jet pump unit ........................................................................... 2-13
Electrical system ..................................................................... 2-13
Hull and hood .......................................................................... 2-14

General tightening torque .............................................. 2-15

Lubrication system ......................................................... 2-16

Cooling system ............................................................... 2-17

Cooling water flow ................................................................... 2-18

Cable and hose routing .................................................. 2-19

Starboard bow view ................................................................. 2-19
Port bow view .......................................................................... 2-20

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5
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7
8
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A
SPEC
Specification

Model data
Model code
Model
Item Unit
VXS VXR
Hull F2M
Engine/jet 6CN/6CN

Dimensions and weight

Model
Item Unit
VXS VXR
Length mm (in) 3220 (126.8) 3270 (128.7)
Width mm (in) 1170 (46.1)
Height mm (in) 1160 (45.7)
Dry weight kg (lb) 327 (721) 330 (728)
Maximum capacity person/kg (lb) 3/240 (530)

Performance
Model
Item Unit
VXS VXR
Full throttle operating range r/min 7600
Trolling speed r/min 1200–1400
L/h (US gal/
Maximum fuel consumption 48.6 (12.8, 10.7)
h, lmp.gal/h)
Cruising range h 1.24

Power unit
Model
Item Unit
VXS VXR
Type 4-stroke L4, DOHC
Cylinder quantity 4
Total displacement cm3 (cu. in) 1812 (110.6)
Bore stroke mm (in) 86 78 (3.39 3.07)
Compression ratio 11: 1
Exhaust system Wet exhaust
Lubrication system Wet sump
Cooling system Water cooled
Starting system Electric starter
Camshaft drive system Chain drive
Timing chain tensioning system Automatic
Ignition system TCI
Maximum ignition timing
degree BTDC 25
advance
Spark plug LFR6A (NGK)
Spark plug gap mm (in) 0.8–0.9 (0.031–0.035)

2-1
 Model data

Model
Item Unit
VXS VXR
Firing order 1–2–4–3
Oil filter type
Oil pump type

Drive unit
Cartridge type
Trochoid 1
Model

Jet pump type

Impeller rotation
Item Unit
VXS VXR
Axial flow, single stage
Counterclockwise (viewed from rear)
2
Transmission Constant mesh 1-speed

3
Jet thrust nozzle horizontal
degree 24 + 24
angle
Trim system —
Jet thrust nozzle trim angle degree 5
Reverse system Reverse gate

Fuel and oil requirement

Item Unit
VXS
Model
VXR
4
Fuel type Regular unleaded gasoline

Fuel minimum rating

Fuel tank capacity

PON
RON
L (US gal,
86
90

60.0 (15.9, 13.2)

5
Imp.gal)

6
Engine oil type 4-stroke motor oil
Engine oil grade API SE, SF, SG, SH, SJ, SL
SAE 10W-30, 10W-40, 20W-40, 20W-50
Engine oil quantity
L (US gal,
Total amount 4.3 (4.5, 3.8)

Without oil filter replacement

Imp.gal)
L (US gal,
Imp.gal)
L (US gal,
3.0 (3.2, 2.6) 7
With oil filter replacement 3.1 (3.3, 2.7)
Imp.gal)

Battery requirement

Item Unit
Model
8
VXS VXR
Type Fluid
Capacity
Specific gravity
At 20 °C (68 °F)
V/Ah 12/19

1.265
9
2-2
A
 SPEC
Specification

Fuel system technical data

Fuel system
Model
Item Unit
VXS VXR
Throttle body
Manufacturer Mikuni
ID mark 6BH**
Throttle cable installation
mm (in) 18.4 ± 1.0 (0.72 ± 0.04)
length
Throttle lever free play mm (in) 4–7 (0.16–0.28)
Fuel pump
Fuel pump type Electrical
kPa (kgf/
Fuel pressure 345–370 (3.45–3.70, 49.1–52.6)
cm2, psi)

Power unit technical data

Power unit
Model
Item Unit
VXS VXR
Cylinder
Minimum compression pres- kPa (kgf/
780 (7.8, 110.9)
sure (*1) cm2, psi)
Oil cooler
Water passage holding pres- kPa (kgf/
200 (2.0, 28.5)
sure cm2, psi)
Thermostat
Valve opening temperature °C (°F) 58–62 (136–144)
Fully open temperature °C (°F) Above 70 (158)
Fully open stroke mm (in) More than 4.3 (0.17)
(*1) Measuring conditions:
Ambient temperature 20 °C (68 °F), with spark plugs removed from all cylinders.
The figures are for reference only.

Cylinder head assy.

Model
Item Unit
VXS VXR
Cylinder head
Warpage limit mm (in) 0.10 (0.0039)
Camshaft cap inside diame-
mm (in) 25.000–25.021 (0.9843–0.9851)
ter

2-3
 Fuel system technical data / Power unit technical data

Model
Item Unit
VXS VXR
Camshaft
Cam lobe height
Intake
Exhaust
Cam lobe width
mm (in)
mm (in)
41.330–41.430 (1.627–1.631)
41.220–41.320 (1.623–1.627)
1
Intake and exhaust mm (in) 31.956–32.056 (1.258–1.262)
Runout
Journal diameter
Intake and exhaust
mm (in)

mm (in)
0.015 (0.0006)

24.960–24.980 (0.9827–0.9835)
2
Journal oil clearance mm (in) 0.020–0.061 (0.0008–0.0024)
Valve
Clearance
Intake
Exhaust
mm (in)
mm (in)
0.14–0.23 (0.0055–0.0091)
0.28–0.37 (0.0110–0.0146)
3
Head diameter
Intake
Exhaust
Face width
mm (in)
mm (in)
33.900–34.100 (1.3346–1.3425)
28.900–29.100 (1.1378–1.1457) 4
Intake and exhaust mm (in) 2.260–2.830 (0.0890–0.1114)
Seat contact width
Intake
Exhaust
Margin thickness
mm (in)
mm (in)
1.400–1.600 (0.0551–0.0630)
1.500–1.700 (0.0591–0.0669) 5
Intake and exhaust mm (in) 0.800–1.200 (0.0315–0.0472)
Valve stem
Diameter
Intake
Exhaust
mm (in)
mm (in)
5.477–5.492 (0.2156–0.2162)
5.464–5.479 (0.2151–0.2157)
6
Runout mm (in) 0.01 (0.0004)
Valve guide
Inside diameter
Intake and exhaust mm (in) 5.504–5.522 (0.2167–0.2174)
7
Stem to guide clearance
Intake mm (in) 0.012–0.045 (0.0005–0.0018)
Exhaust
Valve spring
Free length
mm (in) 0.025–0.058 (0.0010–0.0023)
8
Intake and exhaust mm (in) 45.58 (1.79)
Installed length
Intake and exhaust
Tilt limit
Intake and exhaust
mm (in)

mm (in)
34.0 (1.34)

2.0 (0.08)
9
2-4
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 SPEC
Specification
Crankcase assy.
Model
Item Unit
VXS VXR
Cylinder
Bore mm (in) 86.000–86.015 (3.3858–3.3864)
Piston
Diameter mm (in) 85.915–85.930 (3.3825–3.3831)
Measuring point mm (in) 9.5 (0.37)
Ring groove (top) mm (in) 1.210–1.230 (0.0476–0.0484)
Ring groove (2nd) mm (in) 1.210–1.230 (0.0476–0.0484)
Ring groove (oil) mm (in) 2.510–2.530 (0.0988–0.0996)
Pin boss bore diameter mm (in) 22.004–22.015 (0.8663–0.8667)
Pin outside diameter mm (in) 21.991–22.000 (0.8658–0.8661)
Piston ring
End gap measuring point mm (in) 6 (0.24)
Top ring
Type Barrel
Dimension height (B) mm (in) 1.170–1.190 (0.0461–0.0469)
Dimension width (T) mm (in) 2.850–3.050 (0.1122–0.1201)
End gap (*1) mm (in) 0.300–0.450 (0.0118–0.0177)
Side clearance mm (in) 0.020–0.060 (0.0008–0.0024)
2nd ring
Type Taper
Dimension height (B) mm (in) 1.170–1.190 (0.0461–0.0469)
Dimension width (T) mm (in) 2.600–2.800 (0.1024–0.1102)
End gap (*1) mm (in) 0.450–0.600 (0.0177–0.0236)
Side clearance mm (in) 0.020–0.060 (0.0008–0.0024)
Oil ring
Dimension height (B) mm (in) 2.370–2.470 (0.0933–0.0972)
Dimension width (T) (*1) mm (in) 2.500 (0.0984)
End gap (*1) mm (in) 0.100–0.350 (0.0039–0.0138)
Side clearance mm (in) 0.040–0.160 (0.0016–0.0063)
Connecting rod
Small end inside diameter mm (in) 22.015–22.028 (0.8667–0.8672)
Bearing color code 1.Brown 2.Black 3.Blue 4.Green
Crankshaft
Journal diameter mm (in) 39.976–40.000 (1.5739–1.5748)
Pin diameter mm (in) 41.976–42.000 (1.6526–1.6535)
Runout mm (in) 0.03 (0.0012)
Journal oil clearance mm (in) 0.024–0.053 (0.0009–0.0021)
Pin oil clearance mm (in) 0.020–0.056 (0.0008–0.0022)
Bearing color code 1.Brown 2.Black 3.Blue 4.Green 5.Yellow
(*1) The figures are for reference only.

2-5
 Jet /pump
Power unit technical data / Jet pump unit technical data unit technical data
Electrical

Jet pump unit technical data

Jet pump unit
Model
Item

Impeller housing
Inside diameter
Unit

mm (in)
VXS VXR

155.35–155.45 (6.116–6.120)
1
Impeller-to-housing clear-
mm (in) 0.35–0.45 (0.014–0.018)

2
ance
Clearance limit mm (in) 0.60 (0.024)
Impeller
Material Stainless steel
Blades number 3
Pitch angle
Drive shaft
Runout
Nozzle
degree

mm (in)
15.6

0.3 (0.012)
3
Diameter mm (in) 86.60–87.20 (3.409–3.433)

Electrical technical data

Ignition system
4
Model
Item Unit

ECM unit
Output peak voltage
At cranking (loaded) V
VXS

2.5
VXR

5
At 2000 r/min (loaded) V 2.6
At 3500 r/min (loaded)
Pickup coil
Output peak voltage
V 2.6
6
At cranking (unloaded) V 5.5
At cranking (loaded) V 4.7
At 2000 r/min (loaded)
At 3500 r/min (loaded)
Resistance (*1)
V
V
16.4
21.5 7
At 20 °C (68 °F) Ω 459–561
(*1) The figures are for reference only.
8
9
2-6
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 SPEC
Specification
Charging system
Model
Item Unit
VXS VXR
Stator coil
Output peak voltage
At cranking (unloaded) V 8.3
At 2000 r/min (unloaded) V 36.4
At 3500 r/min (unloaded) V 64.7
Resistance (*1)
At 20 °C (68 °F) Ω 0.31–0.38
Rectifier regulator
Output peak voltage
At 2000 r/min (loaded) V 13.0
At 3500 r/min (loaded) V 13.0
(*1) The figures are for reference only.

Control system
Model
Item Unit
VXS VXR
Oil pressure switch
Input voltage (*1) V 11.0–12.0
kPa (kgf/
Continuity pressure 128–166 (1.28–1.66, 18.2–23.6)
cm2, psi)
Thermoswitch
Input voltage (*1) V 11.0–12.0
Continuity temperature °C (°F) 94–100 (201–212)
No continuity temperature °C (°F) 80–94 (176–201)
Thermo sensor
Input voltage V 4.75–5.25
Resistance (*1)
At 0 °C (32 °F) kΩ 24.0–37.1
At 100 °C (212 °F) kΩ 0.87–1.18
Engine temperature sensor
Input voltage V 4.75–5.25
Resistance (*1)
At 20 °C (68 °F) kΩ 54.2–69.0
At 100 °C (212 °F) kΩ 3.12–3.48
Intake air temperature sensor
Input voltage V 4.75–5.25
Resistance (*1)
At 0 °C (32 °F) kΩ 5.4–6.6
At 80 °C (176 °F) kΩ 0.29–0.39
Intake air pressure sensor
Input voltage V 4.75–5.25

2-7
 Electrical technical data

Model
Item Unit
VXS VXR
TPS
Output voltage
With throttle lever fully
closed
TPS 1 V 0.6–0.9
1
With throttle lever fully
open
TPS 2
Throttle valve opening angle
V 4.5–4.8 2
With throttle lever fully
degree 2–8

3
closed
With throttle lever fully
degree More than 70
open
Input voltage V 4.75–5.25
APS
Output voltage
With throttle lever fully
closed
APS 1 V 0.50–0.90
4
APS 2 V 0.35–1.05
With throttle lever fully
open
APS 1
APS 2
V
V
3.75–4.35
3.60–4.50
5
Input voltage
APS 1
APS 2
Resistance (*1)
V
V
4.75–5.25
4.75–5.25 6
At 20 °C (68 °F)

7
With APS pulley fully
closed
APS 1 kΩ 0.50–0.90
APS 2 kΩ 0.35–1.05
With APS pulley fully open
APS 1
APS 2
ETV relay
Input voltage
kΩ
kΩ

V
3.75–4.35
3.60–4.50

12 (battery voltage)
8
Cam position sensor
Input voltage
Output voltage
Position b, d
V

V
4.75–5.25

More than 4.8

9
Position c V Less than 0.8

A
Slant detection switch
Input voltage V 4.75–5.25

2-8
 SPEC
Specification

Model
Item Unit
VXS VXR
Steering sensor
Input voltage V 4.75–5.25
ECM unit
Input voltage V 12 (battery voltage)
(*1) The figures are for reference only.

Fuel system
Model
Item Unit
VXS VXR
Fuel injector
Input voltage V 12 (battery voltage)
Resistance (*1)
At 20 °C (68 °F) Ω 11.5–12.5
Fuel pump module
Input voltage V 12 (battery voltage)
Fuel sender resistance (*1)
At 20 °C (68 °F)
Lower position Ω 133.5–136.5
Upper position Ω 5.0–7.0
(*1) The figures are for reference only.

Starting system
Model
Item Unit
VXS VXR
Fuse
Rating
Battery V/A 12/30
Main and fuel pump relay
V/A 12/20
(main side)
Main and fuel pump relay
V/A 12/10
(fuel pump side)
ETV relay V/A 12/10
Remote control receiver V/A 12/3
Starter motor
Type Constant mesh
Output kW 0.6
Cranking time limit seconds 30
Commutator diameter mm (in) 27–28 (1.06–1.10)
Commutator undercut (*1) mm (in) 0.2–0.7 (0.008–0.028)
Brush length mm (in) 5.0–12.5 (0.20–0.49)
(*1) The figures are for reference only.

2-9
 Electrical technical data
Meter system
Model
Item Unit
VXS VXR
Remote control transmitter
Battery
Type CR2016
1
Rating V 3

2
Remote control receiver
Input voltage V 12 (battery voltage)
Output voltage (*1) V 11.0–12.0
Multifunction meter unit
Input voltage V 12 (battery voltage)
Buzzer
Input voltage (*1)
Speed sensor
V

mV
11.0–12.0

Less than 400

3
Output voltage (on pulse)
V More than 11.6
(*1) The figures are for reference only.
4
5
6
7
8
9
2-10
A
 SPEC
Specification

Specified tightening torque

Specified tightening torques are provided for specific nuts, bolts, and screws. When tightening these
fasteners, follow the tightening torque specifications indicated throughout the manual to meet the
design aims of the watercraft.

Fuel system
Tightening torques
Part to be tightened Screw size
N·m kgf·m ft·lb
Air intake pipe clamp — 3 0.3 2.2
Air filter case bracket nut — 17 1.7 12.5
Air filter case bolt M8 12 1.2 12.5
Fuel rail bolt M8 13 1.3 9.6
Throttle body assy. nut — 13 1.3 9.6
Throttle body joint bolt M8 24 2.4 17.7
1st 3 0.3 2.2
Fuel pump module nut —
2nd 6 0.6 4.4
Fuel filler hose clamp — 4 0.4 3.0
Fuel filler neck nut — 6 0.6 4.4
Strap bolt M8 16 1.6 11.8

Power unit
Tightening torques
Part to be tightened Screw size
N·m kgf·m ft·lb
Engine cover screw — 5 0.5 3.7
Rectifier regulator bolt M8 26 2.6 19.2
Rectifier regulator cover bolt M6 13 1.3 9.6
1st 22 2.2 16.2
M8
2nd 42 4.2 31.0
Stay bolt
1st 22 2.2 16.2
M10
2nd 42 4.2 31.0
Pipe clamp — 3.5 0.35 2.58
1st 20 2.0 14.8
Exhaust manifold bolt 2nd M8 20 2.0 14.8
3rd 35 3.5 25.8
Oil filter — 18 1.8 13.3
Electrical box bolt M8 17 1.7 12.5
Engine mounting bolt M8 17 1.7 12.5
Engine mount bolt M8 17 1.7 12.5
Damper 1 bolt — 5.5 0.55 4.06
Damper 2 bolt — 5.5 0.55 4.06
Exhaust pipe 3 — 200 20.0 147.5
Thermo sensor — 20 2.0 14.8
1st 20 2.0 14.8
Exhaust pipe 1 bolt M8
2nd 35 3.5 25.8
1st 15 1.5 11.1
Exhaust pipe 2 bolt M8
2nd 29 2.9 21.4

2-11
 Specified tightening torque

Tightening torques
Part to be tightened Screw size
N·m kgf·m ft·lb
Starter motor cable nut — 5 0.5 3.7

Intake manifold bolt

Intake manifold nut

1st
2nd
1st
2nd
M8

—
10
20
10
20
1.0
2.0
1.0
2.0
7.4
14.8
7.4
14.8
1
1st 10 1.0 7.4
Stud bolt

Intake air temperature sensor

Intake manifold stay bolt

2nd

1st
—

M8
20
15
15
2.0
1.5
1.5
14.8
11.1
11.1
2
2nd 30 3.0 22.1
Oil pump assy. bolt
Oil pump drive gear bolt (left-hand threads)
Oil cooler cover bolt
Oil cooler cover bolt
M6
M12
M6
M8
10
80
12
20
1.0
8.0
1.2
2.0
7.4
59.0
8.9
14.8
3
Oil filter joint bolt — 18 1.8 13.3
Spark plug
Cam position sensor bolt
Engine cover grommet bolt
—
M6
M6
25
10
6
2.5
1.0
0.6
18.4
7.4
4.4
4
Camshaft sprocket bolt M7 18 1.8 13.3
Camshaft cap bolt M7 16 1.6 11.8
Oil pipe bolt
Timing chain tensioner bolt
Chain guide plate bolt
—
M6
M6
20
10
10
2.0
1.0
1.0
14.8
7.4
7.4
5
Engine hanger bolt M10 42 4.2 31.0
Engine hanger bolt

Cylinder head bolt

Cylinder head bolt

1st
2nd
M6

M12

M6
12
55

10
1.2
5.5
90°
1.0
8.9
40.6

7.4
6
Holder (left-hand threads) — 80 8.0 59.0
Drive coupling
Generator cover assy. bolt
Flywheel magneto bolt
—
M8
M8
250
26
24
25.0
2.6
2.4
184.4
19.2
17.7
7
Special nut — 250 25.0 184.4
1st 50 5.0 36.9
Transfer shaft

Holder bolt
2nd
3rd
—

M6
250
14
60°
25.0
1.4
184.4
10.3
8
Stator coil assy. bolt M6 14 1.4 10.3
Plate bolt
Oil level pipe plate bolt
Anode cover bolt
Engine temperature sensor
M6
—
M8
—
10

20
15
8
1.0
0.8
2.0
1.5
7.4
5.9
14.8
11.1
9
Oil pipe bolt M6 9 0.9 6.6
Baffle plate bolt M6 12 1.2 8.9

2-12
A
SPEC
Specification

Tightening torques
Part to be tightened Screw size
N·m kgf·m ft·lb
Oil pressure switch lead bolt M4 2 0.2 1.5
Oil pressure switch — 8 0.8 5.9
Oil pan assy. bolt M6 10 1.0 7.4
Oil pan plug M8 20 2.0 14.8
1st 50 5.0 36.9
Connecting rod nut —
2nd 90°
Engine mount bracket bolt M10 50 5.0 36.9
1st 30 3.0 22.1
Crankcase bolt M10
2nd 90°
Crankcase bolt M6 10 1.0 7.4
Baffle plate bolt M6 10 1.0 7.4

Jet pump unit

Tightening torques
Part to be tightened Screw size
N·m kgf·m ft·lb
Intake grate bolt M10 40 4.0 29.5
Ride plate bolt M8 17 1.7 12.5
Speed sensor screw M5 4 0.4 3.0
Steering cable joint nut — 7 0.7 5.2
Spout hose clamp (hull end) — 2 0.2 1.5
Rubber plate bolt M6 7 0.7 5.2
Rubber plate nut — 7 0.7 5.2
M8 17 1.7 12.5
Jet pump unit assy. bolt
M10 40 4.0 29.5
Bracket bolt M8 14 1.4 10.3
Reverse gate assy. bolt M8 15 1.5 11.1
Spring nut — 8 0.8 5.9
Ball joint nut — 8 0.8 5.9
Jet thrust nozzle bolt M8 15 1.5 11.1
Impeller duct bolt M10 40 4.0 29.5
Water inlet cover/water inlet strainer bolt M6 7 0.7 5.2
Impeller — 330 33.0 243.4
Drive shaft nut — 69 6.9 50.9
Flushing hose nut — 5.5 0.55 4.06
Transom plate nut — 26 2.6 19.2
Hose joint bolt M6 3.5 0.35 2.58
Intermediate housing assy. bolt M8 17 1.7 12.5
Driven coupling — 210 21.0 154.9
Grease nipple — 5 0.5 3.7

Electrical system
Tightening torques
Part to be tightened Screw size
N·m kgf·m ft·lb
Slant detection switch screw M6 4 0.4 3.0

2-13
 Specified tightening torque

Tightening torques
Part to be tightened Screw size
N·m kgf·m ft·lb
Starter relay bolt M6 4 0.4 3.0
ECM bolt
Starter motor cover bolt
Starter motor terminal nut
Transmitter cover screw
M6
M6
—
ø2
5
7
9
0.1
0.5
0.7
0.9
0.01
3.7
5.2
6.6
0.07
1
Hull and hood

Part to be tightened Screw size

N·m
Tightening torques
kgf·m ft·lb
2
Upper handlebar cover screw ø4 1 0.1 0.7

3
Upper handlebar cover screw ø5 1 0.1 0.7
Lower handlebar cover screw M6 4 0.4 3.0
Grip end bolt M5 1 0.1 0.7
Left handlebar switch screw M5 3 0.3 2.2
Throttle lever assy. bolt M5 3 0.3 2.2
Handlebar holder bolt
Throttle cable locknut (APS end)
Mirror nut
Hood lock bolt
M8
—
—
M5
20
7
7
4
2.0
0.7
0.7
0.4
14.8
5.2
5.2
3.0
4
Front hood screw M5 2 0.2 1.5
Hinge nut
Hinge bolt
Engine hatch cover nut
—
M6
—
7
7
5
0.7
0.7
0.5
5.2
5.2
3.7
5
Engine hatch cover bolt M6 5 0.5 3.7
Multifunction meter bolt
APS nut
Grip bolt
Shift lever assy. screw
M6
—
M6
M6
4
17
5
5
0.4
1.7
0.5
0.5
3.0
12.5
3.7
3.7
6
Cable stopper bolt M6 7 0.7 5.2
Steering master assy. bolt
Steering arm assy. bolt
Ball joint nut
M8
M8
—
17
16
7
1.7
1.6
0.7
12.5
11.8
5.2
7
Ball joint — 7 0.7 5.2
Buzzer bracket bolt M5 4 0.4 3.0
Steering sensor bolt
Shift lever assy. nut
Steering cable joint locknut
M6
—
—
7
5
7
0.7
0.5
0.7
5.2
3.7
5.2
8
Speed sensor lead grommet nut — 6 0.6 4.4
Shift cable bracket nut
Throttle cable locknut (APS end)
Steering cable locknut (hull)
Shift cable locknut (hull)
—
—
—
—
5
7
7
7
0.5
0.7
0.7
0.7
3.7
5.2
5.2
5.2
9
Shift cable locknut — 4 0.4 3.0
Seat lock assy. bolt M6 6 0.6 4.4

2-14
A
 SPEC
Specification

Tightening torques
Part to be tightened Screw size
N·m kgf·m ft·lb
Projection nut — 26 2.6 19.2
Handgrip nut — 5 0.5 3.7
Seat holder nut — 15 1.5 11.1
Cooling water pilot outlet nut — 4 0.4 3.0
Rubber hose nut — 5 0.5 3.7
Rubber hose clamp — 3.7 0.37 2.73
Exhaust valve nut — 5 0.5 3.7
Ski tow nut — 15 1.5 11.1
Spout nut — 5 0.5 3.7
Stern eye nut — 15 1.5 11.1
Drain plug nut — 2 0.2 1.5
Reboarding step assy. bolt (VXR) M8 15 1.5 11.1
Bow eye bolt M6 13 1.3 9.6
Front protector nut — 7 0.7 5.2
Sponson bolt M8 15 1.5 11.1

General tightening torque

This chart indicates the tightening torques for
standard fasteners with a standard ISO
thread pitch.
Width General torque
Screw
across specifications
size (B)
flats (A) N·m kgf·m ft·lb
8 mm M5 5 0.5 3.7
10 mm M6 8 0.8 5.9
12 mm M8 18 1.8 13.3
14 mm M10 36 3.6 26.6
17 mm M12 43 4.3 31.7

2-15
 Specified tightening torque / General tightening torque / Lubrication system

Lubrication system
The 6CN engine features a wet-sump lubrication system. The oil pan under the engine is divided
into separate feeding and scavenging sections. The engine oil in each section is drawn in and pres-
sure fed by separate oil pumps.

a
1
2
b

3
m

4
c

l
n 5
k
e
6
f

j
7
i h g

a Intake camshaft j Relief valve

8
b Exhaust camshaft k Oil pump assy. (scavenge pump)
c Cylinder block l Oil cooler assy.
d Crankshaft
e Oil separator tank
f Oil pan
m Oil filter
n Oil pump drive gear 9
g Oil strainer
h Oil pipe
i Oil pump assy. (feed pump)

2-16
A
 SPEC
Specification

Cooling system

B
b
a

a Hose joint 1 A From jet pump unit

b Hose joint 3 B To oil cooler assy.
C To drain joint (transom plate)
D To cooling water pilot outlet on port side

2-17
 Cooling system

Cooling water flow

a
1
2
3
A
4
5
B
6
b
7
a Thermostat housing
b Oil cooler assy.
A From jet pump unit
B To cooling water pilot outlet on port side 8
9
2-18
A
 SPEC
Specification

Cable and hose routing

Starboard bow view

b
c
a
e
d

f
g

h
o

n
a
m
c
l j
k

a Shift cable k Fuel tank breather hose (water separator

b Battery breather hose to ventilation socket)
c Speed sensor lead l Wiring harness
d Left handlebar switch lead m Steering cable
e Throttle cable n Negative battery cable
f Buzzer lead o Positive battery cable
g Multifunction meter lead
h Fuel tank breather hose (fuel tank to water
separator)
i Fuel sender lead
j Remote control receiver antenna

2-19
 Cable and hose routing

Port bow view

c
d e
1
b

f
2
h

3
a

g
4
n
5
i

l
k j
6
m

7
a Fuel hose (fuel tank to fuel rail)
b Breather hose (breather assy. to air intake
pipe)
h Cooling water hose (exhaust manifold to
rectifier regulator)
i Cooling water hose (rectifier regulator to
8
c Cooling water hose (thermostat to tran- exhaust pipe 2)

9
som plate) j Cooling water hose (joint to oil cooler)
d Breather hose (head cover to breather k Cooling water hose (cylinder block to recti-
assy.) fier regulator)
e Bilge hose l Cooling water hose (oil cooler to cylinder
f Flushing hose block)

A
g Cooling water hose (jet pump to joint) m Cooling water pilot outlet hose

2-20
 SPEC
Specification

c
d e
b

n
i

k j

n Breather hose (cylinder head cover to oil

separator tank)

2-21
MNT

Maintenance 3

Maintenance interval chart ............................................... 3-1

Periodic service ................................................................. 3-2

Steering system ......................................................................... 3-2
1
Throttle lever free play check ............................................................. 3-2
Throttle lever free play adjustment ..................................................... 3-2
Shift cable check ................................................................................ 3-3
Shift cable adjustment ........................................................................ 3-4
Fuel system ............................................................................... 3-4
2
Fuel tank check .................................................................................. 3-4

3
Water separator check ....................................................................... 3-4
Power unit ................................................................................. 3-5
Spark plug check ................................................................................ 3-5
Compression pressure measurement ................................................ 3-5
Valve clearance measurement ........................................................... 3-6
Engine oil level check ......................................................................... 3-7
Engine oil replacement ....................................................................... 3-8
Oil filter replacement .......................................................................... 3-9
Trolling speed check .......................................................................... 3-9
Nut and bolt check ............................................................................. 3-9
4
Jet pump unit ............................................................................. 3-9
Impeller check .................................................................................... 3-9
Water inlet strainer check ................................................................. 3-10
Jet thrust nozzle steering angle check ............................................. 3-10
Jet thrust nozzle steering angle adjustment ..................................... 3-10
5
Electrical system ..................................................................... 3-11
Battery check ................................................................................... 3-11
Hull and hood .......................................................................... 3-11
Bilge strainer check .......................................................................... 3-11
Drain plug check .............................................................................. 3-12
Lubrication points .................................................................... 3-12
6
Throttle valve lubrication .................................................................. 3-12
Throttle cable (handlebar end) lubrication ........................................ 3-12
Throttle cable (APS end) and return spring lubrication .................... 3-13
Nozzle pivot bolt and steering cable lubrication ............................... 3-13
Steering cable and steering cable joint lubrication ........................... 3-13
7
Shift lever assy., shift cable, and shift cable joint lubrication ........... 3-13

8
Intermediate housing lubrication ...................................................... 3-14

9
A
 MNT
Maintenance

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.
Maintenance interval Initial Thereafter every
10 100 200
50 hours See
hours hours hours
page
6 12 12 24
Item
months months months months
Spark plugs Check, clean,
U U 3-5
replace
Lubrication points Lubricate U 3-12
Internal engine Spray lubricant
U 3-12
components
Intermediate housing Lubricate U U 3-14
Fuel system Check U 3-4
Fuel tank Check, clean U 3-4
Engine idling speed Check, adjust U 3-9
Throttle shaft Check U 4-7
Water inlet strainer Check, clean U 3-10
Bilge strainer Clean U 3-11
Impeller Check U 3-9
Jet thrust nozzle Check, adjust
U 3-10
angle
Shift cable and Check, adjust
U 3-3
reverse gate
Throttle cable Check U U 3-2
Stern drain plugs Check, replace U 3-12
Battery Check, charge U 3-11
Rubber coupling Check U 6-16
Engine mounts Check U 5-10
Nuts and bolts Check U U 3-9
Air filter element Check U 4-4
Engine oil Replace U U 3-8
Oil filter Replace U 3-9
Valve clearance Check, adjust U 3-6

3-1
 Maintenance interval chart / Periodic service

Periodic service 5. If the throttle cable installation length a

Steering system is out of specification, loosen the locknut
Throttle lever free play check b, and then turn the adjusting nut c to

1
1. Measure the throttle lever free play a. adjust the length.
Adjust if out of specification.
6. Apply locking agent to the threads of the
adjusting nut c, and then tighten the
throttle cable locknut b to the specified
torque.

7. Slide the boot a to its original position. 2

b c

Throttle lever free play a:

4–7 mm (0.16–0.28 in)
a

3
a
Throttle lever free play adjustment

After adjusting the throttle lever free play,

a

Throttle cable locknut b:

4
7 N·m (0.7 kgf·m, 5.2 ft·lb)
make sure that the throttle cable is not
pulled when the handlebar is turned to the
right and left.

1. Face the handlebar straight ahead.

8. Remove the upper handlebar cover d.
d 5
2. Remove the service lid.

3. Slide the throttle cable end boot a to the

APS pulley end.
6
4. Check that the throttle cable installation
length a is within specification.
7
8
a
9. Slide the rubber cover e away from the
a

Throttle cable installation length a:

18.4 ± 1.0 mm (0.72 ± 0.04 in)
throttle lever, and then loosen the locknut
f. 9
10. Turn the adjuster g in or out until the
specified free play b is obtained.

3-2
A
 MNT
Maintenance
11. Tighten the locknut f. 14. Slide the rubber cover e to its original
position.

15. Install the upper handlebar cover d, and

then tighten the upper handlebar cover
screws i and j to the specified torque.

d
g

b f g e

h
Turn in Free play b is increased.
Turn out Free play b is decreased.
j
Throttle lever free play b:
4–7 mm (0.16–0.28 in)

12. Squeeze the throttle lever h to the fully

g
open position and check that the APS
pulley stopper c contacts the fully open
stopper d on the APS. i h

c d

Upper handlebar cover screw i

(ø5 16 mm) and j (ø4 10 mm):
1 N·m (0.1 kgf·m, 0.7 ft·lb)

h TIP:
Align the portions g on the upper handlebar
cover with the portions h on the lower han-
13. Release the throttle lever h and check dlebar cover.
that the APS pulley stopper e contacts
the fully closed stopper f on the APS.
16. Install the service lid.
f Shift cable check
h
1. Set the shift lever to the reverse position.

2. Check that the reverse gate a contacts

the stopper a.

TIP: a
If the throttle lever free play cannot be
adjusted properly, check the throttle cable a
routing. If the throttle cable is routed properly,
a
replace the throttle cable.

3-3
 Periodic service
3. Adjust the shift cable joint if the reverse
gate a does not contact the stopper a.

Shift cable adjustment

1. Set the shift lever to the reverse position.

2. Loosen the shift cable locknut a.

1
c
3. Disconnect the shift cable joint b from
the ball joint c.

Turn in
Turn out
Distance b is decreased.
Distance b is increased.
2
a

c
Distance b: 7 mm (0.28 in)

6. Connect the shift cable joint b to the ball

joint c, and then tighten the shift cable
3
b locknut a to the specified torque.

4. Position the reverse gate d so that it is

contacting the stopper a.
Shift cable locknut a:
4 N·m (0.4 kgf·m, 3.0 ft·lb)

Fuel system
4
Fuel tank check

d
1. Check for water in the fuel tank. Extract
the water and fuel if there is water in the
fuel tank. 5
a a

d
6
5. Turn the shift cable joint b in or out until
the specified distance b between the
center of the shift cable joint and the
center of the ball joint c is obtained.
WARNING! The shift cable joint must
7
be screwed in more than 8 mm TIP:
(0.31 in) c. Use a commercially available siphon pump
a.

Water separator check

8
c 1. Check the water separator a. Drain the

9
b water if water has accumulated.
a b
2. Check the O-ring of the drain plug b.
Replace the O-ring if cracked or
damaged.

3-4
A
 MNT
Maintenance

Specified spark plug (manufacturer):

LFR6A (NGK)
a Spark plug gap b:
0.8–0.9 mm (0.031–0.035 in)

5. Install the spark plugs, and then tighten

them to the specified torque.
b Spark plug:
25 N·m (2.5 kgf·m, 18.4 ft·lb)

TIP: TIP:
To drain water from the water separator a, Before installing a spark plug, clean the gas-
loosen the drain plug b. ket surface and spark plug surface.

Power unit Compression pressure measurement

Spark plug check Make sure that the battery voltage is more
1. Remove the spark plugs. than 12 V.

TIP:
Be careful not to get water or any other for- When starting the engine to measure the
eign substances in the spark plug holes. compression pressure on land, make sure
to connect a garden hose to the watercraft
2. Clean the electrodes a. for proper water supply.

3. Check the electrodes a. Replace the 1. Place the watercraft in a horizontal posi-
spark plug if damaged or worn. tion.

a 2. Start the engine and warm it up for 5

minutes or more at engine idle speed.

3. Stop the engine.

4. Remove the spark plugs.

TIP:
Be careful not to get water or any other for-
4. Measure the spark plug gap b. Replace eign substances in the spark plug holes.
if out of specification.
5. Install the special service tools a and b.

b a

3-5
 Periodic service

Compression gauge a:
c
YU-33223/90890-03160
Compression gauge extension b: a
90890-06563

6. Crank the engine until the reading on the

b
1
compression gauge stabilizes.

7. Measure the compression pressure for

all cylinders according to steps 5 and 6.
Compression pressure (reference data):
Gauge stand a: 90890-06725
Dial gauge stand set b: YB-06585
2
780 kPa (7.8 kgf/cm2, 110.9 psi) Dial indicator gauge c: YU-03097

8. If the compression pressure is below

specification, squirt a few drops of engine
oil into the cylinder and measure again.
Dial gauge needle b: 90890-06584
Dial gauge set c: 90890-01252

3. Position piston #1 at TDC by turning the

3
exhaust camshaft sprocket clockwise.
Compression pressure
(with engine oil added into the cylinder)
Reading Check
Higher than without Piston ring and
engine oil piston
d
4
Same as without Valve clearance,
engine oil valve, valve seat,
cylinder head, and
cylinder head
gasket
5
9. Install the spark plugs, and then tighten
them to the specified torque.
Spark plug:
b
a
6
25 N·m (2.5 kgf·m, 18.4 ft·lb)

Valve clearance measurement

Measure the valve clearance when the
engine is cold.
7
1. Remove the ignition coils, spark plugs,
and cylinder head cover.

2. Install the special service tools a, b,

and c into spark plug hole #1.
#1 #2 #3 #4

8
Camshaft wrench d: 90890-06724

TIP:
Check that the punch marks a on the cam-
9
shafts are aligned with the marks b on the
camshaft caps.

3-6
A
 MNT
Maintenance
4. Measure the intake and exhaust valve Engine oil level check
clearances of the specified cylinders.

IN EX • When starting the engine to check the

c d oil level on land, make sure to connect a
garden hose to the watercraft for proper
water supply.
• Make sure that debris or water does not
enter the oil filler hole.

1. Place the watercraft in a horizontal posi-

tion.
Valve clearance (cold)
Intake c:
TIP:
0.14–0.23 mm (0.0055–0.0091 in) If the engine was running, allow the engine oil
Exhaust d: to settle by waiting 5 minutes or more before
0.28–0.37 mm (0.0110–0.0146 in) checking the oil level.
#1 #2 #3 #4
IN ✔ — ✔ — 2. Remove the oil level gauge a, wipe the
EX ✔ ✔ — — gauge clean, and then insert the oil level
gauge a into the oil level pipe
✔: Specified cylinder completely.
—: Not applicable
3. Remove the oil level gauge a again to
5. Install the special service tools a, b, check that the oil level is between the
and c into spark plug hole #4. minimum level mark a and the maximum
level mark b on the gauge.
6. Position piston #4 at TDC by turning the
exhaust camshaft sprocket 180°
clockwise.
a
7. Measure the intake and exhaust valve
clearances of the specified cylinders. b
4

#1 #2 #3 #4 a
IN — ✔ — ✔
EX — — ✔ ✔
✔: Specified cylinder
—: Not applicable 4. If the engine oil is below the minimum
level mark a, remove the oil filler cap b,
8. Adjust the valve clearance if out of and then add sufficient oil of the
specification. See “Valve clearance recommended type to raise it to the
adjustment” (5-39). proper level.

3-7
 Periodic service

b
1
5. If the engine oil is above the maximum
level mark b, extract oil using an oil
5. Insert the tube a of an oil changer
approximately 550 mm (21.7 in) b into
2
changer to lower it to the proper level. the oil level pipe c.
Recommended engine oil:
4-stroke motor oil
API: SE, SF, SG, SH, SJ, SL
SAE: 10W-30, 10W-40, 20W-40, 20W-50
a
3
6. Install the oil filler cap b.

Engine oil replacement c 4

Be careful when handling the engine oil to
avoid burns. The engine oil is hot immedi-
ately after the engine is turned off.
b
5
a

• When starting the engine to check the

oil level on land, make sure to connect a
garden hose to the watercraft for proper
6
water supply.

7
• Make sure that debris or water does not 6. Extract the oil using the oil changer.
enter the oil filler hole.
7. Fill the crankcase with the specified
1. Place the watercraft in a horizontal posi- amount of the recommended engine oil
tion. through the oil filler hole.

2. Start the engine and warm it up for 5

minutes or more at engine idle speed.
Recommended engine oil:
4-stroke motor oil
API: SE, SF, SG, SH, SJ, SL
SAE: 10W-30, 10W-40, 20W-40, 20W-50
8
3. Stop the engine.
Engine oil quantity:
4. Remove the oil filler cap a and oil level
gauge b.
Total amount:
4.3 L (4.5 US qt, 3.8 Imp.qt)
Without oil filter replacement:
3.0 L (3.2 US qt, 2.6 Imp.qt)
9
With oil filter replacement:
3.1 L (3.3 US qt, 2.7 Imp.qt)

3-8
A
 MNT
Maintenance
8. Install the oil filler cap a and oil level 3. Check the trolling speed using the
gauge b. tachometer of the multifunction meter or
using the YDIS. Check the throttle cable,
9. Check the engine oil level. See “Engine APS, or throttle body assy. if out of
oil level check” (3-7). specification.

Oil filter replacement Trolling speed: 1200–1400 r/min

1. Place a rag under the oil filter a.
Nut and bolt check
1. Check the engine, deck, and hull for
2. Remove the oil filter a.
loose bolts and nuts. Tighten if loose.
See “Specified tightening torque” (2-11).

Jet pump unit

Impeller check

Make sure to remove the battery before

checking the jet pump unit.
b a

3. Install the oil filter, and then tighten it to 1. Remove the jet pump unit. See “Jet
the specified torque. pump unit removal” (6-4).

2. Check the impeller a. Replace if

damaged.

3. Measure the impeller-to-housing

clearance a. Measure the impeller
a b housing inside diameter if the impeller-to-
housing clearance a is out of
specification. See “Impeller housing
check” (6-10).

Oil filter wrench b: 90890-06830

a
Oil filter a:
18 N·m (1.8 kgf·m, 13.3 ft·lb)

TIP:
a
Make sure to clean up any oil spills.

4. Check the engine oil level. See “Engine

oil level check” (3-7). Impeller-to-housing clearance a:
0.35–0.45 mm (0.014–0.018 in)
Trolling speed check
1. Place the watercraft in the water. 4. Install the jet pump unit. See “Jet pump
unit installation” (6-4).
2. Start the engine and warm it up for 5
minutes or more.

3-9
 Periodic service
Water inlet strainer check 4. Turn the steering cable joint b in or out
1. Remove the water inlet strainer cover a to adjust distances a and b.
and water inlet strainer b. See “Nozzle, WARNING! The steering cable joint

1
impeller housing, and impeller duct assy.” must be screwed in more than 8 mm
(6-7). (0.31 in) c.

2. Check the water inlet strainer b. Clean if

contaminated.
c
a

b
2
b a

3
4
3. Install the water inlet strainer b and
water inlet strainer cover a. See
“Nozzle, impeller housing, and impeller
a b
duct assy.” (6-7).

5
Jet thrust nozzle steering angle check
1. Turn the handlebar lock to lock.

2. Measure distances a and b. Adjust if

out of specification.

c
6
a b
Turn in
Turn out
Distance a is increased.
Distance b is increased.
7
Difference of distances a and b: 5. Connect the steering cable joint b to the
Maximum 5 mm (0.2 in)

Jet thrust nozzle steering angle adjust-

ball joint c, and then tighten the steering
cable joint locknut a to the specified
torque.
8
ment Steering cable joint locknut a:
1. Remove the service lid.

9
7 N·m (0.7 kgf·m, 5.2 ft·lb)
2. Loosen the steering cable joint locknut 6. Check the difference of distances a and
a. b.

3. Disconnect the steering cable joint b 7. Install the service lid.

from the ball joint c.

3-10
A
 MNT
Maintenance
Electrical system
Battery check

b
a
Battery electrolyte is poisonous and dan-
gerous, causing severe burns, etc. Elec-
trolyte contains sulfuric acid. Avoid
contact with skin, eyes or clothing.
Antidotes
External: Flush with water.
Internal: Drink large quantities of water or 3. Check the specific gravity of the
milk. Follow with milk of magnesia, beaten electrolyte. Charge the battery if below
egg or vegetable oil. Call physician imme- specification.
diately. Specific gravity at 20 °C (68 °F): 1.265
Eyes: Flush with water for 15 minutes and
get prompt medical attention. 4. Install the battery, and then install the
Batteries produce explosive gases. Keep bands.
sparks, flame, cigarettes, etc., well away.
If using or charging the battery in an 5. Connect the battery breather hose a,
enclosed space, make sure that it is well and then fasten it using the clamp b.
ventilated. Always shield your eyes when NOTICE: Make sure that the battery
working near batteries. breather hose is connected properly
KEEP OUT OF THE REACH OF CHIL- and is not obstructed.
DREN.
6. Connect the positive battery cable c,
and then connect the negative battery
cable d. NOTICE: Connect the
Be careful not to place the battery on its positive battery cable to the battery
side. terminal first.
Make sure to remove the battery from the
battery compartment when adding battery
electrolyte or charging the battery.
When checking the battery, make sure the
breather hose is connected to the battery b
and not obstructed. a
d
1. Remove the battery. NOTICE: When c
removing the battery, disconnect the
a
negative battery cable first.

2. Check the battery electrolyte level. If the TIP:

level is at or below the minimum level Apply water resistant grease to the terminals
mark a, add distilled water until the level to minimize corrosion.
is between the maximum level mark b
and the minimum level mark a. Hull and hood
Bilge strainer check
1. Remove the bilge strainer case a.

2. Check the bilge strainer. Clean if

contaminated.

3-11
 Periodic service

a
a

a a 1
TIP:
Remove the bilge strainer case a by pushing
Recommended lubricant: Rust inhibitor 2
3. Connect the air intake pipe b, and then
the hooks a on the bilge strainer inward.
tighten the air intake pipe clamp a.

3. Install the bilge strainer case a.

Drain plug check

Air intake pipe clamp a:
3 N·m (0.3 kgf·m, 2.2 ft·lb)
3
Throttle cable (handlebar end) lubrication
1. Check the O-ring a of each drain plug

4
1. Remove the upper handlebar cover, and
b.
then disconnect the outer cable of the
throttle cable. See “Throttle lever free
play adjustment” (3-2).

5
2. Lubricate the throttle cable (handlebar
b end).

a b

Lubrication points
Throttle valve lubrication
6
1. Loosen the air intake pipe clamp a, and
then disconnect the air intake pipe b.

b
a Recommended lubricant: Rust inhibitor 7
TIP:
After lubricating the throttle cable, make sure
to adjust the throttle lever free play. See
“Throttle lever free play adjustment” (3-2).
8
3. Connect the outer cable, and then install
2. Spray a rust inhibitor into the throttle
valve opening a.
the upper handlebar cover. See “Throttle
lever free play adjustment” (3-2). 9
3-12
A
 MNT
Maintenance
Throttle cable (APS end) and return spring
lubrication
1. Lubricate the throttle cable (APS end)
and return spring.

Recommended lubricant:
Yamaha grease A

Nozzle pivot bolt and steering cable lubri-

cation Recommended lubricant:
1. Lubricate the nozzle pivot bolt and steer- Yamaha grease A
ing cable.

TIP:
Disconnect the joint and apply a small
amount of grease.

Shift lever assy., shift cable, and shift

cable joint lubrication
1. Remove the engine hatch cover. See
“Multifunction meter and engine hatch
cover” (8-10).
Recommended lubricant:
2. Lubricate the shift lever assy., shift cable,
Yamaha grease A
and shift cable joint.
Steering cable and steering cable joint
lubrication
1. Lubricate the steering cable and steering
cable joint.

3-13
 Periodic service

1
Recommended lubricant:
Yamaha grease A
2
TIP:
Disconnect the joint and apply a small
amount of grease.
3
3. Install the engine hatch cover. See
“Multifunction meter and engine hatch
cover” (8-10).

Intermediate housing lubrication

4
1. Lubricate the intermediate housing
through the grease nipple a.
5
a

6
Recommended lubricant:
Yamaha grease A
7
8
9
3-14
A
 MNT
Maintenance

— MEMO —

3-15
FUEL

Fuel system 4

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

Fuel hose disconnection ............................................................ 4-3
Fuel pressure measurement ..................................................... 4-3
Fuel hose disassembly .............................................................. 4-4
1
Air filter element check .............................................................. 4-4
Fuel hose assembly .................................................................. 4-4

Throttle body assy. and fuel injector .............................. 4-6

Throttle body assy. check .......................................................... 4-7
2
Fuel injector check .................................................................... 4-7

3
Fuel rail and injector installation ................................................ 4-7

Fuel tank and fuel pump module assy. ........................... 4-9

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
Fuel sender installation ........................................................... 4-12
4
Fuel pump module installation ................................................. 4-12
Fuel tank installation ................................................................ 4-13

5
6
7
8
9
A
 FUEL
Fuel system

Air filter case and fuel hose

22 21
17 12 N·m (1.2 kgf·m, 8.9 ft·lb)
18

17 13 13 11
20 18 13
19 12
1718 13
14

20 15
19
17
20 20 18 13
19 19
13
8
14 10
11
17 N·m (1.7 kgf·m, 12.5 ft·lb) 13 1
13
11 16

3 N·m (0.3 kgf·m, 2.2 ft·lb)

9
4 7
3
6
2
3
4

No. Part name Q’ty Remarks

1 Plastic tie 1
2 Fuel hose assy. 1
3 Clamp 4 39
4 Quick connector 2
5 Corrugated tube 1
6 Fuel hose 1
7 Clamp 2
8 Clamp 1
9 Air intake pipe 1
10 Connection 1
11 Bolt 4 M8 35 mm
12 Air filter case assy. 1
13 Hook 8
14 Screw 3 M6 15 mm
15 Air filter element 1
16 Drain tube 1

4-1
 Air filter case and fuel hose

22 21
17

1
12 N·m (1.2 kgf·m, 8.9 ft·lb)
18

17 13 13 11
20 18 13
19 12
1718 13
14

20 20
20
19
19
17
18 13
15
2
19 13
8
11
17 N·m (1.7 kgf·m, 12.5 ft·lb) 13
11 16
14

13
10
1 3
4
7

3 N·m (0.3 kgf·m, 2.2 ft·lb)

6
3
4 7

2
5
3
4

5
6
No. Part name Q’ty Remarks
17
18
19
Collar
Grommet
Nut
4
4
4
7
20 Washer 4
21 Bracket 1
22 Plastic tie 1
8
9
4-2
A
 FUEL
Fuel system
Fuel hose disconnection
b

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
1. Disconnect the quick connector from the
a
fuel rail.

2. Install the special service tools a and b.

A

2. Disconnect the quick connector a.

b
WARNING! Make sure to disconnect
the quick connector slowly. a
Otherwise, pressurized fuel could
spray out.
B

a b

A U.S.A. and Canada

TIP: B Worldwide
Make sure to clean up any fuel spills. Fuel pressure gauge adapter a:
YW-06842/90890-06842
3. Cover the quick connector, fuel rail, and Fuel pressure gauge b:
fuel pipe using plastic bags b to protect YB-06766/90890-06786
them from dirt.
3. Start the engine and warm it up for 5
minutes or more at engine idle speed.

4. Measure the fuel pressure. Replace the

fuel pump module assy. if out of
specification.

4-3
 Air filter case and fuel hose
1. Install new clamps a and the quick con-
Fuel pressure:
nector b onto the fuel hose c.
345–370 kPa
(3.45–3.70 kgf/cm2, 49.1–52.6 psi)

Fuel hose disassembly

1. Remove the clamps a and quick con-
nector b. NOTICE: When cutting each
b
c
1
clamp, position the tool.
a

2
a
d b a a c d
3
b

Air filter element check

4
Do not start the engine with the air filter
element removed. Otherwise, the engine
TIP:
could be damaged.

1. Remove the air filter case cover and air

• Align the paint markers a on the fuel hose
with the notch b and projection c on the
quick connectors.
• Make sure to face the locking slider d on
5
filter element. each quick connector in the same direction.

2. Check the air filter element. Replace if

damaged or dirty. 2. Crimp the clamps a.
6
7
h

Fuel hose assembly

a a 8
Do not reuse a clamp, always replace it
with a new one. Otherwise, fuel could
leak.
e
g
9
f

4-4
A
 FUEL
Fuel system

Distance e: 17 mm (0.67 in)

Distance f: 34.5 mm (1.36 in)
Distance h: 1 mm (0.04 in)

TIP:
• Make sure to align the white paint mark g
on the fuel hose with the crimped section of
the clamp.
• Position the crimped sections of the clamps
180° away from each other.

4-5
 Air filter case and fuel hose / Throttle body assy. and fuel injector

Throttle body assy. and fuel injector

13
11

1
12

13
11
10 12

9
13
11
12
2
9

13 N·m (1.3 kgf·m, 9.6 ft·lb)

3
13
11
12

7
13 N·m (1.3 kgf·m, 9.6 ft·lb)

5 1
4
5
A
7
8 4
3
2
5 3
5
6
A 24 N·m (2.4 kgf·m, 17.7 ft·lb) 5
3 2
3
2
6
No. Part name Q’ty Remarks
1
2
3
Plastic tie
Nut
Washer
2
4
4
7
4 Throttle body assy. 1
5 Bolt 4 M8 20 mm
6
7
8
Joint
Holder
Ribbon
1
1
1
8
9 Bolt 3 M8 17 mm

9
10 Fuel rail 1
11 Fuel injector 4
12 Seal 4 39
13 O-ring 4 39

4-6
A
 FUEL
Fuel system
Throttle body assy. check a

• Do not disassemble the throttle body

assy.
• Do not loosen the throttle stop screw
nut a and do not turn the throttle stop
screw b.
• Do not loosen or remove the throttle
valve shaft screws c.
2. While turning the fuel injectors b slowly
to the left and right, install them to the
a b
fuel rail c. NOTICE: Make sure to
c apply a thin coat of engine oil to the O-
rings before installing the fuel
injectors to the fuel rail. Otherwise,
the O-rings could twist and break,
causing fuel leakage.

1. Turn the throttle valve manually and

check that it moves smoothly.
b
Fuel injector check
c
1. Check the fuel injector filter a. Clean
using kerosene or gasoline if clogged or
contaminated.

a 3. Install new seals d and the fuel rail c,

and then tighten the fuel rail bolts e to
the specified torque.

c
2. Measure the fuel injector resistance. See
“Fuel injector resistance” (7-26).

Fuel rail and injector installation

e
Do not reuse an O-ring or seal, always
replace it with a new one.
Fuel rail bolt e:
1. Install new O-rings a onto the fuel injec- 13 N·m (1.3 kgf·m, 9.6 ft·lb)
tors, and then apply a thin coat of engine
oil to the O-rings.

4-7
 Throttle body assy. and fuel injector
4. Install the holders f, and then connect
the fuel injector couplers a.
a

1
f
2
3
4
5
6
7
8
9
4-8
A
 FUEL
Fuel system

Fuel tank and fuel pump module assy.

21 a 3 N·m (0.3 kgf·m, 2.2 ft·lb)

22 b 6 N·m (0.6 kgf·m, 4.4 ft·lb)

16 N·m (1.6 kgf·m, 11.8 ft·lb)

2 23 16
15
1
15
4
26
1 17
3 25 17

1 18
12 5
24
20 6
10
19 14
6 N·m (0.6 kgf·m, 4.4 ft·lb)

13
11
27
9
7

28 7
28 8
4 N·m (0.4 kgf·m, 3.0 ft·lb)

No. Part name Q’ty Remarks

1 Plastic tie 3
2 Breather hose 1
3 Breather hose 1
4 Check valve 1
5 Fuel filler cap 1
6 Packing 1 39
7 Clamp 2
8 Fuel filler hose 1
9 Nut 1
10 Fuel filler neck 1
11 Packing 1 39
12 Tapping screw 1 ø4 9 mm
13 Rivet 1
14 Chain ball 1
15 Bolt 2 M8 18 mm
16 Strap 2

4-9
 Fuel tank and fuel pump module assy.

21 a 3 N·m (0.3 kgf·m, 2.2 ft·lb)

1
22 b 6 N·m (0.6 kgf·m, 4.4 ft·lb)

16 N·m (1.6 kgf·m, 11.8 ft·lb)

2 23 16
15

2
1
15
4
26
1 17
3 25 17

1
24
18
12
6
5 3
20
10
19
6 N·m (0.6 kgf·m, 4.4 ft·lb)

13
14
4
11
27

7
9
5
28
28 8
7
4 N·m (0.4 kgf·m, 3.0 ft·lb)
6
No. Part name Q’ty Remarks
17
18
19
Rivet
Hook
Bolt
2
2
2 M6 9 mm
7
20 Special nut 2
21 Nut 9
22
23
24
Retainer
Fuel pump module assy.
Packing
1
1
1 39
8
25 Stopper 1

9
26 Fuel sender 1
27 Fuel tank 1
28 Pad 2 39

4-10
A
 FUEL
Fuel system
Fuel pump module removal
b
e

Before checking the fuel system, remove d

the battery, and then remove the fuel filler
cap to reduce any pressure inside the fuel
tank.

1. Remove the fuel pump module assy. a.

NOTICE: When removing the fuel
pump module assy. a, make sure that Fuel pump module check
the rubber caps a do not come off.

a Do not disassemble the fuel pump mod-

ule.

b a 1. Check the fuel pump filter a. Clean

using kerosene or gasoline if clogged or
contaminated.

TIP:
Remove the fuel pump module assy. a at an
angle so that the float b does not catch on
the fuel tank.

Fuel sender removal

1. Disconnect the fuel sender coupler a.
Check valve check
2. Squeeze the hooks b on the stopper a, 1. Blow into the end a of the check valve,
and then slide the stopper in direction c and check that airflow from the end b is
to remove it. unrestricted. Replace if the air flow is
restricted.
a
a 2. Blow into the end b of the check valve,
c and check that airflow from the end a is
restricted. Replace if the air flow is
unrestricted.
a
b A a B b

3. Push the tabs d on the fuel sender b,

and then slide the fuel sender in direction
e to remove it.
b a

4-11
 Fuel tank and fuel pump module assy.
A Upright
B Inverted b
b
Fuel filler cap check
1. Install the fuel filler cap a onto the fuel
filler neck b, and then hold the fuel filler
neck b.
c
d
1
2. Turn the fuel filler cap a clockwise a
and check that it clicks when tightened
completely. Replace if it does not click.
TIP:
Make sure that the hooks d on the stopper
2
b are hooked securely onto the fuel pump
a
a module.

Fuel pump module installation

3
b

Fuel sender installation

Do not reuse a packing, always replace it
with a new one. 4
1. Install the fuel sender a. 1. Install a new packing and the fuel pump
a

a
module assy. a. NOTICE: When
installing the fuel pump module assy.
a, make sure that the rubber caps a
do not come off.
5
6
a
b b

b a

TIP:
Make sure that the tabs a on the fuel sender
a are seated securely into the slots b in the
fuel pump module.
7
TIP:
2. Install the stopper b, and then connect
the fuel sender coupler c.
Make sure to insert the float b into the fuel
tank. 8
2. Install the retainer b, and then tighten

9
the fuel pump module nuts c to the
specified torques in 2 stages and in the
order a, b, and so on.

4-12
A
 FUEL
Fuel system

b TIP:
b c
e • Install the straps a so that the rubber band
g portions a of the straps are positioned on
i top.
• Make sure that the metal loops b on the
h
end of the straps a are hooked securely
d a f
onto the holders on the hull.
c
3. Install a new packing d, fuel filler neck
Fuel pump module nut c: e, and the fuel filler cap f.
1st: 3 N·m (0.3 kgf·m, 2.2 ft·lb)
2nd: 6 N·m (0.6 kgf·m, 4.4 ft·lb) 4. Tighten the fuel filler neck nut g to the
specified torque.
Fuel tank installation

c
Do not reuse a packing, always replace it
with a new one. f d g
e
1. Install the straps a, and then tighten the
strap bolts b to the specified torque. d

2. Install the fuel tank c, and then fasten

the fuel tank using the straps a. Fuel filler neck nut g:
6 N·m (0.6 kgf·m, 4.4 ft·lb)
a
b a
TIP:
a Align the protrusion c on the fuel filler neck
b
b e with the holes d in the packing d and
a deck.

b
5. Install the fuel filler hose h, and then
tighten the fuel filler hose clamps i to
the specified torque.
c
6. Check that the distance e is within
specification.

Strap bolt b:
16 N·m (1.6 kgf·m, 11.8 ft·lb)

4-13
 Fuel tank and fuel pump module assy.

e c

f
h
i
1
i

i
2
h

Distance e: 30–40 mm (1.2–1.6 in)

Fuel filler hose clamp i:

3
4 N·m (0.4 kgf·m, 3.0 ft·lb)

TIP:
Align the arrow mark f on the fuel filler hose
h with the protrusion c on the fuel filler
4
neck.

7. Connect the fuel sender coupler g and

fuel pump module coupler h.
5
8. Install the fuel tank breather hoses j
and check valve k.

9. Fasten the fuel tank breather hoses j

using the plastic ties l.
6
l
j

k
k g h
7
j
8
TIP:
Point the arrow mark k toward the fuel tank.
9
4-14
A
POWR

Power unit 5

Engine unit ......................................................................... 5-1

Exhaust manifold .............................................................. 5-2

Engine unit and coupling cover ....................................... 5-5

Engine mount .................................................................... 5-6

Engine unit removal ................................................................... 5-7
Engine mount and damper check ............................................ 5-10
Engine unit installation ............................................................ 5-10

Muffler .............................................................................. 5-17

Exhaust pipe disassembly ....................................................... 5-18
Exhaust pipe assembly ........................................................... 5-18

Wiring harness assy. ...................................................... 5-19

Starter motor and wiring harness assy. removal ..................... 5-20
Thermostat check .................................................................... 5-21
Starter motor and wiring harness assy. installation ................. 5-21

Intake assy. ...................................................................... 5-23

Intake manifold installation ...................................................... 5-24

Oil cooler, oil pump assy., and drive gear .................... 5-25
Oil pump assy. and oil pump drive gear removal .................... 5-27
Oil cooler assy. check ............................................................. 5-27
Oil pump assy. check .............................................................. 5-27
Oil pump drive gear and oil pump assy. installation ................ 5-27

Cylinder head cover ........................................................ 5-29

Camshaft .......................................................................... 5-31

Camshaft removal ................................................................... 5-33
Camshaft sprocket removal ..................................................... 5-34
Camshaft check ....................................................................... 5-34
Camshaft journal oil clearance check ...................................... 5-35
Timing chain tensioner check .................................................. 5-36
Camshaft sprocket installation ................................................ 5-36
Camshaft installation ............................................................... 5-37
Valve clearance adjustment .................................................... 5-39
Valve pad selection table ........................................................ 5-42

Cylinder head .................................................................. 5-43

Valve and valve spring ................................................... 5-44
Cylinder head disassembly ..................................................... 5-45
Cylinder head check ................................................................ 5-45

1
Valve spring check .................................................................. 5-45
Valve check ............................................................................. 5-46
Valve guide check ................................................................... 5-46
Valve guide removal ................................................................ 5-47
Valve guide installation ............................................................ 5-47
Valve seat check ..................................................................... 5-48
Valve seat refacing .................................................................. 5-48
Cylinder head assembly .......................................................... 5-50
Cylinder head installation ........................................................ 5-52
2
Generator cover assy. and flywheel magneto .............. 5-53

Generator cover .............................................................. 5-55

Drive coupling removal ............................................................ 5-56
3
Flywheel magneto removal ..................................................... 5-56
Generator cover assy. disassembly ........................................ 5-58
Starter clutch operation check ................................................. 5-58
Generator cover assy. assembly ............................................. 5-59
Flywheel magneto installation ................................................. 5-60
4
Drive coupling installation ........................................................ 5-63

Cylinder block and electrical part .................................. 5-64

5
Oil separator tank and oil pan ........................................ 5-66

6
Anode check ............................................................................ 5-68
Oil level pipe installation .......................................................... 5-68
Oil separator tank cover installation ........................................ 5-69

Crankcase, connecting rod, and piston ........................ 5-70

Crankcase disassembly .......................................................... 5-72
Connecting rod and piston removal ......................................... 5-72
Crankcase check ..................................................................... 5-73
Piston check ............................................................................ 5-73
7
Piston ring check ..................................................................... 5-73

8
Piston pin check ...................................................................... 5-74
Connecting rod check .............................................................. 5-74
Cylinder block check ............................................................... 5-74
Crankshaft check ..................................................................... 5-75
Crankshaft pin oil clearance check .......................................... 5-75
Connecting rod bearing selection ............................................ 5-76
Crankshaft journal oil clearance check .................................... 5-77
Crankshaft bearing selection ................................................... 5-78
Connecting rod and piston installation .................................... 5-79
Crankcase assembly ............................................................... 5-81
9
A
POWR
Power unit

Engine unit
2
5 N·m (0.5 kgf·m, 3.7 ft·lb)
3
2

4
10

7
8

5
9
6

No. Part name Q’ty Remarks

1 Plastic tie 1
2 Screw 2 M6 12 mm
3 Grommet 2
4 Engine cover 1
5 Clamp 1
6 Breather hose 1
7 Antenna holder 3
8 Clamp 1
9 Cooling water hose 1
10 Clamp 1

5-1
 Engine unit / Exhaust manifold

Exhaust manifold
26 N·m (2.6 kgf·m, 19.2 ft·lb)
2

1
7 a 22 N·m (2.2 kgf·m, 16.2 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb)
4 8 b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
10
9
7 13 17
3 12
12
24 20
15
9 10

9 10
5
6
7

21
18
19
14

20
14
2
19
16 5

3
23 18
22
11
21
26 13 N·m (1.3 kgf·m, 9.6 ft·lb)
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
27
a 22 N·m (2.2 kgf·m, 16.2 ft·lb)
34 b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
25 4
1
34

33
30
5
18 N·m (1.8 kgf·m, 13.3 ft·lb)
29

6
31
32 28
a 20 N·m (2.0 kgf·m, 14.8 ft·lb) a 20 N·m (2.0 kgf·m, 14.8 ft·lb)
b 20 N·m (2.0 kgf·m, 14.8 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
c 35 N·m (3.5 kgf·m, 25.8 ft·lb) c 35 N·m (3.5 kgf·m, 25.8 ft·lb)

No. Part name Q’ty Remarks

1
2
3
Oil filter
Clamp
Clamp
1
1
1
7
4 Breather hose 1
5 Clamp 2
6
7
8
Breather hose
Bolt
Breather assy.
1
3
1
M6 30 mm 8
9 Collar 3

9
10 Grommet 3
11 Plastic tie 1
12 Clamp 2
13 Cooling water hose 1
14 Clamp 2
15
16
Cooling water hose
Clamp
1
1

5-2
A
POWR
Power unit

26 N·m (2.6 kgf·m, 19.2 ft·lb)

2
7 a 22 N·m (2.2 kgf·m, 16.2 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb)
4 8 b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
10
9
7 13 17
3 12
12
24 20
15
9 10 14
7 19
18 20
5
6 21 14
9 10
19
16 5
23 18
22
11
21
26 13 N·m (1.3 kgf·m, 9.6 ft·lb)
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
27
a 22 N·m (2.2 kgf·m, 16.2 ft·lb)
34 b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
25

34
30
33
1
18 N·m (1.8 kgf·m, 13.3 ft·lb)
29
31
32 28
a 20 N·m (2.0 kgf·m, 14.8 ft·lb) a 20 N·m (2.0 kgf·m, 14.8 ft·lb)
b 20 N·m (2.0 kgf·m, 14.8 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
c 35 N·m (3.5 kgf·m, 25.8 ft·lb) c 35 N·m (3.5 kgf·m, 25.8 ft·lb)

No. Part name Q’ty Remarks

17 Bolt 2 M8 35 mm
18 Collar 2
19 Grommet 2
20 Bolt 4 M6 35 mm
21 Bolt 2 M6 25 mm
22 Rectifier regulator 1
23 Gasket 1 39
24 Cover 1
25 Bolt 1 M10 50 mm
26 Bolt 1 M8 47 mm
27 Stay 1
28 Clamp 1
29 Clamp 1
30 Clamp 1
31 Bolt 3 M8 120 mm
32 Bolt 8 M8 70 mm

5-3
 Exhaust manifold

26 N·m (2.6 kgf·m, 19.2 ft·lb)

2

1
7 a 22 N·m (2.2 kgf·m, 16.2 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb)
4 8 b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
10
9
7 13 17
3 12
12
24 20
15
9 10

9 10
5
6
7

21
18
19
14

20
14
2
19
16 5

3
23 18
22
11
21
26 13 N·m (1.3 kgf·m, 9.6 ft·lb)
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
27
a 22 N·m (2.2 kgf·m, 16.2 ft·lb)
34 b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
25 4
1
34

33
30
5
18 N·m (1.8 kgf·m, 13.3 ft·lb)
29

6
31
32 28
a 20 N·m (2.0 kgf·m, 14.8 ft·lb) a 20 N·m (2.0 kgf·m, 14.8 ft·lb)
b 20 N·m (2.0 kgf·m, 14.8 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
c 35 N·m (3.5 kgf·m, 25.8 ft·lb) c 35 N·m (3.5 kgf·m, 25.8 ft·lb)

No. Part name Q’ty Remarks

33
34
Gasket
Dowel pin
1
2
39
7
8
9
5-4
A
POWR
Power unit

Engine unit and coupling cover

17 N·m (1.7 kgf·m, 12.5 ft·lb)

1
5

2
6
3

1 1

5 17 N·m (1.7 kgf·m, 12.5 ft·lb)

6
5

No. Part name Q’ty Remarks

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 unit and coupling cover / Engine mount

Engine mount
17 N·m (1.7 kgf·m, 12.5 ft·lb) 5.5 N·m (0.55 kgf·m, 4.06 ft·lb)

1
1
1
2
2 3
3

5.5 N·m (0.55 kgf·m, 4.06 ft·lb)

2
4

6
5
3
1

4
7

1
1 3

5
2 3

6
No. Part name Q’ty Remarks
1
2
3
Bolt
Engine mount
Liner
8
4
4
M8 35 mm
7
4 Bolt 2 M6 19 mm
5 Damper 1 1
6
7
Bolt
Damper 2
2
1
M6 12 mm
8
9
5-6
A
POWR
Power unit
Engine unit removal

Before removing the engine, make sure to e

take adequate measures to protect the
deck opening from damage.
f
1. Disconnect the negative battery cable,
d
and then disconnect the positive battery
cable.
7. Remove the intake pipe g, air filter case
2. Extract the engine oil. See “Engine oil cover h, air filter, and air filter case i.
replacement” (3-8).
h
i
3. Remove the service lid a. g

8. Remove the plastic tie j from the

cooling water hose k.

4. Remove the plastic tie b, and then j

k
disconnect the quick connector c from
the fuel rail. WARNING! Make sure to
disconnect the quick connector
slowly. Otherwise, pressurized fuel
could spray out.

9. Remove the electrical box cover l.

5. Remove the plastic tie d and engine

cover e.

6. Remove the breather hose f.

10. Remove the antenna holders m.

11. Disconnect the remote control receiver

coupler a and APS coupler b.

5-7
 Engine mount

m b
d

1
a

12. Disconnect the

couplers c.
sensor and switch 15. Disconnect the cooling water hose k
from the oil cooler assy.
2
c

k
3
4
13. Remove the wiring harness from the 16. Disconnect the cooling water hose o
plastic ties n.

n
from the thermostat housing.

o 5
6
n
17. Place a rag under the oil filter p, and
then remove it.
7
p q
8
14. Disconnect
coupler d.
the fuel pump module
9
Oil filter wrench q: 90890-06830

5-8
A
POWR
Power unit
23. Remove the pipe clamp D from the pipe
TIP: E.
Make sure to clean up any oil spills.

18. Remove the breather hoses r and s, D

and breather assy. t.

19. Remove the holder u and plastic tie v,

and then disconnect the thermo sensor
coupler e. E

t
24. Remove the muffler assy. f.

v e r
u

20. Remove the cooling water hoses w, x, TIP:

and y, and rectifier regulator z. When removing the muffler assy. f, move it
forward and separate it from the water lock.
w
z 25. Remove the electrical box F.
x
F

21. Disconnect the cooling water hoses A

and B.

22. Remove the stay C. 26. Remove the coupling cover G.

AB
C

5-9
 Engine mount
27. Remove the throttle body assy. See 32. Lift the engine unit slightly, and then
“Throttle body assy. and fuel injector” (4- lower the front of the unit. Repeat this
6). step until the engine unit can be removed

1
from the engine compartment.
28. Loosen the engine mounting bolts H. NOTICE: When removing the engine
unit, take care to avoid causing
29. Lift the engine unit slightly, remove the damage to the hull liner and deck
shims I, and then lower the unit. opening.

30. Remove the engine mounting bolts H.

H
2
I
3
I
H 33. Lift the engine unit out vertically.

4
TIP:
Write down the position of each removed
shim I so that it can be installed in its origi-
5
nal position.

31. Suspend the engine unit using all 3

engine hangers, and then separate the
unit from the engine mounts and move it
Engine mount and damper check
1. Check the engine mounts and dampers.
Replace if cracked or damaged.
6
forward to disconnect the coupling.
TIP:
• Write down the position of each engine
mount so that it can be installed in its origi-
nal position.
7
• When replacing the engine mounts, make
sure to check the coupling clearance.

Engine unit installation

8
When installing the engine unit, take care
to avoid causing damage to the hull liner
and deck opening.
9
5-10
A
POWR
Power unit
1. Suspend the engine unit using all 3
engine hangers.

2. Lower the front of the engine unit.

3. Lower the engine unit into the engine

compartment vertically.

4. Lift the front of the engine unit slightly,

and then lower the unit. Repeat this step
until the drive and driven couplings are TIP:
aligned. Do not install the rubber coupling until the
coupling clearance adjustment has been
made.

6. Temporarily install the engine mounting

bolts b.

7. Lift the engine unit slightly, install the

shims c, and then lower the unit.

b
5. Move the engine unit rearward to connect
the driven coupling a, and then lower
the unit onto the engine mounts. c

TIP:
Install the shims in their original positions.

5-11
 Engine mount
8. Measure the coupling clearances a and
b. If the clearances are out of
specification, add or remove shims c so a

1
that the clearances are within
specification.

Clearance a:
b

Less than 0.5 mm (0.020 in)

2
(with rubber coupling)

Clearance a:
Less than 1 mm (0.039 in)
b Clearance b:
2–4 mm (0.079–0.157 in)

14. Tighten the engine mounting bolts b to

3
(without rubber coupling) the specified torque, and then recheck

4
Clearance b: the coupling clearances.
2–4 mm (0.079–0.157 in) b

Available shim thicknesses:

0.10, 0.30, 0.50, 1.00, 2.00 mm

9. Lift the engine unit slightly, remove the

shims, and then lower the engine unit.
b
5
10. Remove the engine mounting bolts.

11. Separate the engine unit from the engine

mounts and move it forward to
disconnect the coupling.
Engine mounting bolt b:
17 N·m (1.7 kgf·m, 12.5 ft·lb) 6
15. Install the throttle body assy. See
12. Install the rubber coupling d.

7
“Throttle body assy. and fuel injector” (4-
6).

16. Install the coupling cover e.

d
8
e

13. Install the shims, and then adjust the

position of the engine unit so that the
coupling clearances a and b are within
specification.
9
17. Install the electrical box f, and then
tighten the electrical box bolts g to the
specified torque.

5-12
A
POWR
Power unit

f TIP:
Make sure that the pipe on the end of the
g g muffler assy. is installed securely into the
water lock.

20. Install the stay k, and then tighten the

g stay bolts l and m to the specified
torques in 2 stages.

Electrical box bolt g: 21. Connect the cooling water hoses n and
17 N·m (1.7 kgf·m, 12.5 ft·lb) o.

18. Install the muffler assy. c into the water l

n o
lock, and then tighten the exhaust
manifold bolts h and i to the specified
torques in 3 stages and in the order a, m
b, and so on. NOTICE: Do not reuse a
gasket, always replace it with a new m
one. l
k
i c
Stay bolt l and m:
i f b c g j
1st: 22 N·m (2.2 kgf·m, 16.2 ft·lb)
2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb)
i i
h he a d k
h 22. Install the rectifier regulator p, and then
tighten the rectifier regulator bolts q to
i h the specified torque.

23. Connect the cooling water hoses r, s,

Exhaust manifold bolt h and i:
and t.
1st: 20 N·m (2.0 kgf·m, 14.8 ft·lb)
2nd: 20 N·m (2.0 kgf·m, 14.8 ft·lb)
r
3rd: 35 N·m (3.5 kgf·m, 25.8 ft·lb)
p
t
19. Install the pipe clamp j, and then q
q
tighten it to the specified torque.

q
j s

Rectifier regulator bolt q:

26 N·m (2.6 kgf·m, 19.2 ft·lb)

24. Install the breather hose u, breather

assy. v, and breather hose w.
Pipe clamp j: 25. Connect the thermo sensor coupler d.
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

5-13
 Engine mount
26. Fasten the leads using the holder x and
plastic tie y.

v
C
1
u
30. Connect the fuel pump module coupler
e.
2
y d
x
w

27. Install the oil filter z, and then tighten it

e
3
to the specified torque.

4
31. Connect the sensor and switch couplers
z A f.

f
5
Oil filter wrench A: 90890-06830

Oil filter z:
18 N·m (1.8 kgf·m, 13.3 ft·lb)
6
7
28. Connect the cooling water hose B to the
thermostat housing.
32. Connect the APS coupler g and remote
B control receiver coupler h, and then
install the antenna holders D.

D g
8
29. Connect the cooling water hose C to the
oil cooler assy.
h
9
33. Fasten the wiring harness using the
plastic ties E.

5-14
A
POWR
Power unit

E H

Air filter case bolt I:

E 12 N·m (1.2 kgf·m, 8.9 ft·lb)

37. Install the air filter, air filter case cover J,

and intake pipe K, and then tighten the
air intake pipe clamp L to the specified
torque.
J
K
34. Install the electrical box cover F.

Air intake pipe clamp L:

3 N·m (0.3 kgf·m, 2.2 ft·lb)

38. Install the engine cover M, and then

35. Fasten the cooling water hose C using tighten the engine cover screws N to the
the plastic tie G. specified torque.

G 39. Install the breather hose O, and then

C
fasten it using the plastic tie P.

O k

M
36. Install the air filter case H, and then
tighten the air filter case bolts I to the
specified torque. N

P
O

5-15
 Engine mount

Engine cover screw N:

5 N·m (0.5 kgf·m, 3.7 ft·lb)

TIP:
Slide the corrugated tube k on the breather
hose O until it contacts the clamp Q.
1
40. Connect the quick connector R to the
fuel rail.

41. Pass the fuel hose through the clamp m

on the intake pipe, and then clamp the
2
plastic tie S.

S
m 3
4
R

42. Install the service lid T.

T
5
6
43. Fill the engine with engine oil. See
“Engine oil replacement” (3-8).
7
8
44. Connect the positive battery cable, and
then connect the negative battery cable.

9
5-16
A
POWR
Power unit

Muffler
20 N·m (2.0 kgf·m, 14.8 ft·lb)

a 15 N·m (1.5 kgf·m, 11.1 ft·lb)

3 b 29 N·m (2.9 kgf·m, 21.4 ft·lb)

7
8
9
12
13
7
15
14

14

2
10 1
6
11
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
a 20 N·m (2.0 kgf·m, 14.8 ft·lb)
b 35 N·m (3.5 kgf·m, 25.8 ft·lb)
a 20 N·m (2.0 kgf·m, 14.8 ft·lb) 200 N·m (20.0 kgf·m, 147.5 ft·lb)
b 35 N·m (3.5 kgf·m, 25.8 ft·lb)

No. Part name Q’ty Remarks

1 Clamp 1
2 Pipe 1
3 Thermo sensor 1
4 Clamp 1
5 Cooling water hose 1
6 Exhaust pipe 3 1
7 Bolt 5 M8 35 mm
8 Exhaust pipe 2 1
9 Gasket 1 39
10 Bolt 2 M8 70 mm
11 Bolt 4 M8 120 mm
12 Exhaust pipe 1 1
13 Gasket 1 39
14 Dowel pin 2
15 Exhaust manifold 1

5-17
 Muffler
Exhaust pipe disassembly Exhaust pipe assembly
1. Install exhaust pipe 3 a, and then tighten
it to the specified torque. NOTICE: To

1
Use heat-resistant gloves. Otherwise, allow the LOCTITE 648 to set, wait
burns could result. approximately 1 hour after completing
this procedure.
1. Remove exhaust pipe 3 a.

b
15°
15°
2
a
a
a
3
Exhaust pipe wrench b: 90890-06726

TIP:
Heat the area a of exhaust pipe 3 a to
b
15° 15° 4
approximately 200 °C (392 °F) using a heat
gun.
Exhaust pipe wrench b: 90890-06726

Exhaust pipe 3 a:
5
200 N·m (20.0 kgf·m, 147.5 ft·lb)

6
7
8
9
5-18
A
POWR
Power unit

Wiring harness assy.

4 1
5 N·m (0.5 kgf·m, 3.7 ft·lb)
4 3 2
6

9 UP
a 11
11

A A
9
8

10
11
12

14 15
13

No. Part name Q’ty Remarks

1 Nut 1
2 Spring washer 1
3 Starter motor cable 1
4 Bolt 2 M8 30 mm
5 Negative battery cable 1
6 Starter motor 1
7 Bolt 2 M6 35 mm
8 Thermostat housing 1
9 Thermostat 1 a Hole
10 Holder 1
11 Plastic tie 3
12 Plastic tie 1
13 Plastic tie 1
14 Plastic tie 1
15 Wiring harness 1

5-19
 Wiring harness assy.
Starter motor and wiring harness
assy. removal k
1. Disconnect the starter motor cable a
and negative battery cable b, and then
remove the starter motor c.

a
m
1
6. Disconnect the thermoswitch coupler n,
and then remove the plastic ties e.
2
b
e n 3
c

2. Remove the plastic tie d.

3. Disconnect the fuse box couplers a,

4
main relay coupler b, ETV relay coupler 7. Remove the holder f, and then
c, slant detection switch coupler d, and
ECM couplers e.

4. Disconnect the rectifier regulator coupler

disconnect the engine temperature
sensor coupler p, intake air pressure
sensor coupler r, intake air temperature
sensor coupler s, and cam position
5
f, stator coil coupler g, and pick up coil sensor coupler t.

b
coupler h.

c
r
p
6
d
f
s
7
t
a d e

f
8. Remove the plastic tie g, and then
disconnect the ignition coil couplers u
and fuel injector couplers v.
8
h
9
5. Disconnect the earth plate couplers k
and oil pressure switch coupler m.

5-20
A
POWR
Power unit
Starter motor and wiring harness
u assy. installation
1. Connect the fuel injector couplers a and
ignition coil couplers b, and then fasten
the cam position sensor lead and ignition
coil #3 lead using the plastic tie a.
g
b
v

Thermostat check
1. Suspend the thermostat in a container of
water. a
2. Place a thermometer in the water and a
heat the water slowly.
2. Connect the cam position sensor coupler
c, intake air temperature sensor coupler
d, intake air pressure sensor coupler e,
and engine temperature sensor coupler
f, and then fasten the wiring harness
using the holder b.

f
e

3. Measure the thermostat valve opening a

g
at the specified water temperatures.
Replace if out of specification. d
b

a c

TIP:
Fasten the wiring harness at the gray tape g
using the holder b.

3. Connect the thermoswitch coupler h,

and then fasten the thermoswitch lead
using the plastic ties c.
Water temperature Valve opening a
58–62 °C
Starts opening
(136–144 °F)
c h
above 70 °C 4.3 mm (0.17 in) or
(158 °F) above

5-21
 Wiring harness assy.
4. Connect the oil pressure switch coupler
k and earth plate couplers m. g
h

k
m
1
e
f 2
5. Connect the pick up coil coupler n,
stator coil coupler p, and rectifier
regulator coupler r.

6. Connect the ECM couplers s, slant

Starter motor cable nut h:
5 N·m (0.5 kgf·m, 3.7 ft·lb) 3
detection switch coupler t, ETV relay

4
coupler u, main relay coupler v, and
fuse box couplers w, and then fasten the
wiring harness using the plastic tie d.

v
5
d

p
t s
6
r

7
n

7. Install the starter motor e, and then

connect the negative battery cable f
and starter motor cable g.
8
8. Tighten the starter motor cable nut h to
the specified torque.
9
5-22
A
POWR
Power unit

Intake assy.
15 N·m (1.5 kgf·m, 11.1 ft·lb)
12
10 a 10 N·m (1.0 kgf·m, 7.4 ft·lb)
11 b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
14 13
3 a 10 N·m (1.0 kgf·m, 7.4 ft·lb)
5
b 20 N·m (2.0 kgf·m, 14.8 ft·lb)
7

6
6

2
4

9
a 10 N·m (1.0 kgf·m, 7.4 ft·lb)
b 20 N·m (2.0 kgf·m, 14.8 ft·lb)

a 15 N·m (1.5 kgf·m, 11.1 ft·lb)

b 30 N·m (3.0 kgf·m, 22.1 ft·lb)
8
a 15 N·m (1.5 kgf·m, 11.1 ft·lb)
b 30 N·m (3.0 kgf·m, 22.1 ft·lb) 1
8
9
1

No. Part name Q’ty Remarks

1 Bolt 2 M8 25 mm
2 Bolt 6 M8 35 mm
3 Nut 2
4 Intake manifold 1
5 Gasket 1 39
6 Dowel pin 2
7 Stud bolt 2
8 Bolt 2 M8 40 mm
9 Stay 2
10 Intake air temperature sensor 1
11 Gasket 1 39
12 Intake air pressure sensor 1
13 Grommet 1
14 Hose 1

5-23
 Intake assy.
Intake manifold installation Intake manifold bolt d and nut e:
1. Install the dowel pins a, a new gasket 1st: 10 N·m (1.0 kgf·m, 7.4 ft·lb)
b, and the intake manifold c, and then 2nd: 20 N·m (2.0 kgf·m, 14.8 ft·lb)

1
tighten the intake manifold bolts d and
intake manifold nuts e temporarily. 4. Tighten the intake manifold stay bolts g
NOTICE: Do not reuse a gasket, and h to the specified torques in 2
always replace it with a new one. stages.
e Intake manifold stay bolt g and h:
b 1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb)
2nd: 30 N·m (3.0 kgf·m, 22.1 ft·lb) 2
d
c 3
a
a

2. Install the stays f, and then tighten the

4
intake manifold stay bolts g and h
temporarily.

f
5
gh
6
g
h f

3. Tighten the intake manifold bolts d and

intake manifold nuts e to the specified
torques in 2 stages and in the order a,
7
b, and so on.

e a b
d
f
e 8
h d c g
9
5-24
A
POWR
Power unit

Oil cooler, oil pump assy., and drive gear

80 N·m (8.0 kgf·m, 59.0 ft·lb)

6
5

3 16
2
6 14
4
7
8 7 15
7
8 23
7 18 N·m (1.8 kgf·m, 13.3 ft·lb)

1
20 11
12 9
13
12 21 12 N·m (1.2 kgf·m, 8.9 ft·lb)
22
12
13
12 17

10 N·m (1.0 kgf·m, 7.4 ft·lb)

17
20 22 18
17 10
12 N·m (1.2 kgf·m, 8.9 ft·lb)
19
20 N·m (2.0 kgf·m, 14.8 ft·lb)
10

No. Part name Q’ty Remarks

1 Bolt 12 M6 20 mm
2 Oil pump assy. 1
3 Gasket 1 39
4 Bolt 1 M12 58 mm, left-hand threads
5 Oil pump drive gear 1
6 Dowel pin 2
7 O-ring 4 39
8 Connector 2
9 Bolt 1 M8 55 mm
10 Bolt 2 M8 70 mm
11 Oil cooler assy. 1
12 O-ring 4 39
13 Connector 2
14 Clamp 1
15 Plastic tie 1
16 Cooling water hose 1

5-25
 Oil cooler, oil pump assy., and drive gear

80 N·m (8.0 kgf·m, 59.0 ft·lb)

5
6 1
3 16
2
4

7
8
7
6

7
14

15
2
8 23

1
7 18 N·m (1.8 kgf·m, 13.3 ft·lb)
3
20 11

12
12
13
12
22
21
9
12 N·m (1.2 kgf·m, 8.9 ft·lb)
4
13

10 N·m (1.0 kgf·m, 7.4 ft·lb)

12

17
17
5
20 22 18
17 10
12 N·m (1.2 kgf·m, 8.9 ft·lb)

20 N·m (2.0 kgf·m, 14.8 ft·lb)

19

10
6
No. Part name Q’ty Remarks
17
18
19
Bolt
Washer
Bolt
7
3
1
M6

M8 25 mm
25 mm
7
20 Bolt 4 M6 20 mm
21 Gasket 1 39
22
23
Dowel pin
Oil filter joint
2
1 8
9
5-26
A
POWR
Power unit
Oil pump assy. and oil pump drive
gear removal c b
1. Remove the oil pump assy. NOTICE: Do
not disassemble the oil pump assy. c
2. Hold the drive coupling a using the
special service tool b.
a

Leakage tester b: 90890-06840

Specified positive pressure

(water passage):
200 kPa (2.0 kgf/cm2, 28.5 psi)
b a Oil pump assy. check
Coupler wrench b: 90890-06729 1. Check that the oil pump driven gear turns
smoothly. Replace if the movement is
3. Turn the oil pump drive gear bolt c rough.
clockwise to loosen it, and then remove
the oil pump drive gear bolt c and oil Oil pump drive gear and oil pump
pump drive gear d. assy. installation
1. Install the oil pump drive gear a, and
then tighten the oil pump drive gear bolt
d b temporarily.

c a

Oil cooler assy. check

1. Connect the hose a and special service
tool b to the inlet of the oil cooler water
passage. Block the oil cooler assy. outlet 2. Hold the holder c.
using the rubber plugs c.

2. Apply the specified positive pressure and

check that the pressure is maintained. If
the specified pressure cannot be
c
maintained, replace the oil cooler assy.

5-27
 Oil cooler, oil pump assy., and drive gear
3. Turn the oil pump drive gear bolt b
counterclockwise, and then tighten it to c
the specified torque. d

b
e

c
1
f
2
Oil pump drive gear bolt b:
80 N·m (8.0 kgf·m, 59.0 ft·lb)

4. Fill the oil pump assy. with engine oil

Oil pump assy. bolt f:
10 N·m (1.0 kgf·m, 7.4 ft·lb) 3
through the feed port a and scavenge
port b.

a
4
b
5
TIP:
While turning the oil pump driven gear, make
sure to fill the oil pump assy. with engine oil
6
up to the brim of each port.

5. Install the dowel pins c, a new gasket

d, and the oil pump assy. e, and then
7
tighten the oil pump assembly bolts f to
the specified torque. NOTICE: Do not
reuse a gasket, always replace it with
a new one. 8
9
5-28
A
POWR
Power unit

Cylinder head cover

1 12 10 N·m (1.0 kgf·m, 7.4 ft·lb)

1 9 7
13
8

2
9
2
2
2 9
3
3
3
10 16
3 17
15 15
16 17 6 N·m (0.6 kgf·m, 4.4 ft·lb)

14
4
6
11
25 N·m (2.5 kgf·m, 18.4 ft·lb)

No. Part name Q’ty Remarks

1 Bolt 8 M6 20 mm
2 Ignition coil 4
3 Spark plug 4
4 Clamp 1
5 Clamp 1
6 Breather hose 1
7 Bolt 1 M6 16 mm
8 Cam position sensor 1
9 Bolt 8 M6 30 mm
10 Cylinder head cover 1
11 Gasket 1 39
12 Oil filler cap 1
13 O-ring 1 39
14 Timing chain guide 1
15 Bolt 2 M6 25 mm
16 Collar 2

5-29
 Cylinder head cover

1 12 10 N·m (1.0 kgf·m, 7.4 ft·lb)

1 9
13
7
8 1
2
9

2
2
2

3
9
2
3

3
3
10 16
3 17
15 15
16 17 6 N·m (0.6 kgf·m, 4.4 ft·lb)

14
4
6
11
4
25 N·m (2.5 kgf·m, 18.4 ft·lb)

5
5

6
No. Part name Q’ty Remarks
17 Grommet 2
7
8
9
5-30
A
POWR
Power unit

Camshaft
8 8
16 N·m (1.6 kgf·m, 11.8 ft·lb)
8
10
8
10 13
8
13
9 13 8 12
13
12
18 N·m (1.8 kgf·m, 13.3 ft·lb) 13
13
14 11 13
16
13 13
20 N·m (2.0 kgf·m, 14.8 ft·lb) 17 17
10 N·m (1.0 kgf·m, 7.4 ft·lb) 16
10 N·m (1.0 kgf·m, 7.4 ft·lb) 15
1
2
3 16
2
4 2 1

20 5 6

18 19 21

No. Part name Q’ty Remarks

1 Bolt 2 M10 21 mm
2 Gasket 4 39
3 Oil pipe 1
4 Bolt 2 M6 25 mm
5 Timing chain tensioner 1
6 Gasket 1 39
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
16 Bolt 4 M7 11 mm

5-31
 Camshaft

8 8
16 N·m (1.6 kgf·m, 11.8 ft·lb)
8

10
10

13
8
8 1
13

18 N·m (1.8 kgf·m, 13.3 ft·lb)

9
13
13 8
12
13
13
12
2
14 11 13
16
20 N·m (2.0 kgf·m, 14.8 ft·lb)

10 N·m (1.0 kgf·m, 7.4 ft·lb)

17
16
17
13 13
3
10 N·m (1.0 kgf·m, 7.4 ft·lb) 15
1

4
2
3

2
2

1
16
4
20 5 6 5
18 19 21
7
6
No. Part name Q’ty Remarks
17
18
19
Camshaft sprocket
Bolt
Chain guide plate
2
2
1
M6 30 mm 7
20 Timing chain guide 1 Intake side
21 Timing chain 1

8
9
5-32
A
POWR
Power unit
Camshaft removal
b
When installing the camshafts, piston #1 a
must be positioned at TDC. Therefore, do
not turn the crankshaft after removing the
camshafts.

1. Install the special service tools into spark

plug hole #1.
#1 #2 #3 #4
a
c
b
Coupler wrench e: 90890-06729

TIP:
Make sure that the punch marks a on the
camshafts are aligned with the marks b on
the camshaft caps.
Dial indicator gauge a: YU-03097
Dial gauge stand set b: YB-06585 3. Make marks c on the camshaft
Dial gauge set a: 90890-01252 sprockets and camshafts.
Dial gauge needle b: 90890-06584
Gauge stand c: 90890-06725 c

2. Position piston #1 at TDC by turning the

drive coupling d counterclockwise using
the special service tool e, referring to
the dial gauge to ensure that the piston
has reached TDC.

4. Remove the oil pipe f, gaskets g,

timing chain tensioner h, and gasket i.

g
e d

f
i
g h

5. Remove the timing chain guide (exhaust

side).

5-33
 Camshaft
6. Remove the intake camshaft caps and
exhaust camshaft caps.

TIP:
Loosen the camshaft cap bolts in the oppo-
site order used for tightening.
a
1
7. Remove the intake camshaft j and
b
exhaust camshaft k.

j
k Cam lobe height a:
Intake:
2
IN 41.330–41.430 mm (1.627–1.631 in)
l

EX
Exhaust:
41.220–41.320 mm (1.623–1.627 in)
Cam lobe width b:
Intake and exhaust:
3
31.956–32.056 mm (1.258–1.262 in)

TIP:
Fasten the timing chain using a wire l.
3. Measure the camshaft journal diameter.
Replace if out of specification.
c
4
Camshaft sprocket removal
1. Hold the camshaft sprocket using the
special service tool a, and then loosen
the camshaft sprocket bolts b.
5
a
Camshaft journal diameter c:
6
Intake and exhaust:

b
24.960–24.980 mm
(0.9827–0.9835 in)

4. Measure the camshaft runout. Replace if

7
out of specification.
Camshaft wrench a: 90890-06724

2. Remove the intake camshaft sprocket

and exhaust camshaft sprocket. 8
Camshaft check
1. Check the camshaft lobes. Replace if pit-
ted or scratched.

2. Measure the cam lobe height a and

9
width b.
Camshaft runout: 0.015 mm (0.0006 in)

5-34
A
POWR
Power unit
Camshaft journal oil clearance check f
1. Remove the valve lifters a and valve f
h
pads b.
d
a h
e d
b d

d d
g
d

TIP:
Write down the position of each valve lifter a IN R IN L IN
and valve pad b so that they can be installed
in their original positions.

2. Place the camshafts on the cylinder a a a

head.

3. Put a piece of Plastigauge c on each EX EX R EX L

camshaft journal, parallel to the
camshaft.
TIP:
When installing the camshaft caps, make
sure that the arrow marks a on the camshaft
c caps point toward the camshaft sprockets.

5. Tighten the camshaft cap bolts i until

camshaft caps contact the cylinder head
in the order a, b, and so on.

IN
f
TIP: k g a i d
Do not put the Plastigauge over the oil hole in h
l e b j c
the camshaft journal. g
k f i b c
e
4. Install the dowel pins d, intake camshaft l h j a d
caps e and f, and exhaust camshaft EX i
caps g and h.

TIP:
Make sure to keep the camshafts level.

6. Tighten the camshaft cap bolts i to the

specified torque in the order a, b, and
so on.

5-35
 Camshaft

IN
b
c
a e g i k
b
a
b
d
c
d
f
e
f
h
g
h
j
i
j
l
k
l c
a
1
Camshaft cap bolt i:
EX i

16 N·m (1.6 kgf·m, 11.8 ft·lb)

2
TIP:
Do not turn the camshafts when measuring
the camshaft journal oil clearance using the
Plastigauge.
e 3
e
d
7. Remove the camshaft caps, and then
measure the width of the Plastigauge c.
TIP:
Make sure that the timing chain tensioner rod
4
a is locked in place before releasing the
c snap ring e.

3. Push the timing chain tensioner rod a

slightly. Check that the snap ring e
5
releases the timing chain tensioner rod

Camshaft journal oil clearance:

a, allowing the tensioner rod to pop out.

Camshaft sprocket installation

1. Install the exhaust camshaft sprocket and
6
0.020–0.061 mm (0.0008–0.0024 in)
intake camshaft sprocket.
Timing chain tensioner check
1. While pushing the timing chain tensioner
rod a, turn the timing chain tensioner a
7
housing b in direction c until the groove
d in the tensioner rod is aligned with the
snap ring e.

2. While squeezing the ends of the snap

ring e so that it fits into the groove d in b
8
the timing chain tensioner rod a, release
the tensioner rod slowly until it is locked
in place. 9
5-36
A
POWR
Power unit
3. Install the timing chain guide (exhaust
TIP: side).
• Install each camshaft sprocket with the
punch mark a facing outward. 4. Install the exhaust camshaft c, intake
• When installing an original camshaft camshaft d, and timing chain e.
sprocket, make sure to align the marks b
made during removal. a
IN c
2. Hold the camshaft sprocket using the d
special service tool a, and then tighten e
the camshaft sprocket bolts b to the
specified torque.

EX
a

IN EX

Camshaft wrench a: 90890-06724

Camshaft sprocket bolt b:

18 N·m (1.8 kgf·m, 13.3 ft·lb) TIP:
• Make sure that the punch marks a on the
Camshaft installation camshafts face up.
• Make sure that the exhaust side b of the
timing chain is taut.
Do not reuse a gasket, always replace it
with a new one. 5. Install the dowel pins f, intake camshaft
caps g and h, and exhaust camshaft
1. Position piston #1 at TDC. See “Cam- caps i and j.
shaft removal” (5-33).
h
h
2. Install the valve pads a and valve lifters j
b in their original positions. f
j
b f
g f
a
f f
i
f

5-37
 Camshaft
8. Align the punch marks d on the
IN R IN L IN camshafts with the marks e on the
camshaft caps.

c c c e
d
1
TIP:
EX EX R EX L

When installing the camshaft caps, make

2
sure that the arrow marks c on the camshaft
caps point toward the camshaft sprockets.

6. Tighten the camshaft cap bolts k until

#1 #2 #3 #4
3
camshaft caps contact the cylinder head
9. While pushing the timing chain tensioner
in the order a, b, and so on.

k
f
g
IN

a i d
rod f, turn the timing chain tensioner
housing g in direction h until the groove
k in the tensioner rod is aligned with the
snap ring m.
4
h
l e b j c

5
10. While squeezing the ends of the snap
g
k f i b c ring m so that it fits into the groove k in
e the timing chain tensioner rod f, release
l h j a d
the tensioner rod slowly until it is locked
EX k in place.

TIP:
Make sure to keep the camshafts level.
g 6
f
7. Tighten the camshaft cap bolts k to the
specified torque in the order a, b, and
so on.

IN
h
7
c
a
b
a
d
c
d
e
f
e
g
h
g
i
j
i
k
l
k
8
b f h j l

Camshaft cap bolt k:

EX k
m
k
m

9
16 N·m (1.6 kgf·m, 11.8 ft·lb)

5-38
A
POWR
Power unit
11. Install a new gasket l and the timing
chain tensioner m onto the cylinder
block, and then tighten the timing chain n
tensioner bolts n temporarily.

12. Install new gaskets o and the oil pipe p

to the cylinder block and timing chain
tensioner m, and then tighten the oil pipe
bolts q temporarily.

13. Tighten the timing chain tensioner bolts

Coupler wrench s: 90890-06729
n to the specified torque.

14. Tighten the oil pipe bolts q to the TIP:

specified torque. Check that the portion n of the timing chain
is taut. If the timing chain is not taut, turn the
drive coupling slightly clockwise, and then
check that the timing chain is taut again.
o

q 16. Position piston #1 at TDC. See

n “Camshaft removal” (5-33).

p m Valve clearance adjustment

l 1. Measure the valve clearances. See
o n
“Valve clearance measurement” (3-6).
Timing chain tensioner bolt n:
10 N·m (1.0 kgf·m, 7.4 ft·lb) 2. Remove the camshaft caps and
Oil pipe bolt q: camshafts. See “Camshaft removal” (5-
20 N·m (2.0 kgf·m, 14.8 ft·lb) 33).

15. Turn the drive coupling r 3. Remove the valve lifters a and valve
counterclockwise 2 full turns, and then pads b.
check that the camshaft turns smoothly. a

s r
TIP:
Write down the position of each valve lifter a
and valve pad b so that they can be installed
in their original positions.

4. Check the valve pad number a.

5-39
 Camshaft
10. Measure the intake and exhaust valve
clearances of the specified cylinders.
a

148 1
TIP:
The thickness of each valve pad is marked in
2
hundredths of millimeters on the side that #1 #2 #3 #4
contacts the valve lifter.

5. Round off the original valve pad number

IN
EX
✔
✔
✔: Specified cylinder
—
✔
✔
—
—
—
3
according to the following table. —: Not applicable
Last digit
0, 1, 2
4, 5, 6
8, 9
Rounded value
0
5
10
11. Install the special service tools into spark
plug hole #4.

c
4
e
6. Select the new valve pad number from
the “Valve pad selection table” (5-42).

TIP:
d
5
The valve pads are available in 23 thick-
nesses, ranging from 1.20 mm to 2.30 mm in
0.05 mm increments.

7. Install the selected valve pad b and

Dial indicator gauge c: YU-03097
6
Dial gauge stand set d: YB-06585
valve lifter a. Dial gauge set c: 90890-01252

b
a Dial gauge needle d: 90890-06584
Gauge stand e: 90890-06725

12. Position piston #4 at TDC by turning the

7
drive coupling f 360° counterclockwise
using the special service tool g.
8
8. Turn the valve lifter and check that it
turns smoothly. 9
9. Position piston #1 at TDC, and then
install the camshafts and camshaft caps. g

A
f
See “Camshaft installation” (5-37).

5-40
 POWR
Power unit

Coupler wrench g: 90890-06729

13. Measure the intake and exhaust valve

clearances of the specified cylinders.
4

#1 #2 #3 #4
IN — ✔ — ✔
EX — — ✔ ✔
✔: Specified cylinder
—: Not applicable

5-41
 Camshaft
Valve pad selection table
Intake
Measured Original valve pad number

1
clearance 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.00–0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210
0.03–0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.07–0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.11–0.13 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.14–0.23 Standard clearance
0.24–0.26 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

2
0.27–0.31 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.32–0.36 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.37–0.41 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.42–0.46 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.47–0.51 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.52–0.56 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.57–0.61 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

3
0.62–0.66 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.67–0.71 170 175 180 185 190 195 200 205 210 215 220 225 230
0.72–0.76 175 180 185 190 195 200 205 210 215 220 225 230
0.77–0.81 180 185 190 195 200 205 210 215 220 225 230
0.82–0.86 185 190 195 200 205 210 215 220 225 230 Example:
0.87–0.91 190 195 200 205 210 215 220 225 230 Measured valve clearance is 0.29 mm (0.0114 in)
0.92–0.96 195 200 205 210 215 220 225 230 Original valve pad number is 148 (thickness =

4
0.97–1.01 200 205 210 215 220 225 230 1.48 mm)
1.02–1.06 205 210 215 220 225 230 • Round off the original valve pad number 148 to 150
1.07–1.11 210 215 220 225 230
(thickness = 1.50 mm).
1.12–1.16 215 220 225 230
1.17–1.21 220 225 230
• Select the new valve pad number using the valve pad
1.22–1.26 225 230 selection table.
1.27–1.31 230 New valve pad number is 160 (thickness = 1.60 mm)

Exhaust
Measured
clearance
0.00–0.01
120 125 130 135 140 145 150 155
120
160
125
Original valve pad number
165 170 175 180 185 190 195 200 205 210 215 220 225
130 135 140 145 150 155 160 165 170 175 180 185 190
230
195
5
0.02–0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200

6
0.05–0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205
0.10–0.14 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210
0.15–0.19 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.20–0.24 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.25–0.27 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.28–0.37 Standard clearance
0.38–0.40 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

7
0.41–0.45 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.46–0.50 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.51–0.55 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.56–0.60 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.61–0.65 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.66–0.70 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.71–0.75 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

8
0.76–0.80 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.81–0.85 170 175 180 185 190 195 200 205 210 215 220 225 230
0.86–0.90 175 180 185 190 195 200 205 210 215 220 225 230
0.91–0.95 180 185 190 195 200 205 210 215 220 225 230
0.96–1.00 185 190 195 200 205 210 215 220 225 230 Example:
1.01–1.05 190 195 200 205 210 215 220 225 230 Measured valve clearance is 0.47 mm (0.0185 in)
1.06–1.10 195 200 205 210 215 220 225 230 Original valve pad number is 168 (thickness =

9
1.11–1.15 200 205 210 215 220 225 230 1.68 mm)
1.16–1.20 205 210 215 220 225 230 • Round off the original valve pad number 168 to 170
1.21–1.25 210 215 220 225 230
(thickness = 1.70 mm).
1.26–1.30 215 220 225 230
1.31–1.35 220 225 230
• Select the new valve pad number using the valve pad
1.36–1.40 225 230 selection table.
1.41–1.45 230 New valve pad number is 185 (thickness = 1.85 mm)

5-42
A
POWR
Power unit

Cylinder head

2
9 10
55 N·m (5.5 kgf·m, 40.6 ft·lb)
42 N·m (4.2 kgf·m, 31.0 ft·lb) 90
3
10 N·m (1.0 kgf·m, 7.4 ft·lb) 2
3
10
1
9

4
12 N·m (1.2 kgf·m, 8.9 ft·lb)

No. Part name Q’ty Remarks

1 Bolt 3 M6 55 mm
2 Bolt 10 39 M12 140 mm
3 Washer 10
4 Cylinder head assy. 1
5 Gasket 1 39
6 Dowel pin 2
7 Bolt 1 M10 25 mm
8 Engine hanger 1
9 Bolt 4 M6 12 mm
10 Engine hanger 2

5-43
 Cylinder head / Valve and valve spring

Valve and valve spring

1
1 1
2 2
3 3 3
3
4 4
5 5

6
9 9
6 2
10 10

3
11 4
5
8

6
7

No. Part name Q’ty Remarks

1
2
3
Valve lifter
Valve pad
Valve cotter
16
16
32
7
4 Upper spring seat 16
5 Valve spring 16
6
7
8
Lower spring seat
Intake valve
Exhaust valve
16
8
8
8
9 Valve seal 16 39

9
10 Valve guide 16 39
11 Cylinder head 1

5-44
A
POWR
Power unit
Cylinder head disassembly 3. Remove the valve seals.
1. Remove the valve lifters a and valve
pads b. Cylinder head check
1. Remove carbon deposits from the com-
a bustion chambers.
b
2. Check the cylinder head water jacket.
Clean if there are mineral deposits or
rust.

3. Check the cylinder head warpage using a

straightedge a and thickness gauge b
in the directions shown. Replace if out of
specification.
TIP:
Write down the position of each valve lifter a
and valve pad b so that they can be installed a b
in their original positions.

2. Remove the intake valves and exhaust

valves.

Cylinder head warpage limit:

0.10 mm (0.0039 in)

c Valve spring check

1. Measure the valve spring free length a.
Replace if out of specification.
Valve spring compressor c:
YM-04019/90890-04019
Compressor adapter d: YM-04114
Valve spring compressor attachment d:
90890-04114

TIP:
Write down the position of each valve, spring,
and other parts so that they can be installed
a
in their original positions.

5-45
 Valve and valve spring

Valve spring free length a: Valve margin thickness b:

Intake and exhaust: Intake and exhaust:
45.58 mm (1.79 in) 0.800–1.200 mm (0.0315–0.0472 in)

2. Measure the valve spring tilt b. Replace

if out of specification.
3. Measure the valve stem diameter c.
Replace if out of specification. 1
b
c

2
Valve spring tilt limit b: Valve stem diameter c:
3
Intake and exhaust: Intake:
2.0 mm (0.08 in)

Valve check
1. Measure the valve face width a.
5.477–5.492 mm (0.2156–0.2162 in)
Exhaust:
5.464–5.479 mm (0.2151–0.2157 in)
4
Replace if out of specification. 4. Measure the valve stem runout. Replace
a
if out of specification.

5
6
Valve face width a:
Intake and exhaust:
2.260–2.830 mm (0.0890–0.1114 in)
Valve stem runout:
Intake and exhaust:
0.01 mm (0.0004 in)
7
2. Measure the valve margin thickness b.
Replace if out of specification.
b
Valve guide check
1. Measure the valve guide inside diameter
a. 8
9
5-46
A
POWR
Power unit
Valve guide installation
1. Insert the special service tools a and b
into the camshaft end of the valve guide
c. NOTICE: Do not reuse a valve
a guide, always replace it with a new
one.

2. Strike the special service tool a to drive

the valve guide into the cylinder head.

a
Valve guide inside diameter a:
Intake and exhaust:
5.504–5.522 mm (0.2167–0.2174 in)
b
2. Calculate the valve-stem-to-valve-guide
clearance. Replace the valve and valve a
guide if out of specification.
Valve-stem-to-valve-guide clearance = c
valve guide inside diameter – valve stem
diameter: Valve guide remover a: YB-06801
Intake: Valve guide remover/installer a:
0.012–0.045 mm (0.0005–0.0018 in) 90890-06801
Exhaust: Valve guide installer b:
0.025–0.058 mm (0.0010–0.0023 in) YB-06810/90890-06810

Valve guide removal Valve guide installation height a:

1. Insert the special service tool a into the Intake and exhaust:
combustion chamber side of the valve 12.3–12.7 mm (0.4843–0.5000 in)
guide b.
3. Insert the special service tool d into the
2. Strike the special service tool a to drive valve guide c, and then ream the valve
the valve guide b out of the cylinder guide c.
head.
d

a
c
b

Valve guide reamer d:

Valve guide remover a: YB-06801 YM-01196/90890-06804
Valve guide remover/installer a:
90890-06801

5-47
 Valve and valve spring
4. Measure the valve seat contact width a
TIP: where the blueing dye is adhered to the
• Turn the special service tool d clockwise to valve face. Reface the valve seat if the
ream the valve guide.

1
valve is not seated properly or if the valve
• Do not turn the special service tool d seat contact width a is out of
counterclockwise when removing the tool. specification. Replace the valve guide if
the valve seat contact width a is uneven.
4. Clean the valve guide inner surface.

2
Measure the valve guide inside diameter
b.

b
3
Valve guide inside diameter b:
Intake and exhaust:
4
5.504–5.522 mm (0.2167–0.2174 in)

Valve seat check

1. Remove carbon deposits from the valves
and valve seats.
5
2. Apply a thin, even layer of Mechanic’s
blueing dye (Dykem) onto the valve seat.

3. Press the valve lightly against the valve Valve seat contact width a:
6
seat using the special service tool a. Intake:

7
1.400–1.600 mm (0.0551–0.0630 in)
a Exhaust:
1.500–1.700 mm (0.0591–0.0669 in)

Valve seat refacing

After every lapping procedure, make sure

to clean off any remaining lapping com-
8
pound from the cylinder head and valves.
Valve lapping tool a: YM-A8998
Valve lapper a: 90890-04101 1. Reface the valve seat.
9
5-48
A
POWR
Power unit

A
45
a
30 45 60

30
45

B
a Slag or rough surface
30 45 60 3. Adjust the top edge of the valve seat
contact width using a 30° cutter.

A U.S.A. and Canada

30
B Worldwide
b
Neway valve seat kit: YB-91044
Valve seat cutter holder: 90890-06812
Intake:
Valve seat cutter 30°: 90890-06720
Valve seat cutter 45°: 90890-06325
Valve seat cutter 60°: 90890-06324
Exhaust:
Valve seat cutter 30°: 90890-06818 b Previous contact width
Valve seat cutter 45°: 90890-06555
4. Adjust the bottom edge of the valve seat
Valve seat cutter 60°: 90890-06323
contact width using a 60° cutter.
2. Cut the surface of the valve seat using a
45° cutter by turning the cutter clockwise
until the valve seat face has become b
smooth. NOTICE: Do not over cut the
valve seat. To prevent chatter marks,
make sure to turn the cutter evenly
using a downward force of 40–50 N
(4.0–5.0 kgf, 8.8–11.0 lbf). 60

b Previous contact width

5. Adjust the valve seat contact width to

specification using a 45° cutter.

5-49
 Valve and valve spring
• If the valve seat contact area is too narrow
and situated near the bottom edge of the
b valve face, cut the bottom edge of the valve
c

1
seat using a 60° cutter to center the area,
and then set its width using a 45° cutter.

45 b

b Previous contact width

c Specified contact width
2
60
6. Check the valve seat contact area of the
valve. See “Valve seat check” (5-48).

Example:
• If the valve seat contact area is too wide
b Previous contact width

7. After refacing the valve seat to the

3
and situated in the center of the valve face, specified contact width, apply a thin,
cut the top edge of the valve seat using a
30° cutter, and then cut the bottom edge
using a 60° cutter to center the area and set
its width.
even layer of lapping compound onto the
valve seat, and then lap the valve using
the special service tool a. NOTICE: Do
not get the lapping compound on the
4
valve stem and valve guide.
30
b
a 5
60 6
b Previous contact width

• If the valve seat contact area is too narrow

and situated near the top edge of the valve
face, cut the top edge of the valve seat
Valve lapping tool a: YM-A8998
Valve lapper a: 90890-04101

8. Recheck the valve seat contact area of

7
using a 30° cutter to center the area, and
the valve. See “Valve seat check” (5-48).
then set its width using a 45° cutter.

30
b
Cylinder head assembly
1. Install a new valve seal. NOTICE: Do
not reuse a valve seal, always replace
8
it with a new one.

2. Install the valve a, valve spring seat b,

valve spring c, and valve spring retainer
d in this order, and then install the
9
special service tools e and f.
b Previous contact width

5-50
A
POWR
Power unit

d
c g
b f

4. Tap the valve spring retainer lightly using

a plastic hammer to seat the valve
e cotters g securely.

a
c

g g
b

Valve spring compressor e:

YM-04019/90890-04019
Compressor adapter f: YM-04114
Valve spring compressor attachment f:
90890-04114
5. Install the valve pads h and valve lifters
TIP: i in their original positions.
• When installing a new valve, always replace i
the valve guide and valve seal with new
ones. h
• Install the valve spring with the larger pitch
a toward the camshaft and the smaller
pitch b toward the combustion chamber.
• The upper end c of the valve spring with
the larger pitch is painted red.

3. Compress the valve spring, and then

install the valve cotters g.

5-51
 Valve and valve spring
Cylinder head installation
1. Install the dowel pins a, a new gasket
b, the cylinder head assy. c, the wash-

1
ers d, and the cylinder head bolts e,
and then tighten the cylinder head bolts
e to the specified torques in 2 stages
and in the order a, b, and so on.
NOTICE: Do not reuse a gasket,

2
always replace it with a new one.

2. Install the cylinder head bolts f, and

then tighten them to the specified torque.

f
d
3
c

a
b 4
a

e e e
5
j f b c g

f 6
i e a d h
e

Cylinder head bolt e (M12):

e e
7
1st: 55 N·m (5.5 kgf·m, 40.6 ft·lb)

8
2nd: 90°
Cylinder head bolt f (M6):
10 N·m (1.0 kgf·m, 7.4 ft·lb)

9
5-52
A
POWR
Power unit

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 ft·lb)

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

15
14 16
15

50 N·m (5.0 kgf·m, 36.9 ft·lb) 250 N·m (25.0 kgf·m, 184.4 ft·lb)
13 60
250 N·m (25.0 kgf·m, 184.4 ft·lb)

No. Part name Q’ty Remarks

1 Holder 1 Left-hand threads
2 Drive coupling 1
3 Washer 1 39
4 Holder 1
5 Bolt 2 M6 20 mm
6 Washer 2
7 Grommet 2
8 Bolt 9 M8 50 mm
9 Gasket 1 39
10 Dowel pin 2
11 Shaft 1
12 Idle gear 1
13 Transfer shaft 1 39
14 Special nut 1 39
15 Bolt 6 39 M8 20 mm
16 Flywheel magneto 1 39

5-53
 Generator cover assy. and flywheel magneto

1
12
7
11
6

4
8
10

19
2
7
3

3
1 6
5
2

26 N·m (2.6 kgf·m, 19.2 ft·lb)

250 N·m (25.0 kgf·m, 184.4 ft·lb) 10
80 N·m (8.0 kgf·m, 59.0 ft·lb)
24 N·m (2.4 kgf·m, 17.7 ft·lb)
17
18 9 4
14
15
16
5
15

13
50 N·m (5.0 kgf·m, 36.9 ft·lb)
60
250 N·m (25.0 kgf·m, 184.4 ft·lb)
250 N·m (25.0 kgf·m, 184.4 ft·lb)
6
No. Part name Q’ty Remarks
17
18
19
Starter clutch assy.
Starter gear
Woodruff key
1
1
1 39
7
8
9
5-54
A
POWR
Power unit

Generator cover

EP

8
14 N·m (1.4 kgf·m, 10.3 ft·lb)

14 N·m (1.4 kgf·m, 10.3 ft·lb)

2 9
10

5
4

11
3

No. Part name Q’ty Remarks

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 assy. 1
8 Oil seal 1 39
9 Circlip 1
10 Ball bearing 1 39
11 Generator cover 1

5-55
 Generator cover
Drive coupling removal
d

Use heat-resistant
burns could result.
gloves. Otherwise,

1. Heat the holder a and drive coupling b

1
for 20–30 minutes using a heat gun c. f b
NOTICE: Be careful not to damage
the wiring harness when using the
heat gun.
f
d e
2
c

b
3
a
b

2. Hold the drive coupling b using the

Coupler wrench d: 90890-06729
Crankshaft holder f: 90890-06732

Flywheel magneto removal

4
special service tool d, and then loosen
the holder a by turning it clockwise.
Use heat-resistant
burns could result.
gloves. Otherwise,
5
1. Remove the generator cover assy.

2. Heat the transfer shaft assy. a for 20–30

minutes using a heat gun b.
6
d b

7
b
d a

b
a

3. Hold the flywheel magneto c using the

8
special service tools d and e, and then

9
Coupler wrench d: 90890-06729
loosen the special nut f.
3. Hold the transfer shaft e using the
special service tool f, and then remove
the drive coupling b using the special
service tool d.

5-56
A
POWR
Power unit

e e

g h

d c ad c

d d
g f h a

c c

Shaft holder d: 90890-06721 Shaft holder d: 90890-06721

Driver handle e: 90890-06722 Driver handle e: 90890-06722
Crankshaft holder h: 90890-06732
TIP:
5. Remove the flywheel magneto c and
• Loosen the special nut f until it can no
Woodruff key using the special service
longer be turned.
tools i and j.
• Use a width across flats 12 mm hexagon bit
socket g with a length of 150 mm (5.91 in)
or more. c
i
4. Hold the flywheel magneto c using the
j
special service tools d and e, and then
remove the transfer shaft assy. a using
the special service tool h.

Flywheel puller i: 90890-06723

Rotor puller j: 90890-01080

6. Hold the flywheel magneto c using the

special service tool k, and then loosen
the starter clutch bolts l.

5-57
 Generator cover

c l A

l f g

l
k
h

1
Primary sheave holder k: YS-01880-A
Sheave holder k: 90890-01701
B
i
2
f
j

3
7. Remove the starter clutch.

Generator cover assy. disassembly

1. Remove the washer a, pickup coil a,
holder b, and stator coil assy. c.

b A U.S.A. and Canada

B Worldwide
4
Driver handle (small) g: YB-06229
c

a
Bearing and seal installer h: YW-06356
Driver rod LS i: 90890-06606
Bearing outer race attachment j:
90890-06627
5
a
Starter clutch operation check
1. Install the starter clutch a onto the
starter gear b and hold the starter clutch
a.
6
2. Remove the oil seal d and circlip e.

e
2. Turn the starter gear b clockwise a and
check that it turns smoothly. Replace if it
does not turn smoothly. 7
3. Turn the starter gear b counterclockwise
b and check that it does not turn.
Replace if it turns.
8
3. Remove the ball bearing f.
b

a
9
a
b

5-58
A
POWR
Power unit
Generator cover assy. assembly A
b
h
Do not reuse a bearing or oil seal, always EP
replace it with a new one. g

A
1. Install a new ball bearing a.
A
b
c
B
a
i
E
EP
g

B
d
e
a A U.S.A. and Canada
B Worldwide
E Driver handle (large) b: YB-06071
Forward bearing race installer h:
YB-06258
Bearing pressure C i: 90890-02393

A U.S.A. and Canada 4. Install the stator coil assy. j, holder k,

B Worldwide pickup coil a, and washer l, and then
tighten the holder bolts m and stator coil
Driver handle (large) b: YB-06071 assy. bolts n to the specified torques.
Forward gear outer race installer c:
YB-41446 n
Driver rod LS d: 90890-06606 n
Ball bearing attachment e: 90890-06657 j m

2. Install the circlip f.

f a
b a
c k

Holder bolt m:
14 N·m (1.4 kgf·m, 10.3 ft·lb)
3. Install a new oil seal g.
Stator coil assy. bolt n:
14 N·m (1.4 kgf·m, 10.3 ft·lb)

5-59
 Generator cover
3. Install the flywheel magneto b to the
TIP: starter gear e.
Pass the pickup coil lead b between the gen-
erator cover and the bolt hole c, and then
secure the lead by installing the washer l.

Flywheel magneto installation

e
1
Do not reuse a flywheel magneto, special
nut, flywheel magneto bolt, transfer shaft,
Woodruff key, or gasket, always replace it
b

2
with a new one. TIP:

1. Install the starter clutch a to a new fly-

wheel magneto b. NOTICE: Make sure
that the starter clutch is installed into
Turn the starter gear e clockwise while
installing it onto the flywheel magneto b.
3
4. Remove any grease from a new special
the outer flange so that the side a is nut f and the inner surface of a new
facing toward the flywheel magneto. transfer shaft g, and then install the
special nut f into the transfer shaft g
until it can no longer be turned.
4
a
g f

a 5
b f

2. Hold the flywheel magneto b using the

special service tool c, and then tighten
new flywheel magneto bolts d to the
g 6
5. Clean the tapered portion b of the
specified torque. crankshaft and inner surface c of the

d
d
b
flywheel magneto b.

6. Install a new Woodruff key h and the

7
flywheel magneto b.

c
d 8
Primary sheave holder c: YS-01880-A
Sheave holder c: 90890-01701 9
Flywheel magneto bolt d:
24 N·m (2.4 kgf·m, 17.7 ft·lb)

5-60
A
POWR
Power unit

h Shaft holder i: 90890-06721

Driver handle j: 90890-06722
h Crankshaft holder k: 90890-06732

b Transfer shaft assy. d:

50 N·m (5.0 kgf·m, 36.9 ft·lb)

9. Using the hexagonal portion of the

c special service tool k as reference, mark
the special service tool i at 0°, 60°, and
120°.

b 10. Make a mark e on the transfer shaft

assy. d where the shaft is aligned with
7. Install the transfer shaft assy. d. the 0° mark on the special service tool
i.

d e
0°
i 60°

d 120°
60°
k

8. Hold the flywheel magneto b using the

special service tools i and j, and then Shaft holder i: 90890-06721
tighten the transfer shaft assy. d to the Crankshaft holder k: 90890-06732
specified torque using the special service
tool k. TIP:
The angle from one corner of the hexagonal
b head of the special service tool k to another
i corner is 60°.
d
11. Hold the flywheel magneto b using the
k
special service tools i and j, and then
tighten the transfer shaft assy. d to the
j
specified angle using the special service
tool k.

b b
i i
k d
d
k

5-61
 Generator cover

d b
60° i

l
1
j
k

Shaft holder i: 90890-06721

Driver handle j: 90890-06722
l
i
2
Crankshaft holder k: 90890-06732

Transfer shaft assy. d: 60°

12. Tighten the transfer shaft assy. d to the

f
b
3
specified torque using the special service
tool k. NOTICE: If the mark e on the
transfer shaft assy. d moves past the
120° mark on the special service tool
i before the specified torque is
Shaft holder i: 90890-06721
Driver handle j: 90890-06722

Special nut f:
4
reached, repeat the procedure from 250 N·m (25.0 kgf·m, 184.4 ft·lb)
step 5.

d e
60° j
TIP:
Use a width across flats 12 mm hexagon bit
socket l with a length of 150 mm (5.91 in) or
5
i more.

6
OK
14. Install the idle gear.
120° 15. Install the dowel pins m, a new gasket
k n, and the generator cover assy. f, and
Shaft holder i: 90890-06721
Driver handle j: 90890-06722
Crankshaft holder k: 90890-06732
then tighten the generator cover assy.
bolts o to the specified torque.

m
7
Transfer shaft assy. d:
250 N·m (25.0 kgf·m, 184.4 ft·lb)

13. Hold the flywheel magneto b using the

f
8
special service tools i and j, and then
tighten the special nut f to the specified
torque. NOTICE: To allow the LOCTITE
648 to set, wait approximately 1 hour
after completing this procedure. n
m
9
o

5-62
A
POWR
Power unit
4. Remove any grease from the threaded
Generator cover assy. bolt o:
portion of the holder e.
26 N·m (2.6 kgf·m, 19.2 ft·lb)

Drive coupling installation 5. Install the holder e.

1. Remove any grease from the threaded
portion of the transfer shaft, making sure
that the threads are clean and dry.

2. Install a new washer a and the drive

coupling b. NOTICE: Do not reuse a
washer, always replace it with a new
one.
e

b a 6. Hold the drive coupling b using the

special service tool d, and then turn the
holder e counterclockwise to tighten it to
the specified torque. NOTICE: To allow
the LOCTITE 648 to set, wait
approximately 1 hour after completing
this procedure.

3. Hold the transfer shaft using the special

service tool c, and then tighten the drive d
coupling b to the specified torque using
the special service tool d.

b
d
b
c
d b

d b e
c

Coupler wrench d: 90890-06729

Holder e:
80 N·m (8.0 kgf·m, 59.0 ft·lb)

Crankshaft holder c: 90890-06732

Coupler wrench d: 90890-06729

Drive coupling b:
250 N·m (25.0 kgf·m, 184.4 ft·lb)

5-63
 Generator cover / Cylinder block and electrical part

Cylinder block and electrical part

10 N·m (1.0 kgf·m, 7.4 ft·lb) 14 6
14

5
7

15
7
7
8 N·m (0.8 kgf·m, 5.9 ft·lb) 1
7
16

1
4
9
2
1
2
3 18 17
8 3
1
17
10
11
12
4
25
24 13
23
22
21 20 5
27

15 N·m (1.5 kgf·m, 11.1 ft·lb)

26

20 N·m (2.0 kgf·m, 14.8 ft·lb)

19 6
No. Part name Q’ty Remarks
1
2
3
Bolt
Earth plate
Gasket
3
1
1
M6

39
35 mm
7
4 Clamp 2
5 Oil return hose 1
6
7
8
Oil level gauge
Bolt
Bolt
1
4
2
M8
M6
20 mm
12 mm
8
9 Oil level pipe assy. 1

9
10 Clamp 1
11 Oil level pipe plate 1
12 Grommet 1
13 O-ring 1 39
14 Bolt 2 M6 16 mm
15
16
Plate
Gasket
1
1 39

5-64
A
POWR
Power unit

10 N·m (1.0 kgf·m, 7.4 ft·lb) 14 6

14
7 7
4 7
8 N·m (0.8 kgf·m, 5.9 ft·lb)
5 15
7
16
9

4
1

3 18 17
1 8
2
1
10
17
11
12
25
24 13
23
22
21 20

27
26
19
15 N·m (1.5 kgf·m, 11.1 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb)

No. Part name Q’ty Remarks

17 Bolt 2 M6 16 mm
18 Thermoswitch 1
19 Bolt 1 M8 40 mm
20 Anode assy. 1
21 Bolt 1 M6 20 mm
22 Gasket 1 39
23 Cover 1
24 Grommet 1
25 Anode 1
26 Engine temperature sensor 1
27 Gasket 1 39

5-65
 Cylinder block and electrical part / Oil separator tank and oil pan

Oil separator tank and oil pan

10
9
8

3 4 1
2
6

2
14 13 7

8 N·m (0.8 kgf·m, 5.9 ft·lb) 1

12 N·m (1.2 kgf·m, 8.9 ft·lb)

20
2 N·m (0.2 kgf·m, 1.5 ft·lb)

21 11
11
3
12
20
25

19
31
30
12
11
11
4
26 20 N·m (2.0 kgf·m, 14.8 ft·lb)
9 N·m (0.9 kgf·m, 6.6 ft·lb) 19

5
20 12 N·m (1.2 kgf·m, 8.9 ft·lb)
18

24
22 27
28

23
24

9 N·m (0.9 kgf·m, 6.6 ft·lb)

15
16

10 N·m (1.0 kgf·m, 7.4 ft·lb)

17
29

10 N·m (1.0 kgf·m, 7.4 ft·lb)

10 N·m (1.0 kgf·m, 7.4 ft·lb)
6
No. Part name Q’ty Remarks
1
2
3
Bolt
Oil pressure switch
Clamp
1
1
1
M4 8 mm
7
4 Plastic tie 1
5 Cooling water hose 1
6
7
8
Clamp
Cooling water hose
Bolt
1
1
9 M6 25 mm
8
9 Water jacket cover 1

9
10 Gasket 1 39
11 Bolt 9 M6 20 mm
12 Bolt 2 M6 14 mm
13 Oil separator tank cover 1
14 Gasket 1 39
15
16
Bolt
Bolt
1
16
M6 30 mm
M6 35 mm

5-66
A
POWR
Power unit

5
8
9
3 4
10

2
14 13 7

8 N·m (0.8 kgf·m, 5.9 ft·lb) 1

2 N·m (0.2 kgf·m, 1.5 ft·lb)
12 N·m (1.2 kgf·m, 8.9 ft·lb)
11
20 21 11
12
20 12
25 11
11
19 30
31
26 20 N·m (2.0 kgf·m, 14.8 ft·lb)
9 N·m (0.9 kgf·m, 6.6 ft·lb) 19
20 12 N·m (1.2 kgf·m, 8.9 ft·lb)
18

24
22 27
28

24 29
23 16 10 N·m (1.0 kgf·m, 7.4 ft·lb)
15 17
9 N·m (0.9 kgf·m, 6.6 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb)

No. Part name Q’ty Remarks

17 Bolt 1 M6 20 mm
18 Oil pan 1
19 Dowel pin 2
20 Bolt 13 M6 14 mm
21 Baffle plate 1
22 Bolt 1 M6 35 mm
23 Bolt 3 M6 60 mm
24 Washer 4
25 Oil pipe 1
26 Gasket 1 39
27 Oil pipe 1
28 Gasket 1 39
29 Grommet 1
30 Bolt 1 M8 16 mm
31 Gasket 1 39

5-67
 Oil separator tank and oil pan
Anode check
1. Check the anode. Replace if eroded.
g
Clean if there is grease, oil, or scales.
f

1
NOTICE: Do not apply grease, oil, or
paint to the anode.

Oil level pipe installation

1. Pass the clamp a through the oil level

2
pipe b.

2. Install the oil level pipe plate c, the

grommet d, and a new O-ring e onto
the oil level pipe b. NOTICE: Do not

3
reuse a O-ring, always replace it with a
new one. Oil level pipe plate bolt f:
8 N·m (0.8 kgf·m, 5.9 ft·lb)
b d
c 6. Fasten the grommet d using the clamp
a.
a
c
d
a
e
a
4
b
e

Installation distance a:
42.5 mm (1.67 in)
d
5
TIP:
Make sure that the bottom of the grommet d
is at the specified installation distance a
from the end of the oil level pipe b.
6
3. Install the oil level pipe assy. onto the
cylinder block, and then tighten the oil
level pipe plate bolts f and plate bolt g
temporarily.
7
4. Tighten the oil level pipe plate bolts f to
the specified torque.

5. Tighten the plate bolt g.

8
9
5-68
A
POWR
Power unit
Oil separator tank cover installation
1. Install a new gasket a and the oil sepa-
rator tank cover b, and then tighten the
oil separator tank cover bolts c and d in
the order a, b, and so on. NOTICE: Do
not reuse a gasket, always replace it
with a new one.

a b

c
d

c a d e f d
j
d
i

h c b g k
d d d

5-69
 Oil separator tank and oil pan / Crankcase, connecting rod, and piston

Crankcase, connecting rod, and piston

10 1T
11
9 8
2T
13
50 N·m (5.0 kgf·m, 36.9 ft·lb)

12
1
8 7 17

6
Y
5

50 N·m (5.0 kgf·m, 36.9 ft·lb)

16 18
2
90
13
6
4
22 14 13
13
13 13

3 3
15

4
18
19

16 16

16 18
18
21
20
2
16 5
19 16 1
17
16
10 N·m (1.0 kgf·m, 7.4 ft·lb)
10 N·m (1.0 kgf·m, 7.4 ft·lb)

30 N·m (3.0 kgf·m, 22.1 ft·lb)

90
6
No. Part name Q’ty Remarks
1
2
3
Bolt
Bolt
Crankcase
12
10
1
M6 70 mm
39 M10 85 mm 7
4 Nut 8
5 Connecting rod assy. 4
6
7
8
Connecting rod bearing
Bolt
Piston pin clip
8
8
8
39 M9
39
50 mm 8
9 Piston pin 4

9
10 Piston 4
11 Piston ring set 4
12 Crankshaft 1
13 Crankshaft bearing 10
14 O-ring 1 39
15
16
Dowel pin
Bolt
1
12 M10 30 mm

5-70
A
POWR
Power unit

10 1T
11
9 2T 50 N·m (5.0 kgf·m, 36.9 ft·lb)
8 13

8 7 12 17
5
Y 16 18

6 50 N·m (5.0 kgf·m, 36.9 ft·lb)

90
13
4 13 13
6 13
22 14 13 3

15
18
19

16 16

2
18
16 18 16
21
20
19 16 1
17 10 N·m (1.0 kgf·m, 7.4 ft·lb)
16
10 N·m (1.0 kgf·m, 7.4 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb)
90

No. Part name Q’ty Remarks

17 Bracket 2
18 Dowel pin 8
19 Bracket 2
20 Bolt 1 M6 12 mm
21 Baffle plate 1
22 Cylinder block 1

5-71
 Crankcase, connecting rod, and piston
Crankcase disassembly Connecting rod and piston removal
1. Place the crankcase upside down on a 1. Remove the connecting rod cap a, and
bench. then remove the connecting rod bearings

1
a and piston and connecting rod assy.
2. Loosen the crankcase bolts in the b.
opposite order used for tightening.
a
TIP: c
a

2
The numbers embossed on the crankcase
indicate the crankcase tightening order. c

3. Remove the crankcase a.

a
a

a c
3
c
b
b

a c
4
TIP:
• Insert a flat-head screwdriver between the
reinforced portions a of the cylinder block
b and the crankcase a to separate them.
TIP:
For reference during installation, make identi-
5
• Work carefully and make sure that the cylin-
fication marks c on the connecting rod cap,
der block and crankcase separate evenly.

4. Remove the crankshaft bearings c from

the crankcase.
connecting rod, connecting rod bearings, and
piston crown.

2. Remove the piston pin clips b, piston pin

6
c, connecting rod d, and connecting
c rod bolts d.

d
7
d b

8
TIP: d
Write down the position of each crankshaft
bearing so that it can be installed in its origi-
nal position.
b
c
9
3. Remove the piston rings.

5-72
A
POWR
Power unit
Crankcase check
a b
1. Check the oil passages. Blow out using
compressed air if there are obstructions. B B
T T
Piston check
1. Measure the piston diameter a. Replace
if out of specification. c B
a
T
b
Piston ring dimensions:
Top ring a:
B: 1.170–1.190 mm (0.0461–0.0469 in)
T: 2.850–3.050 mm (0.1122–0.1201 in)
2nd ring b:
B: 1.170–1.190 mm (0.0461–0.0469 in)
T: 2.600–2.800 mm (0.1024–0.1102 in)
Piston diameter a: Oil ring c:
85.915–85.930 mm B: 2.370–2.470 mm (0.0933–0.0972 in)
(3.3825–3.3831 in) T (reference data):
Measuring point b: 9.5 mm (0.37 in) 2.500 mm (0.0984 in)

2. Measure the piston pin boss bore 2. Measure the piston ring end gap d.
diameter c. Replace if out of
specification.

c
e
d d

Piston ring end gap d (reference data):

Top ring:
Piston pin boss bore diameter c: 0.300–0.450 mm (0.0118–0.0177 in)
22.004–22.015 mm 2nd ring:
(0.8663–0.8667 in) 0.450–0.600 mm (0.0177–0.0236 in)
Oil ring:
TIP: 0.100–0.350 mm (0.0039–0.0138 in)
When measuring the piston pin boss bore Measuring point e:
diameter c, do not measure it at the oil 6 mm (0.24 in)
grooves d or piston pin slot e.
3. Measure the piston ring grooves.
Replace if out of specification.
Piston ring check
1. Measure piston ring dimensions B and T.
Replace the piston rings as a set if out of
specification.

5-73
 Crankcase, connecting rod, and piston

a
f

g
1
h

Piston ring groove:

Top ring f:
Piston pin outside diameter a:
21.991–22.000 mm
2
1.210–1.230 mm (0.0476–0.0484 in) (0.8658–0.8661 in)
2nd ring g:
1.210–1.230 mm (0.0476–0.0484 in)
Oil ring h:
2.510–2.530 mm (0.0988–0.0996 in)
Connecting rod check
1. Measure the connecting rod small end
inside diameter a. Replace the connect-
3
ing rod assy. if out of specification.

4
4. Measure the piston ring side clearance.
Replace the piston and piston rings as a
set if out of specification.

a
k

m 5
n

Piston ring side clearance:

Connecting rod small end inside diameter
a: 22.015–22.028 mm (0.8667–0.8672 in)

Cylinder block check

6
Top ring k: 1. Measure the cylinder bore (D1–D6) at
0.020–0.060 mm (0.0008–0.0024 in)
2nd ring m:
0.020–0.060 mm (0.0008–0.0024 in)
Oil ring n:
measuring points a, b, and c, and in
direction d (D1, D3, D5), which is parallel
to the crankshaft, and direction e (D2,
D4, D6), which is at a right angle to the
7
0.040–0.160 mm (0.0016–0.0063 in) crankshaft. Replace the crankcase assy.

Piston pin check

1. Measure the piston pin outside diameter
a. Replace if out of specification.
if out of specification.

b
a D2 D1
8
c d
D4

D6
D3

D5
e
9
5-74
A
POWR
Power unit
a 20 mm (0.79 in)
Crankshaft runout:
b 50 mm (1.97 in)
0.03 mm (0.0012 in)
c 80 mm (3.15 in)
Cylinder bore (D1–D6): Crankshaft pin oil clearance check
86.000–86.015 mm 1. Clean the connecting rod bearings a
(3.3858–3.3864 in) and connecting rod big end.

Crankshaft check 2. Install the upper bearing into the

1. Measure the crankshaft journal diameter connecting rod a and lower bearing into
a and crankshaft pin diameter b. the connecting rod cap b.
Replace if out of specification.
a
d
B

d a
c
5B
b
a

TIP:
• Install the connecting rod bearings a in
their original positions.
• Fit the protrusion c on each bearing into
the slots d in the connecting rod cap b
and connecting rod a.

3. Put a piece of Plastigauge b on the

b
crankshaft pin, parallel to the crankshaft.

b
Crankshaft journal diameter a:
39.976–40.000 mm
(1.5739–1.5748 in)
Crankshaft pin diameter b:
41.976–42.000 mm
(1.6526–1.6535 in)

2. Measure the crankshaft runout. Replace

if out of specification.
TIP:
Do not put the Plastigauge b over the oil
hole in the crankshaft pin.

4. Install the connecting rod onto the

crankshaft pin.

5. Tighten the connecting rod nuts to the

specified torques in 2 stages.

5-75
 Crankcase, connecting rod, and piston

e
5B 1
a

Connecting rod nut:

1st: 50 N·m (5.0 kgf·m, 36.9 ft·lb)
2. Check the crankshaft pin size number b
on the crankshaft web.
2
2nd: 90°
P1 P2 P3 P4

TIP:
• Make sure that the “Y” mark e on the con-
necting rod faces toward the timing chain
P
b
3
drive gear f of the crankshaft.

4
• Make sure that the characters g on the P2 P3
connecting rod cap and connecting rod are
aligned. P1 P4
• Do not turn the connecting rod until the
crankshaft pin oil clearance measurement 3. Select the suitable color c for the
has been completed.

6. Remove the connecting rod cap and

measure the width h of the compressed
connecting rod bearing from the table.

c 5
Plastigauge on each crankshaft pin.

6
h
Calculation formula:
Connecting rod bearing size number =
connecting rod size number a –
7
crankshaft pin size number b
Crankshaft pin oil clearance:
0.020–0.056 mm (0.0008–0.0022 in)

Connecting rod bearing selection

Bearing size num-
ber
1
Bearing color c

Brown
8
2 Black
1. Check the connecting rod size number a

9
3 Blue
on the connecting rod.
4 Green

5-76
A
POWR
Power unit
Example:
“P1” connecting rod size number “5” TIP:
“P1” crankshaft pin size number “1” Do not put the Plastigauge b over the oil
5–1=4 hole in the main journals of the crankshaft.
Select the size “4”, “Green” connecting rod
bearing. 6. Install the crankcase c and crankcase
bolts d, and then tighten the crankcase
Crankshaft journal oil clearance bolts d to the specified torques in 2
check stages and in the order a, b, and so on.
1. Clean the crankshaft bearings, crank-
shaft journals, and bearing portions of d
the crankcase and cylinder block. c d

2. Place the cylinder block upside down on

a bench.

3. Install the crankshaft bearings a into the

cylinder block and crankcase.

a
a

TIP:
• Install the crankshaft bearings a in their g e a c i d
original positions.
• Fit the protrusion a on each bearing into
the slots b in the cylinder block and crank-
case. j d b f h

4. Install the crankshaft.

5. Put a piece of Plastigauge b on each Crankcase bolt d:

crankshaft journal, parallel to the 1st: 30 N·m (3.0 kgf·m, 22.1 ft·lb)
crankshaft. 2nd: 90°

7. Install the crankcase bolts e, and then

b tighten them to the specified torque in the
order a, b, and so on.

5-77
 Crankcase, connecting rod, and piston

1
k g e a c i
a
2
J1 J2 J3 J4 J5

e
TIP:
If the crankcase journal sizes are the same at
all positions, the size number a is stamped
3
lj d b f h only at the “J1” position.

Crankcase bolt e:
10 N·m (1.0 kgf·m, 7.4 ft·lb)
Example:
If “J1”–“J5” are different:

J1 J2 J3 J4 J5
4
8. Remove the crankcase and measure the
width c of the compressed Plastigauge
on each crankshaft journal.
5 5 5 4 5
5
c
55545
If “J1”–“J5” are the same:
6
J1 J2 J3 J4 J5

Crankshaft journal oil clearance:

5 5 5 5 5
7
0.024–0.053 mm (0.0009–0.0021 in)

Crankshaft bearing selection

1. Check the crankcase journal size number
a on the crankcase.
5
8
2. Check the crankshaft journal size
number b on the crankshaft web.
9
5-78
A
POWR
Power unit
2. Assemble the connecting rod a, piston
J1 J2 J3 J4 J5
b, piston pin c, and new piston pin clips
b J d. NOTICE: Do not reuse a
connecting rod cap bolt or piston pin
clip, always replace it with a new one.

d
J1 J2 J3 J4 J5 a a

3. Select the suitable color c for the

crankshaft bearing from the table. b
d
c d

a
c
d
c b
c
Calculation formula:
Main bearing size number = TIP:
crankcase journal size number a – • When installing the connecting rod to the
crankshaft journal size number b piston, make sure that the “Y” mark b on
Bearing size num- the connecting rod faces toward the front
Bearing color c
ber mark c on the piston crown.
1 Brown • Do not allow the piston pin clip ends to align
2 Black with the piston pin slot d.
3 Blue
4 Green 3. Install the oil ring e, 2nd ring f, and top
5 Yellow ring g. NOTICE: Do not scratch the
pistons or break the piston rings.
Example:
“J1” crankcase journal size number “5” 4. Offset the piston ring end gaps.
“J1” crankshaft journal size number “2”
5–2=3
e
Select the size “3”, “Blue” main bearing.
#5
Connecting rod and piston #4
installation #3 f
1. Install new connecting rod cap bolts a to #2
the connecting rod a. #1
45 45
#5 #1
#4

g
#2 #3
5-79
 Crankcase, connecting rod, and piston

TIP: TIP:
• Make sure to install the piston rings so that Make sure that the “Y” mark on the connect-
the “1T” mark on the top ring g and the ing rod faces toward the timing chain drive
“2T” mark on the 2nd ring f face up.
• After installing the piston rings, make sure
that they move smoothly.
gear of the crankshaft.

8. Install half of the crankshaft bearings g

1
into the cylinder block.
5. Clean the connecting rod bearings e
and connecting rod big end.

6. Install the upper bearing into the piston

p
g 2
and connecting rod assy. h and lower
bearing into the connecting rod cap k. r

n h
3
k
e

n
TIP:
• Install the crankshaft bearings in their origi-
nal positions.
• Fit the protrusion p on each bearing into
4
m
the slots r in the cylinder block.

TIP:
• Install the connecting rod bearings e in
their original positions.
9. Install the crankshaft.

10. Install the connecting rod cap k onto the

5
• Fit the protrusion m on each bearing into piston and connecting rod assy., and
the slots n in the connecting rod cap k
and connecting rod assy. h.

7. While compressing the piston rings using

then tighten the connecting rod nuts h to
the specified torques in 2 stages.

h h
6
the special service tool f, install the
piston and connecting rod assy. h into
the cylinder.

s
s k
7
f

h
Y Connecting rod nut h:
8
1st: 50 N·m (5.0 kgf·m, 36.9 ft·lb)
2nd: 90°

Piston ring compressor f:

TIP:
Make sure that the characters s on the con-
9
YM-08037/90890-05158 necting rod cap k and connecting rod assy.

A
are aligned.

5-80
POWR
Power unit
Crankcase assembly
1. Thoroughly clean all the gasket surfaces TIP:
and crankcase mating surfaces. Do not get any sealant on the crankshaft
bearing.
2. Install half of the crankshaft bearings a
into the crankcase. 5. Install the crankcase d and crankcase
bolts e, and then tighten the crankcase
a bolts e to the specified torques in 2
stages and in the order a, b, and so on.

a e
d e
b

TIP:
• Install the crankshaft bearings a in their
original positions.
• Fit the protrusion a on each bearing into
the slots b in the crankcase.

3. Install the dowel pin b and a new O-ring

c. NOTICE: Do not reuse a O-ring,
always replace it with a new one.

c
b
g e a c i e

j d b f h

4. Apply sealant to the mating surface of the

crankcase. Crankcase bolt e:
1st: 30 N·m (3.0 kgf·m, 22.1 ft·lb)
2nd: 90°

6. Install the crankcase bolts f, and then

tighten them to the specified torque in the
order a, b, and so on.

5-81
 Crankcase, connecting rod, and piston

1
k g e a c i
2
f
3
lj d b f h

Crankcase bolt f:
10 N·m (1.0 kgf·m, 7.4 ft·lb)
4
5
6
7
8
9
5-82
A
POWR
Power unit

— MEMO —

5-83
 JET
PUMP
Jet pump unit 6

Intake grate and ride plate ................................................ 6-1

Jet pump unit ..................................................................... 6-2

Jet pump unit removal ............................................................... 6-4
1
Jet pump unit installation ........................................................... 6-4

Reverse gate ...................................................................... 6-6 2

Nozzle, impeller housing, and impeller duct assy. ........ 6-7

Impeller, drive shaft, and impeller duct .......................... 6-8

Impeller duct assy. disassembly ................................................ 6-9
3
Impeller housing check ............................................................ 6-10
Drive shaft check ..................................................................... 6-10
Impeller duct assy. assembly .................................................. 6-10
Impeller duct, impeller housing, and nozzle installation .......... 6-12 4
Transom plate and hoses ............................................... 6-13

5
Bilge strainer check ................................................................. 6-15
Transom plate installation ....................................................... 6-15

Intermediate housing ...................................................... 6-16

Intermediate housing assy. removal ........................................ 6-18
Intermediate housing assy. disassembly ................................. 6-18
Intermediate housing assy. assembly ..................................... 6-19
Intermediate housing assy. installation ................................... 6-20 6
7
8
9
A
 JET
PUMP Jet pump unit

Intake grate and ride plate

8 8
7

6 7
5

17 N·m (1.7 kgf·m, 12.5 ft·lb)

2
9

3
4

1 3 3
40 N·m (4.0 kgf·m, 29.5 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb)
1

No. Part name Q’ty Remarks

1 Bolt 4 M10 25 mm
2 Intake grate 1
3 Screw 4 M5 12 mm
4 Speed sensor 1
5 Bolt 4 M8 35 mm
6 Ride plate 1
7 Plate 2
8 Bracket 2
9 Bracket 1

6-1
 Intake grate and ride plate / Jet pump unit

Jet pump unit

17 14 N·m (1.4 kgf·m, 10.3 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb)
17 N·m (1.7 kgf·m, 12.5 ft·lb) 7 6

1
6
2 N·m (0.2 kgf·m, 1.5 ft·lb) 7
18
19 6
5 7
11

20
2
12 12
2
10
14

4
3 7
8
3
15

4
8

5
7
16

14 7 N·m (0.7 kgf·m, 5.2 ft·lb)

13
9

16
7 N·m (0.7 kgf·m, 5.2 ft·lb)
2
1
14
40 N·m (4.0 kgf·m, 29.5 ft·lb)
6
No. Part name Q’ty Remarks
1
2
3
Nut
Washer
Plastic tie
1
2
1
7
4 Bilge hose 1
5 Clamp 1
6
7
8
Bolt
Collar
Nut
4
6
2
M6 30 mm
8
9 Bolt 2 M6 25 mm

9
10 Rubber plate 1 1
11 Rubber plate 2 1
12 Bolt 2 M8 18 mm
13 Bolt 1 M6 30 mm
14 Bolt 4 M10 45 mm
15
16
Jet pump unit assy.
Dowel pin
1
2

6-2
A
 JET
PUMP Jet pump unit

17 14 N·m (1.4 kgf·m, 10.3 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb)
17 N·m (1.7 kgf·m, 12.5 ft·lb) 7 6 6
2 N·m (0.2 kgf·m, 1.5 ft·lb) 7
18
19 6
5 7
11

2
20
12 12
10
14

4 8
3 7

15

8
7
16

14 7 N·m (0.7 kgf·m, 5.2 ft·lb)

13
9

2 14
16
7 N·m (0.7 kgf·m, 5.2 ft·lb) 1 40 N·m (4.0 kgf·m, 29.5 ft·lb)

No. Part name Q’ty Remarks

17 Bolt 2 M8 13 mm
18 Washer 2
19 Gasket 2 39
20 Bracket 1

6-3
 Jet pump unit
Jet pump unit removal l
m

Make sure to remove the battery before

removing the jet pump unit.

1. Remove the intake grate a, speed sen-

n
1
sor b, and ride plate c. n
a b
5. Remove the jet pump unit o. 2
a

c
3
p
2. Disconnect the shift cable joint d,
steering cable joint e, bilge hose f, and
spout hose g.
A o p B p
o

o
4
g
f
5
e
d

A STBD
a
6
3. Remove the rubber plate bolts h and B PORT
nuts i, and then remove the rubber

h
plates j and k.
h
TIP:
Insert a flat-head screwdriver into the gaps a
between the jet pump unit o and the transom
7
plate p to separate them.

j
k Jet pump unit installation 8
Make sure to remove the battery before
i i

4. Remove the jet pump unit assy. bolts l,

m, and n.
installing the jet pump unit.

1. Clean the mating surfaces of the jet

9
pump unit a and transom plate b.

6-4
A
 JET
PUMP Jet pump unit
2. Apply sealant to the mating surfaces of
the transom plate b. TIP:
• When installing the rubber plate e, pass
a the spout hose i through the hole a in the
b plate.
• When installing the rubber plate f, pass
the shift cable joint j through the hole b in
the plate.

5. Connect the spout hose i, and then

tighten the spout hose clamp k to the
specified torque.
3. Install the jet pump unit a, and then
tighten the jet pump unit assy. bolts c 6. Connect the bilge hose l, and then
and d to the specified torques. install the plastic tie m.

a d 7. Connect the shift cable joint j.

8. Connect the steering cable joint n, and

then tighten the steering cable joint nut
o to the specified torque.

c m k
l i
c
a

Jet pump unit assy. bolt (M10 45 mm) c: n

40 N·m (4.0 kgf·m, 29.5 ft·lb) j
Jet pump unit assy. bolt (M8 18 mm) d:
17 N·m (1.7 kgf·m, 12.5 ft·lb)
o
4. Install the rubber plates e and f, and
Spout hose clamp k:
then tighten the rubber plate bolts g and
2 N·m (0.2 kgf·m, 1.5 ft·lb)
nuts h to the specified torque.
Steering cable joint nut o:
g i g 7 N·m (0.7 kgf·m, 5.2 ft·lb)
a
TIP:
g g
Make sure that steering and shifting operate
b e properly.
f j

h h
Rubber plate bolt g:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
Rubber plate nut h:
7 N·m (0.7 kgf·m, 5.2 ft·lb)

6-5
 Jet pump unit / Reverse gate

Reverse gate

1
2
8 N·m (0.8 kgf·m, 5.9 ft·lb)

2
3

5 3
6
1 A 6
4
9
1 8

3
5
4
2

A
7
15 N·m (1.5 kgf·m, 11.1 ft·lb)
8
6
No. Part name Q’ty Remarks
1
2
3
Spring
Bolt
Collar
1
2
2
M8 25 mm 7
4 Reverse gate 1
5 Nut 2
6
7
8
Washer
Bolt
Collar
3
1
1
M6 35 mm 8
9 Ball joint 1

9
6-6
A
 JET
PUMP Jet pump unit

Nozzle, impeller housing, and impeller duct assy.

40 N·m (4.0 kgf·m, 29.5 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb)

7
9 6
6
3

4
2
6

1
5

8
15 4

3
10
6

13
14
13
12
10
7 N·m (0.7 kgf·m, 5.2 ft·lb) 11

No. Part name Q’ty Remarks

1 Clamp 1
2 Spout hose 1
3 Bolt 2 M8 25 mm
4 Collar 2
5 Jet thrust nozzle 1
6 Bolt 4 M10 125 mm
7 Bracket 1
8 Nozzle 1
9 Impeller housing 1
10 Dowel pin 2
11 Bolt 4 M6 35 mm
12 Water inlet cover 1
13 Gasket 2 39
14 Water inlet strainer 1
15 Impeller duct assy. 1

6-7
 Nozzle, impeller housing, and impeller duct assy. / Impeller, drive shaft, and impeller duct

Impeller, drive shaft, and impeller duct

14

1
69 N·m (6.9 kgf·m, 50.9 ft·lb)

2
2
9 3
4 2

7
8

11
3
1

4
330 N·m (33.0 kgf·m, 243.4 ft·lb) 5
6
10

12

13 5
6
No. Part name Q’ty Remarks
1
2
3
Impeller
Bolt
Cap
1
3
1
M6 20 mm 7
4 O-ring 1 39
5 Nut 1
6
7
8
Washer
Spacer
Oil seal
1
1
1 39
8
9 Oil seal 1 39

9
10 Ball bearing 1 39
11 Spacer 1
12 Ball bearing 1 39
13 Drive shaft 1
14 Impeller duct 1

6-8
A
 JET
PUMP Jet pump unit
Impeller duct assy. disassembly
1. Remove the impeller a.

f
a
4. Remove the ball bearing g.
A g
Drive shaft holder b: YB-06201
Drive shaft holder 6 b: 90890-06520
h
2. Remove the cap c, O-ring d, and nut
e. h

d
c
e
B g

b i j

A U.S.A. and Canada

B Worldwide
e
Slide hammer h: YB-06096
Stopper guide plate i: 90890-06501
Drive shaft holder b: YB-06201 Bearing puller assembly j: 90890-06535
Drive shaft holder 6 b: 90890-06520 Stopper guide stand k: 90890-06538
3. Remove the drive shaft f. NOTICE: Do 5. Remove the oil seals l and m.
not press the drive shaft threads
A
directly.
l
m
h

6-9
 Impeller, drive shaft, and impeller duct

B Impeller housing inside diameter a:

l 155.35–155.45 mm (6.116–6.120 in)
m
j

1
i Drive shaft check
k 1. Measure the drive shaft runout. Replace
if out of specification.
j

A U.S.A. and Canada

B Worldwide
2
Slide hammer h: YB-06096
Stopper guide plate i: 90890-06501
Bearing puller assembly j: 90890-06535
Stopper guide stand k: 90890-06538
Drive shaft runout:
a

3
6. Remove the spacer n, and then remove 0.3 mm (0.012 in)
the ball bearing o using a press.

p
p
q
Distance a:
310 mm (12.20 in)

Impeller duct assy. assembly

4
q

o
n
Do not reuse a bearing, oil seal, or O-ring,
always replace it with a new one.
5
1. Install a new oil seal a halfway into the

Driver handle (large) p: YB-06071

Driveshaft needle bearing installer and
remover q: YB-06194
A
impeller duct, and then install a new oil
seal b. 6
Driver rod L3 p: 90890-06652 c
Needle bearing attachment q:
90890-06609

Impeller housing check

d b a
7
a
1. Measure the impeller housing inside
diameter a. Replace if out of specifica-
tion.
B
8
e
f
b a

9
a a

6-10
A
 JET
PUMP Jet pump unit
A U.S.A. and Canada
B Worldwide
Driver handle (large) c: YB-06071
Bearing cup installer d: YB-06167 j
Driver rod LS e: 90890-06606
Bearing outer race attachment f: h
90890-06628

Distance a:
7.0 ± 0.2 mm (0.28 ± 0.008 in)
Grease quantity: 20 g (0.7 oz)
2. Install a new ball bearing g onto the
drive shaft h. 5. Install a new ball bearing k.

h k i k
g
i

Bearing attachment i: Bearing attachment i: 90890-06728

90890-06728
6. Install the washer l, and then tighten
Distance b: the drive shaft nut m to the specified
23.0 ± 0.1 mm (0.91 ± 0.004 in) torque.

3. Install the drive shaft h (along with the 7. Add EPNOC grease AP #0 to the inside
ball bearing g) and spacer j. of the cap n, and then install the cap n
and a new O-ring o.

h j o
l n
m

g
q

Bearing attachment i:
90890-06728

4. Add EPNOC grease AP #0 to the space

between the drive shaft h and the
spacer j.

6-11
 Impeller, drive shaft, and impeller duct

Drive shaft holder q: YB-06201

Drive shaft holder 6 q: 90890-06520 b
c
Drive shaft nut m:
69 N·m (6.9 kgf·m, 50.9 ft·lb)

Grease quantity: 20 g (0.7 oz)

1
a
8. Install the spacer r and impeller s. c

4. Apply sealant to the mating surfaces of

the nozzle d and impeller duct assy. a.
2
s

3
5. Install the nozzle d.

6. Install the bracket e, and then tighten

the impeller duct bolts f to the specified
r torque.

9. Tighten the impeller s to the specified

torque. f
e f
4
s

q
a f
5
f

Drive shaft holder q: YB-06201

d
6
Drive shaft holder 6 q: 90890-06520 Impeller duct bolt f:

Impeller s:
330 N·m (33.0 kgf·m, 243.4 ft·lb)
40 N·m (4.0 kgf·m, 29.5 ft·lb)

7
Impeller duct, impeller housing, and
nozzle installation
1. Clean the mating surfaces of the impeller
duct assy., impeller housing, and nozzle. 8
2. Apply sealant to the mating surfaces of

9
the impeller duct assy. a and impeller
housing b.

3. Install the dowel pins c, and then install

the impeller housing b.

6-12
A
 JET
PUMP Jet pump unit

Transom plate and hoses

2 5.5 N·m (0.55 kgf·m, 4.06 ft·lb) 26 N·m (2.6 kgf·m, 19.2 ft·lb) 25
24
9 22
4 3 5 1
1 6
10 20
8
7 11 8

12 24
22 3
5
8
23
2 22
13
23
6 13 22
14 3 26
21
26 N·m (2.6 kgf·m, 19.2 ft·lb)

3
27
4 15
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
20 16 3
29

28
18 28

16
3
19 17

No. Part name Q’ty Remarks

1 Cooling water hose 1
2 Hose joint 1
3 Clamp 6
4 Bilge hose 1
5 Bilge hose 1
6 Plastic tie 2
7 Holder 2
8 Rivet 3
9 Clamp 1
10 Cap 1
11 Nut 1
12 Bracket 1
13 Flushing hose 1
14 Clamp 1
15 Hose joint 1
16 Cooling water hose 1

6-13
 Transom plate and hoses

2 5.5 N·m (0.55 kgf·m, 4.06 ft·lb) 26 N·m (2.6 kgf·m, 19.2 ft·lb) 25

1
4 3
6
5 1
9 22
24

20
1
8 10
7 11 8

12 22
24
3
2
5

3
8
23
2 22
13
23
6 13 22
14 3 26

4
21
26 N·m (2.6 kgf·m, 19.2 ft·lb)

3
27
4 15

5
3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
20 16 3
29

28
18 28

19 17
3
16
6
No. Part name Q’ty Remarks
17
18
19
Hose joint
Bilge strainer assy.
Rivet
1
1
1
7
20 Plastic tie 2
21 Cooling water hose 1
22
23
24
Nut
Washer
Washer
4
2
2
8
25 Transom plate 1

9
26 Bolt 3 M6 32 mm
27 Hose joint 1
28 Clamp 2
29 Hose 1

6-14
A
 JET
PUMP Jet pump unit
Bilge strainer check
1. Check the bilge strainer. See “Bilge
strainer check” (3-11).

Transom plate installation

1. Clean the mating surface of the transom
plate a.

2. Apply silicone sealant to the mating

surface of the transom plate a.

3. Install the transom plate a and washers

b and c, and then tighten the transom
plate nuts d to the specified torque.
a
b

d
c

Transom plate nut d:

26 N·m (2.6 kgf·m, 19.2 ft·lb)

6-15
 Transom plate and hoses / Intermediate housing

Intermediate housing

1
17 N·m (1.7 kgf·m, 12.5 ft·lb)

14
15

2
16
4
12
17
5

11
12
13

4 18
2
2
3
3
10
10
4
9
1
8
5 N·m (0.5 kgf·m, 3.7 ft·lb)

5
7

210 N·m (21.0 kgf·m, 154.9 ft·lb)

6
No. Part name Q’ty Remarks
1
2
3
Rubber coupling
Plastic tie
Grease hose
1
2
1
7
4 Bolt 3 M8 48 mm
5 Shim * As required
6
7
8
Dowel pin
Driven coupling
Washer
2
1
1
8
9 Intermediate drive shaft 1

9
10 O-ring 2 39
11 Oil seal 1 39
12 Circlip 2 39
13 Ball bearing 1 39
14 Thrust washer 1 39
15
16
Oil seal
Oil seal
1
1
39
39

6-16
A
 JET
PUMP Jet pump unit

17 N·m (1.7 kgf·m, 12.5 ft·lb)

14
15

16 6
4
12
17
5

13 3
12 2
11
4 18 2

10

10
9 5 N·m (0.5 kgf·m, 3.7 ft·lb)
1
8

210 N·m (21.0 kgf·m, 154.9 ft·lb)

No. Part name Q’ty Remarks

17 Intermediate housing 1
18 Nipple 1

6-17
 Intermediate housing
Intermediate housing assy. removal
1. Remove the engine unit. See “Engine
d
unit removal” (5-7).
e
2. Remove the intermediate housing assy.
a. 1
a

3. Remove the oil seals f, g, and h.

A
2
a f

TIP:
j
i
g j
3
h
If shims a are installed, remove the shims
and write down the position of each removed
shim so that it can be installed in its original
position.
B
j
4
Intermediate housing assy. k
disassembly
1. Remove the driven coupling a.
b
l 5
a
m

c h f
6
l g

7
l

A U.S.A. and Canada

Shaft holder b: 90890-06730 B Worldwide
Coupler wrench c: 90890-06729
Slide hammer i: YB-06096
2. Remove the intermediate drive shaft d
and thrust washer e using a press.
NOTICE: Do not press the
Bearing puller legs j: YB-06523
Stopper guide plate k: 90890-06501
Bearing puller assembly l: 90890-06535
Stopper guide stand m: 90890-06538
8
intermediate drive shaft directly.
4. Remove the circlips n, and then remove
the ball bearing o using a press.
9
6-18
A
 JET
PUMP Jet pump unit

A B
n
p a
e f

n q
b
o

B A U.S.A. and Canada

B Worldwide
n
r Driver handle (large) c: YB-06071
Needle bearing installer d: YB-06434
Driver rod LS e: 90890-06606
n s
Bearing outer race attachment f:
90890-06623
o
3. Install a new oil seal g.

A U.S.A. and Canada A

B Worldwide
Driver handle (large) p: YB-06071 c a
Needle bearing installer q: YB-06434 d
Driver rod LS r: 90890-06606 g
Bearing outer race attachment s:
90890-06623

Intermediate housing assy. assembly

B

Do not reuse a bearing, circlip, oil seal, or

thrust washer, always replace it with a e a
new one. f
g
1. Install a new circlip (rear) a.

2. Install a new ball bearing b until it

contacts the circlip (rear) a using a
press. A U.S.A. and Canada
B Worldwide
A
Driver handle (large) c: YB-06071
Needle bearing installer d: YB-06434
c a
d Driver rod LS e: 90890-06606
Bearing outer race attachment f:
b 90890-06623

Distance a:
6.5 ± 0.2 mm (0.26 ± 0.01 in)

6-19
 Intermediate housing
4. Install the intermediate drive shaft h
using a press. NOTICE: Do not press
n
the intermediate drive shaft directly. m

h
n
d

1
i

b
I

Bearing attachment m: 90890-06727 2

Distance d:

3
Bearing attachment i: 4.4 ± 0.3 mm (0.17 ± 0.01 in)
90890-06728
8. Install the washer o, and then tighten
Distance b: the driven coupling p to the specified
46.0 ± 0.5 mm (1.81 ± 0.02 in) torque.

5. Install a new circlip (front) j, and then

install a new oil seal k. 4
j i

k
j o
p 5
I

Bearing attachment i: 90890-06728

q

p
6
6. Install a new oil seal l.

m
r
7
l c Shaft holder q: 90890-06730
Coupler wrench r: 90890-06729

Driven coupling p:
8
210 N·m (21.0 kgf·m, 154.9 ft·lb)

Bearing attachment m: 90890-06727

Distance c:
Intermediate housing assy.
installation
1. Install the intermediate housing assy. a,
9
1.6 ± 0.2 mm (0.06 ± 0.01 in) and then tighten the intermediate hous-
ing assy. bolts a to the specified torque.
7. Install a new thrust washer n.

6-20
A
 JET
PUMP Jet pump unit

a b
a

Intermediate housing assy. bolt a:

17 N·m (1.7 kgf·m, 12.5 ft·lb)

TIP:
If shims b were removed, install the shims in
their original positions.

6-21
ELEC

Electrical system 7

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

Engine ....................................................................................... 7-1
Deck and hull ............................................................................. 7-3
Electrical box ............................................................................. 7-4
1
2
Electrical box ..................................................................... 7-5

Electrical analysis ............................................................. 7-7

Electrical component check using the YDIS .............................. 7-7
Power supply to the ECM .......................................................... 7-7
Peak voltage measurement ....................................................... 7-7

Ignition system .................................................................. 7-8

3
Ignition coil ................................................................................ 7-8

4
Ignition spark ...................................................................................... 7-8
Ignition coil input voltage (from the battery) ....................................... 7-9
ECM output peak voltage ................................................................... 7-9
Pickup coil ............................................................................... 7-10
Pickup coil output peak voltage ........................................................ 7-10
Pickup coil resistance ....................................................................... 7-10

Charging system ............................................................. 7-10

Stator coil ................................................................................ 7-10
5
Stator coil output peak voltage ......................................................... 7-10
Stator coil resistance ........................................................................ 7-11
Rectifier regulator .................................................................... 7-11
Rectifier regulator output peak voltage ............................................ 7-11
Rectifier regulator continuity ............................................................. 7-12
6
Control system ................................................................ 7-12
Oil pressure switch .................................................................. 7-12
Oil pressure switch input voltage ..................................................... 7-12
Oil pressure switch continuity ........................................................... 7-13
7
Thermoswitch .......................................................................... 7-13
Thermoswitch input voltage ............................................................. 7-13
Thermoswitch continuity temperature .............................................. 7-13
Thermo sensor ........................................................................ 7-14
Thermo sensor input voltage ............................................................ 7-14
8
Thermo sensor resistance ................................................................ 7-14
Engine temperature sensor ..................................................... 7-14
Engine temperature sensor input voltage ........................................ 7-14
Engine temperature sensor resistance ............................................ 7-15
Intake air temperature sensor ................................................. 7-15
9
Intake air temperature sensor operation .......................................... 7-15
Intake air temperature sensor input voltage ..................................... 7-15
A
ELEC
Intake air temperature sensor resistance ......................................... 7-15
Intake air pressure sensor ....................................................... 7-16
Intake air pressure sensor input voltage .......................................... 7-16
Intake air pressure sensor operation ................................................ 7-16
Throttle position sensor ........................................................... 7-16
TPS output voltage and throttle valve opening angle ....................... 7-17
TPS input voltage ............................................................................. 7-18
TPS circuit continuity ........................................................................ 7-18
Accelerator position sensor ..................................................... 7-18
APS output voltage .......................................................................... 7-18
APS input voltage ............................................................................. 7-19
APS resistance ................................................................................. 7-19
APS circuit continuity ....................................................................... 7-21
Electronic throttle valve relay .................................................. 7-21
ETV relay input voltage .................................................................... 7-21
ETV relay continuity ......................................................................... 7-21
Cam position sensor ................................................................ 7-22
Cam position sensor input voltage ................................................... 7-22
Cam position sensor output voltage ................................................. 7-22
Slant detection switch .............................................................. 7-23
Slant detection switch input voltage ................................................. 7-23
Slant detection switch continuity ...................................................... 7-23
Steering sensor ....................................................................... 7-24
Steering sensor operation ................................................................ 7-24
Steering sensor input voltage ........................................................... 7-24
ECM ........................................................................................ 7-24
ECM input voltage ............................................................................ 7-24
ECM circuit continuity ....................................................................... 7-25
Earth plate ............................................................................... 7-25

Fuel system ..................................................................... 7-25

Fuel injector ............................................................................. 7-25
Fuel injector operation sound ........................................................... 7-25
Fuel injector input voltage ................................................................ 7-26
Fuel injector resistance .................................................................... 7-26
Fuel pump module ................................................................... 7-26
Fuel pump module operation sound ................................................. 7-26
Fuel pump module input voltage ...................................................... 7-26
Fuel sender resistance ..................................................................... 7-26

Starting system ............................................................... 7-27

Left handlebar switch assy. ..................................................... 7-27
Engine start switch continuity ........................................................... 7-27
Engine stop switch continuity ........................................................... 7-27
Main and fuel pump relay ........................................................ 7-28
Main and fuel pump relay input voltage ........................................... 7-28
Main relay continuity ........................................................................ 7-28
Fuel pump relay continuity ............................................................... 7-28
Starter relay ............................................................................. 7-29
Starter relay input voltage ................................................................ 7-29
 Starter relay continuity ..................................................................... 7-29

Starter motor ................................................................... 7-30

Starter motor operation ........................................................... 7-31
Armature .................................................................................. 7-31
Armature appearance ...................................................................... 7-31
Commutator diameter ...................................................................... 7-31
1
Commutator undercut ...................................................................... 7-31
Armature continuity .......................................................................... 7-31
Brush holder ............................................................................ 7-32
Brush length ..................................................................................... 7-32
Brush holder assy. continuity ........................................................... 7-32
2
Remote control system .................................................. 7-32
Remote control transmitter ...................................................... 7-32
Remote control transmitter operation ............................................... 7-32
3
Remote control transmitter battery voltage ...................................... 7-33
Remote control receiver .......................................................... 7-34
Remote control receiver input voltage .............................................. 7-34
Remote control receiver output voltage ........................................... 7-34
Transmitter registration ........................................................... 7-34
4
Indication system ............................................................ 7-35
Multifunction meter .................................................................. 7-35
Multifunction meter appearance ....................................................... 7-35
Multifunction meter operation ........................................................... 7-35
5
Multifunction meter input voltage ..................................................... 7-35

6
Speed sensor .......................................................................... 7-36
Speed sensor appearance ............................................................... 7-36
Speed sensor output voltage ........................................................... 7-36
Fuel level meter display and fuel level warning indicator ........ 7-36
Check engine warning indicator .............................................. 7-37
Diagnostic display ................................................................... 7-37
Oil pressure warning indicator ................................................. 7-37
Engine overheat warning indicator .......................................... 7-38
Buzzer ..................................................................................... 7-38
Buzzer input voltage ......................................................................... 7-38
7
Buzzer operation .............................................................................. 7-39

8
9
A
 ELEC
Electrical system

Electrical components
Engine

b
c
a

A
d

e
j
f i
h

B
k

o m
n

a Spark plug and ignition coil i Intake air pressure sensor

b Cam position sensor j Fuel injector
c Electrical box k Thermoswitch
d Thermo sensor l Intake air temperature sensor
e Rectifier regulator m Engine temperature sensor
f Starter motor n Earth plate
g Oil pressure switch o Stator coil and pickup coil
h ETV (TPS)

7-1
 Electrical components

b
1
c
a

2
A
d

3
e
j
4
f i
h

g 5
B

l
k 6
7
o m

8
n

A Port bow view

B Starboard stern view

9
7-2
A
 ELEC
Electrical system

Deck and hull

e f
c
A d

a Remote control receiver i Battery

b APS
c Fuel pump module and fuel sender A Port bow view
d Steering sensor B Starboard stern view
e Buzzer
f Left handlebar switch assy.
g Speed sensor
h Multifunction meter

7-3
 Electrical components

Electrical box

a b c d e
1
A

2
3
4
o
5
k

f
g
n
6
h
i
j
m l 7
A

8
a Starter relay i Fuse (3 A) (remote control receiver)

9
b Main and fuel pump relay j Fuse (20 A) (main and fuel pump relay)
c ETV relay k Positive battery cable (gray tape)
d Slant detection switch l Starter motor cable (white tape)
e ECM m Lead (black)
f Fuse (30 A) (battery) n Lead (brown)

A
g Fuse (10 A) (main and fuel pump relay) o Lead (red)
h Fuse (10 A) (ETV relay)

7-4
 ELEC
Electrical system

Electrical box
4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb)
11
24
12

22
10
20
23
21
15
14 8 N·m (0.8 kgf·m, 5.9 ft·lb)
13
16 25
17 7
18 9
19
8
2
1

4
5
6

3 5 N·m (0.5 kgf·m, 3.7 ft·lb)

No. Part name Q’ty Remarks

1 Electrical box cover 1
2 Plastic tie 1
3 Bolt 4 M6 25 mm
4 ECM 1
5 Collar 4
6 Grommet 4
7 Bolt 6 M6 16 mm
8 Fuse box assy. 1
9 Gasket 1 39
10 Rubber mount 1
11 Main and fuel pump relay 1
12 ETV relay 1
13 Fuse box cap 1
14 Gasket 1 39
15 Fuse puller 1
16 Fuse (30 A) 2

7-5
 Electrical box

4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb)
11

1
24
12

22
10
20

13
14
15
21
23

8 N·m (0.8 kgf·m, 5.9 ft·lb)

2
16
17
18
19
9
25
7
3
8
2
1
4
4
5
5

3
6

5 N·m (0.5 kgf·m, 3.7 ft·lb)

6
No. Part name Q’ty Remarks
17
18
19
Fuse (10 A)
Fuse (3 A)
Fuse (20 A)
4
2
2
7
20 Starter relay 1
21 Starter motor cable 1
22
23
24
Positive battery cable
Screw
Slant detection switch
1
2
1
M6 20 mm 8
25 Electrical box 1

9
7-6
A
 ELEC
Electrical system

Electrical analysis
TIP:
Electrical component check using
• Before checking the electrical components,
the YDIS make sure that the battery is fully charged.
When checking the TPS, APS, or other sen- • If the test leads are connected while using
sors, use the YDIS. the YDIS, diagnostic codes will be
When deleting the diagnosis record in the detected.
YDIS, make sure to check the time when the • If a diagnosis record is displayed and it is
diagnostic codes were detected. caused by the checking steps, delete the
record by using the “Diagnosis record”
function of the YDIS.
• The YDIS requires that you use an exclu-
sive communication cable and CD-ROM to
connect to a computer. For a description of
the communication cable and CD-ROM to
R/Y
W/B

be used, see “YDIS” (9-1). Also, make sure

B

to check the CD-ROM version before using

it.
• To connect the YDIS, see “YDIS” (9-1) or
When checking the input voltage of a part,
the YDIS (Ver. 1.33) Instruction Manual.
the coupler or connector must be discon-
nected. As a result, the ECM determines that
the part is disconnected and a diagnostic Power supply to the ECM
code is detected. Therefore, make sure to Push the unlock button a on the remote con-
delete the diagnosis record after checking the trol transmitter so that power is supplied to
input voltage. the ECM.
Power is supplied to the ECM for about 30
seconds after stopping the engine. Therefore, a
wait for more than 30 seconds before restart-
ing the engine, otherwise the diagnostic
codes will not be cleared from the ECM.
YDIS (CD-ROM, Ver. 1.33):
60V-WS853-06
YDIS USB adapter and cable:
60V-WS850-00

TIP:
To check that the remote control transmitter
is working properly, see “Remote control
transmitter” (7-32).

Peak voltage measurement

When measuring the peak voltage, do not

touch any of the connections of the digital
tester probes.

7-7
 Electrical analysis / Ignition system

TIP:
• When testing the voltage between the • Before measuring the peak voltage, check
terminals of an electrical component all wiring for proper connection and corro-
using the digital tester, do not allow any
of the leads to touch any metal parts.
• When starting the engine on land, make
sure to connect a garden hose to the
sion, and check that the battery is fully
charged.
• Use the peak voltage adapter with the rec-
ommended digital circuit tester.
1
watercraft for proper water supply. • Connect the positive pin of the peak voltage

To check the electrical components or mea-

sure the peak voltage, use the special ser-
adapter to the positive terminal of the digital
circuit tester, and the negative pin to the
negative terminal.
2
vice tools. A faulty electrical component can • When measuring the peak voltage, set the
selector on the digital circuit tester to the

3
be easily checked by measuring the peak
voltage. The specified engine speed when DC voltage mode.
measuring the peak voltage is affected by
many factors, such as fouled spark plugs or a Ignition system
weak battery. If one of these factors is Ignition coil

4
present, the peak voltage cannot be mea- Ignition spark
sured properly.
A
When performing the spark gap check,
keep flammable gas or liquids away, since

5
V
this test can produce sparks.

1. Connect the YDIS.

2. Remove the ignition coil for the cylinder

B
a b that will be tested.

3. Connect the ignition coil to the special

service tool a.
6
c

DC V 4. Using the “Stationary test” of the YDIS,

check the ignition spark. Measure the
ignition coil input voltage (from the
battery) if there is no spark. WARNING!
7
d Do not touch any of the connections

A U.S.A. and Canada

B Worldwide
of the special service tool leads.
a 8
Digital multimeter a: YU-34899-A
Peak volt adapter b: YU-39991
Digital circuit tester c: 90890-03174
Peak voltage adapter B d: 90890-03172
9
7-8
A
 ELEC
Electrical system

Spark checker a: YM-34487

Ignition tester (Spark gap tester) a: R/Y
90890-06754 B
#1 B/R
#2 B/W
5. Disconnect the special service tool, and #3 B/Y
then install the ignition coils. #4 B/G

Ignition coil input voltage (from the bat-

tery)
1. Disconnect the ignition coil couplers a.

2. Supply power to the ECM, and then

measure the input voltage at the ignition
a
coil coupler terminals (wiring harness
end). Check the wiring harness if out of
specification. Check the ECM output
peak voltage if within specification.

R/Y B
ECM output peak voltage:
#1 Black/Red (B/R) –Black (B)
#2 Black/White (B/W) –Black (B)
a #3 Black/Yellow (B/Y) –Black (B)
#4 Black/Green (B/G) –Black (B)
Loaded
r/min
Cranking 2000 3500
V 2.5 2.6 2.6
Ignition coil input voltage (from the
battery): TIP:
Red/Yellow (R/Y)–Black (B) • When measuring the ECM output peak volt-
12 V (battery voltage) age under the “Cranking” condition, discon-
nect the fuel injector couplers for all
3. Connect the ignition coil couplers a. cylinders.
• To crank the engine, connect the engine
ECM output peak voltage shut-off cord (lanyard) to the engine shut-
off switch, and then push the engine start
switch.
When checking the electrical compo- • When measuring the ECM output peak volt-
nents, do not touch any of the connec- age, use only a properly functioning ignition
tions of the digital tester leads. coil. If the ignition coil is not functioning
properly, ECM output peak voltage will not
1. Disconnect the ignition coil couplers a, be generated.
and then connect the test harness.
3. Disconnect the test harness, and then
2. Measure the ECM output peak voltage. connect the ignition coil couplers a.

7-9
 Ignition system / Charging system
Pickup coil 3. Disconnect the special service tool a,
Pickup coil output peak voltage and then connect the pickup coil coupler
1. Disconnect the pickup coil coupler a, a.

1
and then connect the special service tool
a. Pickup coil resistance
1. Disconnect the pickup coil coupler a.
2. Measure the pickup coil output peak
voltage. Measure the pickup coil 2. Measure the pickup coil resistance.
Replace the stator coil assy. if out of

2
resistance if below specification.
specification.
B B/O
W W/B
WB W B
b

3
4
a
a b Pickup coil resistance at 20 °C (68 °F)
(reference data):
a White (W)–Black (B)
BW 459–561 Ω

W B
3. Connect the pickup coil coupler a.

Charging system
5
Test harness (3 pins) a:
Stator coil
YB-06877/90890-06877

Pickup coil output peak voltage:

White (W)–Black (B)
Stator coil output peak voltage
1. Disconnect the stator coil coupler a, and
then connect the special service tool a.
6
Un-
Loaded 2. Measure the stator coil output peak
r/min loaded

V 5.5
Cranking
4.7
2000
16.4
3500
21.5
voltage. Measure the stator coil
resistance if below specification. 7
TIP:
• To crank the engine, connect the engine
shut-off cord to the engine shut-off switch,
and then push the engine start switch and
8
engine stop switch simultaneously.
• If measuring the pickup coil output peak
voltage under the “Cranking” and
“Unloaded” conditions, disconnect the
pickup coil coupler (wiring harness end) b.
9
7-10
A
 ELEC
Electrical system

G G Stator coil resistance at 20 °C (68 °F)

G G (reference data):
G G Green (G)–Green (G)
W R B
0.31–0.38 Ω

3. Connect the stator coil coupler a.

Rectifier regulator
a Rectifier regulator output peak voltage
a
1. Disconnect the rectifier regulator coupler
B a, and then connect the special service
R tool a.
W
2. Measure the rectifier regulator output
peak voltage. Check the rectifier
regulator continuity if below specification.

G
G
Test harness (3 pins) a: G
YB-06870/90890-06870 R R
B B
Stator coil output peak voltage:
Green (G)–Green (G)
Unloaded
r/min
Cranking 2000 3500
V 8.3 36.4 64.7
a
a
3. Disconnect the special service tool a,
and then connect the stator coil coupler
a.
R
Stator coil resistance B
1. Disconnect the stator coil coupler a.

2. Measure the stator coil resistance. Test harness (2 pins) a: 90890-06850

Replace the stator coil assy. if out of
specification. Measure the rectifier Rectifier regulator output peak voltage:
regulator output peak voltage if within Red (R)–Black (B)
specification. Loaded
r/min
2000 3500
V 13.0
G
TIP:
Do not use the peak voltage adapter to mea-
G sure the output voltage.
G

3. Disconnect the special service tool a,

a
and then connect the rectifier regulator
coupler a.

7-11
 Charging system / Control system
Rectifier regulator continuity
Rectifier regulator continuity (testing diode
1. Remove the rectifier regulator. See
mode):
“Exhaust manifold” (5-2).
Tester lead Display value (V)
2. Check the rectifier regulator for
continuity. Replace if out of specification.
a

b
c
(reference data)

OL
1
bG d

2
Gd e
cG
a 0.43–0.51
c
b
d OL
e

aR
Be aR
c
a
b
d
0.43–0.51

OL
3
e

4
bG a 0.43–0.51
b
cG d
c OL
dG e
a 0.66–0.74

A
eB e
b
c
d
0.43–0.51
0.43–0.51
0.43–0.51
5
OL: Indicates an overload

TIP:
Make sure to set the measurement range a
when checking the rectifier regulator continu-
6
a ity.

B
3. Install the rectifier regulator.
“Exhaust manifold” (5-2).
See 7
4. Connect the rectifier regulator coupler.

a
a
Control system
Oil pressure switch
8
Oil pressure switch input voltage
1. Disconnect the oil pressure switch cou-

A U.S.A. and Canada

B Worldwide
pler a.
9
7-12
A
 ELEC
Electrical system
2. Supply power to the ECM, and then 4. Check the oil pressure switch for
measure the input voltage between the continuity. Replace if out of specification.
oil pressure switch coupler terminal
Oil pressure switch continuity:
(wiring harness end) and ground. Check
Terminal thread
the wiring harness if out of specification. Pressure
a–Body b
Below 128–166 kPa
(1.28–1.66 kgf/cm2, Continuity
18.2–23.6 psi)
Above 128–166 kPa
P/W (1.28–1.66 kgf/cm2, No continuity
18.2–23.6 psi)

5. Install the oil pressure switch. See “Oil

a
separator tank and oil pan” (5-66).

Oil pressure switch input voltage 6. Connect the oil pressure switch coupler.
(reference data):
Pink/White (P/W)–Ground Thermoswitch
11.0–12.0 V Thermoswitch input voltage
1. Disconnect the thermoswitch coupler a.
3. Connect the oil pressure switch coupler
a. 2. Supply power to the ECM, and then
measure the input voltage at the
Oil pressure switch continuity thermoswitch coupler terminals (wiring
1. Remove the oil pressure switch. See “Oil harness end). Check the wiring harness
separator tank and oil pan” (5-66). if out of specification.
2. Connect the tester leads to the terminal
thread a and body b of the oil pressure
switch. B P
a
3. Connect the special service tool a to the
oil pressure switch, and then apply
positive pressure.

a a
Thermoswitch input voltage
(reference data):
Pink (P)–Black (B)
b
11.0–12.0 V

3. Connect the thermoswitch coupler a.

Thermoswitch continuity temperature

Lower unit pressure/vacuum tester a: 1. Remove the thermoswitch. See “Cylinder
YB-35956-A block and electrical part” (5-64).
Vacuum/pressure pump gauge set a:
90890-06756 2. Suspend the thermoswitch in a container
filled with water, and then heat the water
slowly.

7-13
 Control system

B/L B/O
P B

1
3. Check the thermoswitch for continuity
when the specified temperatures are
a

Thermo sensor input voltage:

Black/Blue (B/L)–Black/Orange (B/O)
2
reached. Replace if out of specification. 4.75–5.25 V

a
d
d

d
3. Connect the thermo sensor coupler a.

Thermo sensor resistance

3
A 1. Remove the thermo sensor. See “Muf-
b fler” (5-17).

4
c
c
2. Suspend the thermo sensor in a
container filled with water, and then
B slowly heat the water.
c No continuity
d Continuity
A Temperature
B Time B B
5
Thermoswitch continuity temperature:
Pink (P)–Black (B)
a: 94–100 °C (201–212 °F)
b: 80–94 °C (176–201 °F)
6
4. Install the thermoswitch. See “Cylinder
3. Measure the thermo sensor resistance
block and electrical part” (5-64).

Thermo sensor
Thermo sensor input voltage
when the specified temperatures are
reached. Replace if out of specification.
Thermo sensor resistance
7
1. Disconnect the thermo sensor coupler (reference data):
a.

2. Supply power to the ECM, and then

measure the input voltage at the thermo
Black (B)–Black (B)
0 °C (32 °F): 24.0–37.1 kΩ
100 °C (212 °F): 0.87–1.18 kΩ
8
sensor coupler terminals (wiring harness 4. Install the thermo sensor. See “Muffler”

9
end). Check the wiring harness if out of (5-17).
specification.
Engine temperature sensor
Engine temperature sensor input voltage
1. Disconnect the engine temperature sen-

A
sor coupler a.

7-14
 ELEC
Electrical system
2. Supply power to the ECM, and then 4. Install the engine temperature sensor.
measure the input voltage at the engine See “Cylinder block and electrical part”
temperature sensor coupler terminals (5-64).
(wiring harness end). Check the wiring
harness if out of specification. Intake air temperature sensor
Intake air temperature sensor operation
a 1. Measure the ambient temperature.
B/O B/Y
2. Connect the YDIS to display “Intake
temperature.”

3. If the ambient temperature and the

displayed intake air temperature differ by
more than ± 5 °C (± 9 °F), measure the
intake air temperature sensor resistance.
Engine temperature sensor input voltage:
Black/Yellow (B/Y)–Black/Orange (B/O) TIP:
4.75–5.25 V Check the intake air temperature sensor
when the engine is cold.
3. Connect the engine temperature sensor
coupler a. Intake air temperature sensor input volt-
age
Engine temperature sensor resistance 1. Disconnect the intake air temperature
1. Remove the engine temperature sensor. sensor coupler a.
See “Cylinder block and electrical part”
(5-64). 2. Supply power to the ECM, and then
measure the input voltage at the intake
2. Suspend the engine temperature sensor air temperature sensor coupler (wiring
in a container filled with water, and then harness end). Check the wiring harness
heat the water slowly. if out of specification.

B/O B/R
B/Y B/Y

3. Measure the engine temperature sensor Intake air temperature sensor input volt-
resistance when the specified age:
temperatures are reached. Replace if out Black/Red (B/R)–Black/Orange (B/O)
specification. 4.75–5.25 V
Engine temperature sensor resistance
Intake air temperature sensor resistance
(reference data):
1. Remove the intake air temperature sen-
Black/Yellow (B/Y)–Black/Yellow (B/Y)
sor. See “Intake assy.” (5-23).
20 °C (68 °F): 54.2–69.0 kΩ
100 °C (212 °F): 3.12–3.48 kΩ

7-15
 Control system
2. Suspend the intake air temperature 3. Connect the intake air pressure sensor
sensor in a container filled with water, coupler a.
and then slowly heat the water.
Intake air pressure sensor operation
1. Connect the special service tool to the
intake air pressure sensor.

2. Connect the YDIS to display “Intake

1
pressure.”

3. Apply negative pressure to the intake air

pressure sensor slowly and check that
the displayed intake air pressure
2
increases. Replace if it does not
3. Measure the intake air temperature
sensor resistance when the specified
temperatures are reached. Replace if out
of specification.
increase.

a
3
Intake air temperature sensor resistance
(reference data):
0 °C (32 °F): 5.4–6.6 kΩ
80 °C (176 °F): 0.29–0.39 kΩ
4
4. Install the intake air temperature sensor.
See “Intake assy.” (5-23).

Intake air pressure sensor

Intake air pressure sensor input voltage
Lower unit pressure/vacuum tester a:
YB-35956-A
5
Vacuum/pressure pump gauge set a:
1. Disconnect the intake air pressure sen-
90890-06756
sor coupler a.

2. Supply power to the ECM, and then

measure the input voltage at the intake
Throttle position sensor 6
air pressure sensor coupler (wiring
• Do not loosen the throttle stop screw
harness end). Check the wiring harness
if out of specification.
nut a and do not turn the throttle stop
screw b.
• Do not disconnect the throttle body
7
assy. coupler (throttle body end) c.
a B/O O
• TPS 1 and TPS 2 are components of the
electronic throttle valve, which cannot
be disassembled. 8
Intake air pressure sensor input voltage:
Orange (O)–Black/Orange (B/O)
9
4.75–5.25 V

7-16
A
 ELEC
Electrical system

TIP:
To adjust the throttle cable, see “Throttle lever
free play adjustment” (3-2).
c
4. Check the TPS 1 output voltage and
throttle valve opening angle at the fully
closed position A .
TPS 1 output voltage with throttle lever
a b
fully closed: 0.6–0.9 V
Throttle valve opening angle with throttle
lever fully closed: 2–8°

5. Operate the throttle lever a, and then

check the TPS 2 output voltage and
throttle valve opening angle at the fully
open position B .

TPS output voltage and throttle valve

opening angle
1. Connect the YDIS to display “Throttle
position sensor 1,” “Throttle valve open- B
ing,” and “Throttle position sensor 2.”

TIP: a
When checking the TPS using the YDIS, do
not start the engine.
TPS 2 output voltage with throttle lever
2. Squeeze the throttle lever slowly and fully open: 4.5–4.8 V
check that the displayed throttle valve Throttle valve opening angle with throttle
opening increases. lever fully open: More than 70°

3. Check that the APS pulley stopper a TIP:

contacts the fully closed stopper b when The actual TPS output voltage and throttle
the throttle lever a is at the fully closed valve opening angle may vary according to
position A . environmental conditions and engine temper-
ature.
b
a A
6. Operate the throttle lever a so that the
TPS 2 output voltage is 4.5 V or less, and
then check the voltage difference
between TPS 1 and TPS 2. Measure the
TPS input voltage if out of specification.
TPS output voltage difference: 1.9–2.1 V
a
Example:
If the TPS 1 output voltage is 2.5 V and the
TPS 2 output voltage is 4.5 V, then 4.5 – 2.5
= 2.0 V.

7-17
 Control system
TPS input voltage 2. Check the wiring harness for continuity.
1. Disconnect the throttle body assy. cou- Replace if there is no continuity. Replace
pler a. the throttle body assy. if there is

1
continuity.
2. Supply power to the ECM, and then
measure the input voltage at the throttle
a
body assy. coupler terminals (wiring
3 2 1
harness end). Check the TPS circuit 6 5 4
continuity if out of specification.

b c 2
O

B/O
52
44 43 42 41
78 3
a

TPS input voltage:

Orange (O)–Black/Orange (B/O)
4.75–5.25 V
TPS circuit continuity:
Terminal No.
Coupler a
a
Coupler b, c
P
Color
code
P
4
3. Connect the throttle body assy. coupler b R O
a.

TPS circuit continuity

1. Disconnect the throttle body assy. cou-
c
d
e
{
Q
O
G
P/B
B/O
5
f Z L
pler a and ECM couplers b and c.
3. Connect the throttle body assy. coupler
a and ECM couplers b and c. 6
Accelerator position sensor

a
APS 1 and APS 2 are a single unit, which
cannot be disassembled.
7
b c
APS output voltage
1. Connect the YDIS to display “Accelerator
position sensor 1” and “Accelerator posi-
tion sensor 2.”
8
TIP:
When checking the APS using the YDIS, do
not start the engine.
9
7-18
A
 ELEC
Electrical system
2. Check that the APS pulley stopper a
APS output voltage difference (with throttle
contacts the fully closed stopper b when
lever fully open): 0.75 V or less
the throttle lever a is at the fully closed
position A . APS input voltage
1. Disconnect the APS coupler a.
b
a A
2. Supply power to the ECM, and then
measure the input voltage at the APS
coupler terminals (wiring harness end).
Measure the APS resistance if within
specification. Check the APS circuit
continuity if out of specification.
a a

TIP:
To adjust the throttle cable, see “Throttle lever
free play adjustment” (3-2).
O/W B/W O/R B/R
3. Operate the throttle lever a, and then
check the output voltages of APS 1 and
APS 2 at the fully closed position A and
fully open position B .
APS 1 input voltage:
Orange/Red (O/R)–Black/Red (B/R)
4.75–5.25 V
APS 2 input voltage:
Orange/White (O/W)–Black/White (B/W)
B
4.75–5.25 V

3. Connect the APS coupler a.

a
APS resistance
1. Disconnect the APS coupler a.
APS output voltage:
Throttle lever position 2. Loosen the throttle cable locknut a, and
Item then remove the throttle cable b.
Fully closed A Fully open B
APS 1 0.50–0.90 V 3.75–4.35 V 3. Remove the APS nuts c, and then
APS 2 0.35–1.05 V 3.60–4.50 V remove the APS d.

TIP: a b
The actual APS output voltage may vary
according to environmental conditions.

4. Squeeze the throttle lever a to the fully a

open position B , and then check the c
voltage difference between APS 1 and
APS 2. Measure the APS input voltage if d
out of specification.

7-19
 Control system
4. Check that the APS pulley stopper b
contacts the fully closed stopper c when
the APS pulley is at the fully closed
position A .

5. Measure the APS resistance at the fully

closed position A . Replace the APS if
6 7
1
out of specification.

d B e

2
1 3

3
c

A
APS resistance at 20 °C (68 °F) (reference
data):

Item
Termi-
APS pulley position
Fully Fully
4
nal
b closed A open B

6. Check that the APS pulley stopper d

APS 1

APS 2
a–c

f–g
0.50–
0.90 kΩ
0.35–
3.75–
4.35 kΩ
3.60–
5
1.05 kΩ 4.50 kΩ
contacts the fully open stopper e when
the APS pulley is at the fully open
position B .

7. Measure the APS resistance at the fully

8. Install the APS d, and then tighten the
APS nuts c to the specified torque.

9. Install the throttle cable b, and then

6
open position B . Replace the APS if out tighten the throttle cable locknut a to the

7
of specification. specified torque.

10. Connect the APS coupler a.

a b

a
8
c

APS nut c: 17 N·m (1.7 kgf·m, 12.5 ft·lb)

9
Throttle cable locknut a:
7 N·m (0.7 kgf·m, 5.2 ft·lb)

7-20
A
 ELEC
Electrical system

APS circuit continuity:

TIP:
After installing the throttle cable, make sure Terminal No. Color
that the throttle lever free play is within speci- Coupler a Coupler b code
fication. a H B/R
b W O/R
APS circuit continuity c J P/R
1. Remove the ECM cover, and then dis- f K P/W
connect the APS coupler a and ECM g I B/W
coupler b. h X O/W

a 3. Connect the APS coupler a and ECM

coupler b, and then install the ECM
cover.

Electronic throttle valve relay

ETV relay input voltage
1. Disconnect the ETV relay coupler a.

2. Supply power to the ECM, and then

measure the input voltage between the
ETV relay coupler terminals and ground.
b Check the wiring harness if out of
specification.

a
R/Y

2. Check the wiring harness for continuity.

Replace if there is no continuity. R

a b ETV relay input voltage:

Red/Yellow (R/Y)–Ground
Red (R)–Ground
12 V (battery voltage)
8 7 6 3 2 1 37 36 35 34

50 49 3. Connect the ETV relay coupler a.

ETV relay continuity

1. Remove the ETV relay. See “Electrical
box” (7-5).

2. Connect the special service tool a.

3. Connect the tester leads to the

connectors a and b or to the
connectors a and c.

7-21
 Control system
4. Connect the positive battery lead to the Cam position sensor
connectors d or e. Cam position sensor input voltage
1. Disconnect the cam position sensor cou-
5. Connect the negative battery lead to the

1
pler a.
connector f.
2. Supply power to the ECM, and then
6. Check the continuity between connectors measure the input voltage at the cam
a and b or connectors a and c. position sensor coupler terminals (wiring
Replace the ETV relay if out of

2
harness end). Check the wiring harness
specification. if out of specification. Measure the cam
position sensor output voltage if within
specification.

4
2

5
3

6
B/O O 3
a 4
a
f e d Cam position sensor input voltage:
Orange (O)–Black/Orange (B/O)
4.75–5.25 V
5
W/R
W/Y
W/B

1 3. Connect the cam position sensor coupler

2 a.
3
4
5
6
Cam position sensor output voltage
1. Remove the cam position sensor. See 6
W/G
W/L
W/Br

“Cylinder head cover” (5-29), and then

connect the special service tool a to the
cam position sensor and the wiring har-
a b c ness.

2. Supply power to the ECM, and then

measure the output voltage when a
7
Test harness (6 pins) a: screwdriver is passed under the cam
YB-06872/90890-06849

ETV relay continuity:

position sensor in direction a. Replace
the cam position sensor if out of
specification.
8
Battery lead Terminal
d or e–f a–b or c
Disconnected
Connected
No continuity
Continuity 9
7. Install the ETV relay. See “Electrical box”
(7-5).

7-22
A
 ELEC
Electrical system

a
B/O L/B

G/O BW

B/O a

Slant detection switch input voltage:

Blue/Black (L/B)–Black/Orange (B/O)
4.75–5.25 V
a
3. Connect the slant detection switch
coupler a.
a
Slant detection switch continuity
b c d
1. Remove the slant detection switch.

Test harness (3 pins) a: 2. Check the slant detection switch for

YB-06877/90890-06877 continuity. Replace if out of specification.
A
Cam position sensor output voltage:
Green/Orange (G/O)– UP
Black/Orange (B/O)
Position Voltage (V)
b, d More than 4.8 B
c Less than 0.8 L/B B/O B

3. Disconnect the special service tool a,

UP

UP

and then install the cam position sensor.

See “Cylinder head cover” (5-29).

Slant detection switch

Slant detection switch input voltage
1. Disconnect the slant detection switch B
UP
coupler a.

2. Supply power to the ECM, and then

measure the input voltage at the slant Slant detection switch continuity:
detection switch coupler (wiring harness Blue/Black (L/B)–Black/
end). Check the wiring harness if out of Position
Orange (B/O)
specification.
Normal
No continuity
position A
Overturned B Continuity

7-23
 Control system

Steering sensor operation:

TIP:
Make sure to turn the switch over to both the Handlebar YDIS display
left and right. Not pulled OFF

3. Install the slant detection switch. See

“Electrical box” (7-5).
Pulled ON

6. Use the same procedure to check that

the steering sensor operates properly
1
when the handlebar is turned to both the
Steering sensor
Steering sensor operation
1. Connect the YDIS to display “Steering
sensor.”
left and right. Measure the steering
sensor input voltage if the steering
sensor does not operate.
2
Steering sensor input voltage
2. Turn the handlebar all the way to the left
or right.

3. Install a plastic tie a loosely around the

center a of the handlebar grip, and then
1. Disconnect the steering sensor coupler
a.

2. Supply power to the ECM, and then

3
measure the input voltage at the steering
hook a spring gauge b onto the plastic
tie a.

4. Hold the spring gauge b at a 90° angle

from the handlebar grip, and then pull the
sensor coupler terminals (wiring harness
end). Replace the steering sensor if
within specification. Check the wiring
harness if out of specification.
4
spring gauge in direction b using a force
of approximately 100 N (10 kgf, 22 lbf).

TIP:
At this time, the button c in the steering sen-
B/O O/R
5
a
sor c will be pushed in direction d.

5. Check that the following is displayed in

the “Engine monitor” window of the YDIS.
6
Steering sensor input voltage (reference
c

d
c
data):
Orange/Red (O/R)–Black/Orange (B/O)
4.75–5.25 V
7
b 3. Connect the steering sensor coupler a.

b
a
ECM
ECM input voltage
1. Disconnect the ECM coupler a.
8
a
9
7-24
A
 ELEC
Electrical system

a
a b

2. Supply power to the ECM, and then a b

measure the input voltage between the
ECM coupler terminal (wiring harness
end) and ground. Check the ECM circuit 67 62
continuity if out of specification. 70
46

c b
ECM circuit continuity:
Terminal T–Ground
Terminal 0–Ground
Continuity
Terminal ^–Ground
Terminal (–Ground

2. Connect the ECM couplers a and b.

a
Earth plate
27
1. Remove the earth plate.

2. Check the continuity between each

terminal a and the housing b. Replace
the earth plate if there is no continuity.

ECM input voltage: b

Terminal A–Ground
12 V (battery voltage)

TIP:
Do not disconnect the coupler b or coupler
c when measuring the ECM input voltage. a

3. Connect the ECM coupler a.

3. Install the earth plate. See “Cylinder
ECM circuit continuity block and electrical part” (5-64).
1. Disconnect the ECM couplers a and b,
and then check the continuity between Fuel system
the ECM coupler terminals (wiring har- Fuel injector
ness end) and ground. Replace the wir- Fuel injector operation sound
ing harness if there is no continuity. 1. Connect the YDIS.

7-25
 Control system / Fuel system
2. Using the “Stationary test” of the YDIS, 3. Install the fuel injectors. See “Fuel rail
listen for the fuel injector operation and injector installation” (4-7).
sound. Measure the fuel injector input
Fuel pump module

1
voltage if it does not sound.
Fuel pump module operation sound
Fuel injector input voltage 1. Connect the YDIS.
1. Disconnect the fuel injector couplers a.
2. Using the “Stationary test” of the YDIS,
2. Supply power to the ECM, and then listen for the fuel pump module operation
measure the input voltage between the
fuel injector coupler terminals (wiring
harness end) and ground. Measure the
fuel injector resistance if within
sound. Measure the fuel pump module
input voltage if it does not sound.

Fuel pump module input voltage

2
specification. Check the wiring harness if 1. Disconnect the fuel pump module cou-
out of specification.

a
pler a.

2. Supply power to the ECM, and then

measure the input voltage at the fuel
3
R/Y
pump module coupler terminals (wiring
harness end). Replace the fuel pump
module if within specification. Check the
wiring harness if out of specification.
4
Fuel injector input voltage:
Red/Yellow (R/Y)–Ground
a
L B
5
12 V (battery voltage)

3. Connect the fuel injector couplers a.

Fuel injector resistance

1. Remove the fuel injectors. See “Throttle
6
Fuel pump module input voltage:
body assy. and fuel injector” (4-6). Blue (L)–Black (B)

2. Measure the fuel injector resistance.

Replace the fuel injector if out of
specification. TIP:
12 V (battery voltage)
7
After the unlock button is pushed, voltage will

8
only be applied to the fuel pump module for 3
seconds.

3. Connect the fuel pump module coupler

a.

Fuel sender resistance

1. Remove the fuel pump module assy. See
“Fuel tank and fuel pump module assy.”
9
(4-9).
Fuel injector resistance at 20 °C (68 °F)
(reference data): 11.5–12.5 Ω

7-26
A
 ELEC
Electrical system
2. Measure the fuel sender resistance.
Engine start switch continuity:
Replace the fuel sender if out of
Engine
specifications. Red (R)–
Clip a start switch
Brown (Br)
b
B B Free No continuity
R Installed A
Pushed Continuity
Removed Free No continuity
B Pushed No continuity

3. Connect the left handlebar switch coupler

A
(white coupler). See “Handlebar and
handlebar switch assy.” (8-2).
Fuel sender resistance at 20 °C (68 °F) Engine stop switch continuity
(reference data): 1. Disconnect the left handlebar switch cou-
Float position Red (R)–Black (B) pler (black coupler). See “Handlebar and
Lower position A 133.5–136.5 Ω handlebar switch assy.” (8-2).
Upper position B 5.0–7.0 Ω
2. Check the engine stop switch for
3. Install the fuel pump module assy. See continuity. Replace the left handlebar
“Fuel pump module installation” (4-12). switch assy. if out of specification.

Starting system a
Left handlebar switch assy. W B
A
Engine start switch continuity
1. Disconnect the left handlebar switch cou-
b
pler (white coupler). See “Handlebar and
handlebar switch assy.” (8-2).
B
b
2. Check the engine start switch for
continuity. Replace the left handlebar
switch assy. if out of specification. Engine stop switch continuity:
b Engine
White (W)–
Clip a stop switch
R Br Black (B)
A b
Free No continuity
a Installed A
Pushed Continuity
b
Removed Free Continuity
B Pushed Continuity
B
3. Connect the left handlebar switch coupler
(black coupler). See “Handlebar and
handlebar switch assy.” (8-2).

7-27
 Fuel system / Starting system
Main and fuel pump relay
Main and fuel pump relay input voltage
1. Disconnect the main and fuel pump relay

1
coupler a, and then measure the input
voltage between the main and fuel pump 1 2 3 4
relay coupler terminals c or e (wring
5 6 7 8
harness end) and ground.

cR
2
Re
12345678 a 3
e R B c
Main and fuel pump relay input voltage:

4
Red (R)–Ground Y L
12 V (battery voltage) P Br
d b
W O
2. Connect the main and fuel pump relay
f a
coupler a.

Main relay continuity

1. Remove the main and fuel pump relay.
See “Electrical box” (7-5).
Test harness (8 pins) a:
YB-06879/90890-06879 5
Main relay continuity:
2. Connect the special service tool a.

6
Battery lead Terminal
d or e–f a–b or c
3. Connect the tester leads to the
Disconnected No continuity
connectors a and b or to the
Connected Continuity
connectors a and c.

7
7. Install the main and fuel pump relay. See
4. Connect the positive battery lead to the
“Electrical box” (7-5).
connector d or e.
Fuel pump relay continuity
5. Connect the negative battery lead to the
1. Remove the main and fuel pump relay.
connector f.
See “Electrical box” (7-5).
6. Check the continuity between the
connectors a and b or the connectors
a and c. Replace the main and fuel
2. Connect the special service tool a.

3. Connect the tester leads to the main and

8
pump relay if out of specification. fuel pump relay terminals a and b.
NOTICE: Do not reverse the battery
leads. Otherwise, the main and fuel
pump relay may be seriously
damaged.
9
7-28
A
 ELEC
Electrical system
4. Connect the positive battery lead to the
Starter relay input voltage:
connector c.
Red (R)–Ground
12 V (battery voltage)
5. Connect the negative battery lead to the
connector d.
TIP:
6. Check the continuity between the The positive battery cable is marked with
connectors a and b. Replace the main gray tape a.
and fuel pump relay if out of specification.
3. Install the starter relay. See “Electrical
box” (7-5).

Starter relay continuity

1. Remove the starter relay. See “Electrical
a box” (7-5).
d 12345678
b
2. Connect the tester leads between the
R B
a starter relay terminals a and b.
Y L
P Br 3. Connect the positive battery lead to the
W O c terminal c, and the negative battery lead
to the terminal d.

4. Check the continuity between the starter

Fuel pump relay continuity: relay terminals a and b. Replace the
Battery lead c–d Terminal a–b starter relay if out of specification.
Disconnected No continuity
Connected Continuity
a b
7. Install the main and fuel pump relay. See
“Electrical box” (7-5).

Starter relay Br B
Starter relay input voltage
1. Remove the starter relay. See “Electrical c d
box” (7-5).

2. Slide the boot away from the starter relay Starter relay continuity:
terminal a, and then measure the input Battery lead c–d Terminal a–b
voltage between the starter relay Disconnected No continuity
terminal a and ground. Connected Continuity

5. Install the starter relay. See “Electrical

aR box” (7-5).
a

7-29
 Starting system / Starter motor

Starter motor

7
9 9 N·m (0.9 kgf·m, 6.6 ft·lb)

10
1
2
7 N·m (0.7 kgf·m, 5.2 ft·lb) 3

13
3
2
5
4
5
1
6 M

12 11
8

M
4

6
No. Part name Q’ty Remarks
1
2
3
Bolt
Rear cover
Packing
2
1
1
M6

39
120 mm
7
4 Front cover assy. 1
5 Packing 1 39
6
7
8
Plate
Starter motor yoke
Armature
1
1
1
8
9 Brush holder assy. 1

9
10 O-ring 1 39
11 Circlip 1
12 Drive gear 1
13 O-ring 1 39

7-30
A
 ELEC
Electrical system
Starter motor operation
1. Remove the starter motor. See “Starter
motor and wiring harness assy. removal”
(5-20).

2. Hold the starter motor in a vise using

aluminum plates on both sides.

3. Connect the positive battery cable a to

the starter motor terminal bolt a.
Commutator diameter
4. Connect the negative battery cable b to
1. Measure the commutator diameter a.
the starter motor body b, and then check
Replace the armature if below specifica-
the starter motor operation. WARNING!
tion.
Do not touch the drive gear c.

a c
a

b a

Commutator diameter a:
TIP: 27–28 mm (1.06–1.10 in)
• Check the starter motor operation for a few
seconds. Commutator undercut
• If the starter motor is disassembled, make 1. Measure the commutator undercut a.
sure to check the operation again after Replace the armature if below specifica-
assembling it. tion.

5. Disconnect the negative battery cable,

a
and then the positive battery cable from
the battery terminals.

6. Install the starter motor. See “Starter

motor and wiring harness assy.
installation” (5-21).

Armature
Armature appearance Commutator undercut a (reference data):
1. Check the commutator. Clean using 600- 0.2–0.7 mm (0.008–0.028 in)
grit sandpaper and compressed air if
dirty. Armature continuity
1. Check the armature for continuity.
Replace if out of specification.

7-31
 Starter motor / Remote control system

a c

1
b

a b c

Armature continuity:
Commutator
a
c
2
Continuity
segments a
Segment a–
Armature core b
Segment a–
Armature core c
No continuity

No continuity
d

e
b 3
Brush holder
Brush length
1. Measure the brush length a. Replace
the brush holder assy. if below specifica-
Brush holder assy. continuity:
Brush a–Brush b
Brush c–Brush d
Brush c–Terminal e
Continuity
4
tion. Brush d–Terminal e
For all brush and terminal
combinations not listed No continuity
above.
5
Remote control system
a
Remote control transmitter
Remote control transmitter operation
1. Push the unlock button a. The buzzer
sounds twice, and then check that the
6
“SECURITY” indicator light b comes on.
Brush length a:
5.0–12.5 mm (0.20–0.49 in)

Brush holder assy. continuity

2. Push the unlock button a for more than
4 seconds. The buzzer sounds 3 times,
and then check that the “L-MODE”
7
1. Check the brush holder assy. for continu- indicator light c comes on.
ity. Replace if out of specification.
3. Push the lock button d. The buzzer
sounds once, and then check that the
“SECURITY” indicator light b goes off.
8
9
7-32
A
 ELEC
Electrical system
2. Remove the battery (CR2016) c.
NOTICE: Do not touch the battery
d a
directly using your hands. Use a pair
of non-conductive tweezers to replace
the battery.

3. Measure the battery voltage. Replace the

remote control transmitter battery if
below specification.

c
b c

Remote control transmitter battery voltage:

Yamaha Security 3V
Number of beeps
System mode
1 beep Lock TIP:
Unlock Refer to local hazardous waste regulations
2 beeps
(normal mode) when disposing of transmitter batteries.
L-MODE
3 beeps
(low-rpm mode) 4. Install the battery (CR2016) c and
transmitter cover b.
TIP:
While the engine is running, input from the c
remote control transmitter is not received. b

Remote control transmitter battery volt-

age
d
1. Loosen the transmitter screws a in the
order a, b, and so on, and then remove
the transmitter cover b. NOTICE: Do
not touch the internal parts except the
battery. TIP:
d f Install the battery (CR2016) c so that the
positive side d is facing down.
b a
5. Tighten the screws a to the specified
a b torque in the order a, b, and so on.

e c

7-33
 Remote control system

c a a
L/Y
b a

f e
1
b d

Transmitter cover screw a:

0.1 N·m (0.01 kgf·m, 0.07 ft·lb)
Remote control receiver output voltage
(reference data):
2
Blue/Yellow (L/Y)–Ground

3
Remote control receiver 11.0–12.0 V
Remote control receiver input voltage
1. Disconnect the remote control receiver 3. Connect the multifunction meter coupler
coupler a, and then measure the input a.
voltage at the remote control receiver
Transmitter registration

4
coupler terminals (wiring harness end).
• Each remote control transmitter a has a
B unique ID code.
• To add or re-register the ID code of a
remote control transmitter to the remote
control receiver b, connect the entry box

a
R
c.

1. Connect the entry box c to the 2-pin

5
communication coupler a.

Remote control receiver input voltage:

Red (R)–Black (B)
12 V (battery voltage) a
6
7
2. Connect the remote control receiver
coupler a.

Remote control receiver output voltage

1. Disconnect the multifunction meter cou-
Gy Gy
pler a from the remote control receiver.

8
a B B

2. Supply power to the ECM, and then b a c

measure the remote control receiver
output voltage at the multifunction meter 2. Push the lock button b or unlock button
coupler terminal (wiring harness end)

9
c to transmit the ID code from the
and ground. Replace the remote control remote control transmitter to be
receiver if out of specification. registered.

7-34
A
 ELEC
Electrical system

Indication system
b c Multifunction meter
Multifunction meter appearance
1. Check the multifunction meter external
appearance. Replace the multifunction
meter if there is cracked meter housing,
fogged meter, or water intrusion.

Multifunction meter operation

1. Supply power to the ECM, and then
check that all indicator lights a and dis-
TIP:
• At this time, the system enters the registra- play elements b on the multifunction
tion mode to register the first code. All exist- meter come on. Replace the multifunc-
ing ID codes will be deleted from the tion meter if it does not operate properly.
remote control receiver.
• The “SECURITY” indicator light d blinks a b a a
when the registration of the ID code has
been completed. (If the registration could
not be completed, the “SECURITY” indica-
tor light comes on. Re-transmit the ID
code.)

3. After checking that the registration of the

ID code has been completed using the
“SECURITY” indicator light d, transmit TIP:
the next ID code. When the multifunction meter is activated, all
displays come on for 2 seconds, and then the
d multifunction meter starts to operate nor-
mally.

2. Check the multifunction meter display.

Replace the multifunction meter if there
is intermittent or missing segment c.

TIP:
• Up to 5 remote control transmitters can be
registered in any sequence, regardless of
whether they are original equipment or
additional transmitters.
c
• The same ID code cannot be registered
twice in the remote control receiver.
Multifunction meter input voltage
4. After ID code registration has been 1. Disconnect the multifunction meter cou-
completed, disconnect the entry box to pler a.
exit the registration mode.

7-35
 Remote control system / Indication system
2. Supply power to the ECM, and then Speed sensor output voltage
measure the input voltage at the 1. Disconnect the speed sensor coupler a.
multifunction meter coupler terminals

1
(wiring harness end). Replace the wiring
harness if out of specification. Replace
the multifunction meter if within
specification and there is no display on
the multifunction meter.

a 2
R/Y 2. Connect the positive battery lead to the

a B
terminal a, and the negative battery lead
to the terminal b.

3. Connect the tester leads between the

3
terminal c and the terminal b.
Multifunction meter input voltage:
Red/Yellow (R/Y)–Black (B)
12 V (battery voltage)
4. Rotate the paddle wheel b manually and
measure the output voltage between the
terminal c and the terminal b. Replace
4
3. Connect the multifunction meter coupler if out of specification.
a.

Speed sensor
Speed sensor appearance
b B/Yb
aR/Y
5
1. Remove the speed sensor. See “Intake cY
a

6
grate and ride plate” (6-1).

2. Check the speed sensor paddle wheel

a. Replace the speed sensor if there are
cracks, damage, or rough movement.
Speed sensor output voltage (dependant
on the paddle wheel position):
Yellow (Y)–Black/Yellow (B/Y)
Less than 400 mV/More than 11.6 V
7
5. Connect the speed sensor coupler a.

a
Fuel level meter display and fuel
level warning indicator
8
1. Remove the fuel pump module assy. See

9
“Fuel pump module removal” (4-11).

2. Connect the fuel sender coupler a.

3. Install the speed sensor. See “Intake 3. Lift the float to the upper position A .

A
grate and ride plate” (6-1).

7-36
 ELEC
Electrical system
2. Supply power to the ECM, and then
check that the “WARNING” indicator light
A b and the check engine warning
indicator c begin to blink.

b
B
a c

4. Supply power to the ECM, and then

check that all fuel level segments come
on. Replace the multifunction meter if
any one of the segments does not come
on. 3. If the light and indicator do not blink,
check the “Diagnosis record” of the YDIS.
5. Lower the float to the lowest position B , If a diagnosis record is available and the
and then check that the fuel level warning light and indicator do not blink, replace
indicator b, the lowest 2 fuel level the multifunction meter.
segments c, and the “WARNING”
indicator light d blink. If the indicator, 4. Connect the engine temperature sensor
segments, and the light do not blink, coupler a.
replace the multifunction meter.
Diagnostic display
1. Create a condition so that a diagnostic
code is recorded.
d
c
b 2. With the engine running, push the select
button a for approximately 8 seconds
and check that the diagnostic code b is
indicated.

a
b
6. Install the fuel pump module assy. See
“Fuel pump module installation” (4-12).

Check engine warning indicator

1. Disconnect the engine temperature sen-
sor coupler a.

a
3. If the diagnostic code is not indicated,
check the “Diagnosis record” of the YDIS.
If a diagnosis record is available and the
B/O B/Y diagnostic code is not indicated, replace
the multifunction meter.

Oil pressure warning indicator

1. Disconnect the oil pressure switch cou-
pler a, and then ground the terminal.

7-37
 Indication system

a
a
P/W a
B/O P
1
2. Start the engine, and then increase the
engine speed to 4500 r/min or more.
2. Start the engine and operate it at trolling
speed for about 2 minutes.
2
3
3. Check that the “WARNING” indicator light 3. Check that the “WARNING” indicator light
b and the oil pressure warning indicator b and the engine overheat warning
c blink, and the buzzer sounds indicator c blink, and then come on, and
intermittently. the buzzer begins to sound intermittently,
and then it sounds continuously.

c
b
b
4
c

5
4. If the light and indicator do not blink,
check the “Diagnosis record” of the YDIS.
If a diagnosis record is available and the
light and indicator do not blink, replace
the multifunction meter.
4. If the light and indicator do not blink,
check the “Diagnosis record” of the YDIS.
If a diagnosis record is available and the
light and indicator do not blink, replace
6
the multifunction meter.
5. Connect the oil pressure switch coupler
a.

Engine overheat warning indicator

5. Connect the thermoswitch coupler a.

Buzzer
7
1. Disconnect the thermoswitch coupler a, Buzzer input voltage

8
and then connect the test lead a to the 1. Disconnect the buzzer coupler a.
thermoswitch coupler terminals (wiring
harness end). 2. Supply power to the ECM, and then
measure the input voltage at the buzzer
coupler terminals (wiring harness end).

9
Check the wiring harness if out of
specification.

7-38
A
 ELEC
Electrical system

L/R B/L

Buzzer input voltage (reference data):

Blue/Red (L/R)–Black/Blue (B/L)
11.0–12.0 V

3. Connect the buzzer coupler a.

Buzzer operation
1. Remove the buzzer. See “Steering mas-
ter” (8-13).

2. Connect the positive battery lead to the

terminal a and the negative battery lead
to the terminal b.

3. Check that the buzzer sounds. Replace

the buzzer if it does not sound.

Bb aR

4. Install the buzzer. See “Steering master”

(8-13).

7-39
 Indication system

— MEMO —

1
2
3
4
5
6
7
8
9
7-40
A
HULL
HOOD
Hull and hood 8

Steering pad and handlebar cover .................................. 8-1

Handlebar and handlebar switch assy. ........................... 8-2

Left handlebar switch assy. and throttle lever assy. ..... 8-3
Throttle cable removal ............................................................... 8-4
Handlebar check ....................................................................... 8-4
Left handlebar switch assy. check ............................................. 8-4
Handlebar assy. installation ...................................................... 8-4
Steering pad and handlebar cover installation .......................... 8-6

Front hood ......................................................................... 8-8

Multifunction meter and engine hatch cover ................ 8-10

Steering master assy. ..................................................... 8-12

Steering master ............................................................... 8-13

Steering shaft check ................................................................ 8-14
Steering arm assy. installation ................................................ 8-14

Steering cable and speed sensor lead .......................... 8-15

Steering cable installation (steering master end) .................... 8-17
Steering cable installation (jet pump end) ............................... 8-17
Shift cable installation (shift lever end) .................................... 8-17

Seat and handgrip ........................................................... 8-19

Ventilation hose and water separator ........................... 8-20

Cooling water pilot outlet installation ....................................... 8-22
Ventilation hose installation ..................................................... 8-22

Exhaust system ............................................................... 8-23

Exhaust system installation ..................................................... 8-25

Rear section ..................................................................... 8-26

Spout installation ..................................................................... 8-27
Reboarding step assy. installation (VXR) ................................ 8-27
Deck and hull ................................................................... 8-28

1
2
3
4
5
6
7
8
9
A
HULL
HOOD Hull and hood

Steering pad and handlebar cover

1 N·m (0.1 kgf·m, 0.7 ft·lb)

4 6

1 N·m (0.1 kgf·m, 0.7 ft·lb)

4 N·m (0.4 kgf·m, 3.0 ft·lb)

No. Part name Q’ty Remarks

1 Tapping screw 2 ø4 10 mm
2 Tapping screw 4 ø5 16 mm
3 Upper handlebar cover 1
4 Steering pad 1
5 Screw 4 M6 14 mm
6 Lower handlebar cover 1

8-1
 Steering pad and handlebar cover / Handlebar and handlebar switch assy.

Handlebar and handlebar switch assy.

1 1 N·m (0.1 kgf·m, 0.7 ft·lb)

1
2
3 8 3 N·m (0.3 kgf·m, 2.2 ft·lb)
9

20 N·m (2.0 kgf·m, 14.8 ft·lb)

10 9

5 12 7 2
10

11
11
4 3
2
3
4
a 7

6 1

13
3 N·m (0.3 kgf·m, 2.2 ft·lb)
5
14

6
7 N·m (0.7 kgf·m, 5.2 ft·lb)

No. Part name Q’ty Remarks

1
2
3
Bolt
Grip end
Handlebar grip
2
2
2
M5 35 mm
7
4 Corrugated tube 1
5 Throttle cable 1
6
7
8
Screw
Left handlebar switch assy.
Bolt
2
1
2
M5

M5
25 mm

25 mm
8
9 Throttle lever assy. 1

9
10 Bolt 4 M8 45 mm
11 Handlebar holder 2 a Punch mark
12 Handlebar 1
13 Grommet 1
14 Plastic tie 1

8-2
A
HULL
HOOD Hull and hood

Left handlebar switch assy. and throttle lever assy.

9
1
8
4

10 8 2
7
11

No. Part name Q’ty Remarks

1 Left handlebar switch assy. 1
2 Engine shut-off cord 1
3 Stop button 1
4 Start button 1
5 Screw 2 M3 7 mm
6 Throttle lever assy. 1
7 E-clip 1
8 Washer 2
9 Shaft 1
10 Lever 1
11 Spring 1

8-3
 Left handlebar switch assy. and throttle lever assy.
Throttle cable removal
c a
1. Remove the corrugated tube a. a
b

a
b
1
TIP:
Face the chamfered end b of the grommet
2
2. Remove the throttle cable b. NOTICE: b down, with the opening a facing forward.
Make sure to remove the throttle cable
seal a.
2. Install the grommet b into the steering
master d.
3
b
d

b
b
4
d
a

Handlebar check
1. Check the handlebar. Replace if bent.
5
TIP:
Left handlebar switch assy. check
1. Check the left handlebar switch assy.
continuity. See “Left handlebar switch
assy.” (7-27).
Push the grommet b into the steering master
d until it is installed securely.

3. Install the handlebar e and upper

6
handlebar holders f, and then tighten
Handlebar assy. installation the handlebar holder bolts g to the
specified torque.
7
After installing the handlebar assy., make
sure that the throttle cable and left han- e
dlebar switch lead are not pulled when the
handlebar is turned to the right and left.
g

f c
8
1. Install the left handlebar switch lead a
into the opening a in the grommet b, d
and then install the throttle cable c into
the opening a.
a
9
8-4
A
HULL
HOOD Hull and hood

f 5. Install the left handlebar switch assy. j,

and then tighten the left handlebar switch
d d
f screws k to the specified torque.

e
j

k
c
c e

Handlebar holder bolt g: h

k
20 N·m (2.0 kgf·m, 14.8 ft·lb) j

TIP: Left handlebar switch screw k:

• Do not route the left handlebar switch lead 3 N·m (0.3 kgf·m, 2.2 ft·lb)
a and throttle cable c between the han-
dlebar e and the steering master d. TIP:
• The upper handlebar holder f should be Align the protrusion h on the handlebar
installed with the punch mark e facing switch assy. with the handlebar hole k.
down.
• Tighten the handlebar holder bolts g so 6. Install the throttle cable end into the
that there is clearance between the steer- throttle lever.
ing master d and the upper handlebar
holders f at both ends of the upper han- 7. Fit the throttle cable seal m into the
dlebar holders. groove in the bracket.
• Make sure that clearance c is narrower
than clearance d.

4. Install the throttle lever assy. h, and then

tighten the throttle lever assy. bolts i to
the specified torque.
i
f m
g
8. Pull the throttle cable c in the direction
of the arrow shown, and then fit the end
of the throttle cable seal m around the
h inner cable.
h

Throttle lever assy. bolt i:

3 N·m (0.3 kgf·m, 2.2 ft·lb)

TIP:
Align the protrusion f on the throttle lever
c
assy. with the handlebar hole g.
m

8-5
 Left handlebar switch assy. and throttle lever assy.
9. Adjust the throttle lever free play n. See
Grip end bolt q:
“Throttle lever free play check” (3-2).
1 N·m (0.1 kgf·m, 0.7 ft·lb)
10. Tighten the locknut l, and then slide the
rubber cover m to its original position.
Steering pad and handlebar cover
installation
1
After installing the handlebar upper cover,
make sure that the throttle cable is not
pulled when the handlebar is turned to the
right and left.
2
l m 1. Install the lower handlebar cover a, and

3
n
then tighten the lower handlebar cover
Throttle lever free play n: screws b to the specified torque.
4–7 mm (0.16–0.28 in)
a
11. Install the corrugated tube n onto the
throttle cable c, and then route the
throttle cable c and left handlebar switch
lead a.
4
c
n Lower handlebar cover screw b:
b
5
4 N·m (0.4 kgf·m, 3.0 ft·lb)

a
2. Push the steering pad c into the upper
handlebar cover d until it is installed
securely.
6
12. Apply instant adhesive to the handlebars
p and the inner surface of the handlebar

7
c
grips o. d
13. Install the handlebar grips o.

14. Install the grip ends p, and then tighten

the grip end bolts q to the specified
torque. 8
p TIP:

q
p
If the steering pad c is not installed securely,
the upper handlebar cover d cannot be
installed properly onto the lower handlebar
cover.
9
o

8-6
A
HULL
HOOD Hull and hood
3. Install the upper handlebar cover d, and
then tighten the upper handlebar cover
screws e and f to the specified torque.

d
a

e b

Upper handlebar cover screw e

(ø5 16 mm) and f (ø4 10 mm):
1 N·m (0.1 kgf·m, 0.7 ft·lb)

TIP:
Align the portions a on the upper handlebar
cover with the portions b on the lower han-
dlebar cover.

8-7
 Left handlebar switch assy. and throttle lever assy. / Front hood

Front hood
7 N·m (0.7 kgf·m, 5.2 ft·lb)
5 2 1 4 N·m (0.4 kgf·m, 3.0 ft·lb)
6 1 2
1
7

14
2
8 13
4 3

3
2 N·m (0.2 kgf·m, 1.5 ft·lb)
9
10
9
11

28 26
7 N·m (0.7 kgf·m, 5.2 ft·lb)

25
12 4
7 N·m (0.7 kgf·m, 5.2 ft·lb)
27
17

18
19 16
5
29
30
30

31
29
31
24 18
23
22 21
20
15
6
No. Part name Q’ty Remarks
1
2
3
Nut
Washer
Left mirror
4
4
1
7
4 Left mirror spacer 1
5 Right mirror 1
6
7
8
Right mirror spacer
Bolt
Hood lock assy.
1
2
1
M6 20 mm 8
9 Screw 13 M5 15 mm

9
10 Front hood 1
11 Ventilator 1
12 Bolt 4 M6 18 mm
13 Ventilator cover 1
14 Packing 1 39
15
16
Nut
Washer
2
2

8-8
A
HULL
HOOD Hull and hood

7 N·m (0.7 kgf·m, 5.2 ft·lb)

5 2 1 4 N·m (0.4 kgf·m, 3.0 ft·lb)
6 1 2

14
8 13
4 3
2 N·m (0.2 kgf·m, 1.5 ft·lb)
9
10
9
11

7 N·m (0.7 kgf·m, 5.2 ft·lb)

12
28 26 25
7 N·m (0.7 kgf·m, 5.2 ft·lb)
27
17

18 16
19
29
30
30 29 24 18
31 15
23 20
31 22 21

No. Part name Q’ty Remarks

17 Bolt 2 M6 95 mm
18 Pin 2
19 Roller 1
20 Hinge 1
21 Roller 1
22 Spring 1
23 Bracket 1
24 Hinge assy. 1
25 Service lid 1
26 Rivet 5
27 Band 1
28 Fire extinguisher box 1
29 Mat 2 39
30 Rivet 2
31 Hook 2

8-9
 Front hood / Multifunction meter and engine hatch cover

Multifunction meter and engine hatch cover

4 N·m (0.4 kgf·m, 3.0 ft·lb) 3 6 5 N·m (0.5 kgf·m, 3.7 ft·lb)
1

9 10
5

4
15
13

14 2
1
7 4 5 N·m (0.5 kgf·m, 3.7 ft·lb)
20

16
9
2
23

3
20
11

17
18 19

4
10 8
21

17 N·m (1.7 kgf·m, 12.5 ft·lb)

22
27
25

26
26 24 11
12
5
12
29

30 28
12
5 N·m (0.5 kgf·m, 3.7 ft·lb)
11
5 N·m (0.5 kgf·m, 3.7 ft·lb)
6
No. Part name Q’ty Remarks
1
2
3
Beverage holder
Glove box
Lock
1
1
1
VXR
7
4 Hinge pin 2
5 Center console box lid 1
6
7
8
Packing
Screw
Multifunction meter
1
4
1
39
M5 15 mm 8
9 Damper 2

9
10 Screw 6 M6 18 mm
11 Bolt 8 M6 29 mm
12 Nut 6
13 Screw 2 M6 10 mm
14 Grip 1
15
16
Screw
Engine hatch cover
2
1
M6 18 mm

8-10
A
HULL
HOOD Hull and hood

4 N·m (0.4 kgf·m, 3.0 ft·lb) 3 6 5 N·m (0.5 kgf·m, 3.7 ft·lb)
1
5 13

4
10 15 14
9 2
7 4 5 N·m (0.5 kgf·m, 3.7 ft·lb)
20
9

16 23
20
11

17
18 19

10 8
21

17 N·m (1.7 kgf·m, 12.5 ft·lb)

22
27
25

26
24 11
26 12
12
29
12 11
30 28 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb)

No. Part name Q’ty Remarks

17 Spring nut 4
18 Lid lock hook 1
19 Nut 2
20 Rivet 4
21 Bow locker 1
22 Packing 1 39
23 Plug 1
24 Nut 2
25 APS 1
26 Rivet 3
27 Bracket 1
28 Remote control receiver 1
29 Bracket 1
30 Transmitter 1

8-11
 Multifunction meter and engine hatch cover / Steering master assy.

Steering master assy.

4 1
2
8

6
3

3
7

8 5
4
7 17 N·m (1.7 kgf·m, 12.5 ft·lb)

5
6
2

1
7 N·m (0.7 kgf·m, 5.2 ft·lb)

No. Part name Q’ty Remarks

1
2
3
Bolt
Cable stopper bracket
Bolt
1
1
4
M6

M8
18 mm

30 mm
7
4 Steering master assy. 1
5 Plastic tie 1
6
7
8
Grommet
Rivet
Cable stopper bracket
1
2
1
8
9
8-12
A
HULL
HOOD Hull and hood

Steering master

7 N·m (0.7 kgf·m, 5.2 ft·lb) 13

14
7 8

4 N·m (0.4 kgf·m, 3.0 ft·lb)

11

10
12

16 10

9
2 15

5
7 N·m (0.7 kgf·m, 5.2 ft·lb)

3
6
4
16 N·m (1.6 kgf·m, 11.8 ft·lb) 1
7 N·m (0.7 kgf·m, 5.2 ft·lb)

No. Part name Q’ty Remarks

1 Bolt 1 M8 50 mm
2 Nut 1
3 Steering arm assy. 1
4 Nut 1
5 Ball joint 1
6 Arm 1
7 Steering shaft assy. 1
8 Bushing 1
9 Plastic tie 2
10 Buzzer 1
11 Bolt 2 M5 16 mm
12 Bracket 1
13 Bolt 4 M6 25 mm
14 Steering sensor 1
15 Packing 1 39
16 Housing assy. 1

8-13
 Steering master
Steering shaft check
1. Check the steering shaft. Replace if
cracked or damaged. NOTICE: Do not

1
disassemble the board spring a. Oth-
erwise, the OTS will not function prop-
erly.

2
Steering arm assy. installation
a
3
1. Install the steering arm assy. a, nut b,
and plate c, and then tighten the steer-
ing arm assy. bolt d to the specified
torque.
4
a

b
5
d

a
b
6
c

Steering arm assy. bolt d:

16 N·m (1.6 kgf·m, 11.8 ft·lb)
c
7
TIP:
• Align the protrusion on the steering shaft
assy. with the slot on the arm.
8
• Align the tab a on the plate c with the por-
tion b on the steering arm assy. a.
• Bend a tab c along a flat side of the bolt.
9
8-14
A
HULL
HOOD Hull and hood

Steering cable and speed sensor lead

7 N·m (0.7 kgf·m, 5.2 ft·lb)

5 N·m (0.5 kgf·m, 3.7 ft·lb)

12 8
5 6 7
11 3 4
10 11 4 N·m (0.4 kgf·m, 3.0 ft·lb)
9
10 2
2 5 N·m (0.5 kgf·m, 3.7 ft·lb)

4 N·m (0.4 kgf·m, 3.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb)

7 N·m (0.7 kgf·m, 5.2 ft·lb) 14

15 16
7 N·m (0.7 kgf·m, 5.2 ft·lb)
13 14

19
17
19
21 21 21 21
18
20 20 20 20
21

6 N·m (0.6 kgf·m, 4.4 ft·lb)

No. Part name Q’ty Remarks

1 Shift cable joint 1
2 Shift cable 1
3 Nut 1
4 Packing 1 39
5 Packing 1 39
6 Plastic tie 1
7 Grommet 1
8 Nut 2
9 Shift cable bracket 1
10 Nut 2
11 Washer 2
12 Shift lever assy. 1
13 Steering cable joint 1
14 Steering cable 1
15 Nut 1
16 Packing 1 39

8-15
 Steering cable and speed sensor lead

7 N·m (0.7 kgf·m, 5.2 ft·lb)

12
5 N·m (0.5 kgf·m, 3.7 ft·lb)

8
1
5 6 7

10
11
11
3 4
4 N·m (0.4 kgf·m, 3.0 ft·lb)
2
9
10 2

3
2 5 N·m (0.5 kgf·m, 3.7 ft·lb)

4 N·m (0.4 kgf·m, 3.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb)

7 N·m (0.7 kgf·m, 5.2 ft·lb) 14

15 16
7 N·m (0.7 kgf·m, 5.2 ft·lb)
4
13 14

21
19

21 21
19

21
17
5
18
20 20 20 20
21

6 N·m (0.6 kgf·m, 4.4 ft·lb)

6
No. Part name Q’ty Remarks
17
18
19
Speed sensor
Nut
Plastic tie
1
1
5
7
20 Rivet 5
21 Holder 5

8
9
8-16
A
HULL
HOOD Hull and hood
Steering cable installation (steering
master end) a

If a cable becomes damaged, replace it.

Never attempt to repair a damaged cable.
a
1. Install the steering cable a and steering
cable stopper b, and then tighten the
cable stopper bolt c to the specified
Steering cable set length a (jet pump
torque.
end): 14.5 ± 1 mm (0.57 ± 0.04 in)

Steering cable locknut a:

7 N·m (0.7 kgf·m, 5.2 ft·lb)

a 2. Install the washer b and steering cable

a joint c, and then tighten the steering
cable joint c to the specified torque.
b
c 3. Install the washer d and steering cable
joint nut e, and then tighten the steering
Cable stopper bolt c: cable joint nut e to the specified torque.
7 N·m (0.7 kgf·m, 5.2 ft·lb)
c
TIP:
Install the steering cable stopper b into the
groove a in the outer cable. b

2. Connect the steering cable joint d to the

ball joint e. d
e

Steering cable joint c:

e 7 N·m (0.7 kgf·m, 5.2 ft·lb)
Steering cable joint nut e:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
d
Shift cable installation (shift lever
end)
1. Install the packing a and grommet b
onto the shift cable c.
3. Adjust the steering cable. See “Jet thrust
nozzle steering angle check” (3-10). 2. Install the shift cable holder d so that the
slot a in the holder fits into the groove b
Steering cable installation (jet pump in the outer cable.
end)
1. Adjust the steering cable set length a, 3. Install the plastic tie e.
and then tighten the steering cable lock-
nut a to the specified torque.

8-17
 Steering cable and speed sensor lead

d a
a
b

c
b
1
e

b
d

d 2
a

3
Installation distance c:
5–15 mm (0.20–0.59 in)
c

4
TIP:
Make sure that the edge of the packing a is
at the specified distance c from the edge of
the grommet b.
5
4. Install the shift cable assy. f, and then
tighten the shift cable bracket nuts g to
the specified torque.
6
g
g
7
f

Shift cable bracket nut g:

8
5 N·m (0.5 kgf·m, 3.7 ft·lb)

9
8-18
A
HULL
HOOD Hull and hood

Seat and handgrip

A

7
3
1 11
8
2 12

4 5

26 N·m (2.6 kgf·m, 19.2 ft·lb)

B
15
13
3 1
14 10
2 9

5 N·m (0.5 kgf·m, 3.7 ft·lb)

6 N·m (0.6 kgf·m, 4.4 ft·lb)

No. Part name Q’ty Remarks

1 Seat assy. 1 A VXS, B VXR
2 Bolt 2 M6 40 mm
3 Seat lock assy. 1
4 Packing 1 39
5 Nut 1
6 Washer 1
7 Projection 1
8 Washer 1
9 Nut 4
10 Washer 4
11 Bolt 4 M8 30 mm
12 Handgrip 1
13 Plastic tie 1
14 Battery breather hose 1
15 Nipple 1

8-19
 Seat and handgrip / Ventilation hose and water separator

Ventilation hose and water separator

1 15 N·m (1.5 kgf·m, 11.1 ft·lb)

2
16

17 25
2
1
7
1
25
16
5
18
26

8
16

5
2
8
11

8
3
6 10

4
9
25 12 15
26 14
16 13
19
16
24 25
4

3
22
23
21
5
4 20

3
16
25 4 N·m (0.4 kgf·m, 3.0 ft·lb)
6
No. Part name Q’ty Remarks
1
2
3
Rivet
Induction box
Plastic tie
6
2
2
7
4 Ventilation hose 2
5 Grommet 2
6
7
8
Nut
Seat holder
Plastic tie
2
1
3
8
9 Fuel tank breather hose 1 1

9
10 Fuel tank breather hose 2 1
11 Rivet 2
12 Water separator 1
13 Drain bolt 1
14 O-ring 1
15
16
Plate
Rivet
1
7

8-20
A
HULL
HOOD Hull and hood

1 15 N·m (1.5 kgf·m, 11.1 ft·lb)

16

17 25 1
2
2 7

18 16
25 5 26
16 8
5

11
8
8

6 10
9
25 12 15
26 14
16 13
19
16
24 25
4
22
23
21
3 4 20

16
25 4 N·m (0.4 kgf·m, 3.0 ft·lb)
3

No. Part name Q’ty Remarks

17 Ventilation socket 1
18 Ventilation pipe 1
19 Plastic tie 1
20 Nut 1
21 Seal 1 39
22 Clamp 1
23 Cooling water pilot outlet 1
24 Cooling water hose 1
25 Holder 5
26 Plastic tie 5

8-21
 Ventilation hose and water separator
Cooling water pilot outlet installation c

Do not reuse a seal, always replace it with

a new one.

1. Install a new seal a and the cooling

1
a
water pilot outlet b, and then tighten the
cooling water pilot outlet nut c to the
specified torque.
c
2

2
a

b
Installation distance a:
30–40 mm (1.18–1.57 in) 3
a
a TIP:
c
b

Cooling water pilot outlet nut c:

4 N·m (0.4 kgf·m, 3.0 ft·lb)
• Make sure to route the ventilation hose
(PORT) in front of the ventilation hose
(STBD).
• Make sure that the end of the ventilation
4
hose c is at the specified distance a from
TIP:
Align each protrusion a with the slit b.
the groove around the outside of the grom-
met a.
5
Ventilation hose installation
1. Install the grommets a.
a 6
a b
7
b
8
TIP:
Make sure that the grommet a is seated
properly in the hole in the inner hull b.
9
A
2. Install the ventilation hoses c.

8-22
HULL
HOOD Hull and hood

Exhaust system
3.7 N·m (0.37 kgf·m, 2.73 ft·lb) 3.7 N·m (0.37 kgf·m, 2.73 ft·lb)
3.7 N·m (0.37 kgf·m, 2.73 ft·lb)
21 22 11 14

10

12
13
21 22 23
23

12

20 18 16
5 N·m (0.5 kgf·m, 3.7 ft·lb)
19

9 15
5 9
3 7

8
8 7
7 2
1 17
8
9
7 6
9
9
7
24
7
4 8
8

No. Part name Q’ty Remarks

1 Negative battery cable 1
2 Positive battery cable 1
3 Clamp 1
4 Band 2
5 Battery 1
6 Battery case 1
7 Rivet 6
8 Hook 5
9 Pad 5 39
10 Clamp 1
11 Resonator 1
12 Clamp 2
13 Clamp 1
14 Rubber hose 1
15 Band 1
16 Water lock 1

8-23
 Exhaust system

3.7 N·m (0.37 kgf·m, 2.73 ft·lb) 3.7 N·m (0.37 kgf·m, 2.73 ft·lb)
3.7 N·m (0.37 kgf·m, 2.73 ft·lb)
21 22 11

10
14
1
21 22 23
23
12
13
2
12

20
5 N·m (0.5 kgf·m, 3.7 ft·lb)
19
18 16
3
8
9
5
3
9
15
7 4
8 7
7 2

7 6
1 17

9
8 5
9
9

4
7
8
7

8
24
6
No. Part name Q’ty Remarks
17
18
19
Hook
Water tank
Nut
1
1
6
7
20 Washer 6
21 Plate 1
22
23
24
Rubber hose
Exhaust valve
Flotation
1
1
1
8
9
8-24
A
HULL
HOOD Hull and hood
Exhaust system installation
1. Install the plate a onto the rubber hose TIP:
b. Align the mark b on the rubber hose b with
the mark c on the water tank e.
b
a 4. Install the water lock and rubber hose g,
and then tighten the rubber hose clamp
a h to the specified torque.

TIP:
Make sure to fit the protrusions a on the rub- e
ber hose b with the grooves in the plate a. h
d
2. Install the rubber hose b and a new Rubber hose clamp h:
exhaust valve c, and then tighten the 3.7 N·m (0.37 kgf·m, 2.7 ft·lb)
rubber hose nuts d to the specified
torque.
TIP:
Align the parting line d on the rubber hose
b g with the mark e on the water tank.

5. Install the resonator i, and then tighten

c the rubber hose clamp j to the specified
torque.

d i

Rubber hose nut d:

5 N·m (0.5 kgf·m, 3.7 ft·lb)

3. Install the water tank e, and then tighten

the rubber hose clamp f to the specified
torque. j
b f Rubber hose clamp j:
e 3.7 N·m (0.37 kgf·m, 2.7 ft·lb)

c
b

Rubber hose clamp f:

3.7 N·m (0.37 kgf·m, 2.7 ft·lb)

8-25
 Exhaust system / Rear section

Rear section
15 N·m (1.5 kgf·m, 11.1 ft·lb)

BOW 3
2
1
1
2

2
5
3
16

4
5 N·m (0.5 kgf·m, 3.7 ft·lb)
15

4 15 N·m (1.5 kgf·m, 11.1 ft·lb)

13
1

14
13 13
2 5
6
13 6 8
9
2
11
15 N·m (1.5 kgf·m, 11.1 ft·lb) 10 12 7
2 N·m (0.2 kgf·m, 1.5 ft·lb)

No. Part name Q’ty Remarks

1
2
3
Nut
Plate
Ski tow
6
6
1
7
4 Nut 1
5 Spout 1
6
7
8
Packing
Stern eye
Nut
2
2
4
39
8
9 Washer 4

9
10 Screw 4 M5 25 mm
11 Packing 2 39
12 Drain plug 2
13 Bolt 6 VXR, M8 46 mm
14 Reboarding step assy. 1 VXR
15
16
Packing
Bracket
2
2
39 VXR
VXR

8-26
A
HULL
HOOD Hull and hood
Spout installation
1. Install the spout a, and then tighten the
spout nut b to the specified torque.
c
2. Install the hose c, and then tighten the
spout hose clamp d to the specified
torque.

a b
a c
BOW
Reboarding step assy. bolt c:
b
15 N·m (1.5 kgf·m, 11.1 ft·lb)
d
c

Spout nut b: 5 N·m (0.5 kgf·m, 3.7 ft·lb)

Spout hose clamp d:
2 N·m (0.2 kgf·m, 1.5 ft·lb)

TIP:
Face the mark a toward the bow.

Reboarding step assy. installation

(VXR)
1. Fasten the bracket on both sides of the
reboarding step in the down position
using the plastic ties a so that they will
not return to the up position.

a a

2. Install the reboarding step assy. b, and

then tighten the reboarding step assy.
bolts c to the specified torque.

8-27
 Rear section / Deck and hull

Deck and hull

23 22
20

7
25
23

23
23
21
1
24 8 10
8

6
5
15
16
9
8
2
18

3
19
19

29
26

28
27
13
17
16
15
4
14

1
2 3

12
5
3

6
4
15 N·m (1.5 kgf·m, 11.1 ft·lb)
11

13 N·m (1.3 kgf·m, 9.6 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb)

No. Part name Q’ty Remarks

1
2
3
Bolt
Bow eye
Nut
2
1
4
M6 20 mm
7
4 Washer 4
5 Screw 2 M6 25 mm
6
7
8
Front protector
Bolt
Rivet
1
2
9
M6 25 mm 8
9 Rear protector 1

9
10 Rear protector 1
11 Inner gunwale 2
12 Rivet 30
13 Washer 30
14 Side gunwale 2
15
16
Bolt
Collar
10
10
M8 40 mm

8-28
A
HULL
HOOD Hull and hood

23 22
20
23
21
25 23
23
7
24 8 10
8

6 15
9
5 16
8
18
19
19

17
26 16
15
27
28 13
29
14

2 3
1 12
3
4
15 N·m (1.5 kgf·m, 11.1 ft·lb)
11

13 N·m (1.3 kgf·m, 9.6 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb)

No. Part name Q’ty Remarks

17 Sponson 1
18 Sponson 1
19 Bracket 2
20 Mat 1 39
21 Mat 1 39
22 Mat 1 39
23 Mat 4 39
24 Mat 1 39
25 Mat 1 39
26 Nut 2
27 Washer 2
28 Washer 2
29 Nut 2

8-29
TRBL
SHTG
Troubleshooting 9

YDIS .................................................................................... 9-1

Introduction ................................................................................ 9-1
Operating ................................................................................... 9-4 1
Engine unit troubleshooting ............................................ 9-5
Using the YDIS for engine unit troubleshooting ........................ 9-5
Engine unit troubleshooting (diagnostic code not detected) .... 9-12
2
3
4
5
6
7
8
9
A
 TRBL
SHTG Troubleshooting

YDIS
Introduction
Feature
The newly developed YDIS provides a quicker detection and analysis of the engine malfunctions.
By connecting your computer to the ECM of a watercraft using the communication cable, this soft-
ware can be used to display sensor data and the data stored in the ECM on a computer’s monitor.
If this software is run on Microsoft Windows® 2000, Windows XP, or Windows Vista, the information
can be displayed in colorful graphics. Also, the software can be operated using either a mouse or a
keyboard.
In addition, the data for the main functions (Diagnosis, Diagnosis record, Engine monitor, Data log-
ger, and Record of engine oil exchange) can be saved on a disk or printed out.

TIP:
Make sure to use YDIS (Ver. 1.33) with this model.

Function
Scan tool
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
diagnostic codes displayed are the same as those described in “Diagnostic code and checking
step” in this chapter.

9-1
 YDIS
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.

Items: VXS, VXR

Engine speed
Intake pressure (*1)
Ignition timing
Battery voltage (12–16)
Slant detection switch
Oil press switch (*10)
1
Throttle position sensor 1 (*2) Fuel injection duration Engine start switch
Throttle valve opening (0–90)
Throttle position sensor 2 (*3)
Accelerator position sensor 1
(*4)
Engine temperature
Intake temperature (*6)
Ex. manifold water
temperature (*7)
Steering sensor
Main relay (*11)
ETV relay
2
Accelerator position sensor 2 Engine stop lanyard switch Fuel pump relay (*11)
(*5)
Atmospheric pressure
(*1): Intake air pressure
(*8)
Overheat thermoswitch (*9)
(*7): Thermo sensor
3
(*2): TPS 1 (*8): Engine shut-off switch
(*3):
(*4):
(*5):
(*6):
TPS 2
APS 1
APS 2
Intake air temperature
(*9):
(*10):
(*11):
Thermoswitch
Oil pressure switch
Main and fuel pump relay 4
5
4. Stationary test: Operation tests can be performed with the engine off.

Items: VXS, VXR

Ignite ignition coil (#1–#4) Operate injector (#1–#4) Operate electric fuel pump
(*1)
(*1): Operate fuel pump module

5. Active test: With the engine running, each cylinder is dropped and the engine speed is
checked for changes to determine if the cylinder is malfunctioning. These tests can be per-
6
formed quickly.

6. Data logger: From the data stored in the ECM, no more than 2 items of 78 seconds of recorded
data are displayed on a graph. In addition, the operating time as compared to the engine speed
and the total operating time are displayed. This allows you to check the operating status of the
7
engine. You can also save the ECM record data in a file so that you can read and display the
graph later.

Items: VXS, VXR 8

Engine speed Throttle position sensor Intake pressure (*1)
Battery voltage (12–16) Engine temperature Oil press switch (*2)
(*1): Intake air pressure
(*2): Oil pressure switch 9
9-2
A
 TRBL
SHTG Troubleshooting
7. ECM record data graph: When a malfunction occurs in the ETV system or APS system, 4 sec-
onds (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 func-
tion.
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.

Items: VXS, VXR

Engine speed Target TPS voltage (*6) Low-RPM mode
Accelerator position sensor 1 Ref. TPS voltage (*7) Engine stop lanyard switch
(*1) (*11)
Accelerator position sensor 2 Ref. acc. pos. sensor voltage Main relay (*12)
(*2) (*8)
Steering sensor Target TPS voltage for ISC ETV relay
(*9)
Throttle position sensor 1 (*3) Engine stop mode Overheat thermoswitch (*13)
Throttle position sensor 2 (*4) Engine start mode Oil press switch (*14)
Intake pressure (*5) Engine stop mode with SW Warning
(*10)
Battery voltage OTS mode ETV limit
(*1): APS 1 (*8): Reference APS voltage
(*2): APS 2 This item shows the criterion out-
(*3): TPS 1 put voltage of the APS.
(*4): TPS 2 This value is used to detect the
(*5): Intake air pressure APS output voltage when the throt-
(*6): Target TPS voltage tle lever is opened.
This item shows the target output (*9): Target TPS voltage for Idle Speed
voltage of the TPS. Control
This value is the control voltage ECM controls the engine idle
that the ECM requires to set the speed by using the throttle valve
target opening angle of the throttle attached to the TPS.
valve. This target voltage is used by the
(*7): Reference TPS voltage ECM to achieve the target opening
This item shows the criterion out- angle of the throttle valve at the
put voltage of the TPS. engine idle speed.
This value is used to detect the (*10): Engine stop mode with switch
TPS output voltage during engine (*11): Engine shut-off switch
operation. (*12): Main and fuel pump relay
(*13): Thermoswitch
(*14): Oil pressure switch

TIP:
To display the data and graphs, see the YDIS (Ver. 1.33) Instruction Manual.

8. Some files: Other applications can be selected and run while continuing to run the diagnostic
program.

9-3
 YDIS
Contents
a CD-ROM (software + instruction manual)
b Adapter
c Communication cable

1
OUTBOARDS

WATERCRAFT
2
a b c

Operating
Connecting the communication cable to the watercraft 3
b
4
c

a
R/Y
5
W/B
B

a Wiring harness coupler

b Meter coupler
6
c Communication cable coupler

TIP:
Be careful not to pinch the communication cable between the front hood and the deck or to damage
it.
7
8
9
9-4
A
 TRBL
SHTG Troubleshooting

Engine unit troubleshooting

TIP:
• Before troubleshooting the engine unit, make sure that fresh fuel of the specified type has been
used.
• Check that all wiring connections are secured properly and that they are not corroded or rusty.
• Check that the engine shut-off cord is connected to the engine shut-off switch.
• Check that the battery is charged and that its specific gravity is within specification.
• Check the diagnostic code using the YDIS (or self-diagnosis) first, and then check the electronic
control 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 (throttle body assy., 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 trouble-
shooting of the ETV system (throttle body assy., TPS, and APS).
• If a diagnostic code is not detected, check the engine unit according to “Engine unit troubleshoot-
ing (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
result, the ECM determines that the part is disconnected and a diagnostic code is detected.
Therefore, make sure to delete the diagnosis record after checking the input voltage.

Using the YDIS for engine unit troubleshooting

TIP:
• Use the diagnostic codes displayed by the YDIS to check each part according to the “Diagnostic
code and checking step” table.
• Delete the diagnostic codes after checking, repairing, or replacing a part, and check that the diag-
nostic 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, mul-
tiple malfunctions that have been duplicated cannot be limited to these items. The symptoms may
change depending on the operating conditions and other conditions.

9-5
 Engine unit troubleshooting
Self-diagnosis
With the engine running, push the select but- b
ton a for approximately 8 seconds and a
check that a diagnostic code b is indicated
on the multifunction meter.

TIP:
1
Because the multifunction meter cannot dis-
play more than 1 diagnostic code even if
there are multiple diagnostic codes, using the
YDIS is recommended. 2
Diagnostic code table

Code No. Symptom

Diagnostic code output

Multifunc-
tion meter Diagnosis
YDIS
Diagnosis
3
record
01
13

15
Normal
Pulser coil (*1) malfunction
Engine temp sensor (*2)
malfunction
U
U
U
—
U

U U
—
U
4
19 Battery voltage malfunction U U U
23
24

29
Intake temp sensor (*3) malfunction
Cam position sensor malfunction
Intake press sensor (*4)
malfunction
U
U

U
U
U

U
U
U

U
5
47 Slant detection switch malfunction U U U
55
112, 113, 114,
115, 116, 117,
Steering sensor malfunction U U U
6
118, 119, 121,
Electronic throttle system
122, 123, 129, U U U
136, 137, 138,
139, 141, 142,
143, 144, 145
malfunction
7
124, 125, 126, Throttle position sensor
U U U

8
127, 128 malfunction
131, 132, 133, Accelerator position sensor
U U U
134, 135 malfunction
252 Overheat warning — — U
253 Low oil pressure warning — — U
(*1): Pickup coil
(*2): Engine temperature sensor
(*3): Intake air temperature sensor
(*4): Intake air pressure sensor
9
9-6
A
TRBL
SHTG Troubleshooting
Diagnostic code and checking step
Diagnos- See
Item Symptom Checking steps
tic code page
1. Measure the pickup coil output peak 7-10
voltage.
Pulser coil (*1) Engine will not 2. Measure the pickup coil resistance. 7-10
13
malfunction start 3. Check the white/black (W/B) and A-2
black/orange (B/O) pickup coil wiring
harness leads for continuity.
1. Check the engine temperature using 7-14
the YDIS.
2. Measure the engine temperature 7-14
sensor input voltage.
Engine temp
Trolling speed 3. Check the black/yellow (B/Y) and A-2
15 sensor (*2)
is unstable (*3) black/orange (B/O) engine
malfunction
temperature sensor wiring harness
leads for continuity.
4. Measure the engine temperature 7-14
sensor resistance.
1. Check the battery voltage using the 9-1
YDIS.
2. Check the fuse for continuity. 7-4
3. Measure the stator coil output peak 7-10
Battery voltage Trolling speed
19 voltage.
malfunction is unstable (*3)
4. Measure the rectifier regulator output 7-11
peak voltage.
5. Check the battery cables and 8-23
terminals for proper connection.
1. Check the intake air temperature 7-15
using the YDIS.
2. Measure the intake air temperature 7-15
sensor input voltage.
Intake temp
Trolling speed 3. Check the black/red (B/R) and black/ A-2
23 sensor (*4)
is unstable (*3) orange (B/O) intake air temperature
malfunction
sensor wiring harness leads for
continuity.
4. Measure the intake air temperature 7-15
sensor resistance.
(*1): Pickup coil
(*2): Engine temperature sensor
(*3): This symptom may only be exhibited in certain environmental conditions.
(*4): Intake air temperature sensor

9-7
 Engine unit troubleshooting

Diagnos- See
Item Symptom Checking steps
tic code page
1. Measure the cam position sensor 7-22

24
Cam position
sensor
Engine speed
is limited
input voltage.
2. Check the orange (O), green/orange
(G/O), and black/orange (B/O) cam
position sensor wiring harness leads
A-2
1
malfunction
for continuity.
3. Measure the cam position sensor
output voltage.
1. Check the intake air pressure using
the YDIS.
7-22

7-16
2
2. Measure the intake air pressure 7-16

29
Intake press
sensor (*1)
malfunction
Engine stalls
Trolling speed
is unstable (*2)
sensor input voltage.
3. Check the orange (O), pink/green
(P/G), and black/orange (B/O) intake
air pressure sensor wiring harness
A-2 3
leads for continuity.
1. Check the slant detection switch
operation using the YDIS.
2. Measure the slant detection switch
7-23

7-23
4
Slant detection input voltage.
Normal
47 switch 3. Check the blue/black (L/B) and black/ A-2
malfunction
operation
orange (B/O) slant detection switch
wiring harness leads for continuity.
4. Check the slant detection switch for 7-23
5
continuity.

6
1. Check the steering sensor operation 7-24
using the YDIS.
2. Measure the steering sensor input 7-24
Steering
Normal voltage.
55 sensor
operation 3. Check the orange/red (O/R), white/ A-2
malfunction
blue (W/L), and black/orange (B/O)
steering sensor wiring harness leads
for continuity.
1. Measure the thermo sensor input 7-14
7
voltage.

8
Ex. manifold
2. Check the black/blue (B/L) and black/ A-2
water temp. Normal
65 orange (B/O) thermo sensor wiring
sensor (*3) operation
harness leads for continuity.
malfunction
3. Measure the thermo sensor 7-14
resistance.
(*1): Intake air pressure sensor
(*2): This symptom may only be exhibited in certain environmental conditions.
(*3): Thermo sensor
9
9-8
A
TRBL
SHTG Troubleshooting

Diagnos- See
Item Symptom Checking steps
tic code page
1. Check the TPS output voltage and 7-16
throttle valve opening using the
YDIS.
2. Check the ECM circuit for continuity. 7-24
3. Check the ETV relay for continuity. 7-21
4. Check the charging system.
Electronic • Stator coil output peak voltage 7-10
112
throttle system Engine speed • Stator coil resistance 7-10
113
(*1) is limited • Rectifier regulator output peak voltage 7-11
114
malfunction • Rectifier regulator continuity 7-11
5. Check the fuse for continuity. 7-4
6. Check the battery voltage and 3-11
specific gravity.
7. Check the red (R) and black (B) A-2
power supply circuit cables and leads
for continuity.
1. Check the pink (P), orange (O), pink/ A-2
black (P/B), and black/orange (B/O)
throttle body assy. wiring harness
Electronic leads for continuity.
115 throttle system Engine speed
2. Check the TPS output voltage and 7-16
116 (*1) is limited
throttle valve opening using the
malfunction
YDIS.
3. Check the throttle shaft and throttle 4-7
inner surface for damage and wear.
1. Check the throttle body assy. coupler 4-7
Electronic terminals for corrosion and rust.
117
throttle system Engine speed 2. Check the green (G) and blue (L) A-2
118
(*1) is limited throttle body assy. wiring harness
119
malfunction leads for continuity.
3. Check the ECM circuit for continuity. 7-24
Electronic 1. Cross-check the ECM or replace.
throttle system Engine speed
121 —
(*1) is limited
malfunction
Electronic 1. Cross-check the throttle body assy.
throttle system Engine speed
122 —
(*1) is limited
malfunction
Electronic 1. Check the ETV relay and fuse (ETV 7-21
throttle system Engine speed relay) for continuity. 7-4
123
(*1) is limited 2. Check the ECM circuit for continuity. 7-24
malfunction
(*1): Throttle body assy.

9-9
 Engine unit troubleshooting

Diagnos- See
Item Symptom Checking steps
tic code page
1. Check the pink (P), orange (O), pink/ A-2
124 Throttle
125
127
128
position
sensor
malfunction
Engine speed
is limited
black (P/B), and black/orange (B/O)
throttle body assy. wiring harness
leads for continuity.
2. Check the ECM circuit for continuity. 7-24
1
Throttle 1. Check the TPS output voltage using 7-16

126
position
sensor
malfunction
Electronic
Engine speed
is limited
the YDIS.
2. Check the ECM circuit for continuity.

1. Check the TPS output voltage using

7-24

7-16
2
throttle system Engine speed the YDIS.

3
129
(*1) is limited 2. Check the ETV relay and fuse (ETV 7-21
malfunction relay) for continuity. 7-4
131 Accelerator 1. Check the APS output voltage using 7-18
132 position Engine speed the YDIS.
133 sensor is limited 2. Check the APS circuit for continuity. 7-18
134

135
malfunction
Accelerator
position Engine speed
3. Measure the APS 1 and 2 resistance.
1. Measure the APS 1 and 2 resistance.
2. Check the APS circuit for continuity.
7-18
7-18
7-18
4
sensor is limited

5
malfunction
1. Check the ECM circuit for continuity. 7-24
2. Check the ETV relay for continuity. 7-21
3. Check the charging system.
• Stator coil output peak voltage 7-10

6
• Stator coil resistance 7-10
136 Electronic
• Rectifier regulator output peak voltage 7-11
137 throttle system Engine speed
• Rectifier regulator continuity 7-11
138 (*1) is limited
4. Check the fuse for continuity. 7-4
139 malfunction
5. Check the battery voltage and 3-11
specific gravity.
6. Check the red (R) and black (B)
power supply circuit cables and leads
for continuity.
A-2
7
Electronic 1. Check the ECM circuit for continuity. 7-24

141
throttle system
(*1)
malfunction
Engine speed
is limited
2. Check the ETV relay and fuse (ETV
relay) for continuity.

1. Check the TPS output voltage and

7-21
7-4

7-16
8
Electronic throttle valve opening using the

9
throttle system Engine speed
142 YDIS.
(*1) is limited
2. Check the throttle shaft and throttle 4-7
malfunction
inner surface for damage and wear.
(*1): Throttle body assy.

9-10
A
TRBL
SHTG Troubleshooting

Diagnos- See
Item Symptom Checking steps
tic code page
1. Check the ECM circuit for continuity. 7-24
2. Check the ETV relay for continuity. 7-21
3. Check the charging system.
• Stator coil output peak voltage 7-10
• Stator coil resistance 7-10
Electronic • Rectifier regulator output peak voltage 7-11
143 throttle system Engine speed
• Rectifier regulator continuity 7-11
144 (*1) is limited
4. Check the fuse for continuity. 7-4
malfunction
5. Check the battery voltage and 3-11
specific gravity.
6. Check the red (R) and black (B) A-2
power supply circuit cables and leads
for continuity.
Electronic 1. Check the ETV relay and fuse (ETV 7-21
throttle system Engine speed relay) for continuity. 7-4
145
(*1) is limited 2. Check the throttle shaft and throttle 4-7
malfunction inner surface for wear or damage.
1. Check the cooling water passages 2-18
for obstructions.
2. Measure the engine temperature 7-14
sensor resistance.
3. Check that there is no short circuit A-2
between the black/yellow (B/Y) and
black/orange (B/O) engine
temperature sensor wiring harness
leads (*2).
4. Check the thermoswitch for 7-13
Overheat Engine speed
252 continuity.
warning is limited
5. Check that there is no short circuit A-2
between the pink (P) and black (B)
thermoswitch wiring harness leads
(*2).
6. Check the thermo sensor for 7-14
continuity.
7. Check that there is no short circuit A-2
between the black/blue (B/L) and
black/orange (B/O) thermo sensor
wiring harness leads (*2).
(*1): Throttle body assy.
(*2): Disconnect the sensor coupler or switch coupler, and then check that there is no short circuit
at the coupler (wiring harness end).

9-11
 Engine unit troubleshooting

Diagnos- See
Item Symptom Checking steps
tic code page
1. Check the oil level. 3-7

253
Low oil
pressure
Engine speed
is limited
2. Check the oil pressure switch for
continuity.
3. Check that there is no short circuit in
the pink/white (P/W) oil pressure
7-12

A-2
1
warning
switch wiring harness lead (*1).
4. Check the oil passages for
obstructions.
2-16

(*1): Disconnect the sensor coupler or switch coupler, and then check that there is no short circuit
2
at the coupler (wiring harness end).

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
3
Cause: The contents considered to be the trouble factors for symptom 2
—: Not applicable

Symptom 1: Engine does not crank.

4
See
Symptom 2 Cause Checking step
page
Starter motor does
not operate
Yamaha Security System
set to lock mode
Discharged battery
Check that the Yamaha Security
System is set to the unlock mode.
Check the battery voltage and
7-32

3-11
5
specific gravity.

6
Loose connection of Check the battery cable and 8-23
battery terminal terminal for proper connection.
Blown fuse Check the fuse for continuity. 7-4
Starter relay malfunction Check the starter relay. 7-29
Engine start switch Check the engine start switch 7-27
malfunction
Short, open, or loose
connection in starter motor
circuit
(left handlebar switch).
Measure the starter relay input
voltage.
Check the wiring harness.
7-29

A-2
7
Starter motor malfunction Disassemble and check the starter 7-30

Stuck piston or crankshaft

motor.
Disassemble and check the engine
unit.
5-70

6-8
8
Stuck impeller Disassemble and check the jet
pump unit.
Starter motor
operates, but the
engine does not
Idle gear or starter clutch
malfunction
Check the idle gear, starter clutch,
or crankshaft Woodruff key.
7-30
9
crank

9-12
A
TRBL
SHTG Troubleshooting
Symptom 1: Engine will not start (engine cranks).
See
Symptom 2 Cause Checking step
page
Throttle valve does Throttle lever squeezed Check that the throttle lever is in
—
not move properly the fully closed position.
Throttle cable installed Adjust the throttle lever free play. 3-2
improperly
APS malfunction Measure the APS 1 and 2 7-18
resistance.
TPS malfunction Check the throttle valve opening. 7-16
Throttle valve malfunction Check the throttle body assy. 4-7
Discharged battery Battery performance Check the battery voltage and 3-11
decrease specific gravity.
Stator coil malfunction Check the stator coil assy. 7-10
Short, open, or loose Check the battery cable and 8-23
connection in charging terminal for proper connection.
circuit Check the wiring harness. A-2
ECM does not Blown fuse Check the fuse for continuity. 7-4
operate Main and fuel pump relay Check the main and fuel pump 7-28
malfunction relay.
Short, open, or loose Measure the ECM input voltage. 7-24
connection in ECM circuit Check the ECM circuit for 7-24
continuity.
ECM malfunction Replace the ECM. —
Spark plug does not Engine shut-off cord clip Check that the engine shut-off cord 7-27
spark (all cylinders) not installed clip is installed properly.
Engine stop switch Check the engine stop switch 7-27
malfunction continuity. (left handlebar switch)
Pickup coil malfunction Measure the pickup coil output 7-10
peak voltage.
Measure the pickup coil resistance. 7-10
Short, open, or loose Check the white/black (W/B) and A-2
connection in pickup coil black/orange (B/O) pickup coil
circuit wiring harness leads for continuity.
Short, open, or loose Measure the ignition coil input 7-8
connection in ignition coil voltage (from the battery).
circuit Check the red/yellow (R/Y), black/ A-2
red (B/R), black/white (B/W), black/
yellow (B/Y), and black/green (B/G)
ignition coil wiring harness leads for
continuity.
Ignition coil malfunction Exchange the ignition coil with a
different one, and then check the —
ignition spark.
ECM malfunction Measure the ECM output peak 7-8
voltage.

9-13
 Engine unit troubleshooting

See
Symptom 2 Cause Checking step
page
Fuel not supplied (all Fuel leakage Check the fuel hose. 4-1
cylinders) Blown fuse
Clogged fuel pump filter
Fuel pump module
malfunction
Check the fuse for continuity.
Clean the fuel pump filter.
Check the fuel pump module
operation sound using the YDIS.
7-4
4-11
7-26
1
Measure the fuel pump module 7-26
input voltage.
Check the blue (L) and black (B)
fuel pump module wiring harness
leads for continuity.
A-2 2
Measure the fuel pressure. 4-3

Compression
Main and fuel pump relay
malfunction
Compression leakage
Check the main and fuel pump
relay.
Measure the compression
7-28

3-5
3
pressure is low pressure.

4
Measure the valve clearance. 3-6
Check the camshaft for damage. 5-34
Check the cylinder head gasket 5-45
and cylinder head warpage.
Check the valve and valve seat for 5-46
wear.
Check the piston and piston ring for
damage.
Check the cylinder for damage.
5-73
5-73
5-74
5
Improper valve timing Check the timing chain. 5-31

6
7
8
9
9-14
A
TRBL
SHTG Troubleshooting
Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited
engine speed
See
Symptom 2 Cause Checking step
page
Throttle valve does Throttle cable installed Adjust the throttle lever free play. 3-2
not move properly improperly
Throttle valve malfunction Check the throttle body assy. 4-7
Spark plug does not Spark plug malfunction Check the spark plug. 3-5
spark (some Ignition coil malfunction Check the ignition spark. 7-8
cylinders) Short, open, or loose Measure the ignition coil input 7-8
connection in ignition coil voltage (from the battery).
circuit Check the red/yellow (R/Y), black/ A-2
red (B/R), black/white (B/W), black/
yellow (B/Y), and black/green (B/G)
ignition coil wiring harness leads for
continuity.
ECM malfunction Measure the ECM output peak
7-8
voltage.
Fuel not supplied Fuel injector malfunction Check the fuel injector operation 7-25
(some cylinders) sound using the YDIS.
Measure the fuel injector 7-25
resistance.
Short, open, or loose Measure the fuel injector input 7-25
connection in fuel injector voltage.
circuit Check the red/yellow (R/Y), purple/ A-2
red (Pu/R), purple/black (Pu/B),
purple/yellow (Pu/Y), and purple/
green (Pu/G) fuel injector wiring
harness leads for continuity.
Clogged fuel injector filter Clean the fuel injector. 4-7
ECM malfunction Replace the ECM. —
Compression Compression leakage Measure the compression 3-5
pressure is low pressure.
Measure the valve clearance. 3-6
Check the camshaft for damage. 5-34
Check the cylinder head gasket 5-45
and cylinder head warpage.
Check the valve and valve seat for 5-46
wear.
Check the piston and piston ring for 5-73
damage. 5-73
Check the cylinder for damage. 5-74
Improper valve timing Check the timing chain. 5-31

9-15
 Engine unit troubleshooting
Symptom 1: High engine idle speed
See
Symptom 2 Cause Checking step
page
— Throttle cable installed
improperly

Symptom 1: Limited engine speed

Adjust the throttle lever free play
and check the cable routing.
3-2
1
See

2
Symptom 2 Cause Checking step
page
• Buzzer sounds Clogged cooling water Check the cooling water pilot outlet
—
intermittently passage for water discharge.
• Overheat warning Check the cooling water passage. 2-18
indicator blinks Thermostat malfunction Check the thermostat. 5-21
• Check engine
warning indicator
blinks
3
• Buzzer sounds Insufficient engine oil Check the engine oil level. 3-7
intermittently Check for engine oil leakage. —
• Oil pressure warn-
ing indicator blinks Oil pressure switch
malfunction
Check the oil passage.
Check the oil pressure switch
continuity.
2-16
7-12 4
Check that there is no short circuit A-2

5
in the pink/white (P/W) oil pressure
switch wiring harness lead.

Symptom 1: Discharged battery

See
Symptom 2 Cause Checking step
— Battery performance
decrease
Loose connection of
Check the battery voltage and
specific gravity.
Check the battery cable and
page
3-11

8-23
6
battery terminal terminal for proper connection.
Short, open, or loose
connection in charging
circuit
Stator coil malfunction
Check the charging circuit for wiring
connection and damage.

Check the stator coil assy.

A-2

7-10
7
Rectifier regulator Measure the rectifier regulator 7-11
malfunction output peak voltage.
8
9
9-16
A
TRBL
SHTG Troubleshooting
Symptom 1: Poor performance
See
Symptom 2 Cause Checking step
page
Watercraft cannot Jet pump unit malfunction Check the impeller, impeller duct, 6-1
reach high speeds and intake grate. 6-7
Water entered hull Check the drain plugs and O-rings 8-26
for damage.
Check the cooling water hoses for 2-20
damage.
Check the water lock, water tank, 8-23
and rubber hoses for damage.
Check the exterior of the hull for 8-28
damage.

9-17
 Appendix A

Wiring diagram ...................................................................A-1

How to use the wiring diagram ................................................... A-1
VXS, VXR................................................................................... A-1
Wiring diagram
How to use the wiring diagram
Legend symbols in the wiring diagrams
a b

a Double colors wire

b No wire connector

Color code

B : Black O/W : Orange/White

Br : Brown P : Pink
B/G : Black/Green P/B : Pink/Black
B/L : Black/Blue P/G : Pink/Green
B/O : Black/Orange P/R : Pink/Red
B/R : Black/Red P/W : Pink/White
B/W : Black/White Pu/B : Purple/Black
B/Y : Black/Yellow Pu/G : Purple/Green
G : Green Pu/R : Purple/Red
Gy : Gray Pu/Y : Purple/Yellow
G/L : Green/Blue R : Red
G/O : Green/Orange R/Y : Red/Yellow
L : Blue W : White
L/B : Blue/Black W/B : White/Black
L/R : Blue/Red W/L : White/Blue
L/Y : Blue/Yellow Y : Yellow
O : Orange Y/G : Yellow/Green
O/R : Orange/Red Y/W : Yellow/White

VXS, VXR
A To entry box
B Antenna
C Nonuse

a Fuse (30 A) (battery)

b Fuse (20 A) (main and fuel pump relay)
c Fuse (10 A) (ETV relay)
d Fuse (10 A) (main and fuel pump relay)
e Fuse (3 A) (remote control receiver)

A-1
 YAMAHA MOTOR CORPORATION, U.S.A.

Printed in U.S.A.
Oct. 2010 – ** 1 ABE
(E_1)
VXS, VXR Multifunction meter
Remote control R
B W W B R Br Fuel receiver
sender B/G B/Y ETV B
SET SET P Y Buzzer relay Br
R B
PULL PULL R/W
Left handlebar switch a B Starter
W Main and Fuse box Br motor

B
B

W
1 9 fuel pump

R
B
c d e

L/R
L/B
relay

Gy
Br Br B B 10 18
SET W W W B A C b
PULL
Br

10
12
13
14
15
16
18
3
4
6
7
9

L/R
B/L
R R Speed

Gy
B

B
G/L
Br Br Br Battery
sensor

W
4 1

W
R
Y
L/Y

L
Gy

Y/W
B
B

L/B

B/L
1 2 1 4 1

1
2

2
3
4
5
6
7
8
3

L/Y
L/B
L/R
8 5

1
3
4
5
6
1
3
4
5
6
7
8
W/B
B
G/O

R/Y
3 8 5 6 4
1 8 14 20

R
R

Y
R
R
R
R
Br
L
5 L/B R/Y 1

R
R

R
L
Y/G

Y/W
L/R
R/Y
R/Y

R/Y

R/Y
R/Y
R/Y 2
7 R/Y R/Y 3 1 4 8 12
8 W/B R/Y 4
R/Y 5

13 B/L R/Y 8
14 Y/W R/Y 9
15 B/R R/Y 10
16 P/G R/Y 11 3 7 11 14
7 13 19 26 17 W/L
R/Y 13 Joint coupler 2
R/Y 14
20 Y/G
21 Y 1 4
R/Y 1
23 B/Y R/Y 2
R/Y 3
25 O/R R/Y 4
26 O R/Y 5
36
Joint coupler 6
27 R/Y
28 W O 1 1 4
O 2
O 3
27 34 40 46
34 B/R 3 6
35 B/W
36 P/R Joint coupler 1
37 P/W B/O 1
B/O 2 15 8
39 R/Y B/O 3
40 B/O B/O 4
41 B/O B/O 5
42 P B/O 6
43 P/B B/O 7
44 O B/O 8
45 R/Y B/O 9 4 7 10
33 39 45 52 46 B
47 W/B Joint coupler 3
Y 1 1 4
49 O/R Y 2
ECM 50 O/W Y 3
52 L
3 6
Joint coupler 7
B 1 1 4
B 2
B 3
58 Pu/R
59 Pu/B B 5
60 B/G B 6 3 6
61 B/Y Joint coupler 4
53 62 70 78 62 B
B 1 15
64 P B 2
B 3
4
67 B B 5
B 6
B 7
70 B B 8 48

W/B
B/O

G
G
G
Joint coupler 5
P/W

72
G/O

W
W/L
O/R
B/O

B/O

B/O

B/O

B/O
B/Y

B/L
L/B

B/W

B/G

P/G
B/O

B/O
R/Y

R/Y

R/Y

R/Y

B/R
B/R

B/Y
4 8

R
B
O

P
B
B 1
B/O

O
P/B

B
B
L
B 2

Pu/G
Pu/B
Pu/R
G
O

Pu/Y
P
L

78 G B 3
R/Y

R/Y

R/Y

R/Y
1
2
3

61 69 77 86 79 P/W B 4
80 Y/W B 5
O/W
B/W
P/W

81 L/R
O/R
P/R
B/R

82 G/L #1 #2 #3 #4 B 7
83 Pu/G B 8 1 5
84 Pu/Y

G
G
G
85 B/R B 1

G
G
G
86 B/W #1 #2 #3 #4

Intake air Air

pressure temperature Earth
Oil Steering plate
sensor sensor
Throttle body assy. pressure Slant sensor Fuel injector Engine Thermoswitch Pickup coil
Cam Fuel pump Ignition coil
APS position switch detection temperature Thermo Rectifier regulator
switch module sensor
sensor sensor Stator coil

A-2