Yamaha WaveRunner XL1200Ltd Service Manual

LIT186160198 LIT-18616-01-98 F0D-28197-Z9-11 SERVICEMANUAL WaveRunner XL1200Ltd

1-2 EGENINFO SAFETY WHILE WORKING SAFETY WHILE WORKING The procedures given in this manual arethose recommended by Yamaha to be fol-lowed by Yamah

5-21POWRESERVICE POINTSYPVS valve inspection1. Eliminate:● Carbon deposits(with a rounded scraper 1)CAUTION:Do not use a sharp instrument to avoiddama

5-22POWRECYLINDER HEADCYLINDER HEADEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service pointsCYLINDER HEAD REMOVAL Fo

5-23POWRECYLINDER HEADEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6 Cylinder head cover 17 Gasket 18 Cylinder head 19 Gasket 1Reverse

5-24POWR E CYLINDER HEAD SERVICE POINTS Cylinder head inspection 1. Eliminate: ● Carbon deposits(with a rounded scraper 1 )CAUTION: Do not use a sha

5-25POWR E CYLINDERSCYLINDERS EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CYLINDER REMOVAL Follow the

5-26POWR E CYLINDERS SERVICE POINTS Cylinder inspection 1. Eliminate: ● Carbon deposits(with a rounded scraper 1 ) 2. Inspect: ● Cylinder water jack

5-27POWR E PISTONSPISTONS EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points PISTON REMOVAL Follow the left

5-28POWR E PISTONS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points5 Bearing 36 Piston ring 6Reverse the removal steps for installation.

5-29POWR E PISTONS SERVICE POINTS Piston pin clip removal and installation 1. Remove and install: ● Piston pin clipNOTE: Before removing or installin

5-30POWR E PISTONS 4. Calculate: ● Piston-to-cylinder clearanceOut of specification → Replace thepiston, piston rings and cylinder as aset. Cylind

1-3 EGENINFO SAFETY WHILE WORKING Under normal conditions of use thereshould be no hazards from the use of thelubricants mentioned in this manual, b

5-31POWREPISTONS2. Measure:● End gap(with a thickness gauge 1)Out of specification → Replace thepiston rings as a set.NOTE:Push the piston ring into t

5-32POWREPISTONS4. Check:● Piston-pin-to-connecting-rod free play(with the piston pin in the small endof the connecting rod as shown)Free play/small e

5-33POWREGENERATOR AND STARTER MOTORGENERATOR AND STARTER MOTOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service po

5-34POWREGENERATOR AND STARTER MOTOREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7 Spring 18 Packing 19 Pin 210 Bolt 211 Bolt 212 Brack

5-35POWREEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service pointsSTATOR COIL AND PICKUP COIL REMOVALFollow the left

5-36POWREGENERATOR AND STARTER MOTOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service pointsGENERATOR ROTOR AND STA

5-37POWREGENERATOR AND STARTER MOTOREXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSTARTER CLUTCH DISASSEM

5-38POWREGENERATOR AND STARTER MOTOREXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points8 Weight 39 Spring 110 Pinion gear 1Reverse the disas

5-39POWRESERVICE POINTSDrive coupling removal and installation 1. Remove:● Drive couplingNOTE:Install the drive coupling with the samespecial tools th

5-40POWREGENERATOR AND STARTER MOTORDrive coupling inspection1. Inspect:● Drive coupling Damage/wear → Replace.Flywheel magneto inspection1. Inspect:●

1-4 EGENINFO SAFETY WHILE WORKING 3. Non-reusable items Always use new gaskets, packings, O-rings, oil seals, split-pins, circlips, etc.,on reassemb

5-41POWRECRANKCASECRANKCASEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCRANKCASE DISASSEMBLY Follow the

5-42POWR E CRANKCASE EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points7 Bolt 18 Bolt 129 Bolt 410 Lower crankcase 111 Pin 212 Crankshaft

5-43POWRECRANKCASESERVICE POINTSCrankcase inspection1. Inspect:● Mating surfacesScratches → Replace the crankcase.● CrankcaseCracks/damage → Replace.C

5-44POWRECRANKSHAFTCRANKSHAFTEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCRANKSHAFT REMOVAL Follow the l

5-45POWRECRANKSHAFTSERVICE POINTSCrankshaft inspection1. Measure:● Crank width A Out of specification → Replace.Crank width:72.95 ~ 73.00 mm (2.872 ~

5-46POWRECRANKSHAFT5. Inspect:● BearingsDamage/pitting → Replace.NOTE:● Before inspection, thoroughly clean thebearings.● Immediately after inspection

EJETPUMP CHAPTER 6JET PUMP UNIT JET PUMP UNIT ... 6-1EXPLOD

E 1 2 3 4 5 6 7 8 9 JETPUMP BEARING HOUSING ... 6-15EXPLODED DIAGRA

6-1 EJETPUMP JET PUMP UNITJET PUMP UNIT EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points JET PUMP UNIT RE

6-2 EJETPUMP JET PUMP UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points12 Clamp/bilge hose 1/113 Nut/washer 1/214 Steering cable joi

1-5 EGENINFO SPECIAL TOOLSSPECIAL TOOLS Using the correct special tools recom-mended by Yamaha, will aid the work andenable accurate assembly and tun

6-3 EJETPUMP REVERSE GATEREVERSE GATE EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REVERSE GATE REMOVA

6-4 EJETPUMP REVERSE GATE EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points9 Roller 110 Bolt 611 Reverse gate stay 212 Nut 113 Washer 114

6-5 EJETPUMP REVERSE GATE EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points18 Washer 119 Collar 120 Spring 121 Lever 122 Bolt 123 Washer

6-6 EJETPUMP NOZZLE DEFLECTOR AND NOZZLE RINGNOZZLE DEFLECTOR AND NOZZLE RING EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name

6-7 EJETPUMP IMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCTIMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCT EXPLODED DIAGRAMREMOVAL AND INSTALLATIO

6-8 EJETPUMP IMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points7 Bolt 48 Cover 19 Packing

6-9 EJETPUMP IMPELLER DUCT AND DRIVE SHAFTIMPELLER DUCT AND DRIVE SHAFT EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART *1 : EPNOC grease AP #0Step Pr

6-10 EJETPUMP IMPELLER DUCT AND DRIVE SHAFT EXPLODED DIAGRAM *1 : EPNOC grease AP #0Step Procedure/Part name Q’ty Service points8 Drive shaft 19 Rea

6-11 EJETPUMP IMPELLER DUCT AND DRIVE SHAFT SERVICE POINTS Drive shaft removal 1. Remove: ● Impeller NOTE: The impeller has left-hand threads. Turn t

6-12 EJETPUMP IMPELLER DUCT AND DRIVE SHAFT Drive shaft installation 1. Install: ● Oil seal Driver rod:YB-06071/90890-06606Ball bearing attachment:YB

1-6 EGENINFO SPECIAL TOOLS REMOVAL AND INSTALLATION 1. Coupler wrenchP/N. YW-06551 90890-065512. Flywheel holderP/N. YW-0655090890-065503. Flywheel p

6-13 EJETPUMP TRANSOM PLATE AND HOSESTRANSOM PLATE AND HOSES EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service poi

6-14 EJETPUMP TRANSOM PLATE AND HOSES SERVICE POINTS Bilge strainer inspection Refer to “JET PUMP UNIT” in chapter 3. Bilge hose inspection 1. Inspec

6-15EJETPUMPBEARING HOUSINGBEARING HOUSINGEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsBEARING HOUSING RE

6-16EJETPUMPBEARING HOUSINGEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsBEARING HOUSING DISASSEMBLYFollow

6-17EJETPUMPBEARING HOUSINGEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8 O-ring 29 Oil seal 210 Oil seal 111 Circlip 112 Bearing 113 C

6-18EJETPUMPBEARING HOUSINGSERVICE POINTSDriven coupling removal and installation1. Remove and install:● Driven coupling NOTE:Install the driven coupl

6-19EJETPUMPBEARING HOUSINGBearing, driven coupling shaft, and grease hose inspection1. Inspect:● BearingRotate the inner race by hand.Damage/rough mo

6-20EJETPUMPBEARING HOUSING2. Install:● Driven coupling shaft Distance a:9.5 ~ 10.5 mm (0.37 ~ 0.41 in)3. Install:● Oil seal 1 [8 mm (0.31 in)]● Oil s

E–+ELEC CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ... 7-1 ELECTRICAL BO

E 1 2 3 4 5 6 7 8 9 –+ELEC CHARGING SYSTEM ... 7-26WIRING DIAGRAM...

E 1 2 3 4 5 6 7 8 9 SPEC CHAPTER 2SPECIFICATIONS GENERAL SPECIFICATIONS ... 2-

7-1 E–+ELEC ELECTRICAL COMPONENTSELECTRICAL COMPONENTS 1 YPVS servomotor 2 Multi-function meter 3 Fuel level sensor 4 Buzzer 5 Oil level sensor 6 Sta

7-2 E–+ELEC ELECTRICAL BOXELECTRICAL BOX EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ELECTRICAL BOX

7-3 E–+ELEC ELECTRICAL BOX EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points6 Damper 17 Bolt 48 Battery box 19 Coupler 4 For multi-funct

7-4 E–+ELEC ELECTRICAL BOX EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ELECTRICAL BOX DISASSEMBLY Fo

7-5 E–+ELEC ELECTRICAL BOX EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points11 Ground lead 312 Ignition coil 313 Ignition coil lead 314

7-6 E–+ELEC ELECTRICAL BOX EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points23 Lead holder 124 Fuse lead 525 Screw 226 Fuse holder 127 L

7-7 E–+ELEC ELECTRICAL BOX 1 Ignition coil 2 CDI unit 3 Rectifier/regulator 4 Fuse holder 5 Starter relay 6 Tape 7 Clear tube 8 Red tube 9 White tape

7-8 E–+ELEC ELECTRICAL ANALYSISELECTRICAL ANALYSIS INSPECTIONCAUTION: ● All measuring instruments should be han-dled with special care. Damaged or mi

7-9 E–+ELEC ELECTRICAL ANALYSIS Low resistance measurementNOTE: ● When measuring a resistance of 10 Ω orless with the digital tester, the correctme

7-10E–+ELECELECTRICAL ANALYSIS● When measuring the peak voltage, con-nect the peak voltage adaptor to the digi-tal tester and switch the selector to t

2-1SPEC E GENERAL SPECIFICATIONSGENERAL SPECIFICATIONS Item UnitModelXL1200LtdMODEL CODEHull F0DEngine 66VDIMENSIONSLength mm (in) 3,160 (124.4)Widt

7-11E–+ELECIGNITION SYSTEMIGNITION SYSTEMWIRING DIAGRAM1 Engine stop switch2 Engine stop lanyard switch3 Lighting coil4 Pickup coil5 CDI unit6 Ignitio

7-12E–+ELECIGNITION SYSTEMIGNITION SPARK GAPWARNING● When checking the spark gap, do nottouch any of the connections of the sparkgap tester lead wires

7-13E–+ELECIGNITION SYSTEMIGNITION SYSTEM PEAK VOLTAGEWARNINGWhen checking the CDI unit do not touchany of the connections of the digital testerlead w

7-14E–+ELECIGNITION SYSTEM2. Measure:● Pick-up coil output peak voltageBelow specification → Replace thepick-up coil. NOTE:The starter motor will not

7-15E–+ELECIGNITION SYSTEMBATTERYRefer to “ELECTRICAL” in chapter 3.FUSERefer to “STARTING SYSTEM”.SPARK PLUGSRefer to “ELECTRICAL” in chapter 3.SPARK

7-16E–+ELEC2. Measure:● Secondary coil resistanceOut of specification → Replace.Secondary coil resistance:Black/White (B/W) – Spark pluglead terminal3

7-17E–+ELECEXHAUST TEMPERATURE SENSOR1. Measure:● Exhaust temperature sensor resis-tance (at the specified temperature)Out of specification → Replace.

7-18E–+ELECSTARTING SYSTEMSTARTING SYSTEMWIRING DIAGRAM1 CDI unit2 Engine stop lanyard switch3 Starter switch4 Multi-function meter5 Fuse6 Starter rel

7-19E–+ELECSTARTING SYSTEMBATTERYRefer to “ELECTRICAL” in chapter 3.WIRING CONNECTIONS1. Check:● Wiring connectionsPoor connections → Properly connect

7-20E–+ELECSTARTING SYSTEMSTARTER SWITCH1. Check:● ContinuityOut of specification → Replace.Starter continuity(red coupler)Lock plate PositionLeadsRed

2-2SPEC EPON*: Pump Octane NumberRON*: Research Octane NumberYAMALUBE 2-W*: YAMALUBE 2-W is developed for this water vehicle and available from a Yam

7-21E–+ELECSTARTER MOTORSTARTER MOTOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service pointsSTARTER MOTOR DISASSEM

7-22E–+ELECSTARTER MOTOREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8 Starter motor rear cover 19 O-ring 110 Shim * t = 0.2 mm, 0.8 mm

7-23 E–+ELEC STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points18 Spacer 119 Holder 120 Starter motor yoke 1Reverse the disa

7-24 E–+ELEC STARTER MOTOR SERVICE POINTS Armature inspection 1. Inspect: ● Armature shaft 1 Damage/wear → Replace. 2. Inspect: ● CommutatorDirt

7-25 E–+ELEC STARTER MOTOR 6. Inspect: ● Armature coil continuityOut of specification → Replace. Armature coil continuity:Commutator segments 1 Co

7-26 E–+ELEC CHARGING SYSTEMCHARGING SYSTEM WIRING DIAGRAM 1 Lighting coil 2 Battery 3 Fuse (20A) 4 Rectifier/regulatorB : BlackG : GreenR : RedG/W :

7-27 E–+ELEC CHARGING SYSTEM FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in chapter 3. LIGHTING COIL Refer to “IGNITION SYSTEM”. R

7-28 E–+ELEC YPVSYPVS WIRING DIAGRAM 1 Lighting coil 2 Pickup coil 3 CDI unit 4 YPVS servomotor 5 Fuse 6 Battery 7 Rectifier/regulatorB : BlackGy : G

7-29 E–+ELEC YPVS FUSE Refer to “STARTING SYSTEM”. BATTERY Refer to “ELECTRICAL” in chapter 3. PICKUP COIL Refer to “IGNITION SYSTEM”. CDI UNIT Refer

7-30 E–+ELEC YPVS SERVOMOTORYPVS SERVOMOTOR EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points YPVS SERVOMOT

2-3SPEC E MAINTENANCE SPECIFICATIONSMAINTENANCE SPECIFICATIONS ENGINE Item UnitModelXL1200LtdCYLINDER HEADWarpage limit mm (in) 0.1 (0.004)Compressi

7-31 E–+ELEC YPVS SERVOMOTORSERVICE POINTSYPVS cable removal and installation1. Remove:● YPVS cables 1 and 2NOTE:There is a white paint mark a on YPV

7-32E–+ELECYPVS SERVOMOTORCAUTION:Do not disassemble the YPVS servomotorunit. It is a sealed unit and if it is faulty itmust be replaced.YPVS cable ad

7-33E–+ELECINDICATION SYSTEMINDICATION SYSTEMWIRING DIAGRAM1 CDI unit2 Fuel level sensor3 Oil level sensor4 Buzzer5 Multi-function meter6 Speed sensor

7-34E–+ELECINDICATION SYSTEMFUSERefer to “STARTING SYSTEM”.BATTERYRefer to “ELECTRICAL” in chapter 3.LIGHTING COILRefer to “CHARGING SYSTEM”.RECTIFIER

7-35E–+ELECINDICATION SYSTEMFUEL LEVEL SENSOR1. Measure:● Fuel level sensor resistanceOut of specification → Replace.White/blue (W/L) – Black (B)Float

7-36E–+ELECINDICATION SYSTEMEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsMULTI-FUNCTION METER REMOVALFoll

7-37E–+ELECINDICATION SYSTEMDisplay function1. Check:● Display functionNot operate → Replace the multi-function meter.1 Oil level sensor2 Fuel level s

7-38E–+ELECINDICATION SYSTEMChecking steps:● Connect the battery terminals to thewhite six-pin connector as shown. ● Disconnect the blue one-pin conne

7-39E–+ELECINDICATION SYSTEMFuel level gauge1. Check:● Fuel level gaugeNot operating → Replace the multi-function meter. Checking steps:● Supply DC 12

7-40E–+ELECINDICATION SYSTEMOil level gauge1. Check:● Oil level gaugeNot operating → Replace the multi-function meter. Checking steps:● Supply DC 12 v

2-4SPEC E MAINTENANCE SPECIFICATIONS JET PUMP UNIT HULL AND HOOD CRANKSHAFT ASSEMBLYCrank width A mm (in) 72.95 ~ 73.00 (2.872 ~ 2.874)Deflection

7-41E–+ELECINDICATION SYSTEMOverheat warning indicator1. Check:● Overheat 1 warning indicatorNot operating → Replace the multi-function meter. Checkin

7-42E–+ELECINDICATION SYSTEM● Make sure the water temperaturewarning indicator display 3 and the“” message 4 display, the“WARNING” lamp 5 operates pro

7-43E–+ELECINDICATION SYSTEMSpeed meter1. Check:● Speed meter output voltageWithin specification → Check the speedsensor output voltage and pulses.Out

7-44E–+ELECINDICATION SYSTEMSpeed sensor1. Check:● Speed sensor output voltage andpulsesOut of specification → Replace. Speed sensor output voltage (d

EHULLHOOD CHAPTER 8HULL AND HOOD HANDLEBAR ... 8-1EXP

E 1 2 3 4 5 6 7 8 9 HULLHOOD HOSES ... 8-24EX

8-1 EHULLHOOD HANDLEBARHANDLEBAR EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR COVER REMOVAL

8-2 EHULLHOOD HANDLEBAR EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR REMOVAL Follow the left

8-3 EHULLHOOD HANDLEBAR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points6 Buzzer coupler 17 Screw 48 Handle boss cover 19 Band 210 Handl

8-4 EHULLHOOD HANDLEBAR EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR DISASSEMBLY Follow the

E NOTICE This manual has been prepared by the Yamaha Motor Company Ltd. primarily for use byYamaha dealers and their trained mechanics when performin

2-5SPEC E MAINTENANCE SPECIFICATIONS ELECTRICAL Item UnitModelXL1200LtdBATTERYType FluidCapacity V-Ah (kC) 12 - 19 (68.4)CDI UNIT (B/W – B)Output pe

8-5 EHULLHOOD HANDLEBAR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points7 Handlebar switch assembly 18 Screw 29 Throttle lever assembly

8-6 EHULLHOOD HANDLEBAR SERVICE POINTS Handlebar inspection 1. Inspect: ● HandlebarBends/cracks/damage → Replace. Handlebar switch inspection Refer

8-7 EHULLHOOD HANDLEBAR 3. Adjust: ● QSTS cable length a NOTE: ● Before adjusting the QSTS cables, set thetrim grip to the neutral position. ● Adju

8-8 EHULLHOOD QSTS GRIPQSTS GRIP EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points QSTS GRIP DISASSEMBLY Fo

8-9 EHULLHOOD QSTS GRIP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points7 Screw/washer 2/28 Spacer 19 QSTS grip position locator 110 Spr

8-10 EHULLHOOD QSTS GRIP SERVICE POINTS QSTS cable inspection 1. Inspect: ● QSTS cablesFrays/kinks/rough movement → Replace. QSTS grip inspection 1

8-11 EHULLHOOD STEERING MASTERSTEERING MASTER EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING MA

8-12 EHULLHOOD STEERING MASTER EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING MASTER DISASSEMBL

8-13 EHULLHOOD STEERING MASTER EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points11 Tilt stopper 112 Bolt/nut 4/413 Retainer 214 Steering

8-14 EHULLHOODSTEERING MASTERSERVICE POINTSSteering master components inspection1. Inspect:● Each component partDamage/wear → Replace the steer-ing

2-6SPEC E MAINTENANCE SPECIFICATIONS RECTIFIER/REGULATOR(R – B)Output peak voltage lower limit@cranking 1 V —@cranking 2 V 7@2,000 r/min V 12.6@3,500

8-15EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADREMOTE CONTROL CABLES AND SPEED SENSOR LEADEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep

8-16EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8 Nut 29 Steering cable holder 110

8-17EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points17 Nut 118 Shift cable 119 Nut 120

8-18EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADSERVICE POINTSRemote control cables inspection1. Inspect:● Steering cable● QSTS cable● Shift c

8-19EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADQSTS cable (jet pump side) installation1. Install:● QSTS cable (jet pump side) a WARNINGThe QS

8-20EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADShift cable stopper installation1. Install:● Shift cable stopperWARNINGBe sure to fit the proj

8-21EHULLHOODFRONT HOODFRONT HOODEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsFRONT HOOD REMOVAL Follow t

8-22EHULLHOODEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8 Nut 19 Notch 110 Washer 211 Damper 112 Bolt 413 Plate 214 Mirror 215 Packin

8-23 EHULLHOOD STEERING MASTER COVERSTEERING MASTER COVER EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points

8-24 EHULLHOOD HOSESHOSES EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HOSES REMOVAL Follow the left “

2-7SPEC E TIGHTENING TORQUESTIGHTENING TORQUES SPECIFIED TORQUES Part to tightened Part nameThread sizeQ’tyTightening torqueRemarksNm m•kg ft•lb ENGI

8-25 EHULLHOOD HOSES EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points7 Oil tank breather hose 18 Fuel tank breather hose 29 Clamp/pilot

8-26 EHULLHOOD HOSES SERVICE POINTS Check valve inspection 1. Check: ● Check valveFaulty → Replace. Checking steps: ● Connect a hose to the end of

8-27 EHULLHOOD SHIFT LEVERSHIFT LEVER EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SHIFT LEVER REMOVAL

8-28 EHULLHOOD SHIFT LEVERSHIFT LEVER EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points4 Screw 35 Base asse

8-29 EHULLHOOD SHIFT LEVER EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BASE DISASSEMBLY Follow the le

8-30 EHULLHOOD SHIFT LEVER SERVICE POINTS Base assembly 1. Install: ● Shift arm ● Shaft Installation steps: ● Install the shift arm 1 so that it co

8-31 EHULLHOOD SEATS AND HAND GRIPSEATS AND HAND GRIP EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SEA

8-32 EHULLHOOD SEATS AND HAND GRIP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points8 Rear seat stay 19 Nut/washer 4/410 Front seat stay

8-33 EHULLHOOD SEATS AND HAND GRIP SERVICE POINTS Seat lock inspection 1. Inspect: ● Front seat lock ● Rear seat lockDamage/wear → Replace.

8-34 EHULLHOOD EXHAUST SYSTEMEXHAUST SYSTEM EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST SYSTE

2-8SPEC E TIGHTENING TORQUES Stator coil – generator cover Bolt M6 3 15 1.5 11242LT Flywheel magneto – crankshaft Bolt M10 1 75 7.5 54E Upper crankca

8-35 EHULLHOOD EXHAUST SYSTEM EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points9 Hose clamp 110 Rubber hose 1 Align hose parting line wit

8-36 EHULLHOOD EXHAUST SYSTEM SERVICE POINTS Exhaust system inspection 1. Inspect: ● Water lock bandCracks → Replace.2. Inspect: ● Rubber hosesBurn

8-37 EHULLHOOD DECK AND HULLDECK AND HULL EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points DECK AND HULL D

8-38 EHULLHOOD DECK AND HULL EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points10 Plate 111 Cleat 112 Nut 813 Sponson 214 Spacer 815 Nut/w

8-39 EHULLHOOD ENGINE MOUNTENGINE MOUNT EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ENGINE MOUNT REMO

8-40 EHULLHOOD ENGINE MOUNTHULL REPAIRShallow scratches1. Sand the scratches with 400 grit sand-paper (either wet or dry) until thescratches are smoo

8-41EHULLHOODENGINE MOUNTCracks and puncturesNOTE:Before attempting to repair any cracks orpunctures, refer to “WATER VEHICLE FRPREPAIR MANUAL”.1. Rem

8-42EHULLHOODENGINE MOUNTInsert nutNOTE:Use the insert nut when:● A pop nut which was attached to the hullslipped off or,● When a bolt which was faste

8-43EHULLHOODENGINE MOUNT4. First, apply tape 1 to the inner surfaceof the hull and then laminate fiberglassmats over the tape with resin.NOTE:When it

8-44EHULLHOODENGINE MOUNT2. To prevent water from entering the ure-thane foam, apply silicone sealant tothe inside of the hole as shown.3. Install the

2-9SPECETIGHTENING TORQUESGENERAL TORQUEThis chart specifies tightening torques forstandard fasteners with a standard ISOthread pitch. Tightening tor

E 1 2 3 4 5 6 7 8 9 TRBLANLS CHAPTER 9TROUBLE-ANALYSIS TROUBLE-ANALYSIS ...

9-1TRBLANLS E TROUBLE-ANALYSISTROUBLE-ANALYSISNOTE: The following items should be checked before the “Trouble-analysis” chart is consulted.1. The bat

9-2TRBLANLS E TROUBLE-ANALYSIS Rubber coupling 5Pilot water hose 5Water hose 5Water passage 5JET PUMP UNITDuct 6Impeller 6Intake screen 6Bearings 6I

WIRING DIAGRAM 1 Lighting coil2 Pickup coil3 CDI unit4 Oil level sensor5 Fuel level sensor6 Buzzer7 Multi-function meter8 Speed sensor9 Engine stop s

YAMAHA MOTOR CO., LTD. Printed in USAMar. 1999 – ?.? × 1 CR (XA1200X) Printed on recycled paper

2-10SPECECABLE AND HOSE ROUTINGCABLE AND HOSE ROUTING1 Fuel breather hose2 Pilot water hose3 QSTS cable4 Fuel hose5 Shift cable6 Steering cable7 Fuel

2-11SPECECABLE AND HOSE ROUTING1 Throttle cable2 Switch box lead3 QSTS cable4 Buzzer lead5 To pickup coil6 To battery positive terminal7 To starter mo

E 1 2 3 4 5 6 7 8 9 INSPADJ CHAPTER 3PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART ...

3-1INSPADJ E MAINTENANCE INTERVAL CHARTMAINTENANCE INTERVAL CHART The following chart should be considered strictly as a guide to general maintenance

3-2INSPADJ E CONTROL SYSTEMPERIODIC SERVICE CONTROL SYSTEM Steering master inspection 1. Inspect: ● Steering masterExcessive play → Replace the ste

E HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. Theinformation has be

3-3INSPADJ E CONTROL SYSTEMNOTE: If the steering cable cannot be properlyadjusted at the steering column side, make adjustments at the jet pump side.

3-4INSPADJ E CONTROL SYSTEM Choke cable inspection and adjustment 1. Inspect: ● Choke knob (pull the choke knob all the way out)Choke knob automatica

3-5INSPADJ E CONTROL SYSTEM 2. Adjust: ● QSTS cable NOTE: If correct adjustment by using the cablejoint at the wheel end is not obtained, adjust the

3-6INSPADJECONTROL SYSTEMShift cable inspection and adjustment1. Check:● Reverse gate stopper lever positionIncorrect → Adjust.Checking steps:● Set th

3-7INSPADJECONTROL SYSTEMYPVS cable adjustment1. Check:● YPVS valve positionIncorrect position → Adjust the YPVScable.Checking steps:● Initiate the mu

3-8INSPADJECONTROL SYSTEM/FUEL SYSTEM3. Adjust:● YPVS cables 1 and 2Adjustment steps:● Loosen locknuts 1 and 2.● Turn in the adjuster 3 and 4 untilthe

3-9INSPADJEFUEL SYSTEMFuel line inspection1. Inspect:● Fuel filter 1 Contaminants → Replace.Cracks/damage → Replace.Water contamination → Replace andc

3-10INSPADJEFUEL SYSTEM/OIL INJECTION SYSTEM2. Adjust:● Trolling speedAdjustment steps: ● Start the engine and allow it to warmup for several minutes.

3-11INSPADJEOIL INJECTION SYSTEM/POWER UNIT1. Bleed:● AirAir bleeding steps:● Place rags around the air bleed screw1 to catch any oil that might spill

3-12INSPADJEPOWER UNIT/ELECTRICAL3. Measure:● Spark plug gap a Out of specification → Regap.Spark plug gap:1.0 ~ 1.1 mm (0.039 ~ 0.043 in)4. Tighten:●

E IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the followingways.The Safety Alert Symbol means

3-13INSPADJEELECTRICALAntidote (EXTERNAL):● SKIN - Wash with water.● EYES - Flush with water for 15 minutesand get immediate medical attention.Antidot

3-14INSPADJEELECTRICAL2. Inspect:● Electrolyte levelLow → Add distilled water.The electrolyte level should bebetween the upper 1 and lower 2level mark

3-15INSPADJEELECTRICAL/JET PUMP UNIT5. Install:● Battery breather hose 1 ● Battery ● Positive lead 2 ● Negative lead 3 ● Battery band CAUTION:● Connec

3-16INSPADJEJET PUMP UNIT/GENERALWater inlet filter inspection1. Inspect:● Water inlet filterContaminants → Clean.Cracks/damage → Replace.Inspection

3-17INSPADJEGENERALLubrication points1. Lubricate:● Throttle cable (handlebar side)● QSTS control cables (handlebar side)NOTE:● Before lubricating the

3-18INSPADJEGENERAL3. Lubricate:● Nozzle pivot shaft ● Steering cable (nozzle side)● QSTS cable (nozzle side)Recommended grease:Yamaha marine grease,

EFUEL CHAPTER 4FUEL SYSTEM FUEL COCK AND FUEL FILTER ... 4-1EXPLODED DIAGRAM...

E 1 2 3 4 5 6 7 8 9 FUEL CARBURETOR ... 4-18EXPLODED DIAGR

4-1FUEL E FUEL COCK AND FUEL FILTERFUEL COCK AND FUEL FILTER EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service poi

4-2FUEL E FUEL COCK AND FUEL FILTER SERVICE POINTS Fuel filter inspection Refer to “FUEL SYSTEM” in chapter 3. Fuel cock inspection 1. Check: ● Fuel

E HOW TO USE THIS MANUAL 1 To help identify parts and clarify procedure steps, there are exploded diagrams at the startof each removal and disassembl

4-3FUEL E CHOKE CABLECHOKE CABLE EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CHOKE CABLE REMOVAL Foll

4-4FUEL E OIL TANKOIL TANK EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points OIL TANK REMOVAL Follow the le

4-5FUEL E OIL TANK EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points7 Breather hose 18 Oil hose 19 Bolt 210 Tank belt 211 Oil tank assemb

4-6FUEL E OIL TANK SERVICE POINTS Oil filter inspection Refer to “OIL INJECTION SYSTEM” inchapter 3. Oil level switch inspection Refer to “INDICATION

4-7FUEL E FUEL TANKFUEL TANK EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points FUEL TANK REMOVAL Follow the

4-8FUEL E FUEL TANK EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points8 Fuel hose 19 Fuel breather hose 110 Fuel tank assembly 111 Hose cl

4-9FUEL E FUEL TANK SERVICE POINTS Check valve inspection 1. Check: ● Check valveFaulty → Replace. Fuel level switch inspection Refer to “INDICATIO

4-10FUEL E INTAKE DUCT AND SILENCERINTAKE DUCT AND SILENCER EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service poin

4-11FUEL E INTAKE DUCT AND SILENCER EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points5 Hook 56 Silencer case 17 Bolt 68 Filter 19 Silence

4-12FUEL E CARBURETOR UNITCARBURETOR UNIT EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CARBURETOR UNIT

E A50001-1-4 SYMBOLS Symbols 1 to 9 are designed as thumb-tabs to indicate the content of a chapter. 1 General Information 2 Specifications 3 Per

4-13FUEL E CARBURETOR UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points7 Fuel pump vacuum hose 38 Bolt 69 Bolt 410 Carburetor assemb

4-14FUEL E CARBURETOR UNIT EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CARBURETOR UNIT SEPARATION Fol

4-15FUEL E CARBURETOR UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points7 Bolt 38 Cable holder 19 Bolt 610 Carburetor 311 Gasket 312

4-16FUEL E CARBURETOR UNIT SERVICE POINTS Throttle valve synchronization inspection and adjustment 1. Check: ● Throttle valve synchronizationDifferen

4-17FUELECARBURETOR UNITChoke cable and throttle cable installation1. Install:● Choke cable 1 ● Throttle cable 2 Choke cable guide installation positi

4-18FUELECARBURETORCARBURETOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCARBURETOR DISASSEMBLY Follow t

4-19FUELECARBURETOREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points10 Pilot jet 111 Screw 112 Arm 113 Arm pin 114 Spring 115 Screw 116 Nee

4-20FUELECARBURETOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsACCELERATOR PUMP DISASSEMBLYFollow the le

4-21FUELECARBURETORSERVICE POINTSCAUTION:Do not use steel wire for cleaning the jets.This may enlarge the jet diameters andseriously affect performanc

4-22FUELERegulator body inspection1. Inspect:● Regulator bodyContaminants → Clean.Damage → Replace.● Valve (clear film) 1 Damage → Replace.Needle valv

E INDEX GENERAL INFORMATION 1 SPECIFICATIONS 2 SPEC PERIODIC INSPECTION AND ADJUSTMENT 3 FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR JET PUMP UNIT 6 J

4-23FUELEFUEL PUMPFUEL PUMPEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsFUEL PUMP DISASSEMBLY Follow the

4-24FUELEFUEL PUMPEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7 Rubber diaphragm 18 Diaphragm 19 Packing 110 Fuel filter 1Reverse the

4-25FUELEFUEL PUMPSERVICE POINTSFuel pump inspection1. Inspect:● Diaphragm● Rubber diaphragm● Diaphragm body Damage → Replace.Fuel filter inspection1.

4-26FUELEOIL PUMPOIL PUMPEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsOIL PUMP REMOVAL Follow the left “S

4-27FUELEOIL PUMPEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6 Oil pump assembly 17 Gasket 18 Oil hose 1 19 Oil hose 2 1Reverse the re

4-28FUELEOIL PUMPEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsOIL PUMP HOSES AND CABLE REMOVALFollow the

4-29FUELEOIL PUMPSERVICE POINTSOil pump inspection1. Inspect:● Oil pumpContaminants → Clean.Damage/wear → Replace. ● Oil pump joint pieceDamage/wear →

4-30FUELEOIL PUMPOil pump cable adjustment1. Check:● Oil pump lever positionIncorrect → Adjust. Checking steps:● Fully close the carburetor throttleva

EPOWR CHAPTER 5POWER UNIT EXHAUST CHAMBER ASSEMBLY ... 5-1EXPLODED DIAGRAM...

E 1 2 3 4 5 6 7 8 9 POWR CYLINDERS ... 5-25EXPLODED D

E 1 2 3 4 5 6 7 8 9 GENINFO CHAPTER 1GENERAL INFORMATION IDENTIFICATION NUMBERS ...

5-1POWR E EXHAUST CHAMBER ASSEMBLYEXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service poin

5-2POWR E EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points9 Exhaust chamber stay 110 Bolt 311 Bolt 112 Exhaust

5-3POWR E EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST CHAMBER DISAS

5-4POWR E MUFFLER ASSEMBLYMUFFLER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points MUFFLER ASSEM

5-5POWR E MUFFLER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points7 Hose clamp 18 Water lock band 1 Slide the water lock towar

5-6POWR E MUFFLER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points MUFFLER DISASSEMBLY Follow th

5-7POWR E MUFFLER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points10 Catalyst housing 111 Gasket 112 Catalyst 113 Gasket 114 P

5-8POWR E MUFFLER ASSEMBLY SERVICE POINT Catalyst inspection 1. Inspect: ● CatalystCracks/damage → Replace.

5-9POWR E EXHAUST MANIFOLD AND LEADSEXHAUST MANIFOLD AND LEADS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service

5-10POWR E EXHAUST MANIFOLD AND LEADS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points6 Bolt 47 Bolt 68 Nut 29 Exhaust manifold 110 Gas

1-1 EGENINFO IDENTIFICATION NUMBERS A60700-0* IDENTIFICATION NUMBERS PRIMARY l.D. NUMBER The primary l.D. number is stamped on alabel attached to the

5-11POWR E EXHAUST MANIFOLD AND LEADS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST MANIFOLD D

5-12POWR E ENGINE UNITENGINE UNIT EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ENGINE UNIT REMOVAL Fo

5-13POWR E ENGINE UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points4 Coupling cover 15 Bolt/washer 4/46 Engine assembly 17 Shim * In

5-14POWR E ENGINE UNIT SERVICE POINTS Shim removal 1. Remove: ● ShimsNOTE: To ease reassembly and coupling align-ment, remove the shims and organize

5-15POWR E REED VALVESREED VALVES EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REED VALVE REMOVAL Foll

5-16POWR E REED VALVES EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points3 Reed valve assembly 34 Screw 245 Valve stopper 66 Reed valve 6R

5-17POWR E REED VALVES SERVICE POINTS Reed valve inspection 1. Inspect: ● Reed valvesCracks/damage → Replace.2. Measure: ● Valve bending a Out of

5-18POWREYPVSYPVSEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsYPVS REMOVAL Follow the left “Step” for re

5-19POWR E YPVS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points7 Bolt (M4) 38 Circlip 59 Shaft 3 110 Shaft 2 111 Shaft 1 112 Washer 513

5-20POWREYPVSEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points14 Bolt (M5) 315 YPVS valve assembly 316 Oil seal 6Reverse the removal steps