Yamaha FX140 WaveRunner 2003 Service Manual

WaveRunnerFX140F1B-28197-1E-11*LIT186160238*LIT-18616-02-38SERVICE MANUAL

1-1EGENINFOIDENTIFICATION NUMBERSA60700-0*IDENTIFICATION NUMBERSPRIMARY l.D. NUMBERThe primary l.D. number is stamped on a labelattached to the inside

4-21EFUELFUEL INJECTION SYSTEMThrottle bodies synchronization1. Remove:• Throttle bodies• Air filter case2. Adjust:• Throttle bodies synchronizationAd

4-22EFUELFUEL INJECTION SYSTEMc. Turn synchronizing screw #1 3 clock-wise approximately 7 times until it startsto contact the lever.NOTE:• Butterfly v

4-23EFUELFUEL INJECTION SYSTEMNOTE:For best results, use a vacuum gauge(commercially obtainable), like 9 or 0shown in the illustration, that has foura

4-24EFUELFUEL INJECTION SYSTEMThrottle position sensor output voltage:Pink (P) – Black/Orange (B/O)0.8 ± 0.1 VNOTE:• To decrease the output voltage, t

4-25EFUEL3. Remove:• Throttle bodies• Air filter case4. Remove:• Carburetor synchronizer or vacuum gauge5. Install:• Plugs6. Install:• Air filter case

4-26EFUELFUEL INJECTION SYSTEMFuel pressure measurement1. Disconnect:• Fuel hoseRefer to “Fuel hose disconnection”.2. Install:• Fuel pressure gauge ad

EPOWRCHAPTER 5POWER UNITENGINE UNIT ...5-1EXPLODED DIA

EPOWR123456789OIL PUMP...5-26EXPLODED DIAGRAM ...

EPOWRCYLINDER HEAD... 5-57EXPLODED DIAGRAM ...

EPOWRCRANKSHAFT ... 5-97EXPLODED DIAGRAM ...

1-2EGENINFO SAFETY WHILE WORKING SAFETY WHILE WORKINGThe procedures given in this manual are thoserecommended by Yamaha to be followed byYamaha dealer

5-1EPOWRENGINE UNITENGINE UNITEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsENGINE UNIT REMOVALFollow the

5-2EPOWRENGINE UNITEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points3 Electrical box 14 Clamp/cooling water hose 1/1 Cooling water pilot ou

5-3EPOWRENGINE UNITEXPLODED DIAGRAM*: As required.Step Procedure/Part name Q’ty Service points13 Bolt/washer 4/414 Shim *15 Engine unit 1Reverse the r

5-4EPOWRENGINE UNITSERVICE POINTSCompression pressure measurementThe following procedure applies to all of thecylinders.NOTE:Insufficient compression

5-5EPOWRENGINE UNIT7. Measure:• Compression pressureOut of specification → Refer to steps (b)and (c).8. Install:• Spark plugMinimum compression pressu

5-6EPOWRENGINE UNIT9. Install:• Air filter element• Air filter case coverT R..Air filter case cover screw:2.5 N • m (0.25 kgf • m, 1.8 ft • lb)LOCTITE

5-7EPOWRENGINE UNITShim removal1. Remove:• ShimsNOTE:To ease reassembly and coupling alignment,remove the shims and organize them in theirrespective g

5-8EPOWREXHAUST PIPE 3EXHAUST PIPE 3EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsEXHAUST PIPE 3 REMOVALFo

5-9EPOWREXHAUST PIPE 3EXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6 Exhaust joint clamp 2 Slide the outer exhaust joint for exhaust ma

5-10EPOWREXHAUST PIPE 3EXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points15 Gasket 116 Inner exhaust joint 117 Exhaust joint seal 118 Outer

1-3EGENINFO SAFETY WHILE WORKINGUnder normal conditions of use there shouldbe no hazards from the use of the lubricantsmentioned in this manual, but s

5-11EPOWREXHAUST PIPES 1 AND 2EXHAUST PIPES 1 AND 2EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsEXHAUST P

5-12EPOWREXHAUST PIPES 1 AND 2EXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7 Dowel pin 28 Clamp/cooling water hose 2/2ÈFrom cooling wat

5-13EPOWREXHAUST MANIFOLDEXHAUST MANIFOLDEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsEXHAUST MANIFOLD RE

5-14EPOWREXHAUST MANIFOLDEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6Bolt 17Bolt 48 Exhaust manifold 2 19Gasket 110 Dowel pin 2Revers

5-15EPOWROIL TANKOIL TANKEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsOIL TANK REMOVALFollow the left “St

5-16EPOWROIL TANKEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points5 Clamp/breather hose 2/16 Clamp/breather hose 2/1É To oil pumpAlign the

5-17EPOWROIL TANKEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points12 Clamp/cooling water hose 1/1Ì From cooling water inlet13 Clamp/cooling

5-18EPOWROIL TANKEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points23 Nut 224 Oil tank 125 Pin 226 O-ring 427 Connector 228 Bolt 229 Oil tan

5-19EPOWROIL TANKEXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsOIL TANK DISASSEMBLYFollow the left “Step”

5-20EPOWROIL TANKEXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points11 Oil breather plate 1 112 Oil breather plate 2 113 Gasket 114 Bolt 315

1-4EGENINFO SAFETY WHILE WORKING3.Non-reusable itemsAlways use new gaskets, packings, O-rings, oil seals, split-pins, circlips, etc., onreassembly.DIS

5-21EPOWROIL TANKEXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points21 Screw 122 Anode 123 Oil tank 1Reverse the disassembly steps for assem

5-22EPOWROIL TANKSERVICE POINTSOil tank removal1. Remove:• Oil tankNOTE:Loosen the oil tank bolts and nuts in thesequence shown.312456872. Remove:• Oi

5-23EPOWROIL TANK4. Remove:• Oil cooler covers• GasketsNOTE:Loosen the oil cooler cover bolts in thesequence shown.819127651110342Oil strainer inspect

5-24EPOWR2. Install:• Gasket• Oil breather plate 2• Oil breather plate 1NOTE:Tighten the oil breather plate bolts in thesequence shown.T R..Oil breath

5-25EPOWROIL TANK4. Install:• Oil tankNOTE:Tighten the oil tank nuts and bolts in thesequence shown.T R..Bolt 1:1st:15 N • m (1.5 kgf • m, 11 ft • lb)

5-26EPOWROIL PUMPOIL PUMPEXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsOIL PUMP ASSEMBLY REMOVALFollow th

5-27EPOWROIL PUMPSERVICE POINTSOil pump removal1. Remove:• Oil pump assemblyNOTE:Loosen the oil pump bolts in the sequenceshown.567891111231042Oil pum

5-28EPOWROIL PUMPOil pump installation1. Install:• Oil pump assemblyNOTE:• Align the projection a on the oil pumpassembly with the slit b on the oil p

5-29EPOWRREDUCTION DRIVE GEARREDUCTION DRIVE GEAREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsREDUCTION D

5-30EPOWRREDUCTION DRIVE GEAREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7 Reduction drive gear case 18Gasket 19Pin 210 Circlip 211 Re

1-5EGENINFOSPECIAL TOOLSSPECIAL TOOLSUsing the correct special tools recommendedby Yamaha, will aid the work and enable accu-rate assembly and tune-up

5-31EPOWRREDUCTION DRIVE GEAREXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART*1: EPNOC grease AP #0Step Procedure/Part name Q’ty Service pointsREDUCTIO

5-32EPOWRREDUCTION DRIVE GEAREXPLODED DIAGRAM *1: EPNOC grease AP #0Step Procedure/Part name Q’ty Service points9 Circlip 210 Driven gear 111 Washer 2

5-33EPOWRREDUCTION DRIVE GEAREXPLODED DIAGRAM *1: EPNOC grease AP #0Step Procedure/Part name Q’ty Service points18 Bearing 119 Circlip 120 Bearing 121

5-34EPOWRREDUCTION DRIVE GEARSERVICE POINTSDrive coupling removal1. Remove:• Drive coupling 1 NOTE:While holding the flywheel magneto 2 with thesheave

5-35EPOWRREDUCTION DRIVE GEARDrive shaft installing1. Install:• Drive shaftNOTE:Press in the direction of the arrow.2. Install:• Oil seals 1 Distance

5-36EPOWRGENERATOR AND STARTER MOTORGENERATOR AND STARTER MOTOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service po

5-37EPOWRGENERATOR AND STARTER MOTOREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points9Bolt 110 Holder 111 Bolt 812 Generator cover 113 Dowe

5-38EPOWRGENERATOR AND STARTER MOTOREXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points20 Starter clutch 121 Starter gear 122 Woodruff key 1

5-39EPOWRGENERATOR AND STARTER MOTOREXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsGENERATOR DISASSEMBLY F

5-40EPOWRGENERATOR AND STARTER MOTOREXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points5 Holder 16Bolt 37 Lighting coil 1Reverse the disasse

1-6EGENINFOSPECIAL TOOLSAFuel pressure gaugeP/N. YB-0676690890-06786BCompression gauge extensionP/N. 90890-06582CCylinder gauge setP/N. YU-0301790890-

5-41EPOWRGENERATOR AND STARTER MOTORSERVICE POINTSFlywheel magneto removal1. Remove:• Flywheel magneto bolt 1 • WasherNOTE:While holding the flywheel

5-42EPOWRGENERATOR AND STARTER MOTOR2. Check:• Starter clutch 1 • Starter gear 2 Burrs/chips/roughness/wear → Replacethe defective part(s).3. Check:•

5-43EPOWRGENERATOR AND STARTER MOTORFlywheel magneto installation1. Install:• Woodruff key• Flywheel magneto• Washer• Flywheel magneto boltNOTE:• Clea

5-44EPOWRCAMSHAFTSCAMSHAFTSEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCYLINDER HEAD COVER REMOVALFollow

5-45EPOWRCAMSHAFTSEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7Bolt 18 Cooling water pipe 19 O-ring 110 Bolt 611 Rubber mount 612 Cyli

5-46EPOWRCAMSHAFTSEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCAMSHAFT REMOVAL Follow the left “Step” fo

5-47EPOWRCAMSHAFTSEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points5 Timing chain tensioner gasket 16 Timing chain guide (exhaust side) 17B

5-48EPOWRCAMSHAFTSEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points16 Exhaust camshaft 117 Bolt 218 Exhaust camshaft sprocket 119 Pin 120 T

5-49EPOWRCAMSHAFTSSERVICE POINTSCamshaft removal1. Install:• Dial gauge needle• Dial gauge stand 1 (into spark plug hole #1)• Dial gauge 2 Dial gauge

5-50EPOWRCAMSHAFTS4. Remove:• Timing chain tensioner 1 • Gasket15. Remove:• Camshaft caps• Dowel pinsNOTE:Loosen the intake and exhaust camshaft capbo

1-7EGENINFOSPECIAL TOOLSMTest harness (3 pins)P/N. YB-0676990890-06769NVacuum/pressure pump gauge setP/N. YB-35956-A90890-06756OYamaha diagnostic syst

5-51EPOWRCAMSHAFTS3. Measure:• Camshaft runoutOut of specification → Replace.Maximum camshaft runout:0.03 mm (0.0012 in)4. Measure:• Camshaft-journal-

5-52EPOWRCAMSHAFTS5. Measure:• Camshaft journal diameter a Out of specification → Replace the cam-shaft.Within specification → Replace the cyl-inder h

5-53EPOWRCAMSHAFTSCamshaft installation1. Install:• Exhaust camshaft sprocket 1 • Intake camshaft sprocket 2 (with the special tool 3)NOTE:Install the

5-54EPOWRCAMSHAFTS• Install the exhaust and intake camshaftcaps.NOTE:Gradually tighten the intake and exhaustcamshaft cap bolts in 2–3 steps in theseq

5-55EPOWRCAMSHAFTS• Tighten the timing chain tensioner bolts3 to the specified torque.NOTE:The “UP” mark on the timing chain ten-sioner should face u

5-56EPOWRCAMSHAFTS7. Install:• Cylinder head cover gasket• Cylinder head coverNOTE:• Apply Gasket Maker® onto the mating sur-faces of the cylinder hea

5-57EPOWRCYLINDER HEADCYLINDER HEADEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service pointsCYLINDER HEAD REMOVAL Fo

5-58EPOWRCYLINDER HEADEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points4 Nut/washer 2/25 Nut/washer 8/86 Cylinder head 17 Cylinder head gas

5-59EPOWRCYLINDER HEADSERVICE POINTSCylinder head removal1. Remove:• Cylinder head bolts 1 2. Remove:• Cylinder head nutsNOTE:Loosen the cylinder head

5-60EPOWRCYLINDER HEAD3. Measure:• Cylinder head warpageOut of specification → Replace the cyl-inder head.Cylinder head warpage limit:0.1 mm (0.004 in

1-8EGENINFOSPECIAL TOOLSREMOVAL AND INSTALLATION1Oil filter wrenchP/N. YU-38411 90890-014262Coupler wrenchP/N. YW-06551 90890-065513Sheave holderP/N.

5-61EPOWRCYLINDER HEAD2. Tighten:• Cylinder head bolts 1 NOTE:Lubricate the cylinder head bolts with engineoil.T R..Cylinder head bolt:10 N • m (1.0 k

5-62EPOWRVALVES AND VALVE SPRINGSVALVES AND VALVE SPRINGSEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service pointsVA

5-63EPOWRVALVES AND VALVE SPRINGSEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points10 Exhaust valve lifter 811 Exhaust valve pad 812 Exhaust

5-64EPOWRVALVES AND VALVE SPRINGSSERVICE POINTSValve removal1. Remove:• Valve lifter 1 • Valve pad 2 NOTE:Make a note of the position of each valve li

5-65EPOWRVALVES AND VALVE SPRINGSValve spring inspection1. Measure:• Valve spring free length a Out of specification → Replace thevalve spring.2. Meas

5-66EPOWRVALVES AND VALVE SPRINGS4. Measure:• Valve stem diameter a Out of specification → Replace thevalve.Valve stem diameter a:Intake valve:3.975–3

5-67EPOWRVALVES AND VALVE SPRINGS1. Measure:• Valve guide inside diameter a 2. Calculate the valve stem-to-valve guideclearance as follows. Replace th

5-68EPOWRVALVES AND VALVE SPRINGS2. Install the new valve guide 2 by strikingthe special service tool from the camshaftside until the valve guide clip

5-69EPOWRVALVES AND VALVE SPRINGSValve seat inspection1. Eliminate carbon deposits from the valvewith a scraper.2. Apply a thin, even layer of Mechani

5-70EPOWRVALVES AND VALVE SPRINGSValve seat reface1. Reface the valve seat with the valve seatcutter.2. Cut the surface of the valve seat with a 45°cu

1-9EGENINFOSPECIAL TOOLSAValve seat cutterIntakeP/N. 90890-06813 (60°)90890-06814 (45°)90890-06815 (30°)ExhaustP/N. 90890-06315 (60°)90890-06312 (45°)

5-71EPOWRVALVES AND VALVE SPRINGS4. Use a 60° cutter to adjust the contact widthof the bottom edge of the valve seat.b Previous contact width60˚b5. Us

5-72EPOWRVALVES AND VALVE SPRINGS9. Apply a thin, even layer of lapping com-pound onto the valve seat, and then lapthe valve using a valve lapper (com

5-73EPOWRVALVES AND VALVE SPRINGS2. Compress the valve spring, and theninstall the valve cotter 1 using a thinscrewdriver with a small amount of greas

5-74EPOWRCRANKCASECRANKCASEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsOIL PAN AND CRANKCASE REMOVALFoll

5-75EPOWRCRANKCASEEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service pointsOil pump Refer to “OIL PUMP”.Reduction drive gear case Refer to “REDUCTI

5-76EPOWRCRANKCASEEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8Bolt 19 Anode cover 110 Grommet 111 Anode 112 Bolt 413 Bolt 914 Oil pan

5-77EPOWRCRANKCASEEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points19 Cap 420 Bolt/washer 10/1021 Lower crankcase 122 Dowel pin 223 Dowel p

5-78EPOWRCRANKCASEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsOIL PIPE AND OIL FILTER BOLT REMOVALFollow

5-79EPOWRCRANKCASESERVICE POINTSCrankcase disassembly1. Remove:• Oil pan boltsNOTE:• Loosen each bolt 1/4 of a turn at a time, instages and in a criss

5-80EPOWRCRANKCASE4. Remove:• Dowel pinsCrankcase inspection1. Thoroughly wash the crankcase halves ina mild solvent.2. Thoroughly clean all the gaske

1-10EGENINFOSPECIAL TOOLSMBall bearing attachment (jet pump oil seal)P/N. YB-06085 90890-06634NDriver rod (intermediate shaft and jet pump)P/N. YB-060

5-81EPOWRCRANKCASE2. Apply:• Gasket Maker® (onto the crankcase mating surfaces)NOTE:Do not allow any Gasket Maker® to come intocontact with the oil ga

5-82EPOWRCRANKCASETightening steps:• Tighten the bolts in the tighteningsequence cast on the crankcase.T R..Crankcase bolt 1–0:1st:7.8 N • m (0.78 kgf

5-83EPOWRCRANKCASE6. Tighten: • Crankcase bolts A–J NOTE:Tighten the bolts in the tightening sequencecast on the crankcase. T R..Crankcase bolt A–J:12

5-84EPOWRCONNECTING RODS AND PISTONSCONNECTING RODS AND PISTONSEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service poi

5-85EPOWRCONNECTING RODS AND PISTONSEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8Bolt 89 Big end upper bearing 410 Top ring 411 2nd ri

5-86EPOWRCONNECTING RODS AND PISTONSSERVICE POINTSConnecting rod and piston removalThe following procedure applies to all of theconnecting rods and pi

5-87EPOWRCONNECTING RODS AND PISTONS3. Remove: • Top ring • 2nd ring • Oil ringNOTE:When removing a piston ring, open the endgap with your fingers and

5-88EPOWRCONNECTING RODS AND PISTONS• If out of specification, replace the pistonand piston rings as a set. • Measure piston skirt diameter “P” with t

5-89EPOWRCONNECTING RODS AND PISTONS2. Install:• Piston ring (into the cylinder)NOTE:Level the piston ring in the cylinder with thepiston crown. a 5 m

5-90EPOWRCONNECTING RODS AND PISTONS2. Measure: • Piston pin outside diameter a Out of specification → Replace the pis-ton pin.Piston pin outside diam

ENOTICEThis manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trainedmechanics when performing maintenance procedures a

5-91EPOWRCONNECTING RODS AND PISTONSConnecting rod inspection1. Measure: • Crankshaft-pin-to-big-end-bearing clearance Out of specification → Replace

5-92EPOWRCONNECTING RODS AND PISTONSNOTE:• Do not move the connecting rod or crank-shaft until the clearance measurementhas been completed. • Lubricat

5-93EPOWRCONNECTING RODS AND PISTONSFor example, if the connecting rod “P1” and thecrankshaft web “P1” numbers are “5” and “1”respectively, then the b

5-94EPOWRCONNECTING RODS AND PISTONS3. Offset: • Piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ringÈ Intake side4.

5-95EPOWRCONNECTING RODS AND PISTONS7. Install: • Big end bearings • Connecting rod assembly 1 (into the cylinder and onto the crankshaft pin)• Connec

5-96EPOWRCONNECTING RODS AND PISTONS9. Tighten: • Connecting rod nuts WARNING• Replace the connecting rod bolts andnuts with new ones. • Clean the con

5-97EPOWRCRANKSHAFTCRANKSHAFTEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCRANKSHAFT REMOVAL Follow the l

5-98EPOWRCRANKSHAFTSERVICE POINTSCrankshaft removal1. Remove: • Crankshaft 1 • Crankshaft journal lower bearings (from the lower crankcase)• Crankshaf

5-99EPOWRCRANKSHAFTCAUTION:Do not interchange the crankshaft journalbearings. To obtain the correct crankshaft-journal-to-crankshaft-journal-bearing c

5-100EPOWRCRANKSHAFT• Tighten the bolts to specification in thetightening sequence cast on the crank-case.Refer to “Crankcase assembly”—“CRANKCASE”.•

ESPEC123456789CHAPTER 2SPECIFICATIONSGENERAL SPECIFICATIONS ...2-1MAINTENANCE SP

5-101EPOWRCRANKSHAFTCrankshaft installation1. Install: • Crankshaft journal upper bearings (into the upper crankcase)• Crankshaft journal lower bearin

5-102EPOWRTHERMOSTATTHERMOSTATEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsTHERMOSTAT REMOVAL Follow the

5-103EPOWRTHERMOSTATEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service points8 Thermostat 19 Thermostat housing 1Reve

5-104EPOWRTHERMOSTATSERVICE POINTSThermostat inspection1. Check:• Thermostat 1 Does not open at 50–60 °C (123–141 °F) → Replace.1 Thermostat2 Thermom

5-105EPOWRPRESSURE CONTROL VALVEPRESSURE CONTROL VALVEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsPRESSU

5-106EPOWRPRESSURE CONTROL VALVEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service points9Bolt 310 Pressure control v

5-107EPOWRPRESSURE CONTROL VALVEEXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsPRESSURE CONTROL VALVE DISA

5-108EPOWRPRESSURE CONTROL VALVEEXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points8 Grommet 19 Pressure control valve housing 1Reverse the

5-109EPOWRPRESSURE CONTROL VALVESERVICE POINTSPressure control valve inspection1. Check:• Pressure control valve 1 • Spring 2 Damage/wear → Replace th

2-1ESPECGENERAL SPECIFICATIONSGENERAL SPECIFICATIONS Item UnitModelFX140Model codeHull F1BEngine/jet 60EDimensionsLength mm (in) 3,340 (131.5)Width mm

EJETPUMPCHAPTER 6JET PUMP UNITINTAKE GRATE, RIDE PLATE, AND INTAKE DUCT...6-1EXPLODED DIAGRAM ...

EJETPUMP123456789TRANSOM PLATE AND HOSES...6-19EXPLODED DIAGRAM ...

6-1EJETPUMPINTAKE GRATE, RIDE PLATE, AND INTAKE DUCTEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsINTAKE G

6-2EJETPUMPINTAKE GRATE, RIDE PLATE, AND INTAKE DUCTEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7 Ride plate 18Bolt 49 Intake duct 110

6-3EJETPUMPJET PUMP UNITJET PUMP UNITEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsJET PUMP UNIT REMOVALFo

6-4EJETPUMPJET PUMP UNITEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7Bolt 48 Collar 49 Rubber plate 210 Bolt 111 Bolt 412 Jet pump uni

6-5EJETPUMPJET PUMP UNITEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSPEED SENSOR DISASSEMBLYFollow the l

6-6EJETPUMPREVERSE GATEREVERSE GATEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsREVERSE GATE REMOVALFollo

6-7EJETPUMPREVERSE GATEEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points9 Roller 110 Bolt 611 Reverse gate stay 212 Nut 113 Washer 114 Bolt

6-8EJETPUMPREVERSE GATEEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points18 Washer 119 Bolt 120 Washer 121 Collar 122 Spring 123 Lever 2 124

2-2ESPECPON*: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2RON*: Research Octane NumberFuel and oilFuel type Regular unleaded

6-9EJETPUMPREVERSE GATESERVICE POINTSLever 1 installation1. Install:• Bolt 1 • Lever 1 2 • Spacer 3 • Reverse gate 4 • Washer 5 • Nut 6 Lever 2 instal

6-10EJETPUMPJET THRUST NOZZLE AND NOZZLE RINGJET THRUST NOZZLE AND NOZZLE RINGEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q

6-11EJETPUMPIMPELLER DUCT AND IMPELLER HOUSING 1IMPELLER DUCT AND IMPELLER HOUSING 1EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part

6-12EJETPUMPIMPELLER DUCT AND IMPELLER HOUSING 1EXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7Bolt 48 Water inlet cover 19 Packing 110

6-13EJETPUMPIMPELLER DUCT AND DRIVE SHAFTIMPELLER DUCT AND DRIVE SHAFTEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART*1: EPNOC grease AP #0Step Procedu

6-14EJETPUMPIMPELLER DUCT AND DRIVE SHAFTEXPLODED DIAGRAM*1: EPNOC grease AP #0Step Procedure/Part name Q’ty Service points8 Drive shaft 19 Rear bear

6-15EJETPUMPIMPELLER DUCT AND DRIVE SHAFTSERVICE POINTSDrive shaft removal1. Remove:• Impeller NOTE:The impeller has left-hand threads. Turn theimpell

6-16EJETPUMPIMPELLER DUCT AND DRIVE SHAFT5. Remove:• Front bearingNOTE:Remove the front bearing with a press.Drive rod:YB-06071Driver rod L3:90890-066

6-17EJETPUMPIMPELLER DUCT AND DRIVE SHAFTDrive shaft installation1. Install:• Oil sealsDriver rod:YB-06071/90890-06606Ball bearing attachment:YB-06085

6-18EJETPUMPIMPELLER DUCT AND DRIVE SHAFT5. Install:• Rear bearing NOTE:• Press the bearing inner/outer race at thesame time holding the drive shaft a

2-3ESPECMAINTENANCE SPECIFICATIONSMAINTENANCE SPECIFICATIONSENGINE Item UnitModelFX140Cylinder headWarpage limit mm (in) 0.1 (0.004)Compression pressu

6-19EJETPUMPTRANSOM PLATE AND HOSESTRANSOM PLATE AND HOSESEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsTR

6-20EJETPUMPTRANSOM PLATE AND HOSESEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6 Hose clamp 27 Cooling water hose 1 Cooling water outl

6-21EJETPUMPTRANSOM PLATE AND HOSESEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points16 Bilge strainer holder 117 Bilge strainer 118 Nut/was

6-22EJETPUMPTRANSOM PLATE AND HOSESSERVICE POINTSBilge strainer inspectionRefer to “JET PUMP UNIT” in Chapter 3.Electric bilge pump inspectionRefer to

6-23EJETPUMPBEARING HOUSINGBEARING HOUSINGEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART*: As requiredStep Procedure/Part name Q’ty Service pointsBEAR

6-24EJETPUMPBEARING HOUSINGEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsBEARING HOUSING DISASSEMBLYFollow

6-25EJETPUMPBEARING HOUSINGEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7 Oil seal 18 Oil seal 19 Oil seal 110 Circlip 111 Bearing 112

6-26EJETPUMPBEARING HOUSINGSERVICE POINTSDriven coupling removal and installation1. Remove and install:• Driven coupling NOTE:• Install the driven cou

6-27EJETPUMPBEARING HOUSINGBearing removal1. Remove:• Bearing NOTE:• Install the bearing with the same specialtools that were used for removal.• Suppo

6-28EJETPUMPBEARING HOUSINGBearing installation1. Install:• Circlip (rear)2. Install:• BearingNOTE:Support the intermediate housing with steelblocks 1

2-4ESPECMAINTENANCE SPECIFICATIONSValve seat width CIntake mm (in) 0.9–1.1 (0.0354–0.0433)Exhaust mm (in) 0.9–1.1 (0.0354–0.0433)Valve margin thicknes

6-29EJETPUMPBEARING HOUSING3. Install:• Oil seal 1 [8 mm (0.31 in)]• Oil seal 2 [11 mm (0.43 in)]Distance a:10.3–10.7 mm (0.41–0.42 in)Distance b:0.6–

E– +ELEC123456789CHAPTER 7ELECTRICAL SYSTEMELECTRICAL COMPONENTS...7-1ELECTRICAL

E– +ELECFUEL CONTROL SYSTEM ...7-28WIRING DIAGRAM ...

E– +ELECINDICATION SYSTEM ...7-44WIRING DIAGRAM ...

7-1E– +ELECELECTRICAL COMPONENTSELECTRICAL COMPONENTSLKJIHGFEDCBA09876543211 Thermoswitch (engine)2 Starter motor3 Engine temperature sensor4 Spark pl

7-2E– +ELECELECTRICAL BOX AND IGNITION COIL BOXELECTRICAL BOX AND IGNITION COIL BOXEXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part

7-3E– +ELECELECTRICAL BOX AND IGNITION COIL BOXEXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points9 Battery box 110 Spacer 211 Bolt 412 Scre

7-4E– +ELECELECTRICAL BOX AND IGNITION COIL BOXEXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points19 Gasket 120 Bolt 221 Ground lead 222 Hol

7-5E– +ELECELECTRICAL BOX AND IGNITION COIL BOXEXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsELECTRICAL B

7-6E– +ELECELECTRICAL BOX AND IGNITION COIL BOXEXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points9 Battery positive lead 110 Starter motor

2-5ESPECMAINTENANCE SPECIFICATIONSPiston ringTop ringType BarrelDimension (B × T) mm (in) 0.90 × 2.75 (0.04 × 0.11)End gap (installed) mm (in) 0.38–0.

7-7E– +ELECELECTRICAL BOX AND IGNITION COIL BOXEXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points19 Tapping screw 120 Bracket 121 Joint con

7-8E– +ELECELECTRICAL BOX AND IGNITION COIL BOXEXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsIGNITION COI

7-9E– +ELECELECTRICAL BOX AND IGNITION COIL BOXEXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsIGNITION COI

7-10E– +ELECELECTRICAL BOX AND IGNITION COIL BOXUP14321432234567819ÊÉÈ1 Starter relay2 Fuse holder3 ECM4 Joint connector5 Joint connector6 Main and fu

7-11E– +ELECELECTRICAL ANALYSISELECTRICAL ANALYSISINSPECTIONCAUTION:• All measuring instruments should be han-dled with special care. Damaged or mis-h

7-12E– +ELECELECTRICAL ANALYSISLow resistance measurementNOTE:• When measuring a resistance of 10 Ω or lesswith the digital tester, the correct measur

7-13E– +ELECELECTRICAL ANALYSISPeak voltage adaptorNOTE:• Throughout this chapter the peak voltageadaptor’s part number has been omitted.Refer to the

7-14E– +ELECIGNITION SYSTEMIGNITION SYSTEMWIRING DIAGRAMFREEPUSHWBFREEPUSHBrBrFREEPUSHWBRBrP/WP/WP/WKR/YB/WB/WOB/OP/GRL/RR/Y R/YB/OB/OB/YB/OB/OB/OB/OB

7-15E– +ELECIGNITION SYSTEMWIRING DIAGRAMFREEPUSHWBFREEPUSHBrBrFREEPUSHWBRBrP/WP/WP/WKR/YB/WB/WOB/OP/GRL/RR/Y R/YB/OB/OB/YB/OB/OB/OB/OB/WRBB/OR/YL/RBr

7-16E– +ELECIGNITION SYSTEMIGNITION SPARK GAP WARNING• When checking the spark gap, do nottouch any of the connections of the sparkgap tester lead wir

2-6ESPECMAINTENANCE SPECIFICATIONSJET PUMP UNIT HULL AND HOOD ELECTRICALOil filterOil filter type Cartridge typeOil pumpOil pump type TrochoidRotor ti

7-17E– +ELECIGNITION SYSTEMIGNITION SYSTEM PEAK VOLTAGE WARNINGWhen checking the electrical components,do not touch any of the connections of thedigit

7-18E– +ELECIGNITION SYSTEM2. Measure:• Pulser coil output peak voltageBelow specification → Replace thepulser coil. NOTE:To crank the engine, connect

7-19E– +ELEC4. Measure:• Rectifier/regulator output voltageBelow specification → Replace the recti-fier/regulator.NOTE:• Before measuring the output p

7-20E– +ELECIGNITION COIL1. Measure:• Primary coil resistanceOut of specification → Replace.NOTE:When measuring a resistance of 10 Ω or lesswith the d

7-21E– +ELECIGNITION SYSTEMENGINE TEMPERATURE SENSOR1. Measure:• Engine temperature sensor resistance(at the specified temperature)Out of specificatio

7-22E– +ELECIGNITION SYSTEMTHERMOSWITCH (ENGINE)1. Check:• Thermoswitch (engine) continuity(at the specified temperature)Out of specification → Replac

7-23E– +ELECIGNITION SYSTEMMAIN AND FUEL PUMP RELAY1. Check:• Main and fuel pump relay continuityFaulty → Replace. Checking steps:• Connect the tester

7-24E– +ELECIGNITION SYSTEMTHROTTLE POSITION SENSOR1. Measure:• Throttle position sensor output voltageOut of specification → Adjust the throttlebodie

7-25E– +ELECIGNITION SYSTEMCAM POSITION SENSOR1. Measure:• Cam position sensor output voltageOut of specification → Replace.NOTE:When operating the Ya

7-26E– +ELECIGNITION SYSTEMINTAKE AIR PRESSURE SENSOR1. Measure:• Intake air pressure sensor output volt-ageOut of specification → Replace.È: Output v

2-7ESPECMAINTENANCE SPECIFICATIONSStatorPulser coil (W – B, R – B)Output peak voltage@cranking 1 V 4@cranking 2 V 4@2,000 r/min V 23@3,500 r/min V 38

7-27E– +ELECIGNITION SYSTEMSLANT DETECTION SWITCH1. Check:• Slant detection switch continuityOut of specification → Replace.PositionLead colorBlue/bla

7-28E– +ELECFUEL CONTROL SYSTEMFUEL CONTROL SYSTEMWIRING DIAGRAM#4#3#2#157P/WP/WP/WFOB/OP/GL/RB/OB/OB/OB/YP/GB/OB/OR/YR/YR/YR/YR/YR/YPu/GPu/YPu/BPu/RO

7-29E– +ELECFUEL CONTROL SYSTEMWIRING DIAGRAM#4#3#2#157P/WP/WP/WFOB/OP/GL/RB/OB/OB/OB/YP/GB/OB/OR/YR/YR/YR/YR/YR/YPu/GPu/YPu/BPu/ROOPR/YR/YR/YB/OB/OB/

7-30E– +ELECFUEL CONTROL SYSTEMFUEL PUMP1. Check:• Fuel pump operating soundFuel pump does not sound → Measurethe fuel pressure.Refer to “FUEL INJECTI

7-31E– +ELECFUEL CONTROL SYSTEMFUEL INJECTORRefer to “FUEL INJECTION SYSTEM”in Chapter 4.MAIN AND FUEL PUMP RELAYRefer to “IGNITION SYSTEM”.OIL PRESSU

7-32E– +ELECSTARTING SYSTEMSTARTING SYSTEMWIRING DIAGRAMFREEPUSHBrBrFREEPUSHWBRBr43218765R/Y718R/YL/RBrLYR/Y R/YBR/YR/YYRBrBrBrBrRBrRBBR4321876R/YR/YR

7-33E– +ELECSTARTING SYSTEMBATTERYRefer to “ELECTRICAL” in Chapter 3.WIRING CONNECTIONS1. Check:• Wiring connectionsPoor connections → Properly connec

7-34E– +ELECSTARTING SYSTEMSTARTER RELAY1. Inspect:• Brown lead terminal• Black lead terminalLoose → Tighten.2. Check:• Starter relayFaulty → Replace.

7-35E– +ELECSTARTER MOTORSTARTER MOTOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART *: As requiredStep Procedure/Part name Q’ty Service pointsSTARTER

7-36E– +ELECSTARTER MOTOREXPLODED DIAGRAM*: As requiredStep Procedure/Part name Q’ty Service points8 Starter motor rear cover 19 O-ring 110 Shim * t =

2-8ESPECMAINTENANCE SPECIFICATIONSThermoswitchON temperature (Engine) °C (°F) 84–90 (183–194)OFF temperature (Engine) °C (°F) 70–84 (158–183)ON temper

7-37E– +ELECSTARTER MOTOREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points18 Spacer 119 Holder 120 Starter motor yoke 1Reverse the disassem

7-38E– +ELECSTARTER MOTORSERVICE POINTSArmature inspection1. Inspect:• Armature shaft 1 Damage/wear → Replace.12. Inspect:• CommutatorDirt → Clean wit

7-39E– +ELECSTARTER MOTOR6. Inspect:• Armature coil continuityOut of specification → Replace.Armature coil continuity:Commutator segments 1 Continuity

7-40E– +ELECCHARGING SYSTEMCHARGING SYSTEMWIRING DIAGRAMBRR123RRRGGGGGGBGBGGGGG41 Rectifier/regulator2 Fuse (20A)3 Battery4 Lighting coilB: BlackG : G

7-41E– +ELECCHARGING SYSTEMFUSERefer to “STARTING SYSTEM”.BATTERYRefer to “ELECTRICAL” in Chapter 3.LIGHTING COILRefer to “IGNITION SYSTEM”.RECTIFIER/

7-42E– +ELECELECTRIC BILGE PUMPELECTRIC BILGE PUMPWIRING DIAGRAM432187657 18 L/RBrLYR/Y R/YR/YR/YRYBrBrBrBBBBBBRR32145RPPORBR R R 1 2 3 4 5 6 7

7-43E– +ELECELECTRIC BILGE PUMPELECTRIC BILGE PUMP1. Check:• Electric bilge pump operationIncorrect → Replace.Checking steps:• Suspend the electric bi

7-44E– +ELECINDICATION SYSTEMINDICATION SYSTEMWIRING DIAGRAMGGR 43R Br Br L/RBrLYR/Y R/YRBPROR/YR/YR/YRPW/BR/YB/OR/Y R/YR/YR/YYR R P P P1 2 3 5 6

7-45E– +ELECINDICATION SYSTEMFUSERefer to “STARTING SYSTEM”.BATTERYRefer to “ELECTRICAL” in Chapter 3.LIGHTING COILRefer to “IGNITION SYSTEM”.RECTIFIE

7-46E– +ELECINDICATION SYSTEMOIL PRESSURE SWITCH1. Measure: • Oil pressure switch continuityOut of specification → Replace.Vacuum/pressure pump gauge

EHOW TO USE THIS MANUALMANUAL FORMATAll of the procedures in this manual are organized in a sequential, step-by-step format. The informa-tion has been

2-9ESPECTIGHTENING TORQUESTIGHTENING TORQUESSPECIFIED TORQUESPart to tightened Part nameThread sizeQ’tyTightening torqueRemarksN•mkgf•mft•lbFuel syste

7-47E– +ELECINDICATION SYSTEMDisplay function1. Check:• Display functionNot operate → Replace the multifunc-tion meter.L/BL/BBL/RB/YB/YR/WB/GBR/WYYRRW

7-48E– +ELECINDICATION SYSTEMSpeedometer display1. Check:• Speedometer displayDoes not display → Measure the speedsensor output voltage and pulses.Wit

7-49E– +ELECINDICATION SYSTEMTachometer display1. Check:• Tachometer displayDoes not display → Check the enginespeed using the “Engine monitor” of the

7-50E– +ELECINDICATION SYSTEMOverheat warning indicator1. Check:• Overheat warning indicatorNot operating → Replace the multifunc-tion meter. Checking

7-51E– +ELECINDICATION SYSTEMDiagnostic display1. Check:• Diagnostic displayDoes not display → Replace the multi-function meter. Checking steps:• Remo

EHULLHOOD123456789CHAPTER 8HULL AND HOODHANDLEBAR ...8

EHULLHOODFRONT HOOD...8-21EXPLODED DIAGRAM ...

EHULLHOODDECK AND HULL...8-47EXPLODED DIAGRAM ...

8-1EHULLHOODHANDLEBARHANDLEBAREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsHANDLEBAR COVER REMOVALFollow

8-2EHULLHOODHANDLEBAREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsHANDLEBAR REMOVALFollow the left “Step”

2-10ESPECTIGHTENING TORQUESEngineEngine unit – engine mount Bolt M8 4 17 1.7 12271LTOil filter ——117 1.7 12Coupling cover Bolt M6 1 7.8 0.78 5.6572LTT

8-3EHULLHOODHANDLEBAREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points10 Hose packing 111 Buzzer 112 Handlebar assembly 1NOTE:• Pass the QS

8-4EHULLHOODHANDLEBAREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsHANDLEBAR DISASSEMBLYFollow the left “S

8-5EHULLHOODHANDLEBAREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8 Handlebar switch assembly 19Screw 210 Throttle lever assembly 111 H

8-6EHULLHOODHANDLEBARSERVICE POINTSHandlebar inspection1. Inspect:• HandlebarBends/cracks/damage → Replace.Handlebar switch inspectionRefer to “STARTI

8-7EHULLHOODHANDLEBAR3. Install:• Throttle cableNOTE:Fit the seal into the groove in the bracket.4. Adjust:• QSTS cable length a NOTE:• Before adjusti

8-8EHULLHOODQSTS GRIPQSTS GRIPEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsQSTS GRIP DISASSEMBLYFollow th

8-9EHULLHOODQSTS GRIPEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7 Screw/washer 2/28 Spacer 19 QSTS shift lock lever 110 Spring 111 Sp

8-10EHULLHOODQSTS GRIPSERVICE POINTSQSTS cable inspection1. Inspect:• QSTS cablesFrays/kinks/rough movement → Replace.QSTS grip inspection1. Inspect:•

8-11EHULLHOODSTEERING MASTERSTEERING MASTEREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSTEERING MASTER R

8-12EHULLHOODSTEERING MASTEREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSTEERING MASTER DISASSEMBLYFollo

2-11ESPECTIGHTENING TORQUESExhaust manifold 1 – cylinder head1stBolt M8 622 2.2 16242LT2nd 22 2.2 163rd 35 3.5 25Exhaust manifold 2 – cylinder head1st

8-13EHULLHOODSTEERING MASTEREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points11 Tilt stopper 112 Bolt/nut/holder 4/4/413 Retainer 214 Steer

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

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 points6Nut 17 Steering cable 18 Packing

8-17EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points16 Shift cable holder 217 Nut 118

8-18EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADSERVICE POINTS WARNINGWhen routing the cables, do not grasp thecable by the outer crimped shea

8-19EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADQSTS cable (jet pump end) installation1. Install:• QSTS cable (jet pump end) WARNINGThe QSTS

8-20EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADShift cable holder installation1. Install:• Shift cable holdersNOTE:Install the shift cable ho

8-21EHULLHOODFRONT HOODFRONT HOODEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsFRONT HOOD REMOVALFollow th

8-22EHULLHOODEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8Bolt 49 Service lid 1 110 Screw 411 Service lid 2 1Reverse the removal steps

2-12ESPECTIGHTENING TORQUESReduction drive gear case – crankcase1stBolt M6 23.7 0.37 2.7572LT2nd 7.6 0.76 5.51stBolt M8 715 1.5 11572LT2nd 28 2.8 20Ho

8-23EHULLHOODFRONT HOODEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsHINGE DISASSEMBLYFollow the left “Ste

8-24EHULLHOODFRONT HOODEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8Clamp 19 Damper boots 110 Damper 1Reverse the disassembly steps fo

8-25EHULLHOODSTEERING CONSOLE COVEREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsMETER AND MIRROR REMOVAL

8-26EHULLHOODSTEERING CONSOLE COVEREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6Bolt 47 Multifunction meter 18 Hose packing 19 Grommet

8-27EHULLHOODSTEERING CONSOLE COVEREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSIDE COVER REMOVAL Follow

8-28EHULLHOODSTEERING CONSOLE COVEREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSTEERING CONSOLE COVER AN

8-29EHULLHOODSTEERING CONSOLE COVEREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7Bolt 28 Steering console cover 1NOTE:To remove the con

8-30EHULLHOODSTEERING CONSOLE COVEREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsGLOVE COMPARTMENT DISASSE

8-31EHULLHOODSTEERING CONSOLE COVERSERVICE POINTSGlove compartment assembly installation1. Install:• Hinge assemblyNOTE:When installing the hinge asse

8-32EHULLHOODHOSESHOSESEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsHOSES REMOVALFollow the left “Step” f

2-13ESPECTIGHTENING TORQUESPlug (vacuum pressure) Bolt M6 4 10 1.0 7.2Engine temperature sensor – crankcase——115 1.5 11Thermoswitch (engine) – crankca

8-33EHULLHOODHOSESEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points4Clamp 25 Cooling water hose 26Nut 27 Cooling water pilot outlet 28 Pack

8-34EHULLHOODSHIFT LEVERSHIFT LEVEREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSHIFT LEVER REMOVAL Follo

8-35EHULLHOODSHIFT LEVEREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6Screw 37 Base assembly 18 Nut/washer 3/39Screw 310 Plate 1Reverse

8-36EHULLHOODSHIFT LEVEREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsBASE DISASSEMBLYFollow the left “Ste

8-37EHULLHOODSHIFT LEVERSERVICE POINTSBase assembly1. Install:• Shift arm• ShaftInstallation steps:• Install the shift arm 1 so that it comes incontac

8-38EHULLHOODSEATS AND HAND GRIPSEATS AND HAND GRIPEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSEATS AND

8-39EHULLHOODSEATS AND HAND GRIPEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points9Nut 110 Projection 111 Washer 112 Packing 113 Nut 414 Bol

8-40EHULLHOODSEATS AND HAND GRIPEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points17 Projection 118 Washer 219 Nut/washer 4/420 Bolt 421 Han

8-41EHULLHOODSEATS AND HAND GRIPSERVICE POINTSSeat lock inspection1. Inspect:• Front seat lock• Rear seat lockDamage/wear → Replace.

8-42EHULLHOODEXHAUST SYSTEMEXHAUST SYSTEMEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsEXHAUST SYSTEM REMO

2-14ESPECTIGHTENING TORQUESWater inlet cover/water inlet strainer – impeller ductBolt M6 4 6.6 0.66 4.8572LTDrive shaft nut – drive shaft Nut — 1696.9

8-43EHULLHOODEXHAUST SYSTEMEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points5 Exhaust joint clamp 16 Exhaust joint 17 Nut/washer 6/68 Exhau

8-44EHULLHOODEXHAUST SYSTEMEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsEXHAUST JOINT DISASSEMBLYFollow t

8-45EHULLHOODEXHAUST SYSTEMSERVICE POINTSExhaust system inspection1. Inspect:• Water lock bandCracks/damage → Replace.2. Inspect:• Rubber hosesBurns/c

8-46EHULLHOODEXHAUST SYSTEMExhaust system installation1. Install:• Exhaust jointNOTE:Be sure to fit the slit a on the exhaust jointwith the projection

8-47EHULLHOODDECK AND HULLDECK AND HULLEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsDECK AND HULL DISASSE

8-48EHULLHOODDECK AND HULLEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points11 Packing 212 Nut 4NOTE:To remove the cleat, remove the exhaust

8-49EHULLHOODENGINE MOUNTENGINE MOUNTEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsENGINE MOUNT REMOVALFol

8-50EHULLHOODENGINE MOUNTHULL REPAIRShallow scratches1. Sand the scratches with 400 grit sandpa-per (either wet or dry) until the scratchesare smooth.

8-51EHULLHOODENGINE MOUNTCracks and puncturesNOTE:Before attempting to repair any cracks orpunctures, refer to “WATERCRAFT FRPREPAIR MANUAL”.1. Remove

8-52EHULLHOODENGINE MOUNTInsert nutNOTE:Use the insert nut when:• A pop nut which was attached to the hullslipped off or,• When a bolt which was faste

2-15ESPECTIGHTENING TORQUESSteering cable locknut (jet thrust nozzle side)Nut — 1 6.5 0.65 4.7Steering cable grommet – hull Nut — 1 5.9 0.59 4.3Steeri

8-53EHULLHOODENGINE MOUNT4. First, apply tape 1 to the inner surface ofthe hull and then laminate fiberglass matsover the tape with resin.NOTE:When it

8-54EHULLHOODENGINE MOUNT2. To prevent water from entering the ure-thane foam, apply silicone sealant to theinside of the hole as shown.3. Install the

ETRBLANLSCHAPTER 9TROUBLE ANALYSISINTRODUCTION...9-1FEATUR

ETRBLANLS123456789STATIONARY TEST ...9-28Sparking ignition coil procedure:

9-1ETRBLANLSINTRODUCTIONINTRODUCTIONFEATURESThe newly developed Yamaha Diagnostic System provides quicker detection and analysis of enginemalfunctions

9-2ETRBLANLSINTRODUCTIONHARDWARE REQUIREMENTSMake sure that your computer meets the following requirements before using this software.NOTE:• The amoun

9-3ETRBLANLSGETTING STARTEDGETTING STARTEDThis section provides information on installing the Yamaha Diagnostic System under Windows 95,Windows 98, Wi

9-4ETRBLANLSGETTING STARTED4. Click the Next button to start the installation process. (Fig. 3)Fig. 3NOTE:If the Yamaha Diagnostic System has already

9-5ETRBLANLSGETTING STARTED5. Check the target directory and the program name for the Yamaha Diagnostic System which aredisplayed in the dialog box.Cl

9-6ETRBLANLSGETTING STARTED6. After the installation is completed, the following dialog box appears.Click the Finish button to quit the installation p

2-16ESPECTIGHTENING TORQUESBow eye – hull Bolt M6 2 13 1.3 9.4Drain plug/packing – hull Bolt M5 4 2.0 0.2 1.4Engine mount – hull Bolt M8 8 17 1.7 1257

9-7ETRBLANLSGETTING STARTEDUPDATING THE DATABASENOTE:When installing the Yamaha Diagnostic System for the first time, be sure to update the database.1

9-8ETRBLANLSGETTING STARTED4. Click the Update database [F1] button or press the F1 key on your keyboard. (Fig. 12)Fig. 121First menu2Click to update

9-9ETRBLANLSGETTING STARTED5. Insert the compact disc into the computer’s CD-ROM drive.NOTE:• All the database files will be copied from the compact d

9-10ETRBLANLSGETTING STARTED7. When the database is updated a confirmation screen is displayed.To quit, click the OK button or press the Enter key on

9-11ETRBLANLSOPERATINGOPERATINGCONNECTING THE COMPUTER TO THE WATERCRAFTNOTE:Be sure to use the enclosed communication cable to connect the computer a

9-12ETRBLANLSOPERATINGCONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFTModels: FX140Top viewFig. 1813-pin communication coupler2Wire harness couple

9-13ETRBLANLSOPERATINGOPENING THE YAMAHA DIAGNOSTIC SYSTEM1. Push the start switch to start the engine.2. Turn on your computer and start up Windows 9

9-14ETRBLANLSOPERATING5. Click the Starting service tool [Enter] button or press the Enter key on your keyboard.(Fig. 21)Fig. 211First menu2Click to s

9-15ETRBLANLSOPERATING6. Click or press any key to display the main menu.Fig. 22NOTE:If a diagnosis record is stored in the ECM, “Diagnosis record ava

9-16ETRBLANLSOPERATINGSELECTING COMMANDS FROM THE MAIN MENUEight commands appear in the Main Menu. Select a command in any of the following three ways

2-17ESPECTIGHTENING TORQUESGENERAL TORQUEThis chart specifies tightening torques for stan-dard fasteners with a standard ISO threadpitch. Tightening t

9-17ETRBLANLSOPERATINGEXPLANATION OF EACH COMMAND1. DiagnosisThe diagnosis codes, their corresponding part name, the diagnosing results, and the diagn

9-18ETRBLANLSOPERATING6. Data loggerTwo out of six items (engine speed, battery voltage, throttle position, intake air pressure, enginetemperature, an

9-19ETRBLANLSOPERATINGDIAGNOSISThe diagnosis codes of malfunctions recorded in the watercraft’s ECM, the diagnosis codes’ corre-sponding part name, th

9-20ETRBLANLSOPERATINGPrintBy selecting the Print command in the Diagnosis, Diagnosis record, Engine monitor, or Data loggermode, the data from the co

9-21ETRBLANLSOPERATINGSaveBy selecting the Save command in the Diagnosis, Diagnosis record, Engine monitor, or Data loggermode, the corresponding data

9-22ETRBLANLSOPERATING2. Select the disk and folder where the data will be saved and specify its file name. (Fig. 30)Fig. 301Choose folder to save in2

9-23ETRBLANLSOPERATINGDIAGNOSIS RECORDThe diagnosis codes of malfunctions that have been recorded in the watercraft’s ECM, the diagnos-tic codes’ corr

9-24ETRBLANLSOPERATINGDeleting diagnosis record in the ECM:1. Select the item that you wish to delete by either clicking it or pressing the up or down

9-25ETRBLANLSOPERATING3. Click the OK button or press the Enter key on your keyboard. (Fig. 35) The selected item isdeleted. To cancel deleting the it

9-26ETRBLANLSOPERATINGENGINE MONITOR WARNINGDo not use the Engine Monitor function to check the engine condition while operating awatercraft, otherwis

2-18ESPECCABLE AND HOSE ROUTINGCABLE AND HOSE ROUTINGDOWNBOW20˚DOWNUP+GF-FE-EGFFCDAEEDCBBAA-AB-BD-DC-C211143657651890AB65CDEF432G1 Fuel tank breather

9-27ETRBLANLSOPERATINGOperating procedure:1. To scroll the display and view other items, click or in the scroll bar, or press the up or downarrow

9-28ETRBLANLSOPERATINGSTATIONARY TESTSelecting this command displays a window where stationary tests (spark ignition coil #, operateinjector #, and op

9-29ETRBLANLSOPERATING1. Select the test that you wish to perform by either clicking it or pressing the up or down arrowkeys on your keyboard. (Fig. 3

9-30ETRBLANLSOPERATING5. Click the Execute button or press the Enter key on your keyboard. (Fig. 42)Fig. 42Fig. 43

9-31ETRBLANLSOPERATINGNOTE:If the engine is running an error message is displayed. Follow the instructions that appear. (Fig. 44)Fig. 446. While check

9-32ETRBLANLSOPERATING9. To perform the test again to the same cylinder, click the Execute button or press the Enter keyon your keyboard. To perform t

9-33ETRBLANLSOPERATINGOperating injector procedure:A voltage is applied to the injector of the selected cylinder, the injector is activated, and then

9-34ETRBLANLSOPERATING3. Click the Execute button or press the Enter key on your keyboard. (Fig. 49)Fig. 49NOTE:If an error occurs while the test is b

9-35ETRBLANLSOPERATING5. To perform the test again on the same cylinder, click the Execute button or press the Enter keyon your keyboard. To perform t

9-36ETRBLANLSOPERATING1. Select the test to be performed, and then click the Select button or press the Enter key on yourkeyboard. (Fig. 52)Fig. 52NOT

EIMPORTANT INFORMATIONIn this Service Manual particularly important information is distinguished in the following ways.The Safety Alert Symbol means A

2-19ESPECCABLE AND HOSE ROUTING3A3A3A3A3A3AS P A R E20A3A3AMAINABCDBCFD86123455EEAAB01CDEFA3BG9870505BA5E-EF1 Throttle cable2 Handlebar switch lead3 Q

9-37ETRBLANLSOPERATING2. Click the Execute button or press the Enter key on your keyboard. (Fig. 53)Fig. 53NOTE:If an error occurs while the test is b

9-38ETRBLANLSOPERATINGACTIVE TESTSelecting this command displays a window where active tests can be selected. WARNINGAvoid clicking the Execute and Ca

9-39ETRBLANLSOPERATINGDropping a cylinder:Start the engine and observe the changes in engine speed for 20 seconds.For the first ten seconds operate al

9-40ETRBLANLSOPERATINGNOTE:If the engine is not running, an error message is displayed. Follow the instructions that appear. (Fig.57)Fig. 575. While c

9-41ETRBLANLSOPERATINGDATA LOGGERMonitor item selectionA window appears that allows you to select the Data comparison graph or the Engine operatinghou

9-42ETRBLANLSOPERATINGData display item selectionA window appears that allows you to select the items to be graphed. No more than two items can bedisp

9-43ETRBLANLSOPERATINGData comparison graphA line graph appears with the items selected in the Data display item selection window on the ver-tical axe

9-44ETRBLANLSOPERATINGEngine operating hours according to engine speedThe operating hours as compared to the engine speed and the total operating hour

9-45ETRBLANLSOPERATINGECM No.The ECM part number of the watercraft is read from the ECM and is displayed. (Fig. 63)Fig. 63

9-46ETRBLANLSOPERATINGEXITThe program is exited.Operating procedure:1. Click the Exit button or press any number key (1–8).Fig. 642. Click the OK butt

2-20ESPECCABLE AND HOSE ROUTING52A0HBC8DEFG208125928674654321È71 Cooling water hose (cooling water inlet)2 Bilge hose 13 Electric bilge pump4 Bilge ho

9-47ETRBLANLSOPERATINGUNINSTALLING THE YAMAHA DIAGNOSTIC SYSTEMUse the following procedure to uninstall the Yamaha Diagnostic System.1. Exit all progr

9-48ETRBLANLSOPERATING5. Click the Yes button in the confirmation window to uninstall the utility software. To cancel theuninstall operation of the ut

9-49ETRBLANLSOPERATING6. If the following message appears, click the Details... button.Fig. 711Uninstall completed. Some elements could not be removed

9-50ETRBLANLSTROUBLESHOOTINGTROUBLESHOOTINGError content Cause ActionCommunication cable related error occursCommunication cable is discon-nected.Conn

9-51ETRBLANLSAPPENDIXAPPENDIXSETTING THE DESKTOP AREAUse the following procedure to set the Yamaha Diagnostic System desktop area.Compatible with VGA

9-52ETRBLANLSAPPENDIX4. Click the OK button in the confirmation window to set the display area. To cancel, click the Can-cel button. (See figs. 75–76.

9-53ETRBLANLSTROUBLE ANALYSISTROUBLE ANALYSISNOTE:The following items should be checked before the “TROUBLE ANALYSIS CHART” is consulted.1. The batter

9-54ETRBLANLSTROUBLE ANALYSISPOWER UNITCompression 5Cylinder head gaskets 5Cylinder block 5Crankcase 5Piston rings 5Pistons 5Bearings 5Thermostat 5Val

9-55ETRBLANLSTROUBLE ANALYSISJET PUMP UNITDuct 6Impeller 6Intake grate 6Bearings 6Intake duct 6Water inlet hose 6Bilge hose 6Bilge strainer 3Bilge hos

9-56ETRBLANLSTROUBLE ANALYSISStarting system• Start switch 7• Starter relay 7• Starter motor 7Charging system• Lighting coil 7• Rectifier/regulator 7•

2-21ESPECCABLE AND HOSE ROUTINGBCFEAD-DÎÏËËËËÊÈÉÕÖ×ÌÐÌÓØÐÔÌÊÒÒÑÐËCAFEB245311DDÍ1 Thermostat2 Pressure control valve3 Cooling water hose (cooling water

9-57ETRBLANLSTROUBLE ANALYSISSelf-diagnosisWith the engine running, press the hour meter/voltmeter display select switch 1 and thespeedometer display

WIRING DIAGRAMFX1401 Fuse (20A)2 Fuse (3A)3 Starter relay4 Slant detection switch5 Main and fuel pump relay6 ECM7 Rectifier Regulator8 Cam position se

YAMAHA MOTOR CORPORATION, USAPrinted in USAMar. 2002 – ?.? × 1 CRF1B-28197-1E-11(FX1000-A)(E_1)

1234567891011 12 13151718192021232425262728R R FREEPUSHFREEPUSHFREEPUSHG/OR/YB/OL/BL/RB/GR/YB/WR/YB/RB/WPOOPPOB/OP/GR RBBBBPBLLBWBBRRBYYR/WR/WB/YB/YR

RRG/OB/WR/YR/YRR/YRR/YR/YBrBBrBLB/OYL/RL/BR/YP/WGWB/YB/OB/RW/RW/BG/OP/GPB/YW/BBPu/GPu/BPu/RPu/YR/YR/YR/YR/YOPRPPORBB/OR/YLR/YW/BGBrBBBB/OGGGBPP/GOBBB/

2-22ESPECCABLE AND HOSE ROUTINGBCFEAD-DÎÏËËËËÊÈÉÕÖ×ÌÐÌÓØÐÔÌÊÒÒÑÐËCAFEB245311DDÍÒ To exhaust pipeÓ To install the hose, align the white paint mark onth

2-23ESPECCABLE AND HOSE ROUTINGBAAA-AB3456A11789021ËÊÉÈ1 Wire harness2 Ground lead3 Wire harness coupler4 Cam position sensor coupler5 Thermoswitch (e

2-24ESPECCABLE AND HOSE ROUTINGBDAA1243756098A-AÊÉÈËÌÍÎÏÐÑÎÏ1 Engine temperature sensor coupler2 Lighting coil coupler3 Pulser coil coupler4 Thermoswi

2-25ESPECCABLE AND HOSE ROUTINGBDAA1243756098A-AÊÉÈËÌÍÎÏÐÑÎÏÈ To generatorÉ To engine temperature sensorÊ To thermoswitch (engine)Ë To thermoswitch (e

EINSPADJ123456789CHAPTER 3PERIODIC INSPECTION AND ADJUSTMENTMAINTENANCE INTERVAL CHART ...

3-1EINSPADJMAINTENANCE INTERVAL CHARTMAINTENANCE INTERVAL CHARTThe following chart should be considered strictly as a guide to general maintenance int

3-2EINSPADJCONTROL SYSTEMPERIODIC SERVICECONTROL SYSTEMSteering master inspection1. Inspect:• Steering masterExcessive play → Replace the steeringmast

EHOW TO USE THIS MANUAL1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start ofeach removal and disassembly s

3-3EINSPADJCONTROL SYSTEMNOTE:If the steering cable cannot be properlyadjusted by the cable joint at the steering mas-ter end, adjust the cable joint

3-4EINSPADJCONTROL SYSTEM2. Adjust:• Throttle lever free playAdjustment steps:NOTE:• When not replacing the throttle cable orremoving the cable from t

3-5EINSPADJCONTROL SYSTEM WARNINGAfter adjusting the free play, turn the han-dlebar to the right and left and make surethat the trolling speed does no

3-6EINSPADJCONTROL SYSTEM2. Adjust:• QSTS cable NOTE:If the QSTS cable cannot be properly adjustedby the cable joint at the QSTS converter end,adjust

3-7EINSPADJCONTROL SYSTEMShift cable inspection and adjustment1. Check:• Reverse gate stopper lever positionIncorrect → Adjust.Checking steps:• Set th

3-8EINSPADJCONTROL SYSTEMTrolling speed check and adjustment1. Measure:• Trolling speedOut of specification → Adjust. Trolling speed:1,600–1,800 r/mi

3-9EINSPADJFUEL SYSTEMFUEL SYSTEM WARNINGWhen removing fuel system parts, wrapthem in a cloth and take care that no fuelspills into the engine compart

3-10EINSPADJPOWER UNITPOWER UNITValve clearance adjustmentThe following procedure applies to all of thevalves.NOTE:• Valve clearance adjustment should

3-11EINSPADJPOWER UNIT4. Measure:• Valve clearanceOut of specification → Adjust.Valve clearance (cold):Intake valve:0.11–0.20 mm (0.0043–0.0079 in)Exh

3-12EINSPADJPOWER UNIT5. Remove:• Timing chain tensioner cap bolt 1 • Gasket16. Turn the timing chain tensioner rod fullyclockwise with a thin screwdr

EA50001-1-4SYMBOLSSymbols 1 to 9 are designed as thumb-tabsto indicate the content of a chapter.1General Information2Specifications3Periodic Inspectio

3-13EINSPADJPOWER UNIT8. Adjust:• Valve clearanceAdjustment steps:• Remove the valve lifter 1 and the valvepad 2.NOTE:• Cover the timing chain opening

3-14EINSPADJPOWER UNITNOTE:The new valve pad number is only anapproximation. The valve clearance mustbe measured again and the above stepsshould be re

3-15EINSPADJPOWER UNITIntakeExhaustMEASURED CLEARANCEORIGINAL VALVE PAD NUMBER120 125 130 135 140 145150 155 160 165 170 175 180 185 190 195 200 205 2

3-16EINSPADJPOWER UNIT9. Remove:• Dial gauge• Dial gauge stand• Dial gauge needle10. Install:• All removed partsNOTE:For installation, reverse the rem

3-17EINSPADJPOWER UNIT• Remove the oil filler cap 1 and check foroil on the dipstick 2.• If there is no oil on the dipstick, pourenough oil so that th

3-18EINSPADJPOWER UNIT• If the engine oil is below the minimumlevel mark a, add sufficient oil of the rec-ommended type to raise it to the correctleve

3-19EINSPADJPOWER UNIT2. Remove:• Oil filler cap 1 13. Insert the tube of an oil changer into the oilfiller hole.4. Operate the oil changer to extract

3-20EINSPADJPOWER UNIT6. Pour the specified amount of the recom-mended engine oil into the oil filler hole.7. Fill:• Oil tank (with the specified amou

3-21EINSPADJPOWER UNIT2. Remove the air filter element and check itfor dirt and oil. Replace the air filter ele-ment if there is any oil buildup.CAUTI

3-22EINSPADJPOWER UNIT3. Inspect:• Electrodes 1 Damage/wear → Replace.• Insulator color 2 Distinctly different color → Check theengine condition. 4. C

EINDEXGENERAL INFORMATION1GEN INFOSPECIFICATIONS2SPECPERIODIC INSPECTION AND ADJUSTMENT3INSP ADJFUEL SYSTEM4FUELPOWER UNIT5POWRJET PUMP UNIT6JETPUMPEL

3-23EINSPADJPOWER UNIT/ELECTRICAL7. Install:• Air filter element• Air filter case coverT R..Air filter case cover screw:2.5 N • m (0.25 kgf • m, 1.8 f

3-24EINSPADJELECTRICAL1. Remove:• Bands• Battery negative lead 1 • Battery positive lead 2 • Battery• Battery breather hose 3 WARNING• When removing

3-25EINSPADJELECTRICAL3. Inspect:• Specific gravityOut of specification → Charge.4. Install:• Filler capsCAUTION:Before installation, rinse off any fl

3-26EINSPADJJET PUMP UNITJET PUMP UNITImpeller inspection1. Check:• Impeller 1 Damage/wear → Replace.Nicks/scratches → File or grind.2. Measure:• Impe

3-27EINSPADJJET PUMP UNIT/BILGE PUMPWater inlet strainer inspection1. Inspect:• Water inlet strainerContaminants → Clean.Cracks/damage → Replace.Inspe

3-28EINSPADJBILGE PUMP/GENERALElectric bilge pump strainer inspection1. Inspect:• Cap• StrainerContaminants → Clean.Inspection steps:• Remove the band

3-29EINSPADJGENERALLubrication points1. Lubricate:• Throttle cable (handlebar end)NOTE:Before lubricating the throttle cable, squeezethe throttle leve

3-30EINSPADJGENERAL5. Lubricate:• Nozzle pivot shaft • Steering cable (nozzle end)• QSTS cable (nozzle end)Recommended grease:Yamaha marine grease, Ya

3-31EINSPADJGENERAL7. Fill:• Intermediate housingNOTE:Fill the intermediate housing with the recom-mended grease through the grease nipple 1.Recommend

EFUEL123456789CHAPTER 4FUEL SYSTEMFUEL TANK AND FUEL PUMP MODULE...4-1EXPLODED DIAGRAM ...

4-1EFUELFUEL TANK AND FUEL PUMP MODULEFUEL TANK AND FUEL PUMP MODULEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Servic

4-2EFUELFUEL TANK AND FUEL PUMP MODULEEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points4 Fuel tank breather hose 1NOTE:Make sure that the i

4-3EFUELFUEL TANK AND FUEL PUMP MODULEEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points13 Fuel sender assembly 114 Hose clamp 215 Fuel fill

4-4EFUELFUEL TANK AND FUEL PUMP MODULESERVICE POINTSFuel hose disconnection1. Disconnect:• Fuel hoseRefer to “FUEL INJECTION SYSTEM”.Fuel pump module

4-5EFUELFUEL TANK AND FUEL PUMP MODULECheck valve inspection1. Check:• Check valveFaulty → Replace.Checking steps:• Connect a hose to the end of check

4-6EFUELFUEL TANK AND FUEL PUMP MODULEFuel pump filter inspection1. Inspect:• Fuel pump filter 1 Clog/contaminants → Wash the fuelpump filter in keros

4-7EFUELFUEL INJECTION SYSTEMFUEL INJECTION SYSTEMEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsTHROTTLE B

4-8EFUELFUEL INJECTION SYSTEMEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7 Throttle cable 18Bolt 29 Throttle cable holder 110 Cover 11

4-9EFUELFUEL INJECTION SYSTEMEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points17 Throttle bodies 118 Intake air pressure sensor coupler 119

4-10EFUELFUEL INJECTION SYSTEMEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsAIR FILTER CASE REMOVALFollow

EGENINFO123456789CHAPTER 1GENERAL INFORMATIONIDENTIFICATION NUMBERS ...1-1PRIMA

4-11EFUELFUEL INJECTION SYSTEMEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8 Wire harness coupler 19Bolt 310 Air filter case 111 Bolt 2

4-12EFUELFUEL INJECTION SYSTEMEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points18 Grommet 119 Throttle body joint 420 Band 221 Bolt 222 Air

4-13EFUELFUEL INJECTION SYSTEMEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsTHROTTLE BODY DISASSEMBLYFollo

4-14EFUELFUEL INJECTION SYSTEMEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points11 Intake air temperature sensor 112 Screw 113 Bracket 1 114

4-15EFUELFUEL INJECTION SYSTEMEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points23 Screw/spring 4/424 Bypass air screw 425 Spring 426 Washer

4-16EFUELFUEL INJECTION SYSTEMSERVICE POINTSHose clamps removal1. Remove:• Hose clampsCAUTION:If the hose clamps are removed withoutcutting the joint

4-17EFUELCAUTION:• Do not rotate the quick connector tab 1past the stopper position a, otherwise itcould be damaged.• When the fuel hoses are disconne

4-18EFUELFUEL INJECTION SYSTEMFuel hose installation (replacing with new fuel hose)1. Install:• Fuel hose 1 NOTE:• To install the fuel hose, be sure t

4-19EFUELFUEL INJECTION SYSTEMFuel injector inspectionCAUTION:The throttle bodies should not be disas-sembled unnecessarily.1. Check:• InjectorDirt/re

4-20EFUELFUEL INJECTION SYSTEM2. Check:• Fuel passagesObstruction → Clean.Checking steps:• Wash the throttle body in a petroleumbased solvent.Do not u