Service ManualSR2302004
3. Avoid skin contact with lubricants; do not,for example, place a soiled wiping-rag inone’s pocket.4. Hands, and any other part of the bodywhich have
5-5POWER UNIT x5POWR
5-6POWER UNIT5POWRCAUTION:
5-7POWER UNIT x5POWR
5-8POWER UNIT5POWRUNIT.”
5-9POWER UNIT x5POWREXHAUST PIPE 3 (Cont’d.)
5-10POWER UNIT5POWREXHAUST PIPE 3 (Cont’d.)
5-11POWER UNIT x5POWRPIPE 3.”MOTOR.”
5-12POWER UNIT5POWREXHAUST PIPES 1 AND 2 (Cont’d.)
5-13POWER UNIT x5POWRAND 2.”
5-14POWER UNIT5POWREXHAUST MANIFOLD (Cont’d.)
DISASSEMBLY AND ASSEMBLY1. Clean parts with solvent and compressed-air on disassembling them.2. Oil the contact surfaces of moving parts onassembly.3.
5-15POWER UNIT x5POWRUNIT.”“THERMOSTAT.”
5-16POWER UNIT5POWROIL TANK (Cont’d.)
5-17POWER UNIT x5POWROIL TANK (Cont’d.)
5-18POWER UNIT5POWROIL TANK (Cont’d.)
5-19POWER UNIT x5POWROIL TANK (Cont’d.)
5-20POWER UNIT5POWROIL TANK (Cont’d.)
5-21POWER UNIT x5POWROIL TANK (Cont’d.)
5-22POWER UNIT5POWR
5-23POWER UNIT x5POWR
5-24POWER UNIT5POWR
SPECIAL TOOLSUse of the correct special tools recommendedby Yamaha will aid the work and enable accu-rate assembly and tune-up. Improvisations anduse
5-25POWER UNIT x5POWR
5-26POWER UNIT5POWRTANK.”
5-27POWER UNIT x5POWROIL PUMP (Cont’d.)
5-28POWER UNIT5POWROIL PUMP (Cont’d.)
5-29POWER UNIT x5POWR
5-30POWER UNIT5POWR
5-31POWER UNIT x5POWR
5-32POWER UNIT5POWRMOTOR.”PUMP.”
5-33POWER UNIT x5POWRREDUCTION DRIVE GEAR (Cont’d.)
5-34POWER UNIT5POWRREDUCTION DRIVE GEAR (Cont’d.)
SPECIAL TOOLSFuel Pressure GaugeP/N YB-0676690890-06786Compression Gauge ExtensionP/N 90890-06582Cylinder Gauge SetP/N YU-0301790890-06759Compre
5-35POWER UNIT x5POWRREDUCTION DRIVE GEAR (Cont’d.)
5-36POWER UNIT5POWRREDUCTION DRIVE GEAR (Cont’d.)
5-37POWER UNIT x5POWR
5-38POWER UNIT5POWR
5-39POWER UNIT x5POWRUNIT.”
5-40GENERATOR AND STARTER MOTOR (Cont’d.)POWER UNIT5POWR
5-41GENERATOR AND STARTER MOTOR (Cont’d.)POWER UNIT x5POWR
5-42GENERATOR AND STARTER MOTOR (Cont’d.)POWER UNIT5POWRMake sure not to pinch the pulser coilleads between the washers and projec-tions on the case
5-43GENERATOR AND STARTER MOTOR (Cont’d.)POWER UNIT x5POWR
5-44POWER UNIT5POWR
1-7GENERAL INFORMATIONx1GENINFOSPECIAL TOOLSTest Harness (3 pins)P/N YB-0676990890-06769Vacuum/Pressure Pump Gauge SetP/N YB-35956-A90890-06756Yam
5-45POWER UNIT x5POWR
5-46POWER UNIT5POWRCAUTION:washer. Always replace them with new ones.
5-47POWER UNIT x5POWR
5-48POWER UNIT5POWRCAMSHAFTS (Cont’d.)
5-49POWER UNIT x5POWRCAMSHAFTS (Cont’d.)GEAR.”
5-50POWER UNIT5POWRCAMSHAFTS (Cont’d.)
5-51POWER UNIT x5POWRCAMSHAFTS (Cont’d.)
5-52POWER UNIT5POWR
5-53POWER UNIT x5POWR
5-54POWER UNIT5POWR
1-8GENERAL INFORMATION1GENINFOREMOVAL AND INSTALLATION TOOLS1 Oil Filter WrenchP/N YU-3841190890-014262 Coupler WrenchP/N YW-0655190890-065513 She
5-55POWER UNIT x5POWR
5-56POWER UNIT5POWRCAUTION:
5-57POWER UNIT x5POWR
5-58POWER UNIT5POWR
5-59POWER UNIT x5POWRTighten the cylinder head cover bolts in a criss-cross pattern.
5-60POWER UNIT5POWRUNIT.”PIPE 3.”AND 2.”TANK.”“CAMSHAFTS.”
5-61CYLINDER HEAD (Cont’d.)POWER UNIT x5POWR
5-62POWER UNIT5POWR
5-63POWER UNIT x5POWR
5-64POWER UNIT5POWR
1-9GENERAL INFORMATIONx1GENINFOValve Seat CutterIntakeP/N 90890-06813 (60°)90890-06814 (45°)90890-06815 (30°)ExhaustP/N 90890-06315 (60°)90890-06312 (
5-65POWER UNIT x5POWRHEAD.”
5-66POWER UNIT5POWRVALVES AND VALVE SPRINGS (Cont’d.)
5-67POWER UNIT x5POWR
5-68POWER UNIT5POWR
5-69POWER UNIT x5POWRBefore checking the valve guide, make surethe valve stem diameter is within specifica-tion.
5-70POWER UNIT5POWR
5-71POWER UNIT x5POWR
5-72POWER UNIT5POWR
5-73POWER UNIT x5POWRCAUTION:
5-74POWER UNIT5POWR
GENERAL INFORMATION1GENINFO1-10
5-75POWER UNIT x5POWRCAUTION:
5-76POWER UNIT5POWR
5-77POWER UNIT x5POWRUNIT.”PIPE 3.”AND 2.”MOTOR.”TANK.”MANIFOLD.”
5-78POWER UNIT5POWRCRANCASE (Cont’d.)PUMP.”GEAR.”“CAMSHAFTS.”
5-79POWER UNIT x5POWRCRANCASE (Cont’d.)
5-80POWER UNIT5POWRCRANCASE (Cont’d.)
5-81POWER UNIT x5POWRCRANCASE (Cont’d.)“CRANKSHAFT.”
5-82POWER UNIT5POWRTap on one side of the crankcase with asoft-face hammer. Tap only on rein-forced portions of the crankcase, not onthe crankcase mat
5-83POWER UNIT x5POWR
5-84POWER UNIT5POWR
CHAPTER 2SPECIFICATIONSGENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1MAINT
5-85POWER UNIT x5POWRCAUTION:
5-86POWER UNIT5POWR
5-87POWER UNIT x5POWR“CRANKCASE.”
5-88POWER UNIT5POWRCONNECTING RODS AND PISTONS (Cont’d.)
5-89POWER UNIT x5POWRCAUTION:
5-90POWER UNIT5POWRpistons:
5-91POWER UNIT x5POWRformula:
5-92POWER UNIT5POWR
5-93POWER UNIT x5POWR
5-94POWER UNIT5POWRCAUTION:
GENERAL SPECIFICATIONSGENERAL SPECIFICATIONSx22-1SPECJet thrust nozzle trim angle Degree +3Impeller pitch Degree Port 17.3 / Stbd. 16.31.72 (5.67 ft)
5-95POWER UNIT x5POWRLubricate the bolt threads and nut seatsinstallation.”removal.”
5-96POWER UNIT5POWR
5-97POWER UNIT x5POWR
5-98POWER UNIT5POWR
5-99POWER UNIT x5POWRprocedure.”CAUTION:
5-100POWER UNIT5POWR“CRANKCASE.”PISTONS.”
5-101POWER UNIT x5POWR
5-102POWER UNIT5POWRCAUTION:
5-103POWER UNIT x5POWR“CRANKCASE.”
5-104POWER UNIT5POWR
PREFACEThis manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trainedmechanics when performing maintenance procedures a
2-2GENERAL SPECIFICATIONS2SPEC
5-105POWER UNIT x5POWRFWD
5-106POWER UNIT5POWRTHERMOSTAT (Cont’d.)FWD
5-107POWER UNIT x5POWRDoes not open at 50~60°C (123~
5-108POWER UNIT5POWRMANIFOLD.”
5-109POWER UNIT x5POWRPRESSURE CONTROL VALVE (Cont’d.)
5-110POWER UNIT5POWRPRESSURE CONTROL VALVE (Cont’d.)
5-111POWER UNIT x5POWRPRESSURE CONTROL VALVE (Cont’d.)
5-112POWER UNIT5POWR
CHAPTER 6JET PUMP UNITINTAKE GRATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JET PUMP x66-1JETPUMPINTAKE GRATINGEXPLODED DIAGRAMLT242LT24212345LT242Step Procedure / Part Name Q’ty (ea) Service PointsINTAKE GRATING Follow the l
2-3MAINTENANCE SPECIFICATIONSx2SPEC
6-2JET PUMP6JETPUMPApply clear silicone as shown before installingDuct into hull. Install Duct and torque screws to15Nm (1.5m-kg, 11 ft-lb).FILL GAPS
6-3JET PUMP x6JETPUMPPUMP UNITEXPLODED DIAGRAMStep Procedure / Part Name Q’ty (ea.) Service PointsPUMP UNIT REMOVAL Follow the “Step” order for remova
JET PUMP6JETPUMPStep Procedure / Part Name Q’ty (ea) Service PointsREVERSE GATE AND NOZZLE Follow the “Step” order for removal.DEFLECTOR REMOVAL1 Bolt
6-5JET PUMP x6JETPUMPIMPELLER AND DRIVE SHAFTEXPLODED DIAGRAMStep Procedure / Part Name Q’ty (ea) Service PointsIMPELLER DUCT AND DRIVE Follow the “St
JET PUMP6JETPUMP6-6JET PUMP CLEAN-OUT PORTSEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTLT242Step Procedure / Part Name Qty (ea.) Service PointsJET P
JET PUMP x6JETPUMP6-7
JET PUMP6JETPUMP6-8 10 11 2
JET PUMP x6JETPUMP6-9
JET PUMP6JETPUMP6-10
xCHAPTER 7ELECTRICAL SYSTEMELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1ELE
2-4MAINTENANCE SPECIFICATIONS2SPEC
THERMOSWITCH (EXHAUST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31SLANT DETECTION SWITCH . . . . . . . . .
7-1ELECTRICAL SYSTEM x7ELECELECTRICAL COMPONENTSStereoSpeakerRunning Light 23 24 112233445566778899Bow lightFuel pumpsFuel sender 19 22 23
7-2ELECTRICAL SYSTEM7ELECELECTRICAL BOX AND IGNITION COIL BOXEXPLODED DIAGRAM 2Step Procedure / Part Name Qty Service PointsELECTRICAL BOX REMOVA
7-3ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)EXPLODED DIAGRAM 2ELECTRICAL SYSTEM x7ELECStep Procedure / Part Name Qty Service Points9 Bolt
7-4ELECTRICAL SYSTEM7ELECELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)EXPLODED DIAGRAM 2Step Procedure / Part Name Q’ty Service Points17 Gaske
7-5ELECTRICAL SYSTEM x7ELECELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)EXPLODED DIAGRAM
7-6ELECTRICAL SYSTEM7ELECELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)EXPLODED DIAGRAM
7-7ELECTRICAL SYSTEM x7ELECELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)EXPLODED DIAGRAMStep Procedure / Part Name Q’ty Service Points19Tapping sc
7-8ELECTRICAL SYSTEM7ELECELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)EXPLODED DIAGRAM
7-9ELECTRICAL SYSTEM x7ELECELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)EXPLODED DIAGRAMHigh tension code
2-5MAINTENANCE SPECIFICATIONSx2SPEC
7-10ELECTRICAL SYSTEM7ELECELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)
7-11ELECTRICAL SYSTEM x7ELECThroughout this chapter, the digital tester’s partnumber has been omitted. Refer to the followingpart number.“O O” indi
7-12ELECTRICAL SYSTEM7ELEC• When checking the condition of the ignitionsystem, it is vital to know the peak voltage.• Cranking speed is dependant on m
7-13ELECTRICAL SYSTEM x7ELEC• Throughout this chapter, the peak voltageadaptor’s part number has been omitted.Refer to the following part number.tests
7-14ELECTRICAL SYSTEM7ELECIGNITION SYSTEMWIRING DIAGRAMFREEPUSHWBFREEPUSHBrBWBrP/WP/WP/WR/YB/WB/WOB/OP/GRL/RR/Y R/YB/OB/OB/YB/OB/OB/OB/OB/WRBB/OR/YL/R
7-15ELECTRICAL SYSTEM x7ELECIGNITION SYSTEMWIRING DIAGRAMFREEPUSHWBFREEPUSHBrBWBrP/WP/WP/WR/YB/WB/WOB/OP/GRL/RR/Y R/YB/OB/OB/YB/OB/OB/OB/OB/WRBB/OR/YL
7-16ELECTRICAL SYSTEM7ELEC
7-17ELECTRICAL SYSTEM x7ELEC• If there is no spark or the spark is weak, con-tinue with the ignition system test.• If a good spark is obtained, the pr
7-18ELECTRICAL SYSTEM7ELEC
7-19ELECTRICAL SYSTEM x7ELECSYSTEM.”
2-6MAINTENANCE SPECIFICATIONS2SPECPort 17.3 Stbd. 16.3Marine Group 24Dual Purpose 675 CCA100 (12/68.4)
7-20ELECTRICAL SYSTEM7ELECmeasurement.”Lanyard Clip White BlackInstalled O ORemoved O O
7-21ELECTRICAL SYSTEM x7ELEC
7-22ELECTRICAL SYSTEM7ELEC
7-23ELECTRICAL SYSTEM x7ELEC
7-24ELECTRICAL SYSTEM7ELEC
7-25ELECTRICAL SYSTEM x7ELEC
7-26ELECTRICAL SYSTEM7ELEC
7-27ELECTRICAL SYSTEM x7ELECFUEL CONTROL SYSTEMWIRING DIAGRAMThermoswitch (exhaust)Thermoswitch (engine) 6 7 8 9 10 11 12 13 12
7-28ELECTRICAL SYSTEM7ELECFUEL CONTROL SYSTEMWIRING DIAGRAM12 9 10 11 6 7 8 13
7-29ELECTRICAL SYSTEM x7ELEC12VDCPurpleFUEL GAUGE, LOW FUELLED AND WIRING CHECK1. Open the fuel hatch and locate the three wireconnector for the Fuel
2-7MAINTENANCE SPECIFICATIONSx2SPEC
7-30ELECTRICAL SYSTEM7ELEC2. Put the black lead of a voltmeter on theBlack/White wire of the harness. Then usethe red lead of the voltmeter to measure
7-31ELECTRICAL SYSTEM x7ELEC43218765R/Y718R/YL/RBrLYR/Y R/YBR/YR/YYRBrBrBrBrR/BR/BBrRBBR43216R/YR/YRPPORRRRRR1 2 3 4 5 6 7 8 BBB5BrBBB87OFFONSTAR
7-32ELECTRICAL SYSTEM7ELECKEY SWITCH1. Check:• ContinuityOut of specification →→Replace.1. Disconnect switch at harness.2. Turn key to function to be
7-33ELECTRICAL SYSTEM x7ELEC
7-34ELECTRICAL SYSTEM7ELEC
7-35ELECTRICAL SYSTEM x7ELECSTARTER MOTOR (Cont’d.)
7-36ELECTRICAL SYSTEM7ELECSTARTER MOTOR (Cont’d.)
7-37ELECTRICAL SYSTEM x7ELEC
7-38ELECTRICAL SYSTEM7ELEC
7-39ELECTRICAL SYSTEM x7ELEC
2-8MAINTENANCE SPECIFICATIONS2SPECMain (At Battery)Starter (At each engine)B
7-40ELECTRICAL SYSTEM7ELECSYSTEM.”SYSTEM.”SYSTEM.”
7-41ELECTRICAL SYSTEM x7ELECBBBBr BrBrBrELECTRIC BILGE PUMPWIRING DIAGRAMB: BlackBr: Brown
7-42ELECTRICAL SYSTEM7ELEC
7-43ELECTRICAL SYSTEM x7ELECMAIN COMPONENT LOCATIONEXPLODED DIAGRAM12345678910111.Battery2.Fuel Level Sensor3.Bow Light4.Stern Light Connector5.Blower
7-44ELECTRICAL SYSTEM7ELECSWITCH LOCATIONWIRING DIAGRAM123451.Key Switches2.Lanyard Switch3.Neutral Switch4.Hatch Interlock Switches5.Engine Harness #
7-45ELECTRICAL SYSTEM x7ELECMETER PANEL BACK VIEWWIRING DIAGRAMDEUTSCH6 PINPLUG 52506WEDGE 52508SOC 52518STB TACH PWR 2STB TACH 1STB LO OIL 4STB OVERH
7-46ELECTRICAL SYSTEM7ELECELECTRICAL COMPONENTSStep Procedure / Part Name Qty (ea.) Service PointsMETER PANEL DISASSEMBLY Follow the “Step” order for
7-47ELECTRICAL SYSTEM x7ELECSWITCH AND COMPONENTWIRING DIAGRAM1 Circuit Breaker2 Stereo Switch3 Courtesy Light Switch4 Navigation Light Switch5 Bilge
7-48ELECTRICAL SYSTEM7ELEC
7-49ELECTRICAL SYSTEM x7ELEC
2-9MAINTENANCE SPECIFICATIONSx2SPEC1/4-208-3210-24Part To Be Tightened
CHAPTER 8HULL AND DECKENGINE COMPARTMENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1EXPLODED DIAG
GUNWALE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24EXPLODED DIAGRAM
8-1HULL AND DECK x8HULLDECKENGINE COMPARTMENT LAYOUTEXPLODED DIAGRAM12345671. Engine 5. Battery2. Water Lock 6. Blowers3. Jet Pump 7. Bilge Pump4. Fue
8-2HULL AND DECK 8HULLDECKVENTILATION SYSTEM EXPLODED DIAGRAM
8-3Step Procedure / Part Name Q’ty Service PointsVENTILATION SYSTEM Follow the “Step” order for removal.DISASSEMBLY1 Hose Clamp 11 Snap type2 Screw, O
8-4HULL AND DECK 8HULLDECKCOOLING SYSTEMEXPLODED DIAGRAM282829293027273025
8-5Step Procedure / Part Name Q’ty Service PointsCOOLING SYSTEM ANDWATER LOCK REMOVAL Follow the “Step” order for removal.1 Band, Hose 18 22 Clip 23 H
8-6STEERING SYSTEMEXPLODED DIAGRAMHULL AND DECK 8HULLDECK123413AAASSSS11 12 1 2 3 4 5 6 7 8 9 10 NOTE: See REMO
8-7Step Procedure / Part Name Q’ty Service PointsSTEERING HELM REMOVAL Follow the “Step” order for removal.1 Cover 12 Nut 1 1/2"-13, Nylon lock,
8-8REMOTE CONTROL SYSTEMEXPLODED DIAGRAMHULL AND DECK 8HULLDECK
2-10MAINTENANCE SPECIFICATIONS2SPECTIGHTENING TORQUESPart To Be Tightened
8-9Step Procedure / Part Name Q’ty Service PointsREMOTE CONTROL UNIT Follow the “Step” order for removal.REMOVAL1 Throttle Lever Plugs (red) 2 sets Sc
8-10ENGINE HATCHEXPLODED DIAGRAMHULL AND DECK 8HULLDECK
8-11Step Procedure / Part Name Q’ty Service PointsENGINE HATCH REMOVAL Follow the “Step” order for removal.AND DISASSEMBLY1 Support, Engine Hatch 2Sup
8-12HATCH FITTINGS/BOW COVEREXPLODED DIAGRAMHULL AND DECK 8HULLDECK
8-13Step Procedure / Part Name Q’ty Service PointsBOW LOCKER Follow the “Step”DISASSEMBLY order for removal.1 Screw, Tapping 16 #8 x 5/8”2 Hinge 13 Ha
8-14HULL AND DECK 8HULLDECKSEAT FITTINGSEXPLODED DIAGRAM
8-15HULL AND DECK x8HULLDECKStep Procedure / Part Name Q’ty Service PointsSEAT FITTING DISASSEMBLY Follow the “Step” order for removal.DRIVER’S BUCKET
DECK FITTINGSEXPLODED DIAGRAMHULL AND DECK 8HULLDECK8-16
8-17Step Procedure / Part Name Q’ty Service PointsSTERN LIGHT Follow the “Step” order for removal.1 Stern Light Assembly 12 Lens 13 Bulb 1 ML1004 obta
8-18HULL AND DECK 8HULLDECKDECK FITTINGS (Continued)EXPLODED DIAGRAMStep Procedure / Part Name Q’ty Service PointsTABLE39 Table 1 Optional Accy40 S
2-11MAINTENANCE SPECIFICATIONSx2SPECTIGHTENING TORQUESPart To Be Tightened
8-19REMOVAL AND INSTALLATION CHART (Continued)HULL AND DECK x8HULLDECKStep Procedure / Part Name Q’ty Service PointsBIMINI TOP BRACKETS48 Nut, 10-24
8-20DECK FITTINGS (Continued)EXPLODED DIAGRAMHULL AND DECK 8HULLDECK
8-21HULL AND DECK x8HULLDECKREMOVAL AND INSTALLATION CHART (Continued)Step Procedure / Part Name Q’ty Service PointsWINDSHIELD58 Nut, 10-24 Nylon Loc
8-22THROUGH HULL AND DRAIN FITTINGSEXPLODED DIAGRAMQty 3 for Bilge HoseHULL AND DECK 8HULLDECK
8-23Step Procedure / Part Name Q’ty Service PointsTHROUGH HULL AND DRAIN Follow the “Step” order for removal.FITTINGS1 Drain Plug 1 Apply silicone to
8-24GUNWALEEXPLODED DIAGRAM12345Step Procedure / Part Name Q’ty Service PointsGUNWALE Follow the “Step” order for removal.1 Screw, 310 x 2” POH 2 Tor
8-25HULL AND DECK x8HULLDECKHULL CONSTRUCTIONAND CAREThe SRT1000 hull is built of a material calledFRP. This is then finished with a very hardproduct
TROUBLE ANALYSIS x9TRBLANLSWINDOWS®95, WINDOWS®98, WINDOWS®ME,WINDOWS®2000,®OR WINDOWS®XP ... 9-3UPDATING THE D
Operating procedure... 9-41Data display item selection...
9-1TROUBLE ANALYSIS x9TRBLANLSIf this software is run on Microsoft Windows®95, Windows®98, Windows®Me, Windows®2000, orWindows®XP, the information can
HOW TO USE THIS MANUALMANUAL FORMATAll of the procedures in this manual are organized in a sequential, step-by-step format. The infor-mation has been
2-12MAINTENANCE SPECIFICATIONS2SPECTIGHTENING TORQUESPart To Be Tightened
9-2TROUBLE ANALYSIS9TRBLANLSMake sure your computer meets the following requirements before using this software.RS232C (Dsub-9 pin) port, USB portj
TROUBLE ANALYSIS x9TRBLANLS9-3INSTALLING THE YAMAHA DIAGNOSTIC SYSTEM UNDER WINDOWS 95, WINDOWS 98, WINDOWS ME, WINDOWS 2000, OR WINDOWS XP9-2.
9-4TROUBLE ANALYSIS9TRBLANLS
9-5TROUBLE ANALYSIS x9TRBLANLS
9-6TROUBLE ANALYSIS9TRBLANLSInstall the Database file before using the Yamaha Diagnostic System, otherwise, the program will notoperate correctly. For
9-7TROUBLE ANALYSIS x9TRBLANLSAfter about three seconds, the display will automatically go to the first menu display, or you can clickor press any key
9-8TROUBLE ANALYSIS9TRBLANLSDo not click the Starting service tool [Enter] button or press the Enter key on your keyboard untilthe database has been u
9-9TROUBLE ANALYSIS x9TRBLANLS
9-10TROUBLE ANALYSIS9TRBLANLSWhen the database is updated, a confirmation screen is displayed.
9-11TROUBLE ANALYSIS x9TRBLANLS
2-13MAINTENANCE SPECIFICATIONSx2SPECTIGHTENING TORQUESPart To Be Tightened6M83202.014
9-12TROUBLE ANALYSIS9TRBLANLS12
9-13TROUBLE ANALYSIS x9TRBLANLSOpen the Yamaha Diagnostic System window. (Fig. 20) After about three seconds, the display willautomatically go to the
9-14TROUBLE ANALYSIS9TRBLANLS
9-15TROUBLE ANALYSIS x9TRBLANLS
9-16TROUBLE ANALYSIS9TRBLANLSEight commands appear in the main Menu. Select a command in any of the following three ways:
9-17TROUBLE ANALYSIS x9TRBLANLS
9-18TROUBLE ANALYSIS9TRBLANLS
9-19TROUBLE ANALYSIS x9TRBLANLStop.
9-20TROUBLE ANALYSIS9TRBLANLS
9-21TROUBLE ANALYSIS x9TRBLANLS
2-14MAINTENANCE SPECIFICATIONS2SPECTIGHTENING TORQUESThread Tightening torquePart To Be Tightened Part Name size Qty N•m kgf•m ft•lb RemarksWater inle
9-22TROUBLE ANALYSIS9TRBLANLS
9-23TROUBLE ANALYSIS x9TRBLANLS.
9-24TROUBLE ANALYSIS9TRBLANLSCheck that the items deleted are normal in the Diagnosis Record. If the items remain irregular, theywill appear as irregu
9-25TROUBLE ANALYSIS x9TRBLANLSClick the OK button or press the Enter key on your keyboard (Fig. 35): The selected item is deleted.To cancel deleting
9-26TROUBLE ANALYSIS9TRBLANLSDo not use the Engine Monitor function to check the engine condition while operating a water-craft, otherwise, you could
9-27TROUBLE ANALYSIS x9TRBLANLSin the scroll bar or press the up or down(Fig. 38).keyboard
9-28TROUBLE ANALYSIS9TRBLANLSAvoid clicking the Execute and Cancel buttons repeatedly, otherwise, the ECM or PC will notwork properly and they could b
9-29TROUBLE ANALYSIS x9TRBLANLSkeys on your keyboard (Fig. 39).(Spark Gap Tester YM-34487/90890-06754) is needed.keyboard (Fig. 39).
9-30TROUBLE ANALYSIS9TRBLANLSkeyboard (Fig. 42).
9-31TROUBLE ANALYSIS x9TRBLANLSIf the engine is running an error message is displayed, follow the instructions that appear (Fig. 44).instructions in t
2-15MAINTENANCE SPECIFICATIONSx2SPECTIGHTENING TORQUESThread Tightening TorquePart To Be Tightened Part Name size Qty N•m kgf•m ft•lb RemarksMain and
9-32TROUBLE ANALYSIS9TRBLANLSselected (Fig. 46).displayed (Fig. 47).
9-33TROUBLE ANALYSIS x9TRBLANLSkeyboard (Fig. 48).Make sure that there is fuel in the fuel tank, otherwise, an error will occur and the test cannot be
9-34TROUBLE ANALYSIS9TRBLANLSkeyboard (Fig. 49).
9-35TROUBLE ANALYSIS x9TRBLANLSselected (Fig. 51).Do not test the same cylinder three or more times, otherwise, the spark plug insulator could bedamag
9-36TROUBLE ANALYSIS9TRBLANLSSelect the test to be performed, then click the Select button or press the Enter key on your keyboard(Fig. 52).Make sure
9-37TROUBLE ANALYSIS x9TRBLANLSkeyboard (Fig. 53).selected (Fig. 54).
9-38TROUBLE ANALYSIS9TRBLANLSAvoid clicking the Execute and Cancel buttons repeatedly, otherwise, the ECM or PC will notwork properly and they could b
9-39TROUBLE ANALYSIS x9TRBLANLSFor the first ten seconds, operate all four cylinders, then stop one cylinder for five seconds. For the lastfive second
9-40TROUBLE ANALYSIS9TRBLANLSIf the engine is not running, an error message is displayed. Follow the instructions that appear (Fig. 57).displayed (Fig
9-41TROUBLE ANALYSIS x9TRBLANLSboard (Fig. 59).Press the Enter key on your keyboard. The window of the selected item is displayed(Fig. 59).
2-16GENERAL TORQUEThis chart specifies the torques for tighteningstandard fasteners with standard clean dry ISOthreads at room temperature. Torque spe
9-42TROUBLE ANALYSIS9TRBLANLSbar (Fig. 60).displayed (See fig. 61).
9-43TROUBLE ANALYSIS x9TRBLANLSaxis (Fig. 61).value at the time the Enter key on your keyboard was pressed in the Monitor item selection.
9-44TROUBLE ANALYSIS9TRBLANLS(Fig. 62).Although the engine is running, the displayed time refers to the added hours until the Data loggerstarts.
9-45TROUBLE ANALYSIS x9TRBLANLSdisplayed (Fig. 63).
9-46TROUBLE ANALYSIS9TRBLANLS(Fig. 65).
9-47TROUBLE ANALYSIS x9TRBLANLSPrograms (Fig. 66).(Fig. 67).
9-48TROUBLE ANALYSIS9TRBLANLSbutton (see Figs. 68~70).
9-49TROUBLE ANALYSIS x9TRBLANLS
9-50TROUBLE ANALYSIS9TRBLANLStest,
9-51TROUBLE ANALYSIS x9TRBLANLSDisplay (Fig. 73).slider (Fig. 74)..
2-17MAINTENANCE SPECIFICATIONSx2SPECCABLE AND HOSE ROUTING
9-52TROUBLE ANALYSIS9TRBLANLSbutton (see Figs. 75~76).
9-53TROUBLE ANALYSIS x9TRBLANLSconsulted:
9-54TROUBLE ANALYSIS9TRBLANLS
9-55TROUBLE ANALYSIS x9TRBLANLS
LIT-18616-02-52©2003 YAMAHA MOTOR CORPORATION, U.S.A. Printed in U.S.A.
2-18MAINTENANCE SPECIFICATIONS2SPECCABLE AND HOSE ROUTING
2-19MAINTENANCE SPECIFICATIONSx2SPECCABLE AND HOSE ROUTING
2-20MAINTENANCE SPECIFICATIONS2SPECCABLE AND HOSE ROUTING
2-21MAINTENANCE SPECIFICATIONSx2SPECCABLE AND HOSE ROUTING
HOW TO READ DESCRIPTIONS1. A disassembly/installation job instruction mainly consists of the exploded diagram 11.2. The numerical figures represented
CHAPTER 3PERIODIC INSPECTION AND ADJUSTMENTMAINTENANCE INTERVAL CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJ
PERIODIC SERVICECONTROL SYSTEMSteering helm inspection1. Check:●FrictionExcessively heavy ➔Replace the steering helm unit.2. Check:●Free playExcessive
1 Cable Wheel2 Locknuts3 Throttle CableREMOTE CONTROL UNIT1. Check throttle:●Throttle lever at Wide-Open-Throttle(W.O.T.) position.Throttle cable whee
Shift cable inspection and adjustmentThe cable joints must have more than 8mm(0.31 in) engagement after adjustment iscomplete.3. Check:●Mechanical int
3-5PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJ
3-6PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJ•Valve clearance adjustment should be madeon a cold engine at room temperature.• When the valve clearanc
3-7PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJ
3-8PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJ
3-9PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJMake a note of the position of each valvelifter 3 and valve pad 4 so they can beinstalled in the correc
SYMBOLSSymbols 1 to 9 are designed as thumb-tabsto indicate the content of a chapter:General InformationSpecificationsPeriodic Inspection and Adjustme
3-10PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJ
3-11PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJ
3-12PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJCAUTION:
3-13PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJCAUTION:Place the craft in water, and then
3-14PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJIf the oil temperature is low, the reading onthe dipstick will be low. If the temperature ishigh, the r
3-15PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJCAUTION:
3-16PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJWhen starting the engine, make sure the dip-stick is securely fitted into the oil tank.CAUTION:
3-17PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJMake sure the air filter element is installedin the filter case properly.If cleaning the air filter el
3-18PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJ
3-19PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJ
INDEXSPECIFICATIONSSPECGENERAL INFORMATION1GENINFO2PERIODIC INSPECTION AND ADJUSTMENT3INSPADJFUEL SYSTEM4FUELPOWER UNIT5POWRJET PUMP6JETPUMPELECTRICAL
PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJ3-20CAUTION:Be sure the cap is properly positioned andlocked in place. Otherwise, the cap could loosenand b
3-21PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJDisconnect the bilge strainer from the bilgestrainer holder.BILGE PUMP1. Remove inspection cover in pu
3-22PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJ
3-23PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJGENERALDrain plug inspection1. Inspect:●Drain plugCrack/Damage ➔ Replace.●O-RingCrack/Wear ➔ Replace.●
3-24PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJLubrication points1. Lubricate:●Throttle cable (throttle body end)NOTE:Before lubricating the QSTS cont
PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJ4.3-25
xCHAPTER 4FUEL SYSTEMFUEL TANK AND FUEL PUMP MODULEEXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM x4FUEL4-128282828282828282812345101211131613151813171920262524232721221413986729292830Step Procedure / Part Name Q’ty Service PointsFUEL T
4-2FUEL SYSTEM4FUELFUEL TANK AND FUEL PUMP MODULE (Cont’d.)28282828282828282812345101211131613151813171920262524232721221413986729292830Step Procedure
4-3FUEL SYSTEM x4FUELFUEL TANK AND FUEL PUMP MODULE (Cont’d.)28282828282828282812345101211131613151813171920262524232721221413986729292830Step Procedu
CHAPTER 1GENERAL INFORMATIONIDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1PRIM
4-4FUEL SYSTEM4FUELSYSTEM.”ScrewsLoosen the screws in the sequence shown.
4-5FUEL SYSTEM x4FUELSYSTEM.”Screws4.9 Nm (0.49 kgf-m)7.9 Nm (0.8 kgf-m)
4-6FUEL SYSTEM4FUEL
4-7FUEL SYSTEM x4FUELFUEL INJECTION SYSTEM (Cont’d.)
4-8FUEL SYSTEM4FUELFUEL INJECTION SYSTEM (Cont’d.)
4-9FUEL SYSTEM x4FUELFUEL INJECTION SYSTEM (Cont’d.)
4-10FUEL SYSTEM4FUELFUEL INJECTION SYSTEM (Cont’d.)
4-11FUEL SYSTEM x4FUELFUEL INJECTION SYSTEM (Cont’d.)
4-12FUEL SYSTEM4FUELFUEL INJECTION SYSTEM (Cont’d.)Qty
4-13FUEL SYSTEM x4FUELFUEL INJECTION SYSTEM (Cont’d.)
A60700-0*IDENTIFICATION NUMBERSPRIMARY I.D. NUMBERThe primary I.D. number is stamped on a labelattached to the deck under the rear seat.ENGINE SERIAL
4-14FUEL SYSTEM4FUELFUEL INJECTION SYSTEM (Cont’d.)
4-15FUEL SYSTEM x4FUELCAUTION:
4-16FUEL SYSTEM4FUELCAUTION:Disconnect the fuel hose 1 directly from thefuel pipe 2.
4-17FUEL SYSTEM x4FUELCAUTION:If free play is not obtained, disconnect the fuelhose, check the O-ring for damage and that it isproperly installed.
4-18FUEL SYSTEM4FUELCAUTION:
4-19FUEL SYSTEM x4FUELCAUTION:Blow out all passages with compressed air.
4-20FUEL SYSTEM4FUELCAUTION:Only butterfly valve #2 should be fullyclosed. The other valves should be halfwayclosed.
4-21FUEL SYSTEM x4FUEL
4-22FUEL SYSTEM4FUELCAUTION:
4-23FUEL SYSTEM x4FUEL
SAFETY WHILE WORKINGThe procedures given in this manual are thoserecommended by Yamaha to be followed byYamaha dealers and their mechanics.FIRE PREVEN
4-24FUEL SYSTEM4FUEL
4-25FUEL SYSTEM x4FUEL“Fuel hose disconnection.”“Fuel hose connection.”)nection.”)connection.”
POWER UNIT x5POWR5-1Refer to “ENGINE HATCH” in Chapter 8.
5-2ENGINE UNITEXPLODED DIAGRAMPOWER UNIT5POWR
5-3POWER UNIT x5POWR
5-4POWER UNIT5POWRCAUTION:
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