Yamaha WaveRunner User manual

SERVICE MANUAL

FX High Output

WaveRunner

F1S-28197-1G-11LIT-18616-02-83

*LIT186160283*

FX Cruiser High Output

NOTICE

This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained

mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has

been written to suit the needs of persons who have a basic understanding of the mechanical and

electrical concepts and procedures inherent in the work, for without such knowledge attempted

repairs or service to the equipment could render it unsafe or unfit for use.

Because Yamaha has a policy of continuously improving its products, models may differ in detail

from the descriptions and illustrations given in this publication. Use only the latest edition of this

manual. Authorized Yamaha dealers are notified periodically of modifications and significant

changes in specifications and procedures, and these are incorporated in successive editions of this

manual.

A10001-0*

WaveRunner

FX High Output, FX Cruiser High Output

SERVICE MANUAL

1st Edition, February 2004

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, USA

is expressly prohibited.

Printed in USA

LIT-18616-02-83

HOW TO USE THIS MANUAL

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-

tion has been compiled to provide the mechanic with an easy to read, handy reference that contains

comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the

course of action required will follow the symbol, e.g.,

•Bearings

Pitting/scratches → Replace.

To assist you in finding your way through this manual, the section title and major heading is given at

the top of every page.

ILLUSTRATIONS

The illustrations within this service manual represent all of the designated models.

CROSS REFERENCES

The cross references have been kept to a minimum. Cross references will direct you to the appropri-

ate section or chapter.

IMPORTANT INFORMATION

In this Service Manual particularly important information is distinguished in the following ways.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS

INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine

operator, passenger(s), a bystander, or a person inspecting or repairing the watercraft.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the water-

craft.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

IMPORTANT:

This part has been subjected to change of specification during production.

HOW TO USE THIS MANUAL

1To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

2Numbers are given in the order of the jobs in the exploded diagram.

3Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).

4A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

5Dimension figures and the number of parts, are provided for fasteners that require a tightening

torque.

Example:

Bolt or screw size : M10 (D) ×25 mm (L)

6Jobs requiring more information (such as special tools and technical data) are described

sequentially.

10 ×25 mm

A50001-1-4

SYMBOLS

Symbols 1to 9are designed to indicate the

content of a chapter.

1General Information

2Specifications

3Periodic Inspection and Adjustment

4Fuel System

5Power Unit

6Jet Pump Unit

7Electrical System

8Hull and Hood

9Trouble Analysis

Symbols 0to Eindicate specific data.

0Special tool

ASpecified oil or fluid

BSpecified engine speed

CSpecified tightening torque

DSpecified measurement

ESpecified electrical value

(resistance, voltage, electric current)

Symbols Fto Hin an exploded diagram indi-

cate the grade of lubricant and the lubrication

point.

FApply Yamaha 4-stroke motor oil

GApply water resistant grease

(Yamaha grease A, Yamaha marine grease)

HApply molybdenum disulfide grease

Symbols Ito Nin an exploded diagram indi-

cate the type of sealant or locking agent and

the application point.

IApply Gasket Maker

JApply Yamabond No. 4

KApply LOCTITE 271 (red)

LApply LOCTITE 242 (blue)

MApply LOCTITE 572

NApply silicone sealant

NOTE:

Additional symbols may be used in this man-

ual.

GEN

INFO SPEC

INSP

ADJ FUEL

POWR

JET

PUMP

–+

ELEC

HULL

HOOD

TRBL

ANLS

A M

271

242

572

LT SS

INDEX

GENERAL INFORMATION 1

GEN

INFO

SPECIFICATIONS 2

SPEC

PERIODIC INSPECTION AND

ADJUSTMENT 3

INSP

ADJ

FUEL SYSTEM 4

FUEL

POWER UNIT 5

POWR

JET PUMP UNIT 6

JET

PUMP

ELECTRICAL SYSTEM 7

ELEC

HULL AND HOOD 8

HULL

HOOD

TROUBLE ANALYSIS 9

TRBL

ANLS

–+

A30000-0

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

IDENTIFICATION NUMBERS .........................................................................1-1

PRIMARY l.D. NUMBER ...........................................................................1-1

ENGINE SERIAL NUMBER ......................................................................1-1

JET PUMP UNIT SERIAL NUMBER .........................................................1-1

HULL IDENTIFICATION NUMBER (H.l.N.)...............................................1-1

SAFETY WHILE WORKING......................................................................1-2

FIRE PREVENTION ..................................................................................1-2

VENTILATION ...........................................................................................1-2

SELF-PROTECTION.................................................................................1-2

PARTS, LUBRICANTS, AND SEALANTS ................................................1-2

GOOD WORKING PRACTICES ...............................................................1-3

DISASSEMBLY AND ASSEMBLY ............................................................1-4

SPECIAL TOOLS ............................................................................................1-5

MEASURING.............................................................................................1-5

REMOVAL AND INSTALLATION..............................................................1-7

1-1

GEN

INFO IDENTIFICATION NUMBERS

A60700-0*

IDENTIFICATION NUMBERS

PRIMARY l.D. NUMBER

The primary l.D. number is stamped on a label

attached to the inside of the engine compart-

ment.

Starting primary l.D. number:

F1S: 800101

ENGINE SERIAL NUMBER

The engine serial number is stamped on a

label attached to the engine unit.

Starting serial number:

6B6: 1000001

JET PUMP UNIT SERIAL NUMBER

The jet pump unit serial number is stamped on

a label attached to the intermediate housing.

HULL IDENTIFICATION NUMBER

(H.l.N.)

The H.l.N. is stamped on a plate attached to

the aft deck.

1-2

GEN

INFO SAFETY WHILE WORKING

SAFETY WHILE WORKING

To prevent and accident or injury and to

ensure quality service, follow the safety proce-

dures provided below.

FIRE PREVENTION

Gasoline is highly flammable.

Keep gasoline and all flammable products

away from heat, sparks, and open flames.

VENTILATION

Gasoline vapor and exhaust gas are heavier

than air and extremely poisonous. If inhaled in

large quantities they may cause loss of con-

sciousness and death within a short time.

When test running an engine indoors (e.g., in a

water tank), be sure to do so where adequate

ventilation can be maintained.

SELF-PROTECTION

Protect your eyes by wearing safety glasses or

safety goggles during all operation involving

drilling and grinding, or when using an air com-

pressor.

Protect your hands and feet by wearing protec-

tive gloves or safety shoes when necessary.

PARTS, LUBRICANTS, AND

SEALANTS

Use only genuine Yamaha parts, lubricants,

and sealants or those recommended by

Yamaha, when servicing or repairing the

watercraft.

This manual suits for next models

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