Yamaha WaveRunner GP1300R- User Manual

Page 2 - NOTICE

E NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trainedmechanics when performing maintenance procedures and repairs to Yamaha equipment. It hasbeen written to suit the needs of persons who have a basic understanding of the mechanical andelectrical conce...

Page 3 - HOW TO USE THIS MANUAL; MANUAL FORMAT; • Bearings; ILLUSTRATIONS

E 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 containscomprehensive explanations of all disassembly, repair, assembl...

Page 5 - Numbers are given in the order of the jobs in the exploded diagram.

E HOW TO USE THIS MANUAL 1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start ofeach removal and disassembly section. 2 Numbers are given in the order of the jobs in the exploded diagram. 3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”)....

Page 6 - SYMBOLS

E A50001-1-4 SYMBOLS Symbols 1 to 9 are designed to indicate the content of a chapter. 1 General Information 2 Specifications 3 Periodic Inspection and Adjustment 4 Fuel System 5 Power Unit 6 Jet Pump Unit 7 Electrical System 8 Hull and Hood 9 Trouble Analysis Symbols 0 to E indicate specific data. ...

Page 7 - INDEX

E 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

Page 8 - CHAPTER 1

E GEN INFO 123456789 CHAPTER 1 GENERAL INFORMATION IDENTIFICATION NUMBERS ......................................................................... 1-1 PRIMARY l.D. NUMBER ........................................................................... 1-1ENGINE SERIAL NUMBER ...............................

Page 9 - IDENTIFICATION NUMBERS; The primary l.D. number is stamped on a label; ENGINE SERIAL NUMBER; attached to the engine unit.; Starting serial number:; JET PUMP UNIT SERIAL NUMBER; attached to

1-1 E GEN INFO IDENTIFICATION NUMBERS A60700-0* IDENTIFICATION NUMBERS PRIMARY l.D. NUMBER The primary l.D. number is stamped on a label 1 attached inside the engine compartment. Starting primary l.D. number: F1G: 800301 1 ENGINE SERIAL NUMBER The engine serial number is stamped on alabel 1 attached...

Page 10 - SAFETY WHILE WORKING; FIRE PREVENTION

1-2 E GEN INFO SAFETY WHILE WORKING SAFETY WHILE WORKING To prevent and accident or injury and toensure quality service, follow the safety proce-dures provided below. FIRE PREVENTION Gasoline is highly flammable.Keep gasoline and all flammable productsaway from heat, sparks, and open flames. VENTILA...

Page 11 - Maintain good standards of personal and; GOOD WORKING PRACTICES; The right tools

1-3 E GEN INFO SAFETY WHILE WORKING Under normal conditions, the lubricants men-tioned in this manual should not harm or behazardous to your skin. However, you shouldfollow these precautions to minimize any riskwhen working with lubricants. 1. Maintain good standards of personal and industrial hygie...

Page 12 - DISASSEMBLY AND ASSEMBLY

1-4 E GEN INFO SAFETY WHILE WORKING 3. Non-reusable parts Always use new gaskets, seals, O-rings,oil seals, cotter pins, circlips, etc., wheninstalling or assembling parts. DISASSEMBLY AND ASSEMBLY 1. Use compressed air to remove dust and dirt during disassembly. 2. Apply engine oil to the contact s...

Page 13 - SPECIAL SERVICE TOOLS; • For USA and Canada, use the special ser-; MEASURING AND DIAGNOSIS

1-5 E GEN INFO SPECIAL SERVICE TOOLS SPECIAL SERVICE TOOLS Using the special service tools recommendedby Yamaha will aid service and enable accu-rate assembly and tune-up. Improvisationsand using improper tools can damage theequipment. NOTE: • For USA and Canada, use the special ser- vice tools star...

Page 15 - REMOVAL AND INSTALLATION

1-7 E GEN INFO SPECIAL SERVICE TOOLS REMOVAL AND INSTALLATION 1 Coupler wrenchYW-0655190890-06551 2 Flywheel holderYW-0655090890-06550 3 Universal pullerYB-06117 4 Flywheel puller90890-06521 5 Drive shaft holder (impeller)YB-06151Drive shaft holder 5 (impeller)90890-06519 6 Slide hammer and adapters...

Page 17 - SPEC; CHAPTER 2

E SPEC 123456789 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ....................................................................... 2-1 MAINTENANCE SPECIFICATIONS ............................................................... 2-3 ENGINE ............................................................

Page 18 - GENERAL SPECIFICATIONS

2-1 E SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Item Unit Model GP1300R Model code Hull F1G Engine/jet 60T Dimensions Length mm (in) 2,930 (115.4) Width mm (in) 1,150 (45.3) Height mm (in) 1,020 (40.2) Dry weight kg (lb) 297 (653) Maximum capacity Person/kg (lb) 2/160 (353) Performance Maxi...

Page 20 - MAINTENANCE SPECIFICATIONS; ENGINE

2-3 E SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Unit Model GP1300R Cylinder head Warpage limit mm (in) 0.05 (0.002) Minimum compression pressure *1 kPa (kgf/cm 2 , psi) 640 (6.4, 91) Cylinders Bore size mm (in) 84.000–84.018 (3.3071–3.3078) Taper limit mm (in) 0.080 (0.0...

Page 21 - JET PUMP UNIT

2-4 E SPEC MAINTENANCE SPECIFICATIONS JET PUMP UNIT Crankshaft assembly Crank width A mm (in) 72.95–73.00 (2.872–2.874) Deflection limit B mm (in) 0.05 (0.002) Deflection limit C mm (in) 0.15 (0.006) Big end side clearance D mm (in) 0.250–0.750 (0.0098–0.0295) Maximum small end axial play E mm (in) ...

Page 22 - HULL AND HOOD

2-5 E SPEC MAINTENANCE SPECIFICATIONS HULL AND HOOD ELECTRICAL Item Unit Model GP1300R Free play YPVS cable slack mm (in) 0.5–1.5 (0.02–0.06) Throttle lever free play mm (in) 4–7 (0.16–0.28) Item Unit Model GP1300R Battery Type Fluid Voltage, capacity V, Ah 12, 19 Specific gravity 1.28 ECM unit(B/R ...

Page 25 - TIGHTENING TORQUES; SPECIFIED TORQUES; Fuel system

2-8 E SPEC TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Part to be tightened Part name Thread size Q’ty Tightening torques Remarks N•m kgf•m ft•lb Fuel system Strap/fuel tank/oil tank – hull Bolt M8 4 16 1.6 11 572 LT Oil filler hose screw clamp — — 1 0.6 0.06 0.4 Retainer/fuel pump modul...

Page 27 - Jet pump unit

2-10 E SPEC TIGHTENING TORQUES Ground lead – cylinder head 1st Bolt M6 1 3.8 0.38 2.7 2nd 7.6 0.76 5.5 Exhaust chamber stay/cylinder head – cylinder 1st Bolt M8 2 15 1.5 11 572 LT 2nd 35 3.5 25 Cylinder head – cylinder 1st Bolt M8 16 22 2.2 16 572 LT 2nd 22 2.2 16 3rd 35 3.5 25 Anode – cylinder head...

Page 28 - Hull and hood

2-11 E SPEC TIGHTENING TORQUES Jet thrust nozzle – nozzle ring Bolt M8 2 15 1.5 11 271 LT Spout hose screw clamp — — 1 1.2 0.12 0.9 Nozzle/impeller duct assembly – impeller housing 1 Bolt M10 4 40 4.0 29 572 LT Water inlet cover/water inlet strainer – impeller duct Bolt M6 4 6.6 0.66 4.8 572 LT Driv...

Page 30 - Electrical

2-13 E SPEC TIGHTENING TORQUES Electrical Cover – electrical box Tapping screw ø6 11 4.9 0.49 3.5 Lead retainer – electrical box Tapping screw ø6 2 4.9 0.49 3.5 Positive battery lead – starter relay Bolt M6 1 3.4 0.34 2.5 Starter motor lead – starter relay Bolt M6 1 3.4 0.34 2.5 Rectifier/regulator ...

Page 31 - GENERAL TORQUE

2-14 E SPEC TIGHTENING TORQUES GENERAL TORQUE This chart specifies tightening torques for stan-dard fasteners with a standard ISO threadpitch. Tightening torque specifications for spe-cial components or assemblies are provided inapplicable sections of this manual. To avoidwarpage, tighten multi-fast...

Page 32 - CABLE AND HOSE ROUTING

2-15 E SPEC CABLE AND HOSE ROUTING CABLE AND HOSE ROUTING VENT 20˚ K K L H-H I-I K-K M-M H H G G I I I I B D D A E-E D-D F-F 1 F G F F M M C E E J J G-G B C A J-J L 5 7 H 2 KF J H 7 7 H C A B 7 H I 1 1 D C B A 0 9 8 7 6 5 4 3 2 1 È É Ê Ë Ì Í Ì Î L E 1 Fuel tank breather hose 2 Cooling water pilot ou...

Page 34 - Î Í

2-17 E SPEC CABLE AND HOSE ROUTING CD E F G H I J K 8 M L A N O 8 C D E B B F F B-B C F-F E D A 1 2 3 4 5 6 7 8 9 0 A B 7 A 5P B 7 P Î Í È É Ê Ì Ë 1 Buzzer lead 2 Throttle cable 3 YPVS servomotor 4 YPVS cables 5 Positive battery lead 6 Battery breather hose 7 Electrical bilge pump lead 8 Steering ca...

Page 41 - CHAPTER 3

E INSP ADJ 123456789 CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART .............................................................. 3-1 PERIODIC SERVICE ....................................................................................... 3-2 CONTROL SYSTEM ...................

Page 42 - MAINTENANCE INTERVAL CHART; After each use

3-1 E INSP ADJ MAINTENANCE INTERVAL CHART MAINTENANCE INTERVAL CHART Use the following chart as a guide to general maintenance.Adjust the maintenance intervals according to the operating conditions of the watercraft. *1 Grease quantity: 33.0–35.0 cm 3 (1.11–1.18 oz) *2 Grease quantity: 6.0–8.0 cm 3 ...

Page 43 - CONTROL SYSTEM

3-2 E INSP ADJ CONTROL SYSTEM PERIODIC SERVICE CONTROL SYSTEM Steering column inspection 1. Check: • Steering column Excessive play → Replace the steering column.Refer to “STEERING COLUMN” inChapter 8. Checking steps: • Move the handlebar up and down and back and forth. • Check the excessive play of...

Page 44 - WARNING

3-3 E INSP ADJ CONTROL SYSTEM NOTE: If the steering cable cannot be properlyadjusted by the cable joint at the steering col-umn end, adjust the cable joint at the jet pumpend so that the specified distance is obtained.Refer to “REMOTE CONTROL CABLES ANDSPEED SENSOR LEAD” in Chapter 8. WARNING The ca...

Page 45 - QSTS cable inspection and adjustment

3-4 E INSP ADJ CONTROL SYSTEM QSTS cable inspection and adjustment 1. Measure: • Jet thrust nozzle set lengths a and b Out of specification → Adjust. Measurement steps: • Set the control grip to the neutral posi- tion. • Set the jet thrust nozzle in the center position. • Measure jet thrust nozzle s...

Page 46 - Trolling speed check

3-5 E INSP ADJ CONTROL SYSTEM NOTE: If the QSTS cable cannot be properly adjustedby the cable joint at the QSTS converter end,adjust the cable joint at the jet pump end sothat the same lengths are obtained. Refer to“REMOTE CONTROL CABLES AND SPEEDSENSOR LEAD” in Chapter 8. Trolling speed check NOTE:...

Page 48 - FUEL SYSTEM; Fuel line inspection

3-7 E INSP ADJ FUEL SYSTEM FUEL SYSTEM WARNING When removing fuel system parts, wrapthem in a cloth and take care that no fuelspills into the engine compartment. Fuel line inspection 1. Check: • Fuel pump filter Clog/contaminants → Clean. Refer to “FUEL TANK AND FUELPUMP MODULE” in Chapter 4. • Fuel...

Page 49 - OIL INJECTION SYSTEM; Oil line inspection; • Oil filter

3-8 E INSP ADJ OIL INJECTION SYSTEM OIL INJECTION SYSTEM Oil line inspection 1. Check: • Oil filter Contaminants → Clean. Frays/tears → Replace. • Rubber seal Cracks/wear → Replace. • Oil hoses• Oil tank• Oil filler cap Cracks/damage → Replace. • Check valve Malfunction → Replace. CAUTION: Do not al...

Page 50 - POWER UNIT; Spark plug inspection

3-9 E INSP ADJ POWER UNIT POWER UNIT Spark plug inspection 1. Check: • Electrodes 1 Damage/wear → Replace. • Insulator color 2 Distinctly different color → Check the condition of the engine. 2. Clean: • Spark plug (using a spark plug cleaner or wirebrush) Color guide: Medium-to-light tan color: Norm...

Page 51 - YPVS cable adjustment

3-10 E INSP ADJ POWER UNIT 4. Tighten: • Spark plugs NOTE: • Before installing a spark plug, clean the gas- ket surface and spark plug surface. Also, it issuggested to apply a thin coat of anti-seizecompound to the spark plug threads to pre-vent thread seizure. • If a torque wrench is not available,...

Page 52 - Turn in

3-11 E INSP ADJ POWER UNIT 2. Measure: • YPVS cable slack a Out of specification → Adjust. YPVS cable slack: 0.5–1.5 mm (0.02–0.06 in) 3. Adjust: • YPVS cables 1 and 2 Adjustment steps: • Loosen locknuts 1 and 2 . • Turn adjusters 3 and 4 in until there is slack in the cables. • Align the hole a in ...

Page 53 - ELECTRICAL

3-12 E INSP ADJ ELECTRICAL ELECTRICAL Battery inspection WARNING • Battery electrolyte is poisonous and dan- gerous, causing severe burns, etc. Elec-trolyte contains sulfuric acid. Avoidcontact with skin, eyes or clothing. AntidotesExternal: Flush with water. Internal: Drink large quantities of wate...

Page 54 - • When removing the battery, disconnect

3-13 E INSP ADJ ELECTRICAL 1. Remove: • Battery bands• Negative battery lead 1 • Positive battery lead 2 • Battery• Battery breather hose 3 WARNING • When removing the battery, disconnect the negative lead first. • Remove the battery to prevent acid loss before turning the watercraft on its side tos...

Page 56 - Impeller inspection

3-15 E INSP ADJ JET PUMP UNIT JET PUMP UNIT Impeller inspection 1. Check: • Impeller 1 Damage/wear → Replace. Nicks/scratches → File or grind. 2. Measure: • Impeller-to-housing clearance a Out of specification → Replace. Maximum impeller-to-housing clearance: 0.9 mm (0.035 in) Measurement steps: • D...

Page 57 - BILGE PUMP; Bilge strainer inspection

3-16 E INSP ADJ BILGE PUMP BILGE PUMP Bilge strainer inspection 1. Check: • Bilge strainer Contaminants → Clean. Cracks/damage → Replace. Checking steps: • Remove the bilge strainer case 1 from the bilge strainer. • Check the bilge strainer and bilge strainer case. • Install the bilge strainer case....

Page 58 - GENERAL; Drain plug inspection; • Drain plugs; Lubrication points

3-17 E INSP ADJ GENERAL GENERAL Drain plug inspection 1. Check: • Drain plugs Cracks/damage → Replace. • O-rings Cracks/wear → Replace. • Screw threads Contaminants → Clean. Lubrication points 1. Lubricate: • Throttle cable (handlebar end) NOTE: Before lubricating the throttle cable, squeezethe thro...

Page 60 - • Intermediate housing

3-19 E INSP ADJ GENERAL 6. Fill: • Intermediate housing NOTE: Using a grease gun, fill the intermediate hous-ing with the recommended grease through thegrease nipples. Recommended grease: Yamaha marine grease, Yamaha grease A (water-resistant grease) Grease quantity: 33.0–35.0 cm 3 (1.11–1.18 oz)

Page 61 - FUEL; CHAPTER 4

E FUEL CHAPTER 4 FUEL SYSTEM OIL TANK ........................................................................................................ 4-1 EXPLODED DIAGRAM ............................................................................. 4-1REMOVAL AND INSTALLATION CHART ...........................

Page 63 - EXPLODED DIAGRAM; OIL TANK REMOVAL; OIL TANK

4-1 E FUEL OIL TANK EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points OIL TANK REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT” in Chapter 5. Steering console cover assembly Refer to “STEERING CONSOLE COVER” in Chapter 8. 1 Oil...

Page 65 - SERVICE POINTS

4-3 E FUEL OIL TANK SERVICE POINTS Oil line inspection 1. Check: • Oil filter Contaminants → Clean. Frays/tears → Replace. • Rubber seal Cracks/wear → Replace. • Oil hoses• Oil filler cap Cracks/damage → Replace. • Check valve Faulty → Replace. Oil level sensor inspection Refer to “INDICATION SYSTEM...

Page 66 - FUEL TANK AND FUEL PUMP MODULE; FUEL TANK REMOVAL

4-4 E FUEL FUEL TANK AND FUEL PUMP MODULE FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points FUEL TANK REMOVAL Follow the left “Step” for removal. Oil tank Refer to “OIL TANK.” 1 Fuel tank breather hose 1 2 Check valve 1 3 Fuel...

Page 69 - Fuel hose disconnection

4-7 E FUEL FUEL TANK AND FUEL PUMP MODULE SERVICE POINTS Fuel hose disconnection 1. Disconnect: • Fuel hose Refer to “FUEL INJECTION SYSTEM.” Fuel pump module removal 1. Remove: • Nuts• Retainer NOTE: Loosen the nuts in the sequence shown. 1 4 9 6 2 3 8 7 5 2. Remove: • Fuel pump module 1 NOTE: Remo...

Page 70 - Check valve inspection

4-8 E FUEL FUEL TANK AND FUEL PUMP MODULE Check valve inspection 1. Check: • Check valve Faulty → Replace. Fuel pump filter inspection 1. Check: • Fuel pump filter 1 Clog/contaminants → Wash the fuel pump filter in kerosene or gasoline. Checking steps: • Connect a hose to end “A” of the check valve,...

Page 71 - INTAKE DUCT AND INTAKE SILENCER

4-9 E FUEL INTAKE DUCT AND INTAKE SILENCER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points INTAKE DUCT AND INTAKE SILENCER REMOVAL Follow the left “Step” for removal. Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY” in Chapter 5. 1 Intake sile...

Page 72 - Step

4-10 E FUEL INTAKE DUCT AND INTAKE SILENCER EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points 6 Bolt/collar/grommet 1/1/1 7 Intake duct 1 Reverse the removal steps for installation.

Page 73 - Intake silencer installation; Set the screw clamps in the direction shown.

4-11 E FUEL INTAKE DUCT AND INTAKE SILENCER SERVICE POINTS Intake silencer installation 1. Install: • Intake silencer pipe• Intake silencer pipe screw clamps 1 • Intake silencer• Intake silencer screw clamp 2 NOTE: Set the screw clamps in the direction shown. 55˚ 2 1 1

Page 74 - FUEL INJECTION SYSTEM

4-12 E FUEL FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points THROTTLE BODIES ASSEMBLY REMOVAL Follow the left “Step” for removal. Intake silencer pipe Refer to “INTAKE DUCT AND INTAKE SILENCER.” 1 Plastic tie 1 N...

Page 78 - Not reusable

4-16 E FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points THROTTLE BODIES DISASSEMBLY Follow the left “Step” for disassembly. 1 Hose clamp 2 2 Fuel hose 1 3 Grommet 1 4 Quick connector 1 5 Sub-wire harness 1 6 Bolt 3 7 Fuel rail 1 ...

Page 80 - Hose clamp removal

4-18 E FUEL FUEL INJECTION SYSTEM SERVICE POINTS Hose clamp removal 1. Remove: • Hose clamps CAUTION: If the hose clamps are removed withoutcutting the crimp first, the fuel hose can bedamaged. Hose clamp installation 1. Install: • Hose clamps WARNING Do not reuse the hose clamps, alwaysreplace them...

Page 82 - Fuel injector inspection

4-20 E FUEL FUEL INJECTION SYSTEM Fuel injector inspection CAUTION: The throttle bodies should not be disas-sembled unnecessarily. 1. Check: • Fuel injector Dirt/residue → Clean. Damage → Replace. 2. Measure: • Fuel injector resistance Out of specification → Replace. 3. Check the operation of the fu...

Page 84 - Fuel hose connection

4-22 E FUEL FUEL INJECTION SYSTEM Fuel hose connection 1. Apply a thin coat of engine oil to the con- tact surfaces of the fuel pipe. 2. Insert the quick connector into the fuel pipe until you hear a “click.” 3. To check the connection of the quick con- nector, push and pull on the quick connec-tor ...

Page 86 - OIL PUMP; OIL PUMP REMOVAL

4-24 E FUEL OIL PUMP OIL PUMP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points OIL PUMP REMOVAL Follow the left “Step” for removal. Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY” in Chapter 5. Intake duct Refer to “INTAKE DUCT AND INTAKE SILE...

Page 90 - Oil pump lever position adjustment

4-28 E FUEL OIL PUMP Oil pump lever position adjustment 1. Check: • Oil pump lever position Incorrect → Adjust. Checking steps: • Remove the intake duct. Refer to “INTAKE DUCT AND INTAKESILENCER.” • Squeeze the throttle lever to fully open the throttle valve lever. • Check that the gap of the oil pu...

Page 91 - Oil pump bleeding

4-29 E FUEL OIL PUMP Oil pump bleeding 1. Bleed: • Oil pump Bleeding steps: • Place rags around the air bleed screw 1 to catch any oil that might spill. • Fill the oil tank with the recommended oil. NOTE: If the oil pump is replaced or when the oilsuction hose and oil delivery hoses are dis-connecte...

Page 92 - POWR; CHAPTER 5

E POWR CHAPTER 5 POWER UNIT COMPRESSION PRESSURE MEASUREMENT ............................................ 5-1 SERVICE POINTS .................................................................................... 5-1 MUFFLER ASSEMBLY ........................................................................

Page 94 - COMPRESSION PRESSURE MEASUREMENT; Start the engine and warm it up until the

5-1 E POWR COMPRESSION PRESSURE MEASUREMENT COMPRESSION PRESSURE MEASUREMENT SERVICE POINTS The following procedure applies to all of thecylinders. NOTE: Insufficient compression pressure will result ina loss of performance. 1. Start the engine and warm it up until the engine temperature is 48 °C (1...

Page 95 - Compression pressure

5-2 E POWR COMPRESSION PRESSURE MEASUREMENT 6. Measure: • Compression pressure Out of specification → Refer to steps (b) and (c). 7. Install: • Spark plugs Minimum compression pressure (reference data): 640 kPa (6.4 kgf/cm 2 , 91 psi) Measurement steps: a. With the throttle wide open, crank the engi...

Page 96 - MUFFLER ASSEMBLY; MUFFLER REMOVAL

5-3 E POWR MUFFLER ASSEMBLY MUFFLER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points MUFFLER REMOVAL Follow the left “Step” for removal. YPVS servomotor and YPVS servomotor bracket Refer to “YPVS SERVOMOTOR” in Chapter 7. Battery box Refer to “BAT...

Page 100 - MUFFLER DISASSEMBLY

5-7 E POWR MUFFLER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points MUFFLER DISASSEMBLY Follow the left “Step” for disassembly. 1 Exhaust temperature sensor 1 2 Cooling water temperature sensor 1 3 Bolt 2 4 Muffler stay 1 5 Dowel pin 1 6 Bolt 6 7 ...

Page 102 - Catalytic converter inspection

5-9 E POWR MUFFLER ASSEMBLY SERVICE POINTS Catalytic converter inspection 1. Check: • Catalytic converter Cracks/damage → Replace. Muffler installation 1. Install: • Inner exhaust joint• Outer exhaust joint• Muffler assembly• Inner exhaust joint screw clamp• Outer exhaust joint screw clamp NOTE: • A...

Page 103 - EXHAUST CHAMBER ASSEMBLY

5-10 E POWR EXHAUST CHAMBER ASSEMBLY EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST CHAMBER ASSEMBLY REMOVAL Follow the left “Step” for removal. Muffler assembly Refer to “MUFFLER ASSEMBLY.” 1 Screw clamp/cooling water ho...

Page 106 - ENGINE UNIT; ENGINE UNIT REMOVAL

5-13 E POWR ENGINE UNIT ENGINE UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ENGINE UNIT REMOVAL Follow the left “Step” for removal. Muffler assembly Refer to “MUFFLER ASSEMBLY.” Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY.” Silence...

Page 108 - Shim removal

5-15 E POWR ENGINE UNIT SERVICE POINTS Shim removal 1. Remove: • Shims NOTE: To ease reassembly and coupling alignment,remove the shims and organize them in theirrespective groups (e.g., front right, rear left)prior to removing the mounting bolts. Engine mount inspection 1. Check: • Engine mounts Cr...

Page 109 - EXHAUST MANIFOLD; EXHAUST MANIFOLD REMOVAL

5-16 E POWR EXHAUST MANIFOLD EXHAUST MANIFOLD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST MANIFOLD REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT.” 1 Bolt 4 2 Bolt 6 3 Nut 2 4 Exhaust manifold 1 5 Gasket 1 6 Pin ...

Page 111 - REED VALVES; REED VALVE REMOVAL

5-18 E POWR REED VALVES REED VALVES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REED VALVE REMOVAL Follow the left “Step” for removal. Throttle bodies assembly Refer to “FUEL INJECTION SYSTEM” in Chapter 4. Oil delivery hoses Refer to “OIL PUMP” in Ch...

Page 113 - Reed valve inspection; • Reed valves; Valve warpage limit:

5-20 E POWR SERVICE POINTS Reed valve inspection 1. Check: • Reed valves Cracks/damage → Replace. 2. Measure: • Valve warpage a Out of specification → Replace. 3. Measure: • Valve stopper height b Out of specification → Replace. Valve warpage limit: 1.5 mm (0.059 in) Valve stopper height: 10.5–10.9 ...

Page 114 - YPVS; YPVS REMOVAL

5-21 E POWR YPVS YPVS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points YPVS REMOVAL Follow the left “Step” for removal. Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY.” 1 Bolt 12 2 YPVS valve cover 3 3 Gasket 3 4 Spacer 2 5 Link joint/cover 2/...

Page 117 - YPVS valve inspection

5-24 E POWR YPVS SERVICE POINTS YPVS valve inspection 1. Eliminate: • Carbon deposits (using a rounded scraper 1 ) CAUTION: Do not use a sharp instrument to avoiddamaging or scratching the surfaces. 1 2. Check: • YPVS valve assembly Cracks/damage/wear → Replace. YPVS valve installation 1. Install: •...

Page 118 - CYLINDER HEAD; CYLINDER HEAD REMOVAL

5-25 E POWR CYLINDER HEAD CYLINDER HEAD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CYLINDER HEAD REMOVAL Follow the left “Step” for removal. Muffler assembly Refer to “MUFFLER ASSEMBLY.” 1 Spark plug 3 2 Bolt 1 3 Ground lead 1 4 Bolt 2 NOTE: Tighten ...

Page 120 - Cylinder head inspection

5-27 E POWR CYLINDER HEAD SERVICE POINTS Cylinder head inspection 1. Eliminate: • Carbon deposits (using a rounded scraper 1 ) CAUTION: Do not use a sharp instrument to avoiddamaging or scratching the cylinder heador spark plug bore threads. 2. Check: • Cylinder head water jacket Corrosion/mineral d...

Page 121 - CYLINDERS; CYLINDER REMOVAL

5-28 E POWR CYLINDERS CYLINDERS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CYLINDER REMOVAL Follow the left “Step” for removal. YPVS Refer to “YPVS.” Cylinder head Refer to “CYLINDER HEAD.” 1 Engine temperature sensor 1 2 Bolt 12 NOTE: Tighten the bo...

Page 124 - PISTONS; PISTON REMOVAL

5-31 E POWR PISTONS PISTONS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points PISTON REMOVAL Follow the left “Step” for removal. Cylinders Refer to “CYLINDERS.” 1 Piston pin clip 2 CAUTION: Do not align the open end of the clip withthe piston pin slot a . 2...

Page 126 - Piston pin clip removal and installation

5-33 E POWR PISTONS SERVICE POINTS Piston pin clip removal and installation 1. Remove and install: • Piston pin clip NOTE: Before removing or installing the piston pinclip, cover the crankcase opening with a cleanrag to prevent the piston pin clip from fallinginto the crankcase. Piston inspection 1....

Page 127 - Out of specification

5-34 E POWR PISTONS 4. Calculate: • Piston-to-cylinder clearance Out of specification → Replace the pis- ton, piston rings, and cylinder as a set. Cylinder and piston combination Select the appropriate piston to match the cyl-inder size from the table as follows. NOTE: New cylinder bore size = 84.00...

Page 128 - Piston pin and bearing inspection

5-35 E POWR PISTONS 2. Measure: • End gap (using a thickness gauge 1 ) Out of specification → Replace the pis- ton rings as a set. NOTE: Push the piston ring into the cylinder with thepiston crown. End gap: 0.45–0.60 mm (0.018–0.024 in) Piston pin and bearing inspection 1. Check: • Piston pins• Bear...

Page 129 - Piston installation

5-36 E POWR PISTONS 4. Check: • Piston-pin-to-small-end-bearing-to- connecting-rod free play(at the small end of the connecting rod as shown)Free play/wear at the small end → Replace the piston pin, connecting rod,small end bearing, or all parts. Piston installation 1. Install: • Top ring• 2nd ring ...

Page 130 - GENERATOR AND STARTER MOTOR; GENERATOR COVER REMOVAL

5-37 E POWR GENERATOR AND STARTER MOTOR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points GENERATOR COVER REMOVAL Follow the left “Step” for removal. Oil pump Refer to “OIL PUMP” in Chapter 4. 1 Bolt 1 2 Bolt 7 NOTE: Do not apply...

Page 138 - Drive coupling removal and installation; • Drive coupling; Flywheel magneto removal and installation; • Flywheel magneto bolt; Flywheel magneto bolt:

5-45 E POWR GENERATOR AND STARTER MOTOR SERVICE POINTS Drive coupling removal and installation 1. Remove: • Drive coupling NOTE: Install the drive coupling with the same specialservice tools that were used for removal. Coupler wrench: YW-06551/90890-06551 Flywheel holder: YW-06550/90890-06550 T R . ...

Page 139 - Drive coupling inspection

5-46 E POWR GENERATOR AND STARTER MOTOR 2. Remove: • Generator rotor È For USA and Canada É For Worldwide CAUTION: To prevent damage to the engine or specialservice tools, screw in the flywheel pullerset bolts evenly and completely so that thepuller plate is parallel to the generatorrotor. Universal...

Page 140 - CRANKCASE; CRANKCASE DISASSEMBLY

5-47 E POWR CRANKCASE CRANKCASE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CRANKCASE DISASSEMBLY Follow the left “Step” for disassembly. Pistons Refer to “PISTONS.” Generator cover and starter motor Refer to “GENERATOR AND STARTER MOTOR.” 1 Bolt 6 2 ...

Page 142 - Crankcase inspection

5-49 E POWR CRANKCASE SERVICE POINTS Crankcase inspection 1. Check: • Mating surfaces Scratches → Replace the crankcase. • Crankcase Cracks/damage → Replace. Crankcase installation 1. Apply: • Gasket Maker (to the crankcase mating surfaces) NOTE: Before applying Gasket Maker, clean thecrankcase mati...

Page 143 - CRANKSHAFT; CRANKSHAFT REMOVAL

5-50 E POWR CRANKSHAFT CRANKSHAFT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CRANKSHAFT REMOVAL Follow the left “Step” for removal. Crankcase Refer to “CRANKCASE.” 1 Oil seal 1 2 Bearing 1 3 Oil seal 1 1 4 Oil seal 2 1 5 Crankshaft assembly 1 CAUTION...

Page 144 - Crankshaft inspection

5-51 E POWR CRANKSHAFT SERVICE POINTS Crankshaft inspection 1. Measure: • Crank width A Out of specification → Replace the crankshaft. Crank width: 72.95–73.00 mm (2.872–2.874 in) 2. Measure: • Deflection B (using a dial gauge)Out of specification → Replace. Maximum deflection: B 0.05 mm (0.002 in) ...

Page 146 - CHAPTER 6

E JET PUMP 123456789 CHAPTER 6 JET PUMP UNIT JET PUMP UNIT .............................................................................................. 6-1 EXPLODED DIAGRAM ............................................................................. 6-1REMOVAL AND INSTALLATION CHART ................

Page 147 - JET PUMP UNIT REMOVAL

6-1 E JET PUMP JET PUMP UNIT JET PUMP UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points JET PUMP UNIT REMOVAL Follow the left “Step” for removal. 1 Bolt 2 2 Bolt 2 3 Intake grate 1 4 Bolt 4 5 Intake duct 1 6 Felt seal 1 7 Screw 4 8 Speed sensor 1 NOTE:...

Page 150 - SPEED SENSOR DISASSEMBLY

6-4 E JET PUMP JET PUMP UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SPEED SENSOR DISASSEMBLY Follow the left “Step” for disassembly. 1 Paddle wheel set 1 2 Speed sensor 1 Reverse the disassembly steps for assembly. FWD 1 2 Not reusable

Page 151 - JET THRUST NOZZLE AND NOZZLE RING

6-5 E JET PUMP JET THRUST NOZZLE AND NOZZLE RING JET THRUST NOZZLE AND NOZZLE RING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points JET THRUST NOZZLE AND NOZZLE RING REMOVAL Follow the left “Step” for removal. Jet pump unit Refer to “JET PUMP UNIT.” 1 Bolt...

Page 152 - IMPELLER DUCT AND IMPELLER HOUSING 1

6-6 E JET PUMP IMPELLER DUCT AND IMPELLER HOUSING 1 IMPELLER DUCT AND IMPELLER HOUSING 1 EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points IMPELLER DUCT AND IMPELLER HOUSING 1 REMOVAL Follow the left “Step” for removal. Nozzle ring Refer to “JET THRUST NOZZ...

Page 154 - IMPELLER DUCT AND DRIVE SHAFT

6-8 E JET PUMP IMPELLER DUCT AND DRIVE SHAFT IMPELLER DUCT AND DRIVE SHAFT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART *1 EPNOC grease AP #0 Step Procedure/Part name Q’ty Service points IMPELLER DUCT AND DRIVE SHAFT DISASSEMBLY Follow the left “Step” for disassembly. 1 Impeller 1 Left-hand threa...

Page 156 - Drive shaft removal; • Impeller; Drive shaft holder 5:; • Rear bearing; Slide hammer and adapters:

6-10 E JET PUMP IMPELLER DUCT AND DRIVE SHAFT SERVICE POINTS Drive shaft removal 1. Remove: • Impeller NOTE: The impeller has left-hand threads. Turn theimpeller clockwise to loosen it. 2. Remove: • Nut 1 3. Remove: • Drive shaft 1 NOTE: Remove the drive shaft using a press. Drive shaft holder: YB-0...

Page 157 - Needle bearing attachment:

6-11 E JET PUMP IMPELLER DUCT AND DRIVE SHAFT 5. Remove: • Front bearing NOTE: Remove the front bearing using a press. Driver handle—large: YB-06071 Driver rod L3: 90890-06652 Bearing housing needle bearing remover: YB-06112 Needle bearing attachment: 90890-06614 6. Remove: • Oil seal NOTE: Remove t...

Page 158 - • Oil seals

6-12 E JET PUMP IMPELLER DUCT AND DRIVE SHAFT Drive shaft installation 1. Install: • Oil seals Driver handle—large: YB-06071 Driver rod LS: 90890-06606 Outer race installer—forward gear: YB-06085 Ball bearing attachment: 90890-06634 Distance a : 14.2 ± 0.2 mm (0.56 ± 0.01 in) Distance b : 4.7 ± 0.2 ...

Page 159 - Approximately 1/3 of capacity

6-13 E JET PUMP IMPELLER DUCT AND DRIVE SHAFT 5. Install: • Rear bearing NOTE: • Press the bearing inner/outer race at the same time holding the drive shaft and impel-ler duct. • If a bearing inner/outer race attachment is not available, use a washer or pipe with anouter diameter of 47–50 mm (1.85–1...

Page 160 - TRANSOM PLATE AND HOSES

6-14 E JET PUMP TRANSOM PLATE AND HOSES TRANSOM PLATE AND HOSES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points TRANSOM PLATE AND HOSE REMOVAL Follow the left “Step” for removal. Exhaust system Refer to “EXHAUST SYSTEM” in Chapter 8. Jet pump unit assembl...

Page 162 - Refer to “JET PUMP UNIT” in Chapter 3.; Electric bilge pump inspection; • Bilge hoses; Cooling water hose inspection; • Cooling water hoses

6-16 E JET PUMP TRANSOM PLATE AND HOSES SERVICE POINTS Bilge strainer inspection Refer to “JET PUMP UNIT” in Chapter 3. Electric bilge pump inspection Refer to “BILGE PUMP” in Chapter 3.Refer to “ELECTRIC BILGE PUMP” in Chapter7. Bilge hose inspection 1. Check: • Bilge hoses Cracks/damage/wear → Rep...

Page 163 - BEARING HOUSING; BEARING HOUSING REMOVAL

6-17 E JET PUMP BEARING HOUSING BEARING HOUSING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BEARING HOUSING REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT” in Chapter 5. 1 Rubber coupling 1 2 Bolt 3 3 Intermediate housin...

Page 166 - Driven coupling removal and installation

6-20 E JET PUMP BEARING HOUSING SERVICE POINTS Driven coupling removal and installation 1. Remove and install: • Driven coupling NOTE: Install the driven coupling with the same spe-cial service tools that were used for removal. T R . . Driven coupling: 36 N • m (3.6 kgf • m, 25 ft • lb)LOCTITE 572 C...

Page 167 - Bearing removal

6-21 E JET PUMP BEARING HOUSING Bearing removal 1. Remove: • Bearing NOTE: • Install the bearing with the same special ser- vice tools that were used for removal. • Support the intermediate housing with steel blocks 1 and remove the bearing using a press. Bearing, intermediate drive shaft, and greas...

Page 168 - • Bearing; Oil seal installation; • Oil seal; Bearing outer race attachment:

6-22 E JET PUMP BEARING HOUSING 2. Install: • Bearing NOTE: Support the intermediate housing with steelblocks 1 and install the bearing using a press. Oil seal installation 1. Install: • Oil seal NOTE: Before installing the oil seal, lubricate the clipgroove with water-resistant grease. 2. Install: ...

Page 170 - ELEC; CHAPTER 7

E – + ELEC 123456789 CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS........................................................................ 7-1 ELECTRICAL BOX.......................................................................................... 7-2 EXPLODED DIAGRAM ..............................

Page 173 - ELECTRICAL COMPONENTS

7-1 E – + ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 2 3 4 5 6 7890 B 1 8A 8 C N M L J E F G D H I K O P Q 1 Slant detection switch 2 Fuel pump 3 Atmospheric pressure sensor 4 Multifunction meter 5 Steering switch 6 Intake air temperature sensor 7 Throttle position sensor 8 Fuel injectors 9 En...

Page 174 - ELECTRICAL BOX

7-2 E – + ELEC ELECTRICAL BOX ELECTRICAL BOX EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ELECTRICAL BOX DISASSEMBLY Follow the left “Step” for disassembly. 1 Plastic tie 6 2 Tapping screw 11 3 Cover 1 4 Gasket 1 5 Tapping screw 2 6 Lead holder 1 7 Bol...

Page 179 - ECM AND SLANT DETECTION SWITCH

7-7 E – + ELEC ECM AND SLANT DETECTION SWITCH ECM AND SLANT DETECTION SWITCH EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ECM AND SLANT DETECTION SWITCH REMOVAL Follow the left “Step” for removal. 1 Nut/washer 2/2 2 ECM 1 3 ECM coupler 1 4 Nut/washer 2...

Page 180 - ELECTRICAL ANALYSIS; INSPECTION; • All measuring instruments should be han-; ” indicates a continuity of electricity; Digital circuit tester:

7-8 E – + ELEC ELECTRICAL ANALYSIS ELECTRICAL ANALYSIS INSPECTION CAUTION: • All measuring instruments should be han- dled with special care. Damaged or mis-handled instruments will not measureproperly. • On instruments powered by dry batteries, check the battery voltage periodically andreplace the ...

Page 181 - Low resistance measurement

7-9 E – + ELEC ELECTRICAL ANALYSIS Low resistance measurement NOTE: • When measuring a resistance of 10 Ω or less with the digital tester, the correct measure-ment cannot be obtained because of thetester’s internal resistance. • To obtain the correct value, subtract the internal resistance from the ...

Page 182 - Peak voltage adapter; Peak volt meter adapter:

7-10 E – + ELEC ELECTRICAL ANALYSIS Peak voltage adapter NOTE: • Throughout this chapter the part number of the peak voltage adapters have been omit-ted. Refer to the following part numbers. • The peak voltage adapter should be used with the digital tester. • When measuring the peak voltage, connect...

Page 183 - IGNITION SYSTEM; WIRING DIAGRAM

7-11 E – + ELEC IGNITION SYSTEM IGNITION SYSTEM WIRING DIAGRAM FREE PUSH B W FREE PUSH Br Br FREE PUSH W B R Br 19 35 34 33 31 30 29 28 27 20 2 3 5 6 7 8 10 11 12 13 14 32 26 25 24 23 22 21 1 4 9 15 16 17 18 B/ROR/YL/BBP/GPBB/YB/W 19 :20 :27 :28 :29 :30 :31 :33 :34 :35 : YWB/YB/GB/OB/LOW/YW/BW/RL/R ...

Page 185 - IGNITION SPARK GAP; • When checking the spark gap, do not

7-13 E – + ELEC IGNITION SYSTEM IGNITION SPARK GAP WARNING • When checking the spark gap, do not touch any of the connections of the sparkgap tester lead wires. • When performing the spark gap test, take special care not to let sparks leak out ofthe removed spark plug cap. • When performing the spar...

Page 186 - IGNITION SYSTEM PEAK VOLTAGE; ECM output peak voltage:

7-14 E – + ELEC IGNITION SYSTEM IGNITION SYSTEM PEAK VOLTAGE WARNING When checking the electrical components,do not touch any of the connections of thedigital tester lead wires. NOTE: • If there is no spark, or the spark is weak, continue with the ignition system test. • If a good spark is obtained,...

Page 188 - BATTERY; Unloaded

7-16 E – + ELEC 4. Measure: • Rectifier/regulator output peak voltage Below specification → Replace the recti- fier/regulator. NOTE: • Do not use the peak voltage adapter to mea- sure the output voltage. • Disconnect the output lead of the tester har- ness. BATTERY Refer to “ELECTRICAL” in Chapter 3...

Page 189 - IGNITION COIL

7-17 E – + ELEC IGNITION COIL 1. Measure: • Primary coil resistance Out of specification → Replace. NOTE: When measuring a resistance of 10 Ω or less with the digital tester, the correct measurementcannot be obtained because of the tester’sinternal resistance. Refer to “Low resistance measurement.” ...

Page 190 - ENGINE TEMPERATURE SENSOR

7-18 E – + ELEC IGNITION SYSTEM ENGINE TEMPERATURE SENSOR 1. Measure: • Engine temperature sensor resistance (at the specified temperatures)Out of specifications → Replace. Engine temperature sensor resistance: 20 °C (68 °F): 54.2–69.0 k Ω 100 °C (212 °F): 3.12–3.48 k Ω Measurement steps: • Suspend ...

Page 191 - EXHAUST TEMPERATURE SENSOR

7-19 E – + ELEC IGNITION SYSTEM COOLING WATER TEMPERATURE SENSOR 1. Measure: • Cooling water temperature sensor resistance(at the specified temperatures)Out of specifications → Replace. Cooling water temperature sensor resistance: 0 °C (32 °F): 24.0–37.1 k Ω 100 °C (212 °F): 0.87–1.18 k Ω 200 °C (39...

Page 192 - MAIN AND FUEL PUMP RELAY

7-20 E – + ELEC IGNITION SYSTEM MAIN AND FUEL PUMP RELAY 1. Check: • Main and fuel pump relay continuity Out of specification → Replace. Checking steps: • Connect the tester leads between main and fuel pump relay terminals 5 , 6 , and 7 . • Connect terminal 2 or 3 to the positive battery terminal. •...

Page 193 - ATMOSPHERIC PRESSURE SENSOR; • Atmospheric pressure sensor output

7-21 E – + ELEC IGNITION SYSTEM ATMOSPHERIC PRESSURE SENSOR 1. Measure: • Atmospheric pressure sensor output voltageOut of specification → Replace. È : Output voltage É : Vacuum pressure NOTE: While the Yamaha Diagnostic System is oper-ating, electric power is supplied to the atmo-spheric pressure s...

Page 194 - SLANT DETECTION SWITCH; • Slant detection switch continuity; Position

7-22 E – + ELEC IGNITION SYSTEM SLANT DETECTION SWITCH 1. Check: • Slant detection switch continuity Out of specification → Replace. Position Lead color Blue/black (L/B) Black/ orange (B/O) Normal operation È Overturned É UP UP È É

Page 195 - FUEL CONTROL SYSTEM

7-23 E – + ELEC FUEL CONTROL SYSTEM FUEL CONTROL SYSTEM WIRING DIAGRAM 33 31 30 29 28 27 20 2 5 6 7 8 10 14 26 25 24 23 22 21 32 1 4 9 15 16 17 18 19 3 11 12 13 35 34 Pu/YPu/BPu/RR/YL/BBP/GPB 24 :25 :26 :27 :28 :29 :30 :31 :33 : YB/YB/GB/OB/LOL/ROP 2 :5 :6 :7 :8 : 10 :14 :20 :23 : B / O B / O B / O ...

Page 197 - FUEL PUMP; • Fuel pump operating sound; FUEL SENDER; • Fuel sender resistance; Float

7-25 E – + ELEC FUEL CONTROL SYSTEM FUEL PUMP 1. Check: • Fuel pump operating sound No sound → Measure the fuel pressure. Refer to “FUEL INJECTION SYSTEM”in Chapter 4. FUEL SENDER 1. Measure: • Fuel sender resistance Out of specification → Replace. Float position Resistance ( Ω ) A 133.5–136.5 B 5–7

Page 199 - STARTING SYSTEM

7-27 E – + ELEC STARTING SYSTEM STARTING SYSTEM WIRING DIAGRAM FREE PUSH Br Br FREE PUSH W B R Br 19 35 34 33 31 30 29 28 27 20 2 3 5 6 7 8 10 11 12 13 14 32 26 25 24 23 22 21 1 4 9 15 16 17 18 YR/YB 2 : 27 :33 : R Br R Br 1 2 3 4 5 6 7 8 Y B B B B R / Y R / Y B B R / Y R / Y R / Y R / Y R / Y R Br ...

Page 201 - STARTER RELAY

7-29 E – + ELEC STARTING SYSTEM STARTER RELAY 1. Check: • Brown lead terminal• Black lead terminal Loose → Tighten. 2. Check: • Starter relay continuity Out of specification → Replace. Checking steps: • Connect the tester leads between the starter relay terminals as shown. • Connect the brown lead t...

Page 202 - STARTER MOTOR

7-30 E – + ELEC STARTER MOTOR STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STARTER MOTOR DISASSEMBLY Follow the left “Step” for disassembly. Starter motor Refer to “GENERATOR AND STARTER MOTOR” in Chapter 5. 1 O-ring 1 2 Bolt 2 3 Starter ...

Page 205 - Armature inspection

7-33 E – + ELEC STARTER MOTOR SERVICE POINTS Armature inspection 1. Check: • Armature shaft 1 Damage/wear → Replace. 1 2. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 3. Measure: • Commutator diameter Out of specification → Replace. Minimum commutator diameter: 27.0 mm (1.06 in) 4. Chec...

Page 207 - CHARGING SYSTEM

7-35 E – + ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM B R B GGG G G G G G G G G G G G R B R R R R 1 2 3 4 1 Rectifier/regulator 2 Fuse (20 A) 3 Battery 4 Lighting coil B : Black G : Green R : Red

Page 208 - FUSE; Refer to “STARTING SYSTEM.”; Refer to “ELECTRICAL” in Chapter 3.; LIGHTING COIL; Refer to “IGNITION SYSTEM.”

7-36 E – + ELEC CHARGING SYSTEM FUSE Refer to “STARTING SYSTEM.” BATTERY Refer to “ELECTRICAL” in Chapter 3. LIGHTING COIL Refer to “IGNITION SYSTEM.” RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM.”

Page 210 - PICKUP COIL

7-38 E – + ELEC YPVS FUSE Refer to “STARTING SYSTEM.” BATTERY Refer to “ELECTRICAL” in Chapter 3. PICKUP COIL Refer to “IGNITION SYSTEM.” LIGHTING COIL Refer to “IGNITION SYSTEM.” RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM.”

Page 211 - YPVS SERVOMOTOR; YPVS SERVOMOTOR REMOVAL

7-39 E – + ELEC YPVS SERVOMOTOR YPVS SERVOMOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points YPVS SERVOMOTOR REMOVAL Follow the left “Step” for removal. 1 Bolt 2 2 Cable holder 1 3 YPVS servomotor coupler 1 4 Nut/washer 2/2 5 YPVS servomotor 1 6 Thrott...

Page 213 - YPVS cable removal and installation

7-41 E – + ELEC YPVS SERVOMOTOR SERVICE POINTS YPVS cable removal and installation 1. Remove: • YPVS cables 1 and 2 NOTE: • YPVS cable 2 is identifiable by its white paint mark a . • When installing the YPVS cable, make sure that the YPVS cable locknuts 3 are fully turned in. Removal steps: • Remove...

Page 214 - OFF THROTTLE STEERING SYSTEM

7-42 E – + ELEC OFF THROTTLE STEERING SYSTEM OFF THROTTLE STEERING SYSTEM WIRING DIAGRAM 19 35 34 33 31 30 29 28 27 20 2 3 5 6 7 8 10 11 12 13 14 32 26 25 24 23 22 21 1 4 9 15 16 17 18 G/BG/RGG/YR/YBP 15 :16 :17 :18 :27 :29 :31 : W/LB/OW/LOW/YW/BW/R 4 :7 :9 : 10 :11 :12 :13 : Pu / B Pu / R G B / G R...

Page 215 - STEERING SWITCH

7-43 E – + ELEC OFF THROTTLE STEERING SYSTEM STEERING SWITCH 1. Check: • Steering switch Refer to “SELF-DIAGNOSIS” in Chapter9.Malfunction → Check that the steering switch switches on and off when thehandlebar is turned to the right and tothe left using the “Engine monitor” of theYamaha Diagnostic S...

Page 216 - ELECTRIC BILGE PUMP

7-44 E – + ELEC ELECTRIC BILGE PUMP ELECTRIC BILGE PUMP WIRING DIAGRAM 19 35 34 33 31 30 29 28 27 20 2 3 5 6 7 8 10 11 12 13 14 32 26 25 24 23 22 21 1 4 9 15 16 17 18 YR/Y 2 : 27 : 1 2 3 4 5 6 7 8 Br R R / Y R / Y B B B R / Y R / Y R / Y R / Y R / Y R Br B L / R Y L R / Y Y Br B B R / Y R / Y B R / ...

Page 218 - INDICATION SYSTEM

7-46 E – + ELEC INDICATION SYSTEM INDICATION SYSTEM WIRING DIAGRAM 19 35 34 33 31 30 29 28 27 20 2 3 5 6 7 8 10 11 12 13 14 32 26 25 24 23 22 21 1 4 9 15 16 17 18 OR/YBW/BB 20 :27 :29 :32 :33 : GYB/YB/OB/L 1 :2 :5 :7 :8 : B / Y B / Y B / Y B W B B 1 2 3 4 5 6 7 8 R R B R R B B B R / Y R / Y B / O O ...

Page 221 - BUZZER; Positive battery terminal; MULTIFUNCTION METER; Multifunction meter; MULTIFUNCTION METER REMOVAL

7-49 E – + ELEC INDICATION SYSTEM BUZZER 1. Check: • Buzzer Buzzer does not sound → Replace. Checking steps: • Connect a 12 V battery to the buzzer cou- pler as shown. Positive battery terminal → Red (R) terminal 1 Negative battery terminal → Black (B) terminal 2 MULTIFUNCTION METER Multifunction me...

Page 222 - Display function; • Display function

7-50 E – + ELEC INDICATION SYSTEM Display function 1. Check: • Display function Does not operate → Replace the multi- function meter. R / W B / R B / Y P B L B W R Y Y W B / Y R / W L R P B L / R L / B R B B / R B L / B L / R B R 1 5 4 3 2 1 Buzzer 2 Speed sensor 3 ECM 4 Oil level sensor 5 Fuel send...

Page 223 - Speedometer display

7-51 E – + ELEC INDICATION SYSTEM Speedometer display 1. Check: • Speedometer display Does not display → Measure the speed sensor output voltage and pulses. 2. Measure: • Speed sensor output voltage and pulses Out of specification → Replace the speed sensor.Within specification → Replace the mul- ti...

Page 224 - Hour meter display

7-52 E – + ELEC INDICATION SYSTEM Hour meter display 1. Check: • Hour meter display Does not display → Replace the multi- function meter. Voltage meter display 1. Check: • Voltage meter display Does not display → Check the battery voltage using the “Engine monitor” ofthe Yamaha Diagnostic System.If ...

Page 225 - Engine overheat warning indicator

7-53 E – + ELEC INDICATION SYSTEM Engine overheat warning indicator 1. Check: • Engine overheat warning indicator Does not operate → Replace the multi- function meter. Checking steps: • Start the engine.• Disconnect the cooling water tempera- ture sensor coupler 1 . • Check that the warning light co...

Page 226 - Check engine warning indicator

7-54 E – + ELEC INDICATION SYSTEM Check engine warning indicator 1. Check: • Check engine warning indicator Does not operate → Replace the multi- function meter. Checking steps: • Start the engine.• Disconnect the coupler of a sensor (e.g., atmospheric pressure sensor) that nor-mally activates the c...

Page 227 - CHAPTER 8

E HULL HOOD CHAPTER 8 HULL AND HOOD HANDLEBAR .................................................................................................. 8-1 EXPLODED DIAGRAM ............................................................................. 8-1REMOVAL AND INSTALLATION CHART .........................

Page 229 - HANDLEBAR; HANDLEBAR COVER REMOVAL

8-1 E HULL HOOD HANDLEBAR HANDLEBAR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR COVER REMOVAL Follow the left “Step” for removal. 1 Screw 4 2 Handlebar cover 1 3 Screw 4 4 Handlebar cover stay 1 5 Plastic tie 1 6 Throttle cable 1 7 Bolt 4 8 ...

Page 230 - HANDLEBAR REMOVAL

8-2 E HULL HOOD HANDLEBAR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR REMOVAL Follow the left “Step” for removal. QSTS cable (to jet thrust nozzle) Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD.” 1 Grommet 1 NOTE: To ease installatio...

Page 232 - HANDLEBAR DISASSEMBLY

8-4 E HULL HOOD HANDLEBAR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR DISASSEMBLY Follow the left “Step” for disassembly. 1 Plastic tie 1 2 Bolt 2 3 Grip end 2 4 Spacer 1 5 Screw/spring washer/washer 1/1/1 6 QSTS grip assembly 1 7 Screw 2 8 ...

Page 236 - QSTS GRIP; QSTS GRIP DISASSEMBLY

8-8 E HULL HOOD QSTS GRIP QSTS GRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points QSTS GRIP DISASSEMBLY Follow the left “Step” for disassembly. QSTS grip assembly Refer to “HANDLEBAR.” 1 Screw/washer 1/1 2 Cover 1 3 Ball 2 4 Spring 2 5 QSTS cable 1 1 6 ...

Page 238 - QSTS cable inspection; • QSTS cables; QSTS grip inspection; • QSTS grip

8-10 E HULL HOOD QSTS GRIP SERVICE POINTS QSTS cable inspection 1. Check: • QSTS cables Frays/kinks/rough movement → Replace. QSTS grip inspection 1. Check: • QSTS grip Damage/wear → Replace.

Page 239 - STEERING COLUMN; STEERING COLUMN REMOVAL

8-11 E HULL HOOD STEERING COLUMN STEERING COLUMN EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING COLUMN REMOVAL Follow the left “Step” for removal. Steering console cover assembly Refer to “STEERING CONSOLE COVER.” Steering cable end Refer to “RE...

Page 242 - Steering column bushing inspection

8-14 E HULL HOOD STEERING COLUMN SERVICE POINTS Steering column bushing inspection 1. Check: • Bushings Damage/wear → Replace. 2. Check: • Steering column Refer to “CONTROL SYSTEM” in Chap-ter 3. Steering column assembly 1. Install: • Steering switch 1 • Screw clamp 2 • Plastic tie 3 NOTE: Fasten th...

Page 243 - REMOTE CONTROL CABLES AND SPEED SENSOR LEAD

8-15 E HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REMOTE CONTROL CABLES AND SPEED SENSOR LEAD REMOVAL Follow the left “Step” for removal. 1 Speed sensor...

Page 245 - Remote control cable inspection; Steering cable set length; • Steering cable stopper; in the steering cable bracket.

8-17 E HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD SERVICE POINTS WARNING When routing the cables, do not grasp thecable by the outer crimped sheath or steelend. This could deform or loosen the cableend due to extreme angles and or pressure.Always hold the cables by the bracket orouter cov...

Page 246 - QSTS cable installation; QSTS cable set length; • QSTS cable stopper; Be sure to fit the projection

8-18 E HULL HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD QSTS cable installation 1. Install: • QSTS cable (jet pump end) WARNING The QSTS cable must be screwed in a mini-mum of 8 mm (0.31 in). QSTS cable set length a (jet pump end): 12.0–14.0 mm (0.47–0.55 in) QSTS cable stopper installation 1. ...

Page 247 - HOOD; HOOD REMOVAL

8-19 E HULL HOOD HOOD HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HOOD REMOVAL Follow the left “Step” for removal. 1 Bolt 2 2 Screw 8 3 Seal washer 8 4 Visor 1 5 Pop nut 8 6 Bolt 2 7 Hood lock 1 8 Hood 1 10 9 1 11 2 3 5 8 4 6 7 5.4 N • m (0.54 kg...

Page 249 - STEERING CONSOLE COVER

8-21 E HULL HOOD STEERING CONSOLE COVER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING CONSOLE COVER REMOVAL Follow the left “Step” for removal. Handlebar assembly Refer to “HANDLEBAR.” 1 Plastic tie 1 2 Multifunction meter coupler 5 3 Nut/washe...

Page 253 - BUZZER AND HOOD LOCK

8-25 E HULL HOOD BUZZER AND HOOD LOCK BUZZER AND HOOD LOCK EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BUZZER AND HOOD LOCK REMOVAL Follow the left “Step” for removal. Steering console cover assembly Refer to “STEERING CONSOLE COVER.” Steering cable R...

Page 255 - HOSES; HOSE REMOVAL

8-27 E HULL HOOD HOSES HOSES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HOSE REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT” in Chapter 5. Steering console cover assembly Refer to “STEERING CONSOLE COVER.” 1 Plastic tie...

Page 256 - • Check valve; Ventilation hose installation; • Ventilation hose

8-28 E HULL HOOD HOSES SERVICE POINTS Check valve inspection 1. Check: • Check valve Faulty → Replace. Checking steps: • Connect a hose to end “A” of the check valve, and then blow into the hose.Air should come out from end “B.” • Connect the hose to end “B” of the check valve, and then blow into th...

Page 257 - SEAT AND HANDGRIP

8-29 E HULL HOOD SEAT AND HANDGRIP SEAT AND HANDGRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SEAT AND HANDGRIP REMOVAL Follow the left “Step” for removal. 1 Seat 1 2 Bolt 2 3 Seat lock 1 4 Nut 1 5 Projection 1 6 Washer 1 7 Rubber ring 1 8 Nut/wash...

Page 259 - Seat lock inspection; • Seat lock

8-31 E HULL HOOD SEAT AND HANDGRIP SERVICE POINTS Seat lock inspection 1. Check: • Seat lock Damage/wear → Replace.

Page 260 - BATTERY BOX; BATTERY BOX REMOVAL

8-32 E HULL HOOD BATTERY BOX BATTERY BOX EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BATTERY BOX REMOVAL Follow the left “Step” for removal. 1 Battery band 1 2 Fire extinguisher container 1 3 Battery band 1 4 Bolt 1 5 Negative battery lead 1 6 Termina...

Page 262 - EXHAUST SYSTEM; EXHAUST SYSTEM REMOVAL

8-34 E HULL HOOD EXHAUST SYSTEM EXHAUST SYSTEM EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST SYSTEM REMOVAL Follow the left “Step” for removal. Battery box Refer to “BATTERY BOX.” 1 Flotation 1 2 Exhaust joint clamp 1 3 Exhaust joint 1 4 Hose sc...

Page 264 - Exhaust system inspection

8-36 E HULL HOOD EXHAUST SYSTEM SERVICE POINTS Exhaust system inspection 1. Check: • Water lock band Cracks/damage → Replace. 2. Check: • Rubber hoses Burns/cracks/damage → Replace. 3. Check: • Water lock Cracks/leaks → Replace. 4. Check: • Water tank Cracks/damage/leaks → Replace. Water lock instal...

Page 265 - Exhaust component parts assembly

8-37 E HULL HOOD EXHAUST SYSTEM Exhaust component parts assembly 1. Install: • Exhaust outlet• Rubber hose• Water tank NOTE: • Insert the exhaust outlet 45–50 mm (1.77– 1.97 in) a into the rubber hose. • Make sure that there is a distance of 10 mm (0.39 in) b between the parting lines of the exhaust...

Page 266 - DECK AND HULL; DECK AND HULL DISASSEMBLY

8-38 E HULL HOOD DECK AND HULL DECK AND HULL EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points DECK AND HULL DISASSEMBLY Follow the left “Step” for disassembly. 1 Bolt 2 2 Bow eye 1 3 Nut 2 4 Rope hole fitting 2 5 Nut 1 6 Spout 1 7 Bolt 6 8 Sponson 2 NOTE: ...

Page 268 - ENGINE MOUNTS; ENGINE MOUNT REMOVAL

8-40 E HULL HOOD ENGINE MOUNTS ENGINE MOUNTS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ENGINE MOUNT REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT” in Chapter 5. 1 Bolt 4 2 Damper 1 1 3 Damper 2 1 4 Bolt 8 5 Engine mou...

Page 269 - CHAPTER 9; CONNECTING THE COMMUNICATION CABLE TO THE

E TRBL ANLS 123456789 CHAPTER 9 TROUBLE ANALYSIS INTRODUCTION.............................................................................................. 9-1 FEATURES ............................................................................................... 9-1 Functions.........................

Page 270 - INTRODUCTION; FEATURES; Functions; enables you to find malfunctioning parts and controls quickly.; CONTENTS

9-1 E TRBL ANLS INTRODUCTION INTRODUCTION FEATURES The newly developed Yamaha Diagnostic System provides quicker detection and analysis of enginemalfunctions for quicker troubleshooting procedures than traditional methods.By connecting your computer to the ECM (Electronic Control Module) of a waterc...

Page 271 - HARDWARE REQUIREMENTS

9-2 E TRBL ANLS INTRODUCTION HARDWARE REQUIREMENTS Make sure that your computer meets the following requirements before using this software. Computer: IBM-compatible computer Operating system: Microsoft (Windows 95), Windows 98, Windows Me, Windows 2000, orWindows XP (English version) CPU: Windows 9...

Page 272 - OPERATING; CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT; Be careful not to pinch the communication cable between the; hood; and the; deck

9-3 E TRBL ANLS OPERATING OPERATING CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT Model: GP1300RTop view 1 3-pin communication coupler 2 Wire harness coupler 3 Multifunction meter coupler NOTE: Be careful not to pinch the communication cable between the hood and the deck or to damage it. 1 2 ...

Page 273 - TROUBLE ANALYSIS; TROUBLE ANALYSIS CHART; BI

9-4 E TRBL ANLS TROUBLE ANALYSIS TROUBLE ANALYSIS NOTE: Before consulting the “TROUBLE ANALYSIS CHART,” check the following items.1. Check that the battery is charged and that its specified gravity is within specification.2. Check that there are no incorrect wiring connections.3. Check that all wiri...

Page 278 - Color code

WIRING DIAGRAMGP1300R 1 ECM 2 Atmospheric pressure sensor 3 YPVS servomotor 4 Spark plugs 5 Ignition coils 6 Fuse (20 A) 7 Fuses (3 A) 8 Main and fuel pump relay 9 Starter relay 0 Starter motor A Battery B Rectifier/regulator C Throttle switch D Electrical bilge pump E Exhaust temperature sensor F C...

Yamaha WaveRunner GP1300R- User Manual

Table of Contents:

Summary

Other Yamaha Models