If the valve seat contact area is too narrow and situated near the bottom edge of the valve face, use a 60 cutter to cut the bottom edge of the valve seat. Apply a thin, even layer of lapping compound onto the valve seat, and then lap the valve using a valve lapper commercially obtainable.
After every lapping procedure, be sure to clean off any remaining lapping compound from the cylinder head and the valve. Check the valve seat contact area of the valve again.
Valve installation 1. Refer to the following embossed marks. Exhaust valve s : 5LV Install the valve spring with the larger pitch a facing up. Compress the valve spring, and then install the valve cotter 1 using a thin screwdriver with a small amount of grease applied to it.
Lightly tap the valve spring retainer with a plastic hammer to set the valve cotter securely. NOTE: Apply engine oil to the valve pads and valve lifters before installation. After all of the bolts are fully loosened, remove them. Loosen the bolts in decreasing numerical order refer to the numbers in the illustration.
The numbers embossed on the oil pan indicate the oil pan tightening sequence. The numbers embossed on the crankcase indicate the crankcase tightening sequence. Remove: Lower crankcase. Tap only on reinforced portions of the crankcase, not on he crankcase mating surfaces.
Work slowly and carefully and make sure the crankcase halves separate evenly. Crankcase inspection 1. Thoroughly wash the crankcase halves in a mild solvent. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. Oil delivery passages Obstruction Blow out with compressed air. Timing chain inspection 1. Lubricate: Crankshaft journal bearings with the recommended lubricant Recommended lubricant: Engine oil. Finger tighten the crankcase bolts. NOTE: Do not reuse crankcase bolts The tightening procedure of crankcase bolts 10 is angle controlled, therefore tighten the bolts using the following procedure.
Tightening steps: Tighten the bolts in the tightening sequence cast on the crankcase. Crankcase bolt 1st: 7. Loosen and retighten the crankcase bolts in the proper tightening sequence as shown.
Crankcase bolt 2nd: Loosen completely 3rd: 15 N m 1. Tighten the crankcase bolts further to reach the specified angle 49 in the proper tightening sequence as shown. Crankcase bolt Final: Specified angle 49 5. When the bolts are tightened more than the specified angle, do not loosen the bolt and then retighten it.
Replace the bolt with a new one and perform the procedure again. Tighten the bolt until it is at the specified angle. NOTE: When using a hexagonal bolt, note that the angle from one corner to another is Crankcase bolt AJ: 12 N m 1. NOTE: Tighten the bolts in the tightening sequence cast on the oil pan.
Oil pan bolt: 12 N m 1. Not reusable. Connecting rod and piston removal The following procedure applies to all of the connecting rods and pistons. Remove: Connecting rod cap 1 Big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.
NOTE: For reference during installation, put an identification number a on the piston crown. Before removing the piston pin, deburr the piston pin clips groove and the pistons pin bore area. Remove: Top ring 2nd ring Oil ring NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown.
Cylinder and piston inspection The following procedure applies to all of the cylinders and pistons. Check: Piston wall Cylinder wall Vertical scratches Replace the cylinder, and the piston and piston rings as a set. Measure: Piston-to-cylinder clearance.
Measurement steps: Measure cylinder bore C with the cylinder bore gauge. Measure piston skirt diameter P with the micrometer. If out of specification, replace the piston and piston rings as a set. Calculate the piston-to-cylinder clearance with the following formula. Piston ring inspection 1.
Measure: Piston ring side clearance Out of specification Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Side clearance: Top ring: 0.
Measure: Piston ring end gap Out of specification Replace the piston ring. NOTE: The oil ring expander spacers end gap cannot be measured. If the oil ring rails gap is excessive, replace all three piston rings. Piston ring end gap: Top ring: 0. Piston pin inspection The following procedure applies to all of the piston pins.
Measure: Piston pin outside diameter a Out of specification Replace the piston pin. Piston pin outside diameter: Measure: Piston pin bore diameter in the piston b Out of specification Replace the piston. Piston pin bore diameter in the piston : Calculate: Piston-pin-to-piston clearance Out of specification Replace the piston pin. Connecting rod inspection 1. Measure: Crankshaft-pin-to-big-end-bearing clearance Out of specification Replace the big end bearings.
Crankshaft-pin-to-big-endbearing clearance: 0. To obtain the correct crankshaft-pin-to-big-end-bearing clearance and prevent engine damage, the big end bearings must be installed in their original positions. Clean the big end bearings, crankshaft pins, and the inside of the connecting rod halves.
Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap. NOTE: Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap. Put a piece of Plastigauge 1 on the crankshaft pin. Assemble the connecting rod halves. NOTE: Do not move the connecting rod or crankshaft until the clearance measurement has been completed.
Lubricate the bolts threads and nut seats with molybdenum disulfide grease. Make sure the Y mark c on the connecting rod faces towards the front side of the crankshaft.
Make sure the characters d on both the connecting rod and connecting rod cap are aligned. Tighten the connecting rod nuts. Refer to Connecting rod and piston installation. Remove the connecting rod and big end bearings.
Refer to Connecting rod and piston removal. Measure the compressed Plastigauge width e on the crankshaft pin. If the crankshaft-pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings. Select: Big end bearings P1P4 NOTE: The numbers stamped into the crankshaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes.
P1P4 refer to the bearings shown in the crankshaft illustration. Connecting rod and piston installation The following procedure applies to all of the pistons and connecting rods. When installing the connecting rod to the piston, make sure that the Y mark a on the connecting rod faces towards the left when the exhaust valve recesses b on the piston face upward. Refer to the illustration. Reinstall each piston into its original cylinder numbering order starting from the front: 1 to 4.
Offset: Piston ring end gaps a b c Top ring, oil ring expander spacer 2nd ring, lower oil ring rail Upper oil ring rail Exhaust side. Lubricate: Piston Piston rings Cylinder with the recommended lubricant Recommended lubricant: Engine oil.
Lubricate: Bolt threads Nut seats with the recommended lubricant Recommended lubricant: Molybdenum disulfide grease. Lubricate: Crankshaft pins Big end bearings Connecting rod inner surface with the recommended lubricant Recommended lubricant: Engine oil. Install: Big end bearings Connecting rod assembly 1 into the cylinder and onto the crankshaft pin Connecting rod cap onto the crankshaft pin. NOTE: Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps.
Be sure to reinstall each big end bearing in its original place. While compressing the piston rings with piston ring compressor 2, install the connecting rod assembly into the cylinder with the other hand. Make sure the Y marks a on the connecting rods face towards the front side of the crankshaft.
Make sure the characters b on both the connecting rod and connecting rod cap are aligned. Align: Bolt heads with the connecting rod. Clean the connecting rod bolts and nuts. NOTE: The tightening procedure of the connecting rod nuts is angle controlled, therefore tighten the nuts using the following procedure.
Tightening steps: Tighten the connecting rod nuts to the specified torque. Connecting rod nut: 1st: 20 N m 2. Tighten the connecting rod nuts further to reach the specified angle Connecting rod nut: Final: Specified angle 5. When the nuts are tightened more than the specified angle, do not loosen the nut and then retighten it. Replace the bolt and nut with a new one and perform the procedure again.
Tighten the nut until it is at the specified angle. NOTE: When using a hexagonal nut, note that the angle from one corner to another is Qty Service points Follow the left Step for removal. Remove: Crankshaft 1 Crankshaft journal lower bearings from the lower crankcase Crankshaft journal upper bearings from the upper crankcase. NOTE: Identify the position of each crankshaft journal bearing so that it can be reinstalled in its original place.
Crankshaft inspection 1. Measure: Crankshaft runout Out of specification Replace the crankshaft. Maximum crankshaft runout: 0. Measure: crankshaft-journal-to-crankshaft-journalbearing clearance Out of specification Replace the crankshaft journal bearings. Crankshaft-journal-to-crankshaftjournal-bearing clearance: 0. Do not interchange the crankshaft journal bearings. To obtain the correct crankshaftjournal-to-crankshaft-journal-bearing clearance and prevent engine damage, the crankshaft journal bearings must be installed in their original positions.
Measurement steps: Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase. Place the upper crankcase upside down on a bench. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crankcase. NOTE: Align the projections a of the crankshaft journal upper bearings with the notches b in the upper crankcase.
Put a piece of Plastigauge 2 on each crankshaft journal. Install the crankshaft journal lower bearings into the lower crankcase and assemble the crankcase halves. NOTE: Align the projections a of the crankshaft journal lower bearings with the notches b in the lower crankcase.
Do not move the crankshaft until the clearance measurement has been completed. Tighten the bolts to specification in the tightening sequence cast on the crankcase. Remove the lower crankcase and the crankshaft journal lower bearings. Measure the compressed Plastigauge width c on each crankshaft journal. If the crankshaft-journal-to-crankshaftjournal-bearing clearance is out of specification, select replacement crankshaft journal bearings.
Select: Crankshaft journal bearings J1J5 NOTE: The numbers stamped into the crankshaft web and the numbers stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. J1J5 refer to the bearings shown in the crankshaft illustration. If J1J5 are the same, use the same size for all of the bearings. Install: Crankshaft journal upper bearings into the upper crankcase Crankshaft journal lower bearings into the lower crankcase.
NOTE: Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase. Be sure to install each crankshaft journal bearing in its original place. Lubricate: Crankshaft pins Connecting rod inner surface with the recommended lubricant Recommended lubricant: Engine oil. For cooling water outlet on stern side.
For cooling water pilot outlet on starboard side. Thermostat inspection 1. Checking steps: Suspend the thermostat in a container filled with water. Slowly heat the water. Place a thermometer in the water. While stirring the water, observe the thermostat and thermometers indicated temperature.
NOTE: If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious overheating or over cooling. Check: Cooling system Leaks Repair or replace any faulty part. Thermostat installation 1. Install: Thermostat housing 1 Thermostat 2 Gasket Thermostat housing cover. From exhaust manifold To cylinder block To exhaust pipe To cylinder block. Not reusable Reverse the disassembly steps for assembly. NOTE: When installing the spring, hook the spring end a to lever 2 and spring end b to the reverse gate, as shown in the illustration.
When installing the lever 2, hook the lever 2 end c to lever 1 end d, as shown in the illustration. Left-hand threads. Service points Not reusable Not reusable Not reusable Not reusable Reverse the disassembly steps for assembly. Remove: Rear bearing Slide hammer and adapters: YB Stopper guide plate: Bearing puller assembly: Stopper guide stand: Drive shaft inspection 1. Drive shaft installation 1. NOTE: Install the front bearing and drive shaft with a press.
Press the front bearing with a pipe that is more than 85 mm 3. Distance a: 23 0. Install: Nut Impeller Drive shaft nut: 69 N m 6.
Cooling water inlet. Bilge hose inspection 1. Cooling water hose inspection 1. Service points Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Reverse the disassembly steps for assembly. Driven coupling removal and installation 1. Check that the shaft holder and intermediate drive shaft are properly engaged. Intermediate drive shaft removal 1. Remove: Intermediate drive shaft Removal steps: Temporarily install the driven coupling to the intermediate drive shaft.
Insert a long rod to the driven coupling shaft. Press out the intermediate drive shaft by pushing the rod. NOTE: Support the intermediate housing with steel blocks 1 and press the driven coupling shaft with a rod that is more than mm 8. NOTE: Install the bearing with the same special tools that were used for removal. Support the intermediate housing with steel blocks 1 and press the bearing. Bearing, intermediate drive shaft, and grease hose inspection 1. Inspect: Bearing Rotate the inner race by hand.
Driven coupling inspection 1. Install: Circlip front 2. NOTE: Support the intermediate housing with steel blocks 1 and press the bearing. Oil seal installation 1. Install: Oil seal. Distance a: 7. NOTE: Hold the bearing in place as shown with a pipe that is more than 80 mm 3. Distance a: Install: Oil seal 1 [8 mm 0. Install: Intermediate housing Shim Installation steps: Install the intermediate housing.
Measure the clearance a at each bolt hole. Install the suitable shim from the table below. Clearance a Thermoswitch engine Starter motor Engine temperature sensor Spark plugs and ignition coils Electrical box Battery Speed sensor Electric bilge pump Cam position sensor Fuel injectors Thermoswitch exhaust. Oil pressure switch Sensor assembly Bypass valve motor Throttle position sensor Lighting coil and pickup coil Engine stop switch, engine shut-off switch, and start switch H Steering switch I Buzzer J Fuel pump.
All measuring instruments should be handled with special care. Damaged or mishandled instruments will not measure properly. On an instrument powered by dry batteries, check the batterys voltage periodically and replace the batteries if necessary.
Digital tester NOTE: Throughout this chapter the part numbers of the specified digital testers have been omitted. Refer to the following part numbers. NOTE: When measuring a resistance of 10 or less with the digital tester, the correct measurement cannot be obtained because of the testers internal resistance.
To obtain the correct value, subtract the internal resistance from the displayed measurement. The internal resistance of the tester can be obtained by connecting both of its terminals. Peak voltage measurement NOTE: When checking the condition of the ignition system it is vital to know the peak voltage.
Cranking speed is dependant on many factors e. If one of these is defective, the peak voltage will be lower than specification. If the peak voltage measurement is not within specification the engine will not operate properly. A low peak voltage will also cause components to prematurely wear. NOTE: Throughout this chapter the peak voltage adapters part number has been omitted.
Refer to the following part number. The peak voltage adapter should be used with the digital tester. Peak volt meter adapter: YU Peak voltage adapter B: When measuring the peak voltage, connect the peak voltage adapter to the digital circuit tester and switch the selector to the DC voltage mode.
NOTE: Make sure that the adapter leads are properly installed in the digital circuit tester. The test harness is needed for the following tests. Voltage measurement Peak voltage measurement. Test harness Checking steps: Disconnect the coupler connections. Connect the test harness between the couplers. Connect the tester terminals to the terminals which are being checked.
Run the engine and observe the measurement. NOTE: If the lighting coil and pickup coil s are measured unloaded, disconnect the test harness on the output side coupler.
When checking the spark gap, do not touch any of the connections of the spark gap tester lead wires. When performing the spark gap test, take special care not to let sparks leak out of the removed spark plug cap. When performing the spark gap check, keep flammable gas or liquids away, since this test can produce sparks.
Check the ignition coil for resistance. Checking steps: Connect the spark plug cap to the spark gap tester. Spark gap tester: YM Ignition tester: Crank the engine and observe the ignition system spark through the discharge window.
NOTE: If there is no spark, or the spark is weak, continue with the ignition system test. If a good spark is obtained, the problem is not with the ignition system, but possibly with the spark plug s or another component. NOTE: When measuring the ECM output peak voltage while cranking the engine, disconnect the ignition coil couplers for all cylinders except for the cylinder being measured.
To crank the engine, connect the engine shut-off cord lanyard to the engine shut-off switch, and then press the start switch. Measure: Pickup coil output peak voltage Below specification Replace the pickup coil. Above specification Replace the ECM. NOTE: To crank the engine, connect the engine shutoff cord lanyard to the engine shut-off switch, and then press the start switch and engine stop switch simultaneously. Measure: Lighting coil output peak voltage Below specification Replace the lighting coil.
E NOTE: To crank the engine, connect the engine shutoff cord lanyard to the engine shut-off switch, and then press the start switch and engine stop switch simultaneously. NOTE: Do not use the peak voltage adapter to measure the output voltage. Disconnect the output lead of the tester harness.
Measure: Primary coil resistance Out of specification Replace. Primary coil resistance: 1. Refer to Low resistance measurement. Measure: Secondary coil resistance Out of specification Replace. Secondary coil resistance: 8. Check: Engine stop switch continuity Out of specification Replace. Measure: Engine temperature sensor resistance at the specified temperature Out of specification Replace. Engine temperature sensor resistance: 20 C 68 F : Measure the resistance when the specified temperature is reached.
Check: Intake air temperature sensor Out of specification Replace the sensor assembly. Checking steps: Measure the ambient temperature. Connect a computer to the watercraft and use the Yamaha Diagnostic System to display the intake air temperature. Install the ribbon sub assemblies and air filter case cover. Ribbon sub assembly bolt: 6.
Fuel line inspection 1. NOTE: If need the water draining, remove the drain plug 2. Valve clearance cold : Intake valve: 0.
Turn the timing chain tensioner rod fully clockwise with a thin screwdriver 1. NOTE: Make sure that the tensioner rod has been fully set clockwise. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect.
Engine oil level check 1. Insert the tube of an oil changer into the oil filler hole. Operate the oil changer to extract the oil. If the oil filter is also to be replaced, per- form the following procedure. Remove the air filter element and check it for dirt and oil. Replace the air filter ele- ment if there is any oil buildup. Also, it is suggested to apply a thin film of anti- seize compound to the spark plug threads to prevent thread seizure. Electro- lyte contains sulfuric acid.
Avoid contact with skin, eyes or clothing. Antidotes External: Flush with water. Internal: Drink large quantities of water or milk. Maximum impeller-to-housing clearance: 0. Page 75 Before lubricating the throttle cable, squeeze the throttle lever and remove the rubber seal 2. Fuel pump module removal 1. Hose clamps installation 1. Page 98 Fuel injector resistance: reference data Throttle body inspection 1. Page 99 Bypass valve motor inspection 1. Throttle body installation 1.
However, if it is necessary to remove the bypass air screw, be sure to note the number of times the screw is turned from its set position. Turn synchronizing screw 1 3 clock- wise approximately 7 times until it starts to contact the lever.
Butterfly valves 2 and 3 open if the screw is turned more than 7 times. Page Adjust the throttle body synchronization with the air filter case uninstalled. Connect the fuel hose and clamp. Connect the Yamaha Diagnostic Sys- tem.
Remove the sub wiring harness from the air filter case, and then connect it to the throttle bodies and main wiring harness. Adjust the throttle stop screw until trolling 1, speed is within specification. NOTE: Insufficient compression pressure will result in a loss of performance. On them you get not only a charge of adrenaline, but also enjoy the sea spaces.
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Disconnect the engine temperature sensor coupler 1. Push the unlock button, and then measure the input voltage at the engine tempera- ture sensor coupler terminals wiring har- ness end. Measure the resistance when the specified temperatures are reached.
Disconnect the intake air temperature sen- sor coupler 1. Connect the special service tool to the intake air pressure sensor. Connect a computer to the watercraft and use the YDIS to display the intake air pres- sure. NOTE: The actual TPS output voltage and throttle valve opening angle may vary according to environmental conditions and engine tempera- ture. Disconnect the throttle body assembly coupler 1. Disconnect the ECM couplers 2 and 3. Disconnect the APS coupler 1. Push the unlock button, and then measure the input voltage at the APS coupler termi- nals wiring harness end.
Measure the resistance of the APS at the fully closed position and fully open posi- 1 2 3 4 5 6 7 8 tion. Disconnect the ETV relay coupler 1. Push the unlock button, and then measure the input voltage between the ETV relay coupler terminals and ground. Disconnect the cam position sensor cou- pler 1.
Push the unlock button, and then measure the input voltage at the cam position sen- sor coupler terminals wiring harness end. Disconnect the slant detection switch cou- pler 1. Push the unlock button, and then measure the input voltage at the slant detection switch coupler wiring harness end. Connect a computer to the watercraft to use the YDIS. Turn the handlebar all the way to the left or right. Disconnect the steering sensor coupler 1.
Push the unlock button, and then measure the input voltage at the steering sensor coupler terminals wiring harness end. Disconnect the reverse sensor coupler 1. Push the unlock button, and then measure the input voltage at the reverse sensor coupler terminals wiring harness end. Disconnect the right handlebar switch cou- pler 1. Disconnect the ECM coupler 1. Push the unlock button, and then measure the input voltage between the ECM cou- pler terminal wiring harness end and ground. Remove the earth plate.
Check the continuity between each termi- nal 1 and the housing 2. Remove the electrical bilge pump. Disconnect the fuel injector couplers 1. Push the unlock button, and then measure the input voltage between the fuel injector coupler terminals wiring harness end and ground. Remove the fuel pump module. Disconnect the left handlebar switch cou- pler. Check the engine stop switch continuity.
Remove the main and fuel pump relay. Connect the tester leads to the main and fuel pump relay terminals 5 and 6 or to the terminals 5 and 7.
Connect the tester leads to the main and fuel pump relay terminals 7 and 8. Connect the positive battery lead to the main and fuel pump relay terminal 6. Connect the negative battery lead to the main and fuel pump relay terminal 4. Remove the starter relay. Connect the tester leads between the starter relay terminals 1 and 2.
Hold the starter motor in a vise using alu- minum plates on both sides. Connect the positive battery cable 1 to the starter motor terminal bolt 2. Commutator diameter: Commutator undercut a reference data : 0. Brush length a: 5. Starter motor assembly 1. Install the ring gear 1, planetary gears 2, and dowel pin to the front cover 3. Push the lock button 5 or unlock button 6 to transmit the ID code from the remote control transmitter to be registered. All exist- ing ID codes will be deleted from the remote control receiver.
Page 6. NOTE: While the engine is running, input from the remote control transmitter is not received. Remove the battery 3. Measure the battery voltage. Use a pair of non-conductive tweezers to replace the battery.
Disconnect the remote control receiver coupler 1. Measure the input voltage at the remote control receiver coupler terminals wiring harness end. Disconnect the multifunction meter coupler 2. Push the unlock button, and then measure the input voltage at the multifunction meter coupler terminals wiring harness end.
Check the left operation button continuity. Using a compass for reference, point the watercraft north. Measure the ambient air temperature. Select the air temperature display mode of the multifunction meter and check the air temperature displayed on the meter. Disconnect the speed and water tempera- ture sensor coupler 2. Disconnect the speed sensor coupler 1. Remove the fuel pump module assembly. Create a condition so that a diagnostic code is recorded. Push the unlock button.
Disconnect the thermoswitch coupler 1. Connect the jumper lead 2 to the ther- moswitch coupler terminals wiring har- ness end. Remove the buzzer. Connect the positive battery lead to the terminal 1 and the negative battery lead to the terminal 2. Bolt a Punch mark Upper handlebar holder Handlebar switch assembly check 1.
Wrap the packings 1, making sure to align the upper edge a of the packing with the upper edge of the marking tape b on the lead and cable. Route the throttle cable 1 as shown. Install the throttle cable end into the throt- tle lever. Fit the seal 1 into the groove in the bracket. Pull the throttle cable 2 in the direction of the arrow shown, and then fit the end of the seal 1 around the inner cable.
STERN 2. Fit the grip 4 into the housing 3. Fit the QSTS cables 1 into the housing NOTE: Fit the cable with the thin end a into the open- ing with the narrow groove b and the cable with the thick end c into the opening with the wide groove d. Mirror disassembly 1. Push the projections a on the mirror orna- ment 1 shown and remove the ornament from the mirror cover 2.
Push in the rivet pin 1 until it clicks and is below the top of the rivet. Rivet installation 1. Shift lever removal 1. Install the spring 1 1 into the spring holder 2, and then install the holder to the right housing 3. While compressing the spring 1 1, install it into the lever 4. Never attempt to repair a damaged cable. Insert the projection a on the steering cable completely into the indentation b in the cable stopper assembly. Steering cable set length a jet pump end :
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