2012-2015 Yamaha FX HO FB1800 F2T Waverunner Service Manual – PDF Download by www.heydownloads.com

WaveRunner

FX HO FB1800 (F2T)

FX Cruiser HO FB1800A (F2T)

FX SHO FA1800 (F2S)

FX Cruiser SHO FA1800A (F2S) SERVICE MANUAL LIT-18616-03-41

F2S-28197-1R-11

Preface 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 the Bronze Technical Certificate of the YTA (Yamaha Technical Academy) marine or the equivalent 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. Also, up-to-date parts information is available on YDS (Yamaha Dealer System). Additional information and up-to-date information on Yamaha products and services are available on YDS (Yamaha Dealer System).

Important information Particularly important information is distinguished in this manual by the following notations: ď&#x20AC;Ą The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid damages to the watercraft or other property.

TIP: A TIP provides key information to make procedures easier or clearer.

WaveRunner FX HO, FX Cruiser HO, FX SHO, FX Cruiser SHO SERVICE MANUAL ÂŠ2012 by Yamaha Motor Corporation, U.S.A. 1st Edition, February 2012 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-18616-03-41

Contents General information Specification Maintenance Fuel system Power unit Jet pump unit Electrical system Hull and hood Troubleshooting Appendix

GEN INFO

SPEC

MNT

FUEL

POWR

JET PUMP

ELEC

HULL HOOD

TRBL SHTG

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information ď&#x20AC;ĄSafety while working .................................................... 1-1 Rotating part .............................................................................. 1-1 Hot part ...................................................................................... 1-1 Electric shock ............................................................................ 1-1 Impeller ...................................................................................... 1-1 Handling of gasoline .................................................................. 1-1 Ventilation .................................................................................. 1-2 Self-protection ........................................................................... 1-2 Working with crane .................................................................... 1-2 Handling of heat gun ................................................................. 1-3 Part, lubricant, and sealant ........................................................ 1-3 Handling of sealant .................................................................... 1-3 Special service tool ................................................................... 1-3 Tightening torque ...................................................................... 1-3 Non-reusable part ...................................................................... 1-4 Disassembly and assembly ....................................................... 1-4

Identification number ........................................................ 1-5 Primary I.D. number .................................................................. 1-5 Engine serial number ................................................................ 1-5 Jet pump unit serial number ...................................................... 1-5 Hull identification number (H.I.N.) ............................................. 1-5

How to use this manual .................................................... 1-7 Manual format ........................................................................... 1-7 Abbreviation .............................................................................. 1-8

Adhesive, lubricant, sealant, and thread locking agent ......................................................... 1-9 Symbol ...................................................................................... 1-9

Special service tool ......................................................... 1-11 Model feature ................................................................... 1-19 General feature (FX SHO, FX Cruiser SHO) ........................... 1-19 General feature (FX HO, FX Cruiser HO) ............................... 1-20 Model equipment comparison table ........................................ 1-21 Hull and deck ........................................................................... 1-22

Technical tips .................................................................. 1-24 Engine control ......................................................................... 1-24 ETV system ............................................................................. 1-26 Mechanical Neutral .................................................................. 1-27

Engine control system ............................................................. 1-28

YDIS .................................................................................. 1-31 New functions .......................................................................... 1-32 Menu item ................................................................................ 1-32 Logging .................................................................................... 1-33

Engine .............................................................................. 1-34 Lubrication system .................................................................. 1-35 Hose routing (FX SHO, FX Cruiser SHO) ............................... 1-36 Hose routing (FX HO, FX Cruiser HO) .................................... 1-37 Cooling water flow ................................................................... 1-38

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

Safety while working To prevent an accident or injury and to provide quality service, observe the following safety procedures.

Rotating part • Hands, feet, hair, jewelry, clothing, personal flotation device straps, and so on, can become entangled with internal rotating parts of the engine or jet pump unit, resulting in serious injury or death. • Keep hands, feet, hair, jewelry, clothing, personal flotation device straps, and so on, away from any exposed moving parts when operating the engine with the seat removed. • Keep away from intake grate while engine is on. Items such as hair, clothing, or personal flotation device straps can become entangled in moving parts resulting in severe injury.

Hot part During and after operation, engine parts are hot enough to cause burns. Do not touch any parts in the engine compartment until the engine has cooled.

Electric shock Do not touch any electrical parts while starting or operating the engine. Otherwise, shock or electrocution could result.

Impeller Do not hold the impeller with your hands when loosening or tightening the impeller.

1-1

Handling of gasoline • Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. • Gasoline is poisonous and can cause injury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you swallow some gasoline, inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

Safety while working

Ventilation

Working with crane

• Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If gasoline vapor or exhaust gas is inhaled in large quantities, it may cause loss of consciousness and death within a short time. • When test running an engine indoors (for example, in a water tank) make sure to do so where adequate ventilation can be maintained.

• When moving the watercraft, or when lifting the engine during removal or installation, make sure to use a crane with a lifting capacity that is equal to or more than the weight of the watercraft or engine respectively. • When lifting the watercraft, use the watercraft lift harness and make sure that the watercraft is in a stable position when moving it. • Use the wire ropes of adequate strength, and lift up the engine unit using the three point suspension. • If the engine unit does not have three or more points to be suspended, support it using additional ropes or the like so that the engine unit can be lifted and carried in a stable manner.

Self-protection • Protect your eyes by wearing safety glasses or safety goggles during all operations involving drilling and grinding, or when using an air compressor. • Protect your hands and feet by wearing protective gloves and safety shoes when necessary.

1-2

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

Handling of heat gun

Handling of sealant

• Improper handling of a heat gun may result in burns. For information on the proper handling of the heat gun, see the operation manual issued by the manufacturer. • When using a heat gun, keep it away from the gasoline and oil, to prevent a fire. • Components become hot enough to cause burns. Do not touch any hot components directly.

• Wear protective gloves to protect your skin, when using the sealants. • See the material safety data sheet issued by the manufacturer. Some of the sealants may be harmful to human health.

Special service tool Use the recommended special service tools to work safely, and to protect parts from damage.

Part, lubricant, and sealant Use only genuine Yamaha parts, lubricants, and sealants, or those recommended by Yamaha, when servicing or repairing the watercraft.

Tightening torque Follow the tightening torque specifications provided throughout the manual. When tightening nuts, bolts, and screws, tighten the large sizes first, and tighten fasteners starting in the center and moving outward.

1-3

Safety while working

Non-reusable part Always use new gaskets, seals, O-rings, cotter pins, and so on, when installing or assembling parts.

Disassembly and assembly • Use compressed air to remove dust and dirt during disassembly. • Apply engine oil to the contact surfaces of moving parts before assembly.

• Install bearings so that the bearing identification mark is facing in the direction indicated in the installation procedure. In addition, make sure to lubricate the bearings liberally. • Apply a thin coat of water resistant grease to the lip and periphery of an oil seal before installation. • Check that moving parts operate normally after assembly.

1-4

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

Identification number Primary I.D. number

The primary I.D. number is stamped on a label attached to the inside of the engine compartment.

a c

b YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON

c PRI-I.D.

MODEL

F2S

YAMAHA MOTOR CO., LTD. ASSEMBLED IN U.S.A. FROM AMERICAN AND JAPANESE COMPONENTS. ASSEMBLÉ AUX ÉTATS-UNIS DE PIÈCES AMÉRICAINES ET JAPONAISES.

a Model name b Hull type c Primary I.D. number Starting primary I.D. number: F2S: 800101 F2T: 800101

a Engine name b Engine type c Engine serial number Starting engine serial number: A 6CS: 1000001 (F2S) B 6CR: 1000001 (F2T)

Jet pump unit serial number The jet pump unit serial number is stamped on a label attached to the intermediate housing.

Engine serial number The engine serial number is stamped on a label attached to the engine unit.

a Jet pump unit name b Jet pump unit type c Jet pump unit serial number

Hull identification number (H.I.N.) The H.I.N. is stamped on a plate attached to the boarding platform.

1-5

Identification number

U S - Y AM

1-6

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to understand. Use the information below as a guide for effective and quality service. • Parts are shown and detailed in an exploded diagram and are listed in the component list (see a in the following figure for an example page). • The component list consists of part names and quantities, as well as bolt and screw dimensions (see b in the following figure). • Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and the lubrication point (see c in the following figure). • Tightening torque specifications are provided in the exploded diagrams (see d in the following figure), and in the related detailed instructions. Some torque specifications are listed in stages as torque figures or angles in degrees. • Separate procedures and illustrations are used to explain the details of removal, checking, and installation where necessary (see e in the following figure for an example page).

TIP: • The illustrations used in this manual show the FX Cruiser SHO unless otherwise specified. • For troubleshooting procedures, see Chapter 9, “Troubleshooting.”

1-7

How to use this manual

Abbreviation The following abbreviations are used in this service manual. Abbreviation

Description

API

American Petroleum Institute

APS

Accelerator Position Sensor

BOW

Bow side

BTDC

Before Top Dead Center

DOHC

Double Overhead Camshaft

ECM

Electronic Control Module

ETV

Electronic Throttle Valve

Exhaust

Identification

Intake

ISO

International Organization for Standardization

OTS

Off-throttle steering system

PON

Pump Octane Number

PORT

Port side

RON

Research Octane Number

RPM

Revolutions Per Minute

SAE

Society of Automotive Engineers

STBD

Starboard side

STERN

Stern side

TCI

Transistor Controlled Ignition

TDC

Top Dead Center

TPS

Throttle Position Sensor

Upside

YDIS

Yamaha Diagnostic System

1-8

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

Adhesive, lubricant, sealant, and thread locking agent Symbol Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points. Symbol

Name

Application

YAMALUBE 4W or Yamaha 4-stroke motor oil

Lubricant

Water resistant grease (YAMALUBE MARINE GREASE)

Lubricant

Molybdenum disulfide grease

Lubricant

Epnoc grease AP#0

Lubricant

Silicone grease

Lubricant

Symbols in an exploded diagram or illustration indicate the type of adhesive, sealant, or thread locking agent and the application points. Symbol

Name ThreeBond 1207B

Sealant

ThreeBond 1280B

Sealant

ThreeBond 1322

Thread locking agent

ThreeBond 1360

Thread locking agent

ThreeBond 1530D

1-9

Application

Adhesive

LOCTITE 242 (blue)

Thread locking agent

LOCTITE 271 (red)

Thread locking agent

Adhesive, lubricant, sealant, and thread locking agent Symbol

Name

Application

LOCTITE 572 (white)

Sealant

LOCTITE 648 (green)

Thread locking agent

Silicone sealant

Sealant

1-10

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

Special service tool Special service tools numbered â&#x20AC;&#x153;YB/YM/YS/YU/YW-*****â&#x20AC;? are distributed by K & L. Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division. Special service tools with part number 90890-06883 is distributed by the Marine Service Division. Oil filter wrench YB-06830 90890-06830

Gauge stand 90890-06725

Dial gauge stand set YB-06585

Dial indicator gauge YU-03097

1-11

Dial gauge needle 90890-06584

Dial gauge set 90890-01252

Camshaft wrench 90890-06724

Fuel pressure gauge adapter YB-06946 90890-06946

Special service tool Fuel pressure gauge YU-03153M

Exhaust pipe wrench 90890-06726

Fuel pressure gauge 90890-06753

Leakage tester 90890-06840

Compression gauge YU-33223

Coupler wrench 90890-06729

Compression gauge 90890-03160

Bearing puller assembly 90890-06535

Compression gauge extension 90890-06563

Stopper guide plate 90890-06501

1-12

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

Stopper guide stand 90890-06538

Valve guide installer 90890-06810

Valve spring compressor YM-04019 90890-04019

Valve guide reamer YM-01196 90890-06804

Compressor adapter YM-04114 Valve spring compressor attachment 90890-04114

Valve lapping tool YM-A8998 Valve lapper 90890-04101

Valve guide remover YB-06801 Valve guide remover/installer 90890-06801

Neway valve seat kit YB-91044

Valve seat cutter holder 90890-06812 Valve guide installer YB-06810

1-13

Special service tool Valve seat cutter Intake 90890-06720 (30°) 90890-06325 (45°) 90890-06324 (60°) Exhaust 90890-06818 (30°) 90890-06555 (45°) 90890-06323 (60°)

Flywheel puller 90890-06723

Rotor puller 90890-01080

Crankshaft holder 90890-06732 Primary sheave holder YS-01880-A Sheave holder 90890-01701

Shaft holder 90890-06721

Driver handle (small) YB-06229

Driver handle 90890-06722

Bearing and seal installer YW-06356

1-14

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

Driver rod LS 90890-06606

Forward bearing race installer YB-06258

Bearing outer race attachment 90890-06627

Bearing pressure C 90890-02393

Driver handle (large) YB-06071

Piston ring compressor YM-08037

Forward gear outer race installer YB-41446

Piston ring compressor 90890-05158

Ball bearing attachment 90890-06657

Driveshaft holder YB-06201 Drive shaft holder 6 90890-06520

1-15

Special service tool Slide hammer YB-06096

Driveshaft needle bearing installer and remover YB-06194

Driver rod L3 90890-06652

Needle bearing attachment 90890-06609

Bearing attachment 90890-06727

Bearing attachment 90890-06728

Shaft holder 90890-06730

Bearing puller legs YB-06523

Needle bearing installer YB-06434

Needle bearing attachment 90890-06654

1-16

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

YDIS 2 starter kit 90890-06883

Spark checker YM-34487 Ignition tester (Spark gap tester) 90890-06754 ***

****** ******

Digital multimeter YU-34899-A Test harness (3 pins) YB-06877 90890-06877

Peak volt adapter YU-39991 Test harness (3 pins) YB-06870 90890-06870

Digital circuit tester 90890-03189 Test harness (2 pins) YW-06850 90890-06850

Peak voltage adapter B 90890-03172

Lower unit pressure/vacuum tester YB-35956-A

1-17

Special service tool Vacuum/pressure pump gauge set 90890-06756

Test harness (6 pins) YB-06872 90890-06849

Test harness (8 pins) YB-06879 90890-06879

1-18

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

Model feature General feature (FX SHO, FX Cruiser SHO) The F2S is equipped with a newly designed NanoXcel hull and deck. The body length has increased compared to the previous model (F1W). The 6CS engine installed into the F2S is based on a high output, 1.8L supercharged 6AN engine with changes to the lubrication system. The engine has also undergone either an anodic coating or has had a black paint layer added, increasing anti-corrosion properties.

a Power unit • 4-stroke, L4, DOHC, 16 valve, 1812 cm3 engine with electronic fuel injection • Supercharged • Single throttle body • 4-in-1 exhaust system • Wet-sump lubrication b Jet pump • Stainless steel, 3-blade, ø155 mm, 17.6° pitched impeller • Impeller turning direction: counterclockwise (when viewed from the rear) • Aluminum jet thrust nozzle • Mechanical Neutral • Q.S.T.S.

1-19

c Electrical • Electronic control throttle valve system • Electric throttle without wire cable • In-tank fuel pump module • Multifunction meter • L-MODE • No-wake mode • Cruise assist • OTS • YDIS Ver. 2.00 d Deck and hull • V-shaped hull • NanoXcel hull, NanoXcel deck • 2 seat types (different shapes according to the model) • Adjustable tilt steering system • Flushing hose connector placed in the stern storage compartment

Model feature

General feature (FX HO, FX Cruiser HO) The F2T is equipped with the same hull and deck as the F2S. The 6CR engine installed into the F2T is based on a high output, 1.8L 6CN engine with changes to the lubrication system. The engine has also undergone either an anodic coating or has had a black paint layer added, increasing anti-corrosion properties.

a Power unit • 4-stroke, L4, DOHC, 16 valve, 1812 cm3 engine with electronic fuel injection • Single throttle body • 4-in-1 exhaust system • Wet-sump lubrication b Jet pump • Stainless steel, 3-blade, ø155 mm, 15.3° pitched impeller • Impeller turning direction: counterclockwise (when viewed from the rear) • Aluminum jet thrust nozzle • Mechanical Neutral • Q.S.T.S.

1-20

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

Model equipment comparison table Model Total length Width Dry weight Seats Pull-up cleat c “START/STOP” and “MODE/RESET” button d Speed and water temperature sensor e Compass and air temperature sensor g Multifunction display h (*1)

FX HO

373 kg (822 lb) Normal seat a —

FX Cruiser HO FX SHO 3.56 m (140.2 in) 1.23 m (48.4 in) 374 kg (825 lb) 386 kg (851 lb) Cruiser seat b Normal seat a  —

FX Cruiser SHO

387 kg (853 lb) Cruiser seat b 

—



Speed sensor f only



—



—



: Equipped —: Not equipped (*1) Compass, average speed, tripmeter, trip timer, fuel consumption, water temperature, and air temperature display.

b e

g B c

A FX SHO

1-21

B FX Cruiser SHO

Model feature

Hull and deck The F2S and F2T share the same newly designed NanoXcel hull and deck. The length has increased by 190 mm (7.5 in) compared to the previous model, the F1W. The enlarged body has allowed for a bigger seat and boarding platform, more gear capacity, and enhanced riding comfort. The form of the hull improves the handling of the vehicle, and it also is designed to improve agility in spite of the increases in weight. Model Total length a Seat length b Reboarding step height c Storage compartment d

Previous FX series 3.37 m (132.7 in) 610 mm (24 in)

New FX series 3.56 m (140.2 in) 686 mm (27 in)

172 mm (6.8 in)

380 mm (15 in)

4 locations

5 locations

The gear space at the rear of the vehicle will comfortably fit snorkeling gear and tow ropes a. The gear space is designed so that the rope can be housed while fitted to the tow hook. Also in the gear space there is a flushing hose connector b, allowing for the vehicle to be flushed just by opening the gear space and attaching a garden hose c. The reboarding step d is designed so that only a minimal step is required to place your foot. The grip e located in the front part of the platform makes reboarding from the water easier.

1-22

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

a d

A d

d c

a b

d B

d d

d A Previous FX series B New FX series

1-23

Model feature / Technical tips

Technical tips Engine control The ECM controls ignition timing and fuel injection with information received from the sensors and switches installed on the engine as well as utilizing the base map saved in the ECM.

b c

e g h

m n

o j k

1-24

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

i d

f e

m g

n o j l k A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO Part name a Cam position sensor b Slant detection switch c ECM d Thermo sensor e Oil pressure switch f Thermoswitch g Intake air temperature sensor h Knock sensor i TPS j Intake air pressure sensor k Engine temperature sensor l Pickup coil m APS n Steering sensor o Reverse sensor

1-25

Functions Detects the rotational position of the camshaft. Detects whether the watercraft is capsized. Properly controls ignition timing, fuel injection timing and volume, opening angle of the ETV, and fail-safe function with information received from the sensors and switches. Detects the temperature of the exhaust cooling water. Detects the pressure of the engine oil. Detects overheat. Detects the temperature of the intake air. Detects engine knocking. Detects the opening angle of the ETV. Detects the pressure of the intake air. Detects the temperature of the cylinder block. Detects the crankshaft angle. Detects the opening angle of the throttle lever. Detects when the handlebar is turned all the way to the right or left and a load is applied. Detects the N and R positions of the shift lever.

Technical tips

ETV system The F2S and F2T are equipped with a newly developed throttle lever. The throttle lever has an APS which senses the degree of throttle opening and converts the status into electronic signals, delivering the information to the ECM. The ECM controls the ETV based on the input signals of the APS. Employing the APS in the throttle lever has eliminated the need for throttle cables, reducing the number of parts used, thereby improving throttle response and serviceability. The newly developed throttle lever has 2 sensors as per the previous APS â&#x20AC;&#x201C; the APS 1 and APS 2, which mutually diagnose any failures each system may encounter. In addition, an APS full close switch has been newly added. This switch detects the fully closed throttle lever position.

b 5V APS 1 Ground

c a

5V APS 2

Ground

d e B

5V APS 1 Ground 5V Ground

APS 2

5V Ground

APS full close switch

e a Throttle lever b Throttle cable c APS d ECM e ETV f Electric throttle without wire cable

B New ETV system

A Previous ETV system

1-26

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

Mechanical Neutral In addition to the F and R positions, an N position has been added to the F2S and the F2T. The shift lever is used to change the shift position. The shift lever will not slide unless the shift lock lever a is held. An N mark b will be displayed when the shift lever is in the N position. By operating the shift lever, the reverse gate position changes. In the N position, the flow of water is dispersed forwards and backwards, preventing the water craft from moving in either direction. With previous reverse sensor, the mechanism switched on when the shift lever was placed in the R position, and the reverse traction control was engaged. In this model, the reverse sensor turns on in both the N and R positions, activating reverse traction control in both modes. For this reason, the engine speed is also limited in the N position.

B b a

A F position B N position C R position

1-27

Technical tips

Engine control system Item Overheat warning control

Oil pressure warning control

Condition Action • Engine temperature • Opening angle of the ETV is regulated. rises rapidly in a • Maximum engine speed is short time. limited to approximately • Thermoswitch is on. 3000–3300 r/min. • Exhaust cooling water temperature exceeds 75 °C (167 °F).

Control is activated when all of the following conditions are present: • Oil pressure switch is on. • ETV is open. • Engine speed exceeds 4500 r/min. Cam position Control is activated sensor failure when the following control conditions are maintained for 10 seconds: • Cam position sensor failed. • Engine speed exceeds approximately 1000 r/min. Control is activated when all of the following conditions are present: • Cam position sensor failed. • Engine speed exceeds 5000 r/min. ETV failure ETV failed, or open or control short circuit is detected in ETV circuit.

• Opening angle of the ETV is regulated. • Maximum engine speed is limited to approximately 3000–3300 r/min.

Remarks Cancel: • Stop the engine and wait for 30 seconds or more. • Engine temperature is below 140 °C (248 °F) with the thermoswitch off. • Exhaust cooling water temperature is below 70 °C (158 °F) with the ETV fully closed. If the engine is stopped during overheat warning control, it can be restarted. Cancel: • Stop the engine and wait for 30 seconds or more. • Engine is restarted and the oil pressure switch is off. If the engine is stopped during oil pressure warning control, it can be restarted. Cancel: Engine is stopped.

Ignition and fuel injection are Cancel: cut to all cylinders and the Engine is stopped. engine is stopped.

• Opening angle of the ETV is fixed to the default opening angle. • Maximum engine speed is limited to approximately 3000 r/min. • Ignition timing is controlled.

1-28

1 2 3 4 5 6 7 8 9 A

GEN INFO Item Battery disconnection warning Idle speed control Over revolution control

High intake air pressure control

Knock control

Off-throttle steering (OTS) control

Reverse with traction control

1-29

General information Condition Battery lead is disconnected during normal operation. Throttle lever is in the fully closed (idle) position. Engine speed exceeds 7800 r/min.

Action Control is performed using the same actions as the ETV failure control. Engine speed is limited to 1150–1350 r/min. (FX SHO, FX Cruiser SHO) Ignition is controlled. CondiAction tion Normal None Level 1 Ignition is cut off to 1 cylinder. Level 2 Ignition is cut off to 2 cylinders. Level 3 Ignition is cut off to 3 cylinders. Level 4 Ignition is cut off to all cylinders. In a state where The throttle valve is limited engine speed has from opening more than the exceeded 7550 r/min point where the control was and intake pressure is engaged. higher than 145 kPa (21.0 psi) has lasted longer than 1.5 seconds. When engine speed Ignition timing is delayed exceeds 2000 r/min according to the volume of after warming up knocking Engine speed is Slightly opens the throttle sustained at or above valve so that the vehicle can 4000 r/min for several maneuver. seconds and then throttle lever is fully closed – simultaneously, the steering handle is maneuvered to the point the steering sensor is engaged. When the shift lever is Engine speed will be limited in the N or R position. to 3000 r/min.

Remarks

Engine speed is limited to 1200–1400 r/min. (FX HO, FX Cruiser HO)

Completely shutting off the throttle valve will disengage the control. (FX SHO, FX Cruiser SHO)

(FX SHO, FX Cruiser SHO)

Throttle valve opening is controlled based on the APS signal and the amount of force applied to the steering sensor.

The control will be disengaged when the shift lever is moved forward. While the control is engaged, the no-wake mode cannot be activated.

Technical tips Item Condition Slant detection Control is activated control when all of the following conditions are present: • Slant detection switch is on. • Engine speed is 3000 r/min or less. Cruise assist When engine speed is control between 3000–7000 r/min No-wake 5 seconds or more mode control have elapsed since the engine was started. L-MODE L-MODE is activated. control

Action Remarks Ignition and fuel injection are Cancel: cut to all cylinders and the Engine is stopped. engine is stopped. (The check engine warning indicator does not come on and the buzzer does not sound.)

The vehicle can cruise at a Cruise control cannot be set sustained, set engine speed. when the L-MODE is active. Engine speed is limited to 2100 r/min.

The digital speedometer flashes at 8 km/h (5 mph).

• Opening angle of the ETV Cancel: L-MODE is deactivated. is regulated. • Ignition timing is controlled. • Maximum engine speed is limited to approximately 75 % of the maximum engine speed in the normal mode.

1-30

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

YDIS F2S and F2T are only compatible with YDIS version 2.00. YDIS version 2.00 retains the functionality of YDIS version 1 series, while adding new functionality. The screen has been redesigned, improving ease-of-use.

TIP: • There is no compatibility between the YDIS version 2.00 and version 1 series. • Use of the Windows function a to change the screen size and to end programs is now possible. • Displays the current level b. • Displays the communications status. Communicating: c Communications error: d • For details of operation methods, see the YDIS (Ver. 2.00) instruction manual. • These tools are restricted for use by Yamaha service technicians of distributors or dealers only.

a b c d

1-31

YDIS

New functions • The settings function now enables switching of the language (English, French, Spanish, Japanese). The units for measurement cannot be changed. • By connecting commercially available external instruments, the external input function enables display of this information on the engine monitor. • The new adapter has 1.6 MB of memory, meaning that logging of engine monitor information is possible while the computer is not connected. The adapter has an internal battery, which is recharged by being connected to the computer or to the water craft (while the engine start switch is ON), and one hour of recharging is sufficient for 48 hours backup.

While your water craft is connected to the YDIS, the ECM power cannot be turned off. This can drain battery power. Remove the YDIS connection when you are not using the YDIS.

Menu item Top Menu Start

Main Menu Engine

2nd-level Menu Diagnosis

3rd-level Menu

4th-level Menu

Diagnosis

Diagnosis Record Engine operating hours by RPM Engine Monitor

Digital Display

Graph Display

Input Setting

Component Test

Stationary Test

Active Test

Data Logger

Logger Graph

Update

ECM Rec Graph

Setting

Logging

Off Line

Record Set

Show Data

Clear Data

1-32

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

Logging In version 2.00, it is possible to configure items to be logged, and logging intervals. Configure logging, and disconnect the USB cable between the computer and the adapter to start logging. Because the computer is not connected during logging, the adapter can be placed within the bow storage compartment. This enables logging under conditions that are the same as those during normal use. This makes it easier to reproduce trouble conditions, and to investigate the causes of any faults.

Take care when riding while the YDIS is connected as the multifunction meter display will not operate.

e b

f A a Adapter a Logging start b Engine start c Engine stop d Fault occurs e Logging stop

f Adapter recording status A Recording (engine speed: 500 r/min or more) B Stop recording (engine speed: less than 500 r/min)

TIP: • Starts and stops logging by connecting and disconnecting the USB cable between the computer and adapter. • The adapter has a built-in battery. Therefore during operation, this is recharged using electricity from the engine. When the engine stops, backup uses the internal battery. • Guaranteed for 48 hours continuous operation with the battery charged for one hour. If the internal battery becomes depleted, recorded data will be deleted. • Recording normal (default condition) engine data (engine speed ranges) enables comparison with fault data.

1-33

YDIS / Engine

Engine The new 6CS engine is derived from the modified 6AN engine, and the new 6CR engine is based on the modified 6CN engine. Main points of change include discarding the scavenging pump, external breather, simplifying the lubrication system. The parts surrounding the timing chain have been changed to those used in the 6BH engine in order to increase usage of common parts. The engine has also undergone either an anodic coating or has had a black paint layer added, increasing anti-corrosion properties.

A C

B A A A

A B

A Anodic oxide coating B Black paint layer C FX SHO, FX Cruiser SHO

1-34

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

Lubrication system The 6CS and 6CR engines feature a wet-sump lubrication system. The oil pump assy. is different from the oil pump assy. that was used for the base engine and does not contain a scavenge oil pump. In addition, the breather assy. was eliminated. As a result, the blowby gas from the cylinder head cover is sent directly to the oil separator tank.

b n

l c d

m k A e

i a Intake camshaft b Exhaust camshaft c Cylinder block d Crankshaft e Oil separator tank f Oil pan g Oil strainer h Oil pipe i Oil pump assy. (feed pump) j Relief valve

1-35

k Oil cooler assy. l Oil filter m Oil pump drive gear n Super charged (FX SHO, FX Cruiser SHO only) A To air intake pipe B Oil flow C Oil flow (FX SHO, FX Cruiser SHO only)

Engine

Hose routing (FX SHO, FX Cruiser SHO)

F D

E D B

A B C D E F G H I J K L

I J K L

From flushing hose connector From transom plate To cooling water pilot outlet on port side To drain joint (transom plate) To drain joint To drain joint To cooling water pilot outlet on starboard side For water draining when engine is stopped Cooling water flow Blowby gas flow Bilge water flow Fuel flow

1-36

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

Hose routing (FX HO, FX Cruiser HO)

F D

E D B

A B C D E F G H I J K

From flushing hose connector From transom plate To cooling water pilot outlet on port side To drain joint (transom plate) To drain joint To drain joint For water draining when engine is stopped Cooling water flow Blowby gas flow Bilge water flow Fuel flow

1-37

H I J K

Engine

Cooling water flow H

F D

A H

B A B

G A B C D E F G H I

From flushing hose connector From transom plate To cooling water pilot outlet on port side To drain joint To exhaust valve To cooling water pilot outlet on starboard side For water draining when engine is stopped FX SHO, FX Cruiser SHO FX HO, FX Cruiser HO

1-38

1 2 3 4 5 6 7 8 9 A

GEN INFO

General information

— MEMO —

1-39

SPEC

Specification Model data ......................................................................... 2-1 Model code ................................................................................ 2-1 Dimensions and weight ............................................................. 2-1 Performance .............................................................................. 2-1 Power unit ................................................................................. 2-1 Jet pump unit ............................................................................. 2-2 Fuel and oil requirement ............................................................ 2-2 Battery requirement ................................................................... 2-3

Fuel system technical data .............................................. 2-3 Fuel system ............................................................................... 2-3

Power unit technical data ................................................. 2-4 Power unit ................................................................................. 2-4 Cylinder head assy. ................................................................... 2-4 Crankcase assy. ........................................................................ 2-6

Jet pump unit technical data ............................................ 2-8 Jet pump unit ............................................................................. 2-8

Electrical technical data ................................................... 2-8 Ignition system .......................................................................... 2-8 Charging system ....................................................................... 2-9 Control system .......................................................................... 2-9 Fuel system ............................................................................. 2-11 Starting system ........................................................................ 2-11 Meter system ........................................................................... 2-12

Specified tightening torque ............................................ 2-13 Fuel system ............................................................................. 2-13 Power unit ............................................................................... 2-13 Jet pump unit ........................................................................... 2-16 Electrical system ..................................................................... 2-16 Hull and hood .......................................................................... 2-16

Torque wrench reading (setting value) ......................... 2-18 General tightening torque .............................................. 2-18 Cable and hose routing .................................................. 2-19 Starboard bow view ................................................................. 2-19 Top view .................................................................................. 2-20 Port view .................................................................................. 2-22

1 2 3 4 5 6 7 8 9 A

SPEC

Specification

Model data Model code Model Item

Unit

FX Cruiser HO

FX HO

F2T 6CR/6CR

Hull Engine/jet

FX Cruiser SHO

FX SHO

F2S 6CS/6CS

Dimensions and weight Model Item Length Width Height Dry weight Maximum capacity

Unit mm (in) mm (in) mm (in) kg (lb) person/kg (lb)

FX HO

373 (822)

FX Cruiser FX SHO HO 3560 (140.2) 1230 (48.4) 1230 (48.4) 374 (825) 386 (851) 3/240 (530)

FX Cruiser SHO

387 (853)

Performance

Item Full throttle operating range Trolling speed Maximum fuel consumption Cruising range

Unit r/min r/min L/h (US gal/ h, lmp.gal/h) h

Model FX FX FX HO Cruiser FX SHO Cruiser HO SHO 7600 7500 1200–1400 1150–1350 48.7 (12.9, 10.7)

70.6 (18.7, 15.5)

1.44

0.99

Power unit Model Item Type Cylinder quantity Total displacement Bore  stroke Compression ratio Exhaust system Lubrication system Cooling system Starting system Camshaft drive system

2-1

Unit

cm3 (cu. in) mm (in)

FX FX FX HO Cruiser FX SHO Cruiser HO SHO 4-stroke, L4, DOHC 4 1812 (110.6) 86.0 × 78.0 (3.39 × 3.07) 11:1 8.6:1 Wet exhaust Wet sump Water cooled Electric starter Chain drive

Model data

Item Timing chain tensioning system Ignition system Maximum ignition timing advance Spark plug Spark plug gap Firing order Oil filter type Oil pump type

Unit

degree

FX HO

Model FX Cruiser FX SHO HO Automatic TCI

BTDC 25

FX Cruiser SHO

BTDC 20

LFR6A (NGK) 0.8–0.9 (0.031–0.035) 1–2–4–3 Cartridge type Trochoid

mm (in)

Jet pump unit Model Item Jet pump type Impeller rotation Transmission Jet thrust nozzle horizontal angle Trim system Jet thrust nozzle trim angle Shift operation Reverse system

Unit

Degree

FX FX Cruiser FX SHO Cruiser HO SHO Axial flow, single stage Counterclockwise (viewed from rear) Direct drive from engine 24 + 24 Manual 5 positions –10, –5, 0, 5, 10 F-N-R Reverse gate

FX HO

Fuel and oil requirement Model Item

Unit

Fuel type Fuel minimum rating Fuel tank capacity Engine oil type Engine oil grade

PON RON L (US gal, Imp.gal) API SAE

FX HO

FX FX Cruiser FX SHO Cruiser HO SHO Regular unleaded gasoline 86 90 70 (18.5, 15.4)

YAMALUBE 4W or 4-stroke motor oil SE, SF, SG, SH, SJ, SL 10W-30, 10W-40, 20W-40, 20W-50

2-2

1 2 3 4 5 6 7 8 9 A

SPEC

Specification

Item

Unit

FX HO

Model FX Cruiser FX SHO HO

FX Cruiser SHO

Engine oil quantity Total amount Without oil filter replacement With oil filter replacement

L (US gal, Imp.gal) L (US gal, Imp.gal) L (US gal, Imp.gal)

4.3 (4.5, 3.8) 3.0 (3.2, 2.6) 3.1 (3.3, 2.7)

Battery requirement Model Item Type Capacity Specific gravity At 20 °C (68 °F)

Unit

FX HO

FX Cruiser HO

FX SHO

FX Cruiser SHO

Fluid 12/19

V/Ah

1.265

Fuel system technical data Fuel system Model Item

Unit

Throttle body Manufacturer ID mark Fuel pump Fuel pump type Fuel pressure

2-3

FX HO

FX Cruiser HO

FX SHO

FX Cruiser SHO

Mikuni 6BH**

6S5** Electrical

kPa (kgf/ cm2, psi)

345–370 (3.45–3.70, 49.1–52.6)

Model data / Fuel system technical data / Power unit technical data

Power unit technical data Power unit Model Item

Unit

FX Cruiser HO

FX HO

FX SHO

FX Cruiser SHO

Compression pressure Minimum (*1) Air cooler Water passage holding pressure Air passage holding pressure Oil cooler Water passage holding pressure Thermostat Valve opening temperature Fully open temperature Fully open stroke

kPa (kgf/ cm2, psi)

780 (7.8, 113.1)

610 (6.1, 86.8)

—

200 (2.0, 28.5)

—

100 (1.0, 14.2)

kPa (kgf/ cm2, psi) kPa (kgf/ cm2, psi) kPa (kgf/ cm2, psi)

200 (2.0, 28.5)

°C (°F) °C (°F) mm (in)

58–62 (136–144) 48–52 (118–126) 70 (158) 60 (140) 4.3 (0.17)

(*1) Measuring conditions: Ambient temperature 20 °C (68 °F), with spark plugs removed from all cylinders. The figures are for reference only.

Cylinder head assy. Model Item Cylinder head Warpage limit Camshaft cap inside diameter

Unit

FX HO

FX Cruiser HO

FX SHO

FX Cruiser SHO

mm (in)

0.10 (0.0039)

mm (in)

25.000–25.021 (0.9843–0.9851)

2-4

1 2 3 4 5 6 7 8 9 A

SPEC

Specification

Item Camshaft Cam lobe height Intake Limit Exhaust Limit Cam lobe width Intake and exhaust Runout Limit Journal diameter Intake and exhaust Journal oil clearance Limit Valve Clearance Intake Exhaust Head diameter Intake Exhaust Face width Intake and exhaust Seat contact width Intake Limit Exhaust Limit Margin thickness Intake and exhaust Valve stem Diameter Intake Limit Exhaust Limit Runout limit

2-5

Unit

FX HO

Model FX Cruiser FX SHO HO

FX Cruiser SHO

mm (in) mm (in) mm (in) mm (in)

41.330–41.430 (1.627–1.631) 41.320 (1.626) 41.220–41.320 (1.623–1.627) 41.210 (1.622)

mm (in) mm (in) mm (in)

31.956–32.056 (1.258–1.262) 0.015 (0.0006) 0.05 (0.0020)

mm (in) mm (in) mm (in)

24.960–24.980 (0.9827–0.9835) 0.020–0.061 (0.0008–0.0024) 0.08 (0.0031)

mm (in) mm (in)

0.14–0.23 (0.0055–0.0091) 0.28–0.37 (0.0110–0.0146)

mm (in) mm (in)

33.900–34.100 (1.3346–1.3425) 28.900–29.100 (1.1378–1.1457)

mm (in)

2.260–2.830 (0.0890–0.1114)

mm (in) mm (in) mm (in) mm (in)

1.400–1.600 (0.0551–0.0630) 2.100 (0.0827) 1.500–1.700 (0.0591–0.0669) 2.200 (0.0866)

mm (in)

0.800–1.200 (0.0315–0.0472)

mm (in) mm (in) mm (in) mm (in) mm (in)

5.477–5.492 (0.2156–0.2162) 5.447 (0.2144) 5.464–5.479 (0.2151–0.2157) 5.434 (0.2139) 0.01 (0.0004)

Power unit technical data

Item Valve guide Inside diameter Intake and exhaust Stem to guide clearance Intake Limit Exhaust Limit Valve spring Free length Intake and exhaust Limit Installed length Intake and exhaust Tilt limit Intake and exhaust

Unit

FX HO

Model FX Cruiser FX SHO HO

FX Cruiser SHO

mm (in)

5.504–5.522 (0.2167–0.2174)

mm (in) mm (in) mm (in) mm (in)

0.012–0.045 (0.0005–0.0018) 0.080 (0.0031) 0.025–0.058 (0.0010–0.0023) 0.100 (0.0039)

mm (in) mm (in)

45.58 (1.79) 43.30 (1.70)

mm (in)

34.0 (1.34)

mm (in)

2.0 (0.08)

Crankcase assy. Model Item Cylinder Bore Limit Piston Diameter Measuring point Piston clearance Limit Ring groove (top) Ring groove (2nd) Ring groove (oil) Pin boss bore diameter Limit Pin outside diameter Limit

Unit

FX HO

FX Cruiser HO

FX SHO

FX Cruiser SHO

mm (in) mm (in)

86.000–86.015 (3.3858–3.3864) 86.100 (3.3898)

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

85.915–85.930 (3.3825–3.3831) 9.5 (0.37) 10 (0.39) 0.070–0.100 (0.0028–0.0039) 0.200 (0.0059) 1.210–1.230 (0.0476–0.0484) 1.210–1.230 (0.0476–0.0484) 2.510–2.530 (0.0988–0.0996) 22.004–22.015 (0.8663–0.8667) 22.045 (0.8679) 21.991–22.000 (0.8658–0.8661) 21.981 (0.8654)

2-6

1 2 3 4 5 6 7 8 9 A

SPEC

Specification

Item Piston ring End gap measuring point Top ring Type Dimension height (B) Dimension width (T) End gap (*1) Limit Side clearance Limit 2nd ring Type Dimension height (B) Dimension width (T) End gap (*1) Limit Side clearance Limit Oil ring Dimension height (B) Dimension width (T) (*1) End gap (*1) Side clearance Connecting rod Small end inside diameter Bearing color code Big end side clearance Limit Big end width Crankshaft pin width Crankshaft Journal diameter Pin diameter Runout limit Journal oil clearance Limit Pin oil clearance Limit Bearing color code (*1) The figures are for reference only.

2-7

Unit

FX HO

Model FX Cruiser FX SHO HO

FX Cruiser SHO

mm (in)

6.0 (0.24)

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

Barrel 1.170–1.190 (0.0461–0.0469) 2.850–3.050 (0.1122–0.1201) 0.300–0.450 (0.0118–0.0177) 0.700 (0.0276) 0.020–0.060 (0.0008–0.0024) 0.110 (0.0043)

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

Taper 1.170–1.190 (0.0461–0.0469) 2.600–2.800 (0.1024–0.1102) 0.450–0.600 (0.0177–0.0236) 0.850 (0.0335) 0.020–0.060 (0.0008–0.0024) 0.120 (0.0047)

mm (in) mm (in) mm (in) mm (in)

2.370–2.470 (0.0933–0.0972) 2.500 (0.0984) 0.100–0.350 (0.0039–0.0138) 0.040–0.160 (0.0016–0.0063)

mm (in)

22.015–22.028 (0.8667–0.8672) 1.Brown 2.Black 3.Blue 4.Green 0.160–0.262 (0.0063–0.0103) 0.5 (0.0197) 26.788–26.840 (1.0547–1.0566) 27.000–27.050 (1.0630–1.0649)

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

39.976–40.000 (1.5739–1.5748) 41.976–42.000 (1.6526–1.6535) 0.03 (0.0012) 0.024–0.053 (0.0009–0.0021) 0.10 (0.0039) 0.020–0.056 (0.0008–0.0022) 0.09 (0.0035) 1.Brown 2.Black 3.Blue 4.Green 5.Yellow

Jet /pump unit technical data Power unit technical data / Jet pump unit technical data Electrical

Jet pump unit technical data Jet pump unit Model Item Impeller housing Inside diameter Limit Impeller-to-housing ance Clearance limit Impeller Material Blades number Pitch angle Drive shaft Runout limit Nozzle Diameter

Unit

clear-

FX Cruiser HO

FX HO

FX SHO

FX Cruiser SHO

mm (in)

155.35–155.45 (6.116–6.120) 156.45 (6.159)

mm (in)

0.35–0.45 (0.014–0.018)

mm (in)

0.60 (0.024) Stainless steel 3

degree

15.3

17.6

mm (in)

0.3 (0.012)

mm (in)

86.60–87.20 (3.409–3.433)

Electrical technical data Ignition system Model Item ECM unit Output peak voltage At cranking (loaded) At 2000 r/min (loaded) At 3500 r/min (loaded) Pickup coil Output peak voltage At cranking (unloaded) At cranking (loaded) At 2000 r/min (loaded) At 3500 r/min (loaded) Resistance (*1) At 20 °C (68 °F)

Unit

FX HO

FX Cruiser HO

FX SHO

V V V

2.5 2.6 2.6

V V V V

5.5 4.7 16.4 21.5



459–561

FX Cruiser SHO

(*1) The figures are for reference only.

2-8

1 2 3 4 5 6 7 8 9 A

SPEC

Specification

Charging system Model Item

Unit

Stator coil Output peak voltage At cranking (unloaded) At 2000 r/min (unloaded) At 3500 r/min (unloaded) Resistance (*1) At 20 °C (68 °F) Rectifier regulator Output peak voltage At 2000 r/min (loaded) At 3500 r/min (loaded)

FX HO

FX Cruiser HO

FX SHO

V V V

8.3 36.4 64.7



0.31–0.38

V V

13.0 13.0

FX Cruiser SHO

(*1) The figures are for reference only.

Control system Model Item Oil pressure switch Input voltage (*1) Continuity pressure Thermoswitch Input voltage (*1) Continuity temperature No continuity temperature Thermo sensor Input voltage Resistance (*1) At 0 °C (32 °F) At 100 °C (212 °F) Engine temperature sensor Input voltage Resistance (*1) At 20 °C (68 °F) At 100 °C (212 °F) Intake air temperature sensor Input voltage Resistance (*1) At 0 °C (32 °F) At 80 °C (176 °F)

2-9

Unit

V kPa (kgf/ cm2, psi)

FX HO

FX Cruiser HO

FX SHO

FX Cruiser SHO

11.0–12.0 128–166 (1.28–1.66, 18.6–24.1)

V °C (°F) °C (°F)

11.0–12.0 94–100 (201–212) 80–94 (176–201)

4.75–5.25

k k

24.0–37.1 0.87–1.18

4.75–5.25

k k

54.2–69.0 3.12–3.48

4.75–5.25

k k

5.4–6.6 0.29–0.39

Electrical technical data

Item Intake air pressure sensor Input voltage Knock sensor Resistance (*1) At 20 °C (68 °F) TPS Output voltage With throttle lever fully closed TPS 1 With throttle lever fully open TPS 2 Throttle valve opening angle With throttle lever fully closed With throttle lever fully open Input voltage APS Output voltage With throttle lever fully closed APS 1 APS 2 With throttle lever fully open APS 1 APS 2 Input voltage APS 1 APS 2 APS full close switch ETV relay Input voltage Cam position sensor Input voltage Output voltage Position b, d Position c Slant detection switch Input voltage

Unit

Model FX Cruiser FX SHO HO

FX HO

k

FX Cruiser SHO

4.75–5.25

—

504.0–616.0

0.6–0.9

4.5–4.8

degree

2–8

degree

More than 70

4.75–5.25

V V

0.68–0.74 0.68–0.74

V V

3.95–4.15 3.95–4.15

V V V

4.75–5.25 4.75–5.25 4.75–5.25

12 (battery voltage)

4.75–5.25

V V

More than 4.8 Less than 0.8

4.75–5.25

2-10

1 2 3 4 5 6 7 8 9 A

SPEC

Specification

Item Steering sensor Input voltage Electric bilge pump Input voltage ECM unit Input voltage

Unit

FX HO

Model FX Cruiser FX SHO HO

4.75–5.25

12 (battery voltage)

FX Cruiser SHO

(*1) The figures are for reference only.

Fuel system Model Item Fuel injector Input voltage Resistance (*1) At 20 °C (68 °F) Fuel pump module Input voltage Fuel sender resistance (*1) At 20 °C (68 °F) Lower position Upper position

Unit

FX HO

FX Cruiser HO

FX SHO

12 (battery voltage)



11.5–12.5

12 (battery voltage)

 

133.5–136.5 5.0–7.0

Unit

Model FX Cruiser FX SHO HO

FX Cruiser SHO

(*1) The figures are for reference only.

Starting system

Item Fuse Rating Battery Main and fuel pump relay (main side) Main and fuel pump relay (fuel pump side) ETV relay Remote control receiver

2-11

FX HO

V/A

12/30

V/A

12/20

V/A

12/10

V/A V/A

12/10 12/3

FX Cruiser SHO

Electrical technical data

Item Starter motor Type Output Cranking time limit Commutator diameter Commutator undercut (*1) Brush length

Unit

Model FX Cruiser FX SHO HO

FX HO

FX Cruiser SHO

Constant mesh 0.6 30 27–28 (1.06–1.10) 0.2–0.7 (0.008–0.028) 5.0–12.5 (0.20–0.49)

kW seconds mm (in) mm (in) mm (in)

(*1) The figures are for reference only.

Meter system Model Item Remote control transmitter Battery Type Rating Remote control receiver Input voltage Output voltage (*1) Multifunction meter unit Input voltage Buzzer Input voltage (*1) Speed and water temperature sensor Output voltage (on pulse) Water temperature sensor resistance At 20 °C (68 °F) Speed sensor Output voltage (on pulse)

Unit

FX Cruiser HO

FX HO

FX Cruiser SHO

FX SHO

CR2016 3

V V

12 (battery voltage) 11.0–12.0

12 (battery voltage)

11.0–12.0

mV V

— —

Less than 400 More than 4.5

k

—

54.2–69.0

mV V

Less than 400 More than 11.6

— —

(*1) The figures are for reference only.

2-12

1 2 3 4 5 6 7 8 9 A

SPEC

Specification

Specified tightening torque Specified tightening torques are provided for specific nuts, bolts, and screws. When tightening these fasteners, follow the tightening torque specifications indicated throughout the manual to meet the design aims of the watercraft. (*1) FX HO FX, Cruiser HO only (*2) FX SHO FX, Cruiser SHO only

Fuel system Part to be tightened

Screw size

Air intake pipe clamp Air filter case bracket nut Air filter case bolt Fuel rail bolt ETV nut (*1) ETV joint bolt (*1) Fuel pump module nut

— — M8 M8 — M8 1st 2nd

Fuel filler neck nut Fuel filler hose clamp

— — —

Tightening torques N·m kgf·m ft·lb 3.5 0.35 2.58 17 1.7 12.5 13 1.3 9.6 13 1.3 9.6 13 1.3 9.6 24 2.4 17.7 3.5 0.35 2.58 7 0.7 5.2 6 0.6 4.4 4 0.4 3.0

Power unit Part to be tightened

Screw size

Engine cover screw Rectifier regulator bolt Rectifier regulator cover bolt Stay bolt

M6 M8 M6 1st 2nd 1st 2nd

Engine cover stay bolt (*2) Pipe clamp Exhaust manifold bolt Oil filter Electrical box bolt Engine mounting bolt Engine mount bolt Damper 1 bolt Damper 2 bolt Exhaust pipe 3 Thermo sensor

2-13

M8 M10 M6 —

1st 2nd 3rd

M8 — M8 M8 M8 M6 M6 — —

N·m 5 26 13 23 42 23 42 10 2.5 20 20 35 18 17 17 17 5.5 5.5 200 20

Tightening torques kgf·m ft·lb 0.5 3.7 2.6 19.2 1.3 9.6 2.3 17.0 4.2 31.0 2.3 17.0 4.2 31.0 1.0 7.4 0.25 1.84 2.0 14.8 2.0 14.8 3.5 25.8 1.8 13.3 1.7 12.5 1.7 12.5 1.7 12.5 0.55 4.06 0.55 4.06 20.0 147.5 2.0 14.8

Specified tightening torque Part to be tightened Exhaust pipe 1 bolt Exhaust pipe 2 bolt

Screw size 1st 2nd 3rd 1st 2nd

Starter motor lead nut Slant detection switch screw Starter relay bolt ECM bolt Fuse box assy. bolt Boost pipe joint 1 clamp (*2) Boost pipe joint 2 clamp (*2) Boost pipe bolt (*2) Air cooler intake pipe clamp (*2) Air cooler nut (*2) Air cooler bolt (*2) Stud bolt (*2)

Intake manifold nut Stud bolt

1st 2nd 1st 2nd 1st 2nd

— M10 — M10 M6 M8 M5

1st 2nd 1st 2nd 1st 2nd

Intake air temperature sensor Intake manifold stay bolt

M8 — M6 M6 M6 M6 — — M8 —

Air cooler stay bolt (*2) Supercharger bolt (*2) Supercharger bolt (*2) Supercharger oil filler hole bolt Intake manifold bolt

M8 — — —

1st 2nd

ETV nut (*2) ETV joint bolt (*2) Oil pipe bolt (*2) Oil pump assy. bolt Oil pump drive gear bolt (left-hand threads) (*1) Oil cooler assy. bolt Oil cooler cover bolt Oil cooler cover bolt Drive gear assy. bolt (left-hand threads) (*2) Oil filter joint bolt Spark plug

M8 — M8 M10 M6 M12 M8 M6 M8 M12 — —

Tightening torques N·m kgf·m ft·lb 20 2.0 14.8 20 2.0 14.8 35 3.5 25.8 15 1.5 11.1 29 2.9 21.4 7 0.7 5.2 4 0.4 3.0 4 0.4 3.0 5 0.5 3.7 8 0.8 5.9 3.5 0.35 2.58 3.5 0.35 2.58 20 2.0 14.8 4 0.4 3.0 23 2.3 17.0 42 4.2 31.0 23 2.3 17.0 42 4.2 31.0 23 2.3 17.0 42 4.2 31.0 42 4.2 31.0 10 1.0 7.4 20 2.0 14.8 4 0.4 3.0 10 1.0 7.4 20 2.0 14.8 10 1.0 7.4 20 2.0 14.8 10 1.0 7.4 20 2.0 14.8 15 1.5 11.1 15 1.5 11.1 30 3.0 22.1 13 1.3 9.6 24 2.4 17.7 21 2.1 15.5 11 1.1 8.1 80 8.0 59.0 19 1.9 14.0 12 1.2 8.9 20 2.0 14.8 80 8.0 59.0 18 1.8 13.3 25 2.5 18.4

2-14

1 2 3 4 5 6 7 8 9 A

SPEC

Specification Part to be tightened

Screw size

Cam position sensor bolt Engine cover grommet bolt (*1) Camshaft sprocket bolt Camshaft cap bolt Oil pipe bolt Timing chain tensioner bolt Chain guide plate bolt Engine hanger bolt (*1) Engine hanger bolt Cylinder head bolt

M6 M6 M7 M7 M10 M6 M6 M10 M6 1st 2nd

Cylinder head bolt Holder (left-hand threads) Drive coupling Generator cover assy. bolt Flywheel magneto bolt Special nut Transfer shaft

M6 — — M8 M8 — 1st 2nd 3rd

Holder bolt Stator coil assy. bolt Plate bolt (*1) Oil level pipe plate bolt (*1) Anode cover bolt Engine temperature sensor Knock sensor (*2) Oil pipe stay bolt

1st 2nd

Crankcase bolt Baffle plate bolt

2-15

M6 M6 M6 M4 — M6 M8

1st 2nd

Engine mount bracket bolt Crankcase bolt

— M6 M6 M6 M8 M8 — —

Oil pipe bolt Baffle plate bolt Oil pressure switch lead bolt Oil pressure switch Oil pan assy. bolt Oil pan plug Connecting rod nut

M12

— M10

1st 2nd

M10 M6 M6

Tightening torques N·m kgf·m ft·lb 10 1.0 7.4 6 0.6 4.4 18 1.8 13.3 16 1.6 11.8 20 2.0 14.8 10 1.0 7.4 10 1.0 7.4 42 4.2 31.0 12 1.2 8.9 55 5.5 40.6 90° 10 1.0 7.4 80 8.0 59.0 250 25.0 184.4 26 2.6 19.2 24 2.4 17.7 250 25.0 184.4 50 5.0 36.9 60° 250 25.0 184.4 15 1.5 11.1 15 1.5 11.1 11 1.1 8.1 19 1.9 14.0 20 2.0 14.8 15 1.5 11.1 15 1.5 11.1 0.3 0.03 0.2 12 1.2 8.9 9 0.9 6.6 12 1.2 8.9 2 0.2 1.5 9 0.9 6.6 10 1.0 7.4 20 2.0 14.8 51 5.1 37.6 90° 50 5.0 36.9 30 3.0 22.1 90° 10 1.0 7.4 10 1.0 7.4

Specified tightening torque

Jet pump unit Part to be tightened Intake grate bolt Ride plate bolt Speed sensor screw Steering cable joint nut Spout hose clamp (hull end) Rubber plate bolt Rubber plate nut Jet pump unit assy. bolt Bracket bolt Reverse gate assy. bolt Spring nut Ball joint nut Jet thrust nozzle bolt Impeller duct bolt Water inlet cover/water inlet strainer bolt Impeller Drive shaft nut Flushing hose nut Transom plate nut Hose joint bolt Intermediate housing assy. bolt Driven coupling Grease nipple

Screw size M8 M8 M5 — — M6 — M8 M10 M8 M8 — — M8 M10 M6 — — — — M6 M8 — —

Tightening torques N·m kgf·m ft·lb 17 1.7 12.5 17 1.7 12.5 4 0.4 3.0 7 0.7 5.2 2 0.2 1.5 7 0.7 5.2 7 0.7 5.2 17 1.7 12.5 40 4.0 29.5 15 1.5 11.1 20 2.0 14.8 8 0.8 5.9 8 0.8 5.9 16 1.6 11.8 40 4.0 29.5 7 0.7 5.2 330 33.0 243.4 74 7.4 54.6 6 0.6 4.4 26 2.6 19.2 3.5 0.35 2.58 17 1.7 12.5 205 20.5 151.2 3 0.3 2.2

Electrical system Part to be tightened Starter motor cover bolt Starter motor terminal nut Transmitter cover tapping screw

Screw size M6 — M2

Tightening torques N·m kgf·m ft·lb 7 0.7 5.2 9 0.9 6.6 0.1 0.01 0.07

Hull and hood Part to be tightened Upper handlebar cover tapping screw Handlebar grip bolt Handlebar grip end bolt Left handlebar switch screw Throttle lever assy. bolt Handlebar holder bolt Q.S.T.S. cable locknut (grip end) Steering boss cover screw

Screw size M4 M5 M5 M5 M5 M8 — M6

N·m 1 3.5 7 3.5 3.5 20 16 1

Tightening torques kgf·m ft·lb 0.1 0.7 0.35 2.58 0.7 5.2 0.35 2.58 0.35 2.58 2.0 14.8 1.6 11.8 0.1 0.7

2-16

1 2 3 4 5 6 7 8 9 A

SPEC

Specification Part to be tightened

Mirror bolt Mirror bolt Hood lock bolt Hood lock screw Front hood screw Hinge nut Hinge bolt Damper nut Damper bracket bolt Multifunction meter cover screw Multifunction meter bolt Hood lock hook bolt Shift lever screw Side cover bolt Side cover screw Ornament bolt Shift lever bolt Center cover bolt Center console screw Center console bolt Steering master assy. nut Cable stopper bolt Steering arm bolt Ball joint nut Compass nut Steering boss cover bracket bolt Buzzer bracket bolt Steering sensor bolt Shift lever assy. nut Steering cable joint locknut Speed sensor lead grommet nut Shift cable bracket nut Shift cable holder nut Steering cable locknut (hull) Shift cable locknut (hull) Shift cable locknut Q.S.T.S. cable locknut (hull) Q.S.T.S. converter bolt Seat lock assy. bolt Projection nut Handgrip nut Deck beam nut Seat holder nut Cooling water pilot outlet nut

2-17

Screw size M6 M8 M5 M5 M5 M6 M6 M6 M6 M5 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M8 M6 M8 M6 M5 M5 M5 M6 M6 — — M6 M6 — — — — M6 M6 M10 M8 M8 M6 —

Tightening torques N·m kgf·m ft·lb 5 0.5 3.7 13 1.3 9.6 4 0.4 3.0 1.5 0.15 1.11 2 0.2 1.5 5 0.5 3.7 5 0.5 3.7 5 0.5 3.7 5 0.5 3.7 2 0.2 1.5 4 0.4 3.0 4 0.4 3.0 5 0.5 3.7 5 0.5 3.7 5 0.5 3.7 5 0.5 3.7 5 0.5 3.7 5 0.5 3.7 5 0.5 3.7 5 0.5 3.7 21 2.1 15.5 7 0.7 5.2 16 1.6 11.8 7 0.7 5.2 4 0.4 3.0 4 0.4 3.0 4 0.4 3.0 7 0.7 5.2 5 0.5 3.7 7 0.7 5.2 6 0.6 4.4 5 0.5 3.7 5 0.5 3.7 7 0.7 5.2 7 0.7 5.2 4 0.4 3.0 7 0.7 5.2 5 0.5 3.7 6 0.6 4.4 26 2.6 19.2 5 0.5 3.7 16 1.6 11.8 5 0.5 3.7 4 0.4 3.0

Torque wrench reading (setting torque value) Specified tightening torque / General tightening Part to be tightened Rubber hose nut Rubber hose clamp Ski tow nut Spout nut Stern eye nut Drain plug nut Reboarding step assy. bolt Bow eye bolt Bow eye nut Stern storage bolt Stern grip bolt Stern grip nut Front protector nut Cleat bolt Sponson bolt

Torque wrench reading (setting value) The correct setting value of the torque wrench varies depending on its length. When tightening bolts, nuts, or parts using the SST as an extension to the torque wrench, use the following calculation formula to obtain the correct setting value.

When tightening bolts, nuts, or parts using an extension to the torque wrench, do not set the torque wrench to the specified tightening torque. If an extension is attached to the torque wrench, the actual tightening torque will be greater than the setting value on the torque wrench.

Screw size M6 — M8 — M8 M5 M8 M6 — M8 M6 M8 M6 M6 M8 T Am Bm

Tightening torques N·m kgf·m ft·lb 5 0.5 3.7 3.7 0.37 2.73 16 1.6 11.8 5 0.5 3.7 16 1.6 11.8 2 0.2 1.5 16 1.6 11.8 13 1.3 9.6 18 1.8 13.3 5 0.5 3.7 5 0.5 3.7 5 0.5 3.7 5 0.5 3.7 2 0.2 1.5 16 1.6 11.8 Specified tightening torque (N·m) SST length (m) Torque wrench length (m)

General tightening torque This chart indicates the tightening torques for standard fasteners with a standard ISO thread pitch. Width across flats (A) 8 mm 10 mm 12 mm 14 mm 17 mm

Screw size (B) M5 M6 M8 M10 M12

General torque specifications N·m kgf·m ft·lb 5 0.5 3.7 8 0.8 5.9 18 1.8 13.3 36 3.6 26.6 43 4.3 31.7

Torque wrench setting value = T ÷ (A m + B m)  B m

2-18

1 2 3 4 5 6 7 8 9 A

SPEC

Specification

Cable and hose routing Starboard bow view

c d e f g h i

q p o n j

a Right handlebar switch lead b Throttle lever assy. lead c Left handlebar switch lead d Q.S.T.S. cable e Reverse sensor lead f Left operation button lead g Steering sensor lead h Buzzer lead i Right operation button lead (FX Cruiser SHO)

2-19

j Fuel tank breather hose (water separator to ventilation socket) k Fuel tank breather hose (fuel tank to water separator) l Remote control receiver antenna m Wiring harness n Speed sensor lead o Shift cable p Steering cable q Electric bilge pump lead

Cable and hose routing

Top view

f t h k

l i g u j

e b m

a q w p s

v r

o d

j Fuel tank breather hose (water separator to ventilation socket) k Fuel tank breather hose (fuel tank to water separator) l Remote control receiver antenna m Wiring harness n Speed sensor lead o Steering cable p Electric bilge pump lead q Electric bilge pump coupler r Battery breather hose

2-20

1 2 3 4 5 6 7 8 9 A

SPEC

Specification

f t h k

l i g u j

e b m

a q w p s

v r

o d

s Shift cable t Fuel sender lead u Fuel pump module lead v Positive battery lead w Negative battery lead

2-21

Cable and hose routing

Port view

g h f e b c

j n

a Right handlebar switch lead b Throttle lever assy. lead c Left handlebar switch lead d Q.S.T.S. cable e Reverse sensor lead f Steering sensor lead g Left operation button lead h Buzzer lead i Fuel tank breather hose (water separator to ventilation socket)

w v p x

j Fuel tank breather hose (fuel tank to water separator) k Remote control receiver antenna l Wiring harness m Speed sensor lead n Steering cable o Electric bilge pump lead p Battery breather hose q Positive battery lead r Negative battery lead s Shift cable

2-22

1 2 3 4 5 6 7 8 9 A

SPEC

Specification

g h f e b c

j n

t Multifunction meter lead u Bilge hose (hose joint to drain joint) v Bilge hose (electric bilge pump to hose joint) w Bilge hose joint to drain joint x Flushing hose

2-23

w v p x

MNT

Maintenance Maintenance interval chart ............................................... 3-1 Periodic service ................................................................. 3-2 Jet thrust nozzle angle check .................................................... 3-2 Jet thrust nozzle angle adjustment ............................................ 3-2 Steering master check ............................................................... 3-2 Shift cable and reverse gate check ........................................... 3-3 Shift cable adjustment ............................................................... 3-3 Q.S.T.S. mechanism check ....................................................... 3-3 Q.S.T.S. rod adjustment ............................................................ 3-4 Fuel tank check ......................................................................... 3-4 Water separator check .............................................................. 3-4 Spark plug check ....................................................................... 3-5 Engine oil level check ................................................................ 3-5 Engine oil replacement .............................................................. 3-6 Oil filter replacement ................................................................. 3-7 Trolling speed check ................................................................. 3-7 Nut and bolt check ..................................................................... 3-7 Valve clearance measurement .................................................. 3-7 Impeller check ........................................................................... 3-9 Water inlet strainer check .......................................................... 3-9 Battery check ............................................................................. 3-9 Bilge strainer check ................................................................. 3-10 Electric bilge pump strainer check ........................................... 3-10 Drain plug check ...................................................................... 3-11 Throttle valve lubrication (FX SHO, FX Cruiser SHO) ............. 3-11 Throttle valve lubrication (FX HO, FX Cruiser HO) ................. 3-11 Q.S.T.S. cable (handlebar end) lubrication ............................. 3-12 Q.S.T.S. cable (converter end) and Q.S.T.S. rod joint lubrication ................................................... 3-12 Nozzle pivot bolt and steering cable lubrication ...................... 3-12 Steering cable and steering cable joint lubrication .................. 3-12 Shift lever assy., shift cable, and shift cable joint lubrication ....................................................... 3-12 Intermediate housing lubrication ............................................. 3-13

1 2 3 4 5 6 7 8 9 A

MNT

Maintenance

Maintenance interval chart The following chart should be considered strictly as a guide to general maintenance intervals. Depending on the operating conditions, the maintenance intervals should be changed. Maintenance interval

Initial 10 hours

Item Spark plugs Lubrication points

Check, clean, replace Lubricate

Thereafter every 100 200 50 hours hours hours 6 12 12 24 months months months months



3-5

Check, clean Clean Clean

 

3-12 3-12 3-12 3-12 3-12 3-11 3-11 3-13 4-14 3-4 3-7 4-10 5-49 3-9 3-10



3-10

Check Check, adjust



3-9 3-2 3-2 3-2 3-3 3-4 3-3 3-3 3-11 3-9 6-20 5-19 3-7 4-6 3-5 3-6 3-7 3-7



Internal engine components Intermediate housing Fuel system Fuel tank Engine idling speed Throttle shaft Water inlet strainer Bilge strainer Electric bilge pump strainer Impeller Jet thrust nozzle angle Steering master Q.S.T.S. mechanism

Spray lubricant Lubricate Check Check, clean Check, adjust Check

Check, adjust Check, adjust

 

    

 



Shift cable and reverse gate Stern drain plugs Battery Rubber coupling Engine mount Nuts and bolts Air filter element Engine oil

Check, adjust



Check, replace Check, charge Check Check Check Check Replace

 

Oil filter Valve clearance

Replace Check, adjust

3-1

See page

   

    

Maintenance interval chart / Periodic service

Periodic service Jet thrust nozzle angle check 1. Set the Q.S.T.S. grip to the neutral position. 2. Turn the handlebar lock to lock.

3. Measure distances a and b. Adjust if out of specification.

c Difference of distances a and b: Maximum 5 mm (0.2 in)

Jet thrust nozzle angle adjustment 1. Set the Q.S.T.S. grip to the neutral position. 2. Remove the service lid.

Turn in Turn out

Distance a is increased. Distance b is increased.

6. Connect the steering cable joint b to the ball joint c, and then tighten the locknut a to the specified torque. Locknut a: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

3. Loosen the locknut a. 4. Disconnect the steering cable joint b from the ball joint c. 5. Turn the steering cable joint b in or out to adjust distances a and b. WARNING! The steering cable joint must be screwed in more than 8 mm (0.31 in) c.

7. Check the difference of distances a and b again. 8. Install the service lid.

Steering master check 1. Turn the handlebars to the right and left several times to make sure that operation is smooth and unrestricted throughout the whole range, and that the free play is not excessive.

3-2

1 2 3 4 5 6 7 8 9 A

MNT

Maintenance

Shift cable and reverse gate check 1. Set the shift lever to the reverse position. 2. Check that the reverse gate a contacts the stopper a.

5. Turn the shift cable joint b in or out until the specified distance b between the center of the shift cable joint and the center of the ball joint c is obtained. WARNING! The shift cable joint must be screwed in more than 8 mm (0.31 in) c.

b a

a 3. Adjust the shift cable joint if the reverse gate a does not contact the stopper a.

Shift cable adjustment 1. Set the shift lever to the reverse position. 2. Loosen the locknut a. 3. Disconnect the shift cable joint b from the ball joint c.

Turn in Turn out

Distance b is decreased. Distance b is increased.

Distance b: 7.0 mm (0.28 in)

c b 4. Position the reverse gate d so that it is contacting the stopper a.

6. Connect the shift cable joint b to the ball joint c, and then tighten the locknut a to the specified torque. Locknut a: 4 N·m (0.4 kgf·m, 3.0 ft·lb)

Q.S.T.S. mechanism check 1. Set the Q.S.T.S. grip to the neutral position.

2. Set the shift lever to the forward position.

3-3

3. Measure distances a and b. If the distances a and b are not equal, adjust the Q.S.T.S. rod.

Periodic service

c b

Q.S.T.S. rod adjustment 1. Set the Q.S.T.S. grip to the neutral position. 2. Set the shift lever to the reverse position. 3. Loosen the locknut a.

Distance a is increased. Distance b is increased.

6. Connect the Q.S.T.S. rod joint b to the ball joint c, and then tighten the locknut a to the specified torque. Locknut a: 4 N·m (0.4 kgf·m, 3.0 ft·lb)

4. Disconnect the Q.S.T.S. rod joint b from the ball joint c.

b c

Turn out Turn in

Fuel tank check 1. Check for water in the fuel tank. Extract the water and fuel if there is water in the fuel tank.

a a

5. Adjust the Q.S.T.S. rod joint b until the distances a and b are equal. WARNING! The Q.S.T.S. rod joint must be screwed in more than 8 mm (0.31 in) c.

TIP: Use a commercially available siphon pump a.

b a

Water separator check 1. Check the water separator a. Drain the water if water has accumulated.

2. Check the O-ring b of the drain plug c. Replace the O-ring if cracked or damaged.

3-4

1 2 3 4 5 6 7 8 9 A

MNT

Maintenance Specified spark plug (manufacturer): LFR6A (NGK) Spark plug gap b: 0.8–0.9 mm (0.031–0.035 in)

5. Install the spark plugs, and then tighten them to the specified torque.

Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb)

TIP: To drain water from the water separator a, loosen the drain plug b.

Spark plug check

TIP: Before installing a spark plug, clean the gasket surface and spark plug surface.

Engine oil level check

1. Remove the spark plugs.

TIP: Be careful not to get water or any other foreign substances in the spark plug holes. 2. Clean the electrodes a. 3. Check the electrodes a. Replace the spark plug if damaged or worn.

• When starting the engine to check the oil level on land, make sure to connect a garden hose to the watercraft for proper water supply. • Make sure that debris or water does not enter the oil filler hole. 1. Place the watercraft in a horizontal position.

TIP: If the engine was running, allow the engine oil to settle by waiting 5 minutes or more before checking the oil level.

4. Measure the spark plug gap b. Replace if out of specification.

3-5

2. Remove the oil level gauge a, wipe the gauge clean, and then insert the oil level gauge a into the oil level pipe completely. 3. Remove the oil level gauge a again to check that the oil level is between the minimum level mark a and the maximum level mark b on the gauge.

Periodic service A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO

A a b a

Recommended engine oil: YAMALUBE 4W or 4-stroke motor oil API: SE, SF, SG, SH, SJ, SL SAE: 10W-30, 10W-40, 20W-40, 20W-50 6. If the engine oil is above the maximum level mark b, extract oil using an oil changer to lower it to the correct level.

Engine oil replacement

a b a

A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO 4. If the engine oil is below the minimum level mark a, remove the oil filler cap b, and then add sufficient oil of the recommended type to raise it to the correct level. 5. Install the oil filler cap b.

Be careful when handling the engine oil to avoid burns. The engine oil is hot immediately after the engine is turned off.

â&#x20AC;˘ When starting the engine to check the oil level on land, make sure to connect a garden hose to the watercraft for proper water supply. â&#x20AC;˘ Make sure that debris or water does not enter the oil filler hole. 1. Place the watercraft in a horizontal position. 2. Start the engine and warm it up for 5 minutes or more at engine idle speed. 3. Stop the engine. 4. Remove the oil filler cap and oil level gauge.

5. Extract the oil using the oil changer a.

B b

3-6

1 2 3 4 5 6 7 8 9 A

MNT

Maintenance

6. Add the recommended engine oil up to the specified level through the oil filter hole. Recommended engine oil: YAMALUBE 4W or 4-stroke motor oil API: SE, SF, SG, SH, SJ, SL SAE: 10W-30, 10W-40, 20W-40, 20W-50 Engine oil quantity: Without oil filter replacement: 3.0 L (3.2 US qt, 2.6 Imp.qt) With oil filter replacement: 3.1 L (3.3 US qt, 2.7 Imp.qt) 7. Install the oil filler cap and oil level gauge. 8. Check the engine oil level. See “Engine oil level check” (3-5).

Oil filter replacement 1. Place a rag under the oil filter a.

Oil filter a: 18 N·m (1.8 kgf·m, 13.3 ft·lb)

TIP: Make sure to clean up any oil spills. 4. Check the engine oil level. See “Engine oil level check” (3-5).

Trolling speed check 1. Place the watercraft in the water. 2. Start the engine and warm it up for 5 minutes or more. 3. Check the trolling speed using the tachometer of the multifunction meter or using the YDIS. Check the ETV and APS if out of specification. Trolling speed: FX SHO, FX Cruiser SHO: 1150–1350 r/min FX HO, FX Cruiser HO: 1200–1400 r/min

2. Remove the oil filter a.

Nut and bolt check 1. Check the engine, deck, and hull for loose nuts and bolts. Tighten if loose. See “Specified tightening torque” (2-13).

Valve clearance measurement Oil filter wrench b: YB-06830 Oil filter wrench b: 90890-06830 3. Install the oil filter, and then tighten it to the specified torque.

Measure the valve clearance when the engine is cold. 1. Remove the ignition coils, spark plugs, and cylinder head cover. 2. Install the special service tools a, b, and c into spark plug hole #1.

b a

c a b

Oil filter wrench b: YB-06830 Oil filter wrench b: 90890-06830

3-7

Periodic service Gauge stand a: 90890-06725 Dial gauge stand set b: YB-06585 Dial indicator gauge c: YU-03097 Dial gauge needle b: 90890-06584 Dial gauge set c: 90890-01252

3. Position piston #1 at TDC by turning the exhaust camshaft sprocket clockwise.

Valve clearance (cold) Intake c: 0.14–0.23 mm (0.0055–0.0091 in) Exhaust d: 0.28–0.37 mm (0.0110–0.0146 in)

IN EX

#1 ✔ ✔

#2 — ✔

#3 ✔ —

#4 — —

✔: Specified cylinder —: Not applicable

b a

5. Install the special service tools a, b, and c into spark plug hole #4. 6. Position piston #4 at TDC by turning the exhaust camshaft sprocket 180° clockwise.

#4 7. Measure the intake and exhaust valve clearances of the specified cylinders. 4

Camshaft wrench d: 90890-06724

TIP: Check that the punch marks a on the camshafts are aligned with the marks b on the camshaft caps. 4. Measure the intake and exhaust valve clearances of the specified cylinders.

IN EX

#1 — —

#2 ✔ —

#3 — ✔

#4 ✔ ✔

✔: Specified cylinder —: Not applicable 8. Adjust the valve clearance if out of specification. See “Valve clearance adjustment” (5-75). 9. Install the cylinder head cover, spark plugs, and ignition coils. See “Cylinder head cover” (5-64).

3-8

1 2 3 4 5 6 7 8 9 A

MNT

Maintenance

Impeller check

Make sure to remove the battery before checking the jet pump unit.

1. Remove the jet pump unit. See “Jet pump unit removal” (6-4). 2. Check the damaged.

impeller

Replace

3. Measure the impeller-to-housing clearance a. Measure the impeller housing inside diameter if the impeller-tohousing clearance a is out of specification. See “Impeller housing check” (6-12).

Impeller-to-housing clearance a: 0.35–0.45 mm (0.014–0.018 in) Limit: 0.6 mm (0.024 in) 4. Install the jet pump unit. See “Jet pump unit installation” (6-5).

Water inlet strainer check 1. Remove the water inlet cover a and water inlet strainer b. See “Impeller housing and impeller duct assy.” (6-9). 2. Check the water inlet strainer b. Clean if contaminated.

3-9

3. Install the water inlet strainer b and water inlet cover a. See “Impeller housing and impeller duct assy.” (6-9).

Battery check

Battery electrolyte is poisonous and dangerous, causing severe burns, etc. Electrolyte contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidotes External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc., well away. If using or charging the battery in an enclosed space, make sure that it is well ventilated. Always shield your eyes when working near batteries. KEEP OUT OF THE REACH OF CHILDREN.

Be careful not to place the battery on its side. Make sure to remove the battery from the battery compartment when adding battery electrolyte or charging the battery. When checking the battery, make sure the breather hose is connected to the battery and not obstructed.

Periodic service 1. Remove the battery. NOTICE: When removing the battery, disconnect the negative battery lead first. 2. Check the battery electrolyte level. If the level is at or below the minimum level mark a, add distilled water until the level is between the maximum level mark b and the minimum level mark a.

b a

TIP: Apply water resistant grease to the terminals to minimize corrosion.

Bilge strainer check 1. Remove the bilge strainer case a. 2. Check the bilge contaminated.

strainer.

Clean

a a a

3. Check the specific gravity of the electrolyte. Charge the battery if below specification. Specific gravity at 20 Â°C (68 Â°F): 1.265 4. Install the battery, and then install the bands. 5. Connect the battery breather hose a, and then fasten it using the clamp b. NOTICE: Make sure that the battery breather hose is connected properly and is not obstructed. 6. Connect the positive battery lead c, and then connect the negative battery lead d. NOTICE: Connect the positive battery lead to the battery terminal first.

TIP: Remove the bilge strainer case a by pushing the hooks a on the bilge strainer inward. 3. Install the bilge strainer case a.

Electric bilge pump strainer check 1. Disconnect the negative battery lead a. 2. Remove the band b and electric bilge pump c. 3. Check the bilge strainer d. Clean if contaminated.

c b

a c d

4. Install the electric bilge pump c and band b.

a 5. Connect the negative battery lead a.

3-10

1 2 3 4 5 6 7 8 9 A

MNT

Maintenance

Drain plug check 1. Check the O-ring a of each drain plug b.

Recommended lubricant: Rust inhibitor

Throttle valve lubrication (FX SHO, FX Cruiser SHO)

When lubricating the engine internal components on land, make sure to supply sufficient water and water pressure to the cooling water passage. Otherwise, the engine could overheat.

3. Connect the blowby hose b, and then fasten it using the clamp a.

Throttle valve lubrication (FX HO, FX Cruiser HO) 1. Loosen the air intake pipe clamp a, and then disconnect the air intake pipe b.

1. Remove the clamp a, and then disconnect the blowby hose b.

a 2. Spray a rust inhibitor into the throttle valve opening a.

b a

2. Start the engine, and then spray a rust inhibitor into the air intake pipe hole a for about 5 seconds while the engine is running.

TIP: While spraying the rust inhibitor into the air intake pipe, the engine speed will drop.

Recommended lubricant: Rust inhibitor 3. Connect the air intake pipe b, and then tighten the air intake pipe clamp a. Air intake pipe clamp a: 3.5 NÂˇm (0.35 kgfÂˇm, 2.58 ftÂˇlb)

3-11

Periodic service

Q.S.T.S. cable (handlebar end) lubrication 1. Remove the left handlebar grip and Q.S.T.S. grip. 2. Lubricate the Q.S.T.S. cable (handlebar end).

Recommended lubricant: Yamaha grease A

TIP: Disconnect the joint and apply a small amount of grease.

Nozzle pivot bolt and steering cable lubrication 1. Lubricate the nozzle pivot bolt and steering cable.

Recommended lubricant: Rust inhibitor

Recommended lubricant: Yamaha grease A

Steering cable and steering cable joint lubrication Recommended lubricant: Yamaha grease A

1. Lubricate the steering cable and steering cable joint.

Q.S.T.S. cable (converter end) and Q.S.T.S. rod joint lubrication 1. Lubricate the Q.S.T.S. cable (converter end) and Q.S.T.S. rod joint.

Recommended lubricant: Yamaha grease A

Shift lever assy., shift cable, and shift cable joint lubrication 1. Remove the side cover. See â&#x20AC;&#x153;Side cover removalâ&#x20AC;? (8-13). 2. Lubricate the shift lever assy., shift cable, and shift cable joint.

3-12

1 2 3 4 5 6 7 8 9 A

MNT

Maintenance

Recommended lubricant: Yamaha grease A

TIP: Disconnect the joint and apply a small amount of grease. 3. Install the side cover. See â&#x20AC;&#x153;Side cover installationâ&#x20AC;? (8-13).

Intermediate housing lubrication 1. Lubricate the intermediate through the grease nipple a.

housing

Recommended lubricant: Yamaha grease A

3-13

FUEL

Fuel system Air filter case and fuel hose (FX SHO, FX Cruiser SHO) ............................................... 4-1 Air filter case and fuel hose (FX HO, FX Cruiser HO) .................................................... 4-3 Fuel hose disconnection ............................................................ 4-5 Fuel pressure measurement ..................................................... 4-5 Fuel hose disassembly .............................................................. 4-6 Air filter element check .............................................................. 4-6 Fuel hose assembly .................................................................. 4-6

Fuel injector (FX SHO, FX Cruiser SHO) ......................... 4-8 ETV and fuel injector (FX HO, FX Cruiser HO) ................ 4-9 ETV check (FX HO, FX Cruiser HO) ....................................... 4-10 Fuel injector check .................................................................. 4-10 Fuel rail and injector installation .............................................. 4-10

Fuel tank and fuel pump module assy. ......................... 4-12 Fuel pump module removal ..................................................... 4-14 Fuel sender removal ................................................................ 4-14 Fuel pump module check ........................................................ 4-14 Check valve check .................................................................. 4-14 Fuel filler cap check ................................................................. 4-15 Fuel sender installation ........................................................... 4-15 Fuel pump module installation ................................................. 4-15 Fuel tank installation ................................................................ 4-16

1 2 3 4 5 6 7 8 9 A

FUEL

Fuel system

Air filter case and fuel hose (FX SHO, FX Cruiser SHO) 20

13 N·m (1.3 kgf·m, 9.6 ft·lb)

16 19 17 18 16 17 12

12 12

11 13 14

18 16 17 19 18

12 13 10

17 N·m (1.7 kgf·m, 12.5 ft·lb)

7 9

6 12

15 10

8 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

5 3

22 4

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

4-1

Part name Fuel hose assy. Clamp Quick connector Corrugated tube Fuel hose Clamp Clamp Air intake pipe Connection Bolt Air filter case assy. Hook Screw Air filter element Drain tube Collar

Q’ty 1 4 2 1 1 2 1 1 1 4 1 8 3 1 1 4

Remarks 

M8  35 mm

M6  15 mm

Air filter case and fuel hose (FX SHO, FX Cruiser SHO)

13 N·m (1.3 kgf·m, 9.6 ft·lb)

16 19 17 18 16 17 12

12 12

11 13 14

18 16 17 19 18

12 13 10

17 N·m (1.7 kgf·m, 12.5 ft·lb)

7 9

6 12

15 10

8 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

5 3

22 4

No. 17 18 19 20 21 22

Part name Grommet Nut Washer Bracket Plastic tie Holder

Q’ty 4 4 4 1 1 1

Remarks

4-2

1 2 3 4 5 6 7 8 9 A

FUEL

Fuel system

Air filter case and fuel hose (FX HO, FX Cruiser HO) 21

20 13 N·m (1.3 kgf·m, 9.6 ft·lb)

16 17 12

16 19 17 18 12 1617

12 12

10 11 13 14

19 18 19 18

12 13

17 N·m (1.7 kgf·m, 12.5 ft·lb)

9 1

10 7 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

8 3

6 4

3 5

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

4-3

Part name Plastic tie Fuel hose assy. Clamp Quick connector Corrugated tube Fuel hose Clamp Air intake pipe Connection Bolt Air filter case assy. Hook Screw Air filter element Drain tube Collar

Q’ty 1 1 4 2 1 1 2 1 1 4 1 8 3 1 1 4

Remarks



M8  35 mm

M6  15 mm

Air filter case and fuel hose (FX HO, FX Cruiser HO)

20 13 N·m (1.3 kgf·m, 9.6 ft·lb)

16 17 12

16 19 17 18 12 1617

12 12

10 11 13 14

19 18 19 18

12 13

17 N·m (1.7 kgf·m, 12.5 ft·lb)

9 1

10 7 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

8 3

6 4

3 5

No. 17 18 19 20 21

Part name Grommet Nut Washer Bracket Plastic tie

Q’ty 4 4 4 1 1

Remarks

4-4

1 2 3 4 5 6 7 8 9 A

FUEL

Fuel system

Fuel hose disconnection b Before checking the fuel system, remove the battery, and then remove the fuel filler cap to reduce any pressure inside the fuel tank. 1. Spread apart the ends of the retainer a, and then pull the retainer up.

Fuel pressure measurement 1. Disconnect the quick connector from the fuel rail. 2. Install the special service tools a and b.

2. Disconnect the quick connector a. WARNING! Make sure to disconnect the quick connector slowly. Otherwise, pressurized fuel could spray out.

a B

TIP: Make sure to clean up any fuel spills. 3. Cover the quick connector, fuel rail, and fuel pipe using plastic bags b to protect them from dirt.

A U.S.A. and Canada B Worldwide Fuel pressure gauge adapter a: YB-06946/90890-06946 Fuel pressure gauge b: YU-03153M/90890-06753 3. Start the engine and warm it up for 5 minutes or more at engine idle speed. 4. Measure the fuel pressure. Replace the fuel pump module assy. if out of specification.

4-5

Air filter case and fuel hose (FX HO, FX Cruiser HO) Fuel pressure: 345–370 kPa (3.45–3.70 kgf/cm2, 49.1–52.6 psi)

1. Install new clamps a and the quick connector b onto the fuel hose c.

Fuel hose disassembly 1. Remove the clamps a and quick connector b. NOTICE: When cutting each clamp, position the tool.

a b

Air filter element check

Do not start the engine with the air filter element removed. Otherwise, the engine could be damaged. 1. Remove the air filter case cover and air filter element.

TIP: Make sure to face the locking slider a on each quick connector in the same direction. 2. Crimp the clamps a.

2. Check the air filter element. Replace if damaged or dirty.

Fuel hose assembly b Do not reuse a clamp, always replace it with a new one. Otherwise, fuel could leak.

c Distance b: 17 mm (0.67 in) Distance c: 34.5 mm (1.36 in) Distance d: 1 mm (0.04 in)

4-6

1 2 3 4 5 6 7 8 9 A

FUEL

Fuel system

TIP: • Make sure to align the projection e on the quick connector with the crimped section of the clamp. • Position the crimped sections of the clamps 180° away from each other.

4-7

Air filter case and fuel hose (FX HO, FX Cruiser HO) / Fuel injector (FX SHO, FX Cruiser SHO)

Fuel injector (FX SHO, FX Cruiser SHO)

5 3

2 5

1 1 1

13 N·m (1.3 kgf·m, 9.6 ft·lb)

No. 1 2 3 4 5

Part name Bolt Fuel rail Fuel injector Seal O-ring

Q’ty 3 1 4 4 4

Remarks M8  17 mm

 

4-8

1 2 3 4 5 6 7 8 9 A

FUEL

Fuel system

ETV and fuel injector (FX HO, FX Cruiser HO) 13 11

10 13

9 9

13 N·m (1.3 kgf·m, 9.6 ft·lb)

12 13 N·m (1.3 kgf·m, 9.6 ft·lb)

8 5

24 N·m (2.4 kgf·m, 17.7 ft·lb)

2 3

5 3

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

4-9

Part name Plastic tie Nut Washer ETV Bolt Joint Holder Ribbon Bolt Fuel rail Fuel injector Seal O-ring

Q’ty 2 4 4 1 4 1 1 1 3 1 4 4 4

Remarks

M8  20 mm

M8  17 mm

 

3 2

ETV and fuel injector (FX HO, FX Cruiser HO)

ETV check (FX HO, FX Cruiser HO)

• Do not disassemble the ETV. • Do not loosen the throttle stop screw nut a or turn the throttle stop screw b. • Do not loosen or remove the throttle valve shaft screws c.

b c

2. While turning the fuel injectors b slowly to the left and right, install them to the fuel rail c. NOTICE: Make sure to apply a thin coat of engine oil to the Orings before installing the fuel injectors to the fuel rail. Otherwise, the O-rings could twist and break, causing fuel leakage.

1. Turn the throttle valve manually and check that it moves smoothly.

Fuel injector check 1. Check the fuel injector filter a. Clean using kerosene or gasoline if clogged or contaminated.

b c

a 3. Install new seals d and the fuel rail c, and then tighten the fuel rail bolts e to the specified torque. NOTICE: Do not reuse a seal, always replace it with a new one.

A d 2. Measure the fuel injector resistance. See “Fuel injector check” (7-29).

Fuel rail and injector installation

1. Install new O-rings a onto the fuel injectors, and then apply a thin coat of engine oil to the O-rings.

4-10

1 2 3 4 5 6 7 8 9 A

FUEL B

Fuel system

A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO Fuel rail bolt e: 13 N·m (1.3 kgf·m, 9.6 ft·lb) 4. Install the holders f, and then connect the fuel injector couplers a and ignition coil couplers b.

f B

f A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO

4-11

ETV and fuel injector (FX HO, FX Cruiser HO) / Fuel tank and fuel pump module assy.

Fuel tank and fuel pump module assy. a 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) b 7 N·m (0.7 kgf·m, 5.2 ft·lb) 18 19 2

6 12

16 16

13 11

17 1

7 17

6 N·m (0.6 kgf·m, 4.4 ft·lb)

24 27

4 N·m (0.4 kgf·m, 3.0 ft·lb)

25 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Plastic tie Breather hose Breather hose Check valve Fuel filler cap Packing Clamp Fuel filler hose Nut Fuel filler neck Packing Tapping screw Rivet Chain ball Strap Rivet

28 Q’ty 3 1 1 1 1 1 2 1 1 1 1 1 1 1 2 4

Remarks



 M4  9 mm

4-12

1 2 3 4 5 6 7 8 9 A

FUEL

Fuel system

a 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) b 7 N·m (0.7 kgf·m, 5.2 ft·lb) 18 19 2

6 12

16 16

13 11

17 1

7 17

6 N·m (0.6 kgf·m, 4.4 ft·lb)

24 27

4 N·m (0.4 kgf·m, 3.0 ft·lb)

25 No. 17 18 19 20 21 22 23 24 25 26 27 28

4-13

Part name Hook Nut Retainer Fuel pump module assy. Packing Stopper Fuel sender Fuel tank Pad Pad Pad Pad

28 Q’ty 4 9 1 1 1 1 1 1 2 4 2 1

Remarks



   

Fuel tank and fuel pump module assy.

Fuel pump module removal

b e d

Before checking the fuel system, remove the battery, and then remove the fuel filler cap to reduce any pressure inside the fuel tank. 1. Remove the fuel pump module assy. a. NOTICE: When removing the fuel pump module assy. a, make sure that the rubber caps a do not come off.

Fuel pump module check

Do not disassemble the fuel pump module. 1. Check the fuel pump filter a. Clean using kerosene or gasoline if clogged or contaminated.

TIP: Remove the fuel pump module assy. a at an angle so that the float b does not catch on the fuel tank.

Fuel sender removal 1. Disconnect the fuel sender coupler a. 2. Squeeze the hooks b on the stopper a, and then slide the stopper in direction c to remove it.

Check valve check 1. Blow into the end a of the check valve, and check that airflow from the end b is unrestricted. Replace if the air flow is restricted.

a a

2. Blow into the end b of the check valve, and check that airflow from the end a is restricted. Replace if the air flow is unrestricted.

c a b

A a

B b

3. Push the tabs d on the fuel sender b, and then slide the fuel sender in direction e to remove it.

4-14

1 2 3 4 5 6 7 8 9 A

FUEL

Fuel system

A Upright B Inverted

b b

Fuel filler cap check 1. Install the fuel filler cap a onto the fuel filler neck b, and then hold the fuel filler neck b. 2. Turn the fuel filler cap a clockwise a and check that it clicks when tightened completely. Replace if it does not click.

c d

TIP: Make sure that the hooks d on the stopper b are hooked securely onto the fuel pump module.

a a

Fuel pump module installation 1. Install a new packing and the fuel pump module assy. a. NOTICE: When installing the fuel pump module assy. a, make sure that the rubber caps a do not come off.

Fuel sender installation 1. Install the fuel sender a.

a a

b b

TIP: TIP: Make sure that the tabs a on the fuel sender a are seated securely into the slots b in the fuel pump module. 2. Install the stopper b, and then connect the fuel sender coupler c.

Make sure to insert the float b into the fuel tank. 2. Install the retainer b, and then tighten the fuel pump module nuts c to the specified torques in 2 stages and in the order a, b, and so on.

g i h d c

4-15

Fuel tank and fuel pump module assy. Fuel filler neck nut f: 6 N·m (0.6 kgf·m, 4.4 ft·lb)

Fuel pump module nut c: 1st: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 2nd: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

TIP:

Fuel tank installation 1. Install the fuel tank a, and then fasten the fuel tank using the straps b.

Align the protrusion c on the fuel filler neck d with the holes d in the packing c and deck.

b b

a b

4. Install the fuel filler hose g, and then tighten the fuel filler hose clamps h to the specified torque. 5. Check that the distance e is within specification.

b b

h a

c h

f g

h g

TIP: • Install the straps b so that the rubber band portions a of the straps are positioned on top. • Make sure that the metal loops b on the end of the straps b are hooked securely onto the holders on the hull. 2. Install a new packing c, fuel filler neck d, and the fuel filler cap e. 3. Tighten the fuel filler neck nut f to the specified torque.

c d

Distance e: 25–35 mm (1.0–1.4 in)

TIP: Align the arrow mark f on the fuel filler hose g with the protrusion c on the fuel filler neck. 6. Connect the fuel sender coupler g and fuel pump module coupler h.

Fuel filler hose clamp h: 4 N·m (0.4 kgf·m, 3.0 ft·lb)

7. Install the fuel tank breather hoses i and check valve j.

f 8. Fasten the fuel tank breather hoses i using the plastic ties k.

4-16

1 2 3 4 5 6 7 8 9 A

FUEL

Fuel system

j k

g k

TIP: Point the arrow mark k toward the fuel tank.

4-17

Fuel tank and fuel pump module assy.

— MEMO —

4-18

1 2 3 4 5 6 7 8 9 A

POWR

Power unit Engine unit (check and adjustment) ................................ 5-1 Compression pressure check .................................................... 5-1

Engine unit (FX SHO, FX Cruiser SHO) ........................... 5-2 Engine unit (FX HO, FX Cruiser HO) ................................ 5-3 Exhaust manifold (FX SHO, FX Cruiser SHO) ................. 5-4 Exhaust manifold (FX HO, FX Cruiser HO) ..................... 5-6 Engine unit and coupling cover (FX SHO, FX Cruiser SHO) ............................................... 5-8 Engine unit and coupling cover (FX HO, FX Cruiser HO) .................................................... 5-9 Engine mount .................................................................. 5-10 Engine unit removal (FX SHO, FX Cruiser SHO) .................... 5-11 Engine unit removal (FX HO, FX Cruiser HO) ......................... 5-15 Engine mount and damper check ............................................ 5-19 Engine unit installation (FX SHO, FX Cruiser SHO) ................ 5-19 Engine unit installation (FX HO, FX Cruiser HO) .................... 5-25

Muffler .............................................................................. 5-31 Exhaust pipe disassembly ....................................................... 5-32 Exhaust pipe assembly ........................................................... 5-32

Wiring harness assy. (FX SHO, FX Cruiser SHO) ......... 5-33 Wiring harness assy. (FX HO, FX Cruiser HO) ............. 5-34 Electrical box ................................................................... 5-35 Starter motor and wiring harness assy. removal (FX SHO, FX Cruiser SHO) ..................................................... 5-37 Starter motor and wiring harness assy. removal (FX HO, FX Cruiser HO) ......................................................... 5-38 Thermostat check .................................................................... 5-39 Starter motor and wiring harness assy. installation (FX SHO, FX Cruiser SHO) ..................................................... 5-39 Starter motor and wiring harness assy. installation (FX HO, FX Cruiser HO) ......................................................... 5-40

Air cooler and supercharger assy. ................................ 5-42 Intake assy. (FX SHO, FX Cruiser SHO) ........................ 5-45 Intake assy. (FX HO, FX Cruiser HO) ............................. 5-47 ETV and intake manifold (FX SHO, FX Cruiser SHO) ............................................. 5-48 Air cooler check (FX SHO, FX Cruiser SHO) .......................... 5-49 Supercharger check (FX SHO, FX Cruiser SHO) ................... 5-49 ETV check (FX SHO, FX Cruiser SHO) .................................. 5-49 Intake assy. installation (FX SHO, FX Cruiser SHO) .............. 5-49 Intake manifold installation (FX HO, FX Cruiser HO) .............. 5-50 Oil level pipe installation (FX SHO, FX Cruiser SHO) ............. 5-51 Supercharger installation (FX SHO, FX Cruiser SHO) ............ 5-52 Air cooler, air cooler intake hose, and boost pipe installation (FX SHO, FX Cruiser SHO) ..................................................... 5-52

Oil cooler and oil pump assy. (FX SHO, FX Cruiser SHO) ............................................. 5-55 Idle gear assy. and drive gear assy. (FX SHO, FX Cruiser SHO) ............................................. 5-57 Oil cooler, oil pump assy. and drive gear (FX HO, FX Cruiser HO) .................................................. 5-58 Oil pump assy., idle gear assy., and drive gear assy. removal (FX SHO, FX Cruiser SHO) ..................................................... 5-60 Oil pump assy. and oil pump drive gear removal (FX HO, FX Cruiser HO) ......................................................... 5-60 Oil cooler assy. check ............................................................. 5-60 Oil pump assy. check .............................................................. 5-61 Idle gear check (FX SHO, FX Cruiser SHO) ........................... 5-61 Drive gear assy. check (FX SHO, FX Cruiser SHO) ............... 5-61 Drive gear assy., idle gear assy., and oil pump assy. installation (FX SHO, FX Cruiser SHO) ..................................................... 5-61 Oil pump drive gear and oil pump assy. installation (FX HO, FX Cruiser HO) ......................................................... 5-62

Cylinder head cover ........................................................ 5-64 Camshaft (FX SHO, FX Cruiser SHO) ............................ 5-65 Camshaft (FX HO, FX Cruiser HO) ................................. 5-67 Camshaft removal ................................................................... 5-69 Camshaft sprocket removal ..................................................... 5-70

1 2 3 4 5 6 7 8 9 A

POWR Camshaft check ....................................................................... 5-70 Camshaft journal oil clearance check ...................................... 5-71 Timing chain tensioner check .................................................. 5-72 Camshaft sprocket installation ................................................ 5-72 Camshaft installation ............................................................... 5-73 Valve clearance adjustment .................................................... 5-75 Valve pad selection table ........................................................ 5-78

Cylinder head .................................................................. 5-79 Valve and valve spring ................................................... 5-80 Cylinder head disassembly ..................................................... 5-81 Cylinder head check ................................................................ 5-81 Valve spring check .................................................................. 5-81 Valve check ............................................................................. 5-82 Valve guide check ................................................................... 5-82 Valve guide removal ................................................................ 5-83 Valve guide installation ............................................................ 5-83 Valve seat check ..................................................................... 5-84 Valve seat refacing .................................................................. 5-84 Cylinder head assembly .......................................................... 5-86 Cylinder head installation ........................................................ 5-88

Generator cover assy. and flywheel magneto .............. 5-89 Generator cover .............................................................. 5-91 Drive coupling removal ............................................................ 5-92 Flywheel magneto removal ..................................................... 5-92 Generator cover assy. disassembly ........................................ 5-94 Starter clutch operation check ................................................. 5-94 Generator cover assy. assembly ............................................. 5-95 Flywheel magneto installation ................................................. 5-96 Drive coupling installation ........................................................ 5-99

Cylinder block and electrical part (FX SHO, FX Cruiser SHO) ........................................... 5-100 Cylinder block and electrical part (FX HO, FX Cruiser HO) ................................................ 5-102 Oil separator tank and oil pan ...................................... 5-104 Anode check .......................................................................... 5-106 Oil pan assembly ................................................................... 5-106 Oil level pipe installation (FX HO, FX Cruiser HO) ................ 5-106 Oil separator tank cover installation ...................................... 5-107

Crankcase, connecting rod, and piston ...................... 5-108

Crankcase disassembly ........................................................ 5-110 Connecting rod and piston removal ....................................... 5-110 Crankcase check ................................................................... 5-111 Cylinder block check ............................................................. 5-111 Piston check .......................................................................... 5-111 Piston clearance check ......................................................... 5-111 Piston ring check ................................................................... 5-111 Piston pin check .................................................................... 5-112 Connecting rod check ............................................................ 5-113 Crankshaft check ................................................................... 5-113 Crankshaft pin oil clearance check ........................................ 5-113 Connecting rod big end side clearance check ....................... 5-114 Connecting rod bearing selection .......................................... 5-115 Crankshaft journal oil clearance check .................................. 5-116 Crankshaft bearing selection ................................................. 5-117 Connecting rod and piston installation .................................. 5-118 Crankcase assembly ............................................................. 5-120

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Engine unit (check and adjustment) Compression pressure check Make sure that the battery voltage is more than 12 V.

When starting the engine to measure the compression pressure on land, make sure to connect a garden hose to the watercraft for proper water supply. 1. Place the watercraft in a horizontal position. 2. Start the engine and warm it up for 5 minutes or more at engine idle speed. 3. Stop the engine. 4. Remove the ignition coils and spark plugs. 5. Disconnect the fuel injector couplers.

TIP:

8. Measure the compression pressure for all cylinders according to steps 5 and 6. Compression pressure (reference data): FX SHO, FX Cruiser SHO: 610 kPa (6.1 kgf/cm2, 86.8 psi) FX HO, FX Cruiser HO: 780 kPa (7.8 kgf/cm2, 113.1 psi) 9. If the compression pressure is below specification, squirt a few drops of engine oil into the cylinder and measure again. Compression pressure (with engine oil added into the cylinder) Reading Check Higher than without Piston ring and engine oil piston Same as without Valve clearance, engine oil valve, valve seat, cylinder head, and cylinder head gasket 10. Install the spark plugs, and then tighten them to the specified torque. Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb)

Be careful not to get water or any other foreign substances in the spark plug holes.

11. Install the ignition coils.

6. Install the special service tools a and b.

12. Connect the fuel injector couplers.

a b

Compression gauge a: YU-33223/90890-03160 Compression gauge extension b: 90890-06563 7. Crank the engine until the reading on the compression gauge stabilizes.

5-1

Engine unit (check and adjustment) / Engine unit (FX SHO, FX Cruiser SHO)

Engine unit (FX SHO, FX Cruiser SHO) 5 N·m (0.5 kgf·m, 3.7 ft·lb)

1 2

3 8

9 5 4

No. 1 2 3 4 5 6 7 8 9 10

Part name Screw Grommet Engine cover Clamp Breather hose Antenna holder Clamp Clamp Clamp Clamp

Q’ty 2 2 1 1 1 3 1 1 1 1

Remarks M6  12 mm

5-2

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Engine unit (FX HO, FX Cruiser HO) 1 2

5 N·m (0.5 kgf·m, 3.7 ft·lb)

1 2

3 8

7 5 4

No. 1 2 3 4 5 6 7 8

5-3

Part name Screw Grommet Engine cover Clamp Breather hose Antenna holder Clamp Clamp

Q’ty 2 2 1 1 1 3 1 1

Remarks M6  12 mm

Engine unit (FX HO, FX Cruiser HO) / Exhaust manifold (FX SHO, FX Cruiser SHO)

Exhaust manifold (FX SHO, FX Cruiser SHO) a 23 N·m (2.3 kgf·m, 17.0 ft·lb) b 42 N·m (4.2 kgf·m, 31.0 ft·lb)

13 N·m (1.3 kgf·m, 9.6 ft·lb)

26 N·m (2.6 kgf·m, 19.2 ft·lb)

5 9

10 N·m (1.0 kgf·m, 7.4 ft·lb)

12 6

4 10 22

12 6

13 2

14 15

11 10

13 20 21 28

13 N·m (1.3 kgf·m, 9.6 ft·lb) 2.5 N·m (0.25 kgf·m, 1.84 ft·lb)

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) b 42 N·m (4.2 kgf·m, 31.0 ft·lb) 19

24 27

1 18 18 N·m (1.8 kgf·m, 13.3 ft·lb)

a 20 N·m (2.0 kgf·m, 14.8 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb) c 35 N·m (3.5 kgf·m, 25.8 ft·lb) No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Oil filter Plastic tie Plastic tie Clamp Cooling water hose Clamp Cooling water hose Clamp Bolt Collar Grommet Bolt Bolt Rectifier regulator Gasket Cover

a 20 N·m (2.0 kgf·m, 14.8 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb) c 35 N·m (3.5 kgf·m, 25.8 ft·lb) Q’ty 1 1 1 2 1 2 1 1 2 2 2 4 2 1 1 1

Remarks

M8  35 mm

M6  35 mm M6  25 mm 

5-4

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) b 42 N·m (4.2 kgf·m, 31.0 ft·lb)

13 N·m (1.3 kgf·m, 9.6 ft·lb)

26 N·m (2.6 kgf·m, 19.2 ft·lb)

5 9

10 N·m (1.0 kgf·m, 7.4 ft·lb)

12 6

4 10 22

12 6

13 2

14 15

11 10

13 20 21 28

13 N·m (1.3 kgf·m, 9.6 ft·lb) 2.5 N·m (0.25 kgf·m, 1.84 ft·lb)

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) b 42 N·m (4.2 kgf·m, 31.0 ft·lb) 19

24 27

1 18 18 N·m (1.8 kgf·m, 13.3 ft·lb)

a 20 N·m (2.0 kgf·m, 14.8 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb) c 35 N·m (3.5 kgf·m, 25.8 ft·lb) No. 17 18 19 20 21 22 23 24 25 26 27 28

5-5

Part name Clamp Clamp Bolt Bolt Stay Bolt Stay Clamp Bolt Bolt Gasket Dowel pin

a 20 N·m (2.0 kgf·m, 14.8 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb) c 35 N·m (3.5 kgf·m, 25.8 ft·lb) Q’ty 1 1 1 1 1 4 4 1 3 8 1 2

Remarks

M10  50 mm M8  47 mm M6  12 mm

M8  120 mm M8  70 mm 

Exhaust manifold (FX SHO, FX Cruiser SHO) / Exhaust manifold (FX HO, FX Cruiser HO)

Exhaust manifold (FX HO, FX Cruiser HO) 13 N·m (1.3 kgf·m, 9.6 ft·lb)

26 N·m (2.6 kgf·m, 19.2 ft·lb)

4 3

11 5

15 9

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) b 42 N·m (4.2 kgf·m, 31.0 ft·lb) 10

11 5

12 2

13 14

10 9

12 19 20 25

13 N·m (1.3 kgf·m, 9.6 ft·lb) 2.5 N·m (0.25 kgf·m, 1.84 ft·lb)

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) b 42 N·m (4.2 kgf·m, 31.0 ft·lb) 18

21 24

1 17 18 N·m (1.8 kgf·m, 13.3 ft·lb)

a 20 N·m (2.0 kgf·m, 14.8 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb) c 35 N·m (3.5 kgf·m, 25.8 ft·lb) No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Oil filter Plastic tie Clamp Cooling water hose Clamp Cooling water hose Clamp Bolt Collar Grommet Bolt Bolt Rectifier regulator Gasket Cover Clamp

a 20 N·m (2.0 kgf·m, 14.8 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb) c 35 N·m (3.5 kgf·m, 25.8 ft·lb) Q’ty 1 1 2 1 2 1 1 2 2 2 4 2 1 1 1 1

Remarks

M8  35 mm

M6  35 mm M6  25 mm 

5-6

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

13 N·m (1.3 kgf·m, 9.6 ft·lb)

26 N·m (2.6 kgf·m, 19.2 ft·lb)

4 3

11 5

15 9

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) b 42 N·m (4.2 kgf·m, 31.0 ft·lb) 10

11 5

12 2

13 14

10 9

12 19 20 25

13 N·m (1.3 kgf·m, 9.6 ft·lb) 2.5 N·m (0.25 kgf·m, 1.84 ft·lb)

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) b 42 N·m (4.2 kgf·m, 31.0 ft·lb) 18

21 24

1 17 18 N·m (1.8 kgf·m, 13.3 ft·lb)

a 20 N·m (2.0 kgf·m, 14.8 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb) c 35 N·m (3.5 kgf·m, 25.8 ft·lb) No. 17 18 19 20 21 22 23 24 25

5-7

Part name Clamp Bolt Bolt Stay Clamp Bolt Bolt Gasket Dowel pin

a 20 N·m (2.0 kgf·m, 14.8 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb) c 35 N·m (3.5 kgf·m, 25.8 ft·lb) Q’ty 1 1 1 1 1 3 8 1 2

Remarks M10  50 mm M8  47 mm

M8  120 mm M8  70 mm 

Exhaust manifold (FX HO, FX Cruiser HO) / Engine unit and coupling cover (FX SHO, FX Cruiser SHO)

Engine unit and coupling cover (FX SHO, FX Cruiser SHO)

17 N·m (1.7 kgf·m, 12.5 ft·lb)

5 2

3 1

17 N·m (1.7 kgf·m, 12.5 ft·lb)

5 6 6

No. 1 2 3 4 5 6

Part name Bolt Bolt Collar Coupling cover Bolt Shim

Q’ty 4 1 1 1 4 *

Remarks M8  28 mm M6  25 mm

M8  37 mm As required

5-8

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Engine unit and coupling cover (FX HO, FX Cruiser HO) 17 N·m (1.7 kgf·m, 12.5 ft·lb)

1 5 2

3 1

4 5

17 N·m (1.7 kgf·m, 12.5 ft·lb)

6 6

No. 1 2 3 4 5 6

5-9

Part name Bolt Bolt Collar Coupling cover Bolt Shim

Q’ty 4 1 1 1 4 *

Remarks M8  28 mm M6  25 mm

M8  37 mm As required

Engine unit and coupling cover (FX HO, FX Cruiser HO) / Engine mount

Engine mount 17 N·m (1.7 kgf·m, 12.5 ft·lb)

5.5 N·m (0.55 kgf·m, 4.06 ft·lb)

1 2

5.5 N·m (0.55 kgf·m, 4.06 ft·lb)

5 6 1

7 1 2 3

1 1 2

No. 1 2 3 4 5 6 7

Part name Bolt Engine mount Liner Bolt Damper 1 Bolt Damper 2

Q’ty 8 4 4 2 1 2 1

Remarks M8  35 mm

M6  19 mm M6  12 mm

5-10

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Engine unit removal (FX SHO, FX Cruiser SHO)

6. Disconnect the quick connector d from the fuel rail. See “Fuel hose disconnection” (4-5).

Before removing the engine, make sure to take adequate measures to protect the deck opening from damage.

1. Disconnect the negative battery lead, and then disconnect the positive battery lead. 2. Extract the engine oil. See “Engine oil replacement” (3-6). 3. Remove the service lid a.

7. Remove the breather hose e, air intake pipe f, air filter case cover g, air filter, and air filter case h.

h a

8. Remove the plastic tie i from the cooling water hose j.

4. Remove the deck beam b.

5. Remove the engine cover c. 9. Remove the electrical box cover k.

c k

5-11

Engine mount 10. Remove the antenna holders l.

m 11. Disconnect the remote control receiver coupler a.

m a 12. Disconnect the couplers b.

sensor

and

switch

15. Disconnect coupler d.

13. Disconnect coupler c.

the

electric

bilge

the

fuel

pump

module

pump

16. Disconnect the cooling water hose j from the oil cooler assy.

14. Remove the wiring harness from the plastic ties m.

17. Disconnect the cooling water hose n from the thermostat housing.

5-12

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

s 18. Disconnect the cooling water hoses o and p from the air cooler.

21. Disconnect the cooling water hoses u, v, and w. 22. Remove the plastic tie x and rectifier regulator y.

y v

w p 19. Place a rag under the oil filter q, and then remove it.

23. Disconnect the cooling water hoses z and A. 24. Remove the stay B.

r z A B

Oil filter wrench r: YB-06830 Oil filter wrench r: 90890-06830

25. Remove the stays C.

TIP: Make sure to clean up any oil spills. 20. Remove the holder s and plastic tie t, and then disconnect the thermo sensor coupler e.

5-13

C C

Engine mount 26. Remove the pipe clamp D from the pipe E.

30. Loosen the engine mounting bolts I. 31. Lift the engine unit slightly, remove the shims J, and then lower the unit.

32. Remove the engine mounting bolts I.

E 27. Remove the muffler assy. F.

F I

TIP: Write down the position of each removed shim J so that it can be installed in its original position.

TIP: When removing the muffler assy. F, move it forward and separate it from the water lock. 28. Remove the electrical box G.

33. Suspend the engine unit using all 3 engine hangers, and then separate the unit from the engine mounts and move it forward to disconnect the coupling.

29. Remove the coupling cover H.

34. Lift the engine unit slightly, and then lower the front of the unit. Repeat this step until the engine unit can be removed from the engine compartment. NOTICE: When removing the engine unit, take care to avoid causing damage to the hull liner and deck opening.

5-14

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

35. Lift the engine unit out vertically.

5. Remove the plastic tie c, and then disconnect the quick connector d from the fuel rail. See “Fuel hose disconnection” (4-5).

Engine unit removal (FX HO, FX Cruiser HO)

d 6. Remove the engine cover e.

Before removing the engine, make sure to take adequate measures to protect the deck opening from damage. 1. Disconnect the negative battery lead, and then disconnect the positive battery lead. 2. Extract the engine oil. See “Engine oil replacement” (3-6). 3. Remove the service lid a.

e 7. Remove the breather hose f, air intake pipe g, air filter case cover h, air filter, and air filter case i.

4. Remove the deck beam b.

5-15

Engine mount 8. Remove the plastic tie j from the cooling water hose k.

13. Disconnect coupler c.

the

electric

bilge

pump

9. Remove the electrical box cover l.

14. Remove the wiring harness from the plastic ties n.

10. Remove the antenna holders m.

11. Disconnect the remote control receiver coupler a.

n a 12. Disconnect the couplers b.

sensor

and

switch

15. Disconnect coupler d.

the

fuel

pump

module

5-16

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

TIP: Make sure to clean up any oil spills. 19. Remove the holder r and plastic tie s, and then disconnect the thermo sensor coupler e.

d 16. Disconnect the cooling water hose k from the oil cooler assy.

20. Disconnect the cooling water hoses t, u, and v, and then remove the rectifier regulator w.

t w

17. Disconnect the cooling water hose o from the thermostat housing.

21. Disconnect the cooling water hoses x and y. 22. Remove the stay z. 18. Place a rag under the oil filter p, and then remove it.

y z 23. Remove the pipe clamp A from the pipe B.

Oil filter wrench q: YB-06830 Oil filter wrench q: 90890-06830

5-17

Engine mount 27. Remove the ETV. See â&#x20AC;&#x153;ETV and fuel injector (FX HO, FX Cruiser HO)â&#x20AC;? (4-9).

28. Loosen the engine mounting bolts F. 29. Lift the engine unit slightly, remove the shims G, and then lower the unit. 30. Remove the engine mounting bolts F.

B 24. Remove the muffler assy. C.

G F

TIP: When removing the muffler assy. C, move it forward and separate it from the water lock. 25. Remove the electrical box D.

TIP: Write down the position of each removed shim G so that it can be installed in its original position. 31. Suspend the engine unit using all 3 engine hangers, and then separate the unit from the engine mounts and move it forward to disconnect the coupling.

26. Remove the coupling cover E.

5-18

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

32. Lift the engine unit slightly, and then lower the front of the unit. Repeat this step until the engine unit can be removed from the engine compartment. NOTICE: When removing the engine unit, take care to avoid causing damage to the hull liner and deck opening.

33. Lift the engine unit out vertically.

1. Suspend the engine unit using all 3 engine hangers. 2. Lower the front of the engine unit. 3. Lower the engine unit into the engine compartment vertically.

4. Lift the front of the engine unit slightly, and then lower the unit. Repeat this step until the drive and driven couplings are aligned.

Engine mount and damper check 1. Check the engine mounts and dampers. Replace if cracked or damaged.

TIP: â&#x20AC;˘ Write down the position of each engine mount so that it can be installed in its original position. â&#x20AC;˘ When replacing the engine mounts, make sure to check the coupling clearance.

Engine unit installation (FX SHO, FX Cruiser SHO)

When installing the engine unit, take care to avoid causing damage to the hull liner and deck opening.

5-19

5. Move the engine unit rearward to connect the driven coupling a, and then lower the unit onto the engine mounts.

Engine mount 8. Measure the coupling clearances a and b. If the clearances are out of specification, add or remove shims c so that the clearances are within specification.

TIP: Do not install the rubber coupling until the coupling clearance adjustment has been made.

Clearance a: Less than 1 mm (0.039 in) (without rubber coupling) Clearance b: 2â&#x20AC;&#x201C;4 mm (0.079â&#x20AC;&#x201C;0.157 in) Available shim thicknesses: 0.10, 0.30, 0.50, 1.00, 2.00 mm

6. Temporarily install the engine mounting bolts b.

9. Lift the engine unit slightly, remove the shims, and then lower the engine unit.

7. Lift the engine unit slightly, install the shims c, and then lower the unit.

10. Remove the engine mounting bolts. 11. Separate the engine unit from the engine mounts and move it forward to disconnect the coupling. 12. Install the rubber coupling d.

b c

TIP: Install the shims in their original positions.

13. Install the shims, and then adjust the position of the engine unit so that the coupling clearances a and b are within specification.

5-20

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

f a

g b Clearance a: Less than 0.5 mm (0.020 in) (with rubber coupling) Clearance b: 2–4 mm (0.079–0.157 in)

Electrical box bolt g: 17 N·m (1.7 kgf·m, 12.5 ft·lb)

14. Tighten the engine mounting bolts b to the specified torque, and then recheck the coupling clearances.

17. Install the muffler assy. h into the water lock, and then tighten the exhaust manifold bolts i and j to the specified torques in 3 stages and in the order a, b, and so on.

i h j

f j

b ie

c a

g j

j k

Exhaust manifold bolt i and j: 1st: 20 N·m (2.0 kgf·m, 14.8 ft·lb) 2nd: 20 N·m (2.0 kgf·m, 14.8 ft·lb) 3rd: 35 N·m (3.5 kgf·m, 25.8 ft·lb)

Engine mounting bolt b: 17 N·m (1.7 kgf·m, 12.5 ft·lb) 15. Install the coupling cover e.

18. Install the pipe clamp k, and then tighten it to the specified torque.

16. Install the electrical box f, and then tighten the electrical box bolts g to the specified torque.

5-21

Pipe clamp k: 2.5 N·m (0.25 kgf·m, 1.84 ft·lb)

Engine mount 24. Fasten the cooling water hose w using the plastic tie C.

TIP: Make sure that the pipe on the end of the muffler assy. is installed securely into the water lock. 19. Install the stays l, and then tighten the stay bolts m to the specified torque.

B y v

v x

Rectifier regulator bolt v: 26 N·m (2.6 kgf·m, 19.2 ft·lb)

25. Connect the thermo sensor coupler c.

26. Fasten the leads using the holder D and plastic tie E.

Stay bolt m: 10 N·m (1.0 kgf·m, 7.4 ft·lb)

20. Install the stay n, and then tighten the stay bolts o and p to the specified torques in 2 stages. 21. Connect the cooling water hoses q and r, and then fasten them using the clamps s and t.

st r

D 27. Install the oil filter F, and then tighten it to the specified torque.

p o n

p F G

Stay bolts o and p: 1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb) 22. Install the rectifier regulator u, and then tighten the rectifier regulator bolts v to the specified torque. 23. Connect the cooling water hoses w, x, and y, and then fasten them using the clamps z, A, and B.

Oil filter wrench G: YB-06830 Oil filter wrench G: 90890-06830 Oil filter F: 18 N·m (1.8 kgf·m, 13.3 ft·lb) 28. Connect the cooling water hoses H and I, and then fasten them using the clamps J and K.

5-22

1 2 3 4 5 6 7 8 9 A

POWR

Power unit 32. Connect the electric bilge pump coupler e.

K 33. Connect the sensor and switch couplers f.

I 29. Connect the cooling water hose L, and then fasten it using the clamp M.

30. Connect the cooling water hose N, and then fasten it using the clamp O.

34. Connect the remote control receiver coupler g, and then install the antenna holders P.

N O g

31. Connect the fuel pump module coupler d.

35. Fasten the wiring harness using the plastic ties Q.

5-23

Engine mount

U U

Air filter case bolt U: 12 N·m (1.2 kgf·m, 8.9 ft·lb) 39. Install the air filter, air filter case cover V, and air intake pipe W, and then tighten the air intake pipe clamps X to the specified torque. 40. Install the breather hose Y, and then fasten it using the clamp Z.

36. Install the electrical box cover R.

V Z W X

37. Fasten the cooling water hose N using the plastic tie S.

Air intake pipe clamp X: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 41. Connect the quick connector 1 to the fuel rail.

38. Install the air filter case T, and then tighten the air filter case bolts U to the specified torque.

42. Install the engine cover 2, and then tighten the engine cover screws 3 to the specified torque.

5-24

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

3 2 3 Engine cover screw 3: 5 N·m (0.5 kgf·m, 3.7 ft·lb) 43. Install the service lid 4.

4. Lift the front of the engine unit slightly, and then lower the unit. Repeat this step until the drive and driven couplings are aligned.

44. Fill the engine with engine oil. See “Engine oil replacement” (3-6). 45. Connect the positive battery lead, and then connect the negative battery lead.

5. Move the engine unit rearward to connect the driven coupling a, and then lower the unit onto the engine mounts.

Engine unit installation (FX HO, FX Cruiser HO)

When installing the engine unit, take care to avoid causing damage to the hull liner and deck opening. 1. Suspend the engine unit using all 3 engine hangers. 2. Lower the front of the engine unit. 3. Lower the engine unit into the engine compartment vertically.

5-25

Engine mount

TIP: Do not install the rubber coupling until the coupling clearance adjustment has been made. 6. Temporarily install the engine mounting bolts b. 7. Lift the engine unit slightly, install the shims c, and then lower the unit.

Available shim thicknesses: 0.10, 0.30, 0.50, 1.00, 2.00 mm 9. Lift the engine unit slightly, remove the shims, and then lower the engine unit. 10. Remove the engine mounting bolts. 11. Separate the engine unit from the engine mounts and move it forward to disconnect the coupling. 12. Install the rubber coupling d.

c b

TIP: Install the shims in their original positions. 8. Measure the coupling clearances a and b. If the clearances are out of specification, add or remove shims c so that the clearances are within specification.

13. Install the shims, and then adjust the position of the engine unit so that the coupling clearances a and b are within specification.

b Clearance a: Less than 1 mm (0.039 in) (without rubber coupling) Clearance b: 2–4 mm (0.079–0.157 in)

Clearance a: Less than 0.5 mm (0.020 in) (with rubber coupling) Clearance b: 2–4 mm (0.079–0.157 in) 14. Tighten the engine mounting bolts b to the specified torque, and then recheck the coupling clearances.

5-26

1 2 3 4 5 6 7 8 9 A

POWR

Power unit 18. Install the muffler assy. h into the water lock, and then tighten the exhaust manifold bolts i and j to the specified torques in 3 stages and in the order a, b, and so on.

b h

j i h

j Engine mounting bolt b: 17 N·m (1.7 kgf·m, 12.5 ft·lb) 15. Install the ETV. See “ETV and fuel injector (FX HO, FX Cruiser HO)” (4-9). 16. Install the coupling cover e.

f j

b ie

c a

g j

j k

Exhaust manifold bolt i and j: 1st: 20 N·m (2.0 kgf·m, 14.8 ft·lb) 2nd: 20 N·m (2.0 kgf·m, 14.8 ft·lb) 3rd: 35 N·m (3.5 kgf·m, 25.8 ft·lb) 19. Install the pipe clamp k, and then tighten it to the specified torque.

17. Install the electrical box f, and then tighten the electrical box bolts g to the specified torque.

f g

Electrical box bolt g: 17 N·m (1.7 kgf·m, 12.5 ft·lb)

5-27

TIP: g

Pipe clamp k: 2.5 N·m (0.25 kgf·m, 1.84 ft·lb)

Make sure that the pipe on the end of the muffler assy. is installed securely into the water lock. 20. Install the stay l, and then tighten the stay bolts m and n to the specified torques in 2 stages. 21. Connect the cooling water hoses o and p, and then fasten them using the clamps q and r.

Engine mount

r oq p

n m

l Stay bolts m and n: 1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb) 22. Install the rectifier regulator s, and then tighten the rectifier regulator bolts t to the specified torque. 23. Connect the cooling water hoses u, v, and w, and then fasten them using the clamps x, y, and z.

Oil filter wrench D: YB-06830 Oil filter wrench D: 90890-06830 Oil filter C: 18 N·m (1.8 kgf·m, 13.3 ft·lb) 27. Connect the cooling water hose E to the thermostat housing, and then fasten it using the clamp F.

x u F

t t v

y 28. Connect the cooling water hose G, and then fasten it using the clamp H.

Rectifier regulator bolt t: 26 N·m (2.6 kgf·m, 19.2 ft·lb) 24. Connect the thermo sensor coupler c. 25. Fasten the leads using the holder A and plastic tie B.

G H

29. Connect the fuel pump module coupler d.

A 26. Install the oil filter C, and then tighten it to the specified torque.

5-28

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

30. Connect the electric bilge pump coupler e.

J 31. Connect the sensor and switch couplers f.

34. Install the electrical box cover K.

32. Connect the remote control receiver coupler g, and then install the antenna holders I.

K I 35. Fasten the cooling water hose G using the plastic tie L.

g 33. Fasten the wiring harness using the plastic ties J.

5-29

Engine mount

S 36. Install the air filter case M, and then tighten the air filter case bolts N to the specified torque.

Engine cover screw T: 5 N·m (0.5 kgf·m, 3.7 ft·lb) 40. Connect the quick connector U to the fuel rail. 41. Pass the fuel hose through the clamp h on the air intake pipe, and then clamp the plastic tie V.

N N

Air filter case bolt N: 12 N·m (1.2 kgf·m, 8.9 ft·lb) 37. Install the air filter, air filter case cover O, and air intake pipe P, and then tighten the air intake pipe clamps Q to the specified torque.

U 42. Install the service lid W.

38. Install the breather hose R.

O R

Q Air intake pipe clamp Q: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

43. Fill the engine with engine oil. See “Engine oil replacement” (3-6). 44. Connect the positive battery lead, and then connect the negative battery lead.

39. Install the engine cover S, and then tighten the engine cover screws T to the specified torque.

5-30

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Muffler B

20 N·m (2.0 kgf·m, 14.8 ft·lb)

a 15 N·m (1.5 kgf·m, 11.1 ft·lb) b 29 N·m (2.9 kgf·m, 21.4 ft·lb)

3 8 12 15

7 14

13 14

9 4 5 2 1

2.5 N·m (0.25 kgf·m, 2.58 ft·lb)

200 N·m (20.0 kgf·m, 147.5 ft·lb)

a 20 N·m (2.0 kgf·m, 14.8 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb) c 35 N·m (3.5 kgf·m, 25.8 ft·lb) No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

5-31

Part name Clamp Pipe Thermo sensor Clamp Cooling water hose Exhaust pipe 3 Bolt Exhaust pipe 2 Gasket Bolt Bolt Exhaust pipe 1 Gasket Dowel pin Exhaust manifold Exhaust manifold

a 20 N·m (2.0 kgf·m, 14.8 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb) c 35 N·m (3.5 kgf·m, 25.8 ft·lb) Q’ty 1 1 1 1 1 1 5 1 1 2 4 1 1 2 1 1

Remarks

M8  35 mm  M8  70 mm M8  120 mm 

A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO

Muffler

Exhaust pipe disassembly

Use heat-resistant burns could result.

gloves.

Exhaust pipe assembly

Otherwise,

1. Install exhaust pipe 3 a, and then tighten it to the specified torque. NOTICE: To allow the LOCTITE 648 to set, wait approximately 1 hour after completing this procedure.

1. Remove exhaust pipe 3 a.

b 15°

a a

15°

Exhaust pipe wrench b: 90890-06726

TIP: Heat the area a of exhaust pipe 3 a to approximately 200 °C (392 °F) using a heat gun.

15° 15°

Exhaust pipe wrench b: 90890-06726 Exhaust pipe 3 a: 200 N·m (20.0 kgf·m, 147.5 ft·lb)

5-32

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Wiring harness assy. (FX SHO, FX Cruiser SHO) 1

7 N·m (0.7 kgf·m, 5.2 ft·lb)

5 4

UP a

7 6

9 10

11 No. 1 2 3 4 5 6 7 8 9 10 11 12 13

5-33

12 Part name Nut Spring washer Bolt Negative battery lead Starter motor Bolt Thermostat housing Thermostat Holder Plastic tie Plastic tie Plastic tie Wiring harness

Q’ty 1 1 2 1 1 2 1 1 1 1 1 1 1

Remarks

M8  30 mm

M6  35 mm

a Hole

Wiring harness assy. (FX SHO, FX Cruiser SHO) / Wiring harness assy. (FX HO, FX Cruiser HO)

Wiring harness assy. (FX HO, FX Cruiser HO) 1

7 N·m (0.7 kgf·m, 5.2 ft·lb)

5 4

a 10 A

11 No. 1 2 3 4 5 6 7 8 9 10 11 12 13

12 Part name

Nut Spring washer Bolt Negative battery lead Starter motor Bolt Thermostat housing Thermostat Holder Plastic tie Plastic tie Plastic tie Wiring harness

Q’ty 1 1 2 1 1 2 1 1 1 2 1 1 1

Remarks

M8  30 mm

M6  35 mm

a Hole

5-34

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Electrical box 11

4 N·m (0.4 kgf·m, 3.0 ft·lb)

12 22 10 20

23 21

15 13

8 N·m (0.8 kgf·m, 5.9 ft·lb)

14 16 17 18 19

25 7

9 8 2 1

4 5 6 5 N·m (0.5 kgf·m, 3.7 ft·lb)

3 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

5-35

Part name Electrical box cover Plastic tie Bolt ECM Collar Grommet Bolt Fuse box assy. Gasket Rubber mount Main and fuel pump relay ETV relay Fuse box cap Gasket Fuse puller Fuse (30 A)

Q’ty 1 1 4 1 4 4 6 1 1 1 1 1 1 1 1 2

Remarks

M6  25 mm

M6  16 mm 



Electrical box

4 N·m (0.4 kgf·m, 3.0 ft·lb)

12 22 10 20

23 21

15 13

8 N·m (0.8 kgf·m, 5.9 ft·lb)

14 16 17 18 19

25 7

9 8 2 1

4 5 6 5 N·m (0.5 kgf·m, 3.7 ft·lb)

3 No. 17 18 19 20 21 22 23 24 25

Part name Fuse (10 A) Fuse (3 A) Fuse (20 A) Starter relay Starter motor lead Positive battery lead Screw Slant detection switch Electrical box

Q’ty 4 2 2 1 1 1 2 1 1

Remarks

M6  20 mm

5-36

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Starter motor and wiring harness assy. removal (FX SHO, FX Cruiser SHO) 1. Disconnect the starter motor lead a and negative battery lead b, and then remove the starter motor c.

5. Disconnect the earth plate couplers k and oil pressure switch coupler m.

k m

b c 2. Remove the plastic tie d.

6. Remove the plastic tie e and holder f, and then disconnect the thermoswitch coupler n, engine temperature sensor coupler p, intake air pressure sensor coupler r, intake air temperature sensor coupler s, cam position sensor coupler t knock sensor coupler u, and ETV coupler v.

3. Disconnect the fuse box couplers a, main and fuel pump relay coupler b, ETV relay coupler c, slant detection switch coupler d, and ECM couplers e.

4. Disconnect the rectifier regulator coupler f, stator coil coupler g, and pick up coil coupler h.

f b 7. Disconnect the ignition coil couplers w and fuel injector couplers x.

d a

d g

x h

5-37

Electrical box

Starter motor and wiring harness assy. removal (FX HO, FX Cruiser HO) 1. Disconnect the starter motor lead a and negative battery lead b, and then remove the starter motor c.

5. Disconnect the earth plate couplers k and oil pressure switch coupler m.

k m

6. Disconnect the thermoswitch coupler n, and then remove the plastic ties e.

c 2. Remove the plastic tie d. 3. Disconnect the fuse box couplers a, main and fuel pump relay coupler b, ETV relay coupler c, slant detection switch coupler d, and ECM couplers e. 4. Disconnect the rectifier regulator coupler f, stator coil coupler g, and pick up coil coupler h.

7. Remove the holder f, and then disconnect the engine temperature sensor coupler p, intake air pressure sensor coupler r, intake air temperature sensor coupler s, and cam position sensor coupler t.

p r

f a

g f

8. Disconnect the ignition coil couplers u and fuel injector couplers v.

5-38

1 2 3 4 5 6 7 8 9 A

POWR

Power unit A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO

Starter motor and wiring harness assy. installation (FX SHO, FX Cruiser SHO) 1. Connect the fuel injector couplers a and ignition coil couplers b.

v b

Thermostat check 1. Suspend the thermostat in a container of water. 2. Place a thermometer in the water and heat the water slowly.

a 2. Connect the ETV coupler c, knock sensor coupler d, cam position sensor coupler e, intake air temperature sensor coupler f, intake air pressure sensor coupler g, engine temperature sensor coupler h, and thermoswitch coupler k, and then fasten the wiring harness using the holder a and plastic tie b. 3. Measure the thermostat valve opening a at the specified water temperatures. Replace if out of specification.

e c

a Water temperature A : 48–52 °C (118–126 °F) B : 58–62 °C (136–144 °F) A : above 60 °C (140 °F) B : above 70 °C (158 °F)

5-39

Valve opening a

TIP: Starts opening

4.3 mm (0.17 in) or above

Fasten the wiring harness at the gray tape m using the holder a. 3. Connect the oil pressure switch coupler n and earth plate couplers p.

Electrical box

f p

4. Connect the pick up coil coupler r, stator coil coupler s, and rectifier regulator coupler t. 5. Connect the ECM couplers u, slant detection switch coupler v, ETV relay coupler w, main and fuel pump relay coupler x, and fuse box couplers y, and then fasten the wiring harness using the plastic tie c.

e d

Starter motor lead nut g: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

Starter motor and wiring harness assy. installation (FX HO, FX Cruiser HO) 1. Connect the fuel injector couplers a and ignition coil couplers b.

w x

c y

v s

r 6. Install the starter motor d, and then connect the negative battery lead e and starter motor lead f. 7. Tighten the starter motor lead nut g to the specified torque.

2. Connect the cam position sensor coupler c, intake air temperature sensor coupler d, intake air pressure sensor coupler e, and engine temperature sensor coupler f, and then fasten the wiring harness using the holder a.

f e

g a

d c

5-40

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

TIP: Fasten the wiring harness at the gray tape g using the holder a. 3. Connect the thermoswitch coupler h, and then fasten the thermoswitch lead using the plastic ties b.

c w

t p

n 4. Connect the oil pressure switch coupler k and earth plate couplers m.

m k

7. Install the starter motor d, and then connect the negative battery lead e and starter motor lead f. 8. Tighten the starter motor lead nut g to the specified torque.

f g

5. Connect the pick up coil coupler n, stator coil coupler p, and rectifier regulator coupler r. 6. Connect the ECM couplers s, slant detection switch coupler t, ETV relay coupler u, main relay coupler v, and fuse box couplers w, and then fasten the wiring harness using the plastic tie c.

5-41

e d

Starter motor lead nut g: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

Electrical box / Air cooler and supercharger assy.

Air cooler and supercharger assy. 20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb)

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) b 42 N·m (4.2 kgf·m, 31.0 ft·lb)

20 N·m (2.0 kgf·m, 14.8 ft·lb)

26 30 31

4 N·m (0.4 kgf·m, 3.0 ft·lb)

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) 29 b 42 N·m (4.2 kgf·m, 31.0 ft·lb)

12 11

2 4 N·m (0.4 kgf·m, 3.0 ft·lb)

11 24

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

1 23 7

5 6

42 N·m (4.2 kgf·m, 31.0 ft·lb)

9 15

42 N·m (4.2 kgf·m, 31.0 ft·lb)

17 9

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) b 42 N·m (4.2 kgf·m, 31.0 ft·lb)

20 N·m (2.0 kgf·m, 14.8 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Clamp Clamp Bolt Boost pipe Collar Grommet Joint 1 Joint 2 Clamp Cooling water hose Clamp Air cooler intake pipe Nut Bolt Air cooler Collar

Q’ty 3 1 1 1 1 1 1 1 2 1 2 1 1 2 1 1

Remarks

M8  35 mm

M10  45 mm

5-42

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb)

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) b 42 N·m (4.2 kgf·m, 31.0 ft·lb)

20 N·m (2.0 kgf·m, 14.8 ft·lb)

26 30 31

4 N·m (0.4 kgf·m, 3.0 ft·lb)

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) 29 b 42 N·m (4.2 kgf·m, 31.0 ft·lb)

12 11

2 4 N·m (0.4 kgf·m, 3.0 ft·lb)

11 24

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

1 23 7

5 6

42 N·m (4.2 kgf·m, 31.0 ft·lb)

9 15

42 N·m (4.2 kgf·m, 31.0 ft·lb)

17 9

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) b 42 N·m (4.2 kgf·m, 31.0 ft·lb)

20 N·m (2.0 kgf·m, 14.8 ft·lb)

No. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

5-43

Part name Grommet Plate Stud bolt Bolt Bolt Stay Collar Grommet Bolt Washer Bolt Bolt Supercharger assy. Bolt Gasket O-ring

Q’ty 1 1 1 1 1 1 2 2 2 2 3 1 1 1 1 1

Remarks

M10  50 mm M10  80 mm

M6  65 mm M8  65 mm M8  65 mm M5  9 mm  

Air cooler and supercharger assy.

20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb)

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) b 42 N·m (4.2 kgf·m, 31.0 ft·lb)

20 N·m (2.0 kgf·m, 14.8 ft·lb)

26 30 31

4 N·m (0.4 kgf·m, 3.0 ft·lb)

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) 29 b 42 N·m (4.2 kgf·m, 31.0 ft·lb)

12 11

2 4 N·m (0.4 kgf·m, 3.0 ft·lb)

11 24

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

1 23 7

5 6

42 N·m (4.2 kgf·m, 31.0 ft·lb)

9 15

42 N·m (4.2 kgf·m, 31.0 ft·lb)

17 9

a 23 N·m (2.3 kgf·m, 17.0 ft·lb) b 42 N·m (4.2 kgf·m, 31.0 ft·lb)

20 N·m (2.0 kgf·m, 14.8 ft·lb)

No. 33

Part name Dowel pin

Q’ty 2

Remarks

5-44

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Intake assy. (FX SHO, FX Cruiser SHO) 15 N·m (1.5 kgf·m, 11.1 ft·lb)

17 15

a 10 N·m (1.0 kgf·m, 7.4 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb)

13 7

10 9

19 9

11 12 4

a 10 N·m (1.0 kgf·m, 7.4 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb)

25 12

a 15 N·m (1.5 kgf·m, 11.1 ft·lb) b 30 N·m (3.0 kgf·m, 22.1 ft·lb)

20 22

a 15 N·m (1.5 kgf·m, 11.1 ft·lb) b 30 N·m (3.0 kgf·m, 22.1 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

5-45

Part name Holder Plastic tie Bolt Bolt Nut Bolt Intake assy. Gasket Dowel pin Stud bolt Bolt Stay Intake air temperature sensor Gasket Clamp Hose

Q’ty 1 1 1 2 2 6 1 1 2 2 2 2 1 1 2 1

Remarks

M6  12 mm M8  25 mm M8  35 mm 

M8  40 mm



Intake assy. (FX SHO, FX Cruiser SHO)

15 N·m (1.5 kgf·m, 11.1 ft·lb)

17 15

a 10 N·m (1.0 kgf·m, 7.4 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb)

13 7

10 9

19 9

11 12 4

a 10 N·m (1.0 kgf·m, 7.4 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb)

25 12

a 15 N·m (1.5 kgf·m, 11.1 ft·lb) b 30 N·m (3.0 kgf·m, 22.1 ft·lb)

20 22

a 15 N·m (1.5 kgf·m, 11.1 ft·lb) b 30 N·m (3.0 kgf·m, 22.1 ft·lb)

No. 17 18 19 20 21 22 23 24 25

Part name Intake air pressure sensor Grommet Oil level gauge Bolt Oil level pipe assy. Clamp Oil level pipe plate Grommet O-ring

Q’ty 1 1 1 2 1 1 1 1 1

Remarks

M6  12 mm



5-46

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Intake assy. (FX HO, FX Cruiser HO) 15 N·m (1.5 kgf·m, 11.1 ft·lb)

12 14

10 11 13

a 10 N·m (1.0 kgf·m, 7.4 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb) 3

a 10 N·m (1.0 kgf·m, 7.4 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb) 7

7 6 6 2 4

a 10 N·m (1.0 kgf·m, 7.4 ft·lb) b 20 N·m (2.0 kgf·m, 14.8 ft·lb) a 15 N·m (1.5 kgf·m, 11.1 ft·lb) b 30 N·m (3.0 kgf·m, 22.1 ft·lb) a 15 N·m (1.5 kgf·m, 11.1 ft·lb) b 30 N·m (3.0 kgf·m, 22.1 ft·lb)

8 1 8 1

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

5-47

Part name Bolt Bolt Nut Intake manifold Gasket Dowel pin Stud bolt Bolt Stay Intake air temperature sensor Gasket Intake air pressure sensor Grommet Hose

Q’ty 2 6 2 1 1 2 2 2 2 1 1 1 1 1

9 Remarks M8  25 mm M8  35 mm



M8  40 mm



Intake assy. (FX HO, FX Cruiser HO) / ETV and intake manifold (FX SHO, FX Cruiser SHO)

ETV and intake manifold (FX SHO, FX Cruiser SHO)

6 8

A 7 3

24 N·m (2.4 kgf·m, 17.7 ft·lb)

13 N·m (1.3 kgf·m, 9.6 ft·lb)

No. 1 2 3 4 5 6 7 8

Part name Nut Washer ETV Bolt Joint Holder Ribbon Intake manifold

Q’ty 4 4 1 4 1 1 1 1

Remarks

M8  20 mm

5-48

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Air cooler check (FX SHO, FX Cruiser SHO)

Leakage tester b: 90890-06840 Air cooler attachment e: 90890-06731

Do not disassemble the air cooler.

Specified positive pressure (air passage): 100 kPa (1.0 kgf/cm2, 14.2 psi)

1. Connect the hose a and special service tool b to the inlet or outlet of the cooling water passage. Block the inlet or outlet using a rubber plug c.

Supercharger check (FX SHO, FX Cruiser SHO)

Do not disassemble the supercharger. 2. Apply the specified pressure and check that the pressure is maintained. If the specified pressure cannot be maintained, replace the air cooler.

1. Check the impeller and gear. Replace the supercharger if cracked or worn. 2. Check that the supercharger impeller shaft turns smoothly. Replace the supercharger if it does not turn smoothly.

c a

ETV check (FX SHO, FX Cruiser SHO) b

• Do not disassemble the ETV. • Do not loosen the throttle stop screw nut a or turn the throttle stop screw b. • Do not loosen or remove the throttle valve shaft screws c.

Leakage tester b: 90890-06840 Specified positive pressure (water passage): 200 kPa (2.0 kgf/cm2, 28.5 psi)

3. Connect the hoses d and special service tools b and e to the inlet or outlet of the air cooler passage. 4. Apply the specified pressure and check that the pressure is maintained. If the specified pressure cannot be maintained, replace the air cooler.

d e

e b

5-49

b c

1. Turn the throttle valve manually and check that it moves smoothly.

Intake assy. installation (FX SHO, FX Cruiser SHO) 1. Install the dowel pins a, a new gasket b, and the intake assy. c, and then tighten the intake manifold bolts d and nuts e temporarily.

ETV and intake manifold (FX SHO, FX Cruiser SHO) 4. Tighten the intake manifold stay bolts g and h to the specified torques in 2 stages.

e b

Intake manifold stay bolt g and h: 1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 2nd: 30 N·m (3.0 kgf·m, 22.1 ft·lb) 5. Fasten the ETV lead using the plastic tie i.

2. Install the stays f, and then tighten the intake manifold stay bolts g and h temporarily.

i f

Intake manifold installation (FX HO, FX Cruiser HO)

h g

3. Tighten the intake manifold bolts d and nuts e to the specified torques in 2 stages and in the order a, b, and so on.

1. Install the dowel pins a, a new gasket b, and the intake manifold c, and then tighten the intake manifold bolts d and nuts e temporarily.

g d c a

2. Install the stays f, and then tighten the intake manifold stay bolts g and h temporarily.

5-50

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

c a

gh g

c d

b h f

3. Tighten the intake manifold bolts d and intake manifold nuts e to the specified torques in 2 stages and in the order a, b, and so on.

Installation distance a: 49.8 mm (2.0 in)

TIP: Make sure that the bottom of the grommet d is at the specified installation distance a from the end of the oil level pipe b. 3. Install the oil level pipe assy. onto the cylinder block, and then tighten the oil level pipe plate bolts f and oil level pipe bolt g temporarily. 4. Tighten the oil level pipe plate bolts f.

Intake manifold bolt d: 1st: 10 N·m (1.0 kgf·m, 7.4 ft·lb) 2nd: 20 N·m (2.0 kgf·m, 14.8 ft·lb) Intake manifold nut e: 1st: 10 N·m (1.0 kgf·m, 7.4 ft·lb) 2nd: 20 N·m (2.0 kgf·m, 14.8 ft·lb) 4. Tighten the intake manifold stay bolts g and h to the specified torques in 2 stages.

5. Tighten the oil level pipe bolt g.

g f

Intake manifold stay bolt g and h: 1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 2nd: 30 N·m (3.0 kgf·m, 22.1 ft·lb)

Oil level pipe installation (FX SHO, FX Cruiser SHO) 1. Pass the clamp a through the oil level pipe b. 2. Install the oil level pipe plate c, the grommet d, and a new O-ring e onto the oil level pipe b.

5-51

f 6. Fasten the grommet d using the clamp a.

ETV and intake manifold (FX SHO, FX Cruiser SHO)

Supercharger installation (FX SHO, FX Cruiser SHO)

1. Remove the supercharger oil filler hole bolt a and gasket b, and then apply engine oil to the supercharger impeller shaft through the oil filler hole a.

g a b Supercharger bolt (M8  65mm) f: 20 N·m (2.0 kgf·m, 14.8 ft·lb) Supercharger bolt (M6  65mm) g: 10 N·m (1.0 kgf·m, 7.4 ft·lb)

TIP: Apply engine oil to the supercharger impeller shaft through the oil filler hole a while turning the supercharger impeller shaft. 2. Install a new gasket, and then tighten the supercharger oil filler hole bolt a to the specified torque. Supercharger oil filler hole bolt a: 4 N·m (0.4 kgf·m, 3.0 ft·lb)

Air cooler, air cooler intake hose, and boost pipe installation (FX SHO, FX Cruiser SHO) 1. Install the plate a and air cooler b. 2. Tighten the air cooler bolts c and air cooler nut d alternately in 2 stages to the specified torque.

3. Install the dowel pins c, a new O-ring d, and the supercharger e, and then tighten the supercharger bolts f to the specified torque. 4. Tighten the supercharger bolts g to the specified torque.

b a

5-52

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Air cooler bolt c: 1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb) Air cooler nut d: 1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb)

3. Install the air cooler intake pipe e, and then tighten the air cooler intake pipe clamps f to the specified torque.

k i g

e a

Boost pipe joint 1 clamp j: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) Boost pipe joint 2 clamp k: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

TIP: c f Air cooler intake pipe clamp f: 4 N·m (0.4 kgf·m, 3.0 ft·lb)

TIP: • Face the arrow a of the air cooler intake pipe e upward. • Check that the air cooler intake pipe e contacts the protrusion b on the air cooler. • Align the air cooler intake pipe clamps f with the paint marks c on the air cooler intake pipe e. 4. Install boost pipe joint 1 g and boost pipe joint 2 h to the boost pipe i, and then tighten the boost pipe joint 1 clamp j and boost pipe joint 2 clamp k to the specified torque.

5-53

• Position the protrusion d on the boost pipe i between the protrusions e on the boost pipe joint 1 g. • Fit the lip f of the boost pipe i into the groove g in boost pipe joint 2 h. 5. Install the boost pipe assy., and then tighten the boost pipe bolt l to the specified torque. 6. Tighten the boost pipe joint 1 clamp m and boost pipe joint 2 clamp n to the specified torque.

ETV and intake manifold (FX SHO, FX Cruiser SHO)

m n

m n h

Boost pipe bolt l: 20 N·m (2.0 kgf·m, 14.8 ft·lb) Boost pipe joint 1 clamp m: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) Boost pipe joint 2 clamp n: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

TIP: • Fit the lip h of the air cooler b into the groove k in boost pipe joint 1 g. • Fit the lip m of the ETV o into the groove n in boost pipe joint 2 h.

5-54

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Oil cooler and oil pump assy. (FX SHO, FX Cruiser SHO) 11 N·m (1.1 kgf·m, 8.1 ft·lb)

24 23

25 18

20 21

26 2

21 N·m (2.1 kgf·m, 15.5 ft·lb)

19 N·m (1.9 kgf·m, 14.0 ft·lb)

9 7

11 10

17 10

12 N·m (1.2 kgf·m, 8.9 ft·lb)

12 11

12 15

12 N·m (1.2 kgf·m, 8.9 ft·lb)

19 N·m (1.9 kgf·m, 14.0 ft·lb)

5-55

Part name Clamp Cooling water hose Clamp Plastic tie Cooling water hose Oil filter joint Bolt Bolt Oil cooler assy. O-ring Connector Bolt Washer Bolt Bolt Gasket

20 N·m (2.0 kgf·m, 14.8 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Q’ty 2 1 1 1 1 1 1 2 1 4 2 7 3 1 4 1

18 N·m (1.8 kgf·m, 13.3 ft·lb)

Remarks

M8  55 mm M8  70 mm  M6  25 mm M8  25 mm M6  20 mm 

Oil cooler and oil pump assy. (FX SHO, FX Cruiser SHO)

11 N·m (1.1 kgf·m, 8.1 ft·lb)

24 23

25 18

20 21

26 2

21 N·m (2.1 kgf·m, 15.5 ft·lb)

19 N·m (1.9 kgf·m, 14.0 ft·lb)

9 7

11 10

17 10

12 N·m (1.2 kgf·m, 8.9 ft·lb)

12 11

12 15

12 N·m (1.2 kgf·m, 8.9 ft·lb)

19 N·m (1.9 kgf·m, 14.0 ft·lb)

Part name Dowel pin Bolt Bolt Gasket Oil pipe Bolt Oil pump assy. Gasket Dowel pin O-ring Connector

20 N·m (2.0 kgf·m, 14.8 ft·lb)

No. 17 18 19 20 21 22 23 24 25 26 27

Q’ty 2 1 2 4 1 12 1 1 2 2 1

18 N·m (1.8 kgf·m, 13.3 ft·lb)

Remarks M6  12 mm M10  21 mm  M6  20 mm  

5-56

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Idle gear assy. and drive gear assy. (FX SHO, FX Cruiser SHO)

2 3 5 E

1 E

7 8 E

80 N·m (8.0 kgf·m, 59.0 ft·lb)

No. 1 2 3 4 5 6 7 8

5-57

Part name Shaft Idle gear assy. Circlip Washer Washer Collar Bolt Drive gear assy.

Q’ty 1 1 2 1 1 1 1 1

Remarks

M12  58 mm, Left-hand threads

Idle gear assy. and drive gear assy. (FX SHO, FX Cruiser SHO) / Oil cooler, oil pump assy. and drive gear (FX HO, FX Cruiser HO)

Oil cooler, oil pump assy. and drive gear (FX HO, FX Cruiser HO) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 80 N·m (8.0 kgf·m, 59.0 ft·lb)

6 9

6 3

7 8

19 N·m (1.9 kgf·m, 14.0 ft·lb)

17 15

11 19

25 18

12 N·m (1.2 kgf·m, 8.9 ft·lb)

20 14

20 23

12 N·m (1.2 kgf·m, 8.9 ft·lb)

19 N·m (1.9 kgf·m, 14.0 ft·lb)

Part name Bolt Oil pump assy. Gasket Bolt Oil pump drive gear Dowel pin O-ring Connector Clamp Cooling water hose Clamp Plastic tie Cooling water hose Oil filter joint Bolt Bolt

20 N·m (2.0 kgf·m, 14.8 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Q’ty 12 1 1 1 1 2 2 1 2 1 1 1 1 1 1 2

18 N·m (1.8 kgf·m, 13.3 ft·lb)

Remarks M6  20 mm  M12  58 mm, left-hand threads



M8  55 mm M8  70 mm

5-58

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

11 N·m (1.1 kgf·m, 8.1 ft·lb) 80 N·m (8.0 kgf·m, 59.0 ft·lb)

6 9

6 3

7 8

19 N·m (1.9 kgf·m, 14.0 ft·lb)

17 15

11 19

25 18

12 N·m (1.2 kgf·m, 8.9 ft·lb)

20 14

20 23

12 N·m (1.2 kgf·m, 8.9 ft·lb)

19 N·m (1.9 kgf·m, 14.0 ft·lb)

5-59

Part name Oil cooler assy. O-ring Connector Bolt Washer Bolt Bolt Gasket Dowel pin

20 N·m (2.0 kgf·m, 14.8 ft·lb)

No. 17 18 19 20 21 22 23 24 25

Q’ty 1 4 2 7 3 1 4 1 2

18 N·m (1.8 kgf·m, 13.3 ft·lb)

Remarks  M6  25 mm M8  25 mm M6  20 mm 

Oil cooler, oil pump assy. and drive gear (FX HO, FX Cruiser HO)

Oil pump assy., idle gear assy., and drive gear assy. removal (FX SHO, FX Cruiser SHO) 1. Remove the oil pump assy.

Oil pump assy. and oil pump drive gear removal (FX HO, FX Cruiser HO) 1. Remove the oil pump assy. 2. Hold the drive coupling a using the special service tool b.

2. Remove the idle gear assy. 3. Hold the drive coupling a using the special service tool b.

Coupler wrench b: 90890-06729

Coupler wrench b: 90890-06729 4. Turn the drive gear assy. bolt c clockwise to loosen it, and then remove the drive gear assy. bolt c.

3. Turn the oil pump drive gear bolt c clockwise to loosen it, and then remove the oil pump drive gear bolt c and oil pump drive gear d.

c c

Oil cooler assy. check 5. Remove the drive gear assy. d using the special service tools e, f, and g.

f Bearing puller assy. e: 90890-06535 Stopper guide plate f: 90890-06501 Stopper guide stand g: 90890-06538

Do not disassemble the oil cooler assy. 1. Connect the hose a and special service tool b to the inlet of the oil cooler water passage. Block the oil cooler assy. outlet using the rubber plugs c. 2. Apply the specified positive pressure and check that the pressure is maintained. If the specified pressure cannot be maintained, replace the oil cooler assy.

5-60

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

b c

4. Turn the supercharger drive gear b counterclockwise b and check that it does not turn. Replace the drive gear assy. if it turns.

b a

Leakage tester b: 90890-06840 Specified positive pressure (water passage): 200 kPa (2.0 kgf/cm2, 28.5 psi)

Oil pump assy. check

Do not disassemble the oil pump assy.

a b

Drive gear assy., idle gear assy., and oil pump assy. installation (FX SHO, FX Cruiser SHO) 1. Install the drive gear assy. a, and then tighten the drive gear assy. bolt b temporarily.

1. Check that the oil pump driven gear turns smoothly. Replace the oil pump assy. if the movement is rough.

Idle gear check (FX SHO, FX Cruiser SHO) 1. Check the idle gear. Replace the idle gear assy. if cracked or worn. 2. Check the shaft. Replace if bent or worn.

2. Hold the holder c.

Drive gear assy. check (FX SHO, FX Cruiser SHO) c Do not disassemble the drive gear assy. 1. Check the oil pump drive gear a and supercharger drive gear b. Replace the drive gear assy. if cracked or worn. 2. Hold the oil pump drive gear a. 3. Turn the supercharger drive gear b clockwise a and check that it turns smoothly. Replace the drive gear assy. if it does not turn smoothly.

5-61

3. Turn the drive gear assy. bolt b counterclockwise, and then tighten it to the specified torque.

Oil cooler, oil pump assy. and drive gear (FX HO, FX Cruiser HO)

f b

g h

Drive gear assy. bolt b: 80 N·m (8.0 kgf·m, 59.0 ft·lb)

4. Install the idle gear assy. c, collar d, and shaft e.

Oil pump assy. bolt i: 11 N·m (1.1 kgf·m, 8.1 ft·lb)

Oil pump drive gear and oil pump assy. installation (FX HO, FX Cruiser HO)

d e

1. Install the oil pump drive gear a, and then tighten the oil pump drive gear bolt b temporarily.

E E

5. Fill the oil pump assy. with engine oil through the feed port a.

a b

TIP: While turning the oil pump driven gear, make sure to fill the oil pump assy. with engine oil up to the brim of the port. 6. Install the dowel pins f, a new gasket g, and the oil pump assy. h, and then tighten the oil pump assy. bolts i to the specified torque.

2. Hold the holder c.

3. Turn the oil pump drive gear bolt b counterclockwise, and then tighten it to the specified torque.

5-62

1 2 3 4 5 6 7 8 9 A

POWR

Power unit Oil pump assy. bolt g: 11 N·m (1.1 kgf·m, 8.1 ft·lb)

Oil pump drive gear bolt b: 80 N·m (8.0 kgf·m, 59.0 ft·lb) 4. Fill the oil pump assy. with engine oil through the feed port a.

TIP: While turning the oil pump driven gear, make sure to fill the oil pump assy. with engine oil up to the brim of the port. 5. Install the dowel pins d, a new gasket e, and the oil pump assy. f, and then tighten the oil pump assy. bolts g to the specified torque.

d e f d

5-63

Oil cooler, oil pump assy. and drive gear (FX HO, FX Cruiser HO) / Cylinder head cover

Cylinder head cover 10 N·m (1.0 kgf·m, 7.4 ft·lb)

4 11

2 7

2 2 2

3 3

15 13

6 N·m (0.6 kgf·m, 4.4 ft·lb)

12 9

25 N·m (2.5 kgf·m, 18.4 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Part name Bolt Ignition coil Spark plug Bolt Cam position sensor Clamp Bolt Cylinder head cover Gasket Oil filler cap O-ring Timing chain guide Bolt Collar Grommet

Q’ty 8 4 4 1 1 1 8 1 1 1 1 1 2 2 2

Remarks M6  20 mm

M6  16 mm

M6  30 mm  

A FX HO, FX Cruiser HO, M6  25 mm A FX HO, FX Cruiser HO A FX HO, FX Cruiser HO

5-64

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Camshaft (FX SHO, FX Cruiser SHO) 8

16 N·m (1.6 kgf·m, 11.8 ft·lb)

8 10 10

13 13

9 13

8 8

18 N·m (1.8 kgf·m, 13.3 ft·lb)

12 14

11 13 17

20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb)

13 13 13

16 1

15 2

2 1 5

7 18 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

5-65

21 Part name

Bolt Gasket Oil pipe Bolt Timing chain tensioner Gasket Timing chain guide Bolt Intake camshaft cap Intake camshaft cap Exhaust camshaft cap Exhaust camshaft cap Dowel pin Intake camshaft Exhaust camshaft Bolt

Q’ty 2 4 1 2 1 1 1 24 1 2 1 2 12 1 1 4

Remarks M10  21 mm  M6  25 mm  Exhaust side M7  45 mm

M7  11 mm

Camshaft (FX SHO, FX Cruiser SHO)

16 N·m (1.6 kgf·m, 11.8 ft·lb)

8 10 10

13 13

9 13

8 8

18 N·m (1.8 kgf·m, 13.3 ft·lb)

12 14

11 13 17

20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb)

13 13 13

16 1

15 2

2 1 5

7 18 No. 17 18 19 20 21

Part name Camshaft sprocket Bolt Chain guide plate Timing chain guide Timing chain

Q’ty 2 2 1 1 1

Remarks M6  30 mm Intake side

5-66

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Camshaft (FX HO, FX Cruiser HO) 8

16 N·m (1.6 kgf·m, 11.8 ft·lb)

8 10 10

13 13

9 13

8 8

18 N·m (1.8 kgf·m, 13.3 ft·lb)

12 14

11 13 17

20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb)

13 13 13

16 1

15 2

2 1 5

7 18 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

5-67

21 Part name

Q’ty 2 4 1 2 1 1 1 24 1 2 1 2 12 1 1 4

Remarks M10  21 mm  M6  25 mm  Exhaust side M7  45 mm

M7  11 mm

Camshaft (FX HO, FX Cruiser HO)

16 N·m (1.6 kgf·m, 11.8 ft·lb)

8 10 10

13 13

9 13

8 8

18 N·m (1.8 kgf·m, 13.3 ft·lb)

12 14

11 13 17

20 N·m (2.0 kgf·m, 14.8 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb)

13 13 13

16 1

15 2

2 1 5

7 18 No. 17 18 19 20 21

Part name Camshaft sprocket Bolt Chain guide plate Timing chain guide Timing chain

Q’ty 2 2 1 1 1

Remarks M6  30 mm Intake side

5-68

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Camshaft removal b a

When installing the camshafts, piston #1 must be positioned at TDC. Therefore, do not turn the crankshaft after removing the camshafts. 1. Install the special service tools into spark plug hole #1.

a c b

Coupler wrench e: 90890-06729

TIP: Make sure that the punch marks a on the camshafts are aligned with the marks b on the camshaft caps. Dial indicator gauge a: YU-03097 Dial gauge stand set b: YB-06585 Dial gauge set a: 90890-01252 Dial gauge needle b: 90890-06584 Gauge stand c: 90890-06725

3. Make marks c on the sprockets and camshafts.

camshaft

2. Position piston #1 at TDC by turning the drive coupling d counterclockwise using the special service tool e, referring to the dial gauge to ensure that the piston has reached TDC.

4. Remove the oil pipe f, gaskets g, timing chain tensioner h, and gasket i.

g e

d f g

5. Remove the timing chain guide (exhaust side).

5-69

Camshaft (FX HO, FX Cruiser HO) 6. Remove the intake camshaft caps and exhaust camshaft caps.

TIP:

Loosen the camshaft cap bolts in the opposite order used for tightening. 7. Remove the intake camshaft j and exhaust camshaft k.

k j l

TIP: Fasten the timing chain using a wire l.

b Cam lobe height a: Intake: 41.330–41.430 mm (1.627–1.631 in) Limit: 41.320 mm (1.626 in) Exhaust: 41.220–41.320 mm (1.623–1.627 in) Limit: 41.210 mm (1.622 in) Cam lobe width b: Intake and exhaust: 31.956–32.056 mm (1.258–1.262 in) 3. Measure the camshaft journal diameter.

Camshaft sprocket removal 1. Hold the camshaft sprocket using the special service tool a, and then loosen the camshaft sprocket bolts b.

Camshaft wrench a: 90890-06724 2. Remove the intake camshaft sprocket and exhaust camshaft sprocket.

Camshaft journal diameter c: Intake and exhaust: 24.960–24.980 mm (0.9827–0.9835 in) 4. Measure the camshaft runout. Replace if out of specification.

Camshaft check 1. Check the camshaft lobes. Replace if pitted or scratched. 2. Measure the cam lobe height a and width b. Replace if out of specification.

5-70

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

TIP: Do not put the Plastigauge over the oil hole in the camshaft journal. 4. Install the dowel pins d, intake camshaft caps e and f, and exhaust camshaft caps g and h.

f f Camshaft runout: 0.015 mm (0.0006 in) Limit: 0.05 mm (0.0020 in)

Camshaft journal oil clearance check

h d h

1. Remove the valve lifters a and valve pads b.

a b IN

TIP: Write down the position of each valve lifter a and valve pad b so that they can be installed in their original positions.

TIP: 2. Place the camshafts on the cylinder head. 3. Put a piece of Plastigauge c on each camshaft journal, parallel to the camshaft.

When installing the camshaft caps, make sure that the arrow marks a on the camshaft caps point toward the camshaft sprockets. 5. Tighten the camshaft cap bolts i until camshaft caps contact the cylinder head in the order a, b, and so on.

c k l k l

5-71

f h g e

g e

a b

i j

d c

f h

i j

b a

c d

Camshaft (FX HO, FX Cruiser HO)

TIP: Make sure to keep the camshafts level. 6. Tighten the camshaft cap bolts i to the specified torque in the order a, b, and so on.

2. While squeezing the ends of the snap ring e so that it fits into the groove d in the timing chain tensioner rod a, release the tensioner rod slowly until it is locked in place.

IN a b a b

c d c d

a e f

g h

i j

k l

e f

g h

i j

k l

Camshaft cap bolt i: 16 N·m (1.6 kgf·m, 11.8 ft·lb)

TIP: Do not turn the camshafts when measuring the camshaft journal oil clearance using the Plastigauge. 7. Remove the camshaft caps, and then measure the width of the Plastigauge c.

TIP: Make sure that the timing chain tensioner rod a is locked in place before releasing the snap ring e. 3. Push the timing chain tensioner rod a slightly. Check that the snap ring e releases the timing chain tensioner rod a, allowing the tensioner rod to pop out.

Camshaft sprocket installation Camshaft journal oil clearance: 0.020–0.061 mm (0.0008–0.0024 in) Limit: 0.08 mm (0.0031 in)

1. Install the exhaust camshaft sprocket and intake camshaft sprocket.

Timing chain tensioner check 1. While pushing the timing chain tensioner rod a, turn the timing chain tensioner housing b in direction c until the groove d in the tensioner rod is aligned with the snap ring e.

5-72

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

TIP: IN

• Install each camshaft sprocket with the punch mark a facing outward. • When installing an original camshaft sprocket, make sure to align the marks b made during removal.

c d

2. Hold the camshaft sprocket using the special service tool a, and then tighten the camshaft sprocket bolts b to the specified torque.

EX b

TIP: Camshaft wrench a: 90890-06724 Camshaft sprocket bolt b: 18 N·m (1.8 kgf·m, 13.3 ft·lb)

Camshaft installation 1. Position piston #1 at TDC. See “Camshaft removal” (5-69).

• Make sure that the punch marks a on the camshafts face up. • Make sure that the exhaust side b of the timing chain is taut. 5. Install the dowel pins f, intake camshaft caps g and h, and exhaust camshaft caps i and j.

h 2. Install the valve pads a and valve lifters b in their original positions.

b a

j g f

f i f

3. Install the timing chain guide (exhaust side). 4. Install the exhaust camshaft c, intake camshaft d, and timing chain e.

5-73

j f

Camshaft (FX HO, FX Cruiser HO)

8. Align the punch marks d on the camshafts with the marks e on the camshaft caps.

d EX

TIP: When installing the camshaft caps, make sure that the arrow marks c on the camshaft caps point toward the camshaft sprockets. 6. Tighten the camshaft cap bolts k until camshaft caps contact the cylinder head in the order a, b, and so on.

IN k l k l

f h g e

g e

a b

i j

d c

f h

i j

b a

c d

9. While pushing the timing chain tensioner rod f, turn the timing chain tensioner housing g in direction h until the groove k in the tensioner rod is aligned with the snap ring m. 10. While squeezing the ends of the snap ring m so that it fits into the groove k in the timing chain tensioner rod f, release the tensioner rod slowly until it is locked in place.

TIP:

Make sure to keep the camshafts level.

7. Tighten the camshaft cap bolts k to the specified torque in the order a, b, and so on.

IN a b a b

c d c d

e f

g h

i j

k l

e f

g h

i j

k l

Camshaft cap bolt k: 16 N·m (1.6 kgf·m, 11.8 ft·lb)

m m

5-74

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

11. Install a new gasket l and the timing chain tensioner m onto the cylinder head, and then tighten the timing chain tensioner bolts n temporarily.

12. Install new gaskets o and the oil pipe p to the cylinder head and timing chain tensioner m, and then tighten the oil pipe bolts q temporarily. 13. Tighten the timing chain tensioner bolts n to the specified torque. 14. Tighten the oil pipe bolts q to the specified torque.

Coupler wrench s: 90890-06729

TIP: Check that the portion n of the timing chain is taut. If the timing chain is not taut, turn the drive coupling slightly clockwise, and then check that the timing chain is taut again. 16. Position piston #1 at TDC. “Camshaft removal” (5-69).

q n p

Valve clearance adjustment l

See

Timing chain tensioner bolt n: 10 N·m (1.0 kgf·m, 7.4 ft·lb) Oil pipe bolt q: 20 N·m (2.0 kgf·m, 14.8 ft·lb) 15. Turn the drive coupling r counterclockwise 2 full turns, and then check that the camshaft turns smoothly.

1. Measure the valve clearances. See “Valve clearance measurement” (3-7). 2. Remove the camshaft caps and camshafts. See “Camshaft removal” (569). 3. Remove the valve lifters a and valve pads b.

a b

TIP: Write down the position of each valve lifter a and valve pad b so that they can be installed in their original positions. 4. Check the valve pad number a.

5-75

Camshaft (FX HO, FX Cruiser HO)

10. Measure the intake and exhaust valve clearances of the specified cylinders.

148

TIP: The thickness of each valve pad is marked in hundredths of millimeters on the side that contacts the valve lifter. 5. Round off the original valve pad number according to the following table. Last digit 0, 1, 2 4, 5, 6 8, 9

Rounded value 0 5 10

IN EX

#1 ✔ ✔

#2 — ✔

#3 ✔ —

#4 — —

✔: Specified cylinder —: Not applicable 11. Install the special service tools into spark plug hole #4.

c e d

6. Select the new valve pad number from the “Valve pad selection table” (5-78).

TIP: The valve pads are available in 23 thicknesses, ranging from 1.20 mm to 2.30 mm in 0.05 mm increments. 7. Install the selected valve pad b and valve lifter a.

Dial indicator gauge c: YU-03097 Dial gauge stand set d: YB-06585 Dial gauge set c: 90890-01252 Dial gauge needle d: 90890-06584 Gauge stand e: 90890-06725

b 12. Position piston #4 at TDC by turning the drive coupling f 360° counterclockwise using the special service tool g.

8. Turn the valve lifter and check that it turns smoothly. 9. Position piston #1 at TDC, and then install the camshafts and camshaft caps. See “Camshaft installation” (5-73).

5-76

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Coupler wrench g: 90890-06729 13. Measure the intake and exhaust valve clearances of the specified cylinders. 4

IN EX

#1 — —

#2 ✔ —

✔: Specified cylinder —: Not applicable

5-77

#3 — ✔

#4 ✔ ✔

Camshaft (FX HO, FX Cruiser HO)

Valve pad selection table Intake Measured clearance 0.00–0.02 0.03–0.06 0.07–0.10 0.11–0.13 0.14–0.23 0.24–0.26 0.27–0.31 0.32–0.36 0.37–0.41 0.42–0.46 0.47–0.51 0.52–0.56 0.57–0.61 0.62–0.66 0.67–0.71 0.72–0.76 0.77–0.81 0.82–0.86 0.87–0.91 0.92–0.96 0.97–1.01 1.02–1.06 1.07–1.11 1.12–1.16 1.17–1.21 1.22–1.26 1.27–1.31

120 125 130 135 140 120 120 125 120 125 130 120 125 130 135

145 125 130 135 140

150 130 135 140 145

155 135 140 145 150

125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

Original valve pad number 165 170 175 180 185 190 195 200 205 210 215 220 225 145 150 155 160 165 170 175 180 185 190 195 200 205 150 155 160 165 170 175 180 185 190 195 200 205 210 155 160 165 170 175 180 185 190 195 200 205 210 215 160 165 170 175 180 185 190 195 200 205 210 215 220 Standard clearance 165 170 175 180 185 190 195 200 205 210 215 220 225 230 170 175 180 185 190 195 200 205 210 215 220 225 230 175 180 185 190 195 200 205 210 215 220 225 230 180 185 190 195 200 205 210 215 220 225 230 185 190 195 200 205 210 215 220 225 230 190 195 200 205 210 215 220 225 230 195 200 205 210 215 220 225 230 200 205 210 215 220 225 230 205 210 215 220 225 230 210 215 220 225 230 215 220 225 230 220 225 230 Example: 225 230 230 Measured valve clearance is 0.29 mm (0.0114 in) 160 140 145 150 155

230 210 215 220 225

Original valve pad number is 148 (thickness = 1.48 mm) • Round off the original valve pad number 148 to 150 (thickness = 1.50 mm). • Select the new valve pad number using the valve pad selection table. New valve pad number is 160 (thickness = 1.60 mm)

Exhaust Measured clearance 0.00–0.01 0.02–0.04 0.05–0.09 0.10–0.14 0.15–0.19 0.20–0.24 0.25–0.27 0.28–0.37 0.38–0.40 0.41–0.45 0.46–0.50 0.51–0.55 0.56–0.60 0.61–0.65 0.66–0.70 0.71–0.75 0.76–0.80 0.81–0.85 0.86–0.90 0.91–0.95 0.96–1.00 1.01–1.05 1.06–1.10 1.11–1.15 1.16–1.20 1.21–1.25 1.26–1.30 1.31–1.35 1.36–1.40 1.41–1.45

120 125 130 135 140 145 150 155 120 120 125 120 125 130 120 125 130 135 120 125 130 135 140 120 125 130 135 140 145 120 125 130 135 140 145 150 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

Original valve pad number 165 170 175 180 185 190 195 200 205 210 215 220 225 130 135 140 145 150 155 160 165 170 175 180 185 190 135 140 145 150 155 160 165 170 175 180 185 190 195 140 145 150 155 160 165 170 175 180 185 190 195 200 145 150 155 160 165 170 175 180 185 190 195 200 205 150 155 160 165 170 175 180 185 190 195 200 205 210 155 160 165 170 175 180 185 190 195 200 205 210 215 160 165 170 175 180 185 190 195 200 205 210 215 220 Standard clearance 165 170 175 180 185 190 195 200 205 210 215 220 225 230 170 175 180 185 190 195 200 205 210 215 220 225 230 175 180 185 190 195 200 205 210 215 220 225 230 180 185 190 195 200 205 210 215 220 225 230 185 190 195 200 205 210 215 220 225 230 190 195 200 205 210 215 220 225 230 195 200 205 210 215 220 225 230 200 205 210 215 220 225 230 205 210 215 220 225 230 210 215 220 225 230 215 220 225 230 220 225 230 Example: 225 230 230 Measured valve clearance is 0.47 mm (0.0185 in)

160 125 130 135 140 145 150 155

230 195 200 205 210 215 220 225

Original valve pad number is 168 (thickness = 1.68 mm) • Round off the original valve pad number 168 to 170 (thickness = 1.70 mm). • Select the new valve pad number using the valve pad selection table. New valve pad number is 185 (thickness = 1.85 mm)

5-78

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Cylinder head 9

42 N·m (4.2 kgf·m, 31.0 ft·lb)

2 55 N·m (5.5 kgf·m, 40.6 ft·lb) 90°

3 2

10 N·m (1.0 kgf·m, 7.4 ft·lb)

1 9

4 A

12 N·m (1.2 kgf·m, 8.9 ft·lb)

8 5 6

No. 1 2 3 4 5 6 7 8 9 10

5-79

Part name Bolt Bolt Washer Cylinder head assy. Gasket Dowel pin Bolt Engine hanger Bolt Engine hanger

Q’ty 3 10 10 1 1 2 1 1 4 2

Remarks M6  55 mm  M12  140 mm



A FX HO, FX Cruiser HO, M10  25 mm A FX HO, FX Cruiser HO M6  12 mm

Cylinder head / Valve and valve spring

Valve and valve spring 1

1 2 3

2 3 4

4 5

5 6 9

6 9 10

8 7

No. 1 2 3 4 5 6 7 8 9 10 11

Part name Valve lifter Valve pad Valve cotter Upper spring seat Valve spring Lower spring seat Intake valve Exhaust valve Valve seal Valve guide Cylinder head

Q’ty 16 16 32 16 16 16 8 8 16 16 1

Remarks

 

5-80

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Cylinder head disassembly

3. Remove the valve seals.

1. Remove the valve lifters a and valve pads b.

Cylinder head check 1. Remove carbon deposits from the combustion chambers.

a b

2. Check the cylinder head water jacket. Clean if there are mineral deposits or rust. 3. Check the cylinder head warpage using a straightedge a and thickness gauge b in the directions shown. Replace if out of specification.

TIP: Write down the position of each valve lifter a and valve pad b so that they can be installed in their original positions.

2. Remove the intake valves and exhaust valves.

Cylinder head warpage limit: 0.10 mm (0.0039 in)

Valve spring compressor c: YM-04019/90890-04019 Compressor adapter d: YM-04114 Valve spring compressor attachment d: 90890-04114

Valve spring check 1. Measure the valve spring free length a. Replace if out of specification.

TIP: Write down the position of each valve, spring, and other parts so that they can be installed in their original positions.

5-81

Valve and valve spring Valve spring free length a: Intake and exhaust: 45.58 mm (1.79 in) Limit: 43.30 mm (1.70 in)

Valve margin thickness b: Intake and exhaust: 0.800–1.200 mm (0.0315–0.0472 in) 3. Measure the valve stem diameter c. Replace if out of specification.

2. Measure the valve spring tilt b. Replace if out of specification.

Valve stem diameter c: Intake: 5.477–5.492 mm (0.2156–0.2162 in) Limit: 5.447 mm (0.2144 in) Exhaust: 5.464–5.479 mm (0.2151–0.2157 in) Limit: 5.434 mm (0.2139 in)

Valve spring tilt limit b: Intake and exhaust: 2.0 mm (0.08 in)

Valve check 1. Measure the valve face width a.

4. Measure the valve stem runout. Replace if out of specification.

Valve face width a: Intake and exhaust: 2.260–2.830 mm (0.0890–0.1114 in) 2. Measure the valve margin thickness b.

Valve stem runout limit: Intake and exhaust: 0.01 mm (0.0004 in)

Valve guide check 1. Measure the valve guide inside diameter a.

5-82

1 2 3 4 5 6 7 8 9 A

POWR

Power unit Valve guide remover a: YB-06801 Valve guide remover/installer a: 90890-06801

Valve guide installation

1. Insert the special service tools a and b into the camshaft side of the valve guide c. NOTICE: Do not reuse a valve guide, always replace it with a new one. Valve guide inside diameter a: Intake and exhaust: 5.504–5.522 mm (0.2167–0.2174 in)

2. Strike the special service tool a to drive the valve guide into the cylinder head.

2. Calculate the valve-stem-to-valve-guide clearance. Replace the valve and valve guide if out of specification. Valve-stem-to-valve-guide clearance = valve guide inside diameter – valve stem diameter: Intake: 0.012–0.045 mm (0.0005–0.0018 in) Limit: 0.080 mm (0.0031 in) Exhaust: 0.025–0.058 mm (0.0010–0.0023 in) Limit: 0.100 mm (0.0039 in)

Valve guide removal 1. Insert the special service tool a into the combustion chamber side of the valve guide b. 2. Strike the special service tool a to drive the valve guide b out of the cylinder head.

b a c Valve guide remover a: YB-06801 Valve guide remover/installer a: 90890-06801 Valve guide installer b: YB-06810/90890-06810 Valve guide installation height a: Intake and exhaust: 12.3–12.7 mm (0.4843–0.5000 in) 3. Insert the special service tool d into the valve guide c, and then ream the valve guide c.

d a c b

Valve guide reamer d: YM-01196/90890-06804

5-83

Valve and valve spring

TIP: • Turn the special service tool d clockwise to ream the valve guide. • Do not turn the special service tool d counterclockwise when removing the tool.

4. Measure the valve seat contact width a where the blueing dye is adhered to the valve face. Reface the valve seat if the valve is not seated properly or if the valve seat contact width a is out of specification. Replace the valve guide if the valve seat contact width a is uneven.

4. Clean the valve guide inner surface. Measure the valve guide inside diameter b.

a b

Valve guide inside diameter b: Intake and exhaust: 5.504–5.522 mm (0.2167–0.2174 in)

Valve seat check 1. Remove carbon deposits from the valves and valve seats. 2. Apply a thin, even layer of Mechanic’s blueing dye (Dykem) onto the valve seat. 3. Press the valve lightly against the valve seat using the special service tool a.

Valve seat contact width a: Intake: 1.400–1.600 mm (0.0551–0.0630 in) Limit: 2.100 mm (0.0827 in) Exhaust: 1.500–1.700 mm (0.0591–0.0669 in) Limit: 2.200 mm (0.0866 in)

Valve seat refacing Valve lapping tool a: YM-A8998 Valve lapper a: 90890-04101

After every lapping procedure, make sure to clean off any remaining lapping compound from the cylinder head and valves. 1. Reface the valve seat.

5-84

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

a 30

30 45 B 30

a Slag or rough surface

A U.S.A. and Canada B Worldwide Neway valve seat kit: YB-91044 Valve seat cutter holder: 90890-06812 Intake: Valve seat cutter 30°: 90890-06720 Valve seat cutter 45°: 90890-06325 Valve seat cutter 60°: 90890-06324 Exhaust: Valve seat cutter 30°: 90890-06818 Valve seat cutter 45°: 90890-06555 Valve seat cutter 60°: 90890-06323

3. Adjust the top edge of the valve seat contact width using a 30° cutter. 30

b Previous contact width 4. Adjust the bottom edge of the valve seat contact width using a 60° cutter.

2. Cut the surface of the valve seat using a 45° cutter by turning the cutter clockwise until the valve seat face has become smooth. NOTICE: Do not over cut the valve seat. To prevent chatter marks, make sure to turn the cutter evenly using a downward force of 40–50 N (4.0–5.0 kgf, 8.8–11.0 lbf).

b Previous contact width 5. Adjust the valve seat contact width to specification using a 45° cutter.

5-85

Valve and valve spring • If the valve seat contact area is too narrow and situated near the bottom edge of the valve face, cut the bottom edge of the valve seat using a 60° cutter to center the area, and then set its width using a 45° cutter.

b c

b Previous contact width c Specified contact width

6. Check the valve seat contact area of the valve. See “Valve seat check” (5-84). Example: • If the valve seat contact area is too wide and situated in the center of the valve face, cut the top edge of the valve seat using a 30° cutter, and then cut the bottom edge using a 60° cutter to center the area and set its width.

b Previous contact width 7. After refacing the valve seat to the specified contact width, apply a thin, even layer of lapping compound onto the valve seat, and then lap the valve using the special service tool a. NOTICE: Do not get the lapping compound on the valve stem and valve guide.

30 b

60 b Previous contact width • If the valve seat contact area is too narrow and situated near the top edge of the valve face, cut the top edge of the valve seat using a 30° cutter to center the area, and then set its width using a 45° cutter.

Valve lapping tool a: YM-A8998 Valve lapper a: 90890-04101 8. Recheck the valve seat contact area of the valve. See “Valve seat check” (5-84).

Cylinder head assembly b

1. Install a new valve seal. 2. Install the valve a, valve spring seat b, valve spring c, and valve spring retainer d in this order, and then install the special service tools e and f.

b Previous contact width

5-86

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

d c b

g f

4. Tap the valve spring retainer lightly using a plastic hammer to seat the valve cotters g securely.

e a

c a

c g

Valve spring compressor e: YM-04019/90890-04019 Compressor adapter f: YM-04114 Valve spring compressor attachment f: 90890-04114

TIP: â&#x20AC;˘ When installing a new valve, always replace the valve guide with a new one. â&#x20AC;˘ Install the valve spring with the larger pitch a toward the camshaft and the smaller pitch b toward the combustion chamber. â&#x20AC;˘ The upper end c of the valve spring with the larger pitch is painted red. 3. Compress the valve spring, and then install the valve cotters g.

5-87

5. Install the valve pads h and valve lifters i in their original positions.

i h

Valve and valve spring

Cylinder head installation 1. Install the dowel pins a, a new gasket b, the cylinder head assy. c, the washers d, and the cylinder head bolts e, and then tighten the cylinder head bolts e to the specified torques in 2 stages and in the order a, b, and so on. 2. Install the cylinder head bolts f, and then tighten them to the specified torque.

e d

Cylinder head bolt e (M12): 1st: 55 N·m (5.5 kgf·m, 40.6 ft·lb) 2nd: 90° Cylinder head bolt f (M6): 10 N·m (1.0 kgf·m, 7.4 ft·lb)

5-88

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Generator cover assy. and flywheel magneto 12 7 11

6 5

4 8

19 7

2 26 N·m (2.6 kgf·m, 19.2 ft·lb)

250 N·m (25.0 kgf·m, 184.4 ft·lb) 80 N·m (8.0 kgf·m, 59.0 ft·lb)

24 N·m (2.4 kgf·m, 17.7 ft·lb)

15 16 15 50 N·m (5.0 kgf·m, 36.9 ft·lb) 60° 250 N·m (25.0 kgf·m, 184.4 ft·lb)

13 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

5-89

Part name Holder Drive coupling Washer Holder Bolt Collar Grommet Bolt Gasket Dowel pin Shaft Idle gear Transfer shaft Special nut Bolt Flywheel magneto

Q’ty 1 1 1 1 2 2 2 9 1 2 1 1 1 1 6 1

250 N·m (25.0 kgf·m, 184.4 ft·lb)

Remarks Left-hand threads  M6  20 mm

M8  50 mm 

   M8  20 mm 

Generator cover assy. and flywheel magneto

12 7 11

6 5

4 8

19 7

2 26 N·m (2.6 kgf·m, 19.2 ft·lb)

250 N·m (25.0 kgf·m, 184.4 ft·lb) 80 N·m (8.0 kgf·m, 59.0 ft·lb)

24 N·m (2.4 kgf·m, 17.7 ft·lb)

15 16 15

13 No. 17 18 19

50 N·m (5.0 kgf·m, 36.9 ft·lb) 60° 250 N·m (25.0 kgf·m, 184.4 ft·lb)

Part name Starter clutch assy. Starter gear Woodruff key

Q’ty 1 1 1

250 N·m (25.0 kgf·m, 184.4 ft·lb)

Remarks



5-90

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Generator cover

8 15 N·m (1.5 kgf·m, 11.1 ft·lb)

15 N·m (1.5 kgf·m, 11.1 ft·lb)

9 10

1 7

5 4 11 3 6 3 No. 1 2 3 4 5 6 7 8 9 10 11

5-91

Part name Bolt Holder Bolt Bolt Washer Bolt Stator coil assy. Oil seal Circlip Ball bearing Generator cover

Q’ty 2 1 2 1 1 3 1 1 1 1 1

Remarks M6  15 mm M5  15 mm M5  10 mm M6  30 mm  

Generator cover

Drive coupling removal

Use heat-resistant burns could result.

gloves.

Otherwise,

1. Heat the holder a and drive coupling b for 20â&#x20AC;&#x201C;30 minutes using a heat gun c. NOTICE: Be careful not to damage the wiring harness when using the heat gun.

d b

b a

2. Hold the drive coupling b using the special service tool d, and then loosen the holder a by turning it clockwise.

Coupler wrench d: 90890-06729 Crankshaft holder f: 90890-06732

Flywheel magneto removal

Use heat-resistant burns could result.

gloves.

Otherwise,

1. Remove the generator cover assy. 2. Heat the transfer shaft assy. a for 20â&#x20AC;&#x201C;30 minutes using a heat gun b.

d b d

a b Coupler wrench d: 90890-06729

3. Hold the flywheel magneto c using the special service tools d and e, and then loosen the special nut f.

3. Hold the transfer shaft e using the special service tool f, and then remove the drive coupling b using the special service tool d.

5-92

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

e g

h d

c d

d h

TIP: â&#x20AC;˘ Loosen the special nut f until it can no longer be turned. â&#x20AC;˘ Use a width across flats 12 mm hexagon bit socket g with a length of 150 mm (5.91 in) or more.

c Shaft holder d: 90890-06721 Driver handle e: 90890-06722

Shaft holder d: 90890-06721 Driver handle e: 90890-06722 Crankshaft holder h: 90890-06732 5. Remove the flywheel magneto c and Woodruff key using the special service tools i and j.

c i

4. Hold the flywheel magneto c using the special service tools d and e, and then remove the transfer shaft assy. a using the special service tool h.

Flywheel puller i: 90890-06723 Rotor puller j: 90890-01080 6. Hold the flywheel magneto c using the special service tool k, and then loosen the starter clutch bolts l.

5-93

Generator cover

i k l

Primary sheave holder k: YS-01880-A Sheave holder k: 90890-01701

7. Remove the starter clutch.

Generator cover assy. disassembly 1. Remove the washer a, pickup coil b, holder c, and stator coil assy. d.

A U.S.A. and Canada B Worldwide Driver handle (small) h: YB-06229 Bearing and seal installer i: YW-06356 Driver rod LS j: 90890-06606 Bearing outer race attachment k: 90890-06627

Starter clutch operation check 1. Install the starter clutch a onto the starter gear b and hold the starter clutch a.

b 2. Remove the oil seal e and circlip f.

e f

2. Turn the starter gear b clockwise a and check that it turns smoothly. Replace if it does not turn smoothly. 3. Turn the starter gear b counterclockwise b and check that it does not turn. Replace if it turns.

3. Remove the ball bearing g.

b a a

5-94

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Generator cover assy. assembly

1. Install a new ball bearing a.

b h

b c

a A E

B B

d e

a A E

A U.S.A. and Canada B Worldwide A U.S.A. and Canada B Worldwide Driver handle (large) b: YB-06071 Forward gear outer race installer c: YB-41446 Driver rod LS d: 90890-06606 Ball bearing attachment e: 90890-06657 2. Install the circlip f.

Driver handle (large) b: YB-06071 Forward bearing race installer h: YB-06258 Bearing pressure C i: 90890-02393 4. Install the stator coil assy. j, holder k, pickup coil l, and washer m, and then tighten the holder bolts n and stator coil assy. bolts o to the specified torques.

o o j

l b

l k

3. Install a new oil seal g.

m Holder bolt n: 15 N·m (1.5 kgf·m, 11.1 ft·lb) Stator coil assy. bolt o: 15 N·m (1.5 kgf·m, 11.1 ft·lb)

5-95

Generator cover

TIP: Pass the pickup coil lead a between the generator cover and the bolt hole b, and then secure the lead by installing the washer m.

3. Install the flywheel magneto b to the starter gear e.

Flywheel magneto installation b Do not reuse a flywheel magneto, special nut, flywheel magneto bolt, transfer shaft, or woodruff key, always replace it with a new one. 1. Install the starter clutch a to a new flywheel magneto b. NOTICE: Make sure that the starter clutch is installed into the outer flange so that the side a is facing toward the flywheel magneto.

TIP: Turn the starter gear e clockwise while installing it onto the flywheel magneto b. 4. Remove any grease from a new special nut f and the inner surface of a new transfer shaft g, and then install the special nut f into the transfer shaft g until it can no longer be turned.

b 2. Hold the flywheel magneto b using the special service tool c, and then tighten new flywheel magneto bolts d to the specified torque.

d d

f g 5. Clean the tapered portion b of the crankshaft and inner surface c of the flywheel magneto b. 6. Install a new Woodruff key h and the flywheel magneto b.

c d

Primary sheave holder c: YS-01880-A Sheave holder c: 90890-01701 Flywheel magneto bolt d: 24 N·m (2.4 kgf·m, 17.7 ft·lb)

5-96

1 2 3 4 5 6 7 8 9 A

POWR

Power unit Shaft holder i: 90890-06721 Driver handle j: 90890-06722 Crankshaft holder k: 90890-06732

h h b

Transfer shaft g: 50 N·m (5.0 kgf·m, 36.9 ft·lb) 9. Using the hexagonal portion of the special service tool k as reference, mark the special service tool i at 0°, 60°, and 120°.

10. Make a mark d on the transfer shaft g where the shaft is aligned with the 0° mark on the special service tool i.

b 7. Install the transfer shaft g.

d 0° 60°

120°

60°

g k 8. Hold the flywheel magneto b using the special service tools i and j, and then tighten the transfer shaft g to the specified torque using the special service tool k.

Shaft holder i: 90890-06721 Crankshaft holder k: 90890-06732

TIP: The angle from one corner of the hexagonal head of the special service tool k to another corner is 60°.

i g k j

11. Hold the flywheel magneto b using the special service tools i and j, and then tighten the transfer shaft g to the specified angle using the special service tool k.

b i

i g k j

5-97

Generator cover

60°

j k Shaft holder i: 90890-06721 Driver handle j: 90890-06722 Crankshaft holder k: 90890-06732

Transfer shaft g: 60° 12. Tighten the transfer shaft g to the specified torque using the special service tool k. NOTICE: If the mark d on the transfer shaft g moves past the 120° mark on the special service tool i before the specified torque is reached, repeat the procedure from step 5.

f b Shaft holder i: 90890-06721 Driver handle j: 90890-06722 Special nut f: 250 N·m (25.0 kgf·m, 184.4 ft·lb)

d 60°

j OK

120° k Shaft holder i: 90890-06721 Driver handle j: 90890-06722 Crankshaft holder k: 90890-06732

TIP: Use a width across flats 12 mm hexagon bit socket l with a length of 150 mm (5.91 in) or more. 14. Install the idle gear. 15. Install the dowel pins m, a new gasket n, and the generator cover o, and then tighten the generator cover assy. bolts p to the specified torque.

Transfer shaft g: 250 N·m (25.0 kgf·m, 184.4 ft·lb)

o 13. Hold the flywheel magneto b using the special service tools i and j, and then tighten the special nut f to the specified torque. NOTICE: To allow the LOCTITE 648 to set, wait approximately 1 hour after completing this procedure.

m n p

5-98

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Generator cover assy. bolt p: 26 N·m (2.6 kgf·m, 19.2 ft·lb)

Drive coupling installation

4. Remove any grease from the threaded portion of the holder e. 5. Install the holder e.

1. Remove any grease from the threaded portion of the transfer shaft, making sure that the threads are clean and dry. 2. Install a new washer a and the drive coupling b. NOTICE: Do not reuse a washer, always replace it with a new one.

e 6. Hold the drive coupling b using the special service tool d, and then turn the holder e counterclockwise to tighten it to the specified torque. NOTICE: To allow the LOCTITE 648 to set, wait approximately 1 hour after completing this procedure.

3. Hold the transfer shaft using the special service tool c, and then tighten the drive coupling b to the specified torque using the special service tool d.

b d c

b d

c Coupler wrench d: 90890-06729 Holder e: 80 N·m (8.0 kgf·m, 59.0 ft·lb) Crankshaft holder c: 90890-06732 Coupler wrench d: 90890-06729 Drive coupling b: 250 N·m (25.0 kgf·m, 184.4 ft·lb)

5-99

Generator cover / Cylinder block and electrical part (FX SHO, FX Cruiser SHO)

Cylinder block and electrical part (FX SHO, FX Cruiser SHO)

4 5

2 1

6 17

18 14

15 N·m (1.5 kgf·m, 11.1 ft·lb)

12 11

16 15 20 N·m (2.0 kgf·m, 14.8 ft·lb)

15 N·m (1.5 kgf·m, 11.1 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Bolt Earth plate Gasket Clamp Oil return hose Bolt Thermoswitch Bolt Anode assy. Bolt Gasket Cover Grommet Anode Engine temperature sensor Gasket

Q’ty 2 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1

Remarks M6  25 mm 

M6  16 mm M8  40 mm M6  20 mm 



5-100

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

4 5

2 1

6 17

18 14

15 N·m (1.5 kgf·m, 11.1 ft·lb)

12 11

16 15 20 N·m (2.0 kgf·m, 14.8 ft·lb)

15 N·m (1.5 kgf·m, 11.1 ft·lb)

No. 17 18

5-101

Part name Holder Knock sensor

Q’ty 1 1

Remarks

Cylinder block and electrical part (FX SHO, FX Cruiser SHO) / Cylinder block and electrical part (FX HO, FX Cruiser HO)

Cylinder block and electrical part (FX HO, FX Cruiser HO) 11 N·m (1.1 kgf·m, 8.1 ft·lb)

6 14

19 N·m (1.9 kgf·m, 14.0 ft·lb)

7 16 9 3

2 18 17

11 12 25

23 22

27 26 19 15 N·m (1.5 kgf·m, 11.1 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Bolt Earth plate Gasket Clamp Oil return hose Oil level gauge Bolt Bolt Oil level pipe assy. Clamp Oil level pipe plate Grommet O-ring Bolt Plate Gasket

20 N·m (2.0 kgf·m, 14.8 ft·lb)

Q’ty 2 1 1 2 1 1 4 2 1 1 1 1 1 2 1 1

Remarks M6  25 mm 

M8  20 mm M6  12 mm

 M6  16 mm 

5-102

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

11 N·m (1.1 kgf·m, 8.1 ft·lb)

6 14

19 N·m (1.9 kgf·m, 14.0 ft·lb)

7 16 9 3

2 18 17

11 12 25

23 22

27 26 19 15 N·m (1.5 kgf·m, 11.1 ft·lb)

No. 17 18 19 20 21 22 23 24 25 26 27

5-103

Part name Bolt Thermoswitch Bolt Anode assy. Bolt Gasket Cover Grommet Anode Engine temperature sensor Gasket

20 N·m (2.0 kgf·m, 14.8 ft·lb)

Q’ty 2 1 1 1 1 1 1 1 1 1 1

Remarks M6  16 mm M8  40 mm M6  20 mm 



Cylinder block and electrical part (FX HO, FX Cruiser HO) / Oil separator tank and oil pan

Oil separator tank and oil pan 5 8

9 10

7 3

4 6

9 N·m (0.9 kgf·m, 6.6 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb)

12 18 28

20 N·m (2.0 kgf·m, 14.8 ft·lb)

a 0.3 N·m (0.03 kgf·m, 0.2 ft·lb) b 12 N·m (1.2 kgf·m, 8.9 ft·lb) 16

9 N·m (0.9 kgf·m, 6.6 ft·lb)

24 26

22 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

25 23 Part name

Bolt Oil pressure switch Plastic tie Clamp Cooling water hose Clamp Breather hose Bolt Water jacket cover Gasket Bolt Bolt Oil separator tank cover Gasket Bolt Bolt

10 N·m (1.0 kgf·m, 7.4 ft·lb)

Q’ty 1 1 1 1 1 1 1 9 1 1 9 2 1 1 17 1

A Remarks

M4  8 mm

M6  25 mm  M6  20 mm M6  14 mm  M6  35 mm M6  20 mm

5-104

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

5 8

9 10

7 3

4 6

9 N·m (0.9 kgf·m, 6.6 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb)

12 18 28

20 N·m (2.0 kgf·m, 14.8 ft·lb)

a 0.3 N·m (0.03 kgf·m, 0.2 ft·lb) b 12 N·m (1.2 kgf·m, 8.9 ft·lb) 16

9 N·m (0.9 kgf·m, 6.6 ft·lb)

24 26

22 No. 17 18 19 20 21 22 23 24 25 26 27 28

5-105

25 23 Part name

Oil pan Dowel pin Bolt Baffle plate Bolt Bolt Washer Oil pipe Gasket Grommet Oil pan plug Gasket

10 N·m (1.0 kgf·m, 7.4 ft·lb)

Q’ty 1 2 6 1 1 2 2 1 1 1 1 1

A Remarks

M6  14 mm M6  14 mm M6  60 mm

 M8  20 mm 

Oil separator tank and oil pan

Anode check 1. Check the anode. Replace if eroded. Clean if there is grease, oil, or scales. NOTICE: Do not apply grease, oil, or paint to the anode.

Oil pan assembly

5. Install the baffle plate g, and then tighten the baffle plate bolts h to the specified torque. 6. Install a new gasket i and the oil pan plug j, and then tighten the oil pan plug j to the specified torque.

1. Install the grommet a onto the oil pipe b.

2. Install a new gasket c, the oil pipe b, and the washers d, and then tighten the oil pipe stay bolts e temporarily.

Baffle plate bolt h: 12 N·m (1.2 kgf·m, 8.9 ft·lb) Oil pan plug j: 20 N·m (2.0 kgf·m, 14.8 ft·lb)

Oil level pipe installation (FX HO, FX Cruiser HO) e

1. Pass the clamp a through the oil level pipe b.

3. Tighten the oil pipe bolt f to the specified torque for the 1st stage. 4. Tighten the oil pipe stay bolts e to the specified torque, and then tighten the oil pipe bolt f to the specified torque for the 2nd stage.

2. Install the oil level pipe plate c, the grommet d, and a new O-ring e onto the oil level pipe b.

a c

e b

f e

Installation distance a: 42.5 mm (1.67 in)

TIP: Oil pipe stay bolt e: 9 N·m (0.9 kgf·m, 6.6 ft·lb) Oil pipe bolt f: 1st: 0.3 N·m (0.03 kgf·m, 0.2 ft·lb) 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)

Make sure that the bottom of the grommet d is at the specified installation distance a from the end of the oil level pipe b.

5-106

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

3. Install the oil level pipe assy. onto the cylinder block, and then tighten the oil level pipe plate bolts f and oil level pipe bolt g temporarily.

4. Tighten the oil level pipe plate bolts f to the specified torque. 5. Tighten the oil level pipe bolt g.

g c

d c i

h Oil level pipe bolt g: 19 NÂˇm (1.9 kgfÂˇm, 14.0 ftÂˇlb) 6. Fasten the grommet d using the clamp a.

a d

Oil separator tank cover installation 1. Install a new gasket a and the oil separator tank cover b, and then tighten the oil separator tank cover bolts c and d in the order a, b, and so on.

5-107

a d e

Oil separator tank and oil pan / Crankcase, connecting rod, and piston

Crankcase, connecting rod, and piston A

50 N·m (5.0 kgf·m, 36.9 ft·lb)

5 14

51 N·m (5.1 kgf·m, 37.6 ft·lb) 90°

7 8

14 15 16

4 23

19 20 17 2 19

19 20

18 17

10 N·m (1.0 kgf·m, 7.4 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Bolt Bolt Crankcase Nut Connecting rod assy. Connecting rod bearing Bolt Piston pin clip Piston pin Piston Piston Piston ring set Crankshaft Crankshaft bearing O-ring Dowel pin

Q’ty 12 10 1 8 4 8 8 8 4 4 4 4 1 10 1 1

22 21 17

1 10 N·m (1.0 kgf·m, 7.4 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 90°

Remarks M6  70 mm  M10  85 mm

 M9  50 mm 

A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO



5-108

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

50 N·m (5.0 kgf·m, 36.9 ft·lb)

5 14

51 N·m (5.1 kgf·m, 37.6 ft·lb) 90°

7 8

14 15 16

4 23

19 20 17 2 19

19 20

18 17

10 N·m (1.0 kgf·m, 7.4 ft·lb)

No. 17 18 19 20 21 22 23

5-109

Part name Bolt Bracket Dowel pin Bracket Bolt Baffle plate Cylinder block

Q’ty 12 2 8 2 1 1 1

22 21 17

1 10 N·m (1.0 kgf·m, 7.4 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 90°

Remarks M10  30 mm

M6  12 mm

Crankcase, connecting rod, and piston

Crankcase disassembly

Connecting rod and piston removal

1. Place the crankcase upside down on a bench.

1. Remove the connecting rod cap a, and then remove the connecting rod bearings b and piston and connecting rod c.

2. Loosen the crankcase bolts in the opposite order used for tightening.

a a b

TIP: The numbers embossed on the crankcase indicate the crankcase tightening order.

3. Remove the crankcase a.

a a

TIP: â&#x20AC;˘ Insert a flat-head screwdriver between the reinforced portions a of the cylinder block b and the crankcase a to separate them. â&#x20AC;˘ Work carefully and make sure that the cylinder block and crankcase separate evenly. 4. Remove the crankshaft bearings c from the crankcase.

TIP: For reference during installation, make identification marks a on the connecting rod cap, connecting rod, connecting rod bearings, and piston crown. 2. Remove the piston pin clips d, piston pin e, connecting rod c, and connecting rod bolts f.

c f c

f e

TIP: Write down the position of each crankshaft bearing so that it can be installed in its original position.

3. Remove the piston rings.

5-110

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

Crankcase check 1. Check the oil passages. Blow out using compressed air if there are obstructions.

Cylinder block check 1. Measure the cylinder bore (D1–D6) at measuring points a, b, and c, and in direction d (D1, D3, D5), which is parallel to the crankshaft, and direction e (D2, D4, D6), which is at a right angle to the crankshaft. Replace the crankcase assy. if out of specification.

a 20 mm (0.79 in) b 50 mm (1.97 in) c 80 mm (3.15 in) Cylinder bore (D1–D6): 86.000–86.015 mm (3.3858–3.3864 in) Limit: 86.100 mm (3.3898 in)

Piston check 1. Measure the piston diameter a.

A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO 2. Measure the piston pin boss bore diameter c. Replace if out of specification.

c e d

Piston pin boss bore diameter c: 22.004–22.015 mm (0.8663–0.8667 in) Limit: 22.045 mm (0.8679 in)

TIP: When measuring the piston pin boss bore diameter c, do not measure it at the oil grooves d or piston pin slot e.

Piston clearance check 1. Measure the piston diameter. See “Piston check” (5-111). 2. Measure the cylinder bore. See “Cylinder block check” (5-111).

a b

3. Calculate the piston clearance. Replace the piston or cylinder block if out of specification. Piston clearance = maximum cylinder bore – piston outside diameter: 0.070–0.100 mm (0.0028–0.0039 in) Limit: 0.200 mm (0.0079 in)

Piston diameter a: 85.915–85.930 mm (3.3825–3.3831 in) Measuring point b: A : 10 mm (0.39 in) B : 9.5 mm (0.37 in)

5-111

Piston ring check 1. Measure piston ring dimensions B and T. Replace the piston rings as a set if out of specification.

Crankcase, connecting rod, and piston

a B

B T

g c

T Piston ring dimensions: Top ring a: B: 1.170–1.190 mm (0.0461–0.0469 in) T: 2.850–3.050 mm (0.1122–0.1201 in) 2nd ring b: B: 1.170–1.190 mm (0.0461–0.0469 in) T: 2.600–2.800 mm (0.1024–0.1102 in) Oil ring c: B: 2.370–2.470 mm (0.0933–0.0972 in) T (reference data): 2.500 mm (0.0984 in)

Piston ring groove: Top ring f: 1.210–1.230 mm (0.0476–0.0484 in) 2nd ring g: 1.210–1.230 mm (0.0476–0.0484 in) Oil ring h: 2.510–2.530 mm (0.0988–0.0996 in) 4. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification.

2. Measure the piston ring end gap d.

k m n

d e Piston ring end gap d: Top ring: 0.300–0.450 mm (0.0118–0.0177 in) Limit: 0.700 mm (0.0276 in) 2nd ring: 0.450–0.600 mm (0.0177–0.0236 in) Limit: 0.850 mm (0.0335 in) Oil ring: 0.100–0.350 mm (0.0039–0.0138 in) Measuring point e: 6 mm (0.24 in) 3. Measure the piston ring grooves.

Piston ring side clearance: Top ring k: 0.020–0.060 mm (0.0008–0.0024 in) Limit: 0.110 mm (0.0043 in) 2nd ring m: 0.020–0.060 mm (0.0008–0.0024 in) Limit: 0.120 mm (0.0047 in) Oil ring n: 0.040–0.160 mm (0.0016–0.0063 in)

Piston pin check 1. Measure the piston pin outside diameter a at measuring points b, c, and d, and in directions e and f. Replace if out of specification.

5-112

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

d b Piston pin outside diameter a: 21.991–22.000 mm (0.8658–0.8661 in) Limit: 21.981 mm (0.8654 in)

Connecting rod check 1. Measure the connecting rod small end inside diameter a. Replace the connecting rod assy. if out of specification.

Crankshaft journal diameter a: 39.976–40.000 mm (1.5739–1.5748 in) Crankshaft pin diameter b: 41.976–42.000 mm (1.6526–1.6535 in) 2. Measure the crankshaft runout. Replace if out of specification.

Connecting rod small end inside diameter a: 22.015–22.028 mm (0.8667–0.8672 in)

Crankshaft check 1. Measure the crankshaft journal diameter a and crankshaft pin diameter b.

Crankshaft runout limit: 0.03 mm (0.0012 in)

Crankshaft pin oil clearance check 1. Clean the connecting rod bearings a and connecting rod big end. 2. Install the upper bearing into the connecting rod b and lower bearing into the connecting rod cap c.

5-113

Crankcase, connecting rod, and piston Connecting rod nut: 1st: 51 N·m (5.1 kgf·m, 37.6 ft·lb) 2nd: 90°

a b B

b b a 5B

TIP: • Install the connecting rod bearings a in their original positions. • Fit the protrusion a on each bearing into the slots b in the connecting rod cap c and connecting rod b. 3. Put a piece of Plastigauge d on the crankshaft pin, parallel to the crankshaft.

TIP: • When checking the oil clearance, reuse the removed connecting rod bolts. • Make sure that the “Y” mark c on the connecting rod faces toward the timing chain drive gear d of the crankshaft. • Make sure that the characters e on the connecting rod cap and connecting rod are aligned. • Do not turn the connecting rod until the crankshaft pin oil clearance measurement has been completed. 6. Remove the connecting rod cap and measure the width f of the compressed Plastigauge on each crankshaft pin. Replace the connecting rod bearings if out of specification.

TIP: Do not put the Plastigauge d over the oil hole in the crankshaft pin. 4. Install the connecting rod onto the crankshaft pin. 5. Tighten the connecting rod nuts to the specified torques in 2 stages.

e d

Crankshaft pin oil clearance: 0.020–0.056 mm (0.0008–0.0022 in) Limit: 0.09 mm (0.0035 in)

Connecting rod big end side clearance check 1. Measure the connecting rod big end side clearance a. Measure the connecting rod big end width b and crankshaft pin width c if out of specification.

5-114

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

5B a

2. Check the crankshaft pin size number b on the crankshaft web.

P1 P2 P3 P4 P

3. Select the suitable color c for the connecting rod bearing from the table.

c b

Connecting rod big end side clearance: a 0.160–0.262 mm (0.0063–0.0103 in) Limit: 0.5 mm (0.0197 in) Connecting rod big end width: b 26.788–26.840 mm (1.0547–1.0566 in) Crankshaft pin width: c 27.000–27.050 mm (1.0630–1.0649 in)

Connecting rod bearing selection 1. Check the connecting rod size number a on the connecting rod.

Calculation formula: Connecting rod bearing size number = connecting rod size number a – crankshaft pin size number b Bearing size numBearing color c ber 1 Brown 2 Black 3 Blue 4 Green Example: “P1” connecting rod size number “5” “P1” crankshaft pin size number “1” 5–1=4

5-115

Crankcase, connecting rod, and piston Select the size “4”, “Green” connecting rod bearing.

Crankshaft journal oil clearance check 1. Clean the crankshaft bearings, crankshaft journals, and bearing portions of the crankcase and cylinder block.

TIP: Do not put the Plastigauge b over the oil hole in the main journals of the crankshaft. 6. Install the crankcase c and crankcase bolts d, and then tighten the crankcase bolts d to the specified torques in 2 stages and in the order a, b, and so on.

2. Place the cylinder block upside down on a bench.

d c

3. Install the crankshaft bearings a into the cylinder block and crankcase.

a a

TIP: • Install the crankshaft bearings a in their original positions. • Fit the protrusion a on each bearing into the slots b in the cylinder block and crankcase.

4. Install the crankshaft. 5. Put a piece of Plastigauge b on each crankshaft journal, parallel to the crankshaft.

Crankcase bolt d: 1st: 30 N·m (3.0 kgf·m, 22.1 ft·lb) 2nd: 90°

TIP: • When checking the journal oil clearance, reuse the removed crankcase bolts. • Do not turn the crankshaft until the journal oil clearance measurement has been completed.

5-116

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

7. Install the crankcase bolts e, and then tighten them to the specified torque in the order a, b, and so on.

J1 J2 J3 J4 J5 k

c i

TIP: e

If the crankcase journal sizes are the same at all positions, the size number a is stamped only at the “J1” position. Example: If “J1”–“J5” are different:

Crankcase bolt e: 10 N·m (1.0 kgf·m, 7.4 ft·lb) 8. Remove the crankcase and measure the width c of the compressed Plastigauge on each crankshaft journal. Replace the crankshaft bearings if out of specification.

J1 J2 J3 J4 J5 5 5 5 4 5

55545 If “J1”–“J5” are the same:

J1 J2 J3 J4 J5 5 5 5 5 5 c

5 Crankshaft journal oil clearance: 0.024–0.053 mm (0.0009–0.0021 in) Limit: 0.10 mm (0.0039 in)

Crankshaft bearing selection 1. Check the crankcase journal size number a on the crankcase.

5-117

2. Check the crankshaft journal number b on the crankshaft web.

size

Crankcase, connecting rod, and piston

J1 J2 J3 J4 J5 b

2. Assemble the connecting rod b, piston c, piston pin d, and new piston pin clips e. NOTICE: Do not reuse a connecting rod cap bolt or piston pin clip, always replace it with a new one.

e J1

3. Select the suitable color c for the crankshaft bearing from the table.

e c

c Calculation formula: Main bearing size number = crankcase journal size number a – crankshaft journal size number b Bearing size numBearing color c ber 1 Brown 2 Black 3 Blue 4 Green 5 Yellow Example: “J1” crankcase journal size number “5” “J1” crankshaft journal size number “2” 5–2=3 Select the size “3”, “Blue” main bearing.

TIP: • When installing the connecting rod to the piston, make sure that the “Y” mark a on the connecting rod faces toward the front mark b on the piston crown. • Do not allow the piston pin clip ends to align with the piston pin slot c. 3. Install the oil ring f, 2nd ring g, and top ring h. NOTICE: Do not scratch the pistons or break the piston rings. 4. Offset the piston ring end gaps.

f #5

Connecting rod and piston installation

#4 #3 g #2

1. Install new connecting rod cap bolts a to the connecting rod b.

#1 #5

#1 #4 h

5-118

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

TIP:

• Make sure to install the piston rings so that the “1T” mark on the top ring h and the “2T” mark on the 2nd ring g face up. • After installing the piston rings, make sure that they move smoothly.

Make sure that the “Y” mark on the connecting rod faces toward the timing chain drive gear of the crankshaft. 8. Install half of the crankshaft bearings m into the cylinder block.

5. Clean the connecting rod bearings i and connecting rod big end.

f m

6. Install the upper bearing into the connecting rod b and lower bearing into the connecting rod cap j.

b i

TIP:

j e d

TIP: • Install the connecting rod bearings i in their original positions. • Fit the protrusion d on each bearing into the slots e in the connecting rod cap j and connecting rod b.

• Install the crankshaft bearings in their original positions. • Fit the protrusion f on each bearing into the slots g in the cylinder block. 9. Install the crankshaft. 10. Install the connecting rod cap j onto the piston and connecting rod assy., and then tighten the connecting rod nuts n to the specified torques in 2 stages.

7. While compressing the piston rings using the special service tool k, install the piston and connecting rod assy. l into the cylinder.

h k l

Piston ring compressor k: YM-08037/90890-05158

5-119

Connecting rod nut n: 1st: 51 N·m (5.1 kgf·m, 37.6 ft·lb) 2nd: 90°

TIP: Make sure that the characters h on the connecting rod cap j and connecting rod assy. are aligned.

Crankcase, connecting rod, and piston

Crankcase assembly 1. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 2. Install half of the crankshaft bearings a into the crankcase.

5. Install the crankcase d and new crankcase bolts e, and then tighten the crankcase bolts e to the specified torques in 2 stages and in the order a, b, and so on. NOTICE: Do not reuse a crankcase bolt, always replace it with a new one.

a b

TIP: • Install the crankshaft bearings a in their original positions. • Fit the protrusion a on each bearing into the slots b in the crankcase. 3. Install the dowel pin b and a new O-ring c.

c b

4. Apply sealant to the mating surface of the crankcase.

Crankcase bolt e: 1st: 30 N·m (3.0 kgf·m, 22.1 ft·lb) 2nd: 90° 6. Install the crankcase bolts f, and then tighten them to the specified torque in the order a, b, and so on.

5-120

1 2 3 4 5 6 7 8 9 A

POWR

Power unit

c i

Crankcase bolt f: 10 N·m (1.0 kgf·m, 7.4 ft·lb)

5-121

JET PUMP

Jet pump unit Intake grate and ride plate ................................................ 6-1 Jet pump unit ..................................................................... 6-2 Jet pump unit removal ............................................................... 6-4 Jet pump unit installation ........................................................... 6-5

Reverse gate ...................................................................... 6-7 Nozzle and nozzle ring ...................................................... 6-8 Impeller housing and impeller duct assy. ....................... 6-9 Impeller, drive shaft, and impeller duct ........................ 6-10 Impeller duct assy. disassembly .............................................. 6-11 Impeller housing check ............................................................ 6-12 Drive shaft check ..................................................................... 6-12 Impeller duct assy. assembly .................................................. 6-12 Impeller duct, impeller housing, and nozzle installation .......... 6-14

Transom plate and hoses ............................................... 6-15 Bilge and hoses ............................................................... 6-17 Bilge strainer check ................................................................. 6-19 Electric bilge pump strainer check ........................................... 6-19 Transom plate installation ....................................................... 6-19

Intermediate housing ...................................................... 6-20 Intermediate housing assy. removal ........................................ 6-22 Intermediate housing assy. disassembly ................................. 6-22 Intermediate housing assy. assembly ..................................... 6-23 Intermediate housing assy. installation ................................... 6-24

1 2 3 4 5 6 7 8 9 A

JET PUMP

Jet pump unit

Intake grate and ride plate

6 10 6

10 4

4 5

9 7

1 2

4 1

4 4 No. 1 2 3 4 5 6 7 8 9 10

6-1

17 N·m (1.7 kgf·m, 12.5 ft·lb)

Part name Screw Speed and water temperature sensor Speed sensor Bolt Ride plate Bracket Spacer Intake grate Bracket Bracket

Q’ty 4 1 1 10 1 2 1 1 1 2

4 N·m (0.4 kgf·m, 3.0 ft·lb)

Remarks M5  12 mm A FX Cruiser SHO B FX SHO, FX HO, FX Cruiser HO M8  35 mm

Intake grate and ride plate / Jet pump unit

Jet pump unit 15

15 N·m (1.5 kgf·m, 11.1 ft·lb)

17 N·m (1.7 kgf·m, 12.5 ft·lb)

7 N·m (0.7 kgf·m, 5.2 ft·lb)

2 N·m (0.2 kgf·m, 1.5 ft·lb)

9 10

6 7

8 12

3 12

6 7

14 7 N·m (0.7 kgf·m, 5.2 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Nut Washer Clamp Bilge hose Clamp Bolt Collar Rubber plate 1 Rubber plate 2 Bolt Bolt Bolt Jet pump unit assy. Dowel pin Bolt Washer

2 1

40 N·m (4.0 kgf·m, 29.5 ft·lb)

Q’ty 1 2 1 1 1 6 6 1 1 2 1 4 1 2 2 2

Remarks

M6  22 mm

M8  18 mm M6  30 mm M10  45 mm

M8  13 mm

6-2

1 2 3 4 5 6 7 8 9 A

JET PUMP

Jet pump unit

15 N·m (1.5 kgf·m, 11.1 ft·lb)

17 N·m (1.7 kgf·m, 12.5 ft·lb)

7 N·m (0.7 kgf·m, 5.2 ft·lb)

2 N·m (0.2 kgf·m, 1.5 ft·lb)

9 10

6 7

8 12

3 12

14 7 N·m (0.7 kgf·m, 5.2 ft·lb)

No. 17 18

6-3

Part name Gasket Bracket

2 1

40 N·m (4.0 kgf·m, 29.5 ft·lb)

Q’ty 2 1

Remarks 

6 7

Jet pump unit

Jet pump unit removal j k

Make sure to remove the battery before removing the jet pump unit.

l h

1. Remove the rubber plate bolts a.

g 7. Disconnect the bilge hose m. 8. Remove the jet pump unit assy. bolts n, o, and p.

2. Remove the speed sensor b and ride plate c. 3. Remove the spacer d and intake grate e.

m o

c d e 4. Disconnect the steering cable joint f.

5. Disconnect the shift cable joint g, Q.S.T.S. rod joint h, and spout hose i.

o 9. Gradually increase the distance between the jet pump unit q and the transom plate r, and then remove the jet pump unit q.

q s

6. Remove the rubber plate bolts j, and then remove the rubber plates k and l.

6-4

1 2 3 4 5 6 7 8 9 A

JET PUMP

Jet pump unit

TIP: The illustration shows the case where the disk brake piston tool s is used to remove the jet pump unit.

Jet pump unit installation

c c

Make sure to remove the battery before installing the jet pump unit. 1. Clean the mating surfaces of the jet pump unit a and transom plate b. 2. Apply sealant to the mating surfaces of the transom plate b.

Jet pump unit assy. bolt (M10  45 mm) c: 40 N·m (4.0 kgf·m, 29.5 ft·lb) Jet pump unit assy. bolt (M8  18 mm) d: 17 N·m (1.7 kgf·m, 12.5 ft·lb) 6. Install the rubber plates h and i, and then tighten the rubber plate bolts j to the specified torque. 7. Connect the spout hose k, and then tighten the spout hose clamp m to the specified torque.

8. Connect the shift cable joint l and Q.S.T.S. rod joint n.

j i 3. Install the jet pump unit, and then tighten the jet pump unit assy. bolts c and d to the specified torques.

k h

b n

4. Tighten the jet pump unit assy. bolts e. 5. Connect the bilge hose f, and then fasten it using the clamp g.

l Rubber plate bolt j: 7 N·m (0.7 kgf·m, 5.2 ft·lb) Spout hose clamp m: 2 N·m (0.2 kgf·m, 1.5 ft·lb)

TIP:

• When installing the rubber plate h, pass the spout hose k through the hole a in the plate. • When installing the rubber plate i, pass the shift cable joint l through the hole b in the plate.

6-5

Jet pump unit 9. Connect the steering cable joint o, and then tighten the steering cable joint nut p to the specified torque.

13. Tighten the rubber plate bolts x to the specified torque.

Rubber plate bolt x: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

Steering cable joint nut p: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

TIP: Make sure that steering and shifting operate properly. 10. Install the intake grate q, and then tighten the intake grate bolt r to the specified torque. 11. Install the spacer s and ride plate t, and then tighten the ride plate bolt u to the specified torque. 12. Install the speed sensor v, and then tighten the speed sensor screw w to the specified torque.

vt w q s r

Intake grate bolt r: 17 N·m (1.7 kgf·m, 12.5 ft·lb) Ride plate bolt u: 17 N·m (1.7 kgf·m, 12.5 ft·lb) Speed sensor screw w: 4 N·m (0.4 kgf·m, 3.0 ft·lb)

6-6

1 2 3 4 5 6 7 8 9 A

JET PUMP

Jet pump unit

Reverse gate

10 11

11 10 6

5 3

1 7 9

8 2

20 N·m (2.0 kgf·m, 14.8 ft·lb)

1 4 11 No. 1 2 3 4 5 6 7 8 9 10 11

6-7

9 Part name

Spring Bolt Collar Reverse gate Nut Washer Ball joint Bolt Collar Bolt Reverse gate stay

Q’ty 1 2 2 1 2 3 1 1 1 6 2

Remarks M8  25 mm

M6  35 mm M6  25 mm

Reverse gate / Nozzle and nozzle ring

Nozzle and nozzle ring

16 N·m (1.6 kgf·m, 11.8 ft·lb)

1 2 7

16 N·m (1.6 kgf·m, 11.8 ft·lb)

2 1 3

5 2 1 2

No. 1 2 3 4 5 6 7

Part name Bolt Collar Jet thrust nozzle Nozzle ring Nut Washer Ball joint

Q’ty 4 4 1 1 1 2 1

Remarks M8  20 mm

6-8

1 2 3 4 5 6 7 8 9 A

JET PUMP

Jet pump unit

Impeller housing and impeller duct assy. 40 N·m (4.0 kgf·m, 29.5 ft·lb)

1 N·m (0.1 kgf·m, 0.7 ft·lb)

4 6

3 3

1 7 12

7 10 11 10 7 No. 1 2 3 4 5 6 7 8 9 10 11 12

6-9

Part name Clamp Spout hose Bolt Bracket Nozzle Impeller housing Dowel pin Bolt Water inlet cover Gasket Water inlet strainer Impeller duct assy.

9 7 N·m (0.7 kgf·m, 5.2 ft·lb)

Q’ty 1 1 4 1 1 1 4 4 1 2 1 1

8 Remarks

M10  125 mm

M6  35 mm 

Impeller housing and impeller duct assy. / Impeller, drive shaft, and impeller duct

Impeller, drive shaft, and impeller duct 14

74 N·m (7.4 kgf·m, 54.6 ft·lb)

2 9

3 4

8 11

1 330 N·m (33.0 kgf·m, 243.4 ft·lb)

10 12

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Part name Impeller Bolt Cap O-ring Nut Washer Spacer Oil seal Oil seal Ball bearing Spacer Ball bearing Drive shaft Impeller duct

Q’ty 1 3 1 1 1 1 1 1 1 1 1 1 1 1

Remarks M6  20 mm 

   

6-10

1 2 3 4 5 6 7 8 9 A

JET PUMP

Jet pump unit

Impeller duct assy. disassembly 1. Remove the impeller a.

f a

4. Remove the ball bearing g.

Driveshaft holder b: YB-06201 Drive shaft holder 6 b: 90890-06520

g h

2. Remove the cap c, O-ring d, and nut e.

g j

i k j

e Driveshaft holder b: YB-06201 Drive shaft holder 6 b: 90890-06520 3. Remove the drive shaft f. NOTICE: Do not press the drive shaft threads directly.

A U.S.A. and Canada B Worldwide Slide hammer h: YB-06096 Stopper guide plate i: 90890-06501 Bearing puller assembly j: 90890-06535 Stopper guide stand k: 90890-06538 5. Remove the oil seals l and m.

A l m

h h

6-11

Impeller, drive shaft, and impeller duct

l m

i k

Impeller housing inside diameter a: 155.35–155.45 mm (6.116–6.120 in) Limit: 156.45 mm (6.160 in)

Drive shaft check 1. Measure the drive shaft runout. Replace if out of specification.

A U.S.A. and Canada B Worldwide Slide hammer h: YB-06096 Stopper guide plate i: 90890-06501 Bearing puller assembly j: 90890-06535 Stopper guide stand k: 90890-06538 6. Remove the spacer n, and then remove the ball bearing o using a press.

p q

Drive shaft runout limit: 0.3 mm (0.012 in) Distance a: 310 mm (12.20 in)

Impeller duct assy. assembly 1. Install a new oil seal a halfway into the impeller duct, and then install a new oil seal b.

o n

Driver handle (large) p: YB-06071 Driveshaft needle bearing installer and remover q: YB-06194 Driver rod L3 p: 90890-06652 Needle bearing attachment q: 90890-06609

Impeller housing check

a a

1. Measure the impeller housing inside diameter a. Replace if out of specification. Bearing attachment c: 90890-06628 Distance a: 7.0 ± 0.2 mm (0.28 ± 0.008 in)

2. Install a new ball bearing d onto the drive shaft e.

6-12

1 2 3 4 5 6 7 8 9 A

JET PUMP

Jet pump unit

Bearing attachment f: 90890-06728

6. Install the washer i, and then tighten the drive shaft nut j to the specified torque.

Distance b: 23.0 ± 0.1 mm (0.91 ± 0.004 in) 3. Install the drive shaft e (along with the ball bearing d) and spacer g.

7. Apply EPNOC grease AP #0 to the inside of the cap k, and then install a new O-ring k and the cap l.

f e

k j

Bearing attachment f: 90890-06728 4. Apply EPNOC grease AP #0 to the space between the drive shaft e and the spacer g.

j g

Driveshaft holder m: YB-06201 Drive shaft holder 6 m: 90890-06520

e Drive shaft nut j: 74 N·m (7.4 kgf·m, 54.6 ft·lb) Grease quantity: 20 g (0.7 oz) Grease quantity: 20 g (0.7 oz) 8. Install the spacer n and impeller o. 5. Install a new ball bearing h.

6-13

Impeller, drive shaft, and impeller duct 4. Apply sealant to the mating surfaces of the nozzle e and impeller duct assy. a. 5. Install the dowel pins d and nozzle e.

6. Install the bracket f, and then tighten the impeller duct bolts g to the specified torque.

f g

9. Tighten the impeller o to the specified torque.

g e d Impeller duct bolt g: 40 N·m (4.0 kgf·m, 29.5 ft·lb)

Drive shaft holder m: YB-06201 Drive shaft holder 6 m: 90890-06520 Impeller o: 330 N·m (33.0 kgf·m, 243.4 ft·lb)

Impeller duct, impeller housing, and nozzle installation 1. Clean the mating surfaces of the impeller duct assy., impeller housing, and nozzle. 2. Apply sealant to the mating surfaces of the impeller duct assy. a and impeller housing b. 3. Install the dowel pins c, and then install the impeller housing b.

b c

a c

6-14

1 2 3 4 5 6 7 8 9 A

JET PUMP

Jet pump unit

Transom plate and hoses 12

6 N·m (0.6 kgf·m, 4.4 ft·lb)

15 26 N·m (2.6 kgf·m, 19.2 ft·lb)

19 17

17 2

16 16

16 18 2

3 3

6 6

18 11

16 26 N·m (2.6 kgf·m, 19.2 ft·lb)

7 4 3

22 B 10

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

20 3

23 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

5 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

6-15

Part name Clamp Cooling water hose Clamp Cooling water hose Hose joint Clamp Hose joint Cooling water hose Hose joint Hose joint Cooling water hose Nut Cap Clamp Flushing hose Nut

Q’ty 1 1 5 1 1 2 1 1 1 1 1 1 1 1 1 4

Remarks

A A A A B

FX SHO, FX Cruiser SHO FX SHO, FX Cruiser SHO FX SHO, FX Cruiser SHO FX SHO, FX Cruiser SHO FX HO, FX Cruiser HO

Transom plate and hoses

6 N·m (0.6 kgf·m, 4.4 ft·lb)

15 26 N·m (2.6 kgf·m, 19.2 ft·lb)

19 17

17 2

16 16

16 18 2

3 3

6 6

18 11

16 26 N·m (2.6 kgf·m, 19.2 ft·lb)

7 4 3

22 B 10

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

20 3

23 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

5 No. 17 18 19 20 21 22 23

Part name Washer Washer Transom plate Clamp Hose Tapping bolt Hose joint

Q’ty 2 2 1 2 1 3 1

Remarks

M6  32 mm

6-16

1 2 3 4 5 6 7 8 9 A

JET PUMP

Jet pump unit

Bilge and hoses 6

8 7

10 5.5 N·m (0.55 kgf·m, 4.06 ft·lb)

8 9

12 15 13 10 26

20 23 21

14 3 19

14 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

6-17

7 N·m (0.7 kgf·m, 5.2 ft·lb)

Part name Plastic tie Clamp Bilge hose Bilge hose Hose joint Plastic tie Rivet Holder Bilge hose Clamp Bilge hose Band Electric bilge pump assy. Rivet Holder Bilge strainer assy.

Q’ty 1 5 1 1 1 2 2 2 1 2 1 1 1 3 1 1

Remarks

Bilge and hoses

8 7

10 5.5 N·m (0.55 kgf·m, 4.06 ft·lb)

8 9

12 15 13 10 26

20 23 21

14 3 19

14 No. 17 18 19 20 21 22 23 24 25 26

7 N·m (0.7 kgf·m, 5.2 ft·lb)

Part name Nut Packing Hose joint Clamp Bilge hose Hose joint Nut Drain joint Packing Pad

Q’ty 1 1 1 2 1 1 1 1 1 1

Remarks 



6-18

1 2 3 4 5 6 7 8 9 A

JET PUMP

Jet pump unit

Bilge strainer check 1. Check the bilge strainer. See “Bilge strainer check” (3-10).

Electric bilge pump strainer check 1. Check the electric bilge pump strainer. See “Electric bilge pump strainer check” (3-10).

Transom plate installation 1. Clean the mating surface of the transom plate a. 2. Apply sealant to the mating surface of the transom plate a. 3. Install the transom plate a and washers b and c, and then tighten the transom plate nuts d to the specified torque.

a b

d c

d Transom plate nut d: 26 N·m (2.6 kgf·m, 19.2 ft·lb)

6-19

Bilge and hoses / Intermediate housing

Intermediate housing 17 N·m (1.7 kgf·m, 12.5 ft·lb)

13 4

2 10 15

3 11 10 9

17 16

2 8 8 7

3 N·m (0.3 kgf·m, 2.2 ft·lb)

1 6 5 205 N·m (20.5 kgf·m, 151.2 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Rubber coupling Bolt Shim Dowel pin Driven coupling Washer Intermediate drive shaft O-ring Oil seal Circlip Ball bearing Thrust washer Oil seal Oil seal Intermediate housing Nipple

Q’ty 1 3 * 2 1 1 1 2 1 2 1 1 1 1 1 1

Remarks M8  48 mm As required

      

6-20

1 2 3 4 5 6 7 8 9 A

JET PUMP

Jet pump unit

17 N·m (1.7 kgf·m, 12.5 ft·lb)

13 4

2 10 15

3 11 10

2 8 8 7

3 N·m (0.3 kgf·m, 2.2 ft·lb)

6 5 205 N·m (20.5 kgf·m, 151.2 ft·lb)

No. 17

6-21

Part name Cap

Q’ty 1

Remarks

Intermediate housing

Intermediate housing assy. removal 1. Remove the engine unit. See “Engine unit removal (FX SHO, FX Cruiser SHO)” (5-11) or “Engine unit removal (FX HO, FX Cruiser HO)” (5-15).

d e

2. Remove the intermediate housing assy. a.

3. Remove the oil seals f, g, and h.

f j

g j

i h

TIP:

If shims b are installed, remove the shims and write down the position of each removed shim so that it can be installed in its original position.

B k

Intermediate housing assy. disassembly

1. Remove the driven coupling a.

b a

h c

f l

A U.S.A. and Canada B Worldwide Shaft holder b: 90890-06730 Coupler wrench c: 90890-06729 2. Remove the intermediate drive shaft d and thrust washer e using a press. NOTICE: Do not press the intermediate drive shaft directly.

Slide hammer i: YB-06096 Bearing puller legs j: YB-06523 Stopper guide plate k: 90890-06501 Bearing puller assembly l: 90890-06535 Stopper guide stand m: 90890-06538 4. Remove the circlips n, and then remove the ball bearing o using a press.

6-22

1 2 3 4 5 6 7 8 9 A

JET PUMP

Jet pump unit

c p

n o

Needle bearing installer p: YB-06434 Bearing outer race attachment p: 90890-06654

Needle bearing installer c: YB-06434 Bearing outer race attachment c: 90890-06654

Intermediate housing assy. assembly

Do not reuse a thrust washer, always replace it with a new one.

Distance a: 6.5 ± 0.2 mm (0.26 ± 0.01 in) 4. Install the intermediate drive shaft e using a press. NOTICE: Do not press the intermediate drive shaft directly.

1. Install a new circlip (rear) a.

2. Install a new ball bearing b until it contacts the circlip (rear) a using a press.

b c

a Bearing attachment f: 90890-06728

Distance b: 46.0 ± 0.5 mm (1.81 ± 0.02 in) Needle bearing installer c: YB-06434 Bearing outer race attachment c: 90890-06654

5. Install a new circlip (front) g, and then install a new oil seal h.

3. Install a new oil seal d.

f h

g I

Bearing attachment f: 90890-06728

6-23

Intermediate housing 6. Install a new oil seal i.

n m

j c

Bearing attachment j: 90890-06727

Shaft holder n: 90890-06730 Coupler wrench o: 90890-06729

Distance c: 1.6 ± 0.2 mm (0.06 ± 0.01 in)

Driven coupling m: 205 N·m (20.5 kgf·m, 151.2 ft·lb)

7. Install a new thrust washer k.

Intermediate housing assy. installation

1. Install the intermediate housing assy. a, and then tighten the intermediate housing assy. bolts b to the specified torque.

Bearing attachment j: 90890-06727 Distance d: 3.7 ± 0.3 mm (0.17 ± 0.01 in) 8. Install the washer l, and then tighten the driven coupling m to the specified torque.

Intermediate housing assy. bolt b: 17 N·m (1.7 kgf·m, 12.5 ft·lb)

TIP: If shims c were removed, install the shims in their original positions.

m l

6-24

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system Electrical components ...................................................... 7-1 Engine (FX SHO, FX Cruiser SHO) .......................................... 7-1 Engine (FX HO, FX Cruiser HO) ............................................... 7-2 Deck and hull ............................................................................. 7-3 Electrical box ............................................................................. 7-4 ECM circuit diagram .................................................................. 7-5 ECM coupler layout ................................................................... 7-7

Electrical analysis ............................................................. 7-9 Electrical component check using the YDIS .............................. 7-9 Power supply to the ECM .......................................................... 7-9 Peak voltage measurement ....................................................... 7-9

Ignition system ................................................................ 7-10 Ignition spark check ................................................................. 7-10 Ignition coil check .................................................................... 7-11 Pickup coil check ..................................................................... 7-11

Charging system ............................................................. 7-12 Stator coil check ...................................................................... 7-12 Rectifier regulator check .......................................................... 7-13

Control system ................................................................ 7-14 Oil pressure switch check ........................................................ 7-14 Thermoswitch check ................................................................ 7-15 Thermo sensor check .............................................................. 7-16 Engine temperature sensor check ........................................... 7-17 Intake air temperature sensor check ....................................... 7-17 Intake air pressure sensor check ............................................ 7-18 Knock sensor check ................................................................ 7-19 TPS check ............................................................................... 7-19 ETV circuit continuity ............................................................... 7-21 APS check ............................................................................... 7-21 APS circuit continuity ............................................................... 7-22 ETV relay check ...................................................................... 7-23 Cam position sensor check ..................................................... 7-24 Slant detection switch check ................................................... 7-25 Steering sensor check ............................................................. 7-25 Reverse sensor check ............................................................. 7-26 Right handlebar switch check .................................................. 7-26 ECM check .............................................................................. 7-27 Earth plate check ..................................................................... 7-28 Electric bilge pump check ........................................................ 7-28

Fuel system ..................................................................... 7-29 Fuel injector check .................................................................. 7-29

Fuel pump module check ........................................................ 7-29

Starting system ............................................................... 7-30 Left handlebar switch assy. check ........................................... 7-30 Main and fuel pump relay check .............................................. 7-31 Starter relay check .................................................................. 7-32

Starter motor ................................................................... 7-33 Starter motor operation ........................................................... 7-34 Armature check ....................................................................... 7-34 Brush holder check .................................................................. 7-35

Remote control system .................................................. 7-35 Remote control transmitter check ............................................ 7-35 Remote control receiver check ................................................ 7-37 Transmitter registration ........................................................... 7-37

Indication system ............................................................ 7-38 Multifunction meter check ........................................................ 7-38 Multifunction meter operation button check ............................. 7-39 Compass display check (FX Cruiser SHO) ............................. 7-39 Air temperature display check (FX Cruiser SHO) .................... 7-40 Water temperature display check (FX Cruiser SHO) .............. 7-40 Speed sensor check (FX Cruiser SHO) .................................. 7-40 Speed sensor check (FX HO, FX Cruiser HO, and FX SHO) ................................... 7-41 Fuel level meter display and fuel level warning indicator check ............................................ 7-41 Check engine warning indicator check .................................... 7-42 Diagnostic display check ......................................................... 7-42 Oil pressure warning indicator check ...................................... 7-43 Engine overheat warning indicator check ................................ 7-43 Buzzer check ........................................................................... 7-44

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

Electrical components Engine (FX SHO, FX Cruiser SHO)

b c

f h

j g

k l

m p

a Spark plug and ignition coil b Cam position sensor c Electrical box d Thermo sensor e Rectifier regulator f Starter motor g Oil pressure switch h Intake air pressure sensor

7-1

i Fuel injector j Thermoswitch k Intake air temperature sensor l Knock sensor m ETV (TPS) n Engine temperature sensor o Earth plate p Stator coil and pickup coil

Electrical components

Engine (FX HO, FX Cruiser HO)

b c

h d

f i

g k l

o n

a Spark plug and ignition coil b Cam position sensor c Electrical box d Thermo sensor e Rectifier regulator f Starter motor g Oil pressure switch h ETV (TPS)

i Intake air pressure sensor j Fuel injector k Thermoswitch l Intake air temperature sensor m Engine temperature sensor n Earth plate o Stator coil and pickup coil

7-2

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

Deck and hull

d c b

a e f i

h g

l m

a Remote control receiver b Compass and air temperature sensor (FX Cruiser SHO only) c Steering sensor d APS (electric throttle without wire cable) e Speed and water temperature sensor (FX Cruiser SHO)/speed sensor (FX SHO, FX HO, FX Cruiser HO)

7-3

f Buzzer g Fuel pump module and fuel sender h Left handlebar switch assy. i Right handlebar switch j Multifunction meter k Reverse sensor l Electric bilge pump m Battery

Electrical components

Electrical box

o k n f g h i j

m A

a Starter relay b Main and fuel pump relay c ETV relay d Slant detection switch e ECM f Fuse (30 A) (battery) g Fuse (10 A) (main and fuel pump relay) h Fuse (10 A) (ETV relay)

i Fuse (3 A) (remote control receiver) j Fuse (20 A) (main and fuel pump relay) k Positive battery lead (gray tape) l Starter motor lead (white tape) m Lead (black) n Lead (brown) o Lead (red)

7-4

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

ECM circuit diagram

Stator coil

Rectifier regulator

Fuel injector #1 58

Fuse (20 A)

Fuel injector #2

Fuel injector #3

Main relay

Fuel injector #4

Fuse (3 A)

Engine start switch

Remote control receiver

Fuse (30 A)

Ignition coil #1 85

Ignition coil #2

Starter relay 86

Battery Starter motor

Ignition coil #3 Pickup coil

61 8 26

Cam position sensor

Intake air pressure sensor

Ignition coil #4 ECM 60

Fuel pump module Reverse sensor

18 81

Intake air temperature sensor

Fuel pump relay

Fuse (10 A)

Engine temperature sensor 23

Thermo sensor

(YDIS)

Multifunction meter

ETV relay

Steering sensor

80 17

Slant detection switch

45 5

No-Wake mode switch 24 40

: Indicates a connection between the symbols.

7-5

Fuse (10 A)

Electrical components

Knock sensor 1

Oil pressure switch 79

Thermoswitch

TPS

78 64 52

ETV motor

Engine shut-off switch

70 72 44

Cruise assist set switch 19

TPS 1

ECM TPS 2

Cruise assist up switch 54

Cruise assist down switch

Ground

46 63

APS

5V APS full close switch

67 30 22

Ground 5V

APS 1

29 49 36

Ground 5V APS 2

34 50 37

Ground

A FX SHO, FX Cruiser SHO only

7-6

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

ECM coupler layout

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

No.

Lead color

—

G/O

—

L/B

—

R/Y

W/B

—

53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

Lead color

B/G

Intake air pressure sensor

O/G

W/L

Steering sensor

—

G/W

—

Y/B

—

Y/G

B/R

APS 1 ground

Battery power source

B/W

APS 2 ground

Pickup coil

W/G

P/R

APS 1

—

B/Y

P/W

APS 2

—

L/R

—

O/R

R/Y

ETV relay power source (contact)

—

B/O

Sensor ground

B/L

Thermo sensor

R/Y

B/O

TPS ground

Y/W

Main relay drive signal

Reverse sensor Cruise assist set switch Main and fuel pump relay (main relay) Engine start switch APS full close switch Engine temperature sensor No-wake mode switch Steering sensor power source Sensor power source Battery power source Immobilizer serial communication

— Cam position sensor — Slant detection switch —

No.

Lead color

B/R

P/G

External connection lead Intake air temperature sensor

53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86

No.

7-7

External connection lead Knock sensor (*1)

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

External connection lead APS full close switch ground APS full close switch power sourse

TPS 1

Electrical components

Lead color P/B

R/Y

W/B

—

O/R

O/W

—

Y/R

55 56

— —

—

No.

External connection lead TPS 2 TPS power source ETV relay power source (contact) ECM ground Self-diagnosis lead (communication), meter unit communication — APS 1 power source APS 2 power source — ETV motor (negative) — Cruise assist up switch — — —

Lead color Pu/R

External connection lead Fuel injector #1

Lead color —

External connection lead —

Pu/B

Fuel injector #2

—

B/G

Ignition coil #4

—

B/Y

Ignition coil #3

—

ETV ground

—

Y/G

Cruise assist down switch

Thermoswitch

P/W

—

Y/W

—

L/R

G/L

—

Pu/G Fuel injector #4

—

Pu/Y

Fuel injector #3

70 71

B —

85 86

B/R B/W

Ignition coil #1 Ignition coil #2

No.

Ground

ETV ground — Engine shut-off switch

No.

ETV motor (positive) Oil pressure switch ETV relay power source (coil) Main and fuel pump relay (fuel pump relay) —

(*1) FX SHO and FX Cruiser SHO only. Color code B B/G B/O B/R B/W B/Y G G/L G/O G/W L L/B

: Black : Black/Green : Black/Orange : Black/Red : Black/White : Black/Yellow : Green : Green/Blue : Green/Orange : Green/White : Blue : Blue/Black

L/R O O/G O/R O/W P P/B P/G P/R P/W Pu/B Pu/G

: Blue/Red : Orange : Orange/Green : Orange/Red : Orange/White : Pink : Pink/Black : Pink/Green : Pink/Red : Pink/White : Purple/Black : Purple/Green

Pu/R Pu/Y R/Y W W/B W/G W/L Y Y/B Y/G Y/R Y/W

: Purple/Red : Purple/Yellow : Red/Yellow : White : White/Black : White/Green : White/Blue : Yellow : Yellow/Black : Yellow/Green : Yellow/Red : Yellow/White

7-8

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

Electrical analysis

TIP:

Electrical component check using the YDIS

W/B

R/Y

When checking the TPS, APS, or other sensors, use the YDIS. When deleting the diagnosis record in the YDIS, make sure to check the time when the diagnostic codes were detected.

When checking the input voltage of a part, the coupler or connector must be disconnected. As a result, the ECM determines that the part is disconnected and a diagnostic code is detected. Therefore, make sure to delete the diagnosis record after checking the input voltage. Power is supplied to the ECM for about 30 seconds after stopping the engine. Therefore, wait for more than 30 seconds before restarting the engine, otherwise the diagnostic codes will not be cleared from the ECM.

• Before checking the electrical components, make sure that the battery is fully charged. • If the test leads are connected while using the YDIS, diagnostic codes will be detected. • If a diagnosis record is displayed and it is caused by the checking steps, delete the record by using the “Diagnosis record” function of the YDIS. • The YDIS requires that you use an exclusive communication cable and CD-ROM to connect to a computer. For a description of the communication cable and CD-ROM to be used, see “YDIS” (9-1). Also, make sure to check the CD-ROM version before using it. • To connect the YDIS, see “YDIS” (9-1) or the YDIS (Ver. 2.00) Instruction Manual.

Power supply to the ECM Push the unlock button a on the remote control transmitter so that power is supplied to the ECM.

YDIS 2 starter kit: 90890-06883

TIP: To check that the remote control transmitter is working properly, see “Remote control transmitter check” (7-35).

Peak voltage measurement

When measuring the peak voltage, do not touch any of the connections of the digital tester probes.

7-9

Electrical analysis / Ignition system

TIP: • When testing the voltage between the terminals of an electrical component using the digital tester, do not allow any of the leads to touch any metal parts. • When starting the engine on land, make sure to connect a garden hose to the watercraft for proper water supply. To check the electrical components or measure the peak voltage, use the special service tools. A faulty electrical component can be easily checked by measuring the peak voltage. The specified engine speed when measuring the peak voltage is affected by many factors, such as fouled spark plugs or a weak battery. If one of these factors is present, the peak voltage cannot be measured properly.

• Before measuring the peak voltage, check all wiring for proper connection and corrosion, and check that the battery is fully charged. • Use the peak voltage adapter with the recommended digital circuit tester. • Connect the positive pin of the peak voltage adapter to the positive terminal of the digital circuit tester, and the negative pin to the negative terminal. • When measuring the peak voltage, set the selector on the digital circuit tester to the DC voltage mode.

Ignition system Ignition spark check

When performing the spark gap check, keep flammable gas or liquids away, since this test can produce sparks.

1. Connect the YDIS. 2. Remove the ignition coils for the cylinder that will be tested.

b 3. Connect the ignition coil to the special service tool a.

B c

4. Using the “Stationary test” of the YDIS, check the ignition spark. WARNING! Do not touch any of the connections of the special service tool leads.

DC V d

A U.S.A. and Canada B Worldwide Digital multimeter a: YU-34899-A Peak volt adapter b: YU-39991 Digital circuit tester c: 90890-03189 Peak voltage adapter B d: 90890-03172 Spark checker a: YM-34487 Ignition tester (Spark gap tester) a: 90890-06754

7-10

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

5. Disconnect the special service tool, and then install the ignition coils.

R/Y B #1 B/R #2 B/W #3 B/Y #4 B/G

Ignition coil check 1. Disconnect the ignition coil couplers a. 2. Supply power to the ECM, and then measure the input voltage at the ignition coil coupler terminals (wiring harness end). Check the wiring harness if out of specification. Check the ECM output peak voltage if within specification.

R/Y B

Ignition coil input voltage (from the battery): Red/Yellow (R/Y)–Black (B) 12 V (battery voltage)

ECM output peak voltage: #1 Black/Red (B/R) –Black (B) #2 Black/White (B/W) –Black (B) #3 Black/Yellow (B/Y) –Black (B) #4 Black/Green (B/G) –Black (B) Loaded r/min Cranking 2000 3500 V 2.5 2.6 2.6

3. Connect the test harness. 4. Measure the ECM output peak voltage. WARNING! When checking the electrical components, do not touch any of the connections of the digital tester leads.

TIP: • When measuring the ECM output peak voltage under the “Cranking” condition, disconnect the fuel injector couplers for all cylinders. • To crank the engine, connect the engine shut-off cord (lanyard) to the engine shutoff switch, and then push the engine start switch. • When measuring the ECM output peak voltage, use only a properly functioning ignition coil. If the ignition coil is not functioning properly, ECM output peak voltage will not be generated. 5. Disconnect the test harness, and then connect the ignition coil couplers.

Pickup coil check 1. Disconnect the pickup coil coupler a, and then connect the special service tool a.

7-11

Ignition system / Charging system 2. Measure the pickup coil output peak voltage.

B W

B/O W/B b

Pickup coil resistance at 20 °C (68 °F) (reference data): White (W)–Black (B) 459–561 

a BW W

5. Connect the pickup coil coupler.

Test harness (3 pins) a: YB-06877/90890-06877

Charging system Stator coil check

Pickup coil output peak voltage: White (W)–Black (B) UnLoaded r/min loaded Cranking 2000 V 5.5 4.7 16.4

1. Disconnect the stator coil coupler a, and then connect the special service tool a.

3500 21.5

2. Measure the stator coil output peak voltage.

G G G

TIP: • To crank the engine, connect the engine shut-off cord to the engine shut-off switch, and then push the engine start switch and engine stop switch simultaneously. • If measuring the pickup coil output peak voltage under the “Cranking” and “Unloaded” conditions, disconnect the pickup coil coupler (wiring harness end) b. 3. Disconnect the special service tool a.

G G G

W R B

a a B R W

4. Measure the pickup coil resistance. Replace the stator coil assy. if out of specification. Test harness (3 pins) a: YB-06870/90890-06870

7-12

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

Stator coil output peak voltage: Green (G)–Green (G) Unloaded r/min Cranking 2000 V 8.3 36.4

3500 64.7

R B

G G G R B

B R

3. Disconnect the special service tool. 4. Measure the stator coil resistance. Replace the stator coil assy. if out of specification. Measure the rectifier regulator output peak voltage if within specification.

R B

Stator coil resistance at 20 °C (68 °F) (reference data): Green (G)–Green (G) 0.31–0.38  5. Connect the stator coil coupler.

Rectifier regulator check 1. Disconnect the rectifier regulator coupler a, and then connect the special service tool a. 2. Measure the rectifier regulator output peak voltage.

Test harness (2 pins) a: YW-06850 Test harness (2 pins) a: 90890-06850 Rectifier regulator output peak voltage: Red (R)–Black (B) Loaded r/min 2000 3500 V 13.0

TIP: Do not use the peak voltage adapter to measure the output voltage. 3. Disconnect the special service tool. 4. Remove the rectifier regulator. See “Exhaust manifold (FX SHO, FX Cruiser SHO)” (5-4) or “Exhaust manifold (FX HO, FX Cruiser HO)” (5-6). 5. Check the rectifier regulator for continuity. Replace if out of specification.

cG Ge

7-13

Charging system / Control system

bR cG dG eG fB A

g g

Rectifier regulator continuity (testing diode mode): Tester lead Display value (V) (reference data)   c d b OL e f b 0.43–0.51 d c e OL f b 0.43–0.51 c d e OL f b 0.43–0.51 c e d OL f b 0.66–0.74 c 0.43–0.51 f d 0.43–0.51 e 0.43–0.51 OL: Indicates an overload

A U.S.A. and Canada B Worldwide

TIP: Make sure to set the measurement range g when checking the rectifier regulator continuity. 6. Install the rectifier regulator. See “Exhaust manifold (FX SHO, FX Cruiser SHO)” (5-4) or “Exhaust manifold (FX HO, FX Cruiser HO)” (5-6). 7. Connect the rectifier regulator coupler.

Control system Oil pressure switch check 1. Disconnect the oil pressure switch coupler a.

7-14

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

2. Supply power to the ECM, and then measure the input voltage between the oil pressure switch coupler terminal (wiring harness end) and ground. Check the wiring harness if out of specification.

P/W

Oil pressure switch continuity: Terminal thread Pressure b–Body c Below 128–166 kPa Continuity (1.28–1.66 kgf/cm2, 18.6–24.1 psi) Above 128–166 kPa No continuity (1.28–1.66 kgf/cm2, 18.6–24.1 psi) 7. Install the oil pressure switch. See “Oil separator tank and oil pan” (5-104).

8. Connect the oil pressure switch coupler.

Oil pressure switch input voltage (reference data): Pink/White (P/W)–Ground 11.0–12.0 V

Thermoswitch check 1. Disconnect the thermoswitch coupler a.

3. Remove the oil pressure switch. See “Oil separator tank and oil pan” (5-104). 4. Connect the tester leads to the terminal thread b and body c of the oil pressure switch.

2. Supply power to the ECM, and then measure the input voltage at the thermoswitch coupler terminals (wiring harness end). Check the wiring harness if out of specification.

A B/O

5. Connect the special service tool a to the oil pressure switch, and then apply positive pressure.

a B

c B/O

Lower unit pressure/vacuum tester a: YB-35956-A Vacuum/pressure pump gauge set a: 90890-06756 6. Check the oil pressure switch for continuity. Replace if out of specification.

7-15

A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO Thermoswitch input voltage (reference data): Pink (P)–Black/Orange (B/O) 11.0–12.0 V

Control system 3. Remove the thermoswitch. See “Cylinder block and electrical part (FX SHO, FX Cruiser SHO)” (5-100) or “Cylinder block and electrical part (FX HO, FX Cruiser HO)” (5-102). 4. Suspend the thermoswitch in a container filled with water, and then heat the water slowly.

Thermo sensor check 1. Disconnect the thermo sensor coupler a. 2. Supply power to the ECM, and then measure the input voltage at the thermo sensor coupler terminals (wiring harness end). Check the wiring harness if out of specification.

a B/L P

5. Check the thermoswitch for continuity when the specified temperatures are reached. Replace if out of specification.

e e C

B/O

Thermo sensor input voltage: Black/Blue (B/L)–Black/Orange (B/O) 4.75–5.25 V 3. Remove the thermo “Muffler” (5-31).

sensor.

See

4. Suspend the thermo sensor in a container filled with water, and then slowly heat the water.

D d No continuity e Continuity C Temperature D Time Thermoswitch continuity temperature: Pink (P)–Black (B) b: 94–100 °C (201–212 °F) c: 80–94 °C (176–201 °F) 6. Install the thermoswitch. See “Cylinder block and electrical part (FX SHO, FX Cruiser SHO)” (5-100) or “Cylinder block and electrical part (FX HO, FX Cruiser HO)” (5-102). 7. Connect the thermoswitch coupler.

5. Measure the thermo sensor resistance when the specified temperatures are reached. Replace if out of specification. Thermo sensor resistance: Black (B)–Black (B) 0 °C (32 °F): 24.0–37.1 k 100 °C (212 °F): 0.87–1.18 k 6. Install the thermo sensor. See “Muffler” (5-31).

7-16

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

7. Connect the thermo sensor coupler.

Engine temperature sensor check 1. Disconnect the engine temperature sensor coupler a. 2. Supply power to the ECM, and then measure the input voltage at the engine temperature sensor coupler terminals (wiring harness end). Check the wiring harness if out of specification.

A a

B/O

B/Y

5. Measure the engine temperature sensor resistance when the specified temperatures are reached. Replace if out specification. Engine temperature sensor resistance: Black/Yellow (B/Y)–Black/Yellow (B/Y) 20 °C (68 °F): 54.2–69.0 k 100 °C (212 °F): 3.12–3.48 k

B a B/O

B/Y

6. Install the engine temperature sensor. See “Cylinder block and electrical part (FX SHO, FX Cruiser SHO)” (5-100) or “Cylinder block and electrical part (FX HO, FX Cruiser HO)” (5-102). 7. Connect the engine temperature sensor coupler.

Intake air temperature sensor check 1. Measure the ambient temperature. A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO Engine temperature sensor input voltage: Black/Yellow (B/Y)–Black/Orange (B/O) 4.75–5.25 V 3. Remove the engine temperature sensor. See “Cylinder block and electrical part (FX SHO, FX Cruiser SHO)” (5-100) or “Cylinder block and electrical part (FX HO, FX Cruiser HO)” (5-102). 4. Suspend the engine temperature sensor in a container filled with water, and then heat the water slowly.

7-17

2. Connect the YDIS to display “Intake temperature.” 3. If the ambient temperature and the displayed intake air temperature differ by more than ± 5 °C (± 9 °F), measure the intake air temperature sensor resistance.

TIP: Check the intake air temperature sensor when the engine is cold. 4. Disconnect the intake air temperature sensor coupler a.

Control system 5. Supply power to the ECM, and then measure the input voltage at the intake air temperature sensor coupler (wiring harness end). Check the wiring harness if out of specification.

A B/O

B/R

A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO

8. Measure the intake air temperature sensor resistance when the specified temperatures are reached. Replace if out of specification.

B B/O

B/R

Intake air temperature sensor resistance: 0 °C (32 °F): 5.4–6.6 k 80 °C (176 °F): 0.29–0.39 k 9. Install the intake air temperature sensor. See “Intake assy. (FX SHO, FX Cruiser SHO)” (5-45) or “Intake assy. (FX HO, FX Cruiser HO)” (5-47).

a A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO Intake air temperature sensor input voltage: Black/Red (B/R)–Black/Orange (B/O) 4.75–5.25 V 6. Remove the intake air temperature sensor. See “Intake assy. (FX SHO, FX Cruiser SHO)” (5-45) or “Intake assy. (FX HO, FX Cruiser HO)” (5-47). 7. Suspend the intake air temperature sensor in a container filled with water, and then slowly heat the water.

10. Connect the air temperature sensor coupler.

Intake air pressure sensor check 1. Disconnect the intake air pressure sensor coupler a. 2. Supply power to the ECM, and then measure the input voltage at the intake air pressure sensor coupler (wiring harness end). Check the wiring harness if out of specification.

A B

B/O

7-18

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

Intake air pressure sensor input voltage: Orange (O)–Black/Orange (B/O) 4.75–5.25 V

G 3. Connect the intake air pressure sensor coupler a. 4. Disconnect the vacuum hose from the intake air pressure sensor. 5. Connect the special service tool to the intake air pressure sensor. 6. Connect the YDIS to display “Intake air pressure.” 7. Apply negative pressure to the intake air pressure sensor slowly and check that the displayed intake air pressure increases. Replace if it does not increase.

Lower unit pressure/vacuum tester a: YB-35956-A Vacuum/pressure pump gauge set a: 90890-06945 8. Disconnect the special service tool, and then connect the vacuum hose.

a Knock sensor resistance at 20 °C (68 °F) (reference data): 504–616 k 3. Connect the knock sensor coupler a.

TPS check

• Do not loosen the throttle stop screw nut a and do not turn the throttle stop screw b. • Do not disconnect the ETV coupler (throttle body end) c. • TPS 1 and TPS 2 are components of the ETV, which cannot be disassembled.

Knock sensor check 1. Disconnect the knock sensor coupler a. 2. Measure the knock sensor resistance. Replace the knock sensor if out of specification. 1. Connect the YDIS to display “TPS 1,” “Throttle valve opening angle,” and “TPS 2.”

7-19

Control system

TIP:

When checking the TPS using the YDIS, do not start the engine.

The actual TPS output voltage and throttle valve opening angle may vary according to environmental conditions and engine temperature.

2. Squeeze the throttle lever a slowly and check that the displayed throttle valve opening increases. 3. Check the TPS 1 output voltage and throttle valve opening angle at the fully closed position A .

5. Operate the throttle lever a so that the TPS 2 output voltage is 4.5 V or less, and then check the voltage difference between TPS 1 and TPS 2. Measure the TPS input voltage if out of specification. TPS output voltage difference: 1.9–2.1 V

Example: If the TPS 1 output voltage is 2.5 V and the TPS 2 output voltage is 4.5 V, then 4.5 – 2.5 = 2.0 V.

6. Disconnect the ETV coupler d.

TPS 1 output voltage with throttle lever fully closed: 0.6–0.9 V Throttle valve opening angle with throttle lever fully closed: 2–8° 4. Operate the throttle lever a, and then check the TPS 2 output voltage and throttle valve opening angle at the fully open position B .

7. Supply power to the ECM, and then measure the input voltage at the ETV coupler terminals (wiring harness end). Check the TPS circuit continuity if out of specification.

d O

a B/O

B D

O TPS 2 output voltage with throttle lever fully open: 4.5–4.8 V Throttle valve opening angle with throttle lever fully open: More than 70°

B/O

C FX SHO, FX Cruiser SHO D FX HO, FX Cruiser HO

7-20

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

TPS input voltage: Orange (O)–Black/Orange (B/O) 4.75–5.25 V

a 3 2 1 6 5 4

8. Connect the ETV coupler.

ETV circuit continuity 1. Disconnect the ETV coupler a and ECM couplers b and c.

44 43 42 41 52

ETV circuit continuity: Terminal No. Coupler a Coupler b, c a P b R c { d Q e O f Z

Color code P O G P/B B/O L

3. Connect the ETV coupler and ECM couplers.

APS check

A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO

APS 1, APS 2, and APS full close switch are components of the throttle lever, which cannot be disassembled. 1. Connect the YDIS to display “APS 1,” “APS 2,” and “APS full close switch.”

TIP: When checking the APS using the YDIS, do not start the engine. 2. Check the wiring harness for continuity. Replace if there is no continuity. Replace the ETV if there is continuity.

7-21

2. Operate the throttle lever a, and then check the output voltages of APS 1 and APS 2 at the fully closed position A and fully open position B .

Control system

a A

6. Supply power to the ECM, and then measure the input voltage at the APS coupler terminals (wiring harness end). Check the APS circuit continuity if out of specification.

O/R

a APS output voltage: Throttle lever position Item Fully closed A Fully open B APS 1 0.68–0.74 V 3.95–4.15 V APS 2 0.68–0.74 V 3.95–4.15 V

TIP: The actual APS output voltage may vary according to environmental conditions. 3. Squeeze the throttle lever a to the fully open position B , and then check the voltage difference between APS 1 and APS 2. Measure the APS input voltage if out of specification. APS output voltage difference: 0.1 V or less 4. Squeeze the throttle lever a slowly and check that the “APS full close switch” display changes from the “ON” to “OFF.”

APS full close switch: Throttle lever position C D

B/R

O/W O/G

B/W B/G

APS 1 input voltage: Orange/Red (O/R)–Black/Red (B/R) 4.75–5.25 V APS 2 input voltage: Orange/White (O/W)–Black/White (B/W) 4.75–5.25 V APS full close switch input voltage: Orange/Green (O/G)–Black/Green (B/G) 4.75–5.25 V 7. Connect the APS coupler.

APS circuit continuity 1. Disconnect the APS coupler a and ECM couplers b and c.

a D

YDIS display ON OFF

5. Disconnect the APS coupler a.

7-22

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

2. Check the wiring harness for continuity. Replace if there is no continuity.

a R/Y

a 3 2 1 6 5 4 9 8 7

30 29 37 36 35 34 22

50 49

APS circuit continuity: Terminal No. Coupler a Coupler b, c a J b H c W d K e I f X g v h C i D

ETV relay input voltage: Red/Yellow (R/Y)–Ground Red (R)–Ground 12 V (battery voltage) 3. Remove the ETV relay. See “Electrical box” (5-35).

Color code P/R B/R O/R P/W B/W O/W W/G B/G O/G

3. Connect the APS coupler and ECM coupler.

4. Connect the special service tool a. 5. Connect the tester leads to connectors b and c or to connectors b and d.

6. Connect the positive battery lead to the connectors e or f. 7. Connect the negative battery lead to the connector g. 8. Check the continuity between connectors b and c or connectors b and d. Replace the ETV relay if out of specification.

ETV relay check 1. Disconnect the ETV relay coupler a. 2. Supply power to the ECM, and then measure the input voltage between the ETV relay coupler terminals and ground. Check the wiring harness if out of specification.

7-23

the the

Control system

W/Br

W/L

W/G

1 2 3 4 5 6

B/O

W/R

e W/B

W/Y

Cam position sensor input voltage: Orange (O)–Black/Orange (B/O) 4.75–5.25 V 3. Remove the cam position sensor. See “Cylinder head cover” (5-64), and then connect the special service tool a to the cam position sensor and the wiring harness.

Test harness (6 pins) a: YB-06872/90890-06849 ETV relay continuity: Battery lead e or f–g Disconnected Connected

Terminal b–c or d No continuity Continuity

4. Supply power to the ECM, and then measure the output voltage when a screwdriver is passed under the cam position sensor in direction b. Replace the cam position sensor if out of specification.

9. Install the ETV relay. See “Electrical box” (5-35). 10. Connect the ETV relay coupler.

G/O

Cam position sensor check 1. Disconnect the cam position sensor coupler a.

B/O

2. Supply power to the ECM, and then measure the input voltage at the cam position sensor coupler terminals (wiring harness end). Check the wiring harness if out of specification. Measure the cam position sensor output voltage if within specification.

b c

Test harness (3 pins) a: YB-06877/90890-06877

7-24

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

Cam position sensor output voltage: Green/Orange (G/O)– Black/Orange (B/O) Position Voltage (V) c, e More than 4.8 d Less than 0.8

A UP

6. Connect coupler.

the

cam

position

sensor

Slant detection switch check

1. Disconnect the slant detection switch coupler a. 2. Supply power to the ECM, and then measure the input voltage at the slant detection switch coupler (wiring harness end). Check the wiring harness if out of specification.

a B/O

B UP

5. Disconnect the special service tool a, and then install the cam position sensor. See “Cylinder head cover” (5-64).

B/O

L/B

Slant detection switch continuity: Blue/Black (L/B)–Black/ Position Orange (B/O) Normal No continuity position A Overturned B Continuity

TIP: Make sure to turn the switch over to both the left and right. 5. Install the slant detection switch. See “Electrical box” (5-35).

Slant detection switch input voltage: Blue/Black (L/B)–Black/Orange (B/O) 4.75–5.25 V 3. Remove the slant detection switch. 4. Check the slant detection switch for continuity. Replace if out of specification.

6. Connect coupler.

the

slant

detection

switch

Steering sensor check 1. Connect the YDIS to display “Steering sensor.” 2. Turn the handlebar all the way to the left or right. 3. Install a plastic tie a loosely around the center a of the handlebar grip, and then hook a spring gauge b onto the plastic tie a.

7-25

Control system 4. Hold the spring gauge b at a 90° angle from the handlebar grip, and then pull the spring gauge in direction b using a force of approximately 100 N (10 kgf, 22 lbf).

TIP:

8. Supply power to the ECM, and then measure the input voltage at the steering sensor coupler terminals (wiring harness end). Replace the steering sensor if within specification. Check the wiring harness if out of specification.

At this time, the button c in the steering sensor c will be pushed in direction d.

B/O

O/R

5. Check that the following is displayed in the “Engine monitor” window of the YDIS.

c d

c b b

Steering sensor input voltage: Orange/Red (O/R)–Black/Orange (B/O) 4.75–5.25 V 9. Connect the steering sensor coupler.

Reverse sensor check a a

1. Connect the YDIS to display “Reverse switch.” 2. Operate the shift lever a at the F, N, and R positions.

Steering sensor operation: Handlebar YDIS display Not pulled OFF Pulled ON

3. Check that the following is displayed in the “Engine monitor” window of the YDIS.

RNF

6. Use the same procedure to check that the steering sensor operates properly when the handlebar is turned to both the left and right. Measure the steering sensor input voltage if the steering sensor does not operate. 7. Disconnect the steering sensor coupler e.

Reverse sensor operation: Shift lever position YDIS display F position OFF N position ON R position ON

Right handlebar switch check 1. Connect the YDIS to display “Reverse switch.”

7-26

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

2. Push the right handlebar switches a, b, c, and d.

ECM check 1. Disconnect the ECM coupler a.

3. Check that the following is displayed in the “Engine monitor” window of the YDIS.

a b

Right handlebar switch operation: Switch YDIS display Up a Free OFF Down a “SET” c Pushed ON “NO-WAKE MODE” d

2. Supply power to the ECM, and then measure the input voltage between the ECM coupler terminal (wiring harness end) and ground. Check the ECM circuit continuity if out of specification.

4. Disconnect the right handlebar switch coupler a. 5. Supply power to the ECM, and then measure the input voltage between the right handlebar switch coupler terminals (wiring harness end). Check the wiring harness if out of specification.

a 27

L/R Y/B Y/R a

Y/G

ECM input voltage: Terminal A–Ground 12 V (battery voltage)

TIP: Right handlebar switch input voltage: Blue/Red (L/R)–Black (B) Yellow/Black (Y/B)–Black (B) 4.75–5.25 V Yellow/Red (Y/R)–Black (B) Yellow/Green (Y/G)–Black (B) 11.0–12.0 V

7-27

Do not disconnect the coupler b or c when measuring the ECM input voltage. 3. Disconnect the ECM couplers b, and then check the continuity between the ECM coupler terminals (wiring harness end) and ground. Replace the wiring harness if there is no continuity.

Control system

Electric bilge pump check a

1. Disconnect the electric bilge pump coupler a.

2. Supply power to the ECM, and then measure the input voltage between the electric bilge pump coupler terminals (wiring harness end). Check the wiring harness or electric bilge pump fuse if out of specification.

b B

a 67

62 70

ECM circuit continuity: Terminal T–Ground Terminal 0–Ground Terminal ^–Ground Terminal (–Ground

Continuity

4. Connect the ECM couplers.

Earth plate check

Electric bilge pump input voltage: Brown (Br)–Black (B) 12 V (battery voltage) 3. Remove the electric bilge pump. See “Bilge and hoses” (6-17).

1. Remove the earth plate.

4. Set the electric bilge pump in a container filled with water.

2. Check the continuity between each terminal a and the housing b. Replace the earth plate if there is no continuity.

5. Connect the positive battery lead to the terminal b and the negative battery lead to the terminal c.

6. Check that water flows from the electric bilge pump hose a.

a 3. Install the earth plate. See “Cylinder block and electrical part (FX SHO, FX Cruiser SHO)” (5-100) or “Cylinder block and electrical part (FX HO, FX Cruiser HO)” (5-102).

7. Install the electric bilge pump. See “Bilge and hoses” (6-17). 8. Connect the electric bilge pump coupler.

7-28

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

Fuel system

7. Install the fuel injectors. See “Fuel rail and injector installation” (4-10).

Fuel injector check 1. Connect the YDIS.

8. Connect the fuel injector couplers.

2. Using the “Stationary test” of the YDIS, listen for the fuel injector operation sound. 3. Disconnect the fuel injector couplers a. 4. Supply power to the ECM, and then measure the input voltage between the fuel injector coupler terminals (wiring harness end) and ground. Check the wiring harness if out of specification.

R/Y

Fuel pump module check 1. Connect the YDIS. 2. Using the “Stationary test” of the YDIS, listen for the fuel pump module operation sound. 3. Disconnect coupler a.

the

fuel

pump

module

4. Supply power to the ECM, and then measure the input voltage at the fuel pump module coupler terminals (wiring harness end). Replace the fuel pump module if within specification. Check the wiring harness if out of specification.

Fuel injector input voltage: Red/Yellow (R/Y)–Ground 12 V (battery voltage) 5. Remove the fuel injectors. See “Fuel injector (FX SHO, FX Cruiser SHO)” (48) or “ETV and fuel injector (FX HO, FX Cruiser HO)” (4-9). 6. Measure the fuel injector resistance. Replace the fuel injector if out of specification.

Fuel pump module input voltage: Blue (L)–Black (B) 12 V (battery voltage)

TIP: After the unlock button is pushed, voltage will only be applied to the fuel pump module for 3 seconds. 5. Remove the fuel pump module assy. See “Fuel pump module removal” (4-14). 6. Measure the fuel sender resistance. Replace the fuel sender if out of specifications.

Fuel injector resistance at 20 °C (68 °F) (reference data): 11.5–12.5 

7-29

Fuel system / Starting system

Engine start switch continuity: Engine Red (R)– Clip a start switch Brown (Br) b Free No continuity Installed A Pushed Continuity Free No continuity Removed B Pushed No continuity

Fuel sender resistance at 20 °C (68 °F) (reference data): Float position Red (R)–Black (B) Lower position A 133.5–136.5  Upper position B 5.0–7.0 

3. Connect the left handlebar switch coupler (white coupler). 4. Disconnect the left handlebar switch coupler (black coupler).

7. Install the fuel pump module assy. See “Fuel pump module installation” (4-15).

5. Check the engine stop switch for continuity. Replace the left handlebar switch assy. if out of specification.

8. Connect the fuel pump module coupler.

a W

Starting system

Left handlebar switch assy. check 1. Disconnect the left handlebar switch coupler (white coupler). 2. Check the engine start switch for continuity. Replace the left handlebar switch assy. if out of specification.

B a

b R

b B

b Engine stop switch continuity: Engine White (W)– Clip a stop switch Black (B) b Free No continuity Installed A Pushed Continuity Free Continuity Removed B Pushed Continuity 6. Connect the left handlebar switch coupler (black coupler).

7-30

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

Main and fuel pump relay check

Do not reverse the battery leads. Otherwise, the main and fuel pump relay may be seriously damaged.

1. Disconnect the main and fuel pump relay coupler a, and then measure the input voltage between the main and fuel pump relay coupler terminals c or e (wring harness end) and ground.

R Y P W

g Main and fuel pump relay input voltage: Red (R)–Ground 12 V (battery voltage)

3. Connect the special service tool a. the the

5. Connect the positive battery lead to the connector e or f. 6. Connect the negative battery lead to the connector g. 7. Check the continuity between the connectors b and c or the connectors b and d. Replace the main and fuel pump relay if out of specification.

7-31

B L Br O

d c b

Test harness (8 pins) a: YB-06879/90890-06879

2. Remove the main and fuel pump relay. See “Electrical box” (5-35).

4. Connect the tester leads to connectors b and c or to connectors b and d.

12345678

Main relay continuity: Battery lead e or f–g Disconnected Connected

Terminal b–c or d No continuity Continuity

8. Connect the tester leads to connectors d and h. 9. Connect the positive battery lead to the connector c. 10. Connect the negative battery lead to the connector k. 11. Check the continuity between the connectors d and h. Replace the main and fuel pump relay if out of specification.

Starting system

TIP: The positive battery lead is marked with gray tape a. 3. Install the starter relay. See “Electrical box” (5-35).

a 12345678

h B L Br O

R Y P W

Fuel pump relay continuity: Battery lead c–k Terminal d–h Disconnected No continuity Connected Continuity 12. Install the main and fuel pump relay. See “Electrical box” (5-35).

4. Connect the tester leads between the starter relay terminals b and c. 5. Connect the positive battery lead to the terminal d, and the negative battery lead to the terminal e. 6. Check the continuity between the starter relay terminals b and c. Replace the starter relay if out of specification.

13. Connect the main and fuel pump relay coupler.

Starter relay check

Br B d

1. Remove the starter relay cover. See “Electrical box” (5-35). 2. Slide the boot away from the starter relay terminal a, and then measure the input voltage between the starter relay terminal a and ground.

Starter relay continuity: Battery lead d–e Terminal b–c Disconnected No continuity Connected Continuity 7. Install the starter relay. See “Electrical box” (5-35).

Starter relay input voltage: Red (R)–Ground 12 V (battery voltage)

7-32

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

Starter motor 9 N·m (0.9 kgf·m, 6.6 ft·lb)

7 10

7 N·m (0.7 kgf·m, 5.2 ft·lb)

3 13

5 2 1

12 11

8 4

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

7-33

Part name Bolt Rear cover Packing Front cover assy. Packing Plate Starter motor yoke Armature Brush holder assy. O-ring Circlip Drive gear O-ring

Q’ty 2 1 1 1 1 1 1 1 1 1 1 1 1

Remarks M6  120 mm  



Starter motor

Starter motor operation 1. Remove the starter motor. See “Starter motor and wiring harness assy. removal (FX SHO, FX Cruiser SHO)” (5-37) or “Starter motor and wiring harness assy. removal (FX HO, FX Cruiser HO)” (5-38). 2. Hold the starter motor in a vise using aluminum plates on both sides. 3. Connect the positive battery lead a to the starter motor terminal bolt a. 4. Connect the negative battery lead b to the starter motor body b, and then check the starter motor operation. WARNING! Do not touch the drive gear c.

2. Measure the commutator diameter a. Replace the armature if below specification.

TIP: • Check the starter motor operation for a few seconds. • If the starter motor is disassembled, make sure to check the operation again after assembling it.

Commutator diameter a: 27.0–28.0 mm (1.06–1.10 in) 3. Measure the commutator undercut b. Replace the armature if below specification.

5. Disconnect the negative battery lead, and then the positive battery lead from the battery terminals. 6. Install the starter motor. See “Starter motor and wiring harness assy. installation (FX SHO, FX Cruiser SHO)” (5-39) or “Starter motor and wiring harness assy. installation (FX HO, FX Cruiser HO)” (5-40).

Commutator undercut b (reference data): 0.2–0.7 mm (0.008–0.028 in) 4. Check the armature for continuity. Replace if out of specification.

Armature check 1. Check the commutator. Clean using 600grit sandpaper and compressed air if dirty.

7-34

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

e c

f Armature continuity: Commutator segments c Segment c– Armature core d Segment c– Armature core e

b d Continuity No continuity

e c

No continuity

Brush holder check 1. Measure the brush length a. Replace the brush holder assy. if below specification.

f Brush holder assy. continuity: Brush b–Brush c Brush d–Brush e Continuity Brush d–Terminal f Brush e–Terminal f For all brush and terminal combinations not listed No continuity above.

Remote control system Remote control transmitter check 1. Push the unlock button a. The buzzer sounds twice, and then check that the “UNLOCK” indicator light b comes on.

Brush length a: 5.0–12.5 mm (0.20–0.49 in) 2. Check the brush holder assy. for continuity. Replace if out of specification.

2. Push the unlock button a for more than 4 seconds. The buzzer sounds 3 times, and then check that the “L-MODE” indicator light c comes on. 3. Push the lock button d. The buzzer sounds once, and then check that the “UNLOCK” indicator light b goes off.

7-35

Starter motor / Remote control system

5. Remove the battery (CR2016) c. NOTICE: Do not touch the battery directly using your hands. Use a pair of non-conductive tweezers to replace the battery.

6. Measure the battery voltage. Replace the remote control transmitter battery if below specification.

c b

Number of beeps 1 beep 2 beeps 3 beeps

Yamaha Security System mode Lock Unlock (normal mode) L-MODE (low-rpm mode)

Remote control transmitter battery voltage: 3V

TIP: Refer to local hazardous waste regulations when disposing of transmitter batteries. 7. Install the battery (CR2016) c and transmitter cover b.

TIP: While the engine is running, input from the remote control transmitter is not received.

4. Loosen the transmitter screws a in the order a, b, and so on, and then remove the transmitter cover b. NOTICE: Do not touch the internal parts except the battery.

f a

TIP: Install the battery (CR2016) c so that the positive side e is facing down.

8. Tighten the transmitter cover screws a to the specified torque in the order a, b, and so on.

7-36

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

L/Y

b f

Transmitter cover screw a: 0.1 N·m (0.01 kgf·m, 0.07 ft·lb)

Remote control receiver check 1. Disconnect the remote control receiver coupler a, and then measure the input voltage at the remote control receiver coupler terminals (wiring harness end).

Remote control receiver output voltage (reference data): Blue/Yellow (L/Y)–Ground 11.0–12.0 V 5. Connect the remote control receiver coupler.

Transmitter registration • Each remote control transmitter a has a unique ID code. • To add or re-register the ID code of a remote control transmitter to the remote control receiver b, connect the entry box c.

a 1. Connect the entry box c to the 2-pin communication coupler a. Remote control receiver input voltage: Red (R)–Black (B) 12 V (battery voltage)

2. Connect the remote control receiver coupler a. 3. Disconnect the remote control receiver coupler b from the multifunction meter. 4. Supply power to the ECM, and then measure the remote control receiver output voltage at the remote control receiver coupler terminal (wiring harness end) and ground. Replace the remote control receiver if out of specification.

7-37

Gy B b

Gy B a

2. Push the lock button b or unlock button c to transmit the ID code from the remote control transmitter to be registered.

Remote control system / Indication system

Indication system b

Multifunction meter check 1. Check the multifunction meter external appearance. Replace the multifunction meter if there is cracked meter housing, fogged meter, or water intrusion.

TIP: • At this time, the system enters the registration mode to register the first code. All existing ID codes will be deleted from the remote control receiver. • The “UNLOCK” indicator light d blinks when the registration of the ID code has been completed. (If the registration could not be completed, the “UNLOCK” indicator light comes on. Re-transmit the ID code.)

2. Supply power to the ECM, and then check that all indicator lights a and display elements b and c on the multifunction meter come on. Replace the multifunction meter if it does not operate properly.

b 3. After checking that the registration of the ID code has been completed using the “UNLOCK” indicator light d, transmit the next ID code.

TIP: • When the multifunction meter is activated, all displays come on for 2 seconds, and then the multifunction meter starts to operate normally. • Display elements c is FX Cruiser SHO only. 3. Check the multifunction meter display. Replace the multifunction meter if there is intermittent or missing segment d.

TIP: • Up to 5 remote control transmitters can be registered in any sequence, regardless of whether they are original equipment or additional transmitters. • The same ID code cannot be registered twice in the remote control receiver. 4. After ID code registration has been completed, disconnect the entry box to exit the registration mode.

d 4. Disconnect coupler e.

the

multifunction

meter

7-38

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

5. Supply power to the ECM, and then measure the input voltage at the multifunction meter coupler terminals (wiring harness end). Replace the wiring harness if out of specification. Replace the multifunction meter if within specification and there is no display on the multifunction meter.

Left operation button continuity: Leads Button Position Pu/W B G/W “Speed/RPM” Free button a Pushed   Free “Volt/Hour” button b Pushed   3. Connect the left operation button coupler.

R/Y

4. Disconnect the right operation button coupler. See “Multifunction meter” (8-10). 5. Check the right operation button for continuity.

e Multifunction meter input voltage: Red/Yellow (R/Y)–Black (B) 12 V (battery voltage)

R/W

Y/W

B 6. Connect the multifunction meter coupler.

Multifunction meter operation button check

Right operation button is installed in FX Cruiser only. 1. Disconnect the left operation button coupler. See “Multifunction meter” (8-10). 2. Check the left operation button for continuity.

Pu/W

G/W B

Right operation button continuity: Leads Button Position R/W B Y/W Free “Start/Stop” button a Pushed   “Mode/Reset” Free button b Pushed   6. Connect coupler.

the

right

operation

button

Compass display check (FX Cruiser SHO) a b

1. Using a compass for reference, point the watercraft north. 2. Select the compass display mode of the multifunction meter and check that “NORTH” appears on the meter.

7-39

Indication system 3. Check that the arrow a on the compass and air temperature sensor is facing toward the bow. N

Air temperature display check (FX Cruiser SHO)

3. Select the water temperature display mode of the multifunction meter and check the water temperature displayed on the meter. 4. Check that the ambient water temperature and the displayed water temperature differ by less than ± 5 °C (± 9 °F).

1. Measure the ambient air temperature.

5. Disconnect the speed and temperature sensor coupler.

2. Select the air temperature display mode of the multifunction meter and check the air temperature displayed on the meter.

6. Measure the water temperature sensor a resistance.

3. Check that the ambient temperature and the displayed air temperature differ by less than ± 5 °C (± 9 °F).

water

B/Y

Y a Water temperature sensor resistance (reference data): Yellow (Y)–Black/Yellow (B/Y) 20 °C (3268 °F): 10 k

TIP: Check the air temperature display when the engine is cold.

Water temperature display check (FX Cruiser SHO) 1. Place the watercraft in a water.

7. Connect the speed and temperature sensor coupler.

water

Speed sensor check (FX Cruiser SHO) 1. Disconnect the compass and air temperature sensor coupler a.

2. Measure the ambient water temperature.

7-40

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

2. Connect the positive battery lead to the terminal b, and the negative battery lead to the terminal c.

3. Connect the tester leads between the terminal c and the terminal d.

3. Connect the tester leads between the terminal d and the terminal c.

4. Rotate the paddle wheel a manually and measure the output voltage between the terminal c and the terminal d. Replace if out of specification.

4. Rotate the paddle wheel a manually and measure the output voltage between the terminal d and the terminal c. Replace if out of specification.

B/Y c

b R/Y

Speed sensor output voltage (dependant on the paddle wheel position): Yellow (Y)–Black/Yellow (B/Y) Less than 400 mV/More than 11.6 V Speed sensor output voltage (dependant on the paddle wheel position): Green (G)–Black (B) Less than 400 mV/More than 4.5 V 5. Connect the compass temperature sensor coupler.

and

air

Speed sensor check (FX HO, FX Cruiser HO, and FX SHO) 1. Disconnect the speed sensor coupler a.

7-41

5. Connect the speed sensor coupler.

Fuel level meter display and fuel level warning indicator check 1. Remove the fuel pump module assy. See “Fuel pump module removal” (4-14). 2. Connect the fuel sender coupler a. 3. Lift the float to the upper position A .

Indication system 2. Supply power to the ECM, and then check that the “WARNING” indicator light b and the check engine warning indicator c begin to blink.

4. Supply power to the ECM, and then check that all fuel level segments come on. Replace the multifunction meter if any one of the segments does not come on. 5. Lower the float to the lowest position B , and then check that the fuel level warning indicator b, the lowest 2 fuel level segments c, and the “WARNING” indicator light d blink. If the indicator, segments, and the light do not blink, replace the multifunction meter.

3. If the light and indicator do not blink, check the “Diagnosis record” of the YDIS. If a diagnosis record is available and the light and indicator do not blink, replace the multifunction meter. 4. Connect the engine temperature sensor coupler.

Diagnostic display check b

1. Create a condition so that a diagnostic code is recorded. 2. With the engine running, push the 2 buttons a for approximately 8 seconds and check that the diagnostic code b is indicated.

6. Install the fuel pump module assy. See “Fuel pump module installation” (4-15).

Check engine warning indicator check 1. Disconnect the engine temperature sensor coupler a.

a a 3. If the diagnostic code is not indicated, check the “Diagnosis record” of the YDIS. If a diagnosis record is available and the diagnostic code is not indicated, replace the multifunction meter.

7-42

1 2 3 4 5 6 7 8 9 A

ELEC

Electrical system

Oil pressure warning indicator check 1. Disconnect the oil pressure switch coupler a, and then ground the terminal.

a P/W

B/O

B a

2. Start the engine, and then increase the engine speed to 4500 r/min or more. 3. Check that the “WARNING” indicator light b and the oil pressure warning indicator c blink, and the buzzer sounds intermittently.

B/O

A FX SHO, FX Cruiser SHO B FX HO, FX Cruiser HO 2. Start the engine and operate it at trolling speed for about 2 minutes.

4. If the light and indicator do not blink, check the “Diagnosis record” of the YDIS. If a diagnosis record is available and the light and indicator do not blink, replace the multifunction meter.

3. Check that the “WARNING” indicator light b and the engine overheat warning indicator c blink, and then come on, and the buzzer begins to sound intermittently, and then it sounds continuously.

5. Connect the oil pressure switch coupler.

Engine overheat warning indicator check 1. Disconnect the thermoswitch coupler a, and then connect the test lead a to the thermoswitch coupler terminals (wiring harness end).

4. If the light and indicator do not blink, check the “Diagnosis record” of the YDIS. If a diagnosis record is available and the light and indicator do not blink, replace the multifunction meter. 5. Connect the thermoswitch coupler.

7-43

Indication system

Buzzer check 1. Disconnect the buzzer coupler a. 2. Supply power to the ECM, and then measure the input voltage at the buzzer coupler terminals (wiring harness end). Check the wiring harness if out of specification.

L/R

B/L a

Buzzer input voltage (reference data): Blue/Red (L/R)–Black/Blue (B/L) 11.0–12.0 V 3. Remove the buzzer. master” (8-18).

See

“Steering

4. Connect the positive battery lead to the terminal b and the negative battery lead to the terminal c. 5. Check that the buzzer sounds. Replace the buzzer if it does not sound.

6. Install the buzzer. See “Steering master” (8-18). 7. Connect the buzzer coupler.

7-44

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood Steering pad and handlebar cover .................................. 8-1 Handlebar and handlebar switch assy. ........................... 8-2 Left handlebar switch assy. and throttle lever assy. ............................................................ 8-4 Cable and lead routing .............................................................. 8-5 Handlebar assy. installation ...................................................... 8-5

Front hood ......................................................................... 8-8 Multifunction meter ......................................................... 8-10 Side cover ........................................................................ 8-12 Side cover removal .................................................................. 8-13 Side cover installation ............................................................. 8-13

Center cover .................................................................... 8-14 Steering master assy. ..................................................... 8-16 Steering master ............................................................... 8-18 Steering shaft check ................................................................ 8-20 Steering arm assy. installation ................................................ 8-20

Steering cable and speed sensor lead .......................... 8-21 Steering cable installation (steering master end) .................... 8-24 Steering cable installation (jet pump end) ............................... 8-24 Shift cable installation (shift lever end) .................................... 8-25 Q.S.T.S. cable installation (Q.S.T.S. converter end) ............... 8-25

Seat and handgrip ........................................................... 8-27 Ventilation hose and water separator ........................... 8-29 Cooling water pilot outlet installation ....................................... 8-31 Ventilation hose installation ..................................................... 8-31

Exhaust system ............................................................... 8-32 Exhaust system installation ..................................................... 8-34

Rear section ..................................................................... 8-35 Spout installation ..................................................................... 8-38 Reboarding step assy. installation ........................................... 8-38

Deck and hull ................................................................... 8-39

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

Steering pad and handlebar cover 3 2 1 N·m (0.1 kgf·m, 0.7 ft·lb)

1 5

No. 1 2 3 4 5 6

8-1

Part name Tapping screw Upper handlebar cover Steering pad cover Steering pad Screw Lower handlebar cover

Q’ty 8 1 1 1 4 1

Remarks M5  16 mm

M6  14 mm

Steering pad and handlebar cover / Handlebar and handlebar switch assy.

Handlebar and handlebar switch assy. 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb)

10 1

6 5 4

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

1 N·m (0.1 kgf·m, 0.7 ft·lb)

20 N·m (2.0 kgf·m, 14.8 ft·lb)

13 11 13 14 17 16 N·m (1.6 kgf·m, 11.8 ft·lb)

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

20 19

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Bolt Washer Handlebar grip Handlebar grip Bolt Bolt Right handlebar switch Throttle lever assy. Screw Q.S.T.S. grip Screw Left handlebar switch assy. Bolt Upper handlebar holder Handlebar Bolt

Q’ty 2 2 1 1 2 2 1 1 1 1 2 1 4 2 1 4

Remarks M6  12 mm

M5  23 mm M5  30 mm

M6  70 mm M5  30 mm M8  48 mm a Punch mark M6  9 mm

8-2

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb)

10 1

6 5 4

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

1 N·m (0.1 kgf·m, 0.7 ft·lb)

20 N·m (2.0 kgf·m, 14.8 ft·lb)

13 11 13 14 17 16 N·m (1.6 kgf·m, 11.8 ft·lb)

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

20 19

No. 17 18 19 20

8-3

Part name Steering boss cover Plastic tie Packing Grommet

Q’ty 1 1 1 1

Remarks



Handlebar and handlebar switch assy. / Left handlebar switch assy. and throttle lever assy.

Left handlebar switch assy. and throttle lever assy. 1 5 2

6 6

3 No. 1 2 3 4 5 6

Part name Left handlebar switch assy. Engine shut-off cord Screw Stop button Start button Screw

Q’ty 1 1 2 1 1 5

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

Remarks

M5  30 mm

M3  10 mm

8-4

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

Cable and lead routing 1. Wrap the packing a at the paint marks a on the left handle bar switch assy. lead b, right handle bar switch lead c, and throttle lever assy. lead d.

f e h

g i

a a b

Distance g: 10.0 mm (0.4 in)

Handlebar assy. installation 2. Make sure that the upper edge b of the packing a is the specified distance c from the upper edge d of the grommet e. 3. Fasten the grommet e using the plastic tie f.

b d a

c f e

After installing the handlebar assy., make sure that the Q.S.T.S. cable, right handlebar switch, and left handlebar switch lead are not pulled when the handlebar is turned to the right and left. 1. Pass the Q.S.T.S. cables a, left handlebar switch assy. b, right handlebar switch c, and throttle lever assy. d through the opening of the steering boss cover e. 2. Install the steering boss cover e, and then tighten the steering boss cover screws f to the specified torque.

Distance c: 10.0 mm (0.4 in) 4. Wrap the packing g, making sure to align the upper edge of the packing with the upper edge of the marking tape e on the Q.S.T.S. cable. 5. Make sure that the upper edge f of the packing g is specified distance g from the upper edge h of the grommet h.

f e

c a f d df b

6. Fasten the grommet h using the plastic tie i.

8-5

Steering boss cover screw f: 1 N·m (0.1 kgf·m, 0.7 ft·lb)

Left handlebar switch assy. and throttle lever assy. 3. Install the right handlebar switch c and throttle lever assy. d, and then tighten the right handlebar switch screws g to the specified torque.

e i

c g

Cable locknut i: 16 N·m (1.6 kgf·m, 11.8 ft·lb)

d Right handlebar switch screw g: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

TIP: Align the protrusion a on the handlebar switch with the handlebar hole b. 4. Install the left handlebar switch assy. b, and then tighten the left handlebar switch screws h to the specified torque.

Cable length e: 73.0 mm (2.9 in) 7. Route the Q.S.T.S. cables a through the cover j and housing k.

TIP: Make sure to route the Q.S.T.S. cables through the housing e recesses that have the same shapes as the cables f. 8. Fit the cable ends g into the holes h in the Q.S.T.S. grip l.

b c

l h

Left handlebar switch screw h: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

TIP: Align the protrusion c on the handlebar switch assy. with the handlebar hole d. 5. Loosen the cable locknuts i, and then adjust the length e of the Q.S.T.S. cables.

9. Install the Q.S.T.S. grip l onto the handle bar, and then tighten the Q.S.T.S. grip screw m to the specified torque.

6. Tighten the cable locknuts i to the specified torque.

8-6

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

Clearance (reference data): n: 0.4 mm (0.02 in) p: 2.4 mm (0.1 in)

TIP:

m Q.S.T.S. grip screw m: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 10. Install the handlebar n and upper handlebar holders o, and then tighten the handlebar holder bolts p to the specified torque.

• Align the punched marks k on the handlebar n with the top surface of the steering master q. • The upper handlebar holder o should be installed with the punch mark m facing down. • Tighten the bolts p so that there is clearance between the steering master q and the upper handlebar holders o at both ends of the upper handlebar holders. • Make sure that clearance n is narrower than clearance p.

p 11. Tighten the handlebar grip bolts r to the specified torque.

12. Install the handlebar grips s, and then tighten the grip end bolts t to the specified torque.

o q

t s n

s t

r q

o o

p m

n n Handlebar holder bolt p: 20 N·m (2.0kgf·m, 14.8 ft·lb)

8-7

Handlebar grip bolts r: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) Handlebar grip end bolts t: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

Left handlebar switch assy. and throttle lever assy. / Front hood

Front hood 3

1.5 N·m (0.15 kgf·m, 1.11 ft·lb)

4 N·m (0.4 kgf·m, 3.0 ft·lb)

5 N·m (0.5 kgf·m, 3.7 ft·lb)

23 2

5 N·m (0.5 kgf·m, 3.7 ft·lb)

22 7 8

18 21

2 1

5 14 10 4 11

1 16

2 24

13 N·m (1.3 kgf·m, 9.6 ft·lb)

17 19

13 20

14 15 5

29 2 N·m (0.2 kgf·m, 1.5 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Bolt Bolt Right mirror Left mirror Nut Bolt Bolt Damper stay Damper Plastic tie Boot Bolt Hinge Rivet Plate Plate

Q’ty 2 4 1 1 6 2 2 1 1 1 1 4 1 6 1 1

5 N·m (0.5 kgf·m, 3.7 ft·lb)

Remarks M6  23 mm M8  25 mm

M6  18 mm

M6  30 mm

8-8

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

1.5 N·m (0.15 kgf·m, 1.11 ft·lb)

4 N·m (0.4 kgf·m, 3.0 ft·lb)

5 N·m (0.5 kgf·m, 3.7 ft·lb)

23 2

5 N·m (0.5 kgf·m, 3.7 ft·lb)

22 7 8

18 21

2 1

5 14 10 4 11

1 16

2 24

13 N·m (1.3 kgf·m, 9.6 ft·lb)

17 19

13 20

14 15 5

29 2 N·m (0.2 kgf·m, 1.5 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb)

No. 17 18 19 20 21 22 23 24 25 26 27 28 29 30

8-9

Part name Tapping screw Front hood cover Center ornament Front hood Tapping screw Bolt Hood lock assy. Front hood inner Packing Damper Damper Packing Nut Packing

Q’ty 19 1 1 1 2 2 1 1 1 2 4 1 4 2

5 N·m (0.5 kgf·m, 3.7 ft·lb)

Remarks M5  16 mm

M5  9 mm M5  20 mm



 

Front hood / Multifunction meter

Multifunction meter B

2 N·m (0.2 kgf·m, 1.5 ft·lb)

27 17 19

12 5 N·m (0.5 kgf·m, 3.7 ft·lb)

18 19

20 22

13 15

24 25 25

14 4

4 N·m (0.4 kgf·m, 3.0 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Right operation button assy. Cover Left operation button assy. Bolt Lid lock hook Nut Tapping screw Cover Bolt Multifunction meter Multifunction meter Grommet Transmitter Remote control receiver Rivet Bracket

Q’ty 1 1 1 4 1 4 4 1 4 1 1 4 2 1 2 1

Remarks A FX Cruiser SHO B FX SHO, FX HO, FX Cruiser HO M6  29 mm

M5  15 mm M5  12 mm A FX Cruiser SHO B FX SHO, FX HO, FX Cruiser HO FX HO, FX Cruiser HO: 1

8-10

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

2 N·m (0.2 kgf·m, 1.5 ft·lb)

27 17 19

12 5 N·m (0.5 kgf·m, 3.7 ft·lb)

18 19

20 22

13 15

24 25 25

14 4

4 N·m (0.4 kgf·m, 3.0 ft·lb)

No. 17 18 19 20 21 22 23 24 25 26 27 28

8-11

Part name Rivet Service lid Rivet Bow locker Plug Band Fire extinguisher box Mat Rivet Hook Plastic tie Plastic tie

Q’ty 5 1 4 1 1 1 1 2 2 2 1 1

Remarks



A FX Cruiser SHO

Multifunction meter / Side cover

Side cover 5 N·m (0.5 kgf·m, 3.7 ft·lb)

5 N·m (0.5 kgf·m, 3.7 ft·lb)

1 1 2

7 11

7 10

5 N·m (0.5 kgf·m, 3.7 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11

Part name Bolt Nut Left side ornament Right side ornament Screw Shift lever Screw Bolt Right side cover Left side cover Nut

Q’ty 6 8 1 1 2 1 2 1 1 1 4

Remarks M6  30 mm

M6  14 mm M6  18 mm M6  23 mm

8-12

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

Side cover removal

Side cover installation

1. Set the shift lever to the reverse position.

1. Set the shift lever to the forward position.

2. Remove the shift lever a.

2. Install the side cover a, and then tighten the side cover bolts b and c and side cover screws d to the specified torque.

3. Set the shift lever to the forward position.

b F

TIP: Set the shift lever assy. b to the forward position while pushing down the lock lever c. 4. Remove the side cover bolts d and e and side cover screw f.

Side cover bolts b and c: 5 N·m (0.5 kgf·m, 3.7 ft·lb) Side cover screw d: 5 N·m (0.5 kgf·m, 3.7 ft·lb) 3. Set the shift lever to the neutral position. 4. Install the shift lever e, and then tighten the shift lever screws f to the specified torque.

f d R

f 5. Slide the side cover g, and then push down on the side cover near the tab to release the protrusion a on the tab from the center cover h.

8-13

Shift lever screw f: 5 N·m (0.5 kgf·m, 3.7 ft·lb)

Side cover / Center cover

Center cover 13

5 N·m (0.5 kgf·m, 3.7 ft·lb)

13 16

5 1 14 18

5 N·m (0.5 kgf·m, 3.7 ft·lb)

4 8 1

2 N·m (0.2 kgf·m, 1.5 ft·lb)

2 19 22 23

24 25

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Bolt Nut Bolt Center cover Pad Pad Grommet Nut Pad Beverage holder Lock Center console box lid Hinge pin Screw Center console box Plug

Q’ty 4 4 2 1 1 6 2 6 1 1 1 1 2 4 1 1

Remarks M6  29 mm M6  23 mm



M6  18 mm

8-14

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

5 N·m (0.5 kgf·m, 3.7 ft·lb)

13 16

5 1 14 18

5 N·m (0.5 kgf·m, 3.7 ft·lb)

4 8 1

2 N·m (0.2 kgf·m, 1.5 ft·lb)

2 19 22 23

24 25

No. 17 18 19 20 21 22 23 24 25

8-15

Part name Packing Box cap Packing Tapping screw Chain ball Transmitter holder Rivet Box Pad

Q’ty 1 1 1 2 1 1 3 1 1

Remarks 

M6  18 mm



Center cover / Steering master assy.

Steering master assy. 13 13

14 15

18 7

21 N·m (2.1 kgf·m, 15.5 ft·lb)

4 a

11 10

4 5

A 17 16

4 N·m (0.4 kgf·m, 3.0 ft·lb)

8 3 7 N·m (0.7 kgf·m, 5.2 ft·lb)

2 7 N·m (0.7 kgf·m, 5.2 ft·lb)

16 N·m (1.6 kgf·m, 11.8 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Bolt Plate Steering arm assy. Steering arm Nut Ball joint Nut Bolt Cable stopper Nut Washer Bolt Steering master assy. Screw Compass and air temperature sensor Nut

Q’ty 1 1 1 1 1 1 1 1 1 4 4 4 1 2 1 2

Remarks M8  24 mm

a Alignment hole

M6  60 mm

M8  35 mm a Alignment hole A FX Cruiser SHO, M5  25 mm A FX Cruiser SHO A FX Cruiser SHO

8-16

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

13 13

14 15

18 7

21 N·m (2.1 kgf·m, 15.5 ft·lb)

4 a

11 10

4 5

A 17 16

4 N·m (0.4 kgf·m, 3.0 ft·lb)

8 3 7 N·m (0.7 kgf·m, 5.2 ft·lb)

2 7 N·m (0.7 kgf·m, 5.2 ft·lb)

16 N·m (1.6 kgf·m, 11.8 ft·lb)

No. 17 18 19

8-17

Part name Washer Plastic tie Grommet

Q’ty 2 1 1

Remarks A FX Cruiser SHO

Steering master assy. / Steering master

Steering master 4 N·m (0.4 kgf·m, 3.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb)

7 11

4 10 13 8

17 1

13 15

7 N·m (0.7 kgf·m, 5.2 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Steering master assy. Bolt Bracket Bracket Buzzer Bolt Steering sensor Rubber seal Lever Lock Steering shaft Pipe seal Bushing Bushing Rivet Plate

Q’ty 1 2 1 1 1 4 1 1 1 1 1 1 4 1 2 1

Remarks M5  15 mm

M6  25 mm 

8-18

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

4 N·m (0.4 kgf·m, 3.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb)

7 11

4 10 13 8

17 1

13 15

7 N·m (0.7 kgf·m, 5.2 ft·lb)

No. 17

8-19

Part name Pad

Q’ty 2

Remarks 

Steering master

Steering shaft check 1. Check the steering shaft. Replace if cracked or damaged. NOTICE: Do not disassemble the board spring a. Otherwise, the OTS will not function properly.

i g h f

a 4. Assemble the steering master.

Steering arm assy. installation 1. Install the bushings a and b.

5. Apply instant adhesive onto the mating surfaces of the rubber seal j and steering master assy. k in the area a as shown, and then install the seal. NOTICE: Do not reuse the rubber seal, always replace it with a new one.

k a

j a

b a

2. Install the spring c, steering tube d, lock e, and lever f to the right housing g.

f d

g c

3. Install the spring h and spring holder i to the right housing g and lever f.

8-20

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

Steering cable and speed sensor lead 4 N·m (0.4 kgf·m, 3.0 ft·lb)

7 N·m (0.7 kgf·m, 5.2 ft·lb)

20 21

25 5

15 16

7 N·m (0.7 kgf·m, 5.2 ft·lb)

3 8 13

5 N·m (0.5 kgf·m, 3.7 ft·lb)

7 N·m (0.7 kgf·m, 5.2 ft·lb)

4 N·m (0.4 kgf·m, 3.0 ft·lb)

5 N·m (0.5 kgf·m, 3.7 ft·lb)

5 13

30 10 11

33 32

9 18 19

7 N·m (0.7 kgf·m, 5.2 ft·lb)

37 36

28 34

37 36

36 23

7 N·m (0.7 kgf·m, 5.2 ft·lb)

6 N·m (0.6 kgf·m, 4.4 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

8-21

Part name Shift cable joint Shift cable Nut Packing Plastic tie Packing Grommet Nut Shift cable bracket Nut Shift cable holder Shift cable holder Nut Washer Shift lever assy. Screw

Q’ty 1 1 1 1 2 1 1 2 1 2 1 1 2 2 1 2

Remarks

 

M5  12 mm

Steering cable and speed sensor lead

4 N·m (0.4 kgf·m, 3.0 ft·lb)

7 N·m (0.7 kgf·m, 5.2 ft·lb)

20 21

25 5

15 16

7 N·m (0.7 kgf·m, 5.2 ft·lb)

3 8 13

5 N·m (0.5 kgf·m, 3.7 ft·lb)

7 N·m (0.7 kgf·m, 5.2 ft·lb)

4 N·m (0.4 kgf·m, 3.0 ft·lb)

5 N·m (0.5 kgf·m, 3.7 ft·lb)

5 13

30 10 11

33 32

9 18 7 N·m (0.7 kgf·m, 5.2 ft·lb)

37 36

19 35 37 36

28 34

37 36

36 23

7 N·m (0.7 kgf·m, 5.2 ft·lb)

6 N·m (0.6 kgf·m, 4.4 ft·lb)

No. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Part name Reverse sensor Steering cable joint Steering cable Nut Packing Speed and water temperature sensor Speed sensor Nut Q.S.T.S. cable Packing Grommet Nut Packing Bolt Washer Packing

Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 4

Remarks

 FX Cruiser SHO FX SHO, FXHO, FX Cruiser HO



 M6  33 mm 

8-22

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

4 N·m (0.4 kgf·m, 3.0 ft·lb)

7 N·m (0.7 kgf·m, 5.2 ft·lb)

19 20 21

25 5

15 16

7 N·m (0.7 kgf·m, 5.2 ft·lb)

3 8 13

5 N·m (0.5 kgf·m, 3.7 ft·lb)

7 N·m (0.7 kgf·m, 5.2 ft·lb)

4 N·m (0.4 kgf·m, 3.0 ft·lb)

5 N·m (0.5 kgf·m, 3.7 ft·lb)

5 13

30 10 11

33 32

9 18 19

7 N·m (0.7 kgf·m, 5.2 ft·lb)

37 36

28 34

37 36

36 23

7 N·m (0.7 kgf·m, 5.2 ft·lb)

6 N·m (0.6 kgf·m, 4.4 ft·lb)

No. 32 33 34 35 36 37

8-23

Part name Q.S.T.S. rod Q.S.T.S. converter Cable guide Plastic tie Rivet Holder

Q’ty 1 1 1 5 5 5

Remarks

Steering cable and speed sensor lead

Steering cable installation (steering master end) b c

If a cable becomes damaged, replace it. Never attempt to repair a damaged cable.

c 1. Insert the projection a on the steering cable completely into the indentation b in the cable stopper assy. NOTICE: Do not attempt to twist the steering cable to align it. Be sure to turn the drum nut a to install the steering cable.

4. Connect the steering cable joint d to the ball joint e.

5. Adjust the steering cable. See “Jet thrust nozzle angle adjustment” (3-2).

TIP: If the projection a on the steering cable is not aligned properly to fit back the indentation, rotate the drum nut a counterclockwise a maximum of 90° for proper alignment. 2. Slightly pull out the clamp plate b on the cable stopper assy., and then rotate it clockwise to lock it in place securely.

Steering cable installation (jet pump end) 1. Adjust the steering cable set length a, and then tighten the steering cable locknut a to the specified torque.

Steering cable locknut a: 7 N·m (0.7 kgf·m, 5.2 ft·lb) 3. Rotate the clamp plate c on the cable stopper assy. counterclockwise, making sure to fit the projection c on the other clamp plate b into the hole in the plate.

Steering cable set length a (jet pump end): 14.5 ± 1 mm (0.57 ± 0.04 in) 2. Install the washer b and steering cable joint c, and then tighten the steering cable joint c to the specified torque.

8-24

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

3. Install the washer d and steering cable joint nut e, and then tighten the steering cable joint nut e to the specified torque.

TIP: Make sure that the edge of the packing c is at the specified distance e from the edge of the grommet d.

c 4. Install the shift cable holder a and grommet d to the shift cable bracket f, and then tighten the shift cable holder nuts g to the specified torque.

b d

5. Install the plastic tie h.

6. Install the shift cable bracket f, and then tighten the shift cable bracket nuts i to the specified torque.

Steering cable joint c: 7 N·m (0.7 kgf·m, 5.2 ft·lb) Steering cable joint nut e: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

Shift cable installation (shift lever end)

c h

1. Install the shift cable holder a so that the projection a on the holder fits into the groove b in the outer cable.

a a

d i g

Distance e: 5–15 mm (0.20–0.59 in) Shift cable holder nut g: 5 N·m (0.5 kgf·m, 3.7 ft·lb) Shift cable bracket nut i: 5 N·m (0.5 kgf·m, 3.7 ft·lb)

2. Slide the shift cable holder b onto the shift cable holder a so that the marks c and d are positioned as shown.

a c

3. Install the packing c and grommet d onto the shift cable e.

8-25

Q.S.T.S. cable installation (Q.S.T.S. converter end) 1. Make sure to fit the Q.S.T.S. cable end with yellow paint mark a into the STBD hole b of the pulley. NOTICE: Be careful not to twist the Q.S.T.S. cables.

STERN

Steering cable and speed sensor lead 2. Adjust the Q.S.T.S. rod set length c. WARNING! The Q.S.T.S. rod joint must be screwed in more than 8 mm (0.31 in) d. 3. Face the hole e in the joint of the Q.S.T.S. rod a in the direction shown.

d Distance c: 167.0 Âą 0.5 mm (6.93 Âą 0.02 in)

8-26

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

Seat and handgrip 1 A

5 A

16 17 3

18 2

6 N·m (0.6 kgf·m, 4.4 ft·lb)

26 N·m (2.6 kgf·m, 19.2 ft·lb)

13 14 21

3 3

12 23 8

22 27

8 7

6 N·m (0.6 kgf·m, 4.4 ft·lb)

30 5 N·m (0.5 kgf·m, 3.7 ft·lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

8-27

Part name Front seat assy. Bolt Seat lock assy. Packing Rear seat assy. Packing Nut Washer Bolt Handgrip Nut Washer Projection Washer Cap Packing

5 N·m (0.5 kgf·m, 3.7 ft·lb)

24 Q’ty 1 4 2 1 1 1 4 9 4 1 2 2 2 2 1 1

16 N·m (1.6 kgf·m, 11.8 ft·lb)

Remarks A FX Cruiser SHO, FX Cruiser HO M6  40 mm  A FX Cruiser SHO, FX Cruiser HO 

M8  30 mm

Seat and handgrip

1 A

5 A

16 17 3

18 2

6 N·m (0.6 kgf·m, 4.4 ft·lb)

26 N·m (2.6 kgf·m, 19.2 ft·lb)

13 14 21

3 3

23 8 22 27

2 2

12 11

8 7

6 N·m (0.6 kgf·m, 4.4 ft·lb)

30 5 N·m (0.5 kgf·m, 3.7 ft·lb)

No. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Part name Watertight storage compartment Nut Packing Bolt Deck beam Packing Packing Nut Washer Seat holder Plastic tie Battery breather hose Nipple Front seat assy. Rear seat assy.

5 N·m (0.5 kgf·m, 3.7 ft·lb)

24 Q’ty 1 5 1 5 1 1 2 2 2 1 1 1 1 1 1

16 N·m (1.6 kgf·m, 11.8 ft·lb)

Remarks

 M8  30 mm  

B FX SHO, FX HO B FX SHO, FX HO

8-28

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

Ventilation hose and water separator A

27 26 25

29 28

15 31 24 30

30 28

28 29

9 6

10 13 12 11

7 1

6 29 28

20 4

8-29

Part name Rivet Induction box Plastic tie Ventilation hose Grommet Plastic tie Fuel tank breather hose 1 Fuel tank breather hose 2 Rivet Water separator Drain bolt O-ring Plate Rivet Ventilation socket Ventilation pipe

28 29

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Q’ty 6 2 2 2 2 3 1 1 2 1 1 1 1 2 1 1

18 4 N·m (0.4 kgf·m, 3.0 ft·lb)

Remarks



Ventilation hose and water separator

27 26 25

29 28

15 31 24 30

30 28

28 29

9 6

10 13 12 11

7 1

6 29 28

20 4

3 Part name Holder Nut Clamp Cooling water hose Cooling water pilot outlet Seal Nut Clamp Cooling water hose Cooling water pilot outlet Seal Rivet Holder Plastic tie Plastic tie

28 29

No. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Q’ty 1 1 1 1 1 1 1 1 1 1 1 8 8 5 1

18 4 N·m (0.4 kgf·m, 3.0 ft·lb)

Remarks

 A FX SHO, FX Cruiser SHO A FX SHO, FX Cruiser SHO A FX SHO, FX Cruiser SHO A FX SHO, FX Cruiser SHO A FX SHO, FX Cruiser SHO

8-30

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

Cooling water pilot outlet installation

1. Install a new seal a and the cooling water pilot outlet b, and then tighten the cooling water pilot outlet nut c to the specified torque.

a 2 c

Cooling water pilot outlet nut c: 4 N·m (0.4 kgf·m, 3.0 ft·lb)

Installation distance a: 30–40 mm (1.18–1.57 in)

TIP: TIP: Align each protrusion a with the slit b.

Ventilation hose installation 1. Install the grommets a.

TIP: Make sure that the grommet a is seated properly in the hole in the inner hull b. 2. Install the ventilation hoses c.

8-31

• Make sure to route the ventilation hose (PORT) in front of the ventilation hose (STBD). • Make sure that the end of the ventilation hose c is at the specified distance a from the groove around the outside of the grommet a.

Ventilation hose and water separator / Exhaust system

Exhaust system 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

11 23

21 22 23

13 14 13

5 N·m (0.5 kgf·m, 3.7 ft·lb)

3 17

2 9 28

26 16

1 28

24 25

7 24

24 8

25 26

10 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Negative battery lead Positive battery lead Clamp Band Battery Bolt Nut Battery case Pad Flotation Clamp Resonator Clamp Clamp Rubber hose Band

Q’ty 1 1 1 2 1 2 2 1 1 1 1 1 2 1 1 1

Remarks

M6  22 mm

8-32

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

11 23

21 22 23

13 14 13

5 N·m (0.5 kgf·m, 3.7 ft·lb)

3 17

2 9 28

26 16

1 28

24 25

7 24

24 8

25 26

10 No. 17 18 19 20 21 22 23 24 25 26 27 28 29 30

8-33

Part name Water lock Water tank Nut Washer Plate Rubber hose Exhaust valve Rivet Hook Pad Pad Pad Bracket Bracket

Q’ty 1 1 6 6 1 1 1 8 2 4 3 3 1 1

Remarks



  

Exhaust system

Exhaust system installation 1. Install the plate a onto the rubber hose b.

TIP: Align the mark b on the rubber hose b with the mark c on the water tank e.

b a

4. Install the water lock g and band h.

5. Install the rubber hose i, and then tighten the rubber hose clamps j and k to the specified torque.

i a

TIP:

Make sure to fit the protrusions a on the rubber hose b with the grooves in the plate a. 2. Install the rubber hose b and a new exhaust valve c, and then tighten the rubber hose nuts d to the specified torque.

Rubber hose clamp j and k: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

TIP: d

6. Install the resonator l, and then tighten the rubber hose clamp m to the specified torque.

Rubber hose nut d: 5 N·m (0.5 kgf·m, 3.7 ft·lb) 3. Install the water tank e, and then tighten the rubber hose clamp f to the specified torque.

Align the protrusions d on the rubber hose i with the mark e on the water tank.

f e

c b

Rubber hose clamp m: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

Rubber hose clamp f: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)

8-34

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

Rear section 5 N·m (0.5 kgf·m, 3.7 ft·lb)

3 15 16 N·m (1.6 kgf·m, 11.8 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb)

16 14

19 11

7 6

18 12

17 5 4

7 22 21 20

1 5 N·m (0.5 kgf·m, 3.7 ft·lb)

16 N·m (1.6 kgf·m, 11.8 ft·lb)

BOW

5 N·m (0.5 kgf·m, 3.7 ft·lb)

24 23 16 N·m (1.6 kgf·m, 11.8 ft·lb)

31 30 2 N·m (0.2 kgf·m, 1.5 ft·lb)

23 29

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

8-35

Part name Tapping screw Side cover Side cover Nut Washer Grip Packing Bolt Stern storage compartment lid Rivet Latch Nut Washer Bolt Stern storage compartment Damper

32 Q’ty 4 1 1 2 2 1 2 2 1 8 2 2 2 2 1 2

33 Remarks M5  16 mm

 M6  10 mm

M8  30 mm

Rear section

5 N·m (0.5 kgf·m, 3.7 ft·lb)

3 15 16 N·m (1.6 kgf·m, 11.8 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb)

16 14

19 11

7 6

18 12

17 5 4

7 22 21 20

1 5 N·m (0.5 kgf·m, 3.7 ft·lb)

16 N·m (1.6 kgf·m, 11.8 ft·lb)

BOW

5 N·m (0.5 kgf·m, 3.7 ft·lb)

24 23 16 N·m (1.6 kgf·m, 11.8 ft·lb)

31 30 2 N·m (0.2 kgf·m, 1.5 ft·lb)

23 29

No. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Part name Nut Plate Cleat Stern eye Plate Packing Bolt Reboarding step assy. Bracket Packing Nut Spout Screw Nut Washer Drain plug

32 Q’ty 6 2 1 2 4 2 4 1 2 2 1 1 4 4 4 2

33 Remarks

 M8  45 mm



8-36

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

5 N·m (0.5 kgf·m, 3.7 ft·lb)

3 15 16 N·m (1.6 kgf·m, 11.8 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb)

16 14

19 11

7 6

18 12

17 5 4

7 22 21 20

1 5 N·m (0.5 kgf·m, 3.7 ft·lb)

16 N·m (1.6 kgf·m, 11.8 ft·lb)

BOW

5 N·m (0.5 kgf·m, 3.7 ft·lb)

24 23 16 N·m (1.6 kgf·m, 11.8 ft·lb)

31 30 2 N·m (0.2 kgf·m, 1.5 ft·lb)

23 29

No. 33

8-37

Part name Packing

32 Q’ty 2

33 Remarks 

Rear section

Spout installation 1. Install the spout a, and then tighten the spout nut b to the specified torque. 2. Connect the hose c, and then tighten the spout hose clamp d to the specified torque.

a BOW

a b d c

b c c Reboarding step assy. bolt c: 16 N·m (1.6 kgf·m, 11.8 ft·lb)

Spout nut b: 5 N·m (0.5 kgf·m, 3.7 ft·lb) Spout hose clamp d: 2 N·m (0.2 kgf·m, 1.5 ft·lb)

TIP: Face the mark a toward the BOW.

Reboarding step assy. installation 1. Secure the brackets on both sides of the reboarding step in the down position using the plastic ties a so that they will not return to the up position.

2. Install the reboarding step assy. b, and then tighten the reboarding step assy. bolts c to the specified torque.

8-38

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

Deck and hull 2 N·m (0.2 kgf·m, 1.5 ft·lb)

STBD

32 24

33 PORT

24 25

18 N·m (1.8 kgf·m, 13.3 ft·lb)

10 10

8 18

9 7

3 21

10 12

10 7

8 6 5

37 36

28 29 30 31

3 7

19 15 16

13 N·m (1.3 kgf·m, 9.6 ft·lb)

8-39

14 4

Part name Bolt Bow eye Nut Front protector Front protector Front protector Bolt Rivet Front cover Rivet Rear protector Rear protector Inner gunwale Rivet Washer Side gunwale

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

16 N·m (1.6 kgf·m, 11.8 ft·lb)

13 5 N·m (0.5 kgf·m, 3.7 ft·lb)

Q’ty 2 1 12 1 1 1 12 11 1 7 1 1 2 30 30 2

Remarks M6  20 mm

M6  25 mm

Deck and hull

2 N·m (0.2 kgf·m, 1.5 ft·lb)

STBD

32 24

33 PORT

24 25

18 N·m (1.8 kgf·m, 13.3 ft·lb)

10 10

8 18

9 7

3 21

10 12

10 7

8 6 5

37 36

28 29 30 31

3 7

19 15 16

14 4

1 13 N·m (1.3 kgf·m, 9.6 ft·lb)

Part name Bolt Collar Sponson Sponson Bracket Mat Mat Mat Mat Mat Mat Nut Washer Washer Nut Cover

No. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

16 N·m (1.6 kgf·m, 11.8 ft·lb)

13 5 N·m (0.5 kgf·m, 3.7 ft·lb)

Q’ty 8 8 1 1 2 1 1 2 1 1 1 2 2 2 2 2

Remarks M8  40 mm

     

M6  24 mm

8-40

1 2 3 4 5 6 7 8 9 A

HULL HOOD

Hull and hood

2 N·m (0.2 kgf·m, 1.5 ft·lb)

STBD

32 24

33 PORT

24 25

18 N·m (1.8 kgf·m, 13.3 ft·lb)

10 10

8 18

9 7

3 21

10 12

10 7

8 6 5

37 36

28 29 30 31

3 7

19 15 16

13 N·m (1.3 kgf·m, 9.6 ft·lb)

8-41

14 4

Part name Bolt Cleat Packing Bracket Packing

No. 33 34 35 36 37

16 N·m (1.6 kgf·m, 11.8 ft·lb)

13 5 N·m (0.5 kgf·m, 3.7 ft·lb)

Q’ty 6 2 2 2 2

Remarks M6  20 mm  

TRBL SHTG

Troubleshooting YDIS .................................................................................... 9-1 Function ..................................................................................... 9-1 Basic components ..................................................................... 9-3 Connecting the communication cable to the watercraft ............. 9-4

Engine unit troubleshooting ............................................ 9-5 Using the YDIS for engine unit troubleshooting ........................ 9-5 Diagnostic code table ................................................................ 9-7 Diagnostic code and checking step ........................................... 9-8 Engine unit troubleshooting (diagnostic code not detected) ................................................ 9-14

1 2 3 4 5 6 7 8 9 A

TRBL SHTG

Troubleshooting

YDIS The Yamaha Diagnostic System uses precision fault diagnosis to offer better serviceability at a time when there is increasing demand for service tools for electronically controlled products. It provides quick, reliable, safe, and reasonable service, and is intended to obtain customer satisfaction. The Yamaha Diagnostic System features updated software and expanded tool functions that allow it to respond to new models and technologies, maintaining compatibility with regulations. This manual contains the model-specific information. See YDIS (Ver. 2.00) instruction manual for detailed information.

Function 1. Diagnosis: Each sensor’s status and each ECM diagnostic code or item is displayed. This enables you to find malfunctioning parts and controls quickly. The diagnostic codes displayed are the same as those described in “Diagnostic code and checking step” in this chapter. 2. Diagnosis record: Sensors that had been activated and ECM diagnostic codes that have been recorded are displayed. This allows you to check the watercraft’s record of malfunctions. The diagnostic codes displayed are the same as those described in “Diagnostic code and checking step” in this chapter. 3. Engine monitor: Each sensor status and the ECM data are displayed. This enables you to find malfunctioning parts quickly. In addition, the data displayed using the Engine monitor function can be displayed in a graph. Items: FX SHO, FX Cruiser SHO, FX HO, FX Cruiser HO Engine speed Intake air pressure TPS 1 Throttle valve opening angle TPS 2 APS 1 APS 2 Atmospheric pressure Ignition timing Battery voltage

Fuel injection duration Engine temperature Intake air temperature Ex. manifold water temperature (*1) Thermoswitch Slant detection switch Oil pressure switch Engine start switch APS full close switch Steering sensor

(*1): Thermo sensor

No-wake mode switch Cruise assist set switch Cruise assist up switch Cruise assist down switch Reverse switch Main relay (*2) ETV relay Fuel pump relay (*2)

(*2): Main and fuel pump relay

4. Stationary test: Operation tests can be performed with the engine off. Items: FX SHO, FX Cruiser SHO, FX HO, FX Cruiser HO Activate ignition coil (#1–#4)

Activate injector (#1–#4)

Activate electric fuel pump (*1)

(*1): Operate fuel pump module 5. Active test: With the engine running, each cylinder is dropped and the engine speed is checked for changes to determine if the cylinder is malfunctioning. These tests can be performed quickly.

9-1

YDIS 6. Logger graph: Data stored in the ECM for the last 78 seconds (in 6 seconds intervals) is displayed on a graph. Items: FX SHO, FX Cruiser SHO, FX HO, FX Cruiser HO Engine speed Battery voltage

TPS Engine temperature

Intake air pressure Oil pressure switch

7. ECM record graph: When a malfunction occurs in the ETV system or APS system, 4 seconds (2 seconds before and after the malfunction) of recorded data is saved in the ECM. This data can be displayed on a graph using the “ECM record data graph” of the Data logger function. When the communication cable is used to connect a computer to the ECM, the ECM record data can be saved and viewed on the computer. The saved ECM record data can also be viewed offline. Items: FX SHO, FX Cruiser SHO, FX HO, FX Cruiser HO Engine speed APS 1 APS 2 Steering sensor TPS 1 TPS 2 Intake air pressure Battery voltage Target TPS voltage (*1)

Ref. TPS voltage (*2) Ref. APS voltage (*3) Target TPS voltage for ISC (*4) Engine stop mode Engine start mode SW-activated engine stop mode (*5) OTS mode Cruise assist mode Reverse mode

(*1): Target TPS voltage This item shows the target output voltage of the TPS. This value is the control voltage that the ECM requires to set the target opening angle of the throttle valve. (*2): Reference TPS voltage This item shows the criterion output voltage of the TPS. This value is used to detect the TPS output voltage during engine operation.

No-wake mode Low-RPM mode Engine shut-off switch Main relay ETV relay Thermoswitch Oil pressure switch Warning ETV limit

(3):

Reference APS voltage This item shows the criterion output voltage of the APS. This value is used to detect the APS output voltage when the throttle lever is opened. (*4): Target TPS voltage for Idle Speed Control ECM controls the engine idle speed by using the throttle valve attached to the TPS. This target voltage is used by the ECM to achieve the target opening angle of the throttle valve at the engine idle speed. (*5): Engine stop mode with switch

TIP: To display the data and graphs, see the YDIS (Ver. 2.00) Instruction Manual. 8. Logging: While the computer and engine are not connected, record “Engine Monitor” data using the adapter.

9-2

1 2 3 4 5 6 7 8 9 A

TRBL SHTG

Troubleshooting

Basic components 1

4 ***

****** ******

5 6

11 10 9

No. 1 2 3 4 5 6 7 8 9 10 11

9-3

Part name YDIS 2 starter kit CD-ROM Adapter USB cable Adapter cap AD harness CAN-Line harness K-Line harness Power supply harness Trigger switch harness Trigger switch extension harness

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1 1 1 1 1

Remarks 90890-06883 Software and instruction manual 5 m (16.4 ft) For external input

YDIS

Connecting the communication cable to the watercraft

R/Y B

W/B

a Wiring harness coupler b Meter coupler c K-Line harness coupler d Adapter e USB cable f Adapter cap

TIP: Be careful not to pinch the communication cable between the front hood and the deck or to damage it.

9-4

1 2 3 4 5 6 7 8 9 A

TRBL SHTG

Troubleshooting

Engine unit troubleshooting TIP: • Before troubleshooting the engine unit, make sure that fresh fuel of the specified type has been used. • Check that all wiring connections are secured properly and that they are not corroded or rusty. • Check that the engine shut-off cord is connected to the engine shut-off switch. • Check that the battery is charged and that its specific gravity is within specification. • Check the diagnostic code using the YDIS (or self-diagnosis) first, and then check the electronic control system by following the diagnostic code chart. • The multifunction meter cannot display more than 1 diagnostic code. Even if multiple diagnostic codes are present, only 1 will be displayed. • When an ETV system (ETV, TPS, and APS) diagnostic code is detected, check the data logger of the “ECM record data graph” as well. • Using the YDIS is recommended because self-diagnosis may be insufficient for proper troubleshooting of the ETV system (ETV, TPS, and APS). • If a diagnostic code is not detected, check the engine unit according to “Engine unit troubleshooting (diagnostic code not detected).” • When deleting the diagnosis record on the YDIS, make sure to check the time that the diagnostic codes were detected. • When checking the input voltage of a part, the coupler or connector must be disconnected. As a result, the ECM determines that the part is disconnected and a diagnostic code is detected. Therefore, make sure to delete the diagnosis record after checking the input voltage.

Using the YDIS for engine unit troubleshooting TIP: • Use the diagnostic codes displayed by the YDIS to check each part according to the “Diagnostic code and checking step” table. • Delete the diagnostic codes after checking, repairing, or replacing a part, and check that the diagnostic codes are not detected again. If the same diagnostic codes are detected, the ECM may be faulty. • Check the items listed in the table. If all the items are in good condition, delete the diagnostic code, and then check the diagnostic codes again. If the same diagnostic codes are detected again, the ECM is faulty. • A breakdown of the engine symptoms are described in the “Diagnostic code table,” however, multiple malfunctions that have been duplicated cannot be limited to these items. The symptoms may change depending on the operating conditions and other conditions.

9-5

Engine unit troubleshooting Self-diagnosis While the engine is running, the diagnostic codes a can be checked by pushing the 2 buttons b simultaneously for approximately 8 seconds.

TIP: Because the multifunction meter cannot display more than 1 diagnostic code even if there are multiple diagnostic codes, using the YDIS is recommended.

9-6

1 2 3 4 5 6 7 8 9 A

TRBL SHTG

Troubleshooting

Diagnostic code table

Code No.

Symptom

01 13

Normal Pulser coil (*1) malfunction Engine temperature sensor malfunction Knock sensor malfunction (*2) Battery voltage malfunction Air temperature sensor (*3) malfunction Cam position sensor malfunction Air pressure sensor (*4) malfunction Slant detection switch malfunction APS full close switch malfunction Steering sensor malfunction EX. manifold water temp sensor (*5) malfunction No-wake mode switch malfunction Reverse switch (*6) malfunction

15 17 19 23 24 29 47 51 55 65 68 78 112, 113, 114, 115, 116, 117, 118, 119, 121, 122, 123, 129, 136, 137, 138, 139, 141, 142, 143, 144, 145 124, 125, 126, 127, 128 131, 132, 133, 134, 135 252 253



 



  



 

ETV system malfunction



TPS malfunction



APS malfunction



Overheat warning Low oil pressure warning

— —

 

(*1): Pickup coil (*2): FX SHO, FX Cruiser SHO only (*3): Intake air temperature sensor (*4): Intake air pressure sensor (*5): Thermo sensor (*6): Reverse sensor

9-7

Diagnostic code output YDIS MultifuncDiagnosis tion meter Diagnosis record  — —   

Engine unit troubleshooting

Diagnostic code and checking step Diagnostic code

Item

Pulser coil (*1) malfunction

Engine temperature sensor malfunction

Knock sensor malfunction (*2)

Battery voltage malfunction

Air temperature sensor (*4) malfunction

Symptom

Engine will not start

Trolling speed is unstable (*3)

Checking steps 1. Measure the pickup coil output peak voltage. 2. Measure the pickup coil resistance. 3. Check the white/black (W/B) and black/orange (B/O) pickup coil leads for continuity. 1. Check the engine temperature using the YDIS. 2. Measure the engine temperature sensor input voltage. 3. Check the black/yellow (B/Y) and black/orange (B/O) engine temperature sensor leads for continuity. 4. Measure the engine temperature sensor resistance. 1. Measure the knock sensor resistance. 2. Check the green (G) knock sensor lead for continuity. 1. Check the battery voltage using the YDIS. 2. Check the fuse for continuity. 3. Measure the stator coil output peak voltage. 4. Measure the rectifier regulator output peak voltage. 5. Check the battery leads and terminals for proper connection. 1. Check the intake air temperature using the YDIS. 2. Measure the intake air temperature sensor input voltage. 3. Check the black/red (B/R) and black/ orange (B/O) intake air temperature sensor leads for continuity. 4. Measure the intake air temperature sensor resistance.

See page 7-11 7-11 A-1 A-3 7-17 7-17 A-1 A-3

7-17 7-19 A-1 9-1 7-4 7-12 7-13 8-32 7-17 7-17 A-1 A-3 7-17

(*1): Pickup coil (*2): FX SHO, FX Cruiser SHO only (*3): This symptom may only be exhibited in certain environmental conditions. (*4): Intake air temperature sensor

9-8

1 2 3 4 5 6 7 8 9 A

TRBL SHTG Diagnostic code

Troubleshooting Item

Cam position sensor malfunction

Intake press sensor (*1) malfunction

Slant detection switch malfunction

APS full close switch malfunction

Steering sensor malfunction

Symptom

Engine speed is limited

Engine stalls Trolling speed is unstable (*2)

Normal operation

Engine stalls Trolling speed is unstable (*2)

Normal operation

Checking steps 1. Measure the cam position sensor input voltage. 2. Check the orange (O), green/orange (G/O), and black/orange (B/O) cam position sensor leads for continuity. 3. Measure the cam position sensor output voltage. 1. Check the intake air pressure using the YDIS. 2. Measure the intake air pressure sensor input voltage. 3. Check the orange (O), pink/green (P/G), and black/orange (B/O) intake air pressure sensor leads for continuity. 1. Check the slant detection switch operation using the YDIS. 2. Measure the slant detection switch input voltage. 3. Check the blue/black (L/B) and black/ orange (B/O) slant detection switch leads for continuity. 4. Check the slant detection switch for continuity. 1. Check the APS full close switch operation using the YDIS. 2. Measure the APS full close switch input voltage. 3. Check the orange/green (O/G), black/green (B/G), and white/green (W/G) APS full close switch leads for continuity. 1. Check the steering sensor operation using the YDIS. 2. Measure the steering sensor input voltage. 3. Check the orange/red (O/R), white/ blue (W/L), and black/orange (B/O) steering sensor leads for continuity.

(*1): Intake air pressure sensor (*2): This symptom may only be exhibited in certain environmental conditions.

9-9

See page 7-24 A-1 A-3 7-24 7-18 7-18 A-1 A-3

7-25 7-25 A-1 A-3 7-25 7-21 7-21 A-1 A-3

7-25 7-25 A-1 A-3

Engine unit troubleshooting Diagnostic code

112 113 114

Item

Ex. manifold water temp. sensor (*1) malfunction

No-wake mode switch malfunction

Reverse switch (*2) malfunction

ETV system malfunction

Symptom

Normal operation

Engine speed is limited

Checking steps 1. Measure the thermo sensor input voltage. 2. Check the black/blue (B/L) and black/ orange (B/O) thermo sensor leads for continuity. 3. Measure the thermo sensor resistance. 1. Check the right handlebar switch operation using the YDIS. 2. Measure the right handlebar switch input voltage. 3. Check the blue/red (L/R), yellow/ black (Y/B), yellow/red (Y/R), yellow/ green (Y/G), and black (B) right handlebar switch leads for continuity. 1. Check the reverse sensor operation using the YDIS. 2. Measure the reverse sensor input voltage. 3. Check the orange (O), green/white (G/W), and black/orange (B/O) reverse sensor leads for continuity. 1. Check the TPS output voltage and throttle valve opening using the YDIS. 2. Check the ECM circuit for continuity. 3. Check the ETV relay for continuity. 4. Check the charging system. • Stator coil output peak voltage • Stator coil resistance • Rectifier regulator output peak voltage • Rectifier regulator continuity 5. Check the fuse for continuity. 6. Check the battery voltage and specific gravity. 7. Check the red (R) and black (B) power supply circuit cables and leads for continuity.

See page 7-16 A-1 A-3 7-16 7-26 7-26 A-1 A-3

7-26 7-26 A-1 A-3 7-19

7-27 7-23 7-12 7-12 7-13 7-13 7-4 3-9 A-1 A-3

(*1): Thermo sensor (*2): Reverse sensor

9-10

1 2 3 4 5 6 7 8 9 A

TRBL SHTG Diagnostic code

115 116

117 118 119

Troubleshooting Item

ETV system malfunction

Symptom

Engine speed is limited

ETV system malfunction

Engine speed is limited

ETV system malfunction ETV system malfunction

Engine speed is limited Engine speed is limited

123

ETV system malfunction

Engine speed is limited

124 125 127 128

TPS malfunction

Engine speed is limited

126

TPS malfunction

Engine speed is limited

129

ETV system malfunction

Engine speed is limited

131 132 133 134

APS malfunction

Engine speed is limited

135

APS malfunction

Engine speed is limited

121 122

9-11

Checking steps 1. Check the pink (P), orange (O), pink/ black (P/B), and black/orange (B/O) ETV leads for continuity. 2. Check the TPS output voltage and throttle valve opening using the YDIS. 3. Check the throttle shaft and throttle inner surface for damage and wear. 1. Check the ETV coupler terminals for corrosion and rust. 2. Check the green (G) and blue (L) ETV leads for continuity. 3. Check the ECM circuit for continuity. 1. Cross-check the ECM or replace. 1. Cross-check the ETV. 1. Check the ETV relay and fuse (ETV relay) for continuity. 2. Check the ECM circuit for continuity. 1. Check the pink (P), orange (O), pink/ black (P/B), and black/orange (B/O) ETV leads for continuity. 2. Check the ECM circuit for continuity. 1. Check the TPS output voltage using the YDIS. 2. Check the ECM circuit for continuity. 1. Check the TPS output voltage using the YDIS. 2. Check the ETV relay and fuse (ETV relay) for continuity. 1. Check the APS output voltage using the YDIS. 2. Check the APS circuit for continuity. 3. Check the APS circuit for continuity.

See page A-1 A-3 7-19

4-10 5-49 4-10 5-49 A-1 A-3 7-27 â&#x20AC;&#x201D; â&#x20AC;&#x201D; 7-23 7-4 7-27 A-1 A-3 7-27 7-19 7-27 7-19 7-23 7-4 7-21 7-22 7-22

Engine unit troubleshooting Diagnostic code

136 137 138 139

Item

ETV system malfunction

Symptom

Engine speed is limited

141

ETV system malfunction

Engine speed is limited

142

ETV system malfunction

Engine speed is limited

ETV system malfunction

Engine speed is limited

143 144

145

ETV system malfunction

Engine speed is limited

Checking steps 1. Check the ECM circuit for continuity. 2. Check the ETV relay for continuity. 3. Check the charging system. • Stator coil output peak voltage • Stator coil resistance • Rectifier regulator output peak voltage • Rectifier regulator continuity 4. Check the fuse for continuity. 5. Check the battery voltage and specific gravity. 6. Check the red (R) and black (B) power supply circuit cables and leads for continuity. 1. Check the ECM circuit for continuity. 2. Check the ETV relay and fuse (ETV relay) for continuity. 1. Check the TPS output voltage and throttle valve opening using the YDIS. 2. Check the throttle shaft and throttle inner surface for damage and wear. 1. Check the ECM circuit for continuity. 2. Check the ETV relay for continuity. 3. Check the charging system. • Stator coil output peak voltage • Stator coil resistance • Rectifier regulator output peak voltage • Rectifier regulator continuity 4. Check the fuse for continuity. 5. Check the battery voltage and specific gravity. 6. Check the red (R) and black (B) power supply circuit cables and leads for continuity. 1. Check the ETV relay and fuse (ETV relay) for continuity. 2. Check the throttle shaft and throttle inner surface for wear or damage.

See page 7-27 7-23 7-12 7-12 7-13 7-13 7-4 3-9 A-1 A-3 7-27 7-23 7-4 7-19

4-10 5-49 7-27 7-23 7-12 7-12 7-13 7-13 7-4 3-9 A-1 A-3 7-23 7-4 4-10 5-49

9-12

1 2 3 4 5 6 7 8 9 A

TRBL SHTG Diagnostic code

252

253

Troubleshooting Item

Overheat warning

Low oil pressure warning

Symptom

Engine speed is limited

Checking steps 1. Check the cooling water passages for obstructions. 2. Measure the engine temperature sensor resistance. 3. Check that there is no short circuit between the black/yellow (B/Y) and black/orange (B/O) engine temperature sensor leads (*1). 4. Check the thermoswitch for continuity. 5. Check that there is no short circuit between the pink (P) and black (B) thermoswitch leads (*1). 6. Check the thermo sensor for continuity. 7. Check that there is no short circuit between the black/blue (B/L) and black/orange (B/O) thermo sensor leads (*1). 1. Check the oil level. 2. Check the oil pressure switch for continuity. 3. Check that there is no short circuit in the pink/white (P/W) oil pressure switch lead (*1). 4. Check the oil passages for obstructions.

See page 2-19 7-17 A-1 A-3

7-15 A-1 A-3 7-16 A-1 A-3

3-5 7-14 A-1 A-3 2-19

(*1): Disconnect the sensor coupler or switch coupler, and then check that there is no short circuit at the coupler (wiring harness end).

9-13

Engine unit troubleshooting

Engine unit troubleshooting (diagnostic code not detected) Troubleshooting when diagnostic codes are not available consists of the following 3 items. Symptom 1: Specific trouble conditions Symptom 2: Trouble conditions of an area or individual part Cause: The contents considered to be the trouble factors for symptom 2 â&#x20AC;&#x201D;: Not applicable Symptom 1: Engine does not crank. Symptom 2 Starter motor does not operate

Cause Yamaha Security System set to lock mode Discharged battery Loose connection of battery terminal Blown fuse Starter relay malfunction Engine start switch malfunction Short, open, or loose connection in starter motor circuit Starter motor malfunction Stuck piston or crankshaft Stuck impeller

Starter motor operates, but the engine does not crank

Idle gear or starter clutch malfunction

Checking step Check that the Yamaha Security System is set to the unlock mode. Check the battery voltage and specific gravity. Check the battery lead and terminal for proper connection. Check the fuse for continuity. Check the starter relay. Check the engine start switch (left handlebar switch). Measure the starter relay input voltage. Check the wiring harness. Disassemble and check the starter motor. Disassemble and check the engine unit. Disassemble and check the jet pump unit. Check the idle gear, starter clutch, or crankshaft Woodruff key.

See page 7-35 3-9 8-32 7-4 7-32 7-30 7-32 A-1 A-3 7-33 5-108 6-10 5-89 5-94

Symptom 1: Engine will not start (engine cranks). Symptom 2 Throttle valve does not move properly

Cause Throttle lever squeezed APS malfunction TPS malfunction Throttle valve malfunction

Checking step Check that the throttle lever is in the fully closed position. Measure the APS 1 and 2 output voltage. Check the throttle valve opening. Check the ETV.

See page â&#x20AC;&#x201D; 7-21 7-19 4-10 5-49

9-14

1 2 3 4 5 6 7 8 9 A

TRBL SHTG Symptom 2 Discharged battery

ECM does not operate

Spark plug does not spark (all cylinders)

Troubleshooting Cause Battery performance decrease Stator coil malfunction Short, open, or loose connection in charging circuit

Check the battery voltage and specific gravity. Check the stator coil assy. Check the battery lead and terminal for proper connection. Check the wiring harness.

Blown fuse Main and fuel pump relay malfunction Short, open, or loose connection in ECM circuit

Check the fuse for continuity. Check the main and fuel pump relay. Measure the ECM input voltage. Check the ECM circuit for continuity. Replace the ECM. Check that the engine shut-off cord clip is installed properly. Check the engine stop switch continuity. (left handlebar switch) Measure the pickup coil output peak voltage. Measure the pickup coil resistance. Check the white/black (W/B) and black/orange (B/O) pickup coil leads for continuity. Measure the ignition coil input voltage (from the battery). Check the red/yellow (R/Y), black/ red (B/R), black/white (B/W), black/ yellow (B/Y), and black/green (B/G) ignition coil leads for continuity. Exchange the ignition coil with a different one, and then check the ignition spark. Measure the ECM output peak voltage.

ECM malfunction Engine shut-off cord clip not installed Engine stop switch malfunction Pickup coil malfunction

Short, open, or loose connection in pickup coil circuit Short, open, or loose connection in ignition coil circuit

Ignition coil malfunction

ECM malfunction

9-15

Checking step

See page 3-9 7-12 8-32 A-1 A-3 7-4 7-31 7-27 7-27 â&#x20AC;&#x201D; 7-30 7-30 7-11 7-11 A-1 A-3 7-11 A-1 A-3

â&#x20AC;&#x201D; 7-27

Engine unit troubleshooting Symptom 2 Fuel not supplied (all cylinders)

Compression pressure is low

Cause Fuel leakage Blown fuse Clogged fuel pump filter Fuel pump module malfunction

Main and fuel pump relay malfunction Compression leakage

Improper valve timing

Checking step Check the fuel hose. Check the fuse for continuity. Clean the fuel pump filter. Check the fuel pump module operation sound using the YDIS. Measure the fuel pump module input voltage. Check the blue (L) and black (B) fuel pump module leads for continuity. Measure the fuel pressure. Check the main and fuel pump relay. Measure the compression pressure. Measure the valve clearance. Check the camshaft for damage. Check the cylinder head gasket and cylinder head warpage. Check the valve and valve seat for wear. Check the piston and piston ring for damage. Check the cylinder for damage. Check the timing chain.

See page 4-1 7-4 4-14 7-29 7-29 A-1 A-3 4-5 7-31 5-1 3-7 5-70 5-81 5-82 5-111 5-111 5-111 5-72

9-16

1 2 3 4 5 6 7 8 9 A

TRBL SHTG

Troubleshooting

Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited engine speed Symptom 2

Cause

Throttle valve does not move properly Spark plug does not spark (some cylinders)

Throttle valve malfunction

Check the ETV.

Spark plug malfunction Ignition coil malfunction Short, open, or loose connection in ignition coil circuit

Check the spark plug. Check the ignition spark. Measure the ignition coil input voltage (from the battery). Check the red/yellow (R/Y), black/ red (B/R), black/white (B/W), black/ yellow (B/Y), and black/green (B/G) ignition coil leads for continuity. Measure the ECM output peak voltage. Check the fuel injector operation sound using the YDIS. Measure the fuel injector resistance. Measure the fuel injector input voltage. Check the red/yellow (R/Y), purple/ red (Pu/R), purple/black (Pu/B), purple/yellow (Pu/Y), and purple/ green (Pu/G) fuel injector leads for continuity. Clean the fuel injector. Replace the ECM. Measure the compression pressure. Measure the valve clearance. Check the camshaft for damage. Check the cylinder head gasket and cylinder head warpage. Check the valve and valve seat for wear. Check the piston and piston ring for damage. Check the cylinder for damage. Check the timing chain.

ECM malfunction Fuel not supplied (some cylinders)

Fuel injector malfunction

Short, open, or loose connection in fuel injector circuit

Compression pressure is low

Clogged fuel injector filter ECM malfunction Compression leakage

Improper valve timing

9-17

Checking step

See page 4-10 5-49 3-5 7-10 7-11 A-1 A-3

7-27 7-29 7-29 7-29 A-1 A-3

4-10 â&#x20AC;&#x201D; 5-1 3-7 5-70 5-81 5-82 5-111 5-111 5-111 5-69

Engine unit troubleshooting Symptom 1: Limited engine speed Symptom 2 • Buzzer sounds intermittently • Overheat warning indicator blinks • Check engine warning indicator blinks • Buzzer sounds intermittently • Oil pressure warning indicator blinks

Cause Clogged cooling water passage

Thermostat malfunction

Insufficient engine oil

Oil pressure switch malfunction

Checking step Check the cooling water pilot outlet for water discharge. Check the water inlet strainer. Check the cooling water passage. Check the thermostat.

Check the engine oil level. Check for engine oil leakage. Check the oil pump. Check the oil strainer. Check the oil passage. Check the oil pressure switch continuity. Check that there is no short circuit in the pink/white (P/W) oil pressure switch lead.

See page — 3-9 1-38 5-39

3-5 — 5-61 5-104 1-35 7-14 A-1 A-3

Symptom 1: Discharged battery Symptom 2 —

Cause Battery performance decrease Loose connection of battery terminal Short, open, or loose connection in charging circuit Stator coil malfunction Rectifier regulator malfunction

Checking step Check the battery voltage and specific gravity. Check the battery lead and terminal for proper connection. Check the charging circuit for wiring connection and damage. Check the stator coil assy. Measure the rectifier regulator output peak voltage.

See page 3-9 8-32 A-1 A-3 7-12 7-13

9-18

1 2 3 4 5 6 7 8 9 A

TRBL SHTG

Troubleshooting

Symptom 1: Poor performance Symptom 2 Watercraft cannot reach high speeds

9-19

Cause

Checking step

Jet pump unit malfunction

Check the impeller, impeller duct, and intake grate.

Water entered hull

Check the drain plugs and O-rings for damage. Check the cooling water hoses for damage. Check the water lock, water tank, and rubber hoses for damage. Check the exterior of the hull for damage.

See page 3-9 6-1 6-10 8-35 2-20 8-32 8-39

Appendix Wiring diagram ...................................................................A-1 How to use the wiring diagram ................................................... A-1 FX SHO, FX Cruiser SHO .......................................................... A-1 FX HO, FX Cruiser HO............................................................... A-3

1 2 3 4 5 6 7 8 9 A

Wiring diagram How to use the wiring diagram Legend symbols in the wiring diagrams a

a Double colors wire b No wire connector Color Code B Br B/G B/L B/O B/R B/W B/Y G Gy G/L G/O G/W L L/B L/R L/Y O O/G O/R O/W

: Black : Brown : Black/Green : Black/Blue : Black/Orange : Black/Red : Black/White : Black/Yellow : Green : Gray : Green/Blue : Green/Orange : Green/White : Blue : Blue/Black : Blue/Red : Blue/Yellow : Orange : Orange/Green : Orange/Red : Orange/White

FX SHO, FX Cruiser SHO A To entry box B Antenna C Nonuse a Fuse (30 A) (battery) b Fuse (20 A) (main and fuel pump relay) c Fuse (10 A) (ETV relay) d Fuse (10 A) (main and fuel pump relay) e Fuse (3 A) (remote control receiver) f Fuse (3 A) (electric bilge pump)

A-1

P P/B P/G P/R P/W Pu/B Pu/G Pu/R Pu/Y R R/Y W W/B W/G W/L Y Y/B Y/G Y/R Y/W

: Pink : Pink/Black : Pink/Green : Pink/Red : Pink/White : Purple/Black : Purple/Green : Purple/Red : Purple/Yellow : Red : Red/Yellow : White : White/Black : White/Green : White/Blue : Yellow : Yellow/Brack : Yellow/Green : Yellow/Red : Yellow/White

Printed in U.S.A. Feb. 2012 – **  1 ABE (E)

3 4 5 6

1 4

1 2 3 4 5

L/B

7 8

R/Y W/B

R/Y R/Y R/Y R/Y

8 9 10 11

13 14 15 16 17 18 19 20 21 22 23 24 25 26

B/L Y/W B/R P/G W/L G/W Y/B Y/G Y W/G B/Y L/R O/R O

R/Y R/Y

13 14

R/Y R/Y R/Y R/Y R/Y R/Y

1 2 3 4 5 6

27 28 29 30

R/Y W B/G O/G

O O O O

1 2 3 4 5 6 7 8

34 35 36 37

B/R B/W P/R P/W

39 40 41 42 43 44 45 46 47

R/Y B/O B/O P P/B O R/Y B W/B

B/O B/O B/O B/O B/O B/O B/O B/O B/O B/O

1 2 3 4 5 6 7 8 9 10

49 50

O/R O/W

Y/R

58 59 60 61 62 63 64

Pu/R Pu/B B/G B/Y B Y/G P

APS (electric throttle without wire cable)

ETV

Cam position sensor

Slant Oil pressure detection switch switch

Steering sensor

Electric bilge pump

#4 Intake air pressure sensor

Fuel injector Fuel pump module

Ignition coil

Knock sensor Air temperature sensor

Engine temperature sensor

Thermo switch

A-2

G G G

R B

G G G

B/O W/B

B/O B/L

B/O P

B/O B/Y

R/Y B B/G #4

B/O B/R

R/Y B B/Y #3

B/O P/G O

R/Y B B/W #2

G G G

Pu/G R/Y

Pu/Y R/Y

Pu/B R/Y

Pu/R R/Y

R/Y B B/R

f L B

R/Y

B/O W/L O/R

G P/W Y/W L/R G/L Pu/G Pu/Y B/R B/W

1 2 3

78 79 80 81 82 83 84 85 86

B/O

Battery

1 4 8 12

3 7 11 14 Joint coupler 2 1 4

1 2 3

36 Joint coupler 6 15

48 Joint coupler 1 15 8

4 7 10 Joint coupler 3 1 4

3 6 Joint coupler 7

L/B

Y Y Y

P/W

Starter motor

1 5

R/Y R/Y R/Y R/Y R/Y

R Fuse box

2 3 4 5 6 7 8

R R

d 4 8

Br Y L R R R R

3 6

1 2

R/Y

3 4 5 6 7 8

Y/W R R/Y R/Y

R L/R R R/Y R/Y L

Y/G

4 8

B/L L/R

9 10 12 13 14 15 16

C G/L B

6 7

L/Y L/B Gy W L R Y Y/W B/L

A Gy B

3 4

W B R

B Br

61 69 77 86

Br B B Br

9 18

Speed and water temperature sensor

Right operation button

P/W

53 62 70 78

G/O

Br R

O G/O B/O

33 39 45 52

Br R

1 10 Speed sensor

L B/O P/B G O P

27 34 40 46

ECM

B/O W

O/G B/G W/G O/W B/W P/W O/R B/R P/R

7 13 19 26

B W

R ETV relay

Buzzer

B B

Compass and air temperature sensor

Y/W R/W B

Main and fuel pump relay

Remote control receiver

Right handlebar Reverse switch switch

O G/W B/O

W B

FREE PUSH

1 8 14 20

Left operation button G/W Pu/W B

B/Y Y R/W

W/B B R/Y

Br Br Left handlebar switch

R Br

L/B L/R Gy

W B SET PULL

L/B L/R L/Y

B W FREE PUSH

G R B L W

Multifunction meter

B/G P

Fuel sender

Y/G L/R Y/B Y/R

FX SHO, FX Cruiser SHO

Pickup coil

Thermo sensor

Stator coil

Rectifier regulator

B B B B B B

2 3 4 5 6 7

B B

9 10

B B B B B B B B/O B/O

1 2 3 4 5 6 7 8 9

B/O

B B B B B B B

1 2 3 4 5

7 8

15 8

4 7 10 Joint coupler 4 1 4 8 12

3 7 11 14 Joint coupler 5 Earth plate

4 8

1 5

FX HO, FX Cruiser HO A To entry box B Antenna C Nonuse a Fuse (30 A) (battery) b Fuse (20 A) (main and fuel pump relay) c Fuse (10 A) (ETV relay) d Fuse (10 A) (main and fuel pump relay) e Fuse (3 A) (remote control receiver) f Fuse (3 A) (electric bilge pump)

A-3

3 4 5 6

3 6

1 4

Starter motor

2 3 4 5 6 7 8

4 8

1 5

Br Y L R R R R

1 2

R R

Battery

Fuse box

R/Y R/Y R/Y R/Y R/Y

1 2 3 4 5 8 9 10 11

13 14 15 16 17 18 19 20 21 22 23 24 25 26

B/L Y/W B/R P/G W/L G/W Y/B Y/G Y W/G B/Y L/R O/R O

R/Y R/Y

13 14

R/Y R/Y R/Y R/Y R/Y R/Y

1 2 3 4 5 6

27 28 29 30

R/Y W B/G O/G

O O O O

1 2 3 4 5 6 7 8

34 35 36 37

B/R B/W P/R P/W

39 40 41 42 43 44 45 46 47

R/Y B/O B/O P P/B O R/Y B W/B

B/O B/O B/O B/O B/O B/O B/O B/O B/O B/O

1 2 3 4 5 6 7 8 9 10

49 50

O/R O/W

Y/R

58 59 60 61 62 63 64

Pu/R Pu/B B/G B/Y B Y/G P

APS (electric throttle without wire cable)

ETV

Cam position sensor

Slant Oil pressure detection switch switch

R B

G G G

B/O W/B

B/O B/L

B/O P

B/O B/Y

B/O B/R

B/O P/G O

#4 Intake air Intake air pressure temperature sensor sensor Fuel pump module

Ignition coil

Engine temperature sensor

Thermo switch

A-4

G G G

Fuel injector Electric bilge pump

R/Y B B/G

R/Y B B/Y

R/Y B B/W #2

G G G

#1 #1

Steering sensor

R/Y B B/R

Pu/G R/Y

Pu/Y R/Y

Pu/B R/Y

L B

f Pu/R R/Y

G P/W Y/W L/R G/L Pu/G Pu/Y B/R B/W

R/Y

78 79 80 81 82 83 84 85 86

B/O W/L O/R

1 4 8 12

3 7 11 14 Joint coupler 2 1 4

1 2 3

36 Joint coupler 6 15

48 Joint coupler 1 15 8

4 7 10 Joint coupler 3 1 4

3 6 Joint coupler 7

B/O

Y Y Y

L/B

Y/W R R/Y R/Y

1 3 4 5 6 7 8

R L/R R R/Y R/Y L

R/Y

Y/G

B/L L/R

G/L B

Gy B

9 10 12 13 14 15 16

1 5

R/Y R/Y R/Y R/Y

B Br

61 69 77 86

4 8

L/B

P/W

53 62 70 78

R/Y W/B

P/W

33 39 45 52

7 8

O G/O B/O

27 34 40 46

ECM

Speed sensor

Br B B Br

L B/O P/B G O P

7 13 19 26

Br R

G/O

O/G B/G W/G O/W B/W P/W O/R B/R P/R

1 8 14 20

W/B B R/Y

Br 3

Br R

FREE PUSH

B/O W 6 7

B W

9 18

L/Y L/B Gy W L R Y Y/W B/L

Br Br

1 10

3 4

W B

B B

G/W Pu/W B

ETV relay

Buzzer

O G/W B/O

SET PULL

B/Y Y R/W W B R

FREE PUSH

R Br

L/B L/R L/Y

Left handlebar switch

W B

L/B L/R Gy

B W

B/G P Left operation button

Main and relay fuel pump

Remote control receiver

Right handlebar switch Reverse switch

Multifunction meter Fuel sender

Y/G L/R Y/B Y/R

FX HO, FX Cruiser HO

Pickup coil

Thermo sensor

Stator coil

Rectifier regulator

B B B B B B B B

1 2 3

B B B B B B B B/O B/O

1 2 3 4 5 6 7 8 9

B/O

B B B B B

1 2 3 4 5

B B

7 8

5 6 7 8 9

15 8

4 7 10 Joint coupler 4 1 4 8 12

3 7 11 14 Joint coupler 5 Earth plate

4 8

1 5