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WaveRunner FX SHO
Yamaha WaveRunner FX SHO Service Manual
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5-95
E
POWR
Oil pan check
1.
Check:
•
Baffle plate
1
Clog/contaminants
→
Clean the baffle
plate.
Cracks/damage
→
Replace the baffle
plate.
•
Oil pan
2
Cracks/damage
→
Replace the oil pan.
1
2
2.
Check:
•
Oil pipe
Clog/contaminants
→
Clean the oil pipe.
Cracks/damage
→
Replace the oil pipe.
Oil separator tank and oil pan
219
221
Table of Contents
Table of Contents
3
Default Chapter
2
Lit-18616
2
Chapter 1
6
How to Use this Manual
6
Manual Format
6
Contents
7
Abbreviation
8
Grease Table
8
Symbols
7
Safety While Working
9
Fire Prevention
9
Parts, Lubricants, and Sealants
9
Self-Protection
9
Ventilation
9
Disassembly and Assembly
10
Good Working Practices
10
Identification Number
11
Engine Serial Number
11
Hull Identification Number (H.l.n.)
11
Jet Pump Unit Serial Number
11
Primary L.D. Number
11
Special Service Tool
12
Measuring
12
Removal and Installation
14
Feature and Benefit
19
Watercraft Overview
19
Engine Overview
20
Air Filter Case and Air Filter Element
21
Supercharger Assembly
21
Air Cooler Assembly
22
Intake System
22
Electronic Control Throttle Valve (ETV) System
23
Cylinder Head Assembly
24
Hydraulic Timing Chain Tensioner
24
Ignition Coil
25
Piston and Connecting Rod
25
Cylinder Block and Crankcase
26
Knock Sensor
26
Lubrication System
27
Oil Pump Assembly
28
Oil Pan
29
Oil Cooler Assembly
30
Oil Separator Tank
30
Exhaust System
31
Oil Filter
31
Cooling System
32
Water Cooled Rectifier Regulator
33
In-Tank Fuel Pump Module
34
Intake Grate
35
Large Intermediate Housing and Oil Seal
35
Qsts
36
Reverse Gate Assembly
36
Multifunction Meter
37
Right Multifunction Display (FX Cruiser SHO)
40
Average Speed, Tripmeter, and Trip Time Measurements
41
Cruise Assist and No-Wake Mode
42
Electrical System
42
Yamaha Diagnostic System (YDIS)
42
Slant Detection Switch
43
L-MODE (Low-Rpm Mode) and Yamaha Security System
44
Off-Throttle Steering (OTS) System
44
Remote Control Transmitter
46
Technical Tips
47
Engine Control
47
Cruise Assist Control
48
No-Wake Mode Control
49
Idle Speed Control
50
L-MODE (LOW-RPM MODE) Control
50
Over Revolution Control
50
Reverse with Traction Control
50
Slant Detection Control
50
High Intake Air Pressure Control
51
Knock Control
51
Off-Throttle Steering (OTS) Control
52
Remote Control Transmitter Control
53
ETV Failure Control
54
Oil Pressure Warning Control
54
Overheat Warning Control
54
Warning Control
54
Battery Disconnection Warning
55
Cam Position Sensor Failure Control
55
Fail-Safe Function Table
56
Chapter 2 Specification
59
Fuel
60
Maintenance Specifications
62
Engine
62
Fuel System
65
Electrical
66
Hull and Hood
66
Jet Pump Unit
66
Tightening Torques
70
Specified Torques
70
General Torque
76
Cable and Hose Routing
77
Starboard Bow View
77
Top View
78
Port View
80
General Specification
60
Adj Chapter 3 Periodic Check and Adjustment
83
Default Chapter
84
Maintenance Interval Chart
84
Chapter 3
85
Jet Thrust Nozzle Steering Angle Check and Adjustment
85
Periodic Service
85
Control System
85
Steering System Check
85
Jet Thrust Nozzle QSTS Angle Check and Adjustment
87
Throttle Lever Free Play Check and Adjustment
88
Shift Cable Check and Adjustment
90
Trolling Speed Check
90
Fuel System
92
Fuel Line Check
92
Water Separator Check
93
Power Unit
93
Valve Clearance Measurement
93
Compression Pressure Measurement
95
Engine Oil Level Check
96
Engine Oil Change
97
Oil Filter Replacement
98
Air Filter Element Check
99
Spark Plug Check
100
Electrical
102
Battery Check
102
Jet Pump Unit
104
Jet Pump Unit Check
104
Bilge Pump
105
Bilge Strainer Check
105
Electric Bilge Pump Strainer Check
106
General
106
Drain Plug Check
106
Throttle Valve and Engine Internal Components
106
Lubrication Points
107
Chapter 4 Fuel System
111
Fuel Tank Removal
112
Fuel Tank, Fuel Pump Module, and Fuel Hose
112
Fuel Hose Disconnection
116
Fuel Pump Module Removal
116
Fuel Sender Removal
117
Check Valve Check
118
Rollover Valve Check
118
Fuel Filler Neck and Hose Check
119
Fuel Line Check
119
Fuel Pump Module Check
119
Fuel Tank Check
119
Fuel Injector Check
120
Fuel Injector Installation
120
Fuel Sender Installation
120
Fuel Hose Connection
121
Fuel Pump Module Installation
121
Fuel Pressure Measurement
122
Chapter 5 Power Unit
123
Powr
123
Pump
124
Engine Unit Removal 1
126
Hood
126
Breather Assembly Check
142
Engine Mount Check
142
Engine Unit Installation
143
Muffler
150
Muffler Disassembly
150
Exhaust Pipe 3 Installation
152
Exhaust Pipe 3 Removal
152
Muffler Check
152
Thermo Sensor Check
152
Electrical Box and Starter Motor
153
Electrical Box and Starter Motor Removal
153
Air Cooler, Supercharger, and Throttle Body Assembly
156
Air Cooler and Supercharger Removal
156
Intake Assembly Removal
159
Intake Disassembly
161
Air Cooler Check
162
Intake Manifold Check
163
Supercharger Check
163
Throttle Body Assembly Check
163
Intake Manifold Installation
164
Supercharger Installation
164
Air Cooler Intake Hose Installation
165
Boost Pipe Installation
166
Oil Cooler, Oil Pump Assembly, and Drive Gear
167
Oil Cooler and Oil Pump Assembly Removal
167
Drive Gear Assembly Removal
171
Drive Gear Disassembly
171
Oil Cooler Assembly Check
172
Drive Gear Check
173
Idle Gear Check
173
Oil Pump Assembly Check
173
Drive Gear Clutch Check
174
Oil Pump Drive Gear Assembly
174
Drive Gear Assembly Installation
175
Oil Pump Assembly Installation
176
Camshaft
177
Cylinder Head Cover Removal
177
Camshaft and Timing Chain Removal
178
Camshaft Removal
181
Camshaft Check
183
Camshaft Sprocket Check
185
Timing Chain Check
185
Timing Chain Tensioner Check
185
Camshaft Installation
186
Cylinder Head Cover Installation
188
Valve Clearance Adjustment
189
Cylinder Head
192
Cylinder Head Assembly Removal
192
Cylinder Head Disassembly
192
Cylinder Head Assembly Removal
194
Cylinder Head Check
194
Valve Removal
194
Valve Check
195
Valve Spring Check
195
Valve Guide Check
197
Valve Guide Removal
197
Valve Guide Installation
198
Valve Seat Check
199
Valve Seat Refacing
200
Valve Installation
203
Cylinder Head Installation
204
Drive Coupling Removal
208
Flywheel Magneto Removal
208
Bearing Removal
209
Idle Gear and Shaft Check
209
Starter Clutch Check
210
Transfer Shaft Check
210
Bearing Installation
211
Oil Seal Installation
211
Flywheel Magneto Installation
212
Generator Cover Assembly
212
Drive Coupling Installation
214
Oil Separator Tank and Oil Pan
215
Oil Separator Tank and Oil Pan Removal
215
Oil Pan Disassembly
219
Oil Pan Check
220
Crankcase, Connecting Rod, and Piston
222
Connecting Rod and Piston Removal
224
Crankcase Disassembly
224
Anode Check
225
Crankcase Check
225
Piston Check
226
Piston Ring Check
227
Piston Pin Check
228
Connecting Rod Check
229
Cylinder Check
229
Crankshaft Check
230
Crankshaft Pin Oil Clearance Check
230
Crankshaft Journal Oil Clearance Check
233
Connecting Rod and Piston Installation
236
Crankcase Assembly
238
Cooling Water
240
Cooling Water Hose Routing
240
Thermostat Removal
241
Cooling Water Line Check
242
Thermostat Check
242
Pump Chapter 6 Jet Pump Unit
244
Chapter 6 Intake Grate and Ride Plate Removal
246
Intake Grate and Ride Plate
246
Jet Pump Unit
246
Jet Pump Unit Removal
247
Jet Pump Unit Installation
250
Reverse Gate
251
Reverse Gate Removal
251
Jet Thrust Nozzle and Nozzle Ring
253
Jet Thrust Nozzle and Nozzle Ring Removal
253
Impeller Duct and Impeller Housing
254
Impeller Duct and Impeller Housing Removal
254
Impeller Duct and Drive Shaft
255
Impeller Duct and Drive Shaft Disassembly
255
Drive Shaft Removal
257
Drive Shaft Check
259
Impeller Check
259
Impeller Housing Check
259
Drive Shaft Installation
260
Impeller Duct and Impeller Housing Installation
262
Transom Plate and Hoses
264
Transom Plate Installation
266
Water Hose Check
266
Jet Pump
266
Intermediate Housing
270
Driven Coupling Removal
270
Intermediate Drive Shaft Removal
270
Intermediate Housing Removal
270
Bearing Removal
271
Intermediate Drive Shaft and Grease Hose Check
271
Oil Seal Removal
271
Bearing Installation
272
Driven Coupling and Intermediate Housing Check
272
Oil Seal Installation
273
Driven Coupling Installation
274
Intermediate Housing Installation
274
Chapter 7 Electrical System
276
Electrical Components
278
Electrical Box
280
Electrical Components
280
Fuse Box Disassembly
283
Electrical Analysis
286
Check Using the YDIS
286
Input Voltage Measurement
287
Peak Voltage Measurement
287
Ignition System
288
Ignition Coil
288
Pickup Coil
291
Charging System
292
Stator Coil
292
Rectifier Regulator
294
Control System
296
Oil Pressure Switch
296
Thermoswitch
297
Thermo Sensor
299
Engine Temperature Sensor
300
Intake Air Temperature Sensor
301
Intake Air Pressure Sensor
303
Knock Sensor
305
Throttle Position Sensor
305
Accelerator Position Sensor
308
Electronic Throttle Valve Relay
312
Cam Position Sensor
313
Slant Detection Switch
314
Steering Sensor
315
Reverse Sensor
316
Right Handlebar Switch Assembly
317
ECM Circuit
319
Earth Plate
320
Electric Bilge Pump
320
Fuel System
321
Fuel Injector
321
Fuel Pump Module
323
Starting System
324
Fuse
324
Left Handlebar Switch Assembly
325
Main and Fuel Pump Relay
326
Starter Relay
328
Starter Motor
330
Starter Motor Operation
333
Armature
333
Brush Holder
335
Gear Cover
335
Rear Cover
336
Starter Motor Assembly
336
Remote Control System
336
Transmitter Registration
336
Remote Control Transmitter
337
Remote Control Receiver
340
Indication System
341
Multifunction Meter
341
Operation Button Assembly
342
Compass Display (FX Cruiser SHO)
344
Air Temperature Display (FX Cruiser SHO)
345
Water Temperature Display (FX Cruiser SHO)
345
Speed Sensor
346
Digital Speedometer Display (FX SHO)
347
Digital Speedometer Display (FX Cruiser SHO)
348
Fuel Level Meter Display and Fuel Level Warning Indicator
349
Check Engine Warning Indicator
349
Diagnostic Display
350
Oil Pressure Warning Indicator
350
Engine Overheat Warning Indicator
351
Buzzer
351
Hood Chapter 8 Hull and Hood
354
Chapter 8
356
Handlebar
356
Steering Pad Removal (FX SHO)
356
Steering Pad Removal (FX Cruiser SHO)
357
Handlebar Holder Removal
358
Handlebar Assembly Removal
359
Handlebar Check
363
QSTS Grip and Converter
367
QSTS Grip and Converter Disassembly
367
QSTS Cable Removal
369
QSTS Check
369
QSTS Cable Installation
370
Front Hood
372
Front Hood Removal
372
Damper Check
375
Mirror Assembly Installation
375
Mirror Disassembly
375
Rivet Installation
376
Rivet Removal
376
Center Cover Removal
380
Steering Master
384
Steering Master Removal
384
Spring Installation
389
Steering Master Component Check
389
Rubber Seal Installation
390
Remote Control Cables and Speed Sensor Lead
391
Remote Control Cables and Speed Sensor Lead Removal
391
Steering Cable Installation (Steering Master End)
393
Shift Cable Installation (Shift Lever End)
394
Steering Cable Installation (Jet Pump End)
394
Shift Cable Installation (Jet Pump End)
395
Seats and Hand Grip
398
Seat and Hand Grip Removal
398
Seat Lock Check
400
Exhaust System
401
Exhaust System and Battery Removal
401
Exhaust System Check
404
Deck and Hull
405
Drain Plug Check
409
Front Protector 1 Installation
409
Pull-Up Cleat Cover Installation (FX Cruiser SHO)
409
Reboarding Step Installation
409
Introduction
412
Ydis
412
Engine Unit Trouble Analysis
417
Using the YDIS for Engine Unit Trouble Analysis
417
Self-Diagnosis
418
Diagnostic Code Table
419
Diagnostic Code and Checking Step
420
Engine Unit Trouble Analysis (Diagnostic Code Not Detected)
426
Trouble Analysis Chart
426
Chapter 9
412
Features
412
Functions
412
4
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Yamaha WaveRunner FX SHO Specifications
General
Brand
Yamaha
Model
WaveRunner FX SHO
Category
Boat
Language
English
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