Yamaha SUPER JET SJ650Q 1991 User manual

PROTECT YOUR INVESTMENT
Use Genuine YAMAHA Parts And Accessories
LIT-18616-00-77
Service Manual
SUPER JET
SJ650Q
LIT-18616-00-77
Service Manual
YAMAHA MOTOR CORPORATION, U.S.A.
PRINTED IN U.S.A.
SJ650Q
18616-00-77 CVR_R 8/16/05 8:52 PM Page 1

~
) .YAMAHA
) .
) SUPER
JET
SJ650Q

A20000-1
NOTICE
This manual has been prepared by the Yamaha Motor Corporation,
U.S.A.
primarily for use
by Yamaha dealers and theirtrained mechanics when performing maintenance procedures
and repairs to Yamaha equipment. It has been written to suit the needs
of
persons who have
a basic understanding
of
the mechanical and electrical concepts and procedures inherent
in the work, for without such knowledge attempted repairs or service to the equipment could
render it unsafe or unfit for use.
Because the Yamaha Motor Corporation,
U.S.A.
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 pro-
cedures, and these are incorporated in successive editions
of
this manual.
A10001-1"
SUPER
JET
(SJ650Q)
SERVICE MANUAL
©
1991
Yamaha Motor Corporation, U.S.A.
1st Edition, September
1991
All rights reserved.
No part
of
this publication may
be
reproduced
or transmitted in any form
or
by any means
including photocopying and recording without
the written permission
of
the copyright holder.
Such written permission must also be obtained
before any part
of
this
publication is stored
in a retrieval system
of
any nature.
Printed in Japan
P/N
LIT-18616-00·77

A507IJO.O
HOW TO USE THIS MANUAL
MANUAL FORMAT
All
of the procedures in this manual are organized in a sequential, step-by-step format. The
information has been complied to provide the mechanic with
an easy to read, handy refe-
rence that contains comprehensive explanations of all disassembly, repair, assembly, and
inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and
the course
of action required will follow the symbol, e.g.,
• Bearings
Pitting/Damage
..... Replace.
To assist you to find your way about this manual, the Section Title and Major Heading is
given at the head
of every page.
An Index to contents is provided on the first page of each Section.
THE ILLUSTRATIONS
Some illustrations in this manual may differ from the model you
have. This is because a
procedure described may relate to several models, though only one may
be illustrated. (The
name of model described will be mentioned in the description).
REFERENCES
These have been kept to a minimum; however, when you are referred to another section of
the manual, you are told the page number to go to.
WARNINGS, CAUTIONS
AND NOTES
Attention is drawn to the various Warnings, Cautions and Notes which distinguish impor-
tant information in this manual in the following ways.
~The'Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS IN-
VOLVED!
A WARNING
Failure to follow WARNING instructions could result in severe injury or death to the water
vehicle operator, a bystander, or a peason inspecting or repairing the water vehicle.
;lttiiRIII!I;I __________________________ _
A CAUTION indicates special precautions that must be taken to avoid damage to the water
vehicle.
NOTE:----------------------------------------------------
A NOTE provides key information to make procedures easier or clearer.

HOW TO READ DESCRIPTIONS
1. An easy-to-see disassembly illustration is mainly provided for a disassembly job.
2. Numbers are given in the order of a disassembly job in the disassembly illustration.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of
symbol marks. The meanings
of the symbol marks are given on the next page.
4. A job instruction chart accompanies the assembly illustration, providing the order of
jobs, names
of parts, notes in jobs, etc.
5.1n addition to the disassembly illustration, "REMOVAL POINTS" is provided to supple-
ment
in detail the explanation which does or cannot necessarily cover the main jobs.
6. Jobs necessary before and afterthosewhich are not included in the disassembly illustra-
tion are explained before the same illustration as related jobs.
CD Section
® Preparation for removal
@ Order of removal
@)Part name
@O'ty
__.ID
I 1.1
REED VALVE, CYLINDER HEAD, CYLINDER
. POWR. . AND PISTON
REED VALVE, CYLINDER HEAD, CYLINDER AND PISTON
PREPARA110N FOR REMOVAL
J
~§;;;.~;:.
• RernowetM cartlureiOf.
2
®Remarks
0 Removal point
® Extent of removal
®Symbol mark
@ Exploded diagram
I ,., REED VALVE, CYLINDER HEAD, CYLINDER
POWR AND PISTON
N01I ON REMOVAL REASSEMBLY
•With the engine mounted, tht following pans can be removed.
•BeloreS«Vic:ing.cteanti'HtpartJ. and takecareaotl'lat foreign maltlrlal do not .mer the
...........
•RM!ove the gutcet adhclnld on the contec:Ung surtKe.
•Take care not to scratch the contacttng surface when removing the cyfinderand cylinder
.....
•Take care not no $CfKtCtt the cyllndel' and pleton surface.
•For I'UIMiftbly, the removed parts should be c:leanecl with solvent, and appty the two-
cycle OUlboafd oil cmto the sliding surface.
®<
Extent ol removal: @Reed valVe ntniO\'al ® Cylinder head removal
®Cylinder removal ® Piston and I»Ston ring removal
Extent ol rei!IO'Ial Order Part name Q'ty Remarks
2 lntakemanllofd
1 Bolt s 1
! =p 14'
5 Clomp~ ................
6 Exhaust no.
7 Clamp
8 Clamp
9 Boll
10 Mulllef, 2
11 Boll
12 Muffter.t
13 Bolt
14 Cyllnderheacl
15 Bolt
16 Cylinder
17 Clip
18 Piston pin
,. ,_
20 IStnall end bearing
21 Pi$ton ring
Loosen the screw.
Loosen the sorew.

CD
1~~~~1
•
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®
IPOWRI•I
(j)
J
ELEcJUJ
®
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•
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1~1
@
[ij]
@
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572
@
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@
I
SPEC
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@
I
FUEL
I
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®
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JET I
rl
:PUMP:-
--:
®
1~85~1
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@
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®
[g]
@
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@ 1
m
@
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®
a
a
242
@
l
a
A50000·IJ.4
SYMBOLS
Symbols
CD
to
® are designed as thumb-
tabs to indicate the content
of
a chapter:
CD
General Information
@
Specification
@
Inspection and adjustment
@ Fuel System
®Power
Unit
®
Jet
Pump
Unit
(j)
Electrical System
® Hull and Hood
®Trouble-shooting
Symbols
@
to
@
indicate specific data:
@
Special tool
®Lubricant
® Engine speed
@Tightening torque
@ Specified value, Service limit
@ Resistance
(!J),
Voltage
(V),
Electric current
(A)
Symbol @ to
@
in
an
exploded diagram
indicate grade
of
lubricant and location
of
lubrication point:
@Apply
Yamaha two-cycle outboard oil
(Yamalube two-cycle outboard oil,
Yamalube
1)
@ Apply water registance grease
(Yamaha grease
A,
Yamaha marine
grease)
@ Apply water registance grease
(Yamaha grease
D,
Yamaha marine
grease)
Symbols @ to @ in an exploded diagram
indicate grade
of
sealing or locking agent,
and location
of
application point:
@ Apply Gasket maker
@)
Apply LOCTITE No.
242
(Blue
LOCTITE)
@ Apply LOCTITE No.
572
@Apply
Silicone sealant
@Apply
Yamabond
#
(Yamaha bond
No.4)
NOTE:-----------
In this manual, the above symbols may not
be used
in
every case.

ELECTRICAL SYSTEM
HULL AND HOOD
TROUBLE-SHOOTING
ELEC
•
HULL
HOOD
?
•
TRBL
SHTG

CHAPTER
1.
GENERAL INFORMATION
IDENTIFICATION NUMBERS ..........................................................................
1-1
PRIMARY I.D. NUMBER .............................................................................
1-1
ENGINE SERIAL NUMBER ........................................................................
1-1
PUMP SERIAL NUMBER ...........................................................................
1-1
HULL
IDENTIFICATION NUMBER (H.I.N.) ...............................................
1-1
DIMENSIONS ....................................................................................................
1-2
SAFETY
WHILE
WORKING .............................................................................
1-3
FIRE PREVENTION ....................................................................................
1-3
VENTILATION .............................................................................................
1-3
SELF-PROTECTION ....................................................................................
1-3
OILS, GREASES AND SEALING FLUIDS ................................................
1-3
GOOD WORKING PRACTICES .................................................................
1-4
DISASSEMBLY AND ASSEMBLY .............................................................
1-4
SPECIAL TOOLS ...............................................................................................
1-5
FOR TUNE-UP .............................................................................................
1-5
FOR POWER UNIT SERVICE ....................................................................
1-6
FOR JET UNIT SERVICE ...........................................................................
1-7

IDENTIFICATION NUMBERS
MODEL._!
_
___,l
EW2._l
__
_,
1-1
IDENTIFICATION NUMBERS
PRIMARY I.D. NUMBER
The primary
1.0.
number is stamped
on
a
plate attached
to
the inside
of
the engine
compartment.
Starting Primary
J.D.
Number:
811701
-
ENGINE SERIAL NUMBER
The engine serial number is stamped
on
a
plate attached to the intake manifold.
Starting serial number:
016911
-
PUMP SERIAL NUMBER
The
jet
pump unit serial number is stamped
on a plate attached on the intermediate
housing.
Starting serial number:
517111
-
HULL IDENTIFICATION NUMBER (H.I.N.)
The H.I.N. is stamped on the rear end
of
the
footrest floor.

,.~~~
I •
·I
DIMENSIONS
A60750:0'
DIMENSIONS
1,525 mm (60.0 in)
90mm
(3.54
in)
660
mm
(26.0 in)
1-2
c:
-
N
(X)
~
E
E
0
"""
N
-
N
680
mm
(26
8 in)
~
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~
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