Yamaha WaveRunner VX 700 User manual

SERVICE MANUAL
WaveRunner
F2V-28197-ZN-11
VX 700
VX 700 (F2V)

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 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 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 YPEC-web. Additional information and
up-to-date information on Yamaha products and services are available on Yamaha Service Portal.
Important information
Particularly important information is distinguished in this manual by the following notations:
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 water-
craft or other property.
TIP:
A TIP provides key information to make procedures easier or clearer.
WaveRunner
VX 700
SERVICE MANUAL
©2010 by Yamaha Motor Co., Ltd.
1st Edition, September 2010
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

Contents
General information GEN
INFO
Specification SPEC
Maintenance MNT
Fuel system FUEL
Power unit POWR
Jet pump unit JET
PUMP
Electrical system ELEC
Hull and hood HULL
HOOD
Troubleshooting TRBL
SHTG
Appendix
–+
1
2
3
4
5
6
7
8
9
A

GEN
INFO
1
General information
Safety 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....................................................................... 1-3
Disassembly and assembly........................................................ 1-4
How to use this manual ..................................................... 1-5
Manual format ............................................................................ 1-5
Abbreviation ............................................................................... 1-6
Adhesive, lubricant, sealant,
and thread locking agent................................................... 1-7
Symbol ....................................................................................... 1-7
Special service tool............................................................ 1-8
Model feature.................................................................... 1-10
Identification number ................................................................ 1-10

1-1
GEN
INFO General information
Safety while working
To prevent an accident or injury and to pro-
vide quality service, observe the following
safety procedures.
Rotating part
•Hands, feet, hair, jewelry, clothing, per-
sonal flotation device straps, and so on,
can become entangled with internal rotating
parts of the engine or jet pump unit, result-
ing 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 per-
sonal 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 start-
ing 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.
Handling of gasoline
•Gasoline is highly flammable. Keep gaso-
line 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.

1-2
1
Ventilation
•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 con-
sciousness 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 main-
tained.
Self-protection
•Protect your eyes by wearing safety
glasses or safety goggles during all opera-
tions involving drilling and grinding, or when
using an air compressor.
•Protect your hands and feet by wearing
protective gloves and safety shoes when
necessary.
Working with crane
•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 respec-
tively.
•When lifting the watercraft, use the water-
craft lift harness and make sure that the
watercraft is in a stable position when mov-
ing 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 sus-
pended, support it using additional ropes or
the like so that the engine unit can be lifted
and carried in a stable manner.
Safety while working

1-3
GEN
INFO General information
Handling of heat gun
•Improper handling of a heat gun may result
in burns. For information on the proper han-
dling 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.
Part, lubricant, and sealant
Use only genuine Yamaha parts, lubricants,
and sealants, or those recommended by
Yamaha, when servicing or repairing the
watercraft.
Handling of sealant
•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 dam-
age.
Tightening torque
Follow the tightening torque specifications
provided throughout the manual. When tight-
ening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting
in the center and moving outward.
Non-reusable part
Always use new gaskets, seals, O-rings, cot-
ter pins, and so on, when installing or assem-
bling parts.

1-4
1
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 identifi-
cation mark is facing in the direction indi-
cated in the installation procedure. In
addition, make sure to lubricate the bear-
ings 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.
Safety while working

1-5
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 under-
stand. 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 1
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 2in the following figure). To assemble or install the components, reverse the steps indicated
in the component list.
•Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
the lubrication point (see 3in the following figure).
•Tightening torque specifications are provided in the exploded diagrams (see 4in the following fig-
ure), 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 5in the following figure for an example page).
TIP:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
6-6
Impeller duct and drive shaft
*: EPNOC grease AP #0
No. Part name Q’ty Remarks
1 Bolt 3 M6 20 mm
2Cap 1
3O-ring 1 Not reusable
4Cap 1
5 Impeller 1
6 Drive shaft 1
7 Oil seal 1 Not reusable
8 Oil seal 1 Not reusable
9 Rear bearing 1 Not reusable
10 Spacer 1
11 Front bearing 1 Not reusable
12 Impeller duct 1
Jet thrust nozzle, impeller duct, and impeller housing / Impeller duct and drive shaft
6-7
JET
PUMP Jet pump unit
Drive shaft removal
1. Remove the impeller.
TIP:
Hold the impeller duct assy. in a vise
between two aluminum plates a.
2. Remove the drive shaft 1.
TIP:
Remove the drive shaft using a press.
3. Remove the rear bearing.
4. Remove the oil seals.
TIP:
Remove the oil seals using a flat head screw-
driver.
5. Remove the front bearing.
TIP:
Remove the front bearing using a press.
Impeller check
1. Check the impeller. Replace if damaged.
Crankshaft holder 20: 90890-06552
a
a
1
Stopper guide plate: 90890-06501
Bearing puller assembly: 90890-06535
Stopper guide stand: 90890-06538
Driver rod L3: 90890-06652
Needle bearing attachment: 90890-06614
1
5
3
2
4

1-6
1
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
BOW Bow end
CDI Capacitor discharge ignition
EX Exhaust
IN Intake
NMMA National Marine Manufacturers Association
PON Pump Octane Number
PORT Port side
RON Research Octane Number
STBD Starboard side
STERN Stern end
TDC Top Dead Center
How to use this manual

1-7
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.
Symbols in an exploded diagram or illustration indicate the type of adhesive, sealant, or thread lock-
ing agent and the application points.
Symbol Name Application
Yamaha 2-stroke motor oil Lubricant
Water resistant grease
(Yamaha grease A)
Lubricant
Molybdenum disulfide grease Lubricant
Epnoc grease AP#0 Lubricant
Symbol Name Application
Gasket Maker Sealant
LOCTITE 271 (red) Thread locking agent
LOCTITE 242 (blue) Thread locking agent
LOCTITE 572 (white) Sealant
Silicone sealant Sealant
ThreeBond 1207B Sealant
ThreeBond 1207D Sealant
ThreeBond 1322 Thread locking agent
EP
242
LT

1-8
1
Special service tool
Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division.
Digital tachometer
90890-06760
Compression gauge
90890-03160
Flywheel holder
90890-06522
Flywheel puller
90890-06521
Coupler wrench
90890-06425
Driver rod L3
90890-06652
Needle bearing attachment
90890-06614
Ball bearing attachment
90890-06634
Stopper guide plate
90890-06501
Bearing puller assembly
90890-06535
Adhesive, lubricant, sealant, and thread locking agent / Special service tool

1-9
GEN
INFO General information
Stopper guide stand
90890-06538
Driver rod LS
90890-06606
Ball bearing attachment
90890-06631
Crankshaft holder 20
90890-06552
Bearing outer race attachment
90890-06628
Drive shaft holder 5
90890-06519
Digital circuit tester
90890-03174
Peak voltage adapter B
90890-03172
Ignition tester (Spark gap tester)
90890-06754

1-10
1
Model feature
Identification number
Primary I.D. number
The primary I.D. number is stamped on a
label attached to the inside of the engine
compartment.
1Model name
2Hull type
3Primary I.D. number
Engine serial number
The engine serial number is stamped on a
label attached to the engine unit.
1Engine name
2Engine type
3Engine serial number
Jet pump unit serial number
The jet pump unit serial number is stamped
on a label attached to the intermediate hous-
ing.
1Jet pump unit name
2Jet pump unit type
3Jet pump unit serial number
Hull identification number (H.I.N.)
The H.I.N. is stamped on a plate attached to
the boarding platform.
Starting primary I.D. number:
F2V: 800101
MODEL F2V
PRI-I.D.
YAMAHA MOTOR CO., LTD.
ASSEMBLED IN U.S.A. FROM AMERICAN AND JAPANESE
COMPONENTS.
ASSEMBLÉAUX ÉTATS-UNIS DE PIÈCES AMÉRICAINES ET
JAPONAISES.
321
23
1
Starting engine serial number:
6CP: 1000001
2 1 3
Special service tool / Model feature

1-11
GEN
INFO General information
—MEMO —

SPEC
1
2
3
4
5
6
7
8
9
A
Specification
Model data .......................................................................... 2-1
Model code................................................................................. 2-1
Dimension and weight ................................................................ 2-1
Performance............................................................................... 2-1
Power unit .................................................................................. 2-1
Drive unit .................................................................................... 2-2
Fuel and oil requirement............................................................. 2-2
Battery requirement.................................................................... 2-2
Fuel system technical data ............................................... 2-3
Fuel system ................................................................................ 2-3
Power unit technical data.................................................. 2-3
Power unit .................................................................................. 2-3
Cylinder head assy..................................................................... 2-3
Crank case assy......................................................................... 2-4
Jet pump unit technical data............................................. 2-5
Jet pump unit.............................................................................. 2-5
Electrical technical data .................................................... 2-5
Ignition system ........................................................................... 2-5
Charging system ........................................................................ 2-6
Control system ........................................................................... 2-6
Starting system........................................................................... 2-7
Meter system.............................................................................. 2-7
Specified tightening torque............................................... 2-8
Fuel system ................................................................................ 2-8
Power unit .................................................................................. 2-8
Jet pump unit............................................................................ 2-10
Electrical system ...................................................................... 2-10
Hull and hood ........................................................................... 2-11
General tightening torque ............................................... 2-12
Cooling system ................................................................ 2-13
Cable and hose routing ................................................... 2-14
Starboard bow view.................................................................. 2-14
Top view ................................................................................... 2-15
Port view................................................................................... 2-17

2-1
SPEC Specification
Model data
Model code
Dimension and weight
Performance
Power unit
Item Unit Model
VX 700
Hull F2V
Engine/jet 6CP/6CP
Item Unit Model
VX 700
Length mm (in) 3220 (126.8)
Width mm (in) 1170 (46.1)
Height mm (in) 1160 (45.7)
Dry weight kg (lb) 283 (624)
Maximum capacity Person/
kg (lb) 3/240 (530)
Item Unit Model
VX 700
Full throttle operating range r/min 7200
Trolling speed r/min 1250–1350
Maximum fuel consumption L/h (US gal/
h, lmp.gal/h) 34.0 (9.0, 7.5)
Cruising range h 1.47
Item Unit Model
VX 700
Type 2-stroke L2
Cylinder quantity 2
Total displacement cm3(cu. in) 701 (42.8)
Bore ×stroke mm (in) 81.0 ×68.0 (3.19 ×2.68)
Compression ratio 7.2 : 1
Intake system Reed valve
Starting enrichment Choke valve
Scavenging system Loop charge
Exhaust system Wet exhaust
Lubrication system Oil injection
Cooling system Water cooled
Starting system Electric starter
Ignition system CDI
Maximum ignition timing
advance Degree BTDC 21°
Spark plug BR8HS (NGK)
Spark plug gap mm (in) 0.6–0.7 (0.024–0.038)
Firing order 1–2

2-2
1
2
3
4
5
6
7
8
9
A
Drive unit
Fuel and oil requirement
Battery requirement
Item Unit Model
VX 700
Jet pump type Axial flow, single stage
Impeller rotation Counterclockwise (viewed from rear)
Transmission Constant mesh 1-speed
Jet thrust nozzle horizontal
angle Degree 24 + 24
Trim system —
Jet thrust nozzle trim angle Degree 3
Item Unit Model
VX 700
Fuel type Regular unleaded gasoline
Fuel minimum rating PON 86
RON 90
Fuel tank capacity
Total L (US gal,
Imp.gal) 50 (13.2, 11.0)
Reserve L (US gal,
Imp.gal) 12 (3.2, 2.6)
Engine oil type YAMALUBE 2-W
Fuel and oil mixing ratio
(Wide open throttle) 50:1
Engine oil grade NMMA-
certified
TC-W3
Oil tank capacity L (US gal,
Imp.gal) 3.8 (1.0, 0.8)
Item Unit Model
VX 700
Type Fluid
Capacity V/Ah 12/19
Specific gravity at 20 °C (68 °F) 1.265
Model data

2-3
SPEC Specification
Fuel system technical data
Fuel system
Power unit technical data
Power unit
Cylinder head assy.
Item Unit Model
VX 700
Carburetor
Manufacturer Mikuni
Model ×quantity BN38 ×2
Type Floatless
ID mark 62T03F/03R
Main jet (MJ) 120 (front), 130 (rear)
Main nozzle (MN) mm (in) 2.5 (0.10)
Pilot jet (PJ) 67.5
Low speed screw turns out 5/8 ±1/4
Throttle valve 190
Valve seat size mm (in) 1.5 (0.06)
Arm height mm (in) 0–0.2 (0–0.008)
High speed screw turns out 5/8 ±1/4 (front), 1 1/8 ±1/4 (rear)
Throttle lever free play mm (in) 4.0–7.0 (0.16–0.28)
Item Unit Model
VX 700
Cylinder
Minimum compression
pressure (*1)
kPa (kgf/
cm2, psi) 590 (5.9, 84)
(*1) Measuring conditions:
Ambient temperature 20 °C (68 °F), with spark plugs removed from all cylinders.
The figures are for reference only.
Item Unit Model
VX 700
Cylinder head
Warpage limit mm (in) 0.1 (0.004)