Yamaha Waverunner VXS VX1800 User manual

SERVICE MANUAL
WaveRunner
VXS
VX1800 (F2W)
VXR
VX1800A (F2W)
F2W-28197-ZU-11

Preface
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained me-
chanics when performing maintenance procedures and repairs to Yamaha equipment. It has been writ-
ten 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. Au-
thorized Yamaha dealers are notified periodically of modifications and significant changes in specifica-
tions 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 se-
rious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to the watercraft
or other property.
TIP:
A TIP provides key information to make procedures easier or clearer.
WaveRunner
VXS, VXR
SERVICE MANUAL
©2015 by Yamaha Motor Co., Ltd.
1st Edition, March 2015
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

Contents
General information 1
Specification 2
Maintenance 3
Fuel system 4
Power unit 5
Jet pump unit 6
Electrical system 7
Hull and hood 8
Troubleshooting 9
Appendix A

General information
Safety while working.......................................................... 1-1
Rotating parts ............................................................................. 1-1
Hot parts..................................................................................... 1-1
Electric shock ............................................................................. 1-1
Impeller....................................................................................... 1-1
Handling of gasoline................................................................... 1-1
Ventilation................................................................................... 1-1
Self-protection ............................................................................ 1-1
Working with crane..................................................................... 1-2
Handling of heat gun .................................................................. 1-2
Parts, lubricants, and sealants ................................................... 1-2
Handling of sealants................................................................... 1-3
Special service tool .................................................................... 1-3
Tightening torque ....................................................................... 1-3
Non-reusable parts..................................................................... 1-3
Disassembly and assembly........................................................ 1-3
Identification number......................................................... 1-4
Primary I.D. number ................................................................... 1-4
Engine serial number ................................................................. 1-4
Jet pump unit serial number ....................................................... 1-4
Craft identification number (C.I.N.) (Europe).............................. 1-4
Hull identification number (H.I.N.) (Oceania).............................. 1-4
How to use this manual ..................................................... 1-5
Manual format ............................................................................ 1-5
Conditions when testing and adjusting....................................... 1-6
Abbreviation ............................................................................... 1-6
Adhesive, lubricant, sealant,
and thread locking agent................................................... 1-8
Symbols...................................................................................... 1-8
Special service tool............................................................ 1-9
Model feature.................................................................... 1-19
General feature ........................................................................ 1-19
Model equipment comparison table ......................................... 1-20
Technical tips ................................................................... 1-21
Engine control .......................................................................... 1-21

1
General information
RiDE system............................................................................. 1-23
RiDE motor............................................................................... 1-24
ETV system .............................................................................. 1-25
Shift control .............................................................................. 1-26
Engine control system .............................................................. 1-28
Deck and hull............................................................................ 1-31
Lubrication system ................................................................... 1-32
Hose routing ............................................................................. 1-33
Cooling water flow .................................................................... 1-34

Safety while working
1-1
Safety while working
To prevent an accident or injury and to provide
quality service, observe the following safety
procedures.
Rotating parts
Hands, feet, hair, jewelry, clothing, personal
flotation device straps, and so on, can become
entangled with internal rotating parts of the en-
gine or jet pump unit, resulting in serious injury
or death.
• Keep hands, feet, hair, jewelry, clothing, per-
sonal 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.
Hot parts
During and after operation, engine parts are
hot enough to cause burns. Do not touch any
parts in the engine compartment until the en-
gine 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.
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.
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 conscious-
ness and death within a short time.
• When test running an engine indoors (for ex-
ample, 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 operations involv-
ing drilling and grinding, or when using an air
compressor.

1-2
Safety while working
• Protect your hands and feet by wearing pro-
tective gloves and safety shoes when neces-
sary.
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 capac-
ity 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 ad-
ditional ropes or the like so that the engine
unit can be lifted and carried in a stable man-
ner.
Handling of heat gun
• Improper handling of a heat gun may result in
burns. For information on the proper handling
of the heat gun, see the operation manual is-
sued 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 di-
rectly.
Parts, lubricants, and sealants
Use only genuine Yamaha parts, lubricants,
and sealants, or those recommended by Ya-
maha, when servicing or repairing the water-
craft.

Safety while working
1-3
Handling of sealants
• 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.
Tightening torque
Follow the tightening torque specifications pro-
vided throughout the manual. When tightening
nuts, bolts, and screws, tighten the large sizes
first, and tighten fasteners starting in the center
and moving outward.
Non-reusable parts
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 identifica-
tion 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 in-
stallation.
• Check that moving parts operate normally af-
ter assembly.

1-4
Identification number
Identification number
Primary I.D. number
The primary I.D. number is stamped on a label
attached to the inside of the engine compart-
ment.
Engine serial number
The engine serial number is stamped on a la-
bel attached to the engine unit.
Jet pump unit serial number
The jet pump unit serial number is stamped on
a label attached to the intermediate housing.
Craft identification number (C.I.N.)
(Europe)
The C.I.N. is stamped on a plate attached to
the boarding platform.
Hull identification number (H.I.N.)
(Oceania)
The H.I.N. is stamped on a plate attached to
the boarding platform.
1. Model name
2. Hull type
3. Primary I.D. number
Starting primary I.D. number
F2W: 800101
1. Engine name
2. Engine type
3. Engine serial number
Starting engine serial number
6EW: 1000001
MODEL F2W
PRI-I.D.
YAMAHA MOTOR CO., LTD.
ASSEMBLED IN U.S.A. FROM AMERICAN AND JAPANESE
COMPONENTS.
ASSEMBLÉ AUX ÉTATS-UNIS DE PIÈCES AMÉRICAINES ET
JAPONAISES.
321
1
23
1. Jet pump unit name
2. Jet pump unit type
3. Jet pump unit serial number
2
13

How to use this manual
1-5
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
“2” 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 “3” in the following figure).
• Tightening torque specifications are provided in the exploded diagrams (see “4” in 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 instal-
lation where necessary (see “5” in the following figure for an example page).
TIP:
For troubleshooting procedures, see Chapter 9, “Troubleshooting”.
6-12
Impeller housingand impeller duct ASSY
Impeller housingand impeller duct ASSY
No. Part name Q’ty Remarks
1Clamp 1
2Spouthose 1
3Bolt 4 M10
×
125 mm
4Bracket 1
5Nozzle 1
6 Impeller housing 1
7 Dowel pin 4
8Bolt 4 M6
×
35 mm
9 Water inlet cover 1
10 Gasket 2 Not reusable
11 Water inlet strainer 1
12 Impeller duct ASSY 1
5
8
7
7
6
7
7
2
1
4
3
3
3
3
12
9
10
11
10
7 Nm (0.7 kgf·m, 5.2 ft·lb)
40 Nm (4.0 kgf·m, 29.5 ft·lb)
1 Nm (0.1 kgf·m, 0.7 ft·lb)
6-14
Impeller, drive shaft, and impeller duct
Impeller duct ASSY disassembly
1. Remove the impeller “1”.
2. Remove the cap “1”, O-ring “2”, and nut
“3”.
3. Remove the drive shaft “1”.
Do not press the drive shaft threads
directly.
4. Remove the ball bearing “1”.
5. Remove the oil seals “1” and “2”.
Drive shaft holder 6 “2”
90890-06520
Driveshaft holder “2”
YB-06201
Drive shaft holder 6 “4”
90890-06520
Driveshaft holder “4”
YB-06201
1
2
1
2
3
4
3
A. Worldwide
B. U.S.A. and Canada
Stopper guide plate “2”
90890-06501
Bearing puller assembly “3”
90890-06535
Stopper guide stand “4”
90890-06538
Slide hammer “5”
YB-06096
1
A
2
1
3
3
4
1
5
5
B
2
1
5
34

1-6
How to use this manual
Conditions when testing and adjusting
Conditions can affect specifications when checking, measuring and making some adjustments. Service
data in this manual was determined under the following conditions:
• Electrical resistance for components such as pickup coils and sensors was measured at 20 °C (68
°F).
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
API American Petroleum Institute
APS Accelerator Position Sensor
BOW Bow end
BTDC Before Top Dead Center
DOHC Double Overhead Camshaft
ECM Electronic Control Module
ETV Electronic Throttle Valve
EX Exhaust
FForward
ID Identification
IN Intake
ISC Idle Speed Control
ISO International Organization for Standardization
N Neutral
OBD-M On-Board Diagnostics-Marine system
OTS Off-Throttle Steering
PON Pump Octane Number
PORT Port side
RReverse
RiDE Reverse with Intuitive Deceleration Electronics
RON Research Octane Number
RPM Revolutions Per Minute
RPS RiDE Position Sensor
SAE Society of Automotive Engineers
SCU Shift Control Unit
SPS Shift Position Sensor
STBD Starboard side
STERN Stern end
TCI Transistor-Controlled Ignition
TDC Top Dead Center
TPS Throttle Position Sensor

How to use this manual
1-7
UP Upside
YDIS Yamaha Diagnostic System
Abbreviation Description

1-8
Adhesive, lubricant, sealant, and thread locking agent
Adhesive, lubricant, sealant, and thread locking agent
Symbols
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 locking
agent and the application 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
Symbol Name Application
ThreeBond 1207B Sealant
ThreeBond 1280B Sealant
ThreeBond 1322D Thread locking agent
ThreeBond 1360 Thread locking agent
ThreeBond 1530D Adhesive
LOCTITE 242 (blue) Thread locking agent
LOCTITE 271 (red) Thread locking agent
LOCTITE 572 (white) Sealant
LOCTITE 648 (green) Thread locking agent
Silicone sealant Sealant

Special service tool
1-9
Special service tool
Special service tools numbered “YB/YM/YS/YU/YW-*****” are distributed by K & L.
Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division.
Special service tool with part number 90890-06884/LIT-YDIS2-01-KT is distributed by the Marine Ser-
vice Division.
Tool name/Tool No. Illustration Reference
pages
Oil filter wrench
90890-06830
Oil filter wrench
YB-06830
3-5, 3-5, 5-8,
5-13
Gauge stand
90890-06725
3-12, 5-34,
5-42
Dial gauge needle
90890-06584
3-12, 5-34,
5-42
Dial gauge stand set
YB-06585
3-12, 5-34,
5-42
Dial gauge set
90890-01252
3-12, 5-34,
5-42
Dial indicator gauge
YU-03097
3-12, 5-34,
5-42
Camshaft wrench
90890-06724
Camshaft wrench
YW-06724
3-12, 5-35,
5-38

1-10
Special service tool
Fuel pressure gauge adapter
90890-06946
Fuel pressure gauge adapter
YB-06946
4-3
Fuel pressure gauge
90890-06753
Fuel pressure gauge
YU-03153M
4-3
Compression gauge
90890-03160
Compression gauge
YU-33223
5-1
Compression gauge extension
90890-06563
5-1
Exhaust pipe wrench
90890-06726
Exhaust pipe wrench
YW-06726
5-17, 5-17
Coupler wrench
90890-06729
Coupler wrench
YW-06729
5-29, 5-34,
5-40, 5-42,
5-58, 5-58,
5-66, 5-66,
6-20, 6-22
Tool name/Tool No. Illustration Reference
pages
YU-33223

Special service tool
1-11
Leakage tester
90890-06840
5-29
Valve spring compressor
90890-04019
Valve spring compressor
YM-04019
5-47, 5-53
Valve spring compressor attachment
90890-04114
Compressor adapter
YM-04114
5-47, 5-53
Valve guide remover/installer
90890-06801
Valve guide remover
YB-06801
5-49, 5-50
Valve guide installer
90890-06810
Valve guide installer
YB-06810
5-50
Valve guide reamer
90890-06804
Valve guide reamer
YM-01196
5-50
Valve lapper
90890-04101
Valve lapping tool
YM-A8998
5-50, 5-53
Tool name/Tool No. Illustration Reference
pages

1-12
Special service tool
Valve seat cutter holder
90890-06812
5-51
Valve seat cutter 30°
90890-06720
5-51
Valve seat cutter 45°
90890-06325
5-51
Valve seat cutter 60°
90890-06324
5-51
Valve seat cutter 30°
90890-06818
5-51
Valve seat cutter 45°
90890-06555
5-51
Valve seat cutter 60°
90890-06323
5-51
Neway valve seat kit
YB-91044
5-51
Crankshaft holder
90890-06732
Crankshaft holder
YW-06562
5-58, 5-59,
5-63, 5-64,
5-64, 5-65,
5-66
Tool name/Tool No. Illustration Reference
pages

Special service tool
1-13
Shaft holder
90890-06721
Shaft holder
YW-06721
5-59, 5-59,
5-63, 5-64,
5-64, 5-65,
5-65
Drive handle
90890-06722
Drive handle
YW-06722
5-59, 5-59,
5-63, 5-64,
5-65, 5-65
Flywheel puller
90890-06723
Flywheel puller
YW-06723
5-60
Rotor puller
90890-01080
Stator rotor puller
YM-01080-A
5-60
Sheave holder
90890-01701
Primary sheave holder
YS-01880-A
5-60, 5-62
Driver rod LS
90890-06606
5-60, 5-61
Bearing outer race attachment
90890-06627
5-60
Driver handle (small)
YB-06229
5-60
Bearing and seal installer
YW-06356
5-60
Tool name/Tool No. Illustration Reference
pages

1-14
Special service tool
Ball bearing attachment
90890-06657
5-61
Driver handle (large)
YB-06071
5-61, 5-61,
6-12
Forward gear outer race installer
YB-41446
5-61
Bearing pressure C
90890-02393
5-61
Forward bearing race installer
YB-06258
5-61
Piston ring compressor
90890-05158
Piston ring compressor
YM-08037
5-86
Drive shaft holder 6
90890-06520
Driveshaft holder
YB-06201
6-11, 6-11,
6-14, 6-14
Stopper guide plate
90890-06501
6-11, 6-12,
6-20
Bearing puller assembly
90890-06535
6-11, 6-12,
6-20
Tool name/Tool No. Illustration Reference
pages
C

Special service tool
1-15
Stopper guide stand
90890-06538
6-11, 6-12,
6-20
Slide hammer
YB-06096
6-11, 6-12,
6-20
Driver rod L3
90890-06652
6-12
Driver rod SL
90890-06602
6-12
Needle bearing attachment
90890-06609
6-12
Driveshaft needle bearing installer and re-
mover
YB-06194
6-12
Oil seal installer attachment
90890-06733
6-13
Oil seal installer attachment
YW-06628
6-13
Bearing attachment
90890-06728
Bearing attachment
YW-06728
6-13, 6-13,
6-13, 6-21,
6-22
Tool name/Tool No. Illustration Reference
pages