Yamaha WaveRunner User manual

SERVICE MANUAL
FX High Output
WaveRunner
F1S-28197-1G-11LIT-18616-02-83
*LIT186160283*
FX Cruiser High Output

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NOTICE
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.
A10001-0*
WaveRunner
FX High Output, FX Cruiser High Output
SERVICE MANUAL
©2004 by Yamaha Motor Corporation, USA
1st Edition, February 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-02-83

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HOW TO USE THIS MANUAL
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been compiled to provide the mechanic with an easy to read, handy reference 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/scratches → Replace.
To assist you in finding your way through this manual, the section title and major heading is given at
the top of every page.
ILLUSTRATIONS
The illustrations within this service manual represent all of the designated models.
CROSS REFERENCES
The cross references have been kept to a minimum. Cross references will direct you to the appropri-
ate section or chapter.

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IMPORTANT INFORMATION
In this Service Manual particularly important information is distinguished in the following ways.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, passenger(s), a bystander, or a person inspecting or repairing the watercraft.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the water-
craft.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
IMPORTANT:
This part has been subjected to change of specification during production.

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HOW TO USE THIS MANUAL
1To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
2Numbers are given in the order of the jobs in the exploded diagram.
3Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
4A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
5Dimension figures and the number of parts, are provided for fasteners that require a tightening
torque.
Example:
Bolt or screw size : M10 (D) ×25 mm (L)
6Jobs requiring more information (such as special tools and technical data) are described
sequentially.
10 ×25 mm
D
L

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A50001-1-4
SYMBOLS
Symbols 1to 9are designed to indicate the
content of a chapter.
1General Information
2Specifications
3Periodic Inspection and Adjustment
4Fuel System
5Power Unit
6Jet Pump Unit
7Electrical System
8Hull and Hood
9Trouble Analysis
Symbols 0to Eindicate specific data.
0Special tool
ASpecified oil or fluid
BSpecified engine speed
CSpecified tightening torque
DSpecified measurement
ESpecified electrical value
(resistance, voltage, electric current)
Symbols Fto Hin an exploded diagram indi-
cate the grade of lubricant and the lubrication
point.
FApply Yamaha 4-stroke motor oil
GApply water resistant grease
(Yamaha grease A, Yamaha marine grease)
HApply molybdenum disulfide grease
Symbols Ito Nin an exploded diagram indi-
cate the type of sealant or locking agent and
the application point.
IApply Gasket Maker
JApply Yamabond No. 4
KApply LOCTITE 271 (red)
LApply LOCTITE 242 (blue)
MApply LOCTITE 572
NApply silicone sealant
NOTE:
Additional symbols may be used in this man-
ual.
12
34
56
78
90
AB
CD
EF
GH
IJ
KL
MN
GEN
INFO SPEC
INSP
ADJ FUEL
POWR
JET
PUMP
–+
ELEC
HULL
HOOD
TRBL
ANLS
T
R
.
.
E
A M
GM
4
271
LT
242
LT
572
LT SS

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INDEX
GENERAL INFORMATION 1
GEN
INFO
SPECIFICATIONS 2
SPEC
PERIODIC INSPECTION AND
ADJUSTMENT 3
INSP
ADJ
FUEL SYSTEM 4
FUEL
POWER UNIT 5
POWR
JET PUMP UNIT 6
JET
PUMP
ELECTRICAL SYSTEM 7
ELEC
HULL AND HOOD 8
HULL
HOOD
TROUBLE ANALYSIS 9
TRBL
ANLS
–+
A30000-0

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GEN
INFO
1
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION NUMBERS .........................................................................1-1
PRIMARY l.D. NUMBER ...........................................................................1-1
ENGINE SERIAL NUMBER ......................................................................1-1
JET PUMP UNIT SERIAL NUMBER .........................................................1-1
HULL IDENTIFICATION NUMBER (H.l.N.)...............................................1-1
SAFETY WHILE WORKING......................................................................1-2
FIRE PREVENTION ..................................................................................1-2
VENTILATION ...........................................................................................1-2
SELF-PROTECTION.................................................................................1-2
PARTS, LUBRICANTS, AND SEALANTS ................................................1-2
GOOD WORKING PRACTICES ...............................................................1-3
DISASSEMBLY AND ASSEMBLY ............................................................1-4
SPECIAL TOOLS ............................................................................................1-5
MEASURING.............................................................................................1-5
REMOVAL AND INSTALLATION..............................................................1-7

1-1
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GEN
INFO IDENTIFICATION NUMBERS
A60700-0*
IDENTIFICATION NUMBERS
PRIMARY l.D. NUMBER
The primary l.D. number is stamped on a label
attached to the inside of the engine compart-
ment.
Starting primary l.D. number:
F1S: 800101
ENGINE SERIAL NUMBER
The engine serial number is stamped on a
label attached to the engine unit.
Starting serial number:
6B6: 1000001
JET PUMP UNIT SERIAL NUMBER
The jet pump unit serial number is stamped on
a label attached to the intermediate housing.
HULL IDENTIFICATION NUMBER
(H.l.N.)
The H.l.N. is stamped on a plate attached to
the aft deck.

1-2
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GEN
INFO SAFETY WHILE WORKING
SAFETY WHILE WORKING
To prevent and accident or injury and to
ensure quality service, follow the safety proce-
dures provided below.
FIRE PREVENTION
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
VENTILATION
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled in
large quantities they may cause loss of con-
sciousness and death within a short time.
When test running an engine indoors (e.g., in a
water tank), be sure to do so where adequate
ventilation can be maintained.
SELF-PROTECTION
Protect your eyes by wearing safety glasses or
safety goggles during all operation involving
drilling and grinding, or when using an air com-
pressor.
Protect your hands and feet by wearing protec-
tive gloves or safety shoes when necessary.
PARTS, LUBRICANTS, AND
SEALANTS
Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the
watercraft.

1-3
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GEN
INFO SAFETY WHILE WORKING
Under normal conditions, the lubricants men-
tioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Maintain good standards of personal and
industrial hygiene.
2. Change and wash clothing as soon as
possible if soiled with lubricants.
3. Avoid contact with skin. Do not, for exam-
ple, place a soiled rag in your pocket.
4. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.
5. To protect your skin, apply a protective
cream to your hands before working on the
watercraft.
6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.
GOOD WORKING PRACTICES
1. The right tools
Use the recommended special service
tools to protect parts from damage. Use
the right tool in the right manner—do not
improvise.
2. Tightening torques
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.

1-4
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GEN
INFO SAFETY WHILE WORKING
3. Non-reusable parts
Always use new gaskets, seals, O-rings,
oil seals, cotter pins, circlips, etc., when
installing or assembling parts.
DISASSEMBLY AND ASSEMBLY
1. Use compressed air to remove dust and
dirt during disassembly.
2. Apply engine oil to the contact surfaces of
moving parts during assembly.
3. Install bearings with the manufacture iden-
tification mark in the direction indication in
the installation procedure. In addition, be
sure to lubricate the bearings liberally.
4. Apply a thin coat of water-resistant grease
to the lip and periphery of an oil seal
before installation.
5. Check that moving parts operate normally
after assembly.

1-5
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GEN
INFO SPECIAL TOOLS
SPECIAL TOOLS
Using the correct special tools recommended
by Yamaha, will aid the work and enable accu-
rate assembly and tune-up. Improvisations
and using improper tools can damage the
equipment.
NOTE:
•For U.S.A. and Canada, use part numbers
starting with “J-”, “YB-”, “YM-”, “YS-”, “YU-”or
“YW-”.
•For other countries, use part numbers start-
ing with “90890-”.
MEASURING
1Dial gauge
P/N. YU-03097
90890-01252
2Dial gauge stand
P/N. 90890-06583
3Dial gauge needle
P/N. 90890-06584
4Dial gauge stand set
P/N. YW-06585
90890-06585
5Pocket tester
P/N. YU-03112
90890-03112
6Digital multimeter
P/N. YU-34899-A
7Digital circuit tester
P/N. 90890-03174
8Carburetor synchronizer
P/N. YU-08030
9Vacuum gauge
P/N. 90890-03094
0Test connector
P/N. YW-06862
Test connector FMY-8
P/N. 90890-06862
AFuel pressure gauge adapter
P/N. YW-06842
90890-06842
1
23
4
5
9
YU-03097 90890-01252
90890-06583 90890-06584
YW-06585
90890-06585
YU-03112
90890-03112
90890-03094
AYW-06842
90890-06842
78
90890-03174 YU-08030
6YU-34899-A
0YW-06862
90890-06862

1-6
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GEN
INFO SPECIAL TOOLS
BFuel pressure gauge
P/N. YB-06766
90890-06786
CCompression gauge extension
P/N. 90890-06582
DCylinder gauge set
P/N. YU-03017
90890-06759
ECompression gauge
P/N. YU-33223-1
90890-03160
FPeak volt meter adapter
P/N. YU-39991
GPeak voltage adapter B
P/N. 90890-03172
HSpark gap tester
P/N. YM-34487
IIgnition tester
P/N. 90890-06754
JTest harness (2 pins)
P/N. New: YB-06867
Current: YB-06767
Test harness FWY-2 (2 pins)
P/N. New: 90890-06867
Current: 90890-06767
KTest harness (3 pins)
P/N. New: YB-06870
Current: YB-06770
Test harness SMT250-3 (3 pins)
P/N. New: 90890-06870
Current: 90890-06770
LTest harness (6 pins)
P/N. YB-06848
Test harness FSW-6A (6 pins)
P/N. 90890-06848
MTest harness (3 pins)
P/N. YB-06793
Test harness SMHW099-3 (3 pins)
P/N. 90890-06793
B
CD
E
F
H
JK
LM
YB-06766 90890-06786
90890-06582 YU-03017
90890-06759
YU-33223-1 90890-03160
YU-39991 90890-03172
YM-34487 90890-06754
YB-06867 (-06767)
90890-06867 (-06767)
YB-06870 (-06770)
90890-06870 (-06770)
YB-06848
90890-06848
YB-06793
90890-06793
I
G

1-7
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GEN
INFO SPECIAL TOOLS
NTest harness (3 pins)
P/N. New: YB-06877
Current: YB-06777
Test harness HM090-3 (3 pins)
P/N. New: 90890-06877
Current: 90890-06777
OLower unit pressure/vacuum tester
P/N. YB-35956-A
Vacuum/pressure pump gauge set
P/N. 90890-06756
PYamaha diagnostic system
P/N. 60V-85300-02
QYamaha diagnostic system
P/N. 60V-WS853-02
NO
YB-06877 (-06777)
90890-06877 (-06777)
YB-35956-A
90890-06756
Q60V-WS853-02
YAMAHA
DIAGNOSTIC
SYSTEM
INSTALLATION MANUAL
P60V-85300-02
REMOVAL AND INSTALLATION
1Oil filter wrench
P/N. YU-38411
90890-01426
2Coupler wrench
P/N. YW-06551
90890-06551
3Sheave holder
P/N. YS-01880-A
90890-01701
4Rotor puller
P/N. YM-01082
90890-01080
12
34
YU-38411
90890-01426
YW-06551
90890-06551
YS-01880-A
90890-01701
YM-01082
90890-01080

1-8
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GEN
INFO SPECIAL TOOLS
5Universal magneto and rotor holder
P/N. YU-01235
Rotor holder
P/N. 90890-01235
6Bearing housing needle bearing installer
(reduction drive gear)
P/N. YB-06111
7Ball bearing attachment
(reduction drive gear)
P/N. 90890-06631
8Forward gear bearing cup installer
(reduction drive gear)
P/N. YB-06726-B
9Ball bearing attachment
(reduction drive gear)
P/N. 90890-06657
0Valve spring compressor
P/N. YM-01253
90890-04019
AValve spring compressor attachment
P/N. YM-4114 (ø19 mm)
90890-04114 (ø19 mm)
YM-4108 (ø22 mm)
90890-04108 (ø22 mm)
BValve guide remover
P/N. YM-04111 (ø4.0 mm)
90890-04111 (ø4.0 mm)
YM-04116 (ø4.5 mm)
90890-04116 (ø4.5 mm)
CValve guide installer
P/N. YM-04112 (ø4.0 mm)
90890-04112 (ø4.0 mm)
YM-04117 (ø4.5 mm)
90890-04117 (ø4.5 mm)
DValve guide reamer
P/N. YM-04113 (ø4.0 mm)
90890-04113 (ø4.0 mm)
YM-04118 (ø4.5 mm)
90890-04118 (ø4.5 mm)
56
AB
YU-01235
90890-01235
YB-06111
YM-4114 (ø19 mm)
90890-04114 (ø19 mm)
YM-4108 (ø22 mm)
90890-04108 (ø22 mm)
YM-04111 (ø4.0 mm)
90890-04111 (ø4.0 mm)
YM-04116 (ø4.5 mm)
90890-04116 (ø4.5 mm)
78
90890-06631 YB-06726-B
90
90890-06657 YM-01253
90890-04019
CD
YM-04112 (ø4.0 mm)
90890-04112 (ø4.0 mm)
YM-04117 (ø4.5 mm)
90890-04117 (ø4.5 mm)
YM-04113 (ø4.0 mm)
90890-04113 (ø4.0 mm)
YM-04118 (ø4.5 mm)
90890-04118 (ø4.5 mm)

1-9
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GEN
INFO SPECIAL TOOLS
EValve seat cutter
Intake
P/N. 90890-06813 (60°)
90890-06814 (45°)
90890-06815 (30°)
Exhaust
P/N. 90890-06315 (60°)
90890-06312 (45°)
90890-06328 (30°)
FValve seat cutter holder
P/N. 90890-06811 (ø4.0 mm)
90890-06812 (ø4.5 mm)
GValve seat cutter set
P/N. YM-91043-C
HPiston ring compressor
P/N. YM-08037
90890-05158
IDrive shaft holder (impeller)
P/N. YB-06151
Drive shaft holder 5 (impeller)
P/N. 90890-06519
JSlide hammer and adapters
(jet pump bearing and reduction drive
gear)
P/N. YB-06096
KStopper guide plate (jet pump bearing)
P/N. 90890-06501
LBearing puller assembly
(jet pump bearing and reduction drive
gear)
P/N. 90890-06535
MStopper guide stand
(jet pump bearing and reduction drive
gear)
P/N. 90890-06538
NDrive rod L3
(jet pump bearing and reduction drive
gear)
P/N. 90890-06652
90890-06315 (60°)
90890-06312 (45°)
90890-06328 (30°)
YM-08037 90890-05158
YB-06096
90890-06501 90890-06535
F
H
IJ
KL
90890-06811 (ø4.0 mm)
90890-06812 (ø4.5 mm)
YB-06151
90890-06519
E90890-06813 (60°)
90890-06814 (45°)
90890-06815 (30°)
YM-91043-C
G
90890-06538 90890-06652
MN

1-10
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GEN
INFO SPECIAL TOOLS
OBearing housing needle bearing remover
(jet pump bearing)
P/N. YB-06112
Drive shaft needle bearing installer and
remover (jet pump oil seal)
P/N. YB-06196
PNeedle bearing attachment
(jet pump bearing, oil seal, and reduction
drive gear)
P/N. 90890-06614, 90890-06653
QOuter race installer—forward gear
(jet pump oil seal and reduction drive gear)
P/N. YB-06085
RBall bearing attachment
(jet pump oil seal and reduction drive gear)
P/N. 90890-06631
SDriver handle—large
(intermediate shaft, jet pump, and
reduction drive gear)
P/N. YB-06071
TDriver rod LS
(intermediate shaft, jet pump, and
reduction drive gear)
P/N. 90890-06606
UBearing inner/outer race attachment
(jet pump bearing)
P/N. YB-34474
VShaft holder (intermediate shaft)
P/N. YB-06552
Crankshaft holder 20 (intermediate shaft)
P/N. 90890-06552
WDrive shaft taper roller bearing cup
installer (intermediate shaft and reduction
drive gear)
P/N. YB-06156
Bearing outer race attachment
(intermediate shaft and reduction drive
gear)
P/N. 90890-06624, 90890-06626
YB-06071 90890-06606
ST
YB-06552
90890-06552
V
YB-06085
Q
YB-06112 90890-06614
OP
90890-06653YB-06196
90890-06631
R
90890-06624YB-06156
W
90890-06626
YB-34474
U

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SPEC
2
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS .......................................................................2-1
MAINTENANCE SPECIFICATIONS ...............................................................2-3
ENGINE ....................................................................................................2-3
JET PUMP UNIT ......................................................................................2-6
HULL AND HOOD ....................................................................................2-6
ELECTRICAL ............................................................................................2-7
TIGHTENING TORQUES ................................................................................2-9
SPECIFIED TORQUES.............................................................................2-9
GENERAL TORQUE ...............................................................................2-17
CABLE AND HOSE ROUTING .....................................................................2-18

2-1
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SPEC GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Unit Model
FX High Output
FX Cruiser High Output
Model code
Hull F1S
Engine/jet 6B6
Dimensions
Length mm (in) 3,340 (131.5)
Width mm (in) 1,230 (48.4)
Height mm (in) 1,160 (45.7)
Dry weight kg (lb) 350 (772)
Maximum capacity Person/kg (lb) 3/240 (530)
Performance
Maximum output kW (PS) @ r/min 117.7 (160) @ 10,000
Maximum fuel consumption l/h (US gal/h,
lmp gal/h)
45 (11.9, 9.9)
Cruising range h 1.56
Engine
Engine type 4-stroke, L4, DOHC
Displacement cm3(cu. in) 1,052 (64.2)
Bore ×stroke mm (in) 76.0 ×58.0 (2.99 ×2.28)
Compression ratio 11.9:1
Exhaust system Wet exhaust
Lubrication system Dry sump
Cooling system Water cooled
Starting system Electric starter
Ignition system TCI
Ignition timing Degree BTDC 5–BTDC 32
Spark plug model
(manufacturer)
CR9EB (NGK)
Spark plug gap mm (in) 0.7–0.8 (0.028–0.031)
Battery capacity V/Ah 12/19
Generator output A @ r/min 14–16 @ 6,000
Drive unit
Propulsion system Jet pump
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
Jet thrust nozzle trim angle Degree –10, –5, 0, 5, 10
Trim system Manual 5 positions
Reverse system Reverse gate