Yamaha WaveRunner FZR-GX1800 User manual

SERVICE MANUAL
WaveRunner
F2C-28197-1M-11
LIT-18616-03-18
FZR
GX1800 (F2R)
FZS
GX1800A (F2C)

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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.
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!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, passengers, a bystander, or a person inspecting or repairing the watercraft.
NOTICE
A NOTICE indicates special precautions that must be taken to avoid damage to the water-
craft.
TIP
A TIP provides key information to make procedures easier or clearer.
WaveRunner
FZR, FZS
SERVICE MANUAL
©2009 by Yamaha Motor Corporation, USA
1st Edition, January 2009
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-03-18

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Contents
General information GEN
INFO
Specification SPEC
Periodic check and adjustment CHK
ADJ
Fuel system FUEL
Power unit POWR
Jet pump unit JET
PUMP
Electrical system ELEC
Hull and hood HULL
HOOD
Troubleshooting TRBL
SHTG
–+
1
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3
4
5
6
7
8
9

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Chapter 1
General information
How to use this manual.................................................................................1-1
Manual format............................................................................................1-1
Symbols.....................................................................................................1-2
Abbreviation...............................................................................................1-3
Safety while working......................................................................................1-4
Fire prevention...........................................................................................1-4
Ventilation..................................................................................................1-4
Self-protection ...........................................................................................1-4
Parts, lubricants, and sealants ..................................................................1-4
Good working practices .............................................................................1-5
Disassembly and assembly .......................................................................1-5
Identification number.....................................................................................1-6
Primary I.D. number ..................................................................................1-6
Engine serial number.................................................................................1-6
Jet pump unit serial number ......................................................................1-6
Hull identification number (H.I.N.)..............................................................1-6
Special service tool .......................................................................................1-7
Measuring..................................................................................................1-7
Removal and installation ...........................................................................1-9
Feature and benefit......................................................................................1-14
Watercraft overview.................................................................................1-14
Rear seat .................................................................................................1-15
Telescopic steering system .....................................................................1-16
Shift lever assembly ................................................................................1-17
Watertight compartment ..........................................................................1-18
Fire extinguisher location.........................................................................1-18
Hull design...............................................................................................1-19
Engine overview ......................................................................................1-20
Supercharger assembly...........................................................................1-21
Air cooler assembly .................................................................................1-21
ECM.........................................................................................................1-22
Drive shaft ...............................................................................................1-22
Dual analog meter unit ............................................................................1-23
Information display warnings ...................................................................1-24
Self-diagnosis ..........................................................................................1-24
Yamaha Security System ........................................................................1-25

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GEN
INFO
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9
Technical tips ...............................................................................................1-26
Engine control..........................................................................................1-26
ECM circuit diagram..........................................................................1-27
ECM coupler layout...........................................................................1-28
Control system.........................................................................................1-30

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INFO
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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 (refer to
1in the figure below for an example page).
•The component list consists of part names and quantities (refer to 2in the figure below). 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
lubrication point (refer to 3in the figure below).
•Tightening torque specifications are provided in the exploded diagrams (refer to 4in the figure
below for an example), 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 (refer to 5in the figure below for an example page).
TIP
For troubleshooting procedures, refer to “Troubleshooting”in Chapter 9.
How to use this manual

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GEN
INFO
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Symbols
Symbols 1to 6indicate specific data.
1Special service tool
2Specified oil or fluid
3Specified engine speed
4Specified tightening torque
5Specified measurement
6Specified electrical value
(resistance, voltage, electric current)
Symbols 7to Ain an exploded diagram indi-
cate the grade of lubricant and the lubrication
point.
7Apply 4-stroke motor oil
8Apply water resistant grease
(Yamaha grease A)
9Apply molybdenum disulfide grease
0Apply Epnoc grease AP #0
AApply Silicone grease
Symbols Bto Hin an exploded diagram indi-
cate the type of sealant or locking agent and
the application point.
BApply ThreeBond 1194E or ThreeBond 1280B
CApply Gasket Maker
DApply LOCTITE 271 (red)
EApply LOCTITE 242 (blue)
FApply LOCTITE 572
GApply LOCTITE 648
HApply silicone sealant
TIP
Additional symbols may be used in this man-
ual.
12
34
56
78
90
AB
CD
EF
GH
T
R
.
.
E
A
MEP
SG
1280B1194E
GM
271
LT
242
LT
572
LT
648
LT
SS
How to use this manual

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Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
API American Petroleum Institute
APS Accelerator position sensor
BOW Bow end
ECM Electronic Control Module
ETV Electronic throttle valve
EX Exhaust
IN Intake
OL Overload
OTS Off-throttle steering system
PORT Port side
QSTS Quick Shift Trim System
RPM Revolutions Per Minute
SAE Society of Automotive Engineers
STBD Starboard side
STERN Stern end
TCI Transistor Controlled Ignition
TDC Top Dead Center
TPS Throttle Position Sensor
UP Upside
YDIS Yamaha Diagnostic System
How to use this manual

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INFO
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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), make sure to do so where ade-
quate 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 and 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.
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. Avoid contact with skin. Do not, for exam-
ple, place a soiled rag in your pocket.
2. 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.
3. Change and wash clothing as soon as
possible if soiled with lubricants.
4. To protect your skin, apply a protective
cream to your hands before working on the
watercraft.
Safety while working

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5. Keep a supply of clean, lint-free cloths for
wiping up spills, others.
6. Maintain good standards of personal and
industrial hygiene.
Good working practices
Special service tool
Use the recommended special service tools to
protect parts from damage. Use the right tool
in the right manner; do not improvise.
Tightening torques
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 cen-
ter and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cotter
pins, others, when installing or assembling
parts.
Disassembly and assembly
1. Use compressed air to remove dust and
dirt during disassembly.
2. Apply oil or fluid to the contact surfaces of
moving parts before assembly.
3. Install bearings with the manufacture iden-
tification mark in the direction indicated in
the installation procedure. In addition,
make sure to lubricate the bearings liber-
ally.
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.
Safety while working

1-6
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GEN
INFO
1
2
3
4
5
6
7
8
9
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.
Starting primary I.D. number:
F2R: 800101
F2C: 800101
Engine serial number
The engine serial number is stamped on a
label attached to the engine unit.
TIP
•The label stamped with the engine serial
number is located on the cylinder head
cover. Remove the engine cover to check
the engine serial number.
•Slide the engine cover rearward, and then lift
the cover to remove it.
Starting serial number:
6AN: 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.I.N.)
The H.I.N. is stamped on a plate attached to
the boarding platform.
Identification number

1-7
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INFO
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Special service tool
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.
TIP
•For USA and Canada, use part numbers
starting with “YB-”, “YM-”, “YU-”, or “YW-.”
•For other countries, use part numbers start-
ing with “90890-.”
Measuring
1Gauge stand
90890-06725
2Dial gauge stand set (use needle only)
YB-06585
3Dial gauge needle
90890-06584
4Dial gauge
YU-03097
90890-01252
5Compression gauge extension
90890-06582
6Compression gauge
YU-33223
90890-03160
7Fuel pressure gauge adapter
YW-06842
90890-06842
Special service tool

1-8
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GEN
INFO
1
2
3
4
5
6
7
8
9
8Fuel pressure gauge
YB-06766
90890-06786
9Leakage tester
90890-06840
0Air cooler attachment
90890-06731
AYDIS (connecting kit)
60V-85300-04
BYDIS (CD-ROM, Ver. 1.30)
60V-WS853-04
YDIS (CD-ROM, Ver. 1.32)
60V-WS853-05
CDigital multimeter
YU-34899-A
DPeak voltage adapter
YU-39991
EDigital circuit tester
90890-03174
FPeak voltage adapter B
90890-03172
GSpark checker
YM-34487
Ignition tester
90890-06754
Special service tool

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GEN
INFO
2
3
4
5
6
7
8
9
HTest harness (3 pins)
YB-06877
Test harness HM090-3 (3 pins)
90890-06877
ILower unit pressure/vacuum tester
YB-35956-A
JVacuum/pressure pump gauge set
90890-06756
KTest harness (3 pins)
YB-06870
Test harness SMT250-3 (3 pins)
90890-06870
LTest harness (2 pins)
90890-06850
Removal and installation
1Oil filter wrench
90890-06830
2Exhaust pipe wrench
90890-06726
3Bearing separator
90890-06534
4Slide hammer and adapters
YB-06096
5Bearing puller assembly
90890-06535
6Stopper guide plate
90890-06501
Special service tool

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GEN
INFO
1
2
3
4
5
6
7
8
9
7Stopper guide stand
90890-06538
8Shaft holder
90890-06721
9Driver handle
90890-06722
0Bearing inner race attachment
90890-06661
ACoupler wrench
90890-06729
BCamshaft wrench
90890-06724
CValve spring compressor
YM-04019
90890-04019
DCompressor adapter
YM-04114
Valve spring compressor attachment
90890-04114
EValve guide remover
YB-06801
90890-06801
FValve guide installer
YB-06810
90890-06810
GValve guide reamer
YM-01196
90890-06804
Special service tool

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GEN
INFO
2
3
4
5
6
7
8
9
HNeway valve seat kit
YB-91044
IValve seat cutter holder
90890-06812
JValve seat cutter
Intake
90890-06720 (30°)
90890-06325 (45°)
90890-06324 (60°)
Exhaust
90890-06818 (30°)
90890-06555 (45°)
90890-06323 (60°)
KCrankshaft holder
90890-06732
LFlywheel puller
90890-06723
MRotor puller
90890-01080
NDriver handle (small)
YB-06229
ODriver rod LS
90890-06606
PBearing and seal installer
YW-06356
QBearing outer race attachment
90890-06623, 90890-06627, 90890-06628
RForward bearing race installer
YB-06258
Special service tool

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INFO
1
2
3
4
5
6
7
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9
SBearing pressure C
90890-02393
TDriver handle (large)
YB-06071
UForward gear outer race installer
YB-41446
Ball bearing attachment
90890-06657
WPiston ring compressor
YM-08037
90890-05158
XDrive shaft holder
YB-06201
Drive shaft holder 6
90890-06520
YDriver rod L3
90890-06652
ZDrive shaft needle bearing installer and
remover
YB-06194
[Needle bearing attachment
90890-06609
\Bearing attachment
90890-06728
C
Special service tool

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INFO
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3
4
5
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9
]Bearing cup installer
YB-06167
_Shaft holder
90890-06730
aNeedle bearing installer
YB-06434
bBearing puller legs
YB-06523
cBearing attachment
90890-06727
Special service tool

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INFO
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Feature and benefit
Watercraft overview
The FZR and FZS feature a newly designed hull, which is made of NanoXcel. Because the FZR is
designed for 2 riders and the FZS is designed for 3 riders, the shape of the rear seat is different for
each model. Only the FZS is equipped with a reboarding step.
New features
1Rear seat
2Telescopic steering system
3Shift lever assembly
4Watertight compartment
5Fire extinguisher holder and cover
6Dual analog meter unit
546
2
1
3
Feature and benefit

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Rear seat
The rear seats and handgrips for the FZR and FZS have different shape. Therefore, the rear seats
and handgrips are not interchangeable.
1Front seat
2Deck beam
3Rear seat
4Handgrip
ÈFZR
ÉFZS
2
3
4
3
4
1
2
3
4
3
4
È
É
È
É
Feature and benefit