Yamaha WaveRunner VXR VX1800A 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

1st Edition, March 2015

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

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

2

3

1. Jet pump unit name

2. Jet pump unit type

3. Jet pump unit serial number

2

1

3

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 housing and impeller duct ASSY

No. Part name Q’ty Remarks

1Clamp 1

2Spout hose 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

6

7

2

1

4

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

4

1

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

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

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