Yamaha 2009 Wave Runner VX Wartungshandbuch

SERVICE MANUALWaveRunnerF2V-28197-ZN-11VX 700VX 700 (F2V)

1-5GENINFOGeneral informationHow to use this manualManual formatThe format of this manual has been designed to make service procedures clear and easy

5-31POWRPower unitNo. Part name Q’ty Remarks13 Crankshaft assy. 114 Upper crankcase 123 N·m (2.3 kgf·m, 17.0 ft·Ib)52 N·m (5.2 kgf·m, 38.4 ft·Ib)1215

5-32123456789ACrankcase check1. Check the mating surfaces. Replace thecrankcase if scratched.Crankcase installation1. Apply the Gasket Maker (to the c

5-33POWRPower unitCrankshaftNo. Part name Q’ty RemarksCrankcase See “Crankcase” (5-30).1 Oil seal 1Not reusable2 Bearing 13 Oil seal 1 2Not reusable4

5-34123456789ACrankshaft check1. Measure the crank width a. Replace ifout of specification.2. Measure deflection b (using a dialgauge). Replace if out

5-35POWRPower unit— MEMO —

JETPUMP123456789AJet pump unitIntake grate and ride plate... 6-1Jet pump unit...

6-1JETPUMPJet pump unitIntake grate and ride plateNo. Part name Q’ty Remarks1Bolt 2 M6 × 30 mm2Bolt 2 M10 × 25 mm3 Intake grate 14Screw 4 M5 × 12 mm5

6-2123456789AJet pump unitNo. Part name Q’ty Remarks1 Band/Bilge hose 12 Nut/washer 1/23 Steering cable joint 14 Clamp/spout hose 2/15Bolt 4 M6 × 22 m

6-3JETPUMPJet pump unitNo. Part name Q’ty Remarks17 Washer 218 Gasket 219 Bracket 110654215211LT572LT572LT572LT572LT242LT271LT316171816171819131912781

6-4123456789AJet pump unit removalMake sure to remove the battery beforeremoving the jet pump unit.1. Remove the jet pump unit 1.È STBDÉ PORTTIP:Inser

1-61AbbreviationThe following abbreviations are used in this service manual.Abbreviation DescriptionBOW Bow endCDI Capacitor discharge ignitionEX Exha

6-5JETPUMPJet pump unitJet thrust nozzle, impeller duct, and impeller housingNo. Part name Q’ty Remarks1Bolt 2 M8 × 25 mm2 Collar 23 Jet thrust nozzle

6-6123456789AImpeller duct and drive shaft*: EPNOC grease AP #0No. Part name Q’ty Remarks1Bolt 3 M6 × 20 mm2Cap 13O-ring 1Not reusable4Cap 15 Impeller

6-7JETPUMPJet pump unitDrive shaft removal1. Remove the impeller.TIP:Hold the impeller duct assy. in a visebetween two aluminum plates a.2. Remove the

6-8123456789AImpeller housing check1. Measure the impeller housing insidediameter a. Replace if out of specifica-tion.Drive shaft check1. Check the d

6-9JETPUMPJet pump unit5. Install the front bearing.TIP:Press the spacer and the front bearing usinga pipe of the proper size [more than 60 mm(2.36 in

6-10123456789ATransom plate and hosesNo. Part name Q’ty RemarksExhaust system See “Exhaust system” (8-23).Jet pump unit assy. See “Jet pump unit” (6-2

6-11JETPUMPJet pump unitBilge strainer checkSee “Hull and hood” (3-9).Bilge hose check1. Check the bilge hoses. Replace ifcracked or damaged.Cooling w

6-12123456789ABearing housingNo. Part name Q’ty RemarksEngine unit See “Engine unit” (5-1).1 Rubber coupling 12Bolt 4 M8 × 48 mm3 Intermediate housing

6-13JETPUMPJet pump unitIntermediate drive shaft assy.No. Part name Q’ty Remarks1 Driven coupling 12 Washer 13Damper 14 Intermediate drive shaft exten

6-14123456789AJoint removalDo not touch the joint or adhesive thatwas heated by the heat gun with your barehands; they will be very hot and couldcause

1-7GENINFOGeneral informationAdhesive, lubricant, sealant, and thread locking agentSymbolSymbols in an exploded diagram or illustration indicate the g

6-15JETPUMPJet pump unitTIP:• Remove any adhesive that is protruding inor around the hole for the intermediatedrive shaft.• After installing the joint

6-16123456789ATIP:Remove the bearing and oil seals using apress.Driven coupling check1. Check the driven coupling and drivencoupling damper. Replace i

6-17JETPUMPJet pump unitTIP:Fit a wrench into the notches in the interme-diate drive shaft extension.Intermediate drive shaft extension:36 N·m (3.6 kg

ELEC– +123456789AElectrical systemElectrical components... 7-1Electrical box...

7-1ELECElectrical system– +Electrical components1 Multifunction meter2 Oil level sensor3 Spark plugs4 Electrical box (rectifier regulator, CDI unit, s

7-2123456789AElectrical boxNo. Part name Q’ty Remarks1 Nut/washer 2/22 Electrical box cap 13 Screw 14 ø6 × 24 mm4 Electrical box cover 15Gasket 16Scre

7-3ELECElectrical system– +No. Part name Q’ty Remarks16 Positive battery cable 1 Starter relay to positive battery terminal17 Starter relay 118 Screw

7-4123456789A1 CDI unit2 Rectifier regulator3 Spark plug wires4 Ignition coil5 Starter relay6 Fuse holderÈ To base assy.É To multifunction meter, engi

7-5ELECElectrical system– +Electrical analysisTo measure the peak voltageWhen measuring the peak voltage, do nottouch any of the connections of the di

7-6123456789AIgnition coil resistance1. Measure the primary coil resistance.2. Replace the ignition coil if out of specifi-cation.3. Measure the secon

1-81Special service toolSpecial service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division.Digital tachometer90890-067

7-7ELECElectrical system– +[kΩ]È Tester lead + É Tester lead - “” mark: The needle swings toward zeroonce, and then returns to the home position.TIP:•

7-8123456789APickup coilPickup coil output peak voltage1. Measure the pickup coil output peak volt-age.2. Measure the pickup coil resistance ifbelow s

7-9ELECElectrical system– +Charging systemLighting coilLighting coil output peak voltage1. Disconnect the lighting coil connectors.2. Measure the ligh

7-10123456789A[kΩ]È Tester lead + É Tester lead - TIP:• The resistance values will vary from testerto tester, especially with electronic digitaltester

7-11ELECElectrical system– +Starter relay1. Connect the tester leads between thestarter relay terminals 1 and 2.2. Connect the positive battery lead t

7-12123456789AStarter motorNo. Part name Q’ty Remarks1O-ring 1Not reusable2Bolt 2 M5 × 114 mm3 Front cover assy. 14O-ring 2Not reusable5 Washer set 16

7-13ELECElectrical system– +Starter motor operation1. Hold the starter motor in a vise using alu-minum plates on both sides.2. Connect the positive ba

7-14123456789AFront and rear cover1. Check the front cover oil seal. Replacethe front cover if damaged or worn.2. Check the rear cover metal. Replace

7-15ELECElectrical system– +TIP:• Install the spacer 2 so that the notch b inthe spacer is facing in the direction of thearrow.• Align the protrusion

7-16123456789A3. Replace the fuel level sensor if out ofspecification.4. Replace the multifunction meter if thefuel level sensor resistance is withins

1-9GENINFOGeneral informationStopper guide stand90890-06538Driver rod LS90890-06606Ball bearing attachment90890-06631Crankshaft holder 2090890-06552Be

HULLHOODHull and hoodSteering pad and handlebar cover ... 8-1Handlebar and handlebar switch assy...

123456789ADeck and hull... 8-25Rear section...

HULLHOODHull and hood8-1Steering pad and handlebar coverNo. Part name Q’ty Remarks1Screw 2 ø4 × 10 mm2Screw 4 ø5 × 16 mm3 Upper handlebar cover 14 Ste

8-2123456789AHandlebar and handlebar switch assy.No. Part name Q’ty Remarks1Bolt 2 M5 × 35 mm2 Grip end 23 Handlebar grip 24 Corrugated tube 15 Thrott

HULLHOODHull and hood8-3Left handlebar switch assy. and throttle lever assy.No. Part name Q’ty Remarks1 Left handlebar switch assy. 12 Engine shut-off

8-4123456789AThrottle cable removal1. Remove the corrugated tube 1.2. Remove the throttle cable 2. NOTICE:Make sure to remove the throttle cableseal

HULLHOODHull and hood8-5TIP:• Do not route the left handlebar switch lead1 and throttle cable 3 between the han-dlebar 5 and the steering master 4.• T

8-6123456789A10. Tighten the locknut B, and then slide therubber cover C to its original position.11. Insert the seal m completely into the slotin the

HULLHOODHull and hood8-7TIP:If the steering pad 3 is not installed securely,the upper handlebar cover 4 cannot beinstalled properly onto the lower han

8-8123456789AFront hoodNo. Part name Q’ty Remarks1Nut 42 Washer 43Left mirror 14 Left mirror spacer 15 Right mirror 16 Right mirror spacer 17Bolt 2 M5

1-101Model featureIdentification number Primary I.D. numberThe primary I.D. number is stamped on alabel attached to the inside of the enginecompartmen

HULLHOODHull and hood8-9No. Part name Q’ty Remarks17 Hinge assy. 118 Rivet 519 Service lid 112171113181915791652211681034142 N·m (0.2 kgf·m, 1.5 ft·Ib

8-10123456789AService lid installation1. Install the service lid 1, and then insert arivet completely in the holes in both theservice lid 1 and inner

HULLHOODHull and hood8-11Multifunction meter and engine hatch coverNo. Part name Q’ty RemarksSeat assy. See “Seat and handgrip” (8-18).1Glove box 12Lo

8-12123456789ANo. Part name Q’ty Remarks16 Lid lock hook 117 Nut 218 Revet 119 Plug 1666981918141311157125573324171681105 N·m (0.5 kgf·m, 3.7 ft·Ib)5

HULLHOODHull and hood8-13Steering master assy.No. Part name Q’ty Remarks1 Buzzer coupler 12 Steering cable joint 13Bolt 1 M6 × 18 mm4 Cable stopper 15

8-14123456789ASteering masterNo. Part name Q’ty Remarks1 Bolt/plate 1/1 M8 × 50 mm2Nut 13 Steering arm assy. 14Nut 15 Ball joint 16Arm 17 Steering sha

HULLHOODHull and hood8-15Shift lever assy. check1. Check the shift lever assy. Replace ifcracked or damaged. NOTICE: Do notdisassemble the shift leve

8-16123456789ASteering cableNo. Part name Q’ty RemarksService lid See “Front hood” (8-8).Seat assy. See “Seat and handgrip” (8-18).Ride plate/rubber p

HULLHOODHull and hood8-17Steering cable installation (steering master end)If a cable becomes damaged, replace it.Never attempt to repair damaged cable

8-18123456789ASeat and handgripNo. Part name Q’ty Remarks1 Seat assy. 12Bolt 2 M6 × 40 mm3 Seat lock assy. 14 Packing 1Not reusable5Nut 16 Washer 17 P

1-11GENINFOGeneral information— MEMO —

HULLHOODHull and hood8-19Ventilation hose and water separatorNo. Part name Q’ty RemarksOil filler neck See “Oil tank” (4-4).Fuel filter See “Fuel cock

8-20123456789ANo. Part name Q’ty Remarks15 Rivet 2Not reusable16 Ventilation socket 117 Ventilation pipe 118 Plastic tie 119 Nut 120 Seal 1Not reusabl

HULLHOODHull and hood8-21Seat lock check1. Check the seat lock assy. Replace ifcracked, damaged, or worn.2. Check the projection. Replace if dam-aged.

8-22123456789ATIP:Align the projection a with the slit b.Ventilation hose installation1. Install the grommets 1.TIP:Make sure that the grommet 1 is pr

HULLHOODHull and hood8-23Exhaust systemNo. Part name Q’ty RemarksRide plate See “Intake grate and ride plate” (6-1).1Band 12 Clamp 33 Water lock 14Ban

8-24123456789AExhaust system check1. Check the rubber hoses. Replace ifburned, cracked, or damaged.2. Check the water lock. Replace if cracked,damaged

HULLHOODHull and hood8-25Deck and hullNo. Part name Q’ty RemarksFuel cock assy. See “Fuel cock and fuel filter” (4-1).Choke cable See “Choke cable” (4

8-26123456789ANo. Part name Q’ty Remarks15 Collar 1016 Sponson 217 Rivet 2Not reusable18 Fuel cock cover 119 Rivet 2Not reusable20 Choke cover 1127519

HULLHOODHull and hood8-27Rear sectionNo. Part name Q’ty RemarksWater lock See “Exhaust system” (8-23).Flushing hose See “Transom plate and hoses” (6-1

8-28123456789ANo. Part name Q’ty Remarks15 Screw 4 ø5 × 25 mm16 Packing 2Not reusable17 Drain plug 25871591012101143123171614132 N·m (0.2 kgf·m, 1.5 f

SPEC123456789ASpecificationModel data ... 2-1Model code...

HULLHOODHull and hood8-29Drain plug check1. Check the drain plug 1 and O-ring 2.Replace if cracked or damaged.Spout installation1. Install the spout 1

TRBLSHTG123456789ATroubleshootingEngine unit troubleshooting ... 9-1Troubleshooting (engine unit, jet pump u

TRBLSHTGTroubleshooting9-1Engine unit troubleshootingTIP:• Before troubleshooting the engine unit, make sure that fresh fuel of the specified type has

9-2123456789ASymptom 1: Engine will not start (engine cranks).Symptom 2 Cause Checking stepSee pageThrottle valve does not move properlyThrottle cable

TRBLSHTGTroubleshooting9-3Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limitedengine speedFuel not supplied (all cyl

9-4123456789ASymptom 1: High engine idle speedSymptom 1: Limited engine speedSymptom 1: Discharged batteryCompression pres-sure is lowCompression leak

TRBLSHTGTroubleshooting9-5Symptom 1: Poor performanceSymptom 2 Cause Checking stepSee pageWatercraft cannot reach high speeds Jet pump unit malfunctio

123456789AAppendixWiring diagram...A-1

Wiring diagramVX 700 Color code1 Thermoswitch B : Black2 Base assy. (Lighting coil, pickup coil, charge coil) Br : Brown3 Starter motor G : Green4 Oil

2-1SPECSpecificationModel dataModel codeDimension and weightPerformancePower unitItem UnitModelVX 700Hull F2VEngine/jet 6CP/6CPItem UnitModelVX 700Len

YAMAHA MOTOR CO., LTD.Sep. 2010 – ** × 1 CR(E)

VX700214231122121WBrBRSETPULL21BCAGRPLLBLB BW/LBW/LBL/RL/BW/LBBGRPBBrB WBWRGRPBPBOBRBGGBPPGGGPPOBOBBPBBr/WW/RGGBBr/WW/RGGBBW WWPOBBBBBBBBBBBr/WW/RBr/W

2-2123456789ADrive unitFuel and oil requirementBattery requirementItem UnitModelVX 700Jet pump type Axial flow, single stageImpeller rotation Counterc

PrefaceThis manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trainedmechanics when performing maintenance procedures a

2-3SPECSpecificationFuel system technical dataFuel systemPower unit technical dataPower unitCylinder head assy.Item UnitModelVX 700CarburetorManufactu

2-4123456789ACrank case assy.Item UnitModelVX 700CylinderBore mm (in) 81.000–81.020 (3.1890–3.1898)Bore wear limit mm (in) 81.100 (3.1929)Taper limit

2-5SPECSpecificationJet pump unit technical dataJet pump unitElectrical technical dataIgnition systemItem UnitModelVX 700Impeller housingInside diamet

2-6123456789ACharging systemControl systemItem UnitModelVX 700Charge coilOutput peak voltageat cranking (unloaded) V 180at cranking (loaded) V 20at 15

2-7SPECSpecificationStarting systemMeter systemItem UnitModelVX 700FuseRatingMain V/A 12/10Starter motorType Constant meshOutput kW 0.8Cranking time l

2-8123456789ASpecified tightening torqueFuel systemPower unitPart to tightenedScrew sizeTightening torque See pageN·mkgf·mft·lbFuel cock knob screw ø4

2-9SPECSpecificationReed valve assy. bolt M5 4 0.4 3.0 5-14Intake manifold bolt M6 8 0.8 5.9 5-14Thermoswitch bolt M6 8 0.8 5.9 5-16Spark plug — 25 2.

2-10123456789AJet pump unitElectrical systemPart to tightenedScrew sizeTightening torque See pageN·mkgf·mft·lbIntake grate boltM6 8 0.8 5.9 6-1M10 40

2-11SPECSpecificationHull and hoodPart to tightenedScrew sizeTightening torque See pageN·mkgf·mft·lbUpper handlebar cover screwø4 1 0.1 0.7 8-1ø5 1 0.

2-12123456789AGeneral tightening torqueThis chart indicates the tightening torques forstandard fasteners with a standard ISOthread pitch. Tightening t

ContentsGeneral informationGEN INFOSpecificationSPECMaintenanceMNTFuel systemFUELPower unitPOWRJet pump unitJETPUMPElectrical systemELECHull and hoodH

2-13SPECSpecificationCooling system31456721 Exhaust manifold3 Cylinder head6 Exhaust outer cover 1Flushing hoseJet pump7 Water lockExhaust outlet5 Exh

2-14123456789ACable and hose routingStarboard bow view1 Positive battery cable2 Battery breather hose3 Flushing hose4 Bilge hose5 Cooling water pilot

2-15SPECSpecificationTop view1 Positive battery cable2 Battery breather hose3 Flushing hose4 Bilge hose5 Cooling water pilot outlet hose6 Choke cable7

2-16123456789AM Fuel hoseN Fuel reservoir hoseO Negative battery cable8A6C7DGIH12JF4O5EL0MKN93BCable and hose routing

2-17SPECSpecificationPort view1 Positive battery cable2 Battery breather hose3 Flushing hose4 Bilge hose5 Cooling water pilot outlet hose6 Choke cable

2-18123456789AM Fuel hoseN Fuel reservoir hoseO Negative battery cable9 0 8 76 5 G L H I 1 243JOKEFBMNDACCable and hose routing

2-19SPECSpecification— MEMO —

MNT123456789AMaintenanceMaintenance interval chart... 3-1Periodic service...

3-1MNTMaintenanceMaintenance interval chartThe following chart should be considered strictly as a guide to general maintenance intervals.Depending on

3-2123456789APeriodic serviceSteering systemSteering master check1. Turn the handlebar lock to lock and pushit back and forth.2. Check for excessive p

3-3MNTMaintenance7. Remove the upper handlebar cover. See“Steering pad and handlebar cover” (8-1).8. Slide the rubber cover 4 away from thethrottle le

3-4123456789AWater separator check1. Check the water separator 1. Drain thewater if water has accumulated.2. Check the O-ring of the drain plug.Replac

3-5MNTMaintenance4. Measure the spark plug gap b. Replaceif out of specification.5. Tighten the spark plugs to the specifiedtorque.TIP:Before installi

3-6123456789AEngine oil level checkDo not allow the oil tank to become com-pletely empty. If the oil tank becomesempty the oil injection pump must be

3-7MNTMaintenanceNut and bolt check1. Check the engine, deck, and hull forloose bolts and nuts. Tighten if loose.See “Specified tightening torque” (2-

3-8123456789A3. Disconnect the steering cable joint 2from the ball joint 3.4. Turn the steering cable joint 2 in or outto adjust distances a and b.WAR

3-9MNTMaintenanceBe careful not to place the battery on itsside.Make sure to remove the battery from thebattery compartment when adding batteryelectro

3-10123456789ATIP:Remove the bilge strainer case 1 by pushingthe hooks on the bilge strainer inward.3. Install the bilge strainer case 1.Drain plug ch

3-11MNTMaintenanceTIP:Disconnect the joint and apply a smallamount of grease.Recommended lubricant:Yamaha grease A

FUEL123456789AFuel systemFuel cock and fuel filter ... 4-1Fuel filter check ...

GENINFO1General informationSafety while working ... 1-1Rotating part...

4-1FUELFuel systemFuel cock and fuel filterNo. Part name Q’ty Remarks1Screw 1 M4 × 7 mm2 Fuel cock knob 13Nut 14 Washer 15 Fuel cock assy. 16 Fuel hos

4-2123456789AFuel filter checkSee “Fuel system” (3-3).Fuel cock checkBefore checking the fuel system, removethe battery, and then remove the fuel fill

4-3FUELFuel systemChoke cableNo. Part name Q’ty Remarks1Screw 1 M3 × 6 mm2Knob 13 Friction adjusting nut 14Nut 15 Choke cable 1235412 N • m (0.2 kgf •

4-4123456789AOil tankNo. Part name Q’ty Remarks1 Clamp 12Nut 13 Oil filler neck 14 Rubber seal 15 Tank belt 16 Oil level sensor coupler 17 Oil level s

4-5FUELFuel systemOil line check1. Clean the oil filter, and then check the oilfilter. Replace if frayed or teared.2. Check the rubber seal. Replace i

4-6123456789AFuel tankNo. Part name Q’ty RemarksOil tank See “Oil tank” (4-4).Engine unit See “Engine unit” (5-1).1 Clamp 22Nut 13 Fuel filler neck 1

4-7FUELFuel systemCheck valve check1. Blow into the end a of the check valve,and make sure that airflow from the endb is unrestricted. Replace if the

4-8123456789ACarburetor unitNo. Part name Q’ty RemarksFuel cock knob Turn the fuel cock knob to “OFF”.1Bolt 6 M5 × 56 mm2 Cover 13 Flame arrester 24Ba

4-9FUELFuel systemNo. Part name Q’ty Remarks16 Throttle cable 1 a: 13–15 mm (0.51–0.59 in)17 Band 3Not reusable18 Fuel hose 119 Pulse hose 120 Fuel re

4-10123456789AChoke cable and throttle cable installation1. Install the choke cable 1 and throttlecable 2, and then tighten the nuts to thespecified t

1-1GENINFOGeneral informationSafety while workingTo prevent an accident or injury and to pro-vide quality service, observe the followingsafety procedu

4-11FUELFuel systemCarburetor and fuel pumpNo. Part name Q’ty RemarksCarburetor assy. See “Carburetor unit” (4-8).1Screw 4 M5 × 30 mm2 Cover 13 Fuel p

4-12123456789ANo. Part name Q’ty Remarks16 Idle adjusting screw 117 Spring 118 Washer 119 High speed screw 220 O-ring 2Not reusable21 Washer 222 Sprin

4-13FUELFuel systemNo. Part name Q’ty Remarks32 Arm 233 Pin 234 Screw 2 M3 × 6 mm35 Plate 236 Needle valve assy. 237 Screw 4 M4 × 11 mm38 Body assy. 2

4-14123456789ADiaphragm check1. Check the diaphragm. Replace if dam-aged.Arm check1. Check the arm 1. Repair if bent.Replace if damaged.2. Measure the

4-15FUELFuel systemTIP:Before disassembling the carburetor, makesure to note the number of times the speedscrew is turned in from its set position to

4-16123456789ACarburetor assy. check1. Adjust the trolling speed. See “Powerunit” (3-4).Carburetor and fuel pump

4-17FUELFuel systemOil pumpNo. Part name Q’ty Remarks1Band 12 Oil hose 13 Hose clamp 24 Oil delivery hose 1 1 85 mm (3.35 in)5 Oil delivery hose 1 1 7

4-18123456789AOil pump check• If the oil delivery hoses are not full of oil,fill them up.• After installing the oil injection system,bleed the system

POWRPower unitEngine unit... 5-1Engine mount ...

123456789ACrankcase ... 5-30Crankcase check...

1-21Ventilation• Gasoline vapor and exhaust gas areheavier than air and extremely poisonous.If gasoline vapor or exhaust gas is inhaledin large quanti

5-1POWRPower unitEngine unitNo. Part name Q’ty RemarksStorage compartment panel See “Front hood” (8-8).Positive and negative battery lead See “Electri

5-2123456789A*: As required.No. Part name Q’ty Remarks14 Bolt/collar 2/2 M6 × 25 mm15 Coupling cover 116 Bolt/washer 4/4 M8 × 35 mm17 Shim *18 Engine

5-3POWRPower unitEngine mountNo. Part name Q’ty Remarks1Bolt 8 M8 × 35 mm2 Engine mount 43Bolt 44Bracket 15Bracket 16Bracket 2BOW17 N·m (1.7 kgf·m, 12

5-4123456789AEngine unit removalBefore removing the engine, make sure totake adequate measures to protect thedeck opening from damage.1. Disconnect th

5-5POWRPower unit11. Remove the band E, and then discon-nect the fuel hose F.TIP:When removing the fuel hose, remove thefuel filler cap to reduce any

5-6123456789A19. Suspend the engine unit using an enginehangers, and then separate the unit fromthe engine mounts and move it forwardto disconnect the

5-7POWRPower unit5. Lift the engine unit slightly, remove theshims 4, and then lower the engine unit.6. Remove the engine mounting bolts 2and washer 3

5-8123456789A15. Connect the fuel hose A, and then installthe band B.16. Install the plastic ties C.17. Connect the fuel hose D, and then installthe b

5-9POWRPower unit23. Install the fuse box assy. O, and thentighten the nuts P to the specifiedtorque.24. Install the band Q.25. Install the plastic ti

5-10123456789AExhaust ringNo. Part name Q’ty Remarks1 Band/pilot water hose 2/12 Clamp 23 Clamp 14Bolt 2 M8 × 75 mm5Bolt 2 M8 × 115 mm6 Exhaust ring 1

1-3GENINFOGeneral informationHandling of heat gun• Improper handling of a heat gun may resultin burns. For information on the proper han-dling of the

5-11POWRPower unitExhaust chamber assy.No. Part name Q’ty RemarksExhaust ring See “Exhaust ring” (5-10).1 Clamp/exhaust hose 1/12Band 4Not reusable3

5-12123456789AExhaust chamberNo. Part name Q’ty Remarks1Bolt 6 M6 × 70 mm2 Exhaust outer cover 1 13Gasket 1Not reusable4 Exhaust inner cover 15 Rubber

5-13POWRPower unitMufflerNo. Part name Q’ty RemarksExhaust chamber See “Exhaust chamber assy.” (5-11).1 Clamp/cooling water hose 1/1 È Cooling water i

5-14123456789AReed valvesNo. Part name Q’ty RemarksCarburetor assy. See “Carburetor unit” (4-8).1Bolt 2 M6 × 16 mm2Plate 13Bolt 8 M6 × 25 mm4Bolt 3 M6

5-15POWRPower unitReed valve check1. Check the reed valves. Replace ifcracked or damaged.2. Measure the valve warpage a. Replaceif out of specificatio

5-16123456789ACylinder headNo. Part name Q’ty RemarksExhaust chamber assy. See “Exhaust chamber assy.” (5-11).1Bolt 2 M6 × 16 mm2 Thermoswitch 13 Spar

5-17POWRPower unitCylinder head checkDo not use a sharp instrument to avoiddamaging or scratching the cylinder heador spark plug bore threads.1. Elimi

5-18123456789ACylinderNo. Part name Q’ty RemarksCylinder head See “Cylinder head” (5-16).1 Bolt 4 M10 × 40 mm2 Bolt 2 M10 × 55 mm3 Cylinder 14Gasket 1

5-19POWRPower unitCylinder check1. Eliminate the carbon deposits (using arounded scraper 1).2. Check the cylinder water jacket. Clean orreplace the cy

5-20123456789ACylinder bolt:1st: 22 N·m (2.2 kgf·m, 16.2 ft·lb)2nd: 39 N·m (3.9 kgf·m, 28.8 ft·lb)623514Cylinder

1-41Disassembly and assembly• Use compressed air to remove dust and dirtduring disassembly.• Apply engine oil to the contact surfaces ofmoving parts b

5-21POWRPower unitPistonsNo. Part name Q’ty RemarksCylinder See “Cylinder” (5-18).1 Piston pin clip 4Not reusable2 Piston pin 23Piston 2 a Arrow mark4

5-22123456789APiston pin clip removal and installationTIP:Before removing or installing the piston pinclip, cover the crankcase opening with aclean ra

5-23POWRPower unitPiston pin and bearing check1. Check the piston pins and bearings.Replace if there are signs of heat discol-oration.2. Measure the p

5-24123456789ATIP:• Install the piston with the arrow a facingtowards the exhaust port.• Do not align the open end of the clip withthe piston pin slot

5-25POWRPower unitFlywheel magneto and base assy.No. Part name Q’ty RemarksEngine unit See “Engine unit” (5-1).Oil pump See “Oil pump” (4-17).1Bolt 7

5-26123456789ANo. Part name Q’ty Remarks14 Bolt 2 M6 × 16 mm15 Starter motor 15 N·m (0.5 kgf·m, 3.7 ft·Ib)8 N·m (0.8 kgf·m, 5.9 ft·Ib)8 N·m (0.8 kgf·m

5-27POWRPower unitStarter clutch assy.No. Part name Q’ty Remarks1 Clip 1Not reusable2 Clip stopper 13 Spring seat 14Spring 15 Washer 16 Idle gear 17 C

5-28123456789ADrive coupling removal and installation1. Remove the drive coupling.TIP:Install the drive coupling with the same spe-cial service tools

5-29POWRPower unitStarter clutch assy. check1. Check the pinion gear 1. Replace ifdamaged or worn.2. Check the idle gear 2. Replace if dam-aged or wor

5-30123456789ACrankcaseNo. Part name Q’ty RemarksBase assy. and starter motor See “Flywheel magneto and base assy.” (5-25).Pistons See “Pistons” (5-21