2016 Yamaha 190 FSH SPORT Service & Repair Manual

Repair&ServiceManualVyAMiA:A 190FSHSPORT 190FSHDELUXE 190FSH ServiceManual

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written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specificationsandprocedures,andtheseareincorporatedinsuccessiveeditionsofthismanual.Also,up-to- datepartsinformationisavailableonYDS(YamahaDealerSystem).Additionalinformationandup-to- dateinformationonYamahaproductsandservicesareavailableonYDS. 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seriousinjury. NOTICE ANOTICEindicatesspecialprecautionsthatmustbetakentoavoiddamagetotheboatorother property. TIP: ATIPprovideskeyinformationtomakeprocedureseasierorclearer. YamahaBoat 190FSHSport,190FSHDeluxe,190FSH SERVICEMANUAL ©2015byYamahaMotorCorporation,U.S.A. 1stEdition,December2015 Allrightsreserved. Anyreprintingorunauthorizeduse withoutthewrittenpermissionof YamahaMotorCorporation,U.S.A. isexpresslyprohibited. LIT-18616-03-66

Contents Generalinformation Specification Maintenance Fuelsystem Powerunit Jetpumpunit Electricalsystem Hullanddeck Troubleshooting Appendix >| 0} Col NI] >} or] | co} ro]

Generalinformation SafetywhileWOrKing..........:::scsssecsessesseeseseseseeseeseeseeeeneeanenes1- Rotatingparts.. Hotparts....... Electricshock Impeller Handlingofgasolin Ventilation........ Self-protection. Workingwithcrane. Handlingofheatgun Parts,lubricants,andsealant: Handlingofsealants.. Specialservicetool Tighteningtorque Non-reusableparts. Disassemblyandassembly OoHOONHHnHMse+s4e4ttit 4 Sp a CC EC IdentificationMUMDEL..........:eeeeseceeeseeseeeesseeseeeeseeseeeeeeeeee1-4 Primary|.D.number Engineserialnumber... Jetpumpunitserialnumber Hullidentificationnumber(H.I.N.) HowtousethisManual..........:csccececeeceeeeeeseeneeeeeeeeteaeenees1-5 Manualformat Conditionswhentestingandadjusting Abbreviation Adhesive,lubricant,sealant,and threadlockingagent Symbols SpecialSErvicetOwisisiccasinsennsassensensernsemnmrerecececeeecescess1-9 -1-18 1-18 +1-19 1-20 1-20 1-21 1-22 «1-23 Modelfeature... Generalfeature Modelequipmentcomparisontable... Articulatingkeel.......... Leaningpost(driver'sseat) Deckandswimplatformstoragecompartments Centerhelm.. T-top(190FS!

Jetwash Livewell.. Cruiseassistfunction No-wakemodefunction ReverseRPMcontrol... Speedometer...........0. Multi-functiontachometer Warnings Pee OVYOYMYMNYNLD H=DOANDOOH TeChNiICaltiPS.......csecseeeeeesesesseeseeseneeeseeseeeeeseeneeeeeneeneeee Enginecontrolee Enginecontrolsystem..1-34 Lubricationsystem Coolingsystem...... Coolingwaterflow . Drainingwaterflow Drivesystemlayout... Cableandhoserouting.........:ssssssseesssesseseeeseseeseseeeeees1-43 Shift,steering,andthrottlecables(topVIEW)...........cceseeeeeeee1-43 Coolingwater,drain,fuel,breather,and engineflushinghoses(topandstarboardVieW)...........:e1-45 Fishbox,livewell,aerator,anddeckflushinghoses (topandportview). Deckwireharnessrouting.........scsessseseseseeseeeeeessees1-49 Enginewireharnessrouting..we1-51 Topandportview.. Starboardview Rearview.... Electricalboxview.

Safetywhileworking 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engineorjetpumpunit,resultinginseriousinjury ordeath. *Keephands,feet,hair,jewelry,clothing,personal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engine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. 1-1 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. *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example,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. ¢Protectyourhandsandfeetbywearingprotectiveglovesandsafetyshoeswhennecessary.

Safetywhileworking Workingwithcrane «Whenmovingtheboat,orwhenliftingtheengineduringremovalorinstallation,make suretouseacranewithaliftingcapacitythat isequaltoormorethantheweightoftheboat orenginerespectively. *Whenliftingtheboat,usetheboatliftharnessandmakesurethattheboat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additional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issued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 Yamaha,whenservicingorrepairingtheboat. 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.

Safetywhileworking Tighteningtorque 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. 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. <I(Cs ¢Installbearingssothatthebearingidentification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installation. *Checkthatmovingpartsoperatenormallyafterassembly. 1-3

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compartment. AMERICANANDJAPANESE RICAINES ET 1.Modelname 2.Hulltype 3.PrimaryI.D.number Startingprimary|.D.number SH1800A-R/190FSHSport:0710102 SH1800B-R/190FSHDeluxe: 0720102 SH1800C-R/190FSH:0730102 Engineserialnumber Theengineserialnumberisstampedonalabelattachedtotheengineunit. 1.Enginename 2.Enginetype 3.Engineserialnumber 1-4 Startingengineserialnumber 6AP:1038061 Jetpumpunitserialnumber Thejetpumpunitserialnumberisstampedon alabelattachedtotheintermediatehousing. 2. YAMAHAMOTORMANUFACTORING CORP.OFAMERICA MADEINU.S.A 1.Jetpumpunitname 2.Jetpumpunittype 3.Jetpumpunitserialnumber Hullidentificationnumber(H.I.N.) TheH.I.N.isstampedintotherightrearcorner ofthehull.

Howtousethismanual 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figure),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(see“5”inthefollowingfigureforanexamplepage). TIP: Fortroubleshootingprocedures,seeChapter9,“Troubleshooting”. 31 wawAVA Impellerhousing andimpellerductASSYa es]aT Divesanaoee= 2.Removethecap“tng",andnat 2 "NOTICE! 2DenatpesheiveoatBeads ou 1-5

You're Reading a Preview

2016 Yamaha 190 FSH SPORT Service & Repair Manual

Description

Reviews

Q&A

Recently Viewed