2008-2012 Yamaha Waverunner FX HO FB 1800 F2T Service & Repair Manual

SERVICE MANUAL LIT-18616-03-41 F2S-28197-1R-11 WaveRunner FX HO FB1800 (F2T) FX Cruiser HO FB1800A (F2T) FX SHO FA1800 (F2S) FX Cruiser SHO FA1800A (F2S)

Preface 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 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. 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. 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 (Yamaha Dealer System). 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. A NOTICE indicates special precautions that must be taken to avoid damages to the watercraft or other property. TIP: A TIP provides key information to make procedures easier or clearer. WaveRunner FX HO, FX Cruiser HO, FX SHO, FX Cruiser SHO SERVICE MANUAL ©2012 by Yamaha Motor Corporation, U.S.A. 1st Edition, February 2012 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-18616-03-41

1 2 3 4 5 6 7 8 9 A Contents General information GEN INFO Specification SPEC Maintenance MNT Fuel system FUEL Power unit POWR Jet pump unit JET PUMP Electrical system ELEC Hull and hood HULL HOOD Troubleshooting TRBL SHTG Appendix

GEN INFO General information 1 Safety while working .................................................... 1-1 Rotating part .............................................................................. 1-1 Hot part ...................................................................................... 1-1 Electric shock ............................................................................ 1-1 Impeller ...................................................................................... 1-1 Handling of gasoline .................................................................. 1-1 Ventilation .................................................................................. 1-2 Self-protection ........................................................................... 1-2 Working with crane .................................................................... 1-2 Handling of heat gun ................................................................. 1-3 Part, lubricant, and sealant ........................................................ 1-3 Handling of sealant .................................................................... 1-3 Special service tool ................................................................... 1-3 Tightening torque ...................................................................... 1-3 Non-reusable part ...................................................................... 1-4 Disassembly and assembly ....................................................... 1-4 Identification number ........................................................ 1-5 Primary I.D. number .................................................................. 1-5 Engine serial number ................................................................ 1-5 Jet pump unit serial number ...................................................... 1-5 Hull identification number (H.I.N.) ............................................. 1-5 How to use this manual .................................................... 1-7 Manual format ........................................................................... 1-7 Abbreviation .............................................................................. 1-8 Adhesive, lubricant, sealant, and thread locking agent ......................................................... 1-9 Symbol ...................................................................................... 1-9 Special service tool ......................................................... 1-11 Model feature ................................................................... 1-19 General feature (FX SHO, FX Cruiser SHO) ........................... 1-19 General feature (FX HO, FX Cruiser HO) ............................... 1-20 Model equipment comparison table ........................................ 1-21 Hull and deck ........................................................................... 1-22 Technical tips .................................................................. 1-24 Engine control ......................................................................... 1-24 ETV system ............................................................................. 1-26 Mechanical Neutral .................................................................. 1-27

1 2 3 4 5 6 7 8 9 A Engine control system ............................................................. 1-28 YDIS .................................................................................. 1-31 New functions .......................................................................... 1-32 Menu item ................................................................................ 1-32 Logging .................................................................................... 1-33 Engine .............................................................................. 1-34 Lubrication system .................................................................. 1-35 Hose routing (FX SHO, FX Cruiser SHO) ............................... 1-36 Hose routing (FX HO, FX Cruiser HO) .................................... 1-37 Cooling water flow ................................................................... 1-38

1-1 GEN INFO General information Safety while working To prevent an accident or injury and to pro- vide quality service, observe the following safety procedures. Rotating part • 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. Items such as hair, clothing, or personal flotation device straps can become entangled in moving parts resulting in severe injury. Hot part 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. 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.

1-2 Safety while working 1 2 3 4 5 6 7 8 9 A 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 con- sciousness 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 opera- tions involving drilling and grinding, or when using an air compressor. • Protect your hands and feet by wearing protective gloves and safety shoes when nec- essary. 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 capacity that is equal to or more than the weight of the watercraft or engine respec- tively. • 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 additional ropes or the like so that the engine unit can be lifted and carried in a stable manner.

1-3 GEN INFO General information 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 directly. Part, lubricant, and sealant Use only genuine Yamaha parts, lubricants, and sealants, or those recommended by Yamaha, when servicing or repairing the watercraft. Handling of sealant • 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 dam- age. 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.

1-4 Safety while working 1 2 3 4 5 6 7 8 9 A Non-reusable part Always use new gaskets, seals, O-rings, cot- ter pins, and so on, when installing or assem- bling 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 identification mark is facing in the direction indi- cated 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.

1-5 GEN INFO General information Identification number Primary I.D. number The primary I.D. number is stamped on a label attached to the inside of the engine compartment. a Model name b Hull type c Primary I.D. number Engine serial number The engine serial number is stamped on a label attached to the engine unit. a Engine name b Engine type c Engine serial number Jet pump unit serial number The jet pump unit serial number is stamped on a label attached to the intermediate hous- ing. a Jet pump unit name b Jet pump unit type c Jet pump unit serial number Hull identification number (H.I.N.) The H.I.N. is stamped on a plate attached to the boarding platform. Starting primary I.D. number: F2S: 800101 F2T: 800101 MODEL F2S 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. a b c A Starting engine serial number: A 6CS: 1000001 (F2S) B 6CR: 1000001 (F2T) YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON a b c B b a c

2008-2012 Yamaha Waverunner FX HO FB 1800 F2T Service & Repair Manual

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