2004-2007 Yamaha WaveRunner FX1100 Service & Repair Manual

E HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., • Bearings Pitting/scratches → Replace. To assist you in finding your way through this manual, the section title and major heading is given at the top of every page. ILLUSTRATIONS The illustrations within this service manual represent all of the designated models. CROSS REFERENCES The cross references have been kept to a minimum. Cross references will direct you to the appropri- ate section or chapter.

E IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. 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, passenger(s), a bystander, or a person inspecting or repairing the watercraft. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the watercraft. NOTE: A NOTE provides key information to make procedures easier or clearer. IMPORTANT: This part has been subjected to change of specification during production.

E HOW TO USE THIS MANUAL 1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 2 Numbers are given in the order of the jobs in the exploded diagram. 3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”). 4 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5 Dimension figures and the number of parts, are provided for fasteners that require a tightening torque. Example: Bolt or screw size : M10 (D) × 25 mm (L) 6 Jobs requiring more information (such as special tools and technical data) are described sequentially. 10 × 25 mm D L

E A50001-1-4 SYMBOLS Symbols 1 to 9 are designed to indicate the content of a chapter. 1 General Information 2 Specifications 3 Periodic Inspection and Adjustment 4 Fuel System 5 Power Unit 6 Jet Pump Unit 7 Electrical System 8 Hull and Hood 9 Trouble Analysis Symbols 0 to E indicate specific data. 0 Special tool A Specified oil or fluid B Specified engine speed C Specified tightening torque D Specified measurement E Specified electrical value (resistance, voltage, electric current) Symbols F to H in an exploded diagram indicate the grade of lubricant and the lubrication point. F Apply Yamaha 4-stroke motor oil G Apply water resistant grease (Yamaha grease A, Yamaha marine grease) H Apply molybdenum disulfide grease Symbols I to N in an exploded diagram indicate the type of sealant or locking agent and the application point. I Apply Gasket Maker J Apply Yamabond No. 4 K Apply LOCTITE 271 (red) L Apply LOCTITE 242 (blue) M Apply LOCTITE 572 N Apply silicone sealant NOTE: Additional symbols may be used in this manual. 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N GEN INFO SPEC INSP ADJ FUEL POWR JET PUMP – + ELEC HULL HOOD TRBL ANLS T R . . E A M GM 4 271 LT 242 LT 572 LT SS

E INDEX GENERAL INFORMATION 1 GEN INFO SPECIFICATIONS 2 SPEC PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR JET PUMP UNIT 6 JET PUMP ELECTRICAL SYSTEM 7 ELEC HULL AND HOOD 8 HULL HOOD TROUBLE ANALYSIS 9 TRBL ANLS – + A30000-0

E GEN INFO 1 2 3 4 5 6 7 8 9 CHAPTER 1 GENERAL INFORMATION IDENTIFICATION NUMBERS ......................................................................... 1-1 PRIMARY l.D. NUMBER ........................................................................... 1-1 ENGINE SERIAL NUMBER ...................................................................... 1-1 JET PUMP UNIT SERIAL NUMBER ......................................................... 1-1 HULL IDENTIFICATION NUMBER (H.l.N.) ............................................... 1-1 SAFETY WHILE WORKING...................................................................... 1-2 FIRE PREVENTION .................................................................................. 1-2 VENTILATION ........................................................................................... 1-2 SELF-PROTECTION ................................................................................. 1-2 PARTS, LUBRICANTS, AND SEALANTS ................................................ 1-2 GOOD WORKING PRACTICES ............................................................... 1-3 DISASSEMBLY AND ASSEMBLY ............................................................ 1-4 SPECIAL TOOLS ............................................................................................ 1-5 MEASURING ............................................................................................. 1-5 REMOVAL AND INSTALLATION .............................................................. 1-7

1-1 E GEN INFO IDENTIFICATION NUMBERS A60700-0* IDENTIFICATION NUMBERS PRIMARY l.D. NUMBER The primary l.D. number is stamped on a label attached to the inside of the engine compart- ment. Starting primary l.D. number: F1S: 800101 ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the engine unit. Starting serial number: 6B6: 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.l.N.) The H.l.N. is stamped on a plate attached to the aft deck.

1-2 E GEN INFO SAFETY WHILE WORKING SAFETY WHILE WORKING To prevent and accident or injury and to ensure quality service, follow the safety procedures 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), be sure to do so where adequate 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 protective gloves or 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.

1-3 E GEN INFO SAFETY WHILE WORKING 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. Maintain good standards of personal and industrial hygiene. 2. Change and wash clothing as soon as possible if soiled with lubricants. 3. Avoid contact with skin. Do not, for example, place a soiled rag in your pocket. 4. 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. 5. To protect your skin, apply a protective cream to your hands before working on the watercraft. 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. GOOD WORKING PRACTICES 1. The right tools Use the recommended special service tools to protect parts from damage. Use the right tool in the right manner—do not improvise. 2. Tightening torques 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 E GEN INFO SAFETY WHILE WORKING 3. Non-reusable parts Always use new gaskets, seals, O-rings, oil seals, cotter pins, circlips, etc., when installing or assembling parts. DISASSEMBLY AND ASSEMBLY 1. Use compressed air to remove dust and dirt during disassembly. 2. Apply engine oil to the contact surfaces of moving parts during assembly. 3. Install bearings with the manufacture identification mark in the direction indication in the installation procedure. In addition, be sure to lubricate the bearings liberally. 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.

2004-2007 Yamaha WaveRunner FX1100 Service & Repair Manual

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