2023 Yamaha FX Cruiser SVHO w/ audio Service & Repair Manual

@YAMAHA WaveRunner FXHO FX1800H/J(F3V) FXCRUISERHO FX1800F/G(F3V) FXSVHO FX1800D/E(F5G) FXCRUISERSVHO FX1800B/C(F5G) FXLIMITEDSVHO FX1800A(F5G) SERVICEMANUAL LIT-18616-04-16

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hasa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,U.S.A.only)orYPEC-web(except U.S.A.).Additionalinformationandup-to-dateinformationonYamahaproductsandservicesareavailableonYDS,YMPE(YamahaMultimediaProductEncyclopedia,Canadaonly),orYamahaService Portal(exceptU.S.A.andCanada). Importantinformation Particularlyimportantinformationisdistinguishedinthismanualbythefollowingnotations: Z\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. NOTICE ANOTICEindicatesspecialprecautionsthatmustbetakentoavoiddamagetothewatercraft orotherproperty. TIP: ATIPprovideskeyinformationtomakeprocedureseasierorclearer. WaveRunner FXHO,FXCRUISERHO,FXSVHO,FX CRUISERSVHO,FXLIMITEDSVHO SERVICEMANUAL ©2022byYamahaMotorCo.,Ltd. 1stEdition,March2022 Allrightsreserved. Anyreprintingorunauthorizeduse withoutthewrittenpermissionof YamahaMotorCo.,Lid. isexpresslyprohibited. LIT-18616-04-16

Contents Generalinformation Specification Maintenance Fuelsystem Powerunit Jetpumpunit Electricalsystem Hullandhood Troubleshooting Appendix PLOlO!N(O)o}a)o}m]—

Generalinformation SafetywhileWorking.........:ccssssseeseeeeeeeeneneeneneee1- Rotatingparts.. Hotparts....... Electricshock.. Impeller... Handlingofg Ventilation........... Self-protection.... Workingwithcrane Handlingofheatgun.... Parts,lubricants,andseal Handlingofsealants. Specialservicetool Tighteningtorque.. Non-reusableparts... Disassemblyandasse! Engineoil = Sa a Cr a a er ee Ce Or BoHWdHdOONMYNMNHMAAAAASA IdentificationNUMDEL.........:::ccecseeseeesseeesseeesseeensenensennees1-4 PrimaryI.D.number Engineserialnumber... Jetpumpunitserialnumber Craftidentificationnumber(C.1.N.)(Europe)... Hullidentificationnumber(H.I.N.)(exceptEurope)... HowtousethisManual.........c:cccseecsseeessessseeeeseeeseeeneeneees1-6 Manualformat Conditionswhentestingandadjusting Abbreviation Specificationsymbol Adhesive,lubricant,sealant,andthreadlockingagent... Specialservicetool

Generalinformation Modelfeature.......ssccsssssssssessesseesseesseessesseeeseeseeesensseeeses1-15 Generalfeature(FXHO,FXCRUISERHO)..........::ccecceeeeee1-16 Generalfeature(FXSVHO,FXCRUISERSVHO, PXLIMITEDSVAO)esecsecssrceessvererereeneeeerences1-17 Modelequipmentcomparisontable (POEACAUSEIO)crciecansecccaisesasasncnsnnnecsnnximenceresemsic1-18 Modelequipmentcomparisontable (FXSVHO,FXCRUISERSVHO,FXLIMITEDSVHO)...........1-19 TECHNICALtiPS........seceeeeseeeeseeeesseeesscensseeneseeesseeeeseeeeeseennaes1-21 Enginecontrol1-21 Enginecontrolsystem(FXHO,FXCRUISERHO)....1-24 Enginecontrolsystem(FXSVHO,FXCRUISERSVHO, EX.LIMITEDSVAO)eects1-27 Powerunit (FXSVHO,FXCRUISERSVHO,FXLIMITEDSVHO).... Jetpumpunit.. Electrical......... Lubricationsystem... Hoserouting(FXHO,FXCRUISERHO).. Hoserouting(FXSVHO,FXCRUISERSVHO, FXLIMITEDSVHO). Coolingwaterflow

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seri- ous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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. 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.

Safetywhileworking 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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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Ya- maha,whenservicingorrepairingthewatercraft.

Safetywhileworking 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. <a ¢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. Engineoil Draintheengineoilbeforestartinganywork, suchasrepairormaintenancework,inwhich thehullistilted90degrees.Otherwise,theengineoilcouldbackflowandseverelydamage theengine.

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2023 Yamaha FX Cruiser SVHO w/ audio Service & Repair Manual

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