2017 Yamaha SUPER JET Service & Repair Manual

SUPERJET ServiceManual ~LIT-18616-01-43 ~

>) PREFACE ThismanualhasbeenpreparedbytheYamahaMotorCompanyLtd.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a 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theYamahaMotorCompanyLtd.hasapolicyofcontinuouslyimprovingitsprod- ucts,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. ‘A10001-0" SJ700AU SERVICEMANUAL ©1996byYamahaMotorCo.,Ltd. 1stEdition,January1996 Allrightsreserved. Nopartofthispublicationmaybe reproducedortransmittedinanyformorby anymeansincludingphotocopyingand recordingwithoutthewrittenpermissionof thecopyrightholder. Suchwrittenpermissionmustalsobe obtainedbeforeanypartofthispublicationis storedinaretrievalsystemofanynature. PrintedinU.S.A. LIT-18616-01-43

<e> WARNINGS,CAUTIONSANDNOTES AttentionisdrawntothevariousWarnings,CautionsandNoteswhichdistinguishimportant informationinthismanualinthefollowingways. Q)TheSafetyAlertSymbolmeansATTENTION!BECOMEALERT!YOURSAFETYIS INVOLVED! FailuretofollowWARNINGinstructionscouldresultinsevereinjuryordeathtothemachine operator,abystander,orapersoninspectingorrepairingthewatervehicle. . ACAUTIONindicatesspecialprecautionsthatmustbetakentoavoiddamagetothewater vehicle. NOTE: ANOTEprovideskeyinformationtomakeprocedureseasierorclearer.

HOWTOREADDESCRIPTIONS 1.Adisassemblyinstallationjobmainlyconsistsoftheexplodeddiagram©. 2.Thenumericalfiguresrepresentedbythenumber©indicatestheorderofthejobsteps. 3.Thesymbolsrepresentedbythenumber©indicatesthecontentsandnotesofthejob. Forthemeaningsofthesymbols,refertothenextpage(s). 4.TheREMOVALANDINSTALLATIONCHART@isattachedtotheexplodeddiagramand explainsthejobsteps,partnames,notesforthejobs,etc. 5.TheSERVICEPOINTS,otherthantheexplodeddiagram,explainsindetailtheitemsdiffi- culttoexplainintheexplodeddiagramorREMOVALANDINSTALLATIONCHART,the Servicepointsrequiringthedetaileddescription©,etc. ET Pinte|=)DEFLECTOR,NOZZLEANDDUCT(a2) DEFLECTOR,NOZZLEANDDUCT EXPLODEDDIAGRAM_o "REMOVALANDINSTALLATIONCHART Step,Procedure/Pantnameoy‘Servicepoints DEFLECTOR,NOZZLEANDFoliowtheleft“Step”forremoval DUCTREMOVAL Nozzledeflectorassemblydais Reversetheremovalstepsforinstallation.

CE> 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compliedtoprovidethemechanicwithaneasytoread,handyrefer- ence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/Damage—Replace. Toassistyoutofindyourwayaboutthismanual,theSectionTitleandMajorHeadingis givenattheheadofeverypage. AnIndextocontentsisprovidedonthefirstpageofeachSection. MODELINDICATION Multiplemodelsareshowninthismanual.Theseindicationsarenotedasfollows. SuperJet Modelname IndicationSJ700A THEILLUSTRATIONS Someillustrationsinthismanualmaydifferfromthemodelyouhave.Thisisbecauseaproceduredescribedmayrelatetoseveralmodels,thoughonlyonemaybeillustrated.(The nameofmodeldescribedwillbementionedinthedescription). REFERENCES Thesehavebeenkepttoaminimum;however,whenyouarereferredtoanothersectionof themanual,youaretoldthepagenumbertogoto.

CED SYMBOLS Symbols@to©aredesignedasthumb- tabstoindicatethecontentofachapter: @GeneralInformation ®Specifications ©PeriodicInspectionandAdjustment @FuelSystem ©PowerUnit ©JetpumpUnit @ElectricalSystem HullandHood Trouble-analysis Symbols@to@indicatespecificdata: @Specialtool @®Specifiedliquid @Specifiedenginespeed ®Specifiedtorque @Specifiedmeasurement ®Specifiedelectricalvalve [Resistance(Q),Voltage(V),Electriccurrent (A)] Symbol@toinanexplodeddiagram indicategradeoflubricantandlocationof lubricationpoint: @ApplyYamaha2-strokeoutboardmotoroil @Applywaterresistantgrease(Yamaha greaseA,Yamahamarinegrease) @Applymolybdenumdisulfidegrease Symbols@to@inanexplodeddiagram indicategradeofsealingorlockingagent, andlocationofapplicationpoint: @®ApplyGasketMaker® @ApplyYamahabond#4(YamahabondNo.4) ®ApplyLOCTITE®No.271(RedLOCTITE) @ApplyLOCTITE®No.242(BlueLOCTITE) @ApplyLOCTITE®No.572 @ApplySiliconsealant NOTE: Inthismanual,theabovesymbolsmaynot beusedineverycase.

INDEX GENERALINFORMATION SPECIFICATIONS PERIODICINSPECTIONAND ADJUSTMENT FUELSYSTEM POWERUNIT JETPUMPUNIT ELECTRICALSYSTEM HULLANDHOOD TROUBLE-ANALYSIS

© CHAPTER1 GENERALINFORMATION IDENTIFICATIONNUMBERS PRIMARYI.D.NUMBER... ENGINESERIALNUMBER. PUMPSERIALNUMBER.. HULLIDENTIFICATIONNUMBER SAFETYWHILEWORKING FIREPREVENTION VENTILATION... SELF-PROTECTI OILS,GREASESANDSEALINGFLUIDS. GOODWORKINGPRACTICES... DISASSEMBLYANDASSEMBLY. SPECIALTOOLS... MEASURING.. REMOVALANDINSTALLATION

IDENTIFICATIONNUMBERScE 1-1 ‘A60700-0° IDENTIFICATIONNUMBERS PRIMARYI.D.NUMBER Theprimary|.D.numberisstampedona labelattachedtotheinsideoftheengine compartment. StartingprimaryI.D.number: GM6:900101~, 910101~(FRA), 930101~(GUM,AUS) ENGINESERIALNUMBER Theengineserialnumberisstampedona labelattachedtothecrankcase. Startingserialnumber: 64V:000101~ PUMPSERIALNUMBER Thejetpumpunitserialnumberisstamped onalabelattachedontheintermediate housing. Startingserialnumber: 64V:500101~ HULLIDENTIFICATIONNUMBER (H.1.N.) TheH.I.N.isstampedonaplateattachedto thehullbesidethejetnozzle.

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2017 Yamaha SUPER JET Service & Repair Manual

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