2019 Yamaha VXR Service & Repair Manual

Repair&ServiceManualaN 2 22WAVERUNNER aUXS UXR VXCRUISERHO 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: QTheSafetyAlertSymbolmeansATTENTION!BECOMEALERT!YOURSAFETYISINVOLVED! AWARNING AWARNINGindicatesahazardoussituationwhich,ifnotavoided,couldresultindeathorserious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 VXS,VXR SERVICEMANUAL ©2015byYamahaMotorCorporation,U.S.A. 1stEdition,February2015 Allrightsreserved. Anyreprintingorunauthorizeduse withoutthewrittenpermissionof YamahaMotorCorporation,U.S.A. isexpresslyprohibited. LIT-18616-03-63

Contents Generalinformation Specification Maintenance Fuelsystem Powerunit Jetpumpunit Electricalsystem Hullandhood Troubleshooting Appendix >}CO]oO}NI]O|on}Biow}rm]

Generalinformation Safetywhileworking. Rotatingparts......... Hotparts....... Electricshock.. Impeller......... Handlingofgasoline.. Ventilation... Self-protection. Workingwithcrane. Handlingofheatgun. Parts,lubricants,andsealants Handlingofsealants.. Specialservicetool Tighteningtorque... Non-reusableparts. Disassemblyandassembly. o = OHooOoONHAALILA Fnreur IdentificationMUMDEL............:::scsscssescssessssssseeseeessseeeseeeaes Primary|.D.number.. Engineserialnumber Jetpumpunitserialnumber Hullidentificationnumber(H.I.N.). Howtousethismanual..1-5 Manualformat............1-5 Conditionswhentestingandadjusting.1-6 Abbreviation.1-6 Adhesive,lubricant,sealant, andthreadlockingagent Modelequipmentcomparisontable.. TOGICALUD Ssisiigecressoecceeseeseencrceeeseeereece Enginecontrol.. RiDEsystem

Generalinformation RiDEmotor... ETV system.. Shiftcontrol.. Enginecontrolsystem Deck andhull............. Lubricationsystem. Hoserouting........ Coolingwaterflow.. ee OHKWOUMNND ROVSORaRR

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. 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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.

Safetywhileworking ¢Protectyourhandsandfeetbywearingprotectiveglovesandsafetyshoeswhennecessary. 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. *Ifthe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. — BB 2 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. 1-3 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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.

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. + YAMAHAMOTOR0O.,LTO, ASSEMBLEDINU.S.A.FROMAMERICANANDJAPANESE COMPONENTS. ASSEMBLEAUXETATS-UNISDEPIECESAMERICAINESET JAPONAISES. 1.Modelname 2.Hulltype 3.PrimaryI.D.number Startingprimary|.D.number F2W:800101 Engineserialnumber Theengineserialnumberisstampedonalabelattachedtotheengineunit. YAMAHAMOTORCO.,LTD. MADEINJAPAN PAYSD'ORIGINEJAPON 1.Enginename 2.Enginetype 3.Engineserialnumber Startingengineserialnumber 6EW:1000001 Jetpumpunitserialnumber Thejetpumpunitserialnumberisstampedon alabelattachedtotheintermediatehousing. CORP.OFAMES 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onaplateattachedto theboardingplatform. MOOOUO0000

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 Impellerhousing andimpellerductA frost} Impaie,andimpsduct ImpalerductASSYdisassembly USAandCanaca ‘9980008820 onean "NOTICE! 2entpresseineoaBeads ou 1-5

2019 Yamaha VXR Service & Repair Manual

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