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2012-2015 Yamaha FX HO FB1800 F2T Waverunner Service Manual – PDF Download
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2012-2015 Yamaha FX HO FB1800 F2T Waverunner Service Manual
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Description
2012-2015 Yamaha FX HO FB1800 F2T Waverunner Service Manual
FILE DETAILS:
2012-2015 Yamaha FX HO FB1800 F2T Waverunner Service Manual
LANGUAGE:ENGLISH
PAGES:367
DOWNLOADABLE:YES
FILE TYPE:PDF
2012-2015 YAMAHA FX HO FB1800 F2T WAVERUNNER SERVICE MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
- 2012-2015 Yamaha FX HO FB1800 F2T Waverunner Service Manual
- 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).
TABLE OF CONTENTS:
2012-2015 Yamaha FX HO FB1800 F2T Waverunner Service Manual
Contents................................................................................................... 3 General information.................................................................................... 4 !Safety while working.............................................................................. 6 Rotating part.................................................................................. 6 Hot part....................................................................................... 6 Electric shock................................................................................. 6 Impeller....................................................................................... 6 Handling of gasoline........................................................................... 6 Ventilation.................................................................................... 7 Self-protection................................................................................ 7 Working with crane............................................................................. 7 Handling of heat gun........................................................................... 8 Part, lubricant, and sealant................................................................... 8 Handling of sealant............................................................................ 8 Special service tool........................................................................... 8 Tightening torque.............................................................................. 8 Non-reusable part.............................................................................. 9 Disassembly and assembly....................................................................... 9 Identification number.............................................................................. 10 Primary I.D. number............................................................................ 10 Engine serial number........................................................................... 10 Jet pump unit serial number.................................................................... 10 Hull identification number (H.I.N.)............................................................ 10 How to use this manual............................................................................. 12 Manual format.................................................................................. 12 Abbreviation................................................................................... 13 Adhesive, lubricant, sealant, and thread locking agent............................................. 14 Symbol......................................................................................... 14 Special service tool............................................................................... 16 Model feature...................................................................................... 24 General feature (FX SHO, FX Cruiser SHO)....................................................... 24 General feature (FX HO, FX Cruiser HO)......................................................... 25 Model equipment comparison table............................................................... 26 Hull and deck.................................................................................. 27 Technical tips..................................................................................... 29 Engine control................................................................................. 29 ETV system..................................................................................... 31 Mechanical Neutral............................................................................. 32 Engine control system.......................................................................... 33 YDIS............................................................................................... 36 New functions.................................................................................. 37 Menu item...................................................................................... 37 Logging........................................................................................ 38 Engine............................................................................................. 39 Lubrication system............................................................................. 40 Hose routing (FX SHO, FX Cruiser SHO).......................................................... 41 Hose routing (FX HO, FX Cruiser HO)............................................................ 42 Cooling water flow............................................................................. 43 Specification.......................................................................................... 45 Model data......................................................................................... 46 Model code..................................................................................... 46 Dimensions and weight.......................................................................... 46 Performance.................................................................................... 46 Power unit..................................................................................... 46 Jet pump unit.................................................................................. 47 Fuel and oil requirement....................................................................... 47 Battery requirement............................................................................ 48 Fuel system technical data......................................................................... 48 Fuel system.................................................................................... 48 Power unit technical data.......................................................................... 49 Power unit..................................................................................... 49 Cylinder head assy............................................................................. 49 Crankcase assy................................................................................. 51 Jet pump unit technical data....................................................................... 53 Jet pump unit.................................................................................. 53 Electrical technical data.......................................................................... 53 Ignition system................................................................................ 53 Charging system................................................................................ 54 Control system................................................................................. 54 Fuel system.................................................................................... 56 Starting system................................................................................ 56 Meter system................................................................................... 57 Specified tightening torque........................................................................ 58 Fuel system.................................................................................... 58 Power unit..................................................................................... 58 Jet pump unit.................................................................................. 61 Electrical system.............................................................................. 61 Hull and hood.................................................................................. 61 Torque wrench reading (setting value).............................................................. 63 General tightening torque.......................................................................... 63 Cable and hose routing............................................................................. 64 Starboard bow view............................................................................. 64 Top view....................................................................................... 65 Port view...................................................................................... 67 Maintenance............................................................................................ 69 Maintenance interval chart......................................................................... 70 Periodic service................................................................................... 71 Jet thrust nozzle angle check.................................................................. 71 Jet thrust nozzle angle adjustment............................................................. 71 Steering master check.......................................................................... 71 Shift cable and reverse gate check............................................................. 72 Shift cable adjustment......................................................................... 72 Q.S.T.S. mechanism check....................................................................... 72 Q.S.T.S. rod adjustment........................................................................ 73 Fuel tank check................................................................................ 73 Water separator check.......................................................................... 73 Spark plug check............................................................................... 74 Engine oil level check......................................................................... 74 Engine oil replacement......................................................................... 75 Oil filter replacement......................................................................... 76 Trolling speed check........................................................................... 76 Nut and bolt check............................................................................. 76 Valve clearance measurement.................................................................... 76 Impeller check................................................................................. 78 Water inlet strainer check..................................................................... 78 Battery check.................................................................................. 78 Bilge strainer check........................................................................... 79 Electric bilge pump strainer check............................................................. 79 Drain plug check............................................................................... 80 Throttle valve lubrication (FX SHO, FX Cruiser SHO)............................................ 80 Throttle valve lubrication (FX HO, FX Cruiser HO).............................................. 80 Q.S.T.S. cable (handlebar end) lubrication..................................................... 81 Q.S.T.S. cable (converter end) and Q.S.T.S. rod joint lubrication.............................. 81 Nozzle pivot bolt and steering cable lubrication............................................... 81 Steering cable and steering cable joint lubrication............................................ 81 Shift lever assy., shift cable, and shift cable joint lubrication.............................. 81 Intermediate housing lubrication............................................................... 82 Fuel system............................................................................................ 83 Air filter case and fuel hose (FX SHO, FX Cruiser SHO)............................................. 84 Air filter case and fuel hose (FX HO, FX Cruiser HO)............................................... 86 Fuel hose disconnection........................................................................ 88 Fuel pressure measurement...................................................................... 88 Fuel hose disassembly.......................................................................... 89 Air filter element check....................................................................... 89 Fuel hose assembly............................................................................. 89 Fuel injector (FX SHO, FX Cruiser SHO)............................................................. 91 ETV and fuel injector (FX HO, FX Cruiser HO)....................................................... 92 ETV check (FX HO, FX Cruiser HO)............................................................... 93 Fuel injector check............................................................................ 93 Fuel rail and injector installation............................................................ 93 Fuel tank and fuel pump module assy................................................................ 95 Fuel pump module removal....................................................................... 97 Fuel sender removal............................................................................ 97 Fuel pump module check......................................................................... 97 Check valve check.............................................................................. 97 Fuel filler cap check.......................................................................... 98 Fuel sender installation....................................................................... 98 Fuel pump module installation.................................................................. 98 Fuel tank installation......................................................................... 99 Power unit.............................................................................................102 Engine unit (check and adjustment).................................................................106 Compression pressure check.....................................................................106 Engine unit (FX SHO, FX Cruiser SHO)...............................................................107 Engine unit (FX HO, FX Cruiser HO).................................................................108 Exhaust manifold (FX SHO, FX Cruiser SHO)..........................................................109 Exhaust manifold (FX HO, FX Cruiser HO)............................................................111 Engine unit and coupling cover (FX SHO, FX Cruiser SHO)............................................113 Engine unit and coupling cover (FX HO, FX Cruiser HO)..............................................114 Engine mount.......................................................................................115 Engine unit removal (FX SHO, FX Cruiser SHO)...................................................116 Engine unit removal (FX HO, FX Cruiser HO).....................................................120 Engine mount and damper check..................................................................124 Engine unit installation (FX SHO, FX Cruiser SHO)..............................................124 Engine unit installation (FX HO, FX Cruiser HO)................................................130 Muffler............................................................................................136 Exhaust pipe disassembly.......................................................................137 Exhaust pipe assembly..........................................................................137 Wiring harness assy. (FX SHO, FX Cruiser SHO)......................................................138 Wiring harness assy. (FX HO, FX Cruiser HO)........................................................139 Electrical box.....................................................................................140 Starter motor and wiring harness assy. removal (FX SHO, FX Cruiser SHO)........................142 Starter motor and wiring harness assy. removal (FX HO, FX Cruiser HO)..........................143 Thermostat check...............................................................................144 Starter motor and wiring harness assy. installation (FX SHO, FX Cruiser SHO)...................144 Starter motor and wiring harness assy. installation (FX HO, FX Cruiser HO).....................145 Air cooler and supercharger assy...................................................................147 Intake assy. (FX SHO, FX Cruiser SHO)..............................................................150 Intake assy. (FX HO, FX Cruiser HO)................................................................152 ETV and intake manifold (FX SHO, FX Cruiser SHO)...................................................153 Air cooler check (FX SHO, FX Cruiser SHO)......................................................154 Supercharger check (FX SHO, FX Cruiser SHO)....................................................154 ETV check (FX SHO, FX Cruiser SHO).............................................................154 Intake assy. installation (FX SHO, FX Cruiser SHO).............................................154 Intake manifold installation (FX HO, FX Cruiser HO)............................................155 Oil level pipe installation (FX SHO, FX Cruiser SHO)...........................................156 Supercharger installation (FX SHO, FX Cruiser SHO).............................................157 Air cooler, air cooler intake hose, and boost pipe installation (FX SHO, FX Cruiser SHO).......157 Oil cooler and oil pump assy. (FX SHO, FX Cruiser SHO).............................................160 Idle gear assy. and drive gear assy. (FX SHO, FX Cruiser SHO)......................................162 Oil cooler, oil pump assy. and drive gear (FX HO, FX Cruiser HO)...................................163 Oil pump assy., idle gear assy., and drive gear assy. removal (FX SHO, FX Cruiser SHO).........165 Oil pump assy. and oil pump drive gear removal (FX HO, FX Cruiser HO)..........................165 Oil cooler assy. check.........................................................................165 Oil pump assy. check...........................................................................166 Idle gear check (FX SHO, FX Cruiser SHO).......................................................166 Drive gear assy. check (FX SHO, FX Cruiser SHO)................................................166 Drive gear assy., idle gear assy., and oil pump assy. installation (FX SHO, FX Cruiser SHO)....166 Oil pump drive gear and oil pump assy. installation (FX HO, FX Cruiser HO).....................167 Cylinder head cover................................................................................169 Camshaft (FX SHO, FX Cruiser SHO)..................................................................170 Camshaft (FX HO, FX Cruiser HO)....................................................................172 Camshaft removal...............................................................................174 Camshaft sprocket removal......................................................................175 Camshaft check.................................................................................175 Camshaft journal oil clearance check...........................................................176 Timing chain tensioner check...................................................................177 Camshaft sprocket installation.................................................................177 Camshaft installation..........................................................................178 Valve clearance adjustment.....................................................................180 Valve pad selection table......................................................................183 Cylinder head......................................................................................184 Valve and valve spring.............................................................................185 Cylinder head disassembly......................................................................186 Cylinder head check............................................................................186 Valve spring check.............................................................................186 Valve check....................................................................................187 Valve guide check..............................................................................187 Valve guide removal............................................................................188 Valve guide installation.......................................................................188 Valve seat check...............................................................................189 Valve seat refacing............................................................................189 Cylinder head assembly.........................................................................191 Cylinder head installation.....................................................................193 Generator cover assy. and flywheel magneto.........................................................194 Generator cover....................................................................................196 Drive coupling removal.........................................................................197 Flywheel magneto removal.......................................................................197 Generator cover assy. disassembly..............................................................199 Starter clutch operation check.................................................................199 Generator cover assy. assembly.................................................................200 Flywheel magneto installation..................................................................201 Drive coupling installation....................................................................204 Cylinder block and electrical part (FX SHO, FX Cruiser SHO)........................................205 Cylinder block and electrical part (FX HO, FX Cruiser HO)..........................................207 Oil separator tank and oil pan.....................................................................209 Anode check....................................................................................211 Oil pan assembly...............................................................................211 Oil level pipe installation (FX HO, FX Cruiser HO).............................................211 Oil separator tank cover installation..........................................................212 Crankcase, connecting rod, and piston..............................................................213 Crankcase disassembly..........................................................................215 Connecting rod and piston removal..............................................................215 Crankcase check................................................................................216 Cylinder block check...........................................................................216 Piston check...................................................................................216 Piston clearance check.........................................................................216 Piston ring check..............................................................................216 Piston pin check...............................................................................217 Connecting rod check...........................................................................218 Crankshaft check...............................................................................218 Crankshaft pin oil clearance check.............................................................218 Connecting rod big end side clearance check....................................................219 Connecting rod bearing selection...............................................................220 Crankshaft journal oil clearance check.........................................................221 Crankshaft bearing selection...................................................................222 Connecting rod and piston installation.........................................................223 Crankcase assembly.............................................................................225 Jet pump unit..........................................................................................227 Intake grate and ride plate........................................................................228 Jet pump unit......................................................................................229 Jet pump unit removal..........................................................................231 Jet pump unit installation.....................................................................232 Reverse gate.......................................................................................234 Nozzle and nozzle ring.............................................................................235 Impeller housing and impeller duct assy............................................................236 Impeller, drive shaft, and impeller duct...........................................................237 Impeller duct assy. disassembly................................................................238 Impeller housing check.........................................................................239 Drive shaft check..............................................................................239 Impeller duct assy. assembly...................................................................239 Impeller duct, impeller housing, and nozzle installation.......................................241 Transom plate and hoses............................................................................242 Bilge and hoses....................................................................................244 Bilge strainer check...........................................................................246 Electric bilge pump strainer check.............................................................246 Transom plate installation.....................................................................246 Intermediate housing...............................................................................247 Intermediate housing assy. removal.............................................................249 Intermediate housing assy. disassembly.........................................................249 Intermediate housing assy. assembly............................................................250 Intermediate housing assy. installation........................................................251 Electrical system......................................................................................252 Electrical components..............................................................................254 Engine (FX SHO, FX Cruiser SHO)................................................................254 Engine (FX HO, FX Cruiser HO)..................................................................255 Deck and hull..................................................................................256 Electrical box.................................................................................257 ECM circuit diagram............................................................................258 ECM coupler layout.............................................................................260 Electrical analysis................................................................................262 Electrical component check using the YDIS......................................................262 Power supply to the ECM........................................................................262 Peak voltage measurement.......................................................................262 Ignition system....................................................................................263 Ignition spark check...........................................................................263 Ignition coil check............................................................................264 Pickup coil check..............................................................................264 Charging system....................................................................................265 Stator coil check..............................................................................265 Rectifier regulator check......................................................................266 Control system.....................................................................................267 Oil pressure switch check......................................................................267 Thermoswitch check.............................................................................268 Thermo sensor check............................................................................269 Engine temperature sensor check................................................................270 Intake air temperature sensor check............................................................270 Intake air pressure sensor check...............................................................271 Knock sensor check.............................................................................272 TPS check......................................................................................272 ETV circuit continuity.........................................................................274 APS check......................................................................................274 APS circuit continuity.........................................................................275 ETV relay check................................................................................276 Cam position sensor check......................................................................277 Slant detection switch check...................................................................278 Steering sensor check..........................................................................278 Reverse sensor check...........................................................................279 Right handlebar switch check...................................................................279 ECM check......................................................................................280 Earth plate check..............................................................................281 Electric bilge pump check......................................................................281 Fuel system........................................................................................282 Fuel injector check............................................................................282 Fuel pump module check.........................................................................282 Starting system....................................................................................283 Left handlebar switch assy. check..............................................................283 Main and fuel pump relay check.................................................................284 Starter relay check............................................................................285 Starter motor......................................................................................286 Starter motor operation........................................................................287 Armature check.................................................................................287 Brush holder check.............................................................................288 Remote control system..............................................................................288 Remote control transmitter check...............................................................288 Remote control receiver check..................................................................290 Transmitter registration.......................................................................290 Indication system..................................................................................291 Multifunction meter check......................................................................291 Multifunction meter operation button check.....................................................292 Compass display check (FX Cruiser SHO).........................................................292 Air temperature display check (FX Cruiser SHO).................................................293 Water temperature display check (FX Cruiser SHO)...............................................293 Speed sensor check (FX Cruiser SHO)............................................................293 Speed sensor check (FX HO, FX Cruiser HO, and FX SHO)..........................................294 Fuel level meter display and fuel level warning indicator check................................294 Check engine warning indicator check...........................................................295 Diagnostic display check.......................................................................295 Oil pressure warning indicator check...........................................................296 Engine overheat warning indicator check........................................................296 Buzzer check...................................................................................297 Hull and hood..........................................................................................298 Steering pad and handlebar cover...................................................................300 Handlebar and handlebar switch assy................................................................301 Left handlebar switch assy. and throttle lever assy................................................303 Cable and lead routing.........................................................................304 Handlebar assy. installation...................................................................304 Front hood.........................................................................................307 Multifunction meter................................................................................309 Side cover.........................................................................................311 Side cover removal.............................................................................312 Side cover installation........................................................................312 Center cover.......................................................................................313 Steering master assy...............................................................................315 Steering master....................................................................................317 Steering shaft check...........................................................................319 Steering arm assy. installation................................................................319 Steering cable and speed sensor lead...............................................................320 Steering cable installation (steering master end)..............................................323 Steering cable installation (jet pump end).....................................................323 Shift cable installation (shift lever end).....................................................324 Q.S.T.S. cable installation (Q.S.T.S. converter end)...........................................324 Seat and handgrip..................................................................................326 Ventilation hose and water separator...............................................................328 Cooling water pilot outlet installation........................................................330 Ventilation hose installation..................................................................330 Exhaust system.....................................................................................331 Exhaust system installation....................................................................333 Rear section.......................................................................................334 Spout installation.............................................................................337 Reboarding step assy. installation.............................................................337 Deck and hull......................................................................................338 Troubleshooting........................................................................................341 YDIS...............................................................................................342 Function.......................................................................................342 Basic components...............................................................................344 Connecting the communication cable to the watercraft...........................................345 Engine unit troubleshooting........................................................................346 Using the YDIS for engine unit troubleshooting.................................................346 Diagnostic code table..........................................................................348 Diagnostic code and checking step..............................................................349 Engine unit troubleshooting (diagnostic code not detected).....................................355 Appendix...............................................................................................361 Wiring diagram.....................................................................................362 How to use the wiring diagram..................................................................362 FX SHO, FX Cruiser SHO.........................................................................362 FX HO, FX Cruiser HO...........................................................................366
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