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1996-2006 Yamaha SuperJet SJ700 Waverunner Repair Manual
1997-2000 Yamaha GP760/1200 Waverunner Repair Manual
1998-2000 Yamaha GP800 Waverunner Repair Manual
1999-2004 Yamaha SV1200/SUV1200 Waverunner Repair Manual
2000-2004 Yamaha GP1200R Waverunner Repair Manual
2000-2005 Yamaha GP800R Waverunner Repair Manual
2001-2004 Yamaha XLT800 Waverunner Repair Manual
2001-2005 Yamaha XLT1200 Waverunner Repair Manual
2003-2008 Yamaha GP1300R Waverunner Repair Manual
2004-2007 Yamaha FX1100 SHO & FX Cruiser Repair Manual
2005-2009 Yamaha VX110 Sport VX110 Deluxe Repair Manual
2009-2013 Yamaha FZR/FZS GX1800 Waverunner Repair Manual
2010-2010 Yamaha SuperJet Waverunner Repair Manual
2010-2011 Yamaha VX700 Waverunner Repair Manual
2010-2012 Yamaha VX1100 Wavrunner Repair Manual
2011-2011 Yamaha SuperJet Waverunner Repair Manual



SERVICE MANUAL MODELS:

1997 2000 YAMAHA GP1200 (GP 1200) Service Manual

Service Manual Application: 1997, 1998, 1999 & 2000 Yamaha GP1200 (GP-1200) Personal Water Craft (PWC).

1997 2000 Yamaha GP760 (GP 760) Service Manual PWC

Service Manual Application: 1997, 1998, 1999 & 2000 Yamaha GP760 (GP-760) Personal Water Craft (PWC).

1997-2007 Yamaha SJ700AU (SJ700 AU) Service Manual Waverunner

Service Manual Application: 1997-2009 Yamaha SJ700AU, SJ700A, SJ-700-A-AU Super Jet , Superjet Water Craft.

1998 2000 YAMAHA WaveRunner GP800 (GP 800) Service Manual

Service Manual Application: 1998, 1999 & 2000 Yamaha WaveRunner (Wave Runner) GP800 (GP-800) Water Craft

1999-2004 Yamaha SV1200 & SUV1200 Service Manual PWC

Service Manual Application: 1999, 2000, 2001, 2002, 2003 & 2004 Yamaha SV1200 (SV-1200) & SUV, SUV1200 (SUV-1200) WaveRunner (Wave Runner) Water Craft.

1999 2004 YAMAHA Wave Runner XL760 XL1200 Service Manual XL 760/1200 

Service Manual Application: Yamaha WaveRunner (Wave Runner) 1999, 2000, 2001, 2002, 2003 & 2004 XL760 (XL-760) & XL1200 (XL-1200).

2000-2002 Yamaha GP1200R (GP-1200-R, GP1200) Service Manual

Service Manual Application: 2000, 2001 & 2002 Yamaha WaveRunner (Wave Runner) GP1200R (GP-1200-R, GP-1200R) Personal Water Craft.

2001-2005 Yamaha GP800R (GP 800 R) Service Manual & Owners Manual

Service Manual & Owners/Operators Manual Application: 2001, 2002, 2003, 2004 & 2005 Yamaha WaveRunner (Wave Runner) GP800R (GP-800R, GP800-R) Personal Water Craft.

2001 2005 YAMAHA WaveRunner XLT1200 (XLT 1200) Service Manual

Service Manual Application: 2001, 2002, 2003, 2004 & 2005 Yamaha WaveRunner (Wave Runner) XLT1200 (XLT-1200) Water Craft.

2002-2004 Yamaha XLT800 (XLT 800) Service Manual PWC

Service Manual Application: 2002, 2003 & 2004 Yamaha WaveRunner (Wave Runner) XLT800 (XLT-800) Personal Water Craft.

2003-2005 Yamaha Waverunner GP1300R Service Manual

Service Manual Application: 2003, 2004, 2005 Yamaha Wave Runner GP1300R, GP1300-R, GP-1300-R PWC Watercraft Service Manual.

2005-2009 Yamaha VX1100 (VX 1100) Service Manual SPORT DELUXE

Service Manual Manual Application: 2005, 2006, 2007, 2008 and 2009 Yamaha WaveRunner (Wave Runner) VX1100 (VX-1100, VX110, VX-110) Sport/Deluxe Personal Water Craft (PWC).

2004-2007 Yamaha FX1100 FX HO & FX HO Cruiser WaveRunner

Service Manual Application: 2004 2005 2006 2007 Yamaha FX High Output & FX Cruiser High Output WaveRunner (Wave Runner) Water Craft (PWC) FX1100 (FX-1100), FX1100A (FX-1100-A), FX1100B (FX-1100-B).

 

2008 YAMAHA Waverunner FX & FX Cruiser Service Manual FX1100

Service Manual Application: 2008 Yamaha FX High Output, 2008 FX Cruiser High Output WaveRunner (Wave Runner) Water Craft (PWC) FX1100G (FX-1100-G), FX1100LG (FX-1100-LG), FX1100AG (FX-1100-AG), FX1100ALG (FX-1100-ALG).

2008 2009 Yamaha FX SHO & FX Cruiser SHO Service Manual Waverunner

Service Manual Application: 2008-2009 (08, 09) Yamaha FX SHO & FX Cruiser SHO WaveRunner (Wave Runner) Water Craft (PWC).

2009 2010 Yamaha GX1800 GX1800A Service Manual GX 1800 A FZR/FZS WaveRunner

Service Manual Application: 2009-2010 FZR GX1800 (F2R) FZS & GX1800A (GX-1800-A) (F2C)Yamaha WaveRunner (Wave Runner) Water Craft (PWC).


RELATED SEARCHES FOR YAMAHA PWC'S:

MAINTENANCE SCHEDULE - SEE SERVICE YOUR SERVICE MANUAL FOR ALL TECHNICAL INFORMATION

Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period. The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more technical information and tools. Consult an authorized Yamaha dealer.

* Should be serviced by an authorized Yamaha dealer, unless the owner has proper tools and service data and is mechanically qualified.
** In the interest of safety, we recommended these items be serviced only by an authorized Yamaha dealer.

NOTE: Some items will need more frequent service if the PWC is ridden in salt water or at full throttle. Consult an authorized Yamaha PWC dealer for recommendations applicable to your individual needs and use.

Check the fuel feed and return hoses for deterioration, damage or leakage and make sure the hoses are secured with the hose clamp properly. Also, check that the clamp is installed on the oil tank securely. Check the fuel tank for cracks or leakage and that the tank is installed securely with the straps and replace if necessary.

Check the throttle lever for smooth operation. Check that the throttle opens and automatically closes in all steering positions. Check for any deterioration or damage to the throttle cable. Apply a water-displacement corrosion-proof lubricant (without Teflon or molybdenum additives, such as CRC 6-56 or an equivalent) to the throttle cable upper end. Release the rubber shield, and apply a water-displacement corrosion-proof lubricant (without Teflon or molybdenum additives, such as CRC 6-56 or an equivalent) to the throttle cable lower end (throttle drum rolling area) and to the throttle screw tip. With the engine idling, turn the handlebar all the way to the right and left to ensure that the idle speed does not change. If idle speed increases, check the throttle lever free play and the throttle cable connection.

To lubricate and rustproof the inside of the throttle body, proceed as follows after confirming that the engine is stopped and cool.

1. Remove the joint hoses from the clip(s) and disconnect the maintenance joint.
2. Insert the spray nozzle of a water-displacement corrosion-proof lubricant (without Teflon or molybdenum additives, such as CRC 6-56 or an equivalent) into joint hole.
3. Open the throttle fully.
4. Spray the lubricant into joint hole for 3 seconds.
5. Operate the throttle lever slowly, from fully ON to fully OFF, 3 times.
6. Repeat the step 2 – 5 again.
7. Perform the same lubrication procedure for joint hole.
8. Spray the lubricant to the maintenance joint threads and the O-ring.
9. Reconnect the maintenance joint and make sure it tightened securely. Install the joint hoses into the clip(s) properly.

• This watercraft uses direct type ignition coils. The spark plug cap and ignition coil are integrated. Remove the seats. Disconnect the ignition coil connectors. Remove the bolts and the direct ignition coils. Clean around the spark plug bases with compressed air before removing the plugs, and be sure that no debris is allowed to enter the combustion chamber and remove the spark plugs.

Check the insulator for cracks or damage, and the electrodes for wear, fouling or discoloration. Replace the plug if necessary.

Measure the spark plug between the center and side electrodes with a wire-type feeler gauge. Make sure the 1.0 mm (0.04 in) wire-type feeler gauge cannot be inserted into the gap. If the gauge can be inserted into the gap, replace the plug with a new one. Screw the spark plug in the cylinder head by hand to prevent cross-threading. Tighten the spark plug to the specified torque. Install the removed parts in the reverse order of removal.

• Before installing the ignition coil, clean the plug hole (coil seating area) and sealing rubber on the ignition coil, and make sure the sealing rubber is in good condition.
• Do not allow water into the ignition coil connectors

Rotate the crankshaft counterclockwise (viewed from rear side) and align the "T" mark on the drive coupler boss with the index mark (arrow) on the crankcase. The timing marks ("IN" for intake and "EX" for exhaust) on the cam sprockets must be flush with the cylinder head surface and facing outward as shown. If the timing marks are facing inward, rotate the crankshaft counterclockwise 360° (one full turn) and align the "T" mark with the index mark.

AIR FILTER

Remove the seats. Release the four retainers and remove the airbox cover. Replace the air filter in accordance with the maintenance schedule or any time it is excessively dirty or damaged.
Install a new air filter into the housing base properly. Be sure the rubber seal in the cover is in good condition and install the airbox cover. Secure the cover with the retainers Install the seats.

This watercraft’s engine uses a dry sump. Follow the following procedures to determine if the proper amount of oil is in the engine.

LEVEL CHECK

Secure the watercraft on a stand or trailer and keep it level. Remove the rear tray. Before checking the engine oil level: Remove the filler cap/dipstick from the oil tank and wipe it clean.
Insert the filler cap/dipstick until it seats, but do not screw it in. Remove the dipstick and check the oil level.

• If the oil appears on the dipstick, install the filler cap/dipstick and proceed to the Oil Level Check Procedure.
• If there is no oil on the dipstick, perform the following procedure.

Remove the oil drain pipe cap and insert the filler cap/dipstick into the oil drain pipe until it seats, then remove it and check the oil level.

– If oil appears on the dipstick, install the filler cap/ dipstick and drain pipe cap, and proceed to the

Oil Level Check Procedure.

– If there is no oil on the dipstick, do not start the engine. Reinstall the drain pipe cap and tighten it.

Add the recommended engine oil into the oil tank through the filler hole until oil is on the dipstick. Do not over fill. Install the filler cap/dipstick and proceed to the

Oil Level Check Procedure.

OIL CHANGE

• Change the oil with the engine warm to assure complete draining. Secure the watercraft on a stand or trailer. Remove the rear tray. Warm up the engine for a few minutes according to the flushing procedure. Turn off the water and stop the engine. Remove the oil filler cap/dipstick and the drain pipe cap. Pump out the engine oil with a commercially available Fluid Evacuator from the oil filler hole and drain pipe, to drain the oil tank and oil pan. After draining the oil completely, install the drain pipe cap and pour the recommended oil into the oil tank through the filler hole. Install the filler cap/dipstick. Check the oil level.

ENGINE OIL FILTER

Drain the engine oil. Place a shop towel around the oil filter cartridge to avoid spilling the engine oil. Remove the oil filter cartridge and discard it. Clean any oil from the cartridge seating surface of the engine and the oil filter tray. Apply engine oil to the O-ring and threads of a new oil filter cartridge and install the filter using the filter wrench. Fill the oil tank with the recommended oil.

OIL CAPACITY:

4.2 liters (4.4 US qt, 3.7 Imp qt) at draining
4.3 liters (4.5 US qt, 3.8 Imp qt) at draining/filter change
5.3 liters (5.6 US qt, 4.7 Imp qt) at disassembly
4.0 liters (4.2 US qt, 3.5 Imp qt) at draining
4.1 liters (4.3 US qt, 3.6 lmp qt) at draining/filter change
5.0 liters (5.3 US qt, 4.4 Imp qt) at disassembly

ENGINE IDLE SPEED

• Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifications.
• The engine must be warm for accurate adjustment. Five minutes of idling is sufficient. If the air temperature is below 10°C (50°F), let the engine idle for an additional 5 minutes (a total of 10 minutes). Remove the seats. Remove the rear tray. Connect a tachometer. Warm up the engine with the watercraft in the water and check the idle speed. Adjust the idle speed by turning the throttle stop screw as required.

IMPELLER

Check the impeller for deep scratches, pitting or nicks by looking from both the water outlet and inlet sides. Check the jet stator inner wall for scratches. Check the impeller seal for cracks or damage. Measure the clearance between each impeller blade and the jet stator, using a feeler gauge 12-inches long. Impeller clearance is critical for proper performance. If the clearance is out of specification, disassemble and inspect the impeller and impeller housing area.

TROUBLESHOOTING
Oil level too low

• Oil consumption
• External oil leak
• Worn piston rings
• Improperly installed piston rings
• Worn cylinders
• Worn stem seals
• Worn valve guide

Low oil pressure

• Oil level low
• Clogged oil strainer or filter
• Faulty oil pump
• Internal oil leak
• Incorrect oil being used

No oil pressure

• Oil level too low
• Oil pressure relief valve stuck open
• Broken oil pump drive or driven joints
• Damaged oil pump
• Internal oil leak

High oil pressure

• Oil pressure relief valve stuck closed
• Clogged gallery or passage
• Incorrect oil being used

Oil contamination

• Oil or filter not changed often enough
• Worn piston rings
• Worn valve guide or stem seal

Oil emulsification

• Blown cylinder head gasket
• Leaky coolant passage
• Entry of water

TROUBLESHOOTING

Engine cranks but will not start

• Intake air leak
• Fuel contaminated/deteriorated
• Pinched or clogged fuel hose
• Faulty fuel pump
• Clogged fuel injector filter
• Sticking fuel injector needle
• Faulty fuel pump operating system

Engine stalls, hard to start, or idles rough

• Intake air leak
• Fuel contaminated/deteriorated
• Pinched or clogged fuel hose
• Idle speed misadjusted
• Starter valve synchronization misadjusted

Backfiring or misfiring during acceleration

• Ignition system malfunction

Poor performance (driveability) and poor fuel economy

• Pinched or clogged fuel hose
• Faulty pressure regulator

TROUBLESHOOTING

Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. Compression too low, hard starting or poor performance at low speed.

• Valves

– Incorrect valve adjustment
– Burned or bent valve
– Incorrect valve timing
– Broken valve spring
– Uneven valve seating

• Cylinder head

– Leaking or damaged cylinder head gasket
– Warped or cracked cylinder head
– Loose spark plug

• Cylinder/piston problem Compression too high
• Excessive carbon build-up on piston head or combustion chamber

Excessive smoke

• Worn valve stem or valve guide
• Damaged stem seal
• Cylinder/piston problem

Excessive noise

• Incorrect valve adjustment
• Sticking valve or broken valve spring
• Worn or damaged camshaft
• Worn or damaged valve lifter
• Worn cam chain
• Worn or damaged cam chain tensioner
• Worn cam sprocket teeth
• Cylinder/piston problem

Rough idle

• Low cylinder compression

TROUBLESHOOTING

Engine does not turn

• Faulty starter clutch
• Damaged reduction gear/shaft

TROUBLESHOOTING

Compression too low, hard starting or poor performance at low speed

• Leaking cylinder head gasket
• Worn, stuck or broken piston ring
• Worn or damaged cylinder and piston

Compression too high, overheating or knocking

• Excessive carbon built-up on piston head or combustion chamber

Excessive smoke

• Worn cylinder, piston or piston ring
• Improper installation of piston rings
• Scored or scratched piston or cylinder wall

Abnormal noise

• Worn piston pin or piston pin hole
• Worn connecting rod small end
• Worn cylinder, piston or piston rings
• Worn main journal bearings
• Worn crankpin bearings

Engine vibration

• Excessive crankshaft runout
• Improper balancer timing
• Improper engine-to-jet pump alignment

TROUBLESHOOTING

Excessive exhaust noise

• Exhaust component cracked
• Exhaust gas and water leaks

Poor performance

• Exhaust component cracked
• Exhaust gas and water leaks
• Cooling water passage restricted
• Worn or damaged turbocharger wastegate valve (ARX1200T3/T3D)
• Seized turbocharger rotor (ARX1200T3/T3D)
• Faulty turbocharger wastegate actuator (ARX1200T3/T3D)

TROUBLESHOOTING

Abnormal noise from propulsion system

• Weeds/debris caught in intake grate or impeller
• Damaged or deflected drive shaft
• Worn or damaged bearings in jet pump or bearing housing
• Damaged drive shaft bearing housing
• Improper engine-to-jet pump alignment
• Broken engine mounts

Poor performance though engine runs properly

• Water intake area obstructed
• Excessive impeller clearance
• Impeller or water jet stator damaged

Engine runs too fast

• Jet pump cavitation
– Damaged leading or trailing edge of impeller
– Faulty sealing of intake grate or jet pump support
• Foreign material caught on impeller

Engine turns slowly when starting engine

• Restriction in jet pump
• Seizure in jet pump

Engine overheats

• Restricted jet pump water intake (water filter)

TROUBLESHOOTING

Poor steering control

• Steering cable improperly adjusted
• Steering cable damaged or improperly routed
• Steering nozzle pivot cracked or damaged
• No lubricant on steering components

Poor reverse lever and bucket operation

• Reverse cable improperly adjusted
• Reverse cable damaged or improperly routed
• Reverse bucket pivot cracked or damaged
• Reverse bucket arm or bucket catch damaged
• No lubricant on reverse control components

TROUBLESHOOTING

Starter motor does not turn
1. Fuse Inspection
2. Battery Inspection
3. Starter Relay Switch Operation Inspection
4. Starter Motor Inspection
Remove the safety lanyard switch from the engine stop switch. Apply battery voltage to the starter motor directly. Does the starter motor turn?

YES – • Poorly connected starter motor cable
NO – Faulty starter motor

5. Relay Coil Ground Line InspectionRemove the safety lanyard switch from the engine stop switch. Check the ground line of the starter relay switch. Is the ground line normal?

YES – GO TO STEP 6.
NO – Open circuit in the Green wire

6. Relay Coil Power Input Line Inspection

Check the power input line of the starter relay switch. Is the power input line normal?
YES – GO TO STEP 7.
NO – • Faulty engine stop switch

• Faulty starter switch
• Blown sub-fuse B (5 A)
• Faulty main relay or its circuits
• Loose or poor contact of the related connector
• Open circuit in the wire harness

7. Starter Relay Switch Inspection

Check the function of the starter relay switch. Does the starter relay switch function properly?

YES – Loose or poor contact starter relay switch connector
NO – Faulty starter relay switch


Service Manual, Repair Manual, Shop Manual, User's Manual, Workshop Guide, Study Guide, Download PDF Owner's Service Repair Manual, eBook, Learning Book, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 97, 98, 99, 00, 01, 02, 03, 04, 05, 06, 07, 08, 09, 10