Yamaha SUPER JET SJ650Q 1991 Bedienungsanleitung

PROTECT YOUR INVESTMENT

Use Genuine YAMAHA Parts And Accessories

LIT-18616-00-77

Service Manual

SUPER JET

SJ650Q

LIT-18616-00-77

Service Manual

YAMAHA MOTOR CORPORATION, U.S.A.

PRINTED IN U.S.A.

SJ650Q

18616-00-77 CVR_R 8/16/05 8:52 PM Page 1

)

.YAMAHA

) .

) SUPER

JET

SJ650Q

A20000-1

NOTICE

This manual has been prepared by the Yamaha Motor Corporation,

U.S.A.

primarily for use

by Yamaha dealers and theirtrained mechanics when performing maintenance procedures

and repairs to Yamaha equipment. It has been written to suit the needs

persons who have

a basic understanding

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 Corporation,

U.S.A.

has a policy

continuously improving its

products, models may differ in detail from the descriptions and illustrations given in this

publication. Use only the latest edition

this manual. Authorized Yamaha dealers are

notified periodically

modifications and significant changes in specifications and pro-

cedures, and these are incorporated in successive editions

this manual.

A10001-1"

SUPER

JET

(SJ650Q)

SERVICE MANUAL

1991

Yamaha Motor Corporation, U.S.A.

1st Edition, September

1991

No part

this publication may

reproduced

or transmitted in any form

by any means

including photocopying and recording without

the written permission

the copyright holder.

Such written permission must also be obtained

before any part

this

publication is stored

in a retrieval system

any nature.

Printed in Japan

P/N

LIT-18616-00·77

A507IJO.O

HOW

USE

THIS MANUAL

MANUAL FORMAT

All

the procedures in this manual are organized

a sequential, step-by-step format. The

information has been complied to provide the mechanic with

easy to read, handy refe-

rence that contains comprehensive explanations of all disassembly, repair, assembly, and

inspection operations.

this revised format, the condition

a faulty component will precede

arrow symbol and

the course

action required will follow the symbol,

e.g.,

• Bearings

Pitting/Damage

.....

Replace.

To assist you

find your way about this manual, the Section Title and Major Heading is

given at the head

every

page.

Index to contents is provided on the first page

each Section.

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

illustrated.

(The

name of model described will

mentioned in the description).

REFERENCES

These

have

been kept to a minimum; however, when you are referred to another section

the manual, you are told the page number to

to.

WARNINGS, CAUTIONS

AND

NOTES

Attention is drawn

the various Warnings, Cautions and Notes which distinguish impor-

tant information in this manual in the following ways.

~The'Safety

Alert Symbol means ATTENTION!

BECOME

ALERT!

YOUR

SAFETY

IN-

VOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury

death

the water

vehicle operator, a bystander, or a peason inspecting or repairing the water vehicle.

;lttiiRIII!I;I

__________________________

CAUTION

indicates special precautions that must be taken

avoid damage

the water

vehicle.

NOTE:----------------------------------------------------

NOTE

provides key information to make procedures easier or clearer.

HOW

READ DESCRIPTIONS

easy-to-see disassembly illustration is mainly provided for a disassembly job.

Numbers are given

the order

a disassembly job

the disassembly illustration.

explanation

jobs and notes is presented

easy-to-read way by the

use

symbol marks. The meanings

the symbol marks

are

given

the next page.

A job instruction chart accompanies the assembly illustration, providing the order of

jobs, names

parts, notes in jobs, etc.

5.1n

addition

the disassembly illustration, "REMOVAL POINTS" is provided

supple-

ment

detail the explanation which does or cannot necessarily cover the main jobs.

6. Jobs necessary before and afterthosewhich are not included in the disassembly illustra-

tion are explained before the same illustration as related jobs.

Section

® Preparation for removal

@ Order of removal

@)Part

name

@O'ty

__.ID

1.1

REED

VALVE,

CYLINDER

HEAD,

CYLINDER

POWR.

AND

PISTON

REED

VALVE,

CYLINDER

HEAD,

CYLINDER

AND

PISTON

PREPARA110N

FOR

REMOVAL

~§;;;.~;:.

• RernowetM cartlureiOf.

®Remarks

0 Removal point

® Extent of removal

®Symbol

mark

@ Exploded diagram

,.,

REED

VALVE,

CYLINDER

HEAD,

CYLINDER

POWR

AND

PISTON

N01I

REMOVAL

REASSEMBLY

•With the engine mounted,

tht

following

pans

can

removed.

•BeloreS«Vic:ing.cteanti'HtpartJ.

and

takecareaotl'lat

foreign maltlrlal

not

.mer

the

...........

•RM!ove

the

gutcet

adhclnld

the

contec:Ung

surtKe.

•Take

care

not

scratch

the

contacttng surface

when

removing the cyfinderand cylinder

.....

•Take care

not

$CfKtCtt

the cyllndel'

and

pleton surface.

•For

I'UIMiftbly, the

removed

parts

should be

c:leanecl

with solvent,

and

appty the two-

cycle OUlboafd oil

cmto

the sliding surface.

®<

Extent ol

removal:

@Reed

valVe

ntniO\'al ® Cylinder head removal

®Cylinder

removal ® Piston

and

I»Ston ring removal

Extent

rei!IO'Ial

Order

Part

name

Q'ty

Remarks

2 lntakemanllofd

1 Bolt s 1

14'

Clomp~

................

Exhaust

no.

7 Clamp

8 Clamp

9 Boll

10 Mulllef, 2

Boll

Muffter.t

13 Bolt

14 Cyllnderheacl

15 Bolt

16 Cylinder

Clip

18 Piston pin

IStnall

end

bearing

Pi$ton

ring

Loosen

the

screw.

Loosen the

sorew.

1~~~~1

•

·I

l~8~ltitl

IPOWRI•I

(j)

ELEcJUJ

IJ~~~I

? I

•

1~1

[ij]

a·

572

SPEC

o-1

FUEL

_i)

JET I

:PUMP:-

--:

1~85~1

•I I

[g]

@ 1

242

A50000·IJ.4

SYMBOLS

Symbols

® are designed as thumb-

tabs to indicate the content

a chapter:

General Information

Specification

Inspection and adjustment

@ Fuel System

®Power

Unit

Jet

Pump

Unit

(j)

Electrical System

® Hull and Hood

®Trouble-shooting

Symbols

indicate specific data:

Special tool

®Lubricant

® Engine speed

@Tightening torque

@ Specified value, Service limit

@ Resistance

(!J),

Voltage

(V),

Electric current

(A)

Symbol @ to

exploded diagram

indicate grade

lubricant and location

lubrication point:

@Apply

Yamaha two-cycle outboard oil

(Yamalube two-cycle outboard oil,

Yamalube

@ Apply water registance grease

(Yamaha grease

Yamaha marine

grease)

@ Apply water registance grease

(Yamaha grease

Yamaha marine

grease)

Symbols @ to @ in an exploded diagram

indicate grade

sealing or locking agent,

and location

application point:

@ Apply Gasket maker

Apply LOCTITE No.

242

(Blue

LOCTITE)

@ Apply LOCTITE No.

572

@Apply

Silicone sealant

@Apply

Yamabond

(Yamaha bond

No.4)

NOTE:-----------

In this manual, the above symbols may not

be used

every case.

ELECTRICAL

SYSTEM

HULL AND

HOOD

TROUBLE-SHOOTING

ELEC

•

HULL

HOOD

•

TRBL

SHTG

CHAPTER

GENERAL INFORMATION

IDENTIFICATION NUMBERS ..........................................................................

1-1

PRIMARY I.D. NUMBER .............................................................................

1-1

ENGINE SERIAL NUMBER ........................................................................

1-1

PUMP SERIAL NUMBER ...........................................................................

1-1

HULL

IDENTIFICATION NUMBER (H.I.N.) ...............................................

1-1

DIMENSIONS ....................................................................................................

1-2

SAFETY

WHILE

WORKING .............................................................................

1-3

FIRE PREVENTION ....................................................................................

1-3

VENTILATION .............................................................................................

1-3

SELF-PROTECTION ....................................................................................

1-3

OILS, GREASES AND SEALING FLUIDS ................................................

1-3

GOOD WORKING PRACTICES .................................................................

1-4

DISASSEMBLY AND ASSEMBLY .............................................................

1-4

SPECIAL TOOLS ...............................................................................................

1-5

FOR TUNE-UP .............................................................................................

1-5

FOR POWER UNIT SERVICE ....................................................................

1-6

FOR JET UNIT SERVICE ...........................................................................

1-7

IDENTIFICATION NUMBERS

MODEL._!

___,l

EW2._l

1-1

IDENTIFICATION NUMBERS

PRIMARY I.D. NUMBER

The primary

1.0.

number is stamped

plate attached

the inside

the engine

compartment.

Starting Primary

J.D.

Number:

811701

ENGINE SERIAL NUMBER

The engine serial number is stamped

plate attached to the intake manifold.

Starting serial number:

016911

PUMP SERIAL NUMBER

The

jet

pump unit serial number is stamped

on a plate attached on the intermediate

housing.

Starting serial number:

517111

HULL IDENTIFICATION NUMBER (H.I.N.)

The H.I.N. is stamped on the rear end

the

footrest floor.

,.~~~

I •

·I

DIMENSIONS

A60750:0'

DIMENSIONS

1,525 mm (60.0 in)

90mm

(3.54

in)

660

(26.0 in)

1-2

(X)

"""

680

(26

8 in)

~;,-

__,?=

~~I

~~~

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