Yamaha XLT1200 WaveRunner 2003 Bedienungsanleitung

YAMAHA

WaveRunner

LT1200

^SERVICE MANUAL

<pMANUEM)™RETIEN

<S)WARTUNGSHANDBUCH

^MANUAL

SERVICIO

^=-

460068

FOV-28197-2D-C1

"^'

SPEC

TIGHTENING

TORQUES

TIGHTENING

TORQUES

SPECIFIED

TORQUES

Part

tightened

ENGINE

Muffter

cover

muffler

Exhaust

chamber

stay/

1st

cylinder

head-cylinder

2nd

Exhaust

chamber/stay

bracket

Exhaust

chamber

joint -

exhaust

manifold

Exhaust

chamber -

exhaust

chamber

joint

Muffler-eye

Eye-cylinder

head

Muffler

stay

cylinder

body

Muffler

stay

-crankcase

Muffler

muffler

stay 2

Exhaust

temperatur

sensor -

muffler

Muffler

stay-catalyst

1st

housing/muffler

2nd

Water

temperature

sensor -

mixing

Joint

Muffler-catalyst

housing

Muffler-mixing

joint

Exhaust

manifold -

cylinder

1st

2nd

1st

2nd

1st

2nd

1st

2nd

Water

pipe

exhaust

manifold

Engine-engine mount

Reed

valve

plate/reed

valve -

crankcase

Reed

valve

reed

valve

base

YPVS

cable

holder/valve

cover -

cylinder

YPVS

valve

cover

cylinder

YPVS

valve

arm

shaft

YPVS

valve

assembly

cylinder

Spark

plug

cylinder

head

1st

Cylinder

head

cover/

cylinder

head

cylinder

Part

name

Thjead

Q'ty ,

TightemngJ°rque,

size

~''

N'm

kgf'm

ft'lb

Bolt

Nut

Bolt

Nut

Bolt

Screw

Bolt

M10

Spark

plug

M14

M10

Bolt

1.2

1.5

3.5

3.9

1.5

3.9

2.0

1.5

3.3

1.1

2.2

3.9

1.5

3.9

1.2

1.7

1.2

1.0

0.3

0.4

2.5

2.2

3.5

8.7

8.0

8.7

0.6

7.2

2.2

2.9

Remarks

<a.

-<3E

-<UE

<a.

-<3s

-<3a

-<3S

5 S

-<3s

2-7

SPEC

TIGHTENING

TORQUES

Part

tightened

Cylinder

crankcase

Generator

cover -

crankcase

Generator cover/ground

lead

crankcase

Bracket

crankcase

Pickup

coil

generator

cover

Stator

coil

generator

cover

Drive

coupling

crankshaft

1st

2nd

1st

2nd

1st

2nd

Flywheel

magneto-crankshaft

1st

2nd

Upper

crankcase

lower

crankcase

Engine

bracket

lower

1st

crankcase

2nd

JET

PUMP

UNIT

Steering

cable

joint

jet

thrust

nozzle

Ride

plate-

hull

Intake

duct-

hull

Intake

grate-

hull

Speed

sensor

ride

plate

Roller

reverse

gate

stay

Nozzle

ring

nozzle

Jet

thrust

nozzle

ring

Water

inlet

cover/water

inlet

strainer

impeller

duct

Drive

shaft

nut

drive

shaft

Impeller

(left-hand

threads) -

drive

shaft

Transom

plate

hull

Bilge

strainer

holder-

bulkhead

Intermediate

housing

bulkhead

Driven

coupling

shaft

Grease

nipple

intermediate

housing

HULL

AND

HOOD

Handlebar

holder

steering

master

Handlebar

cover

stay

steering

master

Part

name

Thread

Q'ty

Bolt

Drive

coupling

Bolt

Nut

Bolt

Screw

Bolt

Nut

Bolt

Nut

Impeller

Nut

Screw

Bolt

Driven

coupling

M10

M16

M22

M10

M24

Nipple —

Tightening

torque

N'm

kgf'm

ft'lb

3.6

3.7

3.6

7.4

1.5

2.7

1.1

1.5

2.7

0.7

1.7

0.7

0.4

0.8

2.6

1.5

0.7

7.4

1.8

2.6

1.7

3.6

0.5

8.0

5.1

2.9

5.8

5.1

2.8

3.6

Remarks

-<3a

<a.

-Og

E2s

-<3S

a S

-<3e

-<3?i

-d.

<a.

-<3s

-0s,

-<UE

-<3s

Bolt

0.8

2-8

SPEC

TIGHTENING

TORQUES

Part

tightened

Handlebar

handlebar

cover

stay

Handle

boss

cover

steering

master

QSTS

converter-hull

Throttle

lever

assembly -

handlebar

Handlebar

switch

assembly -

handlebar

QSTS

grip

assembly-

handlebar

Grip

end-

handlebar

Cable

housing

QSTS

grip

assembly

Steering

master-deck

Steering

cable

ball

joint -

steering

arm

QSTS

cable

locknut

(nozzle

ring

side)

QSTS

cable

grommet

hull

QSTS

cable

end

QSTS

con-

verter

Shift

cable

locknut

(reverse

gate

side)

Shift

cable

grommet

hull

Shift

cable

holder

shift

lever

base

Steering

cable

locknut

(jet

thrust

nozzle

side)

Steering

cable

grommet

hull

Steering

cable

bracket-deck

Speed

sensor

lead

grommet-

hull

Mirror-front

hood

Notch

deck

Hood

lock

assembly

front

hood

assembly

Hinge

assembly

front

hood

assembly

Hinge

assembly

deck

Steering

console

cover

deck

Shift

lever

handle

shift

lever

lot

water

outlet-

hull

Shift

lever

plate

deck

Shift

lever

plate

deck/shift

lever

base

assembly

Shift

lever

base

assembly

Part

name

Thread

Q'ty

Screw

Bolt

Screw

Bolt

Screw

Nut

Bolt

Nut

Bolt

Nut

Screw

Bolt

Nut

Bolt

Nut

Bolt

Nut

Screw

Bolt

M6 4

M6 2

M5 2

Tightening

torque

N'm

kgf'm

ft'lb

0.8

0.5

0.3

0.1

2.0

0.7

0.3

0.6

0.4

0.3

0.6

0.5

0.6

0.5

0.6

0.7

1.7

0.6

0.5

0.4

0.5

0.7

3.6

2.2

0.7

5.1

2.2

4.3

2.9

2.2

4.3

3.6

4.3

3.6

4.3

5.1

4.3

3.6

2.9

3.6

Remarks

-<3S

-<3r

-^s,

-<3s

2-9

SPEC

TIGHTENING

TORQUES

Part to

tightened

Part

name

Hand

grip-deck

Nut

Front

seat

stay

deck

Nut

Seat

lock

notch

deck

Nut

Rear

seat

stay

deck

Nut

Seat

lock

assembly-seat

Bolt

Plate/exhaust

rubber

hose

hull

Bolt

Sponson-hull

Nut

Cleat-deck

Nut

Spout-hull

Nut

Rope

hole-hull

Nut

Bow

eye-hull

Nut

Drain

plug/packing

hull

Nut

Engine

mount-hull

Bolt

Engine

damper-hull

Bolt

Thread

size

M10

>...

Tightening

torque

N-m

kgf-m

ft-lb

3.6

4.3

6 6

4.3

3.6

1.4

3.6

Remarks

Nut

Bolt i

M10

M12

General

torque

specifications

N'm

kgf'm

ft'lb

3.6

5.8

GENERAL

TORQUE

This

chart

specifies

tightening

torques

for

standard

fasteners

with

standard

ISO

thread

pitch.

Tightening

torque

specifica-

tions

for

special

components

assemblies

are

provided

applicable

sections

this

manual.

avoid

warpage,

tighten

multi-

fastener

assemblies

crisscross

fashion

and

progressive

stages

until

the

specified

tightening

torque

reached.

Unless

other-

wise

specified,

tightening

torque

specifica-

tions

require

clean,

dry

threads.

Components

should

room

tempera-

ture.

2-10

SPEC

CABLE

AND

HOSE

ROUTING

CABLE

AND

HOSE

ROUTING

CE^

IO^D

M-M

L-L

K-K

N-».

~-^

L L

E E

F F

K K

H H

A-A

J_[

L^O

E-E

F-F

J-J

I 8

G-G

H-H

Fuel

tank

breather

hose

Cooling

water

hose

QSTS

cable

Choke

cable

Fuel

hose

Shift

cable

Steering

cable

Fuel

filter

Ventilation

hose

Starter

motor

lead

Electrical

box

lead

Generator

lead

YPVS

cables

Speed

sensor

lead

YPVS

servomotor

Cooling

water

pilot

outlet

Throttle

cable

Battery

positive

lead

Battery

breather

hose

Battery

negative

lead

Oil

pump

cable

Choke

knob

Fuel

cock

2-11

SPEC

CABLE

AND

HOSE

ROUTING

E-E

7 8

E E

<<-D

F F

G-G

Throttle

cable

Handlebar

switch

lead

QSTS

cable

Buzzerlead

(5)

generator

battery

positive

terminal

starter

motor

muttifunction

meter

water/exhaust

temperature

sensor

Battery

negative

lead

Battery

breather

hose

Bilge

hose

Flushing

hose

Speed

sensor

lead

Fuel

tank

breather

hose

fuel

filter

Choke

cable

Fuel

return

hose

Shift

cable

Steering

cable

2-12

POWR

CHAPTER 5

POWER

UNIT

EXHAUST

CHAMBER

ASSEMBLY................................................................

5-1

EXPLODED

DIAGRAM.............................................................................

5-1

REMOVAL

AND

INSTALLATION

CHART...............................................

5-1

MUFFLER

ASSEMBLY...................................................................................

5-5

EXPLODED

DIAGRAM.............................................................................

5-5

REMOVAL

AND

INSTALLATION

CHART...............................................

5-5

SERVICE

POINT......................................................................................

5-10

Catalyst

inspection..........................................................................

5-10

EXHAUST

MANIFOLD

AND

LEADS............................................................

5-1 1

EXPLODED

DIAGRAM...........................................................................

5-11

REMOVAL

AND

INSTALLATION

CHART.............................................

5-11

ENGINE

UNIT ...............................................................................................

5-15

EXPLODED

DIAGRAM...........................................................................

5-15

REMOVAL

AND

INSTALLATION

CHART.............................................

5-15

SERVICE

POINTS...................................................................................

5-17

Shim

removal..................................................................................

5-17

Engine

mount

inspection ...............................................................

5-17

Coupling

clearance

inspection.......................................................

5-17

REED

VALVES..............................................................................................

5-18

EXPLODED

DIAGRAM...........................................................................

5-18

REMOVAL

AND

INSTALLATION

CHART.............................................

5-18

SERVICE

POINTS...................................................................................

5-19

Reed

valve

inspection.....................................................................

5-19

YPVS.............................................................................................................

5-20

EXPLODED

DIAGRAM...........................................................................

5-20

REMOVAL

AND

INSTALLATION

CHART.............................................

5-20

SERVICE

POINTS...................................................................................

5-23

YPVS

valve

inspection....................................................................

5-23

YPVS

valve

installation...................................................................

5-23

CYLINDER

HEAD..........................................................................................

5-24

EXPLODED

DIAGRAM...........................................................................

5-24

REMOVAL

AND

INSTALLATION

CHART ............................................

5-24

SERVICE

POINTS...................................................................................

5-26

Cylinder

head

inspection................................................................

5-26

POWR

CE^

CYLINDERS...................................................................................................

5-27

EXPLODED

DIAGRAM...........................................................................

5-27

REMOVAL

AND

INSTALLATION

CHART.............................................

5-27

SERVICE

POINTS...................................................................................

5-28

Cylinder

inspection.........................................................................

5-28

PISTONS.......................................................................................................

5-29

EXPLODED

DIAGRAM...........................................................................

5-29

REMOVAL

AND

INSTALLATION

CHART.............................................

5-29

SERVICE

POINTS...................................................................................

5-31

Piston

clip

removal

and

installation........................................

5-31

Piston

inspection.............................................................................

5-31

Cylinder

and

piston

combination ..................................................

5-32

Piston

ring

inspection.....................................................................

5-32

Piston

and

bearing

inspection .................................................

5-33

GENERATOR

AND

STARTER

MOTOR........................................................

5-35

EXPLODED

DIAGRAM...........................................................................

5-35

REMOVAL

AND

INSTALLATION

CHART ............................................

5-35

SERVICE

POINTS...................................................................................

5-41

Drive

coupling

removal

and

installation .......................................

5-41

Flywheel

magneto

removal

and

installation ................................

5-41

Drive

coupling

inspection...............................................................

5-42

Flywheel

magneto

inspection........................................................

5-42

Starter

clutch

assembly

inspection ...............................................

5-42

CRANKCASE.................................................................................................

5-43

EXPLODED

DIAGRAM...........................................................................

5-43

REMOVAL

AND

INSTALLATION

CHART.............................................

5-43

SERVICE

POINTS...................................................................................

5-45

Crankcase

inspection......................................................................

5-45

Crankcase

installation.....................................................................

5-45

CRANKSHAFT...............................................................................................

5-46

EXPLODED

DIAGRAM...........................................................................

5-46

REMOVAL

AND

INSTALLATION

CHART.............................................

5-46

SERVICE

POINTS...................................................................................

5-47

Crankshaft

inspection.....................................................................

5-47

POWR

EXHAUST

CHAMBER

ASSEMBLY

EXHAUST

CHAMBER

ASSEMBLY

EXPLODED

DIAGRAM

• m

(3.

kgf

• m,

• Ib)

10x135

• m

(3.

kgf

• m,

• Ib)

10x70

(1.

kgf-m,

• Ib)

6x22

271

1st

N •md.

5kgf.

rn,

• Ib)

2nd

«m

(3.

kgf'm,

25ft*

Ib)

(0.

kgf'm,

ft.

lb)

•'c:

271

• m

(3.

kgf

• m,

• Ib)

10x85

(0.

kgf.

1ft-Ib)

REMOVAL

AND

INSTALLATION

CHART

Q'ty

Step

Procedure/Part

name

EXHAUST

CHAMBER

ASSEMBLY

REMOVAL

Exhaust

temperature

sensor

coupler

Cap/bolt

Cover

Clamp/cooling

water

hose

Hose

clamp

Hose

clamp

Service

points

the

left

"Step"

for

removal.

3/3

4/4

For

cooling

water

pilot

outlet

starboard

side

For

cooling

water

pilot

outlet

port

side

Slide

the

outer

exhaust

joint.

5-1

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