Water Vehicles

WaveRunner
XL760
XL 1200

SERVICE
MANUAL

LIT-18616-01-88 460043
 PREFACE

This manual has been prepared by the Yamaha Motor Company primarily for use by Yamaha dealers
and their trained mechanics when performing maintenance procedures and repairs to Yamaha equip-
ment. It has been written to suit the needs of persons who have a basic understanding of the mechani-
cal 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 Company Ltd. 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 signifi-
cant changes in specifications and procedures, and these are incorporated in successive editions of
this manual.

XL760, XL 1200
SERVICE MANUAL
©1997 Yamaha Motor Co., Ltd.
1st Edition, October 1997
All rights reserved.
No part of this publication may be
reproduced or transmitted in any form or
by any means including photocopying and
recording without the written permission of
the copyright holder.
Such written permission must also be
obtained before any part of this publication
is stored in a retrieval system of any nature.
Printed in USA
PIN L1T-18616-01-88
 HOW TO USE THIS MANUAL
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information
has been complied to provide the mechanic with an easy to read handy reference that contains com-
prehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the course
of action required will follow the symbol, e.g.,
• Bearings
Pitting/Damage --+ Replace.

To assist you to find your way about this manual, the Section Title and Major Heading is given at the
head of every page.

An Index to contents is provided on the first page of each Section.

MODEL INDICATION
Multiple models are shown in this manual. These indications are noted as follows.

WaveRunner XL760 Wave Runner XL 1200

Model name
XL760 XL1200

Indication XL760 XL1200

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 be illustrated. (The name of model de-
scribed will be mentioned in the description).

REFERENCES
These have been kept to a minimum; however, when you are referred to another section of the manual,
you are told the page number to go to.
WARNINGS, CAUTIONS AND NOTES
Attention is drawn to the various Warnings, Cautions and Notes which distinguish important informa-
tion in this manual in the following ways.

& The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS IN-
VOLVED!

A WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the water vehicle .

. CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the water ve-
hicle.

NOTE:-----------------------------------------------------------
A NOTE provides key information to make procedures easier or clearer.

IMPORTAN~ ------------------------------------------------------
This part has been subjected to change of specification during production.
HOW TO READ DESCRIPTIONS
1. A disassembly installation job mainly consists of the exploded diagram CD.
2. The numerical figures represented by the number ® indicates the order of the job steps.
3. The symbols represented by the number @ indicates the contents and notes of the job. For the
meanings of the symbols, refer to the next page(s).
4. The REMOVAL AND INSTALLATION CHART@ is attached to the exploded diagram and explains
the job steps, part names, notes for the jobs, etc.
5. The SERVICE POINTS, other than the exploded diagram, explains in detail the items difficult to
explain in the exploded diagram or REMOVAL AND INSTALLATION CHART, the Service points
requiring the detailed description ®, etc.

l"tJUpl--1 NOZZLE. DUCT AND INTAKE l'4L 1~~pl--1 NOZZLE, DUCT AND INTAKE
NOZZLE, DUCT AND INTAKE ~ ~REMOVAl AND INSTAllATION CHART
EXPLODED DIAGRAM 100 rocedur. ,"~m. IV
NOZZlE. DUCT AND INTAKE
DlSASSEMIl V
Jet pump unit R,f.t to the "JET PUMP UNIT
REMOVAL- hCtion.
Bolt (with wI.h,r'
CollI(
Nonie deflector ....mbty
80"
[Link] duet
Pin
Houslng

I.
Pin
Impen., duct ".embty
Pin
11 NOllie
12 Bolt Iwith washer)

,.
13 St*=8'

,.
n
15
011 ..,1
Bushing
801t (with w ••her)
Inllklscr',n
NOULE DEFLECTOR DfSAS·
IEMBlY
<D Bolt (with w ..h,r) 2 8><20mm
(j) Coli"
(j) Nul
tj) PII1I wisher
(j) [Link]
<il Noule def&tctor
(!) Nut M8
(j) Pletew"h"
(j) a,II;oint
tD Trlmrlnv
[Link] the remov.1 steps for mll.n-lion.

,.,
 CD
SYMBOLS
CD ® Symbols CD to® are designed as thumb-tabs to

I~~I
@
IIiI .IISPECI r
@
I indicate the content of a chapter:

CD General Information
® Specifications

P~gSI~1 IFUELI ,i) I

@ Periodic Inspection and Adjustment
@ Fuel System
@ Power Unit
@ @
@ Jet pump Unit

IPOWRI&I Ipt~pl ..I (J) Electrical System

® Hull and Hood
(J) ~ ® Trouble analysis
HULL
IELEClul HOOD •• Symbols ® to ® indicate specific data:

® Special tool
® ®

I ~
@ Specified liquid

Il~~~ ? @ Specified engine speed

@ Specified torque
~ Specified measurement
@ @

~ ~
® Specified electrical valve
[Resistance (Q), Voltage (V),
Electric current (A)]

@ ~

~ ~
Symbol® to® in an exploded diagram indicate
grade of lubricant and location of lubrication
point:

® ® ® Apply Yamaha 2-stroke outboard motor oil

[iJ ~
@ Apply water resistant grease (Yamaha
grease A, Yamaha marine grease)
® Apply molybdenum disulfide grease
@ ® Symbols @ to @ in an exploded diagram indi-
~ ~ cate grade of sealing or locking agent, and loca-
tion of application point:
@ Apply Gasket maker@
@ @
@ Apply Yamahabond #4 (Yamaha bond No.4)
~ ~ @ Apply LOCTITE@ No.271 (Red LOCTITE)
@ Apply LOCTITE@ No.242 (Blue LOCTITE)
@ @ @ Apply LOCTITE@ No.S72

A271
A
242
@ Apply Silicon sealant
NOTE:-------------------------
In this manual, the above symbols may not be

a
@ @

•
used in every case.

572
 INDEX
GENERAL INFORMATION GEN
INFO

SPECIFICATIONS

PERIODIC INSPECTION AND

ADJUSTMENT

FUEL SYSTEM

POWER UNIT

JET PUMP UNIT

ELECTRICAL SYSTEM
o
HULL AND HOOD

?
TROUBLE ANALYSIS •
 CHAPTER 1
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

SAFETY WHILE WORKING . .................................... 1-2

FIRE PREVENTION ......................................... 1-2
VENTILATION .............................................. 1-2
SELF-PROTECTION ........................................ 1-2
OILS, GREASES AND SEALING FLUiDS ...................... 1-2
GOOD WORKING PRACTiCES .............................. 1-3
DISASSEMBLY AND ASSEMBLy ............................. 1-4

SPECIAL TOOLS .............................................. 1-5

MEASURING ............................................... 1-5
REMOVAL AND INSTALLATION .............................. 1-6

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1~~I+cl_ID_E_N_TI_F_IC_A_TI_O_N_N_U_M_B_E_R_S_ _ _ _ _ _ _C_~_~_
IDENTIFICATION NUMBERS
PRIMARY 1.0. NUMBER
The primary 1.0. number is stamped on a label
CD attached to the inside of the engine com part-
ment.

Starting primary 1.0. number:

GU2: 800101 -,600101 - (EUR)
GU3: 800101 -,600101 - (EUR)

ENGINE SERIAL NUMBER

The engine serial number is stamped on a label
® attached to the crankcase.
Starting serial number:
660: 000101 -
66F:000101 -

t\ 61

PUMP SERIAL NUMBER

The jet pump unit serial number is stamped on a
label @ attached on the intermediate housing.

Starting serial number:

500101 -

HULL IDENTIFICATION NUMBER (H.I.N.)

The H.I.N. is stamped on a plate@ attached to
the rear end of the footrest floor.

1-1

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~IG~~EF~NO~6_'_rt~I
_ . _____ ~WHILE
SAFETY _________________________
WORKING C_gE_~_
SAFETY WHILE WORKING
The procedures given in this manual are those
recommended by Yamaha to be followed by Ya-
maha dealers and their mechanics.

FIRE PREVENTION
Gasoline (petrol) is highly flammable.
Petroleum vapor is explosive if ignited. Do not
smoke while handling gasoline (petrol), and
keep it away from heat, sparks, and open
flames.

VENTILATION
Petroleum vapor is heavier than air and if in-
haled in large quantities will not support life. En-
gine exhaust gases are harmful to breathe.
When test-running an engine indoors, maintain
good ventilation.

SELF-PROTECTION
Protect your eyes with suitable safety spec-
tacles or safety goggles when using com-
pressed air, when grinding or when doing any
operation which may cause particles to fly off.
Protect hands and feet by wearing safety gloves
or protective shoes if appropriate to the work
you are doing.

OILS, GREASES AND SEALING FLUIDS

Use only genuine Yamaha oils, greases and
sealing fluids or those recommended by Yama-
ha.

1-2

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,--IG~_EFNQ~6_'_c~I
_ . ________________________________
SAFETY WHILE WORKING C_g~~_
Under normal conditions of use, there should be
no hazards from the use of the lubricants men-
tioned in this manual, but safety is all-important,
and by adopting good safety practises, any risk
is minimized. A summary of the most important
precautions is as follows
1. While working, maintain good standards of
personal and industrial hygiene.
2. Clothing which has become contaminated
with lubricants should be changed as soon
as practicable, and laundered before fur-
ther use.
3. Avoid skin contact with lubricants; do not,
for example, place a soiled wiping-rag in
one's pocket.
4. Hands, and any other part of the body which
have been in contact with lubricants or lubri-
cant-contaminated clothing, should be thor-
oughly washed with hot water and soap as
soon as practicable.
5. To protect the skin, the application of a suit-
able barrier cream to the hands before
working is recommended.
6. A supply of clean lint-free cloths should be
available for wiping purposes.

GOOD WORKING PRACTICES

1. The right tools
Use the special tools that are designed to
protect parts from damage. Use the right
tool in the right manner - don't improvise.
2. Tightening torque
Follow the torque tightening instructions.
When tightening bolts, nuts and screws,
tighten the larger sizes first, and tighten in-
ner-positioned fixings before outer-posi-
tioned ones.

1-3

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~F~N~~~~~6_'_c~I __SA_F_E_T_Y_W__H_IL_E_W_O_R_K_I_N_G________________C_g__~
3. Non-reusable items
Always use new gaskets, packings, 0-
rings, oil seals, split-pins and circlips etc. on
reassembly.

DISASSEMBLY AND ASSEMBLY

1. Clean parts with compressed-air on disas-
sembling them.
2. Oil the contact surfaces of moving parts on
assembly.

3. After assembly, check that moving parts op-

erate normally.

4. Install bearings with the manufacturer's

markings on the side exposed to view, and
liberally oil the bearings.

CAUTION:
Do not use compressed air to spin the bear-
ings dry. This causes damage to the bearing
surfaces.

5. When installing oil seals, apply a light coat-

ing of water-resistant grease to the outside
diameter.

1-4

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1~~I+·I_s_P_E_C_IA_L_T_O_O_L_S___________C_~_~_
SPECIAL TOOLS
Use of the correct special tools recommended
by Yamaha will aid the work and enable accu-
rate assembly and tune-up. Improvisations and
use of improper tools can cause damage to the
equipment.
NOTE:-------------------------
• For U.S.A. and Canada, use part numbers
starting with "YB-", "YU-" or "YW-".
• For other countries, use part numbers start-
ing with "90890-".

MEASURING
CD ~~~~:! 90890-01252 1. Dial gauge and stand

~
PIN. YU-03097, YU-01256
90890-01252
2. Digital multi meter
PIN. YU-34899-A
90890-06752
® YU-34899-A 90890-06752
3. Pocket tester

~~ !/q/j} PIN. YU-03112

90890-03112
4. Compression gauge
® YU-03112 90890-03112
PIN. YU-33223
90890-06751
5. Cylinder gauge set
PIN. YU-03017
90890-06759
6. Engine tachometer
@ YU-33223 90890-06751 PIN. YU-08036-A

c~
90890-06760
7. Spark gap tester
PIN. YM-34487
@ VU-03017 90890-06759 90890-06754

® YU-0803&-A 90890-06760

(j) YM-34487 90890-06754

1-5

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~IG~~EF~NO~6_·_·~I
_ . ________________________________
SPECIAL TOOLS C_~~)_
REMOVAL AND INSTALLATION
CD 1. Coupler wrench
YW-06546
~ YW·06547 90890.06547 PIN. YW-06546

~ VW~~5
90890-06546
__
2. Flywheel holder
PIN. YW-06547 (XL760)

.~ YW-41528 (XL 1200)

90890-06547 (XL760)
90890-06545 (XL 1200)
3. Flywheel puller
@ YB·06'" PIN. YB-06117
90890-06521
4. Shaft holder (Intermediate shaft)
PIN. YW-38742

90890·06521 &P 90890-06069

5. Driver rod
",JJIJJIJJI (Intermediate shaft and jet pump)
'l'p
PIN. YB-06071, YB-06229
90890-06602
® 90890-06605
YB '1. O X YB-06015 90890·06625
YB-06229 YB·06085 90890·06636 90890-06606
6. Bearing outer race attachment
~~:~~~~::~~
90890-06606
~ ~
~ (Intermediate shaft)

~
PIN. YB-06015, YB-06085
90890-06636, 90890-06625
7. Bearing attachment
(Jet pump bushing and oil seal)
(f) ®
YB·06021 90890·06638 PIN. YB-06021
YB·06155
90890·06611 90890-06638

~
8. Needle bearing attachment
~ ® ® (Jet pump oil seal)
PIN. YB-06155
90890-06611
® @ YB·06096
9. Drive shaft holder (Impeller)
YB·06049 PIN. YB-06049
~C---.~~
~
90890-06518
v'''_~~-:~
10. Slide hammer set (Jet pump bearing)
90890-06518 PIN. YB-06096
90890·06523

~ ~
90890·06531 90890-06523
90890-06531
11. Ball bearing attachment
(Jet pump oil seal)
PIN. YB-06156
@ @ 90890-06634
YB-06156 90890-06634 YB·34474
12. Bearing inner race attachment
(Jet pump bearing)

® @ @ PIN. YB-34474

1-6

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 CHAPTER 2
SPECIFICATIONS

GENERAL SPECIFICATIONS ................................... 2-1

MAINTENANCE SPECIFICATIONS .............................. 2-3

ENGINE ................................................... 2-3
JET UNIT .................................................. 2-4
HULL AND HOOD .......................................... 2-5
ELECTRICAL .............................................. 2-5

TIGHTENING TORQUE . ........................................ 2-6

SPECIFIED TORQUE ....................................... 2-6
GENERAL TORQUE ........................................ 2-7

FUEL LINE ROUTING .......................................... 2-8

XL760 ..................................................... 2-8
XL 1200 .................................................... 2-10

CABLE LINE ROUTING ........................................ 2-12

XL760 ..................................................... 2-12
XL 1200 .................................................... 2-14

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 GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
Item Unit
XL760 XL1200
MODEL CODE:
Hull GU2 GU3
Engine 66D 66F
DIMENSIONS:
Length mm (in) 3,150 (124.0) 3,150 (124.0)
Width mm (in) 1,250 (49.2) 1,250 (49.2)
Height mm (in) 1,100 (43.3) 1,100 (43.3)
Dry weight kg (Ib) 250 (551) 277(611)
Vehicle capacity 3 3
PERFORMANCE:
Maximum output kW (HP)/r/min 66.2 (90)/6,350 99.3 (135)/6,750
Maximum fuel I/h (US gal/h, 38 (10.04, 8.36) 53 (14.0,11.7)
consumption Imp (gal/h)
Crusing range hr. 1.5 0.9
ENGINE:
Engine type 2-stroke 2-stroke
Number of cylinders 2 3
Displacement cm 3 (cu. in) 754 (46.0) 1,131 (69.0)
Bore x stroke mm (in) 84.0 x 68.0 (3.31 x 2.68) 84.0 x 68.0 (3.31 x 2.68)

Compression ratio F: 7.2, R: 6.8 : 1 6:1

Intake system Reed valve Reed valve
Carburetor type Mikuni BN44 Mikuni BN44
Number of carburetors 2 3
Enrichment control Choke valve Choke valve
Scavenging system Loop charge Loop charge
Lubrication system Oil injection Oil injection
Cooling system Water Water
Starting system Electric Electric
Ignition system Digital CDI Digital CDI
Ignition timing Degree 15 BTDC - 22 BTDC 15 BTDC - 20 BTDC
Spark plug (NGK) BR8HS BR8HS
Battery capacity V/kC (Ah) 12 - 68.4 (19) 12 - 68.4 (19)
Lighting coil A/rpm 2 - 4/5500 6 - 8/6500
Propulsion system Jet pump Jet pump
DRIVE UNIT:
Jet pump type Axial flow Axial flow
single stage single stage
Impeller rotation Counter clockwise Counter clockwise
Transmission Direct drive from engine Direct drive from engine
Nozzle angle (horizontal) Degree 24 ± 1 24 ± 1
Trim angle Degree 5 5
Trim system N/A N/A
Reverse system Reverse gate Reverse gate

2-1

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 GENERAL SPECIFICATIONS
Model
Item Unit
XL760 XL1200
FUEL AND OIL:
Fuel Regular unleaded Regular unleaded
gasoline gasoline
Fuel rating PON*1/RON*2 86/90 86/90
Oil 2-stroke outboard 2-stroke outboard
motor oil motor oil
Fuel and oil mixing ratio 50: 1 45: 1
(wide open throttle)
Fuel tank capacity I (US gal, 50 (13.2, 11.0) 50 (13.2, 11.0)
Imp gal)
Reserve capacity I (US gal, 12 (3.17, 2.64) 12 (3.17, 2.64)
Imp gal)
Oil tank capacity I (US gal, 3.8 (1.00, 0,84) 3.8 (1.00, 0.84)
Imp gal)
*1: Pump Octane Number
*2: Research Octane Number

2-2

[Link]
ISPECI g. MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE

Model
Item Unit
XL760 XL1200
Cylinder head:
Warpage limit mm (in) 0.1 (0.004) 0.1 (0.004)
Compression pressure kPa (kg/cm2) - -
Cylinder:
Bore size mm (in) 84.00 - 84.02 84.00 - 84.02
(3.307 - 3.308) (3.307 - 3.308)
Taper limit mm (in) 0.08 (0.003) 0.08 (0.003)
Out of round limit mm (in) 0.05 (0.002) 0.05 (0.002)
Wear limit mm (in) 84.10 (3.31) 84.10 (3.31)
Piston:
Diameter mm (in) 83.902 - 83.921 83.902 - 83.921
(3.3032 - 3.3040) (3.3032 - 3.3040)
Measuring point* mm (in) 10 (0.39) 10 (0.39)
piston Clearanc~ mm (in) 0.100 - 0.105 0.100 - 0.105
o * (0.0039 - 0.0041) (0.0039 - 0.0041)
Wear limit mm (in) 0.155 (0.0061) 0.155 (0.0061)
Piston pin bore inside mm (in) 20.004 - 20.025 20.004 - 20.025
diameter (0.7876 - 0.7884) (0.7876 - 0.7884)
Piston ring:
Top
Type Keystone Keystone
Dimensions (B x T) mm (in) 1.5 x 3.2 (0.06 x 0.13) 1.5 x 3.0 (0.06 x 0.12)
End gap (installed) mm (in)

T~8
0.20 - OAO 0.20 - OAO
(0.008 - 0.016) (0.008 - 0.016)

Ring groove clearance mm (in) 0.02 - 0.07 0.02 - 0.07

(installed) (0.001 - 0.003) (0.001 - 0.003)
2nd
Type Keystone Keystone
Dimensions (B x T) mm (in) 1.5 x 3.2 (0.06 x 0.13) 1.5 x 3.0 (0.06 x 0.12)
End gap (installed) mm (in) 0.20 - OAO 0.20 - 0.40
(0.008 - 0.016) (0.008 - 0.016)
Ring groove clearance mm (in) 0.02 - 0.07 0.02 - 0.07
(installed) (0.0008 - 0.0028) (0.0008 - 0.0028)
Piston pin:
Diameter mm (in) 19.995 - 20.000 19.995 - 20.000
(0.7872 - 0.7874) (0.7872 - 0.7874)
Wear limit mm (in) - -

2-3

[Link]
 MAINTENANCE SPECIFICATIONS
Model
Item Unit
XL760 XL1200
Crankshaft assembly:
Crank width "A" mm (in) 61.95 - 62.00 61.95 - 62.00
(2.439 - 2.441) (2.439 - 2.441)
Deflection limit "8" mm (in) 0.05 (0.002) 0.05 (0.002)
Big end side clearance "e" mm (in) 0.25 - 0.75 0.25 - 0.75
(0.010 - 0.030) (0.010 - 0.030)
Maximum small end mm (in) 2.0 (0.08) 2.0 (0.08)
axial play "D"~

Carburetor:
Type Floatless Floatless
Manufacturer Mikuni Mikuni
Number of carburetours 2 3
Identification mark 64X01/02 65U01/02/03
Main nozzle (M.N.) mm (in) 3.2 (0.13) 3.2 (0.13)
Main jet (M.J.) 135 (01), 137.5 (02) 135
Pilot jet (P.J.) 115 100 (01 )/95 (02)1
97.5 (03)
Low speed screw turns out 1-314 ± 1/4 1 ± 1/4

Throttle valve 160 130

Valve seat mm (in) 1.5 (0.06) 1.2 (0.05)
High speed screw turns out 1/2±1/4 3/4 ± 1/4 (01, 03)
1 ± 1/4 (02)
Trolling speed r/min. 1,300 ± 50 1,300 ± 50
Reed valve:
Thickness mm (in) 0.4 (0.02) 0.5 (0.02)
Valve stopper height mm (in) 9.0 ± 0.2 (0.35 ± 0.01) 12.5 ± 0.2 (0.49 ± 0.01)
Valve warpage limit mm (in) 0.2 (0.01) 0.2 (0.01)

JET UNIT

Model
Item Unit
XL760 XL1200
Jet pump:
Impeller material SUS SUS
Number of impeller 3 3
blades
Impeller pitch degree 13.4 15.8
Impeller clearance mm (in) 0.25 - 0.35 0.25 - 0.35
(0.010 - 0.014) (0.010 - 0.014)
Impeller clearance limit mm (in) 0.6 (0.024) 0.6 (0.024)
Impeller sharf runout limit mm (in) 0.3 (0.012) 0.3 (0.012)
Nozzle diameter mm (in) 86.0 (3.39) 86.0 (3.39)

2-4

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ISPECI g. MAINTENANCE SPECIFICATIONS
HULL AND HOOD

Model
Item Unit
XL760 XL1200
Free play:
Throttle lever free play mm (in) 4 ~ 7 (0.16 ~ 0.28) 4 ~ 7 (0.16 ~ 0.28)
Choke cable free play mm (in) 1 ~ 6 (0.04 ~ 0.24) 1 ~ 6 (0.04 ~ 0.24)
Trim control wheel free play mm (in) - -
ELECTRICAL

Model
Item Unit
XL760 XL1200
Battery:
Type Fluid Fluid
Capacity VlkC (Ah) 12/68.4 (19) 12/68.4 (19)
Ignition timing:
Ignition timing degree 15 BTDC 15 BTDC
(at 1,200 r/min)
Ignition timing degree F: 20, R: 18 BTDC 21 BTDC
(at 5,500 r/min)
Stator assembly:
Pulser coil resistance n (color) 445.5 ~ 544.5 248.0 ~ 372.0
(W/R - W/B) (B-W/R, W/B, WIG)
Charge coil resistance 1 n (color) 316.8~387.2 (Br-L) 172.0 ~ 258.0 (BI R-Br)
Charge coil resistance 2 n (color) - 656.0~984.0 (L-B/R)
Lighting coil resistance n (color) 1.14 ~ 1.40 (G - G) 0.56 ~ 0.84 (G - G)
Charging current A/r/min. 2 ~ 4/5,500 5.8 ~ 7.8/5,500
(minimum)
Ignition coil:
Minimum spark gap mm (in) - -
Primary coil resistance n (color) 0.078~0.106 (Or-B) 0.048 ~ 0.072 (B/W-B)
Secondary coil resistance kn (color) 14.3 ~ 30.5 2.7 ~ 4.1
(High tension cords) (High tension cord-B)
Rectifier-regulator:
Regulated voltage V 14.3 ~ 15.3 14.5 - 15.5
Thermo switch:
On temperature °C (0 F) 90 - 96(194 ~ 205) 90 - 96(194 - 205)
Off temperature °C (OF) 76 - 90 (169 - 194) 76 ~ 90(169 - 194)
Starter motor:
Brush length mm (in) 12.5 (0.49) 12.5 (0.49)
Wear limit mm (in) 6.5 (0.26) 6.5 (0.26)
Comutator undercut mm (in) 0.7 (0.028) 0.7 (0.028)
Limit mm (in) 0.2 (0.008) 0.2 (0.008)
Comutator diameter mm (in) 28.0 (1.10) 28.0 (1.10)
Limit mm (in) 27 (1.06) 27 (1.06)
Fuse:
Rating V-A 12-10 12 -10
SPARK PLUG:
Spark plug gap mm (in) 0.6-0.7 (0.024-0.028) 0.6-0.7 (0.024-0.028)

2-5

[Link]
 TIGHTENING TORQUE
TIGHTENING TORQUE
SPECIFIED TORQUE

Part O'ty Tightening torque

Part to tightened Size Remarks
name 760 1200 Nm kgf-m Rib
ENGINE:
Electric box Bolt M8 2 3 17 1.7 12
Mounting bolt Bolt M8 4 4 17 1.7 12 -C?]~
Reed valve Screw M4 16 24 1 0.1 0.7 -<?],
J "

Exhaust ring Bolt M8 4 4 30 3.0 22 -C?]e

1st 22 2.2 16
Exhaust ring stay Bolt M10 3 - -<?]e
2nd 40 4.0 29
Muffler stay Bolt M10 4 4 40 4.0 29 -C?]~

Muffler stay - 1st 2 0.2 1.4

Bolt M10 2 2 -C?]e
Muffler stay 2 2nd 47 4.7 34
Muffler 2 Bolt M10 2 2 40 4.0 29 -<?]e
1st 22 2.2 16
Bolt M10 8 - -<?]e
2nd 40 4.0 29
Muffler 1
1st 15 1.5 11
Bolt M8 - 12 -<?]s
2nd 30 3.0 22
1st 23 2.3 17
Cylinder body Bolt M10 6 6 -<?lEi
2nd 40 4.0 29
1st 15 1.5 11
2nd
Bolt M8 10 -
36 26
-<?lEi
3.6
Cylinder head
1st 15 1.5 11
2nd
Bolt M8 - 14
30 3.0 22
-<?lEi
1st 15 1.5 11
Bolt M8 - 15 ~~ J n

2nd 30 3.0 22
Cylinder head cover
1st 4 0.4 2.9
Bolt M6 - 2 -<?l~
J n

2nd 8 0.8 5.8

Spark plug Bolt M14 2 3 25 2.5 18
Flywheel bolt Nut M10 1 1 70 7.0 51 --€l
1st 15 1.5 11
Crankcase Bolt M8 8 12 ~5
2nd 28 2.8 20
1st 23 2.3 17
Mount bracket Bolt M10 7 7 ~e
2nd 53 5.3 38
Coupling Nut M27 1 1 37 3.7 27 -<?l5
6 - 2 0.2 1.4 -<?l~
J n

Frame arrestor cover Bolt M6

- 8 5 0.5 3.6 -<?l5
Starter motor terminal nut Nut M6 1 1 5 0.5 3.6
JET UNIT:
M10 4 4 34 3.4 25
Mounting bolt Bolt -<?]"
J :

M6 2 2 12 1.2 8.7
Ride plate Bolt M8 4 4 17 1.7 12 ~i
Impeller (left-hand threads) Bolt M20 1 1 18 1.8 13 ~5
Coupling Nut M27 1 1 37 3.7 27 ~5
Intermediate housing Bolt M8 3 3 17 1.7 12 -C?]e

2-6

[Link]
 TIGHTENING TORQUE
General torque TIGHTENING TORQUE
GENERAL TORQUE
Nut@ Bolt ® specifications
This chart specifies the torque for tightening
Nm kgfem ftelb standard fasteners with standard clean dry ISO
8mm M5 5.0 0.5 3.6 threads at room temperature. Torque specifica-
10 mm M6 8.0 0.8 5.8 tions for special components or assemblies are
12 mm M8 18 1.8 13 given in applicable sections of this manual. To
14 mm M10 36 3.6 25 avoid causing warpage, tighten multifastener
17 mm M12 43 4.3 31 assemblies in a criss-cross fashion, in progres-
sive stages until the specified torque is reached.

2-7

[Link]
 FUEL LINE ROUTING CD
FUEL LINE ROUTING
XL760

Pass the oil hose

out side of belt

2-8

[Link]
ISPECI U· FUEL LINE ROUTING CD

Fuel hose
(Fuel cock-
Fuel filter)
~
~ Fuel hose
(return)
II
~'
"
Align mark

• ).
.
-;/f:) Allgo ma~

~
Fuel hose A-A iiI
i..~.
(Fuel COCk)fI(-Throttle cable .~ .'
Fuel filter) " .: .
(0 ,.~

Fuel hose Choke cable

(retuen) J.

Fuel hose~Throttle
(Fuel cock- h cable
Fuel filter) Choke
Fuel hose cable
(retuen) ~ Fuel tank Ventilation
socket
(!5(' Pilot water
PI hose

rYE~~ot ::::' ""'oc ,,,' DrL '"

it hose ===rr=
M-M
E

OUT--~ Fuel tank

IN~ breather hose Oil sensor lead
G. Fuel sensor

B'
Fuel hose 0-0 lead

~
(RES) Fuel sender lead Fuel tank
~ breather hose
Allgom."
Fuel hose (ON) . ~
Fuel hose (Fuel cock-Fuel filter) Oil senser lead

.!:!.

2-9

[Link]
ISPECI g. FUEL LINE ROUTING
XL1200

Pass the
oil hose
out side
of belt

2-10

[Link]
 FUEL LINE ROUTING

Fuel hose (Fuel cock-Fuel filter)

~ Fuel hose
~A,;gOma~

~
A-A ~..
Fuel hose
(Fuel cock- - - - - -
f5 .. t::::.
~
"
.
'

Fuel fulter) '~

Fuel hose 10±3mm ~

(Fuel cock-
~ t=W
Fuel filter)

Pilot water hose

C-C
-
Fuel hose
(Fuel filter-
cabretor) F,,' taok -g- Ventilation
socket

~
Speed sensor lead
E-E

To nupple
~ Pilot water hose
I

E
°gm~--!#
Fuel tank
breather hose~
J
. c
Oil sensor lead

OUT'-~ .. Fuel sensor lead

IN/
G.

Fuel
Fuel hose (RES) :::;~ laok b,eath" hooe
WJuel hose (ON)

~ Fuel hose
(Fuel cock-
Fuel filter) Oil sensor lead

t!. R-R

2-11

[Link]
ISPECI O· CABLE LINE ROUTING
CABLE LINE ROUTING
XL760

Choke
cable

Throttle
cable

--lo..!---i!Iir To starting motor - terminal

To starting motor + terminal

Speed sensor lead --fF\=f:~~JJr=====7tJMIIr==#=Hl

Steering cable

\\----*--+-- Reverse cable

2-12

[Link]
 CABLE LINE ROUTING CD

Electrical box ~
++ Handlebar switch ~

~
Throttle cable ~ Speed sensor lead

Choke cable ~ Electrical box 0-0

++ Handlebar sWitc~
Meter lead Tube (Meter)

J.
Speed sensor lea~ ___ Electric box Speed sensor lead
p ++ Handlebar switch
E-E

To #2 cylinder To handlebar switch (Gray)

Electric box 8-8

-H'~:::::~::~it'hSP;;~~;;;~,::: :~'~O~"
Fuel sensor lead
...
To CDI magneto (Black)

To thermo switch (Black)

*
Handlebar switch lead To starting To battery + terminal (Red)
C-C motor + terminal (Red)

Electric box
Meter lead Buzzer lead
Fuel sensor lead
Oil sensor lead ~ Th'ottl, "bl,
Handlebar switch lead
M-M Choke cable

~Throttle cable

~ Choke cable
Battery - lead

To CDI magnet~ ~F=====<-_ Battery + lead

To starting Steering cable
motor terminal Grease nipple hose
To thermo switch
'==::::VI[~
Q
Speed sensor ++ Meter (White)
Fuel sensor
++ Meter (Green)
Oil sensor Align with marking-off line
++ Meter (White)
Buzz er ++ Met er --h'TfttttH?;;;E[J-'lD
(Black)
Electric box
++ Handlebar
switch (Black)

Electric box
++ Meter (White) Handlebar switch ++ Meter (Red)
E

2-13

[Link]
ISPECI U· CABLE LINE ROUTING
XL1200

Choke
cable

Throttle
cable

-+F~-::-It+--- To starting motor +

terminal

To starting motor-
terminal

To thermo switch

~1I~rl\:li-=~ill':::==:p;...- Electric equipment box

11--+-- Speed sensor lead

I--t-!I---~-+--- Steering cable

Reverse cable

2-14

[Link]
iSPECi g. CABLE LINE ROUTING

Electric box
+-+Handlebar SWi~
Throttle cable ~

Choke cable -t=V

Electric box
+-+Handlebar switch
Speed sensor le~ Electric box ~
p +-+ Handlebar switch Pv
E-E
Electric Align with marking-off line
+-+ handlebar switch Speed sensor lead

~
Buzzer lead
Meter leads ··0 Oil sensor lead
." Fuel sensor lead
Handlebar switch lead
C-C

To #1 cylinder

Battery - terminal
To battery + terminal (Red)
starting motor-
~~~~l:=- To starting motor + terminal (Red)
+-+
terminal (Black)
To meter (Gray)

Mot" '''d")- To pulse

To thermo switch (Black) Excessive
Cooling water hose
(head cylinder-Ring joint)

cooling water hose

Handlebar switch lead K

Speed sensor +-+ Meter (Whit

Fuel sensor +-+ Meter (Green)

~
Oil sensor +-+ Meter (White)

Buzzer +-+ Meter (Black) ----h-'1tttttw.~..L..!='

Electric box Handlebar switch

+-+ Handlebar switch (Black) Meter (Red)
+-+
Meter lead Tube (Meter)
].t~~g=;r- Electric box 4
+-+ Meter (Natural)

Electric box +-+ Meter (White) G.

2-15

[Link]
II~gr I~I __________
CI)_
CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENT

MAINTANCE INTERVAL CHART ................................ 3-1

PERIODIC SERVICE ........................................... 3-2

CONTROL SYSTEM ........................................ 3-2
Pivot shaft bearing inspection ............................. 3-2
Steering cable inspection and adjustment ................... 3-2
Throttle cable inspection and adjustment .................... 3-3
Choke cable inspection and adjustment ..................... 3-4
Shift cable inspection and adjustment ...................... 3-5
FUEL SYSTEM ............................................. 3-6
Fuel filter inspection ...................................... 3-6
Trolling speed inspection and adjustment ................... 3-6
Carburetor adjustment .................................... 3-8
OIL INJECTION SySTEM .................................... 3-8
Oil filter inspection ....................................... 3-8
Oil pump cable inspection and adjustment .................. 3-8
Oil injection pump air bleeding ............................. 3-9
POWER UNIT .............................................. 3-10
Spark plug inspection .................................... 3-10
ELECTRICAL .............................................. 3-11
Battery inspection ........................................ 3-11
JET PUMP UNIT ............................................ 3-13
Impeller inspection ....................................... 3-13
Bilge strainer inspection .................................. 3-13
GENERAL ................................................. 3-14
Drain plug inspection ..................................... 3-14
Greasing pOint .......................................... 3-14

[Link]
 IANDSJPI(~I
. ~. __________________________
MAINTANCE INTERVAL CAHRT C_gE_)
MAINTANCE INTERVAL CAHRT
The following chart should be considered strictly as a guide to general maintenance intervals.
Depending on operating conditions, the intervals of maintenance should be changed.

Initial Every Refer

Item Remarks 10 hours 50 hours 100 hours 200 hours to
(Break-in) (3 months) (6 months) (1 year) page
CONTROL SYSTEM:
Steering cable Inspection/ Adjustment 0 3-2
Throttle cable Inspection/ Adjustment 0 3-3
Carburetor throttle Inspection 0 -
shaft
Choke cable Inspection/ Adjustment 0 3-4
Shift cable Inspection/ Adjustment 0 3-5
FUEL SYSTEM:
Fuel tank Cleaning 0 4-7
Fuel filter Cleaning/ Replacement 0 0 3-6
Fuel line Inspection 0 4-1
Trolling speed Inspection/ Adjustment 0 3-6
Carburetor setting Inspection/ Adjustment 0 0 3-7
OIL INJECTION SYSTEM:
Oil injection system Inspection/Cleaning 0 0 3-8
POWER UNIT:
Spark plug Inspection/Cleaning/ 0 0 0 3-10
Adjustment
Cooling-water passage Cleaning/Flashing 0 -
Coupling rubber Inspection 0 -
ELECTRICAL:
Battery Inspection 0 3-11
JET PUMP UNIT:
Impeller Inspection 0 0 3-13
Bilge strainer Cleaning 0 0 3-13
GENERAL:
Bolt and nut Retightening 0 0 -
Drain plug Inspection / Replacement 0 3-14
Greasing point Greasing 0 3-14
Bearing housing Greasing 0*1 0*2 3-15
Starter motor idle gear Greasing 0*3 0*4 3-15
*1: Grease capacity 33.0 - 35.0 cm 3 (1.11 - 1.18 oz.)
*2: Grease capacity 6.0 - 8.0 cm 3 (0.20 - 0.27 oz.)
*3: Grease capacity 8.0 cm 3 (0.27 oz.)
*4: Grease capacity 2.0 cm 3 (0.07 oz.)

3-1

[Link]
 Ito)I ____________C_~E_::>
IANOSJP . ~ _ CONTROL SYSTEM
PERIODIC SERVICE
CONTROL SYSTEM
Pivot shaft bearing inspection
1. Inspect:
• Pivot shaft bearing
Excessive play -+ Replace bushing.
Refer to the "STEERING SYSTEM" in
chapter 8.

Inspection steps:
• Move the handlebar up and down.
• Move the handlebar back and forth.
NOTE:----------------------
Check that the pivot shaft support bolt G) is
secured first.

• If the pivot shaft becomes loose, retighten

the clamp ® until a satisfactory feed is ob-
tained.

Steering cable inspection and adjustment

1. Inspect:
• Jet nozzle clearance @, @

Inspection steps:
• Turn the handlebar lock to lock.
• Measure the clearances@ and@.
• If the@ and@ clearances are not even,
adjust the clearances.

2. Adjust:
• Cable joint (handle side) G)

Adjustment steps:
• Loosen the lock nut ®.
• Disconnect the cable jOint from the ball
joint@.
• Turn the cable joint to adjust.
Turn in Clearance ® is increased
Turn out Clearance@ is increased

A WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).

• Connect the cable joint and tighten the

lock nut.

Lock nut:
7 Nm (0.7 mekg, 5.1 ftelb)
3-2

[Link]
IANOSJP I. (Oll
~. ______________
CONTROL SYSTEM C_gE_)

NOTE:-----------------------
If correct adjustment cannot be obtained using

-~([D==:·~-i=-l the cable joint at the handlebar end, adjust the

cable joint at the steering nozzle end.

8 mm (0.31 in)

Throttle cable inspection and adjustment

NOTE:-----------------------
Before adjusting the throttle lever free play, the
trolling speed should be adjusted.

1. Measure:
• Throttle lever free play @
Out of specification -+ Adjust.

Throttle lever free play:

4 - 7 mm (0.16 - 0.28 in)

2. Adjust:
• Throttle lever free play

Adjustment steps:
• Loosen the lock nut CD.
• Turn the adjuster® in/out until the speci-
fied free play is obtained.
Turn in Free play is increased.
Turn out Free play is decreased.

• Tighten the lock nut.

A WARNING
After adjusting the free play, turn the handle-
bar to right and left, and make sure that the
trolling speed does not increase.

3-3

[Link]
IANOSJP I. to)
~.I _ ___
CONTROL _ _ _ _ _ _ _ _ _ _C_IE_=:>
SYSTEM
Choke cable inspection and adjustment
1. Measure:
• Choke cable free play @
Out of specification -+ Adjust.
~-::;=l._ _ _...l.t @
Choke cable free play:
_-rt +
1 - 6 mm (0.04 - 0.24 in)

2. Adjust:
760 • Choke cable free play

Adustment steps:
• Loosen the lock nut CD.
• Turn the adjuster® in/out until the speci-
fied free play is obtained.
Turn in Free play is increased.
Turn out Free play is decreased.
• Tighten the lock nut.

~~
Lock nut:
9 Nm (0.9 m·kg, 6.5 fHb)

3. Inspect:
• Pull knob farthest toward
Knob automatically retuns -+ Adjust.

4. Adjust:
3
• Adjust nut @
Turn in to stop automatic return.

3-4

[Link]
 Ito)I ______________C~_)
IANOSJP . ~. CONTROL SYSTEM
Shift cable inspection and adjustment
1. Check:
• Reverse gate collar head @ position
Out of specification -t- Adjust.

Checking steps:
• Set the shift lever to the reverse posi-
tion.
• Turn the steering fully to the right or
left.
• Check to make sure that the collar head
position should be inside of two marking
lines @ of the shift rod lever.

2. Adjust:
• Shift cable jOint (shift lever side)

Adjustment steps:
• Loosen the lock nut m.
• Disconnect the cable joint® from the ball
joint@.
• Turn the cable joint for adjusting.
Turn in Clearance is increased.
Turn out Clearance is decreased.

A WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).

• Connect the cable joint and tighten the

lock nut.

Lock nut:
4 Nm (0.4 mekg, 2.9 ftelb)

3-5

[Link]
I~~~ I 'il1_F_U_E_L_S_Y_S_TE_M_ _ _ _ _ _ _ _ _ _ _ _C_I_=>
FUEL SYSTEM

A WARNING
• Stop the engine, set the fuel cock to "OFF"
and loosen the fuel filler cap before a fuel
system service .
• When removing fuel system parts, hold
them in a cloth and take care that no fuel
spills into the engine compartment.

Fuel filter inspection

1. Inspect:
• Filter element
Contamination ~ Replace.
• Filter body
Crack/Damage ~ Replace.
• Filter assembly
Water contamination ~ Replace and
check the fuel tank.

Trolling speed inspection and adjustment

1. Check:
• Trolling speed
Out of specification ~ Adjust.

Trolling speed:
1,300 ± 50 r/min

Checking steps: (vehicle on water)

• Start the engine and allow it to warm up for
a few minutes.
• Attach the engine tachometer to the spark
plug lead.

~
Engine tachometer:
YU-08036-A/90890-06760

• Measure the engine trolling speed.

3-6

[Link]
~~~I~I_F_U_E_L_S_Y_S_TE_M_______________________C_~_)
2. Adjust:
• Trolling speed

Adjustment steps:
• Screw in the low speed screws CD until
they are lightly seated.
• Back the screws out by the specified num-
ber of turns.

~
Low speed screw:
XL760
1-3/4 ± 1/4 turns out
1200
XL1200
1 ± 1/4 turns out

• Start the engine and allow it to warm up for

a few minutes.
• Turn the throttle stop screw® in or out un-
til the specified speed is obtained.

Turning in Increase trolling speed.

Turning out Decrease trolling speed.

1200

3-7

[Link]
IANOSJP .I (0)
~.1 _ __
FUEL ___
SYSTEM/OIL _ _ _SYSTEM
INJECTION _____C_gE_::>
Carburetor adjustment
1. Adjust:
• High speed screw

Adjustment steps:
• Screw in the high speed screws CD until
they are lightly seated.
• Back the screws out by the specified num-
ber of turns.

~
High speed screw:
XL760
1/2 ± 1/4 turns out
XL1200
3/4 ± 1/4 (#1, #3)
1 ± 1/4 (#2) turns out

OIL INJECTION SYSTEM

Oil filter inspection
1. Inspect:
• Oil filter
Fray /Tear -+ Replace.
Muddy/Dirt -+ Clean.
• Seal rubber
Wear/Crack -+ Replace.

Oil pump cal be inspection and adjustment

(XL1200)
1. Inspect:
• Oil pump lever position
Incorrect -+ Adjust.

Checking steps:
• Fully close the carburetor . throttle
valve.
• Check that the mark@ on the pump lever
is aligened the mark @ on the pump
body.

2. Adjust
• Oil pump cable

Adjustment steps:
• Loosen the lock nut CD and adjust nut
®.
• Fully close the carburetor throttle
valve.
• Adjust the oil pump cable so that mark @
on the pump lever aligns the mark @ on
the pump body.
• Tighten the lock nut.

3-8

[Link]
 I(c»I ______________
IANOSJP . ~. OIL INJECTION SYSTEM C_gE_)
Oil injection pump air bleeding
NOTE:----------------------
Bleed the oil injection system if:
• The system has been disassembled .
• The oil has been completely used up dur-
ing operation.

1. Bleed:
• Air

Air bleeding steps:

a. Place rags under the oil pump to catch
any oil that spills out.
b. Disconnect the oil hose from the oil
pump.
c. Position the oil hose end above the oil
tank CD.
d. Put 2 liters of oil or more in the oil tank
760 and leave if for 2 minutes.
e. Then, lower the oil hose end and
make sure the oil flows out of the oil
hose.
f. Connect the oil hose to the oil pump.
g. Clamp the oil hose with the hose tie.
h. Loosen the air bleed screw ® 2 turns,
and make sure both oil and air bubbles
flow out.
i. If oil does not come out, squeeze the oil
hose @ near the oil pump inlet a maxi-
mum 20 times.
j. When no air bubbles remain, tighten the
air bleed screw.
k. Wipe out any spilled oil.

Screw:
5 Nm (0.5 m·kg, 3.6 ft-lb)

3-9

[Link]
~grl ~I_P_O_W__ER__U_NI_T_______________________C_~_~
POWER UNIT
Spark plug inspection
1. Inspect:
• Electrode CD
Wear/Damage -+ Replace.
Insulator color ®
Discolor -+ Check the engine condi-
tion.

Color guide:
Medium to light tan color:
Normal
Whitish color:
Lean fuel mixture
Plugged fuel mixture
Air leak
Incorrect settings
Blackish color:
Overly rich mixture
Electrical malfunction
Excess oil used
Defective spark plug

2. Clean:
• Spark plug
Clean the spark plug with a spark plug
cleaner or wire brush.
3. Measure:
® • Spark plug gap @
Out of specification -+ Alter gap.
Use a wire gauge.

Spark plug gap:

0.6-0.7 mm (0.024-0.028 in)

4. Tighten:
• Spark plug

Spark plug:
25 Nm (2.5 m-kg, 18 ft-Ib)

NOTE:-------------------------
• Before installing a spark plug, clean the gas-
ket surface and plug surface. Also it is advis-
able to apply a thin film of Anti Seize Com-
pound to the spark plug threads to prevent
future thread seizure .
• If a torque wrench is not available, a good es-
\, ,II'
timate of the correct torque for the spark plug
..';t;......
_-- is a further 1/4 to 1/2 turns @ on from finger
"\Q;
tightness @.

3-10

[Link]
~8~1~I __EL_E_C_T_R_IC_A_L_______________________C_~_~
ELECTRICAL
Battery inspection
CAUTION:
Be carefu I not to place the battery on its side.
Before adding the battery fluid or recharg-
ing, be sure to remove it from the battery
compartment. When checking the battery,
make sure the breather hose is connected to
the battery and is not pinched shut any-
where in the battery compartment.

A WARNING
• Battery electrolyte is poisonous and dan-
gerous, causing severe burns, etc. Con-
tains sulfuric acid.
• Avoid contact with skin, eyes or clothing.
• Antidote: EXTERNAL-Flush with water.
• INTERNAL-Drink large quantities of water
or milk. Follow with milk of magnesia,
beaten egg or vegetable oil. Call a physi-
cian immediately.
• Eyes: Flush with water for 15 minutes and
get prompt medical attention. Batteries
produce explosive gases.
• Keep sparks, flame, cigarettes, etc., away.
Ventilate when charging or using in an en-
closed space. Always shield your eyes
when working near batteries.
• KEEP OUT OF REACH OF CHILDREN.

1. Remove:
• Battery

A WARNING
• When removing the battery, disconnect
the negative lead first.
• Remove the battery to prevent acid loss
during the impeller service.

2. Inspect:
• Battery fluid level
Battery fluid level low -+ Top up with dis-
tilled water.
Fluid level should be between upper CD
and lower ® level marks.

3-11

[Link]
I~~~ I ~ I_E_L_E_C_T_R_IC_A_L_ _ _ _ _ _ _ _ _ _ _ _C_g_~
Filling steps:
• Remove each filler cap.
• Fill with distilled water using a jug.
• When the acid is up to the UPPER LEV-
EL, allow the cell to stand for 20 minutes.
If the acid level has dropped, add more
acid up to the UPPER LEVEL once
again.

·.·······CAUIION:.··.··.·.·.·.·.·
-------------------
Water other than distilled water contains
minerals which are harmful to a battery; top
up only with distilled water.

3. Inspect:
• Battery fluid specific gravity
Out of speCification ~ Charge.

Specific gravity at 20°C (68°F):

1.28
Charging current:
68.4 kc. (1.9 Amps x 10 hrs)

4. Install:
• Filler cap
CAUTION:i
-------------------
Rinse off any acid from the battery case and
wipe the battery dry prior to installation.

5. Install:
• Breather hose CD
• Battery
• Positive lead ®
• Negative lead @
• Battery babd
CAUTION: \ _ _ _ _ _ _ __
• Connectthe positive red lead@ to the bat-
tery terminal first.
• Make sure the battery leads are connected
properly. Reversing the leads can serious-
ly damage the electrical system.
• Make sure the breather hose is properly
connected and is not obstructed.
• Coat the terminals with a water resistant
grease to minimize terminal corrosion.

3-12

[Link]
I~~r 1_I_JE_T_P_U_M_P_U_N_I_T_ _ _ _ _ _ _ _ _ _ _C_g_=:>_
JET PUMP UNIT
Impeller inspection
1. Check:
• ImpellerCD
Wear/Damage -+ Replace.
Scratch/Nick -+ File/Grind.
2. Measure:
• Impeller clearance@
Out of specification -+ Replace.

,
I~
Impeller clearance limit:
0.6 mm (0.024 in)
tTl
242
Measurement steps:
• Remove the battery.
• Remove the intake screen CD.
• Measure the clearance at all four
points.
• Install the intake screen.
\
~~
Bolt:
11 Nm (1.1 mekg, 8.0 ftelb)

• Install the battery.

Bilge strainer inspection

1. Inspect:
• Strainer
Contamination -+ Clean.
Crack/Damage -+ Replace.

Inspection steps:
• Remove the coupling cover.
• Disconnect the bilge strainer CD from the
strainer holder.
• Inspect the bilge strainer.

3-13

[Link]
I~~r I ~ I_G_E_N_E_R_A_L_____________C_~_::>
GENERAL
Drain plug inspection
1. Inspect:
• Drain plug
Crack/Damage -+ Replace.
• O-ring
Crack/Wear -+ Replace.
• Screw threads
Dirt/Sandy -+ Clean.

Greasing point
1. Apply:
• Throttle cable inner wire

Recommended fluid:
Rust-inhibitor

NOTE:-------------------------
• Squeeze the throttle lever and remove the
seal CD .
• Spray a rust-inhibitor into the outer cable.
1200
2. Apply:
• Throttle cable inner wire
• Choke cable inner wire
• Oil pump cable inner wire

Recommended grease:
Water resistant grease

3. Apply:
• Steering pivot shaft bushing
• Nozzle pivot shaft collar

Recommended grease:
Water resistant grease

3-14

[Link]
~~~I~I_G_E_N_E_R_A_L_________________________C_g_~
4. Apply:
• Steering cable
• Cable joint

Recommended grease:
Water resistant grease

NOTE:-----------------------
Disconnect the cable joint and apply a small
amount of grease to the following parts.

5. Fill:
• Bearing housing
• Starter idle gear

Recommended grease:
Water resistant grease

NOTE:-----------------------
• Fill in the bearing housing and the starter idle
gearwith water resistant grease througt the
grease nipples CD.
• Fill the grease slowly and carefully, as it can
damage the hose and the joints.
• Refer to the "MAINTENANCE INTERVAL
CHART".

3-15

[Link]
 CHAPTER 4
FUEL SYSTEM
FUEL LINE . ................................................... 4-1
EXPLODED DIAGRAM (XL760) .............................. 4-1
REMOVAL AND ISNTALLATION CHART ...................... 4-1
EXPLODED DIAGRAM (XL 1200) ............................. 4-2
REMOVAL AND INSTALLATION CHART ...................... 4-2
SERVICE POINTS .......................................... 4-3
Fuel filter inspection ...................................... 4-3
Fuel cock inspection ..................................... 4-3

OIL TANK . .................................................... 4-4

EXPLODED DIAGRAM ...................................... 4-4
REMOVAL AND INSTALLATION CHART ...................... 4-4
SERVICE POINTS .......................................... 4-5
Check valve inspection ................................... 4-5
Oil filter inspection ....................................... 4-5
Oil lever sensor inspection ................................ 4-5
Oil tank inspection ....................................... 4-5

FUEL TANK REMOVAL ........................................ 4-6

EXPLODED DIAGRAM ...................................... 4-6
REMOVAL AND INSTALLATION CHART ...................... 4-6

FUEL TANK ................................................... 4-7

EXPLODED DIAGRAM ...................................... 4-7
REMOVAL AND INSTALLATION CHART ...................... 4-7
SERVICE POINTS .......................................... 4-8
Check valve inspection ................................... 4-8
Fuel level sensor inspection ............................... 4-8
Fuel tank inspection ...................................... 4-8
Pipe joint inspection ...................................... 4-8
Pipe jOint installation ..................................... 4-8

CARBURETOR UNIT REMOVAL ................................ 4-9

EXPLODED DIAGRAM (XL760) .............................. 4-9
REMOVAL AND INSTALLATION CHART ...................... 4-9
EXPLODED DIAGRAM (XL 1200) ............................. 4-10
REMOVAL AND INSTALLATION CHART ...................... 4-10

[Link]
IruELI~I~~~~~~~~_~_E
CARBURETOR REMOVAL ..................................... 4-11
EXPLODED DIAGRAM ...................................... 4-11
REMOVAL AND INSTALLATION CHART ...................... 4-11
SERVICE POINTS .......................................... 4-12
Throttle valve synchronization inspection and adjustment ..... 4-12
Choke valve synchronization inspection and
adjustment (XL760) ...................................... 4-13

CARBURETOR . ............................................... 4-14

EXPLODED DIAGRAM ...................................... 4-14
REMOVAL AND INSTALLATION CHART ...................... 4-14
SERVICE POINTS .......................................... 4-15
Diaphragm inspection .................................... 4-15
Float arm inspection ..................................... 4-15
Body assembly inspection ................................ 4-15
Needle valve inspection .................................. 4-15
Jet and carburetor body inspection ......................... 4-16
High and low speed screws inspection ...................... 4-16
High and low speed screws adjustment ..................... 4-16
Carburetor assembly ..................................... 4-16

FUEL PUMP .................................................. 4-17

EXPLODED DIAGRAM ...................................... 4-17
REMOVAL AND INSTALLATION CHART ...................... 4-17
SERVICE POINTS .......................................... 4-18
Fuel pump inspection .................................... 4-18
Filter inspection ......................................... 4-18

OIL LINE ............... ....................................... 4-19

EXPLODED DIAGRAM ...................................... 4-19
REMOVAL AND INSTALLATION CHART ...................... 4-19
SERVICE POINTS .......................................... 4-19
Check valve inspection ................................... 4-19

OIL PUMP .................................................... 4-20

EXPLODED DIAGRAM ...................................... 4-20
REMOVAL AND INSTALLATION CHART ...................... 4-20
SERVICE POINTS .......................................... 4-21
Oil pump inspection ...................................... 4-21
Oil hose inspection ....................................... 4-21
Ring rubber inspection ................................... 4-21
Ring rubber installation ................................... 4-21

[Link]
IFUELI~I_F_U_E_L_Ll_N_E______________________C_g_)
FUEL LINE
£ WARNING
Gasoline (Petrol) is highly flammable and explosive. Handle with special care.

EXPLODED DIAGRAM (XL760)

~4 7~4
~ ~5
~

2~,.,~:'c:
3 .:

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

AIR VENTILATION HOSE, Follow the left "Step" for removal.
FUEL COCK AND FUEL FILTER
REMOVAL
1 Hose tie 1
2 Clamp 6
3 Air ventilation hose 1
4 Fuel hose (OUT) 1
5 Fuel filter 1
6 Fuel hose 1
7 Fuel hose 3
8 Check valve 1
9 Fuel cock body 1
Reverse the removal steps for installation.

4-1

[Link]
IFUELI ~1_F_U_E_L_Ll_N_E______________________C_g_)
EXPLODED DIAGRAM (XL 1200)

~4
9

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

AIR VENTILATION HOSE, Follow the left "Step" for removal.
FUEL COCK AND FUEL FILTER
REMOVAL
1 Hose tie 1
2 Clamp 6
3 Air ventilation hose 1
4 Fuel hose (OUT) 1
5 Fuel filter 1
6 Fuel hose 1
7 Fuel hose 3
8 Check valve 1
9 Fuel cock body 1
Reverse the removal steps for installation.

4-2

[Link]
IFUELI~I_F_U_E_L_Ll_N_E______________________C_g__~
SERVICE POINTS
Fuel filter inspection
Refer to the "FUEL SYSTEM" in chapter 3.

Fuel cock inspection

1. Check:
• Fuel cock
Unsmooth movement -+ Replace.
Clog -+ Clean.

4-3

[Link]
IFUELI ~I_O_I_L_TA_N_K_______________________C_~_~
OIL TANK
EXPLODED DIAGRAM

~~~
~ 6",.
"@ i ~8
3 ~ ~_
4 Nm (0.4 m·kgf. 2.9 ft·lb) ~ y.7
1200 ~"
U
4 Nm (0.4 m·kgf. 2.9 ft·lb)

U 8'
L.,- 5

8' ,,0~·

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

OIL TANK REMOVAL Follow the left "Step" for removal.
1 Oil level sensor lead coupler 1
2 Oil hose 1
3 Oil filler hose 1
4 Tank band 1
5 Oil tank assembly 1
6 Check valve 1
7 Oil filter 1
8 Oil level sensor 1
Reverse the removal steps for installation.

4-4

[Link]
IFUELI~I_o_I_L_TA_N_K_______________________C_g__)
. A B
SERVICE POINTS
Check valve inspection
1. Check:
• Check valve
Out of specification ~ Replace.

I~ Flow from A 10 B

Oil filter inspection

Refer to "OIL INJECTION SYSTEM" in
chapter 3.

Oil level sensor inspection

Refer to "INDICATION SYSTEM" in chapter
7.

Oil tank inspection

1. Inspect:
• Oil tank
Crack/damage ~ Replace.

4-5

[Link]
IFUELI ~I __
FUEL TANK REMOVAL
FU_E_L_T_A_N_K_R_E_M_O_V_A_L_________________ C_~_~_
EXPLODED DIAGRAM

5 Nm (0.5 m-kgf, 3.6 ft-Ib)

4 Nm (0.4 m-kgf, 2.9 ft-Ib)

242

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

FUEL TANK REMOVAL Follow the left "Step" for removal.
Engine hood 1 Refer to "ENGINE HOOD REMOVAL" in
chapter 8.
Oil tank assembly 1 Refer to "OIL TANK".
1 Fuel level sensor lead coupler 1
2 Fuel filler hose 1 NOTE:
3 Fuel hose 3 Drain the fuel.
4 Air ventilation hose 1
5 Tank band 2
6 Fuel tank assembly 1
Reverse the removal steps for installation.

4-6

[Link]
IFUELI~I_F_U_E_L_TA_N_K______________________C_~_~
FUEL TANK
EXPLODED DIAGRAM

$-1
'8

o
'8

I
I~ on l
CD 0
r
I
II Ii'"---,
L ___~

'--- - - --

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

FUEL TANK DISASSEMBLY Follow the left "Step" for removal.
Fuel tank disassembly Refer to "FUEL TANK REMOVAL"
1 Check valve 1
2 Pipe joint assembly 1
3 Fuel tank 1
Reverse the removal steps for installation.

4-7

[Link]
IFUELI ~I_F_U_E_L_TA_N_K______________________C_~__~
SERVICE POINTS

"(_[_~Q~I~ JD"
Check valve inspection
1. Check:
• Check valve
Out of specification -.. Replace.

I~ Flow from A to 8

Fuel level sensor inspection

Refer to the "INDICATION SYSTEM" section in
chapter 7.

Fuel tank inspection

1. Inspect:
• Oil tank
• Fuel tank
Crack/Damage -.. Replace.

Pipe joint inspection

1. Inspect:
• Pipe
Bending/Damage -.. Replace.
Contamination -.. Clean.
• Pipe joint
Wear/Crack -.. Replace.

Pipe joint installation

1. Install:
• Pipe joint CD
• Pipe®
ON~ • Pipe@
RES~ Length@:
372.5 ± 2 mm (14.7 ± 0.08 in)
® Length@:
352.5 ± 2 mm (13.8 ± 0.08 in)

4-8

[Link]
IFUEL I Ji) I CARBURETOR UNIT REMOVAL CD
CARBURETOR UNIT REMOVAL
EXPLODED DIAGRAM (XL760)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

CARBURETOR REMOVAL Follow the left "Step" for removal.
1 Carburetor cover 1
2 Flame arrester 2
3 Carburetor cover 1
I~
Cable guide set position @ :
4 Choke cable 1
17 mm (0.67 in)
5 Throttle cable 1

6 Fuel hose 2
7 Pulse hose 2
8 Nut 4
9 Carburetor assembly 1
Reverse the removal steps for installation.

4-9

[Link]
IFUEL I ~ I CARBURETOR UNIT REMOVAL
EXPLODED DIAGRAM (XL 1200)

.~~
a
572

9 Nm (0.9 mekg, 6.5 ftelb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

CARBURETOR REMOVAL Follow the left "Step" for removal.
1 Carburetor cover 1 1
2 Funnel 3
3 Carburetor cover 2 1 ~ Choke cable guide set position
4 Plate 1 @:
5 Choke cable 1 14 mm (0.55 in)
6 Throttle cable 1 Throttle cable guide set
7 Oil pump calbe 1 position@:
8 Fuel hose 2 17 mm (0.67 in)
9 Pulse hose 3
10 Nut 6
11 Carburetor unit 1
Reverse the removal steps for installation.

4-10

[Link]
IFUEL Iii) I CARBURETOR REMOVAL CD
CARBURETOR REMOVAL
EXPLODED DIAGRAM

572

242

4 5 Nm (0.5 mekg, 3.6 ftelb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

760.1200
CARBURETOR ASSEMBLY Follow the left "Step" for removal.
Carburetor unit Refer to "CARBURETOR UNIT REMOVAL".
1 Fuel hose 4,6
2 Pulse hose 2,3
3 Link joint -,2
4 Bolt 4,6
5 Carburetor assembly 2,3
Reverse the removal steps for installation.

4-11

[Link]
IFUELI ~I_C_A_R_B_U_R_E_T_O_R_R_E_M_O_V_A_L_______________C_E_~_
SERVICE POINTS
Throttle valve synchronization inspection
and adjustment
1. Check:
• Throttle valve synchronization
Out of specification -+ Adjust.

Checking steps:
• While turning the throttle lever, check the
opening of all throttle valves.

2. Adjust:
• Throttle valve synchronization
#1 #2
Adjustment steps: XL760
• Turn out the throttle stop screw G) until its
tip is apart from the th rottle lever ®.
NOTE:---------------------
Record the set position of the throttle stop
screw.

• Check that the #1 throttle valve @ is fully

closed.
• Turn the synchronization screw @ in or
out until the #2 throttle valve @ is fully
closed.
• Turn in the throttle stop screw to the set
position.

Adjustment steps: XL 1200

• Turn out the throttle stop screwG) until its
tip is apart from the throttle lever ®.
NOTE:----------------------
Record the set position of the throttle stop
screw.

• Loosen the screws ®.

• Tighten the screws ®.
• Turn in the throttle stop screw to the set
position.

4-12

[Link]
IFUELI ~I_C_A_R_B_U_R_E_T_O_R_R_E_M_O_V_A_L_______________C_~_)_
Choke valve synchronization inspection
and adjustment (XL760)
1. Check:
• Choke valve synchronization
Out of specification -+ Adjust.

Checking steps:
• While pulling the choke knob, check the
opening of all choke valves.

2. Adjust:
• Choke valve synchronization

Adjustment steps:
• Turn in or out the synchronization
screw G) to bring all the choke valves
into a fully closed position when the
choke knob is pushed in the closed
side.

4-13

[Link]
IFUELI ~I_C_A_R_B_U_R_ET_O_R_____________________C_~_)
CARBURETOR
EXPLODED DIAGRAM

2 Nm (0.2 mekg, 1.4 ftelb)

4 Nm (0.4 mekg, 2.9 ftelb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

CARBURETOR ASSEMBLY Follow the left "Step" for removal.

Carburetor assembly Refer to "CARBURETOR REMOVAL".
1 Diaphragm assembly 1
2 Float arm 1
3 Needle valve assembly 1
4 Body assembly 1
5 Main jet 1
6 Pilot jet 1
7 High speed screw 1
8 Low speed screw 1
Reverse the removal steps for installation.

4-14

[Link]
IFUELI~I_c_A_R_B_U_R_ET_O_R_____________________C_~_)
SERVICE POINTS
··CAUTION:>
--------------------
Do not use steel wire for cleaning the jets as
this may enlarge the jet diameters and seri-
ously affect performance.

Diaphragm inspection
1. Inspect:
• Diaphragm assembly
Damage -+ Replace.
Float arm inspection
1. Inspect:
• Float arm CD
Bend/damage -+ Repair or replace.
2. Measure:
• Float arm height @

Float arm height:

o - 0.2 mm (0 - 0.008 in)
NOTE:-------------------------
• Measure the distance between the surface@
of the carburetor body and the top surface of
the float arm .
• The float arm should be resting on the
needle valve, but not compressing the
needle valve.

Body assembly inspection

1. Inspect:
• Body assembly CD
Contamination -+ Clean.
• Valve®
Damage -+ Replace.

Needle valve inspection

1. Inspect:
• Needle valve
• Valve seat
Grooved wear @ -+ Replace.
Dust @ -+ Clean.
NOTE:-------------------------
Always replace the needle valve and valve seat
as a set.

4-15

[Link]
IFUELI~I_c_A_R_B_U_R_ET_O_R_____________________C_g_~
Jet and carburetor body inspection
1. Inspect:
• Main jet
• Pilot jet
• Carburetor body
Contamination --+ Clean.

High and low speed screws inspection

1. Inspect:
• High speed screw
• Low speed screw
Bend/Wear --+ Replace.

High and low speed screws adjustment

1. Adjust:
• High speed screw
• Low speed screw

Adjustment steps:
• Screw in the high speed screwsG) or low-
er speed screws ® until they are lightly
seated .
• Back out by the specified number of
turns.
#3 #2 #1
High speed screw:
XL760
1/2 ± 1/4 turns out
XL1200
3/4 ± 1/4 (#1, #3)
1 ± 1/4 (#2) turns out
Low speed screw:
XL760
1-3/4 ± 1/4 turns out
XL1200
1 ± 1/4 turns out

Carburetor assembly
1. Adjust:
• Trolling speed
Refer to "FUEL SYSTEM" in chapter 3.

4-16

[Link]
!FUEL! ~!_F_U_E_L_P_UM_P______________________C_~__)
FUEL PUMP
EXPLODED DIAGRAM

5 Nm (0.5 m-kg, 3.6 ft-Ib)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

FUEL PUMP DISASSEMBLY Follow the left "Step" for removal.
Carburetor assembly Refer to "CARBURETOR REMOVAL".
1 Pump cover 1
2 Diaphragm 1
3 O-ring 1
4 Diaphragm body assembly 1
5 Diaphragm 1
6 O-ring 1
7 Filter 1
Reverse the removal steps for installation.

4-17

[Link]
IFUELI~I_F_U_E_L_P_UM_P______________________C_g__)
SERVICE POINTS
Fuel pump inspection
1. Inspect:
• Diaphragm
• Diaphragm body assembly
Damage -+ Replace.

Filter inspection
1. Inspect:
• Filter
Contamination -+ Clean.
Damage -+ Replace.

4-18

[Link]
IFUELI~I_o_I_L_Ll_N_E________________________C_g_)
OIL LINE
EXPLODED DIAGRAM

760
2

1200

2 2 2

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

OIL PUMP DISASSEMBLY 1760, 120C Follow the left "Step" for removal.
Carburetor cover 2 Refer to "CARBURETOR UNIT REMOVAL".
1 Oil hose 1
2 Derivaly hose 4,6
3 Check valve 2,3
4 Return hose -, 1
Reverse the removal steps for installation.

SERVICE POINTS
B Check valve inspection
A
Q
9 c> ~ c::> 1. Check:
• Check vavle
Out of specification -+ Replace.
A B

I~
¢:I ¢ Flow from A to B

4-19

[Link]
IFUELI~I_o_I_L_PU_M_P_______________________C_~__)
OIL PUMP
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

770,1200
OIL PUMP REMOVAL Follow the left "Step" for removal.
1 Oil pump cable -, 1
2 Oil hose 1
3 Oil delivery hose 2,3
4 Oil return hose -, 1
5 Bolt (with washer) 2
6 Oil pump 1
7 Joint -, 1
8 Ring rubber -, 1
Reverse the removal steps for installation.

4-20

[Link]
IFUELI~I_o_I_L_PU_M_P_______________________C_~__)
SERVICE POINTS
Oil pump inspection
1. Inspect:
• Oil pump
Clog -+ Clean.
• Driving tooth
Wear/Damage -+ Replace.

Oil hose inspection

1. Inspect:
• Oil hose
Wear/Crack -+ Replace.

···CAOtION:'
-------------------
• If the delivery hoses are not full of oil, fill
them up with oil.
• After installing the oil injection system,
bleed the system of air. Refer to "OIL IN-
JECTION SYSTEM" in chapter 3.

Ring rubber inspection

1. Inspect:
• Ring rubber
Wear/Damage -+ Replace.
• Joint
Wear/Damage -+ Replace.

Ring rubber installation

1. Install:
• Ring rubber CD
• JOint®
NOTE:-------------------------
Install the joint into the joint rubber until the rub-
ber stopper fits in the joint groove.

4-21

[Link]
 CHAPTER 5
POWER UNIT

ENGINE UNIT REMOVAL . ...................................... 5-1

EXPLODED DIAGRAM (XL760) .............................. 5-1
REMOVAL AND INSTALLATION CHART ...................... 5-1
EXPLODED DIAGRAM (XL 1200) ............................. 5-2
REMOVAL AND INSTALLATION CHART ...................... 5-2
SERVICE POINTS .......................................... 5-3
Shim removal ........................................... 5-3
Mount bracket inspection ................................. 5-3
Coupling clearance inspection ............................. 5-3

REED VALVE . ................................................. 5-4

EXPLODED DIAGRAM (XL760) .............................. 5-4
REMOVAL AND INSTALLATION CHART ...................... 5-4
EXPLODED DIAGRAM (XL 1200) ............................. 5-5
REMOVAL AND INSTALLATION CHART ...................... 5-5
SERVICE POINTS .......................................... 5-6
Reed valve inspection .................................... 5-6

EXHAUST RING ............................................... 5-7

EXPLODED DIAGRAM (XL760) .............................. 5-7
REMOVAL AND INSTALLATION CHART ...................... 5-7
EXPLODED DIAGRAM (XL 1200) ............................. 5-8
REMOVAL AND INSTALLATION CHART ...................... 5-8

EXHAUST CHAMBER REMOVAL ............................... 5-9

EXPLODED DIAGRAM (XL760) .............................. 5-9
REMOVAL AND INSTALLATION CHART ...................... 5-9
EXPLODED DIAGRAM (XL1200) ............................. 5-10
REMOVAL AND INSTALLATION CHART ...................... 5-10

EXHAUST CHAMBER . ......................................... 5-11

EXPLODED DIAGRAM (XL760) .............................. 5-11
REMOVAL AND INSTALLATION CHART ...................... 5-11
EXPLODED DIAGRAM (XL 1200) ............................. 5-12
REMOVAL AND INSTALLATION CHART ...................... 5-12

MUFFLER .................................................... 5-13

EXPLODED DIAGRAM (XL760) .............................. 5-13
REMOVAL AND INSTALLATION CHART ...................... 5-13
EXPLODED DIAGRAM (XL 1200) ............................. 5-14
REMOVAL AND INSTALLATION CHART ...................... 5-14

[Link]
Fow~~I~~~~~~~~~~~_
CYLINDER HEAD .. ............................................ 5-15
EXPLODED DIAGRAM (XL760) .............................. 5-15
REMOVAL AND INSTALLATION CHART ...................... 5-15
EXPLODED DIAGRAM (XL1200) ............................. 5-16
REMOVAL AND INSTALLATION CHART ...................... 5-16
SERVICE POINTS .......................................... 5-17
Cylinder head inspection .................................. 5-17

CyLINDER .................................................... 5-18

EXPLODED DIAGRAM (XL760) .............................. 5-18
REMOVAL AND INSTALLATION CHART ...................... 5-18
EXPLODED DIAGRAM (XL 1200) ............................. 5-19
REMOVAL AND INSTALLATION CHART ...................... 5-19
SERVICE POINTS .......................................... 5-20
Cylinder inspection ....................................... 5-20

PISTON . ............................................ .- ......... 5-21

EXPLODED DIAGRAM ...................................... 5-21
REMOVAL AND INSTALLATION CHART ...................... 5-21
SERVICE POINTS .......................................... 5-22
Piston pin clip removal and installation ...................... 5-22
Piston inspection ........................................ 5-22
Piston ring inspection .................................... 5-23
Piston pin and bearing inspection .......................... 5-23

FLYWHEEL MAGNETO AND BASE ............................. 5-25

EXPLODED DIAGRAM (XL760) .............................. 5-25
REMOVAL AND INSTALLATION CHART ...................... 5-25
EXPLODED DIAGRAM (XL 1200) ............................. 5-26
REMOVAL AND INSTALLATION CHART ...................... 5-26
SERVICE POINTS .......................................... 5-27
Coupling flange removal and installation .................... 5-27
Flywheel magneto removal and installation .................. 5-27
Coupling flange inspection ................................ 5-27
Flywheel magneto inspection .............................. 5-27
Idle gear assembly inspection ............................. 5-28

ELECTRICAL UNIT ............................................ 5-29

EXPLODED DIAGRAM (XL760) .............................. 5-29
REMOVAL AND INSTALLATION CHART ...................... 5-29
EXPLODED DIAGRAM (XL 1200) ............................. 5-30
REMOVAL AND INSTALLATION CHART ...................... 5-30

[Link]
Fow~~I~~~~~~~~~_~_
STARTER MOTOR ............................................. 5-31
EXPLODED DIAGRAM ...................................... 5-31
REMOVAL AND INSTALLATION CHART ...................... 5-31
SERVICE POINTS .......................................... 5-32
Pinion inspection ........................................ 5-32
Armature inspection ...................................... 5-32
Brush holder inspection ................................... 5-33
Cover inspection ......................................... 5-33

CRANKCASE ................................................. 5-34

EXPLODED DIAGRAM (XL760) .............................. 5-34
REMOVAL AND INSTALLATION CHART ...................... 5-34
EXPLODED DIAGRAM (XL 1200) ............................. 5-35
REMOVAL AND INSTALLATION CHART ...................... 5-35
SERVICE POINTS .......................................... 5-36
Crankcase inspection .................................... 5-36
Crankcase installation .................................... 5-36

CRANKSHAFT ................................................ 5-37

EXPLODED DIAGRAM (XL760) .............................. 5-37
REMOVAL AND INSTALLATION CHART ...................... 5-37
EXPLODED DIAGRAM (XL 1200) ............................. 5-38
REMOVAL AND INSTALLATION CHART ...................... 5-38
SERVICE POINTS .......................................... 5-39
Crankshaft inspection .................................... 5-39

INTERMEDIATE HOUSING REMOVAL ........................... 5-41

EXPLODED DIAGRAM ...................................... 5-41
REMOVAL AND INSTALLATION CHART ...................... 5-41

INTERMEDIATE HOUSING ..................................... 5-42

EXPLODED DIAGRAM ...................................... 5-42
REMOVAL AND INSTALLATION CHART ...................... 5-42
SERVICE POINTS .......................................... 5-43
Coupling removal and installation .......................... 5-43
Bearing removal and installation ........................... 5-43
Bearing inspection ....................................... 5-43
Coupling inspection ...................................... 5-43
Oil seal installation ....................................... 5-44

[Link]
~OW~~I_EN_G_I_N_E_U_N_IT_R_E_M_O_V_A_L_ _ _ _ _ _ _ _C_~_~_
ENGINE UNIT REMOVAL
EXPLODED DIAGRAM (XL760)

2-~
3 ,
',---,---,~
I

a271

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

ENGINE UNIT REMOVAL Follow the left "Step" for removal.
Engine hood 1 Refer to "ENGINE HOOD REMOVAL" in chapter B.
Oil tank 1 Refer to "OIL TANK" in chapter 4.
Fuel tank 1 Refer to "FUEL TANK REMOVAL" in chapter 4.
1 Battery lead 2
2 Lead coupler 3
3 Electrical box 1
4 Choke cable 1
5 Throttle cable 1
6 Grease hose 1
7 Coupling cover 1
8 Water hose 3
9 Exhaust hose clamp 1
10 Oil hose 1
11 Fuel hose 2
12 Engine mounting bolt 4
13 Shim *
14 Engine nut 1
Reverse the removal steps for installation.
*: As required

5-1

[Link]
Fow~~I_EN_I_G_N_E_U_N_IT_R_E_M_O_~_L_ _ _ _ _ _ _ _ _C_~_~
EXPLODED DIAGRAM (XL 1200)

7 Nm (0.7 mekg, 5.1 ftelb)

8-.-r....-

.>-.. )
.
' / /"~.
')
'~'J.://"
., , .. --..-/"".....:t .. /
, .
'.\.... 9 ~ .J::::..--I1-4~N~m~(0-.4-m-e~k-g,-2-.9~f-te~lb~)...,

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

ENGINE UNIT REMOVAL Follow the left "Step" for removal.

Engine hood 1 Refer to "ENGINE HOOD REMOVAL" in chapter 8.
Oil tank 1 Refer to "OIL TANK" in chapter 4.
Fuel tank 1 Refer to "FUEL TANK REMOVAL" in chapter 4.
1 Battery lead 2
2 Lead coupler 3
3 Electrical box 1
4 Choke cable 1
5 Throttle cable 1
6 Grease hose 1
7 Coupling cover 1
8 Water hose 3
9 Exhaust hose clamp 1
10 Oil hose 2
11 Fuel hose 2
12 Engine mounting bolt 4
13 Shim *
14 Engine unit 1
Reverse the removal steps for installation.
*: As required
5-2

[Link]
Fow~~I_EN_G_IN_E_U_N_I_T_R_E_M_O_V_A_L_ _ _ _ _ _ _ _ _C_E_~
SERVICE POINTS
Shim removal
1. Remove:
• Shim
NOTE:-------------------------
Make the engine mounting shim packs prior to
the mounting bolt removal for ease of reas-
sembly and coupling alignment.

Mount bracket inspection

1. Inspect:
• Mount bracket
Crack/damage --+ Replace.

Coupling clearance inspection

1. Measure:
• Clearance @
@-~- • Clearance @
•
I
Out of specification --+ Adjust using shim.
NOTE:-----------------------
• Before measuring the clearance, remove the
coupling rubber.
• Attach a straight edge and a thickness gauge.

Clearance @:
o - 1.0 mm (0 - 0.039 in)
Clearance @:
2 - 4 mm (0.079 - 0.157 in)

5-3

[Link]
~OW~~I_R_E_E_D_V_A_L_VE_ _ _ _ _ _ _ _ _ _ _ _C_~_~
REED VALVE
EXPLODED DIAGRAM (XL760)

I 6 Nm (0.6 mekg, 4.3 ftelb)

a a
1242~ 0
,"~ ~)
I a '·~/_"'_. __---,
242

: 242 0'"
I ~@ A[~ ~ --------
I 'Z~;;;2J
Vy
@,

~~
I ".

I
4

1 Nm (0.1 mekg, 0.7 ftelb)

2

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

REED VALVE REMOVAL Follow the left "Step" for removal.
Carburetor assembly Refer to "CARBURETOR REMOVAL" in chap-
ter 4.
1 Plate 1
2 Intake manifold assembly 1
3 Reed valve assembly 2
4 Plate 1
5 Valve stopper 4
6 Reed valve 4
Reverse the removal steps for installation.

5-4

[Link]
Fow~~I_R_E_E_D_V_A_L_VE____________C_~_~
EXPLODED DIAGRAM (XL 1200)

n
I

242

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

REED VALVE REMOVAL Follow the left "Step" for removal.
Carburetor assembly Refer to "CARBURETOR REMOVAL" in chap-
ter 4.
1 Bolt (with washer) 6 6 x 35 mm
2 Bolt (with washer) 10 6 x 25 mm

3 Intake manifold assembly NOTE:

4 Reed valve assembly 1 Tighten the bolts in sequence.
5 Valve stopper 3
6 Reed valve 6
6
Reverse the removal steps for installation.

5-5

[Link]
~OW~~I_R_E_E_D_V_A_L_VE~_ _ _ _ _ _ _ _ _ _ _C~E~~
SERVICE POINTS
Reed valve inspection
1. Inspect:
• Reed valve
Crack/Damage -+ Replace.
2. Measure:
• Valve bending @
Out of specification -+ Replace.

Valve bending limit:

0.2 mm (0.01 in)

® 3. Measure:
D • Valve stopper height @
Out of specification -+ Adjust or replace.

Valve stopper height:

XL760:
9.0 ± 0.2 mm (0.35 ± 0.01 in)
XL1200
12.5 ± 0.2 mm (0.49 ± 0.01 in)

5-6

[Link]
IpOVVRI~I __EX_H_A_U_S_T_R_I_N_G_______________________C_g__~
EXHAUST RING
EXPLODED DIAGRAM (XL760)

2 Nm (0.2 mekg, 1.4 ftelb)

271
18t 22 Nm (2.2 mekg, 16 ftelb)
5 2nd 40 Nm (4.0 mekg, 29 ftelb)

30 Nm (3.0 mekg, 22 ftelb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service pOints

EXHAUST RING REMOVAL Follow the left "Step" for removal.
Engine unit Refer to "ENGINE UNIT REMOVAL".
1 Water hose 2
2 Exhaust joint 1 NOTE:
3 Clamp 1 • Loosen the clamp at the muffler side.
4 Bolt (with washer) 2 • Pull and slide the exhaust joint.
S Nut 2
6 Ring 1 NOTE:
7 Clamp 1 Tighten the clamp, before installing the ring on
the muffler.

8 Joint 1
Reverse the removal steps for installation.

5-7

[Link]
IPOVVRI ~I __EX_H_A_U_S_T__R_IN_G________________________C_~__~
EXPLODED DIAGRAM (XL 1200)

30 Nm (3.0 m-kg, 22 ft-Ib) 271

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

EXHAUST RING REMOVAL Follow the left "Step" for removal.
Engine unit Refer to "ENGINE UNIT REMOVAL".
1 Water hose 3
2 Exhaust joint 2 NOTE:
3 Clamp 1 • Loosen the clamp at the muffler side.
4 Bolt (with washer) 1 • Pull and slide the exhaust joint.
S Nut 4
6 Ring 1 NOTE:
7 Clamp 1 Tighten the clamp, before installing the ring on
the muffler.

S Joint 1
Reverse the removal steps for installation.

5-8

[Link]
Fow~~I_EX_H_A_U_S_T_C_H_A_M_B_E_R_R_E_M_O_V_A_L_ _ _ _ _ _C_~_~
EXHAUST CHAMBER REMOVAL
EXPLODED DIAGRAM (XL760)

1st 2 Nm (0.2 m-kg, 1.4 ft-Ib)

3rd 47 Nm (4.7 m-kg, 34 ft-Ib) 40 Nm (4.0 m-kg, 29 ft-Ib)
1
3
--s 271

a
271

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

EXHAUST CHAMBER Follow the left "Step" for removal.
REMOVAL
Ring 1 Refer to "EXHAUST RING".
1 Thermo switch 1
2 Exhaust hose 5 NOTE:
3 Bolt (muffler) 1 Tighten the bolts in sequence.
4 Exhaust chamber assembly 4
5 Bolt (muffler stay) 1
6 Muffler stay Reverse the removal steps for installation.

5-9

[Link]
Fow~~I_EX_H_A_U_S_T_C_H_A_M_B_E_R_R_E_M_O_V_A_L_______C_~_~
EXPLODED DIAGRAM (XL 1200)

1st
3rd
40 Nm (4.0 mekg, 29 ftelb)

1.
a271

6 4

271

40 Nm (4.0 mekg, 29 ftelb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

EXHAUST CHAMBER Follow the left "Step" for removal.
REMOVAL
Ring assembly Refer to "EXHAUST RING".
1 Thermo switch 1
2 Bolt (with washer) 2 M8 x 35 mm .12
3 Bolt (with washer) 2 M8 x 35 mm .14
4 Exhaust chamber assembly 1 NOTE:
Tighten the bolts sequence.

5 Bolt (muffler stay) 4 M10 x 45 mm

6 Muffler stay 1
Reverse the removal steps for installation.

5-10

[Link]
Fow~~I_E_X_H_A_U_S_T_C_HA_M_B_E_R_ _ _ _ _ _ _ _ _C_~_)
EXHAUST CHAMBER
EXPLODED DIAGRAM (XL760)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

CHAMBER DISASSEMBLY Follow the left "Step" for removal.
Exhaust chamber assembly Refer to "EXHAUST CHAMBER REMOVAL".
1 Bolt (with washer) 6
2 Exhaust cover 1 1
3 Bolt (with washer) 2
4 Bolt (with washer) 7
5 Exhaust cover 2 1
6 Muffler 1
7 Screw 3
8 Seal 1
Reverse the removal steps for installation.

5-11

[Link]
Fow~~I_E_X_H_A_U_S_T_C_H_AM_B_E_R_ _ _ _ _ _ _ _ _C_~_)
EXPLODED DIAGRAM (XL 1200)

a
271

1st 15 Nm (1.5 m-kg, 11 ft-Ib)

2nd 30 Nm (3.0 m-kg, 22 ft-Ib)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

CHAMBER DISASSEMBLY Follow te left "Step" for removal.
Exhaust chamber assembly Refer to "EXHAUST CHAMBER REMOVAL".
1 Bolt (with washer) 6 M8 x 60 mm
2 Exhaust outer cover 1 1 NOTE:
3 Muffler 2 1 Tighten the bolts in sequence.
4 Exhaust inner cover 1
5 Seal 1
6 Exhaust outer cover 2 1
7 Stopper 1
8 Seal 1
Reverse the removal steps for installation.

5-12

[Link]
Fow~~I_M_U_F_F_L_ER_____________C_E_~
MUFFLER
EXPLODED DIAGRAM (XL760)

15t 22 Nm (2.2 mekg, 16 ftelb)

2nd 40 Nm (4.0 mekg, 29 ftelb)

/~~

4 /~
~ 1

a271
1 Nm (0.1 mekg, 0.7 ftelb)

15t 22 Nm (2.2 mekg, 16 ftelb) 2

2nd 40 Nm (4.0 mekg, 29 ftelb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

MUFFLER REMOVAL Follow the left "Step" for removal.
Exhaust chamber assembly Refer to "EXHAUST CHAMBER REMOVAL".
1 Water inlet hose 1
2 Bolt (with washer) 8
3 Muffler 1
4 Gasket 1
Reverse the removal steps for installation.

5-13

[Link]
~OW~~I_M_UF_F_L_E_R_ _ _ _ _ _ _ _ _ _ _ _C_~_~
EXPLODED DIAGRAM (XL 1200)

15t 15 Nm (1.5 m-kg, 11 ft-Ib)

2nd 30 Nm (3.0 m-kg, 22 ft-Ib)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

MUFFLER REMOVAL Follow the left "Step" for removal.
Exhaust chamber assembly Refer to "EXHAUST CHAMBER REMOVAL".
1 Water inlet hose 1
2 Bolt (with washer) 12 M8 x 120 mm
3 Muffler assembly 1 NOTE:
4 Bolt (with washer) 5 Tighten the bolts in sequence and two steps of
torque.
5 Muffler 1 1
6 Muffler cover 1
Reverse the removal steps for installation.

5-14

[Link]
Fow~~I_C~Y_L_IN_D_E_R_H_EA_D_ _ _ _ _ _ _ _ _ _C_~_~
CYLINDER HEAD
EXPLODED DIAGRAM (XL760)

25 Nm (2.5 m-kg, 18 ft-Ib)

1st 15 Nm (1.5 m-kg, 11 ft-Ib)

2nd 36 Nm (3.6 m-kg, 26 ft-Ib)
3-~

a
572

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

CYLINDER HEAD REMOVAL Follow the left "Step" for removal.
Muffler Refer to "MUFFLER".
1 Spark plug 2
2 Water hose 2
3 Bolt (with washer) 10 NOTE:
Tighten the bolts in sequence and two steps of
torque.

4 Cylinder head 1
Reverse the removal steps for installation.

5-15

[Link]
IpOVVRI"!l:I~C_Y_LI_N_D_E_R_H_E_A_D_______________________C_~__~
EXPLODED DIAGRAM (XL 1200)

4 Nm (0.4 m-kg, 2.9 ft-Ib)

8 Nm (0.8 m-kg, 5.8 ft-Ib)
~ ..
15 Nm (1.5 m-kg, 11 ft-Ib)
30 Nm (3.0 m-kg, 22 ft-Ib)

L~'I ~..NI'"'
1st 15 Nm (1.5 m-kg, 11 ft-Ib)
2nd 32 Nm (3.2 m-kg, 23 ft-Ib)

tTl
572

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

CYLINDER HEAD REMOVAL Follow the left "Step" for removal.
Muffler stay Refer to "EXHAUST CHAMBER".
1 Spark plug cap 3
2 Spark plug 3
3 Bolt (with washer) 11 M8 x 50 mm
4 Bolt (with washer) 4 M8 x 65 mm
5 Cylinder head 1 NOTE:
6 Bolt (with washer) 15 Tighten the bolts in sequence and two steps of
7 Cylinder head cover 1 torque.

Reverse the removal steps for installation.

5-16

[Link]
Fow~~I_C_Y_L_IN_D_E_R_H_E_A_D_ _ _ _ _ _ _ _ _ _C_~_~
SERVICE POINTS
Cylinder head inspection
1. Eliminate:
• Carbon deposits
Use a rounded scraper CD.
NOTE:-----------------------
Take care to avoid damaging the spark plug
threads. Do not use a sharp instrument. Avoid
scratching the aluminum.

2. Inspect:
• Cylinder head water jacket
Mineral deposits/corrosion -+ Clean.
3. Measure:
• Cylinder head warpage
Out of specification -+ Resurface.

IvAl
~I Warpage limit:
0.1 mm (0.004 in)

Warpage measurement and resurfacing

steps:
• Attach a straight edge and a thickness
gauge on the cylinder head.
• Measure the warpage.
• If the warpage is out of specification, re-
surface the cylinder head.
• Place a 400 - 600 grit wet sandpaper on
the surface plate, and resurface the head
using a figure-eight sanding pattern.

5-17

[Link]
~OW~~I_C_Y_L_IN_D_E_R_ _ _ _ _ _ _ _ _ _ _ _C_~_~
CYLINDER
EXPLODED DIAGRAM (XL760)

1 st 23 Nm (2.3 mekg, 17 ftelb)

2nd 40 Nm (4.0 mekg, 29 ftelb)

o
rn

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

CYLINDER REMOVAL Follow the left "Step" for removal.
Cylinder head Refer to "CYLINDER HEAD".
1 Bolt (with washer) 6 NOTE:
Tighten the bolts in sequence and in two steps
of torque.

2 Cylinder 1 NOTE:
After installing, check the smooth movement of
the piston.

3 Pin 2
Reverse the removal steps for installation.

5-18

[Link]
FOW~.JI_C~Y~L~IN~D~E~R~____________C_~_)
EXPLODED DIAGRAM (XL 1200)

1st 23 Nm (2.3 mekg, 17 ftelb)

2nd 40 Nm (4.0 mekg, 29 ftelb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

CYLINDER REMOVAL Follow the left "Step" for removal.
Cylinder head Refer to "CYLINDER HEAD".
1 Bolt (with washer) 2 M10 x 55 mm
2 Bolt (with washer) 6 M10 x 40 mm
NOTE:
Tighten the bolts in sequence and in tWo steps
of torque.

NOTE:
3 Cylinder 1 After installing, check the smooth movement of
4 Pin 2 the piston.

Reverse the removal steps for installation.

5-19

[Link]
Fow~~I_C_Y_L_IN_D_E_R____________C_g_~
SERVICE POINTS
Cylinder inspection
1. Eliminate:
• Carbon deposits
Use a rounded scraper CD.

2. Inspect:
• Cylinder water jacket
Mineral deposits/Corrosion -+ Clean.
• Cylinder inner surface
Score marks -+ Repair or replace.
Use #600 - 800 grit wet sandpaper.

3. Measure:
• Cylinder bore "D"
Use cylinder gauge.
Out of limit -+ Replace.
NOTE:-------------------------
Measure the cylinder bore "D" in parallel. Then,
find the average of the measurement.

~Cylinder
Standard

84.00 - 84.02 mm
Limit

84.1 mm
bore "0" (3.307 - 3.308 in) (3.31 in)
0.08 mm
Taper"T" - (O.003 in)
/~, Out of
-
0.05 mm
round "R" (O.002 in)
,~
-------
..... .... 0= Maximum (01 - Os)
T= (Maximum 0 1 or O2) - (Maximum
Os or Os)
R= (Maximum 0 1, 0 3 or Os) - (Minimum
O2 ,04 or Os)

5-20

[Link]
Fow~~I_p~I~ST~O~N~____________C_~_)
PISTON
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

760,1200
PISTON REMOVAL Follow the left "Step" for removal.
Cylinder Refer to "CYLINDER".

1 Piston pin clip 4,6 [Link]:

2 Piston pin 2,3 Do not allow the clip open ends to meet the
piston pin slot @.

NOTE:
3 Piston 2,3 Be sure the arrow @ side is positioned ex-
4 Washer 4,6 haust pipe.

CAUtION:j;
5 Piston ring 4,6 Align each end gap with the locating pin.

Reverse the removal steps for installation.

5-21

[Link]
Fow~~I_p_I_ST_O_N_____________C_~_)
SERVICE POINTS
Piston pin clip removal and installation
1. Remove and install:
• Piston pin clip
NOTE:-------------------------
Before removing and installing piston pin clip,
cover crankcase with a clean rag to prevent
piston pin clip from falling into crankcase cav-
ity.

Piston inspection
1. Eliminate:
• Carbon deposits
From the piston crown and ring groove.

2. Inspect:
• Piston wall
Score marks -+ Repair or replace.
Use #600 - 800 grit wet sandpaper.
NOTE:-----------------------
Sand in a criss-cross pattern. Do not sand ex-
cessively.

3. Measure:
• Piston skirt diameter
Use micrometer.
Out of specification -+ Replace.

Piston diameter Distance@

83.902 - 83.921 mm 10mm

(3.3032 - 3.3040 in) (0.39 in)

4. Calculate:
• Piston clearance
Out of limit -+ Replace piston, piston
rings as a set.

PISTON _ CYLINDER PISTON

CLEARANCE BORE DIAMETER

Piston clearance:
0.100 - 0.105 mm
(0.0039 - 0.0041 in)

5-22

[Link]
~OW~~I_P_IS_T_O_N_ _ _ _ _ _ _ _ _ _ _ _C_~_)
Piston ring inspection
1. Measure:
• Side clearance
Out of specification -+ Replace piston
and/ or ring.
Use a thickness gauge CD.

Side clearance:
Top
2nd
0.02 - 0.07 mm
(0.001 - 0.003 in)

2. Measure:
• End gap
Out of specification -+ Replace rings as a
set.
Use a thickness gauge CD.

End gap:
Top
2nd
0.2 - 0.4 mm
(0.008 - 0.016 in)

NOTE:-------------------------
• Install the piston ring into the cylinder.
• Push the ring with the piston crown.

Piston pin and bearing inspection

1. Inspect:
• Piston pin
• Bearing
Signs of heat discoloration -+ Replace.

5-23

[Link]
~OW~~I_P_I_~_O_N_ _ _ _ _ _ _ _ _ _ _ _ _C_~_~
2. Measure:
• Piston pin outside diameter
Use micrometer CD.
Out of limit -+ Replace.

Piston pin outside diameter:

Standard
19.995 - 20.000 mm
(0.7872 - 0.7874 in)
Limit
19.98 mm (0.786 in)

3. Check:
• Free play (when the piston pin is in place
in the piston)
There should be no noticeable free play.
Free play exist -+ Replace piston pin
and/or piston.

4. Check:
• Free play
There should be no noticeable free play.
Free play exist -+ Inspect the connecting
rod for wear/Replace the pin and/
or connecting rod as required.

5-24

[Link]
Fow~~I_FL_Y_W_H_E_E_L_M_A_G_N_E_T_O_A_ND_B_A_S_E______C_~_~
FLYWHEEL MAGNETO AND BASE
EXPLODED DIAGRAM (XL760)

8 Nm (0.8 mekg, 5.8 ftelb)

37 Nm (3.7 mekg, 27 ftelb)

a572

242
5 Nm (0.5 mekg, 3.6 ftelb)
5
70 Nm (7.0 mekg, 50 ftelb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

FLYWHEEL MAGNETO AND Follow the left "Step" for removal.
BASE DISASSEMBLY
Engine unit Refer to "ENGINE UNIT REMOVAL".
Oil pump Refer to "OIL PUMP" in chapter 4.
1 Grease hose 1
2 Flywheel cover 1
3 Base assembly 1
4 Coupling flange 1 NOTE:
5 Flywheel magneto 1 Fill the water resistant grease into the flywheel
6 Idle gear assembly 1 cover groove.

Reverse the removal steps for installation.

5-25

[Link]
Fow~~I_FL_Y_W_H_E_E_L_M_A_G_N_E_ro_A_N_D_B_A_S_E_ _ _ _ _C_~_~_
EXPLODED DIAGRAM (XL1200)

37 Nm (3.7 mekgf, 27 ftelb)

70 Nm (7.0 mekgf, 50 ftelb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

FLYWHEEL MAGNETO AND Follow the left "Step" for removal.
BASE DISASSEMBLY
Engine unit Refer to "ENGINE UNIT REMOVAL".
Oil pump Refer to "OIL PUMP" in chapter 4.
1 Grease hose 1
2 Bolt (with washer) 8 M8 x 30 mm
3 Bolt (with washer) 1 M8 x 55 mm
4 Flywheel cover assembly 1
5 Coupling flange 1
6 Flange bolt 1
7 Flywheel magneto 1
8 Woodruff key 1 NOTE:
9 Idle gear assembly 1 Fill the water resistant grease into the flywheel
cover groove.

Reverse the removal steps for installation.

5-26

[Link]
Fow~~I_FL_Y_W_H_E_E_L_M_A_G_N_E_T_O_A_N_D_B_A_S_E______C_~_~
SERVICE POINTS
Coupling flange removal and installation
1. Remove and install:
• Coupling flange

Coupler wrench:
YW-06546/90890-06546
Flywheel holder:
XL760
YW-06547/90890-06547
XL1200
YW-41528/90890-06545

Flywheel magneto removal and installation

1. Remove and install:
• Bolt

Flywheel holder:
XL760
YW-06547/90890-06547
XL1200
YW-41528/90890-06545

2. Remove:
• Flywheel magneto

Flywheel puller:
YB-06117/90890-06521
Bolt:
M8 x 60 mm

[8] For USA and CANADA

[S] Except for USA and CANADA
"·•·[Link].···.···
-------------------
To prevent damage to the engine or tools, screw
in the flywheel puller set-bolts evenly and com-
pletely so that the puller plate is parallel to the
flywheel.

Coupling flange inspection

1. Inspect:
• Coupling flange
Wear/damage - t Replace.

Flywheel magneto inspection

1. Inspect:
• Flywheel gear
Wear/damage - t Replace.

5-27

[Link]
Fow~~I_FL_Y_W_H_E_E_L_M_A_G_N_E_T_O_A_N_D_B_A_S_E______C_~_~
Idle gear assembly inspection
1. Inspect:
• Pinion gear @
• Inner gear @
Wear/damage -+ Replace.
2. Check:
• Clutch movement
Unsmooth movement -+ Replace.

5-28

[Link]
IpOVVRI~I __E_LE_C_T_R_IC_A__L_U_N_IT______________________C_g__~
ELECTRICAL UNIT
EXPLODED DIAGRAM (XL760)

5 Nm (0.5 mekg, 3.6 ftelb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

ELECTRICAL UNIT REMOVAL Follow the left "Step" for removal.
Electrical box Refer to "ENGINE UNIT REMOVAL".
Base assembly Refer to "FLYWHEEL MAGNETO AND
BASE".
1 Spark plug cap 2
2 Thermo switch 1
3 Starter motor negative lead 1
4 Housing 1
5 Starter motor 1
Reverse the removal steps for installation.

5-29

[Link]
IpOWRI*1 ELECTRICAL UNIT

EXPLODED DIA GRAM (XL1200)

~~~ 4

SNm (0 .S m·kg, 3.6 tt·lb)

~
C'}.
,"ft '.~~
~'llJ ~~<1[
~~f l
~/ 572 I 4 Nm (0.4 !'k9 , 2.9 ft·lb) I

REMOVAL A ND INSTALLATIO N CHART

II
,-
Step I
-
Procedure/Part ~me I O'ty 1 Service points I
-
ELECTRICAL UNIT Follow the left "Step" for removal.
DISASSEMBLY

Refer to "ENGI~~~~ MAGNETO AND

Electrical box IT REMOVAL".
Base assembly Refer to "FLYW
BASE".
1 Spark plug cap 3
2 o switch d 1
3 Therm
Starter motor p ositive lea 1

1
4 1
Housing
Battery ca ble (negative)

1~
5
6 Starter motor
Reverse the removal steps for installation.
L ---.J

5-30

[Link]
IpOWRI*1
STARTER MOTOR
STARTER MOTOR

EXPLODED DIAGRAM

t = 0.5 mm
t = 0.2 mm
2

7 Nm (0.7 mekg, 5.1 ftelb)

t = 0.8 mm

~
()() 4

1...-------,1
t = 0.2 mm

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

STARTER MOTOR Follow the left "Step" for removal.
DISASSEMBLY
Starter motor assembly Refer to "ELECTRICAL UNIT".
1 Through bolt 2
2 Front bracket 1
3 Armature assembly 1
4 Rear bracket 1
5 Bolt 1
6 Brush holder 1
7 York assembly 1
Reverse the removal steps for installation.

5-31

[Link]
I pOWRI~I_~~~~~~~~~_~_
. . ,..... STARTER MOTOR '--S.--I

SERVICE POINTS
Pinion inspection
1. Inspect:
• Pinion teeth CD
Wear/Damage -+ Replace.

Armature inspection
1. Inspect:
• Commutator
Dirty -+ Clean with #600 abrasive paper.

2. Measure:
• Commutator diameter
Out of specification -+ Replace.

Commutator diameter:
Limit 27 mm (1.06 in)

3. Check:
• Commutator undercut
Clog/Dirt -+ Clean.
NOTE:-------------------------
Remove all particles of mica and metal using
compressed air.

4. Measure:
• Commutator undercut
Out of specification -+ Replace.

Commutator undercut:
Limit 0.2 mm (0.01 in)

5-32

[Link]
Fow~~I_s_T_A_R_T_ER_M_O_ro_R__________C_~_~
5. Inspect:
® • Armature coil continuity
Out of specification -i- Replace.

~ Armature coil continuity:

Commutator segments G) Continuity

Segment-Laminations ® Discontinuity
Segment-Shaft Discontinuity

Brush holder inspection

1. Measure:
• Brush length @
Out of specification -i- Replace.

@ Brush length:
Limit 6.5 mm (0.26 in)

2. Check:
• Brush holder continuity
Out of specification -i- Replace.

PJj Brush holder continuity:

Brush holder-Base I Discontinuity

Cover inspection
1. Inspect:
• Cover bushing
Wear/damage -i- Replace the cover.

5-33

[Link]
Fow~~I_c_R_A_N_K_C_A_S_E___________C_~_~
CRANKCASE
EXPLODED DIAGRAM (XL760)

1st 23 Nm (2.3 mekg, 17 ftelb)

1st 15 Nm (1.5 mekg, 11 ftelb)
2nd 53 Nm (5.3 mekg, 38 ftelb)
2nd 28 Nm (2.8 mekg, 20 ftelb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

CRANKCASE DISASSEMBLY Follow the left "Step" for removal.
Base assembly Refer to "FLYWHEEL MAGNETO AND
BASE".
Starter motor Refer to "ELECTRICAL UNIT".
Piston Refer to "PISTON".
1 Engine mount bracket 2
2 Bolt (with washer) 8 NOTE:
Tighten the bolts in sequence and in two steps
of torque.

3 Mount rubber 1 NOTE:

Be sure that the "F" mark @ is on the
flywheel side.

4 Crankcase 1
Reverse the removal steps for installation.

5-34

[Link]
~OW~~I_C_R_A_N_K_C_AS_E_ _ _ _ _ _ _ _ _ _ _C_I_)
EXPLODED DIAGRAM (XL 1200)

:7~r--6

~ 1st 15 Nm (1.5 mekg, 11 ftelb)

28 Nm (2.8 mekg, 20 ftelb)

I
I
!-3
271

1st 23 Nm (2.3 mekg, 17 ftelb)

8 Nm (0.8 mekg, 5.8 ftelb) 2nd 53 Nm (5.3 mekg, 38 ftelb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

CRANKCASE DISASSEMBLY Follow the left "Step" for removal.
Base assembly Refer to "FLYWHEEL MAGNETO AND
BASE".
Starter motor Refer to "ELECTRICAL UNIT".
Piston Refer to "PISTON".
1 Bolt 2
2 Mount rubber 1
3 Bolt (with washer) 9
4 Engine mount bracket 2
5 Bolt (with washer) 8
6 Crankcase 1 NOTE:
Tighten the bolts in sequence and in two steps
of torque.

Reverse the removal steps for installation.

5-35

[Link]
Fow~~I_c_R_A_N_K_C_A_S_E___________C_~_)
SERVICE POINTS
Crankcase inspection
1. Inspect:
• Contacting surface
Scratch -+- Replace.
• Crankcase
Crack/damage -+ Replace.

Crankcase installation
1. Apply:
• Gasket Maker
NOTE:-------------------------
Clean the contacting surface of crankcase be-
fore applying the Gasket Maker.

2. Check:
• Crankshaft
Rough action -+ Repair.
NOTE:-------------------------
After installing, check the smooth movement of
the crankshaft.

5-36

[Link]
Fow~~I_c_R_A_N_K_S_HA_F_T___________C_~_)
CRANKSHAFT
EXPLODED DIAGRAM (XL760)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

CRANKSHAFT REMOVAL Follow the left "Step" for removal.
Crankcase Refer to "CRANKCASE".
1 Crankshaft assembly 1
CAUTION:
• Do not allow the bearing clip open ends to
meet the crankcase contacting surface .
• Place the locating pins on the bearing
into the crankcase body groove.

2 Dowel pin 5
3 Oil seal 3

Reverse the removal steps for installation.

5-37

[Link]
~OW~~I_C_R_A_N_K_S_H_A_~_ _ _ _ _ _ _ _ _ _ _C_~_~
EXPLODED DIAGRAM (XL 1200)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

CRANKSHAFT REMOVAL Follow the left "Step" for removal.
Crankcase Refer to "CRANKCASE".
1 Crankshaft assembly 1
CAUTION:
• Do not allow the bearing clip open ends to
meet the crankcase contacting surface .
• Place the locating pins on the bearing
into the crankcase body groove.

2 Dowel pin 8
3 Oil seal 3
Reverse the removal steps for installation.

5-38

[Link]
Fow~~I_c_R_A_N_K_SH_A_F_T___________C_~_)
SERVICE POINTS
Crankshaft inspection
1. Measure:
• Crank width ®
Out of specification -+ Replace.

Crank width:
61.95 - 62.00 mm
(2.439 - 2.441 in)

2. Measure:
• Deflection ®
Use a dial gauge.
Out of specification -+ Replace.

Maximum deflection:
0.05 mm (0.002 in)

3. Measure:
• Big end side clearance ©
Use a thickness gauge.
Out of specification -+ Replace.

Big end side clearance:

~©
0.25 - 0.75 mm
(0.010 - 0.030 in)

4. Measure:
• Small end free play @
Use a dial gauge.
Out of specification -+ Replace.

Small end free play:

2.0 mm (0.08 in)

5. Inspect:
• Crankshaft bearing
Pitting/damage -+ Replace.
NOTE:-------------------------
Lubricate the bearings immediately after ex-
amining them to prevent rusting.

5-39

[Link]
IpOWR!1J: I CRANKSHAFT
6. Inspect:
• Crankshaft oil seal
Wear/damage ~ Replace.

5-40

[Link]
IpOWRlal INTERMEDIATE HOUSING REMOVAL
INTERMEDIATE HOUSING REMOVAL
EXPLODED DIAGRAM

17 Nm (1.7 mekg, 12 ftelb)

5
2

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

INTERMEDIATE HOUSING Follow the left "Step" for removal.
REMOVAL
Engine unit Refer to "ENGINE UNIT REMOVAL".
1 Bolt (with washer) 3
2 Bearing housing assembly 1
3 Pin 2
4 Bolt (with washer) 3
5 Housing 1
6 Shim * NOTE:
Install the previously marked shims back into
their original location.

Reverse the removal steps for installation.

*: As required

5-41

[Link]
Fow~~I_I_N_T_E_R_M_E_D_IA_T_E_H_O_U_S_IN_G_ _ _ _ _ _ _ _ _C_~_)
INTERMEDIATE HOUSING
EXPLODED DIAGRAM

o o
6Nm(O.6m kgf,4.3ft lb) a ~~3

572~
~~6 ...........- - - -

5
_~

'>
4

'~
1 2~c:9~
~~
a 572

37 Nm (3.7 mekgf, 27 ftelb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

INTERMEDIATE HOUSING Follow the left "Step" for removal.
DISASSEMBLY
Bearing housing assembly Refer to "INTERMEDIATE HOUSING RE-
MOVAL".
1 Coupling 1
2 Shaft 1 ~ Distance: .
3 Oil seal 1 @: 1.6 - 2.0 mm (0.06 - 0.08 m)
4 Oil seal 1 @: 14.5 - 15.5 mm*1
5 Clip 1 (0.57 - 0.61 in)
6 Bearing 1 9.5 - 10.5 mm*2
(0.37 - 0.41 in)
@: 6.8 - 7.2 mm (0.27 - 0.28 in)
@: 17.6 - 17.7 mm (0.69 - 0.70 in)

Reverse the removal steps for installation.

*1: XL760 *2: XL 1200

5-42

[Link]
Fow~~I_I_N_T_ER_M_E_D_I_M_E_H_O_U_S_I_NG_ _ _ _ _ _ _ _C_E_)_
SERVICE POINTS
Coupling removal and installation
1. Remove and install:
• Coupling

Coupler wrench:
YW-06546/90890-06546
Shaft holder:
YW-38742/90890-06069

Bearing removal
1. Remove
• Bearing

Driver rod:
YB-06071 190890-06606
Bearing outer race attachment:
YB-06015/90890-06636

Bearing inspection
1. Inspect:
• Bearing
Rotate inner race by hand.
Rough spots/seizure -+ Replace.
• Shaft
Pitting damage -+ Replace.
• Hose
Wear/cracks -+ Replace.

Coupling inspection
1. Inspect:
• Coupling flange
• Coupling rubber
Wear/damage -+ Replace.

Bearing installation
1. Install:
• Bearing

Driver rod:
YB-06071 190890-06606
Bearing outer race attachment:
YB-06085/90890-06625

5-43

[Link]
Fow~~I_IN_T_E_R_M_E_D_IA_T_E_H_O_U_S_IN_G_ _ _ _ _ _ _ _ _C_~_~
. Oil seal installation
1. install:
• Oil seal [T =8 mm (0.31 in)]

Distance@:
6.8 - 7.2 mm (0.27 - 0.28 in)

Driver rod:
YB-06071 190890-06606
Bearing outer race attachment:
YB-06085/90890-06625

NOTE:-------------------------
Fill the water resistant grease on the clip in-
ner circumference before installing the oil
seal.

2. Install:
• Shaft
Distance@:
XL760
14.5 - 15.5 mm (0.57 - 0.61 in)
XL1200
9.5 - 10.5 mm (0.37 - 0.41 in)

3. Install:
• Oil seal [T = 10 mm (0.38 in)]

Distance@:
1.6 - 2.0 mm (0.06 - 0.08 in)

NOTE:-------------------------
Fill the water resistant grease on the housing
inner circumference before installing the· oil
seal.

5-44

[Link]
 CHAPTER 6
JET PUMP UNIT

JET PUMP UNIT REMOVAL .................................... 6-1

EXPLODED DIAGRAM ...................................... 6-1
REMOVAL AND INSTALLATION CHART ...................... 6-1

NOZZLE DEFLECTOR AND REVERSE GATE .................... 6-2

EXPLODED DIAGRAM ...................................... 6-2
REMOVAL AND INSTALLATION CHART ...................... 6-2

NOZZLE, DUCT AND INTAKE . .................................. 6-3

EXPLODED DIAGRAM ...................................... 6-3
REMOVAL AND INSTALLATION CHART ...................... 6-3
SERVICE POINTS .......................................... 6-4
Housing inspection ....................................... 6-4

IMPELLER AND DRIVE SHAFT ................................. 6-5

EXPLODED DIAGRAM ...................................... 6-5
REMOVAL AND INSTALLATION CHART ...................... 6-5
SERVICE POINTS .......................................... 6-6
Drive shaft removal ...................................... 6-6
Impeller inspection ....................................... 6-6
Drive shaft inspection .................................... 6-6
Bearing inspection ....................................... 6-6
Drive shaft installation .................................... 6-7

INTAKE DUCT . ................................................ 6-9

EXPLODED DIAGRAM ...................................... 6-9
REMOVAL AND INSTALLATION CHART ...................... 6-9
SERVICE POINTS .......................................... 6-10
Oil seal and bushing removal .............................. 6-10
Housing inspection ....................................... 6-10
Seal rubber inspection .................................... 6-10
Bushing and oil seal installation ............................ 6-10

COOLING AND BILGE SYSTEM ................................ 6-11

EXPLODED DIAGRAM ...................................... 6-11
REMOVAL AND INSTALLATION CHART ...................... 6-11
SERVICE POINTS .......................................... 6-11
Bilge strainer inspection .................................. 6-11
Hose inspection ......................................... 6-11

[Link]
 JET PUMP UNIT REMOVAL
JET PUMP UNIT REMOVAL
EXPLODED DIAGRAM

5 {}- 7
~

1.4 Nm (0.14 mekgf, 1.0 ftelb)

~) 6

7 Nm (0.7 mekgf, 5.1 ftelb) 1

4 Nm (0.4 mekg, 2.9 ftelb)

17 Nm (1.7 mekg, 12 ftelb) 17 Nm (1.7 mekg, 12 ftelb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

JET PUMP UNIT REMOVAL Follow the left "Step" for removal.
1 Intake screen 1
2 Speed sensor 1
3 Ride plate 1
4 Bilge hose 1
5 Shift cable joint 1
6 Steering cable joint 1
7 Spout hose 1
8 Engine COOling hose 1
9 Jet pump unit 1 NOTE:
• Pull the jet pump unit straight backward .
• When installing the jet pump unit, align the
drive shaft spline (male) with the intermedi-
ate shaft spline (female).

Reverse the removal steps for installation.

6-1

[Link]
 NOZZLE DEFLECTOR AND REVERSE GATE
NOZZLE DEFLECTOR AND REVERSE GATE
EXPLODED DIAGRAM

19 Nm (1.9 mekgf, 13 ftelb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

NOZZLE DEFLECTOR AND Follow the left "Step" for removal.
REVERSE GATE REMOVAL
Jet pump unit Refer to the "JET PUMP UNIT REMOVAL"
section.
1 Nozzle deflector assembly 1
2 Spring 2
3 Plate 2
4 Shift lever 1
5 Reverse gate 1
6 Ball joint 1
7 Lever 1
8 Ball joint 1 M6
9 Nozzle deflector 1
Reverse the removal steps for installtion.

6-2

[Link]
Lp_ ~JUE~T~p~I.__·~71. _____
NOZZLE, _________________________
~DUCT AND INTAKE C_~E_)
NOZZLE, DUCT AND INTAKE
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

NOZZLE, DUCT AND INTAKE Follow the left "Step" for removal.
REMOVAL
Trim ring Refer to "DEFLECTOR AND TRIM RING" sec-
tion.

1 Bolt 4
2 Nozzle 1 NOTE:
3 Impeller duct assembly 1 Clean the contacting surfacews before applying
4 Housing 1 the Gasket Marker.

S Intake duct assembly 1

6 Pin 6
Reverse the removal steps for installation.

6-3

[Link]
NOZZLE, DUCT AND INTAKE
SERVICE POINTS
Housing installation
1. Fill:
• Intake duct housing

~ Water resistant grease:

•U 130 - 170 cm 3 (7.8 -10.4 cu. in)

6-4

[Link]
 IMPELLER AND DRIVE SHAFT
IMPELLER AND DRIVE SHAFT
EXPLODED DIAGRAM

18 Nm (1.8 m-kg, 13 ft-Ib)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service pOints

IMPELLER AND DRIVE SHAFT 760. 120C Follow the left "Step" for removal
DISASSEMBLY
Impeller duct assembly Refer to "DEFLECTOR, NOZZLE AND DUCT".
1 Impeller 1
2 Cap 1
3 Nut -, 1
4 Drive shaft assembly 1
5 Bearing (rear) 1
6 Spacer -, 1
7 Bearing (front) 1
8 Oil seal 2 Reverse the removal steps for installation.

6-5

[Link]
Lp
_ _JUE~T_p~I. __
4~rl. _______________________________
IMPELLER AND DRIVE SHAFT C ~E_)
__
SERVICE POINTS
Drive shaft removal
[Link]:
• Impeller

Drive shaft holder:

YB-06049/90890-06518
NOTE:-------------------------
The impeller has a left-hand thread. Turn the im-
peller clockwise to loosen it.

2. Remove: (XL 1200)

• NutCD
Drive shaft holder:
YB-06049/90890-06518

3. Remove:
• Drive shaft and bearing (rear) CD
• Bearing (rear) ®
NOTE:---------------------------------
Use a press.

4. Remove:
• Bearing (front)

Slide hammer set:

90890-06523
YB-06096/90890-06531

Impeller inspection
Refer to "JET PUMP UNIT" in chapter 3.

Drive shaft inpsection

1. Inpsect:
• Drive shaft
Damage -+ Replace.

Bearing inspection
1. Inspect:
• Bearing (front and rear)
Rotate inner race by hand.
Rough spot/seizure -+ Replace.

6-6

[Link]
 IMPELLER AND DRIVE SHAFT
Drive shaft installation
1. Install:
• Oil seal

Driver rod:
YB-06071 190890-06606
Ball bearing attachment:
YB-06156/90890-06634

2. Install: (XL760)
• Bearing (front) CD

I~
Distance@:
o mm (0 in)

3. Install: (XL1200)
• Bearing (front) CD
• Drive shaft and bearing

Distance@:
@-4--- 23 ± 0.1 mm (0.91 ± 0.004 in)

4. Fill:
• Between the drive shaft and spacer

Water resistant grease:

760: 21 cm 3 (1.3 cu. in)
1200: 13 cm 3 (0.8 cu. in)

5. Install:
760 1200
• Bearing (rear) CD
NOTE:-----------------------
When install the bearing, press bearing inner
race and outer race together.

6-7

[Link]
IMPELLER AND DRIVE SHAFT
6. Fill:
• Into the cap

Water resistant grease:

18 cm 3 (1.1 cu. in)

7. Install:
• Nut CD (XL 1200)
• Impeller

Drive shaft holder:

YB-06049/90890-06518

6-8

[Link]
 INTAKE DUCT
INTAKE DUCT
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

INTAKE DUCT DISASSEMBLY Follow the left "Step" for removal.
Intake duct assembly Refer to "NOZZLE, DUCT AND INTAKE".
1 Bolt (with washer) 1
2 Spacer 1
3 Oil seal 2
4 Bushing 1
5 Intake duct 1
Reverse the removal steps for installation.

6-9

[Link]
 INTAKE DUCT CD
SERVICE POINTS
Oil seal and bushing removal
1. Remove:
• Oil seal CD
• Bushing®

Driver rod:
27 mm (1.06 in) YB-06229/90890-06605
Ball bearing attachment:
YB-06021 190890-06638

Housing inspection
1. Inspect:
• Housing inner surface
Wear/Damage -t- Replace.
Seal rubber inspection
1. Inspect:
• Seal rubber
Crack/Wear -t- Replace.

Bushing and oil seal installation

1. Install:
• Bushing CD

Driver rod:
Press YB-06071 190890-06602
Needle bearing attachment:
YB-06155/90890-06611

2. Install:
• Oil seal CD

Driver rod:
YB-06071 190890-06602
Needle bearing attachment:
YB-06155/90890-06611

6-10

[Link]
 COOLING AND BILGE SYSTEM
COOLING AND BILGE SYSTEM
EXPLODED DIAGRAM

5 Nm (0.5 m-kg, 3.6 ft-Ib)

1 Nm (0.1 m-kg, 0.7 ft-Ib)

,--~
3~g:
:~:
~:V I I

,.A: I
:
I
, J

5 Nm (0.5 m-kg, 3.6 ft-Ib)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

COOLING AND BILGE Follow the left "Step" for removal.
SYSTEM REMOVAL
1 Bilge strainer 1
2 Bilge hose 1
3 Hose joint 1
Reverse the removal steps for installation.

SERVICE POINTS
Bilge strainer inspection
Refer to "JET PUMP UNIT" in chapter 3.

Hose inpsection
1. Inspect:
• Hose
Crack/wear/damage -+ Replace.

6-11

[Link]
 CHAPTER 7
ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS .................................. 7-1

XL760 ..................................................... 7-1
XL1200 .................................................... 7-2
SERVICE POINTS .......................................... 7-3
Harness installation ...................................... 7-3

ELECTRICAL UNIT ............................................ 7-4

XL760 ..................................................... 7-4
XL 1200 .................................................... 7-5

ELECTRICAL DIAGRAM ....................................... 7-6

XL760 ..................................................... 7-6
XL 1200 .................................................... 7-7

ELECTRICAL ANALySiS ....................................... 7-8

INSPECTION ............................................... 7-8
Low resistance measurement ............................. 7-8

IGNITION SySTEM ............................................ 7-9

WIRING DIAGRAM ......................................... 7-9
XL760 ..................................................... 7-9
XL 1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 0
IGNITION SPARK GAP ...................................... 7-11
SPARK PLUG .............................................. 7-12
SPARK PLUG CAP ......................................... 7-12
IGNITION COIL ............................................. 7-12
ENGINE STOP SWiTCH ..................................... 7-13
CHARGE COIL ................ , ............................ 7-13
PULSER COIL .............................................. 7-14
THERMO SWiTCH .......................................... 7-14
COl UNIT .................................................. 7-15

STARTING SYSTEM ........................................... 7-16

WIRING DIAGRAM ......................................... 7-16
BATTERy .................................................. 7-17
STARTER MOTOR .......................................... 7-17
WIRING CONNECTION ..................................... 7-17
FUSE ..................................................... 7-17
STARTER SWITCH ......................................... 7-17
STARTER RELAy ........................................... 7-17

CHARGING SYSTEM .......................................... 7-19

WIRING DIAGRAM ......................................... 7-19
FUSE ..................................................... 7-20
BATTERy .................................................. 7-20
LIGHTING COIL ............................................ 7-20
RECTIFIER REGULATOR ................................... 7-20

[Link]
INDICATION SySTEM .......................................... 7-21
WIRING DIAGRAM ......................................... 7-21
OIL LEVEL SENSOR ........................................ 7-22
FUEL LEVEL SENSOR ...................................... 7-22
FUSE ..................................................... 7-22
BATTERy .................................................. 7-22
LIGHTING COIL ............................................ 7-22
RECTIFIER REGULATOR ................................... 7-22
MULTI FUNCTION-METER .................................. 7-23
Instrument indicating function ............................. 7-23
Security function ......................................... 7-24
Display function ......................................... 7-25

[Link]
IELECIE=JI __EL_E_C_T_R_IC_A_L_C_O_M_P_O_N_EN_T_S_____________C__E~_
ELECTRICAL COMPONENTS
XL760

A-A

N-N
L-L

~ o

~ J

G) Throttle cable @ Thermo sensor lead

® Fuel level sensor lead @CDI magneto lead
@ Oil level sensor lead @ Reverse cable
@ Battery (positive) lead Q3J Choke cable
@ Battery (negative) lead ® Steering cable
@ Speed sensor lead ® Starter motor (negative) lead
(j) Meter lead @ Grease nipple hose
® Handlebar switch lead ® Tube (meter)
® Buzzer lead @ Electrical box
® Starter motor (positive) lead ® High tension cord
@ Aligh with marking-off line

7-1

[Link]
IELECIc=JI_E_L_E_C_T_RI_C_A_L_C_O_M_P_O_NE_N_T_S_____________ C_~_E)_
XL1200

~ ----,,"' --
... )

!l\ J

CD Fuel level sensor lead @ Flywheel magneto base lead

® Oil level sensor lead @ Starter motor (negative) lead
@ High tension cord @ Steering cable
@ Battery (negative) lead Q3I Reverse cable
® Battery (positive) lead ® Throttle cable
® Speed sensor lead ® Choke cable
(J) Electrical box @ Handlebar switch lead
® Thermo sensor lead ® Meter lead
® Starter motor (positive) lead @ Tube (meter)
® CDI magneto lead ® Cooling water hose
@ Buzzer lead
@ Align with marking-off line
7-2

[Link]
IELECIE=JI __EL_E_C_T_R_IC_A_L_C_O_M_P_O_N_EN_T_S_____________C__~_)
SERVICE POINTS
Harness installation
1. Install:
• ClampeD
• Clamp®
• Clamp@
@Fuel tank breather hose
@Meter lead
@Handlebar switch lead
@Buzzer lead
@Fuellevel sensor lead
(DOil level sensor lead
@Fuel tank breather hose
@Electrical box lead
CDSpeed sensor lead

7-3

[Link]
IELEC I0 I ELECTRICAL UNIT
ELECTRICAL UNIT
XL760

4 Nm (0.4 mekg, 2.9 ftelb)

CD Spark plug cap

® Ignition coil
@Fuse
@ Starter relay
® CDI unit
® Rectifier regulator

7-4

[Link]
IELECIL=JI_E=L~E~C~T~RI~C~A~L~U~NI~T___________________C_g_)
XL1200

#1 #2 #3

4 Nm (0.4 m-kg, 2.9 ft-Ib)

CD Ignition coil
® Starter relay
@Fuse
@ Rectifier regulator
@CDI unit

7-5

[Link]
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@ Pulser coil o
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COl unit
Starter motor
Stop switch
Engine stop switch
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@ Starter switch
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@
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Fuse
Starter relay
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@ Fuel level sensor
@ Multifunction meter
i E\JiDl;tI!1 ®
~::£ij-tt:~:
Oil level sensor
@ Speed sensor

~~
---G:;' B @ Buzzer
\'-l-+------I : .--- R R/Y~R'

---TI..f-- B, Br~Br-----
I

i '
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ t:l..J
___ _ _ _ _ _ _ _ JI
\!!O' -------------------------~
@ B : Black
B/R : Black/Red
BNI : BlackNIhite LlR : BluelRed R/Y : Red/yellow
Br : Brown o : Orange W : White
G : Green O/G : Orange/Green W/B : White/Black
GNI GreenNlhite P : Pink WIG : White/Green
Gy
L
LIB
Gray
Blue
Blue/Black
R
R/B
RNI
: Red
: Red/Black
: RedNIhite
W/L
W/R
Y
: White/Blue
: White/Red
:Yellow 8
[Link]
 @W/R

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@ Lighting coil
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Pulser coil
Charge coil
COl unit
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Starter motor
Stop switch »
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.......
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Engine stop switch
Starter switch
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1 @ Fuse
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@ Starter relay
® Rectifier regulator

r&-..:.;:J ~ ..
w-
II
~ @
@
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Fuel level sensor
Multifunction meter
Oil level sensor
@ Speed sensor
~G
@) Buzzer
:-~3
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IIIIIII J

J~ T.--' ~ciu,
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c -- "" B : Black
u~:@
B/R : Black/Red
B/VV : Black/VVhite LlR : Blue/Red RIY : RedIYellow
e (!l
Br : Brown o : Orange W : White
G : Green O/G ; Orange/Green W/B : White/Black
G/VV : Green/VVhite P : Pink WIG : White/Green
®
8
Gy : Gray R : Red W/L : White/Blue
L : Blue R/B : Red/Black W/R : White/Red
LIB : Blue/Black R/VV : Red/VVhite Y :Yellow

[Link]
IELECIE=JI __EL_E_C_T_R_IC_A_L_A_N_A_LY_S_IS________________C_ _~_)
ELECTRICAL ANALYSIS
INSPECTION
CAUTION:
All measuring instrument should be handled
with special care, or correct measurement is
impossible.
On an instrument powered by dry batteries,
the batteries' voltage should be checked pe-
riodically and the batteries replaced, if nec-
essary.

NOTE:-------------------------
"0--0' indicates the terminals between
which there is electrical continuity; i.e., a closed
circuit in the given switch position.

Low resistance measurement

When measuring resistance of 10 n or less us-
ing the digital tester, the correct measurement
cannot be obtained because of the tester's inter-
nal resistance.
To obtain the correct value, subtract this internal
resistance from the displayed measurement.

Correct value =
Displayed measurement -
Internal resistance

NOTE:------------------------
The internal resistance of the tester can be ob-
tained by connecting both of its terminals.

7-8

[Link]
IELECI~II_I_G_N_IT_IO_N_S_Y_ST_E_M___________________C_g~_
IGNITION SYSTEM
WIRING DIAGRAM
XL760

@ ®

ir===~~ ~~-B~B
...--;....;> '-+--o--{I>C]}-O
Br G
®
----16
~--B~B----------------~

CD Pulser coil B : Black

® Charge coil Br : Brown
@CDI unit L : Blue
@ Stop switch 0 : Orange
@ Engine stop switch P : Pink
® Thermo switch W : White
([) Ignition coil W/B: White/Black
W/R: White/Red

7-9

[Link]
 C_~_)
IELECIc=JI_I_G_NI_T_IO_N_S_y_ST_E_M___________________

XL1200

#3 #2 #1

CD CD CD

BNJ B BNJ B BNJ B

!n
BIY BNJ B/O
I
m[gJ[j]
I I
~ 0 B-+-B~;@-B·
·W~'®-W

®
#3

'---;---W/G-----t----J
~--B----~

CD Ignition coil B : Black

® Thermo switch B/O : Black/Orange
@ Stop switch B/R : Black/Red
@ Engine stop switch B/W : Black/White
@ Pulser coil BIY : BlacklYellow
® Charge coil Br : Brown
(J) COl unit L : Blue
P : Pink
W : White
W /B : White/Black
W/G: White/Green
W /R : White/Red
7-10

[Link]
IELECI~II_I_G_N_IT_IO_N_S_Y_S_T_EM____________________C_~_)
IGNITION SPARK GAP

A WARNING
• While making a spark check be careful not
to touch any of the "Ignition spark gap tes-
ter" lead wires.
• When doing the spark test, take special
care not to allow leakage from the re-
moved plug cap.
• This check is likely to produce sparks, so
be sure that no flammable gas or fluid is in
the vicinity.

1. Check:
• Ignition spark gap
Out of specification -+ Replace.

I~
Spark gap:
9 mm (0.35 in)

Checking steps:
• Adjust the spark gap to specification by
turning the adjusting knob.

Jib Spark gap tester:

YM-34487/90890-06754

• Connect the spark plug cap to the spark

gap tester.
• Remove the spark plugs from the en-
gine.
• Crank the engine and check the sparks
from the ignition system through the dis-
charge window.

7-11

[Link]
 C~_E~_
IELECIL=jI_I_G_N_IT_IO_N_S_y_ST_E_M___________________
SPARK PLUG
Refer to "ELECTRICAL" in chapter 3.

SPARK PLUG CAP

1. Inspect:
• Spark plug cap
Loosen -+ Tighten.
Crack/Damage -+ Replace.

2. Measure:
• Spark plug cap resistance
Out of specification -+ Replace.

Ox 1K Spark plug cap resistance:

4.0 - 6.0 k!2

Replacement steps:
• Remove the spark plug cap by turning the
cap counterclockwise .
• Install the spark plug cap by turning the
cap clockwise until it stops.

IGNITION COIL
1. Inspect:
• High tension cord
Cracks/Damage -+ Replace.
2. Measure:
760
[Q • Primary coil resistance

o Out of specification -+ Replace.

Primary coil resistance:

XL760
Orange (0) - Black (B)
0.078 - 0.106!2at20°C(68°F)
XL1200
Black/White (B/W) - Black (B)
0.048 - 0.072!2 at20°C (68°F)
1200
NOTE:-------------------------
When measuring the resistance of 10 !2 or less
using the digital tester, the correct measure-
ment cannot be obtained. Refer to "Lower resis-
tance measurement".

7-12

[Link]
IELECIE=JI_I_G_N_IT_IO_N_S_Y_S_T_EM____________________C_I_)
3. Measure:
760 [Q] • Secondary coil resistance

o Out of specification -+ Replace.

Secondary coil resistance:

XL760
High tension cords
14.3 - 30.5 kQ at 20°C (68°F)
XL1200
High tension cord - Black (B)
2.7 - 4.1 kQ at 20°C (68°F)
1200
NOTE:--------------
Remove the spark plug cap from the high ten-
sion cord.

ENGINE STOP SWITCH

1. Check:
• Continuity
Out of specification -+ Replace.

IIj Engine stop continuity:

(Black coupler)
Leads
Lock plate Position
White Black
Free
760 Installed
Push 0 -0

G
Bf L
Removed

CHARGE COIL
1. Measure:
Free
Push 0

• Charge coil resistance

Out of specification -+ Replace.

Charge coil resistance:

1200 XL760

Q L SIR Sr
Brown (Br) - Blue (L)
316.8 - 387.2Qat20°C(68°F)
XL1200
Black/Red (B/R) - Brown (Br)
172.0 - 258.0Qat20°C(68°F)
,
'.------------- - Black/Red (B/R) - Blue (L)
656.0 - 984.0 Qat20°C(68°F)

7-13

[Link]
IELECI~I_I_G_N_IT_IO_N_S_Y_S_T_EM____________________C_~_~
PULSER COIL
1. Measure:

Q W/B W/R
• Pulser coil resistance
Out of specification -+ Replace.

Pulser coil resistance:

XL760
White/Red (W /R) -
White/Black (W /B)
445.5 - 544.5Q at20°C (68°F)
XL1200
1200 White/Red (W /R) - Black (B)
OJ White/Black (W /B) - Black (B)
White/Green (W /G) - Black
-0; (B)
248.0 - 372.0Qat20°C(68°F)

THERMO SWITCH
1. Measure:
• Thermo switch continuity
Out of specification -+ Replace.

Thermo switch continuity

temperature:
Pink (P) - Black (B)
@ 90 - 96°C (194 - 205°F)
@ 76 - 90°C (169 - 194°F)

CD Discontinuity [AJ Temperature

® Continuity [6] Time

1Al---"®--~ Measurement steps:

• Suspend thermostat in a vessel.
• Place known reliable thermometer in wa-
ter.
• Heat water slowly.
• Observe thermometer, while stirring water
continually.

7-14

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IELECIc=JI_I~G_N_IT~IO_N~S~Y~ST_E_M___________________C_g_~
COl UNIT
1. Measure:
• COl unit resistance
Out of specification --+ Replace.

Pocket tester:
YU-03112/90890-03112

B : Black NOTE:----------------------------------
B/O : Black/Orange • The resistance values will vary from meter to
B/R : Black/Red meter, especially with electronic digital me-
B/W : Black/White ters. For some testers, the polarity of the
B/Y : BlacklYeliow leads is reversed.
Br : Brown • The needle swings once to the "." mark and
L : Blue then returns to the home position.
0 : Orange • The "00" mark stands for discontinuity.
P : Pink
W : White
W/B : White/Black
W/G: White/Green
W/R : White/Red

XL760 Unit: kQ

---- ---- ----

EB 8 B Br L 0 P W W/B W/R
B 70 - 400 6 - 26 2 - 8.5 00 10 - 45 0-0.6 4.4 - 19
Br 2.4 - 11 16 - 70 7.5 - 35 00 26 - 150 2.4 - 11 9 - 40

---- ---- ----

L 2.4 - 11 80 - 500 7.5 - 35 00 26 - 150 2.4 - 11 9 - 40
0 00 00 00 00 00 00 00

P 17 - 80 70 - 1,000 16 - 70 40 - 300 7.5 - 35 17 - 70 22 - 100

---- ----
W 3.8 - 16 80 - 400 3.4 - 14 11 - 45 00 3.8 - 16 9.5 - 4.0
W/B 0-0.6 70 - 400 6 - 26 2-9 00 10 - 45 4.4 - 18
W/R 4 - 17 70 - 400 13 - 60 8 - 35 00 16 - 70 4 - 17

XL 1200 Unit: kQ
EB 8 B B/O B/R B/W BIY Br L P W W/B WIG W/R
B
B/O
B/R
---- ----
00

00
3.5-5.3 3.3-4.9 3.4-5.1 3.5-5.3

00
~
00 00

00
00

00
00

00

00
3.2-4.8 7.8-11.8 9.2-13.8 400-600 400-600 400-600
00

00
00

00
00

00
00

00
00

00
00

00

B/W
BIY
Br
00

00
00

00
00

00
---- ----
00

76-114 120-180 112-168 120-180 120-190

00 00

00
00

00
00

00

112-168 120-180 120-180

00

00
00

00

00
00

00

00
00

00

00

------
L
P
22-34 50-74 56-84
00
50-74
00
50-74
00
00

00
---- ----
00
38-58 40-60
00
00

00
00

00
00

00

W
W/B
00 00 00 00

112-168 168-252 160-240 168-252 168-252

00 00

00
00 00

---- ------
160-240 168-252 168-252
00 00

00
00

00

WIG
W/R
200-300 312-468 280-420 312-468 312-468
112-168 168-252 160-240 168-252 168-252
00

00
280-420 312-468 312-468
160-240 168-252 168-252
00

00
----
00
~
00

7-15

[Link]
IELECIL=JI_s_T_A_R_T_IN_G_S_Y_ST_E_M___________________C_~_~
STARTING SYSTEM
WIRING DIAGRAM

·1·

r B
(j)

~B-U
~
®

CD Fuse B : Black
® Multifunction meter Br : Brown
@ Engine stop switch R : Red
@ Starter switch R/V : RedlYeliow
@ Battery
® Starter motor
(f) Starter relay

7-16

[Link]
 C~_E)_
IELECIE=JI_s_T_A_RT_I_NG__SY_S_T_E_M__________________
BATTERY
Refer to "ELECTRICAL" in chapter 3.

STARTER MOTOR
Refer to "STARTER MOTOR" in chapter 5.

WIRING CONNECTION
1. Check:
• Wiring connection
Poor connection -+ Correct.
FUSE
1. Check:
• Fuse
Blown -+ Replace.

11M I Fuse rating:

1. . 12V-10A

STARTER SWITCH
1. Check:
• Continuity
Out of specification -+ Replace.

Iij Starter continuity:

(Red coupler)
Leads
Lock plate Position
Red Brown
Free
Installed
Push
Free
Removed
Push

STARTER RELAY
1. Inspect:
• Brown lead terminal
• Black lead terminal
Loose -+ Tighten.

7-17

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IELECIE=JI_s_T_A_R_TI_N_G_S_y_ST_E_M___________________C_g_)
2. Check:
• Relay operation
Not working -+ Replace.

Checking steps:
• Connect the tester between the terminals
of the starter relay as shown.
• Connect a 12 V battery.

Brown lead CD -+ Positive terminal

Black lead ® -+ Negative terminal

• Check that there is continuity between the

starter relay terminals.

7-18

[Link]
IELEC I0 I CHARGING SYSTEM
CHARGING SYSTEM
WIRING DIAGRAM

XL760

XL 1200
~G-~------------

: L-iI>DJ--G
~_~1'!!~~_0

G) Fuse B : Black
® Battery G : Green
@ Lighting coil G/W: Green/White
@ Rectifier regulator R : Red

7-19

[Link]
IELECI~II_c_H_A_R_G_IN_G_S_Y_S_TE_M__________________C_g_~
FUSE
Refer to "STARTING SYSTEM".
BATTERY
Refer to "ELECTRICAL" in chapter 3.
LIGHTING COIL
1. Measure:
• Lighting coil resistance
Out of specification ~ Replace.

Lighting coil resistance:

XL760
Qx 1 Green (G) - Green (G)
1.14 - 1.40 n at 20°C (68°F)
XL1200
Green (G) - Green (G)
0.56 - 0.84 n at 20°C (68°F)

NOTE:-------------------------
When measuring the resistance of 10 n or less
using the digital tester, the correct measure-
ment cannot be obtained. Refer to "Lower resis-
tance measurement".

RECTIFIER REGULATOR
1. Check:
• Continuity
Out of specification ~ Replace.

Pocket tester:
YU-03112/90890-03112

0: Continuity
00: Discontinuity

760 Unit: kn
iffi---e R B G G
R
----- ----
00 00 00

B 2-20 1-10 1-10

1200
G
G
1-10
1-10
2-15
2-15 ---- ----
3-30
3-30

Unit: kn
Iffi---e R B G G/W
R
-----
00 00 00

B 0 ~ 0 0
G 0 00
~ 00

G/W 0 0 0
----
7-20

[Link]
IELECI~II_I_N_D_IC_A_TI_O_N_S_Y_ST_E_M__________________C_g_)
INDICATION SYSTEM
WIRING DIAGRAM

--------p
'-----p+p
r---I--~-_-_-_-_-_R = = R
r- B B
G R G

*: XL 1200 G/W

CD Battery B : Black
CD Fuse G : Green
® Fuel level sensor G/W: Green/White
@ Oil level sensor L : Blue
@ Speed sensor LIB : Blue/Black
® Thermo switch LlR : Blue/Red
® Lighting coil P : Pink
(f) Multi-function meter R : Red
® Buzzer R/W: Red/White
® Handlebar switch (starting switch) W/L : White/Blue
@ Rectifier regulator Y : Yellow

7-21

[Link]
IELECI~II_I_N_D_IC_AT_IO_N__SY_S_T_E_M_________________C_~_~
OIL LEVEL SENSOR
1. Measure:
• Oil level sensor resistance
Out of specification -+ Replace.

Blue- Black

B lij Sensor position Resistance (0)

A 292 - 308

B 0-3

FUEL LEVEL SENSOR

1. Measure:
• Fuel level sensor resistance
Out of specification -+ Replace.

White/Blue - Black

iiJj Sensor position Resistance (0.)

A 757 - 803

o
B 0-8

FUSE
Refer to "STARTING SYSTEM".

BATTERY
Refer to "ELECTRICAL" in chapter 3.

LIGHTING COIL
Refer to "CHARGING SYSTEM".

RECTIFIER REGULATOR
Refer to "CHARGING SYSTEM".

7-22

[Link]
IELECI~II_I_N_D_IC_A_TI_O_N_S_Y_ST_E_M__________________C_~_~
MULTI-FUNCTION METER
Instrument indicating function
1. Check:
e .. • Indicating function
o An indicating error is found -+- Replace
0" the multi-function meter.

Sequential output (1 minute/cycle)

I lei '-11""'- Til I " /
11I1e... L L UI IC I U ~I''--' 1 Display begins operation
[LOCI.; 2 "tJI:::LCOf'lE TO tJ/--//,tl:::F?LltJtJEF?S"
r/ll.-::'
'-ULL 3 All LCD readouts turn on
II 1 I
U/L 4 "L L UL,t(' is displayed
1/111 T
/I UL 1
T C/otlll
5 "F LIE L" is displayed
1 C I /1--
6 "0/ L" is displayed
[LOCI.;
7 "V OL T" is displayed
SET
L ,,/ I /I:J
'-/UU/I.
II 'I
II
8 "/ I::: t1,tj' is displayed
S TOFt tJ 9 "L L UL f(' is displayed
IF? / P 10 "SE / " is displayed
"I 1111 I[J 11-1'
11 nuuri. II is displayed
12 "r TIICJ
':'11 UI .
I I'
1111 is displayed
13 "TF? / FI' is displayed
Checking steps:
• Connect the battery terminals.
NOTE:
If the multi-function meter has been re-
moved, supply battery power to the four-pin
coupler (+: Red, -: Black).

• Remove the blue, one-pin couplers CD.

-+- The warning lamp blinks ®.
• Press the "MODE" @, "A/SET" @, and
"c" ® buttons (all at once) for more than
three seconds.
-+- The self-indicating function is acti-
vated.
• Press either button @, @, ®, or ®.
-+- Self-indication stops and the warning
lamp ® blinks.
• Connect the blue, one-pin couplers.
-+- The warning lamp® turns off and all in-
dications stop.

7-23

[Link]
IELECIL=JI_I_N_DI_C_AT_IO_N__ C_g~_
SY_S_T_EM__________________
Security function
1. Check:
• Sequential output
An error is found -+ Replace the multi-
function meter.

Checking steps:
• Connect the battery terminals.
NOTE: ______________________
If the multi-function meter has been re-
moved, supply battery power to the four-pin
coupler (+: Red, -: Black).
'-'I __Ie
'-'-1'-1'- • Remove the blue, one-pin couplers CD.
u '-- ,- -+ The warning lamp blinks ®.
, I or '-lor '-
,-,- T • Press the "MODE"@ button for more than
:.Jr- I three seconds.
'--I T/--/hi T -+ The warning lamp ® blinks.
-+ "[OdE" is displayed and blinks.
• Enter the four-digit code with either button
@,(§),or@.
1) The buzzer sounds when the button is
pushed.
2) When the warning lamp ® is lit:'R", "b"
or "e" is displayed for code entry,
then"5E /" is displayed and blinks.
3) The buzzer sounds three times and
then"5 TRR T" is displayed.
4) The display then clears and the warning
lamp ® blinks.
• Connect the blue, one-pin couplers CD.
-+ The warning lamp ® turns off.

7-24

[Link]
 INDICATION SYSTEM
Display function
NOTE:------------------------
• Connect all couplers of the multifunction me-
ter.
• If the blue 1-pin coupler CD is disconnected,
the correct checking can not be done.

1. Check
• Display function

---
Not working --+ Replace.

--- Checking steps: (vehicle on water)

• Check the battery voltage.
Voltage range:
10 - 16 V
• a) Press the "MODE" button for more than
three seconds.
--+ The warning lamp blinks.
--+ "COdE" is displayed and blinks.

A • b) Enter the four-digit code.

--+ "START' CD or "LOCK" ® is displayed.
NOTE: _________________________________
• Repeat a) and b) until "START' is dis-
b played.
b • Refer to "Security function".

• Start the engine.

--+ The buzzer sounds twice.
--+ "WELCOME TO WAVERUNNERS" is
displayed.
--+ All segments light up [AJ for 2 seconds.
--+ The engine speed ® is displayed.
• Start the engine.
--+ The buzzer sounds twice.
--+ "WELCOME TO WAVERUNNERS" is
displayed.
--+ All segments light up A for 2 seconds.
--+ The engine speed 3 is displayed.
• Press the "MODE" button.
--+ Each time the "MODE" button is
pressed, the display changes as follows.
rCLOCK-HOUR.M@)-STOP.M-TRIPl

• Check that the above dispay appears.

• Stop the engine.
--+ Segments will continue to light up for 30
seconds for active functions.

7-25

[Link]
IELECIE=jI_I_N_DI_C_AT_IO_N__ C_~_)
SY_S_T_E_M_________________
A 2. Check:
• Fuel level meter [AJ
F4 Not working --+ Replace.
F3 ---..JL.i
F2----U!~\,
Checking steps: (vehicle on water)
• Disconnect the 2-pin green couplers
F1----\'\~
-.>-~~
(White/blue-Black leads).
• Connect the white/blue lead and black
F-AL lead terminals CD.
• Check the battery voltage.

iij Voltage range:

10 - 16 V
• a) Press the "MODE" button for more than
three seconds.
--+ The warning lamp blinks.
G --+ "COdE" is displayed and blinks.
a • b) Enter the four-digit code.
a --+ "START" or "LOCK" is displayed.
NOTE:
• Repeat a) and b) until "START" is dis-
played.
• Refer to "Security function".

• Start the engine.

--+ The buzzer sounds two times.
--+ "WELCOME TO WAVERUNNERS" is
displayed.
--+ All segments light up for 2 seconds.
--+ The engine speed is displayed.
--+ All fuel level segments are displayed.
• Check that fuel level segments are dis-
played.
• Disconnect the white/blue lead and black
lead terminals ®.
• Check that the fuel segments (F1 ... ,
G F_AL)@, "FUEL"@ and WARNING indi-
a cator @ operate properly and that the
a buzzer beeps intermittently.

I~
Second Display/Beep

- 20 F1, F2, F3, F4: ON

20 - 40 F1, F2, F3: ON
40 - 60 F1, F2: ON
A/SET

e
B
60 - 80 F1: ON
80 - F1, F-AL, "FUEL",
o WARNING indicator
Blinking
Buzzer: Beeping

7-26

[Link]
IELECIc=JI_I_N_DI_C_AT_IO_N__ C_g~_
SY_S_T_EM__________________
A 3. Check:
• Oil level meter ~
Not working -+ Replace.
.'<---¥t--\--- 03 Checking steps: (vehicle on water)
+"4t"""""'--t--- 02 • Disconnect the 2-pin natural couplers
(Blue-Black leads).
"'---l~~/k-H-i;=-'~-- 01
• Connect the blue lead and black lead ter-
minalsG').
• Check the battery voltage.

Voltage range:
10 - 16 V
• a) Press the "MODE" button for more than
three seconds.
-+ The warning lamp blinks.
G -+ "COdE" is displayed and blinks.
o • b) Enter the four-digit code.
o -+ "START' or "LOCK" is displayed.
NOTE: ______________________

• Repeat a) and b) until "START" is dis-

played.
• Refer to "Security function".

• Start the engine.

-+ The buzzer sounds two times.
-+ "WELCOME TO WAVERUNNERS" is
displayed.
-+ All segments light up for 2 seconds.
-+ The engine speed is displayed.
-+ All oil level segments are displayed.
• Check that oil level segments are dis-
played.
• Disconnect the blue lead and black lead
terminals ®.
• Check thatthe oil segments (01 ... , O_AL)
@, "OIL" @ and WARNING indicator ®
operate properly and that the buzzer
beeps intermittently.

!~I---s-e-co-n-d---I---D-is-p-la-y-I-B-e-e-p----l
- 20 01,02,03: ON
20 - 40 01,02: ON
40 - 01, O-AL, "OIL",
WARNING indicator
: Blinking
Buzzer: Beeping

7-27

[Link]
 CHAPTER 8
HULL AND HOOD

ENGINE HOOD REMOVAL ..................................... 8-1

EXPLODED DIAGRAM ...................................... 8-1
REMOVAL AND INSTALLATION CHART ...................... 8-1

HANDLEBAR REMOVAL ....................................... 8-2

EXPLODED DIAGRAM ...................................... 8-2
REMOVAL AND INSTALLATION CHART ...................... 8-2
SERVICE POINTS .......................................... 8-3
Handlebar assembly installation ............................ 8-3

HANDLEBAR ................................................. 8-4

EXPLODED DIAGRAM ...................................... 8-4
REMOVAL AND INSTALLATION CHART ...................... 8-4
SERVICE POINTS .......................................... 8-5
Handlebar inspection ...................................... 8-5
Handlebar switch inspection ................................ 8-5
Handlebar switch installation ............................... 8-5

STEERING COLUMN .......................................... 8-6

EXPLODED DIAGRAM ...................................... 8-6
REMOVAL AND INSTALLATION CHART ...................... 8-6
SERVICE POINTS .......................................... 8-7
Bearing inspection ........................................ 8-7
Steering column inspection ................................. 8-7
Bushing joint installation ................................... 8-7

SHIFT LEVER ................................................. 8-8

EXPLODED DIAGRAM ...................................... 8-8
REMOVAL AND INSTALLATION CHART ...................... 8-8

ENGINE HOOD ................................................ 8-9

EXPLODED DIAGRAM ...................................... 8-9
REMOVAL AND INSTALLATION CHART ...................... 8-9

STEERING CABLE ............................................ 8-11

EXPLODED DIAGRAM ...................................... 8-11
REMOVAL AND INSTALLATION CHART ...................... 8-11
SERVICE POINTS ....... , ................................. , 8-12
Cable inspection .......................................... 8-12
Just pump side cable joint installation ........................ 8-12
Steering cable adjustment .................................. 8-12

[Link]
I~~I ~ ~~~~~~~~~~~~~~~~C_~~_
THROTTLE CABLE AND CHOKE CABLE ........................ 8-13
EXPLODED DIAGRAM ...................................... 8-13
REMOVAL AND INSTALLATION CHART ...................... 8-13
SERVICE POINTS .......................................... 8-14
Cable inspection .......................................... 8-14
Cable installation .......................................... 8-14
Throttle cable adjustment .................................. 8-14
Choke cable adjustment ................................... 8-14
SHIFT CABLE ................................................. 8-15
EXPLODED DIAGRAM ...................................... 8-15
REMOVAL AND INSTALLATION CHART ...................... 8-15
SERVICE POINTS .......................................... 8-16
Cable inspection .......................................... 8-16
Jet pump side cable joint installation ......................... 8-16
Shift cable adjustment ..................................... 8-16

SEAT AND STORAGE BOX . .................................... 8-17

EXPLODED DIAGRAM ...................................... 8-17
REMOVAL AND INSTALLATION CHART ...................... 8-17
SERVICE POINTS .......................................... 8-17
Seat inspection ........................................... 8-17
Storage box inspection .................................... 8-17

BATTERY CASE ............................................... 8-18

EXPLODED DIAGRAM ...................................... 8-18
REMOVAL AND INSTALLATION CHART ...................... 8-18
SERVICE POINTS .......................................... 8-18
Battery case inspection .................................... 8-18

EXHAUST SYSTEM ............................................ 8-19

EXPLODED DIAGRAM ...................................... 8-19
REMOVAL AND INSTALLATION CHART ...................... 8-19
SERVICE POINTS .......................................... 8-20
Exhaust system inspection ................................. 8-20

DECK ........................................................ 8-21

EXPLODED DIAGRAM ...................................... 8-21
REMOVAL AND INSTALLATION CHART ...................... 8-21
SERVICE POINTS .......................................... 8-22
Ventilation system inspection ............................... 8-22

GUNWALE .................................................... 8-23

EXPLODED DIAGRAM ...................................... 8-23
REMOVAL AND INSTALLATION CHART ...................... 8-23

MAT .......................................................... 8-24

EXPLODED DIAGRAM ...................................... 8-24
REMOVAL AND INSTALLATION CHART ...................... 8-24
SERVICE POINTS .......................................... 8-24
Mat installation ........................................... 8-24

[Link]
I~~I 4 ~~~~~~~~~~~~~~~~C_~_~
HULL ......................................................... 8-25
EXPLODED DIAGRAM ...................................... 8-25
REMOVAL AND INSTALLATION CHART ...................... 8-25
HULL REPAIR .............................................. 8-26
Light scratching ........................................... 8-26
Deep scratching .......................................... 8-26
Hull damage (punctured) ................................... 8-27
Insert nut ................................................ 8-28
Removing a graphic ....................................... 8-30
Applying a graphic ........................................ 8-30

[Link]
 HOUOLLOI
IH
~ S•I
......_ _....._ - o I ENGINE HOOD REMOVAL
ENGINE HOOD REMOVAL
EXPLODED DIAGRAM

I
I

I
I

I
I

I ~
~.~

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

ENGINE HOOD REMOVAL Follow the left "Step" for removal.
Fuel cock assembly Refer to the "FUEL LINE" in chapter 4.
1 Couplers 8
2 Cable joint (steering cable) 1 NOTE:
3 Cable joint (shift cable) 1 Disconnect the throttle and choke cables from
4 Steering cable brakcet 1 the carburetor.
S Shift cable brakcet 1
6 Throttle cable 1
7 Choke cable 1
8 Oil breather hose 1
9 Oil filler hose 1
10 Fule filler hose 1
11 Engine hood assembly 1
Reverse the removal steps for installation.

8-1

[Link]
I~~I 4 ~_HA_N_D_L_E_B_A_R_R_E_M_O_V_A_L_ _ _ _ _ _ _ _ _C_~_)
HANDLEBAR REMOVAL
EXPLODED DIAGRAM

17 Nm (1.7 mekg, 12 ftelb)

1 Nm (0.1 mekg, 0.7 ftelb)

7

6,?
1 .

~ -7
/
a242
I
I
3

! J-~

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

HANDLEBAR REMOVAL Follow the left "Step" for removal.
1 Steering pad 1
2 Throttle cable 1
3 Handle bar switch lead 2
coupler
4 Bolt (with washer) 4 8 x 55 mm
5 Handlebar holder (upper) 2
6 Handlebar holder (lower) 2
7 Handlebar assembly 1
Reverse the removal steps for installation.

8-2

[Link]
IHHOUOLLO I cf I
•r..;...;....;;......;;...=...1-._ - - - - " HANDLE BAR REMOVAL
SERVICE POINTS
Handlebar assembly installation
1. Install:
• Seal packing CD
NOTE:-----------------------
• Pass the handlebar switch lead through the
steering shaft
• Adjust the throttle cable length @ and han-
dlebar switch lead length @ to 200 mm (7.9
in).
• Seal the steering shaft with the seal packing
at 20 mm (0.79 in) from the end of the steering
column.

2. Install:
• Handlebar holder (lower) CD
• Handlebar holder (upper) ®

CAUTIO
Clearance @ should be narrower than clear-
ance@.

NOTE:-----------------------
• Align the punched mark @ on the handlebar
with the top surface of the handlebar holder
(lower).
• The handlebar holder (upper) should be
installed with the punched mark forward.

8-3

[Link]
1~~651
HANDLEBAR
• ll_H_A_N_D_L_E_B_A_R________________________ __
) C_~
EXPLODED DIAGRAM

4 Nm (0.4 m·kgf, 2.9 tt·lb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

HANDLEBAR DISASSEMBLY Follow the left "Step" for removal.
Handlebar assembly Refer to "HANDLEBAR REMOVAL".
1 Screw 1
2 Grip 2 NOTE:
Apply adhesive to handlebar and inner
surface of grip.

3 Handlebar switch assembly 1

4 Throttle lever assembly 1
5 Handlebar 1
Reverse the removal steps for installation.

8-4

[Link]
I~~I 4 ~_HA_N_D_L_E_ _ _ _ _ _ _ _ _ _ _ _ _C~~_~
SERVICE POINTS
Handlebar inspection
1. Inspect:
• Handlebar
Bend/crack/damage -t Replace.

Handlebar switch inspection

Refer to "STARTING SYSTEM" in chapter 7.

Handlebar switch installation

1. Install:
• Handlebar switch
NOTE:-------------------------
• Tighten the screw 1 on the stop button side
first. Then, tighten the other screw 2 .
• Align the pin on the left handle bar switch with
the hole in the handle bar.

8-5

[Link]
1~~651 .. ,I
STEERING COLUMN
STEERING COLUMN

EXPLODED DIAGRAM

5 Nm (0.5 mekgf, 3.6 ftelb)

J. ___ O!_~ ~-
~____~~~~__________~____--~ 4'J ~
1.5 Nm (0.15 mekgf, 0.11 ftelb) ~- ~ -

5 Nm (0.5 [Link], 3.6 «.Ib)~ 6 ~

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

STEERING COLUMN Follow the left "Step" for removal.
REMOVAL
Handlebar assembly Refer to "HANDLEBAR REMOVAL".
Engine hood cover assembly Refer to "ENGINE HOOD COVER".
1 Steering cable 1
2 Steering pad fixation 1
3 Steering bushing 2
4 Clamp 1
5 Column bushing 2
6 Steering column 1
Reverse the removal steps for installation.

8-6

[Link]
1~~1~4~~_S_T_E_E_R_IN_G_C_O_L_U_M_N_ _ _ _ _ _ _ _ _C__~_)
SERVICE POINTS
Bushing inspection
1. Inspect:
• Bushing
Wear/damage ~ Replace.

Steering column inspection

1. Inspect:
• Handle column
Bend/crack/damage ~ Replace.

Bushing joint installation

1. Install:
• ClampeD
• Bushing joint ®
NOTE:-------------------------
Check for smooth action of the steering column
when tightening the bolt.

8-7

[Link]
I~~I 4 ~_S_H_I_~_LE_V_E_R_ _ _ _ _ _ _ _ _ _ _ _C_~_)
SHIFT LEVER
EXPLODED DIAGRAM

7 Nm (0.7 m-kgf, 5.1 ft-Ib)

5
242

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

SHIFT LEVER REMOVAL Follow the left "Step" for removal.
Shift cable NOTE:
Disconnect the shift cable at the shift lever.

1 Shift lever 1
2 Base assembly 1
3 Lever 1
4 Shaft 1
5 Roller 1
6 Actuator 1
7 Spring 1
8 Wave washer 1
9 Bushing 2
10 Base 1
Reverse the removal steps for installation.

8-8

[Link]
1~~651
ENGINE HOOD
4 'I __ EN_G_I_N_E_H_O_O_D_______________________C_g__
)

EXPLODED DIAGRAM

2 Nm (0.2 m-kgf, 1.4 ft-Ib)

5 Nm (0.5 m-kgf, 3.6 ft-Ib)

5 Nm (0.5 m-kgf, 3.6 ft-Ib)

a
242

5 Nm (0.5 m-kgf, 3.6 ft-Ib)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

ENGINE HOOD DISASSEMBLY Follow the left "Step" for removal.
Engine hood assembly Refer to "ENGINE HOOD REMOVAL".
1 Engine hatch 1
2 Bracket 1
3 Left side cover 1
4 Right side cover 1
5 Holder 1

8-9

[Link]
1~~4~_EN_G_I_N_E_H_O_O_D_ _ _ _ _ _ _ _ _ _ _ _C_E_~

5 Nm (0.5 mokgf, 3.6 ftolb)

5 Nm (0.5 mokgf, 3.6 ftolb)

10

5 Nm (0.5 mokgf, 3.6 ftolb)

242

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

6 Engine hood cover 1
7 Meter assembly 1
8 Bracket 1
9 Adjustable mirror assembly 2
10 Stay 1
Reverse the removal steps for installation.

8-10

[Link]
1~~6~1 .. ,I
STEERING CABLE
STEERING CABLE

EXPLODED DIAGRAM

7 Nm (0.7 m-kgf, 5.1 ft-Ib)

7 Nm (0.7 m-kgf, 5.1 ft-Ib)

10 Nm (1.0 m-kgf, 7.2 ft-Ib)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service pOints

STEERING CABLE REMOVAL Follow the left "Step" for removal.
Ride plate Refer to the "JET PUMP UNIT REMOVAL"
section in chapter 6.
1 Cable joint 1 Refer to "Jet pump side cable joint
installation" .
A WARNING
2 Cable joint 1 The cable joint must be screwed in more
3 Steering cable bracket 1 than 8 mm (0.31 in).
4 Cable stopper 1
A WARNING
Be sure to fit the projection on the cable
stopper into the groove in the outer cable.
1 NOTE: __________________________
5 Packing
6 Steering cable 1 Insert the cable into the clamp.

Reverse the removal steps for installation.

8-11

[Link]
l~g6~1 4 'I~ST_E_E_R_IN_G~C_A_B_LE_____________________C~~~~
STEERING CABLE
SERVICE POINTS
Cable inspection
1. Inspect:
• Steering cable
Kink/Fray/Stick -+ Replace.

Jet pump side cable jOint installation

1. Install:
• Cable joint

Cable joint set length @:

13.7 - 15.3 mm (0.53 - 0.60 in

A WARNING
The cable joint must be screwed in more than 8
mm (0.31 in).

Steering cable adjustment

Refer to "CONTROL SYSTEM" in chapter 3.

8-12

[Link]
I~~I • 3_T_H_O_R_T_T_LE~CA_B_L_E_A_N_D_C_H_O_K_E_C_A_B_L_E~~~C ~_~
THROTTLE CABLE AND CHOKE CABLE
__
EXPLODED DIAGRAM

1~/
~.~
/'
. 'E~
~ ~/
6

\. ~~. 9 Nm (0.9 mokgf, 6.5 ftolb)

~.----- ~ T----Ja
/ \t!!} rJj
7 ~ 242
5

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

THROTTLE CABLE REMOVAL Follow the left "Step" for removal.
1 Spiral tube 1
2 Throttle cable lock nut 1
3 Seal packing 1
4 Throttle cable 1
CHOKE CABLE REMOVAL
5 Choke knob 1
6 Choke cable lock nut 1
7 Choke cable 1
Reverse the removal steps for installation.

8-13

[Link]
IHHOUOLLOI
......;;....~-'-.
L...
•
I THORTTLE CABLE AND CHOKE CABLE
_ " " " _......
'

SERVICE POINTS
Cable inspection
1. Inspect:
e Throttle cable
e Choke cable
Kink/Fray/Stick -+ Replace.

Cable installation
1. Install:
e. Cable guide

Cable guide set position@:

XL760:
17 mm (0.67 in)
XL1200:
Throttle cable: 17 mm (0.67 in)
Choke cable: 14 mm (0.55 in)

1200 2. Install:
e Seal packing
Refer to "HANDLE REMOVAL".
~
~

Throttle cable adjustment

Refer to "CONTROL SYSTEM" in chapter 3.

Choke cable adjustment

Refer to "CONTROL SYSTEM" in chapter 3.

8-14

[Link]
1~~6~1 4 \I_S_H_I_FT__
C_A_B_LE________________________ __
) C_~
SHIFT CABLE
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

SHIFT CABLE REMOVAL Follow the left "Step" for removal.
Ride plate Refer to the "JET PUMP UNIT REMOVAL"
section in chapter 6.
1 Cable jOint 1 Refer to "Jet pump side cable joint
installation" .
A WARNING
2 Cable joint 1 The cable joint must be screwed in more
3 Shift cable braket 1 than 8 mm (0.31 in).
4 Cable stopper 1
A WARNING
Be sure to fit the projection on the cable
stopper into the slit in the outer cable.

5 Shift cable 1 NOTE:-------------------------

6 Packing 1 Insert the cable into the clamp.

Reverse the removal steps for installation.

8-15

[Link]
I~~I 4 ~_S_H_I_R_C_A_B_L_E_ _ _ _ _ _ _ _ _ _ _C__~~_
SERVICE POINTS
Cable inspection
1. Inspect:
• Shift cable
Kink/Fray/Stick -+ Replace.

Jet pump side cable joint installation

1. Install:
• Cable joint

Cable guide set lenght @

12.8 - 14.4 mm (0.50 - 0.57 in)
A WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).

Shift cable adjustment

Refer to "CONTROL SYSTEM" in chapter
3.

8-16

[Link]
1~~5\)1 4 ,I
SEAT AND STORAGE BOX
SEAT AND STORAGE BOX CD

EXPLODED DIAGRAM

.......
/
/
2';;..-//
/
/
/
/
/
(
r

r
r

7 Nm (0.7 mekgf, 3.6 fterb)

5
5 Nm (0.5 mekgf, 3.6 fterb)

7 Nm (0.7 mekgf, 5.1 fterb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

SEAT AND STORAGE BOX Follow the left "Step" for removal.
1 Single seat 1
2 Double seat 1
3 Band 1
4 Case 1
5 Storage box 1
Reverse the removal steps for installation.

SERVICE POINTS
Seat inspection
1. Inspect:
• Seat lock
Wear/damage --+ Replace.
Storage box inspection
1. Inspect:
• Packing
Flat/damage --+ Replace.
• Storage box
Crack/damage --+ Replace.

8-17

[Link]
I~~ 4 ~_BA_T_T_E_~_C_A_SE_ _ _ _ _ _ _ _ _ _ _C_~_~
BATTERY CASE
EXPLODED DIAGRAM

6 Nm (0.6 m-kgf, 4.3 tt-Ib)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

BATTERY CASE REMOVAL Follow the left "Step" for removal.
Seat and storage box Refer to "SEAT AND STORAGE BOX".
1 Band 2
2 Breather hose 1
3 Battery 1
4 Battery case 1
Reverse the removal steps for installation.

Battery case inspection

1. Inspect:
• Battery case
Crack/Damage --+ Replace .
• Packing
Flat/Damage --+ Replace.

8-18

[Link]
 HULL I :.., II
IHOOD . EXHAUST SYSTEM
EXHAUST SYSTEM
EXPLODED DIAGRAM

4 Nm (0.4 mekgf, 2.9 ftelb)

7 Nm (0.7 mekgf, 5.1 ftelb)

4 Nm (0.4 mekgf, 2.9 ftelb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

EXHAUST SYSTEM REMOVAL Follow the left "Step" for removal.
Storage box
1 Band 2
2 Exhaust hose 1
3 Exhaust hose 1
4 Water lock 1
5 Water outlet hose 1
6 Exhaust guide Reverse the removal steps for installation.

8-19

[Link]
I~~I 1 ~_EX_H_A_U_S_T_S_Y_S_T_E_M_ _ _ _ _ _ _ _ _ _C_~_~
SERVICE POINTS
Exhaust system inspection
1. Inspect:
• Band
Crack -+ Replace.
2. Inspect:
• Exhause hose
Crack/Wear/Burn -+ Replace.
3. Inspect:
• Water lock
Crack/Leak -+ Replace.
Gathered water -+ Drain.

8-20

[Link]
1~~6~1 4 ll __ C~_E_~
DE_C_K____________________________
DECK
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

DECK DISASSEMBLY Follow the left "Step" for removal.
Engine hood cover 1 Refer to "ENGINE HOOD".
1 Ventilation hose 1
2 Ventilation socket 1
3 Ventilation hose 1
Reverse the removal steps for installation.

8-21

[Link]
I~~I • ~_DE_C_K
______________
SERVICE POINTS
C~~_~
Ventilation system inspection
1. Inspect:
• Ventilation hose
Wear/Crack -+ Replace .
• Ventilation hose joint
Wear/Damage -+ Replace.

8-22

[Link]
I~~I
GUNWALE
• 3_G_U_N_W_A_L_E~~~~~~~~~~~~C ~_) __
EXPLODED DIAGRAM

2 Nm (0.2 m-kgf, 1.4 ft-Ib)

1 5

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

GUNWALE REMOVAL Follow the left "Step" for removal.
1 Bow gunwale 1
2 Stern gunwale 2
3 Inner gunwale 1
4 Cover gunwale 1
5 Inner gunwale 2
6 Side gunwale 2
Reverse the removal steps for installation.

8-23

[Link]
I~~I 4 ~_MA_T_ _ _ _ _ _ _ _ _ _ _ _ _ _C_~_)
MAT
EXPLODED DIAGRAM

FWD

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name O'ty Service points

MAT REMOVAL Follow the left "Step" for removal.
1 Step mat 6
2 Spout 1
3 Upper mat 2 NOTE:
4 Rope hole bolt The rope hole bolts should be installed
with the projections @facing each other.

Reverse the removal steps for installation.

SERVICE POINTS
Mat installation
1. Install:
• Mat
NOTE:-------------------------
• Clean the step surface before installing the
mat.
• Aplly cyano-acrylate adhesive on the mat.

8-24

[Link]
I~~I d ~_H_U_L_L_ _ _ _ _ _ _ _ _ _ _ _ _ _C_I_E_)
HULL
EXPLODED DIAGRAM

til
242

4
5 Nm (0.5 m-kg, 3.6 ft-Ib)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q'ty Service points

HULL DISASSEMBLY Follow the left "Step" for removal.
1 Bow eye 1
2 Pilot water outlet 1
3 Drain plug socket 2
4 Sponson 2
Reverse the removal steps for installation.

8-25

[Link]
I~~I 43_H_U_L_L_ _ _ _ _ _ _ _ _ _ _ _ _ _ C_~_)
HULL REPAIR
Light scratching
1. Sand the scratched area smooth with #400
grit wet or dry paper, and then with #600 grit
wet or dry paper.
2. Polish the area with rubbing compound and
buff to a high gloss using a wool pad and au-
tomotive wax.

Deep scratching
1. Remove any sharp/rough edges from the
surface.
2. Sand the area smooth for about one inch all
around the scratch with #80 grit wet or dry
paper.
3. Clean the area with acetone and dry it.
4. Mix gel-coat with gel-coat thickener to make
gel-coat putty and then add the catalyst to
make.
5. Apply and spread the catalyzed putty with a
squeegee, then cover the putty with a piece
of waxed paper.
6. When the putty has set, sand the area cata-
lyzed putty. Smooth using #80 grit to #400
grit wet or dry paper and a sanding block.
7. Clean the area with a dry cloth and polish it.

A WARNING
Resin, catalyst and solvet are flammable and
toxic. Use only in a well-ventilated area and
keep away from open flames and sparks.
Observe all warnings given by the manufac-
turer.

8-26

[Link]
1~~651 4 ~1 __ ~
H_U_LL_____________________________C_g__
Hull damage (punctured)
1. Remove any damaged fiberglass.
2. Cut and open the crack approximately 1/4
inch.
3. Grind the opened edge less than 30° on the
outside.
4. Grind the area from inside the hull approxi-
mately 4 inches beyond it.
S. Clean the area with acetone, apply BP-1 or
an equivalent primer on both sides of the
area and cure for 1/2 hour.
6. Tape a piece of cardboard covered with
waxed paper CD over the damaged area.
7. Mix polyester resin and catalyst and apply it
to the hull.
8. Apply a glass mat® (2 inches smaller than
the ground area).
9. Apply catalyzed resin.
10. Apply a 20 oz fiberglass cloth @ (1 inch
smaller than the glass mat).
11. Apply catalyzed resin.
12. Apply a final glass mat @ (1 inch smaller
than the ground area).
13. When the resin has hardened, remove the
piece of cardboard.
14. Finish the outer surface using steps 3-7 in
the "Deep scratching" section.
NOTE:-----------------------
Refer to "WATER VEHICLE FRP REPAIR
MANUAL".

8-27

[Link]
 Insert nut
NOTE:-------------------------
When a pop nut clinched to a hull slipped off or
when a bolt fastened to an insert nut or pop nut
was broken, use this insert nut.

Part
Part No. Remarks
Name
Stainless
EW2-62733-09 Nut
steel, M6

19 mm (O.75 in.) • NutCD

• Direction of thread ®
~ • Slot be threaded @
e....--;""""""""""."..,,,,,,,,,,'M'III
E NOTE:-------------------------
E
o Drilling size
;L-_.YV'>/v\''VV'vv\'~

Material Pilot hold diameter

FRP or SMC 9.1 - 9.2 mm (O.36 in)
Brass 9.4 mm (O.37 in)

Example 1:
The nut is used to repair the pop nut designed
80-100 mm (3-4 in.) t for plate 2.

~~
OUT (by repairing the FRP portion, the new-type nut
can be used for all models)
IN For details of repairs to the FRP portion, refer to
30-50 mm ~ the "Water Vehicle FRP Repair Manual".
(1.2-2 in.) 1. Remove:
• Pop nut
2. Scarf the shaded portion.
3. Clean the surface to be scarfed and the in-

OUT
t side of the hull with acetone.
4. As shown, first tape up the inner surface of
the hull and then laminate fiber-glass mats
over the tape using a resin.
20-30 mm \ NOTE:-------------------------
(0.79- , ... When it is possible to work inside the hull,
1.2 in.) IN
the mats should be laminated from the in-
l side.

8-28

[Link]
I~~I • ~_H_U_L_L
_ _ _ _ _ _ _ _ _ _ _ _ _ _C
__
5. Smooth out the out surface by sanding it.
~_)
6. Install plate 2. Then, using a 9.2 mm (0.36
in) diameter drill, make a hole of depth 20
mm (0.79 in) in the center of the laminated
fiberglass layers.
7. Pass the bolt CD through the insert nut, as
shown, and lock the bolt with the nut ®.
Screw in the insert nut so that the top is flush
with the FRP surface. Loosen the lock nut
and remove the bolt.

• The bolt should be made of steel and its

strength should be 8T or more .
• If the bolt is inferior in strength, or is made
of stainless steel, it may break.

• Bolt CD <Strength is 8T or more>

• Lock nut®

Example 2:
The brass insert nut designed for the Super Jet
Plate 2 or the screen intake is used:
1. If the bolt is broken, remove it using drills.
NOTE:-------------------------
Use a small-diameter drill first, followed by drills
of gradually increasing diameter.

2. Use a 9.4 mm (0.37 in) drill for the final dril-

ling.
3. Apply silicone sealant to the inside of the
hole so that no water can enter the urethane
foam.
4. As in Example 1 above, screw in the insert
nut.
• Brass insert CD
• Hull®
• Urethane foam @
• Silicone sealant @

8-29

[Link]
I~~I 4~_HU_L_L_ _ _ _ _ _ _ _ _ _ _ _ _ _C_~_~
Removing a graphic
BOW
1. Remove:
~ - • GraphicG)

-f NOTE:-------------------------
Using a hair dryer, start at one corner and blow
heat the graphic, holding the heat source at
least 1-1/2" above the graphic.
Slowly peel off the heated part and continue
working towards the other side.

2. Clean:
Once the graphic is removed, clean the en-
tire bow area with Isopropyl Alcohol to re-
move any residual adhesive.

Applying a graphic
1. Preparation:
Mix 1 tablespoon of liquid washing-up de-
tergent with water in a 1qt spray bottle.
Remove the backing from the new graphic
and spray both sides and the area of the full
to which it is to be fitted.
NOTE:-------------------------
Spraying the front of the graphic will protect it
from being scratched during application.
BOW
2. Apply:
~ Align the graphic on the fitting area and
smooth it into position with a small rubber
squeegee, removing all air bubbles in the
process. Begin at the top of the graphic and
work down and outwards from the center
line of the graphic area.
3. Dry:
Let the graphic dry in place prior to waxing
or using the vehicle.

8-30

[Link]
 CHAPTER 9
TROUBLE ANALYSIS

TROUBLE ANALYSIS . ......................................... 9-1

TROUBLE ANALYSIS CHART ................................ 9-1

[Link]
 TROUBLE ANALYSIS
TROUBLE ANALYSIS
NOTE:----------------------------------------------------------
Following items should be obtained before "trouble analysis".
1. Battery is charged and its specified gravity is in specification.
2. There is no incorrect wiring connection.
3. Wiring connections are surely engaged and without any rust.
4. Lanyard is installed to the engine stop switch.
5. Fuel is coming to the carburetor.

TROUBLE ANALYSIS CHART

Trouble mode Check elements

z (!J
I- 0 Z
ex: a.. ~ B
0 ex:
~
UJ ()

(f)
I-
(f)
0
z Ci «
I
~
l- I- « (!J 0
0 0 :2 z UJ <!)
~ >- Reference
z (!J
(f)
....J z ex: (!J a: (f)
« z ex: Relative part
....J z ....J ....J 0 Z UJ UJ 0: UJ Chapter
~ ~
....J ....J U.
::J ex:
~ ~
UJ
~ Cl (f) ~ ex: I- 0
UJ (f) 0:
a.. UJ Z co
UJ
z I UJ
z
UJ
z I UJ :5
(!J ex: ex: (f) UJ =>
<!)
ex:
B :::) (!J B 0 UJ 0 (!J w 0
Z 0
ex:
Z Z 0 > 0 ....J 0:
g; 0
UJ UJ UJ a.. 0 ....J iii a..
FUEL SYSTEM
0 0 0 0 Fuel tank 4
0 0 0 0 Air vent hose 4
0 0 0 Fuel hose 4
0 0 0 0 Fuel filter 4
0 0 0 Fuel pump 4
0 0 0 0 Carburetor 4
0 0 0 Low speed screw setting 4
0 0 High speed screw setting 4
0 0 Carburetor synchronization 4
0 0 Trolling speed 3
POWER UNIT
0 0 0 Compression 5
0 0 0 Reed valve 5
0 0 Cylinder head gasket 5
0 0 Piston ring 5
0 0 Cylinder body 5
0 0 Seal 5
0 0 Crankcase 5
0 0 Piston 5
0 0 Bearing 5
0 0 Intermediate housing 5
0 Coupling 5
0 Coupling rubber 5

9-1

[Link]
 TROUBLE ANALYSIS
Trouble mode Check elements

z C)
0 Z
I-
0: a..
0 w ~ a0:
~
(/)
I-
(/)
az 0
15 «
~ I
l- I- « C)
w <!l a Reference
0 (/) 0 ~ z z >- Relative part
z C) .....J Z 0: C) a:W
(/)
«w za: 0:
.....J z .....J .....J 0 Z w Chapter
~ ~
.....J :J .....J LL

~
W
~
0:
~ 0 (/) ~ 0:
w w
I-
(/)
az a:
W I W W a.. « CD
I W ...J
Z C) Z Z 0: 0: W => 0:
C)
Z
::::l
0
aZ C)
Z
0
0
w
>
(/)
0
0
C)
.....J
<!l
UJ
a:
0
0
w 0: w w a.. 0 .....J (0 !:f a..
0 0 Pilot water hose 5
0 0 Water hose 5
0 0 Water passage 5
JET PUMP UNIT
0 0 0 Duct 6
0 Impeller 6
0 Intake screen 6
0 Bearing 6
0 Duct intake 6
0 0 Water inlet hose 6
0 Bilge hose 6
0 Bilge strainer 6
0 Bilge hose joint 6
0 Valve body 6
ELECTRICAL
0 0 0 0 0 0 Ignition system 7
0 Starting system 7
0 Indication system 7
0 Charging system 7
HULL AND HOOD
0 Column bushing 8
0 0 Water lock 8
0 0 0 Exhaust hose 8
0 0 Muffler 8
0 Drain plug 8

9-2

[Link]
 Marine

WaveRunner
XL700

SUPPLEMENTARY
SERVICE
MANUAL

LIT-18616-02-00 F0M-28197-Z8-1X
[Link]
 PREFACE
This Supplemmentary Service Manual has been prepared to introduce new service and data for
the XL700. For complete service information procedures, it is necessary to use this Supplemen-
tary Service Manual together with the following manual.

XL760, XL1200 SERVICE MANUAL: GU2-28197-Z7-11

For what is not mentioned in this manual, please refer to the descriptions for XL760 in the above
SERVICE MANUAL.

A10001-0*

XL700
SUPPLEMENTARY SERVICE MANUAL
 1998 Yamaha Motor Co., Ltd.
1st Edition, September 1998
All rights reserved.
No part of this publication may be
reproduced or transmitted in any from or
by any means including photocopying and
recording without the written permission of
the copyright holder.
Such written permission must also be
obtalned before any part of this publication
is stored in a retrieval system of any nature.
Printed in USA
P/N F0M-28197-Z8-1X

[Link]
 GENERAL INFORMATION
IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PRIMARY I.D. NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PUMP SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HULL IDENTIFICATION NUMBER (H.I.N.) . . . . . . . . . . . . . . . . . . . . . 1

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
JET UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFIED TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUEL LINE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

CABLE LINE ROTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

PERIODIC INSPECTION AND ADJUSTMENT

MAINTANANCE INTERVAL CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

PERIODIC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Trolling speed adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

FUEL SYSTEM
FUEL LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 13

CARBURETOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 14

CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 16
SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
High and low speed screws adjustment . . . . . . . . . . . . . . . . . . 17
Throttle valve synchronization inspection and adjustment . 17
Choke valve synchronization inspection and adjustment . . . 18
Carburetor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [Link]
18
 POWER UNIT
ENGINE UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 19

REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 21

EXHAUST RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 22

EXHAUST CHAMBER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 23

EXHAUST CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 24

CYLILNDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 25

CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 26
SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cylinder inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 28
SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Piston inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

FLYWHEEL MAGNETO AND BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 30
SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Coupling flange removal and installation . . . . . . . . . . . . . . . . . 32
Flywheel magneto removal and installation . . . . . . . . . . . . . . . 32

ELECTRICAL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 33

INTERMEDIATE SHAFT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 35
SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Coupling removal and installation . . . . . . . . . . . . . . . . . . . . . . . 36
[Link]
 ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

ELECTRICAL ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
PEAK VOLTAGE MEASURMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
IGNITION SISTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Peak voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CHARGE COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
PULSER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
THERMO SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CDI UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
RECTIFIER/REGULATOR OUT PUT PEAK VOLTAGE . . . . . . . . . . . 48
LIGHTING COIL OUT PUT PEAK VOLTAGE . . . . . . . . . . . . . . . . . . . 48

INDICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
OIL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
OIL LEVEL WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

HULL AND HOOD

THORTTLE CABLE AND CHOKE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . 51
EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 51

EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 52

HULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . 53

[Link]
GEN
INFO IDENTIFICATION NUMBERS
A80700-0*

IDENTIFICATION NUMBERS
PRIMARY I.D. NUMBER
The primary I.D. number is stamped on a
plate attached to the hull on the front of the
engine hood.

Starting primary I.D. number:

F0M: 800101 –

ENGINE SERIAL NUMBER

The engine serial number is stamped on a
plate attached to the crankcase.

Starting serial number:

67E : 300101 –

PUMP SERIAL NUMBER

The jet pump unit serial number is stamped
on a plate attached to the intermediate hous-
ing.

HULL IDENTIFICATION NUMBER (H.I.N)

The H.I.N. is stamped on a plate attached to
the rear end of the footrest floor.

1
[Link]
GEN
INFO SPECIAL TOOLS

SPECIAL TOOLS
Use of the correct special tools recom-
mended by Yamaha will aid the work and en-
able accurate assembly and tune-up. Impro-
visations and use of improper tools can
cause damage to the equlpment.

MEASURING
1. Peak voltage adaptor
P/N. 90890-03169

REMOVAL AND INSTALLATION

1. Coupler wrench
P/N. YW-38741
90890-06425

2
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SPEC GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS
Item Unit XL700
MODEL CODE:
Hull F0M
Engine 67E
DIMENSIONS:
Length mm (in) 3,150 (124.0)
Width mm (in) 1,250 (49.2)
Height mm (in) 1,100 (43.3)
Dry weight kg (lb) 245 (54.0)
PERFORMANCE:
Maximum speed km/ h (mph) 74 (46)
Maximum output kW (hp) / rpm 58.8 (80) / 6250
Maximum fuel consumption Vh (US gal / h, 34 (8.98, 7.48)
lmp gal / h)
Cruising range (at full throttle) hr. 1.5
ENGINE:
Engine type 2-stroke
Number of cylinders 2
Displacement cm3 ([Link]) 701 (42.78)
Bore and stroke mm(in) 81
68 (3.19
2.68)
Compression ratio 7.2 : 1
Intake system Reed valve
Carburetor type Floatless
Number of carburetor 2
Carburetor starting system Choke valve
Scavenging system Loop charged
Lubrication system Oil lnjection
Cooling system Water-cooled
Starting system Electric starter
Ignition system C.D.I
Ignition timing Degree 15 BTDC – 21 BTDC
Spark plug (NGK) BR8HS
Battery capacity V/ kC (A
h) 12 / 68.4 (19)
Lighting coil A/ rpm 2 – 4 / 5,500
DRIVE UNIT:
Propulsion system Jet pump
Jet pump type Axial flow, single stage
Impeller rotation (rear view) Counterclockwise
Transmission Direct drive from engine
Nozzle angle Degree 24 ± 1
FUEL AND OIL:
Fuel Unleaded regular gasoline
Oil 2 stroke outboard motor oil
Fuel and oil mixing ratio (Wide 50 : 1
open throttle)
Fuel tank capacity l (US gal, lmp gal) 50 (13.2, 11.0)
Reserve l (US gal, lmp gal) 12 (3.17, 2.64)
Oil tank capacity l (US gal, lmp gal) 3.8 (1.0, 0.8)

3
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 SPEC MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS
ENGINE
Item Unit XL700
Cylinder head:
Warpage limit mm (in) 0.1 (0.004)
Cylinder:
Bore size mm (in) 81.00 – 81.02 (3.189 – 3.190)
Wear limit mm (in) 81.1 (3.193)
Taper limit mm (in) 0.08 (0.003)
Out of round limit mm (in) 0.05 (0.002)
Piston:
Piston size mm (in) 80.925 – 80.950 (3.186 –3.187)
Measuring point* mm (in) 10 (0.39)
Piston clearance mm (in) 0.080 – 0.085 (0.0031 – 0.0033)
Weat limit mm (in) 0.135 (0.0053)
Offset (exhaust side) mm (in) 0.5 (0.02)
Piston ring:
Type Keystone
Sectional sketch mm (in) 1.2
2.9 (0.05
0.11)
Side clearance mm (in) 0.02 – 0.07 (0.001 – 0.003)
End gap (installed) mm (in) 0.2 – 0.4 (0.008 – 0.016)
Piston pin:
Outside diameter mm (in) 19.995 – 20.000 (0.7872 – 0.7874)
Limit mm (in) 19.98 (0.786)
Crankshaft:
Crank width “A” mm (in) 61.95 – 62.00 (2.439 – 2.441)
Run out limit “B” mm (in) 0.05 (0.002)
Connecting rod big end side clearance mm (in) 0.25 – 0.75 (0.010 – 0.030)
“C”
Small end free play limit “D” mm (in) 2.0 (0.08)
Carburetor:
Stamped mark 62T02F / R
Main nozzle ø mm (in) 2.5 (0.10)
Main jet (M.J.) 120 (F), 130 (R)
Pilot jet (P.J.) 67.5
Low speed screw Turns out 5 / 8, ± 1 / 4
Throttle valve (Th.V.) 190
Valve seat (V.S.) ø mm (in) 1.5 (0.06)
High speed screw Turns out 5 / 8 (F), 1-1 / 8 (R) ± 1 / 4
Trolling speed r/ min 1,250 ± 50
Reed valve:
Thickness mm (in) 0.2 (0.01)
Valve lift mm (in) 9.0 ± 0.2 (0.35 ± 0.01)
Bending limit mm (in) 0.2 (0.008)

4
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 SPEC MAINTENANCE SPECIFICATIONS
JET UNIT
Item Unit XL700
Jet pump:
Impeller clearance mm (in) 0.25 – 0.35 (0.010 – 0.014)
Service limit mm (in) 0.6 (0.024)
Impeller shaft run out mm (in) 0.3 (0.012)

ELECTRICAL
Item Unit XL700
Ignition system:
Type CDI magneto
Ignition timing at 1,200 rpm Degree 15 BTDC
at 5,500 rpm Degree 21 BTDC
Stator:
Model / Manufacturer F4T31671/ MITSUBISHI
Pulser coil resistance (color) Ω 12.6 – 15.4 (W / R – B)
Charging coil resistance (color) Ω 497.7 – 608.3 (Br / W – B)
CDI unit:
Stamped mark 62T-01
Model / Manufacturer F8T13175/ MITSUBISHI
Over revolution limit r/ min 7,000 – 7,400
Overheat revolution control r/ min 3,000 – 3,800
Ignition coil:
Stamped mark 62E-11
Model / Manufacturer F6T532 / MITSUBISHI
Primary winding resistance Ω 0.078 – 0.106 (Or – B)
Secondary winding resistance kΩ 14.3 – 30.5 (High tension cords)
Charging system:
Type Flywheel magneto
Lighting coil resistance (color) Ω 1.14 – 1.40 (G – G)
Rectifier regulator:
Model / Manufacturer SH589-12/ SHINDENGEN
Regulator voltage V 14.3 – 15.3
Thermo switch:
ON _C (_F) 76 – 84 (169 – 183)
OFF _C (_F) 63 – 77 (145 – 171)
Starter motor:
Model / Manufacturer SM13237/ MITSUBA
Brush length mm (in) 12.5 (0.44)
Wear limit mm (in) 6.5 (0.26)
Commutator under cut mm (in) 0.7 (0.028)
Limit mm (in) 0.2 (0.008)
Commutator diameter mm (in) 28.0 (1.10)
Limit mm (in) 27.0 (1.06)
Fuse:
Rating V–A 12-10

5
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 SPEC TIGHTENING TORQUE

TIGHTENING TORQUE
SPECIFIED TORCUE

Part Tightening torque

Part to be
e tightened
he e S e
Size Q’
Q’ty Re
Remark
name Nm m
kg ft
lb
ENGINE:
Electric box Bolt M8 2 17 1.7 12

271
271
Mounting bolt Bolt M8 4 17 1.7 12

242
Reed valve Screw M4 16 1 0.1 0.7

271
Exhaust ring Bolt M8 4 30 3.0 22
Exhaust chamber Bolt M10 2 40 4.0 29

271
Muffler stay Bolt M10 4 40 4.0 29

271
E h
Exhaust chamber-
h e- 1st 2 0.2 1.4

271
Bolt
l M10 2
Muffler stay 2nd 47 4.7 34
1st 22 2.2 16

271
M le 1
Muffler Bolt
l M10 8
2nd 40 4.0 29
1st 23 2.3 17

572
Cylinder
l e body Bolt
l M10 6
2nd 40 4.0 29
1st 15 1.5 11

572
Cylinder
l e head
he Bolt
l M8 10
2nd 36 3.6 25
Spark plug Bolt M14 2 25 2.5 18
Flywheel bolt Bolt M10 1 70 7.0 50
Coupling Nut M27 1 37 3.7 27

572
1st 15 1.5 11

572
Crankcase
e Bolt
l M8 8
2nd 28 2.8 20
1st 23 2.3 17 271

M
Mount bracket
e Bolt
l M10 7
2nd 53 5.3 38
Flame arrester cover Bolt M6 6 2 0.2 1.4
572

Starter motor terminal nut Nut M6 1 5 0.5 3.6

JET UNIT:
271

Bolt M10 4 34 3.4 24

M
Mounting bolt
l
242

Bolt M6 2 7 0.7 5.1

242

Ride plate Bolt M8 6 17 1.7 12

Impeller Bolt M20 1 18 1.8 13
572
572

Coupling Nut M27 1 37 3.7 27

271

Intermediate housing Bolt M8 3 17 1.7 12

Housing Bolt M10 4 34 3.4 25

6
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SPEC FUEL LINE ROUTING

FUEL LINE ROUTING

Pilot water hose

Fuel cock
Fuel return hose

Fuel filter

Battery breather hose

Pass the oil hose out of belt

7
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SPEC FUEL LINE ROUTING

Align mark
Align mark
Fuel hose
(Fuel cock-
fuel filter) Fuel return hose
A–A (Carburetor-fuel tank)
Fuel hose I
(Fuel cock-
fuel filter)
B–B J
Align mark
Fuel hose
(Fuel cock-
Fuel hose 10 mm
fuel filter)
C–C (Fuel filter-engine)
K
Fuel tank Ventilation
Pilot water hose socket

E–E L
To nipple

Battery breather
Pilot water hose
hose
Fuel tank
breater hose
M–M 5 mm
F

OUT

N
IN G
Electric equipment box

Handlebar switch lead
Oil sensor lead
Oil level warning
lamp lead
Bow Handlebar switch
Fuel tank
Align mark lead
brether hose
Fuel hose
(RES)
Oil level warning
Fuel tank breather
H lamp lead
Fuel hose hose
(ON)

Fuel hose (Fuel cock-fuel filter) Handlebar switch

Q–Q Oil sensor lead lead

8
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SPEC CABLE LINE ROUTING

CABLE LINE ROUTING

Throttle cable Choke cable Battery positive lead Battery negative lead

To themo
switch lead
To starting Steering cable
motor
negative To starting motor
terminal positibve terminal

9
[Link]
SPEC CABLE LINE ROUTING

Electric equipment box Pilot water hose

Oil level warning lamp
lead
Handlebar switch
lead
Throttle cable Choke cable D–D
J
A–A
Electric equipment
box lead
Handlebar Electric equi- E–E

Handlebar switch
switch lead pment box lead
B–B
Handlber switch
Electric equipment box
To #1 cylinder (Black)

Handlebar Oil sensor lead To #2 cylinder (Black)
switch To CDI magneto (Black)
Handlebar
Oil level warning To handlebar switch (Gray)
C–C switch lead
lamp lead
To thermo switch (Black)
Oil level warning To battery positive terminal (Red)
lamp lead To starting motor positive
terminal (Red)
Handlebar switch
Oil sensor lead Electric equipment box
lead
M–M
To CDI Battery negative lead
To thermo switch
magneto
Grease Battery positive lead
To starting motor nipple Steering cable
positive terminal hose
O

Oil sensor
Meter

(White) H

Handlebar switch
Electric

equipment box (Natural)
Electric equipment Electric equipment box
box
Handlebar
Oil lever warning lamp (White)
switch (Black)
G

10
[Link]
 INSP
ADJ MAINTANCE INTERVAL CHART

MAINTANCE INTERVAL CHART

The following chart should be considered strictly as a guide to general maintenance intervals.
Depending on operating conditions, the intervals of maintenance should be changed.

Initial Every Refer

e
Item Re
Remarks 10 h
hours 50 h hours 100 hours
h 200 hours
h
to
(Break-in) (3 months) (6 months) (1 year)
pagee

CONTROL SYSTEM:
Steering cable Inspection / Adjustment f 3-2
Throttle cable Inspection / Adjustment f 3-3
Carburetor throttle Inspection f –
shaft
Choke cable Inspection / Adjustment f 3-4
FUEL SYSTEM:
Fuel tank Cleaning f 4-7
Fuel filter Cleaning / Replacement f f 3-6
Fuel line Inspection f 13
Trolling speed Inspection / Adjustment f 12
Carburetor setting Inspection / Adfustment f f 12
OIL INJECTION SYSTEM:
Oil injection system Inspection / Cleaning f f 3-8
POWER UNIT:
Spark plug Inspection / Cleaning / f f f 3-10
Adjustment
Cooling-water passage Cleaning / Flashing f –
Coupling rubber Inspection f –
ELECTRICAL:
Battery Inspection f 3-11
JET PUMP UNIT:
Impeller Inspection f f 3-13
Bilge strainer Cleaning f f 3-13
GENERAL:
Bolt and nut Retightening f f –
Drain plug Inspection/Replacement f 3-14
Greasing point Greasing f 3-14
Bearing housing Greasing f*1 f*2 3-15
*1: Grease capacity 33.0 – 35.0 cm3 (1.11 – 1.18 oz.)
*2: Grease capacity 6.0 – 8.0 cm3 (0.20 – 0.27 oz.)

11
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INSP
ADJ PERIODIC SERVICE

PERIODIC SERVICE
FUEL SYSTEM
Trolling speed inspection and adjustment
1. Check:

Trolling speed
Out of specification ! Adjust.

Trolling speed:
1,250 ± 50 r/min

Checking steps: (vehicle on water)

Start the engine and allow it to warm up
for a few minutes.

Attach the engine tachometer to the
spark plug lead.

Engine tachometer:
YU-8036-A/90890-06760

Measure the engine trolling speed.

2. Adjust:

Trolling speed

Adjustment steps:

Screw in the low speed screws 1 until
they are lightly seated.

Back the screws out by the specified
number of turns.

Low speed screw:

5/8 ± 1/4 (turns out)

Start the engine and allow it to warm up
for a few minutes.

Turn the throttle stop screw(s) 2 in or
out until the specified speed is obtained.
Turning in Increase trolling speed.
Turning out Decrease trolling speed.

Carburetor adjustment
1. Adjust:

High speed screw

Adjustment steps:

Screw in the high speed screws 1 until
they are lightly seated.

Back the screws out by the specified
number of turns.

High speed screw:

5/8 (F), 1-1/8 (R) ± 1/4
(turns out)
12
[Link]
 FUEL FUEL LINE

FUEL LINE

Gasoline (Petrol) is highly flammable and explosive. Handle with special care.

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

AIR VENTILATION HOSE, Follow the left “Step” for removal.
FUEL COCK AND FUEL FILTER
REMOVAL
1 Hose tie 1
2 Clamp 6
3 Air ventilation hose 1
4 Fuel hose (RETURN) 1
5 Fuel filter 1
6 Fuel hose 1
7 Fuel hose 3
8 Check valve 1
9 Fuel cock body 1
Reverse the removal steps for
installation.

13
[Link]
 FUEL CARBURETOR UNIT REMOVAL

CARBURETOR UNIT REMOVAL

EXPLODED DIAGRAM

2 Nm (0.2 m
kg, 1.4 ft
lb)

9 Nm (0.9 m
kg, 6.5 ft
lb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

CARBURETOR REMOVAL Follow the left “Step” for removal.
Fuel cock NOTE:
Turn the fuel cock to “OFF”.
High tension cord
1 Bolt 6
2 Cover 1 1
3 Flame arrester 2
4 Hose tie 2
5 Oil delivery hose 2
6 Bolt (with washer) 2
7 Cord clamp 1
8 Plate washer 1
9 Bolt (with washer) 6
10 Cover 2 1
11 Cover gasket 1
12 Plate 1

14
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FUEL CARBURETOR UNIT REMOVAL

2 Nm (0.2 m
kg, 1.4 ft
lb)

9 Nm (0.9 m
kg, 6.5 ft
lb)

Step Procedure/Part name Q’ty Service points

13 Cover gasket 1
14 Choke cable 1 Cable guide set position a :
15 Throttle calbe 1 17 mm (0.67 in)
Between cable guide top
and plate top.
16 Hose tie 3
17 Fuel hose (fuel filter-fuel pump) 1
18 Pulse hose (fuel pump-crank case) 1
19 Fuel hose (carburetor-fuel tank) 1
20 Nut 4
21 Plate washer 4
22 Carburetor assembly 1
23 Gasket 1
Reverse the removal steps for
installation.

15
[Link]
 FUEL CARBURETOR

CARBURETOR
EXPLODED DIAGRAM

1 Nm (0.1 m
kg, 0.7 ft
lb)

4 Nm (0.4 m
kg, 2.9 ft
lb)

2 Nm (0.2 m
kg, 1.4 ft
lb)

2 Nm (0.2 m
kg, 1.4 ft
lb)

1 Nm (0.1 m
kg, 0.7 ft
lb)

5 Nm (0.5 m
kg, 3.6 ft
lb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

CARBURETOR DISASSEMBLY Follow the left “Step” for removal.
Carburetor assembly Refer to “CARBURETOR REMOVAL”.
1 Bolt 4
2 Collar 2
3 Diaphragm assembly 2
4 Float arm 2
5 Needle valve assembly 2
6 Body assembly 2
7 Main jet 2
8 Pilot jet 2
9 High speed screw 2
10 Low speed screw 2
Reverse the removal steps for
installation.

16
[Link]
FUEL CARBURETOR
SERVICE POINTS
High and low speed screws adjustment
1. Adjust:

High speed screw

Low speed screw

Adjustment steps:

Screw in the high speed screw 1 or
lower speed screw 2 until it is lightly
seated.

Back out by the specified number of
turns.

High speed screw:

5/8 (#1), 1-1/8 (#2) ± 1/4
turns out
Low speed screw:
5/8 (#1) ± 1/4 turns out

Throttle valve synchronization inspection

and adjustment
1. Check:

Throttle valve synchronization
Out of specification
Adjust.

Checking steps:

While turning the throttle lever, check
the opening of all throttle valves.

2. Adjust:

Throttle valve synchronization

Adjustment steps:

Turn out the idle adjust screws 1 until
their tips are apart from the throttle le-
ver 2 .
NOTE:
Record the set position of the idle adjust
screw.

Check that the throttle valve “R” 3 is

fully closed.

Turn the synchronization screw 4 in or
out until the throttle valve “F” 5 is ful-
ly closed.

Turn in the idle adjust screws to the set
position.

17
[Link]
FUEL CARBURETOR
Choke valve synchronization inspection and
adjustment
1. Check:

Choke valve synchronization
Out of specification
Adjust.

Checking steps:

While turning the choke lever, check
the opening of all choke valves.

2. Adjust:

Choke valve synchronization

Adjustment steps:
a. Turn in or out the synchronization
screw 1 to bring all the choke valves
into a fully closed position when the
choke lever is turned on the closed
side.

Carburetor assembly
1. Adjust:

Trolling speed
Refer to the “FUEL SYSTEM” section in
chapter 3.

18
[Link]
POWR ENGINE UNIT REMOVAL

ENGINE UNIT REMOVAL

EXPLODED DIAGRAM

7 Nm (0.7 m
kg, 5.1 ft
lb) 1 Nm (0.1 m
kg, 0.7 ft
lb)

17 Nm (1.7 m
kg, 12 ft
lb)

4 Nm (0.4 m
kg, 2.9 ft
lb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

ENGINE UNIT REMOVAL Follow the left “Step” for removal.
Engine hood assembly Refer to the “ENGINE HOOD
REMOVAL” section in chapter 8.
Oil tank assembly Refer to the “OIL TANK AND FUEL
TANK REMOVAL” section in chapter 4.
Fuel tank assembly
Ventilation hose Refer to the “DECK” section in chapter 8.
1 Battery lead 2
2 Wire clamp 4
3 Lead coupler 2
4 Electrical box 1
5 Choke cable 1
6 Throttle cable 1
7 Housing grease nipple plate 1
8 Coupling cover 1
9 Water hose 3

19
[Link]
POWR ENGINE UNIT REMOVAL

7 Nm (0.7 m
kg, 5.1 ft
lb) 1 Nm (0.1 m
kg, 0.7 ft
lb)

17 Nm (1.7 m
kg, 12 ft
lb)

4 Nm (0.4 m
kg, 2.9 ft
lb)

Step Procedure/Part name Q’ty Service points

10 Clamp 1
11 Fuel hose 2
12 Engine mounting bolt 4
13 Shim *
14 Engine unit 1
Reverse the removal steps for
installation.

20
[Link]
POWR REED VALVE

REED VALVE
EXPLODED DIAGRAM

1 Nm (0.1 m
kg, 0.7 ft
lb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

REED VALVE REMOVAL Follow the left “Step” for removal.
Carburetor assembly Refer to the “CARBURETOR
REMOVAL” section in chapter 4.
1 Bolt (with washer) 3 6
35 mm
2 Plate 1
3 Bolt (with washer) 8 6
25 mm
4 Intake manifold assembly 1
5 Reed valve assembly 2
6 Plate 1
7 Valve stopper 4
8 Reed valve 4
Reverse the removal steps for
installation.

21
[Link]
POWR EXHAUST RING

EXHAUST RING
EXPLODED DIAGRAM

2 Nm (0.2 m
kg, 1.4 ft
lb)

2 Nm (0.2 m
kg, 1.4 ft
lb)

30 Nm (3.0 m
kg, 22 ft
lb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

EXHAUST RING REMOVAL Follow the left “Step” for removal.
1 Pilot water hose 1
2 Clamp 2
3 Exhaust joint 1 NOTE:

Pull and side the exhaust joint.

Loosen the clamp on the chamber side.
4 Clamp 1
5 Bolt (with washer) 4
6 Ring assembly 1
7 Clamp 1 CAUTION:
Tighten the clamp before installing the
ring on the muffler.

8 Joint 1
9 Exhaust ring 1
Reverse the removal steps for
installation.
22
[Link]
POWR EXHAUST CHAMBER REMOVAL

EXHAUST CHAMBER REMOVAL

EXPLODED DIAGRAM

40 Nm (4.0 m
kg, 29 ft
lb)

1st 2 Nm (0.2 m
kg, 1.4 ft
lb)

2nd 47 Nm (4.7 m
kg, 34 ft
lb)

40 Nm (4.0 m
kg, 29 ft
lb)

4 Nm (0.4 m
kg, 2.9 ft
lb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

EXHAUST CHAMBER REMOVAL Follow the left “Step” for removal.
Ring Refer to “EXHAUST RING”.
1 Exhaust hose 1
2 Water outlet hose 1
3 Bolt (exhaust chamber) 2 NOTE:
Tighten the bolts in sequence.

4 Bolt (muffler stay) 4

5 Muffler stay 1
6 Bolt 2
7 Exhaust chamber assembly 1
Reverse the removal steps for
installation.

23
[Link]
POWR EXHAUST CHAMBER

EXHAUST CHAMBER
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

CHAMBER DISASSEMBLY Follow the left “Step” for removal.
Exhaust chamber assembly Refer to “EXHAUST CHAMBER
REMOVAL”.
1 Bolt (with washer) 6
2 Exhaust outer cover 1 1
3 Gasket 1
4 Exhaust inner cover 1
5 Seal 1
6 Gasket 1
7 Bolt (with washer) 6
8 Exhaust outer cover 2 1
9 Gasket 1
10 Exhaust chamber 1
Reverse the removal steps for
installation.

24
[Link]
POWR CYLINDER HEAD

CYLINDER HEAD
EXPLODED DIAGRAM

25 Nm (2.5 m
kg, 18 ft
lb)

1st 15 Nm (1.5 m
kg, 11 ft
lb)

2nd 36 Nm (3.6 m
kg, 25 ft
lb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

CYLINDER HEAD REMOVAL Follow the left “Step” for removal.
Muffler Refer to “MUFFLER”.
1 Spark plug 2
2 Water hose 1
3 Bolt (with washer) 10 NOTE:
Tighten the bolts in sequence and two
steps of torque.
4 Cylinder head 1
Reverse the removal steps for
installation.

25
[Link]
POWR CYLINDER

CYLINDER
EXPLODED DIAGRAM

1st 23 Nm (2.3 m
kg, 17 ft
lb)

2nd 40 Nm (4.0 m
kg, 29 ft
lb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

CYLINDER REMOVAL Follow the left “Step” for removal.
Cylinder head Refer to “CYLINDER HEAD”
1 Bolt (with washer) 6 NOTE:
Tighten the bolts in sequence and in two
steps of torque.

2 Cylinder 1 NOTE:
After installing, check the smooth
movement of the piston.

3 Pin 2
Reverse the removal steps for
installation.

26
[Link]
POWR CYLINDER
SERVICE POINTS
Cylinder inspection
1. Eliminate:
D Carbon deposits
Use a rounded scraper 1 .

2. Inspect:
D Cylinder water jacket
Mineral deposits/Corrosion
Clean.
D Cylinder inner surface
Score marks
Repair or replace.
Use #600 X 800 grit wet sandpaper.

3. Measure:
D Cylinder bore “D”
Use cylinder gauge.
Out of limit
Replace.
NOTE:
Measure the cylinder bore “D” in parallel.
Then, find the average of the measurement.

Standard Limit

Cylinder 81.00 X 81.02 mm 81.10 mm

bore “D” (3.189 X 3.190 in) (3.193 in)
0.08 mm
Taper “T” –
(0.003 in)
Out of 0.05 mm
–
round “R” (0.002 in)
D = Maximum (D1 X D6)
T = (Maximum D1 or D2) – (Maximum
D5 or D6)
R = (Maximum D1, D3 or D5) – (Minimum
D2, D4 or D6)

27
[Link]
POWR PISTON

PISTON
EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

PISTON REMOVAL Follow the left “Step” for removal.
Cylinder Refer to “CYLINDER”.
CAUTION:
1 Piston pin clip 4 Do not allow the clip open ends to meet
2 Piston pin 2 the piston pin slot a .

3 Piston 2 NOTE:
4 Washer 4 Be sure the arrow b side is positioned
exhaust pipe.

5 Piston ring 4 CAUTION:

Align each end gap with the locating
pin.

Reverse the removal steps for

installation.
28
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POWR PISTON
SERVICE POINT
Piston inspection
1. Eliminate:

Carbon deposits
From the piston crown and ring groove.

2. Inspect:

Piston wall
Score marks
Repair or replace.
Use #600 – 800 grit wet sandpaper.
NOTE:
Sand in a criss-cross pattern. Do not sand ex-
cessively.

3. Measure:

Piston skirt diameter
Use micrometer.
Out of specification
Replace.

Piston diameter Distance a

80.925 – 80.950 mm 10 mm
(3.186 – 3.187 in) (0.39 in)

4. Calculate:

Piston clearance
Out of limit
Replace piston, piston rings
as a set.

PISTON CYLINDER PISTON

= –
CLEARANCE BORE DIAMETER

Piston clearance:
0.080 – 0.085 mm
(0.0031 – 0.0033 in)

29
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POWR FLYWEEL MAGNETO AND BASE

FLYWEEL MAGNETO AND BASE

EXPLODED DIAGRAM

37 Nm (3.7 m
kg, 27 ft
lb)

70 Nm (7.0 m
kg, 50 ft
lb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

FLYWHEEL MAGNETO AND BASE Follow the left “Step” for removal.
REMOVAL
Engine unit Refoer to the “ENGINE UNIT
REMOVAL” section.
1 Oil pump 1
2 Flywheel cover 1
3 Coupling flange 1
4 Flange bolt 1
5 Flywheel magneto 1 NOTE:
When installing the flywheel magneto
make sure that the woodruff key is
properly seated in the keyway of the
crankshaft.

30
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POWR FLYWHEEL MAGNETO AND BASE

37 Nm (3.7 m
kg, 27 ft
lb)

70 Nm (7.0 m
kg, 50 ft
lb)

Step Procedure/Part name Q’ty Service points

6 Idle gear assembly 1 NOTE:
Fill the flywheel cover groove with
water resistant grease.

7 Base assembly 1 NOTE:

Align the punch mark on the crankcase
with the punch mark on the base
assembly.

Reverse the removal steps for

installation.

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POWR FLYWHEEL COVER AND FLYWHEEL MAGNETO
SERVICE POINTS
Coupling flange removal and installation
1. Remove and install:

Coupling flange

Coupler wrench:
YW-38741/90890-06425
Flywheel holder:
YB-06139/90890-06522

Flywheel magneto removal and installation

1. Remove and install:

Bolt

Flywheel holder:
YB-06139/90890-06522

2. Remove:

Flywheel magneto

Flywheel puller:
YB-06117/90890-06521
A B Bolt:
M8
80 mm

A For USA and CANADA

B Except for USA and CANADA

CAUTION:
To prevent damage to the engine or tools,
screw in the flywheel puller set- bolts evenly
and completely so that the puller plate is
parallel to the flywheel.

32
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POWR ELECTRICAL UNIT

ELECTRICAL UNIT
EXPLODED DIAGRAM

5 Nm (0.5 m
kg, 3.6 ft
lb)

4 Nm (0.4 m
kg, 2.9 ft
lb)

4 Nm (0.4 m
kg, 2.9 ft
lb)

4 Nm (0.4 m
kg, 2.9 ft
lb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

ELECTRICAL UNIT REMOVAL Follow the left “Step” for removal.
Electrical box Refer to the “ENGINE UNIT REMOVAL”
section.
Base assembly Refer to the “FLYWHEEL MAGNETO
AND BASE” section.
1 Spark plug cap 2
2 Bolt (with washer) 2
3 Thermo switch 1
4 Nut 1
5 Spring washer 1
6 Starter motor negative lead 1

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POWR ELECTRICAL UNIT

5 Nm (0.5 m
kg, 3.6 ft
lb)

4 Nm (0.4 m
kg, 2.9 ft
lb)

4 Nm (0.4 m
kg, 2.9 ft
lb)

4 Nm (0.4 m
kg, 2.9 ft
lb)

Step Procedure/Part name Q’ty Service points

ELECTRICAL UNIT DISASSEMBLY
1 Screw 14
2 Case cover 1
3 Screw 2
4 Ignition coil 1
5 Screw 3
6 Clamp 1
7 Rectier-regulator 1
8 Screw 3
9 Clamp bracket 1
10 CDI unit 1
11 Nut 2
12 Spring washer 2
13 Starter relay 1
14 Housing 1
Reverse the removal steps for
installation.

34
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POWR INTERMEDIATE HOUSING

INTERMEDIATE HOUSING
EXPLODED DIAGRAM

6 Nm (0.6 m
kg, 4.3 ft
lb)

37 Nm (3.7 m
kg, 27 ft
lb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

INTERMEDIATE HOUSING Follow the left “Step” for removal.
DISASSEMBLY
Bearing housing assembly Refer to “INTERMEDIATE HOUSING
REMOVAL”.
1 Coupling 1
2 Shaft 1 Distance:
3 Oil seal 1 a : 1.6 X 2.0 mm (0.06 X 0.08 in)
4 Oil seal 1 b : 14.5 X 15.5 mm
5 Clip 1 : (0.57 X 0,61 in)
6 Bearing 1 c : 6.8 X 7.2 mm (0.27 X 0.28 in)
d : 17.6 X 17.7 mm (0.69 X 0.70 in)

Reverse the removal steps for

installation.

35
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POWR INTERMEDIATE SHAFT AND HOUSING
SERVICE POINT
Coupling removal and installation
1. Remove and install:

Coupling

Coupler wrench:
YW-38741/90890-06425
Shaft holder:
YW-38742/90890-06069

36
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 ELEC ELECTRICAL COMPONENTS

ELECTRICAL COMPONENTS

1 Throttle cable 9 CDI magneto lead

2 Oil level sensor lead 10 Choke cable
3 Battery lead (positive) 11 Steering cable
4 Battery lead (negative) 12 Sterter motor lead (nagative)
5 Oil level warning lamp lead 13 Grease nipple hose
6 Handlebar switch lead 14 Electrical box
7 Starter motor lead (positive) 15 High tension cord
8 Thermo sensor lead 16 Pilot water hose

37
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 ELECTRICAL DIAGRAM
1 Thermo switch

ELEC
2 Ignition coil
3 Lighting coil
4 Pulser coil
5 Charge coil
6 CDI unit
7 Starter motor
8 Stop switch
9 Engine stop switch
10 Starter switch

ELECTRICAL DIAGRAM
11 Battery
12 Fuse
13 Starter relay
14 Rectifier regulator
15 Oil level sensor
16 Oil level warning lamp

B : Black
Br : Brown
38

Br/W : Brown/White
G : Green
L : Blue
O : Orange
P : Pink
R : Red
W : White
W/R : White/Red

[Link]
ELEC ELECTRICAL ANALYSIS

ELECTRICAL ANALYSIS
PEAK VOLTAGE MEASUREMENT
NOTE:

If the spark produces no sparks, check the
wiring for any disconnection, looseness, in-
sufficient contact, etc. Then measure the
peak voltage.

The peak voltages are listed for the loaded
and the circuit state. The “loaded value” is
used for measuring a normally operating
system and the “circuit valve” for measur-
ing a coil disconnected from the system.

The peakvoltage value measured at crank-
ing is the one at which no load is applied to
the jet pump.

To measure the peak voltage of lighting coil
and rectifier regulator, take off the output
wire of the rectifier regulator.

Measuring step:

Remove the electrical box and disas-
sembly it.
Refer to “ENGINE UNIT REMOVAL”.

Attach the tachometer to the high ten-
sion lead of the cylinder #1, (No need
during cranking measurement).

Set the peak voltage adaptor to the tes-
ter.
NOTE:
The peak voltage adaptor plugs a have
polarity. Connect the red plug of the peak
voltage adaptor to the volt test plug of the
tester.

39
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ELEC ELECTRICAL ANALYSIS

Set the digital tester dial at the DCV posi-

tion.

Connect the peak voltage adaptor leads
b to the correct terminals to be mea-
sured.
NOTE:

The peak voltage leads have no polarity
connection of either lead to either termi-
nal c for measurement will result in the
same measurement.

Wire colors for connection purposes will
be indicated.

Connect the water vehicles to a fully

charged battery. (In cranking measure-
ment)

Start or crank the engine and read the in-
dication.
CAUTION:
When the peak voltage is measured dur-
ing engine operation, measure it with
cooling water passing through the en-
gine cooling water passage.

NOTE:

Before measuring cranking, remove the
spark plug caps from the spark plug.

Cranking speed changes the output
measurement.

The specified values shown in the
manuals will be indicated as the lower
limit of the specification. If the meter’s
reading is higher, then there is no prob-
lem with the tested component.

If the output reading is lower, then the
component is probably faulty, as long as
the component’s input voltages are cor-
rect at the time when testing.

40
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 ELEC IGNITION SYSTEM

IGNITION SYSTEM
WIRING DIAGRAM

1 Pulser coil B : Black

2 Charge coil Br/ W : Brown / White
3 CDI unit O : Orange
4 Stop switch P : Pink
5 Engine stop switch W : White
6 Thermo switch W/ R : White / Red
7 Ignition coil

41
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ELEC IGNITION SYSTEM
IGNITION SYSTEM
Peak voltage

When checking the peak voltage do not

touch any of the connections of the digital
tester lead wires.

NOTE:

If there is no spark or the spark is weak, con-
tinue with the ignition system test.

If a good spark is obtained, the problem is
not with the ignition system, but possibly
with the spark plug(s) or another compo-
nent.

1. Measure:

CDI unit output peak voltage
Above specification
Replace the igni-
tion coil.
Below specification
Measure the
charge coil output peak voltage.

CDI unit output peak voltage

Orange (O) – Brack (B)
Circuit Loaded
r/min
Cranking 1,500 3,500
V – 105 175 135

2. Measure:

Charge coil output peak voltage
Above specification
Measure the puls-
er coil output peak voltage.
Below specification
Replace the charge
coil.

Charge coil output peak voltage

Brown / White
(Br/W) – Black (B)
Circuit Loaded
r/min
Cranking 1,500 3,500
V 120 115 205 150

42
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ELEC IGNITION SYSTEM
3. Measure:

Pulser coil output peak voltage
Above specification
Replace the CDI
unit.
Below specification
Replace the pulser
coil.

Pulser coil output peak voltage

White/red (W/R) – Black (B)
Circuit Loaded
r/min
Cranking 1,500 3,500
V 3.0 3.0 17.0 29.5

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ELEC IGNITION SYSTEM
CHARGE COIL
1. Measure:
S Charge coil resistance
Out of specification
Replace.

Charge coil resistance:

Brown/White
(Br/W) – Black (B)
497.7 – 608.3 Ω at 20 _C
(68 _F)

PULSER COIL
1. Measure:
S Pulser coil resistance
Out of specification
Replace.

Pulser coil resistance:

White/Red (W/R) – Black (B)
12.6 – 15,4 Ω at 20 _C
(68 _F)

THERMO SWITCH
1. Measure
S Thermo switch continuity
Out of specification
Replace.

Thermo switch continuity

temperature:
Pink (P) – Black (B)
a 66 – 74 _C (100.4 – 125.6 _F)
b 57 – 43 _C (93.2 – 78.8 _F)

1 Discontinuity A Temperature
2 Continuity B Time
3 Discontinuity

Measurement steps:
S Suspend thermostat in a vessel.
S Place known reliable thermometer in
water.
S Heat water slowly.
S Observe thermometer, while stirring
water continually.

44
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ELEC IGNITION SYSTEM
CDI UNIT
1. Measure:

CDI unit resistance
Out of specification
Replace.

Pocket tester:
YU-03112/90890-03112

NOTE:

The resistance values will vary from meter
to meter, especially with electronic digital
meters. For some testers, the polarity of the
leads is reversed.

The needle swings once to the ”
” mark and
then returns to the home position.

The ”∞” mark stands for discontinuity.

Unit: kΩ

 B Br/ W O P W W/ R B : Black
B 2–6
3 – 11 10 – 40 150 – 600 Br/ w : Brown / white
Br/ W 20 – 80
50 – 200 15 – 60 250 – 1000 O : Orange
P : Pink
O





W : White
P ∞ ∞ ∞ ∞ ∞ W/ R : White / Red
W ∞ ∞ ∞ ∞ ∞
W/ R 9 – 36 17 – 70
10 – 40 50 – 200

45
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 ELEC STARTING SYSTEM

STARTING SYSTEM
WIRING DIAGRAM

1 Fuse B : Black
2 Engine stop switch Br : Brown
3 Starter switch R : Red
4 Battery
5 Starter motor
6 Starter relay

46
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 ELEC CHARGING SYSTEM

CHARGING SYSTEM
WIRING DIAGRAM

1 Fuse B : Black
2 Battery G : Green
3 Lighting coil R : Red
4 Rectifier regulator

47
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ELEC CHARGING SYSTEM
RECTIFIER/REFULATOR OUTPUT PEAK
VOLTAGE
1. Measure:

Rectifier/regulator output peak voltage
Below specification
Check the lighting
coil.

Rectifier/regulator output peak

voltage
Red (R) – Black (B)
Circuit Loaded
r/min
Cranking 1,500 3,500
V – – 12.6 12.5

NOTE:
Before measuring the rectifier/regulator
output peak voltage, disconnect the lighting
coil coupler and remove the fuses.

LIGHTING COIL OUTPUT PEAK VOLTAGE

1. Measure:

Lighting coil output peak voltage
Above specification
Replace the rectifi-
er/regulator.
Below specification
Replace the light-
ing coil.

Lighting coil output peak voltage

Green (G) – Green (G)
Circuit Loaded
r/min
Cranking 1,500 3,500
V 7.3 7.3 13.6 12.6

48
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 ELEC INDICATION SYSTEM

INDICATION SYSTEM
WIRING DIAGRAM

1 Oil level sensor B : Black

2 Lighting coil G : Grren
3 Oil levle warning lamp L : Blue
4 Rectifier regulator R : Red

49
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ELEC INDICATION SYSTEM
OIL LEVEL SENSOR
1. Meadure:

Oil level sensor continuity Out of specifi-
cation
Replace.
Checing leads
ON Float position
Max. 2.5 mm L B
(0.010 in.)
OFF OFF
ON
Float length a :
37,0 – 41,0 mm (1,46 – 1,61 in)

OIL LEVEL WARNING LAMP

1. Check:

Display function Not working
Replace.

Checking steps:

Connect the battery.

Voltage range:
10 – 16 V

1 Red lead
Positive terminal.

2 Green lead
Positive terminal.
3 Black lead
Negative terminal.

After connecting the battery, oil, warn-

ing LED starts to lighy up for 3 seconds
and then blinks.

Connect the jumper lead a to the blue
and black terminals to check the oil
warning LED goes off, after blinking for
10 – 30 seconds.

50
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HULL
HOOD THORTTLE CABLE AND CHOKE CABLE

THROTTLE CABLE AND CHOKE CABLE

EXPLODED DIAGRAM

8 Nm (0.8 m
kg, 6.0 ft
lb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

THROTTLE CABLE REMOVAL Follow the left “Step” fot removal.
1 Spiral tube 1
2 Throttle cable lock nut 1
3 Throttle cable adjusting 1
4 Seal packing 1
5 Throttle cable 1
6 Choke knob 1
7 Choke cable lock nut 1
8 Choke cable adjusting nut 1
9 Choke cable 1
Reverse the removal steps for
installation.

51
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HULL
HOOD EXHAUST SYSTEM

EXHAUST SYSTEM
EXPLODED DIAGRAM

4 Nm (0.4 m
kgf, 2.9 ft
lb)

3 Nm (0.3 m
kgf, 2.2 ft
lb)

4 Nm (0.4 m
kgf, 2.9 ft
lb)

7 Nm (0.7 m
kgf, 5.1 ft
lb)

4 Nm (0.4 m
kgf, 2.9 ft
lb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

EXHAUST SYSTEM REMOVAL Follow the left “Step” for removal.
Storage box
1 Band 2
2 Exhaust hose 1
3 Exhaust hose 1
4 Water lock 1
5 Water outlet hose 1
6 Exhaust guide Reverse the removal steps for
installation.

52
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HULL
HOOD HULL

HULL
EXPLODED DIAGRAM

7 Nm (0.7 m
kgf, 5.1 ft
lb)

REMOVAL AND INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

HULL DISASSEMBLY Follow the left “Step” for removal.
1 Nut 8
2 Plate washer 8
3 Packing 8
4 Sponson 2
Reverse the removal steps for
installation.

53
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YAMAHA
YAMAHA MOTOR CO .• LTD.

Printed in USA
Nov. 1998 - 1.0 x 1 CD
(XL700)
(;.;) Printed on ohlorine-free paper

[Link]