Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period. The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more technical information and tools. Consult an authorized Yamaha dealer.
* Should be serviced by an authorized Yamaha dealer, unless the owner has proper tools and service data and is mechanically qualified.
** In the interest of safety, we recommended these items be serviced only by an authorized Yamaha dealer.

NOTE: Some items will need more frequent service if the PWC is ridden in salt water or at full throttle. Consult an authorized Yamaha PWC dealer for recommendations applicable to your individual needs and use.
Check the fuel feed and return hoses for deterioration, damage or leakage and make sure the hoses are secured with the hose clamp properly. Also, check that the clamp is installed on the oil tank securely. Check the fuel tank for cracks or leakage and that the tank is installed securely with the straps and replace if necessary.
Check the throttle lever for smooth operation. Check that the throttle opens and automatically closes in all steering positions. Check for any deterioration or damage to the throttle cable. Apply a water-displacement corrosion-proof lubricant (without Teflon or molybdenum additives, such as CRC 6-56 or an equivalent) to the throttle cable upper end. Release the rubber shield, and apply a water-displacement corrosion-proof lubricant (without Teflon or molybdenum additives, such as CRC 6-56 or an equivalent) to the throttle cable lower end (throttle drum rolling area) and to the throttle screw tip. With the engine idling, turn the handlebar all the way to the right and left to ensure that the idle speed does not change. If idle speed increases, check the throttle lever free play and the throttle cable connection.
To lubricate and rustproof the inside of the throttle body, proceed as follows after confirming that the engine is stopped and cool.
1. Remove the joint hoses from the clip(s) and disconnect the maintenance joint.
2. Insert the spray nozzle of a water-displacement corrosion-proof lubricant (without Teflon or molybdenum additives, such as CRC 6-56 or an equivalent) into joint hole.
3. Open the throttle fully.
4. Spray the lubricant into joint hole for 3 seconds.
5. Operate the throttle lever slowly, from fully ON to fully OFF, 3 times.
6. Repeat the step 2 – 5 again.
7. Perform the same lubrication procedure for joint hole.
8. Spray the lubricant to the maintenance joint threads and the O-ring.
9. Reconnect the maintenance joint and make sure it tightened securely. Install the joint hoses into the clip(s) properly.

• This watercraft uses direct type ignition coils. The spark plug cap and ignition coil are integrated. Remove the seats. Disconnect the ignition coil connectors. Remove the bolts and the direct ignition coils. Clean around the spark plug bases with compressed air before removing the plugs, and be sure that no debris is allowed to enter the combustion chamber and remove the spark plugs.
Check the insulator for cracks or damage, and the electrodes for wear, fouling or discoloration. Replace the plug if necessary.
Measure the spark plug between the center and side electrodes with a wire-type feeler gauge. Make sure the 1.0 mm (0.04 in) wire-type feeler gauge cannot be inserted into the gap. If the gauge can be inserted into the gap, replace the plug with a new one. Screw the spark plug in the cylinder head by hand to prevent cross-threading. Tighten the spark plug to the specified torque. Install the removed parts in the reverse order of removal.
• Before installing the ignition coil, clean the plug hole (coil seating area) and sealing rubber on the ignition coil, and make sure the sealing rubber is in good condition.
• Do not allow water into the ignition coil connectors

Rotate the crankshaft counterclockwise (viewed from rear side) and align the "T" mark on the drive coupler boss with the index mark (arrow) on the crankcase. The timing marks ("IN" for intake and "EX" for exhaust) on the cam sprockets must be flush with the cylinder head surface and facing outward as shown. If the timing marks are facing inward, rotate the crankshaft counterclockwise 360° (one full turn) and align the "T" mark with the index mark.
Remove the seats. Release the four retainers and remove the airbox cover. Replace the air filter in accordance with the maintenance schedule or any time it is excessively dirty or damaged.
Install a new air filter into the housing base properly. Be sure the rubber seal in the cover is in good condition and install the airbox cover. Secure the cover with the retainers Install the seats.

This watercraft’s engine uses a dry sump. Follow the following procedures to determine if the proper amount of oil is in the engine.
Secure the watercraft on a stand or trailer and keep it level. Remove the rear tray. Before checking the engine oil level: Remove the filler cap/dipstick from the oil tank and wipe it clean.
Insert the filler cap/dipstick until it seats, but do not screw it in. Remove the dipstick and check the oil level.

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

Remove the oil drain pipe cap and insert the filler cap/dipstick into the oil drain pipe until it seats, then remove it and check the oil level.
– If oil appears on the dipstick, install the filler cap/ dipstick and drain pipe cap, and proceed to the
Oil Level Check Procedure.
– If there is no oil on the dipstick, do not start the engine. Reinstall the drain pipe cap and tighten it.
Add the recommended engine oil into the oil tank through the filler hole until oil is on the dipstick. Do not over fill. Install the filler cap/dipstick and proceed to the
Oil Level Check Procedure.
• Change the oil with the engine warm to assure complete draining. Secure the watercraft on a stand or trailer. Remove the rear tray. Warm up the engine for a few minutes according to the flushing procedure. Turn off the water and stop the engine. Remove the oil filler cap/dipstick and the drain pipe cap. Pump out the engine oil with a commercially available Fluid Evacuator from the oil filler hole and drain pipe, to drain the oil tank and oil pan. After draining the oil completely, install the drain pipe cap and pour the recommended oil into the oil tank through the filler hole. Install the filler cap/dipstick. Check the oil level.
Drain the engine oil. Place a shop towel around the oil filter cartridge to avoid spilling the engine oil. Remove the oil filter cartridge and discard it. Clean any oil from the cartridge seating surface of the engine and the oil filter tray. Apply engine oil to the O-ring and threads of a new oil filter cartridge and install the filter using the filter wrench. Fill the oil tank with the recommended oil.
4.2 liters (4.4 US qt, 3.7 Imp qt) at draining
4.3 liters (4.5 US qt, 3.8 Imp qt) at draining/filter change
5.3 liters (5.6 US qt, 4.7 Imp qt) at disassembly
4.0 liters (4.2 US qt, 3.5 Imp qt) at draining
4.1 liters (4.3 US qt, 3.6 lmp qt) at draining/filter change
5.0 liters (5.3 US qt, 4.4 Imp qt) at disassembly

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

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

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

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

No oil pressure
• Oil level too low
• Oil pressure relief valve stuck open
• Broken oil pump drive or driven joints
• Damaged oil pump
• Internal oil leak

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

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

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

Engine cranks but will not start
• Intake air leak
• Fuel contaminated/deteriorated
• Pinched or clogged fuel hose
• Faulty fuel pump
• Clogged fuel injector filter
• Sticking fuel injector needle
• Faulty fuel pump operating system

Engine stalls, hard to start, or idles rough
• Intake air leak
• Fuel contaminated/deteriorated
• Pinched or clogged fuel hose
• Idle speed misadjusted
• Starter valve synchronization misadjusted

Backfiring or misfiring during acceleration
• Ignition system malfunction
Poor performance (driveability) and poor fuel economy
• Pinched or clogged fuel hose
• Faulty pressure regulator

Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. Compression too low, hard starting or poor performance at low speed.
• Valves
– Incorrect valve adjustment
– Burned or bent valve
– Incorrect valve timing
– Broken valve spring
– Uneven valve seating

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

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

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

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

Rough idle
• Low cylinder compression
Engine does not turn
• Faulty starter clutch
• Damaged reduction gear/shaft

Compression too low, hard starting or poor performance at low speed
• Leaking cylinder head gasket
• Worn, stuck or broken piston ring
• Worn or damaged cylinder and piston

Compression too high, overheating or knocking
• Excessive carbon built-up on piston head or combustion chamber
Excessive smoke
• Worn cylinder, piston or piston ring
• Improper installation of piston rings
• Scored or scratched piston or cylinder wall

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

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

Excessive exhaust noise
• Exhaust component cracked
• Exhaust gas and water leaks

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

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

Poor performance though engine runs properly
• Water intake area obstructed
• Excessive impeller clearance
• Impeller or water jet stator damaged

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

Engine turns slowly when starting engine
• Restriction in jet pump
• Seizure in jet pump

Engine overheats
• Restricted jet pump water intake (water filter)
Poor steering control
• Steering cable improperly adjusted
• Steering cable damaged or improperly routed
• Steering nozzle pivot cracked or damaged
• No lubricant on steering components

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

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

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

5. Relay Coil Ground Line InspectionRemove the safety lanyard switch from the engine stop switch. Check the ground line of the starter relay switch. Is the ground line normal?
NO – Open circuit in the Green wire

6. Relay Coil Power Input Line Inspection
Check the power input line of the starter relay switch. Is the power input line normal?
NO – • Faulty engine stop switch

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

7. Starter Relay Switch Inspection
Check the function of the starter relay switch. Does the starter relay switch function properly?
YES – Loose or poor contact starter relay switch connector
NO – Faulty starter relay switch

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