Page 102 of 347
5-3
EPOWRENGINE UNIT
EXPLODED DIAGRAM
*: As required.Step Procedure/Part name Q’ty Service points
13 Bolt/washer 4/4
14 Shim *
15 Engine unit 1
Reverse the removal steps for installation.
14 10
10
2
113
3
4
11
15
12
8
7
9
6
5
2nd 18 N m (1.8 kgf m, 13 ft Ib) 1st 8.8 N m (0.88 kgf m, 6.4 ft Ib)
8 × 35 mm
6 × 25 mm
7.8 N m (0.78 kgf m, 5.6 ft Ib)
8 × 35 mm 17 N m (1.7 kgf m, 12 ft Ib)
17 N m (1.7 kgf m, 12 ft Ib)8 × 40 mm
17 N m (1.7 kgf m, 12 ft Ib)
10LT
242
LT
LT
572
LT
LT
271
ProCarManuals.com
Page 103 of 347
5-4
EPOWRENGINE UNIT
SERVICE POINTS
Compression pressure measurement
The following procedure applies to all of the
cylinders.
NOTE:
Insufficient compression pressure will result in
a loss of performance.
1. Measure:
Valve clearance
Out of specification →
Adjust.
Refer to “POWER UNIT” in Chapter 3.
2. Warm the engine up, and then put the
watercraft in a horizontal position.
3. Remove:
Ignition coils
Spark plugs
CAUTION:
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinders.
4. Install:
Compression gauge extension 1
Compression gauge 2
Compression gauge extension:
90890-06582
Compression gauge:
YU-33223-1/90890-03160
2
1
ProCarManuals.com
Page 107 of 347
5-8
EPOWREXHAUST PIPES 1 AND 2
EXHAUST PIPES 1 AND 2
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
EXHAUST PIPES 1 AND 2
REMOVALFollow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT”.
È
For cooling water pilot outlet on port side
É
From water jacket
1 Clamp/cooling water hose 1/1
2 Clamp/cooling water hose 1/1
3Bolt 2
4 Thermoswitch (exhaust) 1
5 Exhaust joint clamp 2 Slide the outer exhaust joint for exhaust
manifold side
6 Exhaust joint clamp 2
6
64 3
É
5
2
È 6 × 16 mm
7.6 N m (0.76 kgf m, 5.5 ft Ib)
2nd 3.4 N m (0.34 kgf m, 2.5 ft Ib) 1st 3.4 N m (0.34 kgf m, 2.5 ft Ib)LT
242
LT
242
LT
572
LT
LT
572
LT
LT
242
1
LT
242
LT
242
ProCarManuals.com
Page 108 of 347
5-9
EPOWREXHAUST PIPES 1 AND 2
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
7Bolt 1
NOTE:
Tighten the bolts in the sequence indicated.
8Bolt 1
9Bolt 2
10 Collar 1
7
10
9
8
É
È
6th 15 N m (1.5 kgf m, 11 ft Ib) 2nd 2.0 N m (0.2 kgf m, 1.4 ft Ib)
10th 39 N m (3.9 kgf m, 28 ft Ib)
10 × 35 mm
5th 15 N m (1.5 kgf m, 11 ft Ib) 1st 2.0 N m (0.2 kgf m, 1.4 ft Ib)
9th 39 N m (3.9 kgf m, 28 ft Ib)
10 × 35 mm
8th 15 N m (1.5 kgf m, 11 ft Ib) 4th 2.0 N m (0.2 kgf m, 1.4 ft Ib)
12th 39 N m (3.9 kgf m, 28 ft Ib)
10 × 45 mm
7th 15 N m (1.5 kgf m, 11 ft Ib) 3rd 2.0 N m (0.2 kgf m, 1.4 ft Ib)
11th 39 N m (3.9 kgf m, 28 ft Ib)
10 × 40 mm
LT
242
LT
242
LT
572
LT
LT
572
LT
LT
242
LT
242
LT
242
ProCarManuals.com
Page 109 of 347
5-10
EPOWR
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
11 Exhaust pipe 2 1
12 Bolt 3
13 Exhaust pipe end 1
14 Gasket 2
15 Silencer 1
16 Inner exhaust joint 1
17 Outer exhaust joint 1
18 Bolt 2
19 Bolt 2
20 Exhaust pipe 1 1
21 Gasket 1
22 Dowel pin 2
Reverse the removal steps for installation.
1417 20
16
1112
13
14
É
18
19
È
22
21
2nd 22 N • m (2.2 kgf m, 16 ft Ib) 1st
22 N m (2.2 kgf m, 16 ft Ib)
3rd 35 N m (3.5 kgf m, 25 ft Ib)
8 × 75 mm
2nd 22 N m (2.2 kgf m, 16 ft Ib) 1st 22 N m (2.2 kgf m, 16 ft Ib)
3rd 35 N m (3.5 kgf m, 25 ft Ib)
8 × 125 mm
2nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
1st 3.7 N m (0.37 kgf m, 2.7 ft Ib)
6 × 16 mm
LT
242
19
18
LT
242
LT
572
LT
LT
572
LT
LT
242
LT
242
LT
242
12
13
15
14
14
15
Not reusable
Not reusable
EXHAUST PIPES 1 AND 2
ProCarManuals.com
Page 110 of 347
5-11
EPOWREXHAUST MANIFOLD
EXHAUST MANIFOLD
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
EXHAUST MANIFOLD REMOVAL
Follow the left “Step” for removal.
Exhaust pipes 1 and 2 Refer to “EXHAUST PIPES 1 AND 2”.
1 Clamp/cooling hose 2/1È
To cylinder block
2Bolt 5
3Bolt 6
4 Exhaust manifold 1
5Gasket 1
6 Dowel pin 2
Reverse the removal steps for installation.
6
5 3È
6
2
4
1
1
1
2nd 22 N m (2.2 kgf m, 16 ft Ib) 1st
22 N m (2.2 kgf m, 16 ft Ib)
3rd 35 N m (3.5 kgf m, 25 ft Ib)
8 × 75 mm
2nd 22 N m (2.2 kgf m, 16 ft Ib) 1st 22 N m (2.2 kgf m, 16 ft Ib)
3rd 35 N m (3.5 kgf m, 25 ft Ib)
8 × 155 mm
LT
242
LT
242
Not reusable
ProCarManuals.com
Page 111 of 347
5-12
EPOWROIL TANK
OIL TANK
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
OIL TANK REMOVAL
Follow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT”.
Intake assembly Refer to “FUEL INJECTION SYSTEM” in
Chapter 4.
1 Clamp/cooling water hose 1/1È
To exhaust pipe 1
2Bolt 4
3 Water jacket 1
4Gasket 1
5 Clamp/breather hose 2/1
6 Clamp/breather hose 2/1É
To oil pump
7Bolt 2
8 Collar 2
Ì
LT
572
LT
572
LT
572
LT
572
LT
572
LT
572
23 1925 24
26
25
2116 17 15
14
1220 22
3
4
6 8
9
72
6
AA
6 × 30 mm
2nd 7.6 N m (0.76 kgf
m, 5.5 ft
Ib) 1st 3.7 N m (0.37 kgf
m, 2.7 ft
Ib)
2nd 15 N m (1.5 kgf
m, 11 ft
Ib) 1st 2.0 N m (0.2 kgf
m, 1.4 ft
Ib)
3rd 39 N m (3.9 kgf
m, 28 ft
Ib)
2nd 39 N m (3.9 kgf
m, 28 ft
Ib) 1st 15 N m (1.5 kgf
m, 11 ft
Ib)
10 × 85 mm2nd 15 N m (1.5 kgf
m, 11 ft
Ib) 1st 2.0 N m (0.2 kgf
m, 1.4 ft
Ib)
10 × 70 mm
3rd 39 N m (3.9 kgf
m, 28 ft
Ib)7.6 N
m (0.76 kgf m, 5.5 ft Ib)
6 × 35 mm
È
ÉÌ13
LT
572
LT
572
LT
572
LT
572
18
102nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
1st 3.7 N m (0.37 kgf m, 2.7 ft Ib)
6 × 20 mm
Ê
Ë
a
1
5
1111
5
6 × 35 mm
Not reusable
ProCarManuals.com
Page 112 of 347
5-13
EPOWROIL TANK
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
9 Oil separator 1
10 Clamp/breather hose 1/1Ê
To air intake pipe
11 Clamp/breather hose 1/1Ë
From cylinder head cover
Mark a
12 Clamp/cooling water hose 1/1Ì
From cooling water inlet
13 Bolt 1
14 Collar 1
15 Band 1
16 Bolt 3
17 Ground lead box 1
18 O-ring 1
19 Bolt 2
Ì
LT
572
LT
572
LT
572
LT
572
LT
572
LT
572
23 1925 24
26
25
2116 17 15
14
1220 22
3
4
6 8
9
72
6
AA
6 × 30 mm
2nd 7.6 N m (0.76 kgf
m, 5.5 ft
Ib) 1st 3.7 N m (0.37 kgf
m, 2.7 ft
Ib)
2nd 15 N m (1.5 kgf
m, 11 ft
Ib) 1st 2.0 N m (0.2 kgf
m, 1.4 ft
Ib)
3rd 39 N m (3.9 kgf
m, 28 ft
Ib)
2nd 39 N m (3.9 kgf
m, 28 ft
Ib) 1st 15 N m (1.5 kgf
m, 11 ft
Ib)
10 × 85 mm2nd 15 N m (1.5 kgf
m, 11 ft
Ib) 1st 2.0 N m (0.2 kgf
m, 1.4 ft
Ib)
10 × 70 mm
3rd 39 N m (3.9 kgf
m, 28 ft
Ib)7.6 N
m (0.76 kgf m, 5.5 ft Ib)
6 × 35 mm
È
ÉÌ13
LT
572
LT
572
LT
572
LT
572
18
102nd 7.6 N m (0.76 kgf m, 5.5 ft Ib)
1st 3.7 N m (0.37 kgf m, 2.7 ft Ib)
6 × 20 mm
Ê
Ë
a
1
5
1111
5
6 × 35 mm
Not reusable
ProCarManuals.com
