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 lubricant-contaminated clothing, should
be thoroughly 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
inner-positioned fasteners before outer-
positioned ones.
3. Non-reusable items
Always use new gaskets, packings,o-rings,
oil seals, split-pins and circlips, etc. on
reassembly.
GENERAL INFORMATION
x
1
1-3
GEN
INFO
Summary of Contents for SR230 2004
Page 1: ...Service Manual SR230 2004 ...
Page 17: ...GENERAL INFORMATION 1 GEN INFO 1 10 ...
Page 20: ...2 2 GENERAL SPECIFICATIONS 2 SPEC ...
Page 21: ...2 3 MAINTENANCE SPECIFICATIONSx 2 SPEC ...
Page 22: ...2 4 MAINTENANCE SPECIFICATIONS 2 SPEC ...
Page 23: ...2 5 MAINTENANCE SPECIFICATIONSx 2 SPEC ...
Page 25: ...2 7 MAINTENANCE SPECIFICATIONSx 2 SPEC ...
Page 26: ...2 8 MAINTENANCE SPECIFICATIONS 2 SPEC Main At Battery Starter At each engine B ...
Page 27: ...2 9 MAINTENANCE SPECIFICATIONSx 2 SPEC 1 4 20 8 32 10 24 Part To Be Tightened ...
Page 28: ...2 10 MAINTENANCE SPECIFICATIONS 2 SPEC TIGHTENING TORQUES Part To Be Tightened ...
Page 29: ...2 11 MAINTENANCE SPECIFICATIONSx 2 SPEC TIGHTENING TORQUES Part To Be Tightened ...
Page 30: ...2 12 MAINTENANCE SPECIFICATIONS 2 SPEC TIGHTENING TORQUES Part To Be Tightened ...
Page 35: ...2 17 MAINTENANCE SPECIFICATIONSx 2 SPEC CABLE AND HOSE ROUTING ...
Page 36: ...2 18 MAINTENANCE SPECIFICATIONS 2 SPEC CABLE AND HOSE ROUTING ...
Page 37: ...2 19 MAINTENANCE SPECIFICATIONSx 2 SPEC CABLE AND HOSE ROUTING ...
Page 38: ...2 20 MAINTENANCE SPECIFICATIONS 2 SPEC CABLE AND HOSE ROUTING ...
Page 39: ...2 21 MAINTENANCE SPECIFICATIONSx 2 SPEC CABLE AND HOSE ROUTING ...
Page 41: ...3 1 PERIODIC INSPECTION AND ADJUSTMENT x 3 INSP ADJ ...
Page 45: ...3 5 PERIODIC INSPECTION AND ADJUSTMENT x 3 INSP ADJ ...
Page 47: ...3 7 PERIODIC INSPECTION AND ADJUSTMENT x 3 INSP ADJ ...
Page 48: ...3 8 PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ ...
Page 50: ...3 10 PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ ...
Page 51: ...3 11 PERIODIC INSPECTION AND ADJUSTMENT x 3 INSP ADJ ...
Page 52: ...3 12 PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ CAUTION ...
Page 55: ...3 15 PERIODIC INSPECTION AND ADJUSTMENT x 3 INSP ADJ CAUTION ...
Page 58: ...3 18 PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ ...
Page 59: ...3 19 PERIODIC INSPECTION AND ADJUSTMENT x 3 INSP ADJ ...
Page 62: ...3 22 PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ ...
Page 65: ...PERIODIC INSPECTION AND ADJUSTMENT x 3 INSP ADJ 4 3 25 ...
Page 70: ...4 4 FUEL SYSTEM 4 FUEL SYSTEM Screws Loosen the screws in the sequence shown ...
Page 71: ...4 5 FUEL SYSTEM x 4 FUEL SYSTEM Screws 4 9 Nm 0 49 kgf m 7 9 Nm 0 8 kgf m ...
Page 72: ...4 6 FUEL SYSTEM 4 FUEL ...
Page 73: ...4 7 FUEL SYSTEM x 4 FUEL FUEL INJECTION SYSTEM Cont d ...
Page 74: ...4 8 FUEL SYSTEM 4 FUEL FUEL INJECTION SYSTEM Cont d ...
Page 75: ...4 9 FUEL SYSTEM x 4 FUEL FUEL INJECTION SYSTEM Cont d ...
Page 76: ...4 10 FUEL SYSTEM 4 FUEL FUEL INJECTION SYSTEM Cont d ...
Page 77: ...4 11 FUEL SYSTEM x 4 FUEL FUEL INJECTION SYSTEM Cont d ...
Page 78: ...4 12 FUEL SYSTEM 4 FUEL FUEL INJECTION SYSTEM Cont d Qty ...
Page 79: ...4 13 FUEL SYSTEM x 4 FUEL FUEL INJECTION SYSTEM Cont d ...
Page 80: ...4 14 FUEL SYSTEM 4 FUEL FUEL INJECTION SYSTEM Cont d ...
Page 81: ...4 15 FUEL SYSTEM x 4 FUEL CAUTION ...
Page 82: ...4 16 FUEL SYSTEM 4 FUEL CAUTION Disconnect the fuel hose 1 directly from the fuel pipe 2 ...
Page 84: ...4 18 FUEL SYSTEM 4 FUEL CAUTION ...
Page 85: ...4 19 FUEL SYSTEM x 4 FUEL CAUTION Blow out all passages with compressed air ...
Page 87: ...4 21 FUEL SYSTEM x 4 FUEL ...
Page 88: ...4 22 FUEL SYSTEM 4 FUEL CAUTION ...
Page 89: ...4 23 FUEL SYSTEM x 4 FUEL ...
Page 90: ...4 24 FUEL SYSTEM 4 FUEL ...
Page 91: ...4 25 FUEL SYSTEM x 4 FUEL Fuel hose disconnection Fuel hose connection nection connection ...
Page 92: ......
Page 93: ......
Page 94: ......
Page 95: ......
Page 96: ...POWER UNIT x 5 POWR 5 1 Refer to ENGINE HATCH in Chapter 8 ...
Page 97: ...5 2 ENGINE UNIT EXPLODED DIAGRAM POWER UNIT 5 POWR ...
Page 98: ...5 3 POWER UNIT x 5 POWR ...
Page 99: ...5 4 POWER UNIT 5 POWR CAUTION ...
Page 100: ...5 5 POWER UNIT x 5 POWR ...
Page 101: ...5 6 POWER UNIT 5 POWR CAUTION ...
Page 102: ...5 7 POWER UNIT x 5 POWR ...
Page 103: ...5 8 POWER UNIT 5 POWR UNIT ...
Page 104: ...5 9 POWER UNIT x 5 POWR EXHAUST PIPE 3 Cont d ...
Page 105: ...5 10 POWER UNIT 5 POWR EXHAUST PIPE 3 Cont d ...
Page 106: ...5 11 POWER UNIT x 5 POWR PIPE 3 MOTOR ...
Page 107: ...5 12 POWER UNIT 5 POWR EXHAUST PIPES 1 AND 2 Cont d ...
Page 108: ...5 13 POWER UNIT x 5 POWR AND 2 ...
Page 109: ...5 14 POWER UNIT 5 POWR EXHAUST MANIFOLD Cont d ...
Page 110: ...5 15 POWER UNIT x 5 POWR UNIT THERMOSTAT ...
Page 111: ...5 16 POWER UNIT 5 POWR OIL TANK Cont d ...
Page 112: ...5 17 POWER UNIT x 5 POWR OIL TANK Cont d ...
Page 113: ...5 18 POWER UNIT 5 POWR OIL TANK Cont d ...
Page 114: ...5 19 POWER UNIT x 5 POWR OIL TANK Cont d ...
Page 115: ...5 20 POWER UNIT 5 POWR OIL TANK Cont d ...
Page 116: ...5 21 POWER UNIT x 5 POWR OIL TANK Cont d ...
Page 117: ...5 22 POWER UNIT 5 POWR ...
Page 118: ...5 23 POWER UNIT x 5 POWR ...
Page 119: ...5 24 POWER UNIT 5 POWR ...
Page 120: ...5 25 POWER UNIT x 5 POWR ...
Page 121: ...5 26 POWER UNIT 5 POWR TANK ...
Page 122: ...5 27 POWER UNIT x 5 POWR OIL PUMP Cont d ...
Page 123: ...5 28 POWER UNIT 5 POWR OIL PUMP Cont d ...
Page 124: ...5 29 POWER UNIT x 5 POWR ...
Page 125: ...5 30 POWER UNIT 5 POWR ...
Page 126: ...5 31 POWER UNIT x 5 POWR ...
Page 127: ...5 32 POWER UNIT 5 POWR MOTOR PUMP ...
Page 128: ...5 33 POWER UNIT x 5 POWR REDUCTION DRIVE GEAR Cont d ...
Page 129: ...5 34 POWER UNIT 5 POWR REDUCTION DRIVE GEAR Cont d ...
Page 130: ...5 35 POWER UNIT x 5 POWR REDUCTION DRIVE GEAR Cont d ...
Page 131: ...5 36 POWER UNIT 5 POWR REDUCTION DRIVE GEAR Cont d ...
Page 132: ...5 37 POWER UNIT x 5 POWR ...
Page 133: ...5 38 POWER UNIT 5 POWR ...
Page 134: ...5 39 POWER UNIT x 5 POWR UNIT ...
Page 135: ...5 40 GENERATOR AND STARTER MOTOR Cont d POWER UNIT 5 POWR ...
Page 136: ...5 41 GENERATOR AND STARTER MOTOR Cont d POWER UNIT x 5 POWR ...
Page 138: ...5 43 GENERATOR AND STARTER MOTOR Cont d POWER UNIT x 5 POWR ...
Page 139: ...5 44 POWER UNIT 5 POWR ...
Page 140: ...5 45 POWER UNIT x 5 POWR ...
Page 141: ...5 46 POWER UNIT 5 POWR CAUTION washer Always replace them with new ones ...
Page 142: ...5 47 POWER UNIT x 5 POWR ...
Page 143: ...5 48 POWER UNIT 5 POWR CAMSHAFTS Cont d ...
Page 144: ...5 49 POWER UNIT x 5 POWR CAMSHAFTS Cont d GEAR ...
Page 145: ...5 50 POWER UNIT 5 POWR CAMSHAFTS Cont d ...
Page 146: ...5 51 POWER UNIT x 5 POWR CAMSHAFTS Cont d ...
Page 147: ...5 52 POWER UNIT 5 POWR ...
Page 148: ...5 53 POWER UNIT x 5 POWR ...
Page 149: ...5 54 POWER UNIT 5 POWR ...
Page 150: ...5 55 POWER UNIT x 5 POWR ...
Page 151: ...5 56 POWER UNIT 5 POWR CAUTION ...
Page 152: ...5 57 POWER UNIT x 5 POWR ...
Page 153: ...5 58 POWER UNIT 5 POWR ...
Page 154: ...5 59 POWER UNIT x 5 POWR Tighten the cylinder head cover bolts in a criss cross pattern ...
Page 155: ...5 60 POWER UNIT 5 POWR UNIT PIPE 3 AND 2 TANK CAMSHAFTS ...
Page 156: ...5 61 CYLINDER HEAD Cont d POWER UNIT x 5 POWR ...
Page 157: ...5 62 POWER UNIT 5 POWR ...
Page 158: ...5 63 POWER UNIT x 5 POWR ...
Page 159: ...5 64 POWER UNIT 5 POWR ...
Page 160: ...5 65 POWER UNIT x 5 POWR HEAD ...
Page 161: ...5 66 POWER UNIT 5 POWR VALVES AND VALVE SPRINGS Cont d ...
Page 162: ...5 67 POWER UNIT x 5 POWR ...
Page 163: ...5 68 POWER UNIT 5 POWR ...
Page 165: ...5 70 POWER UNIT 5 POWR ...
Page 166: ...5 71 POWER UNIT x 5 POWR ...
Page 167: ...5 72 POWER UNIT 5 POWR ...
Page 168: ...5 73 POWER UNIT x 5 POWR CAUTION ...
Page 169: ...5 74 POWER UNIT 5 POWR ...
Page 170: ...5 75 POWER UNIT x 5 POWR CAUTION ...
Page 171: ...5 76 POWER UNIT 5 POWR ...
Page 172: ...5 77 POWER UNIT x 5 POWR UNIT PIPE 3 AND 2 MOTOR TANK MANIFOLD ...
Page 173: ...5 78 POWER UNIT 5 POWR CRANCASE Cont d PUMP GEAR CAMSHAFTS ...
Page 174: ...5 79 POWER UNIT x 5 POWR CRANCASE Cont d ...
Page 175: ...5 80 POWER UNIT 5 POWR CRANCASE Cont d ...
Page 176: ...5 81 POWER UNIT x 5 POWR CRANCASE Cont d CRANKSHAFT ...
Page 178: ...5 83 POWER UNIT x 5 POWR ...
Page 179: ...5 84 POWER UNIT 5 POWR ...
Page 180: ...5 85 POWER UNIT x 5 POWR CAUTION ...
Page 181: ...5 86 POWER UNIT 5 POWR ...
Page 182: ...5 87 POWER UNIT x 5 POWR CRANKCASE ...
Page 183: ...5 88 POWER UNIT 5 POWR CONNECTING RODS AND PISTONS Cont d ...
Page 184: ...5 89 POWER UNIT x 5 POWR CAUTION ...
Page 185: ...5 90 POWER UNIT 5 POWR pistons ...
Page 186: ...5 91 POWER UNIT x 5 POWR formula ...
Page 187: ...5 92 POWER UNIT 5 POWR ...
Page 188: ...5 93 POWER UNIT x 5 POWR ...
Page 189: ...5 94 POWER UNIT 5 POWR CAUTION ...
Page 190: ...5 95 POWER UNIT x 5 POWR Lubricate the bolt threads and nut seats installation removal ...
Page 191: ...5 96 POWER UNIT 5 POWR ...
Page 192: ...5 97 POWER UNIT x 5 POWR ...
Page 193: ...5 98 POWER UNIT 5 POWR ...
Page 194: ...5 99 POWER UNIT x 5 POWR procedure CAUTION ...
Page 195: ...5 100 POWER UNIT 5 POWR CRANKCASE PISTONS ...
Page 196: ...5 101 POWER UNIT x 5 POWR ...
Page 197: ...5 102 POWER UNIT 5 POWR CAUTION ...
Page 198: ...5 103 POWER UNIT x 5 POWR CRANKCASE ...
Page 199: ...5 104 POWER UNIT 5 POWR ...
Page 200: ...5 105 POWER UNIT x 5 POWR FW D ...
Page 201: ...5 106 POWER UNIT 5 POWR THERMOSTAT Cont d FW D ...
Page 202: ...5 107 POWER UNIT x 5 POWR Does not open at 50 60 C 123 ...
Page 203: ...5 108 POWER UNIT 5 POWR MANIFOLD ...
Page 204: ...5 109 POWER UNIT x 5 POWR PRESSURE CONTROL VALVE Cont d ...
Page 205: ...5 110 POWER UNIT 5 POWR PRESSURE CONTROL VALVE Cont d ...
Page 206: ...5 111 POWER UNIT x 5 POWR PRESSURE CONTROL VALVE Cont d ...
Page 207: ...5 112 POWER UNIT 5 POWR ...
Page 215: ...JET PUMP x 6 JET PUMP 6 7 ...
Page 216: ...JET PUMP 6 JET PUMP 6 8 10 11 2 ...
Page 217: ...JET PUMP x 6 JET PUMP 6 9 ...
Page 218: ...JET PUMP 6 JET PUMP 6 10 ...
Page 225: ...7 5 ELECTRICAL SYSTEM x 7 ELEC ELECTRICAL BOX AND IGNITION COIL BOX Cont d EXPLODED DIAGRAM ...
Page 226: ...7 6 ELECTRICAL SYSTEM 7 ELEC ELECTRICAL BOX AND IGNITION COIL BOX Cont d EXPLODED DIAGRAM ...
Page 228: ...7 8 ELECTRICAL SYSTEM 7 ELEC ELECTRICAL BOX AND IGNITION COIL BOX Cont d EXPLODED DIAGRAM ...
Page 230: ...7 10 ELECTRICAL SYSTEM 7 ELEC ELECTRICAL BOX AND IGNITION COIL BOX Cont d ...
Page 236: ...7 16 ELECTRICAL SYSTEM 7 ELEC ...
Page 238: ...7 18 ELECTRICAL SYSTEM 7 ELEC ...
Page 239: ...7 19 ELECTRICAL SYSTEM x 7 ELEC SYSTEM ...
Page 240: ...7 20 ELECTRICAL SYSTEM 7 ELEC measurement Lanyard Clip White Black Installed O O Removed O O ...
Page 241: ...7 21 ELECTRICAL SYSTEM x 7 ELEC ...
Page 242: ...7 22 ELECTRICAL SYSTEM 7 ELEC ...
Page 243: ...7 23 ELECTRICAL SYSTEM x 7 ELEC ...
Page 244: ...7 24 ELECTRICAL SYSTEM 7 ELEC ...
Page 245: ...7 25 ELECTRICAL SYSTEM x 7 ELEC ...
Page 246: ...7 26 ELECTRICAL SYSTEM 7 ELEC ...
Page 248: ...7 28 ELECTRICAL SYSTEM 7 ELEC FUEL CONTROL SYSTEM WIRING DIAGRAM 12 9 10 11 6 7 8 13 ...
Page 253: ...7 33 ELECTRICAL SYSTEM x 7 ELEC ...
Page 254: ...7 34 ELECTRICAL SYSTEM 7 ELEC ...
Page 255: ...7 35 ELECTRICAL SYSTEM x 7 ELEC STARTER MOTOR Cont d ...
Page 256: ...7 36 ELECTRICAL SYSTEM 7 ELEC STARTER MOTOR Cont d ...
Page 257: ...7 37 ELECTRICAL SYSTEM x 7 ELEC ...
Page 258: ...7 38 ELECTRICAL SYSTEM 7 ELEC ...
Page 259: ...7 39 ELECTRICAL SYSTEM x 7 ELEC ...
Page 260: ...7 40 ELECTRICAL SYSTEM 7 ELEC SYSTEM SYSTEM SYSTEM ...
Page 262: ...7 42 ELECTRICAL SYSTEM 7 ELEC ...
Page 268: ...7 48 ELECTRICAL SYSTEM 7 ELEC ...
Page 269: ...7 49 ELECTRICAL SYSTEM x 7 ELEC ...
Page 273: ...8 2 HULL AND DECK 8 HULL DECK VENTILATION SYSTEM EXPLODED DIAGRAM ...
Page 275: ...8 4 HULL AND DECK 8 HULL DECK COOLING SYSTEM EXPLODED DIAGRAM 28 28 29 29 30 27 27 30 25 ...
Page 279: ...8 8 REMOTE CONTROL SYSTEM EXPLODED DIAGRAM HULL AND DECK 8 HULL DECK ...
Page 281: ...8 10 ENGINE HATCH EXPLODED DIAGRAM HULL AND DECK 8 HULL DECK ...
Page 283: ...8 12 HATCH FITTINGS BOW COVER EXPLODED DIAGRAM HULL AND DECK 8 HULL DECK ...
Page 285: ...8 14 HULL AND DECK 8 HULL DECK SEAT FITTINGS EXPLODED DIAGRAM ...
Page 287: ...DECK FITTINGS EXPLODED DIAGRAM HULL AND DECK 8 HULL DECK 8 16 ...
Page 291: ...8 20 DECK FITTINGS Continued EXPLODED DIAGRAM HULL AND DECK 8 HULL DECK ...
Page 298: ...Operating procedure 9 41 Data display item selection 9 42 Operating procedure 9 42 ...
Page 302: ...9 4 TROUBLE ANALYSIS 9 TRBL ANLS ...
Page 303: ...9 5 TROUBLE ANALYSIS x 9 TRBL ANLS ...
Page 307: ...9 9 TROUBLE ANALYSIS x 9 TRBL ANLS ...
Page 309: ...9 11 TROUBLE ANALYSIS x 9 TRBL ANLS ...
Page 310: ...9 12 TROUBLE ANALYSIS 9 TRBL ANLS 1 2 ...
Page 312: ...9 14 TROUBLE ANALYSIS 9 TRBL ANLS ...
Page 313: ...9 15 TROUBLE ANALYSIS x 9 TRBL ANLS ...
Page 315: ...9 17 TROUBLE ANALYSIS x 9 TRBL ANLS ...
Page 316: ...9 18 TROUBLE ANALYSIS 9 TRBL ANLS ...
Page 317: ...9 19 TROUBLE ANALYSIS x 9 TRBL ANLS top ...
Page 318: ...9 20 TROUBLE ANALYSIS 9 TRBL ANLS ...
Page 319: ...9 21 TROUBLE ANALYSIS x 9 TRBL ANLS ...
Page 320: ...9 22 TROUBLE ANALYSIS 9 TRBL ANLS ...
Page 321: ...9 23 TROUBLE ANALYSIS x 9 TRBL ANLS ...
Page 325: ...9 27 TROUBLE ANALYSIS x 9 TRBL ANLS in the scroll bar or press the up or down Fig 38 keyboard ...
Page 328: ...9 30 TROUBLE ANALYSIS 9 TRBL ANLS keyboard Fig 42 ...
Page 330: ...9 32 TROUBLE ANALYSIS 9 TRBL ANLS selected Fig 46 displayed Fig 47 ...
Page 332: ...9 34 TROUBLE ANALYSIS 9 TRBL ANLS keyboard Fig 49 ...
Page 335: ...9 37 TROUBLE ANALYSIS x 9 TRBL ANLS keyboard Fig 53 selected Fig 54 ...
Page 340: ...9 42 TROUBLE ANALYSIS 9 TRBL ANLS bar Fig 60 displayed See fig 61 ...
Page 343: ...9 45 TROUBLE ANALYSIS x 9 TRBL ANLS displayed Fig 63 ...
Page 344: ...9 46 TROUBLE ANALYSIS 9 TRBL ANLS Fig 65 ...
Page 345: ...9 47 TROUBLE ANALYSIS x 9 TRBL ANLS Programs Fig 66 Fig 67 ...
Page 346: ...9 48 TROUBLE ANALYSIS 9 TRBL ANLS button see Figs 68 70 ...
Page 347: ...9 49 TROUBLE ANALYSIS x 9 TRBL ANLS ...
Page 348: ...9 50 TROUBLE ANALYSIS 9 TRBL ANLS test ...
Page 349: ...9 51 TROUBLE ANALYSIS x 9 TRBL ANLS Display Fig 73 slider Fig 74 ...
Page 350: ...9 52 TROUBLE ANALYSIS 9 TRBL ANLS button see Figs 75 76 ...
Page 351: ...9 53 TROUBLE ANALYSIS x 9 TRBL ANLS consulted ...
Page 352: ...9 54 TROUBLE ANALYSIS 9 TRBL ANLS ...
Page 353: ...9 55 TROUBLE ANALYSIS x 9 TRBL ANLS ...
Page 354: ...LIT 18616 02 52 2003 YAMAHA MOTOR CORPORATION U S A Printed in U S A ...