Yamaha SR230 2004 Service Manual Download Page 295

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8-24

GUNWALE

EXPLODED DIAGRAM

Step

Procedure / Part Name

Q’ty

Service Points

GUNWALE

Follow the “Step” order for removal.

Screw, 310 x 2” POH

Torque 2 Nm (0.2m-kg, 1.5 ft-lb)

Cover, rub Rail Joint

Before installing, apply silicone to the join
area.

Inner Gunwale (Rubrail insert)

1 pc

Heat in warm water for installation and
gunwale indent area with a hair dryer or
low temperature heat gun.

Screw, #10 x 1-1/4” PFH

210

Torque 2 Nm (0.2m-kg, 1.5 ft-lb)

Gunwale (Rubrail)

1 pc

Fill in any gaps above or below the
gunwale with white silicone.
Reverse the removal steps for installation.

REMOVAL AND INSTALLATION CHART

HULL AND DECK

HULL

DECK

Summary of Contents for SR230 2004

Page 1: ...Service Manual SR230 2004 ...

Page 2: ...e and or unsafe Because Yamaha 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 significant changes in specifications and procedures and these are incorporated in successive editions of t...

Page 3: ...though only one may be illustrated The name of model described will be mentioned in the description REFERENCES These have been kept to a minimum however when you are referred to another section of the man ual you are told the page number WARNINGS CAUTIONS AND NOTES Attention is drawn to the various Warnings Cautions and Notes which distinguish important infor mation in this manual in the following...

Page 4: ...ates 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 4 4 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 of REMOVAL AND INSTALLATION CHART the S...

Page 5: ...i cate grade of lubricant and location of lubrica tion point Apply Yamaha 2 stroke outboard motor oil 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 Yamabond 4 Yamaha Bond No 4 Apply LOCTITE No 271 Red LOCTITE...

Page 6: ... SPEC GENERAL INFORMATION 1 GEN INFO 2 PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR JET PUMP 6 JET PUMP ELECTRICAL SYSTEM 7 ELEC HULL AND DECK 8 HULL DECK TROUBLE ANALYSIS 9 TRBL ANLS ...

Page 7: ... 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 TOOLS 1 5 SPECIAL TOOLS 1 6 REMOVAL AND INSTALLATION 1 8 x ...

Page 8: ...e rear seat ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the crankcase HULL IDENTIFICATION NUMBER H I N The H I N is stamped into the hull on the star board side of the stern GENERAL INFORMATION x 1 1 1 GEN INFO Starting Primary I D Number F1C 700101 Starting Engine Serial Number 6B5 700101 ...

Page 9: ...sing compressed air when grinding or when doing any operation which may cause particles to fly off Protect hands and feet by wearing safety gloves and 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 Yamaha Under normal conditions of use there should be no hazards from the use o...

Page 10: ...ended 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 pos...

Page 11: ...oving parts operate normally 4 Install bearings with the manufacturer s markings on the side exposed to view and liberally oil the bearings 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 GENERAL INFORMATION 1 4 1 GEN INFO CAUTION ...

Page 12: ...Vacuum Synchronizer P N YU 44456 8 Vacuum Gauge P N 90890 03094 Vacuum attachment P N 90890 03060 9 Test Connector P N YW 06862 90890 06862 Fuel Pressure Gauge Adapter P N YW 06842 90890 06842 GENERAL INFORMATIONx 1 1 5 GEN INFO YU 03097 B 90890 01252 90890 06583 90890 06584 YW 06585 90890 06585 YU 03112 C 90890 03112 YU A1927 90890 03174 YU 44456 90890 03094 90890 03060 YW 06862 90890 06862 YW 06...

Page 13: ...pter P N YU 39991 90890 03172 Spark Gap Tester P N YM34487 90890 06754 Test Harness 2 pins P N YB 06792 90890 06792 Test Harness 3 pins P N YB 06791 90890 06791 Test Harness 3 pins P N YB 06770 90890 06770 Test Harness 6 pins P N YB 06790 90890 06790 Test Harness 3 pins P N YB 06793 90890 06793 Test Harness 3 pins P N YB 0677 90890 06777 1 6 11 12 13 14 15 16 17 18 19 20 21 22 GENERAL INFORMATION ...

Page 14: ...ercraft P N LIT YDIS1 21 00 Yamaha Diagnostic System Connector for Watercraft P N 60V WS850 00 00 USB Cable P N 68F WS850 00 00 Serial Cable 23 24 25 26 YB 06769 90890 06769 YB 35956 A 90890 06756 60V YW 06862 90890 06862 WS853 01 60V 85300 01 YAMAHA DIAGNOSTIC SYSTEM for Watercraft INSTALLATION MANUAL 60E 2819K 10 LIT YDIS1 21 00 60V WS850 00 00 USB Cable 68F WS850 00 00 Serial Cable ...

Page 15: ...111 ø4 0 mm 90890 04111 ø4 0 mm YM 04116 ø4 5 mm 90890 04116 ø4 5 mm 9 Valve Guide Installer P N YM 04112 ø4 0 mm 90890 04112 ø4 0 mm YM 04117 ø4 5 mm 90890 04117 ø4 5 mm Valve Guide Reamer P N YM 04113 ø4 0 mm 90890 04113 ø4 0 mm YM 04118 ø4 5 mm 90890 04118 ø4 5 mm YU 38411 90890 01426 YW 06551 90890 06551 YS 01880 A 90890 01701 YM 01082 90890 01080 YU 01235 90890 01235 YM 45469 90890 04019 YM 4...

Page 16: ...37 90890 05158 Drive Shaft Holder Impeller P N YB 06151 90890 06519 Slide Hammer Set jet pump bearing P N YB 06096 Stopper Guide Plate jet pump bearing P N 90890 06501 Bearing Puller jet pump bearing P N 90890 06535 Bearing Puller Claw 1 jet pump bearing P N 90890 06536 Stopper Guide Stand jet pump bearing P N 90890 06538 Drive Rod L3 jet pump bearing P N 90890 06652 Needle Bearing Attachment jet ...

Page 17: ...GENERAL INFORMATION 1 GEN INFO 1 10 ...

Page 18: ... 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 ENGINE 2 3 JET PUMP UNIT 2 6 HULL AND HOOD 2 6 ELECTRICAL 2 6 TIGHTENING TORQUES 2 9 GENERAL TORQUE 2 16 CABLE AND HOSE ROUTING 2 17 ...

Page 19: ...GENERAL SPECIFICATIONS GENERAL SPECIFICATIONSx 2 2 1 SPEC Jet thrust nozzle trim angle Degree 3 Impeller pitch Degree Port 17 3 Stbd 16 3 1 72 5 67 ft ...

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 24: ...2 6 MAINTENANCE SPECIFICATIONS 2 SPEC Port 17 3 Stbd 16 3 Marine Group 24 Dual Purpose 675 CCA 100 12 68 4 ...

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 31: ...2 13 MAINTENANCE SPECIFICATIONSx 2 SPEC TIGHTENING TORQUES Part To Be Tightened 6 M8 3 20 2 0 14 ...

Page 32: ...l Steering cable locknut Nut 1 6 5 0 65 4 7 jet thrust nozzle side Steering cable grommet hull Nut 1 5 9 0 59 4 3 Pilot water outlet hull Nut 2 4 2 0 42 3 0 Engine mount hull Bolt M8 8 17 1 7 12 Engine damper hull Bolt M6 4 6 4 0 64 4 6 Electrical Electrical box bulk head Bolt M8 4 17 1 7 12 Terminal cover electrical box Screw M5 4 4 9 0 49 3 5 Cover electrical box Tapping ø5 18 4 9 0 49 3 5 screw...

Page 33: ...rt To Be Tightened Part Name size Qty N m kgf m ft lb Remarks Main and fuel pump relay Tapping ø6 1 3 9 0 39 2 8 screw Rectifier regulator Tapping ø6 2 3 9 0 39 2 8 screw Ignition coil oil tank Bolt M6 3 7 6 0 76 5 5 Ignition coil cover ignition coil Tapping ø6 10 4 9 0 49 3 5 case screw ...

Page 34: ...arpage tighten multifastener assemblies in a criss cross fashion in progres sive stages until the specified torque is reached General Torque Nut A Bolt B Specifications Nm M kg ft lb 8 mm M5 5 0 0 5 3 6 10 mm M6 8 0 0 8 5 8 12 mm M8 18 1 8 13 14 mm M10 36 3 6 25 17 mm M12 43 4 3 31 B A General Torque Bolt Specifications Dia Nm M kg ft lb 6 32 1 1 0 11 0 8 8 32 2 3 0 23 1 65 10 24 2 6 0 26 1 9 1 4 ...

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 40: ...3 PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART 3 1 PERIODIC SERVICE 3 2 CONTROL SYSTEM 3 2 Remote Control Unit 3 3 Fuel System 3 5 POWER UNIT 3 6 JET PUMP UNIT 3 20 BILGE PUMP 3 21 GENERAL 3 23 ...

Page 41: ...3 1 PERIODIC INSPECTION AND ADJUSTMENT x 3 INSP ADJ ...

Page 42: ...the center of the steering nozzle joint and the cooling water casting boss on the right side of the pump Incorrect distance Adjust steering cable joint at nozzle end The cable joints must be screwed in more than 8mm 0 31 in 3 2 Steering Adjustment Distance 11 24 in 285 45mm WARNING Lock Nut 4 9 7 8Nm 0 49 0 78 kg m 3 54 5 64 ft lb PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ 8MM 0 31 IN MINIMUM 4...

Page 43: ...to the deck Lift the remote control unit b Check that throttle cable joints are set at 0 75 in 19mm of thread engagement at the control end Adjust if necessary c Adjust each throttle cable so that the cable wheel has 0 001 in 0 025mm to 0 079 in 2 0mm clearance to the stop when the levers are pushed to the Wide Open Throttle W O T position d Check that the cable wheel hits the idle screw when the ...

Page 44: ...he four screws holding the remote control unit cover Remove the four screws holding the remote control unit to the deck Lift the remote control unit b Check that shift cable joint has 15mm 0 6 in thread engagement at the control end Adjust if necessary c Put the shift lever in Neutral Check that the shift cable joint at the reverse gate end has 8mm 0 31 in thread engage ment d Measure the clearanc...

Page 45: ...3 5 PERIODIC INSPECTION AND ADJUSTMENT x 3 INSP ADJ ...

Page 46: ...ND ADJUSTMENT 3 INSP ADJ Valve clearance adjustment should be made on a cold engine at room temperature When the valve clearance is to be measured or adjusted the piston must be at Top Dead Center TDC on the compression stroke ...

Page 47: ...3 7 PERIODIC INSPECTION AND ADJUSTMENT x 3 INSP ADJ ...

Page 48: ...3 8 PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ ...

Page 49: ...3 9 PERIODIC INSPECTION AND ADJUSTMENT x 3 INSP ADJ Make a note of the position of each valve lifter 3 and valve pad 4 so they can be installed in the correct place lowing table ...

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 53: ...3 13 PERIODIC INSPECTION AND ADJUSTMENT x 3 INSP ADJ CAUTION Place the craft in water and then ...

Page 54: ... the reading on the dipstick will be low If the temperature is high the reading on the dipstick will be high Do not run the engine for more than 15 sec onds without supplying water when check ing the oil level on land The engine could overheat CAUTION craft in a horizontal position ...

Page 55: ...3 15 PERIODIC INSPECTION AND ADJUSTMENT x 3 INSP ADJ CAUTION ...

Page 56: ...3 16 PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ When starting the engine make sure the dip stick is securely fitted into the oil tank CAUTION ...

Page 57: ...t is installed in the filter case properly If cleaning the air filter element use cold or lukewarm water and let it air dry complete ly Do not use detergent or a solvent to clean the air filter element or dry it with heat or compressed air otherwise it could be damaged CAUTION 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 60: ...ce Otherwise the cap could loosen and be forced out of the access ports by water pressure causing loss of performance and pos sible damage A Clean out cap 1 by pressing Release Bottom A and lift the cap out of the Port Align the grooved recess on the clean out cap with the projection in the clean out opening A A 1 1 ...

Page 61: ... 3 INSP ADJ Disconnect the bilge strainer from the bilge strainer holder BILGE PUMP 1 Remove inspection cover in pump clean out tray 2 Inspect Bilge strainer Contaminants Clean Cracks damage Replace Inspection Steps Install the coupling cover ...

Page 62: ...3 22 PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ ...

Page 63: ...cable Cable joint Steering cable NOTE Remove the cable joint and apply a small amount of grease to the following parts Nozzle pivot shaft collar Bearing housing NOTE Fill in the bearing housing with water resis tant grease from a nipple Fill the grease slowly and carefully as it can damage the hose and the joints Refer to the MAINTENANCE INTERVAL CHART section Recommended Grease Water resistant gr...

Page 64: ...inner cables 2 Lubricate Nozzle pivot shaft Steering cable nozzle end QSTS cable nozzle end 3 Lubricate Steering cable Steering cable joint Shift cable Shift cable joint NOTE Disconnect the joints and apply a small amount of grease Recommended lubricant Yamaha marine grease Yamaha grease A Water resistant grease Recommended grease Yamaha marine grease Yamaha grease A Water resistant grease Recomme...

Page 65: ...PERIODIC INSPECTION AND ADJUSTMENT x 3 INSP ADJ 4 3 25 ...

Page 66: ...l pump module installation 4 5 Fuel hose connect 4 5 FUEL INJECTION SYSTEM EXPLODED DIAGRAM 4 6 REMOVAL AND INSTALLATION CHART 4 6 SERVICE POINTS 4 15 Hose clamps removal 4 15 Hose clamps installation 4 15 Fuel hose disconnection 4 15 Fuel line inspection 4 16 Fuel hose installation replacing with new fuel hose 4 17 Fuel hose connection 4 17 Throttle body removal 4 17 Fuel injector inspection 4 18...

Page 67: ... Points FUEL TANK PUMP MODULE Follow the Step order for removal 1 Connector harness 2 2 Cover 2 3 Screw Machine 2 4 Clamp 2 5 Fuel hose 2 6 Screw 16 NOTE Apply Loctite torque in 2 steps see page 4 4 Pump Module Removal 4 5 Installation 7 Plate 2 8 Fuel Pump Assembly 2 9 Seal 2 10 Screw 5 Apply Loctite 2 9 Nm 30 kgf cm 4 9 7 9 Nm 50 80 kgf cm See Note REMOVAL AND INSTALLATION CHART ...

Page 68: ... 8 6 7 29 29 28 30 Step Procedure Part Name Q ty Service Points 11 Fuel Level Sender 1 12 Gasket 1 13 Clamp 4 14 Hose Vent 1 15 Hose Vent 1 16 Valve Check 1 17 Nut 1 18 Washer Star 1 19 Washer 1 20 Vent Fuel 1 21 Clamp 4 4 2 Nm 0 42 kgf m 3 0 ft lbs See detail on clamp installation 22 Hose Fuel Filler 1 23 Nut 8 32 Nylon Lock 6 24 Washer 8 Flat 6 25 Screw 8 32 6 ...

Page 69: ...25 24 23 27 21 22 14 13 9 8 6 7 29 29 28 30 Step Procedure Part Name Q ty Service Points 26 Filler Cap Assembly 1 27 Gasket 1 FUEL TANK Note Deck must be cut at outline to access fuel tank for removal 28 Screw Machine 1 4 20 x 1 8 4 9 7 9 Nm 50 80 kgf cm 29 Fix Fuel Tank 2 30 Fuel Tank Assembly 1 Reverse the removal steps for installation ...

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 83: ...4 17 FUEL SYSTEM x 4 FUEL CAUTION If free play is not obtained disconnect the fuel hose check the O ring for damage and that it is properly installed ...

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 86: ...4 20 FUEL SYSTEM 4 FUEL CAUTION Only butterfly valve 2 should be fully closed The other valves should be halfway closed ...

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 137: ...5 42 GENERATOR AND STARTER MOTOR Cont d POWER UNIT 5 POWR Make sure not to pinch the pulser coil leads between the washers and projec tions on the case when installing the bolts CAUTION ...

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 164: ...5 69 POWER UNIT x 5 POWR Before checking the valve guide make sure the valve stem diameter is within specifica tion ...

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 177: ...p on one side of the crankcase with a soft face hammer Tap only on rein forced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves separate evenly CAUTION ...

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 208: ...ATE AND DEFLECTOR 6 4 EXPLODED DIAGRAM 6 4 REMOVAL AND INSTALLATION CHART 6 4 IMPELLER AND DRIVE SHAFT 6 5 EXPLODED DIAGRAM 6 5 REMOVAL AND INSTALLATION CHART 6 5 JET PUMP CLEAN OUT PORTS 6 6 EXPLODED DIAGRAM 6 6 REMOVAL AND INSTALLATION CHART 6 6 INTERMEDIATE SHAFT AND HOUSING 6 7 EXPLODED DIAGRAM 6 7 REMOVAL AND INSTALLATION CHART 6 8 SERVICE POINTS Oil Seal Installation 6 10 ...

Page 209: ...TAKE GRATING Follow the left Step order for removal REMOVAL 1 Screw 2 8 x 35mm 2 Screw 4 8 x 20mm 3 Intake Grating 2 Port and Starboard Units 4 Screw 12 8 x 40mm 5 Intake Duct 2 Port and Starboard Units Reverse the removal steps for installation NOTE Apply clear silicone before installing a duct into the hull REMOVAL AND INSTALLATION CHART ...

Page 210: ...6 2 JET PUMP 6 JET PUMP Apply clear silicone as shown before installing Duct into hull Install Duct and torque screws to 15Nm 1 5m kg 11 ft lb FILL GAPS WITH SILICONE FILL GAPS WITH SILICONE ...

Page 211: ... for removal 1 Shift Cable Joint 1 2 Steering Cable Joint 1 3 Bolt with washer 4 4 Nozzle 1 1 NOTE May be left on to remove pump as an assembly 5 Dowel Pin 2 6 Duct w Driveshaft and Impeller 1 7 Bolt with washer 4 10 x 40mm 8 Dowel Pin 2 9 Impeller Housing Assembly 1 Reverse the removal steps for installation REMOVAL AND INSTALLATION CHART ...

Page 212: ...with washer 2 8 x 20mm 2 Collar 2 3 Reverse Gate 1 4 Bolt with washer 2 8 x 20mm 5 Collar 2 6 Nozzle Deflector 1 REVERSE GATE DISASSEMBLY 1 Bolt with washer 2 6 x 16mm 2 Gate Control Arm 1 3 Bolt with washer 2 4 Collar 2 5 Swivel 1 Reverse the removal steps for installation REVERSE GATE AND DEFLECTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART 6 4 ...

Page 213: ...eft hand threads 2 Spacer 1 3 Bolt 3 4 Cap 1 Fill cap approximately 1 3 full with EPNOC AP 0 or equivalent grease 5 O ring 1 6 Nut 1 7 Washer 1 8 Drive shaft 1 9 Rear Bearing 1 Not reusable 10 Spacer 1 11 Front Bearing 1 Not reusable 12 Oil Seal 1 Not reusable 13 Oil Seal 1 Not reusable 14 Bolts 4 15 Cover O rings and filter 1 Reverse the removal steps for installation REMOVAL AND INSTALLATION CHA...

Page 214: ...6 Clean out Tray 1 Apply silicone sealant to outside of clean out port flanges 7 Hatch Interlock Switch 2 Set height a 14mm 0 55 Apply one 1 drop of removable thread lock LT242 to threads 8 Clamp lower 2 Do not need to remove unless replacing clean out hose 9 Hose clean out 2 If hose is removed apply silicone sealant to inside of hose at bottom remove sealant from Cap locking grooves in jet pump c...

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 219: ...SPARK GAP 7 16 IGNITION SYSTEM PEAK VOLTAGE 7 17 BATTERY 7 19 FUSE 7 19 SPARK PLUGS 7 19 SPARK PLUG LEAD ASSEMBLY 7 19 IGNITION COIL 7 20 ENGINE STOP SWITCH 7 20 ENGINE TEMPERATURE SENSOR 7 21 INTAKE AIR TEMPERATURE SENSOR 7 21 THERMOSWITCH ENGINE 7 22 THERMOSWITCH EXHAUST 7 22 MAIN AND FUEL PUMP RELAY 7 23 THROTTLE POSITION SENSOR 7 24 CAM POSITION SENSOR 7 25 INTAKE AIR PRESSURE SENSOR 7 26 FUEL...

Page 220: ... Inspection 7 39 CHARGING SYSTEM 7 40 WIRING DIAGRAM 7 40 FUSE 7 41 BATTERY 7 41 LIGHTING COIL 7 41 RECTIFIER REGULATOR 7 41 ELECTRIC BILGE PUMP 7 42 WIRING DIAGRAM 7 42 ELECTRIC BILGE PUMP 7 43 MAIN COMPONENT LOCATION 7 44 EXPLODED DIAGRAM 7 44 SWITCH LOCATION 7 45 WIRING DIAGRAM 7 45 METER PANEL BACK VIEW 7 46 WIRING DIAGRAM 7 46 ELECTRICAL COMPONENTS 7 47 EXPLODED DIAGRAM 7 47 REMOVAL AND INSTA...

Page 221: ...L SYSTEM x 7 ELEC ELECTRICAL COMPONENTS Stereo Speaker Running Light 23 24 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 Bow light Fuel pumps Fuel sender 19 22 23 23 18 23 23 20 21 24 7 1 2 3 4 10 5 6 17 16 11 15 14 13 12 9 8 ...

Page 222: ...IAGRAM 2 Step Procedure Part Name Qty Service Points ELECTRICAL BOX REMOVAL Follow the left Step for removal 1 Battery negative lead 1 2 Battery positive lead 1 3 Bolt 2 4 Battery hold down bracket 1 5 Battery 1 6 Battery tray 1 7 Nut 4 8 Washer 4 REMOVAL AND INSTALLATION CHART ...

Page 223: ...t d EXPLODED DIAGRAM 2 ELECTRICAL SYSTEM x 7 ELEC Step Procedure Part Name Qty Service Points 9 Bolt 4 10 Screw 4 11 Terminal cover 1 12 Gasket 1 Not reusable 13 Screw 1 14 Starter motor lead 1 15 Bolt 3 16 Cover 1 REMOVAL AND INSTALLATION CHART ...

Page 224: ...COIL BOX Cont d EXPLODED DIAGRAM 2 Step Procedure Part Name Q ty Service Points 17 Gasket 1 Not reusable 18 Bolt 2 19 Ground led 2 20 Holder 1 21 Coupler 15 NOTE Disconnect all couplers Reverse the removal steps for installation REMOVAL AND INSTALLATION CHART ...

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 227: ...L BOX Cont d EXPLODED DIAGRAM Step Procedure Part Name Q ty Service Points 19 Tapping screw 1 20 Bracket 1 21 Joint connector 2 22 Tapping screw 1 23 Main and fuel pump relay 1 24 Tapping screw 2 25 Rectifier regulator 1 Reverse the disassembly steps for assembly ...

Page 228: ...7 8 ELECTRICAL SYSTEM 7 ELEC ELECTRICAL BOX AND IGNITION COIL BOX Cont d EXPLODED DIAGRAM ...

Page 229: ...7 9 ELECTRICAL SYSTEM x 7 ELEC ELECTRICAL BOX AND IGNITION COIL BOX Cont d EXPLODED DIAGRAM High tension code ...

Page 230: ...7 10 ELECTRICAL SYSTEM 7 ELEC ELECTRICAL BOX AND IGNITION COIL BOX Cont d ...

Page 231: ...STEM x 7 ELEC Throughout this chapter the digital tester s part number has been omitted Refer to the following part number O O indicates a continuity of electricity e g a closed circuit at the respective switch posi tion ...

Page 232: ... speed is dependant on many factors e g fouled or weak spark plugs or a weak battery If one of these is defective the peak voltage will be lower than specification If the peak voltage measurement is not within specification the engine will not operate prop erly A low peak voltage will also cause compo nents to prematurely wear ...

Page 233: ...7 13 ELECTRICAL SYSTEM x 7 ELEC Throughout this chapter the peak voltage adaptor s part number has been omitted Refer to the following part number tests ...

Page 234: ... G G B P R W Br G R B G G G G G O Pu R Pu G Pu B B O Pu G Pu B Pu R Bu Y B Y R Y B Y B O P G R Y Pu Y P B O R B B P B O B P B O 2 3 R Y B R B W R B W R 1 4 B O R R Br B B R B O B O B O B O W Br Br Br B B B P B P B 3 2 1 8 5 6 7 9 4 R Y R Y R Y R P P O R R R R R P P O O 2 W 3 P W 4 P 5 B Y 6 B O 7 Y 8 O 9 W R 10 W B 11 L R 13 B R 15 G O 17 L B 18 R Y 19 P G 20 P 21 B Y 27 B 28 B W 1 2 3 4 5 6 7 8 B...

Page 235: ...W G G B P R W Br G R B G G G G G O Pu R Pu G Pu B B O Pu G Pu B Pu R Bu Y B Y R Y B Y B O P G R Y Pu Y P B O R B B P B O B P B O 2 3 R Y B R B W R B W R 1 4 B O R R Br B B R B O B O B O B O W Br Br Br B B B P B P B 3 2 1 8 5 6 7 9 4 R Y R Y R Y R P P O R R R R R P P O O 2 W 3 P W 4 P 5 B Y 6 B O 7 Y 8 O 9 W R 10 W B 11 L R 13 B R 15 G O 17 L B 18 R Y 19 P G 20 P 21 B Y 27 B 28 B W 1 2 3 4 5 6 7 8 ...

Page 236: ...7 16 ELECTRICAL SYSTEM 7 ELEC ...

Page 237: ...EM x 7 ELEC 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 component ...

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 247: ... SYSTEM WIRING DIAGRAM Thermoswitch exhaust Thermoswitch engine 6 7 8 9 10 11 12 13 12 9 10 11 6 7 8 Engine temperature sensor Intake air temperature sensor Intake air pressure sensor Throttle position sensor Fuel injector Oil pressure switch 13 ...

Page 248: ...7 28 ELECTRICAL SYSTEM 7 ELEC FUEL CONTROL SYSTEM WIRING DIAGRAM 12 9 10 11 6 7 8 13 ...

Page 249: ...FUEL LED AND WIRING CHECK 1 Open the fuel hatch and locate the three wire connector for the Fuel Sensor Unplug the sensor s connector and turn the starboard key to the ON position The gauge should then read below EMPTY and the Low Fuel LED should be illuminated ...

Page 250: ...to the PURPLE wire connector and jumping the PINK to BLACK wire connectors to ground The gauge needle should read above the FULL mark If it does not read above Full replace the gauge CONNECTOR WIRING FUEL LEVEL SENSOR LOW FUEL SWITCH The Fuel Level Sensor and Low Fuel Switch are tested by eliminating other causes Test the gauge low fuel LED and wiring as above in the Fuel Gauge section If the gaug...

Page 251: ...C 4 3 2 1 8 7 6 5 R Y 7 18 R Y L R Br L Y R Y R Y B R Y R Y Y R Br Br Br Br R B R B Br R B B R 4 3 2 1 6 R Y R Y R P P O R R R R R R 1 2 3 4 5 6 7 8 B B B 5 Br B B B 8 7 OFF ON START SET PULL Br B W Br STARTING SYSTEM WIRING DIAGRAM ...

Page 252: ...t of specification Replace 1 Disconnect switch at harness 2 Turn key to function to be checked 3 Check continuity between the indicated wire leads No continuity Replace switch assembly Start continuity Brown Red Black White Black Purple OFF O O ON O O START O O O ...

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 261: ...7 41 ELECTRICAL SYSTEM x 7 ELEC B B B Br Br Br Br ELECTRIC BILGE PUMP WIRING DIAGRAM B Black Br Brown ...

Page 262: ...7 42 ELECTRICAL SYSTEM 7 ELEC ...

Page 263: ...MPONENT LOCATION EXPLODED DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 1 Battery 2 Fuel Level Sensor 3 Bow Light 4 Stern Light Connector 5 Blower Motors 6 Bilge Pump 7 Horn 8 Stereo Unit 9 Hull Harness 3 10 Deck Harness 11 12V Outlet and Circuit Breaker ...

Page 264: ...7 44 ELECTRICAL SYSTEM 7 ELEC SWITCH LOCATION WIRING DIAGRAM 1 2 3 4 5 1 Key Switches 2 Lanyard Switch 3 Neutral Switch 4 Hatch Interlock Switches 5 Engine Harness 2 ...

Page 265: ...WG BLK 4 10 AWG BLK 4 10 AWG BLK 4 10 AWG BLK 4 10 AWG BLUE 9 HORN 52268 53089 LIGHTS 52267 52329 ORG 4 ORG 4 ORG 4 ORG 4 CT LT 52266 51342 GRAY GREEN 23 GRAY BLUE 23 5A 5A 5A 5A 5A 5A 5A RD BLK 4 10 AWG BLUE 22 BRN 19 BLUE 22 RED PURPLE 22 14 AWG YELLOW 21 STEREO 52265 51342 BILGE 52264 51342 ORG 4 BLK 20 14 AWG RED BLK 5 10 AWG BLOWER 52263 51342 BLK 19 14 AWG RED BLK 4 10 AWG PINK 20 PURPLE 20 ...

Page 266: ...removal 1 Cover Steering Wheel 1 2 Nut w Washer 1 3 Steering Wheel 1 4 Woodruff Key 1 5 Nut 2 6 Key Switch 2 7 Screw 3 8 x 3 4 PTH 8 Nut w Washer 3 8 x 32 Hex 9 Meter Panel 1 10 Speedometer 1 11 Fuel Gauge 1 12 Tachometer 2 13 Nut 7 14 Breaker 7 15 Nut 2 16 Controller Stereo 1 Reverse the removal steps for installation REMOVAL AND INSTALLATION CHART ...

Page 267: ...WIRING DIAGRAM 1 Circuit Breaker 2 Stereo Switch 3 Courtesy Light Switch 4 Navigation Light Switch 5 Bilge Pump Switch 6 Blower Switch 7 Horn Switch 8 Stereo 9 Courtesy Lead 10 Blower Motors 11 Bilge Pump 12 Horn 13 Stern Light 14 Bow Light 10 11 12 13 14 ...

Page 268: ...7 48 ELECTRICAL SYSTEM 7 ELEC ...

Page 269: ...7 49 ELECTRICAL SYSTEM x 7 ELEC ...

Page 270: ...RT 8 7 REMOTE CONTROL SYSTEM 8 8 EXPLODED DIAGRAM 8 8 REMOVAL AND INSTALLATION CHART 8 9 ENGINE HATCH 8 10 EXPLODED DIAGRAM 8 10 REMOVAL AND INSTALLATION CHART 8 11 HATCH FITTINGS BOW COVER 8 12 EXPLODED DIAGRAM 8 12 REMOVAL AND INSTALLATION CHART 8 13 SEAT FITTINGS 8 14 EXPLODED DIAGRAM 8 14 REMOVAL AND INSTALLATION CHART 8 15 DECK FITTINGS 8 16 EXPLODED DIAGRAM 8 16 REMOVAL AND INSTALLATION CHAR...

Page 271: ...GUNWALE 8 24 EXPLODED DIAGRAM 8 24 REMOVAL AND INSTALLATION CHART 8 24 HULL CONSTRUCTION AND CARE 8 25 FRP 8 25 WHAT IS FRP 8 25 CHARACTERISTICS OF FRP 8 25 MAINTENANCE OF FRP 8 25 ...

Page 272: ...8 1 HULL AND DECK x 8 HULL DECK ENGINE COMPARTMENT LAYOUT EXPLODED DIAGRAM 1 2 3 4 5 6 7 1 Engine 5 Battery 2 Water Lock 6 Blowers 3 Jet Pump 7 Bilge Pump 4 Fuel Tank ...

Page 273: ...8 2 HULL AND DECK 8 HULL DECK VENTILATION SYSTEM EXPLODED DIAGRAM ...

Page 274: ...g 28 3 Ventilator White 5 4 Ventilator Black 2 5 Hose Ventilation 3 Intake 36 6 Hose Ventilation 2 Exhaust 24 7 Hose Ventilation 1 8 Screw Truss Head Tapping 4 9 Blower Assembly 2 10 Ventilator 2 11 Band 4 12 Hose Ventilation 2 2 13 Joint Drain 2 14 Clamp Cable 5 Reverse the removal steps for installation REMOVAL AND INSTALLATION CHART HULL AND DECK x 8 HULL DECK ...

Page 275: ...8 4 HULL AND DECK 8 HULL DECK COOLING SYSTEM EXPLODED DIAGRAM 28 28 29 29 30 27 27 30 25 ...

Page 276: ...tat 2 18 Band Hose 6 Oetiker type clamps 19 Hose 8 2 20 Joint Pipe 2 Straight connector for Port pilot water hose 21 Clip 2 22 Hose 2 STARBOARD hose is shortened to fit 23 Nut M14 1 5mm 4 24 Pilot Water 4 Apply clear silicone around the flange of the water pilots 25 Band Hose 1 Located in engine compartment 26 Clean out Tray Assembly 1 See pg 6 6 Jet Pump Clean out Tray RemovaL 27 Band Hose 2 28 H...

Page 277: ...EERING SYSTEM EXPLODED DIAGRAM HULL AND DECK 8 HULL DECK 1 2 3 4 13 A A A SS SS 11 12 1 2 3 4 5 6 7 8 9 10 NOTE See REMOVAL AND INSTALLATION CHART on next page for torque specs and locking agent instructions ...

Page 278: ...kg 10 ft lb LT 242 19 Washer 3 20 Steering Master 1 21 Nut 3 1 4 20 Nylon lock 7 Nm 0 7 m kg 5 ft lb 22 Washer 3 1 4 fender 23 Hex Head Bolt 3 1 4 20 24 Steering Mount 1 STEERING CABLE 1 Nut w Washer 2 12 Nm 1 2 m kg 8 7 ft lb LT 242 2 Block Pivot Arm 1 3 Screw 2 3 7 Nm 0 37 m kg 2 7 ft lb 4 Connector Sub Assembly 1 Cleanout Tray Refer to Jet Pump Clean Out Ports in Chapter 6 5 Nut 4 33 Nm 3 3 m k...

Page 279: ...8 8 REMOTE CONTROL SYSTEM EXPLODED DIAGRAM HULL AND DECK 8 HULL DECK ...

Page 280: ... 8 Nut 1 9 Plate Retaining 2 10 Remote Control Assembly 1 11 Screw 1 12 Switch Neutral 1 CABLE REMOVAL 13 Clevis Assembly 4 14 Nut 4 15 Nut 2 16 Cable Throttle 2 17 Shaft Joint Ball 2 18 Nut 2 Clean out Tray Refer to JET PUMP CLEAN OUT PORTS in Chapter 6 19 Thru hull Fitting 2 20 Cable Shift 2 REMOTE CONTROL UNIT MOUNT PLATES 21 Nut 10 24 Nylon Lock 4 22 Washer 10 Flat 4 23 Screw 10 24 4 24 Plate ...

Page 281: ...8 10 ENGINE HATCH EXPLODED DIAGRAM HULL AND DECK 8 HULL DECK ...

Page 282: ...4 20 x 1 3 4 6 9 Engine Hatch Assembly 1 10 Nut 1 4 20 Nylon Lock 6 11 Washer Fender 1 4 6 12 Screw 1 4 20 x 1 3 4 6 13 Hinge Engine Hatch 2 14 Nut 10 24 Nylon Lock 6 15 Washer 10 Fender 3 4 O D 6 16 Screw 10 20 x 2 5 6 17 Base hatch Support 2 18 Nut 1 4 20 Nylon Lock 4 19 Washer 1 4 4 20 Screw 1 4 20 x 1 3 4 4 21 Seat Lock Assembly 2 22 Nut 10 24 Nylon Lock 2 23 Washer 7 16 Fender 1 1 2 O D 4 24 ...

Page 283: ...8 12 HATCH FITTINGS BOW COVER EXPLODED DIAGRAM HULL AND DECK 8 HULL DECK ...

Page 284: ...4 Catch 1 35 Screw 5 8 x 3 4 36 Cushion 5 REMOVAL AND INSTALLATION CHART HULL AND DECK x 8 HULL DECK Step Procedure Part Name Q ty Service Points GLOVEBOX HATCH 37 Screw 3 10 X 3 4 38 Nut 3 10 24 39 Glovebox Hatch Assem 1 FUEL HATCH 40 Screw 12 8 x 3 8 41 Hinge Fuel Hatch 2 42 Nut Nylon Lock 2 10 24 43 Washer Flat 2 10 44 Screw 2 10 24 x 1 1 4 45 Catch 1 46 Screw Machine 2 47 Latch 2 48 Seal Fuel ...

Page 285: ...8 14 HULL AND DECK 8 HULL DECK SEAT FITTINGS EXPLODED DIAGRAM ...

Page 286: ...P SEATING 11 Seat Cushions 2 12 Nut 1 4 20 4 Access nuts through under seat storage 13 Washer Flat 1 4 x 1 1 2 Fender 4 14 Seat Backrests 2 Lift backrests off mounting clips ENGINE HATCH SEATS 15 Nut 1 4 20 4 Open engine hatch 16 Lock Washer 1 4 20 4 17 Washer Flat 1 4 x 1 1 2 Fender 4 18 Seat Cushions 3 19 Nut 1 4 20 4 20 Lock Washer 1 4 20 4 21 Washer Flat 1 4 x 1 1 2 Fender 4 22 Backrest 2 23 S...

Page 287: ...DECK FITTINGS EXPLODED DIAGRAM HULL AND DECK 8 HULL DECK 8 16 ...

Page 288: ... 4 21 Washer Flat 5 16 4 22 Rail Hand Bow 2 23 Nut 5 16 18 4 LT242 Torque 13Nm 1 35m kg 9 5ft lb 24 Washer Lock 5 16 4 25 Washer Flat 5 16 6 Washers are placed on center 2 studs of the Grip Ass y Ski Tow before installing on hull The remaining 4 washers are placed on all 4 studs after inserting thru holes in hull 26 Grip Assembly Ski Tow 1 Silicone sealer around base of studs 27 Bolt M8 x 35mm HH ...

Page 289: ...Post Short Swim Deck 1 330mm 13 in Optional Accy 41 Stanchion Table Post Long Cockpit 1 622mm 24 5 in Optional Accy 42 Screw 1 4 20 x 1 3 4 POH 12 43 Nut 1 4 20 Nylon Lock 12 Torque 8Nm 0 8m kg 6 ft lb 44 Washer 1 4 x 1 OD Fender 12 45 Table Mount 2 Silicon sealer around bolt holes and mount opening in deck ANCHOR ROPE RETAINER 46 Screw 10 X 1 1 2 POH 6 47 Bracket 2 ...

Page 290: ... BIMINI TOP BRACKETS 48 Nut 10 24 Nylon Lock 8 Torque 4Nm 0 4m kg 3 ft lb 49 Washer 10 x 3 4 OD 8 50 Screw 10 24 x 1 1 2 POH 4 51 Bracket Awning front 2 52 Screw 10 24 x 1 POH 4 53 Bracket Awning 2 rear 2 54 Nut 8 32 Nylon Lock 4 Torque 3Nm 0 3m kg 2 ft lb 55 Washer 10 x 3 4 OD 4 56 Screw 8 32 x 1 POH 4 57 Eye Strap 2 ...

Page 291: ...8 20 DECK FITTINGS Continued EXPLODED DIAGRAM HULL AND DECK 8 HULL DECK ...

Page 292: ...4m kg 3 ft lb 59 Washer 10 Flat 4 60 Screw 10 24 x 2 PPH 4 61 Screw 8 x 3 8 PPH Type B 4 62 Windshield Brace 2 63 Windshield Trim Remove to access screws 64 Screw 8 x 3 4 POH 14 65 Nut 8 32 Nylon Lock 8 Torque 3Nm 0 3m kg 2 ft lb 66 Washer 8 Flat 8 67 Screw 8 32 x 2 POH 2 68 Screw 8 32 x 1 1 2 POH 6 69 Windshield Assembly 1 70 Pad Windshield 1 71 Windshield Tie down 1 ...

Page 293: ...8 22 THROUGH HULL AND DRAIN FITTINGS EXPLODED DIAGRAM Qty 3 for Bilge Hose HULL AND DECK 8 HULL DECK ...

Page 294: ...pply clear silicone to the base 12 Hose Drain 1 13 Joint Drain Y Fitting 1 14 Fuel Tank Compartment Drain 1 Apply clear silicone to the base 15 Hose Drain 1 16 Cleanout Tray Drain 1 Apply clear silicone to the base 17 Hose Drain 1 18 Hose Drain 1 19 Drain Outlet 1 Apply clear silicone to the base 20 Clamp Cable Tiewrap 8 8 21 Screw 8 x 5 8 PPH 8 22 Drink Holder 7 23 Bilge Pump 1 24 5 16 Worm Gear ...

Page 295: ...ng apply silicone to the join area 3 Inner Gunwale Rubrail insert 1 pc Heat in warm water for installation and gunwale indent area with a hair dryer or low temperature heat gun 4 Screw 10 x 1 1 4 PFH 210 Torque 2 Nm 0 2m kg 1 5 ft lb 5 Gunwale Rubrail 1 pc Fill in any gaps above or below the gunwale with white silicone Reverse the removal steps for installation REMOVAL AND INSTALLATION CHART HULL ...

Page 296: ...l steps when nec essary 1 Maintenance of luster The gelcoat layer is 0 3 to 0 5mm 0 12 to 0 20 in thick When it has faded or has lost its luster the original luster can be restored by polishing to remove the oxidized layer Polishing procedures a Clean the gelcoat surface with water and neutral detergent b Polish with a fine rubbing compound If no polisher is available polish with a rag and compoun...

Page 297: ...TROUBLE ANALYSIS x 9 TRBL ANLS WINDOWS 95 WINDOWS 98 WINDOWS ME WINDOWS 2000 OR WINDOWS XP 9 3 UPDATING THE DATABASE 9 7 ENGINE MONITOR 9 26 Operating procedure 9 27 ...

Page 298: ...Operating procedure 9 41 Data display item selection 9 42 Operating procedure 9 42 ...

Page 299: ...LS If this software is run on Microsoft Windows 95 Windows 98 Windows Me Windows 2000 or Windows XP the information can be displayed in colorful graphics Also the software can be operat ed using either a mouse or a keyboard 1 2 3 4 5 ...

Page 300: ...9 2 TROUBLE ANALYSIS 9 TRBL ANLS Make sure your computer meets the following requirements before using this software RS232C Dsub 9 pin port USB portj ...

Page 301: ...TROUBLE ANALYSIS x 9 TRBL ANLS 9 3 INSTALLING THE YAMAHA DIAGNOSTIC SYSTEM UNDER WINDOWS 95 WINDOWS 98 WINDOWS ME WINDOWS 2000 OR WINDOWS XP 9 2 ...

Page 302: ...9 4 TROUBLE ANALYSIS 9 TRBL ANLS ...

Page 303: ...9 5 TROUBLE ANALYSIS x 9 TRBL ANLS ...

Page 304: ...ANALYSIS 9 TRBL ANLS Install the Database file before using the Yamaha Diagnostic System otherwise the program will not operate correctly For installation procedures refer to UPDATING THE DATABASE on the next page ...

Page 305: ...9 7 TROUBLE ANALYSIS x 9 TRBL ANLS After about three seconds the display will automatically go to the first menu display or you can click or press any key to go to the first menu See fig 12 ...

Page 306: ...TROUBLE ANALYSIS 9 TRBL ANLS Do not click the Starting service tool Enter button or press the Enter key on your keyboard until the database has been updated otherwise the program will not operate correctly ...

Page 307: ...9 9 TROUBLE ANALYSIS x 9 TRBL ANLS ...

Page 308: ...9 10 TROUBLE ANALYSIS 9 TRBL ANLS When the database is updated a confirmation screen is displayed ...

Page 309: ...9 11 TROUBLE ANALYSIS x 9 TRBL ANLS ...

Page 310: ...9 12 TROUBLE ANALYSIS 9 TRBL ANLS 1 2 ...

Page 311: ...LE ANALYSIS x 9 TRBL ANLS Open the Yamaha Diagnostic System window Fig 20 After about three seconds the display will automatically go to the first menu or click or press any key to go to the first menu See fig 21 ...

Page 312: ...9 14 TROUBLE ANALYSIS 9 TRBL ANLS ...

Page 313: ...9 15 TROUBLE ANALYSIS x 9 TRBL ANLS ...

Page 314: ...9 16 TROUBLE ANALYSIS 9 TRBL ANLS Eight commands appear in the main Menu Select a command in any of the following three ways ...

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 322: ...LYSIS 9 TRBL ANLS Check that the items deleted are normal in the Diagnosis Record If the items remain irregular they will appear as irregular in the Diagnosis Record Even if you try to delete them they are undeletable ...

Page 323: ...LE ANALYSIS x 9 TRBL ANLS Click the OK button or press the Enter key on your keyboard Fig 35 The selected item is deleted To cancel deleting the item click the Cancel button or press the Esc key on your keyboard ...

Page 324: ...TROUBLE ANALYSIS 9 TRBL ANLS Do not use the Engine Monitor function to check the engine condition while operating a water craft otherwise you could become distracted which could result in a collision display ...

Page 325: ...9 27 TROUBLE ANALYSIS x 9 TRBL ANLS in the scroll bar or press the up or down Fig 38 keyboard ...

Page 326: ...9 28 TROUBLE ANALYSIS 9 TRBL ANLS Avoid clicking the Execute and Cancel buttons repeatedly otherwise the ECM or PC will not work properly and they could be damaged item test ...

Page 327: ...9 29 TROUBLE ANALYSIS x 9 TRBL ANLS keys on your keyboard Fig 39 Spark Gap Tester YM 34487 90890 06754 is needed keyboard Fig 39 ...

Page 328: ...9 30 TROUBLE ANALYSIS 9 TRBL ANLS keyboard Fig 42 ...

Page 329: ...running an error message is displayed follow the instructions that appear Fig 44 instructions in the messages that are displayed see Fig 43 instructions that appear in the error message Fig 45 To stop the stationary test click the Cancel button see Fig 43 ...

Page 330: ...9 32 TROUBLE ANALYSIS 9 TRBL ANLS selected Fig 46 displayed Fig 47 ...

Page 331: ...9 33 TROUBLE ANALYSIS x 9 TRBL ANLS keyboard Fig 48 Make sure that there is fuel in the fuel tank otherwise an error will occur and the test cannot be per formed keyboard Fig 48 ...

Page 332: ...9 34 TROUBLE ANALYSIS 9 TRBL ANLS keyboard Fig 49 ...

Page 333: ...NLS selected Fig 51 Do not test the same cylinder three or more times otherwise the spark plug insulator could be damaged Make sure there is fuel in the fuel tank otherwise an error will occur and the test cannot be performed CAUTION ...

Page 334: ...9 36 TROUBLE ANALYSIS 9 TRBL ANLS Select the test to be performed then click the Select button or press the Enter key on your keyboard Fig 52 Make sure the engine is not running ...

Page 335: ...9 37 TROUBLE ANALYSIS x 9 TRBL ANLS keyboard Fig 53 selected Fig 54 ...

Page 336: ...9 38 TROUBLE ANALYSIS 9 TRBL ANLS Avoid clicking the Execute and Cancel buttons repeatedly otherwise the ECM or PC will not work properly and they could be damaged ...

Page 337: ...NALYSIS x 9 TRBL ANLS For the first ten seconds operate all four cylinders then stop one cylinder for five seconds For the last five seconds operate all four cylinders keyboard Fig 55 keyboard Fig 55 keyboard Fig 56 ...

Page 338: ...9 40 TROUBLE ANALYSIS 9 TRBL ANLS If the engine is not running an error message is displayed Follow the instructions that appear Fig 57 displayed Fig 56 appear Fig 58 ...

Page 339: ...9 41 TROUBLE ANALYSIS x 9 TRBL ANLS board Fig 59 Press the Enter key on your keyboard The window of the selected item is displayed Fig 59 ...

Page 340: ...9 42 TROUBLE ANALYSIS 9 TRBL ANLS bar Fig 60 displayed See fig 61 ...

Page 341: ...9 43 TROUBLE ANALYSIS x 9 TRBL ANLS axis Fig 61 value at the time the Enter key on your keyboard was pressed in the Monitor item selection ...

Page 342: ...9 44 TROUBLE ANALYSIS 9 TRBL ANLS Fig 62 Although the engine is running the displayed time refers to the added hours until the Data logger starts ...

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 ...

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Yamaha SR230 2004, Service Manual

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Summary of Contents for SR230 2004

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