Yamaha 2006 Service Manual Ar230

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PREFACEThis manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trainedmechanics when performing maintenance procedures and repairs to Yamaha equipment. It is notpossible to put an entire mechanic’s education into one manual, so it is assumed that persons usingthis book to perform maintenance and repairs on Yamaha machines have a basic understanding ofthe mechanical concepts and procedures inherent in machine repair technology. Without suchknowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe.

Because Yamaha has a policy of continuously improving its products, models may differ in detailfrom the descriptions and illustrations given in this publication. Use only the latest edition of thismanual. Authorized Yamaha dealers are notified periodically of modifications and significantchanges in specifications and procedures, and these are incorporated in successive editions of thismanual.

x

AR230 High Output / SX230 High OutputSRT1100A-D / SRT1100-D

Service Manual - 2005First Edition

©2005 by Yamaha Motor Corporation, USAMarch 2005

All rights reserved. Any reprintingor unauthorized use

without the written permission ofYamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

Specifications, features and options are subject tochange without notice.

04-574

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HOW TO USE THIS MANUALMANUAL FORMATAll of the procedures in this manual are organized in a sequential, step-by-step format. The infor-mation has been compiled to provide the mechanic with an easy-to-read, handy reference that con-tains comprehensive 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 thecourse of action required will follow the symbol, e.g.:● Bearings

Pitting/Damage ➔ Replace.

To assist you in finding your way about this manual, the Section Title and Major Heading is given atthe head of every page.

An index to contents is provided on the first page of each section.

THE ILLUSTRATIONSSome illustrations in this manual may differ from the model you have. This is because a proceduredescribed may relate to several models, though only one may be illustrated. (The name of modeldescribed will be mentioned in the description).

REFERENCESThese 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 NOTESAttention is drawn to the various Warnings, Cautions, and Notes which distinguish important infor-mation in this manual in the following ways:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the machineoperator, a bystander, or a person inspecting or repairing the jet boat.

A CAUTION indicates special precautions that must be taken to avoid damage to the jet boat.

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

IMPORTANT: __________________________________________________________________This part has been subjected to change of specification during production.

WARNING

CAUTION:

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HOW TO READ DESCRIPTIONS1. A disassembly/installation job instruction mainly consists of the exploded diagram 11.

2. The numerical figures represented by the number 22 indicates the order of the job steps.

3. The symbols represented by the number 33 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 44 is attached to the exploded diagram andexplains 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 toexplain in the exploded diagram of REMOVAL AND INSTALLATION CHART, the Service Pointsrequiring the detailed description 55, etc.

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SYMBOLSSymbols 1 to 9 are designed as thumb-tabsto indicate the content of a chapter:

General InformationSpecificationsPeriodic Inspection and AdjustmentFuel SystemPower UnitJet Pump UnitElectrical SystemHull and DeckTrouble Analysis

Symbols to indicate specific data:Special ToolSpecified LiquidSpecified Engine SpeedSpecified TorqueSpecified MeasurementSpecified Electrical Valve[Resistance (Ω), Voltage (V),Electric Current (A)]

Symbol to in an exploded diagram indi-cate grade of lubricant and location of lubrica-tion point:

Apply Yamaha 2-stroke outboard motor oilApply water resistant grease (Yamahagrease 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)Apply LOCTITE® No. 242 (Blue LOCTITE)Apply LOCTITE® No. 567 (PST)Apply Silicone Sealant

NOTE: ______________________________In this manual, the above symbols may not beused in every case.

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2

3

4

5

6

7

8

9

10 15

10

11

12

13

14

15

16 18

16

17

18

19 24

19

20

21

22

23

24

HULLDECK

567

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INDEX

SPECIFICATIONSSPEC

GENERAL INFORMATION 1GENINFO

2

PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJ

FUEL SYSTEM 4FUEL

POWER UNIT 5POWR

JET PUMP 6JETPUMP

ELECTRICAL SYSTEM 7ELEC

HULL AND DECK 8HULLDECK

TROUBLE ANALYSIS 9TRBLANLS

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CHAPTER 1

GENERAL INFORMATION

IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

PRIMARY I.D. NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

ENGINE 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 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

REMOVAL AND INSTALLATION TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

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A60700-0*

IDENTIFICATION NUMBERSPRIMARY I.D. NUMBERThe primary I.D. number is stamped on a labelattached to the deck under the rear seat.

ENGINE SERIAL NUMBERThe engine serial number is stamped on alabel 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 1GENINFO

1-1

Starting Primary I.D. Number:SRT1100-D/SX230HO F1U-700101SRT1100 A-D/AR230HO. F1U-720101

Starting Engine Serial Number:

6P6: 1000401

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SAFETY WHILE WORKINGThe procedures given in this manual are thoserecommended by Yamaha to be followed byYamaha dealers and their mechanics.

FIRE PREVENTIONGasoline (petrol) is highly flammable.Petroleum vapor is explosive if ignited. Do notsmoke while handling gasoline (petrol), andkeep it away from heat, sparks, and openflames.

VENTILATIONPetroleum vapor is heavier than air and ifinhaled in large quantities will not support life.Engine exhaust gases are harmful to breathe.When test-running an engine indoors, maintaingood ventilation.

SELF-PROTECTIONProtect your eyes with suitable safety specta-cles or safety goggles when using compressedair, when grinding or when doing any operationwhich may cause particles to fly off.

Protect hands and feet by wearing safetygloves and protective shoes if appropriate tothe work you are doing.

OILS, GREASES AND SEALING FLUIDSUse only Genuine Yamaha oils, greases andsealing fluids or those recommended byYamaha.

Under normal conditions of use, there shouldbe no hazards from the use of the lubricantsmentioned in this manual. However, safety isall-important, and by adopting good safetypractices, any risk is minimized. A summary ofthe most important precautions is as follows:

1. While working, maintain good standards ofpersonal and industrial hygiene.

2. Clothing which has become contaminatedwith lubricants should be changed as soonas practicable and laundered before furtheruse.

GENERAL INFORMATION

1-2

1 GENINFO

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3. Avoid skin contact with lubricants; do not,for example, place a soiled wiping-rag inone’s pocket.

4. Hands, and any other part of the bodywhich have been in contact with lubricantsor lubricant-contaminated clothing, shouldbe thoroughly washed with hot water andsoap as soon as practicable.

5. To protect the skin, the application of a suit-able barrier cream to the hands beforeworking is recommended.

6. A supply of clean lint-free cloths should beavailable for wiping purposes.

GOOD WORKING PRACTICES1. The right tools

Use the special tools that are designed toprotect parts from damage. Use the righttool in the right manner – don’t improvise.

2. Tightening torqueFollow the torque tightening instructions.When tightening bolts, nuts and screws,tighten the larger sizes first, and tighteninner-positioned fasteners before outer-positioned ones.

3. Non-reusable itemsAlways use new gaskets, packings,o-rings,oil seals, split-pins and circlips, etc. onreassembly.

GENERAL INFORMATIONx 1

1-3

GENINFO

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DISASSEMBLY AND ASSEMBLY1. Clean parts with solvent and compressed-

air on disassembling them.

2. Oil the contact surfaces of moving parts onassembly.

3. After assembly, check that moving partsoperate normally.

4. Install bearings with the manufacturer’smarkings on the side exposed to view andliberally oil the bearings.

Do not use compressed air to spin the bear-ings dry.This causes damage to the bearingsurfaces.

5. When installing oil seals, apply a light coat-ing of water-resistant grease to the outsidediameter.

GENERAL INFORMATION

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1 GENINFO

CAUTION:

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SPECIAL TOOLSUse of the correct special tools recommendedby Yamaha will aid the work and enable accu-rate assembly and tune-up. Improvisations anduse of improper tools can cause damage to theequipment.

NOTE:• For U.S.A. and Canada, use part numbers

starting with “J-”, “YB-”, “YM-”,“YS-”, “YU-” or“YW-”.

• For other countries, use part numbers startingwith “90890-.”

MEASURING TOOLS

1 Dial GaugeP/N YU-03097-B

90890-01252

2 Dial Gauge StandP/N 90890-06583

3 Dial Gauge NeedleP/N 90890-06584

4 Dial Gauge Stand SetP/N YW-06585

90890-06585

5 Pocket TesterP/N YU-03112-C

90890-03112

6 Digital Circuit TesterP/N YU-A1927

90890-03174

7 Vacuum SynchronizerP/N YU-44456

8 Vacuum GaugeP/N 90890-03094Vacuum attachmentP/N 90890-03060

9 Test ConnectorP/N YW-06862

90890-06862

Fuel Pressure Gauge AdapterP/N YW-06842

90890-06842

GENERAL INFORMATIONx 1

1-5

GENINFO

10

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SPECIAL TOOLS

Fuel Pressure GaugeP/N YB-06766

90890-06786

Compression Gauge ExtensionP/N 90890-06582

Cylinder Gauge SetP/N YU-03017

90890-06759

Compression GaugeP/N YU-33223-1

90890-03160

Peak Voltage AdapterP/N YU-39991

90890-03172

Spark Gap TesterP/N YM34487

90890-06754

Test Harness (2 pins)P/N YB-06792

90890-06792


90890-06791


90890-06770


90890-06790


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 INFORMATION1 GENINFO

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1-7

GENERAL INFORMATIONx 1GENINFO

SPECIAL TOOLS


90890-06769

Vacuum/Pressure Pump Gauge SetP/N YB-35956-A

90890-06756

Yamaha Diagnostic System for WatercraftP/N LIT-YDIS1-23-00

Yamaha Diagnostic System Connector for Watercraft

P/N 60V-WS850-00-00 USB CableP/N 68F-WS850-00-00 Serial Cable

23

24

25

26

YB-0676990890-06769

YB-35956-A90890-06756

60V

YW-0686290890-06862

-WS853-01

60V-85300-01

YAMAHA DIAGNOSTIC SYSTEMfor Watercraft

INSTALLATION MANUAL

60E-2819K-10

LIT-YDIS1-21-00

60V-WS850-00-00 USB Cable /68F-WS850-00-00 Serial Cable

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1-8


REMOVAL AND INSTALLATION TOOLS

1 Oil Filter WrenchP/N YU-38411

90890-01426

2 Coupler WrenchP/N YW-06551

90890-06551

3 Sheave HolderP/N YS-01880-A

90890-01701

4 Rotor PullerP/N YM-01082

90890-01080

5 Rotor HolderP/N YU-01235

90890-01235

6 Valve Remover/Installer KitP/N YM-45469

90890-04019

7 Valve Spring Compressor AttachmentP/N YM-4114 (ø19 mm)

90890-04114 (ø19 mm)YM-4108 (ø22 mm)90890-04108 (ø22 mm)

8 Valve Guide RemoverP/N YM-04111 (ø4.0 mm)

90890-04111 (ø4.0 mm)YM-04116 (ø4.5 mm)90890-04116 (ø4.5 mm)

9 Valve Guide InstallerP/N YM-04112 (ø4.0 mm)

90890-04112 (ø4.0 mm)YM-04117 (ø4.5 mm)90890-04117 (ø4.5 mm)

Valve Guide ReamerP/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-A90890-01701

YM-0108290890-01080

YU-0123590890-01235

YM-4546990890-04019

YM-4114 (¯19 mm )90890-04114 (¯19 mm)YM-4108 (¯22 mm )90890-04108 (¯22 mm)

YM-04111 (¯ 4.0 mm)90890-04111 (¯ 4.0 mm)YM-04116 (¯ 4.5 mm)90890-04116 (¯ 4.5 mm)

YM-04112 (¯4. 0 mm)90890-04112 (¯4. 0 mm)YM-04117 (¯4. 5 mm)90890-04117 (¯4. 5 mm)

YM-04113 (¯ 4.0 mm)90890-04113 (¯ 4.0 mm)YM-04118 (¯ 4.5 mm)90890-04118 (¯ 4.5 mm)

10

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1-9

GENERAL INFORMATIONx 1GENINFO

Valve Seat CutterIntakeP/N 90890-06813 (60°)

90890-06814 (45°)90890-06815 (30°)

ExhaustP/N 90890-06315 (60°)

90890-06312 (45°)90890-06328 (30°)

Valve Seat Cutter HolderP/N 90890-06811 (ø4.0 mm)

90890-06812 (ø4.5 mm)

Valve Seat Cutter SetP/N YM-91043-C

Piston Ring CompressorP/N YM-08037

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 pump bearing and oil seal)P/N YB-06112, YB-06196

90890-06614, 90890-06653

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13

14

15

16

17

18

19

20

21

22

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1-10

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CHAPTER 2

SPECIFICATIONS

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

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

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

JET PUMP UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

GENERAL TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

CABLE AND HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

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GENERAL SPECIFICATIONS

SPECIFICATIONSx 2SPEC

2-1

Jet thrust nozzle trim angle Degree +3Impeller pitch Degree Port 18.1° / Stbd. 15.1°

SX: 2.1 (6.92 ft); AR: 3.1 (10.3 ft)

SRT1100

F1U

6P6

SX: 1372 (3025 lb); AR: 1406 (3100 lb)

117.7 (160) @ 10,000

45 (11.9, 9.9)

1.56

1,052 (64.2)76.0 x 58.0 (2.99 x 2.28)

11.9:1

BTDC 5-BTDC 32

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2-2

SPECIFICATIONS2 SPEC

SRT1100

SE, SF, SG, SH, SJ, SL

L(US qt, Imp qt)

L(US qt, Imp qt)

L(US qt, Imp qt)

GENERAL SPECIFICATIONS

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2-3


SRT1100

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2-4


SRT1100

0.020–0.047 (0.0008–0.0019)

16.971 (0.6681)

MAINTENANCE SPECIFICATIONS

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2-5


SRT1100

6P601

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2-6


Port 18.1 Stbd. 15.1

Marine Group 24Dual Purpose 675 CCA

100 (12/68.4)

SRT1100

SRT1100

SRT1100


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2-7


SRT1100


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2-8


SRT1100


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2-9


Screw 1/4-20 164.9

7.9

0.49

0.79

3.5

5.6Nut 8-32 6 2.3 0.23 1.6

Fuel sender 10-24 5 2.9 0.29 2.1

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TIGHTENING TORQUES

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2-11

TIGHTENING TORQUES

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TIGHTENING TORQUES

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2-13


6

3

20

20

2.0

2.0

14

14M8

TIGHTENING TORQUES

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2-14


Thread Tightening torquePart To Be Tightened Part Name size Qty N•m kgf•m ft•lb Remarks

Water inlet cover/water inlet Bolt M6 43 6.6 0.66 4.8strainer - impeller duct

Drive shaft nut - drive shaft Nut – 1 69 6.9 50

Impeller (left-hand threads) – Impeller M20 1 18 1.8 13drive shaft

Intermediate housing - bulkhead Bolt M8 3 17 1.7 12

DrivenDriven coupling - shaft

coupling M24 1 36 3.6 25

Grease nipple - intermediate Nipple – 1 5.4 0.54 3.9housing

Hull:

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 3.5screw

Starter motor lead - electrical box Screw M6 1 7.6 0.76 5.5

Battery positive lead - Screw M6 1 7.6 0.76 5.5electrical boxFuse holder stay - electrical box Tapping ø6 1 3.9 0.39 2.8

screwECM - electrical box Tapping ø6 4 3.9 0.39 2.8

screwBracket (coupler) - electrical box Tapping ø6 1 3.9 0.39 2.8

screw

4

TIGHTENING TORQUES

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2-15


Thread Tightening TorquePart 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 2.8screw

Rectifier/regulator Tapping ø6 2 3.9 0.39 2.8screw

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 3.5case screw

TIGHTENING TORQUES

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2-16

GENERAL TORQUE

This chart specifies the torques for tighteningstandard fasteners with standard clean dry ISOthreads at room temperature. Torque specifica-tions for special components or assemblies aregiven in applicable sections of this manual. Toavoid causing warpage, tighten multifastenerassemblies in a criss-cross fashion, in progres-sive stages until the specified torque isreached.

General Torque

Nut A Bolt BSpecifications

Nm M•kg ft•lb

8 mm M5 5.0 0.5 3.610 mm M6 8.0 0.8 5.812 mm M8 18 1.8 1314 mm M10 36 3.6 2517 mm M12 43 4.3 31

BA

General Torque

BoltSpecifications

Dia. Nm M•kg ft•lb

6-32 1.1 0.11 0.88-32 2.3 0.23 1.6510-24 2.6 0.26 1.91/4-20 8.6 0.86 6.255/16-18 15 1.5 11.0


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CABLE AND HOSE ROUTING

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2-18



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2-19



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2-22

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CHAPTER 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

POWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

JET PUMP UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

BILGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

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3-1

PERIODIC INSPECTION AND ADJUSTMENT x 3INSPADJ

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PERIODIC SERVICE

CONTROL SYSTEM

Steering helm inspection

1. Check:● Friction

Excessively heavy ➔Replace the steering helm unit.

2. Check:● Free play

Excessive free play ➔ Replace the steering helm unit.

Steering cable adjustment

1. Measure:● Distance between the center of the

steering nozzle joint and the coolingwater casting boss on the right side ofthe pump. Incorrect distance ➔ Adjuststeering cable joint at nozzle end.

The cable joints must be screwed in morethan 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 INSPADJ

8MM (0.31 IN) MINIMUM

4.9~7.8 Nm (0.49~.78 kg•m, 3.54~5.64 ft-lb)

285.45MM

TRADEMARK2005

3-3


1 Cable Wheel2 Locknuts3 Throttle Cable

REMOTE CONTROL UNIT

Throttle Cables1. Remove:

• Airbox cover.2. Set:

• Remote Control levers to Neutral posi-tion.

3. Check:• Throttle Cable Wheel 1 should contact

the idle screw and there should be freeplay in the cable.

• If adjustment is necessary, loosen theLocknuts 2 at the throttle body end and turn the cable adjuster.

4. Tighten:• Locknuts 2 when adjustment is com-

plete.

Adjust Throttle Lever Stops:

1. Remove:• Four screws holding the remote con-

trol unit cover.2. Set:

• Remote control levers forward to the Forward Wide-Open-Throttle (W.O.T.)position.

3. Check:• Each throttle cable at the throttle

body assemblies so that the Cablewheel has 0.001” (0.025mm) to 0.079” (2.0mm) clearance to theStop. If incorrect → Adjust.

4. Adjust:• Cable-Wheel-to-Stop clearance with

the Forward Throttle Stop bolts on the Remote Control unit.

Be careful not to over-adjust, as the throttlebodies can be damaged.

CAUTION:

TRADEMARK2005

3-4


TRADEMARK2005

3-5


TRADEMARK2005

3-6


TRADEMARK2005

3-7


• Valve clearance adjustment should be madeon a cold engine at room temperature.

• When the valve clearance is to be measuredor adjusted, the piston must be at Top DeadCenter (TDC) on the compression stroke.

TRADEMARK2005

3-8


TRADEMARK2005

3-9


TRADEMARK2005

3-10


Make a note of the position of each valvelifter 3 and valve pad 4 so they can beinstalled in the correct place.

lowing table:

TRADEMARK2005

3-11


TRADEMARK2005

3-12


TRADEMARK2005

3-13


CAUTION:

TRADEMARK2005

3-14


CAUTION:

Place the craft in water, and then

TRADEMARK2005

3-15


If the oil temperature is low, the reading onthe dipstick will be low. If the temperature ishigh, 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 couldoverheat.

CAUTION:

craft in a horizontal position.

TRADEMARK2005

3-16


CAUTION:

TRADEMARK2005

3-17


When starting the engine, make sure the dip-stick is securely fitted into the oil tank.

CAUTION:

TRADEMARK2005

3-18


Make sure the air filter element is installedin the filter case properly.

If cleaning the air filter element, use cold orlukewarm water and let it air dry complete-ly. Do not use detergent or a solvent toclean the air filter element, or dry it withheat or compressed air, otherwise it couldbe damaged.

CAUTION:

CAUTION:

TRADEMARK2005

3-19


TRADEMARK2005

3-20


TRADEMARK2005

3-21


TRADEMARK2005


Disconnect the bilge strainer from the bilgestrainer holder.

3-22

BILGE PUMP

1. Remove inspection cover in pump clean-outtray.

2. Inspect:• Bilge strainer

Contaminants → Clean.Cracks/damage → Replace.

Inspection Steps:

• Install the coupling cover.

TRADEMARK2005

3-23


TRADEMARK2005

3-24


GENERALDrain plug inspection

1. Inspect:● Drain plug

Crack/Damage ➔ Replace.● O-Ring

Crack/Wear ➔ Replace.● Screw threads

Dirt/Sand ➔ Clean.

Greasing points

1. Apply:● Throttle cable inner wire● Shift control cable● Cable joint● Steering cable

NOTE:Remove the cable joint and apply a smallamount 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 grease

Recommended Grease:Water resistant grease

TRADEMARK2005

3-25


Lubrication points

1. Lubricate:● Throttle cable (throttle body end)

NOTE:Before lubricating the QSTS control cables,remove the QSTS cable housing cover. Spraythe rust inhibitor into the outer cables, andapply grease to the 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 amountof grease.

Recommended lubricant:Yamaha marine grease,Yamaha grease A(Water resistant grease)

Recommended grease:Yamaha marine grease,Yamaha grease A(Water resistant grease)

Recommended grease:Yamaha marine grease,Yamaha grease A(Water resistant grease)

TRADEMARK2005

3-26


4.

TRADEMARK2005

CHAPTER 4

FUEL SYSTEM

FUEL TANK AND FUEL PUMP MODULEEXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Fuel hose disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Fuel pump module removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Check valve inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Fuel tank inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Fuel hose inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Fuel pump filter inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Fuel pump module installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Fuel hose connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

FUEL INJECTION SYSTEMEXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Hose clamps removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Hose clamps installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Fuel hose disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Fuel line inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16Fuel hose installation (replacing with new fuel hose) . . . . . . . . . . . . . . . . . . . . . . . 4-17Fuel hose connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17Throttle body removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17Fuel injector inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18Throttle body inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18Bypass valve motor inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19Throttle body installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19Throttle bodies synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20Fuel pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

TRADEMARK2005

FUEL SYSTEM x 4FUEL

4-1

28

28

28

2828

28

2828

28

1

2

3

45

10

12

11

1316

13

15

18

1317

1920

26

252423

2721

22

1413

9

8

6

7

29

29

28

30

Step Procedure / Part Name Q’ty Service PointsFUEL TANK PUMP MODULE Follow the “Step” order for removal.

1 Connector, harness 22 Cover 23 Screw, Machine 24 Clamp 25 Fuel hose 26 Screw 16 NOTE: Apply Loctite, torque in 2 steps

see page 4-4 Pump Module Removal,4-5 Installation

7 Plate 28 Fuel Pump Assembly 29 Seal 210 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

TRADEMARK2005

4-2

FUEL SYSTEM4 FUEL

FUEL TANK AND FUEL PUMP MODULE (Cont’d.)

28

28

28

2828

28

2828

28

1

2

3

45

10

12

11

1316

13

15

18

1317

1920

26

252423

2721

22

1413

9

8

6

7

29

29

28

30

Step Procedure / Part Name Q’ty Service Points11 Fuel Level Sender 112 Gasket 113 Clamp 414 Hose, Vent 115 Hose, Vent 116 Valve, Check 117 Nut 118 Washer, Star 119 Washer 120 Vent, Fuel 121 Clamp 4 4.2 Nm (0.42 kgf-m, 3.0 ft-lbs)

See detail on clamp installation22 Hose, Fuel Filler 123 Nut, #8-32 Nylon Lock 624 Washer, #8 Flat 625 Screw, #8-32 6

TRADEMARK2005

4-3

FUEL SYSTEM x 4FUEL

FUEL TANK AND FUEL PUMP MODULE (Cont’d.)

28

28

28

2828

28

2828

28

1

2

3

45

10

12

11

1316

13

15

18

1317

1920

26

252423

2721

22

1413

9

8

6

7

29

29

28

30

Step Procedure / Part Name Q’ty Service Points26 Filler Cap Assembly 127 Gasket 1

FUEL TANK Note: Deck must be cut at outline toaccess 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 230 Fuel Tank Assembly 1

Reverse the removal steps for installation.

TRADEMARK2005

4-4

FUEL SYSTEM4 FUEL

SYSTEM.”

Screws

Loosen the screws in the sequence shown.

TRADEMARK2005

4-5

FUEL SYSTEM x 4FUEL

SYSTEM.”

Screws

4.9 Nm (0.49 kgf-m)

7.9 Nm (0.8 kgf-m)

TRADEMARK2005

4-6

FUEL SYSTEM4 FUEL

TRADEMARK2005

4-7

FUEL SYSTEM x 4FUEL

FUEL INJECTION SYSTEM (Cont’d.)

TRADEMARK2005

4-8

FUEL SYSTEM4 FUEL


TRADEMARK2005

4-9

FUEL SYSTEM x 4FUEL


TRADEMARK2005

4-10

FUEL SYSTEM4 FUEL


TRADEMARK2005

4-11

FUEL SYSTEM x 4FUEL


TRADEMARK2005

4-12

FUEL SYSTEM4 FUEL


TRADEMARK2005

4-13

FUEL SYSTEM x 4FUEL


TRADEMARK2005

4-14

FUEL SYSTEM4 FUEL


TRADEMARK2005

4-15

FUEL SYSTEM x 4FUEL

CAUTION:

TRADEMARK2005

4-16

FUEL SYSTEM4 FUEL

CAUTION:

TRADEMARK2005

4-17

FUEL SYSTEM x 4FUEL

CAUTION:

TRADEMARK2005

4-18

FUEL SYSTEM4 FUEL

CAUTION:

TRADEMARK2005

4-19

FUEL SYSTEM x 4FUEL

CAUTION:

TRADEMARK2005

4-20

FUEL SYSTEM4 FUEL

CAUTION:

TRADEMARK2005

4-21

FUEL SYSTEM x 4FUEL

TRADEMARK2005

4-22

FUEL SYSTEM4 FUEL

CAUTION:

TRADEMARK2005

4-23

FUEL SYSTEM x 4FUEL

TRADEMARK2005

4-24

FUEL SYSTEM4 FUEL

TRADEMARK2005

4-25

FUEL SYSTEM x 4FUEL

TRADEMARK2005

5-215-215-225-22

TRADEMARK2005

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

Oil pump inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30Check valve inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30Oil strainer inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31Oil pump installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

REDUCTION DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

Drive coupling removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-36Drive shaft removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36Bearing removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36Oil pump driven gear inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37Drive shaft inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37Bearing installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38Drive shaft installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40Drive coupling installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

GENERATOR AND STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

Flywheel magneto removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46Starter clutch inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46Flywheel magneto installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

Camshaft removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55Camshaft inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56Camshaft sprockets inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58Timing chain tensioner inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58Camshaft installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59

TRADEMARK2005

5-635-635-635-655-655-655-66

5-685-685-685-705-705-715-715-725-735-755-765-78

5-805-805-805-855-855-865-865-87

5-905-905-905-925-925-935-945-965-975-99

TRADEMARK2005

5-1035-1035-1035-1045-1045-1045-107

5-1085-1085-1085-1105-1105-110

5-1115-1115-111

COOLING WATER HOSE ..............................................................................

TRADEMARK2005

POWER UNIT x 5POWR

5-1

TRADEMARK2005

5-2

ENGINE UNITEXPLODED DIAGRAM

POWER UNIT5 POWR

TRADEMARK2005

5-3

POWER UNIT x 5POWR

TRADEMARK2005

5-4

POWER UNIT5 POWR

CAUTION:

TRADEMARK2005

5-5

POWER UNIT x 5POWR

TRADEMARK2005

5-6

POWER UNIT5 POWR

CAUTION:

TRADEMARK2005

5-7

POWER UNIT x 5POWR

TRADEMARK2005

5-8

POWER UNIT5 POWR

TRADEMARK2005

5-9

POWER UNIT x 5POWR

EXHAUST PIPE 3 (Cont’d.)

TRADEMARK2005

5-10

POWER UNIT5 POWR

EXHAUST PIPE 3 (Cont’d.)

TRADEMARK2005

5-11

POWER UNIT x 5POWR

TRADEMARK2005

5-12

POWER UNIT5 POWR

EXHAUST PIPES 1 AND 2 (Cont’d.)

TRADEMARK2005

5-13

POWER UNIT x 5POWR

TRADEMARK2005

5-14

POWER UNIT5 POWR

EXHAUST MANIFOLD (Cont’d.)

TRADEMARK2005

5-15

POWER UNIT x 5POWR

TRADEMARK2005

5-16

POWER UNIT5 POWR

OIL TANK (Cont’d.)

TRADEMARK2005

5-17

POWER UNIT x 5POWR


TRADEMARK2005

5-18

POWER UNIT5 POWR


TRADEMARK2005

5-19

POWER UNIT x 5POWR


TRADEMARK2005

5-20

POWER UNIT5 POWR


TRADEMARK2005

5-21

POWER UNIT x 5POWR


TRADEMARK2005

5-22

POWER UNIT5 POWR


TRADEMARK2005

5-23

POWER UNIT x 5POWR


TRADEMARK2005

5-24

POWER UNIT5 POWR


TRADEMARK2005

5-25

POWER UNIT x 5POWR

TRADEMARK2005

5-26

POWER UNIT5 POWR

OIL PUMP (Cont’d.)

TRADEMARK2005

5-27

POWER UNIT x 5POWR


TRADEMARK2005

5-28

POWER UNIT5 POWR


TRADEMARK2005

5-29

POWER UNIT x 5POWR


TRADEMARK2005

5-30

POWER UNIT5 POWR


TRADEMARK2005

5-31

POWER UNIT x 5POWR


TRADEMARK2005

5-32

POWER UNIT5 POWR

TRADEMARK2005

5-33

POWER UNIT x 5POWR

REDUCTION DRIVE GEAR (Cont’d.)

TRADEMARK2005

5-34

POWER UNIT5 POWR


TRADEMARK2005

5-35

POWER UNIT x 5POWR


TRADEMARK2005

5-36

POWER UNIT5 POWR


TRADEMARK2005

5-37

POWER UNIT x 5POWR


Oil pump driven gear inspection

TRADEMARK2005

5-38

POWER UNIT5 POWR


TRADEMARK2005

5-39

POWER UNIT x 5POWR


TRADEMARK2005

5-40


POWER UNIT5 POWR

TRADEMARK2005

5-41

POWER UNIT x 5POWR

TRADEMARK2005

5-42

GENERATOR AND STARTER MOTOR (Cont’d.)

POWER UNIT5 POWR

TRADEMARK2005

5-43


POWER UNIT x 5POWR

TRADEMARK2005

5-44

POWER UNIT5 POWR


TRADEMARK2005

5-45

POWER UNIT x 5POWR


TRADEMARK2005

5-46

POWER UNIT5 POWR


TRADEMARK2005

5-47

POWER UNIT x 5POWR


TRADEMARK2005

5-48

POWER UNIT5 POWR


TRADEMARK2005

5-49

POWER UNIT x 5POWR

TRADEMARK2005

5-50

POWER UNIT5 POWR

CAMSHAFTS (Cont’d.)

TRADEMARK2005

5-51

POWER UNIT x 5POWR


TRADEMARK2005

5-52

POWER UNIT5 POWR


TRADEMARK2005

5-53

POWER UNIT x 5POWR


TRADEMARK2005

5-54

POWER UNIT5 POWR


TRADEMARK2005

5-55

POWER UNIT x 5POWR


TRADEMARK2005

5-56

POWER UNIT5 POWR


TRADEMARK2005

5-57

POWER UNIT x 5POWR


TRADEMARK2005

5-58

POWER UNIT5 POWR


TRADEMARK2005

5-59

POWER UNIT x 5POWR


TRADEMARK2005

5-60

POWER UNIT5 POWR


TRADEMARK2005

5-61

POWER UNIT x 5POWR


TRADEMARK2005

5-62

POWER UNIT5 POWR


TRADEMARK2005

5-63

POWER UNIT x 5POWR

Hanger

TRADEMARK2005

5-64

POWER UNIT5 POWR

CYLINDER HEAD

TRADEMARK2005

5-65

POWER UNIT x 5POWR

CYLINDER HEAD (Con’t.d)

TRADEMARK2005

5-66

POWER UNIT5 POWR

CYLINDER HEAD (Cont’d.)

TRADEMARK2005

5-67

POWER UNIT x 5POWR

CYLINDER HEAD (Cont’d.)

TRADEMARK2005

5-68

POWER UNIT5 POWR

TRADEMARK2005

5-69

POWER UNIT x 5POWR

VALVES AND VALVE SPRINGS

TRADEMARK2005

5-70

POWER UNIT5 POWR

VALVES AND VALVE SPRINGS (Cont’d.)

TRADEMARK2005

5-71

POWER UNIT x 5POWR


TRADEMARK2005

5-72

POWER UNIT5 POWR


TRADEMARK2005

5-73

POWER UNIT x 5POWR


TRADEMARK2005

5-74

POWER UNIT5 POWR


TRADEMARK2005

5-75

POWER UNIT x 5POWR


TRADEMARK2005

5-76

POWER UNIT5 POWR


TRADEMARK2005

5-77

POWER UNIT x 5POWR


TRADEMARK2005

5-78

POWER UNIT5 POWR


TRADEMARK2005

5-79

POWER UNIT x 5POWR


TRADEMARK2005

5-80

POWER UNIT5 POWR

TRADEMARK2005

5-81

POWER UNIT x 5POWR

CRANCASE (Cont’d.)

TRADEMARK2005

5-82

POWER UNIT5 POWR


TRADEMARK2005

5-83

POWER UNIT x 5POWR


TRADEMARK2005

5-84

POWER UNIT5 POWR


TRADEMARK2005

5-85

POWER UNIT x 5POWR

CAUTION:


TRADEMARK2005

5-86

POWER UNIT5 POWR


TRADEMARK2005

5-87

POWER UNIT x 5POWR


TRADEMARK2005

5-88

POWER UNIT5 POWR


TRADEMARK2005

5-89

POWER UNIT x 5POWR

CAUTION:CRANCASE (Cont’d.)

TRADEMARK2005

5-90

POWER UNIT5 POWR

CON

TRADEMARK2005

5-91

POWER UNIT x 5POWR

CONNECTING RODS AND PISTONS (Cont’d.)

TRADEMARK2005

5-92

POWER UNIT5 POWR


CAUTION:

TRADEMARK2005

5-93

POWER UNIT x 5POWR


TRADEMARK2005

5-94

POWER UNIT5 POWR


TRADEMARK2005

5-95

POWER UNIT x 5POWR


TRADEMARK2005

5-96

POWER UNIT5 POWR


TRADEMARK2005

5-97

POWER UNIT x 5POWR


CAUTION:

TRADEMARK2005

5-98

POWER UNIT5 POWR


TRADEMARK2005

5-99

POWER UNIT x 5POWR


TRADEMARK2005

5-100

POWER UNIT5 POWR


TRADEMARK2005

5-101

POWER UNIT x 5POWR


TRADEMARK2005

5-102

POWER UNIT5 POWR

CAUTION:


TRADEMARK2005

5-103

POWER UNIT x 5POWR

TRADEMARK2005

5-104

POWER UNIT5 POWR

CRANKSHAFT (Cont’d.)

TRADEMARK2005

5-105

POWER UNIT x 5POWR

CRANKSHAFT (Cont’d.) CAUTION:

TRADEMARK2005

5-106

POWER UNIT5 POWR


TRADEMARK2005

5-107

POWER UNIT x 5POWR


TRADEMARK2005

5-108

POWER UNIT5 POWR

TRADEMARK2005

5-109

POWER UNIT x 5POWR

THERMOSTAT (Cont’d.)

TRADEMARK2005

5-110

POWER UNIT5 POWR

THERMOSTAT (Cont’d.)

TRADEMARK2005

5-111

POWER UNIT x 5POWR

TRADEMARK2005

CHAPTER 6

JET PUMP UNIT

INTAKE GRATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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

PUMP UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3



REVERSE GATE AND DEFLECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4



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



JET PUMP CLEAN-OUT PORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6



INTERMEDIATE SHAFT AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7



SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-9

TRADEMARK2005

JET PUMP x 6

6-1

JETPUMP

INTAKE GRATINGEXPLODED DIAGRAM

LT

242

LT

2421

23

4

5

LT

242

Step Procedure / Part Name Q’ty (ea) Service PointsINTAKE GRATING Follow the left “Step” order for removal.REMOVAL

1 Screw 2 8 x 35mm2 Screw 4 8 x 20mm3 Intake Grating 2 Port and Starboard Units4 Screw 12 8 x 40mm5 Intake Duct 2 Port and Starboard Units

Reverse the removal steps for installation.NOTE: Apply clear silicone beforeinstalling a duct into the hull.


TRADEMARK2005

6-2

JET PUMP6 JETPUMP

Apply clear silicone as shown before installingDuct into hull. Install Duct and torque screws to15Nm (1.5m-kg, 11 ft-lb).

TRADEMARK2005

6-3

JET PUMP x 6JETPUMP

PUMP UNITEXPLODED DIAGRAM

Step Procedure / Part Name Q’ty (ea.) Service PointsPUMP UNIT REMOVAL Follow the “Step” order for removal.

1 Shift Cable Joint 12 Steering Cable Joint 13 Bolt (with washer) 44 Nozzle 1

1 NOTE:May be left on to remove pump as anassembly.

5 Dowel Pin 26 Duct w/Driveshaft and Impeller 17 Bolt (with washer) 4 10 x 40mm8 Dowel Pin 29 Impeller Housing Assembly 1



TRADEMARK2005

JET PUMP6 JETPUMP

Step Procedure / Part Name Q’ty (ea) Service PointsREVERSE GATE AND NOZZLE Follow the “Step” order for removal.DEFLECTOR REMOVAL

1 Bolt (with washer) 2 8 x 20mm2 Collar 23 Reverse Gate 14 Bolt (with washer) 2 8 x 20mm5 Collar 26 Nozzle Deflector 1

REVERSE GATEDISASSEMBLY

1 Bolt (with washer) 2 6 x 16mm2 Gate Control Arm 13 Bolt (with washer) 24 Collar 25 Swivel 1


REVERSE GATE AND DEFLECTOR EXPLODED DIAGRAM


6-4

TRADEMARK2005

6-5

JET PUMP x 6JETPUMP

IMPELLER AND DRIVE SHAFTEXPLODED DIAGRAM

Step Procedure / Part Name Q’ty (ea) Service PointsIMPELLER DUCT AND DRIVE Follow the “Step” order for removal.SHAFT ASSEMBLY

1 Impeller, Port 1 18.1° Pitch, 6P600, casting marks on hexLeft-hand threads

Impeller, Starboard 1 15.1° Pitch, 6P610, Left-hand threads2 Spacer 13 Bolt 34 Cap 1 Fill cap approximately 1/3 full with

EPNOC AP#0 or equivalent grease.5 O-ring 16 Nut 17 Washer 18 Drive shaft 19 Rear Bearing 1 Not reusable10 Spacer 111 Front Bearing 1 Not reusable12 Oil Seal 1 Not reusable13 Oil Seal 1 Not reusable14 Bolts 415 Cover, O-rings and filter 1



NOTE *1: EPNOC AP #0or equivalent

DISTINCT MARK(PORT IMPELLER)

PART NUMBER

PART NUMBER

STARBOARDIMPELLER

6P600

6P610

TRADEMARK2005

JET PUMP6 JETPUMP

6-6

JET PUMP CLEAN-OUT PORTSEXPLODED DIAGRAM


LT

242

Step Procedure / Part Name Qty (ea.) Service PointsJET PUMP CLEAN-OUT Follow the “Step” order for removal.TRAY REMOVAL

1 Inspection Cover 22 Clamp, Upper 2 Access top hose clamps through inner inspection holes,

loosen both top clamps to remove Clean-out Tray.Clamp screw heads must be on forward (bow side) of clean-out Hose and face center of boat (See A).

3 Screw #8 44 Rubber Cushion 45 Screw #10 146 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 clean-out port.

10 Packing 111 Drain Hose 112 Drain Hose Clamp 1 Lift Clean-out Tray to loosen drain hose clamp and

remove drain hose.13 Cap 2 Leave Caps in place unless jet pump clean out is

required.NOTE: Follow Cap removal and installation instructions in JET PUMP UNIT INSPECTION,” Chapter 3.

�

AA

TRADEMARK2005

JET PUMP x 6JETPUMP

6-7

TRADEMARK2005

JET PUMP6 JETPUMP

6-8

10

11

2

TRADEMARK2005

JET PUMP x 6JETPUMP

6-9

SERVICE POINTS

TRADEMARK2005

JET PUMP6 JETPUMP

6-10

TRADEMARK2005

x

CHAPTER 7

ELECTRICAL SYSTEM

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

ELECTRICAL BOX AND IGNITION COIL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

ELECTRICAL ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Digital Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9Low Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Peak Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10Peak Voltage Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11Test Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12IGNITION SPARK GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14IGNITION SYSTEM PEAK VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18ENGINE STOP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18ENGINE TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19INTAKE AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19THERMOSWITCH (ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20THERMOSWITCH (EXHAUST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20MAIN AND FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22CAM POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23NOISE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

FUEL CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28LOW FUEL LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29MAIN AND FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29THERMOSWITCH (ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

TRADEMARK2005

THERMOSWITCH (EXHAUST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31WIRING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Armature Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36Brush Holder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37Starter Motor Front cover Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39LIGHTING COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39RECTIFIER REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39

ELECTRIC BILGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40ELECTRIC BILGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

MAIN COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

SWITCH LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43

METER PANEL BACK VIEW - AR230 HO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44WIRING DIAGRAM - AR230 HO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

METER PANEL BACK VIEW SX230 HO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45WIRING DIAGRAM - SX230 HO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45

METER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46

SWITCH AND COMPONENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48PANEL SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49BILGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49

TRADEMARK2005

7-1

ELECTRICAL SYSTEM x 7ELEC

ELECTRICAL COMPONENTS

StereoSpeakerRunning Light

23

24

11

22

33

44

55

66

77

88

99

Bow lightFuel pumpsFuel 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

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7-2

ELECTRICAL SYSTEM7 ELEC

ELECTRICAL BOX AND IGNITION COIL BOXEXPLODED DIAGRAM

Step Procedure / Part Name Qty Service PointsELECTRICAL BOX REMOVAL Follow the left “Step” for removal.

1 Battery negative lead 12 Battery positive lead 13 Bolt 24 Battery hold down bracket 15 Battery 16 Battery tray 17 Nut 48 Washer 4


x

x

x

x

x

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7-3

ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)EXPLODED DIAGRAM


Step Procedure / Part Name Qty Service Points9 Bolt 410 Screw 411 Terminal cover 112 Gasket 1 Not reusable13 Screw 114 Starter motor lead 115 Bolt 316 Cover 1


x

x

x

x

x

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7-4


ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)EXPLODED DIAGRAM

Step Procedure / Part Name Q’ty Service Points17 Gasket 1 Not reusable18 Bolt 219 Ground led 220 Holder 121 Coupler 15 NOTE: Disconnect all couplers.



x

x

x

x

x

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7-5


ELECTRICAL BOX (Cont’d.)EXPLODED DIAGRAM

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7-6



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7-7



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7-8



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7-9



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7-10


ELECTRICAL ANALYSIS

• When measuring a resistance of 10Ω or less,the correct measurement value may not be dis-played due to the meter's internal resistance.

• Obtain the correct value by subtracting theinternal resistance of the meter from the dis-played measurement.

• Obtain the meter's internal resistance by con-necting the meter's leads directly together andreading the display.

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7-11


ELECTRICAL ANALYSIS (Cont’d.)

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7-12


ECMMain and fuel pump relayFuse (20A)BatteryEngine shut-off switchEngine stop swichStart switchThermoswitch (exhaust)Thermoswitch (engine)

Engine temperature sensorCam position sensorRectifier/regulatorLighting coilPickup coilSensor assembly(Intake air temperature,intake air pressure)Throttle position sensor

Spark plugIgnition coilOil pressure switchNoise filterNeutral switch

⁄1

⁄2

⁄3

⁄4

⁄5

⁄6

⁄7

⁄8

⁄9

⁄17

⁄18

⁄19

⁄20

⁄21

⁄10

⁄11

⁄12

⁄13

⁄14

⁄15

⁄16

FREEPUSH

W B

FREEPUSH

BrBW Br

B

R/B

P

W

Br

Br

Br

B

B

B

5

6

7

Br

OFF

ON

START

W

W

W

R/B

R/B

B WPUR

⁄1

⁄19

⁄17

⁄17

⁄17

⁄17

⁄18

⁄18

⁄18

⁄18

⁄15

⁄12

⁄8

⁄2

3

⁄4

⁄21

⁄9

⁄10

⁄11

⁄20

⁄14

⁄13

⁄14

⁄16

IGNITION SYSTEMWIRING DIAGRAM

TRADEMARK2005

7-13


ECMMain and fuel pump relayFuse (20A)BatteryFuel pumpThermoswitch (exhaust)Thermoswitch (engine)

Engine temperature sensorSensor asssemblyThrottle position sensorFuel injectorOil pressure switch

⁄1

⁄1

⁄2

⁄2

⁄3

⁄3

⁄4

⁄4

⁄5

⁄5

⁄6

⁄6

⁄7

⁄7

⁄8

⁄8

⁄9

⁄9

⁄10

⁄10

⁄11

⁄11

⁄11

⁄11

⁄11

⁄12

⁄12

IGNITION SYSTEM (Cont’d.)WIRING DIAGRAM

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7-14


IGNITION SYSTEM (Cont’d.)

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7-15



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7-16



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7-17



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7-18



Lanyard Clip White Black

Installed O O

Removed O O

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7-19



INTAKE AIR

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7-20



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7-21



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7-22



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7-23



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7-24



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7-25


FUEL CONTROL SYSTEMWIRING DIAGRAM

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7-26


FUEL CONTROL SYSTEM (Cont’d.)WIRING DIAGRAM

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7-27


FUEL CONTROL SYSTEM (Cont’d.)

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7-28


12VDC

PURPLE

BLACK

PINK

Black

Jumper Leads

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7-29


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7-30


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7-31


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7-32


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7-33


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7-34


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7-35


STARTER MOTOR (Cont’d.)

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7-36


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7-37


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7-38


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7-39


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7-40


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7-41


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7-42


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7-43


TRADEMARK2005

METER PANEL BACK VIEW (AR230 HO) - WIRING DIAGRAM

7-44


1 Starboard Tach2 Speedometer

3 Port Tach4 Fuel Gauge

1122

33

44

TRADEMARK2005

7-45


METER PANEL BACK VIEW (SX230 HO) - WIRING DIAGRAM

1 Starboard Tach2 Speedometer

3 Port Tach4 Fuel Gauge

1122

33

44

TRADEMARK2005

7-46


Step Procedure / Part Name Qty (ea.) Service PointsMETER PANEL DISASSEMBLY Follow the “Step” order for removal.

1 Nut 22 Key Switch 23 Screw 4 20-3/4 x 2”4 Meter Panel 15 Speedometer 16 Fuel Gauge 17 Tachometer 18 Depth Sounder 19 Nut 710 Breaker 711 Nut and Washer 212 Screw 2 6-32 x 1”13 Controller, Stereo 1



METER PANEL EXPLODED DIAGRAM

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7-47


SWITCH AND COMPONENTWIRING DIAGRAM

14

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7-48


TRADEMARK2005

7-49


NOTE: The horn switch and no-wake switcheshave no light.

TRADEMARK2005

CHAPTER 8

HULL AND DECK

ENGINE COMPARTMENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1


VENTILATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2



COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4



STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6



REMOTE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8



SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

THROTTLE/SHIFT CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

INSTALL REVERSE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

ENGINE HATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

HATCH FITTINGS/BOW COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14



SEAT FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16



DECK FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18



THROUGH HULL AND DRAIN FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24



TRADEMARK2005

GUNWALE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26



HULL CONSTRUCTION AND CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

WHAT IS FRP? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

CHARACTERISTICS OF FRP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

MAINTENANCE OF FRP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

TRADEMARK2005

HULL AND DECK x 8HULLDECK

ENGINE COMPARTMENT LAYOUTEXPLODED DIAGRAM

1

2

3

4

5

6

7

1. Engine 5. Battery2. Water Lock 6. Blowers3. Jet Pump 7. Bilge Pump4. Fuel Tank

8-1

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8-2

HULL AND DECK 8 HULLDECK

VENTILATION SYSTEM EXPLODED DIAGRAM

TRADEMARK2005

8-3

Step Procedure / Part Name Q’ty Service PointsVENTILATION SYSTEM Follow the “Step” order for removal.DISASSEMBLY

1 Hose Clamp 11 Snap type2 Screw, Oval Head Tapping 283 Ventilator (White) 54 Ventilator (Black) 25 Hose, Ventilation 3 Intake 36”6 Hose, Ventilation 2 Exhaust 24”7 Hose, Ventilation 18 Screw, Truss Head Tapping 49 Blower Assembly 210 Ventilator 211 Band 412 Hose, Ventilation 2 213 Joint, Drain 214 Clamp, Cable 5




TRADEMARK2005

8-4


COOLING SYSTEMEXPLODED DIAGRAM

28 28

2929

30

27

27

30

25

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8-5

Step Procedure / Part Name Q’ty Service PointsCOOLING SYSTEM ANDWATER LOCK REMOVAL Follow the “Step” order for removal.

1 Band, Hose 18 22 Clip 23 Hose 1 24 Joint, Hose 1 25 Clip 26 Nut 27 Cap, 1 28 Joint Assy 29 Band, Hose 18 210 Clip 211 Hose (L=1250) 212 Clip 213 Band, Hose 18 214 Hose (L=900) 215 Floor, Drain 2 Apply clear silicone around the flange of

the fitting.16 Clip 217 Housing, Thermostat 218 Band, Hose 6 Oetiker type clamps.19 Hose 8 220 Joint, Pipe 2 Straight connector for Port pilot water hose.21 Clip 222 Hose 2 STARBOARD hose is shortened to fit.23 Nut, M14-1.5mm 424 Pilot, Water 4 Apply clear silicone around the flange of

the water pilots.25 Band, Hose 1 Located in engine compartment26 Clean-out Tray Assembly 1 See pg. 6-6 “Jet Pump Clean-out

Tray RemovaL27 Band, Hose 228 Hose, Exhaust Outlet 129 Strap 230 Water Lock 1 Apply soapy water to inside of hose ends

on reassembly so that hoses seatcompletely on Water Lock



TRADEMARK2005

8-6

STEERING SYSTEMEXPLODED DIAGRAM


123

4

13

A

A

A

SS

SS

11

12

1 2 3

4

5

6

7

8

9

10

NOTE: See REMOVAL AND INSTALLATION CHARTon next page for torque specs and locking agentinstructions.

TRADEMARK2005

8-7

Step Procedure / Part Name Q’ty Service PointsSTEERING HELM REMOVAL Follow the “Step” order for removal.

1 Cover 12 Nut 1 1/2"-13, Nylon lock, 18 Nm (1.8 m-kg, 13 ft-lb)3 Washer 1 1/2"4 Steering Wheel 15 Key 16 Boot 17 Screw 2 #8 x 1", 1.8 Nm (0.18 m-kg, 1.3 ft-lb)8 Helm, Bezel 19 Screw, socket head 1 3/16"-24 x 1", LT 24210 Screw 211 Steering Pivot 112 Nut 1 3/8" Nylon lock, 20 Nm (2.0 m-kg, 14 ft-lb)13 Washer 3/8"14 Bolt 115 Bearing 116 Bolt, Shoulder 1 1/4"-20, shoulder bolt, 6.4 Nm (0.64 m-kg, 4.6 ft-lb)17 Bearing 118 Bolt 3 1/4"-20, 14 Nm (1.4 m-kg, 10 ft-lb), LT 24219 Washer 320 Steering Master 121 Nut 3 1/4"-20 Nylon lock, 7 Nm (0.7 m-kg, 5 ft-lb)22 Washer 3 1/4" fender23 Hex Head Bolt 3 1/4"-2024 Steering Mount 1

STEERING CABLE1 Nut w/Washer 2 12 Nm (1.2 m-kg, 8.7 ft-lb), LT 2422 Block, Pivot Arm 13 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-kg, 24 ft-lb),1 drop LT 242 on threads

6 Washer 4 Seal with Silicone sealer on inside of hull7 Clip 2 3.5 Nm (0.35 m-kg, 2.5 ft-lb)8 Washer 29 Pin 2

Bushing, Nylon 4Nut 2 17 Nm (1.7 m-kg, 12 ft-lb)Steering Clevis 2Steering Cables 2




10

11

12

13

TRADEMARK2005

8-8


REMOTE CONTROL SYSTEMEXPLODED DIAGRAM

Step Procedure / Part Name Qty Service PointsREMOTE CONTROL UNIT Follow the “Step” order for removal.REMOVAL

1 SCREW 4 M4-0.7 X 10 mm, 2 Nm (0.2 kgf-m, 0.4 ft-lb)2 COVER 13 SCREW 4 #10-24 X 1" PPH, 4 Nm (0.4 kgf-m, 0.9 ft-lb)4 REMOCON ASSY 1 Lift from deck for access to wire and cable

connections.5 NEUTRAL SWITCH ASSY 26 NUT 1 M5-0.8 HH, 4 Nm (0.4 kgf-m, 0.9 ft-lb)7 SCREW 3 M5-0.8 X 55 mm8 SCREW 3 M5-0.8 X 10 mm9 BACK PLATE 210 CIRCLIP 411 THROTTLE CABLE 2 Remove air cleaner top to access throttle cable

ends.12 REVERSE CABLE 213 EYELET 414 JOINT, BALL 215 CONNECTOR CABLE 216 BOLT 4 M6-1.5 X 18 mm, 6.4 Nm (0.65 kgf-m, 1.4 ft-lb)17 PLATE (THROTTLE) 218 PACKING, CABLE 219 NUT, SELF LOCKING 4 #10-24 NYLON LOCK, 2 Nm (0.2 kgf-m, 0.4 ft-lb)20 WASHER, PLAIN 4 #10 FLAT21 SCREW 4 #10-24 X 1 1/4" PFH22 PLATE (SHIFTER) 2



TRADEMARK2005

8-9


SERVICE POINTS

Throttle/ Shift Cable Installation

Install Cables into Remote Control1. Remove:

• Four screws holding the remote controlunit cover.

• Four screws holding the remote control unit to the deck.

• Lift the remote control unit.• Disassemble remote control unit.

2. Set:• Remote Control levers in Neutral posi-

tion.3. Install:

• Cables joints 1 onto each cable so there is 11mm (0.44 in.) of thread engagement on the cable ends - see Detail A.

4. Tighten:• Cable Joint lock nuts 2.

2.9 Nm (0.3 kgf-m, 2.2 ft-lb)5. Install:

• Reverse cable 3 onto Shift Arm pin and into the housing clamp so that the groove in the outer cable fits into the ridge in the housing clamp 4.

• Insert Throttle cable 5 in same man-ner.

• Secure Cable joints to the Shift and Throttle arm pins with circlip 6.

6. Assemble:• Backplate 7 and screws 8.• Remote Control assembly 9 with

screws and bolt/ nut .3.9 Nm (0.4 kgf-m, 2.9 ft-lb)

7. Install:• Remote Control Assembly in boat deck.

4.4 Nm (0.45 kgf-m, 3.3 ft-lb)8. Install:

• Remote Control cover.1.9 Nm (0.2 kgf-m, 1.4 ft-lb)

10

DETAIL A

TRADEMARK2005

8-10


Install Throttle Cables

1. Remove:• Air box cover.

2. Install:• Pass Throttle Cable through the Plate

Throttle, Packing Cable and Air box fit-ting.

• Throttle cable end into the Cable Wheel on throttle body assembly.

• Throttle cable adjuster into Bracket.3. Tighten:

• Plate, Throttle Bolts:6.4 Nm (0.65 kgf-m, 4.7 ft-lb)

4. Adjust:• Throttle cable adjustment per the steps

in Chapter 3 - Periodic Inspection and Adjustment.

CABLEWHEEL

THROTTLE CABLE

BRACKET

PACKINGCABLE

PLATETHROTTLE

BOLT

TRADEMARK2005

8-11


Install Reverse Cables

1. Install:• Ball Joints onto shift cable ends making

sure the joint has at least 8mm (0.31 in.) of thread engagement on the shift cable 1.

2. Tighten:• Ball Joint lock nut 2.

2.8 Nm (0.29 kgf-m, 2.1 ft-lb)3. Adjust:

• Shift cable per the steps in Chapter 3 - Periodic Inspection and Adjustment.

8mm (0.31 in.)

11

TRADEMARK2005

8-12


ENGINE HATCHEXPLODED DIAGRAM

TRADEMARK2005

8-13

Step Procedure / Part Name Q’ty Service PointsENGINE HATCH REMOVAL Follow the “Step” order for removal.AND DISASSEMBLY

1 Support, Engine Hatch 2 Support Hatch Lid before removal.2 Nut, #10-24 Nylon Lock 43 Washer, 310 Fender 3/4” O.D. 44 Screw #10-24 x 1” 45 Bracket, Support 26 Nut, 1/4-20 Nylon Lock 67 Washer, Fender 1/4” 68 Screw 1/4-20 x 1-3/4” 69 Engine Hatch Assembly 110 Nut, 1/4-20 Nylon Lock 611 Washer, Fender 1/4” 612 Screw 1/4-20 x 1-3/4” 613 Hinge, Engine Hatch 214 Nut, #10-24 Nylon Lock 615 Washer, #10 Fender 3/4” O.D. 616 Screw, #10-20 x 2.5” 617 Base, hatch Support 218 Nut, 1/4-20 Nylon Lock 419 Washer, 1/4” 420 Screw, 1/4-20 x 1-3/4” 421 Seat Lock Assembly 222 Nut, #10-24 Nylon Lock 223 Washer, 7/16” Fender 1-1/2” O.D. 424 Washer, Special Cotton 225 Pin 2




TRADEMARK2005

8-14

HATCH FITTINGS/BOW COVEREXPLODED DIAGRAM


TRADEMARK2005

8-15

Step Procedure / Part Name Q’ty Service PointsBOW LOCKER Follow the “Step”DISASSEMBLY order for removal.

1 Screw, Tapping 16 #8 x 5/8”2 Hinge 13 Hatch 14 Screw, Machine 25 Latch 16 Screw, Tapping 27 Catch 18 Screw 2 #8 x 3/4”9 Cushion 210 Screw 1 #10 x 1/2”11 Screw 1 #8 x 3/4”12 Hatch Support 1 Twist one turn

when re-attaching13 Screw 614 Anchor Retainer Bracket 215 Anchor Retainer 2

BI-FOLD DOOR

16 Screw 28 #6 X 3/4”17 Hinge 118 Bi-Fold Door Assembly 119 Screw 4 #8 x 5/8”20 Catch 321 Screw 5 #8 x 3/4”22 U-Channel 123 Edge Guard 1/2” x 3/8” 1 Re-install with hot

melt adhesiveSTARBOARDCONSOLE DOOR

24 Screw 10 #8 X 5/8”25 Door Assembly, Console 1

SKI LOCKER HATCH

26 Screw 627 Support, Ski Hatch 128 Screw 12 #8 x 3/4”29 Hinge 230 Hatch Assem., Ski Hatch 131 Screw, Machine 232 Latch 133 Screw 2 #8 x 5/8”34 Catch 135 Screw 5 #8 x 3/4”36 Cushion 5



Step Procedure / Part Name Q’ty Service PointsGLOVEBOX HATCH

37 Screw 3 #10 X 3/4”38 Nut 3 10-2439 Glovebox Hatch Assem. 1

FUEL HATCH

40 Screw 12 #8 x 3/8”41 Hinge, Fuel Hatch 242 Nut, Nylon Lock 2 #10-2443 Washer, Flat 2 #1044 Screw 2 10-24 x 1-1/4”45 Catch 146 Screw, Machine 247 Latch 248 Seal, Fuel Hatch 149 Hatch, Fuel Hatch 1

STERN LOCKERHATCHES

50 Support, Locker hatch 251 Screw 4 #10 x 1/2”52 Bracket 253 Screw, Machine 454 Lock Assembly 255 Nut, Nylon Lock 4 #10-2456 Washer, Flat 4 #10 7/16” O.D.57 Catch 258 Screw 2 #10-24x1.0”59 Nut, Nylon Lock 2 1/4-2060 Washer, Flat 2 1/4-Flat61 Screw 2 1/4-20x1”62 Bracket 563 Screw, #10-24 x 1.5” 1 Starboard only64 Screw 6 #10 x 3/4”65 Hinge,Stern

Locker Hatch 266 Packing, 4 2

CLEANOUT HATCH

67 Hatch 168 Screw 14 #10 x 1/2”69 Screw 12 #10 x 3/4”70 Hinge, Cleanout Hatch 171 Machine Screw 272 Lock Asembly 173 Hatch, Cleanout 1

Reverse theremoval stepsfor installation.

TRADEMARK2005

8-16


SEAT FITTINGSEXPLODED DIAGRAM

TRADEMARK2005

8-17


Step Procedure / Part Name Q’ty Service PointsSEAT FITTING DISASSEMBLY Follow the “Step” order for removal.

DRIVER’S BUCKET SEATS

1 Screw, 1/4-20 x 1/2" 82 Washer, Flat 1/4 x 1" Fender 83 Driver Seat Assembly 24 Seat Slider 25 Screw, 1/4-20 x 1 1/4" 126 Pedestal Base 2

BOW SEATS

7 Seat Cushions 38 Nut 1/4-20 24 Access nuts through under seat storage9 Washer, Flat 1/4 x 1 1/2" Fender 2410 Bow Seat Backrests 3 Lift backrests off mounting clips

MIDSHIP SEATING

11 Seat Cushions 212 Nut 1/4-20 4 Access nuts through under seat storage13 Washer, Flat 1/4 x 1 1/2" Fender 414 Seat Backrests 2 Lift backrests off mounting clips

ENGINE HATCH SEATS

15 Nut 1/4-20 4 Open engine hatch16 Lock Washer 1/4-20 417 Washer, Flat 1/4 x 1 1/2" Fender 418 Seat Cushions 319 Nut 1/4-20 420 Lock Washer 1/4-20 421 Washer, Flat 1/4 x 1 1/2" Fender 422 Backrest 223 Screw, Tapping 824 Hinge 125 Folding Backrest 1

SWIM PLATFORM PADS

26 Nut 1/4-20 18 Access nuts through stern port and27 Washer, Flat 1/4 x 1 1/2" Fender 18 starboard hatch inspection covers28 Backrest Pads 4



TRADEMARK2005

DECK FITTINGSEXPLODED DIAGRAM


8-18

TRADEMARK2005

8-19

Step Procedure / Part Name Q’ty Service PointsSTERN LIGHT Follow the “Step” order for removal.

1 Stern Light Assembly 12 Lens 13 Bulb 1 ML1004 obtain locally4 Screw, Tapping 35 Socket Assembly 16 Collar (Shim) 1 Position so that Stern Light angles towards stern.

BOW LIGHT7 Screw, Tapping 18 Cover 19 Lens 110 Bulb 1 Festoon 12V 8W, obtain locally11 Screw 312 Socket Assembly 1

DECK FITTINGS13 Screw, #8 X 3/4” 414 Handle, Grip 1 Apply silicone sealer to mounting holes15 Nut, 5/16-18 12 LT242,Torque 13 Nm (1.35m-kg. 9.5ft-lb)16 Washer, Lock 5/16” 1217 Washer, Flat 5/16” 1218 Cleat 6 Silicone sealer in cleat mount holes.19 Nut, 5/16-18 4 LT242, Torque 13Nm (1.35m-kg, 9.5 ft-lb)20 Washer, Lock 5/16” 421 Washer, Flat 5/16” 422 Rail, Hand (Bow) 223 Nut, 5/16-18 4 LT242, Torque 13Nm (1.35m-kg, 9.5ft-lb)24 Washer, Lock 5/16” 425 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 washersare 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 4 LT242, Torque 17Nm (1.7 m-kg, 12 ft-lb)28 Washer, M8 Flat 429 Ladder, Transom 130 Screw (w/ nut & washer) 1 Attaches Band to Ladder31 Band 132 Screw, #8 x 5/8” PPH 133 Clamp 134 Clamp, Cable

(Tiewrap, 6”) 135 Tube (Speedometer) 136 Screw, #8 X 3/4” PPH 337 Speedometer Sensor 1 Silicone sealer on back side of speedo sensor and in

the 3 mounting holes in hull38 Bow and Stern Eyes 3 Torque 15Nm (1.5m-kg, 11 ft-lb)

(w/ nuts and plates) Apply silicone sealer to mounting surfaces.



TRADEMARK2005

8-20


DECK FITTINGS (Continued)EXPLODED DIAGRAM

Step Procedure / Part Name Q’ty Service PointsTABLE

39 Table 140 Stanchion (Table Post)

Short, Swim Deck 1 330mm, 13 in41 Stanchion (Table Post)

Long, Cockpit 1 622mm, 24.5 in42 Screw 1/4-20 x 1-3/4”

POH 1243 Nut, 1/4-20 Nylon Lock 12 Torque 8Nm (0.8m-kg, 6 ft-lb)44 Washer, 1/4” x 1” OD

Fender 1245 Table Mount 2 Silicon sealer around bolt holes and mount opening in

deck.ANCHOR ROPERETAINER

46 Screw, #10 X 1-1/2”POH 6

47 Bracket 2

TRADEMARK2005

8-21

REMOVAL AND INSTALLATION CHART (Continued)


Step Procedure / Part Name Q’ty Service PointsBIMINI TOP BRACKETS

48 Nut, 10-24 Nylon Lock 8 Torque 4Nm (0.4m-kg, 3 ft-lb)49 Washer, 10 x 3/4” OD 850 Screw, 10-24 x 1-1/2”

POH 451 Bracket, Awning (front) 252 Screw, 10-24 x 1” POH 453 Bracket, Awning 2 (rear) 254 Nut, #8-32 Nylon Lock 4 Torque 3Nm (0.3m-kg, 2 ft-lb)55 Washer, #10 x 3/4” OD 456 Screw, #8-32 x 1” POH 457 Eye, Strap 2

TRADEMARK2005

8-22

DECK FITTINGS (Continued)EXPLODED DIAGRAM


TRADEMARK2005

8-23


REMOVAL AND INSTALLATION CHART (Continued)

Step Procedure / Part Name Q’ty Service PointsWINDSHIELD

58 Nut, 10-24 Nylon Lock 4 Torque 4Nm (0.4m-kg, 3 ft-lb)59 Washer, #10 Flat 460 Screw, 10-24 x 2” PPH 461 Screw, #8 x 3/8” PPH-

Type B 462 Windshield Brace 263 Windshield Trim Remove to access screws64 Screw, #8 x 3/4” POH 1465 Nut, 8-32 Nylon Lock 8 Torque 3Nm (0.3m-kg, 2 ft-lb)66 Washer, #8 Flat 867 Screw, 8-32 x 2” POH 268 Screw, 8-32 x 1-1/2 POH 669 Windshield Assembly 170 Pad, Windshield 171 Windshield Tie-down 1

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8-24

THROUGH HULL AND DRAIN FITTINGSEXPLODED DIAGRAM


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8-25

Step Procedure / Part Name Q’ty Service PointsTHROUGH HULL AND DRAIN Follow the “Step” order for removal.FITTINGS

1 Drain Plug 1 Apply silicone to the drain plug assy flange.2 Screw #8 x 3/4 POH 33 Clamp, Hose 2 (SAE #24) 14 Cockpit Drain 15 Scupper Drain for Cockpit 1 Apply clear silicone to the base.6 Pipe, Bilge (Hose, 1 1/2" X 72") 17 Clamp, Hose 2 (SAE #24) 18 Ski Hatch Drain 1 Apply clear silicone to the base.9 5/16" Worm Gear Clamp 1210 Hose, Drain 211 Thru Hull Fitting 1 Apply clear silicone to the base.12 Hose, Drain 113 Joint Drain - Y Fitting 114 Fuel Tank Compartment Drain 1 Apply clear silicone to the base.15 Hose, Drain 116 Cleanout Tray Drain 1 Apply clear silicone to the base.17 Hose, Drain 118 Hose, Drain 119 Drain Outlet 1 Apply clear silicone to the base.20 Clamp, Cable (Tiewrap 8") 821 Screw, #8 x 5/8" PPH 822 Drink Holder 723 Bilge Pump 124 5/16" Worm Gear Clamp 225 Bilge Outlet 1 Apply clear silicone to the base.26 Hose,1 (3/4" x 48" Bilge Hose) 127 Screw, #10 x 1/2 PPH 228 3/4" Through Hull (90°) 2 Apply clear silicone to the base.29 5/16" Worm Gear Clamp 230 Hose, Drain, 23.75" 1 Ice box drain.



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8-26

GUNWALEEXPLODED DIAGRAM

12

3

4

5

Step Procedure / Part Name Q’ty Service PointsGUNWALE Follow the “Step” order for removal.

1 Screw, 310 x 2” POH 2 Torque 2 Nm (0.2m-kg, 1.5 ft-lb)2 Cover, rub Rail Joint 1 Before installing, 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 orlow 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.



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8-27


HULL CONSTRUCTIONAND CAREThe SRT1100 hull is built of a material calledFRP. This is then finished with a very hardproduct called gelcoat to protect the fiberglassand provide a durable finish.

WHAT IS FRP?

FRP stands for Fiberglass Reinforced Plastic.It is a composite material in which a fiberglassreinforcement material such as chopped strandmat (mat) and/or a woven fabric (cloth) isimpregnated with a catalyzed polyester resinand allowed to cure into a rigid state. Also,included in this definition are fabrics impregnat-ed with epoxy resins and hardeners.

CHARACTERISTICS OF FRP

FRP has the following characteristics:

1. High strength yet light-weight2. Excellent malleability3. Corrosion free4. Easy to care for and easy to repair. On the

other hand, it is liable to get scratched andis vulnerable to shocks and, therefore, mustbe handled with care.NOTE: Should any of the FRP or Gelcoatrequire repair, refer to the Basic Hull RepairVideo and Workbook (VID-10660-00-43).

MAINTENANCE OF FRP

Routine care is important for FRP as it helps inmaintaining the high luster. During mainte-nance, any damage to the FRP can be detect-ed early so repairs can be easily accomplishedensuring long service life.

After use, wash down the hull with fresh water.Wax the hull with a non-abrasive wax such asYamaha Ultra-gloss Cleaner Wax or other waxdesigned for marine gelcoat.

Take the following additional steps when nec-essary:

1. Maintenance of lusterThe gelcoat layer is 0.3 to 0.5mm (0.12 to0.20 in) thick. When it has faded or has lostits luster, the original luster can be restoredby 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 arag and compound.

c. After polishing, apply several coats of agood marine wax, allowing each coat todry prior to buffing and applying thenext coat.

2. Fading and discolorationHow to clean:a. Fading may require the use of a heavy

duty rubbing compound and subse-quent polishing to restore the original gelcoat luster. If this does not work, seeitem “d” below.

b. Discoloration due to oil stains, fuelstains, or environmental factors may beremoved with detergents or industrialsolvents if needed. A rag or sponge moistened with acetone may also help.However, avoid excessive exposure of gelcoat to acetone as the surface may become permanently damaged.

c. Marine growth can be scraped off usingsharpened wooden sticks. Avoid metalputty knives, etc. as they will tend to scratch the gelcoat.

d. If all else fails, use a wet/dry sandpaperto color sand the gelcoat down to consistent color. Use extreme care astoo much sanding will remove all thegelcoat and new gelcoat will have to beapplied. Start with #600 grit and endwith #1200 to #1500 grit with lots ofwater. For best results, final sandingshould always be in the same direc-tions (e.g., back and forth). Follow with polishing procedures given above.

e. If none of the above helps, it is time tore-gelcoat.

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TROUBLE ANALYSIS x 9TRBLANLS

WINDOWS® 95, WINDOWS® 98, WINDOWS® ME,WINDOWS® 2000,® OR WINDOWS® XP .......................................... 9-3UPDATING THE DATABASE ............................................................ 9-7

ENGINE MONITOR.................................................................................... 9-26Operating procedure............................................................................ 9-27

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Operating procedure............................................................................ 9-41Data display item selection.................................................................. 9-42Operating procedure............................................................................ 9-42

YDIS ERROR CODE CHART .................................................................... 9-56

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9-1


If this software is run on Microsoft Windows®

95, Windows®

98, Windows®

Me, Windows®

2000, orWindows

®XP, the information can be displayed in colorful graphics. Also, the software can be operated

using either a mouse or a keyboard.

1 2 3 4 5

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9-2

TROUBLE ANALYSIS9 TRBLANLS

Make sure your computer meets the following requirements before using this software.

RS232C (Dsub-9 pin) port, USB portj

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9-3

INSTALLING THE YAMAHA DIAGNOSTIC SYSTEM UNDER WINDOWS 95,WINDOWS 98, WINDOWS ME, WINDOWS 2000, OR WINDOWS XP

9-2.

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9-4


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9-5


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9-6


Install the Database file before using the Yamaha Diagnostic System, otherwise, the program will notoperate correctly. For installation procedures, refer to “UPDATING THE DATABASE” on the next page.

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9-7


After about three seconds, the display will automatically go to the first menu display, or you can clickor press any key to go to the first menu. (See fig. 12.)

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9-8


Do not click the Starting service tool [Enter] button or press the Enter key on your keyboard untilthe database has been updated, otherwise, the program will not operate correctly.

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9-9


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9-10


When the database is updated, a confirmation screen is displayed.

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9-11


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9-12


12

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9-13


Open the Yamaha Diagnostic System window. (Fig. 20) After about three seconds, the display willautomatically go to the first menu, or click or press any key to go to the first menu. (See fig. 21.)

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9-14


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9-15


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9-16


Eight commands appear in the main Menu. Select a command in any of the following three ways:

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9-17


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9-18


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9-19


top.

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9-20


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9-21


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9-22


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9-23


.

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9-24


Check that the items deleted are normal in the Diagnosis Record. If the items remain irregular, theywill appear as irregular in the Diagnosis Record. Even if you try to delete them, they are undeletable.

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9-25


Click the OK button or press the Enter key on your keyboard (Fig. 35): The selected item is deleted. Tocancel deleting the item, click the Cancel button or press the Esc key on your keyboard.

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9-26


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.

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9-27


in the scroll bar or press the up or down

(Fig. 38).keyboard

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9-28


Avoid clicking the Execute and Cancel buttons repeatedly, otherwise, the ECM or PC will notwork properly and they could be damaged.

item.test.

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9-29


keys on your keyboard (Fig. 39).

(Spark Gap Tester YM-34487/90890-06754) is needed.

keyboard (Fig. 39).

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9-30


keyboard (Fig. 42).

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9-31


If the engine is 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).

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9-32


selected (Fig. 46).

displayed (Fig. 47).

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9-33


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).

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9-34


keyboard (Fig. 49).

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9-35


selected (Fig. 51).

Do not test the same cylinder three or more times, otherwise, the spark plug insulator could bedamaged.

Make sure there is fuel in the fuel tank, otherwise, an error will occur and the test cannot be performed.

CAUTION:

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9-36


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.

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9-37


keyboard (Fig. 53).

selected (Fig. 54).

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9-38


Avoid clicking the Execute and Cancel buttons repeatedly, otherwise, the ECM or PC will notwork properly and they could be damaged.

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9-39


For the first ten seconds, operate all four cylinders, then stop one cylinder for five seconds. For the lastfive seconds, operate all four cylinders.

keyboard (Fig. 55).

keyboard (Fig. 55).

keyboard (Fig. 56).

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9-40


If the engine is not running, an error message is displayed. Follow the instructions that appear (Fig. 57).


appear (Fig. 58).

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9-41


board (Fig. 59).

Press the Enter key on your keyboard. The window of the selected item is displayed(Fig. 59).

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9-42


bar (Fig. 60).

displayed (See fig. 61).

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9-43


axis (Fig. 61).

value at the time the Enter key on your keyboard was pressed in the Monitor item selection.

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9-44


(Fig. 62).

Although the engine is running, the displayed time refers to the added hours until the Data loggerstarts.

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9-45



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9-46


(Fig. 65).

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9-47


Programs (Fig. 66).

(Fig. 67).

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9-48


button (see Figs. 68~70).

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9-49


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9-50


test,

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9-51


Display (Fig. 73).

slider (Fig. 74).

.

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9-52


button (see Figs. 75~76).

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9-53


consulted:

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9-54


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9-55


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9-56


YDIS Error Code Chart

When a flashing Check Engine signal is dis-played you should connect the YamahaDiagnostic System to the affected engine inorder to identify the cause. YDIS is capable ofdetecting the cause and indicating one or mul-tiple codes for a variety of problems. Codesand other running data can be saved anddownloaded for further troubleshooting.

NOTE: At the time of this publication it is rec-ommended that YDIS versions 1.23 or later beused with the boats covered in this manual.

Please check for newer versions of the YDISsoftware.

NOTE: For complete Instructions on use of theYamaha Diagnostic System, see the SR230Service Manual LIT-18616-02-52, Chapter 9.

1020

3035

40 4550

55

60

1

2

34

5 67

89

1011

RPMx 1000

MPH

1

2

34

5 67

89

1011

RPMx 1000

Code Symptom

01 No malfunction

13 Incorrect pickup coil signal

15 Incorrect engine temp sensor signal

18 Incorrect throttle position sensor signal

19 Incorrect battery voltage

23 Incorrect intake air temperature sensor signal

24 Incorrect cam position sensor signal

29 Incorrect intake air pressure sensor signal

48 Incorrect data transmission

54 Incorrect bypass valve motor signal

63 Incorrect intake air system signal

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LIT-18616-02-89

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Documents

Yamaha 2006 Service Manual Ar230