Service Manual 2004 - SR230 PDF
Service Manual 2004 - SR230 PDF
Service Manual 2004 - SR230 PDF
Service Manual
2004
x
PREFACE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It is not
possible to put an entire mechanic’s education into one manual, so it is assumed that persons using
this book to perform maintenance and repairs on Yamaha machines have a basic understanding of
the mechanical concepts and procedures inherent in machine repair technology. Without such
knowledge, 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 detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
SR230
SRT1000-B/BC Service Manual - 2003
First Edition
©2003 by Yamaha Motor Corporation, U.S.A.
July 2003
Printed in U.S.A.
In this revised format, the condition of a faulty component will precede an arrow symbol and the
course 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
at the head of every page.
THE ILLUSTRATIONS
Some illustrations in this manual may differ from the model you have. This is because a procedure
described may relate to several models, though only one may be illustrated. (The name of model
described will be mentioned in the description).
REFERENCES
These have been kept to a minimum, however, when you are referred to another section of the man-
ual, you are told the page number.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the jet boat.
CAUTION:
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.
HOW TO READ DESCRIPTIONS
1. A disassembly/installation job instruction mainly consists of the exploded diagram 1.
2. The numerical figures represented by the number 2 indicates the order of the job steps.
3. The symbols represented by the number 3 indicates the contents and notes of the job.
4. The REMOVAL AND INSTALLATION CHART 4 is attached to the exploded diagram and
explains the job steps, part names, notes for the jobs, etc.
5. The SERVICE POINTS, other than the exploded diagram, explains in detail the items difficult to
explain in the exploded diagram of REMOVAL AND INSTALLATION CHART, the Service Points
requiring the detailed description 5, etc.
SYMBOLS
Symbols 1 to 9 are designed as thumb-tabs
to indicate the content of a chapter:
1 General Information
2 Specifications
3 Periodic Inspection and Adjustment
4 Fuel System
5 Power Unit
6 Jet Pump Unit
7 Electrical System
8 Hull and Deck
9 Trouble Analysis
NOTE: ______________________________
In this manual, the above symbols may not be
used in every case.
567
INDEX
SPEC SPECIFICATIONS 2
HULL
DECK
HULL AND DECK 8
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION NUMBERS
PRIMARY I.D. NUMBER
The primary I.D. number is stamped on a label
attached to the deck under the rear seat.
F1C-700101~
6B5: 700101~
1-1
1 GEN
INFO GENERAL INFORMATION
FIRE PREVENTION
Gasoline (petrol) is highly flammable.
Petroleum vapor is explosive if ignited. Do not
smoke while handling gasoline (petrol), and
keep it away from heat, sparks, and open
flames.
VENTILATION
Petroleum vapor is heavier than air and if
inhaled in large quantities will not support life.
Engine exhaust gases are harmful to breathe.
When test-running an engine indoors, maintain
good ventilation.
SELF-PROTECTION
Protect your eyes with suitable safety specta-
cles or safety goggles when using compressed
air, when grinding or when doing any operation
which may cause particles to fly off.
1-2
GEN 1
GENERAL INFORMATIONx INFO
3. Avoid skin contact with lubricants; do not,
for example, place a soiled wiping-rag in
one’s pocket.
2. Tightening torque
Follow the torque tightening instructions.
When tightening bolts, nuts and screws,
tighten the larger sizes first, and tighten
inner-positioned fasteners before outer-
positioned ones.
3. Non-reusable items
Always use new gaskets, packings,o-rings,
oil seals, split-pins and circlips, etc. on
reassembly.
1-3
1 GEN
INFO GENERAL INFORMATION
CAUTION:
Do not use compressed air to spin the bear-
ings dry. This causes damage to the bearing
surfaces.
1-4
GEN 1
GENERAL INFORMATIONx INFO
SPECIAL TOOLS
Use of the correct special tools recommended
by Yamaha will aid the work and enable accu-
rate assembly and tune-up. Improvisations and
use of improper tools can cause damage to the
equipment.
NOTE:
YU-03097-B 90890-01252
• For U.S.A. and Canada, use part numbers
starting with “J-”, “YB-”, “YM-”,“YS-”, “YU-” or
“YW-”.
• For other countries, use part numbers starting
with “90890-.”
YU-03112-C YU-A1927
4 Dial Gauge Stand Set
90890-03112 90890-03174 P/N YW-06585
90890-06585
5 Pocket Tester
P/N YU-03112-C
90890-03112
7 Vacuum Synchronizer
VacuumMate®
RPM 1
2500
25
24
2 AVE 40
39
38
3 55
54
53
4 DYN
P/N YU-44456
2400 23 52
37 51
2300 22 36
2200 21 50
35 49
2100 20 34
2000 19 48
33 47
1900 18 32 46 P
8 Vacuum Gauge
1800 17 31 45
1700 16 30 44
1600 15 29 43
1500 14 28 42
1400 13 27 41 Pa
1300 12 26 40
1200 11 25 39
1100 10 24 38
1000 9 23 37
8 P
900 22 36
800 7 21
cm Hg
P/N 90890-03094
700 6
cm Hg
600
DYN
cm Hg 5 AVE
25
Vacuum attachment
35
VAC 5
40
RPM
20
12V
4
4-t 3 Pa
2 Pa
2-t 1 Pa
Pa
P/N 90890-03060
9 Test Connector
YW-06862 YW-06842 P/N YW-06862
90890-06862 90890-06842
90890-06862
10 Fuel Pressure Gauge Adapter
P/N YW-06842
90890-06842
1-5
1 GEN
INFO GENERAL INFORMATION
SPECIAL TOOLS
11 Fuel Pressure Gauge
P/N YB-06766
90890-06786
12 Compression Gauge Extension
P/N 90890-06582
13 Cylinder Gauge Set
P/N YU-03017
90890-06759
14 Compression Gauge
P/N YU-33223-1
90890-03160
15 Peak Voltage Adapter
P/N YU-39991
90890-03172
16 Spark Gap Tester
P/N YM34487
90890-06754
17 Test Harness (2 pins)
P/N YB-06792
90890-06792
1-6
GEN 1
GENERAL INFORMATIONx INFO
SPECIAL TOOLS
YB-06769 YB-35956-A
90890-06769 90890-06756
23 Test Harness (3 pins)
P/N YB-06769
90890-06769
60V-WS853-01
60V-WS850-00-00 USB Cable /
68F-WS850-00-00 Serial Cable
INSTALLATION MANUAL
60E-2819K-10
YW-06862
90890-06862
1-7
1 GEN
INFO GENERAL INFORMATION
REMOVAL AND INSTALLATION TOOLS
YU-38411 YW-06551
90890-01426 1 Oil Filter Wrench
90890-06551
P/N YU-38411
90890-01426
2 Coupler Wrench
P/N YW-06551
90890-06551
YS-01880-A YM-01082
90890-01701 90890-01080
3 Sheave Holder
P/N YS-01880-A
90890-01701
4 Rotor Puller
P/N YM-01082
90890-01080
YU-01235 YM-45469
90890-01235 90890-04019 5 Rotor Holder
P/N YU-01235
90890-01235
1-8
GEN 1
GENERAL INFORMATIONx INFO
11 Valve Seat Cutter
Intake
P/N 90890-06813 (60°)
90890-06814 (45°)
90890-06815 (30°)
Exhaust
P/N 90890-06315 (60°)
90890-06312 (45°)
90890-06328 (30°)
12 Valve Seat Cutter Holder
P/N 90890-06811 (ø4.0 mm)
90890-06812 (ø4.5 mm)
13 Valve Seat Cutter Set
P/N YM-91043-C
14 Piston Ring Compressor
P/N YM-08037
90890-05158
15 Drive Shaft Holder (Impeller)
P/N YB-06151
90890-06519
16 Slide Hammer Set (jet pump bearing)
P/N YB-06096
17
Stopper Guide Plate (jet pump bearing)
P/N 90890-06501
18 Bearing Puller (jet pump bearing)
P/N 90890-06535
19 Bearing Puller Claw 1 (jet pump bearing)
P/N 90890-06536
20 Stopper Guide Stand (jet pump bearing)
P/N 90890-06538
21 Drive Rod L3 (jet pump bearing)
P/N 90890-06652
22 Needle Bearing Attachment
(jet pump bearing and oil seal)
P/N YB-06112, YB-06196
90890-06614, 90890-06653
1-9
1 GEN
INFO GENERAL INFORMATION
1-10
CHAPTER 2
SPECIFICATIONS
2-1
2 SPEC GENERAL SPECIFICATIONS
2-2
MAINTENANCE SPECIFICATIONSx SPEC 2
2-3
2 SPEC MAINTENANCE SPECIFICATIONS
2-4
MAINTENANCE SPECIFICATIONSx SPEC 2
2-5
2 SPEC MAINTENANCE SPECIFICATIONS
Marine Group 24
Dual Purpose 675 CCA
100 (12/68.4)
2-6
MAINTENANCE SPECIFICATIONSx SPEC 2
2-7
2 SPEC MAINTENANCE SPECIFICATIONS
2-8
MAINTENANCE SPECIFICATIONSx SPEC 2
Part To Be Tightened
1/4-20
8-32
10-24
2-9
2 SPEC MAINTENANCE SPECIFICATIONS
TIGHTENING TORQUES
Part To Be Tightened
2-10
MAINTENANCE SPECIFICATIONSx SPEC 2
TIGHTENING TORQUES
Part To Be Tightened
2-11
2 SPEC MAINTENANCE SPECIFICATIONS
TIGHTENING TORQUES
Part To Be Tightened
2-12
MAINTENANCE SPECIFICATIONSx SPEC 2
TIGHTENING TORQUES
Part To Be Tightened
6
M8 3 20 2.0 14
2-13
2 SPEC MAINTENANCE SPECIFICATIONS
TIGHTENING TORQUES
Thread Tightening torque
Part 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 4.8
strainer - impeller duct
Drive shaft nut - drive shaft Nut – 1 69 6.9 50
Impeller (left-hand threads) – Impeller M20 1 18 1.8 13
drive shaft
Intermediate housing - bulkhead Bolt M8 3 17 1.7 12
Driven
Driven coupling - shaft
coupling M24 1 36 3.6 25
Grease nipple - intermediate Nipple – 1 5.4 0.54 3.9
housing
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 3.5
screw
Starter motor lead - electrical box Screw M6 1 7.6 0.76 5.5
Battery positive lead - Screw M6 1 7.6 0.76 5.5
electrical box
Fuse holder stay - electrical box Tapping ø6 1 3.9 0.39 2.8
screw
ECM - electrical box Tapping ø6 4 3.9 0.39 2.8
screw
Bracket (coupler) - electrical box Tapping ø6 1 3.9 0.39 2.8
screw
2-14
MAINTENANCE SPECIFICATIONSx SPEC 2
TIGHTENING TORQUES
Thread Tightening Torque
Part To Be Tightened Part Name size Qty N•m kgf•m ft•lb Remarks
Main and fuel pump relay Tapping ø6 1 3.9 0.39 2.8
screw
Rectifier/regulator Tapping ø6 2 3.9 0.39 2.8
screw
Ignition coil - oil tank Bolt M6 3 7.6 0.76 5.5
Ignition coil cover - ignition coil Tapping ø6 10 4.9 0.49 3.5
case screw
2-15
2 SPEC MAINTENANCE SPECIFICATIONS
A B
General Torque
Specifications
Bolt
Dia. Nm M•kg ft•lb
2-16
MAINTENANCE SPECIFICATIONSx SPEC 2
CABLE AND HOSE ROUTING
2-17
2 SPEC MAINTENANCE SPECIFICATIONS
CABLE AND HOSE ROUTING
2-18
MAINTENANCE SPECIFICATIONSx SPEC 2
CABLE AND HOSE ROUTING
2-19
2 SPEC MAINTENANCE SPECIFICATIONS
CABLE AND HOSE ROUTING
2-20
MAINTENANCE SPECIFICATIONSx SPEC 2
CABLE AND HOSE ROUTING
2-21
CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENT
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
INSP 3
PERIODIC INSPECTION AND ADJUSTMENT x ADJ
3-1
3 INSP
ADJ PERIODIC INSPECTION AND ADJUSTMENT
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.
285.45MM
WARNING
The cable joints must be screwed in more
than 8mm (0.31 in). 4.9~7.8 Nm (0.49~.78 kg•m, 3.54~5.64 ft-lb)
3-2
INSP 3
PERIODIC INSPECTION AND ADJUSTMENT x ADJ
REMOTE CONTROL UNIT
1. Check throttle:
● Throttle lever at Wide-Open-Throttle
(W.O.T.) position.
Throttle cable wheel, clearance to stop
on carburetor incorrect ➔ Adjust.
a
● Throttle lever at idle position.
Throttle cable wheel does not touch idle
screw ➔ Adjust.
No free play ➔ Adjust.
1 Cable Wheel d) Check that the cable wheel hits the idle
2 Locknuts screw when the throttle levers are pulled
3 Throttle Cable back to the idle position and that there is
free play in the cable. If adjustment is
necessary, loosen the locknuts at the
carburetor end and turn the cable
adjuster. Tighten the locknuts.
REVERSE GATE
2. Check shifting:
● Reverse gate clearance with shift lever
in Neutral position.
Out of specification ➔ Adjust.
30+ 2MM
NOZZLE
3-3
3 INSP
ADJ PERIODIC INSPECTION AND ADJUSTMENT
WARNING
SHIFTER
The cable joints must have more than 8mm ADJUSTER
(0.31 in) engagement after adjustment is
complete.
3. Check:
● Mechanical interlock
Shift lever can move when throttle
levers are not in idle position ➔
Replace interlock. PORT
4. Check: ADJUSTER
THROTTLE
● Neutral switch
Refer to the “STARTING SYSTEM” BOW STARBOARD
section in Chapter 7. THROTTLE
5. Check: ADJUSTER
● Friction
BOW
Loose/stiff ➔ Adjust the friction control
screw NOTE:
The remote control unit must be raised to
adjust the throttle tension screws.
3-4
INSP 3
PERIODIC INSPECTION AND ADJUSTMENT x ADJ
3-5
3 INSP
ADJ PERIODIC INSPECTION AND ADJUSTMENT
3-6
INSP 3
PERIODIC INSPECTION AND ADJUSTMENT x ADJ
3-7
3 INSP
ADJ PERIODIC INSPECTION AND ADJUSTMENT
3-8
INSP 3
PERIODIC INSPECTION AND ADJUSTMENT x ADJ
lowing table:
3-9
3 INSP
ADJ PERIODIC INSPECTION AND ADJUSTMENT
3-10
INSP 3
PERIODIC INSPECTION AND ADJUSTMENT x ADJ
3-11
3 INSP
ADJ PERIODIC INSPECTION AND ADJUSTMENT
CAUTION:
3-12
INSP 3
PERIODIC INSPECTION AND ADJUSTMENT x ADJ
CAUTION:
3-13
3 INSP
ADJ PERIODIC INSPECTION AND ADJUSTMENT
CAUTION:
3-14
INSP 3
PERIODIC INSPECTION AND ADJUSTMENT x ADJ
CAUTION:
3-15
3 INSP
ADJ PERIODIC INSPECTION AND ADJUSTMENT
CAUTION:
When starting the engine, make sure the dip-
stick is securely fitted into the oil tank.
3-16
INSP 3
PERIODIC INSPECTION AND ADJUSTMENT x ADJ
CAUTION:
Make sure the air filter element is installed
in the filter case properly.
CAUTION:
3-17
3 INSP
ADJ PERIODIC INSPECTION AND ADJUSTMENT
3-18
INSP 3
PERIODIC INSPECTION AND ADJUSTMENT x ADJ
3-19
3 INSP
ADJ PERIODIC INSPECTION AND ADJUSTMENT
CAUTION:
Be sure the cap is properly positioned and A
locked in place. Otherwise, the cap could loosen
and be forced out of the access ports by water
pressure, causing loss of performance and pos-
sible damage.
3-20
INSP 3
PERIODIC INSPECTION AND ADJUSTMENT x ADJ
BILGE PUMP
2. Inspect:
• Bilge strainer
Contaminants → Clean.
Cracks/damage → Replace.
Inspection Steps:
• Install the coupling cover.
3-21
3 INSP
ADJ PERIODIC INSPECTION AND ADJUSTMENT
3-22
INSP 3
PERIODIC INSPECTION AND ADJUSTMENT x ADJ
GENERAL
Drain 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
Recommended Grease:
Water resistant grease
NOTE:
Remove the cable joint and apply a small
amount of grease to the following parts.
Recommended Grease:
Water resistant grease
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.
3-23
3 INSP
ADJ PERIODIC INSPECTION AND ADJUSTMENT
Lubrication points
1. Lubricate:
● Throttle cable (throttle body end)
Recommended lubricant:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
NOTE:
Before lubricating the QSTS control cables,
remove the QSTS cable housing cover. Spray
the rust inhibitor into the outer cables, and
apply grease to the inner cables.
2. Lubricate:
● Nozzle pivot shaft
● Steering cable (nozzle end)
● QSTS cable (nozzle end)
Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
3. Lubricate:
● Steering cable
● Steering cable joint
● Shift cable
● Shift cable joint
NOTE:
Disconnect the joints and apply a small amount
of grease.
Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
3-24
INSP 3
PERIODIC INSPECTION AND ADJUSTMENT x ADJ
4.
3-25
x
CHAPTER 4
FUEL SYSTEM
FUEL TANK AND FUEL PUMP MODULE
EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Fuel hose disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Fuel pump module removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Check valve inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Fuel tank inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Fuel hose inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Fuel pump filter inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Fuel strainer inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Fuel pump module installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Fuel hose connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
6 1
7 2
5
4.9~7.9 Nm (50~80 kgf-cm) 4
See Note 28 10
8
28
29
28
28
12
28
28 29
11
28
28
9
28
15
13
16
18
14 13
13 13
17
30 19
20
26
27
21
22 23 24 25
1 Connector, harness 2
2 Cover 2
3 Screw, Machine 2
4 Clamp 2
5 Fuel hose 2
6 Screw 16 NOTE: Apply Loctite, torque in 2 steps
see page 4-4 Pump Module Removal,
4-5 Installation
7 Plate 2
8 Fuel Pump Assembly 2
9 Seal 2
10 Screw 5 Apply Loctite, 2.9 Nm (30 kgf-cm)
4-1
4 FUEL FUEL SYSTEM
6 1
7 2
5
4
28 10
8
28
29
28
28
12
28
28 29
11
28
28
9
28
15
13
16
18
14 13
13 13
17
30 19
20
26
27
21
22 23 24 25
4-2
FUEL SYSTEM x FUEL 4
FUEL TANK AND FUEL PUMP MODULE (Cont’d.)
6 1
7 2
5
4
28 10
8
28
29
28
28
12
28
28 29
11
28
28
9
28
15
13
16
18
14 13
13 13
17
30 19
20
26
27
21
22 23 24 25
4-3
4 FUEL FUEL SYSTEM
SYSTEM.”
Screws
4-4
FUEL SYSTEM x FUEL 4
Screws
SYSTEM.”
4-5
4 FUEL FUEL SYSTEM
4-6
FUEL SYSTEM x FUEL 4
FUEL INJECTION SYSTEM (Cont’d.)
4-7
4 FUEL FUEL SYSTEM
4-8
FUEL SYSTEM x FUEL 4
FUEL INJECTION SYSTEM (Cont’d.)
4-9
4 FUEL FUEL SYSTEM
4-10
FUEL SYSTEM x FUEL 4
FUEL INJECTION SYSTEM (Cont’d.)
4-11
4 FUEL FUEL SYSTEM
FUEL INJECTION SYSTEM (Cont’d.)
Qty
4-12
FUEL SYSTEM x FUEL 4
FUEL INJECTION SYSTEM (Cont’d.)
4-13
4 FUEL FUEL SYSTEM
4-14
FUEL SYSTEM x FUEL 4
CAUTION:
4-15
4 FUEL FUEL SYSTEM
CAUTION:
4-16
FUEL SYSTEM x FUEL 4
CAUTION:
4-17
4 FUEL FUEL SYSTEM
CAUTION:
4-18
FUEL SYSTEM x FUEL 4
CAUTION:
4-19
4 FUEL FUEL SYSTEM
CAUTION:
4-20
FUEL SYSTEM x FUEL 4
4-21
4 FUEL FUEL SYSTEM
CAUTION:
4-22
FUEL SYSTEM x FUEL 4
4-23
4 FUEL FUEL SYSTEM
4-24
FUEL SYSTEM x FUEL 4
nection.”)
connection.”
4-25
POWER UNIT x POWR 5
5-1
5 POWR POWER UNIT
ENGINE UNIT
EXPLODED DIAGRAM
5-2
POWER UNIT x POWR 5
5-3
5 POWR POWER UNIT
CAUTION:
5-4
POWER UNIT x POWR 5
5-5
5 POWR POWER UNIT
CAUTION:
5-6
POWER UNIT x POWR 5
5-7
5 POWR POWER UNIT
UNIT.”
5-8
POWER UNIT x POWR 5
EXHAUST PIPE 3 (Cont’d.)
5-9
5 POWR POWER UNIT
5-10
POWER UNIT x POWR 5
PIPE 3.”
MOTOR.”
5-11
5 POWR POWER UNIT
5-12
POWER UNIT x POWR 5
AND 2.”
5-13
5 POWR POWER UNIT
5-14
POWER UNIT x POWR 5
UNIT.”
“THERMOSTAT.”
5-15
5 POWR POWER UNIT
5-16
POWER UNIT x POWR 5
OIL TANK (Cont’d.)
5-17
5 POWR POWER UNIT
5-18
POWER UNIT x POWR 5
OIL TANK (Cont’d.)
5-19
5 POWR POWER UNIT
5-20
POWER UNIT x POWR 5
OIL TANK (Cont’d.)
5-21
5 POWR POWER UNIT
5-22
POWER UNIT x POWR 5
5-23
5 POWR POWER UNIT
5-24
POWER UNIT x POWR 5
5-25
5 POWR POWER UNIT
TANK.”
5-26
POWER UNIT x POWR 5
OIL PUMP (Cont’d.)
5-27
5 POWR POWER UNIT
OIL PUMP (Cont’d.)
5-28
POWER UNIT x POWR 5
5-29
5 POWR POWER UNIT
5-30
POWER UNIT x POWR 5
5-31
5 POWR POWER UNIT
MOTOR.”
PUMP.”
5-32
POWER UNIT x POWR 5
REDUCTION DRIVE GEAR (Cont’d.)
5-33
5 POWR POWER UNIT
5-34
POWER UNIT x POWR 5
REDUCTION DRIVE GEAR (Cont’d.)
5-35
5 POWR POWER UNIT
5-36
POWER UNIT x POWR 5
5-37
5 POWR POWER UNIT
5-38
POWER UNIT x POWR 5
UNIT.”
5-39
5 POWR POWER UNIT
5-40
POWER UNIT x POWR 5
GENERATOR AND STARTER MOTOR (Cont’d.)
5-41
5 POWR POWER UNIT
CAUTION:
Make sure not to pinch the pulser coil
leads between the washers and projec-
tions on the case when installing the
bolts.
5-42
POWER UNIT x POWR 5
GENERATOR AND STARTER MOTOR (Cont’d.)
5-43
5 POWR POWER UNIT
5-44
POWER UNIT x POWR 5
5-45
5 POWR POWER UNIT
CAUTION:
5-46
POWER UNIT x POWR 5
5-47
5 POWR POWER UNIT
CAMSHAFTS (Cont’d.)
5-48
POWER UNIT x POWR 5
CAMSHAFTS (Cont’d.)
GEAR.”
5-49
5 POWR POWER UNIT
CAMSHAFTS (Cont’d.)
5-50
POWER UNIT x POWR 5
CAMSHAFTS (Cont’d.)
5-51
5 POWR POWER UNIT
5-52
POWER UNIT x POWR 5
5-53
5 POWR POWER UNIT
5-54
POWER UNIT x POWR 5
5-55
5 POWR POWER UNIT
CAUTION:
5-56
POWER UNIT x POWR 5
5-57
5 POWR POWER UNIT
5-58
POWER UNIT x POWR 5
5-59
5 POWR POWER UNIT
UNIT.”
PIPE 3.”
AND 2.”
TANK.”
“CAMSHAFTS.”
5-60
POWER UNIT x POWR 5
CYLINDER HEAD (Cont’d.)
5-61
5 POWR POWER UNIT
5-62
POWER UNIT x POWR 5
5-63
5 POWR POWER UNIT
5-64
POWER UNIT x POWR 5
HEAD.”
5-65
5 POWR POWER UNIT
VALVES AND VALVE SPRINGS (Cont’d.)
5-66
POWER UNIT x POWR 5
5-67
5 POWR POWER UNIT
5-68
POWER UNIT x POWR 5
5-69
5 POWR POWER UNIT
5-70
POWER UNIT x POWR 5
5-71
5 POWR POWER UNIT
5-72
POWER UNIT x POWR 5
CAUTION:
5-73
5 POWR POWER UNIT
5-74
POWER UNIT x POWR 5
CAUTION:
5-75
5 POWR POWER UNIT
5-76
POWER UNIT x POWR 5
UNIT.”
PIPE 3.”
AND 2.”
MANIFOLD.”
MOTOR.”
TANK.”
5-77
5 POWR POWER UNIT
CRANCASE (Cont’d.)
PUMP.”
GEAR.”
“CAMSHAFTS.”
5-78
POWER UNIT x POWR 5
CRANCASE (Cont’d.)
5-79
5 POWR POWER UNIT
CRANCASE (Cont’d.)
5-80
POWER UNIT x POWR 5
CRANCASE (Cont’d.)
“CRANKSHAFT.”
5-81
5 POWR POWER UNIT
CAUTION:
Tap on one side of the crankcase with a
soft-face hammer. Tap only on rein-
forced portions of the crankcase, not on
the crankcase mating surfaces. Work
slowly and carefully and make sure the
crankcase halves separate evenly.
5-82
POWER UNIT x POWR 5
5-83
5 POWR POWER UNIT
5-84
POWER UNIT x POWR 5
CAUTION:
5-85
5 POWR POWER UNIT
5-86
POWER UNIT x POWR 5
“CRANKCASE.”
5-87
5 POWR POWER UNIT
CONNECTING RODS AND PISTONS (Cont’d.)
5-88
POWER UNIT x POWR 5
CAUTION:
5-89
5 POWR POWER UNIT
pistons:
5-90
POWER UNIT x POWR 5
formula:
5-91
5 POWR POWER UNIT
5-92
POWER UNIT x POWR 5
5-93
5 POWR POWER UNIT
CAUTION:
5-94
POWER UNIT x POWR 5
installation.”
removal.”
5-95
5 POWR POWER UNIT
5-96
POWER UNIT x POWR 5
5-97
5 POWR POWER UNIT
5-98
POWER UNIT x POWR 5
procedure.”
CAUTION:
5-99
5 POWR POWER UNIT
“CRANKCASE.”
PISTONS.”
5-100
POWER UNIT x POWR 5
5-101
5 POWR POWER UNIT
CAUTION:
5-102
POWER UNIT x POWR 5
“CRANKCASE.”
5-103
5 POWR POWER UNIT
5-104
POWER UNIT x POWR 5
D
FW
5-105
5 POWR POWER UNIT
THERMOSTAT (Cont’d.)
D
FW
5-106
POWER UNIT x POWR 5
5-107
5 POWR POWER UNIT
MANIFOLD.”
5-108
POWER UNIT x POWR 5
PRESSURE CONTROL VALVE (Cont’d.)
5-109
5 POWR POWER UNIT
5-110
POWER UNIT x POWR 5
PRESSURE CONTROL VALVE (Cont’d.)
5-111
5 POWR POWER UNIT
5-112
CHAPTER 6
JET PUMP UNIT
INTAKE GRATING
EXPLODED DIAGRAM
5
LT
242
LT
4
242
2
3
LT
242
1
1 Screw 2 8 x 35mm
2 Screw 4 8 x 20mm
3 Intake Grating 2 Port and Starboard Units
4 Screw 12 8 x 40mm
5 Intake Duct 2 Port and Starboard Units
Reverse the removal steps for installation.
NOTE: Apply clear silicone before
installing a duct into the hull.
6-1
6 JET
PUMP JET PUMP
6-2
JET 6
JET PUMP x PUMP
PUMP UNIT
EXPLODED DIAGRAM
5 Dowel Pin 2
6 Duct w/Driveshaft and Impeller 1
7 Bolt (with washer) 4 10 x 40mm
8 Dowel Pin 2
9 Impeller Housing Assembly 1
Reverse the removal steps for installation.
6-3
6 JET
PUMP JET PUMP
REVERSE GATE
DISASSEMBLY
1 Bolt (with washer) 2 6 x 16mm
2 Gate Control Arm 1
3 Bolt (with washer) 2
4 Collar 2
5 Swivel 1
Reverse the removal steps for installation.
6-4
JET 6
JET PUMP x PUMP
6B5
PART NUMBER
NO MARK
68N
PART NUMBER
6-5
6 JET
PUMP JET PUMP
LT
242
A
6-6
JET 6
JET PUMP x PUMP
6-7
6 JET
PUMP JET PUMP
10
11
6-8
JET 6
JET PUMP x PUMP
6-9
6 JET
PUMP JET PUMP
6-10
x
CHAPTER 7
ELECTRICAL SYSTEM
23
23
18
23 23
20 21
24
7
9
1 Bow light
2 Fuel pumps
3 Fuel sender
4 Stereo
5 23 Speaker
6 24 Running Light
7
8
9
7-1
7 ELEC ELECTRICAL SYSTEM
7-2
ELECTRICAL SYSTEM x ELEC 7
ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)
EXPLODED DIAGRAM
7-3
7 ELEC ELECTRICAL SYSTEM
7-4
ELECTRICAL SYSTEM x ELEC 7
ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)
EXPLODED DIAGRAM
7-5
7 ELEC ELECTRICAL SYSTEM
7-6
ELECTRICAL SYSTEM x ELEC 7
ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)
EXPLODED DIAGRAM
7-7
7 ELEC ELECTRICAL SYSTEM
7-8
ELECTRICAL SYSTEM x ELEC 7
ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)
EXPLODED DIAGRAM
7-9
7 ELEC ELECTRICAL SYSTEM
7-10
ELECTRICAL SYSTEM x ELEC 7
7-11
7 ELEC ELECTRICAL SYSTEM
7-12
ELECTRICAL SYSTEM x ELEC 7
tests:
7-13
7 ELEC ELECTRICAL SYSTEM
IGNITION SYSTEM
WIRING DIAGRAM
Br Y
B
2 :W 13 : B/R L/R
R R
1
L
3 : P/W 15 : G/O 4 3 2 1
4 :P 17 : L/B 8 7 6 5 3
R/Y R/Y R/Y R/Y R
5 : B/Y 18 : R/Y R/Y 2 P
R
R
6 : B/O 19 : P/G
P
7 :Y 20 : P Br B R
R/Y
8 :O 21 : B/Y R/Y O
9 : W/R 27 : B
10 : W/B 28 : B/W
12 3 456 7 8
R/Y R/Y
11 : L/R O O P P R R R
Y
4
L/R
P/W 5 6
OFF W B
B ON FREE
Pu/B R/Y B/O START PUSH
Pu/G
P/W R/B
Pu/R W
Bu/Y B Br
W B
B/Y
G/O W W
O P
P/G B B/O B
P/W B
B/Y B/O B
Pu/B B/O R/Y
Pu/Y
W B Br Br
7
Pu/R
FREE
⁄
20 Pu/G B/O
G/O
PUSH
R/B
R/Y W
Br
⁄
R B
11 R/B
Br Br
R/Y B/R
P Br
W/R W B R
P
P
B/W B
8
B/O
B/O B
B/O W/B
R P
P P
R B/W
B/O B
9
B/O
#1 #4 B/O B
⁄
18 ⁄
18 R G
R
B/O B/Y
⁄
19 B/O
G
B/O
⁄
12 G
G
B/O B/Y
B/Y
⁄
10
B/W W B R B/Y
R/Y
B
⁄
15 B G
G
B/Y
B/O
B/Y
G
B/W B/O
G
R ⁄
16 ⁄
13
G
G G G B/O
B/O B/O
P/G
R B/W
P
O
⁄
14 ⁄
14
B/O
#2 #3 O
⁄
18 ⁄
18 ⁄
17 B/O
⁄
19 B/O
B/O
7-14
ELECTRICAL SYSTEM x ELEC 7
IGNITION SYSTEM
WIRING DIAGRAM
Br Y
B
2 :W 13 : B/R L/R
R R
1
L
3 : P/W 15 : G/O 4 3 2 1
4 :P 17 : L/B 8 7 6 5 3
R/Y R/Y R/Y R/Y R
5 : B/Y 18 : R/Y R/Y 2 P
R
R
6 : B/O 19 : P/G
P
7 :Y 20 : P Br B R
R/Y
8 :O 21 : B/Y R/Y O
9 : W/R 27 : B
10 : W/B 28 : B/W
12 3 456 7 8
R/Y R/Y
11 : L/R O O P P R R R
Y
4
L/R
P/W 5 6
OFF W B
B ON FREE
Pu/B R/Y B/O START PUSH
Pu/G
P/W R/B
Pu/R W
Bu/Y B Br
W B
B/Y
G/O W W
O P
P/G B B/O B
P/W B
B/Y B/O B
Pu/B B/O R/Y
Pu/Y
W B Br Br
7
Pu/R
FREE
⁄
20 Pu/G B/O
G/O
PUSH
R/B
R/Y W
Br
⁄
R B
11 R/B
Br Br
R/Y B/R
P Br
W/R W B R
P
P
B/W B
8
B/O
B/O B
B/O W/B
R P
P P
R B/W
B/O B
9
B/O
#1 #4 B/O B
⁄
18 ⁄
18 R G
R
B/O B/Y
⁄
19 B/O
G
B/O
⁄
12 G
G
B/O B/Y
B/Y
⁄
10
B/W W B R B/Y
R/Y
B
⁄
15 B G
G
B/Y
B/O
B/Y
G
B/W B/O
G
R ⁄
16 ⁄
13
G
G G G B/O
B/O B/O
P/G
R B/W
P
O
⁄
14 ⁄
14
B/O
#2 #3 O
⁄
18 ⁄
18 ⁄
17 B/O
⁄
19 B/O
B/O
7-15
7 ELEC ELECTRICAL SYSTEM
7-16
ELECTRICAL SYSTEM x ELEC 7
7-17
7 ELEC ELECTRICAL SYSTEM
7-18
ELECTRICAL SYSTEM x ELEC 7
SYSTEM.”
7-19
7 ELEC ELECTRICAL SYSTEM
measurement.”
Installed O O
Removed O O
7-20
ELECTRICAL SYSTEM x ELEC 7
7-21
7 ELEC ELECTRICAL SYSTEM
7-22
ELECTRICAL SYSTEM x ELEC 7
7-23
7 ELEC ELECTRICAL SYSTEM
7-24
ELECTRICAL SYSTEM x ELEC 7
7-25
7 ELEC ELECTRICAL SYSTEM
7-26
ELECTRICAL SYSTEM x ELEC 7
FUEL CONTROL SYSTEM
WIRING DIAGRAM
13
12
7
9
8
10
11
7-27
7 ELEC ELECTRICAL SYSTEM
13
12
7
9
8
10
11
7-28
ELECTRICAL SYSTEM x ELEC 7
Purple
12VDC
7-29
7 ELEC ELECTRICAL SYSTEM
2. Put the black lead of a voltmeter on the FUEL INJECTOR
Black/White wire of the harness. Then use Refer to “FUEL INJECTION SYSTEM” in
the red lead of the voltmeter to measure the Chapter 4.
voltage on the other two pins.
MAIN AND FUEL PUMP RELAY
PURPLE = More than +12 VDC (or close to Refer to “IGNITION SYSTEM.”
Battery terminal voltage)
OIL PRESSURE SWITCH
PINK = More than +7 VDC (sensor discon- Refer to “IGNITION SYSTEM.”
nected).
THERMOSWITCH (ENGINE)
3. If the above voltages are as indicated turn the Refer to “IGNITION SYSTEM.”
key off and insert a jump lead between the
PINK and BLACK/WHITE pins of the harness THERMOSWITCH (EXHAUST)
connector to ground. Turn the starboard key Refer to “IGNITION SYSTEM.”
on. The gauge should read above the “FULL”
mark.
CONNECTOR WIRING
Signal Sender Harness Gauge
Positive (12V) Red Purple Purple
Ground Black Blk/Wht Black
Send White Pink Pink
7-30
ELECTRICAL SYSTEM x ELEC 7
STARTING SYSTEM
WIRING DIAGRAM
Br Y
L/R B
L R
4 3 2 1
1 8 7 6 5
R/Y R/Y
R/Y
2
R/Y R R
R/Y P
R/Y O
12 3 456 7 8
R/Y R/Y
7 18 R R R
3
R
B
B
B Br
B
B
B
Br
4
B
8 7
5
OFF W B Br Br
ON SET
START PULL
B
Br
R/B
Br 6
R/B R
Br Br
7-31
7 ELEC ELECTRICAL SYSTEM
KEY SWITCH
1. Check:
• Continuity
Out of specification → Replace.
Start continuity
7-32
ELECTRICAL SYSTEM x ELEC 7
7-33
7 ELEC ELECTRICAL SYSTEM
7-34
ELECTRICAL SYSTEM x ELEC 7
STARTER MOTOR (Cont’d.)
7-35
7 ELEC ELECTRICAL SYSTEM
7-36
ELECTRICAL SYSTEM x ELEC 7
7-37
7 ELEC ELECTRICAL SYSTEM
7-38
ELECTRICAL SYSTEM x ELEC 7
7-39
7 ELEC ELECTRICAL SYSTEM
SYSTEM.”
SYSTEM.”
SYSTEM.”
7-40
ELECTRICAL SYSTEM x ELEC 7
ELECTRIC BILGE PUMP
WIRING DIAGRAM
Br Br
Br Br
B B
B
B: Black
Br: Brown
7-41
7 ELEC ELECTRICAL SYSTEM
7-42
ELECTRICAL SYSTEM x ELEC 7
MAIN COMPONENT LOCATION
EXPLODED DIAGRAM
3
8 11
1
2
5
6 4
10
1. Battery
2. Fuel Level Sensor
3. Bow Light
4. Stern Light Connector
5. Blower Motors
6. Bilge Pump
7. Horn
8. Stereo Unit
9. Hull Harness #3
10. Deck Harness
11. 12V Outlet and Circuit Breaker
7-43
7 ELEC ELECTRICAL SYSTEM
SWITCH LOCATION
WIRING DIAGRAM
1. Key Switches
2. Lanyard Switch
3. Neutral Switch
4. Hatch Interlock Switches
5. Engine Harness #2
7-44
1 2 3
STB G L PORT
2 Speedometer
TACH TACH
SW 53105 SW 53105
1 Starboard Tach
WIRING DIAGRAM
BLUE -5"
BLACK -5"
4
5251 8 PIN DEUTSCH
8 PIN DEUTSCH 9495 CAP
FEMALE MALE
PLUG 52510 CAP BLK 2 PLUG 52510
2
WEDGE 52512 S S
1 3 1 3 WEDGE 52512
SOC. 52518 SOC. 52518
ST TO HARNESS RED -6" RED 4 COMPASS 4 BLACK BLACK -6"
1 STB TACH PWR 1 53232 2 PORT TACH GND 2 3 PORT TACH GND
RED -6" BLUE -9" WHITE BLUE BLUE -6"
BLUE -4"
STB TACH PWR 2 4 STB LIGHT 4 8 PORT CHECK ENG. 8 6 PORT CHECK ENG.
BLK
GRAY -6" G TAN/WHITE -6"
DEUTSCH YELLOW BLK -5" GREEN
STB TACH 1 3 STB TACH 3 7 PORT OVERHEAT 7 5 PORT OVERHEAT
6 PIN BLUE/WHITE -6" PURPLE FUEL PURPLE BLUE/WHITE -6"
STB LO OIL 4 6 STB LO OIL 6 B+ 53107 BLUE -5" 6 PORT LO OIL 6 4 PORT LO OIL
PLUG 52506 TAN/WHITE -6" GREEN YELLOW GRAY -6"
WEDGE 52508 STB OVERHEAT 5 BLUE -8" COPPER 3 PORT TACH 3 1 PORT TACH
BLUE -6" 7 STB OVERHEAT 7
BLUE 5251 WHITE BLUE -14"
SOC 52518 STB CHECK ENG. 6 8 STB CHECK ENG. 8 S 9495 4 PORT LIGHT 4 2 PORT TACH PWR
BLACK -6" BLACK I RED RED -6"
MALE FEMALE
-9"
STB TACH GND 3 2 STB TACH GND 2 1 PORT TACH PWR 1
SILVER
DEUTSCH
52519 5 - 5 52519 52519 5 - 5 52519
51078
6 PIN PT
PLUG 52506
PINK
BLACK -5"
BLACK -5"
PURPLE -9"
BLUE -9"
BLUE -14"
WEDGE 52508
BLACK -8"
51078 SOC. 52518
METER PANEL BACK VIEW
PINK -9"
5251 9495
PURPLE -9" FEMALE MALE TO HARNESS
MOUNT USING
4 STUDS
CAP 52505
#20888B
WEDGE 52507
52519
52519
BLUE -4"
BLACK -4"
SMALL
WEEP HOLE PIN52517 3 1 2 4 5 6
THRU-BOLT
DEUTSCH
FOR RADIO REMOTE
-
-
6 PIN BLOWER BILGE STEREO CSTY. LT
LIGHTS HORN
#2 #1
FUEL
LIGHTS
GROUND
IGNITION
18275
PLUG 52506
3 1 2 4 5 6
WEDGE 52508
7-45
SOC 52518
18274
52519
52519
18467 BLUE -9"
BLK -21"
MOUNT USING BLK -4" 10 AWG
4 SCREWS (BLACK) BLK -4" 10 AWG ON
MOUNT USING
BLACK -41" 10 AWG BLK -4" 10 AWG BLK -4" 10 AWG ON OFF START
OFF START
4 STUDS
BLOWER #20888B
STEREO BILGE 52263 PLACE BLOWER
LIGHTS CT LT 52264 51342 WARNING HERE
HORN 52266 52265
52267 51342
ORG -4"
52268 51342 51342
52329
PINK -20"
PURPLE -20"
53089
10 AWG
RED/BLK -4"
ORG -4"
ORG -4"
STBD
ORG -4"
PORT
BLUE -9"
BLACK -19" 14 AWG
ORG -4"
TO STEREO
ORG -4"
3 GROUND 53051 53051
BLUE -22"
TO IPA 1 12V REC. PWR SEAL 52014
3 Port Tach
YELLOW -21" YELLOW -21" 4 STEREO REMOTE PIN 52024
GRAY/BLUE -23"
DEUTSCH
RED
2 PIN 10 AWG
RED
GRAY/GREEN -23"
ORANGE -24"
CAP 52769 RD/BLK -4" PINK -20"
4 Fuel Gauge
WHITE
BLACK
TO IPA
WHITE
BLACK
10 AWG 5 FUEL
BROWN
BROWN
BRN -19"
PIN 52767 5A 5A 5A 5A 10 IGNITION
5A 5A RD/BLK -4" YELLOW -18" 14 AWG DEUTSCH
BLACK -41" 10 AWG
YELLOW/RED
52519
52519 12 - SI PI
STBD STOP GND
PORT STOP GND
52519 9 -
STBD PWR START
PORT PWR START
52519 6 -
7 ELEC
7 ELEC ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
7-46
ELECTRICAL SYSTEM x ELEC 7
SWITCH AND COMPONENT
WIRING DIAGRAM
6 Blower Switch 13
13 Stern Light
7 Horn Switch 14
14 Bow Light
7-47
7 ELEC ELECTRICAL SYSTEM
7-48
ELECTRICAL SYSTEM x ELEC 7
7-49
CHAPTER 8
HULL AND DECK
1. Engine 5. Battery
2. Water Lock 6. Blowers
3. Jet Pump 7. Bilge Pump
4. Fuel Tank
8-1
8 HULL
DECK HULL AND DECK
VENTILATION SYSTEM
EXPLODED DIAGRAM
8-2
HULL 8
HULL AND DECK x DECK
REMOVAL AND INSTALLATION CHART
8-3
HULL
8 DECK HULL AND DECK
COOLING SYSTEM
EXPLODED DIAGRAM
25
28 28
27
27
29
29
30
30
8-4
HULL 8
HULL AND DECK x DECK
REMOVAL AND INSTALLATION CHART
1 Band, Hose 18 2
2 Clip 2
3 Hose 1 2
4 Joint, Hose 1 2
5 Clip 2
6 Nut 2
7 Cap, 1 2
8 Joint Assy 2
9 Band, Hose 18 2
10 Clip 2
11 Hose (L=1250) 2
12 Clip 2
13 Band, Hose 18 2
14 Hose (L=900) 2
15 Floor, Drain 2 Apply clear silicone around the flange of
the fitting.
16 Clip 2
17 Housing, Thermostat 2
18 Band, Hose 6 Oetiker type clamps.
19 Hose 8 2
20 Joint, Pipe 2 Straight connector for Port pilot water hose.
21 Clip 2
22 Hose 2 STARBOARD hose is shortened to fit.
23 Nut, M14-1.5mm 4
24 Pilot, Water 4 Apply clear silicone around the flange of
the water pilots.
25 Band, Hose 1 Located in engine compartment
26 Clean-out Tray Assembly 1 See pg. 6-6 “Jet Pump Clean-out
Tray RemovaL
27 Band, Hose 2
28 Hose, Exhaust Outlet 1
29 Strap 2
30 Water Lock 1 Apply soapy water to inside of hose ends
on reassembly so that hoses seat
completely on Water Lock
8-5
HULL
8 DECK HULL AND DECK
STEERING SYSTEM
EXPLODED DIAGRAM
A
12
11
10
7
A
SS
1
33 22
44
A
SS
13
8-6
HULL 8
HULL AND DECK x DECK
REMOVAL AND INSTALLATION CHART
1 Cover 1
2 Nut 1 1/2"-13, Nylon lock, 18 Nm (1.8 m-kg, 13 ft-lb)
3 Washer 1 1/2"
4 Steering Wheel 1
5 Key 1
6 Boot 1
7 Screw 2 #8 x 1", 1.8 Nm (0.18 m-kg, 1.3 ft-lb)
8 Helm, Bezel 1
9 Screw, socket head 1 3/16"-24 x 1", LT 242
10 Screw 2
11 Steering Pivot 1
12 Nut 1 3/8" Nylon lock, 20 Nm (2.0 m-kg, 14 ft-lb)
13 Washer 3/8"
14 Bolt 1
15 Bearing 1
16 Bolt, Shoulder 1 1/4"-20, shoulder bolt, 6.4 Nm (0.64 m-kg, 4.6 ft-lb)
17 Bearing 1
18 Bolt 3 1/4"-20, 14 Nm (1.4 m-kg, 10 ft-lb), LT 242
19 Washer 3
20 Steering Master 1
21 Nut 3 1/4"-20 Nylon lock, 7 Nm (0.7 m-kg, 5 ft-lb)
22 Washer 3 1/4" fender
23 Hex Head Bolt 3 1/4"-20
24 Steering Mount 1
STEERING CABLE
1 Nut w/Washer 2 12 Nm (1.2 m-kg, 8.7 ft-lb), LT 242
2 Block, Pivot Arm 1
3 Screw 2 3.7 Nm (0.37 m-kg, 2.7 ft-lb)
4 Connector Sub-Assembly 1
8-7
HULL
8 DECK HULL AND DECK
8-8
HULL 8
HULL AND DECK x DECK
REMOVAL AND INSTALLATION CHART
CABLE REMOVAL
13 Clevis Assembly 4
14 Nut 4
15 Nut 2
16 Cable, Throttle 2
17 Shaft Joint Ball 2
18 Nut 2
19 Thru-hull Fitting 2
20 Cable, Shift 2
8-9
HULL
8 DECK HULL AND DECK
ENGINE HATCH
EXPLODED DIAGRAM
8-10
HULL 8
HULL AND DECK x DECK
REMOVAL AND INSTALLATION CHART
8-11
HULL
8 DECK HULL AND DECK
8-12
HULL 8
HULL AND DECK x DECK
REMOVAL AND INSTALLATION CHART
Step Procedure / Part Name Q’ty Service Points Step Procedure / Part Name Q’ty Service Points
BOW LOCKER Follow the “Step” GLOVEBOX HATCH
DISASSEMBLY order for removal.
37 Screw 3 #10 X 3/4”
1 Screw, Tapping 16 #8 x 5/8” 38 Nut 3 10-24
2 Hinge 1 39 Glovebox Hatch Assem. 1
3 Hatch 1
4 Screw, Machine 2 FUEL HATCH
5 Latch 1
6 Screw, Tapping 2 40 Screw 12 #8 x 3/8”
7 Catch 1 41 Hinge, Fuel Hatch 2
8 Screw 2 #8 x 3/4” 42 Nut, Nylon Lock 2 #10-24
9 Cushion 2 43 Washer, Flat 2 #10
10 Screw 1 #10 x 1/2” 44 Screw 2 10-24 x 1-1/4”
11 Screw 1 #8 x 3/4” 45 Catch 1
12 Hatch Support 1 Twist one turn 46 Screw, Machine 2
when re-attaching 47 Latch 2
13 Screw 6 48 Seal, Fuel Hatch 1
14 Anchor Retainer Bracket 2 49 Hatch, Fuel Hatch 1
15 Anchor Retainer 2
STERN LOCKER
BI-FOLD DOOR HATCHES
8-13
HULL
8 DECK HULL AND DECK
SEAT FITTINGS
EXPLODED DIAGRAM
8-14
HULL 8
HULL AND DECK x DECK
REMOVAL AND INSTALLATION CHART
BOW SEATS
7 Seat Cushions 3
8 Nut 1/4-20 24 Access nuts through under seat storage
9 Washer, Flat 1/4 x 1 1/2" Fender 24
10 Bow Seat Backrests 3 Lift backrests off mounting clips
MIDSHIP SEATING
11 Seat Cushions 2
12 Nut 1/4-20 4 Access nuts through under seat storage
13 Washer, Flat 1/4 x 1 1/2" Fender 4
14 Seat Backrests 2 Lift backrests off mounting clips
8-15
HULL
8 DECK HULL AND DECK
DECK FITTINGS
EXPLODED DIAGRAM
8-16
HULL 8
HULL AND DECK x DECK
REMOVAL AND INSTALLATION CHART
DECK FITTINGS
13 Screw, #8 X 3/4” 24
14 Handle, Grip 6 Apply silicone sealer to mounting holes
15 Nut, 5/16-18 12 LT242,Torque 13 Nm (1.35m-kg. 9.5ft-lb)
16 Washer, Lock 5/16” 12
17 Washer, Flat 5/16” 12
18 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” 4
21 Washer, Flat 5/16” 4
22 Rail, Hand (Bow) 2
23 Nut, 5/16-18 4 LT242, Torque 13Nm (1.35m-kg, 9.5ft-lb)
24 Washer, Lock 5/16” 4
25 Washer, Flat 5/16” 6 Washers are placed on center 2 studs of the Grip Ass’y,
Ski Tow before installing on hull. The remaining 4 washers
are placed on all 4 studs after inserting thru holes in hull.
26 Grip Assembly, Ski Tow 1 Silicone sealer around base of studs.
27 Bolt, M8 x 35mm HH 4 LT242, Torque 17Nm (1.7 m-kg, 12 ft-lb)
28 Washer, M8 Flat 4
29 Ladder, Transom 1
30 Screw (w/ nut & washer) 1 Attaches Band to Ladder
31 Band 1
32 Screw, #8 x 5/8” PPH 1
33 Clamp 1
34 Clamp, Cable
(Tiewrap, 6”) 1
35 Tube (Speedometer) 1
36 Screw, #8 X 3/4” PPH 3
37 Speedometer Sensor 1 Silicone sealer on back side of speedo sensor and in
the 3 mounting holes in hull
38 Bow and Stern Eyes 3 Torque 15Nm (1.5m-kg, 11 ft-lb)
(w/ nuts and plates) Apply silicone sealer to mounting surfaces.
8-17
HULL
8 DECK HULL AND DECK
8-18
HULL 8
HULL AND DECK x DECK
8-19
HULL
8 DECK HULL AND DECK
8-20
HULL 8
HULL AND DECK x DECK
REMOVAL AND INSTALLATION CHART (Continued)
8-21
HULL
8 DECK HULL AND DECK
8-22
HULL 8
HULL AND DECK x DECK
REMOVAL AND INSTALLATION CHART
Step Procedure / Part Name Q’ty Service Points
THROUGH HULL AND DRAIN Follow the “Step” order for removal.
FITTINGS
8-23
HULL
8 DECK HULL AND DECK
GUNWALE
EXPLODED DIAGRAM
1
2
4
8-24
HULL 8
HULL AND DECK x DECK
8-25
TRBL 9
TROUBLE ANALYSIS x ANLS
® ® ®
WINDOWS 95, WINDOWS 98, WINDOWS ME,
® ® ®
WINDOWS 2000, OR WINDOWS XP .......................................... 9-3
UPDATING THE DATABASE ............................................................ 9-7
® ® ® ®
If this software is run on Microsoft Windows 95, Windows 98, Windows Me, Windows 2000, or
®
Windows XP, the information can be displayed in colorful graphics. Also, the software can be operat-
ed using either a mouse or a keyboard.
1 2 3 4 5
9-1
9 TRBL
ANLS TROUBLE ANALYSIS
Make sure your computer meets the following requirements before using this software.
9-2
TRBL 9
TROUBLE ANALYSIS x ANLS
9-2.
9-3
9 TRBL
ANLS TROUBLE ANALYSIS
9-4
TRBL 9
TROUBLE ANALYSIS x ANLS
9-5
9 TRBL
ANLS TROUBLE ANALYSIS
Install the Database file before using the Yamaha Diagnostic System, otherwise, the program will not
operate correctly. For installation procedures, refer to “UPDATING THE DATABASE” on the next page.
9-6
TRBL 9
TROUBLE ANALYSIS x ANLS
After about three seconds, the display will automatically go to the first menu display, or you can click
or press any key to go to the first menu. (See fig. 12.)
9-7
9 TRBL
ANLS TROUBLE ANALYSIS
Do not click the Starting service tool [Enter] button or press the Enter key on your keyboard until
the database has been updated, otherwise, the program will not operate correctly.
9-8
TRBL 9
TROUBLE ANALYSIS x ANLS
9-9
9 TRBL
ANLS TROUBLE ANALYSIS
9-10
TRBL 9
TROUBLE ANALYSIS x ANLS
9-11
9 TRBL
ANLS TROUBLE ANALYSIS
1
2
9-12
TRBL 9
TROUBLE ANALYSIS x ANLS
Open the Yamaha Diagnostic System window. (Fig. 20) After about three seconds, the display will
automatically go to the first menu, or click or press any key to go to the first menu. (See fig. 21.)
9-13
9 TRBL
ANLS TROUBLE ANALYSIS
9-14
TRBL 9
TROUBLE ANALYSIS x ANLS
9-15
9 TRBL
ANLS TROUBLE ANALYSIS
Eight commands appear in the main Menu. Select a command in any of the following three ways:
9-16
TRBL 9
TROUBLE ANALYSIS x ANLS
9-17
9 TRBL
ANLS TROUBLE ANALYSIS
9-18
TRBL 9
TROUBLE ANALYSIS x ANLS
top.
9-19
9 TRBL
ANLS TROUBLE ANALYSIS
9-20
TRBL 9
TROUBLE ANALYSIS x ANLS
9-21
9 TRBL
ANLS TROUBLE ANALYSIS
9-22
TRBL 9
TROUBLE ANALYSIS x ANLS
9-23
9 TRBL
ANLS TROUBLE ANALYSIS
Check that the items deleted are normal in the Diagnosis Record. If the items remain irregular, they
will appear as irregular in the Diagnosis Record. Even if you try to delete them, they are undeletable.
9-24
TRBL 9
TROUBLE ANALYSIS x ANLS
Click the OK button or press the Enter key on your keyboard (Fig. 35): The selected item is deleted.
To cancel deleting the item, click the Cancel button or press the Esc key on your keyboard.
9-25
9 TRBL
ANLS TROUBLE ANALYSIS
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.
9-26
TRBL 9
TROUBLE ANALYSIS x ANLS
keyboard
(Fig. 38).
9-27
9 TRBL
ANLS TROUBLE ANALYSIS
Avoid clicking the Execute and Cancel buttons repeatedly, otherwise, the ECM or PC will not
work properly and they could be damaged.
item.
test.
9-28
TRBL 9
TROUBLE ANALYSIS x ANLS
9-29
9 TRBL
ANLS TROUBLE ANALYSIS
9-30
TRBL 9
TROUBLE ANALYSIS x ANLS
If the engine is running an error message is displayed, follow the instructions that appear (Fig. 44).
To stop the stationary test, click the Cancel button (see Fig. 43).
9-31
9 TRBL
ANLS TROUBLE ANALYSIS
9-32
TRBL 9
TROUBLE ANALYSIS x ANLS
Make sure that there is fuel in the fuel tank, otherwise, an error will occur and the test cannot be per-
formed.
9-33
9 TRBL
ANLS TROUBLE ANALYSIS
keyboard (Fig. 49).
9-34
TRBL 9
TROUBLE ANALYSIS x ANLS
CAUTION:
Do not test the same cylinder three or more times, otherwise, the spark plug insulator could be
damaged.
Make sure there is fuel in the fuel tank, otherwise, an error will occur and the test cannot be performed.
9-35
9 TRBL
ANLS TROUBLE ANALYSIS
Select the test to be performed, then click the Select button or press the Enter key on your keyboard
(Fig. 52).
9-36
TRBL 9
TROUBLE ANALYSIS x ANLS
keyboard (Fig. 53).
9-37
9 TRBL
ANLS TROUBLE ANALYSIS
Avoid clicking the Execute and Cancel buttons repeatedly, otherwise, the ECM or PC will not
work properly and they could be damaged.
9-38
TRBL 9
TROUBLE ANALYSIS x ANLS
For the first ten seconds, operate all four cylinders, then stop one cylinder for five seconds. For the last
five seconds, operate all four cylinders.
9-39
9 TRBL
ANLS TROUBLE ANALYSIS
If the engine is not running, an error message is displayed. Follow the instructions that appear (Fig. 57).
9-40
TRBL 9
TROUBLE ANALYSIS x ANLS
Press the Enter key on your keyboard. The window of the selected item is displayed
(Fig. 59).
9-41
9 TRBL
ANLS TROUBLE ANALYSIS
9-42
TRBL 9
TROUBLE ANALYSIS x ANLS
value at the time the Enter key on your keyboard was pressed in the Monitor item selection.
9-43
9 TRBL
ANLS TROUBLE ANALYSIS
(Fig. 62).
Although the engine is running, the displayed time refers to the added hours until the Data logger
starts.
9-44
TRBL 9
TROUBLE ANALYSIS x ANLS
9-45
9 TRBL
ANLS TROUBLE ANALYSIS
(Fig. 65).
9-46
TRBL 9
TROUBLE ANALYSIS x ANLS
(Fig. 67).
9-47
9 TRBL
ANLS TROUBLE ANALYSIS
9-48
TRBL 9
TROUBLE ANALYSIS x ANLS
9-49
9 TRBL
ANLS TROUBLE ANALYSIS
test,
9-50
TRBL 9
TROUBLE ANALYSIS x ANLS
9-51
9 TRBL
ANLS TROUBLE ANALYSIS
9-52
TRBL 9
TROUBLE ANALYSIS x ANLS
consulted:
9-53
9 TRBL
ANLS TROUBLE ANALYSIS
9-54
TRBL 9
TROUBLE ANALYSIS x ANLS
9-55
LIT-18616-02-52