2007 Yamaha Ar230 Ho Sx230 Ho Boat Service Manual – PDF DOWNLOAD

AR/SR/SX230 HIGH OUTPUT

2007 Service Manual

AR230 High Output / SR230 High Output / SX230 High Output SXT1100-F / SXT1100A-F / SXT1100B-F / SXT1100C-F / SXT1100D-F Service Manual - 2007 First Edition Š2007 by Yamaha Motor Corporation, U.S.A. February 2007 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in U.S.A. Specifications, features and options are subject to change without notice.

2007043

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 know­ ledge, 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.

HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy-to-read, handy reference that contains 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 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.

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

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 manual, you are told the page number.

WARNINGS, CAUTIONS AND NOTES Attention is drawn to the various Warnings, Cautions, and Notes which distinguish important information in this manual in the following ways: 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.

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.

For the meanings of the symbols, refer to the next page(s).

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 1

2 3 4 5 6 7 8 9 10 1 General Information 1 2 Specifications 3 4 5 6 7 8 9 10 11 Periodic 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6Inspection 7 8 and 9 10 Adjustment 11 12 13 14 15 16 17 18 1 2 3 4 Fuel 5 6System 7 8 9 10 19 20 11 12 14 15 16 17 24 25 18 26 1927 2028 29 30 1 2 3 4 21 13 5 22 6 23 7 Unit 8 9 10 Power 11 12 13 14 15 16 17 18 19 21 22 23 24 25 26 27 2028 29 30 1 2 3 4 5 6 Jet 7 Pump 8 9 Unit 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 2 3 4 5 6 7 Electrical 8 9 10System 28 29 30 21 22 23 24 25 26 27 2028 29 30 11 12 13 14 15 16 17 18 19 3 4 5 6 7 8 Hull 9 10 Deck and 21 22 23 24 25 26 27 12 13 14 15 16 17 18 19 2028 29 30 210 3 Analysis 4 5 6 7 8 9 10 4 5 6 7 8 19 Trouble

2 11 1 2 3 25 18 26 1927 2028 29 30 11 12 2113 2214 23 15 24 16 17 21 22 23 24 25 26 27 2914 30 20 11 121 132 14 19 20 3 15 4 16 5 17 6 18 7 Symbols 8 212 92831310 specific data: 111 4to 515 indicate 616 717 818 919 10 24 29 30 1 2 213 22 4 23 5 6 725 826 19 27 21028Special Tool 3 4 5 6 7 8 9 10 14 26 15 16 17 1822 1923 20 14 21 11 24 21 22 11 2312 2413 25 12 13 15 Specified 1 27 2 28 3 29 4 30 5 6 Liquid 725 16 826 17 9 27 18 102819 2920 30 11 12 13 14 15 16 17 18 11 19 12 20 13 14 15 16 17 18 19 20 1 2 3 4 Specified 5 6 7 Engine 8 9 Speed 10 21 22 23 24 25 11 2612 21 2713 22 28 29 30 17 23 24 25 18 26 27 28 29 30 14 15 16

Specified Torque 1 2 3 4 5 6 7 8 9 10 19 20 21 22 23 24 25 26 27 28 29 30 26 19 27 2028 29 30 11 122113 22 14 23 15 24 16 25 17Measurement 18 Specified 21 22 23 24 25 26 27 29 30 11 12 13 14 15 Specified 16 17 18Electrical 19 2028 Valve

HULL DECK

21

22

23

24

25 26 27 (Ω), 28 Voltage 29 30 (V), [Resistance Current 728 9930 10 7 8829 (A)] 10

22 11 2322 2433 25 26 44 Electric 55 27 66

21

11 14 20 11 12 12 13 13 Symbol 14 15 15 16 16 17 17 18 18 19 19 20 exploded to in an

1

1

2

21 21 3

2 11

3 12

4 13

22 23 23 422 5

diagram= indicate grade of lubricant and location of lubri24 725 25 269 27 2710 28 28 29 29 30 30 624 8 26 cation point:

5 14

7 16

6 15

12 13 14 15 16 3 4 5 6 7 21 22 23 24 25 11 2112122132 23 143 24 154 16 255 17 266 1

11 2

8

9

10

17 18Yamaha 19 20 2-stroke outboard motor oil Apply 17 18 20 3 resistant water 8 Apply 9 119 10 2 4 5 6 grease 7 8 (Yamaha 9 10 26 grease 27 28A, 29 30 marine grease) Yamaha 1827 1928 20929 30 12 10 13 14 15 16 17 grease 18 19 20 7 Apply molybdenum disulfide 8 11

16Symbols 17 21 18 19 22 1123 1224 13 2514 2615 27 28 29 22 30 20 23 to 24

21

422 523 6 24 7 25 8 5 6 7 8 9 1 102 3 4 5 6 7 8 9 10 14 15 16 17 20 13 614 715 18 19 20 11Apply Maker® 1 18 2 19 3 412 5Gasket 816 917 10 11 12 13 14 15 16 17 18 1911 2012 Apply 18 19 20Bond No. 4) Yamabond #4 10 (Yamaha 1 2 3 4 513 614 715 816 917 21 22 23 24 25 26 11 27 12 28 21 22 23 24 1725 18No. 26 19271 2720 (Red 28 29 30 1329Apply 1430 15 16 LOCTITE® LOCTITE) 21 22 23 24 25 26 11 27 122821 29 30 23 16 24 25 1826 19No. 2720 242 28 (Blue 29 30LOCTITE) LOCTITE® 13 22 14 Apply 15 17 1

1

2

2 11

3 12

25 an26exploded 27 28 diagram 29 30 in indicate grade of sealing or locking agent and 9 127102 28 6point: 7 8 9 10 26location 29 4 305 of3application

3 21 4 13

21

21

22

22

23

24 25 26 27 No. 28 567 29 (PST) 30 23 Apply LOCTITE® 24 Apply Silicone Sealant 25 26 27 28 29 30

NOTE:________________________________ In this manual, the above symbols may not be used in every case.

567

INDEX

GEN INFO

GENERAL INFORMATION

1

SPEC

SPECIFICATIONS

2

INSP ADJ

PERIODIC INSPECTION AND ADJUSTMENT

3

FUEL

FUEL SYSTEM

4

POWR

POWER UNIT

5

JET PUMP

JET PUMP

6

ELEC

ELECTRICAL SYSTEM

7

HULL DECK

HULL AND DECK

8

TRBL ANLS

TROUBLE ANALYSIS

9

x 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

GENERAL INFORMATION x

GEN INFO

1

A60700-0*

IDENTIFICATION NUMBERS PRIMARY I.D. NUMBER

1

The primary I.D. number is stamped on a label 1 attached to the deck under the rear seat.

Starting Primary I.D. Number: SXT1100-F / SR230HO, F2A-700101 SXT1100A-F / SX230HO, F2A-710101 SXT1100B-F / SX230HO, F2A-720102 SXT1100C-F / AR230HO, F2A-730102 SXT1100D-F / AR230HO, F2A-740102 2

ENGINE SERIAL NUMBER The engine serial number is stamped on a label on top of the oil tank 2.

Starting Engine Serial Number: 6P6: 1010101

HULL IDENTIFICATION NUMBER (H.I.N.)

3

The H.I.N. is stamped into the hull on the starboard side of the stern 3, just below the rubrail.

1-1

1

GEN INFO

GENERAL INFORMATION

SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be followed by Yamaha dealers and their mechanics.

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 spectacles or safety goggles when using compressed air, when grinding or when doing any operation which may cause particles to fly off.

Protect hands and feet by wearing safety gloves and protective shoes if appropriate to the work you are doing.

OILS, GREASES AND SEALING FLUIDS Use only Genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha.

Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual. However, safety is all-important, and by adopting good safety practices, any risk is minimized. A summary of the most important precautions is as follows: 1. While working, maintain good standards of personal and industrial hygiene.

2. Clothing which has become contaminated with lubricants should be changed as soon as practicable and laundered before further use.

1-2

GENERAL INFORMATIONx

GEN INFO

1

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

4. Hands, and any other part of the body which have been in contact with lubricants or lubricant-contaminated clothing, should be thoroughly washed with hot water and soap as soon as practicable.

5. To protect the skin, the application of a suitable barrier cream to the hands before working is recommended.

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

GOOD WORKING PRACTICES 1. The right tools Use the special tools that are designed to protect parts from damage. Use the right tool in the right manner – don’t improvise.

2. Tightening torque Follow the torque tightening instructions.

When tightening bolts, nuts and screws, tighten the larger sizes first, and tighten inner-positioned fasteners before outer­ positioned ones.

3. Non-reusable items Always use new gaskets, packings,­­­o-rings, oil seals, split-pins and circlips, etc. on reassembly.

1-3

1

GEN INFO

GENERAL INFORMATION

DISASSEMBLY AND ASSEMBLY 1. Clean parts with solvent and compressedair on disassembling them.

2. Oil the contact surfaces of moving parts on assembly.

3. After assembly, check that moving parts operate normally.

4. Install bearings with the manufacturer’s markings on the side exposed to view and liberally oil the bearings.

Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

5. When installing oil seals, apply a light coating of water-resistant grease to the outside diameter.

1-4

GENERAL INFORMATIONx

GEN INFO

1

SPECIAL TOOLS Use of the correct special tools recommended

by Yamaha will aid the work and enable accurate assembly and tune-up. Improvisations and use of improper tools can cause damage to the equipment.

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 starting with “90890-.”

MEASURING TOOLS 1 Dial Gauge P/N YU-03097-B 90890-01252 2 Dial Gauge Stand P/N 90890-06583 3 Dial Gauge Needle P/N 90890-06584 4 Dial Gauge Stand Set P/N YW-06585 90890-06585 5 Pocket Tester P/N YU-03112-C 90890-03112 6 Digital Circuit Tester P/N YU-A1927 90890-03174 7 Vacuum Synchronizer P/N YU-44456 8 Vacuum Gauge P/N 90890-03094 Vacuum attachment P/N 90890-03060 9 Test Connector P/N YW-06862 90890-06862 1

2

3

4

5

6

7

8

9

11

12

13

14

15

16

17

18

19

24

25

21

22

23

26

27

28

10 Fuel Pressure Gauge Adapter P/N YW-06842 20 90890-06842

29 1-5

30

1 1

2

GEN INFO 3

4

GENERAL INFORMATION 5

SPECIAL TOOLS

7

12 13 14 15 Gauge 16 17 11 Fuel Pressure P/N YB-06766 4 90890-06786 5 6 212 223 23 24 25 726 827

1

8

9

10

18

19

20

9 28 1029

21 22 23 24 25 26 27 28 29 11 12 13 Cylinder 14 15 16 17 18 Gauge Set 19 20 4 23

11

15 16 17 18Gauge 19 20 14 Compression P/N YU-33223-1 5 6 827 9 28 1029 30 24 25 72690890-03160

212 223

1

12 223

2

P/N YU-03017 5 6 726 827 9 28 1029 24 2590890-06759

1 212 223 12

13 4 23

13 234

14 5 24

5 24

6 25

14

15

16

24 5

625

726

4

15

16

17

4

6 25

726

19 20 18 Test Harness (3 pins) P/N YB-06791 827 9 28 1029 90890-06791 30

5

16

17

18

5

726 827

20 Harness (3 pins) 19 Test P/N YB-06770 9 28 1029 30 90890-06770

6

17

19

26

27

18 28

30

17 18Gap 19 Tester 20 16 Spark P/N YM34487 726 8 27 9 90890-06754 28 10 29 30

15

4 23

30

16 17Voltage 18 19Adapter 20 15 Peak P/N YU-39991 6 726 827 9 28 1029 30 25 90890-03172

14

3

13

30

13 14 15 16Gauge 17 18Extension 19 20 12 Compression 3 P/N 4 5 90890-06582 6 7 8 9 10

11 2

1

6

18 19 20 17 Test Harness (2 pins) P/N YB-06792 29 30 8 27 9 28 1090890-06792

2 Harness 3 4 (6 5 pins) 6 7 20 1 Test P/N YB-06790 13 14 15 16 17 29 11 30 12 90890-06790

8

9

10

18

19

20

1 212 11 21

22 23 25 pins) 3 Harness 4 524 6(3 7 26 8 27 9 2810 29 Test P/N YB-06793 12 13 14 15 16 17 18 19 20 90890-06793

22 Test 23 Harness 24 25 (263 pins) 27 28 P/N YB-0677 90890-06777

29

30

30

1-6

1

2

11

12

3

4

5

6

7

8

9

10

13

14

15

16

17

18

19

20

GENERAL INFORMATIONx YB-06769 90890-06769

YB-35956-A 90890-06756

1 212 223 11 1 212

11 21

223

13 4 23

24 25 726 8 27 28 10 29 4 Test 5 6 23 Harness (3 9pins) P/N YB-06769 14 15 16 17 18 19 20 90890-06769

30

7

8

9

10

21 22 23 12 13 14

24 15

26 27 Diagnostic 28 29 30System 25 Yamaha 16 17 18 19 20

22

25

27 28 Diagnostic 29 30 26 Yamaha System Connector for Watercraft P/N 60V-WS850-00-00 USB Cable P/N 68F-WS850-00-00 Serial Cable

23

24

YAMAHA DIAGNOSTIC SYSTEM for Watercraft

INSTALLATION MANUAL

60E-2819K-10

YW-06862 90890-06862

1-7

for Watercraft

P/N LIT-YDIS1-23-00

60V -WS853-01 60V-WS850-00-00 USB Cable / 68F-WS850-00-00 Serial Cable

1

5 Vacuum/Pressure 625 726 8 27 9 28 10 29 30 Gauge Set 24 Pump P/N YB-35956-A 15 16 17 18 19 20 90890-06756

11 12 13 14 2 3 4 5 6

1

LIT-YDIS1-21-00 60V-85300-01

12

SPECIAL TOOLS

GEN INFO

1

GEN INFO

GENERAL INFORMATION REMOVAL AND INSTALLATION TOOLS

YU-38411 90890-01426

YW-06551

1 Oil Filter Wrench P/N YU-38411 90890-01426

90890-06551

YS-01880-A 90890-01701

2 Coupler Wrench P/N YW-06551 90890-06551

YM-01082 90890-01080

3 Sheave Holder P/N YS-01880-A 90890-01701 4 Rotor Puller P/N YM-01082 90890-01080

YU-01235 90890-01235

YM-45469 90890-04019

5 Rotor Holder P/N YU-01235 90890-01235 6 Valve Remover/Installer Kit P/N YM-45469 90890-04019

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)

7 Valve Spring Compressor Attachment P/N YM-4114 (ø19 mm) 90890-04114 (ø19 mm) YM-4108 (ø22 mm) 90890-04108 (ø22 mm) 8 Valve Guide Remover P/N YM-04111 (ø4.0 mm) 90890-04111 (ø4.0 mm) YM-04116 (ø4.5 mm) 90890-04116 (ø4.5 mm)

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

9 Valve Guide Installer P/N YM-04112 (ø4.0 mm) 90890-04112 (ø4.0 mm) YM-04117 (ø4.5 mm) 90890-04117 (ø4.5 mm)

1

2

3

4

5

6

7

11

12

13

14

15

16

17

24

25

21

22

23

26

8

27

9

10

Valve Guide Reamer P/N YM-04113 (ø4.0 mm) 18 19 20 90890-04113 (ø4.0 mm) YM-04118 (ø4.5 mm) 28 29 30 90890-04118 (ø4.5 mm)

1-8

1-8

GENERAL INFORMATIONx 1 2 3 4 5 6

7

8

GEN 10 INFO

1

9

12 13 14 15 16 17 18 19 20 11 Valve Seat Cutter Intake 21 22 23 24 25 26 27 28 29 30 P/N 90890-06813 (60°)

90890-06814 (45°)

90890-06815 (30°)

1 11 1 21 2 11 2

1 11

12

1 212 223

1

1

1

1

11 2

11 2

11 2

4 23

13 4

14 5 24

14 5

15 6

21 22 23 24 12 13 14 15 3 4 5 6

25 16 7

21 22 23 24 12 13 14 15 3 4 5 6

14 15Seat 16 Cutter 17 18 Set 19 13 Valve 4 5 6 7 8 9 10 P/N YM-91043-C

25 16 7

5 24

25

26

27

28

20

29

16 17 18 19 20 Piston Ring Compressor P/N YM-08037 6 7 827 9 28 1029 30 25 2690890-05158

30

16 17 18 19 20 15 Drive Shaft Holder (Impeller) P/N YB-06151 6 7 8 9 28 1029 30 25 26 2790890-06519 17 18 19 20 16 Slide Hammer Set (jet pump bearing) 7 8 9 10 P/N YB-06096 26 27 28 29 30 17 18 19 20 Stopper Guide Plate 8 9 10

(jet pump bearing)

P/N 90890-06501

(jet pump bearing) P/N 90890-06535

26 27 28 29 30 17 18 19 20 Bearing Puller 8 9 10

21 22 23 24 11 12 13 14 15

25 16

2

7 8 9 26 27 28 29 30 17 18 19 20 Stopper Guide Stand (jet pump bearing) 11 12 13 14 15 16 17 18 19 20

3 4 5 21 22 23 24 11 12 13 14 15 21

12 3

12 3

4 23

13

10

13 14Seat 15 Cutter 16 17 Holder 18 19 20 12 Valve P/N 90890-06811 (ø4.0 mm) 5 90890-06812 6 726 827 9(ø4.5 223 23 25 28 1029 4 24 mm)30

21 22 23 24 12 13 14 15

1 212 223 11

2

Exhaust P/N 90890-06315 (60°)

90890-06312 (45°) 3 4 5 6 7 8(30°) 9

90890-06328

22

23

24

25

6 25 16 26

27

26 27 28 29 17 18 19 20

30

Bearing Puller Claw 1 (jet pump bearing) 101 P/N 90890-06536 2 3 4 5 6 7 8 9 10

P/N 90890-06538

4 5 6 7 8 9 10 28 129 2 30 3 21 22 23 24 25 26 27 28 Drive Rod L3 (jet pump bearing)29 11 12 13 14 15 16 17 18 19 20

21

1-9

P/N 90890-06652

23 24 Bearing 25 26 Attachment 27 28 29 30 22 Needle (jet pump bearing and oil seal) P/N YB-06112, YB-06196

90890-06614, 90890-06653

30

1

GEN INFO

GENERAL INFORMATION

1-10

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

SPECIFICATIONSx

SPEC

2

GENERAL SPECIFICATIONS

SXT1100 F2A 6P6C/6P63

SR/SX: 1.9 (6.23 ft); AR: 2.71 (8.89 ft) SR/SX: 1439 (3172 lb); AR: 1484 (3272 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

Jet thrust nozzle trim angle Impeller pitch

Degree Degree

+3 Port 18.1° / Stbd. 15.1°

2-1

2

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

SXT1100

SE, SF, SG, SH, SJ, SL L (US qt, Imp qt) L (US qt, Imp qt) L (US qt, Imp qt)

2-2

SPECIFICATIONSx

SXT1100

2-3

SPEC

2

2

SPEC

SPECIFICATIONS

MAINTENANCE SPECIFICATIONS SXT1100

0.020–0.047 (0.0008–0.0019)

75.955-75.970 (2.9903-2.9909)

16.971 (0.6681) 2-4

SPECIFICATIONSx

SXT1100

6P601

2-5

SPEC

2

2

SPEC

SPECIFICATIONS

MAINTENANCE SPECIFICATIONS SXT1100

SXT1100

Port 18.1 Stbd. 15.1

SXT1100 Marine Group 24 Dual Purpose 675 CCA 100 (12/68.4)

2-6

2-6

SPECIFICATIONSx MAINTENANCE SPECIFICATIONS

SRT1100

2-7

SPEC

2

2

SPEC

SPECIFICATIONS

MAINTENANCE SPECIFICATIONS SXT1100

2-8

SPECIFICATIONSx

Screw

1/4-20

16

Nut

8-32 10-24

6 5

Fuel sender

2-9

4.9 7.9 2.3 2.9

0.49 0.79 0.23 0.29

SPEC

3.5 5.6 1.6 2.1

2

2

SPEC

SPECIFICATIONS

TIGHTENING TORQUES

2-10

SPECIFICATIONSx TIGHTENING TORQUES

2-11

SPEC

2

2

SPEC

SPECIFICATIONS

TIGHTENING TORQUES

2-12

SPEC

SPECIFICATIONSx TIGHTENING TORQUES

M8

2-13

6

20

2.0

14

3

20

2.0

14

2

2

SPEC

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 4 strainer - impeller duct Drive shaft nut - drive shaft Impeller (left-hand threads) – drive shaft

Nut Impeller

6.9 1.8

50 13

Intermediate housing - bulkhead

Driven coupling - shaft

Grease nipple - intermediate housing Hull:

Bolt M8 3 17 1.7 Driven coupling M24 1 36 3.6 Nipple – 1 5.4 0.54

12

Steering cable locknut (jet thrust nozzle side) Steering cable grommet – hull Pilot water outlet - hull Engine mount – hull Engine damper – hull Electrical: Electrical box - bulk head Terminal cover - electrical box Cover - electrical box

Starter motor lead - electrical box Battery positive lead - electrical box Fuse holder stay - electrical box

ECM - electrical box

Bracket (coupler) - electrical box

– M20

Nut

–

Nut – Nut Bolt M8 Bolt M6

1 1

69 18

25 3.9

1

6.5

0.65

4.7

1 2 8 4

5.9 4.2 17 6.4

0.59 0.42 1.7 0.64

4.3 3.0 12 4.6

Bolt Screw Tapping screw Screw Screw

M8 M5 ø5

4 4 18

17 4.9 4.9

1.7 0.49 0.49

12 3.5 3.5

M6 M6

1 1

7.6 7.6

0.76 0.76

5.5 5.5

Tapping screw Tapping screw Tapping screw

ø6

1

3.9

0.39

2.8

ø6

4

3.9

0.39

2.8

ø6

1

3.9

0.39

2.8

2-14

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

SPECIFICATIONS

Nut A Bolt B

Nm

M•kg

ft•lb

5.0 8.0 18 36 43

0.5 0.8 1.8 3.6 4.3

3.6 5.8 13 25 31

8 mm 10 mm 12 mm 14 mm 17 mm

M5 M6 M8 M10 M12

Bolt Dia.

6-32 8-32 10-24 1/4-20 5/16-18

This chart specifies the torques for tightening standard fasteners with standard clean dry ISO threads at room temperature. Torque specifications for special components or assemblies are given in applicable sections of this manual. To avoid causing warpage, tighten multifastener assemblies in a criss-cross fashion, in progressive stages until the specified torque is reached.

B

A

GENERAL TORQUE

General Torque Specifications

General Torque Specifications Nm

M•kg

ft•lb

1.1 2.3 2.6 8.6 15

0.11 0.23 0.26 0.86 1.5

0.8 1.65 1.9 6.25 11.0

2-16

SPECIFICATIONSx CABLE AND HOSE ROUTING

2-17

SPEC

2

2

SPEC

SPECIFICATIONS

CABLE AND HOSE ROUTING

2-18

SPECIFICATIONSx CABLE AND HOSE ROUTING

2-19

SPEC

2

2

SPEC

SPECIFICATIONS

CABLE AND HOSE ROUTING

2-20

SPECIFICATIONSx CABLE AND HOSE ROUTING

2-21

SPEC

2

2

SPEC

SPECIFICATIONS

CABLE AND HOSE ROUTING

2-22

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

PERIODIC INSPECTION AND ADJUSTMENT x

3-1

INSP ADJ

3

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.

Steering cable adjustment 1. Measure: ● Distance between the center of the steering nozzle joint and the transom plate mounting surface of the pump.

Incorrect distance ➔ Adjust steering cable joint at nozzle end.

Steering Adjustment Distance: 11.24 in (285.45mm) 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)

Lock Nut: 4.9 ~ 7.8Nm (0.49~0.78 kg-m, 3.54~5.64 ft-lb)

8MM (0.31 IN) MINIMUM

3-2

PERIODIC INSPECTION AND ADJUSTMENT x

INSP ADJ

3

REMOTE CONTROL UNIT Throttle Cables 1. Remove: • Airbox cover.

2. Set: • Remote Control levers to Neutral position.

1 Cable Wheel 2 Locknuts 3 Throttle Cable

3. Check: • Throttle Cable Wheel 1 should contact the idle screw and there should be free play in the cable.

• If adjustment is necessary, loosen the Locknuts 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 control 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 Cable wheel has 0.001Æ (0.025mm) to 0.079Æ (2.0mm) clearance to the Stop. 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 throttle bodies can be damaged.

3-3

3

INSP ADJ

PERIODIC INSPECTION AND ADJUSTMENT

3-4

PERIODIC INSPECTION AND ADJUSTMENT x

3-5

INSP ADJ

3

3

INSP ADJ

PERIODIC INSPECTION AND ADJUSTMENT

3-6

PERIODIC INSPECTION AND ADJUSTMENT x

INSP ADJ

3

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

• When the valve clearance is to be measured or adjusted, the piston must be at Top Dead Center (TDC) on the compression stroke.

3-7

3

INSP ADJ

PERIODIC INSPECTION AND ADJUSTMENT

3-8

PERIODIC INSPECTION AND ADJUSTMENT x

3-9

INSP ADJ

3

3

INSP ADJ

PERIODIC INSPECTION AND ADJUSTMENT

Make a note of the position of each valve lifter 3 and valve pad 4 so they can be installed in the correct place. lowing table:

3-10

PERIODIC INSPECTION AND ADJUSTMENT x

3-11

INSP ADJ

3

3

INSP ADJ

PERIODIC INSPECTION AND ADJUSTMENT

3-12

PERIODIC INSPECTION AND ADJUSTMENT x

3-13

INSP ADJ

3

3

INSP ADJ

PERIODIC INSPECTION AND ADJUSTMENT

Place the craft in water, and then

3-14

PERIODIC INSPECTION AND ADJUSTMENT x

INSP ADJ

If the oil temperature is low, the reading on the dipstick will be low. If the temperature is high, the reading on the dipstick will be high.

Do not run the engine for more than 15 seconds without supplying water when checking the oil level on land. The engine could overheat.

craft in a horizontal position.

3-15

3

3

INSP ADJ

PERIODIC INSPECTION AND ADJUSTMENT

3-16

PERIODIC INSPECTION AND ADJUSTMENT x

INSP ADJ

When starting the engine, make sure the dipstick is securely fitted into the oil tank.

3-17

3

3

INSP ADJ

PERIODIC INSPECTION AND ADJUSTMENT

Make sure the air filter element is installed in the filter case properly.

If cleaning the air filter element, use cold or lukewarm water and let it air dry completely. Do not use detergent or a solvent to clean the air filter element, or dry it with heat or compressed air, otherwise it could be damaged.

3-18

PERIODIC INSPECTION AND ADJUSTMENT x

3-19

INSP ADJ

3

3

INSP ADJ

PERIODIC INSPECTION AND ADJUSTMENT

3-20

PERIODIC INSPECTION AND ADJUSTMENT x

3-21

INSP ADJ

3

3

INSP ADJ

PERIODIC INSPECTION AND ADJUSTMENT

BILGE PUMP 1. Remove inspection cover in pump clean-out tray.

2. Inspect: • Bilge strainer Contaminants → Clean.

Cracks/damage → Replace.

Inspection Steps: • Install the coupling cover.

Disconnect the bilge strainer from the bilge strainer holder.

3-22

PERIODIC INSPECTION AND ADJUSTMENT x

3-23

INSP ADJ

3

3

INSP ADJ

PERIODIC INSPECTION AND ADJUSTMENT 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.

● ●

Nozzle pivot shaft collar Bearing housing Recommended Grease: Water resistant grease

NOTE: ● Fill in the bearing housing with water resistant 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.

3-24

PERIODIC INSPECTION AND ADJUSTMENT x

INSP ADJ

3

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)

3-25

3

INSP ADJ

PERIODIC INSPECTION AND ADJUSTMENT 4.

3-26

CHAPTER 4 FUEL SYSTEM FUEL TANK AND FUEL PUMP MODULE

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Fuel hose disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel pump module removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check valve inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel hose inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel pump filter inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel pump module installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel hose connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL

4-1 4-1 4-4 4-4 4-4 4-4 4-4 4-4 4-5 4-5 4-5

INJECTION SYSTEM EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Hose clamps removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Hose clamps installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Fuel hose disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Fuel line inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Fuel hose installation (replacing with new fuel hose) . . . . . . . . . . . . . . . . . . . . . . . 4-17 Fuel hose connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Throttle body removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Fuel injector inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Throttle body inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Bypass valve motor inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Throttle body installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Throttle bodies synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Fuel pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

FUEL SYSTEM x

FUEL

REMOVAL AND INSTALLATION CHART Step

Procedure / Part Name

Q’ty

FUEL TANK PUMP MODULE

1 Connector, harness 2 2 Cover 2 3 Screw, Machine 2 4 Clamp 2 5 Fuel hose 2 6 Screw 16

7 Plate 2 8 Fuel Pump Assembly 2 9 Seal 2 10 Screw 5 4-1

Service Points Follow the “Step” order for removal.

NOTE: Apply Loctite, torque in 2 steps see page 4-4 Pump Module Removal, 4-5 Installation

Apply Loctite, 2.9 Nm (30 kgf-cm)

4

4

FUEL

FUEL SYSTEM

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

Step Procedure / Part Name Q’ty 11 Fuel Level Sender 1 12 Gasket 1 13 Clamp 4 14 Hose, Vent 1 15 Hose, Vent 1 16 Valve, Check 1 17 Nut 1 18 Washer, Star 1 19 Washer 1 20 Vent, Fuel 1 21 Clamp 4

22 Hose, Fuel Filler 1 23 Nut, #8-32 Nylon Lock 6 24 Washer, #8 Flat 6 25 Screw, #8-32 6 4-2

Service Points

4.2 Nm (0.42 kgf-m, 3.0 ft-lbs) See detail on clamp installation

FUEL SYSTEM x

FUEL

4

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

Step Procedure / Part Name Q’ty 26 Filler Cap Assembly 1 27 Gasket 1

FUEL TANK

28 Screw, Machine 1/4” - 20 x 1” 4 29 Fuel Tank Hold Downs 2 30 Fuel Tank Assembly 1

4-3

Service Points

Note: Deck must be cut at outline to access fuel tank for removal 4.9~7.9 Nm (50~80 kgf-cm) Reverse the removal steps for installation.

4

FUEL

FUEL SYSTEM SERVICE POINTS

Fuel hose disconnection 1. Disconnect: • Fuel hose Refer to “FUEL INJECTION SYSTEM.”

Fuel pump module removal 1. Remove: • Screws • Retainer NOTE: Loosen the screws in the sequence shown.

2. Remove: • Fuel pump module 1

?

Fuel pump module removal 1. Check: • Check valve Faulty ➔ Replace.

Fuel tank inspection 1. Inspect: • Fuel tank Cracks/damage ➔ Replace.

Fuel hose inspection Refer to “FUEL INJECTION SYSTEM.”

4-4

FUEL SYSTEM x

FUEL

Screws

4.9 Nm (0.49 kgf-m) 7.9 Nm (0.8 kgf-m)

?

SYSTEM.”

4-5

4

4

FUEL

FUEL SYSTEM

4-6

FUEL SYSTEM x FUEL INJECTION SYSTEM (Cont’d.)

4-7

FUEL

4

4

FUEL

FUEL SYSTEM

FUEL INJECTION SYSTEM (Cont’d.)

4-8

FUEL SYSTEM x FUEL INJECTION SYSTEM (Cont’d.)

4-9

FUEL

4

4

FUEL

FUEL SYSTEM

FUEL INJECTION SYSTEM (Cont’d.)

4-10

FUEL SYSTEM x FUEL INJECTION SYSTEM (Cont’d.)

4-11

FUEL

4

4

FUEL

FUEL SYSTEM

FUEL INJECTION SYSTEM (Cont’d.)

4-12

FUEL SYSTEM x FUEL INJECTION SYSTEM (Cont’d.)

4-13

FUEL

4

4

FUEL

FUEL SYSTEM

FUEL INJECTION SYSTEM (Cont’d.)

4-14

FUEL SYSTEM x

4-15

FUEL

4

4

FUEL

FUEL SYSTEM

4-16

FUEL SYSTEM x

4-17

FUEL

4

4

FUEL

FUEL SYSTEM

4-18

FUEL SYSTEM x

4-19

FUEL

4

4

FUEL

FUEL SYSTEM

4-20

FUEL SYSTEM x

4-21

FUEL

4

4

FUEL

FUEL SYSTEM

4-22

FUEL SYSTEM x

4-23

FUEL

4

4

FUEL

FUEL SYSTEM

4-24

FUEL SYSTEM x

4-25

FUEL

4

4

FUEL

FUEL SYSTEM

4-26

CHAPTER 5 POWER UNIT ENGINE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Compression pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil filter removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shim removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine mount inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coupling clearance inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 5-1 5-1 5-4 5-4 5-6 5-6 5-7 5-7 5-7

EXHAUST PIPE 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 EXHAUST PIPES 1 AND 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Oil tank removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil strainer inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil tank installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-15 5-15 5-15 5-21 5-21 5-22 5-22

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

Oil pump inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

Check valve inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

Oil strainer inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Oil pump installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

REDUCTION DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

Drive coupling removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

Drive shaft removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

Bearing removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

Oil pump driven gear inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

Drive shaft inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

Bearing installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Drive shaft installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

Drive coupling installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 GENERATOR AND STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Flywheel magneto removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter clutch inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flywheel magneto installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-41 5-41 5-41 5-46 5-46 5-46 5-48

CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Camshaft removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft sprockets inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing chain tensioner inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-49 5-49 5-49 5-55 5-55 5-56 5-58 5-58 5-59

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Cylinder head removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder head inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder head installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-63 5-63 5-63 5-65 5-65 5-65 5-66

VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Valve removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve spring inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-68 5-68 5-68 5-70 5-70 5-71 5-71

Valve Valve Valve Valve Valve

guide inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . guide replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . seat inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . seat reface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-72 5-73 5-75 5-76 5-78

CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Crankcase disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing chain inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-80 5-80 5-80 5-85 5-85 5-86 5-86 5-87

CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Connecting rod and piston removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder and piston inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston ring inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston pin inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting rod inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting rod and piston installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-90 5-90 5-90 5-92 5-92 5-93 5-94 5-96 5-97 5-99

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Crankshaft removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-103 5-103 5-103 5-104 5-104 5-104 5-107

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Thermostat inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermostat installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-108 5-108 5-108 5-110 5-110 5-110

COOLING WATER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111

POWER UNIT x

5-1

POWR

5

5

POWR

POWER UNIT

ENGINE UNIT EXPLODED DIAGRAM

5-2

POWER UNIT x

5-3

POWR

5

5

POWR

POWER UNIT

5-4

POWER UNIT x

5-5

POWR

5

5

POWR

POWER UNIT

5-6

POWER UNIT x

5-7

POWR

5

5

POWR

POWER UNIT

5-8

POWER UNIT x EXHAUST PIPE 3 (Cont’d.)

5-9

POWR

5

5

POWR

POWER UNIT

EXHAUST PIPE 3 (Cont’d.)

5-10

POWER UNIT x

5-11

POWR

5

5

POWR

POWER UNIT

EXHAUST PIPES 1 AND 2 (Cont’d.)

5-12

POWER UNIT x

5-13

POWR

5

5

POWR

POWER UNIT

EXHAUST MANIFOLD (Cont’d.)

5-14

POWER UNIT x

5-15

POWR

5

5

POWR

POWER UNIT

OIL TANK (Cont’d.)

5-16

POWER UNIT x OIL TANK (Cont’d.)

5-17

POWR

5

5

POWR

POWER UNIT

OIL TANK (Cont’d.)

5-18

POWER UNIT x OIL TANK (Cont’d.)

5-19

POWR

5

5

POWR

POWER UNIT

OIL TANK (Cont’d.)

5-20

POWER UNIT x OIL TANK (Cont’d.)

5-21

POWR

5

5

POWR

POWER UNIT

OIL TANK (Cont’d.)

5-22

POWER UNIT x OIL TANK (Cont’d.)

5-23

POWR

5

5

POWR

POWER UNIT

OIL TANK (Cont’d.)

5-24

POWER UNIT x

5-25

POWR

5

5

POWR

POWER UNIT

OIL PUMP (Cont’d.)

5-26

POWER UNIT x OIL PUMP (Cont’d.)

5-27

POWR

5

5

POWR

POWER UNIT

OIL PUMP (Cont’d.)

5-28

POWER UNIT x OIL PUMP (Cont’d.)

5-29

POWR

5

5

POWR

POWER UNIT

OIL PUMP (Cont’d.)

5-30

POWER UNIT x OIL PUMP (Cont’d.)

5-31

POWR

5

5

POWR

POWER UNIT

5-32

POWER UNIT x REDUCTION DRIVE GEAR (Cont’d.)

5-33

POWR

5

5

POWR

POWER UNIT

REDUCTION DRIVE GEAR (Cont’d.)

5-34

POWER UNIT x REDUCTION DRIVE GEAR (Cont’d.)

5-35

POWR

5

5

POWR

POWER UNIT

REDUCTION DRIVE GEAR (Cont’d.)

5-36

POWER UNIT x

POWR

REDUCTION DRIVE GEAR (Cont’d.)

Oil pump driven gear inspection

5-37

5

5

POWR

POWER UNIT

REDUCTION DRIVE GEAR (Cont’d.)

5-38

POWER UNIT x REDUCTION DRIVE GEAR (Cont’d.)

5-39

POWR

5

5

POWR

POWER UNIT

REDUCTION DRIVE GEAR (Cont’d.)

5-40

POWER UNIT x

5-41

POWR

5

5

POWR

POWER UNIT

GENERATOR AND STARTER MOTOR (Cont’d.)

5-42

POWER UNIT x GENERATOR AND STARTER MOTOR (Cont’d.)

5-43

POWR

5

5

POWR

POWER UNIT

GENERATOR AND STARTER MOTOR (Cont’d.)

5-44

POWER UNIT x GENERATOR AND STARTER MOTOR (Cont’d.)

5-45

POWR

5

5

POWR

POWER UNIT

GENERATOR AND STARTER MOTOR (Cont’d.)

5-46

POWER UNIT x GENERATOR AND STARTER MOTOR (Cont’d.)

5-47

POWR

5

5

POWR

POWER UNIT

GENERATOR AND STARTER MOTOR (Cont’d.)

5-48

POWER UNIT x

5-49

POWR

5

5

POWR

POWER UNIT

CAMSHAFTS (Cont’d.)

5-50

POWER UNIT x CAMSHAFTS (Cont’d.)

5-51

POWR

5

5

POWR

POWER UNIT

CAMSHAFTS (Cont’d.)

5-52

POWER UNIT x CAMSHAFTS (Cont’d.)

5-53

POWR

5

5

POWR

POWER UNIT

CAMSHAFTS (Cont’d.)

5-54

POWER UNIT x CAMSHAFTS (Cont’d.)

5-55

POWR

5

5

POWR

POWER UNIT

CAMSHAFTS (Cont’d.)

5-56

POWER UNIT x CAMSHAFTS (Cont’d.)

5-57

POWR

5

5

POWR

POWER UNIT

CAMSHAFTS (Cont’d.)

5-58

POWER UNIT x CAMSHAFTS (Cont’d.)

5-59

POWR

5

5

POWR

POWER UNIT

CAMSHAFTS (Cont’d.)

5-60

POWER UNIT x CAMSHAFTS (Cont’d.)

5-61

POWR

5

5

POWR

POWER UNIT

CAMSHAFTS (Cont’d.)

5-62

POWER UNIT x

Hanger

5-63

POWR

5

5

POWR

POWER UNIT

CYLINDER HEAD

5-64

POWER UNIT x CYLINDER HEAD (Con’t.d)

5-65

POWR

5

5

POWR

POWER UNIT

CYLINDER HEAD (Cont’d.)

5-66

POWER UNIT x CYLINDER HEAD (Cont’d.)

5-67

POWR

5

5

POWR

POWER UNIT

5-68

POWER UNIT x VALVES AND VALVE SPRINGS

5-69

POWR

5

5

POWR

POWER UNIT

VALVES AND VALVE SPRINGS (Cont’d.)

5-70

POWER UNIT x VALVES AND VALVE SPRINGS (Cont’d.)

5-71

POWR

5

5

POWR

POWER UNIT

VALVES AND VALVE SPRINGS (Cont’d.)

5-72

POWER UNIT x VALVES AND VALVE SPRINGS (Cont’d.)

5-73

POWR

5

5

POWR

POWER UNIT

VALVES AND VALVE SPRINGS (Cont’d.)

5-74

POWER UNIT x VALVES AND VALVE SPRINGS (Cont’d.)

5-75

POWR

5

5

POWR

POWER UNIT

VALVES AND VALVE SPRINGS (Cont’d.)

5-76

POWER UNIT x VALVES AND VALVE SPRINGS (Cont’d.)

5-77

POWR

5

5

POWR

POWER UNIT

VALVES AND VALVE SPRINGS (Cont’d.)

5-78

POWER UNIT x VALVES AND VALVE SPRINGS (Cont’d.)

5-79

POWR

5

5

POWR

POWER UNIT

5-80

POWER UNIT x CRANCASE (Cont’d.)

5-81

POWR

5

5

POWR

POWER UNIT

CRANCASE (Cont’d.)

5-82

POWER UNIT x CRANCASE (Cont’d.)

5-83

POWR

5

5

POWR

POWER UNIT

CRANCASE (Cont’d.)

5-84

POWER UNIT x

POWR

5

CRANCASE (Cont’d.)

1 11 21 31 41 51

1

2

3

4 1 5 2 6 3 7 4 8 5 9 6 10 7

8

9

10

4 5 6 7 8 9 10 3 x 4105mm 5 6 bolts: 7 8 19 210 3 M9 11 22 33 44 55 66 77 88 99 10 10 11 12 13 14 1115 1216 1317 1418 1519 1620 17 18 19 20 M6 x 55mm bolts: 111 212 313 414 515 616 717 818 911 12 19 10 20 13 14 15 16 17 18 19 20 11 11 x12 1255mm 13 13 14 14bolts: 15 15 16 16 17 17 , 18 18 19 19 20 20 M6 2 3 4 5 6 7 8 9 10 21 25 22 26 23 27 24 28 25 29 26 30 27 28 29 30 21 22 23 24 11 12 13 14 15 16 17 18 19 20 M6 x 70mm bolts: 21 22 23 24 25 26 27 21 28 22 29 23 30 24 25 26 27 28 29 30 21 21 22 22 23 23 24 24 25 25 26 26 27 27 28 28 29 29 30 30 12 13 M6 14 x 1555mm 16 17bolts: 18 19 20 31 35 32 36 33 37 34 38 35 39 36 40 37 38 39 40 31 32 33 34 1

2

21 31 32 33 31 22 32 23 33 24 34 25 35 26 36 27 37 28 38 29 39 30 40 34 31 31 32 32 33 33 34 34 35 35 36 36 37 37 38 38 39 39 22 23 24 25 26 27 28 29 30 41 42 43 44 41 42 43 44 45 46 47 31 41 42 43 41 32 42 33 43 34 44 35 45 36 46 37 47 38 48 39 49 40 50 44 41 41 42 42 43 43 44 44 45 45 46 46 47 47 48 48 49 49 32 33 5-85 34 35 51 36 52 37 53 38 54 39 40 51 55 52 56 53 57 54 51 52 53 58 49 59 50 60 54 4151 4252 4353 4454 4555 4656 4757 48 51 51 52 52 53 53 54 54 55 55 56 56 57 57 58 58 59 59 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 52

53

54

55

56

57

58

59

60

35 36 37 40 40 45 46 50 47 48 49 45 46 47 50 50 55 59 56 60 57 58 55 56 57 60 60

38

39

40

48 48

49 49

50 50

58 58

59 59

60 60

5

POWR

POWER UNIT

CRANCASE (Cont’d.)

5-86

POWER UNIT x

5

POWR

CRANCASE (Cont’d.)

1 11 21 31 41 51

1

2

3

4 1 5 2 6 3 7 4 8 5 9 6 10 7

8

9

10

4 5 6 7 8 9 10 3 x 4105mm 5 6 bolts: 7 8 19 210 3 M9 11 22 33 44 55 66 77 88 99 10 10 11 12 13 14 1115 1216 1317 1418 1519 1620 17 18 19 20 M6 x 55mm bolts: 111 212 313 414 515 616 717 818 911 12 19 10 20 13 14 15 16 17 18 19 20 11 11 x12 1255mm 13 13 14 14bolts: 15 15 16 16 17 17 , 18 18 19 19 20 20 M6 2 3 4 5 6 7 8 9 10 21 22 23 27 24 28 25 29 26 30 27 28 29 30 21 22 17 23 1824 1925 20 26 11 12 13 14 15 16 M6 x 70mm bolts: 21 22 23 24 25 26 27 21 28 22 29 23 30 24 25 26 27 28 29 30 21 21 22 22 23 23 24 24 25 25 26 26 27 27 28 28 29 29 30 30 12 13 M6 14 x 1555mm 16 17bolts: 18 19 20 31 35 32 36 33 37 34 38 35 39 36 40 37 38 39 40 31 32 33 34 1

2

21 31 32 33 31 22 32 23 33 24 34 25 35 26 36 27 37 28 38 29 39 30 40 34 31 31 32 32 33 33 34 34 35 35 36 36 37 37 38 38 39 39 22 23 24 25 26 27 28 29 30 41 45 42 46 43 47 44 41 42 43 44 31 41 42 43 41 32 42 33 43 34 44 35 45 36 46 37 47 38 48 39 49 40 50 44 41 41 42 42 43 43 44 44 45 45 46 46 47 47 48 48 49 49 32 33 34 35 51 36 52 37 53 38 54 39 40 51 55 52 56 53 57 54 51 52 53 58 49 59 50 60 54 4151 4252 4353 4454 4555 4656 4757 48 51 51 52 52 53 53 54 54 55 55 56 56 57 57 58 58 59 59 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 52

53

54

5-87

55

56

57

58

59

60

35 36 37 40 40 45 49 46 50 47 48 45 46 47 50 50 55 59 56 60 57 58 55 56 57 60 60

38

39

40

48 48

49 49

50 50

58 58

59 59

60 60

5

POWR

POWER UNIT

CRANCASE (Cont’d.)

5-88

POWER UNIT x CRANCASE (Cont’d.)

5-89

POWR

5

5

POWR

POWER UNIT

5-90

POWER UNIT x CONNECTING RODS AND PISTONS (Cont’d.)

5-91

POWR

5

5

POWR

POWER UNIT

CONNECTING RODS AND PISTONS (Cont’d.)

5-92

POWER UNIT x CONNECTING RODS AND PISTONS (Cont’d.)

5-93

POWR

5

5

POWR

POWER UNIT

CONNECTING RODS AND PISTONS (Cont’d.)

5-94

POWER UNIT x CONNECTING RODS AND PISTONS (Cont’d.)

5-95

POWR

5

5

POWR

POWER UNIT

CONNECTING RODS AND PISTONS (Cont’d.)

5-96

POWER UNIT x CONNECTING RODS AND PISTONS (Cont’d.)

5-97

POWR

5

5

POWR

POWER UNIT

CONNECTING RODS AND PISTONS (Cont’d.)

5-98

POWER UNIT x CONNECTING RODS AND PISTONS (Cont’d.)

5-99

POWR

5

5

POWR

POWER UNIT

CONNECTING RODS AND PISTONS (Cont’d.)

5-100

POWER UNIT x CONNECTING RODS AND PISTONS (Cont’d.)

5-101

POWR

5

5

POWR

POWER UNIT

CONNECTING RODS AND PISTONS (Cont’d.)

5-102

POWER UNIT x

5-103

POWR

5

5

POWR

POWER UNIT

CRANKSHAFT (Cont’d.)

5-104

POWER UNIT x CRANKSHAFT (Cont’d.)

5-105

POWR

5

5

POWR

POWER UNIT

CRANKSHAFT (Cont’d.)

5-106

POWER UNIT x CRANKSHAFT (Cont’d.)

5-107

POWR

5

5

POWR

POWER UNIT

5-108

POWER UNIT x THERMOSTAT (Cont’d.)

5-109

POWR

5

5

POWR

POWER UNIT

THERMOSTAT (Cont’d.)

5-110

POWER UNIT x

5-111

POWR

5

CHAPTER 6 JET PUMP UNIT INTAKE GRATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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

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

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

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

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

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

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

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

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

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

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

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

6-9 Oil Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

JET PUMP x

JET PUMP

6

INTAKE GRATING EXPLODED DIAGRAM

5 LT

242 LT

2

242

4

3 LT

242

1

REMOVAL AND INSTALLATION CHART Step

Procedure / Part Name

Q’ty (ea) Service Points

INTAKE GRATING REMOVAL

1 Screw 2 2 Screw 4 3 Intake Grating 2 4 Screw 12 5 Intake Duct 2

6-1

Follow the left “Step” order for removal.

8 x 35mm 8 x 20mm Port and Starboard Units 8 x 40mm Port and Starboard Units Reverse the removal steps for installation.

NOTE: Apply clear silicone before installing a duct into the hull.

6

JET PUMP

JET PUMP

Apply clear silicone as shown before installing Duct into hull. Install Duct and torque screws to 15Nm (1.5m-kg, 11 ft-lb).

6-2

JET PUMP x

JET PUMP

6

PUMP UNIT

EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty (ea.)

PUMP UNIT REMOVAL 1 Shift Cable Joint 1 2 Steering Cable Joint 1 3 Bolt (with washer) 4 4 Nozzle 1

1

5 Dowel Pin 2 6 Duct w/Driveshaft and Impeller 1 7 Bolt (with washer) 4 8 Dowel Pin 2 9 Impeller Housing Assembly 1

6-3

Service Points Follow the “Step” order for removal.

NOTE: May be left on to remove pump as an assembly.

10 x 40mm Reverse the removal steps for installation.

6

JET PUMP

JET PUMP

REVERSE GATE AND DEFLECTOR EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART Step

Procedure / Part Name

Q’ty (ea) Service Points

REVERSE GATE AND NOZZLE DEFLECTOR REMOVAL

Follow the “Step” order for removal.

Bolt (with washer) Collar Reverse Gate Bolt (with washer) Collar Nozzle Deflector

8 x 20mm

1 2 3 4 5 6

2 2 1 2 2 1

REVERSE GATE

DISASSEMBLY 1 Bolt (with washer) 2 2 Gate Control Arm 1 3 Bolt (with washer) 2 4 Collar 2 5 Swivel 1

6-4

8 x 20mm

6 x 16mm

Reverse the removal steps for installation.

JET PUMP

JET PUMP x

6

IMPELLER AND DRIVE SHAFT EXPLODED DIAGRAM

DISTINCT MARK (PORT IMPELLER)

6P600 PART NUMBER STARBOARD IMPELLER

6P610 PART NUMBER

NOTE *1: EPNOC AP #0 or equivalent

REMOVAL AND INSTALLATION CHART Step

Procedure / Part Name

Q’ty (ea) Service Points

IMPELLER DUCT AND DRIVE SHAFT ASSEMBLY

1 Impeller, Port 1

Impeller, Starboard 1 2 Spacer 1 3 Bolt 3 4 Cap 1

5 O-ring 1 6 Nut 1 7 Washer 1 8 Drive shaft 1 9 Rear Bearing 1 10 Spacer 1 11 Front Bearing 1 12 Oil Seal 1 13 Oil Seal 1 14 Bolts 4 15 Cover, O-rings and filter 1

6-5

Follow the “Step” order for removal.

18.1° Pitch, 6P600, casting marks on hex Left-hand threads 15.1° Pitch, 6P610, Left-hand threads Fill cap approximately 1/3 full with EPNOC AP#0 or equivalent grease.

Not reusable Not reusable Not reusable Not reusable Reverse the removal steps for installation.

6

JET PUMP

JET PUMP

JET PUMP CLEAN-OUT PORTS EXPLODED DIAGRAM

A Í

REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Qty (ea.) Service Points

JET PUMP CLEAN-OUT Follow the “Step” order for removal.

TRAY REMOVAL 1 Inspection Cover 2 2 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 #10 22 4 Clean-out Tray 1 Apply silicone sealant to outside of clean-out port

flanges.

5 Hatch Interlock Switch 2 Set height a = 14mm (0.55”). Apply one (1) drop of

removable thread lock (LT242) to threads.

6 Clamp, lower 2 Do not need to remove unless replacing clean-out hose.

7 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.

8 Drain Hose 1 9 Drain Hose Clamp 1 Lift Clean-out Tray to loosen drain hose clamp and

remove drain hose.

10 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.

6-6

JET PUMP x

6-7

JET PUMP

6

6

JET PUMP

JET PUMP

2

5

6

7

8

9

1 10

2

3

4

5

6

7

8

9

10

15

16

17

18

19

11 20

12

13

14

15

16

17

18

19

20

25

26

27

28

21 29

22 30

23

24

25

26

27

28

29

30

35

36

37

38

31 39

32 40

33

34

35

36

37

38

39

40

45

46

47

48

41 49

42 50

43

44

45

46

47

48

49

50

55

56

57

58

51 59

52 60

53

54

55

56

57

58

59

60

6-8

JET PUMP x Service Points

6-9

JET PUMP

6

6

JET PUMP

JET PUMP

6-10

x CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 ELECTRICAL BOX AND IGNITION COIL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 ELECTRICAL ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Digital Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Low Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Peak Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Peak Voltage Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Test Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

IGNITION SPARK GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

IGNITION SYSTEM PEAK VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

ENGINE STOP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

ENGINE TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

INTAKE AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

THERMOSWITCH (ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

THERMOSWITCH (EXHAUST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

MAIN AND FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

CAM POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

NOISE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 FUEL CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

LOW FUEL LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

MAIN AND FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

THERMOSWITCH (ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

THERMOSWITCH (EXHAUST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Armature Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brush Holder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter Motor Front cover Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIGHTING COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RECTIFIER REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC BILGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC BILGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAIN COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWITCH LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

METER PANEL BACK VIEW - (AR230 HO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM - (AR230 HO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

METER PANEL BACK VIEW - (SR230 HO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM - (SR230 HO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

METER PANEL BACK VIEW (SX230 HO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM - (SX230 HO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

METER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWITCH AND COMPONENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PANEL SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BILGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-29 7-29 7-30 7-30 7-30 7-30 7-31 7-32 7-32 7-32 7-35 7-35 7-36 7-36 7-37 7-37 7-38 7-38 7-38 7-38 7-39 7-39 7-39 7-40 7-40 7-42 7-42 7-43 7-43 7-44 7-44 7-45 7-45 7-46 7-46 7-46 7-48 7-48 7-49 7-49 7-49 7-50 7-50

ELECTRICAL SYSTEM x ELECTRICAL COMPONENTS

1 2 3 4 5 6 7 8 9

1 1 11 21

(AR model)

7-1

2

2 3 11 12 12 13 21 22 22

23

Bow light 4 5pumps 6 7 8 9 10 Fuel 4 Fuel 5 6 sender 7 8 9 10 13 14 15 16 17 18 19 20 14 Stereo 15 16 17 18 19 20 23 Speaker 24 25 26 27 28 29 30 24 Running 25 26 27 28 29 30 Light 3

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

ELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM

x x

x

x

x

REMOVAL AND INSTALLATION CHART Step

1 2 3 4 5 6 7 8

Procedure / Part Name

Qty

ELECTRICAL BOX REMOVAL

Battery negative lead Battery positive lead Bolt Battery hold down bracket Battery Battery tray Nut Washer

1 1 2 1 1 1 4 4

Service Points Follow the left “Step” for removal.

7-2

ELECTRICAL SYSTEM x ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)

EXPLODED DIAGRAM

x x

x

x

x

REMOVAL AND INSTALLATION CHART Step Procedure / Part Name 9 Bolt

10 11 12 13 14 15 16

Screw Terminal cover Gasket Screw Starter motor lead Bolt Cover

Qty 4 4 1 1 1 1 3 1

Service Points

Not reusable

7-3

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

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

EXPLODED DIAGRAM

x x

x

x

x

REMOVAL AND INSTALLATION CHART Step Procedure / Part Name 17 Gasket

18 19 20 21

Bolt Ground led Holder Coupler

Q’ty 1 2 2 1 15

Service Points Not reusable

NOTE: Disconnect all couplers.

Reverse the removal steps for installation.

7-4

ELECTRICAL SYSTEM x ELECTRICAL BOX (Cont’d.)

EXPLODED DIAGRAM

7-5

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

ELECTRICAL BOX (Cont’d.)

EXPLODED DIAGRAM

7-6

ELECTRICAL SYSTEM x ELECTRICAL BOX (Cont’d.)

EXPLODED DIAGRAM

7-7

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

ELECTRICAL BOX (Cont’d.)

EXPLODED DIAGRAM

7-8

ELECTRICAL SYSTEM x ELECTRICAL BOX (Cont’d.)

EXPLODED DIAGRAM

7-9

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

ELECTRICAL ANALYSIS

NOTE: • When measuring a resistance of 10W or less • When measuring a resistance of 10Ω or less, with the digital readout tester, the correct the correct measurement value may not be dismeasurement value will internal not be displayed played due to the meter's resistance.due the tester’s internal resistance.

• to Obtain the correct value by subtracting the • To obtain the correct value, subtract thedisinterinternal resistance of the meter from the nal resistance of the tester from the displayed played measurement.

• measurement.

Obtain the meter's internal resistance by connecting the meter's leads directly andbe • The internal resistance of the together tester can reading the display. obtained by connecting [the tester’s leads directly together and reading the display.]

7-10

ELECTRICAL SYSTEM x ELECTRICAL ANALYSIS (Cont’d.)

7-11

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

IGNITION SYSTEM WIRING DIAGRAM

1 ⁄

3 2 ⁄

4 ⁄

5

B

PUR

W

6

OFF ON START

B

19 ⁄

W B

20 ⁄

7

FREE PUSH R/B

W

B

B

Br Br

21 ⁄

W B Br

P

17 ⁄

18 ⁄

Br R/B

Br

8 ⁄ 11 ⁄

17 ⁄

W B

R/B

W

Br

W

FREE PUSH

9 ⁄

18 ⁄ 12 ⁄ 10 ⁄

17 ⁄

18 ⁄

15 ⁄

13 ⁄ 14 ⁄

14 ⁄

16 ⁄ 17 ⁄

18 ⁄

1 ECM ⁄ 2 Main and fuel pump relay ⁄ 3 Fuse (20A) ⁄ 4 Battery ⁄ 5 Engine shut-off switch ⁄ 6 Engine stop swich ⁄ hatch switch Start switch 7 Cleanout ⁄ 8 Thermoswitch (exhaust) ⁄ 9 Thermoswitch (engine) ⁄

10 Engine temperature sensor ⁄ 11 Cam position sensor ⁄ 12 Rectifier/regulator ⁄ 13 Lighting coil ⁄ 14 Pickup coil ⁄ 15 Sensor assembly ⁄

(Intake air temperature, intake air pressure) 16 Throttle position sensor ⁄

7-12

17 Spark plug ⁄ 18 Ignition coil ⁄ 19 Oil pressure switch ⁄ 20 Noise filter ⁄ 21 Neutral switch ⁄

ELECTRICAL SYSTEM x

7

ELEC

IGNITION SYSTEM (Cont’d.)

WIRING DIAGRAM

1 ⁄

3 ⁄

2 ⁄ 4 ⁄

5 ⁄ 12 ⁄

6 ⁄ 9 ⁄

7 ⁄

11 ⁄ 10 ⁄ 11 ⁄

11 ⁄

11 ⁄

1 ⁄ 2 ⁄ 3 ⁄ 4 ⁄ 5 ⁄ 6 ⁄ 7 ⁄

8 Engine temperature sensor ⁄ 9 Sensor asssembly ⁄ 10 Throttle position sensor ⁄ 11 Fuel injector ⁄ 12 Oil pressure switch ⁄

ECM Main and fuel pump relay Fuse (20A) Battery Fuel pump Thermoswitch (exhaust) Thermoswitch (engine) 7-13

8 ⁄

7

ELEC

ELECTRICAL SYSTEM

IGNITION SYSTEM (Cont’d.)

7-14

ELECTRICAL SYSTEM x IGNITION SYSTEM (Cont’d.)

7-15

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

IGNITION SYSTEM (Cont’d.)

7-16

ELECTRICAL SYSTEM x IGNITION SYSTEM (Cont’d.)

7-17

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

IGNITION SYSTEM (Cont’d.)

Lanyard Clip

White

Black

Installed

O

O

Removed

O

O

7-18

ELECTRICAL SYSTEM x IGNITION SYSTEM (Cont’d.)

INTAKE AIR

7-19

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

IGNITION SYSTEM (Cont’d.)

7-20

ELECTRICAL SYSTEM x IGNITION SYSTEM (Cont’d.)

7-21

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

IGNITION SYSTEM (Cont’d.)

7-22

ELECTRICAL SYSTEM x IGNITION SYSTEM (Cont’d.)

7-23

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

IGNITION SYSTEM (Cont’d.)

7-24

ELECTRICAL SYSTEM x FUEL CONTROL SYSTEM WIRING DIAGRAM

7-25

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

FUEL CONTROL SYSTEM (Cont’d.)

WIRING DIAGRAM

7-26

ELECTRICAL SYSTEM x

ELEC

Jumper Leads Ground

PURPLE PINK

12VDC BLACK

7-27

7

7

ELEC

ELECTRICAL SYSTEM

7-28

ELECTRICAL SYSTEM x

7-29

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

7-30

ELECTRICAL SYSTEM x

7-31

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

7-32

ELECTRICAL SYSTEM x

7-33

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

STARTER MOTOR (Cont’d.)

7-34

ELECTRICAL SYSTEM x

7-35

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

7-36

ELECTRICAL SYSTEM x

7-37

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

7-38

ELECTRICAL SYSTEM x

7-39

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

MAIN COMPONENT LOCATION

B

2

3

4

11

12

13

14

21

22

23

24

31

32

33

34

41

42

43

44

51

52

53

54

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

1 2 28 29

31

32

33

34

35

36

37

38

41

42

43

44

45

46

47

51

52

53

54

55

56

57

D 4

5

6

7

8

9

10

12 13 39 40

14

15

16

17

18

19

20

21 48

22 49

23 50

24

25

26

31 58

32 59

33 60

34

35

41

42

43

44

51

52

53

54

11

3 30

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

B

27

28

29

30

36

37

38

39

40

45

46

47

48

49

50

55

56

57

58

59

60

C

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

1 2 3 4 5 6 7 8 9 10 43 44 45 46 47 48 49 50 3 4 5 6 7 18 29 310 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 11 12 13 14 15 16 17 11 18 12 19 13 20 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 219 2210 23 24 25 26 27 28 29 30 5 6 7 8 9 10 3 28 4 29 5 624 725 8 26 9 2710 28 29 30 21 22 23 24 25 1 26 2 27 30 21 22 23 11 12 13 14 15 16 17 18 3119 3220 33 34 35 36 37 38 39 40 15 16 17 18 19 20 13 38 14 39 15 16 31 32 33 34 35 1136 12 37 31 32 33 40 34 17 35 1836 193720 38 39 40 41 29 42 30 43 44 45 46 47 48 49 50 21 22 23 24 25 26 27 28 25 26 27 28 29 30 21 46 22 47 23 48 24 49 25 50 26 45 27 46 28 47 29 48 30 49 50 41 42 43 44 45 41 42 43 44 51 52 53 54 55 56 MODEL SHOWN 57 58 59 60 AR230 31 32 33 34 35 36 37 38 39 A 40 35 36 37 38 39 40 51 52 53 54 55 51 52 53 54 31 56 32 57 33 58 34 59 35 60 36 55 37 56 38 57 39 58 40 59 60 41 42 43 44 45 46 47 48 49 50 45 46 47 48 49 50 41 42 7-40 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 55 56 57 58 59 60 51 52 53 54 55 56 57 58 59 60 41 1

1

1

42 2

ELECTRICAL SYSTEM x

Location of Main Components: 1 Bow 2 3 Light 4 5 6 7 8 9 10 1 2 Fuel 3 4 Level 5 6 7 8 9 10 Sensor 11 12 13 14 15 16 17 18 19 20 1 2 3 Battery 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 24 1 2 3 21 4 22 5 23 6 Light 7 825 926 1027 28 29 30 Stern Connector 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 Motors 32Blower 35 36 2037 38 39 40 11 12 13 3114 15 33 16 34 17 18 19 21 22 23 24 25 26 27 28 29 30 2 3 4 315 326 33 7 8 9 10 Bilge Pump 34 35 19 36 20 37 38 39 40 11 12 13 14 4115 4216 43 17 44 18 23 24 26 1027 4528 4629 4730 48 49 50 3 214 225 32 6 33 7 Horn 825 935 34 36 37 38 39 40 12 13 3114 41 15 42 16 17 44 18 19 43 45 20 46 47 48 49 50 214 225 23 24 27 54 28 55 29 56 30 57 58 59 60 51825 52926 53 6 7 10 Hull Harness

31 32 33 34 35 36 37 38#339 40 13 14 15 4216 43 17 44 18 19 4528 20 4629 56 4730 57 48 58 49 59 50 60 55 22 23 4124 51 25 5226 53 27 54 5 6 7 8 9 10 Deck Harness

3114 3215 33 34 35 36 37 38 39 40 17 44 18 19 41 4216 43 45 20 46 47 48 49 50 23 24 51825 52 26 53 27 5428 5529 5630 57 58 59 60 6 33 7 935 10 12V Outlet

32 34 36 37 38 39 and 40 Circuit Breaker 15 16 17 18 19 20

4124 51 4225 52 4326 53 4427 54 4528 55 4629 56 4730 57 48 58 49 59 50 60 33 34 35 36 37 38 39 40 16 43 17 18 42 44 19 45 2046 47 48 49 50 5125 5226 5327 5428 5529 5630 57 58 59 60 34 35 36 37 LOCATION OF STEREO COMPONENTS: 38 39 40 43 44 45 46 47 48 49 50 5226 5327 5428 5529 5630 57 58 59 60 Control Keypad (AR and SX only) 35 36 37 38A 39Remote 40 44 54 45 55 46 56 47 57 48 58 49 59 50 60 53 36 37 38 39B 40Speakers 45 55 46 56 47 57 48 58 49 59 50 60 54

C Speakers 50 D 59CD60Player/Receiver

46 55

47 56

48 57

49 58

56

57

58

59

60

7-41

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

SWITCH LOCATION WIRING DIAGRAM

AR230 MODEL SHOWN

1. Key Switches 2. Lanyard Switch 3. Neutral Switch 4. Hatch Interlock Switches 5. Engine Harness #2

7-42

ELECTRICAL SYSTEM x METER PANEL BACK VIEW (AR230 HO) -

WIRING DIAGRAM

3

2

1

4

1 Starboard Tach

3 Port Tach

2 Speedometer

4 Fuel Gauge 7-43

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

METER PANEL BACK VIEW (SR230 HO) -

WIRING DIAGRAM

3

2

1

4

1 Starboard Tach

3 Port Tach

2 Speedometer

4 Fuel Gauge 7-44

ELECTRICAL SYSTEM x METER PANEL BACK VIEW (SX230 HO) -

WIRING DIAGRAM

3

2

1

4

1 Starboard Tach

3 Port Tach

2 Speedometer

4 Fuel Gauge 7-45

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

METER PANEL EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART Step

Procedure / Part Name

Qty (ea.) Service Points

METER PANEL DISASSEMBLY

1 Nut 2 2 Key Switch 2 3 Screw 4 4 Meter Panel 1 5 Speedometer 1 6 Fuel Gauge 1 7 Tachometer 1 8 Depth Sounder 1 9 Nut 7 10 Breaker 7 11 Nut and Washer 2 12 Screw 2 13 Controller, Stereo 1

7-46

Follow the “Step” order for removal.

20-3/4 x 2Æ

6-32 x 1Æ Reverse the removal steps for installation.

ELECTRICAL SYSTEM x

ELEC

7

METER PANEL EXPLODED DIAGRAM (Cont’d.)

REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Qty (ea.) Service Points 14 Blower Switch 1 15 Screw 2 16 Breaker Panel 1 17 Cover 4 18 Nut 4 19 Breaker 4 20 Switch 4 21 Screw 4 22 Switch Panel 1 23 Cover 2 24 Nut 2 25 Breaker 2 26 Switch 1 27 12 Volt Outlet 1

Reverse the removal steps for installation.

7-47

7

ELEC

ELECTRICAL SYSTEM

SWITCH AND COMPONENT WIRING DIAGRAM

7-48

ELECTRICAL SYSTEM x

7-49

ELEC

7

7

ELEC

ELECTRICAL SYSTEM

NOTE: The horn and no-wake switches have no light.

7-50

CHAPTER 8 HULL AND DECK ENGINE COMPARTMENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 VENTILATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2 8-2 8-3 8-4 8-4 8-5

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

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 REMOTE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

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

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

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

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

INSTALL THROTTLE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

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

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 SEAT FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DECK FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WINDSHIELD

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-16 8-16 8-17 8-18 8-18 8-19 8-20 8-20

THROUGH HULL AND DRAIN FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GUNWALE SR230 HO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GUNWALE AR/SX230 HO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HULL CONSTRUCTION AND CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WHAT IS FRP? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHARACTERISTICS OF FRP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE OF FRP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-22 8-22 8-23 8-24 8-24 8-24 8-25 8-25 8-25 8-26 8-26 8-26 8-26

HULL AND DECK x

HULL DECK

8

ENGINE COMPARTMENT LAYOUT EXPLODED DIAGRAM

4

5

1

6

2

7

3

1. Engine 2. Water Lock 3. Jet Pump 4. Fuel Tank

5. Battery 6. Blowers 7. Bilge Pump

8-1

8

HULL DECK

HULL AND DECK

VENTILATION SYSTEM EXPLODED DIAGRAM

8-2

HULL AND DECK x

HULL DECK

8

REMOVAL AND INSTALLATION CHART Step

Procedure / Part Name

Q’ty

Service Points

VENTILATION SYSTEM

DISASSEMBLY

Follow the “Step” order for removal.

1 Hose Clamp 6 2 Screw, Oval Head Tapping 8 3 Ventilator 2 4 Band 4 5 Hose, Ventilation 1 6 Hose, Ventilation 1 7 Hose, Ventilation 1 8 Hose, Ventilation 1 9 Screw, Truss Hed Tapping 4 10 Blower Assembly 2 11 Ventilator 1

Snap type

8-3

Intake Intake Exhaust Exhaust

Reverse the removal steps for installation.

8

HULL DECK

HULL AND DECK

COOLING SYSTEM EXPLODED DIAGRAM

8-4

HULL AND DECK x

HULL DECK

8

REMOVAL AND INSTALLATION CHART Step

Procedure / Part Name

Q’ty

Service Points

COOLING SYSTEM AND

WATER LOCK REMOVAL

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

16 Clip 2 17 Housing, Thermostat 2 18 Band, Hose 6 19 Hose 8 2 20 Joint, Pipe 2 21 Clip 2 22 Hose 2 23 Nut, M14-1.5mm 4 24 Pilot, Water 4

25 Band, Hose 1 26 Clean-out Tray Assembly 1

27 Band, Hose 2 28 Hose, Exhaust Outlet 1 29 Strap 2 30 Water Lock 1

8-5

Follow the “Step” order for removal.

Apply clear silicone around the flange of the fitting.

Oetiker type clamps.

Straight connector for Port pilot water hose.

STARBOARD hose is shortened to fit.

Apply clear silicone around the flange of the water pilots.

Located in engine compartment See pg. 6-6 “Jet Pump Clean-out Tray RemovaL

Apply soapy water to inside of hose ends on reassembly so that hoses seat completely on Water Lock

8

HULL DECK

HULL AND DECK

STEERING SYSTEM EXPLODED DIAGRAM

1

2

11

1

2

11

12

12

4 1 5 2 6 3 7 4 8 5 9 6 10 7

13

1 2 3 4 5 6 7A 8 9 10 14 1115 1216 1317 1418 1519 1620 17 18 19 20

8

9

10

11 12 13 14 15 16 17 18 19 20 211 22 24 2 23 3 421 525 9 29 10 30 22 626 237 27 248 28 25 26 27 28 29 30 3 4 5 6 7 8 9 10 21 22 23 24 25 26 27 28 29 30 3111 32 34 35 36 37 38 39 40 113 214 3 4 5 6 7 8 9 12 33 15 16 17 18 19 20 34 35 36 37 10 38 39 40 13 14 15 16 3117 32 18 33 19 20

21

22

31

32

41

42

31 32 33 34 35 36 37 38 39 40 41 22 42 23 43 44 45 46 47 48 49 50 11 12 16 28 17 29 18 19 21 24 25 41 13 421426 431527 44 45 46 30 47 20 48 49 50 23 24 25 26 27 28 29 30 41 56 42 57 43 58 44 59 45 60 46 47 48 49 50 51 52 2153 2254 55 51 52 53 54 55 56 57 31 32 33 34 2335 2436 2537 2638 2739 2840 29 5830 59 60 33 34 35 36 SS 37 38 39 40 51 52 53 54 55 56 57 58 59 60 41 42 3143 3244 3345 3446 3547 3648 3749 3850 391 40 2 33 4 51 43 44 45 46 47 48 49 50

51

52

51 53

52

53

54

55

56

1

2

3

4

11

12

13

14

A

11 2 3 4 5 6 2 6 7 8 9 10 62 73 84 95 10 11 12 13 14 15 16 11 12 13 14 15 20 16 17 18 19 20 7 16 8 17 9 18 10 19 15

52 4153 4254 4355 4456 4557 4658 47591 4860 2 4911 3 50 44 13 5 12 54 55 56 57 58 59 60 51

13

3

6 14 21 A 57 1158 1221 591322 6014 2315 24 162125 17 2226 18 23 19 20 27 24 28 2529 31 21 22 3123 3224 3325 34263135273236283337293438303539 5 6 7 8 9 10 41 31 32 4133 4234 4335 44364145374246384347394448404549 15 16 17 18 19 20 51 SS 5155 5256 5357 5458 5559 41 42 5143 5244 5345 54 46 47 48 49 50 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 51 52 53 54 55 56 57 58 59 60 35 36 37 38 39 40 11 12 13 14 15 16 17 18 19 20

21

22

23

24

31

32

33

34

41

42

43

44

45 21

46 22

47 23

48 24

49 25

50 26

27

28

29

30

51

52

53

54

55 31

56 32

57 33

58 34

59 35

60 36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

22 2630 32 3640 42 4650 52 5660

7

8

9

10

17

18

19

20

23 24 25 26 27 28 29 30

27

28

29

30

33 34 35 36 37 38 39 40

37

38

39

40

43 44 45 46 47 48 49 50

47

48

49

50

53 54 55 56 57 58 59 60

57

58

59

60

NOTE: See REMOVAL AND INSTALLATION CHART 54 55 56 57 58 59 60 on next page for torque specs and locking agent instructions.

8-6

HULL AND DECK x

HULL DECK

8

REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty Service Points

STEERING HELM REMOVAL Follow the “Step” order for removal.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

1 2 3 4

5

6

15

16

25

26

35

36

45

46

55

56

Cover 1 Nut 1 Washer 1 Steering Wheel 1 Key 1 Boot 1 Screw 2 Helm, Bezel 1 Screw, socket head 1 Screw 2 Steering Pivot 1 Nut 1 Washer Bolt 1 Bearing 1 Bolt, Shoulder 1 Bearing 1 Bolt 3 Washer 3 Steering Master 1 Nut 3 Washer 3 Hex Head Bolt 3 Steering Mount 1 STEERING CABLE Nut w/Washer Block, Pivot Arm Screw Connector Sub-Assembly

2 1 2 1

Cleanout Tray

5 Nut 4

6 Washer 4 7 Clip 2 8 Washer 2 9 2 1 2 Pin 3 4 5 6 7 8 9 10 7 8 9 10 3 Bushing, 4 1 2 4 5 6 Nylon 7 8 9 10 11 12 13 14 15 16 17 18 2 1 2 3 4 Nut 5 6 7 8 9 10 19 20 17 18 19 20 13 14 15 16 17 18 19 20 11 12

Steering Clevis 2 25 18 26 1927 2028 29 30 11 12 2113 2214 23 15 24 16 17 Steering Cables 2 27 28 29 30 21 22 23 24 25 26 27 28 29 30 31 21 22 23 32 24 33 25 34 26 35 27 36 28 37 29 38 30 39 40

37 38 31 39 32 40 33 34 35 36 37 38 39 40 31 32 41 33 42 34 43 35 44 36 45 37 46 38 47 39 48 40 49 50 47 48 41 49 42 50 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 41 42 43 44 45 46 47 48 49 50 57 58 51 59 52 60 53 54 55 56 57 58 59 60 51

52

53

54

55

56

57

58

59

1/2"-13, Nylon lock, 18 Nm (1.8 m-kg, 13 ft-lb) 1/2"

#8 x 1", 1.8 Nm (0.18 m-kg, 1.3 ft-lb) 3/16"-24 x 1", LT 242 3/8" Nylon lock, 20 Nm (2.0 m-kg, 14 ft-lb) 3/8" 1/4"-20, shoulder bolt, 6.4 Nm (0.64 m-kg, 4.6 ft-lb) 1/4"-20, 14 Nm (1.4 m-kg, 10 ft-lb), LT 242 1/4"-20 Nylon lock, 7 Nm (0.7 m-kg, 5 ft-lb) 1/4" fender 1/4"-20

12 Nm (1.2 m-kg, 8.7 ft-lb), LT 242 3.7 Nm (0.37 m-kg, 2.7 ft-lb) Refer to "Jet Pump Clean-Out Ports" in Chapter 6.

33 Nm (3.3 m-kg, 24 ft-lb), 1 drop LT 242 on threads Seal with Silicone sealer on inside of hull 3.5 Nm (0.35 m-kg, 2.5 ft-lb)

17 Nm (1.7 m-kg, 12 ft-lb)

Reverse the removal steps for installation.

60

8-7

8

HULL DECK

HULL AND DECK

REMOTE CONTROL SYSTEM EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART Step

Procedure / Part Name Qty REMOTE CONTROL UNIT REMOVAL

1 SCREW 4

2 COVER 1

3 SCREW 4

4 REMOCON ASSY 1

5 NEUTRAL SWITCH ASSY 2

6 NUT 1

7 SCREW 3

8 SCREW 3

9 BACK PLATE 2 10 CIRCLIP 4 11 THROTTLE CABLE 2

12 REVERSE CABLE 2 13 EYELET 4 14 JOINT, BALL 2 15 CONNECTOR CABLE 2 16 BOLT 4 17 PLATE (THROTTLE) 2 18 PACKING, CABLE 2 19 NUT, SELF LOCKING 4 20 WASHER, PLAIN 4 21 SCREW 4 22 PLATE (SHIFTER) 2

Service Points Follow the “Step” order for removal.

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

M5-0.8 HH, 4 Nm (0.4 kgf-m, 0.9 ft-lb) M5-0.8 X 55 mm M5-0.8 X 10 mm Remove air cleaner top to access throttle cable ends.

M6-1.5 X 18 mm, 6.4 Nm (0.65 kgf-m, 1.4 ft-lb) #10-24 NYLON LOCK, 2 Nm (0.2 kgf-m, 0.4 ft-lb) #10 FLAT #10-24 X 1 1/4" PFH Reverse the removal steps for installation.

8-8

HULL AND DECK x SERVICE POINTS Throttle/ Shift Cable Installation Install Cables into Remote Control 1. Remove: • Four screws holding the remote control unit 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 1 2 3 4 screws 5 6 and 7 bolt/ 8 nut 9 10 .

3.9 Nm (0.4 kgf-m, 2.9 ft-lb) 11 12 13 14 15 16 17 18 19 20 7. Install: • Remote Control Assembly in boat 21 22 23 24 25 26 27 28 29 30 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)

DETAIL A

8-9

HULL DECK

8

8

HULL DECK

HULL AND DECK

Install Throttle Cables

CABLE WHEEL

1.

2.

Remove: • Air box cover.

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.

THROTTLE CABLE BRACKET

P L A T E THROTTLE PAC K I N G CABLE BOLT

8-10

HULL AND DECK x

HULL DECK

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.)

1

8-11

8

8

HULL DECK

HULL AND DECK

ENGINE HATCH

EXPLODED DIAGRAM

8-12

HULL AND DECK x

HULL DECK

8

REMOVAL AND INSTALLATION CHART Step

Procedure / Part Name

Q’ty

ENGINE HATCH REMOVAL AND DISASSEMBLY

Service Points Follow the “Step” order for removal.

1 Support, Engine Hatch 2 Support Hatch Lid before removal.

2 Nut, #10-24 Nylon Lock 4 3 Washer, #10 Flat 4 4 Screw #10-24 x 1” 4 5 Bracket, Support 2 6 Screw 4 7 Washer, Fender 1/4” 6 8 Engine Hatch Assembly 1 9 Screw 4 10 Washer 4 11 Hinge, Engine Hatch 2 12 Nut, #10-24 Nylon Lock 4 13 Washer, #10 Flat 4 14 Screw, #10-24 x 2” 4 15 Base, hatch Support 2 16 Nut, 1/4-20 Nylon Lock 2 17 Washer, 1/4” 2 18 Screw, 1/4-20 x 1-3/4” 2 19 Seat Lock Assembly 1 20 Nut, #10-24 Nylon Lock 1 21 Washer, 7/16” Fender 2 22 Washer, Special Cotton 1 23 Pin 1 24 Soundproofing 1 1 25 Soundproofing 2 1 26 Soundproofing 3 1

Reverse the removal steps for installation.

8-13

8

HULL DECK

HULL AND DECK

HATCH FITTINGS/BOW COVER EXPLODED DIAGRAM

8-14

HULL DECK

HULL AND DECK x

8

REMOVAL AND INSTALLATION CHART Step Procedure/Part Name

Qty.

Service Points

Step Procedure/Part Name

BOW LOCKER DISASSEMBLY 1

Screw, Tapping

1

#10 x 1-1/2”

2

Screw, Tapping

1

#8 x 3/4”

3

Hatch Support

1

4

Screw, Tapping

4

5

Hatch

6

Screw, Machine

Nut

2

#6-32 Nylon Lock

36

Washer

2

#6 Flat

37

Screw

2

#6-32 x 3/4”

1

38

Screw, Tapping

8

#6 x 1/2”

2

39

Screw, Tapping

16

40

Hinge

1

41

Door

1

42

Screw, Tapping

2

43

Catch

1

Latch

1

8

Screw

2

9

Catch

1

10

Screw

2

Cushion

#8 x 3/4”

#8 x 3/4” #8 x 1”

Screw, Tapping

#6 x 3/4”

FUEL HATCH

2 44

Screw

14

14

45

Washer, Nylon Shoulder

14

Hatch, Fuel

1

Packing 4

1

BI-FOLD DOOR 12

Service Points

35

7

11

Qty.

DECK COMPARTMENT DOOR

13

Rivet, Blind

8

46

14

Hinge 1

1

47

15

Bi-Fold Door

1

16

Screw, Tapping

2

17

Catch

1

18

Cap

5

19

Nut

5

20

Washer

5

21

Screw, Countersunk

5

22

Guide

1

5/16-18 X 2”

CLEANOUT HATCH

SKI LOCKER HATCH 23

Nut

2

#10-24

24

Washer

2

#10 Flat

25

Screw

2

#10-24 x 3/4”

26

Bracket, Hatch Support

1

27

Screw, Tapping

3

28

Bracket, Hatch Support

1

29

Support, Hatch

1

30

Screw, Tapping

12

31

Hinge

2

32

Hatch, Floor 1

1

33

Screw, Machine

2

34

Latch

1

#10 x 1/2”

#10 x 3/4”

8-15

48

Nut

2

#10-24 Nylon Lock

49

Washer

2

#10 Flat

50

Screw

2

#10-24 x 3/4”

51

Bracket Support 2

1

52

Screw, Tapping

2

53

Bracket Support 2

1

54

Support, Hatch

1

55

Screw

12

56

Hinge

2

57

Hatch, Cleanout

1

58

Screw, Machine

4

59

Latch

4

#10 x 1/2”

#10 x 3/4”

8

HULL DECK

HULL AND DECK

SEAT FITTINGS

EXPLODED DIAGRAM

8-16

HULL AND DECK x

HULL DECK

REMOVAL AND INSTALLATION CHART Step Procedure/Part Name

Qty.

SEAT FITTING DISASSEMBLY

Service Points Follow the “Step” order for removal.

DRIVER’S BUCKET SEAT 1

Screw, 1/4-20 X 1/2”

4

2

Washer Flat 1/4 x 1” Fender

4

3

Driver Seat Assembly

1

4

Set Slider

1

5

Screw, 1/4-20 x 1-1/4”

6

6

Pedestal Base

1

BOW & MIDSHIP BACKRESTS 7

Screw, #8 X 5/8”

1

Access screw through Bow Locker

8

Bow Backrest

1

9

Nut 1/4-20

22

10

Washer, Lock 1/4”

22

11

Washer, Flat 1/4” Fender

22

12

Backrests

7

Lift backrests off mounting clips Access nuts through under seat storage

Access nuts through under seat storage

FOLDING DOUBLE SEAT 13

Nut 1/4-20 Nylon Lock

4

14

Washer, 1/4” Lock

4

15

Screw, 1/4-20 x 1-1/2”

4

16

Double Seat Assembly

1

ENGINE HATCH SEATS 17

Nut 1/4-20 Nylon Lock

4

18

Washer, 1/4” Lock

4

19

Washer, Flat 1/4” Fender

4

20

Seat Cushions

2

21

Nut 1/4-20 Nylon Lock

8

22

Washer, Lock 1/4”

8

23

Washer, Flat 1/4” Fender

8

24

Backrest

1

Open engine hatch

SWIM PLATFORM PADS 25

Nut 1/4-20 Nylon Lock

18

26

Washer, 1/4” Lock

18

27

Washer, Flat 1/4” Fender

18

28

Backrest Pas

2

Access nuts through engine compartment

Reverse the removal steps for installation.

8-17

8

8

HULL DECK

HULL AND DECK

DECK FITTINGS

EXPLODED DIAGRAM

8-18

HULL AND DECK x

HULL DECK

8

REMOVAL AND INSTALLATION CHART Step Procedure/Part Name

Qty.

DECK FITTINGS

Service Points Follow the “Step” order for removal.

1

Bow and Stern Eyes (w/ nuts and plates)

3

Torque 15Nm (1.5 m-kg, 11 ft-lb) Apply silicone sealer to mounting surfaces.

2

Nut, 5/16-18

4

Apply LT242, Torque 13Nm (1.35m-kg, 9.5ft-lb)

3

Washer, Lock 5/16”

4

4

Washer, Flat 5/16”

4

5

Rail, Hand (Bow)

2

6

Cup Holder

7

Apply silicone sealer to mounting surfaces

7

Cleat

6

Apply LT242, Torque 13Nm (1.35m-kg, 9.5ft-lb)

8

Nut, 5/16-18

2

Apply LT242, Torque 13 Nm (1.35m-kg, 9.5ft-lb)

9

Washer, Lock 5/16”

2

10

Washer, Flat 5/16”

2

11

Hand Grip

1

Apply silicone sealer to mounting surfaces

12

Nut, 5/16-18

4

Apply LT242, Torque 13Nm (1.35m-kg, 9.5ft-lb)

13

Washer, Lock 5/16”

4

14

Washer, Flat 5/16”

4

15

Hand Grip, Deck

2

Apply silicone sealer to mounting surfaces

16

Nut, 1/4-20 Nylon Lock

12

Remove Fuel Tank Cover to access forward Table Mount.

Remove Cleanout Tray to access rear Table Mount.

Torque 8Nm (0.8m-kg, 6ft-lb)

17

Washer, 1/4” x 1 OD

12

18

Screw 1/4-20 x 1-3/4”

12

19

Table Mount

2

Apply Silicone Sealer to mounting surfaces

20

Nut, 5/16-18

4

LT242, Torque 13Nm (1.35m-kg, 9.5 ft-lb) Access nuts through Engine Compartment

21

Ski Tow

1

22

Bolt, M8 x 35mm HH

4

23

Washer, M8 Flat

4

24

Ladder, Transom

1

25

Nut, 5/16-18

2

26

Washer, Lock 5/16”

2

27

Washer, Flat 5/16”

2

28

Hand Rail, Stern

1

29

Screw, Tapping #10 x 1-1/4

4

30

Hand Grip, Stern

1

LT242, Troque 17Nm (1.7m-kg, 12ft-lb)

Apply LT242, Torque 13Nm (1.35m-kg, 9.5ft-lb)

Apply silicone sealer to mounting surfaces

8-19

8

HULL DECK

HULL AND DECK

WINDSHIELD

EXPLODED DIAGRAM

8-20

HULL AND DECK x

HULL DECK

REMOVAL AND INSTALLATION CHART Step Procedure/Part Name

Qty.

WINDSHIELD

Service Points Follow the “Step” order for removal.

1

Nut, 10-24 Nylon Lock

4

2

Washer, #10 Flat

4

3

Screw, 10-24 x 2” PPH

4

4

Screw, #8 x 3/8” PPH

2

5

Windshield Brace

2

6

Windshield Trim

2

7

Screw, Tapping #8 x 3/4”

16

8

Cap

4

9

Washer, 1/4” Snap Cap

4

10

Nut, 8-32 Nylon Lock

10

11

Washer, #8 Flat

10

12

Screw, 8-32 x 1-1/2” POH

8

13

Screw, 8-32 x 2” POH

2

14

Windshield Assembly LH

1

15

Windshield Assembly RH

1

16

Pad, Windshield

1

17

Hinge Pin

1

18

Windshield Door

1

19

Windshield Tie-down

1

Torque 4Nm (0.4m-kg, 3 ft-lb)

Pull up from channel to access screws

Torque 3Nm (0.3m-klg, 2 ft-lb)

8-21

8

8

HULL DECK

HULL AND DECK

THROUGH HULL AND DRAIN FITTINGS EXPLODED DIAGRAM

8-22

HULL AND DECK x

HULL DECK

REMOVAL AND INSTALLATION CHART Step Procedure/Part Name

Qty.

THROUGH HULL AND DRAIN FITTINGS

Service Points Follow the “Step” order for removal.

1

Drain Plug

1

Apply silicone to the drain plug assembly flange.

2

Screw #8 x 3/4 POH

3

3

Clamp, Hose 2 (SAE #24)

1

4

Cockpit Drain

1

5

Clamp, Hose 2 (SAE #24)

1

6

Scupper Drain for Cockpit

1

7

Pipe, Bilge

1

8

Clamp

2

9

Hose, Drain Ice Chest

1

10

3/4” Through Hull (90°)

1

11

Clamp

2

12

Hose, Drain Engine Hatch

1

13

Drain, Engine Hatch

1

14

Drain Outlet, Engine Hatch

1

Behind Swim Deck Cushion

15

Clamp

2

Access at Cleanout Tray Inspection Cover

16

Hose, Cleanout Tray Drain

1

17

Drain Outlet

1

18

Drain, Cleanout Tray

1

19

Packing, Drain

1

20

5/16” Worm Gear Clamp

2

21

Screw, #8 x 5/8” PPH

8

22

Hose, Bilge

1

23

Screw, #10 x 1/2 PPH

2

24

Bilge Pump

1

25

Bilge Outlet

1

26

Screw, Tapping

8

27

Drain Plug Assembly

4

At Engine Compartment Bulkheads

28

Drain, Bow Locker

1

Apply clear silicone to the base.

Apply clear silicone to the base.

Apply clear silicone to the base.

Apply clear silicone to the base.

Apply clear silicone to the base.

8-23

8

8

HULL DECK

HULL AND DECK

GUNWALE SR230HO EXPLODED DIAGRAM

REMOVAL AND INSTALLATION CHART Step

Procedure / Part Name

Q’ty

GUNWALE (SR230HO)

1 Screw, 10 x 2” POH 2 2 Cover, rub Rail Joint 1

3 Inner Gunwale (Rubrail insert) 1 pc

4 Screw, #10 x 1-1/4” PFH 210 5 Gunwale (Rubrail) 3 pc

8-24

Service Points Follow the “Step” order for removal.

Torque 2 Nm (0.2m-kg, 1.5 ft-lb) Before installing, apply silicone to the join area.

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

Torque 2 Nm (0.2m-kg, 1.5 ft-lb) Fill in any gaps above or below the gunwale with white silicone.

Reverse the removal steps for installation.

HULL AND DECK x

HULL DECK

GUNWALE AR/SX230HO EXPLODED DIAGRAM

APPLY BEAD OF CLEAR SILICONE SEALER

GUNWALE CROSS SECTION

REMOVAL AND INSTALLATION CHART Step

Procedure / Part Name

Q’ty

GUNWALE (AR/SX230HO)

1 Screw, Tapping #8 x 1-1/4” 1 2 Cover, Gunwale 1 3 Screw, Tapping #8 x 1-1/4” 112 4 Gunwale, Inner 20 ft.

2 5 Screw, Tapping #10 x 1 17

6 Gunwale, Inner 16 ft.

1 7 Screw, Tapping #8 x 1-1/4” 84 8 Gunwale 16 ft.

1

9 Gunwale 20 ft.

2

8-25

Service Points Follow the “Step” order for removal.

Start at center of stern Take care not to crease Inner Gunwale Install first screw at center of bow and then every 39-1/2” apart.

Apply clear silicone sealer between gunwale and deck.

Apply clear silicone sealer between gunwale and deck.

Reverse order for reassembly.

8

8

HULL DECK

HULL AND DECK

HULL CONSTRUCTION AND CARE

1. Maintenance of luster The gelcoat layer is 0.3 to 0.5mm (0.12 to 0.20 in) thick. When it has faded or has lost its luster, the original luster can be restored by polishing to remove the oxidized layer.

The SRT1100 hull is built of a material called FRP. This is then finished with a very hard product called gelcoat to protect the fiberglass and provide a durable finish.

WHAT IS FRP?

FRP stands for Fiberglass Reinforced Plastic.

It is a composite material in which a fiberglass reinforcement material such as chopped strand mat (mat) and/or a woven fabric (cloth) is impregnated with a catalyzed polyester resin and allowed to cure into a rigid state. Also, included in this definition are fabrics impregnated with epoxy resins and hardeners.

2. Fading and discoloration How 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, see item “d� below. b. Discoloration due to oil stains, fuel stains, or environmental factors may be removed with detergents or industrial solvents 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 using sharpened wooden sticks. Avoid metal putty knives, etc. as they will tend to scratch the gelcoat. d. If all else fails, use a wet/dry sandpaper to color sand the gelcoat down to consistent color. Use extreme care as too much sanding will remove all the gelcoat and new gelcoat will have to be applied. Start with #600 grit and end with #1200 to #1500 grit with lots of water. For best results, final sanding should 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 to re-gelcoat.

CHARACTERISTICS OF FRP FRP has the following characteristics: 1.

2.

3.

4.

Polishing procedures: a. Clean the gelcoat surface with water and neutral detergent. b. Polish with a fine rubbing compound. If no polisher is available, polish with a rag and compound. c. After polishing, apply several coats of a good marine wax, allowing each coat to dry prior to buffing and applying the next coat.

High strength yet light-weight Excellent malleability Corrosion free Easy to care for and easy to repair. On the other hand, it is liable to get scratched and is vulnerable to shocks and, therefore, must be handled with care.

NOTE: Should any of the FRP or Gelcoat require repair, refer to the Basic Hull Repair Video and Workbook (VID-10660-00-43).

MAINTENANCE OF FRP Routine care is important for FRP as it helps in maintaining the high luster. During maintenance, any damage to the FRP can be detected early so repairs can be easily accomplished ensuring long service life.

After use, wash down the hull with fresh water.

Wax the hull with a non-abrasive wax such as Yamaha Ultra-gloss Cleaner Wax or other wax designed for marine gelcoat.

Take the following additional steps when necessary:

8-26

TROUBLE ANALYSIS x

TRBL ANLS

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

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

9

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

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

TRBL ANLS

TROUBLE ANALYSIS x

9

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 operated using either a mouse or a keyboard.

1

2

9-1

3

4

5

9

TRBL ANLS

TROUBLE ANALYSIS

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

RS232C (Dsub-9 pin) port, USB portj

9-2

TRBL ANLS

TROUBLE ANALYSIS x

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

9-2.

9-3

9

9

TRBL ANLS

TROUBLE ANALYSIS

9-4

TROUBLE ANALYSIS x

9-5

TRBL ANLS

9

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

TROUBLE ANALYSIS x

TRBL ANLS

9

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

TROUBLE ANALYSIS x

9-9

TRBL ANLS

9

9

TRBL ANLS

TROUBLE ANALYSIS

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

9-10

TROUBLE ANALYSIS x

9-11

TRBL ANLS

9

9

TRBL ANLS

TROUBLE ANALYSIS BOAT

SXT1100

9-12

TROUBLE ANALYSIS x

TRBL ANLS

9

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

TROUBLE ANALYSIS x

9-15

TRBL ANLS

9

9

TRBL ANLS

TROUBLE ANALYSIS

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

9-16

TROUBLE ANALYSIS x

9-17

TRBL ANLS

9

9

TRBL ANLS

TROUBLE ANALYSIS

9-18

TROUBLE ANALYSIS x

top.

9-19

TRBL ANLS

9

9

TRBL ANLS

TROUBLE ANALYSIS

9-20

TROUBLE ANALYSIS x

9-21

TRBL ANLS

9

9

TRBL ANLS

TROUBLE ANALYSIS

9-22

TROUBLE ANALYSIS x

.

9-23

TRBL ANLS

9

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

TROUBLE ANALYSIS x

TRBL ANLS

9

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 watercraft, otherwise, you could become distracted which could result in a collision.

display.

9-26

TROUBLE ANALYSIS x

TRBL ANLS

in the scroll bar or press the up or down

keyboard (Fig. 38).

9-27

9

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

TROUBLE ANALYSIS x keys on your keyboard (Fig. 39).

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

keyboard (Fig. 39).

9-29

TRBL ANLS

9

9

TRBL ANLS

TROUBLE ANALYSIS keyboard (Fig. 42).

9-30

TROUBLE ANALYSIS x

TRBL ANLS

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).

9-31

9

9

TRBL ANLS

TROUBLE ANALYSIS

selected (Fig. 46).

displayed (Fig. 47).

9-32

TROUBLE ANALYSIS x

TRBL ANLS

9

keyboard (Fig. 48).

Make sure that there is fuel in the fuel tank, otherwise, an error will occur and the test cannot be performed. keyboard (Fig. 48).

9-33

9

TRBL ANLS

TROUBLE ANALYSIS keyboard (Fig. 49).

9-34

TROUBLE ANALYSIS x

TRBL ANLS

9

selected (Fig. 51).

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

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

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).

Make sure the engine is not running.

9-36

TROUBLE ANALYSIS x keyboard (Fig. 53).

selected (Fig. 54).

9-37

TRBL ANLS

9

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

TROUBLE ANALYSIS x

TRBL ANLS

9

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

keyboard (Fig. 55).

keyboard (Fig. 55). keyboard (Fig. 56).

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).

displayed (Fig. 56).

appear (Fig. 58).

9-40

TROUBLE ANALYSIS x

TRBL ANLS

board (Fig. 59).

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

9-41

9

9

TRBL ANLS

TROUBLE ANALYSIS

bar (Fig. 60).

displayed (See fig. 61).

9-42

TROUBLE ANALYSIS x

TRBL ANLS

axis (Fig. 61).

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

9-43

9

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

TROUBLE ANALYSIS x

TRBL ANLS

displayed (Fig. 63).

9-45

9

9

TRBL ANLS

TROUBLE ANALYSIS

(Fig. 65).

9-46

TROUBLE ANALYSIS x

Programs (Fig. 66).

(Fig. 67).

9-47

TRBL ANLS

9

9

TRBL ANLS

TROUBLE ANALYSIS button (see Figs. 68~70).

9-48

TROUBLE ANALYSIS x

9-49

TRBL ANLS

9

9

TRBL ANLS

TROUBLE ANALYSIS

test,

9-50

TROUBLE ANALYSIS x

TRBL ANLS

.

Display (Fig. 73).

slider (Fig. 74).

9-51

9

9

TRBL ANLS

TROUBLE ANALYSIS

button (see Figs. 75~76).

9-52

TROUBLE ANALYSIS x

TRBL ANLS

consulted:

9-53

9

9

TRBL ANLS

TROUBLE ANALYSIS

9-54

TROUBLE ANALYSIS x

9-55

TRBL ANLS

9

9

TRBL ANLS

TROUBLE ANALYSIS YDIS Error Code Chart When a flashing Check Engine signal is displayed you should connect the Yamaha Diagnostic System to the affected engine in order to identify the cause. YDIS is capable of detecting the cause and indicating one or multiple codes for a variety of problems. Codes and other running data can be saved and downloaded for further troubleshooting.

N

30

4

5

6

HIGH OUTPUT

3 2

20

HIGH OUTPUT

7 8 9 10

1

11

0 YAMAHA

40 50

10 0

60 YAMAHA

4

3 2

5

6

HIGH OUTPUT

7 8 9

1

10 11

0

0

1/2

YAMAHA

F

DEPTH

FUEL

YAMAHA

PORT

STBD

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

68

No wake

NOTE: At the time of this publication it is recommended that YDIS versions 1.23 or later be used with the boats covered in this manual.

Please check for newer versions of the YDIS software.

NOTE: For complete Instructions on use of the Yamaha Diagnostic System, see the SR230 Service Manual LIT-18616-02-52, Chapter 9.

9-56

LIT-18616-03-01

2007 AR/SR/SX230 High Output Service Manual

©2007 YAMAHA MOTOR CORPORATION, U.S.A. Printed in U.S.A.