Page 1 SR230 Service Manual 2004...
Page 2 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.
Page 3: How To Use 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 infor- mation has been compiled to provide the mechanic with an easy-to-read, handy reference that con- tains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.: Bearings...
Page 4 HOW TO READ DESCRIPTIONS 1. A disassembly/installation job instruction mainly consists of the exploded diagram 1 1 . 2. The numerical figures represented by the number 2 2 indicates the order of the job steps. 3. The symbols represented by the number 3 3 indicates the contents and notes of the job. For the meanings of the symbols, refer to the next page(s).
Page 5 Apply Gasket Maker® Apply Yamabond #4 (Yamaha Bond No. 4) Apply LOCTITE® No. 271 (Red LOCTITE) Apply LOCTITE® No. 242 (Blue LOCTITE) Apply LOCTITE® No. 567 (PST)
Page 6 INDEX GENERAL INFORMATION INFO SPEC SPECIFICATIONS INSP PERIODIC INSPECTION AND ADJUSTMENT FUEL FUEL SYSTEM POWR POWER UNIT JET PUMP PUMP ELEC ELECTRICAL SYSTEM HULL HULL AND DECK DECK TRBL TROUBLE ANALYSIS ANLS...
Page 7: Table Of Contents
CHAPTER 1 GENERAL INFORMATION IDENTIFICATION NUMBERS ..........1-1 PRIMARY I.D.
Page 8: Identification Numbers
GENERAL INFORMATION INFO A60700-0* IDENTIFICATION NUMBERS PRIMARY I.D. NUMBER The primary I.D. number is stamped on a label attached to the deck under the rear seat. Starting Primary I.D. Number: F1C-700101~ ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the crankcase.
Page 9: Safety While Working
GENERAL INFORMATION INFO 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) highly flammable. Petroleum vapor is explosive if ignited. Do not...
Page 10: Good Working Practices
GENERAL INFORMATIONx INFO 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.
Page 11: Disassembly And Assembly
GENERAL INFORMATION INFO DISASSEMBLY AND ASSEMBLY 1. Clean parts with solvent and compressed- air 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.
Page 12: Special Tools
GENERAL INFORMATIONx INFO SPECIAL TOOLS Use of the correct special tools recommended by Yamaha will aid the work and enable accu- rate assembly and tune-up. Improvisations and use of improper tools can cause damage to the equipment. NOTE: YU-03097-B 90890-01252 •...
Page 13: Special Tools
GENERAL INFORMATION INFO SPECIAL TOOLS Fuel Pressure Gauge P/N YB-06766 90890-06786 Compression Gauge Extension P/N 90890-06582 Cylinder Gauge Set P/N YU-03017 90890-06759 Compression Gauge P/N YU-33223-1 90890-03160 Peak Voltage Adapter P/N YU-39991 90890-03172 Spark Gap Tester P/N YM34487 90890-06754 Test Harness (2 pins) P/N YB-06792 90890-06792 Test Harness (3 pins)
Page 14 Test Harness (3 pins) 90890-06769 90890-06756 P/N YB-06769 90890-06769 Vacuum/Pressure Pump Gauge Set P/N YB-35956-A 90890-06756 Yamaha Diagnostic System for Watercraft P/N LIT-YDIS1-21-00 LIT-YDIS1-21-00 60V-85300-01 Yamaha Diagnostic System Connector for Watercraft P/N 60V-WS850-00-00 USB Cable P/N 68F-WS850-00-00 Serial Cable -WS853-01...
Page 15: Removal And Installation
GENERAL INFORMATION INFO REMOVAL AND INSTALLATION TOOLS YU-38411 YW-06551 1 Oil Filter Wrench 90890-01426 P/N YU-38411 90890-06551 90890-01426 2 Coupler Wrench P/N YW-06551 90890-06551 YS-01880-A YM-01082 90890-01701 90890-01080 3 Sheave Holder P/N YS-01880-A 90890-01701 4 Rotor Puller P/N YM-01082 90890-01080 YU-01235 YM-45469 5 Rotor Holder...
Page 16 GENERAL INFORMATIONx INFO Valve Seat Cutter Intake 90890-06813 (60°) 90890-06814 (45°) 90890-06815 (30°) Exhaust 90890-06315 (60°) 90890-06312 (45°) 90890-06328 (30°) Valve Seat Cutter Holder 90890-06811 (ø4.0 mm) 90890-06812 (ø4.5 mm) Valve Seat Cutter Set YM-91043-C Piston Ring Compressor YM-08037 90890-05158 Drive Shaft Holder (Impeller) YB-06151 90890-06519...
Page 17 GENERAL INFORMATION INFO 1-10...
Page 18 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ..........2-1 MAINTENANCE SPECIFICATIONS .
Page 19: General Specifications
SPEC GENERAL SPECIFICATIONSx GENERAL SPECIFICATIONS 1.72 (5.67 ft) Jet thrust nozzle trim angle Degree Impeller pitch Degree Port 17.3 / Stbd. 16.3...
Page 20 SPEC GENERAL SPECIFICATIONS...
Page 21 SPEC MAINTENANCE SPECIFICATIONSx...
Page 22 SPEC MAINTENANCE SPECIFICATIONS...
Page 23 SPEC MAINTENANCE SPECIFICATIONSx...
Page 24 SPEC MAINTENANCE SPECIFICATIONS Port 17.3 Stbd. 16.3 Marine Group 24 Dual Purpose 675 CCA 100 (12/68.4)
Page 25 SPEC MAINTENANCE SPECIFICATIONSx...
Page 26 SPEC MAINTENANCE SPECIFICATIONS Main (At Battery) Starter (At each engine)
Page 27 SPEC MAINTENANCE SPECIFICATIONSx Part To Be Tightened 1/4-20 8-32 10-24...
Page 28 SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES Part To Be Tightened 2-10...
Page 29 SPEC MAINTENANCE SPECIFICATIONSx TIGHTENING TORQUES Part To Be Tightened 2-11...
Page 30 SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES Part To Be Tightened 2-12...
Page 31 SPEC MAINTENANCE SPECIFICATIONSx TIGHTENING TORQUES Part To Be Tightened 2-13...
Page 32: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES Thread Tightening torque Part To Be Tightened Part Name size N•m kgf•m ft•lb Remarks Water inlet cover/water inlet Bolt 0.66 strainer - impeller duct Drive shaft nut - drive shaft – Impeller (left-hand threads) – Impeller drive shaft Intermediate housing - bulkhead...
Page 33: Tightening Torques
SPEC MAINTENANCE SPECIFICATIONSx TIGHTENING TORQUES Thread Tightening Torque Part To Be Tightened Part Name size N•m kgf•m ft•lb Remarks Main and fuel pump relay Tapping ø6 0.39 screw Rectifier/regulator Tapping ø6 0.39 screw Ignition coil - oil tank Bolt 0.76 Ignition coil cover - ignition coil Tapping ø6...
Page 34: General Torque
SPEC MAINTENANCE SPECIFICATIONS GENERAL TORQUE General Torque Specifications This chart specifies the torques for tightening Nut A Bolt B standard fasteners with standard clean dry ISO M•kg ft•lb threads at room temperature. Torque specifica- tions for special components or assemblies are 8 mm given in applicable sections of this manual.
Page 35: Cable And Hose Routing
SPEC MAINTENANCE SPECIFICATIONSx CABLE AND HOSE ROUTING 2-17...
Page 36 SPEC MAINTENANCE SPECIFICATIONS CABLE AND HOSE ROUTING 2-18...
Page 37 SPEC MAINTENANCE SPECIFICATIONSx CABLE AND HOSE ROUTING 2-19...
Page 38 SPEC MAINTENANCE SPECIFICATIONS CABLE AND HOSE ROUTING 2-20...
Page 39 SPEC MAINTENANCE SPECIFICATIONSx CABLE AND HOSE ROUTING 2-21...
Page 40 CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART ......... . . 3-1 PERIODIC SERVICE .
Page 41 INSP PERIODIC INSPECTION AND ADJUSTMENT...
Page 42: Periodic Service
INSP 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 cooling water casting boss on the right side of the pump.
Page 43 INSP PERIODIC INSPECTION AND ADJUSTMENT REMOTE CONTROL UNIT 1. Check throttle: Throttle lever at Wide-Open-Throttle (W.O.T.) position. Throttle cable wheel, clearance to stop on carburetor incorrect Adjust. Throttle lever at idle position. Throttle cable wheel does not touch idle screw Adjust.
Page 44 INSP PERIODIC INSPECTION AND ADJUSTMENT Shift cable inspection and adjustment 2.9 Nm (0.29 kg•m, 2.09 ft-lb) Shift Cable Adjustment Steps: a) Remove the four screws holding the remote control unit cover. Remove the four screws holding the remote control unit to the deck. Lift the remote control unit.
Page 45 INSP PERIODIC INSPECTION AND ADJUSTMENT...
Page 46 INSP PERIODIC INSPECTION AND ADJUSTMENT • Valve clearance adjustment should be made on a cold engine at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at Top Dead Center (TDC) on the compression stroke.
Page 47 INSP PERIODIC INSPECTION AND ADJUSTMENT...
Page 48 INSP PERIODIC INSPECTION AND ADJUSTMENT...
Page 49 INSP 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:...
Page 50 INSP PERIODIC INSPECTION AND ADJUSTMENT 3-10...
Page 51 INSP PERIODIC INSPECTION AND ADJUSTMENT 3-11...
Page 52 INSP PERIODIC INSPECTION AND ADJUSTMENT CAUTION: 3-12...
Page 53 INSP PERIODIC INSPECTION AND ADJUSTMENT Place the craft in water, and then CAUTION: 3-13...
Page 54 INSP PERIODIC INSPECTION AND ADJUSTMENT 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. CAUTION: Do not run the engine for more than 15 sec- onds without supplying water when check- ing the oil level on land.
Page 55 INSP PERIODIC INSPECTION AND ADJUSTMENT CAUTION: 3-15...
Page 56 INSP PERIODIC INSPECTION AND ADJUSTMENT CAUTION: When starting the engine, make sure the dip- stick is securely fitted into the oil tank. 3-16...
Page 57 INSP PERIODIC INSPECTION AND ADJUSTMENT CAUTION: 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 complete- ly. Do not use detergent or a solvent to clean the air filter element, or dry it with heat or compressed air, otherwise it could be damaged.
Page 58 INSP PERIODIC INSPECTION AND ADJUSTMENT 3-18...
Page 59 INSP PERIODIC INSPECTION AND ADJUSTMENT 3-19...
Page 60 INSP PERIODIC INSPECTION AND ADJUSTMENT Clean-out cap 1 by pressing Release Bottom A and lift the cap out of the Port. Align the grooved recess on the clean-out cap with the projection in the clean-out opening. CAUTION: Be sure the cap is properly positioned and locked in place.
Page 61 INSP 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.
Page 62 INSP PERIODIC INSPECTION AND ADJUSTMENT 3-22...
Page 63 INSP 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.
Page 64 INSP PERIODIC INSPECTION AND ADJUSTMENT Lubrication points 1. Lubricate: Throttle cable (throttle body end) Recommended lubricant: Yamaha marine grease, Yamaha grease A (Water resistant grease) NOTE: Before lubricating the QSTS control cables, remove the QSTS cable housing cover. Spray the rust inhibitor into the outer cables, and apply grease to the inner cables.
Page 65 INSP PERIODIC INSPECTION AND ADJUSTMENT 3-25...
Page 66: Fuel System
CHAPTER 4 FUEL SYSTEM FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM ..........4-1 REMOVAL AND INSTALLATION CHART .
Page 67 FUEL FUEL SYSTEM 4.9~7.9 Nm (50~80 kgf-cm) See Note REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty Service Points FUEL TANK PUMP MODULE Follow the “Step” order for removal. Connector, harness Cover Screw, Machine Clamp Fuel hose Screw NOTE: Apply Loctite, torque in 2 steps see page 4-4 Pump Module Removal, 4-5 Installation...
Page 68 FUEL FUEL SYSTEM FUEL TANK AND FUEL PUMP MODULE (Cont’d.) Step Procedure / Part Name Q’ty Service Points Fuel Level Sender Gasket Clamp Hose, Vent Hose, Vent Valve, Check Washer, Star Washer Vent, Fuel Clamp 4.2 Nm (0.42 kgf-m, 3.0 ft-lbs) See detail on clamp installation Hose, Fuel Filler Nut, #8-32 Nylon Lock...
Page 69 FUEL FUEL SYSTEM FUEL TANK AND FUEL PUMP MODULE (Cont’d.) Step Procedure / Part Name Q’ty Service Points Filler Cap Assembly Gasket FUEL TANK Note: Deck must be cut at outline to access fuel tank for removal Screw, Machine 1/4” - 20 x 1” 4.9~7.9 Nm (50~80 kgf-cm) Fix, Fuel Tank Fuel Tank Assembly...
Page 70 FUEL FUEL SYSTEM SYSTEM.” Screws Loosen the screws in the sequence shown.
Page 71 FUEL FUEL SYSTEM Screws 4.9 Nm (0.49 kgf-m) 7.9 Nm (0.8 kgf-m) SYSTEM.”...
Page 72 FUEL FUEL SYSTEM...
Page 73 FUEL FUEL SYSTEM FUEL INJECTION SYSTEM (Cont’d.)
Page 74 FUEL FUEL SYSTEM FUEL INJECTION SYSTEM (Cont’d.)
Page 75 FUEL FUEL SYSTEM FUEL INJECTION SYSTEM (Cont’d.)
Page 76 FUEL FUEL SYSTEM FUEL INJECTION SYSTEM (Cont’d.) 4-10...
Page 77 FUEL FUEL SYSTEM FUEL INJECTION SYSTEM (Cont’d.) 4-11...
Page 78 FUEL FUEL SYSTEM FUEL INJECTION SYSTEM (Cont’d.) 4-12...
Page 79 FUEL FUEL SYSTEM FUEL INJECTION SYSTEM (Cont’d.) 4-13...
Page 80 FUEL FUEL SYSTEM FUEL INJECTION SYSTEM (Cont’d.) 4-14...
Page 81 FUEL FUEL SYSTEM CAUTION: 4-15...
Page 82 FUEL FUEL SYSTEM CAUTION: Disconnect the fuel hose 1 directly from the fuel pipe 2. 4-16...
Page 83 FUEL FUEL SYSTEM If free play is not obtained, disconnect the fuel hose, check the O-ring for damage and that it is properly installed. CAUTION: 4-17...
Page 84 FUEL FUEL SYSTEM CAUTION: 4-18...
Page 85 FUEL FUEL SYSTEM Blow out all passages with compressed air. CAUTION: 4-19...
Page 86 FUEL FUEL SYSTEM CAUTION: Only butterfly valve #2 should be fully closed. The other valves should be halfway closed. 4-20...
Page 87 FUEL FUEL SYSTEM 4-21...
Page 88 FUEL FUEL SYSTEM CAUTION: 4-22...
Page 89 FUEL FUEL SYSTEM 4-23...
Page 90 FUEL FUEL SYSTEM 4-24...
Page 91 FUEL FUEL SYSTEM “Fuel hose disconnection.” “Fuel hose connection.”) nection.”) connection.” 4-25...
Page 96: Powr Power Unit
POWR POWER UNIT Refer to “ENGINE HATCH” in Chapter 8.
Page 97 POWR POWER UNIT ENGINE UNIT EXPLODED DIAGRAM...
Page 98 POWR POWER UNIT...
Page 99 POWR POWER UNIT CAUTION:...
Page 100 POWR POWER UNIT...
Page 101 POWR POWER UNIT CAUTION:...
Page 102 POWR POWER UNIT...
Page 103 POWR POWER UNIT UNIT.”...
Page 104 POWR POWER UNIT EXHAUST PIPE 3 (Cont’d.)
Page 105 POWR POWER UNIT EXHAUST PIPE 3 (Cont’d.) 5-10...
Page 106 POWR POWER UNIT PIPE 3.” MOTOR.” 5-11...
Page 107 POWR POWER UNIT EXHAUST PIPES 1 AND 2 (Cont’d.) 5-12...
Page 108 POWR POWER UNIT AND 2.” 5-13...
Page 109 POWR POWER UNIT EXHAUST MANIFOLD (Cont’d.) 5-14...
Page 110 POWR POWER UNIT UNIT.” “THERMOSTAT.” 5-15...
Page 111 POWR POWER UNIT OIL TANK (Cont’d.) 5-16...
Page 112 POWR POWER UNIT OIL TANK (Cont’d.) 5-17...
Page 113 POWR POWER UNIT OIL TANK (Cont’d.) 5-18...
Page 114 POWR POWER UNIT OIL TANK (Cont’d.) 5-19...
Page 115 POWR POWER UNIT OIL TANK (Cont’d.) 5-20...
Page 116 POWR POWER UNIT OIL TANK (Cont’d.) 5-21...
Page 117 POWR POWER UNIT 5-22...
Page 118 POWR POWER UNIT 5-23...
Page 119 POWR POWER UNIT 5-24...
Page 120 POWR POWER UNIT 5-25...
Page 121 POWR POWER UNIT TANK.” 5-26...
Page 122 POWR POWER UNIT OIL PUMP (Cont’d.) 5-27...
Page 123 POWR POWER UNIT OIL PUMP (Cont’d.) 5-28...
Page 124 POWR POWER UNIT 5-29...
Page 125 POWR POWER UNIT 5-30...
Page 126 POWR POWER UNIT 5-31...
Page 127 POWR POWER UNIT MOTOR.” PUMP.” 5-32...
Page 128 POWR POWER UNIT REDUCTION DRIVE GEAR (Cont’d.) 5-33...
Page 129 POWR POWER UNIT REDUCTION DRIVE GEAR (Cont’d.) 5-34...
Page 130 POWR POWER UNIT REDUCTION DRIVE GEAR (Cont’d.) 5-35...
Page 131 POWR POWER UNIT REDUCTION DRIVE GEAR (Cont’d.) 5-36...
Page 132 POWR POWER UNIT 5-37...
Page 133 POWR POWER UNIT 5-38...
Page 134 POWR POWER UNIT UNIT.” 5-39...
Page 135 POWR POWER UNIT GENERATOR AND STARTER MOTOR (Cont’d.) 5-40...
Page 136 POWR POWER UNIT GENERATOR AND STARTER MOTOR (Cont’d.) 5-41...
Page 137 POWR POWER UNIT GENERATOR AND STARTER MOTOR (Cont’d.) CAUTION: Make sure not to pinch the pulser coil leads between the washers and projec- tions on the case when installing the bolts. 5-42...
Page 138 POWR POWER UNIT GENERATOR AND STARTER MOTOR (Cont’d.) 5-43...
Page 139 POWR POWER UNIT 5-44...
Page 140 POWR POWER UNIT 5-45...
Page 141 POWR POWER UNIT CAUTION: washer. Always replace them with new ones. 5-46...
Page 142 POWR POWER UNIT 5-47...
Page 143 POWR POWER UNIT CAMSHAFTS (Cont’d.) 5-48...
Page 144 POWR POWER UNIT CAMSHAFTS (Cont’d.) GEAR.” 5-49...
Page 145 POWR POWER UNIT CAMSHAFTS (Cont’d.) 5-50...
Page 146 POWR POWER UNIT CAMSHAFTS (Cont’d.) 5-51...
Page 147 POWR POWER UNIT 5-52...
Page 148 POWR POWER UNIT 5-53...
Page 149 POWR POWER UNIT 5-54...
Page 150 POWR POWER UNIT 5-55...
Page 151 POWR POWER UNIT CAUTION: 5-56...
Page 152 POWR POWER UNIT 5-57...
Page 153 POWR POWER UNIT 5-58...
Page 154 POWR POWER UNIT Tighten the cylinder head cover bolts in a criss- cross pattern. 5-59...
Page 155 POWR POWER UNIT UNIT.” PIPE 3.” AND 2.” TANK.” “CAMSHAFTS.” 5-60...
Page 156 POWR POWER UNIT CYLINDER HEAD (Cont’d.) 5-61...
Page 157 POWR POWER UNIT 5-62...
Page 158 POWR POWER UNIT 5-63...
Page 159 POWR POWER UNIT 5-64...
Page 160 POWR POWER UNIT HEAD.” 5-65...
Page 161 POWR POWER UNIT VALVES AND VALVE SPRINGS (Cont’d.) 5-66...
Page 162 POWR POWER UNIT 5-67...
Page 163 POWR POWER UNIT 5-68...
Page 164 POWR POWER UNIT Before checking the valve guide, make sure the valve stem diameter is within specifica- tion. 5-69...
Page 165 POWR POWER UNIT 5-70...
Page 166 POWR POWER UNIT 5-71...
Page 167 POWR POWER UNIT 5-72...
Page 168 POWR POWER UNIT CAUTION: 5-73...
Page 169 POWR POWER UNIT 5-74...
Page 170 POWR POWER UNIT CAUTION: 5-75...
Page 171 POWR POWER UNIT 5-76...
Page 172 POWR POWER UNIT UNIT.” PIPE 3.” AND 2.” MANIFOLD.” MOTOR.” TANK.” 5-77...
Page 173 POWR POWER UNIT CRANCASE (Cont’d.) PUMP.” GEAR.” “CAMSHAFTS.” 5-78...
Page 174 POWR POWER UNIT CRANCASE (Cont’d.) 5-79...
Page 175 POWR POWER UNIT CRANCASE (Cont’d.) 5-80...
Page 176 POWR POWER UNIT CRANCASE (Cont’d.) “CRANKSHAFT.” 5-81...
Page 177 POWR POWER UNIT CAUTION: Tap on one side of the crankcase with a soft-face hammer. Tap only on rein- forced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves separate evenly. 5-82...
Page 178 POWR POWER UNIT 5-83...
Page 179 POWR POWER UNIT 5-84...
Page 180 POWR POWER UNIT CAUTION: 5-85...
Page 181 POWR POWER UNIT 5-86...
Page 182 POWR POWER UNIT “CRANKCASE.” 5-87...
Page 183 POWR POWER UNIT CONNECTING RODS AND PISTONS (Cont’d.) 5-88...
Page 184 POWR POWER UNIT CAUTION: 5-89...
Page 185 POWR POWER UNIT pistons: 5-90...
Page 186 POWR POWER UNIT formula: 5-91...
Page 187 POWR POWER UNIT 5-92...
Page 188 POWR POWER UNIT 5-93...
Page 189 POWR POWER UNIT CAUTION: 5-94...
Page 190 POWR POWER UNIT Lubricate the bolt threads and nut seats installation.” removal.” 5-95...
Page 191 POWR POWER UNIT 5-96...
Page 192 POWR POWER UNIT 5-97...
Page 193 POWR POWER UNIT 5-98...
Page 194 POWR POWER UNIT procedure.” CAUTION: 5-99...
Page 195 POWR POWER UNIT “CRANKCASE.” PISTONS.” 5-100...
Page 196 POWR POWER UNIT 5-101...
Page 197 POWR POWER UNIT CAUTION: 5-102...
Page 198 POWR POWER UNIT “CRANKCASE.” 5-103...
Page 199 POWR POWER UNIT 5-104...
Page 200 POWR POWER UNIT 5-105...
Page 201 POWR POWER UNIT THERMOSTAT (Cont’d.) 5-106...
Page 202 POWR POWER UNIT Does not open at 50~60°C (123~ 5-107...
Page 203 POWR POWER UNIT MANIFOLD.” 5-108...
Page 204 POWR POWER UNIT PRESSURE CONTROL VALVE (Cont’d.) 5-109...
Page 205 POWR POWER UNIT PRESSURE CONTROL VALVE (Cont’d.) 5-110...
Page 206 POWR POWER UNIT PRESSURE CONTROL VALVE (Cont’d.) 5-111...
Page 207 POWR POWER UNIT 5-112...
Page 208 CHAPTER 6 JET PUMP UNIT INTAKE GRATING ............6-1 EXPLODED DIAGRAM .
Page 209 JET PUMP PUMP INTAKE GRATING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty (ea) Service Points INTAKE GRATING Follow the left “Step” order for removal. REMOVAL Screw 8 x 35mm Screw 8 x 20mm Intake Grating Port and Starboard Units Screw 8 x 40mm...
Page 210 JET PUMP PUMP FILL GAPS WITH SILICONE FILL GAPS WITH SILICONE Apply clear silicone as shown before installing Duct into hull. Install Duct and torque screws to 15Nm (1.5m-kg, 11 ft-lb).
Page 211: Removal And Installation Chart
JET PUMP PUMP PUMP UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty (ea.) Service Points PUMP UNIT REMOVAL Follow the “Step” order for removal. Shift Cable Joint Steering Cable Joint Bolt (with washer) Nozzle NOTE: May be left on to remove pump as an assembly.
Page 212: Removal And Installation Chart
JET PUMP PUMP REVERSE GATE AND DEFLECTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty (ea) Service Points REVERSE GATE AND NOZZLE Follow the “Step” order for removal. DEFLECTOR REMOVAL Bolt (with washer) 8 x 20mm Collar Reverse Gate Bolt (with washer)
Page 213: Exploded Diagram
JET PUMP PUMP IMPELLER AND DRIVE SHAFT EXPLODED DIAGRAM DISTINCT MARK (BY CASTING) PART NUMBER NO MARK 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 Follow the “Step”...
Page 214: Jet Pump Clean-Out Ports
JET PUMP PUMP JET PUMP CLEAN-OUT PORTS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Qty (ea.) Service Points JET PUMP CLEAN-OUT Follow the “Step” order for removal. TRAY REMOVAL Inspection Cover Clamp, Upper Access top hose clamps through inner inspection holes, loosen both top clamps to remove Clean-out Tray.
Page 215 JET PUMP PUMP...
Page 216 JET PUMP PUMP...
Page 217 JET PUMP PUMP...
Page 218 JET PUMP PUMP 6-10...
Page 219 CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ..........7-1 ELECTRICAL BOX AND IGNITION COIL BOX .
Page 220 THERMOSWITCH (EXHAUST) ........7-31 SLANT DETECTION SWITCH .
Page 221 ELEC ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 20 21 Bow light Fuel pumps Fuel sender Stereo Speaker Running Light...
Page 222 ELEC ELECTRICAL SYSTEM ELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Service Points ELECTRICAL BOX REMOVAL Follow the left “Step” for removal. Battery negative lead Battery positive lead Bolt Battery hold down bracket Battery Battery tray Washer...
Page 223 ELEC ELECTRICAL SYSTEM ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.) EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Service Points Bolt Screw Terminal cover Gasket Not reusable Screw Starter motor lead Bolt Cover...
Page 224: Elec Electrical System
ELEC ELECTRICAL SYSTEM ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.) EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty Service Points Gasket Not reusable Bolt Ground led Holder Coupler NOTE: Disconnect all couplers. Reverse the removal steps for installation.
Page 225: Elec Electrical System
ELEC ELECTRICAL SYSTEM ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.) EXPLODED DIAGRAM...
Page 226 ELEC ELECTRICAL SYSTEM ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.) EXPLODED DIAGRAM...
Page 227: Electrical System
ELEC ELECTRICAL SYSTEM ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.) EXPLODED DIAGRAM Step Procedure / Part Name Q’ty Service Points Tapping screw Bracket Joint connector Tapping screw Main and fuel pump relay Tapping screw Rectifier/regulator Reverse the disassembly steps for assembly.
Page 228 ELEC ELECTRICAL SYSTEM ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.) EXPLODED DIAGRAM...
Page 229 ELEC ELECTRICAL SYSTEM ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.) EXPLODED DIAGRAM High tension code...
Page 230 ELEC ELECTRICAL SYSTEM ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.) 7-10...
Page 231 ELEC ELECTRICAL SYSTEM Throughout this chapter, the digital tester’s part number has been omitted. Refer to the following part number. “O O” indicates a continuity of electricity (e.g., a closed circuit at the respective switch posi- tion). 7-11...
Page 232 ELEC ELECTRICAL SYSTEM • When checking the condition of the ignition system, it is vital to know the peak voltage. • Cranking speed is dependant on many factors (e.g., fouled or weak spark plugs or a weak battery). If one of these is defective, the peak voltage will be lower than specification.
Page 233 ELEC ELECTRICAL SYSTEM • Throughout this chapter, the peak voltage adaptor’s part number has been omitted. Refer to the following part number. tests: 7-13...
Page 234: Ignition System
ELEC ELECTRICAL SYSTEM IGNITION SYSTEM WIRING DIAGRAM 13 : B/R 2 : W 3 : P/W 15 : G/O 4 3 2 1 8 7 6 5 17 : L/B 4 : P 5 : B/Y 18 : R/Y 6 : B/O 19 : P/G 20 : P 7 : Y...
Page 235 ELEC ELECTRICAL SYSTEM IGNITION SYSTEM WIRING DIAGRAM 13 : B/R 2 : W 3 : P/W 15 : G/O 4 3 2 1 8 7 6 5 17 : L/B 4 : P 5 : B/Y 18 : R/Y 6 : B/O 19 : P/G 20 : P 7 : Y...
Page 236 ELEC ELECTRICAL SYSTEM 7-16...
Page 237 ELEC ELECTRICAL SYSTEM • If there is no spark or the spark is weak, con- tinue with the ignition system test. • If a good spark is obtained, the problem is not with the ignition system but possibly with the spark plug(-s) or another component.
Page 238 ELEC ELECTRICAL SYSTEM 7-18...
Page 239 ELEC ELECTRICAL SYSTEM SYSTEM.” 7-19...
Page 240 ELEC ELECTRICAL SYSTEM measurement.” Lanyard Clip White Black Installed Removed 7-20...
Page 241 ELEC ELECTRICAL SYSTEM 7-21...
Page 242 ELEC ELECTRICAL SYSTEM 7-22...
Page 243 ELEC ELECTRICAL SYSTEM 7-23...
Page 244 ELEC ELECTRICAL SYSTEM 7-24...
Page 245 ELEC ELECTRICAL SYSTEM 7-25...
Page 246 ELEC ELECTRICAL SYSTEM 7-26...
Page 247 ELEC ELECTRICAL SYSTEM FUEL CONTROL SYSTEM WIRING DIAGRAM Engine temperature sensor Intake air temperature sensor Intake air pressure sensor Throttle position sensor Fuel injector Oil pressure switch Thermoswitch (exhaust) Thermoswitch (engine) 7-27...
Page 248 ELEC ELECTRICAL SYSTEM FUEL CONTROL SYSTEM WIRING DIAGRAM 7-28...
Page 249 ELEC ELECTRICAL SYSTEM Purple 12VDC FUEL GAUGE, LOW FUEL LED AND WIRING CHECK 1. Open the fuel hatch and locate the three wire connector for the Fuel Sensor. Unplug the sensor's connector and turn the starboard key to the “ON” position. The gauge should then read below “EMPTY”...
Page 250: Thermoswitch (Exhaust)
ELEC ELECTRICAL SYSTEM 2. Put the black lead of a voltmeter on the FUEL INJECTOR Black/White wire of the harness. Then use Refer to “FUEL INJECTION SYSTEM” in the red lead of the voltmeter to measure the Chapter 4. voltage on the other two pins. MAIN AND FUEL PUMP RELAY PURPLE = More than +12 VDC (or close to Refer to “IGNITION SYSTEM.”...
Page 251: Starting System
ELEC ELECTRICAL SYSTEM STARTING SYSTEM WIRING DIAGRAM 4 3 2 1 8 7 6 5 1 2 3 4 5 6 7 8 PULL START 7-31...
Page 252: Key Switch
ELEC ELECTRICAL SYSTEM KEY SWITCH 1. Check: • Continuity Out of specification → → Replace. Start continuity Brown Red/Black White Black Purple START 1. Disconnect switch at harness. 2. Turn key to function to be checked. 3. Check continuity between the indicated wire leads.
Page 253 ELEC ELECTRICAL SYSTEM 7-33...
Page 254 ELEC ELECTRICAL SYSTEM 7-34...
Page 255 ELEC ELECTRICAL SYSTEM STARTER MOTOR (Cont’d.) 7-35...
Page 256 ELEC ELECTRICAL SYSTEM STARTER MOTOR (Cont’d.) 7-36...
Page 257 ELEC ELECTRICAL SYSTEM 7-37...
Page 258 ELEC ELECTRICAL SYSTEM 7-38...
Page 259 ELEC ELECTRICAL SYSTEM 7-39...
Page 260 ELEC ELECTRICAL SYSTEM SYSTEM.” SYSTEM.” SYSTEM.” 7-40...
Page 261: Electric Bilge Pump
ELEC ELECTRICAL SYSTEM ELECTRIC BILGE PUMP WIRING DIAGRAM Black Br: Brown 7-41...
Page 262 ELEC ELECTRICAL SYSTEM 7-42...
Page 263: Main Component Location
ELEC ELECTRICAL SYSTEM MAIN COMPONENT LOCATION EXPLODED DIAGRAM 1. Battery 2. Fuel Level Sensor 3. Bow Light 4. Stern Light Connector 5. Blower Motors 6. Bilge Pump 7. Horn 8. Stereo Unit 9. Hull Harness #3 10. Deck Harness 11. 12V Outlet and Circuit Breaker 7-43...
Page 264: Switch Location
ELEC ELECTRICAL SYSTEM SWITCH LOCATION WIRING DIAGRAM 1. Key Switches 2. Lanyard Switch 3. Neutral Switch 4. Hatch Interlock Switches 5. Engine Harness #2 7-44...
Page 265: Meter Panel Back View
ELEC ELECTRICAL SYSTEM METER PANEL BACK VIEW WIRING DIAGRAM 1 Starboard Tach 3 Port Tach 2 Speedometer 4 Fuel Gauge 7-45...
Page 266: Electrical Components
ELEC ELECTRICAL SYSTEM ELECTRICAL COMPONENTS REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Qty (ea.) Service Points METER PANEL DISASSEMBLY Follow the “Step” order for removal. Cover, Steering Wheel Nut w/Washer Steering Wheel Woodruff Key Key Switch Screw #8 x 3/4” PTH Nut w/Washer #8 x 32 Hex Meter Panel...
Page 267: Switch And Component
ELEC ELECTRICAL SYSTEM SWITCH AND COMPONENT WIRING DIAGRAM 1 Circuit Breaker 8 Stereo 2 Stereo Switch 9 Courtesy Lead 3 Courtesy Light Switch 10 Blower Motors 4 Navigation Light Switch 11 Bilge Pump 5 Bilge Pump Switch 12 Horn 6 Blower Switch 13 Stern Light 7 Horn Switch 14 Bow Light...
Page 268 ELEC ELECTRICAL SYSTEM 7-48...
Page 269 ELEC ELECTRICAL SYSTEM 7-49...
Page 270 CHAPTER 8 HULL AND DECK ENGINE COMPARTMENT LAYOUT ......... . . 8-1 EXPLODED DIAGRAM .
Page 271 GUNWALE ............8-24 EXPLODED DIAGRAM .
Page 272: Engine Compartment Layout
HULL HULL AND DECK DECK ENGINE COMPARTMENT LAYOUT EXPLODED DIAGRAM 1. Engine 5. Battery 2. Water Lock 6. Blowers 3. Jet Pump 7. Bilge Pump 4. Fuel Tank...
Page 273: Ventilation System
HULL HULL AND DECK DECK VENTILATION SYSTEM EXPLODED DIAGRAM...
Page 274: Removal And Installation Chart
HULL HULL AND DECK DECK REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty Service Points VENTILATION SYSTEM Follow the “Step” order for removal. DISASSEMBLY Hose Clamp Snap type Screw, Oval Head Tapping Ventilator (White) Ventilator (Black) Hose, Ventilation Intake 36”...
Page 275: Cooling System
HULL HULL AND DECK DECK COOLING SYSTEM EXPLODED DIAGRAM...
Page 276: Removal And Installation Chart
HULL HULL AND DECK DECK REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty Service Points COOLING SYSTEM AND WATER LOCK REMOVAL Follow the “Step” order for removal. Band, Hose 18 Clip Hose 1 Joint, Hose 1 Clip Cap, 1 Joint Assy Band, Hose 18 Clip...
Page 277: Steering System
HULL HULL AND DECK DECK STEERING SYSTEM EXPLODED DIAGRAM NOTE: See REMOVAL AND INSTALLATION CHART on next page for torque specs and locking agent instructions.
Page 278: Removal And Installation Chart
HULL HULL AND DECK DECK REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty Service Points STEERING HELM REMOVAL Follow the “Step” order for removal. Cover 1/2"-13, Nylon lock, 18 Nm (1.8 m-kg, 13 ft-lb) Washer 1/2" Steering Wheel Boot Screw #8 x 1", 1.8 Nm (0.18 m-kg, 1.3 ft-lb)
Page 279: Remote Control System
HULL HULL AND DECK DECK REMOTE CONTROL SYSTEM EXPLODED DIAGRAM...
Page 280: Removal And Installation Chart
HULL HULL AND DECK DECK REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty Service Points REMOTE CONTROL UNIT Follow the “Step” order for removal. REMOVAL Throttle Lever Plugs (red) 2 sets Screws face starboard Shift Lever Plugs (black) 1 set Screws face starboard Screw, Oval Head...
Page 281: Engine Hatch
HULL HULL AND DECK DECK ENGINE HATCH EXPLODED DIAGRAM 8-10...
Page 282: Removal And Installation Chart
HULL HULL AND DECK DECK REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty Service Points ENGINE HATCH REMOVAL Follow the “Step” order for removal. AND DISASSEMBLY Support, Engine Hatch Support Hatch Lid before removal. Nut, #10-24 Nylon Lock Washer, 310 Fender 3/4”...
Page 283: Hatch Fittings/Bow Cover
HULL HULL AND DECK DECK HATCH FITTINGS/BOW COVER EXPLODED DIAGRAM 8-12...
Page 284: Removal And Installation Chart
HULL HULL AND DECK DECK REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty Service Points Step Procedure / Part Name Q’ty Service Points BOW LOCKER Follow the “Step” GLOVEBOX HATCH DISASSEMBLY order for removal. Screw #10 X 3/4” Screw, Tapping #8 x 5/8”...
Page 285: Seat Fittings
HULL HULL AND DECK DECK SEAT FITTINGS EXPLODED DIAGRAM 8-14...
Page 286: Removal And Installation Chart
HULL HULL AND DECK DECK REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty Service Points SEAT FITTING DISASSEMBLY Follow the “Step” order for removal. DRIVER’S BUCKET SEATS Screw, 1/4-20 x 1/2" Washer, Flat 1/4 x 1" Fender Driver Seat Assembly Seat Slider Screw, 1/4-20 x 1 1/4"...
Page 287: Deck Fittings
HULL HULL AND DECK DECK DECK FITTINGS EXPLODED DIAGRAM 8-16...
Page 288: Removal And Installation Chart
HULL HULL AND DECK DECK REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty Service Points STERN LIGHT Follow the “Step” order for removal. Stern Light Assembly Lens Bulb ML1004 obtain locally Screw, Tapping Socket Assembly Collar (Shim) Position so that Stern Light angles towards stern. Drawing F1C-U268B-00 BOW LIGHT Screw, Tapping...
Page 289 HULL HULL AND DECK DECK DECK FITTINGS (Continued) EXPLODED DIAGRAM Step Procedure / Part Name Q’ty Service Points TABLE Table Optional Accy Stanchion (Table Post) Short, Swim Deck 330mm, 13 in, Optional Accy Stanchion (Table Post) Long, Cockpit 622mm, 24.5 in, Optional Accy Screw 1/4-20 x 1-3/4”...
Page 290: Nut, #8-32 Nylon Lock
HULL HULL AND DECK DECK REMOVAL AND INSTALLATION CHART (Continued) Step Procedure / Part Name Q’ty Service Points BIMINI TOP BRACKETS Nut, 10-24 Nylon Lock Torque 4Nm (0.4m-kg, 3 ft-lb) Washer, 10 x 3/4” OD Screw, 10-24 x 1-1/2” Bracket, Awning (front) Screw, 10-24 x 1”...
Page 291 HULL HULL AND DECK DECK DECK FITTINGS (Continued) EXPLODED DIAGRAM 8-20...
Page 292: Washer, #8 Flat
HULL HULL AND DECK DECK REMOVAL AND INSTALLATION CHART (Continued) Step Procedure / Part Name Q’ty Service Points WINDSHIELD Nut, 10-24 Nylon Lock Torque 4Nm (0.4m-kg, 3 ft-lb) Washer, #10 Flat Screw, 10-24 x 2” PPH Screw, #8 x 3/8” PPH- Type B Windshield Brace Windshield Trim...
Page 293 HULL HULL AND DECK DECK THROUGH HULL AND DRAIN FITTINGS EXPLODED DIAGRAM Qty 3 for Bilge Hose 8-22...
Page 294: Through Hull And Drain Fitting
HULL HULL AND DECK DECK REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty Service Points THROUGH HULL AND DRAIN Follow the “Step” order for removal. FITTINGS Drain Plug Apply silicone to the drain plug assy flange. Screw #8 x 3/4 POH Clamp, Hose 2 (SAE #24) Cockpit Drain Scupper Drain for Cockpit...
Page 295 HULL HULL AND DECK DECK GUNWALE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure / Part Name Q’ty Service Points GUNWALE Follow the “Step” order for removal. Screw, 310 x 2” POH Torque 2 Nm (0.2m-kg, 1.5 ft-lb) Cover, rub Rail Joint Before installing, apply silicone to the join area.
Page 296 #1200 to #1500 grit with lots of Wax the hull with a non-abrasive wax such as water. For best results, final sanding Yamaha Ultra-gloss Cleaner Wax or other wax should always be in the same direc- designed for marine gelcoat.
Page 297 TRBL TROUBLE ANALYSIS ANLS ® ® ® WINDOWS 95, WINDOWS 98, WINDOWS ® ® ® WINDOWS 2000, OR WINDOWS XP .......... UPDATING THE DATABASE ............ENGINE MONITOR..................9-26 Operating procedure................9-27...
Page 298 Operating procedure................9-41 Data display item selection..............9-42 Operating procedure................9-42...
Page 299 TRBL TROUBLE ANALYSIS ANLS ® ® ® ® If this software is run on Microsoft Windows 95, Windows 98, Windows Me, Windows 2000, or ® Windows XP, the information can be displayed in colorful graphics. Also, the software can be operat- ed using either a mouse or a keyboard.
Page 300 TRBL TROUBLE ANALYSIS ANLS Make sure your computer meets the following requirements before using this software. RS232C (Dsub-9 pin) port, USB portj...
Page 301 TRBL TROUBLE ANALYSIS ANLS INSTALLING THE YAMAHA DIAGNOSTIC SYSTEM UNDER WINDOWS 95, WINDOWS 98, WINDOWS ME, WINDOWS 2000, OR WINDOWS XP 9-2.
Page 302 TRBL TROUBLE ANALYSIS ANLS...
Page 303 TRBL TROUBLE ANALYSIS ANLS...
Page 304 TRBL TROUBLE ANALYSIS ANLS Install the Database file before using the Yamaha Diagnostic System, otherwise, the program will not operate correctly. For installation procedures, refer to “UPDATING THE DATABASE” on the next page.
Page 305 TRBL TROUBLE ANALYSIS ANLS After about three seconds, the display will automatically go to the first menu display, or you can click or press any key to go to the first menu. (See fig. 12.)
Page 306 TRBL TROUBLE ANALYSIS ANLS Do not click the Starting service tool [Enter] button or press the Enter key on your keyboard until the database has been updated, otherwise, the program will not operate correctly.
Page 307 TRBL TROUBLE ANALYSIS ANLS...
Page 308 TRBL TROUBLE ANALYSIS ANLS When the database is updated, a confirmation screen is displayed. 9-10...
Page 309 TRBL TROUBLE ANALYSIS ANLS 9-11...
Page 310 TRBL TROUBLE ANALYSIS ANLS 9-12...
Page 311 TROUBLE ANALYSIS ANLS Open the Yamaha Diagnostic System window. (Fig. 20) After about three seconds, the display will automatically go to the first menu, or click or press any key to go to the first menu. (See fig. 21.) 9-13...
Page 312 TRBL TROUBLE ANALYSIS ANLS 9-14...
Page 313 TRBL TROUBLE ANALYSIS ANLS 9-15...
Page 314 TRBL TROUBLE ANALYSIS ANLS Eight commands appear in the main Menu. Select a command in any of the following three ways: 9-16...
Page 315 TRBL TROUBLE ANALYSIS ANLS 9-17...
Page 316 TRBL TROUBLE ANALYSIS ANLS 9-18...
Page 317 TRBL TROUBLE ANALYSIS ANLS top. 9-19...
Page 318 TRBL TROUBLE ANALYSIS ANLS 9-20...
Page 319 TRBL TROUBLE ANALYSIS ANLS 9-21...
Page 320 TRBL TROUBLE ANALYSIS ANLS 9-22...
Page 321 TRBL TROUBLE ANALYSIS ANLS 9-23...
Page 322 TRBL TROUBLE ANALYSIS ANLS Check that the items deleted are normal in the Diagnosis Record. If the items remain irregular, they will appear as irregular in the Diagnosis Record. Even if you try to delete them, they are undeletable. 9-24...
Page 323 TRBL TROUBLE ANALYSIS ANLS Click the OK button or press the Enter key on your keyboard (Fig. 35): The selected item is deleted. To cancel deleting the item, click the Cancel button or press the Esc key on your keyboard. 9-25...
Page 324 TRBL TROUBLE ANALYSIS ANLS Do not use the Engine Monitor function to check the engine condition while operating a water- craft, otherwise, you could become distracted which could result in a collision. display. 9-26...
Page 325 TRBL TROUBLE ANALYSIS ANLS in the scroll bar or press the up or down keyboard (Fig. 38). 9-27...
Page 326 TRBL TROUBLE ANALYSIS ANLS Avoid clicking the Execute and Cancel buttons repeatedly, otherwise, the ECM or PC will not work properly and they could be damaged. item. test. 9-28...
Page 327 TRBL TROUBLE ANALYSIS ANLS keys on your keyboard (Fig. 39). (Spark Gap Tester YM-34487/90890-06754) is needed. keyboard (Fig. 39). 9-29...
Page 328 TRBL TROUBLE ANALYSIS ANLS keyboard (Fig. 42). 9-30...
Page 329 TRBL TROUBLE ANALYSIS 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.
Page 330 TRBL TROUBLE ANALYSIS ANLS selected (Fig. 46). displayed (Fig. 47). 9-32...
Page 331 TRBL TROUBLE ANALYSIS ANLS keyboard (Fig. 48). Make sure that there is fuel in the fuel tank, otherwise, an error will occur and the test cannot be per- formed. keyboard (Fig. 48). 9-33...
Page 332 TRBL TROUBLE ANALYSIS ANLS keyboard (Fig. 49). 9-34...
Page 333 TRBL TROUBLE ANALYSIS ANLS selected (Fig. 51). CAUTION: Do not test the same cylinder three or more times, otherwise, the spark plug insulator could be damaged. Make sure there is fuel in the fuel tank, otherwise, an error will occur and the test cannot be performed. 9-35...
Page 334 TRBL TROUBLE ANALYSIS ANLS Select the test to be performed, then click the Select button or press the Enter key on your keyboard (Fig. 52). Make sure the engine is not running. 9-36...
Page 335 TRBL TROUBLE ANALYSIS ANLS keyboard (Fig. 53). selected (Fig. 54). 9-37...
Page 336 TRBL TROUBLE ANALYSIS ANLS Avoid clicking the Execute and Cancel buttons repeatedly, otherwise, the ECM or PC will not work properly and they could be damaged. 9-38...
Page 337: Trouble Analysis
TRBL TROUBLE ANALYSIS ANLS For the first ten seconds, operate all four cylinders, then stop one cylinder for five seconds. For the last five seconds, operate all four cylinders. keyboard (Fig. 55). keyboard (Fig. 55). keyboard (Fig. 56). 9-39...
Page 338 TRBL TROUBLE ANALYSIS ANLS If the engine is not running, an error message is displayed. Follow the instructions that appear (Fig. 57). displayed (Fig. 56). appear (Fig. 58). 9-40...
Page 339 TRBL TROUBLE ANALYSIS ANLS board (Fig. 59). Press the Enter key on your keyboard. The window of the selected item is displayed (Fig. 59). 9-41...
Page 340 TRBL TROUBLE ANALYSIS ANLS bar (Fig. 60). displayed (See fig. 61). 9-42...
Page 341 TRBL TROUBLE ANALYSIS ANLS axis (Fig. 61). value at the time the Enter key on your keyboard was pressed in the Monitor item selection. 9-43...
Page 342 TRBL TROUBLE ANALYSIS ANLS (Fig. 62). Although the engine is running, the displayed time refers to the added hours until the Data logger starts. 9-44...
Page 343 TRBL TROUBLE ANALYSIS ANLS displayed (Fig. 63). 9-45...
Page 344 TRBL TROUBLE ANALYSIS ANLS (Fig. 65). 9-46...
Page 345 TRBL TROUBLE ANALYSIS ANLS Programs (Fig. 66). (Fig. 67). 9-47...
Page 346 TRBL TROUBLE ANALYSIS ANLS button (see Figs. 68~70). 9-48...
Page 347 TRBL TROUBLE ANALYSIS ANLS 9-49...
Page 348 TRBL TROUBLE ANALYSIS ANLS test, 9-50...
Page 349 TRBL TROUBLE ANALYSIS ANLS Display (Fig. 73). slider (Fig. 74). 9-51...
Page 350 TRBL TROUBLE ANALYSIS ANLS button (see Figs. 75~76). 9-52...
Page 351 TRBL TROUBLE ANALYSIS ANLS consulted: 9-53...
Page 352 TRBL TROUBLE ANALYSIS ANLS 9-54...
Page 353 TRBL TROUBLE ANALYSIS ANLS 9-55...

Yamaha SR230 2004 Service Manual

X Chapter 1 General Information

Chapter 2 Specifications

Chapter 6 Jet Pump Unit

Table of Contents

Chapter 8 Hull and Deck

Quick Links

Chapters

Related Manuals for Yamaha SR230 2004

Summary of Contents for Yamaha SR230 2004

Table of Contents