2024 Yamaha 222XE Service & Repair Manual

Repair&ServiceManua @YAMAHA YamahaBoat 222series ~TMHXT1800A/B/C/D/E(F6D) 220series ~HLT1050A/B(F5N) SERVICEMANUAL LIT-18616-04-29 FSN-28197-Z2-11

Preface ThismanualhasbeenpreparedbyYamahaprimarilyforusebyYamahadealersandtheirtrainedme- chanicswhenperformingmaintenanceproceduresandrepairstoYamahaequipment.Ithasbeen writtentosuittheneedsofpersonswhohavetheBronzeTechnicalCertificateoftheYTA(Yamaha TechnicalAcademy)marineortheequivalentbasicunderstandingofthemechanicalandelectrical conceptsandproceduresinherentinthework,forwithoutsuchknowledgeattemptedrepairsorservicetotheequipmentcouldrenderitunsafeorunfitforuse. BecauseYamahahasa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.Also,up- to-datepartsinformationisavailableonYDS(YamahaDealerSystem).Additionalinformationandup- to-dateinformationonYamahaproductsandservicesareavailableonYDS. Importantinformation Particularlyimportantinformationisdistinguishedinthismanualbythefollowingnotations: QZ\TheSafetyAlertSymbolmeansATTENTION!BECOMEALERT!YOURSAFETYISINVOLVED! AWARNINGindicatesahazardoussituationwhich,ifnotavoided,couldresultindeathorseriousinjury. NOTICE ANOTICEindicatesspecialprecautionsthatmustbetakentoavoiddamagetotheboatoroth- erproperty. TIP: ATIPprovideskeyinformationtomakeprocedureseasierorclearer. Yamahaboat 222series,220series SERVICEMANUAL ©2023byYamahaMotorCorporation,U.S.A. 1stEdition,September2023 Allrightsreserved. Anyreprintingorunauthorizeduse withoutthewrittenpermissionof YamahaMotorCorporation,U.S.A. isexpresslyprohibited. LIT-18616-04-29

Contents Generalinformation Specification Maintenance Fuelsystem Powerunit Jetpumpunit Electricalsystem Hullanddeck Troubleshooting Appendix FedBededBdel

Generalinformation SafetywhileWOrkKiNg........:csscssseeeeeeeeeeceeseeseeeeeeeeneeeeeees1- Rotatingparts.. Hotparts...... Electricshock.. Impeller......... Handlingofgasoline.. Ventilation... Self-protection. Workingwithcrane Handlingofheatgun. Parts,lubricants,andsealants Handlingofsealants.. Specialservicetool Tighteningtorque... Non-reusableparts Disassemblyandassembly. paeea OoOvMyymynynyMsettttia Identificationnumber... PrimaryI.D.number.. Engineserialnumber. Jetpumpunitserialnumber Hullidentificationnumber(H.I.N.). Howtousethismanual...1-6 Manualformat .1-6 Conditionswhentestingandadjusting1-7 Abbreviation1-7 Adhesive,lubricant,sealant,andthreadlocking Symbols SpecialServicetOO]......cscecceceeceeeteeeeeeteeeeeeeeeeeeeeeneeeenee1-9 Modelfeature+1-16 1-16 1-18 1-20 1-20 1-21 1-22 a1-23 Generalfeature Modelequipmentcomparisontable. Accessportcap.. Transomplate. Jetpumpunit.. Batteryleadconnectiondiagram(222SD).. Batteryleadconnectiondiagram(222XD)..

Generalinformation Batteryleadconnectiondiagram(222SE,2228S). Batteryleadconnectiondiagram(222XE) Batteryleadconnectiondiagram(AR220,SX220) DBWsystem(222SD,222XD,222SE,222XE).. Steeringsystem(222SD,222XD).. DRIVEmode(222SD,222XD).... Ballastsystem(222XD,222XE).. Singlelevermode(222SD,222XD,222SE,222XE) . Drivecontrolfunction(222SD,222XD,222SE,222xXE).. Cruiseassistfunction... No-wakemodefunction ReverseRPMcontrol.... CANcommunicationdiagram(222SD,222XD,222SE, 222XE) CANcommunicationdiagram(2228S) CANcommunicationdiagram(AR220, ContrOlscccccsccesssvsccesccesscctives Multi-functiondisplayelements. Leftandrightgauges(runningmode)(12inchdisplay). Leftandrightgauges(floatmode)(12inchdisplay) Leftandrightgauges(7inchdisplay).. Centerdisplay. Screentabbar. Statusindicatorbar Homescreen.......... Mapscreen(12inchdisplay,7inchdisplay). Tripscreen... Drivecontrolscreen(Hiy‘1 Mediascreen(12inchdisplay,7inchdisplay)............ Systemcontrolscreen(12inchdisplay,7inchdisplay) Settingscreen..... Diagnosisscreen. WaMiNGStsescccrccnccrersevereearmnnimmmTaenineeeT eT BOWNN]|OONDOL OKHOHBWONONMYYNND SeenGuianaSER Se RARABRARABRAAAAARARAOODOD NOORRRRRWWWNNNM=|==—ONTH ere f Technicaltips Enginecontrol(222series[3-starmodels]) Enginecontrol(222series[4-starmodels]) Enginecontrol(220series)............ Enginecontrolsystem(222series) Enginecontrolsystem(220series) Lubricationsystem(222series).. Lubricationsystem(220series).. Coolingsystem(222series[3-starmodels]).. Coolingwaterflow(222series[3-starmodels]) Coolingsystem(222series[4-starmodels]).. Coolingwaterflow(222series[4-starmodels]) Coolingsystem(220series) Coolingwaterflow(220Series)........:cscccecssesesesteeecseeeseeeeeeneee1-69

Generalinformation Drainingwaterflow. Drivesystemlayout(222series[3-starmodels)). Drivesystemlayout(222series[4-starmodels)). Drivesystemlayout(220series) DBWsystem(222SD,222XD,222SE,222XE).. Steeringsystem(222SD,222XD).......::ee Replacementpartsandcalibrationtable(222SD,222XD). Calibration(222SD,222XD) mo NENENNENINENIES BUARBYIS Cableandhoserouting.. Steeringcablesandsteeringhoses(222SD,222XD) (LOPIVIOW)sesessscsecsesesrersesesesenresstearsr sensceerneareestenaraserereeyeeeaerceis1-85 Steeringcables(222SE,222XE,222S,AR220,SX220) (topview) Shiftcables(222SD,222XD,222SE,222XE)(topview). Shiftandthrottlecables(222S,AR220,SX220)(topview) Drainhoses(fronttopview) Drainhoses(reartopview).. Coolingwaterandflushinghoses(topview)(222series).. Coolingwaterandflushinghoses(topview)(220series).. Fuelandbreatherhoses(topview) Enginewireharnessrouting(222series)...1-102 TOpANdPortVIOW.....cccseccecsseeeeeeseeeeeceeeeseeseceeceesaseeensaseeseeeeees1-102 Starboardview(222SD,222XD,222SE,222XE) (8-starmodels) Starboardview(222S)(8-starmodels). Starboardview(4-starmodels).. Rearview(222SD,222XD,222SE, Rearview(2228S)(3-starmodels).. Rearview(4-starmodels). Electricalboxview(222SD,222XD,222SE,222XE) (8-starmodels) Electricalboxview(2228S)(3-starmodels).5 Electricalboxview(222SE,222XE,222S)(4-starmodels)....1-115 Enginewireharnessrouting(220series)...1-116 Portview Starboardview Frontview

Safetywhileworking Safetywhileworking Topreventanaccidentorinjuryandtoprovide qualityservice,observethefollowingsafety procedures. Rotatingparts Hands,feet,hair,jewelry,clothing,personal flotationdevicestraps,andsoon,canbecomeentangledwithinternalrotatingpartsof theengineorjetpumpunit,resultinginserious injuryordeath. ¢Keephands,feet,hair,jewelry,clothing,personalflotationdevicestraps,andsoon, awayfromanyexposedmovingpartswhen operatingtheenginewiththeseatremoved. ¢Keepawayfromintakegratewhileengineis on. Hotparts Duringandafteroperation,enginepartsare hotenoughtocauseburns.Donottouchany partsintheenginecompartmentuntiltheenginehascooled. Electricshock Donottouchanyelectricalpartswhilestarting oroperatingtheengine.Otherwise,shockor electrocutioncouldresult. Impeller Donotholdtheimpellerwithyourhandswhen looseningortighteningtheimpeller. Handlingofgasoline ¢Gasolineishighlyflammable.Keepgasoline andallflammableproductsawayfromheat, sparks,andopenflames. ¢Gasolineispoisonousandcancauseinjury ordeath.Handlegasolinewithcare.Never siphongasolinebymouth.Ifyouswallow somegasoline,inhalealotofgasolinevapor, orgetsomegasolineinyoureyes,seeyour doctorimmediately.Ifgasolinespillsonyour skin,washwithsoapandwater.Ifgasoline spillsonyourclothing,changeyourclothes. Ventilation ¢Gasolinevaporandexhaustgasareheavier thanairandextremelypoisonous.Ifgasoline vapororexhaustgasisinhaledinlarge quantities,itmaycauselossofconscious- nessanddeathwithinashorttime. ¢Whentestrunninganengineindoors(forex- ample,inawatertank)makesuretodoso whereadequateventilationcanbemain- tained. Self-protection Protectyoureyesbywearingsafetyglasses orsafetygogglesduringalloperationsin- volvingdrillingandgrinding,orwhenusing anaircompressor. ¢Protectyourhandsandfeetbywearingprotectiveglovesandsafetyshoeswhenneces- sary.

Safetywhileworking Workingwithcrane ¢Whenmovingtheboat,orwhenliftingthe engineduringremovalorinstallation,make suretouseacranewithaliftingcapacitythat isequaltoormorethantheweightofthe boatorenginerespectively. ¢Whenliftingtheboat,usetheboatliftharnessandmakesurethattheboatisinastablepositionwhenmovingit. ¢Usethewireropesofadequatestrength, andliftuptheengineunitusingthethree pointsuspension. elftheengineunitdoesnothavethreeor morepointstobesuspended,supportitusingadditionalropesor thelikesothattheengineunitcanbeliftedandcarriedinastable manner. Handlingofheatgun ¢Improperhandlingofaheatgunmayresult inburns.Forinformationontheproperhandlingoftheheatgun,seetheoperationmanualissuedbythemanufacturer. ¢Whenusingaheatgun,keepitawayfrom thegasolineandoil,topreventafire. ¢Componentsbecomehotenoughtocause burns.Donottouchanyhotcomponentsdi- rectly. Parts,lubricants,andsealants UseonlygenuineYamahaparts,lubricants, andsealants,orthoserecommendedby Yamaha,whenservicingorrepairingtheboat. Handlingofsealants ¢Wearprotectiveglovestoprotectyourskin, whenusingthesealants. ¢Seethematerialsafetydatasheetissuedby themanufacturer.Someofthesealantsmay beharmfultohumanhealth. Specialservicetool Usetherecommendedspecialservicetoolsto worksafely,andtoprotectpartsfromdamage. Tighteningtorque Followthetighteningtorquespecifications providedthroughoutthemanual.Whentighteningnuts,bolts,andscrews,tightenthelarge sizesfirst,andtightenfastenersstartinginthe centerandmovingoutward.

Safetywhileworking Non-reusableparts Alwaysusenewgaskets,seals,O-rings,cotter pins,andsoon,wheninstallingorassembling parts. Disassemblyandassembly ¢Usecompressedairtoremovedustanddirt duringdisassembly. ¢Applyengineoiltothecontactsurfacesof movingpartsbeforeassembly. ¢Installbearingssothatthebearingidentificationmarkisfacinginthedirectionindicat- edintheinstallationprocedure.Inaddition, makesuretolubricatethebearingsliberally. ¢Applyathincoatofwaterresistantgreaseto thelipandperipheryofanoilsealbeforeinstallation. *Checkthatmovingpartsoperatenormally afterassembly.

2024 Yamaha 222XE Service & Repair Manual

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