2005-2006 Yamaha AR230/SX230 HO Boats OEM Service & Repair Manual

TRADEMARK2005

PREFACE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha machines have a basic understanding of the mechanical concepts and procedures inherent in machine repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe. Because Yamaha has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual. x AR230 High Output / SX230 High Output SRT1100A-D / SRT1100-D Service Manual - 2005 First Edition ©2005 by Yamaha Motor Corporation, USA March 2005 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. 04-574 TRADEMARK2005

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 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 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! Failure to follow WARNING instructions could result in se vere injur y 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. WARNING CAUTION: TRADEMARK2005

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. TRADEMARK2005

SYMBOLS Symbols 1 to 9 are designed as thumb-tabs to indicate the content of a chapter: General Information Specifications Periodic Inspection and Adjustment Fuel System Power Unit Jet Pump Unit Electrical System Hull and Deck Trouble Analysis Symbols to indicate specific data: Special Tool Specified Liquid Specified Engine Speed Specified Torque Specified Measurement Specified Electrical Valve [Resistance (Ω), Voltage (V), Electric Current (A)] Symbol to in an exploded diagram indicate grade of lubricant and location of lubrica- tion point: Apply Yamaha 2-stroke outboard motor oil Apply water resistant grease (Yamaha grease A, Yamaha marine grease) Apply molybdenum disulfide grease Symbols to in an exploded diagram indicate grade of sealing or locking agent and location of application point: Apply Gasket Maker® Apply Yamabond #4 (Yamaha Bond No. 4) Apply LOCTITE® No. 271 (Red LOCTITE) Apply LOCTITE® No. 242 (Blue LOCTITE) Apply LOCTITE® No. 567 (PST) Apply Silicone Sealant NOTE: ______________________________ In this manual, the above symbols may not be used in every case. 1 2 3 4 5 6 7 8 9 10 15 10 11 12 13 14 15 16 18 16 17 18 19 24 19 20 21 22 23 24 HULL DECK 567 TRADEMARK2005

INDEX SPECIFICATIONS SPEC GENERAL INFORMATION 1 GEN INFO 2 PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR JET PUMP 6 JET PUMP ELECTRICAL SYSTEM 7 ELEC HULL AND DECK 8 HULL DECK TROUBLE ANALYSIS 9 TRBL ANLS TRADEMARK2005

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 x TRADEMARK2005

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. ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the crankcase. HULL IDENTIFICATION NUMBER (H.I.N.) The H.I.N. is stamped into the hull on the star- board side of the stern. GENERAL INFORMATION x 1 GEN INFO 1-1 Starting Primary I.D. Number: SRT1100-D/SX230HO F1U-700101 SRT1100 A-D/AR230HO. F1U-720101 Starting Engine Serial Number: 6P6: 1000401 TRADEMARK2005

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 specta- cles 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. GENERAL INFORMATION 1-2 1 GEN INFO TRADEMARK2005

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. GENERAL INFORMATIONx 1 1-3 GEN INFO TRADEMARK2005

2005-2006 Yamaha AR230/SX230 HO Boats OEM Service & Repair Manual

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