2004-2006 HONDA Aquatrax Service Manual

HOW TO USE THIS MANUAL This service manual describes the service procedures for the ARX1200T3, ARX1200T3D and ARX1200N3. Follow the Maintenance Schedule (Section 4) recommendations to ensure that the personal watercraft is in peak operating condition. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1, 4 and 5 apply to the whole personal watercraft. Section 3 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Section 6 through 19 describe parts of the personal watercraft, grouped according to location. Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedures. If you are not familiar with this personal watercraft, read Technical Features in Section 2. If you do not know the source of vehicle trouble, go to section 21 Troubleshooting. Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgement. You will find important safety information in a variety of forms including: • Safety Labels – on the vehicle • Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. • Instructions – how to service this vehicle correctly and safely. As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment. Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE CONTENTS GENERAL INFORMATION MAINTENANCE FLUSHING AND STORAGE LUBRICATION SYSTEM COOLING SYSTEM FUEL SYSTEM (Programmed Fuel Injection) ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVE ALTERNATOR/STARTER CLUTCH CRANKSHAFT/BALANCER (ARX1200T3/T3D)/ PISTON EXHAUST SYSTEM/ TURBOCHARGER (ARX1200T3/T3D) PROPULSION SYSTEM STEERING/REVERSE SYSTEM BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER METER/SWITCHES WIRING DIAGRAMS TROUBLESHOOTING BODY ELECTRICAL 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 2 3 1 HULL/HOOD/BODY PANELS TECHNICAL FEATURES ENGINE INDEX 22

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly. Use the recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of engine oil and molybdenum grease in a ratio of 1 : 1). Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use water resistant grease #0 (Urea based multi-purpose grease NLGI #0 or equivalent). Example: EXCELITE EP0 manufactured by KYODO YUSHI, Japan Use water resistant grease #2 (Urea based multi-purpose grease NLGI #2 or equivalent). Example: EXCELITE EP2 manufactured by KYODO YUSHI, Japan Use water resistant molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). Example: UNILITE M No.2 manufactured by KYODO YUSHI, Japan Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote ® BR-2 plus manufactured by Dow Corning, U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote ® G-n Paste manufactured by Dow Corning, U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent. Use a medium strength locking agent unless otherwise specified. Apply sealant (engine). Apply silicone sealant (SHIN-ETSU KE45T or equivalent).

1-1 1 1. GENERAL INFORMATION SERVICE RULES ············································ 1-2 MODEL IDENTIFICATION······························ 1-2 GENERAL SPECIFICATIONS: ARX1200T3 ···················································· 1-5 GENERAL SPECIFICATIONS: ARX1200T3D·················································· 1-6 GENERAL SPECIFICATIONS: ARX1200N3···················································· 1-7 LUBRICATION SYSTEM SPECIFICATIONS··········································· 1-9 FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS··········································· 1-9 CYLINDER HEAD/VALVE SPECIFICATIONS: ’04 model ····················································· 1-10 CYLINDER HEAD/VALVE SPECIFICATIONS: After ’04························································ 1-10 ALTERNATOR/STARTER CLUTCH SPECIFICATIONS········································· 1-11 CRANKSHAFT/BALANCER (ARX1200T3/T3D)/ PISTON SPECIFICATIONS ·························· 1-11 PROPULSION SYSTEM SPECIFICATIONS: ’04 model ····················································· 1-12 PROPULSION SYSTEM SPECIFICATIONS: After ’04························································ 1-12 BATTERY/CHARGING SYSTEM SPECIFICATIONS··········································1-12 IGNITION SYSTEM SPECIFICATIONS: ’04 model ······················································1-13 IGNITION SYSTEM SPECIFICATIONS: After ’04 ························································1-13 ELECTRIC STARTER SPECIFICATIONS ······1-13 METER/SWITCHES SPECIFICATIONS········1-13 STANDARD TORQUE VALUES ···················1-14 ENGINE & BODY TORQUE VALUES: ’04 model ······················································1-14 ENGINE & BODY TORQUE VALUES: After ’04 ························································1-18 LUBRICATION & SEAL POINTS: ’04 model ······················································1-23 LUBRICATION & SEAL POINTS: After ’04 ························································1-27 CABLE & HARNESS ROUTING: ARX1200T3/T3D···········································1-31 CABLE & HARNESS ROUTING: ARX1200N3···················································1-52 EMISSION CONTROL SYSTEMS ················1-71 EMISSION CONTROL INFORMATION LABEL····························································1-72

GENERAL INFORMATION 1-2 GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to the watercraft. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the watercraft. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-31 or 1-52). MODEL IDENTIFICATION This manual covers two types of ARX1200 models: • T3: Turbocharger model • T3D: Turbocharger model equipped with GPS receiver and boarding step (After ’04) • N3: Standard (no turbocharger) Be sure to refer to the procedure that pertains to the appropriate version of the ARX1200. ’04 model shown:

GENERAL INFORMATION 1-3 The engine serial number and hull identification number are used to register the watercraft. They are unique numbers that distinguish each watercraft from other similar models. If the watercraft is ever stolen these numbers will help identify it. The owner should keep a record of these numbers in a place other than the watercraft. Month code: A = January, B = February·····L = December Year of certification: 04 = 2004, 05= 2005; etc. The hull identification numbers are located on the rear of the hull. The engine serial number is located on the upper side of the oil tank. Manufacturer sI.D. Month & Year of Certification Hull Serial Number Model Year of Watercraft (Model type code) HULL NUMBER IDENTIFICATION HULL IDENTIFICATION NUMBER ’04 model: HULL IDENTIFICATION NUMBER After ’04: ENGINE SERIAL NUMBER

GENERAL INFORMATION 1-4 The throttle body identification number is stamped on the lower side of the throttle body. The color label is attached on the inside of the front hood. When order- ing color-coded parts, always specify the designated color code. THROTTLE BODY IDENTIFICATION NUMBER COLOR LABEL

GENERAL INFORMATION 1-5 GENERAL SPECIFICATIONS: ARX1200T3 ITEM SPECIFICATIONS MODEL CODE Hull ARX1200T3 (SW01) Engine SW01E DIMENSIONS Overall length 3,200 mm (126.0 in) Overall width 1,245 mm (49.0 in) Overall height 1,060 mm (41.7 in) Dry weight ’04 model 358 kg (789 lbs) After ’04 359 kg (791 lbs) Rider capacity 3 person Maximum weight capacity 238 kg (525 lbs) PERFORMANCE Maximum output 121.4 kW (165 PS) at 6,100 rpm Maximum torque 191.8 N·m (19.6 kgf·m) at 5,500 rpm Maximum fuel consumption 53 liters (14.0 US gal, 11.7 Imp gal)/hour Cruising range at full throttle 1.2 hour Fuel tank capacity 63 liters (16.6 US gal, 13.9 lmp gal) Fuel tank reserve capacity 12.9 liters (3.41 US gal, 2.84 lmp gal) HULL Hull type Deep V Hull material FRP ENGINE Engine type 4 stroke Cylinder arrangement 4 cylinders in-line, longitudinal installed Bore and stroke 79.0 X 63.0 mm (3.11 X 2.48 in) Displacement 1,235 cm 3 (75.3 cu-in) Compression ratio 8.5 : 1 Intake system Turbocharged with intercooler Valve train Chain driven, DOHC Intake valve opens at 1 mm lift 10° BTDC closes at 1 mm lift 20° ABDC Exhaust valve opens at 1 mm lift 25° BBDC closes at 1 mm lift 5° ATDC Lubrication system Dry sump Oil pump type Trochoid Cooling system Water cooled Engine dry weight 94.5 kg (208 lbs) Firing order 1 - 3 - 4 - 2 FUEL DELIVERY SYSTEM Type PGM-FI (Programmed Fuel Injection) Throttle bore 38 mm (1.5 in) PROPULSION Jet pump type Single stage, axial flow Impeller rotation (viewed from rear) Counterclockwise Transmission Direct drive from engine Steering nozzle angle (horizontal) 23° Impeller type Stainless steel, 3-blades Impeller diameter 154.6 mm (6.09 in) Minimum water level for jet pump 90 cm (35 in) Bilge pump type Automatic siphon type Reverse system Reverse bucket type ELECTRICAL Ignition system Computer-controlled digital transistorized Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier SCR shorted, triple phase full-wave rectifica- tion

GENERAL INFORMATION 1-6 GENERAL SPECIFICATIONS: ARX1200T3D ITEM SPECIFICATIONS MODEL CODE Hull ARX1200T3D (SW01) Engine SW01E DIMENSIONS Overall length 3,200 mm (126.0 in) Overall width 1,245 mm (49.0 in) Overall height 1,060 mm (41.7 in) Dry weight 361 kg (796 lbs) Rider capacity 3 person Maximum weight capacity 238 kg (525 lbs) PERFORMANCE Maximum output 121.4 kW (165 PS) at 6,100 rpm Maximum torque 191.8 N·m (19.6 kgf·m) at 5,500 rpm Maximum fuel consumption 53 liters (14.0 US gal, 11.7 Imp gal)/hour Cruising range at full throttle 1.2 hour Fuel tank capacity 63 liters (16.6 US gal, 13.9 lmp gal) Fuel tank reserve capacity 12.9 liters (3.41 US gal, 2.84 lmp gal) HULL Hull type Deep V Hull material FRP ENGINE Engine type 4 stroke Cylinder arrangement 4 cylinders in-line, longitudinal installed Bore and stroke 79.0 X 63.0 mm (3.11 X 2.48 in) Displacement 1,235 cm 3 (75.3 cu-in) Compression ratio 8.5 : 1 Intake system Turbocharged with intercooler Valve train Chain driven, DOHC Intake valve opens at 1 mm lift 10° BTDC closes at 1 mm lift 20° ABDC Exhaust valve opens at 1 mm lift 25° BBDC closes at 1 mm lift 5° ATDC Lubrication system Dry sump Oil pump type Trochoid Cooling system Water cooled Engine dry weight 94.5 kg (208 lbs) Firing order 1 - 3 - 4 - 2 FUEL DELIVERY SYSTEM Type PGM-FI (Programmed Fuel Injection) Throttle bore 38 mm (1.5 in) PROPULSION Jet pump type Single stage, axial flow Impeller rotation (viewed from rear) Counterclockwise Transmission Direct drive from engine Steering nozzle angle (horizontal) 23° Impeller type Stainless steel, 3-blades Impeller diameter 154.6 mm (6.09 in) Minimum water level for jet pump 90 cm (35 in) Bilge pump type Automatic siphon type Reverse system Reverse bucket type ELECTRICAL Ignition system Computer-controlled digital transistorized Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier SCR shorted, triple phase full-wave rectifica- tion

GENERAL INFORMATION 1-7 GENERAL SPECIFICATIONS: ARX1200N3 ’04 model ITEM SPECIFICATIONS MODEL CODE Hull ARX1200N3 (SW02) Engine SW02E DIMENSIONS Overall length 3,200 mm (126.0 in) Overall width 1,245 mm (49.0 in) Overall height 1,060 mm (41.7 in) Dry weight 338 kg (745 lbs) Vehicle capacity 3 person Maximum weight capacity 238 kg (525 lbs) PERFORMANCE Maximum output 91.9 kW (125 PS) at 7,000 rpm Maximum torque 125.5 N·m (12.8 kgf·m) at 7,000 rpm Maximum fuel consumption 35 liters (9.2 US gal, 7.7 Imp gal)/hour Cruising range at full throttle 1.8 hour Fuel tank capacity 63 liters (16.6 US gal, 13.9 lmp gal) Fuel tank reserve capacity 12.9 liters (3.41 US gal, 2.84 lmp gal) HULL Hull type Deep V Hull material FRP ENGINE Engine type 4 Stroke Cylinder arrangement 4 cylinders in-line, longitudinal installed Bore and stroke 79.0 X 63.0 mm (3.11 X 2.48 in) Displacement 1,235 cm 3 (75.3 cu-in) Compression ratio 11 : 1 Intake system Normal aspiration Valve train Chain driven, DOHC Intake valve opens at 1 mm lift 10° BTDC closes at 1 mm lift 30° ABDC Exhaust valve opens at 1 mm lift 30° BBDC closes at 1 mm lift 10° ATDC Lubrication system Dry sump Oil pump type Trochoid Cooling system Water cooled Engine dry weight 80 kg (176 lbs) Firing order 1 - 3 - 4 - 2 FUEL DELIVERY SYSTEM Type PGM-FI (Programmed Fuel Injection) Throttle bore 38 mm (1.5 in) PROPULSION Jet pump type Single stage, axial flow Impeller rotation (viewed from rear) Counterclockwise Transmission Direct drive from engine Nozzle angle (horizontal) 23° Impeller type Stainless steel, 3-blades Impeller diameter 154.6 mm (6.09 in) Minimum water level for jet pump 90 cm (35 in) Bilge pump type Automatic siphon type Reverse system Reverse bucket type ELECTRICAL Ignition system Computer-controlled digital transistorized Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier SCR shorted, triple phase full-wave rectifica- tion

GENERAL INFORMATION 1-8 After ’04 ITEM SPECIFICATIONS MODEL CODE Hull ARX1200N3 (SW02) Engine SW02E DIMENSIONS Overall length 3,200 mm (126.0 in) Overall width 1,245 mm (49.0 in) Overall height 1,060 mm (41.7 in) Dry weight 339 kg (747 lbs) Vehicle capacity 3 person Maximum weight capacity 238 kg (525 lbs) PERFORMANCE Maximum output 101 kW (137 PS) at 7,750 rpm Maximum torque 127.7 N·m (13.0 kgf·m) at 7,000 rpm Maximum fuel consumption 40 liters (10.6 US gal, 8.8 Imp gal)/hour Cruising range at full throttle 1.6 hour Fuel tank capacity 63 liters (16.6 US gal, 13.9 lmp gal) Fuel tank reserve capacity 12.9 liters (3.41 US gal, 2.84 lmp gal) HULL Hull type Deep V Hull material FRP ENGINE Engine type 4 Stroke Cylinder arrangement 4 cylinders in-line, longitudinal installed Bore and stroke 79.0 X 63.0 mm (3.11 X 2.48 in) Displacement 1,235 cm 3 (75.3 cu-in) Compression ratio 11 : 1 Intake system Normal aspiration Valve train Chain driven, DOHC Intake valve opens at 1 mm lift 12° BTDC closes at 1 mm lift 38° ABDC Exhaust valve opens at 1 mm lift 33° BBDC closes at 1 mm lift 10° ATDC Lubrication system Dry sump Oil pump type Trochoid Cooling system Water cooled Engine dry weight 80 kg (176 lbs) Firing order 1 - 3 - 4 - 2 FUEL DELIVERY SYSTEM Type PGM-FI (Programmed Fuel Injection) Throttle bore 38 mm (1.5 in) PROPULSION Jet pump type Single stage, axial flow Impeller rotation (viewed from rear) Counterclockwise Transmission Direct drive from engine Nozzle angle (horizontal) 23° Impeller type Stainless steel, 3-blades Impeller diameter 146.7 mm (5.78 in) Minimum water level for jet pump 90 cm (35 in) Bilge pump type Automatic siphon type Reverse system Reverse bucket type ELECTRICAL Ignition system Computer-controlled digital transistorized Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier SCR shorted, triple phase full-wave rectifica- tion

2004-2006 HONDA Aquatrax Service Manual

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